Pulsar 200NS Spare Parts Catalogue

Bajaj Auto Limited Akurdi Pune 411 035 India Tel +91 20 27472851 Fax +91 20 27407385 www.bajajauto.com

Spare Parts Catalogue

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.: 71111474

REV. 00, JUNE 12

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 200 NS’ Motorcycle. This catalogue has been specially designed to assist you in selecting the correct parts for procurement to maintain 100% availability.

1. How to Read the Catalogue : Open the catalogue and from the pictorial index locate the group in which the part you want to find is present. Turn over to the concerned page number (as given by pictorial index). Now find out the figure of the part you wish to order. Write down the part number against that particular figure number from the text.

The Bajaj spares are subjected to the stringent quality control standards to ensure longer life of the vehicle. It is therefore necessary that only the Genuine Bajaj Spares are used. In a continual effort to improve Performance and Efficiency of the vehicles, Specifications, Diagrams, Illustrations and Part Numbers can change without notice. Consequently, the description in this Spare Parts Catalogue cannot therefore be final and binding on us. The modifications / alterations which are carried out after the issue of catalogue, will be conveyed to you through our Service Circulars. You requested to make necessary corrections in the Parts Catalogue as per circulars so as to keep your catalogue up-to-date. This will ensure appropriate and speedy delivery of the Spare Parts as the order placed bear the latest part numbers.

this are the the will

In case, if you need any technical assistance contact the concerned Regional Office or write to us on the following address : Bajaj Auto Limited Service Department Akurdi, Pune 411 035 India Phone : 020-27406557 Fax : 020-27407385

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 number of the part you wish to order. 2. How to Order Spare Parts : The part number and the description of the part required should be invariably mentioned in the order as per the catalogue text. 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 quantity shown against the part number is the quantity per vehicle for that group so that particular quantity should be multiplied by the number of sets required. 3. Part Number System : We have used 8 digit system for part numbers. The model or 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 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 identify the spare parts easily. 4. Abbreviations : The following abbreviations are used in this catalogue. Assly Assembly V Volts 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

Index Plate No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Index Description Cover Cylinder Head Cylinder Head Valve Camshaft / Tensioner Cylinder and Piston Crankshaft Transmission Change Drum / Shift Fork Gear Change Mechanism Engine Assly / Crankcase RH Crankcase LH Balancer Idler Gear / Water Pump Oil Pump Radiator Cover Clutch Cover Magneto Clutch Assly Carburettor Air Cleaner Complete Silencer Assly Starter Assly Magneto, C.D.I. & H.T. Coil Seat Assly / Seat Lock Engine Mountings Frame and Frame Fitting Swing Arm / Rear Shock Absorber Pillion Foot Rest / Holder Mudguard- Front & Rear Stand Assembly Tyre/ Tube / Rim

Page No. 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60

Plate No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Description Front Hub Front Master Cylinder Front Disc Brake Rear Hub Rear Disc Brake System Rear Brake Pedal Handle Bar Assly Front Fork Painted Parts & Decals Radiator Cover Petrol Tank, Cap Tank & Gauge Fuel Fittings - Petrol Tank, Side Cover & Cover Seat Meter Assly. Control Cables Chain Case Head Lamp & Fairing Indicator Light Assly. Tail Lamp Assly. / Front No. Plate Electrical Equipments Tool Kit Accessories / Grab Handle Kits List For Pulsar 200 NS

Page No. 62 64 66 68 70 72 74 76, 78 80, 82 84 86 88 90 92 94 96 98 100 102 104 106

Amendment Sheet (Parts Added)

107, 108 109 111

Amendment Sheet (Parts Deleted)

112

Part Index

Pictorial Index

Pictorial Index

PLATE NO. : 1 COVER CYLINDER HEAD

PAGE NO. 1

PLATE NO. : 2 CYLINDER HEAD

PAGE NO. 3

PLATE NO. : 5 CYLINDER & PISTON

PAGE NO. 9

PLATE NO. : 6 CRANKSHAFT

PAGE NO. 11

PLATE NO. : 3 VALVE

PAGE NO. 5

PLATE NO. : 4 CAMSHAFT / TENSIONER

PAGE NO. 7

PLATE NO. : 7 TRANSMISSION

PAGE NO. 13

PLATE NO. : 8 CHANGE DRUM / SHIFT FORK

PAGE NO. 15

6

Pictorial Index

Pictorial Index

PLATE NO. : 9 GEAR CHANGE MECHANISM

PAGE NO. 17

PLATE NO. : 10 ENGINE ASSLY & CRANKCASE RH

PAGE NO. 19

PLATE NO. : 13 OIL PUMP

PAGE NO. 25

PLATE NO. : 14 RADIATOR

PAGE NO. 27

PLATE NO. : 11 CRANKCASE LH

PAGE NO. 21

PLATE NO. : 12 BALANCER IDLER GEAR/WATER PUMP

PAGE NO. 23

PLATE NO. : 15 COVER CLUTCH

PAGE NO. 29

PLATE NO. : 16 COVER MAGNETO

PAGE NO. 31

Pictorial Index

Pictorial Index

PLATE NO. : 17 CLUTCH ASSEMBLY

PAGE NO. 33

PLATE NO. : 18 CARBURETTOR

PAGE NO. 35

PLATE NO. : 21 STARTER ASSEMBLY

PAGE NO. 41

PLATE NO. : 22 MAGNETO, CDI & H.T. COIL

PAGE NO. 43

PLATE NO. : 19 AIR CLEANER COMPLETE

PAGE NO. 37

PLATE NO. : 20 SILENCER ASSEMBLY

PAGE NO. 39

PLATE NO. : 23 SEAT ASSEMBLY / SEAT LOCK

PAGE NO. 45

PLATE NO. : 24 ENGINE MOUNTINGS

PAGE NO. 47

Pictorial Index

Pictorial Index

PLATE NO. : 25 FRAME & FITTINGS

PAGE NO. 49

PLATE NO. : 26 SWING ARM/REAR SHOCK ABSORBER

PAGE NO. 51

PLATE NO. : 29 STAND ASSEMBLY

PAGE NO. 57

PLATE NO. : 30 TUBE / TYRE / RIM

PAGE NO. 59

PLATE NO. : 27 PILLION FOOT REST / HOLDER

PAGE NO. 53

PLATE NO. : 28 MUD GUARD - FRONT & REAR

PAGE NO. 55

PLATE NO. : 31 FRONT HUB

PAGE NO. 61

PLATE NO. : 32 FRONT MASTER CYLINDER

PAGE NO. 63

Pictorial Index PLATE NO. : 33 FRONT DISC BRAKE

Pictorial Index PAGE NO. 65

PLATE NO. : 34 REAR HUB

PAGE NO. 67

PAGE NO. 69

PLATE NO. : 36 REAR BRAKE PEDAL

PAGE NO. 71

PLATE NO. : 37 HANDLE BAR ASSEMBLY

PAGE NO. 73

PLATE NO. : 38 FRONT FORK

PAGE NO. 75, 77

x

PLATE NO. : 35 REAR DISC BRAKE SYSTEM

PLATE NO. : 39 PAINTED PARTS & DECALS

PAGE NO. 79, 81

PLATE NO. : 40 RADIATOR COVERS

PAGE NO. 83

9

Pictorial Index

Pictorial Index

PLATE NO. : 41 PETROL TANK, CAP TANK & GAUGE FUEL

PAGE NO. 85

PLATE NO. : 43 METER ASSEMBLY

PAGE NO. 89

PLATE NO. : 42 FITTING PETROL TANK COVER, SIDE COVERS & SEAT COVER

PLATE NO. : 44 CONTROL CABLES

PAGE NO. 87

PLATE NO. : 45 CHAIN CASE

PAGE NO. 93

PLATE NO. : 46 HEAD LAMP & FAIRING

PAGE NO. 96

PAGE NO. 91

PLATE NO. : 47 INDICATOR LIGHT ASSEMBLY

PAGE NO. 97

PLATE NO. : 48 TAIL STOP ASSEMBLY / FRONT NUMBER PLATE

PAGE NO. 99

Pictorial Index

Pictorial Index

PLATE NO. : 49 ELECTRICAL EQUIPMENTS

PAGE NO. 101

PLATE NO. : 51 ACCESSORIES / GRAB HANDLE

PAGE NO. 105

PLATE NO. : 50 TOOL KIT

PAGE NO. 103

Brand ID: 001MC629

Plate No.: 1 Cover Cylinder Head No.

Part No.

1 2 3 4

JL 5110 02 JL 5110 01 JG 5110 21 JG 5110 22

Description Cover Cylinder Head Gasket Head Cover(Rubber) Washer Bolt Special

Qty.

Remarks

1 1 4 4

4

3

1

2

1

Front Wheel Direction

2

Brand ID: 001MC629

Plate No.: 2 Cylinder Head

1

3

7

4 8

15

9

2

13 5

10 11 12

Description

Qty.

No.

Part No.

1 2 3 4 5

JG 5410 68 LD A000 08 JL 5110 09 36 JL00 10 JG 5110 46

Hex Flange Head Bolt M10 Washer 11.2*20*2T M6 Stud Bolt Cylinder Head Stud (M8*1.25)

4 4 2 1 2

6 7 8 9 10

JL JL 39 39 39

Gasket Cylinder Head Sleeve Spark Plug ‘O’ Ring Sleeve ‘O’ Ring Sleeve Bolt - Flange :- M6

1 1 1 1 2

Cover Thermostat Thermostat Assembly Thermostat Assembly Seal Thermostat Coolant Water Temp Sensor Switch Oil Pressure Grub Screw

1 1 1 1 1 1 1

5110 5112 2629 1283 1673

22 19 21 21 04

11 JL 5110 29 12 BF 6012 07 JL 6012 24 12A JL 6012 25 13 JG 3514 00 14 DK 1012 25 15 39 2608 01

Remarks

Top side Bottom side

14 6

3

Front Wheel Direction

4

Brand ID: 001MC629

Plate No.: 3 Valve No.

9

1 2 3 4 5

6

5

Part No. 39 JL JL JL JL

2017 5110 5110 5110 5110

19 10 11 06 07

Description

Qty.

Seal - Oil Valve Intake Valve Exhaust Assembly Rocker Arm Intake Assembly Rocker Arm Exhaust

4 2 2 1 1

Rocker Arm Shaft Plate Stopper Rocker Arm Bolt Flanged M5X0.8X6L-Precoated Cotter Valve Valve Repair Kit

1 1 1 8 4

Remarks

6

6 JL 5112 05 7 JF 5112 07 8 LA E000 16 9 DG 1010 29 10 36 JL00 11

4 10

1

8

7 2/3

5

Front Wheel Direction

6

Brand ID: 001MC629

Plate No.: 4 Camshaft / Tensioner

12 9 11

13

8 3 1

15

No.

Part No.

1 2 3 4 5

JF 5112 28 JG 5312 20 AP 1012 36 LE B000 01 JL 5112 21

Description

Qty.

Assembly Camshaft Bearing - Ball 6202/HN3 Bearing - Ball :- 12 X 28 X 8 Circlip - Internal Spacer Camshaft

1 1 1 1 1

6 JL 5112 20 7 DU 1012 25 8 JL 5112 22 9 JC 1010 34 10 39 2669 21

Sprocket Camshaft Bolt Special Flanged (Camshaft) Timing Chain Tensioner Assembly Ring - O (Tensioner Bolt)

1 1 1 1 1

11 12 13 14 15

Bolt Hexagonal Gasket Bolt Flanged M6X1X6L-Special Chain Guide Pivot Bolt Kit Cam Chain Guide

2 1 1 1 1

KA DQ06 20 CS 1011 28 JG 5112 70 DH 1013 92 36 JL00 01

Remarks

N.I.

