Boxer BM 100 ES SPC - 2021.pdf

Spare Parts Catalogue
Bajaj Auto Limited
Akurdi Pune 411 035 India

All information contained in this manual is based on the latest
product information at the time of publication. Bajaj Auto Limited
accepts no liability for any inaccuracies or omissions in this
publication, although every possible care has been taken to
make it as complete and accurate as possible. All procedures
and speciﬁcations subject to change without prior notice. The
right is reserved to make such changes at any time without prior
notice and without incurring an obligation to make such changes
to product manufactured previously. Contact your authorized
Bajaj Dealer for the latest information on product improvements
incorporated after this manual was issued.
REV. APRIL 2021
Copy rights : All rights reserved. No part of this publicatin may
be reproduced, stored in a retrival system, Or transmitted in any
form or by any means, electromic mechanical photocopying,
recording or otherwise, without the prior written permission of
Bajaj Auto LTD.
Notice

In a continual effort to improve Performance and Efficiency of the vehicles,
Specifications, Diagrams, Illustrations and Part Numbers can change without
notice. Consequently, the description in this Spare Parts Catalogue cannot
therefore be final and binding on us.
We have pleasure in presenting the Spare Parts Catalogue for ‘Boxer BM
100 ES’ Motorcycle. This catalogue has been specially designed to assist you
in selecting the correct parts for procurement to maintain 100% availability.
The Bajaj spares are subjected to the stringent quality control standards to
ensure longer life of the vehicle. It is therefore necessary that only the
Genuine Bajaj Spares are used.
The modifications / alterations which are carried out after the issue of this
catalogue, will be conveyed to you through our Service Circulars. You are
requested to make necessary corrections in the Parts Catalogue as per the
circulars so as to keep your catalogue up-to-date. This will ensure the
appropriate and speedy delivery of the Spare Parts as the order placed will
bear the latest part numbers.
In case, if you need any technical assistance contact the concerned Regional
Office or write to us on the following address :
Bajaj Auto Limited.
Spares - International Business
Akurdi, Pune 411 035 India
Foreword
In case, if you have the part number and you need the other details, the
part index can be used. The part index (at the end of the catalogue) will
give you the figure and page number of the part you wish to order.
1. How to Read the Catalogue : Open the catalogue and from the pictorial
index locate the group in which the part you want to find is present. Turn
over to the concerned page number (as given by pictorial index). Now
find out the figure of the part you wish to order. Write down the part
number against that particular figure number from the text.
The quantity shown against the part number is the quantity per vehicle for
that group so that particular quantity should be multiplied by the number
of sets required.
2. How to Order Spare Parts : The part number and the description of the
part required should be invariably mentioned in the order as per the
catalogue text.
The latest part number as conveyed through our service circulars should
only appear on the order. In case of ordering painted components, colour
shade of the components should be mentioned.
Assly Assembly V Volts
3. Part Number System : We have used 8 digit system for part numbers.
The model or hardware item is indicated by first two digits or
alphanumeric, the next two or four digits indicate main group and the last
four or two digits indicate serial number in main group or serial number or
subgroup of fastener respectively. Thus the part numbers will be indicated
by 2-2-4 or 2-4-2 digit system. Understanding this system will enable you
to identify the spare parts easily.
4. Abbreviations : The following abbreviations are used in this catalogue.
Cyl Cylinder Comp. Complete
N.I. Not illustrated W Watts
C'case Crankcase Accl. Accelerator
L Length A/t. Alternate
O/s Over size Fr. Front
Rr. Rear Std. Standard
R.H. Right hand L.H. Left hand
Hex. Hexagonal AR As required
Instructions

12 Clutch Cover 24
21 Magneto / C.D.I. / H.T. Coil 42
16 Carburettor 32
20 Starter Assembly 40
24 Fender - Front & Rear 48
22 Frame & Frame Fitting 44
23 Swing Arm / Rear Shock Absorber 46
27 Front Wheel - Alloy 54
25 Foot Rest / Holder / Stand 50
26 Wheel Rim / Spoke / Tyre / Tube 52
30 Rear Hub - Spoke Wheel 60
28 Front Hub - Spoke Wheel 56
29 Front Hub - Alloy Wheel 58
31 Rear Hub - Alloy Wheel 62
18 Silencer Assembly 36
1 Cover Cylinder Head 2
4 Camshaft / Tensioner 8
2 Cylinder Head 4
3 Valve 6
7 Transmission 14
5 Cylinder & Piston 10
6 Crankshaft 12
10 Engine Assembly / Crankcase RH 20
8 Change Drum / Shift Fork 16
9 Gear Change Mechanism 18
11 Crankcase LH 22
17 Air Cleaner Complete 34
15 Kick Starter Mechanism 30
13 Cover Magneto 26
14 Clutch Assembly 28
19 Oil Pump 38
Plate No. Page No.
Description Plate No. Page No.
Description
32 Brake Pedal 64
34 Front Fork 68
33 Handle Bar 66
37 Chain Case 74
35 Fittings - Petrol Tank, Side Covers & Cover Seat 70
36 Petrol Tank, Cap Tank and Gauge Fuel 72
40 Control Cables 80
38 Meter Assembly 76
39 Head Lamp Assembly 78
43 Seat Assembly & Grip Frame 86
41 Indicator Light Assembly 82
42 Tail Lamp Assembly & Number Plate 84
46 Accessories 92
44 Electrical Equipments 88
45 Tool Kit 90
47 Painted Set With Decals 94
Index Index

PLATE NO. : 1
COVER CYLINDER HEAD
PAGE NO.
2
Pictorial Index
PLATE NO. : 2
CYLINDER HEAD
PAGE NO.
4
PLATE NO. : 3
VALVE
PAGE NO.
6
PLATE NO. : 4
CAMSHAFT / TENSIONER
PAGE NO.
8
PLATE NO. : 5
CYLINDER & PISTON
PAGE NO.
10
PLATE NO. : 6
CRANKSHAFT
PAGE NO.
12
PLATE NO. : 7
TRANSMISSION
PAGE NO.
14
PLATE NO. : 8
CHANGE DRUM / SHIFT FORK
PAGE NO.
16
Pictorial Index FI
FI
FI
FI

PLATE NO. : 9
GEAR CHANGE MECHANISM
PAGE NO.
18
PLATE NO. : 10
ENGINE ASSLY / CRANKCASE RH
PAGE NO.
20
PLATE NO. : 11
CRANKCASE LH
PAGE NO.
22
PLATE NO. : 12
COVER RH
PAGE NO.
24
Pictorial Index
PLATE NO. : 13
COVER MAGNETO
PAGE NO.
26
PLATE NO. : 14
CLUTCH ASSEMBLY
PAGE NO.
28
PLATE NO. : 15
KICK STARTER MECHANISM
PAGE NO.
30
PLATE NO. : 16
CARBURETOR
PAGE NO.
32
Pictorial Index
3
FI
FI
FI
FI

Pictorial Index
PLATE NO. : 17
AIR CLEANER COMPLETE
PAGE NO.
34
PLATE NO. : 18
SILENCER ASSEMBLY
PAGE NO.
36
PLATE NO. : 19
OIL PUMP
PAGE NO.
38
PLATE NO. : 20
STARTER ASSEMBLY
PAGE NO.
40
PLATE NO. : 21
MAGNETO, CDI & H.T. COIL
PAGE NO.
42
Pictorial Index
PLATE NO. : 23
SWING ARM / REAR SHOCK
ABSORBER
PAGE NO.
46
PLATE NO. : 24
FENDER - FRONT & REAR
PAGE NO.
48
3
11
FI
FI
FI
FI
PLATE NO. : 22
FRAME & FRAME FITTINGS
PAGE NO.
44

