Thunderbird 500 350 Parts Catalogue PDF

1
Foreword
We take pleasure in releasing THUNDERBIRD 350 & THUNDERBIRD 500 Spare Parts Catalogue.
The Catalogue has been specially designed for identification of correct part number to help in ordering Spare Parts, Special Tools and Service Publications
from the company.
The Royal Enfield Spare Parts are manufactured under stringent quality control to ensure ultimate riding experience. It is therefore important to use only
Royal Enfield Genuine Spares.
The illustration of the various parts are not to scale and is intended to serve only as a means of identification of the component for its shape and relative
location in its respective assembly.
Due to continuous improvements in the motorcycle, the part nos and / or illustrations are subject to change without prior notice. However the changes will
be intimated through technical Service Bulletin subsequently and periodically which must be updated by you in the catalogue at your end.
The part numbers and description were correct at the time of printing. While extreme care is taken in publishing this catalogue. We shall not be held
responsible for any errors/omissions or wrong interpretations and consequent loss of any nature due to any of the above.
For enquiry, suggestions or feedback may write to us ...
SERVICE HEADQUARTERS :
ROYAL ENFIELD
(A Unit of Eicher Motors Limited)
Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. India.
Tel : +91-44-4223 0400, Fax : +91-44-4201 1719. Website : www.royalenfield.com
E-mail : customerservice@royalenfield.com
“ © Copyright 2012 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this Service technical manual shall be copied, distributed
or otherwise dealt without the express permission in written from the Eicher Motors Limited, Royal Enfield Unit who remains the sole owner of
this manual .”
Part No. 888189/a , Version 1.01 / TRAB / Qty. 300 / Apr. 2013
Developed & Printed at Jiju Graphics  98400 57140
2
00-00 General Information
For easy reference and quick identification, the parts are grouped into relevant categories. Details are given in the illustrated Group index. Kindly follow
the below tips on usage of this catalogue
 ILLUSTRATION
Illustration given with this catalogue helps in identifying the shape of part in its relative assembly.
02-30 Air Filter (500cc)

Alpha-Numeric Key
No. for Assembly Group No.
10 A1
A1
9
Key Nos.
1 to 14
A2
Key Nos. 8 14
6
2 to 5, 7, 8, 13, 13
(Qty. 4 Nos. 1)
Numeric Key No.
A3
7
Key Nos. 6
4&5
Key No. Which make up

the Assembly
3
 PART NUMBER LIST

1 2 3 4 5 6 7
KEY PART NUMBER MOQ

Thunderbird Thunderbird DESCRIPTION QTY. REFERENCE REMARKS Nos.
No.
350 500
1. KEY NUMBER (KEY NO.)

The numeric key number is provided to serve as the identification of the part with its part number.
Serviceable assemblies or kits in a particular group are identified by alpha-numeric key numbers. e.g. A1, A2 etc. In such cases, key numbers of
individual items or group number which make up such assembly / kit are given in illustration.
4
2. PART NUMBER
The Part number of the individual item, kit OR assembly is given in this column for unique identification. The parts for which part numbers
are not given, are not individually serviced. The applicable part numbers are shown as per Thunderbird 350 & 500 models. The numbers
which are mentioned in Remarks column are for reference only along with Service Bulletin Index.
3. DESCRIPTION
The description of the part assigned to the individual item, kit / assembly is mentioned in this column.
4. QUANTITY
The number of individual items, kits or assemblies required for one vehicle is mentioned here.
Though quantity is indicated for oversize (O/S) or undersize (U/S) of some items, it is to be understood that for a vehicle the sizes only is
applicable, depending upon the repair / matching requirements.
5. REFERENCE
Parts Revision / Modifications related to Technical Service Bulletin Number mentioned in this column. The part numbers which are
displayed in this column are meant for reference only (Belongs to Kits Child Part or Not Served Items).
6. REMARKS
Updated / Modified or Child / alternate Part Numbers is mentioned for reference purpose. However Service Bulletin are issued from
SHQ for updating the catalogue. Kindly note, this catalogue is updated upto SB / Tech / 687.
7. M.O.Q.
Number of Items Minimum Quantity to be ordered to our Spare Parts department (SPD). So that they can serve you minimum packed /
ordered quantity. It may varies from item to item by Price, Size or Shape as applicable.
5
Contents
Group No. Description Page No. Group No. Description Page No.
00-00 GENERAL INFORMATION ...................................................................................... 2 05-00 REAR SHOCK ABSORBER & CENTER STAND ASSEMBLY ............................. 111
00-10 GROUP INDEX PICTORIAL .................................................................................... 6 05-10 SWING ARM ASSEMBLY & REAR CHAIN GUARD ........................................... 113
01-10 ENGINE ................................................................................................................ 13 05-20 REAR WHEEL .................................................................................................... 117
01-20 ENGINE COVER RH ............................................................................................. 15 05-30 REAR MASTER CYLINDER ASSEMBLY- BBI .................................................... 121
01-30 CRANK CASE RH - COVER SIDE ...................................................................... 21 05-40 REAR CALIPER ASSEMBLY- BBI ...................................................................... 125
01-40 CYLINDER & HEAD ASSEMBLY ......................................................................... 29 05-50 CRADLE ASSEMBLY RH ................................................................................... 129
01-50 ENGINE COVER LH ............................................................................................. 35 05-60 REAR MUDGUARD ............................................................................................ 131
01-60 CRANK CASE LH - COVER SIDE ........................................................................ 37 05-70 TAIL LAMP BRACKET, TRAFFICATOR & SAREE GUARD ............................... 133
01-70 CLUTCH ............................................................................................................... 41 06-00 CRADLE ASSEMBLY LH & PILLION FOOT REST ASSEMBLY ......................... 135
01-80 CRANK CASE LH ................................................................................................ 43 06-10 SIDE PANEL LH & RH ........................................................................................ 139
01-90 CRANK CASE RH ................................................................................................ 45 06-20 SIDE DECOR LH & RH ....................................................................................... 143
01-100 GEAR TRAIN ASSEMBLY (OLD TYPE) .............................................................. 51 06-30 FRAME ............................................................................................................... 145
01-110 GEAR TRAIN ASSEMBLY (ANTI SKIP MECHANISM) ......................................... 55 07-00 BATTERY, BATTERY CARRIER AND HARNESS .............................................. 151
02-00 CV CARBURETOR (BS 29) ................................................................................ 59 07-10 HEAD LAMP ....................................................................................................... 153
02-10 EFI COMPONENTS IN CYLINDER HEAD ............................................................. 65 07-20 TAIL LAMP ......................................................................................................... 155
02-20 AIR FILTER (350CC) ............................................................................................ 69 07-30 INSTRUMENTAL CLUSTER ................................................................................ 157
02-30 AIR FILTER (550CC) ............................................................................................ 71 07-40 SWITCHES, HORN & RELAYS .......................................................................... 159
02-40 SILENCER & EXHAUST PIPE ............................................................................... 73 07-50 TCI & EFI IGNITION COMPONENTS ................................................................... 163
03-00 HANDLE BAR & CONTROLS .............................................................................. 75 07-60 TRAFFICATOR LIGHTS, TOOLS & FIRST AID KIT ............................................ 167
03-10 CONTROL CABLES ............................................................................................. 79 08-00 SPECIAL TOOLS LIST - A (COMMON) ............................................................. 169
03-20 FRONT MASTER CYLINDER ASSEMBLY - BBI .................................................. 81 08-10 SPECIAL TOOLS LIST - B (COMMON & ........................................................... 171
03-30 FRONT CALIPER ASSEMBLY - BBI .................................................................... 85 (EXCL. FOR THUNDERBIRD 350 & 500 MODELS)
03-40 HEAD BRACKET & STEERING STEM .................................................................. 89 09-00 WALL CHARTS LIST - A (UCE) ........................................................................ 173
03-50 FRONT FORK (GIL - DIA 41) ............................................................................... 93 09-10 WALL CHARTS LIST - B (DOMESTIC) ............................................................. 175
03-60 FRONT MUDGUARD ............................................................................................ 97 09-20 ALL UCE SERVICE PUBLICATION LIST - A (DOMESTIC) ................................. 177
03-70 FRONT WHEEL .................................................................................................... 99 09-30 ALL UCE SERVICE PUBLICATION LIST - B (DOMESTIC) ................................ 179
04-00 FUEL TANK ........................................................................................................ 103 09-40 AFTER MARKET PARTS ................................................................................... 181
04-10 SEAT ASSEMBLY .............................................................................................. 107 10-00 PART NUMBER INDEX ....................................................................................... 184
04-20 SEAT SUB FRAME ............................................................................................. 109 11-00 SERVICE BULLETINS CHECKLIST FOR PARTS CATALOGUE UPDATE .......... 191
6
00-10 Group Index - Pictorial
01-10 Engine 01-20 Engine Cover RH 01-30 Crankcase RH - Cover Side

Page Page Page
12 14 20
01-40 Cylinder & Head assembly 01-50 Engine Cover LH 01-60 Crankcase LH - Coverside
Page Page Page
28 34 36
LOCTITE
01-70 Clutch 01-80 Crankcase LH 01-90 Crankcase RH

Page Page LOCTITE
Page
40 42 44
7
01-100 Gear Train Assembly (Old Type) 01-110 Gear Train Assembly (Anti Skip Mechanism) 02-00 CV Carburetor (BS 29)
Page Page Page
50 54 58
02-10 EFI Components in Cylinder Head 02-20 Air Filter (350cc) 02-30 Air Filter (500cc)
Page Page Page
64 68 70
02-40 Silencer & Exhaust Pipe 03-00 Handle Bar & Controls 03-10 Control Cables
Page Page Page
72 74 78
8
03-20 Front Master Cylinder Assembly (BBI) 03-30 Front Caliper Assembly (BBI) 03-40 Head Bracket & Steering Stem
Page Page Page
80 84 88
03-50 Front Fork (GIL-Dia 41) 03-60 Front Mudguard 03-70 Front Wheel
Page Page Page
92 96 98
04-00 Fuel Tank 04-10 Seat Assembly 04-20 Seat Sub Frame
Page Page Page
102 106 108
9
05-00 Rear Shock Absorber & Center Stand Assy. 05-10 Swing Arm Assembly & Rear Chain Guard 05-20 Rear Wheel
Page Page Page
110 112 116
05-30 Rear Master Cylinder Assembly 05-40 Rear Caliper Assembly 05-50 Cradle Assembly RH
Page Page Page
120 124 128
05-60 Rear mudguard 05-70 Tail Lamp Bracket, Trafficator & Saree Guard 06-00 Cradle Assembly LH & Pillion Foot Rest Assy
Page Page Page
130 132 134
10
06-10 Side Panel LH & RH 06-20 Side Decor LH & RH 06-30 Frame
Page Page Page
138 142 144
07-00 Battery, Battery Carrier & Harness 07-10 Head Lamp 07-20 Tail Lamp
Page Page Page
150 152 154
07-30 Instrumental Cluster 07-40 Switches, Horn & Relays 07-50 TCI & EFI Ignition Components
Page Page Page
156 158 162
11
07-60 Trafficator Lights, Tools & First Aid Kit 08-00 Special Tools List - A (Common) 08-10 Special Tools List - B (Common &
(Exclusive for Thunderbird 350 & 500 Models)
Page Page
Page
166 168
170
09-00 Wall Charts List - A (UCE) 09-10 Wall Charts List - B (Domestic) 09-20 All UCE Models Service Publication List - A
Page Page
(Domestic)
Page
172 174
176
09-30 All UCE Models Service Publication List - B 09-40 After Market Parts 11-00 SB Checklist for
10-00 Part Number Index
(Domestic) Parts Catalogue Update
Page
Page Part Number Page No. Key No. Page SB Page
RECEIVED UPDATED DATE & SIGN OF
180 NO. DATE BY PARTS
178 184 191
INCHARGE
12
01-10 Engine
1 1
5&6
3&4
2
13
01-10 Engine
KEY PART NUMBER

DESCRIPTION REMARKS MOQ
Thunderbird Thunderbird QTY. REFERENCE
No. 350 500 Nos.
869033 Unit Construction Engine with Electric Starter - 350 1 Matt Black-Powder Coated 1
1
869032 Unit Construction Engine with Electric Starter - 500 1 Matt Black-Powder Coated 1
888207 Cr. Case Assy. Black LH & RH with Bearings - 350 1 1
Cr. Case Assy. Black LH & RH with Bearings - 350 (Anti Skip Mechanism) 1 1
2
888208 Cr. Case Assy. Black LH & RH with Bearings - 500 1 1
Cr. Case Assy. Black LH & RH with Bearings - 500 (Anti Skip Mechanism) 1 1
3 390066 390066 15W 50 API SL Engine Oil (210 Ltrs.) Recommended oil for replacement 1
4 390067 390067 15W 50 API SL Engine Oil (50 Ltrs.) Recommended oil for replacement 1
5 390068 390068 15W 50 API SL Engine Oil (2.50 Ltrs.) 1 Recommended oil for replacement 10
6 390069 390069 15W 50 API SL Engine Oil (1.0 Ltr.) Recommended oil for Top-up 20
14
01-20 Engine Cover RH
A1 44
45 42
Key No’s 43
1
All Except 5, 6, 7,
41
32, 33 & 47
38 40
A2 39
2 37
Key No’s 3
36
4
34 to 40 34 35
5
A3 22 33
6
Key No’s 8
7 32
(Qty. 3 Nos. 11), 29
31
(Qty. 2 Nos. 21 & 25), 9 28
(Qty. 7 Nos. 23) 30
48
27
10 48
26
A4
Key No’s
19
12,13,14,15,16 & 17 20 21
19
18
A4
17 22 1
A5 15
16
14
Key No’s 13 23
12 25
1, 44 & 45 11 24
46
47
15
KEY PART NUMBER

No. 350 500 Nos.
A1 869005 869005 RH Cover Assembly Complete - Black 1 Matt Black-Powder Coated 1
A2 888101 888101 Kick Boss Repair Kit 1 1
A3 888112 888112 Bolt Reapir Kit RH Crankcase Cover 1 1
A4 888169 888169 Cap, Oil Filter Sub Assembly - Black 1 Black 1
A5 869006 869006 Cover RH Sub Assembly - Black 1 Matt Black-Powder Coated 1
1 Cover RH - Black 869007 Served in Kit Ref. A5 1
2 570183/D 570183/D Jet, Crankshaft RH 1 20
3 500622/B 500622/B Oil Seal, Crank Feed 24 x 10 x 7 1 1
4 550028 550028 Circlip 24N 1 10
5 570013 570013 Pulser Coil Fixing Screw (Hex Socket Head Cap Screw M5X16) 2 20
6 550095 550095 Hex Socket Head Cap Screw M6X 30 3 10
7 570416/I 570416/I Gasket - Cover RH 1 2
8 570425 570425 Hex. Screw, M5 X 12 6 50
9 570426/H 570426/H Gasket, Cover Plate 1 5
10 570424/D 570424/D Cover Plate, Breather Chamber 1 1
11 572011/A 572011/A Hex Flange Bolt M6 X 1 X 20 3 40
12 Cap, Oil Filter (Matt Black-Powder Coated) 1 869008 Served in Kit Ref. A4
13 572014/A 572014/A ‘O’ - Ring, Filter Cap 1 6
14 500637/B 500637/B Spring 1 20
15 500617/A 500617/A Washer 1 20
16 500621/A 500621/A ‘O’ - Ring 1 20
17 571201/A 571201/A Screw Spring Cap 1 10
18 500616/A 500616/A Spring Cap 1 10
16
A1 44
45 42
Key No’s 43
1
All Except 5, 6, 7,
41
32, 33 & 47
38 40
A2 39
2 37
Key No’s 3
36
4
34 to 40 34 35
5
A3 22 33
6
Key No’s 8
7 32
(Qty. 3 Nos. 11), 29
31
(Qty. 2 Nos. 21 & 25), 9 28
(Qty. 7 Nos. 23) 30
48
27
10 48
26
A4
Key No’s
19
12,13,14,15,16 & 17 20 21
19
18
A4
17 22 1
A5 15
16
14
Key No’s 13 23
12 25
1, 44 & 45 11 24
46
47
17
KEY PART NUMBER

No. 350 500 Nos.
19 500619/A 500619/A ‘O’ - Ring 2 20
20 500613/A 500613/A Element - Oil Filter 1 1
21 572019/A 572019/A Hex. Flange Bolt M6X1X45 1 10
22 570241 570241 Oil Seal Kick Starter, g20 x 27 x 5 double lip 2 10
24 570059/C 570059/C Oil Level Window 1 2
26 144846/A 144846/A Washer, Inspection Screw 1 14
27 570176/D 570176/D Inspection Screw, Ignition Timing 1 6
28 146459/A 146459/A ‘O’ - Ring 1 20
29 570467/A 570467/A Oil Filler Cap, Metal 1 1
30 570155 570155 Sealing Washer 1 20
31 573968/A 573968/A Bolt Breather 1 4
32 573964/A 573964/A Clip Breather Pipe 1 20
570286/C Breather Pipe 1 2
33
581084/C Breather Pipe 1 2
34 141051 141051 Hex Nut M8 1 Served in Kit Ref. Key 43 40
35 Circlip 10 - IS 3075 1 570259/D Served in Kit Ref. A2 30
36 Ball Dia 6.35 (1/4”) 1 140201 Served in Kit Ref. A2 50
37 Boss, Kick Start Crank 1 570814/C Served in Kit Ref. A2 1
38 Hex. Bolt M8X40 1 111914 Served in Kit Ref. Key 43 20
39 Spring - Kick Crank 1 570257/C Served in Kit Ref. A2
40 Pin - Kick Start Crank 1 570815/B Served in Kit Ref. A2
18
A1 44
45 42
Key No’s 43
1
All Except 5, 6, 7,
41
32, 33 & 47
38 40
A2 39
2 37
Key No’s 3
36
4
34 to 40 34 35
5
A3 22 33
6
Key No’s 8
7 32
(Qty. 3 Nos. 11), 29
31
(Qty. 2 Nos. 21 & 25), 9 28
(Qty. 7 Nos. 23) 30
48
27
10 48
26
A4
Key No’s
19
12,13,14,15,16 & 17 20 21
19
18
A4
17 22 1
A5 15
16
14
Key No’s 13 23
12 25
1, 44 & 45 11 24
46
47
19
KEY PART NUMBER

No. 350 500 Nos.
41 570808/D 570808/D Lever Kick Start Crank 1 Kit Ref. Key No. 43 1
42 145157/C 145157/C Sleeve Kick Start Lever 1 Alt. No. 146642/A 5
43 570807/C 570807/C Kick Start Crank Assembly 1 1
44 570723/A 570723/A Plug Dummy 1 25
45 570182/B 570182/B Plug ID 2.3 mm Restrictor - LEE Plug 1 20
46 144636/A 144636/A Copper Washer 2 20
47 570604/A 570604/A Circlip Oil Window 1 2
48 570298/A 570298/A Dowel Pin 2 20
20
01-30 Crankcase RH - Cover Side
A1
A1 (350cc) 350cc 5
10
4 9
Key No’s W
9K c c 11
3 0. 0
2, 3, 4, 5 & 6 5 0
2 6 10
9
A1 (500cc) W
500cc 1 7K c c
A1 57 0. 0
5 3 5
8
Key No’s 7
4
2 to 4 56
53
52 40
51 45
1 46
A4 2 3 50 44
49 47
1 43 41
1 12
Key No’s 48 42
46 & 48 13
40 14 54
15
55
A5, A6, A7 16
17
37 A2 18
Key No’s 39 19
38 26
Each Qty 2 Nos. 34 27 20
38, 39, 41 & 42 36
35
A3
29 29 28
32 21
31 30
31 30 32 23
33 22
33 28
25
24
21
KEY PART NUMBER

No. 350 500 Nos.
570048/F Oil Pump Assembly 1 1
A1
571047/D Oil Pump Assembly 1 1
A2 570309/B 570309/B Cam Gear Assembly - Exhaust with Decompressor Assembly 1 Served in Kit Assy. 1
A3 570600/A 570600/A Gear Changer Assembly 1 Served in Kit Assy. 1
A4 888170 888170 Cover Kick Start with Oil Seal 1 Black Colour 1
A5 888179 888179 Eccentric Cam Spindle Repair Kit - STD 1 1
A6 888180 888180 Eccentric Cam Spindle Repair Kit - 0.1mm oversize 1 1
A7 888181 888181 Eccentric Cam Spindle Repair Kit - 0.2mm oversize 1 1
570051/A Hex. Socket Head Cap Screw M4 X 30 4 20
1
571155/A Hex. Socket Head Cap Screw M6 X 30 3 20
2 570052 570052 Circlip - Oil Pump 1 14
3 571166/B 571166/B Pump Drive Pinion 1 2
4 570293/A 570293/A ‘O’ Ring, Oil Pump Outlet 1 5
570294/A ‘O’ Ring, Oil Pump Base 1 10
5
571115/C Gasket, Oil Pump 1 10
6 570292/A ‘O’ Ring, Oil Pump Inlet 1 10
573928/A Cover Starter Motor (350cc) Black 1 1
7
573929/A Cover Starter Motor (500cc) Black 1 1
570813/A Button Head Screw M4 X 10-SS 1 50
8
570300/B Hex. Socket Button Head Screw M5 X 12 1 50
570302/A Mounting Allen Screw 2 14
9
570303/A Hex. Socket Head Cap Screw M6x60 2 10
22
A1
A1 (350cc) 350cc 5
10
4 9
Key No’s W
9K c c 11
3 0. 0
2, 3, 4, 5 & 6 5 0
2 6 10
9
A1 (500cc) W
500cc 1 7K c c
A1 57 0. 0
5 3 5
8
Key No’s 7
4
2 to 4 56
53
52 40
51 45
1 46
A4 2 3 50 44
49 47
1 43 41
1 12
Key No’s 48 42
46 & 48 13
40 14 54
15
55
A5, A6, A7 16
17
37 A2 18
Key No’s 39 19
38 26
38, 39, 41 & 42 36
35
A3
29 29 28
32 21
31 30
31 30 32 23
33 22
33 28
25
24
23
KEY PART NUMBER

No. 350 500 Nos.
573993/A Starter Motor 0.7KW 1 1
10
573992/A Starter Motor 0.9KW 1 1
11 570181/B 570181/B Restrictor (Lee Plug 1.8 MM) - RCC 1 20
570102/D 570102/D Plug dummy hole 4 25
12
570723/A 570723/A Dummy Plug AVDEL Dia 7 X10 L 4 25
13 570304/B 570304/B Hex. Socket Head Cap Screw, M6 X 12 2 50
14 869020 869020 Pivot Bearing, Rocker Shaft Upper Matt Black-Powder Coated 1 Alt. No. 570228/G 1
15 570234 570234 ‘O’ Ring Black Nitrile Rubber 1 10
16 550072/B 550072/B Spring 1 10
17 570227/F 570227/F Spacer 1 5
18 550256/A 550256/A ‘O’ Ring 1 25
19 570229/D 570229/D Stop Pin 1 25
20 570230/F 570230/F Spring, Gear Change Striker 1 10
21 570235/E 570235/E Dowel, Lower Pivot Bearing 1 50
22 570219/F 570219/F Assembly, Gear Lever Shaft 1 1
23 570231/H 570231/H Pivot Bearing, Rocker Shaft Bottom 1 1
24 570184/B 570184/B Spacer - Shaft, Gear Lever 1 20
25 570233 570233 Hex. Socket Head Cap Screw, M5 X 40 2 14
869011 Tappet Door Matt Black-Powder Coated 1 Alt. No. 570817/B 1
26
869031 Tappet Door Matt Black-Powder Coated 1 Alt. No. 572305/B 1
27 570198/C 570198/C CSK Socket Head Screw M5 X 0.8 X 12 4 20
570866/A Fly Wheel Magneto Assembly (3 Phase TCI) 1 Dia M 5.5 MTG Holes 1
28
570862/A Fly Wheel Magneto Assembly (EFI) 1 Dia M 5.5 MTG Holes 1
24
A1
A1 (350cc) 350cc 5
10
4 9
Key No’s W
9K c c 11
3 0. 0
2, 3, 4, 5 & 6 5 0
2 6 10
9
A1 (500cc) W
500cc 1 7K c c
A1 57 0. 0
5 3 5
8
Key No’s 7
4
2 to 4 56
53
52 40
51 45
1 46
A4 2 3 50 44
49 47
1 43 41
1 12
Key No’s 48 42
46 & 48 13
40 14 54
15
55
A5, A6, A7 16
17
37 A2 18
Key No’s 39 19
38 26
38, 39, 41 & 42 36
35
A3
29 29 28
32 21
31 30
31 30 32 23
33 22
33 28
25
24
25
KEY PART NUMBER

