Professional Documents
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SPC CT 100 Es KS BS Vi Ug Rev 05 Aug 212
SPC CT 100 Es KS BS Vi Ug Rev 05 Aug 212
ES & KS UG ES & KS UG
A: Add A: Add
REV. NO., PART SR. PAGE D: Delete Reason for change REV. NO., PART SR. PAGE D: Delete Reason for change
SHORT DESCRIPTION QTY. SHORT DESCRIPTION QTY.
MM YY NUMBER NO. NO. C: Change MM YY NUMBER NO. NO. C: Change
1 8
9
11 2 5 7
10 1
1
1
2
9
3 8
6
4 6
5 2
6
5 7 4
7 3
6
4
3 4
5 3
4
6 3
10
13
12
13
PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
VALVE 5 CAMSHAFT / TENSIONER 7 TRANSMISSION 13 CHANGE DRUM / SHIFT FORK 15
1 2
1 4
4 2
5
4
2
6
3 6
5
4 1
5 15
7
7
6 6
12 13
2
7
5 4
11 3
3 14
8
4 3
10 4 8
2
12 4
9 13 9
1 10
18
19
11
20
17
15 14 16
3
3
Pictorial Index BS VI Pictorial Index BS VI
PLATE NO. : 9 PAGE NO. PLATE NO. : 10 PAGE NO. PLATE NO. : 13 PAGE NO. PLATE NO. : 14 PAGE NO.
GEAR CHANGE MECHANISM 17 ENGINE ASSLY / CRANKCASE RH 19 KICK STARTER MECHANISM 25 COVER CLUTCH 27
7
10 1
5
3
1
12 2 4
5 4
7 6 2
14
2 5
4 8
13 3
1 7A 17
6
8
4
16
3 5
6 6 10
12
7 1
9
8
15
7 2 9
10
10 11
9
12
11
13
18
3 9 15
8
11 11 14
PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO. PLATE NO. : 15 PAGE NO. PLATE NO. : 16 PAGE NO.
CRANKCASE LH 21 OIL PUMP 23 COVER MAGNETO 29 CLUTCH ASSEMBLY 31
17 6
2 1
5
1
11 5
1
2 3A
4
1 10
12
2 3 9
8
2 7 3A 7
10
5
9
3 5
4
3
4
14 12
N
1 15
13
2
13
3 6
4 3 4
14
16
15 11
8
7
2
6 8
Pictorial Index BS VI Pictorial Index BS VI
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
CARBURETTOR ASSEMBLY 33 AIR CLEANER COMPLETE 35 STARTER ASSEMBLY - FOR ES ONLY 41 MAGNETO, H.T. COIL & ECU EMS 43
4 1
5 3
7 1 5 3 22
21 2
9
17
2
17
16
16
6
6 8
14 20 18
10
8 21
14 7 13
16 9 10
1 15
12 2 1 9
19
13
5
12 3 4
4 14
9 10 16
22 8
23
11
10
6 11
10 7 18
13
24 19
15 20
6 6 12
11 14 17
4
2
PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
EVAP MECHANISM 37 SILENCER ASSLY 39 SEAT ASSLY & MOUNTING 45 ENGINE MOUNTINGS 47
10 1 3 3
9
7 5 1
1
6 2 2
5 3 16
5 5
2 16
2 4
4 16 1 5
14
2 11
7 8
12 9
15 7 9
6
3
13 10 4
7 7
8
8
2 10
6
16 7 6
Pictorial Index BS VI Pictorial Index BS VI
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO. PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
FRAME AND FRAME FITTING 49 SWING ARM / REAR SHOCK ABSORBER 51 STAND ASSEMBLY 57 TYRE / TUBE / RIM 59
21 8 1 3
13
7 2
14 6
5
16 8 18
6
17 5 16 1
11
2 4 4 2
17 4A
15 3 9
12 5
9
16 10
20
19 8 6
10 9
9
6 8 11 20
24 22 3 3 4
7 6
4A 5
23 2
27
25
26 18 12
13
7 19 14 1
15
2 3 13 14A
1A
14
3 14A
4
4
1
21
PLATE NO. : 27 PAGE NO. PLATE NO. : 28 PAGE NO. PLATE NO. : 31 PAGE NO. PLATE NO. : 32 PAGE NO.
