Disc 1005 G

Bajaj Auto Limited
Akurdi Pune 411 035 India

Tel +91 20 27472851
Fax +91 20 27407385
www.bajajauto.com
Spare Parts Catalogue
( EXPORT )
Notice
All information contained in this manual is based on the latest
product information at the time of publication. Bajaj Auto
Limited accepts no liability for any inaccuracies or omissions in
this publication, although every possible care has been taken to
make it as complete and accurate as possible. All procedures
and specifications subject to change without prior notice. The
right is reserved to make such changes at any time without
prior notice and without incurring an obligation to make such
changes to product manufactured previously. Contact your
authorized Bajaj Dealer for the latest information on product
improvements incorporated after this manual was issued.
DOC. NO.: 71110890 REV. 00, MAY. 10

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

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

7 JA 5110 29 Clamp 2 2
6
8 JB 5110 15 Flange Bolt 1 1 For head mtg.
5
4
1 2
Front Wheel Direction
Cylinder Head
Description KS ES
Drum Drum
1 52 JB02 32 Head Cylinder Comp. 1 1 With Studs

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

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

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

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

10
2 JA 5112 16 Spacer Cam Sprocket 1 1
3 DS 1012 76 Sprocket Cam Shaft 1 1
11
4 DH 1013 87 Precoated Socket Bolt M8 X 20 1 1
8
5 DH 1010 48 Special Washer (’O’ Washer) 1 1
13
6 36 PA00 02 Guide Chain Kit 1 1 Refer Page No. 113

7 7 DH 1013 92 Bolt Special 1 1
9
8 JA 5210 17 Adjuster Assly Chain 1 1
9 CS 1011 28 Gasket 1 1
10 JA 5210 18 Bolt 1 1 N.S
DD 1010 62 Bolt 1 1 alt for JA521018
11 JA 5210 19 Flange Bolt 2 2 N.S

14 39 1673 04 Flange Bolt 2 2 alt for JA521019
12 39 0594 17 Circlip for Camshaft 1 1
1
13 39 2669 21 ‘O’ Ring (Tensioner) 1 1
6
14 JA 5310 11 Cam Chain (92 Link) 1 1
12
5
2
3
4
7 8
Cylinder and Piston
Description KS ES
Drum Drum
1 JD 5210 02 Gasket Cylinder 1 1

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

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

2A 59 1200 03 Belleville Washer 1 2
6 2B 59 1100 08 Plain Washer 1 1
4 3 31 1011 73 Woodruff Key 1 1
10 4 JB 5310 18 Crank Shaft Assly. 1 1
9 5 39 1864 20 Ball Bearing 1 1
8
3
6 DS 1011 54 Parallel Key 1 1
11
7 36 PA00 06 Set Primary Drive / Driven 1 1 Refer Page No. 115
1 1
8 JA 531012 Spring 1 1
9 JA 5310 15 Parallel Pin 1 1
2A 10 JB 5310 21 Plunger Oil 1 1
5
2A
2B
11 JD 5310 04 Spacer Crank shaft Clutch Side 1 1
11 12
Transmission
Description KS ES
Drum Drum
1 JD 5510 00 Shaft Input Transmission 1 1

JZ 5510 10 Shaft Input Transmission 1 1 Shaft Input Transmission
2 JD 5512 07 Gear 4th Drive 1 1
JZ 5512 02 Gear 4th Drive 1 1 Shaft Input Transmission
3 39 0987 17 Ring Snap 5 5
4 JA 5510 02 Spline Washer 4 4
5 JD 5512 06 Gear 3rd Drive 1 1
JZ 5512 01 Gear 3rd Drive 1 1 * from Eng. no. BUA40423
1 5A JD 5512 05 Gear 5th Drive 1 1
JZ 5512 13 Gear 5th Drive 1 1 * from Eng. no. BUA40423
6 JD 5512 01 Gear 2nd Drive 1 1
16
JZ 5512 00 Gear 2nd Drive 1 1 * from Eng. no. BUA40423
7 JA 5510 04 Washer Thrust 2nd Drive 1 1
2
3 4 8 JD 5510 02 Shaft Output Transmission 1 1
14 JV 5510 02 Shaft Output Transmission 1 1 Ref. Cir. IB-12 (wef Jul.10)
3 5 13
12 JZ 5510 08 Shaft Output Transmission 1 1 * from Eng. no. BUA40423
4 3 9 JD 5512 08 Bush 2nd Driven 1 1
4
JZ 5512 10 Bush 2nd Driven 1 1 * from Eng. no. BUA40423
5A
6 9A JD 5512 02 Gear 2nd Driven 1 1
7 4 11 JZ 5512 06 Gear 2nd Driven 1 1 * from Eng. no. BUA40423
3
10 JD 5512 03 Gear 5th Driven 1 1
10 JZ 5512 11 Gear 5th Driven 1 1 * from Eng. no. BUA40423
3
11 JD 5512 04 Gear 3rd Driven 1 1
8 15
JZ 5512 12 Gear 3rd Driven 1 1 * from Eng. no. BUA40423
9 9A 12 JD 5512 00 Gear 4th Driven 1 1
JZ 5512 08 Gear 4th Driven 1 1 * from Eng. no. BUA40423
18 13 JA 5510 07 Bush 1st Driven 1 1
17 JZ 5512 05 Bush 1st Driven 1 1 Ref. Cir. IB-12
14 JA 5512 06 Gear 1st Driven 1 1
20 19
JZ 5512 04 Gear 1st Driven 1 1 Ref. Cir. IB-12
21
15 JD 5512 09 Spline Washer 1 1
16 JA 5510 08 Washer Thrust 1st Driven 1 1
17 JA 5510 09 Collar Sprocket Drive 1 1
18 59 2100 24 ‘O’ Ring Collar Sprocket 1 1
19 JB 5510 00 Sprocket Drive (Allen Bolt) 1 1
20 DU 1012 13 Plate Lock Sprocket 1 1
21 39 1981 04 Socket Head Bolt 2 2
Note : * The Gear Transmission components are changed in view of commonisation

13 with other models. This is implemented from Eng. No. BUA40423 (Ref. Circular IB-15) 14
These are not interchangeable with old vehicles.
Change Drum / Shift Fork
Description KS ES
Drum Drum
1 JW 5610 00 Drum Complete Gear Shift 1 1

JZ 5610 00 Drum Complete Gear Shift 1 1 * from Eng.no. BUA40423
2 39 0992 06 Dowel (Pin Drum Change) 4 4
5 3 JD 5610 11 Special Bolt 1 1
5
4 JD 5610 06 Shaft Gear Shift Fork 2 2
5 JB 5610 01 Fork Gear Shift Output 2 2
7
1 6 JB 5610 00 Fork Gear Shift Input 1 1

7
4
JZ 5610 02 Fork Gear Shift Input 1 1 * from Eng.no. BUA40423
7 DK 1011 35 Bush (Fork Shift) 3 3
8 JD 5610 02 Cam Drum Change 1 1
Note : * The Gear Transmission components are changed in view of commonisation

4
6 8 with other models. This is implemented from Eng. No. BUA40423 (Ref. Circular IB-15)
3
These are not interchangeable with old vehicles.
15 16
Gear Change Mechanism
Description KS ES
Drum Drum
1 JW 5612 05 Lever Complete Gear Shift 1 1 N.S

52 JZ02 64 Lever Complete Gear Shift 1 1 Alternate
1 2 JW 5612 06 Extension Spring 1 1

2 3 JW 5612 08 Spring Gear Shift Return 1 1
4 JD 5612 03 Inhibitor Complete Gear Shift 1 1
5 JD 5612 04 Spring Inhibitor 1 1
3
8 6 JA 5612 09 Step Washer (Collar) 1 1

7 7 39 2704 11 Plain Washer 1 1
12 8 39 0817 15 Nut 1 1
4
6 9 JA 5614 00 Lever Complete Gear Shifter 1 1 With Rubber
5 (Gear Pedal) Damper
10 DH 1015 09 Damper 1 1
11 DG 1013 39 Damper 1 1
12 JA 5612 11 Flange Bolt 1 1
10
39 1902 04 Flange Bolt 1 1 alt for JA561211
11
17 18
Engine Assembly / Crankcase RH
Description KS ES
Drum Drum
1 JB 5010 02 Engine Assly. -- 1 N.I.