14

2 4 5 6 7

7

Front Wheel Direction

8

Brand ID: 001MC629

Plate No.: 5 Cylinder and Piston

3

1

No.

Part No.

1 2 3 4

36 JL00 07 36 JU00 01 39 2181 06 JL 5210 02 JG 5210 08 39 2132 17

5

Description Kit Asly Block Piston Kit Piston Ring Pin - Hollow Dowel :- 14 X 20 Gasket Cylinder Block Gasket Cylinder Block Ring - Snap

Qty. 1 1 2 1 1 2

Remarks

or

3

2

4

5

5

9

Front Wheel Direction

10

Brand ID: 001MC629

Plate No.: 6 Crankshaft No.

Part No.

1 2 3 4 5

JU 5310 27 JF 5310 07 JF 5310 14 JU 5310 21 39 2203 07

Description

Qty.

Remarks

1

2

8 5

6 7

9

10 15

1 1 2 2 2

6 39 1931 20 7 31 1011 73 8 JG 5310 27 9 JG 5310 31 10 39 2200 11

Bearing - Ball : 28 X 68 X 18 Key-Woodruff for Crankshaft Cl. Side Sprocket Crankshaft Spacer Crankshaft Washer - Plain (Primary Drive Gear)

1 3 1 1 1

11 12 13 14 15

Nut Sprocket Drive Lock Balancer Drive Gear Belleville Washer Nut Balancer Drive Lock Washer - Plain

1 1 1 1 2

11

13

14

Crankshaft Assembly Comp Conrod Assly Compl Bolt (Jf Con Rod) Bush Big End Pin - Parallel

LC D000 01 JG 5310 41 JG 5310 39 JG 5310 40 39 2165 11

4

15 12

3

11

Front Wheel Direction

12

Brand ID: 001MC629

Plate No.: 7 Transmission 1 2 3 4 6

5 17

7

8

6

5

19

18 16

15

3

14

23

10 12

24

13 22 21

11

20

18

15

1 2 3 4 5 6 7 8 9 10

JG 5510 27 39 2158 11 JG 5510 13 JG 5512 13 JG 5512 10 BF 5510 37 JG 5512 14 JG 5512 20 JG 5512 27 JG 5510 22

Shaft Input T/M Comp Washer - Plain Bush 6th Drive / Bush 2nd Driven Gear 6th Drive Washer Splined Ring - Snap Gear Drive Multiple 3&4 Gear 5th Drive Gear 2nd Drive Washer - Plain

1 1 1 1 2 2 1 1 1 1

JG DH DH JG BF JG JG JG JG JG

11 12 13 14 15 \ 16 17 18 19 20 21 22 23 24 25 26 27 28 29

25 26

29

13

Qty.

Part No.

Remarks

15

9

28

Description

No.

27

Front Wheel Direction

5510 1012 1013 5512 5510 5512 5512 5510 5510 5512

25 35 36 28 37 22 23 22 21 15

Output Shaft Assy With Plug Circlip Washer Special Gear 2nd Driven Ring - Snap Gear 5th Driven Gear 3rd Driven Spline Thrust Washer Lock Washer Splined Thrust Gear 4th Driven

1 1 1 1 3 1 1 2 1 1

JG 5512 JG 5510 JG 5512 JG 5510 DK 1013 JG 5510 JG 5510 LA E000 DV 1010

24 00 25 21 52 10 19 17 48

Gear 6th Driven Bush 1st Driven Gear 1st Driven Washer - Plain O-Ring Sprocket Collar(17.5*1.5) Collar Sprocket Plate Drive Sprocket Bolt Flanged M6X1X10L-Precoated Sprocket Output (14T)

1 1 1 1 1 1 1 2 1 14

Brand ID: 001MC629

Plate No.: 8 Change Drum / Shift Fork

8

Description

Qty.

No.

Part No.

1 2 3 4 5

JG 5610 11 EC 5610 23 39 2606 07 JG 5610 10 JG 5612 22

Drum Complete Gear Shift Spring Gear Switch Indicator Pin - Parallel Spacer-Guide Gear Shift Guide Gear Shift

1 1 1 1 1

6 7 8 9 10

LA C000 24 JG 5610 12 JG 5610 13 JG 5610 16 JG 5612 25

Bolt Socket Head M6X1X20L Fork Gear Shift Input Fork Gear Shift Output Shaft Gear Shift Fork Shaft Gear Shift Fork Output

1 1 2 2 1

Remarks

8 3 2

10

1

4

7

5 6

15

9

Front Wheel Direction

16

Brand ID: 001MC629

Plate No.: 9 Gear Change Mechanism

15

No.

Part No.

1 1A 2 3 4 5

JL 5614 00 JL 5614 01 JL 5614 04 DH 1015 09 JL 5614 05 JD 5614 16

Description

Qty.

Remarks

12 11

10

13

1

6 39 0808 08 7 JL 5614 07 8 JL 5614 08 9 39 2453 04 10 JG 5612 00

9 2

4

7

14

1A

16

Assembly Lever Complete Change Lever Complete Change Assembly Lever Change Arm Damper Rod Tie Washer - Nylon (Dia6.5Xd15X2.0)

1 1 1 1 1 2

Pin - Split Boot -Change Arm Boot -Change Lever Bolt - Flange :- M6 Lever Gear Shift Assy Comp.

2 1 1 1 1

11 JG 5612 15 Compression Spring 12 JG 5612 18 Torsion Spring 13 JG 5612 17 Bush-Torsion Spring 14 JL 5614 09 Bolt Gear Change Lever 15 JL 5614 10 Washer - Steel

1 1 1 1 1

16

2

01 1100 05

‘O’ Ring

15

6 3

5 8

17

Front Wheel Direction

18

Brand ID: 001MC629

Plate No.: 10 Engine Assembly / Crankcase RH 3

No. 2

7

4

5

6

8

9 10

12

14 22 21

18

15

1 2 3 5

JL 36 39 LA

5010 03 JL00 04 1931 20 D000 77

4 6 7 8 9 10

JG 5410 46 JG 6010 07 JU 5312 13 39 2602 20 DH 1013 83 JG 5410 59

Description

Qty.

Assembly Engine 200 Kit Asly Crankcase RH Ball Bearing 28 X 68 X 18 Bolt Flanged M6x16

1 1 1 1

Balancer Bearing Stopper Special Shaft Seal Ring (oil) Balancer Assly. Bearing - Ball 6202/HN3 Precoated Flanged Bolt M6 Plate Stopper Bearing Drum

1 2 1 1 1 1

11 39 2601 20 12 LB B000 06 13 JU 5410 05 14 59 2000 28 15 JG 5612 04

Bearing - Ball :- 61905 (25 X 42 X 9) Screw Pan head Breather Plate Bearing Ball RH Bolt Drum Stopper

1 3 1 1 1

16 JG 5612 05 17 JG 5610 09 18 39 2005 11 19 JG 5612 26 20 39 2562 20

Washer Stopper Drum Complete Washer Spring Bearing - Needle Roller :- 13X19X12

1 1 1 1 1

21 22 23 24 25

Screw Pan Cross - M6 Input Shaft Bearing Stopper Bolt Shifter Oil Filter O-Ring

1 1 1 1 1

Remarks N.I.

11

13

17

Part No.

28

20

6

39 0746 01 JG 5410 45 DP 1011 91 JG 5710 14 JG 5710 16

19 16

23

27 24

19

25

26

Front Wheel Direction

26 JL 5412 21 Cap Oil Filter 27 KA DP05 16 Hexagonal Flange Bolt 28 LE B000 01 Circlip Internal

1 2 1

20

Brand ID: 001MC629

Plate No.: 11 Crankcase LH

1

2

4

3 2

5 6

7 8

15

11

9

10

14

16

Description

Qty.

No.

Part No.

1 2 3 4 5

36 JL00 03 LA E000 14 DH 1013 81 JG 5410 63 JG 5410 44

Kit Assly. Crankcase LH Bolt Flanged Pre Coated pan Screw Bracket Harness Upper Bracket Harness Lower

1 2 1 1 1

6 39 1773 04 7 JL 3518 00 8 39 1043 19 9 KE BA37 15 10 DG 1014 56

Bolt M-5 x 16 Neutral Indicator Switch Seal Oil Circlip Internal Seal Oil

2 1 1 1 1

11 59 2000 06 Bearing Ball 12 JG 5410 15 Needle Bearing 13 39 2562 20 Needle Bearing 14 JG 5710 24 Mesh Oil Filter Assly. 15 JA 5410 48 Strainer Cap with ‘O’ Ring

1 1 1 1 1

16 JG 5410 41 Gasket Crankcase 17 36 JL00 14 Kit Engine Gasket

1 1

Remarks

Gear Change lever Output Shaft Output Shaft Output Shaft Drum

N.I.

12

13

21

Front Wheel Direction

22

Brand ID: 001MC629

Plate No.: 12 Balancer Idler Gear / Water Pump

7 8 1

14

2 10

9

11

4

Description

Qty.

No.

Part No.

1 2 3 4 5

JU 5312 13 59 2000 36 JG 5312 11 JG 5312 12 JG 5312 15

Balancer Assy Balancer Bearing (6203/HN3C3D8) Sleeve Balancer Driven O Ring Balancer Driven Washer (2.5MM)

1 2 1 1 1

6 7 8 9 10

JG JG DS DH DK

Dome Nut Gear Balancer Driven Key Washer - Special :- Camshaft Pre-coated Soc Hd Cap Bolt M8X40

1 1 1 1 1

11 JG 6010 13 12 JL 5412 16 13 JG6010 12 14 KADQ06 20 15 39 1665 11

Water Pump Rotor Cover Water Pump O-Ring (Water Pump Cover) Bolt Hexagonal Washer - Seal :- 6

1 1 1 5 1

N.I.

16

Pin - Parallel

2

N.I.

6010 5312 1011 1010 1013

05 07 54 48 86

Remarks

13 5

39 2606 07

3 6 12

23

Front Wheel Direction

24

Brand ID: 001MC629

Plate No.: 13 Oil Pump

7 3

4

Description

No.

Part No.

1 2 3 4 5

JU 5710 00 JG 5710 22 JG 5710 18 KE AA11 10 28 1210 08

6 7

39 0999 06 Pin - Hollow Dowel LA E000 18 Bolt Flanged M6X1X30L-Precoated

Oil Pump Assy Comp Rotor Oil pump Inner With Shaft Gear Oil Pump Drive Circlip Outer Rotor

Qty.

Remarks

1 1 1 1 1 2 3

6

5

2

1

25

Front Wheel Direction

26

Brand ID: 001MC629

Plate No.: 14 Radiator 5 4

3

2

25

1

No.

Description

Qty.

Remarks

18 21 20

24 19

23 5

22

7

1 JL 6012 10 2 DJ 1810 65 3 JL 1812 56 4 JW 1710 15 5 KA DA06 16

Cowl Radiator Nut - Clip :- M6 Grommet For Radiator Cowl Collar Spoiler Central Bolt-Flange Dia-06 L-12

1 3 3 3 3

6 JL 6010 00 7 JG 6012 10 8 JG 6012 09 9 JL 6012 20 10 JL 6012 19

Hose Thermostat To Radiator Clamp Radiator Pipe Clamp Radiator Pipe Dia 19.8 Coolant Hose Radiator To T Hose By Pass To Pump

1 1 2 1 1

11 JL 6012 12 12 JL 6012 08 13 JG 6012 21 14 39 2204 04 15 JL 6012 00

Clamp Radiator Dia 19 Coolant Pipe T Assembly O-Ring Coolant Pipe Bolt - Hexagon Head With Flange:M6 Radiator

1 1 1 2 1

16 17 18 19 20

Radiator Fan Pressure Cap Radiator Cap Expansion Tank Clamp -Expansion Tank Spring Band Clip 10 Mm

1 1 1 2 3

21 JL 6012 09 22 DJ 1810 65 23 39 1944 04 24 JL 6012 13 25 JL 6012 14

Tank Expansion Nut - Clip :- M6 Bolt - Flanged Hose -Expansion Tank Hose -Expansion Tank Top

1 2 2 1 1

26 27

Bleeding Screw-Radiator O ring Bleeding Screw

1 1

15 17

16

6

8

9

11 10 12 14 13

27

Part No.

