Brand ID: 001MC631
Foreward We have pleasure in presenting the Spare Parts Catalogue for ‘Discover DTS-i 135cc’ Motorcycle. This catalogue has been specially designed to assist you in selecting the correct parts for procurement to maintain 100% availability. The Bajaj Bajaj spa spare res s ar are e sub subje jecte cted d to th the e str strin inge gent nt qua quali lity ty con contr trol ol sta stand ndar ards ds to en ensur sure e longer life of the vehicle. It is therefore necessary that only the Genuine Bajaj Spares are used.
All information contained in this manual is based on the latest product information at the time of publication. Bajaj
In a continual effort to improve Performance and Efficiency of the vehicles, 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.
Auto Limited accepts no liability for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without prior notice. The right is reserved to make such changes at any time without prior notice and without incurring an obligation to make such changes to product
The modi modifi ficat cation ions s / al alte tera rati tions ons which which are are carrie carried d ou outt after after the issue issue of th this is catalog catalogue ue,, will be conveyed to you through our Service Circulars. You are requested to make necessary corrections in the Parts Catalogue as per the circulars so as to keep your catalogue up-to-date. This will ensure the appropriate and speedy delivery of the Spare Parts as the order placed will bear the latest part numbers. In case, if you need any technical assistance contact the concerned Regional Office or write to us on the following address :
manufactured previously. Contact your authorized Bajaj Dealer for the latest information on product improvements incorporated after this manual was issued.
Bajaj Auto Limi Limite te d Se rvi rvice ce Depa rtme nt Akurdi, Pune 411 035 India
DOC. NO.: 71110430
REV. 00, DEC. 07
Phone : 020-27406557 Fax : 020-27407385 E-mail :
[email protected]
Brand ID: 001MC631
Brand ID: 001MC631
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 conc erned page number (as given given by pictorial index). Now find out the figure of the part you wish to order. Write down the part number against that particular figure number number from the text. 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 (at the end of the catalogue) will give give you the figure 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 la late test st par partt nu num mbe berr as con conve veye yed d th thro roug ugh h ou ourr ser servi vice ce cir circul cular ars s sho shoul uld d onl only y appear on the order. In case of ordering painted components, colour shade of the components should be mentioned. The quanti quantity ty shown shown ag agai ainst nst the par partt nu num mber is th the e qua quant ntit ity y pe perr ve vehi hicle cle for that that group so that particular quantity should be multiplied multiplied by the number number of sets required.
3. Part Number System: We have used 8 digit system for part numbers. 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.
Assembly
V
Volts
N.I.
Not illustrated
W
Watts
C'case
Crankcase
accl.
Accelerator
Cyl
Cylinder
Comp.
Complete
o/s.
Over size
Fr
Front
Std.
Standard
L
Length
A/t.
Alternate
Rr
Rear
R.H.
Right hand
Hex.
Hexagonal
L.H.
Left hand
AR
As required
INDEX No.. No
Description
Page No.. No
1 2 3 4 5 6 7 8 9 10
Cover Cylinder Head Cylinder Head Valve Camshaft / Tensioner Cylinder & P iston Crank nksh shaf aftt Transmission Change Drum/ Shift Fork Gear Change Mechanism Eng En gine As Assl sly y & Cr Cra ankca case se RH
1 2 3 4 5 6 7 &8 9 10 11
11 12 13 14 15
Crankcase LH Cover RH Cover Magneto Clutch Cl Kick Starter Mechanism
12 13&14 15 16&17 18
16 17 18 19 20
Carburettor Air Cleaner Comp. Silence Sile ncerr Assl Assly y Seat Assly / Seat Lock Oill Pu Oi Pum mp
19 20 21 22 23
21 22 23 24 25
Magneto/C .D .D.I./H.T.C oi oil 24&25 Starter Star ter Assly (For Elect Electric ric Star Start) t) 26&27 Engine Mountings 28 Frame & Frame fitting 29 Swing Arm Arm / Rear Rear Shock Absorber 30-32
26 27 28 29 30
Rider Foot rest Pillion Foot rest / Holder Mudguard Front & Rear Stand Assembly Tyre/ Tube /Rim
31 32 33 34
Frontt Hu Fron Hub b Front Master Cylinder Front disc brake Rear Hub
33 34 35 36 37 38-40 41 42 43&44
No.. No 35
Description Rear Brake Pedal
36 37 38 39
Page No.. No 45
Handle Bar Front Fro nt For Fork k P ainted Parts & Decals Petrol Cock, Cock, Cap Tank & Gauge Fuel 40 Fit Fitti ting ngs s - P et etrol rol Tan Tank, k, Side Cover & Cover seat
46&47 48&49 48& 50&51
41 42 43 44 45
54&55 56 57&58 59&60 61
46 47 48 49
Meter Assly. Control Cables Chain Case Head Lamp & fairing Indicator Light Assly. Taill Lamp Assly. Tai Assly./Fro /Front nt No. Plate Plate
Electrical Equipments Tool Kit Accessories / Grab Handle Kits List For Discover
52 53
62 63&64 65 66 67
Amendmend Sheet (P arts Added)
68
Amendmend Sheet (P arts Deleted)
69
Part index
70
Brand ID: 001MC631
Brand ID: 001MC631
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 conc erned page number (as given given by pictorial index). Now find out the figure of the part you wish to order. Write down the part number against that particular figure number number from the text. 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 (at the end of the catalogue) will give give you the figure 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 la late test st par partt nu num mbe berr as con conve veye yed d th thro roug ugh h ou ourr ser servi vice ce cir circul cular ars s sho shoul uld d onl only y appear on the order. In case of ordering painted components, colour shade of the components should be mentioned. The quanti quantity ty shown shown ag agai ainst nst the par partt nu num mber is th the e qua quant ntit ity y pe perr ve vehi hicle cle for that that group so that particular quantity should be multiplied multiplied by the number number of sets required.
3. Part Number System: We have used 8 digit system for part numbers. 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.
Assembly
V
Volts
N.I.
Not illustrated
W
Watts
C'case
Crankcase
accl.
Accelerator
Cyl
Cylinder
Comp.
Complete
o/s.
Over size
Fr
Front
Std.
Standard
L
Length
A/t.
Alternate
Rr
Rear
R.H.
Right hand
Hex.
Hexagonal
L.H.
Left hand
AR
As required
INDEX No.. No
Description
Page No.. No
1 2 3 4 5 6 7 8 9 10
Cover Cylinder Head Cylinder Head Valve Camshaft / Tensioner Cylinder & P iston Crank nksh shaf aftt Transmission Change Drum/ Shift Fork Gear Change Mechanism Eng En gine As Assl sly y & Cr Cra ankca case se RH
1 2 3 4 5 6 7 &8 9 10 11
11 12 13 14 15
Crankcase LH Cover RH Cover Magneto Clutch Cl Kick Starter Mechanism
12 13&14 15 16&17 18
16 17 18 19 20
Carburettor Air Cleaner Comp. Silence Sile ncerr Assl Assly y Seat Assly / Seat Lock Oill Pu Oi Pum mp
19 20 21 22 23
21 22 23 24 25
Magneto/C .D .D.I./H.T.C oi oil 24&25 Starter Star ter Assly (For Elect Electric ric Star Start) t) 26&27 Engine Mountings 28 Frame & Frame fitting 29 Swing Arm Arm / Rear Rear Shock Absorber 30-32
26 27 28 29 30
Rider Foot rest Pillion Foot rest / Holder Mudguard Front & Rear Stand Assembly Tyre/ Tube /Rim
31 32 33 34
Frontt Hu Fron Hub b Front Master Cylinder Front disc brake Rear Hub
33 34 35 36 37 38-40 41 42 43&44
No.. No 35
Description Rear Brake Pedal
36 37 38 39
Page No.. No 45
Handle Bar Front Fro nt For Fork k P ainted Parts & Decals Petrol Cock, Cock, Cap Tank & Gauge Fuel 40 Fit Fitti ting ngs s - P et etrol rol Tan Tank, k, Side Cover & Cover seat
46&47 48&49 48& 50&51
41 42 43 44 45
54&55 56 57&58 59&60 61
46 47 48 49
Meter Assly. Control Cables Chain Case Head Lamp & fairing Indicator Light Assly. Taill Lamp Assly. Tai Assly./Fro /Front nt No. Plate Plate
Electrical Equipments Tool Kit Accessories / Grab Handle Kits List For Discover
52 53
62 63&64 65 66 67
Amendmend Sheet (P arts Added)
68
Amendmend Sheet (P arts Deleted)
69
Part index
70
Brand ID: 001MC631
Brand ID: 001MC631
Pictorial Index PLATE NO. : 1 COVER CYLINDER HEAD
PLATE NO. : 3 VALVE
PLATE NO. : 5 CYLINDER & PISTON
Pictorial Index PAGE NO.: 1
PAGE NO.: 3
PLATE NO. : 2 CYLINDER HEAD
PLATE NO. : 4 CAMSHAFT / TENSIONER
PAGE NO.: 2
PAGE NO.: 4
PLATE NO. : 7 TRANSMISSION
PLATE NO. : 9 GEAR CHANGE MECHANISM
PAGE NO.: 7 &8
PAGE NO.: 10
PAGE NO.:
PLATE NO. : 6
PAGE NO.:
PLATE NO. : 11
PAGE NO.:
5
CRANKSHAFT
6
CRANKCASE LH
12
PLATE NO. : 8 CHANGE DRUM / SHIFT FORK
PLATE NO. : 10 ENGINE ASSLY. & CRANKCASE RH
PLATE NO. : 12 COVER RH
PAGE NO.: 9
PAGE NO.: 11
PAGE NO.: 13 & 14
Brand ID: 001MC631
Brand ID: 001MC631
Pictorial Index PLATE NO. : 13
Pictorial Index PAGE NO.:
COVER MAGNETO
15
PLATE NO. N O. : 14A
PAGE NO.:
CLUTCH
17
PLATE NO. : 16
PAGE NO.:
CARBURETTOR
19
PLATE NO. : 14 CLUTCH
PLATE NO. : 15 KICK STARTER MECHANISM
PLATE NO. : 17 AIR CLEANER COMP.