JB 5010 03 Engine Assly. 1 – N.I.
2 52 JB02 30 Crankcase Clutch Side 1 1 NRB+Bush+Stud
10
3 59 2000 36 Bearing Ball 1 1 For I/P Shaft.
9 4 JA 5410 11 Needle Roller Bearing 1 1 For O/P Shaft.
11 5 JA 5410 10 Stopper Plate 1 1
6 39 1000 06 Dowel Pin 2 2

6 8
7 DU 1010 85 Bushing 1 1
5
8 39 0746 01 Screw 1 1
3
12 9 JA 5410 15 Stud Inhibitor Mounting 1 1
14 52 Ja00 27 Stud Inhibitor Mounting 1 1 alt for JA541015
10 JA 5412 35 Bolt 2 2 Crankcase Mtg.
13
11 59 0400 38 Bolt Flange 1 1 Crankcase Mtg.
12 52 JA00 29 Bolt Precoated 1 1
7
13 JA 5410 12 Guide Kick 1 1
2 14 39 1964 04 Hexagon Bolt 2 2
19 20
Crankcase LH
Description KS ES
Drum Drum
1 52 JB02 33 Crankcase Mag. Side -- 1 NRB + Bush+

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

8 JA 5410 05 Bush Starter Clutch 1 1 Starter Clutch
11
9 39 0747 01 Pan Head Screw 2 2
17 10 JA 5410 34 Stopper Gear Starter Clutch 1 1
20
10
1 11 39 1000 06 Hollow Dowel Pin 2 2
9
12 39 0999 06 Hollow Dowel Pin 2 2
18 13 JA 5410 19 Mesh Filter Oil strainer 1 1
5 6
13 7 12 14 59 2100 23 ‘O’ Ring Cap Strainer 1 1
14 15 JA 5410 21 Cap Strainer 1 1
15
4
16
16 59 0400 38 Bolt Flange 6 6 Crankcase Mtg.
17 39 1759 04 Bolt 1 1 Crankcase Mtg.
18 JA 5410 20 ‘O’ Ring Mesh Filter Oil Strainer 1 1
19 JA 5410 27 Damper 1 1
20 DH 1011 25 Spring Kick Start Return 1 1
21 22
Cover RH
Description KS ES
Drum Drum
21 22 1 52 JB02 34 Clutch Cover 1 1

19 20
36 JB00 23 Clutch Cover Flower Type 1 1 Ref. Cir. A-17 (Aug.10) N.S
JB 5412 12 Clutch Cover Flower Type 1 1 alt for 36JB0023
2 JE 5412 11 Decal Clutch Cover 1 1
3 39 1041 19 Oil Seal Clutch Lever 1 1
18
4 30 1011 42 Oil Seal (Kick Shaft) 1 1
5 JW 5410 05 Shaft Clutch Release 1 1
10
11
5 6 DP 1012 69 Rod Push 1 1
3 7 DG 1014 18 Gauge 1 1 Oil Level Check
12
9 8 DS 1012 15 Wire Circilp 1 1
9 JA 5412 36 Plain Washer 1 1
17
13 2 10 JA 5412 37 Spring Torsion Clutch Lever 1 1
8
7 11 JA 5412 11 Cap Oil Filler 1 1
12 JA 5412 25 ‘O’ Ring Cap Oil Filler 1 1
15
4 13 JA 5412 15 Damper 1 1 Old
14
JE 5412 09 Damper Flower Type 1 1 New from Aug. 2010
24
17 14 JA 5412 16 Plate Damper 1 1
15 39 2208 04 Bolt Flange 3 3
16 JA 5412 12 Gasket Clutch Cover 1 1

17 59 0400 38 Bolt Flange 8 8 Clutch Cover to
6 Crankcase Mtg
1
18 JW 5410 00 Bracket Clutch Cable 1 1
23
19 DD 1211 81 Oil Filter Element 1 1
16
25 20 39 1671 21 ‘O’ Ring 1 1
21 JA 5412 19 Cap Filter 1 1 Old

JZ 5412 14 Cap Filter 1 1 New From Aug.2010
22 JA 5210 19 Bolt Flange 3 3 N.S
39 1673 04 Bolt Flange 3 3 alt for JA521019
23 39 1001 20 Bearing Push Rod 1 1
24 JB 5412 01 Jet Clutch Cover 1 1
25 39 0999 06 Pin Hollow Dowel 2 2
23 24
Cover Magneto
Description KS ES
Drum Drum
7
1 JA 5412 41 Cover Magneto -- 1
36 JZ0015 Cover Magneto Flower Type -- 1 Ref. Cir. A-17 27.10.2010
JP 5412 05 Cover Magneto 1 --
8 2 JA 5410 44 Bolt Flange 8 8
3 JA 5412 05 Gasket Magneto Cover -- 1
6
3 JP 5412 08 Gasket Magneto Cover 1 --
4 59 0400 38 Bolt 2 2
5 JZ 5412 02 Cover LH Rear Complete -- 1
9
10 JZ 5412 03 Cover LH Rear Complete 1 –
11
6 JA 5412 20 Damper Cover LH 1 1 Old
JE 5412 10 Damper Cover LH 1 1 New 27.10.2010
2 7 39 2208 04 Flanged Bolt 3 3
8 JA 5412 21 Plate Damper Cover LH 1 1
12
DT 9 JA 5410 05 Bush 1 1 For Drive Gear Assly
S-i
10 JA 5412 33 Threaded Cap TDC Finder 1 1
13
11 30 1011 95 ‘O’ Ring 1 1

12 JW 2330 00 Gear Shift Lable 1 1 N.S
13 13 JE 5412 12 Decal Magneto Cover (DTS-i) 1 1
1
4
5
12
25 26
Clutch
Description KS ES
Drum Drum
11
10
1 JB 5514 00 Clutch Assly Complete 1 1
3
1A JD 5514 00 Spacer Clutch Assely 1 1 ‘JD’ Mark for I.D.
9
2 JA 5514 06 Collar Clutch 1 1
4 8
3 39 2600 11 Washer 1 1
1A 2
4 JB 5514 04 Clutch Plate Assly 1 1
5 JB 5514 08 Wheel Clutch 1 1
6 30 1010 96 Plate Clutch 4 4

7 DD 1014 80 Plate Friction 5 5 (45 Segments)
8 JB 5514 11 Hub Clutch 1 1
6 9 28 1012 14 Compression Spring 6 6
7 10 JB 5514 06 Holder Clutch 1 1
5
12
13 11 39 0980 04 Bolt Flange 6 6
15 12 JA 5514 16 Belleville Washer 1 1
14
13 JA 5514 20 Plain Washer 1 1
14 52 JA00 28 Nut Special 1 1 L.H. Threads
15 39 1001 20 Bearing Clutch Lifter 1 1
1
16 36 PA00 06 Set Primary Drive & Driven 1 1 Refer Page No. 115
16
27 28
Kick Starter Mechanism
Description KS ES
Drum Drum
1 JA 6212 01 Lever Assly Kick 1 1

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

10
5 2 12 39 2408 17 Circlip 1 1
13 DD 1010 97 Kick Rubber 1 1
12 1 14 DH 1011 25 Spring Kick Starter Return 1 1
5
14 3
29 30
Carburettor
Description KS ES
Drum Drum
2 1 JB 5812 78 Carburettor assly. 1 1

3
2 JB 5812 37 Adjuster throttle cable 1 1
3 JB 5812 38 Nut adjuster 1 1 N.S
18
10 4 36 PA00 12 Air screw Kit 1 1 Refer Page No. 113
36 JB00 22 Air screw Kit 1 1 Ref. Cir. A-16
15
5 36 PA00 11 Jet Kit 1 1 Refer Page No. 113
4 36 JB00 21 Jet Kit 1 1 Ref. Cir. A-16
11
12
10
6 36 PA00 13 Idling screw kit 1 1 Refer Page No. 114
17 6 7 JB 5812 29 Valve complete float (Float pin) 1 1
14
8 JB 5812 30 Float complete 1 1
1 13 9 JB 5812 32 Screw washers bowl M4x14 1 1
7
10 JB 5812 48 Screw TPS & Solenoid choke 1 1
15
8
20 11 JB 5812 55 Solenoid choke assly 1 1
12 JB 5812 47 "O" ring solenoid choke 1 1
5
13 JB 5812 02 Throttle position sensor 1 1
14 JB 5812 04 "O" Ring (TPS) 1 1
15 JB 5812 57 Tube Over Flow 1 1
21
16 JB 5812 58 Tube Air Vent 1 1

9 17 JB 5812 59 Clip 1 2
18 36 PA00 14 Throttle Value Kit 1 1 Refer Page No. 114
19 36 PA00 15 Carb. Gasket ‘O’ ring 1 1 Refer Page No. 114
20 JB 5812 56 Arm Pin Float 1 1
31 32
Air Cleaner Complete
Description KS ES
Drum Drum
1 JB 5810 21 Air Filter Assly 1 1