No. 350 500 Nos.
592237/A Rotor and Reluctor Assembly (Olive Green) 1 1
29
571062/B Rotor and Reluctor Assembly - 24T (Olive Green) 1 N.S. 1
570867/A Stator and Pulser Coil Assembly (ES) - 3 Phase - 350cc 1 Dia M5.5 MTG Holes 1
30
570863/A Stator and Pulser Coil Assembly (ES) - 3 Phase - 500cc 1 Dia M5.5 MTG Holes 1
31 502070/A 502070/A Magneto Key 1 20
32 586008/A 586008/A Plain Washer 1 Old No. 145708/A, 580344/A, 593023/B 14
33 550025 550025 Hex. Nut M12 X 1.25 1 10
34 570421/A 570421/A Hex. Socket Head Cap Screw, M6 X 30 2 10
35 570132/A 570132/A Hex. Socket Head Cap Screw, M6 X 25 1 10
36 570044/J 570044/J Cam Steady Plate 1 1
37 570298/A 570298/A Dowel 6 mm 2 10
38 570100/B 570100/B Nut - Cam Spindle 2 10
39 570280/B 570280/B Shim, Cam Gear 2 20
40 570298/A 570298/A Dowel Pin 2 10
570039/D 570039/D Cam Spindle Adjustable (Standard Size) 2 Served in Kit, Ref. A5 2
41 570040/C 570040/C Cam Spindle Adjustable (0.1 mm Over Size) 2 Served in Kit, Ref. A6 2
570041/C 570041/C Cam Spindle Adjustable (0.2 mm Over Size) 2 Served in Kit, Ref. A7 2
42 570099/C 570099/C Cam Sleeve 2 2
43 571164/A 571164/A Cam, Gear - Inlet Sub Assembly 1 1
44 146450/B 146450/B Spring Kick 1 5
45 145090 145090 Hex Screw M6 X 16 1 20
46 869019 869019 Cover, Kick Start Shaft - Matt Black Powder Coated 1 Served in Kit, Ref. A4 1
47 570300/B 570300/B Hex Socket Pan Head Screw M5 X 12 4 50
26
A1
A1 (350cc) 350cc 5
10
4 9
Key No’s W
9K c c 11
3 0. 0
2, 3, 4, 5 & 6 5 0
2 6 10
9
A1 (500cc) W
500cc 1 7K c c
A1 57 0. 0
5 3 5
8
Key No’s 7
4
2 to 4 56
53
52 40
51 45
1 46
A4 2 3 50 44
49 47
1 43 41
1 12
Key No’s 48 42
46 & 48 13
40 14 54
15
55
A5, A6, A7 16
17
37 A2 18
Key No’s 39 19
38 26
38, 39, 41 & 42 36
35
A3
29 29 28
32 21
31 30
31 30 32 23
33 22
33 28
25
24
27
KEY PART NUMBER

No. 350 500 Nos.
48 570241 570241 Oil Seal Kick Starter G20 X 27 X 5 Double Lip 1 10
49 570246/E 570246/E Nut, Sleeve Gear 1 1
50 570247/D 570247/D Tab Washer 1 5
570809/A FD Sprocket 16 Teeth 1 1
51
571032/B FD Sprocket 18 Teeth 1 1
52 570214/F 570214/F Distance Piece 1 1
53 570213 570213 Oil Seal 1 2
54 144600/A 144600/A Copper Washer 1 25
55 570713 570713 Hex. Socket Head Screw M8 X 1.25 X 14 1 10
56 570132/A CSK Socket Head Screw M6 X 25 2 50
57 580286/A Grommet (Starter Motor Cover) 1 40
28
01-40 Cylinder & Head Assembly
4
A1 (350cc) 23
2 5
Key No’s 3 43
(Qty. 4 Nos. 16), 15 to 19, 21, 28 28
22, (Qty. 2 Nos. 40), 41 & 42 6 25
28
A1 (500cc) 26
1
29
Key No’s 8
27 27
(A1 350cc), 43 & 44
7
26
A2 A3 9 9
27
26
Key No’s Key No’s
30 & 38 20 & 24 12
14 15
34
A10 33
A4 A5 16
10 13 30
17
Key No’s Key No’s 15 11 35
16
6&8 1&7 18
17 36
19
31
A6 (350 & 500 cc) 18 31
19 40
Key No’s 40 38
24 37
(Qty. 2 Nos. 17, 18 & 40), (Qty.
4 Nos. 16), 21, 22, 41 & 42
20
A7 A8 A9 41
42 32 39
A10 22
Key No’s Key No’s Key No’s 21
10 & 12 13 & 14 (Qty. 2 Nos. 40), Key No’s
41 & 42 30 & 32 A9
29
KEY PART NUMBER

No. 350 500 Nos.
869046 Cylinder Head Assembly with Valves - Black 350cc 1 Powder Coated 1
A1
869043 Cylinder Head Assembly with Valves - Black 500 cc 1 Powder Coated 1
888171 Cylinder Barrel & Piston with Rings Assembly (350cc) - Black 1 Black 1
A2
888172 Cylinder Barrel & Piston with Rings Assembly (500cc) - Black 1 Black 1
888003 Spark Plug Kit UCE 350cc Domestic 1 M14 & M10 Plugs 1
A3
888004 Spark Plug Kit UCE 500cc Domestic 1 M14 & M10 Plugs 1
A4 888174 888174 Rocker Cover with Gasket - Exhaust - Black 1 Black 1
A5 888173 888173 Rocker Cover with Gasket - Inlet - Black 1 Black 1
888111 Valve Repair Major Kit UCE 350cc 1 1
A6
888113 Valve Repair Major Kit UCE 500cc 1 1
A7 888109 888109 Rocker Bearing Set with Rocker Arm - Exhaust 1 1
A8 888110 888110 Rocker Bearing Set with Rocker Arm - Inlet 1 1
869047 Cylinder Head Sub Assembly (Cyl. Head, Valve Guide, Valve Seats) 350cc 1 Matt Black-Powder Coated 1
A9
869044 Cylinder Head Sub Assembly (Cyl. Head, Valve Guide, Valve Seats) 500cc 1 Matt Black-Powder Coated 1
570272/A Piston Assembly with Rings (Std size) Kit 350cc 1 1
A10
Piston Assembly with Rings (Std size) Kit 500cc 1 1
1 869009 869009 Rocker Cover - Inlet - Black Powder Coated 1 Matt Black 1
2 573932/A 573932/A Bolt Rocker Cover (white Passivation) 1 Old No. 570129/H 1
3 573906/A 573906/A Washer Seal 1 5
4 573933/A 573933/A Bolt Rocker Cover (white Passivation) 3 Old No. 571117/C 1
5 573907/A 573907/A Washer Seal 3 30
6 869010 869010 Rocker Cover - Exhaust 1 Matt Black-Powder Coated 1
7 572021/B 572021/B Gasket, Rocker Cover - Inlet 1 1
8 572022/B 572022/B Gasket, Rocker Cover - Exhaust 1 1
30
4
A1 (350cc) 23
2 5
Key No’s 3 43
(Qty. 4 Nos. 16), 15 to 19, 21, 28 28
22, (Qty. 2 Nos. 40), 41 & 42 6 25
28
A1 (500cc) 26
1
29
Key No’s 8
27 27
(A1 350cc), 43 & 44
7
26
A2 A3 9 9
27
26
30 & 38 20 & 24 12
14 15
34
A10 33
A4 A5 16
10 13 30
17
16
6&8 1&7 18
17 36
19
31
A6 (350 & 500 cc) 18 31
19 40
Key No’s 40 38
24 37
(Qty. 2 Nos. 17, 18 & 40), (Qty.
4 Nos. 16), 21, 22, 41 & 42
20
A7 A8 A9 41
42 32 39
A10 22
10 & 12 13 & 14 (Qty. 2 Nos. 40), Key No’s
41 & 42 30 & 32 A9
31
KEY PART NUMBER

No. 350 500 Nos.
9 570131/A 570131/A Hex. Socket Head Cap Screw, M6 X 55 - Black 8 20
10 570533/B 570533/N Rocker Bearing Set - Exhaust 1 Served in Kit, Ref. A7 1
11 570298/A 570298/A Dowel (6 mm) 8 10
12 570535/G 570535/G Rocker Arm - Exhaust 1 Served in Kit, Ref. A7 1
13 570536/G 570536/G Rocker Arm - Inlet 1 Served in Kit, Ref. A8 1
14 570532/N 570532/N Rocker Bearing Set-Inlet 1 Served in Kit, Ref. A8 1
15 500352/A 500352/A Retainer, Spring 2 5
16 500307/A 500307/A Split Collar 4 20
17 500309/B 500309/B Valve Spring 2 2
18 500322/A 500322/A Valve Stem Seal 2 2
19 500347/A 500347/A Seat, Spring 2 20
500904/A Spark Plug (W5DC) M14 1 1
20
572339/A Spark Plug (WQR8DP) M14 1 1
570164/D Valve Exhaust - 350cc 1 1
21
571035/C Valve Exhaust - 500cc 1 1
570163/D Valve Inlet - 350cc 1 1
22
571034/C Valve Inlet - 500cc 1 1
23 572318/A Adaptor - Cylinder Head (PAV Connection) 1 1
580395/A Spark Plug (UR5DC) M10 1 1
24
572328/A Spark Plug (UR6DC) M10 1 1
25 570478/B 570478/B Damper Pad LH - Cylinder Head 2 10
26 570482/B 570482/B Damper Pad - Cylinder Barrel Tapper 6 2
27 570480/B 570480/B Damper Pad - Cylinder Barrel 3 2
28 570479/B 570479/B Damper Pad RH - Cylinder Head 4 1
32
4
A1 (350cc) 23
2 5
Key No’s 3 43
(Qty. 4 Nos. 16), 15 to 19, 21, 28 28
22, (Qty. 2 Nos. 40), 41 & 42 6 25
28
A1 (500cc) 26
1
29
Key No’s 8
27 27
(A1 350cc), 43 & 44
7
26
A2 A3 9 9
27
26
30 & 38 20 & 24 12
14 15
34
A10 33
A4 A5 16
10 13 30
17
16
6&8 1&7 18
17 36
19
31
A6 (350 & 500 cc) 18 31
19 40
Key No’s 40 38
24 37
(Qty. 2 Nos. 17, 18 & 40), (Qty.
4 Nos. 16), 21, 22, 41 & 42
20
A7 A8 A9 41
42 32 39
A10 22
10 & 12 13 & 14 (Qty. 2 Nos. 40), Key No’s
41 & 42 30 & 32 A9
33
KEY PART NUMBER

No. 350 500 Nos.
29 573931/A 573931/A Stud - Exhaust 2 10
Piston Assembly (Std size) Kit 350cc 1 1
30
571108 Piston Assembly (Std size) Kit 500cc 1 1
500207/A Circlip (UCE 350) 2 20
31
571119/A Circlip 20 X 1 (UCE 500) 2 20
570273 Piston Ring Set Std (350cc) 1 1
32
571109 Piston Ring Set Std (500cc) 1 1
33 570537/D 570537/D Push Rod Assembly, Exhaust 1 1
34 570538/D 570538/D Push Rod Assembly, Inlet 1 1
570192/C MLS Gasket (Cylinder Head to Cylinder Barrel) (350cc) 1 1
35
571039/B MLS Gasket (Cylinder Head to Cylinder Barrel) (500cc) 1 1
36 500123/A 500123/A Dowel Pin, Inlet 1 10
37 500116/A 500116/A Dowel Pin, Exhaust 1 20
869052 Cylinder Barrel Assembly - 350cc 1 Matt Black-Powder Coated 1
38
869049 Cylinder Barrel Assembly - 500cc 1 Matt Black-Powder Coated 1
570018/G Gasket (Crankcase to Cylinder Barrel) 1 1
39
571043/C Gasket (Crankcase to Cylinder Barrel) 1 1
40 570165/C 570165/C Valve Guide UCE 2 Served in Kit, Ref. A6 2
570166/C Valve Seat Insert - Inlet (350cc) 1 Served in Kit, Ref. A6 10
41
571036/B Valve Seat Insert - Inlet (500cc) 1 Served in Kit, Ref. A6 10
500303/2 Valve Seat Insert - Exhaust (350cc) 1 Served in Kit, Ref. A6 10
42
571037/B Valve Seat Insert - Exhaust (500cc) 1 Served in Kit, Ref. A6 10
43 144844 Sealing Washer 16 X 20 (TC Feed Plug Washer) 1 10
34
01-50 Engine Cover LH
A1
Key Nos.
1, 3, 4,
(Qty. 11 Nos. 5),
6, 7, 8, A2
11
(Qty. 2 Nos. 12), 10 1
A3
Key Nos.
3&4 2
10
12
9
A4
14
Key Nos.
6, (Qty. 11
Nos. 5)
8 3
A5
7
Key Nos. 12
3, 6, (Qty. 11 4
Nos. 5) 13
6 LOCT IT E
5
35
01-50 Engine Cover LH
KEY PART NUMBER

No. 350 500 Nos.
A1 869002 869002 LH Cover Assembly - Black 1 Powder Coated 1
A2 573926/a 573926/A Clutch Operating Lever Clevis and Lock Pin Spring Assembly 1 1
A3 869003 869003 LH Cover Sub Assembly 1 Matt Black-Powder Coated 1
A4 888115 888115 Seal and Bolt Repair Kit LH Engine Cover 1 1
A5 888175 888175 Bolt, Bush & Seal Repair Kit LH Engine Cover 1 1
1 573925/A 573925/A Clutch Operating Lever and Clevis Assembly 1 1
2 570291/A 570291/A Lock Pin Spring, Clutch Operating Mech. 1 10
3 550061/B 550061/B Bush 1 1
4 Cover, LH - Black 1 869004 Served in Kit, Ref A3 1
5 572015/A 572015/A Hex Flange Bolt M6 X 1 X 30 11 20
6 550661/A 550661/A Oil Seal 1 1
7 502019/A 502019/A ‘O’ - Ring (Plug) 1 2
8 502018/B 502018/B Oil Filler Plug 1 1
9 570409/F 570409/F Clutch Cable Assembly 1 1
10 570407 570407 Oil Seal INA G 12 X 18 X 5, Clutch Operating Lever 1 1
11 570452/E 570452/E Spring, Clutch Operating Lever 1 20
12 570298/A 570298/A Dowel Pin 2 10
13 Liquid Gasket (Loctite 5699) - 30 ML (Liquid Sealent) 1 570278 Recommended Sealent 1
14 570410/F 570410/F Gasket LH Cover 1 After Market usage 10
36
01-60 Crankcase LH - Cover Side
A1 2
4
Key No’s
3
31 & 32 1 5
6 7
40 26
39
22
36
37
38
34 35
6 6
33
32
A1
23 20
22
31
21 19
18 8
30 18
29 24
25
27
17
28 16
9
350cc
15
5
14
10 9
11
12 500cc
13
37
KEY PART NUMBER

No. 350 500 Nos.
A1 592593/A 592593/A Sprag Clutch Gear Set Assembly (Tsubaki) 1 1
3 869001 869001 Housing Starter Drive - Powder Coated Matt Black 1 Alt. No. 570017/K 1
4 570025 570025 Hex. Socket Head Cap Screw, M6 x 90 4 10
5 593090/C 593090/C Nut M6 X 1, Flange Nyloc Type 22 Old No. 593090/A 30
6 570298/A 570298/A Dowel (6mm) 2 10
591494/A 591494/A Neutral Switch with Packing 1 Old Type 1
7
582510/A 582510/A Neutral Switch with Packing 1 New Type 1
8 570249/G 570249/G Collar, Mainshaft 1 1
570443/C Clutch Assembly Complete (6 Plates) - 350cc 1 1
9
571113/A Clutch Assembly Complete (7 Plates) - 500cc 1 1
10 570465/C 570465/C Plain Washer 1 20
11 593038/D 593038/D Hex. Nut with Nylock Insert M16 X 1.5 1 Old No. 560525/A 10
12 570442 570442 Ball Bearing 6001 1 1
13 570446/K 570446/K Clutch Push Pad 1 1
14 570090/D 570090/D Stud M6 X 106 L 1 25
15 570088/D 570088/D Stud M6 X 168 L 1 10
16 144636/A 144636/A Copper Washer (for Stud) 2 20
17 570089/D 570089/D Stud M6 X 196 L 2 10
19 573918/A 573918/A Auto Chain Tensioner Assembly - Pricol Powder Coated Matt Black 1 1
20 570295/A 570295/A ‘O’ Ring, Chain Tensioner Assembly 1 10
38
A1 2
4
Key No’s
3
31 & 32 1 5
6 7
40 26
39
22
36
37
38
34 35
6 6
33
32
A1
23 20
22
31
21 19
18 8
30 18
29 24
25
27
17
28 16
9
350cc
15
5
14
10 9
11
12 500cc
13
39
KEY PART NUMBER

No. 350 500 Nos.
21 570086/D 570086/D Stud M6 X 226 L 2 10
23 571221/A 571221/A Stud, Chain Tensioner Pad 1 Alt. No. 570095/e 20
24 570029/D 570029/D Chain Tensioner Pad 1 1
25 141246/C 141246/C Bush, Chain Tensioner Pad 1 6
26 Gasket Neutral Switch 1 After Market 10
27 586084/A 586084/A Flanged U Nut M8 X 1.25 1 Alt. No. 141051, Old Type 20
28 570414/B 570414/B Primary Chain 1 1
29 571216/A 571216/A Hex Flange Screw M12 X 1.25 X 25 1 Old No. 570064, Old Type 5
30 570063/F 570063/F Washer M12 Thick 5 MM 1 10
31 Engine Sprocket (Tsubaki) 1 570551/C Alt. No. 570070 1
32 570073 570073 Needle Bearing 1 N.S. 1
33 570074/I 570074/I Distance Washer, Sprag Clutch 1 1
35 570091/D 570091/D Stud M6 X 80 L 1 10
36 570007/F 570007/F Gear - Jack Shaft 1 1
37 500635/A 500635/A Key - Jack Shaft 1 20
38 570032 570032 Circlip 12 X 1N 1 20
39 570072/C 570072/C Shaft, Double Gear 1 1
40 570570/C 570570/C Double Gear - Starter Drive 1 With 2 bush 1
40
01-70 Clutch
A3 (500cc) 500CC 11
Key Nos. 9
10 12 7 Plate Clutch
(Qty. 7 Nos. 7),
(Qty. 6 Nos. 8) 8
7
6
4 5 A1
1 3
2
A1 6 Plate Clutch
11
9 12
10
8
7
6
350CC 5
4
1 3
2
A2 (350cc)
Key Nos.
(Qty. 6 Nos. 7),
(Qty. 5 Nos. 8)
41
01-70 Clutch
KEY PART NUMBER

No. 350 500 Nos.
570443/C Clutch Assembly Complete (6 Plates Kit) - 350cc 1 1
A1
571113/A Clutch Assembly Complete (7 Plates Kit) - 500cc 1 1
597459 Clutch Plates Kit - 350cc 1 1
A2
888102 Clutch Plates Kit - 500cc 1 1
1 570440 570440 Hex. Screw M6 6 10
2 570442 570442 Ball Bearing 6001 1 1
3 570447/B 570447/B Bearing Cup 1 1
4 570439/B 570439/B Holder, Clutch Spring 1 1
5 570438/B 570438/B Clutch Spring 6 6
6 570434/D 570434/D Clutch Hub / Back Plate 1 1
570436/C Clutch Friction Plate - 350cc 6 6
7
570436/C Clutch Friction Plate - 500cc 7 7
570437/C Clutch Plain Plate - 350cc 5 5
8
570437/C Clutch Plain Plate - 500cc 6 6
570435/B Wheel Clutch - (6 Plates Type) - 350cc 1 1
9
571100/A Wheel Clutch - (7 Plates Type) - 500cc 1 1
10 570451/B 570451/B Thrust Washer 1 2
11 570433/B 570433/B Clutch Drum / Sprocket 1 1
12 570441 570441 Needle Roller Bearing - SCE 228 1 1
42
01-80 Crankcase LH
1
16
15
2
3
4
5
4
10
12
9 6
11
13
14
7
8
43
01-80 Crankcase LH
KEY PART NUMBER

No. 350 500 Nos.
1 586005/A 586005/A Flange Hex Nut - M8 X 1.25 1 Old Type 593008/A, 145867/A 30
2 500104/D 500104/D Stud, M8 X 128L 3 2
3 570008/F 570008/F Jack Shaft 1 2
4 110037/3 110037/3 Circlip 62 X 2N 2 Alt. No. 110037/ 7 10
5 110050 110050 Ball Bearing 6305 C3 1 1
6 570006/E 570006/E Bearing Spacer Crankcase LH 1 10
7 570005/C 570005/C Bearing Spacer - LH Crankshaft 1 10
571205/A 571205/A NU 305E Cylinderical Roller Bearing with Cage, Single Row 1 Polymide Cage 1
8
570898/A 570898/A NU 305, ECP Cylinderical Roller Bearing 1 1
9 570201/F 570201/F Washer, Thrust 1 10
10 550032/A 550032/A Needle Bearing Counter Shaft 1 1
12 570012/C 570012/C Retainer Plate, Main Shaft Bearing 1 10
13 570087/D 570087/D Stud M6 X 133 L 2 10
14 570011 570011 Ball Bearing 6006 C3 1 1
15 570715/A 570715/A Copper Washer M8 2 8
16 570716/A 570716/A Nut M8 -Cylinder Head (Cap Nut) 2 8
44
01-90 Crankcase RH
42
A1 A2 2
3
53
Key No’s Key No’s 4 54
1
LOCT IT E 55
17 to 23 20 to 23 43
5
A3 52 44 45
50 46 40
49 47
Key No’s
48
21 to 23
51
52 9
6
7
8
10 9
11
13
12
14
25
15
24 26 39
27
16 38
37
28
21 29 36
22 56 35
A2 23
19 30
34
41
20
31
18
33
A1 32
17 18
45
01-90 Crankcase RH
KEY PART NUMBER

No. 350 500 Nos.
A1 570804 570804 Kick Starter Shaft Assembly 1 1
A2 570805/B 570805/B Kick Start Shaft Sub Assembly 1 1
A3 888182 888182 Kick Pawl, Plunger and Spring Kit 1 1
A4 Conrod Kit (UCE 350 / 500) 1 1
1 570097/B 570097/B Hydraulic Valve Lifter Roller 2 1
2 586005/A 586005/A Flange Hex Nut - M8 X 1.25 1 Old Type 593008/A, 145867/A 30
3 570716/A 570716/A Nut M8 - Cylinder Head (Cap Nut) 2 8
5 500104/D 500104/D Stud, M8 X 128 3 2
6 570141/E 570141/E Bracket - Pin - Hydraulic - Tappet 1 2
500355 Hex Socket Head Cap Screw M6 X 16 1 10
7
570232 Hex. Socket Head Cap Screw, M6 X 12 1 10
570125 Needle Roller -NRB-Type-BP-DIA 4 X 37 L 1 10
8
571116/B Needle Roller - DIA. 4 X 29.8L (Lockpin Hydraulic Tappet) 2 10
9 120005/B 120005/B Dowel - Hallow (Centre Crankcase) 2 20
10 570037 570037 Bearing NRB (NBI 30 X 45 X 20) 1 1
11 570028 570028 Locating Pin, (Pivot) - NRB 3 X 21.8 1 10
12 550032/A 550032/A Needle Bearing - Layshaft TS 1 1
13 570201/F 570201/F Washer, Thrust 1 10
14 570208/B 570208/B Needle Bearing 1 1
15 570206/J 570206/J Sleeve Gear 1 1
16 570207 570207 Needle Bearing - INA HK 2012 1 1
17 570209 570209 Circlip 18N 1 20
46
01-90 Crankcase
01-30 CrankcaseRH RH
42
A1 A2 2
3
53
1
LOCT IT E 55
17 to 23 20 to 23 43
5
A3 52 44 45
50 46 40
49 47
Key No’s
48
21 to 23
51
52 9
6
7
8
10 9
11
13
12
14
25
15
24 26 39
27
16 38
37
28
21 29 36
22 56 35
A2 23
19 30
34
41
20
31
18
33
A1 32
17 18
47
01-90
01-30Crankcase
CrankcaseRH RH
KEY PART NUMBER

