PARTS CATALOGUE

TVS MOTOR COMPANY

FIG.NO. 01 CYLINDER HEAD ASSEMBLY FIG.NO. 01
45 40 40A
42 46
NO. OFF
55 41 REF PART DESCRIPTION XL 100 REMARKS
47
56 NO. NO. KS ES
1 S1010320 COTTER VALVE 4 4
44 2 N2011040 RETAINER VALVE SPRING 2 2
48 3 N2010350 VALVE SPRING OUTER 2 2
4 N2010340 VALVE SPRING INNER 2 2
43
53 49 5 M1010620 SEAL VALVE STEM OIL 2 2
51
6 K3010680 SEAT VALVE SPRING 2 2
52 54
7A 7 P6010210 VALVE INTAKE 1 1
7A K3010570 VALVE INTAKE 1 1 BSVI
9A 8 K3011090 STOPPER ROCKER SHAFT 1 1
9 P6010020 HEAD CYLINDER COMP. 1 1
9A P7010020 HEAD CYLINDER COMP. 1 1 BSVI
20A
9B P7010100 HEAD CYLINDER COMP. 1 1 W/O SAI
10 K6040480 INSULATOR PAD 1 1
11 K3040180 O RING INSULATOR PAD 1 1
12 409047000 NYLON LOCK NUT M6 2 2
13 P6040020 PIPE INTAKE COMP 1 1
25A
14 M1200900 HEX FLANGE NUT M6x1 2 2
15 P6040040 GASKET PIPE INTAKE 1 1
16 M1200780 STUD BOLT CYLINDER No.1 1 1
17 T4200150 WASHER CYLINDER HEAD NUT 4 4
18 K3200760 HEX FLANGE NUT M7x1 4 4
32A
19 K6010200 ARM VALVE ROCKER ASSY. 2 2
20 N3011780 SPARK PLUG UR5DC 1 1
20A N5011050 SPARK PLUG UR5DC 1 1 BSVI
21 P6010180 COVER CYLINDER HEAD 1 1
22 M1200470 HEX FLANGE BOLT M6x30 4 4
50
23 S1010250 NUT TAPE SET ADJUSTING 2 2
24 P6010050 PACKING SEAL COVER CYLINDER HEAD 1 1
25 P6010220 VALVE EXHAUST 1 1
CYLINDER HEAD ASSEMBLY 25A T4010690 VALVE EXHAUST 1 1 BSVI
26 S1010240 SCREW TAPPET ADJUSTING 2 2
FIG.NO. 01 CYLINDER HEAD ASSEMBLY FIG.NO. 01
45 40 40A
42 46 NO. OFF
41 REF PART DESCRIPTION XL 100 REMARKS
55 47 NO. NO. KS ES
56 27 P6010060 STOPPER CAMSHAFT 1 1
28 N8200090 CRR CSK HEAD SCREW M5x15 1 1
44 29 M1200510 HEX FLANGE BOLT M6x25 4 4
48 30 T4010760 SHAFT ROCKER ARM 1 1
43 31 0333558 STUD BOLT CYLINDER No.1 2 2
53 49 32 P6010100 CAMSHAFT COMP. 1 1
51
52 54 32A P7010070 CAMSHAFT COMP. 1 1 BSVI
7A 33 N5010320 SPROCKET 34T CAMSHAFT 1 1
34 N5010400 WASHER SPROCKET 1 1
9A 35 M1200940 HEX SCREW M5x10 2 2
36 M1010490 PIN SPROCKET KNOCK 1 1
37 R1200500 HEX FLANGE BOLT M6x10 1 1
20A
38 N2010960 WASHER A6.6 1 1
39 S1125320 CABLE OIL HOSE 1 1
40 P6010110 CYLINDER HEAD ASSY. KIT 1 1
40A P7010050 CYLINDER HEAD ASSY. KIT 1 1 BSVI
25A 40B P7010110 CYLINDER HEAD ASSY. KIT W/O SAI 1 1 W/O SAI
41 P6321020 O RING THROTTLE BODY 1 1 BSVI
42 P6060110 EFI INJECTOR 1 1 BSVI
43 P6040220 BODY THROTTLE ASSY 1 1 BSVI
44 A200050 HEX SOC HD CAP SCREW 2 2 BSVI
45 P6040310 CAP INJECTOR 1 1 BSVI
32A
46 K6041220 COVER INJECTOR 1 1 BSVI
47 P6040300 PIPE INTAKE COMP 1 1 BSVI
48 P6040290 INSULATOR PAD 1 1 BSVI
49 N2040940 O RING 2 2 BSVI
50 R4060090 THERMAL SENSOR 1 1 BSVI
50 51 P6060130 SOLENOID VALVE 1 1 BSVI
52 --- THROTTLE POSITION SENSOR 1 1 BSVI / NS
53 P6321010 M4 SCREW 2 2 BSVI
54 --- M6 SCREW 1 1 BSVI / NS
CYLINDER HEAD ASSEMBLY 55 0332068 CRR PAN HEAD SCREW M6x12 1 1 BSVI
56 P6321000 BRKT THROTTLE CABLE 1 1 BSVI
N.S - NOT SERVICE
FIG.NO. 02 CYLINDER BLOCK & CRANK SHAFT ASSEMBLY FIG.NO. 02

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
1 P6010120 GASKET CYLINDER HEAD 1 1
2 S1200270 TUBLER DOWEL 4 4
3 --- CYLINDER BLOCK 1 1 REF. KIT LIST
3A 3A --- CYLINDER BLOCK 1 1 BSVI
4 P6010130 GASKET CYLINDER 1 1
5 N5320440 RING SET 1 1 REF. KIT
12A
6 N2200340 CIRCLIP PIN PISTON 2 2
7 P010680 PIN PISTON 1 1
21 8 N8200750 BALL BEARING 25x52x15 1 1
9 P6020040 CRANKSHAFT COMP 1 1
10 420702000 WOODRUFF KEY 1 1
11 B5020100 PISTION KIT STD 1 1
11A P6320070 PISTON KIT I O/S 1 1
14A 11B P6320080 PISTON KIT II O/S 1 1
12 P6010070 GUIDE CAMCHAIN 1 1
12A P7010080 GUIDE CAMCHAIN 1 1 BSVI
13 P6010150 CAMCHAIN 1 1
14 P6010080 TENSIONER CAMCHAIN 1 1
20A 14A P7010090 TENSIONER CAMCHAIN 1 1 BSVI
15 K3010640 BOLT CAM CHAIN TENSIONER 1 1
16 P6010160 GASKET TENSIONER ADJUSTER 1 1
17 K3010430 ADJUSTER ASSY. TENSIONER 1 1
18 N2200490 HEX SCREW M6x20 2 2
19 M1200530 HEX FLANGE BOLT M6x20 2 2
20 P6320110 CYLINDER BLOCK & PISTON KIT 1 1 REF. KIT LIST
20A P7320260 CYLINDER BLOCK & PISTON KIT 1 1 BSVI
CYLINDER BLOCK & CRANK SHAFT ASSEMBLY 21 P7020050 PISTON KIT STD 1 1 BSVI
FIG.NO. 03 DRUM CLUTCH ASSEMBLY FIG.NO. 03

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 B5070010 DRUM CLUTCH COMP. 1 1

2 B5070020 PLATE ASSY. PRIMARY DRIVE 1 1
3 R1200050 DISC SPRING 1 1
4 R1200060 NUT CRANKSHAFT 1 1
5 R1020310 GASKET COVER OIL FILTER 1 1
6 R1020309 COVER OIL FILTER 1 1
7 C1200020 HEX SCREW M5x8 3 3
8 B5080220 GEAR OIL PUMP DRIVE 1 1
9 P6070010 SPACER CLUTCH 1 1
10 M7010810 THRUST WASHER 17x26x1.5 1 1
11 K3200100 E -RING SIDE WASHER 3 3
12 R1070590 BUSH CARRIER COMP. 3 3
13 P6180020 ENGINE ASSEMBLY 1 KS
13A P7180010 ENGINE ASSEMBLY 1 ES
13B P7180060 ENGINE ASSEMBLY 1 ES
13C P6180140 ENGINE ASSEMBLY BSVI KS 1 BSVI
13D P7180060 ENGINE ASSEMBLY BSVI ES 1 BSVI
13E P7180120 ENGINE ASSEMBLY W/O SAI 1

13 13A 13B 13C 13D

13E

DRUM CLUTCH ASSEMBLY

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

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
4B NO. NO. KS ES

1 420462700 HEX BOLT M8x70 2 2

2 P6080260 LIFTER RATCHET 1 1
3 0074010 DOWEL PIN 4 4
4 P6030030 CRANKCASE LH KIT ASSY. 1 REF. KIT LIST
4A 4A P7030070 CRANKCASE LH KIT ASSY. 1
4B P7030220 CRANKCASE SUB ASSY. LH KIT 1 1 BSVI
5 M1200440 HEX FLANGE BOLT M6x75 1 1
6 M1200510 HEX FLANGE BOLT M6x25 2 2
6A N5200500 HEX FLANGE BOLT M6x25 2 2 BSVI
7 B5080410 OIL PUMP ASSY. 1 1
8 K4080150 TDB 1 1
9 K3200730 O RING 29.5x3 1 1
10 P6080220 OIL FILTER 1
10A P7080010 OIL FILTER 1
11 S1080409 PIPE INLET OIL PUMP 1
11A P7080020 PIPE INLET OIL PUMP 1
11B P7080020 PIPE INLET OILPUMP 1 1
12 K3200180 STUD CYLINDER 2 2
11A 11B

