Notice DOC. NO.: REV. 00, SEP. 11

Transcription

1

2 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.: REV. 00, SEP.

3 Foreword We have pleasure in presenting the Spare Parts Catalogue for BOXER 0 Motorcycle. This catalogue has been specially designed to assist you in selecting the correct parts for procurement to maintain 0% availability. 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 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. The modifications / alterations which are carried out after the issue of this catalogue, will be conveyed to you through our Service Circulars. You are requested to make necessary corrections in the Parts Catalogue as per the circulars so as to keep your catalogue up-to-date. This will ensure the appropriate and speedy delivery of the Spare Parts as the order placed will bear the latest part numbers. In case, if you need any technical assistance contact the concerned Regional Office or write to us on the following address : Bajaj Auto Limited Service Department Akurdi, Pune 0 India Phone : 00-0 Fax : 00-0 Instructions. 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. Write 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.. 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 painted components, colour shade 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.. Part Number System : We have used 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 -- or -- digit system. Understanding this system will enable you to identify the spare parts easily.. 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 Rr. Rear Std. Standard L Length A/t. Alternate R.H. Right hand L.H. Left hand Hex. Hexagonal AR As required

4 Index Index Plate Description Page Plate Description Page Cover Cylinder Head Cylinder Head Valve Camshaft / Tensioner Cylinder & Piston Crankshaft Transmission Change Drum / Shift Fork 9 Gear Change Mechanism Engine Assly / Crankcase RH 0 Crankcase LH Cover RH Cover Magneto Clutch Kick Starter Mechanism 0 Carburettor Air Cleaner Complete Silencer Assly 9 Oil Pump 0 Starter Assly 0 Magneto / C.D.I. / H.T. Coil Seat Assly / Grip Frame Engine Mountings Frame & Frame Fitting Swing Arm / Rear Shock Absorber 0 Rider Foot Rest / Pillion Foot Rest Mudguard - Front & Rear Stand Assembly 9 Tyre / Tube / Rim 0 Front Hub 0 Rear Hub Rear Brake Pedal Handle Bar, Front Fork 0 Painted Parts & Decals Petrol Tank, Cap Tank & Gauge Fuel Fittings - Petrol Tank, Side Cover Meter Assembly 9 Control Cables 0 0 Chain Case Head Lamp & Fairing Indicator Light Assembly Tail Lamp Assembly / Front Number Plate Electrical Equipments 90 Tool Kit 9 Accessories 9 Kits List 9, 9, 9, 9 Amendment Sheet (Parts Added & Deleted) 99, 0 Part Index

5 Pictorial Index Pictorial Index PLATE NO. : COVER CYLINDER HEAD PLATE NO. : CYLINDER HEAD PLATE NO. : CYLINDER & PISTON PLATE NO. : CRANKSHAFT PLATE NO. : VALVE PLATE NO. : CAMSHAFT / TENSIONER PLATE NO. : TRANSMISSION PLATE NO. : CHANGE DRUM / SHIFT FORK

6 Pictorial Index Pictorial Index PLATE NO. : 9 GEAR CHANGE MECHANISM PLATE NO. : ENGINE ASSLY / CRANKCASE RH 0 PLATE NO. : COVER MAGNETO PLATE NO. : CLUTCH PLATE NO. : CRANKCASE LH PLATE NO. : COVER RH PLATE NO. : KICK STARTER MECHANISM 0 PLATE NO. : CARBURETOR Nozzle Oil Jet (Press Fitted)

7 Pictorial Index Pictorial Index PLATE NO. : AIR CLEANER COMPLETE PLATE NO. : SILENCER ASSLY PLATE NO. : MAGNETO / C.D.I. / H.T. COIL PLATE NO. : SEAT ASSLY / GRIP FRAME PLATE NO. : 9 OIL PUMP PLATE NO. : 0 STARTER ASSLY 0 PLATE NO. : ENGINE MOUNTINGS PLATE NO. : FRAME & FRAME FITTINGS

8 Pictorial Index Pictorial Index PLATE NO. : SWING ARM / RR. SHOCK ABSORBER 0 PLATE NO. : RIDER FOOT REST / PILLION FOOT REST PLATE NO. : 9 TYRE / TUBE / RIM PLATE NO. : 0 FRONT HUB 0 PLATE NO. : MUDGUARD - FRONT & REAR PLATE NO. : STAND ASSEMBLY PLATE NO. : REAR HUB, PLATE NO. : REAR BRAKE PEDAL

9 Pictorial Index Pictorial Index PLATE NO. : HANDLE BAR, PLATE NO. : FRONT FORK 0 PLATE NO. : FITTINGS - PETROL TANK, SIDE COVERS PLATE NO. : METER ASSEMBLY / / PLATE NO. : PAINTED PARTS PLATE NO. : PETROL TANK, CAP TANK & GAUGE FUEL PLATE NO. : 9 CONTROL CABLES 0 PLATE NO. : 0 CHAIN CASE

10 Pictorial Index Pictorial Index PLATE NO. : HEAD LAMP & FAIRING PLATE NO. : INDICATOR LIGHT ASSEMBLY PLATE NO. : TOOL KIT 9 PLATE NO. : ACCESSORIES 9 / PLATE NO. : TAIL LAMP ASSLY / FRONT NUMBER PLATE PLATE NO. : ELECTRICAL EQUIPMENTS 90

11 Plate : Cover Cylinder Head Brand ID: 00MC JV 0 Bolt Flange JZ Cover Cylinder Head Assly DP Clamp JA Hose Breather JD Gasket Head Cover JA 0 Bolt Head Mounting M X. X 9L PF Plate Cylinder Head PF Flange Bolt M X

