Boxer BM 150 270415

Notice
All information contained in this manual is based on the latest

product information at the time of publication. Bajaj Auto
Limited accepts no liability for any inaccuracies or omissions in
this publication, although every possible care has been taken to
make it as complete and accurate as possible. All procedures
and specifications subject to change without prior notice. The
right is reserved to make such changes at any time without
prior notice and without incurring an obligation to make such
changes to product manufactured previously. Contact your
authorized Bajaj Dealer for the latest information on product
improvements incorporated after this manual was issued.
DOC. NO.: 71111461 REV. 00, MAR. 12

Foreword Instructions
We have pleasure in presenting the Spare Parts Catalogue for ‘BOXER 150’ 1. How to Read the Catalogue : Open the catalogue and from the pictorial
Motorcycle. This catalogue has been specially designed to assist you in index locate the group in which the part you want to find is present.
Turn over to the concerned page number (as given by pictorial index).
selecting the correct parts for procurement to maintain 100% availability.
Now find out the figure of the part you wish to order. Write down the
part number against that particular figure number from the text.
The Bajaj spares are subjected to the stringent quality control standards to
In case, if you have the part number and you need the other details, the
ensure longer life of the vehicle. It is therefore necessary that only the part index can be used. The part index (at the end of the catalogue) will
Genuine Bajaj Spares are used. give you the figure and page number of the part you wish to order.
2. How to Order Spare Parts : The part number and the description of the
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.
4. Abbreviations : The following abbreviations are used in this catalogue.

Bajaj Auto Limited
Assly Assembly V Volts
Export Service Department
N.I. Not illustrated W Watts
Akurdi, Pune 411 035 India
C'case Crankcase Accl. Accelerator
Phone : 020-27406557 Cyl Cylinder Comp. Complete
Fax : 020-27407385 O/s Over size Fr. Front
Rr. Rear Std. Standard
L Length A/t. Alternate
R.H. Right hand L.H. Left hand
Hex. Hexagonal AR As required
Index Index
Plate No. Description Page No. Plate No. Description Page No.
1 Cover Cylinder Head 2 27 Mudguard Front & Rear 54

2 Cylinder Head 4 28 Stand Assembly 56
3 Valve 6 29 Tyre / Tube / Rim 58, 60
4 Camshaft / Tensioner 8 30 Front Hub 62, 64
5 Cylinder & Piston 10 31 Rear Hub 66, 68
6 Crankshaft 12 32 Rear Brake Pedal 70
7 Transmission 14 33 Handle Bar 72, 74
8 Change Drum / Shift Fork 16 34 Front Fork 76, 78
9 Gear Change Mechanism 18 35 Painted Parts & Decals 80
10 Engine Assly & Crankcase RH 20 36 Petrol Tank, Cap Tank & Gauge Fuel 82
11 Crankcase LH 22 37 Fittings - Petrol Tank, Side Cover & Cover Seat 84
12 Cover RH 24 38 Meter Assembly 86
13 Cover Magneto 26 39 Control Cables 88
14 Clutch 28 40 Chain Case 90
15 Kick Starter Mechanism 30 41 Head Lamp & Fairing 92, 94
16 Carburettor 32 42 Indicator Light Assembly 96
17 Air Cleaner Complete 34 43 Tail Lamp Assembly / Front Number Plate 98
18 Silencer Assly 36 44 Electrical Equipments 100
19 Oil Pump 38 45 Tool Kit 102
20 Starter Assly 40 46 Accessories / Grab Handle 104
21 Magneto / C.D.I. / H.T. Coil 42 Kits List 105 to 108
22 Seat Assly / Grip Frame 44 Amendment Sheet (Parts Added & Deleted) 109, 110
23 Engine Mountings 46
Part Index 111 to 124
24 Frame & Frame Fitting 48
25 Swing Arm / Rear Shock Absorber 50
26 Rider Foot Rest / Pillion Foot Rest 52
Pictorial Index Pictorial Index
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 & PISTON 10 CRANKSHAFT 12
VALVE 6 CAMSHAFT / TENSIONER 8 TRANSMISSION 14 CHANGE DRUM / SHIFT FORK 16
GEAR CHANGE MECHANISM 18 ENGINE ASSLY / CRANKCASE RH 20 COVER MAGNETO 26 CLUTCH 28
CRANKCASE LH 22 COVER RH 24 KICK STARTER MECHANISM 30 CARBURETOR 32
4
AIR CLEANER COMPLETE 34 SILENCER ASSLY 36 MAGNETO, CDI & H.T. COIL 42 SEAT ASSEMBLY 44
OIL PUMP 38 STARTER ASSEMBLY 40 ENGINE MOUNTING 46 FRAME & FRAME FITTING 48
SWING ARM / REAR SHOCK ABSORBER 50 RIDER FOOT REST / PILLION FOOT REST 52 TYRE, TUBE & RIM 58 TYRE, TUBE & RIM (ALLOY WHEEL) 60
MUD GUARD - FRONT & REAR 54 STAND ASSEMBLY 56 FRONT HUB (FOR SPOKE WHEEL) 62 FRONT HUB (FOR ALLOY WHEEL) 64
REAR HUB (FOR SPOKE WHEEL) 66 REAR HUB (FOR ALLOY WHEEL) 68 FRONT FORK (FOR W/O FAIRING) 76 FRONT FORK (FOR FAIRING) 78
REAR BRAKE PEDAL 70 HANDLE BAR 72,74 PAINTED PARTS & DECALS 80 FUEL TANK, CAP TANK & GAUGE FUEL 82
PLATE NO. : 37
PAGE NO. PLATE NO. : 38 PAGE NO. PLATE NO. : 41 PAGE NO. PLATE NO. : 41 PAGE NO.
FITTING - FUEL TANK, SIDE COVER
84 METER ASSLY 86 HEADLAMP WITHOUT FAIRING 92 HEADLAMP WITH FAIRING 94
& COVER SEAT
CONTROL CABLES 88 CHAIN CASE 90 INDICATOR LIGHT ASSLY 96 TAIL LIGHT ASSLY / FR NUMBER PLATE 98
PLATE NO. : 44 PAGE NO. PLATE NO. : 45 PAGE NO. PLATE NO. : PAGE NO. PLATE NO. : PAGE NO.
ELECTRICAL EQUIPMENTS 100 TOOL KIT 102
BOXER S
5
PLATE NO. : 46 PLATE NO. : PAGE NO. PLATE NO. : PAGE NO. PLATE NO. : PAGE NO.
ACCESSORIES
Plate No.: 1
Cover Cylinder Head
No. Part No. Description Qty Remarks

2
1 JZ 5110 21 Cover Cylinder Head Assly 1
2 JV 5410 07 Bolt Flange 4
1
59 0400 38 Bolt 1 Alt. For JV 5410 07
3 JD 5110 10 Gasket Head Cover 1
4 JA 5110 08 Bolt Head Mounting 4 M8 X 1.25 X 196L
7 5 PF 5110 27 Plate Cylinder Head 1
6 JA 5110 11 Hose Breather 1

6 7 DP 1210 25 Clamp 3
8 PF 5110 21 Flange Bolt 1 M8 X 142
3
5
4
1 2
Front Wheel Direction
Plate No.: 2
Cylinder Head
1 36 PF00 01 Kit Asly Cylinder Head 1 With studs &

Valve Guide
2 JA 5110 28 Stud 2
2
3 JZ 5110 16 Gasket Cylinder Head 1
4 PF 5814 01 Intake Manifold 1
5 JA 5814 06 Bolt Flange 2
2
6 PF 5814 02 Sleeve (Carb - Duct Rubber) 1
1 7 DH 1210 38 Clamp 2
8 39 2539 21 ‘O’ Ring (Intake Pipe) 1
8
3 6
7
4
7
3 4
Plate No.: 3
Valve
1 JA 5112 11 Shaft Rocker Arm 2 48.2 mm

2 JZ 5112 03 Rocker Arm with Roller 2
3 DG 1010 29 Cotter Valve (Collet) 4
3
4 36 JZ00 01 Valve Kit 1 Refer Page No. 105
1 5 36 JZ00 04 Valve Repair Kit 1 Refer Page No. 105
6 39 2017 19 Seal Valve Stem 2

1
5
2
5 6
Plate No.: 4
Camshaft / Tensioner
1 JZ 5110 04 Camshaft Complete 1

10
2 JA 5112 16 Spacer Cam Sprocket 1
3 DS 1012 76 Sprocket Cam Shaft - 32 T 1
11
4 DH 1013 87 Hex Head Bolt 1
8
DK 1013 86 Precoated soc. Head Cap Bolt 1 From Dec 12
13 5 DH 1010 48 Special Washer Cam Shaft 1 ’O’ Washer
7
9 6 36 JE00 03 Guide Chain Kit 1 Refer Page No. 105
15
7 DH 1013 92 Cam chain Tensioner Pivot Bolt 1
8 JV 5210 03 Adjuster Chain Silver 1
16 9 CS 1011 28 Gasket 1
10 JA 5210 18 Bolt M6 Chain Tensioner 1
DD 1010 62 Bolt flange M6 1 Alt. For JA 5210 18
14
11 JA 5210 19 Bolt M6 X 20 Silver 2 Adjuster Mounting
39 1673 04 Bolt M6 X 20 Silver 2 Alt. For. JA 5210 19
1 6
12 39 0594 17 Circlip for Camshaft 1
13 39 2669 21 ‘O’ Ring (Tensioner) 1
12 14 DS 1099 05 Cam Chain (94 Link) 1
5 15 39 1880 20 Bearing Ball - Small 15 X 32 X 9 1 W X OD X ID
2
3 16 39 2683 20 Bearing Ball - Big 17 X 35 X 10 1

4
7 8
Plate No.: 5
Cylinder and Piston
1 JD 5210 02 Gasket Cylinder Block 1

2 39 1000 06 Dowel Pin 2
3 36 JZ00 05 Piston Ring Set 1 Refer Page No. 105
2 4 DP 1011 65 Ring Snap 2
5 5 36 PF00 02 Kit Cylinder Block / Piston Assly. 1 Refer Page No. 107
6 JA 5210 15 Damper Cylinder Block 3
1
4
4
6
9 10
Plate No.: 6
Crankshaft
1 59 1500 14 Flange Nut 2

6
4 2A 59 1200 03 Belleville Washer 2
2B 59 1100 08 Plain Washer 1
3 31 1011 73 Key Woodruff 1
4 PF 5310 00 Crank Shaft Assly 1
5 JE 5310 01 Ball Bearing 56 X 22 X 16 2
3
6 DS 1011 54 Parallel Key 1
7 36 JZ00 03 Set Primary Drive / Driven 1 Refer Page No. 107
1
1 8 JA 531012 Spring 1
9 JA 5310 15 Pin Crank Shaft Plunger 1
2A 10 JB 5310 21 Plunger Oil Crank Shaft 1
5
2A
2B
10
9
8
11 12
Plate No.: 7
Transmission
1 PF 5510 02 Shaft Input Transmission (Drive) 1