10A

6A

CRANKCASE LH ASSEMBLY
FIG.NO. 05 CRANKCASE RH ASSEMBLY FIG.NO. 05

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
6B
1 M1200820 REC PAN HEAD SCREW M6x25 3 3
2 N5030200 BUSH MANETO COVER MTG 3 3
3 P6080240 COVER KICK STARTER 1 1
4 T4080540 OIL SEAL SHAFT DRIVE DIA 17x29x6 1 1
5 N5200160 HEX FLANGE BOLT M6x45 8 8
6 P6030150 CRANKCASE KIT ASSY. RH 1 REF. KIT LIST
6A P7030100 CRANKCASE KIT ASSY. RH 1
6B P7030260 CRANKCASE SUB ASSY. RH KIT 1 1 BSVI
6A
7 0074010 DOWEL PIN 2 2
8 P6030060 GASKET CRANKCASE 1 1
8A 8A P7030250 GASKET CRANKCASE 1 1 BSVI
9 420602000 BALL BEARING 12x32x10 1 1
10 K3200640 OIL SEAL 17x26x6 1 1
11 K3200180 STUD CYLINDER 1 1

CRANKCASE RH ASSEMBLY
FIG.NO. 06 MAGNETO ASSEMBLY FIG.NO. 06

5A
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
8B 1 8200120 CRR PAN HEAD SCREW M5x12 7 7
2 P6180070 COVER FAN 1 1
3 M1200820 CRR PAN HEAD SCREW M6x25 7 7
4 P1200140 PUNCHED WASHER 5.5x12x1 3 3
8A 5 P6180060 COWL FAN 1 1
10A 11A
5A P7180080 COWL BOTTOM 1 1 BSVI
12A 6 P1200150 WAVE SPRING WASHER M5 3 3
7 0332808 CRR PAN HEAD SCREW M5x25 3 3
8 P6180050 FAN ENGINE COOLING 1
8A P7180030 FAN ENGINE COOLING 1
8B P7180070 FAN ENGINE COOLING 1 1 BSVI
9 M1200770 U NUT M8x1.25 1 1
10 P6320060 ROTOR ASSY. KS 1 BSIV
10A P6320060 ROTOR ASSY. KS 1 BSVI
16A
11 P6060010 MAGNETO ASSY. KS 1
15A
11A P6060080 MAGNETO ASSY. KS 1 BSVI
15B 12 P6320050 STATOR ASSY. KS 1
12A P6321080 STATOR ASSY. KS 1 BSVI
13 M1200530 HEX FLANGE BOLT M6x20 1 1
14 P6180080 DEFLECTOR 1 1
15 P7060010 STARTER GENERATOR ES 1 ES
16B
15A P7320180 STARTER GENERATOR ES 1 "
15B P7060060 STARTER GENERATOR ES 1 BSVI
17B
17A 16 P7320020 ROTOR ASSY. SG 1
16A P7320160 ROTOR ASSY. SG 1
16B P7320290 ROTOR ASSY. SG 1 BSVI
17 P7320010 STATOR ASSY. SG 1
MAGNETO ASSEMBLY 17A P7320150 STATOR ASSY. SG 1
17B P7320280 STATOR ASSY. SG 1 BSVI
FIG.NO. 07 COVER CLUTCH ASSEMBLY FIG.NO. 07

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
1 P200030 CIRCLIP 16x1 1 1
2 0335024 SHIIM 17x24x1 1 1
3 P6080150 GEAR KS IDLER 1 1
4 G2200980 CIRCLIP 2 2
19A 5 G2200970 SHIM 28x38x1 2 2
6 B5080360 GEAR COMP. PRIMARY DRIVEN 1 1
7 P6080020 SHAFT GEAR PRIMARY DRIVEN 1 1
8 P6030070 GASKET COVER CLUTCH 1 1
10A
9 N2200150 BALL BEARING 12x40x12 1 1
10 P6030090 COVER CLUTCH 1 1
10A P6030170 COVER CLUTCH 1 1 BSVI
11 T4080540 OIL SEAL SHAFT DRIVE DIA 17x29x6 1 1
12 M1200510 HEX FLANGE BOLT M6x25 9 9
13 N3080250 LOCK PLATE SPROCKET 1 1
14 C1200020 HEX SCREW M5x8 2 2
15 P6080090 SPROCKET 13T 1 1
16 S1200860 O RING 1 1
17 G2081880 OIL GUAGE LEVEL 1 1
18 N2200550 OIL SEAL CRANKSHAFT RH 1 1
19 P6080010 COVER ENGINE SPROCKET 1 1
22A 19A P6080310 COVER ENGINE SPROCKET 1 1
20 P200270 CRPH SCREW M6x12 2 2
21 420001700 PUNCHED WASHER A6.6 2 2
22 P6110160 CHAIN ASSY. 104 1 1
22A P6110390 CHAIN ASSY. 106 1 KS HD
23 P321420 CONNECTING LINK SET 1 1
24 P6320140 CHAIN SPROCKET KIT 1 1 **
COVER CLUTCH ASSEMBLY 24A P6320640 CHAIN SPROCKET KIT 1 KS HD
25 P6080290 BUFFER CHAIN 1 1
FIG.NO. 08 KICK STARTER ASSEMBLY FIG.NO. 08

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 0258040 RUBBER KICK STARTER LEVER 1 1

2 F084088 PEDAL LEVER M/C 1 1
3 0330208 CIRCLIP 8.0 1 1
4 F084100 WASHER LEVER KICK STARTER 1 1
5 P6080050 LEVER KICK STARTER ASSY. 1 1
6 0331268 HEX BOLT M8x1.25x25 1 1
7 0330164 CIRCLIP 3RD DRIVE GEAR 1 1
17 8 0335024 SHIM 17x24x1 1 1
18
9 N5081280 GUIDE KICK STARTER SPRING 1 1
10 P6080119 SHAFT KICK STARTER 1 1
11 P6080130 SPRING KICK STARTER RATCHET 1 1
12 N5081370 SPRING KICK STARTER 1 1
13 N5081330 RATCHER KICK STARTER 1 1
14 0330174 CIRCLIP 16x1 1 1
15 N5200140 SHIM 20.5x25.5x1.2 1 1
16 P6080250 GEAR KICK STARTER 1 1
17 3030515 SPRING PILLION FOOTREST NEW 1 1
18 F084100 WASHER KICKSTARTER LEVER 1 1

KICK STARTER ASSEMBLY

 CARBURETTOR ASSY. FIG.NO. 09

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 P6040030 CARBURETTOR ASSY. 1 1

2 N8320270 RUBBER CAP 2 2
3 N8320940 HOUSING CHOCK 1 1
4 N8320730 O RING 1 1
5 P320110 SPRING 1 1
6 N8320950 VALVE SPINDLE CHOKE 1 1
7 P6320390 RUBBER PIPE 1 1
8 P320330 TUBE CLIP 2 2
9 P6320290 SPRING THROTTLE VALVE 1 1
10 P6320430 RETAINER DISC 1 1
11 N8320310 SPRING COMPRESSION 1 1
12 P1320570 GASKET 1 1
13 P320280 CIRCLIP 1 1
14 P6320220 JET NEEDLE TYPE H1 1 1
15 P1320500 MIXING CHAMBER COVER 1 1
16 P6320470 SPRING VALVE CONTROLLER 1 1
17 P1320560 VALVE CONTROLLER 1 1
18 P6320460 AIR ADJUSTER 1 1
19 N8320360 SPRING AIR ADJ. 1 1
20 N8320370 WASHER AIR ADJ. 1 1
21 N8320380 O RING AIR ADJ. 1 1
22 N8320440 GASKET 1 1
23 P6320310 FC COVER ASSY. 1 1
24 P6320410 HOSE DRAIN 1 1
25 P320050 SCREW + SPRING WASHER 2 2
26 P6320320 PETROL STOP NEEDLE 1 1
27 P6320260 NEEDLE JET 1 1
28 P6320280 NEEDLE JET HOLDER 1 1
29 P6320230 MAIN JET No.52 1 1
30 N8323590 SLOW JET NO.32 1 1
31 N8320490 PIN FLOAT 1 1
32 N8320500 FLOAT 1 1
33 P6320420 O RING INSULATOR PAD 1 1
34 P6320440 THROTTLE VALVE 1 1
FIG.NO. 10 AIRCLEANER ASSEMBLY FIG.NO. 10

