FIG.No.

01
CYLINDER HEAD ASSEMBLY FIG.NO.01

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 M1010540 PLUG ROCKER SHAFT 2 2

2 M1080520 WASHER ROCKER SHAFT 2 2

3 M1200050 DOMED NUT WITH FLANGE 4 4

4 S1010130 WASHER CYLINDER HEAD 3 3

5 R1011010 CAP INSPECTION HOLE 2 2

6 R1200490 O RING 2 2

7 M1200500 HEX FLANGE BOLT M6x40 6 6

8 --- COVER CYLINDER HEAD 1 1 **

9 S1010320 COTTER VALVE 4 4

10 N2011040 RETAINER VALVE SPRING 2 2

11 K3011260 SPRING VALVE 2 2

12 N4011100 SEAL VALVE STEM 2 2

13 M1010610 SEAT VALVE SPRING 2 2

14 M1010550 VALVE INTAKE 1 1

15 S1200270 TUBULAR DOWEL 2 2

16 K6011090 SPARK PLUG 1 1

17 R1011000 VALVE ROCKER ASSY. 2 2

CYLINDER HEAD ASSEMBLY 18 S1010250 NUT TAPPET ADJUSTING 2 2

** - REF. KIT & KIT CONTENTS

FIG.No.01
CYLINDER HEAD ASSEMBLY FIG.NO.01

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

19 S1010240 SCREW TAPPET ADJUSTING 2 2

20 R10109102P CYLINDER HEAD COMP. 1 1 **

21 M1200780 STUD CYLINDER 4 4

22 M1080370 GASKET OIL PIPE UNION 1 1

23 R1010810 BOLT CAM CHAIN TENSIONER 1 1

24 M7010910 PLUG CYLINDER HEAD 1 1

25 0333548 STUD BOLT EXHAUST PIPE 2 2

26 M1010560 VALVE EXHAUST 1 1

27 K6010560 CAMSHAFT COMP. 1 1

28 M1010490 PIN SPROCKET 1 1

29 N5010320 SPROCKET CAMSHAFT COMP. 1 1

30 N5010400 WASHER SPROCKET 1 1

31 M1200940 BOLT SPROCKET 2 2

32 M7010840 C- RING CAMSHAFT 1 1

33 M1010360 GASKET CYLINDER HEAD 1 1

34 R1010850 SHAFT ROCKER ARM 2 2

35 M1200430 HEX FLANGE BOLT M6x55 1 1

CYLINDER HEAD ASSEMBLY

** - PL. REF. KIT AND KIT CONTENTS

FIG.No.01
CYLINDER HEAD ASSEMBLY FIG.NO.01

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

35A M1200470 HEX FLANGE BOLT M6x30 1 1

36 8200130 PUNCHED WASHER 6.5x11x1.6 2 2

37 K6040620 PIPE COMP INTAKE 1 1

37A K6040950 PIPE INTAKE COMP 2 1 1 BSIV

38 N2040940 O-RING 2 2

38A K3040180 O-RING PIPE INTAKE 1 1

39 K6040480 INSULATOR PAD WEGO 1 1

39A K6040960 INSULAOR PAD 1 1 BSIV

40 0334108 NUT CYLINDER 2 2

41 K6040610 INSULATOR PAD 1 1

42 K6010500 CYLINDER HEAD ASSY. 1 1 N.I

43 K6320460 CYLINDER HEAD ASSY. KIT 1 1 "

44 K6040970 GASKET CARBURETTOR 1 1 BSIV

CYLINDER HEAD ASSEMBLY

N.I - NOT ILLUSTRATED

FIG.No.02
CYLINDER BLOCK & CRANK SHAFT ASSY. FIG.NO.02

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 R1011050 GASKET CYLINDER HEAD 1 1

2 S1200270 TUBULAR DOWEL 4 4

3 R1011040 CYLINDER BLOCK 1 1

4 K6180130 GROMMET TENSIONER ADJ 1 1

5 M7011370 ADJUSTER ASSY. 1 1

6 M1200510 HEX FLANGE BOLT M6x25 2 2

7 R1010930 GASKET CYLINDER 1 1

8 N2200340 CIRCLIP PIN PISTON 2 2

9 N2010690 PISTION PIN 1 1

10 N8020300 PISTON KIT STD 1 1 **

10A N8020340 PISTON KIT I O/S 1 1 **

10B N8020350 PISTON KIT II O/S 1 1 **

11 N8020310 RING SET PISTON STD 1 1 **

11A N8020320 RING SET PISTON I O/S 1 1 **

11B N8020330 RING SET PISTON II O/S 1 1 **

12 420702000 WOODRUFF KEY 1 1

CYLINDER BLOCK & CRANK SHAFT ASSY. 13 R1020430 PIN GEAR OILPUMP DRIVE BEBEK 1 1

** - PL. REF. KIT AND KIT CONTENTS

FIG.No.02
CYLINDER BLOCK & CRANK SHAFT ASSY. FIG.NO.02

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

14 M1200770 HEX FLANGE NUT M12x1.25 1 1

15 0330174 CIRCLIP 20x1.2 N 2ND DRIVE GR 1 1

16 K6080780 GEAR OIL PUMP DRIVE 1 1

17 F200230 OIL SEAL 1 1

18 K6200110 BALL BEARING 6205 25x52x15 1 1

19 K6020030 CRANKSHAFT ASSY. 1 1

20 M1200780 STUD BOLT CYL. HEAD 4 4

21 N3010860 CAMCHAIN 1 1

22 K6010540 TENSIONER CAMCHAIN 1 1

23 K6010550 GUIDE CAMCHAIN 1 1

24 S1200680 OILSEAL 30 x 40 x 7 1 1

25 K6180350 ENGINE ASSY. VARIO 1 1

25A K6180760 ENGINE ASSY. VARIO 1 1 BSIV

25A
26 K6320350 CYLINDER BLOCK & PISTION KIT 1 1 **

CYLINDER BLOCK & CRANK SHAFT ASSY.

** - PL. REF. KIT AND KIT CONTENTS

FIG.No.03 CLUTCH & VARIAMATIC ASSY. FIG.NO.03

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6070300 CLUTCH ASSY. 1 1

2 K6081130 SHEET MOVABLE DRIVEN FACE 1 1

3 K6081120 SPRING MOVABLE DRIVEN 1 1

4 K3200850 BALL BEARING 1 1

5 M1200730 CIRCLIP 3 3

6 K6070340 CLUTCH SHOE 3 3

7 K6070350 SPRING CLUTCH 3 3

8 K6070370 DAMPER CLUTCH SHOE 3 3

9 K6070330 PLATE COMP. CLUTCH DRIVE 1 1

10 K6070320 NUT CLUTCH 1 1

11 K6070310 HOUSING COMP. CLUTCH 1 1

12 0330328 WAVE SPRING WASHER M10 1 1

13 420308700 HEX NUT M10 1 1

14 K3200090 NEEDLE ROLLER BEARING 1 1

15 K6081070 FACE COMP FIXED DRIVEN ASSY. 1 1

16 K3082510 V-BELT DRIVE (18x215x28) 1 1

17 K6081080 FACE COMP. MOVABLE ASSY. 1 1

CLUTCH & VARIAMATIC ASSY. 18 K6081110 O RING MOVABLE DRIVEN 2 2

FIG.No.03
CLUTCH & VARIAMATIC ASSY. FIG.NO.03

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

19 K6081160 SEAL MOVABLE DRIVEN 2 2

20 K6081150 SPACER MOVABLE DRIVEN PIN 3 3

21 K6081140 PIN MOVABLE DRIVEN 3 3

22 K6080600 SPACER PLATE DRIVE 1 1

23 K6080990 O RING 15.2x 2.2 1 1

24 K6081170 DAMPER MOVABLE DRIVE PLATE 3 3

25 K6081040 PLATE MOVABLE DRIVE 1 1

26 K6080310 ROLLER COMP MOVABLE DRIVE 6 6

27 K4080050 FACE COMP MOVABLE DRIVE NEW 1 1

28 K6081030 SPACER MOVABLE DRIVE 17.0 1 1

29 K6080370 FACE COMP. FIXED DRIVE 1 1

30 K3081260 RATCHET NUT KICK STARTER 1 1

31 K6081090 COLLAR SPRING 1 1

32 K6081100 O-RING 38.70 2.00 1 1

33 K6080820 SPACER RATCHET NUT 1 1

34 K6081060 CVT DRIVEN ASSY. 1 1 N.I

35 M7070110 SPRING WASHER CLUTCH SHAFT 1 1

CLUTCH & VARIAMATIC ASSY.