FOOT REST - RIDER / PILLION 53 MUDGUARD - FRONT & REAR 55 FRONT HUB 61 REAR HUB 63
23 3
9
8 5
1 4
1 6 7
3
5 16
2
2 2
7 25
15 3 14 13
1 6
13 26 7
2 4
13
18
2
17
1 18 19 8
20 19
20
9 21
16
10
9
22 15
17 14 17
3 24 16
13 15
6 10 11
4/5 18
12 27
5 12 23
6 22
4
12 25 24
14 26
8 7
8 11 21
10
6
10
11
9 7
11
12 11
9
Pictorial Index BS VI Pictorial Index BS VI
PLATE NO. : 37
PLATE NO. : 33 PAGE NO. PLATE NO. : 34 PAGE NO. PAGE NO. PLATE NO. : 38 PAGE NO.
FITTINGS - PETROL TANK,
REAR BRAKE PEDAL 65 HANDLE BAR ASSLY 67 - 69 77 SPEEDOMETER ASSEMBLY - ES 79
SIDE COVERS & SEAT COWL
17 23
20 5/9
1 11
12
10 11 20 8
19
2
8 27 10
29 24 3
20
19 28 21
22 6 28 3 14
14
21 18 16 1 4 28 2/6
21 2
23 2 15 13 5 7
6 12 4
4 11 10
5 9 6
24 3
12
25 10
13
24 3/7
25 16
26 14
1
27 15 9
7
17
10A 5
7 7 18 11
13
22 15 4/8
8
3
5 6
PLATE NO. : 35 PAGE NO. PLATE NO. : 36 PAGE NO. PLATE NO. : 39 PAGE NO. PLATE NO. : 40 PAGE NO.
FRONT FORK 71 - 73 PETROL TANK CAP & FUEL COCK 75 SPEEDOMETER ASSEMBLY - KS 81 CONTROL CABLES 83
1
2
18
14 3
19
1
25 13 10
12
20 9
29 7
6 26
3
7 28
9
27
8
2 1
5
11 6
10
4
2/3
15 8
7 11 10 9
3 2
5
30 4
4 16 17 6
17 16 11
5 5
7 4
8
1
8 7 12
22
13
21
Pictorial Index BS VI Pictorial Index BS VI
PLATE NO. : 41 PAGE NO. PLATE NO. : 42 PAGE NO. PLATE NO. : 45 PAGE NO. PLATE NO. : 46 PAGE NO.
CHAIN CASE 85 HEAD LAMP & FAIRING 87 ELECTRICAL EQUIPMENTS 93 TOOL KIT 95
19 20
18 8
21 7 2
1
6 2
1
15
16 3 10
14 11
4 3
2 12 13
5 4
1
17 7
17 19
15/16
5
3 18
5 2
1
6
12
22
17
4 17
8 9 22 14
5 9
23 10
11
13 17
PLATE NO. : 43 PAGE NO. PLATE NO. : 44 PAGE NO. PLATE NO. : 47 PAGE NO. PLATE NO. : 48 PAGE NO.
INDICATOR LIGHT ASSLY 89 TAIL LAMP ASSLY / NUMBER PLATE 91 ACCESSORIES / GRAB HANDLE 97 PAINTED PARTS & DECALS 99 - 101
2 2
2 6
3 3
5 1 12
11
3 4
5/6 1
7
1
4
4 10 6 2
2 3
7 4
1 5
4 9
6
8
7/8 9 10
8
4 9
4
13
5 2
7
11 11
10
2
Pictorial Index BS VI Pictorial Index BS VI
PLATE NO. : 49 PAGE NO. PLATE NO. : 49 PAGE NO.
