Boxer BM 100 ES_SPC 2022.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. JAN. 2022
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

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.
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.
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.
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.
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
Rr. Rear Std. Standard
C'case Crankcase Accl. Accelerator
Cyl Cylinder Comp. Complete
O/s Over size Fr. Front
R.H. Right hand L.H. Left hand
Hex. Hexagonal AR As required
L Length A/t. Alternate
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 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.
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.
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.
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.
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.
Assly Assembly V Volts
N.I. Not illustrated W Watts
Instructions

2 Cylinder Head 4
4 Camshaft / Tensioner 8
1 Cover Cylinder Head 2
3 Valve 6
5 Cylinder & Piston 10
6 Crankshaft 12
7 Transmission 14
8 Change Drum / Shift Fork 16
10 Engine Assembly / Crankcase RH 20
12 Clutch Cover 24
14 Clutch Assembly 28
15 Kick Starter Mechanism 30
11 Crankcase LH 22
16 Carburettor 32
17 Air Cleaner Complete 34
18 Silencer Assembly 36
20 Starter Assembly 40
23 Swing Arm / Rear Shock Absorber 46
9 Gear Change Mechanism 18
13 Cover Magneto 26
24 Fender - Front & Rear 48
25 Foot Rest / Holder / Stand 50
26 Wheel Rim / Spoke / Tyre / Tube 52
27 Front Wheel - Alloy 54
19 Oil Pump 38
21 Magneto / C.D.I. / H.T. Coil 42
22 Frame & Frame Fitting 44
31 Rear Hub - Alloy Wheel 62
29 Front Hub - Alloy Wheel 58
30 Rear Hub - Spoke Wheel 60
28 Front Hub - Spoke Wheel 56
Plate No. Page No.
Description Plate No. Page No.
Description
47 Painted Set With Decals 94
38 Meter Assembly 76
42 Tail Lamp Assembly & Number Plate 84
33 Handle Bar 66
34 Front Fork 68
36 Petrol Tank, Cap Tank and Gauge Fuel 72
41 Indicator Light Assembly 82
37 Chain Case 74
43 Seat Assembly & Grip Frame 86
40 Control Cables 80
46 Accessories 92
39 Head Lamp Assembly 78
32 Brake Pedal 64
45 Tool Kit 90
35 Fittings - Petrol Tank, Side Covers & Cover Seat 70
44 Electrical Equipments 88
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
2 59 0400 38 Bolt 4
7 DP 1210 25 Clamp (ID 12.5 MM) 2
5 JV 5110 11 Plate Cylinder Head 1
6 DY 5810 09 Tube Breather 1
1 JV 5110 13 Cover Cylinder Head Assly 1
3 JV 5110 12 Gasket Head Cover 1
4 JB 5110 11 Bolt Head Mounting 4 M8 X 1.25 X 190L
2
4
1
3
5
6
7
8

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

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

8 JE 5210 16 Tensioner Chain 1
1 Assly. Camshaft 1
PF 5112 09
6 36 PF00 61 Guide Chain Kit 1
36 JZ01 22 Kit Guide Cam Chain-D106A 1 Ref.Cir.IB-397
PF 5112 55 Camshaft Assembly 1 Ref.Cir.IB-397
14 DS 1099 05 Cam Chain (94 Link) 1
2 JA 5112 16 Spacer Cam Sprocket 1
16 JE 5110 49 Bearing Cam Shaft D102c 1
7 DH 1013 92 Cam chain Tensioner Pivot Bolt 1
PF 5112 58 Sprocket Camshaft 1 Ref.Cir.IB-397
11 KA ED06 20 Bolt M6 X 20 Silver 2
13 39 2669 21 ‘O’ Ring (Tensioner) 1
4 DK 1013 86 Precoated Soc Hd Cap Bolt 1
3 PF 5112 03 Sprocket Cam 1
10 DD 1010 62 Bolt M6 Chain Tensioner 1
PF 5112 57 Chain 1 Ref.Cir.IB-397
15 39 1988 20 Bearing Ball - Small 12 X 28 X 8 1
12 39 0594 17 Internal Circlip 1
17 DD 1010 62 Bolt 1 N.I.
9 CS 1011 28 Gasket 1
5 DH 1010 48 Special Washer Cam Shaft 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
2 39 1000 06 Dowel Pin 2
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
10
9
4
2
2
3
1
Qty

