Spare Parts Catalogue: (Export)

Bajaj Auto Limited
Akurdi Pune 411 035 India

Tel +91 20 27472851
Fax +91 20 27407385
www.bajajauto.com
Spare Parts Catalogue
( EXPORT )
Notice
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.
DOC. NO.: 71110890 REV. 00, MAY. 10

Foreword Instructions
We have pleasure in presenting the Spare Parts Catalogue for ‘Discover 1. How to Read the Catalogue : Open the catalogue and from the pictorial
DTS-Si’ Motorcycle. This catalogue has been specially designed to assist 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).
you in selecting the correct parts for procurement to maintain 100%
Now find out the figure of the part you wish to order. Write down the
availability. 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
The Bajaj spares are subjected to the stringent quality control standards to part index can be used. The part index (at the end of the catalogue) will
ensure longer life of the vehicle. It is therefore necessary that only the give you the figure and page number of the part you wish to order.
Genuine Bajaj Spares are used.
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
In a continual effort to improve Performance and Efficiency of the vehicles, catalogue text.
Specifications, Diagrams, Illustrations and Part Numbers can change without
The latest part number as conveyed through our service circulars should
notice. Consequently, the description in this Spare Parts Catalogue cannot only appear on the order. In case of ordering painted components,
therefore be final and binding on us. colour shade of the components should be mentioned.
The quantity shown against the part number is the quantity per vehicle
The modifications / alterations which are carried out after the issue of this for that group so that particular quantity should be multiplied by the
catalogue, will be conveyed to you through our Service Circulars. You are number of sets required.
requested to make necessary corrections in the Parts Catalogue as per the
3. Part Number System : We have used 8 digit system for part numbers.
circulars so as to keep your catalogue up-to-date. This will ensure the The model or hardware item is indicated by first two digits or
appropriate and speedy delivery of the Spare Parts as the order placed will alphanumeric, the next two or four digits indicate main group and the last
bear the latest part numbers. 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
In case, if you need any technical assistance contact the concerned Regional enable you to identify the spare parts easily.
Office or write to us on the following address :
4. Abbreviations : The following abbreviations are used in this catalogue.
Assly Assembly V Volts
Bajaj Auto Limited
N.I. Not illustrated W Watts
Service Department
C'case Crankcase Accl. Accelerator
Akurdi, Pune 411 035 India Cyl Cylinder Comp. Complete
Phone : 020-27406557 O/s Over size Fr. Front
Fax : 020-27407385 Rr. Rear Std. Standard
L Length A/t. Alternate
R.H. Right hand L.H. Left hand
Hex. Hexagonal AR As required
Index Index
Plate No. Description Page No. Plate No. Description Page No.
1 Cover Cylinder Head 2 31 Front Hub 62, 64

2 Cylinder Head 4 32 Rear Hub 66, 68
3 Valve 6 33 Rear Brake Pedal 70
4 Camshaft / Tensioner 8 34 Handle Bar 72, 74
5 Cylinder & Piston 10 35 Front Fork 76, 78
6 Crankshaft 12 36 Painted Parts & Decals 80, 82, 84
7 Transmission 14 37 Petrol Tank, Cap Tank & Gauge Fuel 86
8 Change Drum / Shift Fork 16 38 Fittings - Petrol Tank, Side Cover & Cover Seat 88
9 Gear Change Mechanism 18 39 Meter Assly. 90
10 Engine Assly & Crankcase RH 20 40 Control Cables 92
11 Crankcase LH 22 41 Chain Case 94
12 Cover RH 24 42 Head Lamp & Fairing 96, 98, 100
13 Cover Magneto 26 43 Indicator Light Assly. 102
14 Clutch 28 44 Tail Lamp Assly. / Front No. Plate 104
15 Kick Starter Mechanism 30 45 Electrical Equipments 106, 108
16 Carburettor 32 46 Tool Kit 110
17 Air Cleaner Complete 34 47 Accessories / Grab Handle 112
18 Silencer Assly 36
19 Oil Pump 38 Kits List For Discover 113, 114,115
20 Starter Assly 40
21 Magneto / C.D.I. / H.T. Coil 42 Amendment Sheet (Parts Added) 116,117
22 Seat Assly / Seat Lock 44
23 Engine Mountings 46 Amendment Sheet (Parts Deleted) 118
24 Frame & Frame Fitting 48
25 Swing Arm / Rear Shock Absorber 50 Part Index 119 - 131
26 Rider Foot Rest 52
27 Pillion Foot Rest / Holder 54
28 Mudguard Front & Rear 56
29 Stand Assembly 58
30 Tyre/ Tube / Rim 60
Pictorial Index Pictorial Index
PLATE NO. : 1 PAGE NO. PLATE NO. : 2 PAGE NO. PLATE NO. : 5 PAGE NO. PLATE NO. : 6 PAGE NO.
COVER CYLINDER HEAD 2 CYLINDER HEAD 4 CYLINDER & PISTON 10 CRANKSHAFT 12
VALVE 6 CAMSHAFT / TENSIONER 8 TRANSMISSION 14 CHANGE DRUM / SHIFT FORK 16
GEAR CHANGE MECHANISM 18 ENGINE ASSLY & CRANKCASE RH 20 COVER MAGNETO 26 CLUTCH 28
DT
S-i
CRANKCASE LH 22 COVER RH 24 KICK STARTER MECHANISM 30 CARBURETOR 32
AIR CLEANER COMPLETE 34 SILENCER ASSLY 36 MAGNETO / C.D.I. / H.T. COIL 42 SEAT ASSLY / SEAT LOCK 44
OIL PUMP 38 STARTER ASSLY 40 ENGINE MOUNTINGS 46 FRAME & FRAME FITTINGS 48
SWING ARM / RR. SHOCK ABSORBER 50 RIDER FOOT REST 52 STAND ASSLY 58 TYRE / TUBE / RIM 60
PILLION FOOT REST / HOLDER 54 MUDGUARD FRONT & REAR 56 FRONT HUB 62, 64 REAR HUB 66, 68
PLATE NO. : 37 PLATE NO. : 38
PLATE NO. : 33 PAGE NO. PLATE NO. : 34 PAGE NO. PAGE NO. PAGE NO.
PETROL TANK, CAP TANK & FITTINGS- PETROL TANK, SIDE
REAR BRAKE PEDAL 70 HANDLE BAR 72, 74 86 88
GAUGE FUEL COVERS & COVER SEAT
FRONT FORK 76, 78 PAINTED PARTS & DECALS 80,82,84 METER ASSEMBLY 90 CONTROL CABLE 92
CHAIN CASE 94 HEAD LAMP & FAIRING 96,98,100 ELECTRICAL EQUIPMENTS 106, 108 TOOL KIT 110
PLATE NO. : 44
PLATE NO. : 43 PAGE NO. PAGE NO. PLATE NO. : 47 PAGE NO.
TAIL LAMP ASSLY. / FRONT
INDICATOR LIGHT ASSEMBLY 102 104 ACCESSORIES / GRAB HANDLE 112
NUMBER PLATE
Plate No.: 1 Brand ID: 001MC639
Cover Cylinder Head
No. Part No. Description Qty Remarks
2
1 JZ 5110 21 Cover Cylinder Head 1
2 59 0400 38 Bolt Flange 4
1 3 JD 5110 10 Gasket Head Cover 1
4 JB 5110 11 Bolt Head Mounting 4
5 PF 5110 27 Plate Cylinder Head 1
7
6 JZ 5810 04 Hose C’ case Breather 1

7 JA 5110 29 Clamp 2
6
8 JB 5110 15 Flange Bolt 1 For head mtg.
5
4
1 2
Front Wheel Direction
Cylinder Head
Description ES
No. Part No. Remarks
Drum
1 52 JB02 32 Head Cylinder Comp. 1 With Studs

and valve guide
2 10
2
2 JA 5110 28 Stud 2
11 3 JB 5110 19 Gasket Cylinder Head 1
1 4 JZ 5814 01 Manifold PTE-16 1
5 JA 5814 06 Bolt Flange 2
13
12
6 JZ 5812 04 Sleeve (Carburettor - Duct Rubber) 1
7 JZ 5812 05 Connector Carb. PTE16 1
8 JA 5812 17 Clamp (39mm) 2
5
9 39 1283 21 ‘O’ Ring (Intake Pipe) 1
10 JB 5110 18 Sleeve Spark Plug R.H 1
9
3 6
8 11 39 2608 01 Grub Screw 1
12 39 2629 21 ‘O’ Ring Sleeve 1
4
13 39 1283 21 ‘O’ Ring Sleeve 1
8
Single Piece Manifold

15 14 JB 5814 04 Intake Manifold 1 Ref. Circular A-11
15 JB 5812 71 Insulator Manifold 1 Ref. Circular A-11
7
(2.2.2010)
16 JB 5812 72 'O' Ring Insulator 1 Ref. Circular A-11
(2.2.2010)
16
14
3 4
Valve
Description ES
Drum
1 JA 5112 10 Shaft Rocker Arm Intake 1 (Length 36mm)

2 JA 5112 11 Shaft Rocker Arm Exhaust 1 (Length 48mm)
3 JA 5112 04 Rocker Arm with Roller 2
4
4 DG 1010 29 Cotter Valve (Collet) 4
2 5 36 PA00 04 Valve Kit 1 Refer Page No. 113
6 36 JA00 03 Valve Repair Kit 1 Refer Page No. 113

1 7 39 2017 19 Seal Valve Stem 2
6
3
5 6
Camshaft / Tensioner
Description ES
Drum
1 JB 5112 06 Camshaft Complete 1

10
2 JA 5112 16 Spacer Cam Sprocket 1
3 DS 1012 76 Sprocket Cam Shaft 1
11
4 59 0400 31 Hex. Socket Head Bolt 1 alt DK101386
8
5 DH 1010 48 Special Washer (’O’ Washer) 1
13
6 36 PA00 02 Guide Chain Kit 1 Refer Page No. 113

7 7 DH 1013 92 Bolt Special 1
9
8 JA 5210 17 Adjuster Assly Chain 1
9 CS 1011 28 Gasket 1
10 JA 5210 18 Bolt 1 alt DD101062
11 JA 5210 19 Flange Bolt 2 alt 39167306

12 39 0594 17 Circlip for Camshaft 1
14 13 39 2669 21 ‘O’ Ring (Tensioner) 1
14 JA 5310 11 Cam Chain (92 Link) 1
1 6
12
5
2
3
4
7 8
Cylinder and Piston
Description ES
Drum
1 JD 5210 02 Gasket Cylinder 1

2 39 1000 06 Dowel Pin 4
3 36 PA00 03 Piston Ring Set 1 Refer Page No. 113
2 4 JB 5212 11 Wire Circlip 2 N.S
5 5 52 JB02 31 Cylinder Block / Piston Assly. 1 Molycoat Piston
6 JW 3514 00 Thermal Sensor 1

