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PLATE NO.

: CYLINDER HEAD
21 20

ByK

16 15 10 6 8

13 22

18

19

16 17 11 6

19 4 2/3 23 24 7

16

8 1 12 5 9 14

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

FD 1010 15 FA 1012 45 FA 1012 44 39 1661 21 FA 1012 52 FA 1012 76 FD 1010 21 FA 1012 79 39 1543 21 39 2275 15 39 1622 11 39 0999 06 39 1673 04 39 1672 04 39 1633 04

Head Cylinder complete Guide Exhaust valve Guide Intake valve 'O' ring Cover Camshaft side Cover Tappet hole Gasket Cylinder head 'O' ring Tappet cover 'O' ring Domed cap nut Plain washer Hollow dowel pin Flanged Bolt Flange bolt Hex bolt SPL

1 1 1 2 1 2 1 2 1 4 1 2 2 2 1

Includes Sr.No. 2 to 4

FRONT WHEEL DIRECTION

PLATE NO. 1

: CYLINDER HEAD
21 20

ByK

16 15 10 6 8

13 22

18

19

16 17 11 6

19 4 2/3 23 24 7

16

8 1 12 5 9 14

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

16 17 18 19 20 21 22 23 24

39 1696 15 39 1750 05 FD 1210 37 39 1754 21 CB 1210 13 39 1674 04 CB 1210 29 FD 1210 30 FD 1210 29

Hex nut with flange Bolt stud Pipe intake ' O ' ring Gasket carburettor Flange bolt B.S.Valve Tube - BSV - in to Air Filter Tube - For B.S.Valve-out to carb.

4 4 1 2 1 2 1 1 1

For Phillipines Market

Not For Phillipines Market Not For Phillipines Market Not For Phillipines Market

FRONT WHEEL DIRECTION

PLATE NO. 2 : VALVE

ByK
11

10

11 13 12

5 8 3 1/2

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 5A 6 7 8 9 10 11 12 13

CB 1010 16 CB 1010 17 CB 1010 09 CB 1010 18 CB 1010 19 FD 1010 74 CB 1010 20 CB 1010 22 CB 1010 21 FA 1012 86 39 1024 01 CB 1010 15 CB 1012 54 FA 1012 59

Valve intake Valve exhaust Seal valve stem Spring valve outer Spring valve inner Spring Valve - Single Retainer valve spring Cotter valve(Collet) Seat valve spring outer Rocker arm Assly. Screw Shaft rocker arm Plate comp. rocker arm shaft set Screw pan

1 1 2 2 2 2 2 4 2 2 2 2 1 1

New P. No. for Single Spring

Alt. to DD 1013 06

FRONT WHEEL DIRECTION

PLATE NO. 3 : CAMSHAFT AND CHAIN TENSIONER

ByK
12

1 6

10 9

11 8

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

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

FD 1010 59 CB 1010 25 CB 1012 33 CB 1010 32 FA 1012 58 CB 1010 26 FA 1013 26 39 0748 01 39 1673 04 FA 1013 11 39 0999 06 39 2350 04 FD 1011 34

Cam shaft comp. Sprocket camshaft Gasket cam chain adjuster Guide cam chain Flange bolt Chain camshaft drive Tensioner comp cam chain Screw pan cross Flange bolt Adjuster Assly. Cam Chain Hollow dowel pin Flange bolt Guide Cam chain with rubber pad

1 1 1 1 1 1 1 1 2 1 1 1 1 FA 1012 75 - Alternate no.

Ratchet type

Not Separately Serviceable New part added below Crankshaft area

FRONT WHEEL DIRECTION

PLATE NO. 4 : CYLINDER / PISTON / CRANKSHAFT COMPLETE


1

ByK

2 10 8 5 8 18 17

4 7 5 12 13 9 15 14 16 6

11 Fig. No. Part No. Description Qty/ Veh. Remark

1 2 3 3A 3B 3C 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

FD 1010 64 FD 1010 39 CF 1010 23 CF 1010 10 CF 1010 11 CF 1010 12 CF 1010 09 39 1694 17 FA 1013 23 01 1006 10 31 1011 73 39 1055 15 31 1010 76 FA 1013 08 FA 1010 24 FA 1010 23 31 1210 07 39 1046 19 39 1672 04 FA 1013 34 39 2487 11

Cylinder / block piston kit Gasket cylinder block Piston ring set Piston ring - Top Piston ring - Second Piston ring - Oil Pin piston Wire circlip Crankshaft comp Woodruff key for magneto Key woodruff for c'shaft clutch side Hex.nut / flange Gear primary helical Filter Nut Special Washer Spring Cover Seal oil Flange bolt Gear Oil pump drive Plain washer

1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 3 1 1

Individual part nos. for rings

FRONT WHEEL DIRECTION

PLATE NO. 5 : TRANSMISSION

ByK

1 6 7 5 2 3 4 9 10 12 4 11

13 15

14

16

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

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

FA 1010 25 31 1011 93 FA 1010 27 39 2078 11 31 1010 79 31 1010 82 39 0987 17 FA 1011 53 31 1010 83 31 1010 84 31 1012 21 39 0987 17 39 1018 21 39 0989 17 31 1011 17 DD 1011 36

