PARTS CATALOGUE

EURO_V
REV_1

CLASSIC LEGENDS
INDEX
INSTRUCTION
PAGE: A TO B

BLOCK INDEX
PAGE: C TO D : ENGINE GROUP
PAGE: E TO H : FRAME GROUP

ENGINE GROUP
PAGE: 01 TO 34

FRAME GROUP
PAGE: 35 TO 94

PART NUMBER INDEX

PAGE: -- TO --

SPARE PART CATALOGUE PART NO: XXXXXXXXXXXXX

INSTRUCTION FOR USE OF SPARE PARTS CATALOGUE How to use the Flat Rate Time (F.R.T.)
This parts catalogue is compiled of all service items of JAWA This F.R.T. (Flat Rate Time) is used to determine the standard labour
PERAK incorporates parts changes introduced upto Date............... time allowed for replacement of parts covered by the warranty during
the period of warranty is in effect. The F.R.T. for those parts, that are
How to order parts
not listed herein, should be determined from the operation closely
1. Always specify the part numbers when ordering a part.
related to the replacement of the part.
2. Always check the models, type, serial numbers, color, make
and the size as needed before placing the order of parts.
1.The F.R.T. is based on the following servicing conditions
3. Required quantity to be specified.
a) A liberal allowance is added to the net servicing time.
Revision in part numbers
b) Standard time specified are based on the conditions that the usgae
New parts are introduced when old parts are deleted & or when
of necessary servicing tools listed in the service manual & the work
when modification are incorporated in parts or part assembly.
performed by a technician with normal skill.
Such changes are notified by change of parts numbers.
c) Time required for inspection & operational test following the servicing
The information regarding change of part numbers is informed
is included in the F.R.T.
through parts news, which you are requested to note & update
into your "Parts Catalogue" & in your "Price List" also with
2. Methods of computing
effective date of introduction.
The job time are listed in tenth of hour to simplify complication
This updation into "Part Catalogue" & "Price List" will help you
Examples: 1) 0.3 = 18 minutes
in procurement / stocking / billing & in turn will give better service
2) 5.1 = 5 hour & 6 minutes
to the customer.
How to refer with the part information CONVERSION CHART
Reference with "Illustrated Index" HOUR MINUTES HOUR MINUTES
Reference with "Part Number Index", 0.1 6 0.6 36
0.2 12 0.7 42
0.3 18 0.8 48
0.4 24 0.9 54
0.5 30 1.0 60

PAGE : A
 3. Computing the F.R.T. (2) Adjustment
Following are the examples when several jobs are performed at No Service Item F.R.T.
the same time. Make the calculations in the following manner 1 CLUTCH - ADJUSTMENT
a) Jobs of non-duplicated nature. (INCLUDE CLUTCH LEVER ADJUSTMENT) 0.1
The F.R.T. for the job is obtained by totaling the F.R.T. for each part
2 HEADLIGHT - AIMING 0.1
replaced.
3 SPARK PLUG - ADJUSTMENT & CLEANING 0.6
Example: 1. Replacement of Clutch Housing Assembly
2. Magneto Rotor 4 DRIVE CHAIN - ADJUSTMENT 0.1
SERVICE ITEM F.R.T. 5 THROTTLE OPERATION - ADJUSTMENT 0.1
CLUTCH HOUSING ASSY 1 6 TAPPET - ADJUSTMENT 1.2
MAGNETO ROTOR 0.3 7 ENGINE OIL LEVEL 0.6
F.R.T. for the Job is 1 + 0.3 = 1.3 INSPECTION, DRAIN & TOP UP
b) Jobs of duplicated nature.
Take the F.R.T. for the last part to be replaced
Example: Replacement of Crankshaft Assy & Cylinder Block (3) Inspection & Measurement

SERVICE ITEM F.R.T. No Service Item F.R.T.

CRANKSHAFT ASSEMBLY 4.2 1 COMPRESSION PRESSURE - MEASUREMENT 0.6

2 IGNITION TIMING - INSPECTION 0.5
CYLINDER BLOCK 3.4
F.R.T. for the Job is = 4.2 (4) Other work
4. Operation Other than replacing parts No Service Item F.R.T.
(1) Removal and Installation 1 OIL STRAINER - CLEANING 0.6
2 CLEANER ELEMENT - CLEANING 0.3
No Service Item F.R.T.
1 3 FRONT BRAKE - AIR BLEEDING 0.3
ENGINE REMOVAL & INSTALLATION 2.5
2 CYLINDER HEAD ASSEMBLY 4 REAR BRAKE - AIR BLEEDING 0.3
3.0 5 RADIATOR COOLANT - CHANGE 0.5
(INCLUDE ENGINE REMOVAL & INSTALLATION)

3 THROTTLE BODY ASSEMBLY Method of calculating Labour Charges

REMOVAL & INSTALLATION 1.0
Labour charges rate: Rs 100/- per man hour
4 CRANKCASE SEPARATION Example: Tappet Adjustment F.R.T. is 1.2
(INCLUDE ENGINE REMOVAL & INSTALLATION) 4.0
Labour charges = F.R.T. x Labour Rate
5 RADIATOR ASSEMBLY 1.0 For all cities : 1.2 x 100 = Rs. 120/-
REMOVAL & INSTALLATION

PAGE : B
INDEX ENGINE GROUP - 01

CAMCHAIN AND TENSIONER & CYLINDER HEAD PAGE PAGE PAGE

CRANKCASE LH CRANKCASE RH
COVER 01-02 03-04 05-06
17 17

17

16
22 2 3
16 22
22
3
7
13
16 2
18
16
14 8 16
6
25 2
19 8 14 16
6 7 2
21 7 26 6
23 2
3
2
24 11 12 13
4
15
12
1 9 20
14
25
3
17
17
11 17