7 JB 4022 02 Grommet for Thermal Sensor 1
2
6
1
7 4
9 10
Crankshaft
Description ES
Drum
1 59 1500 14 Flange Nut 2

2A 59 1200 03 Belleville Washer 2
6 2B 59 1100 08 Plain Washer 1
4 3 31 1011 73 Woodruff Key 1
10 4 PF 5310 02 Crank Shaft Assly. 1
9 5 39 1864 20 Ball Bearing 1
8
3
6 DS 1011 54 Parallel Key 1
11
7 36 JZ00 23 Set Primary Drive / Driven 1
1 1
8 JA 531012 Spring 1
9 JA 5310 15 Parallel Pin 1
2A 10 JB 5310 21 Plunger Oil 1
5
2A
2B
11 JD 5310 04 Spacer Crank shaft Clutch Side 1
11 12
Transmission
Description ES
Drum
1 PF 5510 02 Shaft Input Transmission 1

2 PF 5512 02 Gear 4th Drive 1
3 39 0987 17 Ring Snap 5
4 JA 5510 02 Spline Washer 4
5 PF 5512 01 Gear 3rd Drive 1
6 PF 5512 00 Gear 2nd Drive 1

7 JA 5510 04 Washer Thrust 2nd Drive 1
1 8 PF 5510 03 Shaft Output Transmission 1
9 PF 5512 06 Washer Gear 2nd Driven 1
10 PF 5512 03 Gear 2nd Driven 1
16
11 PF 5512 04 Gear 3rd Driven 1
2
3 4 12 PF 5512 05 Gear 4th Driven 1
14 13 JZ 5512 05 Bush 1st Driven 1
3 5 13
12 14 JZ 5512 04 Gear 1st Driven 1
4 3 15 JD 5512 09 Spline Washer 1
4
16 JA 5510 08 Washer Thrust 1st Driven 1
6 17 JA 5510 09 Collar Sprocket Drive 1
7 4 11 18 59 2100 24 ‘O’ Ring Collar Sprocket 1
3
19 JB 5510 00 Sprocket Drive (Allen Bolt) 1
20 DU 1012 13 Plate Lock Sprocket 1
3
21 39 1981 04 Socket Head Bolt 2
8 15
9
10
18
17
20 19
21
13 14
Change Drum / Shift Fork
Description ES
Drum
1 PF 5610 00 Drum Complete Gear Shift 1

2 39 0992 06 Dowel (Pin Drum Change) 4
3 JD 5610 11 Special Bolt 1
5 4 PF 5610 02 Shaft Gear Shift Fork 2
5
5 JD 5610 04 Fork Gear Shift Output 2
7
6 JZ 5610 02 Fork Gear Shift Input 1
1 7 DK 1011 35 Bush (Fork Shift) 3
7
4
8 JA 5610 02 Cam Drum Change 1
4
6 8
3
15 16
Gear Change Mechanism
Description ES
Drum
1 PF 5612 00 Lever Complete Gear Shift 1

2 JW 5612 06 Extension Spring 1
1 3 JW 5612 08 Spring Gear Shift Return 1

2 4 JA 5612 07 Inhibitor Complete Gear Shift 1
5 JA 5612 08 Spring Inhibitor 1

3
8 6 JA 5612 09 Step Washer (Collar) 1

7 7 39 2704 11 Plain Washer 1
12 8 39 0817 15 Nut 1
4
6 9 JA 5614 00 Lever Complete Gear Shifter 1 With Rubber
5 (Gear Pedal) Damper
10 DH 1015 09 Damper 1
11 DG 1013 39 Damper 1
12 JA 5612 11 Flange Bolt 1 alt 39190204
10
11
17 18
Engine Assembly / Crankcase RH
Description ES
Drum
1 JB 5010 08 Engine Assly 1

2 36 JB00 25 Crankcase RH (Clutch Side) 1 Refer Page No. 115
3 59 2000 36 Bearing Ball 1 For I/P Shaft.
10
4 JA 5410 11 Needle Roller Bearing 1 For O/P Shaft.
9 5 JA 5410 10 Stopper Plate 1
11
6 39 1000 06 Dowel Pin 2

7 PF 5410 18 Bushing 1
6 8
8 39 0746 01 Screw 1
5
9 JA 5410 15 Stud Inhibitor Mounting 1 alt 52JA0027
3
12 10 JA 5412 35 Bolt 2 Crankcase Mtg.
14
11 59 0400 38 Bolt Flange 1 Crankcase Mtg.
12 52 JA00 29 Bolt Precoated 1
13
13 JA 5410 12 Guide Kick 1
14 39 1964 04 Hexagon Bolt 2
7
19 20
Crankcase LH
Description ES
Drum
1 52 JB02 33 Crankcase Mag. Side 1 NRB + Bush+

Nozzle Oil Jet
(Press Fitted) 52 JB02 29 Crankcase Mag. Side – Nozzle Oil Jet
2 39 2562 20 Needle Roller Bearing 1
3 59 2000 36 Ball Bearing 1
4 39 1715 19 Seal Oil 1 Output Shaft
2
5 31 2010 81 Neutral Switch 1
8 19
6 DH 1017 84 Gasket Neutral Switch 1
3 7 39 2190 19 Oil Seal 1 Shifter Shaft

8 JA 5410 05 Bush Starter Clutch 1 Starter Clutch
11
9 39 0747 01 Pan Head Screw 2
17 10 JA 5410 34 Stopper Gear Starter Clutch 1
20
10
1 11 39 1000 06 Hollow Dowel Pin 2
9
12 39 0999 06 Hollow Dowel Pin 2
18 13 JA 5410 19 Mesh Filter Oil strainer 1
5 6
13 7 12 14 59 2100 23 ‘O’ Ring Cap Strainer 1
14 15 JA 5410 21 Cap Strainer 1
15
4
16
16 59 0400 38 Bolt Flange 6 Crankcase Mtg.
17 39 1759 04 Bolt 1 Crankcase Mtg.
18 JA 5410 20 ‘O’ Ring Mesh Filter Oil Strainer 1
19 JA 5410 27 Damper 1
20 DH 1011 25 Spring Kick Start Return 1
21 22
Cover RH
Description ES
Drum
21 22 1 36 JB00 23 Clutch Cover Flower Type 1 Refer Page No. 115

19 20
JB 5412 12 Clutch Cover Flower Type 1 alt for 36 JB00 23
2 JE 5412 11 Decal Clutch Cover 1
3 39 1041 19 Oil Seal Clutch Lever 1
4 30 1011 42 Oil Seal (Kick Shaft) 1
18
5 JW 5410 05 Shaft Clutch Release 1
6 DP 1012 69 Rod Push 1
10 7 DG 1014 18 Gauge 1 Oil Level Check
11
5 8 DS 1012 15 Wire Circilp 1
3 9 JA 5412 36 Plain Washer 1
12
9 10 JA 5412 37 Spring Torsion Clutch Lever 1
11 JA 5412 11 Cap Oil Filler 1
17
13 2 12 JA 5412 25 ‘O’ Ring Cap Oil Filler 1
8 13 JE 5412 09 Damper Flower Type 1
7 14 JA 5412 16 Plate Damper 1
15 39 2208 04 Bolt Flange 3
15
4 16 JA 5412 12 Gasket Clutch Cover 1
14
17 59 0400 38 Bolt Flange 8 Clutch Cover to
24
17 Crankcase Mtg
18 JW 5410 00 Bracket Clutch Cable 1
19 DD 1211 81 Oil Filter Element 1
20 39 1671 21 ‘O’ Ring 1
21 JZ 5412 14 Cap Filter 1
6 22 JA 5210 19 Bolt Flange 3 alt 39167304
1
23 39 1001 20 Bearing Push Rod 1
23
24 JB 5412 01 Jet Clutch Cover 1
16
25 25 39 0999 06 Pin Hollow Dowel 2
23 24
Cover Magneto
Description ES
Drum
7
1 36 JZ0015 Cover Magneto Flower Type 1 Refer Page No. 115
2 JA 5410 44 Bolt Flange 8
3 JA 5412 05 Gasket Magneto Cover 1
8 4 59 0400 38 Bolt 2
5 JZ 5412 02 Cover LH Rear Complete 1
6
3
6 JE 5412 10 Damper Cover LH 1
7 39 2208 04 Flanged Bolt 3
9
10 8 JA 5412 21 Plate Damper Cover LH 1
9 JA 5410 05 Bush 1 For Drive Gear Assly
11
10 JA 5412 33 Threaded Cap TDC Finder 1
2 11 30 1011 95 ‘O’ Ring 1

12 DS 1611 50 Gear Shift Lable 1
12
DT 13 JE 5412 12 Decal Magneto Cover (DTS-i) 1
S-i
13
13 1
4
5
12
25 26
Clutch
Description ES
Drum
11
10
1 JZ 5514 13 Clutch Assly Complete 1
3
1A JD 5514 00 Spacer Clutch Assly 1 ‘JD’ mark for ID
9
2 JA 5514 06 Collar Clutch 1
4 8
3 39 2600 11 Washer 1
1A 2
4 JB 5514 04 Clutch Plate Assly 1
5 JB 5514 08 Wheel Clutch 1
6 30 1010 96 Plate Clutch 4

7 36 JZ00 37 Plate Friction 1 Refer Page No. 115
8 JB 5514 11 Hub Clutch 1
6 9 JZ 5514 15 Compression Spring 6
7 10 JB 5514 06 Holder Clutch 1
5
12
13 11 39 0980 04 Bolt Flange 6
15 12 JA 5514 16 Belleville Washer 1
14
13 JA 5514 20 Plain Washer 1
14 52 JA00 28 Nut Special 1 L.H. Threads
15 39 1001 20 Bearing Clutch Lifter 1
1
16 36 JZ00 23 Set Primary Drive & Driven 1 Refer Page No. 115
16
27 28
Kick Starter Mechanism
Description ES
Drum
1 JA 6212 01 Lever Assly Kick 1

2 JA 6212 06 Bolt Special 1
3 36 DU10 07 Boss Kick Set 1 Refer Page No. 113
6 4 22 1502 41 Plain Washer 1
11
5 39 0993 11 Plain Washer Small 3
7
6 39 0738 17 Circlip Shaft 2
7 JA 6210 01 Shaft Kick 1
13
8 DS 1011 17 Spring Kick Starter 1
8 9 JA 6210 02 Ratchet 1
9 10 JB 6210 03 Gear Spur Kick Starter 1
5
11 JA 6210 06 Washer Thrust 1

10
5 2 12 39 2408 17 Circlip 1
13 DD 1010 97 Kick Rubber 1
12 1 14 DH 1011 25 Spring Kick Starter Return 1
5
14 3
29 30
Carburettor
Description ES
Drum
2 1 JB 5812 84 Carburettor assly. 1

