Discover 135 DTSiPart Catalogue PDF

Brand ID: 001MC631
Foreward
We have pleasure in presenting the Spare Parts Catalogue for ‘Discover DTS-i
135cc’ Motorcycle. This catalogue has been specially designed to assist you in
selecting the correct parts for procurement to maintain 100% availability.
The Bajaj spares are subjected to the stringent quality control standards to ensure
longer life of the vehicle. It is therefore necessary that only the Genuine Bajaj Spares
are used.
In a continual effort to improve Performance and Efficiency of the vehicles,

Specifications, Diagrams, Illustrations and Part Numbers can change without notice.
All information contained in this manual is based on the Consequently, the description in this Spare Parts Catalogue cannot therefore be final
latest product information at the time of publication. Bajaj and binding on us.
Auto Limited accepts no liability for any inaccuracies or
The modifications / alterations which are carried out after the issue of this catalogue,
omissions in this publication, although every possible care
will be conveyed to you through our Service Circulars. You are requested to make
has been taken to make it as complete and accurate as necessary corrections in the Parts Catalogue as per the circulars so as to keep your
possible. All procedures and specifications subject to change catalogue up-to-date. This will ensure the appropriate and speedy delivery of the
without prior notice. The right is reserved to make such Spare Parts as the order placed will bear the latest part numbers.
changes at any time without prior notice and without

In case, if you need any technical assistance contact the concerned Regional Office
incurring an obligation to make such changes to product or write to us on the following address :
manufactured previously. Contact your authorized Bajaj
Dealer for the latest information on product improvements Bajaj Auto Limited
incorporated after this manual was issued. Service Department
Akurdi, Pune 411 035 India
Phone : 020-27406557
DOC. NO.: 71110430 REV. 00, DEC. 07 Fax : 020-27407385
E-mail : [email protected]
Brand ID: 001MC631 Brand ID: 001MC631
Instructions for using the Catalogue INDEX
1. How to Read the Catalogue : Open the catalogue and from the pictorial index No. Description Page
No. Description Page
locate the group in which the part you want to find is present. Turn over to the No. No.
concerned page number (as given by pictorial index). Now find out the figure of 1 Cover Cylinder Head 1 35 Rear Brake Pedal 45
the part you wish to order. Write down the part number against that particular 2 Cylinder Head 2
figure number from the text. 3 Valve 3 36 Handle Bar 46&47
4 Camshaft / Tensioner 4 37 Front Fork 48&49
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 5 Cylinder & Piston 5 38 Painted Parts & Decals 50&51
and page number of the part you wish to order. 6 Crankshaft 6 39 Petrol Cock, Cap Tank &
7 Transmission 7 & 8 Gauge Fuel 52
2. How to Order Spare Parts : The part number and the description of the part 8 Change Drum/ Shift Fork 9 40 Fittings - Petrol Tank,
required should be invariably mentioned in the order as per the catalogue text. 9 Gear Change Mechanism 10 Side Cover & Cover seat 53
10 Engine Assly & Crankcase RH 11
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 41 Meter Assly. 54&55
components should be mentioned. 11 Crankcase LH 12 42 Control Cables 56
12 Cover RH 13&14 43 Chain Case 57&58
The quantity shown against the part number is the quantity per vehicle for that 13 Cover Magneto 15 44 Head Lamp & fairing 59&60
group so that particular quantity should be multiplied by the number of sets 14 Clutch 16&17 45 Indicator Light Assly. 61
required.
15 Kick Starter Mechanism 18
3. Part Number System: We have used 8 digit system for part numbers. The model 46 Tail Lamp Assly./Front No. Plate 62
or hardware item is indicated by first two digits or alphanumeric, the next two or 16 Carburettor 19 47 Electrical Equipments 63&64
four digits indicate main group and the last four or two digits indicate serial number 17 Air Cleaner Comp. 20 48 Tool Kit 65
in main group or serial number or subgroup of fastener respectively. Thus the part 18 Silencer Assly 21 49 Accessories / Grab Handle 66
numbers will be indicated by 2-2-4 or 2-4-2 digit system. Understanding this 19 Seat Assly / Seat Lock 22 Kits List For Discover 67
system will enable you to identify the spare parts easily. 20 Oil Pump 23
Amendmend Sheet
4. Abbreviations : The following abbreviations are used in this catalogue.
21 Magneto/C.D.I./H.T.Coil 24&25 (Parts Added) 68
assly. Assembly V Volts 22 Starter Assly (For Electric Start) 26&27
23 Engine Mountings 28 Amendmend Sheet
N.I. Not illustrated W Watts
24 Frame & Frame fitting 29 (Parts Deleted) 69
C'case Crankcase accl. Accelerator 25 Swing Arm / Rear Shock
Cyl Cylinder Comp. Complete Absorber 30-32 Part index 70
o/s. Over size Fr Front 26 Rider Foot rest 33

Std. Standard L Length 27 Pillion Foot rest / Holder 34
28 Mudguard Front & Rear 35
A/t. Alternate Rr Rear 29 Stand Assembly 36
R.H. Right hand Hex. Hexagonal 30 Tyre/ Tube /Rim 37
L.H. Left hand AR As required

31 Front Hub 38-40
32 Front Master Cylinder 41
33 Front disc brake 42
34 Rear Hub 43&44
Pictorial Index Pictorial Index
PLATE NO. : 1 PAGE NO.: PLATE NO. : 2 PAGE NO.: PLATE NO. : 7 PAGE NO.: PLATE NO. : 8 PAGE NO.:
COVER CYLINDER HEAD 1 CYLINDER HEAD 2 TRANSMISSION 7 & 8 CHANGE DRUM / SHIFT FORK 9
VALVE 3 CAMSHAFT / TENSIONER 4 GEAR CHANGE MECHANISM 10 ENGINE ASSLY. & CRANKCASE RH 11
CYLINDER & PISTON 5 CRANKSHAFT 6 CRANKCASE LH 12 COVER RH 13 & 14

COVER MAGNETO 15 CLUTCH 16 SILENCER ASSEMBLY 21 SEAT ASSEMBLY / SEAT LOCK 22
PLATE NO. : 14A PAGE NO.: PLATE NO. : 15 PAGE NO.: PLATE NO. : 20 PAGE NO.: PLATE NO. : 21 PAGE NO.:
CLUTCH 17 KICK STARTER MECHANISM 18 OIL PUMP 23 MAGNETO /C.D.I./H.T. COIL 24 & 25
CARBURETTOR 19 AIR CLEANER COMP. 20 STARTER ASSLY. 26 & 27 ENGINE MOUNTINGS 28

FRAME & FRAME FITTING 29 SWING ARM / REAR SHOCK ABSORBER 30 STAND ASSEMBLY 36 TYRE / TUBE / RIM 37
PLATE NO. : 25A PAGE NO.: PLATE NO. : 26 PAGE NO.: PLATE NO. : 31 PAGE NO.: PLATE NO. : 31A PAGE NO.:
SWING ARM / REAR SHOCK ABSORBER 31 & 32 RIDER FOOT REST 33 FRONT HUB(FOR DRUM BRAKE SYSTEM) 38 & 39 FRONT HUB (FOR DISC BRAKE SYSTEM) 40
PILLION FOOT REST / HOLDER 34 MUDGUARD FRONT & REAR 35 FRONT MASTER CYLINDER 41 FRONT DISC BRAKE 42
FITTINGS-PETROL TANK, SIDE COVER
REAR HUB 43 & 44 REAR BRAKE PEDAL 45 53 METER ASSEMBLY 54 & 55
& COVER SEAT
HANDLE BAR 46 & 47 FRONT FORK 48 & 49 CONTROL CABLES 56 CHAIN CASE 57
PLATE NO. : 38 PAGE NO.: PLATE NO. : 39 PAGE NO.: PLATE NO. : 43A PAGE NO.: PLATE NO. : 44 PAGE NO.:
PETROL COCK, CAP TANK &
PAINTED PARTS AND DECALS 50 & 51 GAUGE FUEL 52 CHAIN CASE 58 HEAD LAMP & FAIRING 59 & 60
Pictorial Index Plate No. 1 : COVER CYLINDER HEAD
PLATE NO. : 45 PAGE NO.: PLATE NO. : 46 PAGE NO.:
INDICATOR LIGHT ASSEMBLY 61 TAIL LAMP ASSLY. / FRONT NO.PLATE 62

6
8
9 4
2 7
11 2
PLATE NO. : 47 PAGE NO.: PLATE NO. : 48 PAGE NO.:

10
ELECTRICAL EQUIPMENTS 63 & 64 TOOL KIT 65
10
1
11
1A 1B
No. Part No. Description Remarks
Drum Br. Disc Br.
1 JN 5110 06 Head Cylinder with Cover 1 1

2 DJ 1012 17 Cover Tappet 2 2
3 36 DS10 01 ‘O’ Ring Kit for Cover Cyl. Head 1 1 Ref. Page No. 67
4 DS 1011 93 Bush Cylinder Head Cover 1 1
PLATE NO. : 49 PAGE NO.:
5 DS 1010 96 Camshaft Cap 1 1
ACCESSORIES / GRAB HANDLE 66
6 39 2647 15 Dommed Cap Nut 4 4
7 DS 1010 84 Copper Washer 4 4
8 39 2532 04 Bolt Flange Small 2 2
9 39 1075 04 Bolt Flange Small 4 4
10 DH 1012 72 Plug 1 1
11 DG 1014 98 Gasket 2 2
: Front Wheel Direction 1