10 11 26 5 2
1 15 5 9
10 8 2
9 9

13 3 4
11
15
12
1 19

4
10
13
17
5 18

PAGE PAGE PAGE

CYLINDER HEAD EXPLOSION DRUM ASM & SHIFT SHAFT MECH CAMBINE MAGNETO ASSEMBLY
07-08 09-10 11-12
12 22

4 16
15 23

3
14 11
26 20 1
17
8 12
1
10 15
23
19 7
7
21 4 6
25
3 8 5
6
24 13
9
5 5
11 10

18 2 9
6
24 10
17 7
2
4
7 8
13
17 8
6
14
17
22 1 19

9 17 8
18
20
16 14
3
2

PAGE PAGE PAGE

STARTING SYSTEM & STARTER MOTOR VALVE TRAIN AND CAM SHAFT BALANCER SHAFT ASSEMBLY
13-14 15-18 19-20
5 1
3
10 12
9

3
5
2
10 5
13
12
4
4

4
8
11 11

7 9
4 2 1
8
7 4 5

8 4
9
14 10

6
3
2
15

7
6

PAGE : C
 INDEX ENGINE GROUP - 02
PAGE PAGE PAGE
TRANSMISSION SYSTEM R CRANKCASE COVER CRANKSHAFT AND PISTON
21-24 25-28 29-30
33

14
9
10 7 8
15

4 5 14
6 29 28
5 3
4 30 29 43
1 17 16
3
13 2
11 35
17 18
33 21 9
16 18
19 32 37
16
8 15 8
13 34 2
40
35 31

5 41
4
13 36 4 39
2
38
26
12
13 19 3
41
15
6 4
21 13 24

22 27
23 12 10 1
1 11
20 13
24 25
32 20 5
21 21 14
6
25 26 27 7 23
6
22
34 29 7
28 9

30 31 10 11
41

10 12

42

PAGE PAGE
MAGNETO COVER LH CLUTCH ASSEMBLY
31-32 33-34
21 17

6 22 9
3
4 9 8 16
4
24
7 15
5

23
11 4 10
1
15
10 24
4 22 2
23
11 13
22
5 12

3
5 14

22
2 11
7
19
8 17
18
6
1 22

20 13
18 12
14
18
16 17
17
17

PAGE : D
INDEX FRAME GROUP - 01
PAGE PAGE PAGE
EVAPORATIVE EMISSION SYSTEM 35-36 AIR FILTER ASSEMBLY 37-38 BRAKE SYSTEM - FRONT 39-40
29 27
3 10
2 5
4 6 1 24 19
9 5
8 2

1 4
4 1
23
3 3
7 19
1 4
5 3

1 7
25
2 10 2
8
7
4 26 8
5 9
1 19
6
14
6
27
19 18
26
15 22
22 17
28 9
24
13 10
18
1
11 21
12
16 21 25 19
14 13
18 12 16
11 18
10 15
23 17
16 11 17 20
20
18

PAGE PAGE FOOT REST ASSEMBLY/ REAR BRAKE PEDAL / PAGE

BRAKE SYSTEM - REAR ANTI-LOCK BRAKING SYSTEM (ABS)
41-42 43-44 GEAR SHIFT LEVER / LOCK SET 45-46

20
7 15
21

5 15
1
22 5

2
5
8 3
5
3

5
23 9
4 4
16
24 12
3
4 9

2 11 10
13 4
13
4 1 25 6 2 2
12
14 5 1
11 6 7 3
10
18
19 16 8
17
14
18 17 5 7
6

PAGE PAGE PAGE

FRONT WHEEL ASSEMBLY FUEL TANK ASSEMBLY FRONT MUDGUARD ASSEMBLY
47-48 49-50 51-52
1 12 10 9 6
2 3
22 10
11
10
18
13
17 11
16 10
3 7
23
18
15 4
7 8 14
6
13
4 12 5
1
2
15
8

1 4
3
5

14
15
6
9 24 3

16

17
25 16
10
1
12
12 18
21
13
13
7
2 19
5
20 4
16
3 20

PAGE : E
INDEX FRAME GROUP - 02
PAGE PAGE PAGE
RADIATOR 53-54 REAR FENDER ASSEMBLY 55-56 REAR WHEEL ASSEMBLY 57-58
24
4 10
1 29 17
21 16
22 18 15
29 1 5 30 18
26 15 4
4 3 13
19
14 12 17
4
20 29 9
23 27
18
7 11 30
4
6 12 11
27 19
2 18
28 2 3
29 25 4
26 17
15
9 4 7
18 6
28 4 9 10
2 17
8 8
5 10 5
3 4 11
29 4
12
7
11 1 19
13 5
16 14 8
13 16 20

4 3 24
14 21
6
25
14
26
7 22
15 24
28
23
27
5
8

PAGE PAGE PAGE

SEAT AND TAIL LAMP ASSEMBLY 59-60 SILENCER ASSEMBLY 61-62 STEERING 63-64
11
10
11 24 15
8 10
9
10
7 25
18 9
16
20 21
19
11 8
5
6
27 2
9 7
7 26
11 17 5 13
6
12
4 15 1
20 23
6 6 1 7
10
16 6
12 19
14 21 5
18
5
3 22 4
27 25
3

26 8
1 13 17
12
5
4 12

2 4 3 12
14 22
2

PAGE PAGE PAGE

FRONT FORK ASSEMBLY FRONT FORK MOUNTINGS FAIRING ASSEMBLY
65-66 67-68 69-70
9
23
16

5
15 7 6
5
18 6 4
7 8
21
20 8
22
PAGE : F
2

13
9 3 11
12
14
11 2
25 12
10 25 12
9

10
9
4
1 11 4
6 3
19 13 17
3 19
1 18
19
4
2 20
4
21 12 1 1
1
10

13 24 26 16
5
15 10
24 2
17
14 10 2
4
7 10
15 14 14
8

16

17
18
 INDEX FRAME GROUP - 03
SIDE PANEL LH & RH ASSY ECU & RELAY / PAGE PAGE PAGE
FRAME & FOOT REST ASSEMBLY ENGINE MOUNTING SYSTEM
FUSEBOX 71-72 73-74 75-76