N.I - NOT ILLUSTRATED

FIG.No.04
CRANKCASE LH ASSEMBLY FIG.NO.04

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 0331748 CRPH SCREW M6x16 2 2

2 P1200050 WAVE SPRING WASHER M6 2 2

3 K6060200 STARTER MOTOR 1 1

4 N4320740 O RING & GASKET - FLAME 1 1

5 K6320330 CRANKCASE KIT . LH 1 1 K6321020

6 K3060190 BUSH BINDIX RH 11x 9 2 2

7 K6080870 BENDIX DRIVE NP.015 1 1

8 0074010 DOWEL PIN 2 2

9 K6080950 BRKT BENDIX MTG COMP. 1 1

10 0332078 CRPH SCREW M6x30 1 1

11 N2200450 HEX FL BOLT - M6x50 1 1

12 F084010 GASKET OIL DRAIN 2 2

13 F085230 BOLT OIL DRAIN 2 2

14 S1090500 SILENT BLOC SHOCK ABSORBER 1 1

15 0339110 BALL BEARING 12x37x12 6301 1 1

16 420602000 BALL BEARING 12x32x10 - 6201 1 1

17 0332248 REC CSK HD SCR M6x20 3 3

CRANKCASE RH & MAGNETO ASSEMBLY 18 K6030230 COVER BREATHER 1 1

FIG.No.04
CRANKCASE LH ASSEMBLY FIG.NO.04

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

19 K6200170 O-RING DIA 114X2 1 1

20 K6081020 GASKET COVER BREATHER 1 1

21 S1200680 OILSEAL 30 X 40 X 7 1 1

22 K6121720 HOOK STAND SPRING 1 1

23 K3090380 SILENT BLOC BUSH 1 1

24 M1200780 STUD BOLT CYL HEAD 2 2

25 R1010700 STUD CYLINDER HEAD 2 2

26 N2080920 PIPE BREATHER 1 1

27 420464700 HEX SCREW M6x16 1 1

28 K6170100 CABLE GUIDE REAR 1 1

CRANKCASE RH & MAGNETO ASSEMBLY

FIG.No.05
CRANKCASE RH & MAGNETO ASSY. FIG.NO.05

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 S1125320 HOLDER HOSE 1 1

2 K6180100 COVER FAN 1 1
2A K4180160 COVER FAN 1 1
3 S1201000 CRR PAN HD TAP SCR ST4.2x25 7 7
4 F200098 CRPH SCREW M6x16 3 3
5 P1200050 WAVE SPRING WASHER M6 4 4
6 0335558 PUNCHED WASHER 5.5x12.0x1.0 8 8
7 K6180230 BEADING RH 1 1
8 K3180280 FAN 1 1
9 M1200770 HEX FLANGE NUT M12x1.25 1 1
10 K6320990 ROTOR ASSEMBLY 1 1
10A K6320990 ROTOR ASSEMBLY 1 1
10B K3322200 ROTOR ASSEMBLY 1 1 BSIV
11 K3060600 MAGNETO ASSEMBLY 1 1
11A K6060340 MAGNETO ASSEMBLY 1 1
11B K2060010 MAGNETO ASSEMBLY 1 1 BSIV
12 K6180120 GROMMET PIPE INTAKE 1 1
13 420518700 REC.PAN HD SCREW M6X20 5 5
14 8200120 CRR FL PAN HEAD SCREW M5x12 2 2
15 K6180090 HOUSING FAN 1 1
15A K6180500 HOUSING FAN 1 1
16 K3321520 STATOR PLATE ASSY. 1 1
16A K3322190 STATOR PLATE ASSY. 1 1 BSIV
17 N5200270 OILSEAL 20x30x6 2 2
18 M1080400 O RING 1 1
19 K3082010 GAUGE OIL LEVEL 1 1
20 K6320340 KIT CRANKCASE ASSY. RH 1 1
21 F200230 OIL SEAL 1 1
CRANKCASE RH & MAGNETO ASSY. 22 K6180110 DEFLECTOR 1 1
FIG.No.05
CRANKCASE RH & MAGNETO ASSY. FIG.NO.05

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

22A K4180170 DEFLECTOR 1 1

23 K6180220 BEADING DEFLECTOR 1 1

24 R1010700 STUD CYLINDER HEAD 2 2

25 K3081750 OIL FILTER 1 1

26 K3200730 O RING DIA 37.5x3 1 1

27 K3081880 DRAIN PLUG 1 1

28 K3090380 SILENT BLOCK BUSH 1 1

29 K6030250 BUSH CENTER STAND 1 1

30 N5200500 HEX SCREW M6x25 2 2

31 N4080280 OIL PUMP ASSY. 1 1

32 R1200180 HEX FL BOLT M6x60 [CR.CASE L&R] 4 4

33 K3081720 PIPE INLET OIL PUMP 1 1

34 K6030180 COVER OIL PUMP 1 1

35 K6030210 O RING COVER OIL PUMP 1 1

36 S1010390 PIN SPROCKET 1 1

37 0332248 REC CSK HD SCREW M6x20 3 3

38 P1200150 WAVE SPRING WASHER M5 3 3

39 N9060320 PULSAR COIL 1 1

CRANKCASE RH & MAGNETO ASSY.

FIG.No.06
GEAR & GEARCASE ASSEMBLY FIG.NO.06

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K200120 CIRCLIP 47x2 H IS:3075 1 1

2 K6200160 BALL BEARING 25 x 47 x 12 1 1

3 K6200200 OILSEAL 30 X 40 X 7 1 1

4 K6080460 SHAFT COMP. REAR WHEEL 1 1

5 N2200150 BALL BEARING 17x40x12 - 6203 1 1

6 0339110 BALL BEARING 12x37x12 6301 2 2

7 K6080450 GEAR INTERMEDIATE MC 1 1

8 K6080440 SHAFT INTERMEDIATE MC 1 1

9 420602000 BALL BEARING 1 1

10 T4080540 OILSEAL CLUTCH SHAFT 1 1

11 K3082470 SHAFT CLUTCH NEW PEP 1 1

12 K3081490 GASKET GEAR CASE 1 1

13 K6030140 GEARCASE COMP M/C 1 1

14 M1200470 HEX FLANGE BOLT M6x30 7 7

15 K1200040 BALL BEARING 1 1

GEAR & GEARCASE ASSEMBLY

FIG.No.07
COVER VARIATOR & KICKSTARTER ASSY. FIG.NO.07

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 0332248 REC CSK HD SCREW M6x20 6.8 4 4

2 K6080800 COVER FAN CVT 1 1

3 K6080750 GEAR COMP KICKSTARTER DRIVE 1 1

4 K3081320 GEAR COMP. KS IDLER 1 1

5 P080610 SHIM 11.2x18.5x0.5 1 1

6 K3081530 SPRING KICK STARTER SHAFT 1 1

7 K3082190 BUSH KICK STARTER SHAFT 1 1

8 P200270 CRPH SCREW M6x12 1 1

9 P1200050 WAVE SPRING WASHER M6 1 1

10 K6180170 COVER CVT AIR OUTLET 1 1

11 K60301607D COVER VERIATOR ASSY. 1 1

12 K3081500 SPRING KS 1 1

13 K3081240 GEAR KICK STATER DRIVEN 1 1

14 P200150 CIRCLIP 11x1 1 1

15 K3081950 TUBE INLET CVT 1 1

16 K3081970 FOAM FILTER 1 1

17 K3081960 HOLDER FILTER 1 1

COVER VARIATOR & KISKSTARTER ASSY.
FIG.No.07
COVER VARIATOR & KICKSTARTER ASSY. FIG.NO.07

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

18 K3082000 CLAMP TUBE INLET 1 1

19 K3082740 PEDAL LEVER 1 1

20 420701700 COTTER PIN 1 1

21 K60811805D KICK STARTER LEVER 1 1

22 420051000 SPRING WASHER 1 1

23 420307700 HEX NUT M7x 1 1 1

24 F084100 WASHER LEVER KICK STARTER 1 1

25 420919000 CIRCLIP 8.0 1 1

26 K3081590 SPRING KS LEVER 1 1

27 K3200380 BALL KICK LEVER 7/3 1 1

28 K6081390 LEVER ASSY. KICKSTARTER 1 1

29 K3082170 BUSH K S SUPPORT PLATE 1 1

30 0074010 DOWEL PIN 2 2

31 N2200450 HEX FLANGE BOLT M6x1x50 2 2

32 M1200470 HEX FLANGE BOLT M6x30 5 5

COVER VARIATOR & KISKSTARTER ASSY.