Plate No. 2 : CYLINDER HEAD Plate No. 3 : VALVE
13 5
6 4
2
10
5
1 11
1
12 7
3
2
9
6
9
8
5 8
3 7
8
2A 2B 3A 3B
No. Part No. Description Remarks No. Part No. Description Remarks
Drum Br. Disc Br. Drum Br. Disc Br.
1 JN 5110 06 Head Cylinder with Cover 1 1 1 DS 1013 35 Rocker Arm Shaft - Intake 1 1
2 39 1660 05 Stud (Exhaust) 2 2 2 DS 1013 36 Rocker Arm Shaft - Exhaust 1 1
3 DH 1016 80 Gasket Cylinder Head 1 1 3 DS 1013 33 Rocker Arm with Roller 2 2
4 DH 1015 08 Damper Cylinder Head 5 5 4 DS 1013 66 Wave washer 2 2
5 JN 5814 00 Intake Pipe 1 1 5 59 1100 02 Plain washer 4 4
6 39 1283 21 ‘O’ Ring (Intake Pipe) 1 1 6 DG 1010 29 Cotter valve 4 4

7 DS 1210 12 Carburetor Insulator 1 1 7 36 DS10 03 Valve Repair Kit 1 1 Ref. Page No. 67
8 DH 1210 38 Clamp for Insulator 2 2 8 36 DS10 02 Valve Kit 1 1 Ref. Page No. 67
9 39 1674 04 Hex. Bolt / Flange 2 2 9 39 2017 19 Seal Oil 2 2
10 DH 1110 12 Sleeve Spark Plug 1 1
11 39 2608 01 Grub Screw 1 1

12 36 DS10 01 ‘O’ Ring Kit for Cover Cyl. Head 1 1 Ref. Page No. 67
13 39 2181 06 Hollow Dowel Pin 2 2
2 : Front Wheel Direction : Front Wheel Direction 3

Plate No. 4 : CAMSHAFT / TENSIONER Plate No. 5 : CYLINDER AND PISTON
2
5
2 3
6
15 4 5 6 7
1
3
8 13
14
4
12
9 10
4
11
4A 4B 5A 5B
1 JN 5112 02 Camshaft Assly 1 1 1 DH 1010 16 Gasket Cylinder 1 1

2 39 1880 20 Bearing cam LH side 1 1 2 39 2181 06 Pin dowel 4 4
3 DH 1014 20 Washer behind small bearing 1 1 3 36 DJ40 08 Ring Set Piston 1 1 Ref. Page No. 67
4 DH 1014 12 Collar cam Sprocket 1 1 4 DH 101671 Ring Snap 2 2
5 DS 1012 76 Sprocket 1 1 5 JN 5210 01 Cylinder Block / Piston Assly 1 1
6 DH 1010 48 Special camshaft washer 1 1 6 JF 5212 00 Piston Assembly 1 1

7 DH 1013 87 Hex. Soc. Head cap Bolt 1 1
8 36 DS10 04 Guide chain Kit 1 1 Ref. Page No. 67
9 DS 1010 36 Cam Chain (94 Links) 1 1
10 39 1674 04 Hex Bolt / Flange 2 2
11 DH 1010 11 Cam chain Tensioner pivot Bolt 1 1

12 DJ 1012 16 Tensioner Assly 1 1
13 39 1014 21 Ring’O’ 1 1
14 DD 1010 62 Bolt 1 1
15 39 2542 20 Bearing Ball 1 1

Plate No. 6 : CRANK SHAFT Plate No. 7 : TRANSMISSION
13 9
4
10
6
1
2 16
12 4 1
13 14
19
5 3 17
17 23 11 12
5 15
17
7 9
17 8
15 16
14 20
10
11
19
18 7
2 8 22 21
3 18
6
6A 6B 7A 7B
1 JN 5310 00 Crankshaft assly. Comp. 1 1 1 DS 1012 91 Shaft Input Transmission 1 1

2 DH 101195 Nut 1 1 2 DS 1012 05 Collar 1 1
3 39 2200 11 Washer 1 1 3 DS 1010 49 Gear 4th Drive 1 1
4 DS 1013 63 Gear primary driver 1 1 4 39 0987 17 Ring Snap 1 1
5 DS 1012 75 Sprocket cam drive 1 1 5 DS 1010 48 Gear 3rd Drive 1 1
6 DS 1010 77 Body centrifugal oil filter 1 1
7 DS 1012 60 Cover centrifugal oil filter 1 1 6 39 0337 17 External Circlip 1 1
8 39 2713 21 ‘O’ Ring 1 1 7 DS 1010 47 Gear 2nd drive 1 1
9 DS 1011 54 Key 1 1 8 DS 1011 29 Thrust washer 1 1
10 DH 1010 66 Joint Oil Delivery - B 1 1 9 DS 1099 07 Shaft output Transmission 1 1 With Plug & Collar
11 DS 1011 12 Spring Oil Delivery- B 1 1 10 DS 1012 04 Washer Plain 1 1
12 31 1011 73 Key woodruff 1 1
13 39 2203 07 Parallel pin 1 1 11 DS 1010 54 Gear 3rd Driven 1 1
14 DS 1013 55 Bolt 1 1 12 DH 1010 79 Washer Spline 1 1
15 39 2165 11 Plain washer 1 1 13 DS 1010 55 Gear 4th Driven 1 1
14 DH 1011 11 Bush 1st driven 1 1
16 28 1011 10 Damper 1 1
15 DS 1010 52 Gear 1st driven 1 1
17 39 2561 20 Ball Bearing 2 2
18 39 2712 17 Circlip 1 1
19 DS 1011 52 Spacer 1 1
Plate No. 7 : TRANSMISSION Plate No. 8 : CHANGE DRUM / SHIFT FORK
10
6
2 16
7 4
4 1
13 14
3 6
17 3
23 11 12
5 15
17 5
7 9
8
20
19
22 21
18 2
3
7A 7B 8A 8B
16 DS 1012 03 Washer Plain 1 1 1 DS 1010 63 Fork Gear Shift Input 1 1

17 DH 1012 35 Circlip 2 2 2 DS 1010 64 Fork Gear Shift output 1 1
DH 1012 35 Circlip 1 1 For DS 1099 07 3 DS 1010 62 Shaft Gear Shift Fork 2 2
18 DS 1013 55 Hex. Socket Bolt 2 2 4 DS 1010 79 Guide Gear Shifter 1 1
19 DH 1013 34 Collar Sprocket 1 1 5 DS 1011 35 Drum Assly. Gear Shift 1 1
20 30 1010 61 ‘O’ Ring Sprocket Collar 1 1
6 39 2639 04 Bolt Socket 1 1
21 DS 1011 97 Sprocket Drive 1 1 7 DS 1011 32 Parallel pin 1 1
22 DS 1011 98 Plate Drive Sproket 1 1
23 DS 1011 07 Spline washer 1 1

Plate No. 9 : GEAR CHANGE MECHANISM Plate No. 10 : ENGINE ASSEMBLY, CRANKCASE R.H.
12 13
3
3
4
2 10 11
9
1
7 3
2
10
8
4
6
7
8
6 9
5
9A 9B 10A 10B
1 DS 1011 34 Lever comp. Gear Shifter 1 1 1 JN 5010 00 Engine Assly. 1 1

2 DS 1011 18 Spring slider arm reset 1 1 1 JN 5010 01 Engine Assly. 1 - For KS Drum Brake
3 DS 1011 73 Stopper Comp.gear shifter drum 1 1 2 JN 5410 02 Crankcase RH 1 1
4 DS 1011 04 Bolt shift change 1 1 3 39 2531 05 Stud 2 2
5 DS 1012 51 Lever comp. change 1 1 4 DG 1210 02 Spring Clip 1 1
with Damper 5 DS 1011 67 Gasket Crankcase 1 1
6 31 1011 08 Damper 1 1 6 39 2583 20 Bearing Ball (For input shaft) 1 1

7 39 1673 04 Flanged Bolt 1 1 7 39 2662 20 Needle Brg. (For Output shaft) 1 1
8 DH 1012 25 Bolt Gear Shift drum Stopper 1 1 8 39 2181 06 Dowel Pin 2 2
9 DS 1011 19 Spring gear shifter return 1 1 9 DU 1010 85 Bushing (For Drum Change) 1 1
10 DS 1011 03 Spring gear shifter drum stopper 1 1 10 DH 1012 25 Bolt 1 1 For Holding Spring
11 DS 1012 14 Rubber tube 1 1

12 39 0746 01 Screw 1 1
13 DS 1010 08 Breather Plate 1 1

Plate No. 11 : CRANKCASE LH Plate No. 12 : COVER RH
10
2 2 6 4
13 7 12
3 13
20
17
15 18
4
14
15 2
9
16 3 19
5
6
10
12
11 1 8
17
7
8 9 16
5
14 11
11A 11B 12A 12B