12 Plate : Cylinder Head Brand ID: 00MC JA Stud M X Silver PF00 0 Kit Asly Cylinder Head Studs &Valve Guide Fitted JZ Gasket Cylinder Head 9 9 O Ring (Intake Pipe) PF 0 Intake Manifold JV Bolt Flange DP 9 Clamp (9mm) PF 0 Sleeve (Carb - Duct Rubber)

13 Plate : Valve Brand ID: 00MC DG 9 Cotter Valve (Collet) JZ00 0 Valve Repair Kit Refer Page Seal Valve Stem JZ00 0 Valve Kit Refer Page 9 JZ 0 Rocker Arm with Roller JA Shaft Rocker Arm. mm

14 Plate : Camshaft / Tensioner Brand ID: 00MC JV 0 Bolt M Chain Tensioner JV Bolt M X 0 Silver Adjuster Mounting JV 0 Adjuster Chain Silver 9 9 O Ring (Tensioner) CS Gasket JZ 0 Camshaft Complete Bearing Ball - Small X X 9 W X OD X ID 9 0 Bearing Ball - Big X X Circlip for Camshaft JA Spacer Cam Sprocket DS Sprocket Cam Shaft - T DH Special Washer Cam Shaft O Washer Hex Head Bolt JE00 0 Guide Chain Kit Refer Page 9 DS 99 0 Cam Chain (9 Link) 9 DH 9 Cam chain Tensioner Pivot Bolt

15 Plate : Cylinder & Piston Brand ID: 00MC Dowel Pin PF00 0 Kit Cylinder Block / Piston Assly. JD 0 Gasket Cylinder Block JA Damper Cylinder Block JZ00 0 Piston Ring Set Refer Page 9 DP Ring Snap 9

16 Plate : Crankshaft Brand ID: 00MC 9 00 Flange Nut A Belleville Washer B Plain Washer Key Woodruff PF 00 Crank Shaft Assly JE 0 Ball Bearing X X DS Parallel Key JZ00 0 Set Primary Drive / Driven JA Spring A 9 B A 9 JA Pin Crank Shaft Plunger JB Plunger Oil Crank Shaft

17 Plate : Transmission Brand ID: 00MC PF 0 Shaft Input Transmission (Drive) PF 0 Gear th Drive JA 0 Spline Washer (.X0.X.) 9 09 Ring Snap (. X 0. X.) PF 0 Gear rd Drive PF 00 Gear nd Drive JA 0 Washer Thrust nd Drive PF 0 Shaft Output Transmission 9 PF 0 nd Driven Washer PF 0 Gear nd Driven 9 PF 0 Gear rd Driven PF 0 Gear th Driven JZ 0 Bush st Driven JZ 0 Gear st Driven JA 0 Washer Thrust st Driven 0 9 JA 09 Collar Sprocket Drive 9 0 O Ring Collar Sprocket JZ 0 Sprocket Drive (Engine Sprocket) Teeth 9 DU Plate Lock Sprocket Socket Head Bolt

18 Plate : Change Drum / Shift Fork Brand ID: 00MC PF 00 Drum Complete Gear Shift Dowel (Pin Drum Change) JA 0 Cam Drum Change JD Special Bolt Drum Change M X PF 0 Shaft Gear Shift Fork JD 0 Fork Gear Shift Output JZ 0 Fork Gear Shift Input

19 Plate : 9 Gear Change Mechanism Brand ID: 00MC PF 00 Lever Gear Shift Comp JW 0 Extension Spring JW 0 Spring Gear Shift Return JA 0 Spring Inhibitor JA 09 Step Washer (Collar) JA 0 Inhibitor Complete Gear Shift 9 0 Plain Washer 9 0 Hex Nut / Flange - M 9 JZ 0 Lever Gear Shift (Gear Pedal) DH 09 Damper DG 9 Damper JA Flange Bolt 9

20 Plate : Engine Assembly / Crankcase RH Brand ID: 00MC PF 0 0 Engine Assly SS BM-0 N.I. PF 0 Engine Assly KS BM-0 -- N.I. PF00 0 Kit Asly C case RH BM0 NRB & Bush Drum Fitted JV Bolt M X Silver Crankcase Mounting JV 0 Flange Bolt Crankcase Mounting JA Stud Inhibitor Mounting Ball Bearing For I/P Shaft. JA Stopper Plate DH 0 Screw 9 JA Bolt Shift Change Flange Bolt - Small JA Guide Kick JA Needle Roller Bearing For O/P Shaft. PF Bushing Drum BM Dowel Pin 9 0

21 Plate : Crankcase LH Brand ID: 00MC Nozzle Oil Jet (Press Fitted) PF00 0 Kit Asly C case Mag Side ES NRB, Bush & Nozzle Oil Jet Fitted Pf00 Kit Asly C case Mag Side KS -- NRB, Nozzle Oil Jet Fitted JD 00 Damper Crankshaft 9 0 Needle Roller Bearing Ball Bearing JA 0 Bush Bendix Pin Dowel Bolt (M X X L) Crankcase Mounting JA Stopper Gear Starter Aluminium Screw Pan Cross M JV 0 Cap Oil Filter Ring O JG Mesh Oil Filter Assembly 9 LJ A000 0 O Ring Strainer 0 Switch Complete Neutral Switch DH Gasket Neutral Switch (T.I.S) 9 9 Seal Oil Output Shaft Oil Seal Shifter Shaft JV 0 Flange - Bolt Crankcase Mounting Hollow Dowel Pin