Front Wheel Direction

JG 6014 00 JG 6012 29 JG 6012 11 JL 6012 15 JG 1710 29

– –

28

Brand ID: 001MC629

Plate No.: 15 Cover Clutch 14

Description

Qty.

No.

Part No.

1 2 3 4 5

36 JL00 02 39 1990 20 LD B000 20 JG 5510 17 JG 5510 15

Kit Asly Clutch Cover Bearing - Needle Washer 12.5X24X0.8T Spring Shaft Clutch Release Assy

1 1 1 1 1

6 7 7A 8 9 10

JU 5514 01 JG 5412 30 39 1537 21 DG 1014 18 DS 1012 15 39 1041 19

Rod Push Cap Oil Filling Ring ‘O’ Gauge Clip - Wire Seal - Oil

1 1 1 1 1 1

Pin - Hollow Dowel Gasket Clutch Cover Bracket Clutch Cable Bolt Flanged Seal - Oil

2 1 1 11 1

Remarks

13 5 18 3 7

With Nozzle, NRB, Jet

4

11 7A 17 16 15 2

11 39 0999 06 12 JL 5412 07 13 JL 5412 10 14 KA DQ06 30 15 39 1046 19

1

6

N.I.

12

16 JG 5412 31 Plate -position 17 DH 1013 83 Bolt M6 18 JL 5412 22 Decal Triple Spark

1 2 1

9 8

29

Front Wheel Direction

30

Brand ID: 001MC629

Plate No.: 16 Cover Magneto

2 4

No.

Part No.

1 2 3 4 5

JL 5412 02 JA 5412 33 30 1011 95 39 0999 06 JL 5412 08

Description Cover Magneto Cap TDC Finder Ring - O Pin - Hollow Dowel Gasket Magneto Cover

Qty.

Remarks

1 1 1 2 1

6 3

1 7

6 8

6

6 KA DQ06 30 Bolt Flanged 7 JL 5412 03 Cover LH RR 8 KA DQ06 45 Hex Headed Bolt Flange 9 JL 2330 15 Gear Shift Label 10 JL 5412 23 Decal ‘Bajaj logo’

9 1 3 1 1

11

1

JL 2330 15

Gear Shift Label-6 Speed

8

8 11 10

31

6

6

Front Wheel Direction

32

Brand ID: 001MC629

Plate No.: 17 Clutch Assly

1

3

Description

Qty.

No.

Part No.

1 2 3 4 5

JU 5514 04 JG 5514 27 36 JL00 05 JG 5514 28 JG 5514 49

Clutch Assy Comp Collared Bush Kit Set Primary Drive & Driven Gear Washer Clutch Plate (Wheel Clutch)

1 1 1 1 1

6 7 8 9 10

36 JU00 JG 5514 JG 5514 JU 5514 JU 5514

Kit Friction Plate Pressure Plate Clutch Holder (Hub Clutch) Clutch Center (Holder Clutch) Spring -Clutch

1 6 1 1 4

11 12 13 14 15

JG 5514 51 39 2200 11 DH 1016 48 JG 5514 23 DP 1011 43

Bolt Sh 6*22 Washer - Plain (Primary Drive Gear) Nut Clutch Center Lock (Pre-coated) Clutch Lifter Bearing Plate Judder Spring

4 1 1 1 1

Remarks

4

9

2 8

11

10

16 15

7

5

02 47 43 06 02

16 DP 1011 14 Spring Anti Judder

12 6

1

14 13

33

Front Wheel Direction

34

Brand ID: 001MC629

Plate No.: 18 Carburettor No.

Part No.

Description

Qty.

Remarks

9

5

1 2 3 4 5

JL JL JL JL 36

5812 5813 5110 5810 JL00

01 00 16 27 19

Carburettor Clamp (Duct Carburettor) Insulator Rubber Clamp Kit Jet P200

1 1 1 1 1

6 7 8 9 10

36 JL 36 36 36

JL00 5812 JL00 JL00 JL00

20 07 22 24 23

Kit VC Screw P200 Cable Idling Screw Kit Piston Valve P200 Kit Jet Needle Hardware P200 Kit Gasket / O-ring P200

1 1 1 1 1

11 12 13 14 15

JA 5813 14 CB 1210 42 DH 1210 64 DH 1210 63 DK 1210 47

Drain Screw Float Chamber Screw Screw Needle Shaft Float Needle Needle Assly.

1 2 1 1 1

Screw Pan - M5 TPS Assly. Choke Lever Tube Drain Carb.

2 1 1 1

Refer Page No. 109

8

6 18

Refer Page No. 109 Refer Page No. 109 Refer Page No. 109 Refer Page No. 109

20 16

17 2

3

15

4

5 7 14 21

16 39 1780 01 17 JD 3518 00 18 JL 5812 04 19 JL 5812 05

13

12

11

20 JL 5812 06 Tube Breather 21 DK 1510 45 Float Assembly 22 JG 5814 42 Clamp Intake Pipe

1 1 1

19

35

Front Wheel Direction

36

Brand ID: 001MC629

Plate No.: 19 Air Cleaner Complete No.

1

1 2 3 4 5

9 5

2 4

3

17

8

Part No. JL JL LB JL JL

5810 00 5810 23 B000 04 5810 25 5810 07

Description

Qty.

Remarks

Air Filter Assembly Assembly Top Cover Screw Cross Pan Hd Bt6*11L Seal Top Cover Entry Duct

1 1 6 1 1

6 JL 5810 24 7 JL 5810 18 8 JL 5810 09 9 KA EM06 22 10 JL 5810 16

Assembly Bottom Cover Plate Air Filter Mounting Filter Element Bolt-Flange Tube Breather Assly

1 1 1 4 1

11 JL 5810 15 12 DG 1210 02 13 DS 1211 26 14 JL 5810 10

Tube Drain Assembly Clamp Plug Tube Connecting

1 2 1 1

15 16 17 18 19 20

AP 1210 64 JL 5810 04 KB QA35 06 JL 5810 22 KA DM06 10 KA DA06 30

Clamp Flame Arrester Screw Tapping Pan Slotted Plate Top Cover Mtg Bolt Flange M6-L10mm Bolt Flange M6-L33mm

1 1 3 1 1 1

RH Mounting RH Mounting

21

39 0239 11

Plain Washer

2

N.I. RH Mounting

18

7 16 6 15

14

10

12

11

12 13

37

19 20

Front Wheel Direction

38

Brand ID: 001MC629

Plate No.: 20 Silencer Assembly

10

Description

Qty.

No.

Part No.

1 2 3 4 5

JL 5910 52 JL 5910 48 JG 5910 38 JL 5911 44 DH 1016 07

Assembly Muffler Pipe Exhaust A Assly Band Clip Shield Catalytic Converter Truss Screw

1 1 1 1 4

6 7 8 9 10

JG 5910 39 JG 5910 96 JG 5910 97 JL 5910 75 JG 5910 70

Gasket Muffler Pipe-A Bush Silencer Mounting Damper Silencer Mounting Heat Shield Gasket Exhaust

1 4 4 1 1

11 39 2754 04 12 39 2492 11 13 JG 5910 53 14 KA DQ06 25 15 JG 5910 88

Bolt Hex Plain Washer Damper Silencer Mounting Bolt M6 Clip Nut M6

1 1 4 2 2

16 17

Bolt Stepped Bolt Hex Flange

2 2

Remarks

8 7 17 2

1

11

9

12

JL 5910 86 JL 5911 48

4 5 16

3 6

39

Front Wheel Direction

40

Brand ID: 001MC629

Plate No.: 21 Starter Assembly Description

Qty.

No.

Part No.

1 1A 2 3 4 5

JL 3516 00 KA DQ06 25 JG 6214 13 JG 6214 12 JG 5310 41 JG 5310 39

Starter Motor Assly. Bolt M6-Motor mtg. Gear Starter Counter 2 Assy Gear Starter Counter 1 Balancer Drive Gear Belleville Washer

1 2 1 1 1 1

6 7 8 9 10

JG 5310 40 JG 6214 17 39 2165 11 DH 1013 96 JG 3510 19

Nut Balancer Assembly Gear Starter Clutch Plain Washer Hex Bolt Flanged Body Complete Starter Clutch

1 1 1 1 1

Remarks

1

2 3

4 5

N.I.

7 6

8 9 13

11 JY 5514 02 Clutch One Way Assly 12 39 0849 14 Washer - Lock :- Toothed 13 DH 10 13 89 Pre-coated Screw

1 4 4

12 10

11

41

Front Wheel Direction

42

Brand ID: 001MC629

Plate No.: 22 Magneto, CDI & H.T. Coil

3

Part No.

1 2 3 4 5

JL 4020 01 JL 3510 09 JL 3510 03 JL 3510 05 DK 1012 84

Description

Qty.

Remarks

10

2

6 7 8 9

6 7 14

No. 5

11

21

21

1

DH 1011 99 LA E000 10 DK 1110 28 JL 3512 15 JG 3512 09 10 JL 3512 00

Regulator Assly Rotor Assy. (W/O Clutch Assy) Stator Assly Compl Grommet G Hex Socket Head Screw(M5X0.8X35)

1 1 1 1 3

Plate - Stopper (Wiring Harness) Bolt Flange M5 X 13L Spark Plug RG6HC Ignition Spark Plug Ignition Spark Plug DC CDI With Sealed Coupler

1 2 2 1 1 1

N.I. Stator Cable

Or

15

21 21

17

20

13

16 12

18 8

43

16

9

11 DD 1110 12 Grommet For H. T. Cable 12 JD 3512 07 Spark Plug Cap 13 AN 1110 15 Spark Plug Cap 14 JL 3512 01 Ignition Coil with Cable LH 15 JL 3512 02 Ignition Coil with Cable RH

2 1 1 1 1

16 17 18 20

DH DH DD DK

Grommet - Spark Plug Grommet - Sleeve Spark Plug Grommet - Spark Plug Cap Cap Spark Plug

2 1 1 1

21

39 1944 04

Bolt - Flanged

4

1110 1110 1110 1110

13 16 11 11

8

Front Wheel Direction

44

Brand ID: 001MC629

Plate No.: 23 Seat Assembly / Seat Lock Description

Qty.

No.

Part No.

1

JL 1910 01

Seat Assy Comp Front

1

2

36 JL00 13

Kit Damper For Seat

1

3

DK 2110 07 Damper Seat Front

1

4

JG 1910 08 Collar -Seat

2

5

FD 2110 06 Grommet - Seat

2

6

DS 1612 87 Flange Bolt - M6

2

7

JL 1910 04

Seat Assy Comp Rear

1

8

JD 1910 06

Damper Round

2

9

JG 2326 01 Lock Assy Seat Rear

Remarks

3

1 6

6

5

2

Refer Page No.107

1

4 4

10 JG 2326 06 Seat Lock Cable

1

11

2

39 1913 04

Bolt - Flanged

7

11

8 10 9

45

Front Wheel Direction

46

Brand ID: 001MC629

Plate No.: 24 Engine Mountings

3

8

6

2 6

9

Description

Qty.

No.

Part No.