PLATE NO. : 31
REAR HUB - ALLOY WHEEL
PAGE NO.
62
PLATE NO. : 30
REAR HUB - SPOKE WHEEL
PAGE NO.
60
Pictorial Index Pictorial Index
PLATE NO. : 26
WHEEL RIM / SPOKES / TYRE / TUBE
PAGE NO.
52
PLATE NO. : 27
FRONT WHEEL - ALLOY
PAGE NO.
54
PLATE NO. : 28
FRONT HUB - SPOKE WHEEL
PAGE NO.
56
PLATE NO. : 25
FOOT REST / HOLDER / STAND
PAGE NO.
50
PLATE NO. : 29
FRONT HUB - ALLOY WHEEL
PAGE NO.
58
PLATE NO. : 32
BRAKE PEDAL
PAGE NO.
64
FI
FI
FI
FI

PLATE NO. : 33
HANDLE BAR
PAGE NO.
66
PLATE NO. : 38
METER ASSEMBLY
PAGE NO.
76
PLATE NO. : 36
PETROL TANK, CAP TANK &
GAUGE FUEL
PAGE NO.
72
PLATE NO. : 35
FITTING - PETROL TANK, SIDE
COVER & COVER SEAT
PAGE NO.
70
PLATE NO. : 37
CHAIN CASE
PAGE NO.
74
PLATE NO. : 39
HEADLAMP ASSEMBLY
PAGE NO.
78
PLATE NO. : 40
CONTROL CABLES
PAGE NO.
80
FI
FI
FI
FI
PLATE NO. : 34
FRONT FORK
PAGE NO.
68

PAGE NO.
82
PLATE NO. : 41
INDICATOR LIGHT ASSEMBLY
PAGE NO.
84
PLATE NO. : 42
TAIL LAMP ASSLY / NUMBER PLATE
PLATE NO. : 43
SEAT ASSLY & GRIP FRAME
PAGE NO.
86
BOXER S
PLATE NO. : 45
TOOL KIT
PAGE NO.
90
PAGE NO.
88
PLATE NO. : 44
ELECTRICAL EQUIPMENTS
FI
FI
FI
FI
PLATE NO. :47
PAINTED PARTS AND DECALS
PAGE NO.
94
PLATE NO. : 46
ACCESSORIES
PAGE NO.
92

Plate No.: 1
Cover Cylinder Head
2
1
Front Wheel Direction
No. Part No. Description Remarks
Qty
8 JB 5110 15 Flange Bolt 1
7 DP 1210 25 Clamp (ID 12.5 MM) 2
5 JV 5110 11 Plate Cylinder Head 1
4 JB 5110 11 Bolt Head Mounting 4 M8 X 1.25 X 190L
6 DY 5810 09 Tube Breather 1
2 59 0400 38 Bolt 4
1 JV 5110 13 Cover Cylinder Head Assly 1
3 JV 5110 12 Gasket Head Cover 1
2
4
1
3
5
6
7
8

Plate No.: 2
Cylinder Head
4
3
1
2
2
4
7
8
5
3
6
7 PA 5812 24 Insulator PTE-16 1
6 LJ A000 11 O Ring 1
8 JB 5812 72 O Ring Insulator 1
4 Intake Manifold 1
52 PF10 39
3 JB 5110 19 Gasket Cylinder Head 1
5 KA ED06 25 Bolt Flange 2
1 Head Cylinder 1
PF 5111 24
2 Stud 2
39 1660 05
Qty

Plate No.: 3
Valve
5 6
2
1
4
6
5
3
1
6 CB 1010 09 Seal Valve Stem 2
4 36 DU40 76 Valve Kit 1
3 CB 1010 22 Cotter Valve (Collet) 4
5 36 JV00 06 Valve Repair Kit 1
1 JH 5112 12 Shaft Rocker Arm 2
2 DU 1010 60 Rocker Arm with Roller 2
Qty

1 Assly. Camshaft 1
PF 5112 09
2 JA 5112 16 Spacer Cam Sprocket 1
PF 5112 55 Camshaft Assembly 1 Ref.Cir.IB-397
3 PF 5112 03 Sprocket Cam 1
PF 5112 58 Sprocket Camshaft 1 Ref.Cir.IB-397
16 JE 5110 49 Bearing Cam Shaft D102c 1
15 39 1988 20 Bearing Ball - Small 12 X 28 X 8 1
17 DD 1010 62 Bolt 1 N.I.
14 DS 1099 05 Cam Chain (94 Link) 1
13 39 2669 21 ‘O’ Ring (Tensioner) 1
PF 5112 57 Chain 1 Ref.Cir.IB-397
11 KA ED06 20 Bolt M6 X 20 Silver 2
10 DD 1010 62 Bolt M6 Chain Tensioner 1
12 39 0594 17 Internal Circlip 1
8 JE 5210 16 Tensioner Chain 1
7 DH 1013 92 Cam chain Tensioner Pivot Bolt 1
9 CS 1011 28 Gasket 1
6 36 PF00 61 Guide Chain Kit 1
5 DH 1010 48 Special Washer Cam Shaft 1
36 JZ01 22 Kit Guide Cam Chain-D106A 1 Ref.Cir.IB-397
4 DK 1013 86 Precoated Soc Hd Cap Bolt 1
Plate No.: 4
Camshaft / Tensioner
8
7
12
1
2
3
4
14
10
11
7
8
9
6
5
13
15
16
Qty

Plate No.: 5
Cylinder and Piston
4 JH 5210 07 Gasket Cylinder Block 1
3 36 PF00 62 Kit Piston Ring Set 1
1 Kit Cyl Block & Piston 1
36 PF00 45
2 39 1000 06 Dowel Pin 2
10
9
4
2
2
3
1
Qty

Plate No.: 6
Crankshaft
11 JB 5310 21 Plunger Oil Crank Shaft 1
10 JA 5310 15 Pin Crank Shaft Plunger 1
12 36 DM00 10 Kit Connecting Rod 1
8 JZ 5310 06 Gear Primary Drive 1
7 DS 1011 54 Parallel Key 1
9 JA 5310 12 Spring 1
5 39 1864 20 Ball Bearing 20 X 52 X 15 2
PF 5310 66 Crankshaft Assembly 1 Ref.Cir.IB-397
6 PF 5310 27 Sprocket Crankshaft 1
3 31 1011 73 Key Woodruff 1
LD A000 25 Washer Plain-id 14.5xod 26xthk 3 1 Ref.Cir.IB-397
4 PF 5310 23 Crankshaft Assembly 1
2 59 1200 03 Belleville Washer 2
1 59 1500 14 Flange Nut 2
2a 59 1100 08 Plain Washer 1
12
11
4
5
3
7
6
9
11
2
10
1
2a 2
1
Qty
12

Plate No.: 7
Transmission
8 PF 5510 03 Shaft Output Transmission (Driven) 1
7 JA 5510 04 Washer Thrust 2nd Drive 1
9 PF 5512 06 2nd Driven Washer 1
5 PF 5512 01 Gear 3rd Drive 1
4 JA 5510 02 Spline Washer (17.2 X 20.5 X 1.5) 3
6 PF 5512 00 Gear 2nd Drive 1
2 PA 5512 07 Gear 4th Drive 1
1 PA 5510 02 Shaft Input Transmission (Drive) 1
3 39 0987 17 Ring Snap (17.2 X 20.5 X 1.5) 5
11 PF 5512 04 Gear 3rd Driven 1
10 PF 5512 03 Gear 2nd Driven 1
20 DS 1013 55 Socket Head Bolt 2
19 DU 1012 13 Plate Lock Sprocket 1
17 59 2100 24 ‘O’ Ring Collar Sprocket (13.8 X 1.9) 1
16 JA 5510 09 Collar Sprocket Drive 1
18 JZ 5510 04 Sprocket Drive (Engine Sprocket) 1 14 Teeth N.S
14 PA 5512 05 Gear 1st Driven 1
13 JZ 5512 05 Bush 1st Driven 1
15 JA 5510 08 Washer Thrust 1st Driven 1
12 PA 5512 06 Gear 4th Driven 1
14
13
20
19 18
16
17
4
3
9
4
15
13
3
4
14
10
8
1
5
7
6
2
12
11
3
Qty

