Spare Parts Catalogue: Bajaj Auto Limited

Bajaj Auto Limited
Spare Parts Catalogue

Akurdi Pune 411 035 India
Tel +91 20 27472851
Fax +91 20 27407385
Brand ID: 001MC630
We have pleasure in presenting the Spare Parts Catalogue for ‘Avenger DTS-i 220cc’
Motorcycle. This catalogue has been specially designed to assist you in selecting the
correct parts for procurement to maintain 100% availability.
The Bajaj spares are subjected to the stringent quality control standards to ensure
longer life of the vehicle. It is therefore necessary that only the Genuine Bajaj Spares
are used.
In a continual effort to improve Performance and Efficiency of the vehicles,

Specifications, Diagrams, Illustrations and Part Numbers can change without notice.
All information contained in this manual is based on the Consequently, the description in this Spare Parts Catalogue cannot therefore be final
latest product information at the time of publication. Bajaj and binding on us.
Auto Limited accepts no liability for any inaccuracies or
The modifications / alterations which are carried out after the issue of this catalogue,
omissions in this publication, although every possible care
will be conveyed to you through our Service Circulars. You are requested to make
has been taken to make it as complete and accurate as necessary corrections in the Parts Catalogue as per the circulars so as to keep your
possible. All procedures and specifications subject to change catalogue up-to-date. This will ensure the appropriate and speedy delivery of the
without prior notice. The right is reserved to make such Spare Parts as the order placed will bear the latest part numbers.
changes at any time without prior notice and without

In case, if you need any technical assistance contact the concerned Regional Office
incurring an obligation to make such changes to product or write to us on the following address :
manufactured previously. Contact your authorized Bajaj
Dealer for the latest information on product improvements Bajaj Auto Limited
incorporated after this manual was issued. Service Department
Akurdi, Pune 411 035 India
Phone : 020-27406557
Fax : 020-27407385
DOC. NO.: 7111119 REV. 00, JUNE 10
E-mail : [email protected]
Brand ID: 001MC630 Brand ID: 001MC630
Instructions for using the Catalogue INDEX
1. How to Read the Catalogue : Open the catalogue and from the pictorial index No. Description Page
No. Description Page
locate the group in which the part you want to find is present. Turn over to the No. No.
concerned page number (as given by pictorial index). Now find out the figure of 1 Cover Cylinder Head 1 36 Handle Bar 44&45
the part you wish to order. Write down the part number against that particular 2 Cylinder Head 2 37 Front Fork 46&47
figure number from the text. 3 Valve 3 38 Fuel Tank 48&49
4 Camshaft / Tensioner 4 39 Seat / Grip Frame Rear
In case, if you have the part number and you need the other details, the part index
5 Cylinder & Piston 5 Cover Grip Frame 50
can be used. The part index (at the end of the catalogue) will give you the figure
40 Speedometer 51
and page number of the part you wish to order.
6 Crankshaft 6
2. How to Order Spare Parts : The part number and the description of the part 7 Balancer & Balancer Idler Gear 7 41 Control Cables 52
required should be invariably mentioned in the order as per the catalogue text. 8 Transmission 8 & 9 42 Side Cover / Chain Cover 53
9 Change Drum/ Shift Fork 10 43 Guards 54
The latest part number as conveyed through our service circulars should only 10 Gear Change Mechanism 11 44 Head Light 55
appear on the order. In case of ordering painted components, colour shade of the 45 Tail Light / Reflector Reflex 56
components should be mentioned. 11 Engine Assly & Crankcase RH 12
The quantity shown against the part number is the quantity per vehicle for that 12 Crankcase LH 13&14 46 Indicator Light 57
group so that particular quantity should be multiplied by the number of sets 13 Cover RH 15&16 47 Electrical Equipments 58
required. 14 Cover Magneto 17 48 Ignition Switch 59
15 Clutch 18&19 49 Tool Kit 60
3. Part Number System: We have used 8 digit system for part numbers. The model 50 Painted Parts 61&62
or hardware item is indicated by first two digits or alphanumeric, the next two or 16 Oil Pump 20 Kits List 63
four digits indicate main group and the last four or two digits indicate serial number 17 Oil Cooler Assly. 21 Amendment Sheet (Part Added) 64
in main group or serial number or subgroup of fastener respectively. Thus the part 18 Carburettor 22 Amendment Sheet (Part Deleted) 65
numbers will be indicated by 2-2-4 or 2-4-2 digit system. Understanding this 19 Silencer Assly 23 Part Index 66
system will enable you to identify the spare parts easily.
20 Air Cleaner Comp. 24
4. Abbreviations : The following abbreviations are used in this catalogue.
21 Magneto/C.D.I./H.T.Coil 25&26
assly. Assembly V Volts 22 Starter Assly 27
23 Frame 28
N.I. Not illustrated W Watts
24 Frame Fitting 29&30
C'case Crankcase accl. Accelerator 25 Swing Arm 31
Cyl Cylinder Comp. Complete

26 Rear Shock Absorber 32
o/s. Over size Fr Front 27 Foot Rest 33
28 Mudguard Front & Rear 34
Std. Standard L Length
29 Stand 35
A/t. Alternate Rr Rear 30 Tyre/ Tube & Wheel Rim 36
R.H. Right hand Hex. Hexagonal

31 Front Hub 37
L.H. Left hand AR As required 32 Rear Hub 38&39
33 Brake Pedal 40
34 Front Master Cylinder 41&42
35 Front Brake 43
Pictorial Index
PLATE NO. : 1 PAGE NO.: PLATE NO. : 2 PAGE NO.:
COVER CYLINDER HEAD 1 CYLINDER HEAD 2
VALVE 3 CAMSHAFT / TENSIONER 4
CYLINDER AND PISTON 5 CRANK SHAFT 6

Pictorial Index Pictorial Index
PLATE NO. : 7 PAGE NO.: PLATE NO. : 8 PAGE NO.: PLATE NO. : 13 PAGE NO.: PLATE NO. : 14 PAGE NO.:
BALANCER & BALANCER IDLER GEAR 7 TRANSMISSION 8 & 9 COVER RH 15 & 16 COVER MAGNETO 17
CHANGE DRUM / SHIFT FORK 10 GEAR CHANGE MECHANISM 11 CLUTCH 18 & 19 OIL PUMP 20
ENGINE ASSLY. & CRANKCASE RH 12 CRANKCASE LH 13 & 14 OIL COOLER ASSEMBLY 21 CARBURETTOR 22
SILENCER ASSLY. 23 AIR CLEANER COMP 24 & 25 SWING ARM 32 REAR SHOCK ABSORBER 33
MAGNETO / C.D.I. / H.T. COIL 26 & 27 STARTER MOTOR 28 FOOT REST 34 & 35 MUDGUARD FRONT & REAR 36
FRAME 29 FRAME FITTING 30 & 31 STAND 37 TYRE, TUBE & WHEEL RIM 38
FRONT HUB 39 REAR HUB 40 & 41 FRONT FORK 48 & 49 FUEL TANK 50 & 51
SEAT/GRIP FRAME RR./COVER
BRAKE PEDAL 42 FRONT MASTER CYLINDER 43 & 44 GRIP FRAME 52 SPEEDOMETER 53
FRONT BRAKE 45 HANDLE BAR 46 & 47 CABLES 54 SIDE COVERS / CHAIN COVER 55
GUARDS 56 HEAD LIGHT 57 TOOL KIT 62 PAINTED PARTS & DECALS 63 & 64
TAIL LIGHT / REFLECTOR REFLEX 58 INDICATOR LIGHT 59
ELECTRICAL EQUIPMENT 60 IGNITION SWITCH 61

Brand ID: 001MC630
Plate No. 1 : COVER CYLINDER HEAD
6 8
2 4
9 7
11 2
10 3
10
11 1
Qty/
No. Part No. Description Veh. Remarks
1 36 PD00 01 Kit Head Cylinder with Cover 1

2 DS 1010 26 Cover Tappet 2
3 36 DS10 01 ‘O’ Ring Kit for Cover Cyl. Head 1 Refer Page No. 63
4 DS 1011 66 Silent Bush (V) 1
5 DS 1010 96 Camshaft Cap 1
6 39 2647 15 Domed Cap Nut 4

7 DS 1010 84 Copper gasket 4
8 59 0400 23 Hex. Bolt with Flange 2
9 39 1075 04 Hex. Bolt with Flange M6 x 35 4
10 DH 1012 72 Plug 2
11 31 1011 06 Gasket 2
1
Plate No. 2 : CYLINDER HEAD Plate No. 3 : VALVE
9
4 8
2
9 9
1
10 1
6 3
11
8 5
5
4 12
6
7
7
3
7
13
Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks
1 36 PD00 01 Head Cylinder with Cover 1 Part No. For Spare Part 1 DS 1013 35 Rocker Arm Shaft - Intake 1
36 PD00 08 Head Cylinder with Cover W/o NRB 1 From Eng. no. BUF08386 DK 1017 48 Rocker Arm Shaft - Intake 1 W/o NRB From Eng. no. BUF08386
2 39 1660 05 Stud (Exhaust) 2 2 DS 1013 36 Rocker Arm Shaft - Exhaust 1
3 DK 1010 03 Gasket Cylinder Head 1 DK 1017 51 Rocker Arm Shaft - Exhaust 1 W/o NRB From Eng. no. BUF08386
4 DH 1015 08 Damper Cylinder Head 5 3 DS 1013 33 Rocker Arm with roller 2
5 39 1283 21 ‘O’ Ring for Intake Pipe 1 DK 1017 55 Rocker Arm 2 W/o NRB From Eng. no. BUF08386
4 DG 1010 29 Cotter valve 4
6 PD 5814 01 Carburetor Insulator 1 5 39 2017 19 Seal valve stem 2
7 DH 1210 38 Clamp for Insulator 2
8 39 1674 04 Hex. Bolt / Flange 2 6 DK 1013 26 Valve Repair Kit 1 Refer Page No. 63
9 DH 1110 12 Sleeve - Spark Plug 1 7 DK 1013 27 Valve Kit 1 Refer Page No. 63
10 39 2608 01 Grub Screw 1 For Sleeve Spark Plug 8 DS 1013 66 Wave washer 2
DH 1012 95 Wave washer 2 From Eng. no. BUF08386
11 36 DS10 01 ‘O’ Ring Kit for Cover Cyl. Head 1 Refer Page No. 63 9 59 1100 02 Plain washer 4
12 PD 5090 00 Manifold 1 39 2440 11 Plain washer 4 From Eng. no. BUF08386
13 39 1075 04 Hex. Bolt 1
2 3 3
Plate No. 4 : CAMSHAFT / TENSIONER Plate No. 5 : CYLINDER AND PISTON
2
6
4
3 7 6 8 9
3 2
1
4
7
1
5
15
5
10 12
14
9
11 5
13
8
Qty/ Qty/
1 39 2669 21 Ring ‘O’ Tension assly 1 1 DK 1010 63 Gasket Cylinder 1

