BS VI

Bajaj Auto Limited

Akurdi, Pune - 411 035. India.
Tel
Fax
: +91 20 27472851
: +91 20 27407385
Customer care : +91 7219821111
Spare Parts Catalogue
Website : www.bajajauto.com
CIN L65993PN2007PLC130076
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.: 71120225 REV. 00 JUN 24

Copy rights : All rights reserved. No part of this publicatin may be reproduced,
stored in a retrival system, Or transmitted in any form or by any means,
electromic mechanical photocopying, recording or otherwise, without the prior
written permission of Bajaj Auto LTD.
Foreword Instructions
We have pleasure in presenting the Spare Parts Catalogue for ‘Pulsar NS400Z. This 1. How to Read the Catalogue : Open the catalogue and from the pictorial index locate the
catalogue has been specially designed to assist you in selecting the correct parts for group in which the part you want to find is present. Turn over to the concerned page
number (as given by pictorial index). Now find out the figure of the part you wish to
procurement to maintain 100% availability.
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 ensure longer life In case, if you have the part number and you need the other details, the part index can
be used. The part index (at the end of the catalogue) will give you the figure and page
of the vehicle. It is therefore necessary that only the Genuine Bajaj Spares are used.
number of the part you wish to order.

In a continual effort to improve Performance and Efficiency of the vehicles, Specifications, 2. How to Order Spare Parts : The part number and the description of the part required
Diagrams, Illustrations and Part Numbers can change without notice. Consequently, the should be invariably mentioned in the order as per the catalogue text.
description in this Spare Parts Catalogue cannot therefore be final and binding on us. The latest part number as conveyed through our service circulars should 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 catalogue, will be
conveyed to you through our Service Circulars. You are requested to make necessary The quantity shown against the part number is the quantity per vehicle for that group so
corrections in the Parts Catalogue as per the circulars so as to keep your catalogue up-to- that particular quantity should be multiplied by the number of sets required.
date. This will ensure the appropriate and speedy delivery of the Spare Parts as the order 3. Part Number System : We have used 8 digit system for part numbers. The model or
placed will bear the latest part numbers. hardware item is indicated by first two digits or alphanumeric, the next two or four digits
indicate main group and the last four or two digits indicate serial number in main group or
In case, if you need any technical assistance contact the concerned Regional Office or write to serial number or subgroup of fastener respectively. Thus the part numbers will be
indicated by 2-2-4 or 2-4-2 digit system. Understanding this system will enable you to
us on the following address : identify the spare parts easily.

Bajaj Auto Limited 4. Abbreviations : The following abbreviations are used in this catalogue.
Service Department Assly Assembly V Volts
Akurdi, Pune 411 035 India N.I. Not illustrated W Watts
C'case Crankcase Accl. Accelerator
Cyl Cylinder Comp. Complete
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
Revision No. & Revision No. &
Change Details Change Details

A: Add A: Add
REV. NO., PART SR. PAGE D: Delete Reason for change REV. NO., PART SR. PAGE D: Delete Reason for change
SHORT DESCRIPTION QTY. SHORT DESCRIPTION QTY.
MM YY NUMBER NO. NO. C: Change MM YY NUMBER NO. NO. C: Change
Revision No. & Revision No. &
Change Details Change Details

A: Add A: Add
REV. NO., PART SR. PAGE D: Delete Reason for change REV. NO., PART SR. PAGE D: Delete Reason for change
SHORT DESCRIPTION QTY. SHORT DESCRIPTION QTY.
MM YY NUMBER NO. NO. C: Change MM YY NUMBER NO. NO. C: Change
Index Index
Plate No. Description Page No. Plate No. Description Page No.

1 Cover Cylinder Head 2 34 Master Cylinder - Front 80

2 Cylinder Head 4 35 Caliper Assembly - Front 82
3 Rocker arm & Camshaft 6 - 10 36 Anti Lock Brake System 84
4 Chain Guide & Tensioner Assembly 12 37 Rear Disc Brake Master Cylinder & Caliper 86
5 Cylinder & Piston 14 38 Rear Wheel Hub 88
6 Crankshaft Assembly 16 39 Rear Brake Pedal 90
7 Transmission 18 40 Handle Bar Assembly 92 - 94
8 Change Drum / Shift Fork 20 41 Front Fork 96
9 Gear Change Mechanism 22 42 Petrol Tank, Cap Tank & Gauge Fuel 98
10 Engine Assembly / Crankcase RH 24 43 EVAP Mechanism 100
44 Fitting - Petrol Tank Cover 102
11 Crankcase LH 26 - 28
45 Fitting - Side Covers, Seat Cowls 104
12 Balancer Idler Gear & Water Pump 30
46 Instrument Cluster & Socket Charger 106
13 Oil Pump & Evacuation Pump 32
47 LED Head Lamp & Fairig 108 - 110
14 Cooling System 34 - 36
48 Indicator Light Assembly 112
15 Cover Clutch 38 49 Tail Lamp Assembly & Number Plate Mounting 114
16 Cover Magneto 40 50 Electrical Equipments 116 - 118
17 Clutch Assembly & Clutch Cable 42 51 Tool Kit 120
18 Throttle Body & Sensors 44 52 Accessories - Mirror, Leg Guards, Grab Handles & Saree Guard 122
19 Air Cleaner Assembly 46 53 Painted Parts and Decals 124 - 130
20 Silencer Assembly 48 54 Consumable Parts 132 - 134
21 Starter Assembly 50 Kit List 134- 140
22 Magneto, Regulator & ECU 52 Amended Sheet (Parts Added) 141
23 H.T. Coils 54 Amended Sheet (Parts Deleted) 142
24 Seat Assembly & Seat Lock 56 Part Index 143
25 Engine Mountings 58
26 Frame & Frame Fittings 60
27 Swing Arm & Rear Shock Absorber 62 - 64
28 Belly Pan & Radiator Shroud 66
29 Rider & Pillion Foot Rest 68 - 70
30 Front Fender 72
31 Side Stand Assembly 74
32 Tubeless Tyre & Wheel 76
33 Front Wheel Hub 78
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 1 CYLINDER HEAD 3 CYLINDER & PISTON 13 CRANKSHAFT ASSEMBLY 15

1 5
2

2
3
4

12
1

11
8 9 10
6
3 4

5
7

5 13

PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
ROCKER ARM & CAMSHAFT 7-11 CHAIN GUIDE & TENSIONER ASSEMBLY 11 TRANSMISSION 17 CHANGE DRUM / SHIFT FORK 19

1 10 9
6 8
7 1
9 2
8 8
7
5 3
4
2 7 4
6
8 9
9

2
3
2 25 23
1
24
5 2 4
4
26 3
27
1 4 5
2
15-67 3
14 7 21 22
8 3 19 20
5
16 18
17 6
14 15
13 13
10
12
4 11
10 7

11/12
5

11
6
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 21 ENGINE ASSEMBLY / CRANKCASE RH 23 OIL PUMP & EVACUATION PUMP 31 COOLING SYSTEM 33 - 35

2
3
1
2

4
10
11
7
8

9
5
6 3
4
5

9
8

14

15 7
16

17 6

PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO.

PLATE NO. : 15 PAGE NO. PLATE NO. : 16 PAGE NO.
CRANKCASE LH 25 - 27 BALANCER IDLER GEAR & 29
COVER CLUTCH 37 COVER MAGNETO 39
WATER PUMP
15 12
1
9 5
13
14 1
27
10

26

14
3

11
4 4 10
5 2 6 6
7
2 3
31 12 7
17 8
18 11 8 8
16
19 7

25 24
13 13A 23 1
15
6
30

5
3 4 9
29 20
10
28 21
2
9
22

25
Pictorial Index Pictorial Index
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
CLUTCH ASSEMBLY 41 THROTTLE BODY & SENSORS 43 STARTER ASSEMBLY 49 MAGNETO, REGULATOR & ECU 51

17 16 1
2 12
1 1 11
7
1 2

2 3 13

19
4
6
5 9
4 18
10 2
15
4 4
8 5 14
3
3
10
17
15 16
14
3 13
5
12
11
19 5 6
18
23
21 9
24
7
20

20
22
6

7 8 8
21

PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
AIR CLEANER ASSEMBLY 45 SILENCER ASSEMBLY 47 H T COIL 53 SEAT ASSEMBLY & SEAT LOCK 55

3
3 14 15/16 2
1
2

5 1

6 7 13
14
5 11
17 8
6 15 6
7 3 5
4 14
4 11 4 7 13
2
13
1
3
9
1 15
16
8 12 4
4

12
5
13
11 11 8
8 2
10
9
12
10
6
10
11 9
2

7
Pictorial Index Pictorial Index
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO. PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
ENGINE MOUNTINGS 57 FRAME AND FRAME FITTINGS 59 RIDER & PILLION FOOT REST 67 - 69 FRONT FENDER 71

26
21
11
24 2
6 27
7 12
19
8 5
4 3

3 17 1
2 13 22
18 24
14 13 19
14A
16 11

16 4 7 15
2/3 13
5 18
6
8 1
6 7 10 3
4
4 3
2 11 12
16
6 2

8 19
9
19 1
10 17
13 19 6
19 15 18
1 18 23
10
22
5 4 9 20
21
14 14A
13
18
25
8
21 7
20
20
9 6

PLATE NO. : 27 PAGE NO. PLATE NO. : 28 PAGE NO. PLATE NO. : 31 PAGE NO. PLATE NO. : 32 PAGE NO.
SWING ARM & RSA 61 - 63 BELLY PAN & RADIATOR SHROUD 65 SIDE STAND ASSEMBLY 73 TUBELESS TYRE & WHEELS 75

3 1
3
4 2
2 4 3
5
4 1 6 5
3 11
2
4
4
3
19 14

7 13
1
3 7 3
17
5 15 12 13
9 23 10 2
10
24 9
16 21 16 12
22 7 8 9 4 5
8 28
1 27 9 2
6
20 11
25 13 10
6 14
26
11 12
14
14

13

15
Pictorial Index Pictorial Index
PLATE NO. : 37
PLATE NO. : 33 PAGE NO. PLATE NO. : 34 PAGE NO. PAGE NO. PLATE NO. : 38 PAGE NO.
REAR DISC BRAKE MASTER CYLINDER
FRONT WHEEL HUB 77 MSTER CYLINDER - FRONT 79 85 REAR HUB 87
& CALIPER
21
9 3
1 4 9
7 8
25
8 7
4 6 6
2
7 5
13 10
1
3 21
20
5 20
3
22
19
16 18
17
6
3 4
16 5
5 14
E

6
: US 4
ING T3-

BR
RN DO FROM
WA LY ID
ON FLU
E
AIN
NT P
AK CO CA G
LED LER VIN
ER
15
FIL MO
SEA N RE
A EA
CL FORE
BE

8 4 15
14 11
10
10 9 17
14
3 10 16
2 11
14 12
7
12
2
4
13 13
12 17 5
13
1 8
10 9
12 11
11

10 1
15
24
10 4
11 23
22

PLATE NO. : 35 PAGE NO. PLATE NO. : 36 PAGE NO. PLATE NO. : 40 PAGE NO.
PLATE NO. : 39 PAGE NO.
CALIPER ASSEMBLY - FRONT 81 ANTI-LOCK BRAKE SYSTEM 83 HANDLE BAR ASSEMBLY 40
REAR BRAKE PEDAL 89

4 2
1
20

1 1 5 17
2
16
3 18
5
19
4 7
7

14 6 2 21 12
2
6 22 33
x
15 10
6 8 11
1 23
12 6 9
5
15 24
PISTON SEAL 25 29
5 2 14 34
7
13 26
DUST SEAL 10 3
11 10 3 27
BLEEDER CAP

