Bajaj Auto Limited Service Department Akurdi, Pune India Phone : Fax :

Transcription

1 We have pleasure in presenting the Spare Parts Catalogue for Avenger DTS-i 200cc Motorcycle. This catalogue has been specially designed to assist you in selecting the correct parts for procurement to maintain 100% 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. 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. 08 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 India Phone : Fax : service@bajajauto.co.in

2 Instructions for using the Catalogue 1. How to Read the Catalogue : Open the catalogue and from the pictorial index locate the group in which the part you want to find is present. Turn over to the concerned page number (as given by pictorial index). Now find out the figure of the part you wish to order. 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. 2. How to Order Spare Parts : The part number and the description of the part required should be invariably mentioned in the order as per the catalogue text. The latest part number as conveyed through our service circulars should only appear on the order. In case of ordering 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. 3. Part Number System: We have used 8 digit system for part numbers. The model or hardware item is indicated by first two digits or alphanumeric, the next two or four digits indicate main group and the last four or two digits indicate serial number in main group or serial number or subgroup of fastener respectively. Thus the part numbers will be indicated by or 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 Description Page 1 Cover Cylinder Head 1 2 Cylinder Head 2 3 Valve 3 4 Camshaft / Tensioner 4 5 Cylinder & Piston 5 6 Crankshaft 6 7 Balancer & Balancer Idler Gear 7 8 Transmission 8 & 9 9 Change Drum/ Shift Fork Gear Change Mechanism Engine Assly & Crankcase RH Crankcase LH 13&14 13 Cover RH 15&16 14 Cover Magneto Clutch 18&19 16 Oil Pump Oil Cooler Assly Carburettor Silencer Assly Air Cleaner Comp Magneto/C.D.I./H.T.Coil 25&26 22 Starter Assly Frame Frame Fitting 29&30 25 Swing Arm Rear Shock Absorber Foot Rest Mudguard Front & Rear Stand Tyre/ Tube & Wheel Rim Front Hub Rear Hub 38&39 33 Brake Pedal Front Master Cylinder 41&42 35 Front Brake 43 Description Page 36 Handle Bar 44&45 37 Front Fork 46&47 38 Fuel Tank 48&49 39 Seat / Grip Frame Rear C over Grip Frame Speedometer Control Cables Side Cover / Chain Cover Guards Head Light Tail Light / Reflector Reflex Indicator Light Electrical Equipments Ignition Switch Tool Kit Painted Parts 61&62 Kits List 63 Amendment Sheet (Part Added) 64 Amendment Sheet (Part Deleted) 65 Part Index 66

3 Pictorial Index PLATE NO. : 1 PLATE NO. : 2 COVER CYLINDER HEAD 1 CYLINDER HEAD 2 PLATE NO. : 3 PLATE NO. : 4 VALVE 3 CAMSHAFT / TENSIONER 4 PLATE NO. : 5 PLATE NO. : 6 CYLINDER AND PISTON 5 CRANK SHAFT 6

4 Pictorial Index Pictorial Index PLATE NO. : 7 PLATE NO. : 8 PLATE NO. : 13 PLATE NO. : 14 BALANCER & BALANCER IDLER GEAR 7 TRANSMISSION 8 & 9 COVER RH 15 & 16 COVER MAGNETO 17 PLATE NO. : 9 PLATE NO. : 10 PLATE NO. : 15 PLATE NO. : 16 CHANGE DRUM / SHIFT FORK 10 GEAR CHANGE MECHANISM 11 CLUTCH 18 & 19 OIL PUMP 20 PLATE NO. : 11 PLATE NO. : 12 PLATE NO. : 17 PLATE NO. : 18 ENGINE ASSLY. & CRANKCASE RH 12 CRANKCASE LH 13 & 14 OIL COOLER ASSEMBLY 21 CARBURETTOR 22

5 Pictorial Index Pictorial Index PLATE NO. : 19 PLATE NO. : 20 PLATE NO. : 25 PLATE NO. : 26 SILENCER ASSLY. 23 AIR CLEANER COMP 24 & 25 SWING ARM 32 REAR SHOCK ABSORBER 33 PLATE NO. : 21 PLATE NO. : 22 PLATE NO. : 27 PLATE NO. : 28 MAGNETO / C.D.I. / H.T. COIL 26 & 27 STARTER MOTOR 28 FOOT REST 34 & 35 MUDGUARD FRONT & REAR 36 PLATE NO. : 23 PLATE NO. : 24 PLATE NO. : 29 PLATE NO. : 30 FRAME 29 FRAME FITTING 30 & 31 STAND 37 TYRE, TUBE & WHEEL RIM 38