PAGE NO.: 16
PAGE NO.: 18
PAGE NO.: 20
PLATE NO. : 18 SILENCER ASSEMBLY
PLATE NO. : 20 OIL PUMP
PLATE NO. : 22 STARTER ASSLY.
PAGE NO.: 21
PAGE NO.: 23
PAGE NO.: 26 & 27
PLATE NO. : 19 SEAT ASSEMBLY / SEAT LOCK
PLATE NO. : 21 MAGNETO /C.D.I./H.T. COIL
PLATE NO. : 23 ENGINE MOUNTINGS
PAGE NO.: 22
PAGE NO.: 24 & 25
PAGE NO.: 28
Brand ID: 001MC631
Brand ID: 001MC631
Pictorial Index PLATE NO. : 24 FRAME & FRAME FITTING
PLATE NO. : 25A SWING ARM / REAR SHOCK ABSORBER
PLATE NO. : 27 PILLION FOOT REST / HOLDER
Pictorial Index PAGE NO.: 29
PAGE NO.: 31 & 32
PAGE NO.: 34
PLATE NO. : 25 SWING ARM / REAR SHOCK ABSORBER
PLATE NO. : 26 RIDER FOOT REST
PLATE NO. : 28 MUDGUARD FRONT & REAR
PAGE NO.: 30
PAGE NO.: 33
PAGE NO.: 35
PLATE NO. : 29 STAND ASSEMBLY
PLATE NO. : 31 FRONT HUB(FOR DRUM BRAKE SYSTEM)
PLATE NO. : 32 FRONT MASTER CYLINDER
PAGE NO.: 36
PAGE NO.: 38 & 39
PAGE NO.: 41
PLATE NO. : 30 TYRE / TUBE / RIM
PLATE NO. : 31A FRONT HUB (FOR DISC BRAKE SYSTEM)
PLATE NO. : 33 FRONT DISC BRAKE
PAGE NO.: 37
PAGE NO.: 40
PAGE NO.: 42
Brand ID: 001MC631
Brand ID: 001MC631
Pictorial Index PLATE NO. : 34 REAR HUB
PLATE NO. : 36 HANDLE BAR
PLATE NO. : 38 PAINTED PARTS AND DECALS
Pictorial Index PAGE NO.: 43 & 44
PAGE NO.: 46 & 47
PAGE NO.: 50 & 51
PLATE NO. : 35 REAR BRAKE PEDAL
PLATE NO. : 37 FRONT FORK
PLATE NO. : 39 PETROL COCK, CAP TANK & GAUGE FUEL
PAGE NO.: 45
PAGE NO.: 48 & 49
PAGE NO.: 52
PLATE NO. : 40 FITTINGS-PETROL TANK, SIDE COVER & COVER SEAT
PLATE NO. : 42 CONTROL CABLES
PLATE NO. : 43A CHAIN CASE
PAGE NO.: 53
PAGE NO.: 56
PAGE NO.: 58
PLATE NO. : 41 METER ASSEMBLY
PLATE NO. : 43 CHAIN CASE
PLATE NO. : 44 HEAD LAMP & FAIRING
PAGE NO.: 54 & 55
PAGE NO.: 57
PAGE NO.: 59 & 60
Brand ID: 001MC631
Brand ID: 001MC631
Pictorial Index PLATE NO. : 45 INDICATOR LIGHT ASSEMBLY
Plate No. 1 : COVER CYLINDER HEAD PAGE NO.: 61
PLATE NO. : 46 TAIL LAMP ASSLY. / FRONT NO.PLATE
PAGE NO.: 62
6
8
9 2
4 7
5
3 2
11
PLATE NO. : 47 ELECTRICAL EQUIPMENTS
PAGE NO.: 63 & 64
PLATE NO. : 48 TOOL KIT
PAGE NO.:
10
65 10
1 11
No.
PLATE NO. : 49 ACCESSORIES / GRAB HANDLE
PAGE NO.:
1 2 3 4 5
Part No. J N 5110 DJ 1012 36 DS10 DS 1011 DS 1010
06 17 01 93 96
Description
1A
1B
Drum Br. Disc Br.
Head Cylinder with Cover Cover Tappet ‘O’ Ring Kit for C over C yl. Head B ush C ylinder Head C over Camshaft Cap
1 2 1 1 1
1 2 1 1 1
Dommed Cap Nut Copper Washer Bolt Flange Small Bolt Flange Small Plug Gasket
4 4 2 4 1 2
4 4 2 4 1 2
66
6 7 8 9 10 11
39 2647 15 DS 1010 84 39 2532 04 39 1075 04 DH 1012 72 DG 1014 98
Remarks
Ref. P age No. 67
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 2 : CYLINDER HEAD
Plate No. 3 : VALVE
5
13 6
4 2
10 5 1
11 1 7
12
3
2 2
9 6 9 4
8 8
5 3
7 8
No.
Part No.
Description
2A
2B
Drum Br. Disc Br.
Remarks
No.
Part No.
1 2 3 4 5
J N 5110 06 Head C ylinder with C over 39 1660 05 Stud (Exhaust) DH 1016 80 Gasket Cylinder Head DH 1015 08 Damper Cylinder Head J N 5814 00 Intake Pipe
1 2 1 5 1
1 2 1 5 1
1 2 3 4 5
DS DS DS DS 59
6 7 8 9 10
39 1283 21 DS 1210 12 DH 1210 38 39 1674 04 DH 1110 12
‘O’ Ring (Intake Pipe) Carburetor Insulator Clamp for Insulator Hex. Bolt / Flange Sleeve Spark Plug
1 1 2 2 1
1 1 2 2 1
6 7 8 9
DG 1010 29 Cotter valve 36 DS10 03 Valve Repair Kit 36 DS10 02 Valve Kit 39 2017 19 Seal Oil
11 12 13
39 2608 01 36 DS10 01 39 2181 06
Grub Screw ‘O’ Ring Kit for Cover C yl. Head Hollow Dowel Pin
1 1 2
1 1 2
Ref. P age No. 67
1013 35 1013 36 1013 33 1013 66 1100 02
Description Rocker Arm Shaft - Intake Rocker Arm Shaft - Exhaust Rocker Arm with Roller Wave washer Plain washer
3A
3B
Drum Br. Disc Br.
1 1 2 2 4
1 1 2 2 4
4 1 1 2
4 1 1 2
Remarks
Ref. Page No. 67 Ref. Page No. 67
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 4 : CAMSHAFT / TENSIONER
Plate No. 5 : CYLINDER AND PISTON
2
5
2 3 6 15
4
5
6
7
1 2
1 3 13
8
14
4 12
9
10
4 11
No.
Part No.
Description
4A
4B
Drum Br. Disc Br.
Remarks
No.
Part No.
Description
5A
5B
Drum Br. Disc Br.
1 2 3 4 5
J N 5112 02 Camshaft Assly 39 1880 20 Bearing cam LH side DH 1014 20 Washer behind small bearing DH 1014 12 Collar cam Sprocket DS 1012 76 Sprocket
1 1 1 1 1
1 1 1 1 1
1 2 3 4 5
DH 1010 16 39 2181 06 36 DJ 40 08 DH 101671 J N 5210 01
Gasket Cylinder Pin dowel Ring Set P iston Ring Snap Cylinder Block / Piston Assly
1 4 1 2 1
1 4 1 2 1
6 7 8 9 10
DH 1010 48 Special camshaft washer DH 1013 87 Hex. Soc. Head cap Bolt 36 DS10 04 Guide chain Kit DS 1010 36 Cam Chain (94 Links) 39 1674 04 Hex Bolt / Flange
1 1 1 1 2
1 1 1 1 2
6
J F 5212 00
Piston Assembly
1
1
11 12 13 14 15
DH 1010 11 DJ 1012 16 39 1014 21 DD 1010 62 39 2542 20
1 1 1 1 1
1 1 1 1 1
Cam chain Tensioner pivot Bolt Tensioner Assly Ring’O’ Bolt Bearing Ball
Ref. Page No. 67
Remarks
Ref. P age No. 67
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 6 : CRANK SHAFT
Plate No. 7 : TRANSMISSION
13
9 4
10 6
1
16
2 4
12
1 14
13
19 3
5
17
23
17
12
11
15
5 17 9
7 8
17 15
16 20
14 10 11 19
3
2
8
7
18
22 21 18
6
Description
6A
6B
No.
Part No.
1 2 3 4 5
J N 5310 00 DH 101195 39 2200 11 DS 1013 63 DS 1012 75
C rankshaft assly. C omp. Nut Washer Gear primary driver Sprocket cam drive
1 1 1 1 1
1 1 1 1 1
6 7 8 9 10
DS 1010 77 DS 1012 60 39 2713 21 DS 1011 54 DH 1010 66
Body centrifugal oil filter Cover centrifugal oil filter ‘O’ Ring Key J oint Oil Delivery - B
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
DS 31 39 DS 39
1011 12 1011 73 2203 07 1013 55 2165 11
Spring Oil Delivery- B Key woodruff Parallel pin Bolt Plain washer
1 1 1 1 1
1 1 1 1 1
16 17 18 19
28 39 39 DS
1011 10 Damper 2561 20 Ball Bearing 2712 17 C irclip 1011 52 Spacer
1 2 1 1
1 2 1 1
Drum Br. Disc Br.