No. 350 500 Nos.
18 550030/C 550030/C Washer Thrust 2 10
19 570248/D 570248/D Kick Start Gear with Bush 35T 1 1
20 Kick Starter Shaft 1 570806/D 1
21 140333/B 140333/B Pawl Kick 1 Served in Kit, Ref. A3 1
22 140332/B 140332/B Plunger Kick Starter 1 Served in Kit, Ref. A3 10
23 140331/A 140331/A Spring Kick 1 Served in Kit, Ref. A3 50
24 110037/3 110037/3 Circlip 62 x 2N 1 10
25 570469/A 570469/A Deep Groove Ball Bearing - Sleeve Gear 1 1
26 550082/C 550082/C Pawl, Cam Plate 1 Old Type 2
27 550083/B 550083/B Spring, Pawl 1 10
550087 550087 Machined Washer 6.4 1 Old Type 10
28
570664/A 570664/A Washer Shift Cam Plate Stopper 1 Anti Skip Mechanism 10
29 570702/A 570702/A Hex. Nut M6X1 ( U-type Nut) 1 5
30 570240 570240 Hex Socket Head Cap Screw M5 X 35 3 10
31 570239/C 570239/C Oil Thrower 1 10
32 146714/A 146714/A Hex Screw M8 X 23 1 10
33 142257/B 142257/B Stop Plate (KSS) 1 5
34 570431 570431 Hex. Flange Bolt M5 X 16 2 20
35 869023 869023 Sump Drain Cap Assembly with Magnetic Tip, Matt Black-Powder Coated 1 Alt. No. 570078/D 4
36 570057/B 570057/B ‘O’ Ring - Drain Cap 1 10
37 570054/G 570054/G Suction Filter Assembly 1 5
38 570276/D 570276/D Magnetic Plug Assembly (Oil Drain Bolt) 1 2
48
01-90 Crankcase RH
42
A1 A2 2
3
53
1
LOCT IT E 55
17 to 23 20 to 23 43
5
A3 52 44 45
50 46 40
49 47
Key No’s
48
21 to 23
51
52 9
6
7
8
10 9
11
13
12
14
25
15
24 26 39
27
16 38
37
28
21 29 36
22 56 35
A2 23
19 30
34
41
20
31
18
33
A1 32
17 18
49
01-90 Crankcase RH
KEY PART NUMBER

No. 350 500 Nos.
39 144846/A 144846/A Washer Drain Plug (Inspection Screw Ignition Timing) 1 14
40 573983/A 573983/A Bolt, Pawl ( White Passivation) 1 2
571170/C Crank Shaft Assembly (UCE 350) 1 1
41
571172/C Crank Shaft Assembly (UCE 500) 1 1
42 Loctite 5699 (Alternate : Liquid Sealent 5702) 30 ML 1 570278 Recommended Sealent 1
43 570481 570481 Hex Flange Bolt M5 X 12 1 20
44 144636/A 144636/A Copper Washer 1 20
45 570468/B 570468/B Cap, Pivot Pin 1 5
46 146031/A 146031/A ‘O’ Ring, Oil Pump Outlet 1 14
47 550108 550108 ‘O’ Ring 1 20
48 570218/C 570218/C Pivot, Cam Plate 1 4
49 570186/D 570186/D Crank Pin 1 1
50 570185/B 570185/B Connecting Rod Assembly 1 1
51 570193/B 570193/B Bearing Needle Roller - Conrod 1 1
52 570187/B 570187/B Thrust Washer - Conrod 2 10
53 572338/B 572338/B Hex. Flange Bolt Anti Skip Plate M6 X 1 X 20 1 Alt No. 586042/A 10
55 570665/B 570665/B Plate Anti Skip 1 1
56 570658/B 570658/B Stopper Assy. Shift Cam Plate (Roller Type) 1 Anti Skip Mechanism 1
50
01-100 Gear Train Assembly (Old Type)
A1
1
2
Key No’s 21 A3
22
8 to 14
A2
Key No’s 4 3
12 (2 Nos), 5
6
15 to 20
7 13
14
A3
8
Key No’s A1 9
1, 2 & 21
12 15
11
10
A2
16
12
18 12 17
19
20
51
KEY PART NUMBER

No. 350 500 Nos.
A1 570157 570157 Lay Shaft Sub Assembly 1 1
A2 570158/B 570158/B Main Shaft Sub Assembly 1 1
A3 570615 570615 Cam Plate, Neutral Pin with Rollers Complete UCE 1 1
1 550075/A 550075/A Roller 4 12
2 Cam Plate Assembly 1 570216/E Served in Kit, Ref. A3
3 550091/C 550091/C Selector Fork Long RH 1 1
4 550081/C 550081/C Selector Fork Short (Centre) 1 1
5 550090/C 550090/C Selector Fork Middle LH 1 1
6 550078/A 550078/A Selector Fork Shaft 1 2
7 550141 550141 Circlip (10N) 1 20
8 570202/E 570202/E Lay Shaft 1st Gear Assembly (with Bush) 1 1
9 550030/C 550030/C Washer Thrust 1 10
10 550011/C 550011/C Lay Shaft 3rd Gear / 4th Double Gear 1 1
11 550216/D 550216/D Lay Shaft 1 1
12 550023/E 550023/E Washer, Thrust 1 5
13 570596/B 570596/B Lay Shaft 2nd Gear Assembly (with Bush) 3 1
14 550007/C 550007/C Lay Shaft High Gear 1 1
15 550008/B 550008/B Main Shaft 2nd Gear 1 1
16 570205/N 570205/N Main Shaft UCE 5S 1 1
17 570823/A 570823/A Main Shaft 4th Gear Assembly (with Bush) 1 1
18 550024 550024 Circlip 1 14
19 570821/A 570821/A Main Shaft 3rd Gear Assembly (with Bush) 1 1
20 570204/H 570204/H Main Shaft 1st Gear 1 1
52
A1
1
2
Key No’s 21 A3
22
8 to 14
A2
Key No’s 4 3
12 (2 Nos), 5
6
15 to 20
7 13
14
A3
8
Key No’s A1 9
1, 2 & 21
12 15
11
10
A2
16
12
18 12 17
19
20
53
KEY PART NUMBER

No. 350 500 Nos.
21 550119/B 550119/B Neutral Pin, Finder 1 10
22 572044/A 572044/A Washer Special Cam Plate Assembly (Top Side) 1 5
54
01-110 Gear Train Assembly (Anti Skip Mechanism)
A1 A3
1
Key No’s 21
2
8 to 14 22
A2
Key No’s
(Qty. 3 Nos. 12), 4
5 3
15 to 20 6
7 13
A1 14
A3
8
Key No’s
1, 2 & 21 9
12 15
11
A2 10
16
12
18 12 17
19
20
55
KEY PART NUMBER

No. 350 500 Nos.
A1 570157 570157 Lay Shaft Sub Assembly 1 1
A2 570158/B 570158/B Main Shaft Sub Assembly 1 1
A3 570706/B 570706/B Cam Plate, Neutral Pin with Rollers Complete UCE (Anti Skip Mechanism) 1 1
1 550075/A 550075/A Roller 4 12
2 Cam Plate Assy. (Anti Skip Mechanism) 1 570707/B New Type, Served in Kit, Ref.A3 1
3 550091/C 550091/C Selector Fork Long 1 1
4 550081/C 550081/C Selector Fork Short (Centre) 1 1
5 550090/C 550090/C Selector Fork Middle (Length Cut) 1 1
6 550078/A 550078/A Shaft, Selector Fork 1 2
7 550141 550141 Circlip 10 N 1 20
8 570202/E 570202/E Assy., Layshaft 1st Gear 1 1
9 550030/C 550030/C Washer, Thrust MS & L 1 10
10 550011/C 550011/C Layshaft 3rd / 4th Gear 1 1
11 550216/D 550216/D Layshaft 1 1
12 550023/E 550023/E Washer, Thrust 3 5
13 570596/B 570596/B Assy., Layshaft 2nd Gear 1 1
14 550007/C 550007/C Layshaft High Gear 1 1
15 550008/B 550008/B Mainshaft 2nd Gear 1 1
16 570205/N 570205/N Mainshaft 1 1
17 570823/A 570823/A Assy., 4th Gear Main Shaft 1 1
18 550024 550024 Circlip, Din:5108 Inv. External, Dia 24 1 14
19 570821/A 570821/A Assy., 3rd Gear, Main Shaft 1 1
20 570204/H 570204/H Main Shaft 1st Gear 1 1
56
A1 A3
1
Key No’s 21
2
8 to 14 22
A2
Key No’s
(Qty. 3 Nos. 12), 4
5 3
15 to 20 6
7 13
A1 14
A3
8
Key No’s
1, 2 & 21 9
12 15
11
A2 10
16
12
18 12 17
19
20
57
KEY PART NUMBER

No. 350 500 Nos.
21 550119/B 550119/B Pin, Neutral Finder 1 10
22 572044/A 572044/A Washer - Cam Plate (Top Side) 1 1
58
02-00 CV Carburetor (BS 29)
A1 A2 A3 A4 A5 A6 A7
Key No’s Key No’s Key No’s Key No’s Key No’s Key No’s Key No’s
35, 36, 37, 43 & 44 27 & 45 11, 14, 26, 33 28, 29 & 30 12, 13 & 46 12, 16, 21, 35, 2, 5, 9, 10, 12, 15, 16, 18, 21,
44, 45, 47 & 50 31, 32, 35, 44, 45, 47 & 50
32
11
14
50
5
1 2 2 34
6
7
8
9 48
49
15
42 41 3 10 16
40 38 47 31
17
30 35 36
18
37
4 46 19 29 43
20 44
12 22 28
21
23
39 13
24 27
25
33
45
26
A5
59
KEY PART NUMBER

No. 350 500 Nos.
A1 888083 Mixture (Pilot) Screw Repair Kit CV Carb BS 29 1 2
A2 888084 Drain Screw Repair Kit CV Carb BS 29 1 2
A3 888085 Drain and Vent Pipe Kit CV Carb BS 29 1 2
A4 888086 Idle Screw Repair Kit CV Carb BS 29 1 2
A5 570944 Piston Valve and Diaphragm Assembly Kit - CV Carb. BS 29 1 1
A6 888224 Carburetor BS 29 Minor Kit 1 1
A7 888225 Carburetor BS 29 Major Kit 1 1
1 570282/K Carburetor BS 29 1 570282/H New Type, Pilot Air Screw 1
Press Fit, > Apr. ‘12
2 570936 Top Cover Fixing Screw - CV Carb. (Shank Type) 2 10
3 570943 Diaphragm Top Cover - CV Carb. (PET Type - Single Piece) 1 Old No. 500831/A or 570831/A 3
New Type, > Mar. 2013
4 570833/A Piston Valve Spring - CV Carb. 1 2
5 500848 Jet Needle Plate Fixing Screw - CV Carb. 2 10
6 500836 Jet Needle Fixing Plate - CV Carb. 1 10
7 500837 Jet Needle Retainer Spring - CV Carb. 1 10
8 500839 Jet Needle Washer - CV Carb. 1 10
9 500838 Jet Needle “E” - Ring - CV Carb. 1 10
10 570834/A Jet Needle - CV Carb. (4DHL42-2/3) 1 2
11 570874/A Clip, Air Vent - CV Carb. 1 Served in Kit, Ref. A3 20
12 500835 Diaphragm - CV Carb. 1 Alt. No. Ref. A5 (N.S) 1
13 500834 Diaphragm Retainer Ring - CV Carb. 1 Served in Kit, Ref. A5 10
14 570873/A Air Vent Hose - CV Carb. 1 Served in Kit, Ref. A3, 5
Alt. No. 570843
60
A1 A2 A3 A4 A5 A6 A7
35, 36, 37, 43 & 44 27 & 45 11, 14, 26, 33 28, 29 & 30 12, 13 & 46 12, 16, 21, 35, 2, 5, 9, 10, 12, 15, 16, 18, 21,
44, 45, 47 & 50 31, 32, 35, 44, 45, 47 & 50
32
11
14
50
5
1 2 2 34
6
7
8
9 48
49
15
42 41 3 10 16
40 38 47 31
17
30 35 36
18
37
4 46 19 29 43
20 44
12 22 28
21
23
39 13
24 27
25
33
45
26
A5
61
KEY PART NUMBER

No. 350 500 Nos.
15 570835/A Needle Jet - CV Carb. (P-2M-922) 1 2
16 500845 ‘O’ Ring Jet Holder - CV Carb. 1 Alt. No. 570845/A 10
17 570838/A Main Jet Holder - CV Carb. 1 2
18 570837/A Main Jet (BS29-110) 1 2
19 500846 Float Pin - CV Carb. 1 2
20 500847 Float Pin Fixing Screw - CV Carb. 1 10
21 500841 ‘O’ Ring Float Chamber Cover - CV Carb. 1 2
22 500843 Float Assembly - CV Carb. 1 2
23 570732/B Float Body Assembly New Type - CV Carb. 1 OldNo.500860 With ‘O’ Ring type Drain Screw 1
and ‘L’ Type Bend, > Apr. ‘12
24 141963 Spring Washer - CV Carb. 2 20
25 500842 Screw Bowl MTG with Washer - CV Carb. 2 10
26 570842/A Hose Drain - CV Carb. 1 Served in Kit, Ref. A3 5
27 500871 Screw - Drain - CV Carb. 1 Served in Kit, Ref. A2 2
28 500857 Idle Adjuster Screw - CV Carb. (Yellow) 1 Served in Kit, Ref. A4 1
29 500856/A Packing, Idle Adjusting Screw - CV Carb. (White Plastic) 1 Served in Kit, Ref. A4 20
30 500855 Spring, Idle Adjusting - CV Carb. (Yellow) 1 Served in Kit, Ref. A4 10
31 570840/A Pilot (Slow) Jet (BS 29-12.5) - CV Carb. 1 2
32 570839/A Pilot Air Jet - CV Carb. (Thread Type - ID 1.2) 1 Old Type < Apr’ 2012 2
33 500874 Clip Drain Hose - CV Carb. 1 Served in Kit, Ref. A3 10
34 570841/A Plunger Assembly - CHOKE - CV Carb. 1 1
35 500870 ‘O’ Ring Pilot Screw Front - CV Carb. 1 Served in Kit, Ref. A1 20
36 500869 Washer Pilot Screw - CV Carb. 1 Served in Kit, Ref. A1 20
62
A1 A2 A3 A4 A5 A6 A7
35, 36, 37, 43 & 44 27 & 45 11, 14, 26, 33 28, 29 & 30 12, 13 & 46 12, 16, 21, 35, 2, 5, 9, 10, 12, 15, 16, 18, 21,
44, 45, 47 & 50 31, 32, 35, 44, 45, 47 & 50
32
11
14
50
5
1 2 2 34
6
7
8
9 48
49
15
42 41 3 10 16
40 38 47 31
17
30 35 36
18
37
4 46 19 29 43
20 44
12 22 28
21
23
39 13
24 27
25
33
45
26
A5
63
KEY PART NUMBER

No. 350 500 Nos.
37 500862 Spring Pilot Screw - CV Carb. 1 Served in Kit, Ref. A1 20
38 143144/2 Clip Carb Flange - CV Carb. 2 Alt. No. 146882/A 2
39 570261/B Flange (Carburetor to Cylinder Head) - CV Carb. 1 1
40 521200/A ‘O’ Ring Flange 1 5
41 571206/A SS Hex Socket Head Cap Screw M6 X 25 2 New Type 10
42 144636/A Sealing Washer 2 10
43 570844/B Adjuster ‘E’ Pilot (Mixture) Screw - CV Carb. 1 Modified Taperness, 2
Alt. No. Ref. A1
44 570846/A ‘O’ Ring - Mixture / Pilot Screw Head - CV Carb. 1 Served in Kit, Ref. A1 20
45 570845/A ‘O’ Ring - Drain Screw - CV Carb. 1 Served in Kit, Ref. A2 20
46 570832/A Piston C.V Carburetor (BS 29) 1 Served in Kit, Ref. A5 1
47 570836/B Needle Assy. 1.5 - (BS 29) 1 5
48 500872 Cap Throttle Shaft 1 5
49 571253 Shim Jet Needle 1 5
50 570940/A ‘O’ Ring Plunger Assembly Choke 1 10
64
02-10 EFI Components in Cylinder Head
A1 A2 A3 A4
Key No’s Key No’s Key No’s Key No’s

12, 13 & 14 3, 4 & 5 3&8 5, 6, 10, 12 to 17
15 14 12 13
10
23
10 7
17 16
22
24 7
9
21
19
10 9 7 6 5 4 2 1
20
18 9 7 8 3
11
65
KEY PART NUMBER

No. 350 500 Nos.
A1 571086 Injector Kit Assembly 1 1
A2 888183 Insulator Kit 1 1
A3 888192 Adaptor with PAV Connection & ‘O’ Ring Kit 1 1
A4 888176 Sub Assembly Manifold - Inlet, Thunderbird 500 1 1
1 Cylinder Head (500cc) Black 1 869045 1
2 571055/A Engine Temperature Sensor with ‘O’ Ring 1 1
3 521200/A ‘O’ Ring for Insulator and Adaptor 2 2
4 571079/D Insulator 1 N.S., Ref. A2
5 144981/B ‘O’ Ring for Manifold 1 10
6 869025 Manifold - Inlet - Black 1 Matt Black-Powder Coated 1
7 144636/A Copper Washer M6 4 10
8 572304/A Adaptor with PAV Connection 1 1
9 571206/A Hex. Socket Head Cap Screw M6 X 25 4 10
10 593055/A Hex. Nut with Nylon Insert M6 3 10
11 571051/B Throttle Body Assy. 1 1
12 571053/A Injector 1 N.S., Ref. A1
13 571090/A Seal Ring 1 10
14 571087/A ‘O’ Ring, Injector (I.D 7.47 X Wire Dia 3.6) 1 10
15 571088/C Cap, Injector Assembly 1 1
16 573935/A Spacer - EFI 1 1
17 571249/A Stud Injector M6 1 Alt. No. 573966/A, Old Type 1
18 143144/2 Clip Hose - Adaptor 1 1
19 572607/A ‘O’ Ring - Temperature Sensor 1 10
66
A1 A2 A3 A4
Key No’s Key No’s Key No’s Key No’s

12, 13 & 14 3, 4 & 5 3&8 5, 6, 10, 12 to 17
15 14 12 13
10
23
10 7
17 16
22
24 7
9
21
19
10 9 7 6 5 4 2 1
20
18 9 7 8 3
11
67
KEY PART NUMBER

No. 350 500 Nos.
20 571226/A Valve BI-Starter 1 2
21 571227/A Spring Compression Valve BI-Starter 1 10
22 571228/A Holder Cable Valve 1 5
23 571229/A Guide Cable Valve 1 5
24 571230/A Cap Cable Sealing 1 10
68
A1
Key Nos.
1 to 14 1
A2
14
Key Nos.
2
2, 4, 6, 8,
(Qty. 5 Nos. 9)
4
7 5
6
7
12
8 13
11
9
10
9
69
KEY PART NUMBER

No. 350 500 Nos.
A1 580559 Air Filter Assembly Complete 1 1
A2 521237 Air Filter Assembly 1 1
1 586025/A Flange Hex Bolt M8 X 16 2 Old No. 591534/a 30
2 521238/B Air Filter Body 1 1
3 141051 Hex Nut M8 3 1
4 521129/B ‘O’ Ring 1 1
5 521172/A Air Filter Element (350cc) 1 1
6 521093/D Cover, Filter Element 1 2
7 142065 Slotted Cheese Head Screw M5 X 20 3 40
8 521092/D Lid - Air Filter 1 10
9 521125 Cross Recessed Pan Head Screw M5 X 25 5 40
10 141560 Air Polution Sticker 1 10
11 572611/A Clip Hose 1 Alt. No. 500712/2 1
12 500823/B Bellow Air Filter Outlet 1 1
13 147897/B Hose Clip 1 1
14 586036/A Washer 2 Old No. 140437/1, 593028/A, 140080/2 20
70
A1
Key Nos.
1 to 14 A1
10
A2
9
Key Nos.
2 to 5, 7, 8, 13
(Qty. 4 Nos. 1)
A3
8
Key Nos. 6 14
4&5 11 13
12
7
6
5
4
3
2
1
71
KEY PART NUMBER

No. 350 500 Nos.
A1 581114/A Air Filter Assembly Complete 1 1
A2 581004/E Air Filter Assembly 1 1
A3 888127 Air Filter with Cover 1 1
1 142095 Slotted Cheese Head Screw M5 X 18 4 20
2 581006/B Air Filter - LID 1 1
3 586004/A Hex Nut with Nylock Insert M8 1 Old No. 593030/A, 142182/A 30
4 581008/A Cover - Filter Element 1 2
5 581007/A Air Filter Element 1 1
6 586014/A Flanged Hex. Bolt M8 X 1.25 X 10 2 Old No. 145872/A 10
7 581005/D Air Filter Body 1 1
8 581044/C Arrester Comp. – Air Filter 1 1
9 500712/A Clip Hose 1 6
10 500823/B Bellow (C.V. B) 1 1
11 111098/2 Washer, Plain 1 20
12 560506 Hex. Socket Head Cap Screw M8 X 25 1 5
13 ‘O’ Ring 1 581009/A 5
500917/B Strap - White 1 Alt. No. 582511/A 10
14
582511/A Strap - Black 1 Old No. 500917/B 10
72
02-40 Silencer & Exhaust Pipe
A1 16
15
Key Nos.
ALL
16
7
10
6 8
5
2 8
3 9
17 14
14 14
New Type
4
13 14
12
14
Old Type 11
73
02-40 Silencer & Exhaust Pipe
KEY PART NUMBER

No. 350 500 Nos.
888210 Exhaust Pipe Assembly Kit (350cc) 1 1
A1
888211 Exhaust Pipe Assembly Kit (500cc) 1 1
A2 888209 888209 Silencer Assembly Kit TB 350 / 500 cc 1 1
594191/B Exhaust Pipe Assembly - 350cc 1 1
1
594076/B Exhaust Pipe Assembly - 500cc 1 1
2 594077/B 594077/B Silencer Assembly 1 Served in Kit, Ref. A2 1
3 867072 867072 End Cone Silencer (Cup) 1 Dual Tone Colour 1
4 581122/A 581122/A Mushroom Head Screw, M6 X 8 X 1 3 10
5 594079/B 594079/B Bracket - Silencer Front Mounting 1 1
6 586038/A 586038/A Spring Washer M8 2 Old No. 210026 50
7 586025/A 586025/A Flange Hex Bolt M8 X 16 2 Old No. 591534/A 30
8 586032/A 586032/A Plain Washer 2 Old No. 141061/ 1 50
9 591578/A 591578/A Flanged Hex. Bolt, M6 X 1 X 35 1 10
10 586029/A 586029/A Hex. Nut M6 1 Old No. 141060 40
11 594081/B 594081/B Exhaust Guard (with Clip) 1 Old Type, < Feb. ‘13 1
12 500711/A 500711/A Hose Clip 2 Old Type, < Feb. ‘13 2
13 594209/A 594209/A Guard - Silencer 1 1
147896/A 147896/A Philips Pan Head Screw M6 X 6 3 Old Type 10
14
147896/A 147896/A Philips Pan Head Screw M6 X 6 5 New Type 10
15 582638/A 582638/A Gasket - Exhaust Pipe (Copper Type) 1 Old No. 510804/A 10
16 586005/A 586005/A Flanged Hex. Nut M8 X 1.25 2 Old Type 593008/A, 145867/A 5
17 594474/C 594474/C Guard - Exhaust Pipe (without Clip) 1 New Type, > Mar. ‘13 1
74
03-00 Handle Bar & Controls
A1 A2 A3 A4
Key Nos. Key Nos. Key Nos. Key Nos.