PROTECTION BOOT
4
INSULATOR 3
29 32
8 28 35
CALIPER PISTON 4
30
9
9 31
BLEEDER SCREW

PAD SPRING

7
Pictorial Index Pictorial Index
PLATE NO. : 42 PLATE NO. : 45 PLATE NO. : 46
PLATE NO. : 41 PAGE NO. PAGE NO. PAGE NO. PAGE NO.
PETROL TANK, CAP TANK & GAUGE FITTING - SIDE COVERS, SEAT COWL INSTRUMENT CLUSTER & SOCKET
FRONT FORK 95 97 103 105
FUEL CHARGER
3 3
3
2 1
14 16
11 2 5
13 17
4 18
1/6
5 5
6 18
5 5
6 6 7
2 2
9 9 8 10
1 2
11
9
4
12
19 13 7 2
4
2
15 15
7 7
10
6
8 10
24
17 18 3
18 10 18 8 19 9
16
7
12
19 19 8
14
11 11
4 5
13 15 14
9 9 11 13
13 16 19
15 15 17 19 12
15 15 14 17
15 15 15
12
15 16 17

Fuel Tank Front Mounting Fuel Tank Rear Mounting

PLATE NO. : 43 PAGE NO. PLATE NO. : 44 PAGE NO. PLATE NO. : 47 PAGE NO. PLATE NO. : 48 PAGE NO.
EVAP SYSTEM 99 FITTING - PETROL TANK COVER 101 LED HEAD LAMP & FAIRING 107 INDICATOR LIGHT ASSEMBLY 111

20
21
4 5
21 10
1 3 21 21 6 1
19
18 17 4
11
4 3
17 5
25 8 2
9
13
18
19 27
17
10
16 18
20 26 7 7
9
2 7
6 2 22
13 15 6
16 15 8 12

10 13 14
9 11
4 2 8
13
14 23
1 14
3 8
11 20 16 13
7 6 16 7
3
10 1 15
12 8
15
5
7
10
23
12 22

5
Pictorial Index Pictorial Index
PLATE NO. : 49
PAGE NO. PLATE NO. : 40 PAGE NO. PLATE NO.: 53 PAGE NO. PLATE NO. : 54 PAGE NO.
TAIL LAMP ASSEMBLY & NUMBER PAINTED PARTS & DECALS
113 ELECTRICAL EQUIPMENTS 115 - 117 123 - 129 CONSUMABLE PARTS 131 - 133
PLATE MOUNTING
3 3
11
2 10 17 18/19 1 2 3
19 11/12
9
1 25 1
20 8
1/2
9/10
5/6 3/4
BS-6
liant
comp

21 2
12

17 15/16
1
4 5 6 4 5 6
13

13
4

20 40
7
22 36 7/8 7 8 9
5
6 39
17 27 28/29 30/31
11 21 14
13 7
12 30 15
16
23
14 34
7 10 24
8 9 18 19 20 21
26 31 10 11 12
16 33 32
15
29 35

10 27 24/25 26
37
18 28
46

PLATE NO. : 51 PAGE NO. PLATE NO.: 52 PAGE NO.

TOOL KIT 119 ACCESSORIES - MIRROR GRAB 121
HANDLES & SAREE GUARD
2
3
9 20
18 23
19
2

1 1
13 14
13 22
14

10
12
20
18
19
Screw Driver
11

16
23 17
23
16
4
21

5
6
8
7

15
 Plate No.: 1
Cover Cylinder Head
No. Part No. Description Qty. Remarks
1
2 1 JG511022 Bolt special 4
2 JG511021 Washer 4
3 52DT0657 Cylinder head cover assembly 1
4 JY511128 Gasket Rubber - Head Cover 1
5 JY511139 Gasket head cylinder 1

1 2
Front Wheel Direction
 Plate No.: 2
Cylinder Head
No. Part No. Description Qty. Remarks
5 3
1 KAED0635 Bolt flanged small 4
2 KAEQ0640 Bolt flange small - M6 2
3 KAEG0645 Bolt flanged small 2
2 4 JY511058 Guide chain top 1
1 4 5 52JF2943 Head cylinder - holder camshaft 1
1
1
1 6 JY511068 Sleeve spark plug 1
2
7 LJA00001 ‘O’ Ring 2
8 JY511074 Gasket sleeve spark plug 1
19
9 LAC00032 Bolt socket head M10 4
10 DK101225 Oil Pressure Switch 1
9
11 DK101340 ‘O’ Ring 1
8 12 JG351400 Coolant Water Temp Sensor 1
13 JG511020 ‘O’ Ring 1
6 14 JL581406 Pipe Intake 1
15 LBC00003 Screw 3
7
7 16 JY581404 O - ring intake pipe 1
17 JY581405 Clamp intake pipe 2
18 JG511046 Stud 2
18
17 19 JL402219 Pigtail oil pressure switch 1

16 14

10 13 15
12
11

3 4
Front Wheel Direction
 Plate No.: 3
Rocker arm & Camshaft
No. Part No. Description Qty. Remarks

1 JY511212 Rocker arm decomp 1

6
2 JU511204 Rocker arm 3
9
3 JY511226 Rocker arm shaft 2
4 JG511016 Plug 2
5 39102121 Ring - O 2

6 JF511255 Camshaft assembly exhaust 1

7 CB101022 Cotter Valve 8
8 36JF0198 Kit valve repair K10UG 1
9 JF511253 Camshaft assembly intake 1
2 10 CB101009 Seal Valve Stem 4
3

5 2
4 11 JY511221 Valve intake 2
12 DT511270 Valve exhaust 2
13 36JY0029 Kit Shim 2 mm 1
1 4
14 36JF0104 Kit Shim 3.18 mm 1
2 15 36JF0105 Kit Shim 3.20 mm 1
13-67 3
7 16 36JY0030 Kit Shim 2.04 mm 1
5 17 36JY0031 Kit Shim 2.08 mm 1
18 36JY0032 Kit Shim 2.12 mm 1
8 19 36JY0033 Kit Shim 2.16 mm 1
20 36JY0034 Kit Shim 2.20 mm 1
10

21 36JY0035 Kit Shim 2.24 mm 1

22 36JY0036 Kit Shim 2.28 mm 1
23 36JY0056 Kit Shim 2.30 mm 1
24 36JY0037 Kit Shim 2.32 mm 1
11/12
25 36JY0057 Kit Shim 2.34 mm 1

5 6
Front Wheel Direction
 Plate No.: 3
Rocker arm & Camshaft
No. Part No. Description Qty. Remarks

26 36JY0038 Kit Shim 2.36 mm 1

6
27 36JY0058 Kit Shim 2.38 mm 1
9
28 36JY0039 Kit Shim 2.40 mm 1
29 36JY0059 Kit Shim 2.42 mm 1
30 36JY0040 Kit Shim 2.44 mm 1

31 36JY0060 Kit Shim 2.46 mm 1

32 36JY0041 Kit Shim 2.48 mm 1
33 36JY0061 Kit Shim 2.50 mm 1
34 36JY0042 Kit Shim 2.52 mm 1
2 35 36JY0062 Kit Shim 2.54 mm 1
3

5 2
4 36 36JY0043 Kit Shim 2.56 mm 1
37 36JY0063 Kit Shim 2.58 mm 1
38 36JY0044 Kit Shim 2.60 mm 1
1 4
39 36JY0064 Kit Shim 2.62 mm 1
2 40 36JY0045 Kit Shim 2.64 mm 1
13-67 3
7
5 41 36JY0046 Kit Shim 2.68 mm 1
42 36JF0089 Kit Shim 2.70 mm 1
8 43 36JY0047 Kit Shim 2.72 mm 1
44 36JF0090 Kit Shim 2.74 mm 1
10
45 36JY0048 Kit Shim 2.76 mm 1

46 36JF0091 Kit Shim 2.78 mm 1

47 36JY0049 Kit Shim 2.80 mm 1
48 36JF0092 Kit Shim 2.82 mm 1
11/12 49 36JY0050 Kit Shim 2.84 mm 1
50 36JF0093 Kit Shim 2.86 mm 1

7 8
Front Wheel Direction
 Plate No.: 3
Rocker arm & Camshaft
No. Part No. Description Qty. Remarks

51 36JY0051 Kit Shim 2.88 mm 1

6
52 36JF0094 Kit Shim 2.90 mm 1
9
53 36JY0052 Kit Shim 2.92 mm 1
54 36JF0095 Kit Shim 2.94 mm 1
55 36JY0053 Kit Shim 2.96 mm 1

56 36JF0096 Kit Shim 2.98 mm 1

57 36JY0054 Kit Shim 3.00 mm 1
58 36JF0097 Kit Shim 3.02 mm 1
59 36JY0055 Kit Shim 3.04 mm 1
2 60 36JF0098 Kit Shim 3.06 mm 1
3

5 2
4 61 36JF0099 Kit Shim 3.08 mm 1
62 36JF0100 Kit Shim 3.10 mm 1
63 36JF0101 Kit Shim 3.12 mm 1
1 4
64 36JF0102 Kit Shim 3.14 mm 1
2 65 36JF0103 Kit Shim 3.16 mm 1
13-67 3
7
5

10

11/12

9 10
Front Wheel Direction
 Plate No.: 4
Chain Guide & Tensioner Assembly
No. Part No. Description Qty. Remarks

1
1 36JF0197 Kit cam chain guide 1
2 JY511220 Chain timing 1
3 JY541009 Bolt Special Pivot Guide Chain 1
4 CS101128 Gasket 1
5 JF511249 Tensioner Assembly 1
2
6 KAEW0620 Hex Bolt With Flange 2
7 39266921 O - Ring 1
8 JG511270 Bolt flanged - M6 1

3
7
8

11 12
Front Wheel Direction
 Plate No.: 5
Cylinder & Piston
No. Part No. Description Qty. Remarks

1 36JF0196 Kit block piston 1

2 2 39218106 Hollow Dowel Pin 2
3 JF521017 Gasket Cylinder Block 1
4 36JF0060 Kit Piston Ring 1
5 JF521300 Circlip 2

3 4

13 14
Front Wheel Direction
 Plate No.: 6
Crankshaft Assembly
No. Part No. Description Qty. Remarks

1 JF531021 Balancer Drive Gear 1

2 LDH00002 Belleville Washer 1
1 5
3 LDB00033 Plain Washer 1
4 JG531040 Nut Balancer Drive Lock 1
2
3 5 39260607 Parallel Pin 1
4

6 JY551212 Gear Primary Drive 1

7 LFB00001 Sunk Key 1
8 JY531026 Sprocket crankshaft (18T) 1
9 JY531008 Plain Washer 1
10 DG101275 Washer 1

12 11 LCG00002 Nut Sprocket Drive Lock 1

12 JP531025 Crankshaft Assembly Comp. 1
11 13 36JF0054 Kit Primary Drive & Driven 1
8 9 10
6 14 KFAB4050 Key Woodruff 1
14 15 LAD00263 Bolt Flanged M8.5X0.75 2

15

13

15 16
Front Wheel Direction
 Plate No.: 7
Transmission
No. Part No. Description Qty. Remarks

1 JY551022 Shaft Input 1

2 JY551230 Gear 5th Drive 1
3 JY551010 Bush 5th Drive 1
1 4 JY551214 Circlip 2
2 5 JY551229 Gear 3rd - 4th Drive 1
5 3
4
6 JY551021 Bush 6th Drive 1
7 4
6 7 JY551231 Gear 6th Drive 1
8 8 JY551228 Gear 2nd Drive 1
9
9 JY551215 Thrust Washer 1
10 JY551006 Bush 2nd Driven 1

