Notice: DOC. NO.: 71111029 REV. 00, FEB. 10

Notice
All information contained in this manual is based on the latest

product information at the time of publication. Bajaj Auto
Limited accepts no liability for any inaccuracies or omissions in
this publication, although every possible care has been taken to
make it as complete and accurate as possible. All procedures
and specifications subject to change without prior notice. The
right is reserved to make such changes at any time without
prior notice and without incurring an obligation to make such
changes to product manufactured previously. Contact your
authorized Bajaj Dealer for the latest information on product
improvements incorporated after this manual was issued.
DOC. NO.: 71111029 REV. 00, FEB. 10

Foreword Instructions
We have pleasure in presenting the Spare Parts Catalogue for ‘Bajaj Platina 1. How to Read the Catalogue : Open the catalogue and from the pictorial
125’ Motorcycle. This catalogue has been specially designed to assist you in 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).
selecting the correct parts for procurement to maintain 100% availability.
Now find out the figure of the part you wish to order. Write down the
part number against that particular figure number from the text.
The Bajaj spares are subjected to the stringent quality control standards to
In case, if you have the part number and you need the other details, the
ensure longer life of the vehicle. It is therefore necessary that only the part index can be used. The part index (at the end of the catalogue) will
Genuine Bajaj Spares are used. 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
In a continual effort to improve Performance and Efficiency of the vehicles, part required should be invariably mentioned in the order as per the
Specifications, Diagrams, Illustrations and Part Numbers can change without catalogue text.
notice. Consequently, the description in this Spare Parts Catalogue cannot
The latest part number as conveyed through our service circulars should
therefore be final and binding on us. only appear on the order. In case of ordering painted components,
colour shade of the components should be mentioned.
The modifications / alterations which are carried out after the issue of this The quantity shown against the part number is the quantity per vehicle
catalogue, will be conveyed to you through our Service Circulars. You are for that group so that particular quantity should be multiplied by the
requested to make necessary corrections in the Parts Catalogue as per the number of sets required.
circulars so as to keep your catalogue up-to-date. This will ensure the
3. Part Number System : We have used 8 digit system for part numbers.
appropriate and speedy delivery of the Spare Parts as the order placed will The model or hardware item is indicated by first two digits or
bear the latest part numbers. 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
In case, if you need any technical assistance contact the concerned Regional
indicated by 2-2-4 or 2-4-2 digit system. Understanding this system will
Office or write to us on the following address : enable you to identify the spare parts easily.
4. Abbreviations : The following abbreviations are used in this catalogue.

Bajaj Auto Limited
Assly Assembly V Volts
Service Department
N.I. Not illustrated W Watts
Akurdi, Pune 411 035 India
C'case Crankcase Accl. Accelerator
Phone : 020-27406557 Cyl Cylinder Comp. Complete
Fax : 020-27407385 O/s Over size Fr. Front
Rr. Rear Std. Standard
L Length A/t. Alternate
R.H. Right hand L.H. Left hand
Hex. Hexagonal AR As required
Index Index
Plate No. Description Page No. Plate No. Description Page No.
1 Cover Cylinder Head 2 31 Rear Hub 64, 66

2 Cylinder Head 4 32 Rear Brake Pedal 68
3 Valve 6 33 Handle Bar 70, 72
4 Camshaft / Tensioner 8 34 Front Fork 74
5 Cylinder Block & Piston 10 35 Painted Parts & Decals 76
6 Crankshaft 12 36 Petrol Tank, Cap Tank & Gauge Fuel 78
7 Transmission 14 37 Fittings - Petrol Tank, Side Cover & Cover Seat 80
8 Change Drum / Shift Fork 16 38 Meter Assly. 82
9 Gear Change Mechanism 18 39 Control Cables 84
10 Engine Assly & Crankcase RH 20 40 Chain Case 86
11 Crankcase LH 22 41 Head Lamp & Fairing 88
12 Cover Clutch 24 42 Indicator Light Assly. 90
13 Cover Magneto 26 43 Tail Lamp Assly. / Front No. Plate 92
14 Clutch 28 44 Electrical Equipments 64
15 Kick Starter Mechanism 30 45 Tool Kit 94
16 Carburettor 32 46 Accessories / Grab Handle 98
17 Air Cleaner Complete 34
18 Silencer Assly 36 Kits List 99,100,101,102
19 Oil Pump 38
20 Starter & Motor Assly 40 Amendment Sheet (Parts Added) 103
21 Magneto / C.D.I. / H.T. Coil 42
22 Seat Assly / Seat Lock 44 Amendment Sheet (Parts Deleted) 104
23 Engine Mountings 46
24 Frame & Frame Fitting 48
25 Swing Arm / Rear Shock Absorber 50
26 Rider & Pillion Foot Rest 52
27 Mudguard Front & Rear 54
28 Stand Assembly 56
29 Tyre/ Tube / Rim 58
30 Front Hub 60, 62
Plate No.: 1 Brand ID: 001MC636
Cover Cylinder Head
Description KS ES
No. Part No. Remarks
Drum Drum
2 1 JV 5110 13 Cylinder head cover complete 1 1

2 JV 5410 07 Bolt flange 4 4
1 3 JV 5110 12 Gasket head cover 1 1
4 JB 5110 11 Bolt head Mounting 4 4
5 JV 5110 11 Plate breather 1 1
6 JA 5110 11 Hose Breather 1 1

7
7 JA 5110 29 Clamp Breather Tube 1 1
6 3
5
4
1 2
Front Wheel Direction
Cylinder Head
Description KS ES
Drum Drum
1 xx xxxx xx Head cylinder complete with

valve guide & studs 1 1
2 JA 5110 05 Bolt head mounting 2 2 M8x1.25x196L
3 JA 5110 28 Stud 2 2
2 4 JA 5110 06 Gasket cylinder head 1 1
5 JK 5814 01 Intake manifold (Rubber) 1 1
6 JA 5814 06 Bolt flange 2 2 M6x1x25L

1 7 39 1674 04 ‘O’ Ring 2 2
8 JK 5814 00 Sleeve carburettor 1 1
3
9 JA 5812 18 Clamp 35mm 1 1
3 10 JA 5814 07 Clamp 39mm 1 1
7
8
4
10
5
3 4
Valve
Description KS ES
Drum Drum
1 JV 5110 06 Shaft Rocker arm 2 2

2 31 1010 20 Rocker arm Pad Type 2 2
3 DG 1010 29 Cotter Valve 4 4
3 4 36 JK00 11 Valve kit 1 1 Ref. page no. 99
1
5 36 JA00 03 Valve repair kit 1 1 Ref. page no. 99
6 39 2017 19 Seal valve stem 2 2

1
5
2
5 6
Camshaft / Tensioner
Description KS ES
Drum Drum
1 JV 5110 07 Camshaft assly complete 1 1

2 JA 5112 16 Spacer cam sprocket 1 1
3 JA 5112 17 Sprocket cam shaft 1 1
4 DH 1010 48 Special washer 1 1
10
5 JB 5310 05 Cam chain (90 links) 1 1
14 11
8 6 36 JK00 12 Guide chain kit 1 1 Ref. page no. 99
7 DH 1013 92 Bolt special 1 1
8 JA 5210 17 Tensioner (Black) assly chain 1 1
7
9 9 CS 1011 28 Gasket 1 1
10 JA 5210 18 Bolt tensioner 1 1
11 JA 5210 19 Flange bolt 2 2 Adjuster assly chain mtg.