1, (Qty. 2 Nos. 2), 3, 4, 8&9 7, 13, (Qty. 2 Nos. 14) 18 & 21
(Qty. 4 Nos. 5), 6, 7, 10,
11, 12, 14 & 23 6
18 21
19
13
14 17 20 22
16 23
15
14
7
(500cc)
12
Choke Lever
1
4
11
5 2 3
10 8 9 2
10
24
25
12
(350cc)
75
KEY PART NUMBER

No. 350 500 Nos.
594397/A Handle Bar Assembly - 350cc 1 1
A1
594004/A Handle Bar Assembly - 500cc 1 1
A2 888193 888193 Mirror Set - Thunderbird (Black) 500cc 1 1
A3 888168 888168 Clutch Switch Repair Kit 1 1
A4 888128 888128 Clutch & Front Brake Lever Kit 1 Clear Coated 1
1 594005/B 594005/B Handle Bar Comp. (Classic) 1 1
2 580404/A 580404/A Damper Weight (Nickle Plated) 2 2
146044/A Hand Grip Comp. (with Rotor) Throttle Assembly - 350cc 1 1
3
581098/A Grip Comp. Throttle RH (Twin Cable Type) - 500cc 1 1
560195/A Switch Module RH - 350cc 1 Single Hole Throttle Cable 1
4
581097/A Switch Module RH - 500cc 1 Two Holes for Twin Cable 1
5 594425/A 594425/A Cable Tie 4 Alternate No. 560195/A 10
6 581083/A 581083/A Lever and Holder Assembly LH 1 1
7 560632/A 560632/A Clutch Switch 1 Served in Kit, Ref. A3 5
8 594013/A 594013/A Rear View Mirror - LH 1 Served in Kit, Ref. A2 2
9 594014/A 594014/A Rear View Mirror - RH 1 Served in Kit, Ref. A2 2
10 594426/A 594426/A Counter Weight Screw, M8 X 50 (White) 2 Old No. 521202/a 10
11 521186/A 521186/A Grip LH FR Counter Weight 1 1
580441/A Switch Module LH - 350cc 1 1
12
581029/A Switch Module LH - 500cc 1 With Choke Lever 1
13 147270/A 147270/A Add on Lead Clutch Switch 1 Served in Kit, Ref. A3 5
14 Screw Clutch Switch 2 560633/A Served in Kit, Ref. A3 10
15 Stud Release Lever 1 591975 10
76
A1 A2 A3 A4
Key Nos. Key Nos. Key Nos. Key Nos.

1, (Qty. 2 Nos. 2), 3, 4, 8&9 7, 13, (Qty. 2 Nos. 14) 18 & 21
(Qty. 4 Nos. 5), 6, 7, 10,
11, 12, 14 & 23 6
18 21
19
13
14 17 20 22
16 23
15
14
7
(500cc)
12
Choke Lever
1
4
11
5 2 3
10 8 9 2
10
24
25
12
(350cc)
77
KEY PART NUMBER

No. 350 500 Nos.
16 Screw 1 591972 10
17 Washer 1 591973 10
18 594635/A 594635/A Lever Assy. LH - Clutch (P.U. Clear Coated) 1 Alt. No. 418083 1
19 Nut Nyloc 1 591974 10
20 Bracket LH Lever (Holder) 1 594683 Alt. No. 143332 1
21 Lever RH - Disc Brake (P.U. Clear Coated) - BBI 1 594621 Alt. No. 594551/A 1
22 592857/B 592857/B Add On Lead (Disc Brake) 1 5
23 Mirror Thread Guard 2 141460/A N.S. 10
24 591521/A 591521/A Rotor Plate 1
25 591522/A 591522/A Pan Head Screw M5 X 10 10 20
78
03-10 Control Cables
A1 (350cc) A1 (500cc)
Key Nos. Key Nos.

1&2 1, 2 & 3
350cc 500cc
1 1
1
3
3 2
79
03-10 Control Cables
KEY PART NUMBER

No. 350 500 Nos.
888186 Control Cable Kit Thunderbird - 350cc 1 1
A1
888187 Control Cable Kit Thunderbird - 500cc 1 1
580387/D Throttle Cable 1 1
1
594279/A Throttle Cable Assembly (Twin Cable) 1 1
2 570409/E 570409/E Clutch Cable Assembly (350cc) 1 1
3 594278/A Choke Cable Assembly 1 1
80
03-20 Front Master Cylinder Assembly - BBI
A1 A2
17 17
Key Nos. Key Nos. 24
All except 26, (Qty. 2 Nos. 27)
26 to 28 (Qty. 4 Nos. 28)
16 30 27 28 28
A3 A4
11 23
Key Nos. Key Nos.
14, 15, 16, 23 & 24
(Qty. 2 Nos. 17) 10
A5 A6 15 9
Key Nos. Key Nos.
(Qty. 2 Nos. 27)
2 16 & 172to
(Qty. 4 Nos. 28)
12
3 4 26
A7 A8 14 8
Key Nos. Key Nos. 5

2 to 8 & 31 2,2 to 5 & 315
A9 A10 25
2 6 7
Key Nos. Key Nos. 1
18,19 & 202 21 & 222 22
13 29
A11 A12 A13 19
Key Nos. Key Nos. Key Nos. 18 22 27 28 28

All except 21
14 & 152 9,11,12 & 31
9, 26 to 28 20
81
KEY PART NUMBER

No. 350 500 Nos.
A1 594631/A 594631/A Master Cylinder Assembly with Brake Lever - (BBI) 1 Alt. No. 592825/A 1
A2 594704/A 594704/A Front Brake Hose Assy. and Banjo Bolt Kit Front M/C 1 1
A3 888009 888009 Reservoir Cover Kit and Diaphragm Front M/C 1 1
A4 594710/A 594710/A Switch Repair Kit Front Brake - (BBI) 1 1
A5 594712/A 594712/A Reservoir Cover Kit Front M/C 1 1
A6 594721/A 594721/A Banjo Bolt Kit 1 1
A7 594705/A 594705/A Major Kit Front Master Cylinder Front M/C 1 1
A8 594706/A 594706/A Minor Kit Front Master Cylinder Front M/C 1 1
A9 594707/A 594707/A Oil Window Kit Front M/C 1 1
A10 594708/A 594708/A Clamp Kit Front M/C 1 1
A11 594709/A 594709/A Diaphragm Kit Front M/C 1 1
A12 594711/A 594711/A Lever Brake Kit Front M/C - Buffed 1 Clear Coated 1
A13 Master Cylinder without Brake Lever 1 Common 1
1 Master Cylinder Body Front 1 594602/A N.S., Served in Kit, Ref. A1
2 Piston - Front Master Cylinder 1 594603/A N.S., Served in Kit, Ref. A7, A8
3 Primary Seal Disc 1 594604/A N.S., Served in Kit, Ref. A7, A8
4 Secondary Seal Disc 1 594605/A N.S., Served in Kit, Ref. A7, A8
5 Spring Disc 1 594606/A N.S., Served in Kit, Ref. A7, A8
6 Circlip Disc 1 594607/A N.S., Served in Kit, Ref. A7,
7 Boot Disc 1 594608/A N.S., Served in Kit, Ref. A7,
8 Push Rod Disc 1 594609/A N.S., Served in Kit, Ref. A7,
9 Brake Lever (Clear Coated) 1 594621/A N.S., Served in Kit, Ref. A12
10 Shim FR Disc 1 594610 N.S., Served in Kit, Ref. A1
82
A1 A2
17 17
Key Nos. Key Nos. 24
All except 26, (Qty. 2 Nos. 27)
26 to 28 (Qty. 4 Nos. 28)
16 30 27 28 28
A3 A4
11 23
Key Nos. Key Nos.
14, 15, 16, 23 & 24
(Qty. 2 Nos. 17) 10
A5 A6 15 9
Key Nos. Key Nos.
(Qty. 2 Nos. 27)
2 16 & 172to
(Qty. 4 Nos. 28)
12
3 4 26
A7 A8 14 8
Key Nos. Key Nos. 5

2 to 8 & 31 2,2 to 5 & 315
A9 A10 25
2 6 7
Key Nos. Key Nos. 1
18,19 & 202 21 & 222 22
13 29
A11 A12 A13 19
Key Nos. Key Nos. Key Nos. 18 22 27 28 28

All except 21
14 & 152 9,11,12 & 31
9, 26 to 28 20
83
KEY PART NUMBER

No. 350 500 Nos.
11 Bolt Handle Lever 1 594611/A N.S., Served in Kit, Ref. A12
12 Hex. Nut Lever Disc 1 594612/A N.S., Served in Kit, Ref. A12 10
13 Cap Sub Assembly Disc 1 594613/A N.S., Served in Kit, Ref. A1
14 Diaphragm Front Disc 1 592257/A N.S., Served in Kit, Ref. A3, A11
15 Plate Diaphragm Disc 1 592258/A N.S., Served in Kit, Ref. A3, A11
16 Reservoir Cover Front Disc 1 594614/A N.S., Served in Kit, Ref. A3, A5
17 Reservoir Screw Disc 2 592260/A N.S., Served in Kit, Ref. A3,A5
18 Window Assembly FR Disc 1 594615/A N.S., Served in Kit, Ref. A9
19 ‘O’ Ring FR Disc 1 594616/A N.S., Served in Kit, Ref. A9
20 Clip FR Disc 1 594617/A N.S., Served in Kit, Ref. A9
21 Clamp FR Disc 1 594618/A N.S., Served in Kit, Ref. A10
22 Screw Clamp 2 594619/A N.S., Served in Kit, Ref. A10
23 Switch Assembly Front 1 580892/A N.S., Served in Kit, Ref. A4
24 Screw Switch FR M/C 1 594620/A N.S., Served in Kit, Ref. A4
25 Thread Protector 1 N.S.
26 Brake Hose Assembly - Black Trivalant 1 594622/A N.S., Served in Kit, Ref. A2
27 Banjo Bolt Disc 2 594507/A N.S., Served in Kit, Ref. A2, A6
28 Copper Washer Disc 4 594508/A N.S., Served in Kit, Ref. A2, A6
29 Mirror Thread Guard 1 141460/A N.S., Served in Kit, Ref. A1
30 582519/A 582519/A Addon Lead Front Brake Switch - Disc (BBI) 1 Alt. No. 592857/a 10
31 Grease Pouch (Reference only) 1 594728/A N.S., Served in Kit,
Ref. A7,A8, A12
84
03-30 Front Caliper Assembly - BBI
A1 A2 A3 A4 A5 A6 A7 A8 A9
Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos.
All Except 18 to 20, All Except 18 14 & 15 19, (Qty. 2 Nos. 20) 4, 10 & 21 2, 3, 4, 7, 8, 3, 4, 7, 8, 5&9 3, 11, 17, 21 & 22
(A1, A2 in 12, 13 & 21 12, 13 & 21
Page No. 76)
9
6
5
14 15
18
8 7 2
18
3 22
16 11
1
13 12
19 20 20 4
10
17
85
KEY PART NUMBER

No. 350 500 Nos.
A1 594517/A 594517/A Disc Brake System Assembly Kit Front - (BBI) 1 1
A2 147649/B 147649/B Caliper Assembly - (BBI) 1 1
A3 594715/A 594715/A Disc Pad Kit Front - (BBI) 1 1
A4 594721/A 594721/A Banjo Bolt Kit (Disc Brake Caliper) 1 1
A5 594720/A 594720/A Primary Pin Kit Front Caliper - (BBI) - Thunderbird 1 1
A6 594713/A 594713/A Major Kit Front Caliper - (BBI) 1 1
A7 594714/A 594714/A Minor Kit Front Caliper - (BBI) 1 1
A8 594717/A 594717/A Pad Pin Kit Front Caliper - (BBI) 1 1
A9 594718/A 594718/A Bracket Sub Assy. Front Caliper 1 1
1 Caliper Body Front Kit 1 594623/A N.S., Served in Kit, Ref. A2 1
2 Piston - Front Caliper 2 594624/A N.S., Served in Kit, Ref. A6
3 Insulator FR Disc 1 594625/A N.S., Served in Kit, Ref. A6,A7,A9
4 Dust Cover FR Disc 1 594626/A N.S., Served in Kit, Ref. A6, A7
5 Pin Sub Assembly FR Disc 1 594627/A N.S., Served in Kit, Ref. A8
6 592256/A 592256/A Spring Pad FR Disc 1 10
7 Scrapper Ring FR Disc 2 594628/A N.S., Served in Kit, Ref. A6, A7
8 Seal FR Disc 2 594629/A N.S., Served in Kit, Ref. A6, A7
9 Clip Special FR Disc 1 594632/A N.S., Served in Kit, Ref. A8
10 Primary Pin FR Disc 1 594737/A N.S., Served in Kit, Ref. A5
11 Caliper Bracket Assembly Front Disc 1 594738/A N.S., Served in Kit, Ref. A9
12 Bleeder Screw Front 1 594742/A N.S., Served in Kit, Ref. A6, A7
13 Bleeder Cap 1 594741/A N.S., Served in Kit, Ref. A6, A7
86
A1 A2 A3 A4 A5 A6 A7 A8 A9
Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos.
All Except 18 to 20, All Except 18 14 & 15 19, (Qty. 2 Nos. 20) 4, 10 & 21 2, 3, 4, 7, 8, 3, 4, 7, 8, 5&9 3, 11, 17, 21 & 22
(A1, A2 in 12, 13 & 21 12, 13 & 21
Page No. 76)
9
6
5
14 15
18
8 7 2
18
3 22
16 11
1
13 12
19 20 20 4
10
17
87
KEY PART NUMBER

No. 350 500 Nos.
14 Pad (Piston Side) 1 592254/A N.S., Served in Kit, Ref. A3
15 Pad (Opposite Side) 1 592255/A N.S., Served in Kit, Ref. A3
17 594630/A 594630/A Wear Pad 1 N.S., Served in Kit, Ref. A9 5
18 586022/A 586022/A Flange Hex. Bolt M8 X 1.25 X 45 2 10
19 Banjo Bolt 1 594507/A
20 Washer (Copper) 2 594508/A
21 Grease Pouch (Reference only) 1 594728/A N.S., Served in Kit,
Ref. A5, A6, A7, A9
22 Secondary Pin FR Caliper 1 594740/A N.S., Served in Kit, Ref. A9
88
03-40 Head Bracket & Steering Stem
A1 24
20
Key Nos. 20
2, 21, (Qty. 38 Nos. 3),
(Qty. 2 Nos. 22 & 27)
23
19 22
A2
21
16 3 27
Key Nos. 16
(Qty. 4 Nos. 6), 22
7&8
15 6
27
14 6
14
7 26
30
25 13 13
25 31
30
8
9
3
13 32
13
14 2 6 29
14 32
6 28
17 17 1 29
18 18 28
25
10 25
4
11
12 5 5
11
12
89
KEY PART NUMBER

No. 350 500 Nos.
A1 888133 888133 Ball Race Kit with Cover (Thunderbird 350 & 500) 1 1
A2 888134 888134 Rubber, Head Lamp Holder RH & LH Kit (Thunderbird 350 & 500) 1 1
1 859045 859045 Steering Assembly (Metalic Silver) - Bottom Yoke Assembly 1 Alt.No. 594218/C 1
2 144581/E 144581/E Ball Race - Fork Crown 1 Served in Kit, Ref. A1 2
3 140201 140201 Ball Dia 6.35 (Dia 1/4”) 38 Top:19 + Bottom Race:19 Balls 38
4 845019 845019 Number Plate Assembly - Front (Milky White) 1 1
5 586042/A 586042/A Flanged Hex. Bolt M6 X 20 2 Old No. 145861/A 10
6 140193/B 140193/B Rubber Head Lamp Holder 4 Alt. No. 594503/B 10
7 594161/B 594161/B Holder RH-Head Lamp Assembly Plated 1 1
8 594160/B 594160/B Holder LH-Head Lamp Assembly Plated 1 1
9 594195/A 594195/A Topyoke (Metalic Silver) 1 Alt. No. 859044 1
10 888056/A 888056/A Ignition Switch cum Steering Lock Assembly with Keys 1 1
11 586031/A 586031/A Lock Washer M6, Internal Teeth 2 Old No. 140129 40
12 570030 570030 Hex. Socket Head Cap Screw M6 X 20 2 10
13 594253/A 594253/A Rubber Damper Sleeve Handle Bar 4 4
14 594252/B 594252/B Cover - Bottom Raiser 4 4
15 859043 859043 Bottom Raiser (Metalic Silver) 1 Alt. No. 594251/A 1
16 594008/A 594008/A Hex. Bolt M10X60 2 10
17 586008/A 586008/A Washer 2 Old No. 145708/A, 580344/A, 593023/B 20
18 594009/B 594009/B Hex. Nyloc Nut M10 2 10
19 859042 859042 Top Raiser - Handle Bar (Metalic Silver) 1 Alt. No. 594212/A 1
20 594356/B 594356/B Domed Cap Bolt 4 4
21 594288/A 594288/A Upper Ball Race - Topyoke 1 Served in Kit, Ref. A1
90
A1 24
20
Key Nos. 20
2, 21, (Qty. 38 Nos. 3),
(Qty. 2 Nos. 22 & 27)
23
19 22
A2
21
16 3 27
Key Nos. 16
(Qty. 4 Nos. 6), 22
7&8
15 6
27
14 6
14
7 26
30
25 13 13
25 31
30
8
9
3
13 32
13
14 2 6 29
14 32
6 28
17 17 1 29
18 18 28
25
10 25
4
11
12 5 5
11
12
91
KEY PART NUMBER

No. 350 500 Nos.
22 145446/A 145446/A Cover Ball Race 2 Served in Kit, Ref. A2 10
23 594287/A 594287/A Ring Nut 1 2
24 594286/A 594286/A Lock Nut 1 2
25 594215/A 594215/A Hex. Allen Bolt M8 X 25 4 10
26 594121/A 594121/A Head Lamp Stopper (Plated) 1 5
27 144581/E 144581/E Ball Race Frame 2 Served in Kit, Ref. A1
28 591702/A 591702/A Hex. Bolt M6 X 1 X 12 2 20
29 586032/A 586032/A Plain Washer 2 Old No. 141061/1 20
30 586002/A 586002/A Flanged Hex. Bolt M8 X 20 2 Old No. 580349/A, 145862/A, 5
594310/A, 593927/A
31 586025/A 586025/A Flanged Hex. Bolt M8 X 16 1 10
92
03-50 Front Fork (GIL - Dia 41)
A1 A2 A3 A4 A5 A6 A7
Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos.
All Except 10 All Except 5 & 7 Each Qty. 2 Nos. Qty. 2 Nos. 2, 8, Qty. 2 Nos. 15, 2, 8, 9, 10, 2, 5, 7 to 9,
2, 4, 8, 12, 14 & 18 12, 14 & 18 18 & 19 12 & 14 12 & 14
10
6 1 3 2 15 16 17 18 19
7 4
11 12 13 14
9 8
5
93
KEY PART NUMBER

No. 350 500 Nos.
A1 594018/A 594018/A Front Fork Assembly LH 1 1
A2 594019/A 594019/A Front Fork Assembly RH 1 1
A3 888135 888135 Fork Pipe Spining Replacement Kit 1 1
A4 888136 888136 Fork Oil Seal, ‘O’ Ring & Piston Ring Kit 1 1
A5 888137 888137 Main Spring Fork Major Kit 1 1
A6 888139 888139 Bottom Tube LH Sub Assembly Kit 1 1
A7 888138 888138 Bottom Tube RH Sub Assembly Kit 1 1
1 594403/A 594403/A Piston - Front Fork 2 2
2 Piston Ring Dia 41 2 594552/A Served in Kit, Ref. A3,A4,A6&A7 10
3 594553/A 594553/A Spring 2 (Sub Spring) - Rebound Fork 2 2
4 594402/A 594402/A Inner Tube Assembly with Bush 2 Served in Kit, Ref. A3 2
5 594419/A 594419/A Allen Bolt M8 X 1.25 X 45 1 10
6 594409/A 594409/A Spindle Tapper - Oil Lock Piece 2 2
7 594400/A 594400/A Outer Tube RH Kit Dia 41 1 Served in Kit, Ref. A7 1
8 594410/A 594410/A Gasket - Washer 2 Served in Kit, Ref. A3,A4,A6&A7 20
9 594411/A 594411/A Bolt M10 X 1 2 10
10 594401/A 594401/A Outer Tube LH Kit Dia 41 1 Served in Kit, Ref. A6 1
11 594405/A 594405/A Bush Washer 2 10
12 594406/A 594406/A Oil Seal Dia 41 2 Served in Kit, Ref. A3,A4,A6&A7 2
13 594407/A 594407/A Circlip (Snap Ring) Dia 41 2 10
14 594408/A 594408/A Dust Seal Dia 41 2 Served in Kit, Ref. A3,A4,A6&A7 2
15 Spring - Main Dia 41 2 594412/a Served in Kit, Ref. A5 2
16 594413/A 594413/A Washer Spring Top 2 10
94
A1 A2 A3 A4 A5 A6 A7
Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos.
All Except 10 All Except 5 & 7 Each Qty. 2 Nos. Qty. 2 Nos. 2, 8, Qty. 2 Nos. 15, 2, 8, 9, 10, 2, 5, 7 to 9,
2, 4, 8, 12, 14 & 18 12, 14 & 18 18 & 19 12 & 14 12 & 14
10
6 1 3 2 15 16 17 18 19
7 4
11 12 13 14
9 8
5
95
KEY PART NUMBER

No. 350 500 Nos.
17 594414/A 594414/A Spacer Dia 41 2 2
18 ‘O’ Ring Dia 41 2 594416/A Served in Kit, Ref. A3,A4 & A5 10
19 594415/A 594415/A Bolt Cap (Special Square 38mm Head) 2 2
96
03-60 Front Mudguard
A1
1
Key Nos.
(Qty. 2 Nos. 4, 6, 8), 2
7, 9, 10,
(Qty. 4 Nos. 5) 3
8 10
5
3
4 2
5
6
9
5
8
7
6
5
4
97
03-60 Front Mudguard
KEY PART NUMBER

No. 350 500 Nos.
A1 888140 888140 Front Mudguard Extension & Clip Kit 1 1
874001 874001 Front Mudguard, Twilight 1 1
1 875001 Front Mudguard, Stone Black 1 1
879007 879007 Front Mudguard, Flicker 1 1
2 586002/A 586002/A Flange Hex. Bolt M8 X 20 4 Old No. 580349/A, 145862/A, 10
594310/A, 593927/A, 593016/A
4 145882/A 145882/A Cross Recessed Pan Head Screw M6 2 20
5 586032/A 586032/A Punched Washer 6.4 4 Old No. 141061/1 20
6 586021/A 586021/A Hex. Nut with Nylon Insert 2 Old No. 141306/2 20
7 146797/A 146797/A Mudguard Extension 1 Served in Kit, Ref. A1 10
8 591702/A 591702/A Hex. Bolt M6 X 1 X 12 2 20
9 594078/B 594078/B Cable Guide - Speedo Cable (Metal) 1 5
10 594233/A 594233/A Cable Guide (Metal) 1 5
98
03-70 Front Wheel
2
20
1
19
3 4
14
12
13 15
5 16 17 18
A1 A2
Key Nos. Key Nos.

1, 2,(Qty. 40 Nos. 5), (Qty. 20 Nos. 6 & (Qty. 40 Nos. 5), (Qty. 20 Nos. 6 & 10),
10), 7, (Qty. 2 Nos. 8), 9, 11, 12, 7, (Qty. 2 Nos. 8), 9, 11, 12,
7 (Qty. 6 Nos. 13 & 15) 14, 19 & 20 (Qty. 6 Nos. 13 & 15) 14, 19 & 20
8
11 8
A3 A4 A5 A6 A7 A8
9
10 Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos.
(Qty. 2 Nos. 8), (Qty. 2 Nos. 7 (Qty. 20 Nos. 6 & 7, (Qty. 2 Nos. 8), 9,
3, 17 & 18 1&2
7, 9, & 11 & 8) 10), (Qty. 40 Nos. 5) 11, 12, (Qty. 6 Nos. 13)
99
03-70 Front Wheel
KEY PART NUMBER

No. 350 500 Nos.
A1 594006/A 594006/A Front Wheel Assembly Adaptor Plate, Disc with Tyre and Tube 1 1
A2 888166 888166 Front Wheel Assembly Adaptor Plate, Disc without Tyre and Tube 1 1
A3 888141 888141 Front Hub Sub Assembly 1 1
A4 888142 888142 Front Spindle Kit 1 1
A5 888118 888118 Front Wheel Bearing and Seal Kit 1 2 Seals are packed in Common Kit 1
A6 888051 888051 Front Wheel Tyre & Tube Kit - 90/90-19" 1 1
A7 888119 888119 Spokes & Nipple Kit Front Wheel 19” 1 1
A8 888143 888143 Hub Front Adaptor Plate and Bolt Kit 1 1
1 Tyre - Front 90/90-19" 1 591985/A N.S., Ref. A6
2 Tube - Front 90/90-19" 1 591986/A N.S., Ref. A6
3 594421/A 594421/A Spindle - Front Wheel 1 Served in Kit, Ref. A4 2
4 594238/A 594238/A Wheel Speed Sensor Assembly 1 2
5 110349 110349 Nipple 40 40
6 560519/E 560519/E Spokes Short (Outer) 20 20
7 141109/1 141109/1 Grease Seal, 25X40X7 1 5
8 150324/A 150324/A Deep Groove Ball Bearing (6203 17 X 40 X 12) 2 10
9 859040 859040 Hub-Front Wheel (Metalic Silver) 1 Alt No. 594007/C 1
10 560502/E 560502/E Spokes Long (Inner) 20 20
11 560521/B 560521/B Spacer Assembly 1 1
12 859041 859041 Adaptor Plate (Metalic Silver) 1 Alt. No. 560504/C 1
13 560546/A 560546/A Hex. Flange Bolt M8X25 6 6
14 594071/A 594071/A Disc, Front (Black) 1 1
15 560530/D 560530/D Socket Button Head Cap Screw 6 6
100
03-70 Front Wheel
2
20
1
19
3 4
14
12
13 15
5 16 17 18
A1 A2
Key Nos. Key Nos.

