Foreword

We have pleasure in presenting the Spare Parts Catalogue for ‘Boxer S’ 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 latest Consequently, the description in this Spare Parts Catalogue cannot therefore be final
and binding on us.
product information at the time of publication. Bajaj Auto
Limited accepts no liability for any inaccuracies or omissions The modifications / alterations which are carried out after the issue of this catalogue,
in this publication, although every possible care has been will be conveyed to you through our Service Circulars. You are requested to make
taken to make it as complete and accurate as possible. All necessary corrections in the Parts Catalogue as per the circulars so as to keep your
catalogue up-to-date. This will ensure the appropriate and speedy delivery of the
procedures and specifications subject to change without prior
Spare Parts as the order placed will bear the latest part numbers.
notice. The right is reserved to make such changes at any
time without prior notice and without incurring an obligation to In case, if you need any technical assistance contact the concerned Regional Team or
make such changes to product manufactured previously. write to us on the following address :
Contact your authorized Bajaj Dealer for the latest information
on product improvements incorporated after this manual was Bajaj Auto Limited
issued. International Marketing
Akurdi, Pune 411 035 India
Phone : 020-27472851
Fax : 020-27407395
DOC. NO.: 71110595 REV. 01. NOV. 09 E-mail : [email protected]
Instructions for using the Catalogue Index
1. How to Read the Catalogue : Open the catalogue and from the pictorial index locate No. Description Page
No. Description Page
the group in which the part you want to find is present. Turn over to the concerned No. No.
page number (as given by pictorial index). Now find out the figure of the part you 1 Cylinder head 1 38 Turn Signal Lamp 46
wish to order. Write down the part number against that particular figure number from 2 Valve 2 39 Front & Rear Number Plate 47
the text. 3 Camshaft & Tensioner 3 40 Tail Lamp Assly. 48
4 Cylinder & piston 4
In case, if you have the part number and you need the other details, the part index
5 Crank shaft 5 41 Electrical Equipment 49
can be used. The part index (at the end of the catalogue) will give you the figure
and page number of the part you wish to order. 42 Tool kit 50
6 Transmission 6 43 Seat Assly. 51
2. How to Order Spare Parts : The part number and the description of the part required 7 Change drum / Shift fork 7 44 Accessories 52
should be invariably mentioned in the order as per the catalogue text. 8 Gear change mechanism 8 45 Kit List 53&54
9 Crankcase RH / Engine assly. 9
The latest part number as conveyed through our service circulars should only appear 10 Crankcase LH 10 46 Added Deleted Part List 55&56
on the order. In case of ordering painted components, colour shade of the 47 Part Index 57
components should be mentioned. 11 Pipe Oil 11
12 Cover Magneto 12
The quantity shown against the part number is the quantity per vehicle for that group
13 Clutch Cover 13
so that particular quantity should be multiplied by the number of sets required.
14 Clutch 14
3. Part Number System: We have used 8 digit system for part numbers. The model or 15 Kick starter Mechanism 15
hardware item is indicated by first two digits or alphanumeric, the next two or four
digits indicate main group and the last four or two digits indicate serial number in 16 Carburettor 16
main group or serial number or subgroup of fastener respectively. Thus the part 17 Air Filter Assly. & Battery Box 17
numbers will be indicated by 2-2-4 or 2-4-2 digit system. Understanding this system 18 Muffler 18
will enable you to identify the spare parts easily. 19 Oil pump 19
20 Magneto assly 20
4. Abbreviations : The following abbreviations are used in this catalogue.
21 Frame 21
assly. Assembly V Volts 22 Swing arm / Rear shock absorber 22
N.I. Not illustrated W Watts 23 Stand, Step & Stay LH / RH 23
24 Fender (Front & Rear) 24
C'case Crankcase accl. Accelerator 25 Wheel Rim/Spokes/Tyre/Tube 25
Cyl Cylinder Comp. Complete
26 Front Hub 27&28
o/s. Over size Fr Front 27 Rear Hub 29to32
Std. Standard L Length 28 Brake pedal 33
29 Handle bar 34&35
A/t. Alternate Rr Rear 30 Front Fork 36&37
R.H. Right hand Hex. Hexagonal
31 Painted Parts 38&39
L.H. Left hand AR As required 32 Fuel Tank Cap, Tap Assly.
& Fuel Gauge 40
33 Chain case 41
34 Fittings-Petrol tank &Side cover 42
35 Meter Assly. 43
36 Control Cables 44
37 Head Lamp Assly. 45
Pictorial Index
PLATE NO. : 1 PAGE NO.: PLATE NO. : 2 PAGE NO.:

CYLINDER HEAD 1 VALVE 2

PLATE NO. : 3 PAGE NO.: PLATE NO. : 4 PAGE NO.:

CAMSHAFT / TENSIONER 3 CYLINDER AND PISTON 4

PLATE NO. : 5 PAGE NO.: PLATE NO. : 6 PAGE NO.:

CRANKSHAFT 5 TRANSMISSION 6
Pictorial Index Pictorial Index
PLATE NO. : 31 PAGE NO.: PLATE NO. : 32 PAGE NO.: PLATE NO. : 37 PAGE NO.: PLATE NO. : 38 PAGE NO.:

PAINTED PARTS 38 & 39 MAGNETO ASSLY. 40 HEAD LAMP ASSLY 45 TURN SIGNAL LAMP 46

PLATE NO. : 33 PAGE NO.: PLATE NO. : 34 PAGE NO.: PLATE NO. : 39 PAGE NO.: PLATE NO. : 40 PAGE NO.:

CHAIN CASE 41 FITTINGS-PETROL TANK & SIDE COVER 42 FRONT AND REAR NUMBER PLATE 47 TURN SIGNAL LAMP 48

PLATE NO. : 35 PAGE NO.: PLATE NO. : 36 PAGE NO.: PLATE NO. : 41 PAGE NO.: PLATE NO. : 42 PAGE NO.:

METER ASSLY. 43 CONTROL CABLES 44 ELECTRICAL EQUIPMENT 49 TOOL KIT 50

Pictorial Index Plate No. 1 : CYLINDER HEAD

PLATE NO. : 43 PAGE NO.: PLATE NO. : 44 PAGE NO.:

SEAT ASSLY 51 ACCESSORIES 52

6 8

3 2
9
18
7
7

4
2
5
3
10

14
15
1 11
12 14

12 16

3
13

17

Qty/
No. Part No. Description Veh. Remarks

1 36 DU10 01 O Ring Kit 1 Ref. Page No. 50

2 31 1010 06 Cap 2
3 39 1673 04 Flanged bolt 6
4 31 1010 05 Guide Valve 2
5 39 1021 21 O Ring 2

6 DD 1013 47 Bolt 2
7 DD 1013 50 Stud 2
8 DD 1013 49 Bolt 4
9 DU 1012 08 Head Comp. Cylinder 1
10 31 1010 07 Cover (OHC) 1

11 DU 1012 28 Bolt 2
12 39 1000 06 Hollow Dowel Pin 2
13 DD 1013 43 Gasket head 1
14 39 1017 21 O Ring 2
15 DD 1014 81 Damper Cylinder Head 4

16 31 1011 75 Insulator (Head Side) 1

17 DU 1010 58 Pipe Intake 1
18 DD 1015 21 Plain washer 4

: Front Wheel Direction 1

Plate No. 2 : VALVE Plate No. 3 : CAMSHAFT / TENSIONER

3 4
5
5
13
3 4 10 6
12

6 11
5

8 1
7
10

11

2
7

14
9
9

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DU 1011 91 Shaft Rocker 2 1 36 3110 06 Chain Guide Kit 1 Ref. Page No. 50
2 DF 1010 55 Screw 2 2 39 1017 21 O Ring 1
3 DU 1011 90 Rocker arm assembly 2 3 DU 1010 96 Hex. Soc.HD Screw 1
4 31 1011 04 Stopper 1 4 DU 1010 56 Sprocket (28 T) 1
5 39 0702 01 Screw Pan Cros 2 5 DU 1010 78 Camshaft assly. 1 Old
5 DX 1010 75 Camshaft Assly 1 New
6 31 1010 18 Retainer Valve Spring 2
7 DD 1014 40 Spring Stiffer 2 6 31 1010 33 Chain 1
8 36 3110 08 Collet Seal Oil Kit 1 Ref. Page No. 50 7 DD 1014 07 Tensioner Assly. / O ring 1 Advik make alt. DD 1014 08
9 36 3110 28 Valve Kit 1 Ref. Page No. 50 DD 1014 87 Tensioner Assly. / O ring 1 Pricol make
8 39 1959 04 Bolt Flanged Small 2
9 DD 1010 62 Bolt 1
10 39 0748 01 Screw Pan Cross 2