Plate No.: 8
Change Drum / Shift Fork
7 JZ 5610 02 Fork Gear Shift Input 1
5 PF 5610 02 Shaft Gear Shift Fork 2
4 JD 5610 11 Special Bolt Drum Change 1 M6 X 1
6 JD 5610 04 Fork Gear Shift Output 1
2 39 0992 06 Dowel (Pin Drum Change) 5
1 PF 5610 00 Drum Complete Gear Shift 1
3 JA 5610 02 Cam Drum Change 1
16
15
4
7
6
1
3
5
2
Qty

Plate No.: 9
Gear Change Mechanism
12 39 1902 04 Flange Bolt 1
10 DH 1015 09 Damper 1
9 Lever Gear Shift (Gear Pedal) 1
DY 5614 00
11 JH 5614 04 Rubber Damper 1
7 BF 5612 19 Bolt Detent Lever 1
6 LD B000 44 Washer Plain 1
8 39 0817 15 Hex Nut / Flange - M6 1
4 JH 5612 00 Inhibitor Complete Gear Shift 1
3 JW 5612 08 Spring Gear Shift Return 1
5 PF 5612 03 Spring Inhibitor 1
1 PF 5612 00 Lever Gear Shift Complete 1
2 JW 5612 06 Extension Spring 1
18
17
3
4
5
6
1
2
Qty
7
12
9
10
11

Plate No.: 10
Engine Assembly / Crankcase RH
12 52 JA00 29 Bolt Shift Change 1
11 59 0400 38 Flange Bolt 1
13 JA 5410 12 Guide Kick 1
9 DH 1016 39 Lock Screw Earthing 2
8 DH 1013 80 Screw 1
10 KA ED06 85 Bolt M6 X 85 Silver 2
6 39 1000 06 Dowel Pin 2
5 JA 5410 10 Stopper Plate 1
7 PF 5410 18 Bushing Drum BM-150 1
3 59 2000 36 Bearing Ball 1
2 PF 5410 74 Crankcase RH 1
4 KP BF62 01 Bearing Ball 1
1 PF 5010 66 Engine Assly. 1
PF 5011 62 Engine Assembly 1 Ref.Cir.IB-406
20
19
3
5
8
7
4
10
11
6
2
12
13
9
Qty

Plate No.: 11
Crankcase LH
18 KA ED06 25 Bolt-Flange 2
17 59 0400 38 Flange - Bolt 7
15 JV 5410 06 Cap Strainer 1
14 LJ A000 04 ‘O’ Ring Strainer 1
16 59 2100 23 Ring ‘O’ 1
12 39 0999 06 Oil Pump 2
Pin Dowel -
11 39 1000 06 Hollow Dowel Pin 4 N.I.
13 JG 5710 24 Mesh Oi Filterl 1
9 DH 1013 80 Screw Pan Head (m6x12) 1
8 JA 5410 05 Bush Bendix 1
10 JH 5410 21 Bracket Gear Stopper C101d 1
6 DH 1017 84 Gasket Neutral Switch (T1.5) 1 N.I.
5 31 2010 81 Switch Complete 1
7 39 2190 19 Oil Seal 1
3 59 2000 36 6203 Ball Bearing 1
2 39 2562 20 Needle Roller Bearing 1
4 39 1715 19 Seal Oil 1
1 PF 5410 72 Crankcase LH 1
22
21
Qty
1
7
15
16
12
3
2
13
14
9
4
8
5
17
18
10

Plate No.: 12
Clutch Cover
7 JL 5412 27 Window Oil Guage 1
22 JB 5412 01 Jet Clutch Cover Disco M 1
21 31 1010 64 Plug 1
23 BA 1020 04 Plug 1
19 LA E000 05 Bolt - Flange :- M6 3
18 PF 5412 54 Cap Filter B104e 1
20 39 0999 06 Pin - Hollow Dowel 2
16 DD 121 181 Element Oil Filter 1
15 PF 5412 55 Bracket Clutch Cable 1
17 39 1671 21 Ring - O 1
13 JA 5412 12 Gasket Clutch Cover 1
12 JA 5412 25 O Ring Cap Oil Filler 1
14 59 0400 38 Bolt 8
10 JE 5412 14 Spring TTorsion Clutch Lever 1
9 39 2443 11 Washer - Plain 1
11 JA 5412 11 Cap Oil Filler 1
6 PF 5514 07 Rod Push 1
5 JV 5412 08 Shaft Clutch Release Assy 1
8 DS 1012 15 Clip - Wire 1
3 39 1041 19 Seal - Oil 1
2 JV 5412 25 Label Cover Clutch 1
4 30 1011 42 Seal - Oil 1
1 36 DU40 79 Cover Clutch 1
24
23
Qty
20
1
2
3
4
5
7 8
10
11
13
7
9
12
16
17 18
19
15
6
14

1
3
2
5
7
6
9
2
4
8
Plate No.: 13
Cover Magneto
9 Decal Magneto Cover 1
PF 5412 49
8 DS 1611 50 Sticker Gear Shifting 1
6 JA 5412 11 Cap Oil Filler 1
5 JA 5410 05 Bush 1
7 JA 5412 25 O Ring Cap Oil Filler 1
3 JB 5412 24 Gasket Cover Magneto 1
2 Bolt 9
59 0400 38
4 PF 5412 63 Assembly Cover LH 1
1 Assembly Magneto Cover 1
52 JV01 43
26
25
Qty

Plate No.: 14
Clutch Assembly
3 39 2600 11 Washer 1
15 36 JZ00 23 Set Primary Drive & Driven 1
13 52 JA00 28 Nut Special M14 1
12 JA 5514 20 Plain Washer 1
14 39 1001 20 Bearing Ball 1
10 39 0980 04 Bolt Hexagon Head 6
9 Holder Clutch (Modified) 1
JB 5514 06
11 Belleville Washer 1
JE 5514 09
7 PF 5514 11 Hub Clutch 1
6 30 1010 96 Plate Clutch (Steel Plate) 4
8 28 1012 14 Spring Clutch 6
4 Plate Clutch Friction 5
36 JE00 24
2 JA 5514 06 Collar Clutch 1
5 JB 5514 08 Wheel Clutch 1
1 PF 5514 12 Assembly Clutch 1
28
27
15
8
7
5
13
2
11
12
4 14
6
3
10
9
1 No. Part No. Description Remarks
Qty

Plate No.: 15
Kick Starter Mechanism
14 JE 6210 03 Spring 1
13 30 1011 54 Kick Rubber 1
11 JA 6210 06 Washer Thrust (16.2 X 25 X 0.5) 1
10 Gear Kick Pinion 1
PA 6210 05
12 39 2408 17 External Circlip 1
8 DS 1011 17 Spring Kick Starter Ratchet 1
7 PF 6210 03 Shaft Kick 1
9 JA 6210 02 Ratchet 1
5 39 0993 11 Plain Washer Small 3
4 22 1502 41 Plain Washer 1
6 39 0738 17 Circlip Shaft 2
2 JA 6212 06 Bolt Flange 1
1 DU 1010 50 1
Assembly Kick Shaft
3 Boss 1
36 DU10 07
30
29
1
14
2
4
3
12
6
7
8
9
10
5
11
13
5
5
Qty