3
2 JB 5812 37 Adjuster throttle cable 1
3 JB 5812 38 Nut adjuster 1 N.S
18 4 36 JB00 22 Air screw Kit 1
10
22 5 36 JB00 21 Jet Kit 1
15
6 36 PA00 13 Idling screw kit 1 Refer Page No. 114

23 4
11 7 JB 5812 29 Valve complete float (Float pin) 1
12
10 8 JB 5812 30 Float complete 1
9 JB 5812 32 Screw washers bowl M4x14 1
17 6
10 JB 5812 48 Screw TPS & Solenoid choke 1
14
1 13
7
11 JB 5812 55 Solenoid choke assly 1
12 JB 5812 47 "O" ring solenoid choke 1
15
8 13 JB 5812 02 Throttle position sensor 1
20 14 JB 5812 04 "O" Ring (TPS) 1
15 JB 5812 57 Tube Over Flow 1
5
16 JB 5812 58 Tube Air Vent 1

17 JB 5812 59 Clip 2
21 18 36 PA00 14 Throttle Value Kit 1 Refer Page No. 114
19 36 PA00 15 Carb. Gasket ‘O’ ring 1 Refer Page No. 114
20 JB 5812 56 Arm Pin Float 1
9
21 JB 5812 60 Drain Screw 1

22 JB 5812 76 Jet Needle 1
23 PF 5813 09 Lever Complete Starter- Manual Choke 1
31 32
Air Cleaner Complete
Description ES
Drum
1 JB 5810 21 Air Filter Assly 1

2 DS 1211 16 Air Filter Duct 1 Intake
3 DX 1210 07 Assly Catridge Air filter 1
10
4 DX 1210 10 Element Air Filter 1
1 5 DX 1210 11 Flame Arrestor 1
11
15 6 DS 1211 17 Tube Drain 1

16 13 7 DS 1211 26 Plug 1
8 DG 1210 02 Clamp 1
5 9 JZ 5810 04 Hose Breather 1 N.I.
17 10 39 0071 04 Hex Head Screw 3
11 39 1765 11 Washer 3
4 12 DH 1210 38 Band Insualtor 1
14 13 DS 1610 69 Bracket Side Cover Mtg. 1
6 14 JB 5810 20 Connecting Tube 1
2 3
15 39 1779 02 Self Tapping Screw 2
8
7 16 DX 1210 05 Filter Air Cover 1
17 DX 1210 06 ‘O’ Ring 1 alt JZ581029
33 34
Silencer Assembly
Description ES
Drum
1 JB 5910 51 Silencer Assly Without Shield 1

JB 5910 54 Silencer Assly. (Non Cat) 1
2 CB 1011 14 Gasket Exhaust Mounting 1
3
2 3 JA 5910 40 Flange Nut 2 alt 39229515
4 JZ 5910 43 Shield Silencer 1
5 JW 5910 28 Truss Screw 2
5 5
6 JW 5910 30 Grommet Shield 1
4 7 39 2754 04 Bolt Hex with Flange M5 1
8 39 2492 11 Plain Washer 1
7
9 JB 1130 04 Bolt M10X 1.25 1 alt 39185004
9 10 JB 1130 05 Washer 2
8 10 11 DH 1611 57 Tube Silencer Mtg. 1
6 1 12 DH 1611 55 Silencer Damper 1
13 39 2588 11 Washer 1
11 14 DD 1610 71 U Nut M10X1.25 1
12
10
13
14
35 36
Oil Pump
Description ES
Drum
1 JB 5710 05 Oil Pump Assly 1

2 JA 5410 16 Gasket Case Oil Pump 1
3 39 0753 01 Pan Head Screw 3
4 39 0992 06 Dowel 2
1
4
3
37 38
Starter Assembly
Description ES
Drum
4
1 JA 6214 14 Body Complete Starter Clutch 1
3
2 DH 1017 81 Plate Roller Clutch 1
7 3 JA 6214 10 Gear Starter Clutch 1
5
4 JA 6214 02 Washer 2
1 5 JA 6214 06 Drive Assly 1

2
6 6 36 JW00 14 Starter Clutch Repair Kit 1 Refer Page No. 114
7 JA 3516 00 Motor Assly 1
8 JA 3516 04 ‘O’ Ring For Tie Bolt (Flash) 1 N.S
9 JA 3516 06 Sealing Ring (Flash) 1
JA 3516 26 Sealing Ring (Lucas-TVS) 1
10 DH 1011 63 Flange Bolt (Flash) 2
11 JA 3516 02 ‘O’ Ring For Spigot (Flash) 1

12
JA 3516 27 ‘O’ Ring For Spigot (Lucas-TVS)
12 JA 3516 08 +ve Brush Holder Assly (Flash) 1
13 JA 3516 09 -ve Brush Holder Assly (Flash) 1
16 14 JA 3516 18 Brush & Earth Plate Assly 1 N.I. (Lucas-TVS)
15 JA 3516 24 Brush Spring (Lucas-TVS) 1 N.I.
7 10 13
16 JA 3516 19 Terminal Assly (Lucas-TVS) 1

8
10
11 9
39 40
Magneto, CDI & H.T. Coil
Description ES
Drum
1 JB 3510 24 Rotor Assly 1

2 PF 3510 06 Stater Assly Complete 1
3 39 1674 04 Bolt Flange 2
4 39 0746 01 Pan Head Screw 3 For lock Plate &
5
6 Pick Up Coil mtg.
5 PA 3512 01 H T Coil LH 1
9
11 10B 6 PA 3512 02 H T Coil RH 1
7 7 JB 3512 01 C.D.I. Assly 1
8 DD 1110 18 Spark Plug PRZ9 HC Or 2
9
CF 1110 19 Spark Plug Bosch UR4AC 2
9 DD 1110 48 Spark Plug Cap 2
11
4 10A DD 1110 11 Grommet Spark Plug Cap LH 1
9
12 10B JD 3512 06 Grommet Spark - Plug Cap RH 1
14
3
10A 1
4 11 DD 1110 12 Grommet for HT Cable 2
12 39 1943 04 Bolt Flange 2
13 JN 4020 00 Regulator 1
8
13 14 JA 5410 28 Lock plate 1
2
15 59 0400 14 Bolt Flange (N.I.) 4 For HT Coil mtg.
41 42
Seat Assembly / Seat Lock
Description ES
Drum
1 JN 1910 00 Seat Assly Comp 1

2 36 DS21 01 Seat Damper Kit 1 Refer Page No. 113
3 DS 2110 06 Lock Assly seat 1
4 39 1902 04 Flanged bolt 2
4
2
43 44
Engine Mountings
Description ES
Drum
1 JA 1134 03 Flange Bolt M10×10 2

2 39 1970 15 Nut Flanged 3
3 39 1556 04 Bolt Flanged 4
4 LA D000 41 Bolt Flanged 1
3 5 JA 1134 04 Bolt Flanged 1
8 6
2 6 39 2723 15 Flanged Nut 2
6 9
2
7 JZ 1134 00 BKT Comp LH Engine Front 1
8 JZ 1134 03 BKT Comp RH Engine Front 1
9 JZ 1134 02 Engine Mtg. BKT Rear Top 2
5
7
4 5
3
9
1
3
45 46
Frame and Frame Fittings
Description ES
Drum
1 PA 1110 75 Frame Assly. Comp. 1

2 DS 1810 18 Nut Fork 1
4 3 DH 1810 14 Cup - Steering 1
2
4 36 DS18 02 Bearing Cone Kit 1 Refer Page No. 114
3
5 30 1810 06 Ball Steel 46
5
6 PA 4010 00 Side Reflector 2
7 DP 1710 06 Silent Bush 2
8 DP 1612 60 End Cap 2
1 8
7
47 48
Swing Arm / Rear Shock Absorber
Description ES
Drum
1 JB 1220 16 Hex. Bolt/ Flange - M10 2 For RSA

8 7
2A JB 1220 11 Plain washer 4 For RSA
2B
2B JB 1220 10 Plain Washer 4
3 JN 1220 00 Rear Shock Absorber 2
2A
2B 4 39 0258 11 Plain Washer 2 For Mud Flap
18 17
5 PA 1220 01 Swing Arm Assly. 1
9 4 2A
6 6 DS 1710 15 Cap Swing Arm 2
10
11 13 7 JB 1220 09 Domed Cap Nut 2
8 39 2726 12 Spring Washer 2
9 DS 1710 07 Chain Slider 1
1
10 39 0553 02 Screw 2 For Chain Sider
11 39 0454 11 Plain Washer 2 For Chain Sider

6
3 12 DS 1710 13 Shaft Swing Arm 1
5
13 39 1358 15 Flanged Nut 1
12
14 DJ 1510 36 Adjuster Chain LH 1
15 DX 1510 14 Adjuster Chain RH 1
1
15
16 39 0292 15 Hexagon Nut 4
16
14 16 17 DS 1710 14 Mud Flap 1
19 18 39 2060 04 Flange Bolt 2 For Mud Flap
19 DJ 1510 47 Plate Chain Adjuster 2
49 50
Rider Foot Rest
Description ES
Drum
1 JZ 1130 01 Assly. Comp. Main Step LH 1 With Rubber

Main Step
2 4 2 39 2310 04 Flange Bolt 4
3 PA 1130 15 Main Step RH Assly. Comp. 1
6 4 DF 1614 13 Rubber Main Step 2
5 DH 1611 94 Damper 1 For Kick stopper
3 2 6 39 2726 12 Spring Washer 4
6
6
2 5
4 1
2
51 52
Pillion Foot Rest / Holder
Description ES
Drum
5
1 JZ 1130 06 Holder LH Step 1
3 2 JZ 1130 09 Holder RH Step 1 N.S
3 DP 1611 70 Step Pillion Fort rest 2
4 JK 1130 08 Rubber Pillion Step 2
4 5 30 1710 22 Pin Pillion Step 2

8
7
6
6 DP 1611 63 Plain Washer 2 For Rear Foot Rest
7 39 0784 08 Split Pin 2
8 39 2722 04 Soc. Head Bolt 4
8
1
6
2
4 7
53 54
Mudguard - Front & Rear
Description ES
Drum
1 DS 1611 25 Cable Guide 1

2 JB 1814 16 Brace Fender 1
3 JB 1814 12 Flange Bolt 4 Fender Front Mtg.
39 1075 04 Flange Bolt 4 Alt for JB 1814 12
4 JZ 1814 02 Fender Rear Front 1
5 DS1612 87 Flange Bolt 2
2 11
16
15 15
6 39 0798 15 Flange Nut 2
6 14
12 17 8 JZ 1814 01 Fender Rear 1
9 39 1943 04 Flange Bolt 2
10
5 10 DJ 1610 69 Nail for Cable Guide 1
1 7 9
3 11 39 0326 15 Nyloc Nut 3

12 JB 1814 03 Flap Front fender 1
13 DL 1610 15 Grommet 2
4 13
14 JZ 1814 06 Grommet Saree Gaurd 1
8 15 39 0242 11 Washer 6
16 39 2420 01 Screw 3 alt 39169801

