BOXER SPARE PARTS CATALOGUE
Back
NOTICE The description and illustrations in this catalogue are not to be taken as binding on the manufacturer. The essential features of the type described and illustrated herein remaining unaltered, BAJAJ AUTO LIMITED reserve the right to carry out at any moment, without being obliged to bring this catalogue up-to-date, modifications on the vehicle, parts or accessories, as may be convenient and necessary. Copying, quoting or reproducing any part of this catalogue without the written permission of BAJAJ AUTO LIMITED, is expressly prohibited.
DOC. NO. 36 02 0186
REV. 02, DEC. 2000
FOREWORD We have pleasure in presenting the spare parts catalogue for BOXER & 4S-CHAMPION This catalogue has been specially designed to assist you in selecting the correct part to maintain your vehicle in the best running condition. The bajaj spares are subjected to the stringent quality control standards to ensure longer life of the vehicle. It is therefore necessary that only the genuine bajaj spares are used. In a continual effort to improve performance and efficiency of the vehicle, specifications, diagrams, illustrations and part numbers can change without notice. Consequently, the description in this Spare Parts Catalogue cannot therefore be final and binding on us. 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 upto-date. This will ensure the appropriate and speedy delivery of the spare parts as the order placed will bear the latest part numbers. In case, if you need any technical assistance contact our nearest authorised dealer or write to us on the following address :
Bajaj Auto Ltd., Service Dept. Akurdi, Pune - 411 035. TELEX
: 0146-208 BAL-IN : 0146-263 BAL-IN
PHONE
: 7472851
CABLE
: AUTORIKSHA
FAX
: 020-7407385
INSTRUCTIONS FOR USING THE CATALOGUE :1.
How to read the catalogue : Open the catalogue and from the pictorial 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. Jot down the 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 part index can be used. The part index (at the end of the catalogue) will give you the figure and page number of the part you wish to order.
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 catalogue text. The latest part number as conveyed through our service circulars should only appear on the order. In case of ordering coloured components, colour code of the components should be mentioned. The quantity shown against the part number is the quantity per vehicle for that group so that particular quantity should be multiplied by the number of sets required.
3.
Part number system: We have used 8 digit system for part numbers. The model or hardware item is indicated by first two digits or alphanumeric, the next two or four digits indicate main group and the last four or two digits indicate serial number in 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 enable you to identify the spare parts easily.
4.
Abbreviations : The following abbreviations are used in this catalogue. assly. N.I. C'case Cyl o/s. Std. A/t. R.H. L.H. W
Assembly Not illustrated Crankcase Cylinder Over size Standard Alternate Right hand Left hand Waluj
V AR accl. Comp. Fr L Rr Hex. A
Volts As required Accelerator Complete Front Length Rear Hexagonal Akurdi
INDEX PLATE NO.
DESCRIPTION
PAGE NO.
1
Cylinder head
1
2
Valve
2
3
Camshaft & Tensioner
3
4
Cylinder & piston
5
Crank shaft
6
6
Transmission
7
7
Change drum / Shift fork
8
8
Gear change mechanism
9
9
Crankcase RH / Engine assly.
10
10
Crankcase LH / Pipe oil
11
11
Engine cover
12
4&5
PLATE NO.
DESCRIPTION
PAGE NO.
31
Front fork (Gabrial)
52 to 54
32
Petrol tank & Side covers
55 to 57
with decal 33
Decal
34
Petro tank cap, Tap assly,
58 to 60 61&62
Fuel filter 35
Chain case
63
36
Fittings-Petrol tank, Side cover &
64
Cover seat 37
Meter assly
12&13
38
Control Cables
67
Clutch
14&15
39
Head lamp assly (4S Champion)
68
13
Kick starter mechanism
16&17
39A
Head lamp assly (Boxer)
69
14
Carburettor (keihin)
18 to 20
40
Turn signal lamp (4S Champion)
70
15
Air cleaner assly compl.
21
40A
Turn signal lamp (Boxer)
71
16
Muffler
22
41
Tail lamp assly / Bracket
72&73
17
Oil pump
23
42
Electrical equipments
74&75
18
Magneto assly (Nippon denso-NDIN)24to26
43
Tool kit
76
18A
Magneto assly (INEL)
27&28
44
Emblem & Marks
77
18B
Magneto assly (VARROC)
29&30
45
Seat assly
78
19
Frame and Stay
31&32
46
Accessories
79
20
Frame fitting
47
Fairing
80
21
Swing arm / Rear shock absorber
34&35
48
Main bracket
81
22
Stand and Step
36
49
Cover seat
82
23
Fender (Mudguard)
37&38
50
Rider seat & Pillion seat
83
24
Tyre
25
Front Hub
40&41
26
Rear hub
42&43
27
Brake pedal
44
28
Handle bar
45&46
29
Front fork (MSL)
47&48
30
Front fork (Endurance)
33
39
49 to 51
Part index
65&66
84 to 91
PICTORIAL INDEX PLATE NO. :
1
CYLINDER HEAD
PLATE NO. :
1
3
CAMSHAFT / TENSIONER
PLATE NO. : CRANK SHAFT
PAGE NO.
5
PAGE NO. 3
PAGE NO. 6
PLATE NO. :
BOXER & 4S CHAMPION 2
VALVE
PLATE NO. :
2
4
CYLINDER AND PISTON
PLATE NO. : TRANSMISSION
PAGE NO.
6
PAGE NO. 4&5
PAGE NO. 7
A
PICTORIAL INDEX PLATE NO. :
7
CHANGE DRUM / SHIFT FORK
PLATE NO. :
8
PAGE NO.
CRANKCASE RH / ENGINE ASSLY
10
11
PAGE NO.
PLATE NO. : ENGINE COVER
B
9
PAGE NO.
12 & 13
PLATE NO. :
BOXER & 4S CHAMPION 8
GEAR CHANGE MECHANISM
PLATE NO. :
10
CRANKCASE L.H. / PIPE OIL
PLATE NO. : CLUTCH
12
PAGE NO. 9
PAGE NO. 11
PAGE NO. 14 & 15
PICTORIAL INDEX PLATE NO. :
13
KICK STARTER MECHANISM
PLATE NO. :
15
AIR CLEANER ASSLY COMP.
PLATE NO. : OIL PUMP
17
PAGE NO. 16 & 17
PAGE NO. 21
PAGE NO. 23
PLATE NO. :
BOXER & 4S CHAMPION 14
CARBURETTER (KEIHIN)
PLATE NO. :
16
MUFFLER
18 PLATE NO. : MAGNETO ASSLY (NIPPON DENSO NDIN)
PAGE NO. 18 to 20
PAGE NO. 22
PAGE NO. 24 to 26
C
PICTORIAL INDEX PLATE NO. : 18A MAGNETO ASSLY (INEL)
PLATE NO. :
19
FRAME AND STAY
21 PLATE NO. : SWING ARM / REAR SHOCK ABSORBER
D
PAGE NO. 27 & 28
PAGE NO. 31 & 32
BOXER & 4S CHAMPION
PLATE NO. : 18B MAGNETO ASSLY (VARROC)
PLATE NO. :
20
FRAME FITTING
PAGE NO. 29 & 30
PAGE NO. 33
22
PAGE NO.
PLATE NO. :
34 & 35
STAND AND STEP
PAGE NO. 36
PICTORIAL INDEX PLATE NO. :
23
FENDER (MUDGUARD)
PLATE NO. :
25
FRONT HUB
PLATE NO. : BRAKE PEDAL
PAGE NO. 37 & 38
PAGE NO. 40 & 41
27
PLATE NO. :
BOXER & 4S CHAMPION 24
TYRE
PLATE NO. :
39
26
REAR HUB
PAGE NO.
PLATE NO. :
44
HANDLE BAR
PAGE NO.
PAGE NO. 42 & 43
28
PAGE NO. 45 & 46
E
PICTORIAL INDEX PLATE NO. :
29
FRONT FORK (MSL)
PLATE NO. :
31
FRONT FORK (GABRIAL)
PLATE NO. : DECAL
F
33
PAGE NO. 47 & 48
PAGE NO. 52 to 54
PAGE NO. 58 to 60
PLATE NO. :
BOXER & 4S CHAMPION 30
FRONT FORK (ENDURANCE)
PAGE NO. 49 to 51
32 PLATE NO. : PETROL TANK & SIDE COVERS WITH DECALS
PAGE NO.
34 PLATE NO. : PETROL TANK CAP, TAP ASSLY, FUEL FILTER
PAGE NO.
55 to 57
61 & 62
PICTORIAL INDEX PLATE NO. :
35
PAGE NO.
CHAIN CASE
PLATE NO. :
63
37
METER ASSLY
PLATE NO. :
39
HEAD LAMP ASSLY (4S CHAMPION)
PAGE NO.
BOXER & 4S CHAMPION
36 PLATE NO. : FITTINGS-PETROL TANK, SIDE COVER & COVER SEAT
PAGE NO.
PLATE NO. :
PAGE NO.
38
65 & 66
CONTROL CABLES
PAGE NO.
PLATE NO. : 39A
68
HEAD LAMP ASSLY (BOXER)
64
67
PAGE NO. 69
G
PICTORIAL INDEX 40
PAGE NO.
TURN SIGNAL LAMP (4S-CHAMPION)
70
41
PAGE NO.
PLATE NO. :
PLATE NO. :
TAIL LAMP ASSLY / BRACKET
PLATE NO. : TOOL KIT
H
43
72 & 73
PAGE NO. 76
BOXER & 4S CHAMPION
PLATE NO. : 40A TURN SIGNAL LAMP (BOXER)
PLATE NO. :
42
ELECTRICAL EQUIPMENT
PLATE NO. :
44
EMBLEM AND MARKS
PAGE NO. 71
PAGE NO. 74 & 75
PAGE NO. 77
PICTORIAL INDEX PLATE NO. :
45
SEAT ASSLY
PLATE NO. :
78
47
FAIRING
PLATE NO. : COVER SEAT
PAGE NO.
PAGE NO. 80
49
PAGE NO. 82
PLATE NO. :
BOXER & 4S CHAMPION 46
ACCESSORIES
PLATE NO. :
79
48
MAIN BRACKET
PLATE NO. :
PAGE NO.
PAGE NO. 81
50
RIDER SEAT AND PILLION SEAT
PAGE NO. 83
I
PLATE NO. 1 : CYLINDER HEAD
BOXER & 4S CHAMPION
6 3
8
2
4
9 1 7
5
4
7 10
11
3 1
2
19 5
18
17
14 12
14 12
4
15
13
5 16
3
Fig. No.
Part No.
Description
Qty / Veh.
1 2 3 4 5
39 1020 21 31 1010 06 39 1063 01 39 0732 12 39 0198 11
Ring O Cap Hex Screw Washer Spring Plain Washer
2 2 6 6 6
2 2 6 6 6
2 2 6 6 6
6 7 8 9 10
39 1012 04 39 0946 05 39 1010 04 31 10 1130 31 10 1005
Bolt Stud Bolt Head Comp. Cylinder Guide Valve
2 2 4 1 2
2 2 4 1 2
2 2 4 1 2
11 12 13 14 15
39 1021 21 39 1000 06 31 1011 31 39 1017 21 31 1011 75
Ring O Hollow Dowel Pin Gasket Head Ring O Insulator
2 2 1 2 1
2 2 1 2 1
2 2 1 2 1
16 17 18 19
31 1011 32 39 1074 04 31 1010 07 39 1016 21
Pipe Intake Bolt Cover Ring O
1 2 1 1
1 2 1 1
1 2 1 1
4S Champ. Boxer CT
Remark Boxer AT
1
PLATE NO.
2 : VALVE
BOXER & 4S CHAMPION
2
14
14
3
2
4
5
6 4
1
3
7 8
7
6 8 1
9
9 10 11
10 11
13 12
2
Fig. No.
Part No.
Description
Qty / Veh.
1
31 1010 21
Shaft Rocker
2
2
2
2 3
DD 1011 20 39 0973 15
Screw Nut
2 2
2 2
2 2
4 5
31 1010 20 31 1011 04
Arm Rocker Stopper
2 1
2 1
2 1
6
39 0702 01
Screw Pan Cros
2
2
2
7 8
31 1010 19 31 1010 18
Collet Retainer Valve Spring
4 2
4 2
4 2
9 10
31 1010 22 39 1035 19
Spring Engine Valve Seal Oil
2 2
2 2
2 2
11
31 1010 45
Seat Spring
2
2
2
12 13
DD 1011 34 DD 1011 35
Valve Intake Valve Exhaust
1 1
1 1
1 1
14
31 1012 35
Rocker arm assembly
2
2
2
4S Champ. Boxer CT
Remark Boxer AT
Alt. 31101200 or 31101016 Alt. 31101201 or 31101017
3 : CAMSHAFT / TENSIONER
PLATE NO.
BOXER & 4S CHAMPION 5 4
3 4
6
9 2
1
8
7 19
18 10
2 1
15
17
14
16 11
13
12
Fig. No.
Part No.
Description
Qty / Veh.
1 2 3 4 5
39 0748 01 39 0999 06 31 1010 26 22 1504 51 31 1010 24
Screw Pan Cros Hollow dowel Pin Guide Chain Screw Sprocket (28 T)
2 2 1 2 1
2 2 1 2 1
2 2 1 2 1
6 7 8 9 10
DD 1010 63 31 1011 21 31 1010 33 31 1010 25 31 1011 70 39 1049 04
Camshaft Comp. Camshaft Comp. Chain Guide Chain Tensioner Assembly Bolt
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
11 12 13 14 15
30 1011 41 31 1010 27 39 1063 01 39 0732 12 39 0198 11
Washer Tensioner Hex. Screw Washer Spring Plain Washer
1 1 2 2 2
1 1 2 2 2
1 1 2 2 2
16 17 18 19 20
39 1014 21 31 1011 20 31 1010 30 31 1010 28 31 1010 29
Ring O Retainer Spring Rod Push Collar
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
4S Champ. Boxer CT
Remark Boxer AT
From May 99 (Similar to Caliber) Upto April 99
Not illustrated
3
PLATE NO.
4 : CYLINDER AND PISTON
BOXER & 4S CHAMPION
10 2 4/6
1 3 1
5/7
8 9
8
Fig. No.
Part No.
1
39 1000 06
Hollow dowel Pin
2
2
2
2
31 1012 78 31 1010 10
Cylinder complete Cylinder Complete
1 1
1 1
1 1
From Aug. 99.
31 1012 77 31 1010 09
Gasket Gasket
1 1
1 1
1 1
For 31101278
31 1011 82 31 1011 85
Piston assly std Piston assly 1st o/s
1 1
1 1
1 1
KHI
31 1011 87 31 1013 02
Piston assly 2nd o/s Piston ring set std.
1 1
1 1
1 1
KHI
31 1013 03
Piston ring set 1st o/s
1
1
1
3 4
5
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
Upto July 99
For 31101010
KHI
KHI with chrome plated taper 2nd piston ring KHI with chrome plated taper 2nd piston ring
31 1013 04
Piston ring set 2nd o/s
1
1
1
31 1012 49
Piston ring set std.
1
1
1
KHI with chrome plated taper 2nd piston ring KHI whithout chrome plating & taper 2nd piston ring
31 1012 50
Piston ring set - 1st o/s
1
1
1
31 1012 51
Piston ring set - 2nd o/s
1
1
1
KHI whithout chrome plating & taper 2nd piston ring
4
KHI whithout chrome plating & taper 2nd piston ring
PLATE NO.
4 : CYLINDER AND PISTON
BOXER & 4S CHAMPION 10 2 4/6
1 3 1
5/7
8 9
8
Fig. No.
Part No.
6
31 1013 07 31 1013 10
Piston assly std Piston assly 1st o/s
1 1
1 1
1 1
Shriram Piston & Rings Ltd
31 1013 12 31 1012 88
Piston assly 2nd o/s Piston rings set std
1 1
1 1
1 1
Shriram Piston & Rings Ltd
31 1012 89 31 1012 90
Piston rings set 1st o/s Piston rings set 2nd o/s
1 1
1 1
1 1
Shriram Piston & Rings Ltd
8 9
39 0985 17 31 1010 34
Wire Circlip Pin Piston
2 1
2 1
2 1
10
31 1013 14
Cylinder Block Piston assly
1
1
1
7
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
Shriram Piston & Rings Ltd
Shriram Piston & Rings Ltd
Shriram Piston & Rings Ltd
5
PLATE NO.
5 : CRANK SHAFT
BOXER & 4S CHAMPION
4 4
2
1 5 6
3
13
8 9 11
10
12 7
6
Fig. No.
Part No.
Description
Qty / Veh.
1 2
39 1055 15 01 1006 10
Nut Woodruff Key
1 1
1 1
1 1
3 4
31 1012 91 31 1011 73
Crankshaft Comp. Key Woodruff
1 2
1 2
1 2
5
31 1010 76
Gear Primary, Helical (23 T)
1
1
1
6 7
31 1010 75 31 1210 07
Gear (21 T) Cover
1 1
1 1
1 1
8 9
39 1072 01 39 0732 12
Hex. Screw Washer Spring
3 3
3 3
3 3
10
39 0198 11
Washer Plain
3
3
3
11 12
39 1046 19 39 1053 15
Seal Oil Nut
1 1
1 1
1 1
13
31 1011 18
Filter
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
Alt. to 31101107
PLATE NO.
6 : TRANSMISSION
BOXER & 4S CHAMPION
6 5 4
7
3 2
8
1 9
4
10
14 13 12
11
Fig. No.
Part No.
1 2 3 4 5
39 0994 11 31 1010 78 31 1010 79 39 0987 17 31 1010 82
Plain washer Gear Transmission Spur(2nd,17T) Gear Transmission Spur(3rd,26T) Ring Snap (16 mm) Gear Transmission Spur(Top,29T)
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
6 7 8 9 10
31 1012 19 31 1012 21 31 1010 84 31 1010 83 31 1010 80
Shaft Transmission Input(1st,13T) Gear Transmission Spur(Low,43T) Gear Transmission Spur(Top 28T) Gear Transmission Spur(3rd, 31T) Shaft Transmission Output (2nd, 30T)
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
11 12
39 0989 17 DD 1011 36 31 101115 31 1011 17 31 1012 16 39 1018 21
Circlip Sprocket Output Sprocket Output Collar (Steel) Collar (Sintered) ‘O’ Ring
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
13 14
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
From Jan 00 Upto Dec. 99
Alt. to 31 10 1117
7
PLATE NO.
