Spare Parts Catalogue: Bajaj Auto Limited Akurdi Pune 411 035 India
Spare Parts Catalogue: Bajaj Auto Limited Akurdi Pune 411 035 India
Spare Parts Catalogue: Bajaj Auto Limited Akurdi Pune 411 035 India
COUNTRIES
All Information Contained In This Manual Is Based On The Latest We Have Pleasure In Presenting The Spare Parts Catalogue For ‘Dominar
Product Information At The Time Of Publication. Bajaj Auto Limited 400 UG’ Motorcycle. This Catalogue Has Been Specially Designed To Assist
You In Selecting The Correct Parts For Procurement To Maintain 100%
Accepts No Liability For Any Inaccuracies Or Omissions In This
Availability.
Publication, Although Every Possible Care Has Been Taken To Make
It As Complete And Accurate As Possible. All Procedures And The Bajaj Spares Are Subjected To The Stringent Quality Control Standards
To Ensure Longer Life Of The Vehicle. It Is Therefore Necessary That Only
Specifications Subject To Change Without Prior Notice. The Right Is
The Genuine Bajaj Spares Are Used.
Reserved To Make Such Changes At Any Time Without Prior Notice
And Without Incurring An Obligation To Make Such Changes To In A Continual Effort To Improve Performance And Efficiency Of The Vehicles,
Product Manufactured Previously. Contact Your Authorized Bajaj Specifications, Diagrams, Illustrations And Part Numbers Can Change Without
Notice. Consequently, The Description In This Spare Parts Catalogue Cannot
Dealer For The Latest Information On Product Improvements
Therefore Be Final And Binding On Us.
Incorporated After This Manual Was Issued.
The Modifications / Alterations Which Are Carried Out After The Issue Of This
Catalogue, Will Be Conveyed To You Through Our Service Circulars. You Are
Requested To Make Necessary Corrections In The Parts Catalogue As Per
The Circulars So As To Keep Your Catalogue Up-to-date. This Will Ensure
The Appropriate And Speedy Delivery Of The Spare Parts As The Order
Placed Will Bear The Latest Part Numbers.
Revision 00 In Case, If You Need Any Technical Assistance Contact The Concerned
Regional Office Or Write To Us On The Following Address :
COUNTRIES
Instructions Index
1. How To Read The Catalogue : Open The Catalogue And From The Pictorial Plate No. Description Page No.
Index Locate The Group In Which The Part You Want To Find Is Present.
Turn Over To The Concerned Page Number (as Given By Pictorial Index).
Now Find Out The Figure Of The Part You Wish To Order. Write Down The
1 Cover Cylinder Head 2
Part Number Against That Particular Figure Number From The Text. 2 Cylinder Head 4
In Case, If You Have The Part Number And You Need The Other Details, 3 Valve 6,8
The Part Index Can Be Used. The Part Index (at The End Of The 4 Camshaft / Tensioner 10
Catalogue) Will Give You The Figure And Page Number Of The Part You 5 Cylinder and Piston 12
Wish To Order.
6 Crankshaft 14
2. How To Order Spare Parts : The Part Number And The Description Of The 7 Transmission 16
Part Required Should Be Invariably Mentioned In The Order As Per The 8 Change Drum / Shift Fork 18
Catalogue Text.
9 Gear Change Mechanism 20
The Latest Part Number As Conveyed Through Our Service Circulars Should 10 Engine Assembly / Crankcase RH 22
Only Appear On The Order. In Case Of Ordering Painted Components,
Colour Shade Of The Components Should Be Mentioned. 11 Crankcase LH 24
12 Balancer Idler Gear / Water Pump 26
The Quantity Shown Against The Part Number Is The Quantity Per Vehicle
For That Group So That Particular Quantity Should Be Multiplied By The 13 Oil Pump 28
Number Of Sets Required. 14 Radiator 30
3. Part Number System : We Have Used 8 Digit System For Part Numbers. 15 Cover Clutch 32
The Model Or Hardware Item Is Indicated By First Two Digits Or 16 Cover Magneto 34
Alphanumeric, The Next Two Or Four Digits Indicate Main Group And The 17 Clutch Assembly 36
Last Four Or Two Digits Indicate Serial Number In Main Group Or Serial
18 Throttle Body 38
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 19 Air Cleaner Complete 40
Enable You To Identify The Spare Parts Easily. 20 Silencer Assembly 42
4. Abbreviations : The Following Abbreviations Are Used In This Catalogue. 21 Starter Assembly 44
Assly Assembly V Volts 22 Magneto, C.D.I. & H.T. Coil 46
N.I. Not Illustrated W Watts 23 Seat Assembly / Seat Lock 48
C'Case Crankcase Accl. Accelerator 24 Engine Mountings 50
Cyl Cylinder Comp. Complete 25 Frame and Frame Fitting 52
O/S Over Size FR. Front 26 Swing Arm / Rear Shock Absorber 54
RR. Rear Std. Standard 27 Pillion Foot Rest / Holder 56
L Length A/t. Alternate
28 Mudguard- Front & Rear 58
R.H. Right Hand L.H. Left Hand
29 Stand Assembly 60
Hex. Hexagonal AR As Required
30 Tube / Tyre / Rim 62
COUNTRIES
Index Index
Plate No. Description Page No. Plate No. Description Page No.