17 DH 1611 58 Grommet 2 For Seat Cowl Mtg.
55 56
Stand Assembly
Description ES
Drum
1 DS 1611 13 Center Stand 1

3 2 DS 1611 12 Shaft Stand 1
2 3 39 0797 08 Pin Cotter 1
4 DH 1611 21 Spring Main Stand 1
5 DH 1611 45 Cover Spring Main Stand 1
8 6 DS 1610 77 Stand Side 1
4
7 DH 1612 40 Spring Side Stand with Cover 1
10 8 DF 1611 02 Bolt 1
9 39 0422 15 Nut 1
10 JN 1132 00 Damper Main Stand 1
5 11 DH 1611 46 Cover Side Stand Spring 1

1 9
11
57 58
Tube / Tyre / Rim
Description ES
2 No. Part No. Remarks
Drum
3
1 PA 1310 10 Wheel Fron Drum 1.4 x 17 1
1
2 DS 1510 48 Tyre Front 1 N.S
3 DS 1510 49 Tube Front 1 N.S
4 JB 1312 22 Wheel Rim Rear 1
5 DS 1510 52 Tyre Rear 1
6 DS 1510 53 Tube Rear 1

} Proprietary Items
Not Serviceable
7 DS 1510 47 Tyre with Tube Front 1

8 DS 1510 51 Tyre with Tube Rear 1
6 5
59 60
Front Hub
Description ES
Drum
3 2 1 LC J000 01 U Nut (M10) 1 alt DU 1510 31

5A 1A PA 1310 02 Axle Front Wheel 1
1
5
2 39 1510 11 Plain Washer 1 N.S
3 PA 1316 02 Collar Assembly 1
4 PA 1316 02 Spacer + Dust Seal (Assembly) 1 (N.I.)
5 39 2680 20 Bearing Ball 1
5A PA 1310 03 Oil Seal 1
6
6 PA 1316 00 Collar Bearing 1
7 39 2681 20 Ball Bearing 1
7 8 30 1511 05 Shoe Brake 2
10
JN 1318 12 Kit Shoe Brake Non Asbestos 1
11 9 30 1510 69 Spring 2
15 12 9 8 10 14 1510 21 Oil Seal 1
13
14
11 DS 1510 89 Cam Brake Assly. 1

12 PA 1318 01 Panel Front Brake 1
22
13 30 1510 38 Ring ‘O’ 1
16 21 14 DS 1510 91 Indicator 1
17 15 DS 1510 95 Bolt 1 N.S
24 23
24 25 16 DS 1510 92 Lever Brake Cam 1
26
1A 17 DS 1510 94 Nut 1
18 39 0840 01 Pan Headed Screw 1
19 39 0732 12 Washer Spring 1 For Bushing
20
20 30 1511 18 Stopper for Bushing 1 Speedo Gear
19
21 LB D000 01 Screw 1 To Secure Speedo
18 Cable
61 62
Front Hub
Description ES
Drum
3 2 22 DL 1510 14 Speedometer Gear 1 POP of 36DS1502

5A
5
1 23 30 1510 41 Gear Meter Screw 1 POP of 36DS1502
24 30 1510 42 Washer Plain 2 For Gear Meter Screw
39 0242 11 Washer Plain 2 alt for 30 1510 42
25 39 1013 21 ‘O’ Ring 1
6 26 JA 1316 06 Bushing Speedo Gear 1
7
10
11
15 12 9 8
13
14
22
16 21
17
24 23
24 25
26
1A
20
19
18
63 64
Rear Hub
Description ES
Drum
8
11 1 DX 1510 81 Drive Chain Lock 1
9
2 6 2 36 PA00 43 Chain Sprocket Kit 1
5 3 JB 1312 25 Nut 1 alt 39 0988 15

4
4 DX 1510 15 Plain washer 1
7 5 DX 1510 12 Collar Assly. 1
3 6 39 2240 20 Bearing ball 1

10 7 PA 1312 08 Coupling 1
15 8 DX 1510 10 ‘D’ Bolt 4

9 39 0794 15 Hex. lock nut 4
10 31 1510 29 Washer 2
14
13
11 DX 1510 09 Sleeve 1
12 27
12 39 1364 20 Bearing Ball 1
25 13 31 1510 18 Collar Bearing 1
14 31 1510 21 Damper 1
24
15 39 2682 20 Bearing Ball 1
26
23
16 30 1510 69 Spring 2
17
17 30 1511 05 Shoe Brake Assly 2
16
JN 1318 12 Kit Shoe Brake Non Asbestos 1
20 21 22
18 JA 1312 05 Panel Rear Brake 1
19 19A 18
16 19 JB 1312 23 Cam Brake 1
19A 39 0723 11 Plain Washer 1 N.S
65 66
Rear Hub
Description ES
Drum
8
11 20 30 1510 38 Ring ‘O’ 1
9
2 6 21 DS 1510 91 Indicator 1
22 PA 1318 06 Lever Brake 1 alt PA 1318 09
5 23 LA D000 26 Bolt 1
4
24 DX 1510 16 Axle 1
7 25 JA 1312 02 Collar 1
3 26 DX 1510 18 Plain washer 1

10 27 JB 1310 19 ‘U’ nut 1 alt 59 1500 03
15
14
13
12 27
25
24
26
23
17
16
20 21 22
19 19A 18
16
67 68
Rear Brake Pedal
Description ES
Drum
1 JA 1610 03 Pad Lever Brake 1

2 JZ 1610 02 Brake Pedal 1
1 3 39 1680 04 Hex. Bolt 1
2 4 DG 1910 45 Washer 1
5 DS 1910 11 Brake Pedal Spring 1
8
3 10 6 PA 1610 00 Rod Brake 1
5 7 30 1910 38 Pin 1
7 11
4 8 39 0198 11 Plain Washer 2
20 9 39 0808 08 Split Pin 1
10 30 1910 35 Spring 1
8
14 12
11 15 1910 26 Pin 1
9 12 30 1910 36 Brake Adjuster Nut 1
6
13 DJ 1510 42 Rod Torque 1
16
16 14 DH 1510 29 Step Bolt 1
17 15 39 0789 12 Spring Washer 2
19
15 16 39 0694 15 Nut Hex. Lock 2
13 17 39 0807 08 Pin Snap 2
17 15
18 30 1510 96 Hex. Bolt 1
19 39 1540 11 Plain Washer 1
18 20 DD 1610 78 Damper Rubber 1 N.I.
21 39 1672 04 Bolt M - 6 (Not illustrated) 1

22 39 0292 15 Hex Nut M-6 (Not illustrated) 1 } From Date 17.08.2009
For Brake Pedal
Adjustment On Frame
69 70
Handle Bar
Description ES
Drum
1 JZ 1510 16 Handle Bar 1

2 JB 4014 00 Control Switch LH 1
31
3 JB 4014 01 Control Switch RH 1
15 DS 2010 33 Control Switch RH – Minda Make
18 DU 2010 18 Control Switch RH -- Varroc Make
14 30 16 3 4 DJ 1910 54 Holder Assly. LH 1
1 33
DX 1910 08 Holder Assly. LH --
27 26
5 DS 1910 38 Holder Assly. RH 1
17
19
20 6 JZ 1510 18 Grip LH 1
32 13
2 7 JZ 1510 19 Grip Assly. RH 1
7
25 21 22 9 8 DD 1910 69 Lever Grip Left 1
23 35 9 DX 1910 09 Lever Brake RH 1
8 12
10 JB 4014 09 Clutch Switch With Sealed Coupler 1
24 34
11
28
11 DD 2011 70 Front Brake Switch 1
29
10 12 DS 1910 52 Boot For Lever LH 1
5 13 DS 1910 18 Boot For Lever RH 1
28
29 4 14 DJ 2210 03 Mirror Assly. LH 1
6 15 DJ 2210 04 Mirror Assly. RH 1
16 FD 1810 30 Holder Upper 2 POP of 36DS1801
71 72
Handle Bar
Description ES
Drum
17 DS 1810 06 Holder Lower 2 POP of 36DS1801

FD 1810 31 Holder Lower 2 Ref. Cir. IB-57
31
18 39 2582 04 Flanged bolt 4
39 1074 04 Flanged bolt 4 Ref. Cir. IB-57
15
19 DS 1810 07 Washer Handle Upper 2
18
FD 1810 19 Washer Handle Upper 2 Ref. Cir. IB-57
14 30 16 3 20 DS 1810 08 Damper Handle Upper 2
1 33
DF 1810 91 Damper Handle Upper 2 Ref. Cir. IB-57
27 26 21 DS 1810 09 Damper Handle Lower 2
17 DF 1810 92 Damper Handle Upper 2 Ref. Cir. IB-57
19 22 DS 1810 10 Washer Handle Lower 2
20
32 13 FD 1810 20 Washer Handle Lower 2 Ref. Cir. IB-57 N.S
2
7 23 39 0422 15 Nylock Nut 2
25 21 22 9 24 36 DF10 01 Kit Cable Adjuster Assly. 1 Refer Page No. 115
23 35 25 DD 1910 85 Stud Lever Handle (L.H) 1
8 12
24 34 26 DL 1910 14 Stud Lever Handle (R.H) 1
11
28 27 30 1910 48 Band 2
29 28 30 1910 17 Nut (For Stud R.H) 2
10 29 39 1553 04 Bolt Flange 2
28 5 30 PF 2326 01 3 in One Lock Set 1
29 4
31 39 1943 04 Flange Bolt 2 For Ignition Switch
6
32 PA 1510 06 Upper Bracket Assly 1
33 DU 2010 46 Plunger With Spring 1 Part of Ride
Control Switch
34 DX 1910 01 Throttle Pipe 1
35 36 DU19 01 Cable Adjuster Kit 1 Refer Page No. 114
73 74
Front Fork
Description ES
Drum
1 PA 1210 25 Fork Front 1

2 36 DZ00 20 Front Fork Seal Kit 1 Refer Page No. 115
1 3 30 1810 26 Gasket 2
4 30 1810 25 Bolt 2
7
8 5 JA 1510 13 Fork Pipe Inner 2
23 9
20 24 6 DJ 1811 04 Spring Front Fork 2
7 59 0400 06 Bolt Fork 2 Hex Head Bolts
15 10
With Washer
21
2
8 DS 1810 15 Cap Nut Fork 1
16
9 DS 1810 16 Plain Washer 1 For Cap Nut
22 19
10 PA 1510 06 Upper Bracket Assly 1

6 11
5 11 30 1810 09 Bearing Cone 1
25/26
17/18 12 JZ 1510 36 Under Bracket Fork 1
13 39 0789 12 Spring washer 2
14 39 1181 01 Bolt 2
3
15 JW 1510 29 Nylon spacer 2 N.S
12
4 PA 1210 45 Nylon spacer 2 Ref. Cir. IB-57
13 16 DS 1810 16 Washer 2
14
17 PA 1210 22 Outer Tube LH 1
18 PA 1210 24 Outer Tube RH 1
75 76
Front Fork
Description ES
Drum
19 JK 1210 07 Anti Friction Bush 2