22 Plate : Cover RH Brand ID: 00MC 9 0 PF00 0 Kit Asly Cl Cover BM-0 Gauge & Circlip Fitted JK Decal 9 9 Oil Seal Clutch Lever 0 Oil Seal (Kick Shaft) JV 0 Shaft Clutch Release 9 JE 0 Rod Push DG Gauge Oil Level Check DS Wire Circilp 9 JE Plain Washer JE Spring Torsion Clutch Lever JA Cap Oil Filler JA O Ring Cap Oil Filler JK Damper Clutch Cover JA Plate Damper DH Bolt Flange JA Gasket Clutch Cover JV 0 Bolt Flange Cl. Cover to C case Mtg JV 09 Bracket Clutch Cable 9 DD Oil Filter Element 0 9 O Ring JV 0 Cap Filter JV Bolt Flange Bearing Push Rod Pin Hollow Dowel

23 Plate : Brand ID: 00MC Cover Magneto DH Flanged Bolt JA Plate Damper Cover Magneto JK Damper Cover Magneto PF00 0 Kit Assly Cover Magneto ES Bush Fitted PF00 Kit Assly Cover Magneto KS -- With Decal JV 0 Cap TDC Finder 0 9 O Ring 9 JV Bolt M Silver colour JK Decal 9 JA 0 Bush For Drive Gear Assly JA 0 Gasket Magneto Cover JV Cover LH Rear Complete JV 0 Bolt DS 0 Sticker Gear Shifting

24 Plate : Brand ID: 00MC Clutch PF 0 Clutch Assembly Complete JD 00 Spacer Clutch Assly JA 0 Collar Clutch 9 00 Washer JA Wheel Clutch PF00 09 Kit Plate Friction Refer Page 9 9 JA 9 Plate Clutch (Steel Plate) JA Hub Clutch 9 PF 0 Compression Spring PF 0 Holder Clutch 9 0 Bolt Flange M 9 00 Plain Washer 9 00 Belleville Washer DH Nut Special Clutch Center Lock L.H. Threads Bearing Clutch Lifter X 0 X 9 JZ00 0 Set Primary Drive & Driven Refer Page 9

25 Plate : Brand ID: 00MC Kick Starter Mechanism JA 0 Lever Assly Kick Bolt Special DU 0 Boss Kick Set Refer Page 9 0 Plain Washer DD 9 Kick Rubber JA 0 Washer Thrust (. X X 0.) JA 0 Shaft Kick Circlip Shaft 9 DS Spring Kick Starter Ratchet JA 0 Ratchet Plain Washer Small JZ 00 Gear Kick Pinion 9 0 Circlip JE 0 Spring Kick Starter Return 9 0

26 Plate : Brand ID: 00MC Carburettor PF 00 Carburettor Assly JA 9 Cable Adjuster JA Mixing Cap Assembly JZ Spring PF00 Kit Piston Valve BM 0 Refer Page 9 DH 9 Pilot Screw Kit Refer Page 9 9 JZ00 Idling Screw Kit Refer Page 9 JA Needle Valve Assembly 9 Float Complete JA Screw TPS 9 JB 0 Throttle Position Sensor JB 0 "O" Ring (TPS) 9 Arm Pin Float PF00 Kit Jet BM 0 Refer Page 9 JA Gasket Float Chamber CB Screw Washers Bowl Mx JA Drain Screw JZ 0 Hose Drain 9 PF00 Kit Choke Plunger BM 0 0 PF00 Kit Carburetor Gasket/O Ring N.I. Refer Page 9

27 Plate : Brand ID: 00MC Air Cleaner Complete Part Description Qty Remarks PF 0 Air Filter Assly JB 0 Air Intake Duct 9 0 Hex Head Screw DF Washer DH Clamp N.I. PF 0 Duct Air Intake Intake 9 0 Flange Bolt JA Filter Air Cover 9 JA O Ring Cartridge Cover 9 JA Hose Breather N.I. DP Clamp JA Tube Drain DS Plug JA 0 Element Air Filter JA 09 Flame Arrester JA 0 Assly Catridge Air filter

28 Plate : Brand ID: 00MC Silencer Assembly PF00 Kit Assly Silencer W/O Shields CB Gasket Exhaust Mounting JA 9 0 Flange Nut 9 0 Bolt Hex with Flange M 9 9 Plain Washer 9 0 Bolt M x. JB 0 0 Washer PF 9 Shield Muffler 9 DH 0 Truss Screw 9 9 PF 9 Wire Shield

29 Plate : 9 Brand ID: 00MC Oil Pump PF 00 Oil Pump Assly JA Gasket Case Oil Pump Dowel FD Pan Head Screw M X X DL PF 0 Gear Oil Pump

30 Plate : 0 Starter Assembly Brand ID: 00MC JA 0 Washer JA 0 Starter Drive Assly JA Gear Starter Clutch -- DH 0 Screw - Pan - Precoated 9 09 Washer lock - Toothed -- JA Body Complete Starter Clutch -- DH Plate Roller Clutch -- JZ00 0 Starter Clutch Repair Kit -- Refer Page 9 9 PF 00 Motor Assly -- JV 9 Flange Bolt -- Motor Mounting 9 JA 0 O Ring For Spigot (Flash) -- JA O Ring For Spigot (Lucas-TVS) JA 0 O Ring For Tie Bolt (Flash) -- JA 0 Sealing Ring (Flash) -- JA Sealing Ring (Lucas-TVS) -- JA 0 +ve Brush Holder Assly (Flash) -- JA 09 -ve Brush Holder Assly (Flash) -- JA 9 Terminal Assly (Lucas-TVS) JA Brush & Earth Plate Assly -- N.I. (Lucas-TVS) JA Brush Spring (Lucas-TVS) -- N.I. 9 0