23 11 JY551233 Gear 2nd Driven 1

24/24A 12 JY551008 Shaft Output T/M With Plug 1
13 JY551237 Gear 6th Driven 1
26 14 JY551235 Gear 4th Driven 1
25
15 JY551005 Thrust Washer 3rd Driven 1

16 JY551234 Gear 3rd Driven 1

21 22 17 JY551027 Bush 3rd Driven 1
19 20 18 JY551218 Circlip 1
16 18 19 JY551236 Gear 5th Driven 1
17
14 15 20 JY551205 Bush 1st Driven 1
13
21 JY551232 Gear 1st Driven 1
12
11 22 JY551217 Thrust Washer 1
10
23 JY551018 ‘O’ RING 1
24 36JY0102 Kit Out Put Shaft Oil Seal 1
24A JY551033 Collar Sprocket 1
25 LAE00017 Bolt Flanged 2

26 JY551030 Plate Drive Sprocket 1

17 18
Front Wheel Direction
 Plate No.: 8
Change Drum / Shift Fork
No. Part No. Description Qty. Remarks

1 JG561222 Guide Gear Shift 1

2 DH101389 Socket Head Bolt 1
3 JG561010 Spacer 1
10 9 4 39260607 Parallel Pin 1
5 JY561013 Drum Gear Shift 1
8
6 JP351005 Sensor Assembly Pick Up 1
7 JY561004 Shaft Input Gear Shift Fork 1
9
8 JF561001 Shaft Output Fork Shift 1
9 JY541039 Compression Spring 2
2 10 JY561008 Fork Shift Output 2
1
4 11 JY561002 Fork Gear Shift Input 1
3
5
12 JN181033 Bolt 2

12

11

19 20
Front Wheel Direction
 Plate No.: 9
Gear Change Mechanism
No. Part No. Description Qty. Remarks

1 JY561205 Lever Complete Change Shaft 1

2 JG561215 Spring Compression 1
1 3 JG561217 Bush Torsion Spring 1
4 4 JG561218 Torsion Spring 1
3 2 5 JG561216 Plain Washer 1
5

7 KADD0622 Bolt Flange M6 1

8 JL561410 Washer Steel 1
7 9 JL561409 Bolt socket - M8 1
10 1100905 ‘O’ Ring 2

11 JL561222 Lever Change Assembly 1

13 12 52JL2033 Tie Rod 1
13 JL561414 Arm Change Lever with ball joint 1
14 DH101509 Damper 1
12 15 52JL2034 Lever Change Assembly complete 1

15 8
11

14

9
10
10

21 22
Front Wheel Direction
 Plate No.: 10
Engine Assembly / Crankcase RH
No. Part No. Description Qty. Remarks
1 1 36JF0052 Kit Assembly Crankcase RH 1
2
2 JL501145 Engine assembly 1
3 39218520 Deep Groove Ball Bearing 1
4 39256220 Needle Roller Bearing 1
5 39260120 Ball Bearing 1
10
11 6 39186420 Ball Bearing 20 X 52 X 15 1
7
7 KPBF6304 Ball Bearing 1
8 8 JY541047 Stopper I/P Shaft Bearing 3
9 AA101437 Bolt Flanged 3
9 10 JG601007 Special Shaft Seal 1
5
6 3
4 11 JL601010 Water Seal Double Lip 1
12 JG561204 Bolt Stopper Drum 1
13 DP101191 Bolt Shifter 1
14 JG571014 Oil Filter 1
15 JG571016 ‘O’ RING 1

16 56JF1X36 Cap oil filter Silk matte blue 1

17 KAEW0616 Flange Bolt 2
18 LAE00001 Bolt Flanged 1
13 19 JG561226 Spring Stopper Drum 1
20 39200511 Washer 1

21 21 JG561009 Stopper Drum Complete 1

22 JG561205 Washer 1
19 14
12 20
18
22
15
16

17

23 24
Front Wheel Direction
 Plate No.: 11
Crankcase LH
No. Part No. Description Qty. Remarks
1
9 1 52JF1711 Assembly Crankacse LH 1
2 LJA00002 ‘O’ Ring 2
3 JY571008 Strainer Evacuation 1
27 4 LJA00006 ‘O’ Ring 1
10
5 JY571009 Cap Strainer Evacuation 1

26 6 39104319 Oil Seal 1

14 7 JY541058 Oil Seal 1
3 8 KEBA3715 Circlip Internal 1
9 JY541031 Chain Guard 1
4
5
10 LBB00007 Screw Pan Cross 3
2 6 7
31 12 11 JY571030 Mesh Oil Filter Assembly 1
17 8
18 11
12 LJA00004 ‘O’ Ring 1
16
19 13 JA541021 Cap strainer 1
13A 59210023 O - Ring 1
25 24 14 JP351005 Sensor assembly pick up 1
13 13A 23 15 JN181033 Bolt flange 2
15
30

16 AA101437 Bolt M5 x 13 5
17 JY541081 Bracket Harness 1
18 JY541080 Plate Harness 1
19 JY541082 Bracket Harness 1
29 20
20 LPB00003 Bearing Ball 1
28 21
22 21 LPB00002 Bearing Ball 1
22 39256220 Needle Roller Bearing 1
25 23 JF541017 Bracket 1
24 LBB00012 Screw pan cross - M6 1

25 26
Front Wheel Direction
 Plate No.: 11
Crankcase LH
No. Part No. Description Qty. Remarks
1
9 25 39218106 Hollow Dowel Pin 4

26 KAEW0635 Bolt Flange Small 15

27 27 LAE00002 Bolt Flanged 5
10
28 JY571029 Oil Rail 1
29 LJA00002 O Ring 1
26 30 JF541016 Nozzle 1
14
3 31 LAE00010 Bolt flange - M5 2

4
5 2 6 7
31 12
17 8
18 11
16
19

25 24
13 13A 23
15
30

29 20

28 21
22

25

27 28
Front Wheel Direction
 Plate No.: 12
Balancer Idler Gear & Water Pump
No. Part No. Description Qty. Remarks
15 12
1 JP531206 Assembly balancer 1
2 KPBF6304 Ball Bearing 2
13 3 36JL0039 Rotor Water Pump 1
14 4 JG531215 Washer 1
1
5 JG601005 Domed Nut 1

6 JG601012 ‘O’ Ring 1

7 39260607 Parallel Pin 2
8 JL601008 Cover Water Pump 1
9 39166511 Washer 1
11
10 LAE00048 Bolt 1

2 11 KAEW0622 Bolt flange small M6 5

8 12 DS101154 Key 1
7
13 LDB00051 Washer 1
14 LAC00086 Bolt Socket 1
15 JF531213 Scissor Gear Assembly 1

5
3 4 9
10

29 30
Front Wheel Direction
 Plate No.: 13
Oil Pump & Evacuation Pump
No. Part No. Description Qty. Remarks

1 JY571015 Evacuation Oil Pump Assly. 1

3
1 2 LHD00001 Pin Parallel 3
2 3 39099906 Pin Dowel 4
4 LAE00018 Bolt Flanged M6 Pre Coated 6
5 JY571024 Shaft Oil Pump 1
4

6 JY571012 Oil Pump Assembly Complete 1

7 JY571023 Gear Oil Pump Drive 1
8 LDA00017 Washer Plain 1
9 KEAB1010 Circlip External 1

9
8

31 32
Front Wheel Direction
 Plate No.: 14
Cooling System
No. Part No. Description Qty. Remarks

29 1 JL601269 Radiator 1
2 JL601260 Hose Radiator-thermostat 1
31
30 3 JL601261 Pipe Coolant 1
4 JG601235 Pressure Cap Radiator 1
5 JF601400 Fan Radiator 1
35 16 19
17 6 DT181265 Grommet Side Cover 2
34
15 7 JG171029 Clamp 1
13
9 8 JF601219 Tank Expansion 1
20 22 9 JG601211 Cap Expansion Tank 1
4 10 JL171101 Clamp Band Spring 9.5x8.4 1
12 11

14 11 JF601220 Pipe Tank Expansion 1

8 12 JG601230 Expansion Tank O Ring 1
5
1 13 JG601213 Tube Drain - Expansion Tank 1
6
28 14 DJ181065 Clip Nut M6 2
7
15 JL601216 Rubber Damper Radiator Mounting 4
3
16 LCG00029 Nut Hex Flanged M6x1 4
2 26
17 JL601268 Cowl Radiator 1
18 18 JP181233 Spacer Radiator Shroud 2
29 32 19 JL601270 Collar 2
23 20 JL181943 Bracket Shroud Rh 1
33
24
21 JG601210 Clap Radiator Pipe Dia 28 3
29
22 LAE00055 Bolt Flange-m6x1xl16xcl8.8xblack 2
25 23 JG601014 Unit Thermostat 1
26
27 24 JY601215 Hose Coolant(eng To Therm) 1
25 JF601210 Pipe Thermostat-joint T 1

33 34
Front Wheel Direction
 Plate No.: 14
Cooling System
No. Part No. Description Qty. Remarks

29 26 JG601016 Clamp Radiator Pipe Dia 26 2

27 JG601234 Clamp Dia 23 1
31
30 28 JG601209 Clamp Radiator Pipe Dia 24 1
29 JL113858 Bracket Radiator Rh 1
30 JL113857 Bracket Radiator Lh 1
35 16 19
17 31 KADD0610 Bolt Flanged M6x1 4
34
15 32 JF601211 Joint Assembly T 1
13
9 33 LJA00005 O Ring 1
20 22 34 JL601215 Clamp Expansion Tank 1
4 35 DK181074 Beading 1
12 11

14
8
5
1 6
28 7

2 26

18
29 32

23
33
24
29

25
26
27

35 36
Front Wheel Direction
 Plate No.: 15
Cover Clutch
No. Part No. Description Qty. Remarks
6
1 52JF3163 Clutch cover assembly 1
17 8
2 39199020 Needle Bearing 1
3 39104119 Seal Oil 1
7
5 4 LDB00020 Washer 1
4 5 JF541210 Spring Lever Clutch 1
9A
3
6 JF541208 Clutch Release Shaft Assembly 1
2
7 KJAA1424 ‘O’ Ring 1
8 JG541230 Cap Oil Filling 1
13 12
9 JF233560 Decal cover clutch 1
11 10 JL541227 Window Oil Gauge 1
10
11 DS101215 Wire Circlip 1
12 39201619 Seal Oil 1
13 JY541220 Plate Position 1
14 AA101437 Bolt Flanged Small 2
15 JY541225 Gasket Clutch Cover 1

15 16 JF541204 Bracket Clutch Cable 1

17 KAEW0635 Blot Flanged 12
18 JF161204 Clutch Cable 1

18

37 38
Front Wheel Direction
 Plate No.: 16
Cover Magneto
No. Part No. Description Qty. Remarks

1 52JF3142 Magneto Cover Assembly 1

5
2 JF233565 Decal cover magneto 1
3 30101195 ‘O’ Ring 1
4 JL541245 Cap TDC Finder 1
5 JY541214 Gasket Cover Magneto 1

6 KAEW0635 Bolt Flange 12

7 DT541202 Cover LH RR 1
8 KAEW0650 Bolt Flange 3
4 10 9 JF233036 Label Gear Shift 6 Speed 1
6
3 10 39099906 Pin - Hollow Dowel 2
7
8

2
9

39 40
Front Wheel Direction
 Plate No.: 17
Clutch Assembly & Clutch Cable
No. Part No. Description Qty. Remarks

