Professional Documents
Culture Documents
HD
HD
XL SUPER / HD / SPORT
ASSEMBLY INDEX
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
3
2 1 420307700 HEX NUT M7 4 4 4 4 4
1
2 420051000 SPRING WASHER 4 4 4 4 4
10
3 420002700 PUNCHED WASHER A7.6 4 4 4 4 4
12
NO. OFF
11
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
6 9 NO. NO. SUPER HD SPORT UPG. HD UPG.
7 10
8 1 P030190 CRANKCASE ASSY. 1 1 1 1 1
9
2 P030200 GASKET CRANKCASE 1 1 1 1 1
16 P200170 STUD 2 2 2 2 2
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
14 P080510 SHIELD 1 1 1 1 1
19 P081130 O RING 1 1 1 *
# - Replaces 420667000
* - APPLICABLE FOR THE VEHICLES PRODUCED BEFORE MAY 2005, REF.SIB REF No.SIB/MOPED/01/05-06 DATED 10.09.2006
FIG.No.04 CRANKSHAFT, PISTON ASSEMBLY FIG.NO.04
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
5 K200120 CIRCLIP 1 1 1 1 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
2 P320090 CAP 2 2 2 2 2
3 404037000 ADJUSTER 2 2 2 2 2
4 404049000 NUT 2 2 2 2 2
6 P320240 GASKET 1 1 1 1 1
7 P320250 SPRING 1 1 1 1 1
9 P320280 CIRCLIP 1 1 1 1 1
15 P320070 SPRING 1 1 1 1 1
16 P320080 WASHER 1 1 1 1 1
18 P320200 SCREW 1 1 1 1 1
20 P320210 SPRING 1 1 1 1 1
CARBURETTOR ASSEMBLY 21 P320100 HOUSING 1 1 1 1 1
FIG.No.05 CARBURETTOR ASSEMBLY FIG.NO. 05
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
22 P320110 SPRING 1 1 1 1 1
28 404377000 NUT 1 1 1 1 1
31 P320310 SPINDLE 1 1 1 1 1
35 P320330 CLIP 1 1 1 1 1
CARBURETTOR ASSEMBLY
FIG.No.06 AIR CLEANER ASSEMBLY FIG.NO. 06
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
6 P040260 SPACER 2 2 2 2
14 0086010 CLAMP 1 1 2 1 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
7 0333558 STUD M8 x 33 2 2 2 2 2
18 P050270 O - RING 1
CAT:- CATALYTIC
FIG.No.07 EXHAUST SYSTEM ASSEMBLY FIG.NO. 07
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
**- REF. KIT & KIT CONTENTS CAT -- CATALYTIC CONVERTOR VERSION
FIG.No.08
6A
FAN AND COWL FAN ASSEMBLY FIG.NO. 08
1
2 3 NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
4
2 0335578 SPRING WASHER 6.5x13x1 4 4 5 4 4
6
5 3 7130140 WASHER 1
9 P180200 FAN 1 1 1 1 1
8
9
REP. - REPLACE
FIG.No.09
CLUTCH ASSEMBLY FIG.NO. 09
1 2 NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
12
CLUTCH ASSEMBLY
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
2
1 NO. NO. SUPER HD SPORT UPG. HD UPG.
7 7 0339480 BEARING 1 1 1 1 1
8
8 F200230 OIL SEAL 24 x 35 x 6 1 1 1 1 1
21 408003000 SHIM 1 1 1 1 1
9
22 P200030 CIRCLIP 16x1 1 1 1 1 1
6 7
23 420701700 COTTER PIN 1 1 1 1 1
18 14
16
15,15A
22 27
19 20 21
24 26
25
23
KICKSTARTER ASSEMBLY
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
13 --- SCREW 1 1 1 1 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
6 420011700 WASHER 2 2
FOOTREST ASSEMBLY
FIG.No.14 FRONT SUSPENSION ASSY. FIG.NO.14
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
13 410055700 . SHIM 1 1 1 1
14 410056700 SHIM 1 1 1 1
' * ' ADD COLOR CODE. XL SUP/HD - 2L-BUS GREEN, OL-GREEN(XL), 0A-M RED, OD-BLACK, 0B-BLUE.
XL SUPER UPGD - 0D -HG BLACK,8B -METALLIC BLUE, 7L - MOSS GREEN, SPORT - 2G-W RED, 1D-CH GREY, 6L-LIV GREEN.
FIG.No.14
FRONT SUSPENSION ASSY. FIG.NO.14
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
23 P100360 SPRING 2 2 2
' * ' - ADD COLOR CODE. XL SUP/HD - 2L-BUS GREEN, OL-GREEN(XL), 0A-M RED, OD-BLACK, 0B-BLUE.
XL SUPER UPGD - 0D -HG BLACK,8B -METALLIC BLUE, 7L - MOSS GREEN, SPORT - 2G-W RED, 1D-CH GREY, 6L-LIV GREEN.