31 Plate : Brand ID: 00MC Magneto / CDI / H.T. Coil PF 0 Rotor Assly ES PF 09 Rotor Assly KS PF 0 Stater Assly Complete 9 0 Bolt Flange M X DH 0 Pan Head Screw M X For Lock Plate & JA Lock Plate JV 0 H. T. Coil With Cable Pick Up Coil Mounting DD Grommet for HT Cable DD Spark Plug Cap LH 9 DD Grommet Spark Plug Cap LH DD Spark Plug PRZ9 HC CF 9 Spark Plug URAC PF 0 C.D.I. Assly Red Colour Bolt Flange M JN DC Regulator With Capacitor Bolt Flange (N.I.) For HT Coil Mounting 9

32 Plate : Brand ID: 00MC Seat Assly / Grip Frame Part Description Qty Remarks PF 9 00 Seat assly. complete DP 09 Damper For Seat LA C000 Bolt Hexagon Socket Head 9 Washer Plain FD 0 Spacer Seat FD 0 Grommet Seat PF 0 Grip Frame 9 0 Bolt Flange

33 Plate : Brand ID: 00MC Engine Mountings Part Description Qty Remarks 9 90 Nut Flanged For engine mtg. Top & Front PF 0 Bracket Engine Hanger 9 0 Bolt Flanged For engine mtg. Top Hex Bolt Flanged For engine mtg. Front JA 0 Engine Mounting Bracket Front 9 Hex Nut Flanged For engine mtg. Rear JA 0 Bolt Flanged For engine mtg. Rear

34 Plate : Brand ID: 00MC Frame & Frame Fittings PF 00 Frame Assly. DS Nut with Dust Cap 0 Bearing cone Kit Refer Page 9 DJ Cage Bearing DH Cup Steering N.I.

35 Plate : Swing Arm / Rear Shock Absorber Brand ID: 00MC Part Description Qty Remarks A B PF 0 Rear Shock Absorber A 9 0 Plain Washer For RSA B 9 9 Plain Washer 9 09 Spring Washer 9 Domed Cap Nut JB Hex Bolt / Flange - M For RSA B Nylock Nut DP 0 Bushing Rubber PF00 Kit Asly Swing Arm With Bushes 9 JA 0 Shaft Swing Arm JB 0 Chain Slider Screw For Chain Sider 9 0 Plain Washer For Chain Sider 9 DJ Adjuster Chain LH DJ Plate Chain Adjuster 9 09 Hexagon Nut DJ Adjuster Chain RH 9 0

36 Plate : Brand ID: 00MC Rider Foot Rest / Pillion Foot Rest DF Rubber Main Step KA DF0 Bolt Flanged 9 9 Washer - Spring PF 0 0 Main Step RH DH 9 Kick Stopper For Kick stopper PF 0 00 Main Step LH 9 0 Bolt Hex With Flange M PF 0 0 Stay LH 9 PF 0 0 Stay RH 0 Pin Pillion Step Split Pin DP 0 Step RH / LH DP Washer for foot step For Rear Footrest / 9 JK 0 0 Rubber Pillion Step

37 Plate : Brand ID: 00MC Mudguard - Front & Rear 9 0 Flange Bolt Fender Front Mounting DF 9 0 Cable Guide 9 09 Washer Plain 9 0 Bolt Hex M 9 0 Nyloc Nut Front & Rear Fender Flap 9 0 Washer Front Fender Flap PF 0 Mud Flap Front Fender Screw Front & Rear Fender Flap Hex. Bolt Flange M 9 0 Washer Plain 9 JV 0 Fender Rear Bolt Flange 9 0 Washer Plain KA DF0 0 Bolt Flange 9 90 Nut Hexagon M 9 0 Washer Plain 9 9 Washer Rear Fender Flap JV Fender Rear Flap

38 Plate : Brand ID: 00MC Stand Assembly JA 0 Shaft Stand PF 0 Center Stand Pin Cotter DH Spring Stand Center DG Damper Main Stand DF 0 Bolt JA 0 Stand Side 9 0 Nut Nyloc M 9 DH Spring Side Stand 9

39 Plate : 9 Brand ID: 00MC Tube / Tyre / Rim Nipple Spoke DS 0 Spoke Inner Front DS 0 Spoke Outer Front DS 0 Wheel Rim Front. X DG Band Rim DS Tube Front X PF 0 Tyre Front X RIM DS Wheel Rim Rear. X 9 DS 9 Tube Rear 90 / 90- PF Tyre Rear 0 x 90,, P DS 09 Spoke Inner Rear DS Spoke Outer Rear 9

40 Plate : 0 Front Hub Brand ID: 00MC 9 0 Ball Bearing x x JA 0 Drum Front 0 Collar Bearing 0 Oil Seal DS 0 Spacer Plain washer U Nut M DJ Axle Front Bolt M X 0 JA 0 Lever Brake Front 9 09 Nut Hex. Flange M DD 09 Indicator Front 0 'O' Ring JA 0 Panel Front Brake 0 0 Cam Brake 0 Gear Speedometer 0 Seal Oil 0 9 Spring 9 0 Shoe Brake 0 0 Washer for Speedo Gear 0 Gear Meter Screw JA 0 Bush for Speedo Gear Screw Pan Cross M For Speedo Cable Washer Spring 0 Stopper For Bushing 9 0