6 Pictorial Index Pictorial Index PLATE NO. : 31 PLATE NO. : 32 PLATE NO. : 37 PLATE NO. : 38 FRONT HUB 39 REAR HUB 40 & 41 FRONT FORK 48 & 49 FUEL TANK 50 & 51 PLATE NO. : 33 BRAKE PEDAL 42 PLATE NO. : 34 FRONT MASTER CYLINDER 43 & 44 PLATE NO. : 39 SEAT/GRIP FRAME RR./COVER GRIP FRAME 52 PLATE NO. : 40 SPEEDOMETER 53 PLATE NO. : 35 PLATE NO. : 36 PLATE NO. : 41 PLATE NO. : 42 FRONT BRAKE 45 HANDLE BAR 46 & 47 CABLES 54 SIDE COVERS / CHAIN COVER 55

7 Pictorial Index Pictorial Index PLATE NO. : 43 PLATE NO. : 44 PLATE NO. : 49 PLATE NO. : 49 GUARDS 56 HEAD LIGHT 57 TOOL KIT 62 PAINTED PARTS & DECALS 63 & 64 PLATE NO. : 45 PLATE NO. : 46 TAIL LIGHT / REFLECTOR REFLEX 58 INDICATOR LIGHT 59 PLATE NO. : 47 PLATE NO. : 48 ELECTRICAL EQUIPMENT 60 IGNITION SWITCH 61

8 Plate 1 : COVER CYLINDER HEAD 1 JM Head Cylinder with Cover 1 2 DJ Cover Tappet DS10 01 O Ring Kit for Cover Cyl. Head 1 Refer Page 63 4 DS Silent Bush (V) 1 5 DS Camshaft Cap Domed Cap Nut 4 7 DS Copper gasket Hex. Bolt with Flange Hex. Bolt with Flange 4 10 DH Plug Gasket 2 1

9 Plate 2 : CYLINDER HEAD Plate 3 : VALVE 1 JM Head Cylinder with Cover Stud (Exhaust) 2 3 DK Gasket Cylinder Head 1 4 DH Damper Cylinder Head O Ring 1 6 JC Carburettor Insulator 1 7 DH Clamp for Insulator Hex. Bolt / Flange 2 9 DH Sleeve - Spark Plug Grub Screw 1 For Sleeve Spark Plug 1 DS Rocker Arm Shaft - Intake 1 2 DS Rocker Arm Shaft - Exhaust 1 3 DS Rocker Arm with roller 2 4 DG Collet Seal valve stem 2 6 DK Valve Repair Kit 1 Refer Page 63 7 DK Valve Kit 1 Refer Page 63 8 DS Wave washer Plain washer DS10 01 O Ring Kit for Cover Cyl. Head 1 Refer Page JM Manifold "O" ring insulator Hex bolt with flange 2 Manifold mtg

10 Plate 4 : CAMSHAFT / TENSIONER Plate 5 : CYLINDER AND PISTON Ring O 1 2 JC Camshaft Assembly Bearing cam RH side Bearing cam LH side 1 5 JC Guide chain Kit 1 Refer Page 63 6 DS Sprocket cam Driven (32 T) 1 7 DH Collar cam Sprocket 1 8 DH Special camshaft washer Hex. Soc. Head cap Bolt 1 10 JC Cam Chain 1 1 DK Gasket Cylinder Pin dowel 4 3 DH Damper 6 4 DK Ring Set Piston Ring Snap 2 6 JM Cylinder Block / Piston Assly 1 7 DK Banjo oil cooler pipe 1 8 DK Bolt special 2 9 DK Washer copper 4 11 DH Cam chain Tensioner pivot Bolt 1 12 DK Tensioner Assly Hex Bolt / Flange 2 14 CS Tensioner assly. gasket 1 15 DD Bolt

11 Plate 6 : CRANK SHAFT Plate 7 : BALANCER & BALANCER IDLER GEAR 1 JC Crankshaft assly. comp Bolt Plain washer Key woodruff 1 5 DS Parallel key Bearing Ball 1 7 DK Sprocket cam drive (16 T) Parallel pin DK00 29 Set primary driver driven 1 Refer Page DH Body centrifugal oil filter 1 11 DH Nut primary drive 1 12 DH Cover centrifugal oil filter DK00 07 Kit centrifugal oil filter 1 Refer Page 63 1 DJ Body Balancer Assly. 1 2 DH Bearing stopper Bolt 1 4 DH Assly. Balancer Idler Gear comp Needle roller bearing 2 6 DJ Spring torsion Balancer Idler Circlip ext Dowel Pin Spring steel washer DH01 77 Balancer Idler Holder Hex bolt with flange