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

16 13 7 DS 1211 26 Plug 1 1
8 DG 1210 02 Clamp 1 1
5 9 JZ 5810 04 Hose Breather 1 1 N.I.
17 10 39 0071 04 Hex Head Screw 3 3
11 39 1765 11 Washer 3 3
4 12 DH 1210 38 Band Insualtor 1 1
14 13 DS 1610 69 Bracket Side Cover Mtg. 1 1
6 14 JB 5810 20 Connecting Tube 1 1
2 3
15 39 1779 02 Self Tapping Screw 2 2
8
7 16 DX 1210 05 Filter Air Cover 1 1
17 DX 1210 06 ‘O’ Ring 1 1 N.S
JZ 5810 29 ‘O’ Ring 1 1 alt for Dx121006
33 34
Silencer Assembly
Description KS ES
Drum Drum
1 JB 5910 51 Silencer Assly Without Shield 1 1

JB 5910 54 Silencer Assly. (Non Cat) 1 1
2 CB 1011 14 Gasket Exhaust Mounting 1 1
3
2 3 JA 5910 40 Flange Nut 2 2
39 2295 15 Flange Nut 2 2 alt for JA591040
4 JZ 5910 43 Shield Silencer 1 1
5 5 5 JW 5910 28 Truss Screw 2 2
4 6 JW 5910 30 Grommet Shield 1 1

7 39 2754 04 Bolt Hex with Flange M5 1 1
7
8 39 2492 11 Plain Washer 1 1
9 9 JB 1130 04 Bolt M10X 1.25 1 1 N.S
8 10 39 1850 04 Bolt M10X 1.25 1 1 alt for JB113004
6 1 10 JB 1130 05 Washer 2 2
11 DH 1611 57 Tube Silencer Mtg. 1 1
11 12 DH 1611 55 Silencer Damper 1 1
12 13 39 2588 11 Washer 1 1
10 14 DD 1610 71 U Nut M10X1.25 1 1
13
14
35 36
Oil Pump
Description KS ES
Drum Drum
1 JB 5710 00 Oil Pump Assly 1 1

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

2
6 6 36 JW00 14 Starter Clutch Repair Kit -- 1 Refer Page No. 115
7 JA 3516 00 Motor Assly -- 1
8 JA 3516 04 ‘O’ Ring For Tie Bolt (Flash) – 1 N.S
9 JA 3516 06 Sealing Ring (Flash) -- 1
JA 3516 26 Sealing Ring (Lucas-TVS) -- 1
10 DH 1011 63 Flange Bolt (Flash) -- 2
11 JA 3516 02 ‘O’ Ring For Spigot (Flash) -- 1

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

8
10
11 9
39 40
Magneto, CDI & H.T. Coil
Description KS ES
Drum Drum
1 JB 3510 14 Rotor Assly (ES) -- 1

JB 3510 17 Rotor Assly (KS) 1 --
2 JB 3510 22 Stater Assly Complete 1 1
3 39 1674 04 Bolt Flange 2 2
5
6 4 39 0746 01 Pan Head Screw 3 3 For lock Plate &
Pick Up Coil mtg.
9
5 PA 3512 01 H T Coil LH 1 1
11 10B
7 6 PA 3512 02 H T Coil RH 1 1
7 PA 3512 00 C.D.I. Assly 1 1
9
8 DD 1110 18 Spark Plug PRZ9 HC Or 2 2
CF 1110 19 Spark Plug Bosch UR4AC 2 2
11
4 9 DD 1110 48 Spark Plug Cap 2 2
9
12 10A DD 1110 11 Grommet Spark Plug Cap LH 1 1
14
3 10B JD 3512 06 Grommet Spark - Plug Cap RH 1 1
10A 1
4
11 DD 1110 12 Grommet for HT Cable 2 2
12 39 1943 04 Bolt Flange 2 2
8
13 13 JK 4020 00 DC Regulator With Capacitor 1 1
2
14 JA 5410 28 Lock plate 1 1
15 59 0400 14 Bolt Flange (N.I.) 4 4 For HT Coil mtg.
41 42
Seat Assembly / Seat Lock
Description KS ES
Drum Drum
1 JN 1910 00 Seat Assly Comp 1 1

2 36 DS21 01 Seat Damper Kit 1 1 Refer Page No. 114
3 DS 2110 06 Lock Assly seat 1 1
4 39 1902 04 Flanged bolt 2 2
4
2
43 44
Engine Mountings
Description KS ES
Drum Drum
1 JA 1134 03 Flange Bolt M10×10 2 2

2 39 1970 15 Nut Flanged 3 3
3 39 1556 04 Bolt Flanged 4 4
4 LA D000 41 Bolt Flanged 1 1
3 5 JA 1134 04 Bolt Flanged 1 1
8 6
2 6 39 2723 15 Flanged Nut 2 2
6 9
2
7 JZ 1134 00 BKT Comp LH Engine Front 1 1
8 JZ 1134 03 BKT Comp RH Engine Front 1 1
9 JZ 1134 02 Engine Mtg. BKT Rear Top 2 2
5
7
4 5
3
9
1
3
45 46
Frame and Frame Fittings
Description KS ES
Drum Drum
1 JZ 1110 01 Frame Assly. Comp. 1 1 Incl. Swing Arm Bush

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

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

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

Main Step
2 4 2 39 2310 04 Flange Bolt 4 4
3 JZ 1130 03 Main Step RH Assly. Comp. 1 1 With Rubber
6 Damper
4 DF 1614 13 Rubber Main Step 2 2
3 2 5 DH 1611 94 Damper 1 1 For Kick stopper
6 6 39 2726 12 Spring Washer 4 4
6
2 5
4 1
2
51 52
Pillion Foot Rest / Holder
Description KS ES
Drum Drum
5
1 JZ 1130 06 Holder LH Step 1 1
3 2 JZ 1130 07 Holder RH Step 1 1
3 DP 1611 70 Step Pillion Fort rest 2 2
4 JK 1130 08 Rubber Pillion Step 2 2
4 5 30 1710 22 Pin Pillion Step 2 2

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

2 JB 1814 16 Brace Fender 1 1
3 JB 1814 12 Flange Bolt 4 4 Fender Front Mtg. N.S
39 1075 04 Flange Bolt 4 4 alt for JB181412
4 JZ 1814 02 Fender Rear Front 1 1
5 DS1612 87 Flange Bolt 2 2
2 11
16
15 15
6 39 0798 15 Flange Nut 2 2
7 39 0211 11 Plain Washer 2 2
6 14
12 17 8 JZ 1814 01 Fender Rear 1 1
9 39 1943 04 Flange Bolt 2 2
10
5 10 DJ 1610 69 Nail for Cable Guide 1 1
1 7 9
3 11 39 0326 15 Nyloc Nut 3 3

12 JB 1814 03 Flap Front fender 1 1
13 DL 1610 15 Grommet 2 2
4 13
14 JZ 1814 06 Grommet Saree Gaurd 1 1
8 15 39 0242 11 Washer 6 6
16 39 2420 01 Screw 3 3
39 1698 01 Screw 3 3 alt for 39242001
17 DH 1611 58 Grommet 2 2 For Seat Cowl Mtg.
55 56
Stand Assembly
Description KS ES
Drum Drum
1 DS 1611 13 Center Stand 1 1

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

1 9
11
57 58
Tube / Tyre / Rim
Description KS ES
2 No. Part No. Remarks
Drum Drum
3
1 PA 1310 10 Wheel Fron Drum 1.4 x 17 1 1
1
2
3
DS 1510 48 Tyre Front
DS 1510 49 Tube Front
1
1
1
1
} Proprietary Items
Not Serviceable
4 JB 1312 22 Wheel Rim Rear 1 1
5 DS 1510 52 Tyre Rear 1 1
6 DS 1510 53 Tube Rear 1 1

} Proprietary Items
Not Serviceable
7 DS 1510 47 Tyre With Tube Fr 1 1

8 DS 1510 51 Tyre With Tube Rear 1 1
6 5
59 60
Front Hub
Description KS ES
Drum Drum
3 2 1 LC J000 01 U Nut (M10) 1 1 N.S

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

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

5A
5
1 23 30 1510 41 Gear Meter Screw 1 1
24 30 1510 42 Washer Plain 2 2 For Gear Meter Screw
39 0242 11 Washer Plain 2 2 alt for 30151042
25 39 1013 21 ‘O’ Ring 1 1
6 26 JA 1316 06 Bushing Speedo Gear 1 1
7
10
11
15 12 9 8
13
14
22
16 21
17
24 23
24 25
26
1A
20
19
18
63 64
Rear Hub
Description KS ES
Drum Drum
8
11 1 JB 1410 01 Drive Chain Lock 1 1
9
2 6 DX 1510 81 Drive Chain Lock 1 1 (A-16) From 23.03.2011
5 2 36 PA00 08 Chain Sprocket kit 1 1 Refer Page No. 114 N.S