11 39 0999 06 Hollow Dowel Pin 2

12 DU 1010 66 Washer Spl. Cam Shaft 1
13 DU 1010 67 Collar Cam 1
14 39 1790 21 O Ring 1

2 : Front Wheel Direction : Front Wheel Direction 3

Plate No. 4 : CYLINDER AND PISTON Plate No. 5 : CRANKSHAFT

3 4
16
2

1
1
2
1
5
6

6 4
3 8

14 13

15

5 7
7
5
11
9
10 12

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 39 1000 06 Hollow dowel Pin 2 1 39 1055 15 Nut 1

2 DD 1010 07 Gasket - Cyl. Block 1 2 01 1006 10 Woodruff Key 1
3 DU 1010 94 Cylinder Block Piston assly 1 Old 3 DU 1010 05 Crankshaft Assly. 1
DU 1012 18 Cylinder Block Piston assly 1 New w.e.f. 2006 4 28 1011 07 Key Woodruff 2
4 36 DD40 01 Kit Piston ring set std. 1 5 DX 1010 47 Gear Primary, Helical (23 T) 1
5 39 0985 17 Wire Clip 2
6 FA 1013 34 Gear 1
6 DH 1014 30 Damper 3 7 DU 1010 41 Cover 1
7 DD 1010 13 Pin Piston 1 8 39 1699 01 Countersunk Screw 3
9 DH 1011 95 Nut 1
10 DX 1010 53 Body Centrifugal Oil Filter(C.I.) 1

11 DU 1010 10 Gasket Central Oil Filter 1

12 39 2200 11 Washer 1
13 DH 1010 66 Joint Oil Delivery 1
14 39 2199 08 Pin Snap 1
15 DH 1010 67 Spring Oil Delivery 1

16 28 1011 07 Key Woodruff 1 Alt. DU 1012 11

4 : Front Wheel Direction : Front Wheel Direction 5

Plate No. 6 : TRANSMISSION Plate No. 7 : CHANGE DRUM / SHIFT FORK

6 2

5
8
4 7
7 1
3

2 4
8
1

16
4 9
9

3
14 6
10 2
12 13

11

5
15

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DD 1013 09 Bushing Floating 1 1 31 1011 91 Fork Shift 1

2 DX 1010 45 Gear 2nd Input 1 2 31 1010 51 Rod shift 2
3 DX 1010 48 Gear Transmission Spur(3rd) 1 3 DU 1010 81 Drum assly. change 1
4 39 0987 17 Ring Snap (16 mm) 2 4 DM 1010 98 Cup Stopper 1
5 DX 1010 49 Gear 4th Input 1 5 31 10 1192 Fork shift 1
6 DU 1010 11 Shaft Transmission Input 1
7 DU 1010 80 Gear 1st Output 1 6 39 0992 06 Pin Dowel 5
8 DX 1010 51 Gear 4th Output 1 7 DP 1013 40 Bolt Soc. Head 1
9 DX 1010 50 Gear Transmission Spur(3rd) 1 8 DM 1010 99 Plate Spacer 1
10 DX 1010 46 Shaft Transmission Output 1 9 DU 1010 83 Cam Drum Change 1

11 DU 1012 13 Plate For Sprocket Output 1

12 DM 1011 14 Sprocket Output 1 For Kit 36 DU15 05
DX 1010 52 Front Sprocket 1 For Kit 36 DM00 01
13 DP 1011 55 Collar (Sintered) 1
14 DP 1011 68 ‘O’ Ring 1
15 39 1981 04 Bolt 2

16 DD 1014 75 Washer Special 1

6 : Front Wheel Direction : Front Wheel Direction 7

Plate No. 8 : GEAR CHANGE MECHANISM Plate No. 9 : CRANKCASE RH / ENGINE ASSLY.

6
6

2 7
3
7
1

4 2
1 8
5 13
12 1
13 11
11

2
3 4
8
5 12

12 9
3
9 10
10

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 52 DU01 04 Lever Comp. Gear Shift Drum 1 1 39 1225 15 Nut 3

2 39 1994 04 Bolt 1 2 39 0248 11 Plain Washer 3
3 36 DU10 04 Gear Lever Spring Kit 1 Ref. Page No. 50 3 39 1068 04 Bolt 2
4 DU 1010 74 Plate Position 1 4 39 1056 04 Bolt 1
5 39 0746 01 Screw Pan Cross 1 5 39 1864 20 Bearing Ball 1 Alt. to 39229320

6 52 DU01 04 Stopper Comp. Gear Shift Drum 1 6 39 0999 06 Dowel Pin 5

7 DD 1011 06 Bolt 1 7 01 1701 11 Bearing 1
8 39 2474 04 Flanged bolt 1 8 DP 1014 52 Oil Strainer 1
9 DU 1011 85 Lever Change / Damper 1 9 DG 1014 98 Gasket 1
10 31 10 1108 Damper 1 10 DD 10 1275 Plug (Drain) 1

11 31 1011 09 Collar 1 11 01 1701 10 Bearing 1

12 39 2704 11 Washer Spring Steel 1 12 DU 1010 75 Crankcase Comp. RH 1
13 DU 1011 13 Spacer 1 13 DU 1010 85 Bushing 1
14 DU 1012 20 Engine Assembly 1 N.I.

8 : Front Wheel Direction : Front Wheel Direction 9

Plate No. 10 : CRANKCASE LH Plate No. 11 : PIPE OIL

15 3
11
14
2 4

12
10 2
9 1
1

8
3
2 2
7 2
7
5

4 13

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 01 1701 11 Ball Bearing 1 1 DU 1210 05 Pipe Oil 1 Use with Bkt. Engine Front
2 39 1050 06 Dowel Pin 1 RH DU161094
3 39 1066 04 Bolt Flanged Small 3 2 DD 1015 17 Gasket 4
4 39 1043 19 Oil Seal 1 3 39 1023 04 Bolt 2
5 39 1080 19 Seal Oil 1 4 39 1062 04 Bolt flanged small 2

6 39 1008 20 Bearing Needle 1

7 39 0702 01 Screw Pan Cros 2
8 31 1010 56 Guide 1
9 31 2010 81 Switch Comp. (Neutral) 1
10 39 0703 11 Plain Washer 1

11 39 1075 04 Bolt Flanged Small 7

12 30 1010 15 Gasket 1
DG 1014 98 Gasket 1
13 DD 1011 01 Crankcase LH 1
14 DZ 1010 34 Tube rubber 1
15 30 1410 15 Clamp 1
DP 1210 25 Clamp 1

10 : Front Wheel Direction : Front Wheel Direction 11

Plate No. 12 : COVER GENERATOR AND COVER CHAIN Plate No. 13 : CLUTCH COVER

6
4

2 7
1 10
8 9 3 8

3
EXHAUSTTECH 2

7
1

10 3
6
9 5

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 31 1010 62 Bolt 1 1 DZ 1010 47 Clutch cover / Graphics / Gauge 1

2 39 1019 21 Ring "O" 1 2 DZ 1010 46 Label “BAJAJ EXHAUSTEC” 1
3 31 1012 95 Cover Generator 1 3 39 0999 06 Dowel Pin 2
4 31 1010 61 Plug 1 4 31 1010 67 Guage 1
5 31 1011 13 Gasket 1 5 39 1041 19 Seal oil 1

6 DD 1010 58 Gasket - Generator Cover 1 6 30 1011 42 Seal oil 1

7 39 1074 04 Bolt Flanged Small 5 7 DD 1013 25 Cap oil filler 1
8 39 0999 06 Pin 2 8 39 2134 21 O ring 1
9 52 DM00 86 Cover Chain (Engine) 1 9 DD 1010 60 Gasket (Clutch cover) 1
10 39 2147 04 Bolt Flanged Small 3 10 39 1075 04 Bolt flanged small 10

