Professional Documents
Culture Documents
2. How to Order Spare Parts : The part number and the description of the
In a continual effort to improve Performance and Efficiency of the vehicles, part required should be invariably mentioned in the order as per the
Specifications, Diagrams, Illustrations and Part Numbers can change without catalogue text.
notice. Consequently, the description in this Spare Parts Catalogue cannot
The latest part number as conveyed through our service circulars should
therefore be final and binding on us. only appear on the order. In case of ordering painted components,
colour shade of the components should be mentioned.
The modifications / alterations which are carried out after the issue of this The quantity shown against the part number is the quantity per vehicle
catalogue, will be conveyed to you through our Service Circulars. You are for that group so that particular quantity should be multiplied by the
requested to make necessary corrections in the Parts Catalogue as per the number of sets required.
circulars so as to keep your catalogue up-to-date. This will ensure the
3. Part Number System : We have used 8 digit system for part numbers.
appropriate and speedy delivery of the Spare Parts as the order placed will The model or hardware item is indicated by first two digits or
bear the latest part numbers. alphanumeric, the next two or four digits indicate main group and the last
four or two digits indicate serial number in main group or serial number
or subgroup of fastener respectively. Thus the part numbers will be
In case, if you need any technical assistance contact the concerned Regional
indicated by 2-2-4 or 2-4-2 digit system. Understanding this system will
Office or write to us on the following address : enable you to identify the spare parts easily.
PLATE NO. : 1 PAGE NO. PLATE NO. : 2 PAGE NO. PLATE NO. : 5 PAGE NO. PLATE NO. : 6 PAGE NO.
COVER CYLINDER HEAD 2 CYLINDER HEAD 4 CYLINDER BLOCK & PISTON 10 CRANKSHAFT 12
PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
VALVE 6 CAMSHAFT / TENSIONER 8 TRANSMISSION 14 CHANGE DRUM / SHIFT FORK 16
Pictorial Index Pictorial Index
PLATE NO. : 9 PAGE NO. PLATE NO. : 10 PAGE NO. PLATE NO. : 13 PAGE NO. PLATE NO. : 14 PAGE NO.
GEAR CHANGE MECHANISM 18 ENGINE ASSLY & CRANKCASE RH 20 COVER MAGNETO 26 CLUTCH 28
PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO. PLATE NO. : 15 PAGE NO. PLATE NO. : 16 PAGE NO.
CRANKCASE LH 22 COVER CLUTCH 24 KICK STARTER MECHANISM 30 CARBURETOR 32
Pictorial Index Pictorial Index
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
AIR CLEANER COMPLETE 34 SILENCER ASSLY 36 MAGNETO / C.D.I. / H.T. COIL 42 SEAT ASSLY / SEAT LOCK 44
PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
OIL PUMP 38 STARTER ASSLY 40 ENGINE MOUNTINGS 46 FRAME & FRAME FITTINGS 48
8
1
8
5 5
6 2
4
Pictorial Index Pictorial Index
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO. PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
SWING ARM / RR. SHOCK ABSORBER 50 RIDER & PILLION FOOT REST 52 TYRE / TUBE / RIM 58 FRONT HUB 60, 62
PLATE NO. : 27 PAGE NO. PLATE NO. : 28 PAGE NO. PLATE NO. : 31 PAGE NO. PLATE NO. : 32 PAGE NO.
MUDGUARD FRONT & REAR 54 STAND ASSLY 56 REAR HUB 64, 66 REAR BRAKE PEDAL 68
Pictorial Index Pictorial Index
PLATE NO. : 37
PLATE NO. : 33 PAGE NO. PLATE NO. : 34 PAGE NO. PAGE NO. PLATE NO. : 38 PAGE NO.
FITTINGS- PETROL TANK, SIDE
HANDLE BAR 70, 72 FRONT FORK 74 80 METER ASSEMBLY 82
COVERS & COVER SEAT
PLATE NO. : 36
PLATE NO. : 35 PAGE NO. PAGE NO. PLATE NO. : 39 PAGE NO. PLATE NO. : 40 PAGE NO.
PETROL TANK, CAP TANK &
PAINTED PARTS & DECALS 76 78 CONTROL CABLE 84 CHAIN CASE 86
GAUGE FUEL
Pictorial Index Pictorial Index
PLATE NO. : 41 PAGE NO. PLATE NO. : 42 PAGE NO. PLATE NO. : 45 PAGE NO. PLATE NO. : 46 PAGE NO.