1 JN 5410 00 Crankcase LH 1 1 1 JN 5412 00 Cover comp. RH 1 1

2 39 2531 05 Stud 2 2 2 39 1917 19 Oil Seal 1 1
3 39 1715 19 Oil Seal 1 1 3 39 1041 19 Seal Oil 1 1
4 39 2562 20 Needle Bearing (For Input shaft) 1 1 4 DS 1010 67 Lever Assly. Clutch 1 1
5 39 2583 20 Bearing Ball (For Output shaft) 1 1 5 DS 1010 50 Rod Push (For Clutch Lever) 1 1
6 39 2189 19 Oil Seal (For Output shaft) 1 1
7 39 2190 19 Oil Seal (For Shift lever) 1 1 6 DS 1012 63 Dip Stick with O Ring 1 1
8 JN 5710 01 Cap Strainer 1 1 7 DH 1011 52 ‘O’ ring Oil level Gauge 1 1
9 39 1754 21 ‘O’ ring 1 1 8 39 1075 04 Bolt 8 8
10 39 1283 21 ‘O’ ring 1 1 9 39 0999 06 Pin Dowel 2 2
10 DS 1010 73 Bracket Clutch Cable 1 1
11 31 2010 81 Switch comp.(Neutral) 1 1
12 DH 1012 64 Gasket Neutral Switch 1 1 11 DS 1010 72 Gasket cover RH 1 1
13 39 1963 04 Flanged Bolt 1 1 12 DS 1011 23 Spring clutch lever 1 1
14 39 1677 04 Bolt 6 6 13 39 2443 11 Washer 1 1
15 39 1845 04 Bolt 1 1
14 DS 1012 11 Damper Cover RH 1 1
16 DH 1011 69 Bush starter gear inner 1 1 15 39 2544 04 Hex. HD Bolt / Flange 1 1
17 DS 1210 04 Mesh Filter oil Comp. 1 1

Plate No. 12 : COVER RH Plate No. 13 : COVER MAGNETO
10 11
6 4
7 12
3 13 13
20 10
17
4
18
14
15 2
9 3
19
12
1 8 6
8
16 7
5 2
11 1
9
12A 12B 13A 13B

16 DS 1012 52 ‘bajaj’ Decal 1 1 Fixed on cover comp. RH 1 JN 5412 04 Cover Mag.with gauge & decal 1 1 JN 5412 03
17 DG 1014 18 Gauge 1 1 2 39 1674 04 Bolt Hex. 3 3
18 DS 1012 15 Wire Circlip 1 1 3 DG 1014 18 Gauge 1 1
19 DS 1012 12 Plate Cover Damper RH 1 1 4 DS 1013 07 Gasket Magneto cover 1 1
20 DS 1012 01 Bushing 1 1 5 39 1075 04 Bolt 4 4
6 39 0999 06 Pin Dowel 2 2

7 DH 1011 57 Cap Crank Center 1 1
8 39 1283 21 ‘O’ Ring 1 1
9 52 JN00 08 Cover LH Rear with Decal 1 1 JN 5412 06
10 DS 1012 10 Damper Cover LH 1 1
11 39 2208 04 Flanged Bolt 4 4

12 DS 1012 53 ‘bajaj’ Decal 1 1 Fixed on Cover magneto
13 DH 1012 83 Plate Damper Cover LH 1 1

Plate No. 14 : CLUTCH Plate No. 14A : ANTI-JUDDER CLUTCH
4 4
5 5
12 12
4 4
2 2
5 5
4 4
11 7 11 7
5 5
8 8
6 6
3 3
9 9
4 4 16
1 1
13 15
10 10
14A 14B 14A 14B

1 39 2200 11 Plain Washer 1 1 1 39 2200 11 Plain Washer 1 1

2 DS 1013 19 Clutch Center 1 1 2 DS 1013 19 Clutch Center 1 1
3 DH 1013 44 Plate Clutch pressure 1 1 3 DH 1013 44 Plate Clutch pressure 1 1
4 JN 5514 10 Disc Clutch friction Adler (E type) 4 4 4 JN 5514 10 Disc Clutch friction Adler (E type) 4 4
5 DH 1015 57 Plate Clutch 3 3 5 DH 1015 57 Plate Clutch 3 3
6 JN 5514 00 Spring Clutch 6 6 6 JN 5514 00 Spring Clutch 6 6

7 39 1553 04 Bolt 6 6 7 39 1553 04 Bolt 6 6
8 DH 1014 84 Holder Clutch 1 1 8 DH 1014 84 Holder Clutch 1 1
9 DS 1011 05 Guide Plate Clutch Pressure 1 1 9 DS 1011 05 Guide Plate Clutch Pressure 1 1
10 DH 1015 20 Nut Primary drive lock 1 1 LH Thread 10 DH 1015 20 Nut Primary drive lock 1 1 LH Thread
11 JN 5514 01 Assembly Clutch Complete 1 1 11 JN 5514 17 Assembly Clutch Complete 1 1

12 JN 5514 02 Clutch Plate Assly 1 1 12 JN 5514 16 Clutch Plate Assly 1 1
13 DH 1014 85 Rod Clutch Lifter 1 1 13 JN 5514 08 Anti Judder Spring 1 1 N.I.
14 JN 5514 09 Anti Judder Washer 1 1 N.I.
15 JN 5514 15 Assembly Recess Cup 1 1
16 JN 1514 14 Rod Push 1 1

Plate No. 15 : KICK STARTER MECHANISM Plate No. 16 : CARBURETTOR
13
6
13
10
4
3
12
7 11
14
2
7
11 5
2 8
3 1
16 8 15 16 8 6 10
9 6
12
4 9
1
15A 15B 16A 16B

1 DS 1012 06 Lever Kick Starter complete 1 1 1 JN 5812 01 Carburetor Assly. 1 1

2 DD 1010 97 Damper 1 1 2 36 DS12 01 Vacuum Piston Kit 1 1 Ref. Page No. 67
3 36 DS10 07 Boss Kick Set 1 1 Ref. Page No. 67 3 JN 5812 08 Jet Holder Kit 1 1
4 DS 1012 09 Bolt Special 1 1 4 JN 5812 15 Jet needle 1 1 Ref. Page No. 67
5 DS 1010 58 Collar Spring 1 1 5 DS 1210 89 Packing 1 1
6 DS 1010 57 Spindle Kick Starter Assly 1 1
7 DS 1010 60 Pinion Kick Starter 1 1 6 DS 1210 90 Screw Pan 4 4
8 39 2276 11 Washer 2 2 7 DS 1210 80 Float Comp. 1 1
9 39 0993 11 Washer Thrust 1 1 8 DH 1211 01 Magnet Assly. 1 1
10 39 2276 11 Plain Washer 1 1 9 DH 1211 02 Reed Switch Assly. 1 1
10 39 0899 01 Pan Head Screw 2 2
11 DS 1010 61 Guide Kick 1 1
12 DH 1013 85 Bolt Flanged 3 3 For KS qty is 4 11 JN 5812 07 Idling Screw Kit 1 1 Ref. Page No. 67
13 DS 1010 59 Spring Kick Starter 1 1 12 DS 1210 76 Float Valve Comp. 1 1
14 DS 1011 90 Ratchet 1 1 13 DS 1211 15 Set Plunger 1 1
15 DH 1011 21 Spring 1 1
14 JN 5812 12 Choke Plunger Housing with Gasket 1 1 N.I.
16 39 0738 17 Circlip 2 2
17 39 1373 04 Bolt 1 - For KS

Plate No. 17 : AIR CLEANER COMP Plate No. 18 : SILENCER ASSEMBLY
1 6
5
2 8
7
10
2 8
2
10 3
7
6
9
9
5
3
11
4
1
13
12
17A 17B 18A 18B

1 JN 5810 02 Air Cleaner comp. -- 1 1 JN 5910 00 Silencer Assly. -- 1

DS 1211 29 Air Cleaner comp. 1 -- DS 1013 89 Silencer Assly. 1 --
2 DS 1610 69 Bracket Side Cover Mtg. 1 1 2 DH 1013 01 Seal Shield Muffler 2 2
3 JN 5810 01 Connecting Tube -- 1 3 DH 1014 68 Shield Muffler 1 1
DS 1211 31 Connecting Tube 1 -- 4 DD 1610 71 ‘U’ Nut 1 1
4 DX 1210 07 Cartridge Assly. 1 1 5 DJ 1010 64 Gasket Exhaust 1 1
5 DX 1210 10 Element Air Filter 1 1
6 39 1970 15 Flanged Nut 2 2
6 39 0071 04 Hex. Bolt 3 3 7 39 2730 04 Hexagonal Bolt 1 1
7 39 1765 11 Plain Washer 3 3 8 DH 1013 02 Truss Screw 2 2
8 31 1210 43 Collar 2 2 9 DH 1014 81 Grommet Shield 1 1
9 39 1940 04 Flanged Bolt 2 2 10 JN 5910 16 Wire Shield Assly. 1 1
10 DX 1210 06 O ring 1 1
11 DS 1211 17 Drain Tube 1 1