12 Plate 8 : TRANSMISSION Plate 8 : TRANSMISSION 1 DK Shaft Input Transmission Washer plain 1 3 DK Gear 4th Drive 1 4 DH Washer Spline 3 5 DH External Circlip 4 6 DK Gear 3rd Drive 1 7 DK Gear 5th drive 1 8 DH Gear 2nd drive Plain washer 1 10 DK Shaft output Transmission 1 16 DK Gear 5th Driven 1 17 DH Bush 2nd driven 1 18 DH Gear 2nd Driven 1 19 DK Collar Sprocket O Ring Sprocket Coller 1 21 DV Sprocket Drive 1 22 DJ Plate Drive Sprocket Bolt flange 2 11 DH Washer Thrust 2 12 DK Gear 3rd Driven 1 13 DK Gear 4th Driven 1 14 DH Bush 1st driven 1 15 DK Gear 1st driven

13 Plate 9 : CHANGE DRUM / SHIFT FORK Plate 10 : GEAR CHANGE MECHANISM 1 DK Fork Gear Shift Input 1 2 DK Fork Gear Shift output 2 3 DH Shaft Gear Shift Fork 1 4 DH Shaft Gear Shift Fork 1 5 DK Drum comp. Gear Shift Bolt Socket Parallel pin 1 8 DK Guide Gear Shifter 1 9 DH Spacer 1 10 DK Bush Fork Gear Shift 3 1 DV Lever comp. Gear Shifter 1 2 DH Spring Slider arm reset 1 3 DV Spring Gear Shifter return JM00 20 Change Lever Assly. 1 5 DG Damper change pedal(rear) 1 6 DG Bolt 1 7 DH Bolt Gear Shift drum Stopper 1 8 DH Stopper gear shifter drum 1 9 DV Spring gear shifter drum stopper 1 10 DH Bolt shift change Domed cap Nut Washer Oil Seal 2 14 DG Damper Change Pedal(Front) 1 15 DV Rod assly. Tie DV00 55 Lever Assly. Change Hex. Bolt / Flange 1 11

14 Plate 11 : ENGINE ASSLY. & CRANKCASE RH Plate 12 : CRANKCASE LH 1 JM Engine Assly. with starter motor 1 N I 2 DK Crankcase RH Stud 2 4 DH Bolt Flanged 1 5 DH Gasket Crankcase Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Dowel Pin NRB 1 10 DH Plate Stopper 1 1 JM Crankcase LH Stud 2 3 DK Guide starter assly Oil Seal O Ring 1 6 DK Damper C Sunk Head Screw Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Balancer LH Bearing Oil Seal (For Output shaft) Oil Seal (For Shift lever) 1 13 DH Breather pipe 1 14 DH Plug (Drain Bolt) Gasket (For Drain Bolt)

15 Plate 12 : CRANKCASE LH Plate 13 : COVER RH Switch comp.(neutral) 1 17 DH Gasket Neutral Switch Bolt Bolt 1 20 DV Cable assly. (Battery to Earth) Plain Washer Hallow dowel pin Hallow dowel pin 2 1 DK Cover comp RH 1 2 DH Grommet Breather Oil Seal 1 4 DH Rack 1 5 DH Shaft clutch release 1 6 DK Parallel pin 1 7 DG Gauge 1 8 DS Wire circlip 1 9 DS Bolt Pin Dowel 2 11 DK Bracket Clutch Cable 1 12 DH Gasket cover RH 1 13 DH Plunger Oil 1 14 DH Plate Plunger Oil 1 15 DH Spring Joint A

16 Plate 13 : COVER RH Plate 14 : COVER MAGNETO 16 DH Spring torsion clutch lever Washer 1 18 DH Damper 1 19 DH Flanged Bolt 7 20 JC Bajaj Decal 1 Fitted on Cover comp. RH NRB 2 22 DH Plate 1 23 DK Spring relief valve Ball steel 1 25 DK Bold relief valve Intrigal circlip 1 1 JM Cover Magneto 1 2 DV Gasket Magneto cover Bolt Pin Dowel 2 5 JM Cover LH RR JM00 01 Set Damper 1 Refer Page 63 7 DH Flanged Bolt JM00 02 Set of Plate 1 Refer Page 63 9 DJ Gear Shift Label 1 10 AP NR bearing 1 11 DH Cap crank center O ring 1 13 DH Decal cover magneto

17 Plate 15 : CLUTCH Plate 15 : CLUTCH 1 DH Special Nut 1 2 DK Clutch assembly comp. 1 3 DK Clutch Plate Assly 1 4 DK Clutch Center 1 5 DK Plate Clutch pressure 1 6 DK Disc Clutch friction 4 DK Disc Clutch friction (B type) 1 DK Disc Clutch friction (C type) 1 7 DK Plate Clutch 5 8 DK Spring Clutch Capacity 4 9 DK Bolt Bearing Clutch lifter thrust 1 11 DK Holder Clutch 1 12 DK Rod Clutch lifter 1 13 DK Spacer Clutch 1 14 DH Nut Primary drive lock 1 LH Thread 15 DK Lever Assly. Clutch Washer Primary Drive Gear 1 17 DK Judder spring 1 18 DK Spring 1 19 DK Friction clutch plate kit

