Brand ID: 001MC632

We have pleasure in presenting the Spare Parts Catalogue for Bajaj XCD 125cc
DTS-Si 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

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 :

manufactured previously. Contact your authorized Bajaj

Dealer for the latest information on product improvements
incorporated after this manual was issued.

Bajaj Auto Limited

Service Department
Akurdi, Pune 411 035 India

DOC. NO.: 71110580

REV. 00. JAN. 08

Phone : 020-27406557
Fax : 020-27407385
E-mail : service@bajajauto.co.in

Brand ID: 001MC632

Brand ID: 001MC632

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 2-2-4 or 2-4-2 digit system. Understanding this
system will enable you to identify the spare parts easily.
4. Abbreviations : The following abbreviations are used in this catalogue.
assly.

Assembly

Volts

N.I.

Not illustrated

Watts

C'case

Crankcase

accl.

Accelerator

Cyl

Cylinder

Comp.

Complete

o/s.

Over size

Fr

Front

Std.

Standard

Length

A/t.

Alternate

Rr

Rear

R.H.

Right hand

Hex.

Hexagonal

L.H.

Left hand

AR

As required

INDEX
No.
1
2
3
4
5

Description
Cover Cylinder head
Cylinder Head
Rocker Arm / Valve
Camshaft Tensioner
Cylinder & Piston

Page
No.

No.

Description

Page
No.

1
2
3
4
5

34
35

Handle Bar
Front Fork

41&42
43&44

36
37

45&46

38

Painted Parts
Fuel Tank Cap, Tap Assembly
& Fuel Gauge
Fittings - Petrol Tank &
Side Cover
Chain Case
Meter Assembly
Control Cables
Head Lamp Assembly / Fairing
Turn Signal Lamp
Tail Lamp Assembly
Tail Lamp Assembly / Front
Number Plate

51
52&53
54
55

6
7
8
9
10

Crankshaft
Transmission
Change Drum / Shift Fork
Gear Change Mechanism
Crankcase RH

6
7 & 8
9
10
11

11
12
13
14
15

Crankcase LH
Clutch cover
Cover Magneto
Clutch
Kick starter Mechanism

12&13
14&15
16
17
18

16
17
18
19
20

Carburetor Assembly
Air Filter Assembly
Silencer Assembly
Seat Assembly
Oil Pump

19&20
21
22
23
24

21
22
23
24
25

Magneto Assembly
Starter Assembly
Frame Fittings
Frame & Frame Fittings
Swing Arm / Rear Shock
Absorber

29&30

26
27
28
29
30

Stay Main Step

Pillion Foot Rest / Holder
Fender - Front & Rear
Stand Assembly
Tyre / Tube / Rim

31
32
33
34
35

31
32
33

Front Hub
Rear Hub
Brake Pedal

39
40
41
42
43
44
45

46
47
48

Electrical Equipment
Tool Kit
Accessories Leg Guard &
Saree Guard
Kits List

25
26
27
28

36&37
38&39
40

47
48
49
50

56
57
58
59
60&61

Amendment Sheet
(Parts Added)

62

Amendment Sheet
(Parts Deleted)

63

Parts Index

64

Brand ID: 001MC632

PICTORIAL INDEX
PLATE NO. : 1A & 1B
COVER CYLINDER HEAD

PLATE NO. : 3A & 3B

VALVE

PLATE NO. : 5A & 5B

CYLINDER AND PISTON

PAGE NO.:
1

PAGE NO.:
3

PAGE NO.:
5

PLATE NO. : 2A & 2B

CYLINDER HEAD

PLATE NO. : 4A & 4B

CAMSHAFT / TENSIONER

PLATE NO. : 6A & 6B

CARNKSHAFT

PAGE NO.:
2

PAGE NO.:
4

PAGE NO.:
6

Brand ID: 001MC632

Index

Brand ID: 001MC632

Plate No. 1 : COVER CYLINDER HEAD
2
1

6
3

No.

Part No.

1
2
3
4
5

JA
59
JA
JA
JA

5110
0400
5110
5110
5110

10
38
12
08
07

6
7

JA 5110 11
JA 5110 29

1A 1B
ES KS

Description
Cover cylinder head
Bolt flange
"O" ring head cover
Bolt flange
Plate breather

1
4
1
4
1

1
4
1
4
1

Breather tube
Wire Clip

1
1

1
1

Remarks

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 2 : CYLINDER HEAD

Plate No. 3 : ROCKER ARM / VALVE

4
2

1
6

3
7
7
8
6
4

5
5

No.

Part No.

1
2
3
4
5

JA
JA
JA
JA
JA
JA

6
7
8

DU 1010 57
JA 5814 06
39 1283 21

5110
5110
5110
5110
5814
5814

30
08
28
06
05
03

Description

2A 2B
ES KS

Head Cylinder complete

Bolt head mtg.
Stud
Gasket Cylinder Head
Intake manifold (Rubber)
Intake manifold (Alu. Casting)

1
2
2
1
1
1

1
2
2
1
1
1

Insulator
Bolt flange
O Ring (Intake Pipe)

1
2
2

1
2
2

Remarks
with Valve guides & Studs

For Ucal Carburettor

For Kehin Carburettor

Description

3A 3B
ES KS

No.

Part No.

1
2
3
4
5

JA 5112 10
JA 5112 11
JA 5112 04
DG 1010 29
36 JA00 02

Shaft Rocker arm intake

Shaft rocker arm exhaust
Rocker arm with roller
Collet Valve
Valve kit

1
1
2
4
1

1
1
2
4
1

6
7

36 JA00 03
39 2017 19

Valve repair kit

Seal valve stem

1
2

1
2

Remarks
(Length 36mm)
(Length 48mm)

Ref. page no.

Ref. page no.

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 4 : CAMSHAFT / TENSIONER

Plate No. 5 : CYLINDER AND PISTON

2

10
11
8

7
3
1

5
2
3

No.

Part No.

Description

4A 4B
ES KS

Remarks

1
2
3
4
5

JA
JA
JA
JA
JA

5112
5112
5112
5112
5310

12
16
17
18
11

Camshaft assly.
Specer cam sprocket
Sprocket cam shaft
Bolt integral coller
Cam chain link

1
1
1
1
1

1
1
1
1
1

6
7
8
9
10

36 JA00
DH 1010
JA 5210
CS 1011
JA 5210

04
11
17
28
18

Guide chain kit

Bolt special
Adjuster assly chain
Gasket
Bolt

1
1
1
1
1

1
1
1
1
1

Ref. page no. 60

11

JA 5210 19

Flange bolt

Adjuster assly chain mtg.

No.

Part No.

1
2
3
4
5

JA
39
JA
DP
JA

5210
1000
5212
1011
5210

01
06
07
65
14

6
7
8

JA 5210 15
JA 3514 00
JB 4022 02

Description

5A 5B
ES KS

Gasket cylinder
Dowel Pin
Piston ring set
Wire circlip
Cylinder block / Piston assly.

1
2
1
2
1

1
2
1
2
1

Damper
Thermal sensor
Grommet for thermal sensor

3
1
1

3
1
1

Remarks

(Escorts)

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 6 : CRANK SHAFT

Plate No. 7 : TRANSMISSION

21
6

14

10
8

2
4

3
6

11

4
10

13

12

9
17

8
2

15

5
16
19

18

20

No.

Part No.