4
36 PA00 42 Chain Sprocket Kit 1 1 From 23.03.2011
7 (Ref. Circular A-16)
3 3 JB 1312 25 Nut 1 1 N.S

10 39 0988 15 Nut 1 1 alt for JB131225
15 4 DX 1510 15 Plain washer 1 1

5 DX 1510 12 Collar Assly. 1 1
6 39 2240 20 Bearing ball 1 1

14
13
7 DX 1510 08 Coupling 1 1
12 27
PA 1312 08 Coupling 1 1 (A-16) From 23.03.2011
25 8 DX 1510 10 ‘D’ Bolt 4 4
9 39 0794 15 Hex. lock nut 4 4
24
10 31 1510 29 Washer 2 2
26
23
11 DX 1510 09 Sleeve 1 1
17
12 39 1364 20 Bearing Ball 1 1
16
13 31 1510 18 Collar Bearing 1 1
20 21 22
14 31 1510 21 Damper 1 1
19 19A 18
16 15 39 2682 20 Bearing Ball 1 1
KP Bb63 Bearing Ball 1 1 alt for 39268220
65 66
Rear Hub
Description KS ES
Drum Drum
8
11
9
2 6 16 30 1510 69 Spring 2 2
17 30 1511 05 Shoe Brake Assly 2 2
5 JN 1318 12 Kit Shoe Brake Non Asbestos 1 1
4
18 JA 1312 05 Panel Rear Brake 1 1
7 19 JB 1312 23 Cam Brake 1 1
19A 39 0723 11 Plain Washer 1 1 N.S
3 20 30 1510 38 Ring ‘O’ 1 1
10 21 DS 1510 91 Indicator 1 1
15 22 PA 1318 06 Lever Brake 1 1 N.S

PA 1318 09 Lever Brake 1 1 alt for PA131806
23 LA D000 26 Bolt 1 1
24 DX 1510 16 Axle 1 1
14
13
25 JA 1312 02 Collar 1 1
12 27
25 26 DX 1510 18 Plain washer 1 1

27 JB 1310 19 ‘U’ nut 1 1 N.S
24
59 1500 03 ‘U’ nut 1 1
26
23
17
16
20 21 22
19 19A 18
16
67 68
Rear Brake Pedal
Description KS ES
Drum Drum
1 JA 1610 03 Pad Lever Brake 1 1

2 JZ 1610 01 Brake Pedal 1 1
1 3 39 1680 04 Hex. Bolt 1 1
2 4 DG 1910 45 Washer 1 1
5 DS 1910 11 Brake Pedal Spring 1 1
8
3 10 6 PA 1318 07 Rod Brake 1 1
5 7 30 1910 38 Pin 1 1
7 11
4 8 39 0198 11 Plain Washer 2 2
20 9 39 0808 08 Split Pin 1 1
10 30 1910 35 Spring 1 1
8
14 12
11 15 1910 26 Pin 1 1
9 12 30 1910 36 Brake Adjuster Nut 1 1
6
13 DJ 1510 42 Rod Torque 1 1
16
16 14 DH 1510 29 Step Bolt 1 1
17 15 39 0789 12 Spring Washer 2 2
19
15 16 39 0694 15 Nut Hex. Lock 2 2
13 17 39 0807 08 Pin Snap 2 2
17 15
18 30 1510 96 Hex. Bolt 1 1
19 39 1540 11 Plain Washer 1 1
18 20 DD 1610 78 Damper Rubber 1 1 N.I.
21 39 1672 04 Bolt M - 6 (Not illustrated) 1 1

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

2 JB 4014 00 Control Switch LH 1 1
31
3 JB 4014 01 Control Switch RH -- 1
15 DS 2010 33 Control Switch RH 1 – Minda Make
18 DU 2010 18 Control Switch RH 1 -- Varroc Make
14 30 16 3 4 DJ 1910 54 Holder Assly. LH -- 1
1 33
DX 1910 08 Holder Assly. LH 1 --
27 26
5 DS 1910 38 Holder Assly. RH 1 1
17
19
20 6 JZ 1510 18 Grip LH 1 1
32 13
2 7 JZ 1510 19 Grip Assly. RH 1 1
7
25 21 22 9 8 DD 1910 69 Lever Grip Left 1 1
23 35 9 DX 1910 09 Lever Brake RH 1 1
8 12
10 JB 4014 09 Clutch Switch With Sealed
24 34
11 Coupler – 1
28
29
10 11 DD 2011 70 Front Brake Switch 1 1
5 11 PA 4014 03 Front Brake Switch 1 1 N.S
28
29 4 12 DS 1910 52 Boot For Lever LH 1 1
6 13 DS 1910 18 Boot For Lever RH 1 1

14 DJ 2210 03 Mirror Assly. LH 1 1
15 DJ 2210 04 Mirror Assly. RH 1 1
16 DS 1810 19 Holder Upper 2 2
71 72
Handle Bar
Description KS ES
Drum Drum
17 DS 1810 06 Holder Lower 2 2

18 39 2582 04 Flanged bolt 4 4
31
19 DS 1810 07 Washer Handle Upper 2 2
15 20 DS 1810 08 Damper Handle Upper 2 2
18
14 30 16 3 21 DS 1810 09 Damper Handle Lower 2 2

1 33
22 DS 1810 10 Washer Handle Lower 2 2
27 26
23 39 0422 15 Nylock Nut 2 2
17
24 36 DF10 01 Kit Cable Adjuster Assly. 1 1
19
20 25 DD 1910 85 Stud Lever Handle (L.H) 1 1
32 13
2
7
25 21 22 9 26 DL 1910 14 Stud Lever Handle (R.H) 1 1
23 35 27 30 1910 48 Band 2 2
8 12
28 30 1910 17 Nut (For Stud R.H) 2 2
24 34
11 29 39 1553 04 Bolt Flange 2 2
28
30 JZ 2326 00 3 in One Lock Set 1 1
29
10
5 31 39 1943 04 Flange Bolt 2 2 For Ignition Switch
28
29 4 32 JZ 1510 11 Holder Fork Upper 1 1
6 33 DU 2010 46 Plunger With Spring 1 1 Part of Ride

Control Switch
34 DX 1910 01 Throttle Pipe 1 1
35 36 DU19 01 Cable Adjuster Kit 1 1
73 74
Front Fork
Description KS ES
Drum Drum
1 PA 1210 00 Fork Front 1 1

2 36 DZ00 20 Front Fork Seal Kit 1 1
1 3 30 1810 26 Gasket 2 2
4 30 1810 25 Bolt 2 2
7
8 5 JA 1510 13 Fork Pipe Inner 2 2
23 9
20 24 6 DJ 1811 04 Spring Front Fork 2 2
7 59 0400 06 Bolt Fork 2 2 Hex Head Bolts
15 10
With Washer
21
2
8 DS 1810 15 Cap Nut Fork 1 1
16
9 DS 1810 16 Plain Washer 1 1 For Cap Nut
22 19
10 JZ 1510 11 Holder Fork upper 1 1

6 11
5 11 30 1810 09 Bearing Cone 1 1
25/26
17/18 12 JZ 1510 13 Under Bracket Fork 1 1
13 39 0789 12 Spring washer 2 2
14 39 1181 01 Bolt 2 2
3
15 JW 1510 29 Nylon spacer 2 2 N.S
12
4
13 16 DS 1810 16 Washer 2 2
14
17 PA 1210 05 Outer Tube LH With Guide Bush 1 1
18 PA 1210 06 Outer Tube RH With Guide Bush 1 1
75 76
Front Fork
Description KS ES
Drum Drum
19 JK 1210 07 Anti Friction Bush 2 2

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

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

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

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

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

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

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

2 39 0761 01 Screw Pan Cross 2 2
5 3 39 2179 24 Washer 2 2
2 3A 30 1410 31 ‘O’ Ring 2 2
1 3 4 DS 1410 18 Fuel Tap Assly 1 1 N.S
JZ 1718 09 Fuel Tap Assly 1 1 From 02 Jul.2013
3A
5 JZ 2326 00 3 In 1 Lock Set with Key 1 1
10
4
6 30 1410 39 Packing 1 1 For Petrol Cock
7 DD 1410 22 Bolt Flanged 2 2 For Petrol Cock N.S
6 DD 1412 27 Bolt Flanged 2 2 alt for DD141022