Shaft transmission input Gear transmission spur (2nd) Collar input shaft Plain washer Gear transmission spur (3rd) Gear transmission spur (Top) Ring snap Shaft transmission output Gear transmission spur (3rd) Gear transmission spur (Top) Gear transmission spur comp (Low) Ring snap ' O 'ring External circlip Collar Sprocket output

1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1

Alt. to DD 1010 90

FRONT WHEEL DIRECTION

PLATE NO. 6 : CHANGE DRUM / SHIFT FORK

ByK

4 1 5 7 6

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7

31 1011 91 31 1011 92 31 1010 51 FA 1010 28 31 1010 48 DD 1012 64 39 0992 06

Fork shift Fork shift Rod shift Drum assly change Holder for Drum Screw pan cross Dowel

1 1 2 1 1 1 5 39 0702 01 - Alternate No.

FRONT WHEEL DIRECTION

PLATE NO.

7 : GEAR SHIFTER MECHANISM

ByK

4 8 7 5 2

10 11

13 14 12

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14

FA 1012 60 FD 1010 23 31 1010 55 FA 1010 46 FA 1010 47 FA 1010 48 FA 1012 65 30 1010 83 31 1010 54 FD 1010 02 31 1011 08 39 1069 01 39 0198 11 39 0732 12

Bolt Lever comp change shaft Spring Plate stopper Spacer plate stopper Spring plate stopper Bolt hex head Collar Spring Lever Gear change Damper Hex. head screw Plain washer Washer spring

1 1 1 1 1 1 1 1 1 1 1 1 1 1

FRONT WHEEL DIRECTION

PLATE NO. 8 : ENGINE ASSLY / CRANKCASE RH


15 16 11

ByK

12 16 15 4

5 6 7 9 16 13 10 3 15 14

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

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

FD 1010 01 39 0135 06 39 1050 06 FA 1012 93 39 1864 20 01 1701 11 01 1010 09 FA 1013 29 28 1011 41 39 2594 11 39 1280 05 39 2113 04 39 2114 04 39 2115 04 39 0248 11 39 1225 15

Engine assly comp. Dowel Hollow dowel pin Crankcase comp. RH Ball bearing (Crankshaft) Ball bearing(Shaft transmission input) Ball bearing(Shaft transmission output) Gasket crankcase Oil Plug Plain washer Bolt stud cylinder Hex.head bolt Hex.head bolt Hex.head bolt Plain washer Hex. nut / Flange

1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 3

N.I.

Alt to 39 2611 20

For Engine Mounting

FRONT WHEEL DIRECTION

PLATE NO. 9 : CRANKCASE LH


11 5 4 10 3 13 15 6 7

ByK

14 1

2 9

12 Fig. No. Part No. Description Qty/ Veh. Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

FD 1011 00 FA 1012 92 FA 1210 53 39 1280 05 31 2010 81 39 0703 11 01 1701 10 01 1701 11 39 1080 19 39 1855 19 FD 1010 95 FD 1010 96 39 1065 04 39 0999 06 39 1963 04 DG 1210 02

Crankcase LH assly. Crankcase LH Oil Strainer Bolt stud cylinder Neutral switch Plain washer Ball bearing(Shaft transmission input) Ball bearing(Shaft transmission output) Seal oil Oil seal Fitting Breather tube Flanged Bolt Hollow dowel pin Bolt flanged small Clamp

1 1 1 2 1 1 1 1 1 1 1 1 8 2 1 1

'L' type Breather tube

10

FRONT WHEEL DIRECTION

PLATE NO. 10 : COVER CLUTCH AND COVER GENERATOR


12 15 13 5 7 3

ByK
9

17

10 16 2 8 6

18 1 2

11

14 13

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

FD 1010 62 39 2261 06 39 1074 04 FD 1010 04 FD 10 1128 52 FD00 15 39 1041 19 30 1011 42 FA 1010 38 CB 1012 45 FA 1013 28 FD 1910 28 39 1672 04 39 1675 04 05 1910 33 39 1075 04 39 2079 04 FD 1011 29

Generator cover with decal Hollow dowel pin Bolt flanged small Cover Generator Rear Cover clutch decal Cover clutch with decal Seal oil Seal oil Gauge oil level ' O ' ring Gasket cover clutch Bracket clutch cable Flange bolt Flange bolt Cable holder Bolt Flanged small Flanged bolt Decal Generator Cover

1 2 7 1 1 1 1 1 1 1 1 1 4 3 1 2 1 1

Alt. to DG101518

11

FRONT WHEEL DIRECTION

PLATE NO. 11 : CLUTCH

ByK

9 7 8

6 5 4 3 16 15 10 1

11

14

12

13

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

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

DD 1010 70 39 1053 15 31 1011 35 DD 1010 99 30 1010 96 31 1011 36 30 1010 98 31 1011 37 39 0980 04 DD 1010 69 DD 1010 79 31 1011 48 FA 1010 34 39 2403 20 39 1058 11 31 1011 46

Clutch assly comp Hex nut / Flange Wheel clutch Plate friction Plate clutch Hub clutch Spring Holder Hex head bolt Housing comp clutch Holder Rod push Lever comp Deep Groove Bearing ball Plain washer Collar

1 1 1 4 3 1 6 1 6 1 1 1 1 1 1 1

DD 1011 78 - Alternate no.