1
12 39 0594 17 Circlip for locking cam shaft
5
13
13 39 2683 20 Ball bearing 1 1
12
14 39 1880 20 Ball bearing 1 1
2 6 15 39 2198 04 Bolt camshaft 1 1
3 4
16 16 39 2669 21 ‘O’ ring tensioner 1 1
15
7 8
Cylinder Block and Piston
Description KS ES
Drum Drum
1 JA 5210 01 Gasket cylinder black 1 1

2 39 1000 06 Hollow dowel pin 2 2
3 36 JW00 10 Piston ring set 1 1 Ref. Page No. 99
2
5 4 DP 1011 65 Ring snap 2 2
5 xx xxxx xx Cylinder block / Piston assly. 1 1
6 JA 5210 15 Damper cylinder block 3 3
2
6
1
4
9 10
Crankshaft
Description KS ES
Drum Drum
1 59 1500 14 Nut flange 1 1

2 59 1100 08 Washer Plain 1 1
3 59 1200 03 Belleville Washer 1 1
4 31 1011 73 Key woodruff 1 1
5 JV 5310 03 Crank shaft assly. 1 1
7
5 6 39 1864 20 Ball bearing 1 1 20x52x15
7 DS 1011 54 Key Parallel 1 1
11
8 36 PA00 06 Set primary drive / driven 1 1 Ref. page no. 99
9 10
9 JA 531012 Spring 1 1
4
10 JA 5310 15 Pin (Crankshaft plunger) 1 1
1
11 JB 5310 21 Plunger oil 1 1
3
12 JD 5310 04 Spacer crankshaft 1 1
6
2
11 12
Transmission
Description KS ES
Drum Drum
1 JD 5510 00 Shaft Input Transmission 1

2 JD 5512 07 Gear 4th Drive 1
3 39 0987 17 Ring Snap 5
4 JA 5510 02 Spline Washer 4
5 JD 5512 06 Gear 3rd Drive 1
1
6 JD 5512 05 Gear 5th Drive 1
18 7 JD 5512 01 Gear 2nd Drive 1
8 JA 5510 04 Washer Thrust 2nd Drive 1
2
3 4 9 JD 5510 02 Shaft Output Transmission 1
16
3 5 15 10 JD 5512 08 Bush 2nd Driven 1
4 14
3
4
11 JD 5512 02 Gear 2nd Driven 1
6
7 12 JD 5512 03 Gear 5th Driven 1
8 4 13
3
13 JD 5512 04 Gear 3rd Driven 1
12 14 JD 5512 00 Gear 4th Driven 1
3
9 17 15 JA 5510 07 Bush 1st Driven 1
10 11
16 JA 5512 06 Gear 1st Driven 1
20 17 JD 5512 09 Spline Washer 1
18 JA 5510 08 Washer Thrust 1st Driven 1
22 21
23 19 19 JA 5510 09 Collar Sprocket Drive 1
20 59 2100 24 ‘O’ Ring Collar Sprocket 1
21 JV 5510 00 Sprocket Drive (15 T) 1

22 DU 1012 13 Plate Lock Sprocket 1
23 39 1981 04 Socket Head Bolt 2
13 14
Change Drum / Shift Fork
Description KS ES
Drum Drum
1 JW 5610 00 Drum Complete Gear Shift 1 1

2 39 0992 06 Dowel (Pin Drum Change) 4 4
3 JD 5610 11 Special Bolt 1 1
4 JD 5610 06 Shaft Gear Shift Fork 2 2
5 JD 5610 04 Fork Gear Shift Output 2 2
5
5 6 JD 5610 05 Fork Gear Shift Input 1 1
7 JD 5610 02 Cam Drum Change 1 1
8 8 DK 1011 35 Bush (Fork Shift ) 1 1
1
4 8
4
6 7
3
8
15 16
Gear Change Mechanism
Description KS ES
Drum Drum
1 JW 5612 04 Lever comp. gear shift 1 1

2 JW 5612 06 Extension spring 1 1
3 JW 5612 08 Spring gear shift return 1 1
4 JD 5612 03 Inhibitor com. gear shift 1 1
5 JD 5612 04 Spring (Inhibitor) 1 1
1
2 6 JA 5612 09 Step washer 1 1

7 39 2704 11 Washer 1 1
3 8 JA 5312 11 Flange bolt 1 1 M6/Hex nut
12 9 JB 5614 00 Lever comp. gear shifter 1 1 With rubber damper
7
10 DH 1015 09 Damper 1 1
8 4
6
11 DG 1013 39 Damper 1 1
5
12 39 0817 15 Nut hex with flange 1 1 M6
10
9
11
17 18
Engine Assembly / Crankcase RH
Description KS ES
Drum Drum
1 JK 5010 00 Engine assembly 1 -- N.I.

JK 5010 01 Engine assembly -- 1 N.I.
2 xx xxxx xx Crankcase RH 1 1 NRB + bush + stud
3 59 2000 36 Ball bearing 1 1
10
9 4 JA 5410 11 Needle roller bearing 1 1 HK 1312
11 5 JA 5410 10 Stopper plate input bearing 1 1
6 39 1000 06 Hollow dowel pin 2 2

6 8 7 DU 1010 85 Bushing (PTFE) 1 1
5
8 DH 1013 80 Screw pan cross M6 1 1
3 9 JA 541015 Stud inhibitor mounting 1 1 Alt.52JA0027
12
10 JA 5412 35 Flange bolt M6x1x85L 2 2 Crankcase mounting
14
near block face
13
11 59 0400 38 Flange bolt 1 1
12 JA 5410 14 Bolt shift change 1 1
7 13 JA 5410 12 Guide kick 1 1
14 39 1964 04 Bolt flanged small 2 2
2
19 20
Crankcase LH
Description KS ES
Drum Drum
1 xx xxxx xx Crankcase LH 1 -- NRB + Bush + Orifice

xx xxxx xx Crankcase LH -- 1 NRB + Orifice
2 39 2562 20 Needle roller bearing 1 1 Input Shaft
3 59 2000 36 Ball bearing 1 1 Output Shaft
4 39 1715 19 Oil seal 22x3.5x7 1 1 Output shaft
2 5 31 2010 81 Switch neutral 1 1
8 19
6 DH 1012 64 Gasket neutral switch 1 1 Alt. Dh101784
3 7 39 2190 19 Oil seal 1 1 Shifter shaft
11 8 JA 5410 05 Bush bendix 1 1 Starter clutch
9 39 0746 01 Pan cross screw 2 2
17
10 JA 5410 34 Stopper gear starter clutch 1 1
10
1
9 11 39 1000 06 Hollow dowel pin 2 2 Crankcase block mtg
clutch cover + magneto
18 cover
5 6
13 7 12 12 39 0999 06 Dowel pin oil pump 2 2
14 13 JA 5410 19 Mesh filter oil pump 1 1
15
4 14 59 2100 23 "O" ring cap strainer 1 1
16
15 JA 5410 21 Cap strainer 1 1
16 59 0400 38 Flange bolt 6 6