1

JL 1134 00

Engine Stay Lh

1

2

JL 1134 01

Engine Stay Rh

1

3

39 1951 04

Bolt - Flanged Small

4

4

JL 1110 54

Engine Mtg Bolt Front

1

5

JA 1134 03

Flanged Bolt M10X110

2

6

39 2723 15

Nut Flanged M10

2

7

JL 1110 92

Bkt. Radiator Lower LH

1

8

JL 1110 93

Bkt. Radiator Lower RH

1

9

39 1062 04

Bolt Flanged

4

Remarks

5

6

5

3

9 7 1

4

47

Front Wheel Direction

48

Brand ID: 001MC629

Plate No.: 25 Frame and Frame Fittings

2 5

1

4 3 7

Description

Qty.

No.

Part No.

1

JL 1111 06

Frame Assly Complete

1

2

JL 1111 03

Cap Tube End

2

3

JL 1110 81

Bracket Loose H.T. Coil 1

1

4

JL 1110 82

Bracket Loose H.T. Coil 2

1

5

39 1944 04

Bolt - Flanged

4

6

JL 1110 78

Bracket Horn Mtg Lh

1

7

36 JG00 11 Kit Steering head bearing

1

8

JG 5810 14 Silent Block

4

9

LA D000 40 Bolt Flange

2

Remarks

9 6

8

49

Front Wheel Direction

50

Brand ID: 001MC629

Plate No.: 26 Swing Arm / Rear Shock Absorber

1 2

Description

Qty.

No.

Part No.

1

JL 1220 06

2

LA C000 19 Bolt Socket M10 X 1.25 X 55

2

3

JL 1220 14

1

4

DG 1710 16 Sleeve

2

5

DG 1710 18 Bearing - Needle

2

6

DG 1710 19 Seal - Oil

4

7

JL 1220 02

Cap Swing Arm Tube

2

8

JL 1220 01

Adjuster Chain Lh

1

9

JL 1220 09

Adjuster Chain Rh

1

10

JL 1220 03

Slider Chain

1

11

39 0454 11

Washer - Plain

2

12

39 0553 02

Screw - Self Tapping

2

13

JL 1220 04

Spacer Chain Adjuster

2

14

JL 1220 08

Spacer Central Swing Arm

2

15

JL 1812 24

Grommet I

1

16

JL 1812 25

Grommet Ii

1

Shockabsorber Mono Assembly Swing Arm Comp

Remarks

1

2

5

14

6

19

18

16

12 11

3

6

10

9 4 15 17

5 6 7

18

8 13

17 DG 1710 15 Shaft - Swing Arm

1

18

2

JL 1111 09

Cap -Swing Armpivot

19 DG 1710 17 Nut

51

Front Wheel Direction

1

52

Brand ID: 001MC629

Plate No.: 27 Pillion Foot Rest / Holder No.

Part No.

Description

Qty.

Remarks

2

1 2 3 4 5

6 3

5

JL JL JL JL 39

1130 1130 1130 1130 2475

02 07 12 33 04

Holder Step RH Step Assy Main RH Spring Torsion Bracket Rear Brake Switch Bolt - Hexagon Head Flange M6

1 1 1 1 1

6 KA CA08 20 7 JL 1130 34 8 JL 1130 00 9 DG 1611 44 10 LD A000 13

Bolt-Socket Dia-08 L-20 Holder Step LH Step Assly Main LH Bolt Washer Plain Dia 6.4Xdia 12.5X 2

2 1 1 1 1

11 LA C000 16 12 JL 1130 13 13 JL 1130 26 14 JL 1130 14 15 JL 1130 16

Bolt Socket M8X35 Step Holder- Pillion LH Flap Pillon Holder LH Step Pillion Assy Complete LH Step Pillion Assy Complete RH

2 1 1 1 1

16 17 18 19

Step Holder - Pillion RH Flap Pillon Holder RH Bolt - Flanged :- Small Rubber Main Step

1 1 4 2

1 19

4

7

15 16 12

8

18

17

18

JL JL 39 JL

1130 1130 1954 1130

15 27 04 28

13 14

53

Front Wheel Direction

54

Brand ID: 001MC629

Plate No.: 28 Mudguard - Front & Rear

12

9

13

Description

Qty.

No.

Part No.

1 2 3 4 5

JL 1814 05 DS 1611 25 DJ 1610 69 JL 1814 02 JL 1814 11

Mudflap -Front Guide - Cable Nail - Cable Guide Bracket Brace Fender Washer Front-Fender-Mtg

1 1 1 1 2

6 7 8 9 10

39 39 39 39 39

Bolt - Hexagon Socket Head :- M6 Bolt - Flanged M8 Bolt - Flanged Washer - Plain Screw - Pan Head M5

2 4 2 6 3

11 39 0326 15 12 JL 1318 11 13 JL 1318 12 14 KA Ca08 30

Nut - Nyloc M5 X 0.8 Bracket -Hose Clamp Bracket Hose Clamp Top Bolt - Flanged

3 1 1 2

15 16 17

Fender Rear Front Foam-Rear Fender Front Washer - Plain

1 1 2

Remarks

N.I.

10

4

2038 1946 1943 0242 2420

04 04 04 11 01

3

1

7 2

16

15

JL 1812 09 JL 1812 21 39 0239 11

17 8

55

Front Wheel Direction

56

Brand ID: 001MC629

Plate No.: 29 Stand Assembly Description

Qty.

No.

Part No.

1 2 3 4 5

36 JL00 25 DG 1611 24 JL 1132 10 39 1941 04 39 1946 04

Kit Center Stand Damper Bush Main Stand LH Bolt - Flanged M8 Bolt - Hexagon M8 X 1.25

1 1 2 1 1

6 7 8 9 10

39 JL JL JL JL

Bolt Flanged Spring Main Stand Cover Spring Main Stand Assembly Side Stand Switch Side Stand

1 1 1 1 1

Nut - Nyloc M10 Bolt For Side Stand Mounting Bolt - Flanged Magnet Assembly Spring Side Stand

1 1 1 1 1

Remarks

4

3

7

8 1

2

6 17 5

10

12

04 07 12 01 02

11 39 0422 15 12 DF 1611 02 13 39 2060 04 14 JL 4036 00 15 JL 1132 09

16 DH 1611 46 Cover - Spring Side Stand 17 JL 1132 02 Bracket Side Stand Mtg

11 9

2469 1132 1132 1132 4014

As an accessories

1 1

14 15 16

57

Front Wheel Direction

58

Brand ID: 001MC629

Plate No.: 30 Tube / Tyre / Rim

1

3

No.

Part No.

1 2 3 4 5

JL 1310 06 DK 1510 26 JL 1310 04 JL 1312 09 JL 1312 19

Description Tyre Tubeless (Size 100/80-17) Valve Tubeless Tyre Wheel Rim 2.5X17 Wheel Rim 3.5X17 Tyre 130/70-17

Qty. 1 2 1 1 1

Remarks Not Serviceable

Not Serviceable

5

4 2

2

59

Front Wheel Direction

60

Brand ID: 001MC629

Plate No.: 31 Front Hub

6 5

1

4 3

2

14

No.

Part No.

1 2 3 4 5

JL 1310 04 JG 1310 01 39 2241 20 DG 1510 05 JL 1310 05

Description

Qty.

Wheel Front Spacer Bearing - Ball Seal - Oil Disc Front

1 1 2 1 1

6 JD 1318 11 7 JL 1310 00 8 JC 1510 20 10 JC 2010 46

Special Bolt M8 Collar Case Meter Housing(W/O Sensor) Stopper

6 1 1 1

11 59 12 39 13 39 14 JL 15 LD

‘O’ Ring Washer - Spring Screw Pan Cross - M4 Axle Washer

1 1 1 1 1

2100 19 0900 12 0840 01 1310 01 B000 09

Remarks

N.I. Sensor Mtg N.I. Sensor N.I. Sensor Mtg N.I. Sensor Mtg

3

16 LC J000 02 Nut - U M14

1

7

8 15 16

61

Front Wheel Direction

62

Brand ID: 001MC629

Plate No.: 32 Front Master Cylinder No.

1

2

3

5

5 USE

-4 G: IN T3 RN DO ROM F WA NLY R O FLUID INE TA E O N AP AK BR D C R C ING E OV ALE ILL SE N F REM A A E LE C FO R BE

6 4

Part No.

Description

Qty.

1 2 3 4 5

DJ 1910 DJ 1910 DJ 1910 36 Dh19 DJ 1910

57 29 30 02 31

Lever Front Brake Bolt Front Bracket l Nut Oil Window Kit Screw

1 1 1 1 2

6 7 8 9 10

DE DE DJ DJ DE

29 28 56 00 10

Cover - Reservoir Diaphragm Master Cylinder with lever Spring - Return Washer - Copper

1 1 1 1 4

11 12 13 14 15

DE 1910 11 JL 1318 02 LA D000 37 DJ 1910 23 DE 1910 33

Bolt - Banjo Hose Assembly Bolt Flanged M8X1X50 Major Kit M-11 Clamp - Holder : RH

2 1 2

1910 1910 1910 2011 1910

Remarks

10 10 11

14

7

13 12 9

8

1

13 15

10 10 11

63

Front Wheel Direction

64

Brand ID: 001MC629

Plate No.: 33 Front Disc Brake

1

2 3

Description

Qty.

No.

Part No.

1 2 3 4 5

JL 1318 04 JL 1318 06 DE 1510 47 JL 1318 07 JL 1318 08

Caliper Assy Brake Front Screw Bleeder Bleeder Cap Boot Spring

1 1 1 1 1

6 7 8

JL 1318 05 DJ 1510 74 DJ 1510 75

Pad Minor Kit Major Kit

1 1 1

Remarks

4

5 x

7 3

6

2

PISTON SEAL DUST SEAL BLEEDER CAP PROTECTION BOOT INSULATOR CALIPER PISTON BLEEDER SCREW PAD SPRING

8

65

Front Wheel Direction

66

Brand ID: 001MC629

Plate No.: 34 Rear Hub

1

3 5

2

16

4

17

6 7 9

8

19 18

Description

Qty.

No.

Part No.

1 2 3 4 5

DK 1510 36 36 JL00 09 39 2241 20 39 2242 20 JL 1312 16

Lock Set Kit Chain Sprocket Bearing - Ball Bearing - Ball Collar Bearing Assy

1 1 1 1 1

6 7 8 9 10

JG 1312 19 JL 1312 25 DK 1510 13 DK 1510 12 LA A000 19

Coupling Rubber Coupling Bearing Coupling Oil Seal D Bolt

1 1 1 2 6

11 JL 1312 26 Washer 6 Rubber 12 LC A000 09 Nut 13 JL 1312 03 Axle 14 DK 1510 15 Sleeve 15 JL 1312 11 Spacer for Coupling

3 6 1 1 1

16 JL 1312 18 17 39 2038 04 18 LD B000 29 19 LC J000 02 20 DK 1510 81

1 6 2 1 1

Remarks

10

11 12 13

Disc Rear Bolt Hex Washer Nut - U Spacer I

21 DK 1510 82 Spacer II

67

Front Wheel Direction

1

68

Brand ID: 001MC629

Plate No.: 35 Rear Disc Brake System Description

Qty.

No.

Part No.

1 2 3 4 5

DK 1510 83 DK 1510 31 JL 1318 03 DK 1510 69 JG 1318 21

Assembly Caliper Assembly Master Cyl. Rear Hose Disc Brake Rear Banjo Bolt Reservoir Rear Brake

1 1 1 2 1

6 7 8 9 10

JL 1312 20 DK 1510 63 DE 1910 10 DE 1510 47 DE 1510 46

Hose - Reservoir Clip Reservoir Copper Washer Cap Bleeder Screw Bleeder Screw

1 1 4 1 1

Remarks

5

6 4 2

3 12

4 1

PISTON SEAL

11 DK 1510 31 Master Cyl. Major kit 12 DK 1510 74 Master Cyl. Minor kit 13 DK 1510 85 Set Disc Pad

1 1 1

Cap Reservoir Banjo Bolt

N.I. N.I.