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

2 1 P6040050 AIR FILTER ASSY. 1 1

1 1A 1A P6040320 AIR FILTER ASSY. 1 1 BSVI
2 P6040150 TUBE INLET 1 1
3 4 3 P6040060 COVER AIR CLEANER 1 1
3A P6040340 COVER AIR CLEANER 1 1 BSVI
5
4 4 P6040090 SEAL AIR CLEANER 1 1
5 P6040070 FILTER HOLDER COMP. 1 1
6
6 P6040080 CASE COMP AIR CLEANER 1 1
7 7 M1200660 SELF TAP SCREW 5 5
8 R1040460 CLIP HOSE BREATHER 1 1
9 N3040360 DRAIN PIPE 1 1
10 P6040100 TUBE OUTLET 1 1
10A --- TUBE OUTLET 1 1 BSVI
11 0086010 HOSE CLIP 41.5 1 1
16A
11A P100480 HOSE CLIP 41.5 1 1 BSVI
12 K140820 HOSE CLIP 1 1
3A
13 P6040160 HOSE BREATHER PVC COMP 1 1
8 14 R2040400 HOSE CLAMP DIA 12.5 1 1
9 15 P6040110 DRAIN PIPE 1 1
16 R1140440 HOSE CLIP DIA13 1 1
10A 16A N2041150 HOSE CLIP DIA13 1 1 BSVI
11A 17 N9051860 CUP WASHER 2 2
18 0332275 SCREW CRPH M6x16 2 2

AIRCLEANER ASSEMBLY
FIG.NO. 11 SECONDARY AIR INJECTION ASSY. FIG.NO.11
1
1 NO. OFF
3A
2 REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
2
1 R2040400 HOSE CLIP DIA 12.5 4 4
2 P6040180 HOSE AIR INLET 1 1
3 P6040170 BRKT AIR FILTER 1 1
3A P7120220 BRKT AIR FILTER 1 1 BSVI
15
14 1 4 P1040170 AIR CLEANER SAI 1 1
4A P6040240 SAI VALVE SUB ASSY. 1 1 BSVI
5 N8040350 HOSE CLIP AIR INJECTION 2 2
6 N8040620 HOSE SAI OUTLET 1 1
17 16 3 6A P6040350 HOSE SAI OUTLET 1 BSVI
10A 6B R3040060 HOSE SAI OUTLET 1 BSVI
9 4A 7 N8040340 O RING 1.9x10 1 1
8 P1200050 WAVE SPRING WASHER M6 1 1
9 M1200520 HEX FLANGE BOLT M6x16 2 2
6A 6B 10 P6040140 PIPE COMP. SAI 1 1
10A P6040260 PIPE COMP. SAI 1 1 BSVI
5 9
11 P1040220 BOOT SAI FILTER 1 1
12 N9041670 CLEANER SAI 1 1
6 4
13 P6040190 HOSE SAI INLET 1 1
14 P6040250 SAI BRKT ASSY. 1 1 BSVI
5
15 P6040270 HOSE SAI INLET 1 1 BSVI
7 16 M1200510 HEX FLANGE BOLT M6x25 2 2 BSVI
17 P7040020 BRKT SAI MTG 1 1
1
8
9

SECONDARY AIR INJECTION ASSY.

FIG NO.12 1 MUFFLER ASSEMBLY FIG.NO. 12

NO. OFF
3 4 5 5A
REF PART DESCRIPTION XL 100 REMARKS

2 NO. NO. KS ES

6 1 P6050020 MUFFLER SUB ASSY. 1 1

1A P7050020 MUFFLER SUB ASSY. BSIV 1 1
1B P6050110 MUFFLER SUB ASSY. BSIV 1 1 SPL. EDITION
1C P7050120 MUFFLER SUB ASSY. BSVI I TOUCH 1 BSVI
1D P7050150 MUFFLER SUB ASSY. COMFORT/HD I TOUCH 1 BSVI
7 2 N3200250 HEX SCREW M6x10 2 2
3 R2200160 SPRING WASHER 2 2
4 420001700 PUNCHED WASHER 6.5x13x1 2 2
5 P6220260 GUARD MUFFLER 1 1
5A P6050100 GUARD MUFFLER 1 1 SPL. EDITION
6 P6050030 MUFFLER COMP. 1 1
6A P7050030 MUFFLER COMP. BSIV 1 1
7 T4050180 GASKET EXHAUST 1 1
8 M1200890 U NUT M8x1.25 2 2
9 P6060100 OXYGEN SENSOR 1 1 BSVI
8

MUFFLER ASSEMBLY
FIG.NO. 13 FUELTANK ASSEMBLY FIG.NO. 13

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 P6220200 COVER FUEL TANK 1 1

1A P6221140 COVER FUEL TANK 1 COMFORT ES
1B P6221940 COVER FUEL TANK BEIGE 1 1
2 --- FUEL TANK COMP. 1 REF.COLOUR VEH.

2A --- FUEL TANK COMP. 1 REF.COLOUR VEH.

3 0332928 PLAIN WASHER 18x6.5x1.6 2 2

4 P1200050 WAVE SPRING WASHER M6 2 2
5 M1200640 HEX SCREW M6x16 2 2
6 T140160 TANK ASSY. FUEL CAP 1 1
7 P1200040 CRR PAN HD SCREW M6x16 2 2
8 P1200110 CUP WASHER 2 2
9 N9142120 HOSE FUEL COCK (WITH HOSE CLIP) 1 1
10 P6140080 FUEL COCK COMP. 1 1
11 N3140120 GASKET OIL LEVEL PLUG 2 2
12 N3200220 HEX FLANGE BOLT M6x1.25x16 2 2
13 P6221010 TAPESET KS 1 1 HD
REF.COLOUR VEH.

FUELTANK ASSEMBLY
FIG.NO. 13A FUELTANK ASSEMBLY - BSVI FIG.NO. 13A

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 P6140350 ROLLOVER VALVE 1 1 BSVI

2 N9141990 BOOT ROLL OVER VALVE 1 1 BSVI
3 P6140290 HOSE ROLL OVER VALVE 1 1 BSVI
4 N4200130 HOSE CLAMP 1 1 BSVI
5 M1200660 CRPH SCR M5x16 ZNG 2 2 BSVI
6 P6160160 LOW FUEL WARNING SWITCH 1 1 BSVI
7 P6140190 TANK ASSY. FUEL CAP 1 1 BSVI
8 --- FUEL TANK COMP 1 1 BSVI, REF.COL.

9 P1200040 CRR PAN HD SCREW M6x16 2 2 BSVI

10 7130140 WASHER CUP 2 2 BSVI
11 M1200590 HEX FLANGE BOLT M6x35 2 2 BSVI
12 P6140390 HOSE AIR INLET 1 1 BSVI
13 N9220760 GROMMET 2 2 BSVI
14 P6140320 HOSE THROTTLE BODY 1 1 BSVI
15 N8040370 HOSE CLIP VACUUM 4 4 BSVI
16 P6140410 PURGE VALVE 1 1 BSVI
17 P6140230 BOOT PURGE VALVE 1 1 BSVI
18 K4140140 CANISTER COMP. 1 1 BSVI
19 R1040460 CLIP HOSE BREATHER 3 3 BSVI
20 P6140310 HOSE PURGE VALVE 1 1 BSVI
21 P6140160 BRKT COMP FUEL PUMP MTG 1 1 BSVI
22 P6140180 FUEL PUMP ASSY. 1 1 BSVI
23 R2040400 HOSE CLAMP DIA 12.5 1 1 BSVI
24 P6140210 HOSE FUEL OUTLET 1 1 BSVI
FUELTANK ASSEMBLY - BSVI 25 N3200220 HEX FLANGE BOLT M6x1.25x16 1 1 BSVI
FIG.NO. 13A FUELTANK ASSEMBLY - BSVI FIG.NO. 13

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

26 N3140120 GASKET OIL LEVEL PLUG 1 1 BSVI

27 P6140150 FUEL FILTER ASSY 1 1 BSVI
28 K2140210 QUICK CONNECTOR L TYPE 1 1 BSVI
29 P6140340 HOSE FUEL RETURN 2 2 BSVI
30 P6140300 HOSE CANISTER 2 2 BSVI
31 NB140110 EAR CLAMP 2 2 BSVI
32 P6140200 HOSE INJECTOR ASSY 1 1 BSVI
33 P1200060 HEXAGONEL NUT M6 2 2 BSVI
34 N7201480 CUP WASHER 2 2 BSVI
35 P6140330 SEAL FUEL FILTER 1 1 BSVI
36 414147000 CLIP FUEL HOSE 1 1 BSVI
37 P6140370 HOSE DRAIN CANISTER 1 1 BSVI
 HEADLAMP & TSL FRONT ASSEMBLY FIG.NO. 14