Remarks
No.
Part No.
Description
7A
7B
Drum Br. Disc Br.
1 2 3 4 5
DS DS DS 39 DS
1012 91 1012 05 1010 49 0987 17 1010 48
Shaft Input Transmission Collar Gear 4th Drive Ring Snap Gear 3rd Drive
1 1 1 1 1
1 1 1 1 1
6 7 8 9 10
39 DS DS DS DS
0337 17 1010 47 1011 29 1099 07 1012 04
External Circlip Gear 2nd drive Thrust washer Shaft output Transmission Washer Plain
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
DS DH DS DH DS
1010 1010 1010 1011 1010
Gear 3rd Driven Washer Spline Gear 4th Driven Bush 1st driven Gear 1st driven
1 1 1 1 1
1 1 1 1 1
54 79 55 11 52
Remarks
With Plug & Collar
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 7 : TRANSMISSION
Plate No. 8 : CHANGE DRUM / SHIFT FORK 1
10 6 16
2
4
7 4
1 14
13 3
6
3
17
23
12
11
15
5 17
5
9
7 8
20
19 22 21 18
2 3
Description
7A
7B
No.
Part No.
16 17 18 19 20
DS 1012 03 DH 1012 35 DH 1012 35 DS 1013 55 DH 1013 34 30 1010 61
Washer Plain Circlip Circlip Hex. Socket Bolt Collar Sprocket ‘O’ Ring S procket C ollar
1 2 1 2 1 1
1 2 1 2 1 1
21 22 23
DS 1011 97 DS 1011 98 DS 1011 07
Sprocket Drive Plate Drive Sproket Spline washer
1 1 1
1 1 1
Drum Br. Disc Br.
Remarks
For DS 1099 07
No.
Part No.
1 2 3 4 5
DS DS DS DS DS
1010 1010 1010 1010 1011
63 64 62 79 35
6 7
39 2639 04 DS 1011 32
Description
8A
8B
Drum Br. Disc Br.
Fork Gear Shift Input Fork Gear Shift output Shaft Gear Shift Fork Guide Gear Shifter Drum Assly. Gear Shift
1 1 2 1 1
1 1 2 1 1
Bolt Socket Parallel pin
1 1
1 1
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 9 : GEAR CHANGE MECHANISM
Plate No. 10 : ENGINE ASSEMBLY, CRANKCASE R.H.
3
3
13
12 4
2
10
11 8
9 1 3
7
2 10
8 4
6
7 8 9
6
5 5
No.
Part No. 1011 1011 1011 1011 1012
34 18 73 04 51
Description
9A
9B
Drum Br. Disc Br.
Remarks
No.
Part No.
1 2 3 4 5
DS DS DS DS DS
Lever comp. Gear Shifter Spring slider arm reset Stopper Comp.gear shifter drum Bolt shift change Lever comp. change with Damper
1 1 1 1 1
1 1 1 1 1
1 1 2 3 4 5
J N 5010 00 J N 5010 01 J N 5410 02 39 2531 05 DG 1210 02 DS 1011 67
6 7 8 9 10
31 1011 08 Damper 39 1673 04 Flanged Bolt DH 1012 25 Bolt Gear Shift drum Stopper DS 1011 19 Spring gear shifter return DS 1011 03 Spring gear shifter drum stopper
1 1 1 1 1
1 1 1 1 1
6 7 8 9 10 11 12 13
Description Engine Assly. Engine Assly. Crankcase RH Stud Spring Clip Gasket Crankcase
10A
10B
Drum Br. Disc Br.
1 1 1 2 1 1
1 1 2 1 1
39 2583 20 Bearing Ball (For input shaft) 39 2662 20 Needle Brg. (For Output shaft) 39 2181 06 Dowel Pin DU 1010 85 Bushing (For Drum Change) DH 1012 25 Bolt
1 1 2 1 1
1 1 2 1 1
DS 1012 14 39 0746 01 DS 1010 08
1 1 1
1 1 1
Rubber tube Screw Breather Plate
Remarks
For KS Drum Brake
For Holding Spring
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 11 : CRANKCASE LH
Plate No. 12 : COVER RH
10 2
2
4
6
13
7
12 13
3 20
15
17 18
4 14
2
15 3
16
9 19
5 6
10
1
11 17 8
9
12
8
1
7 16 5 11
14
No.
Part No.
Description
11A
11B
Drum Br. Disc Br.
1 2 3 4 5
JN 39 39 39 39
5410 2531 1715 2562 2583
00 05 19 20 20
Crankcase LH Stud Oil Seal Needle Bearing (For Input shaft) Bearing Ball (For Output shaft)
1 2 1 1 1
1 2 1 1 1
6 7 8 9 10
39 39 JN 39 39
2189 2190 5710 1754 1283
19 19 01 21 21
Oil Seal (For Output shaft) Oil Seal (For Shift lever) Cap Strainer ‘O’ ring ‘O’ ring
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
31 2010 81 DH 1012 64 39 1963 04 39 1677 04 39 1845 04
Switch comp.(Neutral) Gasket Neutral Switch Flanged Bolt Bolt Bolt
1 1 1 6 1
1 1 1 6 1
1 1
1 1
16 DH 1011 69 Bush starter gear inner 17 DS 1210 04 Mesh Filter oil Comp.
Remarks
No.
Part No.
1 2 3 4 5
JN 39 39 DS DS
6 7 8 9 10
DS 1012 63 DH 1011 52 39 1075 04 39 0999 06 DS 1010 73
11 12 13 14 15
DS DS 39 DS 39
Description
5412 00 Cover comp. RH 1917 19 Oil Seal 1041 19 Seal Oil 1010 67 Lever Assly. Clutch 1010 50 Rod Push (For Clutch Lever) Dip Stick with O Ring ‘O’ ring Oil level Gauge Bolt Pin Dowel Bracket Clutch Cable
1010 72 Gasket cover RH 1011 23 Spring clutch lever 2443 11 Washer 1012 11 Damper Cover RH 2544 04 Hex. HD Bolt / Flange
12A
12B
Drum Br. Disc Br.
1 1 1 1 1
1 1 1 1 1
1 1 8 2 1
1 1 8 2 1
1 1 1 1 1
1 1 1 1 1
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 12 : COVER RH
Plate No. 13 : COVER MAGNETO
11
10 4
6 7
12 13
3 20
13 10
17
4 18
14
2
15
9
3
19
5
12
6
8
1
8 16
7 2
5
1
11
No. 16 17 18 19 20
Part No. DS DG DS DS DS
1012 1014 1012 1012 1012
52 18 15 12 01
Description ‘bajaj’ Decal Gauge Wire Circlip Plate Cover Damper RH Bushing
9
12A
12B
Drum Br. Disc Br.
1 1 1 1 1
1 1 1 1 1
Remarks Fixed on cover comp. RH
No.
Part No.
1 2 3 4 5
J N 5412 04 39 1674 04 DG 1014 18 DS 1013 07 39 1075 04
Description Cover Mag.with gauge & decal Bolt Hex. Gauge Gasket Magneto cover Bolt
13A
13B
Drum Br. Disc Br.
1 3 1 1 4
1 3 1 1 4
6 7 8 9 10
39 0999 06 Pin Dowel DH 1011 57 Cap Crank Center 39 1283 21 ‘O’ Ring 52 J N00 08 Cover LH Rear with Decal DS 1012 10 Damper Cover LH
2 1 1 1 1
2 1 1 1 1
11 12 13
39 2208 04 DS 1012 53 DH 1012 83
4 1 1
4 1 1
Flanged Bolt ‘bajaj’ Decal Plate Damper Cover LH
Remarks J N 5412 03
J N 5412 06
Fixed on Cover magneto
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 14 : CLUTCH
Plate No. 14A : ANTI-J UDDER CLUTCH
4
4
5
5
12
12 4
4
2
5
2
5
4
4
11
7
11
7
5
5 8
8
6
6
3
3
9
9 4
16
4 1
1
13
10
No.
Part No.
Description
15
10
14A
14B
Drum Br. Disc Br.
Remarks
No.
Part No.
Description
14A
14B
Drum Br. Disc Br.
1 2 3 4 5
39 2200 11 Plain Washer DS 1013 19 Clutch Center DH 1013 44 Plate Clutch pressure J N 5514 10 Disc C lutch friction Adler (E type) DH 1015 57 Plate Clutch
1 1 1 4 3
1 1 1 4 3
1 2 3 4 5
39 2200 11 DS 1013 19 DH 1013 44 J N 5514 10 DH 1015 57
Plain Washer Clutch Center Plate Clutch pressure Disc Clutch friction Adler (E type) Plate Clutch
1 1 1 4 3
1 1 1 4 3
6 7 8 9 10
J N 5514 00 39 1553 04 DH 1014 84 DS 1011 05 DH 1015 20
6 6 1 1 1
6 6 1 1 1
6 7 8 9 10
J N 5514 00 39 1553 04 DH 1014 84 DS 1011 05 DH 1015 20
Spring Clutch Bolt Holder Clutch Guide Plate Clutch Pressure Nut Primary drive lock
6 6 1 1 1
6 6 1 1 1
11 12 13
J N 5514 01 Assembly Clutch Complete J N 5514 02 Clutch Plate Assly DH 1014 85 Rod Clutch Lifter
1 1 1
1 1 1
11 12 13 14 15
JN JN JN JN JN
Assembly Clutch Complete Clutch Plate Assly Anti J udder Spring Anti J udder Washer Assembly Recess Cup
1 1 1 1 1
1 1 1 1 1
16
J N 1514 14 Rod Push
1
1
Spring Clutch Bolt Holder Clutch Guide Plate Clutch Pressure Nut Primary drive lock
LH Thread
5514 5514 5514 5514 5514
17 16 08 09 15
Remarks
LH Thread
N.I. N.I.