17 39 1759 04 Bolt (M6x1x55L) 1 1 Near starter motor
18 JA 5410 20 "O" ring mesh filter oil pump 1 1
19 JA 5410 27 Damper crank Shaft 1 1
21 22
Cover Clutch
Description KS ES
Drum Drum
1 JA 5412 08 Clutch cover 1 1

2 JK 5412 01 Decal clutch cover 1 1
3 39 1041 19 Oil seal clutch cover 1 1
19 20 21 22
4 30 1011 42 Oil seal kick shaft 1 1
5 JW 5410 05 Shaft clutch release assly 1 1
6 DP 1012 69 Rod push 1 1

18
7 DG 1014 18 Gauge 1 1 oil level check
10
11 5 8 DS 1012 15 Wire circilp 1 1
9 JA 5412 36 Plain washer (12.5x24x0.8) 1 1
12 3
9 10 JA 5412 37 Spring torsion clutch cover 1 1
17 2
13
8 11 JA 5412 11 Cap oil filler 1 1
7 12 JA 5412 25 "O" ring cap oil filler 1 1
15 13 JA 5412 15 Damper clutch cover 1 1
4
14 14 JA 5412 16 Plate damper 1 1
15 DH 1013 88 Bolt flange M5x10 3 3
17
16 16 JA 5412 12 Gasket clutch cover 1 1

17 59 0400 38 Flange bolt 8 8 Clutch cover to
6 Crankcase mounting
1
18 JW 5410 00 Bracket clutch cable 1 1
19 DD 1211 81 Oil filter Element 1 1
20 39 1671 21 "O" ring 1 1
21 JA 5412 19 Cap filter 1 1

22 JA 5210 19 Bolt flange 3 3
23 JK 5412 02 Sleeve bearing plastic 1 1
23 24
Cover Magneto
Description KS ES
Drum Drum
1 JA 5412 41 Cover magneto -- 1 Threaded cap design

JP 5412 05 Cover magneto 1 -- Threaded cap design
9
2 59 0400 38 Flange bolt 2 2
3 JA 5412 33 Cap TDC finder 1 1 Threaded cap
4 30 1011 95 ‘O’ Ring 15.8x2.4 1 1
10 5 JA 5412 05 Gasket magneto cover -- 1
JP 5412 08 Gasket magneto cover 1 --
8
5
6 JA 5410 44 Flange bolt M6x1x40L 8 8
11 7 JB 5412 03 Cover LH rear -- 1 Without Sticker
3 JB 5412 05 Cover LH rear 1 -- Without Sticker
4
8 JA 5412 20 Damper magneto cover 1 1
9 DH 1013 88 Flanged bolt M5x10 3 3
10 JA 5412 21 Plate damper magneto cover 1 1
6
11 JA 5410 05 Bush Bendix 1 1

12 JW 2330 00 Gear shifter label 1 1
2
1 12 7
25 26
Clutch Assly
Description KS ES
Drum Drum
11
10
1 JK 5514 00 Clutch Assly Complete 1 1
3
1A JD 5514 00 Spacer Clutch Assely 1 1 ‘JD’ Mark for I.D.
9
2 JA 5514 06 Collar Clutch 1 1
4 8
3 39 2600 11 Washer 1 1
1A 2
4 JK 5514 01 Clutch Plate Assly 1 1
5 JB 5514 08 Wheel Clutch 1 1
6 30 1010 96 Plate Clutch 4 4

7 DD 1014 80 Plate Friction 5 5 (45 Segments)
8 JB 5514 11 Hub Clutch 1 1
6 9 JK 5514 02 Compression Spring 6 6
7 10 JB 5514 12 Holder Clutch 1 1
5
12
13 11 39 0980 04 Bolt Flange 6 6
15 12 JA 5514 16 Belleville Washer 1 1
14
13 JA 5514 20 Plain Washer 1 1
14 JA 5310 07 Nut Special 1 1 L.H. Threads
15 39 1001 20 Bearing Clutch Lifter 1 1
1
16 36 PA00 06 Set Primary Drive & Driven 1 1 Refer Page No. 99
16
27 28
Kick Starter Mechanism
Description KS ES
Drum Drum
1 JA 6212 01 Lever assly. kick 1 1

2 DP 1510 18 Bolt 1 1
3 36 DU10 07 Boss kick set 1 1 Ref. page no. 99
4 DH 1011 25 Spring kick start return 1 1
6
11 5 39 0993 11 Plain washer 3 3
7 6 39 0738 17 External circlip type C 2 2

7 JD 6210 01 Shaft kick 1 1
13 8 DS 1011 17 Spring kick starter ratchet 1 1
9 JA 6210 02 Ratchet 1 1
8
10 JA 6210 03 Gear spur kick starter 1 1
5 9 11 JA 6210 06 Washer thrust (16.2x25x0.5 ) 1 1

10 12 39 2408 17 External circlip 1 1
5 2 13 DD 1010 97 Damper 1 1
12 1
5
4 3
29 30
Carburettor
Description KS ES
Drum Drum
1 JB 5812 08 Carburettor assly. 1 1

2 JA 5812 32 Gasket float chamber 1 1
1
3 CB 1210 61 Cable adjuster 1 1
4 36 JK00 22 Piston valve kit 1 1 Ref. page no. 100
5 24 1213 65 Float assly 1 1
3
6
6 JB 5812 02 Throttle position sensor 1 1
7 JA 5812 38 "O" ring (TPS) 1 1
10 8 36 JK00 27 Choke Plunger Kit 1 1 Ref. page no. 101
16
9 JA 5812 33 Screw TPS 1 1
10 36 JK00 19 Air screw kit 1 1 Ref. page no. 99
9
7
4 8
11 11 36 JK00 20 Idling screw kit 1 1 Ref. page no. 100
2 12 36 JK00 21 Jet kit 1 1 Ref. page no. 100

12
13 JA 5812 21 Needle valve assly 1 1
19 14 24 1210 69 Pin float 1 1 N.I.
15 36 JK00 26 Carburetor Gasket ‘O’ ring kit 1 1 Ref. page no. 101
13 16 JK 5812 11 Lever Assly 1 1

18 14
5 17 CB 1210 46 Screw Float Body 1 1
17
18 JK 5812 09 Drain Pipe 1 1
19 JA 5813 14 Drain Screw 1 1
31 32
Air Cleaner Complete
Description KS ES
Drum Drum
1 JK 5810 00 Air filter assly 1 1

2 JK 5812 00 Air Filter duct 1 1
3 JB 5810 13 Cartridge assly. 1 1
4 JB 5810 08 Holder element A 1 1
5 JB 5810 09 Holder element B 1 1
10
6 JB 5810 05 Element air filter 1 1