31 Front Hub 64
32 Front Master Cylinder 66
33 Front Disc Brake 68
34 Rear Hub 70
35 Anti Brake Lock System 72
36 Rear Disc Brake System 74
37 Rear Brake Pedal 76
38 Handle Bar Assembly 78
39 Front Fork 80
40 Radiator Covers & Belly Pan Assembly 82
41 Petrol Tank, Cap Tank & Gauge Fuel 84
42 Mechanism EVAP 86
43 Fittings - Petrol Tank Cover & Side Cover 88
44 Fittings - Side Covers & Cover Seat 90
45 Meter Assembly 92
46 Control Cables 94
47 Chain Case 96
48 Head Lamp & Fairing 98
49 Indicator Light Assembly 100
50 Tail Lamp Assembly. / Front Number Plate 102
51 Electrical Equipments 104,106
52 Tool Kit 108
53 Accessories / Grab Handle 110
54 Painted Parts and Decals 112,114
COUNTRIES
Pictorial Index Pictorial Index
COUNTRIES
Pictorial Index Pictorial Index
PLATE NO. 9 ENGINE ASSEMBLY, PLATE NO. 10 PLATE NO. 13 PLATE NO. 14
GEAR CHANGE MECHANISM OIL PUMP RADIATOR
PAGE NO. 20 CRANCKASE RH PAGE NO. 22 PAGE NO. 28 PAGE NO. 30
PLATE NO. 11 BALANCER IDLER GEAR, PLATE NO. 12 PLATE NO. 15 PLATE NO. 16
CRANCKASE LH COVER CLUTCH COVER MAGNETO
PAGE NO. 24 WATER PUMP PAGE NO. 26 PAGE NO. 32 PAGE NO. 34
COUNTRIES
Pictorial Index Pictorial Index
COUNTRIES
Pictorial Index Pictorial Index
PLATE NO. 25 SWING ARM / REAR SHOCK PLATE NO. 26 PLATE NO. 29 PLATE NO. 30
FRAME & FRAME FITTINGS STAND ASSEMBLY TUBE / TYRE / RIM
PAGE NO. 52 ABSORBER PAGE NO. 54 PAGE NO. 60 PAGE NO. 62
LH
E
: US 4
ING T3-
RN DO FROM
WA LY ID ER
ON FLU AIN
E NT P
AK CO CA G
BR
LED LER VIN
SEA N FIL REMO
A EA
CL FORE
BE
RH
COUNTRIES
Pictorial Index Pictorial Index
PLATE NO. 35 PLATE NO. 36 PLATE NO. 39 RADIATOR COVERS & BELLY PLATE NO. 40
ANTI BRAKE LOCK SYSTEM REAR DISC BRAKE SYSTEM FRONT FORK
PAGE NO. 72 PAGE NO. 74 PAGE NO. 80 PAN ASSEMBLY PAGE NO. 82
PISTON SEAL
DUST SEAL
CALIPER PISTON
COUNTRIES
Pictorial Index Pictorial Index
PETROL TANK, CAP TANK AND PLATE NO. 41 PLATE NO. 42 PLATE NO. 45 PLATE NO. 46
MECHANISM EVAP METER ASSEMBLY CONTROL CABLES
GAUGE FUEL PAGE NO. 84 PAGE NO. 86 PAGE NO. 92 PAGE NO. 94
FITTINGS - PETROL TANK, PLATE NO. 43 FITTINGS - SIDE COVER & PLATE NO. 44 PLATE NO. 47 PLATE NO. 48
CHAIN CASE HEAD LAMP & FAIRING
COVER & SIDE COVER PAGE NO. 88 COVER SEAT PAGE NO. 90 PAGE NO. 96 PAGE NO. 98
COUNTRIES
Pictorial Index Pictorial Index
PLATE NO. 49 TAIL LAMP ASSEMBLY, FRONT PLATE NO. 50 PLATE NO. 53 PLATE NO. 54
INDICATOR LIGHT ASSEMBLY ACCESSORIES / GRAB HANDLE PAINTED PARTS & DECALS
PAGE NO. 100 NUMBER PLATE PAGE NO. 102 PAGE NO. 110 PAGE NO. 112,114
COUNTRIES
Cover Cylinder Head
1
No. Part No Description Qty Remarks
1 52 DT06 57 Head Cover Assembly 1
2 JY 5111 28 Gasket Head Cover 1
3 JG 5110 22 Bolt Flanged L46 4
4 JG 5110 21 Washer 4
1 COUNTRIES
2
Cylinder Head
2
No. Part No Description Qty Remarks
1 DT 5110 32 Head Cylinder-Holder Camshaft 1
2 LD A000 14 Washer Plain 4
19 3 LA C001 07 Bolt Socket 2
4 LD A000 15 Washer Plain 2
11 5 LC G000 24 Nut Hex Flanged 2
20 6 JG 5110 46 Stud 2
21 22 7 JG 5110 16 Bolt Flange 2
16a 24
8 39 1021 21 Ring O 2
17 9 DK 1012 25 Oil Pressure Switch 1
23 12
10 DK 1013 40 O Ring 1
14 11 JL 3512 18 Plug Spark 1
12 DK 1110 28 Spark Plug 2
16 26
30 15 13 JG 3514 00 Coolant Water Temp Sensor 1
1 25 29 14 39 2608 01 Grub Screw 1
2 4 3
15 KJ AC18 24 O Ring 1
27 16 39 1283 21 O Ring 1
7 8
16a LJ A000 01 O Ring 2
17 JF 5110 52 Sleeve Spark Plug 1
9 18 JY 5111 39 Gasket Cylinder Head 1
19 JY 5110 74 Gasket Sleeve Spark Plug 1
5 6 20 JY 5110 68 Sleeve Spark Plug 1
28
10 21 JY 5110 58 Guide Chain Top 1
22 KA EG06 45 Bolt Flanged Small 2
12 23 KA ED06 35 Bolt Flanged Small 4
24 KA EQ06 40 Bolt Flange Small 2
25 39 0999 06 Pin Dowel Oil Pump 2
13 26 LB C000 03 Screw Csk Cross 3
27 DT 5814 01 Pipe Intake 1
18 28 JY 5814 04 O Ring Intake Pipe 1
29 JG 5410 21 Oil Nozzle 4
30 LA C000 32 Bolt Socket 4
3 COUNTRIES
4
Valve
3
No. Part No Description Qty Remarks
1 JY 5112 26 Rocker Arm Shaft 2
2 3 2 JU 5112 04 Rocker Arm 3
1
2 3 JY 5112 12 Rocker Arm Decomp 1
2
4 JY 5112 31 Shim 4 N.I.
10-62 5 CB 1010 22 Cotter Valve 8
5 6 CB 1010 09 Seal Valve Stem 4
7 DT 5112 70 Valve Exhaust 2
8 JY 5112 21 Valve Intake 2
9 36 JF01 98 Kit Valve Repair 1
10 36 JF01 03 Kit Shim 3.16 mm 1
9 11 36 JF01 04 Kit Shim 3.18 mm 1
12 36 JF01 05 Kit Shim 3.20 mm 1
13 36 JY00 29 Kit Shim 2 mm 1
6 14 36 JY00 30 Kit Shim 2.04 mm 1
15 36 JY00 31 Kit Shim 2.08 mm 1
16 36 JY00 32 Kit Shim 2.12 mm 1
17 36 JY00 33 Kit Shim 2.16 mm 1
7 18 36 JY00 34 Kit Shim 2.20 mm 1
19 36 JY00 35 Kit Shim 2.24 mm 1
20 36 JY00 36 Kit Shim 2.28 mm 1
8 21 36 JY00 56 Kit Shim 2.30 mm 1
22 36 JY00 37 Kit Shim 2.32 mm 1
23 36 JY00 57 Kit Shim 2.34 mm 1
24 36 JY00 38 Kit Shim 2.36 mm 1
25 36 JY00 58 Kit Shim 2.38 mm 1
26 36 JY00 39 Kit Shim 2.40 mm 1
27 36 JY00 59 Kit Shim 2.42 mm 1
28 36 JY00 40 Kit Shim 2.44 mm 1
29 36 JY00 60 Kit Shim 2.46 mm 1
30 36 JY00 41 Kit Shim 2.48 mm 1
31 36 JY00 61 Kit Shim 2.50 mm 1
5 COUNTRIES
6
Valve
3
No. Part No Description Qty Remarks
32 36 JY00 42 Kit Shim 2.52 Mm 1
2 3 33 36 JY00 62 Kit Shim 2.54 mm 1
1
2 34 36 JY00 43 Kit Shim 2.56 mm 1
2
35 36 JY00 63 Kit Shim 2.58 mm 1
10-62 36 36 JY00 44 Kit Shim 2.60 mm 1
5 37 36 JY00 64 Kit Shim 2.62 mm 1
38 36 JY00 45 Kit Shim 2.64 mm 1
39 36 JY00 46 Kit Shim 2.68 mm 1
40 36 JF00 89 Kit Shim 2.70 mm 1
41 36 JY00 47 Kit Shim 2.72 mm 1
9 42 36 JF00 90 Kit Shim 2.74 mm 1
43 36 JY00 48 Kit Shim 2.76 mm 1
44 36 JF00 91 Kit Shim 2.78 mm 1
6 45 36 JY00 49 Kit Shim 2.80 mm 1
46 36 JF00 92 Kit Shim 2.82 mm 1
47 36 JY00 50 Kit Shim 2.84 mm 1
48 36 JF00 93 Kit Shim 2.86 mm 1
7 49 36 JY00 51 Kit Shim 2.88 mm 1
50 36 JF00 94 Kit Shim 2.90 mm 1
51 36 JY00 52 Kit Shim 2.92 mm 1
8 52 36 JF00 95 Kit Shim 2.94 mm 1
53 36 JY00 53 Kit Shim 2.96 mm 1
54 36 JF00 96 Kit Shim 2.98 mm 1