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

Plate No.: 7
Transmission
10 PF 5512 03 Gear 2nd Driven 1
19 DU 1012 13 Plate Lock Sprocket 1
8 PF 5510 03 Shaft Output Transmission (Driven) 1
1 PA 5510 02 Shaft Input Transmission (Drive) 1
15 JA 5510 08 Washer Thrust 1st Driven 1
6 PF 5512 00 Gear 2nd Drive 1
11 PF 5512 04 Gear 3rd Driven 1
13 JZ 5512 05 Bush 1st Driven 1
3 39 0987 17 Ring Snap (17.2 X 20.5 X 1.5) 5
16 JA 5510 09 Collar Sprocket Drive 1
17 59 2100 24 ‘O’ Ring Collar Sprocket (13.8 X 1.9) 1
2 PA 5512 07 Gear 4th Drive 1
12 PA 5512 06 Gear 4th Driven 1
18 JZ 5510 04 Sprocket Drive (Engine Sprocket) 1 14 Teeth N.S
20 DS 1013 55 Socket Head Bolt 2
5 PF 5512 01 Gear 3rd Drive 1
7 JA 5510 04 Washer Thrust 2nd Drive 1
14 PA 5512 05 Gear 1st Driven 1
4 JA 5510 02 Spline Washer (17.2 X 20.5 X 1.5) 3
9 PF 5512 06 2nd Driven Washer 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
6 JD 5610 04 Fork Gear Shift Output 1
7 JZ 5610 02 Fork Gear Shift Input 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
4 JD 5610 11 Special Bolt Drum Change 1 M6 X 1
5 PF 5610 02 Shaft Gear Shift Fork 2
16
15
4
7
6
1
3
5
2
Qty

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

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

Plate No.: 11
Crankcase LH
4 39 1715 19 Seal Oil 1
2 39 2562 20 Needle Roller Bearing 1
15 JV 5410 06 Cap Strainer 1
12 39 0999 06 Oil Pump 2
Pin Dowel -
16 59 2100 23 Ring ‘O’ 1
5 31 2010 81 Switch Complete 1
1 PF 5410 72 Crankcase LH 1
3 59 2000 36 6203 Ball Bearing 1
6 DH 1017 84 Gasket Neutral Switch (T1.5) 1 N.I.
7 39 2190 19 Oil Seal 1
11 39 1000 06 Hollow Dowel Pin 4 N.I.
13 JG 5710 24 Mesh Oi Filterl 1
14 LJ A000 04 ‘O’ Ring Strainer 1
9 DH 1013 80 Screw Pan Head (m6x12) 1
17 59 0400 38 Flange - Bolt 7
18 KA ED06 25 Bolt-Flange 2
10 JH 5410 21 Bracket Gear Stopper C101d 1
8 JA 5410 05 Bush Bendix 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
10 JE 5412 14 Spring TTorsion Clutch Lever 1
1 36 DU40 79 Cover Clutch 1
2 JV 5412 25 Label Cover Clutch 1
11 JA 5412 11 Cap Oil Filler 1
5 JV 5412 08 Shaft Clutch Release Assy 1
6 PF 5514 07 Rod Push 1
8 DS 1012 15 Clip - Wire 1
3 39 1041 19 Seal - Oil 1
4 30 1011 42 Seal - Oil 1
7 JL 5412 27 Window Oil Guage 1
13 JA 5412 12 Gasket Clutch Cover 1
20 39 0999 06 Pin - Hollow Dowel 2
9 39 2443 11 Washer - Plain 1
22 JB 5412 01 Jet Clutch Cover Disco M 1
21 31 1010 64 Plug 1
23 BA 1020 04 Plug 1
18 PF 5412 54 Cap Filter B104e 1
17 39 1671 21 Ring - O 1
15 PF 5412 55 Bracket Clutch Cable 1
16 DD 121 181 Element Oil Filter 1
19 LA E000 05 Bolt - Flange :- M6 3
14 59 0400 38 Bolt 8
12 JA 5412 25 O Ring Cap Oil Filler 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
5 JA 5410 05 Bush 1
6 JA 5412 11 Cap Oil Filler 1
3 JB 5412 24 Gasket Cover Magneto 1
9 Decal Magneto Cover 1
PF 5412 49
8 DS 1611 50 Sticker Gear Shifting 1
1 Assembly Magneto Cover 1
52 JV01 43
7 JA 5412 25 O Ring Cap Oil Filler 1
2 Bolt 9
59 0400 38
4 PF 5412 63 Assembly Cover LH 1
26
25
Qty