DUST SEAL BLEEDER CAP 9

PROTECTION BOOT INSULATOR CALIPER PISTON 10

BLEEDER SCREW 13

PAD SPRING

11

69

Front Wheel Direction

70

Brand ID: 001MC629

Plate No.: 36 Rear Brake Pedal Description

Qty.

No.

Part No.

1 2 3 4 5

JL 1610 01 39 1769 04 JL 1610 10 DH 1910 13 31 2010 79

Brake Pedal Bolt - Flanged : M8 Shaft Assy Brake Lever Spacer Brake Shaft assly. Switch - Rear Brake

1 1 1 1 1

6 7 8 9

39 2475 04 JL 1130 33 JL 1610 06 DH 1910 06

Hex. head bolt Bracket Rear brake switch Spring Rear Brake Switch Spring - Brake Pedal

1 1 1 1

Remarks

1

2

N.I.

4

6 3

5 7

8

71

Front Wheel Direction

72

Brand ID: 001MC629

Plate No.: 37 Handle Bar Assly No. 1 2 2A 3 4 5

21

20

3 7

4

11

2A 12 10 9

5

1

6

3 2A

16

2 8

15 10

73

19

9

Front Wheel Direction

Part No. JL JL JL 39 LA JL

1510 21 1510 26 1510 38 1180 11 C000 20 1510 28

Description

Qty.

Handle Bar Tube LH assly. Holder Handle LH O ring Washer - Plain Bolt Socket M8X1.25Px55L Plug Handle Holder

1 1 4 2 2 2

6 JL 1510 30 7 JL 1510 34 8 DG 1810 08 9 JL 1510 35 10 39 2427 04

Holder Handle Handlebar Tube Assy RH Bolt - Socket Handlebar Weight Bolt - Hexagon Socket Head Cap:M6

1 1 4 2 2

11 12 13 14 15

Lever & Support Holder Assly LH Lever LH For New Clutch Switch Clutch Switch (6Amp Diode) Clamp - Rubber Handle Grip LH

1 1 1 1 1

16 JL 1610 08 17 DH 1910 17 18 JL 1510 23 19 JL 4014 03 20 JL 4014 00

Grip Hand Assy RH Pipe - Throttle Lock Set 3 In 1 Switch Ignition Switch Control LH

1 1 1 1 1

21

Switch Control RH

1

DJ 1910 82 DJ 1910 83 DJ 2012 46 DD 1910 15 JL 1610 03

JL 4014 01

Remarks

N.I.

N.I. N.I.

74

Brand ID: 001MC629

Plate No.: 38 Front Fork

1

Description

Qty.

No.

Part No.

1 2 3 4 5

JL 1510 24 JL 1510 02 JL 1510 03 DK 1810 06 DK 1810 07

Fork Assly- Front Tube Outer LH Tube Outer RH Socket Headed Bolt - M10 X1.5X35 Copper Washer

1 1 1 2 2

6 7 8 9 10

DK DK DK DK DK

Inner Dust Seal Washer Seal Oil Seal Guide Bush Oil Seal Stopper

2 2 2 2 2

11 DK 1810 15 12 JL 1510 12 13 JL 1510 04 14 DK 1810 09 DK 1810 10 DK 1810 12 DK 1810 13 15 DK 1810 73

Washer Spacer Tube Fork Pipe Spinning Cap Oil Lock Seat Pipe Piston Ring Rebound Spring Spring Main Spring

2 2 2 2 2 2 2 2

16 DK 1810 22 17 DK 1810 23 18 JL 1510 32 19 JL 1812 35 20 JC 1810 23

Fork Bolt O' Ring Upper Bracket Lamp Shade Assy Cover Cushion

2 2 1 1 4

21 JC 1810 22

Cove Trail B

4

Remarks

26 16 14

17 11

6 7

18

12

25 20

8

1810 1810 1810 1810 1810

21 18 19 17 20

9 10

21

13

19

15

10

2/3 21 20 5 22

4 24

75

23

Front Wheel Direction

76

Brand ID: 001MC629

Plate No.: 38 Front Fork

1

26

Description

Qty.

No.

Part No.

22 23 24 25

JL 1510 37 DK 1810 25 DK 1810 28 DG 1810 08

Under Bkt Assy Complete Spring Washer Bolt Bolt - Socket

1 2 2 2

26

JL 1510 36

Steering Top Bolt

1

Remarks

16 14

17 11

6 7

18

12

25 20

8 9 10

21

13

19

15

10

2/3 21 20 5 22

4 24

77

23

Front Wheel Direction

78

Brand ID: 001MC629

Plate No.: 39 Painted Parts and Decals

13

7

Description

Qty.

No.

Part No.

1

JL 7401 5P JL 7401 5N JL 7401 5Q JL 7401 5M

Tank Tank Tank Tank

Cover Cover Cover Cover

Top Top Top Top

P200 P200 P200 P200

Saffire Blue Black Yellow Red

1 1 1 1

2

JL 7301 5P JL 7301 5N JL 7301 5Q JL 7301 5M

Tank Tank Tank Tank

Cover Cover Cover Cover

Side Side Side Side

LH LH LH LH

-

Saffire Blue Black Yellow Red

1 1 1 1

3

JL 7302 5P JL 7302 5N JL 7302 5Q JL 7302 5M

Tank Tank Tank Tank

Cover Cover Cover Cover

Side Side Side Side

RH RH RH RH

-

Saffire Blue Black Yellow Red

1 1 1 1

4

JL 7602 5P JL 7602 5N JL 7602 5Q JL 7602 5M

Side Side Side Side

Mask Mask Mask Mask

RH RH RH RH

-

Saffire Blue Black Yellow Red

1 1 1 1

5

JL 7601 5P JL 7601 5N JL 7601 5Q JL 7601 5M

Side Side Side Side

Mask Mask Mask Mask

LH LH LH LH

-

Blue Black Yellow Red

1 1 1 1

6

52 52 52 52

Front Front Front Front

12

Remarks

10/11

9 1 16 8 2

5

3 6

15

4 14

79

Front Wheel Direction

JL00 JL00 JL00 JL00

65 66 67 59

Fender Fender Fender Fender

Blue Black Yellow Red

1 1 1 1

80

Brand ID: 001MC629

Plate No.: 39 Painted Parts and Decals

13

7

Description

Qty.

No.

Part No.

7

JL 7801 5P JL 7801 5N JL 7801 5Q JL 7801 5M

Seat Seat Seat Seat

8 9 10

52 JL00 54 52 JL00 55 JL 2330 04

Cover Side LH Assly Cover Side H Assly 3D Decal Tank RH

1 1 1

11 12 13 14

JL JL 36 36 36 36 36 JL JL

3D Decal Tank LH ‘B’ Logo Fairing DCL Fender DCL-Red Fender DCL-Blue Fender DCL-Black Fender DCL-Yellow Decal Side Cover 4 Valve Decal Seat Cowl 200 NS

1 1 1 1 1 1 1 2 2

12

Cowl Cowl Cowl Cowl

Assy Assy Assy Assy

-

Blue Black Yellow Red

Remarks

1 1 1 1

10/11

9 1 16 8 2

5

3 6

15 16

15

2330 2330 JL00 JL00 JL00 JL00 JL00 2330 2330

03 02 26 27 28 29 30 05 06

Common

4 14

81

Front Wheel Direction

82

Brand ID: 001MC629

Plate No.: 40 Radiator Covers No.

1

5 7

4

Part No.

Description

Qty.

1 JL 1812 29 Shroud Assy RH 2 KB UB05 12 Screw Trus 3 JW 1812 36 Clip Nut M5 4 KB UA06 12 Screw - Truss 5 39 1672 04 Bolt - Flange : M6 X 16

1 4 4 4 2

6 7 8 9

1 4 1 4

Remarks

2

6

3

JL 1812 32 39 2141 24 JL 1812 26 DJ 1810 85

Shroud Mtg Bkt RH Washer (Non Metallic Round Washer) Shroud Assy LH Clip Nut M5

9

9

4 3

7

8 2

83

Front Wheel Direction

84

Brand ID: 001MC629

Plate No.: 41 Petrol Tank, Cap Tank and Gauge Fuel 2

1

5

3

7

6

4 8 5 17 13 14 16

12

Bottom View

9 Top / Side View

Description

Qty.

No.

Part No.

1 2 3 4 5

JL 1710 44 JL 1716 00 39 2381 04 JL 1710 49 36 Jl00 12

Tank Assembly Cap Tank Bolt - Hexagon Socket Head Cap:M5 Damper Ring Tank Cap Kit Tank Damper

1 1 6 1 1

6 6A 7 8 9 10

JL 39 39 JL JL JL

4026 2758 2484 1710 1710 1718

00 21 15 37 63 02

Sensor Fuel Level ‘O’ ring for Fuel Sensor Nut - Flange :- M5 Breather Tube Pipe - Drain Filter Inline

1 1 4 1 1 1

11 12 13 14 15

JL JL JL JL JL

1710 1710 1718 1710 1718

36 35 00 60 03

Tube Fuel (Carburettor) Tube Fuel (Tank) Tap Fuel Assembly O Ring-For Knob Pin Snap For Knob

1 1 1 1 1

16 JL 1718 01 17 DD 1410 22 18 39 1946 04 19 JL 1710 19 20 JL 1710 18

Knob Fuel Tap Bolt - Flanged Bolt Tank mtg Front Sleeve Tank Mtg Front Grommet Tank Mtg Front

1 2 1 3 1

21 BA 1220 03 21 39 0983 08 22 39 1054 11 23 JL 1710 20

Clip - Pipe Pin Snap Washer Plain Grommet Tank Mtg Rear

6 1 2 2

Remarks

N.I.

10 11

22 21 18 23

19 20

Front Mounting

85

Rear Mounting

Front Wheel Direction

86

Brand ID: 001MC629

Plate No.: 42

Fittings - Petrol Tank Cover, Side Covers & Cover Seat 1

No.

Part No.

4

1 2 2A 3 4 5

JL 1710 57 JL 1710 23 JL 1710 22 39 2060 04 DJ 1612 29 JL 1710 24

13

6 JL 7 39 8 39 9 39 10 LA

Description

Qty.

Remarks

2 2A 3 5 7

4

Damper Bracket Side Cover Mtg Rh Bracket Side Cover Mtg LH Bolt - Flanged Clip Nut Damper Structure Mtg

4 1 1 2 16 2

Tank Cover Central Screw - Tapping : 4 X 14 Screw - Truss Cross : M5 Washer (Non Metalic Round Washer) Bolt Socket-Special Head

1 12 8 8 4

11 31 1610 78 12 DS 1410 12 13 39 1781 01 14 59 0200 01 15 JL 1710 62

Washer Grommet Side Cover Screw Screw Self Tapping 3.5X9.5 Cover Mesh Rh

4 4 4 5 1

16 17 17A 18 19 20

61 14 04 04 11 01

Cover Mesh LH Bolt Flanged M6X1 Bolt - Flanged Bolt - Socket : M6 Washer Screw - M6

1 4 2 2 2 2

21 DL 1610 15 22 JL 1812 19 23 JL 1812 14 24 LD A000 07 25 39 1776 02

Grommet Grommet Seal cowl inner Washer Plain Small Screw

2 2 1 4 4

10 6 11

9

4 8 13 12 14 8 24

9

19

25

15/16

17

20 21

23

JL 59 39 39 39 39

1710 48 1778 02 1907 01 2141 24 C000 22

1710 0400 1943 1197 0239 1076

17 17A

87

18

Front Wheel Direction

88

Brand ID: 001MC629

Plate No.: 43 Meter Assembly

6

Part No.