2 PF 5512 02 Gear 4th Drive 1
3 39 0987 17 Ring Snap (17.2 X 20.5 X 1.5) 5
4 JA 5510 02 Spline Washer (17.2 X 20.5 X 1.5) 3
5 PF 5512 01 Gear 3rd Drive 1
1 6 PF 5512 00 Gear 2nd Drive 1

15 7 JA 5510 04 Washer Thrust 2nd Drive 1
8 PF 5510 03 Shaft Output Transmission (Driven) 1
2 9 PF 5512 06 2nd Driven Washer 1
3 4
14 10 PF 5512 03 Gear 2nd Driven 1
5 13
12
11 PF 5512 04 Gear 3rd Driven 1
6
7 3 12 PF 5512 05 Gear 4th Driven 1
4
13 JZ 5512 05 Bush 1st Driven 1
11 14 JZ 5512 04 Gear 1st Driven 1
15 JA 5510 08 Washer Thrust 1st Driven 1
8
10 16 JA 5510 09 Collar Sprocket Drive 1
9
17 59 2100 24 ‘O’ Ring Collar Sprocket (13.8 X 1.9) 1
16 18 JZ 5510 04 Sprocket Drive (Engine Sprocket) 1 14 Teeth N.S
17 19 DU 1012 13 Plate Lock Sprocket 1
19 18
20 20 39 1981 04 Socket Head Bolt 2
13 14
Plate No.: 8
Change Drum / Shift Fork
4 1 PF 5610 00 Drum Complete Gear Shift 1

3
2 39 0992 06 Dowel (Pin Drum Change) 5
3 JA 5610 02 Cam Drum Change 1
4 JD 5610 11 Special Bolt Drum Change 1 M6 X 1
5 PF 5610 02 Shaft Gear Shift Fork 2
2 6 JD 5610 04 Fork Gear Shift Output 1
7 JZ 5610 02 Fork Gear Shift Input 1
15 16
Plate No.: 9
Gear Change Mechanism
1 PF 5612 00 Lever Gear Shift Comp 1

2 JW 5612 06 Extension Spring 1
3 JW 5612 08 Spring Gear Shift Return 1
4 JA 5612 07 Inhibitor Complete Gear Shift 1
1
2 5 JA 5612 08 Spring Inhibitor 1
6 JA 5612 09 Step Washer (Collar) 1

3 7 39 2704 11 Plain Washer 1
8 8 39 0817 15 Hex Nut / Flange - M6 1

9 JZ 5614 01 Lever Gear Shift (Gear Pedal) 1
7
12 10 DH 1015 09 Damper 1
4
6
11 DG 1013 39 Damper 1
5
12 JA 5612 11 Flange Bolt 1
39 1902 04 Flange Bolt 1 Alt. For. JA 5612 11
10
11
17 18
Plate No.: 10
Engine Assembly / Crankcase RH
1 PF 5010 04 Engine Assly SS BM-150 4 Speed 1 N.I.

2 36 PF00 05 Kit Asly C’case RH BM150 1
3 59 2000 36 6203 Ball Bearing 1 For I/P Shaft.
10
4 JA 5410 11 Needle Roller Bearing 1 For O/P Shaft.
9 5 JA 5410 10 Stopper Plate 1
11
6 39 1000 06 Dowel Pin 2

7 PF 5410 18 Bushing Drum BM-150 1
6 8
8 DH 1013 80 Screw 1
5
9 52 JA00 27 Stud Inhibitor Mounting 1
3
12 10 JV 5412 16 Bolt M6 X 85 Silver 2 Crankcase Mounting
14 39 1740 04 Bolt M6 X 85 Silver 2 Alt. For. JV 5412 16
11 JV 5410 07 Flange Bolt 1 Crankcase Mounting

13
59 0400 38 Bolt 1 Alt. For.JV 5410 07
12 52 JA00 29 Bolt Shift Change 1
7
13 JA 5410 12 Guide Kick 1
2 14 39 1964 04 Flange Bolt - Small 2
19 20
Plate No.: 11
Crankcase LH
1 36 PF00 04 Kit Asly C’case Magneto Side BM-150 1 NRB + Bush

Nozzle Oil Jet
(Press Fitted) 2 39 2562 20 Needle Roller Bearing 1
3 59 2000 36 6203 Ball Bearing 1
4 39 1715 19 Seal Oil 1 Output Shaft
5 31 2010 81 Switch Complete 1 Neutral Switch
6 DH 1017 84 Gasket Neutral Switch (T.I.S) 1

7 39 2190 19 Oil Seal 1 Shifter Shaft
2
8 JA 5410 05 Bush Bendix 1
8 19
9 39 0747 01 Screw Pan Cross M6 2
10 JA 5410 34 Stopper Gear Starter Aluminium 1
3
11 11 39 1000 06 Pin Dowel 4

12 39 0999 06 Hollow Dowel Pin 4
17
13 JG 5710 24 Mesh Oil Filter Assembly 1
10
1 14 LJ A000 04 ‘O’ Ring Strainer 1
9
15 JV 5410 06 Cap Oil Filter 1
14
5 6
13 7 12 16 JV 5410 07 Flange - Bolt 6 Crankcase Mounting
18 59 0400 38 Bolt 6 Alt. For. JV 5410 07
15
17 39 1759 04 Bolt (M6 X 1 X 55L) 1 Crankcase Mounting
4
16
18 59 2100 23 Ring ‘O’ 1
19 JD 5410 00 Damper Crankshaft 1
21 22
Plate No.: 12
Cover RH
1 36 PF00 08 Kit Asly Cl Cover BM-150 1 Gauge +Circlip

2 JK 5412 14 Decal 1
3 39 1041 19 Oil Seal Clutch Lever 1
19 20 21 22
4 30 1011 42 Oil Seal (Kick Shaft) 1
5 JV 5412 08 Shaft Clutch Release 1
6 JE 5514 01 Rod Push 1
7 DG 1014 18 Gauge 1 Oil Level Check
18
8 DS 1012 15 Wire Circilp 1
10
11 9 JA 5412 36 Plain Washer 1
5
10 JA 5412 37 Spring Torsion Clutch Lever 1
12 3
9
11 JA 5412 11 Cap Oil Filler 1
17 12 JA 5412 25 ‘O’ Ring Cap Oil Filler 1
13 2
8
13 JK 5412 12 Damper Clutch Cover PL BM-150 1
7
14 JA 5412 16 Plate Damper 1
15 15 DH 1013 88 Bolt Flange 3
4
14 16 JA 5412 12 Gasket Clutch Cover 1
17 17 JV 5410 07 Bolt Flange 8 Cl. Cover to C’case Mtg
59 0400 38 Bolt Flange 8 Alt For. JV 5410 07
18 JV 5412 09 Bracket Clutch Cable 1
19 DD 1211 81 Oil Filter Element 1
6
1 20 39 1671 21 ‘O’ Ring 1
23 21 JV 5412 05 Cap Filter 1
16 22 JA 5210 19 Bolt Flange 3
24 39 1673 04 Bolt flange M6 3 Alt. For JA 5210 19
23 14 1510 33 Bearing- Ball 1
24 39 0999 06 Pin Hollow Dowel 2
23 24
Plate No.: 13
Cover Magneto
7
1 36 PF00 07 Kit Assly Cover Magneto 1 With Bush
2 JV 5412 15 Bolt M8 Silver colour 8
39 1065 04 Bolt M8 Silver colour 8 Alt. For JV 5412 15
8 3 JA 5412 05 Gasket Magneto Cover 1
4 JV 5410 07 Bolt 2
6 59 0400 38 Bolt 2 Alt. For JV 5410 07
3
5 JV 5412 12 Cover LH Rear Complete 1
9 6 JK 5412 13 Damper Cover Magneto 1

10 7 DH 1013 88 Flanged Bolt 3
11 8 JA 5412 21 Plate Damper Cover Magneto 1
9 JA 5410 05 Bush 1 For Drive Gear Assly
2
10 JA 5412 33 Cap TDC Finder 1
5
11 30 1011 95 ‘O’ Ring 1
12 DS 1611 50 Sticker Gear Shifting 1
13 JK 5412 14 Decal 1
4
13 1
12
25 26
Plate No.: 14
Clutch
1 No. Part No. Description Qty Remarks
1 PF 5514 03 Clutch Assembly Complete 1

2 JD 5514 00 Spacer Clutch Assly 1
4
3 JA 5514 06 Collar Clutch 1
11 4 39 2600 11 Washer 1
10 5 36 PF00 09 Kit Plate Friction 1 Refer Page No. 107
2 3 6 JA 5514 14 Wheel Clutch 1
9
8
7 JA 5514 19 Plate Clutch (Steel Plate) 4
8 JA 5514 15 Hub Clutch 1
9 PF 5514 05 Compression Spring 4
10 PF 5514 06 Holder Clutch 1
7
11 39 1553 04 Bolt Flange M6 4
6 12 39 2200 11 Belleville Washer 1
12
13 39 0240 11 Plain Washer 1
13
5 15 14 DH 1016 48 Nut Special Clutch Center Lock 1 L.H. Threads
14
15 14 1510 33 Bearing - Ball 1 10 X 30 X 9
16 36 JZ00 03 Set Primary Drive & Driven 1 Refer Page No. 107
16
27 28
Plate No.: 15
Kick Starter Mechanism
1 JA 6212 01 Lever Assly Kick 1

2 JA 6212 06 Bolt Special 1
6 3 36 DU10 07 Boss Kick Set 1 Refer Page No. 105
4 22 1502 41 Plain Washer 1
11
5 39 0993 11 Plain Washer Small 3
7
6 39 0738 17 Circlip Shaft 2
7 JA 6210 01 Shaft Kick 1
13 8 DS 1011 17 Spring Kick Starter Ratchet 1
8
9 JA 6210 02 Ratchet 1
9
5 10 JZ 6210 00 Gear Kick Pinion 1
11 JA 6210 06 Washer Thrust (16.2 X 25 X 0.5) 1

5 10 12 39 2408 17 Circlip 1
2 13 DD 1010 97 Kick Rubber 1
5 12
14 JE 5410 08 Spring Kick Starter Return 1
14
1
29 30
Plate No.: 16
Carburettor

18
2 1 PF 5812 00 Carburettor Assly 1

17
12 2 JA 5812 23 Mixing Cap Assembly 1
3 DH 1211 69 Pilot Screw Kit 1 Refer Page No. 105
4 36 PF00 21 Kit Jet BM 150 1
5 36 JZ00 16 Idling Screw Kit 1 Refer Page No. 106
3
6 JA 5812 21 Needle Valve Assembly 1