** -REF KIT & KIT CONTENTS
FIG.No.14A FRONT SUSPENSION ASSY. (HYDRAULIC FORK) FIG.NO.14A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
12 1257466 WASHER 2 2 2
17 T4100290 SLIDER 4 4 4
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
33 410056700 SHIM 1 1 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 NO. OFF
2 REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
6 0178030 O - RING 1
15
7 1 0330048 SPLIT PIN 2x20 1 1 1 1 1
13 0335698 WASHER 2 2 2 2 2
34
14 0178030 O - RING BRAKE CAM 1 1 1 1 1
35
36
15 0234038 CAM BRAKE 1 1 1 1 1
38 39 5 6
37 16 0339480 BEARING 20x42x12 1 1 1 1 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
25 3207018 SPRING 1
# - OPTIONAL
FIG.No.19 SEAT ASSEMBLY FIG.NO.19
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
23 0138010 CUSHION 3 3
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
10 7130140 WASHER 1 1 3 1 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
SUPER
23 420305700 HEX NUT M6 4 4 4 4
26 P210500 CUSHION 2 2 2 2
* ADD COLOR CODE. XL SUP/HD - 2L-BUS GREEN, OL-GREEN(XL), 0A-M RED, OD-BLACK, 0B-BLUE.
XL SUPER UPGD - 0D -HG BLACK,8B -METALLIC BLUE, 7L - MOSS GREEN SPORT - 2G-W RED, 1D-CH GREY, 6L-LIV GREEN.
MUDGUARD, COVER FRAME & CHAIN GUARD FIG.NO. 21
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
20 420011700 WASHER 4 4
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
24 7130140 WASHER 4 4 4 4
26 7130140 WASHER 8
44 J120410 MUDGUARD 1
* ADD COLOR CODE. XL SUP/HD - 2L-BUS GREEN, OL-GREEN(XL), 0A-M RED, OD-BLACK, 0B-BLUE.
XL SUPER UPGD - 0D -HG BLACK,8B -METALLIC BLUE, 7L - MOSS GREEN 'SPORT -2G-W RED, 1D-CH GREY, 6L-LIV GREEN.
HANDLE BAR, SPEEDOMETER ASSY. FIG.NO.22
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
11 415005700 . SUPPORT 2 2 2 2
16 P150290 WASHER 4 4 4 4
HANDLE BAR, SPEEDOMETER ASSY.
17 0330408 WAVE SPRING WASHER 4 4 4 4
HANDLE BAR, SPEEDOMETER ASSY. FIG.NO. 22
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
HO
RN
4 P150450 BRAKE LEVER LH - NEW 1 1
6 3160278 U NUT 1 1 1 1
11 0332458 SCREW 1 1 1 1
HO
RN
12 P160420 CORD SET 1
13 P150330 GRIP LH 1 1 1 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
8 0332458 SCREW 2 2 2 2
9 3160278 U NUT 1 1 1 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
5 J150240 GRIP LH 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
7 0335516 WASHER 4 4 4 4
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
7 S1160200 WASHER 4
23 7130140 WASHER 2
HEAD LAMP & TAIL LAMP ASSY (SPORT) 26 J160340 SWITCH HORN 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
34 7130140 WASHER 1
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
TOOL KIT
1 P320320 FLOAT 1
17 P321350 FLOAT KIT CARBURETTOR
2 P320310 PIN 1
1 P320220 VALVE CONTROLLER 1
2 P320210 SPRING 1
3 P320060 MIXTURE CONTROLLER 1
18 P321320 ADJUSTMENT KIT - CARBURETTOR
4 P320070 SPRING 1
5 P320080 WASHER 1
6 D046090 O RING 1
1 K200630 OIL SEAL 20 X 30 X 6 ( MAGNETO SIDE ) 1
19 P1320070 ENGINE OIL SEAL KIT 2 P200110 OIL SEAL 20 X 47 X 6 ( CLUTCH SIDE ) 1
3 F200230 OIL SEAL 24 X 35 X 6 1
1 404077000 MAIN JET NO.52 1
20 P321330 MINOR KIT - CARBURETTOR 2 P320480 PILOT JET - NO.34 1
3 P320300 GASKET- FLOAT CHAMBER 1
1 P320130 SEALING RING DIA 24*18 1
21 P321310 CARBURETTOR BUSH KIT
2 P320140 ADAPTOR DIA 24*18 1
1 P320160 ATOMIZER, TYPE - 03 1
2 P320290 CONICAL NEEDLE, TYPE - Z-3 1
3 P320280 CIRCLIP 1
4 P320260 CABLE END SPINDLE 1
5 404053000 PETROL STOP NEEDLE 1
22 P321300 MAJOR KIT - CARBURETTOR 6 404037000 ADJUSTER 1
7 404049000 NUT 1
8 P320100 HOUSING 1
9 P320110 SPRING 1
10 P320120 VALVE SPINDLE 1
11 P320150 SPRAY NOZZLE TYPE 258 1
1 P320090 CAP 1
23 P321360 THROTTLE VALVE - KIT 2 P320250 SPRING 1
3 P320270 THROTTLE VALVE 1