CONSUMABLE PARTS 103 CONSUMABLE PARTS 105
1 2 3 13 14 15
4 5 6 16 17 18
7 8 9 19 20 21
10 11 12 22 23 24
BS VI Plate No.: 1
Cover Cylinder Head
1 2
Front Wheel Direction
BS VI Plate No.: 2
Cylinder Head
6
4 11 39 2608 01 Grub screw 1
6 12 PF 5812 74 Sleeve Carburettor 1
5 52 PF21 34 Sleeve Carburettor with Clamp 1 Alternate
7
13 GL 5814 79 Clamp 2
13
12
13
3 4
Front Wheel Direction
BS VI Plate No.: 3
Valve
5 6
Front Wheel Direction
BS VI Plate No.: 4
Camshaft / Tensioner
11 CS 1011 28 Gasket 1
8 12 JE 5210 16 Chain Tensioner 1
13 KA ED06 20 Bolt Flange M6 2
14 39 2669 21 Ring - ‘O’ (ID 10.15X1.5) 1
15 JE 3514 07 Sensor Temperature Engine 1
12
9 13
10
11
15 14
3
7 8
Front Wheel Direction
BS VI Plate No.: 5
Cylinder and Piston
7
6
3 4
9 10
Front Wheel Direction
BS VI Plate No.: 6
Crankshaft
3
4
10
11 12
Front Wheel Direction
BS VI Plate No.: 7
Transmission
4
9 16 JA 5510 09 Collar Sprocket Drive 1
17 59 2100 24 O-Ring 1
18 DU 1012 13 Plate Lock-sprocket output 1
18 19 DS 1013 55 Bolt Flanged 2
19
17
16
13 14
Front Wheel Direction
BS VI Plate No.: 8
Change Drum / Shift Fork
15 16
Front Wheel Direction
BS VI Plate No.: 9
Gear Change Mechanism
9 11 DH 1015 09 Damper 1
10
11
17 18
Front Wheel Direction
BS VI Plate No.: 10
Crankcase RH / Engine Assembly
10
1 36 PA02 10 Kit Assembly crankcase RH 1 Refer Kit List
2 PF 5410 18 Bushing Drum 1
1 3 KP BF62 01 Bearing ball C3 clearances 1
12 2
4 KP BF62 03 Bearing ball C3 clearance Hn3 1
5 JA 5410 10 Stopper plate input bearing 1
5
4
6 JG 1312 20 Screw pan cross - M6 1
7 52 JA00 29 Bolt shift change 1
8 JA 5410 12 Guide Kick 1
9 LA E000 15 Bolt flanged - M6 2
6 10 KA ED06 85 Bolt 2
11 JE 5410 28 Pin 1
12 59 0400 38 Bolt Flange 1
KA ED06 55 Bolt Flanged Small (KS) 1
7 13 PF 5010 96 Engine Assembly (ES) 1 Not Illustrated
PF 5011 50 Engine Assembly (KS) 1 Not Illustrated
11
3 9
8
19 20
Front Wheel Direction
BS VI Plate No.: 11
Crankcase LH
21 22
Front Wheel Direction
BS VI Plate No.: 12
Oil Pump
4 3
13
11 14
25 26
Front Wheel Direction
BS VI Plate No.: 14
Cover Clutch
1
11 DS 1012 15 Clip - Wire 1
12 JL 5412 27 Window Oil Gauge 1
13 JA 5412 25 O Ring Cap Oil Filler 1
9 14 JA 5412 11 Cap Oil Filler 1
11
15 JA 5412 12 Gasket Clutch Cover 1
12
27 28
Front Wheel Direction
BS VI Plate No.: 15
Cover Magneto
3
4
N
1
2
3
4
2
8
29 30
Front Wheel Direction
BS VI Plate No.: 16
Clutch Assembly
3A 7
6 36 JE00 24 Kit Friction Plate 1 Refer Kit List
36 JZ01 98 Kit Friction Plate 1 DU31-CT100 KS
7 PF 5514 11 Hub Clutch 1
PF 5514 33 Hub Clutch 1 DU31-CT100 KS
8 JB 5514 06 Holder Clutch Modified 1
5
PF 5514 38 Holder Clutch 1 DU31-CT100 KS
9 28 1012 14 Compression Spring 6
4
12 PF 5514 37 Compression Spring 4 DU31-CT100 KS
15 10 KA AD05 25 Bolt 6