Plate No.: 14
Clutch Assembly
2 JA 5514 06 Collar Clutch 1
4 Plate Clutch Friction 5
36 JE00 24
14 39 1001 20 Bearing Ball 1
3 39 2600 11 Washer 1
11 Belleville Washer 1
JE 5514 09
10 39 0980 04 Bolt Hexagon Head 6
12 JA 5514 20 Plain Washer 1
13 52 JA00 28 Nut Special M14 1
7 PF 5514 11 Hub Clutch 1
15 36 JZ00 23 Set Primary Drive & Driven 1
8 28 1012 14 Spring Clutch 6
9 Holder Clutch (Modified) 1
JB 5514 06
1 PF 5514 12 Assembly Clutch 1
5 JB 5514 08 Wheel Clutch 1
6 30 1010 96 Plate Clutch (Steel Plate) 4
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
2 JA 6212 06 Bolt Flange 1
1 DU 1010 50 1
Assembly Kick Shaft
4 22 1502 41 Plain Washer 1
5 39 0993 11 Plain Washer Small 3
6 39 0738 17 Circlip Shaft 2
3 Boss 1
36 DU10 07
7 PF 6210 03 Shaft Kick 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
11 JA 6210 06 Washer Thrust (16.2 X 25 X 0.5) 1
9 JA 6210 02 Ratchet 1
13 30 1011 54 Kick Rubber 1
14 JE 6210 03 Spring 1
30
29
1
14
2
4
3
12
6
7
8
9
10
5
11
13
5
5
Qty

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

Plate No.: 17
Air Cleaner Complete
6 DH 1211 03 Duct 1
12 JY 5810 28 Clamp 1
2 DY 5810 02 Cover Air Filter 1
4a PF 5811 36 Element Filter Air 1 Single Element Air Filter
10 DY 5810 09 Tube Breather 1
9 DY 5810 10 Tube Drain 1
11 DG 1210 40 Clamp 1
17 DY 4018 01 Pad Battery 1
8 DP 1210 25 Clamp 2
13 PF 5810 58 Tube Connecting 1
16 DY 5810 05 Spacer Battery 1
3 LB U000 07 Screw Truss 8
14 DM 2210 01 Band For Tool Kit 1
7 DS 1211 26 Plug 1
15 JL 1810 26 Clip Nut 2
5 DU 1210 52 Ring Seal 1
1 PF 5810 57 Assembly Air Filter 1
4 PF 5811 35 Element Assembly Filter Air 1 Added Ref.Cir.IB-370
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
JE 5912 80 Gasket Exhaust 1 Ref.Cir.IB-406
6 39 2722 04 Socket HD Bolt 1
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
3 39 2295 15 Nut Flanged- Ex.tube-cyl Head 1
4 DK 1016 10 Bolt (m5) (ss 304) 1
36
35
Qty
3
1
2
4
6
5

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

Plate No.: 20
Starter Assembly
40
39
16 PF 5412 42 Bracket Stator Harness 1
PF 3510 22 Rotor Assembly 1 Ref.Cir.IB-406
14 DH 1013 80 Screw Pan Head 2
13 LA C000 52 Bolt Socket 2
PF 3510 56 Stator Assembly 1 Ref.Cir.IB-406
15 KB BC06 08 Screw Pan Cross 1
17 DY 3510 04 Assembly Stator 1
11 DK 1016 05 Plate Roller Clutch 1
12 PF 3510 46 Rotor Assembly 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
10 36 DK00 76 Kit Starter Clutch Assembly Dk101595 1
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
8 39 0972 04 Bolt Socket (m6x14) 3
9 39 0849 14 Washer - Lock Toothed 3
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
2 PF 3512 43 CDI 1
3 CF 1110 19 Plug - Spark 1
5 DD 1110 11 Grommet Spark Plug Cap LH 1
6 DD 1110 12 Grommet for HT Cable 1
PF 3512 52 CDI 1 Ref.Cir.IB-406
4 DD 1110 48 Spark Plug Cap LH 1
7 39 1943 04 Bolt Flange M6 2
1 DY 3512 01 COIL HT With Cable 1
42
41
3
5
7
4
6
1
2
Qty