18 Plate 16 : OIL PUMP Plate 17 : OIL COOLER ASSEMBLY 1 DH Oil Pump Assly Hex. Bolt with flange 3 3 DH Mesh filter Oil pump Hollow dowel pin 1 5 DH Clip Mesh Oil filter O Ring JM00 08 Oil cooler assembly Washer Bolt 1 4 JM Pipe inlet oil cooler 1 5 JM Pipe outlet oil cooler 1 6 DK Banjo bolt 2 7 DK Gasket 4 8 DK Rubber 2 9 JM Sleeve Bolt 2 For oil cooler mtg

19 Plate 18 : CARBURETTOR Plate 19 : SILENCER ASSLY. 1 JM Carburettor Assly. 1 2 DJ Vacuum Piston Kit 1 3 DJ Idling Screw Kit 1 4 JM Jet needle(jn) 1 5 DJ O ring 1 6 DJ Screw 2 7 DJ Float Assly. 1 8 JC Jet Holder 1 9 JM Jet kit 1 Refer Page JC Magnet Assly JC Reed Switch Assly Pan Head Screw 2 13 JC Needle Assly DJ Set Adjuster (PS) 1 15 DJ Set Plunger Assly JM Air jet (Fixed in body) 1 N.I. 1 JM Silencer Assly. (with CAT & Resonator) 1 JM Silencer assly (Stainless steel) 1 2 DG Holder Exhaust pipe 1 3 DG Gasket Exhaust pipe holder 1 4 DG Bolt Domed cap Nut Nut flanged 1 7 DG Washer 1 8 DG Collar 2 9 DG Bushing rubber, muffler 2 Alt. DG DG Collar 1 11 DG Damper Bolt Flanged 1 13 DG Guard Muffler 1 14 DV Cover Muffler 1 15 DV Shield Exhaust tube 1 16 DH Truss Screw 2 17 DV Cover Muffler

20 Plate 20 : AIR CLEANER Plate 21 : MAGNETO / CDI / SPARK PLUG / H.T. COIL 1 JM Air Filter Assly. 1 2 DG Element Air filter 1 3 DG Gasket Air filter 1 4 DG Tube 1 5 DG Plate Element 1 1 JM Rotor 1 2 JM Stator Assly. comp Hex. Bolt with Flange Pan Head Screw 2 5 DH Stopper plate (wiring harness) 1 6 DV Tube Rubber 1 7 JM Connecting tube 1 8 DV Tube Breather 1 9 DG Flame Arrester Screw Screw Pan head 1 7 DG Spark plug 2 8 DV C.D.I Assly. / Damper 1 9 DD Grommet Spark Plug cap LH 1 10 DS AC/DC Regulator 1 With Aluminum bracket Screw 5 12 DG Clamp 5 11 DV H.T. Coil Kit 1 Refer Page DV H.T. coil LH 1 13 DV H.T. coil RH 1 14 DH Grommet Sleeve Spark Plug 1 15 DD Cap Spark Plug LH 1 16 DH Cap Spark Plug RH 1 17 DD Grommet H.T. Cable

21 Plate 21 : MAGNETO / CDI / SPARK PLUG / H.T. COIL Plate 22 : STARTER MOTOR 18 DH Grommet Spark Plug cap RH 1 19 DV Regulator Voltage Flange Bolt small Flange Bolt 2 22 DJ Bracket H.T.Coil Flange Bolt Spring dowel 1 N.I. 1 DH Body comp. starter clutch 1 2 DH Bush Spring Starter Clutch 5 3 DH Plate roller clutch 1 4 DH Gear starter clutch 1 5 DH Plate starter clutch gear return 1 Stopper plate Bolt 1 For stopper plate 7 DK Shaft starter counter 1 8 DH Collar starter counter 1 9 DH Gear comp. starter counter assly Needle roller bearing Bolt socket 3 12 DK Starter Motor Bolt 2 14 DH Cover starter motor Slotted c sunk screw 1 16 DH Spring 5 17 DJ Bush For Spring Starter 5 18 DH Roller

22 Plate 23 : FRAME Plate 24 : FRAME FITTING 1 JM Frame comp. 1 2 DG Cap Steering Stem 1 3 DG Bolt flanged DV00 07 Steering Cone Kit 1 Refer Page 63 5 DG Nut Ball Steel 39 1 DG Cap, Pivot 2 2 DG Bracket, Igniter 1 3 DG Bracket Electric 1 4 DG Cap, Tool case 1 5 DV Stopper Kick 1 6 JM Bracket, Engine Rear (Silent) 1 7 JM Bracket, Engine Mtg. Front LH 1 8 JM Bracket, Engine Mtg. Front RH 1 9 JM Bracket, Engine Top LH 1 10 JM Bracket, Engine Top RH Bolt Bolt, Flanged Bolt Bolt, Allen 1 15 DG Screw