 CARBURETTOR ASSY. - UCAL FIG.NO.08

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6040640 CARBURETTOR ASSY. 1 1

2 K3320270 CAP THROTTLE & STARTER 1 1

3 K3320250 MIXING CAP ASSY. 1 1

4 K3320260 GASKET (PACKING) 1 1

5 K6320850 SPRING HOLDER 1 1

6 K6320870 RING HOLDER 1 1

7 K6320800 E RING JET NEEDLE 1 1

8 K6320760 JET NEEDLE 1 1

9 K6320100 PISTON VALVE 1 1

10 K3320540 OVER FLOW & AIR VENT HOSE 2 2

11 K6320840 AIR ADJUSTER 1 1

12 K3321540 SPRING AIR ADJUSTER 1 1

13 K3320500 WASHER AIR ADJUSTER 1 1

14 K3320490 O RING AIR ADJUSTER 1 1

15 K6320370 ADJUSTER 1 1

16 K3320400 SPRING ( IDLE ADJUSTER) 1 1

17 K3320300 O RING FLANGE 1 1

18 K3320330 FLOAT ASSY. 1 1

19 N4320400 PILOT JET 1 1

 CARBURETTOR ASSY. - UCAL FIG.NO.08

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

19 N4320400 PILOT JET 1 1

20 K6320770 JET HOLDER 1 1

21 K6320780 MAIN JET (JET) 1 1

22 K6320790 NEEDLE JET 1 1

23 K3320310 PIN FLOAT 1 1

24 K3320320 NEEDLE VALVE ASSY. 1 1

25 K6320190 GUIDE HOLDER ASSY. 1 1

26 K320710 O RING (PLUNGER) 1 1

27 K320720 SPRING (PLUNGER) 1 1

28 K6320390 PLUNGER 1 1

29 K3320360 SEAL FLOAT BODY 1 1

30 K3321500 FLOAT BODY ASSY. NEW 1 1

31 K3320530 SCREW SET FLOAT BODY 4 4

32 N5320400 CLIP 2 2

33 K320640 CAP STARTER 1 1

34 N2320610 HOLDER 1 1

35 K6321810 FILTER FUEL INLET 1 1

 CARBURETTOR ASSY. - SPACO MAKE - BSIV FIG.NO.08A

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6040980 CARBURETTOR ASSY. 1 1 BSIV

2 K6321800 RUBBER CAP 1 1

3 K6321690 MIXING CHAMBER COVER 1 1

4 P1320570 GASKET (PACKING) 1 1

5 N8320310 COMPRESSION SPRING RET. DISC 1 1

6 N8320600 WASHER RETAINER DISC 1 1

7 P1320530 CIRCLIP 1 1

8 K6321780 JET NEEDLE 1 1

8A K6322090 JET NEEDLE 1 1
9 K6321710 THROTTLE VALVE TYPE29 1 1
9A K6322040 THROTTLE VALVE TYPE29 1 1
10 N8320460 RUBBER PIPE 2 2

11 K6321660 AIR ADJUSTER 1 1

12 N8320360 SPRING AIR ADJUSTER 1 1

13 N8320370 WASHER AIR ADJUSTER 1 1

14 N8320380 O RING AIR ADJUSTER 1 1

15 P1320560 VALVE CONTROLLER 1 1

16 K6321790 SPRING VALVE CONTROLLER 1 1

17 P6320420 O RING FLANGE 1 1

18 N8320500 FLOAT 1 1

19 K6321760 SLOW JET NO. 45 1 1

 CARBURETTOR ASSY. - SPACO MAKE FIG.NO.08A

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

20 K6321680 NEEDLE JET HOLDER TYPE03 1 1

20A k6322060 NEEDLE JET HOLDER TYPE03 1 1 UCAL
21 K6321670 MAIN JET (JET) NO.65 1 1
21A K6322050 MAIN JET (JET) NO.65 1 1 UCAL
22 K6321770 NEEDLE JET 1 1
22A K6320790 NEEDLE JET 1 1 UCAL
23 N8320490 ARM PIN FLOAT 1 1

24 P6320320 PETROL STOP NEEDLE 1 1

25 N8320930 HOUSING CHOKE 1 1

26 N8320730 O RING CHOKE 1 1

27 K6321820 SPRING CHOKE 1 1

28 N8320950 VALVE SPINDLE CHOKE 1 1

29 P1320620 GASKET FC 1 1

30 K6321830 F C COVER ASSY. 1 1

30A K6322070 F C COVER ASSY. 1 1 UCAL
31 N8320450 SCREW ASSEMBLY 2 2

32 P320330 TUBE CLIP 2 2

33 N8320270 CAP STARTER 1 1

34 P6320430 RETAINER DISC 1 1

35 K6321720 SPRING FOR THROTTLE VALVE 1 1

36 K6321810 FILTER FUEL INLET 1 1

37 N8320780 O RING DRAIN PLUG 1 1

38 N8320470 DRAIN PLUG 1 1

38A K6322120 DRAIN PLUG 1 1 UCAL
FIG.No. 09 AIR CLEANER ASSEMBLY FIG.NO. 09
1

20
2 NO. OFF
REF PART DESCRIPTION REMARKS
3 NO. NO. DRUM DISC
7 8
2
14
4
1 K6040660 AIR CLEANER ASSY. 1 1 BSIV, **
2 0086010 HOSE CLIP DIA 41.5 2 2
5 6
3 K6040710 HOSE OUT LET 1 1

7
4 --- COVER AIR 1 1 N.S
13
11 5 0335578 PUNCHED WASHER 2 2
7 7
10
12 6 M1200470 HEX FLANGE BOLT M6x30 2 2
7 K140820 HOSE CLIP 4 4
8 G4040330 DRAIN PIPE 1 1
9
9 K6040690 FILTER HOLDER COMP. 1 1
10 --- COVER HOLDER 1 1 1 N.S
11 --- COVER HOLDER 2 1 1 "
12 K6040770 DRAIN PIPE 1 1
13 K6040900 HOSE BREATHER PVC 1 1
14 K6040680 SEAL AIR CLEANER BOTTOM 1 1
16
15
17 15 K6040730 SEAL AIR CLEANER 1 1
16
21 16 M1200660 CRR PAN HEAD SCREW M6x16 6 6
17 K6040700 COVER AIR CLEANER LH 1 1
18 P6040110 DRAIN PIPE SHORT 1 1
22
19 R1140440 HOSE CLIP DIA13 mm 1 1
20 K6040920 RESONATOR INTAKE 1 1
23
21 R1040460 CLIP HOSE BREATHER 1 1
18
22 K6040490 HOSE CRANKCASE BREATHER 1 1
19
23 R1140340 HOSE CLIP DIA 1 1
AIR CLEANER ASSEMBLY

N.S - NOT SERVICE

** - E4 MARKING ON TOP COVER AREA
FIG.No.10
SECONDARY AIR INJECTION ASSY. FIG.NO.10

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6040400 HOSE AIR CUT VALVE 1 1

2 R1140350 HOSE CLIP DIA 7MM 3 3

3 0332048 CRPH SCR M5x55 6.8 2 2

4 N9041060 SEC AIR INJECTION VALVE 1 1

4A KA040010 SEC AIR INJECTION VALVE 1 1 BSIV

5 M1200660 CRPH SCREW M5x16 1 1

6 M1200520 HEX FLANGE BOLT M6x16 1 1

7 K3040620 COVER FILTER COMP. AIR INJ. 1 1

8 K3040640 SEAL AIR INJ. FILTER 1 1

9 K6040430 STICK COMP. AIR FILTER 1 1

10 K6040380 FOAM AIR INJECTION 1 1

11 K6040360 CASE FILTER AIR INJECTION 1 1

12 N2041150 HOSE CLIP 1 1

13 K3040670 HOSE AIR ENTRY 1 1

14 K3040650 GROMMET AIR INJECTION 1 1

15 K6040350 AIR FILTER ASSY. SAI 1 1

16 N2041160 HOSE CLIP No. 2 2 2

SECONDARY AIR INJECTION ASSY. 17 K3040230 HOSE AIR OUTLET 1 1

FIG.No.10
SECONDARY AIR INJECTION ASSY. FIG.NO.10

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

18 K6040320 PIPE COMP. AIR INJECTION 1 1

19 N8040340 O RING AIR INJECTION 1 1

20 0330408 WAVE SPRING WASHER M6 1 1

21 M1200520 HEX FLANGE BOLT M6x16 1 1

22 N4040560 TEE INSERT PIPE INTAKE 1 1

23 N8040370 HOSE CLIP VACUUM 2 2

24 N4040680 HOSE TEE INSERT 1 1

25 K6140180 HOSE VACUUM 1 1

26 N3160220 SPACER RC LAMP MTG 1 1

SECONDARY AIR INJECTION ASSY.