1
2
3
4
5

59
59
31
JA
39

6
7
8
9
10

DS 1011 54
36 JA00 10
JA 531012
JA 5310 15
28 1010 58

1500
1100
1011
5310
1864

14
08
73
00
20

Description

6A 6B
ES KS

Flange Nut
Belleville washer
Woodruff key
Crank shaft assly.
Ball bearing

1
1
1
1
1

1
1
1
1
1

Parallel key
Set primary drive / driven
Spring
Parallel pin
Plunger oil

1
1
1
1
1

1
1
1
1
1

Remarks

Ref. page no.

No.

Part No.

Description

7A 7B
ES KS

1
2
3
4
5

JB
JA
JA
39
JA

5510
5512
5510
0987
5512

01
00
02
17
01

Shaft input transmission (12T)

Gear 4th drive (24T)
Spline washer
Ring snap
Gear 3rd drive (22T)

1
1
1
4
1

1
1
1
4
1

6
7
8
9
10

DS
JA
JA
JA
JA

1012
5512
5510
5510
5512

90
02
04
06
03

Washer 2nd drive

Gear 2nd drive (17T)
Washer thrust 2nd drive
Shaft output transmission (34T)
Gear 2nd driven (29T)

1
1
1
1
1

1
1
1
1
1

11
12
13
14
15

JA
JA
JA
JA
JA

5512
5512
5510
5512
5510

04
05
07
06
08

Gear 3rd driven (26T)

Gear 4th driven (23T)
Bush 1st driven
Gear 1st driven
Washer thrust

1
1
1
1
1

1
1
1
1
1

Remarks

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 7 : TRANSMISSION

Plate No. 8 : CHANGE DRUM / SHIFT FORK

4
21

14

15
7

2
12

3
4

4
10

22

11

3
9

13

22

1
2

9
5

17

4
16
19

18

20

Remarks

No.

Part No.

Description

8A 8B
ES KS

Part No.

16
17
18
19
20

JA 5510 09
59 2100 24
JA 5510 10
DU 1012 13
39 1981 04

Caller sprocket drive

"O" ring caller sprocket
Sprocket drive (15T)
Plate lock sprocket
Socket head bolt

1
1
1
1
2

1
1
1
1
2

1
2
3
4
5

JA
39
DP
JA
JA

5610
0992
1013
5610
5610

00
06
40
04
05

Drum complete gear shift

Dowel
Allen bolt
Shaft gear shift fork
Fork gear shift output

1
5
1
2
1

1
5
1
2
1

21
22

JA 5310 07
JA 5510 02

Flange nut
Spline Washer

1
2

1
2

6
7
8
9

JA
DK
JA
JA

5610
1011
5610
5610

06
35
02
03

Fork gear shift input

Bush
Cam drum change
Cup washer

1
2
1
1

1
2
1
1

Description

7A 7B
ES KS

No.

Remarks

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 9 : GEAR CHANGE MECHANISM

Plate No. 10 : CRANKCASE RH

10
2

9
11

1
3

6
5

12

14

13
7

10
9

2
4

11

No.

Part No.

9A 9B
ES KS

1
2
3
4
5

JA
JA
JA
JA
JA

00
05
06
07
08

Lever comp. gear shift

Extension spring
Spring gear shift return
Inhibitor com. gear shift
Spring

1
1
1
1
1

1
1
1
1
1

6
7
8
9
10

JA 5612 09
39 2704 11
39 0817 15
JA 5614 00
DH 1015 09

Step washer
Washer
Flange bolt
Lever comp. gear shifter
Damper

1
1
1
1
1

1
1
1
1
1

11

DG 1013 39

Damper

10

5612
5612
5612
5612
5612

Description

Remarks

No.
1

with rubber damper

Part No.
5010
5010
5410
2000
5410
5410

Description

10A 10B
ES KS

2
3
4
5

JA
JP
JA
59
JA
JA

00
00
45
36
11
10

Engine Assly.
Engine Assly.
Crankcase RH
Bearing Ball
Needle Roller Brg.
Stopper Plate

1
-1
1
1
1

-1
-1
1
1

6
7
8
9
10

39 1000 06
DU 1010 85
39 0746 01
JA 5410 15
JA 5412 35

Dowel Pin
Bushing
Screw
Stud inhibitor mtg.
Bolt

2
1
1
1
2

2
1
1
1
2

11
12
13
14

59
JA
JA
39

Bolt flange
Bolt shift change
Guide kick
Hexagon bolt

1
1
1
2

1
1
1
2

0400
5410
5410
1964

38
14
12
04

Remarks
N.I.
N.I.
NRB + bush + stud

Cr. case mtg.

11

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 11 : CRANKCASE LH

Plate No. 11 : CRANKCASE LH

11

11

17

17

10

10
1

9
18
13
15

5 6

18
7

Part No.

14

15

11A 11B
ES KS

6
7
8
9
10

DH 1012 64
39 2190 19
JA 5410 05
39 0747 01
JA 5410 34

Gasket neutral switch

Oil seal
Bush brass
Pan head screw
Stopper gear starter clutch

1
1
1
2
1

1
1
1
2
1

11
12
13
14
15

39
39
JA
59
JA

Hollow dowel pin

Hollow dowel pin
Mesh filter oil pump
"O" ring cap strainer
Cap strainer

2
2
1
1
1

2
2
1
1
1

06
06
19
23
21

12

2
3
4
5

1000
0999
5410
2100
5410

46
09
20
36
19
81

Description

5 6

14

16

JA
JP
39
59
39
31

12

5410
5410
2562
2000
1715
2010

13

12

No.

Crankcase LH
Crankcase LH
Needle roller bearing
Ball bearing
Seal oil
Neutral switch

1
-1
1
1
1

-1
1
1
1
1

Remarks

No.

Part No.

NRB + Bush + Orifice

NRB + Orifice

16
17
18

59 0400 38
39 1759 04
JA 5410 20

Description
Bolt flange
Bolt
"O" ring mesh filter oil pump

16

11A 11B
ES KS
6
1
1

Remarks

6
1
1

Output shaft

Shifter shaft
Starter clutch

13

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 12 : CLUTCH COVER

Plate No. 12 : CLUTCH COVER

21

20

19

22

21

20

19

18

22

18
10

11

5
3

12

13

5
3

12

9
17

10

11

9
17

13

2
8

7
15

7
15

14

14
17

17

16

16
6

No.

Part No.

1
2
3
4
5

JA
JA
39
30
JA

6
7
8
9
10
11
12
13
14
15

14

5412
2330
1041
1011
5412

12A 12B
ES KS

Clutch cover
Decal clutch cover
Oil seal clutch cover
Oil seal (kick shaft)
Shaft clutch release

1
1
1
1
1

1
1
1
1
1

DP 1012 69
DG 1014 18
DS 1012 15
39 2443 11
DS 1011 23

Rod push
Gauge
Wire circilp
Plain washer
Spring torsion clutch lever

1
1
1
1
1

1
1
1
1
1

JA
JA
JA
JA
39

Cap oil filler

"O" ring cap oil filler
Damper
Plate damper
Bolt flange

1
1
1
1
3

1
1
1
1
3

5412
5412
5412
5412
2208

40
00
19
42
09

Description

11
25
15
16
04

Remarks
with Decal + Gauge + Circlip

oil level check

Description

12A 12B
ES KS

No.

Part No.