17 5 11
10 12
2
19

22
4
1 18 22 3
20 16 23
3 11 2 6
9 6 21
4 5
4 12 7 7
7
2
8 7
4 6
20

1
19 2 7
2
5
11
15 1
24
13 6
10
ual
er’s Man
Own

16 17
12
8 13
23 9
6 25
15
11 21 7
26

24 8
8 2 10
18
11
14 12 14
5 9 9

PAGE SWING ARM ASSEMBLY / REAR SHOCK ABSORBER / PAGE HEADLAMP, TAIL LAMP, INDICATOR FRT & REAR, PAGE
HANDLE BAR ASSEMBLY 77-78 SIDE STAND ASSEMBLY 79-80 81-82
LICENSE PLATE LAMP & SPEEDOMETER ASSY
18
11 28
20
30 10
23 4 19 18
21 14
9 1 27
20 17 12
1
30 11
14 15 28 15 6
19 10
36
17 21
37
16 13
16 25
17
22 21 27
18 8
12 14 22
8
7 26
21 4 13
3 23 10
33 12 11
6
24 5
7
5 29 32 15 5 12 2
4 27 11
13 31 10
4 7
30 3 13
4 13 12
29 20
3
2
1 3
2

6 8
19
1 15

28 24 13
11
25 16 9
9 10
26
11
27 10 12 20

WIRING HARNESS & BATTERY STARTER RELAY PAGE PAGE PAGE

83-84 ELECTRONIC FUEL INJECTION (EFI) ASSEMBLY 85-86 DECALS 87-92
& RELAY CORDSET- SINGLE CHANNEL BSIV
18
15
1 2 3 4
16
8 17

20

22
19 5 6 7 8
6
18
5 16
24

1 21

23

17 2 9 10 11
14 15

8
9

3 10 5
9
6
11
4 13 4
14

1
7 12 13
12
11 12
13 3
4

10
2

PAGE : G
INDEX FRAME GROUP - 04
PAGE
ACCESSORIES
93-94
1

8
5

6
8 4

6
3

14

15

7
10
13
12

9 11

PAGE : H
 ILLUSTRATION
WITH PART NUMBERS
CAMCHAIN AND TENSIONER & CYLINDER HEAD COVER

17
17 17

16

16

7
16
8
14 6

15
1

11

10

13 4
11 3
9
12

13
5

PAGE: 01
CAMCHAIN AND TENSIONER & CYLINDER HEAD COVER
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0202CUF0340N GUIDE CHAIN SLACK SIDE 5.4 1

2 T0202AUF0450N GUIDE CHAIN TIGHT SIDE 5.4 1
3 T0202CUF0810N GUIDE CHAIN PIVOT BOLT 0.9 2
4 T0202CUF0360N GUIDE CHAIN WITH INSERT BOTTOM 1.6 1
5 SP0906029 BOLT, HEX FLANGE SH - M6X20 1.6 1
6 T0208AUF0640N GUIDE CHAIN (TOP) WITH INSERT 1.6 1
7 93500-04010-OH PAN HEAD SCREW (M4*10) 1.6 1
8 T0208BUF0390N TIMING CHAIN 1.9 1
9 T0208EVE0020N ASM TENSIONER AND MTG BOLTS KIT 0.8 1
10 T0208EUF0660N GASKET, TENSIONER 0.8 1
11 T18010UF0150N WASHER, STAR DRUM BOLT (Ø6.4*Ø15*1) 1.6 2
12 TSF0102282 BOLT, HEX FLANGE SH - M6X14 0.9 1
13 90001-M9Q-0000-IK SHF FLANGE BOLT 6*22 0.1 2
14 T0202DVG0160E COVER CYLINDER HEAD (BLACK COLOUR) 0.5 1
15 T0209AVE0010N GASKET/SEAL, COVER CYLINDER HEAD_5 LUGS 0.6 1
15.1 T0209AVG0010N GASKET/SEAL, COVER CYLINDER HEAD_7 LUGS 0.6 1
16 T18010UF0050N RUBBER WASHER 0.6 3
17 T02010VG0010N CYLINDER HEAD COVER SPECIAL BOLT 0.5 3

PAGE: 02
CRANKCASE LH

27

22 2
22
22
13
2
18
16
16

19 25 8
21 7 26 6
23
3 24

4
12
9 20
14
25
17
17
17

10 11 26 5
1 15

PAGE: 03
CRANKCASE LH
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0202CVG0100E CCLH WITH OIL PLUG & BREATHER PIPE 8.2 1

2 T0202CUF0760N STUD - M10 3.3 2
3 T18050UF0180N BEARING BALL CRANKSHAFT (DIA30*DIA72*19) 8.2 1
4 T18050UF0130N BEARING BALL INPUT (DIA15*DIA35*11) 8.2 1
5 T18050UF0140N BEARING BALL OUTPUT - ONE SIDE SEAL (DIA22*DIA50*14) 8.2 1
6 T18050UF0320N BEARING BALL BALANCER (6303.C3) (Ø17*Ø47*14) 8.2 1
7 T18020UF0080N OIL SEAL, OUTPUT SHAFT (DIA22*DIA34*7) FKM 0.6 1
8 TSF0602039 INTERNAL CIRCLIP (Ø35*1.75) 0.6 1
9 T18020UF0090N OIL SEAL, LEVER SHIFT SHAFT (DIA14*DIA28*7) FKM 0.6 1
10 T0202CUF2440N BOLT, DRAIN MAGNETIC - M12X1.5 0.2 1
11 MJ01700006100 WASHER -OIL DRAIN PLUG (DIA14.2*DIA20*2) (COMMON E01) 0.2 1
12 T0217AUF0030N SLIDING CONTACT NEUTRAL SWITCH 0.4 1
13 T18050UF0160N NEEDLE BRG STRATER INTERIM GEAR (DIA10*DIA14*10) 0.8 1
14 T18050UF0310N NEEDLE BRG (DIA14*DIA20*12) SHIFT SHAFT LH SIDE 8.2 1
15 T0202CUF0780N BOLT, SHIFTER STOPPER - M8X1.25 8.2 1
16 T18070UF0030N DOWEL PIN, HOLLOW DIA12*15 4.0 2
17 SP0906043 BOLT, HEX FLANGE SH - M6X60 0.1 3
18 TSF0102290 BOLT, HEX FLANGE SH - M6X35 0.1 1
19 T0217AUF0010N NEUTRAL SWITCH WITH O RING 0.4 1
20 T18020UF0100N OIL SEAL, NEUTRAL SWITCH 0.6 1
21 SP0906029 BPLT, HEX FLANGE SH-M6X20 0.2 1
22 TSF0102291 BOLT, HEX FLANGE SH - M6X75 0.1 3
23 SP0906033 BOLT, HEX FLANGE SH - M6X65 0.1 1
24 T02090VE0020N GASKET, CRANKCASE 8.2 1
25 SP0906034 BOLT, HEX FLANGE SH - M6X85 0.1 2
26 T0202DVG0200E GUAGE INSPECTION COVER 0.1 1
27 T0202CVG0110E CCLH KIT 8.2 1