7 : CHANGE DRUM / SHIFT FORK
BOXER & 4S CHAMPION
2 4 5
6 1
7
2 8
3
9
8
Fig. No.
Part No.
Description
Qty / Veh.
1
31 10 1081 31 10 1191
Fork Shift Fork Shift
1 1
1 1
1 1
2 3
31 10 1051 31 10 1168
Rod shift Drum assly. change
2 1
2 1
2 1
4 5
39 0702 01 31 10 1048
Screw pan cros Holder
1 1
1 1
1 1
6
39 0992 06
Pin dowel
5
5
5
7 8
31 10 1049 15 18 1034
Drum change Hammer drive screw
1 1
1 1
1 1
9
31 10 1047 31 10 1192
Fork shift Fork shift
1 1
1 1
1 1
4S Champ. Boxer CT
Remark Boxer AT
Alt. to 31 10 1081
Alt. to 31 10 1047
PLATE NO.
8 : GEAR CHANGE MECHANISM
BOXER & 4S CHAMPION
5 3 4
5 1
2
7 10
9
6
8
12 14
11 13
15
Fig. No.
Part No.
Description
Qty / Veh.
1 2
31 10 1103 30 10 1086
Lever Bolt
1 1
1 1
1 1
3 4
31 10 1110 31 10 1105
Spring Plate Position
1 1
1 1
1 1
5
39 0746 01
Screw Pan Cros
2
2
2
6
DD 1010 77 31 10 1099
Lever Comp. Change Shaft Lever Comp. Change Shaft
1 1
1 1
1 1
7 8
31 10 1054 31 10 1109
Spring Collar
1 1
1 1
1 1
9 10
31 10 1055 DD 1011 06
Spring Bolt
1 1
1 1
1 1
4S Champ. Boxer CT
Remark Boxer AT
11
39 0198 11
Plain Washer
1
1
1
12 13
39 0732 12 39 1069 01
Washer Spring Hex. Screw
1 1
1 1
1 1
14
DD 1010 71 31 10 1149
Lever Change Lever Change
1 1
1 1
1 1
15
31 10 1108
Damper
1
1
1
From Jan. 99 (Similar to Caliber) Upto Dec. 98
From Jan. 99 (Similar to Caliber) Upto Dec. 98
9
PLATE NO. 9 : CRANKCASE RH / ENGINE ASSLY.
BOXER & 4S CHAMPION 1
6 7
2 3 1 5
8 1 12 2 4
3
9
2
10 11
Fig. No.
Part No.
Description
Qty / Veh.
1 2
39 1225 15 39 0248 11
Nut Plain Washer
3 3
3 3
3 3
3 4
39 1068 04 39 1056 04
Bolt Bolt
2 1
2 1
2 1
5
39 1864 20
Bearing Ball
1
1
1
6 7
39 0999 06 01 1701 11
Dowel Pin Bearing
3 1
3 1
3 1
8 9
31 12 1100 31 10 1106
Oil Strainer Gasket
1 1
1 1
1 1
10
39 1048 04
Plug
1
1
1
11 12
36 3110 21 01 1701 10
Gasket (Liquid) Bearing
* 1
* 1
* 1
* as required
13
31 10 1002 DF 1010 10
Engine Assembly Engine Assembly
1 --
1 --
-1
Not Illustrated
14
31 1012 73
Crank case assly.
1
1
1
Upto July 98 (M5 size stator
15
DD 1011 03
Crank case assly
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
Alt. to 39100720
Not Illustrated
plate mounting bolts)
10
From August 98 (M6 size stator plate mounting bolts)
PLATE NO.
10 : CRANKCASE - L.H. / PIPE OIL
BOXER & 4S CHAMPION
2
3
1 1
4
2 1 6
1 18
5
7
19
17
8
16 15 9 14 14 12 13 11
Fig. No.
Part No.
1 2 3 4 5
31 12 1006 39 1023 04 31 12 1034 39 1062 04 31 10 1172
Gasket Bolt Pipe Oil Bolt Flanged Small Fitting
4 2 1 1 1
4 2 1 1 1
4 2 1 1 1
6 7 8 9 10
30 14 1015 31 10 1176 01 1701 11 39 1050 06 39 1066 04
Clamp Tube Rubber Ball Bearing Dowel Pin Bolt Flanged Small
1 1 1 1 3
1 1 1 1 3
1 1 1 1 3
11 12 13 14 15
39 1043 19 39 1080 19 39 1008 20 39 0702 01 31 10 1056
Oil Seal Seal Oil Bearing Needle Screw Pan Cros Guide
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
16
31 20 1026 31 2010 81 39 0703 11 39 1075 04 30 1010 15
Switch Comp. Switch Comp. Plain Washer Bolt Flanged Small Gasket
1 1
1 -* 6 1
1 -* 6 1
17 18 19
Description
10 Qty / Veh. 4S Champ. Boxer CT
* 6 1
Remark Boxer AT
Upto Nov 97 for 4S Champion * as required
11
PLATE NO.
11 : ENGINE COVER
BOXER & 4S CHAMPION 4
6
5 2
1
9 3
11
7
9
12 13
8
10 14 19 9 22
15 16
18 17
12
Description
20
Fig. No.
Part No.
Qty / Veh.
1 2
31 1010 62 39 1019 21
Bolt Ring O
1 1
1 1
1 1
3 4
31 1012 95 31 1010 61
Cover Generator Plug
1 1
1 1
1 1
5
31 1011 13
Gasket
1
1
1
6 7
DD 1010 58 39 1074 04
Gasket Bolt Flanged Small
1 5
1 5
1 5
8 9
DD 1010 60 39 0999 06
Gasket Pin
1 4
1 4
1 4
10
31 1012 69
Clutch Cover / Graphics
1
1
1
11 12
31 1010 63 39 1015 21
Cap Oil Filler Ring O
1 1
1 1
1 1
13 14
39 1075 04 31 1010 67
Bolt Flanged Small Gauge
10 1
10 1
10 1
15
30 1011 42
Seal Oil
1
1
1
4S Champ. Boxer CT
21 Remark
Boxer AT
PLATE NO.
11 : ENGINE COVER
BOXER & 4S CHAMPION 4
6
5 2
1
9 3
11
7
9
12 13
8
10 14 19 9 22
15 16
18 17 Fig. No.
Part No.
Description
20 Qty / Veh.
4S Champ. Boxer CT
21 Remark
Boxer AT
16 17
39 1041 19 DD 1010 74
Seal Oil Cover Chain
1 1
1 1
1 1
18 19
39 2147 04 31 1012 76
Bolt Flanged Small Decal (Race Technology)
3 1
3 1
3 1
20
DD 1010 75
Damper
1
1
1
21 22
DD 1010 76 39 1791 04
Plate Bolt
1 5
1 5
1 5
From August 98.
13
PLATE NO.
12 : CLUTCH
BOXER & 4S CHAMPION 6
5
3 1
8
2
9
7 4
12
13
11 1
20
19
10
18 15 14
25 17
18
16
22
23
24
21
14
Fig. No.
Part No.
Description
Qty / Veh.
1 2
DD 1010 69 39 1033 09
Housing Comp. Clutch Rivet
1 3
1 3
1 3
3 4
31 10 1140 DD 1010 67
Holder Spring
1 2
1 2
1 2
Alt. to 31101143
5
DD 1011 10
Spring
3
3
3
Alt. to 31101142
6 7
31 10 1077 DD 1010 68
Gear Primary Helical Spring
1 1
1 1
1 1
Alt. to 31101141
8 9
39 1057 11 31 10 1139
Washer Housing Clutch
1 1
1 1
1 1
10
DD 1010 70
Clutch Assly.
1
1
1
11 12
39 1058 11 31 10 1146
Plain Washer Collar
1 1
1 1
1 1
13 14
DD 1010 98 31 10 1135
Plate Assly. Clutch Wheel Clutch
1 1
1 1
1 1
Alt. to 31101134
15
DD 1010 99
Plate Friction
4
4
4
Alt.to 31101046
4S Champ. Boxer CT
Remark Boxer AT Alt. to 31101138
Alt. to 31101133
PLATE NO.
12 : CLUTCH
BOXER & 4S CHAMPION
6
5
3 1
8
2
9
7 4
12
13
11 1
20
19
10
18 15 14
25 17
18
16
22
23
24
21
Fig. No.
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
16 17
30 10 1096 31 10 1136
Plate Clutch Hub Clutch
3 1
3 1
3 1
18 19
30 10 1098 DD 1010 79
Spring Holder
6 1
6 1
6 1
20
39 0980 04
Hex. Bolt
6
6
6
21 22
39 1053 15 31 10 1147
Nut Holder
1 1
1 1
1 1
23 24
39 1034 20 31 10 1148
Bearing Rod Push
1 1
1 1
1 1
25
31 10 1144
Lever Complete
1
1
1
Alt to DD101178 Alt. to 31101137
15
PLATE NO. 13 : KICK STARTER MECHANISM
BOXER & 4S CHAMPION
5 3
7 4
8
2
12
6
14
1
17 19
11
10
14
9 18 17 16
14
15 17 20
14 21
22 13
16
23
Fig. No.
Part No.
Description
Qty / Veh.
1 2
39 0198 11 39 0732 12
Plain Washer Washer Spring
1 1
1 1
1 1
3 4
39 1069 01 31 1012 64
Hex. screw Lever Assly Kick
1 1
1 1
1 1
Lever Assly Kick Damper
1 1
1 1
1 1
From Feb. 99 (Similar to Caliber)
5
DD 1010 94 DD 1010 97
6
DD 1010 95
Lever kick
1
1
1
For DD101094
Lever Kick Pin
-1
1 1
1 1
For 31101264
7
31 1011 27 31 1010 44
8 9
30 1012 34 30 1012 36
Spring Ball Steel
2 2
2 2
2 2
Qty. 1 for 31101127
10
31 1012 60 31 1012 63
Boss Kick Boss Kick
1 1
1 1
1 1
For 31101264
DD 1010 96
Boss Kick
1
1
1
For DD101094
4S Champ. Boxer CT
Remark Boxer AT
Upto Jan. 99
For DD101094
Qty. 1 for 31101127
Alt. to 31101260
13 : KICK STARTER MECHANISM
PLATE NO.
BOXER & 4S CHAMPION
5 3
7 4
8
2
12
6
14
1
17 19
11
10
14
9 18 17 16
14
15 17 20
14 21
22 13
23
Fig. No.
Part No.
Description
Qty / Veh.
11 12
39 0855 17 31 1011 23
Circlip Shaft Assly Kick
1 1
1 1
1 1
13 14
39 0993 11 39 0738 17
Washer Circlip Type C
1 4
1 4
1 4
15
31 1010 39
Coil Spring
1
1
1
16 17
31 1010 38 39 0995 11
Ratchet (Forging) Washer
1 2
1 2
1 2
18 19
31 1011 24 31 1012 18
Shaft Kick Gear Spur
1 1
1 1
1 1
20
31 1010 40
Guide
1
1
1
21 22
31 1010 41 39 1920 01
Spring Screw Pan Cros
1 2
1 2
1 2
23
DD 1012 54
Guide Kick
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
17
PLATE NO.
14 : CARBURETTOR (KEIHIN)
BOXER & 4S CHAMPION 5
38
39
4
3 2 7
35
8
34
37
9 10
6
33
11
32
12
31 36 41
13
40
14
43 44 15
42
16
18 29
20
30
1
17
19
28 21 27
22
25 23
26
24
18
Fig. No.
Part No.
Description
Qty / Veh.
1
31 1211 48 31 12 1001
Carburettor Assly. (Keihin PC 18) Carburettor Assly. (Keihin PC 18)
1 1
1 --
1 --
2 3
31 12 1062 31 12 1063
Nut Adjuster Cable
1 1
1 1
1 1
4 5
30 12 1004 31 12 1064
Ring Snap Cap Top
1 1
1 1
1 1
6
31 12 1061
Top Complete
1
1
1
7 8
31 12 1060 31 12 1059
Top gasket Spring Throttle
1 1
1 1
1 1
9 10
31 12 1058 31 12 1057
Plate Needle Clip Clip
1 1
1 1
1 1
11
31 1211 55
Jet Needle (N7EB)
1
1
1
12
31 12 1056 31 12 1055
Jet Needle (N97 G) Valve Throttle (28 B)
1 1
-1
-1
13 14
31 12 1068 31 12 1067
Spring Screw
1 1
1 1
1 1
15
31 12 1066
Spring
1
1
1
4S Champ. Boxer CT
Remark Boxer AT From Sept. 99
For 31121148
PLATE NO.
14 : CARBURETTOR (KEIHIN)
BOXER & 4S CHAMPION 5
38
39
4
3 2 7
35 34
37
9 10
6 8
33
11
32
12
31 36 41
13
40
14
43 44 15
42
16
18 29
17
19 20
30
1
28 21 27
22
25 23
26
24 Fig. No.
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
16
31 12 1065 31 12 1098
Screw (120) Screw (50)
1 1
-1
-1
17 18
31 12 1070 31 12 1071
Slow Jet Valve Complete
1 1
1 1
1 1
19 20
31 12 1072 31 12 1074
Float Complete Gasket
1 1
1 1
1 1
21
31 12 1076
Screw
1
1
1
22 23
31 12 1075 30 12 1018
Ring O Ring Snap
1 2
1 2
1 2
24 25
31 12 1087 31 12 1069
Tube (Over flow) Screw
1 2
1 2
1 2
26
31 12 1077
Main Jet (78)
1
1
1
27 28
31 12 1078 31 12 1079
Holder Holder
1 1
1 1
1 1
29 30
31 12 1089 DD 1210 31
Needle Jet Pin
1 1
1 1
1 1
31 12 1073
Pin
1
--
--
For 31121148
19
PLATE NO.
14 : CARBURETTOR (KEIHIN)
BOXER & 4S CHAMPION 5
38
39
4
3 2 7
35
8
34
37
9 10
6
33
11
32
12
31 36 41
13
40
14
43 44 15
42
16
18 29
17
19 20
30
1
28 21 27
22
25 23
26
24
20
Fig. No.
Part No.
Description
Qty / Veh.
31 32
39 0287 15 31 12 1085
Nut Dish Lock Washer
1 1
1 1
1 1
33 34
39 0900 12 39 1204 11
Spring Washer Plain Washer
1 1
1 1
1 1
35
31 12 1084
Sealing seat/Seat ring
1
1
1
36
DD 1210 19 31 12 1083
Choke link Choke link
1 1
1 --
1 --
37 38
31 12 1082 31 12 1081
Choke dust cap Choke shaft
1 1
1 1
1 1
39 40
31 12 1086 31 12 1080
Choke valve complete 'O' Ring
1 1
1 1
1 1
41
31 12 1008
Holder Carburettor
1
1
1
42 43
39 0972 04 31 12 1015
Bolt Socket Clamp
2 1
2 1
2 1
44
31 1211 49
Body Complete
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
For 31121148
PLATE NO.
15 : AIR CLEANER ASSLY. COMP.
BOXER & 4S CHAMPION 3
2
4 5
1
9 6
7
19
8
15
18 11
10
14
17 16
13
12
Fig. No.
Part No.
1 2
5
31 12 1050 31 12 1014 31 12 1134 31 12 1016 31 12 1135 DD 1211 00 31 12 1028 31 12 1133 31 12 1038
Tube (Air vent) Clamp Clamp Filter Assly Air Filter Assly Air Filter Assly Air Duct Duct Arrester Comp. Flame
1 1 -1 --1 -1
1 -2 -1 --1 1
1 -2 -1 1 -1 1
6 7 8 9 10
31 12 1041 31 12 1043 39 0711 11 39 0747 01 31 12 1029
Clamp Collar Washer plain Screw Pan Cros Element Air Filter
1 2 2 2 1
-2 2 2 1
-2 2 2 1
11 12 13 14 15
31 12 1037 31 12 1030 31 12 1021 39 0830 01 01 1106 09
Plate Duct Case Air Filter Screw Pan Cross Plain Washer
1 1 1 4 4
1 1 1 4 4
1 1 1 4 4
16 17 18 19
31 12 1023 31 12 1042 31 12 1052 39 1189 23
Cap 'O' ring for air filter Gasket for air filter Grommet
1 1 1 1
1 1 1 1
1 1 1 1
3
4
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
21
PLATE NO.
16 : MUFFLER
BOXER & 4S CHAMPION
1
12 11
3
10
4
2
5
9
13 8 7 6
22
Fig. No.
Part No.
Description
Qty / Veh.
1 2
31 10 1014 39 0198 11
Gasket Plain Washer
1 2
1 2
1 2
3 4
39 0732 12 39 0834 15
Spring washer Nut
2 2
2 2
2 2
5
31 10 1111 DD 1012 15
Muffler Muffler
1 1
1 1
1 1
6
39 1071 01
Hex. Screw
1
1
1
7 8
39 0789 12 39 0248 11
Washer Spring Plain Washer
1 1
1 1
1 1
9 10
31 10 1197 30 15 1042
Shield Washer A
1 2
1 2
1 2
4S Champ. Boxer CT
Remark Boxer AT
11
39 0790 12
Spring washer
2
2
2
12
39 0007 01 39 1489 01
Bolt Bolt
2 2
2 2
2 2
13
31 10 1266
Tail end piece
1
1
1
Upto June 2000 From July 2000
PLATE NO. 17 : OIL PUMP
BOXER & 4S CHAMPION
1
2
3
4
1
6
5
Description
6
Fig. No.
Part No.
Qty / Veh.