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 15 : KICK STARTER MECHANISM
Plate No. 16 : CARBURETTOR
5
13 6 13 10
4 3 12
7
11
14
2 7 11
5 2
8
3
9
16 8 15
16
1 6
8
10
6
12 4
9
1
No.
Part No.
1 2 3 4 5
DS 1012 DD 1010 36 DS10 DS 1012 DS 1010
06 97 07 09 58
6 7 8 9 10
DS DS 39 39 39
1010 57 1010 60 2276 11 0993 11 2276 11
11 12 13 14 15
DS DH DS DS DH
1010 1013 1010 1011 1011
16 17
39 0738 17 39 1373 04
Description
15A
15B
Drum Br. Disc Br.
Lever Kick Starter complete Damper Boss Kick Set Bolt Special Collar Spring
1 1 1 1 1
1 1 1 1 1
Spindle Kick Starter Assly Pinion Kick Starter Washer Washer Thrust Plain Washer
1 1 2 1 1
1 1 2 1 1
1 3 1 1 1
1 3 1 1 1
2 1
2 -
61 Guide Kick 85 Bolt Flanged 59 S pring K ic k S tarter 90 Ratchet 21 Spring C irclip Bolt
Remarks
Ref. Page No. 67
For KS qty is 4
For KS
No. 1 2 3 4 5
Part No. J N 5812 36 DS12 J N 5812 J N 5812 DS 1210
01 01 08 15 89
Description Carburetor Assly. Vacuum Piston Kit J et Holder Kit J et needle Packing
16A
16B
Drum Br. Disc Br.
1 1 1 1 1
1 1 1 1 1
6 7 8 9 10
DS 1210 90 Screw Pan DS 1210 80 Float Comp. DH 1211 01 Magnet Assly. DH 1211 02 Reed Switch Assly. 39 0899 01 Pan Head Screw
4 1 1 1 2
4 1 1 1 2
11 12 13 14
JN DS DS JN
1 1 1 1
1 1 1 1
5812 1210 1211 5812
07 Idling Screw Kit 76 Float Valve Comp. 15 Set Plunger 12 Choke Plunger Housing with Gasket
Remarks
Ref. Page No. 67 Ref. Page No. 67
Ref. Page No. 67
N.I.
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 17 : AIR CLEANER COMP
Plate No. 18 : SILENCER ASSEMBLY
6
1
5
8 2
8
7 10
8
2
2 10
3
7
6
9
9
5 3
11 4 1
12
13 4
No. 1
Part No.
4 5
JN DS DS JN DS DX DX
6 7 8 9 10
39 0071 04 39 1765 11 31 1210 43 39 1940 04 DX 1210 06
11 12 13
DS 1211 17 Drain Tube DS 1211 26 Plug DG 1210 02 Spring Clip
2 3
5810 1211 1610 5810 1211 1210 1210
02 29 69 01 31 07 10
Description
17A
17B
Drum Br. Disc Br.
Air Cleaner comp. Air Cleaner comp. Bracket Side Cover Mtg. Connecting Tube Connecting Tube Cartridge Assly. Element Air Filter
-1 1 -1 1 1
1 -1 1 -1 1
Hex. Bolt Plain Washer Collar Flanged Bolt O ring
3 3 2 2 1
3 3 2 2 1
1 1 2
1 1 2
Remarks
Description
18A
18B
No.
Part No.
1 2 3 4 5
J N 5910 00 DS 1013 89 DH 1013 01 DH 1014 68 DD 1610 71 DJ 1010 64
Silencer Assly. S ilenc er Assly. Seal Shield Muffler Shield Muffler ‘U’ Nut Gasket Exhaust
-1 2 1 1 1
1 -2 1 1 1
6 7 8 9 10
39 1970 15 39 2730 04 DH 1013 02 DH 1014 81 J N 5910 16
Flanged Nut Hexagonal Bolt Truss Screw Grommet Shield Wire Shield Assly.
2 1 2 1 1
2 1 2 1 1
Drum Br. Disc Br.
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 19 : SEAT ASSEMBLY / SEAT LOCK
Plate No. 20 : OIL PUMP
5 4
1
4
2
4
3
2
No.
Part No.
1 2 3 4
DS 2110 01 36 DS21 01 DS 2110 06 39 1902 04
Description Seat Assly comp Seat Damper Kit Lock Assly seat Flanged bolt
19A
19B
Drum Br. Disc Br.
1 1 1 2
1 1 1 2
Remarks
No.
Part No.
1 2 3 4 5
DS 28 28 39 DS
1211 18 1210 07 1210 08 1674 04 1013 65
6
39 1686 06
3
6
Description
1
20A
20B
Drum Br. Disc Br.
Oil Pump Body Rotor Oil Pump inner Rotor Oil Pump outer Bolt Gear oil Pump Driven
1 1 1 3 1
1 1 1 3 1
Hollow Dowel Pin
3
3
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 21 : MAGNEO / C.D.I / H.T.COIL
Plate No. 21 : MAGNEO / C.D.I / H.T.COIL
9
9 10
10
21
19
21
19
18
7
13
12
18
20
7
13
12 20
11
8
11
8
12
12
6
16
6
16
5
5
3
3
14
14 4
15 17
15
Description
7
17
2
21A
21B
No.
Part No.
1
3 4 5
DS 1110 56 DS 1110 18 DS 1110 49 DS 1110 16 39 1674 04 39 0761 01 DH 1011 99
Rotor Assly. Rotor Assly. Stator Assly. comp Stator Assly. comp Hex. Bolt with Flange Pan Head Screw Stopper plate (wiring harness)
1 1 1 1 2 2 1
1 1 1 1 2 2 1
6 7 8 9 10
39 0746 01 DG 1110 08 DS 1110 43 DS 1110 35 DS 1110 36
Screw Pan head Spark plug (Champion RG4HC) C.D.I Assly H.T. Coil LH with Grommet H.T. Coil RH with Grommet
1 2 1 1 1
1 2 1 1 1
11 12 13 14 14 15
DH 1110 15 Cap Spark Plug DD 1110 12 Grommet H.T. Cable DH 1110 13 Grommet Spark Plug DS 2010 03 Regulator Voltage DH 2010 18 Regulator Voltage 31 2010 82 Capacitor
2 2 1 1 1 1
2 2 1 1 ---
2
4
1
7
Drum Br. Disc Br.
2
Remarks
No.
For For For For
16 17 18 19 20
39 39 39 DJ 39
21
DH 1110 16
new vehicle old vehicle new vehicle old vehicle
For KS For KS
Part No. 1943 0798 1902 1610 1680
04 15 04 67 04
Description
21A
21B
Drum Br. Disc Br.
Flange Bolt Flange Nut Flange Bolt Bracket H.T.Coil Flange Bolt
1 1 2 1 2
1 1 2 1 2
Grommet Sleeve Spark Plug
1
1
Remarks
1
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 22 : STARTER ASSEMBLY
Plate No. 22 : STARTER ASSEMBLY (FOR ELECTRCI START)
17
12
17
12
18
13
18
13 19
19
16
16
14
14 4
4
1 22
1
3
22 11
11
8 7
5
8
9
7
10
21
8
3
5
9
6
10
21
8
2
15
20
No. 1
Part No.
22A
20
22B
Drum Br. Disc Br.
4 5
DH DH DH DH DH DH DH
82 Body comp. starter clutch 34 Body comp. starter clutch 64 Spring 81 Plate roller clutch 86 Plate roller clutch 01 Gear starter clutch 81 P late starter clutch gear return
1 1 5 1 1 1 1
1 1 5 1 1 1 1
6 7 8 9 10
39 1672 04 Bolt DS 1011 01 Shaft starter counter DS 1011 79 Special Washer starter counter DH 1014 72 Gear starter c ounter 39 2152 20 Needle roller bearing
1 1 2 1 1
1 1 2 1 1
11 12
39 JN DS 39 JN DJ
3 -1 4 1 5
3 1 -4 1 5
2 3
13 14 15
1017 1015 1011 1017 1011 1014 1015
Description
2437 04 3516 00 1110 51 1074 04 5514 07 1011 09
Bolt socket Motor assly. starter Motor assly. starter Bolt Body Starter Counter Bush for Spring Starter
6
2
15
For new vehicle For old vehicle
16 17 18 19 20
39 1062 04 Bolt DS 1011 44 Cap 39 2547 17 Circlip 39 0999 06 Dowel Pin DH 1011 63 Roller
2 1 1 2 5
2 1 1 2 5
21 22 23
DH 1015 33 DS 1012 94 59 1000 02
5 1 1
5 1 1
Stopper plate For stopper plate
Description
22B
No.
For new vehicle For old vehicle
Part No.
22A
Remarks
Bush Spring Starter Clutch Gasket Spring dowel
Drum Br. Disc Br.
Remarks
N.I.