2 DK 1016 14 Camshaft Assembly 1 2 39 2181 06 Pin dowel 4
3 JC 1010 86 Bearing cam RH side 1 3 DH 1014 14 Damper 6
4 JC 1010 85 Bearing cam LH side 1 4 DK 1013 28 Ring Set Piston 1
5 DK 1013 30 Guide chain Kit 1 Refer Page No. 63 5 39 2132 17 Ring Snap 2
6 DS 1012 76 Sprocket cam Driven (32 T) 1 6 DK 1013 29 Kit Cylinder Block / Piston Assly. 1
7 DH 1014 12 Collar cam Sprocket 1 7 DK 1012 38 Banjo oil cooler pipe 1
8 DH 1010 48 Special camshaft washer 1 8 DD 1210 07 Bolt special 2
9 DK 1013 86 Hex. Soc. Head cap Bolt 1 9 31 1210 06 Washer copper 4
10 DK 1010 64 Cam Chain 1
11 DH 1013 92 Cam chain Tensioner pivot Bolt 1

12 DK 1010 25 Tensioner Assly 1
13 39 1673 04 Hex Bolt / Flange 2
14 CS 1011 28 Tensioner assly. gasket 1
15 DD 1010 62 Bolt 1
4 3 5
Plate No. 6 : CRANK SHAFT Plate No. 7 : BALANCER & BALANCER IDLER GEAR
5 8
9
4 7
3
6 2 10
8
12 11
3 5
2
9 8
11
7
12
6
6
13 4
7 12
10 9
5
Qty/ Qty/
1 DK 1010 65 Crankshaft assly. comp. 1 1 DK 1014 16 Body Balancer Assly. 1

2 DH 1013 96 Bolt 1 DK 1017 76 Body Balancer Assly. 1 from Eng. PDZCCG10552
3 39 2165 11 Plain washer 1 2 DH 1010 72 Bearing stopper 1
4 31 1011 73 Key woodruff 1 3 DH 1013 85 Bolt stopper 1
5 DS 1011 54 Parallel key 1 4 DH 1014 32 Assly. Balancer Idler Gear comp. 1
5 39 2152 20 Needle roller bearing 2
6 39 1931 20 Bearing Ball 1
7 DK 1012 48 Sprocket cam drive (16 T) 1 6 DH 1014 24 Spring torsion Balancer Idler 2
8 39 2203 07 Parallel pin 1 7 39 2557 17 Circlip ext. 2
9 36 DK00 38 Primary Driven Gear 1 8 39 1686 06 Dowel Pin 2
10 DH 1010 64 Body centrifugal oil filter 1 9 39 1620 11 Spring steel washer 2
10 52 DH01 77 Balancer Idler Holder 1
11 DH 1011 95 Nut primery drive 1
12 DH 1010 65 Cover centrifugal oil filter 1 11 39 1674 04 Hex bolt with flange 3
13 36 DK00 07 Kit centrifugal over screw oil filter 1 Refer Page No. 12 DH 1013 73 Scissor Balancer Idler nylon 2
6 3 7
Plate No. 8 : TRANSMISSION Plate No. 8 : TRANSMISSION
1 1
16 13 16 13
2 2
15 15
3 14 3 14
4 4
5 5
12 5 12 5
4 4
6 6
5 5
4 11 4 11
7 7
8 10 8 10
9 9
17 17
19 18 19 18
11 21 11 21
20 20
5 5
22 22
23 23
24 24
Qty/ Qty/
1 DK 1014 71 Shaft Input Transmission 1 16 DK 1011 18 Gear 1st driven 1

2 39 2158 11 Washer plain 2 DK 1017 17 Gear 1st driven 1 from Eng. no. BUC25622
3 DK 1011 03 Gear 4th Drive 1 17 DK 1016 33 Gear 5th Driven 1
4 DH 1010 79 Washer Spline 3 DK 1017 20 Gear 5th Driven 1 from Eng. no. BUC25622
5 DH 1012 35 External Circlip 4 18 DH 1013 19 Bush 2nd driven 1
19 DK 1016 60 Gear 2nd Driven 1
6 DK 1011 02 Gear 3rd Drive 1
DK 1017 19 Gear 2nd Driven 1 from Eng. no. BUC25622
7 DK 1016 32 Gear 5th drive 1
8 DH 1010 84 Gear 2nd drive 1 20 DK 1012 45 Collar Sprocket 1
9 39 2160 11 Plain washer 1
10 DK 1011 44 Shaft output Transmission 1 21 DK 1013 52 ‘O’ Ring Sprocket Coller 1
22 DV 1010 48 Sprocket Drive 1
11 39 2166 11 Washer Thrust 2 23 DJ 1010 63 Plate Drive Sprocket 1
12 DK 1011 05 Gear 3rd Driven 1 24 39 1062 04 Bolt (Sprocket mtg) 2 for circlip crankcase
13 DH 1010 79 Washer spline 2
14 DK 1011 06 Gear 4th Driven 1
DK 1017 18 Gear 4th Driven 1 from Eng. no. BUC25622
15 DH 1011 11 Bush 1st driven 1
8 3 9
Plate No. 9 : CHANGE DRUM / SHIFT FORK Plate No. 10 : GEAR CHANGE MECHANISM
1
13 9
14
4 6
7 8 12
8
4
10
6 11 13
9
2
5 15
2 1
17
10
2 16
3 3
7
Qty/ No. Part No. Description Qty/Veh. Remarks

1 52 JM00 20 Lever comp. Gear Shifter 1
1 DK 1011 59 Fork Gear Shift Input 1 DK 1017 33 Lever comp. Gear Shifter 1 from Eng. no. BUC25622
2 DK 1011 60 Fork Gear Shift output 2 2 DH 1011 43 Spring Slider arm reset 1
3 DH 1011 46 Shaft Gear Shift Fork 1 3 DV 1010 44 Spring Gear Shifter return 1
4 DH 1014 93 Shaft Gear Shift Fork 1 4 52 DV00 52 Lever comp. change 1
5 DK 1013 82 Drum comp. Gear Shift 1 5 DG 1013 39 Damper change pedal(Rear) 1
DK 1017 32 Drum comp. Gear Shift 1 from Eng no. BUC25622
6 DG 1011 87 Bolt Pivot lever 1
7 DH 1013 93 Bolt Gear Shift drum Stopper 1
6 39 1197 04 Bolt Socket 1 8 DH 1015 03 Stopper gear shifter drum 1
7 39 2606 07 Parallel pin 1 DK 1017 25 Stopper gear shifter drum 1 from Eng. no. BUC25622
8 DK 1013 61 Guide Gear Shifter 1 9 DV 1010 45 Spring gear shifter drum stopper 1
9 DH 1014 96 Spacer 1 10 DH 1013 94 Bolt shift change pre coated 1
10 DK 1011 35 Bush Fork Gear Shift 1
11 39 2228 15 Domed cap Nut 1
12 39 2400 11 Washer 1
13 39 1998 19 Oil Seal 2
14 31 1011 08 Damper Change Pedal(Front) 1
15 DV 1010 34 Rod assly. Tie 1
16 52 DV00 51 Lever Assly Change 1

17 39 2354 04 hex Bolt/ Flange 1
10 3 11
Plate No. 11 : ENGINE ASSLY. & CRANKCASE RH Plate No. 12 : CRANKCASE LH
13
2
3 3 2
18
8 23 10
20
2 19 8
6 5
4
7
9 25
8 15 11
6
14 21
7 9
5 3 17
16 1
10
4
24 12 22
Qty/ Qty/
1 PD 5010 00 Engine Assly. with starter motor 1 N I 1 DK 1013 85 Crankcase LH 1

2 DK 1010 57 Crankcase RH 1 2 59 0500 02 Stud 2
3 59 0500 02 Stud 2 3 DK 1010 94 Guide starter assly 1
4 DJ 1013 00 Bolt Flanged 1 4 39 2188 19 Oil Seal 1
5 DH 1018 96 Gasket Crankcase 1 5 59 2100 06 ‘O’ Ring 1
6 39 2583 20 Bearing Ball (For Input shaft) 1

6 DK 1010 97 Damper 1
7 39 2601 20 Bearing Ball (For Output shaft) 1
8 39 2180 06 Dowel Pin 2 7 39 0752 01 C’ Sunk Head Screw 3
9 59 2000 27 NRB 1 8 39 2603 20 Bearing Ball (For Input shaft) 1
10 DH 1014 87 Plate Stopper 1 9 59 2000 06 Bearing Ball (For Output shaft) 1
10 39 2185 20 Balancer LH Bearing 1
59 2000 28 Balancer LH Bearing 1 from Eng. PDZCCG10552
11 39 2189 19 Oil Seal (For Output shaft) 1
12 39 2190 19 Oil Seal (For Shift lever) 1
13 DH 1012 03 Breather pipe fitting 1
14 DH 1016 61 Plug (Drain Bolt) 1
15 DG 1014 98 Gasket (For Drain Bolt) 1
12 3 13
Plate No. 12 : CRANKCASE LH Plate No. 13 : COVER RH
3
16
13 17
11 21
2
2 8 5
6
22 7
18
18
10 19
23
20 2
19 8
12 10
4
6 5
4
1
7
9 25 9
15 11
14 21
20
3 17 15
16 1 14
13 23
24 12 22
Qty/ Qty/
16 DK 1013 80 Switch comp. (Neutral) 1 1 DK 1010 76 Cover comp RH With Relief Valve 1
17 39 1013 21 ‘O’ ring neutral switch 1 36 PD00 06 Cover comp RH Flower Type 1 from Eng. no. BTH09115
18 39 1677 04 Bolt 8 2 DH 1011 97 Grommet Breather 1
3 39 1041 19 Oil Seal 1
19 DH 1013 90 Bolt 1
4 DH 1011 41 Rack 1
20 DJ 2010 21 Cable assly. (Battery to Earth) 1 5 DH 1011 42 Shaft clutch release 1
21 39 2180 06 Hallow dowel pin 2 6 DK 1012 51 Parallel pin 1

22 39 2181 06 Hallow dowel pin 2 7 DG 1014 18 Gauge 1
8 DS 1012 15 Wire circlip 1
23 DH 1013 85 Bolt M6X16 (Neutral Switch) 1
9 DS 1013 53 Bolt 10
24 KE BA37 15 Circlip for output shaft 1 10 39 0999 06 Pin Dowel 2
11 DK 1012 52 Bracket Clutch Cable 1

12 DH 1011 54 Gasket cover RH 1
13 DK 1014 80 Plunger Oil 1
14 DH 1210 11 Plate Plunger Oil 1
15 DH 1210 12 Spring Joint ‘A’ 1
16 DK 1017 38 Decal Clutch Cover 1 N.I. from Eng. no. BTH09115
14 3 15
Plate No. 13 : COVER RH Plate No. 14 : COVER MAGNETO
3
16
11 17
21
8 5
6
22 7
18
19
2
12 10
2
4
3 8
1
9 4
6
20
5
15
14
5
4 3 2 N 1
13 23
7
Qty/ Qty/
16 DH 1015 44 Spring torsion clutch lever 1 1 DK 1010 84 Cover Magneto 1