1 2
39 1078 01 39 0753 01
Screw Pan Cros Screw Pan Cros
2 1
2 1
2 1
3
31 12 1044 DF 1210 03
Pump Assly. Oil Pump Assly. Oil without lug
1 1
1 1
1 1
4 5
31 12 1045 39 0999 06
Gear Pin dowel
1 1
1 1
1 1
6
39 1013 21
Ring ‘O’
2
2
2
4S Champ. Boxer CT
Remark Boxer AT
Upto August. 2000. From Sept. 2000.
23
BOXER & 4S CHAMPION
PLATE NO. 18 : MAGNETO ASSLY (NIPPON DENSO- NDIN) 6
7 4
5
3
1 2
10
26
11 12
8 9
25
13
24 10 23 11
22
12
14 18 21
17 15
10
19
11 12
27
16
20
Fig. No.
Part No.
1
31 1110 39
Magneto assly (For M6 Screw)
1
1
--
From Aug. 98 Alt. to 31111053
31 1110 19
Magneto assly (For M5 Screw) (For R/R Unit)
1
--
--
From Feb. 95
31 1110 10
Magneto assly (For Rectifier & AC Regulator)
1
--
--
31 1110 46 31 1110 17
Rotor assly Rotor assly
1 1
1 --
---
For 31111039 & 31111019
31 1110 61 31 1110 47
Stator assly (For M6 Screws) Stator assly (For M5 Screws)
1 1
1 --
---
For 31111039
Stator assly Seal Oil
1 1
-1
---
For 31111010
4
31 1110 18 39 1042 19
5
39 1003 20
Bearing ball
1
1
--
6 7
39 1028 21 31 1110 04
Ring ‘O’ Gasket
1 1
1 1
---
8
31 1110 38 31 1110 11
Gasket Ignitor
1 1
1 1
---
9 10
31 1110 08 39 0092 04
Damper Bolt
1 2
1 2
---
2 3
24
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
Upto July 98.
Upto Jan 95.
For 31111010
For 31111019
Upto July 98. (For M5 Screw) From Aug. 98. (For M6 Screw)
BOXER & 4S CHAMPION
PLATE NO. 18 : MAGNETO ASSLY (NIPPON DENSO- NDIN) 6
7 4
5
3
1 2
10
26
11 12
8 9
25
13
24 10 23 11
22
12
14 18 21
17 15
10
19
11 12
27
16
20
Fig. No.
Part No.
Description
Qty / Veh.
11 12
39 0732 12 39 0219 11
Washer Spring Plain Washer
2 2
2 2
---
13 14
31 2010 45 30 2010 77
Regulator/Rectifire (R/R) unit Rectifire
1 1
1 --
---
From Feb. 95
15
30 2010 86
Regulator voltage assly
1
--
--
Upto Jan. 95.
16
31 2010 32 31 2010 46
D.C. Regulator assly Charging regulator
1 1
---
---
Upto Jan. 95
17 18
31 1110 01 31 1110 14
Cap assly plug Grommet
1 1
1 1
---
19
DD 1110 12 31 1110 12
Grommet Cap Spark Plug (With resistor)
1 1
1 1
---
20
31 1110 05
Plug Spark (NGKC7HSA or MICO 2A)
1
1
--
31 1110 30 31 1110 27
Plug Spark UR2A Plug Spark UR2AS
1 1
1 1
---
4S Champ. Boxer CT
Remark Boxer AT
Upto Jan. 95
Alt to 31201032
From Dec. 98 Alt. to 31111028
25
BOXER & 4S CHAMPION
PLATE NO. 18 : MAGNETO ASSLY (NIPPON DENSO-NDIN) 6
7 4
5
3
1 2
10
26
11 12
8 9
25
13
24 10 23 11 12
22 14 18 21
17 15
10
19
11 12
27
16
20
Fig. No.
Part No.
Description
Qty / Veh.
21
31 1110 07
Coil Ignition with cap
1
1
--
Upto Jan. 98
Coil Ignition without cap Screw pan cross
1 2
1 2
---
From Feb. 98
22
TE 0063 03 39 0745 01
23
39 0991 04 39 1613 04
Bolt Bolt
3 3
3 3
---
Upto Jul. 98 (M5 Screws)
24
31 1110 50 31 1110 26
Pulser coil Pluser coil
1 1
1 --
---
For Magneto assly 31111039
4S Champ. Boxer CT
Remark Boxer AT
From Aug. 98 (M6 Screws)
For Magneto assly 31111010 & P.No. 31111019
25
31 1110 49
Exciter Coil
1
1
--
For Magneto assly 31111039
31 1110 25
Exciter coil
1
--
--
For Magneto assly 31111010 & 31111019
26
26
31 1110 48
Lamp coil assly
1
1
--
For Magneto assly 31111039
27
31 1110 13 DD 1110 11
Grommet Grommet
1 1
1 1
---
From Dec. 98.
BOXER & 4S CHAMPION
PLATE NO. 18A : MAGNETO ASSLY (INEL) 6
5
4 3
1 2 23
7 9
8
21
22
20 19 10 11 12
15
13
18 16 14
24 17
Fig. No.
Part No.
Description
Qty / Veh.
1
31 1110 53 31 1110 19
Magneto assly (For M6 Screws) Magneto assly (For M5 Screws)
1 1
1 1
---
From July 99 Alt. to. 31111039
2
31 1110 20
Rotor assly
1
1
--
For 3111053, 31111039 &
4S Champ. Boxer CT
Remark Boxer AT
Upto July 98
31111019
3
31 1110 40 31 1110 21
Startor assly (For M6 Screws) Startor assly (For M5 Screws)
1 1
1 1
---
4 5
39 1042 19 39 1003 20
Seal Oil Bearing ball
1 1
1 1
---
6
39 1028 21
Ring ‘O’
1
1
--
7
31 1110 04 31 1110 38
Gasket Gasket
1 1
1 1
---
8 9
31 1110 22 31 1110 08
Ignitor assly Damper
1 1
1 1
---
10
39 0092 04
Bolt
2
2
--
11 12
39 0732 12 39 0219 11
Washer Spring Plain Washer
2 2
2 2
---
13 14
31 2010 45 31 1110 01
Regulator/Rectifire (R/R) unit Cap assly plug
1 1
1 1
---
For 31111039 & 31111053 For 31111019
Upto July 98. From Aug. 98
27
BOXER & 4S CHAMPION
PLATE NO. 18A : MAGNETO ASSLY (INEL) 6
5
4 3
1 2 23
7 9
8
21
22
20 19 10 11 12
15
13
18 16 14
24 17
Fig. No.
Part No.
15
31 1110 14
Grommet
1
1
--
DD 1110 12
Grommet
1
1
--
From Dec. 98
31 1110 12 31 1110 05
Cap Spark Plug (With resistor) Plug Spark (NGKC7HSA or
1 1
1 1
---
Alt. to 31111028
31 1110 30
MICO 2A) Plug Spark UR2A
1
1
--
18
31 1110 27 31 1110 07
Plug Spark UR2AS Coil Ignition with cap
1 1
1 1
---
Coil Ignition without cap Screw pan cross
1 2
1 2
---
From Feb. 98
19
TE 0063 03 39 0745 01
20
39 0991 04 39 1613 04
Bolt Bolt
3 3
3 3
---
Upto Jul. 98 (M5)
21 22
31 1110 33 31 1110 34
Exciter coil Pulser Coil
1 1
1 1
---
23 24
31 1110 32 31 1110 13
Lamp coil assly Grommet
1 1
1 1
---
DD 1110 11
Grommet
1
1
--
16 17
28
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
Upto Jan. 98
From Aug. 98 (M6)
From Dec. 98.
BOXER & 4S CHAMPION
PLATE NO. 18B : MAGNETO ASSLY (VARROC) 6
5
4 3
1 2 23
7 21
9
8
22
20 19 10 11 12
15
13
18 16 14
24 17
Fig. No.
Part No.
Description
Qty / Veh.
1
31 1110 53
Magneto assly
1
1
--
Alt. to 31111039
2
DF 1110 01 31 1110 54
Magneto assly Rotor assly
-1
-1
1 1
For 3111053, DF111001
3
31 1110 55 DF 1110 04
Startor assly Startor assly
1 --
1 --
-1
4 5
39 1042 19 39 1003 20
Seal Oil Bearing ball
1 1
1 1
1 1
6
39 1028 21
Ring ‘O’
1
1
1
7 8
31 1110 38 31 1110 52
Gasket Ignitor assly
1 1
1 1
1 1
9 10
31 1110 08 39 0092 04
Damper Bolt
1 2
1 2
1 2
11
39 0732 12
Washer Spring
2
2
2
12 13 14 15
39 0219 11 31 2010 45 31 1110 01 31 1110 14 DD 1110 12
Plain Washer Regulator/Rectifire (R/R) unit Cap assly plug Grommet Grommet
2 1 1 1 1
2 1 1 1 1
2 1 1 1 1
4S Champ. Boxer CT
Remark Boxer AT
For 31111053 For DF111001
From Dec. 98
29
BOXER & 4S CHAMPION
PLATE NO. 18B : MAGNETO ASSLY (VARROC) 6
5
4 3
1 2 23
7 9
8
21
22
20 19 10 11 12
15
13
18 16 14
24 17
Fig. No.
Part No.
16 17
31 1110 12 31 1110 05
18 19 20 21 22 23 24
30
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
1 1
1 1
1 1
31 1110 30 31 1110 27 31 1110 07 TE 0063 03 39 0745 01 39 1613 04
Cap Spark Plug (With resistor) Plug Spark (NGKC7HSA or MICO 2A) Plug Spark UR2A Plug Spark UR2AS Coil Ignition with cap Coil Ignition without cap Screw pan cross Bolt
1 1 1 1 2 3
1 1 1 1 2 3
1 1 1 1 2 3
31 1110 56 31 1110 58 31 1110 57 DF 1110 05 31 1110 13 DD 1110 11
Exciter coil assly Pulser Coil assly Lamp coil assly Lamp coil assly Grommet Grommet
1 1 1 -1 1
1 1 1 -1 1
1 1 -1 1 1
Alt., to 31111028
Upto Jan. 98 From Feb. 98
For 31111053 & DF111001 For 31111053 & DF111001 For 31111055 For DF111004
From Dec. 98.
BOXER & 4S CHAMPION
PLATE NO. 19 : FRAME AND STAY
5 6 8 9
4
7 12 11
3
11 14
1 9
2
10 13 8
16
15
17
13
18 20
11 14 19
Fig. No.
Part No.
Description
Qty / Veh.
1 2
39-0062-04 39-0732-12
Bolt Washer Spring
1 1
1 1
1 1
3 4
39-0219-11 31-19-1002
Washer Plain Clamp
1 1
1 1
1 1
5
30-18-1011
Nut
1
1
1
6 7
30-18-1010 30-18-1007
Cap Bearing Cone
1 1
1 1
1 1
8 9
30-18-1006 30-18-1008
Ball Steel Bearing Race
46 2
46 2
46 2
10
39 1784 04
Bolt
3
3
3
From Mar. 99
11 12
39-1040-11 DD-1610-52
Plain Washer Bracket Engine
10 2
10 2
10 2
From Mar. 99 (Similar to Caliber)
Barcket Engine Washer Spring
2 5
2 5
2 5
Upto Feb. 99
13
31 1610 20 39-0788-12
14
39-0792-15 39-0694-15
Nut Hex. Small (12 A/F) Hex. Lock Nut (13 A/F)
5 5
-5
-5
Upto Apr. 97
15
39-0876-04
Bolt
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
From May 97
31
PLATE NO.
BOXER & 4S CHAMPION
19 : FRAME AND STAY
5 6 8 9
4
7 12 11
3
11 14
1 9
2
10 13 8
16
15
17
13
18 20
Fig. No. 16 17 18
19
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
31-16-1097 31 1610 01 31-2210-27 31 2210 10 DF 2210 05 DD 1610 53 31 1610 19 39-1060-04 39-1412-04
Bracket Assly. Frame Complete Stay With Kawasaki Label Stay with Kawasaki Label Stay with Kawasaki Label Bracket Engine Bracket Engine Bolt (12 A/F) Bolt (13 A/F)
1 1 1 -1 2 2 2 2
1 1 1 1 1 2 2 -2
1 -1 1 1 2 2 -2
21 22
36-2222-45 DF 1810 07
Bearing Cone Kit Lock assly (4 In 1)
1 1
1 1
1 1
Not Illustrated
23 24
31 2210 29 31 1611 34
“Kawasaki PU Emblem” Frame with brg. rase
1 1
1 1
1 1
Upto June 200 (N.I.)
19 20
32
Part No.
11 14
From Jan. 99 to June 2000 Upto Dec. 98 From July 2000 From Mar. 99 (Similar to Caliber) Upto Feb. 99 Upto Apr. 97 From May 97
Not Illustrated
Not Illustrate
PLATE NO.
BOXER & 4S CHAMPION
20 : FRAME FITTING 2 3
1
4 1
2
3
5
6
7 2 3
8
12 13 11
1
10
9 12 13 11
Fig. No.
Part No.
Description
Qty / Veh.
1 2
39-0062-04 39-0732-12
Bolt Washer Spring
5 5
5 5
---
3 4
39-0219-11 39-0986-08
Plain washer Pin Cotter
6 1
6 1
---
5
DD 1610 56
Case Battery Assly.
1
1
--
6 7
31-20-1011 31-16-1017
Damper Band
1 1
1 1
---
8 9
31-16-1007 31-14-1004
Damper Battery Band
2 1
2 1
-1
10
DF-1610-43
Bracket Assly
--
--
1
11 12
39-0062-04 39-0219-11
Hex. Head Screw Plain Washer
---
---
1 1
13
39-0732-12
Washer Spring
--
--
1
4S Champ. Boxer CT
Remark Boxer AT
33
PLATE NO.
BOXER & 4S CHAMPION
21 : SWING ARM / REAR SHOCK ABSORBER
5 28
2
1
3
3
6
3
30 29
10
9
26
5 11
12 7
8
6
7
27
4
13
12
11
14
18 25
15 /16 3 17
2
1
19
23 24
23
24
24 24
22 20 21
34
Fig. No.
Part No.
Description
Qty / Veh.
1 2 3 4
5
39-0712-15 39-0737-12 39-0714-11 30-17-1045 30-17-1053 DB 1710 02 30-17-1030
Domed Cap Nut Washer Spring Washer Plain Rear Shock Absorber (MSL) Resr Shock Absorber(Gabriel) Resr Shock Absorber(Endurance) Rubber Bush
4 4 8 2 2 2 4
4 4 8 2 2 2 4
4 4 8 2 2 2 4
6 7 8 9 10
30-17-1031 39-0248-11 31-17-1006 39-0788-12 39-0390-04
Inner bush Plain Washer Shaft Swing Arm Washer Spring Bolt
4 2 1 2 2
4 2 1 2 2
4 2 1 2 2
11 12 13 14 15
39-0201-11 30-17-1018 39-0708-15 31-17-1001 31-1612-53 31-16-1207 31 1610 74
Plain Washer Bushing Rubber Nut Hex Arm Comp. Swing / Bush Holder Step (LH) Holder Step (LH)(for M8 Bolt) Holder step (LH) (for M10 Bolt)
2 2 1 1 1 1 1
2 2 1 1 1 ---
2 2 1 1 1 ---
4S Champ. Boxer CT
Remark Boxer AT
From Jan. 99 (Pipe in Pipe const.) From Mar. 96 to Dec. 98. Upto Feb. 96.
PLATE NO.
BOXER & 4S CHAMPION
21 : SWING ARM / REAR SHOCK ABSORBER
5 2
1
28
3
3
6
3
30 29
10
9
26
5 11
12 7
8
6
7
4
13
27
12
11
14
18 25
15 /16 3 17 19
2
1
23 24
23
24
24 24
22 20 21 Fig. No. 16
17 18 19 20
21 22 23 24 25
26 27 28 29 30
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
31-16-1254 31-16-1208 31 1610 75 30-17-1013 DD 1710 06 30-17-1022 39-0784-08 30-17-1012 DD 1710 11
Holder Step (RH) Holder Step (RH) (for M8 bolt) Holder Step (RH) (for M10 bolt) Step RR Step RR Pin Pin Cottor Step RR Rubber Step RR Rubber
1 1 1 2 2 2 2 -2
1 --2 2 2 2 2 --
1 --2 2 2 2 2 --
30-17-1017 31-15-1033 15-15-1061 39-0711-11 39-0292-15 31-15-1032 15-15-1062
Washer, Step Fitting Adjuster Chain (RH) Adjuster Chain (RH) Washer Plain Hex Nut Adjuster Chain (LH) Adjuster Chain (LH)
2 1 1 2 4 1 1
2 1 1 2 4 1 1
2 1 1 2 4 1 1
39-0200-11 39-0789-12 31 1710 12 39 0454 11 39 0553 02
Plain Washer Spring Washer Damper for Swing arm Plain washer Self tapping Screw
2 1 1 2 2
2 1 1 2 2
2 1 1 2 2
From Jan. 99 (Pipe in Pipe const.) From Mar. 96 to Dec. 98. Upto Feb. 96 From Jan. 99 (Similar to Caliber)
Alt. to 31-15-1033
Alt. to 31-15-1032
35
PLATE NO.
BOXER & 4S CHAMPION
22 : STAND AND STEP 1
1
2
3 4
11
5 8
6
7
9 8
36
Description
10
Fig. No.
Part No.
Qty / Veh.
1 2
30-16-1116 31-16-1022
Damper Holder - Step
2 1
2 1
2 1
3 4
39-0788-12 39-0119-04
Washer Spring Bolt (13 A/F)
4 4
4 4
4 4
5
39-0773-04
Bolt
1
1
1
6 7
39-0794-15 31-16-1021
Nut Hex. Fine Stand Side
1 1
1 1
1 1
8 9
30-16-1158 30-16-1157
Spring Shaft Stand
2 1
2 1
2 1
10
31-16-1009
Stand Centre
1
1
1
11
39-0787-08
Pin Cotter
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
PLATE NO.