9 7 24 1213 65 Float Complete 1
5 8 CB 1210 42 Screw Washers Bowl M4x14 4
19
11 9 39 1062 04 Screw TPS 1
10
1 10 JB 5812 02 Throttle Position Sensor 1
6
11 JB 5812 04 "O" Ring (TPS) 1
7 12 36 PF00 22 Kit Piston Valve BM 150 1 Refer Page No. 106
14
13 36 PF00 24 Kit Carburetor Gasket/O Ring 1 N.I. Refer Page No. 106
14 24 1210 69 Arm Pin Float 1
4 15 JA 5813 14 Drain Screw 1
13
16 JZ 5812 20 Hose Drain 1

17 JZ 5812 16 Spring 1
8 18 JA 5812 91 Cable Adjuster 1
15 19 36 PF00 23 Kit Choke Plunger BM 150 1 Refer Page No. 106
16
31 32
Plate No.: 17
Air Cleaner Complete
1 PF 5810 03 Air Filter Assly 1

2 PF 5810 02 Duct Air Intake 1 Intake
3 JA 5810 05 Assly Catridge Air filter 1
16 17 4 JA 5810 06 Element Air Filter 1
13
14 5 JA 5810 09 Flame Arrester 1
10
2
6 JA 5810 12 Tube Drain 1
7 DS 1211 26 Plug 1
11 8 DP 1210 25 Clamp 1
12 9 JA 5110 11 Hose Breather 1
10 JB 5810 01 Air Intake Duct 1
9
8 3
11 JA 5810 13 Cartridge Cover Assly. 1
8 PF 5810 19 Cartridge Cover Assly. 1 Alt for JA581013
4 12 JA 5810 11 ‘O’ Ring Cartridge Cover 1
7
13 39 1773 04 Flange Bolt 4
14 DH 1210 38 Clamp 1
5
6
15 39 1779 02 Self Tapping Screw 2

16 39 1677 04 Hex Head Screw 2
1
17 DF 1614 26 Bolt - Stepped with Flange 2
33 34
Plate No.: 18
Silencer Assembly
1 36 PF00 25 Kit Silencer Without Shield 1

PF 5910 17 Silencer Assly 1 CAT, Wire Shield
PF 5910 65 Silencer Assly 1 CAT, Without Wire Shield
3
2 PF 5910 79 Silencer Assly. 1 Without CAT, Wire with
Shield
PF 5910 59 Silencer Assly. 1 Without CAT, Without
Wire Shield
2 CB 1011 14 Gasket Exhaust Mounting 1
3 39 2295 15 Flange Nut 2
4 39 2754 04 Bolt Hex with Flange M5 1
4 6
9 5 39 2492 11 Plain Washer 1
7 9
8
5 6 39 2722 04 Bolt M10 x 1.25 1
7 JB 1130 05 Washer 2
1
8 PF 5910 45 Shield Muffler 1
9 DH 1016 07 Truss Screw 4
10 PF 5910 43 Wire Shield 1
10
35 36
Plate No.: 19
Oil Pump
1 PF 5710 00 Oil Pump Assly 1

2 JA 5410 16 Gasket Case Oil Pump 1
3 FD 1010 78 Pan Head Screw M6 X 1 X 3DL 3
4 39 0999 06 Dowel 2
5 PF 5710 01 Gear Oil Pump 1
1
4
3
37 38
Plate No.: 20
Starter Assembly
3
1 JA 6214 14 Body Complete Starter Clutch 1
2 DH 1017 81 Plate Roller Clutch 1
5
3 JA 6214 10 Gear Starter Clutch 1
1 4 JA 6214 02 Washer 2
2 5 JA 6214 06 Starter Drive Assly 1
17
6 36 JZ00 08 Starter Clutch Repair Kit 1 Refer Page No. 107
18
7 PF 3516 00 Motor Assly 1
8 JA 3516 04 ‘O’ Ring For Tie Bolt (Flash) 1 N.S
9 JA 3516 06 Sealing Ring (Flash) 1
JA 3516 26 Sealing Ring (Lucas-TVS) 1
6
10 LA D000 11 Flange Bolt M6x20 2 Motor Mounting
11 JA 3516 02 ‘O’ Ring For Spigot (Flash) 1

7 12 JA 3516 27 ‘O’ Ring For Spigot (Lucas-TVS)
12 JA 3516 08 +ve Brush Holder Assly (Flash) 1
13 JA 3516 09 -ve Brush Holder Assly (Flash) 1
14 JA 3516 18 Brush & Earth Plate Assly 1 N.I. (Lucas-TVS)
16 15 JA 3516 24 Brush Spring (Lucas-TVS) 1 N.I.
13
10
16 JA 3516 19 Terminal Assly (Lucas-TVS) 1
17 39 0849 14 Washer lock - Toothed 3
8 18 DH 1013 80 Screw - Pan - Precoated 3
10
11 9
39 40
Plate No.: 21
Magneto, CDI & H.T. Coil
1 PF 3510 03 Rotor Assly 1

2 PF 3510 04 Stater Assly Complete 1
3 39 1674 04 Bolt Flange M6 X 28 2
4 4 DH 1013 80 Pan Head Screw M6 X 12 3 For Lock Plate &
Pick Up Coil Mounting
5 JV 3512 04 H. T. Coil With Cable 1
13 1 6 PF 3512 01 C.D.I. Assly 1
3
7 DD 1110 18 Spark Plug PRZ9 HC 1
4 CF 1110 19 Spark Plug UR4AC 1
8 DD 1110 48 Spark Plug Cap 1
9 DD 1110 11 Grommet Spark Plug Cap 1
10 DD 1110 12 Grommet for HT Cable 1
5
2 11 39 1943 04 Bolt Flange M6 2

12 JN 4020 00 DC Regulator With Capacitor 1
6
13 JA 5410 28 Lock Plate 1
11 14 59 0400 14 Bolt Flange (N.I.) 4 For HT Coil Mounting
10
8
12 9
41 42
Plate No.: 22
Seat Assembly
1 PF 1910 00 Seat assly. complete (Profile Seat) 1

1
JV 1910 01 Seat assly. complete (Flat Seat) 1
2 FD 2110 06 Grommet Seat 2
3 FD 2110 07 Spacer Seat 2
4 39 1211 11 Washer Plain 2
5 LA C000 21 Bolt Hexagon Socket Head 2
6 PF 2314 05 Grip Frame 1

7 39 1556 04 Bolt Flange 2
4 3 2 8 DP 2110 09 Damper For Seat 7
8 5
43 44
Plate No.: 23
Engine Mountings
1 PF 1134 02 Bracket Engine Hanger 2

2 JA 1134 02 Engine Mounting Bracket Front 1
3 39 2723 15 Hex Nut Flanged 2 for engine mtg. Rear
4 JA 1134 03 Bolt Flanged 2 for engine mtg. Rear
5 39 2312 04 Bolt Flanged 3 for engine mtg. Top
6
6 39 1970 15 Nut Flanged 7 for engine mtg. Top &

Front
7 59 0400 17 Hex Bolt Flanged 4 for engine mtg. Front
1
6
5 3
7
2
45 46
Plate No.: 24
Frame and Frame Fittings
1 PF 1110 00 Frame Assly. 1

2 DS 1810 18 Nut with Dust Cap 1
3 36 3140 01 Bearing cone Kit 1 Refer Page No. 106
2
36 3140 05 Bearing cone Kit 1 Alt. For 36 3140 01
4 4 DJ 1811 15 Cage Bearing 2
5 DH 1810 14 Cup Steering 1 N.I.
3
1
47 48
Plate No.: 25
Swing Arm / Rear Shock Absorber
1 JB 1220 16 Hex Bolt / Flange - M10 2 For RSA

8 7
2A 39 0714 11 Plain Washer 2 For RSA
2B
2B 39 2349 11 Plain Washer 4
3 PF 1220 05 Rear Shock Absorber 2
2A
2B DZ 1910 16 Rear Shock Absorber 2 (For Philippines)
5 52 PF02 19 Kit Asly Swing Arm 1 With Bush
9 2A
6 DP 1710 06 Bushing Rubber 2
7 39 2366 15 Domed Cap Nut 2
10
11 13 8 39 0789 12 Spring Washer 2
6
9 JB 1220 03 Chain Slider 1
10 39 0553 02 Screw 2 For Chain Sider
1
6 11 39 0454 11 Plain Washer 2 For Chain Sider

12 JA 1210 03 Shaft Swing Arm 1
3 13 39 0939 15 Nylock Nut 1
5
14 DJ 1510 36 Adjuster Chain LH 1
12
15 DJ 1510 37 Adjuster Chain RH 1
1 17
15 16 39 0292 15 Hexagon Nut 4
17 DJ 1510 47 Plate Chain Adjuster 2
16
14 16 18 Pf 1220 23 Statutory Plate 1 N.S
17 19 PF 1220 24 Tape Double Sided 1 N.S
49 50
Plate No.: 26
Rider Foot Rest / Pillion Foot Rest

2 4
14
1 PF 1130 00 Main Step LH 1
2 KA DF08 22 Bolt Flanged 4
14 3 PF 1130 01 Main Step RH 1
3
2
4 DF 1614 13 Rubber Main Step 2
5 DH 1611 94 Kick Stopper 1 For Kick stopper
5 6 PF 1130 02 Stay LH 1
14 7 PF 1130 03 Stay RH 1
2 8 DP 1611 70 Step RH / LH 2
9 JK 1130 08 Rubber Pillion Step 2
13 10 30 1710 22 Pin Pillion Step 2
14
2
1 11 DP 1611 63 Washer for foot step 2 For Rear Footrest
12 39 0784 08 Split Pin 2
4 13 39 2481 04 Bolt Hex With Flange M8 4
6/7
14 39 2659 12 Washer - Spring 4
15 PF 1130 23 Footrest Pillion Assly LH 1 NI
10 16 PF 1130 24 Footrest Pillion Assly RH 1 NI
12
8
11
51 52
Plate No.: 27
Mudguard - Front & Rear
1 PF 1814 04 Fender Assly. Front (Chrome Plated) 1

2 DF 1910 20 Cable Guide 1
3 PF 1814 08 Mud Flap Front Fender 1
4 39 2222 04 Flange Bolt 4 Fender Front Mounting
1 5 JV 1814 08 Fender Rear 1
6 JV 1814 10 Fender Rear Flap 1
7 39 0326 15 Nyloc Nut 6
78 8 39 0242 11 Washer - Plain 6 Front Fender Flap
8A 39 1839 11 Washer 6 Rear Fender Flap
3
19 9 39 2420 01 Screw 6 Front & Rear Fender Flap
4
39 1698 01 Screw 6 Alt. For 39 2420 01
8 9
2 10 39 1309 11 Washer Plain 1
14
11 10 5 11 39 2473 04 Bolt Hex M6 1
15
12 39 1943 04 Bolt Flange 1
13 39 0211 11 Washer Plain 1
12 13 14 39 1556 04 Bolt Flange 1
20 15 39 1507 11 Washer Plain 1
8A 6 16 KA DF08 20 Bolt Flange 2
7
16 17 18
17 39 1970 15 Nut Hexagon M8 2
8A
18 39 1507 11 Washer Plain 2
9
19 PF 1814 10 Fender Brace 1
20 30 2010 69 Reflector Reflex 1
53 54
Plate No.: 28
Stand Assembly
1 PF 1132 02 Center Stand 1