12

FRONT WHEEL DIRECTION

PLATE NO. 12 : KICK STARTER MECHANISM

ByK

20

13

16 3 14 19 8

15

17 18 6 4

8 5 7 8

11 10

12

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

FA 1010 04 FA 1012 61 39 2474 04 FA 1012 31 31 1010 38 31 1012 18 31 1010 39 39 0738 17 39 0995 11 31 1010 41 31 1010 40 39 0993 11 FD 1010 68 FD 1010 65 FA 1013 38

Guide kick Screw pan cross Hex. Bolt / Flange Shaft kick Ratchet Gear spur Coil spring External Circlip Plain washer Spring Guide Plain washer Lever assly kick Lever kick Boss kick

1 2 1 1 1 1 1 3 2 1 1 1 1 1 1

13

FRONT WHEEL DIRECTION

PLATE NO. 12 : KICK STARTER MECHANISM

ByK

20

13

16 3 14 19 8

15 18

17 6 4

8 5 7 8

11 10

12

2 Description Qty/ Veh. Remark

Fig. No.

Part No.

16 17 18 19 20

31 1010 44 39 0855 17 30 1012 36 30 1012 34 FD 1010 66

Pin E - type Circlip Ball steel Spring Rubber Sleeve

1 1 2 2 1

15 1010 87 - Alternate no.

14

FRONT WHEEL DIRECTION

PLATE NO. 13 : SILENCER

ByK

5 6 3

4 11 13 12 8 9

10 1

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

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

FD 1010 25 39 2275 15 CB 1011 14 FD 1010 28 39 1830 12 30 1510 42 39 0007 01 39 2425 11 39 1770 04 FD 1010 71 39 0422 15 FD 1610 94 FD 1610 95

Silencer assly comp Domed Cup nut Gasket exhaust pipe Shield silencer Spring washer Washer 'A' Screw hex. head Plain washer Flange bolt Damper Nyloc Nut Damper Silencer Tube Silencer Mounting

1 2 1 1 3 3 3 1 1 1 1 1 1

39 2345 01 - Alternate no.

For Stand

15

FRONT WHEEL DIRECTION

PLATE NO.

14 : CARBURETTOR
12 13 14 16 17 14 4 15 15

ByK

2 8 6 7 1 9 5

10

11

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

FD 1210 40 CB 1210 41 FA 1210 48 CB 1210 54 CB 1210 52 FD 1210 26 FD 1210 25 FA 1210 50 FD 1210 16 CB 1210 32 CB 1210 46 CB 1210 50 24 1210 64 24 1210 63 CB 1210 45 CB 1210 43 CB 1210 44

Carburettor assly Spring Jet needle 'O' Ring (Flange) Needle assly. Needle Jet Main jet Pilot jet Float assly. Seal F.C.B. Fixing Screw Adjuster (Air Screw) Spring (Air Screw) Washer (Idle) 'O'Ring (Idle) Adjuster (Idle screw) Spring (Idle Screw)

1 1 1 1 1 1 1 1 1 1 4 1 1 2 2 1 1

For Phillipines Market

Not Separately Serviceable Not Separately Serviceable

16

FRONT WHEEL DIRECTION

PLATE NO. 15 : AIR CLEANER


1

ByK

5 9

4 10 8 3

6 7 2

11

8 Fig. No. Part No. Description Qty/ Veh.

10 Remark

1 2 3 4 5 6 7 8 9 10 11

FD 1210 01 FD 1210 04 FD 1210 05 FD 1210 06 FD 1210 10 39 0758 01 39 2492 11 39 1672 04 CB 1210 14 FD 1610 78 FD 1210 13

Filter assly air Element air filter Duct inlet Duct outlet Seal air filter Screw pan cross Plain washer Flanged bolt Band A/C connecting tube Collar brace Cover Duct Outlet

1 1 1 1 1 4 4 2 1 2 1

17

FRONT WHEEL DIRECTION

PLATE NO. 16 : OIL PUMP ASSLY

ByK

4 5

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5

DF 1210 03 FD 1010 77 FD 1010 78 39 0999 06 39 1013 21

Oil pump assly Screw Pan Cross Screw Pan Cross Hollow Dowel pin 'O' Ring

1 2 1 1 2

18

FRONT WHEEL DIRECTION

PLATE NO. 17 : MAGNETO ASSLY

ByK

5 4

2 1

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7

FD 1110 06 FD 1110 10 FA 1110 46 39 1920 01 39 0263 12 39 1626 19 39 1858 21

Magneto assly/'O' Ring & Oil Seal Stator assly Pulser coil Screw pan cross Spring washer Oil Seal 'O' Ring

1 1 1 2 2 1 1

Stator assly. Mounting

19

FRONT WHEEL DIRECTION

PLATE NO. 18 : SPARK PLUG AND H. T. COIL

ByK

1 2 3

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6

DD 1110 18 FA 1110 28 FA 1110 29 TE 0066 01 39 1673 04 DD 1110 12

Spark plug Cap spark plug (Non resistive) Grommet spark plug cap H. T. coil Flanged Bolt Grommet for H. T. cable

1 1 1 1 2 1

20

FRONT WHEEL DIRECTION

PLATE NO. 19 : PETROL TANK ASSLY. / FUEL COCK COMP.