 MUFFLER ASSEMBLY FIG.NO.11

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6050410 MUFFLER GUARD 1 1

2 N9200100 HEX FLANGE BOLT M6x8.0 4 4

3 K6200310 PUNCHED WASHER 13x6.5x1.6 4 4 BSIV

4 M7200070 HEX FLANGE BOLT M8x1.25x55 2 2

5 0330318 WAVE SPRING WASHER M8 2 2

6 K6050430 MUFFLER GUARD FRONT 1 1

7 N3200210 PUNCHED WASHER 8.2x25x2 2 2

8 M1050310 GASKET EXHAUST PIPE 1 1

9 0334548 HEX NUT M8 2 2

10 K6050380 MUFFLER SUB ASSY. 1 1

10A K6050690 MUFFLER SUB ASSY. 1 1 BSIV

11 K6050390 MUFFLER COMP ASSY. 1 1

11A K6050710 MUFFLER COMP ASSY. 1 1 BSIV

12 M1200890 U NUT M8x1.25 2 2

13 K6222550 CVTI LOGO GUARD 1 1

FIG.No. 12 HANDLE BAR & CABLE ASSY. FIG.NO.12
4A 6A

NO. OFF
REF PART DESCRIPTION REMARKS
1
4 NO. NO. DRUM DISC

2
7 1 R3150060 GRIP COMP THROTTLE 1 1
29 7
5 2 0332038 CRPH SCR M5x45 1 1
5
41
6 3 P1200150 WAVE SPRING WASHER M5 1 1
38
39
13 37
35 4 K6221890 MIRROR ASSY. RH 1 1
31 40 7
36 8 4A K6223720 MIRROR ASSY. RH 1 1 MIL.EDITION
5
34 5 K6222160 GROMMET MIRROR LH 2 2
9
33 6 K6221880 MIRROR ASSY. LH 1 1
30
6A K6223710 MIRROR ASSY. LH 1 1 MIL.EDITION
28 11 10
48
32 7 K6320910 NUT MIRROR RH 2 2
13
15
27 25
24 8 K6150280 HANDLE BAR COMP 1 1
17 12
19
9 R3150050 GRIP LH 1 1
14
10 K200570 U NUT 10 X 1.25 FLANGED 1 1
16
26 11 P1200180 PUNCHED WASHER A11 1 1
46
43 18
12 K6150190 CONTROL LEVER ASSY. LH 1
21 47
42 13 K3200420 PAN HEAD SCREW SPECIAL 2
22 22 44
23 23
14 N3320510 ASSY. SWITCH STOP LAMP 2
45
20
15 K6150200 BRKT LEVER LH 1

HANDLEBAR & CABLE ASSY. 16 K3150270 CLAMP LEVER BRKTLH 1

FIG.No. 12 HANDLE BAR & CABLE ASSY. FIG.NO.12
4A 6A

NO. OFF
REF PART DESCRIPTION REMARKS
1
4 NO. NO. DRUM DISC
17 K3150250 BRAKE LEVER LH 1
2
7 18 409047000 NYLON LOCK NUT M6X 8 2
29 7 19 K6170010 CABLE ASSY. FRONT BRAKE 1
5
20 N2110690 SPRING FRONT BRAKE CABLE 1
5
41 21 N2110680 DUST SEAL FRONT BRAKE CABLE 1
6 22 0254038 PIN FR.BR. LEVER - BREAK 2
38
39 23 0334268 NUT FR.BR. CABLE ADJ.- BREAK 2
13 37
31 40 35 7 24 K6170080 CABLE ASSY. CHOKE 1 1
25 K6170190 CABLE ASSY. THROTTLE 1 1
36 8
26 8200120 CRPH TAPPING SCREW M5*12 1 1
5
16 K3150270 CLAMP LEVER BRKT LH 1 1
34 17 K3150250 BRAKE LEVER LH 1 1
9
33 27 K6170180 CABLE ASSY. REAR BRAKE 1 1
28 420302700 HEX NUT M5x8 1 1
30 29 P1200150 WAVE SPRING WASHER M5 1 1
28 30 0335558 PUNCHED WASHER 5.5x12.0x1.0 1 1
11 10
48 31 K3150260 BRAKE LEVER RH 1 1
32
13 35 K6150380 BRKT LEVER RH 1 1
15
27 25 36 420957700 PHILIPS HD SCREW M4x15 1 1
24 17 12 37 0330448 WAVE SPRING WASHER M4 1 1
19
38 K3150570 CASE THROTTLE UNDER 1 1
14 39 0254096 PIECE THROTTLE CABLE END 1 1
40 K6150140 CONTROL LEVER ASSY. RH 1 1
16 41 K150420 CASE THROTTLE UPPER 1 1
26
42 K3110690 SPRING BRAKE CABLE REAR 1 1
46
43 18 32 K3200660 HEX FLANGE BOLT M10x1.25x45 1 1
33 S1150500 BUSH ROUND 1 1
21 47
42 34 K3150280 CLAMP LEVER BRKT RH 1 1
22 22 44
43 --- SCREW M3 1 1
23 23
44 K6150210 STOPPER PARKING BRAKE COMP. 1 1
45 45 S1200820 CIRCLIP 2.3 E CLIP 1 1
20
46 K6150250 HINGE PARKING BRAKE 1 1
47 K6150249 SPRING PARKING BRAKE 1 1
HANDLEBAR & CABLE ASSY.
FIG.No. 12A HANDLE BAR & CABLE ASSY. - SBS FIG.NO.12A

4 NO. OFF NO. OFF

1 1A REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC
6
2
1 R3150060 GRIP COMP THROTTLE 1 1
3 7
1A R3150040 GRIP COMP THROTTLE 1 CLASSIC
5 2 0332038 CRPH SCR M5x45 1 1
41 3 P1200150 WAVE SPRING WASHER M5 1 1
7
48 38 4 K6221890 MIRROR ASSY. RH 1 1
39
13 37
5 5 K6222160 GROMMET MIRROR LH 2 2
31 40 35
6 K6221880 MIRROR ASSY. LH 1 1
36 7 K6320910 NUT MIRROR RH 2 2
8 8A
9 9A 8 K6150280 HANDLE BAR COMP 1 1
34 8A K6150630 HANDLE BAR COMP 1 CLASSIC
33 9 R3150050 GRIP LH 1 1
9A R3150030 GRIP LH 1 CLASSIC
30 10 K200570 U NUT 10 X 1.25 FLANGED 1 1
28 10 11 P1200180 PUNCHED WASHER A11 1 1
29 11 K6150400 CONTROL LEVER ASSY LH
32 12 1 SBS
12
48 13 K3200420 PAN HEAD SCREW SPECIAL 2
27 25
24 13A K6150450 SPECIAL SCREW 1 SBS
13A
19 15 14 K160240 ASSY. SWITCH STOP LAMP 2
15 K6150430 BRKT LEVER LH 1 SBS
19A 16 16 K6150570 CLAMP LEVER BRKT LH 1 ,,
17 K6150550 SUPPORT BRAKE LEVER 1 ,,
18
26 18 409047000 NYLON LOCK NUT M6X 8 2
46 19 K6170210 CABLE ASSY BRAKE FRONT LH 1 SBS
17 43
19A K6170220 CABLE ASSY BRAKE FRONT RH 1 ,,
14
21 44 20 N2110690 SPRING FRONT BRAKE CABLE 1 ,,
45
22 22 21 N2110680 DUST SEAL FRONT BRAKE CABLE 2 2
23 47 22 0254038 PIN FR.BR. LEVER - BREAK 2 2
23 0334268 NUT FR.BR. CABLE ADJ.- BREAK 2 2
42
20 24 K6170080 CABLE ASSY. CHOKE 1 1
25 K6170190 CABLE ASSY. THROTTLE 1 1
HANDLEBAR & CABLE ASSY. - SBS 26 8200120 CRPH TAPPING SCREW M5*12 1 1
FIG.No. 12A HANDLE BAR & CABLE ASSY. - SBS FIG.NO.12A

4
1 1A NO. OFF
REF PART DESCRIPTION REMARKS
6
NO. NO. DRUM DISC
2
7 27 K6170180 CABLE ASSY. REAR BRAKE 1 1
3
28 420302700 HEX NUT M5x8 1 1
5
41 29 0330308 WAVE SPRING WASHER M5 1 1
7
48 38 30 0335558 PUNCHED WASHER 5.5x12.0x1.0 1 1
39
13 37 31 K3150260 BRAKE LEVER RH 1 1
5
31 40 35 32 K3200660 HEX FLANGE BOLT M10x1.25x45 1 1
36 33 S1150500 BUSH ROUND 1 1
8 8A
9 9A 34 K3150280 CLAMP LEVER BRKT RH 1 1
34 35 K6150380 BRKT LEVER RH 1 1
33 36 420957700 PHILIPS HD SCREW M4x15 1 1
37 0330448 WAVE SPRING WASHER M4 1 1
30
38 K3150570 CASE THROTTLE UNDER 1 1
28 10 39 0254096 PIECE THROTTLE CABLE END 1 1
29 11
32 40 K6150140 CONTROL LEVER ASSY. RH 1 1
12
48
27 25 41 K150420 CASE THROTTLE UPPER 1 1
24
15 13A 42 --- SCREW M3 1 SBS
19
43 K6321540 KIT PARKING BRAKE 1 ,,
19A 16 K6150580 KIT BRAKE LEVER ASSY RR ,,
44 1
45 K6111390 SPRING BRAKE CABLE REAR 1
18 K6111340 SPRING BRAKE RETURN DRUM
26 46 1 SBS
46 47 K6111350 BRAKE ADJUSTER 2 ,,
17 43
14 48 K6150650 DAMPER HANDLE BAR 2 CLASSIC
21 44
45
22 22

23 47

42
20

HANDLEBAR & CABLE ASSY. - SBS

FIG.No. 13
FUEL TANK & AUTO FUEL COCK ASSY. FIG.NO.13
1
21
NO. OFF
REF PART DESCRIPTION REMARKS
20 6
NO. NO. DRUM DISC

7 7A
1 R1200380 HEX FLANGE BOLT M5x14 4 4
2 22
2 K6160520 FUEL SENDER UNIT 1 1
3 G5141700 UPPER CUP BREATHER 1 1
4 G5141710 LOWER CUP BREATHER 1 1
3
5 K6140300 FUEL TANK COMP. 1 1
4 8 9 10
6 R1200280 CRR PAN HEAD SCREW M4x20 3 3
7 K6140160 FUEL TANK CAP ASSY. 1 1

5 7A K6140460 CAP FUEL TANK 1 1 REF.