23 Plate 24 : FRAME FITTING Plate 25 : SWING ARM Nut Flanged DG Band 1 18 DG Damper Bolt Flanged Bolt Flanged Bolt Flanged Bolt 3 1 DG Cap chain Adjuster 2 2 JM Arm Comp. Swing 1 3 DG Shaft Swing Arm 1 4 DG Adjuster Chain 2 5 DG Sleeve 2 6 DG Guard, Chain 1 7 DG Nut 1 8 DG Nut 2 9 DG Bearing Needle 2 10 DG Seal Oil Nut Hex small Washer Plain small

24 Plate 26 : REAR SHOCK ABSORBER Plate 27 : FOOT REST 1 DV Rear Shock Absorber 2 2 DG Collar, shock Absorber 2 3 DG Damper, Lower 2 4 DG Damper, Upper 2 5 DG Nut cap 2 6 DG Washer Spring Washer 2 8 DG Bolt Flanged 2 1 DV Holder Step Front LH Assly. 1 2 DV Guard Step LH Bolt Flanged small 1 4 JM Holder Step Front RH Assly. 1 5 JM Cover cable Bolt Flanged small 1 7 DG Step Rear 2 8 DG Bolt socket 2 9 DG Pin 2 10 DG Holder Step Rear Split Pin 2 12 DG Washer 2 13 DG Step Rubber Rear 2 14 DV Rubber Main Step

25 Plate 28 : MUDGUARD FRONT & REAR Plate 29 : STAND 1 DG Flap 1 2 DG Stay rear fender 1 3 DG Bolt 2 4 DP Number Plate Plain Washer Hex. head Bolt Spring Washer Hex. Nut 2 9 DF Bkt. Rear Number Plate 1 1 DV Side Stand 1 2 DG Spring 1 3 DG Bolt 1 4 DD Lock Nut 1 5 DV Stand Centre 1 6 DG Shaft Stand Pin Cotter 1 8 DG Damper 1 9 DV Spring Plain washer

26 Plate 30 : TYRE, TUBE & WHEEL RIM Plate 31 : FRONT HUB 1 DG Tyre Front 1 } 2 DG Tyre Rear 1 Proprietory Items 3 DG Tube for Tyre Front 1 Not to Service 4 DG Tube for Tyre Rear 1 5 DG Rim Rear 1 6 DG Rim Front 1 7 DG Spoke Inner Front 18 8 DG Spoke Inner Rear 18 9 DG Spoke Outer Front DG Spoke Outer Rear 18 1 DG Drum Front Brake 1 2 DV Axle, Front 1 3 DG Case Assly Meter Gear Nut Castle 1 5 DG Collar Ball Bearing 2 7 DG Seal oil 1 8 DG Collar Front Axle Nipple Spoke

27 Plate 32 : REAR HUB Plate 32 : REAR HUB 1 DG Drum Rear Brake 1 2 DG Panel Assly Brake Rear 1 3 DG Shoe Brake Rear (Pair) 1 4 DG Cam Brake 1 5 DG Lever Brake Cam 1 6 DG Axle Rear Indicator Brake Shoe Damper Rear Hub Shock JM00 15 Coupling Assly Rear Hub JM00 03 Chain - Sprocket - Kit 1 Refer Page DG Nut Flanged lock Seal Oil Bearing Ball 1 14 DG Joint Chain 1 15 DG Spring Brake Shoe Spring Brake Shoe Nut Castle 1 18 DG Collar Rear Brake Drum 1 19 DG Collar Rear Axle 1 20 DG Collar Rear Hub Coupling 1 21 DG Washer Bolt Upset Split Pin Bearing Ball Bearing Ball 1 26 DG Sleeve 1 27 DG Bolt 6 28 DG Nut for sprocket

28 Plate 33 : BRAKE PEDAL Plate 34 : FRONT MASTER CYLINDER 1 JM Lever Brake Pedal 1 2 DG Rod Torque Nut Nut Flanged 2 5 DG Spring Brake Pedal Return Hex. Head Bolt Bolt Upset WS Pin Snap 2 9 DG Switch Brake Lamp 1 10 JM Spring Rear Brake Switch 1 1 DE Major Kit - Master Cylinder 1 2 DG Hose Brake Front 1 3 DG Lever Grip RH 1 4 DE Banjo Bolt 2 5 DE Washer Copper 4 6 DK Clamp Holder RH 1 7 DE Bolt 1 8 DE Bolt Front Brake Lever 1 9 DE Nut Flanged 1 10 DE Screw 2 11 JM Brake lever plate 1 N.I. 12 JM Pin rear brake link 1 13 JM Bracket rear brake link