17 39 2443 11 Washer 1 52 PD00 13 Cover Magneto Flower Type 1 from Eng. no. BTH09115
18 DH 1015 10 Damper 1 2 DV 1010 42 Gasket Magneto cover 1
19 DH 1013 88 Flanged Bolt 8 3 DH 1013 96 Bolt 7
20 JC 1010 40 ‘Bajaj’ Decal 1 Fitted on Cover comp. RH 4 39 0999 06 Pin Dowel 2
5 52 JM00 13 Cover LH RR 1
21 39 1990 20 NRB 2
22 DH 1014 82 Plate 1 6 DH 1012 93 Plate Damper Cover LH Rear 1
23 DK 1014 69 Pressure relief valve assly. 1 7 DJ 1610 12 Gear Shift Label 1
8 39 2240 20 NR bearing 1
9 JE 5412 12 Decal Magneto Cover 1 N.I. from Eng. no. BTH09115
16 3 17
Plate No. 15 : CLUTCH Plate No. 15 : CLUTCH
17 17
6 6
7 7
4 4
3 3
6 18 6 18
7 7
1 1
6 6
8 8
7 11 7 11
9 9
19 19
5 5
13 13
15 15
6 16 12 6 16 12
2 10 2 10
14 14
Qty/ Qty/
1 DK 1015 60 Clutch assembly comp. 1 16 39 2200 11 Washer Primary Drive Gear 1

2 DK 1015 63 Clutch Plate Assly 1 17 DK 1015 70 Seat Judder Spring 1
3 DK 1015 64 Clutch Center 1 18 DK 1015 71 Spring Judder 1
4 DK 1013 56 Friction clutch plate kit 1 19 DH 1012 75 Special Nut 1
5 DK 1015 69 Plate Clutch pressure 1
6 DJ 1013 69 Friction Plate Kit 1

7 DK 1015 65 Plate Clutch 4
8 DK 1015 72 Spring Clutch Capacity 6
9 DK 1015 74 Bolt 6
10 39 1880 20 Bearing Clutch lifter thrust 1
11 DK 1015 73 Holder Clutch 1

12 DK 1010 72 Rod Clutch lifter 1
13 DK 1011 26 Spacer Clutch 1
14 DH 1016 48 Nut Primary drive lock 1 LH Thread
15 DK 1016 36 Lever Assly. Clutch 1
18 3 19
Plate No. 16 : OIL PUMP Plate No. 17 : OIL COOLER ASSEMBLY
8
10
2
9
4
2
1
11
6
1
4
3
5 6
5
Qty/ Qty/
1 52 DH01 69 Oil Pump Assly 1 1 PD 5712 00 Oil cooler assembly 1

2 39 1674 04 Hex. Bolt with flange 3 2 DH 1013 85 Bolt 1
3 DH 1210 10 Mesh filter Oil pump 1 3 PD 5712 01 Pipe inlet oil cooler 1
4 39 1686 06 Hollow dowel pin 1 4 PD 5712 03 Pipe outlet oil cooler 1
5 DH 1210 35 Clip Mesh Oil filter 1 5 DK 1013 66 Banjo bolt 2
6 39 2194 21 ‘O’ Ring 1 6 DK 1012 37 Gasket Banjo bolt 4

7 DK 1012 79 Washer Oil Cooler 1
8 DK 1610 81 Rubber 2
9 DK 1013 40 ‘O’ ring oval 1
10 39 2637 04 Hexagon Head Screw 2
11 DK 1016 35 Oil cooler jali 1
20 3 21
Plate No. 18 : CARBURETTOR Plate No. 19 : SILENCER ASSLY.
15 7
2
3
15
6
4 9 17 13
8 8
13 8 14
12
3
14
7
5
2 1
1
10 10 16
6 12
6
9
11
5
11
Qty/ Qty/
1 PD 5812 00 Carburettor Assly. 1 1 PD 5910 05 Silencer Assly. without cover

2 PD 5812 02 Vacuum Piston Kit 1 (With CAT & Resonator) 1
3 PD 5812 03 Idling Screw Kit 1 2 DG 1014 17 Gasket Exhaust pipe holder 1
4 PD 5812 05 Jet needle(JN) 1 3 DG 1012 85 Bolt 1
5 PD 5812 04 Float bowl “O” ring 1 4 39 2228 15 Domed cap Nut 2
5 39 1225 15 Nut flanged 1
6 PD 5812 06 Float bowl Screw 2
6 DG 1012 49 Washer 1
7 PD 5812 07 Float Assly. 1
7 DG 1012 50 Collar 2
8 PD 5812 08 Jet Holder 1
8 DG 1014 19 Bushing rubber, muffler 2
9 PD 5812 09 Jet kit 1 Refer Page No. 63
9 DG 1014 10 Collar 1
10 DH 1211 01 Magnet Assly. 1
10 DG 1012 53 Damper 1
11 DJ 1210 70 Reed Switch Assly. 1 11 39 2209 04 Bolt Flanged 1
12 39 1780 01 Pan Head Screw 2 12 DG 2210 38 Gaurd Muffler 1
13 PD 5812 11 Needle Assly. 1 13 DV 1010 57 Cover Muffler 1
14 PD 5812 12 Set Adjuster (PS) 1 14 DV 1010 35 Shield Exhaust tube 1
15 DJ 1210 59 Set Plunger Assly. 1 15 DH 1016 07 Truss Screw 6
PD 5911 01 Truss Screw 6 **From Chassis. MD2A22EZ9CCE06487
16 JM 1200 05 Air jet (Fixed in body) 1 N.I. 16 DV 1010 56 Cover Muffler 1
17 PD 5911 00 Washer 4 **From Chassis. MD2A22EZ9CCE06487
22 3 Note : For ** Refer Circular IB-47 23

Plate No. 20 : AIR CLEANER Plate No. 21 : MAGNETO/ CDI/ SPARK PLUG/ H.T. COIL
10
11
7
8 1
6 7
12 16 9
15
12
8
6
12 15
4 12
12 18
9 5
11 3
2 9
10
5
14
13 4
3 7
Qty/ Qty/
1 PD 5810 00 Air Filter Assly. 1 1 JC 1110 28 Rotor 1

2 DG 1210 10 Element Air filter 1 2 JC 1110 26 Stator Assly. comp 1
3 DG 1210 12 Gasket Air filter 1 3 39 1674 04 Hex. Bolt with Flange 2
4 DG 1210 20 Tube 1 4 39 0761 01 Pan Head Screw 2
5 DG 1210 14 Plate Element 1 5 DH 1011 99 Stopper plate (wiring harness) 1
6 52 DV00 32 Tube Breather 1

6 39 0746 01 Screw Pan head 1
7 PD 5090 01 Connecting tube 1
8 DV 1210 05 Tube Rubber 1 7 DK 1110 28 Spark plug 2
9 DG 1210 23 Flame Arrester 1 8 PD 3512 00 C.D.I Assly. / Damper 1
10 39 2044 01 Screw 5 9 DH 1110 13 Grommet Spark Plug cap 2
10 PD 3512 05 H.T. Coil Kit 1 Refer Page No. 63
11 39 0747 01 Screw 5
12 DG 1210 26 Clamp 2 11 DH 1110 16 Grommet Sleeve Spark Plug 1
12 DH 1110 15 Cap Spark Plug 2
13 PD 4020 02 Capacitor with bracket 1
14 PD 4020 03 Regulator Voltage 1
15 DD 1110 12 Grommet H.T. Cable 2
24 3 25
Plate No. 21 : MAGNETO/ CDI/ SPARK PLUG/ H.T. COIL Plate No. 22 : STARTER MOTOR
10 12
11
11
14
7
16 9
15
3
13
12
9
8 7 1
6
15 2
6
10
12
4
18 8
5
3
9 21
16
14 5
15
13 4
7
Qty/ Qty/
16 39 1902 04 Flange Bolt 2 1 36 DK00 76 Kit comp. starter clutch 1 Ref. Cir. D-40
17 59 1000 02 Spring dowel 1 N.I. 2 DK 1016 05 Plate roller clutch 1
3 JC 1011 14 Gear starter clutch 1
18 39 1950 04 Flange Bolt small (regulator) 2 4 DH 1015 81 Plate starter clutch gear return 1 Stopper plate
5 DH 1013 85 Bolt 1 For stopper plate
6 DK 1011 76 Shaft starter counter 1

7 DK 1011 76 Collar starter counter 1
8 JC 1011 15 Gear comp. starter counter assly. 1
9 59 2000 07 Needle roller bearing 1
10 39 0972 04 Bolt socket 3
11 DK 1110 09 Starter Motor 1

12 39 1074 04 Bolt 2
13 DH 1011 84 Cover starter motor 1
14 39 2285 01 Slotted c’sunk screw 1
15 36 DK00 77 Kit Spring Starter Clutch 1 Ref. Cir. D-40
16 DH 1011 63 Roller 5
18 DK 1015 96 Spring comp st. clutch 1
20 36 DK00 45 Molicoat grease 1
21 39 0849 14 Star Washer 3

26 3 27
Plate No. 23 : FRAME Plate No. 24 : FRAME FITTING
3 14 11
14
5 6
2 11
16
18
6 7
15 2 17
4 14
14
12
1
9
7 10 19 3
4
11
13
Qty/ Qty/
1 PD 1110 01 Frame comp. 1 1 DG 1611 54 Cap, Pivot 2

PD 1110 09 Frame comp. 1 from Chs. no. TCL16332 2 DG 1611 63 Bracket, Igniter 1
(Ign. switch Position Change) 3 DG 1612 08 Engine Bracket 1
2 DG 1810 42 Cap Steering Stem 1 4 DG 1611 65 Cap, Tool case 1
3 59 0400 05 Bolt flanged 1
4 36 DV00 07 Steering Cone Kit 1 Refer Page No. 63
5 JM 1610 04 Bracket, Engine Rear 1
5 DG 1810 48 Nut 1
6 JM 1610 02 Bracket, Engine Mtg. Front LH 1
6 DK 1810 50 Cage bearing upper 1 7 JM 1610 03 Bracket, Engine Mtg. Front RH 1
7 DK 1810 51 Cage bearing lower 1 8 PD 1134 00 Bracket, Engine Top LH 1
9 PD 1134 01 Bracket, Engine Top RH 1
10 39 2681 04 Bolt 4
11 39 1966 04 Bolt, Flanged 1

12 39 2157 04 Bolt 3
13 59 0400 43 Bolt, Allen 1
14 39 0291 15 Nut Flanged 11
15 DG 1612 24 Damper 1
28 29
Plate No. 24 : FRAME FITTING Plate No. 25 : SWING ARM
14 11
14 5
6
11 9
16 10 10
18 3
7
15 2 17
10
14
14
12
10 19 3
4 9
5 2
6
8 10
7
11
13
12
1 4
11
1
5 8
Qty/ Qty/
16 39 1912 04 Bolt Flanged 2 1 JM 1710 04 Cap chain Adjuster 2

17 39 1944 04 Bolt Flanged 2 2 PD 1220 00 Arm Comp. Swing 1
18 39 2455 04 Bolt 3 3 DG 1710 15 Shaft Swing Arm 1
19 DG 1612 08 Bracket Engine 1 4 JM 1710 03 Adjuster Chain 2
5 DG 1710 16 Sleeve 2
6 DG 1710 34 Guard, Chain 1

7 DG 1710 17 Nut 1
8 DG 1710 22 Nut 2
9 DG 1710 18 Bearing Needle 2
10 DG 1710 19 Seal Oil 4
11 39 1997 15 Nut Hex small 2

12 39 1224 11 Washer Plain small 2
30 31
Plate No. 26 : REAR SHOCK ABSORBER Plate No. 27 : FOOT REST
12
1
5 15
6 7
12
1
18
4 16
15A
4 14
13 19
17
7 6
5 6
2
8
3 5
8
7
3
2 6
10
5 11 9
Qty/ Qty/
1 DV 1710 01 Rear Shock Absorber 2 1 DV 1610 46 Holder Step Front LH Assly. 1