16
17
18
19
20

JA 5412 12
59 0400 38
JA 5412 22
DD 1211 81
39 1671 21

Gasket clutch cover

Bolt flange
Bkt. clutch cable
Oil filter assly.
"O" ring

1
8
1
1
1

1
8
1
1
1

21
22

JA 5412 19
JA 5410 19

Cap filter
Bolt flange

1
3

1
3

Remarks

Clutch cover to C'case mtg.

15

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 13 : COVER MAGNETO

Plate No. 14 : CLUTCH

14
13

3
12
10

11

10
2

11

8
6

3
7

6
6
5

15
16
2
1

13A 14B
ES KS

No.

Part No.

JA 5412 41
JP 5412 05
59 0400 38
DG 1014 18
DS 1012 15
JA 5412 05
JP 5412 08

Cover magneto
Cover magneto
Bolt
Gauge
Wire Circlip
Gasket Magneto Cover
Gasket Magneto Cover

1
-2
1
1
1
--

-1
2
1
1
-1

8
9
10

JA
JA
JP
JA
39
JA

Bolt flange
Cover LH Rear with Decal
Cover LH Rear with Decal
Damper Cover LH
Flanged Bolt
Plate Damper Cover LH

8
1
-1
3
1

8
-1
1
3
1

11
12
13

JA 5410 05
JA 5412 33
30 1011 95

Bush
Threaded Cap
"O" Ring

1
1
1

1
1
1

2
3
4
5

6
7

16

5410
5412
5412
5412
2208
5412

44
14
03
20
04
21

Description

17

Remarks
With bush (Threaded cap design)
(Gauge + Circlip)

N.I. From Nov. 2007

N.I. From Nov. 2007

No.

Part No.

Description

14A 14B
ES KS

1
2
3
4
5

JA
JA
39
JA
JA

5514
5514
2600
5514
5514

00
06
11
13
14

Clutch assly. complete

Collar clutch
Washer
Clutch plate assly.
Wheel clutch

1
1
2
1
1

1
1
2
1
1

6
7
8
9
10

JA
JA
JA
JA
JA

5514
5514
5514
5514
5514

19
18
17
21
22

Plate clutch
Plate friction
Plate friction reduced
Plate judder
Spring judder

4
4
1
1
1

4
4
1
1
1

11
12
13
14
15

JA
JA
JA
39
JA

5514
5514
5514
1553
5514

15
23
08
04
16

Hub clutch
Compression spring
Holder
Bolt upset
Belleville washer

1
4
1
4
1

1
4
1
4
1

16
17

JA 5514 20
JA 5310 07

Plain Washer
Nut

1
1

1
1

Remarks

(45 Segments)
(30 Segments)
One side chamfer

Hub clutch lock

17

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 16 : CARBURETOR ASSEMBLY (UCAL MAKE)

Plate No. 15 : KICK STARTER MECHANISM

2
4

6
11

5
6

10

7
13

12

11

13

5
15
10

14

16

5
1

17

18

12

19

20

Part No.

1
2
3
4
5

JA 6212 01
DP 1510 18
36 DU10 07
DH 1011 25
39 0993 11

Lever assly. kick

Bolt Special
Boss Kick Set
Spring Kick Start Return
Plain Washer small

1
1
1
1
3

1
1
1
1
3

6
7
8
9
10

39
JA
DS
JA
JA

Circlip
Spindle Kick Starter
Spring Kick Starter
Ratchet
Gear spur kick starter

2
1
1
1
1

11
12
13

JA 6210 06
39 2408 17
DD 1010 97

Washer Thrust
Circlip
Kick rubber

1
1
1

18

0738
6210
1011
6210
6210

17
01
17
02
03

Description

15A 15B
ES KS

No.

Remarks

No.

Part No.

Description

16A 16B
ES KS

1
2
3
4
5

JA
JA
CB
JA
JA

5812
5812
1210
5812
5812

09
23
61
45
41

Carburettor assly.
Mixing cap assly
Cable adjuster
Piston valve kit
Needle jet kit

1
1
1
1
1

1
1
1
1
1

2
1
1
1
1

6
7
8
9
10

JB
JA
JA
JA
JA

5812
5812
5812
5812
5812

02
38
39
40
33

Throttle position sensor

"O" ring (TPS)
Solenoid choke assly
"O" ring (solenoid fixing)
Screw

1
1
1
1
2

1
1
1
1
2

1
1
--

11
12
13
14
15

JA
JA
JA
JA
24

5812
5812
5812
5812
1213

42
43
44
21
65

Air screw kit

Idling screw kit
Jet kit
Needle valve assly
Float assly

1
1
1
1
1

1
1
1
1
1

Ref. page no. 60

Remarks

Ref. page no.

Ref. page no.

Ref. page no.

Ref. page no.
Ref. page no.

19

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 16 : CARBURETOR ASSEMBLY (KEHIN MAKE)

Plate No. 16 : CARBURETOR ASSEMBLY (UCAL MAKE)

3

4
5
4
6

10

5
6

9
8

15
12
11

11

13

12

15

14
13

16
17

18

19

No.

Part No.

16
17
18
19
20

24 1210 69
JA 5812 32
JA 5812 20
CB 1210 46
24 1210 86

20

Description
Float pin
"O" ring
Float body assly
Screw
Drain screw

10

14

20

16A 16B
ES KS
1
1
1
4
1

1
1
1
4
1

Remarks

No.

Part No.

Description

16A 16B
ES KS

1
2
3
4
5

JB
JA
JA
JA
JB

5812
5812
5813
5813
5812

00
91
10
07
05

Carburettor assly.
Cable adjuster
Needle jet kit
Screw
Solenoid choke assly

1
1
1
1
1

1
1
1
1
1

6
7
8
9
10

JA
JA
JA
JA
JB

5812
5813
5813
5813
5812

40
11
12
09
02

"O" ring
Air screw kit
Idling screw kit
Screw
Throttle position sensor

1
1
1
1
1

1
1
1
1
1

11
12
13
14
15

JA
JA
JA
JA
JA

5812
5812
5813
5812
5813

38
68
13
76
01

"O" Ring
Float Complete
Jet kit
Gasket
"O" ring

1
1
1
1
1

1
1
1
1
1

Remarks

Ref. page no.

Ref. page no.

Ref. page no.

Ref. page no.

21

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 17 : AIR FILTER ASSEMBLY

Plate No. 18 : SILENCER ASSEMBLY

14

15

6
7

1
9

4
11
10

13

10

4
4

No.

Part No.

JA 5810 17
JP 5810 00
JA 5810 16
JA 5810 15
JA 5810 05
JA 5810 06
JA 5810 09
JA 5810 10
JA 5810 11
39 1773 04
JA 5810 12
DS 1211 26
DP 1210 25
JA 5110 11
JA 5110 29
39 1673 04
JA 5812 17
DH 1210 38

2
3
4
5
6
7
8
9
10
11
12
13
14
15

20

Description
Air filter assly
Air Filter Assly.
Air Filter duct
Connecting Tube
Cartridge assly.
Element air filter
Flame arrestor
Cartridge cover
"O" ring cartridge
Flange bolt
Tube drain
Plug
Clamp
Hose breather
Clamp breather
Flange bolt
Clamp
Clamp

11

12

17A 17B
ES KS
1
1
1
1
1
2
1
1
1
4
1
1
1
1
1
3
1
1

1
1
1
1
1
2
1
1
1
4
1
1
1
1
1
3
1
1

Remarks
For
For
For
For

Ucal Carburettor
Kehin Carburettor
Ucal Carburettor
Kehin Carburettor

Description

18A 18B
ES KS

No.