PAGE: 04
CRANKCASE RH

1A

3
3

2
6 7 2 14 16

2
11 12 13

5 2
9
8 2
9

15
1 19
4
10
17
18

PAGE: 05
CRANKCASE RH
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0202CVG0010E CRANKCASE RH (BLACK COLOUR) 8.2 1

1A T0202CVG0030E ASM CRANKCASE RH (BLACK COLOUR) 8.2 1
2 MJ01760000600 DOWEL PIN, HOLLOW DIA10*14 (COMMON WITH E01) 8.2 5
3 T0202CUF0760N STUD - M10 3.3 2
4 T18050UF0280N BEARING INPUT SHAFT (DIA20*DIA47*14) 8.2 1
5 T18050UF0170N BEARING OUTPUT SHAFT (DIA17*DIA40*12) 8.2 1
6 T18050UF0180N BEARING BALL CRANKSHAFT (DIA30*DIA72*19) 8.2 1
7 T18050UF0320N BEARING BALL BALANCER (6303.C3) (Ø17*Ø47*14) 8.2 1
8 T18050UF0190N BEARING NEEDLE SKF HK2012 (DIA20*DIA26*12) 8.2 1
9 MJ01760000500 DOWEL PIN, HOLLOW (Ø8*12) 1.4 2
10 T0203BUF0150N OIL STRAINER 0.6 1
11 T0202CUF2430N BREATHER HOLE COVER PLATE 1.4 1
12 T0202CUF0510N LOCK PLATE INPUT BEARING 1.4 1
13 96001-06010-00-IK BOLT, HEX FLANGE SH - M6X10 (LOCK PLATE) 1.4 2
14 T0209DUF0210N GASKET, COVER RH 0.7 1
15 T0203AUF0160N OIL PUMP COMPLETE - ADVIK 0.7 1
16 SP0906034 BOLT, HEX FLANGE SH - M6X85 0.7 1
17 T0202CUF0480N DRUMLOCK SPRING 0.8 1
18 T18010UF0150N WASHER, STAR DRUM BOLT(Ø6.4*Ø15*1) 0.7 1
19 T0215CUF0650N ASSEMBLY STOPPER COMP GEAR SHIFT DRUM 0.7 1

PAGE: 06
CYLINDER HEAD EXPLOSION

4
15
3
14
26 20
17
8 12
1

23 10
19
7
25
6
24 13
5
11
21
18

7
17
6

22
9
27
16

PAGE: 07
CYLINDER HEAD EXPLOSION
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0202BVG0020N SUB ASM CYLINDER HEAD & CAM SHAFT HOLDER C334 5.2 1
2 T1502HUF0060N WATER SENSOR 0.3 1
3 T1502DUF0070N SPARK PLUG 0.5 1
4 T02010UF0020N GROMATE, SPARK PLUG 0.5 1
5 T0202BVG0040N STUD MUFFLER (M8X48) 2.4 4
6 MJ01760000500 DOWEL PIN, HOLLOW (Ø8*12) 0.6 2
7 T18040UF0090N O-RING, CAMSHAFT HOLDER 0.5 2
8 TSF0102290 BOLT, HEX FLANGE SH - M6X35 0.6 7
9 T0202AUF0820N DOWEL PIN, SOLID (Ø6X14) 4.2 2
10 T0202BUF0420N UPPER VALVE SPRING RETAINER 4.6 4
11 T0202BUF0410N LOWER VALVE SPRING RETAINER 4.6 4
12 T0202BUF1660N HEAD NUT WASHER CYLINDER HEAD (Ø10.2*Ø18*2) 1.1 4
13 T0208BUF0510N VALVE STEM SEAL 4.6 4
14 T0202BUF0580N VALVE SPRING INNER 4.6 4
15 T0202BUF0430N VALVE SPRING OUTER 4.6 4
16 T02090VG0010N GASKET CYLINDER HEAD 334 4.2 1
17 TSF0102293 BOLT, HEX FLANGE SH - M6X130 (HEAD MOUNT) 3.2 2
18 93500-04010-OH PAN HEAD SCREW (M4*10) 0.5 1
19 T0208AUF0640N GUIDE CHAIN (TOP) WITH INSERT 0.5 1
20 T0202BUF2140N HEAD NUT CAP TYPE 1.1 4
21 T0202BVG0010N ASM CYLINDER HEAD C334 1 1
22 T0209AVE0020N RUBBER GROMMET CYLINDER HEAD 0.6 1
23 T04000VE0010N COVER THERMOSTAT 0.4 1
24 T0401EVE0030N THERMOSTAT VALVE TWO WAY 0.4 1
25 T0209BVE0020N O RING THEMOSTAT 1.78X33.05 0.4 1
26 SP0906041 BOLT, HEX FLANGE SH-M6X12 0.2 2
27 SF0601062 WASHER 0.3 1

PAGE: 08
DRUM ASM & SHIFT SHAFT MECH CAMBINE

12 22
16
23

11

15
7
21 4 6
3 8
9
5

24 10
17

13
8
14
17
1 19
17
18
20
14

PAGE: 09
DRUM ASM & SHIFT SHAFT MECH CAMBINE
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0215CUF0580N LEVER COMPLETE GEAR SHIFT WITH TORSION SPRING 8.2 1