BOXER & 4S CHAMPION
23 : FENDER (MUDGUARD)
4
5 8 1
6
2
7
9
3
10 24
11
4 6 17 2 13
14 16
18
5 15 15 5
20
Description
21 19 12
Fig. No.
Part No.
Qty / Veh.
1
39-0967-04
Hex. Bolt
4
--
---
2
39-0874-04 39-0788-12
Hex. Bolt Washer Spring
-6
4 6
4 6
3 4
39-0200-11 39-0892-04
Plain Washer Bolt
4 3
4 3
4 3
5
39-0732-12
Washer Spring
7
7
7
6 7
39-0219-11 30-19-1047
Plain Washer Clamp
3 1
3 1
3 1
8 9
30-16-1118 39-0197-11
Fender Assly. Front Plain Washer
1 2
1 2
1 2
10
22-1504-35
Bolt
2
2
2
11 12
31-16-1278 39-0062-04
Mud-Flap Front Bolt
1 4
1 3
1 3
13 14
30-16-1124 39-0711-11
Fender Rear Front Washer
1 2
1 2
1 2
15
39 0817 15
Hex. Nut
4
4
4
4S Champ. Boxer CT
Remark Boxer AT
37
PLATE NO.
BOXER & 4S CHAMPION
23 : FENDER (MUDGUARD)
4
5 8 1
6
2
7
9
3
10 24
11
4 6 17 2 13
14 16
18
5 15 15 5
20
Fig. No.
38
Part No.
Description
21 19 12
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
16
30-16-1221
Flap Fender Rear Fr.
1
1
1
17 18
39-0390-04 31-16-1008
Hex. Screw Fender Complete Rear
2 1
2 1
2 1
19 20
39-0198-11 31-16-1195
Plain Washer Mud-Flap Rear
2 1
2 1
2 1
21
39-0239-11
Plain Washer
2
2
2
22 23
01 1106 09 39 0291 15
Plain washer Hex nut
---
2 4
2 4
24
30 1612 42
Reinforcement assly
1
1
1
PLATE NO.
BOXER & 4S CHAMPION
24 : TYRE 1 3
2
6
4
7
5
9 / 11 10
4
8
3
1 2 Fig. No.
Part No.
Description
Qty / Veh.
1 2
30-15-1025 31-15-1041
Nipple Spoke Spoke Inner
72 36
72 36
72 36
3 4
31-15-1042 30-15-1029
Spoke Outer Band Rim
36 2
36 2
36 2
5
31-15-1035
Wheel Rim (FRONT 1.4x18 )
1
1
1
6 7
31-15-1044 30-15-1019
Tyre Front (2.50-18", 4PR) Tube (2.50 /2.75 x 18")
1 1
1 1
1 1
Proprietory item
8 9
31-15-1065 31-15-1027
Wheel Rim (REAR 1.85 x 18) Tyre Rear (2.75-18", 6PR)
1 1
1 --
1 --
For 2.75/3.00 tyre
10
31-15-1045 30-15-1108
Tyre Rear (2.75-18", 6PR) Tube (2.75/3.00 x 18")
-1
-1
1 --
4S Champ. Boxer CT
Remark Boxer AT
Not Serviced
Proprietory item Not Serviced
11
30-15-1027
Tyre Rear (3.00-18, 4PR)
--
1
--
(To be used with Wheel Rim 1.85X18 &Tube 2.75/3.00X18")
39
PLATE NO.
BOXER & 4S CHAMPION
25 : FRONT HUB
8
7 6 5 4
9
3 2
1 16 17 15 14 12
18
13 19
23
10 11
23 27 25
24
21
22
29
28
26
40
Fig. No.
Part No.
Description
Qty / Veh.
1
39-1006-20 39-1148-20
Bearing Ball Bearing Ball
1 1
1 1
1 1
2 3
31-15-1002 31-15-1004
Drum Front Collar
1 1
1 1
1 1
4 5
39-1004-20 14-1510-21
Bearing Ball Oil Seal
1 1
1 1
1 1
6
31-15-1056
Collar Axle Assly.
1
1
1
7 8
39-0248-11 39-0990-08
Plain Washer Pin Cotter
1 1
1 1
1 1
9 10
39-0981-15 39-0775-04
Nut Castle Bolt
1 1
1 1
1 1
11
30-15-1003
Lever Brake Cam
1
1
1
12 13
30-15-1005 30-15-1038
Indicator Ring O
1 1
1 1
1 1
14 15
31-15-1039 31-15-1011
Panel Front Brake Cam Brake
1 1
1 1
1 1
4S Champ. Boxer CT
Remark Boxer AT
Alt. 39-1006-20
PLATE NO.
BOXER & 4S CHAMPION
25 : FRONT HUB
8
7 6 5 4
9
3 2
1 16 17 15 14 12
18
13 19
23
10 11
23 27 25
24
22
29
28
26
Fig. No.
Part No.
Description
21
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
16
31-15-1014
Oil Seal
1
1
1
17 18
30-15-1037 35 1510 60
Spring Shoe Brake Assly.
2 2
2 2
2 2
19 20
31-15-1064 30-15-1118
Speedometer Gear (Plastic) Stopper for Bushing
1 1
1 1
1 1
21
30-15-1119
Bushing
1
1
1
22 23
39-1013-21 30-15-1042
Ring 'O' Washer 'A'
1 2
1 2
1 2
24 25
30-15-1041 39-0900-12
Gear Meter Screw Washer Spring
1 1
1 1
1 1
26
39-0840-01
Screw-Pan-Cross
1
1
1
27 28
39-0798-15 31-15-1036
Nut Axle
1 1
1 1
1 1
29
39 0842 11
Washer Plain
1
1
1
Not Illustrated
41
PLATE NO.
BOXER & 4S CHAMPION
26 : REAR HUB 1
3
6
9
2
4
12 13
5 7
10
8
11
18 15
14
17 16 23
33 25
20
26 21
31
24 22
19
28
27
42
Description
29
Fig. No.
Part No.
1 2 3 4 5
16-15-1008 30-15-1085 31-15-1048 39-0978-04 31-15-1027
Connecting Link Assembly Chain Coupling Assembly Bolt Coupling
1 1 1 4 1
1 1 1 4 1
1 1 1 4 1
6 7 8 9 10
31-15-1028 31-15-1029 39-0794-15 30-10-1192 30-15-1082
Sleeve Washer Nut Hex. Fine Bearing Ball Seal Oil
1 2 4 1 1
1 2 4 1 1
1 2 4 1 1
11 12 13 14 15
31-15-1043 31-15-1030 39-0988-15 39-1005-20 31-15-1018
Sprocket Collar Nut Hex. Bearing Ball Collar Bearing
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16 17 18
31-15-1021 31-15-1016 30-15-1060
Shock Damper Drum Rear Bearing Ball
4 1 1
4 1 1
4 1 1
30
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
PLATE NO.
BOXER & 4S CHAMPION
26 : REAR HUB 1
3
6
9
2
4
12 13
5 7
10
8
11
18 15
14
17 16 23
33 25
20
26 21
31
24 22
19
27 Fig. No.
Part No.
Description
28
30
29
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
19 20
30-15-1069 31 1510 60
Spring Shoe Brake Assly.
2 1
2 1
2 1
21
31 1510 23
Brake Cam
1
1
1
22 23
31-15-1024 30-15-1038
Panel Rear Brake Ring O
1 1
1 1
1 1
24 25
30-15-1005 31-15-1037
Indicator Lever Brake (Sheet Metal)
1 1
1 1
1 1
31-15-1058
Lever Brake (Forging)
1
1
1
Alt. 31151037
26 27
39-0092-04 31-15-1001
Bolt Axle
1 1
1 1
1 1
For 31151058
28 29
31-15-1026 39-0714-11
Collar Washer Plain
1 1
1 1
1 1
30
39-0982-15
Nut Castle
1
1
1
31 32
39-0787-08 36-1531-01
Pin Cotter Chain Sprocket Set
1 1
1 1
1 1
33
39 0798 15
Hex Nut
1
1
1
Not Illustrated
43
PLATE NO.
BOXER & 4S CHAMPION
27 : BRAKE PEDAL
5
7
18
6
4 2
3
1 8
13 14 12
17 15
9 17
10 11
16
14 13
15
44
Description
12
Fig. No.
Part No.
Qty / Veh.
1 2 3 4 5 6 7 8 9 10
39-0808-08 39-0198-11 31-19-1016 30-19-1038 31-19-1008 DD 1910 12 39-0805-11 39-0797-08 30-19-1031 30-19-1035 15-19-1026
Pin Cotter Plain Washer Rod Brake Pin Lever Brake Lever Brake Washer Pin Cotter Spring Spring Pin
1 2 1 1 1 1 1 1 1 1 1
1 2 1 1 1 1 1 1 1 1 1
1 2 1 1 1 1 1 1 1 1 1
11 12 13 14 15
30-19-1036 39-0807-08 39-0708-15 39-0789-12 30-15-1095
Brake Adjusting Nut Pin Snap Nut Hex. Washer Spring Bolt
1 2 2 2 2
1 2 2 2 2
1 2 2 2 2
16 17 18
31-15-1059 39 0198 11 DD 1610 78
Rod Torque Plain washer Damper
1 2 1
1 2 1
1 2 1
4S Champ. Boxer CT
Remark Boxer AT
PLATE NO.
28 : HANDLE BAR
BOXER & 4S CHAMPION 3 5
1/2 4
6
7 8 9
10 11
12 12
25 15
15
26
16
27
21
16
13
17
14
28
20 24
18
19
20 19 21 23 22
Fig. No.
Part No.
1
31 2210 22 30-22-1014 31 2210 23 30-22-1013 39 1714 04 30-18-1003 31-18-1054
Mirror assly LH Mirror Assly. - LH Mirror assly - RH Mirror Assly. - RH Flanged Bolt Holder - Handle Handle
1 1 1 1 4 2 1
1 ---4 2 1
1 -1 1 4 2 1
Rod type Stay
32-20-1021 30 1910 10 39-0724-01 39-0716-01 30-19-1048 31 2010 80 DF 2010 21
Control Switch RH Control Switch RH Screw-Pan-Cros Screw-Pan-Cros Band Control Switch LH Control Switch LH
1 1 1 1 2 1 --
1 -1 1 2 1 --
1 --1 2 -1
Lockable Coupler
39-0830-01 30-19-1030 30-19-1021 30-19-1023 39-0726-04
Screw-Pan-Cros Boot Lever-Assly. Grip, LH Lever- Grip, Left Bolt
2 2 1 1 2
2 2 1 1 2
2 2 1 1 2
For 31 2010 80
2 3 4 5 6 7 8 9 10
11 12 13 14 15
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
Upto Nov. 99 Pipe type Stay Rod type Stay Upto Nov. 99 Pipe type Stay
Upto Oct. 97 For 32 2010 21
For 32 2010 21
45
PLATE NO.
28 : HANDLE BAR
BOXER & 4S CHAMPION 3 5
1/2 4
6
7 8 9
10 11
12 12
25 15
15
26
16
27
21
16
13
17
14
28
20 24
18
19
20 19 21 23 22
Fig. No.
46
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
16
30-19-1017
Nut
2
2
2
17 18
30-19-1024 30-19-1022
Screw Holder Left Hand
1 1
1 1
1 1
19 20
39-0725-04 39-0198-11
Hex Bolt Washer Plain
2 2
2 2
2 2
21
39-1184-15
Self Locking Nut
2
2
2
22 23
30-19-1020 31-19-1037
Grip LH Lever-Assly. Grip, RH
1 1
1 1
1 1
24
31-20-1078 30 2010 18
Switch Switch
1 1
1 --
1 --
25
30-19-1016
Screw
1
1
1
26 27
30-19-1014 30-19-1015
Holder Right Hand Lever- Grip, Right
1 1
1 1
1 1
28
30-19-1007
Grip-Assly.
1
1
1
Lockable Coupler Upto Oct. 97
29 : FRONT FORK(MSL)
PLATE NO.
BOXER & 4S CHAMPION
19
20 11
21 22
16
23
1
35
12 2
10
13
24
3 14 25 33
26
27
34
15 4/5 8
6 7
28 36
17/18
29
9
30 31 32
Fig. No.
Part No.
Description
Qty / Veh.
1 2 3 4 5
30-18-1024 30-18-1023 30-18-1022 31-18-1013 31-18-1010
Seal Ring Snap Seal Oil Pipe Left Fork Outer Pipe Right Fork Outer
2 2 2 1 1
------
------
6 7 8 9 10
30-18-1016 39-0778-04 30-18-1026 30-18-1025 31-18-1015
Gasket Bolt Gasket Bolt Cy. Complete Fork
2 2 2 2 2
------
------
11 12 13 14 15
31-18-1016 30-18-1020 30-18-1021 30-18-1019 31-18-1014
Cylinder Fork Ring Fork Piston Spring Front Fork Cap Oil Lock Pipe Fork Inner
2 2 2 2 2
------
------
16 17 18 19 20
31-18-1017 31-18-1007 31-18-1006 30-18-1044 30-18-1030
Spring Front Fork Damper assly (LH) Damper Assly. (RH) Bolt Bolt Fork
2 1 1 1 2
------
------
4S Champ. Boxer CT
Remark Boxer AT
Upto May’98
47
29 : FRONT FORK (MSL)
PLATE NO.
BOXER & 4S CHAMPION
19
20 11
21 22
16
23
1
35
12 2
10
13
24
3 14 25 33
26
27
34
15 4/5 8
6 7
28 36
17/18
29
9
30 31 32
Fig. No. 21 22 23 24
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
30-18-1029 30-18-1028 30-18-1043 30-18-1042 DD 1810 16 DD-18-1090
RingO Seat Fork Spring Holder Fork Upper Cover Fork RH Cover Fork RH Cover Trail ‘B’
2 2 1 1 1 2
-------
-------
27 28 29 30
30-18-1041 DD 1810 15 DD-18-1091 30-18-1045 31-18-1009 39-0789-12
Cover Fork LH Cover Fork LH Cover Trail Damper Holder Fork Under Washer Spring
1 1 2 2 1 2
-------
-------
31 32 33 34 35
39-0777-04 DD 1810 51 30-18-1009 39-1011-01 31-18-1023
Bolt Small Fine Steering lock with key Bearing Cone Screw Fork Front (Without Boot)
2 1 1 2 1
------
------
36
31 1810 44
Gasket
2
--
--
25 26
48
Part No.
PLATE NO.
30 : FRONT FORK(ENDURANCE)
BOXER & 4S CHAMPION 18
19 20 21
10
22
1 11 2
36
12
23
3 13 35
24 32
25
26
15
33 27
14 4/5 8
37
16/17
6 7
28
9
29 30 34
Description
31
Fig. No.
Part No.
Qty / Veh.
1
DD-18-1032
Seal
2
2
2
2 3
31-18-1108 DD 1811 02
Ring Snap Seal Oil
2 2
2 2
2 2
4 5
DD-18-1031 DD-18-1034
Pipe Left Fork Outer Pipe Right Fork Outer
1 1
1 1
1 1
6
31-18-1103
Gasket
2
2
2
7 8
31-18-1104 31-18-1105
Bolt Gasket
2 2
2 2
2 2
9 10
31-18-1106 31-18-1109
Bolt Cylinder Fork
2 2
2 2
2 2
11
31-18-1111
Ring Fork Piston
2
2
2
12 13
30-18-1112 30-18-1110
Spring Front Fork Cap Oil Lock
2 2
2 2
2 2
14 15
31-18-1098 31-18-1099
Pipe Fork Inner Spring Front Fork
2 2
2 2
2 2
16
31-18-1096
Damper Assly. (LH)
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
49
PLATE NO.
30 : FRONT FORK (ENDURANCE)
BOXER & 4S CHAMPION 18
19 20 21
10
22
1 11 2
36
12
23
3 13 35
24 32
25
26
15
33 27
14 4/5
6 7
8
37
16/17
28
9
29 30 34
Fig. No.
Part No.
Description
31
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
17 18 19 20
31-18-1113 31-18-1120 31-18-1100 31-18-1102
Damper Assly. (RH) Bolt Bolt Fork Ring ‘O’
1 1 2 2
1 1 2 2
1 1 2 2
21 22 23
31-18-1101 31-18-1119 30-18-1042 DD-18-1089 31 1811 17 DD-18-1090
Seat Fork Spring Holder Fork Upper Cover Fork RH Cover Fork RH Cover Fork RH Cover Trail ‘B’
2 1 1 -1 2
2 1 1 1 1 2
2 1 1 1 1 2
31 1811 18 30-18-1041 DD-18-1088 31 1811 16
Cover Trail ‘B’ Cover Fork LH Cover Fork LH Cover Fork LH
2 1 -1
2 -1 1
2 -1 1
For Fork Front P. No. 31181083
DD-18-1091 31 1811 15 31-18-1114 31-18-1095 39-0789-12
Cover Trail Cover Trail Damper Holder Fork Under Washer Spring
2 2 2 1 2
2 2 2 1 2
2 2 2 1 2
For Fork Front P. No. DF181001
24 ,
For Fork Front P. No. DF181001 For Fork Front P. No. 31181089 For Fork Front P. No. 31181089 Fork Front P. No. DF181001
25
26
50
For Fork Front P. No. 31181089
27 28 29
For Fork Front P. No. 31181089 For Fork Front P. No. DF181001 For Fork Front P. No. 31181093
For Fork Front P. No. 31181093
PLATE NO. 30 : FRONT FORK (ENDURANCE)
BOXER & 4S CHAMPION 18
19 20 21
10
22
1 11 2
36
12
23
3 13 35
24 32
25
26
15
33 27
14 4/5
6 7
8
37
16/17
28
9
29 30 34
Fig. No.
Part No.