12 DS 1211 26 Plug 1 1
13 DG 1210 02 Spring Clip 2 2

Plate No. 19 : SEAT ASSEMBLY / SEAT LOCK Plate No. 20 : OIL PUMP
5
4
2 4
4
2 3 6 1
19A 19B 20A 20B

1 DS 2110 01 Seat Assly comp 1 1 1 DS 1211 18 Oil Pump Body 1 1

2 36 DS21 01 Seat Damper Kit 1 1 2 28 1210 07 Rotor Oil Pump inner 1 1
3 DS 2110 06 Lock Assly seat 1 1 3 28 1210 08 Rotor Oil Pump outer 1 1
4 39 1902 04 Flanged bolt 2 2 4 39 1674 04 Bolt 3 3
5 DS 1013 65 Gear oil Pump Driven 1 1
6 39 1686 06 Hollow Dowel Pin 3 3

Plate No. 21 : MAGNEO / C.D.I / H.T.COIL Plate No. 21 : MAGNEO / C.D.I / H.T.COIL
9 9
10 10
19 21 19 21
18 13 7 18 13 7
12 12
20 20
8 11 8 11
12 6 12 6
16 5 16 5
3 3
14 14
4 1 4 1
15 7 15 7
17 2 17 2
21A 21B 21A 21B

1 DS 1110 56 Rotor Assly. 1 1 For new vehicle 16 39 1943 04 Flange Bolt 1 1

DS 1110 18 Rotor Assly. 1 1 For old vehicle 17 39 0798 15 Flange Nut 1 1
2 DS 1110 49 Stator Assly. comp 1 1 For new vehicle 18 39 1902 04 Flange Bolt 2 2
DS 1110 16 Stator Assly. comp 1 1 For old vehicle 19 DJ 1610 67 Bracket H.T.Coil 1 1
3 39 1674 04 Hex. Bolt with Flange 2 2 20 39 1680 04 Flange Bolt 2 2
4 39 0761 01 Pan Head Screw 2 2
5 DH 1011 99 Stopper plate (wiring harness) 1 1
21 DH 1110 16 Grommet Sleeve Spark Plug 1 1
6 39 0746 01 Screw Pan head 1 1
7 DG 1110 08 Spark plug (Champion RG4HC) 2 2
8 DS 1110 43 C.D.I Assly 1 1
9 DS 1110 35 H.T. Coil LH with Grommet 1 1
10 DS 1110 36 H.T. Coil RH with Grommet 1 1
11 DH 1110 15 Cap Spark Plug 2 2

12 DD 1110 12 Grommet H.T. Cable 2 2
13 DH 1110 13 Grommet Spark Plug 1 1
14 DS 2010 03 Regulator Voltage 1 1
14 DH 2010 18 Regulator Voltage 1 -- For KS
15 31 2010 82 Capacitor 1 -- For KS

Plate No. 22 : STARTER ASSEMBLY Plate No. 22 : STARTER ASSEMBLY (FOR ELECTRCI START)
17 12 17 12
13 18
13 18
19
16 19
16
14
14
4
4
1
22 1
3 22 3
11
11
8
5 8
7 5
9 7 9
10 6
8 21 10
21 6
2 8
15 2
15
20
20
22A 22B 22A 22B

1 DH 1017 82 Body comp. starter clutch 1 1 For new vehicle 16 39 1062 04 Bolt 2 2
DH 1015 34 Body comp. starter clutch 1 1 For old vehicle 17 DS 1011 44 Cap 1 1
2 DH 1011 64 Spring 5 5 18 39 2547 17 Circlip 1 1
3 DH 1017 81 Plate roller clutch 1 1 For new vehicle 19 39 0999 06 Dowel Pin 2 2
DH 1011 86 Plate roller clutch 1 1 For old vehicle 20 DH 1011 63 Roller 5 5
4 DH 1014 01 Gear starter clutch 1 1
5 DH 1015 81 Plate starter clutch gear return 1 1 Stopper plate
21 DH 1015 33 Bush Spring Starter Clutch 5 5
6 39 1672 04 Bolt 1 1 For stopper plate 22 DS 1012 94 Gasket 1 1
7 DS 1011 01 Shaft starter counter 1 1 23 59 1000 02 Spring dowel 1 1 N.I.
8 DS 1011 79 Special Washer starter counter 2 2
9 DH 1014 72 Gear starter counter 1 1
10 39 2152 20 Needle roller bearing 1 1
11 39 2437 04 Bolt socket 3 3

12 JN 3516 00 Motor assly. starter -- 1
DS 1110 51 Motor assly. starter 1 --
13 39 1074 04 Bolt 4 4
14 JN 5514 07 Body Starter Counter 1 1
15 DJ 1011 09 Bush for Spring Starter 5 5

Plate No. 23 : ENGINE MOUNTINGS Plate No. 24 : FRAME AND FRAME FITTINGS
4
2 2
4 3
4
4 5
9
5
5
3
5
3
4 8
4
3
9
1
4
6 10
3
4
8 5 6
9
7
8
11
5
9
23A 23B 24A 24B

1 36 DS16 02 Engine Mounting Bracket Set 1 1 1 DS 1612 57 Frame Assly. comp. -- 1 Incl bush, races & Cup rear
2 36 DS16 01 Engine Mounting Plate Set 1 1 DS 1611 19 Frame Assly. comp. 1 --
3 39 2312 04 Bolt Flanged 4 4 2 DS 1810 18 Nut Fork 1 1
4 39 1970 15 Nut Flanged 7 7 3 DH 1810 14 Cup - Steering 1 1
5 39 1556 04 Bolt flanged 4 4 4 36 DS18 02 Bearing cone Kit 1 1
5 30 1810 06 Ball steel 46 46
6 39 2718 04 Bolt Flanged 1 1
7 39 1225 15 Hex. Nut /Flanged 3 3 6 DH 1611 00 Spacer Main Step 4 4
8 39 2702 04 Bolt Flanged 2 2 7 DG 1611 21 Screw 4 4
9 39 2723 15 Flanged Nut 3 3 8 DS 2010 27 Side Reflector 2 2
9 DP 1710 06 Silent Bush 2 2
10 DS 1611 42 Bash Plate 1 1
11 DS 1611 02 Grommet Bash Plate 4 4

Plate No. 25 : SWING ARM / REAR SHOCK ABSORBER Plate No. 25A : SWING ARM / REAR SHOCK ABSORBER
2 2
17 17
18 7 18 7
8 8
2 2 2 2
9 2 9 2
4 6 4 6
10 10
11 13 11 13
1 1
12 12
3 3
6 5 6 5
1 1
15 15
16 16
20 16 20 16
19 19
14 14
16 16
16 16
25A 25B 25A 25B

1 DG 1710 38 Hex. Bolt/ Flange -- 2 1 DG 1710 38 Hex. Bolt/ Flange 2 --

2 39 0714 11 Plain washer -- 8 2 39 0714 11 Plain washer 8 --
3 JN 1220 00 Rear Shock Absorber -- 2 3 DX 1710 03 Rear Shock Absorber 2 --
4 39 0258 11 Plain Washer -- 2 4 39 0258 11 Plain Washer 2 --
5 JN 1220 02 Swing arm assly. -- 1 5 DS 1710 02 Swing arm assly. 1 --
6 DS 1710 15 Cap Swing Arm -- 2
7 39 0712 15 Domed Cap Nut -- 2 6 DS 1710 15 Cap Swing Arm 2 --
8 39 0737 12 Spring Washer -- 2 7 39 0712 15 Domed Cap Nut 2 --
9 DS 1710 07 Chain slider -- 1
8 39 0737 12 Spring Washer 2 --
10 39 0553 02 Screw -- 2
9 DS 1710 07 Chain slider 1 --
11 39 0454 11 Plain washer -- 2 10 39 0553 02 Screw 2 --
12 DS 1710 13 Shaft swing arm -- 1
13 39 1358 15 Flanged Nut -- 1
11 39 0454 11 Plain washer 2 --
14 DJ 1510 36 Adjuster chain LH -- 1
15 DJ 1510 37 Adjuster chain RH -- 1 12 DS 1710 13 Shaft swing arm 1 --
13 39 1358 15 Flanged Nut 1 --
16 39 0292 15 Hexagon nut -- 4
14 DJ 1510 36 Adjuster chain LH 1 --
17 DS 1710 14 Mud Flap -- 1
15 DJ 1510 37 Adjuster chain RH 1 --
18 39 1773 04 Flange Bolt -- 2
19 39 1943 04 Bolt -- 1
20 39 0711 11 Washer -- 1
Plate No. 25 : SWING ARM / REAR SHOCK ABSORBER Plate No. 26 : RIDER FOOT REST
2
4
17
18 7
2 2 8
9 8
4 2
10 6 9 6
11 13 7 10
11
1
12
3
6 5 5
3
1 1
15 11
16
20 16
4
19
14
16 10
9
16
6 7
25A 25B 26A 26B