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 23 : ENGINE MOUNTINGS
Plate No. 24 : FRAME AND FRAME FITTINGS 4
2
2
4
3
4 4
5 9
5 5
3 5 3 4
8 4
3 9 1
6
4
10
3 4 8
5
6
9
7 8
11 5
23A
23B
No.
Part No.
1 2 3 4 5
36 DS16 02 36 DS16 01 39 2312 04 39 1970 15 39 1556 04
Engine Mounting Bracket Set Engine Mounting Plate Set Bolt Flanged Nut Flanged Bolt flanged
1 1 4 7 4
1 1 4 7 4
6 7 8 9
39 39 39 39
Bolt Flanged Hex. Nut /Flanged Bolt Flanged Flanged Nut
1 3 2 3
1 3 2 3
2718 1225 2702 2723
04 15 04 15
Description
9
Drum Br. Disc Br.
Remarks
No.
Part No.
1
DS 1612 57 DS 1611 19 DS 1810 18 DH 1810 14 36 DS18 02 30 1810 06
2 3 4 5 6 7 8 9 10
DH DG DS DP DS
11
DS 1611 02
Description Frame Assly. comp. Frame Assly. comp. Nut Fork Cup - Steering Bearing cone Kit Ball steel
1611 00 Spacer Main Step 1611 21 Screw 2010 27 Side Reflector 1710 06 Silent Bush 1611 42 Bash Plate Grommet Bash Plate
24A
24B
Drum Br. Disc Br.
-1 1 1 1 46
1 -1 1 1 46
4 4 2 2 1
4 4 2 2 1
4
4
Remarks Incl bush, races & Cup rear
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 25 : SWING ARM / REAR SHOCK ABSORBER
Plate No. 25A : SWING ARM / REAR SHOCK ABSORBER
2
2
17
17 7
18 2
9 10
4
18
8
2
2
6
11
7 2
9 10
2
4
6
11
13
8
2
13
1
12 6
1
12
3 5
6
1
3 5
1
15
15
16
20 19
16
19 14
14 16
16
16
Description
16
20
16
25A
25B
No.
Part No.
1 2 3 4 5
DG 1710 38 39 0714 11 J N 1220 00 39 0258 11 J N 1220 02
Hex. Bolt/ Flange Plain washer Rear Shock Absorber Plain Washer Swing arm assly.
------
2 8 2 2 1
6 7 8 9 10
DS 39 39 DS 39
1710 15 0712 15 0737 12 1710 07 0553 02
Cap Swing Arm Domed Cap Nut Spring Washer Chain slider Screw
------
2 2 2 1 2
11 12 13 14 15
39 DS 39 DJ DJ
0454 11 1710 13 1358 15 1510 36 1510 37
Plain washer Shaft swing arm Flanged Nut Adjuster chain LH Adjuster chain RH
------
2 1 1 1 1
16 17 18 19 20
39 DS 39 39 39
0292 15 1710 14 1773 04 1943 04 0711 11
Hexagon nut Mud Flap Flange Bolt Bolt Washer
-----
4 1 2 1 1
Drum Br. Disc Br.
16
Remarks
No. 1 2 3 4 5
Part No.
Description
25A
25B
Drum Br. Disc Br.
DG 1710 38 Hex. Bolt/ Flange 39 0714 11 Plain washer DX 1710 03 Rear Shock Absorber 39 0258 11 Plain Washer DS 1710 02 Swing arm assly.
2 8 2 2 1
------
6 7 8 9 10
DS 39 39 DS 39
1710 15 0712 15 0737 12 1710 07 0553 02
Cap Swing Arm Domed Cap Nut Spring Washer Chain slider Screw
2 2 2 1 2
------
11 12 13 14 15
39 DS 39 DJ DJ
0454 11 1710 13 1358 15 1510 36 1510 37
Plain washer Shaft swing arm Flanged Nut Adjuster chain LH Adjuster chain RH
2 1 1 1 1
------
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 25 : SWING ARM / REAR SHOCK ABSORBER
Plate No. 26 : RIDER FOOT REST
2 4
17 18
7 2
9 10
8
2
8
2
4
9
6
11
13
7
6
10
11 1 2
12 6
3 5
5
3
1
1
15
11
16
20
16
4
19 14
10
16
9
16
6
No. 16 17 18 19 20
Part No. 39 DS 39 39 39
Description
0292 15 Hexagon nut 1710 14 M ud Flap 1773 04 Flange Bolt 1943 04 Bolt 0711 11 Washer
25A
25B
Drum Br. Disc Br.
4 1 2 1 1
------
Remarks
No. 1 2 3 4 5
Part No.
7
Description
26A
26B
Drum Br. Disc Br.
DJ 1611 26 Assly. C omp.Main step LH 39 1940 04 Flange bolt DJ 1611 27 Main step RH assly. comp. DH 1610 53 Rubber Main Step DG 1612 24 Damper
1 4 1 2 1
1 4 1 2 1
6 7 8 9 10
39 1282 15 39 0897 04 DS 1611 17 DH 1611 00 DH 1610 56
Domed Cap nut Bolt Stay Main Step Spacer Main Step Plate Comp. Lower Mounting
2 2 1 2 2
2 2 1 2 2
11
DJ 1610 90
Damper Footrest
2
2
Remarks
For Kick stopper
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 27 : PILLION FOOT REST / HOLDER
Plate No. 28 : MUDGUARD FRONT & REAR
5
6
10
10
4 7 8
10
10
13
9
1
2
8 7 6 16 10
12
17 6
14
1
3 5
4
2
8
11
7
3 5
15 9
9
11
13
No.
Part No.
1 2 3 4 5
DS DS DH DH DH
6 7 8 9 10 11 12 13
1610 1610 1613 1613 1613
Description
85 Holder LH step 86 Holder RH step 13 Pillion step assly. comp. LH 15 Pillion step assly. comp. RH 17 Rubber pillion step
27A
27B
Drum Br. Disc Br.
Remarks
Description
28B
Part No. DS 1611 25 DX 1610 65 39 2310 04 39 1507 11 DX 1610 34
Cable Guide Brace fender Flange bolt Plain Washer Fender rear front
1 1 4 4 1
1 1 4 4 1
Flange bolt Plain washer Flange nut Fender rear Flange bolt
2 2 2 1 2
2 2 2 1 2
Sleeve Front Fender Nail for Cable Guide Nyloc Nut Flap Front fender Grommet Side Cover
4 1 3 1 2
4 1 3 1 2
2 1 1
2 1 1
1 1 1 1 2
1 1 1 1 2
1 2 3 4 5
DD 1613 81 Pin pillion step 30 1410 31 ‘O’ ring 39 1040 11 Plain washer 39 0784 08 Split pin 39 2722 04 Soc. Head Bolt
2 2 2 2 4
2 2 2 2 4
6 7 8 9 10
39 39 39 DS 39
DX 1610 67 Plate Lock Pillion Step DH 1611 00 Spacer Main Step 22 1504 51 Bolts- Cylinder
2 2 2
2 2 2
11 12 13 14 15
DS 1611 08 DJ 1610 69 39 0326 15 DS 1611 41 DH 1611 58
16 17 18
39 0211 11 Plain Washer J N 1814 03 Hose Clamp DX 1610 66 Damper
N. I.
28A
No.
2701 04 0211 11 0798 15 1610 62 1943 04
Drum Br. Disc Br.
Remarks
Fender front mtg.
NI
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 29 : STAND ASSEMBLY
Plate No. 30 : TYRE / TUBE / RIM
3
3 2
2
8 1
4
E U R
10
O P I R G
5
9
1 6
5
7
4
E U R
O P I R G
6
No.
Part No.
Description
29A
29B
Drum Br. Disc Br.
1 2 3 4 5
DS 1611 13 Center Stand DS 1611 12 Shaft stand 39 0797 08 Pin cotter DH 1611 21 Spring main stand DH 1611 45 Cover spring main stand
1 1 1 1 1
1 1 1 1 1
6 7 8 9 10
DS 1610 77 DH 1612 40 DF 1611 02 39 0422 15 DG 1611 24
1 1 1 1 1
1 1 1 1 1
Stand side Spring side stand with cover Bolt Nut Damper Main Stand
Remarks
30B
Part No.
1
DJ 1510 77 DS 1510 86 DS 1510 48
Wheel rim front Wheel rim front Tyre front
-1 1
1 -1
5
DS DJ DS DS
Tube front Wheel rim rear Wheel rim rear Tyre rear
1 -1 1
1 1 -1
6
DS 1510 29 Tube rear
1
1
2 3 4
1510 1510 1510 1510
49 87 84 31
Description
30A
No.
Drum Br. Disc Br.
Remarks
Proprietary items Not to service
Proprietary items service
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 31 : FRONT HUB (FOR DRUM BRAKE SYSTEM)
2
Plate No. 31 : FRONT HUB (FOR DRUM BRAKE SYSTEM)
2
8
24
8
24 7
7
1
1
6
6
25
25
3
1
3
1
16
10 12
17
10
18
12
14
13
17
19
22
11
5
5 23 20
9
No.
Part No.
Description
23 23
20
21
9
4
30A
30B
Drum Br. Disc Br.
Remarks
No.
Part No.
23 21
4
Description
31A
31B
Drum Br. Disc Br.