41 Plate : Rear Hub Brand ID: 00MC 9 JN 0 Drive Chain Lock PF00 Kit Chain Sprocket Refer Page Nut Hex. M0 X 9 Washer Plain DS Collar Coupling Side 9 09 Hex Lock Nut DS Washer Four Rubber Ball Bearing 9 DS Coupling DS D Bolt DJ Sleeve Rear Axle DK 9 Damper Shock 9 0 Bearing Sprocket Side 0 Collar Bearing DS Drum Rear Rubber Bearing Brake Side 0 9 Spring 0 Shoe Brake 9 0 Cam Brake Rear 9A 9 0 Washer 0 DS 9 Panel Rear Brake 0 Ring O 0 0 Indicator Wear 9 09 Nut M JW 0 Lever Brake Rear 9 0 Hex. Head Bolt M PF 0 Axle Rear Wheel (Dia.) PF 0 Spacer Panel Side 9 Washer Plain 9 DH 9 Nut 'U' M Swing Arm

42 Plate : Brand ID: 00MC Rear Brake Pedal PF 0 Brake Pedal Pin Cotter 9 00 Plain Washer JV Brake Pedal Return Spring 0 9 Pin Plain washer PF 0 Rod brake DS 9 Packing Brake rod Split pin 9 DH 9 Step Bolt Torque Rod 9 0 Plain Washer 9 09 Spring Washer 9 09 Hex. Lock Nut M x Split Pin JW 0 Rod Torque 0 9 Bolt Hex Nut Hex. M X 9 09 Washer Plain Spring 0 JB 0 Pin Brake Rod 0 9 Nut Brake Adjuster

43 Plate : Brand ID: 00MC Handle Bar Flange Bolt For Ignition Switch DS Switch Ignition Assly A PF 0 in One Lock Set DJ 0 Mirror Assly. LH DJ 0 Mirror Assly. RH DU 9 09 Grip LH JB 0 00 Control Switch LH 9 9 DJ 9 Holder LH JB 0 Lever & Holder assly LH DH 9 Holder LH -- DX 9 0 Lever & Holder Assly LH -- DJ 9 Lever Control LH DL 9 Lever Grip Left 9 DK00 Kit Mirror Holder Refer Page DD 9 Screw for Cable Adjuster DS 9 Boot For Lever LH 9 0 Flanged Bolt DS 0 Kit Holder Handle DS 9 Boot For Lever RH DD 9 Lever RH DX 9 09 Lever Assly RH PF 0 0 Control Switch RH-ES PF 0 09 Control Switch RH -KS --

44 Plate : Brand ID: 00MC Handle Bar DU 9 0 Hand Grip Assly RH DU 9 0 Throttle Pipe 9 DS 9 Holder RH 0 PF 0 0 Brake Switch DU Handle Bar DS 0 Washer Handle Upper DS 0 Damper Handle Upper 9 9 DS 0 Holder Fork Upper DS 09 Damper Handle Lower DS Washer Handle Lower 9 9 Nylock Nut JB 0 09 Clutch Switch Band 9 0 9

45 Plate : Front Fork Brand ID: 00MC / 9 / 9 0 / PF Fork Front PF Fork Front DK00 0 Kit Outer Tube Refer Page 9 DJ Seal Oil PF Pipe Left Fork Outer PF 9 Pipe Right Fork Outer 0 Gasket 0 Bolt DE Cylinder Complete Fork 9 DS Washer Guide Bush DM 0 Rebound Spring DS 0 Bush Guide PF Fork Pipe Inner DS Spring Front Fork Bolt Fork With Washer DS Bolt Fork 0 9 O Ring DS 0 Holder Fork upper PF Damper Cover Fork DS Spacer Nylon - 9 DJ Cover Trail A 0 PF Lamp Shade Assly. 0A PF Cover Fork LH -- 0B PF Cover Fork RH -- DJ Cover Trail B DJ Cushion Rubber 9 0 Bolt JC 0 Spring Washer PF 0 Under Bracket Fork Alt. Ds0 0A 0B DH Bearing Cone DS Plain Washer For Cap Nut DS Cap Nut Fork 9 0

46 Plate : Painted Parts & Decals Brand ID: 00MC PF 09 Wind Shield PF 0 X Cowling Painted Ebony Black PF 0 E Cowling Painted Electron Blue PF 0 F Cowling Painted Flame Red PF 0 X Front Fender Painted Ebony Black PF 0 E Front Fender Painted Elect Blue PF 0 F Front Fender Painted Flame Red PF X P.Tank Ebony Black Decal Black Decal PF E P.Tank Elctron Blue Decal Blue Decal PF F P.Tank Flame Red Decal Red Decal PF 0 X Side Cover RH Ebony Black Decal PF 0 E Side Cover RH Electron Blue Decal PF 0 F Side Cover RH Flame Red Decal PF 0 X Side Cover LH Ebony Black Decal PF 0 E Side Cover LH Electron Blue Decal PF 0 F Side Cover LH Flame Red Decal PF00 Kit Tank Dcl Red PF00 Kit Tank Dcl Blue PF00 Kit Tank Dcl Black PF00 Kit Dcl Side Cover Red BM0 PF00 9 Kit Dcl Side Cover Blue BM0 PF00 0 Kit Dcl Side Cover Black BM0