16 39 0292 15 Hexagon nut 4 -- 1 DJ 1611 26 Assly. Comp.Main step LH 1 1

17 DS 1710 14 Mud Flap 1 -- 2 39 1940 04 Flange bolt 4 4
18 39 1773 04 Flange Bolt 2 -- 3 DJ 1611 27 Main step RH assly. comp. 1 1
19 39 1943 04 Bolt 1 -- 4 DH 1610 53 Rubber Main Step 2 2
20 39 0711 11 Washer 1 -- 5 DG 1612 24 Damper 1 1 For Kick stopper
6 39 1282 15 Domed Cap nut 2 2

7 39 0897 04 Bolt 2 2
8 DS 1611 17 Stay Main Step 1 1
9 DH 1611 00 Spacer Main Step 2 2
10 DH 1610 56 Plate Comp. Lower Mounting 2 2
11 DJ 1610 90 Damper Footrest 2 2

Plate No. 27 : PILLION FOOT REST / HOLDER Plate No. 28 : MUDGUARD FRONT & REAR
6 5
10 10
4
7
8
10 13
10 9
1 2 8
7
6
12 16 10
17
6 14
1
3
3
5 2 4
8 5
7 11 15
9 9
11
13
27A 27B 28A 28B

1 DS 1610 85 Holder LH step 1 1 1 DS 1611 25 Cable Guide 1 1

2 DS 1610 86 Holder RH step 1 1 2 DX 1610 65 Brace fender 1 1
3 DH 1613 13 Pillion step assly. comp. LH 1 1 3 39 2310 04 Flange bolt 4 4 Fender front mtg.
4 DH 1613 15 Pillion step assly. comp. RH 1 1 4 39 1507 11 Plain Washer 4 4
5 DH 1613 17 Rubber pillion step 2 2 5 DX 1610 34 Fender rear front 1 1
6 DD 1613 81 Pin pillion step 2 2 6 39 2701 04 Flange bolt 2 2

7 30 1410 31 ‘O’ ring 2 2 7 39 0211 11 Plain washer 2 2
8 39 1040 11 Plain washer 2 2 8 39 0798 15 Flange nut 2 2
9 39 0784 08 Split pin 2 2 9 DS 1610 62 Fender rear 1 1
10 39 2722 04 Soc. Head Bolt 4 4 10 39 1943 04 Flange bolt 2 2
11 DX 1610 67 Plate Lock Pillion Step 2 2 11 DS 1611 08 Sleeve Front Fender 4 4

12 DH 1611 00 Spacer Main Step 2 2 N. I. 12 DJ 1610 69 Nail for Cable Guide 1 1
13 22 1504 51 Bolts- Cylinder 2 2 13 39 0326 15 Nyloc Nut 3 3
14 DS 1611 41 Flap Front fender 1 1
15 DH 1611 58 Grommet Side Cover 2 2
16 39 0211 11 Plain Washer 2 2

17 JN 1814 03 Hose Clamp 1 1
18 DX 1610 66 Damper 1 1 N.I.
Plate No. 29 : STAND ASSEMBLY Plate No. 30 : TYRE / TUBE / RIM
3 3
2
8
4 1
EU
10
R
OGRIP
5 9
1
6
5
7 4
EU
R
OGRIP
29A 29B 30A 30B

1 DS 1611 13 Center Stand 1 1 1 DJ 1510 77 Wheel rim front -- 1

2 DS 1611 12 Shaft stand 1 1 DS 1510 86 Wheel rim front 1 --
3 39 0797 08 Pin cotter 1 1 2 DS 1510 48 Tyre front 1 1 Proprietary items
4 DH 1611 21 Spring main stand 1 1 Not to service
5 DH 1611 45 Cover spring main stand 1 1 3 DS 1510 49 Tube front 1 1
4 DJ 1510 87 Wheel rim rear -- 1
6 DS 1610 77 Stand side 1 1 DS 1510 84 Wheel rim rear 1 --
7 DH 1612 40 Spring side stand with cover 1 1 5 DS 1510 31 Tyre rear 1 1 Proprietary items
8 DF 1611 02 Bolt 1 1 service
9 39 0422 15 Nut 1 1 6 DS 1510 29 Tube rear 1 1
10 DG 1611 24 Damper Main Stand 1 1

Plate No. 31 : FRONT HUB (FOR DRUM BRAKE SYSTEM) Plate No. 31 : FRONT HUB (FOR DRUM BRAKE SYSTEM)
2 8 2 8
24 24
7 7
1 1
6 6
25 25
3 3
1 1
16 16
15 17 15 17
10 14 18 10 14 18
13 17 13 17
12 12
19 19
11 22 11 22
5 5
23 23
20 23 20 23
21 21
9 4 9 4
30A 30B 31A 31B

1 39 2688 20 Bearing Ball 2 -- 16 30 1510 35 Oil seal 1 --

2 DS 1510 56 Dusct Seal 1 -- 17 30 1510 69 Spring 2 --
3 30 1510 32 Collar Bearing 1 -- 18 30 1511 05 Shoe brake 1 --
4 39 0840 01 Screw pan cross 1 -- 19 36 DS15 02 Speedometer gear Kit 1 -- Ref. Page No. 67
5 39 0798 15 Nut 1 -- 20 30 1511 18 Stopper for bushing 1 --
6 39 0781 11 Plain washer 1 -- 21 JA 1316 06 Bushing Speedo Cable 1 --

7 39 0786 15 Nut castle 1 -- 22 39 1013 21 Ring ‘O’ 1 --
8 39 0787 08 Pin cotter 1 -- 23 30 1510 42 Washer ‘A’ 2 --
9 DJ 1510 41 Axle 1 -- 24 30 1510 33 Oil Seal 1 --
10 39 0775 04 Bolt 1 -- 25 DS 1510 42 Spacer 1 --
11 JA 1316 07 Lever brake cam 1 --

12 DD 1510 09 Indicator 1 --
13 30 1510 38 Ring ‘O’ 1 --
14 DS 1510 87 Panel front brake 1 --
15 DD 1510 08 Cam brake 1 --

Plate No. 31A : FRONT HUB (FOR DISC BRAKE SYSTEM) Plate No. 32 : FRONT MASTER CYLINDER
4
2
8 3
3
10 5 9
6 10
10
13
E
: US -4
NG
NI DOT3 OM
R
WAR NLY D F R
O FLUI AINE
1
NT
AKE CO CAP
BR R VING
ED
AL FILLE MO
SE RE
9
A AN
CLE FORE
BE
15
5
7 5
4
14
1
7
7
2
11 6
13 12
8
11 5
5
12
4
31A 31B 32A 32B

1 39 0787 08 Pin cotter -- 1 1 DJ 1910 23 Major Kit - Master Cylinder -- 1

2 39 2688 20 Bearing ball -- 2 2 DJ 1510 76 Hose Brake Front -- 1
3 DE 1510 06 Spacer assly. -- 1 3 DJ 1910 06 Lever Grip RH -- 1
4 30 1510 33 Seal oil -- 1 4 DE 1910 11 Banjo Bolt -- 2
5 DE 1510 12 Plate drive -- 1 5 DJ 1910 26 Washer Copper -- 4
6 DE 1510 08 Seal oil -- 1 6 DJ 1910 27 Clamp Holder RH -- 1

7 DJ 1510 14 Disc -- 1 7 DJ 1910 28 Bolt -- 1
8 39 0781 11 Plain washer -- 1 8 DJ 1910 29 Bolt Front Brake Lever -- 1
9 39 2038 04 Hex. soc. hd. bolt -- 6 9 DJ 1910 30 Nut Flanged -- 1
10 DJ 1910 31 Screw -- 2
10 DJ 1510 57 Case meter gear Assly -- 1
11 DS 1510 58 Spacer -- 1 11 DJ 1910 32 Cylinder Master -- 1
12 DJ 1510 41 Axle -- 1 12 DJ 2011 00 Front brake switch -- 1
13 39 0786 15 Hex. Slotted Nut -- 1 13 DJ 1910 34 Reservoir Cover -- 1
14 DJ 1910 35 Diaphragm -- 1
15 36 DH19 02 Oil Window Kit -- 1 Ref. Page No. 67

Plate No. 33 : FRONT DISC BRAKE Plate No. 34 : REAR HUB
1
21
17
29 16
9
4
5 26
28 20
11A PISTON SEAL
15
8 18
11A 11B DUST SEAL
21
11B 25
12A BLEEDER CAP
7 5 19
x
PROTECTION BOOT 2
8
3 INSULATOR 23
7
27
5
6 12A CALIPER PISTON 4
2 22
3
4 BLEEDER SCREW 24
12
1 11
3
PAD SPRING
13
14
10 9
8 10
7 6
14
33A 33B 34A 34B