Description
31
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
30
39-0777-04
Bolt Small Fine
2
2
2
31 32 33 34
35
DD 1810 51 30-18-1009 39-1011-01 31 1810 89 DF-18-1001 31 1810 93 31-18-1097
Steering lock with key Bearing Cone Screw Fork Front (With Boot) Fork Front (With Boot) Frok front (With Boot) Boot
1 1 2 1 -1 2
1 1 2 -1 1 2
1 1 2 -1 1 2
36 37
DD-18-1028 31 1810 44
Band Assembly Gasket
2 2
2 2
2 2
From Dec. 99 From Dec. 99 Upto Nov. 99
51
PLATE NO. 31 : FRONT FORK(GABRIAL)
BOXER & 4S CHAMPION 19
20 21 22
11
23
1 12 2
10
13
37 24
3 14 36 25 33
26
15 4/5
34 28 38
17/18
6 7
8
27
16
29
9
30 31 32
35
52
Fig. No.
Part No.
Description
Qty / Veh.
1
DD-18-1045
Seal
2
2
2
2 3
31-18-1052 39-13-4719
Ring Snap Seal Oil
2 2
2 2
2 2
4 5
DD-18-1044 DD-18-1047
Pipe Left Fork Outer Pipe Right Fork Outer
1 1
1 1
1 1
6
31-18-1034
Gasket
2
2
2
7 8
39-0778-04 31-18-1035
Bolt Gasket
2 2
2 2
2 2
9 10
31-18-1053 31-18-1037
Bolt Cy. Complete Fork
2 2
2 2
2 2
11
31-18-1038
Cylinder Fork
2
2
2
12 13
31-18-1040 31-18-1041
Ring Fork Piston Spring Front Fork
2 2
2 2
2 2
14 15
31-18-1039 31-18-1030
Cap Oil Lock Pipe Fork Inner
2 2
2 2
2 2
4S Champ. Boxer CT
Remark Boxer AT
PLATE NO.
31 : FRONT FORK(GABRIAL)
BOXER & 4S CHAMPION 19
20 21 22
11
23
1 12 2
10
13
37 24
3 14 36 25 33
26
15 4/5
6 7
8
27
16
34 28 38
17/18
29
9
30 31 32
35
Fig. No.
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
16
31-18-1031
Spring Front Fork
2
2
2
17
31 1810 17 31-18-1122
Spring Front Fork Damper Assly (LH)
2 1
2 1
2 1
18 19
31-18-1006 31-18-1050
Damper Assly. (RH) Bolt
1 1
1 1
1 1
20
31-18-1051
Bolt Fork
2
2
2
21 22
39-1261-21 31-18-1032
RingO Seat Fork Spring
2 2
2 2
2 2
23 24
31-18-1049 30-18-1042
Holder Fork Upper Cover Fork RH
1 1
1 --
1 --
DD-18-1089 31 1810 47
Cover Fork RH Cover Fork RH
-1
1 1
1 1
For Fork Front P. No. DF181001
DD-18-1090
Cover Trail ‘B’
2
2
2
For Fork Front P. No. 31181089,
25
For 31181093
For Fork Front P. No. 31181089
For Fork Front P. No. 31181121
Fork Front P. No. DF181001
26
31 1810 48
Cover Trail ‘B’
2
2
2
For Fork Front P. No. 31181121
30-18-1041 DD-18-1088
Cover Fork LH Cover Fork LH
1 --
-1
-1
For Fork Front P. No. 31181089
31 1810 46
Cover Fork LH
1
1
1
For Fork Front P. No. 31181121
For Fork Front P. No. DF181001
53
PLATE NO.
31 : FRONT FORK(GABRIAL)
BOXER & 4S CHAMPION 19
20 21 22
11
23
1 12 2
10
13
37 24
3 14 36 25 33
26
15 4/5
34 28 38
17/18
6 7
8
27
16
29
9
30 31 32
35
Fig. No.
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
27
DD-18-1091
Cover Trail
2
2
2
28 29 30
31 1810 45 31-18-1044 31-18-1027 39-0789-12
Cover Trail Damper Holder Fork Under Washer Spring
2 2 1 2
2 2 1 2
2 2 1 2
31 32 33 34 35
39-0777-04 DD 1810 51 30-18-1009 39-1011-01 31-18-1089 DF-18-1001 31 1811 21
Bolt Small Fine Steering lock with key Bearing Cone Screw Fork Front Fork Front Fork Front
2 1 1 2 1 -1
2 1 1 2 -1 1
2 1 1 2 -1 1
36 37 38
DD-18-1041 31 1811 24 31 1810 44
Band Assembly Boot Gasket
2 2 2
2 2 2
2 2 2
For Fork Front P. No. 31181089, Fork Front P. No. DF181001
54
For Fork Front P. No. 31181121
From Dec. 99
PLATE NO. 32 : PETROL TANK & SIDE COVERS WITH DECAL
BOXER & 4S CHAMPION
1
3
2
Fig. No.
Part No.
Description
Qty / Veh.
1
31 1410 93
Petrol tank with decal
1
--
--
31 1410 94
(Wine Red) Petrol tank with decal
1
--
--
DF 1410 32
(Jet black) Petrol tank with decal
--
1
--
DF 1410 20
(Jet Black) Petrol tank with decal
--
1
--
DF 1410 34
(Jet Black) Petrol tank with decal
--
1
--
DF 1410 22
(Wine Red) Petrol tank with decal
--
1
--
DF 1410 40
(Imperial Maroon) Petrol tank with decal
--
--
1
DF 1410 42
(Jet Black) Petrol tank with decal
--
--
1
Upto Nov. 2000.
DF 1410 57
(Imperial Maroon) Petrol tank with decal
--
--
1
From Dec. 2000.
DF 1410 52
(Imperial Maroon) Petrol tank with decal
--
--
1
Upto Nov. 2000.
4S Champ. Boxer CT
(Wine Red)
Remark Boxer AT
55
PLATE NO. 32 : PETROL TANK & SIDE COVERS WITH DECAL
BOXER & 4S CHAMPION
1
3
2
Fig. No.
2
56
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
DF 1410 58
Petrol tank with decal (Wine Red)
--
--
1
31 1612 74
Side Cover LH with Decal (Wine Red)
1
--
--
31 1612 76
Side Cover LH with Decal (Jet Black)
1
--
--
DF 1610 29
Side Cover LH with Decal (Jeb Black)
--
1
--
DF 1610 19
Side Cover LH with Decal (Jeb Black)
--
1
--
DF 1610 30
Side Cover LH with Decal (Wine Red)
--
1
--
DF 1610 21
Side Cover LH with Decal (Imperial Maroon)
--
1
--
DF 1610 35
Side Cover LH with Decal (Jet Black)
--
1
--
DF 1610 36
Side Cover LH with Decal (Imperial Maroon)
--
1
--
DF 1610 44
Side Cover LH with Decal (Wine Red)
--
--
1
From Dec. 2000.
PLATE NO. 32 : PETROL TANK & SIDE COVERS WITH DECAL
BOXER & 4S CHAMPION
1
3
2
Fig. No.
Part No.
Description
Qty / Veh.
3
31 1612 75
Side Cover RH with Decal (Wine Red)
1
--
--
31 1612 77
Side Cover RH with Decal (Jet Black)
1
--
--
DF 1610 31
Side Cover RH with Decal (Jeb Black)
--
1
--
DF 1610 20
Side Cover RH with Decal (Jeb Black)
--
1
--
DF 1610 32
Side Cover RH with Decal (Wine Red)
--
1
--
DF 1610 22
Side Cover RH with Decal (Imperial Maroon)
--
1
--
DF 1610 37
Side Cover RH with Decal (Jet Black)
--
--
1
DF 1610 38
Side Cover RH with Decal (Imperial Maroon)
--
--
1
DF 1610 45
Side Cover RH with Decal (Wine Red)
--
--
1
4S Champ. Boxer CT
Remark Boxer AT
57
PLATE NO.
33 : DECAL
BOXER & 4S CHAMPION 4S - Champion
7/10 1/4
Boxer - CT
8/11 2/5
Boxer - AT 9/12 3/6
Fig. No.
Part No.
1
31 1410 62
DF 1410 26 DF 1410 01 DF 1410 28
3
DF 1410 44 DF 1410 46 DF 1410 61 DF 1410 46 DF 1410 61
4
58
Qty / Veh. 4S Champ. Boxer CT
31 1410 60 2
Description
31 1410 63
Petrol Tank Decal LH (Wine Red) Petrol Tank Decal LH (Jet Black) Petrol Tank Decal LH (Jet Black) Petrol Tank Decal LH (Jet Black) Petrol Tank Decal LH (Wine Red) Petrol Tank Decal LH (Jet Black) Petrol Tank Decal LH (Imperial Maroon) Petrol Tank Decal LH (Imperial Maroon) Petrol Tank Decal LH (Wine Red) Petrol Tank Decal LH (Wine Red) Petrol Tank Decal RH (Wine Red)
Remark Boxer AT
1
--
--
1
--
--
--
1
--
--
1
--
--
1
--
--
--
1
--
--
1
--
--
1
--
--
1
For Petrol Tank DF141052
--
--
1
For Petrol Tank DF141058
1
--
--
For DF141057
PLATE NO. 33 : DECAL
BOXER & 4S CHAMPION 4S - Champion
7/10 1/4
Boxer - CT
8/11 2/5
Boxer - AT 9/12 3/6
Fig. No.
5
6
7
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
31 1410 61
Petrol Tank Decal RH
1
--
--
DF 1410 27
(Jet Black) Petrol Tank Decal RH
--
1
--
DF 1410 02
(Jet Black) Petrol Tank Decal RH
--
1
--
DF 1410 29
(Jet Black) Petrol Tank Decal RH
--
1
--
DF 1410 45
(Wine Red) Petrol Tank Decal RH
--
--
1
DF 1410 47
(Jet Black) Petrol Tank Decal RH
--
--
1
For DF141057
DF 1410 62
(Imperial Maroon) Petrol Tank Decal RH
--
--
1
For DF141042
DF 1410 47
(Imperial Maroon) Petrol Tank Decal RH
--
--
1
For Petrol Tank DF141052
DF 1410 62
(Wine Red) Petrol Tank Decal RH
--
--
1
For Petrol Tank DF141052
31 1612 70
(Wine Red) Decal Side Cover LH
1
--
--
(Wine Red)
59
PLATE NO. 33 : DECAL
BOXER & 4S CHAMPION 4S - Champion
7/10 1/4
Boxer - CT
8/11 2/5
Boxer - AT 9/12 3/6
Fig. No.
Part No.
8
DF 1610 09
9
DF 1610 39 DF 1610 41 31 1612 71 31 1612 73
11
DF 1610 26 DF 1610 10 DF 1610 28
12
DF 1610 40 DF 1610 42
60
Qty / Veh. 4S Champ. Boxer CT
31 1612 72
10
Description
Decal Side Cover LH (Jet Black) Decal Side Cover LH (Jet Black) Decal Side Cover LH (Jet Black) Decal Side Cover LH (Imperial Maroon & Wine Red) Decal Side Cover RH (Wine Red) Decal Side Cover RH (Jet Black) Decal Side Cover RH (Jet Black) Decal Side Cover RH (Jet Black) Decal Side Cover RH (Wine Red) Decal Side Cover RH (Jet Black) Decal Side Cover RH (Imperial Maroon & Wine Red)
Remark Boxer AT
1
--
--
--
1
--
--
--
1
--
--
1
1
--
--
1
--
--
--
1
--
--
1
--
--
1
--
--
--
1
--
--
1
PLATE NO. 34 : PETROL TANK CAP, TAP ASSLY, FUEL FILTER
BOXER & 4S CHAMPION
2 4
3
1
7 5 6
8 9 23
11
12 13
10 18 17
16
25
15
20 21 22
19
14 25
26
Description
24
24
19
26
Fig. No.
Part No.
Qty / Veh.
1 2
31-14-1010 31-14-1030
Cap Assly. Tank Compl. Rotor with key
1 1
1 1
1 1
3 4
30-14-1051 30-14-1055
Cap Assly. Tank Pin
1 1
1 1
1 1
5
39-0761-01
Screw-Pan-Cros
2
2
2
6 7
30-14-1030 30-14-1054
Washer Hinge
2 1
2 1
2 1
8 9
30-14-1031 30-14-1052
Ring O Packing
2 1
2 1
2 1
10
DD 1410 21
Tap assly
1
1
1
From May 99 (Similar to Caliber)
30-14-1014
Tap Assly.
1
1
1
Upto April 99
11 12
30-14-1039 DD 1410 89
Packing Packing (Adeep)
1 1
1 1
1 1
13
DD 1410 90 30-14-1038
Packing (Jaina die cast) Ring O
1 1
1 1
1 1
1•4 15
30-14-1037 30-14-1049
Screw-Pan-Cros Packing
2 1
2 1
2 1
4S Champ. Boxer CT
Remark Boxer AT
Alt to DD141055
61
PLATE NO. 34 : PETROL TANK CAP, TAP ASSLY, FUEL FILTER
BOXER & 4S CHAMPION
2
3 7
4
1
5 6
8 9 23
11
12 13
10 18 17
16
25
15
20 21 22
19
14 25
26
Fig. No.
Description
Qty / Veh. 4S Champ. Boxer CT
24
19
26
Remark Boxer AT
16 17
30-14-1048 DD 1410 22
Filter Bolt
1 2
1 2
1 2
18
39-0739-04 39-0740-11
Bolt Washer
2 2
2 2
2 2
19 20
31-14-1006 39-0375-11
Clamp Tube Washer Plain
4 2
4 2
4 2
For 31121010
21
39-0900-12
Washer Spring
2
2
2
For 31121010
22 23
39-0899-01 07-1410-26
Screw-Pan-Cros Label
2 1
2 --
2 --
For 31121010
24
DD 1210 14 31 1410 07
Tube Fuel Tube Fuel
1 1
1 1
1 1
For DD121013
25
DD 1210 13 31 1210 10
Filter Fuel Filter Fuel
1 1
1 1
1 1
From May 99 (Similar to Caliber)
DD 1210 15
Tube Fuel
1
1
1
For DD121013
31 1210 51
Tube Fuel
1
1
1
For 31121010
26
62
Part No.
24
For Tap assly P. No. DD141021 For Tap assly P. No. 30141014
Upto March 98
For 31121010
Upto April 99
PLATE NO. 35 : CHAIN CASE
BOXER & 4S CHAMPION
2 1
4 5 7 3
4
6 5 8 Fig. No.
Part No.
Description
Qty / Veh.
1
30-16-1271
Rubber Pad
1
1
1
2 3
31-16-1094 31-16-1011
Case Chain Upper Assly. Case Chain Lower Assly
1 1
1 1
1 1
4 5
39 0219 11 39-0732-12
Washer Plain (6.4x13x1.5) Washer Spring (6.1x11.8x1.6)
2 4
2 4
2 4
6
15-16-1069
Rubber Cap
1
1
1
7 8
39-0897-04 39-0876-04
Bolt (M6x1x10x10) Bolt (M6 x 1 x 10 x 12 )
2 2
2 2
2 2
4S Champ. Boxer CT
Remark Boxer AT
63
PLATE NO. 36 :FITTINGS -PETROL TANK, SIDE COVER & COVER SEAT
BOXER & 4S CHAMPION
7
9 8
10 11 7 1 2
5 6 4 3
64
Fig. No.
Part No.
Description
Qty / Veh.
1 2
39-0983-08 39-1054-11
Pin Snap Washer
1 1
1 1
1 1
3 4
31-14-1005 31-14-1009
Damper Damper
1 1
1 1
1 1
5
30-14-1026
Damper
2
2
2
6 7
31-14-1037 30-21-1001
Damper (Fuel tank) Damper
1 4
1 4
1 4
8 9
31-16-1078 39-1076-01
Washer Screw (M6x1x14)
1 1
1 1
1 1
10
31-16-1018
Damper
1
1
1
11
31-16-1136
Lock for side cover with keys
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
Upto April 94
Alt. to DD161007
PLATE NO. 37 : METER ASSEMBLY
BOXER & 4S CHAMPION
2 1 3
4
7
6 5 8 16 9
10
12
8
11
17
13 14 21
22
20 18
15 9 10 11
Fig. No.
Part No.
Description
Qty / Veh.
1 2
31-19-1012 31-19-1017
Meter Assembly Cover Meter Case Upper (Black)
1 1
1 1
1 1
3 4
31-19-1018 31-19-1019
Speedometer Rubber Gasket
1 1
1 1
1 1
5
31-19-1020
Cover (White)
1
1
1
6
30 2011 28 30-20-1029
Bulb 12V, 4 W (Imported) Bulb 12V, 4 W
1 1
1 1
1 1
Neutral Indicator
7
30-20-1084 30 2011 29
Bulb 12 V, 2W Bulb 12V, 2W
2 --
-2
-2
TPI & HI beam
8
39-1210-02
Cros Recssed Pan Head Screw
5
5
5
9 10
39-0900-12 39-0842-11
Washer Spring Washer Plain Small
4 4
4 4
4 4
11
39-0920-01
Screw-Pan-Cros
4
4
4
12 13
31-19-1015 39-0814-11
Damper Washer
2 2
2 2
2 2
14 15
39-0292-15 31-19-1021
Nut Cover Meter Lower (Black)
2 1
2 1
2 1
4S Champ. Boxer CT
Remark Boxer AT
Speedometer
TPI & HI beam
65
PLATE NO. 37 : METER ASSEMBLY
BOXER & 4S CHAMPION
2 1 3
4
7
6 5 8 9
16 10
12
8
11
17
13 14 21
22
20 18
15 9 10 11
Fig. No.
66
Part No.
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
16
31-19-1014
Bracket Meter
1
1
1
17 18
31-19-1013 31-20-1040
Socket Assembly Ignition switch Assly.
1 1
1 1
1 --
Alt to DD201072
19
31-18-1020
with keys Four in one lock/keys set
1
1
--
Not Illustrated Alt to DD181050
Four in one lock/keys set Nut
-2
-2
1 --
Not Illustrated
20
DF 1810 07 39-0292-15
21
39-0849-14
Toothed Washer
2
2
2
22
31-2010-51
Nut for Ignition Switch
1
1
--
PLATE NO. 38 : CONTROL CABLES
BOXER & 4S CHAMPION 1
2 3 4 5
6
7
8
10 9
11
Fig. No.