1 2 3 4 5
39 DS 30 39 39
2688 20 1510 56 1510 32 0840 01 0798 15
Bearing Ball Dusct Seal Collar Bearing Screw pan cross Nut
2 1 1 1 1
------
16 17 18 19 20
30 1510 35 Oil seal 30 1510 69 Spring 30 1511 05 Shoe brake 36 DS15 02 Speedometer gear Kit 30 1511 18 Stopper for bushing
1 2 1 1 1
------
6 7 8 9 10
39 39 39 DJ 39
0781 0786 0787 1510 0775
Plain washer Nut castle Pin cotter Axle Bolt
1 1 1 1 1
------
21 22 23 24 25
JA 39 30 30 DS
1 1 2 1 1
------
11 12 13 14 15
J A 1316 07 DD 1510 09 30 1510 38 DS 1510 87 DD 1510 08
Lever brake cam Indicator Ring ‘O’ Panel front brake Cam brake
1 1 1 1 1
------
11 15 08 41 04
18
19 22
11
17
15
14
13
16
17
15
1316 06 1013 21 1510 42 1510 33 1510 42
Bushing Speedo Cable Ring ‘O’ Washer ‘A’ Oil Seal Spacer
Remarks
Ref. Page No. 67
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 31A : FRONT HUB (FOR DISC BRAKE SYSTEM)
Plate No. 32 : FRONT MASTER CYLINDER
4 2
8
3
3
2
10
6
5
9
10
10 E S : U - 4 3 M N G T I N O R O R Y D F W A N L R D N E I O F U L A T I E N P K R A D C O R C A I G B E I E O V N L L L E A N F M E A S E A E R R C L F O E B
9
13 1 15
5 7
4
5 14
1
7
7
2 13
12
8 11
5 5
12
No.
Part No.
Description
31A
31B
Drum Br. Disc Br.
6
11
4
Remarks
No.
Part No.
Description
32A
32B
Drum Br. Disc Br.
1 2 3 4 5
39 39 DE 30 DE
0787 08 Pin cotter 2688 20 Bearing ball 1510 06 Spacer assly. 1510 33 S eal oil 1510 12 Plate drive
------
1 2 1 1 1
1 2 3 4 5
DJ DJ DJ DE DJ
1910 1510 1910 1910 1910
23 76 06 11 26
Major Kit - Master Cylinder Hose Brake Front Lever Grip RH Banjo Bolt Washer Copper
------
1 1 1 2 4
6 7 8 9
DE DJ 39 39
1510 08 1510 14 0781 11 2038 04
Seal oil Disc Plain washer Hex. soc. hd. bolt
-----
1 1 1 6
6 7 8 9 10
DJ DJ DJ DJ DJ
1910 1910 1910 1910 1910
27 28 29 30 31
Clamp Holder RH Bolt Bolt Front Brake Lever Nut Flanged Screw
------
1 1 1 1 2
10 11 12 13
DJ DS DJ 39
1510 57 1510 58 1510 41 0786 15
Case meter gear Assly Spacer Axle Hex. Slotted Nut
-----
1 1 1 1
11 12 13 14 15
DJ DJ DJ DJ 36
1910 32 2011 00 1910 34 1910 35 DH19 02
Cylinder Master Front brake switch Reservoir Cover Diaphragm Oil Window Kit
------
1 1 1 1 1
Remarks
Ref. Page No. 67
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 33 : FRONT DISC BRAKE
Plate No. 34 : REAR HUB 1 21
29 9
4
17
16
26
5
28
11A
DUST SEAL
11B
x
3
19
23
INSULATOR 27 4
CALIPER PISTON
12A
5 22
3
4 1
2
PROTECTION BOOT
7 2
21 25
BLEEDER CAP
5 8
7
6
15
18
8
11A 11B 12A
20
PISTON SEAL
BLEEDER SCREW
3
12
PAD SPRING 14
8
9
6
7 14
33A
33B
No.
Part No.
1 2 3 4 5
DG 1510 89 39 1769 04 DJ 1510 68 DJ 1510 69 DJ 1510 70
Caliper Assly. Front Bolt Flanged Spring Pad Bleeder Screw Bleeder Cap
------
1 2 1 1 1
1
6 7 8 9 10
DJ DJ DJ DJ DJ
Disc Pad Set Insulator Protection Boot Minor Kit - Caliper Major Kit - Caliper
------
1 1 1 1 1
6
1510 1510 1510 1510 1510
71 72 73 74 75
Drum Br. Disc Br.
Remarks
11
13
10
Description
24
No.
Part No. 53 02 20 20 75 88
Drive Chain Lock Drive Chain Lock Bearing ball Bearing ball Collar bearing Damper
34B -1 1 1 1 1
DJ 1510 92 Panel rear brake J N 1316 00 Panel rear brake 7 DD 1510 08 Cam brake 8 30 1510 38 Ring ‘O’ 9 30 1510 05 Indicator 10 DJ 1510 59 Lever brake DS 1510 23 Lever brake
-1 1 1 1 -1
1 -1 1 1 1 --
11 12 13 14 15
1 1 1 2 -1
1 1 1 2 1 --
39 39 30 30 JN DS
1510 1410 2686 2687 1510 1510
34A
Drum Br. Disc Br.
1 -1 1 1 1
2 3 4 5
DJ J N 39 39 30 DJ
Description
2447 04 Bolt 0798 15 Nut 1510 68 Shoe brake assly. 1510 69 Spring 1312 03 Coupling 1510 68 C oupling
Remarks
10
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 34 : REAR HUB
Plate No. 35 : REAR BRAKE PEDAL
1 21
29
17
1
16
26
8
28
2
20
4
15
18
5 21
7
25 5
19 2
15
10 6
23
3
27 4
5
16
13
22 3 12
14
24 11 12
13
9 14
14 8
9
12
10
6
7
11
14
No.
Part No.
16 17 18 19 20
39 DJ 30 30 DJ
2240 1510 1510 1510 1510
21 22 23 24 25
39 0694 15 DJ 1510 32 DH 1710 19 39 2567 11 39 0801 15
26 27 28 29
DJ 1510 35 DX 1510 22 39 2566 11 36 J N00 06 36 DS40 07
Description
20 Bearing ball 33 Sleeve 82 S eal oil 81 Lock washer 48 ‘D’ Bolt
34A
34B
Drum Br. Disc Br.
Remarks
No.
1 1 1 3 6
1 1 1 3 6
1 2 3 4 5
Hex. lock nut Axle ‘U’ nut Plain washer Nut
6 1 1 1 1
6 1 1 1 1
6 7 8 9 10
Collar Collar Plain washer Chain sprocket kit Chain sprocket kit
1 1 1 -1
1 1 1 1 --
Part No. DS DS DS 30 39
Description
1910 02 Brake Pedal 1910 11 Brake Pedal Spring 1910 03 Rod brake 1910 38 Pin 0219 11 Plain washer
35A
35B
Drum Br. Disc Br.
1 1 1 1 2
1 1 1 1 2
39 0808 08 Split pin 30 1910 35 Spring 39 1680 04 Hex. Bolt DS 1510 25 Rod torque DH 1510 29 Hex. bolt
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
30 39 39 39 15
Hex. bolt Spring washer Nut hex. Pin snap Pin
1 2 2 2 1
1 2 2 2 1
16
30 1910 36
Brake Adjuster Nut
1
1
1510 0789 0694 0807 1910
95 12 15 08 26
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 36 : HANDLE BAR
Plate No. 36 : HANDLE BAR
24
24
21
21
2
2
23
20
4 29
23
20
4 29
28
1 22
22
30
30
26
26
10 3
10 27
3
25
15 11
27 25
15 11
9
12
13 16 8
7
8
7
17
19 19
18
14
19
6
18
5
Part No. 1810 44 1714 04 2010 24 2010 28 2010 33 1910 53 1910 36
Description Handle Flanged bolt Control switch LH Control switch RH Control switch RH Holder Assly. LH Holder Assly. LH
5
36A
36B
Drum Br. Disc Br.
1 4 1 1 1 1 1
1 4 1 1 -1 --
6 7 8 9 10
DS 1910 38 Holder Assly. RH DJ 1910 55 Lever grip Left 29 2011 17 Front Brake Switch DD 1911 42 Lever Brake RH DS 1810 08 Damper handle upper
1 1 1 1 2
1 1 1 1 2
11 12 13 14 15
DS DS 39 DS DS
2 2 2 1 1
2 2 2 1 1
1810 09 1810 10 0422 15 1910 15 1910 16
6
18 5
DS 39 DJ DS DS DJ DS
17
19 18
14
1 2 3 4
9
12
13 16
No.
28
1
Damper handle lower Washer handle lower Nylock Nut Grip LH Grip Assly. RH
36B
No.
Part No.
For KS
16 17 18 19 20
DS 1910 52 DH 1810 22 39 2427 04 DJ 2010 35 DJ 2210 03
Boot for lever LH Handle bar weight Hex. soc.hd. cap screw Clutch Switch Mirror assly. LH
1 2 2 1 1
1 2 2 1 1
21 22 23 24 25
DJ 30 DS 39 DS
Mirror assly. RH Band Switch assly.ignition Flange bolt Holder Fork Upper
1 2 1 2 1
1 2 1 2 1
26 27 28
DS 1810 07 DS 1910 18 DU 2010 46
Washer handle Upper Boot For Lever RH Plunger with Spring
2 1 1
2 1 1
29 30
DS 1810 06 DS 1810 19
Holder Up Holder lower
1 1
1 1
For KS
2210 04 1910 48 1810 22 1943 04 1810 05
Description
36A
Remarks
Drum Br. Disc Br.