Plate No.: 16
Carburettor
6 36 JH00 12 Kit Carb O Rings & Gasket 1
5 36 DM00 05 Kit Throttle Valve 1
3 36 JH00 40 Kit Carb Air Screw / Slow Jet 1
2 36 DU40 84 Kit Carb Jet 1
4 36 DU40 83 Kit Carb Idling Screw 1
1 PF 5812 26 Carburator Assembly 1
15 36 JH00 44 Float Chamber Kit 1
12 36 DU40 82 Top Cap 1
11 JB 5812 60 Drain Screw 1
13 JB 5812 58 Tube Air Vent 1
9 JB 5812 56 Arm Pin Float 1
8 JB 5812 30 Float 1
10 PA 5812 21 Screw Float Chamber 1
7 JB 5812 29 Valve Comp Float 1
32
31
Qty

Plate No.: 17
Air Cleaner Complete
2 DY 5810 02 Cover Air Filter 1
3 LB U000 07 Screw Truss 8
4 PF 5811 35 Element Assembly Filter Air 1 Added Ref.Cir.IB-370
4a PF 5811 36 Element Filter Air 1 Single Element Air Filter
5 DU 1210 52 Ring Seal 1
6 DH 1211 03 Duct 1
7 DS 1211 26 Plug 1
8 DP 1210 25 Clamp 2
9 DY 5810 10 Tube Drain 1
10 DY 5810 09 Tube Breather 1
11 DG 1210 40 Clamp 1
12 JY 5810 28 Clamp 1
13 PF 5810 58 Tube Connecting 1
14 DM 2210 01 Band For Tool Kit 1
15 JL 1810 26 Clip Nut 2
16 DY 5810 05 Spacer Battery 1
17 DY 4018 01 Pad Battery 1
1 PF 5810 57 Assembly Air Filter 1
34
33
Qty
2
1
4
14
15
16
17
13
10
7
8 11
12
9
5
6
3
4a

Plate No.: 18
Silencer Assembly
PF 5912 69
1 Assembly Silencer Complete 1
PF 5912 39 Silencer Assembly 1 Ref.Cir.IB-426
2 JE 5910 02 Gasket Exhaust 1
JE 5912 80 Gasket Exhaust 1 Ref.Cir.IB-406
3 39 2295 15 Nut Flanged- Ex.tube-cyl Head 1
4 DK 1016 10 Bolt (m5) (ss 304) 1
6 39 2722 04 Socket HD Bolt 1
36
35
Qty
3
1
2
4
6
5

Plate No.: 19
Oil Pump
1 JB 5710 05 Assly Oil Pump 1
2 JA 5410 16 Gasket Case Oil Pump 1
3 FD 1010 78 Pan Head Screw M6 X 1 X 3DL 3
4 39 0999 06 Dowel 2
5 JB 5710 06 Gear Oil Pump 1
38
37
2
3
3
3
1
4
5
Qty

Plate No.: 20
Starter Assembly
40
39
1 JH 3516 01 Motor Assembly Starter 1
2 KA ED06 25 Bolt-flanged-small 2
3 PF 6214 00 Starter Drive Assembly 1
4 JH 5410 21 Bracket Gear Stopper 1
5 DH 1013 80 Screw Pan Head(m6x12) 1
6 PF 6214 11 Gear Assembly Starter 1
7 PF 6214 04 Nrb Gear Starter 1
8 39 0972 04 Bolt Socket (m6x14) 3
9 39 0849 14 Washer - Lock Toothed 3
10 36 DK00 76 Kit Starter Clutch Assembly Dk101595 1
11 DK 1016 05 Plate Roller Clutch 1
12 PF 3510 46 Rotor Assembly 1
PF 3510 22 Rotor Assembly 1 Ref.Cir.IB-406
13 LA C000 52 Bolt Socket 2
14 DH 1013 80 Screw Pan Head 2
15 KB BC06 08 Screw Pan Cross 1
16 PF 5412 42 Bracket Stator Harness 1
17 DY 3510 04 Assembly Stator 1
PF 3510 56 Stator Assembly 1 Ref.Cir.IB-406
Qty
1
2
3
4
6
7
10
11
12
13
17
16
14
15 8
9
5

Plate No.: 21
Magneto, CDI & H.T. Coil
1 DY 3512 01 COIL HT With Cable 1
2 PF 3512 43 CDI 1
PF 3512 52 CDI 1 Ref.Cir.IB-406
3 CF 1110 19 Plug - Spark 1
4 DD 1110 48 Spark Plug Cap LH 1
5 DD 1110 11 Grommet Spark Plug Cap LH 1
6 DD 1110 12 Grommet for HT Cable 1
7 39 1943 04 Bolt Flange M6 2
42
41
3
5
7
4
6
1
2
Qty

Plate No.: 22
FRAME & FRAME FITTING
44
43
1 DM 1612 01 Frame Assembly 1
DM 1612 17 Frame Assembly 1 Ref.Cir.IB-406
2 DF 1810 90 Nut Steering Bearing 1
3 36 DZ20 08 Kit St. Cone With Grease 1
4 DJ 1811 15 Cage Bearing 2
5 DM 1611 92 Bracket engine hanger LH 1
5a DM 1611 93 Bracket engine hanger RH 1
6 DY 1134 00 Engine Mounting bracket front 1
7 KA DD08 80 Hex Nut Flanged 2
8 KA DD08 85 Bolt Flanged 2
10 39 1970 15 Nut Flanged 7
11 KC GD08 08 Hex Bolt Flanged 4
12 DU 1611 96 Tape - Frame 1
13 DH 1810 14 Cup Steering 1 N.I.
1
4
4
2
3 10
10
5a
9
5 7
8
12
11
6
Qty

Plate No.: 23
SWING ARM / REAR SHOCK ABSORBER
1 39 2366 15 Nut Domed Cap 2
2 39 0737 12 Washer Spring 4
3 39 0714 11 Washer Plain 4
4 DM 1710 27 Rear Shock Absorber 2
5 39 0454 11 Plain washer 2
6 KB RB35 13 Screw Tapping Pan Cross 2
7 31 1710 06 Shaft Swing Arm 1
9 30 1710 18 Bushing Rubber 2
10 39 1225 15 Nut Hex./ flange 1
11 DM 1713 19 Arm Comp. Swing / Bush 1
12 52 DZ00 46 Chain Adjuster (RH) 1
13 39 0711 11 Washer Plain 2
14 39 0292 15 Hex Nut 4
15 52 DZ00 47 Adjuster Chain (LH) 1
16 31 1710 12 Damper for Swing arm 1
45
46
Qty
5
6
1 2
10
16
3
3
3
9
8
12
1
15 14
14
13 14
14
13
2
3
9
8
7
11
16
4

9
10
Plate No.: 24
Fender - Front & Rear
1 DF 1612 42 Fender Front 1
2 DF 1612 45 Mud Flap Front 1
3 22 1504 35 Bolt 2
5 39 2484 15 Nut Flange M5 2
6 DF 1910 20 Clamp 1
7 KA DD06 12 Bolt Flange 1
8 39 2222 04 Bolt Flange M8 4
9 DF 1611 04 Fender Rear 1
10 30 2010 69 Reflector Reflex 1
11 39 2484 15 Nut 1 N.I.
12 CB 1611 06 Nut - Clip M6 1 N.I.
13 DM 1610 09 Fender Rear FR 1
14 DD 1610 51 Flap For Fender Rear Front 1
15 39 2483 04 Hex. Head Bolt Flange M6 2
48
47
Qty
13
15
14