1 DG 1510 89 Caliper Assly. Front -- 1 1 DJ 1510 53 Drive Chain Lock 1 --

2 39 1769 04 Bolt Flanged -- 2 JN 1410 02 Drive Chain Lock -- 1
3 DJ 1510 68 Spring Pad -- 1 2 39 2686 20 Bearing ball 1 1
4 DJ 1510 69 Bleeder Screw -- 1 3 39 2687 20 Bearing ball 1 1
5 DJ 1510 70 Bleeder Cap -- 1 4 30 1510 75 Collar bearing 1 1
5 DJ 1510 88 Damper 1 1
6 DJ 1510 71 Disc Pad Set -- 1 6 DJ 1510 92 Panel rear brake -- 1
7 DJ 1510 72 Insulator -- 1 JN 1316 00 Panel rear brake 1 --
8 DJ 1510 73 Protection Boot -- 1 7 DD 1510 08 Cam brake 1 1
9 DJ 1510 74 Minor Kit - Caliper -- 1 8 30 1510 38 Ring ‘O’ 1 1
10 DJ 1510 75 Major Kit - Caliper -- 1 9 30 1510 05 Indicator 1 1
10 DJ 1510 59 Lever brake -- 1
DS 1510 23 Lever brake 1 --
11 39 2447 04 Bolt 1 1
12 39 0798 15 Nut 1 1
13 30 1510 68 Shoe brake assly. 1 1
14 30 1510 69 Spring 2 2
15 JN 1312 03 Coupling -- 1
DS 1510 68 Coupling 1 --
Plate No. 34 : REAR HUB Plate No. 35 : REAR BRAKE PEDAL
1
21
17 1
29 16
26 8
28 20 2
15 4
18 5
21
25 7
19 5 15
2 10
23 6
3
27
5
4 16
22 13
3 14
12 24
11
12
13 9
14 14 12
8 9 10
7 6 11
14
34A 34B 35A 35B

16 39 2240 20 Bearing ball 1 1 1 DS 1910 02 Brake Pedal 1 1

17 DJ 1510 33 Sleeve 1 1 2 DS 1910 11 Brake Pedal Spring 1 1
18 30 1510 82 Seal oil 1 1 3 DS 1910 03 Rod brake 1 1
19 30 1510 81 Lock washer 3 3 4 30 1910 38 Pin 1 1
20 DJ 1510 48 ‘D’ Bolt 6 6 5 39 0219 11 Plain washer 2 2
21 39 0694 15 Hex. lock nut 6 6 6 39 0808 08 Split pin 1 1

22 DJ 1510 32 Axle 1 1 7 30 1910 35 Spring 1 1
23 DH 1710 19 ‘U’ nut 1 1 8 39 1680 04 Hex. Bolt 1 1
24 39 2567 11 Plain washer 1 1 9 DS 1510 25 Rod torque 1 1
25 39 0801 15 Nut 1 1 10 DH 1510 29 Hex. bolt 1 1
26 DJ 1510 35 Collar 1 1 11 30 1510 95 Hex. bolt 1 1

27 DX 1510 22 Collar 1 1 12 39 0789 12 Spring washer 2 2
28 39 2566 11 Plain washer 1 1 13 39 0694 15 Nut hex. 2 2
29 36 JN00 06 Chain sprocket kit -- 1 14 39 0807 08 Pin snap 2 2
36 DS40 07 Chain sprocket kit 1 -- 15 15 1910 26 Pin 1 1
16 30 1910 36 Brake Adjuster Nut 1 1

Plate No. 36 : HANDLE BAR Plate No. 36 : HANDLE BAR
24 24
21 21
2 2
23 4 23 4
20 20
29 1 28 29 1 28
22 22
30 30
26 26
10 10
3 27 3 27
25 25
15 15
11 12 9 11 12 9
13 13
16 16
7 8 7 8
17 17
19 19
14 18 14 18
19 6 19 6
18 18
5 5
36A 36B 36A 36B

1 DS 1810 44 Handle 1 1 16 DS 1910 52 Boot for lever LH 1 1

2 39 1714 04 Flanged bolt 4 4 17 DH 1810 22 Handle bar weight 2 2
3 DJ 2010 24 Control switch LH 1 1 18 39 2427 04 Hex. soc.hd. cap screw 2 2
4 DS 2010 28 Control switch RH 1 1 19 DJ 2010 35 Clutch Switch 1 1
DS 2010 33 Control switch RH 1 -- For KS 20 DJ 2210 03 Mirror assly. LH 1 1
5 DJ 1910 53 Holder Assly. LH 1 1
DS 1910 36 Holder Assly. LH 1 -- For KS 21 DJ 2210 04 Mirror assly. RH 1 1
22 30 1910 48 Band 2 2
6 DS 1910 38 Holder Assly. RH 1 1 23 DS 1810 22 Switch assly.ignition 1 1
7 DJ 1910 55 Lever grip Left 1 1 24 39 1943 04 Flange bolt 2 2
8 29 2011 17 Front Brake Switch 1 1 25 DS 1810 05 Holder Fork Upper 1 1
9 DD 1911 42 Lever Brake RH 1 1
10 DS 1810 08 Damper handle upper 2 2 26 DS 1810 07 Washer handle Upper 2 2
27 DS 1910 18 Boot For Lever RH 1 1
11 DS 1810 09 Damper handle lower 2 2 28 DU 2010 46 Plunger with Spring 1 1 Part of
12 DS 1810 10 Washer handle lower 2 2 Ride Control Switch
13 39 0422 15 Nylock Nut 2 2 29 DS 1810 06 Holder Up 1 1
14 DS 1910 15 Grip LH 1 1 30 DS 1810 19 Holder lower 1 1
15 DS 1910 16 Grip Assly. RH 1 1

Plate No. 37 : FRONT FORK Plate No. 37 : FRONT FORK
12 12
21 11 21 11
8 13 8 13
1 1
14 14
2 24 2 24
15 15
3 3
20 20
22 22
10 10
4/5 4/5
9 9
6 20 6 20
7 23 7 23
17 17
18 18
19 19
16 16
37A 37B 37A 37B

1 DJ 1810 89 Seal dust 2 2 16 JN 1510 02 Fork front -- 1

2 DJ 1810 88 Ring snap 2 2 DS 1811 17 Fork front 1 --
3 DJ 1810 87 Oil seal 2 2 17 DS 1810 20 Holder fork under Assly. 1 1
4 JN 1510 04 Outer Tube LH -- 1 18 39 0789 12 Spring washer 2 2
DS 1811 20 Outer Tube LH 1 -- 19 39 1813 04 Bolt 2 2
5 JN 1510 06 Outer Tube RH -- 1 20 DS 1810 72 Guide Bush Washer 2 2
DS 1811 21 Outer Tube RH 1 --
21 DS 1810 12 Bolt Fork 2 2
6 31 1811 05 Gasket 2 2 22 DS 1810 70 Guide Bush 2 2
7 31 1811 06 Bolt 2 2 23 DS 1810 71 Slide Bush 2 2
8 DS 1810 77 Cylinder comp. fork 2 2 24 DS 1810 86 Plain Washer 2 2
9 DS 1810 83 Pipe comp. suspension inner 2 2
10 DS 1810 84 Spring front fork 2 2
11 DS 1810 15 Cap Nut Fork 1 1

12 DS 1810 75 Bolt fork 2 2
13 31 1811 02 O ring 2 2
14 DS 1810 85 Seat fork spring 2 2
15 DS 1810 05 Holder fork upper 1 1

Plate No. 38 : PAINTED PARTS AND DECALS Plate No. 38 : PAINTED PARTS AND DECALS
6 6
1 1
3 3
5 5
4 4
2 2
7 7
38A 38B 38A 38B

1 JN 7104 3B Fuel Tank with Decal 1 1 Black with Blue 5 DS 7302 X3 Fender Front 1 1 Black with Blue
JN 7104 3C Fuel Tank with Decal 1 1 Black with Red DS 7302 X4 Fender Front 1 1 Black with Red
DS 7134 3F Fuel Tank with Decal 1 -- Red with Red DS 7307 X4 Fender Front 1 -- Red with Red
DS 7134 3E Fuel Tank with Decal 1 -- Blue with Blue DS 7307 X6 Fender Front 1 -- Blue with Blue
2 JN 7303 3B Side cover LH 1 1 Black with Blue 6 JN 7301 3B Fairing 1 1 Black with Blue
JN 7303 3C Side cover LH 1 1 Black with Red JN 7301 3C Fairing 1 1 Black with Red
DS 7413 3F Side cover LH 1 -- Red with Red DS 7411 3F Fairing 1 -- Red with Red
DS 7413 3E Side cover LH 1 -- Blue with Blue DS 7411 3E Fairing 1 -- Blue with Blue
3 JN 7304 3B Side cover RH 1 1 Black with Blue 7 36 JN00 02 Decal Set 1 1 Black with Blue
JN 7304 3C Side cover RH 1 1 Black with Red 36 JN00 04 Decal Set 1 1 Black with Red
DS 7414 3F Side cover RH 1 -- Red with Red
DS 7414 3E Side cover RH 1 -- Blue with Blue
4 JN 7302 3B Seat Cowl Assly. 1 1 Black with Blue

JN 7302 3C Seat Cowl Assly. 1 1 Black with Red
DS 7422 3F Seat Cowl Assly. 1 -- Red with Red
DS 7422 3E Seat Cowl Assly. 1 -- Blue with Blue

Plate No. 39 : PETROL COCK ,CAP TANK & GAUGE FUEL Plate No. 40 : FITTINGS-PETROL TANK, SIDE COVER & COVER SEAT
5 6
2
1
3
7
14
1
4 4
2
9
10
6
5
3
5
8
7
13
9
12
11
8
39A 39B 40A 40B