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 N3160210 BULB 12V 10W 2 2

2 P1200040 CRR PAN HEAD SCREW M6x16 2 2
3 420001700 PUNCHED WASHER A6.6 2 2
4 B1160190 TURN SIGNAL LAMP FRONT RH 1 1
5 P1160030 HEAD LAMP ASSY. 1 1
5A P7220200 HEAD LAMP ASSY. 1
6 P1320650 RIM HEADLAMP 1 1
7 P1320660 GASKET HEAD LAMP 1 1
5A
8 P1320640 REFLECTOR UNIT 1 1
9 K160790 BULB HEADLAMP 1 1
10 0334548 HEX NUT M8 2 2
11 0335516 WASHER 4 4
12 P1320830 LENS COMP. TSL 2 2
13 P1320670 SHELL HEADLAMP 1 1
14 0331058 HEX BOLT+WAVE SPRING WASHER M8x16 2 2
15 420465700 SCH SCREW M5x16 2 2
16 0330308 WAVE SPRING WASHER 2 2
17 P3160020 BULB HOLDER ASSY. 1 1
18 B1160180 TURN SIGNAL LAMP FRONT LH 1 1
19 P320540 RUBBER BUSH ASSY. 2 2
20 P6220690 DAY LIGHT RUNNING LAMP 1 1
21 N8220560 GROMMET SPEEDO METER 2 2
22 0335608 PUNCHED WASHER A6.6 2 2
23 420305700 HEX NUT M6 2 2
24 P7220190 HOSUING HEADLAMP REAR 1
FIG.NO. 14A HEADLAMP ASSEMBLY FIG.NO. 14A

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 --- HOUSING HEAD LAMP 1 REF. COLOUR

2 P6222220 VISOR HEADLMAP 1 COMFORT
3 S1200700 RETAINER CLIP COMP PANEL 7 "
4 P6222210 HOUSING HEAD LAMP REAR 1 "
5 0332275 CRR PAN HD SCREW M6x16 7 "
6 0330308 WAVE SPRING WASHER 2 "
7 420465700 SCH SCREW M5x16 2 "
8 P7220560 HOUSING 1 "
9 0331058 HEX BOLT+WAVE SPRING WASHER M8x16 1 "
10 P7220570 HEADLAMP ASSY. 1 "
11 R3220650 CUSHION RC LAMP 2 "
12 N5226120 CUSHION HEAD LAMP 2 "
13 P160460 H L BULB 12V 35A 1 "
14 P3160020 BULB HOLDER ASSY 1 "

HEADLAMP ASSEMBLY
FIG NO.15 6 FRAME ASSEMBLY FIG.NO. 15
9
NO. OFF
8
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

7 1 P6120110 FRAME COMP 1

1A P7120040 FRAME COMP 1
2 N8200040 HEX SCREW M8x65 2 2
3 N5200330 HEX FLANGE BOLT M8x100 1 1
1 1A 4 P6120340 BRKT TCI MTG 1 1
36 35
32 34 5 K130190 STOPPER SEAT 2 2
33 6 P1200070 HEX SCREW M6x16 5 5
7 P6120350 CARRIER COMP 1 1
8 N3130100 CUSHION 1 1
9 420001700 PUNCHED WASHER A6.6 3 3
10 8200120 CRPH SCREW M5x12 2 2
2
11 P1200150 WAVE SPRING WASHER M5 2 2
3 4
12 K130110 SEAT LOCK 1 1
13 P1200060 HEX NUT 4 4
14 P1200050 WAVE SPRING WASHER 5 5
15 M1200890 U NUT M8x1.25 3 3
16 P6120170 CENTER STAND COMP. 1 1
17 420015700 PUNCHED WASHER 12.5x20x1.2 2 2
18 0330028 SPLIT PIN 3.20x25 1 1
2
19 410114700 CUP BOTTOM 1 1
6 20 F123718 PIVOT PIN STAND 1 1
21 409115000 STAND SPRING 1 1
22 K101430 CUP TOP 1 1
23 P6300010 CRAUSHGUARD COMP 1 1
5 24 M1200840 HEX FLANGE BOLT M8x50 1 1
6 9 25 0330318 WAVE SPRING WASHER M8 1 1
26 G5200490 PUNCHED WASHER 8.5x16x1.2 1 1
27 P6220210 SAREE GUARD COMP. LH 1 1
FRAME ASSEMBLY 28 P6300020 HOLDER 1 1
 6 FRAME ASSEMBLY FIG.NO. 15

9
NO. OFF
8 REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

29 P1320920 KIT PILLION HANDLE REAR 1 1

7 30 P6220680 PILLION HANDLE COMP 1 1
31 P7120080 BRKT IGN COIL MTG 1
32 D128330 LOCK ASSY. STEERING 1
33 P7120230 BRKT CANISTER MTG 1 1 BSVI
1 1A
36 35 34 P1200040 CRR PAN HEAD SCREW M6x16 3 3 BSVI
32 34 35 P7120290 CABLE GUIDE LH 1 1 BSVI
33
36 P7120300 CABLE GUIDE RH 1 1 BSVI
37 P7120310 MTG BKT CAPACITOR 1 1

2
3 4

5
6 9

FRAME ASSEMBLY
FIG.NO. 16 RIDER FOOTREST ASSEMBLY FIG.NO. 16

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 P6120810 RIDER FOOTREST SUB ASSY. 1 1

13 2 P6120790 FOOTREST COMP. 1 1
3 N3122460 RUBBER RIDER FOOTREST 2 2
4 N9200010 HEX BOLT M8x1.25x30 1 1
5 N8121890 SPRING PROP STAND 1 1
6 P6120710 PROP STAND COMP 1 1
7 0334548 HEX NUT M8 1 1
8 N8200030 HEX FLANGE BOLT M8x75 1 1
9 G5200400 PUNCHED WASHER 8.5x16x1.2 1 1
10 420454700 HEX SCREW M8x20 1 1
11 P6320100 PROP STAND KIT 1 1
12 M1200890 U NUT M8x1.25 2 2
13 G5200490 PUNCHED WASHER 8.5x20x2 4 4
14 N5200330 HEX FLANGE BOLT M8x100 1 1
15 P6120800 STAY FOOTREST COMP. 1 1
16 0330318 WAVE SPRING WASHER M8 1 1
17 P6320500 KIT RIDER FOOTREST 1 1 REF. KIT

RIDER FOOTREST ASSEMBLY

FIG.NO. 17
35C
35A FRONT SUSPENSION ASSY. (HYDRAULIC FORK) FIG.NO. 17

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

28A 1 P3320040 FRONT FORK SUSPENSION - SIL. GR 1 1

1A
1A P7100120 FORK LEG SET W/O OIL 1 1 NEW
2 T4100139 LOCK PLATE COMP. UPPER 2 2
3 T4100300 GUIDE BUSH 4 4
4 P100790 SPRING OIL FORK 2 2
4A P6100100 SPRING OIL FORK 2 2 NEW
5 T4100110 SPRING ANCHOR COMP. 2 2
5A P6100110 SPRING ANCHOR COMP. 2 2 NEW
6 T4100280 BUMP STOPPER 2 2
7 T4100080 FORK TUBE COMP. LOWER RH 1 1
8 A054190 HOSE CLIP 35 2 2
9 P3100120 BELLOW DUST 2 2
9A P6100120 BELLOW DUST 2 2 NEW
16A
10 M100050 HOSE CLIP 48 2 2
11 1257281 SNAP RING 2 2
12 1257466 WASHER 2 2
42 21A
13 1257290 OIL SEAL 2 2
14 7100610 SLIDE METAL 2 2
15 0334548 HEX NUT M8 2 2
16 T4100510 FORK TUBE COMP. UPPER 2 2
16A P6100090 FORK TUBE COMP. UPPER 2 2 NEW
17 T4100290 SLIDER 2 2
18 410115700 CONE BOTTOM PLATED 4 4
40
19 410073000 TOLLERENCE RING 1 1
35B 41 20 T4100200 CROWN PLATE COMP. BOTTOM 1 1
21 T4100600 STRAP CABLE 1 1
21A P6170060 CABLE GUIDE FRONT 1 1
22 420106000 UNDULATED WASHER 2 2
FIG.NO. 17 35C
35A FRONT SUSPENSION ASSY. (HYDRAULIC FORK) FIG.NO. 17

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
28A
1A
23 A200030 DOMED CAP NUT M8 4 4
24 420469700 HEX BOLT M8x65 2 2
25 T4100050 FORK TUBE COMP. LOWER LH 1 1
26 410058700 STEERING LOCK NUT 1 1
27 410043700 SPECIAL WASHER 1 1
28 T41004400D UPPER BRKT 1 1
28A P6100040 CROWN PLATE COMP TOP 1 1 SBS
29 410013700 CONE TOP PLATED 1 1
30 420402000 BALLS 5/32" (DIA 3.9) 52 52
31 K101430 CUP TOP 1 1
32 410055700 SHIM 26x32x1 1 1
33 410056700 SHIM 1 1
16A
34 410114700 CUP BOTTOM PLATED 1 1
35 P3100100 BRKT COMP. HEAD LAMP MTG. 1
42 35A P6220650 BRKT COMP. HEAD LAMP MTG. 1
21A
35B P6220700 BRKT COMP. HEAD LAMP MTG. BSIV 1
35C P7220230 BRKT COMP. HEAD LAMP MTG 1
36 T4100550 PACKING 4
37 P3320020 FORK LEG ASSY RH - SIL. GREY 1
37A P6100080 FORK LEG ASSY. RH 1 1
38 P3320030 FORK LEG ASSY LH - SIL. GREY 1
38A P6100070 FORK LEG ASSY. LH 1 1
40
35B 39 410059000 CAP LOCK NUT 1 1
41 40 P3320060 FRONT SUSPENSION KIT 1 1
41 P6320520 FRONT SUSPENSION KIT W/O OIL 1 1
42 P7170040 CABLE GUIDE 1
FIG.NO. 17A
39 FRONT SUSPENSION ASSY. FIG.NO. 17A