2 7 DP 1210 30 Flame arrestor 1 1
16
8 JB 5810 11 Cap Air Filter 1 1
8 9 JB 5810 12 "O" ring 1 1
1 9 10 39 1773 04 Flange bolt 4 4
11
4
13 3 11 JB 5810 18 Tube Oil Drain 1 1
12 DS 1211 26 Plug (Drain tube) 1 1
12 15
13 DP 1210 25 Clamp 1 1
6
5 14 JA 5110 11 Hose breather 1 1
15 JA 5110 29 Clamp breather tube 1 1
14 7
16 39 2044 01 Screw Air Filter Cover 4 4
33 34
Silencer Assembly
Description KS ES
Drum Drum
1 xx xxxx xx Silencer assly. W/o shield 1 1

2 CB 1011 14 Gasket exhaust mtg. 1 1
2
3 JA 5910 40 Flange nut 2 2
4 JB 591037 Shield muffler 1 1
5 DH 1016 07 Trues screw 4 4
7
3 6 JB 1130 04 Hex head bolt flange 1 1
6
7 JB 5910 26 Shield CAT 1 1
8 39 2492 11 Plain washer 1 1
7
9 39 2754 04 Bolt 1 1
5
5
1
8
9
35 36
Oil Pump
Description KS ES
Drum Drum
1 52 JA00 23 Oil pump assly. 1 1

2 JA 5410 16 Gasket case oil pump 1 1
3 FD 1010 78 Screw pan cross M6 3 3
4 JA 5410 18 Gear driven + shaft oil pump 1 1
37 38
Starter & Motor Assembly

3 KS ES
No. Part No. Description Remarks
4 Drum Drum
1 JA 6214 14 Body comp. starter clutch -- 1

2 DH 1017 81 Plate roller clutch -- 1
6 3 JA 6214 10 Gear starter clutch -- 1
4 JA 6214 02 Washer -- 2
1 5 39 2437 04 Bolt socket -- 3
2
5
6 JA 6214 06 Starter drive assly. -- 1
7 JA 3516 00 Motor Assly -- 1
8 JA 3516 04 ‘O’ Ring For Tie Bolt (Flash) – 1
9 JA 3516 06 Sealing Ring (Flash) -- 1
JA 3516 26 Sealing Ring (Lucas-TVS) -- 1
10 DH 1011 63 Flange Bolt (Flash) -- 2
17
11 JA 3516 02 ‘O’ Ring For Spigot (Flash) -- 1

JA 3516 27 ‘O’ Ring For Spigot (Lucas-TVS)
12
12 JA 3516 08 +ve Brush Holder Assly (Flash) -- 1
13 JA 3516 09 -ve Brush Holder Assly (Flash) -- 1
14 JA 3516 18 Brush & Earth Plate Assly -- 1 N.I. (Lucas-TVS)
16
15 JA 3516 24 Brush Spring (Lucas-TVS) -- 1 N.I.
7 10 13
16 JA 3516 19 Terminal Assly (Lucas-TVS) – 1
17 36 Jw0014 Starter Clutch Repair Kit – 1
8
10
11 9
39 40
Magneto, CDI & H.T. Coil
Description KS ES
Drum Drum
1 JK 3510 08 Rotor assly. -- 1

JK 3510 10 Rotor assly. 1 –
2 JK 3510 05 Stater assly. complete 1 1
5 3 39 1674 05 Bolt flange 2 2
4 DH 1013 80 Pan head screw M6 3 3
5 JK 3512 02 H.T. Coil LH 1 1
14 6 JK 3512 10 C.D.I. assly. 1 1

7 DG 1110 08 Spark plug 1 1 Champion RG4HC
6
7A JA 3512 09 Spark plug 1 1 Bosch UR4DCO
8 DD 1110 48 Spark plug cap 1 1
10
9 DD 1110 11 Grommet spark plug cap 1 1
10 DD 1110 12 Grommet for HT cable 2 2
4
8
11 39 1553 04 Bolt flange M6 x 25 2 2
13 12 JK 4020 03 Regulator AC+DC 1 1
11 3
9 13 JA 5410 28 Lock plate 1 1
1 14 JK 3510 06 Magneto assembly complete -- 1
JK 3510 09 Magneto assembly complete 1 –
4
7/7A
12
41 42
Seat Assembly / Seat Lock
Description KS ES
Drum Drum
1 JK 1910 03 Seat assly. complete 1 1

2 36 JB00 08 Seat damper kit 1 1 Ref. page no. 61
3 DP 1611 02 Lock assly. seat 1 1
4 39 0743 01 Screw CSK cross (M6) 2 2
4
2
43 44
Engine Mountings
Description KS ES
Drum Drum
1 JK 1134 03 Bracket engine hanger LH 2 2

2 JK 1134 00 Engine mounting bracket front 1 1
3 39 2723 15 Hex nut flanged 2 2
4 JA 1134 03 Bolt flanged M10 x 110 2 2 for engine mtg.
5 JA 1134 04 Bolt flanged M8 x 75 3 3 for engine mtg.
6 39 2312 04 Bolt flanged M8 3 3

1
7 59 0400 17 Hex bolt flanged M8 1 1
8 39 1970 15 Nut flanged 7 7
8
1
5 5
6 2
4
45 46
Frame and Frame Fittings
Description KS ES
Drum Drum
1 JK 1110 55 Frame assly. comp. 1 1

2 DF 1810 90 Nut fork 1 1
3 DF 1810 52 Steering cap 1 1
4 36 3140 01 Bearing cone kit 1 1 Ref. page no. 61
2 5 DJ 1811 15 Cage bearing steering 2 2
3
6 JK 2314 00 Grip frame 1 1
5 7 39 2205 04 Flanged bolt M8 2 2
8 DZ 1611 41 Cap for Pipe 2 2
4 1
5
7
47 48
Swing Arm / Rear Shock Absorber
Description KS ES
Drum Drum
1 DZ 1710 14 Arm Comp. Swing / Bush 1 1

2 JK 1220 06 Shaft Swing Arm 1 1
3 JB 1310 18 Plain Washer 4 4
4 DP 1710 06 Bushing Rubber 2 2
12
5 JK 1220 08 Nut Hex./ flange M12 1 1
6 9 11 12 12
6 DZ 1710 09 Damper for Swing arm 1 1
8
7 39 0454 11 Plain washer 2 2
7 8 39 0553 02 Self tapping Screw 2 2
19
13 13 9 JK 1220 07 Domed Cap Nut M12 1 1
11 5 10 JK 1220 10 Hex nut M12x1 1 1
3
4
4
3
2 11 JK 1220 09 Washer Spring 4 4
1 12 JB 1220 11 Washer Plain 8 8
13 36 DF17 01 Rubber Inner Bush kit 1 1 Refer page no. 62
14 JK 1220 05 Adjuster Chain (RH) 1 1
14
15 39 1309 11 Washer Plain 2 2
12 15
17
9 11 15 16 16 39 2122 15 Hex Nut M6x1 2 2
17
18 16 17 39 1903 15 Hex nut M6x1 2 2
18 JK 1220 03 Adjuster Chain (LH) 1 1
19 DZ 1710 16 Rear Shock Absorber 2 2
49 50
Rider & Pillion Foot Rest
Description KS ES
Drum Drum
1 JK 1130 12 Stay main step fix 1 1