Part No.

JA 5910 42
JA 5910 43

Silencer assly. W/o shield

Silencer assly W/o shield

1
1

1
1

2
3
4
5

JA
CB
JA
JA
DH

5910
1011
5910
5910
1016

46
14
40
36
07

Silencer assly W/o cat

Gasket exhaust mtg.
Flange nut
Shield silencer
Trues screw

1
1
2
1
4

1
1
2
1
4

6
7
8
9
10

JB
39
JA
39
39

1130
2492
5910
2492
2754

04
11
37
11
04

Hex head bolt flange

Plain washer
Shield exhaust tube
Plain washer
Bolt

1
1
1
1
1

1
1
1
1
1

11

JN 1132 00

Stand stopper rubber

Remarks
Stand rubber mtd. on silencer
Stand rubber mtd. on Frame
From Nov. 2007 onwords

(CAT)

For Ucal Carburettor

For Kehin Carburettor

21

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 19 : SEAT ASSEMBLY

Plate No. 20 : OIL PUMP

1
3

No.
1
2
3
4

22

Part No.
JB 1910
36 DS12
JB 1910
39 1902

00
01
03
04

Description
Seat assly. complete
Seat damper kit
Lock assly. seat
Bolt flange small

19A 19B
ES KS
1
1
1
2

1
1
1
2

Remarks

Ref. page no.

No.
1
2
3
4

Part No.
52
JA
39
JA

JA00
5410
0753
5410

23
16
01
18

Description
Oil pump assly.
Gasket case oil pump
Pan head screw
Gear driven + shaft oil pump

20A 20B
ES KS
1
1
3
1

Remarks

1
1
3
1

23

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 21 : MAGNETO ASSEMBLY

Plate No. 22 : STARTER ASSEMBLY

6
5
21
4

10

11

10

1
3

11

4
9
13

16
3
10

1
15

8
14

12

No.
1

Part No.

21A 21B
ES KS

Remarks

No.

Part No.

2
3
4
5

JA
JP
JA
39
39
JA

00
01
12
04
01
03

Roter assly.
Roter assly.
Stater assly. complete
Bolt flange
Pan head screw
Ignition coil with cable & cap LH

1
-1
2
3
1

-1
1
2
3
1

1
2
3
4
5

JA
JA
DH
JA
JA

6
7
8
9
10

JA 3512 04
JA 3512 00
DG 1110 08
DD 1110 48
DD 1110 11

Ignition coil with cable & cap RH

C.D.I. assly.
Spark plug
Spark plug cap
Grommet spark plug cap

1
1
2
2
2

1
1
2
2
2

6
7
8
9
10

39 2437 04
DJ 1011 09
DH 1011 63
JA 6214 11
JA 6214 06

11
12
13
14
15

DD 1110 12
DJ 1810 65
39 1943 04
DK 2010 36
JB 4020 00
JB 4020 01

Grommet for HT cable

Clip nut
Bolt flange
Condenser
DC Regulator
Capacitor integral with regulator

2
1
2
1
1
1

2
1
2
1
-1

16

JA 5410 28

Lock plate

24

3510
3510
3510
1674
0746
3512

Description

6214
6214
1017
6214
6214

03
12
81
10
02

Description

22A 22B
ES KS

Body comp. starter clutch

Spring
Plate roller clutch
Gear starter clutch
Washer

1
5
1
1
2

------

Bolt socket
Bush for Spring Starter
Roller
Bush Spring Starter Clutch
Drive assly.

3
5
5
5
1

------

Remarks

Till 1st week of Dec. 2007

(ES) From 2nd week of Dec. 2007
(KS) Since beginning.

25

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 22 : MOTOR ASSEMBLY STARTER (TVS MAKE)

Plate No. 22 : MOTOR ASSEMBLY STARTER (FLASH MAKE)

4
10
8
2

1
7

12

13

10

2
6
5

11
9

16

15
15

14

4
3
17
1

22A 22B
ES KS

No.

Part No.

1
2
3
4
5

JA 3516 02
JA 3516 01
JA 516 04
JA 3516 03
JA 3516 05

"O" ring for Motor Assly.

DE bracket assly
"O" ring for tie screw
Tie screw
Yoke assly

1
1
1
1
1

------

6
7
8
9
10

JA
JA
JA
JA
JA

3516
3516
3516
3516
3516

06
07
08
09
11

Sealing Ring
Armature assly
Positive brush holder assly
Negative brush holder assly
CE bracket assly

1
1
1
1
1

------

11
12
13
14
15

JA
JA
JA
JA
JA

3516
3516
3516
3516
5210

10
12
13
00
19

Positive terminal assly

"O" ring inside insulator bush
"O" ring
Motor Assly. Stater
Flange Bolt

1
1
1
1
2

------

26

Description

14

Remarks

No.

Part No.

Description

22A 22B
ES KS

1
2
3
4
5

JA
JA
JA
JA
JA

3516
3516
3516
3516
3516

14
15
16
17
18

Yoke Assly.
Armature Assly.
DE Bracket Assly.
CE Bracket Assly.
Brush & Earth Plate Assly.

1
1
1
1
1

------

6
7
8
9
10

JA
JA
JA
JA
JA

3516
3516
3516
3516
3516

19
20
21
22
23

Terminal Assly.
Insul Bush
"O" Ring (Terminal Insul)
Insul Bush Outer
"O" Ring Terminal

1
1
1
1
1

------

11
12
13
14
15

JA
JA
JA
JA
JA

3516
3516
3516
3516
3516

24
25
26
27
00

Brush Spring
"O" Ring (Terminal Bolt)
Seal Yoke
"O" Ring Spigot
Motor Assly.

2
2
2
1
1

------

16
17

JA 5210 19
JA 3516 02

Flange Bolt
"O" ring for motor assly.

2
1

---

Remarks

N.I.

27

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 23 : FRAME FITTING

Plate No. 24 : FRAME AND FRAME FITTINGS

2
3
2
5
9
1

8
5

6
5

No.

Part No.

Description

23A 23B
ES KS

1
2
3
4
5

JA
JA
JA
39
JA

1134
1134
1134
2723
1134

00
01
02
15
03

Bracket engine hanger LH

Bracket engine hanger RH
Engine Mounting bracket front
Hex Nut Flanged
Bolt Flanged

1
1
1
2
2

1
1
1
2
2

6
7
8
9

JA
39
59
39

1134
2312
0400
1970

04
04
17
15

Bolt flanged
Bolt Flanged
Hex Bolt Flanged
Nut Flanged

3
3
1
7

3
3
1
7

Remarks

for engine mtg.

for engine mtg.

Part No.

JB 1110 31
JB 1110 43

Frame Assly. comp.

Frame Assly. comp

1
1

1
1

2
3
4
5

DS 1810
DH 1810
36 DS18
DJ 1811

Nut Fork
Cup - Steering
Bearing cone Kit
Cage Bearing

1
1
1
2

1
1
1
2

DU 1011 35

Bush

18
14
02
15

Description

24A 24B
ES KS

No.

Remarks
Stand rubber Mtd. on silencer
Stand rubber Mtd. on Frame
From Nov. 2007 onwords

Ref. page no.

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 25 : SWING ARM / REAR SHOCK ABSORBER

Plate No. 25 : SWING ARM / REAR SHOCK ABSORBER

18

19

2 3

18

2
6

19

2 3

9
10

10

12

12

17
11

17
11

16

16

14

13

14

1
15

16

15

16

15
13

15

1
2
3
4

Part No.