55 36 JY00 54 Kit Shim 3.00 mm 1
56 36 JF00 97 Kit Shim 3.02 mm 1
57 36 JY00 55 Kit Shim 3.04 mm 1
58 36 JF00 98 Kit Shim 3.06 mm 1
59 36 JF00 99 Kit Shim 3.08 mm 1
60 36 JF01 00 Kit Shim 3.10 mm 1
61 36 JF01 01 Kit Shim 3.12 mm 1
62 36 JF01 02 Kit Shim 3.14 mm 1
7 COUNTRIES
8
Camshaft / Tensioner
4
No. Part No Description Qty Remarks
1 JF 5112 55 Camshaft Assembly Exhaust 1
2 JF 5112 54 Camshaft Intake 1
3 JP 5112 15 Sprocket Camshaft 2
4 LA C001 44 Bolt Socket 2
5 JY 5112 29 Guide Chain Tight Side 1
6 5a JY 5112 27 Guide Chain Slack Side 1
6 JY 5112 20 Chain Timing 1
7 JY 5410 09 Bolt Special Pivot Guide Chain 1
1
8 CS 1011 28 Gasket 1
4 9 JF 5112 49 Tensioner Assembly 1
3
10 KA EW06 20 Bolt Flange 2
11 39 2669 21 O Ring 1
12 JG 5112 70 Bolt Flanged 1
2 5a 9
8
10 11
12
9 COUNTRIES
10
Cylinder and Piston
5
No. Part No Description Qty Remarks
1 36 JF01 96 Kit Block Piston 1
2 36 JF00 60 Kit Piston Ring 1
3 JY 5210 06 Gasket Cylinder Block 1
4 4 39 2181 06 Hollow Dowel Pin 4
5 JF 5213 00 Circlip 2 N.I.
6 JF 5212 16 Piston Assembly 1
11 COUNTRIES
12
Crankshaft
6
No. Part No Description Qty Remarks
1 JF 5310 20 Crankshaft Assembly 1
2 JY 5310 36 Con Rod Assembly with Bush 1
3 JY 5310 27 Bush Big End 2
1 4 39 2203 07 Parallel Pin 2
5 JY 5310 05 Bolt Con Rod 2
6 LF B000 01 Key Sunk 1
2 7 31 1011 73 Key Wood Ruff 1
8 JG 5310 40 Nut Balancer Drive Lock 1
9 LD H000 02 Washer Conical 1
10 LD B000 33 Washer Plain 1
12 14 16
11 JF 5310 21 Balancer Drive Gear 1
12 JY 5512 12 Gear Primary Drive 1
3 13 JY 5310 26 Sprocket Crankshaft 1
15 14 JY 5310 08 Washer Plain 1
13 15 DG 1012 75 Washer Special 1
16 LC G000 02 Nut Flanged 1
10 6 17 36 JF00 54 Kit Primary Drive & Driven 1 N.I
8
3
7 4
9 11
5
13 COUNTRIES
14
Transmission
7
No. Part No Description Qty Remarks
1 JY 5510 23 Shaft Input TM Assly 1 N.I
2 JY 5510 22 Shaft Input 1
3 JY 5512 30 Gear 5th Drive 1
4 JY 5510 10 Bush V Drive 1
5 JY 5512 29 Gear 3rd -4th Drive 1
6 JY 5512 14 Circlip External I/P shaft 2
2 7 JY 5510 21 Bush VI Drive 1
3 8 JY 5512 31 Gear 6th Drive 1
24
5 4 9 JY 5512 28 Gear 2nd Drive 1
10 JY 5512 15 Washer Thrust 2nd Drive 1
8 7 6 11 JY 5510 24 Shaft Output TM Assly 1 N.I
9 12 JY 5510 08 Shaft Output Assly with Plug 1
22 13 JY 5510 06 Bush 2nd Driven 1
10 6 23
14 JY 5512 33 Gear 2nd Driven 1
20 21
19 15 JY 5512 37 Gear 6th Driven 1
17 16 JY 5512 35 Gear 4th Driven 1
18 17 JY 5510 05 Washer Thrust 3rd Driven 1
16 18 JY 5512 34 Gear 3rd Driven 1
15 19 JY 5510 27 Bush 3rd Driven 1
12 13 20 JY 5512 18 Circlip External O/P Shaft 1
14
25 21 JY 5512 36 Gear 5th Driven 1
26
22 JY 5512 05 Bush 1st Driven 1
29 28 23 JY 5512 32 Gear 1st Driven 1
27 24 JY 5512 17 Washer Thrust 1st Driven 1
25 JY 5510 18 O Ring sprocket Collar 1
26 36 JY01 02 Collar Sprocket 1
27 JY 5510 29 Sprocket Drive 1
28 JY 5510 30 Plate Sprocket Drive 1
29 LA E000 17 Bolt Flanged 2
15 COUNTRIES
16
Change Drum / Shift Fork
8
No. Part No Description Qty Remarks
1 JF 5610 00 Drum Gear Shift 1
2 JG 5610 08 Gear Indicator Pin 1
3 JG 5610 10 Spacer Guide Gear shift 1
4 JG 5612 22 Guide Gear Shift 1
7 5 LA C000 24 Bolt Socket Head 1
5 6 JY 5610 04 Shaft Input Gear Shift Fork 1
4 7 JY 5610 02 Fork Gear Shift Input 1
8 JY 5410 39 Spring 2
3 8 9 JY 5410 38 Bush 2
10 JF 5610 01 Shaft Output Fork Shift 1
1 9 11 JY 5610 08 Fork Shift Output 2
6
11
10
17 COUNTRIES
18
Gear Change Mechanism
9
No. Part No Description Qty Remarks
1 JY 5612 05 Lever Gear Shift Assly Comp. 1
2 JG 5612 18 Torsion Spring 1
3 JG 5612 17 Bush Torsion Spring 1
4 JG 5612 16 Washer 1
1 5 KA DD06 22 Bolt Flange (Dia-06 L-22) 1
6 JF 5614 08 Change Arm Assly 1
7 52 JF00 62 Tie Rod with Nut 1
8 JF 5614 10 Lever Change Assly 1
9 DT 5612 05 Damper 1
10 JL 5614 09 Bolt Gear Change Lever 1
4 11 01 1009 05 ‘O’ Ring 2
6 12 JL 5614 10 Washer Steel 1
2 3
9 8 7
12
1111
10
19 COUNTRIES
20
Engine Assembly / Crankcase RH
10
No. Part No Description Qty Remarks
2 5 4
1 JF 5010 15 Engine Assembly 1
2 36 JF00 52 Kit Assembly Crankcase RH 1
3 39 1864 20 Ball Bearing 1
4 JY 5410 47 Stopper I/P Shaft Bearing 3
5 AA 1014 37 Bolt flanged Small 3
3
21 6 39 2601 20 Bearing Ball 1
5 7 39 2185 20 Deep Groove Ball Bearing 1
8 39 2562 20 Needle Roller Bearing 1
22 6 9 DP 1011 91 Bolt Shifter 1
4
10 JG 5612 26 Spring Stopper Drum 1
11 JG 5610 09 Stopper Drum Comp 1
12 JG 5612 05 Washer Drum Stopper 1
13 39 2005 11 Washer OD 1
14 JG 5612 04 Bolt Stopper Drum 1
7 15 LA E000 01 Bolt 1
16 JG 6010 07 Special Shaft Seal Ring 1
17 JG 5710 14 Oil Filter 1
18 JG 5710 16 ‘O’ RING 1
19 JL 5710 01 Cap Oil Filter 1
20 KA EW06 16 Flange Bolt 2
21 JG 6010 07 Special Shaft Seal 1
16 22 JL 6010 10 Water Seal Double Lip 1
15 17 18 19
20
10 11 12 13
9 14
21 COUNTRIES
22
Crankcase LH
11
No. Part No Description Qty Remarks
1
14 1 36 JF00 51 Kit Assly Crankcase LH 1
13
2 2 JY 3518 00 Sensor Assembly Pick Up 1
10 3 LA E000 10 Bolt Flange 2
4 LA D000 63 Bolt flanged 2
5 JA 5410 21 Cap Strainer 1
3 6 JY 5710 30 Mesh Strainer Assly 1
12 7 LJ A000 04 Strainer O Ring 1
11 8 39 1043 19 Seal Oil 1
9 KA EW06 35 Bolt Flanged 14
10 JY 5410 31 Chain Guard 1
11 KE BA37 15 Circlip Internal 1
4 12 JY 5410 58 Oil Seal O/P Shaft 1
9
5
13 LB B000 07 Screw Pan Cross 3
7 8 14 JY 5410 34 Bush Starter Shaft 2
6
15 LP B000 03 Bearing Ball 1
16 27
24 2526 16 LP B000 02 Bearing Ball 1
30 17 39 2181 06 Hollow Dowel Pin 2
18 39 2562 20 Needle Roller Bearing 1
19 JY 5410 24 Jet Evacuation Oil 1
20 JY 5710 08 Strainer Evacuation 1
15 21 LJ A000 02 O ring For E-20 2
22 LJ A000 06 Ring O 1
23 JY 5710 09 Cap Strainer Evacuation 1
24 JG 5410 74 Oil Nozzle 1
25 JF 5410 16 Nozzle 1
26 JF 5410 17 Bracket 1
17
27 LB B000 07 Screw Pan Cross 1
21 23
18 28 JY 5410 81 Bracket Harness 1 N.I.