2 DF 1614 13 Damper step front in PVC 2 2
3 DH 1611 94 Stopper kick 1 1
4 JA 1130 11 Flange bolt M8 4 4
5 JK 1130 06 Stay LH 1 1
2
6 JK 1130 07 Stay RH 1 1
7 JK 1130 08 Damper step 2 2
8 JK 1130 09 Hex bolt (M8) 2 2
9 30 1710 22 Pin 2 2
1 10 DP 1611 63 Washer 2 2
3
11 39 0784 08 Split Pin 2 2

8
4
2 5/6
10
11
51 52
Mudguard - Front & Rear
Description KS ES
Drum Drum
1 DP 1610 07 Fender rear 1 1

2 DU 1610 98 Brace fender front 1 1
3 39 2222 04 Flanged bolt (M8) 4 4
4 DS 1611 25 Cable guide 1 1
5 DJ 1610 69 Nail for cable guide 1 1
6 DP 1610 06 Fender Rear Front 1 1

5 7 DP 1610 94 Bolt Stepped M6 1 1
4
53 54
Stand Assembly
Description KS ES
Drum Drum
1 JK 1132 01 Center stand 1 1

2 JK 1132 02 Shaft stand 1 1
3 39 0797 08 Pin cotter 1 1
4 DD 1613 80 Spring main stand 1 1
3
2 5 DG 1612 24 Damper 1 1
5 6 JK 1132 03 Stand side 1 1

7 DH 1610 66 Spring side stand 1 1
8 8 DF 1611 02 Bolt 1 1
4 9 39 0422 15 Nut nyloc M10 1 1
9
7
6
55 56
Tube / Tyre / Rim
Description KS ES
Drum Drum
1 JK 1310 21 Wheel Rim Front 1.4 x 17 1 1

2 JB 1312 22 Wheel Rim Rear 1 1
}
3 DM 1510 25 Tyre Front 2.75 x 17 Rib 1 1
4 4 DS 1510 49 Tube Front 2.75 x 17 1 1
5 DM 1510 28 Tyre Rear 3.00 x 17 1 1 Not Serviceable
3 6 DS 1510 53 Tube Rear 3 x 17 1 1
57 58
Front Hub
Description KS ES
Drum Drum
1 39 2680 20 Bearing Ball 10 x 35 x 11 2 2

2 JK 1310 21 Front Wheel 1.4 x 17 1 1
5 3 31 1510 04 Collar 1 1
4 14 1510 21 Oil Seal 30 x 17 x 6 1 1
7 5 JK 1318 07 Collar Axle Assly. 1 1

6
2 3
6 39 1510 11 Plain Washer 1 1
4
7 LC J000 01 ‘U’ Nut M10 x 1.25 1 1
1 8
8 JK 1310 23 Axle 1 1
9 JA 1316 06 Bushing 1 1
16 10 39 1013 21 Ring 'O' 1 1
24
23 11 30 1510 42 Washer 2 2
22
1 12 36 DZ00 08 Gear Meter Screw Kit 1 1 Refer page no. 61
21 25
13 JK 1310 16 Stopper For Bushing 1 1
12 14 JK 1310 18 Screw Pan Cross M4 1 1
20
19 10 15 JK 1310 19 Spring Washer 1 1
18 11
11 16 31 1510 14 Oil Seal 1 1
17 15 9
17 DS 1510 94 Flange Nut M6 1 1
14 13
18 JK 1310 24 Lever Brake Cam 1 1
19 DS 1510 95 Bolt Hex M6 x 1 1 1
20 DS 1510 91 Indicator Front 1 1
59 60
Front Hub
Description KS ES
Drum Drum
21 30 1510 38 "O" ring 1 1

22 JK 1318 06 Panel Front Brake 1 1
5 23 JK 1310 25 Cam Brake 1 1
24 30 1510 37 Spring 2 2
7 25 31 1510 60 Shoe Brake 2 2

6
2 3
4
1 8
16
24
23
22
1
21 25
12
20
19 10
18 11
11
17 15 9
14 13
61 62
Rear Hub
Description KS ES
Drum Drum
1 JB 1312 25 Nut Hex M8 x 1.25 1 1

2 JK 1312 04 Collar 1 1
27
4 7
3 36 JB00 03 Chain Sprocket Kit 1 1 Refer page no. 61
4 39 2240 20 Bearing Ball 1 1
5 JK 1312 02 Sleeve 1 1
1 5
6
3
6 DU 1510 10 Coupling 1 1
9
8 10A 7 39 0978 04 'D' bolt M-10 4 4
2 8 39 0794 15 Nut Hex Fine M10 x 1.25 4 4

9 31 1510 29 Lock Washer 2 2
10 10 39 2682 20 Ball bearing (12x37x12) 1 1
13 10A 39 1364 20 Ball bearing (12x32x10) 1 1
12 11 31 1510 18 Collar Bearing 2 2

11 12 31 1510 21 Coupling Rubber 4 4
22 24
25 13 JB 1312 22 Wheel 1.6 x 17 1 1
15 26
14 30 1510 69 Spring 2 2
16 19
23 15 31 1510 60 Shoe Brake 1 1
17
14
16 31 1510 23 Brake Cam 1 1
20 21 17 JA 1312 05 Panel Rear Brake 1 1
18
18 JK 1312 01 Axle 1 1
19 DS 1510 90 Indicator 1 1
20 DX 1510 18 Washer Plain 1 1
63 64
Rear Hub
Description KS ES
Drum Drum
21 JB 1310 19 ‘U’ nut M12x1.25 1 1

22 30 1510 38 Ring 'O' 1 1
27
4 7
23 JK 1312 03 Collar 1 1
24 DS 1510 94 Hex Nut Flange M6 1 1
25 JB 1316 05 Lever Brake 1 1
1 5
6
3
26 JB 1312 24 Hex Nut / Flange M6 1 1
9
8 10A 27 JB 1410 01 Chain lock set 1 1
10
13
12
11
22 24
25
15 26
16 19
23
17
14
20 21
18
65 66
Rear Brake Pedal
Description KS ES
Drum Drum
1 39 0808 08 Split pin 1 1