8 39 0740 11 Washer (Non-Metallic) 2 2 For Petrol Cock
9 DS 2010 79 Fuel Gauge - Tank Unit 1 1 With ‘O’ Ring
9A 39 2758 21 ‘O’ Ring 1 1 For Tank Unit N.S
DK 1410 28 ‘O’ Ring 1 1 alt for 39275821
8 9A
7
10 DS 1410 13 Seat Tape 1 1 Pasted on Tank
13
9
11 39 2484 15 Flanged Nut 4 4
12
11 12 JB 1718 02 Tube Fuel 1 1 Cock to Carb.
13 30 1410 15 Pipe Clip 2 2
DK 1410 41 Pipe Clip 2 2 alt for 30141015
85 86
Fittings - Petrol Tank, Side Covers & Cover Seat
Description KS ES
Drum Drum
1 36 DS14 01 Grommet Kit for Side Cover 1 1 Refer Page No. 114
2 DG 1611 21 Screw 1 1
8 3 39 1943 04 Flanged Bolt 2 2
4 JN 1710 00 Damper Rear 1 1 For Tank
6
5 39 1789 24 Washer Nylon 3 3
6 39 0983 08 Pin Snap 1 1

7
7 39 1054 11 Plain Washer 1 1
8 DJ 1410 08 Damper Front 2 2 For Tank Mtg.
1 2
8 9 31 1610 18 Damper 1 1
3
5
87 88
Meter Assembly
Description KS ES
Drum Drum
1 PA 4024 00 Speedometer Assly. -- 1

PA 4024 06 Speedometer Assly. KS 1 -- Ref. Cir. A-10
2 JZ 4024 03 Speedometer Assly 1 1 From 10.02.2011
2 JZ 1812 00 Flap Cowling 1 1
1 3 PA 4024 01
Speedometer Machine With Dial -- 1
PA 4024 07
Speedometer Machine With Dial 1 --
PA 4024 21
Speedometer Machine With Dial -- 1 Minda
4 PA 4024 02
Fuel Gauge Machine with dial -- 1
PA 4024 08
Fuel Gauge Machine with dial 1 --
14 PA 4024 18
Fuel Gauge Machine with dial -- 1 Minda
15 5 PA 4024 03
Speedo meter Top Cover 1 1
PA 4024 19
Speedo meter Top Cover -- 1 Minda
6 PA 4024 04
Speedometer wiring harness -- 1
4 PA 4024 09
Speedometer wiring harness 1 --
PA 4024 20
Speedometer wiring harness -- 1 Minda
7 CL 2010 42
Bulb 12V - 1.7 W 4 4
a. Neutral Indicator
16 b. Low Battery Indicator
8 c. High Beam Indicator
5
17 3 d. Turn Signal indicator
7 10 8 DH 1910 37 Bulb 12V - 3 W 2 2
9 39 0798 15 Flanged Nut 2 2
10 PA 4024 05 Speedometer Bracket 1 1
11 DS 1810 60 Foam side Flap 1 1 N.I.

8
12 JN 1810 14 Foam Speedo Flap 2 2 N.I.
13 JN 1814 06 Beading Speedo Flap 4 4 N.I.
14 PA 4024 10 Cover Speedo Black 1 1
6 PA 4024 14 Cover Speedo Black -- 1 Minda
15 PA 4024 11 Assly Speedo Case 1 1 PA402415-Minda
9
16 PA 4024 12 Trip Meter Knob 1 1 PA402416-Minda
17 PA 4024 13 Screw Trip Meter Knob 1 1 PA402417-Minda
89 90
Control Cables
Description KS ES
Drum Drum
1 JZ 1612 01 Cable Accelerator 1 1

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

2 15 1610 69 Rubber Cap 1 1
3 JB 1812 39 Bolt 4 4 Front & Rear Side Mtg. N.S
DH 1612 83 Bolt 4 4 alt for JB181239

4 DX 1610 52 Beading Chain Case 1 1 N.I.
1
3
3
2 3
93 94
Head Lamp & Fairing

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

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

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

22 JN 1810 24 Bracket H/L Mtg Lower RH 1 1
23 59 0100 05 Screw Mushroom Head 2 2
24 JN 1810 04 Bracket Cowling 1 1
8
25 39 0219 11 Washer 2 2 For Bracket
6 Cowling Mounting
1
4 5 35
26 39 2060 04 Bolt Hex 2 2 For Bracket
11 Cowling Mounting
10
12 27 JN 2328 02 Bracket Cowling Lower 1 1
13 14 7 27A JZ 1510 08 Blinker mtg. bracket 1 1 Mounted on ‘Bkt.
9
9 Cowling Lower’
30 28 39 1943 04 Bolt Flange 2 2
14 29 39 1961 04 Bolt Hex Flange 1 1
19
30 39 1907 01 Mushroom Head Screw 4 4
16 18
30
15
31 39 2141 24 Washer Non-Metallic 4 4
20 32 39 1508 11 Washer for H/L Adjustment Bolt 2 2 N.S
24
21 9 22 25 31 33 39 0798 15 Hex. Flange Nut 1 1
34 JZ 1810 02 Damper Assly. (N.I.) 1 1 On Fairing N.S
33
17 23 32 JZ 1810 06 Damper Assly. (N.I.) 1 1 alt for JZ181002
19 27 35 JZ 1810 04 Foam Strip Head Lamp 6 6
28
26
29
32
27A
97 98
Head Lamp & Fairing

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

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

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

7
7 8 Bkt.
11
1/2
10
101 102
Tail Lamp Assly / Front Number Plate
Description KS ES
Drum Drum
1 JZ 4010 06 LED Tail Lamp -- 1

18 17
DS 2010 08 Tail Lamp 1 --
2 DD 2010 11 Damper 2 2 For Front No. Plate
3 31 2010 01 Collar 2 2 For Front No. Plate
4 39 2124 15 Flange Nut 1 1
5 DJ 1610 72 Bracket Rear No. Plate -- 1 For Front No.
Plate mtg.
JZ 2328 01 Bracket Rear No. Plate 1 --
6 39 1553 04 Bolt Flange 2 2 For Front No. Plate

7 DP 1611 45 Number Plate Rear 1 1
8 39 2476 04 Hex Flanged Bolt 2 2 For Front No. Plate
20 1 9 DP 1611 44 Number Plate Front 1 1
10 JZ 2328 00 Front No. Plate Mounting Bkt. 1 1
4 4 13 11 39 1783 01 Truss Screw Front No. Plate 2 2

12 12 JW 4010 11 No. Plate Lamp With 2 pt.
14 Coupler -- 1
15
PA 4010 01 Reflex Reflector 1 --
13 DJ 2010 72 Bulb 12V/ 5W 1 1 Rr. No. Plate Lamp
5
14 39 0705 01 Screw 2 2 For Rr. No. Plate
11
Lamp
10 15 39 0711 11 Plain washer 2 2
9 - Do -
7
2
16 39 1211 11 Washer 2 2
17 39 0740 11 Washer (Non Metalic) -- 4 For LED Tail Lamp
3 8
16 18 39 0746 01 Screw For LED Tail Lamp – 4
6 39 0817 15 Hex Nut 4 – Tail Lamp
19 DJ 1610 07 Damper Rear No. Plate 1 1
20 JZ 1810 04 Foam Strip 1 1
103 104
Electrical Equipments
Description KS ES
Drum Drum
1 JW 4016 00 Horn LH with Stay 1 1

2 39 1507 11 Plain Washer 1 1
3 39 1956 04 Flange Bolt 1 1 N.S
31 2010 79 Flange Bolt 1 1 alt for 39195604
4 PA 4022 11 Wiring Harness (ES) -- 1
1 17 PA 4022 13 Wiring Harness (KS) 1 --

14
5 DS 2010 29 Rear Brake Switch 1 1
6 DS 1910 07 Spring Brake Switch 1 1
2 8 7 JZ 4010 13 Head Lamp Control Unit 1 1
18
3 8 31 2010 27 Battery 2.5 AH 1 1 N.S.