2 T0215CUF0430N SHAFT, FORK GEAR SHIFT 8.2 1
3 T0215CUF0440N FORK, GEAR SHIFT 3RD,4TH - INPUT / MIDDLE 8.2 1
4 T0215CUF0450N FORK, GEAR SHIFT 2ND,6TH - OUTPUT / BOTTOM 8.2 1
5 T0215CUF0460N FORK, GEAR SHIFT 1ST,5TH - OUTPUT / TOP 8.2 1
6 T0215CUF0400N PIN STAR DRUM 0.7 1
7 T0215CUF0410N STAR DRUM 0.8 1
8 T18010UF0150N WASHER, STAR DRUM BOLT(Ø6.4*Ø15*1) 0.7 1
9 SP0906029 BOLT,HEX FLANGE SH - M6X20 0.7 1
10 T0215CUF0650N ASSEMBLY STOPPER COMP GEAR SHIFT DRUM 0.7 1
11 T0215CUF0490N ASSEMBLY, SHIFT DRUM 8.2 1
12 SP0906029 BOLT, HEX FLANGE SH - M6X20 8.2 1
13 T0202CUF0480N DRUMLOCK SPRING 0.7 1
14 T0215CUF0350N CIRCLIP, Ø12*Ø20*0.5 8.2 2
15 T18050UF0190N BEARING NEEDLE SKF 8.2 1
16 T0217AUF0030N SLIDING CONTACT NEUTRAL SWITCH 8.2 1
17 T18010UF0120N WASHER, SHIFT SHAFT (Ø14*Ø20*0.5) 8.2 3
18 T0215CUF0340N SLECTOR TORSION SPRING 8.2 1
19 T0215CUF0570N TORSION SPRING 8.2 1
20 T18010UF1000N WASHER, SHIFT SHAFT (Ø14*Ø20*1) 8.2 1
21 T0202CUF0780N BOLT, SHIFTER STOPPER - M8X1.25 4 1
22 T0217AUF0010N NEUTRAL SWITCH WITH O RING 0.2 1
23 T18020UF0100N OIL SEAL, NEUTRAL SWITCH 8.2 1
24 T02200KE0010N CHAIN SLIDER BUSH 0.3 1

PAGE: 10
MAGNETO ASSEMBLY

11
5

10
6
7
2
4
8

PAGE: 11
MAGNETO ASSEMBLY
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T1502AVE0030N ROTOR ASSEMBLY 0.5 1

2 T1502AVE0020N STATOR ASSEMBLY 0.7 1
3 T1502AVE0010N MAGNETO ASSEMBLY 0.6 1
4 TSF0224076 BOLT, SOCKET HEAD_M6X1X20 0.6 8
5 T1502AUF0120N ONE WAY CLUTCH COMPONENT 0.6 1
6 TSF0224075 BOLT, HEX SOCKET HEAD - M5X30 (STATOR MOUNT) 0.5 3
7 SP0805020 PAN HEAD SCREW - M5X12 0.5 1
8 TSF0224077 BOLT, HEX SOCKET HEAD - M5*10 0.7 2
9 T18010UF0950N WASHER PLAIN (Ø10.1*Ø30*3.1) 0.5 1
10 T1502AUF0180N BOLT, MAGNETO (M10X1.25) 0.5 1
11 T1502AUF0190N FLANGE ONE WAY CLUTCH 0.6 1

PAGE: 12
STARTING SYSTEM & STARTER MOTOR

1
3
10

13 12 5 10
2
16 4
4

11

4
8
7
4

14

15

PAGE: 13
STARTING SYSTEM & STARTER MOTOR
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0205BUF0530N ASSEMBLY, SLIPPER CLUTCH 0.1 1

2 T0205BUF0350N SHAFT, STARTER COUNTER 0.1 1
3 T1503BUF0060N ASSEMBLY, STARTER MOTOR 0.2 1
4 T18010UF0920N WASHER_10.3*20*0.8 (STRATER INTRM GEAR) 0.1 4
5 TSF0102296 BOLT, HEX FLANGE SH - M6X30 (STARTER MOTOR COUNT) 0.1 2
6 T18010UF0940N WASHER ONE WAY CLUTCH 0.3 1
7 T0205BUF0310N GEAR, STARTER OWC 0.3 1
8 T0205BUF0320N GEAR, INTERIM STARTER COUNTER 0.2 1
9 T18050UF0260N NEEDLE ROLLER BEARING (Ø26XØ31X24) - SINGLE ROW 0.5 1
10 T18050UF0160N NEEDLE BRG STARTER INTERIM GEAR (DIA10*DIA14*10) 0.6 2
11 T1501BKE0010E BRUSH HOLDER SET 0.5 1
12 T1501BKE0020E SQUARE RING 0.4 2
13 T1503BKE0030E O RING 0.4 1
14 T0202DVG0150E COVER STARTER MOTOR (BLACK COLOUR) 0.4 1
15 T0209CVE0010N RUBBER GROMMET STARTER MOTOR COVER 0.4 1
16 TSF0318007 M6 NYLOC NUT (BLACK) 0.1 1