HEAD LAMP & FAIRING 88 INDICATOR LIGHT ASSEMBLY 90 TOOL KIT 96 ACCESSORIES / GRAB HANDLE 98
PLATE NO. : 43
PAGE NO. PLATE NO. : 44 PAGE NO.
TAIL LAMP ASSLY. / FRONT
92 ELECTRICAL EQUIPMENTS 94
NUMBER PLATE
Plate No.: 1 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
6 3
5
4
1 2
Front Wheel Direction
Plate No.: 2 Brand ID: 001MC636
Cylinder Head
Description KS ES
No. Part No. Remarks
Drum Drum
7
8
4
10
5
3 4
Front Wheel Direction
Plate No.: 3 Brand ID: 001MC636
Valve
Description KS ES
No. Part No. Remarks
Drum Drum
1
5 36 JA00 03 Valve repair kit 1 1 Ref. page no. 99
5
2
5 6
Front Wheel Direction
Plate No.: 4 Brand ID: 001MC636
Camshaft / Tensioner
Description KS ES
No. Part No. Remarks
Drum Drum
7 8
Front Wheel Direction
Plate No.: 5 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
2
6
1
4
9 10
Front Wheel Direction
Plate No.: 6 Brand ID: 001MC636
Crankshaft
Description KS ES
No. Part No. Remarks
Drum Drum
1
11 JB 5310 21 Plunger oil 1 1
3
12 JD 5310 04 Spacer crankshaft 1 1 N.I.
6
2
11 12
Front Wheel Direction
Plate No.: 7 Brand ID: 001MC636
Transmission
Description KS ES
No. Part No. Remarks
Drum Drum
13 14
Front Wheel Direction
Plate No.: 8 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
4
6 7
3
8
15 16
Front Wheel Direction
Plate No.: 9 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
10
9
11
17 18
Front Wheel Direction
Plate No.: 10 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
13
12 JA 5410 14 Bolt shift change 1 1
13 JA 5410 12 Guide kick 1 1
7 14 39 1964 04 Bolt flanged small 2 2
19 20
Front Wheel Direction
Plate No.: 11 Brand ID: 001MC636
Crankcase LH
Description KS ES
No. Part No. Remarks
Drum Drum
21 22
Front Wheel Direction
Plate No.: 12 Brand ID: 001MC636
Cover Clutch
Description KS ES
No. Part No. Remarks
Drum Drum
23 24
Front Wheel Direction
Plate No.: 13 Brand ID: 001MC636
Cover Magneto
Description KS ES
No. Part No. Remarks
Drum Drum
4
11 JA 5410 05 Bush Bendix 1 1
12 JW 2330 00 Gear shifter label 1 1
6
2
1 12 7
25 26
Front Wheel Direction
Plate No.: 14 Brand ID: 001MC636
Clutch Assly
Description KS ES
No. Part No. Remarks
Drum Drum
11
10
1 JK 5514 00 Clutch Assly Complete 1 1
3
1A JD 5514 00 Spacer Clutch Assely 1 1 ‘JD’ Mark for I.D.