1, 2,(Qty. 40 Nos. 5), (Qty. 20 Nos. 6 & (Qty. 40 Nos. 5), (Qty. 20 Nos. 6 & 10),
10), 7, (Qty. 2 Nos. 8), 9, 11, 12, 7, (Qty. 2 Nos. 8), 9, 11, 12,
7 (Qty. 6 Nos. 13 & 15) 14, 19 & 20 (Qty. 6 Nos. 13 & 15) 14, 19 & 20
8
11 8
A3 A4 A5 A6 A7 A8
9
10 Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos.
(Qty. 2 Nos. 8), (Qty. 2 Nos. 7 (Qty. 20 Nos. 6 & 7, (Qty. 2 Nos. 8), 9,
3, 17 & 18 1&2
7, 9, & 11 & 8) 10), (Qty. 40 Nos. 5) 11, 12, (Qty. 6 Nos. 13)
101
03-70 Front Wheel
KEY PART NUMBER

No. 350 500 Nos.
16 594422/A 594422/A Spacer Disc Side 1 2
17 586070/A 586070/A Plain Washer 1 Served in Kit, Ref. A4 10
Alt. No. 593005/A
Old No. 142835
18 593038/D 593038/D Hex. Nut with Nyloc Insert M16X1.5 1 Served in Kit, Ref. A4 5
19 140355/B 140355/B Rim Tape 1
20 147507/A 147507/A Rim (1.85X19” - 1.5 THK) 1 1
102
04-00 Fuel Tank
350cc 500cc
27 12 27
11
18 A2 18
A2
2
2 12 11
12
12
7
7
A1 6 32
3
7
7 13
A1
6 6 33
4 14
13
1 4
14
A1 15
A1
16
Key Nos. 8
3 Key Nos.
9 19 15
1, (Qty. 2 Nos. 2) 10 30
34 1, (Qty. 2 Nos. 2)
8 16
29 28 8
A2 31 A2
26 31 9
9
Key Nos. 25 8 Key Nos.
22 9
11, 18 & 27 24
20 17 18 & 27
23 21 10
103
04-00 Fuel Tank
KEY PART NUMBER

No. 350 500 Nos.
874002 874002 Fuel Tank with Sticker, Twilight 1 1
A1 875002 Fuel Tank with Sticker, Stone 1 1
879006 879006 Fuel Tank with Sticker, Flicker 1 Alt. No. 855013 1
A2 888057 888057 Cap Assembly Fuel Filler with Key 1 1
A3 594816/A Fuel Hose and Clip Assembly Set (L 150mm) 1 1
1 594002/A Cover - Fuel Tap, Silver Ash 1 Alt. No. 813044 1
2 594208/A 594208/A Sticker 2 2
3 594264/B 594264/B Rear Damper Tank 2 10
4 571063/A 571063/A ‘O’ Ring – Fuel Pump Module 1 10
5 571052/A Fuel Pump Module 1 1
6 594538/A 594538/A Washer - Tank 2 10
7 586042/A 586042/A Flanged Hex. Bolt M6 X 1 X 20 2 Old No. 145861/A 10
8 143496/A 143496/A Washer 5 10
9 144636/A 144636/A Copper Washer 5 20
10 500355 500355 M6 Screw 5 10
11 594513/A 594513/A Ring - Fuel Cap, Metallic Silver 1 Alt. No. 859048 2
12 594514/A 594514/A CSK Screw - M4 3 20
13 594222/A 594222/A ‘O’ Ring - Fuel Guage 1 Alt. No. 170374 5
14 594244/A 594244/A Fuel Gauge Unit 1 1
15 586032/A 586032/A Plain Washer - Fuel Gauge MTG 4 Old No. 141061/1 50
16 586048/A 586048/A Hex. Screw, M6 X 10 4 Old No. 141093 20
17 594470/A 594470/A Drain Hose - Tank 2 2
18 Fuel Tank Cap Filler 1 594131/B Served in Kit, Ref. A2
104
04-00 Fuel Tank
350cc 500cc
27 12 27
11
18 A2 18
A2
2
2 12 11
12
12
7
7
A1 6 32
3
7
7 13
A1
6 6 33
4 14
13
1 4
14
A1 15
A1
16
Key Nos. 8
3 Key Nos.
9 19 15
1, (Qty. 2 Nos. 2) 10 30
34 1, (Qty. 2 Nos. 2)
8 16
29 28 8
A2 31 A2
26 31 9
9
Key Nos. 25 8 Key Nos.
22 9
11, 18 & 27 24
20 17 18 & 27
23 21 10
105
04-00 Fuel Tank
KEY PART NUMBER

No. 350 500 Nos.
19 594165/A Fuel Tap 1 1
20 143496/A Washer 2 20
21 500355 Hex. Bolt M6 X 14 2 10
22 570262/F Steady Bracket - Cylinder Head Engine 1 5
23 586004/A Hex. Nut with Nylon Insert M8 1 Old No. 593030/A, 142182/A 10
24 570263/B Spacer 1 5
25 586056/A Spacer Steady Bracket 1 Old No. 570299/a 20
26 594210/B Flanged Hex. Bolt M8 X 90 1 5
27 594231/B 594231/B Key Complete - Blank 2 10
28 594089/B Fuel Hose 1 10
29 146318/A Clip Fuel Hose 2 50
30 141454 Fuel Pipe (L 150mm) 1 594815/A 10
31 Clip Fuel Pipe 2 594814/A 50
32 594092/B 594092/B Tank Decor Plate RH 1 Alt. No. 867037 1
33 594091/B 594091/B Tank Decor Plate LH 1 Alt. No. 867036 1
34 147870/A Joint Packing Fuel Tap 1 20
106
04-10 Seat Assembly
14
7
A2
9
8
16
9 9
9
13
1 5
5
2 10
A1
2
12
15 4
17
3
3
4 17
11
5 5
6
107
04-10 Seat Assembly
KEY PART NUMBER

No. 350 500 Nos.
A1 594094/A 594094/A Seat Assembly - Rider 1 1
A2 594298/A 594298/A Seat Assembly - Pillion 1 1
1 594281/B 594281/B Seat - Cover Rider Rexine 1 1
2 594284/A 594284/A Rubber Boot - Rider Seat 2 2
3 580290/A 580290/A Rubber - Support 2 2
4 594655/A 594655/A Grommet Rear - Rider Seat 2 Alternate No. 594096/B 2
5 594660/A 594660/A CSK Screw M6 X 20 4 4
6 594102/A 594102/A Rider Seat Lock (Latch) with Cable 1 1
7 594305/A 594305/A Seat - Cover Pillion Rexine 1 1
8 594453/A 594453/A Rubber Boot - Pillion Seat 2 2
9 594306/A 594306/A Grommet Rear - Pillion Seat 4 4
10 594106/A 594106/A Pillion Seat Lock (Latch) with Cable 1 1
11 594681/A 594681/A Cable, Rider Seat Latch 1 10
12 594682/A 594682/A Cable, Pillion Seat Latch 1 10
13 Seat Cushion Rider 1 594280/B N.S. 1
14 Seat Cushion Pillion 1 594299/A N.S. 1
15 594275/C 594275/C Seat Pan Assembly Rider 1 1
16 594300/A 594300/A Seat Pan Assembly Pillion 1 1
17 592030/A 592030/A Plug (Rubber) Cable Seat Latch 2 20
108
04-20 Seat Sub Frame
A1
Key Nos. 14
5
2, 3, 5, (Qty 2 Nos. 6)
11
11
10
13
7 1
8
9
8
9
12
2
4
4
6
109
04-20 Seat Sub Frame
KEY PART NUMBER

No. 350 500 Nos.
A1 Pillion Gabriel and Back Rest Kit 1 594097/A 1
1 594125/B 594125/B Sub Frame (Black Powder Coated) 1 Alt. No. 867045 1
2 859049 859049 Pillion Grab Rail - LH (Metalic Silver) 1 Alt. No. 594099/A 1
3 859050 859050 Pillion Grab Rail - RH (Metalic Silver) 1 Alt. No. 594100/A 1
4 586002/A 586002/A Flanged Hex. Bolt, M8 X 20 4 Old No. 580349/A, 145862/A, 10
594310/A, 593927/A, 593016/A
5 594097/A 594097/A Back Rest - Pillion 1 1
6 586002/A 586002/A Hex. Socket Head Screw M8 X 1.25 X 20 2 Old No. 580349/A, 145862/A, 10
594310/A, 593927/A, 593016/A
7 145882/A 145882/A Cross Recessed Pan Head Screw M6 X 14 2 20
8 586032/A 586032/A Punched Washer 6.4 2 Old No. 141061/A 50
9 586021/A 586021/A Hex. Nut with Nylon Insert B M6 2 Old No. 141306/2 40
10 594108/B 594108/B Luggage Carrier Plate (Black Powder Coated) 1 Alt. No. 867039 1
11 594046/A 594046/A Hex. Socket Button Head Screw M6 X 1 4 10
12 580431/E 580431/E Side Handle LH 1 2
13 594601/A 594601/A Side Handle RH 1 2
14 594680/A 594680/A Rexine Back Rest 1 1
110
05-00 Rear Shock Absorbers & Center Stand Assembly
LH 13
RH
4
1
2 12
14 3 9
6
2
1 11
8
9
4 12
10
2
11
7
5
A1 2
2 A2
6 3
Key Nos. 6
(Qty. 2 Nos. 4 & 5), 2 3 Key Nos.
(Qty. 3 Nos. 3 & 6), 2 (Qty. 2 Nos. 9, 11 & 12),
5
(Qty. 7 Nos. 2) 7, 8, 10
111
05-00 Rear Shock Absorbers & Center Stand Assembly
KEY PART NUMBER

No. 350 500 Nos.
A1 888195 888195 Bolt, Washer & Nut Kit Rear Shocks (Thunderbird 350 & 500) 1 1
A2 888146 888146 Center Stand and Spindle Kit 1 1
1 146347/B 146347/B Shock Absorber - Gas Filled 2 1
2 593046/A 593046/A Plain Washer 8 5
3 593109/A 593109/A Single Coil Spring Lock Washer M10 4 5
4 594492/A 594492/A Domed Bolt - 3/8"X60 2 10
5 594491/A 594491/A Domed Bolt - 3/8"X45 2 10
6 594493/B 594493/B Hex. Nut 3/8” BSF 3 20
7 867003 867003 Center Stand, Black-Powder Coated 1 Alt. No. 592159/B 1
8 586015/A 586015/A Spindle Main (Center) Stand 1 Old No. 580295/C 1
9 586016/A 586016/A Washer Plain - Center Stand 2 Old No. 141234 40
10 145186/C 145186/C Rubber Stop Center Stand Main 1 5
11 144766/A 144766/A Spring New 2 10
12 586012/A 586012/A Split Pin Rear Spindle 2 Old No. 580361/A 20
13 594601/A 594601/A Side Handle RH 1
14 580431/E 580431/E Side Handle LH 1
112
05-10 Swing Arm Assembly & Rear Chain Guard
A4
5
Key Nos.
3
(Qty. 2 Nos. 2 & 3), 4
4 19 20
9
8 9 17
A1 12
2
11 18 A3
1
11
3
6
7
10
15
14 13 16
15
16
16
16
A2
113
KEY PART NUMBER

No. 350 500 Nos.
A1 867034 867034 Swing Arm Sub Assembly Black (Powder Coated) 1 1
A2 888147 888147 Chain Adjuster Kit (RH & LH) 1 1
888148 Chain and Sprocket Kit (350cc) 1 16T (102 Pitches ‘O’ Ring Type) 1
A3
888149 Chain and Sprocket Kit (500cc) 1 18T (102 Pitches ‘O’ Ring Type) 1
A4 888079 888079 Swing Arm End Cap, Bush and Spacer Kit 1 1
1 594028/B 594028/B Swing Arm Complete, Black-Powder Coated 1 1
2 580038/E 580038/E Bush - Celcon 2 2
3 580749/D 580749/D End Cup 2 2
4 580037/H 580037/H Spacer - Chain Stay 1 1
5 580347/A 580347/A Flanged Hex. Bolt 1/2 X 16 TPI X 235 1 1
6 586008/A 586008/A Washer - Shake Proof M12 1 Old No. 145708/A, 580344/A, 593023/A 10
7 593050/C 593050/C Hex Nylock nut 1 Old No. 580343/A, 593050/B 10
8 594540/A 594540/A Chain Pad 1 1
9 146435/A 146435/A CSK Screw M6 X 12 2 Alt. No. 594660/A 20
10 594484/B 594484/B Bracket Complete - Chain Guard, Black-Powder Coated 1 Alt. No. 867035 1
11 593108/A 593108/A Flange Bolt with Collar - M6 X 1 2 10
12 591667/B 591667/B Chain Guard 1 1
13 594533/A 594533/A Chain Tensioner RH 1 Served in Kit, Ref. A2 10
14 594216/B 594216/B Chain Tensioner LH 1 Served in Kit, Ref. A2 10
15 594365/A 594365/A Plate-Chain Adjuster 2 Served in Kit, Ref. A2 20
16 586005/A 586005/A Flanged Hex. Nut M8 X 1.25 4 Old Type 593008/A, 145867/A 20
17 581085/B 581085/B Chain - Rear (102 Pitches ‘O’ Ring Type LGB) 1 Served in Kit, Ref. A3 1
18 145854 145854 Connecting Link 1 1
114
A4
5
Key Nos.
3
(Qty. 2 Nos. 2 & 3), 4
4 19 20
9
8 9 17
A1 12
2
11 18 A3
1
11
3
6
7
10
15
14 13 16
15
16
16
16
A2
115
KEY PART NUMBER

No. 350 500 Nos.
570809/A FD Sprocket 16 Teeth 1 1
19
571032/B FD Sprocket 18 Teeth 1 1
20 594048/B 594048/B Sprocket Rear Drive 38T 1 Served in Kit, Ref. A3 1
116
05-20 Rear Wheel
A1 A2 1 2
Key Nos. Key Nos.
1, 2, 3, (Qty. 2 Nos. 4), 3, (Qty. 2 Nos. 4), 21
27
5, 6, 7, (Qty. 20 Nos. 8 5, 6, 7, (Qty. 20 Nos. 8 22 25 28
& 9), (Qty. 40 Nos. 10), & 9), (Qty. 40 Nos. 10), 17 13
(Qty. 6 Nos. 15), (Qty. 6 Nos. 15), 20
14 18
11, 14 & 16 19 12
11, 14 & 16 24
22
A3 15
Key Nos.
27 23
3, (Qty. 2 Nos. 26
4), 5, 6
15
A4
11
Key Nos. 7 8 10
(Qty. 2 Nos. 4), 6
3
16
A5 A6 A7
4
Key Nos. Key Nos. Key Nos. 5
6 4
1&2 (Qty. 2 Nos. 4), (Qty. 20 Nos.8
6, 18 & 20 & 9), (Qty. 40
Nos. 10)
A8 A9 A10
Key Nos. Key Nos. Key Nos.

12, 13, 26, 9
17, 18, 20 25 & 28
(Qty. 2 Nos. 27)
117
05-20 Rear Wheel
KEY PART NUMBER

No. 350 500 Nos.
A1 594042/A 594042/A Rear Wheel Assembly with Tyre & Tube 1 1
A2 888167 888167 Rear Wheel Sub Assembly without Tyre & Tube 1 1
A3 594043/C 594043/C Rear Hub Assembly 1 1
A4 888150 888150 Rear Wheel Bearing Kit 1 2 Seals are packed in Kit 1
A5 888050 888050 Rear Wheel Tyre & Tube Kit - 120/ 80 - 18” 1 1
A6 888151 888151 Bearing and Seal Kit Rear Wheel TB 350 & 500cc 1 1
A7 888152 888152 Wheel Spokes and Nipple Kit - Thunderbird 500 1 1
A8 888153 888153 Adaptor Rear Sprocket Sub Assembly Kit 1 1
A9 888154 888154 Short Spindle and Nut Kit 1 1
A10 888178 888178 Rear Spindle, Washer and Nut Kit 1 1
1 Tube, Rear 120/ 80 - 18” 1 591984/A N.S., Ref. A5
2 Tyre, Rear 120/ 80 - 18” Zapper C 1 591983/A N.S., Ref. A5
3 859046 859046 Centre Hub, Rear (Metalic Silver) 1 1
4 150324/A 150324/A Deep Groove Ball Bearing 6203 (17 X 40 X 12) 2 Served in Kit, Ref. A3 10
5 146499/A 146499/A Rear Hub Spacer Assembly 1 Served in Kit, Ref. A3, 5
Old No. 141105/C
6 141109/1 141109/1 Grease Seal, 25 X 40 X 7 1 Served in Kit, Ref. A3 10
7 591210/A 591210/A Rim - Rear 1 1
8 594427/A 594427/A Spokes Inner, Rear (Long) 20 Served in Kit, Ref. A7 20
9 594428/A 594428/A Spokes Outer, Rear (Short) 20 Served in Kit, Ref. A7 20
10 110349 110349 Nipple 40 Served in Kit, Ref. A7 40
11 140355/B 140355/B Rim Tape 1
12 586010/A 586010/A Hex. Castle Nut, M16 x 1.5 1 Old No. 593043/2 10
118
05-20 Rear Wheel
A1 A2 1 2
Key Nos. Key Nos.
1, 2, 3, (Qty. 2 Nos. 4), 3, (Qty. 2 Nos. 4), 21
27
5, 6, 7, (Qty. 20 Nos. 8 5, 6, 7, (Qty. 20 Nos. 8 22 25 28
& 9), (Qty. 40 Nos. 10), & 9), (Qty. 40 Nos. 10), 17 13
(Qty. 6 Nos. 15), (Qty. 6 Nos. 15), 20
14 18
11, 14 & 16 19 12
11, 14 & 16 24
22
A3 15
Key Nos.
27 23
3, (Qty. 2 Nos. 26
4), 5, 6
15
A4
11
Key Nos. 7 8 10
(Qty. 2 Nos. 4), 6
3
16
A5 A6 A7
4
Key Nos. Key Nos. Key Nos. 5
6 4
1&2 (Qty. 2 Nos. 4), (Qty. 20 Nos.8
6, 18 & 20 & 9), (Qty. 40
Nos. 10)
A8 A9 A10
Key Nos. Key Nos. Key Nos.

12, 13, 26, 9
17, 18, 20 25 & 28
(Qty. 2 Nos. 27)
119
05-20 Rear Wheel
KEY PART NUMBER

No. 350 500 Nos.
13 586012/A 586012/A Split Pin 1 Alt. No. 593044/A 50
14 594045/A 594045/A Rear Disc Plate 1 1
15 590906/B 590906/B Hex. Socket Head Screw M6 X 1 X 14 6 Alt. No. 594046/A, Old Type 10
16 144471/A 144471/A Cushion Rubber 4 4
17 859047 859047 Adaptor - RD Sprocket (Metalic Silver) 1 1
18 145553/B 145553/B Bearing 6005 (25 X 47 X12) (double side rubber sealed) 1 Served in Kit, Ref. A8 5
19 594054/A 594054/A Rear Caliper Assembly 1 1
20 594562/A 594562/A Dust Seal - RD Sprocket 1 Served in Kit, Ref. A8 10
21 594048/B 594048/B Sprocket - Rear Drive 1 1
22 560530/D 560530/D Socket Button Head Cap Screw 6 6
23 594050/A 594050/A Spacer - Disc Side 1 5
24 594051/A 594051/A Spacer - Sprocket Side 1 5
25 594087/A 594087/A Spindle Short 1 Served in Kit, Ref. A9
26 594088/A 594088/A Spindle Long 1 Served in Kit, Ref. A10 5
27 593095/A 593095/A Plain Washer 2 Served in Kit, Ref. A10 10
28 586009/A 586009/A Hex. Nut, M22X1.5 1 Old No. 593042/B 10
120
05-30 Rear Master Cylinder Assembly - BBI
A1
14 13 10
Key Nos. 11
1 to 15 12 1 7 8 9
2 3 4 5 6 10A 10D 10C 10B
A2
15
Key Nos.
16, (Qty. 2 Nos. 17),
(Qty. 4 Nos. 18)
A3 18
17
Key Nos. A1
16
24 & 25
A4
A7
Key Nos. A1
19 to 23, (Qty. 2 Key Nos.
Nos. 24), 25 2 to 9 & 10E
A5 A8 19 17
20 18
Key Nos. Key Nos.
24
20, 21 & 22 12 & 13 21
22 25
A6 A9
24
Key Nos. Key Nos.
2 to 5, 8 & 9 17, (Qty. 2 Nos. 18) 26
23
121
KEY PART NUMBER

No. 350 500 Nos.
A1 594055/A 594055/A Rear Master Cylinder Assembly 1 1
A2 594688/A 594688/A Rear Brake Hose Assembly Kit with Banjo Bolt - BBI 1 1
A3 594695/A 594695/A Reservoir Tube Kit Rear M/C 1 1
A4 888157 888157 Rear Reservoir Kit 1 1
A5 594694/A 594694/A Reservoir Kit Rear M/C Threaded 1 1
A6 594690/A 594690/A Minor Kit Rear M/C 1 1
A7 594689/A 594689/A Major Kit Rear M/C 1 1
A8 594693/A 594693/A Connector Kit Rear M/C 1 1
A9 594721/A 594721/A Banjo Bolt Kit (Disc Brake) 1 1
1 Master Cylinder M/C - Rear Body 1 N.S., Ref. A1
2 Spring Rear M/C 1 594595/A (N.S.) Served in Kit, Ref.A6, A7
3 Spring Guide Rear M/C 1 594594/A (N.S.) Served in Kit, Ref.A6, A7
4 Primary Seal Rear M/C 1 594593/A (N.S.) Served in Kit, Ref.A6, A7
5 Primary Washer 1 594592/A (N.S.) Served in Kit, Ref.A6, A7
6 Piston - Rear Master Cylinder 1 594591/A (N.S.) Served in Kit, Ref. A7
7 Seal (‘O’ Ring) Rear M/C 1 594590/A (N.S.) Served in Kit, Ref. A7
8 Spacer Rear M/C 1 594722/A (N.S.) Served in Kit, Ref.A6, A7
9 Circlip Rear M/C 1 594510/A (N.S.) Served in Kit, Ref.A6, A7
10 594691/A 594691/A Push Rod Assembly Kit Rear M/C 1 (N.S.) Served in Kit 5
10A Push Rod Rear M/C 1 594723/A (N.S.) Served in Kit, Ref. Key 10
10B Fork Push Rod Rear M/C 1 594724/A (N.S.) Served in Kit, Ref. Key 10
10C Lock Nut Rear M/C 1 594725/A (N.S.) Served in Kit, Ref. Key 10
10D Push Rod Assembly Rear M/C 1 594509/A (N.S.) Served in Kit, Ref. Key 10
122
A1
14 13 10
Key Nos. 11
1 to 15 12 1 7 8 9
2 3 4 5 6 10A 10D 10C 10B
A2
15
Key Nos.
16, (Qty. 2 Nos. 17),
(Qty. 4 Nos. 18)
A3 18
Key Nos. A1
16
24 & 25 17
A4
A7
Key Nos. A1
19 to 23, (Qty. 2 Key Nos.
Nos. 24), 25 2 to 9 & 10E
A5 A8 19 17
20 18
Key Nos. Key Nos.
24
20, 21 & 22 12 & 13 21
22 25
A6
24
Key Nos.
2 to 5, 8 & 9 26
23
123
KEY PART NUMBER