1 DS 1410 09 Cap Assly. Tank 1 1 1 36 DS14 01 Grommet Kit for Side Cover 1 1 Ref. Page No. 67
2 39 0761 01 Screw Pan Cross 2 2 2 DG 1611 21 Screw 1 1
3 39 2179 24 Washer 2 2 3 39 1943 04 Flanged Bolt 2 2
4 DS 1410 18 Fuel Tap Assly 1 1 DS 1810 36 Lock Set (3 in 1) with Key 1 1 N.I.
5 DS 1810 36 3 In 1 Lock set With Key 1 1 4 JN 1710 00 Damper Front 1 1
5 39 1789 24 Washer Nylon 3 3
6 30 1410 39 Packing 1 1
7 DD 1410 22 Bolt flanged 2 2 6 39 0983 08 Pin Snap 1 1
8 39 0740 11 Washer (Non-Metallic) 2 2 7 39 1054 11 Plain Washer 1 1
9 DS 2010 55 Gauge Fuel 1 1 8 DS 1610 82 Grommet Side Cover 2 2
10 DS 1410 13 Seat Tape 1 1 9 DJ 1410 08 Damper 1 1
11 39 1972 15 Bolt 4 4
12 DS 1410 14 Tube fuel 1 1
13 30 1410 15 Pipe clip 2 2
14 39 2758 21 ‘O’ Ring 2 2

Plate No. 41 : METER ASSEMBLY Plate No. 41 : METER ASSEMBLY
10 10
7 15 7 15
5 5
9 12 9 12
13 3 11 13 3 11
8 8
6 6
4 2 4 2
14 14
1 1
41A 41B 41A 41B

1 DS 1910 39 Meter Assly 1 -- For Pricol 9 DG 2010 40 Lamp 12V - 3.4W 2 2 For Speedometer
DS 1910 14 Meter Assly 1 -- For VDO 10 DS 1910 45 Cover (white) 1 1 For Pricol
DS 1910 49 Meter Assly -- 1 For Pricol DS 1910 29 Cover (White) 1 1 For VDO
DS 1910 05 Meter Assly -- 1 For VDO
2 DS 1910 40 Cover Meter case upper 1 1 For Pricol 11 DS 1910 30 Grommet special 2 2
DS 1910 22 Cover Meter case Upper 1 1 For VDO 12 DS 1910 31 Knob for Tripmeter 1 1
3 DS 1910 41 Speedometer 1 1 For Pricol 13 DS 1910 32 Screw for ‘Tripmeter Knob’ 1 1
DS 1910 23 Speedometer 1 1 For VDO 14 39 0798 15 Nut 2 2
4 DS 2010 34 Harness Speedo Console 1 1 15 DS 1910 50 Tachometer 1 1 For Pricol
5 DS 1910 42 Meter Fuel 1 -- For Pricol DS 1910 24 Tachometer 1 1 For VDO
DS 1910 26 Meter Fuel 1 -- For VDO
DS 1910 50 Meter Fuel -- 1 For Pricol
DS 1910 24 Meter Fuel -- 1 For VDO
6 GH 2010 12 Lamp 12 V-1.7W 4 4

7 DS 1910 43 Cover meter lower 1 1 For Pricol
DS 1910 27 Cover meter lower 1 1 For VDO
8 DS 1910 44 Bracket meter 1 1 For Pricol
DS 1910 28 Bracket meter 1 1 For VDO

Plate No. 42 : CONTROL CABLES Plate No. 43 : CHAIN CASE
2 1
2
5
3
1
2
4
42A 42B 43A 43B

1 DS 1910 12 Cable Accelerator 1 1 1 JN 1812 00 Chain Cover -- 1

2 DS 1910 01 Cable Clutch 1 1 JN 1812 04 Chain Cover -- 1 For 3 point mtg.
3 DS 1910 13 Cable Starter (Choke) 1 1 2 JN 1812 02 Stepped bolt -- 2
4 DS 1910 53 Cable Speedometer 1 1 3 39 1942 04 Bolt -- 1 For 3 point mtg.
5 DS 1910 56 Inner cable Speedometer 1 1

Plate No. 43A : CHAIN CASE Plate No. 44 : HEAD LAMP & FAIRING
5
22
8
10
3
7
4 9
13 2 15
3
12 14
4 18 10
1
6 17
3
19 10
14 3 5
10
1
11 4 5
16
4 20
4
2 21
3
43A 43B 44A 44B

1 36 DS40 20 Case Chain Assly Kit 1 -- 1 DS 2010 35 Head Lamp Housing with Lens 1 1
2 15 1610 69 Rubber Cap 1 -- 2 39 1778 02 Self Tapping Screw 4 4
3 39 0711 11 Plain Washer 4 -- 3 39 0716 01 Pan Head Screw 2 2
4 39 0897 04 Bolt 4 -- Front & Rear side Mtg. 4 CL 2010 23 Lamp 12V 35/35W-HS1 1 1
5 DS 1611 64 Rubber Strip 2 -- 5 DJ 2010 72 Lamp 12V 5W 2 2
6 39 1961 04 Hex. Flange Bolt 1 1

7 DS 1810 66 Wind Shield 1 1
8 DF 1810 98 Screw SS 4 4
9 DL 1810 10 Well Nut 4 4
10 39 2141 24 Non Metallic Washer 9 9
11 DS 1810 31 Flap Cowling 1 1

12 39 0817 15 Hex. Flange Nut 1 1
13 35 1610 60 Clip Nut 5 5
14 39 1907 01 Screw 3 3
15 DS 1810 45 Fairing mounting upper bracket 1 1

Plate No. 44 : HEAD LAMP & FAIRING Plate No. 45 : INDICATOR LIGHT ASSEMBLY
22
8
10 1/2
7
9
13 2 15
12 14
18 10
5
1
6 17
19 10 3/4
14 3 5
10
11 4 5
6
16
20
21
44A 44B 45A 45B

16 DG 1611 21 Screw 2 2 1 DJ 2011 48 Indicator Assly FR. LH 1 1

17 39 1943 04 Flange Bolt 2 2 2 DJ 2011 49 Indicator Assly FR. RH 1 1
18 DS 1810 29 Bracket Cowling 1 1 3 DJ 2011 46 Indicator Assly RR. LH 1 1
19 DS 1810 27 Number Plate Bracket 1 1 4 DJ 2011 47 Indicator Assly RR. RH 1 1
20 DS 2010 36 Head Lamp Bulb Clip 1 1 5 GH 2010 12 Lamp 12 V - 10W 4 4
21 DS 2010 39 Head lamp Harness Branch 1 1 6 39 1970 15 Hex. nut with flange 4 4
22 DS 1810 69 ‘B’ Monogram 1 1 On Wind shield

Plate No. 46 : TAIL LAMP ASSLY. / FRONT NO.PLATE Plate No. 47 : ELECTRICAL EQUIPMENTS
17
6 1
20
2
3
2
21
3
1 7 15
8 10
15 15
7 9
18 22
4
14 19 6
13 8 16
12
4 13
5 10 5
13/14
9
11
16
46A 46B 47A 47B

1 DS 2010 08 Tail light with Lamp 1 1 1 DS 2010 16 Horn LH with Stay 1 1

2 DS 2010 09 Lens tail light 1 1 2 39 1507 11 Plain Washer 1 1
3 30 2010 06 Lamp 12 V 21/5 W 1 1 3 39 1956 04 Flange Bolt 1 1
4 DD 2010 11 Damper 2 2
4 DS 1611 23 Bracket Battery Arrestor 1 1
5 DJ 1810 83 Collar 2 2
5 39 1942 04 Flanged Bolt 1 1
6 39 0817 15 Nut/Flange 4 4
7 39 1972 15 Flange Nut 1 1 6 JN 4022 00 Wiring Harness 1 1
8 DJ 1610 72 Bracket Rear No. Plate 1 1 DS 2010 57 Wiring Harness 1 -- For KS
9 39 1062 04 Bolt flange 2 2 7 DS 2010 29 Rear Brake Switch 1 1
10 DP 1611 45 Number plate Rear 1 1 8 DS 1910 07 Spring Brake Switch 1 1
9 DH 2010 19 Grommet Rear Brake Switch 1 1
11 39 1943 04 Hex Flanged Bolt 2 2 10 DS 1611 06 Band Battery II 1 1
12 DP 1611 44 Number plate front 1 1
13 DS 1810 26 Front No. Plate Mounting Bkt. 1 1
11 DS 2010 82 Battery 5AH 1 1 N.I. & N.S.
14 39 1783 01 Truss Screw (For Front No. Plate) 2 2
15 DS 2010 15 Reflector Reflex 1 1 12 DS 1611 18 Base Battery II 1 1 N.I.
13 DS 1611 05 Band Battery I 1 1
16 39 1972 15 Flanged Nut 2 2 14 DS 1611 16 Base Battery I 1 1
17 JN 1510 09 Hose Clamp -- 1 15 DS 2010 25 Assly DC flasher / damper 1 1

Plate No. 47 : ELECTRICAL EQUIPMENTS Plate No. 48 : TOOL KIT
1 2
17
1
20
21
3
7 15
8 10
15
9
18 22
4
19 6
16
13 5
13/14
16
47A 47B 48A 48B