9
2 JA 5514 06 Collar Clutch 1 1
8
3 39 2600 11 Washer 1 1
1A 2
4 36 PA00 06 Set Primary Drive & Driven 1 1 Refer Page No. 99
5 JB 5514 08 Wheel Clutch 1 1
27 28
Front Wheel Direction
Plate No.: 15 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
4 3
29 30
Front Wheel Direction
Plate No.: 16 Brand ID: 001MC636
Carburettor
Description KS ES
No. Part No. Remarks
Drum Drum
31 32
Front Wheel Direction
Plate No.: 17 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
14 7
33 34
Front Wheel Direction
Plate No.: 18 Brand ID: 001MC636
Silencer Assembly
Description KS ES
No. Part No. Remarks
Drum Drum
5
5
1
8
9
35 36
Front Wheel Direction
Plate No.: 19 Brand ID: 001MC636
Oil Pump
Description KS ES
No. Part No. Remarks
Drum Drum
37 38
Front Wheel Direction
Plate No.: 20 Brand ID: 001MC636
7
9 JA 3516 06 Sealing Ring (Flash) -- 1
JA 3516 26 Sealing Ring (Lucas-TVS) -- 1
10 DH 1011 63 Flange Bolt (Flash) -- 2
17
16
15 JA 3516 24 Brush Spring (Lucas-TVS) -- 1 N.I.
13
16 JA 3516 19 Terminal Assly (Lucas-TVS) – 1
17 36 Jw0014 Starter Clutch Repair Kit – 1
11 9
39 40
Front Wheel Direction
Plate No.: 21 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
4
7/7A
12
41 42
Front Wheel Direction
Plate No.: 22 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
4
2
43 44
Front Wheel Direction
Plate No.: 23 Brand ID: 001MC636
Engine Mountings
Description KS ES
No. Part No. Remarks
Drum Drum
5 5
6 2
4
45 46
Front Wheel Direction
Plate No.: 24 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
5
7
47 48
Front Wheel Direction
Plate No.: 25 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
12
5 JK 1220 08 Nut Hex./ flange M12 1 1
6 9 11 12 12
6 DZ 1710 09 Damper for Swing arm 1 1
8
7 39 0454 11 Plain washer 2 2
7 8 39 0553 02 Self tapping Screw 2 2
19
13 13 9 JK 1220 07 Domed Cap Nut M12 1 1
11 5 10 JK 1220 10 Hex nut M12x1 1 1
3
4
4
3
2 11 JK 1220 09 Washer Spring 4 4
1 12 JB 1220 11 Washer Plain 8 8
13 36 DF17 01 Rubber Inner Bush kit 1 1 Refer page no. 62
14 JK 1220 05 Adjuster Chain (RH) 1 1
14
15 39 1309 11 Washer Plain 2 2
12 15
17
9 11 15 16 16 39 2122 15 Hex Nut M6x1 2 2
17
18 16 17 39 1903 15 Hex nut M6x1 2 2
18 JK 1220 03 Adjuster Chain (LH) 1 1
19 DZ 1710 16 Rear Shock Absorber 2 2
49 50
Front Wheel Direction
Plate No.: 26 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
2 5/6
10
11
51 52
Front Wheel Direction
Plate No.: 27 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
53 54
Front Wheel Direction
Plate No.: 28 Brand ID: 001MC636
Stand Assembly
Description KS ES
No. Part No. Remarks
Drum Drum
9
7
6
55 56
Front Wheel Direction
Plate No.: 29 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
}
3 DM 1510 25 Tyre Front 2.75 x 17 Rib 1 1
4 4 DS 1510 49 Tube Front 2.75 x 17 1 1
5 DM 1510 28 Tyre Rear 3.00 x 17 1 1 Not Serviceable
57 58
Front Wheel Direction
Plate No.: 30 Brand ID: 001MC636
Front Hub
Description KS ES
No. Part No. Remarks
Drum Drum
18 11
11 16 31 1510 14 Oil Seal 1 1
17 15 9
17 DS 1510 94 Flange Nut M6 1 1
14 13
18 JK 1310 24 Lever Brake Cam 1 1
19 DS 1510 95 Bolt Hex M6 x 1 1 1
20 DS 1510 91 Indicator Front 1 1
59 60
Front Wheel Direction
Plate No.: 30 Brand ID: 001MC636
Front Hub
Description KS ES
No. Part No. Remarks
Drum Drum
4
1 8
16
24
23
22
1
21 25
12
20
19 10
18 11
11
17 15 9
14 13
61 62
Front Wheel Direction
Plate No.: 31 Brand ID: 001MC636
Rear Hub
Description KS ES
No. Part No. Remarks
Drum Drum
1 5
6
3
6 DU 1510 10 Coupling 1 1
9
8 10A 7 39 0978 04 'D' bolt M-10 4 4