Part No.
Description
Qty / Veh.
1 2
31 1910 29 30-19-1070
Cable Brake (FR) Spring
1 1
1 1
1 1
3 4
30-19-1069 30-19-1071
Dust Seal Rod End
1 1
1 1
1 1
5
30-19-1072
Adjusting Nut
1
1
1
6 7
31-19-1028 31-19-1003
Cable - Clutch Cable Speedometer
1 1
1 1
1 1
8 9
30-19-1067 31-19-1004
Oil Seal Inner Cable Speedo
1 1
1 1
1 1
10
31-19-1027
Cable - Throttle
1
1
1
11
31-19-1032
Accelerator boot
1
1
1
4S Champ. Boxer CT
Remark Boxer AT
67
PLATE NO. 39 : HEAD LAMP ASSLY (4S-CHAMPION)
BOXER & 4S CHAMPION 1
2
3
18 4
15 8
13
9
11 12
5
10 14
6
7
16 17
68
Fig. No.
Part No.
1
31-20-1075
2 3 4 5
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
1
1
--
Upto July 98 For Boxer CT
31 2011 02 30-20-1025 30-20-1119 30-20-1103 30-20-1137
Head Light Assly (With lamp With Coupler) Head light Assly (Without coupler) Rim Lamp Clip for Head Lamp Reflector with Glass Lamp Holder Assly.
1 1 2 1 1
-1 2 1 1
------
Upto Oct. 97
6 7 8 9 10
31-20-1004 30-20-1037 30-20-1033 39-0886-04 39-0792-15
Body Comp. Head Lamp Damper Washer Bolt Nut
1 2 2 2 2
1 2 2 2 2
------
For 31201075
11 12 13 14 15
39-0788-12 39-0200-11 30-20-1035 30-20-1036 30-20-1030 20 2010 24 25 2010 09 39 0902 11 39 0901 04 39 0790 12
Washer spring Washer plain Collar Damper Bulb (12 V, 35/35 W) Bulb (12 V, 35/35 W) Bulb (12V 35/35 Watt) Plain Washer Bolt Washer spring
2 2 2 2 1 1 1 2 2 2
2 2 2 2 1 1 -2 2 2
-----1 -----
16 17 18
For 31201075 For 31201075 For 31201075 For 31201075
S2 type Alt. to 20 2010 24
PLATE NO. 39A : HEAD LAMP ASSLY (BOXER)
BOXER & 4S CHAMPION 1
2 5 6 3
4
12 9
8
11 10 7 Fig. No.
Part No.
Description
Qty / Veh.
1 2 3 4 5
DF 2010 01 DF 2010 05 DF 2010 04 DF 2010 06 DF 2010 19
Head light assly with lamp Rim Lamp Reflector with Glass Lamp Holder assly Cup washerr
------
1 1 1 1 2
1 1 1 1 2
6 7 8 9 10
39 0886 01 DF 2010 08 DF 2010 09 DF 2010 10 39 1394 04
Screw pan cross Damper Collar Special Nut Flanged bolt
------
2 2 2 2 2
2 2 2 2 2
11 12
DF 2010 07 20 2010 24
Housing head light Bulb (12 V 35/35 W)
---
1 --
1 1
4S Champ. Boxer CT
Remark Boxer AT
Rim mounting
Rim mounting
Head light mounting. Head light mounting.
69
BOXER & 4S CHAMPION
PLATE NO. 40 : TURN SIGNAL LAMP (4S-CHAMPION) 8 13
1
12 11
9
5
7
6
14 10
4
3 2
Fig. No.
Part No.
1 2
31-20-1084 31-20-1035 31 2010 94
3 4 5 6 7 8 9 10
11 12 13 14
70
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
1 -1
1 1 1
----
31-20-1018 31 2010 86 31-20-1019 30 2010 88 06-2010-83
Direction Ind. Front RH with Lamp Lamp Assly Signal Front - LH Lamp assly signal front LH with lamp Lamp Signal Rear - LH with lamp Lamp signal rear LH with lamp Lamp signal rear - RH with lamp Lamp signal rear - RH with lamp Bulb 12 V 10 W
1 1 1 1 4
1 1 1 1 4
------
31-20-1016 30 2010 41 31-20-1017 30 2010 46 30 2010 48 39 0810 02 31 2010 83 30 2010 47
Gasket Gasket Lens Lens Damper Cr. Rec. Pan Head screw Bracket for signal light Bracket for signal ligh
4 4 4 4 8 4 4 4
4 4 4 4 8 4 4 4
---------
39 0201 11 39 0267 12 39 0794 15 39 1225 15
Plain Washer Spring washer Hex nut Hex nut with Flange
4 4 4 4
4 4 4 4
-----
Upto July 98 for Boxer CT Upto Dec. 98 From Jan. 99 Upto July 98 for Boxer CT Upto July 98 for Boxer CT From Jan. 99 Upto July 98 for Boxer CT From Jan. 99
For 31201035 For 31201094 For 31201035 For 31201094 For Lens mounting
PLATE NO. 40A : TURN SIGNAL LAMP (BOXER)
BOXER & 4S CHAMPION
1 3
4
9
13
8
7 11
6
10
12
5
Fig. No.
Part No.
Description
Qty / Veh.
1 2 3 4 5
DF 2010 13 DF 2010 11 DF 2010 15 DF 2010 17 06-2010-83
Direction ind. Front RH with Lamp Direction ind. Front LH with Lamp Direction ind. Rear LH with Lamp Direction ind. Rear RH with Lamp Bulb 12 V 10 W
------
1 1 1 1 4
-1 1 1 4
6 7
32 2010 29 39 0736 15
Lens Nut
---
4 4
4 4
8 9
39 1225 15 DF201054
Hex nut with flange Bracket Signal Lamp
---
4 4
4 4
10
DF201055
Gasket
--
4
4
11 12
39 0781 11 39 0466 12
Plain washer Spring washer
---
4 4
4 4
13
DF201056
Screw
--
4
4
4S Champ. Boxer CT
Remark Boxer AT
71
PLATE NO. 41 : TAIL LAMP ASSLY / BRACKET
BOXER & 4S CHAMPION
5
7
6 2
4
8
3
9
10 28
9 11
2
29
1 1 4
2
2
5
6
26 27
28 25 13 12
17 19
18
21 24
16 15
20 21 22
23
Fig. No.
Part No.
1
39-0798-15
Nut
4
4
4
2 3
39-0211-11 31-20-1010
Plain Wahser Bracket Tail Lamp
4 1
4 --
4 --
4
31-20-1048 31-20-1002
Bracket Tail Lamp Damper
1 4
1 4
1 4
5
31-20-1001
Collar
4
4
4
6 7
39-0882-04 31-18-1018
Hex. Bolt Plate No. Front
4 1
4 1
4 1
8 9
39-1290-04 39-0732-12
Bolt Washer Spring
2 2
2 2
2 2
10
39-0219-11
Plain Washer
2
2
2
11 12
39-0062-04 31 2010 74
Bolt Tail light comp. with lamp
2 1
2 1
2 1
13
31-20-1073 31 2010 12
Lamp Tail Lamp Tail
1 1
1 1
1 --
31-20-1014 39-1038-01
Lens Screw Pan Cross
1 2
1 2
1 2
14 15
72
14
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
Upto Feb. 94 From March 94.
Lockable Coupler From Nov. 97 Upto Oct. 97
PLATE NO. 41 : TAIL LAMP ASSLY / BRACKET
BOXER & 4S CHAMPION
5
7
6 2
4
8
3
9
10 28
9 11
2
29
1 1 4
2
5
2
6
26 27
28 25 13 12
17 19
18
21 24
16 15
20 21 22
14 23
Fig. No.
Part No.
Description
Qty / Veh.
16 17
31-20-1013 31-20-1060
Gasket Bulb 12 V, 5/10W
1 1
1 1
1 1
18 19
31-20-1036 39-0291-15
Body Comp. Tail Lamp Nut Hex. (M5x0.8x8x4)
1 2
1 2
1 2
20
16-16-1042
Plate No. RR (Rear)
1
1
1
21 22
01-1106-09 39-0790-12
Plain Washer (5.2x14x0.8) Washer Spring (5.1x9.2x1.3)
4 2
4 2
4 2
23 24
01-1605-09 39-1209-24
Bolt (M5x0.8x8x18) Spacer (5.5x22x5)
2 2
2 2
2 2
25
39-1285-23
Grommet
2
2
2
26 27
31-20-1042 39-1290-04
Packing tail lamp Bolt
1 2
1 2
1 2
28 29
39-0211-11 31 2010 23
Plain Washer Damper
4 2
2 --
2 --
4S Champ. Boxer CT
Remark Boxer AT
73
PLATE NO. 42 : ELECTRICAL EQUIPMENT
BOXER & 4S CHAMPION 1 2 23 3
21
26
4
25 5
24
7
6 8
27 25
20 19
26
9
18
10
22 11 16
13
15
12 17
Fig. No.
Part No.
1 2 3
39-0119-04 39-0788-12 31-20-1008 DF-20-1023 31-20-1009 30-20-1064
Bolt Washer Spring Horn Horn DC Band Band
1 1 1 -1 2
1 1 1 -1 2
1 1 -1 1 2
30-19-1048 30-20-1073 31 2010 79 30-20-1074 31-20-1025 DF 2010 20 31 2010 53 31 2010 52 31 2011 08 31-20-1027 DL 2010 08
Band Switch Switch Spring Brake Switch Harness Harness Wiring Harness Wiring Harness Wiring Harness Battery (12V, 2.5 AH) Battery
3 1 1 1 1 -1 1 1 1 1
3 -1 1 1 --1 1 1 1
3 -1 1 -1 ------
31-20-1037 30-20-1060 30-20-1085 31-2010-30 31 2010 90
Filling Plug (Amco) Fuse - Assly. Fuse, 15A Relay DC Flasher
6 1 1 1 1
6 1 1 1 1
------
4 5 6 7 8 9
10
74
14
11 12 13 14
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
Upto Oct. 97 Coupler type
From Nov. 97
Upto Sept. 2000 With coupler From : Oct. 2000
PLATE NO. 42 : ELECTRICAL EQUIPMENT
BOXER & 4S CHAMPION
1 2 23 3
21
26
4
25 5
24
7
6 8
27 25
20 19
26
9
18
10
22 11 16
13
15
12 17
14
Fig. No.
Part No.
Description
Qty / Veh.
15
31-2010-29
Rubber Holder
1
1
--
16 17
31-20-1038 31-20-1003
Exhaust Pipe (Amco) Relay assly.
-1
1 1
---
18 19
35 2011 40 35 2011 33
Flasher assly Flasher
---
---
1 1
20
06 2013 03
Damper
--
--
1
21 22
DF 2010 22 CD 2010 30
AC / DC Unit Regulator assly
---
---
1 1
23 24
31 2010 82 39 1079 01
Capacitor Hex Screw
1 1
1 1
1 1
25
39 0263 12
Spring Washer
--
--
1
26 27
39 0198 11 39 0745 01
Plain wahser Screw
---
---
1 1
4S Champ. Boxer CT
Remark Boxer AT
Alt. to 31201104
75
BOXER & 4S CHAMPION
PLATE NO. 43 : TOOL KIT
1
76
Fig. No.
Part No.
Description
Qty / Veh.
1
31-22-1001 31-22-1003
Tool Kit Tool Wrench (Box, 16 mm)
1 1
1 1
1 1
30-22-1008
Tool Wrench (Open End 10 x 12 )
1
1
1
30-22-1033
Tool Wrench (Open End 10 x 13 )
1
1
1
30-22-1004 30 2210 01
Tool Driver (philips & slot) Tool Driver
1 1
1 1
1 1
30-22-1011
Tool Wrench (Open End 14 x 17 )
1
1
1
30-22-1002 30 2210 09 30 2210 10 31 2210 04 30 2210 03
Tool Bag Tool bar Tool Plier Tool wrench (24 A/F) Tool Driver
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
4S Champ. Boxer CT
Remark Boxer AT
PLATE NO. 44 : EMBLEM AND MARKS
BOXER & 4S CHAMPION 1/2 3
4
4
6
Fig. No.
Part No.
Description
Qty / Veh.
1 2
31-14-1017 31-14-1018
Emblem - LH Emblem - RH
1 1
---
---
Upto Nov. 98
3 4
39-0763-01 31-16-1116
Screw C.S.K. Cross 4S - Four Stroke Name Plate
4 2
---
---
Upto Nov. 98
31-16-1202
For Cover Side 4S - Champion Name Plate
2
--
--
Upto Nov. 98
5
01-1605-08
For Cover Side Lock Washer
8
--
--
Upto Nov. 98 (N.I.)
6
31-22-1009
Kawasaki Label
1
--
--
Upto Nov. 98
7 8
31 1410 91 31 1612 46 DF 1610 01
‘KBajaj’ Label Emblem Boxer Emblem Boxer
3 ---
2 2 2
2 2 2
From Dec. 98
4S Champ. Boxer CT
Remark Boxer AT
Upto Nov. 98
Upto Nov. 98
Upto Dec. 98 Upto Dec. 98
77
PLATE NO. 45 : SEAT ASSLY.
BOXER & 4S CHAMPION
6
7
6
2
1/3
10 9
4
8 5
78
Fig. No.
Part No.
Description
Qty / Veh.
1
31 2110 17
Seat assly
1
--
--
From Frame No. 31495
2 3
DF 2110 17 DF 2110 13
Seat assly with Damper Seat assly with damper
---
-1
1 --
From Oct. 99
4 5
39 0788 12 39 0390 04
Washer spring Bolt
2 2
2 2
2 2
6
31 2110 04
Damper
6
6
6
7 8
31 2110 15 39 0292 15
Bracket Hex Nut
2 4
2 4
2 4
9 10
39 0732 12 39 0198 11
Washer Spring Plain washer
4 4
4 4
4 4
4S Champ. Boxer CT
Remark Boxer AT
PLATE NO. 46 : ACCESSORIES
BOXER & 4S CHAMPION 2 3
6 1
9
8
7
3
5
11
2 3
10 12
4 13 14
Fig. No.
Part No.
Description
Qty / Veh.
1
31 2210 20
Leg guard
1
1
1
2
DD 2210 03 39 0119 04
Leg guard Bolt
-3
-3
1 3
3 4
39-0788-12 31-16-1108
Washer Spring Saree Guard Complete
3 1
3 1
3 1
5
DF 2210 04 31-16-1123
Saree Guard Complete Plug For Saree Guard
-2
-2
1 2
6
31 1910 31
Clamp (Coil Ignition)
1
1
1
7 8
39 1060 04 39 1040 11
Bolt Plain washer
1 2
---
---
Leg guard mounting
9 10
39 0792 15 39 0292 15
Hex nut Hex nut
1 1
---
---
Leg guard mounting
11
39 0732 12
Spring washer
1
--
--
Saree guard mounting
12 13
39 0239 11 39 0198 11
Plain washer Plain washer
1 1
---
---
Saree guard mounting
14
39 0892 04
Bolt
1
--
--
Saree guard mounting
4S Champ. Boxer CT
Remark Boxer AT
Leg guard mounting
Saree guard mounting
Saree guard mounting
79
PLATE NO. 47 : FAIRING
BOXER & 4S CHAMPION
1
2
7 6 5
5
4
3
6 8 7 Fig. No.
Part No.
1
31 1810 91
Description
Qty / Veh. 4S Champ. Boxer CT
Fairing with decal (Wine red)
1
1
Remark Boxer AT
--
From Dec. 98 Upto July 98 Boxer CT
31 1810 92
Faring with decal (Jet black)
1
1
--
31 1810 72
Decal Fairing LH (Jet black)
1
1
--
Upto July 98 Boxer CT
31 1810 73 31 1810 75
Decal Fairing RH (Jet black) Decal Fairing LH (Wine red)
1 1
1 1
---
Upto July 98 Boxer CT
31 1810 76 31 1810 65
Decal Fairing RH (Wine red) Bracket left
1 1
1 1
---
Upto July 98 Boxer CT
3 4 5
31 1810 66 31 1810 67
Bracket right Guide bush
1 2
1 2
---
Upto July 98 Boxer CT
6
39 1789 24
Washer
2
1
--
Upto July 98 Boxer CT
7 8
DG 1611 21 31 1810 90
Screw Label “Kawasaki”
2 1
1 1
---
Upto July 98 Boxer CT
From Dec. 98. Upto July 98 Boxer CT
2
80
Upto July 98 Boxer CT
Upto July 98 Boxer CT
Upto July 98 Boxer CT
Upto July 98 Boxer CT
PLATE NO. 48 : MAIN BRACKET
BOXER & 4S CHAMPION
12 9
8
10
11
7
1 3 4
6 5
4 2 Fig. No.
Part No.
Description
Qty / Veh.
1
31 1612 39
Bracket Main
--
1
--
2 3
39 0390 04 39 1803 04
Hex Screw Hex bolt
---
3 1
---
4 5
39 0788 12 39 0237 11
Washer spring Plain washer
---
4 1
---
4S Champ. Boxer CT
Remark Boxer AT
To be assembed in between sareeguard & main bracket
6 7
30 1611 69 31 1612 40
Grommet Carrier Assly
---
2 1
---
8
DF 1610 04 39 0062 04
Carrier Assly Hex bolt
---
1 4
---
9 10
39 1309 11 39 0732 12
Plain washer Washer spring
---
4 4
---
11
31 1612 51
Lock assembly - seat
--
1
--
12
39 0743 01
Screw Csk cross
--
2
--
From Oct. 98
81
BOXER & 4S CHAMPION
PLATE NO. 49 : COVER SEAT
9 8 7 6 5
3
1 4
2
Fig. No.
Part No.