12 : Front Wheel Direction : Front Wheel Direction 13

Plate No. 14 : CLUTCH Plate No. 15 : KICK STARTER MECHANISM

5
1
1

4
3 4
14
16 10 14
13
9
15
7 12
6 6
5 15
13
14
11
14
10

8 14 16
9 9
7 8
13
12
11 2 2
3

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DX 1010 54 Housing Comp. clutch 1 1 59 0400 25 Flanged bolt 1

2 28 1011 95 Holder 1 2 DD 1012 64 Screw Pan Cross 2
3 39 2600 11 Plain Washer 2 3 DD 1012 54 Guide Kick 1
4 DU 1011 09 Collar 1 4 DU 1010 50 Lever Assly Kick Comp. 1
5 DD 1014 92 Wheel Clutch 1 5 30 1011 54 Bush(Damper) 1

6 DD 1014 80 Plate Friction 5 6 36 DU10 07 Boss Kick Set 1 Ref. Page No. 50
7 30 1010 96 Plate Clutch 4 7 22 1502 41 Plain Washer 1
8 DD 1014 93 Hub Clutch 1 8 31 1010 41 Spring 1
9 28 1012 14 Spring 6 9 39 0993 11 Plain Washer 1
10 39 0980 04 Hex. Bolt 6 10 31 1010 39 Coil Spring

11 39 1053 15 Hex. Nut / Flange 1 11 31 1010 38 Ratchet 1

12 39 2403 20 Bearing 1 12 DU 1010 38 Gear Spur Kick Start 1
13 31 10 1148 Rod Push 1 13 39 0995 11 Plain Washer 2
14 DX 1010 35 Lever Assly. Complete 1 14 39 0738 17 External Circlip Type C 4
15 DX 1010 55 Clutch Assly. Complete 1 15 DU 1010 45 Shaft Kick 1

16 31 1011 37 Holder 1 16 31 1010 40 Guide 1

14 : Front Wheel Direction : Front Wheel Direction 15

Plate No. 16 : CARBURETTOR Plate No. 17 : AIR FILTER ASSLY. AND BATTERY BOX

9 1

2
4

3 7

6
12 7
10
3

12/13 5 6
5 13
15
9 15
14 1
4
11 8
11 14
10

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DU 1210 09 Carburettor Assly. (PB-16) 1 1 DF 1210 23 Filter assly air 1

2 DU 1010 57 Insulator (Carburettor / Intake) 1 2 DU 1210 04 Case air filter 1
3 39 1283 21 O ring 1 3 39 0986 08 Pin Cotter 1
4 36 DU12 06 Carburettor Holder / Jet Kit 1 Ref. Page No. 51 4 DU 1210 08 Duct (A/F to Carburettor) 1
5 36 DU12 04 Gasket O ring Kit for Carb. 1 Ref. Page No. 51 5 31 1210 29 Element air filter 1

6 36 DU12 05 Carburettor Float pin Kit 1 Ref. Page No. 51 6 36 DU12 01 Air filter Kit 1 Ref. Page No. 50
7 36 DU12 02 Idling Screw kit 1 Ref. Page No. 51 7 DH 1211 03 Duct (Inlet) 1
8 36 DU12 03 Air Control Screw Kit 1 Ref. Page No. 51 8 DM 2210 01 Band - Tool kit 1
9 DU 1012 28 Flanged bolt 2 For mounting Carburettor 9 39 1680 04 Flanged bolt (Battery) 1
10 DU 1210 28 Seat for Jet Needle 1 10 39 2407 01 Screw (Mounting air filter) 2

11 DD 1211 71 Screw with washer 2 11 39 1789 24 Washer (Nylon) 2

12 DU 1210 17 Valve throttle 1 12 DM 1210 10 Band (Battery) 1
13 DH 1211 01 Magnet Assly. 1 TPS Assly. 13 31 1610 07 Damper battery 2
14 DH 1211 02 Reed Switch Assly. 1 Parts 14 DM 1210 14 Tube oil drain 1
15 39 1062 04 Bolt Flanged Small 1 TPS Mounting 15 DM 1210 26 Clamp 1

16 : Front Wheel Direction : Front Wheel Direction 17

Plate No. 18 : MUFFLER Plate No. 19 : OIL PUMP

1 1 2

2 3

4
4
5

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 31 10 1014 Gasket 1 1 39 1078 01 Screw Pan Cros 2

2 DU 1012 06 Nut 2 2 39 0753 01 Screw Pan Cros 1
3 DU 1011 96 Assembly Silencer Comp. 1 Exhaust-Tec 3 DF 1210 03 Pump Assly. Oil 1
4 DD 1013 66 Flanged Bolt 1 4 39 0999 06 Pin dowel 1
5 39 1013 21 Ring O 2

18 : Front Wheel Direction : Front Wheel Direction 19

Plate No. 20 : MAGNETO ASSLY. Plate No. 21 : FRAME

6
4 5
3
3 4
18 6
5

1 19 15 16
2
1

7 9 11
8
6 8

15
13
14 11 7
13 10
10

17

11
17
14 12
12 9
2
16

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DF 1110 15 Magneto assly/Brg. & Oil Seal 1 Alt. DX 1110 03 1 39 2473 04 Flanged Bolt 1
2 DD 1110 48 Cap Spark plug (R) 1 2 31 1910 02 Clamp 1
3 DF 1110 20 Stator assly 1 3 DF 1810 90 Nut 1
4 39 1042 19 Seal Oil (HTA make) 1 4 DF 1810 52 Cap Steering 1
5 39 1003 20 Bearing ball 1 5 36 3118 03 Bearing cone kit 1 Ref. Page No. 50
6 30 18 1006 Ball Steel 46
6 39 1028 21 Ring O 1 7 DM 1611 20 Frame Comp./Brg.races 1
7 39 1659 11 Plain washer 3 8 39 2222 04 Flange Bolt 4
8 DZ 1110 02 Ignitor assly (C.D.I.) / Damper 1 9 39 1068 04 Hex. Bolt 1 Engine Mounting Rubber
9 31 1110 58 Pulser Coil 1 10 39 2469 04 Flanged Bolt 1
10 39 1553 04 Flanged Bolt 2 11 59 1500 05 Flange Nut 5
12 DM 2210 08 Grip frame 1 Black Powder Coated
11 DU 2010 62 Regulator/Rectifier (R/R) unit 1 13 39 1556 04 Flanged bolt 2
12 DD 1110 18 Plug Spark (P-RZ9HC) 1 Alt.DD 1110 36 14 DU 1610 93 Bracket Engine Front/Bush LH 1
13 DF 1110 40 H. T. Coil 1 DU 1610 94 Bracket Engine Front/Bush RH 1
14 39 0745 01 Screw pan cross 1 15 DD 1610 53 Bracket Engine Upper LH 1
15 DD 1013 18 Bolt 3 16 DF 1611 68 Bracket Engine Upper RH 1
17 39 2700 04 Flange Bolt 1
16 DD 1110 11 Grommet Spark plug Cap 1 18 DF 1810 24 Lock Set (4 in 1) 1
17 DD 1110 12 Grommet H.T.Cable 1 19 39 2455 04 Bolt 2
18 DD 1110 41 Rotor 1

20 : Front Wheel Direction : Front Wheel Direction 21

Plate No. 22 : SWING ARM / REAR SHOCK ABSORBER Plate No. 23 : STAND, STEP AND STAY LH / RH

3 2

1 2 3 3A 1
16

1 17/18
18 16
17
4
5 5 4
5
6 10 3
8 10
9
9 14
6 8 8
7
7
11
6
11
7
15
12/13

3 13
2 13 14 9
1 14A
14 15
12 14

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 39 0712 15 Domed Cap Nut 4 1 DF 1614 13 Damper (PVC) 2 Alt. DF161096