13
6
KA DD06 25 Bolt 4
14
31 32
Front Wheel Direction
BS VI Plate No.: 17
Carburetor Assembly
33 34
Front Wheel Direction
BS VI Plate No.: 18
Air Cleaner Complete
1
No. Part No. Description Qty. Remarks
21 DP 1210 18 Clamp 1
JL 5810 66 Clamp SAI Pipe 1
22 LD B000 68 Washer Plain 1
23 KA DA06 10 Bolt Flanged 1
24 DU 1613 11 Bracket Box Fuse 1
27 25 DU 1210 85 Foam Breather 1
26 26 DU 1210 84 Plate Breather 1
25 27 KB RA48 13 Screw Plate Mounting 1
35 36
Front Wheel Direction
BS VI Plate No.: 19
EVAP Mechanism
1 JY 1710 77 Canister 1
2 JY 1710 70 Spring Band Clamp 9 x 8.4 3
10 9 1 3 DH 1410 70 Tube T Connector To Canister 1
7 4 GL 1710 36 Conn. For Breather & Vapor Tube 1
5 DU 1412 77 Tube Tank To T Connector 1
16
37 38
Front Wheel Direction
BS VI Plate No.: 20
Silencer Assembly
7 8
9
10
39 40
Front Wheel Direction
BS VI Plate No.: 21
Starter Assembly - For ES Only
41 42
Front Wheel Direction
BS VI Plate No.: 22
Magneto, H.T. Coil & ECU EMS
1
5 3 No. Part No. Description Qty. Remarks
22
1 JB 3510 34 Rotor assembly W/o Clutch (ES) 1
PF 3510 85 Rotor assembly W/o Clutch (KS) 1
21 22 2 PF 3510 56 Stator assembly (ES) 1
JE 3510 05 Stator assembly (KS) 1
3 PF 3514 10 ECU EMS Assembly (ES) 1
PF 3514 38 ECU EMS Assembly (KS) 1
4 DH 2011 58 Regulator - DC 1
JZ 4020 02 Regulator Assembly (KS) 1
5 LA C000 52 Bolt Socket 2
JG 1312 20 Screw Pan Cross (KS) 2
6
8
6 PF 5412 42 Bracket Stator Harness 1
JA 5410 28 Lock plate (KS) 1
13 8 KB BC06 08 Screw pan cross - M6 1
JG 1312 20 Screw Pan Cross (KS) 1
13
9 DY 3512 01 Coil HT with cable 1
9 10 DD 1110 12 Grommet HT coil 2
43 44
Front Wheel Direction
BS VI Plate No.: 23
Seat Assembly & Mounting
8
3
6
7
45 46
Front Wheel Direction
BS VI Plate No.: 24
Engine Mountings
7
8
10
47 48
Front Wheel Direction
BS VI Plate No.: 25
Frame & Frame Fittings
21
13 No. Part No. Description Qty. Remarks
14
1 PF 1610 29 Lever distributor LH 1
8
2 PF 1610 30 Lever distributor RH 1
16
3 PF 1138 01 Collar 2
6 4 DU 1510 58 Spring 1
17 5
11 5 KD AB06 11 Washer plain small 1
2
9 26 KD BA06 13 Washer 1
27 KA DD08 35 Bolt Flanged 2
49 50
Front Wheel Direction
BS VI Plate No.: 26
Swing Arm / Rear Shock Absorber
51 52
Front Wheel Direction
BS VI Plate No.: 27
Foot Rest - Rider / Pillion
6
4/5
12
10
11
9
53 54
Front Wheel Direction
BS VI Plate No.: 28
Mudguard - Front & Rear
16 9 11 KC GA05 05 Nut 1
12 DD 2010 02 Reflector Reflex 1
9
JG 4010 36 Reflector Reflex 1 DU31-CT100 KS
17
13 CZ 1814 07 Plug 1
10 14 DU 1610 65 Nut clip - M6 2
15 DU 1613 94 Brace Assembly 1
5
6
4 16 JB 4010 12 Foam Tail Lamp 4
14 17 DU 1613 46 Plug 1
8 7
18 PF 1814 43 Bracket ECU 1
7
11
12
55 56
Front Wheel Direction
BS VI Plate No.: 29
Stand Assembly
5 9
6 30 1611 57 Shaft Center Stand 1