DS 2010 82 Battrery MF Dry 5AH 1 1
7 5
6 9 DX 1610 32 Base Battery (ES) -- 1
12
9 DS 1611 18 Base Battery (KS) 1 – N.S
11 10 DX 1610 44 Band Battery (ES) -- 1
15
DX 1610 31 Band Battery (KS) 1 – N.S
4 13
16 11 DS 1611 04 Battery Arrester 1 1 N.S
12 DS 2010 25 Assly DC Flasher 1 1
10
13 39 2208 04 Bolt Flange 2 2
9
14 JN 3516 04 Starter Relay – 1 With Grommet
13
15 30 2011 04 Fuse Box Assly. 2 2 For Light Main Fuse
20 16 30 2010 85 Fuse 2 2 Light & Main Fuse
21 17 DS 2010 22 Cable Assly. 1 1 (Battery to St. Relay)
18 PA 4022 03 St. Relay to Motor Relay -- 1
105 106
Electrical Equipments
Description KS ES
Drum Drum
19 PA 4022 02 Cable Assly. (Battery to Earth) 1 1 N.I.

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

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

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

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

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

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

Kit Description Kit Description
No Part No. Part No. Description Qty/Kit No Part No. Part No. Description Qty/Kit
1 36PA0004 Valve Kit JB511200 Valve Intake 1 8 36PA0013 Idling Screw Kit JB581241 Screw Stop 1
JB511201 Valve Exhaust 1 JB581240 ‘O’ - Ring 1
JB581242 Spring Compr
2 36JA0003 Valve Repair Kit 39201719 Seat Valve Stem 2
DG101029 Cotter Valve 2 9 36DS2101 Seat Damper Kit DS211004 Damper Seat - I 7
JA511203 Retainer Valve Spring 2 DS211005 Damper Seat - II 2
28101129 Seat Valve Spring 2
JA511202 Spring Washer 2 10 36DS1802 Bearing Cone Kit DH181025 Bearing cone 1
DH181026 Bearing race 1
3 36PA0002 Kit Guide Camchain JB511004 Guide Camchain (Slack Side) 1 DH181024 Upper bearing race 1
JB521007 Guide Camchain (Tight Side) 1 DS211004 Seat Damper 1
11 36DS1801 Holder Handle Set DS181019 Holder Handle 2

4 36PA0003 Piston Ring Set JB411207 Ring Piston Top 1
DS181006 Holder Handle 2
JB521208 Ring Piston Second 1
JB521209 Ring Piston Oil 1 12 36DS1401 Grommet Kit - Side Cover DS141012 Grommet Side Cover Front 2
DS161082 Grommet Side Cover Rear 2
5 36DU1007 Boss Kick Set 30101233 Boss Kit 1
30101234 Spring 1 14 52PA0054 Case Chain Kit PA181206 Case Chain Upper Assly. 1
30101236 Ball Steel 1 PA181207 Case Chain Lower Assly. 1
30101235 Pin 1 15161069 Cap Rubber 1
39085517 E - Type Clip 1
15 36PA0014 Throttle Valve Kit JB581265 Valve Throttle 1
JB581235 Bar Clip 1
6 36PA0011 Jet Kit JB581225 Jet Needle 1 JZ581206 Collar Magnet Holder 1
Jb581268 Needle Jet 1 JB581249 Spring Compr 1
JB581261 Holder Needle Jet 1
JB581262 Jet Main # 80 1 16 36PA0015 Carb. Gasket- 'O' Ring Kit JB581231 Gasket Float Chamber 1
JB581239 Top Gasket 1
JB581263 Jet Main # 80 1
JB581240 ‘O’ - Ring 3
JB581269 ‘O’ - Ring 24x26 (eng Side) 1
7 36PA0012 Air Screw Kit JB581266 Screw Adjuster 1
JB581240 ‘O’ - Ring 1
17 36PA0008 Chain Sprocket Kit JA131206 Sprocket Hub (42T) 1
JB581244 Spring Compr Coil 1
JB581245 Plain Washer 1 Jb551000 Sprocket Drive (14T) 1
JB581246 ‘O’ - Ring 1 PA141000 Chain 118 Link - 420 Series 1
113 114
Kit List Amendment Sheet
Sr Kit Consisting of Following Parts AMENDMENT SHEET (PARTS ADDED)

Kit Description
No Part No. Part No. Description Qty/Kit SR.
PART NUMBER DESCRIPTION QTY.
PAGE FIGURE
NO. NO. NO.
18 36PA0006 Set Primary Drive & Driven JB551401 Housing Compl Clutch 1
JA531010 Gear Primary Drive 1
19 36JW0014 Starter Clutch Repair Kit JA621411 Bush Spring Starter Clutch 5
DH101163 Roller Clutch 5
JA621412 Spring 5
DJ101109 Bush For Spring Starter Clutch 5
20 36DF1901 Kit Cable Adjuster Assly. 39191017 Nut 2

39191024 Screw 2
21 36DU1901 Cable Adjuster Kit. 39191017 Nut 2

DD191147 Screw 2
115 116
SPC Updation Details SPC Updation Details
Page Fig. Old part New part Description
Updation Remarks Page Fig. Old part New part Description
Updation Remarks
no. no. no. no. date no. no. no. no. date
106 4 PA402200 PA402211 Wiring Harness 13.02.12 Rationalization of Wiring Harness
106 4 PA402201 PA402213 Wiring Harness 13.02.12 ----------"do"--------------
108 22 -------- 60111415 Guide Tie Lock 13.02.12 ----------"do"--------------
108 23 -------- 60111417 Clip Positive Lock 13.02.12 ----------"do"--------------
14,16 Gear Transmission commonisation 16.03.12 Ref. Page No. 14 & 16 (Circular IB-15)
117 118
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
14151021 10 62 31151018 13 66 39074601 18 104 39128321 9 4

15161069 2 94 31151021 14 66 39074701 9 22 39128321 13 4
15191026 11 70 31151029 10 66 39075301 3 38 39135815 13 50
22150241 4 30 31161018 9 88 39076101 2 86 39136420 12 66
28101214 9 28 31181099 21 78 39078408 7 54 39150711 2 106
30101096 6 28 31181102 24 78 39078912 15 70 39150811 32 98
30101142 4 24 31201001 7 102 39078912 13 76 39150811 37 100
30101195 11 26 31201001 3 104 39079415 9 66 39151011 2 62
30141015 13 86 31201027 8 106 39079708 3 58 39154011 19 70
30141031 3A 86 31201081 5 22 39079815 6 56 39155304 29 74
30141039 6 86 35161060 6 96 39079815 9 90 39155304 6 104
30151038 13 62 39007104 10 34 39079815 33 98 39155604 3 46
30151038 20 68 39019811 8 70 39079815 9 102 39155604 3 112
30151041 23 64 39021111 7 56 39080708 17 70 39167121 20 24
30151042 24 64 39021911 25 98 39080808 9 70 39167204 21 70
30151069 9 62 39024211 15 56 39081715 8 18 39167404 3 42
30151069 16 66 39025811 4 50 39081715 18 104 39168004 3 70
30151096 18 70 39029215 16 50 39084001 18 62 39168104 10 112
30151105 8 62 39029215 22 70 39098004 11 28 39171519 4 22
30151105 17 68 39032615 11 56 39098308 6 88 39175904 17 22
30151118 20 62 39042215 9 58 39098717 3 14 39176511 11 34
30171022 5 54 39042215 23 74 39099206 2 16 39177802 10 96
30181006 5 48 39045411 11 50 39099206 4 38 39177902 15 34
30181009 11 76 39045411 9 96 39099311 5 30 39178301 11 104
30181025 4 76 39055302 10 50 39099906 12 22 39178924 5 88
30181026 3 76 39059417 12 8 39099906 25 24 39186420 5 12
30191017 28 74 39069415 16 70 39100006 2 10 39190204 4 44
30191035 10 70 39070501 14 104 39100006 6 20 39190701 30 98
30191036 12 70 39071111 15 104 39100006 11 22 39194304 12 42
30191038 7 70 39072311 19A 68 39100120 23 24 39194304 9 56
30191048 27 74 39073212 19 62 39100120 15 28 39194304 3 88
30191048 20 108 39073817 6 30 39101321 25 64 39194304 20 96
30201064 21 108 39074011 8 86 39104119 3 24 39194304 28 98
30201085 16 106 39074011 17 104 39105411 7 88 39194304 11 102
30201104 15 106 39074601 8 20 39118101 14 76 39194304 14 112
31101173 3 12 39074601 4 42 39121111 16 104 39194304 31 74
119 120
39195004 8 102 39268120 7 62 36JB0022 4 32 52PA0027 3 80