47 Plate : Brand ID: 00MC Petrol Tank, Cap Tank & Gauge Fuel PF 0 In Lock Set DS 09 Cap Assly. Tank Screw Pan Cross 9 9 Washer 0 O Ring PF 0 Seat Lab Front PF 0 Seat Lab Down PF 0 Fuel Tap 9 DK Pipe Clip PF 0 Pipe Fuel Cock to Carburettor PF 0 00 Sensor Fuel Level With O Ring 9 O Ring For Tank Unit 9 Flanged Nut 9

48 Plate : Brand ID: 00MC Fittings - Petrol Tank, Side Covers DJ 0 Damper Front For Tank Mounting Pin Snap 9 Plain Washer DS 0 Grommet Kit for Side Cover DS Grommet Side Cover Front A JV 0 Damper Tank Rear For Tank 0 9 Grommet Side Cover For Side Cover RH 9 9 Washer Nylon DG Screw 9 DH Grommet Side Cover For Side Cover LH A DU 0 Damper 9

49 Plate : Brand ID: 00MC Meter Assembly PF 0 00 Speedometer Assly. PF 0 0 Speedo meter Bottom Cover PF 0 0 Speedometer Machine With Dial PF 0 0 Fuel Gauge Machine with dial PF 0 0 Speedo meter Top Cover PF 0 0 Speedometer wiring harness DH 0 Bulb V -. W DL 9 0 Bulb V - W 9 PF 0 0 Speedometer Bracket 9 09 Flanged Nut 9

50 Plate : 9 Brand ID: 00MC Control Cables PF 0 Cable Speedometer PF Cable front Brake PF Cable Accelerator PF 09 Cable Speedometer Inner 9 O Ring PF Cable Clutch 9 0

51 Plate : 0 Brand ID: 00MC Chain Case JB 9 Bolt M JB Flange Bolt M X P X 0 L JB 0 Flange Bolt M X P X L PF00 Kit Chain Case Refer Page 9 9 Rubber Cap

52 Plate : Head Lamp & Fairing Brand ID: 00MC PF 09 Windshield DL 09 Screw - M X L 9 Washer (Non Metallic Washer) -- DL Nut-well M -- 0 Nut - Clip / 9 Washer - Plain Screw - Pan Head -- PF 0 00 Head light assly PF 0 0 Head light assly Without Bulb 9 DJ 0 Head Light Rim DJ 0 Reflector with Lens CL 0 Lamp V / W HS DF 0 Lamp Holder (Socket) Assly. DU 0 9 Special Screw 9 90 Flange Nut M- DS 0 9 Collar DS 0 Damper II DS 0 0 Damper I 9 0 Flange Bolt M- L 9 PF Fairing Structure -- 0 JW Bolt Flange M -- 0 JW 9 Plain Washer -- JB Grommet Fairing Mounting -- JB Sleeve Fairing Mounting Hex Nut -- PF Grommet - Cowling Mtg --

53 Plate : Brand ID: 00MC Indicator Light Assembly DU 0 0 Dir. ind. Front LH with Lamp With Lamp base DU 0 Dir. ind. Front RH with Lamp With Lamp base DU 0 Dir. ind. Rear LH with Lamp With Lamp base DU 0 Dir. ind. Rear RH with Lamp 0 0 Lamp V - W DU 0 Lens 9 Hex. Nut Flange

54 Plate : Tail Lamp Assly / Front Number Plate Brand ID: 00MC Hex Nut. / Flange 9 9 Plain Washer 0 0 Collar DD 0 Damper PF 0 Bracket Tail Light Assly Bolt Flange Small DM 0 Boot DF 0 Tail Light Assly. with lamp 9 0 Lamp V, /W 9 0 Truss Screw Front Plate DP Number Plate Front DD Front Plate Mtg Bracket 0 0 Damper 0 Collar 9 Washer Bolt Flange DP Plate Rear 9 0 Screw Truss M Reflector Reflex Nut Hexagon with Flange M

55 Plate : Electrical Equipments Brand ID: 00MC JV 0 0 DC Horn Alternate - Jv Flange Bolt (M) Horn mounting Bolt Flanged -- St. Relay mounting JK 00 Starter Relay -- With Grommet JV 0 0 Cable Assly. (Battery to Earth) -- 9 JV 0 0 Starter Relay to Motor Relay -- DS 0 Battery Ah MF dry Charged -- N.S. 0 Battery. Ah MF dry Charged -- N.S. DS 0 Assly DC Flasher 9 PF 0 00 Wiring Harness ES -- PF 0 0 Wiring Harness KS -- DS Step Bolt 9 0 DJ Clip Nut M Side cover mounting JA 0 0 Band Battery ES -- JV 0 0 Band Battery KS -- PF 0 0 Clamp Battery Cable -- JV 0 0 Case Battery Fuse Box Assly For Light Main Fuse GF 0 Fuse ( Amp.) Light & Main Fuse PF 0 0 Rear Brake Switch PF 0 0 Spring Brake Switch 9 DK 0 9 Clamp Harness 0 PF 0 0 Damper Battery

56 Plate : Brand ID: 00MC Tool Kit DM Tool Kit For Reference Only DJ 0 Screw Driven DZ Tool Wrench A/F X DF Spanner Box- X DF 9 Tool Bar DM Tool Bag Bag Polythene BOXER S 9 9

57 Plate : Brand ID: 00MC Accessories JW00 Kit Hardware for Leg Refer Page 9 PF 0 Leg Guard Bolt Socket M X. PF 00 Sari Guard JB 0 Bolt Socket M 9 9