ByK

15 16

14

4 3 1 2

12 13 11 11

12 6 9 10 12

12

8 Fig. No. Part No.

7 Qty/ Veh. Remark

Description

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

FD 1410 28 DF 1411 29 39 1211 11 39 1577 04 FD 1410 05 FD 1410 15 FD 1410 16 39 1472 01 39 0740 11 DD 1410 22 DD 1210 14 33 1410 08 DD 1210 13 DF 1810 24 DF 1410 71 DD 1412 28

Damper Tank Damper (Fuel tank mounting) Plain Washer Hex head screw Cap assly Tank Comp. Tap Assly. Petrol cock knob Screw WSP Washer (Non Metallic) Flanged Bolt Tube Fuel Clamp (Cock outlet) Filter fuel Lock Set (4 in 1) Rotor with Key Label For Unleaded Fuel

2 1 1 1 1 1 1 1 2 2 2 4 1 1 1 1

Rear Mtg. Rear Mtg. FD 1410 06 - Alternate no.

21

FRONT WHEEL DIRECTION

PLATE NO. 20 : FRONT WHEEL


2

ByK

3 4

8 9

3 8

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9

16 1510 63 FD 1510 18 15 1510 66 15 1510 10 15 1510 13 15 1510 34 FD 1510 08 39 0248 11 39 2249 15

Wheel rim Front wheel brake drum Ball bearing Spacer assly Oil seal Spacer assly Front hub pin Plain washer Nylock nut

1 1 2 1 1 1 1 2 1

22

FRONT WHEEL DIRECTION

PLATE NO.

21 : FRONT BRAKE ASSLY

ByK

16 15 14 13 1

17 18

19

12 6 8 2 11 9 10

6 7

5 3 4

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

FD 1510 07 16 1510 33 FD 1510 14 16 1510 38 16 1510 55 16 1510 54 16 1510 29 39 1146 19 39 1434 01 39 0198 11 39 1826 12 39 0292 15 39 2245 01 39 1831 12 39 0375 11 16 1510 28 15 1510 78 39 0199 11 30 1510 38

Front brake drum cover Front actuating shaft Indiactor Front Front brake lever Brake shoe assly Spring Speedometer gear Oil seal Hex. screw Plain washer Spring washer Hex. nut Screw cheese head Spring washer Plain washer Support Nylon gear assly Plain washer 'O' ring

1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 2 1

For brake lever tightening For brake lever tightening For brake lever tightening For brake lever tightening

23

FRONT WHEEL DIRECTION

PLATE NO. 22 :

REAR BRAKE ASSLY

ByK

9 13 10 23 7 8 2 11 12 15 3 1

14 14 19

22 21 17

14 14 19 18 20

5 16

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

FD 1510 20 39 0529 04 39 0690 15 39 0240 11 39 0147 08 FA 1510 18 16 1510 54 16 1510 55 16 1510 15 FD 1510 15 16 1510 17 39 0505 04 39 0798 15 39 0292 15 FA 1510 19

Rear brake drum cover Special bolt Nylock nut Plain washer Split pin Tie plate Spring Brake shoe assly Actuating shaft Indicator Rear Rear brake lever Hex. bolt Hex. nut with flange Hex.Nut Spacer hub side

1 1 1 1 1 1 2 2 1 1 1 1 1 4 1

24

FRONT WHEEL DIRECTION

PLATE NO. 22 :

REAR BRAKE ASSLY

ByK

9 13 10 23 7 8 2 11 12 15 3 1

14 14 19

22 21 17

14 14 19 18 20

5 16

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

16 17 18 19 20 21 22 23

FA 1510 20 FD 1510 26 FD 1510 25 39 0711 11 FD 1510 16 39 0714 11 39 0939 15 30 1510 38

Spacer cover side Chain adjuster LH Chain adjuster RH Plain washer Rear hub pin Plain washer Hex Nylock nut 'O' ring

1 1 1 2 1 1 1 1

25

FRONT WHEEL DIRECTION

PLATE NO. 23 : REAR WHEEL / CHAIN

ByK

11 1 3 14 5 13 6 10 11 12

15

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

16 1510 63 FD 1510 17 39 2362 20 15 1510 42 15 1510 47 15 1510 53 30 1011 92 FA 1510 15 15 1510 56 FA 1510 16 15 1510 58 39 0527 04 39 0694 15 15 1510 46 FD 1510 05

Wheel rim Rear wheel brake drum Ball bearing Spacer assly Rubber pad Rear wheel hub Bearing ball Bearing carrier Oil seal Sprocket wheel Lock plate Hex bolt Hex. lock nut 'O' ring Chain