29 Plate 34 : FRONT MASTER CYLINDER Plate 35 : FRONT BRAKE 11 DE Reservoir Cover 1 12 DE Diaphragm 1 13 DE Cover Seal Master Cylinder (Boot) 1 14 DE Front brake switch 1 15 DE Return spring 1 16 DE Winow 1 17 DE 'O' ring 1 18 DE Clip 1 19 DE Push rod 1 20 DE Conical spring 1 1 DG Disc, Front 1 2 DG Caliper Assly. Front 1 3 DG Bolt, Disc Plate 6 4 DG Bolt Flanged 2 5 DE Spring Pad 1 6 DE Bleeder Screw 1 7 DE Bleeder Cap 1 8 DE Disc Pad Set 1 9 DE Insulator 1 10 DE Dust cover 1 11 DE Minor Kit - Caliper 1 12 DE Major Kit - Caliper

30 Plate 36 : HANDLE BAR Plate 36 : HANDLE BAR 1 JM Handle 1 (2.6 mm thick) 2 DV Weight, Handle 2 3 DG Holder Clutch Lever 1 4 DG Plate 1 5 DG Bracket speedometer 1 6 DG Holder Handle Upper 1 7 DG Holder Handle Lower LH 1 8 DG Holder Handle Lower RH 1 9 DH Grip RH 1 10 DH Grip LH 1 11 DG Lever Assly. Grip Clutch LH 1 12 DV Housing Assly. Control RH 1 13 JM Mirror Assly LH 1 14 JM Mirror Assly RH 1 15 DG Bolt Clutch Lever Screw cable Adjust Allen bolt 2 18 DG Nut Lock Nut Cable Adjust Lock 1 20 DG Nut Cap 2 21 DG Damper Bolt Upset Bolt Flanged small Bolt Flanged small Screw CSK Cross Washer Plain small Washer spring 2 28 JM Housing Assly. Control LH 1 29 DG Lever Grip LH 1 30 DG Clutch switch 1 N.I

31 Plate 37 : FRONT FORK Plate 37 : FRONT FORK Bolt Flanged small 2 2 DG Grommet, Hose Clamp 2 3 DG Pipe - Left Fork Outer 1 4 DG Pipe - Right Fork Outer 1 5 DV Pipe, Fork Inner 2 6 DG Spring Front Fork 2 7 DG Seat Fork Spring 2 8 DG Cover Fork 1 9 DG Holder Fork Under 1 10 DG Holder Fork Upper 1 11 DG Ring, Oil Seal Stopper Bolt Flange 3 13 DG Bushing - Front Fork, Inner Pipe 2 14 DG Bushing - Front Fork, Outer Tube 2 15 DV Fork Front 1 Includes Sr. 10,11,38 & DG Bolt, Fork Cylinder 2 17 DG Nut, Cap 2 18 DG Washer 1 19 DG Spacer 2 20 DG Race, Steering Stem Bearing 1 21 DG Seal Oil, Fork Outer Tube 2 22 DG Ring 'O' Fork Top 2 23 DG Seal Oil, Steering Stem 1 24 DG Seal, Fork Outer Tube 2 25 DG Damper Assly. RH 1 26 DG Damper Assly. LH 1 27 DG Bolt 4 28 DG Bolt Socket 2 29 DG Bolt 2 30 DG Bolt Fork Top 2 31 DP Plate Number Front 1 32 DG Clamp for cable (Top) 2 33 DG Clamp brake hose 1 34 DG Clamp speedo cable

32 Plate 38 : FUEL TANK Plate 38 : FUEL TANK 1 DG Bracket Fuel Tank Cover 1 2 JM Cover Assly. Fuel Tank 1 3 DK Fuel Cock Assly. 1 4 DG Cap Tank Fuel 1 5 DG Trim Washer Collar 2 8 DG Clamp 1 9 DG Clamp, Tube Ring 'O' 2 16 DG Bolt 2 17 DG Tube 1 18 DG Washer Bolt Flanged Bolt Flanged Screw Pan Cross 2 22 JM Tank Unit 1 JM Fuel gauge sender 1 23 JM Fuel meter Ring 'O' Fuel Tap Packing 1 12 DG Plug 2 13 DG Damper Damper Fuel Tank 2 15 DG Damper

33 Plate 39 : SEAT/GRIP FRAME RR./COVER GRIP FRAME Plate 40 : SPEEDOMETER 1 DG Plate Seat 1 2 DG Seat Assly Bolt Flanged Bolt Flanged Small 1 5 DV Emblem Back Rest 1 6 DG Cover, Pad 1 7 DG Cover, Rear Fender LH 1 8 DG Cover RH 1 9 DG Grip frame rear 1 10 DG Cover Grip frame LH 1 11 DG Cover Grip frame RH 1 12 DG Grip frame LH 1 13 DG Grip frame RH 1 14 DG Pad seat Bolt Upset Bolt flanged Small Bolt Flanged Small 4 1 DG Lamp Assly 1 2 DG Lens - TPI & Neutral 2 3 DG Lens - Hi Beam 1 4 DV Meter Assly. 1 5 DG Lamp 12V W Bolt Flanged Small 2 For Meter Assly. 7 DG Assly. lamp holder 1 8 DG Washer 2 For Machine mtg. 9 DG Screw pan head 2 For Machine mtg. 10 DG Trip meter knob 1 11 DG Screw (Knob reset trip meter)