3 2 JA 1132 01 Shaft Stand 1
2 3 39 0797 08 Pin Cotter 1
4 DH 1611 21 Spring Stand Center 1
5 JA 1132 02 Stand Side 1
6 DH 1610 66 Spring Side Stand 1
7 7 DF 1611 02 Bolt 1
4
8 39 0422 15 Nut Nyloc M10 1
9 9 DG 1611 24 Damper Main Stand 1
10 DH 1611 46 Cover Spring Side Stand 1
11 DH 1611 45 Cover Spring Main Stand 1
1 8
6
11 5
10
55 56
Plate No.: 29
Tube / Tyre / Rim
1 DS 1510 03 Wheel Rim Front 1 1.6 X 17

2 PF 1310 01 Tyre Front 3 X 17 RIM with Tube 1
3 DS 1510 53 Tube Front 3 X 17 1 N.S
9
8 4 DS 1510 34 Wheel Rim Rear 2.15 X 17 1
7 3
5 PF 1312 10 Tyre Rear 100 x 90, 17, 55P with Tube 1
6 DS 1510 29 Tube Rear 90 / 90-17 1 N.S

7 DS 1510 04 Spoke Inner Front 18
2
8 DS 1510 05 Spoke Outer Front 18
9 16 1510 66 Nipple Spoke 72
10 DS 1510 09 Spoke Inner Rear 18
12
1 11 DS 1510 10 Spoke Outer Rear 18
11
9 12 DG 1510 22 Band Rim 2
10
5
6
57 58
Plate No.: 29
Tube / Tyre / Rim (Alloy Wheel)

3
1 DS 1510 80 Wheel Rim Front (6 Spoke) 1
1
PF 1310 12 Wheel Rim Front (5 Spoke) 1 from May 2012
2 PF 1310 02 Tyre Front 1 N.S
3 DS 1510 53 Tube Front 1
4 DH 1510 57 Wheel Rim Rear (6 Spoke) 1
PF 1312 22 Wheel Rim Rear (5 Spoke) 1 from May 2012
5 PF 1312 11 Tyre Rear 1
6 DS 1510 29 Tube Rear 1

7 PF 1310 01 Tyre with Tube Front 1 N.I
9 PF 1312 10 Tyre with Tube Rear 1 N.I
6 5
59 60
Plate No.: 30
Front Hub (for Spoke Wheel)
5
1 39 2688 20 Ball Bearing 12 x 37 x 12 2
7 2 JA 1316 03 Drum Front 1
6 8 3 30 1510 32 Collar Bearing 1
3
4 30 1510 33 Oil Seal 1
2
4 5 DS 1510 60 Spacer Assy 1
1
6 39 0781 11 Plain washer 1
7 59 1500 03 U Nut M12 1
8 DJ 1510 81 Axle Front 1
DJ 1510 41 Axle Front 1 Alt. For DJ 1510 81
18
9 39 0775 04 Bolt M6 X 30 1
1
10 JA 1316 07 Lever Brake Front 1
15 17
19 11 39 0798 15 Nut Hex. Flange M6 1
16 12 DD 1510 09 Indicator Front 1
14 13 30 1510 38 'O' Ring 1
14 JA 1316 05 Panel Front Brake 1
13 15 30 1510 11 Cam Brake 1
12
9 20 21 16 30 1511 16 Gear Speedometer 1
20 17 30 1510 35 Seal Oil 1
10 18 30 1510 69 Spring 2
19 30 1511 05 Shoe- Brake for Spare Parts 1
11 22 JN 1318 12 Shoe Brake Non Asbestos type 1
25
23 24 20 30 1510 42 Washer for Speedo Gear 2
39 0242 11 Washer - Plain 2 Alt. For 30 1510 42
21 30 1510 41 Gear Meter Screw 1

22 JA 1316 06 Bush for Speedo Gear 1
23 39 0840 01 Screw Pan Cross M4 1
24 39 0900 12 Washer Spring 1
25 30 1511 18 Stopper For Bushing 1
61 62
Plate No.: 30
Front Hub (for Alloy Wheel)
3 2 1 59 1500 03 U Nut (M12) 1

5A 59 1500 03 U Nut (M12) 1 Alt. For 59 1500 03
1
5
1A JB 1310 17 Axle Front Wheel 1
2 JB 1310 18 Plain Washer 1
3 DS 1510 56 Dust Seal 1
4 4 DS 1510 60 Spacer Assy 1 (N.I.)
5 39 2688 20 Bearing Ball 1
5A 30 1510 33 Oil Seal 1
6
6 30 1510 32 Collar Bearing 1

7 39 2688 20 Ball Bearing 1
7
10 8 30 1511 05 Shoe- Brake for Spare Parts 1
11 JN 1318 12 Shoe Brake Non Asbestos type 1
8
9 30 1510 69 Spring 2
15 12 9
13 10 14 1510 21 Oil Seal 1
14
11 DS 1510 89 Cam Brake Assly. 1
12 DS 1510 87 Panel Front Brake 1
22 13 30 1510 38 Ring ‘O’ 1
16
14 DS 1510 91 Indicator 1
21
15 DS 1510 95 Bolt 1 N.S
17 16 DS 1510 92 Lever Brake Cam 1
24 23 17 DS 1510 94 Nut 1
24 25 18 39 0840 01 Screw Pan Cross M4 1
26
1A 19 39 0732 12 Washer Spring 1
20 30 1511 18 Stopper for Bushing 1
21 LB D000 01 Screw 1 To Secure Speedo Cable
20
22 36 DS 15 02 Speedometer Gear Kit 1
19 23 30 1510 35 Seal Oil 1
18 24 30 1510 42 Washer Plain 2 For Gear Meter Screw
39 0242 11 Washer Plain 2 Alt. For 30 1510 42
25 39 1013 21 ‘O’ Ring 1
26 JA 1316 06 Bushing Speedo Gear 1
63 64
Plate No.: 31
Rear Hub (for Spoke Wheel)
1
9 1 JN 1410 02 Drive Chain Lock 1
2
2 36 PF00 10 Kit Chain Sprocket 1 Refer Page No. 107
3 39 0801 15 Nut Hex. M20 X 1 1
8 4 39 2567 11 Washer Plain 1
11 5 DJ 1510 35 Collar 1
5 10
6 39 0794 15 Hex Lock Nut 4
3
7 DS 1510 74 Washer Four Rubber 2
8 39 2240 20 Ball Bearing 1
9 DS 1510 68 Coupling 1
4 10 DS 1510 73 ‘D’ Bolt 4
6 7 15 11 DJ 1510 33 Sleeve Rear Axle 1
12 DK 1510 94 Coupling Rubber 1
16 13 39 2686 20 Bearing Sprocket Side 1
13
PF 1312 28 Collar Bearing 1 Ref. Cir. IB-120
15 DS 1510 67 Drum Rear (4 Rubber) 1
PF 1316 14 Drum Rear (4 Rubber) 1 Ref. Cir. IB-120
16 39 2687 20 Bearing Brake Side 1
12
14 17 30 1510 69 Spring 2
23 18 30 1511 05 Shoe- Brake for Spare Parts 1
JN 1318 12 Shoe Brake Non Asbestos type 1
20 19 30 1510 11 Cam Brake Rear 1
19A 39 0722 11 Washer 1
24
18 21
25 20 DS 1510 76 Panel Rear Brake 1
22 21 30 1510 38 Ring ‘O’ 1
19
22 30 1510 05 Indicator 1
17 27 23 39 0798 15 Nut M6 1
24 JW 1316 01 Lever Brake Rear 1
25 39 2447 04 Hex. Head Bolt M6 1
28 29
26 26 PF 1312 08 Axle Rear Wheel (Dia.15) 1
27 DX 1510 22 Collar 1
28 39 2566 11 Washer Plain 1
29 DH 1710 19 Nut 'U' M14 Swing Arm 1
65 66
Plate No.: 31
Rear Hub (for Alloy Wheel)
8
11 1 DJ 1510 53 Drive Chain Lock 1
9
2 2 36 PF00 10 Chain Sprocket Kit 1
6
3 LC A000 01 Nut 1
39 0801 15 Nut 1 Alt for LC A000 01
5 4 LD B000 02 Plain Washer 1
4
39 2567 11 Plain Washer 1 Alt. For LD B000 02
5 DJ 1510 35 Collar 1
7
6 39 2240 20 Bearing Ball 1
7 DS 1510 68 Coupling 1
3 8 DS 1510 73 ‘D’ Bolt 4
9 39 0794 15 Hex Lock Nut 4
10
10 DS 1510 74 Washer 2
15 11 DJ 1510 33 Sleeve 1
12 39 2686 20 Bearing Ball 1
PF 1312 28 Collar Bearing 1 Ref. Cir. IB-120
14 DK 1510 94 Coupling Rubber 1
14
13 15 39 2687 20 Bearing Ball 1
27 16 30 1510 69 Spring 2
12
17 30 1511 05 Shoe- Brake for Spare Parts 1
25 JN 1318 12 Shoe Brake Non Asbestos type 1
18 DJ 1510 92 Panel Rear Brake 1
24 19 30 1510 11 Cam Brake 1
19A 39 0722 11 Plain Washer 1
28 26 20 30 1510 38 Ring ‘O’ 1
23 21 30 1510 05 Indicator 1
17 22 JZ 1318 03 Lever Brake 1
23 JB 1312 24 Bolt 1 N.S
16
24 PF 1312 08 Axle 1
20 21 22 25 DX 1510 22 Collar 1
19 19A 18 26 39 2567 11 Plain Washer 1
16 27 DH 1710 19 ‘U’ Nut 1
28 DS 1510 94 Nut M6 1
67 68
Plate No.: 32
Rear Brake Pedal
1 PF 1610 02 Brake Pedal 1

2 PF 1610 01 Rod brake 1
1 3 30 1910 38 Pin 1
8
4 DS 1910 35 Packing Brake rod 1
7
5 39 0198 11 Plain washer 2
3 9
2 5 6 39 0808 08 Split pin 1
4 7 39 0805 11 Plain Washer 1
5
6 8 39 0797 08 Pin Cotter 1
9 JV 1610 14 Brake Pedal Return Spring 1
10 10 39 0198 11 Washer Plain 2

17 11 30 1910 35 Spring 1
19 12 JB 1610 02 Pin Brake Rod 1
15
11 13 30 1910 36 Nut Brake Adjuster 1
16 14 JW 1220 04 Rod Torque 1
18 10
12
15 DH 1510 29 Step Bolt Torque Rod 1
14 134 16 39 1540 11 Plain Washer 1
17 39 0789 12 Spring Washer 2
18 39 0694 15 Hex. Lock Nut M8 x 1.25 1
19 19 39 0807 08 Split Pin 2
20 17 21
20 30 1510 95 Bolt Hex. 1