Description

1220
1220
1220
1220
1220
1220
1220
1220

16
11
10
13
14
05
15
07

Hex. Bolt/ Flange

Plain washer
Plain washer
Rear Shock Absorber
Rear Shock Absorber
Rear Shock Absorber
Rear Shock Absorber
Swing arm assly.

2
4
4
2
2
2
2
1

2
4
4
2
2
2
2
1

6
7
8
9
10

JB
39
JB
39
39

1220
2726
1220
0553
0454

09
12
03
02
11

Domed Cap Nut

Spring Washer
Chain slider
Screw
Plain washer

2
2
1
2
2

2
2
1
2
2

28

15

25A 25B
ES KS

JB
JB
JB
JB
JB
JB
JB
JB

15

15

15

No.

Remarks

For
For
For
For

Orange Colour
Blue Colour
Red Colour
Silver Colour

No.

Part No.

Description

25A 25B
ES KS

11
12
13
14
15

JB
JB
DJ
DX
39

1220
1220
1510
1510
0292

04
08
36
14
15

Shaft swing arm

Special Nylock Nut
Adjuster chain LH
Adjuster chain RH
Hexagon nut

1
1
1
1
4

1
1
1
1
4

16
17
18
19

DJ
DP
JA
DS

1510
1710
1814
1612

46
06
20
24

Plate Chain Adjuster

Silent bush
Hugger
Bolt step flange

2
2
1
3

2
2
1
3

Remarks

29

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 26 : STAY MAIN STEP

Plate No. 27 : PILLION FOOT REST / HOLDER

8
2

4
6

6
1
6
1
3

3
4
2
2
5

No.
1
2
3
4

30

Part No.
JA
DF
DH
JA

1130
1614
1611
1130

10
13
94
11

Description
Stay main step fix
Damper step front in PVC
Stopper kick
Bolt flange

26A 26B
ES KS
1
2
1
4

1
2
1
4

Remarks

No.

Part No.

1
2
3
4
5

JB
JB
DX
DX
DX

6
7
8
9
10
11
12

1130
1130
1610
1610
1610

01
03
21
24
56

Description

27A 27B
ES KS

Holder LH step
Holder RH step
Pillion step assly. comp. LH
Pillion step assly. comp. RH
Rubber pillion step

1
1
1
1
2

1
1
1
1
2

JB 1130 06
39 0254 11
39 0463 12
DD 1613 81
30 1410 31

Special Bolt
Plain washer
Spring washer
Pin Pillion Step
"O" Ring

4
4
4
2
2

4
4
4
2
2

39 1040 11
39 0784 08

Plain Washer
Split Pin

2
2

2
2

Remarks

31

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 28 : FENDER -FRONT & REAR

Plate No. 29 : STAND ASSEMBLY

12

15

2
9

14

11
1

13

4
17

6
10

15

10

5
14

7
8

8
7

No.
1
2

Part No.

Description

28A 28B
ES KS

3
4
5

DS
JB
JB
JB
JB
39

1611
1814
1814
1814
1814
1943

25
01
14
12
04
04

Cable Guide
Brace fender
Brace fender
Flange bolt
Fender rear front
Flange bolt

1
1
1
4
1
3

1
1
1
4
1
3

6
7
8
9
10

39
JB
JB
JB
JB

0211
1814
1814
1814
1814

11
06
07
08
09

Plain washer
Fender rear
Stay RR fender
Clip nut LH
Clip nut RH

3
1
2
1
1

3
1
2
1
1

11
12
13
14
15

DJ
39
JB
39
39

1610
0326
1814
0242
2420

69
15
03
11
01

Nail for Cable Guide

Nyloc Nut
Flap Front fender
Plain Washer
Screw pan head

1
3
1
3
3

1
3
1
3
3

16
17

DK 1810 41
DK 1810 42

Speed sensor holding clamps

Rubber

2
2

2
2

32

Remarks

Brace fender11
Fender front mtg.

29A 29B
ES KS

No.

Part No.

Description

JA 1132 00
JB 1132 00

Center Stand
Center Stand

1
1

1
1

2
3
4
5

JA 1132 01
39 0797 08
DH 1611 21
DH 1611 45

Shaft stand
Pin cotter
Spring main stand
Cover spring main stand

1
1
1
1

1
1
1
1

6
7
8
9
10

DH 1612 39
JA 1132 02
DH 1612 40
DF 1611 02
39 0422 15

Spring main stand with cover

Stand side
Spring side stand with cover
Bolt
Nut

1
1
1
1
1

1
1
1
1
1

Remarks
Stand rubber mtd. on silencer
Stand rubber mtd. on frame
From Nov. 2007

NI

33

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 30 : TYRE / TUBE / RIM

Plate No. 31 : FRONT HUB

18

16
6

1
3

5
17
2

1
EU

14

OGRIP

13
8

11

10

3
4

EU

OGRIP

Part No.

1
2
3
4
5

JB
JB
DS
DS
DS

DS 1510 53

34

1310
1312
1510
1510
1510

16
22
48
49
52

15

12

No.

14

Description

30A 30B
ES KS

Wheel Rim Front

Wheel Rim Rear
Tyre Front
Tube Front
Tyre Rear

1
1
1
1
1

1
1
1
1
1

Tube Rear

Remarks

Not Serviceable

No.

Part No.

Description

19

31A 31B
ES KS

1
2
3
4
5

39
30
JB
DS
JB

2688
1510
1310
1510
1310

20
32
08
94
18

Bearing Ball
Collar Bearing
Ring speed sensor
Nut
Plain washer

2
1
1
1
1

2
1
1
1
1

6
7
8
9
10

JB
JB
DS
DS
DS

1310
1310
1510
1510
1510

19
17
95
92
91

U Nut
Axle
Bolt
Lever brake cam
Indicator

1
1
1
1
1

1
1
1
1
1

11
12
13
14
15

30
JB
DS
30
30

1510
1316
1510
1510
1510

38
01
89
69
68

Ring O
Panel front brake
Cam brake
Spring
Shoe brake

1
1
1
2
1

1
1
1
2
1

Remarks

35

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 31 : FRONT HUB

Plate No. 32 : REAR HUB

1

18

20

16

18

17

29
9 26

5
28

17

20
16

21
25

19

14
13

11

10

14

15

23

12
4

27

5
22

3
3

13

24
12

14
15

No.
16
17
18
19

36

Part No.
30
JB
DS
JB

1510
1310
1510
1310

33
21
56
20

Description
Oil Seal
Spacer
Dust Seal
Pan head screw

10

11

15

19

31A 31B
ES KS
1
1
1
1

1
1
1
1

Remarks

No.

Part No.

Description

32A 32B
ES KS

1
2
3
4
5

JB
39
39
31
31

1410
2682
1364
1510
1510

02
20
20
18
21

Drive Chain Lock

Bearing ball
Bearing ball
Collar bearing
Damper

1
1
1
1
1

1
1
1
1
1

6
7
8
9
10

JA
JB
30
DJ
DS

1312
1312
1510
1510
1510

05
23
38
57
90

Panel rear brake

Cam brake
Ring O
Dust cover
Indicator

1
1
1
1
1

1
1
1
1
1

11
12
13
14
15

JB
JB
DS
31
30

1316
1312
1510
1510
1510

05
24
94
60
69

Lever brake
Flange Bolt
Nut
Shoe brake
Spring

1
1
1
2
2

1
1
1
2
2

Remarks

37

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 32 : REAR HUB

Plate No. 33 : BRAKE PEDAL

1
20

18

17

29

19

9 26
28

20

16

16
21

25

19

23
4

18
15

11

22
13

24
12

10

14

8
12

15
6

10

13
11
17

15

Part No.