1
31 1612 55 DF 1610 15
Cover Seat LH (Alfa red) Cover Seat LH (Jet Black)
---
1 1
---
DF 1610 16 31 1612 56
Cover Seat LH (Imperial Maroon) Cover Seat RH (Alfa red)
---
1 1
---
DF 1610 17 DF 1610 18
Cover Seat RH (Jet Black) Cover Seat RH (Imperial Maroon)
---
1 1
---
3 4
39 1607 01 39 1789 24
Screw Washer (Nylon)
---
2 2
---
5
30 1810 60
Damper
--
2
--
6 7
30 1810 61 39 0211 11
Collar Plain washer
---
2 2
---
8 9
39 0732 12 39 0882 04
Spring washer Hex bolt
---
2 2
---
2
82
Description
Qty / Veh. 4S Champ. Boxer CT
Remark Boxer AT
PLATE NO. 50 : RIDER SEAT AND PILLION SEAT
BOXER & 4S CHAMPION
4
3
1 2 5
10 6
9
7
6
8 7
6
8
7 8
Fig. No.
Part No.
Description
Qty / Veh.
1 2
31 2110 21 39 1802 04
Seat assly front comp Bolt (Allen)
---
1 2
---
3 4
39 0732 12 31 2110 25
Washer spring Seat assly Rear comp.
---
2 1
---
5
DF 2110 03 31 2110 28
Seat ally Rear comp. Bracket Front
---
1 1
---
6
39 0198 11
Plain washer
--
6
--
7 8
39 0732 12 39 0292 15
Spring washer Hex nut
---
6 6
---
9 10
31 1210 29 31 2110 24
Lock bar Bracket assly
---
1 1
---
4S Champ. Boxer CT
Remark Boxer AT
Upto Nov. 98. From Dec. 98
83
PART INDEX PART NO.
01 1006 10 01 1106 09 01 1106 09 01 1106 09 01 1605 08 01 1605 09 01 1701 10 01 1701 11 01 1701 11 06 2010 83 06 2010 83 06 2013 03 07 1410 26 14 1510 21 15 1510 61 15 1510 62 15 1610 69 15 1810 34 15 1910 26 16 1510 08 16 1610 42 20 2010 24 20 2010 24 22 1504 35 22 1504 51 25 2010 09 30 1810 41 30 0777 04 30 1010 15 30 1010 86 30 1010 96 30 1010 98 30 1011 41 30 1011 42 30 1011 92 30 1012 34 30 1012 36 30 1210 04 30 1210 18 30 1410 14 30 1410 15 30 1410 26 30 1410 30 30 1410 31 30 1410 37 30 1410 38 30 1410 39 30 1410 48 30 1410 49 30 1410 51 30 1410 52 30 1410 54 30 1410 55 30 1510 03 30 1510 05 30 1510 05
84
FIG. NO.
2 15 22 21 5 23 12 7 8 5 5 20 23 5 22 25 6 8 10 1 20 15 12 10 4 15 26 30 19 2 16 18 11 15 9 8 9 4 23 10 6 5 6 8 14 13 11 16 15 3 9 7 4 11 12 24
PAGE NO.
6 21 38 73 77 73 10 10 11 70 71 75 62 40 35 35 63 8 44 42 73 68 69 37 3 68 48 51 11 9 15 15 3 12 42 16 16 18 19 61 11 64 61 61 61 61 61 62 61 61 61 61 61 40 40 43
PART NO.
30 1510 19 30 1510 25 30 1510 27 30 1510 29 30 1510 37 30 1510 38 30 1510 38 30 1510 41 30 1510 42 30 1510 42 30 1510 60 30 1510 69 30 1510 82 30 1510 85 30 1510 95 30 1511 08 30 1511 18 30 1511 19 30 1611 16 30 1611 18 30 1611 24 30 1611 57 30 1611 58 30 1611 69 30 1612 21 30 1612 42 30 1612 71 30 1710 12 30 1710 13 30 1710 17 30 1710 18 30 1710 22 30 1710 30 30 1710 31 30 1710 45 30 1710 53 30 1810 42 30 1810 03 30 1810 06 30 1810 07 30 1810 08 30 1810 09 30 1810 09 30 1810 09 30 1810 10 30 1810 11 30 1810 16 30 1810 19 30 1810 20 30 1810 21 30 1810 22 30 1810 23 30 1810 24 30 1810 25 30 1810 26 30 1810 28
BOXER & 4S CHAMPION
FIG. NO.
PAGE NO.
7 1 11 4 17 13 23 24 10 23 18 19 10 2 15 10 20 21 1 8 13 9 8 6 16 24 1 20 17 21 12 18 5 6 4 4 24 4 8 7 9 33 32 33 6 5 6 14 12 13 3 2 1 9 8 22
39 39 39 39 41 40 43 41 22 41 42 43 42 42 44 39 41 41 36 37 37 36 36 81 38 38 63 35 35 35 34 35 34 34 34 34 53 45 31 31 31 48 51 54 31 31 47 47 47 47 47 47 47 47 47 48
PART NO.
30 1810 29 30 1810 30 30 1810 41 30 1810 41 30 1810 42 30 1810 42 30 1810 43 30 1810 44 30 1810 45 30 1810 60 30 1810 61 30 1811 10 30 1811 12 30 19 10 36 30 1910 07 30 1910 10 30 1910 14 30 1910 15 30 1910 16 30 1910 17 30 1910 20 30 1910 21 30 1910 22 30 1910 23 30 1910 24 30 1910 3 30 1910 30 30 1910 31 30 1910 38 30 1910 47 30 1910 48 30 1910 48 30 1910 67 30 1910 69 30 1910 70 30 1910 71 30 1910 72 30 2010 18 30 2010 25 30 2010 29 30 2010 30 30 2010 33 30 2010 35 30 2010 36 30 2010 37 30 2010 41 30 2010 46 30 2010 47 30 2010 48 30 2010 48 30 2010 60 30 2010 64 30 2010 73 30 2010 74 30 2010 77 30 2010 84
FIG. NO.
21 20 25 26 24 23 23 19 28 5 6 13 12 11 28 6 26 27 25 16 22 13 18 14 17 9 12 8 4 7 9 6 8 3 2 4 5 24 2 6 15 8 13 14 7 6 7 10 8 14 12 5 7 8 14 7
PAGE NO.
48 47 50 53 48 50 48 47 48 82 82 49 49 44 46 45 46 46 46 46 46 45 46 45 46 44 45 44 44 37 45 74 67 67 67 67 67 46 68 65 68 68 68 68 68 70 70 70 70 71 74 74 74 74 25 65
PART INDEX PART NO.
30 2010 85 30 2010 86 30 2010 88 30 2011 03 30 2011 19 30 2011 28 30 2011 29 30 2011 37 30 2110 01 30 2210 02 30 2210 03 30 2210 04 30 2210 08 30 2210 09 30 2210 10 30 2210 11 30 2210 13 30 2210 14 30 2210 33 31 2010 08 31 1008 20 31 1010 02 31 1010 06 31 1010 07 31 1010 09 31 1010 10 31 1010 14 31 1010 16 31 1010 17 31 1010 18 31 1010 19 31 1010 20 31 1010 21 31 1010 22 31 1010 24 31 1010 25 31 1010 26 31 1010 27 31 1010 28 31 1010 29 31 1010 30 31 1010 33 31 1010 34 31 1010 38 31 1010 39 31 1010 40 31 1010 41 31 1010 44 31 1010 45 31 1010 46 31 1010 47 31 1010 48 31 1010 49 31 1010 51 31 1010 54 31 1010 55
FIG. NO.
PAGE NO.
13 15 4 4 3 6 7 5 7 1 1 1 1 1 1 1 2 1 1 3 13 13 2 18 3 2 1 12 13 8 7 4 1 9 5 8 3 12 19 20 18 7 9 16 15 20 21 7 11 15 9 5 7 2 7 9
74 25 70 68 68 65 65 68 64 76 76 76 76 76 76 76 45 45 76 74 11 10 1 1 4 4 22 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 5 17 17 17 17 16 2 14 8 8 8 8 9 9
PART NO.
31 1010 56 31 1010 61 31 1010 62 31 1010 63 31 1010 67 31 1010 75 31 1010 76 31 1010 77 31 1010 78 31 1010 79 31 1010 80 31 1010 81 31 1010 82 31 1010 83 31 1010 84 31 1010 99 31 1011 03 31 1011 04 31 1011 05 31 1011 06 31 1011 07 31 1011 08 31 1011 09 31 1011 10 31 1011 11 31 1011 13 31 1011 15 31 1011 17 31 1011 18 31 1011 20 31 1011 21 31 1011 23 31 1011 24 31 1011 27 31 1011 31 31 1011 32 31 1011 33 31 1011 34 31 1011 35 31 1011 36 31 1011 37 31 1011 38 31 1011 39 31 1011 40 31 1011 41 31 1011 42 31 1011 43 31 1011 44 31 1011 46 31 1011 47 31 1011 48 31 1011 49 31 1011 68 31 1011 70 31 1011 72 31 1011 73
BOXER & 4S CHAMPION
FIG. NO.
PAGE NO.
15 4 1 11 14 6 5 6 2 3 10 1 5 9 8 6 1 5 4 9 3 15 8 3 5 5 12 13 13 17 6 12 18 6 13 16 10 13 14 17 19 1 9 3 7 5 4 25 12 22 24 14 3 9 5 4
11 12 12 12 12 6 6 14 7 7 7 8 7 7 7 9 9 2 9 10 6 9 9 9 22 12 7 7 6 3 3 17 17 16 1 1 14 14 14 15 15 14 14 14 14 14 14 15 14 15 15 9 8 3 11 6
PART NO.
31 1011 75 31 1011 76 31 1011 82 31 1011 85 31 1011 87 31 1011 91 31 1011 92 31 1011 97 31 1012 00 31 1012 01 31 1012 16 31 1012 18 31 1012 19 31 1012 21 31 1012 35 31 1012 49 31 1012 50 31 1012 51 31 1012 60 31 1012 63 31 1012 64 31 1012 66 31 1012 69 31 1012 73 31 1012 76 31 1012 77 31 1012 78 31 1012 88 31 1012 89 31 1012 90 31 1012 91 31 1012 95 31 1013 02 31 1013 03 31 1013 04 31 1013 07 31 1013 10 31 1013 12 31 1013 14 31 1110 01 31 1110 01 31 1110 01 31 1110 04 31 1110 04 31 1110 05 31 1110 05 31 1110 05 31 1110 07 31 1110 07 31 1110 07 31 1110 08 31 1110 08 31 1110 08 31 1110 10 31 1110 11 31 1110 12
FIG. NO.
PAGE NO.
15 7 4 4 4 1 9 9 12 13 13 19 6 7 14 5 5 5 10 10 4 13 10 14 19 3 2 7 7 7 3 3 5 5 5 6 6 6 10 17 14 14 7 7 20 17 17 21 18 18 9 9 9 1 8 19
1 11 4 4 4 8 8 22 2 2 7 17 7 7 2 4 4 4 16 16 16 22 12 10 13 4 4 5 5 5 6 12 4 4 4 5 5 5 5 25 27 29 24 27 25 28 30 26 28 30 24 27 29 24 24 25
85
PART INDEX PART NO.
31 1110 12 31 1110 12 31 1110 13 31 1110 13 31 1110 13 31 1110 14 31 1110 14 31 1110 14 31 1110 17 31 1110 18 31 1110 19 31 1110 19 31 1110 20 31 1110 21 31 1110 22 31 1110 25 31 1110 26 31 1110 27 31 1110 27 31 1110 27 31 1110 28 31 1110 28 31 1110 28 31 1110 30 31 1110 30 31 1110 30 31 1110 32 31 1110 33 31 1110 34 31 1110 38 31 1110 38 31 1110 38 31 1110 39 31 1110 39 31 1110 39 31 1110 40 31 1110 46 31 1110 47 31 1110 48 31 1110 49 31 1110 50 31 1110 52 31 1110 53 31 1110 53 31 1110 53 31 1110 54 31 1110 55 31 1110 56 31 1110 57 31 1110 58 31 1110 61 31 1210 01 31 1210 06 31 1210 07 31 1210 08 31 1210 10
86
FIG. NO.
16 16 27 24 24 18 15 15 2 3 1 1 2 3 8 25 24 20 17 17 19 16 16 20 17 17 23 21 22 7 7 7 1 1 1 3 2 3 26 25 24 8 1 1 1 2 3 21 23 22 3 1 1 7 41 25
PAGE NO.
28 30 26 28 30 25 28 29 24 24 24 27 27 27 27 26 26 25 28 30 25 28 30 25 28 30 28 28 28 24 27 29 24 27 29 27 24 24 26 26 26 29 24 27 29 29 29 30 30 30 24 18 11 6 20 62
PART NO.
31 1210 14 31 1210 15 31 1210 16 31 1210 21 31 1210 23 31 1210 28 31 1210 29 31 1210 29 31 1210 30 31 1210 34 31 1210 37 31 1210 38 31 1210 41 31 1210 42 31 1210 43 31 1210 44 31 1210 45 31 1210 50 31 1210 51 31 1210 52 31 1210 55 31 1210 56 31 1210 57 31 1210 58 31 1210 59 31 1210 60 31 1210 61 31 1210 62 31 1210 63 31 1210 64 31 1210 65 31 1210 66 31 1210 67 31 1210 68 31 1210 69 31 1210 70 31 1210 71 31 1210 72 31 1210 73 31 1210 74 31 1210 75 31 1210 76 31 1210 77 31 1210 78 31 1210 79 31 1210 80 31 1210 81 31 1210 82 31 1210 83 31 1210 84 31 1210 85 31 1210 86 31 1210 87 31 1210 89 31 1210 98 31 1211 00
BOXER & 4S CHAMPION
FIG. NO.
PAGE NO.
2 43 3 13 16 4 10 9 12 3 11 5 6 17 7 3 4 1 26 18 12 11 10 9 8 7 6 2 3 5 16 15 14 13 25 17 18 19 30 20 22 21 26 27 28 40 38 37 36 35 32 39 24 29 16 8
21 20 21 21 21 21 21 83 21 11 21 21 21 21 21 23 23 21 62 21 18 18 18 18 18 18 18 18 18 18 19 18 18 18 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20 20 20 19 19 19 10
PART NO.
31 1211 33 31 1211 34 31 1211 35 31 1211 48 31 1211 49 31 1211 55 31 1410 04 31 1410 05 31 1410 06 31 1410 07 31 1410 09 31 1410 10 31 1410 17 31 1410 18 31 1410 30 31 1410 37 31 1410 60 31 1410 61 31 1410 62 31 1410 63 31 1410 91 31 1410 93 31 1410 94 31 1510 01 31 1510 02 31 1510 04 31 1510 11 31 1510 14 31 1510 16 31 1510 18 31 1510 21 31 1510 23 31 1510 24 31 1510 26 31 1510 27 31 1510 27 31 1510 28 31 1510 29 31 1510 30 31 1510 32 31 1510 33 31 1510 35 31 1510 36 31 1510 37 31 1510 39 31 1510 41 31 1510 42 31 1510 43 31 1510 44 31 1510 45 31 1510 48 31 1510 56 31 1510 58 31 1510 59 31 1510 60 31 1510 64
FIG. NO.
4 2 3 1 44 11 9 3 19 24 4 1 1 2 2 6 1 4 1 4 7 1 1 27 2 3 15 16 17 15 16 21 22 28 9 5 6 7 12 25 22 5 28 25 14 2 3 11 6 9 3 6 25 16 20 19
PAGE NO.
21 21 21 18 20 18 33 64 62 62 64 61 77 77 61 64 58 59 58 58 77 55 55 43 40 40 40 41 42 42 42 43 43 43 39 42 42 42 42 35 35 39 41 43 40 39 39 42 39 39 42 40 43 44 43 41
PART INDEX PART NO.
31 1510 65 31 1610 01 31 1610 07 31 1610 08 31 1610 09 31 1610 11 31 1610 17 31 1610 18 31 1610 19 31 1610 20 31 1610 21 31 1610 22 31 1610 74 31 1610 75 31 1610 78 31 1610 94 31 1610 97 31 1611 08 31 1611 16 31 1611 23 31 1611 34 31 1611 36 31 1611 95 31 1612 02 31 1612 07 31 1612 08 31 1612 39 31 1612 40 31 1612 46 31 1612 51 31 1612 53 31 1612 54 31 1612 55 31 1612 56 31 1612 70 31 1612 71 31 1612 72 31 1612 73 31 1612 74 31 1612 75 31 1612 76 31 1612 77 31 1612 78 31 1710 01 31 1710 06 31 1710 12 31 1810 06 31 1810 06 31 1810 07 31 1810 09 31 1810 10 31 1810 13 31 1810 14 31 1810 15 31 1810 16 31 1810 17
FIG. NO.
PAGE NO.
8 17 8 18 10 3 7 10 19 12 7 2 15 16 8 2 16 4 4 5 24 11 20 4 15 16 1 7 8 11 15 16 1 2 7 10 7 10 2 3 2 3 11 14 8 28 18 18 17 29 5 4 15 10 11 16
39 32 33 38 36 63 33 64 32 31 36 36 34 35 64 63 32 79 77 79 32 64 38 77 34 35 81 81 77 81 34 35 82 82 59 60 60 60 56 57 56 57 37 34 34 35 47 53 47 48 47 47 47 47 47 47
PART NO.
31 1810 17 31 1810 18 31 1810 20 31 1810 23 31 1810 27 31 1810 30 31 1810 31 31 1810 32 31 1810 34 31 1810 35 31 1810 37 31 1810 38 31 1810 39 31 1810 40 31 1810 41 31 1810 44 31 1810 44 31 1810 44 31 1810 44 31 1810 45 31 1810 46 31 1810 47 31 1810 48 31 1810 49 31 1810 50 31 1810 51 31 1810 52 31 1810 53 31 1810 54 31 1810 65 31 1810 66 31 1810 67 31 1810 72 31 1810 73 31 1810 75 31 1810 76 31 1810 89 31 1810 89 31 1810 90 31 1810 91 31 1810 92 31 1810 93 31 1810 95 31 1810 96 31 1810 97 31 1810 98 31 1810 99 31 1811 00 31 1811 01 31 1811 02 31 1811 03 31 1811 04 31 1811 05 31 1811 06 31 1811 08 31 1811 09
BOXER & 4S CHAMPION
FIG. NO.