7 DM 1611 72 Center Stand 1
8 KH AA32 25 Pin cotter 1
9 DG 1611 24 Damper Center Stand 1
57 58
Front Wheel Direction
BS VI Plate No.: 30
Tube / Tyre / Rim
1 3
1 56 JZ60 7B Wheel Front Drum - 1.4 x 17 - 1
2 DS 1510 49 Tube front - 2.75 x 17 1 Not Serviceable
2
3 DM 1510 25 Tyre 2.75 X 17 1 Not Serviceable
4 PA 1312 04 Wheel rear 1.60 x 17 (110 Dia) Drum 1
5 DS 1510 53 Tube rear 3 X 17 1 Not Serviceable
4 6
5
59 60
Front Wheel Direction
BS VI Plate No.: 31
Front Hub
23
No. Part No. Description Qty. Remarks
8
6 7
1 JK 1310 15 Axle Front 1
3 2 DU 1510 44 Lever panel brake front 1
5 16
2 3 39 0775 04 Bolt 1
4 LC L000 02 Nut flanged - M6 1
5 DD 1510 09 Wear Indicator 1
25
1 26 6 PF 1316 16 Panel Front Brake 1
4 7 30 1510 38 O Ring 1
8 30 1510 04 Cam Brake 2
18
9 30 1511 05 Set Shoe Brake 2
17 10 30 1510 69 Spring 2
19
20
21 11 KP BB63 01 Bearing-Ball-C3 Clearance 2
12 30 1510 32 Collar bearing 1
22 15 13 30 1510 33 Seal - Oil 1
14 14 KD AA12 22 Washer plain small 1
24
13 15 59 1500 03 Nut U - M12 1
11
12
16 36 DS15 02 Kit Gear Meter 1
17 39 0242 11 Washer A 2
18 JA 1316 06 Bushing 1
19 30 1511 18 Stopper For Bushing 1
20 39 1013 21 O Ring 1
11
10
21 39 0900 12 Washer Spring 1
22 KB BA04 08 Screw Pan Cross 1
23 PA 1310 03 Seal oil 1
24 DZ 1510 32 Collar assembly 1
25 DL 1510 14 Speedometer gear 1
9
26 30 1510 41 Gear Meter Screw 1
61 62
Front Wheel Direction
BS VI Plate No.: 32
Rear Hub
6 31 1510 21 Damper 4
14 13 7 DU 1510 10 Coupling 1
6
7 8 KP BC60 04 Ball Bearing 1
9 JA 1312 05 Panel brake rear 1
10 LA A000 34 Bolt D - M10 x 1.25 x L36 4
11 DZ 1510 14 Axle 1
8
19 DU 1510 29 Axle M12 X 1.25 1 DU31-CT100 KS
20
12 KC BA10 06 Nut Hex Thin - M10 x 1.25 4
10 13 31 1510 60 Shoe Brake 2 For 110 Dia Drum
14 30 1510 69 Spring 2
17 15 JB 1312 23 Cam brake assly. 1
16
15
18 16 30 1510 38 ‘O’ Ring 1
27 17 30 1510 05 Wear Indicator 1
12 23 18 DU 1510 46 Lever Panel Brake Rear 1
22
19 39 1074 04 Hex Bolt with Flange 1
25 24 20 LC L000 02 Flange Nut 1
26
21 21 KC BA18 11 Nut Hex Thin - M18 x 1.5 1
22 KD AA12 22 Washer Plain Small 1
23 59 1500 03 Nut U - M12 1
24 31 1510 26 Collar 1
25 31 1510 28 Sleeve 1
11 26 DU 1510 06 Collar 1
27 31 1510 29 Washer 2
63 64
Front Wheel Direction
BS VI Plate No.: 33
Rear Brake Pedal
26 16 LA A000 49 Bolt - M6 1
17 JH 1610 38 Collar 1
27 18 30 1910 38 Pin 1
19 LD B000 19 Washer plain 1
1 20 KH AA20 18 Pin cotter 1
7
21 DY 1610 03 Rod brake 1
7/7A 22 JD 1610 02 Spring brake pedal 1
23 JD 1610 06 Sleeve brake return spring 1
24 LD A000 69 Plain washer 2
25 30 1910 35 Spring 1
65 66
Front Wheel Direction
BS VI Plate No.: 34
Handle Bar Assly
1 DU 1811 14 Handlebar 1
1A 1A DU 1811 55 Handlebar 1 DU31-CT100 KS
23