2 DG 1710 35 Collar, shock Absorber 2 2 DV 1610 45 Guard Step LH 1
3 DG 1710 37 Damper, Lower 2 3 39 2544 04 Bolt Flanged small 1
4 JM 1610 37 Holder Step Front RH Assly. 1
4 DG 1710 36 Damper, Upper 2
5 DG 1710 39 Nut cap 2 5 52 DV00 22 Step Rear LH 2
6 DG 1611 53 Bolt socket 2
6 DG 1710 25 Washer 2 7 DG 1611 45 Pin 2
8 52 DV 00 24 Holder Step Rear RH 2
7 39 1829 12 Spring Washer 2 9 39 0146 08 Split Pin 2
8 DG 1710 38 Bolt Flanged 2 10 DG 1611 50 Washer 2
11 DG 1611 52 Step Rubber Rear 2

12 DG 1611 43 Rubber Main Step 2
13 DG 1611 44 Bolt 1
14 36 DV00 05 Kit Holder Step 1
15 DG 1611 87 Step Front RH 1
15A DG 1611 86 Step Front LH 1
16 DG 1611 45 Pin 1
17 39 1937 17 Circlip 1
18 DV 1610 50 Rubber stopper 1
19 JM 1610 38 Assly. comp stay RH 1
20 DG 1612 22 Bolt for step 1
32 33
Plate No. 28 : MUDGUARD FRONT & REAR Plate No. 29 : STAND
2 4
5
7
2
4
11 9 8
8
7 5 6
5 1
Qty/ Qty/
1 DG 1612 67 Flap 1 1 DV 1610 17 Side Stand 1

2 DG 1612 06 Stay rear fender 1 2 DG 1612 19 Spring 1
3 DG 1611 10 Bolt 2 3 DG 1611 29 Bolt 1
4 DP 1611 45 Number Plate 1 4 DD 1610 71 Lock Nut 1
5 39176511 Plain Washer 4 5 DV 1610 33 Stand Centre 1
6 39 1943 04 Hex. head Bolt 2 6 DG 1612 30 Shaft Stand 1

7 39 0790 12 Spring Washer 2 7 39 0797 08 Pin Cotter 1
8 39 0291 15 Hex. Nut 2 8 DG 1611 24 Damper 1
9 DF 1612 48 Bkt. Rear Number Plate 1 N.I. 9 DV 1610 60 Spring 1
10 39 2423 11 Plain washer 1
11 DH 1611 45 Cover Spring main stand 1
34 35
Plate No. 30 : TYRE, TUBE & WHEEL RIM Plate No. 31 : FRONT HUB
11 2
8
11
8
7
7
3
6
4
5
6
3
4
11
10
11
5
9
Qty/ Qty/
}
1 DG 1510 97 Tyre Front 1 1 DG 1510 03 Drum Front Brake 1
2 DG 1510 70 Tyre Rear 1 Proprietory Items 2 DG 1510 06 Axle, Front 1
3 DG 1510 21 Tube for Tyre Front 1 Not to Service 3 DG 1510 09 Case Assly Meter Gear 1
4 DG 1510 71 Tube for Tyre Rear 1 4 39 0800 15 Nut Castle 1
5 DG 1510 94 Rim Rear 1 5 DG 1510 04 Collar 1
6 DG 1510 93 Rim Front 1 6 39 2241 20 Ball Bearing 2

7 DG 1510 25 Spoke Inner Front 18 7 DG 1510 05 Seal oil 1
8 DG 1510 75 Spoke Inner Rear 18 8 DG 1510 07 Collar Front Axle 1
9 DG 1510 26 Spoke Outer Front 18
10 DG 1510 76 Spoke Outer Rear 18
11 16 1510 66 Nipple Spoke 72
36 37
Plate No. 32 : REAR HUB Plate No. 32 : REAR HUB
17 17
21 21
19 23 19 23
2 2
7 5 22 7 5 22
3 16 4 3 16 4
15 15
13 28 13 28
25 25
26 26
18 18
8 14 9 8 14 9
24 24
12 12
27 27
6 6
21 10 21 10
20 11 20 11
Qty/ Qty/
1 DG 1510 84 Drum Rear Brake 1 16 30 1510 69 Spring Brake Shoe 1

2 DG 1510 81 Panel Assly Brake Rear 1 17 39 0800 15 Nut Castle 1
3 DG 1510 96 Shoe Brake Rear (Pair) 1 18 DG 1510 62 Collar Rear Brake Drum 1
4 DG 1510 59 Cam Brake 1 19 DG 1510 62 Collar Rear Axle 1
5 DG 1510 60 Lever Brake Cam 1 20 DG 1510 67 Collar Rear Hub Coupling 1
6 JM 1510 05 Axle Rear 1 21 DG 1510 08 Washer 2

7 30 1510 09 Indicator Brake Shoe 1 22 39 1916 04 Bolt Upset 1
8 30 1510 76 Damper Rear Hub Shock 1 23 39 0148 08 Split Pin 1
9 PD 1312 01 Coupling Assly Rear Hub 1 24 39 2240 20 Bearing Ball 1
10 36 JM00 03 Chain - Sprocket - Kit 1 Refer Page No. 63 25 39 2241 20 Bearing Ball 1
11 DG 1510 66 Nut Flanged lock 6 26 DG 1510 65 Sleeve 1

12 30 1510 82 Seal Oil 1 27 DG 1510 68 Bolt 6
13 39 2242 20 Bearing Ball 1 28 DV 1510 05 Caupling 1
14 DG 1510 95 Joint Chain 1
15 DG 1510 58 Spring Brake Shoe 1
38 39
Plate No. 33 : BRAKE PEDAL Plate No. 34 : FRONT MASTER CYLINDER
8
4
3
10
4
13
5
1 5
9
14
15
11
10 9
12,14
2 1
12
7 7
6
15
5,6 2 8 11
3 5 5
13
Qty/ Qty/
1 JM 1610 37 Stay RH assly. 1 1 DE 1510 15 Major Kit - Master Cylinder 1

2 KA AC06 30 Hexagon head bolt M6X1 1 2 DG 0100 14 Hose Brake Front 1
3 39 0292 15 Hexagon Nut-M6X1 1 3 DV 1910 07 Lever Grip RH 1
4 JM 1910 11 Lever Brake 1 4 DE 1910 11 Banjo Bolt 2
5 39 0805 11 Washer 1 5 DE 1910 10 Washer Copper 4
6 LE C000 01 Circlip E type 1 6 DK 1810 52 Clamp Holder RH 1

7 JM 1910 12 Spring 1 7 DE 1910 34 Bolt 2
8 JM 1910 13 Rear brake cable 1 8 DE 1910 31 Bolt Front Brake Lever 1
9 DG 1910 51 Pin 1
9 DE 1910 32 Nut Flanged 1
10 DG 1910 66 Washer 1
10 DE 1910 30 Screw 2
11 39 0146 08 Slip Pin 1
11 DJ 1910 32 Cylinder Master 1
12 JM 1910 15 Guard Brake pedal 1
12 DJ 2011 09 Front brake switch 1
13 KB UA06 12 Mushroom Head screw - M6-L12 1
14 LB U000 08 Mushroom Head screw - M6-L40 1 13 DE 1910 29 Reservoir Cover 1
15 JM 1910 14 Spring Brake Switch 1 14 DE 1910 28 Diaphragm 1
15 DE 1910 35 Oil Window Kit 1 (window / ‘O’ ring / clip)
40 41
Plate No. 34 : FRONT MASTER CYLINDER Plate No. 35 : FRONT BRAKE
6
7
11A
10 11A
11B
12A
11B
9 9
5
EMPTY PAGE
8 10
7
4
2 11
3 12A
6
1
12
Qty/ Qty/
1 DG 1511 02 Disc, Front 1

2 DG 1510 89 Caliper Assly. Front 1
3 DG 1510 49 Bolt, Disc Plate 6
4 DG 1510 88 Bolt Flanged 2
5 DE 1510 48 Spring Pad 1
6 DE 1510 46 Bleeder Screw 1

7 DE 1510 47 Bleeder Cap 1
8 DE 1510 37 Disc Pad Set 1
9 DE 1510 43 Insulator 1
10 DE 1510 45 Dust cover 1
11 DE 1510 51 Minor Kit - Caliper 1

12 DE 1510 52 Major Kit - Caliper 1
42 43
Plate No. 36 : HANDLE BAR Plate No. 36 : HANDLE BAR
16 2 17 16 17
19 19
15 9 15 9
22 11 22 11
26 26
29 29
18 14 18 14
34 34
25 33 25 33
16 16
23 1 23
8 8
5 5
32 24 32 24
28 13 12 28 13 12
31 31
7 6 7 6
10 10
4
21 21
2 27 27
20 20
17 17
Qty/ Qty/
1 JM 1810 08 Handle 1 19 30 1910 17 Nut Cable Adjust Lock 1

2 DV 1810 03 Weight, Handle 2 20 DG 1810 87 Nut Cap 2
3 DG 1910 80 Holder Clutch Lever 1
4 JM 1810 07 Plate Wind Shield 1 21 DG 1810 54 Damper 4
5 DV 1810 08 Bracket speedometer 1 22 39 1993 04 Bolt Upset 1
23 39 1953 04 Bolt Flanged small 2
6 DG 1810 67 Holder Handle Upper 1 24 39 1952 04 Bolt Flanged small 4
7 DG 1810 70 Holder Handle Lower LH 1 25 39 1995 01 Screw CSK Cross 2
8 DG 1810 71 Holder Handle Lower RH 1
9 DH 1910 08 Grip RH 1 26 39 1506 11 Washer Plain small 1
10 DH 1910 07 Grip LH 1 27 39 0789 12 Washer spring 2
28 PD 4014 04 Housing Assly. Control LH 1
11 DG 1910 10 Lever Assly. Grip Clutch LH 1 29 DG 1910 10 Lever Grip LH 1
12 PD 4014 01 Housing Assly. Control RH 1
13 JM 2210 01 Mirror Assly LH 1 30 JM 2210 04 Mirror Rubber boot 2
14 JM 2210 02 Mirror Assly RH 1 31 JM 2210 05 Nut Mirror LH 1
15 DG 1910 13 Bolt Clutch Lever 1 32 JM 2210 06 Nut Mirror RH 1
33 DG 2010 30 Clutch Switch 1
16 30 1910 24 Screw cable Adjust 1 34 JM 1910 10 Lever Boot 1
17 39 2427 04 Allen key bolt 2
18 DG 1910 14 Nut Lock 1
44 45
Plate No. 37 : FRONT FORK Plate No. 37 : FRONT FORK
17 17
31 31
10 10
8 8
35 20 35 20
29 23 29 23
27 12 27 12
27 18 27 18
9 9
26 30 26 30
30 30
24 28 24 24 28 24
27 22 22 11 27 22 22 11
11 11
21 21 25 21 21 25
19 19 19 19
32 14 7 14 32 14 7 14
7 7
6 6 6 6
34 34
12 13 13 12 13 13
27 27
16 16 16 16
Qty/ Qty/
1 39 1951 04 Bolt Flanged small 2 16 DG 1810 27 Bolt, Fork Cylinder 2