Description

32A 32B
ES KS

16
17
18
19
20

DX
39
DX
31
DX

1510
2240
1510
1510
1510

08
20
09
29
10

Coupling
Bearing ball
Sleeve
Lock Washer
D Bolt

1
1
1
4
4

1
1
1
4
4

21
22
23
24
25

39
DX
JB
DX
JB

0794
1510
1310
1510
1312

15
16
19
15
25

Hex. lock nut

Axle
U nut
Plain washer
Nut

4
1
1
1
1

4
1
1
1
1

26
27
28
29

JA
DX
DX
36

1312
1510
1510
JA00

02
13
18
05

Collar
Collar
Plain washer
Chain sprocket kit

1
1
1
1

1
1
1
1

38

27

No.

14

Remarks

Refer page no. 61

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Part No.
JA
JA
JB
30
39
39
30
JA
JA
39
39
39
39
JB
JB
DS
30
JK
JB

1610
1610
1610
1910
0198
0808
1910
1210
1210
1540
0694
0789
0807
1610
1610
1910
1510
1610
1610

00
03
05
38
11
08
35
04
05
11
15
12
08
02
03
35
96
00
04

Description
Brake Pedal
Pad Brake Lever (PVC)
Rod brake
Pin
Plain washer
Split pin
Spring
Rod torque
Step bolt
Plain washer
Hex. lock nut
Washer spring
Pin snap
Pin
Brake Adjuster Nut
Packing brake rod
Hex bolt
Washer
Brake pedal spring

33A 33B
ES KS
1
1
1
1
2
1
1
1
1
1
2
2
2
1
1
1
1
1
1

Remarks

1
1
1
1
2
1
1
1
1
1
2
2
2
1
1
1
1
1
1

39

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 34 : HANDLE BAR

Plate No. 34 : HANDLE BAR

24

24
21

21

23

20

28

23

20

28

22

22

29
10
3

29

26

10

27

25

3
15

11

1
2
3
4

Description

34A 34B
ES KS

DS
39
JB
JB
JB
DJ

1810
1714
4014
4014
4014
1910

44
04
00
01
04
53

Handle
Flanged bolt
Control switch LH
Control switch RH
Control switch RH
Holder Assly. LH

1
4
1
1
-1

1
4
1
-1
1

8
9
10

DX
DJ
DX
29
JA
DS

1910
1910
1910
2011
1316
1810

34
55
08
17
02
08

Holder Assly. RH
Lever grip Left
Lever grip Left
Front Brake Switch
Lever Brake RH
Damper handle upper

1
1
-1
1
2

1
-1
1
1
2

11
12
13
14
15

DS
DS
39
DS
DS

1810
1810
0422
1910
1910

09
10
15
15
16

Damper handle lower

Washer handle lower
Nylock Nut
Grip LH
Grip RH

2
2
2
1
1

2
2
2
1
1

5
6
7

40

14

Remarks

18

19

17

Part No.

17

18

18

19

17

18

No.

12
13
16

17

15
11

16

14

27

25

12
13

26

Description

34A 34B
ES KS

No.

Part No.

16
17
18
19
20

DS 1910 52
DH 1810 22
39 2427 04
JB 4014 05
DJ 2210 03

Boot for lever LH

Handle bar weight
Hex. soc. head cap screw
Clutch Switch
Mirror assly. LH

1
2
2
1
1

1
2
2
1
1

21
22
23
24
25

DJ
30
JB
39
JB

2210
1910
4014
1943
1510

04
48
02
04
03

Mirror assly. RH
Band
Switch assly. ignition
Flange bolt
Holder Fork Upper

1
2
1
2
1

1
2
1
2
1

26
27
28
29

DS
DS
DS
DS

1810
1910
1810
1810

07
18
06
19

Washer handle Upper

Boot For Lever RH
Holder Up
Holder lower

2
1
2
2

2
1
2
2

Remarks

41

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 35 : FRONT FORK

Plate No. 35 : FRONT FORK

8

8
10

23

10
23

11
2

11
2

23

23

13

13

14

15

14

16

14

21/22

15

1
21/22

13

13

3
17

4
19

No.

Part No.

Description

35A 35B
ES KS

17

18

Remarks

1
2
3
4
5

JB 1510
36 DZ00
30 1810
30 1810
JA 1510

00
20
26
25
13

Fork front
Front fork seal kit
Gasket
Bolt
Fork Pipe Spring

1
1
2
2
2

1
1
2
2
2

Common for Endurance & Gabrial

6
7
8
9
10

DJ
DH
DS
DS
DS

1811
1810
1810
1810
1810

04
09
12
18
15

Spring front fork

Grommet Top
Bolt fork
Washer
Cap Nut Fork

2
2
2
2
1

2
2
2
2
1

------------"do"----------------------------"do"----------------------------"do"----------------------------"do"----------------------------"do"-----------------

11
12
13
14
15

JB
DG
DJ
DJ
JB

1510
1810
1810
1810
1510

03
08
85
25
01

Holder fork upper

Socket Bolt
Cushion Rubber
Cover Trail B
Lamp Shade asly.

1
2
2
4
1

1
2
2
4
1

------------"do"----------------N.I. ------------"do"---------------------------"do"----------------------------"do"----------------N.I. ----------"do"-----------------

42

16

14

------------"do"----------------------------"do"----------------------------"do"----------------------------"do"-----------------

19

35A 35B
ES KS

No.

Part No.

16
17
18
19
20

DH 1810 23
JA 1510 03
39 0789 12
39 1714 04
DS 1810 17

Bearing cone
Holder fork under
Spring washer
Bolt
Nylon spacer

1
1
2
2
2

1
1
2
2
2

------------"do"----------------------------"do"----------------------------"do"----------------------------"do"----------------------------"do"-----------------

21

JB
JB
JB
JB
DS
JB

Outer Tube LH
Outer Tube LH
Outer Tube RH
Outer Tube RH
Shaft complete steering
Shaft complete steering

1
1
1
1
2
2

1
1
1
1
2
2

For
For
For
For
For
For

22
23

1510
1510
1510
1510
1810
1510

05
23
06
24
14
25

Description

18

Remarks

Endurance
Gabrial
Endurance
Gabrial
Endurance
Gabrial

43

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 36 : PAINTED PARTS

Plate No. 36 : PAINTED PARTS

12

12

11

11

2
10

10

No.

Part No.

36A 36B
ES KS

Description

JB
JB
JB
JB

7101
7101
7101
7101

22
2V
3A
3Q

Petrol
Petrol
Petrol
Petrol

JB
JB
JB
JB

7301
7301
7301
7301

22
2V
3A
3Q

Side
Side
Side
Side

cover
cover
cover
cover

LH
LH
LH
LH

with
with
with
with

JB
JB
JB
JB

7302
7302
7302
7302

22
2V
3A
3Q

Side
Side
Side
Side

cover
cover
cover
cover

RH
RH
RH
RH

with
with
with
with

JB
JB
JB
JB

7303
7303
7303
7303

22
2V
3A
3Q

Seat
Seat
Seat
Seat

cover
cover
cover
cover

with
with
with
with

44

tank
tank
tank
tank

with
with
with
with

decal
decal
decal
decal

Remarks

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

decal
decal
decal
decal

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

decal
decal
decal
decal

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

decal
decal
decal
decal

No.