1 2 3 4 5

JL 4024 00 JG 1812 38 39 0291 15 JL 1812 41 JB 1812 23

Description Speedometer Assembly Grommet Dashboard Nut - Hexagon :- M5 X 0.8 Assembly Speedo Flap Beading Speedo Flap

6 KA CB05 14 Bolt-Socket-Kac St-B Dia-05 L-14 7 LD B000 07 Washer Plain 8 JL 4024 03 Speedometer Harness

4

5

No.

Qty.

Remarks

1 3 3 1 2 4 3 1

N.I.

1

2 7 3

89

Front Wheel Direction

90

Brand ID: 001MC629

Plate No.: 44 Control Cables No.

Part No.

1 2 3

JL 1612 01 JL 1612 00 JC 1510 19

Description Cable Throttle Cable Clutch Speed Sensor Assly.

Qty. 1 1 1

Remarks

N.I.

1

2

91

Front Wheel Direction

92

Brand ID: 001MC629

Plate No.: 45 Chain Case

1 3

No.

Part No.

1 2 3 4 5

JL 1812 05 JG 1220 28 39 1791 04 JL 1814 09 JL 1810 06

Description

Qty.

Cover Assly Chain Extruded Washer Bolt Flanged M6X8 Asly Hugger Rear Tube Rear Hugger Mtg

1 2 2 1 1

Cover 1- Hugger Rear Cover 2- Hugger Rear Screw Bolt Soc-special Head Spring Washer

1

Remarks

2

6 JL 1814 07 7 JL 1814 08 8 KB UB04 10 9 LA C000 37 10 39 0265 12

4

5

6

11 LA C000 36 Bolt Special Socket 12 JL1814 10 Collar Hugger Rear

8

6 3 2 2 2

9

7

93

11 10

Front Wheel Direction

94

Brand ID: 001MC629

Plate No.: 46 Head Lamp & Fairing

1 4 5

6

7 8

17

No.

Part No.

1 2 3 4 5

JL 1810 08 JG 1812 36 JG 1812 35 LB S000 01 JL 1812 47

6 7 8 9

1812 03 A000 07 R000 02 4010 12 4010 10 1943 04

Description

Qty.

Remarks

Windshield Assembly Well Nut - M5 X 16 L Washer Special Screw M5X20Lx4.8 Grommet Wind Screen Mounting

1 2 2 2 2

Fairing Washer Plain Small Self Tapping Screw - Dia 5 Head Lamp Assy Head Lamp W/O Bulb Bolt - Flanged

1 6 6 1 1 2

11 39 0198 11 12 KB UC05 16 13 39 2141 24 14 39 1781 01 15 JL 1812 36

Washer - Plain Screw - Truss - M5 X 16L, 4.8 Washer (Non Metalic Round Washer) Round Head Screw Bracket Lower Mtg

3 2 2 1 1

16 JL 17 JL 18 JL 19 KA

Damper Head Lamp Bracket Upper Mtg Lamp Shade assly. Bolt Pivot Mass Carrier

1 1 1 4

N.I.

1 2 1

N.I. N.I.

JL LD LB JL JL 10 39

N.I. N.I.

10

11

9 22 12 13

14

18 10 15

20 JL 4010 11 Harness Head Lamp 21 DK 2010 44 Bulb-Pilot (12V, W5W) 22 EC 4010 30 Head Lamp Bulb 60/55W (H4)

19

95

1812 49 1812 37 1812 35 Cb08 35

Front Wheel Direction

96

Brand ID: 001MC629

Plate No.: 47 Indicator Light Assembly No. 1 2 3 4 5

Part No. JL JL JL JL 39

4010 4010 4010 4010 1225

05 06 03 04 15

Description Indicator Assy FR LH Indicator Assy FR RH Indicator Assy RR LH Indicator Assy RR RH Nut - Hexagon With Flange : M10

Qty.

Remarks

1 1 1 1 4

2 1

5 4 5

3 5

97

Front Wheel Direction

98

Brand ID: 001MC629

Plate No.: 48 Tail Lamp Assly / Front Number Plate No.

Part No.

Description

Qty.

Remarks

1 3

2

5 4 6

8

18 7

9

10

17

11

1 LB U000 09 2 39 2141 24 3 JU 2328 00 4 LC A000 08 5 KA CB08 25

Screw Mashroom Head Washer None Metallic Front Number Plate Flange Nut Bolt Socket

2 2 1 2 2

6 7 8 9 10

Bracket Number Plate Mtg Lamp Tail Assly Screw - Truss Cross : M5 Bracket Rear Blinker Mtg Bolt M-6

1 1 3 1 2

11 JD 4010 07 12 DD 2010 02 13 JL 1138 03 14 39 0705 01 15 39 1972 15

Rear Number Plate Lamp Reflector - Reflex Bracket -Reflector Reflex Mtg Screw - M5 Nut

1 1 1 2 1

16 JL 2328 00 17 39 2476 04 18 DJ 1612 29 19 PA 4022 04

Rear Number Plate Bolt - Hexagon Head With Flange:M6 Nut Clip Band (Length 110Mm)

1 2 3 2

JZ JL 39 JL 39

1812 4010 1907 1138 1681

99 02 01 00 04

16

14 13

N.I.

15 12

99

Front Wheel Direction

100

Brand ID: 001MC629

Plate No.: 49 Electrical Equipments No.

8

9

Part No.

Description

Qty.

Remarks

1 2 3 4 5

JL JL 30 30 JL

4022 4030 1910 2010 4022

03 00 48 64 01

Harness Wiring Relay Inter lock Band Band Cable Assy Relay To Motor

1 1 5 3 1

6 7 8 9 10

JL JZ JL 39 39

4022 4010 4016 1507 2205

02 13 00 11 04

Cable Earth Headlamp Control Unit Horn LH Washer - Plain Hex Head Bolt - Flanged M8

1 1 1 1 1

11 JL 1812 18 12 JL 4018 03 13 JL 4018 01 14 39 1944 04 15 JG 4018 00

Battery Case Foam Bottom Battery Battery Band Bolt - Flanged 12V 8Ah VRLA Battery

1 11 1 4 1

16 17 18 19 20

Starter Relay- With Grommet Fuse - 20A (Blade Type) Fuse 15A (Blade Type) Flasher - D. C. Solid State Band (Length 110 mm)

1 2 2 1 2

N.I.

Band (Length 200 mm) Band (Length 150 mm)

1 2

N.I. N.I.

N.I.

10

16 1 3

4 15 17 18

7

13

2

JN 3516 04 JL 4022 08 AP 2010 25 DS 2010 25 PA 4022 04

N.I.

14

19

21 JD 4022 12 22 JD 4022 17

11 12

101

Front Wheel Direction

102

Brand ID: 001MC629

Plate No.: 50 Tool Kit

1

103

Description

No.

Part No.

1

DJ 2210 19

2

DK 2210 24 Band Tool Kit

Tool Kit

Qty. 1

Remarks Not Serviceable

2

2

Front Wheel Direction

104

Brand ID: 001MC629

Plate No.: 51 Accessories / Grab Handle

11

10

10

11

5

4

12

105

Qty.

Part No.

1

JL 2312 01

Guard Leg LH

1

2

JL 2312 03

Guard Leg Guard Rh

1

3

JL 2314 04

Grab Handle Assy Lh

1

4

JL 2314 05

Grab Handle Assy Rh

1

5

LA C000 17 Bolt Socket M8 X 1.25

4

6

JL 2312 02

1

Remarks

2

1

7

Description

No.

10

Guard Saree

7 KA CB06 22 Bolt Socket L-22

3

8

JL 2316 00

Mirror Assly LH

1

9

JL 2316 01

Mirror Assly RH

1

10 KD BE06 13 Washer

2

11 KA CA06 35 Bolt Socket

2

12 LA D000 40 Bolt Flanged M6-6L

1

13 JU 2312 07

1

6 3

Front Wheel Direction

Nut Nyloc M8X1.25

106

Kit List Kit Sr No Part No.

Kit List Consisting of Following Parts

Kit Description Part No.

Description

Qty/Kit

1.

36JL0005

Kit Primary Drive+driven-P200 JG551216 JU551405

Gear Primary Drive 22T Housing Clutch Assy Comp

1 1

2.

36JL0009

Kit Chain Sprocket-P200

DV101048 JL141000 JL131228

Sprocket Output (14T) Chain O Ring Type Sprocket 39T O Ring Chain

1 1 1

39201719 JF511215 JF511217 JF511214 DG101029

Seal - Oil Seat Valve Spring Valve Spring Retainer Valve Spring Collet

1 1 1 1 2

JL171028 JL171029 JL171030 JL171031 JL171032 JL171038

Damper Tank Cover Damper Tank Cover Damper Tank Cover Damper Tank Cover Damper Tank Cover Beading Tank LH

1 1 1 1 1 1

JL191007 DK211007

Damper For Seat Damper Seat Front

6 1

JL541207 JL541208 JL521002 JL511022 JG541041 CS101128 JL511001 JG591070

Gasket Gasket Gasket Gasket Gasket Gasket Gasket Gasket

1 1 1 1 1 1 1 1

JL541009 JC101077 JG541021 JG541015 39256220 JG541020

Crankcase LH Black Plug Taper Oil Nozzle Needle Bearing HK 1514 RS Bearing - Needle Roller Jet Oil Crankcase RH

3.

4.

5.

6.

7.

107

36JL0011

36JL0012

36JL0013

36JL0014

36JL0003

Kit Valve Repaire-P200

Kit Tank Damper-P200

Kit Seat Damper-P200

Kit Engine Gasket-P200

Kit Assly C'case LH-P200

Fr LH Fr RH Center LH Center RH Rear

Clutch Cover Magneto Cover Cylinder Block Cylinder Head Crankcase Head Cover(rubber) Exhaust

1 2 1 1 1 1

Consisting of Following Parts

Kit Sr No Part No.

Kit Description

8.

36JL0004

Assly C' Case RH-P200

JL541010 BA102003 39256220 JL541008

Crankcase RH Black Plug - Oil Hole Bearing - Needle Roller Pipe Breather Crankcase

1 3 1 1

9.

36JL0007

Block & Piston-P200

JL521200 JL521004

Piston Assly Compl Cylinder Block With Pipe Breather

1 1

10. 36JL0010

Assly Cyl Head-P200

JL511019 39128321 JG511046

Cylinder Head Ring - O Stud (M8*1.25)

1 1 2

11. 36JL0001

Chain Guide-P200

JL531004 JL531005

Guide Chain (Slack Side) Guide Chain (Tight Side)

1 1

12. 36JL0002

Asly Cl Cover-P200

JL541206 JC101077 JL541218 JG541021 39199020

Clutch Cover P2011 Plug Taper Jet Oil Cover Clutch Oil Nozzle Bearing - Needle

1 1 1 2 1

13. 36JU0001

Piston Ring-P200

JU521206 JU521207 JU521208

Ring Piston Top Ring Piston Second Ring Piston Oil

1 1 1

14. 36JU0002

Friction Plate-P200

JG551448 JG551455

Friction Disk A Disc C-Clutch Friction

5 1

15. 36JL0015

Pillion Hardware-P200

JD113019 30141031 39104011 39078408

Pin Foot Step Ring - O Washer - Plain Pin - Split

1 1 1 1

16. 36JL0016

S Cowl Grommet-P200

JL181219 JL181220 DL161015

Grommet -1 Seat Cowl Grommet -2 Seat Cowl Grommet

2 2 2

Part No.