Remarks
Part of Ride Control Switch
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 37 : FRONT FORK
Plate No. 37 : FRONT FORK
12
12
21 8
21
11 8
13
1
1
14
2
24
11
13 14
2
24
15
15
3
3
20
20
22
22 10
10
4/5
4/5 9
9
6 7
6
20
7
23
20 23
17
17
18
18
19
19
16
No. 1 2 3 4
Part No.
16
Description
DJ DJ DJ JN DS JN DS
1810 1810 1810 1510 1811 1510 1811
6 7 8 9 10
31 31 DS DS DS
1811 05 1811 06 1810 77 1810 83 1810 84
11 12 13 14 15
DS DS 31 DS DS
1810 15 Cap Nut Fork 1810 75 Bolt fork 1811 02 O ring 1810 85 Seat fork spring 1810 05 Holder fork upper
5
89 Seal dust 88 Ring snap 87 Oil seal 04 Outer Tube LH 20 Outer Tube LH 06 Outer Tube RH 21 Outer Tube RH Gasket Bolt Cylinder comp. fork Pipe comp. suspension inner Spring front fork
37A
37B
Drum Br. Disc Br.
2 2 2 -1 -1
2 2 2 1 -1 --
2 2 2 2 2
2 2 2 2 2
1 2 2 2 1
1 2 2 2 1
Remarks
No. 16
Part No.
17 18 19 20
JN DS DS 39 39 DS
1510 02 1811 17 1810 20 0789 12 1813 04 1810 72
21 22 23 24
DS DS DS DS
1810 1810 1810 1810
Description Fork front Fork front Holder fork under Assly. Spring washer Bolt Guide Bush Washer
12 B olt Fork 70 Guide Bush 71 Slide Bush 86 Plain Washer
37A
37B
Drum Br. Disc Br.
-1 1 2 2 2
1 -1 2 2 2
2 2 2 2
2 2 2 2
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 38 : PAINTED PARTS AND DECALS
Plate No. 38 : PAINTED PARTS AND DECALS
6
6
1
1
3
3
5
5
4
2
4
2
7
7
No.
Part No.
1
J N 7104 3B J N 7104 3C DS 7134 3F DS 7134 3E
Fuel Fuel Fuel Fuel
2
J N 7303 3B J N 7303 3C DS 7413 3F DS 7413 3E
3
4
38A
Description Tank Tank Tank Tank
Decal Decal Decal Decal
Remarks
No.
1 1 1 1
1 1 ---
Black with Blue Black with Red Red with Red Blue with Blue
5
Side cover LH Side cover LH Side cover LH Side cover LH
1 1 1 1
1 1 ---
Black with Blue Black with Red Red with Red Blue with Blue
J N 7304 3B J N 7304 3C DS 7414 3F DS 7414 3E
Side cover RH Side cover RH Side cover RH Side cover RH
1 1 1 1
1 1 ---
Black with Blue Black with Red Red with Red Blue with Blue
J N 7302 3B J N 7302 3C DS 7422 3F DS 7422 3E
Seat Seat Seat Seat
1 1 1 1
1 1 ---
Black with Blue Black with Red Red with Red Blue with Blue
Cowl Cowl Cowl Cowl
with with with with
38B
Drum Br. Disc Br.
Assly. Assly. Assly. Assly.
Part No. DS DS DS DS
7302 7302 7307 7307
Description
X3 X4 X4 X6
Fender Fender Fender Fender
6
J N 7301 3B J N 7301 3C DS 7411 3F DS 7411 3E
7
36 J N00 02 36 J N00 04
Front Front Front Front
38A
38B
Drum Br. Disc Br.
Remarks
1 1 1 1
1 1 ---
Black with Blue Black with Red Red with Red Blue with Blue
Fairing Fairing Fairing Fairing
1 1 1 1
1 1 ---
Black with Blue Black with Red Red with Red Blue with Blue
Decal Set Decal Set
1 1
1 1
Black with Blue Black with Red
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 39 : PETROL COCK ,CAP TANK & GAUGE FUEL
Plate No. 40 : FITTINGS-PETROL TANK, SIDE COVER & COVER SEAT
5
6 2
1
3 7
14
1 4
4 2
9 10
6
5
3 5
8 7 13 9 12 11
8
No.
Part No.
1 2 3 4 5
DS 39 39 DS DS
6 7 8 9 10 11 12 13 14
1410 09 0761 01 2179 24 1410 18 1810 36
Description
39B
1 2 2 1 1
1 2 2 1 1
30 1410 39 Packing DD 1410 22 Bolt flanged 39 0740 11 Washer (Non-Metallic) DS 2010 55 Gauge Fuel DS 1410 13 Seat Tape
1 2 2 1 1
1 2 2 1 1
39 DS 30 39
4 1 2 2
4 1 2 2
1972 15 1410 14 1410 15 2758 21
Cap Assly. Tank Screw Pan Cross Washer Fuel Tap Assly 3 In 1 Lock set With Key
39A
Drum Br. Disc Br.
Bolt Tube fuel Pipe clip ‘O’ Ring
Remarks
No.
Part No.
1 2 3 4 5
36 DS14 01 DG 1611 21 39 1943 04 DS 1810 36 J N 1710 00 39 1789 24
6 7 8 9
39 39 DS DJ
Description Grommet Kit for Side Cover Screw Flanged Bolt Lock Set (3 in 1) with Key Damper Front Washer Nylon
0983 08 P in Snap 1054 11 Plain Washer 1610 82 Grommet Side Cover 1410 08 Damper
40A
40B
Drum Br. Disc Br.
1 1 2 1 1 3
1 1 2 1 1 3
1 1 2 1
1 1 2 1
Remarks Ref. Page No. 67
N.I.
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 41 : METER ASSEMBLY
Plate No. 41 : METER ASSEMBLY
10
10
7
7
15
15
5
9
12 13
5
9
3
12 13
11
3
11
8
8
6
6 2
4
2
4
14
14
1
No. 1
2 3 4 5
6 7 8
Part No. DS DS DS DS DS DS DS DS DS DS DS DS DS
1910 1910 1910 1910 1910 1910 1910 1910 2010 1910 1910 1910 1910
39 14 49 05 40 22 41 23 34 42 26 50 24
GH DS DS DS DS
2010 12 1910 43 1910 27 1910 44 1910 28
Description
1
41A
41B
Drum Br. Disc Br.
9 10
DG 2010 40 Lamp 12V - 3.4W DS 1910 45 Cover (white) DS 1910 29 Cover (White)
2 1 1
2 1 1
For Speedometer For Pricol For VDO
11 12 13 14 15
DS DS DS 39 DS DS
2 1 1 2 1 1
2 1 1 2 1 1
For Pricol For VDO
1 1 --1 1 1 1 1 1 1 ---
--1 1 1 1 1 1 1 --1 1
For For For For For For For For
Pricol VDO Pricol VDO Pricol VDO Pricol VDO
For For For For
Pricol VDO Pricol VDO
Lamp 12 V-1.7W Cover meter lower Cover meter lower Bracket meter Bracket meter
4 1 1 1 1
4 1 1 1 1
For For For For
Pricol VDO Pricol VDO
1910 30 1910 31 1910 32 0798 15 1910 50 1910 24
Description
41B
No.
Meter Assly Meter Assly Meter Assly Meter Assly Cover Meter case upper Cover Meter case Upper Speedometer Speedometer Harness Speedo Console Meter Fuel Meter Fuel Meter Fuel Meter Fuel
Part No.
41A
Remarks
Grommet special Knob for Tripmeter Screw for ‘Tripmeter Knob’ Nut Tachometer Tachometer
Drum Br. Disc Br.
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 42 : CONTROL CABLES
Plate No. 43 : CHAIN CASE
1
2
3
2
5
3 1
2 4
No. 1 2 3 4 5
Part No. DS DS DS DS DS
1910 1910 1910 1910 1910
12 01 13 53 56
Description Cable Accelerator Cable Clutch Cable Starter (Choke) Cable Speedometer Inner cable Speedometer
42A
42B
Drum Br. Disc Br.
1 1 1 1 1
1 1 1 1 1
Remarks
No. 1 2 3
Part No. JN J N JN 39
1812 1812 1812 1942
00 04 02 04
Description Chain Cover Chain Cover Stepped bolt Bolt
43A
43B
Drum Br. Disc Br.
-----
1 1 2 1
Remarks
For 3 point mtg. For 3 point mtg.
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 43A : CHAIN CASE
Plate No. 44 : HEAD LAMP & FAIRING
5
22 8 10
3 7 4
9 13
3
15
2
12 4
14 10
18
6
1
17
3 19
10 14
10
3
5
1 11
5
4
16 20
4 2
4 21
3 5
No.
Part No.
1 2 3 4 5
36 DS40 20 15 1610 69 39 0711 11 39 0897 04 DS 1611 64
Description Case Chain Assly Kit Rubber Cap Plain Washer Bolt Rubber Strip
43A
43B
Drum Br. Disc Br.
1 1 4 4 2
------
Remarks
Front & Rear side Mtg.
No.
Part No.
1 2 3 4 5
DS 39 39 CL DJ
2010 35 1778 02 0716 01 2010 23 2010 72
6 7 8 9 10
39 DS DF DL 39
11 12 13 14 15
DS 39 35 39 DS
Description Head Lamp Housing with Lens Self Tapping Screw Pan Head Screw Lamp 12V 35/35W-HS1 Lamp 12V 5W
44A
44B
Drum Br. Disc Br.