20 2 56 DU6B Y9 Holder Handle Upper 2
12 56 DU9T Y9 Holder Handle Upper 2 DU31-CT100 KS
11 20 8
19
3 39 1074 04 Flanged Bolt 4
KA Ed08 30 Flanged Bolt 4 DU31-CT100 KS
24 27 4 JZ 4014 08 Control Switch RH 1
6 21 DU 1910 56 Control Switch RH (KS) 1
28 3
1 4 28 5 JB 4014 00 Control Switch LH 1
21 2
25 16
11 DS 1910 52 Lever boot LH 1
14
12 DS 1910 18 Lever boot RH 1
15
17 13 56 DU6A Y9 Holder Handle Lower 2
7 18 56 DU9U Y9 Holder Handle Lower 2 DU31-CT100 KS
14 DF 1810 91 Damper Handle Upper 2
15 DF 1810 92 Damper Handle Lower 2
22
16 FD 1810 19 Washer Plain Upper 2
17 FD 1810 20 Washer Plain Lower 2
18 LC H000 01 Nut nyloc - M10 2
19 PF 1610 10 Holder lever LH 1
20 JZ 1610 28 Lever Pivot Bolt 2
67 68
Front Wheel Direction
BS VI Plate No.: 34
Handle Bar Assly
21 39 1184 15 Nut 2
1A
23
22 DD 1812 05 Holder Fork Upper 1
20 23 PF 1610 11 Assembly Lever Holder RH 1
12
11 20 8 24 PF 1610 09 Assembly Lever Holder LH 1
19
PF 1610 16 Assembly Lever LH (KS) 1
24 27 25 JZ 4014 03 Switch Clutch (VB) Diode 1
6 21
28 3
1 4 28
2 26 LB U000 12 Screw (Clutch switch mtg.) 2
21
27 PF 1610 12 Holder Lever RH 1
5
28 KA DT06 25 Bolt flanged - M6 2
9
13 10
25 16
14
15
17
7 18
22
69 70
Front Wheel Direction
BS VI Plate No.: 35
Front Fork
71 72
Front Wheel Direction
BS VI Plate No.: 35
Front Fork
7 28
9
26 30 1810 20 Piston Ring 2
27
8 27 31 1810 19 Cap Oil Lock 2
28 31 1810 99 Rebound Spring 2
11 31 1810 99 Rebound Spring 2
10
29 DU 1811 44 Bellow Fork Front 2 DU31-CT100 KS
2/3
30 PF 1210 54 Clamp For Bellow 2 DU31-CT100 KS
15
5
30
4 16 17
17 16
22 29
21
30
73 74
Front Wheel Direction
BS VI Plate No.: 36
Petrol Tank Cap & Fuel Cock
3
1 DU 1412 58 Cap Fuel Tank EVAP 1
1
10 2 LB B000 06 Screw Pan Cross - M5 2
3 LD A000 43 Washer 2
9
4 DU 1410 95 Fuel Cock Assy 1
5 DD 1412 27 Bolt Flanged 2
8 7 12
13
14
15
75 76
Front Wheel Direction
BS VI Plate No.: 37
Fittings - Petrol Tank, Side Covers & Seat Cowl
5 11
77 78
Front Wheel Direction
BS VI Plate No.: 38
Speedometer Assembly - ES & KS-DU31
1 DU 1910 70 Speedometer 1
2 YD U250 01 Housing - Minda 1 Make - Minda
2 YD U250 05 Housing - Pricol 1 Make - Pricol
8 3 CM 2010 54 Lamp 12V 2W 5
4 YD U250 02 Wiring Harness 1 Make - Minda
YD U250 06 Wiring Harness 1 Make - Pricol
3 5 YD U250 03 Fuel Machine with Mtg. Hardware 1 Make - Minda
YD U250 07 Fuel Machine with Mtg. Hardware 1 Make - Pricol
9
4
6 YD U250 04 Dial 1 Make - Minda
YD U250 08 Dial 1 Make - Pricol
7 YD U160 04 Speedo Machine 1 Make - Minda
YD U160 08 Speedo Machine 1 Make - Pricol
10 5 8 DU 1910 29 Bracket Speedo Mtg. 1 Make - Pricol
9 LC L000 02 Nut flanged - M6 2
10 YD U100 03 Speedo Meter Back Cover 1 Make - Minda
DU 1910 23 Speedo Meter Black Cover 1 Make - Pricol
6
11
79 80
Front Wheel Direction