Description

Qty/Kit

108

Kit List

Kit List

Kit Sr No Part No.

Kit Description

17. 36JL0017

Consisting of Following Parts Part No.

Description

Wind Shield MtG-P200

JG181236 JG181235 JL181247 JL171057

Well Nut - M5 X 16 L Washer Special Grommet Wind Screen Mounting Damper -Tank Sidecover

2 2 2 2

18. 36JL0019

Jet P200

-- ---- --- ---- --- ---- --- ---- -DK121063

Jet Needle Needle Jet Je Holder Main Jet Pilot Jet

1 1 1 1 1

19. 36JL0020

VC Screw P200

-- ---- -DH121130 DH121086 DH121087 DH121088

Screw Adjuster VC O- Ring Screw VC Spring Screw VC Plain Washer O- Ring Screw VC

1 1 1 1 1

20. 36JL0021

Idling Screw P200

-- ---- -DH121163 DH121077

Screw Idling Adjustment Plain Washer Spring

1 1 1

21. 36JL0022

Piston Valve P200

-- ---- -DK121055 DK121054

Vacuum Piston Compl. Diapragm Spring

1 1 1

22. 36JL0023

Gasket / ‘O’ ring P200

DK121058 DH121118 DH121088 DH121130

O-Ring O-Ring O-Ring O-Ring

1 1 1 1

23. 36JL0024

Jet Needle Hardware P200

DD121056 DD121050 DD121052 Dd121054

Holder For Jet Needle Spring-Jet Needle Washer-Jet Needle E-Clip

109

/ -

Gasket Float Chamber Drain Screw VC Screw VC Screw

Qty/Kit

Kit Sr No Part No.

Consisting of Following Parts

Kit Description Part No.

Description

Qty/Kit

1 1 1 1

110

Amendment Sheet

Amendment Sheet

AMENDMENT SHEET (PARTS ADDED) SR. NO.

111

PART NUMBER

DESCRIPTION

AMENDMENT SHEET (PARTS DELETED) QTY.

PAGE NO.

FIGURE NO.

SR. NO.

PART NUMBER

DESCRIPTION

QTY.

PAGE NO.

FIGURE NO.

112

Parts Index

113

Parts Index

Part Number

Figure No.

Page No.

Part Number

Figure No.

Page No.

Part Number

– – 28 1210 08 30 1011 95 30 1910 48 30 2010 64 31 1011 73 31 1610 78 31 2010 79 36 DH19 02 36 JG00 11 36 JL00 01 36 JL00 02 36 JL00 03 36 JL00 04 36 JL00 05 36 JL00 07 36 JL00 09 36 JL00 10 36 JL00 11 36 Jl00 12 36 JL00 13 36 JL00 17 36 JL00 19 36 JL00 20 36 JL00 22 36 JL00 23 36 JL00 24 36 JL00 25 36 JL00 26 36 JL00 27

26 27 5 3 3 4 7 11 5 4 7 15 1 1 2 3 1 2 4 10 5 2 20 5 6 8 10 9 1 13 14

28 28 26 32 102 102 12 88 72 64 50 8 30 22 20 34 10 68 4 6 86 46 96 36 36 36 36 36 58 82 82

36 JL00 28 36 JL00 29 36 JL00 30 36 JU00 01 36 JU00 02 39 0198 11 39 0239 11 39 0239 11 39 0239 11 39 0242 11 39 0265 12 39 0291 15 39 0326 15 39 0422 15 39 0454 11 39 0553 02 39 0705 01 39 0746 01 39 0808 08 39 0840 01 39 0849 14 39 0900 12 39 0983 08 39 0999 06 39 0999 06 39 0999 06 39 1041 19 39 1043 19 39 1046 19 39 1054 11 39 1062 04

14 14 14 2 6 11 21 17 19 9 10 3 11 11 11 12 14 21 6 13 15 12 21 6 11 4 10 8 15 22 9

82 82 82 10 34 96 38 56 88 56 94 90 56 58 52 52 100 20 18 62 42 62 86 26 30 32 30 22 30 86 48

39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39

1076 1180 1197 1225 1283 1507 1537 1665 1672 1673 1681 1769 1773 1776 1778 1780 1781 1781 1791 1907 1907 1913 1931 1931 1941 1943 1943 1943 1944 1944 1944

01 11 04 15 21 11 21 11 04 04 04 04 04 02 02 01 01 01 04 01 01 04 20 20 04 04 04 04 04 04 04

Figure No.

Page No.

Part Number

20 3 18 5 9 9 7A 15 5 10 10 2 6 25 7 16 13 14 3 8 8 11 6 3 4 8 17A 10 23 21 5

88 74 88 98 4 102 30 24 84 4 100 72 22 88 88 36 88 96 94 88 100 46 12 20 58 56 88 96 28 44 50

39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39

1944 1946 1946 1946 1951 1954 1972 1990 2005 2017 2038 2038 2060 2060 2132 2141 2141 2141 2141 2158 2165 2165 2181 2200 2200 2203 2204 2205 2241 2241 2242

04 04 04 04 04 04 15 20 11 19 04 04 04 04 17 24 24 24 24 11 11 11 06 11 11 07 04 04 20 20 20

Figure No.

Page No.

14 7 5 18 3 18 15 2 18 1 6 17 13 3 5 7 9 13 2 2 15 8 3 10 12 5 14 10 3 3 4

102 56 58 86 48 54 100 30 20 6 56 68 58 88 10 84 88 96 100 14 12 42 10 12 34 12 28 102 62 68 68 114

Parts Index Part Number

39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 39 52 52 52 52 52 52 59 59 59 115

2381 2420 2427 2453 2469 2475 2475 2476 2484 2492 2562 2562 2601 2602 2606 2606 2608 2629 2669 2723 2754 2758 JL00 JL00 JL00 JL00 JL00 JL00 0200 0400 1000

04 01 04 04 04 04 04 04 15 11 20 20 20 20 07 07 01 21 21 15 04 21 54 55 59 65 66 67 01 14 02

Parts Index Figure No.

Page No.

3 10 10 9 6 5 6 17 7 12 20 13 11 8 3 16 15 8 10 6 11 6A 8 9 6 6 6 6 14 17 16

86 56 74 18 58 54 72 100 86 40 20 22 20 20 16 4 4 8 48 40 86 82 82 80 80 80 80 88 88 42

Part Number

Figure No.

Page No.

Part Number

59 2000 06 59 2000 28 59 2000 36 59 2100 19 AN 1110 15 AP 1012 36 AP 1210 64 AP 2010 25 BA 1220 03 BF 5510 37 BF 5510 37 BF 6012 07 CB 1210 42 CS 1011 28 DD 1110 11 DD 1110 12 DD 1410 22 DD 1910 15 DD 2010 02 DE 1510 46 DE 1510 47 DE 1510 47 DE 1910 10 DE 1910 10 DE 1910 11 DE 1910 28 DE 1910 29 DE 1910 33 DF 1611 02 DG 1010 29 DG 1014 18

11 14 2 11 13 3 15 18 21 6 15 12 12 12 18 11 17 14 12 10 3 9 10 8 11 7 6 15 12 9 8

22 20 24 62 44 8 38 102 86 14 14 4 36 8 44 44 86 74 100 70 66 70 64 70 64 64 64 64 58 6 30

DG DG DG DG DG DG DG DG DG DG DG DG DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH

1014 1210 1510 1611 1611 1710 1710 1710 1710 1710 1810 1810 1010 1011 1011 1012 1013 1013 1013 1013 1013 1013 1013 1015 1016 1016 1110 1110 1210 1210 1611

56 02 05 24 44 15 16 17 18 19 08 08 48 63 99 35 36 81 82 83 83 92 96 09 07 48 13 16 63 64 46

Figure No.

Page No.

Part Number

Figure No.

Page No.

10 12 4 2 9 17 4 19 5 6 8 25 9 11 6 12 13 3 14 9 17 14 9 3 5 13 16 17 14 13 16

22 38 62 58 54 52 52 52 52 52 74 78 24 42 44 14 14 22 42 20 30 8 42 18 40 34 44 44 36 36 58

DH 1910 06 DH 1910 13 DH 1910 17 DJ 1510 74 DJ 1510 75 DJ 1610 69 DJ 1612 29 DJ 1612 29 DJ 1810 65 DJ 1810 65 DJ 1810 85 DJ 1910 23 DJ 1910 29 DJ 1910 30 DJ 1910 31 DJ 1910 56 DJ 1910 57 DJ 1910 82 DJ 1910 83 DJ 2011 00 DJ 2012 46 DJ 2210 19 DK 1012 25 DK 1012 84 DK 1013 52 DK 1013 86 DK 1015 95 DK 1015 96 DK 1016 05 DK 1110 11 DK 1110 28

9 4 17 7 8 3 4 18 2 22 9 14 2 3 5 8 1 11 12 9 13 1 14 5 25 10 10 12 13 20 8

72 72 74 66 66 56 88 100 28 28 84 64 64 64 64 64 64 74 74 64 74 104 4 44 14 24 42 42 42 44 44 116

Parts Index Part Number

DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK 117

1210 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1810 1810 1810 1810 1810 1810 1810 1810 1810 1810 1810 1810 1810 1810 1810

47 12 13 15 26 31 31 36 45 63 69 74 81 82 83 85 06 07 09 10 12 13 15 17 18 19 20 21 22 23 25

Parts Index Figure No.

Page No.

Part Number

Figure No.

Page No.

15 9 8 14 2 2 11 1 21 7 4 12 20 21 1 13 4 5 14 14 14 14 11 9 7 8 10 6 16 17 23

36 68 68 68 60 70 70 68 36 70 70 70 68 68 70 70 76 76 76 76 76 76 76 76 76 76 76 76 76 76 78

DK 1810 28 DK 1810 73 DK 2110 07 DK 2210 24 DL 1610 15 DP 1011 14 DP 1011 43 DP 1011 91 DS 1011 54 DS 1012 15 DS 1211 26 DS 1410 12 DS 1611 25 DS 1612 87 DS 2010 25 DU 1012 25 DV 1010 48 EC 5610 23 FD 2110 06 JA 1134 03 JA 5410 48 JA 5412 33 JA 5813 14 JB 1812 23 JC 1010 34 JC 1510 19 JC 1510 20 JC 1810 22 JC 1810 23 JC 2010 46 JD 1318 11

24 15 3 2 21 16 15 23 8 9 13 12 2 6 19 7 29 2 5 5 15 2 11 5 9 3 8 21 20 10 6

78 76 46 104 88 34 34 20 24 30 38 88 56 46 8 14 16 46 48 22 32 36 90 8 92 62 76 76 62 62

Part Number

Figure No.

Page No.

Part Number

JD 1910 06 JD 3512 07 JD 3518 00 JD 4010 07 JD 5614 16 JF 5112 07 JF 5112 25 JF 5112 28 JF 5310 07 JF 5310 14 JG 1220 28 JG 1310 01 JG 1312 19 JG 1318 21 JG 1710 29 JG 1812 35 JG 1812 36 JG 1812 38 JG 1910 08 JG 2326 01 JG 2326 06 JG 3514 00 JG 4018 00 JG 5110 21 JG 5110 22 JG 5110 46 JG 5112 70 JG 5210 08 JG 5310 31 JG 5310 39 JG 5310 39

8 12 17 11 5 7 8 1 2 3 2 2 6 5 20 3 2 2 4 9 10 13 15 3 4 5 11 4 9 13 5

46 44 36 100 18 6 12 8 12 12 94 62 68 70 28 96 96 90 46 46 46 4 102 2 2 4 8 10 12 12 42

JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG

5310 5310 5310 5310 5312 5312 5312 5312 5312 5410 5410 5410 5410 5410 5410 5410 5410 5412 5412 5510 5510 5510 5510 5510 5510 5510 5510 5510 5510 5510 5510

40 40 41 41 07 11 12 15 20 15 41 44 45 46 59 63 68 30 31 00 10 13 15 17 19 21 21 22 22 25 27

Figure No.