8 P1200050 WAVE SPRING WASHER M6 2 2
9 420011700 WASHER 6.4 2 2
10 420462700 HEX BOLT M6x20 2 2
11 R1140410 FUEL FILTER 1 1
12 K140820 HOSE CLIP 2 2
11 13 K6140320 HOSE FUEL TUBE 1 1
14
12
12 14 N2200500 HEX FLANGE BOLT M6x1.25 1 1
15 15A
15 K3140060 AUTO FUEL COCK 1 1
13
18 15A K6140540 AUTO FUEL COCK 1 1 BSIV
16 17 16 N8040370 HOSE CLIP VACUUM 4 4
17 K3140240 HOSE FUEL CARBURETTOR 1 1

18 18 K3140260 SPRING VACUUM HOSE 2 2

19 19 K3140620 HOSE VACUUM 1 1
20 K6140290 FUEL TANK ASSY. 1 1
21 K6320480 COVER CAP FUEL TANK 1 1
22 K6140470 LOGO FUEL TANK LOCK 1 1 REF.
23 K6123140 BRKT FUEL TNAK MTG 1 1
FUEL TANK & AUTO FUEL COCK ASSY.
FIG.No.14
HEAD LAMP ASSY. HOUSING ASSY. FIG.NO.14

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 --- HOUSING HEAD LAMP FRONT 1 1 REF. COLOUR

MATRIX
2 K6320430 GROMMET HEAD LAMP 2 2

3 K3161510 POSITION BULB HEAD LAMP 2 2

4 K6160480 CORD SET POSITION LAMP 1 1

5 K6321070 P CLAMP 2 2

6 K200300 S T SCREW 3.5x16 2 2

7 K6221430 HEAD LAMP ASSY. 1 1

8 M7160190 BULB HEAD LAMP 1 1

9 K6320720 SPRING CLIP + SPRING BRKT 1 1

10 K6320720 SCREW 2 2

11 N8324800 BOOT HEADLAMP HOLDER 1 1

12 N8324800 AIR VENT 1 1

13 K6320720 SPRING CLIP + SPRING BRKT 1 1

14 K6320420 CLIP NUT M6 1 1

15 0336088 PUNCHED WASHER 4.3x9x1 4 4

16 R1160190 SWITCH LIGHTING 1 1

16A K6224020 HOUSING HEAD LAMP REAR CAP 1 BSIV

17 K6221410 HOUSING HEAD LAMP REAR 1 1

HEAD LAMP ASSY & HOUSING ASSY.
17A K6223040 HOUSING HD LAMP RR COLOUR MAT. BEIGE 1 1 (Li.E)

17B K6222390 HOUSING HEAD LAMP REAR DISC 1 1 BSIV

Li.E - LIMITED EDITION

FIG.No.14
HEAD LAMP ASSY. HOUSING ASSY. FIG.NO.14

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

17C K6224840 HOUSING HEADLAMP REAR 1 CLASSIC

18 R1160200 SWITCH START 1 1
19 K6160470 BEAM CONTROL CUM PASS SWITCH 1 1
20 R1200280 CRR PAN HD SCREW M4x20 4 4
21 R1160210 SWITCH TSL 1 1
21A K6160400 SWITCH TSL 1 1 BSIV
22 R1160230 SWITCH HORN 1 1
23 M1200670 CRR PAN HEAD SCREW M6x16 2 2
24 0335608 PUNCHED WASHER 6.5x16x1.2 1 1
25 420464700 HEX SCREW M6x16 1 1
26 K200320 CRR PAN HEAD S TAP SCREW 4.2x16 7 7
27 K6321090 HEAD LAMP W/O BULB 1 1 N.I
28 K6321100 TSL LH W/O BULB 1 1 "
29 K6321110 TSL RH W/O BULB 1 1 "
30 K6224880 MIRROR ASSY. RH 1 CLASSIC
31 K6224870 MIRROR ASSY. LH 1 CLASSIC
32 K6224930 WIND SHIELD MTG 2 CLASSIC
33 0332238 RECESSED CSK HEAD SCREW M6x12 2 CLASSIC
34 K6225040 GROMMET MIRROR RH 1 CLASSIC
35 K6224940 BRACKET 2 CLASSIC
36 0334548 HEX NUT M8 2 CLASSIC
37 K2200080 TRUSS HEAD CAP SCREW M6x16 2 CLASSIC
38 K6225020 WINDSHIELD ASSY. (WITH MTG) 1 CLASSIC
39 K6225030 GROMMET MIRROR LH 1 CLASSIC
40 N3120130 GROMMET HEAD LAMP 4 CLASSIC
41 N9051860 CUP WASHER 4 CLASSIC

HEAD LAMP ASSY & HOUSING ASSY.

FIG.No.15
SEAT ASSEMBLY FIG.NO.15

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6130150 SEAT ASSEMBLY 1 1

DARK BROWN
1A K6130190 SEAT ASSEMBLY (NEW) 1 1 TWIN COLOUR

1B K6130220 SEAT ASSEMBLY (NEW) 1 1 MIL.EDITION

1C K6130320 SEAT ASSEMBLY 1 1 CLASSIC

2 K6130140 COVER COMP SEAT 1 1

DARK BROWN
2A K6130180 COVER COMP SEAT (NEW) 1 1 TWIN COLOUR

2B K6130230 COVER COMP SEAT 1 1 MIL.EDITION

2C K6130330 COVER COMP SEAT 1 1 CLASSIC

3 K6130130 SEAT FOAM 1 1

4 K6130120 SEAT BASE 1 1

5 R1130090 BOLT PLATE COMP SEAT 1 1

6 R1130110 HEX SCREW M6 1 1

7 M1200900 HEX FLANGE NUT M6x1 1 1

8 R1130100 HINGE COMP. SEAT 1 1

9 K6130160 PACKING SEAT 1 1

10 K210800 O RING 1 1

11 K6130100 CUSHION SEAT REAR 2 2

SEAT ASSEMBLY
 FRAME & FOOTREST ASSEMBLY FIG.NO.16

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6150270 IGNITION LOCK 1 1

2 K3100590 CUP BOTTOM 1 1
3 S1125290 RACE STEERING INNER 1 1
4 0332238 REC CSK HD SCREW M6x12 2 2
5 N3200190 HEX FL. BOLT M6x30 2 2
6 P1200050 WAVE SPRING WASHER M6 2 2
7 K6122300 BUSH FOOTREST 2 2
8 0335605 PUNCHED WASHER 2 2
9 K6122650 PILLION FOOTREST RH 1 1
10 3030515 SPRING KS LEVER 2 2
11 0339204 BALL KICK STARTER 2 2
12 K6122760 FRAME COMP. 1 1
13 K6210100 REAR LATCH ASSY. 1 1
14 0335558 PUNCHED WASHER 5.5x12x1.0 2 2
15 0331708 CRPH SCREW M5X12 2 2
16 U2200010 HEX FL. BOLT M8x30 4 4
17 K6221600 PILLION HANDLE COMP. 1 1
18 420496700 HEX BOLT M10x40 1 1
19 0330328 WAVE SPRING WASHER M10 1 1
20 K6122660 PILLION FOOTREST LH 1 1
21 K6121480 FOOTREST ASSY. PILLION 1 1
21A K61214807D FOOTREST ASSY. PILLION 1 1
22 N9200030 HEX FL . BOLT M845 2 2
23 K3122840 COTTER PIN FOOTREST FOLDABLE 1 1
 FRAME & FOOTREST ASSEMBLY FIG.NO.16