2 39 0737 12 Washer Spring 4 2 DF 1614 25 Holder Step/Damper/Kick Stopper 1 Alt. DD161417
3 39 0714 11 Washer Plain 8 3 39 2481 04 Flanged Bolt 4
3A DM 1710 22 Spacer 1 4 DF 1611 02 Bolt for Side Stand Mounting 1
4 DM 1710 26 Rear Shock Absorber 2
5 39 0422 15 Nyloc Nut
5 36 DF17 01 Rubber Inner Bush kit 1 Ref. Page No. 50
6 DL 1610 48 Stand Side 1
6 39 0248 11 Plain Washer 2 7 30 1611 58 Spring 2
7 31 1710 06 Shaft Swing Arm 1 8 30 1611 57 Shaft Stand 1
8 39 0201 11 Plain Washer 2 9 DU 1610 32 Stand Centre / Damper 1
9 30 1710 18 Bushing Rubber 2
10 39 0787 08 Pin Cotter 1
10 39 1225 15 Nut Hex./ flange 1
11 DG 1611 24 Damper 1
11 DM 1710 18 Arm Comp. Swing / Bush 1 12 DU 1611 44 Stay LH / PVC Damper 1
12 52 DZ00 46 Adjuster Chain S/A (RH) 1 13 DU 1611 45 Stay RH / PVC Damper 1
13 39 0711 11 Washer Plain 2 14 39 2481 04 Hex bolt flanged 2
14 39 2764 15 Hex Nut 4
15 DX 1610 56 Rubber Pillion Step (PVC) 2 Alt. DU161027
15 52 DZ00 47 Adjuster Chain S/A (LH) 1
16 31 1710 12 Damper for Swing arm 1 16 DH 1611 94 Kick Stopper 1
17 39 0454 11 Plain washer 2 17 DM 1611 46 Third Footrest LH 1
18 39 0553 02 Self tapping Screw 2 18 DM 1611 47 Third Footrest RH 1

22 : Front Wheel Direction : Front Wheel Direction 23

Plate No. 24 : FENDER - FRONT & REAR Plate No. 25 : WHEEL RIM / SPOKES / TYRE / TUBE (130mm)

8
7

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 39 2222 04 Flanged Bolt 4 1 16 1510 66 Nipple Spoke 72

2 DF 1910 20 Clamp 1 2 DU 1510 25 Spoke Inner Front 18
3 39 2483 04 Flanged Bolt 4 3 DU 1510 26 Spoke Outer Front 18
4 DD 1610 51 Flap 1 4 DM 1510 29 Wheel Rim Front (1.6 x 17) 1
5 DF 1611 04 Fender Rear 1 5 DS 1510 48 Tyre Front 2.75 X 17 1

6 DM 1610 09 Fender Rear Front 1 6 DS 1510 49 Tube Front 2.75 X 17 1

7 39 0711 11 Plain Washer 4 7 DM 1510 28 Tyre Rear 3 X 17 1
8 39 0817 15 Hex. Nut Flanged 4 8 DS 1510 46 Wheel Rim Rear (1.85 x 17) 1
9 DF 1612 42 Front Fender 1 9 DG 1510 22 Band Rim 2
10 DF 1612 45 Mudflap - Front 1 10 DS 1510 09 Spoke Inner Rear 18

11 01 1106 09 Plain Washer 2 Alt. 39171111 11 DS 1510 10 Spoke Outer Rear 18

12 22 1504 35 Bolt 2 12 DS 1510 53 Tube Rear 1
13 39 2484 15 Flange Nut 2 13 DS 1510 47 Tyre and Tube Front 2.75 x 17 1
14 39 2473 04 Flange Bolt 1 14 DM 1510 27 Tyre and Tube Rear 1

24 : Front Wheel Direction : Front Wheel Direction 25

Plate No. 25A : WHEEL RIM / SPOKES / TYRE / TUBE (110mm) Plate No. 26 : FRONT HUB

1
3 10
2 6

7 9 12
3
2
7 20
5

8 22
6 17
15
14
1
13 18
4
4
8
10 19
9
11 11 25
8 16 25
5 26 24
3
1 21 23
2

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 16 1510 66 Nipple Spoke 72 1 39 2680 20 Ball Bearing 1 6300RS1/C3

2 DF 1510 05 Spoke Inner 36 2 DF 15 10 03 Drum Front 1
DU 1510 25 Spoke Inner 36 For 17" Wheel 3 31 15 10 04 Collar 1
3 DF 1510 06 Spoke Outer 36 4 36 DU15 03 Gear Meter Screw Kit 1 Ref. Page No. 50
DU 1510 26 Spoke Outer 36 For 17" Wheel 5 39 2681 20 Ball Bearing 1 6200RS1/C3
4 DM 1510 08 Wheel Rim Rear and Front 2 For 18" Wheel
5 DU 1510 18 Wheel Rim Rear 1 For 17" Wheel 6 DU 1510 05 Collar Axle Assly. 1
7 39 0248 11 Plain Washer 1
6 DM 1510 29 Wheel Rim Front 1 For 17" Wheel 8 DD 1510 09 Indicator Front 1
7 DS 1510 48 Tyre Front 1 For 17" Wheel 9 DZ 1510 40 Nut Hex. Slotted 1
8 30 1510 19 Tube 2 DU 1510 31 Nut Hex. Slotted 1
DS 1510 49 Tube 2 10 39 0775 04 Bolt 1
9 DS 1510 52 Tyre Rear 1 For 17" Wheel
10 DM 1510 24 Tyre with Tube Front 1 For 17" Wheel 11 DD 1510 08 Lever Brake Cam 1
DS 1510 47 Tyre with Tube Front 1 12 31 1510 36 Axle 1 Upto 2005
DZ 1510 12 Axle 1 From 2006
11 DM 1510 27 Tyre with Tube Rear 1 For 17" Wheel 13 30 1510 38 Ring O 1
14 DZ 1510 27 Panel Front Brake 1
15 31 1510 11 Cam Brake 1

26 : Front Wheel Direction : Front Wheel Direction 27

Plate No. 26 : FRONT HUB Plate No. 27 : REAR HUB (130 MM)

29
28 5 2
23
6

7 9 27
12 8 26
3 3
1
2
20 4

5 25

22
17 7
15 11
14
1
13 18 10
12
17 6
4 18
8
10 19 14 19

15 24
11 25
9
16 25
26 24 16
21 13
23
21 22
20

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 39 0798 15 Flange Nut 1 1 36 DU15 05 Chain Sprocket Kit 110mm Rr. Dr. 1 Ref. Page No. 53
17 30 15 1037 Spring 2 36 DM00 01 Chain Sprocket Kit 130mm Rr. Dr. 1
18 31 1510 07 Shoe Brake Assly. 2 Upto 2 DP 1510 28 ‘D’ bolt 6
31 1510 60 Shoe Brake Assly. 2 From 3 30 1510 81 Washer 2
19 39 1013 21 Ring 'O' 1 4 39 0794 15 Nut Hex. Fine 4
20 14 1510 21 Oil Seal 1 5 39 2240 20 Bearing Ball 1

21 39 0840 01 Screw pan Cross 1 6 39 0798 15 Hex. nut 1

22 31 1510 14 Oil Seal 1 7 36 DU15 06 Rear Wheel Bearing Kit 1 Ref. Page No. 50
23 30 1511 18 Stopper Fro bushing 1 8 39 0988 15 Nut Hex. 1
24 JA 1316 06 Bushing 1 9 31 1510 26 Collar 1
25 30 1510 42 Washer 2 10 DP 1510 27 Shock Damper 4

26 39 0900 12 Spring Washer 1 11 30 1510 63 Drum Rear 1 Alt. DF 1510 09

12 301510 75 Collar Assly. 1
13 30 1510 69 Spring 2
14 30 1510 68 Shoe Brake Assly. 1
15 30 1510 11 Brake Cam assly 1

28 : Front Wheel Direction : Front Wheel Direction 29

Plate No. 27 : REAR HUB (130 MM) Plate No. 27A : REAR HUB (110 MM)

29 29

28 5 2 28 5 2
23
23
27 27
8 26 8 26
1 3 1 3
4 4
25 25

7 7
11 11
10
10
12 12 17
17 6 6
18 18
14 19 14 19

15 24 15 24
9 9
16 16
13 13

21 22 21 22
20 20

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 30 1510 08 Panel Rear Brake 1 1 36 DU15 05 Chain Sprocket Kit 1 Upto Aug. 05 R. P. N. 66
17 30 1510 38 Ring O 1 36 DU40 03 Chain Sprocket Kit 1 Between Sep. 05 till
18 DD 1510 15 Lever Brake 1 Dec. 05 R. P. N. 66
19 39 0092 04 Bolt 1 36 DU40 17 Chain Sprocket Kit 1 w.e.f. Jan. 06 R. P. N. 66
20 DM 1510 32 Axle 1 2 39 0978 04 ‘D’ bolt 4
3 31 15 1029 Washer 2
4 39 0794 15 Nut Hex. Fine 4
21 39 2566 11 Washer Plain 1 5 39 2240 20 Bearing Ball 1
22 DH 1710 19 Nut Castle 1
23 DJ 1510 18 Sprocket 1 6 39 0798 15 Hex. nut 1
24 30 1510 05 Indicator 1 7 36 DU15 06 Rear Wheel Bearing Kit 1 Ref. Page No.63
25 31 1510 30 Collar 1 8 39 0988 15 Nut Hex. 1
9 31 1510 26 Collar 1
26 30 1510 78 Coupling 1 10 31 15 1021 Shock Damper 4
27 30 1510 79 Sleeve 1
28 DF 1510 23 Chain 1 11 DF 15 1009 Drum Rear 1
12 31 1510 18 Collar Assly. 1
29 DX 1510 81 Drive Chain Connecting Link 1
13 30 15 1069 Spring 2
14 31 1510 60 Shoe Brake Assly. 1
15 31 1510 23 Brake Cam Assly. 1

