Professional Documents
Culture Documents
2. How to Order Spare Parts : The part number and the description of the
In a continual effort to improve Performance and Efficiency of the vehicles,
part required should be invariably mentioned in the order as per the
Specifications, Diagrams, Illustrations and Part Numbers can change without catalogue text.
notice. Consequently, the description in this Spare Parts Catalogue cannot
The latest part number as conveyed through our service circulars should
therefore be final and binding on us. only appear on the order. In case of ordering painted components,
colour shade of the components should be mentioned.
The modifications / alterations which are carried out after the issue of this The quantity shown against the part number is the quantity per vehicle
catalogue, will be conveyed to you through our Service Circulars. You are for that group so that particular quantity should be multiplied by the
requested to make necessary corrections in the Parts Catalogue as per the number of sets required.
circulars so as to keep your catalogue up-to-date. This will ensure the
3. Part Number System : We have used 8 digit system for part numbers.
appropriate and speedy delivery of the Spare Parts as the order placed will The model or hardware item is indicated by first two digits or
bear the latest part numbers. alphanumeric, the next two or four digits indicate main group and the last
four or two digits indicate serial number in main group or serial number
or subgroup of fastener respectively. Thus the part numbers will be
In case, if you need any technical assistance contact the concerned Regional
indicated by 2-2-4 or 2-4-2 digit system. Understanding this system will
Office or write to us on the following address : enable you to identify the spare parts easily.
PLATE NO. : 1 PAGE NO. PLATE NO. : 2 PAGE NO. PLATE NO. : 5 PAGE NO. PLATE NO. : 6 PAGE NO.
COVER CYLINDER HEAD 1 CYLINDER HEAD 3 CYLINDER & PISTON 9 CRANKSHAFT 11
PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
VALVE 5 CAMSHAFT / TENSIONER 7 TRANSMISSION 13 CHANGE DRUM / SHIFT FORK 15
Pictorial Index Pictorial Index
PLATE NO. : 9 PAGE NO. PLATE NO. : 10 PAGE NO. PLATE NO. : 13 PAGE NO. PLATE NO. : 14 PAGE NO.
GEAR CHANGE MECHANISM 17 ENGINE ASSLY & CRANKCASE RH 19 COVER CLUTCH 25 COVER MAGNETO 27
PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO. PLATE NO. : 15 PAGE NO. PLATE NO. : 16 PAGE NO.
CRANKCASE LH 21 OIL PUMP 23 CLUTCH ASSEMBLY 29 CARBURETOR 31
4
Pictorial Index Pictorial Index
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
SAI UNIT 33 AIR CLEANER COMPLETE 35 H T COIL AND REGULATOR ASSEMBLY 41 SEAT ASSEMBLY 43
PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
SILENCER ASSEMBLY 37 STARTER ASSEMBLY 39 FRAME AND FITTINGS 45 FRAME & FITTINGS 47
Pictorial Index Pictorial Index
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO. PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
SWING ARM ASSEMBLY 49 PILLION FOOTREST & HOLDER 51 TYRE & TUBE 57 FRONT HUB 59
LH
RH
PLATE NO. : 27 PAGE NO. PLATE NO. : 28 PAGE NO. PLATE NO. : 31 PAGE NO. PLATE NO. : 32 PAGE NO.
MUD GUARD FRONT & REAR 53 STAND ASSEMBLY 55 FRONT MASTER CYLINDER 61 FRONT DISC BRAKE 63
: USE 4
ING T3- M x
RN DO
WA LY FRO R
ON FLUID INE
KE NTA P
BRA CO CA
ER ING
LED OV
SEA FILL
A EAN E REM
CL OR
BEF
PISTON SEAL
DUST SEAL
BLEEDER CAP
PROTECTION BOOT
INSULATOR
CALIPER PISTON
BLEEDER SCREW
PAD SPRING
Pictorial Index Pictorial Index
PLATE NO. : 33 PAGE NO. PLATE NO. : 34 PAGE NO. PLATE NO. : 37 PAGE NO. PLATE NO. : 38 PAGE NO.