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

Plate No.: 23
SWING ARM / REAR SHOCK ABSORBER
9 30 1710 18 Bushing Rubber 2
1 39 2366 15 Nut Domed Cap 2
4 DM 1710 27 Rear Shock Absorber 2
7 31 1710 06 Shaft Swing Arm 1
3 39 0714 11 Washer Plain 4
6 KB RB35 13 Screw Tapping Pan Cross 2
13 39 0711 11 Washer Plain 2
2 39 0737 12 Washer Spring 4
14 39 0292 15 Hex Nut 4
5 39 0454 11 Plain washer 2
10 39 1225 15 Nut Hex./ flange 1
11 DM 1713 19 Arm Comp. Swing / Bush 1
15 52 DZ00 47 Adjuster Chain (LH) 1
DM 1713 20 Shock Absorber Rear 2
16 31 1710 12 Damper for Swing arm 1
12 52 DZ00 46 Chain Adjuster (RH) 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
8 39 2222 04 Bolt Flange M8 4
2 DF 1612 45 Mud Flap Front 1
11 39 2484 15 Nut 1 N.I.
10 30 2010 69 Reflector Reflex 1
5 39 2484 15 Nut Flange M5 2
1 DF 1612 42 Fender Front 1
3 22 1504 35 Bolt 2
6 DF 1910 20 Clamp 1
7 KA DD06 12 Bolt Flange 1
9 DF 1611 04 Fender Rear 1
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
7 DF 1611 02 Bolt 1
9 DH 1610 66 Spring Side Stand 1
4 39 0797 08 Pin Cotter 1
16 DU 1612 59 Stay Pillion LH 1
18 Dx 1610 56 Rubber Pillion Step 1
15 DX 1610 67 Plate Lock Pillion Step 1 N.I.
13 DF 1614 13 Rubber Main Step 2
24 30 1410 31 Ring O 1
1 DU 1610 32 Stand - Center 1
2 DG 1611 24 Damper 1
3 30 1611 57 Shaft Stand 1
5 30 1611 58 Spring 1
6 DY 1132 00 Stand Side 1
8 39 0422 15 Nut Nyloc M10 1
10 DU 1613 25 Holder Assembly Step Rider 1
12 39 2481 04 Bolt Hexagon Head With Flange M8 2 N.I.
14 DG 1612 24 Damper 1
17 DM 1612 06 Holder Assembly Step Pillion RH 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
26 KH AA25 20 Pin - Split 1
25 39 1040 11 Washer-plain 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
8 DS 1510 10 Spoke Outer Rear 18
7 DS 1510 09 Spoke Inner Rear 18
10 DM 1510 27 Tyre and Tube Rear 1
5 DS 1510 46 Rim 1.85 X 17 Rear 1
9 DM 1510 24 Tyre With Tube Front 2.75x17 1
3 DU 1510 26 Spoke Outer Front 18
6 DG 1510 22 Band Rim 2
1 16 1510 66 Nipple Spoke 72
2 DU 1510 25 Spoke Inner Front (Drum) 18
4 DM 1510 29 Rim - 1.60 X 17 Drum bake -Dia. 110 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
3 DM 1513 23 Wheel Rim Rear (5 Spoke) 1
4 DM 1510 27 Tyre with Tube Rear 1
2 DM 1510 24 Tyre with Tube Front 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
14 DD 1510 09 Indicator Front 1
15 DD 1510 08 Lever Brake Cam 1
13 30 1510 38 'O' Ring 1
16 39 0775 04 Bolt M6 X 30 1
25 39 1013 21 O Ring 1
19 31 1510 64 Gear Speedometer 1
21 39 0242 11 Washer for Speedo Gear 1
22 JA 1316 06 Bush for Speedo Gear 1
24 30 1511 18 Stopper For Bushing 1
20 30 1510 41 Gear Meter Screw 1
17 39 0798 15 Nut Hex. Flange M6 1
18 31 1510 14 Seal Oil 1
23 KB BA04 08 Screw Pan Cross M4 for Speedo Cable 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
2 31 1510 04 Collar 1
1 KP BB62 02 Ball Bearing 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
11 39 0248 11 Washer Plain 2
25 JB 1318 04 Shoe Brake 2 Non Asbestos
15 39 0900 12 Spring Washer 1
19 39 0775 04 Bolt 1
21 30 1510 38 Ring O 1
20 DD 1510 09 Indicator Front 1
14 39 0840 01 Screw Pan Cross 1
23 31 1510 11 Cam Brake 1
22 DZ 1510 27 Panel Front Brake 4
12 30 1510 41 Gear Meter Screw 1
16 31 1510 14 Oil Seal 1
24 30 1510 69 Spring 2
13 30 1511 18 Stopper for Bushing 1
17 DS 1510 94 Flange Nut 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 Drive Chain Connecting Link 1
3 30 1510 78 Coupling 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
2 36 DU41 69 Kit Chain Sprocket 1
10 KP BB63 02 Bearing-Ball-C3 Clearance 1
4 39 2240 20 Bearing - Ball 1
14 JN 1318 12 Brake Shoe Kit (Non Asbestos) 1
22 DM 1510 32 Axle M14 X 1.5 1
18 30 1510 05 Indicator 1
15 30 1510 69 Spring 2
17 30 1510 38 O Ring 1
11 30 1510 75 Collar Bearing 1
19 DD 1510 15 Lever - Brake Cam In Forging 1
20 KC AA10 08 Screw - Hexagon Head 1
12 30 1510 76 Damper 1
13 DM 1513 17 Panel Rear Brake 1
21 39 0798 15 Nut Hexagon With Flange M6 1
23 DM 1710 22 Spacer 1
16 30 1510 11 Cam Brake Assly 1
25 DH 1710 19 U Nut Swing Arm 1
24 39 2566 11 Plain Washer 1