PAGE NO.
16 7 19 35 29 15 16 22 6 8 10 11 14 12 13 36 37 28 38 27 26 24 25 23 19 20 2 9 5 3 4 5 2 2 2 2 34 35 8 1 1 34 28 16 35 14 15 19 21 20 6 7 8 9 2 10
53 72 66 48 54 52 53 53 52 52 52 52 52 52 52 48 51 54 54 54 53 53 53 53 53 53 52 52 45 80 80 80 80 80 80 80 51 54 80 80 80 51 50 49 51 49 49 50 50 50 49 49 49 49 49 49
PART NO.
31 1811 11 31 1811 13 31 1811 14 31 1811 15 31 1811 16 31 1811 17 31 1811 18 31 1811 19 31 1811 20 31 1811 21 31 1811 22 31 1811 24 31 1910 02 31 1910 03 31 1910 04 31 1910 08 31 1910 12 31 1910 13 31 1910 14 31 1910 15 31 1910 16 31 1910 17 31 1910 18 31 1910 19 31 1910 20 31 1910 21 31 1910 27 31 1910 28 31 1910 29 31 1910 31 31 1910 32 31 1910 37 31 2010 01 31 2010 02 31 2010 03 31 2010 04 31 2010 09 31 2010 10 31 2010 11 31 2010 12 31 2010 13 31 2010 14 31 2010 16 31 2010 17 31 2010 18 31 2010 19 31 2010 23 31 2010 25 31 2010 26 31 2010 27 31 2010 29 31 2010 30 31 2010 32 31 2010 35 31 2010 36 31 2010 37
FIG. NO.
PAGE NO.
11 17 27 26 25 23 24 22 18 35 17 37 4 7 9 5 1 17 16 12 3 2 3 4 5 15 10 6 1 6 11 23 5 4 17 6 4 3 6 13 16 14 6 7 3 4 29 9 16 10 15 14 16 2 18 11
49 50 50 50 50 50 50 50 50 54 53 54 31 67 67 44 65 66 66 65 44 65 65 65 65 65 67 67 67 79 67 46 72 72 75 68 74 72 33 72 73 72 70 70 70 70 73 74 11 74 75 74 25 70 73 74
87
PART INDEX PART NO.
31 2010 38 31 2010 40 31 2010 42 31 2010 45 31 2010 45 31 2010 45 31 2010 46 31 2010 48 31 2010 51 31 2010 52 31 2010 53 31 2010 60 31 2010 73 31 2010 74 31 2010 75 31 2010 78 31 2010 79 31 2010 80 31 2010 81 31 2010 82 31 2010 83 31 2010 84 31 2010 86 31 2010 90 31 2010 94 31 2011 02 31 2011 04 31 2011 08 31 2110 04 31 2110 15 31 2110 17 31 2110 21 31 2110 24 31 2110 25 31 2110 28 31 2210 01 31 2210 03 31 2210 04 31 2210 09 31 2210 10 31 2210 20 31 2210 22 31 2210 23 31 2210 27 31 2210 29 3110 1130 311010 05 32 2010 21 32 2010 29 35 1510 60 35 2011 33 35 2011 40 36 1531 01 36 2222 45 36 3110 21 39 0007 01
88
FIG. NO.
16 18 26 13 13 13 16 3 22 9 9 17 13 12 1 24 7 10 16 23 10 1 3 14 2 1 17 9 6 7 1 1 10 4 5 1 1 1 6 18 1 1 2 18 23 9 10 6 6 18 19 18 32 21 11 12
PAGE NO.
75 66 73 25 27 29 25 72 66 74 74 73 72 72 68 46 74 45 11 75 70 70 70 74 70 68 75 74 78 78 78 83 83 83 83 76 76 76 77 32 79 45 45 32 32 1 1 45 71 41 75 75 43 32 10 22
PART NO.
39 0062 04 39 0062 04 39 0062 04 39 0062 04 39 0062 04 39 0062 04 39 0092 04 39 0092 04 39 0092 04 39 0092 04 39 0119 04 39 0119 04 39 0119 04 39 0197 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0198 11 39 0200 11 39 0200 11 39 0200 11 39 0201 11 39 0201 11 39 0211 11 39 0211 11 39 0211 11 39 0219 11 39 0219 11 39 0219 11 39 0219 11 39 0219 11 39 0219 11 39 0219 11 39 0219 11 39 0219 11 39 0237 11 39 0239 11 39 0239 11 39 0248 11 39 0248 11 39 0248 11 39 0248 11 39 0263 12 39 0267 12 39 0287 15 39 0291 15
BOXER & 4S CHAMPION
FIG. NO.
PAGE NO.
1 1 11 12 11 8 10 10 10 26 4 1 2 9 5 15 10 11 1 2 19 2 17 20 26 10 13 6 26 3 12 11 11 2 28 7 12 12 12 3 3 12 6 4 10 5 21 12 2 8 7 7 25 12 31 23
31 33 33 37 72 81 24 27 29 43 36 74 79 37 1 3 6 9 16 22 38 44 44 46 75 78 79 83 35 37 68 34 70 72 73 82 25 27 29 31 33 33 37 63 72 81 38 79 10 22 34 40 75 70 20 38
PART NO.
39 0291 15 39 0292 15 39 0292 15 39 0292 15 39 0292 15 39 0292 15 39 0292 15 39 0375 11 39 0390 04 39 0390 04 39 0390 04 39 0390 04 39 0454 11 39 0466 12 39 0553 02 39 0694 15 39 0702 01 39 0702 01 39 0702 01 39 0703 11 39 0708 15 39 0708 15 39 0711 11 39 0711 11 39 0711 11 39 0712 15 39 0714 11 39 0714 11 39 0716 01 39 0724 01 39 0725 04 39 0726 04 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0732 12 39 0736 15 39 0737 12 39 0738 17
FIG. NO.
19 24 14 20 8 10 8 20 10 17 5 2 29 12 30 14 6 4 14 17 13 13 8 23 14 1 3 29 8 7 19 15 4 14 9 12 2 3 11 11 11 2 2 13 5 5 9 9 11 10 8 3 7 7 2 14
PAGE NO.
73 35 65 66 78 79 83 62 34 38 78 81 35 71 35 31 2 8 11 11 34 44 21 35 37 34 34 43 45 45 46 45 1 3 6 9 16 22 25 27 29 31 33 33 37 63 72 78 79 81 82 83 83 71 34 17
PART INDEX PART NO.
39 0739 04 39 0740 11 39 0743 01 39 0745 01 39 0745 01 39 0745 01 39 0745 01 39 0746 01 39 0747 01 39 0748 01 39 0753 01 39 0761 01 39 0763 01 39 0773 04 39 0775 04 39 0777 04 39 0777 04 39 0778 04 39 0778 04 39 0781 11 39 0784 08 39 0787 08 39 0787 08 39 0788 12 39 0788 12 39 0788 12 39 0788 12 39 0788 12 39 0788 12 39 0788 12 39 0788 12 39 0788 12 39 0789 12 39 0789 12 39 0789 12 39 0789 12 39 0789 12 39 0789 12 39 0790 12 39 0790 12 39 0790 12 39 0792 15 39 0792 15 39 0792 15 39 0794 15 39 0794 15 39 0794 15 39 0797 08 39 0798 15 39 0798 15 39 0798 15 39 0805 11 39 0807 08 39 0808 08 39 0810 02 39 0814 11
FIG. NO.
17 18 12 22 19 19 27 5 9 1 2 5 3 5 10 31 31 7 7 11 19 11 31 13 9 3 2 11 2 4 3 4 7 27 14 30 29 30 11 18 22 14 10 9 6 8 13 7 27 33 1 6 12 1 9 13
PAGE NO.
PART NO.
62 62 81 26 28 30 75 9 21 3 23 61 77 36 40 48 54 47 52 71 35 36 43 31 34 36 37 68 74 78 79 81 22 35 44 48 50 54 22 68 73 31 68 79 36 42 70 44 41 43 72 44 44 44 70 65
39 0817 15 39 0830 01 39 0830 01 39 0834 15 39 0840 01 39 0842 11 39 0842 11 39 0849 14 39 0855 17 39 0874 04 39 0876 04 39 0876 04 39 0882 04 39 0882 04 39 0886 01 39 0886 04 39 0892 04 39 0892 04 39 0897 04 39 0899 01 39 0900 12 39 0900 12 39 0900 12 39 0900 12 39 0901 04 39 0902 11 39 0920 01 39 0946 05 39 0967 04 39 0972 04 39 0973 15 39 0978 04 39 0980 04 39 0981 15 39 0982 15 39 0983 08 39 0985 17 39 0986 08 39 0987 17 39 0988 15 39 0989 17 39 0990 08 39 0991 04 39 0991 04 39 0992 06 39 0993 11 39 0994 11 39 0995 11 39 0999 06 39 0999 06 39 0999 06 39 0999 06 39 1000 06 39 1000 06 39 1003 20 39 1003 20
FIG. NO.
15 14 11 4 26 29 10 21 11 1 15 8 6 9 6 9 4 14 7 22 33 25 21 9 17 16 11 7 1 42 3 4 20 9 30 1 8 4 4 13 11 8 23 20 6 13 1 17 2 6 9 5 12 1 5 5
BOXER & 4S CHAMPION
PAGE NO.
PART NO.
37 21 45 22 41 41 65 66 17 37 31 63 72 82 69 68 37 79 63 62 20 41 62 65 68 68 65 1 37 20 2 42 15 40 43 64 5 33 7 42 7 40 26 28 8 17 7 17 3 10 12 23 1 4 24 27
39 1003 20 39 1004 20 39 1005 20 39 1006 20 39 1007 20 39 1010 04 39 1011 01 39 1011 01 39 1011 01 39 1012 04 39 1013 21 39 1013 21 39 1014 21 39 1015 21 39 1016 21 39 1017 21 39 1018 21 39 1019 21 39 1020 21 39 1021 21 39 1023 04 39 1028 21 39 1028 21 39 1028 21 39 1033 09 39 1034 20 39 1035 19 39 1038 01 39 1040 11 39 1040 11 39 1041 19 39 1042 19 39 1042 19 39 1042 19 39 1043 19 39 1046 19 39 1048 04 39 1049 04 39 1050 06 39 1053 15 39 1053 15 39 1054 11 39 1055 15 39 1056 04 39 1057 11 39 1058 11 39 1060 04 39 1060 04 39 1062 04 39 1063 01 39 1063 01 39 1066 04 39 1068 04 39 1069 01 39 1069 01 39 1071 01
FIG. NO.
5 4 14 1 5 8 34 33 34 6 6 22 16 12 19 14 14 2 1 11 2 6 6 6 2 23 10 15 11 8 16 4 4 4 11 11 10 10 9 12 21 2 1 4 8 11 20 7 4 3 13 10 3 13 3 6
PAGE NO.
29 40 42 40 10 1 48 51 54 1 23 41 3 12 1 1 7 12 1 1 11 24 27 29 14 15 2 72 31 79 13 24 27 29 11 6 10 3 11 6 15 64 6 10 14 14 32 79 11 1 3 11 10 9 16 22
89
PART INDEX PART NO.
39 1072 01 39 1074 04 39 1074 04 39 1075 04 39 1075 04 39 1076 01 39 1078 01 39 1079 01 39 1080 19 39 1148 20 39 1184 15 39 1189 23 39 1204 11 39 1209 24 39 1210 02 39 1225 15 39 1225 15 39 1225 15 39 1261 21 39 1285 23 39 1290 04 39 1290 04 39 1309 11 39 1347 19 39 1394 04 39 1412 04 39 1489 01 39 1607 01 39 1613 04 39 1613 04 39 1613 04 39 1714 04 39 1784 04 39 1789 24 39 1789 24 39 1791 04 39 1802 04 39 1803 04 39 1864 20 39 1920 01 39 2147 04 CD 2010 30 DB 1710 02 DD 1010 58 DD 1010 60 DD 1010 63 DD 1010 67 DD 1010 68 DD 1010 69 DD 1010 70 DD 1010 71 DD 1010 74 DD 1010 75 DD 1010 76 DD 1010 76 DD 1010 77
90
FIG. NO.
8 17 7 18 13 9 1 24 12 1 21 19 34 24 8 1 14 8 21 25 8 27 9 3 10 20 12 3 23 20 20 3 10 6 4 22 2 3 5 22 18 22 4 6 8 6 4 7 1 10 14 17 20 21 19 6
PAGE NO.
6 1 12 11 12 64 23 75 11 40 46 21 20 73 65 10 70 71 53 73 72 73 81 52 69 32 22 82 26 28 30 45 31 80 82 13 83 81 10 17 13 75 34 12 12 3 14 14 14 14 9 13 13 13 15 9
PART NO.
DD 1010 94 DD 1010 95 DD 1010 96 DD 1010 97 DD 1010 98 DD 1010 99 DD 1011 03 DD 1011 06 DD 1011 10 DD 1011 20 DD 1011 34 DD 1011 35 DD 1011 36 DD 1011 78 DD 1012 15 DD 1012 54 DD 1110 11 DD 1110 11 DD 1110 11 DD 1110 12 DD 1110 12 DD 1110 12 DD 1210 13 DD 1210 14 DD 1210 15 DD 1210 19 DD 1210 31 DD 1211 00 DD 1410 21 DD 1410 22 DD 1410 55 DD 1410 89 DD 1410 90 DD 1610 07 DD 1610 52 DD 1610 53 DD 1610 56 DD 1610 78 DD 1710 06 DD 1710 11 DD 1810 15 DD 1810 16 DD 1810 28 DD 1810 31 DD 1810 32 DD 1810 34 DD 1810 41 DD 1810 44 DD 1810 45 DD 1810 47 DD 1810 50 DD 1810 51 DD 1810 51 DD 1810 51 DD 1810 88 DD 1810 88
FIG. NO.
4 6 10 5 13 15 15 10 5 2 12 13 12 18 5 23 27 24 24 18 15 15 25 24 26 36 30 3 10 17 2 12 12 11 12 19 5 18 17 20 26 24 36 4 1 5 36 4 1 5 19 32 31 32 25 26
BOXER & 4S CHAMPION
PAGE NO.
16 16 16 16 14 14 10 9 14 2 2 2 7 15 22 17 26 28 30 25 28 29 62 62 62 20 19 21 61 62 61 61 61 64 31 32 33 44 35 35 48 48 51 49 49 49 54 52 52 52 66 48 51 54 50 53
PART NO.
DD 1810 89 DD 1810 89 DD 1810 90 DD 1810 90 DD 1810 90 DD 1810 91 DD 1810 91 DD 1810 91 DD 1811 02 DD 1910 12 DD 2010 72 DD 2210 03 DF 1010 10 DF 1110 01 DF 1110 04 DF 1110 05 DF 1210 03 DF 1410 01 DF 1410 02 DF 1410 20 DF 1410 22 DF 1410 26 DF 1410 27 DF 1410 28 DF 1410 29 DF 1410 34 DF 1410 40 DF 1410 42 DF 1410 44 DF 1410 45 DF 1410 46 DF 1410 46 DF 1410 47 DF 1410 47 DF 1410 52 DF 1410 57 DF 1410 58 DF 1410 61 DF 1410 61 DF 1410 62 DF 1410 62 DF 1411 32 DF 1610 01 DF 1610 04 DF 1610 09 DF 1610 10 DF 1610 15 DF 1610 16 DF 1610 17 DF 1610 18 DF 1610 19 DF 1610 20 DF 1610 21 DF 1610 22 DF 1610 26 DF 1610 28
FIG. NO.
23 24 25 24 25 27 26 27 3 5 18 1 13 1 3 23 3 2 5 1 1 2 5 2 5 1 1 1 3 6 3 3 6 6 1 1 1 3 3 6 6 1 8 7 8 11 1 1 2 2 2 3 2 3 11 11
PAGE NO.
50 53 48 50 53 48 50 54 49 44 66 79 10 29 29 30 23 58 59 55 55 58 59 58 59 55 55 55 58 59 58 58 59 59 55 55 56 58 58 59 59 55 77 81 60 60 82 82 82 82 56 57 56 57 60 60
PART INDEX PART NO.
DF 1610 29 DF 1610 30 DF 1610 31 DF 1610 32 DF 1610 35 DF 1610 36 DF 1610 37 DF 1610 38 DF 1610 39 DF 1610 40 DF 1610 41 DF 1610 42 DF 1610 43 DF 1610 44 DF 1610 45 DF 1810 01 DF 1810 01 DF 1810 07 DF 1810 07 DF 2010 01 DF 2010 04 DF 2010 05 DF 2010 06 DF 2010 07 DF 2010 08 DF 2010 09 DF 2010 10 DF 2010 11 DF 2010 13 DF 2010 15 DF 2010 17 DF 2010 19 DF 2010 20 DF 2010 21 DF 2010 22 DF 2010 23 DF 2010 54 DF 2010 55 DF 2010 56 DF 2110 03 DF 2110 13 DF 2110 17 DF 2210 04 DF 2210 05 DG 1611 21 DL 2010 08 TE 0063 03 TE 0063 03 TE 0063 03
FIG. NO.
2 2 3 3 2 2 3 3 9 12 9 12 10 2 3 34 35 22 19 1 3 2 4 11 7 8 9 2 1 3 4 5 9 10 21 3 9 10 13 4 3 2 4 18 7 10 21 18 18
PAGE NO.
PART NO.
FIG. NO.
BOXER & 4S CHAMPION
PAGE NO.
PART NO.
FIG. NO.
PAGE NO.
56 56 57 57 56 56 57 57 60 60 60 60 33 56 57 51 54 32 66 69 69 69 69 69 69 69 69 71 71 71 71 69 74 45 75 74 71 71 71 83 78 78 79 32 80 74 26 28 30
91
"Genuine bajaj spares ensure Optimum performance and longer life of the vehicle . "
AKURDI, PUNE 411 035 INDIA