58 Kit List Kit List Sr No Kit Part Kit Description Consisting of Following Parts Part Description Qty/Kit Sr No Kit Part Kit Description Consisting of Following Parts Part Description Qty/Kit JZ000 Valve Kit JZ0 Valve Intake JZ Valve Exhaust JZ000 Valve Repair Kit 909 Seat Valve Stem DG9 Cotter Valve JA Retainer Valve Spring 9 Seat Valve Spring JZ Spring Washer JE000 Kit Guide Cam Chain JW Guide Cam Chain (Slack Side) JA0 Guide Cam Chain (Tight Side) JZ000 Piston Ring Set JZ Ring Piston Top JZ Ring Piston Second JZ Ring Piston Oil DU0 Boss Kick Set 0 Boss Kit 0 Spring 0 Ball Steel 0 Pin 90 E - Type Clip PF00 Kit Jet BM 0 JZ Needle Jet JZ9 Holder Needle Jet JZ Jet Main JE Jet Pilot DH9 Pilot Screw Kit DH Screw Adjuster DH0 O - Ring DH Spring Compr Coil DH Plain Washer DH O - Ring JZ00 Idling Screw Kit JZ Screw Stop DH0 O - Ring CB Spring Compression 9 PF00 Kit Piston Valve BM 0 PF Valve Piston DD E-Ring JZ Holder Assly Magnet DD Spring Compression JZ Packing PF Jet Needle PF Ring PF00 Kit Carburetor Gasket/O Ring JA Gasket Float Chamber DH0 O - Ring Idling Screw DH O Ring Air Screw DH O Ring Drain screw JA O Ring TPS PF00 Kit Choke Plunger BM 0 Plunger Assembly Guide Holder PF Lever Assembly Choke DH Cap Dd Spring Choke Plunger CF0 O Ring Choke Plunger 0 Bearing Cone Kit DH Bearing cone DH Bearing race DH Upper bearing race DS0 Holder Handle Set DS9 Holder Handle DS0 Holder Handle 9 9

59 Kit List Kit List Sr No Kit Part Kit Description Consisting of Following Parts Part Description Qty/Kit Sr No Kit Part Kit Description Consisting of Following Parts Part Description Qty/Kit PF00 Kit Chain Sprocket BM 0 DX Sprocket Hub (T) JZ0 Sprocket Drive (T) JV0 Chain Link JZ000 Set Primary Drive & Driven JZ Housing Complete Clutch HTTS JZ0 Gear Primary Drive DK00 Kit Mirror Holder 9 Nut - Nylock :- M X 0. Dl9 Stud - Lever Handle 09 Nut 909 Washer - Plain 900 Bolt - Hexagon :- M X JZ000 Starter Clutch Repair Kit JA Bush Spring Starter Clutch DH Roller Clutch DH Spring DJ9 Bush For Spring Starter Clutch PF0009 Kit Friction Plate BM 0 JV Plate Friction Clutch PF000 Kit Block-Piston BM 0 PF0 Assly Cylinder Block PF Piston Assly 9 JW00 Leg Gaurd Hardware Kit JA Hook Leg Gaurd JA Leg Gaurd Spacer 909 Nut Hexagon with Flange 0 PF00 Case Chain Kit PF Case Chain Upper Assly. Pf0 Case Chain Lower Assly. DK000 Kit Outer Tube DJ9 Seal Dust DJ Stopper Seal Oil DS Washer Guide Bush DS0 Guide Bush 9 9

60 Amendment Sheet Amendment Sheet AMENDMENT SHEET (PARTS ADDED) AMENDMENT SHEET (PARTS DELETED) SR. NO. PART NUMBER DESCRIPTION QTY. PAGE NO. FIGURE NO. SR. NO. PART NUMBER DESCRIPTION QTY. PAGE NO. FIGURE NO. 99 0

61 Parts Index Parts Index Part Number Figure Page Part Number Figure Page Part Number Figure Page Part Number Figure Page DK DK00 9 DS 0 DS 0 DU 0 0 JE00 0 JW00 9 JZ00 0 JZ00 0 JZ00 0 JZ00 0 JZ00 0 JZ JZ00 PF00 0 PF00 0 PF00 0 PF PF00 0 PF00 0 PF00 09 PF00 PF00 PF00 0 PF00 PF00 PF00 PF00 PF00 9 PF00 0 PF00 PF00 PF00 9 PF00 0 PF00 PF00 Pf Brand ID: 00MC (DISCOVER 0) Brand ID: 00MC (DISCOVER )

62 Parts Index Parts Index Part Number Figure Page Part Number Figure Page Part Number Figure Page Part Number Figure Page A A B Brand ID: 00MC (DISCOVER 0) Brand ID: 00MC (DISCOVER )

63 Parts Index Parts Index Part Number Figure Page Part Number Figure Page Part Number Figure Page Part Number Figure Page B A CB CB CF 9 CL 0 CS DD 9 0 DD 9 DD DD DD DD 9 DD 09 0 DD DD 9 DD 9 DD 0 DE 0 DF 0 DF DF DF 9 0 DF 0 DF 0 DG 9 DG 9 DG DG DG DG DH DH DH 0 0 DH 0 0 DH 0 DH DH DH 9 DH 09 DH 0 9 DH DH 0 DH DH 9 DH 9 DH 9 DH DH 9 DH 9 DH 9 9 DH DH 0 DH 9 DH 0 DJ 0 DJ DJ 0 DJ 0 DJ 0 DJ 0 DJ 9 0 DJ 0 Brand ID: 00MC (DISCOVER 0) Brand ID: 00MC (DISCOVER )