30 : Front Wheel Direction : Front Wheel Direction 31

Plate No. 27A : REAR HUB (110 MM) Plate No. 28 : BRAKE PEDAL

29

28 5 2

5 7
23
17 6
8 27
26
1 3
4
4 3
2
25
1

7 2
11
11 12
10 10
15
12 17 9
6
18
14 19 13

15 24 16 14
9
16
13
10
21 22 15 12 11
20

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 31 15 1024 Panel Rear Brake 1 1 39 0808 08 Split pin 1

17 30 15 1038 Ring O 1 2 DF 1910 67 Plain Washer 2
18 31 15 1037 Lever Brake 1 3 DM 1910 10 Rod Brake 1 DU 1910 30
19 39 0775 04 Bolt 1 4 30 19 1038 Pin 1
20 31 15 1001 Axle 1 5 DM 1910 16 Lever Brake Tubular 1

21 39 0714 11 Washer Plain 1 6 39 0805 11 Washer Plain 1

22 DH 1710 19 Nut Castle 1 7 39 0797 08 Pin Cotter 1
23 DM 1510 09 Sprocket 47 T 1 Upto Dec. 05 8 30 19 1031 Spring 1
DU 1510 27 Sprocket 42 T 1 w.e.f. Jan. 06 9 30 1910 35 Spring 1
24 30 1510 05 Indicator 1 10 39 0807 08 Pin Snap 2
25 31 1510 30 Collar 1
11 39 0708 15 Nut Hex. 2
26 31 1510 27 Coupling 1 12 39 0789 12 Washer Spring 2
27 31 1510 28 Sleeve 1 13 30 1910 38 Pin 1
28 DM 1510 05 Chain 114 Link 1 Upto Dec. 05 14 30 1910 36 Brake adjusting nut 1
DF 1510 23 Chain 112 Link 1 w.e.f. Jan. 06 15 30 1510 95 Bolt 2
29 DX 1510 81 Drive Chain Connecting Link 1
16 DD 1510 14 Torque rod 1
17 DD 1610 78 Damper 1

32 : Front Wheel Direction : Front Wheel Direction 33

Plate No. 29 : HANDLE BAR Plate No. 29 : HANDLE BAR

3 3
4 4

2 2
27 15 27 15
1 1
8 8

16 16
17 17
19 19
5 5
7 7
20 24 20 24
18 18
21 21
13 10 13 10

7 7
14 14
11 14 23 12 11 14 23 12
9 9
22 22
6 6
9 23 9 23
25 25
22 22
26 26

9 9

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DF 1811 17 Handle 1 16 FD 1810 31 Holder Handle Lower 2

2 FD 1810 30 Holder Handle Upper 2 17 DF 1810 91 Damper Handle Upper 2
3 39 1074 04 Flanged Bolt 4 18 DF 1810 92 Damper Handle Lower 2
4 DF 2010 53 Control Switch RH 1 19 FD 1810 19 Washer Plain Upper 2
5 DU 1910 34 Control Switch LH 1 20 FD 1810 20 Washer Plain Lower 2

6 DU 1910 35 Lever grip - Left 1 21 39 2249 15 Nylock Nut 2

7 39 0830 01 Stud Lever handle 2 22 39 0725 04 Hex.Bolt 2
8 30 1910 48 Band 2 23 39 0198 11 Plain Washer 2
9 DF 1910 26 Grip - Left hand 1 24 DM 1910 15 Boot For Lever RH 1
10 DF 1910 66 Lever grip - Right 1 25 DM 1910 13 Lever Assly. grip RH 1

11 DD 2011 70 Front brake switch 1 26 DU 1910 33 Lever Assly. grip LH 1

12 DF 1910 27 Grip - Right hand 1 27 DF 2210 37 Mirror LH 1
13 DM 1910 14 Boot For Lever LH 1
14 36 DU19 01 Cable Adjuster kit 1 Ref. Page No. 51
15 DF 2210 07 Mirror RH 1

34 : Front Wheel Direction : Front Wheel Direction 35

Plate No. 30 : FRONT FORK Plate No. 30 : FRONT FORK

10 10
9 9
6 11 6 11
22/23 12 22/23 12

19 19
13 13
20 20

1 1
24 24

7 7
8 8
21 21
2/3 14/15 2/3 14/15

25 25
4 4
16 16
5 5
17 17
18 18

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DL 1810 80 Seal Oil 1 16 DF 1810 83 Holder Fork Under 1

2 DD 1810 10 Pipe Left Fork Outer 1 17 39 0789 12 Washer Spring 2
3 DD 1810 14 Pipe Right Fork Outer 1 18 39 1813 04 Bolt Hex. 2
4 30 1810 26 Gasket 2 19 DD 1810 11 Dust seal 2
5 30 1810 25 Bolt 2 20 30 1810 23 Ring snap 2

6 30 1810 53 Cyl. Complete Fork 2 21 DM 1810 28 Front Fork 1

7 DM 1810 36 Pipe Comp. Susp. Inner 2 22 DM 1810 29 Damper Assly.LH 1
8 DE 1810 31 Spring Front Fork 2 23 DM 1810 30 Damper Assly.RH 1
9 FD 1810 12 Cap Special Nut 1 24 DD 1810 91 Cover Trail Top 2
10 30 1810 44 Bolt Fork 2 25 DD 1810 90 Cover Trail Bottom 2

11 30 1810 29 Ring ‘O’ 2

12 DF 1810 85 Seat Fork Spring 2
13 DF 1810 77 Holder Fork Upper 1
14 DM 1810 39 Cover Fork RH 1
15 DM 1810 38 Cover Fork LH 1

36 : Front Wheel Direction : Front Wheel Direction 37

Plate No. 31 : PAINTED PARTS Plate No. 31 : PAINTED PARTS

1 1
3 3

2 2

4 4

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DM 7105 22 Tank fuel with Decal 1 Jet Black 4 DU 1410 74 Decal set LH 1 Red
DM 7105 X4 Tank fuel with Decal 1 Flame Red DU 1410 75 Decal set RH 1 Red
DM 7105 Y7 Tank fuel with Decal 1 Star Blue DU 1410 72 Decal set LH 1 Black
DU 1410 73 Decal set RH 1 Black
2 DM 7305 22 Cover Side LH with Decal 1 Jet Black DU 1410 76 Decal set LH 1 Blue
DM 7305 X4 Cover Side LH with Decal 1 Flame Red DU 1410 77 Decal set RH 1 Blue
DM 7305 Y7 Cover Side LH with Decal 1 Star Blue DU 1611 52 Decal set LH 1 Common for all
DU 1611 53 Decal set RH 1 Common for all
3 DM 7306 22 Cover Side RH with Decal 1 Jet Black(Full Painted)
DM 7306 X4 Cover Side RH with Decal 1 Flame Red
DM 7306 Y7 Cover Side RH with Decal 1 Star Blue

38 : Front Wheel Direction : Front Wheel Direction 39

Plate No. 32 : FUEL TANK CAP, TAP ASSLY. Plate No. 33 : CHAIN CASE

7 3

8
10

8 1

3
7

5
9
6

4 4
6

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DU 1410 41 Tube Fuel 1 1 30 16 1271 Rubber Pad 1

2 DF 1810 24 Lock set Assly. (3 IN 1) 1 (N.I.) 2 52 DU01 75 Chain Case Upper S/A 1
3 DF 1411 20 Cap Assly. Tank 1 3 DF 1614 15 Trim case chain 1
4 DF 1411 66 Tap Assly. 1 4 DF 1614 16 Rubber Cap 1
DU 1412 28 Tap Assly. 1 Pavana Make 5 39 2475 04 Flanged Bolt 2
5 30 1410 39 Packing For Tap 1
6 39 2473 04 Flanged Bolt 2
6 33 1410 08 Clamp Tube 2 7 39 1211 11 Washer plain 1 For case chain
7 30 1410 52 Packing (For Cap) 1 8 52 DU01 76 Chain Case Lower 1
8 39 0761 01 Screw Pan Cross 2
9 DD 1412 27 Bolt Flanged 2
10 30 1410 31 O Ring 2

40 : Front Wheel Direction : Front Wheel Direction 41

Plate No. 34 : FITTINGS-PETROL TANK & SIDE COVER Plate No. 35 : METER ASSLY.