1 JF551419 Clutch Assembly 1

1 2 36JF0054 Kit Primary Drive & Driven 1
7 3 JY551403 Washer Clutch 1
4 JY551435 Clutch Center 1
5 JY551442 Spring Seat Judder 1

6 JY551441 Spring Judder 1

7 36JF0195 Kit friction plate 1
6 8 JY551436 Pressure Plate - A 5
5 9
4 9 JY551437 Pressure Plate - B 1
10 2
10 JY551401 Bush Collared 1

8
11 LCG00009 Nut Hex Flanged - M16 x 1.5 1
12 LPA00004 Thrust Bearing 1
17
15 16
14 13 JY551438 Plate Clutch Pressure 1
3 13
14 JY551404 Rod Pull 1
12 15 JY551439 Seat spring 3
11
19
18 16 JY551443 Plate Stopper 1
21 17 LAD00166 Bolt Flanged - M6 x 35 3
18 JY551019 Washer Plain 1
19 DG101275 Washer Special 1
20
20 JF161204 Clutch Cable 1

21 JY551440 Seat Spring 3

41 42
Front Wheel Direction
 Plate No.: 18
Throttle Body & Sensors
No. Part No. Description Qty. Remarks

1 JL611210 Body Throttle Assembly 1

1
2 JL611211 Cap Injector-connector Quick 1
3 JG611006 Injector Clip 1
4 JP611003 Injector 1
2 5 JG351805 Sensor Tmap 1

43 44
Front Wheel Direction
 Plate No.: 19
Air Cleaner Assembly
4 14 No. Part No. Description Qty. Remarks

1 JL581134 Filter assembly air 1

3 2 JH581202 Clamp Carb Sleeve Dia 44 1
1 3 JL581144 Duct Intake 1
2 4 JL581146 Seal Top Cover 2
5 KBUA0630 Screw Truss 4
5

6 JL581138 Tube Breather 1

15/16 7 JY581016 Clamp 1
8 JG581056 Clamp (breather tube) 1
6
9 JL581142 Air Filter Element 1
7
4
10 JY581028 Clamp (Breather Tube) 1

11 JP581018 Assembly Tube Drain 1

9 12 JY581028 Clamp 2
13 DT581074 Assly Breather Oil Return Tube 1
14 JL113868 Bracket Filter Mounting 1
4
15 JG181265 Washer 4

12 16 KACF0612 Bolt Socket 4

17 JL581148 Tape insulation 1
13
18 JL581149 Tape insulation 1

18 10

17 11
2

45 46
Front Wheel Direction
 Plate No.: 20
Silencer Assembly
No. Part No. Description Qty. Remarks

1 JL591454 Pipe Assembly A 1

2 JL591447 Muffler Assembly 1
3 JL591462 Shield Pipe A 1
4 JL591149 Bolt Socket M5x0.8 3
5 LCG00024 Nut Hex Flanged-m8x1.25xht.8xbrt 2

6 JP591106 Gasket Exhaust 1

6 7 7 JP591065 Sensor Oxygen 1
13
14 8 JG591038 Band Clip 1
5 11 9 KADD0635 Bolt Flanged M6x1 2
17
15 10 JL591157 Sleeve Bottom 3
3
4 14
11 11 JL591165 Damper Silencer Mounting Lower 4
13 12 JG591039 Gasket Muffler Pipe-a 1
13 JL591148 Bolt Hexagonal Flange 2
14 JL591156 Sleeve Top 4
15 15 DH101607 Truss Screw 6
1
16
12
16 JL591486 Cap End 1
17 JL591508 Shield Muffler 1

8 11 2
10
9

47 48
Front Wheel Direction
 Plate No.: 21
Starter Assembly
No. Part No. Description Qty. Remarks

1 JF351600 Starter Motor 1

2 KADQ0625 Bolt Flanged 2
3 JY551225 Gear Starter Counter 2 1
4 JY551226 Gear Starter Counter 1 Assy. 1
2 5 LAE00042 Bolt Flanged 1

1 6 JY621411 Assembly Gear Starter Clutch 1

7 JY541040 Retainer Gear Starter 1

7 5

49 50
Front Wheel Direction
 Plate No.: 22
Magneto, Regulator & ECU
No. Part No. Description Qty. Remarks

1 JF351013 Rotor Without Clutch & BSC 1

1 2 JL351068 Stator Assembly 1
17 16
12 3 DK101284 Hex Socket Head Screw 3
11
4 JF402004 Regulator Assembly 1
2 5 KAED0630 Bolt - Flanged - Small 2

3 13 6 JF181282 Bracket ECU lower 1

7 TA351404 ECU 1
10 8 JY113864 Bracket ECU mtg top C smple 1
9 KCGA0606 Nut hex flanged 4
4 18 10 JY551402 Clutch One Way Assly 1
5
15
11 LDB00041 Plain Washer 1
14
12 LAD00124 Bolt Flange 1
13 JY541222 Plate Harness 1
14 JY541208 Bracket Harness Magneto 1
15 KADD0508 Bolt 3
23
9
19 16 LDF00001 Washer toothed 4
7 17 LAC00122 Bolt Socket 4
18 JF351014 Body clutch starter 1
20 19 JY113873 Pad resting ECU C sample RH 1
22
6
20 JY113877 Damper ECU Locator 1

21 JY113874 Damper ECU C smple mtg top 1

8 22 JY171007 Pad rubber new ECU My16 2
21
23 JY113872 Pad resting ECU C sample LH 1

51 52
Front Wheel Direction
 Plate No.: 23
H.T. Coils
No. Part No. Description Qty. Remarks

1 JF351219 Coil HT Assembly 1

2 KAED0625 Bolt flanged small 2
2
3 DD111012 Grommet For H. T. Cable 1
4 JY351203 Grommet spark plug cap 1
5 JY351200 Cap spark plug 1

6 JF351206 Grommet Spark Plug 1

7 JL351218 Spark Plug BOSCH central 1
8
8 DT113855 Clamp HT coils 1

1
3

53 54
Front Wheel Direction
 Plate No.: 24
Seat Assembly & Seat Lock
No. Part No. Description Qty. Remarks
3
1 JL191001 Seat Assy Comp Front 1
2 36JL0013 Kit Damper For Seat 1
3 DK211007 Damper Seat Front 1
1 4 JG191008 Collar -Seat 2
5 FD211006 Grommet - Seat 2

6 DS161287 Flange Bolt - M6 2

7 JL191004 Seat Assy Comp Rear 1
6
8 JD191006 Damper Round 2
5 9 DT232605 Lock Assy Seat Rear 1
4 7 13
2 10 JG232606 Seat Lock Cable 1

11 KADD0622 Bolt Flanged 2

12 JL232604 Cover Seat Lock Assembly 1
13 DK211009 Damper 2

11 8

12

10
9

55 56
Front Wheel Direction
 Plate No.: 25
Engine Mountings
No. Part No. Description Qty. Remarks

1 56DT0233 Stay hanger LH matt black 1

11 2 56DT0333 Stay hanger RH matt black 1
3 KAED0820 Bolt flanged small 4
4 DT181323 Plug 2 2
4 5 LAJ00020 Bolt stud - M10 X L153 1
3
2
12
6 KDDB1018 Washer spring thin 1
7 KDAA1018 Washer Plain 1
8 LAA00051 Bolt - M8 (For LH & RH) 2
9 LAD00006 Bolt Flange 2
8 10 LCL00001 Hex Nut / Flange 2
6 7
4 3
11 DT113827 Cover Seal Heat 1
12 DX161066 Plug 2

10

5 4

57 58
Front Wheel Direction
 Plate No.: 26
Frame and Frame Fittings
No. Part No. Description Qty. Remarks

1 56JL09CA Frame Assembly Matt Gray+black 1

7 12 2 JL111103 Cap Tube End 2
8 3 DT111106 Frame Rubber Pad LH 1
4 DT111107 Frame Rubber Pad RH 1
17 5 36DK0159 Kit Steering Cone 1

14 13 6 DK181051 Cage Bearing Steering Bottom 1

16 7 DK181075 Nut Steering 1
16 8 DK181076 Cup Steering 1
2/3
5 9 JL113809 Grommet Air Filter Resting 1
1 10 DT181323 Plug 2 1

12 KAED0610 Bolt Flanged Small 1

2
13 JF113859 Bkt. Valve Purge Rly Interlock 1
6 14 DS161166 Frame Tape II 2
15 JL113841 Clamp Tie Cable 10

9
19 16 DS211004 Damper Seat I 2 For Fuel Tank Resting
19 17 DK181050 Cage Bearing Steering Top 1
15
18 18 JL113865 Bracket Assembly 1
10
19 JL171024 Damper Structure Mtg 2
20 KADA0610 Bolt Flanged M6x1 2

21 LAE00021 Bolt Flanged M6x1 2

21
20
20

59 60
Front Wheel Direction
 Plate No.: 27
Swing Arm & Rear Shock Absorber
No. Part No. Description Qty. Remarks

1 JL122044 Arm Assembly Swing 1

2 JL122058 Shock absorber Rear 1
3 JL113408 Bracket Engine Middle Rear 1
4 LAC00019 Bolt Socket 2
5 LAD00073 Bolt Flanged 2
2
4 6 LAD00108 Axle 1
7 DT113848 Cap Swing Arm Pivot 2
8 DG171019 Seal-oil 2
9 DK171006 Sleeve For Swing Arm 2
19 14
10 DG171018 Bearing-needle 2

11 JL122054 Slider Chain 1

3 7
12 LBU00168 Screw Socket Step M6x1 2
17 13 JL122060 Shield Slider Chain 1
5 15
9 23
14 KAAD0610 Bolt M6x1 2
10 15 JF113422 Spacer 1
24
16 21
22 16 JF113423 Washer Plain 1
8 28
1 27 17 DG171017 Nut 1
20 18 JL181903 Cover Chain 1
25
19 JL181944 Cap Cover Chain 1
6 20 LBU00237 Screw Button Head Step M6x1 2
26
11 12
21 JL181902 Pin 1
14
22 DT131875 Clamp 1
23 KAEF0622 Bolt Flanged M6x1 1
13
24 AA111141 Clip H.t. Cable Holding 1
25 KCBC0805 Nut Hex M8x1.25 2

61 62
Front Wheel Direction
 Plate No.: 27
Swing Arm & Rear Shock Absorber
No. Part No. Description Qty. Remarks

26 KCGC0808 Nut Hex Flanged 2

27 JF122104 Cap Tube Arm Swing 2
28 JL122052 Adjuster Chain 2

2
4

19 14

3 7
17
5 15
9 23
10
24
16 21
22
8 28
1 27
20
25

6
26
11 12

14

13

63 64
Front Wheel Direction
 Plate No.: 28
Belly Pan & Radiator Shroud
No. Part No. Description Qty. Remarks

1 JL181933 Bracket Belly Pan Rh 1

3 2 JL181901 Bracket Belly Pan Lh 1
3 KBUC0620 Screw Truss M6x1 4
4
5 4 JY181255 Washer End Cap 8
1
3 5 KADF0614 Bolt Flanged M6x1 2
2
4
4 6 JL181723 Shroud Inner Lh 1
3
7 JL181725 Shroud Rear Lh 1
8 56JL24CA Shroud Outer Lh 1
9 KBRC4213 Screw Tapping Pan Cross Dia 4.2 8
10 JL181724 Shroud Inner Rh 1
3
12 13 11 JL181726 Shroud Rear Rh 1
10 12 56JL25CA Shroud Outer Rh 1
9 13 JY181285 Screw Button Head-m6x1xl10xblack 2
16
7 14 LBU00155 Screw Button Head Step M6x1 4
9 15 DJ181065 Clip Nut 4
6
11
13
16 JL181033 Tape Insulation LH 1