NO. OFF
2
REF PART DESCRIPTION XL 100 REMARKS
4 NO. NO. KS ES

11 1 P7100020 FORK ASSY FR 21300 67800 14000 5500 1 COMFORT

12 2 P7220230 BRKT COMP. HEAD LAMP MTG 1 "
3 P7170040 CABLE GUIDE FRONT 4 "
13 4 P6100170 SPRING FR FORK 2 "
14 5 P6100190 DAMPER PISTON FRONT FORK 2 "
15 6 P7100130 SPRING RETURN 2 "
5 16 7 K2100230 DUST SEAL FRONT FORK 2 "
17
8 P6100210 FORK TUBE LOWER COMP R 2 "
9 P7100100 FORK TUBE INNER COMP 2 "
10 T4100290 SLIDER 4 "
11 P6100250 NUT FRONT FORK 2 "
6
12 P6100220 O-RING FR FORK 2 "
7 13 P6100180 SPACER FR FORK 2 "
40
14 N8101240 WASHER 2 "
8
15 1257281 SNAP RING 2 "
16 1257290 OIL SEAL 2 "
9 3 21 17 P3100160 SLIDE METAL 2 "
18 410115700 CONE BOTTOM PLATED 4 "
19 410073000 TOLLERENCE RING 1 "
10 20 T4100200 CROWN PLATE COMP. BOTTOM 1 "
21 P6170060 CABLE GUIDE FRONT 1 "
22 420106000 UNDULATED WASHER 2 "
23 A200030 DOMED CAP NUT M8 4 "
24 420469700 HEX BOLT M8x65 2 "
25 P6100200 FORK TUBE COMP LOWER L 1 "
26 410058700 STEERING LOCK NUT 1 "
FIG.NO.17A
39 FRONT SUSPENSION ASSY. (HYDRAULIC FORK) FIG.NO. 17A

NO. OFF
2
REF PART DESCRIPTION XL 100 REMARKS
4 NO. NO. KS ES

11 27 410043700 SPECIAL WASHER 1 COMFORT

12 28 T41004400D UPPER BRKT 1 "
29 P6100060 CONE TOP 1 "
13
30 420402000 BALLS 5/32" (DIA 3.9) 52 "
14 31 K101430 CUP TOP 1 "
15 32 410055700 SHIM 26x32x1 1 "
5 16 33 410056700 SHIM 1 "
17
34 410114700 CUP BOTTOM PLATED 1 "
35 T4100550 PACKING 2 "
36 P6220660 PACKING 2 "
37 P7100040 FORK LEG ASSY RH 1 "
6
38 P7100030 FORK LEG ASSY LH 1 "
7 39 410059000 CAP LOCK NUT 1 "
40
8
40 0334548 HEXAGONAL NUT M8 2 "

9 3 21

10
FIG.NO. 18 COVER FRAME & TOOL BOX ASSY. FIG.NO. 18

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
1 D046200 LOCK TOOL BOX 1
2 P6220190 LID TOOL BOX 1
3 --- TOOL BOX COMP. 1 REF. COLOUR VEH.

4 P1200060 HEX NUT M6 12 4

5 P6220180 COVER TOOL BOX CTR RR 1
6 M1200610 HEX SCREW M6x20 4
7 P1200050 WAVE SPRING WASHER M6 12 2
8 420001700 PUNCHED WASHER A6.6 4
9 7130140 WASHER 6 6
8 10 M1200670 CRR PAN HEAD SCREW M6x20 6 6
11 A128730 SOCKET FLOOR MAT 2 2
12A 12B 12C 12 P6220140 FLOOR BOARD 1 1
12A P6221150 FLOOR BOARD 1 COMFORT ES
12B P6222400 FLOOR BOARD 1
12C P6222290 FLOOR BOARD 1 BSVI
13 --- COVER FRAME RH 1 1 REF. COLOUR VEH.

14 --- COVER FRAME LH 1 1 "

15 S1200700 RETAINER CLIP PANEL 4 4
26 16 P1200070 HEX SCREW M6x16 2 2
17 P1100090 BRKT STABILISER 1 1
4 18 410019000 PAD STABILISER 1 1
27 19 --- STABILISER TUBE 1 1 REF. COLOUR VEH.

20 0332275 CRR PAN HD SCREW M6x16 6 6

21 --- FENDER FRONT 1 1 REF. COLOUR VEH.

22 P300050 MUDFLAP FRONT 1 1

23 P6100030 CABLE GUIDE SPEEDO 2 2
24 --- STAY MUDGUARD 1 1 REF. COLOUR VEH.

25 P1200120 PUNCHED WASHER 4 4

26 N9227200 REIFLEX REFLECTOR ASSY 2 2
27 P7220620 MTG BRKT SIDE RETRO REFLECTOR 2 2 BSVI
28 P7300160 FLOOR MAT 1 1
COVER FRAME & TOOL BOX ASSY
FIG.NO. 18A COVER FRAME & TOOL BOX ASSY. - ES FIG.NO. 19

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
1 K3200860 CRR PAN HEAD SCREW M6x30 2
2 P1200050 WAVE SPRING WASHER M6 6
3 N8122610 CUP WASHER 2
4 --- TOOL BOX LH 1 REF. COLOUR

11A 5 P7220110 BEADING LID TOP 2

6 P7220080 COVER UTILITY BOX 1
6A P6222250 COVER UTILITY BOX 1 SPL. EDITION
6B P6221720 COVER UTILITY BOX 1 COMFORT ES
7 P7220170 CLAMP BATTERY 1
8 P7060020 CONTROLE UNIT ISG 1
9 --- BATTERY VRL UNCHARGED 1
10 420001700 PUNCHED WASHER A6.6 4
11 P7220100 COVER TOOL BOX CTR REAR 1
11A P7220520 COVER TOOL BOX CTR REAR 1 BSVI
12 M1200610 HEX SCREW M6x20 4
13 0335608 PUNCHED WASHER 6.5x16x1.2 4
14 P1200060 HEX NUT M6 4
15 S1200700 RETAINER CLIP COMP. PANEL 2
16 M1200530 HEX BOLT M6x20 3
17 G5200340 PUNCHED WASHER 5.5x12x1 2
18 K200320 CRR PAN HEAD TAP SCREW ST 4.2x16 2
19 K6220620 REATINER CLIP PANEL 2
24
22A 20 P7220160 ADAPTOR 1
22B
21 --- TOOL BOX RH 1 REF. COLOUR
22 P7220060 LID TOOL BOX 1
22A P6222260 LID TOOL BOX ES 1 SPL. EDITION
22B P6221160 LID TOOL BOX 1 COMFORT ES
23 --- TOOL BOX CENTER 1 REF. COLOUR
24 D046200 LOCK TOLL BOX 1
COVER FRAME & TOOL BOX ASSY. - ES 25 P6222310 ADAPTOR KS 1 BSVI
FIG.NO. 19 REAR FENDER ASSEMBLY FIG.NO. 19

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 --- FENDER REAR 1 1 REF. COLOUR VEH.