Part No.

36A 36B
ES KS

Description

Remarks

JB
JB
JB
JB

7304
7304
7304
7304

22
2V
3A
3Q

Spoiler
Spoiler
Spoiler
Spoiler

cover
cover
cover
cover

LH
LH
LH
LH

with
with
with
with

decal
decal
decal
decal

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

JB
JB
JB
JB

7305
7305
7305
7305

22
2V
3A
3Q

Spoiler
Spoiler
Spoiler
Spoiler

cover
cover
cover
cover

RH
RH
RH
RH

with
with
with
with

decal
decal
decal
decal

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

JB
JB
JB
JB
JB

7306
7306
7306
7306
1814

22
2V
3A
3Q
15

Front
Front
Front
Front
Front

1
1
1
1
1

1
1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

JB
JB
JB
JB

7401
7401
7401
7401

22
2V
3A
3Q

Fairing
Fairing
Fairing
Fairing

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

fender
fender
fender
fender
Fender
with
with
with
with

decal
decal
decal
decal

45

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 36 : PAINTED PARTS

Plate No. 37 : FUEL TANK CAP, TAP ASSLY. & FUEL GAUGE

2
1

13

3
4

12

11

5
14

13

15

10

12
8
11
10

No.

Part No.

Description

36
36
36
36

JA00
JB00
JB00
JA00

07
01
02
08

Decal
Decal
Decal
Decal

10

52
52
52
52

JB00
JB00
JB00
JB00

32
24
25
33

Grip
Grip
Grip
Grip

36A 36B
ES KS

set
set
set
set

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

frame
frame
frame
frame

1
1
1
1

1
1
1
1

Jet black
Cocktail wine red
Long beach blue
Silver

11

JB 1710 10

Spoiler mtg. bkt. LH

12

JB 1710 11

Spoiler mtg. bkt. RH

13

DS 1610 82

Rubber Grommet for spoiler

46

Remarks

No.

Part No.

1
2
3
4
5

DS
39
39
JB
JB

6
7
8
9
10
11
12
13
14
15

1410
0761
2179
1718
2326

37A 37B
ES KS

Cap Assly. Tank

Screw Pan Cross
Washer
Fuel Tap Assly
3 In 1 Lock set With Key

1
2
2
1
1

1
2
2
1
1

DD 1410 22
39 0740 11
JA 4026 00
JB 1710 20
30 1410 32

Bolt flanged
Washer (Non-Metallic)
Gauge Fuel
Seat Tape
Bolt

2
2
1
1
4

2
2
1
1
4

JA
30
30
39
DZ

Tube fuel
Pipe clip
"O" Ring
"O" ring
4 hole washer

1
2
2
1
1

1
2
2
1
1

1718
1410
1410
2758
1410

09
01
24
00
00

Description

01
15
31
21
75

Remarks

47

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 38 : FITTINGS-PETROL TANK & SIDE COVER

Plate No. 39 : CHAIN CASE

7
2
10
11

4
1

3
3
5

4
5

8
5

Part No.

1
2
3
4
5

36 DS14 01
DG 1611 21
39 1943 04
36 DS14 02
39 1789 24

Grommet Kit for Side Cover

Screw
Flanged Bolt
Damper Kit Petrol Tank
Washer Nylon

1
5
2
1
3

1
5
2
1
3

6
7
8
9
10

39
39
JB
JB
JB

Pin Snap
Plain Washer
Rubber ring
Cover LH side lower
Cover RH side lower

1
1
1
1
1

1
1
1
1
1

11

JC 1410 17

Rubber Grommet for Tank

0983
1054
1812
1812
1812

08
11
15
06
07

Description

38A 38B
ES KS

No.

Remarks
Ref. page no. 61

Ref. page no. 61

No.

Part No.

1
2
3
4
5

36 JA00
JB 1812
JB 1812
JB 1812
DH 1612

06
18
20
21
83

JB 1812 15

Description

39A 39B
ES KS

Case Chain Kit

Rubber Cap
Flange bolt
Flange bolt
Bolt flange

1
1
2
1
2

1
1
2
1
2

Rubber beading

Remarks
Ref. page no. 61

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 40 : METER ASSEMBLY

Plate No. 41 : CONTROL CABLES

4
4
5

1
1
2
3

No.
1
2
3
4

48

Part No.
JB
39
JB
JB

4024
1778
1812
1812

00
02
12
23

Description
Meter assly.
Self tapping screw
Speedo cap
Beading Speedo Flap

40A 40B
ES KS
1
4
1
4

1
4
1
4

Remarks

No.
1
2
3
4
5

Part No.
JB
JB
JA
JA
JB
JB

1612
1612
1612
1612
1310
1310

03
00
01
03
07
23

Description
Cable accelerator
Cable accelerator
Cable clutch
Brake cable
Speed sensor
Speed sensor "O" ring

41A 41B
ES KS
1
1
1
1
1
1

1
1
1
1
1
1

Remarks
For Ucal
For Kehin

49

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 42 : HEAD LAMP ASSEMBLY / FAIRING

Plate No. 42 : HEAD LAMP ASSEMBLY / FAIRING

15

15

2
5

5
8

6
20

20

9
1

1
17

10

17

10
19

19

18

18

16

16
3

21
4

12

21
4

12

13

13

11

11
4

4
14

No.

Part No.

Description

42A 42B
ES KS

14

Remarks

No.

Part No.

1
2
3
4
5

JB
39
CL
DJ
39

4010
1778
2010
2010
2141

11
02
23
72
24

Head Lamp Without Bulb

Self Tapping Screw
Lamp 12V 35/35W-HS1
Lamp 12V 5W
Washer

1
8
1
2
4

1
8
1
2
4

16
17
18
19
20

JB
JB
JB
JB
JB

6
7
8
9
10

JB
DF
JB
DL
DJ

1812
1810
1812
1810
1810

10
98
11
10
65

Cowling
Bolt
Wind Shield
Well Nut
Clip Nut

1
4
1
4
2

1
4
1
4
2

21

JB 4010 20

11
12
13
14
15

39
39
DS
DS
JB

0716
1553
2010
2010
1812

01
04
36
39
13

Screw
Flange Bolt
Head Lamp Bulb Clip
Head lamp Harness Branch
B Monogram

2
4
1
1
1

2
4
1
1
1

50

1510
1510
1510
1510
1812

08
09
12
13
14

Description

42A 42B
ES KS

Head lamp mtg. bkt. LH

Head lamp mtg. bkt. RH
Grommet fairing mounting
Sleeve fairing mounting
Packing fairing

1
1
4
4
1

1
1
4
4
1

Cap for head lamp bulb holder

Remarks

On Wind shield

51

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 43 : TURN SIGNAL LAMP

Plate No. 44 : TAIL LAMP ASSEMBLY

1/2

1
3

3
4
1/2
5

7
6

No.

Part No.

1
2
3
4

JB 4010 06
JB 4010 09
GH 2010 12
39 1970 15

52

Description
Blinker front LH / rear RH
Blinker rear RH / front LH
Lamp 12V 10W
Hex nut / flange

43A 43B
ES KS
1
1
4
2

1
1
4
2

Remarks

No.

Part No.