BS VI Plate No.: 39
Speedometer Assembly - KS
1 DU 1910 76 Speedometer 1
2 CM 2010 54 Lamp 12V 3W 5
3 DU 1910 29 Bracket Speedo Mtg. 1 Make-JCPPL
4 DU 1910 23 Cover Meter Lower Black 1 Make-JCPPL
YD U100 03 Cover Meter Lower Black 1 Make-Minda
5 DU 1910 25 Speedo Machine 1 Make-Pricol
10 YD U100 06 Speedo Machine 1 Make-Minda
8
1
81 82
Front Wheel Direction
BS VI Plate No.: 40
Control Cables
83 84
Front Wheel Direction
BS VI Plate No.: 41
Chain Case
3
5
85 86
Front Wheel Direction
BS VI Plate No.: 42
Head Lamp & Fairing
87 88
Front Wheel Direction
BS VI Plate No.: 43
Indicator Light Assembly
4
4
5 2
89 90
Front Wheel Direction
BS VI Plate No.: 44
Tail Lamp Assly / Number Plate
2
6
3 5 1 1 DU 2010 23 Tail light assembly with bulb 1
2 KC GA06 06 Hex Nut / Flange 3
3 31 2010 01 Collar 3
4 31 2010 28 Lamp 12 V, 10/5W 1
5 DD 2010 11 Damper 3
7
11
10
91 92
Front Wheel Direction
BS VI Plate No.: 45
Electrical Equipments
8
7 1 KA DD08 12 Flanged Bolt 1
1 2 DZ 2010 38 Horn 1
2 3 31 2010 79 Switch Rear Brake 1
4 DY 4014 00 Spring rear brake switch 1
3 10
11 5 DU 2011 27 Harness wiring 1
DU 2011 60 Harness wiring (KS) 1
DU 2012 22 Harness wiring (KS) 1 DU31 KS
6 JF 4018 03 Battery VRLA 4Ah (ES) 1 Not Serviceable
PA 4018 10 Battery VRLA 3Ah (KS) 1 Not Serviceable
12 13 7 DU 2011 47 Switch brake - spring 1
4 8 AK 2010 12 Fuse 10A 3
9 DS 2010 25 Module Light Control 1
10 JZ 4022 16 Cap (Starter Motor) 1
19
15/16 11 JV 4022 04 Cable assly. Starter relay to motor 1
5
18 12 JD 4022 17 Band 3
13 DY 4022 02 Cable earth 1
14 DY 1138 03 Clamp Battery 1
15 60 1114 20 Cable Tie Lock 4
6
16 JZ 4022 18 Cable Tie (White Color L200) 2
17 KA DD06 14 Bolt flanged 1
18 DK 2010 78 Starter Relay 1
19 KA DF06 10 Bolt Flanged 1
20 AP 2010 25 Fuse 15A Blade Type 2
9
22 24 14
23 21 JD 4022 12 Band 200mm 2
22 JL 4030 00 Relay Interlock 1
23 JL 4022 07 Fuse Box Assy With Fuse 1
17
93 94
Front Wheel Direction
BS VI Plate No.: 46
Tool Kit
95 96
Front Wheel Direction
BS VI Plate No.: 47
Accessories / Grab Handle
97 98
Front Wheel Direction
BS VI Plate No.: 48
Painted Parts and Decals
99 100
Front Wheel Direction
BS VI Plate No.: 48
Painted Parts and Decals
101 102
Front Wheel Direction
BS VI Plate No.: 49
Consumable Parts
1 2 3 No. Part No. Description Supply Application
Unit
* Marked items to be arrange from vendor or local market. Not applicable against
chassis number.
103 104
Front Wheel Direction
BS VI Plate No.: 49
Consumable Parts
13 14 15 No. Part No. Description Supply Application
Unit
17 37 0043 53 Touch up paint Matte Silk black* 440 ml Touch up of Grab Handle,
Handle Bar & Handle Holder
* Marked items to be arrange from vendor or local market. Not applicable against
chassis number.