REAR HUB 65 REAR BRAKE PEDAL 67 PETROL TANK, CAP TANK 73 CABLES 75
1 2
Plate No.: 2
Cylinder Head
5
10
8 4
7
6
3 4
Plate No.: 3
Valve
1
2 1 DK 1017 51 Shaft Rocker Arm 2
3 2 39 2440 11 Plain washer 4
2
3 DH 1012 95 Wave washer 2
4
4 JH 5112 07 Assly Rocker Arm 2
5 DG 1010 29 Cotter Valve 4
6 36 JH00 08 Kit Valve Repair 1
5 7 36 JH00 19 Valve Kit 1
7/8
5 6
Plate No.: 4
Camshaft / Tensioner
2
3 1 JH 5112 08 Assly Camshaft 1
2 JE 5112 37 Sprocket Camshaft 1
3 JH 5110 17 Camshaft Cap 1
1 4 36 JZ01 22 Kit Guide Chain 1
5 DH 1013 92 Cam Chain Tensioner Pivot Bolt 1
6 PA 1410 16 Chain 428 H Series 124 Links 1
7 CS 1011 28 Gasket 1
8 JE 5210 16 Chain Tensioner 1
9 39 2669 21 O-Ring 1
10 DD 1010 62 Bolt Tensioner 1
7
11 39 1673 04 Flange Bolt 2
8
11
9
10
6
5
4
7 8
Plate No.: 5
Cylinder and Piston
9 10
Plate No.: 6
Crankshaft
5
8
11 12
Plate No.: 7
Transmission
24 23
25
13 14
Plate No.: 8
Change Drum / Shift Fork
15 16
Plate No.: 9
Gear Change Mechanism
10
8
17 18
Plate No.: 10
Engine Assembly / Crankcase RH
9
3
4
5
8 7
19 20
Plate No.: 11
Crankcase LH
10
11
21 22
Plate No.: 12
Oil Pump
2
5
23 24
Plate No.: 13
Kick Assembly
5
7 6
9 8
8
8 10
25 26
Plate No.: 14
Cover Clutch
11 10
27 28
Plate No.: 15
Cover Magneto
5
1 JH 5412 02 Assly Magneto cover 1
2 30 1011 95 O Ring 1
3 3 JA 5412 33 Cap TDC Finder 1
1 4 4 JA 5410 05 Bush Bendix 1
5 PF 5412 40 Gasket Magneto Cover 1
2 6 59 0400 38 Flange Bolt 6
6 7 JH 5412 05 Assly Cover LH RR 1
8 PA 5412 10 Label Gear Shift 1
9 KA Ef06 45 Bolt Flange 2
29 30
Plate No.: 16
Clutch Assly
15
14 No. Part No. Description Qty. Remarks
12
13
1 JH 5514 00 Clutch Assy Comp 1
2 JA 5514 06 Collared Clutch 1
11
3 JZ 5514 03 Primary Drive & Driven Gear 1
10
4 39 2600 11 Washer Clutch 1
9
5 JA 5514 14 Plate (Wheel Clutch) 1
8 6 36 JH00 04 Kit Friction Plate 1
7 JA 5514 19 Plate Clutch 4
8 JH 5514 04 Hub Clutch 1
1 9 JH 5514 05 Spring Compression 4
10 PF 5514 06 Holder Clutch 1
11 39 1553 04 Bolt - Flange M6 4
12 39 2200 11 Washer - Plain (Primary Drive Gear) 1
13 39 0240 11 Washer Plain 1
6 14 DH 1016 48 Nut Clutch Center Lock (Pre-coated) 1
7
15 14 1510 33 Clutch Lifter Bearing 1
5
4
2
3
31 32
Plate No.: 17
Carburetor
4 12
14
13
33 34
Plate No.: 18
SAI Unit
6
7
3
35 36
Plate No.: 19
Air Cleaner Complete
13
14
15