14

14

15

65 66
Front Wheel Direction
 Plate No.: 29
Rider & Pillion Foot Rest
No. Part No. Description Qty. Remarks
26
21 1 56JL5F4X Holder Step RH 1
24 2 2 56JRV64X Step Assembly RH 1
6 27
3 JL113012 Spring Torsion 2
19
4 JL113033 Bracket Rear Brake Switch 1
5 3 5 KADD0610 Bolt Flanged 1

1
13 22 6 LAC00045 Bolt-Socket Dia-08 L-20 4
24
18 7 56JL3X4X Step Holder LH 1
19
14A 8 56JR3S4X Step Assly Main LH 1
11
9 36JL0041 Kit Main Step Hardware 2
4 7 15 10 LDA00013 Washer Plain Dia 6.4XDia 1
13
6 18
11 LAC00016 Bolt Socket 4
10 12 56JL4J4X Step Holder- Pillion LH 1
13 LDB00018 Washer Plain 3
11 12 14 56JL184X Step Pillion LH 1
16
14A 36JL0015 Kit Pillion Hardware 2
15 56JL194X Step Pillion RH 1

8 19
16 56JL4K4X Step Holder RH 1
17
17 JR113091 Rubber Main Step 2
13 19 18 KHAA2520 Pin Cotter 4
18
23 19 JL113037 Pin Foot Step 4
22 20 39105515 Nut 1
9 20
21 21 JZ113061 Rubber Pad Footrest-Main 2
14 14A
13 22 JL113036 Rubber Pad Pillion Step 2
18
25

67 68
Front Wheel Direction
 Plate No.: 29
Rider & Pillion Foot Rest
No. Part No. Description Qty. Remarks
26
21 23 DT113014 Lock Plate LH 1
24 2 24 DT113015 Lock Plate RH 1
6 27
25 JL113035 Bolt M6x1 2
19
5 3

1
13 22
18 24
19
14A
11

4 7 15
13
6 18

10

11 12
16

8 19

17
13 19
18
23
22
9 20
21
14 14A
13
18
25

69 70
Front Wheel Direction
 Plate No.: 30
Front Fender
No. Part No. Description Qty. Remarks

1 JL181484 Protector Fork Lh 1

2 JL181485 Protector Fork Rh 1
3 JF181473 Collar 6
4 LAC00063 Bolt Socket 6
5 JL181209 Fender Rear Front 1
6 KADD0614 Bolt Flanged M6x1 2
7 JL181325 Plug 1
8 JL181221 Foam-rear Fender Front 1

4 3

1
6

8
7
6

71 72
Front Wheel Direction
 Plate No.: 31
Side Stand Assembly
No. Part No. Description Qty. Remarks
15 16
1 JL113229 Stand Side 1
2 JL113231 Bracket Side Stand Mtg 1
17
3 KADF0812 Bolt Flanged 1
4 LAD00135 Bolt Flange - M8 x L70 1
19 5 JF401405 Side Stand Switch 1
18
6 LCH00001 Nut Nyloc - M10 1
13 7 DF161102 Bolt For Side Stand Mounting 1
8 JL401417 Magnet Holder 1
9 JL113209 Spring Side Stand 1
10 DH161146 Cover - Spring Side Stand 1
14

11 JL113237 Cover Switch Stand Side 1

12 KCBA0604 Nut Hex 1
13 36JL0025 Kit Center Stand 1
4 2 14 DG161124 Damper 1
3
6 15 JL113210 Bush Main Stand LH 2
11 5
16 LAD00134 Bolt Flange - M8 x L60 1
17 JL113207 Spring Main Stand 1
18 JL113212 Cover Spring Main Stand 1
13 19 JL113206 Spring Main Stand With Cover 1
1 7

12
8 9

10

73 74
Front Wheel Direction
 Plate No.: 32
Tubeless Tyre & Wheel
No. Part No. Description Qty. Remarks

1 JL131039 Tyre Front 1

3 1 2 DK151026 Valve Tubeless Tyre 2
3 56JL604X Front Wheel Satin Black 1
4 56JL614X Rear Wheel Satin Black 1
5 JL131266 Tyre Rear 1

4 5
2

75 76
Front Wheel Direction
 Plate No.: 33
Front Wheel Hub
No. Part No. Description Qty. Remarks
9
1 1 JL131057 Axle 1
7 2 JG131020 Collar Assembly Wheel Front 1
3 KPBC6202 Bearing - Ball 2
4 DG151005 Seal Oil 1
5 JG131001 Spacer Assembly Front Wheel 1

3
6 DG151005 Seal - Oil 1
5
7 JG131889 Disc 320 mm 1
17 8 JL131058 Sensor Disc Front 1
6
16 9 JD131811 Special Bolt M8 6
10 JG131020 Collar 1

8 11 LDB00029 Washer 1
14 12 LCJ00002 Nut - U M14 1
13 DK201164 Sensor speed wheel 1
3 14 KADD0614 Bolt Flanged 1
2 15 DT131878 Clamp W ABS Hose 1

16 KEBB3515 Circlip Internal 1

17 KACA0508 Bolt Socket 5
4
13

10
12
11

15

77 78
Front Wheel Direction
 Plate No.: 34
Master Cylinder - Front
No. Part No. Description Qty. Remarks

1 JL132018 Cylinder master assly. front 1

2 DJ191029 Bolt Front Bracket l 1
3 DJ191030 Nut 1
2 4 DH191062 Oil Window Kit 1
13
5 DJ191031 Screw 2

6 DE191029 Cover - Reservoir 1

7 36PD0053 Kit Diaphragm 1
3 8 36JL0319 Kit Fasting Cap 1
5
5 9 DJ201109 Switch brake 1
SE

6
:U
G T3-4
NIN O OM
AR LY D FR ER
W

BR
S E
N
E
ID
O FLU TAIN
AK CO CA G
N P
D LER VIN
ALE FIL MO
E
10 DJ191026 Washer - Copper 8
A AN E R
CLE FO
R
BE

4
11 GL131827 Bolt - Banjo 4
10
12 36PD0051 Minor Kit M Cylinder 1
10 13 36JL0320 Lever Kit 1
11
14 14 36PD0050 Major Kit M Cylinder 1
7
12

1 8
9

10

10
11

79 80
Front Wheel Direction
 Plate No.: 35
Caliper Assembly - Front
No. Part No. Description Qty. Remarks

1 JL132013 Caliper Assy Brake Front 1

4
2 YJR05034 Screw Bleeder 1
3 DJ151070 Bleeder Cap 1
1 4 DH151039 Bolt Flange :- Re-coated (M8) 2
2
5 JR131827 Disc Pad 1
3

6 36JR0047 Minor Kit 1

7 36JR0046 Major Kit 1

5 2 PISTON SEAL

DUST SEAL

BLEEDER CAP

PROTECTION BOOT

INSULATOR

CALIPER PISTON

BLEEDER SCREW

PAD SPRING

81 82
Front Wheel Direction
 Plate No.: 36
Anti-Lock Brake System
No. Part No. Description Qty. Remarks

1 JL132024 ABS Unit Wet 1

2 36JL0318 Hose Front M Cylinder to ABS Unit 1
3 36JL0317 Hose ABS Unit to Front Caliper 1
1 4 JF1138 52 Bracket ABS 1
5 LAE000 42 Bolt flanged small 2
5
4 7 6 DT131875 Clamp brake hose 1
7 KAAA0622 Bolt 1
14 6 8 DJ191026 Copper Washer 8
2
9 GL131827 Benjo Bolt 4
15
10 36JL0244 Hose Rear M Cylinder to ABS unit 1
12
11 36JL0245 Hose ABS unit to Rear Caliper 1
12 JL131992 Bracket Hose Brake Rear 1
13 KCGC0606 Nut For Bracket Hose Brake Rear 1
10 3
11 14 JL132023 Clamp Hose 1
15 LAC00010 Bolt 2

83 84
Front Wheel Direction
 Plate No.: 37
Rear Disc Brake Master Cylinder & Caliper
No. Part No. Description Qty. Remarks

1 JR131883 Caliper assembly rear 1

21
2 JL132022 Assly Cylinder Master Brake Rr 1
3 4 3 36JR0052 Kit Brake Fluid Reservoir 1
4 DK151069 Banjo Bolt 2
5 36DH4180 Kit Holder Bracket Caliper End 1
4 6 8

7 6 36JL0323 Kit Hose - Reservoir 1

1 7 LAD00077 Bolt 2
20 8 DE191010 Copper Washer 4
9 36DH4178 Kit Bleeder Screw End 1
16 22 10 36DH4179 Kit Caliper Hardwares End 1

11 36DH4175 Major Kit Rear Caliper 1

14
12 36DH4177 Kit Minor Rear Caliper 1
15
13 36DH4174 Disc Pad Set Rear Caliper 1
11 14 30191038 Pin 1
10 15 KDAA0611 Washer Plain 1
9

16 KHAA2015 Pin Cotter 1

17 36DH4176 Kit Piston Seal Rear Caliper 1
18 36JR0049 Master Cyl. Major Kit 1
19 36JL0322 Master Cyl. Minor Kit 1
20 36DH4181 Kit Filler Union 1
13
12 17 5
21 KADD0614 Bolt 1
22 36JL0321 Master Cylinder Push Rod-fork Kit 1

85 86
Front Wheel Direction
 Plate No.: 38
Rear Wheel Hub
No. Part No. Description Qty. Remarks

1 DK201164 Sensor speed wheel 1

9 2 KADD0614 Bolt Flanged 1
8 3 JL131203 Axle Rear 1
25
7 4 LDB00175 Washer Rear Axle RH 2
6 5 LCL00004 Nut U Flange - M8 6
5
10 6 JL131211 Spacer for Coupling 1
21 7 DT131214 Seal Oil 1
20 8 KPAC6205 Bearing Ball Ordinary Clearance 1
3
19 9 DT131213 Coupling - 6 Plug 1
18
10 JG131228 Bolt - D 6
4
11 DT131210 Sleeve 1
12 JU131222 Damper Coupling 6
13 KPBC6202 Bearing - Ball - C3 Clearance 1
15 14 KEBB4217 Circlip Internal 1
15 JL131216 Collar Bearing Assy 1
17
14
16 KPBC6302 Bearing - Ball - C3 Clearance 1
12 17 30151082 Seal Oil 2
18 JF131861 Disc Rear Dia - 230 mm 1
19 DH151040 Bolt Socket - M6 x 1 x L16 6
2 20 TA131845 Sensor Disc Rear 1

13 21 JG131220 Screw Pan Cross - M6 x 1 x L12 3

22 DK151082 Spacer II 1
26 23 DK151081 Spacer I 1
11
24 LCJ00002 Nut - U - M14 1
1 25 36Jl0316 Kit Chain Sprocket 1
24
4
26 JF131871 Clip separator 1
23
22

87 88
Front Wheel Direction
 Plate No.: 39
Rear Brake Pedal
No. Part No. Description Qty. Remarks

1 JL161017 Brake Pedal 1

2 KADD0610 Bolt Flanged 1
3 JL131928 Assembly Brake Shaft 1
5
4 DH191013 Spacer Brake Shaft assly. 1
5 JL401406 Brake Switch - Rear 1

6 59040025 Bolt Flanged 1

7 7 JL113033 Bracket Rear brake switch 1
2 8 JL161006 Spring Rear Brake Switch 1
9 DH191006 Spring - Brake Pedal 1
8 10 KJAA1424 ‘O’ Ring 2
1
6