17 2 39 0198 11 Plain washer 2 2
3 JK 1610 01 Rod brake 1 1
6
4 30 1910 38 Pin 1 1
16 5 JK 1318 00 Lever Brake Tubular 1 1
4
6 39 0797 08 Pin Cotter 1 1
3 7 30 1910 31 Spring 1 1
2
8 30 1910 35 Spring 1 1
1
9 39 0807 08 Pin Snap 2 2
7 10 39 0708 15 Nut Hex M10 x 1.25 2 2
2
11 39 0789 12 Washer Spring 2 2
10 11
9 12 JB 1610 02 Pin 1 1
14
8 13 JB 1610 03 Brake Adjusting Nut 1 1
14 30 1510 95 Bolt M10 x 1.25 2 2
15 JK 2210 11 Torque Rod 1 1
12
13
15 16 DD 1610 78 Damper 1 1
17 JA 1610 03 Pad Brake Pedal 1 1
9
14 11 10
67 68
Handle Bar
Description KS ES
Drum Drum
1 DU 1810 21 Handle 1 1
2 FD 1810 30 Holder handle upper 2 2
3 39 1074 04 Flanged bolt 4 4
4 JK 4014 01 Control switch RH 1 --
3
JK 4014 02 Control switch RH -- 1
2 26 5 JB 4014 00 Control switch LH 1 1
25 1
4
6 DJ 1910 54 Holder left hand 1 1
7 DJ 1910 55 Lever grip - Left 1 1
17 8 DL 1910 14 Stud Lever handle 2 2
18
20 8 9 39 1184 15 Nyloc nut 2 2
5
24
21 10 DU 1910 09 Grip - Left hand 1 1
19
22 12
15
11 11 DS 1910 38 Holder Right hand 1 1
8
16 12 DD 1911 42 Lever grip - Right 1 1
13 16 14
9 13 DD 2011 70 Front brake switch 1 1 With Wiring Harness
23
7 27
14 DU 1910 03 Grip assly RH 1 1
10 15 DS 1910 52 Boot Lever LH 1 1
6 23
9 16 36 DU19 01 Cable Adjuster kit 2 2

17 FD 1810 31 Holder Handle Lower 2 2
18 DF 1810 91 Damper Handle Upper 2 2
19 DF 1810 92 Damper Handle Lower 2 2
20 FD 1810 19 Washer Plain Upper 2 2
69 70
Handle Bar
Description KS ES
Drum Drum
21 FD 1810 20 Washer Plain Lower 2 2

22 39 2249 15 Bolt Flange M6 2 2
23 39 1553 04 Adjusting screw 2 2
24 DS 1910 18 Boot Lever RH 1 1
3
25 DJ 2210 03 Mirror assly. LH 1 1
2 26
25 1
4 26 DJ 2210 04 Mirror assly. RH 1 1
27 JB 4014 09 Clutch switch (6A Diode) 1 --
17
18
20 8
5
24
21
19
22 12
15
11
8
16
13 16 14
9
23
7 27
10
6 23
71 72
Front Fork
Description KS ES
Drum Drum
1 DL 1810 80 Seal Oil Hi Tec. 2 2

2 JK 1210 12 Pipe Left Fork Outer 1 1
3 JK 1210 13 Pipe Right Fork Outer 1 1
10
9
4 30 1810 26 Gasket 2 2
6 11 5 30 1810 25 Bolt 2 2
12
17 6 30 1810 53 Cyl. Complete Fork 2 2

13
18 7 DM 1810 36 Pipe Comp. Susp. Inner 2 2
1 8 DE 1810 31 Spring Front Fork 2 2
9 FD 1810 12 Cap Special Nut 1 1
10 DU 1810 69 Bolt Fork 2 2
7 20
8
11 30 1810 29 Ring ‘O’ 2 2
2/3
12 DF 1810 85 Seat Fork Spring 2 2
13 DD 1812 05 Holder Fork Upper 1 1
14 DD 1812 07 Holder Fork Under 1 1
4
14
15 39 0789 12 Washer Spring 2 2
5
15
16 16 39 1813 04 Bolt Hex. <10 x 1.25 2 2
17 DD 1810 11 Dust seal 2 2
19
18 30 1810 23 Ring snap 2 2
19 JK 1210 14 Front Fork 1 1
20 36 3140 01 Bearing cone Kit 1 1 Ref. page No. 100
73 74
Painted Parts and Decals
Description KS ES
Drum Drum
1 JK 7103 4C Petrol tank with decal 1 1 Black - Blue

JK 7103 4D Petrol tank with decal 1 1 Black - Red
JK 7103 4N Petrol tank with decal 1 1 Black - Green
JK 7103 3F Petrol tank with decal 1 1 Flame Red - Red
2 36 JK00 15 Decal Set 1 1 Black - Blue

7 36 JK00 16 Decal Set 1 1 Black - Red
3 36 JK00 17 Decal Set 1 1 Black - Green
36 JK00 18 Decal Set 1 1 Flame Red - Red
1
3 JK 7401 4C Fairing with decal 1 1 Black - Blue
5 JK 7401 4D Fairing with decal 1 1 Black - Red
JK 7401 4N Fairing with decal 1 1 Black - Green
JK 7401 3F Fairing with decal 1 1 Flame Red - Red
4 JK 7303 4C Seat cover with decal 1 1 Black - Blue

JK 7303 4D Seat cover with decal 1 1 Black - Red
JK 7303 4N Seat cover with decal 1 1 Black - Green
JK 7303 3F Seat cover with decal 1 1 Flame Red - Red
6 5 JK 7304 4C Fender Front 1 1 Black
JK 7304 3F Fender Front 1 1 Flame Red
4 6 JK 7301 4C Side Cover LH with Decals 1 1 Black - Blue

JK 7301 4D Side Cover LH with Decals 1 1 Black - Red
JK 7301 4N Side Cover LH with Decals 1 1 Black - Green
JK 7301 3F Side Cover LH with Decals 1 1 Flame Red - Red
2
7 JK 7302 4C Side Cover RH with Decals 1 1 Black - Blue
JK 7302 4D Side Cover RH with Decals 1 1 Black - Blue
JK 7302 4N Side Cover RH with Decals 1 1 Black - Blue
JK 7302 3F Side Cover RH with Decals 1 1 Black - Blue
75 76
Petrol Tank, Cap Tank and Gauge Fuel
No. Part No. Description KS ES Remarks
1 DS 1410 09 Cap Assly. Tank 1 1

2 39 2179 24 Washer 2 2
3 1 3 39 0761 01 Screw Pan Cross 2 2
4 4 30 1410 31 O Ring 2 2
2
5 DZ 1410 40 Tap Assly. 1 1
6 30 1410 36 Packing For Tap 1 1

7 DD 1412 27 Bolt Flanged 2 2
8 DU 1410 41 Tube Fuel 1 1
9 DZ 2010 02 Gauge Fuel 1 1 Bolt type design-Waluj
DZ 2010 19 Gauge Fuel (Octagonal - N.I.) 1 1
14
10 30 1410 28 Gasket for Gauge Fuel 1 1
6 39 2758 21 ‘O’ ring 1 1 N.I. (Pantnagar)
11 30 1410 32 Bolt 4 4
10 12 DZ 1010 34 Tube Rubber 1 1
13 33 1410 08 Clamp 1 1
7
14 DZ 1810 04 Lock Assly. 3 IN 1 1 1
9
13
8 11
12
5
77 78
Fittings - Petrol Tank, Side Covers & Cover Seat
1 DG 1410 19 Damper 2 2 Petrol tank fixing plate