2 P1200070 HEX SCREW M6x16 4 4

3 P1200060 HEX NUT M6 4 4
4 P1200050 WAVE SPRING WASHER M6 4 4
5 0335928 PLAIN WASHER 18x6.5x1.6 4 4
6 1228880 CHSHION RC LAMP 2 2
7 N3160220 SPACER RC LAMP 2 2
8 P3120160 BRKT TURN SIGNAL LAMP 1 1
9 P121630 LICENCE PLATE COMP. 1 1
10 M1200610 HEX SCREW M6x20 2 2
11 412069000 TANK REST COMP TOP 1 1
12 P6220500 MUDFLAP REAR 1 1
13 0332275 CRR PAN HD SCREW M6x16 2 2
14 420001700 PUNCHED WASHER A6.6 10 10
15 412092000 PAD 1 1
16 P121060 PAD FENDER REAR 1 1
17 420302700 HEX NUT M5 1 1
18 M7160120 REFLEX REFLECTOR ASSY. 1 1
19 P1200140 PUNCHED WASHER 18x6.5x1.6 1 1
20 P6222350 BRKT TAIL LAMP COMP. 1 1

REAR FENDER ASSEMBLY

FIG.NO.20 6 SEAT ASSEMBLY FIG.NO.20

NO. OFF
1 REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 P6130020 SEAT COMP FRONT 1 1

1A P6130200 SEAT COMP FRONT 1 1 SPL. EDITION
1B P7130150 SEAT COMP FRONT 1 1
2 7
2 P6130050 COVER COMP SEAT FRONT 1 1
9 2A P6130230 COVER COMP SEAT FRONT 1 1 SPL. EDITION
1B P7130170 COVER COMP SEAT FRONT 1 1
3 P6130040 SEAT FOAM FRONT 1 1
4 P6130100 BOLT PLATE FRONT 4 4
5 P6130030 SEAT BASE FRONT 1 1
3 8 6 P6130090 COVER COMP SEAT REAR 1 1
6A P6130240 COVER COMP SEAT REAR 1 1 SPL. EDITION
6B P7130180 COVER COMP SEAT REAR 1 1
7 P6130080 SEAT FOAM REAR 1 1
8 P3130030 SEAT BASE REAR 1 1
4
9 P6130060 SEAT COMP REAR 1 1
9A P6130240 SEAT COMP REAR 1 1 SPL. EDITION
9B P7130160 SEAT COMP REAR 1 1
5 10 420464700 HEX SCREW M6x16 1 1
11 P3130240 SEAT LATCH 1 1
12 P1200050 WAVE SPRING WASHER M6 5 5
13 0335876 PUNCHED WASHER 6.5x24x1.6 1 1
14 420305700 HEX NUTM6 1 1
15 0138010 CUSHION 3 3
SEAT ASSEMBLY 16 P120060 HEX NUT M6 4 4
FIG.NO.20A SEAT ASSEMBLY - NEW FIG.NO.20A

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS

2 NO. NO. KS ES
1 P130050 SEAT ASSEMBLY 1 1
1 2 P130079 REXIN ASSEMBLY 1 1
3 3 P130069 SEAT FOAM 1 1
4 P130029 SEAT BASE 1 1
5 P130200 REINFORCEMENT REAR 1 1
6 P130190 REINFORCEMENT REAR 1 1
5 7 P130160 REINFORCEMENT FRONT 1 1
6
8 0258570 CLAMP REAR FENDER 2 2
7 9 420001700 WASHER 6.5x13x10 8 6
10 409047000 NYLON LOCK NUT 10 6
4 11 P6130190 COVER COMP SEAT 1 1
8
11A P6130130 COVER COMP SEAT 1 COMFORT ES

9 12 P6130150 SEAT FOAM 1 1

13 P6130100 BOLT PLATE COMP 1 1
14 P6130140 SEAT BASE 1 1
15 P1200070 HEX BOLT M6x16 2 2
16 P6221840 PILLION HANDLE COMP 1 1
16A P6221050 PILLION HANDLE COMP 1 1 COMFORT ES
17 P1200050 WAVE SPRING WASHER M6 2 2
18 P6221730 HOLDER 1 1
19 P6130170 SEAT ASSY. KS 1 1
19A P6130160 SEAT ASSY. KS 1 1 COMFORT ES
20 P1200060 HEX NUT M6 4 4
21 P6221220 BACKREST PILLION ASSY 1 COMFORT ES
22 P6221210 PILLION HANDLE COMP 1 "
23 P6221230 COVER BACKREST PILLION 1 "
24 0334146 NUT LICENSE PLATE BRACKET 2 "

SEAT ASSEMBLY - NEW 25 K3200830 RETAINER CLIP M5 2 "

26 0331718 CRPH SCR M5x16 6.8 ZNB 2 "
 TAIL LAMP & TSL REAR ASSY. FIG.NO. 21

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 B1160080 LENS TURN SIGNAL REAR RH 1 1

2 5227350 BULB 12V / 10W 1 1
3 P6220520 LAMP ASSY. REAR COMP. 12V 1 1
4 F200058 CRPH SCREW M5x35 2 2
5 P320550 LENS R.C. LAMP 1 1
6 F160490 BULB TAIL LAMP 12V / 5W 1 1
7 P1200050 WAVE SPRING WASHER M6 2 2
8 P1200060 HEX NUT M6 2 2
9 420001700 PUNCHED WASHER A6.6 2 2
10 B1160150 LAMP ASSY. TSL REAR LH 1 1
11 P1320830 LENS COMP. TSL 2 2
12 P1200040 CRR PAN HD SCREW M6x16 2 2
 FRONT WHEEL ASSY. FIG.NO.22
29A
21
20 NO. OFF
REF PART DESCRIPTION XL 100 REMARKS

5A NO. NO. KS ES

19A
1 411199000 TYRE FRONT 2.5x16 1 1
2 411341000 TUBE - BUTYL 1 1
3 411173000 RIM NUT 1 1
4 411016000 RIM TAPE 1 1
5 111048700 WHEEL RIM 1.5 - 16 1 1
5A P3110080 WHEEL RIM 1.5 - 16 1 1 SBS
6A
6 411004000 SPOKE aid 2.98x159 LONG INNER 18 18
7A
6A P3110050 SPOKE aid 2.98x159 LONG INNER 1 1 SBS
7 411209000 SPOKE aid 2.98 - 159 LONG OUTER 18 18
7A P3110060 SPOKE aid 2.98 - 159 LONG OUTER 1 1 SBS
8 420313700 HEX NUT M12x1 1 1
9 0335538 PUNCHED WASHER A12.5x22x2.3 1 1
10 211204800 HUB DRIVE 1 1
10A 311325000 HUB DRIVE 1 COMFORT ES
17A 11 420661000 SEALING RING 2 2
15 12 0339100 BALL BEARING 12x32x10 2 2
13 411257000 SPACER BUSH FRONT 1 1
22A 14 211204800 WHEEL HUB FRONT 1 1
10A 26A
14A P6110500 WHEEL HUB FRONT 1 1 SBS
15 P6110300 BRAKE SHOE SET FRONT 1 1
16 411187000 SPRING BRAKE SHOE 2 2
17 P6110220 BRAKE PANEL COMP. 1 1
14A 17A P6110540 BRAKE PANEL COMP. 1 1 SBS
18 P110060 AXLE FRONT 1 1
28A
19 411005000 NIPPLE SPOKE 36 36
28B 19A N3110200 NIPPLE SPOKE 1 1 SBS
20 A326070 SPOKE & NIPPLE ASSY INNER (SET) 1 1
21 A326080 SPOKE & NIPPLE ASSY OUTER (SET) 1 1
22 P6110010 CAM BRAKE 1 1
22A K3110470 CAM BRAKE 1 1 SBS
 FRONT WHEEL ASSY. FIG.NO.22
29A
21
20 NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
5A

19A 23 0331248 HEX BOLT M6x1x33 1 1

24 0178030 O RING BRAKE CAM 1 1
25 0335698 PUNCHED WASHER 14.5x22x1.6 1 1
26 420001700 PUNCHED WASHER A6.6 1 1
26A 0335578 PUNCHED WASHER A6.6 1 1 SBS
6A 27 420305700 HEX NUT M6 1 1
7A 28 P6110240 LEVER CAM FRONT 1 1
28A K4110410 LEVER CAM FRONT 1 1 SBS
28B P6110570 LEVER CAM FRONT 1 COMFORT ES
29 111227000 WHEEL ASSY. FRONT 1 1
29A P6110550 WHEEL ASSY. FRONT 1 1 SBS

17A

15
10A 22A
26A

14A

28A

28B
 REAR WHEEL ASSY. FIG.NO.23

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

19A
1 0330048 SPLIT PIN 2x20 1 1
2 K200570 SLOTTED NUT M10x1.25 1 1

22A
3 0335628 PUNCHED WASHER 1 1
23A 4 P1090210 ADJUSTER ASSY. CHAIN RH NEW 1 1
5 P1200060 HEX NUT M6 2 2
6 0331308 BOLT CHAIN ADJUSTER 2 2
24A 7 P1110290 SPACER REAR AXLE RH 1 1
8 420305700 HEX NUT M6x1 2 2
9 420001700 PUNCHED WASHER 1 1
10 N3110420 LEVER REAR BRAKE CAM 1 1
11 0331248 HEX BOLT M6x33 1 1
12 3171043 PANEL COMP. RR BRAKE 1 1
13 0335698 WASHER 1 1

42A
14 0178030 O - RING BRAKE CAM 1 1
15 0234038 CAM BRAKE 1 1
33A 16 0339480 BEARING 20x42x12 1 1
17 C8110090 BRAKE SHOE SET 110DIA 1 1
18 3230515 SPRING BRAKE SHOE 2 2
19 411018000 TYRE 2.50 - 16 1 1
19A P7110010 TYRE 2.50 16 REAR 1 1 HD
20 411341000 TUBE - BUTYL 1 1
21 411016000 RIM TAPE 1 1
22 P3110080 WHEEL RIM 1.5 x 16 NEW 1 1
22A P6110460 WHEEL RIM 1.5 x 16 NEW 1 1 HD
23 N3110200 NIPPLE DIA3.5 NEW 36 36
23A N6110140 NIPPLE NEW 36 36 HD
24 P3110050 SPOKE REAR WHEEL INNER NEW 18 18
24A P6110410 SPOKE INNER 18 18 HD
 REAR WHEEL ASSY. FIG.NO.23