9
10

4 3

3
1
6 13
5 4/6
5
11

7
12
8

1 8
2
10

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DF 1411 29 Damper 1 1 31 1910 12 Meter Assly/ Lamp 1

2 30 1611 69 Grommet 2 2 31 1910 21 Cover Meter Lower Black 1
3 39 1789 24 Washer Nylon 1 3 31 1910 18 Speedometer 1
4 DG 1611 21 Screw 1 4 30 2010 29 Lamp 12V 4W 1
5 DU 1611 02 Damper 1 5 30 2011 29 Lamp 12V 2W 2 Imported

6 DF 1810 24 Lock set (4 in 1) 1 N.I. 6 30 2011 28 Lamp 12V 4W 1

7 DL 1410 35 Flange Bolt 1 7 DF 1810 24 Lock Set 1 N.I. 3 in one
8 39 1054 11 Plain Washer 1 8 39 0798 15 Nut 1
9 DL 1610 17 Damper - cover side 2 9 DF 1810 24 Lock Set Steering, P.Tank,
10 DF 1411 30 Damper 1 Side cover, DC Ing. 1
10 31 1910 17 Cover meter case upper 1 Black

11 31 1910 20 Cover (white) 1

12 31 1910 14 Bracket Meter 1
13 31 1910 19 Gasket Rubber 1

42 : Front Wheel Direction : Front Wheel Direction 43

Plate No. 36 : CONTROL CABLES Plate No. 37 : HEAD LAMP ASSLY

1
2 14 16
3 4
4
5
6

6
7
5

13
7 3

10 10
8
1
9 11
8 15
9 11
2
12 17

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DU 1910 41 Cable Brake (FR) 1 1 DM 2010 22 Head light assly with lamp 1
2 30 19 1070 Spring 1 2 DD 2010 45 Screw 1
3 30 19 1069 Dust Seal 1 3 DU 2010 57 Head Light Housing 1
4 30 19 1071 Rod End 1 4 DJ 2010 46 Head Light Rim 1
5 30 19 1072 Adjusting Nut 1 5 DJ 2010 51 Reflector with Lens 1

6 DM 1910 17 Cable Clutch 1 6 DU 2010 29 Special Screw 2

7 DU 1910 13 Cable Speedometer 1 Old 7 DU 2010 60 Collar 2
DZ 1910 14 Cable Speedometer 1 New 8 DD 2010 47 Washer 1
8 DZ 1910 19 Inner Cable Speedo 1 9 DD 2010 10 Damper 2
9 DM 1910 05 Cable Throttle 1 10 DD 2010 09 Damper 2

10 DM 1910 02 Cable starter 1 11 DD 2010 46 Spring for Adjustment 1

11 39 1561 21 "O" Ring 1 12 39 1683 04 Flange Bolt 2
13 39 2479 15 Flange Nut 2
14 DF 2011 64 Lamp 12 V 35/35 W 1
15 DD 2010 48 Nut (Nylon) 1
16 DF 2010 58 Lamp Holder (Socket) Assly. 1
17 DD 2010 17 Bracket Head Lamp 1

44 : Front Wheel Direction : Front Wheel Direction 45

Plate No. 38 : TURN SIGNAL LAMP Plate No. 39 : FRONT AND REAR NUMBER PLATE

3
1/2
3 4 3

4
1

6 7
6
10

5
5
8

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DM 2010 28 Dir. ind. Front RH with Lamp 1 1 DP 1611 44 Front Number plate 1
2 DM 2010 27 Dir. ind. Front LH with Lamp 1 2 DF 1810 97 Bracket Front No. Plate 1
3 DM 2010 29 Dir. ind. Rear LH with Lamp 1 3 39 1783 01 Truss Screw 2
4 DM 2010 30 Dir. ind. Rear RH with Lamp 1 4 39 2473 04 Flanged bolt 2
5 06 2010 83 Lamp 12 V 10 W 4 5 DP 1611 45 Number plate Rear 1

6 39 1225 15 Hex. Nut 4 6 DF 1612 48 Bracket No. Plate 1

7 39 2476 04 Hex head bolt / Flange 2
8 39 2475 04 Hex. bolt / Flange 2
9 30 2010 69 Reflector Reflex 1
10 39 2484 15 Flanged Nut 1

46 : Front Wheel Direction : Front Wheel Direction 47

Plate No. 40 : TAIL LIGHT ASSLY. Plate No. 41 : ELECTRICAL EQUIPMENT

2
3
6 10 8
4

5 3

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DF 2011 38 Tail Light Assly. with lamp 1 1 39 1940 04 Flanged Bolt 1

2 30 2010 06 Lamp 12 V, 21/5W 1 2 DF 2012 52 Horn 1
3 39 2430 15 Hex Nut. / Flange 2 3 31 2010 79 Switch Rear Brake 1
4 DD 2010 11 Damper 2 4 30 2010 74 Spring Brake Switch 1
5 31 2010 01 Collar 2 5 DM 2010 32 Wiring Harness 1 Nigeria
For Mtg. Tail light DM 2010 33 Wiring Harness 1 Non Nigeria
6 39 2429 11 Plain Washe 2 6 31 2010 27 Battery 1
7 31 2010 03 Relay assly. 1
8 DU 2010 63 Capacitor Electrolytic 1
9 39 2473 04 Hex Head Bolt / Flange 1
10 30 1910 48 Band 3

48 : Front Wheel Direction : Front Wheel Direction 49

Plate No. 42 : TOOL KIT Plate No. 43 : SEAT ASSLY

2 3

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DM 220 13 Tool Kit 1 1 DM 2110 21 Seat assly. 1 Nigeria

DM 2110 18 Seat Assly. Rear Hook + Front
End Bolting 1 Non Nigeria
2 39 1802 04 Hex. Soc. Hd. Bolt 2
3 39 1211 11 Washer 2

50 : Front Wheel Direction : Front Wheel Direction 51

Plate No. 44 : ACCESSORIES KIT LIST

Sr. Consisting of Following Parts

Kit Part No. Kit Description
No. Part No. Description Qty./Kit

1 36DU1001 O Ring Kit 39102021 O Ring 2

39256921 O Ring 1
2 36311008 Collet Seal Oil Kit 31101019 Collet 4
39103519 Oil Seal 2
31101045 Seat Spring 2
3 36311028 Valve Kit DD101134 Valve Intake 1
3 DD101135 Valve Exhaust 1
2 4 4 36311006 Chain Guide Kit 31101026 Guide Chain RH 1
31101025 Guide Chain LH 1
1 5 36DU1004 Gear Lever Spring Kit 31101055 Spring 1