63 64
Front Wheel Direction
Plate No.: 31 Brand ID: 001MC636
Rear Hub
Description KS ES
No. Part No. Remarks
Drum Drum
1 5
6
3
26 JB 1312 24 Hex bolt / Flange M6 1 1
9
8 10A 27 JB 1410 01 Chain lock set 1 1
10
13
12
11
22 24
25
15 26
16 19
23
17
14
20 21
18
65 66
Front Wheel Direction
Plate No.: 32 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
4
6 39 0797 08 Pin Cotter 1 1
3 7 30 1910 31 Spring 1 1
2
8 30 1910 35 Spring 1 1
1
9 39 0807 08 Pin Snap 2 2
7 10 39 0708 15 Nut Hex M10 x 1.25 2 2
2
11 39 0789 12 Washer Spring 2 2
10 11
9 12 JB 1610 02 Pin 1 1
14
8 13 30 1910 36 Brake Adjusting Nut 1 1
14 30 1510 95 Bolt M10 x 1.25 2 2
15 JK 1220 11 Torque Rod 1 1
12
13
15 16 DD 1610 78 Damper 1 1
17 JA 1610 03 Pad Brake Pedal 1 1
9
14 11 10
67 68
Front Wheel Direction
Plate No.: 33 Brand ID: 001MC636
Handle Bar
Description KS ES
No. Part No. Remarks
Drum Drum
1 DU 1810 21 Handle 1 1
2 FD 1810 30 Holder handle upper 2 2
3 39 1074 04 Flanged bolt 4 4
4 JK 4014 01 Control switch RH -- 1
3
5 JB 4014 00 Control switch LH 1 1
2 26
25 1 6 DJ 1910 54 Holder left hand 1 1
4
7 DJ 1910 55 Lever grip - Left 1 1
8 DL 1910 14 Stud Lever handle 2 2
17 9 39 1184 15 Nyloc nut 2 2
18
20 8 10 DU 1910 09 Grip - Left hand 1 1
5
24
21
19
22 12 11 DS 1910 38 Holder Right hand 1 1
15
11 12 DD 1911 42 Lever grip - Right 1 1
8
16 13 DD 2011 70 Front brake switch 1 1 With Wiring Harness
13 16 14
9 14 DU 1910 03 Grip assly RH 1 1
23
7 27
15 DS 1910 52 Boot Lever LH 1 1
10
6 23
16 36 DU19 01 Cable Adjuster kit 2 2
9 17 FD 1810 31 Holder Handle Lower 2 2
18 DF 1810 91 Damper Handle Upper 2 2
19 DF 1810 92 Damper Handle Lower 2 2
20 FD 1810 19 Washer Plain Upper 2 2
69 70
Front Wheel Direction
Plate No.: 33 Brand ID: 001MC636
Handle Bar
Description KS ES
No. Part No. Remarks
Drum Drum
71 72
Front Wheel Direction
Plate No.: 34 Brand ID: 001MC636
Front Fork
Description KS ES
No. Part No. Remarks
Drum Drum
73 74
Front Wheel Direction
Plate No.: 35 Brand ID: 001MC636
Description KS ES
No. Part No. Remarks
Drum Drum
75 76
Front Wheel Direction
Plate No.: 36 Brand ID: 001MC636
Description ES
No. Part No. KS Remarks
Drum
11 30 1410 32 Bolt 4 4
10 12 DZ 1010 34 Tube Rubber 1 1
13 33 1410 08 Clamp 1 1
7
14 DZ 1810 04 Lock Assly. 3 IN 1 1 1
9
13
8 11
12
5
77 78
Front Wheel Direction
Plate No.: 37 Brand ID: 001MC636
Description ES
No. Part No. KS Remarks
Drum
5
7 DZ 1810 04 Lock Assly. 3 IN 1 1 1
4 8 39 1553 04 Flange Bolt 2 2
9 30 2110 05 Collar Assly. 2 2
7
10 30 1611 69 grommet 1 1 RH side cover
6
3 1
79 80
Front Wheel Direction
Plate No.: 38 Brand ID: 001MC636
Meter Assembly
Description KS ES
No. Part No. Remarks
Drum
10/11
6 DZ 1910 08 Cover case upper 1 1
7 DU 1910 24 Cover (white) W/o Support Plate 1 1 Pricol
2
6 8 39 0798 15 Hex. Nut / Flange 2 2
9 39 1943 04 Bolt Flanged 2 2
10 DZ 1910 10 Fuel Meter 1 1 Pricol
7
3
4 11 JK 4024 09 Fuel Meter 1 1 Minda
5
9
8
1
81 82
Front Wheel Direction
Plate No.: 39 Brand ID: 001MC636
Control Cables
Description ES
No. Part No. KS Remarks
Drum
83 84
Front Wheel Direction
Plate No.: 40 Brand ID: 001MC636
Chain Case
Description ES
No. Part No. KS Remarks
Drum
4
1
3
2
3
85 86
Front Wheel Direction
Plate No.: 41 Brand ID: 001MC636
Description ES
No. Part No. KS Remarks
Drum
87 88
Front Wheel Direction
Plate No.: 42 Brand ID: 001MC636
Description ES
No. Part No. KS Remarks
Drum
3/4
89 90
Front Wheel Direction
Plate No.: 43 Brand ID: 001MC636
11
11 39 1783 01 Truss Screw 2 2
11 12 39 1972 15 Flanged Nut 1 1 N.S.