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

24 K3122830 PIN FOOTREST FOLDABLE 1 1

25 K3122800 SPRING FOOTREST FOLDABLE 1 1
26 K3122850 COTTOR PIN FOOTREST FOLDABLE 1 1
27 K3123140 PAD FOOTREST FOLDABLE 1 1
28 K6121490 FOOTREST COMP. PILLION 1 1
29 K3122820 PIN FOOTREST FOLDABLE 1 1
30 N5111200 AXLE 10x221.5 1 1
31 K6090640 SHOCK ABSORBER 1 1
32 K6200060 HEX BOLT M10x1.5x250 1 1
33 0330328 WAVE SPRING WASHER M10 1 1
34 K200160 HEX NUT M10 1 1
35 K6090530 TOGGLE LINK ASSY. 1 1
36 K6090680 SILENT BLOCK 2 2
37 K6090590 SPACER ASSY. TOGGLE LINK 1 1
38 K6090510 BUMP STOPPER TOGGLE LINK 1 1
39 0330318 WAVE SPRING WASHER M8 2 2
40 0335528 PUNCHED WASHER 10.5x18x1.6 2 2
41 K6225060 BACK REST PILLION ASSY. 1 CLASSIC
42 K6224810 PILLION HANDLE ASSY. 1 CLASSIC
43 K6225050 END CAP 1 CLASSIC
44 0334146 HEX FLANGE NUT M6 2 CLASSIC
45 K6225070 COVER BACKREST PILLION 1 CLASSIC
46 K3200840 RETAINER CLIP COMP. 2 CLASSIC
47 P3200010 CRR PAN HEAD SCREW M6x12 2 CLASSIC
FIG.No.17
CENTER STAND & PROP STAND ASSY. FIG.NO.17

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6121040 CENTER STAND ASSY 1 1

2 N8110710 SPLIT PIN 3 3

3 K6200080 CLEVIS PIN CENTER STAND 2 2

4 K6121470 CENTER STAND COMP 1 1

5 S1125310 CUSHION 1 1

6 K3124270 LEVER COMP. CENTER STAND 1 1

7 K3122140 SPRING CENTER STAND 1 1

8 0334548 HEX NUT M8 1 1

9 K6121090 PROP STAND COMP. 1 1

10 N9200010 HEX BOLT M8 x 1.25 x 30 1 1

11 N8121890 SPRING PROP STAND 1 1

12 K6320450 PROP STAND KIT 1 1

13 K6170090 CABLE GUIDE FRONT 1 1

CENTER STAND & PROP STAND ASSY.

FIG.No. 18
15 16 FRONT FORK ASSEMBLY FIG.NO.18
34
17
7 NO. OFF
18 REF PART DESCRIPTION REMARKS
1 23 NO. NO. DRUM DISC
8 22
9 19 1 K6101000 LEG ASSY. RH FRONT FORK 1 1
10 20
1A K61008207D LEG ASSY FRONT FORK R - TITAN GREY 1 DISC REF.
21
11 24 25 26 2 K6100880 INNER TUBE 2 2

2 28 3 U1100120 PIECE OIL LOWER 2 2

4 K6101010 OUTER TUBE RH 1 1

12
28 27 4A K61008407D OUTER TUBE R TITAN GREY 1 REF.

13 5 N8101220 PACKING 2 2
33 33A
6 N8101230 HEX ALEN BOLT 2 2
3 29
7 K6100960 NUT FRONT FORK 2 2
14
30
8 N3102410 SEAL DUST FRONT FORK 2 2
4
9 N3100290 SNAP RING 2 2
31
30A
32 10 N3102420 OIL SEAL 1 1

31A 11 K6100900 SPRING - 1 2 2

5 12 N3100330 RING DAMPER PISTON 2 2

6 13 K6100870 CYLINDER FORK 2 2

24 26 14 K6320560 REBOUND SPRING 2 2

1A
25
15 410058700 LOCK NUT STEERING 1 1

16 K3100830 WASHER STEERING STEM 1 1

FRONT FORK ASSEMBLY 17 K3100800 ARRESTER STEERING STEM 1 1

FIG.No. 18
15 16 FRONT FORK ASSEMBLY FIG.NO.18
34
17
7 NO. OFF
18 REF PART DESCRIPTION REMARKS
1 23 NO. NO. DRUM DISC
8 22
9 19
18 M7101170 DUST SEAL 1 1
10 20
19 420404000 STEERING BALL 22 22
21
11 24 25 26 20 K3200450 BALL CAGE COMP. LOWER 1 1

2 28 21 K3100600 CONE BOTTOM 1 1

22 K3101080 CONE TOP 1 1

12
28 27 23 K6100890 LOWER BRKT COMP. 1 1

13 24 0335578 PUNCHED WASHER 6.5x13x1 2 2

33 33A
25 P1200050 WAVE SPRING WASHER 2 2
3 29

14 26 420464700 HEX SCREW M6x16 2 2

30
27 K6170140 CABLE GUIDE FRONT TOP 1 1
4
28 R1200160 HEX BOLT M10x1.25x40 4 4
31
30A
32 29 N3200220 HEX FLANGE BOLT M6x1.25x16 4 4

31A 30 K6100990 LEG ASSY. LH FRONT FORK 1 1

30A K61008107D LEG ASSY FRONT FORK LH - TITAN GREY 1 DISC REF.
5
31 K6101020 OUTER TUBE LH 1 1
31A K61008307D OUTER TUBE LH - TITAN GREY 1 REF.
6
32 K6170130 CABLE GUIDE FRONT LH 1 1
24 26
1A
25 33 K6100980 FRONT FORK ASSY. 1 1

33A K61008507D FORK ASSY FRONT - TITAN GREY 1 DISC REF.

34 K6101040 CAP LOCK NUT COMP. BRKT 1 1

FRONT FORK ASSEMBLY

** - PL. REF. KIT AND KIT CONTENTS

FIG.No.19
FRONT WHEEL ASSEMBLY FIG.NO.19

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 0334158 NUT REAR SWING ARM PIVOT 1

2 0335538 PUNCHED WASHER 12.5x22x2.3 2

3 K6110830 SPACER COMP FRONT AXLE 1

4 K3200770 BALL BEARING 6201 2

5 K6111170 WHEEL ASSY. FRONT 1

6 K6111160 TYRE 90/90-12 1

7 K4110140 VALVE TUBE 1

8 K61108705D ALLOY WHEEL FRONT 1.85*12 1

9 K6110730 SPACER COMP. FRONT HUB 1

10 K6110920 SEAL BRAKE PANEL 2 1

11 K6110490 GEAR SPEEDO 1

12 N5110790 WASHER SPEEDOMETER GEAR THR 1

13 K61110605D PANEL SUB ASSY. FRONT BRAKE 1

14 K6320590 SHOE SET BRAKE 130 DIA 1

15 N2110130 CAM BRAKE 1

16 K61110505D PANEL COMP. FRONT BRAKE 1

16A K6111510 BRAKE PANEL FRONT 1 SBS
FRONT WHEEL ASSEMBLY 17 N3110120 SHIM 5.7x10x0.4 OILED 1
FIG.No.19
FRONT WHEEL ASSEMBLY FIG.NO.19

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

18 K6110480 PINION SPEEDO 1

19 N8111570 BUSHING SPEEDO GEAR PINION 1

20 N8200240 OIL SEAL 4.8x15x4.8 1

21 0335078 SHIM 5.1x9x0.4 1

22 N3110990 AXLE FRONT 1

23 0331718 CRPH SCREW M5x16 6.8 1

24 0335558 PUNCHED WASHER 5.5x12.0x1.0 1

25 420305700 HEX NUT M6 8 1

26 420001700 PUNCHED WASHER A6.6 1

27 N3110400 LEVER FRONT BRAKE CAM 1

27A K6111330 LEVER CAM BRAKE 1 SBS
28 0335698 PUNCHED WASHER 14.5x22x1.6 1

29 0178030 O RING BRAKE CAM-BR 1

30 0331248 HEX BOLT M6X1.0X33 4.8 1

31 3230515 SPRING BRAKE SHOE 2

FRONT WHEEL ASSEMBLY

FIG.No. 19A
FRONT WHEEL ASSEMBLY (DISC) FIG.NO.19A

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 0331718 CRPH SCREW M5x16 1

2 0335558 WASHER 1
3 S1111170 SHIM SPEEDO DRIVE 2
4 S1111180 ARRESTOR SPEEDO DRIVE 1
5 --- PINNION SPEEDO DRIVE 1
6 K6111000 SPEEDO HUB DRIVE ASSY. 1
7 S1111190 DUST SEAL 1
8 --- GEAR SPEEDO WHEEL DRIVE 1
9 K3110680 RETAINER RING SPEEDO GEAR 1
10 K3110670 SHIM 7.5x15x0.5 1
11 K3200770 BALL BEARING 6201 2
12 K6110730 SPACER COMP FRONT HUB 1
13 K61110105D WHEEL ASSY. FRONT 1
14 K6111160 TYRE 90/90 - 12 1
15 K4110140 VALVE TUBELESS TYRE 1
16 K61109705D ALLOY WHEEL FRONT 12x90 5SPOKE 1
17 R1110430 DISC FRONT WHEEL 1
18 K6110830 SPACER HUB FRONT AXLE 1
19 M7110280 HEX FLANGE BOLT M8x30 4
20 0335538 PUNCHED WASHER 12.5x22x2.3 2
21 N3110990 AXLE FRONT 12x221.5 1
22 0334158 U NUT M12x1.25 1
23 K6111290 SPACER COMP 1