37 38
Plate No.: 20
Silencer Assembly
10 9
6
8
7
39 40
Plate No.: 21
Starter Assembly
8
9
5
10
41 42
Plate No.: 22
H.T. Coil & Regulator Assembly
6
4
4
8
9
7
43 44
Plate No.: 23
Seat Assembly
4 2
9
8
11
10
45 46
Plate No.: 24
Engine Mountings
3
7 8
5 4 6
47 48
Plate No.: 25
Frame and Frame Fittings
4
6
49 50
Plate No.: 26
Swing Arm / Rear Shock Absorber
15 16
13 14 1 JH 1220 11 Assly Swing Arm 1
2 JH 1220 04 Shaft Swing Arm 1
12 3 JH 1220 09 Seal Dust 4
4 JH 1220 12 Sleeve 2
5 JH 1220 13 Bearing Needle 2
6 JH 1220 14 Chain Slider 1
17
7 39 1053 15 Nut 1
37 8 DJ 1510 36 Adjuster Chain LH 1
5 4
3 9 DJ 1510 37 Adjuster Chain RH 1
6 3
5 19 1 10 DJ 1510 47 Plate chain Adjuster 2
4
3 18 11 39 0292 15 Nut 4
2
12 JH 1220 03 Shock Absorber Rear 2
13 39 0714 11 Washer Plain 2
14 JB 1220 10 Plain Washer 4
9
15 39 2726 12 Spring Washer 2
10 16 39 2366 15 Dome Cap Nut 2
11
8 11 17 JB 1220 16 Flange Bolt 2
18 39 0454 11 Plain Washer 1
10
11
19 39 0553 02 Self Tapping Screw 1
11
51 52
Plate No.: 27
Pillion Foot Rest / Holder
10
6
11
12 2
13
9 RH
15 14 8
16
53 54
Plate No.: 28
Mudguard - Front & Rear
7
14
11
10
13
12
55 56
Plate No.: 29
Stand Assembly
8
9
57 58
Plate No.: 30
Tube / Tyre / Rim
59 60
Plate No.: 31
Front Hub
61 62
Plate No.: 32
Front Master Cylinder
13
13
12
15
9
10
10
11
63 64
Plate No.: 33
Front Disc Brake
12
15
11
13
16
14
65 66
Plate No.: 34
Rear Hub
67 68
Plate No.: 35
Rear Brake Pedal
69 70
Plate No.: 36
Handle Bar Assly
71 72
Plate No.: 37
Front Fork
73 74
Plate No.: 38
Petrol Tank, Cap Tank and Gauge Fuel
4
9 10
11
5
14 12
13 6
15
8
16
75 76
Plate No.: 39
Control Cables
77 78
Plate No.: 40
Chain Case
79 80
Plate No.: 41
Fairing
1 JH 1812 15 Windshield 1
2 39 2141 24 Washer nylon 4
1
3 LB U000 23 Screw Truss 6
4 JH 2328 00 Bkt no. Plate Mtg. 1
8
5 JZ 2328 14 Pad Rubber no. Plate Bkt 2
7
6 6 39 0044 01 Screw Round Head 2
7 39 1501 11 Washer plain 2
5 8 KB UC05 25 Screw Truss 2
4 9 JH 1812 63 Collar For Wind shield Mtg 2
9 10 JH 1812 62 Sleeve for Fairing Mtg 2
11 LB U000 02 Screw Truss 2
14 12 JG 1812 36 Well Nut 2
15 13 JH 1812 23 Head Lamp Bezel 1
3 2
14 KD BA05 12 Washer Plain 6
11 10 12 15 KB RA42 16 Screw Tapping Pan 2
13
3
15
81 82
Plate No.: 42
Head Lamp
2 6
10
11 5
7
8
9
83 84
Plate No.: 43
Fairing Structure & Speedometer