29 JY 5410 80 Plate Harness 1 N.I.
20 22
30 JY 5710 29 Oil Rail 1
19
23 COUNTRIES
24
Balancer Idler Gear / Water Pump
12
No. Part No Description Qty Remarks
1 JL 6010 05 Cover Water Pump 1
2 KA EW06 20 Bolt Flanged Small 5
3 39 1665 11 Plain Washer 1
4 LA E000 48 Bolt Flange 1
5 JG 6010 12 O Ring (Water Pump Cover) 1
6 36 JL00 39 Water Pump Rotor 1
7 JL 5312 03 Sleeve Balancer Driven 1
8 JY 5312 20 Assembly Balancer 1
1 2 9 KP BF63 04 Bearing Ball 2
5 10 DS 1011 54 Key 1
11 JF 5312 13 Scissor Gear Assly 1
12 LD B000 51 Washer Plain 1
13 LA C000 86 Bolt Socket 1
6
9 15 14 JG 6010 05 Dome nut 1
7 15 JG 5312 15 Washer (2.5 mm) 1
11 9
10 14
12
13 3
4
25 COUNTRIES
26
Oil Pump
13
No. Part No Description Qty Remarks
1 JY 5710 12 Oil Pump Assly comp. 1
2 KE AB10 10 Circlip 1
3 LD A000 17 Washer Plain 1
4 JY 5710 23 Gear Oil Pump Drive 1
5 LH D000 01 Pin Parallel 2
8 6 JY 5710 24 Shaft Oil Pump 1
7 JY 5710 15 Pump Evacuation Assly 1
8 LA E000 18 Bolt flanged 6
1
6
8
4
7
3
2
27 COUNTRIES
28
Radiator
14
1 No. Part No Description Qty Remarks
4 56 1 JF 6012 01 Assembly Radiator 1
3
2 JF 6012 05 Radiator Core 1
3 JG 6012 35 Pressure Cap Radiator 1
4 JL 6012 16 Rubber Damper Radiator Mtg 4
5 39 2704 11 Washer 4
6 39 2711 15 Nut Flange M6 4
4 56 2 7 JG 6012 37 Fan Radiator 1
3 8 JY 6012 41 Flange Nut 3
9 JG 6010 14 Thermostat Assembly External G2 1
15 7 10 JF 6012 03 Hose Radiator to Thermostat 1
21 11 JY 6012 15 Hose Coolant 1
10 23 12 DT 6012 18 Hose Coolant (Therm to T pipe) 1
22
13 DT 6012 19 Pipe Coolant T Assembly 1
14 JF 6012 02 Hose Radiator to Pipe T 1
16
9 2 20 15 JG 6012 09 Clamp Radiator Pipe Dia 24 2
11
16 JG 6012 10 Clamp Radiator Pipe Dia 28 3
12 8 27 17 JG 6010 16 Clamp Radiator Pipe Dia 26 3
17 26 18 LJ A000 05 Pipe Coolant T O Ring 1
13 19 LA E000 49 Bolt Flange M6 2
25 20 JL 6012 35 Expansion Tank Assembly 1
14 28
21 JG 6012 11 Cap Expansion Tank 1
24
22 JG 6012 30 Expansion Tank O Ring 1
19 23 JG 6012 13 Tube Drain Expansion Tank 1
18 24 JG 1710 29 Spring Band Clip 10 MM 3
25 JL 6012 13 Hose Expansion Tank 1
26 JL 6012 15 Clamp Expansion Tank 1
29 27 JF 1812 62 Shroud Mtg Bkt RH 1
30
28 KA EW06 16 Bolt Flange Small 2
29 JF 1138 48 Bracket Radiator LH 1
30 JF 1138 49 Bracket Radiator RH 1
29 COUNTRIES
30
Cover Clutch
15
No. Part No Description Qty Remarks
1 52 JF12 24 Assembly Clutch Cover (Speckled Blk) 1
2 2 JG 5412 30 Cap Oil Filling 1
18 3 39 1537 21 O Ring 1
3
4 JF 5412 04 Bracket Clutch Cable 1
17 5 JY 5412 25 Gasket Clutch Cover 1
4 1 16 6 JG 5410 21 Oil Nozzle 2
15 7 39 2016 19 Seal- Oil 1
14
8 JY 5412 20 Plate Oil Seal 1
9 AA 1014 37 Bolt Flanged Small 2
10 KA EW06 35 Bolt Flange 11
5
11 JL 5412 27 Window Oil Guage 1
12 DS 1012 15 Wire Circlip 1
6
13 JF 2332 19 Decal Cover Clutch 1
13a JF 2332 35 Decal Ring Cover Clutch 1
7
14 39 1990 20 Bearing Needle 1
12 15 39 1041 19 Seal - Oil 1
11 16 LD B000 20 Washer 1
8
17 JF 5412 10 Spring Clutch Lever 1
9 18 JF 5412 08 Shaft Clutch Release Assembly 1
10
13 13a
31 COUNTRIES
32
Cover Magneto
16
No. Part No Description Qty Remarks
1 52 JF12 25 Magneto Cover Assembly 1
2 JG 5412 32 Cap TDC Finder 1
3 30 1011 95 O Ring 1
4 JF 2332 18 Decal Cover Magneto 1
4a JF 2332 34 Decal Ring Cover Magneto 1
1 5 KA EW06 35 Bolt Flanged Small 12
2 8 6 DT 5412 02 Cover LH RR 1
6
7 7 KA EW06 50 Bolt Flanged Small 3
8 JY 5412 76 Gasket Magneto cover 1
3
4a
33 COUNTRIES
34
Clutch Assembly
17
No. Part No Description Qty Remarks
1 JF 5514 19 Clutch Assembly 1
2 36 JF00 54 Kit Primary Drive & Driven 1 Refer Kit List
3 JY 5514 03 Washer Clutch 1
1 4 JY 5514 35 Clutch Center 1
5 JY 5514 42 Spring Seat Judder 1
7 6 JY 5514 41 Spring Judder 1
7 36 JF01 95 Kit Friction Plate 1
8 JY 5514 36 Pressure Plate - A 5
9 JY 5514 37 Pressure Plate - B 1
10 JY 5514 01 Bush Collared 1
11 LC G000 09 Nut Hex Flanged - M16 x 1.5 1
6 12 LP A000 04 Thrust Bearing 1
5 9
4
13 JY 5514 38 Plate Clutch Pressure 1
2 14 JY 5514 04 Rod Pull 1
10
15 JY 5514 39 Spring Clutch 3
8 16 JY 5514 43 Plate Stopper 1
17 LA D001 66 Bolt Flanged - M6 x 35 3
17
15 16
14
13
12
11
35 COUNTRIES
36
Throttle Body
18
1 No. Part No Description Qty Remarks
1 JF 6112 03 Assembly Throttle Body 1 EVAP
8 JF 6112 02 Assembly Throttle Body 1 Non EVAP
9 2 JY 5814 05 Clamp Intake Pipe 1
3 DT 5814 01 Pipe Intake 1
2
3 4 LB C000 03 Screw CSK Cross 3
5
5 JG 6112 06 Motor Stepper 1
6 JF 6112 01 Cap Injector with Assembly QC 1
7 JY 6110 00 Fuel Injector 1
7 8 JG 6110 06 Injector Clip 1
9 JG 3518 05 Sensor T Map 1
37 COUNTRIES
38
Air Cleaner Complete
19
No. Part No Description Qty Remarks
1 DT 5810 79 Assembly Air Filter 1
2 JF 5810 22 Entry Duct 1
3 KB UA06 30 Screw Truss 4
4 DT 5810 28 Seal Top Cover 2
2 5 DT 5810 62 Filter Element 1
6 JY 5814 05 Clamp Intake Pipe 1
7 DT 5810 72 Assembly Breather Tube 1
8 JY 5810 16 Clamp 1
1 9 JY 5810 28 Clamp 3
3 10 DT 5810 74 Breather Oil Return Tube 1
11 JP 5810 18 Tube Drain 1
4
12 JG 5810 56 Clamp (Breather Tube) 1
5
8
7 6
10
9 11
12
39 COUNTRIES
40
Silencer Assembly
20
No. Part No Description Qty Remarks
1 JF 5912 13 Pipe Assembly Complete 1
2 JF 5910 99 Assembly Muffler 1
3 JF 5912 22 Shield Muffler 1
4 KA CH06 14 Bolt Socket M6 3
5 KA CH06 10 Bolt Socket M6 1
6 JF 5911 82 Muffler Assembly W/O Shield 1
7 JP 5910 12 Clamp 1
4 8 8 JG 5910 70 Gasket 1
4
9 JP 5910 42 Gasket Muffler Primary 1
5 10 10 LC G000 24 Nut hex Flanged - M8 2
13 11 KA DW10 50 Bolt Flanged - M10 1
4 12
12 15 12 JF 1510 47 Washer Cup 2
9
13 DH 1611 55 Damper Silencer 1
11 7
1 14 36 DK00 09 Kit Hardware Silencer 1
23
6 21 22 15 DD 1610 71 U - Nut M10 1
18 20 16 LA C000 99 Bolt Socket - M6 1
17 LD B000 68 Washer Plain 2
18 18 JY 5913 03 Grommet Shield Muffler 2
17 19 KA DA06 12 Bolt Flanged 1
20 KA DD08 40 Bolt Flanged 1
16 2 21 DT 5913 05 Sleeve Bottom 1
3 22 JG 5911 00 Damper Silencer Mounting 1
17
19 23 JG 5110 10 O2 Sensor 1
41 COUNTRIES
42
Starter Assembly
21
No. Part No Description Qty Remarks
1 JF 3510 16 Stator Assembly 1
2 DK 1012 84 Hex Socket Head Screw 3
3 LA D001 24 Bolt Flange 1
4 LD B000 41 Washer Plain 1
5 JF 3510 13 Rotor Assly with Clutch Assembly 1
15 6 JY 5514 02 Clutch One Way Assembly 1
14 7 JY 6214 11 Assembly Gear Starter Clutch 1
13 8 BF 6214 02 Needle Bearing 1
9 JY 5512 21 Gear Starter Clutch 1
10 JY 5410 40 Retainer Gear Starter 1
11 LA E000 42 Bolt Flange 1
12 12 JY 5512 25 Gear Starter Counter 2 1
7 13 JY 5512 26 Gear Starter Counter 1 Assembly 1
5 14 JF 3516 00 Starter Motor 1
6 15 KA DQ06 25 Bolt Flange 2
1 16 JF 4022 34 Magneto Pigtail to RR 1 N.I.