23
16 / 17
18
22
24
25
26
19
20
21
11
22
Plate No.: 25
Foot Rest / Holder / Stand
1 DU 1610 32 Stand - Center 1
2 DG 1611 24 Damper 1
3 30 1611 57 Shaft Stand 1
4 39 0797 08 Pin Cotter 1
5 30 1611 58 Spring 1
6 DY 1132 00 Stand Side 1
7 DF 1611 02 Bolt 1
8 39 0422 15 Nut Nyloc M10 1
9 DH 1610 66 Spring Side Stand 1
10 DU 1613 25 Holder Assembly Step Rider 1
12 39 2481 04 Bolt Hexagon Head With Flange M8 2 N.I.
13 DF 1614 13 Rubber Main Step 2
14 DG 1612 24 Damper 1
15 DX 1610 67 Plate Lock Pillion Step 1 N.I.
16 DU 1612 59 Stay Pillion LH 1
17 DM 1612 06 Holder Assembly Step Pillion RH 1
18 Dx 1610 56 Rubber Pillion Step 1
19 DH 1611 78 Spacer I Main Step 2
20 DX 1610 67 Plate Lock Pillion Step 1
21 22 1504 51 Bolt Hex Head 2
22 DJ 1611 86 Plate Side Pil.step 1
23 DD 1613 81 Pin Pillion Step 1
24 30 1410 31 Ring O 1
25 39 1040 11 Washer-plain 1
26 KH AA25 20 Pin - Split 1
50
49
4
5
3
2
1
8
7
6
9
Qty
10
14
13
13

Plate No.: 26
Wheel Rim / Spokes / Tyre / Tube
1 16 1510 66 Nipple Spoke 72
2 DU 1510 25 Spoke Inner Front (Drum) 18
3 DU 1510 26 Spoke Outer Front 18
4 DM 1510 29 Rim - 1.60 X 17 Drum bake -Dia. 110 1
5 DS 1510 46 Rim 1.85 X 17 Rear 1
6 DG 1510 22 Band Rim 2
7 DS 1510 09 Spoke Inner Rear 18
8 DS 1510 10 Spoke Outer Rear 18
9 DM 1510 24 Tyre With Tube Front 2.75x17 1
10 DM 1510 27 Tyre and Tube Rear 1
52
51
5
2
1
3
5
7
1
8
12
6
6
9
10
Qty

Plate No.: 27
Front Wheel - Alloy
1 DM 1513 20 Wheel Rim Front (5 Spoke) 1
2 DM 1510 24 Tyre with Tube Front 1
3 DM 1513 23 Wheel Rim Rear (5 Spoke) 1
4 DM 1510 27 Tyre with Tube Rear 1
54
53
Qty
1
2
3
4

Plate No.: 28
Front Hub - Spoke Wheel
1 39 2680 20 Bearing-Ball 1
1A 39 2681 20 Bearing-Ball 1
2 DF 1510 03 Drum Front 1
3 31 1510 04 Collar 1
4 14 1510 21 Oil Seal 30 X 17 X 6s 1
5 DU 1510 05 Collar Assly Axle 1
7 DU 1510 31 NUT - U :- M10 X 1.25 1
8 DZ 1510 12 Axle Front 1
9 DZ 1510 27 Panel Front Brake 1
10 JB 1318 04 Brake Shoe Kit (Non Asbestos) 1
11 30 1510 69 Spring 2
12 31 1510 11 Cam Brake 1
13 30 1510 38 'O' Ring 1
14 DD 1510 09 Indicator Front 1
15 DD 1510 08 Lever Brake Cam 1
16 39 0775 04 Bolt M6 X 30 1
17 39 0798 15 Nut Hex. Flange M6 1
18 31 1510 14 Seal Oil 1
19 31 1510 64 Gear Speedometer 1
20 30 1510 41 Gear Meter Screw 1
21 39 0242 11 Washer for Speedo Gear 1
22 JA 1316 06 Bush for Speedo Gear 1
23 KB BA04 08 Screw Pan Cross M4 for Speedo Cable 1
24 30 1511 18 Stopper For Bushing 1
25 39 1013 21 O Ring 1
26 39 0900 12 Washer - Spring 1
56
55
12
11
10
2
3
5
13
25
9
1
16
22
26
24
21
17
8
15
14
1A
4
18
23
7
6
19
20
Qty

Plate No.: 29
Front Hub - Alloy Wheel
11 39 0248 11 Washer Plain 2
12 30 1510 41 Gear Meter Screw 1
13 30 1511 18 Stopper for Bushing 1
14 39 0840 01 Screw Pan Cross 1
15 39 0900 12 Spring Washer 1
16 31 1510 14 Oil Seal 1
17 DS 1510 94 Flange Nut 1
19 39 0775 04 Bolt 1
20 DD 1510 09 Indicator Front 1
21 30 1510 38 Ring O 1
22 DZ 1510 27 Panel Front Brake 4
23 31 1510 11 Cam Brake 1
24 30 1510 69 Spring 2
25 JB 1318 04 Shoe Brake 2 Non Asbestos
1 KP BB62 02 Ball Bearing 1
2 31 1510 04 Collar 1
3 KP BB62 02 Ball Bearing 1
4 31 1510 14 Oil Seal 1
5 DU 1510 05 Collar Axle Assly 1
7 39 0798 15 Nut- Hex. 1
8 DZ 1510 12 Axle 1
9 JA 1316 06 Bushing 1
10 39 1013 21 Ring ‘ O’ 1
58
57
Qty
12
23
24
25
2
5
7
21
22
1
19
9
10
17
8
18
20
3
4
16
14
15
13
11
11
6

19
12
8
15
14
13
16
24 25
22
17
11
23
18
9
10
20
21
Plate No.: 30
Rear Hub - Spoke Wheel
60
59
Qty
3
2
1
6 5
4
7
1 DX 1510 81 Chain 124 Links (Cross Slit) 1
2 36 DM00 03 Kit Chain Sprocket 1
3 30 1510 78 Coupling 1
4 39 2240 20 Bearing - Ball 1
5 30 1510 81 Washer Lock 3
6 39 0694 15 Hex Lock Nut 6
7 DP 1510 28 Bolt (square)rr Wheel 6
8 30 1510 63 Drum Rear 1
9 KP BB62 02 Bearing-Ball-C3 Clearance 1
10 KP BB63 02 Bearing-Ball-C3 Clearance 1
11 30 1510 75 Collar Bearing 1
12 30 1510 76 Damper 1
13 DM 1513 17 Panel Rear Brake 1
14 JN 1318 12 Brake Shoe Kit (Non Asbestos) 1
15 30 1510 69 Spring 2
16 30 1510 11 Cam Brake Assly 1
17 30 1510 38 O Ring 1
18 30 1510 05 Indicator 1
19 DD 1510 15 Lever - Brake Cam In Forging 1
20 KC AA10 08 Screw - Hexagon Head 1
21 39 0798 15 Nut Hexagon With Flange M6 1
22 DM 1510 32 Axle M14 X 1.5 1
23 DM 1710 22 Spacer 1
24 39 2566 11 Plain Washer 1
25 DH 1710 19 U Nut Swing Arm 1

Plate No.: 31
Rear Hub - Alloy Wheel
21 39 0798 15 Flange Nut 1
23 39 0798 15 Hex Nut 1
19 DH 1710 19 ‘U’ Nut Swing Arm 1
18 39 2566 11 Washer Plain 1
20 30 1510 38 Ring O 1
16 DS 1510 69 Panel Rear Brake 1
15 30 1510 11 Brake Cam 1
17 DM 1510 32 Axle 1
13 30 1510 69 Spring 2
12 30 1510 76 Damper 4
14 30 1511 05 Shoe Brake 1
10 DF 1510 23 Chain 2
9 30 1510 81 Lock Washer 2
11 30 1510 75 Collar Bearing 2
7 DP 1510 28 Bolt 4
6 DM 1513 24 Coupling 1
8 39 0694 15 Nut Hex. 4
4 39 2240 20 Bearing Ball 1
3 DJ 1510 18 Sproket 1
5 30 1510 79 Sleeve 1
1 39 0292 15 Nut Hex. 1
2 30 1510 05 Indicator 1
62
61
Qty
17
23
22
10
12
1
3
8
4
9
7
1
13
14
16
15
18 19
21
2
6
5
11
20
27