Plate No.: 31
Rear Hub - Alloy Wheel
2 30 1510 05 Indicator 1
4 39 2240 20 Bearing Ball 1
9 30 1510 81 Lock Washer 2
1 39 0292 15 Nut Hex. 1
3 36 DU41 69 Kit Chain Sprocket 1
5 30 1510 79 Sleeve 1
6 DM 1513 24 Coupling 1
7 DP 1510 28 Bolt 4
8 39 0694 15 Nut Hex. 4
10 KP BB63 02 Bearing-ball-c3 Clearance 1
13 30 1510 69 Spring 2
14 30 1511 05 Shoe Brake 1
16 DS 1510 69 Panel Rear Brake 1
17 DM 1510 32 Axle 1
19 DH 1710 19 ‘U’ Nut Swing Arm 1
12 30 1510 76 Damper 4
11 30 1510 75 Collar Bearing 2
20 30 1510 38 Ring O 1
21 39 0798 15 Flange Nut 1
23 39 0798 15 Hex Nut 1
24 KP BB62 02 Bearing-ball-c3 Clearance 1
15 30 1510 11 Brake Cam 1
18 39 2566 11 Washer Plain 1
62
61
Qty
17
23
22
12
1
3
8
4
9
7
1
13
14
16
15
18 19
21
2
6
5
11
20
24
10

Plate No.: 32
Brake Pedal
64
1 DY 1610 04 Assembly Pedal Brake 1
2 DM 1910 10 Rod brake 1
19 30 1510 95 Bolt Hex. 1
7 39 0797 08 Pin Cotter 1
21 1
JA 1610 03 Pad Brake Lever
20 39 0708 15 Nut Hex. M10 X 1.25 1
3 30 1910 38 Pin 1
11 30 1910 37 Pin Brake Rod 1
12 30 1910 36 Nut Brake Adjuster 1
22 DD 1610 78 Damper 1
8 30 1910 31 Spring 1
10 30 1910 35 Spring 1
18 39 0807 08 Split Pin 2
17 39 0694 15 Hex. Lock Nut M8 x 1.25 1
15 39 1540 11 Plain Washer 1
5 39 0808 08 Split pin 1
13 DM 1513 17 Rod Torque 1
14 DH 1510 29 Step Bolt Torque Rod 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
7 DS 1910 52 Boot for Lever LH 1
14 39 1074 04 Bolt Flanged Small 4
11 Mirror Assy RH 1
DJ 2210 04
9 DS 1910 18 Boot for Lever RH 1
3 Control Switch RH 1
PF 4014 17
8 1
DD 1911 42 Lever - Grip :- Right
1 Handle Bar 1
DU 1811 14
12 FD 1810 30 Holder Handle Upper 2
10 Mirror Assy Left Hand 1
DJ 2210 03
17 39 2249 15 Nut- Nyloc M-10 2
5 PF 1610 07 Grip Assly. RH 1
6 PF 1610 15 Lever Clutch 1
15 DF 1810 91 Damper Handle Upper 2
18 FD 1810 19 Washer Plain 1
20 59 0400 06 Hex Head Bolt 2
16 DF 1810 92 Damper Handle Lower 2
2 JB 4014 00 Control Switch LH 1
4 PF 1610 05 Grip LH 1
13 FD 1810 31 Holder Handle Lower 2
21 JD 4022 17 Band 2
22 PF 2326 03 Lock Set 1
19 FD 1810 20 Washer Plain 1
DY 2326 00 Set Lock 1 Ref.Cir.IB-406
23 39 1943 04 Bolt Flanged 2
24 JZ 1610 28 Lever Pivot Bolt 1 N.I.
25 DX 1910 09 Switch Assembly (with Lever) 1 N.I.
26 JZ 4014 03 Switch Clutch (vb) Diode 1
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
27 DD 1810 91 Cover - Trail 1
2 DU 1811 08 Oil Seal 2
21 DF 1810 85 Seat 2
15 Tube Outer LH 1
DU 1811 01
6 DE 1810 31 Spring Front Fork 2
26 DD 1810 90 Cover - Trail :-B 1
31 30 1810 29 Ring ‘O’ 2
2A 31 1811 08 Ring Snap 2
14 39 1813 04 Bolt M10X1.25 2
18 30 1810 20 Piston Ring 1
19 31 1810 19 Cap Oil Lock 1
4 KA CF08 30 socket Head Bolt 2
DM 1810 54 Fork Front 1 Ref.Cir.IB-406
2B DD 1810 32 Seal Dust 2
5 DM 1810 36 Pipe Complete-Suspension - Inner 2
8 FD 1810 12 Cap Nut Fork 1
9 DF 1810 89 Plain Washer 1
17 PA 1210 41 Seat Pipe 1
23 DM 1810 38 Cover : Cover Fork LH 2
25 DM 1810 10 Washer 2
3 30 1810 26 Gasket 2
DM 1810 55 Cover Fork RH 1 Ref.Cir.IB-406
1 Front Fork 1
DM 1810 43
10 DD 1812 05 Holder Fork Upper 1
11 Bearing Cone Fork 1
30 1810 09
12 DD 1812 07 Holder Fork Under W/o Lock Bracket 1
16 Tube Outer RH 1
DU 1811 02
20 Rebound Spring 1
31 1810 99
7 31 1811 20 Bolt Fork with Washer 2
22 DM 1810 39 Cover : Cover Fork RH 1
24 JK 1210 08 Spacer Tube 2
28 DF 1810 88 Damper Fork Covr Fr.fork 1
29 DU 1810 99 Leg Assembly LH 1 N.I.
30 DU 1811 00 Leg Assembly RH 1 N.I.
Qty