34 Plate 41 : CABLES Plate 42 : SIDE COVERS / CHAIN COVER Spring, Brake Rod 1 2 DV Cable- Speedometer 1 3 JM Cable Brake 1 4 DV Cable Clutch 1 5 DV Cable Throttle Pin Cotter Nut Brake Rod 1 8 DG Washer 1 9 DG Pin Brake Rod 1 10 DG Pin 1 1 DG Cover Side RH Rear 1 DG Cover Side LH Rear 1 2 DG Case Chain 1 3 DG Screw Tapping Screw 2 5 DG Screw Washer 2 7 DG Grommet 2 8 DD Damper 2 9 DG Damper 1 11 DV Clamp Clutch cable 1 12 JC Guide clutch cable 1 13 DV Choke cable 1 14 DV Speedometer inner cable

35 Plate 43 : GUARDS Plate 44 : HEAD LIGHT 1 DG Guard Sari 1 2 JM Guard- Front Bumper Bolt Flanged Bolt Flanged Bolt Flanged JM00 18 Frame wind shield assly 1 N.I. 7 DD Damper 4 8 JM Wind Shield with grommet 1 N.I Bolt Flanged 2 2 DG Screw Pan Cross 1 For holding head light Spring Washer 2 4 DG Body Comp. Head Lamp Washer 2 For mtg. Head light on body 6 DG Cap for Head lamp 1 7 DG Screw Focus Adjust 2 8 DG Screw 2 For mtg. Head light on body 9 DG Nut 1 For holding head light 10 DG Nut Flanged 1 11 DG Collar 2 For Head Light Mtg. 12 DG Lamp 12V - 60/55W 1 13 DG Spring Focus Adjust 2 14 DG Clamp Harness 1 15 DG Tube 2 16 DV Head Lamp Assly DG Wire assly. parking 1 18 DG Lamp 12V - 4W 1 Imported bulb 'E' mark 54 55

36 Plate 45 : TAIL LIGHT / REFLECTOR REFLEX Plate 46 : INDICATOR LIGHT 1 DG Gasket Tail Lamp Lens 1 2 DV Tail Lamp Assly. 1 3 DG Lens Tail Lamp- Red 1 4 DG Lens Tail Lamp- Clear 1 5 DG Screw Tapping 2 6 DG Nut Flanged Collar Lamp 12V - 21/5W 1 9 DG Damper 3 10 DD Reflector Reflex Nut Flanged 1 1 DV Lamp Assly Signal FR. LH 1 2 DV Lamp Assly Signal FR. RH 1 3 DV Lamp Assly Signal Rear. LH Nut Cap Nut Flanged Collar Bolt Flanged Small 2 8 DV Lamp Assly. Signal Rear RH 1 9 DG Housing Signal Light 4 10 DG Lens Signal Light 4 11 DG Reflector Signal Light 4 12 DG Stay Signal Light Fr. LH 1 13 DG Stay Signal Light Fr. RH 1 14 DG Stay Signal Light Rear 2 15 DG Screw Signal Light 8 16 DG Washer Signal Light Light Lamp 12V-21W

37 Plate 47 : ELECTRICAL EQUIPMENT Plate 48 : IGNITION SWITCH 1 JM Horn Bolt Flanged Band 2 4 DG Cover Head Gusset Clamp wiring harness 1 6 DJ Battery 12V 9Ah charging 1 7 JM Wiring Harness 1 JM Wiring Harness 1 For solenoid relay July 08 8 AP Starter Relay Assly. 1 DV Starter Relay Assly. 1 For solenoid relay July Relay Turn Signal 1 10 DV Band Battery Bracket 1 11 DG Mat Battery Grommet 1 13 DG Grommet 1 14 DJ Relay for Interlock 1 15 DG Fuse Assly Fuse 3 17 DV Cable Assly. (Batt. to Starter Rly.) 1 18 DV Cable Assly. (Battery to Earth) JM00 05 Relay Conversion Kit 1 N.I. 1 DG Cap, Steering Lock 1 2 DG Rotor, Lock, Tank Cap 1 3 DV Switch Assly. Ignition 1 4 DG Lock Assly Steering 1 5 DG Lock Assly Helmet 1 6 DG Lock Assly Side Cover 1 7 JM Lock Set (5 in 1) 1 8 DG Screw 1 9 DG Screw 1 10 DG Plug 1 11 DG Washer Wave 1 12 DG Spring Steering Lock Bolt Socket