8
9
10
3
4
6
5
85 86
Plate No.: 44
Fittings - Seat Cover & Tail Lamp
1
1 KA DF06 12 Bolt Flange 2
11
2 LD A000 18 Washer 2
2
3 3 JL 1812 19 Grommet 1 Seat Cowl 2
4 5 4 LB R000 03 Screw Cr Pan 8
7
5 LD A000 07 Washer Plain Small 8
6
6 LB U000 43 Screw Truss 4
8 10
7 KA DF06 14 Bolt Flange 2
9 8 JH 1812 28 Bkt Seat Cowl Mtg Rear 1
9 KC GC05 05 Nut Hex Flanged 4
10 JH 1812 34 Grommet Tail Lamp 4
11 JH 4010 03 Tail Lamp 1
12 JZ 1813 22 Grommet Side Cover 1
13 DG 1611 21 Screw 1
14 39 1789 24 Washer Nylon 1
15 DS 1610 35 Clip Nut 1 N.I
14 13
12
87 88
Plate No.: 45
Indicator Light Assembly
4
5
7
6 6
89 90
Plate No.: 46
Mirror Assly & Number Plate
1 2
1 JH 2316 00 Mirror assly LH 1
2 JH 2316 01 Mirror assly RH 1
3 DP 1611 45 Number Plate Rear 1
4 KA DD06 10 Bolt flanged 2
5 DJ 1610 72 Bkt Rear No. Plate 1
6 JZ 2328 05 Foam Rear Number Plate 1
3 4
5
91 92
Plate No.: 47
Electrical Equipments
14
16
93 94
Plate No.: 48
Tool Kit
95 96
Plate No.: 49
Grab Handle , Leg Guard & Saree Guard
97 98
Plate No.: 50
Painted Parts & Decals
99 100
Plate No.: 50
Painted Parts & Decals
10/11
12
13 14 15
101 102
Kit List Kit List
3 36JH0004 FRICTION PLATE JH551402 PLATE FRICTION C101 5 18 36JH0001 PISTON RINGS JH521203 PISTON RING TOP C101 1
JH521204 PISTON RING SECOND C101 1
4 36JZ0122 CHAIN GUIDE JE521025 GUIDE TIGHT SIDE SILENT CHAIN D106A 1 JH521205 PISTON RING OIL C101 1
JE541037 GUIDE SLACK SIDE SILENT CHAIN D106A 1
19 JH541000 ASSEMBLY CRANKCASE LH 39218919 OIL SEAL 1
5 36JH0006 CHAIN SPROCKET JH551201 SPROCKET OUTPUT C101 1 39256220 NEEDLE ROLLER BRG. 1
DX151023 SPROCKET 42 T 4 RUBBER 1 JH541001 CRANKCASE LH C101 1
Pa141016 CHAIN 428 H SERIES 124 LINKS 1 PF541044 INSERT CRANKCASE LH B104D 1
39258320 BEARING BALL6004-SKF 1
6 36JH0007 CLUTCH COVER JH541201 COVER CLUTCH C101 1 DH101264 GASKET NEUTRAL SWITCH (T1.5) 1
JL541227 WINDOW OIL GUAGE 1 31201081 SWITCH COMPLETE 1
DS101215 WIRE CIRCLIP 1 JA541005 BUSH BENDIX 1
30101142 SEAL OIL 1 39219019 OIL SEAL 1
31101064 PLUG 1 JZ541005 NOZZLE OIL JET 1
BA102004 PLUG 1
20 JH541008 ASSEMBLY CRANKCASE RH JH541007 CRANKCASE RH 1
7 36JH0008 VALVE REPAIR 28101129 SEAT SPRING 1 PF541045 INSERT CRANKCASE RH B104D 1
39201719 SEAL VALVE STEM 1 59200036 6203 HN3 C3 BALL BEARING 1