Plate No.: 35
Fittings - Petrol Tank, Side Covers & Cover Seat
5 39 1789 24 Washer Nylon 3
6 39 1902 04 Pin Snap 1
2 DG 1611 21 Screw 1
1 DH 1611 58 Grommet Side Cover Front 2
4 DG 1410 19 Damper Tank Rear 2
3 DU 1611 02 Damper 1
7 DP 2010 37 Plain Washer 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
1 DF 1411 20 Cap Assy-tank With Plastic Hub 1
2 AP 1012 55 Screw Pan Cross 2
3 39 2179 24 Washer 2
4 DU 1410 95 Fuel Cock Assy 1
5 PF 2326 03 Lock Kit 1
DY 2326 00 Set Lock 1 Ref.Cir.IB-406
3A 30 1410 31 ‘O’ Ring 2
6 PF 1718 03 Pipe Fuel 1 Cock to Carburettor
7 33 1410 08 Clamp 2
8 DG 1410 19 Damper 2
9 DL 1610 17 Damper For Side Cover 2 N.I.
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
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.
3 DH 1612 83 Bolt Flanged M6 4
5 DF 1614 16 Cap - Case Chain 1
4 DF 1614 15 Beading Chain Case 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
6 Damper I 2
DD 2010 09
8 Flange Bolt M-8 L 35 2
39 1683 04
10 Lamp 12 V 35/35 W HS1 1
25 2010 09
3 30 2010 69 Reflector Reflex 1
11 DF 2010 58 Lamp Holder (Socket) Assly. 1
2 DJ 2010 46 Head Light Rim 1
4 DU 2010 29 Special Screw 2
5 DU 2010 60 Collar 2
1 Head Light Assy/ Lmp 1
DM 2010 22
7 Damper II 2
DD 2010 10
9 39 1970 15 Flange Nut M-8 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
4 39 1225 15 Hex. Nut Flange M-10 4
DM 2010 30 Indicator Assly RR RH With Lamp 2
2 DM 2010 29 Indicator Assly RR LH With Lamp 2
DM 2010 28 Indicator Assly FR RH With Lamp 2
3 18 2010 44 Lamp :- 12V - 10W - R 10W 4
82
81
1
2
3
4
Qty

Plate No.: 42
Tail Lamp Assly & Number Plate
8 39 2476 04 Bolt - Hex Head With Flange 2
16 PF 4022 10 Boot 1
7 DF 161248 BKT- Number. Plate 1
1 PF 4010 05 Tail Light Assly 1
13 39 1783 01 Truss Screw 2
2 20 2010 29 Lamp 12 V, 21/5W 1
10 39 2475 04 Hex. Head Bolt/flange M6 2
5 31 2010 01 Collar 2
9 DF 1612 52 Plate - Number :- Rear In Black 1
11 DF 1612 51 Plate - Number :- Front In Black 1
4 DD 2010 11 Damper 2
15 39 1211 11 Plain Washer 2
3 39 2430 15 Hex Nut. / Flange 2
12 DF 1810 97 Bracket Plate No. Front 1
14 39 1553 04 Bolt Flange 2
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
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
1 DM 2110 21 Seat Asy. comp. rear Hook 1
2 FD 2110 06 Grommet Seat 2
86
85
7
8
Qty
1
2
3
4
5
6