38 Plate 49 : TOOL KIT Plate 50 : PAINTED PARTS & DECALS 1 DG Tool Kit 1 1 JM 7101 X3 Tank fuel with decal 1 Ebony black JM T Tank fuel with decal 1 Tittanium Silver JM V Tank fuel with decal 1 Cocktail wine Red JM A Tank fuel with decal 1 Long Beatch Blue 2 JM 7301 X3 Cover side left with decal 1 Ebony black JM T Cover side left with decal 1 Tittanium Silver JM V Cover side left with decal 1 Cocktail wine Red JM A Cover side left with decal 1 Long Beatch Blue 3 JM 7302 X3 Cover side right with decal 1 Ebony black JM T Cover side right with decal 1 Tittanium Silver JM V Cover side right with decal 1 Cocktail wine Red JM A Cover side right with decal 1 Long Beatch Blue 60 61

39 Plate 50 : PAINTED PARTS & DECALS 4 DV 7303 X3 Fender assly. front 1 Ebony Black DV T Fender assly. front 1 Tittanium Silver DV V Fender assly. front 1 Cocktail wine Red DV A Fender assly. front 1 Long Beatch Blue 5 DV 7304 X3 Fender rear 1 Ebony Black DV T Fender rear 1 Tittanium Silver DV V Fender rear 1 Cocktail wine Red DV A Fender rear 1 Long Beatch Blue 6 JM Oil Cooled decal 1 For Black, Blue & Red JM Oil Cooled decal 1 For Silver 7 JM Tank Decal 1 KIT LIST FOR Sr. Kit Part Kit Description Consisting of Following Parts Part Discription Qty./Kit 1 36DS1001 Cyl.Head O Ring Kit O Ring (Cover tappet) O ring 2 2 DK Valve Kit DK Valve Intake 1 DK Valve Exhaust 1 3 DK Valve Repair Kit DK Retainer valve spring 2 DK Spring valve inner 2 DK Spring valve outer 2 DK Seat valve spring 2 4 JC Guide Chain Kit DH Guide chain (Tight) 1 DK Guide Chain (slack) DK0029 Set primary Drive/Driven DK Clutch Housing 1 DH Gear Primary Drive DK0007 Kit Centrifugal Oil Filter Washer 1 DH Gasket Centrifugal Oil Filter Oval Screw 1 DH Join Oil Deliver 1 DH Spring Oil Deliver Pin Oil Deliver Joint JM0001 Set Damper DH Damper Cover Magneto 1 DH Damper A Cover LH RR 1 DH Damper B Cover LH RR 1 JM Damper C Cover LH RR JM0002 Set of Plate DH Plate Damper for Cover Mgt. 1 DH Plate Damper Cover LH Rear 1 JM Plate Damper Cover LH RR 1 9 DV H.T.Coil Kit DV H.T.Coil LH 1 DV H.T.Coil RH DV0007 Steering cone kit DG Bearing Cone Upper 1 DG Bearing race Upper 1 DG Bearing race Lower 1 DG Bearing Cone JM0003 Chain Sprocket Kit JM Sprocket (38 T) 1 JM Chain 1 DV Sprocket 1 12 JM Jet Kit JM Main Jet 1 JM Needle Jet

40 Amendment Sheet (Parts Deleted) Sr. Qty. Page Fig. Amendment Sheet (Parts Deleted) Sr. Qty. Page Fig

41 PART INDEX PART INDEX Part Figure Page Part Figure Page Part Figure Page Part Figure Page

42 PART INDEX PART INDEX Part Figure Page Part Figure Page Part Figure Page Part Figure Page DK DK DS DS DV JM JM JM DH DV JM JM JM JM AP AP CS DD DD DD DD DD DD DD DD DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DF DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG

43 PART INDEX PART INDEX Part Figure Page Part Figure Page Part Figure Page Part Figure Page DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH

44 PART INDEX PART INDEX Part Figure Page Part Figure Page Part Figure Page Part Figure Page DH DH DH DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DP DP DS DS DS DS DS DS DS DS DS DS DS DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV DV73032T 4 62 DV73032V 4 62 DV73033A 4 62 DV7303X DV73042T 5 62 DV73042V 5 62 DV73043A 5 62 DV7304X JC JC JC JC JC JC JC JC JC JC JC JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM

45 PART INDEX Part Figure Page Part Figure Page JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM JM71012T 1 61 JM71012V 1 61 JM71013A 1 61 JM7101X JM73012T 2 61 JM73012V 2 61 JM73013A 2 61 JM7301X JM73022T 3 61 JM73022V 3 61 JM73023A 3 61 JM7302X