PAGE: 14
VALVE TRAIN AND CAM SHAFT

12

5
4

10
11 5

7 9

3
4

8
10
6

3 2
8

PAGE: 15
VALVE TRAIN AND CAM SHAFT
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0208DUF0430N VALVE, INTAKE 4.6 2

2 T0208DVG0010N VALVE, EXHAUST C334 4.6 2
3 T0208BUF0490N COTTER 4.6 8
4 T0202BUF0420N UPPER VALVE SPRING RETAINER 4.6 4
5 T0208BUF0480N SHIM KIT 1.5 1
5 T0208EUF0670N SHIM 2.000-2.020 1.5 4
5 T0201AUF0340N SHIM 2.021-2.040 1.5 4
5 T0208EUF0680N SHIM 2.041-2.060 1.5 4
5 T0201AUF0350N SHIM 2.061-2.080 1.5 4
5 T0208EUF0690N SHIM 2.081-2.100 1.5 4
5 T0201AUF0360N SHIM 2.101-2.120 1.5 4
5 T0208EUF0700N SHIM 2.121-2.140 1.5 4
5 T0201AUF0370N SHIM 2.141-2.160 1.5 4
5 T0208EUF0710N SHIM 2.161-2.180 1.5 4
5 T0201AUF0380N SHIM 2.181-2.200 1.5 4
5 T0208EUF0720N SHIM 2.201-2.220 1.5 4
5 T0201AUF0390N SHIM 2.221-2.240 1.5 4
5 T0208EUF0730N SHIM 2.241-2.260 1.5 4
5 T0201AUF0400N SHIM 2.261-2.280 1.5 4
5 T0208EUF0740N SHIM 2.281-2.300 1.5 4
5 T0201AUF0410N SHIM 2.301-2.320 1.5 4
5 T0208EUF0750N SHIM 2.321-2.340 1.5 4
5 T0201AUF0420N SHIM 2.341-2.360 1.5 4
5 T0208EUF0760N SHIM 2.361-2.380 1.5 4
5 T0201AUF0430N SHIM 2.381-2.400 1.5 4
5 T0208EUF0770N SHIM 2.401-2.420 1.5 4
5 T0201AUF0440N SHIM 2.421-2.440 1.5 4
5 T0208EUF0780N SHIM 2.441-2.460 1.5 4
5 T0201AUF0450N SHIM 2.461-2.480 1.5 4
5 T0208EUF0790N SHIM 2.481-2.500 1.5 4
5 T0201AUF0460N SHIM 2.501-2.520 1.5 4
5 T0208EUF0800N SHIM 2.521-2.540 1.5 4
5 T0201AUF0470N SHIM 2.541-2.560 1.5 4
5 T0208EUF0810N SHIM 2.561-2.580 1.5 4

PAGE: 16
VALVE TRAIN AND CAM SHAFT

12

5
4

10
11 5

7 9

3
4

8
10
6

3 2
8

PAGE: 17
VALVE TRAIN AND CAM SHAFT
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

5 T0201AUF0480N SHIM 2.581-2.600 1.5 4

5 T0208EUF0820N SHIM 2.601-2.620 1.5 4
5 T0201AUF0490N SHIM 2.621-2.640 1.5 4
5 T0208EUF0830N SHIM 2.641-2.660 1.5 4
5 T0201AUF0500N SHIM 2.661-2.680 1.5 4
5 T0208EUF0840N SHIM 2.681-2.700 1.5 4
5 T0201AUF0510N SHIM 2.701-2.720 1.5 4
5 T0201AUF0520N SHIM 2.721-2.740 1.5 4
5 T0201AUF0530N SHIM 2.741-2.760 1.5 4
5 T0201AUF0640N SHIM 2.761-2.780 1.5 4
5 T0201AUF0540N SHIM 2.781-2.800 1.5 4
5 T0201AUF0550N SHIM 2.801-2.820 1.5 4
5 T0201AUF0560N SHIM 2.821-2.840 1.5 4
5 T0201AUF0570N SHIM 2.841-2.860 1.5 4
5 T0201AUF0580N SHIM 2.861-2.880 1.5 4
5 T0201AUF0590N SHIM 2.881-2.900 1.5 4
5 T0201AUF0600N SHIM 2.901-2.920 1.5 4
5 T0202AUF2110N SHIM 2.921-2.940 1.5 4
5 T0201AUF0610N SHIM 2.941-2.960 1.5 4
5 T0201AUF0620N SHIM 2.961-2.980 1.5 4
5 T0201AUF0630N SHIM 2.981-3.000 1.5 4
6 T0202BUF0410N LOWER VALVE SPRING RETAINER 4.6 4
7 T0208BUF0500N TAPPET 1.2 4
8 T0208BUF0510N VALVE STEM SEAL 4.6 4
9 T0202BUF0580N VALVE SPRING INNER 4.6 4
10 T0202BUF0430N VALVE SPRING OUTER 4.6 4
11 T0208AVG0010N ASSEMBLY, CAMSHAFT INTAKE C334 1.1 1
12 T0208AVG0030N ASSEMBLY, CAMSHAFT EXHAUST C334 1.1 1

PAGE: 18
BALANCER SHAFT ASSEMBLY

5
9

8
4

PAGE: 19
BALANCER SHAFT ASSEMBLY
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0204EUF0070N BALANCER SHAFT FIXED GEAR 8.2 1

2 T0204EUF0100N PLATE SPRING 8.2 1
3 T0204EUF0110N CIRCLIP (F30) 8.2 1
4 T0204EUF0090N CYLINDER SPRING 8.2 2
5 T0204EUF0080N BALANCER GEAR, DAMPING 8.2 1
6 T0204EUF0120N CIRCLIP A17X1 8.2 1
7 T0204EUF0060N BODY BALANCER 8.2 1
8 T18080UF0030N KEY LOCK 8.2 1
9 T0204EUF0050N ASSEMBLY BALANCER SHAFT COMPLETE 8.2 1

PAGE: 20
TRANSMISSION SYSTEM

33
14
10 9
7 8

4 5 6
5 3
4
1
13 2
11 17
16 19 18
13
35

13

12
13
15
21
22
23
20
24 32
21

25 26 27
34 29
28

30 31

PAGE: 21
TRANSMISSION SYSTEM
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T18010UF0140N WASHER_20.2*30*0.5 8.2 1