17 JF 3510 14 Body Starter Clutch 1 N.I.
3 4 9
11
2
10
43 COUNTRIES
44
Magneto, CDI & H.T. Coil
22
No. Part No Description Qty Remarks
1 DT 3512 02 Coil Ht1 With Cap 1
2 KA ED06 20 Bolt Flange 4
3 DT 1138 55 Clamp HT Coils 1
12 4 DD 1110 12 Grommet HT Cable 3
2 5 JD 3512 07 Spark Plug Cap 1
6 DT 3512 04 Coil Ht2 With Cap 1
7 JD 3512 07 Spark Plug Cap 1
1 2 8 DD 1110 11 Grommet Spark Plug Cap 1
13
9 AN 1110 15 Spark plug Cap 1
6 10 DH 1110 16 Grommet Sp. Plug Cap 1
11 DH 1110 13 Grommet Spark Plug 1
3 12 JF 4020 04 Regulator 1
13 KA ED06 22 Bolt Flange Small 2
5 9
7
11 4
4
10
8
45 COUNTRIES
46
Seat Assembly / Seat Lock
23
No. Part No Description Qty Remarks
5 9 11
12
13 10
47 COUNTRIES
48
Engine Mountings
24
No. Part No Description Qty Remarks
1 56 DT02 33 Stay Hanger LH-DT113409 1
2 56 DT03 33 Stay Hanger RH-DT113410 1
3 LA J000 13 Bolt Stud-m10x1.25xl 224xbright 1
4 LA A000 51 Bolt 2
5 LC H000 02 Nut Nyloc 1
6 KA ED08 20 Bolt Flange 4
7 JL 1111 03 Cap Tube End 4
8 KA DW10 B0 Bolt Flange-m10x1.25xl110xbright 2
9 39 2723 15 Hex Nut 2
10 DT 1138 48 Cap Swing Arm Pivot 2
11 LA J000 20 Bolt Stud 1
7 6
12 KD DB10 18 Washer Spring Thin 1
13 JF 1134 24 Bracket Engine Middle Rear 1
14 KA DT08 14 Bolt Flange 1
2 1 15 JF 1813 48 Cap 1
16 JF 1813 46 Cover Frame Front 1
17 LA E000 54 Bolt Flange 1
8
10 18 LA D001 91 Bolt Flanged 1
12 5 4
3
9
14
13 11
17
15 18
16
49 COUNTRIES
50
Frame and Frame Fittings
25
No. Part No Description Qty Remarks
1 JF 1111 92 Frame Assembly 1
2 DT 1138 27 Cover Sheath Heat 1
3 JF 1111 79 Grommet Frame 2
4 JL 1138 09 Grommet Air Filter Resting 1
5 DK 1810 75 Nut Steering 1
6 DK 1810 76 Cup Steering 1
7 DG 1810 04 Seal Oil 1
8 DG 1810 03 Washer 1
5
9 36 DV00 07 Kit Steering Cone 1
6 1
2
10 DK 1810 50 Cage Bearing Steering Top 1 N.I.
11 DK 1810 51 Cage Bearing Steering Bottom 1 N.I.
9
3
7
4
8
51 COUNTRIES
52
Swing Arm / Rear Shock Absorber
26
No. Part No Description Qty Remarks
1 56 DT28 Y9 Swing Arm - Sprint Matte Black 1
2 LA D001 08 Axle 1
3 DG 1710 19 Seal Oil 4 N.I
11 4 DK 1710 06 Sleeve For Swing Arm 2
5 DG 1710 18 Bearing Needle 2
6 JF 1220 48 Spacer Swing Arm Central 1
7 39 1053 15 Nut 1
8 JF 1220 16 Chain Slider 1
12 9 KC AM08 06 Nut Hex Thick 2
10 JF 1220 15 Stud Chain Adjuster 2
16
11 JF 1220 69 Shock Absorber Rear 1
7
4 12 LA C001 05 Bolt Socket 2
5 13 DT 1138 48 Cap Swing Arm Pivot 1 N.I.
14 JF 1220 90 Bracket Slider Chain 1
6 1 15 LA C001 15 Bolt Socket 1
5 16 JF 1134 23 Washer 1
4 17 JF 1134 22 Spacer 1
2
13 8
9
10
15 14
17
53 COUNTRIES
54
Pillion Foot Rest / Holder
27
No. Part No Description Qty Remarks
1 56 JF3X Y9 Step Holder LH (JF113031) 1
LH 2 KA CA08 20 Bolt Socket 4
2 3 LA C000 79 Bolt Socket 2
19 4 LH E000 03 Pin Clevis with Hole 4
20 3 1 5 JF 1130 12 Spring Torsion 2
4 6 30 1410 31 Ring O 4
7 KD AA08 16 Washer 4
9 5 8 KH AA25 20 Pin Cotter 4
6
7 9 56 DT3S Y9 Step Rider LH Sprint Matte Black 1
8
4 10 56 DT4J Y9 Step Pill. Assembly LH Sprint Matt Black 1
18
11 17
11 JL 1130 36 Rubber Pillion Step 2
10 12 12 DT 1130 14 Lock Plate LH 1
6 7 13 56 JF3Y Y9 Step Holder RH (JF113033) 1
8
14 DT 1130 15 Lock Plate RH 1
15 56 DT3T Y9 Step Rider RH Sprint Matte Black 1
16 56 DT4K Y9 Step Pill. Assembly RH Sprint Matt Black 1
17 30 1012 36 Ball - Steel 2
RH 2
18 GF 1611 43 Spring :- Pillion Footrest 2
19 KA DD06 20 Bolt Flange 1
3 20 KC AD06 05 Nut Hex Thick 1
13 4
15
6
5
7
8
18
4
17
11
14 16
7 5
8
55 COUNTRIES
56
Mudguard - Front & Rear
28
No. Part No Description Qty Remarks
1 JF 1814 23 Flap Fender Front 1
2 KD AE05 10 Washer Plain Small 3
3 39 0326 15 Nut Nyloc 3
4 LA C000 71 Bolt Socket 6
5 JF 1814 73 Collar 6
6 LB B000 15 Screw Pan Cross 3
3 2
5
4
57 COUNTRIES
58
Stand Assembly
29
No. Part No Description Qty Remarks
1 JF 1132 12 Stand Assembly Side 1
2 JF 1132 09 Bracket Stand Side 1
3 LA D001 84 Bolt Flanged 1
4 LA D002 00 Bolt Flanged 1
5 LA D002 31 Bolt Flanged 1
6 LC H000 01 Nut Nyloc 1
7 KB AA05 10 Screw Pan 1
8 JD 1610 06 Sleeve Brake Return Spring 1
9 AH 4014 08 Holder Magnet 1
10 JF 1138 55 Bracket Cover Switch Stand Side 1
12 11 KA DS05 16 Bolt Flange 1
12 JF 4014 15 Switch Stand Side 1
2 12 12 13 JF 1132 10 Spring Tension Cover 1
4 14 JF 1132 08 Bracket Holder Magnet 1
3
10
5 11
6
14
1 13
9 8
59 COUNTRIES
60
Tube / Tyre / Rim
30
No. Part No Description Qty Remarks
1 JG 1310 38 Tyre Front MRF VER 7 1
3 1 2 DK 1510 26 Valve Tubeless Tyre 2
3 56 JF6T 33 Front Wheel(JF131026) - Matt Black 1
4 56 JF6R 33 Rear Wheel(JF131217) - Matt Black 1
5 JG 1312 45 Tyre Real MRF VER 7 1
4 5
2
61 COUNTRIES
62
Front Hub
31
No. Part No Description Qty Remarks
1 JG 1310 03 Front Axle 1
2 JG 1310 20 Collar 1
3 DG 1510 05 Seal Oil 2
4 KP BC62 02 Bearing Ball 2
5 JF 1318 76 Disc Brake Dia 320 1
6 DT 1318 67 Sensor Disc Front 1
7 JG 1318 02 Disc Mtg Bolt 6
8 LD B000 57 Washer Plain 1
2 1 9 DT 4024 04 Sensor Speed Wheel 1
4 3
10 LA E000 55 Bolt Flange 1
11 JG 1310 01 Spacer Assembly FR Wheel 1
12 DT 1310 17 Collar Assembly Front wheel 1
13 JG 1310 07 Flange Bolt M8 1
10
9
8
11 7 6
4
3 5
2
12
13
63 COUNTRIES
64
Front Master Cylinder
32
No. Part No Description Qty Remarks
1 JG 1610 10 Lever Front Brake 1
2 DJ 1910 29 Bolt Front Bracket l 1
3 DJ 1910 30 Nut 1
2 1 4 36 DH19 02 Oil Window Kit 1
5 DJ 1910 31 Screw 2
8 6 DE 1910 29 Cover - Reservoir 1
7 DE 1910 28 Diaphragm 1
8 JF 1318 89 Cylinder Master Assembly Front 1
9 DJ 2011 09 Front Brake Switch 1
3
5 10 DE 1910 10 Washer - Copper 4
5
US
E
11 DK 1510 69 Bolt - Banjo 2
W
AR
G: 3-4
NIN DOT ROM
LY ID F ER 6
A
ON FLU AIN
AK
E
BR D C R C VIN
A LE IL