1 1 2 1 4 1 1 1 1 1 2 4 4 1 1

26

FRONT WHEEL DIRECTION

PLATE NO. 24 : TYRES AND TUBES

ByK

4 4

8/9

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9

16 1510 63 16 1510 64 16 1510 65 16 1510 66 15 1510 31 FD 1510 04 FD 1510 13 15 1510 33 15 1510 84

Wheel rim Spoke inner 3.5 dia Spoke outer 3.5 dia Nipple 3.5 dia Rubber tape Tyre Tyre Tube Tube (Front) (Rear) (Front) (Rear)

2 36 36 72 2 1 1 1 1 Alt.FD151027 Alt. FD151028

Proprietory items not serviced

27

FRONT WHEEL DIRECTION

PLATE NO. 25 : CHASSIS


6 5 3 2 4 3 2 14 13 23 22 21 12 8 25 1 17 18 15 11 28 19 24

ByK

20

16

16

26 17 10 27

18

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

FD 1610 01 FD 1810 06 FD 1810 07 FD 1810 09 FD 1810 10 FD 1810 11 FD 1610 48 FD 2210 19 FD 2210 15 FD 2210 05 39 2495 04 39 1940 04 FD 2210 13 FD 1610 78 39 1913 04 FD 1610 83

Frame assly comp Bearing Race Bearing Cage Steering Upper Bearing Cone Lock Nut Special Dust Cover Upper Grab Handle Special Bolt Sari Guard Comp. Sari Guard Comp. Hex. Soc.Hd.Cap Bolt Bolt Flanged Utility Box Assly. Collar Brace Bolt Flanged Tube Frame Assly.

1 2 1 1 1 1 1 4 1 1 1 2 1 2 2 1

For Grab mounting Not For Phillipines Market Not For Phillipines Market Not For Phillipines Market Not For Phillipines Market

28

FRONT WHEEL DIRECTION

PLATE NO. 25 : CHASSIS


6 5 3 2 4 3 2 14 13 23 22 21 12 8 25 1 17 18 15 11 28 19 24

ByK

20

16

16

26 17 10 27

18

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

16 17 18 19 20 21 22 23 24 25 26 27 28 29

39 0200 11 39 1828 12 39 0390 04 FD 1611 61 FD 1610 45 39 0198 11 39 0732 12 39 1079 01 39 1689 04 FD 1611 39 FD 2210 14 FD 2210 22 39 2222 04 FD 1612 01

Plain washer Spring Washer Screw Hex.Head Damper step Bracket Assly. Rear Plain Washer Spring Washer Hex Screw Flange Bolt Spacer Grab Front Mounting Leg Guard Clamp - Leg Guard Flanged Bolt Label VECI

4 4 4 2 1 2 2 2 2 4 1 2 2 1

Qty. 2 for Leg guard lower mtg.

Not For Phillipines Market

Not For Phillipines Market Not For Phillipines Market Not Illustrated

29

FRONT WHEEL DIRECTION

PLATE NO. 26 : SWING ARM / REAR SHOCK ABSORBER

ByK

8 3 2 5 1 9 11 12 10

2 7 6 23 24 22 13 15/21 28 27 14

29 4 17 18 16 20 27 28 30 19 27 25

26

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

FD 1710 16 30 1710 18 FA 1710 39 FD 1710 11 39 1305 11 39 0248 11 39 1829 12 39 1225 15 FD 1710 10 39 0714 11 39 1827 12 39 0712 15 39 2425 11 39 2366 15 FD 1610 32

Swing Arm assly. Complete Bushing Rubber Damper Chain Pivot Pin Swing Arm Plain washer Plain Washer Spring Washer Hex nut / Flange Rear Shock absorber/Spring Plain washer Spring washer Domed cap Nut Plain washer Domed Cap Nut Stay Left

1 2 1 1 1 1 2 1 2 4 2 2 2 2 1

Alt. FD 1710 20

Rear shock absorber bottom mtg.

30

FRONT WHEEL DIRECTION

PLATE NO. 26 : SWING ARM / REAR SHOCK ABSORBER

ByK

8 3 2 5 1 9 11 12 10

2 7 6 23 24 22 13 15/21 28 27 14 31

29 4 17 18 16 20 27 28 30 19 27 25

26

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

DF 1611 62 DF 1611 63 15 1611 03 39 0535 11 39 0146 08 FD 1610 33 39 0200 11 39 1828 12 39 0390 04 FD 1610 99 FD 1611 00 39 0239 11 39 0667 04 39 0876 04 15 1610 69 FD 1612 02 39 1054 11

Step Pin Rubber sleeve Plain Washer Split Pin Stay Right Plain Washer Spring Washer Hex.Screw Chain cover assly.lower Chain cover assly.upper Plain washer Hex.Bolt Hex.Bolt Rubber Cap Label Tyre Pressure Washer Plain for Shock Absorber

2 2 2 2 2 1 2 2 2 1 1 4 3 1 1 1 2

At Lower Mounting (Not Illustrated)