2 DG 1810 34 Grommet, Hose Clamp 2 17 DG 1810 85 Nut, Cap 2
3 DG 1810 12 Pipe - Left Fork Outer 1 18 DG 1810 03 Washer 1
19 DG 1810 24 Spacer 2
4 DG 1810 89 Pipe - Right Fork Outer 1 20 DG 1810 05 Race, Steering Stem Bearing 1
5 DV 1810 13 Pipe, Fork Inner 2
21 DG 1810 23 Seal Oil, Fork Outer Tube 2
6 DG 1810 14 Spring Front Fork 2 22 DG 1810 26 Ring 'O' Fork Top 2
23 DG 1810 04 Seal Oil, Steering Stem 1
7 DG 1810 15 Seat Fork Spring 2 24 DG 1810 21 Seal, Fork Outer Tube 2
8 DG 1810 93 Cover Fork 1 25 DG 1810 88 Damper assly. RH 1
9 DG 1810 95 Holder Fork Under 1
10 DG 1810 91 Holder Fork Upper 1 26 DG 1810 09 Damper assly. LH 1
27 DG 1810 36 Bolt 4
28 DG 1810 06 Bolt Socket 2
11 DG 1810 22 Ring, Oil Seal Stopper 2 29 DG 1810 08 Bolt 2
12 39 1943 04 Bolt Flange 3 30 59 0400 05 Bolt Fork Top 2
13 DG 1810 11 Bushing - Front Fork, Inner Pipe 2
14 DG 1810 13 Bushing - Front Fork, Outer Tube 2 31 DP 1611 44 Plate Number Front 1
32 DG 1810 41 Clamp S’ cable clamp 1
15 DV 1810 01 Fork Front assly. 1 Includes Sr.No. 9,10,25 & 26 34 36 3140 04 Front Fork oil Bottle 160ml 1
35 DG 1810 40 Clamp 2
46 47
Plate No. 38 : FUEL TANK Plate No. 38 : FUEL TANK
21 21
6 6
4 4
10 10
12 12
16 16
26 18 26 18
9 9
19 13 5 19 13 5
20 20
14 7 14 7
14 14
15 15
3 3
11 11
8 8
23 23
17 17
28 28
24 24
27 25 27 25
Qty/ Qty/
1 DG 1410 20 Bracket Fuel Tank Cover 1 16 DG 1410 26 Bolt 2

2 PD 1710 00 Cover Assly. Fuel Tank 1 17 DG 1410 29 Tube 1
3 DK 1410 01 Fuel Cock Assly. 1 18 DG 1410 27 Washer 2
4 DG 1410 52 Cap Tank Fuel 1 19 39 1912 04 Bolt Flanged 2
5 DG 1410 59 Trim 1 20 39 1913 04 Bolt Flanged 2
6 39 2179 24 Washer 2 21 39 0761 01 Screw Pan Cross 2

7 30 2110 05 Collar 2 22 JM 1410 02 Cover with fuel gauge 1
8 DG 1410 28 Clamp 1 23 JM 2010 04 Fuel gauge sender 1
9 DG 1410 43 Clamp, Tube 1 24 30 1410 28 Gasket Tank Unit 1
10 30 1410 31 Ring 'O' 2 25 30 1410 32 Bolt for tank Unit 4
11 30 1410 39 Ring 'O' Fuel Tap Packing 1 26 PD 4026 00 Fuel gauge (Meter) 1
12 DG 1410 24 Plug 2 27 DJ 1410 06 Fuel Cock Tube 1
13 DG 1410 25 Damper 2 28 30 1410 15 Clip for Tube 1
14 30 1410 26 Damper Fuel Tank 2
15 DG 1410 19 Damper 2
48 49
Plate No. 39 : SEAT/GRIP FRAME RR./COVER GRIP FRAME Plate No. 40 : SPEEDOMETER
18 17
2 4 8
10
16 6
11
13 3
2
11
2
14
4 5
12 5
5
18 1
3
10
1
7
16 6
9
7 15
8
12
5
15 9
19
17
16
Qty/ Qty/
1 DG 2110 07 Plate Seat 1 1 DG 1910 69 Lamp Assly 1

2 DG 2110 01 Seat Assly. 1 2 DG 1910 03 Lens - TPI & Neutral 2
3 39 1942 04 Bolt Flanged 2 3 DG 1910 05 Lens - Hi Beam 1
4 39 1949 04 Bolt Flanged Small 1 4 DV 1910 08 Meter Assly. 1
5 DV 2210 01 Emblem Back Rest 1 5 DG 2010 40 Lamp 12V - 3.4 W 4
6 DG 2210 28 Cover, Pad 1
7 DG 1611 82 Cover, Rear Fender LH 1 6 39 1953 04 Bolt Flanged Small 2 For Meter Assly.
8 DG 1611 83 Cover RH 1 7 DG 1910 93 Assly. lamp holder 1
9 DG 2210 22 Grip frame rear 1 8 DG 1910 95 Washer 2 For Machine mtg.
10 DG 2210 31 Cover Grip frame LH 1 9 DG 1910 96 Screw pan head 2 For Machine mtg.
10 DG 1910 97 Trip meter knob 1
11 DG 2210 32 Cover Grip frame RH 1
12 DG 2210 16 Grip frame LH 1 11 DG 1910 98 Screw (Knob reset trip meter) 1
13 DG 2210 19 Grip frame RH 1 12 JM 2010 19 Loose cover speedo 1
14 DG 2210 27 Pad seat 1
15 39 2147 04 Bolt Upset 2
16 39 1952 04 Bolt flanged Small 4
17 39 1951 04 Bolt Flanged Small 4
18 DG 2110 06 Seat Damper 1
19 DG 2210 41 Screw emblem 2
50 51
Plate No. 41 : CABLES Plate No. 42 : SIDE COVERS / CHAIN COVER
1
11
5
2
12
5 7
5
4
5 7
8
9
10
8
6
6 4
4
6
3 2
9 3
1 7
8 3 3
Qty/ Qty/
1 30 1910 35 Spring, Brake Rod 1 1 DG 1612 20 Cover Side RH Rear 1

2 JM 1910 07 Cable- Speedometer 1 2 DG 1611 20 Case Chain 1
3 JM 1910 13 Cable Brake 1 3 DG 1611 21 Screw Tapping 3
4 DV 1910 02 Cable Clutch 1 4 39 1076 01 Screw 2
5 DV 1910 04 Cable Throttle 1 5 DG 1611 17 Screw 3
6 39 0146 08 Pin Cotter 1 6 31 1610 78 Washer 2

7 30 1910 36 Nut Brake Rod 1 7 DG 1611 18 Grommet 2
8 DG 1910 66 Washer 1 8 DD 1610 22 Damper 2
9 DG 1910 50 Pin Brake Rod 1 9 DG 1612 25 Damper 1
10 DG 1910 51 Pin 1
11 DV 1910 06 Clamp Clutch cable 1
12 DV 1910 07 Speedo Inner 1
13 PD 1220 03 Torque Rod 1
14 PD 1220 04 Bolt Torque Rod 1
15 39 0694 15 Nut 1
16 39 0789 12 Spring Washer 1
17 39 1540 11 Plain Washer 1
52 53
Plate No. 43 : GUARDS Plate No. 44 : HEAD LIGHT
15
7
9
2
13
16 12
6
3 18
17
14
3
4 10
5 3 10
1 11
5 5
1
4 8
Qty/ Qty/
1 DG 2210 33 Guard Sari 1 1 39 2029 04 Bolt Flanged 2

2 JM 1610 17 Guard- Front Bumper 2 2 DG 2010 66 Screw Pan Cross 1 For holding head light
3 39 1940 04 Bolt Flanged 4 3 39 0790 12 Spring Washer 2
4 39 1814 04 Bolt Flanged 1 4 DG 2010 10 Body Comp. Head Lamp 1
5 39 1941 04 Bolt Flanged M8 2 5 30 2010 33 Washer 2 For mtg. Head light on body
6 DG 2010 68 Cap for Head lamp 1
7 DG 2010 69 Screw Focus Adjust 2
8 DG 2010 43 Screw 2 For mtg. Head light on body
9 DG 2010 70 Nut 1 For holding head light
10 DG 1910 64 Nut Flanged 1
11 DG 2010 57 Collar 2 For Head Light Mtg.
12 DG 2010 71 Lamp 12V - 60/55W 1
13 DG 2010 72 Spring Focus Adjust 2
14 DG 2010 12 Clamp Harness 1
15 DG 2010 73 Tube 2
16 DV 2010 10 Head Lamp Assly. 1
17 DG 2010 74 Wire assly. parking 1
18 DG 2010 40 Lamp 12V - 4W 1 Imported bulb 'E' mark
54 55
Plate No. 45 : TAIL LIGHT / REFLECTOR REFLEX Plate No. 46 : INDICATOR LIGHT
6 13
4
4 2
7
12
9
1
6
7
6
8
7
1
11
8 14
3 3 10
5
4
11
9
2
10 16
5
5
15
Qty/ Qty/
1 DG 2010 75 Gasket Tail Lamp Lens 1 1 JM 2010 28 Lamp Assly Signal FR. LH 1
2 PD 4010 00 Tail Lamp Assly. 1 2 JM 2010 29 Lamp Assly Signal FR. RH 1
PD 4010 01 Tail Lamp Assly with Pig Tail 1 3 JM 2010 30 Lamp Assly Signal Rear. LH 1
3 DG 2010 49 Lens Tail Lamp- Red 1 4 39 2124 15 Nut Cap 2
4 DG 2010 50 Lens Tail Lamp- Clear 1 5 39 1225 15 Nut Flanged 2
5 DG 2010 76 Screw Tapping 2
6 31 2010 01 Collar 2
7 39 1950 04 Bolt Flanged Small 2
6 DG 1910 64 Nut Flanged 3 8 JM 2010 31 Lamp Assly. Signal Rear RH 1
7 31 2010 01 Collar 3 9 20 2010 51 Lamp 12V-10W 4
8 AA 2012 27 Lamp 12V - 21/5W 1 10 DG 2010 52 Lens Signal Light 4
9 DG 2010 15 Damper 3
10 DD 2010 02 Reflector Reflex 1 11 DG 2010 53 Reflector Signal Light 4
12 DG 2010 54 Stay Signal Light Fr. LH 1
11 39 1972 15 Nut Flanged 1b 13 DG 2010 55 Stay Signal Light Fr. RH 1
14 DG 2010 56 Stay Signal Light Rear 2
15 DG 2010 77 Screw Signal Light 8
16 DG 2010 78 Washer Signal Light Light 8
56 57
Plate No. 47 : ELECTRICAL EQUIPMENT Plate No. 48 : IGNITION SWITCH
3
3
12
1
13 8
7 10
2
11
14
2 5
12
4 5
13
9
12
8
1 15
6
13
16 4 6
11
9
4
14 10 7
Qty/ Qty/
1 JM 2010 02 Horn 1 1 DG 1810 55 Cap, Steering Lock 1