20 JW 1510 23 Cylinder Complete Fork 2
1
7 21 31 1810 99 Rebound Spring 2

8
22 JK 1210 09 Washer Anti Friction Bush 2
23 9
20 24 23 DS 1810 12 Bolt Fork 2
24 31 1811 02 ‘O’ Ring 2
15 10
25 PA 1210 01 Leg Assly. LH 1
21
2
16
22 26 PA 1210 03 Leg Assly. RH 1
19
6 11
5
25/26
17/18
3
12
4
13
14
77 78
Painted Parts and Decals
Description ES
Drum
1 PA 7101 3B Fuel Tank with Decal 1 Black With Blue Decals

PA 7101 3C Fuel Tank with Decal 1 Black With Red Decals
PA 7101 4N Fuel Tank with Decal 1 Black With Green Decals
PA 7101 3F Fuel Tank with Decal 1 Red With Red Decals
PA 7101 3E Fuel Tank with Decal 1 Blue With BlueDecals
6 PA 7101 5D Fuel Tank with Decal 1 Black With Gold Decals
PA 7101 5E Fuel Tank with Decal 1 Black With Magenta Red
Decals
7
1 2 52 PA00 20 Side Cover LH 1 Black With Blue Decals
52 PA00 22 Side Cover LH 1 Black With Red Decals
3 52 PA00 51 Side Cover LH 1 Black With GreenDecals
52 PA00 26 Side Cover LH 1 Red With Red Decals
52 PA00 24 Side Cover LH 1 Blue With BlueDecals
5 52 PA01 42 Side Cover LH 1 Black With Gold Decals
52 PA01 37 Side Cover LH 1 Black With Magenta Red
Decals
4
2
3 52 PA00 21 Side Cover RH 1 Black With Blue Decals
52 PA00 23 Side Cover RH 1 Black With Red Decals
52 PA00 52 Side Cover LH 1 Black With GreenDecals
52 PA00 27 Side Cover RH 1 Red With Red Decals
52 PA00 25 Side Cover RH 1 Blue With BlueDecals
52 PA01 43 Side Cover RH 1 Black With Gold Decals
52 PA01 38 Side Cover RH 1 Black With Magenta Red
Decals
79 80
Description ES
Drum
4 PA 7501 3B Seat Cowl Assembly 1 Black With Blue Decals

PA 7501 3C Seat Cowl Assembly 1 Black With Red Decals
PA 7501 4N Seat Cowl Assembly 1 Black With Green Decals
PA 7501 3F Seat Cowl Assembly 1 Red With Red Decals
PA 7501 3E Seat Cowl Assembly 1 Blue With Blue Decals
6 PA 7501 5D Seat Cowl Assembly 1 Black With Gold Decals
PA 7501 5E Seat Cowl Assembly 1 Black With Magenta Red
Decals
7
1
5 PA 7201 3B Fender Front 1 Green
PA 7201 3C Fender Front 1 E B Back
3 PA 7201 3B Fender Front 1 alt for PA72013C
PA 7201 3F Fender Front 1 Red
PA 7201 3E Fender Front 1 Blue
5
6 52 PA00 15 Head Lamp Cowling 1 Black With Blue Decals
4
52 PA00 16 Head Lamp Cowling 1 Black With Red Decals
2 52 PA00 19 Head Lamp Cowling 1 Black With GreenDecals
52 PA00 17 Head Lamp Cowling 1 Red With Red Decals
52 PA00 18 Head Lamp Cowling 1 Blue With BlueDecals
52 PA01 45 Head Lamp Cowling 1 Black With Gold Decals
52 PA01 40 Head Lamp Cowling 1 Black With Magenta Red
Decals
81 82
Description ES
Drum
7 PA 2330 00 Tank Decal Set 1 Black With Blue Decals

PA 2330 10 Tank Decal Set 1 Black With Red Decals
PA 2330 40 Tank Decal Set 1 Black With Green Decals
PA 2330 20 Tank Decal Set 1 Blue With Blue Decals
6 PA 2330 30 Tank Decal Set 1 Red With Red Decals

PA 2330 73 Tank Decal Set 1 Black With Gold Decals
PA 2330 85 Tank Decal Set 1 Black With Magenta Red
7 Decals
1
8 PA 2330 03 Kit Decal 1 Black With Blue Decals

3
PA 2330 13 Kit Decal 1 Black With Red Decals
PA 2330 45 Kit Decal 1 Black With Green Decals
5 PA 2330 23 Kit Decal 1 Blue With Blue Decals
PA 2330 33 Kit Decal 1 Red With Red Decals
4 PA 2330 72 Kit Decal 1 Black With Gold Decals
2
PA 2330 84 Kit Decal 1 Black With Magenta Red
Decals
83 84
Petrol Tank, Cap Tank and Gauge Fuel
Description ES
Drum
1 DS 1410 09 Cap Assly. Tank 1

2 39 0761 01 Screw Pan Cross 2
5 3 39 2179 24 Washer 2
2 3A 30 1410 31 ‘O’ Ring 2
1 3 4 DS 1410 18 Fuel Tap Assly 1 N.S
5 PF 2326 01 3 In 1 Lock Set with Key 1
3A
10
6 30 1410 39 Packing 1 For Petrol Cock
4
7 DD 1410 22 Bolt Flanged 2 For Petrol Cock
DD 1412 27 Bolt Flanged 2 alt for DD 1410 22
6 8 39 0740 11 Washer (Non-Metallic) 2 For Petrol Cock

9 DS 2010 79 Fuel Gauge - Tank Unit 1 With ‘O’ Ring
9A 39 2758 21 ‘O’ Ring 1 For Tank Unit
DK 1410 28 ‘O’ Ring 1 alt for 39 2758 21
10 DS 1410 13 Seat Tape 1 Pasted on Tank
8 9A
7
13
11 39 2484 15 Flanged Nut 4
9
12 JB 1718 02 Tube Fuel 1 Cock to Carb.
12
11 13 30 1410 15 Pipe Clip 2 alt DK 1410 41
85 86
Fittings - Petrol Tank, Side Covers & Cover Seat
Description ES
Drum
1 36 DS14 01 Grommet Kit for Side Cover 1 Refer Page No. 114
2 DG 1611 21 Screw 1
8 3 39 1943 04 Flanged Bolt 2
4 JN 1710 00 Damper Rear 1 For Tank
6
5 39 1789 24 Washer Nylon 3
6 39 0983 08 Pin Snap 1

7
8 DJ 1410 08 Damper Front 2 For Tank Mtg.
1 2
8 9 31 1610 18 Damper 1
10 DS 1610 35 Clip Nut 1 N.I.
4
3
5
87 88
Meter Assembly
Description ES
Drum
1 JZ 4024 03 Speedometer Assly 1 From 10.02.2011

2 JZ 1812 00 Flap Cowling 1
2
3 PA 4024 01
Speedometer Machine With Dial 1
PA 4024 21
Speedometer Machine With Dial 1 Minda
1 4 PA 4024 02
Fuel Gauge Machine with dial 1
PA 4024 18
Fuel Gauge Machine with dial 1 Minda
5 PA 4024 03
Speedo meter Top Cover 1
PA 4024 19
Speedo meter Top Cover 1 Minda
6 PA 4024 04
Speedometer wiring harness 1
14 PA 4024 20
Speedometer wiring harness 1 Minda
15 7 CL 2010 42
Bulb 12V - 1.7 W 4
a. Neutral Indicator
b. Low Battery Indicator
4 c. High Beam Indicator
d. Turn Signal indicator
8 DH 1910 37 Bulb 12V - 3 W 2
9 39 0798 15 Flanged Nut 2
16 10 PA 4024 05 Speedometer Bracket 1
8
5
17 3 11 DS 1810 60 Foam side Flap 1 N.I.
7 10 12 JN 1810 14 Foam Speedo Flap 2 N.I.
13 JN 1814 06 Beading Speedo Flap 4 N.I.
14 PA 4024 10 Cover Speedo Black 1
PA 4024 14 Cover Speedo Black 1 Minda
15 PA 4024 11 Assly Speedo Case 1 PA402415-Minda
8
16 PA 4024 12 Trip Meter Knob 1 PA402416-Minda
17 PA 4024 13 Screw Trip Meter Knob 1 PA402417-Minda
6
89 90
Control Cables
Description ES
Drum
1 JZ 1612 01 Cable Accelerator 1

2 JZ 1612 00 Cable Clutch 1
3 DS 1910 06 Cable Speedometer 1
4 DS 1910 08 Inner cable Speedometer 1
5 DS 1910 54 Front Brake Cable 1
91 92
Chain Case
Description ES
Drum
1 52 PA00 54 Chain Case Assly Kit 1 Refer Page No. 114

2 15 1610 69 Rubber Cap 1
3 JB 1812 39 Bolt 4 Front & Rear
Side Mtg.
DH 1612 83 Bolt 4 alt for JB 1812 39
4 DX 1610 52 Beading Chain Case 1 N.I.
1
3
3
2 3
93 94
Head Lamp & Fairing

2 Description ES
3 Drum
1 JN 1810 01 Wind Shield 1

2 JZ 1812 06 Screw S.S. 4
3 39 2141 24 Non Metallic Washer 4
4 JZ 1810 03 Well Nut 4
8
5 JN 1810 10 Bush-1 for Well Nut 2
6 JN 1810 11 Bush-2 for Well Nut 2
1
4 5
6 35 1610 60 Clip Nut 5
11 7 39 2238 01 Screw M.S. 2
10
12 8 JZ 4010 12 Head Lamp Assly 1 Without Bulb
13 14 7 DS 2010 05 Head Lamp Assly –
9
9 9 39 0454 11 Washer Metallic 6
30 10 39 1778 02 Screw Tapping 2
14
19
11 JN 1810 05 Bracket Head Lamp Mounting 1 For Bkt. H/L Mtg
16 18
30 12 CL 2010 23 Lamp 12V 35/35W-HS1 1
15
13 DS 2010 36 Head Lamp Bulb Clip 1
20 14 DJ 2010 72 Lamp 12V 5W 2 Pilot Lamp
24
21 9 22 25 31 15 JZ 4010 15 Head Lamp Harness Branch 1
33
17 23 32 16 JN 1810 03 Bracket Fairing Top 1
19 27 17 JN 1810 17 Bracket Flap Support LH 1
28
26 18 JN 1810 18 Bracket Flap Support RH 1
19 JN 1810 21 Bolt Flange 2 Fairing Top
29
32 20 39 1943 04 Bolt Flange 2
27A
95 96
Head Lamp & Fairing