21 39 0708 15 Nut Hex. M10 X 1 1
69 70
Plate No.: 33
Handle Bar
1 DU 1810 21 Handle Bar 1

2 DS 1810 22 Switch Ignition Assly 1
25 2A PF 2326 01 3 in One Lock Set 1 N.I.
3 DJ 2210 03 Mirror Assly. LH 1
4 DJ 2210 04 Mirror Assly. RH 1
28 5 DX 1910 09 Lever Control LH 1
DJ 1910 83 Lever Control LH 1 Ref. Cir. IB-114
2 4 6 DJ 1910 54 Holder LH 1
DJ 1910 81 Holder LH 1 Ref. Cir. IB-114
3 14 27 7 DS 1910 52 Boot For Lever LH 1
12 8 DU 1910 09 Grip LH 1
15 9 JB 4014 00 Control Switch LH 1
13
7 10 JB 4014 09 Clutch Switch 1 N.I.
5
11 16 JZ 4014 05 Clutch Switch 1 N.I. Ref. Cir. IB-114
1 26 11 DD 1911 47 Screw for Cable Adjuster 2 N.S
12 39 1074 04 Flanged Bolt 4
6 13 17 13 36 DS18 01 Holder Handle Set 2 Refer Page No. 106
27 28
18 14 DS 1910 18 Boot For Lever RH 1
19
20 15 DD 1911 42 Lever RH 1
9 24 16 PF 4014 08 Control Switch RH 1
21 22 PF 4014 17 Control Switch RH 1 Ref. Cir. IB-113
8 23 17 DU 1910 03 Hand Grip Assly RH 1
10 18 DS 1810 07 Washer Handle Upper 2
19 DS 1810 08 Damper Handle Upper 2
71 72
Plate No.: 33
Handle Bar
20 DS 1810 05 Bracket Upper Front Fork 1 For Fairing Version
25
21 DS 1810 09 Damper Handle Lower 2
22 DS 1810 10 Washer Handle Lower 2
23 39 0422 15 Nut Nyloc M10 2
28 24 30 1910 48 Band 2
2 4 25 39 1943 04 Flange Bolt 2 For Ignition Switch
3 14 27 26 DS 1910 33 Holder RH 1
12 DS 1910 38 Holder RH 1 alt for DS 1910 33
15 27 36 DK00 37 Kit Mirror Holder 2 Refer Page No.108
13
7
28 PF 4014 14 Switch Stop Light 1
5
11 16
1 26
6 13 17
27
18
19
20
9 24
21 22
8 23
10
73 74
Plate No.: 34
Front Fork ( for Without Fairing Version)
1 PF 1210 12 Fork Front 1

2 36 DK00 20 Front Fork Seal Kit 1 Refer Page No. 107
2A DJ 1810 87 Seal - Oil for 31 Dia. Fork 2
1
3 30 1810 26 Gasket 2
4 30 1810 25 Bolt 2
7
5 PF 1210 17 Fork Pipe Inner 2
8
19 9 6 DS 1810 84 Spring Front Fork 2
17 20
7 59 0400 06 Bolt Fork 2 With Washer
8 DS 1810 15 Cap Nut Fork 1
10
9 DS 1810 16 Plain Washer 1 For Cap Nut
2 18 10 DS 1810 05 Bracket Upper Front Fork 1
23
22 11 30 1810 09 Bearing Cone 1
2A
12 DS 1810 20 Under Bracket Fork 1
6 21
5 11 14 39 1181 01 Bolt 2
15 PF 1210 18 Pipe Left Fork Outer 1
15/16 24
25
16 PF 1210 19 Pipe Right Fork Outer 1
17 DE 1810 33 Cylinder Complete Fork 2
3 18 31 1810 99 Rebound Spring 2
12 19 DS 1810 12 Bolt Fork 2
4 20 31 1811 02 ‘O’ Ring 2
13
14
21 DJ 1810 42 Cover Trail A 2
22 PF 1210 28 Damper Cover Fork 2
23 DJ 1810 43 Cover Trail B 2
24 DJ 1810 85 Cushion Rubber 2
25 PF 1210 15 Cover Fork LH 1
26 PF 1210 16 Cover Fork RH 1
75 76
Plate No.: 34
Front Fork (For Fairing Version)
1 PF 1210 26 Fork Front 1

2 36 DK00 20 Front Fork Seal Kit 2 Refer Page No. 107
2A DJ 1810 87 Seal Oil 2
1 3 30 1810 26 Gasket 2
4 30 1810 25 Bolt 2
7 5 PF 1210 17 Fork Pipe Inner 2
8
19 9 6 DS 1810 84 Spring Front Fork 2
17 20 7 59 0400 06 Bolt Fork 2 With Washer
8 DS 1810 15 Cap Nut Fork 1
10 9 DS 1810 16 Plain Washer 1 For Cap Nut
2 18 10 DS 1810 05 Holder Fork upper 1
23
11 30 1810 09 Bearing Cone 1
22
2A 12 DS 1810 20 Under Bracket Fork 1
21 14 39 1813 04 Bolt 2
6 11
5 15 PF 1210 18 Pipe Left Fork Outer 1
15/16 24
16 PF 1210 19 Pipe Right Fork Outer 1
25
17 DE 1810 33 Cylinder Complete Fork 2
18 31 1810 99 Rebound Spring 2
3 19 DS 1810 12 Bolt Fork 2
20 30 1810 29 ‘O’ Ring 2
12
4
13 21 PF 1210 24 Lamp Shade Assly. 1
14
22 DJ 1810 42 Cover Trail A 2
23 PF 1210 28 Damper Cover Fork 2
24 DJ 1810 43 Cover Trail B 2
25 DJ 1810 85 Cushion Rubber 2
26 DS 1810 70 Bush Guide 2

27 DS 1810 72 Washer Guide Bush 2
77 78
Plate No.: 35
Painted Parts and Decals
6 1 1 PF 1812 09 Wind Shield 1

2 PF 7201 X3 Front Fender Painted 1 Ebony Black
PF 7201 3E Front Fender Painted 1 Elect Blue
PF 7201 3F Front Fender Painted 1 Flame Red
PF 7201 2D Front Fender Painted 1 Artic White
3 PF 7101 X3 P.Tank Ebony Black Decal 1 Black Decal
3 PF 7101 3E P.Tank Elctron Blue Decal 1 Blue Decal
PF 7101 3F P.Tank Flame Red Decal 1 Red Decal
PF 7101 2D P.Tank Arctic White Black Decal 1 Artic White Black Decal
4 PF 7302 X3 Side Cover Rh 1 Ebony Black Decal
2
PF 7302 3E Side Cover Rh 1 Electron Blue Decal
PF 7302 3F Side Cover Rh 1 Flame Red Decal
PF 7302 2D Side Cover Rh 1 Artic White Black Decal N.S
5 4 5 PF 7301 X3 Side Cover Lh 1 Ebony Black Decal
PF 7301 3E Side Cover Lh 1 Electron Blue Decal
PF 7301 3F Side Cover Lh 1 Flame Red Decal
PF 7301 2D Side Cover Lh 1 Artic White Black Decal N.S
6 PF 7401 X3 Cowling Painted 1 Ebony Black
PF 7401 3E Cowling Painted 1 Electron Blue
7
PF 7401 3F Cowling Painted 1 Flame Red
PF 7401 2D Cowling Painted 1 Artic White
7 36 PF00 15 Kit Tank Dcl Red 1
36 PF00 16 Kit Tank Dcl Blue 1
36 PF00 17 Kit Tank Dcl Black 1
8 36 PF00 18 Kit Dcl Side Cover Red BM150 1
36 PF00 19 Kit Dcl Side Cover Blue BM150 1
8 36 PF00 20 Kit Dcl Side Cover Black BM150 1
79 80
Plate No.: 36
Fuell Tank, Cap Tank and Gauge Fuel
1 DS 1410 09 Cap Assly. Tank 1

2 39 0761 01 Screw Pan Cross 2
5 3 39 2179 24 Washer 2
2 3A 30 1410 31 ‘O’ Ring 2
1 3 4 PF 1718 02 Fuel Tap 1
5 PF 2326 01 3 In 1 Lock Set with Key 1
3A
7 6 PF 4026 00 Sensor Fuel Level 1 With ‘O’ Ring

4
6A 39 2758 21 ‘O’ Ring 1 For Tank Unit
DK 1410 28 O’ Ring 1 Alt. For 39 2758 21
7 DS 1410 13 Seat Tape 1 Pasted on Tank
8 39 2484 15 Flanged Nut 4
9 PF 1718 03 Pipe Fuel 1 Cock to Carburettor
10 30 1410 15 Pipe Clip 2
DK 1410 41 Pipe Clip 2 Alt. For 30 1410 15
6A
10
6
9
8
81 82
Plate No.: 37
Fittings - Fuel Tank, Side Covers & Cover Seat
1 36 DS14 01 Grommet Kit for Side Cover 1 Refer Page No. 107
2 DG 1611 21 Screw 1
8 3 DU 1611 02 Damper 1
4 JV 1710 01 Damper Tank Rear 1 For Tank
6
5 39 1789 24 Washer Nylon 3
6 39 0983 08 Pin Snap 1

7
8 DJ 1410 08 Damper Front 2 For Tank Mounting
1
8
4
2
83 84
Plate No.: 38
Meter Assembly
1 PF 4024 00 Speedometer Assly. 1

2 PF 4024 01 Speedometer Machine With Dial 1
3 PF 4024 05 Fuel Gauge Machine with dial 1
1 4 PF 4024 02 Speedo meter Top Cover 1
5 PF 4024 06 Speedo meter Bottom Cover 1
6 PF 4024 03 Speedometer wiring harness 1

5 7 CL 2010 42 Bulb 12V - 2 W 4
8 DH 1910 37 Bulb 12V - 3 W 3
9 PF 4024 04 Speedometer Bracket 1
3
10 39 0798 15 Flanged Nut 2
8
4
2
7 9
10
85 86
Plate No.: 39
Control Cables
1 PF 1612 11 Cable Accelerator 1

PF 1612 17 Cable Accelerator 1 Ref. Cir. IB-113
2 PF 1612 12 Cable Clutch 1
3 PF 1612 08 Cable Speedometer 1
4 PF 1612 09 Cable Speedometer Inner 1
5 PF 1612 13 Cable front Brake 1
3
6 39 1561 21 ‘O’ Ring 1 N.I.