2 T0215DUF0110N SHAFT, INPUT T/M 8.2 1
3 T0215DUF0120N GEAR, 5TH DRIVE 8.2 1
4 T18010UF0060N SPLINE WASHER_20.3X26X1.6 8.2 2
5 T0215AUF0130N CIRCLIP 8.2 2
6 T0215DUF0170N GEAR, 3RD & 4TH DRIVE (INTEGRAL) 8.2 1
7 T0215AUF0140N SPLINE BUSH - 6TH DRIVE 8.2 1
8 T0215DUF0150N GEAR, 6TH DRIVE 8.2 1
9 T0215DUF0160N GEAR, 2ND DRIVE 8.2 1
10 T18010UF0070N WASHER_15.2X25X1 8.2 1
11 T0215DUF0080N SPROCKET, DRIVE 0.3 1
12 T0215DUF0090N LOCK PLATE DRIVE SPROCKET 0.3 1
13 96001-06010-00 BOLT, HEX FLANGE SH - M6X10 0.3 4
14 T18050UF0130N BEARING BALL INPUT 8.2 1
15 T18020UF0080N OIL SEAL, OUTPUT SHAFT 8.2 1
16 TSF0602039 INTERNAL CIRCLIP (Ø35*1.75) 0.2 1
17 T18050UF0280N BEARING INPUT SHAFT 8.2 1
18 T0202CUF0510N LOCK PLATE INPUT BEARING 0.8 1
19 T0202CUF2430N BREATHER HOLE COVER PLATE 0.8 1
20 T0215DUF0190N SHAFT, OUTPUT T/M 8.2 1
21 T0215AUF0200N BUSH, 2ND GEAR 8.2 3
22 T0215DUF0210N GEAR, 2ND DRIVEN 8.2 1
23 T0215DUF0220N GEAR, 6TH DRIVEN 8.2 1
24 T0215DUF0230N GEAR, 4TH DRIVEN 8.2 1
25 T0215DUF0240N GEAR 3RD, DRIVEN 8.2 1
26 T18010UF0090N WASHER_22.2*28*0.5 8.2 1
27 T0215AUF0150N CIRCLIP 8.2 1
28 T0215DUF0250N GEAR, 5TH DRIVEN 8.2 1
29 T0215AUF0260N BUSH, 1ST GEAR 8.2 1
30 T0215DUF0270N GEAR, 1ST DRIVEN 8.2 1
31 T18010UF0100N *WASHER_Ø17.2*Ø26*1 8.2 1
31 T0215AUF0990N WASHER 17.2 X 26 X THK. (1.000 TO 1.050) 8.2 1
31 T0215AUF1000N WASHER 17.2 X 26 X THK. (1.051 TO 1.100) 8.2 1
31 T0215AUF1010N WASHER 17.2 X 26 X THK. (1.101 TO 1.150) 8.2 1

PAGE: 22
TRANSMISSION SYSTEM

33
14
10 9
7 8

4 5 6
5 3
4
1
13 2
11 17
16 19 18
13
35

13

12
13
15
21
22
23
20
24 32
21

25 26 27
34 29
28

30 31

PAGE: 23
TRANSMISSION SYSTEM
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

31 T0215AUF1020N WASHER 17.2 X 26 X THK. (1.151 TO 1.200) 8.2 1

31 T0215AUF1030N WASHER 17.2 X 26 X THK. (1.201 TO 1.250) 8.2 1
31 T0215AUF1040N WASHER 17.2 X 26 X THK. (1.251 TO 1.300) 8.2 1
32 T18050UF0170N BEARING OUTPUT SHAFT 8.2 1
33 T0215AUF0100N ASSEMBLY, INPUT SHAFT 8.2 1
34 T0215AUF0180N ASSEMBLY, OUTPUT SHAFT 8.2 1
35 T18050UF0140N BEARING OUTPUT SHAFT 8.2 1

PAGE: 24
R CRANKCASE COVER

15

29 28 44

30 29 43
17
3
35
21 18 9
33
32 37 16
8
34 40
31

5 41
4
36 4 39
38
26

41 19
2
13 24 20
27
12 10
1 11
25
14
6
7 23
22

42

PAGE: 25
R CRANKCASE COVER
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0202DVG0210E COVER RH C334 WITH OIL PLUG 0.6 1

2 SF0102034 FLANGE HEAD BOLT SH M6X28 0.2 3
3 T0401EUF0140N PIPE, COVER RH 0.4 1
4 T18020UF0110N OIL SEAL CRANKSHAFT 0.8 2
5 T0202DUF0750N CIRCLIP - OIL SEAL CRANKSHAFT 0.8 1
6 T02090UH0010N LENS, OIL LEVEL CHECK 0.4 1
7 T0202CUF2410N WIRE CLIP GLASS WINDOW 0.1 1
8 T0203BUF0250N CAP OIL FILLER 0.2 1
9 T0209AVN0300N O RING CAP OIL FILLER 0.2 1
10 SP0206021 BOLT, HEX FLANGE SH - M6X25 0.2 3
11 T0202DVE0080N COVER OIL FILTER C300 0.2 1
12 T02090VE0030N GASKET COVER OIL FILTER 0.2 1
13 0302AB0560N PLUG M8X1.25 0.2 1
14 SP0906029 BOLT, FLANGE HEX HEAD SH M6X20 0.2 4
15 T0219AUF0010N ASSEMBLY CLUTCH LIFTER 0.6 1
16 T0219AUF0060N CLUTCH LIFTER SPRING 0.6 1
17 T18020UF0130N SELECTOR SEAL 0.6 1
18 T18050UF0220N NEEDLE ROLLER BEARING (12*16*10) 0.8 2
19 T0202DVE0130N ASM COVER COOLANT PUMP 0.2 1
20 T0202DVG0180E SERVICE COVER RH (BLACK COLOUR) 0.1 1
21 SF0602068 CIRCLIP INT - LUG 25X1.2 0.7 1
22 SP0906033 BOLT, HEX FLANGE SH - M6X65 0.3 2
23 SP0906035 BOLT, HEX FLANGE SH - M6X50 0.3 5
24 TSF0102281 FLANGE BOLT M6*10 0.2 1
25 MJ01700005400 SEALING WASHER (6.2 X 12 X 2) 0.2 1
26 T0209BVE0010N O-RING, COVER COOLANT PUMP 0.2 1
27 T0203BUF0260N OIL FILTER ASSEMBLY 0.3 1
28 T04000KW0050N HOSE PIPE TO CYLINDER BLOCK 0.3 1
29 T0401DKE0290N SPRING BAND CLAMP DIA 24 0.3 2
30 T0204AVE0070N ASM COOLANT PUMP SHAFT 0.4 1
31 T0401EVE0010N SHAFT COOLANT PUMP C300 0.6 1
32 MF01850000300 DG BALL BRG 12X28X8 6001 0.6 1
33 T0401EUF0090N COOLANT PUMP GEAR 0.5 1
34 SF0601216 CIRCLIP EXT - LUG 12X1.5 0.6 1
35 T0202DUF0850N PIN WATER PUMP GEAR 0.6 1
36 SF0211009 SCREW FTCS CR SL M6X1X18X8.8 0.3 1
PAGE: 26
R CRANKCASE COVER