5 31101054 Spring 1
DU101084 Spring 1
6 36DU1007 Boss Kick Kit 30101233 Boss Kick 1
30101234 Spring 1
30101236 Ball Steel 1
30101235 Pin 1
39085517 E - Type Circlip 1
7 36DU1201 Air Filter Kit DM121007 O Ring for Air Filter 1
DM121004 Cap 1
01110609 Plain Washer 4
39083001 Screw Pan cross 4
DF161426 Bolt Steeped Flanged 2
Qty/ 8 36311803 Bearing Cone kit DH181025 Bearing Cone 1
No. Part No. Description Veh. Remarks
DH181026 Bearing race 1
DH181024 Upper Bearing Race 1
1 DZ 2210 03 Leg guard 1
2 39 1814 04 Bolt Flanged 1 DH181023 Bearing Cone 1
3 39 1940 04 Flanged Bolt 2 For mounting Leg guard 9 36DF1701 Rubber - Inner Bush Kit 30171030 Rubber Bush 4
4 DF 2210 54 Saree Guard 1 30171031 Inner Bush 4
5 39 1608 04 Hex. soc. hd. bolt 2 10 36DU1601 Chain Case Kit 52DU0175 Case Chain Upper Assly. 1
52DU0176 Case Chain Lower Assly. 1
11 36DU1503 Gear Meter Screw Kit 31151064 Speedo Gear (22T) 1
30151041 Gear Meter Screw 1
12 36DM0001 Chain Sprocket Kit DF151023 Chain (112 Links) 1
DJ151018 Sprocket (42 T) 1
DX101052 Sprocket 0/P 1
13 36DU1506 Rear Wheel Bearing Kit 39268620 Ball Bearing (6301RS1/C3) 1
39268720 Ball Bearing (6201RS1/C3) 1
14 36DU1901 Cable Adjuster Kit 30191017 Nut 2
DD191147 Screw 2
15 36DU1202 Idling Screw Kit DU121024 Screw Idling (Stop Screw) 1

52 : Front Wheel Direction : Front Wheel Direction 53

KIT LIST AMENDMENT SHEET (PARTS ADDED)

Sr. Consisting of Following Parts Sr. Page Fig.

Kit Part No. Kit Description Part No. Description Qty.
No. Part No. Description Qty./Kit No. No. No.

DD121176 Spring - Idling Screw 1

16 36DU1203 Air Control Screw Kit DU121025 Screw - Air (Adjust) 1
DD121178 Spring - Screw Air 1
17 36DU1204 Gasket O ring Kit for Carb. DD121170 Gasket - Float Chamber 1
DU121023 Gasket Top 1
18 36DU1205 Carburettor Float Pin Kit DD121168 Valve complete Float 1
DU121015 Float Complete 1
19 36DU1206 Carburettor Holder/Jet Kit DU121018 Needle Jet 1
DU121012 Holder - Needle Jet 1
DU121013 Main Jet 1
DU121014 Slow Jet complete 1
DU121021 Spring - Valve throttle 1

54 55
AMENDMENT SHEET (PARTS DELETED) Part Index
Sr.
Part No. Description Qty. Page Fig. Figure Page Figure Page
No. No. No. Part No. No. No. Part No. No. No.

1100610 2 5 30161169 2 42
1110609 11 24 30161271 1 41
1170110 11 9 30171018 9 22
1170111 7 9 30181006 6 21
1170111 1 10 30181023 20 37
14151021 20 28 30181025 5 36
16151066 1 25 30181026 4 36
16151066 1 26 30181029 11 36
22150241 7 15 30181044 10 36
22150435 12 24 30181053 6 36
28101107 4 5 30191031 8 33
28101107 16 5 30191035 9 33
28101195 2 14 30191036 14 33
28101214 9 14 30191038 4 33
30101015 12 10 30191038 13 33
30101096 7 14 30191048 34 8
30101142 6 13 30191048 49 10
30101154 5 15 30191069 3 44
30141015 15 10 30191070 2 44
30141031 10 40 30191071 4 44
30141039 5 40 30191072 5 44
30141052 7 40 30201006 2 48
30151005 24 30 30201029 4 43
30151005 24 32 30201069 9 47
30151008 16 30 30201074 4 49
30151011 15 29 30201128 6 43
30151019 8 26 30201129 5 43
30151037 17 28 31101005 4 1
30151038 13 27 31101006 2 1
30151038 17 30 31101007 10 1
30151038 17 32 31101014 1 18
30151042 25 28 31101018 6 2
30151063 11 29 31101033 6 3
30151068 14 29 31101038 11 15
30151069 13 29 31101039 10 15
30151069 13 31 31101040 16 15
30151075 12 29 31101041 8 15
30151078 26 30 31101051 2 7
30151079 27 30 31101056 8 10
30151081 3 29 31101061 4 12
30151095 15 33 31101062 1 12
30151118 23 28 31101067 4 13
30161157 8 23 31101104 4 2
30161158 7 23 31101108 10 8

56 3 57
Part Index Part Index
Figure Page Figure Page Figure Page Figure Page
Part No. No. No. Part No. No. No. Part No. No. No. Part No. No. No.

31101109 11 8 31201079 3 49 39071411 21 32 39100006 1 4

31101113 5 12 31201081 9 10 39072504 22 35 39100320 5 20
31101137 16 14 33141008 6 40 39073712 2 22 39100820 6 10
31101148 13 14 36311006 1 3 39073817 14 15 39101321 5 19
31101175 16 1 36311008 8 2 39074501 14 20 39101321 19 28
31101191 1 7 36311028 9 2 39074601 5 8 39101721 14 1
31101192 5 7 36311803 5 21 39074801 10 3 39101721 2 3
31101295 3 12 36DD4001 4 4 39075301 2 19 39101921 2 12
31111058 9 20 36DF1701 5 22 39076101 8 40 39102121 5 1
31121029 5 17 36DM0001 1 29 39077504 10 27 39102304 3 11
31151001 20 32 36DU1001 1 1 39077504 19 32 39102821 6 20
31151004 3 27 36DU1004 3 8 39078708 10 23 39104119 5 13
31151007 18 28 36DU1007 6 15 39078912 12 33 39104219 4 20
31151011 15 27 36DU1201 6 17 39078912 17 37 39104319 4 10
31151014 22 28 36DU1202 7 16 39079415 4 29 39105006 2 10
31151018 12 31 36DU1203 8 16 39079415 4 31 39105315 11 14
31151021 10 31 36DU1204 5 16 39079708 7 33 39105411 8 42
31151023 15 31 36DU1205 6 16 39079815 16 28 39105515 1 5
31151024 16 32 36DU1206 4 16 39079815 6 29 39105604 4 9
31151026 9 29 36DU1503 4 27 39079815 6 31 39106204 4 11
31151026 9 31 36DU1505 1 29 39079815 8 43 39106204 15 16
31151027 26 32 36DU1505 1 31 39080511 6 33 39106604 3 10
31151028 27 32 36DU1506 7 29 39080708 10 33 39106804 3 9
31151029 3 31 36DU1506 7 31 39080808 1 33 39106804 9 21
31151030 25 30 36DU1901 14 35 39081715 8 24 39107404 7 12
31151030 25 32 36DU4003 1 31 39083001 7 34 39107404 3 34
31151036 12 27 36DU4017 1 31 39084001 21 28 39107504 11 10
31151037 18 32 39009204 19 30 39090012 26 28 39107504 10 13
31151060 18 28 39019811 23 35 39097804 2 31 39107801 1 19
31151060 14 31 39020111 8 22 39098004 10 14 39108019 5 10
31161007 13 17 39024811 2 9 39098517 5 4 39121111 7 41
31171006 7 22 39024811 6 22 39098608 3 17 39121111 3 51
31171012 16 22 39024811 7 27 39098717 4 6 39122515 1 9
31191002 2 21 39042215 5 23 39098815 8 29 39122515 10 22
31191012 1 43 39045411 17 22 39098815 8 31 39122515 6 46
31191014 12 43 39055302 18 22 39099206 6 7 39128321 3 16
31191017 10 43 39070201 5 2 39099311 9 15 39155304 10 20
31191018 3 43 39070201 7 10 39099511 13 15 39155604 13 21
31191019 13 43 39070311 10 10 39099906 11 3 39156121 11 44
31191020 11 43 39070815 11 33 39099906 6 9 39160804 5 52
31191021 2 43 39071111 13 22 39099906 8 12 39165911 7 20
31201001 5 48 39071111 7 24 39099906 3 13 39167304 3 1
31201003 7 49 39071215 1 22 39099906 4 19 39168004 9 17
31201027 6 49 39071411 3 22 39100006 12 1 39168304 12 45

58 59
Part Index Part Index
Figure Page Figure Page Figure Page Figure Page
Part No. No. No. Part No. No. No. Part No. No. No. Part No. No. No.