39195604 3 106 39268220 15 66 36JB0023 1 24 52PA0051 2 80
39196104 29 98 39270411 7 18 36JW0014 6 40 52PA0052 3 80
39196404 14 20 39272204 8 54 36JZ0015 1 26 52PA0054 1 94
39197015 2 46 39272315 6 46 36PA0002 6 8 52PA0137 2 80
39197015 6 102 39272612 8 50 36PA0003 3 10 52PA0138 3 80
39197015 4 112 39272612 6 52 36PA0004 5 6 52PA0140 6 82
39198104 21 14 39273104 7 112 36PA0006 7 12 52PA0142 2 80
39201719 7 6 39275404 7 36 36PA0006 16 28 52PA0143 3 80
39206004 18 50 39275821 9A 86 36PA0008 2 66 52PA0145 6 82
39206004 26 98 59010005 23 98 36PA0011 5 32 CB101114 2 36
39212415 4 104 59040006 7 76 36PA0012 4 32 CF111019 8 42
39214124 3 96 59040014 15 42 36PA0013 6 32 CL201023 12 96
39214124 31 98 59040038 2 2 36PA0014 18 32 CL201042 7 90
39217924 3 86 59040038 11 20 36PA0015 19 32 CS101128 9 8
39219019 7 22 59040038 16 22 36PA0043 2 66 DD101097 13 30
39220804 15 24 59040038 17 24 52JA0028 14 28 DD101480 7 28
39220804 7 26 59040038 4 26 52JA0029 12 20 DD111011 10A 42
39220804 13 106 59110008 2B 12 52JB0229 1 22 DD111012 11 42
39223801 7 96 59120003 2A 12 52JB0230 2 20 DD111018 8 42
39224020 6 66 59150014 1 12 52JB0231 5 10 DD111048 9 42
39231004 2 52 59200036 3 20 52JB0232 1 4 DD121181 19 24
39240817 12 30 59200036 3 22 52JB0233 1 22 DD141022 7 86
39242001 16 56 59210023 14 22 52JB0234 1 24 DD161071 14 36
39247604 8 104 59210024 18 14 52PA0015 6 82 DD161078 20 70
39248415 11 86 60111415 22 108 52PA0016 6 82 DD191069 8 72
39249211 8 36 60111417 23 108 52PA0017 6 82 DD191085 25 74
39249504 8 112 36DF1001 24 74 52PA0018 6 82 DD201011 2 104
39256220 2 22 36DS1401 1 88 52PA0019 6 82 DD201170 11 72
39258204 18 74 36DS1802 4 48 52PA0020 2 80 DF161102 8 58
39258811 13 36 36DS2101 2 44 52PA0021 3 80 DF161413 4 52
39260011 3 28 36DU1007 3 30 52PA0022 2 80 DG101029 4 6
39260801 11 4 36DU1901 35 74 52PA0023 3 80 DG101339 11 18
39262921 12 4 36DZ0020 2 76 52PA0024 2 80 DG101418 7 24
39266921 13 8 36JA0003 6 6 52PA0025 3 80 DG121002 8 34
39268020 5 62 36JB0021 5 32 52PA0026 2 80 DG161121 2 88
121 122
DG191045 4 70 DJ201207 4 102 DS161069 13 34 DS201025 12 106

DH101048 5 8 DJ221003 14 72 DS161077 6 58 DS201029 5 106
DH101125 20 22 DJ221004 15 72 DS161104 11 106 DS201033 3 72
DH101125 14 30 DK101135 7 16 DS161112 2 58 DS201036 13 96
DH101163 10 40 DL151014 22 64 DS161113 1 58 DS201079 9 86
DH101387 4 8 DL161015 13 56 DS161118 9 106 DS201082 8 106
DH101392 7 8 DL191014 26 74 DS161125 1 56 DS211006 3 44
DH101509 10 18 DP101269 6 24 DS161188 9 112 DU101085 7 20
DH101781 2 40 DP161144 9 104 DS161287 5 56 DU101213 20 14
DH101784 6 22 DP161145 7 104 DS171007 9 50 DU201018 3 72
DH121038 12 34 DP161163 6 54 DS171013 12 50 DU201046 33 74
DH151029 14 70 DP161170 3 54 DS171014 17 50 DX121005 16 34
DH161121 4 58 DP161260 8 48 DS171015 6 50 DX121006 17 34
DH161145 5 58 DP171006 7 48 DS181006 17 74 DX121007 3 34
DH161146 11 58 DP221011 2 110 DS181007 19 74 DX121010 4 34
DH161155 12 36 DS101117 8 30 DS181008 20 74 DX121011 5 34
DH161157 11 36 DS101154 6 12 DS181009 21 74 DX151008 7 66
DH161158 17 56 DS101215 8 24 DS181010 22 74 DX151009 11 66
DH161194 5 52 DS101276 3 8 DS181012 23 78 DX151010 8 66
DH161240 7 58 DS121116 2 34 DS181015 8 76 DX151012 5 66
DH181014 3 48 DS121117 6 34 DS181016 9 76 DX151014 15 50
DH191037 8 90 DS121126 7 34 DS181016 16 76 DX151015 4 66
DJ141008 8 88 DS141009 1 86 DS181018 2 48 DX151016 24 68
DJ151036 14 50 DS141013 10 86 DS181019 16 72 DX151018 26 68
DJ151042 13 70 DS141018 4 86 DS181060 11 90 DX151081 1 66
DJ151047 19 50 DS151048 2 60 DS191006 3 92 DX161031 10 106
DJ161007 19 104 DS151049 3 60 DS191007 6 106 DX161032 9 106
DJ161069 10 56 DS151052 5 60 DS191008 4 92 DX161044 10 106
DJ161072 5 104 DS151053 6 60 DS191011 5 70 DX161052 4 94
DJ161079 11 112 DS151089 11 62 DS191018 13 72 DX191001 34 74
DJ161080 12 112 DS151091 14 62 DS191038 5 72 DX191008 4 72
DJ181104 6 76 DS151091 21 68 DS191052 12 72 DX191009 9 72
DJ191054 4 72 DS151092 16 62 DS191054 5 92 GH201012 5 102
DJ201072 14 96 DS151094 17 62 DS201005 8 96 JA113403 1 46
DJ201072 13 104 DS151095 15 62 DS201008 1 104 JA113404 5 46
DJ201206 3 102 DS161066 2 112 DS201022 17 106 JA113404 5 112
123 124
JA131202 25 68 JA541019 13 22 JA621002 9 30 JB511019 3 4

JA131205 18 68 JA541020 18 22 JA621006 11 30 JB511206 1 8
JA131606 26 64 JA541021 15 22 JA621201 1 30 JB521211 4 10
JA151013 5 76 JA541027 19 22 JA621206 2 30 JB531018 4 12
JA161003 1 70 JA541028 14 42 JA621402 4 40 JB531021 10 12
JA351600 7 40 JA541034 10 22 JA621406 5 40 JB541201 24 24
JA351602 11 40 JA541044 2 26 JA621410 3 40 JB551000 19 14
JA351604 8 40 JA541205 3 26 JA621414 1 40 JB551400 1 28
JA351606 9 40 JA541211 11 24 JB113004 9 36 JB551404 4 28
JA351608 12 40 JA541212 16 24 JB113005 10 36 JB551406 10 28
JA351609 13 40 JA541215 13 24 JB122009 7 50 JB551408 5 28
JA351618 14 40 JA541216 14 24 JB122010 2B 50 JB551411 8 28
JA351619 16 40 JA541219 21 24 JB122011 2A 50 JB561000 6 16
JA351624 15 40 JA541220 6 26 JB122016 1 50 JB561001 5 16
JA351626 9 40 JA541221 8 26 JB131019 27 68 JB571000 1 38
JA351627 11 40 JA541225 12 24 JB131222 4 60 JB581020 14 34
JA511028 2 4 JA541233 10 26 JB131223 19 68 JB581021 1 34
JA511029 7 2 JA541235 10 20 JB131225 3 66 JB581202 13 32
JA511204 3 6 JA541236 9 24 JB141001 1 66 JB581204 14 32
JA511210 1 6 JA541237 10 24 JB171802 12 86 JB581229 7 32
JA511211 2 6 JA541241 1 26 JB181239 3 94 JB581230 8 32
JA511216 2 8 JA551002 4 14 JB181403 12 56 JB581232 9 32
JA521017 8 8 JA551004 7 14 JB181412 3 56 JB581237 2 32
JA521018 10 8 JA551007 13 14 JB181416 2 56 JB581238 3 32
JA521019 11 8 JA551008 16 14 JB351014 1 42 JB581247 12 32
JA521019 22 24 JA551009 17 14 JB351017 1 42 JB581248 10 32
JA531011 14 8 JA551206 14 14 JB351022 2 42 JB581255 11 32
JA531012 8 12 JA551406 2 28 JB401400 2 72 JB581256 20 32
JA531015 9 12 JA551416 12 28 JB401401 3 72 JB581257 15 32
JA541005 8 22 JA551420 13 28 JB401409 10 72 JB581258 16 32
JA541005 9 26 JA561209 6 18 JB402202 7 10 JB581259 17 32
JA541010 5 20 JA561211 12 18 JB501002 1 20 JB581271 15 4
JA541011 4 20 JA561400 9 18 JB501003 1 20 JB581272 16 4
JA541012 13 20 JA581217 8 4 JB511011 4 2 JB581278 1 32
JA541015 9 20 JA581406 5 4 JB511015 8 2 JB581404 14 4
JA541016 2 38 JA591040 3 36 JB511018 10 4 JB591051 1 36
125 126
JB591054 1 36 JN131812 17 68 JW561208 3 18 JZ231204 15 112