31

FRONT WHEEL DIRECTION

PLATE NO. 27 : MUDGUARD - FRONT / REAR AND REAR NUMBER PLATE

ByK

2 3 4 1 10

This "Kit Mudflap Front" Includes 1) Mudflap Front Fender - Qty.1 2) Plain Washer Qty.6 3) Screw Pan Cross Qty.3 4) Nyloc Nut Qty.3

5 11

13 9 6 7 14 19 15 16 17 12 18

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 10A 11 12 13 14 15 16 17 18 19

39 2124 15 FD 1610 78 39 1944 04 DD 1610 38 FD 1610 52 FD 1610 51 FD 1610 81 FD 1612 11 39 0211 11 FD 2210 24 FD 2210 23 39 0817 15 22 1611 93 DP 1611 45 30 2010 69 39 0258 11 39 1830 12 39 2207 04 39 1506 11 39 0291 15

Hex. / Flange Nut Collar Brace Flanged Bolt Clamp (Front Fender) Fender Rear Front Fender Rear Comp. Clamp Assly.Blinker Rear Bracket Number Plate (Rear) Plain washer KIT Mudflap Front Mud Flap Hex / Flange nut Foam strip Rear Number plate Reflex Reflector Plain washer Spring washer Hex. Head bolt Plain washer Hex nut

2 4 4 1 1 1 1 1 2 1 1 2 1 1 1 1 1 2 2 1

New Number With mounting hardwares

Not For Phillipines Market Not For Phillipines Market

Not For Phillipines Market Not For Phillipines Market For Reflex Reflector
FRONT WHEEL DIRECTION

32

PLATE NO. 28 : STAND ASSLY.

ByK

2 9 10

8 7

1 3

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10

FD 1610 60 39 0422 15 FD 1611 02 FD 1610 62 FD 1610 87 39 0797 08 DL 1610 48 30 1611 58 DF 1611 02 39 0526 11

Stand assly comp. Nyloc nut Pivot pin assly stand Bracket stand spring Spring for stand Pin Cotter Stand side Spring Hex.bolt Plain washer

1 1 1 1 1 1 1 1 1 1

New Number

33

FRONT WHEEL DIRECTION

PLATE NO. 29 : FRONT SUSPENSION

ByK
31 18

30 26 28 7 27 1 10 11 25 22 6 9 16 15 14 4 5 21 20 19 12 13 24 29 23 29 17

2/3 8 Description Qty/ Veh. Remark

Fig. No.

Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

FA 1710 08 FD 1710 04 FD 1710 05 31 1811 05 31 1811 06 FD 1710 07 FD 1710 06 FD 1710 01 FA 1710 06 FD 1710 09 FA 1710 52 FD 1810 01 FD 1810 05 FD 1710 17 39 1829 12

Seal oil - Front Fork Pipe left fork outer Pipe right fork outer Gasket Bolt Cyl. comp. fork Pipe fork inner Front fork Main spring fork Bolt fork 'O' ring fork Holder fork under comp. Lower bearing cone Bkt. assly for Number plate Spring washer

2 1 1 2 2 2 2 2 2 2 2 1 1 1 2

Not For Phillipines Market

34

FRONT WHEEL DIRECTION

PLATE NO. 29 : FRONT SUSPENSION

ByK
31 18

30 26 28 7 27 1 10 11 25 22 6 9 16 15 14 4 5 21 20 19 12 13 24 29 23 29 17

2/3 8

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

39 1813 04 FD 1810 04 FD 1810 12 FD 1810 16 39 0219 11 39 0732 12 39 0062 04 DP 1611 44 39 0757 01 39 0197 11 FD 1810 23 FA 1710 49 FA 1710 50 FD 1810 26 FD 1810 39 FD 1810 40 36 3118 07

Hex.Bolt Plate Upper Front Fork Cap nut special Bkt. Number plate front Plain washer Spring washer Hex. head screw Number plate front Screw pan cross Plain washer Head lamp Mtg. Bracket Assly. Circlip for Oil Seal Dust Cover - Front Fork Damper Boot for Front Fork Band Assly. for Front Fork Refill fork oil 1/2 Ltr.

2 1 1 1 2 2 2 1 2 2 1 2 2 2 2 2 1

Not For Phillipines Market

Not For Phillipines Market Not For Phillipines Market Not For Phillipines Market

For FD 1810 23

N.I.