SE N F REM
A E
LE
T
ON AP G
O
12 36 JF00 64 Kit Hose Abs To Fr M Cyl 1
CLE FOR
BE
15
9
10
10
11
65 COUNTRIES
66
Front Disc Brake
33
No. Part No Description Qty Remarks
1 JG 1318 04 Caliper Assembly Brake Front 1
2 JG 1318 11 Bleeder Screw 1
3 LA D000 79 Bolt Flanged 1
4 59 0400 48 Bolt Flange M8x1.25 1
7 5 JG 1318 13 Spring 1
2
6 36 JY01 88 Fr Caliper Brake Pad Kit-sintered 1
7 JU 1318 16 Kit Minor Front 1
8 JU 1318 15 Kit Major Front 1
6
3
4
1
5
67 COUNTRIES
68
Rear Hub
34
No. Part No Description Qty Remarks
1 LC J000 05 Nut U 1
2 LD B000 57 Washer Plain 2
3 JF 1220 14 Chain Adjuster 2
4 DK 1510 81 Spacer I 1
5 DK 1510 82 Spacer II 1
6 DT 4024 04 Wheel Speed Sensor (ABS) 1
7 KA EW06 16 Bolt Flanged Small 1
8 JU 1318 02 Sensor Disc Rear 1
10 9 JG 1312 20 Screw for ABS 3
3 1
8 67 4 10 JF 1318 61 Disc Rear 1
11 39 2038 04 Hex Socket Head Bolt 6
13 9 12 30 1510 82 Seal Oil 1
14 2
11 5 13 KP BC63 02 Bearing Ball 1
14 JL 1312 16 Collar Bearing Assembly 1
17 12
18 16 15 KP BC62 02 Bearing Ball 1
21 16 DT 1312 10 Sleeve 1
19 17 JU 1312 22 Damper 6 Rubber 6
23 15 18 JG 1312 35 Coupling Assembly 1
3 19 KP AC62 05 Bearing Ball Ordinary Clearance 1
2
20 JG 1312 28 D Bolt 6
20
21 36 JF00 56 Kit Chain Sprocket 1
24 22 LC L000 04 Nut U Flange 6
25 22
23 DT 1312 14 Seal Oil 1
24 JL 1312 11 Spacer for Coupling 1
25 JF 1312 30 Axel Rear 1
69 COUNTRIES
70
Anti Brake Lock System
35
No. Part No Description Qty Remarks
1 1 JF 9904 09 Unit Abs Wet 1
2 36 JF01 79 Kit Hose Cyl Master FR Unit ABS 1
3 36 JF01 80 Kit Hose Unit ABS Caliper Front 1
4 36 JF01 81 Kit Hose Cyl Master RR Unit ABS 1
5 36 JF01 82 Kit Hose Unit ABS Caliper Rear 1
6 JF 1138 52 Bracket Unit ABS 1
7 DH 1013 85 Flanged Bolt 1
6 8 KA DA06 14 Bolt Flange (DIA-06 L-14) 3
16 9 39 0254 11 Washer - Plain 3
9
10 DT 1318 75 Clamp For ABS Hose 1
7
8 11 KA EW06 25 Bolt Flange Small - M6x1xL25 1
2 12 DE 1910 10 Copper Washer 8
13 DK 1510 69 Benjo Bolt 4
10
14 DT 1318 78 Clamp W 1
11
15 JF 1318 54 Clamp W 1
4 16 39 1309 11 Washer - Plain 1
13
12
3
14 15
71 COUNTRIES
72
Rear Disc Brake System
36
No. Part No Description Qty Remarks
1 DT 1318 26 Assembly Caliper 1
2 JF 1318 88 Cylinder Master Assembly Rear 1
5 24 3 36 JF00 79 Hose Disc Brake Rear 1
23
20 4 DK 1510 69 Banjo Bolt 2
5 JG 1318 21 Reservoir Rear Brake 1
6 JL 1312 20 Hose - Reservoir 1
6 22
7 DK 1510 63 Clip Reservoir 1 Cap Reservoir (N.I.)
4 19 8 DE 1910 10 Copper Washer 4 Banjo Bolt (N.I.)
26 9 DE 1510 47 Cap Bleeder Screw 1
2 10 DE 1510 46 Bleeder Screw 1
25
11 DK 1510 88 Caliper Piston Kit 1
12 DK 1510 89 Caliper Piston Seal Kit 1
3 13 DK 1510 85 Set Disc Pad 1
9
10 14 30 1910 38 Pin 1
14 12 4 15 39 0198 11 Washer Plain 1
16 15
16 39 0808 08 Split Pin 1
1 17 DK 1510 73 Master Cylinder Major kit 1 N.I.
PISTON SEAL 18 DK 1510 74 Master Cylinder Minor kit 1 N.I.
19 JL 1318 77 Clamp 1
DUST SEAL 20 DK 1510 45 Cap Reservoir Rear Brake 1
21 36 JG00 83 Kit Brake Fluid Reservoir 1 N.I.
22 JF 1130 36 Bracket Reservoir 1
23 JL 1318 78 Bracket Reservoir Cap 1
CALIPER PISTON 24 39 2420 01 Screw - Pan Head :- M5 1
25 LA D000 85 Bolt Flanged 2
26 JG 1812 39 Collar Bushing 1
11 13
73 COUNTRIES
74
Rear Brake Pedal
37
No. Part No Description Qty Remarks
1 JF 1610 06 Brake Pedal 1
2 JF 1610 07 Damper Brake Pedal 1
3 JZ 1318 75 Pin Brake Rod 1
4 KH AA20 15 Pin Snap 1
5 JF 1610 04 Brake Return Spring 1
8 6 DP 1610 94 Bolt Stepped 1
12
7 JM 1910 14 Spring Brake Switch Rear 1
8 JL 4014 06 Brake Switch Rear 1
6 9 JC 1910 09 Bolt Brake Pedal 1
10 39 1998 19 Seal Oil 2
11 LD B000 56 Washer Pivot Bolt 1
12 JF 1130 37 Bracket Switch Brake Rear 1
13
5 13 LA D000 85 Bolt Flanged 1
7
1
2
9 4
10
11
75 COUNTRIES
76
Handle Bar Assembly
38
No. Part No Description Qty Remarks
1 JF 1510 41 Handle Bar 1
2 KA CJ06 55 Bolt Socket 2
26 3 DH 1810 22 Handle Bar Weight 2
4 DH 1910 67 Handle Grip LH 1
31
5 DH 1910 68 Hand Grip Assembly RH 1
25 29 6 JG 1510 22 Throttle Pipe 1
30 7 JF 4014 13 Switch Control LH 1
5 3 2 8 JF 4014 14 Switch Control RH 1
13 9 JF 1610 13 Assembly Lever Holder LH 1
28
10 JG 1610 08 Clutch Lever 1
11 39 1553 04 Bolt Flange 1
9 6 12 JZ 1610 28 Lever Pivot Bolt 1
10 8 13 JG 1610 10 Brake Lever Front 1
12 14 LA C001 03 Bolt Socket 4
24
14 15 56 JF5A W4 Handle Holder Upper 1
11
16 LA C001 48 Bolt Socket 2
4 7 15 17 56 JF5B W4 Handle Holder Lower 1
16 18 JF 1510 47 Washer Cup 2
3 1
18 19 JF 1510 54 Damper 2
17 20 JY 1210 11 Bolt Socket 2
2
19 21 JF 2326 16 Set Lock 1 EVAP
20 JF 2326 18 Set Lock 1 NON EVAP
22 LA D002 44 Bolt Flanged 2
23
23 56 JF33 33 Brkt Upper JF151040 1
21 24 JY 4014 04 Switch Clutch 1
27
25 JF 2316 08 Mirror LH 1
26 JF 2316 09 Mirror RH 1
27 JF 1510 55 Spacer 2
22 28 JF 1610 14 Holder Lever LH 1
29 KD DA08 15 Washer Spring Thin 2
30 KD AA08 16 Washer Plain Small 2
31 LA C001 41 Bolt Socket - M8 2
77 COUNTRIES
78
Front Fork
39
No. Part No Description Qty Remarks
23
1 JF 1210 18 Fork Front 1
14 16 2 JF 1210 22 Leg Assembly LH 1
13 17 3 JF 1210 23 Leg Assembly RH 1
4 YJ F190 03 LH Pipe Inner with Axle Clamp 1
5 YJ F190 04 RH Pipe Inner with Axle Clamp 1
3 6 JG 1210 12 Fork Top Bolt 2
2 6 6
7 JF 1210 16 Fork Outer Tube 2
22 22 8 LD B000 36 Washer Plain 2
9 JF 1814 71 Protector Fork LH 1
10 JU 1210 09 Oil Seal Stopper (Circlip) 2
11 JF 1814 72 Protector Fork RH 1
7 7
15 15 12 JG 1210 28 Outer Dust Cap 2
13 LA C000 10 Bolt Socket - M6 2
14 JG 1138 32 Sleeve for ABS Hose Clamp 2
9
15 YJ F190 07 Main Spring & Spacer Assembly 2
16 JF 1210 20 Bracket Assembly Under 1
8
17 JY 1210 11 Bolt Socket - M8 6
18 18 18 JG 1210 57 Oil Seal Kit 2