64 Parts Index Parts Index Part Number Figure Page Part Number Figure Page Part Number Figure Page Part Number Figure Page DJ 90 DP DS DS 9 DJ 0 DP DS 9 DS 9 DJ 0 DP DS 9 0 DS 0 9 DJ DP 0 DS DS 0 0 DJ 9 DP 0 0 DS DS 0 DJ 9 DP 09 DS 0 DS 0 90 DJ 0 9 DS 9 0 DS 90 DS 0 90 DJ 0 DS DS 0 DU 9 DJ 0 DS DS 0 0 DU 0 DJ 0 DS DS 0 DU DK 9 DS 99 0 DS 0 DU 9 0 DK 9 DS DS 09 DU 9 0 DK DS 09 DS DU 9 09 DL 09 DS DS 0 DU 0 0 DL DS 0 DS 0 DU 0 DL 9 DS 0 DS 0 DU 0 DL 9 0 DS 0 DS 0 DU 0 DM 0 0 DS 09 DS DU 0 DM 0 DS DS DU 0 9 DM 9 DS 9 9 DS 0 0 DX 9 0 DP DS DS 9 0 DX 9 09 DP 9 DS DS 0 FD DP DS DS 9 FD 0 DP DS 0 0 DS 9 9 FD 0 Brand ID: 00MC (DISCOVER 0) Brand ID: 00MC (DISCOVER )

65 Parts Index Parts Index Part Number Figure Page Part Number Figure Page Part Number Figure Page Part Number Figure Page GF 0 90 JA JA 0 JA 0 0 JA 0 JA JA 09 JA 0 0 JA 0 JA JA 0 JA 0 0 JA 0 JA JA JA 0 0 JA 0 JA 9 JA JA 0 0 JA JA JA 9 JA 0 0 JA 0 0 JA 0 JA 0 JA 0 JA 0 0 JA 0 9 JA 0 JA 0 JA 0 0 JA 0 JA 0 JB 0 0 JA 0 0 JA 0 JA 09 JB 0 0 JA 0 0 JA 0 JA JB 0 JA 0 0 JA 9 0 JA 0 JB JA 0 0 JA 0 JA 0 JB JA 0 0 JA JA 09 JB 0 0 JA 09 0 JA JA 9 JB 0 JA 0 JA JA JB 0 JA 9 0 JA 0 JA JB JA 0 JA JA JB 9 JA 0 JA JA JB 0 9 JA 0 JA JA JB 0 00 JA JA JA JB 0 09 JA 0 JA JA 9 JB JA JA 0 JA JB 0 JA JA 0 JA 9 0 JB 0 9 Brand ID: 00MC (DISCOVER 0) Brand ID: 00MC (DISCOVER )

66 Parts Index Parts Index Part Number Figure Page Part Number Figure Page Part Number Figure Page Part Number Figure Page JB 0 JC 0 0 JD JD 0 JD 00 JD 00 JD 0 JD JE 0 JE 0 0 JE 9 JE JE 0 JG JK 0 0 JK JK JK JK JK JN 0 JN JV JV 0 A JV 0 JV JV 0 JV JV JV JV JV JV 0 JV 0 JV 0 JV 0 JV 0 0 JV 0 JV 0 JV 0 JV 0 JV 0 JV 0 JV 09 JV JV JV 0 JV JV JV JV 9 0 JW 0 JW 0 JW 9 JW 0 JW 0 JW 0 JZ 0 JZ JZ JZ 0 JZ 0 JZ 0 JZ 0 JZ 0 JZ 0 9 JZ JZ 0 JZ 00 0 KA DF0 0 KA DF0 LA C000 LJ A000 0 PF 0 0 PF 00 PF 0 00 PF 0 0 PF PF 0 PF 0 PF 0 PF 0A 0 PF 0B 0 PF 0 PF 0 PF 9 0 PF 0 0 PF 0 0 PF 9 PF 0 PF 0 PF 0 0 PF 0 PF 0 PF 0 PF Brand ID: 00MC (DISCOVER 0) Brand ID: 00MC (DISCOVER )

67 Parts Index Parts Index Part Number Figure Page Part Number Figure Page Part Number Figure Page Part Number Figure Page PF 0 PF 09 PF PF 0 PF 0 PF 0 PF PF 0 PF 0 0 PF PF 00 PF 9 PF 09 0 PF 0 00 PF 0 PF 9 PF 0 PF 0 0 PF 0 PF E PF 0 PF PF 0 PF F PF 0 PF PF 00 PF X PF 0 PF PF 0 PF 0 E PF 0 PF 0 0 PF 0 PF 0 F PF 0 PF 0 09 PF 0 PF 0 X PF 0 PF PF 0 PF 0 E PF 09 PF PF 0 PF 0 F PF 09 PF PF 0 9 PF 0 X PF PF PF 0 PF 0 E PF 0 PF 0 00 PF 0 9 PF 0 F PF 9 00 PF 0 0 PF 0 PF 0 X PF 00 9 PF 0 0 PF 00 PF 0 E PF 0 9 PF 0 0 PF 0 PF 0 F PF 0 PF PF 00 PF 0 X PF 0 PF 0 0 PF 00 PF 0 A PF 0 0 PF 0 PF 0 PF 0 00 PF 0 PF 0 PF PF 0 PF 0 PF 0 0 PF 00 Brand ID: 00MC (DISCOVER 0) Brand ID: 00MC (DISCOVER )

68 Parts Index Parts Index Part Number Figure Page Part Number Figure Page Part Number Figure Page Part Number Figure Page Brand ID: 00MC (DISCOVER 0) Brand ID: 00MC (DISCOVER )