35

FRONT WHEEL DIRECTION

PLATE NO. 30 : SIDE COVER LH & RH / COVER SEAT

ByK

4 2 1

5 1 1 2 3

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5

31 1610 78 FD 1611 01 DD 1610 22 30 1611 69 DG 1611 21

Washer Screw for side cover Damper Grommet Screw

6 4 2 4 2

36

FRONT WHEEL DIRECTION

PLATE NO. 31 : HANDLE BAR

ByK

1/21 20

20 3

13 22 15 13 16 12 14 15 22 9 5 6 7 11 8 10 14

18 17 19

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

FD 2210 03 31 1810 54 FD 1810 30 39 1074 04 FD 1810 14 FD 1810 19 FD 1810 15 FD 1810 20 FD 1810 31 39 0422 15 DF 1910 11 DF 1910 12 39 0830 01 39 1184 15 30 1910 17

Mirror assly RH Handle Holder handle upper Flanged bolt Damper handle upper Washer plain Damper handle lower Washer plain Holder handle assly lower Nyloc nut Lever / switch assly LH Lever LH Screw pan cross Nyloc nut Nut

1 1 2 4 2 2 2 2 2 2 1 1 2 2 2

37

FRONT WHEEL DIRECTION

PLATE NO. 31 : HANDLE BAR

ByK

1/21 20

20 3

13 22 15 13 16 12 14 15 22 9 5 6 7 11 8 10 14

18 17 19

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

16 17 18 19 20 21 22

DF 1910 26 DF 1910 13 DF 1910 14 DF 1910 27 DF 1910 25 FD 2210 07 30 1910 24

Grip LH Lever switch assly RH Lever RH Grip assly RH Boot adjuster Mirror Assly.LH Screw

1 1 1 1 2 1 2

38

FRONT WHEEL DIRECTION

PLATE NO. 32 : CONTROL CABLES / BRAKE PEDAL

ByK

3 2 18

6 7 4 5 10

19

13

11

12 14 15 16

17

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

FD 1910 01 FD 1910 02 FD 1910 03 30 1910 70 CF 1910 07 39 0242 11 30 1910 72 FD 1910 09 FD 1910 30 FD 1910 27 FD 1910 08 FD 1910 19 39 0146 08 39 0198 11 15 1910 25 FA 1910 63 15 1910 27 30 1910 69 31 1910 32

Cable throttle Clutch control cable comp Front brake cable comp Spring Rod end Washer plain Adjusting nut Speedometer cable Brake pedal assly Boot clutch cable Brake pedal spring Tie rod Split pin Plain washer Spring Pin Brake adjuster Dust seal Boot for Acc. Cable

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FD 1910 05 - Alternate no.

FD 1910 17 - Alternate no.

AA 1210 68 - Alternate no.


FRONT WHEEL DIRECTION

39

PLATE NO. 33 : SPEEDOMETER COMPLETE

ByK

5 3

9 2 6

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9

FD 1910 24 FD 1910 15 FD 1910 13 FD 1910 14 DL 1910 20 FD 1910 16 39 2140 04 FD 1810 32 22 1611 93

Speedometer with lamp Speedometer Cover meter top Cover meter bottom Lamp 12 V - 3 W without cap Bkt. meter Bolt Flanged Special Bolt Foam Strip

1 1 1 1 5 1 2 2 1

Speedo Mtg. Speedo Mtg.(N.I.)

40

FRONT WHEEL DIRECTION

PLATE NO. 34 : HEAD LAMP ASSLY. / FAIRING / WIRING HARNESS

ByK

1 4

9 10 8 2

5 6 Fig. No. Part No. Description Qty/ Veh. Remark

1 2 3 4 5 6 7 8 9 10

FD 2010 02 FD 2010 25 FD 2010 27 DF 2011 64 39 1506 11 39 1943 04 FD 2010 58 FD 1810 34 29 1611 57 39 2141 24

Head light assly comp./lamp Holder assly head light Frame Head light Lamp 12 V - 35 / 35 W Plain washer Flanged bolt Wiring harness Screw SS Clip Nut Washer (Non metallic)

1 1 1 1 4 4 1 2 2 2

N .I.

41

FRONT WHEEL DIRECTION

PLATE NO. 35 : TAIL LIGHT ASSLY

ByK

4 6 9 5

1 3

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9

FD 2010 04 FD 2010 21 31 2010 28 39 0817 15 31 2010 01 39 0211 11 FA 2010 44 FA 2010 45 FD 2010 44

Tail light assly / lamp Lens tail light Lamp 12 V - 10 / 5 W Hex nut / Flange Collar Plain washer Screw pan cross Washer Damper

1 1 1 3 3 3 2 2 3

Tail light mtg.

Tail light mtg. Not Separately serviceable

42

FRONT WHEEL DIRECTION

PLATE NO. 36 : DIRECTION INDICATORS

ByK

2 7 6 5 3

1/4 3

10

8/9

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6 7 8 9 10

FD 2010 51 FD 2010 33 06 2010 83 FD 2010 53 39 1305 11 39 1829 12 39 0794 15 FD 2010 08 FD 2010 09 39 1225 15

Light assly signal Front LH with lamp Lens (side indicator) Lamp 12 V - 10 W Light assly signal Front RH with lamp Plain washer Spring washer Nut Hex. fine Assly DIR. IND. rear LH / lamp Assly DIR. IND. rear RH / lamp Hex. nut / Flange

1 4 4 1 2 2 2 1 1 2

For front indicator mtg. For front indicator mtg. For front indicator mtg.

For rear indicator mtg.