105 106
Front Wheel Direction
Kit List BS VI Kit List BS VI
Sr Kit Consisting of Following Parts Sr Kit Consisting of Following Parts
Kit Description Kit Description
No Part No. Part No. Description Qty/Kit No Part No. Part No. Description Qty/Kit
1 36DU4076 Kit Valve Intake + Exhaust PF511212 Valve Intake 1 9 36PF0045 Kit Block Piston Pf521022 Block Cylinder 1
PF511213 Valve Exhaust 1 Pf521210 Piston Assembly 1
2 36JV0006 Valve Repair Kit 28101129 Seat Spring 2 10 36JZ0023 Kit Pri Drive & Driven PF551401 Clutch Hsg. Assly. Comp 1
CB101009 Seal Valve Stem 2 JZ531006 Gear Primary Drive 1
JA511202 Spring Valve 2
DY511202 Retainer Valve 2 11 36DS1802 Bearing Cone Kit DH181025 Bearing Cone 1
CB101022 Cotter Valve 4 DH181023 Bearing Cone (Fork) 1
DH181026 Bearing Race 2
3 36JZ0122 Kit Guide Cam Chain JE521025 Guide Tight Side Silent Chain 1
JE541037 Guide Slack Side Silent Chain 1 12 36DU4085 Kit Chain Sprocket DZ151051 Sprocket Hub (43t) 1
JZ551004 Sprocket Output 14t Disco-H 1
4 36PF0062 Kit Piston Ring Set JB521207 Ring Piston (Top) 1 DY141001 Chain 108 Links 1
PF521215 Steel 2nd Ring Piston 1
PF521204 Ring Piston Oil 1 13 36PA0121 Kit Cyl. Comp Fork 31181019 Cap Oil Lock 1
PA121041 Seat Pipe 1
5 36PF0118 Kit Piston Rings PF521231 Ring Piston Top 1 30181020 Piston Ring 1
PF521232 Ring Piston Second 1 DM181008 Rebound Spring 1
PF521233 Ring Piston Oil 1 DE181031 Spring - Front Fork From ESIPL 1
6 36PA0210 Kit Assly Crankcase RH JH541010 Crankcase RH 1 14 36JE0024 Kit Friction - D102 B&C JE551410 Plate Clutch Friction 5
KPBF6203 Bearing-Ball-C3 Clearance 1
KPBF6201 Bearing-Ball-C3 Clearance 1 15 36DS1502 Kit Gear Meter Dl151014 Gear - Speedometer 1
PF541018 Bushing Drum BM150 4 Speed 1 30151041 Gear Meter Screw 1
BA102004 Plug 1
8 36DU4152 Kit Assly Clutch Cover 56DU1V67 Silver Cover Slick Black 1
31101064 Plug 1
BA102004 Plug 1
107 108
Kit List BS VI Kit List BS VI
Sr Kit Consisting of Following Parts Sr Kit Consisting of Following Parts
Kit Description Kit Description
No Part No. Part No. Description Qty/Kit No Part No. Part No. Description Qty/Kit
109 110
Parts Index BS VI Parts Index BS VI
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 BS VI Parts Index BS VI
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 BS VI Parts Index BS VI
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
DD 2010 11 5 92 DG 1910 64 19 36
59 2100 24 17 14 DD 1010 62 3 8
DD 2011 70 9 68 DH 1010 48 6 8
60 1114 20 15 94 DD 1013 66 10 40
DE 1810 31 11 72 DH 1013 92 10 8
62 3050 84 22 106 DD 1110 11 12 44
DF 1411 28 1 78 DH 1015 09 11 18
75 6802 36 20 106 DD 1110 12 10 44
DF 1510 16 1 66 DH 1017 84 8 22
76 0109 36 14 106 DD 1110 18 14 44 DH 1021 18 17 36
DF 1611 02 3 58
76 0109 37 15 106 DD 1110 48 11 44 DF 1614 13 2 54 DH 1023 29 9 4
83 0201 73 7 104 DD 1211 81 8 28 DF 1614 15 3 86 DH 1110 13 19 44
115 116
Parts Index BS VI Parts Index BS VI
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
117 118
Parts Index BS VI Parts Index BS VI
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
119 120
Parts Index BS VI Parts Index BS VI
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
121 122
Parts Index BS VI Parts Index BS VI
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
123 124
Parts Index BS VI Parts Index BS VI
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
123 124
Parts Index BS VI Parts Index BS VI
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
123 124