JZ511202 SPRING VALVE 1 JA541010 STOPPER PLATE INPUT BEARING 1
JA511203 RETAINER VALVE SPRING 1 DH101380 SCREW PAN HEAD(M6X12) 1
DG101029 COTTER VALVE 2 KPBF6201 BEARING BALL C3 CLEARANCES 1
PF541018 BUSHING DRUM BM150 4 SPD 1
8 36JH0009 BOSS KICK SET JA621202 LEVER KICK 1 JA541012 GUIDE KICK 1
PA621202 BOSS KICK LEVER D105A UG 1 39196404 BOLT-FLANGED-SMALL 2
30101234 SPRING 1 JA541014 BOLT SHIFT CHANGE 1
30101236 BALL STEEL 1 BA102004 PLUG 1
22150241 WASHER - PLAIN 1 JE541028 PIN K11 1
30101235 PIN 1
39085517 E-TYPE CIRCLIP 1 21 JH511000 ASSEMBLY CYLINDER HEAD JH511001 CYLINDER HEAD MACHINED 1
JZ511017 SEAT VALVE INLET 1
9 36JH0010 PRIMARY DRIVE & DRIVEN GEAR JZ531006 GEAR PRIMARY DRIVE 1 JZ511018 SEAT VALVE EXHAUST 1
JZ551403 CLUTCH HSG ASSLY HTTS DISCO-H 1 JF511008 GUIDE VALVE WITH CLIP 2
JF511216 VALVE GUIDE 4
10 36JH0011 FORK CYLINDER COMP JH121015 SEAT PIPE 1 DH101174 CLIP VALVE GUIDE 4
DG181017 RING-FORK PISTON 1
JH121049 CAP OIL LOCK 1 22 JH232602 ASSEMBLY LOCK SET - NON EVAP Jz401400 IGNITION SWITCH 2 PT. MOUNTING 1
DG181019 SPRING-REBOUND 1 JH232600 KEY SET 1
JH171033 CAP FUEL TANK 1
11 36JH0012 CARB O RINGS&GASKET DH161231 LOCK SIDE COVER 1
23 JH541202 ASSEMBLY MAGNETO COVER JH541203 MAGNETO COVER C101 1
12 36JH0013 CARB JETS 24 36JH0019 VALVE INTAKE & EXHAUST JH511202 VALVE INTAKE 1
JH511203 VALVE EXHAUST 1
13 36JH0014 CARB THROTTLE VALVE
14 36JH0015 CARB FLOAT CHAMBER BODY
103 104
Kit List Kit List
105
Amendment Sheet Amendment Sheet
Page Fig. Old part New part Updation Remarks Page Fig. Old part New part Updation Remarks
no. no. no. no. Description date no. no. no. no. Description date
66 18 30151105 JN131812 SHOE BRAKE 13.05.16 NON ASBESTOS PART NO ADDED
66 12 JH121022 JH121079 HOOK FOR BRAKE HOSE 01.10.16 REF. CIR. IB-253
100 1 -------- 52JH0366 F TANK DARK M BLUE WH DCL 27.10.16 REF. CIR. IB-257
100 2 -------- 52JH0359 S COVER LH DARK M BLUE DCL 27.10.16 REF. CIR. IB-257
100 3 -------- 52JH0361 S COVER RH DARK M BLUE 27.10.16 REF. CIR. IB-257
100 4 -------- 56JH057M FRONT FENDER DARK M BLUE 27.10.16 REF. CIR. IB-257
100 5 -------- 56JH047M FAIRING ASSLY. DARK M BLUE 27.10.16 REF. CIR. IB-257
100 7 -------- 52JH0364 CVR SEAT PILLION DARK M B 27.10.16 REF. CIR. IB-257
48 1 JH113402 JH113415 ASSLY BRACKET ENG MTG TOP 15.12.16 REF. CIR. IB-263