2 Description ES
3 Drum
21 JN 1810 23 Bracket H/L Mtg Lower LH 1

22 JN 1810 24 Bracket H/L Mtg Lower RH 1
23 59 0100 05 Screw Mushroom Head 2
24 JN 1810 04 Bracket Cowling 1
8
25 39 0219 11 Washer 2 For Bracket
6 Cowling Mounting
1
4 5 35
26 39 2060 04 Bolt Hex 2 For Bracket
11 Cowling Mounting
10
12 27 JN 2328 02 Bracket Cowling Lower 1
13 14 7 JZ 1812 08 Bracket Cowling Lower 1 Ref. Cir. IB-57
9
9 27A JZ 1510 08 Blinker mtg. bracket 1 Mounted on ‘Bkt.
30 Cowling Lower’
14 JZ 1510 24 Blinker mtg. bracket 1 Ref. Cir. IB-57
19
28 39 1943 04 Bolt Flange 2
16 18
30 29 39 1961 04 Bolt Hex Flange 1
15
30 39 1907 01 Mushroom Head Screw 4
20 24
21 9 22 25 31 31 39 2141 24 Washer Non-Metallic 4
32 39 1508 11 Washer for H/L Adjustment Bolt 2 N.S
33
17 23 32 33 39 0798 15 Hex. Flange Nut 1
19 27 34 JZ 1810 02 Damper Assly. (N.I.) 1 On Fairing
28
26 JZ 1010 06 Damper Assly. (N.I.) 1 alt for JZ 1810 02
35 JZ 1810 04 Foam Strip Head Lamp 6
29
32
27A
97 98
Head Lamp & Fairing

2 Description ES
3 Drum
35 JZ 1810 04 Foam Strip 1 N.I.

JZ 1810 05 Foam Strip -- N.I.
36 JN 1810 14 Foam Flap Cowling (LH/RH) 2 N.I.
8
37 39 1508 11 Washer for H/L Adjustment Bolt 2 N.I. N.S
6
1
5 38 JN 1814 06 Beading Speedo Flap (N.I.) 4 For Flap Cowling
4
39 JN 1810 14 Foam Speedo Flap (N.I.) 1 On Head Lamp
11 Assly.
10
12 40 JN 1810 19 Foam (N.I.) 1 Between Fairing
13 14 7 & Wind Shield
9
9
30
14
19
16 18
30
15
20 24
21 9 22 25 31
33
17 23 32
19 27 28
26
29
32
27A
99 100
Indicator Light Assembly
Description ES
Drum
6
1 JZ 4010 00 Indicator Assly FR. LH 1
2 JZ 4010 01 Indicator Assly FR. RH 1
3 DJ 2012 06 Indicator Assly RR. LH 1
3/4
4 DJ 2012 07 Indicator Assly RR. RH 1
5 GH 2010 12 Lamp 12 V - 10W 4 N.I.
6 39 1970 15 Hex. Nut with Flange 2 N.I.

7 31 2010 01 Collar 2
8 39 1950 04 Bolt Flange 2
9
9 39 0798 15 Nut M - 6 2
10 JZ 1510 08 Blinker mtg. Bracket 1 Mounted on ‘Bkt.
9
Cowling Lower’
11 39 1943 04 Flange Bolts 2 For Blinker mtg.

7
7 8 Bkt.
11
1/2
10
101 102
Tail Lamp Assly / Front Number Plate
Description ES
Drum
1 JZ 4010 41 Tail Lamp 1 alt JZ401045

18 17
2 DD 2010 11 Damper 2 For Front No. Plate
3 31 2010 01 Collar 2 For Front No. Plate
4 39 2124 15 Flange Nut 1
5 DJ 1610 72 Bracket Rear No. Plate 1 For Front No.
Plate mtg.
6 39 1553 04 Bolt Flange 2 For Front No. Plate

7 DP 1611 45 Number Plate Rear 1
8 39 2476 04 Hex Flanged Bolt 2 For Front No. Plate
9 DP 1611 44 Number Plate Front 1
10 JZ 2328 00 Front No. Plate Mounting Bkt. 1
20 1
11 39 1783 01 Truss Screw Front No. Plate 2
12 JW 4010 11 No. Plate Lamp With 2 pt. Coupler 1
4 4 13 13 DJ 2010 72 Bulb 12V/ 5W 1 Rr. No. Plate Lamp
12 14 39 0705 01 Screw 2 For Rr. No. Plate
14 Lamp
15
15 39 0711 11 Plain washer 2
- Do -
5
16 39 1211 11 Washer 2
11
17 39 0740 11 Washer (Non Metalic) 4 For Tail Lamp
10 18 39 0746 01 Screw For Tail Lamp 4
9 19 DJ 1610 07 Damper Rear No. Plate 1
7
2
20 JZ 1810 04 Foam Strip 1
3 8
16
6
103 104
Electrical Equipments
Description ES
Drum
1 JW 4016 00 Horn LH with Stay 1

3 39 1956 04 Flange Bolt 1
4 PA 4022 18 Wiring Harness 1
5 DS 2010 29 Rear Brake Switch 1 alt 32 2010 79
1 17 6 DS 1910 07 Spring Brake Switch 1

14
7 JZ 4010 13 Head Lamp Control Unit 1
2 8 8 DS 2010 82 Battrery MF Dry 5AH 1

18
9 DX 1610 32 Base Battery 1
3 10 DX 1610 44 Band Battery 1
11 DS 1611 04 Battery Arrester 1 N.S
7 5
6 12 DS 2010 25 Assly DC Flasher 1
12
9 13 39 2208 04 Bolt Flange 2
11 14 JN 3516 04 Starter Relay 1 With Grommet
15
15 30 2011 04 Fuse Box Assly. 2 For Light Main Fuse
4 13
16 16 30 2010 85 Fuse 2 Light & Main Fuse
17 DS 2010 22 Cable Assly. 1 (Battery to St. Relay)
10
18 PA 4022 03 St. Relay to Motor Relay 1
9
13
20
21
105 106
Electrical Equipments
Description ES
Drum
19 PA 4022 02 Cable Assly. (Battery to Earth) 1 N.I.

20 30 1910 48 Band (Harness) 5 Length 123 mm
21 30 2010 64 Band (Harness) 3 Length 149 mm

22 60 1114 15 Cable Tie Lock 1 N.I. (Fairing Mtg Bkt)
1 17 23 60 1114 17 Clip Positive Lock 1 N.I. (Frame)

14
2 8
18
7 5
6
12
9
11
15
4 13
16
10
13
20
21
107 108
Tool Kit
Description ES
Drum
1 PA 2310 00 Tool Kit 1 For Reference Only

PA 2310 02 Tool Kit 1 alt for PA 2310 00
2 DP 2210 11 Band Tool Kit 1 not Serviced
1 2 Separately.
109 110
Accessories / Grab Handle
Description ES
Drum
3
3 1 JZ 2312 01 Leg Guard 1
10 2 DS 1610 66 Frame Tape 1 N.I.
3 39 1556 04 Bolt Flange 2
13 12
4 39 1970 15 Nut 1
1
5 JA 1134 04 Bolt Flange (M8) 1
6 JZ 2312 02 Saree Guard 1

7 39 2731 04 Hex Bolt 1
9
8 39 2495 04 Socket Head Bolt 1
4
9 DS 1611 88 Grab Handle with Foam 1
5
10 39 1681 04 Flange Bolt 4 For Mounting
11
Grab Handle
7
11 DJ 1610 79 Foam LH 1
12 DJ 1610 80 Foam RH 1
13 PA 1138 00 Hook Clutch Cable 1
JZ 1138 02 Hook Clutch Cable 1 Ref. Circular A-10
24.1.2010
6 14 39 1943 04 Bolt Flange M6 1 Ref. Circular A-10

15
24.1.2010
15 JZ 2312 04 Small Sarre Guard 1 Ref. Circular A-10
8 24.1.2010
111 112
Kit List Kit List
Sr Kit Consisting of Following Parts Sr Kit Consisting of Following Parts

Kit Description Kit Description
No Part No. Part No. Description Qty/Kit No Part No. Part No. Description Qty/Kit
1 36PA0004 Valve Kit JB511200 Valve Intake 1 8 36DS1802 Bearing Cone Kit DH181025 Bearing cone 1
JB511201 Valve Exhaust 1 DH181026 Bearing race 1
DH181024 Upper bearing race 1
2 36JA0003 Valve Repair Kit 39201719 Seat Valve Stem 2 DS211004 Seat Damper 1
DG101029 Cotter Valve 2
JA511203 Retainer Valve Spring 2 9 36DS1401 Grommet Kit - Side Cover DS141012 Grommet Side Cover Front 2
28101129 Seat Valve Spring 2 DS161082 Grommet Side Cover Rear 2
JA511202 Spring Washer 2
10 36PA0014 Throttle Valve Kit JB581265 Valve Throttle 1
JB581235 Bar Clip 1
3 36PA0002 Kit Guide Camchain JB511004 Guide Camchain (Slack Side) 1 JZ581206 Collar Magnet Holder 1
JB521007 Guide Camchain (Tight Side) 1 JB581249 Spring Compr 1
11 36PA0015 Carb. Gasket- 'O' Ring Kit JB581231 Gasket Float Chamber 1
4 36PA0003 Piston Ring Set JB411207 Ring Piston Top 1
JB581239 Top Gasket 1
JB521208 Ring Piston Second 1 JB581240 ‘O’ - Ring 3
JB521209 Ring Piston Oil 1 JB581269 ‘O’ - Ring 24x26 (eng Side) 1
5 36DU1007 Boss Kick Set 30101233 Boss Kit 1 12 36PA0006 Set Primary Drive & Driven JB551401 Housing Compl Clutch 1
30101234 Spring 1 JA531010 Gear Primary Drive 1
30101236 Ball Steel 1
30101235 Pin 1 13 36JW0014 Starter Clutch Repair Kit JA621411 Bush Spring Starter Clutch 5
39085517 E - Type Clip 1 DH101163 Roller Clutch 5
1 JA621412 Spring 5
DJ101109 Bush For Spring Starter Clutch 5
6 36PA0013 Idling Screw Kit JB581241 Screw Stop 1
JB581240 ‘O’ - Ring 1
JB581242 Spring Compr 1 14 36DU1901 Cable Adjuster Kit. 39191017 Nut 2
DD191147 Screw 2
7 36DS2101 Seat Damper Kit DS211004 Damper Seat - I 7

DS211005 Damper Seat - II 2
113 114
Kit List Amendment Sheet
Sr Kit Consisting of Following Parts AMENDMENT SHEET (PARTS ADDED)

Kit Description
No Part No. Part No. Description Qty/Kit SR.
PART NUMBER DESCRIPTION QTY.
PAGE FIGURE
NO. NO. NO.
15 36DF1001 Kit O Ring for Cover 39101621 Ring - O 1