2 DF 1411 28 Damper 2 2 Steering tube
3 DG 1611 18 Grommet 2 2 Side cover
4 DP 1610 77 Collar 1 1
10 5 DZ 1611 43 Screw 1 1
6 31 1610 18 Damper 1 1 LH side cover ‘C’ shape
5
7 DZ 1810 04 Lock Assly. 3 IN 1 1 1
4 8 39 1553 04 Flange Bolt 2 2
9 30 2110 05 Collar Assly. 2 2
7
10 30 1611 69 grommet 1 1 RH side cover
6
3 1
79 80
Meter Assembly
1 DZ 1910 05 Speedometer Assly Lamp 1 1

2 DL 1910 20 Lamp 12V 3W (W/o Cap) 5 5
3 DU 1910 21 Bracket Speedo Mtg. 1 1
4 DU 1910 23 Cover Meter Lower Black 1 1
5 DZ 1910 09 Speedometer with dial 1 1 Minda
JK 4024 03 Speedometer with dial 1 1 Pricol
10/11
6 DZ 1910 08 Cover case upper 1 1
7 DU 1910 24 Cover (white) W/o Support Plate 1 1 Pricol
2
6 8 39 0798 15 Hex. Nut / Flange 2 2
9 39 1943 04 Bolt Flanged 2 2
10 DZ 1910 10 Fuel Meter 1 1 Pricol
7
3
4 11 JK 4024 09 Fuel Meter 1 1 Minda
5
9
8
1
81 82
Control Cables
1 JK 1612 02 Cable Brake Front 1 1

2 30 1910 70 Spring 1 1
1 3 30 1910 69 Dust Seal 1 1
2 4 30 1910 71 Rod End 1 1
3 5 30 1910 72 Adjusting Nut 1 1
4
5
6 6 JK 1612 01 Cable Clutch 1 1
7 DZ 1910 14 Cable Speedometer 1 1
8 DZ 1910 19 Inner Cable Speedo 1 1
7
9 JK 1612 00 Cable Throttle 1 1
83 84
Chain Case
1 36 DZ00 09 Case Chain Kit 1 1 Refer page no. 100

2 DF 1614 16 Rubber Cap 1 1
3 59 0400 28 Flanged Bolt 3 3
4 59 0400 27 1 1
1
3
2
3
85 86
Head Lamp & Fairing
1 DU 2011 01 Head Light Assy. / Lamp 1 1

DU 2011 08 Head Light Assy. (w/o bulb) 1 1
2 CL 2010 23 Lamp 12V-35/35W 1 1
3 DZ 1810 01 Flap Cowling 1 1
5
15 4 DL 1810 10 Nut Well 4 4
12
13
6 11 5 DL 1810 09 Screw 5 5
1 6 39 2141 24 Washer (Non metallic) 4 4
3
7 DP 1810 12 Bracket Cowling side 1 1
14
4 8 DP 1810 13 Bracket 1 1
9 KA DF06 10 Bolt Flanged Small 1 1
19 10 39 1943 04 Hex. Bolt/ Flange 2 2

2 11 DZ 1810 03 Bracket Cowling Upper 1 1
12 DP 1810 40 Collar 2 2
13 39 2585 01 Screw M6 x 20 2 2
7
8 14 39 0813 02 Cross Rec. Pan Hd. Tp Screw 4 4
15 JK 1810 01 Wind Shield 1 1
9
10
87 88
Indicator Light Assembly
1 JK 4010 09 Dir. ind. Front LH with Lamp 1 1

2 JK 4010 10 Dir. ind. Front RH with Lamp 1 1
3 JK 4010 07 Dir. ind. Rear LH with Lamp 1 1
4 JK 4010 08 Dir. ind. Rear RH with Lamp 1 1
5 06 2010 83 Lamp 12 V 10 W Natural 4 4
1/2 6 DZ 1810 63 Bracket Signal Front 1 1

7 39 1225 15 Hex. Nut M10 2 2
3/4
89 90
Tail Lamp Assly / Front Number Plate

1
8 No. Part No. Description KS ES Remarks
7
1 39 0817 15 Hex Nut / Flange 3 3

5 2 DZ 2010 16 Tail Light Assly. with lamp 1 1
3 DP 2010 19 Lens Tail Light 1 1
4 DP 1610 75 Screw For Lens 2 2
3
5 DZ 2010 15 Collar 3 3
6 6 31 2010 28 Lamp 12 V, 10/5W 1 1

4
7 DD 2010 11 Damper 3 3
8 DP 2010 44 Plain Washer 3 3
9 DP 1611 44 Front Number plate 1 1
2
10 DP 1810 21 Bracket Front No. Plate 1 1
11
11 39 1783 01 Truss Screw 2 2
11 12 39 1972 15 Flanged Nut 1 1 N.S.
13 DP 1611 45 Number plate Rear 1 1
9
14 DP 1611 01 Bracket No. Plate Rear 1 1
18
15 39 2483 04 Hex head bolt / Flange 2 2
10
19 16 39 2765 01 Truss Screw M6 x 10 2 2

14 15 17 DP 1611 00 Bracket Fender Rear 1 1
18 DD 2010 02 Reflector Reflex 1 1
17
19 39 1972 15 Hex Nut Flange M5 1 1
13
16
16
91 92
Electrical Equipments
1 JW 4016 00 Horn with Stay 1 1

2 39 1940 04 Flange Bolt - M8 1 1
3 JK 4022 09 Wiring Harness 1 --
JK 4022 10 Wiring Harness -- 1
13 4 JK 4022 05 Cable starter relay to st. motor 1 --
6
1
5 JK 4022 01 Earth cable 1 --
7 6 31 2010 79 Rear brake switch assly 1 1

7 JK 1318 02 Spring Brake Switch 1 1
8
2 14 8 JK 1318 03 Hook brake switch spring 1 1
9 DS 2010 81 Battery 5Ah 1 -- Not Serviceable
10 31 2010 27 Battery 2.5Ah -- 1 Not Serviceable
11 10 JK 1138 00 Bracket Battery 1 --
JK 4018 00 Band Battery -- 1
13 3 4
11 DS 2010 25 DC flasher solid state 1 1
14
12 DK 2010 78 Starter Relay 1 1
5 9 13 GF 2010 36 Fuse box Assly. 2 1
30 2011 04 Fuse box Assly. -- 1
14 GF 2010 53 Fuse 4 4
93 94
Tool Kit
1 DZ 2210 05 Tool kit 1 1
95 96
Accessories / Grab Handle
1 JK 2312 01 Leg guard 1 1

2 JK 2312 03 Saree guard 1 1
3 36 JK00 02 Hardware kit 1 1 Refer page no. 61
3
2
97 98
Kit List Kit List
Sr Kit Consisting of Following Parts Sr Kit Consisting of Following Parts