Page No.

14 6 12 4 7 3 4 5 2 12 16 5 22 4 10 4 1 7 16 22 26 3 5 4 27 19 24 10 18 11 1

12 42 12 42 24 24 24 24 8 22 22 22 20 20 20 22 4 30 30 14 14 14 30 30 14 14 14 14 14 14 14 118

Parts Index Part Number

JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG JG 119

5512 5512 5512 5512 5512 5512 5512 5512 5512 5512 5512 5514 5514 5514 5514 5514 5514 5514 5610 5610 5610 5610 5610 5610 5612 5612 5612 5612 5612 5612 5612

10 13 14 15 20 22 23 24 25 27 28 23 27 28 43 47 49 51 09 10 11 12 13 16 00 04 05 15 17 18 22

Parts Index Figure No.

Page No.

Part Number

Figure No.

Page No.

5 4 7 20 8 16 17 21 23 9 14 14 2 4 8 7 5 11 17 4 1 7 8 9 10 15 16 11 13 12 5

14 14 14 14 14 14 14 14 14 14 14 34 34 34 34 34 34 34 20 16 16 16 16 16 18 20 20 18 18 18 16

JG 5612 25 JG 5612 26 JG 5710 14 JG 5710 16 JG 5710 18 JG 5710 22 JG 5710 24 JG 5810 14 JG 5910 38 JG 5910 39 JG 5910 53 JG 5910 70 JG 5910 88 JG 5910 96 JG 5910 97 JG 6010 05 JG 6010 07 JG 6010 12 JG 6010 13 JG 6012 09 JG 6012 10 JG 6012 11 JG 6012 21 JG 6012 29 JG 6014 00 JG 6214 12 JG 6214 13 JG 6214 17 JL 1110 54 JL 1110 78 JL 1110 81

10 19 24 25 3 2 14 8 3 6 13 10 15 7 8 6 6 13 11 8 7 18 13 17 16 3 2 7 4 6 3

16 20 20 20 26 26 22 50 40 40 40 40 40 40 40 24 20 24 24 28 28 28 28 28 28 42 42 42 48 50 50

Part Number

JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL

1110 1110 1110 1111 1111 1111 1130 1130 1130 1130 1130 1130 1130 1130 1130 1130 1130 1130 1130 1130 1132 1132 1132 1132 1132 1132 1134 1134 1138 1138 1220

82 92 93 03 06 09 00 02 07 12 13 14 15 16 26 27 28 33 33 34 01 02 07 09 10 12 00 01 00 03 01

Figure No.

Page No.

4 7 8 2 1 18 8 1 2 3 12 14 16 15 13 17 19 4 7 7 9 17 7 15 3 8 1 2 9 13 8

50 48 48 50 50 52 54 54 54 54 54 54 54 54 54 54 54 72 54 58 58 58 58 58 58 48 48 100 100 52

Part Number

JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL

1220 1220 1220 1220 1220 1220 1220 1310 1310 1310 1310 1310 1310 1312 1312 1312 1312 1312 1312 1312 1312 1312 1318 1318 1318 1318 1318 1318 1318 1318 1318

02 03 04 06 08 09 14 00 01 04 04 05 06 03 09 11 16 18 19 20 25 26 02 03 04 05 06 07 08 11 12

Figure No.

Page No.

7 10 13 1 14 9 3 7 14 3 1 5 1 13 4 15 5 16 5 6 7 11 12 3 1 6 2 4 5 12 13

52 52 52 52 52 52 52 62 62 60 62 62 60 68 60 68 68 68 60 70 68 68 64 70 66 66 66 66 66 56 56 120

Parts Index Part Number

JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL 121

1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1510 1610 1610 1610 1610 1610 1612 1612 1710 1710 1710 1710 1710 1710 1710 1710

02 03 04 12 21 23 24 26 28 30 32 34 35 36 37 38 01 03 06 08 10 00 01 18 19 20 22 23 24 35 36

Parts Index Figure No.

Page No.

2 3 13 12 1 18 1 2 5 6 18 7 9 26 22 2A 1 15 8 16 3 2 1 20 19 23 2A 2 5 12 11

76 76 76 76 74 74 76 74 74 74 76 74 74 78 78 74 72 74 72 74 72 92 92 86 86 86 88 88 88 86 86

Part Number

JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL

1710 1710 1710 1710 1710 1710 1710 1710 1710 1716 1718 1718 1718 1718 1810 1810 1812 1812 1812 1812 1812 1812 1812 1812 1812 1812 1812 1812 1812 1812 1812

37 44 48 49 57 60 61 62 63 00 00 01 02 03 06 08 03 05 09 14 18 19 21 24 25 26 29 32 35 35 36

Figure No.

Page No.

Part Number

8 1 6 4 1 14 16 15 9 2 13 16 10 15 5 1 6 1 15 23 11 22 16 15 16 8 1 6 19 18 15

86 86 88 86 88 86 88 88 86 86 86 86 86 86 94 96 96 94 56 88 102 88 56 52 52 84 84 84 76 96 96

JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL

1812 1812 1812 1812 1812 1814 1814 1814 1814 1814 1814 1814 1910 1910 2312 2312 2312 2314 2314 2316 2316 2328 2330 2330 2330 2330 2330 2330 2330 3510 3510

37 41 47 49 56 02 05 07 08 09 10 11 01 04 01 02 03 04 05 00 01 00 02 03 04 05 06 15 15 03 05

Figure No.

Page No.

Part Number

17 4 5 16 3 4 1 6 7 4 12 5 1 7 1 6 2 3 4 8 9 16 12 11 10 15 16 9 11 3 4

96 90 96 96 28 56 56 94 94 94 94 56 46 46 106 106 106 106 106 106 106 100 82 82 82 82 82 32 32 44 44

JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL

3510 3512 3512 3512 3512 3516 3518 4010 4010 4010 4010 4010 4010 4014 4014 4014 4014 4016 4018 4018 4020 4022 4022 4022 4022 4024 4024 4026 4030 4036 5010

09 00 01 02 15 00 00 02 03 04 05 06 12 00 01 02 03 00 01 03 01 01 02 03 08 00 03 00 00 00 03

Figure No.

Page No.

2 10 14 15 9 1 7 7 3 4 1 2 9 20 21 10 19 8 13 12 1 5 6 1 17 1 8 6 2 14 1

44 44 44 44 44 42 22 100 98 98 98 98 96 74 74 58 74 102 102 102 44 102 102 102 102 90 90 86 102 58 20 122

Parts Index Part Number

JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL 123

5110 5110 5110 5110 5110 5110 5110 5110 5110 5110 5112 5112 5112 5112 5112 5210 5412 5412 5412 5412 5412 5412 5412 5412 5412 5614 5614 5614 5614 5614 5614

01 02 06 07 09 10 11 16 22 29 05 19 20 21 22 02 02 03 07 08 10 16 21 22 23 00 01 04 05 07 08

Parts Index Figure No.

Page No.

2 1 4 5 3 2 3 3 6 11 6 7 6 5 8 4 1 7 12 5 13 12 26 18 10 1 1A 2 4 7 8

2 2 6 6 4 6 6 36 4 4 6 4 8 8 8 10 32 32 30 32 30 24 20 30 32 18 18 18 18 18 18

Part Number

JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL JL

5614 5614 5810 5810 5810 5810 5810 5810 5810 5810 5810 5810 5810 5810 5810 5812 5812 5812 5812 5812 5813 5910 5910 5910 5910 5911 5911 6010 6012 6012 6012

09 10 00 04 07 09 10 15 16 18 22 23 24 25 27 01 04 05 06 07 00 48 52 75 86 44 48 00 00 04 08

Figure No.

Page No.

Part Number

Figure No.

Page No.

Part Number

Figure No.

Page No.

14 15 1 16 5 8 14 11 10 7 18 2 6 4 4 1 18 19 20 7 2 2 1 9 16 4 17 6 15 9 12

18 18 38 38 38 38 38 38 38 38 38 38 38 38 36 36 36 36 36 36 36 40 40 40 40 40 40 28 28 28 28

JL 6012 09 JL 6012 10 JL 6012 12 JL 6012 13 JL 6012 14 JL 6012 15 JL 6012 19 JL 6012 24 JL 6012 25 JL 7301 5M JL 7301 5N JL 7301 5P JL 7301 5Q JL 7302 5M JL 7302 5N JL 7302 5P JL 7302 5Q JL 7401 5M JL 7401 5N JL 7401 5P JL 7401 5Q JL 7601 5M JL 7601 5N JL 7601 5P JL 7601 5Q JL 7602 5M JL 7602 5N JL 7602 5P JL 7602 5Q JL 7801 5M JL 7801 5N

21 1 11 24 25 19 10 12 12A 2 2 2 2 3 3 3 3 1 1 1 1 5 5 5 5 4 4 4 4 7 7

28 28 28 28 28 28 28 4 4 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 82 82

JL 7801 5P JL 7801 5Q JN 3516 04 JU 2328 00 JU 5310 21 JU 5310 27 JU 5312 13 JU 5312 13 JU 5410 05 JU 5514 01 JU 5514 02 JU 5514 04 JU 5514 06 JU 5710 00 JW 1710 15 JW 1812 36 JZ 1812 99 JZ 4010 13 KA CA06 35 KA CA08 20 KA Ca08 30 KA CB05 14 KA Cb06 22 KA CB08 25 KA Cb08 35 KA DA06 16 KA DA06 30 KA DM06 10 KA DP05 16 KA DQ06 20 KA DQ06 25

7 7 16 3 4 1 7 1 13 6 10 1 9 1 4 3 6 7 11 6 14 6 7 5 19 5 20 19 27 13 14

82 82 102 100 12 12 20 24 20 30 34 34 34 26 28 84 100 102 106 54 56 90 106 100 96 28 38 38 20 8 40 124

Parts Index

125

Part Number

Figure No.

Page No.

KA DQ06 25 KA DQ06 30 KA DQ06 30 KA DQ06 45 KA EM06 22 KADQ06 20 KB QA35 06 KB UA06 12 KB UB04 10 KB UB05 12 KB UC05 16 KD BE06 13 KE AA11 10 KE BA37 15 LA A000 19 LA C000 16 LA C000 17 LA C000 19 LA C000 20 LA C000 22 LA C000 24 LA C000 29 LA C000 36 LA C000 37 LA D000 37 LA D000 40 LA D000 77 LA E000 10 LA E000 14 LA E000 16 LA E000 17

1A 14 6 8 9 14 17 4 8 2 12 10 4 9 10 11 5 2 4 10 6 2A 11 9 13 9 5 7 2 8 28

42 30 32 32 38 24 38 84 94 84 96 106 26 22 68 54 106 52 74 88 16 106 94 94 64 50 20 44 22 6 14

Part Number

Figure No.

Page No.

LA E000 18 LB B000 04 LB B000 06 LB R000 02 LB S000 01 LB U000 09 LC A000 08 LC A000 09 LC D000 01 LC J000 02 LC J000 02 LD A000 07 LD A000 07 LD A000 08 LD A000 13 LD B000 07 LD B000 09 LD B000 20 LD B000 29 LE B000 01 LE B000 01 PA 4022 04

7 3 12 8 4 1 4 12 11 16 19 24 7 2 10 7 15 3 18 4 28 19

26 38 20 96 96 100 100 68 12 62 68 88 96 4 54 90 62 30 68 8 20 100