10

4
9

89 90
Front Wheel Direction
 Plate No.: 40
Handle Bar Assembly
No. Part No. Description Qty. Remarks

1 JL401425 Switch Control Lh 1

2 JL401426 Switch Control Rh 1
3 JY161008 Lever Assembly Clutch 1
2 4 JL161018 Assly Lever & Holder LH 1
1
20 5 56JL3333 Bracket Upper 1

17
6 LAD00244 Bolt 2
16
18 7 JL401403 Igition Switch 1
19 8 39242511 Plain Washer 2
9 LCH00001 Nut Nyloc 2
10 36JL0279 Lock Set 1
21 12
22 10 11 JY151011 Bolt Flanged 1
12 JZ161028 Lever Pivot Bolt 1
23
13 LBU00012 Screw Pan Cross 1
15 24 14 JG401426 Switch Clutch 1
25 28
14 7 15 KADT0625 Bolt Flanged 1
13 26
3 27 16 JL151069 Grip Lh 1
17 56JU5A1Q Handle Holder Top 1
4 18 DH181022 Weight Handlebar 2
19 KACJ0655 Bolt Socket 2
29 11 20 LAC00111 Bolt Socket 4
5 6
8
21 56JLP24X Handlebar 1
9
22 56JU5B1Q Handle Holder Bottom 1
23 LAC00092 Bolt Soket 2

91 92
Front Wheel Direction
 Plate No.: 40
Handle Bar Assembly
No. Part No. Description Qty. Remarks

24 39242511 Plain Washer 2

25 TA151015 Damper 2

2 26 TA151026 Spacer 2
1
20 27 TA151015 Damper 2
28 KACF0830 Bolt Socket M8x1.25 2
17
16
18
19

21 12
22 10

23
15 24
25 28
14 7
13 26
3 27

29 11
5 6
8
9

93 94
Front Wheel Direction
 Plate No.: 41
Front Fork
No. Part No. Description Qty. Remarks
3
1 JL121035 Fork front 1
14 16 2 YJF19009 Lock Nut 2
13 17 3 JF113851 Clamp hose 2
4 YJL23001 LH Pipe Inner with Axle Clamp 1
5 YJL23002 RH Pipe Inner with Axle Clamp 1
6 6
6 JG121012 Fork top bolt 2
2 2
7 YJL23006 Fork Outer Yube Sub Assembly 2
8 LDB00036 Washer plain 2
9 YJL23004 Piston rod assembly 2
10 JU121009 Oil seal stopper (Circlip) 2

11 YJL23005 Screw cap inner pipe 2

15 15 12 JG121028 Outer dust cap 2
7 7
13 LAC00010 Bolt socket - M6 2
14 JG113832 Sleeve for abs hose clamp 2
8
15 YJL23003 Main spring & Washer 2
18 10 18
16 JF121020 Bracket assembly under 1
12 17 JY121011 Bolt socket - M8 6
19 19 18 JG121057 Oil seal kit for single leg assly. 2
11 11
19 YJF19008 Rubber damper 2

4 5

9 9

15 15 17
15 15
15 15

95 96
Front Wheel Direction
 Plate No.: 42
Petrol Tank, Cap Tank & Gauge Fuel
No. Part No. Description Qty. Remarks
3 1 JL171841 Fuel Tank Assly 1
2 JL171073 Damper Tank Cvr Resting RR 1
11 2 5 3 KACF0516 Bolt Socket 6
4 4 JL171049 Damper Ring Tank Cap 1
5 5
5 36JL0012 Kit Tank Damper 1

6 JF171822 Fuel Pump 1

7 JP171820 Plate Pressure Fuel Pump 1
9 1 8 LAD00154 Bolt 6
9 JL171063 Pipe Drain 1
12 10 JY171146 Ring - O Fuel Pump 1

11 JD171059 Damper 1
10
12 JG171030 Clamp 1
6 13 LAD00151 Bolt Flange - M8x1.25xL21.5 3
24 14 DT171075 Collar 1
18 15 JL171018 Grommet Tank Mtg Front 1
8
7
16 JL171019 Collar 2
17 JL171020 Grommet Tank Mtg Rear 2
18 36JF0288 Kit Strainer Fuel Pump Pricol 1

13

13 16

14 17
15

Fuel Tank Front Mounting Fuel Tank Rear Mounting

97 98
Front Wheel Direction
 Plate No.: 43
EVAP System
No. Part No. Description Qty. Remarks

1 JR171620 Canister 1
2 JU171606 Valve Purge 1
3 JL171867 Pipe Fuel 1
4 JF171659 Pipe Fuel 1
5 KADA0612 Bolt Flanged M6x1 2

6 JG171086 Connector Tube Evap 1

7 JF171807 Tube Canister Drain -k16b 1
8 KCGA0606 Nut Hex Flanged M6x1 1
9 JG171030 Clamp 2
10 33141008 Clamp 4
6 2
13 11 JZ171055 Strap Canister 2
16 15 8
12 JL113830 Bracket Canister Mtg (k14) 1
13 DG121025 Clamp 1
10 14 DP121028 Clamp 1
9
4 15 JL171618 Pipe Purge Valve to Connector 1
14 1
11 16 DT171847 Pipe Fuel 1
7
3
10

10

12

99 100
Front Wheel Direction
 Plate No.: 44
Fitting - Petrol Tank Cover
No. Part No. Description Qty. Remarks

1 JL171140 Cover Assembly Tank Middle 1

2 JL171149 Bracket Cover Tank Lh 1
21 3 JL171150 Bracket Cover Tank Rh 1
21 4 JG171031 Nut Clip M5 8
1 3 21 5 JL171049 Damper Ring 1
18 17 4
6 JL171078 Pad Tank Cover 1
9 7 KADD0514 Bolt Flanged 2
8 39214124 Washer, Nylon 8
19 9 LAC00022 Bolt Socket-special Head 2
17
10
16 18 10 31161078 Washer Plain 2
20
11 LAC00034 Bolt Socket 4
2
4 12 LDB00023 Washer Plain 4
13 JL171070 Tank Cover Grommet 4
14 JL171071 Collar 4
15 JL171024 Damper Structure Mtg 4

13 14
11 16 JL171057 Damper -tank Sidecover 4
5
17 KADA0516 Bolt Flanged 2
18 KADD0616 Bolt Flanged 2
20 19 JL171040 Collar 2
6 20 KBUA0516 Screw Truss 8

12 8 21 KBRC4213 Screw Tapping Pan Cross 16

15
5
7

101 102
Front Wheel Direction
 Plate No.: 45
Fitting - Side Covers, Seat Cowl
No. Part No. Description Qty. Remarks
3 1 LAL00003 Bolt 6
2
2 JZ171124 Grommet 4
3 JL181288 Screw Stepped 2
4 KBUA0612 Screw Truss 2
18/19
5 59020001 Self Tap Screw 10
5

6 LDA00007 Washer Plain 6

7 JL181729 Cowl Seat Middle Inner 1
8 JL181939 Cowl Seat Lh 1
9 JL181940 Cowl Seat Rh 1
10 JL181728 Cowl Seat Middle Upper 1
1 13 7
4 2
11 JL181938 Cowl Seat Central 1
12 JL181220 Grommet -2 Seat Cowl 2
13 JL181219 Grommet -1 Seat Cowl 2
10
14 KBUA0514 Screw Truss 7
17 6
1 9 15 JK401801 Foam Battery Band 1
16

16 JG171031 Nut Clip M5 7

8 17 KBRC4813 Screw Tapping Pan 16

18 JL181954 Side cover Mesh LH 1

15 14
11 19 JL181955 Side cover Mesh RH 1
1

12

103 104
Front Wheel Direction
 Plate No.: 46
Instrument Cluster & Socket Charger
No. Part No. Description Qty. Remarks

1 JL402424 Instrument Cluster 1

2 JL181710 Structure Fairing 1
1
3 JL403403 Socket Charger 1
4 JL181922 Cover Speedometer Front 1
18
5 JL181921 Flap Speedometer 1

6 18 5 6 JG181238 Grommet Dashboard 2

7
7 LDB00007 Washer Plain 2
9 10 8 KCAA0504 Nut Hex 2
8
11 9 GL181263 Bead Front Shield 6
9
4 10 JU181912 Collar 2

2 11 JL181730 Grommet 2
12 LAD00311 Bolt Flanged Step 1
13 JR181781 Grommet 2
14 JG113404 Clip Nut 1
3 15 LAC00054 Bolt Socket 2

16 JP181232 Sleeve Radiator 2

14 17 JL181931 Bracket Pivot Lower 1
18 LBU00145 Screw Button Head 2
19 JH181426 Grommet Under Tray 2
13

19 12

15 16 17

105 106
Front Wheel Direction
 Plate No.: 47
LED Head Lamp & Fairing
No. Part No. Description Qty. Remarks

20 1 JL401030 Lamp DRL Lh 1

4 5 2 JL401031 Lamp DRL Rh 1
10
3 JL401032 Lamp Head 1
21 6
19
4 LBU00065 Screw Truss 2
11 5 LDB00074 Washer Plain 2
17
25 8
13
18
6 JL181919 Carrier Mask 1
27 7 BF182539 Washer 10
8 KBUC0510 Screw Truss 4
26 7 9 KBRA4216 Screw Tapping 4
9
10 05161256 Clip Nut-m6 2
7

15 11 39183911 Washer Plain 4

12 12 JF181362 Foam 2
13 JG171031 Nut Clip M5 2
14 JL181925 Fairing Rear Lh 1
2
13 15 KBRA4213 Screw Tapping Pan Cross 6
3 14
16 13 16 DT401017 Pivot Screw 2
16 7 17 JL181920 Windshield 1
1 15
18 JL181247 Grommet Wind Screen Mounting 1
19 JF181277 Well-nut For Mask 2
20 JG181235 Washer Special 2

23
21 LBS00002 Screw Csk-socket 2
22
22 JL181926 Fairing Rear Rh 1
23 GL181817 Tape Dual Lock 4
24 JL181950 Tape 2

107 108
Front Wheel Direction
 Plate No.: 47
LED Head Lamp & Fairing
No. Part No. Description Qty. Remarks

20 25 JL181947 Protector Assly 1

4 5
10
26 JL181948 Tape 1
21 6
19
27 JL181949 Tape 2
11
17
25 8
13
18
27

26 7
9
7

15

12

2
13

3 14
16 13
16 7

1 15

23
22

109 110
Front Wheel Direction
 Plate No.: 48
Indicator Light Assembly
No. Part No. Description Qty. Remarks

1 JP401019 Indicator Assembly Fr Rh 1

2 JP401018 Indicator Assembly Fr Lh 1
3 KCBA1006 Nut Hex M10x1.25 2
4 KDFB1018 Washer Toothed Internal 2
5 KDAA1018 Washer Plain 2
1

3 6 JY401024 Indicator Assembly Rr Lh 1

5 4
2 7 JY401025 Indicator Assembly Rr Rh 1
8 LCL00001 Nut Flanged 2

111 112
Front Wheel Direction
 Plate No.: 49
Tail Lamp Assembly & Number Plate Mounting
No. Part No. Description Qty. Remarks

1 JL401002 Lamp Tail Assy 1

3
2 2 JG171031 Nut Clip M5 3
19
3 KBUA0514 Screw Truss 3
1
20 4 56JLBP4X Bracket Indicator Rear 1
5 LAD00149 Bolt Flanged 2

21
6 PA402204 Band(length 110mm) 4
17 7 JY401042 Reflector Reflex 2
8 KCAC0605 Nut Hex M6x1 1
9 PF181416 Collar 2
10 KCGA0606 Nut Hex Flanged M6x1 4
4