1
2
3
4
5

JB
DK
59
39
DJ

4010
2010
0200
2124
1610

01
24
01
15
72

6
7

39 2476 04
DP 1611 45

Description

44A 44B
ES KS

Tail light with Lamp

Lamp Assly. for Rear No. Plate
Screw Tapping
Flange Nut
Bracket Rear No. Plate

1
1
4
2
1

1
1
4
2
1

Bolt flange
Number plate Rear

2
1

2
1

Remarks

53

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 45 : NUMBER PLATE

Plate No. 46 : ELECTRICAL EQUIPMENT

14
1
5

2
2
3
12
11
1

10

13
9
17
15
16

4
18

Part No.

JB 2328 10

Number Plate Assly.

2
3
4
5

JB
DP
39
JB
JB

Fixed Number Plate

Number plate front
Truss Screw (For Fr. No. Plate)
Number plate kit
Front number plate sub. assly.

1
1
2
1
1

1
1
2
1
1

6
7
8

JB 2328 28
JB 2328 25
DF 1612 52

Damper Front Number Plate

Front Number Plate
Rear Number Palte

1
1
1

1
1
1

2328
1611
1783
2328
2328

27
44
01
12
26

Description

45A 45B
ES KS

No.

Remarks
Without mtg. screw bolt
(Inclusive JB232812)
For Export

No.
1
2
3
4

(Inclusive JB232826)

For Export
For Export
For Export

5
6
7

8
9
10

54

Part No.
JB
39
39
JB

4016
1507
1689
4022

Description

46A 46B
ES KS

00
11
04
04

Horn with Stay

Plain Washer
Flange Bolt
Wiring Harness

1
1
1
1

1
1
1
--

JB 4022 05

Wiring Harness

--

JB 4022 01
DS 2010 29

Wiring Harness
Rear Brake Switch assly.

-1

1
1

DS
DS
DS
31
JB
JA
JA
JA
JA

Spring Brake Switch

Battery 5AH
Battery 5AH Dry Battery MF
Battery 2.5 AH
Head lamp controller
Case Battery
Case Battery
Band Battery
Band Battery

1
1
1
-1
1
-1
--

1
--1
1
-1
-1

1910
2010
2010
2010
4010
4018
4018
4018
4018

07
81
82
27
13
00
02
01
03

Remarks

Separate capacitor and regulator

can be till 1st week of Dec. 07
Intrigal capacitor with regulator
from 2nd week of Dec. 07

For Export
N.I.

55

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 46 : ELECTRICAL EQUIPMENT

Plate No. 47 : TOOL KIT

14

1
5

3
12
11

10

13
9
17
15
16

4
18

No.

Part No.

Description

46A 46B
ES KS

11
12
13
14
15

DS
JK
DS
AP
30

1612
1110
2010
2010
2011

24
27
25
29
04

Stepped Bolt
Stepped Bolt
Assly DC flasher
Starter Relay /
Fuse box Assly.

2
1
1
1
1

2
1
1
1
1

16
17
18
19

30
DS
JA
DK

2010
2010
4022
2010

85
22
02
36

Fuse
Cable assly. (Battery to St.Relay)
Cable assly. (Battery to Earth)
Capacitor

4
1
1
1

4
1
1
1

56

Remarks

No.

Part No.

JA 2310 00

Description
Tool kit

47A 47B
ES KS
1

Remarks

N.I.

57

Brand ID: 001MC632

Brand ID: 001MC632

Plate No. 48 : ACCESSORIES LEG GUARD, SAREE GUARD)

KIT LIST
Sr.
Kit Part No. Kit Description
No.

36JA0002 Valve kit

36JA0003 Valve Repair Kit

10
4
3

36JA0004 Chain Guide Kit

1
2

JA521207 Set Piston Ring

36JA0010 Set Drive Driven

6
6

No.

Part No.

36 JA00 01

2
3
4
5
6
7
8
9
10

Description

Saree / Leg Guard kit

with hardware
JB 2312 03 Utility Box
JA 2312 00 Leg Guard
JA 21312 01 Hook Leg Guard
39 0798 15 Nut Hexagon with flange
JB
39
39
39

2312
0589
2228
2495
xxxx

00
15
15
04

Saree Guard
Nut Hexagon weld
Nut domed cap
Bolt Hexagon
PVC packing

48A 48B
ES KS

36DU1007 Boss Kick Kit

Remarks
7 JA 5812 41 Needle jet kit

1
1
1
2
2
1
3
1
1
1

1
1
1
2
2
1
3
1
1
1

8 JA 5812 42 Air Screw Kit

99 JA581243 Idling screw kit

10 JA581244 Jet Kit

58

Consisting of Following Parts

Part No.

Description

Qty./Kit

JA511200 Valve intake

JA511201 Valve Exhaust

28101129 Seat Spring

39201719 Seal Oil

JA511202 Spring washer

JA511203 Retainer valve spring

DG101029 Collet

JA541013 Guide Chain Slack side

JA521002 Guide Chain Tight side

JP521201 Ring Piston (Second)

JP521202 Ring Piston (Oil)

JP521203 Ring Piston (Piston)

JA531010 Gear Primary Drive

JA551401 Housing

30101233

Boss Kick

30101234 Spring

30101236 Ball Steel

30101235 Pin

39085517 E - Type Circlip

JA 5812 22 Needle jet

JA 5812 26 Jet needle

JA 5812 31 Jet holder

DD 1210 54 E ring

JA581236 Screw - Air (Adjust)

24121064 Spring - Screw Air

24121062 "O" ring

16121032 Washer

JA581230 Adjuster

CB121044 Sping

24121062 "O" ring

24121063 Washer

24121360 Pilot jet

24121367 Main jet

59

Brand ID: 001MC632

Brand ID: 001MC632

KIT LIST
Sr.
Kit Part No. Kit Description
No.

11 36DS2101 Seat Damper Kit

12 36DS1802 Bearing Cone kit

13 36JA0005 Chain Sprocket Kit

14 36DS1401 Grommet Kit for Side Cover

15 36DS1402 Damper Kit Petrol Tank

16 36JA0006 Chain Case Kit

17 JA581245 Piston Valve Kit

60

Consisting of Following Parts

Part No.

Description

Qty./Kit

DS211004 Seat Damper

DS211005 Seat Damper

DH181025 Bearing Cone

DH181026 Bearing race

DH181024 Upper Bearing Race

JB141000 Chain (122 Links)

JA131206 Sprocket (42 T)

JA551010 Sprocket Drive

DS141012 Grommet Side Cover Front

DS161082 Grommet Side Cover Rear

DS141021 Damper

DJ141008 Damper Front

JB181224 Chain Case Upper Assly.

JB181227 Chain Case Lower Assly.

JA581224 Ring

JA581228 Spring

JA581229 Piston Valve Assembly

Amendment Sheet (Parts Deleted)

Sr.No.

Part No.

Description

Qty.

Page No. Fig.No.

61

Brand ID: 001MC632

Brand ID: 001MC632

Amendment Sheet (Parts Deleted)

Sr.No.

62

Part No.

Description

Part No.
Qty.

Page No. Fig.No.

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

63

Brand ID: 001MC632

Part No.

64

Brand ID: 001MC632

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

65

Brand ID: 001MC632

Part No.

66

Brand ID: 001MC632

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

67

Brand ID: 001MC632

Part No.

68

Brand ID: 001MC632

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.

69

Brand ID: 001MC632

Part No.

70

Figure
No.

Page
No.

Part No.

Figure
No.

Page
No.