1 4 2 1 2
1 4 2 1 2
1961 04 Hex. Flange Bolt 1810 66 Wind Shield 1810 98 Screw SS 1810 10 Well Nut 2141 24 Non Metallic Washer
1 1 4 4 9
1 1 4 4 9
1810 31 0817 15 1610 60 1907 01 1810 45
1 1 5 3 1
1 1 5 3 1
Flap Cowling Hex. Flange Nut Clip Nut Screw Fairing mounting upper bracket
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 44 : HEAD LAMP & FAIRING
Plate No. 45 : INDICATOR LIGHT ASSEMBLY
22 8 10
1/2 7
9 13
15
2
12
14 10
18
5 6
1
17 19
10 14
10 11
3/4
3
5
5
4
6
16 20 21
Description
44A
44B
No.
Part No.
16 17 18 19 20
DG 1611 21 39 1943 04 DS 1810 29 DS 1810 27 DS 2010 36
Screw Flange Bolt Bracket Cowling Number Plate Bracket Head Lamp Bulb Clip
2 2 1 1 1
2 2 1 1 1
21 22
DS 2010 39 DS 1810 69
Head lamp Harness Branch ‘B’ Monogram
1 1
1 1
Drum Br. Disc Br.
Remarks
On Wind shield
Description
45A
45B
No.
Part No.
1 2 3 4 5
DJ 2011 48 DJ 2011 49 DJ 2011 46 DJ 2011 47 GH 2010 12
Indicator Assly FR. LH Indicator Assly FR. RH Indicator Assly RR. LH Indicator Assly RR. RH Lamp 12 V - 10W
1 1 1 1 4
1 1 1 1 4
6
39 1970 15
Hex. nut with flange
4
4
Drum Br. Disc Br.
Remarks
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 46 : TAIL LAMP ASSLY. / FRONT NO.PLATE
Plate No. 47 : ELECTRICAL EQUIPMENTS
17
6
1 20
2
3
2
21 3
7
1 15
7
15
8
15
10
9 18
22 4 19
14 13
6 16
8
12 4 5
13
10
5 13/14
9
11 16
No.
Part No.
Description
46A
46B
Drum Br. Disc Br.
1 2 3 4 5
DS 2010 08 Tail light with Lamp DS 2010 09 Lens tail light 30 2010 06 Lamp 12 V 21/5 W DD 2010 11 Damper DJ 1810 83 Collar
1 1 1 2 2
1 1 1 2 2
6 7 8 9 10
39 39 DJ 39 DP
0817 15 1972 15 1610 72 1062 04 1611 45
Nut/Flange Flange Nut Bracket Rear No. Plate Bolt flange Number plate Rear
4 1 1 2 1
4 1 1 2 1
11 12 13 14 15
39 DP DS 39 DS
1943 04 1611 44 1810 26 1783 01 2010 15
Hex Flanged Bolt Number plate front Front No. Plate Mounting Bkt. Truss S crew (For Front No. P late) Reflector Reflex
2 1 1 2 1
2 1 1 2 1
16 17
39 1972 15 J N 1510 09
Flanged Nut Hose Clamp
2 --
2 1
Remarks
No.
Part No.
Description
47A
47B
Drum Br. Disc Br.
1 2 3 4 5
DS 39 39 DS 39
2010 16 1507 11 1956 04 1611 23 1942 04
Horn LH with Stay Plain Washer Flange Bolt Bracket Battery Arrestor Flanged Bolt
1 1 1 1 1
1 1 1 1 1
6 7 8 9 10
JN DS DS DS DH DS
4022 00 2010 57 2010 29 1910 07 2010 19 1611 06
Wiring Harness Wiring Harness Rear Brake Switch Spring Brake Switch Grommet Rear Brake Switch Band Battery II
1 1 1 1 1 1
1 -1 1 1 1
11 12 13 14 15
DS DS DS DS DS
2010 1611 1611 1611 2010
Battery 5AH Base Battery II Band Battery I Base Battery I Assly DC flasher / damper
1 1 1 1 1
1 1 1 1 1
82 18 05 16 25
Remarks
For KS
N.I. & N.S. N.I.
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 47 : ELECTRICAL EQUIPMENTS
Plate No. 48 : TOOL KIT 2
1
17
1 20
2
21 3
7
15
8
15
10
9 18
22 4 19
6 16
13
5 13/14 16
No.
Part No.
16 17 18 19 20
39 AP 30 30 DS
2208 04 2010 29 2011 04 2010 85 2010 22
21 22
DS 2010 23 DS 1611 04
Description
47A
47B
Drum Br. Disc Br.
Mushroom head Screw Starter Relay / Fuse box Assly. Fuse C able assly. (B attery to S t.Relay)
2 1 1 1 1
2 1 1 1 1
Cable assly. (Battery to Earth) Battery Arrestor
1 1
1 1
Remarks
No.
Part No.
1 * * * *
DS 2210 02
* * * * 2
DP 2210 24
Description Tool Tool Tool Tool Tool
Kit Driver Wrench (Box 16 mm) Wrench (10 X 13) Wrench (14 X 17)
Tool wrench (27 A/F) Tool wrench (22 A/F) Extension Rod Tool Bag Band Tool Kit
48A
48B
Drum Br. Disc Br.
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Remarks
For reference only. Not serviced separately
Brand ID: 001MC631
Brand ID: 001MC631
Plate No. 49 : ACCESSORIES / GRAB HANDLE
KIT LIST Sr. Kit Part No. Kit Description No.
8 6
2
Description
49A
49B
No.
Part No.
1 2 3 4 5
J N 2312 02 DS 1610 89 J N 2312 11 J N 2312 00 39 1714 04 39 2495 04
Leg Guard kit Leg guard Bracket Sari Guard Sari Guard Flange Bolt Soc. Head Bolt
1 2 -1 2 1
1 2 1 -2 1
6 7 8
39 1681 04 DS 1611 88 39 2214 04
Flange Bolt Grab Handle with foam Bolt
4 1 4
4 1 4
Drum Br. Disc Br.
Remarks
39239121 O Ring (Cover tappet) 39128321 O ring
2 2
2
36DS1002 Valve Kit
DS101023 Valve Intake DS101024 Valve Exhaust
1 1
3
36DS1003 Valve Repair Kit
DS101083 DS101110 DS101111 DH101026
2 2 2 2
4
36DS1004 Guide Chain Kit
DS101012 Guide chain (Tight) DS101011 Guide Chain (slack)
1 1
5
36DJ 4008 Ring Set Piston
DH101666 R ing piston top DH101667 Ring piston second DH101669 Ring piston oil
1 1 1
6
36DS1007 Boss Kick Set
DH101185 DH101068 DS101208 DH101320 39204501
1 1 1 1 1
7
36DS1201 Carb. Vaccum Piston Kit
DS121055 Vaccum Piston Comp. DS121057 Diaphragm DS121058 Diaphragm Plate
1 1 1
8
J N581208 J et Holder Kit
DS121071 J et DS121069 Jet Comp. DS121067 Needle J et Holder
1 1 1
9
J N581207 Idling Screw Set
DS121097 DS121094 DS121095 DS121096
1 1 1 1
10
36DS2101 Seat Damper Kit
DS211004 Damper Seat - I DS211005 Damper Seat - II
7 2
11
36DS1601 Eng. Mtg.Plate Set
DS161031 Bkt. Engine Hanger LH DS161128 Bkt. Engine Hanger RH DS161056 Bkt. RH eng.rear Mounting II
1 1 2
12
36DS1602 Eng. Mtg.Bkt. Set With Silent Bush
DS161130 Bkt. LH eng.mtg.front Assly. DS161131 Bkt. RH eng.mtg.front Assly.
1 1
13
36DS1802 Bearing cone kit
DH181025 B earing cone DH181026 Bearing race DH181024 Upper bearing race
1 1 1
14
36DS1801 Holder Handle Set
DS181019 Holder handle DS181006 Holder handle
2 2
15
36DS1401 Grommet Kit-Side Cover
DS141012 Grommet side cover Front DS161082 Grommet side cover Rear
2 2
with cover
For Mounting Leg Guard
Qty./Kit
36DS1001 Cyl.Head O Ring Kit
5
3
Description
1
1
7
Consisting of Following Parts Part No.
Retainer valve spring Spring valve inner Spring valve outer Seat valve spring
Spring Kick Starter Arm Ball steel Base kick lever Hex. bolt with flange(N.I.) C’sunk Head Screw
Coil Spring (CO) Adjust Screw Adjust Holder Plain Washer
Brand ID: 001MC631
Brand ID: 001MC631
Amendment Sheet (Parts Added) Sr.No.
Part No.
Description
Amendment Sheet (Parts Deleted) Qty. Page No. Fig.No.
Sr.No.
Part No.
Description
Qty. Page No. Fig.No.
Brand ID: 001MC631
Part No.
Brand ID: 001MC631
Figure Pa ge No. No.
Part No.
Figure No.
Pa ge No.
Pa rt No.
Figure No.
Pag e No.
Pa rt No.
Figure No.
Pag e No.
Brand ID: 001MC631
Pa rt No.
Brand ID: 001MC631
Figure No.
Pag e No.
Part No.
Figure Pa ge No. No.
Part No.
Figure No.
Pa ge No.
Part No.
Figure No.
Page No.
Brand ID: 001MC631
Pa rt No.
Brand ID: 001MC631
Figure No.
Pag e No.
Part No.
Figure No.
Page No.
Part No.
Figure No.
Page No.
Pa rt No.
Figure No.
Page No.
Brand ID: 001MC631
Pa rt No.
Brand ID: 001MC631
Figure No.
Pag e No.
Pa rt No.
Figure No.
Page No.
Part No.
Figure No.
Page No.
Pa rt No.
Figure No.
Page No.