Plate No.: 32
Brake Pedal
64
22 DD 1610 78 Damper 1
20 39 0708 15 Nut Hex. M10 X 1.25 1
19 30 1510 95 Bolt Hex. 1
21 1
JA 1610 03 Pad Brake Lever
17 39 0694 15 Hex. Lock Nut M8 x 1.25 1
18 39 0807 08 Split Pin 2
13 DM 1513 17 Rod Torque 1
14 DH 1510 29 Step Bolt Torque Rod 1
15 39 1540 11 Plain Washer 1
11 30 1910 37 Pin Brake Rod 1
10 30 1910 35 Spring 1
12 30 1910 36 Nut Brake Adjuster 1
8 30 1910 31 Spring 1
7 39 0797 08 Pin Cotter 1
5 39 0808 08 Split pin 1
2 DM 1910 10 Rod brake 1
1 DY 1610 04 Assembly Pedal Brake 1
3 30 1910 38 Pin 1
63
2
18
17
12
11
1
22
21
3
6
4
8
19
10
10
7
13
20
15
14
5
16
19 17
9
Qty

Plate No.: 33
Handle Bar
66
65
25 DX 1910 09 Switch Assembly (with Lever) 1 N.I.
24 JZ 1610 28 Lever Pivot Bolt 1 N.I.
26 JZ 4014 03 Switch Clutch (vb) Diode 1
DY 2326 00 Set Lock 1 Ref.Cir.IB-406
22 PF 2326 03 Lock Set 1
23 39 1943 04 Bolt Flanged 2
20 59 0400 06 Hex Head Bolt 2
19 FD 1810 20 Washer Plain 1
21 JD 4022 17 Band 2
17 39 2249 15 Nut- Nyloc M-10 2
16 DF 1810 92 Damper Handle Lower 2
18 FD 1810 19 Washer Plain 1
14 39 1074 04 Bolt Flanged Small 4
13 FD 1810 31 Holder Handle Lower 2
15 DF 1810 91 Damper Handle Upper 2
11 Mirror Assy RH 1
DJ 2210 04
10 Mirror Assy Left Hand 1
DJ 2210 03
12 FD 1810 30 Holder Handle Upper 2
8 1
DD 1911 42 Lever - Grip :- Right
7 DS 1910 52 Boot for Lever LH 1
9 DS 1910 18 Boot for Lever RH 1
5 PF 1610 07 Grip Assly. RH 1
4 PF 1610 05 Grip LH 1
6 PF 1610 15 Lever Clutch 1
2 JB 4014 00 Control Switch LH 1
1 Handle Bar 1
DU 1811 14
3 Control Switch RH 1
PF 4014 17
7
21
6
16
5
8
13
1
12
14
17
15
20
18
19
3
23
22
10
11
4
26
9
2
Qty

Plate No.: 34
Front Fork
68
67
22/23
1
6
17
18
20
19
5
4
3
26
28
27
15/16
7
8
10
14
11
12
13
2B
2
9
2A
24
25
21
31
31 30 1810 29 Ring ‘O’ 2
29 DU 1810 99 Leg Assembly LH 1 N.I.
28 DF 1810 88 Damper Fork Covr Fr.fork 1
30 DU 1811 00 Leg Assembly RH 1 N.I.
26 DD 1810 90 Cover - Trail :-B 1
25 DM 1810 10 Washer 2
27 DD 1810 91 Cover - Trail 1
23 DM 1810 38 Cover : Cover Fork LH 2
DM 1810 55 Cover Fork RH 1 Ref.Cir.IB-406
24 JK 1210 08 Spacer Tube 2
21 DF 1810 85 Seat 2
20 Rebound Spring 1
31 1810 99
22 DM 1810 39 Cover : Cover Fork RH 1
18 30 1810 20 Piston Ring 1
17 PA 1210 41 Seat Pipe 1
19 31 1810 19 Cap Oil Lock 1
15 Tube Outer LH 1
DU 1811 01
14 39 1813 04 Bolt M10X1.25 2
16 Tube Outer RH 1
DU 1811 02
12 DD 1812 07 Holder Fork Under W/o Lock Bracket 1
11 Bearing Cone Fork 1
30 1810 09
9 DF 1810 89 Plain Washer 1
8 FD 1810 12 Cap Nut Fork 1
10 DD 1812 05 Holder Fork Upper 1
6 DE 1810 31 Spring Front Fork 2
5 DM 1810 36 Pipe Complete-Suspension - Inner 2
7 31 1811 20 Bolt Fork with Washer 2
3 30 1810 26 Gasket 2
2B DD 1810 32 Seal Dust 2
4 KA CF08 30 socket Head Bolt 2
2 DU 1811 08 Oil Seal 2
DM 1810 54 Fork Front 1 Ref.Cir.IB-406
2A 31 1811 08 Ring Snap 2
1 Front Fork 1
DM 1810 43
Qty

Plate No.: 35
Fittings - Petrol Tank, Side Covers & Cover Seat
1 DH 1611 58 Grommet Side Cover Front 2
4 DG 1410 19 Damper Tank Rear 2
2 DG 1611 21 Screw 1
3 DU 1611 02 Damper 1
7 DP 2010 37 Plain Washer 1
5 39 1789 24 Washer Nylon 3
6 39 1902 04 Pin Snap 1
8 DF 1411 28 Damper Front 2
70
69
2
8
7
6
1
5
4
8
3
Qty

Plate No.: 36
Petrol Tank, Cap Tank and Gauge Fuel
2 AP 1012 55 Screw Pan Cross 2
1 DF 1411 20 Cap Assy-tank With Plastic Hub 1
4 DU 1410 95 Fuel Cock Assy 1
3 39 2179 24 Washer 2
3A 30 1410 31 ‘O’ Ring 2
6 PF 1718 03 Pipe Fuel 1 Cock to Carburettor
5 PF 2326 03 Lock Kit 1
DY 2326 00 Set Lock 1 Ref.Cir.IB-406
9 DL 1610 17 Damper For Side Cover 2 N.I.
7 33 1410 08 Clamp 2
8 DG 1410 19 Damper 2
10 DD 1412 27 Bolt - Flanged 2
11 DF 1411 28 Damper Fuel Tank Mounting 1
74
71
6
10
8
7
2
1
4
12
3
5
3A
72
Qty

Plate No.: 37
Chain Case
3 DH 1612 83 Bolt Flanged M6 4
1 52 DM01 59 Chain Case Upper / Lower 1
52 DY01 33 Chain Case U/L With Packing 1 Ref.Cir.IB-406
2 DH 1610 73 Instruction Lable 1 N.I.
4 DF 1614 15 Beading Chain Case 1
5 DF 1614 16 Cap - Case Chain 1
74
73
3
4
1
1
3
5
3
3
Qty

Plate No.: 38
Meter Assembly
1 DM 1910 09 Speedometer Asy+Lmp W/o F.gaug 1
76
75
Qty
1
2
6
3
8
5
8
10
4
7 9

Plate No.: 39
Head Lamp Assembly
5 DU 2010 60 Collar 2
6 Damper I 2
DD 2010 09
7 Damper II 2
DD 2010 10
8 Flange Bolt M-8 L 35 2
39 1683 04
9 39 1970 15 Flange Nut M-8 2
10 Lamp 12 V 35/35 W HS1 1
25 2010 09
11 DF 2010 58 Lamp Holder (Socket) Assly. 1
1 Head Light Assy/ Lmp 1
DM 2010 22
2 DJ 2010 46 Head Light Rim 1
3 30 2010 69 Reflector Reflex 1
4 DU 2010 29 Special Screw 2
78
77
2
4
6
5 1
7
10
9
3
8
11
Qty