2 5
4
1
87 88
Plate No.: 40
Chain Case
1 36 PF00 11 Kit Chain Case 1 Refer Page No. 107

2 15 1610 69 Rubber Cap 1
3 JB 1812 39 Bolt M6 2
DH 1612 83 Bolt M6 2 Alt For. JB 1812 39
4 JB 1812 20 Flange Bolt M6 X 1P X 62 L 2
1
3
5
2 3
89 90
Plate No.: 41
Head Lamp (Without Fairing)
1 PF 4010 00 Head light assly 1

PF 4010 07 Head light assly Without Bulb 1 1
3 DU 2010 29 Special Screw 2
4 DS 2010 19 Collar 2
5 DS 2010 20 Damper I 2 N.S
9
6 DS 2010 21 Damper II 2
10
7 39 2582 04 Flange Bolt M-8 L 35 2
8 39 1970 15 Flange Nut M-8 2
9 CL 2010 23 Lamp 12 V 35/35 W HS1 1
10 PF 4010 09 Lamp Holder (Socket) Assly. 1
8
4 1
6
91 92
Plate No.: 41
Head Lamp (With Fairing)

22
23 1 PF 4010 00 Head light assly 1

PF 4010 07 Head light assly Without Bulb 1
3 DJ 2010 51 Reflector with Lens 1
18 4 DU 2010 29 Special Screw 2
19 25 24
20 5 DS 2010 19 Collar 2
6 DS 2010 20 Damper I 2 N.S

10 11
7 DS 2010 21 Damper II 2
8 39 2582 04 Flange Bolt M-8 L 35 2
9 39 1970 15 Flange Nut M-8 2
10 CL 2010 23 Lamp 12 V 35/35 W HS1 1
11 PF 4010 09 Lamp Holder (Socket) Assly. 1

12 PF 1210 25 Fairing Structure 1
4 3 13 JW 1812 32 Bolt Flange M6 4
14 JW 1812 29 Plain Washer 6
9 15 JB 1510 12 Grommet Fairing Mounting 4
5 1
7 16 JB 1510 13 Sleeve Fairing Mounting 4
17 39 0798 15 Hex Nut 2
18 35 1610 60 Nut - Clip 4
19 39 1765 11 Washer - Plain 4
6 20 39 2238 01 Screw - Pan Head 4
8 12 21 PF 1812 11 Grommet - Cowling Mtg 2 N.I.

22 PF 1812 09 Windshield 1
23 DL 1810 09 Screw - M5 X L 16 4
24 39 2141 24 Washer (Non Metallic Washer) 4
13 25 DL 1810 10 Nut-well M5 4
17
14 15 16
93 94
Plate No.: 42
Indicator Light Assembly
1 DM 2010 27 Dir. ind. Front LH with Lamp 1 With Lamp base

2 DM 2010 28 Dir. ind. Front RH with Lamp 1 With Lamp base
3 DM 2010 29 Dir. ind. Rear LH with Lamp 1 With Lamp base
4 DM 2010 30 Dir. ind. Rear RH with Lamp 1
PF 4010 04 Dir. ind. Rear RH with Lamp 1
2
5 06 2010 83 Lamp 12 V - 10W 4
1
6 DU 2010 16 Lens 4
7 39 1225 15 Hex. Nut 4
3 4
6 6
5 5
95 96
Plate No.: 43
Tail Lamp Assly / Front Number Plate
1 DF 2011 38 Tail Light Assly. with lamp 1
3
2 31 2010 28 Lamp 12 V, 10/5W 1
6 3 39 2430 15 Hex Nut. / Flange 2
4
19 1 4 DD 2010 11 Damper 2
5 31 2010 01 Collar 2
5
7

7 PF 2314 01 Bracket Tail Light Assly 1
2
8 39 1956 04 Bolt Flange Small (for No. Plate) 2
9 DP 1611 45 Plate No. Rear Black 1
10 39 2765 01 Screw Truss M6 2
8 11 DP 1611 44 Number Plate Front 1

12 DD 1811 76 Front No. Plate Mtg Bracket 1
9 13 39 1783 01 Truss Screw Front No. Plate 2
13
14 30 1810 60 Damper 2
12
15 30 1810 61 Collar 2
11
10
14
16 39 1553 04 Bolt Flange 2
15 10
17 17 39 1211 11 Washer 2
16 19 DM 2010 26 Boot 1
20 30 2010 69 Reflector Reflex 1 N.I.
21 39 1972 15 Nut Hexagon with Flange M5 1 Reflector Mtg.
97 98
Plate No.: 44
Electrical Equipments
19
1 JV 4016 02 DC Horn 1
2 39 1689 04 Flange Bolt (M8) 1
3 PF 4022 00 Wiring Harness 1
4 PF 4014 04 Rear Brake Switch 1
18 5 PF 4014 03 Spring Brake Switch 1
1 10 13 6 DS 2010 82 Battery 5 MF dry Charged 1

7 JV 4018 01 Case Battery 1
14
8 JA 4018 01 Band Battery 1
6 9 DS 2010 25 Assly DC Flasher 1
2 10 JK 3516 00 Starter Relay 1 With Grommet

11 30 2011 04 Fuse Box Assly 2 For Light Main Fuse
4
5
12 GF 2010 53 Fuse (10 Amp.) 2 Light & Main Fuse
9 13 JV 4022 04 Starter Relay to Motor Relay 1
15
11 14 JV 4022 05 Cable Assly. (Battery to Earth) 1
3 15 39 1942 04 Bolt Flanged 1
12
16 30 1910 48 Band 1
8
17 30 2010 64 Band (Harness) 1
7
18 DS 2010 22 Cable assly Battery to Starter Relay 1
16
17
99 100
Plate No.: 45
Tool Kit
1 DM 2210 13 Tool Kit 1 For Reference Only

Screw Driven 1
Tool Wrench A/F 17 X 22 1
Spanner Box- 16 X 14 1
1
Tool Bar 1
BOXER S
101 102
Plate No.: 46
Accessories
3 1 PF 1130 08 Footrest Third LH 1

2 PF 1130 09 Footrest Third RH 1
3 39 1298 04 Screw Hex. Socket M8x1.25x35 2
4 JB 2312 06 Bolt Socket Head 2
1 4 2 5 PF 2312 01 Leg Guard 1
\ 6 JA 2312 01 Hook Leg Guard 1

7 JA 2312 02 Spacer Leg Guard 1
8 39 0798 15 Nut Hex with Falnge M6 2
8 5
103 104
Kit List Kit List
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 36JZ0001 Valve Kit JZ511200 Valve Intake 1 8 36JZ0016 Idling Screw Kit JZ581217 Screw Stop 1
JZ511201 Valve Exhaust 1 DH121130 ‘O’ - Ring 1
CB121044 Spring Compression 1
2 36JZ0004 Valve Repair Kit 39201719 Seat Valve Stem 2
DG101029 Cotter Valve 2 9 36PF0022 Kit Piston Valve BM 150 PF581206 Valve Piston 1
JA511203 Retainer Valve Spring 2 DD121054 E-Ring 1
28101129 Seat Valve Spring 2 JZ581211 Holder Assly Magnet 1
JZ511202 Spring Washer 2 DD121055 Spring Compression 1
JZ581223 Packing 1
3 36JE0003 Kit Guide Cam Chain JW541012 Guide Cam Chain (Slack Side) 1 PF581208 Jet Needle 1
JA521002 Guide Cam Chain (Tight Side) 1 PF581207 Ring 1
10 36PF0024 Kit Carburetor Gasket/O Ring JA581232 Gasket Float Chamber 1

4 36JZ0005 Piston Ring Set JZ521204 Ring Piston Top 1
DH121130 ‘O’ - Ring Idling Screw 2
JZ521205 Ring Piston Second 1
DH121088 O Ring Air Screw 2
JZ521206 Ring Piston Oil 1
DH121118 ‘O’ Ring Drain screw 1
JA581238 ‘O’ Ring TPS 1
5 36DU1007 Boss Kick Set 30101233 Boss Kit 1
30101234 Spring 1
30101236 Ball Steel 1 11 36PF0023 Kit Choke Plunger BM 150 – Plunger Assembly 1
30101235 Pin 1 – Guide Holder 1
39085517 E - Type Clip 1 PF581205 Lever Assembly Choke 1
DH121071 Cap 1
6 36PF0021 Kit Jet BM 150 JZ581234 Needle Jet 1 Dd121058 Spring Choke Plunger 1
JZ581219 Holder Needle Jet 1 CF121004 O Ring Choke Plunger 1
JZ581218 Jet Main 1
JE581205 Jet Pilot 1 12 36314001 Bearing Cone Kit DH181025 Bearing cone 1
DH181026 Bearing race 1
7 DH121169 Pilot Screw Kit DH121131 Screw Adjuster 1 DH181024 Upper bearing race 1
DH121130 ‘O’ - Ring 1
DH121186 Spring Compr Coil 1
13 36DS1801 Holder Handle Set DS181019 Holder Handle 2
DH121187 Plain Washer 1
DS181006 Holder Handle 2
DH121188 ‘O’ - Ring 1
105 106
Kit List Kit List
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
14 36PF0010 Kit Chain Sprocket BM 150 DX151023 Sprocket Hub (42T) 1 23 36DK0037 Kit Mirror Holder 39118415 Nut - Nylock :- M5 X 0.8 1
JZ551004 Sprocket Drive (14T) 1 Dl191014 Stud - Lever Handle 1
JV141004 Chain 122 Link 1 30191017 Nut 1
39019811 Washer - Plain 1
15 36JZ0003 Set Primary Drive & Driven JZ551403 Housing Complete Clutch HTTS 1 39072504 Bolt - Hexagon :- M6 X 1 1
JZ531006 Gear Primary Drive 1
16 36JZ0008 Starter Clutch Repair Kit JA621411 Bush Spring Starter Clutch 5
DH101163 Roller Clutch 5
DH101164 Spring 5
DJ101109 Bush For Spring Starter Clutch 5
17 36PF0009 Kit Friction Plate BM 150 JV551402 Plate Friction Clutch 5
18 36PF0002 Kit Block-Piston BM 150 PF521007 Assly Cylinder Block 1

PF521205 Piston Assly 1
19 36JW0013 Leg Gaurd Hardware Kit JA231201 Hook Leg Gaurd1 1

JA231202 Leg Gaurd Spacer 1
39079815 Nut Hexagon with Flange 2
20 36DS1401 Grommet Kit - Side Cover DS141012 Grommet Side Cover Front 2
DS161082 Grommet Side Cover Rear 2
21 36PF0011 Case Chain Kit PF181202 Case Chain Upper Assly. 1

Pf181200 Case Chain Lower Assly. 1
22 36DK0020 Kit Outer Tube DJ181089 Seal Dust 2