FRONT WHEEL ASSEMBLY (DISC)

FIG.No.20
REAR WHEEL ASSEMBLY FIG.NO.20

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 S1200910 FLANGE U NUT M16x1.5 1 1

2 S1111430 PUNCHED WASHER A6.6 1 1

3 K6111160 TYRE 90/90-12 1 1

4 K6111190 WHEEL ASSY. REAR 1 1

5 K4110140 VALVE TUBE 1 1

6 K61108805D ALLOY WHEEL REAR 2.15*12 1 1

7 1110020 SHOE SET BRAKE 130 DIA 1 1

8 K6110840 BRAKE CAM REAR NP.015 1 1

9 0178030 O RING BRAKE CAM 1 1

10 3230515 SPRING BRAKE SHOE 2 2

11 0331248 HEX BOLT M6x1.0x33 4.8 1 1

12 K6110800 LEVER COMP. BRAKE REAR 1 1

13 420001700 PUNCHED WASHER16.5x33.2x3.15 1 1

REAR WHEEL ASSEMBLY

FIG.No.21
TAIL LAMP & REAR FENDER ASSEMBLY FIG.NO.21

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 --- TAIL COVER CENTER 1 1 REF. COLOUR

MATRIX
2 0332275 CRR PAN HEAD SCREW 2 2

3 K200320 CRR PAN HD TAPPING SCREW 2 2

4 K6220620 RETAINER CLIP 2 2

5 K6221460 TAIL LAMP ASSY. 1 1

6 0332275 CRPH SCREW M6x20 6.8 2 2

7 N8122610 CUP WASHER 4 4

8 N3120130 GROMMET 6 6

9 M1200820 CRPH SCREW M6x20 6.8 2 2

10 K3160450 BULB TSL AMBER 2 2

11 K6321080 CORD SET TSL REAR 1 1

12 --- NPL WIRE ASSY. 1 1

13 --- BULB NPL 1 1

14 K6221590 FENDER REAR 1 1

15 N4221270 RUBBER TOOL BOX 1 1

16 M7160120 REFLEX REFLECTOR 1 1

TAIL LAMP & REARFENDER ASSEMBLY 17 --- COVER BOTTOM TAIL CENTER 1 1 REF. COLOUR
MATRIX
FIG.No.21
TAIL LAMP & REAR FENDER ASSEMBLY FIG.NO.21

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

18 N3200220 HEX FLANGE BOLT M6x1.25x16 2 2

19 K3200840 RETAINER CLIP NUT M6 2 2

20 0332275 CRR PAN HEAD SCREW 2 2

21 D127420 LICENSE PLATE PAINTED 1 1

22 P1200050 WAVE SPRING WASHER M6 2 2

23 P1200060 HEX NUT M6 ZNG 2 2

24 0330408 WAVE SPRING WASHER M6 2 2

25 0334560 HEX NUT M5 1 1

26 0335558 PUNCHED WASHER 5.5x12x1 1 1

TAIL LAMP & REARFENDER ASSEMBLY

FIG.No.22
SPEEDOMETER ASSEMBLY FIG.NO.22

1 NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC
2
1 K6221420 SPEEDOMETER ASSY. 1 1

1A K6224860 SPEEDOMETER ASSY. 1

2 K6221959 TOP COVER SPEEDO METER 1 1

3 --- SPEEDO COVER DIAL 1 1

3
4 K6170120 SPEEDO CABLE ASSY. 1 1

4A K3170040 CABLE ASSY. SPEEDO 1 1 REF.

5 N5320860 BULB 12V 1.7W 5 5

6 K6160530 CORD SET SPEEDOMETER 1 1

7
4
7 K6320880 INNER SPEEDO CABLE 1 1

8 K3110700 O RING SPEEDO 1 1

6
8

SPEEDOMETER ASSEMBLY
FIG.No.23
FRONT & REAR PANEL ASSEMBLY FIG.NO.23

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 N8200220 CRR PAN HD TAP SCREW ST4.2x16 1 1

2 N3211120 LICENCE PLATE FRONT 1 1

3 420462700 HEX SCREW 2 2

4 K6221110 BRKT LICENCE PLATE FRONT 1 1

5 K6221450 TURN SIGNAL LAMP ASSY FR RH 1 1

6 K6321110 TURN SIGNAL LAMP FR RH W/O BULB 1 1

7 K3160450 BULB TSL AMBER 2 2

8 K6160500 CORD SET TSL FRONT RH 1 1

9 K6160490 CORD SET TSL FRONT LH 1 1

REF. COLOUR
10 --- PANEL FRONT TOP 1 1 MATRIX
10A --- PANEL FRONT TOP 1 1 MIL.EDITION
11 7130020 NUT SEAT TAIL COVER CENTRE 8 8

12 N3200340 CRR FL. PAN HD TAP SCRST4.2x13 18 18

13 K3220870 RETAINER HINGE PEP+ REF 1 1

13A KA220870 RETAINER HINGE 1 1 CLASSIC VER.
14 K6221500 PANEL REAR 1 1
14A K6223050 PANEL REAR (COLOUR MAT. BEIGE) 1 1 LI.E
14B K6224690 PANEL REAR ASSY. 1 CLASSIC VER.
15 K6222180 GROMMET, DASHBOARD 1 1
16 --- PIN BAG HOOK 1 1

17 K3220860 BAG HOOK 1 1

FRONT & REAR PANEL ASSEMBLY
17A KA220500 BAG HOOK 1 1 CLASSIC VER.
18 N3200220 HEX FL BOLT M6x16 ZNG 1 1

LI.E - LIMITED EDITION

FIG.No.23
FRONT & REAR PANEL ASSEMBLY FIG.NO.23

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

19 K6221790 GRILL PANEL FRONT 1 1

20 --- PANEL FR BOTTOM UNPAINTED BLACK 1 1 REF. COLOUR

MATRIX
21 K6221440 TURN SIGNAL LAMP ASSY FR LH 1 1

22 K6321100 TURN SIGNAL LAMP FR LH W/O BULB 1 1

23 --- FRONT FENDER 1 1 REF. COLOUR

23A --- FRONT FENDER 1 1 MATRIX
24 0331748 CRR PAN HEAD SCREW 1 1

25 K6222230 MUD FLAP 1 1

26 K6222000 FENDER FRONT REAR 1 1

26A K6223820 FENDER FRONT REAR 1 REF.
27 N3200220 HEX FLANGE BOLT M6x1.25x16 4 4

28 N8200060 HEX FLANGE BOLT M6x40 2 2

29 K6221800 GLOVE BOX 1 1

29A K6225080 GLOVE BOX 1 CLASSIC VER.
30 K6321370 KIT GLOVE BOX 1 1 N.I

31 K6223350 COVER BACK 1 1 "

32 K6222470 LOGO TVS 3D 1 1 "

33 K6222450 LOGO JUPITER SIDE PANEL 3D 1 LE

34 K6223300 DOME STICKER 1 LE

35 K6223400 STICKER INFO USER JUPITER 1 LE

FRONT & REAR PANEL ASSEMBLY 36 K6223290 SCOOTER OF THE YEAR 1 LE

37 N3100230 CLIP 1 1 REF.
38 P6100030 GUIDE CABLE 1 1 REF.
39 K6224950 STICKER SPECIAL 1 CLASSIC VER.

LE - LIMITED EDITION
FIG.No.24
PANEL SIDE LH, RH & REAR ASSY. FIG.NO.24

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC
1 K6221940 COVER FUEL TANK 1 1
2 P200270 CRPH SCR M6x12 6.8 2 2
3 K6221810 UTILITY BOX 1 1
4 N3200210 PUNCHED WASHER 8.2x25.0x2 4 4
5 K200320 CRR PAN HEAD TAP SCREW 4.2x16 4 4
6 0331748 CRPH SCREW M6x16 6.8 3 3
7 P3200010 CRPH SCREW M6x12 6.8 2 2
8 U2200010 HEX FLANGED BOLT M8x27 2 2
9 --- SIDE PANEL LH 1 1 REF. COLOUR PAGE

10 N8220400 CUSHION FUEL TANK 2 2

11 --- COVER FRONT RH 1 1 ,,
11A K6222280 COVER FRONT ASSY. RH 1 1
11B K6223160 COVER FRONT ASSY. RH (COL. MAT. BEIGE) 1 1 LE
11C K6224770 COVER FRONT ASSY. RH 1 CLASSIC VER.