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

19A 25 P3110060 SPOKE REAR WHEEL OUTER NEW 18 18

25A P6110420 SPOKE OUTER 18 18 HD
26 0181013 HUB COMPLETE REAR WHEEL M/C 1 1
27 P110650 SHOCK ABSORBER RR WHEEL HUB 1 1
22A
23A 28 1182190 SPACER REAR HUB BEARING 1 1
24A 29 0339100 BEARING 12x32x10 1 1
30 0331318 BOLT REAR SPROCKET 4 4
31 3181043 DRUM REAR SPROCKET 1 1
32 3184038 SHAFT RR SPROCKET MTG DRUM 1 1
33 P6110170 CHAIN WHEEL 50T 1 1
33A P6110370 SPROCKET RR WHEEL 46 52 68 1 1 HD
34 N3110470 WASHER REAR SPROCKET 2 2
42A 35 0334548 HEX NUT M8x1.25 4 4
36 N3200010 BEARING 12x37x12 1 1
33A 37 0259520 OIL SEAL REAR SPROCKET DRUM 1 1
38 P1110300 SPACER REAR AXLE LH 1 1
39 P1090200 ADJUSTER ASSY. CHAIN LH NEW 1 1
40 J200030 HEX NUT M18 1 1
41 P3110230 AXLE 12 x 244 1 1
42 P3110220 WHEEL ASSY. REAR 1 1
42A P6110430 WHEEL ASSY. REAR 1 1 HD
43 P3320070 SPOKE & NIPPLE KIT INNER 1 1 REF. KIT LIST
43A P6320670 SPOKE & NIPPLE KIT INNER 1 1 HD
44 P3320080 SPOKE & NIPPLE KIT OUTER 1 1 "
44A P6320680 SPOKE & NIPPLE KIT OUTER 1 1 HD
45 P6320690 KIT SPROCKET 1 1 HD
FIG.NO.24 SPEEDOMETER ASSEMBLY FIG.NO.24

1A
12B
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS

21 NO. NO. KS ES
24 1 P1150050 HOUSING INSTRUMENT PANEL 1
2A 2B 1A P6222340 HOUSING INSTRUMENT PANEL 1 BSVI
2 P3160060 ASSY. SWITCH IGNITION 1
2A P6160210 ASSY. SWITCH IGNITION 1 SBS
5A 2B P7160290 ASSY. SWITCH IGNITION 1 BSVI
12A 3 P1160100 INDICATOR ASSEMBLY, TSL NEW 1
4 P1160090 INDICATOR ASSEMBLYM HI-BEAM NEW 1
5 P1150030 SPEEDO METER 12 V NEW 1 1
5A P7220460 SPEEDO METER 12 V NEW 1 BSVI
21A
5B P7220530 SPEEDO METER 12 V NEW 1 BSVI
5B
6 420302700 HEX NUT M5 8 ZNB 2 4
11A
7 B1150099 COVER INSTRUMENT PANEL NEW 1
11B
8 P1200150 WAVE SPRING WASHER M5 ( Ref.A200140) 3 3
15B 15A 11C 9 420010700 PUNCHED WASHER A5.5 ZNC 3 3
10 420465700 CH HD SCR M5x16 6.6 ZNB 3 3
11 --- SPEEDO METER ASSY. 1
11A P6222330 SPEEDO METER ASSY. 1 BSVI
11B P7220530 SPEEDO METER ASSY. 1 BSVI
11C P7220690 SPEEDO METER ASSY. HD I-TOUCH 1 BSVI
23 12 P7220140 HOSUING SPEEDOMETER TOP 1
12A P6221040 HOSUING SPEEDOMETER TOP 1 SBS
12B P7220540 HOUSING SPEEDOMETER TOP 1 BSVI
13 P7220150 HOUSING SPEEDOMETER BOTTOM 1 1
14 P7160050 IGNITION LOCK 1 1
15 P7160080 CORD SET SPEEDOMETER 1
SPEEDOMETER ASSEMBLY 15A P6160250 CORD SET SPEEDOMETER 1 BSVI
15B P7160210 CORD SET SPEEDOMETER 1 BSVI
 SPEEDOMETER ASSEMBLY FIG.NO.24
1A
12B NO. OFF
REF PART DESCRIPTION XL 100 REMARKS

21 NO. NO. KS ES
24
2A 2B 16 420462700 CH HD SCR M5x16 3 3
17 P7160060 MOBILE CHARGER 1
18 0336088 PUNCHED WASHER 4.3x9x1 1
5A 19 K200320 CRR PAN HEAD TAP SCR 4.2x16 1
12A 20 P1150010 BRKT INSRUMENT PANEL MTG. 1 1
21 P3210020 KEY BLANK 1
21A P7150060 KEY BLANK 1
22 P7320050 LED LAMP 12V 0.25W 1
21A
5B
23 NB110190 CABLE CLAMP 1 1 SBS
11A 24 P7220660 CAP MOBILE CHARGER 1

11B

15B 15A 11C

23

SPEEDOMETER ASSEMBLY
FIG.NO.24A SPEEDOMETER ASSEMBLY FIG.NO.24A

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
2
NO. NO. KS ES

1 P7220490 SPEEDOMETER ASSY 1 1 NEW VERSION

1 2 P7320120 HOUSING SPEEDOMETER TOP 1 1 "

3 P7160050 IGNITION LOCK 1 1 "
3 4 P7320100 CASE 1 1 "
4 5 P7160060 MOBILE CHARGER 1 1 "
6 P7320130 ODO MOVEMENT ASSEMBLY 1 1 "
6 7 P7160080 CORESET SPEEDOMETER 1 1 "
7 8 P7320110 BRKT COMP, Speedometer MTG COMP 1 1 "
9 P7320090 HOUSING SPEEDOMETER BOTTOM 1 1 "
5

SPEEDOMETER ASSEMBLY
FIG.NO.25 HANDLE BAR ASSEMBLY FIG.NO.25
1A
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
1 P1150090 HANDLE BAR NEW 1 1
1A P7150140 HANDLE BAR 1 1 BSVI
2 P150250 CLAMP BOLT 2 2
3 N3160310 CLAMP HANDLE SWITCH HARNESS 2 2
4 415005700 SUPPORT 2 2
14A
13A 5 P1150010 BRKT INSRUMENT PANEL MTG. 1 1
26 15A 6 P150280 SPACER BUSH 4 4
7 T41004400D CROWN PLATE COMP BOTTOM PAINTED 1 1
8 P150270 DAMPER RUBBER LOWER 4 4
9 P1200050 WAVE SPRING WASHER M6 4 4
10 P1200060 HEX NUT M6 4 4
11 412124700 SPL WASHER 4 4
12 P320590 SPEEDO INNER CABLE 1 1
13 P6170010 CABLE ASSY. THROTTLE 1 1
13A P6170100 CABLE ASSY. THROTTLE 1 1 BSVI
14 P6170050 CABLE ASSY. BRAKE FRONT 1 1
14A P7170030 CABLE ASSY. BRAKE FRONT 1 1 SBS
15 P6170030 CABLE ASSY BRAKE REAR 1 1
15A P7170020 CABLE ASSY BRAKE REAR 1 1 SBS
16 P6170020 CABLE ASSY CHOKE 860.0 47.0 1 1
17 P170080 CABLE ASSY SPEEDOMETER XL/HD BAS/UPG1 1
18 N3110360 SPRING REAR BRAKE ROD ADJUSTER 1 1
19 S1111940 PIN FR CABLE LEVER ZNC 2 2
20 0334268 NUT FR.BR.CABLE ADJ.-BR 2 2
25 21 P150260 DAMPER RUBBER UPPER 4 4
22 3250508 SPRING FR BRAKE CABLE 1 1
23 0258130 DUST SEAL FR BRK CABLE 1 1
28
29 24 P6170070 CLIP CABLE 1 1
25 D128330 LOCK ASSY. STEERING 1 1
26 P7170060 CABLE ASSY BRAKE FRONT L 1 1 SBS
27
27 N2110690 SPRING FRONT BRAKE CABLE 2 2 SBS
30
28 N2110680 DUST SEAL FR BRK CABLE 2 2 SBS
HANDLE BAR ASSEMBLY 29 0254038 PIN FR. BR LEVER 2 2 SBS
30 K6111350 BRAKE ADJUSTER 2 2 SBS
FIG.NO.26 BRAKE LEVER ASSY. LH & RH FIG.NO.26