39102021 Ring - O 1
16 36DZ0020 Kit Front Fork Seal DL181080 Seal-Oil:Fork+2Gartr Sprng,Hi-Tech 1

DD181011 Seal - Dust 1
17 36JB0023 Kit Clutch Cover JB541207 Cover Clutch Star Type 1

31101064 Plug 1
JE541211 Decal Clutch Cover 1
JB541201 Jet Clutch Cover 1
18 36JB0025 Kit Assly Crankcase RH PF541018 Bushing Drum 1

JA541011 Needle Roller Bearing Hk1212 1
JB541026 Crankcase Rh Dm100 Ug 1
52JA0027 Stud (JA541015) Precoated 1
59200036 Bearing - Ball 6203 Hn3 C3 1
31101064 Plug 1
19 36JZ0015 KIT Cover Magneto JZ541210 Cover Magneto(Self Start) 1

JA541005 Bush Bendix 1
JE541212 Decal Magneto Cover 1
20 36JZ0023 Kit Primary Drive & Driven PF551401 Clutch Hsg Assly Comp (Bm100) 1
JZ531006 Gear Primary Drive 1
21 36JZ0037 Kit Friction Plate JZ551416 Plate Friction 5
115 116
SPC Updation Details SPC Updation Details
Page Fig. Old part New part Description
Updation Remarks Page Fig. Old part New part Description
Updation Remarks
no. no. no. no. date no. no. no. no. date
117 118
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
14151021 10 62 31101173 3 12 36PA0043 2 66 39079708 3 58

15161069 2 94 31151018 13 66 39007104 10 34 39079815 6 56
15191026 11 70 31151021 14 66 39019811 8 70 39079815 9 90
22150241 4 30 31151029 10 66 39021111 7 56 39079815 33 98
30101096 6 28 31161018 9 88 39021911 25 98 39079815 9 102
30101142 4 24 31181099 21 78 39024211 15 56 39080708 17 70
30101195 11 26 31181102 24 78 39025811 4 50 39080808 9 70
30141015 13 86 31201001 7 102 39029215 16 50 39081715 8 18
30141031 3A 86 31201001 3 104 39029215 22 70 39084001 18 62
30141039 6 86 31201081 5 22 39032615 11 56 39098004 11 28
30151038 13 62 35161060 6 96 39042215 9 58 39098308 6 88
30151038 20 68 36DF1001 24 74 39042215 23 74 39098717 3 14
30151041 23 64 36DS1401 1 88 39045411 11 50 39099206 2 16
30151042 24 64 36DS1802 4 48 39045411 9 96 39099206 4 38
30151069 9 62 36DS2101 2 44 39055302 10 50 39099311 5 30
30151069 16 66 36DU1007 3 30 39059417 12 8 39099906 12 22
30151096 18 70 36DU1901 35 74 39069415 16 70 39099906 25 24
30151105 8 62 36DZ0020 2 76 39070501 14 104 39100006 2 10
30151105 17 66 36JA0003 6 6 39071111 15 104 39100006 6 20
30151118 20 62 36JB0021 5 32 39072311 19A 66 39100006 11 22
30171022 5 54 36JB0022 4 32 39073212 19 62 39100120 23 24
30181006 5 48 36JB0023 1 24 39073817 6 30 39100120 15 28
30181009 11 76 36JB0025 2 20 39074011 8 86 39101321 25 64
30181025 4 76 36JW0014 6 40 39074011 17 104 39104119 3 24
30181026 3 76 36JZ0015 1 26 39074601 8 20 39105411 7 88
30191017 28 74 36JZ0023 7 12 39074601 4 42 39118101 14 76
30191035 10 70 36JZ0023 16 28 39074601 18 104 39121111 16 104
30191036 12 70 36JZ0037 7 28 39074701 9 22 39128321 9 4
30191038 7 70 36PA0002 6 8 39075301 3 38 39128321 13 4
30191048 27 74 36PA0003 3 10 39076101 2 86 39135815 13 50
30191048 20 108 36PA0004 5 6 39078408 7 54 39136420 12 66
30201064 21 108 36PA0013 6 32 39078912 15 70 39150711 2 106
30201085 16 106 36PA0014 18 32 39078912 13 76 39150811 32 98
30201104 15 106 36PA0015 19 32 39079415 9 66 39150811 37 100
119 120
39151011 2 62 39197015 6 102 39272204 8 54 52PA0145 6 82

39154011 19 70 39197015 4 112 39272315 6 46 59010005 23 98
39155304 29 74 39198104 21 14 39272612 8 50 59040006 7 76
39155304 6 104 39201719 7 6 39272612 6 52 59040014 15 42
39155604 3 46 39206004 18 50 39273104 7 112 59040031 4 8
39155604 3 112 39206004 26 98 39275404 7 36 59040038 2 2
39167121 20 24 39212415 4 104 39275821 9A 86 59040038 11 20
39167204 21 70 39214124 3 96 52JA0028 14 28 59040038 16 22
39167404 3 42 39214124 31 98 52JA0029 12 20 59040038 17 24
39168004 3 70 39217924 3 86 52JB0229 1 22 59040038 4 26
39168104 10 112 39219019 7 22 52JB0231 5 10 59110008 2B 12
39171519 4 22 39220804 15 24 52JB0232 1 4 59120003 2A 12
39175904 17 22 39220804 7 26 52JB0233 1 22 59150014 1 12
39176511 11 34 39220804 13 106 52PA0015 6 82 59200036 3 20
39177802 10 96 39223801 7 96 52PA0016 6 82 59200036 3 22
39177902 15 34 39224020 6 66 52PA0017 6 82 59210023 14 22
39178301 11 104 39231004 2 52 52PA0018 6 82 59210024 18 14
39178924 5 88 39240817 12 30 52PA0019 6 82 60111415 22 108
39186420 5 12 39242001 16 56 52PA0020 2 80 60111417 23 108
39190204 4 44 39247604 8 104 52PA0021 3 80 CB101114 2 36
39190701 30 98 39248415 11 86 52PA0022 2 80 CF111019 8 42
39194304 12 42 39249211 8 36 52PA0023 3 80 CL201023 12 96
39194304 9 56 39249504 8 112 52PA0024 2 80 CL201042 7 90
39194304 31 74 39256220 2 22 52PA0025 3 80 CS101128 9 8
39194304 3 88 39258204 18 74 52PA0026 2 80 DD101097 13 30
39194304 20 96 39258811 13 36 52PA0027 3 80 DD111011 10A 42
39194304 28 98 39260011 3 28 52PA0051 2 80 DD111012 11 42
39194304 11 102 39260801 11 4 52PA0052 3 80 DD111018 8 42
39194304 14 112 39262921 12 4 52PA0054 1 94 DD111048 9 42
39195004 8 102 39266921 13 8 52PA0137 2 80 DD121181 19 24
39195604 3 106 39268020 5 62 52PA0138 3 80 DD141022 7 86
39196104 29 98 39268120 7 62 52PA0140 6 82 DD161071 14 36
39196404 14 20 39268220 15 66 52PA0142 2 80 DD161078 20 70
39197015 2 46 39270411 7 18 52PA0143 3 80 DD191069 8 72
121 122
DD191085 25 74 DJ151036 14 50 DS121126 7 34 DS181012 23 78

DD201011 2 104 DJ151042 13 70 DS141009 1 86 DS181015 8 76
DD201170 11 72 DJ151047 19 50 DS141013 10 86 DS181016 9 76
DF161102 8 58 DJ161007 19 104 DS141018 4 86 DS181016 16 76
DF161413 4 52 DJ161069 10 56 DS151048 2 60 DS181018 2 48
DF181091 20 74 DJ161072 5 104 DS151049 3 60 DS181060 11 90
DF181092 20 74 DJ161079 11 112 DS151052 5 60 DS191006 3 92
DG101029 4 6 DJ161080 12 112 DS151053 6 60 DS191007 6 106
DG101339 11 18 DJ181104 6 76 DS151089 11 62 DS191008 4 92
DG101418 7 24 DJ191054 4 72 DS151091 14 62 DS191011 5 70
DG121002 8 34 DJ201072 14 96 DS151091 21 68 DS191018 13 72
DG161121 2 88 DJ201072 13 104 DS151092 16 62 DS191038 5 72
DG191045 4 70 DJ201206 3 102 DS151094 17 62 DS191052 12 72
DH101048 5 8 DJ201207 4 102 DS151095 15 62 DS191054 5 92
DH101125 20 22 DJ221003 14 72 DS161035 10 88 DS201005 8 96
DH101125 14 30 DJ221004 15 72 DS161066 2 112 DS201022 17 106
DH101163 10 40 DK101135 7 16 DS161069 13 34 DS201025 12 106
DH101392 7 8 DL151014 22 64 DS161077 6 58 DS201029 5 106
DH101509 10 18 DL161015 13 56 DS161104 11 106 DS201033 3 72
DH101781 2 40 DL191014 26 74 DS161112 2 58 DS201036 13 96
DH101784 6 22 DP101269 6 24 DS161113 1 58 DS201079 9 86
DH121038 12 34 DP161144 9 104 DS161125 1 56 DS201082 8 106
DH151029 14 70 DP161145 7 104 DS161150 12 26 DS211006 3 44
DH161121 4 58 DP161163 6 54 DS161188 9 112 DU101213 20 14
DH161145 5 58 DP161170 3 54 DS161287 5 56 DU201018 3 72
DH161146 11 58 DP161260 8 48 DS171007 9 50 DU201046 33 74
DH161155 12 36 DP171006 7 48 DS171013 12 50 DX121005 16 34
DH161157 11 36 DP221011 2 110 DS171014 17 50 DX121006 17 34
DH161158 17 56 DS101117 8 30 DS171015 6 50 DX121007 3 34
DH161194 5 52 DS101154 6 12 DS181006 17 74 DX121010 4 34
DH161240 7 58 DS101215 8 24 DS181007 19 74 DX121011 5 34
DH181014 3 48 DS101276 3 8 DS181008 20 74 DX151009 11 66
DH191037 8 90 DS121116 2 34 DS181009 21 74 DX151010 8 66
DJ141008 8 88 DS121117 6 34 DS181010 22 74 DX151012 5 66
123 124
DX151014 15 50 JA351627 11 40 JA541233 10 26 JB122016 1 50