2 39 1912 04 Bolt Flanged 2 2 DG 1410 17 Rotor, Lock, Tank Cap 1
3 30 1910 48 Band 2 3 PD 4014 00 Switch Assly. Ignition 1
4 JM 2010 32 Battery adapter with Tube 1
4 JM 1810 03 Lock Assly Steering 1
5 31 2010 21 Clamp wiring harness 1
5 DG 2210 09 Lock Assly Helmet 1
6 DJ 2011 26 Battery 12 V 9 Ah Dry Charged 1
7 PD 4022 00 Wiring Harness 1 6 DG 1611 68 Lock Assly Side Cover 1
PD 4022 02 Wiring Harness 1 from Chs. no. TCL16332 7 PD 4014 02 Lock Set (5 in 1) 1
(Ign. switch Position Change) PD 4014 08 Lock Set (5 in 1) 1 from Chs. no. TCL16332
8 DV 2010 16 Starter Relay Assly. 1 (Ign. switch Position Change)
9 PD 4020 01 Relay Turn Signal 1
8 DG 1810 57 Screw 1
10 DV 1610 36 Band Battery Bracket 1
9 DG 2210 10 Screw 1
11 DG 2010 27 Mat Battery 1 10 DG 2010 23 Plug 1
12 JZ 4010 13 Head lamp Controller unit 1
13 DK 2010 99 Fuse assly. 1 11 DG 1810 58 Washer Wave 1
14 30 2010 85 Fuse 3 12 DG 1810 59 Spring Steering Lock 1
15 JM 2010 12 Cable Assly. (Batt. to Starter Rly.) 1 13 39 1975 04 Bolt Socket 1
16 DV 2010 06 Cable Assly. (Battery to Earth) 1
58 59
Plate No. 49 : TOOL KIT Plate No. 50 : PAINTED PARTS & DECALS
1 7
2 5
Qty/ Qty/
1 JM 2210 03 Tool Kit 1 1 JM 7101 4M Tank fuel with decal 1 Black

2 52 JM00 18 Wind Shield Kit 1 JM 7101 4L Tank fuel with decal 1 Silver
3 JM 1810 06 Frame Wind Shield 1 JM 7101 2V Tank fuel with decal 1 Red
4 DD 2010 11 Rubber Damper 4 JM 7101 4K Tank fuel with decal 1 Blue
PD 7101 23 Tank Fuel Primered 1 No Color
2 JM 7301 4M Cover side left with decal 1 Black

JM 7301 4L Cover side left with decal 1 Silver
DV 7301 2V Cover side left with decal 1 Red
JM 7301 4K Cover side left with decal 1 Blue
52 DG01 91 Cover Side LH (Semi Finished) 1 No Color
3 JM 7302 4M Cover side right with decal 1 Black

JM 7302 4L Cover side right with decal 1 Silver
DV 7302 2V Cover side right with decal 1 Red
JM 7302 4K Cover side right with decal 1 Blue
52 DG01 92 Cover Side RH (Semi Finished) 1 No Color
60 61
Plate No. 50 : PAINTED PARTS & DECALS KIT LIST FOR
Sr. Consisting of Following Parts

Kit Part No. Kit Description
No. Part No. Discription Qty./Kit
1 36DS1001 Cyl.Head O Ring Kit 39239121 O Ring (Cover tappet) 2
4
39128321 O ring 2
2 DK101327 Valve Kit DK101052 Valve Intake 1
DK101011 Valve Exhaust 1
3 DK101326 Valve Repair Kit DK101247 Retainer valve spring 2
1
DK101108 Spring valve inner 2
DK101110 Spring valve outer 2
3
DK101246 Seat valve spring 2
7
4 DK101330 Guide Chain Kit DK101060 Guide chain (Tight) 1
DK101059 Guide Chain (slack) 1
6
5 36DK0029 Set primary Drive/Driven DK101241 Clutch Housing 1
DH101628 Gear Primary Drive 1
6 36DK0007 Kit Centrifugal Oil Filter 39220011 Washer 1
DH101234 Gasket Centrifugal Oil Filter 1
2 39226701 Oval Screw 3

DH101066 Join Oil Deliver 1
DH101067 Spring Oil Deliver 1
5
39219908 Pin Oil Deliver Joint 1
7 36DH1005 Set Damper DK101191 Damper Cover Magneto 1
DH101292 Damper A Cover LH RR 1
Qty/ DH101294 Damper B Cover LH RR 1
JM100040 Damper C Cover LH RR 1
4 JM 1612 4M Fender assly. front 1 Black 8 36DH1004 Set of Plate DK101192 Plate Damper for Cover Mgt. 1
JM 1612 4L Fender assly. front 1 Silver DH101293 Plate Damper Cover LH Rear 1
JM 1612 2V Fender assly. front 1 Red JM100041 Plate Damper Cover LH RR 1
JM 1612 4K Fender assly. front 1 Blue
9 PD351205 H.T.Coil Kit PD351201 H.T.Coil LH 1
52 DG02 88 Fender assly. front 1 No Color
PD351202 H.T.Coil RH 1
5 JM 7401 4M Fender rear 1 Black 10 36DV0007 Steering cone kit DG181045 Bearing Cone Upper 1
JM 7401 4L Fender rear 1 Silver DG181046 Bearing race Upper 1
JM 7401 2V Fender rear 1 Red DG181047 Bearing race Lower 1
JM 7401 4K Fender rear 1 Blue
DG181005 Bearing Cone Lower 1
6 PD 1812 00 Oil Cooled decal 1 11 36PD0003 Chain Sprocket Kit PD131200 Sprocket (38 T) 1
PD 1812 01 Oil Cooled decal 1 JM151002 Chain 1
7 JM 1410 06 Tank Decal 1 DV101048 Sprocket 1
8 JM 1610 32 “Casa Blanka White” decal 1 12 JM120008 Jet Kit JM120004 Main Jet 1
JM120007 Needle Jet 1
62 63
KIT LIST FOR
Sr. Consisting of Following Parts Amendment Sheet (Parts Deleted)

Kit Part No. Kit Description
No. Part No. Discription Qty./Kit
Sr.No. Part No. Description Qty. Page No. Fig.No.
13 DK101328 Ring Set Piston DK101049 Top Ring 1
DK101050 Second Piston ring 1
DK101051 Ring Piston 1
14 36PD0005 Fork Seal kit Tube DG181021 Seal fork outer Tube 1
DG181023 Seal oil fork outer Tube 1
DG181022 Ring Snap 1
15 36PD0004 Kit Hardware saree guard 39194004 Bolt Flanged 1
39181404 Bolt Flanged 1
39194104 Bolt Flanged 1
16 DJ101369 Friction Clutch Plate Kit DK101566 Disc Clutch friction 4
DK101568 Disc Clutch friction (B type 1
DK101567 Disc Clutch friction (C type 1
64 65
PART INDEX
Figure Page Figure Page Figure Page Figure Page Figure Page Figure Page
Part No. Part No. Part No. Part No. Part No. Part No.
No. No. No. No. No. No. No. No. No. No. No. No.
20 2010 51 9 57 39 0148 08 23 39 39 1902 04 16 26 39 2181 06 2 5 52 DV00 51 16 11 DE 1910 30 10 41

30 1012 36 24 16 39 0291 15 14 29 39 1912 04 16 30 39 2181 06 23 14 52 DV00 52 4 11 DE 1910 31 8 41
30 1410 15 28 49 39 0291 15 8 34 39 1912 04 19 49 39 2185 20 10 13 52 JM00 13 5 17 DE 1910 32 9 41
30 1410 26 14 48 39 0746 01 6 25 39 1912 04 2 58 39 2188 19 4 13 52 JM00 18 2 60 DE 1910 34 7 41
30 1410 28 24 49 39 0752 01 7 13 39 1913 04 20 49 39 2189 19 11 13 52 JM00 20 1 11 DE 1910 35 16 42
30 1410 31 10 48 39 0761 01 4 25 39 1916 04 22 39 39 2190 19 12 13 59 0400 23 8 1 DF 1612 48 9 34
30 1410 32 25 49 39 0761 01 21 49 39 1931 20 6 6 39 2194 21 6 20 59 0400 43 13 29 DG 0100 14 2 41
30 1410 39 11 48 39 0789 12 27 45 39 1937 17 17 33 39 2200 11 16 19 59 0500 02 3 12 DG 1010 29 4 3
30 1510 09 7 38 39 0790 12 7 34 39 1940 04 3 54 39 2203 07 8 6 59 0500 02 2 13 DG 1011 87 6 11
30 1510 69 16 39 39 0790 12 3 55 39 1941 04 5 54 39 2209 04 12 23 59 1000 02 17 26 DG 1011 88 14 11
30 1510 76 8 38 39 0797 08 7 35 39 1942 04 3 50 39 2209 04 12 24 59 1100 02 9 3 DG 1012 45 2 23
30 1510 82 12 38 39 0800 15 4 37 39 1943 04 6 34 39 2228 15 11 11 59 2000 06 9 13 DG 1012 45 2 24
30 1511 13 11 36 39 0800 15 17 39 39 1943 04 12 46 39 2228 15 5 23 59 2000 07 9 27 DG 1012 49 7 23
30 1910 17 19 45 39 0805 11 5 40 39 1944 04 17 30 39 2228 15 5 24 59 2000 27 9 12 DG 1012 49 7 24
30 1910 24 16 44 39 0849 14 21 27 39 1949 04 4 50 39 2240 20 24 39 59 2000 28 10 13 DG 1012 50 8 23
30 1910 35 1 52 39 0999 06 10 15 39 1950 04 18 26 39 2241 20 6 37 59 2100 06 5 13 DG 1012 50 8 24
30 1910 36 7 52 39 0999 06 4 17 39 1950 04 7 57 39 2241 20 25 39 59 2100 28 13 2 DG 1012 51 9 23
30 1910 48 3 58 39 1013 21 17 14 39 1951 04 1 46 39 2242 20 13 38 AA 2012 27 8 56 DG 1012 51 9 24
30 2010 33 5 55 39 1041 19 3 15 39 1951 04 17 50 39 2285 01 14 27 AP 1010 43 10 17 DG 1012 53 11 23
30 2010 85 14 58 39 1074 04 12 27 39 1952 04 24 45 39 2305 04 19 14 CS 1011 28 14 4 DG 1012 53 11 24
30 2110 05 7 48 39 1075 04 9 1 39 1952 04 16 50 39 2354 04 17 11 DD 1010 62 15 4 DG 1012 85 4 23
31 1011 06 11 1 39 1076 01 4 53 39 1953 04 23 45 39 2400 11 12 11 DD 1110 12 15 25 DG 1012 85 4 24
31 1011 06 15 13 39 1224 11 12 31 39 1953 04 6 51 39 2423 11 10 35 DD 1210 07 8 5 DG 1013 39 5 11
31 1011 73 4 6 39 1225 15 6 23 39 1966 04 11 29 39 2427 04 17 44 DD 1610 22 8 53 DG 1014 10 10 23
31 1210 06 9 5 39 1225 15 6 24 39 1972 15 11 56 39 2443 11 17 16 DD 1610 71 4 35 DG 1014 10 10 24
31 1610 78 6 53 39 1225 15 5 57 39 1975 04 13 59 39 2448 11 20 14 DD 2010 02 10 56 DG 1014 17 3 23
31 2010 01 7 56 39 1283 21 5 2 39 1990 20 21 16 39 2455 04 18 30 DD 2010 11 4 60 DG 1014 17 3 24
31 2010 01 6 57 39 1506 11 26 45 39 1993 04 22 45 39 2544 04 3 33 DE 1510 15 1 41 DG 1014 18 7 15
31 2010 21 5 58 39 1513 15 3 40 39 1995 01 25 45 39 2547 17 26 16 DE 1510 37 8 43 DG 1410 17 2 59
36 3140 04 34 47 39 1620 11 9 7 39 1997 15 11 31 39 2557 17 7 7 DE 1510 43 9 43 DG 1410 19 15 48
36 DH10 04 8 17 39 1660 05 2 2 39 1998 19 13 11 39 2583 20 6 12 DE 1510 45 10 43 DG 1410 20 1 48
36 DH10 05 6 17 39 1673 04 13 4 39 2017 19 5 3 39 2601 20 7 12 DE 1510 46 6 43 DG 1410 24 12 48
36 DK00 07 13 6 39 1674 04 8 2 39 2029 04 1 55 39 2603 20 8 13 DE 1510 47 7 43 DG 1410 25 13 48
36 DK00 45 20 27 39 1674 04 11 7 39 2124 15 4 57 39 2606 07 7 10 DE 1510 48 5 43 DG 1410 26 16 49
36 DS10 01 3 1 39 1674 04 2 20 39 2132 17 5 5 39 2608 01 10 2 DE 1510 51 11 43 DG 1410 27 18 49
36 DS10 01 11 2 39 1674 04 3 25 39 2147 04 15 50 39 2637 04 10 21 DE 1510 52 12 43 DG 1410 28 8 48
36 DV00 07 4 28 39 1677 04 18 14 39 2152 20 5 7 39 2639 04 6 10 DE 1910 10 5 41 DG 1410 29 17 49
36 JM00 03 10 38 39 1686 06 8 7 39 2157 04 12 29 39 2647 15 6 1 DE 1910 11 4 41 DG 1410 43 9 48
36 PD00 01 1 1 39 1686 06 4 20 39 2158 11 2 8 39 2669 21 1 4 DE 1910 23 15 42 DG 1410 52 4 48
36 PD00 01 1 2 39176511 5 34 39 2160 11 9 8 39 2681 04 10 29 DE 1910 25 19 42 DG 1410 59 5 48
36 PD00 02 6 5 39 1780 01 12 22 39 2165 11 3 6 52 DH01 69 1 20 DE 1910 26 20 42 DG 1510 03 1 37
39 0146 08 9 33 39 1814 04 4 54 39 2179 24 6 48 52 DH01 77 10 7 DE 1910 27 13 41 DG 1510 04 5 37
39 0146 08 11 40 39 1829 12 7 32 39 2180 06 8 12 52 DV 00 24 8 33 DE 1910 28 12 41 DG 1510 05 7 37
39 0146 08 6 52 39 1880 20 10 18 39 2180 06 22 14 52 DV00 22 5 33 DE 1910 29 11 41 DG 1510 06 2 37
66 3 67
PART INDEX PART INDEX
DG 1510 07 8 37 DG 1611 53 6 33 DG 1810 22 11 46 DG 1910 93 7 51 DG 2210 31 10 50 DH 1014 14 3 5