12 N3200340 CRR FL PAN HD TAP SCREW 4.2x13 16 16

13 --- SIDE TRIM FLOOR L H 1 1 REF. COLOUR PAGE

14 K3200840 RETAINER CLIP NUT M6 2 2

15 K6222170 BAGHOOK 1 1
16 K6221580 COVER FRONT 1 1
16A K6223070 COVER FRONT (COLOUR MAT. BEIGE) 1 1 LE
16B K6224720 COVER FRONT 1 CLASSIC VER.

17 K3200320 CRR PAN HD TAP SCREW 4.2x16 1 1

18 K6220870 LID UTILITY BOX 1 1
19 0332275 SCREW - CRPH M6x16 6.8 7 7
20 K6210140 SEAT LOCK ASSY. 1 1
21 --- SIDE PANEL RH 1 1
SIDE PANEL LH, RH & REAR ASSEMBLY 22 P1200070 HEX SCREW M6x16 2 2
23 --- COVER REAR TOP RH 1 1 REF. COLOUR
23A K6224790 COVER REAR TOP RH 1 CLASSIC VER.
24 --- SIDE TRIM FLOOR RH 1 1 PAGE

LE - LIMITED EDITION
FIG.No.24 PANEL SIDE LH, RH & REAR ASSY. FIG.NO.24

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

25 K3200860 CRR PAN HEAD SCREW M6X30 2 2

26 K3200840 RETAINER CLIP NUT M6 2 2
27 M1200530 HEX FLANGE BOLT M6x20 6 6
28 N5200430 PUNCHED WASHER 8.5x16.0x1.2 4 4
29 K6221510 FLOOR BOARD 1 1
29A K6223060 FLOOR BOARD (COLOUR MAT. BEIGE) 1 1 L.E
29B K6224710 FLOOR BOARD 1 CLASSIC VER.

30 7130020 NUT SEAT TAIL COVER CENTER 2 2

31 --- COVER FRONT LH 1 1 NS
31A K6222270 COVER FRONT ASSY. LH 1 1
31B K6223150 COVER FRONT ASSY.LH (COL.MAT.BEIGE) 1 1 L.E
31C K6224750 COVER FRONT ASSY. LH 1 CLASSIC VER.

32 K6221610 COVER REAR TOP LH 1 1

32A K6224760 COVER REAR TOP LH 1 CLASSIC VER.

33 K6220260 COVER BOTTOM FLOOR - WEGO 1 1

34 K6150360 CAM SEAT LOCK 1 1
35 K6170160 CABLE SEAT LOCK 1 1
36 K6170150 CABLE FUEL TANK 1 1
37 K6222240 BRKT SIDE PANEL LH 1 1
38 K6222250 BRKT SIDE PANEL RH 1 1
39 M1200520 HEX FLANGED BOLT M6x30 1 1
40 M1121060 CUP WASHER 1 1
41 K6220130 MUDGUARD REAR 1 1
42 M1200470 HEX FL. BOLT M8x45 1 1
43 K6223790 SIDE PANEL TOP L PURPLE T.SET (3D) 1
44 K6223800 SIDE PANEL TOP R PURPLE T.SET (3D) 1

45 K6222450 LOGO JUPITER SIDE PANEL 3D 1 1 L.E

46 K62218702R FLOOR MAT BROWN GOLD BEIGE 1 1 BSIV
SIDE PANEL LH, RH & REAR ASSEMBLY 46A K6224830 FLOOR MAT KIT 1 CLASSIC VER.
47 K6224420 UTILITY BOX CAP 1
L.E - LIMITED EDITION
FIG.No.25
WIRING HARNESS & ELECTRICALS ASSY. FIG.NO.25

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6060240 CORD SET MOTOR 1 1

2 K6160440 CORD SET SWITCHES 1 1
2A K6160880 CORD SET SWITCHES 1 1 BSIV
3 M1160600 FUSE 10AMPS 1 1
4 N9160380 ELECTRONIC FLASHER UNIT 1 1
5 R2160100 STARTER RELAY ASSY 1 1
6 K6160430 WIRING HARNESS 1 1
6A K6160770 WIRING HARNESS 1 1 BSIV
7 K3160270 HORN ASSY. 1 1
8 0332068 CRPH SCREW M6x12 6.8 1 1
9 P1200050 WAVE SPRING WASHER M6 2 2
10 K3060590 REGULATOR CUM RECTIFIER 1 1
11 K6060360 TCI UNIT 1 1
12 K6160510 CORD SET STARTER RELAY 1 1
13 0332275 SCREW CRPH M6x16 1 1
14 K6210480 LOCK SET 1 1
15 K6122670 BATTERY HOLDER COMP. 1 1
16 N3160060 BAND BATTERY 1 1
17 R3160090 BOOT STARTER RELAY 1 1
18 K06012000 BATTERY (CHARGED) 1 1
19 K3160990 MOBILE CHARGER PORT 1 1
20 K6060120 IGNITION COIL 1 1
20A K6060260 CDI & IGNITION COIL COMP. 1 1
20B K6060440 COMBINED IDI & IGNITION COIL 1 1 BSIV
21 R1060200 SEAL HT CORD 1 1
22 N8060170 SUPPRESSOR CAP ASSY. 1 1
23 S1060310 SEAL SPARK PLUG 1 1
23A K6320470 SEAL SPARK PLUG 1 1
24 K3160190 BEEPER 1 1
WIRING HARNESS & BATTERY ASSY. 25 K6321060 KIT IGNITION SWITCH BASE 1 1
FIG.No.26
DISC BRAKE ASSEMBLY FRONT FIG.NO.26

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC
REF. KIT. No.
1 --- BOOTS ASSEMBLY 1 N9321490

2 --- CIRCLIP 1 K6320950

3 --- S CUP 1 "
4 --- PISTON 1 N9321490
5 --- P CUP 1 N9321490

6 --- SPRING 1 N9321490

7 --- HAND LEVER BOLT 1 R1320240
8 --- SCREW RESERVOIR CAP 2 N9321530
9 --- RESERVOIR CAP 1 "
10 R1150820 DIAPHRAGM PLATE 1 N9321490
11 --- PROTECTOR 1 "
12 --- HOLDER 1 N9321510
13 --- HOLDER BOLT 2 "
14 R1150390 MASTER CYLINDER ASSY. 1
15 --- LEVER RH 1 R1320240
16 --- FLANGE NUT 1 "
17 --- SWITCH SAYS 1 N9321520
18 --- SCREW & WASHER 2 "
19 --- SUB HARNESS 1 "
20 K6111070 HOSE COMP BRAKE 1 REF.
21 N9111330 WASHER BANJO 4
22 N9111320 BANJO BOLT 2
23 K6111030 CLAMP HOSE UNDER BRACKET 1
24 P200270 CTR PAN HEAD SCREW M6x12 1
25 0330408 WAVE SPRING WASHER 1
DISC BRAKE ASSEMBLY FRONT
FIG.No.26
DISC BRAKE ASSEMBLY FRONT FIG.NO.26

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC
REF. KIT. No.
26 K6111470 CALIPER ASSY. 1 REF.
27 --- COTTER PIN 2 K6321860
28 --- BRKT COMP FRONT 1 K6321880
29 --- PAD COMP. OUTER 1 K6321900
30 --- SPRING PLATE 1 K6321860
31 --- PAD SPRING 1 "
32 --- PAD COMP. INNER 1 K6321900
33 --- PLUG PIN 1 K6321880
34 --- PISTON CALIPER 1 K6321860
35 --- DUST SEAL 1 K6321870
36 --- SEAL PISTON 1 "
37 --- BUSH BOOT PIN 1 K6321890
38 --- PINT BOLT A 1 K6321880
39 --- BODY CALIPER FRONT 1 K6321860
40 --- BLEEDER 1 K6321910
41 --- CAP BLEEDER 1 "
42 --- BOOT B 1 K6321890
43 --- PIN HANGER 1 K6321860
44 --- PIN BOLT B 1 K6321880
45 --- SPRING WASHER 1 "
46 --- PLATE DIAPHRAGM 1 N9321530
47 --- GUAGE COMP LEVEL 1 N9321490
48 ---- O RING 1 N9321490

DISC BRAKE ASSEMBLY FRONT

FIG.No.26
TOOL KIT ASSY. FIG.NO.27

NO. OFF
REF PART DESCRIPTION REMARKS
NO. NO. DRUM DISC

1 K6210090 TOOL KIT NP.015 1 1

2 --- TOOL BAG 1 1

3 --- BIT (+) ( - ) 1 1

4 --- GRIP DRIVER 1 1

5 --- BOX SPANNER 1 1

6 --- SPANNER DIA 10x12 1 1

7 --- TOMMY BAR 1 1

8 --- RING SPANNER 1 1

9 --- HANDLE RING SPANNER 1 1

TOOL KIT