Plate No.: 44
Electrical Equipments
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
1 DZ 2010 38 Dc Horn 1
6 PF 4018 06 3AH Vrla Dry Battery (Without Acid Bottle) 1
JG 4018 06 Battery 12v 6ah Vrla Dry Without Acid Bo 1 Ref.Cir.IB-428
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
13 DK 2010 78 Starter Relay- With Nut 1
18 JZ 4022 18 Cable Tie (white Color L200) 1 N.I
16 JZ 4022 16 Cap (Starter Motor) 1
JG 4018 07 Bottle Acid 6ah 1 Ref.Cir.IB-428
PF 4022 39 Cable Assly. Battery To Earth 1 Ref.Cir.IB-428
JZ 4020 02 Regulator Assembly 1 Ref.Cir.IB-406
19 31 2010 21 Clamp 1
20 PF 4034 00 Socket Charger 1 Ref.Cir.IB-406
21 PF 4018 13 Acid Bottle For 3ah Vrla Dry Battery 1
17 DJ 2012 19 Assy. Fuse Box 1
15 JV 4022 04 Cable Assly. St Relay To Motor 1
12 KA DF06 16 Bolt Flanged 2 N.I.
14 DY 4022 02 Cable Earth 1
11 JN 4020 00 RR Unit With Capacitor 1
88
87
Qty
6
4 5
3
1
2
16
19
17
11
7
10
13
15
14
20
21

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
5 DZ 2210 03 Leg Guard 1
8 DF 2210 54 Guard Sari 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
6 KA DF08 85 Bolt Flanged 1
7 KC GA08 08 Nut Hex Flanged 1
4
1
8
2
3
Qty
5
6
7
4

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

4 36PF0062 KIT PISTON RING SET JB521207 RING PISTON (TOP) 1
6 36PF0045 KIT BLOCK PISTON-B104D PF521022 BLOCK CYLINDER 1
7 36JZ0023 KIT PRIMY DRIVE & DRIVEN PF551401 CLUTCH HSG ASSLY COMP 1
JE541016 GUIDE CAM CHAIN SLACK SIDE 1
PF521229 PISTON ASSEMBLY 1
8 36314005 KIT ST. CONE KIT 36314001 KIT STEERING CONE NEW 1
PF521204 RING PISTON OIL 1
5 36DK0076 KIT STARTER CLUTCH DK101595 BODY STARTER CLUTCH 1
36314002 KIT BALL STEEL STEERING 1
PF511212 VALVE INTAKE 1
DM141042 DECAL TANK LH BLACK BODY 1
JZ531006 GEAR PRIMARY DRIVE 1
CB101009 SEAL - VALVE STEM 1
1 36DU4076 VALVE KIT PF511213 VALVE EXHAUST 1
39084914 WASHER - LOCK :- TOOTHED 1
DY511202 RETAINER VALVE 1
JA511202 SPRING VALVE 1
CB101022 COTTER VALVE
3 36PF0061 GUIDE CHAIN KIT JE521019 GUIDE CAM CHAIN TIGHT 1
1
PF521215 STEEL 2ND RING PISTON B104D 1
2 36JV0006 VALVE REPAIR KIT 28101129 SPRING - SEAT 1
DK101596 SPRING STARTER CLUTCH 1
PF521210 PISTON ASSEMBLY 1
9 36DM0007 KIT TANK DCL EB BLACK DM141043 DECAL TANK RH BLACK BODY 1
36001052 GREASE LETHON RR3 -10GM 1
Kit List
Kit
Part No.
Kit Description
Part No. Description Qty/Kit
Consisting of Following Parts
Sr
No
11 36DM0009 KIT TANK DCL EC BLUE DM141047 DECAL TANK RH 1
10 36DM0008 KIT TANK DCL FLAME RED DM141039 DECAL TANK RH RED BODY 1
DM141038 DECAL TANK LH RED BODY 1
DM141046 DECAL TANK LH 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.
34 4 31121029 PF581135 Element Assly. Filter Air 31.07.19 Added Ref.Cir.IB-370
8 3 ----------- PF511258 Sprocket Camsha 01.07.20 Added Ref.Cir.IB-397
40 17 ----------- PF351056 Stator Assembly 07.09.20 Added Ref.Cir.IB-406
18 1 DY561400 PF561200 Lever Gear Shi Comp. 26.03.19 Upda on
68 22 ----------- DM181055 Cover Fork RH 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
88 7 ----------- DY113803 Clamp Assembly Ba ery 07.09.20 Added Ref.Cir.IB-406
8 6 ----------- 36JZ0122 Kit Guide Cam Chain 01.07.20 Added Ref.Cir.IB-397
88 11 ----------- JZ402002 Regulator Assembly 07.09.20 Added Ref.Cir.IB-406
66 22 ----------- DY232600 Set Lock 07.09.20 Added Ref.Cir.IB-406
36 1 ----------- PF591239 Silencer Assembly 13.04.21 Added Ref.Cir.IB-426
42 2 ----------- PF351252 CDI 07.09.20 Added Ref.Cir.IB-406
12 2a ----------- LDA00025 Washer Plain-id 01.07.20 Added Ref.Cir.IB-397
20 1 ----------- PF501162 Engine Assembly 07.09.20 Added Ref.Cir.IB-406
8 14 ----------- PF511257 Chain 01.07.20 Added Ref.Cir.IB-397
12 12 ----------- 36DM0010 Kit Connec ng Rod 16.07.19 Added
12 4 ----------- PF531066 Cranksha Assembly 01.07.20 Added Ref.Cir.IB-397
4 3 JH521007 JB511019 Gasket Cylinder Head 26.03.19 Upda on
36 2 ----------- JE591280 Gasket Exhaust 07.09.20 Added Ref.Cir.IB-406
8 1 ----------- PF511255 Camsha Assembly 01.07.20 Added Ref.Cir.IB-397
40 12 ----------- PF351022 Rotor Assembly 07.09.20 Added Ref.Cir.IB-406
44 1 ----------- DM161217 Frame Assembly 07.09.20 Added Ref.Cir.IB-406
68 1 ----------- DM181054 Fork Front 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
88 20 ----------- PF403400 Socket Charger 07.09.20 Added Ref.Cir.IB-406
88 21 --------- JG401807 Bo le Acid 6ah 30.06.21 Ref.Cir.IB-428
88 14 --------- PF402239 Cable Ba ery To Earth 30.06.21 Ref.Cir.IB-428
88 6 --------- JG401806 Ba ery 12v 6ah Vrla Dry 30.06.21 Ref.Cir.IB-428