DG 1510 08 21 39 DG 1611 54 1 29 DG 1810 23 21 47 DG 1910 95 8 51 DG 2210 32 11 50 DH 1014 32 4 7
DG 1510 09 3 37 DG 1611 63 2 29 DG 1810 24 19 47 DG 1910 96 9 51 DG 2210 33 1 54 DH 1014 82 22 16
DG 1510 21 3 36 DG 1611 65 4 29 DG 1810 26 22 47 DG 1910 97 10 51 DG 2210 38 13 23 DH 1014 87 10 12
DG 1510 25 7 36 DG 1611 68 6 59 DG 1810 27 16 47 DG 1910 98 11 51 DG 2210 38 13 24 DH 1014 93 4 10
DG 1510 26 9 36 DG 1611 82 7 50 DG 1810 34 2 46 DG 2010 10 4 55 DG 2210 41 19 50 DH 1014 96 9 10
DG 1510 49 3 43 DG 1611 83 8 50 DG 1810 36 27 47 DG 2010 12 14 55 DH 1010 48 8 4 DH 1015 03 8 11
DG 1510 58 15 38 DG 1611 86 15A 33 DG 1810 40 35 47 DG 2010 15 9 56 DH 1010 64 10 6 DH 1015 08 4 2
DG 1510 59 4 38 DG 1611 87 15 33 DG 1810 41 32 47 DG 2010 23 10 59 DH 1010 65 12 6 DH 1015 10 18 16
DG 1510 60 5 38 DG 1612 06 2 34 DG 1810 42 2 28 DG 2010 27 11 58 DH 1010 72 2 7 DH 1015 44 16 16
DG 1510 62 18 39 DG 1612 08 3 29 DG 1810 44 3 28 DG 2010 30 34 45 DH 1010 79 4 8 DH 1015 81 4 27
DG 1510 62 19 39 DG 1612 08 19 30 DG 1810 44 30 47 DG 2010 40 5 51 DH 1010 79 13 8 DH 1016 07 16 23
DG 1510 65 26 39 DG 1612 19 2 35 DG 1810 48 5 28 DG 2010 40 18 55 DH 1010 84 8 8 DH 1016 07 16 24
DG 1510 66 11 38 DG 1612 20 1 53 DG 1810 54 21 45 DG 2010 43 8 55 DH 1011 11 15 8 DH 1016 28 9 6
DG 1510 67 20 39 DG 1612 22 20 33 DG 1810 55 1 59 DG 2010 49 3 56 DH 1011 41 4 15 DH 1016 48 14 18
DG 1510 68 27 39 DG 1612 24 15 29 DG 1810 57 8 59 DG 2010 50 4 56 DH 1011 42 5 15 DH 1016 61 14 13
DG 1510 70 2 36 DG 1612 25 9 53 DG 1810 58 11 59 DG 2010 52 10 57 DH 1011 46 3 10 DH 1017 14 2 11
DG 1510 71 4 36 DG 1612 30 6 35 DG 1810 59 12 59 DG 2010 53 11 57 DH 1011 54 12 15 DH 1018 96 5 12
DG 1510 75 8 36 DG 1612 67 1 34 DG 1810 67 6 44 DG 2010 54 12 57 DH 1011 63 16 27 DH 1110 12 9 2
DG 1510 76 10 36 DG 1710 15 3 31 DG 1810 69 4 44 DG 2010 55 13 57 DH 1011 64 15 27 DH 1110 13 9 25
DG 1510 82 2 38 DG 1710 16 5 31 DG 1810 70 7 44 DG 2010 56 14 57 DH 1011 84 13 27 DH 1110 15 12 25
DG 1510 84 1 38 DG 1710 17 7 31 DG 1810 71 8 44 DG 2010 57 11 55 DH 1011 95 11 6 DH 1110 16 11 25
DG 1510 88 4 43 DG 1710 18 9 31 DG 1810 85 17 47 DG 2010 66 2 55 DH 1011 97 2 15 DH 1210 10 3 20
DG 1510 89 2 43 DG 1710 19 10 31 DG 1810 87 20 45 DG 2010 68 6 55 DH 1011 99 5 25 DH 1210 11 14 15
DG 1510 93 6 36 DG 1710 22 8 31 DG 1810 88 25 47 DG 2010 69 7 55 DH 1012 03 13 13 DH 1210 12 15 15
DG 1510 94 5 36 DG 1710 25 6 32 DG 1810 89 4 46 DG 2010 70 9 55 DH 1012 35 5 8 DH 1210 35 5 20
DG 1510 95 14 38 DG 1710 34 6 31 DG 1810 91 10 46 DG 2010 71 12 55 DH 1012 72 10 1 DH 1210 38 7 2
DG 1510 96 3 38 DG 1710 35 2 32 DG 1810 93 8 46 DG 2010 72 13 55 DH 1012 75 19 19 DH 1211 01 10 22
DG 1510 97 1 36 DG 1710 36 4 32 DG 1810 95 9 46 DG 2010 73 15 55 DH 1013 19 18 9 DH 1611 45 11 35
DG 1511 02 1 43 DG 1710 37 3 32 DG 1910 03 2 51 DG 2010 74 17 55 DH 1013 36 11 8 DH 1910 07 10 44
DG 1611 10 3 34 DG 1710 38 8 32 DG 1910 05 3 51 DG 2010 75 1 56 DH 1013 73 12 7 DH 1910 08 9 44
DG 1611 17 5 53 DG 1710 39 5 32 DG 1910 10 11 44 DG 2010 76 5 56 DH 1013 82 10 27 DH 1910 14 30 45
DG 1611 18 7 53 DG 1810 03 18 47 DG 1910 13 15 44 DG 2010 77 15 57 DH 1013 85 3 7 DJ 1010 63 23 9
DG 1611 20 2 53 DG 1810 04 23 47 DG 1910 14 18 44 DG 2010 78 16 57 DH 1013 85 24 14 DJ 1011 33 6 7
DG 1611 21 3 53 DG 1810 05 20 47 DG 1910 15 29 45 DG 2110 01 2 50 DH 1013 85 2 21 DJ 1013 00 24 9
DG 1611 24 8 35 DG 1810 06 28 47 DG 1910 50 9 52 DG 2110 06 18 50 DH 1013 85 5 27 DJ 1013 00 4 12
DG 1611 29 3 35 DG 1810 08 29 47 DG 1910 51 9 40 DG 2110 07 1 50 DH 1013 88 19 16 DJ 1013 69 6 18
DG 1611 43 12 33 DG 1810 09 26 47 DG 1910 51 10 52 DG 2210 09 5 59 DH 1013 88 7 17 DJ 1017 76 1 7
DG 1611 44 13 33 DG 1810 11 13 46 DG 1910 64 10 55 DG 2210 10 9 59 DH 1013 92 11 4 DJ 1210 59 15 22
DG 1611 45 7 33 DG 1810 12 3 46 DG 1910 64 6 56 DG 2210 16 12 50 DH 1013 93 7 11 DJ 1210 70 11 22
DG 1611 45 16 33 DG 1810 13 14 46 DG 1910 66 10 40 DG 2210 19 13 50 DH 1013 94 10 11 DJ 1410 06 27 49
DG 1611 47 14 33 DG 1810 14 6 46 DG 1910 66 8 52 DG 2210 22 9 50 DH 1013 96 2 6 DJ 1610 12 9 17
DG 1611 50 10 33 DG 1810 15 7 46 DG 1910 69 1 51 DG 2210 27 14 50 DH 1013 96 3 17 DJ 2010 21 21 14
DG 1611 52 11 33 DG 1810 21 24 47 DG 1910 80 3 44 DG 2210 28 6 50 DH 1014 12 7 4 DJ 2011 09 14 42
68 3 69
PART INDEX PART INDEX
DJ 2011 25 6 58 DK 1014 16 1 7 DS 1012 76 6 4 JC 1010 85 4 4 JM 2210 02 14 44 PD 5010 00 1 12