10 19 YJ F190 08 Rubber Damper 2
11
20 YJ F190 06 Screw Cap Inner Pipe 2
12 21 YJ F190 05 Piston Rod Assembly 2
1
19 19 22 YJ F190 09 Lock Nut 2
23 JF 1138 51 Clamp Hose 2
20 20
4 5
21 21
17
79 COUNTRIES
80
Radiator Covers & Belly Pan Assembly
40
No. Part No Description Qty Remarks
1 1 56 JF24 4X Shroud LH Satin Black 1
2 56 JF25 4X Shroud RH Satin Black 1
5 3 LB U000 53 Screw Button Head M6 4
4 JY 1812 84 Washer Nylon 4
5 JF 1812 57 Shroud Center 1
6 JG 1812 59 Rivet Snap 4
7 KA CF06 12 Bolt socket M6 2
2 8 LB U000 55 Screw Button Head M6 2
9 KB UA05 12 Screw Truss 4
6 10 DJ 1612 29 Clip Nut 4
11 BF 1850 19 Clio Plastic Rivet 1
12 DT 1813 07 Bkt Belly Pan Mtg 1
4 13 KA CA06 35 Bolt Socket 2
3
14 39 0198 11 Washer Plain 4
15 JF 1813 09 Bkt Belly Pan Mtg Rear 1
16 LB U000 57 Screw Button Head M6 2
17 JY 1812 55 Washer End Cap 2
12
14
7
15
8 13
10
17
16
11
9
81 COUNTRIES
82
Petrol Tank, Cap Tank and Gauge Fuel
41
No. Part No Description Qty Remarks
2 6
21 7 1 JF 1710 72 Tank Assembly Fuel 1 EVAP
8 JF 1710 73 Tank Assembly Fuel 1 NON EVAP
2 KA DC05 16 Bolt Flange 6
3 9
3 KA DW08 20 Bolt Flanged M8 3
4
4 DT 1710 75 Sleeve Tank Mtg Front 1
5
5 DT 1710 78 Grommet Tank Mtg Front 1
6 JF 1710 23 Tank Damper Top Front LH 1
1
7 JF 1710 24 Tank Damper Top Front RH 1
8 JF 1710 25 Tank Damper Top Central LH 1
9 JF 1710 26 Tank Damper Top Centra RH 1
10 DT 1710 61 Drain Tube 1
11 JF 1716 03 Tube Tank To Y Connector 1
3 12 JY 1710 90 Spring Band Clamp 2
10 13
11 13 JL 1710 19 Sleeve Tank Mtg 2
14 14 JL 1710 20 Grommet Tank Mtg RR 2
12
15 JF 1718 02 Assembly Fuel Pump 1
16 DT 1718 39 Plate Pressure Fuel pump Mtg 1
17 LA D001 54 Bolt Flanged M6 6
18 DT 1710 87 Assembly Tube Pump To Filter 1
15
19 DT 1710 89 Assembly Tube Filter To Regulator 1
20 DT 1718 14 Inline Fuel Filter 1
21 JF 2326 11 Lock Set 3 in 1 with Fuel Tank Cap 1
22 JY 4022 35 Pigtail Fuel Pump 1 N.I.
16 17
18
19
20
83 COUNTRIES
84
Mechanism EVAP
42
No. Part No Description Qty Remarks
1 JY 1710 77 Canister 1
2 JZ 1710 55 Strap Canister 2
3 DT 1138 41 Bracket Canister Mtg 1
4 KA DA06 12 Bolt Flanged 2
5 JY 1710 69 Spring Band Clamp 15x10 1
5 1 6 JF 1716 24 Pipe Connector Valve Purge 1
6
8 7 JY 1710 90 Spring Band Clamp 13x12 8
7 11
7 8 JU 1716 06 Valve Purge 1
9 11
7 9 JF 1716 25 Pipe Valve Purge-connector 1
11 10 18
13 10 JG 1710 86 Connector Tube Evap 1
2 11 JY 1710 70 Spring Band Clamp 9 X8.4 4
2
12 DT 1718 47 Tube Conn. To Throttle Body-K8 1
11 7 13 JF 1716 23 Pipe Canister Connector 1
12
7 14 JY 1138 42 Connector Y Shape 1
15 15 JL 1718 36 Tube Tank To Y Connector 1
7 3
7 16 JF 1716 07 Tube Connector To Plug 1
14 17 JY 1718 25 Plug Fuel Drain 1
4
18 JF 1718 07 Tube Canister Drain -K16b 1
16
19 JF 1138 53 Bracket Valve Purge 1
7 20 KC GA06 06 Nut Hex Flanged 1
22 17
21 21 KA EA06 10 Bolt Flanged Small 3
22 JF 1138 21 Bracket Canister Mtg 1
20
21
21 19
85 COUNTRIES
86
Fittings - Petrol Tank, Cover & Side Cover
43
16 No. Part No Description Qty Remarks
1 JF 1710 22 Tank Central Cover 1
2 JF 1710 37 Bolt Special Tank Cover Mtg 2
18
3 JF 1710 48 Collar Cover Tank 6
17 22
11 4 JF 1710 47 Grommet Cover Tank 6
20 5 JL 1810 27 Clip Nut M6 2
6 39 1907 01 Mushroom Head Screw 12
14 7 DJ 1612 29 Clip Nut M5 12
8 JF 1710 35 Bkt Tank Side Cover LH 1
19 9 JF 1710 36 Bkt Tank Side Cover RH 1
21 10 KA DA05 10 Bolt Flanged 6
11 KB RF35 10 Screw Tapping Pan Cross 13
23 12 JF 1710 28 Bkt Tank Cover Rear 1
13 39 2141 24 Washer Nylon 2
7 14 14 KB UH05 14 Screw Truss M5 2
13 15 JF 1710 54 Damper Cover Side 2
12 16 JF 1710 19 Tank Cap Cover 1
11 17 DT 4024 10 Console Tell Tale 1
18 JF 1710 29 Beading Fuel Tank 1
19 JF 1710 87 Bracket Speedometer 1
10 20 39 1839 11 Washer Plain 2
15
11 9 21 JF 1710 57 Pad Tank Cover Top 1
22 JB 4010 12 Foam 2
23 JF 4024 15 Foam 1
8
11 1
5
34 4
2 3
6
87 COUNTRIES
88
Fittings - Side Covers & Cover Seat
44
No. Part No Description Qty Remarks
1 DT 1810 07 Assembly Under Tray Front 1
2 LB U000 65 Screw Truss M5 10
3 39 0239 11 Plain Washer 4
4 KA DD06 10 Bolt Flanged 4
5 JH 1812 55 Washer Retaining 2
6 LB U000 69 Screw Truss M6 6
7 DS 1410 12 Grommet Side Cover FR 2
8 7 8 JZ 1812 71 Damper Side Cover 2
9 DJ 1612 29 Clip Nut M5 10
6
5 3 4
2
2 34
1
89 COUNTRIES
90
Meter Assembly
45
No. Part No Description Qty Remarks
1 1 DT 4024 09 Speedometer 1
2 JF 1812 69 Bkt Speedo Mtg Upper 1
3 KD BA05 12 Washer Plain 2
4 KB UB05 08 Screw Truss 2
5 JZ 1813 65 Grommet 3
6 LD B000 07 Washer Plain 3
2 7 KC AA05 04 Nut Hex Thick 3
8 LA D001 02 Bolt Step M6 2
3 9 JF 1812 65 Back Cover cum Speedo Flap 1
4 5 10 KB UF06 14 Screw Truss 4
6
7 8 13 11 39 0239 11 Plain Washer 4
12 DJ 1810 65 Clip Nut 4
13 YJ F190 02 Top Cover & Ring Main Speedo 1
14 YJ F190 01 Top Cover & Ring Tank Speedo 1
9
10
1112
14
91 COUNTRIES
92
Control Cables
46
No. Part No Description Qty Remarks
1 JF 1612 05 Cable Throttle 1
2 JF 1612 04 Cable Clutch 1
93 COUNTRIES
94
Chain Case
47
No. Part No Description Qty Remarks
1 DT 1813 08 Chain Cover Assembly 1
2 LA C000 54 Screw Button Head 5
3 JF 1813 16 Collar Cover Chain Mtg 5
4 DT 1812 97 Cap Chain Cover 1
2 3
4
95 COUNTRIES
96
Head Lamp & Fairing
48
No. Part No Description Qty Remarks
1 1 DT 1813 06 Windshield 1
2 KB BP05 30 Screw Pan Cross 4
2 3 KD AA05 10 Washer Plain Small 4
5
4 JH 1812 55 Washer Retaining 4
7
3 8 5 JF 1812 66 Mask Carrier 1
4
11 6 6 JF 1812 77 Well Nut For Mask 4
12 7 KB UF06 14 Screw Truss M6 4
8 39 0239 11 Plain Washer 4
9 DJ 1612 29 Clip Nut M5 4
10 BF 1850 19 Clip Plastic Rivet 2
11 KB UH05 14 Screw Truss M5 4