11 JL232893 Extension Structure Plate No Rr 1

12 JG401006 Number Plate Illumination Lamp 1
13 KBRD4213 Screw Tapping 2
5 14 JU401024 Reflector Reflex 1
6
15 KCGC0505 Nut Hex Flanged 1
11
13 7
12 16 JF232807 Bracket Plate Number Rear 1
17 LBU00128 Screw Button Head M6x1 2
14
7 10 18 JZ232805 Foam Rear Number Plate 1
8 9
19 05161256 Clip Nut-m6 2
16 20 JL232883 Bracket Plate Number Front 1
15

10 21 39150811 Washer Plain 2

18

113 114
Front Wheel Direction
 Plate No.: 50
Electrical Equipments
3 No. Part No. Remarks
11 Description Qty.
10 17 18/19
9 1 JL402311 Harness wiring 1
25 2 JL403000 Relay Inter lock 5
8
3 JG402229 Fuse 15A 6
4 JG402230 Fuse Mini 30A 1
5 DT402226 Fuse 7.5A Mini 2
2
12
6 JG402228 Fuse 10A 1
4 5 6 7 JP403002 Damper Relay Starter 1
1
8 JL380605 Earth Cable 1
9 JU401602 Horn 1
13 10 KDBB0818 Washer Plain 1

11 KADF0814 Bolt Flanged 1

12 PA402207 Cable Relay - Motor 1
13 DH201124 Relay Starter 1
20 40
7 14 JF181272 Battery Case 1 With grommets
22 36
15 KAEA0622 Bolt flanged 3
39
16 KADD0616 Bolt Flanged 1
21 14
17 PA402204 Band (Length 110 mm) 2
15 18 JD402212 Band (Length 200 mm) 17
16 30
19 JD402217 Band (Length 150 mm) 7
23
34
20 KACF0612 Bolt Socket - M6 x 1 x L12 2
24
26 31 21 JF113842 Bracket Sensor Roll Over 1
33 32 22 LAC00008 Screw Button Head - M6 2
29 35 23 JY403604 Sensor Roll Over 1
24 KCHA0608 Nut Nyloc 2
27 25 JF171064 Band Cable 1
37 26 JY113864 Bracket ECU Mtg Top C Sample 1
28 27 JY171007 Pad Rubber New ECU 2
46

115 116
Front Wheel Direction
 Plate No.: 50
Electrical Equipments
3 No. Part No. Remarks
11 Description Qty.
10 17 18/19
9 28 JY113874 Damper ECU C Sample Mtg Top 1
25 29 JY113877 Damper ECU Locator 1
8
30 JF181282 Bracket ECU Lower 1

31 JY113872 Pad Resting ECU C Sample LH 1

2
12 32 JY113873 Pad Resting ECU C Sample RH 1
33 KCGA0606 Nut Hex Flanged 4
4 5 6 34 TA351404 ECU EMS 1
1
35 JF181308 Rubber Battery Case 1

13 36 JL113825 Band Battery Case - Vert ECU 1

37 DT181022 Band Battery Case 1
38 36JU0015 Kit Battery 12V 8Ah 1
39 JF402004 Regulator 1
40 KAED0630 Bolt Flanged 2
20 40
7
22 36

39

21 14

30 15
16
23
34
24
26 31
33 32
29 35

27
37
28
46

117 118
Front Wheel Direction
 Plate No.: 51
Tool Kit
No. Part No. Description Qty. Remarks

1 JF231068 Tool kit 1 Not Serviceable

2 DK221024 Tool kit band 2

Screw Driver
Spanner Flat 08 x 10
Key Allen - 6 MM

119 120
Front Wheel Direction
 Plate No.: 52
Accessories - Mirror, Grab Handles & Saree Guard
No. Part No. Description Qty. Remarks

1 56JL5U33 Grab Handle LH 1

3
9 20
2 56JL5V33 Grab Handle RH 1
3 LAC00035 Bolt Master 4
18 23
19 4 JL231222 Guard Saree 1
2 5 JL231236 Cover Structure Inner 1
6 JL231237 Cover Structure Outer 1
1 7 LBU00247 Screw Button Head M10x1.25 2
13 14 8 KDBB1022 Washer Plain 2
9 JF231608 Mirror LH 1
13 22
14 10 JF231609 Mirror RH 1
10
11 JF231239 Guard Leg LH 1
12
20 12 JF231240 Guard leg RH 1
13 KDAB0816 Washer Plain Small 2
18
19 14 LAC00165 Bolt socket - M8 x 1.25 2
15 LBR00002 Screw Tapping Pan Dia 5 2
11

16 16 LCL00007 Nut U flanged - M8 2

23
17 JL181489 Fender Hugger 1
17
23 18 LDH00016 Washer conical 2
16 19 KDAA0816 Washer plain small 2
4
20 LAC00141 Bolt socket - M8 2
21

21 LAC00037 Screw Butn 2

22 JL231402 Foam Grab Handle LH 1
5
23 JL231403 Foam Grab Handle RH 1
6
8
7

15

121 122
Front Wheel Direction
 Plate No.: 53
Painted Parts and Decals
No. Part No. Description Qty. Remarks

1 52JL2968 Cowl Seat Outer Lh Pewter Grey 1

11/12
52JL2946 Cowl Seat Outer Lh Brooklyn Black 1
14
52JL2935 Cowl Seat Outer Lh+Decal 1
1/2 52JL2956 Cowl Seat Outer Lh Pearl Met White 1
9/10
5/6 3/4 2 52JL2969 Cowl Seat Outer Rh Pewter Grey 1
52JL2947 Cowl Seat Outer Rh Brooklyn Black 1
52JL2936 Cowl Seat Outer Rh+Decal 1
15/16
52JL2957 Cowl Seat Outer Rh Pearl Met White 1
13

3 52JL2959 Side Mask Lh Assly Pewter Grey 1

52JL2931 Side Mask Lh Assly Racing Red 1
52JL2941 Side Mask Lh Assly Brooklyn Black 1
52JL2949 Side Mask Lh Assly Pearl Met White 1

4 52JL2960 Side Mask Rh Assly Pewter Grey 1

7/8
52JL2930 Side Mask Rh Assly Racing Red 1
52JL2942 Side Mask Rh Assly Brooklyn Black 1
17 27 28/29 30/31 52JL2950 Side Mask Rh Assly Pearl Met White 1

5 52JL2928 Asly Side Cover Lh Satin Black 1

6 52JL2927 Assy Side Cover Rh Satin Black 1

18 19 20 21 7 52JL2869 Belly Pan Assly Lh Ebony Black 1

52JL2962 Belly Pan Assly Lh Pewter Grey 1

8 52JL2868 Belly Pan Assly Rh Ebony Black 1

52JL2961 Belly Pan Assly Rh Pewter Grey 1
24/25 26

9 56JLCU4X Cvr Tank Lh Jl171147 Satin Black 1

10 56JLCV4X Cvr Tank Rh Jl171148 Satin Black 1

123 124
Front Wheel Direction
 Plate No.: 53
Painted Parts and Decals
No. Part No. Description Qty. Remarks

11 56JLT195 Fairing S Inner Lh Rac Red 1

11/12
56JLT19V Fairing Side Inner Lh Brooklyn Black 1
14
56JLT142 Fairing Side Inner Lh Perl Met Whit 1
1/2 56JLT132 Fairing Side Inner Lh Pewter Grey 1
9/10
5/6 3/4 12 56JLT295 Fairing S Inner Rh Rac Red 1
56JLT29V Fairing Side Inner Rh Brooklyn Black 1
56JLT242 Fairing Side Inner Rh Perl Met Whit 1
15/16
56JLT232 Fairing Side Inner Rh Pewter Grey 1
13

13 52JL2937 Frnt Fnder Assly + White Red Decal 1

52JL2970 Frnt Fnder Assly+Pewter Grey Decal 1

14 52JL2954 Tank cover Top Pearl Met White+Decal 1

52JL2966 Tank Cover Top Pewter Grey+Decal 1
52JL2938 Tank Cover Top Racing Red+Decal 1
7/8
52JL2945 Tank Cover Top Brooklyn Black+Decal 1

17 27 28/29 30/31 15 52JL2952 Tank Flap Lh Pearl Met White+Dcl 1

52JL2964 Tank Flap Lh Pewter Grey+Dcl 1
52JL2939 Tank Flap Lh Racing Red+Dcl 1
52JL2943 Tank Flap Lh Brooklyn Black+Dcl 1

18 19 20 21 16 52JL2953 Tank Flap Rh Pearl Met White +Dcl 1

52JL2965 Tank Flap Rh Pewter Grey +Dcl 1
52JL2940 Tank Flap Rh Racing Red+Dcl 1
52JL2944 Tank Flap Rh Brooklyn Black+Dcl 1

24/25 26
17 36JL0314 Kit Decal Belly Pan Lh 1
36JL0313 Kit Decal Belly Pan P Grey Lh 1

125 126
Front Wheel Direction
 Plate No.: 53
Painted Parts and Decals
No. Part No. Description Qty. Remarks

18 36JL0300 Kit Decal Cover Tank E Blk 1

11/12
36JL0302 Kit Decal Cover Tank P Grey 1
14
36JL0301 Kit Decal Cover Tank P M Wh 1
1/2 36JL0299 Kit Decal Cover Tank Red 1
9/10
5/6 3/4 19 36JL0308 Kit Decal Cowl Seat E Black 1
36JL0310 Kit Decal Cowl Seat P Grey 1
36JL0309 Kit Decal Cowl Seat P M White 1
15/16
36JL0307 Kit Decal Cowl Seat R Red 1
13

20 36JL0311 Kit Decal Fender Front 1

36JL0312 Kit Decal Fender Front P Grey 1

21 36JL0304 Kit Decal Flap Tank E Black 1

36JL0306 Kit Decal Flap Tank P Grey 1
36JL0305 Kit Decal Flap Tank P M White 1
7/8
36JL0303 Kit Decal Flap Tank R Red 1

17 27 28/29 30/31 22 JF233560 Decal Cover Clutch 1

23 JF233565 Decal Cover Magneto 1

24 JL233506 Decal Fairing Ebony Black Lh 1

18 19 20 21 JL233520 Decal Fairing Pearl M White Lh 1
JL233528 Decal Fairing Pewter Grey Lh 1
JL233492 Decal Fairing Racing Red Lh 1

25 JL233507 Decal Fairing Ebony Black Rh 1

24/25 26
JL233521 Decal Fairing Pearl M White Rh 1
JL233529 Decal Fairing Pewter Grey Rh 1
JL233493 Decal Fairing Racing Red Rh 1

127 128
Front Wheel Direction
 Plate No.: 53
Painted Parts and Decals
No. Part No. Description Qty. Remarks

26 JL233556 Decal Faring Front 1

11/12
14
27 JF233611 Decal Pulsar 2
1/2
9/10
28 JL233554 Decal Wheel Lh 2
5/6 3/4 JL233546 Decal Wheel Pewter Grey Lh 2

29 JL233547 Decal Wheel Pewter Grey Rh 2

15/16
JL233555 Decal Wheel Rh 2
13

30 JF233288 Emblem Fuel Injection Lh 1

31 JF233289 Emblem Fuel Injection Rh 1

7/8

17 27 28/29 30/31

18 19 20 21

24/25 26

129 130
Front Wheel Direction
 Plate No.: 54
Consumable Parts
1 2 3 No. Part No. Description Supply Application
Unit

1 83020576 Oil Bajaj DTS-i 10W50 BS VI 1.2 Ltr.