DK 1010 03 3 2 DK 1014 49 23 16 DS 1013 33 3 3 JC 1010 86 3 4 JM 2210 03 1 60 PD 5090 00 12 2
DK 1010 25 12 4 DK 1014 65 28 16 DS 1013 35 1 3 JC 1011 14 3 27 JM 2210 04 31 45 PD 5712 00 1 21
DK 1010 57 2 12 DK 1014 69 27 16 DS 1013 36 2 3 JC 1011 15 8 27 JM 2210 05 32 45 PD 5712 01 3 21
DK 1010 63 1 5 DK 1014 71 1 8 DS 1013 53 9 15 JC 1110 26 2 25 JM 2210 06 33 45 PD 5712 03 4 21
DK 1010 64 10 4 DK 1014 72 29 16 DS 1013 66 8 3 JC 1110 27 1 25 JM 7101 2V 1 61 PD 5812 00 1 22
DK 1010 65 1 6 DK 1014 80 13 15 DV 1010 34 15 11 JM 1200 05 16 22 JM 7101 4K 1 61 PD 5812 02 2 22
DK 1010 72 12 18 DK 1015 60 1 18 DV 1010 35 15 23 JM 1410 02 22 49 JM 7101 4L 1 61 PD 5812 03 3 22
DK 1010 76 1 15 DK 1015 61 14 6 DV 1010 35 15 24 JM 1410 06 7 62 JM 7101 4M 1 61 PD 5812 04 5 22
DK 1010 84 1 17 DK 1015 63 2 18 DV 1010 42 2 17 JM 1510 05 6 38 JM 7301 4K 2 61 PD 5812 05 4 22
DK 1010 94 3 13 DK 1015 64 3 18 DV 1010 44 3 11 JM 1610 02 6 29 JM 7301 4L 2 61 PD 5812 06 6 22
DK 1010 97 6 13 DK 1015 65 7 18 DV 1010 45 9 11 JM 1610 03 7 29 JM 7301 4M 2 61 PD 5812 07 7 22
DK 1011 02 6 8 DK 1015 69 5 18 DV 1010 48 22 9 JM 1610 04 5 29 JM 7302 2L 3 61 PD 5812 08 8 22
DK 1011 03 3 8 DK 1015 70 17 19 DV 1010 56 17 23 JM 1610 17 2 54 JM 7302 4K 3 61 PD 5812 09 9 22
DK 1011 05 12 8 DK 1015 71 18 19 DV 1010 56 17 24 JM 1610 32 8 62 JM 7302 4M 3 61 PD 5812 11 13 22
DK 1011 06 14 8 DK 1015 72 8 18 DV 1010 57 14 23 JM 1610 37 4 33 JM 7401 2V 5 62 PD 5812 12 14 22
DK 1011 18 16 9 DK 1015 73 11 18 DV 1010 57 14 24 JM 1610 37 1 40 JM 7401 4K 5 62 PD 5814 01 6 2
DK 1011 26 13 18 DK 1015 74 9 18 DV 1510 05 28 39 JM 1610 38 19 33 JM 7401 4L 5 62 PD 5910 05 1 23
DK 1011 35 10 10 DK 1015 95 1 27 DV 1610 17 1 35 JM 1612 2V 4 62 JM 7401 4M 5 62 PD 5910 05 1 24
DK 1011 45 10 8 DK 1015 96 18 27 DV 1610 33 5 35 JM 1612 4K 4 62 KA AC06 30 2 40 PD 5911 00 17 23
DK 1011 59 1 10 DK 1016 05 2 27 DV 1610 36 10 58 JM 1612 4L 4 62 KB UA06 12 13 40 PD 5911 01 15 23
DK 1011 60 2 10 DK 1016 14 2 4 DV 1610 45 2 33 JM 1612 4M 4 62 KE BA37 15 25 14
DK 1011 76 6 27 DK 1016 32 7 8 DV 1610 46 1 33 JM 1710 03 4 31 LB U000 08 14 40
DK 1011 76 7 27 DK 1016 33 17 9 DV 1610 50 18 33 JM 1710 04 1 31 LE C000 01 6 40
DK 1012 37 6 21 DK 1016 35 11 21 DV 1610 60 9 35 JM 1810 02 4 59 PD 1110 01 1 28
DK 1012 38 7 5 DK 1016 36 15 18 DV 1710 01 1 32 JM 1810 06 3 60 PD 1134 00 8 29
DK 1012 45 20 9 DK 1016 59 17 9 DV 1810 01 15 46 JM 1810 08 1 44 PD 1134 01 9 29
DK 1012 48 7 6 DK 1016 60 19 9 DV 1810 03 2 44 JM 1910 07 2 52 PD 1220 02 2 31
DK 1012 51 6 15 DK 1110 09 11 27 DV 1810 08 5 44 JM 1910 11 4 40 PD 1312 01 9 38
DK 1012 52 11 15 DK 1110 28 7 25 DV 1810 13 5 46 JM 1910 12 7 40 PD 1710 00 2 48
DK 1012 79 7 21 DK 1410 01 3 48 DV 1910 02 4 52 JM 1910 13 8 40 PD 1812 00 6 62
DK 1013 26 6 3 DK 1610 81 8 21 DV 1910 04 5 52 JM 1910 13 3 52 PD 1812 01 6 62
DK 1013 27 7 3 DK 1810 50 6 28 DV 1910 06 11 52 JM 1910 14 15 40 PD 3512 00 8 25
DK 1013 28 4 5 DK 1810 51 7 28 DV 1910 07 3 41 JM 1910 15 12 40 PD 3512 05 10 25
DK 1013 30 5 4 DK 1810 52 6 41 DV 1910 07 12 52 JM 2010 02 1 58 PD 4010 00 2 56
DK 1013 40 9 21 DK 2010 99 13 58 DV 1910 08 4 51 JM 2010 04 23 49 PD 4014 00 3 59
DK 1013 52 21 9 DP 1611 44 31 47 DV 2010 06 16 58 JM 2010 12 15 58 PD 4014 01 12 44
DK 1013 56 4 18 DP 1611 45 4 34 DV 2010 10 16 55 JM 2010 19 12 51 PD 4014 02 7 59
DK 1013 61 8 10 DS 1010 26 2 1 DV 2010 16 8 58 JM 2010 28 1 57 PD 4014 04 28 45
DK 1013 66 5 21 DS 1010 84 7 1 DV 2210 01 5 50 JM 2010 29 2 57 PD 4020 01 9 58
DK 1013 80 16 14 DS 1010 96 5 1 DV 7301 2V 2 61 JM 2010 30 3 57 PD 4020 02 13 25
DK 1013 82 5 10 DS 1011 54 5 6 DV 7302 2V 3 61 JM 2010 31 8 57 PD 4020 03 14 25
DK 1013 85 1 13 DS 1011 66 4 1 JB 4010 13 12 58 JM 2010 32 4 58 PD 4022 00 7 58
DK 1013 86 9 4 DS 1012 15 8 15 JC 1010 40 20 16 JM 2210 01 13 44 PD 4026 00 26 49
70 3 71

Spare Parts Catalogue: Bajaj Auto Limited

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Spare Parts Catalogue: Bajaj Auto Limited

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Bajaj Auto Limited

Spare Parts Catalogue

In a continual effort to improve Performance and Efficiency of the vehicles,

changes at any time without prior notice and without

Cyl Cylinder Comp. Complete

R.H. Right hand Hex. Hexagonal

COVER CYLINDER HEAD 1 CYLINDER HEAD 2

PLATE NO. : 3 PAGE NO.: PLATE NO. : 4 PAGE NO.:

VALVE 3 CAMSHAFT / TENSIONER 4

PLATE NO. : 5 PAGE NO.: PLATE NO. : 6 PAGE NO.:

CYLINDER AND PISTON 5 CRANK SHAFT 6

PLATE NO. : 45 PAGE NO.: PLATE NO. : 46 PAGE NO.:

TAIL LIGHT / REFLECTOR REFLEX 58 INDICATOR LIGHT 59

PLATE NO. : 47 PAGE NO.: PLATE NO. : 48 PAGE NO.:

ELECTRICAL EQUIPMENT 60 IGNITION SWITCH 61

1 36 PD00 01 Kit Head Cylinder with Cover 1

6 39 2647 15 Domed Cap Nut 4

1 39 2669 21 Ring ‘O’ Tension assly 1 1 DK 1010 63 Gasket Cylinder 1

11 DH 1013 92 Cam chain Tensioner pivot Bolt 1

1 DK 1010 65 Crankshaft assly. comp. 1 1 DK 1014 16 Body Balancer Assly. 1

1 DK 1014 71 Shaft Input Transmission 1 16 DK 1011 18 Gear 1st driven 1

Qty/ No. Part No. Description Qty/Veh. Remarks

16 52 DV00 51 Lever Assly Change 1

1 PD 5010 00 Engine Assly. with starter motor 1 N I 1 DK 1013 85 Crankcase LH 1

6 39 2583 20 Bearing Ball (For Input shaft) 1

21 39 2180 06 Hallow dowel pin 2 6 DK 1012 51 Parallel pin 1

11 DK 1012 52 Bracket Clutch Cable 1

16 DH 1015 44 Spring torsion clutch lever 1 1 DK 1010 84 Cover Magneto 1

1 DK 1015 60 Clutch assembly comp. 1 16 39 2200 11 Washer Primary Drive Gear 1

6 DJ 1013 69 Friction Plate Kit 1

11 DK 1015 73 Holder Clutch 1

1 52 DH01 69 Oil Pump Assly 1 1 PD 5712 00 Oil cooler assembly 1

6 39 2194 21 ‘O’ Ring 1 6 DK 1012 37 Gasket Banjo bolt 4

11 DK 1016 35 Oil cooler jali 1

1 PD 5812 00 Carburettor Assly. 1 1 PD 5910 05 Silencer Assly. without cover

22 3 Note : For ** Refer Circular IB-47 23

1 PD 5810 00 Air Filter Assly. 1 1 JC 1110 28 Rotor 1

6 52 DV00 32 Tube Breather 1

6 DK 1011 76 Shaft starter counter 1

11 DK 1110 09 Starter Motor 1

21 39 0849 14 Star Washer 3

1 PD 1110 01 Frame comp. 1 1 DG 1611 54 Cap, Pivot 2

11 39 1966 04 Bolt, Flanged 1

16 39 1912 04 Bolt Flanged 2 1 JM 1710 04 Cap chain Adjuster 2

6 DG 1710 34 Guard, Chain 1

11 39 1997 15 Nut Hex small 2

1 DV 1710 01 Rear Shock Absorber 2 1 DV 1610 46 Holder Step Front LH Assly. 1

11 DG 1611 52 Step Rubber Rear 2

1 DG 1612 67 Flap 1 1 DV 1610 17 Side Stand 1

6 39 1943 04 Hex. head Bolt 2 6 DG 1612 30 Shaft Stand 1

11 DH 1611 45 Cover Spring main stand 1

6 DG 1510 93 Rim Front 1 6 39 2241 20 Ball Bearing 2

11 16 1510 66 Nipple Spoke 72

1 DG 1510 84 Drum Rear Brake 1 16 30 1510 69 Spring Brake Shoe 1

6 JM 1510 05 Axle Rear 1 21 DG 1510 08 Washer 2

11 DG 1510 66 Nut Flanged lock 6 26 DG 1510 65 Sleeve 1

1 JM 1610 37 Stay RH assly. 1 1 DE 1510 15 Major Kit - Master Cylinder 1

6 LE C000 01 Circlip E type 1 6 DK 1810 52 Clamp Holder RH 1

15 DE 1910 35 Oil Window Kit 1 (window / ‘O’ ring / clip)