DJ181088 Stopper Seal Oil 2
DS181072 Washer Guide Bush 2
DS181070 Guide Bush 2
107 108
SPC Updation Details SPC Updation Details
Page Fig. Old part New part Updation Remarks Page Fig. Old part New part Updation Interchan
Remarks
no. no. no. no. Description date no. no. no. no. Description date geability
60 1 DS151080 PF131012 Wheel Rim Front 10.05.12 6 Spoke wheel introduction
60 4 DH151057 PF131222 Wheel Rim Rear 10.05.12 6 Spoke wheel introduction
68 2 36JZ0026 36PF0010 Kit chain sprocket 04.10.13 Correction
48 1 Pf111000 Pf111074 FrameAssly. 03.04.14 Alternate updation
52 1 Pf113000 Pf113020 MainStepLH 03.04.14 Alternate updation
50 5 36PF0014 Pf122022 Swing Arm Complete 03.04.14 Alternate updation
50 5 36PF0014 56PF0219 Swing Arm Complete 26.11.14 Correction
8 4 DH101387 DK101386 Soc Head Bolt 28.01.15 Mail by Mr Gaurav Khanna
60 7 DS151047 PF131001 Tyre with tube FR 16.03.15 Correction
60 8 DS151051 PF131210 Tyre with tube RR 16.03.15 Correction
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.
06201083 5 96 30151075 13 68 36314001 3 48 39079815 11 62

14151021 10 64 30151095 20 70 36314005 3 48 39079815 23 66
14151033 23 24 30151105 19 62 39019811 5 70 39079815 10 86
14151033 15 28 30151105 8 64 39019811 10 70 39079815 17 94
15161069 2 90 30151105 18 66 39021111 13 54 39079815 8 104
16151066 9 58 30151105 17 68 39024011 13 28 39080115 3 66
22150241 4 30 30151116 16 62 39024211 8 54 39080115 3 68
24121069 14 32 30151118 25 62 39024211 20 62 39080511 7 70
24121365 7 32 30151118 20 64 39024211 24 64 39080708 19 70
30101142 4 24 30171022 10 52 39029215 16 50 39080808 6 70
30101195 11 26 30181009 11 76 39032615 7 54 39081715 8 18
30141015 10 82 30181009 11 78 39042215 8 56 39084001 23 62
30141031 3A 82 30181025 4 76 39042215 23 74 39084001 18 64
30151005 22 66 30181025 4 78 39045411 11 50 39084914 17 40
30151005 21 68 30181026 3 76 39055302 10 50 39090012 24 62
30151011 15 62 30181026 3 78 39059417 12 8 39093915 13 50
30151011 19 66 30181029 20 78 39069415 18 70 39098308 6 84
30151011 19 68 30181060 14 98 39070815 21 70 39098717 3 14
30151032 3 62 30181061 15 98 39071411 2A 50 39099206 2 16
30151032 6 64 30191035 11 70 39072211 19A 66 39099311 5 30
30151033 4 62 30191036 13 70 39072211 19A 68 39099906 12 22
30151033 5A 64 30191038 3 70 39073212 19 64 39099906 24 24
30151035 17 62 30191048 24 74 39073817 6 30 39099906 4 38
30151035 23 64 30191048 16 100 39074701 9 22 39100006 2 10
30151038 13 62 30201064 17 100 39076101 2 82 39100006 6 20
30151038 13 64 30201069 20 54 39077504 9 62 39100006 11 22
30151038 21 66 30201069 20 98 39078111 6 62 39101321 25 64
30151038 20 68 30201104 11 100 39078408 12 52 39104119 3 24
30151041 21 62 31101173 3 12 39078912 8 50 39105411 7 84
30151042 20 62 31181099 18 76 39078912 17 70 39106204 9 32
30151042 24 64 31181099 18 78 39078912 13 76 39106504 2 26
30151069 18 62 31181102 20 76 39078912 13 78 39107404 12 72
30151069 9 64 31201001 5 98 39079415 6 66 39118101 14 76
30151069 17 66 31201028 2 98 39079415 9 68 39121111 4 44
30151069 16 68 31201081 5 22 39079708 3 56 39121111 17 98
30151075 14 66 35161060 18 94 39079708 8 70 39122515 7 96
111 112
39129804 3 104 39197015 17 54 39265912 14 52 36DK0020 2 78

39130911 10 54 39197015 8 92 39266921 13 8 36DK0037 27 74
39150711 15 54 39197015 9 94 39268320 16 8 36DS1401 1 84
39150711 18 54 39197215 21 98 39268620 13 66 36DS1502 22 64
39154011 16 70 39198104 20 14 39268620 12 68 36DS1801 13 72
39155304 11 28 39201719 6 6 39268720 16 66 36DU1007 3 30
39155304 16 98 39214124 24 94 39268720 15 68 36JE0003 6 8
39155604 7 44 39217924 3 82 39268820 1 62 36JZ0001 4 6
39155604 14 54 39219019 7 22 39268820 5 64 36JZ0003 7 12
39156121 6 88 39220011 12 28 39268820 7 64 36JZ0003 16 28
39167121 20 24 39222204 4 54 39270411 7 18 36JZ0004 5 6
39167304 11 8 39223801 20 94 39272204 6 36 36JZ0005 3 10
39167304 22 24 39224020 8 66 39272315 3 46 36JZ0008 6 40
39167404 3 42 39224020 6 68 39275404 4 36 36JZ0016 5 32
39167704 16 34 39229515 3 36 39275821 6A 82 36PF0001 1 4
39168904 2 100 39231204 5 46 39276501 10 98 36PF0002 5 10
39169801 9 54 39234911 2B 50 59040006 7 76 36PF0004 1 22
39171519 4 22 39236615 7 50 59040006 7 78 36PF0005 2 20
39174004 10 20 39240817 12 30 59040014 14 42 36PF0007 1 26
39175904 17 22 39242001 9 54 59040017 7 46 36PF0008 1 24
39176511 19 94 39242911 6 98 59040038 2 2 36PF0009 5 28
39177304 13 34 39243015 3 98 59040038 11 20 36PF0010 2 66
39177902 15 34 39244704 25 66 59040038 16 22 36PF0010 2 68
39178301 13 98 39247304 11 54 59040038 17 24 36PF0011 1 90
39178924 5 84 39248104 13 52 59040038 4 26 36PF0015 7 80
39181304 14 78 39248415 8 82 59110008 2B 12 36PF0016 7 80
39183911 8A 54 39249211 5 36 59120003 2A 12 36PF0017 7 80
39188020 15 8 39253921 8 4 59150003 7 62 36PF0018 8 80
39190204 12 18 39256220 2 22 59150003 1 64 36PF0019 8 80
39194204 15 100 39256611 28 66 59150003 1 64 36PF0020 8 80
39194304 11 42 39256711 4 66 59150014 1 12 36PF0021 4 32
39194304 12 54 39256711 4 68 59200036 3 20 36PF0022 12 32
39194304 25 74 39256711 26 68 59200036 3 22 36PF0023 19 32
39195604 8 98 39258204 7 92 59210023 18 22 36PF0024 13 32
39196404 14 20 39258204 8 94 59210024 17 14 36PF0025 1 36
39197015 6 46 39260011 4 28 36DK0020 2 76 52JA0027 9 20
113 114
52JA0029 12 20 DH101380 18 40 DJ151081 8 62 DP161170 8 52

52PF0219 5 50 DH101380 4 42 DJ151092 18 68 DP171006 6 50
CB101114 2 36 DH101387 4 8 DJ181042 21 76 DP211009 8 44
CB121042 8 32 DH101388 15 24 DJ181042 22 78 DS101117 8 30
CF111019 7 42 DH101388 7 26 DJ181043 23 76 DS101154 6 12
CL201023 9 92 DH101392 7 8 DJ181043 24 78 DS101215 8 24
CL201023 10 94 DH101509 10 18 DJ181085 24 76 DS101276 3 8
CL201042 7 86 DH101607 9 36 DJ181085 25 78 DS109905 14 8
CS101128 9 8 DH101648 14 28 DJ181087 2A 76 DS121126 7 34
DD101062 10 8 DH101781 2 40 DJ181087 2A 78 DS141009 1 82
DD101097 13 30 DH101784 6 22 DJ181115 4 48 DS141013 7 82
DD111011 9 42 DH121038 7 4 DJ191054 6 72 DS151003 1 58
DD111012 10 42 DH121038 14 34 DJ191081 6 72 DS151004 7 58
DD111018 7 42 DH121169 3 32 DJ191083 5 72 DS151005 8 58
DD111048 8 42 DH151029 15 70 DJ201051 3 94 DS151009 10 58
DD121181 19 24 DH151057 4 60 DJ221003 3 72 DS151010 11 58
DD151009 12 62 DH161066 6 56 DJ221004 4 72 DS151029 6 58
DD181176 12 98 DH161121 4 56 DK101386 4 8 DS151029 6 60
DD191142 15 72 DH161145 11 56 DK141028 6A 82 DS151034 4 58
DD191147 11 72 DH161146 10 56 DK141041 10 82 DS151053 3 58
DD201011 4 98 DH161194 5 52 DK151094 12 66 DS151053 3 60
DE181033 17 76 DH161283 3 90 DK151094 14 68 DS151056 3 64
DE181033 17 78 DH171019 29 66 DL181009 23 94 DS151060 5 62
DF161102 7 56 DH171019 27 68 DL181010 25 94 DS151060 4 64
DF161413 4 52 DH181014 5 48 DM201026 19 98 DS151067 15 66
DF161426 17 34 DH191037 8 86 DM201027 1 96 DS151068 9 66
DF191020 2 54 DJ141008 8 84 DM201028 2 96 DS151068 7 68
DF201138 1 98 DJ151033 11 66 DM201029 3 96 DS151073 10 66
DG101029 3 6 DJ151033 11 68 DM201030 4 96 DS151073 8 68
DG101339 11 18 DJ151035 5 66 DM221013 1 102 DS151074 7 66
DG101418 7 24 DJ151035 5 68 DP101165 4 10 DS151074 10 68
DG151022 12 58 DJ151036 14 50 DP121025 7 2 DS151076 20 66
DG161121 2 84 DJ151037 15 50 DP121025 8 34 DS151080 1 60
DG161124 9 56 DJ151041 8 62 DP161144 11 98 DS151087 12 64
DH101048 5 8 DJ151047 17 50 DP161145 9 98 DS151089 11 64
DH101380 8 20 DJ151053 1 68 DP161163 11 52 DS151091 14 64
115 116
DS151092 16 64 DS201021 7 94 JA351609 13 40 JA551002 4 14