15

29 28 44

30 29 43
17
3
35
21 18 9
33
32 37 16
8
34 40
31

5 41
4
36 4 39
38
26

41 19
2
13 24 20
27
12 10
1 11
25
14
6
7 23
22

42

PAGE: 27
R CRANKCASE COVER
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

37 SP010102309 BEARING DG BALL SR 12X24X6 0.3 1

38 T0401EUF0030N IMPELLER 0.6 1
39 T0401EUF0040N WATER SEAL 0.6 1
40 T0401BVE0010N PLATE RETAINER 0.3 1
41 MJ01760000500 DOWEL PIN, HOLLOW (Ø8*12) 0.3 4
42 SP0906032 FLANGE BOLT SH - M6 X 40 0.3 4
43 T0202DVG0220E CLUTCH COVER WITH CLUTCH LIFTER'S BOTH NRB 0.3 1
44 T0202DVG0120E ASM COVER RH (BLACK COLOUR) 0.6 1

PAGE: 28
CRANKSHAFT AND PISTON

14

16

15
2

6 4
8
1
13
5

6
7 9

11

10 12

PAGE: 29
CRANKSHAFT AND PISTON
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0210BVG0020N PISTON 4.0 1

2 T0210BVG0030N RING PISTON TOP 4.0 1
3 T0210BVG0040N RING PISTON SECOND 4.0 1
4 T0210BVG0050N RING PISTON OIL 4.0 1
5 T0210BVG0080N PIN PISTON 4.0 1
6 T0210BVG0070N RING SNAP 4.0 2
7 T0210AUF0230N ASSEMBLY, CRANKSHAFT 8.2 1
8 T0202AVG0110E BLOCK PISTON KIT SPD C334 3.6 1
9 T18080UF0020N KEY PRIMARY DRIVE (5*5*12) 1.5 1
10 T0215EUF0060N GEAR, PRIMARY DRIVE (26T) (GPD) 1.5 1
11 T18010UF0020N WASHER, GEAR PRIMARY DRIVE (<O>18.2*<O>29*3) 1.5 1
12 T0210AUF0320N LOCK NUT, GEAR PRIMARY DRIVE (M18*1.25) 1.5 1
13 T1502AUF0170N KEY WOODRUFF (4*13) 0.7 1
14 T0202AVG0040E CYLINDER BLOCK C334 (BLACK COLOUR) 3.4 1
15 T0209DUF0180N GASKET, CYLINDER BLOCK 3.4 1
16 T0210BVG0010N ASSEMBLY, PISTON 3.4 1

PAGE: 30
MAGNETO COVER LH

21

6 22
3
4 9
4
24

23
11
15
10 24
4 22 2
23
11 13
22
5 12

5 14

22
7
19
8 17
18
1 22

20
18

18
16 17
17
17

PAGE: 31
MAGNETO COVER LH
SR.
PART NO. PART DESCRIPTION FRT QTY
NO.

1 T0202DVG0130E COVER LH FRONT (BLACK COLOUR) 0.3 1

2 T18050UF0160N NEEDLE BRG STARTER INTERIM 0.5 1
3 T1502AUF0140N STATOR ASSEMBLY 0.3 1
4 TSF0224075 BOLT, HEX SOCKET HEAD - M5X30 0.7 3
5 TSF0224077 BOLT, HEX SOCKET HEAD - M5X10 0.5 2
6 SP0805020 PAN HEAD SCREW - M5X12 0.7 1
7 T0202DVG0200E GAUGE INSPECTION COVER (BLACK COLOUR) 0.1 1
8 MJ01660001800 O-RING, GAUGE INSPECTION COVER 0.1 1
9 T0209DVE0010N RUBBER GROMMET MAGNETO COVER WIRE ROUTING 0.3 1
10 T0205BUF0350N SHAFT, STARTER COUNTER 0.1 1
11 T18010UF0920N WASHER_10.3*20*0.8 (STARTER INTRM GEAR) 0.1 2
12 T0202DVG0190E COVER STARTER COUNTER (BLACK COLOUR) 0.1 1
13 SP040111500 O-RING, COVER GEAR STARTER COUNTER 0.1 1
14 SP0906041 BOLT, HEX FLANGE SH-M6X12 0.1 1
15 T0205BUF0610N ASSEMBLY, SLIPPER CLUTCH WITH NRB 0.1 1
16 T0209DUF0220N GASKET- MAGNETO COVER 0.4 1
17 SP0906038 BOLT, HEX FLANGE SH - M6X70 0.1 4
18 SP0906043 BOLT, HEX FLANGE SH - M6X60 0.1 3
19 TSF0102290 BOLT, HEX FLANGE SH - M6X35 0.1 1
20 SF0102034 FLANGE HEAD BOLT SH M6X28 0.1 1
21 T0202DVG0170E COVER LH REAR HALF (BLACK COLOUR) 0.3 1
22 MJ01760000500 DOWEL PIN, HOLLOW (Ø8*12) 0.1 6
23 SP0906035 BOLT, HEX FLANGE SH - M6X50 0.1 2
24 SF0102034 FLANGE HEAD BOLT SH M6X28 0.3 2

PAGE: 32
CLUTCH ASSEMBLY

17

8 16

7 15
5

1 4 10

2 11

13 12

14

PAGE: 33