DX151015 4 66 JA511028 2 4 JA541235 10 20 JB131019 27 68
DX151016 24 68 JA511029 7 2 JA541236 9 24 JB131222 4 60
DX151018 26 68 JA511204 3 6 JA541237 10 24 JB131223 19 66
DX151081 1 66 JA511210 1 6 JA551002 4 14 JB131225 3 66
DX161032 9 106 JA511211 2 6 JA551004 7 14 JB171802 12 86
DX161044 10 106 JA511216 2 8 JA551008 16 14 JB181239 3 94
DX161052 4 94 JA521017 8 8 JA551009 17 14 JB181403 12 56
DX191001 34 74 JA521018 10 8 JA551406 2 28 JB181412 3 56
DX191008 4 72 JA521019 11 8 JA551416 12 28 JB181416 2 56
DX191009 9 72 JA521019 22 24 JA551420 13 28 JB351024 1 42
FD181019 19 74 JA531011 14 8 JA561002 8 16 JB351201 7 42
FD181020 22 74 JA531012 8 12 JA561207 4 18 JB401400 2 72
FD181030 16 72 JA531015 9 12 JA561208 5 18 JB401401 3 72
FD181031 17 74 JA541005 8 22 JA561209 6 18 JB401409 10 72
GH201012 5 102 JA541005 9 26 JA561211 12 18 JB402202 7 10
JA113403 1 46 JA541010 5 20 JA561400 9 18 JB501008 1 20
JA113404 5 46 JA541011 4 20 JA581217 8 4 JB511011 4 2
JA113404 5 112 JA541012 13 20 JA581406 5 4 JB511015 8 2
JA131202 25 68 JA541015 9 20 JA591040 3 36 JB511018 10 4
JA131205 18 66 JA541016 2 38 JA621001 7 30 JB511019 3 4
JA131606 26 64 JA541019 13 22 JA621002 9 30 JB511206 1 8
JA151013 5 76 JA541020 18 22 JA621006 11 30 JB521211 4 10
JA161003 1 70 JA541021 15 22 JA621201 1 30 JB531021 10 12
JA351600 7 40 JA541027 19 22 JA621206 2 30 JB541201 24 24
JA351602 11 40 JA541028 14 42 JA621402 4 40 JB551000 19 14
JA351604 8 40 JA541034 10 22 JA621406 5 40 JB551404 4 28
JA351606 9 40 JA541044 2 26 JA621410 3 40 JB551406 10 28
JA351608 12 40 JA541205 3 26 JA621414 1 40 JB551408 5 28
JA351609 13 40 JA541211 11 24 JB113004 9 36 JB551411 8 28
JA351618 14 40 JA541212 16 24 JB113005 10 36 JB571005 1 38
JA351619 16 40 JA541216 14 24 JB122009 7 50 JB581020 14 34
JA351624 15 40 JA541221 8 26 JB122010 2B 50 JB581021 1 34
JA351626 9 40 JA541225 12 24 JB122011 2A 50 JB581202 13 32
125 126
JB581204 14 32 JK113008 4 54 JW541000 18 24 JZ181406 14 56

JB581229 7 32 JK121007 19 78 JW541005 5 24 JZ231201 1 112
JB581230 8 32 JK121009 22 78 JW561206 2 18 JZ231202 6 112
JB581232 9 32 JN113200 10 58 JW561208 3 18 JZ231204 15 112
JB581237 2 32 JN122000 3 50 JW591028 5 36 JZ232800 10 104
JB581238 3 32 JN131812 8 62 JW591030 6 36 JZ401000 1 102
JB581247 12 32 JN131812 17 66 JZ113001 1 52 JZ401001 2 102
JB581248 10 32 JN171000 4 88 JZ113006 1 54 JZ401012 8 96
JB581255 11 32 JN181001 1 96 JZ113009 2 54 JZ401013 7 106
JB581256 20 32 JN181003 16 96 JZ113400 7 46 JZ401015 15 96
JB581257 15 32 JN181004 24 98 JZ113402 9 46 JZ401041 1 104
JB581258 16 32 JN181005 11 96 JZ113403 8 46 JZ402403 1 90
JB581259 17 32 JN181010 5 96 JZ113802 13 112 JZ511021 1 2
JB581260 21 32 JN181011 5 96 JZ151008 27A 98 JZ541202 5 26
JB581271 15 4 JN181014 12 90 JZ151008 10 102 JZ541214 21 24
JB581272 16 4 JN181014 36 100 JZ151016 1 72 JZ551204 14 14
JB581276 22 32 JN181014 39 100 JZ151018 6 72 JZ551205 13 14
JB581284 1 32 JN181017 17 96 JZ151019 7 72 JZ551413 1 28
JB581404 14 4 JN181018 18 96 JZ151024 27A 98 JZ551415 9 28
JB591051 1 36 JN181019 40 100 JZ151036 12 76 JZ561002 6 16
JB591054 36 JN181021 19 96 JZ161002 2 70 JZ581004 6 2
JB621003 10 30 JN181023 21 98 JZ161200 2 92 JZ581004 9 34
JD351206 10B 42 JN181024 22 98 JZ161201 1 92 JZ581204 6 4
JD511010 3 2 JN181406 13 90 JZ181002 34 98 JZ581205 7 4
JD521002 1 10 JN181406 38 100 JZ181003 4 96 JZ581401 4 4
JD531004 11 12 JN191000 1 44 JZ181004 35 98 JZ591043 4 36
JD551209 15 14 JN232802 27 98 JZ181004 35 100 LAD00026 23 68
JD551400 1A 28 JN351604 14 106 JZ181004 20 104 LAD00041 4 46
JD561004 5 16 JN402000 13 42 JZ181005 35 100 LBD00001 21 62
JD561011 3 16 JW151023 20 78 JZ181200 2 90 LCJ00001 1 62
JE541209 13 24 JW151029 15 76 JZ181206 2 96 PA111075 1 48
JE541210 6 26 JW351400 6 10 JZ181208 27 98 PA113015 3 52
JE541211 2 24 JW401011 12 104 JZ181401 8 56 PA113800 13 112
JE541212 13 26 JW401600 1 106 JZ181402 4 56 PA121001 25 78
127 128
PA121003 26 78 PA351202 6 42 PA75014N 4 82

PA121022 17 76 PA401000 6 48 PA75015D 4 82
PA121024 18 76 PA402202 19 108 PA75015E 4 82
PA121025 1 76 PA402203 18 106 PF232601 30 74
PA121045 15 76 PA402218 4 106 PF232601 5 86
PA122001 5 50 PA402401 3 90 PF351006 2 42
PA131002 1A 62 PA402402 4 90 PF511027 5 2
PA131003 5A 62 PA402403 5 90 PF531002 4 12
PA131010 1 60 PA402404 6 90 PF541018 7 20
PA131208 7 66 PA402405 10 90 PF551002 1 14
PA131600 6 62 PA402410 14 90 PF551003 8 14
PA131602 3 62 PA402411 15 90 PF551200 6 14
PA131602 4 62 PA402412 16 90 PF551201 5 14
PA131801 12 62 PA402413 17 90 PF551202 2 14
PA131806 22 68 PA402414 14 90 PF551203 10 14
PA151006 32 74 PA402418 4 90 PF551204 11 14
PA151006 10 76 PA402419 5 90 PF551205 12 14
PA161000 6 70 PA402420 6 90 PF551206 9 14
PA231000 1 110 PA402421 3 90 PF561000 1 16
PA233000 7 84 PA71013B 1 80 PF561002 4 16
PA233003 8 84 PA71013C 1 80 PF561200 1 18
PA233010 7 84 PA71013E 1 80 PF581309 23 32
PA233013 8 84 PA71013F 1 80
PA233020 7 84 PA71014N 1 80
PA233023 8 84 PA71015D 1 80
PA233030 7 84 PA71015E 1 80
PA233033 8 84 PA72013B 5 82
PA233040 7 84 PA72013C 5 82
PA233045 8 84 PA72013E 5 82
PA233072 8 84 PA72013F 5 82
PA233073 7 84 PA75013B 4 82
PA233084 8 84 PA75013C 4 82
PA233085 7 84 PA75013E 4 82
PA351201 5 42 PA75013F 4 82
129 130

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Bajaj Auto Limited

Akurdi Pune 411 035 India

DOC. NO.: 71110890 REV. 00, MAY. 10

1 Cover Cylinder Head 2 31 Front Hub 62, 64

Cover Cylinder Head

No. Part No. Description Qty Remarks

6 JZ 5810 04 Hose C’ case Breather 1

1 52 JB02 32 Head Cylinder Comp. 1 With Studs

Single Piece Manifold

1 JA 5112 10 Shaft Rocker Arm Intake 1 (Length 36mm)

2 5 36 PA00 04 Valve Kit 1 Refer Page No. 113

6 36 JA00 03 Valve Repair Kit 1 Refer Page No. 113

1 JB 5112 06 Camshaft Complete 1

6 36 PA00 02 Guide Chain Kit 1 Refer Page No. 113

11 JA 5210 19 Flange Bolt 2 alt 39167306

Cylinder and Piston

1 JD 5210 02 Gasket Cylinder 1

6 JW 3514 00 Thermal Sensor 1

1 59 1500 14 Flange Nut 2

1 PF 5510 02 Shaft Input Transmission 1

6 PF 5512 00 Gear 2nd Drive 1

Change Drum / Shift Fork

1 PF 5610 00 Drum Complete Gear Shift 1

Gear Change Mechanism

1 PF 5612 00 Lever Complete Gear Shift 1

1 3 JW 5612 08 Spring Gear Shift Return 1

5 JA 5612 08 Spring Inhibitor 1

8 6 JA 5612 09 Step Washer (Collar) 1

Engine Assembly / Crankcase RH

1 JB 5010 08 Engine Assly 1

6 39 1000 06 Dowel Pin 2

1 52 JB02 33 Crankcase Mag. Side 1 NRB + Bush+

3 7 39 2190 19 Oil Seal 1 Shifter Shaft

21 22 1 36 JB00 23 Clutch Cover Flower Type 1 Refer Page No. 115

2 11 30 1011 95 ‘O’ Ring 1

6 30 1010 96 Plate Clutch 4

Kick Starter Mechanism

1 JA 6212 01 Lever Assly Kick 1

11 JA 6210 06 Washer Thrust 1

2 1 JB 5812 84 Carburettor assly. 1

6 36 PA00 13 Idling screw kit 1 Refer Page No. 114

16 JB 5812 58 Tube Air Vent 1

21 JB 5812 60 Drain Screw 1

Air Cleaner Complete

1 JB 5810 21 Air Filter Assly 1

15 6 DS 1211 17 Tube Drain 1

1 JB 5910 51 Silencer Assly Without Shield 1

1 JB 5710 05 Oil Pump Assly 1

1 5 JA 6214 06 Drive Assly 1

11 JA 3516 02 ‘O’ Ring For Spigot (Flash) 1

16 JA 3516 19 Terminal Assly (Lucas-TVS) 1

Magneto, CDI & H.T. Coil

1 JB 3510 24 Rotor Assly 1

Seat Assembly / Seat Lock

1 JN 1910 00 Seat Assly Comp 1

1 JA 1134 03 Flange Bolt M10×10 2

Frame and Frame Fittings

1 PA 1110 75 Frame Assly. Comp. 1

Swing Arm / Rear Shock Absorber

1 JB 1220 16 Hex. Bolt/ Flange - M10 2 For RSA

11 39 0454 11 Plain Washer 2 For Chain Sider

Rider Foot Rest