DS151094 17 64 DS201022 18 100 JA351618 14 40 JA551004 7 14
DS151094 28 68 DS201025 9 100 JA351619 16 40 JA551008 15 14
DS151095 15 64 DS201082 6 100 JA351624 15 40 JA551009 16 14
DS161150 12 26 DU101213 19 14 JA351626 9 40 JA551406 3 28
DS181005 20 74 DU161102 3 84 JA351627 11 40 JA551414 6 28
DS181005 10 76 DU181021 1 72 JA401801 8 100 JA551415 8 28
DS181005 10 78 DU191003 17 72 JA511008 4 2 JA551419 7 28
DS181007 18 72 DU191009 8 72 JA511011 6 2 JA561002 3 16
DS181008 19 72 DU201016 6 96 JA511011 9 34 JA561207 4 18
DS181009 21 74 DU201029 3 92 JA511028 2 4 JA561208 5 18
DS181010 22 74 DU201029 4 94 JA511211 1 6 JA561209 6 18
DS181012 19 76 DX151022 27 66 JA511216 2 8 JA561211 12 18
DS181012 19 78 DX151022 25 68 JA521015 6 10 JA581005 3 34
DS181015 8 76 DX191009 5 72 JA521018 10 8 JA581006 4 34
DS181015 8 78 DZ191016 3 50 JA521019 11 8 JA581009 5 34
DS181016 9 76 FD101078 3 38 JA521019 22 24 JA581011 12 34
DS181016 9 78 FD211006 2 44 JA531012 8 12 JA581012 6 34
DS181018 2 48 FD211007 3 44 JA531015 9 12 JA581013 11 34
DS181020 12 76 GF201053 12 100 JA541005 8 22 JA581221 6 32
DS181020 12 78 JA113201 2 56 JA541005 9 26 JA581223 2 32
DS181022 2 72 JA113202 5 56 JA541010 5 20 JA581291 18 32
DS181070 26 78 JA113402 2 46 JA541011 4 20 JA581314 15 32
DS181072 27 78 JA113403 4 46 JA541012 13 20 JA581406 5 4
DS181084 6 76 JA121003 12 50 JA541016 2 38 JA621001 7 30
DS181084 6 78 JA131603 2 62 JA541028 13 42 JA621002 9 30
DS191018 14 72 JA131605 14 62 JA541034 10 22 JA621006 11 30
DS191033 26 74 JA131606 22 62 JA541205 3 26 JA621201 1 30
DS191035 4 70 JA131606 26 64 JA541211 11 24 JA621206 2 30
DS191038 26 74 JA131607 10 62 JA541212 16 24 JA621402 4 40
DS191052 7 72 JA231201 6 104 JA541216 14 24 JA621406 5 40
DS201019 4 92 JA231202 7 104 JA541221 8 26 JA621410 3 40
DS201019 5 94 JA351602 11 40 JA541225 12 24 JA621414 1 40
DS201020 5 92 JA351604 8 40 JA541233 10 26 JB113005 7 36
DS201020 6 94 JA351606 9 40 JA541236 9 24 JB122003 9 50
DS201021 6 92 JA351608 12 40 JA541237 10 24 JB122016 1 50
117 118
JB131017 1A 64 JN402000 12 42 JZ551004 18 14 PF121024 21 78

JB131018 2 64 JV161014 9 70 JZ551204 14 14 PF121025 12 94
JB131224 23 68 JV171001 4 84 JZ551205 13 14 PF121026 1 78
JB151012 15 94 JV181408 5 54 JZ561002 7 16 PF121028 22 76
JB151013 16 94 JV181410 6 54 JZ561401 9 18 PF121028 23 78
JB161002 12 70 JV191001 1 44 JZ581216 17 32 PF122005 3 50
JB181220 4 90 JV351204 5 42 JZ581220 16 32 Pf122023 18 50
JB181239 3 90 JV401602 1 100 JZ621000 10 30 PF122024 19 50
JB231206 4 104 JV401801 7 100 KADF0820 16 54 PF131001 2 58
JB401400 9 72 JV402204 13 100 KADF0822 2 52 PF131001 7 60
JB401409 10 72 JV402205 14 100 LAC00021 5 44 PF131002 2 60
JB531021 10 12 JV521003 8 8 LAD00011 10 40 PF131012 1 60
JB581001 10 34 JV541006 15 22 LBD00001 21 64 PF131208 26 66
JB581202 10 32 JV541007 2 2 LCA00001 3 68 PF131208 24 68
JB581204 11 32 JV541007 11 20 LDB00002 4 68 PF131210 5 58
JD511010 3 2 JV541007 16 22 LJA00004 14 22 PF131210 9 60
JD521002 1 10 JV541007 17 24 PF111000 1 48 PF131211 5 60
JD541000 19 22 JV541007 4 26 PF113000 1 52 PF131222 4 60
JD551400 2 28 JV541205 21 24 PF113001 3 52 PF131228 14 66
JD561004 6 16 JV541208 5 24 PF113002 6 52 PF131228 13 68
JD561011 4 16 JV541209 18 24 PF113003 7 52 PF131614 15 66
JE531001 5 12 JV541212 5 26 PF113008 1 104 PF161001 2 70
JE541008 14 30 JV541215 2 26 PF113009 2 104 PF161002 1 70
JE551401 6 24 JV541216 10 20 PF113023 15 52 PF161208 3 88
JG571024 13 22 JW122004 14 70 PF113024 16 52 PF161209 4 88
JK113008 9 52 JW131601 24 66 PF113202 1 56 PF161211 1 88
JK351600 10 100 JW181229 14 94 PF113402 1 46 PF161212 2 88
JK541212 13 24 JW181232 13 94 PF121012 1 76 PF161213 5 88
JK541213 6 26 JW561206 2 18 PF121015 25 76 PF161217 1 88
JK541214 2 24 JW561208 3 18 PF121016 26 76 PF171802 4 82
JK541214 13 26 JZ131803 22 68 PF121017 5 76 PF171803 9 82
JN131812 19 62 JZ401405 10 72 PF121017 5 78 PF181209 1 80
JN131812 8 64 JZ511004 1 8 PF121018 15 76 PF181209 22 94
JN131812 18 66 JZ511016 3 4 PF121018 15 78 PF181211 21 94
JN131812 17 68 JZ511021 1 2 PF121019 16 76 PF181404 1 54
JN141002 1 66 JZ511203 2 6 PF121019 16 78 PF181408 3 54
119 120
PF181410 19 54 PF541018 7 20 PF72013F 2 80

PF191000 1 44 PF551002 1 14 PF7201X3 2 80
PF231201 5 104 PF551003 8 14 PF73012D 5 80
PF231401 7 98 PF551200 6 14 PF73013E 5 80
PF231405 6 44 PF551201 5 14 PF73013F 5 80
PF232601 2A 72 PF551202 2 14 PF7301X3 5 80
PF232601 5 82 PF551203 10 14 PF73022D 4 80
PF351003 1 42 PF551204 11 14 PF73023E 4 80
PF351004 2 42 PF551205 12 14 PF73023F 4 80
PF351201 6 42 PF551206 9 14 PF7302X3 4 80
PF351600 7 40 PF551403 1 28 PF74012D 6 80
PF401000 1 92 PF551405 9 28 PF74013E 6 80
PF401000 1 94 PF551406 10 28 PF74013F 6 80
PF401004 4 96 PF561000 1 16 PF7401X3 6 80
PF401007 1 92 PF561002 5 16
PF401007 1 94 PF561200 1 18
PF401009 10 92 PF571000 1 38
PF401009 11 94 PF571001 5 38
PF401403 5 100 PF581002 2 34
PF401404 4 100 PF581003 1 34
PF401408 16 72 PF581019 11 34
PF401414 28 74 PF581200 1 32
PF401417 16 72 PF581401 4 4
PF402200 3 100 PF581402 6 4
PF402400 1 86 PF591017 1 36
PF402401 2 86 PF591043 10 36
PF402402 4 86 PF591045 8 36
PF402403 6 86 PF591059 1 36
PF402404 9 86 PF591065 1 36
PF402405 3 86 PF591079 1 36
PF402406 5 86 PF71012D 3 80
PF402600 6 82 PF71013E 3 80
PF501004 1 20 PF71013F 3 80
PF511021 8 2 PF7101X3 3 80
PF511027 5 2 PF72012D 2 80
PF531000 4 12 PF72013E 2 80
121 122
123 124

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All information contained in this manual is based on the latest

DOC. NO.: 71111461 REV. 00, MAR. 12

4. Abbreviations : The following abbreviations are used in this catalogue.

1 Cover Cylinder Head 2 27 Mudguard Front & Rear 54

No. Part No. Description Qty Remarks

6 JA 5110 11 Hose Breather 1

No. Part No. Description Qty Remarks

1 36 PF00 01 Kit Asly Cylinder Head 1 With studs &

No. Part No. Description Qty Remarks

1 JA 5112 11 Shaft Rocker Arm 2 48.2 mm

1 5 36 JZ00 04 Valve Repair Kit 1 Refer Page No. 105

6 39 2017 19 Seal Valve Stem 2

No. Part No. Description Qty Remarks

1 JZ 5110 04 Camshaft Complete 1

3 16 39 2683 20 Bearing Ball - Big 17 X 35 X 10 1

No. Part No. Description Qty Remarks

1 JD 5210 02 Gasket Cylinder Block 1

6 JA 5210 15 Damper Cylinder Block 3

No. Part No. Description Qty Remarks

1 59 1500 14 Flange Nut 2

No. Part No. Description Qty Remarks

1 PF 5510 02 Shaft Input Transmission (Drive) 1

1 6 PF 5512 00 Gear 2nd Drive 1

No. Part No. Description Qty Remarks

4 1 PF 5610 00 Drum Complete Gear Shift 1

2 6 JD 5610 04 Fork Gear Shift Output 1

7 JZ 5610 02 Fork Gear Shift Input 1

No. Part No. Description Qty Remarks

1 PF 5612 00 Lever Gear Shift Comp 1

6 JA 5612 09 Step Washer (Collar) 1

8 8 39 0817 15 Hex Nut / Flange - M6 1

No. Part No. Description Qty Remarks

1 PF 5010 04 Engine Assly SS BM-150 4 Speed 1 N.I.

6 39 1000 06 Dowel Pin 2

11 JV 5410 07 Flange Bolt 1 Crankcase Mounting

No. Part No. Description Qty Remarks

1 36 PF00 04 Kit Asly C’case Magneto Side BM-150 1 NRB + Bush

6 DH 1017 84 Gasket Neutral Switch (T.I.S) 1

11 11 39 1000 06 Pin Dowel 4

No. Part No. Description Qty Remarks

1 36 PF00 08 Kit Asly Cl Cover BM-150 1 Gauge +Circlip

No. Part No. Description Qty Remarks

9 6 JK 5412 13 Damper Cover Magneto 1

1 No. Part No. Description Qty Remarks

1 PF 5514 03 Clutch Assembly Complete 1

No. Part No. Description Qty Remarks

1 JA 6212 01 Lever Assly Kick 1

11 JA 6210 06 Washer Thrust (16.2 X 25 X 0.5) 1

No. Part No. Description Qty Remarks

2 1 PF 5812 00 Carburettor Assly 1

6 JA 5812 21 Needle Valve Assembly 1

16 JZ 5812 20 Hose Drain 1

No. Part No. Description Qty Remarks

1 PF 5810 03 Air Filter Assly 1

15 39 1779 02 Self Tapping Screw 2

No. Part No. Description Qty Remarks

1 36 PF00 25 Kit Silencer Without Shield 1

No. Part No. Description Qty Remarks