83020578 Oil Bajaj DTS-i 10W50 BS VI 1 Ltr.
-6nt
BSlia
comp
83020577 Oil Bajaj DTS-i 10W50 BS VI 100 ML. Top Up

2 36001058 Bajaj Coolant Koolex* 1 Ltr. Coolant Top-up/Replace

3 36DH4061 Brake Fluid DOT4 100 ml Disc Brake Top-up/Replace

4 5 6
4 36DH4052 Silicon grease 3 gm Caliper Pin

5 83020473 Grease Petamo GHY 441 3 gm Water Pump Seals

36DK0045 Grease Molycoat 200 gm For Starter Clutch Lubrication

6 36JL0181 Limaplex HTX 3 Grease 10 gm Steering Race

7 83020173 Multi Purpose Grease* -- Lubrication of Clutch Lever,

(Local Purchase) Brake Lever, Brake Pedal &
7 8 9 Side Stand

8 36001055 Chain Lubricant HP Make 1 kg Non - Sealed Chain

Lubrication
9 36001062 Liquid gasket L5910 50 ml Crankcase Joining

10 36314004 Fork oil 160 ml Front Fork Top-up/Replace\

36JG0087 Fork oil 480 ml (Dominar UG) 480 ml Front Fork Top-up/Replace\

11 36DH4029 Kit Spray Chain Lub 100 ml Sealed Drive Chain

10 11 12
12 36DH4071 Wonderfill Chain Spray 100 ml Sealed Drive Chain

* Marked items to be arrange from vendor or local market. Not applicable against
chassis number.

131 132
Front Wheel Direction
 Plate No.: 54
Consumable Parts
13 14 15 No. Part No. Description Supply Application
Unit

13 36DH4072 Rust Remover Spray Make - 100 ml For Removing Rust

Zorric 88 & Wonder fill easiner from Components

14 76010936 Loctite Thread locker 243* 50 ml For Screws & Bolts

15 76010937 Loctite retaining compound 638* 50 ml For Screws & Bolts

16 17 18 16 37004352 Touch up paint slate grey* 440 ml Touch up of Frame, Swing

Arm & Step Holder

17 37004353 Touch up paint Matte Silk black* 440 ml Touch up of Grab Handle,
Handle Bar & Handle Holder

18 36001060 Kibatsu touch up paint* 400 cc Touch up of Cylinder head,

Block & Alloy Wheels

19 37224018 Paint Bottle Schwartz Black* -- P-200NS Frame Touch-up

19 20 21
20 75680236 Petroleum Jelly (Local Purchase) -- For Battery Terminals
NA Distilled Water (Local Purchase) 1 Ltr. For Battery Level Top-up

21 NA SAE 90 oil (Local Purchase) –

22 62305084 WD40 Spray (Local Purchase) 400 ml Electrical Contact Cleaning

Spray

23 36001056 Carburetor Cleaning Spray* For Cleaning Carburetor/

22 23 24 Throttle Body

24 37254039 Corrosion Protection Spray* -- For Preventing vehicle

Proto quick LTP902 parts from rusting

* Marked items to be arrange from vendor or local market. Not applicable against
chassis number.

133 134
Front Wheel Direction
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 36JF0052 Assembly crankcase RH JF541013 Crankcase RH sub assembly
(Plug + breather pipe) 1 10 36DT0004 Tie band-W harness JD402212 Band 200 mm 8
JY541023 Bush crankshaft 1 JD402217 Band 150 mm 2
39256220 Needle roller bearing 1 PA402204 Band 110 mm 2
JY541038 Bush 1
JY541018 Bush insert 1 11 36JL0316 Kit Chain Sprocket JY551029 Sprocket Drive 1
JG601007 Special shaft seal ring (oil) 2 JG141001 Chain 520 H O Rings 1
LEB00001 Circlip internal 1 JG141002 Sprocket Driven 1

2 36JF0198 Kit valve repair K10UG JF511257 Seat spring valve 4

PD511246 Spring valve 4 12 36JL0317 Kit Hose Unit Abs-Caliper Front JL132019 Hose Unit Abs-Caliper Front 1
PD511208 Retainer spring valve 4 GL131827 Bolt Banjo 2
CB101022 Cotter valve 8 DJ191026 Copper Washer 4
CB101009 Seal valve stem 4
13 36JL0318 Kit Hose Cyl Master Fr-Unit Abs JL132020 Hose Cylinder Master Fr-Unit Abs 1
3 36JF0053 Assly clutch cover With Nozel DT541204 Clutch cover with plug 1 GL131827 Bolt Banjo 2
39199020 Bearing - needle 1 DJ191026 Copper Washer 4
JG541021 Oil nozzle 2
14 36JL0319 Fastening Cap Kit YJL23007 Fastening Cap Finished 1
4 36JF0054 Primary drive & driven JY551212 Gear primary drive 1 YJL23008 Fastening Cap Screw 2
JF551412 Clutch outer complete 1
15 36JL0320 Lever Kit YJL23009 Brake Lever Primary 1
5 36JF0195 Kit friction plate K10UG JF551421 Disc friction - A 4 YJL23011 Brake Lever Secondary 1
JY551420 Disc friction - C 3 YJL23012 Knob For Adjustable Cam 1
YJL23013 Rivet 1
6 36JF0197 Kit cam chain guide K10UG JY511227 Guide chain slack side 1 YJL23014 Lever Spring 1
JY511229 Guide chain tight side 1 YJL23015 Plain Washer 3 1
YJL23016 Plain Washer 2 1
YJL23017 Plain Washer 1 2
7 36JF0196 Kit block piston K10UG JF521009 Block cylinder 1 YJL23018 Bush 1
JF521216 Piston assembly 1
16 36JL0321 Master Cylinder Push Rod-Fork KitYJL23019 Push Rod For Rear M/Cyl.-K4/K11 2Ch 1
8 36JF0060 Piston ring set JF521215 Ring piston top 1 YJL23021 Push Rod Fork 1
JF521212 Ring piston second 1 YJL23022 Hexagonal Lock Nut,M6X1 1
JF521213 Ring piston oil 1
17 36JL0322 Master Cyl Seal Kit YJL23023 Primary Lip Seal Dia 12 1
9 36DK0159 Steering cone DK181050 Cage Bearing Steering Top 1 YJL23024 Secondary Grommet Dia 12 1
36DV0007 Kit Steering Cone ( New ) 1 YJL23025 Diaphragm Seal 1
DG181003 Washer 1 YJL23026 Protection Boot 1
DG181004 Seal - Oil 1
DK181051 Cage Bearing Steering Bottom 1

135 136
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

18 36JL0323 Hose Tube -Clamp Kit YJL23027 Reservoir Hose Tube 1 JL233604 Decal Flap Tank Upper P Grey Lh 1
YJL23028 Hose Clamp 2 JL233605 Decal Flap Tank Upper P Grey Rh 1

19 36JL0299 Kit Decal Cover Tank Red JL233495 Decal Cover Tank Upper R Red Rh 1 27 36JL0307 Kit Decal Cowl Seat R Red JL233502 Decal Cowl Seat Upper R Red Lh 1
JL233494 Decal Cover Tank Upper R Red Lh 1 JL233503 Decal Cowl Seat Upper R Red Rh 1
JL233497 Decal Cover Tank Lower R Red Rh 1 JL233504 Decal Cowl Seat Lower R Red Lh 1
JL233496 Decal Cover Tank Lower R Red Lh 1 JL233505 Decal Cowl Seat Lower R Red Rh 1

20 36JL0300 Kit Decal Cover Tank E Blk JL233508 Decal Cover Tank Upper E Blk Lh 1 28 36JL0308 Kit Decal Cowl Seat E Black JL233516 Decal Cowl Seat Upper E Black Lh 1
JL233510 Decal Cover Tank Lower E Blk Lh 1 JL233517 Decal Cowl Seat Upper E Black Rh 1
JL233509 Decal Cover Tank Upper E Blk Rh 1 JL233518 Decal Cowl Seat Lower E Black Lh 1
JL233511 Decal Cover Tank Lower E Blk Rh 1 JL233519 Decal Cowl Seat Lower E Black Rh 1

21 36JL0301 Kit Decal Cover Tank P M Wh JL233522 Decal Cover Tank Upper P M Wh Lh 1 29 36JL0309 Kit Decal Cowl Seat P M White JL233530 Decal Cowl Seat Upr P M White Lh 1
JL233523 Decal Cover Tank Upper P M Wh Rh 1 JL233531 Decal Cowl Seat Upr P M White Rh 1
JL233524 Decal Cover Tank Lower P M Wh Lh 1 JL233602 Decal Cowl Seat Lwr P M White Lh 1
JL233525 Decal Cover Tank Lower P M Wh Rh 1 JL233603 Decal Cowl Seat Lwr P M White Rh 1

22 36JL0302 Kit Decal Cover Tank P Grey JL233535 Decal Cover Tank Upper P Grey Rh 1 30 36JL0310 Kit Decal Cowl Seat P Grey JL233538 Decal Cowl Seat Upper P Grey Lh 1
JL233534 Decal Cover Tank Upper P Grey Lh 1 JL233539 Decal Cowl Seat Upper P Grey Rh 1
JL233532 Decal Cover Tank Lower P Grey Lh 1 JL233606 Decal Cowl Seat Lower P Grey Lh 1
JL233533 Decal Cover Tank Lower P Grey Rh 1 JL233607 Decal Cowl Seat Lower P Grey Rh 1

23 36JL0303 Kit Decal Flap Tank R Red JL233498 Decal Flap Tank Lower R Red Lh 1 31 36JL0311 Kit Decal Fender Front JL233548 Decal Fender Front Lh 1
JL233499 Decal Flap Tank Lower R Red Rh 1 JL233549 Decal Fender Front Rh 1
JL233500 Decal Flap Tank Upper R Red Lh 1
JL233501 Decal Flap Tank Upper R Red Rh 1 32 36JL0312 Kit Decal Fender Front P Grey JL233557 Decal Fender Front P Grey Lh 1
JL233558 Decal Fender Front P Grey Rh 1
24 36JL0304 Kit Decal Flap Tank E Black JL233512 Decal Flap Tank Lower E Black Lh 1
JL233513 Decal Flap Tank Lower E Black Rh 1 33 36JL0313 Kit Decal Belly Pan P Grey Lh JL233541 Decal Belly Pan Lower P Grey Lh 1
JL233514 Decal Flap Tank Upper E Black Lh 1 JL233545 Decal Belly Pan Lower P Grey Rh 1
JL233515 Decal Flap Tank Upper E Black Rh 1 JL233543 Decal Belly Pan Upper P Grey Lh 1
JL233544 Decal Belly Pan Upper P Grey Rh 1
25 36JL0305 Kit Decal Flap Tank P M White JL233526 Decal Flap Tank Lwr P M White Lh 1
JL233527 Decal Flap Tank Lwr P M White Rh 1 34 36JL0314 Kit Decal Belly Pan Lh JL233550 Decal Belly Pan Lower Lh 1
JL233600 Decal Flap Tank Upr P M White Lh 1 JL233551 Decal Belly Pan Lower Rh 1
JL233601 Decal Flap Tank Upr P M White Rh 1 JL233552 Decal Belly Pan Upper Lh 1
JL233553 Decal Belly Pan Upper Rh 1
26 36JL0306 Kit Decal Flap Tank P Grey JL233536 Decal Flap Tank Lower P Grey Lh 1
JL233537 Decal Flap Tank Lower P Grey Rh 1

137 138
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

139 140
Amendment Sheet Amendment Sheet
AMENDMENT SHEET (PARTS ADDED) AMENDMENT SHEET (PARTS DELETED)
SR. PAGE FIGURE SR. PAGE FIGURE
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