3
2
1
4
5
6
Plate No.: 40
Control Cables
1 DU 1910 58 Cable Throttle 1
2 DY 1612 01 Clutch Cable 1
3 DU 1910 62 Brake Cable 1
4 30 19 1070 Spring 1
5 30 19 1069 Dust Seal 1
6 DZ 1910 14 Cable Speedometer W/O Bent Tube 1
80
79
Qty

Plate No.: 41
Indicator Light Assembly
1 DM 2010 27 Indicator Assly FR LH With Lamp 2
DM 2010 28 Indicator Assly FR RH With Lamp 2
2 DM 2010 29 Indicator Assly RR LH With Lamp 2
DM 2010 30 Indicator Assly RR RH With Lamp 2
3 18 2010 44 Lamp :- 12V - 10W - R 10W 4
4 39 1225 15 Hex. Nut Flange M-10 4
82
81
1
2
3
4
Qty

Plate No.: 42
Tail Lamp Assly & Number Plate
1 PF 4010 05 Tail Light Assly 1
2 20 2010 29 Lamp 12 V, 21/5W 1
3 39 2430 15 Hex Nut. / Flange 2
4 DD 2010 11 Damper 2
5 31 2010 01 Collar 2
7 DF 161248 BKT- Number. Plate 1
8 39 2476 04 Bolt - Hex Head With Flange 2
9 DF 1612 52 Plate - Number :- Rear In Black 1
10 39 2475 04 Hex. Head Bolt/flange M6 2
11 DF 1612 51 Plate - Number :- Front In Black 1
12 DF 1810 97 Bracket Plate No. Front 1
13 39 1783 01 Truss Screw 2
14 39 1553 04 Bolt Flange 2
15 39 1211 11 Plain Washer 2
16 PF 4022 10 Boot 1
84
83
Qty
9
10
10
1
2
7
6
4
5
3
14
15
12
11
13
8
16

Plate No.: 43
Seat Assly & Grip Frame
1 DM 2110 21 Seat Asy. comp. rear Hook 1
2 FD 2110 06 Grommet Seat 2
3 FD 2110 07 Spacer Seat 2
5 39 1802 04 Hex Soc Head Cap Bolt 2
6 31 2110 04 Damper 7
7 DM 2210 20 Grip Frame 1
8 39 1556 04 Hex. Head Bolt / Flange M8 2
86
85
7
8
Qty
1
2
3
4
5
6

Plate No.: 44
Electrical Equipments
1 DZ 2010 38 Dc Horn 1
2 KA DD08 14 Bolt Flange 1
3 DM 2010 41 Wiring Harness 1
DM 2010 50 Harness Wiring 1 Ref.Cir.IB-406
4 31 2010 79 Rear Brake Switch 1
5 DY 4014 00 Spring Rear Brake Switch 1
6 PF 4018 06 3AH Vrla Dry Battery (Without Acid Bottle) 1
PF 4018 13 Acid Bottle For 3ah Vrla Dry Battery 1
7 DY 4018 00 Clamp Battery 1
DY 1138 03 Clamp Assembly Battery 1 Ref.Cir.IB-406
8 JD 4022 17 Band 1 N.I.
9 PA 4022 04 Band 1 N.I.
10 DS 2010 25 Assly D.c. Flasher 1
11 JN 4020 00 RR Unit With Capacitor 1
JZ 4020 02 Regulator Assembly 1 Ref.Cir.IB-406
12 KA DF06 16 Bolt Flanged 2 N.I.
13 DK 2010 78 Starter Relay- With Nut 1
14 DY 4022 02 Cable Earth 1
15 JV 4022 04 Cable Assy St Relay To Motor 1
16 JZ 4022 16 Cap (starter Motor) 1
17 DJ 2012 19 Assy. Fuse Box 1
18 JZ 4022 18 Cable Tie (white Color L200) 1 N.I
19 31 2010 21 Clamp 1
20 PF 4034 00 Socket Charger 1 Ref.Cir.IB-406
88
87
Qty
6
4 5
3
1
2
16
19
17
11
7
10
13
15
14
20

Plate No.: 45
Tool Kit
1 DM 221013 Tool Kit with Value Engineered Tools 1
90
89
1
Qty

Plate No.: 46
Accessories
92
91
1 PF 1130 08 Footrest Third LH 1
2 PF 1130 09 Footrest Third RH 1
3 39 1298 04 Screw Hex. Socket M8x1.25x35 2
4 JB 2312 06 Bolt Socket Head 2
5 DZ 2210 03 Leg Guard 1
6 KA DF08 85 Bolt Flanged 1
7 KC GA08 08 Nut Hex Flanged 1
8 DF 2210 54 Guard Sari 1
4
1
8
2
3
Qty
5
6
7
4

Plate No.: 47
Painted Set With Decals
1 52 DM05 51 Tank Eb.Black With Dkl 1
52 DM05 52 Tank Flame Red With Decal 1
52 DM05 53 Tank Elec.blue With Decal 1
2 52 DM05 58 Sd.cvr LH Eb Blk Dkl 1
52 DM05 61 Sd.cvr LH Flame Red Dkl 1
52 DM05 64 Sd.cvr LH El.blu Dkl 1
3 52 DM05 59 Sd.cvr RH Eb Blk Dkl 1
52 DM05 62 Sd.cvr RH Flame Red Dkl 1
52 DM05 65 Sd.cvr RH El.blu Dkl 1
4 DF 1612 42 Fender Assembly - Front 1
5 36 DM00 07 Kit Tank Dcl Ebony Black 1
36 DM00 08 Kit Tank Dcl Flame Red 1
36 DM00 09 Kit Tank Dcl Electron Blue 1
6 DM 1612 10 Decal Cover Side LH 1
7 DM 1612 11 Decal Cover Side RH 1
94
93
Qty
6 7
2/3
1
4
5

9 36DM0007 KIT TANK DCL EB BLACK DM141043 DECAL TANK RH BLACK BODY 1
DM141042 DECAL TANK LH BLACK BODY 1
36001052 GREASE LETHON RR3 -10GM 1
8 36314005 KIT ST. CONE KIT 36314001 KIT STEERING CONE NEW 1
36314002 KIT BALL STEEL STEERING 1
JZ531006 GEAR PRIMARY DRIVE 1
7 36JZ0023 KIT PRIMY DRIVE & DRIVEN PF551401 CLUTCH HSG ASSLY COMP 1
PF521229 PISTON ASSEMBLY 1
PF521210 PISTON ASSEMBLY 1
39084914 WASHER - LOCK :- TOOTHED 1
6 36PF0045 KIT BLOCK PISTON-B104D PF521022 BLOCK CYLINDER 1
5 36DK0076 KIT STARTER CLUTCH DK101595 BODY STARTER CLUTCH 1
DK101596 SPRING STARTER CLUTCH 1
PF521215 STEEL 2ND RING PISTON B104D 1
4 36PF0062 KIT PISTON RING SET JB521207 RING PISTON (TOP) 1
PF521204 RING PISTON OIL 1
JE541016 GUIDE CAM CHAIN SLACK SIDE 1
3 36PF0061 GUIDE CHAIN KIT JE521019 GUIDE CAM CHAIN TIGHT 1
CB101022 COTTER VALVE
DY511202 RETAINER VALVE 1
1
CB101009 SEAL - VALVE STEM 1
2 36JV0006 VALVE REPAIR KIT 28101129 SPRING - SEAT 1
JA511202 SPRING VALVE 1
PF511212 VALVE INTAKE 1
1 36DU4076 VALVE KIT PF511213 VALVE EXHAUST 1
Kit List
Kit
Part No.
Kit Description
Part No. Description Qty/Kit
Consisting of Following Parts
Sr
No
DM141046 DECAL TANK LH 1
11 36DM0009 KIT TANK DCL EC BLUE DM141047 DECAL TANK RH 1
DM141038 DECAL TANK LH RED BODY 1
10 36DM0008 KIT TANK DCL FLAME RED DM141039 DECAL TANK RH RED BODY 1
Kit List
Kit
Part No.
Kit Description
Sr
No