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
14151021 4 56
16151066 1 52
18201044 3 82
20201029 2 84
30151041 20 56
30101154 13 30
22150451 21 50
30101096 6 28
30141031 3A 72
30151011 15 62
30151038 17 60
30151041 12 58
30101142 4 24
30151038 21 58
30151038 20 62
22150435 3 48
30151005 18 60
22150241 4 30
30141031 24 50
30151038 13 56
30151005 2 62
25201009 10 78
30151011 16 60
28101214 8 28 30151076 12 62
30151118 13 58
30161158 5 50
30181009 11 68
30151069 11 56
30151075 11 60
30151069 15 60
30151069 13 62
30151076 12 60
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36DZ2008 3 44
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36JV0006 5 6
36JZ0122 6 8
36PF0061 6 8
36JH0040 3 32
36JH0044 15 32
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39019811 4 64
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39198820 15 8
39224020 4 62
39224020 4 60

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39240817 12 30
39268120 1A 56
52DM0553 1 94
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39248415 11 48
39256220 2 22
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DF161242 4 94
DD201011 4 84
DF161252 9 84

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DG151022 6 52
DF181092 16 66
DF181088 28 68
DF181090 2 44
DF181097 12 84
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DM201050 3 88
DM221020 7 86

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DS191052 7 66
DU101050 1 30
DS151094 17 58
DU141095 4 72
DU101213 19 14
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DS151010 8 52
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DY113200 6 50
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DY232600 5 72
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DY401800 7 88
DY113803 7 88
DY161004 1 64
DY401400 5 88
DY401801 17 34
DY581009 6 2
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FD181031 13 66
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JA161003 21 64
JA531012 9 12
JA541005 5 26
JA541012 13 20
JA541211 11 24
JA541211 6 26
JA541212 13 24

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JA551009 16 14
JA541225 12 24
JA541225 7 26
JA551002 4 14
JA551004 7 14
JA551008 15 14
JA551420 12 28
JA561002 3 16
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JB401400 2 66
JB541201 22 24
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JB581230 8 32
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JV511011 5 2
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JV541208 5 24
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JW561206 2 18
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JZ402216 16 88
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KAED0625 2 40
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KADD0814 2 88
KADF0885 6 92
KACF0830 4 68
KBBA0408 23 56
KAED0625 5 4
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KADD0612 7 48
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KCAA1008 20 60
KADD0885 8 44
KADD0880 7 44
KAED0625 18 22
JZ561002 7 16
KCGA0808 7 92
KADD0814 11 50

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KPBB6302 10 62
LJA00004 14 22
PA402204 9 88
PA551205 14 14
LDA00025 2a 12
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KHAA2520 26 50
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LAC00052 13 40
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LAE00005 19 24
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PF232603 22 66
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PF501162 1 20
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PF621400 3 40
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