3A 1A 1B 1C 1D
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES
1 P6150030 CONTROL LEVER ASSY LH 1
11
1A P6150190 CONTROL LEVER ASSY LH 1
1B P7150090 CONTROL LEVER ASSY LH 1
1C P6150080 CONTROL LEVER ASSY LH 1 SBS
1D P7150180 CONTROL LEVER ASSY LH 1 SBS
2 3160218 LEVER SET SCREW 2 2
3 P6150050 BRAKE LEVER LH 1
4 3168610 BODY CHOCK LEVER 1 1
5 3160424 ADJUSTER WASHER 1 1
6 3168600 LEVER STARTER 1 1
7 3160725 SET SCREW CHOKE 1 1
8 P1150160 CASE UNDER LH 1 1
12A 9 P1150130 CASE UPPER LH 1 1
10 41502100 U NUT M8x1.25 2 2
11 --- SET BRAKE LIGHT SWITCH 2
11A P7160110 SWITCH ASSY. STOP LAMP FRONT 1
12 P6150040 CONTROL LEVER ASSY. RH 1
12A P7150010 CONTROL LEVER ASSY. RH 1
13A
14A 12B --- CASE UPPER RH 1 1
13 P1150120 CASE UPPER RH 1 1
13A P150040 CASE UPPER RH 1
14 P1150170 CASE UNDER RH 1
14A --- CASE LOWER RH 1 P7150010
15 P6150060 BRAKE LEVER RH 1 1
16 0332808 SCREW 2 2
17 P150330 GRIP LH 1 1
18 P150320 GRIP COMP. THROTTLE RH 1 1
19 P150510 MIRROR ASSY. LH, RH 2 2
BRAKE LEVER ASSY. LH & RH 20 0254096 PIECE THROTTLE CABLE END 1 1
21 P7160140 SWICH ASSY STOP LAMP REAR 1
FIG.NO.26A 2 BRAKE LEVER ASSY. LH & RH - BSVI FIG.NO.26A

NO. OFF
1A 2A 3 REF PART DESCRIPTION XL 100 REMARKS
4
1 NO. NO. KS ES
5
1 P6150310 CONTROLE LEVER ASSY. RH KS 1 BSVI
1A P7150280 CONTROLE LEVER ASSY. RH ES 1 BSVI
2 --- CASE UPPER KS RH 1 BSVI / NS
2A --- CASE UPPER ES RH 1 BSVI / NS
3 3160268 LEVER SET SCREW 1 1

7 4 P6150390 CONTROL LEVER RH 1 1 BSVI

6 5 P7160220 SWITCH ASSY. STOP LAMP FRONT 1 1 BSVI
8 6 3160278 U NUT 2 2
9 7 --- CASE LOIWER 1 1 BSVI / NS
8 0331718 CRR PAN HEAD SCREW M5x16 1 2
12 9 P6150320 GRIP COMP. THROTTLE RH 1 1 BSVI
10 10 P6150380 CONTROL LEVER L 1 1 BSVI
11 P6150250 SPECIAL BOLT LH 1 1 BSVI
11 12 P6150260 CONTROL LEVER ASSY L 1 BSVI
15 12A P7150290 CONTROL LEVER ASSY L 1 BSVI
13 0332458 CRPH SCR M5x22 6.6 ZNB 1 1
12A 14 3160725 SET SCREW 1 1
15 P7160230 SWITCH ASSY STOP LAMP REAR 1 1 BSVI

14

13
6
BRAKE LEVER ASSY. LH & RH - BSVI

N.S - NOT SERVICE

FIG.NO.27 27 WIRING HARNESS & IGNITION COIL ASSY. FIG.NO.27
3A
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS

1A NO. NO. KS ES

1 P6060020 COMBINED IDI & IGNITION COIL 1

1A P7060030 IGNITION COIL ASSY. 1 1 SBS
2 P6160040 AC FLASHER UNIT 1 1
3 P6060030 REGULATOR CUM RECTIFIER 1
3A P6060090 REGULATOR CUM RECTIFIER 1 BSVI
26 4 420001700 PUNCED WASHER A6 2 2
7A 7B 7C 7D 28
5 P1200070 HEX FLANGE BOLT M6x16 1 1
6 N8200060 HEX FLANGE BOLT M6x10 1 1
7 P6160010 WIRING HARNESS 1
7A P6160110 WIRING HARNESS 1
31 7B P7160010 WIRING HARNESS 1
7C P6160230 WIRING HARNESS KS 1 BSVI
7D P7160200 WIRING HARNESS ES 1 BSVI
8 N8060170 SUPPRESOR CAP 1 1
12A 9 S1060310 SEAL SPARK PLUG 1 1
10 P210650 CABLE ASSY. STRAPPING 2 3
11 2162280L HORN ASSY. 12V 1 1
12 P3210160 LOCK SET XL HD 1
12A P1210630 LOCK SET XL HD 1 COMFORT
12B P3210210 LOCK SET KS 1 SBS
12C P7150030 LOCK SET ES 1 SBS
12D P7150340 LOCK SET ES 1 COMFORT ES
12E P7150350 LOCK SET ES 1 1 BSVI
17A 12F P7150360 LOCK SET KS/ES COMFORT 1 1 BSVI
12B 12C 12D 12E 12F 13 P1200050 SPRING WASHER 2 2
24
14 P200310 HEX SCREW 2 2
25 15 R1060200 SEAL HT CORD 1 1
16 P6160130 CONTROL UNIT (LED LIGHT) 1
29
17B 17 P7060020 CONTROL UNIT (3 SHOCKET) 1
17A P7320170 CONTROL UNIT ISG (4 SHOCKET) 1
30 17B P7060050 CONTROL UNIT ISG (3 SHOCKET) 1 BSVI
WIRING HARNESS & IGNITION COIL ASSY. 18 P7160020 CORD SET BATTERY 1
 27
3A WIRING HARNESS & IGNITION COIL ASSY. FIG.NO.27

NO. OFF
1A REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

19 P7160150 CABLE STRAP 2

20 N9160380 ELECTRONIC FLASHER UNIT 1 1
21 M1200530 HEX FLANGE BOLT M6x20 3 3

32 22 C8060020 SUPPRESOR CAP 1

26
7A 7B 7C 7D 28 23 P7060040 SEAL SPARK PLUG 1
24 P7320040 FUSE 15AMP 1
25 N9325830 FUSE 10AMP 1
26 P6170090 CABLE CLAMP 1 COMFORT ES
31 N9060420 CAPACITOR ASSY
27 1 BSVI
28 P6060070 ECU UNIT ASSY 1 BSVI
29 NF160590 CONTROL RELAY EFI 1 1 BSVI
12A 30 KA160420 BOOT CONTROL RELAY 1 1 BSVI
31 P6222320 CLAMP BATTERY KS 1 1 BSVI
32 P7160240 CABLE GUIDE

17A 12B 12C 12D 12E 12F

24

25
29
17B

30
FIG.NO.28 SWINGARM ASSEMBLY FIG.NO.28

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 R1090420 SILENT BLOCK 2 2

2 0330048 SPLIT PIN 2x20 2 2
3 G5200310 PUNCHED WASHER 10.5x18x1.6 2 2
4 0334218 HEX NUT M8x1.25 2 2
5 P3090290 TORQUE LINK REAR 1 1
6 0330318 WAVE SPRING WASHER M8 1 1
7 J110270 ABUTMENT REAR BRAKE CABLE 1 1
8 F113620 BOLT CABLE ABUTMENT 1 1
9 P6320380 SWING ARM COMP. (WITH BUSH) 1 1
10 0331348 BOLT TORQUE LINK REAR 1 1
11 K6200060 HEX BOLT M10x250 1 1
12 0335528 PUNCHED WASHER 10.5x10x1.6 2 2
13 P090840 PAD CHAIN PROTECTION 1 1
14 0330328 WAVE SPRING WASHER M10 ZNG 1 1
15 P200530 HEX NUT M10 1 1

SWINGARM ASSEMBLY
FIG.NO. 29 SHOCK ABSORBER ASSY. FIG.NO.29

3A
NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 420496700 HEX BOLT M10x40 2 2

2 0335628 PUNCHED WASHER 10.5x24x2.3 4 4
3 P30900100D SHOCK ABSORBER BLACK 2 2
3A P6090180 SHOCK ABSORBER BLACK 2 COMFORT ES
4 P3090210 PLATE COMP. FOOTREST LH 1 1
3A 5 P1200240 HEX NUT M10x1.25 2 2
6 P3090240 PLATE COMP. FOOTREST RH 1 1
7 P3090270 CHAIN COVER 1 1
8 7130140 WASHER 4 4
9 P1200070 HEX SCREW M6x16 4 4
10 P1200050 WAVE SPRING WASHER M6 4 4

SHOCK ABSORBER ASSY.

 TOOL KIT ASSEMBLY FIG.NO. 30

NO. OFF
REF PART DESCRIPTION XL 100 REMARKS
NO. NO. KS ES

1 P6210030 TOOL KIT 1 1

2 --- TOOL BAG 1 1
3 --- GRIP DRIVER 1 1
4 --- BIT STAR + NORMAL SCREW DRIVER 1 1
5 --- DOUBLE ENDED SPANNER 17x19 1 1

6 P7320070 PARTS CATALOGUE REV. 01 1 1

7 P6310020 MANDREL FOR OIL SEAL 1 1