Kit List
Kit
Part No.
Kit Description
Sr
No
Kit
Part No.
Kit Description
Sr
No
Kit List

Amendment Sheet Amendment Sheet
Page Fig. Old part New part
Description
Updation Remarks
no. no. date
no. no.
Page Fig. Old part New part Description Updation Remarks
no. no. date
no. no.
36 1 ----------- PF591239 Silencer Assembly 13.04.21 Added Ref.Cir.IB-426
88 11 ----------- JZ402002 Regulator Assembly 07.09.20 Added Ref.Cir.IB-406
88 7 ----------- DY113803 Clamp Assembly Ba ery 07.09.20 Added Ref.Cir.IB-406
88 20 ----------- PF403400 Socket Charger 07.09.20 Added Ref.Cir.IB-406
74 1 ----------- 52DY0133 Chain Case U/L With Pa. 07.09.20 Added Ref.Cir.IB-406
72 5 ----------- DY232600 Set Lock 07.09.20 Added Ref.Cir.IB-406
88 3 ----------- DM201050 Harness Wiring 07.09.20 Added Ref.Cir.IB-406
68 1 ----------- DM181054 Fork Front 07.09.20 Added Ref.Cir.IB-406
66 22 ----------- DY232600 Set Lock 07.09.20 Added Ref.Cir.IB-406
68 22 ----------- DM181055 Cover Fork RH 07.09.20 Added Ref.Cir.IB-406
42 2 ----------- PF351252 CDI 07.09.20 Added Ref.Cir.IB-406
40 17 ----------- PF351056 Stator Assembly 07.09.20 Added Ref.Cir.IB-406
44 1 ----------- DM161217 Frame Assembly 07.09.20 Added Ref.Cir.IB-406
36 2 ----------- JE591280 Gasket Exhaust 07.09.20 Added Ref.Cir.IB-406
20 1 ----------- PF501162 Engine Assembly 07.09.20 Added Ref.Cir.IB-406
40 12 ----------- PF351022 Rotor Assembly 07.09.20 Added Ref.Cir.IB-406
12 2a ----------- LDA00025 Washer Plain-id 01.07.20 Added Ref.Cir.IB-397
12 4 ----------- PF531066 Cranksha Assembly 01.07.20 Added Ref.Cir.IB-397
8 14 ----------- PF511257 Chain 01.07.20 Added Ref.Cir.IB-397
8 1 ----------- PF511255 Camsha Assembly 01.07.20 Added Ref.Cir.IB-397
8 6 ----------- 36JZ0122 Kit Guide Cam Chain 01.07.20 Added Ref.Cir.IB-397
8 3 ----------- PF511258 Sprocket Camsha 01.07.20 Added Ref.Cir.IB-397
12 12 ----------- 36DM0010 Kit Connec ng Rod 16.07.19 Added
18 1 DY561400 PF561200 Lever Gear Shi Comp. 26.03.19 Upda on
34 4 31121029 PF581135 Element Assly. Filter Air 31.07.19 Added Ref.Cir.IB-370
4 3 JH521007 JB511019 Gasket Cylinder Head 26.03.19 Upda on

Page
No.
Figure
No.
Part Number
Page
No.
Figure
No.
Part Number
Parts Index Parts Index
Page
No.
Figure
No.
Part Number
Page
No.
Figure
No.
Part Number
30151041 12 58
30151038 20 62
30151038 17 60
30151041 20 56
30151038 13 56
30151011 15 62
30151038 21 58
30151005 2 62
30151005 18 60
30151011 16 60
30141031 24 50
30101154 13 30
30141031 3A 72
30101096 6 28
28101214 8 28
30101142 4 24
22150451 21 50
22150435 3 48
25201009 10 78
20201029 2 84
18201044 3 82
22150241 4 30
14151021 4 56
16151066 1 52
30151075 11 60
30151069 15 60
30151069 24 58
30151069 13 62
30151063 8 60
30151069 11 56
30181029 31 68
30181026 3 68
30181009 11 68
30171018 9 46
30181020 18 68
30161157 3 50
30151118 13 58
30161158 5 50
30151105 14 62
30151095 19 64
30151118 24 56
30151081 5 60
30151079 5 62
30151081 9 62
30151076 12 62
30151076 12 60
30151078 3 60
30151075 11 62
31181108 2A 68
31181099 20 68
31171012 16 46
31171006 7 46
31181019 19 68
31151014 16 58
31151014 4 58
31151064 19 56
31151011 23 58
31151011 12 56
31151014 18 56
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39071111 13 46
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31211004 6 86
31201081 5 22
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31201001 5 84
31201079 4 88
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39098004 10 28
39097204 8 40
39090012 26 56
39084914 9 40
39090012 15 58
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36JH0012 6 32
36DZ2008 3 44
36DU4084 2 32
36JE0024 4 28
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DD141227 10 72
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DD111012 6 42
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DD111048 4 42
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52PF1039 4 4
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DD181090 26 68
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DD181032 2B 68

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DH101380 5 40
DH101380 8 20
DH101048 5 8
DH101380 9 22
DG161124 2 50
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DL161017 9 72
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DK101610 4 36
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DM171027 4 46
DM171319 11 46

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DU151005 5 56
DU121052 5 34
DU101213 19 14
DU141095 4 72
DU101050 1 30
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DX191009 25 66
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DY581002 2 34
DY402202 14 88
DY401801 17 34
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DY401400 5 88
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DY232600 22 66
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JA541212 13 24
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JA541005 5 26
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JA531012 9 12
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FD181031 13 66
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FD181019 18 66
FD181030 12 66
FD101078 3 38
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FD181012 8 68
DZ201038 1 88

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Figure
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JB551408 5 28
JB551406 9 28
JB541201 22 24
JB531021 11 12
JB541224 3 26
JB511015 8 2
JB511011 4 2
JB511019 3 4
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JB571005 1 38
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JZ401403 26 66
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KAED0625 5 4
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KADD0885 8 44
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KADD0814 2 88
JZ561002 7 16
JZ551205 13 14
KACF0830 4 68
JZ551004 18 14

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Part Number
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PF161005 4 66
PF113009 2 92
PA621005 10 30
PA581224 7 4
PF113008 1 92
PA551207 2 14
PA551206 12 14
PA581221 10 32
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PA551205 14 14
LJA00011 6 4
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LDA00025 2a 12
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KPBF6201 4 20
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KPBB6202 9 60
KPBB6202 3 58
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KPBB6202 1 58
PF511258 3 8
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PF511209 1 8
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PF511255 1 8
PF501162 1 20
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PF511124 1 4
PF402210 16 84
PF401813 6 88
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PF401417 3 66
PF401005 1 84
PF401806 6 88
PF351243 2 42
PF351056 17 40
PF351252 2 42
PF351022 12 40
PF232603 5 72
PF351046 12 40
PF171803 6 72
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PF232603 22 66
PF161007 5 66
PF561203 5 18
PF561200 1 18
PF561000 1 16
PF551412 1 28
PF561002 5 16
PF551407 6 24
PF551206 9 14
PF551411 7 28
PF551203 10 14
PF551201 5 14
PF551204 11 14
PF551003 8 14
PF541263 4 26
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PF541254 18 24
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PF541074 2 20
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PF531066 4 12
PF531027 6 12
PF541018 7 20
PF531023 4 12
PF581058 13 34
PF581057 1 34
PF621411 6 40
PF621400 3 40
PF621003 7 30
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PF591239 1 36
PF581226 1 32
PF591269 1 36
PF581136 4a 34
PF581135 4 34

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