13 DP 1611 45 Number plate Rear 1 1
9
14 DP 1611 01 Bracket No. Plate Rear 1 1
18
15 39 2483 04 Hex head bolt / Flange 2 2
10
13
16
16
91 92
Front Wheel Direction
Plate No.: 44 Brand ID: 001MC636
Electrical Equipments
Description ES
No. Part No. KS Remarks
Drum
5 9
93 94
Front Wheel Direction
Plate No.: 45 Brand ID: 001MC636
Tool Kit
Description ES
No. Part No. KS Remarks
Drum
95 96
Front Wheel Direction
Plate No.: 46 Brand ID: 001MC636
Description ES
No. Part No. KS Remarks
Drum
3
2
97 98
Front Wheel Direction
Kit List Kit List
1 36JK0011 Valve kit JV511004 Valve intake 1 8 36JK0020 Idling Screw Kit JK581208 Idling Screw 1
JV511005 Valve Exhaust 1 CB121044 Spring 1
DH121130 O' Ring 1
2 36JA0003 Valve Repair Kit 28101129 Seat Spring 2
39201719 Seal Valve Stem 2 9 36JK0021 Jet Kit JK581203 Needle Jet 1
JA511202 Spring washer 2 JB581218 Pilot Jet 1
JA511203 Retainer valve spring 2 JB581222 Main Jet 1
JB581223 Jet Holder 1
DG101029 Collet 4
JK581205 Jet Needle 1
4 36JW0010 Set Piston Ring JW521204 Ring Piston (Second) 1 11 36314001 Bearing Cone kit DH181023 Bearing Cone 1
JW521203 Ring Piston (Oil) 1 DH181025 Bearing Cone 1
JW521205 Ring Piston (Top) 1 DH181026 Bearing race 1
DH181024 Upper Bearing Race 1
5 36PA0006 Set Drive Driven JA531010 Gear Primary Drive 1
Jb551401 Clutch Housing Complete 1 12 36JB0003 Chain Sprocket Kit JK141001 Chain (122 Links) 1
JA131206 Sprocket (42 T) 1
6 36DU1007 Boss Kick Kit 30101233 Boss Kick 1 JA551010 Sprocket Drive(15 T) 1
30101234 Spring 1
30101236 Ball Steel 1 13 36DZ0009 Chain Case Kit Dz161023 Chain Case Upper Assly. 1
30101235 Pin 1 DZ161027 Chain Case Lower Assly. 1
39085517 E - Type Circlip 1
14 36JK0022 Piston Valve Kit DD121054 E clip 1
JA581224 Ring 1
7 36JK0019 Air screw kit DH121130 O' Ring 1
JK581204 Spring Jet Needle 1
24121062 O' Ring 1
JK581207 Piston Valve assembly 1
JK581210 Air Screw 1
JK581206 Ring Jet Needle 1
24121064 Spring Air Screw 1
DD121056 Holder Magnet 1
16121032 Washer 1
99 100
Kit List Kit List
15 36JK0026 Carburetor gasket 'O' ring kit JA581232 O' ring float bowl 1
DH121118 O' ring drain screw 1
24121062 O' ring air screw 1
DH121130 O' ring idling screw / Air screw 2
101 102
Amendment Sheet Amendment Sheet
AMENDMENT SHEET (PARTS ADDED) AMENDMENT SHEET (PARTS DELETED)
SR. PAGE FIGURE SR. PAGE FIGURE
PART NUMBER DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY.
NO. NO. NO. NO. NO. NO.
103 104
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
105 106
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
107 108
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
109 110
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
111 112
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
113 114
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
JK 7301 4C 6 76 JW 5410 00 18 24
JK 7301 4D 6 76 JW 5410 05 5 24
JK 7301 4N 6 76 JW 5610 00 1 16
JK 7302 3F 7 76 JW 5612 04 1 18
JK 7302 4C 7 76 JW 5612 06 2 18
JK 7302 4D 7 76 JW 5612 08 3 18
JK 7302 4N 7 76 KA DF06 10 9 88
JK 7303 3F 4 76 LC J000 01 7 60
JK 7303 4C 4 76
JK 7303 4D 4 76
JK 7303 4N 4 76
JK 7304 3F 5 76
JK 7304 4C 5 76
JK 7401 3F 3 76
JK 7401 4C 3 76
JK 7401 4D 3 76
JK 7401 4N 3 76
JP 5412 05 1 26
JP 5412 08 5 26
JV 5110 06 1 6
JV 5110 07 1 8
JV 5110 11 5 2
JV 5110 12 3 2
JV 5110 13 1 2
JV 5310 03 5 12
JV 5410 07 2 2
JV 5510 00 21 14
JW 2330 00 12 26
JW 4016 00 1 94
115