Kit Description Kit Description
No Part No. Part No. Description Qty/Kit No Part No. Part No. Description Qty/Kit
1 36JK0011 Valve kit JV511004 Valve intake 1 8 36JK0020 Idling Screw Kit JK581208 Idling Screw 1
JV511005 Valve Exhaust 1 CB121044 Spring 1
DH121130 O' Ring 1
2 36JA0003 Valve Repair Kit 28101129 Seat Spring 2
39201719 Seal Valve Stem 2 9 36JK0021 Jet Kit JK581203 Needle Jet 1
JA511202 Spring washer 2 JB581218 Pilot Jet 1
JA511203 Retainer valve spring 2 JB581222 Main Jet 1
JB581223 Jet Holder 1
DG101029 Collet 4
JK581205 Jet Needle 1
3 36JK0012 Chain Guide Kit JV541001 Guide Chain Slack side 1

10 36JB0008 Seat Damper Kit DP211009 Seat Damper 9
JA521002 Guide Chain Tight side 1
DP211014 Seat Damper 1
4 36JW0010 Set Piston Ring JW521204 Ring Piston (Second) 1 11 36314001 Bearing Cone kit DH181023 Bearing Cone 1
JW521203 Ring Piston (Oil) 1 DH181025 Bearing Cone 1
JW521205 Ring Piston (Top) 1 DH181026 Bearing race 1
DH181024 Upper Bearing Race 1
5 36PA0006 Set Drive Driven JA531010 Gear Primary Drive 1
JA551401 Clutch Housing Complete 1 12 36JB0003 Chain Sprocket Kit JK141001 Chain (122 Links) 1
JA131206 Sprocket (42 T) 1
6 36DU1007 Boss Kick Kit 30101233 Boss Kick 1 JA551010 Sprocket Drive(15 T) 1
30101234 Spring 1
30101236 Ball Steel 1 13 36DZ0009 Chain Case Kit Dz161023 Chain Case Upper Assly. 1
30101235 Pin 1 DZ161027 Chain Case Lower Assly. 1
39085517 E - Type Circlip 1
14 36JK0022 Piston Valve Kit DD121054 E clip 1
JA581224 Ring 1
7 36JK0019 Air screw kit DH121130 O' Ring 1
JK581204 Spring Jet Needle 1
24121062 O' Ring 1
JK581207 Piston Valve assembly 1
JK581210 Air Screw 1
JK581206 Ring Jet Needle 1
24121064 Spring Air Screw 1
DD121056 Holder Magnet 1
16121032 Washer 1
99 100
Kit List Kit List
Sr Kit Consisting of Following Parts Sr Kit Consisting of Following Parts

Kit Description Kit Description
No Part No. Part No. Description Qty/Kit No Part No. Part No. Description Qty/Kit
15 36JK0026 Carburetor gasket 'O' ring kit JA581232 O' ring float bowl 1
DH121118 O' ring drain screw 1
24121062 O' ring air screw 1
DH121130 O' ring idling screw / Air screw 2
16 36JK0027 Choke Plunger Kit FD121017 Guide holder 1

CF121004 O' ring choke plunger 1
JK581211 Lever assembly choke 1
FD121015 Cap 1
JK581212 Spring Choke plunger 1
JK581213 Plunger assembly 1
17 36JK0002 Kit Hardware(Leg, Saree gua.) 39220504 Flanged bolt 2

3273104 Bolt hexagonal socket 2
JK231204 Hex socket head bolt M10 2
18 36DZ0008 Gear Meter Screw Kit 31151064 Speedo gear (21T) 1

30151041 Gear meter screw 1
19 36DU1901 Cable Adjuster Kit 30191017 Nut 1

DD191147 Screw 1
20 36051701 Rubber Inner Bush Kit 30171030 Bush Rubber 4

30171031 Bush Inner 4
101 102
Amendment Sheet Amendment Sheet
AMENDMENT SHEET (PARTS ADDED) AMENDMENT SHEET (PARTS DELETED)
SR. PAGE FIGURE SR. PAGE FIGURE
PART NUMBER DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY.
NO. NO. NO. NO. NO. NO.
103 104

Notice: DOC. NO.: 71111029 REV. 00, FEB. 10

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

Notice: DOC. NO.: 71111029 REV. 00, FEB. 10

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Notice: DOC. NO.: 71111029 REV. 00, FEB. 10

Uploaded by

Copyright:

Available Formats

Notice

All information contained in this manual is based on the latest

DOC. NO.: 71111029 REV. 00, FEB. 10

4. Abbreviations : The following abbreviations are used in this catalogue.

1 Cover Cylinder Head 2 31 Rear Hub 64, 66

Cover Cylinder Head

2 1 JV 5110 13 Cylinder head cover complete 1 1

6 JA 5110 11 Hose Breather 1 1

1 xx xxxx xx Head cylinder complete with

6 JA 5814 06 Bolt flange 2 2 M6x1x25L

1 JV 5110 06 Shaft Rocker arm 2 2

6 39 2017 19 Seal valve stem 2 2

1 JV 5110 07 Camshaft assly complete 1 1

11 JA 5210 19 Flange bolt 2 2 Adjuster assly chain mtg.

Cylinder Block and Piston

1 JA 5210 01 Gasket cylinder black 1 1

6 JA 5210 15 Damper cylinder block 3 3

1 59 1500 14 Nut flange 1 1

1 JD 5510 00 Shaft Input Transmission 1

21 JV 5510 00 Sprocket Drive (15 T) 1

Change Drum / Shift Fork

1 JW 5610 00 Drum Complete Gear Shift 1 1

Gear Change Mechanism

1 JW 5612 04 Lever comp. gear shift 1 1

2 6 JA 5612 09 Step washer 1 1

Engine Assembly / Crankcase RH

1 JK 5010 00 Engine assembly 1 -- N.I.

6 39 1000 06 Hollow dowel pin 2 2

1 xx xxxx xx Crankcase LH 1 -- NRB + Bush + Orifice

16 59 0400 38 Flange bolt 6 6

1 JA 5412 08 Clutch cover 1 1

6 DP 1012 69 Rod push 1 1

16 16 JA 5412 12 Gasket clutch cover 1 1

21 JA 5412 19 Cap filter 1 1

1 JA 5412 41 Cover magneto -- 1 Threaded cap design

11 JA 5410 05 Bush Bendix 1 1

6 30 1010 96 Plate Clutch 4 4

16 36 PA00 06 Set Primary Drive & Driven 1 1 Refer Page No. 99

Kick Starter Mechanism

1 JA 6212 01 Lever assly. kick 1 1

7 6 39 0738 17 External circlip type C 2 2

5 9 11 JA 6210 06 Washer thrust (16.2x25x0.5 ) 1 1

1 JB 5812 08 Carburettor assly. 1 1

2 12 36 JK00 21 Jet kit 1 1 Ref. page no. 100

13 16 JK 5812 11 Lever Assly 1 1

Air Cleaner Complete

1 JK 5810 00 Air filter assly 1 1

6 JB 5810 05 Element air filter 1 1

16 39 2044 01 Screw Air Filter Cover 4 4

1 xx xxxx xx Silencer assly. W/o shield 1 1

1 52 JA00 23 Oil pump assly. 1 1

Starter & Motor Assembly

1 JA 6214 14 Body comp. starter clutch -- 1

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

Magneto, CDI & H.T. Coil

1 JK 3510 08 Rotor assly. -- 1

14 6 JK 3512 10 C.D.I. assly. 1 1