No. 350 500 Nos.
10E Grease Pouch (Reference Only) 1 594728/A (N.S.) Served in Kit, Ref. A7, 10
Figure not shown
11 594511/A 594511/A Boot Rear M/C 1 (N.S.) Served in Kit, Ref. A1 10
12 Bush Rear M/C 1 594726/A (N.S.) Served in Kit, Ref. A8
13 Connector Rear M/C 1 594586/A (N.S.) Served in Kit, Ref. A8
14 Cap 1 N.S.
16 Brake Hose Rear 1 594056/A (N.S.) Served in Kit, Ref. A2
17 Banjo Bolt (Black Tri-Valent) 2 594507/A (N.S.) Served in Kit, Ref. A2, A9
18 Copper Washer Disc 4 594508/A (N.S.) Served in Kit, Ref. A2, A9
19 594046/A 594046/A Hex. Socket Button Head Screw M6 X 1 1 (N.S.) Served in Kit, Ref. A4 10
20 Reservoir Rear (Threaded) 1 594057/A (N.S.) Served in Kit, Ref. A4, A5
21 Diaphragm Rear Disc Reservoir 1 594504/A (N.S.) Served in Kit, Ref. A4, A5
22 Lid Reservoir Threaded 1 594633/A (N.S.) Served in Kit, Ref. A4, A5
23 594518/A 594518/A Cover Reservoir 1 (N.S.) Served in Kit, Ref. A4, A4 5
24 Clip (Reservoir) 2 594727/A (N.S.) Served in Kit, Ref. A3
25 Rubber Tube - Rear Disc 1 594059/A (N.S.) Served in Kit, Ref. A3
26 582511/A 582511/A Cable Strap 8” (Black) 2 20
124
05-40 Rear Caliper Assembly - BBI
A1 A2 A3 A4 A5 A6 A7 A8
Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos.
A2, 2, 3, 4, 10, 12, 2, 3, 10, 12, 8, 11, 12 & 21 10, 15, 17, 18,
1 to 20 6&7
(In Page No. 116 - 13, 14 & 21 13, 14 & 21 (Qty. 2 Nos. 9) 19 & 21
A1, 16, (Qty. 2 Nos. 17 & 24),
(Qty. 4 Nos. 18), 20 to 23 & 25) 5 15
9 9
20
8
2 3 4
10 19
16 17
14 13 6 7
1
11 12
18
125
KEY PART NUMBER

No. 350 500 Nos.
A1 594053/A 594053/A Disc Brake Assembly Rear - BBI 1 1
A2 594054/A 594054/A Caliper Assembly Rear - BBI 1 1
A3 594698/A 594698/A Disc Pad Kit Rear Caliper - BBI 1 1
A4 594696/A 594696/A Major Kit Rear Caliper 1 1
A5 594697/A 594697/A Minor Kit Rear Caliper 1 1
A6 594700/A 594700/A Pad Pin Kit Rear Caliper 1 1
A7 594703/A 594703/A Primary Pin Kit Rear Caliper 1 1
A8 594701/A 594701/A Bracket Sub Assembly Rear Caliper 1 1
1 Caliper Body 1 (N.S.) Served in Kit, Ref. A1
2 Piston Seal Rear Caliper 1 594432/A (N.S.) Served in Kit,Ref. A4, A5
3 Scrapper Ring Rear Caliper 1 594433/A (N.S.) Served in Kit,Ref. A4, A5
4 Piston - Rear Caliper 1 594431/A (N.S.) Served in Kit,Ref. A4
5 594729/A 594729/A Pad Spring Rear Caliper 1 10
6 Pad (Piston Side) Rear Caliper 1 594430/A (N.S.) Served in Kit, Ref. A3
7 Pad (Opposite Piston Side) Rear Caliper 1 594429/A (N.S.) Served in Kit, Ref. A3
8 Pad Pin Rear Caliper 1 594730 (N.S.) Served in Kit, Ref. A6
9 Clip Hanger Rear Caliper 2 594600/A (N.S.) Served in Kit, Ref. A6
10 Insulator Rubber Rear Caliper 1 594599/A (N.S.) Served in Kit,Ref.A4,A5,A8
11 Primary Pin Rear Caliper 1 594598/A (N.S.) Served in Kit, Ref. A7
12 Dust Cover Rear Caliper 1 594597/A (N.S.) Served in Kit, Ref.A4,A5,A7
13 Bleeder Screw Rear Caliper 1 594435/A (N.S.) Served in Kit,Ref. A4, A5
14 Bleeder Cap Rear Caliper 1 594434/A (N.S.) Served in Kit, Ref. A4, A5
15 Bracket Sub Assembly Rear Caliper 1 594731/A (N.S.) Served in Kit, Ref. A2, A8
126
A1 A2 A3 A4 A5 A6 A7 A8
Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos. Key Nos.
A2, 2, 3, 4, 10, 12, 2, 3, 10, 12, 8, 11, 12 & 21 10, 15, 17, 18,
1 to 20 6&7
(In Page No. 116 - 13, 14 & 21 13, 14 & 21 (Qty. 2 Nos. 9) 19 & 21
A1, 16, (Qty. 2 Nos. 17 & 24),
(Qty. 4 Nos. 18), 20 to 23 & 25) 5 15
9 9
20
8
2 3 4
10 19
16 17
14 13 6 7
1
11 12
18
127
KEY PART NUMBER

No. 350 500 Nos.
16 Thread Protector 1 N.S., Ref. A2
17 Wear Pad Rear Caliper 1 594733/a (N.S.) Served in Kit, Ref. A8
18 Bracket Machined Rear Caliper 1 594732/a (N.S.) Served in Kit, Ref. A8
19 Secondary Pin Rear Caliper 1 594734/a (N.S.) Served in Kit, Ref. A8
20 Pad Spacer 1 N.S., Ref. A2
21 Grease Pouch ( Reference Only) 594728/a (N.S.) Served in Kit,Ref. A4,A5,A7,A8
128
05-50 Cradle Assembly RH
17
18 18
16
6
4
5
13 15
2 7
12
9
A1 A2 A3 A4
8 14 11 10 Key Nos. Key Nos. Key Nos. Key Nos.

9
(Qty. 4 Nos. 17), 2, (Qty. 2 Nos. 3),
12 & 16 All 1 to 18
(Qty. 8 Nos. 18) 4, 5, 6 & 7
129
05-50 Cradle Assembly RH
KEY PART NUMBER

No. 350 500 Nos.
A1 888164 888164 Foot Rest Rubber Kit 1 1
A2 888162 888162 Foot Rest Assembly RH with Holder Kit 1 1
A3 888197 888197 Rear Brake Pedal with Rubber 1 1
A4 594220/A 594220/A Cradle Tube Sub Assembly RH 1 1
1 594116/B 594116/B Cradle Tube Complete - RH Black (Powder Coated) 1 Alt. No. 867043 1
2 594358/B 594358/B Foot Rest Holder - RH, Metalic Silver 1 Alt. No. 859052 1
594310/A, 593927/A, 593016/A
4 594118/A 594118/A Foot Rest Assembly - RH 1 1
5 594334/B 594334/B Spring - Rider Foot Rest 1 Served in Kit, Ref. A2 20
6 5943702/B 594372/B Lock Pin - Foot Rest 1 Served in Kit, Ref. A2 20
7 550141 550141 Circlip 10 X 1N 1 Served in Kit, Ref. A2 20
8 594055/A 594055/A Master Cylinder Assembly 1 1
10 594067/A 594067/A Spring - Pedal Return 1 40
11 594393/A 594393/A Brake Light Switch with Spring 1 1
12 594526/A 594526/A Rear Brake Pedal 1 Served in Kit, Ref. A3 1
13 594537/A 594537/A Pin Master Cylinder 1 10
14 594066/A 594066/A Split Pin 1 40
15 586032/A 586032/A Punched Washer 6.4 1 Old No. 593004/A, 141061/A 20
16 144886/C 144886/C Brake Pedal Rubber 1 7
17 594351/A 594351/A Foot Rest Rubber Large 1 5
18 594350/A 594350/A Foot Rest Rubber Small 2 10
130
05-60 Rear Mudguard
10
9
2
12 4
6
11
6 5
3
4
6 5
131
05-60 Rear Mudguard
KEY PART NUMBER

No. 350 500 Nos.
874007 874007 Rear Mudguard Assembly, Twilight 1 1
1 875005 Rear Mudguard Assembly, Stone 1 1
879001 879001 Rear Mudguard Assembly, Flicker 1 1
2 586052/A 586052/A Hex. Screw M6 X 16 1 Old No. 142274 40
4 586035/A 586035/A Plain Washer 2 Old No. 140383/A 50
5 140090/1 140090/1 Star Washer 2 50
6 586029/A 586029/A Hex. Nut M6 2 Old No. 141060 40
7 586021/A 586021/A Hex. Nut with Nylon Insert B M6 1 Old No. 141306/2 40
10 594214/A 594214/A Reflex Reflector 1 5
11 580811/B 580811/B Piece Mudguard Assembly 1 1
12 586035/A 586035/A Plain Washer M6 1
132
05-70 Tail Lamp Bracket, Trafficator & Saree Guard
A1
9
Key No’s
8
10, 11,
(Qty. 2 Nos. 12)
7
3 10
13 2
2 11
3
7
1 6 12
5 12
5
133
05-70 Tail Lamp Bracket, Trafficator & Saree Guard
KEY PART NUMBER

No. 350 500 Nos.
A1 888159 888159 Saree Guard Complete Kit 1 1
1 594101/B 594101/B Bracket Assembly - Tail Lamp Plated 1 1
2 586028/A 586028/A Hex. Nut M12 2 Old No. 580368/B 10
3 502006/A 502006/A Spring Washer M12 2 50
4 594015/A 594015/A Trafficator Assembly LH 2 1
5 146375 146375 Hex. Screw M6 X 14 2 5
6 845020 845020 Number Plate - Rear, Milky White 1 1
7 581122/A 581122/A Mushroom Head Screw M6X8 2 10
8 594016/A 594016/A Trafficator Assembly RH 2 1
9 594036/A 594036/A Tail Lamp Led 1 1
10 867070 867070 Saree Guard (Powder Coating Black) 1 868037 Served in Kit, Ref. A1 1
11 867071 867071 Saree Guard - Add On (Powder Coating Black) 1 1
12 594046/A 594046/A Hex. Socket Button Head Screw M6 X 1 2 20
13 591023/A 591023/A Beading 1 5
134
06-00 Cradle Assembly LH & Pillion Foot Rest Assembly
A3
A1 RH
Key No’s
Key No’s
19 16 24, 26 to 30
16, 17, 21,
(Qty. 2 Nos. 22 & 23) 26
1
20
24
18 27
6 17
2 28
4
21
23 22
29
5 30
23 22
7 32
3
3
LH 26
4
31 25 25 10 15 27
11
8 28
14
15
13
9
A4 A5 12
29
A6 A2
30
2, (Qty. 2 Nos. 3) (Qty. 8 Nos. 25) Key No’s Key No’s
4, 5, 6 & 7 (Qty. 4 Nos. 31) 1 to 23 4, 26 to 30
135
KEY PART NUMBER

No. 350 500 Nos.
A1 594047/A 594047/A Gear Shifter Assembly without Rubber 1 1
A2 594221/A 594221/A Pillion Foot Rest Sub Assembly LH 1 1
A3 594371/A 594371/A Pillion Foot Rest Sub Assembly RH 1 1
A4 888163 888163 Foot Rest Assembly LH with Holder Kit 1 1
A5 888164 888164 Foot Rest Rubber Kit 1 1
A6 594063/A 594063/A Cradle Tube Sub Assembly LH 1 1
1 594117/B 594117/B Cradle Tube Complete LH - Black-Powder Coated 1 Alt. No. 867041 1
2 594120/B 594120/B Foot Rest Holder - LH, Metalic Silver 1 Alt. No. 859051 1
594310/A, 593927/A, 593016/A
4 594119/A 594119/A Foot Rest Assembly - LH 2 Old No. 594521/B 1
5 594334/C 594334/C Spring Rider Foot Rest 1 Served in Kit Ref. A4
6 594372/B 594372/B Lock Pin - Foot Rest 1 Served in Kit Ref. A4 20
7 550141 550141 Circlip 10 X 1N 1 Served in Kit Ref. A4 20
8 594122/B 594122/B Side Stand Mounting Complete, Black-Powder Coated 1 867042 1
9 591713/C 591713/C Side Stand Assembly 1 1
10 521199 521199 Hex. Socket Head Screw M8 X 45 1 4
11 586036/A 586036/A Washer 1 Old No. 140437/1, 593028/A, 140080/2 5
12 586004/A 586004/A Hex. Nut with Nylon Insert, M8 1 Old No. 593030/A, 142182/A 5
13 591992/B 591992/B Spring 1 Old No. 147849/A 5
14 581738/A 581738/A Switch, Side Stand 1 Alt. No. 146147/C 1
15 500632 500632 Hex. Screw Head Cap Screw M5 X 20 2 10
16 594177/B 594177/B Gear Lever (Shifter Complete) 1 N.S. Ref. A1 1
136
A3
A1 RH
Key No’s
Key No’s
19 16 24, 26 to 30
16, 17, 21,
(Qty. 2 Nos. 22 & 23) 26
1
20
24
18 27
6 17
2 28
4
21
23 22
29
5 30
23 22
7 32
3
3
LH 26
4
31 25 25 10 15 27
11
8 28
14
15
13
9
A4 A5 12
29
A6 A2
30
2, (Qty. 2 Nos. 3) (Qty. 8 Nos. 25) Key No’s Key No’s
4, 5, 6 & 7 (Qty. 4 Nos. 31) 1 to 23 4, 26 to 30
137
KEY PART NUMBER

No. 350 500 Nos.
17 Actuator Complete 1 594452/A Served in Kit Ref. A1
18 594065/A 594065/A Pivot Pin 1 5
19 550507/A 550507/A Gear Lever Rubber (Sleeve) 1 5
20 572015/A 572015/A Hex. Socket Head Cap Screw M6X 30 1 10
21 Link Rod 1 594235/B Served in Kit Ref. A1 5
22 Punched Washer 6.4 2 594641/B Served in Kit Ref. A1 20
23 593019/B 593019/B Split Pin 4 X 32 2 594066/B Served in Kit Ref. A1 20
24 594118/A 594118/A Foot Rest Assembly Pillion / Rider - RH 1 Old No. 594522/B 1
25 594350/A 594350/A Foot Rest Rubber Small 2 10
26 594372/B 594372/B Lock Pin - Foot Rest 2 Served in Kit Ref. A3, A4 20
27 580381/D 580381/D Spring Pillion Foot Rest 2 Served in Kit Ref. A3, A4 20
28 594447/B 594447/B Bracket Assembly - Pillion Foot Rest 2 594448/B 1
29 580380/A 580380/A Ball 2 Served in Kit Ref. A3, A4 50
30 550141 550141 Circlip 10 X 1- Foot Rest 2 Served in Kit Ref. A3, A4 50
31 594351/A 594351/A Foot Rest Rubber Large 1 5
32 586003/A 586003/A Hex. Flange Bolt M8 X 1.25 X 30 1 Old No. 593014/A
138
06-10 Side Panel LH & RH
A1 4 4
Key No’s
6&7
4
4
A2
Key No’s
8&9
2
A3 1
Key No’s
3, 10 &
(Qty. 4 Nos. 4)
A4 10
6
Key No’s
5 3
6&7 7
8 9
8 9
139
KEY PART NUMBER

No. 350 500 Nos.
A1 888058 888058 Side Panel Lock Assembly with Key Kit 1 1
888160 Sticker Side Panel RH and LH Kit 350cc 1 1
A2
888161 Sticker Side Panel RH and LH Kit 500cc 1 1
A3 888198 888198 Side Panel Grommet, Washer and Boot Repair Kit 1 1
A4 888058 888058 Side Panel Lock with Key 1 1
879004 Side Panel RH (with Sticker), Flicker 1 1
874004 Side Panel RH (with Sticker), Twilight 1 1
1 874003 Side Panel RH (with Sticker), Twilight 1 1
875003 Side Panel RH (with Sticker), Stone Black 1 1
879005 Side Panel RH (with Sticker), Flicker 1 1
879002 Side Panel LH (with Sticker), Flicker 1 1
874006 Side Panel LH (with Sticker), Twilight 1 1
2 874005 Side Panel LH (with Sticker), Twilight 1 1
875004 Side Panel LH (with Sticker), Stone Black 1 1
879003 Side Panel LH (with Sticker), Flicker 1 1
3 594500/A 594500/A Washer Side Panel 1 10
4 521112/B 521112/B Grommet 4 10
5 594501/A 594501/A Side Panel Screw M6 (Special) 1 20
6 Side Panel Lock 1 594473/A Served in Kit, Ref. A1 1
7 594231/B 594231/B Key Set Blank 1 Served in Kit, Ref. A1
594109/A Sticker RH - 350cc 1 Served in Kit, Ref. A2 2
8
594138/A Sticker RH - 500cc 1 Served in Kit, Ref. A2 2
140
A1 4 4
Key No’s
6&7
4
4
A2
Key No’s
8&9
2
A3 1
Key No’s
3, 10 &
(Qty. 4 Nos. 4)
A4 10
6
Key No’s
5 3
6&7 7
8 9
8 9
141
KEY PART NUMBER

No. 350 500 Nos.
594110/A Sticker LH - 350cc 1 Served in Kit, Ref. A2 2
9
594136/A Sticker LH - 500cc 1 Served in Kit, Ref. A2 2
10 521066/B 521066/B Side Panel Boot 1 10
142
06-20 Side Decor LH & RH
1
7
2
6
7
4 3
5
11 3 4 5
13
12
10
13 12
4 3
5
3 4 5
9
8 9
8
143
06-20 Side Decor LH & RH
KEY PART NUMBER

No. 350 500 Nos.
1 594543/A 594543/A Back Plate Assembly LH Black (Powder Coated) ) 1 Alt. No. 801526 1
2 594144/A 594144/A Back Plate Assembly RH Black (Powder Coated) ) 1 Alt. No. 867038 1
5 586052/A 586052/A Hex. Screw, M6 X 16 4 Old No. 142274 40
6 860009 860009 Side Decor - LH (Chrome Plated) 2 2
7 521088/B 521088/B Grommet 2 14
8 580447/A 580447/A Beading 2 10
9 147559/A 147559/A Mushroom Head Screw M5 2 20
10 521089/B 521089/B Strap Rubber 1 5
11 147098/C 147098/C R/R Unit - 3 Phase 1 1
12 591702/A 591702/A Hex. Bolt M6 X 1 X 12 2 50
144
06-30 Frame
3 6 52 53 54
2 51
7 50
49 57 59
1
61 60
65
46 64 59
5 63 56 58
62 45 55
61 57
44
7
47 31
2 32 23
12 33
4 28 29 22 17 34
48 21 16
19
9 11 17 43
7 17 16 41
16 39
27 40 42
17
8
35
16
10
18 30
67
13 26 30 41 39
40
15 14 38 37
20 14
66
25
32 24 37
31 34
33
145
06-30 Frame
KEY PART NUMBER

No. 350 500 Nos.
1 867040 867040 Frame Assembly - Black (Powder Coated) 1 Alternate No. 594115/C 1
2 144582/E 144582/E Ball Race Frame 2 1
3 140201 140201 Ball, Dia 1/4” (6.35 MM) 19 38
4 145446/A 145446/A Cover Ball Race 1 20
5 594091/B 594091/B Tank Decor - Plate LH - Black (Powder Coated) 1 Alt. No. 867036 1
6 594092/B 594092/B Tank Decor - Plate RH - Black (Powder Coated) 1 Alt. No. 867037 1
7 147896/A 147896/A Philips Pan Head Screw, M5 X 6 6 50
8 594202/B 594202/B Engine Mounting Bracket - LH, Black-Powder Coated 1 Alt. No. 867031 1
9 594469/B 594469/B Engine Mounting Bracket - RH, Black-Powder Coated 1 Alt. No. 867032 1
10 593049/C 593049/C Flanged Hex. Bolt 1/2"x120 1 5
11 586008/A 586008/A Plain Washer M12 1 Old No. 145708/A, 580344/A, 593023/A 5
12 593050/C 593050/C Hex. Nut with Nyloc Insert 1 5
13 593060/C 593060/C Flanged Hex. Bolt M8 X 120 1 10
15 594420/A 594420/A Hex. Flange Bolt M8 X 1.25 X 176 1 10
16 586036/A 586036/A Plain Washer 5 Old No. 140437/1, 593028/A, 140080/2 5
18 594389/A 594389/A Engine Mounting Plate Rear Complete - LH, Black Matt , Black-Powder Coated 1 Alt. No. 867033 1
19 801529 801529 Engine Mounting Plate Rear “R” 1 1
20 593022/C 593022/C Hex. Bolt M12 X 266 1 1
21 586008/A 586008/A Plain Washer M12 1 Old No. 145708/A, 580344/A, 593023/A 5
22 593024/D 593024/D Hex. Nut with Nyloc M12 1 10
23 594330/A 594330/A Flanged Hex. Bolt M10 1 10
146
06-30 Frame
3 6 52 53 54
2 51
7 50
49 57 59
1
61 60
65
46 64 59
5 63 56 58
62 45 55
61 57
44
7
47 31
2 32 23
12 33
4 28 29 22 17 34
48 21 16
19
9 11 17 43
7 17 16 41
16 39
27 40 42
17
8
35
16
10
18 30
67
13 26 30 41 39
40
15 14 38 37
20 14
66
25
32 24 37
31 34
33
147
06-30 Frame
KEY PART NUMBER

No. 350 500 Nos.
24 593011/C 593011/C Flanged Hex. Nut M10x1.25 1 Old No. 593011/B 5
25 580203/D 580203/D Cap Swing Pivot 2 2
26 867044 867044 Spacer - Cradle Tube, Black-Powder Coated 1 Alt. No. 594333 5
570262/F Steady Bracket 1 4
28
581048/B Steady Bracket 1 4
29 593011/C 593011/C Flanged Hex. Nut M10 X 1.25 1 Old No. 593011/B 5
30 142258 142258 Hex. Screw M8 X 16 2 50
31 586046/A 586046/A Washer Faced Hex. Nut 3/8” 2 Old No. 140402/C 14
32 586047/A 586047/A Stud 3/8” X 26” TPI 2 Old No. 146143/B 6
33 586070/A 586070/A Plain Washer 2 Old No. 142835 20
34 586057/A 586057/A Hex. Nut 2 Old No. 140302/3 10
35 594545/A 594545/A Flanged Hex. Bolt M10 X 1.25 X 75 1 10
36 593011/C 593011/C Flanged Hex. Nut M10 X 1.25 1 5
37 594009/B 594009/B Hex. Nyloc Nut M10 X 1.5 2 10
39 586035/A 586035/A Plain Washer 2 Old No. 140383/A 50
40 140090/1 140090/1 Star Washer 2 50
41 586029/A 586029/A Hex. Nut M6 2 Old No. 141060 40
43 801530 801530 Bracket (Piece Mudguard), Black-Powder Coated 1 Alt. No. 580314/A 1
44 581019/B ECU Carrier Assembly, Black-Powder Coated 1 Alt. No. 801538 1
45 571056/A ECU Unit 1 1
148
06-30 Frame
3 6 52 53 54
2 51
7 50
49 57 59
1
61 60
65
46 64 59
5 63 56 58
62 45 55
61 57
44
7
47 31
2 32 23
12 33
4 28 29 22 17 34
48 21 16
19
9 11 17 43
7 17 16 41
16 39
27 40 42
17
8
35
16
10
18 30
67
13 26 30 41 39
40
15 14 38 37
20 14
66
25
32 24 37
31 34
33
149
06-30 Frame
KEY PART NUMBER

No. 350 500 Nos.
46 521089/B Strap 1 5
594210/B Flanged Hex. Bolt M8 X 90 1 5
47
593144/A Flanged Hex. Bolt M8 X 55 1 5
49 591578/A Flanged Hex. Bolt M6 X 35 2 10
50 147504/A Bush - PAV 2 N.S., Old No. 573977/A 2
51 147502/A Grommet - PAV 2 50
52 510187/B Pulse Air Valve - Ucal 1 1
53 586031/A Lock Washer M6, Internal Teeth 2 Old No. 140129 50
54 586029/A Hex. Nut M6 2 Old No. 141060 40
55 573986/A Braided Hose Assembly 1 1
56 146318/A SS Hose Clip 1 2
57 140573/B Clip - PAV 2 40
58 573984/A PAV Hose - Air Filter 1 1
59 147701/A Wire Clip 2 50
60 573985/A PAV Tube Adaptor 1 1
61 594268/B 594268/B Front Damper Tank 2 2
62 594158/A Bracket Filter Box Mounting, Black-Powder Coated - 350cc 1 Alt. No. 867046 1
63 586032/A Punched Washer 2 Old. No. 141061/1 50
65 586052/A Hex. Screw M6 X 16 2 Old No. 142274 40
66 580314/A 580314/A Bracket Piece Mudguard 1 Alt. No. 801630 1
67 586001/A 586001/A Flanged Hex. Bolt M8 X 1.25 X 112 1 5
150
07-00 Battery, Battery Carrier and Harness
1 1
350-TCI 500-EFI
4
2
11
5
6 7 8 9
3
6
15 14 17
13 12
10
16
18
19
151
07-00 Battery, Battery Carrier and Harness
KEY PART NUMBER