12 39 1839 11 Washer Plain 4
10
13 DT 4010 20 Head Lamp Assembly 1
9 14 KB UA06 14 Screw Truss 3
15 39 2704 11 Washer Plain 3
16 DJ 1810 65 Clip Nut M6 3
17 JF 1812 70 Bkt Mask Carrier Mtg Lower 1
16 18 PF 1812 11 Grommet Cowling Mtg 1
15 14
19 LA D001 02 Bolt Step M6 2
18
19
13
17
97 COUNTRIES
98
Indicator Light Assembly
49
No. Part No Description Qty Remarks
1 DT 4010 02 Indicator Front LH 1
2 DT 4010 03 Indicator Front RH 1
3 JY 4010 24 Indicator Rear LH 1
4 JY 4010 25 Indicator Rear RH 1
5 LA C000 05 Nut Hex 4
6 LD F000 02 Washer Toothed 4
7 LD A000 12 Washer Plain 4
1 2
56 7
3
4
99 COUNTRIES
100
Tail Lamp Assembly / Front Number Plate
50
4 25 No. Part No Description Qty Remarks
2 1 JU 2328 00 Number Plate Front 1
2 JF 1812 71 Bkt Number Plate Mtg 1
3 JZ 2328 14 Pad Rubber Plate Bkt 2
1 4 KB UH05 14 Screw Truss M5 13
3
5 JF 4010 22 Lamp Tail 1
6 DJ 1612 29 Clip Nut 10
7 JF 1814 20 Fender Rear 1
8 JG 1812 55 Step Bolt 2
4
8 9 KA DT06 12 Bolt Flanged-m6x1xl12xcl8.8xblak 4
4 4 10 39 0239 11 Plain Washer 4
6 11 JG 4010 06 Number Plate Illumination Lamp 1
6
7 12 LB R000 03 Screw CR Pan Head Tap 2
9 13 DP 1611 45 Number Plate Rear 1
10 14 JF 1813 07 Bkt Rear No Plate 1
5 15 KA DA06 10 Bolt Flanged 2
12 11
13 15 16 LC G000 08 Nut Flange 2
14
22 21 17 JG 4010 36 Reflector Reflex 1
18 LC A000 08 Nut 1
19
19 JF 1814 22 Reinforcement Rear Fender 1
16 20 JF 1138 18 Bkt RR Fender Middle Mtg 1
6
20 21 KA DD06 10 Bolt Flanged 5
22 DJ 2011 73 Grommet for Cables RR Fender 2
21 4
18 23 JF 1814 24 Flap Rear Fender 1
4
24 JF 1814 21 Under Tray Fender Rear 1
17
24 25 LD B000 74 Washer Plain 2
10 4
9
6
23
101 COUNTRIES
102
Electrical Equipments
51
No. Part No Description Qty Remarks
1 1 JF 4022 48 Harness Wiring 1
10 9
2 JL 4030 00 Relay Inter lock 1
3 30 1910 48 Band 5
4 30 2010 64 Band 3
7 8 5 JF 4022 12 Cable Assembly Relay To Motor 1 N.I.
6 JF 4022 11 Cable Earth 1 N.I.
3 7 JG 4020 02 DC Flasher 1
24 8 PA 4016 00 Horn 1
2 9 39 1507 11 Washer - Plain 1
10 39 1956 04 Hex Head Bolt - Flanged M8 1
4 11 36 JU00 15 12V 8AH VRLA Battery 1
13
25 12 DT 1810 22 Band Battery Case 1
13 JL 1138 25 Band Battery Case -Vrt ECU 1
26 14 JF 1813 08 Rubber Battery Case 1
15 JF 1812 72 Battery Case Epm 44 1
11 32 16 KA ED06 22 Bolt Flange 2
17 DT 1813 16 Sleeve Battery Case 4
12 18 DT 1813 17 Grommet Battery Case 4
23 19 KA ED06 25 Bolt Flange 2
21 20 14 16
20 52 JF03 28 Sub Assembly Bkt ECU Mtg Lower 1
17 36 21 JF 3514 04 EPM44 MTB Series 1
22 22 52 JY06 67 Sub Assembly Bkt C Sample Top 1
23 KC GD06 06 Nut Hex 3
35
37 24 JL 4032 00 Termination Unit 1
19
25 JL 4030 01 Relay Auxi Diode 1
34
26 JN 3516 04 Starter Relay - With Grommet 1
15
18 27 DT 4022 26 Fuse - 7.5A 5 N.I.
28 JG 4022 29 Fuse 15A 4 N.I.
29 JG 4022 30 Fuse 30A 2 N.I.
33 38
30 JG 4022 28 Fuse 10A 2 N.I.
31 JG 4022 34 Fuse 25A 1 N.I.
103 COUNTRIES
104
Electrical Equipments
51
No. Part No Description Qty Remarks
1 32 DT 1138 51 Bracket Fuse Box Mtg Loose 1
10 9
33 JY 4036 04 Roll Over Sensor 1
34 JF 1138 42 Bracket Roll Over Sensor 1
35 KA CF06 12 Bolt Socket 2 M6 x 1 x L12
7 8 36 LA C000 08 Screw Truss 2 M6 x 1 x L25
37 LD B000 72 Plain Washer 2
3 38 39 1353 15 Nut 2
24
2
4
13
25
26
11 32
12
23
21 20 14 16
17 36
22
35
19 37
34
15
18
33 38
105 COUNTRIES
106
Tool Kit
52
No. Part No Description Qty Remarks
1 JF 2310 10 Tool Kit 1
2 JL 2310 03 Band Tool Kit 2
1 2
107 COUNTRIES
108
Accessories / Grab Handle
53
No. Part No Description Qty Remarks
1 JF 2312 09 Guard LEG LH 1
2 JF 2312 10 Guard Leg RH 1
3 LA C001 49 Bolt Socket 2
2
4 LD B000 76 Washer Plain-id6.5xod13xthk1xblk 3
3 4 5 LC L000 07 Nut U Flanged 1
1 6 JF 2312 08 Guard Sari 1
7 JL 2312 09 Plug Sari Guard 1
8 JF 2312 11 Plug Sari Gurad 2
9 KA CB06 22 Bolt Socket 1
10 KA CA08 18 Bolt Socket 2
11 56 DT5U 36 Grab Handle LH 1
12 56 DT5V 36 Grab Handle RH 1
13 LA C001 19 Bolt Socket 4
5
6
12
13
7 9 11
8 10
109 COUNTRIES
110
Painted Parts and Decals
54
No. Part No Description Qty Remarks
1 56 JF14 4x Side Mask LH 1 Satin Black
8/9 19/20 3/4 5 6/7 18 1/2 17 10
11 JF 2331 98 Decal 3D 1
111 COUNTRIES
112
Painted Parts and Decals
54
No. Part No Description Qty Remarks
13 JF 5412 11 Label Cover 1
8/9 19/20 3/4 5 6/7 18 1/2 17 10
113 COUNTRIES
114
Kit List Kit List
1 36JF0051 ASSEMBLY CRANKCASE LH BA102003 PLUG - OIL HOLE 1 9 36JF0196 KIT BLOCK PISTON K10UG JF521216 PISTON ASSEMBLY 1
JC101077 PLUG TAPER 2 JF521009 BLOCK CYLINDER 1
DT541009 CRANKCASE LH 1
JF541016 NOZZLE 1 10 36JY0102 KIT OUT PUT SHAFT OIL SEAL JY541058 OIL SEAL OUTPUT SHAFT 1
JY541034 BUSH STARTER SHAFT 2 JY551033 COLLAR SPROCKET 1
JY541024 JET EVACUATION OIL 1 JY551018 O RING SPROCKET COLLAR 1
JY541050 JET OIL 1
JY541038 BUSH 1 11 36DV0007 KIT STEERING CONE ( NEW ) DG181045 BEARING CONE :- UPPER 1
JY541052 JET TRANS 1 DG181046 BEARING RACE - UPPER 1
JF541017 BRACKET 1 DG181047 BEARING RACE - LOWER 1
LBB00007 SCREW PAN CROSS - M6x1xL12 1 DG181005 BEARING CONE 1
115 COUNTRIES
116
Amendment Sheet Amendment Sheet
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
74 21 36JG0018 36JG0083 Kit Brake Fluid Reservoir 13.06.19 Alternate Updation
117 COUNTRIES
118
Amendment Sheet Amendment Sheet
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
119 COUNTRIES
120
Part Index Part Index
121 COUNTRIES
122
Part Index Part Index
123 COUNTRIES
124
Part Index Part Index
125 COUNTRIES
126
Part Index Part Index
127 COUNTRIES
128
Part Index Part Index
129 COUNTRIES
130
Part Index Part Index
131 COUNTRIES
132
Part Index Part Index
133 COUNTRIES
134
Part Index Part Index
135 COUNTRIES
136