39169901 8 5 39256611 21 30 DD101521 18 1 DF151009 11 31

39178301 3 47 39260011 3 14 DD111011 16 20 DF151023 29 30
39178924 11 17 39268020 1 27 DD111012 17 20 DF151023 28 32
39178924 3 42 39268120 5 27 DD111018 12 20 DF161102 4 23
39179021 14 3 39270004 17 21 DD111041 18 20 DF161104 5 24
39180204 2 51 39270411 12 8 DD111048 2 20 DF161168 16 21
39181304 18 37 39276415 14 22 DD121171 11 16 DF161242 9 24
39181404 2 52 52DM0086 9 12 DD141227 9 40 DF161245 10 24
39186420 5 9 52DU0104 1 8 DD151008 11 27 DF161248 6 47
39194004 1 49 52DU0104 6 8 DD151009 8 27 DF161413 1 23
39194004 3 52 52DU0175 2 41 DD151014 16 33 DF161415 3 41
39195904 8 3 52DU0176 8 41 DD151015 18 30 DF161416 4 41
39198104 15 6 52DZ0046 12 22 DD161051 4 24 DF161425 2 23
39199404 2 8 52DZ0047 15 22 DD161053 15 21 DF181024 18 21
39213421 8 13 59040025 1 15 DD161078 17 33 DF181024 2 40
39214704 10 12 59150005 11 21 DD181010 2 36 DF181024 6 42
39219908 14 5 6201083 5 46 DD181011 19 37 DF181024 7 43
39220011 12 5 DD101007 2 4 DD181014 3 36 DF181024 9 43
39222204 8 21 DD101013 7 4 DD181090 26 37 DF181052 4 21
39222204 1 24 DD101058 6 12 DD181091 24 37 DF181077 13 36
39224020 5 29 DD101060 9 13 DD201009 10 45 DF181083 16 37
39224020 5 31 DD101062 9 3 DD201010 9 45 DF181085 12 36
39224915 21 35 DD101101 13 10 DD201011 4 48 DF181090 3 21
39240320 12 14 DD101106 7 8 DD201017 17 45 DF181091 17 35
39240701 10 17 DD101254 3 15 DD201045 2 45 DF181092 18 35
39242911 6 48 DD101264 2 15 DD201046 11 45 DF181097 2 47
39243015 3 48 DD101275 10 9 DD201047 8 45 DF181117 1 34
39245504 19 21 DD101309 1 6 DD201048 15 45 DF191020 2 24
39246904 10 21 DD101318 15 20 DD201170 11 34 DF191026 9 34
39247304 1 21 DD101325 7 13 DE181031 8 36 DF191027 12 34
39247304 14 24 DD101343 13 1 DF101055 2 2 DF191066 10 34
39247304 6 41 DD101347 6 1 DF111015 1 20 DF191067 2 33
39247304 4 47 DD101349 8 1 DF111020 3 20 DF201053 4 34
39247304 9 49 DD101350 7 1 DF111040 13 20 DF201058 16 45
39247404 8 8 DD101366 4 18 DF121003 3 19 DF201138 1 48
39247504 5 41 DD101407 7 3 DF121023 1 17 DF201164 14 45
39247504 8 47 DD101440 7 2 DF141120 3 40 DF201252 2 49
39247604 7 47 DD101475 16 6 DF141129 1 42 DF221007 15 35
39247915 13 45 DD101480 6 14 DF141130 10 42 DF221037 27 35
39248104 3 23 DD101481 15 1 DF141166 4 40 DF221054 4 52
39248104 14 23 DD101487 7 3 DF151003 2 27 DG101498 9 9
39248304 3 24 DD101492 5 14 DF151005 2 26 DG101498 12 10
39248415 13 24 DD101493 8 14 DF151006 3 26 DG151022 9 25
39248415 10 47 DD101517 2 11 DF151009 11 29 DG161121 4 42

60 61
Part Index Part Index
Figure Page Figure Page Figure Page Figure Page
Part No. No. No. Part No. No. No. Part No. No. No. Part No. No. No.

DG161124 11 23 DM181036 7 36 DS151047 13 25 DU121005 1 11

DH101066 13 5 DM181038 15 36 DS151047 10 26 DU121008 4 17
DH101067 15 5 DM181039 14 36 DS151048 5 25 DU121009 1 16
DH101195 9 5 DM191002 10 44 DS151048 7 26 DU121017 12 16
DH101430 6 4 DM191005 9 44 DS151049 6 25 DU121028 10 16
DH121101 13 16 DM191010 3 33 DS151049 8 26 DU141041 1 40
DH121102 14 16 DM191013 25 35 DS151052 9 26 DU141072 4 39
DH121103 7 17 DM191014 13 34 DS151053 12 25 DU141073 4 39
DH161194 16 23 DM191015 24 35 DU101005 3 5 DU141074 4 39
DH171019 22 30 DM191016 5 33 DU101010 11 5 DU141075 4 39
DH171019 22 32 DM191017 6 44 DU101011 6 6 DU141076 4 39
DJ151018 23 30 DM201022 1 45 DU101038 12 15 DU141077 4 39
DJ201046 4 45 DM201027 2 46 DU101041 7 5 DU141228 4 40
DJ201051 5 45 DM201028 1 46 DU101045 15 15 DU151005 6 27
DL141035 7 42 DM201029 3 46 DU101050 4 15 DU151018 5 26
DL161017 9 42 DM201030 4 46 DU101056 4 3 DU151025 2 25
DL161048 6 23 DM201032 5 49 DU101057 2 16 DU151025 2 26
DL181080 1 36 DM201033 5 49 DU101058 17 1 DU151026 3 25
DM101098 4 7 DM211018 1 51 DU101066 12 3 DU151026 3 26
DM101099 8 7 DM211021 1 51 DU101067 13 3 DU151027 23 32
DM101114 12 6 DM22013 1 50 DU101074 4 8 DU151031 9 27
DM121010 12 17 DM221001 8 17 DU101075 12 9 DU161032 9 23
DM121014 14 17 DM221008 12 21 DU101078 5 3 DU161093 14 21
DM121026 15 17 DM710522 1 38 DU101080 7 6 DU161094 14 21
DM151005 28 32 DM7105X4 1 38 DU101081 3 7 DU161102 5 42
DM151008 4 26 DM7105Y7 1 38 DU101083 9 7 DU161144 12 23
DM151009 23 32 DM730522 2 38 DU101085 13 9 DU161145 13 23
DM151024 10 26 DM7305X4 2 38 DU101094 3 4 DU161152 4 39
DM151027 14 25 DM7305Y7 2 38 DU101096 3 3 DU161153 4 39
DM151027 11 26 DM730622 3 38 DU101109 4 14 DU191013 7 44
DM151028 7 25 DM7306X4 3 38 DU101113 13 8 DU191033 26 35
DM151029 4 25 DM7306Y7 3 38 DU101185 9 8 DU191034 5 34
DM151029 6 26 DP101155 13 6 DU101190 3 2 DU191035 6 34
DM151032 20 30 DP101168 14 6 DU101191 1 2 DU191041 1 44
DM161009 6 24 DP101340 7 7 DU101196 3 18 DU201029 6 45
DM161120 7 21 DP101452 8 9 DU101206 2 18 DU201057 3 45
DM161146 17 23 DP121025 15 10 DU101208 9 1 DU201060 7 45
DM161147 18 23 DP151027 10 29 DU101211 16 5 DU201062 11 20
DM171018 11 22 DP151028 2 29 DU101213 11 6 DU201063 8 49
DM171022 3A 22 DP161144 1 47 DU101218 3 4 DX101035 14 14
DM171026 4 22 DP161145 5 47 DU101220 14 9 DX101045 2 6
DM181028 21 37 DS151009 10 25 DU101228 11 1 DX101046 10 6
DM181029 22 37 DS151010 11 25 DU101228 9 16 DX101047 5 5
DM181030 23 37 DS151046 8 25 DU121004 2 17 DX101048 3 6

62 63
Part Index
Figure Page Figure Page
Part No. No. No. Part No. No. No.

DX101049 5 6
DX101050 9 6
DX101051 8 6
DX101052 12 6
DX101053 10 5
DX101054 1 14
DX101055 15 14
DX101075 5 3
DX151081 30 30
DX151081 29 32
DX161056 15 23
DZ101034 14 10
DZ101046 2 13
DZ101047 1 13
DZ111002 8 20
DZ151012 12 27
DZ151027 14 27
DZ151040 9 27
DZ191014 7 44
DZ191019 8 44
DZ221003 1 52
FA101334 6 5
FD181012 9 36
FD181019 19 35
FD181020 20 35
FD181030 2 34
FD181031 16 35
JA131606 24 28

64