No. 350 500 Nos.
594440/A Harness Main Cable - 350 TCI 1 1
1
594038/A Harness Main Cable - 500 EFI 1 1
2 592212/A 592212/A Battery, 12V-14 AH MF14-A2 1 Alt. No. 146134/C 1
3 521204/F 521204/F Battery Carrier Complete (ES) 1 Alt. No. 801541 1
4 594104/B 594104/B Cover Battery 1 1
5 521204/F 521204/F Back Plate Assembly 1 Alt. No. 801292 1
6 142258 142258 Hex. Bolt M8 X 16 2 50
7 141162/C 141162/C Cable Strap - Long 8” 4 40
8 141161/C 141161/C Cable Strap - Small 6” 5 40
9 582511/A 582511/A Strap (White) 3 Old No. 500917/B 30
10 594542/A 594542/A Cable - Battery Negative 1 Alt. No.147956/A 1
11 594173/A 594173/A Wiring Harness - Tail Light 1 2
12 594525/A Mini Blade Fuse 10 Amps (Red Colour) (4+1) 4 10
13 594524/A Mini Blade Fuse 15 Amps (Blue Colour) (2+1) 4 10
14 582512/A Blade Fuse 10 Amps (Red Colour) (1+1) 3 10
15 582513/A Blade Fuse 15 Amps (Blue Colour) (1+1) 3 10
16 594744/A Rubber Holder Fuse Carrier 1 10
17 573993/A Starter Motor 0.7KW 1 1
18 573992/A Starter Motor 0.9KW 1 1
19 591494/A 591494/A Neutral Switch with Gasket 1 1
152
07-10 Head Lamp
A1
Key Nos. A2
All
4
5
3
A3
2
6
153
07-10 Head Lamp
KEY PART NUMBER

No. 350 500 Nos.
A1 594029/A 594029/A Head Lamp Assembly with Bulb 1 1
A2 594579/A 594579/A Lens & Inner Housing Sealed Body with Bulb 1 1
A3 594580/A 594580/A Lens & Inner Housing Sealed Body without Bulb 1 1
1 594573/A 594573/A Outer Housing Chrome Plating 1 1
2 594574/A 594574/A Rim Chrome Plating 1 1
3 594575/A 594575/A HL Installation (Addon Lead - Head Lamp) 1 5
4 594576/A 594576/A Mounting Grommet 2 10
5 594577/A 594577/A Bulb H7 12V 55W 2 5
6 594578/A 594578/A Bolt M6 HL (NT) 2 20
154
07-20 Tail Lamp
A1
Key Nos.
All A2
3
1
2
155
07-20 Tail Lamp
KEY PART NUMBER

No. 350 500 Nos.
A1 594036/A 594036/A Tail Lamp LED Assembly Complete 1 1
A2 594572/A 594572/A Lens & Inner House Sealed Body Tail Lamp 1 1
1 594570/A 594570/A Outer Housing Chrome Plating 1 2
2 594571/A 594571/A Screw 8 X 19 mm (Mask & Housing) 1 20
3 Cover-LH Chrome Plating 1 2
4 Cover-RH Chrome Plating 1 2
156
07-30 Instrument Cluster
A1
500cc
MIL
6 A2
350cc
6
1
2
3
5
4
157
07-30 Instrument Cluster
KEY PART NUMBER

No. 350 500 Nos.
A1 594030/A Instrument Cluster Assembly, TB 500cc (EFI) 1 1
A2 594634/A Instrument Cluster Assembly, TB 350cc (TCI) 1 1
1 594652/A 594652/A Rubber Grommet Bulb Window 1 10
2 594650/A 594650/A Mounting Bracket - Instrument Cluster Bracket 1 1
3 594656/A 594656/A Grommet - Instrument Cluster Bracket 2 10
4 594657/A 594657/A Nut - Instrument Cluster Bracket 2 20
5 594658/A 594658/A Washer - Instrument Cluster 2 20
6 594651/A 594651/A Bulb 12V, 1.4W (Neutral and Side Stand) 2 10
158
07-40 Switches, Horn & Relays
A1 A2 A3 A4
5 Key Nos. Key Nos. Key Nos.

1&2 1&5 1&4
3
2 11 12
10
13
1
4
16
15 14
17
18
8
19
7 9
6
20
15 14
21
22
159
KEY PART NUMBER

No. 350 500 Nos.
A1 594129/B 594129/B Common Key Set 1 1
A2 888056 888056 Switch Assembly Combination and Key 1 1
A3 888057 888057 Cap Assembly Fuel Filler and Key 1 1
A4 888058 888058 Side Panel Lock and Key 1 1
1 594231/B 594231/B Key Complete - Blank 2 1
2 Ignition Switch cum Steering Lock Assembly 1 594130/B Served in Kit, Ref. A2 1
3 Cap Assembly Fuel Tank 1 594131/B Served in Kit, Ref. A3 1
4 Side Panel Lock 1 594473/A Served in Kit, Ref. A4 1
5 594513/A 594513/A Ring Fuel Cap, Metalic Silver 1 Alt. No. 859048 2
6 594102/A 594102/A Rider Seat Latch with Cable 1 1
7 594106/A 594106/A Pillion Seat Latch with Cable 1 1
8 147955/B 147955/B Relay Starter 1 1
9 Holder (For Relay Starter) 1 5
10 571059/A Relay 2 1
11 594228/B 594228/B Bracket LH Assembly - Horn MTG, Black-Powder Coated 1 Alt. No. 867047 1
12 594332/B 594332/B Bracket RH Assembly - Horn MTG, Black-Powder Coated 1 Alt. No. 867048 1
13 591980/A 591980/A Horn LT 1 1
15 586002/A 586002/A Flanged Hex. Bolt M8X20 2 Old No. 580349/A, 145862/A, 20
594310/A, 593927/A, 593016/A
16 580397/A 580397/A Suppressor Cap, M10 (Spark Plug) 1 1
17 500905/C 500905/C Suppressor Cap, M14 (Spark Plug) 1 1
18 594541/A 594541/A Electronic Flasher Unit - 40W 1 Alt. No. 594437/A 1
160
A1 A2 A3 A4
5 Key Nos. Key Nos. Key Nos.

1&2 1&5 1&4
3
2 11 12
10
13
1
4
16
15 14
17
18
8
19
7 9
6
20
15 14
21
22
161
KEY PART NUMBER

No. 350 500 Nos.
19 591981/A 591981/A Horn HT 1 1
20 594681/A 594681/A Cable, Rider Seat Latch 1 10
21 594682/A 594682/A Cable, Pillion Seat Latch 1 10
22 144519 Flashet Bracket AC/DC 1 10
162
07-50 TCI & EFI Ignition Components
EFI System
2 20
3
1
7
21
8
9
2
3 10
11 22
23
15 12
16
18 16 15
19
A1
17 13
24 24 Key Nos.
19 18 23, (16 & 17 in
16 Page No. 158)
15 4
25 A2
14 Key Nos.
5 23, 25, (Qty. 2
Nos. 24)
6
163
KEY PART NUMBER

No. 350 500 Nos.
A1 591837/A Dual Ignition Coil Assembly with Spark Plug Caps 1 1
A2 591879/A Dual Ignition Coil Assy. C5 1 1
1 147098/C 147098/C R/R Unit - 3 Phase 1 1
2 591702/A 591702/A Hex. Bolt M6 X 12 2 50
4 581054/B Roll Over Sensor 1 1
5 141061 Punched Washer 6.4 1 20
6 586053/A Hex. Screw M6 x 25 1 Old No. 143498 10
7 592238/A Digital TCI - Unit 1 1
8 586052/A Hex. Screw M6 X 16 2 Old No. 142274 40
10 586032/A Plain Washer 2 Old No. 141061/1 50
11 502026/B Bracket - TCI Unit 1 10
12 147096/A Primary Ignition Coil without Bracket 1 1
13 581027/B Secondary Ignition Coil with Resistive Cable 1 1
14 580377/B Bracket, Ignition Coil 1 1
15 142606 Lock Washer Internal Teeth 4 40
16 502071 Hex. Screw M5 4 50
17 580288/D Throttle Position Switch 1 1
18 142606 Lock Washer Internal Teeth 2 40
19 502071 Hex. Screw M5 2 20
20 521089/B Strap - Rubber (Thunderbird) 1 2
21 592861/B Electronic Control Unit - ECU 500 EFI - Domestic 1 1
164
EFI System
2 20
3
1
7
21
8
9
2
3 10
11 22
23
15 12
16
18 16 15
19
A1
17 13
24 24 Key Nos.
19 18 23, (16 & 17 in
16 Page No. 158)
15 4
25 A2
14 Key Nos.
5 23, 25, (Qty. 2
Nos. 24)
6
165
KEY PART NUMBER

No. 350 500 Nos.
22 592862/B Sticker - ECU 1 10
23 591837/B Dual Ignition Coil without Bracket 1 1
24 500632 Hex. Screw Head Cap Screw M5 2 20
25 591874/A Bracket, Dual Ignition Coil 1 1
166
07-60 Trafficator Lights & Tools, First Aid Kit
Front LH Front RH A2
A3 A2 Key Nos.
4 1, 3, 4 & 6
A3
3
A1 Key Nos.
A2
1 2, 3, 4 & 5
Rear LH Rear RH
6
RH A2 A3
A4
A4
7 8 9 10 11 12 13 Key Nos.
4
7 to 13
A3 3 15
2
14
LH
167
07-60 Trafficator Lights, Tools & First Aid Kit
KEY PART NUMBER

No. 350 500 Nos.
A1 888199 888199 Trafficator Kit - Thunderbird 1 1
A2 594016/A 594016/A Trafficator Assembly RH 2 1
A3 594015/A 594015/A Trafficator Assembly LH 2 1
A4 570828/B 570828/B Tool Kit Assembly 1 1
1 594583/A 594583/A Lens & REF Sealed Body FLH / RRH 1 2
2 594584/A 594584/A Lens & REF Sealed Body FRH / RLH 1 2
3 594581/A 594581/A Bulb 12V R10W 1 Alt. No. 146348 or 142721 10
4 Screw M2, 9 X 13 Trafficator 1 594582/a 20
5 594404/A 594404/A TSL Gum Arm FLH / RRH 2 2
6 594418/A 594418/A TSL Gum Arm FRH / RLH 2 2
7 Tool Bag 1 521150/B N.S., Ref. A1
8 Screw Driver 1 521104/A N.S., Ref. A1
9 Tommy Bar 1 570827/B N.S., Ref. A1
10 Box Spanner 20.9X24 1 142631 N.S., Ref. A1
11 Tool Spark Plug 1 570826/B N.S., Ref. A1
12 Double End Spanner 10 X 12mm 1 580695/A N.S., Ref. A1
13 Double End Spanner 1/4” X 5/16” 1 140501 N.S., Ref. A1
14 595008/A 595008/A Allen Key 4mm 1 10
15 First Aid Kit 1 521097/A N.S. 1
168
08-00 Special Tools List - A (Common)
2
1 3 4
5 6 7 8
9 10 11 12
169
08-00 Special Tools List - A (Common)
KEY PART NUMBER

No. 350 500 Nos.
1 ST 26199-3 ST 26199-3 Cylinder Head Nut Tightening Tool (UCE models) 1 Old No.ST-25118/4, N.S. 1
(New Design, Common)
2 ST 25123-1 ST 25123-1 Valve Spring Compressor 1 Common 1
3 ST 25128-2 ST 25128-2 Puller for Magneto Rotor 1 Common 1
4 ST 25151-4 ST 25151-4 Puller for Chaincase Outer 1 Common 1
5 ST 25153-4 ST 25153-4 Extractor for Gear Box Rocker Pivot Pin - 5 Speed 1 Common 1
6 ST 25110-3 ST 25110-3 Gauge Plate for Tightening Chain Stay 1 Common 1
7 Mandrel for Oil Seal Pressing 1 Reference only, ST 25113-4 1
8 Expander for Front Fork Oil Seal 1 Reference only, ST 25112-4 1
9 Extractor for Fork Oil Seal 1 Reference only, ST 25114-4 1
10 ST-25244-4 ST-25244-4 Special Spanner Adjuster Rear Shox 1 Common 1
11 ST-25612-4 ST-25612-4 Rotor Tightening & Loosening Tool 1 Common 1
12 ST-25592-4 ST-25592-4 Connecting Rod Locking Tool 1 Common 1
170
08-10 Special Tools List - B (Common & Exclusive for Thunderbird 350 & 500 Models)
13 14 15 16
17 18
19 20 21
171
08-10 Special Tools List - B (Common & Exclusive for Thunderbird 350 & 500 Models)
KEY PART NUMBER

No. 350 500 Nos.
13 ST-25591-4 ST-25591-4 Sprocket & Clutch Tightening Tool 1 1
14 ST-25594-4 ST-25594-4 Clutch Plate Tightening Tool 1 1
15 ST-25835-2 ST-25835-2 FD Sprocket Removing Tool 1 1
16 NA NA Front Fork Dismantling Tool 1 Reference only, ST-25834-2 1
17 NA NA Front Fork Tool 1/2” SD 1 Reference only, ST-25833-4 1
18 NA CR0060 DOL Tool for EFI Diagnosis, ECU 1 1
19 ST-26461-2 ST-26461-2 Front Fork Assembling & Dismantling Tool Dia 41mm 1 1
20 ST-26455-4 ST-26455-4 Steering Ring Nut “C” Spanner 1 1
21 ST-26485-3 ST-26485-3 Front Fork Oil Seal Driver Dia 41mm 1 1
172
09-00 Wall Charts - A (UCE)
A1
Key Nos.
1 to 5
1 2 3 4
5 6 7 8
173
09-00 Wall Charts - A (UCE)
KEY PART NUMBER

No. 350 500 Nos.
A1 888081 888081 UCE Bike Wiring Diagram & Torque Value Wall Charts 8 Kit 1 Reference only, 888081 1
consists of Sl. No.1 to 8
1 NA NA Complete Wiring Diagram - Bullet 350 UCE - KS 1 Served in Kit Reference only, 888092, Ref. A1
2 NA NA Complete Wiring Diagram - Electra 350 UCE - ES 1 Served in Kit Reference only, 888091, Ref. A1
3 NA NA Complete Wiring Diagram - Classic 350 (Version 2.0) 1 Served in Kit Reference only, 888185, Ref. A1
4 NA Complete Wiring Diagram - Thunderbird 350 (Version 1.0) 1 888090 Served in Kit, Ref. A1
5 NA NA Complete Wiring Diagram - Classic 500 (Version 2.0) 1 Served in Kit Reference only, 888088, Ref. A1
6 NA Complete Wiring Diagram - Thunderbird 500 (Version 1.0) 1 888089 Served in Kit, Ref. A1
7 Torque Value Chart - Thunderbird 350 & 500 1 888188 Served in Kit, Ref. A1
8 NA NA Torque Value Chart - Electra 1 Served in Kit Reference only, 888204, Ref. A1
174
09-10 Wall Charts - B (Domestic)
A1
Key Nos.
1 to 9
1 2 3
4 5 6
7 8 9
175
09-10 Wall Charts - B (Domestic)
KEY PART NUMBER

No. 350 500 Nos.
A1 597473 597473 Classic Model Blow up Charts Kit 1 Reference only, 597473 1
consists of Sl. No.1 to 9
1 NA Crankcase RH 500 - Exploded View 1 597464 From Sl. No. 1 to 9 are
Served in Kit, Ref. A1
2 NA Crankcase RH 350 - Exploded View 1 597465 Served in kit, Ref. A1
3 Cylinder & Head 500 & 350 - Exploded View 1 597466 Served in kit, Ref. A1
4 Crankcase LH 500 & 350 - Exploded View 1 597467 Served in kit, Ref. A1
5 Cover LH & RH 500 & 350 - Exploded View 1 597468 Served in kit, Ref. A1
6 Crankcase LH & RH 500 & 350 - Exploded View 1 597469 Served in kit, Ref. A1
7 NA EFI Components - Exploded View 1 597470 Served in kit, Ref. A1
8 NA NA Complete Wiring Diagram - Classic 500 (Version 1.0) 1 Reference only, 597472, Ref. A1
9 NA NA Complete Wiring Diagram - Classic 350 (Version 1.0) 1 Reference only, 597471, Ref. A1
176
09-20 All UCE Models Service Publication List - A (Domestic)
1
2
3 4 5
177
09-20 All UCE Models Service Publication List - A (Domestic)
KEY PART NUMBER

No. 350 500 Nos.
1 Owner’s Manual Thunderbird 350 1 594069 1
2 Owner’s Manual Thunderbird 500 1 594132 1
3 888189 888189 Spare Parts Catalogue Thunderbird 500 & 350 - Book 1 1
4 Spare Parts Catalogue Thunderbird 500 & 350 (+TBTS) DVD 1 888190 1
5 Service Manual Thunderbird 500 & 350 1 1
178
09-30 All UCE Models Service Publication List - B (Domestic)
1 2 3 4
6-a 7 8
6-b
5
13
11 12
9 10
179
09-30 All UCE Models Service Publication List - B (Domestic)
KEY PART NUMBER

No. 350 500 Nos.
1 NA NA Bullet 350 UCE Owner’s Manual 1 Reference only, 592814/B 1
2 NA NA Electra 350 UCE Owner’s Manual 1 Reference only, 592579/A 1
3 NA NA Classic 350 Owner’s Manual 1 Reference only, 592025/A 1
4 NA NA Classic 500 Owner’s Manual 1 Reference only, 591822/B 1
5 Dealer’s Directory 1 581677/A New Layout, Jan. 13 Version 1
6 NA NA DVD Spare Parts Catalogue & Service Manual - Classic models 1 Reference only, 597475 1
7 NA NA DVD Parts Catalogue - Electra & Bu 350UCE 1 Reference only, 597480 1
8 888002 888002 Self Learning UCE Service Module DVD 1 1
9 NA NA Thunderbird Twinspark Parts Catalogue (2012 Revision 2.0) 1 Reference only, 597435 1
10 NA NA Thunderbird Twinspark Service Manual 1 Reference only, 597436 1
11 NA NA TBTS Owner’s Manual 1 Reference only, 580589/B 1
12 NA NA Combined UCE Models Spare Parts Catalogue 1 Reference only, 888005 1
13 NA NA Combined UCE & Retired Models Spare Parts Catalogue DVD 1 Reference only, 888006 1
180
09-40 After Market Parts
4 7
4
5
3 6
1
2
181
KEY PART NUMBER

No. 350 500 Nos.
A1 888216 888216 Off Road Silencer Kit (TB 350 & 500) 1 1
320050 320050 Touch Up Paint Aerosal, Black (440 ML) 1 1
320051 320051 Touch Up Paint Aerosal, Black (180 ML) 1 1
320038 320038 Touch Up Paint Aerosal, PU Clear (Lacquer) 440 ML 1 1
320118 320118 Touch Up Paint Spray, Twilight (440 ML) 1 AW Black Apply vehicle body 1
painted sheet metal parts
320119 320119 Touch Up Paint Spray, RJ 1580 Silver (400 ML) Thunderbird 1 Apply NT/VT powder coating parts 1
321010 321010 Touch Up Paint Spray, Dead Matt Black (440 ML) 1 Apply engine black parts like crank- 1
case, covers, cylinder & head etc.
NA Touch Up Paint Aerosol, Stone 1 1
Touch Up Paint Aerosal, Flicker 1 1
1 NA NA Touch Up Paint Aerosal, Royal Maroon C5 (440 ML) 1 Reference Only, 320040 1
NA NA Touch Up Paint Aerosal, Classic Green C5 (440 ML) 1 Reference Only, 320039 1
NA NA Touch Up Paint Aerosal, Classic Green C5 (180 ML) 1 Reference Only, 320052 1
NA NA Touch Up Paint Aerosal, Desert Storm (180 ML) 1 Reference Only, 320064 1
NA NA Touch Up Paint Aerosal, Rivera Red 1 Reference Only, 320321 1
NA NA Touch Up Paint Aerosal, Magic Black 1 Reference Only, 320012 1
NA NA Touch Up Paint Aerosal, Dark Silver 1 Reference Only, 320055 1
NA NA Touch Up Paint Aerosol, Olive Green (180 ML) 1 Reference Only, 320060 1
NA NA Touch Up Paint Aerosol, PO Red 1 Reference Only, 320014 1
NA NA Touch Up Paint Spray, Desert Storm (440 ML) 1 Reference Only, 320062 1
2 Off Road Silencer 1 595549/B 1
182
4 7
4
5
3 6
1
2
183
KEY PART NUMBER

No. 350 500 Nos.
3 Heat Shield 1 595230/B 1
4 Flange Hex. Bolt M8 X 16 2 586025/A Old No. 591534/A 50
5 Spring Washer M8 2 586038/A Old No. 210026 50
6 Phillips Pan Head Screw M6 X 6 2 147896/A 50
7 Bracket Silencer Mounting (Off Road) 1 595244/A 1
184

Page Key Page Key Page Key Page Key Page Key Page Key
Part No. No. No. Part No. No. No. Part No. No. No. Part No. No. No. Part No. No. No. Part No. No. No.
110050 43 5 140355/B 117 11 145157/C 19 42 147896/A 73 14 500845 61 16 570011 43 14
110349 99 5 140573/B 149 57 145186/C 111 10 147896/A 145 7 500846 61 19 570013 15 5
110349 117 10 141109/1 99 7 145446/A 91 22 147897/B 69 13 500847 61 20 570013 43 11
140201 89 3 141109/1 117 6 145446/A 145 4 147955/B 159 8 500848 59 5 570016 37 2
140201 145 3 141161/C 151 8 145553/B 119 18 150324/A 99 8 500855 61 30 570024 39 22
141051 17 34 141162/C 151 7 145882/A 97 4 150324/A 117 4 500857 61 28 570025 37 4
141051 69 3 141246/C 39 25 145882/A 109 7 320038 181 1 500862 63 37 570028 45 11
141061 163 5 141560 69 10 146031/A 49 46 320050 181 1 500869 61 36 570030 37 18
141963 61 24 142257/B 47 33 146044/A 75 3 320051 181 1 500870 61 35 570030 89 12
142065 69 7 143144/2 63 38 146318/A 105 29 320118 181 1 500871 61 27 570032 39 38
142095 71 1 143144/2 65 18 146318/A 149 56 320119 181 1 500872 63 48 570037 45 10
142258 147 30 143496/A 103 8 146347/B 111 1 321010 181 1 500874 61 33 570052 21 2
142258 151 6 143496/A 105 20 146435/A 113 9 390066 13 3 502071 163 16 570073 39 32
142606 163 15 144471/A 119 16 146450/B 25 44 390067 13 4 502071 163 19 570094 37 1
142606 163 18 144581/E 89 2 146459/A 17 28 390068 13 5 521125 69 9 570125 45 8
144519 161 22 144581/E 91 27 146499/A 117 5 390069 13 6 521199 135 10 570130 39 34
145854 113 18 144582/E 145 2 146714/A 47 32 500355 45 7 521237 69 A2 570155 17 30
146375 133 5 144600/A 27 54 146797/A 97 7 500355 103 10 550024 51 18 570157 51 A1
144844 33 43 144636/A 19 46 147096/A 163 12 500355 105 21 550024 55 18 570157 55 A1
110037/3 43 4 144636/A 37 16 147098/C 143 11 500632 135 15 550025 25 33 570207 45 16
110037/3 47 24 144636/A 49 44 147098/C 163 1 500632 165 24 550028 15 4 570209 45 17
111098/2 71 11 144636/A 63 42 147270/A 75 13 500834 59 13 550087 47 28 570213 27 53
120005/B 45 9 144636/A 65 7 147502/A 149 51 500835 59 12 550095 15 6 570232 45 7
140090/1 131 5 144636/A 103 9 147504/A 149 50 500836 59 6 550108 49 47 570233 23 25
140090/1 147 40 144766/A 111 11 147507/A 101 20 500837 59 7 550141 51 7 570234 23 15
140193/B 89 6 144846/A 17 26 147559/A 143 9 500838 59 9 550141 55 7 570240 47 30
140331/A 47 23 144846/A 49 39 147649/B 85 A2 500839 59 8 550141 129 7 570241 17 22
140332/B 47 22 144886/C 129 16 147701/A 149 59 500841 61 21 550141 135 7 570241 27 48
140333/B 47 21 144981/B 65 5 147870/A 105 34 500842 61 25 550141 137 30 570273 33 32
140355/B 101 19 145090 25 45 147896/A 73 14 500843 61 22 560506 71 12 570407 35 10
185