16 39 2208 04 Mushroom head Screw 2 2 1 DS 2210 02 Tool Kit 1 1

17 AP 2010 29 Starter Relay / 1 1 * Tool Driver 1 1
18 30 2011 04 Fuse box Assly. 1 1 * Tool Wrench (Box 16 mm) 1 1
19 30 2010 85 Fuse 1 1 * Tool Wrench (10 X 13) 1 1
20 DS 2010 22 Cable assly. (Battery to St.Relay) 1 1 * Tool Wrench (14 X 17) 1 1 For reference only. Not
serviced separately
* Tool wrench (27 A/F) 1 1
21 DS 2010 23 Cable assly. (Battery to Earth) 1 1 * Tool wrench (22 A/F) 1 1
22 DS 1611 04 Battery Arrestor 1 1 * Extension Rod 1 1
* Tool Bag 1 1
2 DP 2210 24 Band Tool Kit 1 1

Plate No. 49 : ACCESSORIES / GRAB HANDLE KIT LIST
Sr. Consisting of Following Parts

8 Kit Part No. Kit Description
No. Part No. Description Qty./Kit
6 1 36DS1001 Cyl.Head O Ring Kit 39239121 O Ring (Cover tappet) 2
39128321 O ring 2
2 2 36DS1002 Valve Kit DS101023 Valve Intake 1

DS101024 Valve Exhaust 1
3 36DS1003 Valve Repair Kit DS101083 Retainer valve spring 2

DS101110 Spring valve inner 2
DS101111 Spring valve outer 2
1 DH101026 Seat valve spring 2
4 36DS1004 Guide Chain Kit DS101012 Guide chain (Tight) 1

DS101011 Guide Chain (slack) 1
5 36DJ4008 Ring Set Piston DH101666 Ring piston top 1

7 DH101667 Ring piston second 1
DH101669 Ring piston oil 1
6 36DS1007 Boss Kick Set DH101185 Spring Kick Starter Arm 1

DH101068 Ball steel 1
DS101208 Base kick lever 1
5 DH101320 Hex. bolt with flange(N.I.) 1
39204501 C’sunk Head Screw 1
3 7 36DS1201 Carb. Vaccum Piston Kit DS121055 Vaccum Piston Comp. 1

DS121057 Diaphragm 1
DS121058 Diaphragm Plate 1
8 JN581208 Jet Holder Kit DS121071 Jet 1

DS121069 Jet Comp. 1
DS121067 Needle Jet Holder 1
49A 49B 9 JN581207 Idling Screw Set DS121097 Coil Spring (CO) 1
No. Part No. Description Remarks DS121094 Adjust Screw 1
Drum Br. Disc Br.
DS121095 Adjust Holder 1
DS121096 Plain Washer 1
1 JN 2312 02 Leg Guard kit 1 1
2 DS 1610 89 Leg guard Bracket 2 2 10 36DS2101 Seat Damper Kit DS211004 Damper Seat - I 7
3 JN 2312 11 Sari Guard -- 1 with cover DS211005 Damper Seat - II 2
JN 2312 00 Sari Guard 1 -- 11 36DS1601 Eng. Mtg.Plate Set DS161031 Bkt. Engine Hanger LH 1
4 39 1714 04 Flange Bolt 2 2 DS161128 Bkt. Engine Hanger RH 1
5 39 2495 04 Soc. Head Bolt 1 1 DS161056 Bkt. RH eng.rear Mounting II 2
12 36DS1602 Eng. Mtg.Bkt. Set DS161130 Bkt. LH eng.mtg.front Assly. 1

6 39 1681 04 Flange Bolt 4 4 With Silent Bush DS161131 Bkt. RH eng.mtg.front Assly. 1
7 DS 1611 88 Grab Handle with foam 1 1
13 36DS1802 Bearing cone kit DH181025 Bearing cone 1
8 39 2214 04 Bolt 4 4 For Mounting Leg Guard DH181026 Bearing race 1
DH181024 Upper bearing race 1
14 36DS1801 Holder Handle Set DS181019 Holder handle 2

DS181006 Holder handle 2
15 36DS1401 Grommet Kit-Side Cover DS141012 Grommet side cover Front 2

DS161082 Grommet side cover Rear 2

Amendment Sheet (Parts Added) Amendment Sheet (Parts Deleted)

Sr.No. Part No. Description Qty. Page No. Fig.No. Sr.No. Part No. Description Qty. Page No. Fig.No.

Figure Page Figure Page Figure Page Figure Page

Part No. Part No. Part No. Part No.
No. No. No. No. No. No. No. No.
70 71

72 3 73

74 3 75

76 77
Brand ID: 001MC631
Figure Page Figure Page

Part No. Part No.
No. No. No. No.
78 3

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Brand ID: 001MC631

In a continual effort to improve Performance and Efficiency of the vehicles,

changes at any time without prior notice and without

o/s. Over size Fr Front 26 Rider Foot rest 33

L.H. Left hand AR As required

CYLINDER & PISTON 5 CRANKSHAFT 6 CRANKCASE LH 12 COVER RH 13 & 14

COVER MAGNETO 15 CLUTCH 16 SILENCER ASSEMBLY 21 SEAT ASSEMBLY / SEAT LOCK 22

CARBURETTOR 19 AIR CLEANER COMP. 20 STARTER ASSLY. 26 & 27 ENGINE MOUNTINGS 28

PLATE NO. : 45 PAGE NO.: PLATE NO. : 46 PAGE NO.:

INDICATOR LIGHT ASSEMBLY 61 TAIL LAMP ASSLY. / FRONT NO.PLATE 62

PLATE NO. : 47 PAGE NO.: PLATE NO. : 48 PAGE NO.:

1 JN 5110 06 Head Cylinder with Cover 1 1

: Front Wheel Direction 1

6 39 1283 21 ‘O’ Ring (Intake Pipe) 1 1 6 DG 1010 29 Cotter valve 4 4

11 39 2608 01 Grub Screw 1 1

2 : Front Wheel Direction : Front Wheel Direction 3

1 JN 5112 02 Camshaft Assly 1 1 1 DH 1010 16 Gasket Cylinder 1 1

6 DH 1010 48 Special camshaft washer 1 1 6 JF 5212 00 Piston Assembly 1 1

11 DH 1010 11 Cam chain Tensioner pivot Bolt 1 1

4 : Front Wheel Direction : Front Wheel Direction 5

1 JN 5310 00 Crankshaft assly. Comp. 1 1 1 DS 1012 91 Shaft Input Transmission 1 1

16 DS 1012 03 Washer Plain 1 1 1 DS 1010 63 Fork Gear Shift Input 1 1

8 : Front Wheel Direction : Front Wheel Direction 9

1 DS 1011 34 Lever comp. Gear Shifter 1 1 1 JN 5010 00 Engine Assly. 1 1

6 31 1011 08 Damper 1 1 6 39 2583 20 Bearing Ball (For input shaft) 1 1

11 DS 1012 14 Rubber tube 1 1

10 : Front Wheel Direction : Front Wheel Direction 11

11A 11B 12A 12B

1 JN 5410 00 Crankcase LH 1 1 1 JN 5412 00 Cover comp. RH 1 1

12 : Front Wheel Direction : Front Wheel Direction 13

12A 12B 13A 13B

6 39 0999 06 Pin Dowel 2 2

11 39 2208 04 Flanged Bolt 4 4

14 : Front Wheel Direction : Front Wheel Direction 15

14A 14B 14A 14B

1 39 2200 11 Plain Washer 1 1 1 39 2200 11 Plain Washer 1 1

6 JN 5514 00 Spring Clutch 6 6 6 JN 5514 00 Spring Clutch 6 6

11 JN 5514 01 Assembly Clutch Complete 1 1 11 JN 5514 17 Assembly Clutch Complete 1 1

16 JN 1514 14 Rod Push 1 1

16 : Front Wheel Direction : Front Wheel Direction 17

15A 15B 16A 16B

1 DS 1012 06 Lever Kick Starter complete 1 1 1 JN 5812 01 Carburetor Assly. 1 1

18 : Front Wheel Direction : Front Wheel Direction 19

17A 17B 18A 18B

1 JN 5810 02 Air Cleaner comp. -- 1 1 JN 5910 00 Silencer Assly. -- 1

11 DS 1211 17 Drain Tube 1 1

20 : Front Wheel Direction : Front Wheel Direction 21

19A 19B 20A 20B

1 DS 2110 01 Seat Assly comp 1 1 1 DS 1211 18 Oil Pump Body 1 1

6 39 1686 06 Hollow Dowel Pin 3 3

22 : Front Wheel Direction : Front Wheel Direction 23

21A 21B 21A 21B

1 DS 1110 56 Rotor Assly. 1 1 For new vehicle 16 39 1943 04 Flange Bolt 1 1

11 DH 1110 15 Cap Spark Plug 2 2

24 : Front Wheel Direction : Front Wheel Direction 25

22A 22B 22A 22B

11 39 2437 04 Bolt socket 3 3

26 : Front Wheel Direction : Front Wheel Direction 27

23A 23B 24A 24B