JB621003 10 30 JN171000 4 88 JW591028 5 36 JZ232600 30 74
JD351206 10B 42 JN181001 1 96 JW591030 6 36 JZ232600 5 86
JD511010 3 2 JN181003 16 96 JZ111001 1 48 JZ232800 10 104
JD521002 1 10 JN181004 24 98 JZ113001 1 52 JZ232801 5 104
JD531004 11 12 JN181005 11 96 JZ113003 3 52 JZ401000 1 102
JD551000 1 14 JN181010 5 96 JZ113006 1 54 JZ401001 2 102
JD551002 8 14 JN181011 5 96 JZ113007 2 54 JZ401006 1 104
JD551200 12 14 JN181014 12 90 JZ113400 7 46 JZ401012 8 96
JD551201 6 14 JN181014 36 100 JZ113402 9 46 JZ401013 7 106
JD551202 9A 14 JN181014 39 100 JZ113403 8 46 JZ401015 15 96
JD551203 10 14 JN181017 17 96 JZ113802 13 112 JZ402403 1 90
JD551204 11 14 JN181018 18 96 JZ151008 27A 98 JZ511020 5 2
JD551205 5A 14 JN181019 40 100 JZ151008 10 102 JZ511021 1 2
JD551206 5 14 JN181021 19 96 JZ151011 32 74 JZ541202 5 26
JD551207 2 14 JN181023 21 98 JZ151011 10 76 JZ541203 5 26
JD551208 9 14 JN181024 22 98 JZ151013 12 76 JZ541214 21 24
JD551209 15 14 JN181406 13 90 JZ151016 1 72 JZ551008 8 14
JD551400 1A 28 JN181406 38 100 JZ151018 6 72 JZ551010 1 14
JD561002 8 16 JN191000 1 44 JZ151019 7 72 JZ551200 6 14
JD561006 4 16 JN232802 27 98 JZ161001 2 70 JZ551201 5 14
JD561011 3 16 JN351604 14 106 JZ161200 2 92 JZ551202 2 14
JD561203 4 18 JP541205 1 26 JZ161201 1 92 JZ551204 14 14
JD561204 5 18 JP541208 3 26 JZ181002 34 98 JZ551205 13 14
JD621001 7 30 JV551002 8 14 JZ181003 4 96 JZ551206 9A 14
JE541209 13 24 JW151023 20 78 JZ181004 35 98 JZ551208 12 14
JE541210 6 26 JW151029 15 76 JZ181004 35 100 JZ551210 9 14
JE541211 2 24 JW233000 12 26 JZ181004 20 104 JZ551211 10 14
JE541212 13 26 JW351400 6 10 JZ181005 35 100 JZ551212 11 14
JK113008 4 54 JW401011 12 104 JZ181200 2 90 JZ551213 5A 14
JK121007 19 78 JW401600 1 106 JZ181206 2 96 JZ561000 1 16
JK121009 22 78 JW541000 18 24 JZ181401 8 56 JZ561002 6 16
JK402000 13 42 JW541005 5 24 JZ181402 4 56 JZ581004 6 2
JN113200 10 58 JW561000 1 16 JZ181406 14 56 JZ581004 9 34
JN122000 3 50 JW561205 1 18 JZ231201 1 112 JZ581204 6 4
JN131812 8 62 JW561206 2 18 JZ231202 6 112 JZ581205 7 4
127 128
JZ581401 4 4 PA233084 8 84 PA71015E 1 80

JZ591043 4 36 PA233085 7 84 PA72013B 5 82
LAD00026 23 68 PA351200 7 42 PA72013C 5 82
LAD00041 4 46 PA351201 5 42 PA72013E 5 82
LBD00001 21 62 PA351202 6 42 PA72013F 5 82
LCJ00001 1 62 PA401000 6 48 PA75013B 4 82
PA113800 13 112 PA401001 12 104 PA75013C 4 82
PA121000 1 76 PA402202 19 108 PA75013E 4 82
PA121001 25 78 PA402203 18 106 PA75013F 4 82
PA121003 26 78 PA402211 4 106 PA75014N 4 82
PA121005 17 76 PA402213 4 106 PA75015D 4 82
PA121006 18 76 PA402400 1 90 PA75015E 4 82
PA122001 5 50 PA402401 3 90
PA131002 1A 62 PA402402 4 90
PA131003 5A 62 PA402403 5 90
PA131010 1 60 PA402404 6 90
PA131208 7 66 PA402405 10 90
PA131600 6 62 PA402406 1 90
PA131602 3 62 PA402407 3 90
PA131602 4 62 PA402408 4 90
PA131801 12 62 PA402409 6 90
PA131806 22 68 PA402410 14 90
PA131807 6 70 PA402411 15 90
PA231000 1 110 PA402412 16 90
PA233000 7 84 PA402413 17 90
PA233003 8 84 PA402414 14 90
PA233010 7 84 PA402418 4 90
PA233013 8 84 PA402419 5 90
PA233020 7 84 PA402420 6 90
PA233023 8 84 PA402421 3 90
PA233030 7 84 PA71013B 1 80
PA233033 8 84 PA71013C 1 80
PA233040 7 84 PA71013E 1 80
PA233045 8 84 PA71013F 1 80
PA233072 8 84 PA71014N 1 80
PA233073 7 84 PA71015D 1 80
129 130

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Bajaj Auto Limited

Akurdi Pune 411 035 India

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

1 Cover Cylinder Head 2 31 Front Hub 62, 64

Cover Cylinder Head

6 JZ 5810 04 Hose C’ case Breather 1 1

1 52 JB02 32 Head Cylinder Comp. 1 1 With Studs

Single Piece Manifold

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

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

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

1 JB 5112 06 Camshaft Complete 1 1

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

11 JA 5210 19 Flange Bolt 2 2 N.S

Cylinder and Piston

1 JD 5210 02 Gasket Cylinder 1 1

6 JW 3514 00 Thermal Sensor 1 1

1 59 1500 14 Flange Nut 1 2

1 JD 5510 00 Shaft Input Transmission 1 1

Note : * The Gear Transmission components are changed in view of commonisation

Change Drum / Shift Fork

1 JW 5610 00 Drum Complete Gear Shift 1 1

1 6 JB 5610 00 Fork Gear Shift Input 1 1

Note : * The Gear Transmission components are changed in view of commonisation

Gear Change Mechanism

1 JW 5612 05 Lever Complete Gear Shift 1 1 N.S

1 2 JW 5612 06 Extension Spring 1 1

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

Engine Assembly / Crankcase RH

1 JB 5010 02 Engine Assly. -- 1 N.I.

6 39 1000 06 Dowel Pin 2 2

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

3 7 39 2190 19 Oil Seal 1 1 Shifter Shaft

21 22 1 52 JB02 34 Clutch Cover 1 1

16 JA 5412 12 Gasket Clutch Cover 1 1

21 JA 5412 19 Cap Filter 1 1 Old

11 30 1011 95 ‘O’ Ring 1 1

6 30 1010 96 Plate Clutch 4 4

Kick Starter Mechanism

1 JA 6212 01 Lever Assly Kick 1 1

11 JA 6210 06 Washer Thrust 1 1

2 1 JB 5812 78 Carburettor assly. 1 1

16 JB 5812 58 Tube Air Vent 1 1

Air Cleaner Complete

1 JB 5810 21 Air Filter Assly 1 1

15 6 DS 1211 17 Tube Drain 1 1

1 JB 5910 51 Silencer Assly Without Shield 1 1

4 6 JW 5910 30 Grommet Shield 1 1

1 JB 5710 00 Oil Pump Assly 1 1

1 5 JA 6214 06 Drive Assly -- 1

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

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

Magneto, CDI & H.T. Coil

1 JB 3510 14 Rotor Assly (ES) -- 1

Seat Assembly / Seat Lock

1 JN 1910 00 Seat Assly Comp 1 1

1 JA 1134 03 Flange Bolt M10×10 2 2

Frame and Frame Fittings