570425 15 8 500616/A 15 18 521172/A 69 5 550090/C 51 5 570048/F 21 A1 570182/B 19 45
570431 47 34 500617/A 15 15 521186/A 75 11 550090/C 55 5 570051/A 21 1 570183/D 15 2
570440 41 1 500619/A 17 19 521200/A 63 40 550091/C 51 3 570054/G 47 37 570184/B 23 24
570441 41 12 500621/A 15 16 521200/A 65 3 550091/C 55 3 570057/B 47 36 570185/B 49 50
570442 37 12 500622/B 15 3 521204/F 151 3 550119/B 53 21 570059/C 17 24 570186/D 49 49
570442 41 2 500635/A 39 37 521204/F 151 5 550119/B 57 21 570063/F 39 30 570187/B 49 52
570481 49 43 500637/B 15 14 521238/B 69 2 550216/D 51 11 570072/C 39 39 570192/C 33 35
570615 51 A3 500711/A 73 12 550007/C 51 14 550216/D 55 11 570074/I 39 33 570193/B 49 51
570804 45 A1 500712/A 71 9 550007/C 55 14 550256/A 23 18 570086/D 39 21 570198/C 23 27
570936 59 2 500823/B 69 12 550008/B 51 15 550507/A 137 19 570087/D 43 13 570201/F 43 9
570943 59 3 500823/B 71 10 550008/B 55 15 550661/A 35 6 570088/D 37 15 570201/F 45 13
570944 59 A5 500856/A 61 29 550011/C 51 10 560195/A 75 4 570089/D 37 17 570202/E 51 8
571086 65 A1 500904/A 31 20 550011/C 55 10 560502/E 99 10 570090/D 37 14 570202/E 55 8
571109 33 32 500905/C 159 17 550023/E 51 12 560519/E 99 6 570091/D 39 35 570204/H 51 20
571253 63 49 500917/B 71 14 550023/E 55 12 560521/B 99 11 570097/B 45 1 570204/H 55 20
580559 69 A1 502006/A 133 3 550030/C 47 18 560530/D 99 15 570099/C 25 42 570205/N 51 16
597459 41 A2 502018/B 35 8 550030/C 51 9 560530/D 119 22 570100/B 25 38 570205/N 55 16
597473 175 A1 502019/A 35 7 550030/C 55 9 560546/A 99 13 570102/D 23 12 570206/J 45 15
500104/D 43 2 502026/B 163 11 550032/A 43 10 560632/A 75 7 570131/A 31 9 570208/B 45 14
500104/D 45 5 502070/A 25 31 550032/A 45 12 570005/C 43 7 570132/A 25 35 570214/F 27 52
500116/A 33 37 510187/B 149 52 550061/B 35 3 570006/E 43 6 570132/A 27 56 570218/C 49 48
500123/A 33 36 521066/B 141 10 550072/B 23 16 570007/F 39 36 570141/E 45 6 570219/F 23 22
500207/A 33 31 521088/B 143 7 550075/A 51 1 570008/F 43 3 570158/B 51 A2 570227/F 23 17
500303/2 33 42 521089/B 143 10 550075/A 55 1 570012/C 43 12 570158/B 55 A2 570229/D 23 19
500307/A 31 16 521089/B 149 46 550078/A 51 6 570018/G 33 39 570163/D 31 22 570230/F 23 20
500309/B 31 17 521089/B 163 20 550078/A 55 6 570029/D 39 24 570164/D 31 21 570231/H 23 23
500322/A 31 18 521092/D 69 8 550081/C 51 4 570039/D 25 41 570165/C 33 40 570235/E 23 21
500347/A 31 19 521093/D 69 6 550081/C 55 4 570040/C 25 41 570166/C 33 41 570239/C 47 31
500352/A 31 15 521112/B 139 4 550082/C 47 26 570041/C 25 41 570176/D 17 27 570246/E 27 49
500613/A 17 20 521129/B 69 4 550083/B 47 27 570044/J 25 36 570181/B 23 11 570247/D 27 50
186

570248/D 47 19 570410/F 35 14 570536/G 31 13 570823/A 51 17 571037/B 33 42 571206/A 63 41
570249/G 37 8 570414/B 39 28 570537/D 33 33 570823/A 55 17 571039/B 33 35 571206/A 65 9
570261/B 63 39 570416/I 15 7 570538/D 33 34 570828/B 167 A4 571043/C 33 39 571216/A 39 29
570262/F 105 22 570421/A 25 34 570570/C 39 40 570832/A 63 46 571047/D 21 A1 571221/A 39 23
570262/F 147 28 570424/D 15 10 570596/B 51 13 570833/A 59 4 571051/B 65 11 571226/A 67 20
570263/B 105 24 570426/H 15 9 570596/B 55 13 570834/A 59 10 571052/A 103 5 571227/A 67 21
570272/A 29 A10 570433/B 41 11 570600/A 21 A3 570835/A 61 15 571053/A 65 12 571228/A 67 22
570276/D 47 38 570434/D 41 6 570604/A 19 47 570836/B 63 47 571055/A 65 2 571229/A 67 23
570280/B 25 39 570435/B 41 9 570658/B 49 56 570837/A 61 18 571056/A 147 45 571230/A 67 24
570282/K 59 1 570436/C 41 7 570664/A 47 28 570838/A 61 17 571059/A 159 10 571249/A 65 17
570286/C 17 33 570437/C 41 8 570665/B 49 55 570839/A 61 32 571062/B 25 29 572011/A 15 11
570291/A 35 2 570438/B 41 5 570666/A 49 54 570840/A 61 31 571063/A 103 4 572014/A 15 13
570292/A 21 6 570439/B 41 4 570702/A 47 29 570841/A 61 34 571079/D 65 4 572015/A 35 5
570293/A 21 4 570443/C 37 9 570706/B 55 A3 570842/A 61 26 571087/A 65 14 572015/A 137 20
570294/A 21 5 570443/C 41 A1 570713 27 55 570844/B 63 43 571088/C 65 15 572016/A 17 25
570295/A 37 20 570446/K 37 13 570715/A 43 15 570845/A 63 45 571090/A 65 13 572017/A 17 23
570298/A 19 48 570447/B 41 3 570715/A 45 4 570846/A 63 44 571100/A 41 9 572019/A 17 21
570298/A 25 37 570451/B 41 10 570716/A 43 16 570862/A 23 28 571108 33 30 572021/B 29 7
570298/A 25 40 570452/E 35 11 570716/A 45 3 570863/A 25 30 571113/A 37 9 572022/B 29 8
570298/A 31 11 570465/C 37 10 570723/A 19 44 570866/A 23 28 571113/A 41 A1 572044/A 53 22
570298/A 35 12 570467/A 17 29 570723/A 23 12 570867/A 25 30 571115/C 21 5 572044/A 57 22
570298/A 37 6 570468/B 49 45 570732/B 61 23 570873/A 59 14 571116/B 45 8 572304/A 65 8
570300/B 21 8 570469/A 47 25 570805/B A2 570874/A 59 11 571119/A 33 31 572318/A 31 23
570300/B 25 47 570478/B 31 25 570807/C 19 43 570898/A 43 8 571155/A 21 1 572328/A 31 24
570302/A 21 9 570479/B 31 28 570808/D 19 41 570940/A 63 50 571164/A 25 43 572338/B 49 53
570303/A 21 9 570480/B 31 27 570809/A 27 51 571032/B 27 51 571166/B 21 3 572339/A 31 20
570304/B 23 13 570482/B 31 26 570809/A 115 19 571032/B 115 19 571170/C 49 41 572607/A 65 19
570309/B 21 A2 570532/N 31 14 570813/A 21 8 571034/C 31 22 571172/C 49 41 572611/A 69 11
570409/E 79 2 570533/N 31 10 570821/A 51 19 571035/C 31 21 571201/A 15 17 573906/A 29 3
570409/F 35 9 570535/G 31 12 570821/A 55 19 571036/B 33 41 571205/A 43 8 573907/A 29 5
187

573918/A 37 19 580387/D 79 1 581738/A 135 14 586008/A 145 21 586032/A 103 15 586052/A 163 8
573925/A 35 1 580395/A 31 24 582510/A 37 7 586009/A 119 28 586032/A 109 8 586053/A 163 6
573926/A 35 A2 580397/A 159 16 582511/A 123 26 586010/A 117 12 586032/A 129 15 586056/A 105 25
573928/A 21 7 580404/A 75 2 582511/A 151 9 586012/A 111 12 586032/A 143 4 586057/A 147 34
573929/A 21 7 580431/E 109 12 582512/A 151 14 586012/A 119 13 586032/A 143 13 586070/A 101 17
573931/A 33 29 580431/E 111 14 582513/A 151 15 586014/A 71 6 586032/A 149 63 586070/A 147 33
573932/A 29 2 580441/A 75 12 582519/A 83 30 586015/A 111 8 586032/A 163 3 586084/A 39 27
573933/A 29 4 580447/A 143 8 582638/A 73 15 586016/A 111 9 586032/A 163 10 590906/B 119 15
573935/A 65 16 580749/D 113 3 586001/A 149 67 586021/A 97 6 586035/A 131 4 591023/A 133 13
573964/A 17 32 580811/B 131 11 586002/A 91 30 586021/A 109 9 586035/A 131 12 591210/A 117 7
573968/A 17 31 581004/E 71 A2 586002/A 97 2 586021/A 131 7 586035/A 147 39 591494/A 37 7
573983/A 49 40 581005/D 71 7 586002/A 109 4 586022/A 87 18 586036/A 69 14 591494/A 151 19
573984/A 149 58 581006/B 71 2 586002/A 109 6 586025/A 69 1 586036/A 135 11 591521/A 77 24
573985/A 149 60 581007/A 71 5 586002/A 129 3 586025/A 73 7 586036/A 145 16 591522/A 77 25
573986/A 149 55 581008/A 71 4 586002/A 135 3 586025/A 91 31 586038/A 73 6 591578/A 73 9
573992/A 23 10 581019/B 147 44 586002/A 159 15 586025/A 131 9 586038/A 97 3 591578/A 149 49
573992/A 151 18 581027/B 163 13 586003/A 137 32 586028/A 133 2 586038/A 159 14 591667/B 113 12
573993/A 23 10 581029/A 75 12 586004/A 71 3 586029/A 73 10 586042/A 89 5 591702/A 91 28
573993/A 151 17 581044/C 71 8 586004/A 105 23 586029/A 131 6 586042/A 103 7 591702/A 97 8
580037/H 113 4 581048/B 147 28 586004/A 135 12 586029/A 147 41 586042/A 129 9 591702/A 143 12
580038/E 113 2 581054/B 163 4 586004/A 145 17 586029/A 149 54 586042/A 131 8 591702/A 163 2
580203/D 147 25 581083/A 75 6 586004/A 149 48 586031/A 149 53 586046/A 147 31 591713/C 135 9
580286/A 27 57 581084/C 17 33 586005/A 43 1 586031/A 149 64 586047/A 147 32 591837/A 163 A1
580288/D 163 17 581085/B 113 17 586005/A 45 2 586031/A 89 11 586048/A 103 16 591837/B 165 23
580290/A 107 3 581097/A 75 4 586005/A 73 16 586031/A 91 32 586051/A 131 3 591874/A 165 25
580314/A 149 66 581098/A 75 3 586005/A 113 16 586031/A 143 3 586051/A 147 42 591879/A 163 A2
580347/A 113 5 581114/A 71 A1 586008/A 25 32 586031/A 163 9 586052/A 131 2 591980/A 159 13
580377/B 163 14 582511/A 71 14 586008/A 89 17 586032/A 73 8 586052/A 143 5 591981/A 161 19
580380/A 137 29 581122/A 73 4 586008/A 113 6 586032/A 91 29 586052/A 147 38 591992/B 135 13
580381/D 137 27 581122/A 133 7 586008/A 145 11 586032/A 97 5 586052/A 149 65 592030/A 107 17
188

592212/A 151 2 594005/B 75 1 594053/A 125 A1 594108/B 109 10 594216/B 113 14 594334/C 135 5
592237/A 25 29 594006/A 99 A1 594054/A 119 19 594109/A 139 8 594220/A 129 A4 594350/A 129 18
592238/A 163 7 594008/A 89 16 594054/A 125 A2 594110/A 141 9 594221/A 135 A2 594350/A 137 25
592256/A 85 6 594009/B 89 18 594055/A 121 A1 594116/B 129 1 594222/A 103 13 594351/A 129 17
592593/A 37 A1 594009/B 147 37 594055/A 129 8 594117/B 135 1 594228/B 159 11 594351/A 137 31
592857/B 77 22 594013/A 75 8 594063/A 135 A6 594118/A 129 4 594231/B 105 27 594356/B 89 20
592861/B 163 21 594014/A 75 9 594065/A 137 18 594118/A 137 24 594231/B 139 7 594358/B 129 2
592862/B 165 22 594015/A 133 4 594066/A 129 14 594119/A 135 4 594231/B 159 1 594365/A 113 15
593010/C 147 27 594015/A 167 A3 594067/A 129 10 594120/B 135 2 594233/A 97 10 5943702/B 129 6
593011/C 147 24 594016/A 133 8 594071/A 99 14 594121/A 91 26 594238/A 99 4 594371/A 135 A3
593011/C 147 29 594016/A 167 A2 594076/B 73 1 594125/B 109 1 594244/A 103 14 594372/B 135 6
593011/C 147 36 594018/A 93 A1 594077/B 73 2 594129/B 159 A1 594252/B 89 14 594372/B 137 26
593022/C 145 20 594019/A 93 A2 594078/B 97 9 594136/A 141 9 594253/A 89 13 594389/A 145 18
593024/D 145 22 594028/B 113 1 594079/B 73 5 594138/A 139 8 594264/B 103 3 594393/A 129 11
593038/D 37 11 594029/A 153 A1 594081/B 73 11 594144/A 143 2 594268/B 149 61 594397/A 75 A1
593038/D 101 18 594030/A 157 A1 594087/A 119 25 594158/A 149 62 594275/C 107 15 594400/A 93 7
593046/A 111 2 594036/A 133 9 594088/A 119 26 594160/B 89 8 594278/A 79 3 594401/A 93 10
593049/C 145 10 594036/A 155 A1 594089/B 105 28 594161/B 89 7 594279/A 79 1 594402/A 93 4
593050/C 113 7 594038/A 151 1 594091/B 105 33 594165/A 105 19 594281/B 107 1 594403/A 93 1
593050/C 145 12 594042/A 117 A1 594091/B 145 5 594173/A 151 11 594284/A 107 2 594404/A 167 5
593055/A 65 10 594043/C 117 A3 594092/B 105 32 594177/B 135 16 594286/A 91 24 594405/A 93 11
593060/C 145 13 594045/A 119 14 594092/B 145 6 594191/B 73 1 594287/A 91 23 594406/A 93 12
593061/C 145 14 594046/A 109 11 594094/A 107 A1 594195/A 89 9 594288/A 89 21 594407/A 93 13
593090/C 37 5 594046/A 123 19 594097/A 109 5 594202/B 145 8 594298/A 107 A2 594408/A 93 14
593095/A 119 27 594046/A 133 12 594101/B 133 1 594208/A 103 2 594300/A 107 16 594409/A 93 6
593108/A 113 11 594047/A 135 A1 594102/A 107 6 594209/A 73 13 594305/A 107 7 594410/A 93 8
593109/A 111 3 594048/B 115 20 594102/A 159 6 594210/B 105 26 594306/A 107 9 594411/A 93 9
593144/A 149 47 594048/B 119 21 594104/B 151 4 594210/B 149 47 594330/A 145 23 594413/A 93 16
594002/A 103 1 594050/A 119 23 594106/A 107 10 594214/A 131 10 594332/B 159 12 594414/A 95 17
594004/A 75 A1 594051/A 119 24 594106/A 159 7 594215/A 91 25 594334/B 129 5 594415/A 95 19
189

594418/A 167 6 594537/A 129 13 594651/A 157 6 594709/A 81 A11 860009 143 6 874003 139 1
594419/A 93 5 594538/A 103 6 594652/A 157 1 594710/A 81 A4 867003 111 7 874004 139 1
594420/A 145 15 594540/A 113 8 594655/A 107 4 594711/A 81 A12 867034 113 A1 874005 139 2
594421/A 99 3 594541/A 159 18 594656/A 157 3 594712/A 81 A5 867040 145 1 874006 139 2
594422/A 101 16 594542/A 151 10 594657/A 157 4 594713/A 85 A6 867044 147 26 874007 131 1
594425/A 75 5 594543/A 143 1 594658/A 157 5 594714/A 85 A7 867071 133 11 875001 97 1
594426/A 75 10 594545/A 147 35 594660/A 107 5 594715/A 85 A3 867072 73 3 875002 103 A1
594427/A 117 8 594553/A 93 3 594680/A 109 14 594717/A 85 A8 869001 37 3 875003 139 1
594428/A 117 9 594562/A 119 20 594681/A 107 11 594718/A 85 A9 869002 35 A1 875004 139 2
594440/A 151 1 594570/A 155 1 594681/A 161 20 594720/A 85 A5 869003 35 A3 875005 131 1
594453/A 107 8 594571/A 155 2 594682/A 107 12 594721/A 81 A6 869005 15 A1 879001 131 1
594469/B 145 9 594572/A 155 A2 594682/A 161 21 594721/A 85 A4 869006 15 A5 879002 139 2
594470/A 103 17 594573/A 153 1 594688/A 121 A2 594721/A 121 A9 869009 29 1 879003 139 2
594474/C 73 17 594574/A 153 2 594689/A 121 A7 594729/A 125 5 869010 29 6 879004 139 1
594484/B 113 10 594575/A 153 3 594690/A 121 A6 594744/A 151 16 869011 23 26 879005 139 1
594491/A 111 5 594576/A 153 4 594691/A 121 10 594816/A 103 A3 869019 25 46 879006 103 A1
594492/A 111 4 594577/A 153 5 594693/A 121 A8 595008/A 167 14 869020 23 14 879007 97 1
594493/B 111 6 594578/A 153 6 594694/A 121 A5 801529 145 19 869023 47 35 888002 179 8
594500/A 139 3 594579/A 153 A2 594695/A 121 A3 801530 147 43 869025 65 6 888003 29 A3
594501/A 139 5 594580/A 153 A3 594696/A 125 A4 845019 89 4 869031 23 26 888004 29 A3
594511/A 123 11 594581/A 167 3 594697/A 125 A5 845020 133 6 869032 13 1 888009 81 A3
594513/A 103 11 594583/A 167 1 594698/A 125 A3 859040 99 9 869033 13 1 888050 117 A5
594513/A 159 5 594584/A 167 2 594700/A 125 A6 859041 99 12 869043 29 A1 888051 99 A6
594514/A 103 12 594601/A 109 13 594701/A 125 A8 859042 89 19 869044 29 A9 888056 159 A2
594517/A 85 A1 594601/A 111 13 594703/A 125 A7 859043 89 15 869046 29 A1 888057 103 A2
594518/A 123 23 594630/A 87 17 594704/A 81 A2 859045 89 1 869047 29 A9 888057 159 A3
594524/A 151 13 594631/A 81 A1 594705/A 81 A7 859046 117 3 869049 33 38 888058 139 A1
594525/A 151 12 594634/A 157 A2 594706/A 81 A8 859047 119 17 869052 33 38 888058 139 A4
594526/A 129 12 594635/A 77 18 594707/A 81 A9 859049 109 2 874001 97 1 888058 159 A4
594533/A 113 13 594650/A 157 2 594708/A 81 A10 859050 109 3 874002 103 A1 888079 113 A4
190

888081 173 A1 888148 113 A3 888182 45 A3 NA 179 1 ST-25592-4 169 12
888083 59 A1 888149 113 A3 888183 65 A2 NA 179 2 ST-25594-4 171 14
888084 59 A2 888150 117 A4 888186 79 A1 NA 179 3 ST-25612-4 169 11
888085 59 A3 888151 117 A6 888187 79 A1 NA 179 4 ST-25835-2 171 15
888086 59 A4 888152 117 A7 888189 177 3 NA 179 6 ST-26455-4 171 20
888101 15 A2 888153 117 A8 888192 65 A3 NA 179 7 ST-26461-2 171 19
888102 41 A2 888154 117 A9 888193 75 A2 NA 179 9 ST-26485-3 171 21
888109 29 A7 888157 121 A4 888195 111 A1 NA 179 10 13 2
888110 29 A8 888159 133 A1 888197 129 A3 NA 179 11 13 2
888111 29 A6 888160 139 A2 888198 139 A3 NA 179 12 29 A10
888112 15 A3 888161 139 A2 888199 167 A1 NA 179 13 33 30
888113 29 A6 888162 129 A2 888207 13 2 NA 181 1 39 26
888115 35 A4 888163 135 A4 888208 13 2 NA 181 1 45 A4
888118 99 A5 888164 129 A1 888209 73 A2 NA 181 1 81 A13
888119 99 A7 888164 135 A5 888210 73 A1 NA 181 1 83 25
888127 71 A3 888166 99 A2 888211 73 A1 NA 181 1 87 16
888128 75 A4 888167 117 A2 888216 181 A1 NA 181 1 121 1
888133 89 A1 888168 75 A3 888224 59 A6 NA 181 1 123 14
888134 89 A2 888169 15 A4 888225 59 A7 NA 181 1 123 15
888135 93 A3 888170 21 A4 888056/A 89 10 NA 181 1 125 1
888136 93 A4 888171 29 A2 NA 171 16 NA 181 1 127 16
888137 93 A5 888172 29 A2 NA 171 17 NA 181 1 127 20
888138 93 A7 888173 29 A5 CR0060 171 18 ST 25110-3 169 6 155 3
888139 93 A6 888174 29 A4 NA 173 1 ST 25123-1 169 2 155 4
888140 97 A1 888175 35 A5 NA 173 2 ST 25128-2 169 3 159 9
888141 99 A3 888176 65 A4 NA 173 3 ST 25151-4 169 4 171 7
888142 99 A4 888178 117 A10 NA 173 5 ST 25153-4 169 5 171 8
888143 99 A8 888179 21 A5 NA 173 8 ST 26199-3 169 1 171 9
888146 111 A2 888180 21 A6 NA 175 8 ST-25244-4 169 10 181 5
888147 113 A2 888181 21 A7 NA 175 9 ST-25591-4 171 13 181 1
191
11-00 Service Bulletins Checklist for Parts Catalogue Update
SB NO. RECEIVED DATE UPDATED BY DATE & SIGN OF PARTS INCHARGE SB NO. RECEIVED DATE UPDATED BY DATE & SIGN OF PARTS INCHARGE
SB - 687 Last SB No. 687 had been updated in this parts catalogue
SB - 688
SB - 689
SB - 690
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00-00 General Information

02-30 Air Filter (500cc)

Key No. Which make up

00-00 General Information

 PART NUMBER LIST

KEY PART NUMBER MOQ

1. KEY NUMBER (KEY NO.)

00-00 General Information

00-10 Group Index - Pictorial

01-10 Engine 01-20 Engine Cover RH 01-30 Crankcase RH - Cover Side

01-70 Clutch 01-80 Crankcase LH 01-90 Crankcase RH

00-10 Group Index - Pictorial

00-10 Group Index - Pictorial

00-10 Group Index - Pictorial

00-10 Group Index - Pictorial

00-10 Group Index - Pictorial

KEY PART NUMBER

01-20 Engine Cover RH

01-20 Engine Cover RH

KEY PART NUMBER

01-20 Engine Cover RH

01-20 Engine Cover RH

KEY PART NUMBER

01-20 Engine Cover RH

01-20 Engine Cover RH

KEY PART NUMBER

01-30 Crankcase RH - Cover Side

01-30 Crankcase RH - Cover Side

KEY PART NUMBER

01-30 Crankcase RH - Cover Side

01-30 Crankcase RH - Cover Side

KEY PART NUMBER

01-30 Crankcase RH - Cover Side

01-30 Crankcase RH - Cover Side

KEY PART NUMBER

01-30 Crankcase RH - Cover Side

01-30 Crankcase RH - Cover Side

KEY PART NUMBER

01-40 Cylinder & Head Assembly

01-40 Cylinder & Head Assembly

KEY PART NUMBER

01-40 Cylinder & Head Assembly

01-40 Cylinder & Head Assembly

KEY PART NUMBER

01-40 Cylinder & Head Assembly

01-40 Cylinder & Head Assembly

KEY PART NUMBER

01-50 Engine Cover LH

01-50 Engine Cover LH

KEY PART NUMBER

01-60 Crankcase LH - Cover Side

01-60 Crankcase LH - Cover Side

KEY PART NUMBER

01-60 Crankcase LH - Cover Side

01-60 Crankcase LH - Cover Side

KEY PART NUMBER

KEY PART NUMBER

KEY PART NUMBER

KEY PART NUMBER

KEY PART NUMBER

KEY PART NUMBER