43

FRONT WHEEL DIRECTION

PLATE NO. 37 : ELECTRICAL EQUIPMENTS


23 24 12 18 20

ByK

16

21 17

19 14 25 6 26 15

13

4 5 7

3 11 2 1 9 10 Fig. No. Part No. Description Qty/ Veh. Remark

1 2 3 4 5 6 7 8 9 10

31 2010 03 29 2010 32 CF 2010 15 39 1672 04 06 1112 44 39 1551 04 FD 1110 08 FD 2010 17 FD 1610 43 FD 2010 43 FD 2010 50 39 2222 04 FD 2010 42 DF 1810 24 31 2010 27 31 2010 82

Relay assly Holder Relay R / R unit Hex. bolt / Flange Damper Flange bolt C.D.I. unit with damper Rear brake switch Spring brake switch Horn (12 V D. C.) Horn (12 V D. C.) Flanged bolt Ignition Switch / Key Lock Set (4 in 1) Battery Capacitor electrolytic

1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1

Single point mounting

11 12 13 14 15

44

FRONT WHEEL DIRECTION

PLATE NO. 37 : ELECTRICAL EQUIPMENTS


23 24 12 18 20

ByK

16

21 17

19 14 25 6 26 15

13

4 5 7

3 11 2 1 9 10 Fig. No. Part No. Description Qty/ Veh. Remark

16 17 18 19 20 21 22 23 24 25 26

FD 1611 03 FD 1611 04 22 1611 93 39 2568 08 FD 1611 06 FD 1611 09 39 1174 23 39 0239 11 39 1062 04 FD 1611 10 FD 1611 17

Case Battery Bkt.Battery Retainer Foam strip Split Pin Cover tool kit Damper Lock Cut grommet Plain Washer Bolt flanged small Band Tool kit Grommet

1 1 1 1 1 1 1 3 3 1 1

N.I.

45

FRONT WHEEL DIRECTION

PLATE NO. 38 :

SEAT ASSEMBLY

ByK

1 6 5 2 3

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

1 2 3 4 5 6

FD 2110 01 FD 2110 08 31 2110 04 FD 2110 07 391290 04 39 1211 11

Seat assly comp. Damper seat Damper Spacer seat Hex bolt Plain washer

1 2 6 2 2 2

N.I.

46

FRONT WHEEL DIRECTION

PLATE NO. 39 :

PAINTED PARTS

ByK

2A 2

1 4

7/8 3

9/10

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

FD 7102 W4 FD 7102 X4 FD 7102 Y5 FD 7102 X5 FD 1810 35 FD 1810 36 FD 1810 37 FD 1810 38 FD 1810 56 FD 1611 32 FD 7301 X4 FD 7301 X6 FD 7301 X5 FD 1611 33 FD 7302 X4 FD 7302 X6 FD 7302 X5

Tank Fuel with Decal Tank Fuel with Decal Tank Fuel with Decal Tank Fuel with Decal Fairing Fairing Fairing Fairing Decal For Fairing Cover Side LH Cover Side LH Cover Side LH Cover Side LH Cover Cover Cover Cover Side Side Side Side RH RH RH RH

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Black Red Blue Green Black Red Blue Green For Phillipines Market Black Red Blue Green Black Red Blue Green

2A 3

47

FRONT WHEEL DIRECTION

PLATE NO. 39 :

PAINTED PARTS

ByK

1 4

7/8 3

9/10

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

FD 1611 36 FD 7304 X4 FD 7304 X6 FD 7304 X5 FD 1611 20 FD 7303 X4 FD 7303 X6 FD 7303 X5 FD 1410 39 FD 1410 40 FD 1611 43 FD 1611 45 FD 1611 47 FD 1611 49 FD 1611 44 FD 1611 46 FD 1611 48 FD 1611 50

Fender Fender Fender Fender Cover Cover Cover Cover

Front Front Front Front

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Black Red Blue Green Black Red Blue Green Common for all colours Common for all colours Black Red Blue Green Black Red Blue Green
FRONT WHEEL DIRECTION

Seat/Decal Seat/Decal Seat/Decal Seat/Decal

7 8 9

Tank decal LH Tank Decal RH Cover Cover Cover Cover Seat Decal LH Seat Decal LH Seat Decal LH Seat Decal LH

10

Cover Seat Decal RH Cover Seat Decal RH Cover Seat Decal RH Cover Seat Decal RH

48

PLATE NO. 40 : TOOL KIT

ByK

Fig. No.

Part No.

Description

Qty/ Veh.

Remark

11 1 * * * * * * *

FD 1810 55 FD 2210 01 CB 2210 03 FA 2210 07 30 2210 33 30 2210 04 FD 2210 02 31 2210 04 30 2210 09

Label B Bajaj For BYK Tool kit Tool wrench Tool wrench - 17 x 19 Tool wrench - 10 x 13 Tool driver Tool bag Tool wrench Tool bar

1 1 1 1 1 1 1 1 1

Not Illustrated FD 2210 29 - New No.

Not to service only for reference

49

FRONT WHEEL DIRECTION

ByK
Amendment Sheet (Parts Added)
Sr.No. Part No. Description Qty. Page No. Fig.No.

50

ByK
Amendment Sheet (Parts Deleted)
Sr.No. Part No. Description Qty. Page No. Fig.No.

51

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