PLATE NO.

1 : CYLINDER HEAD BOXER AR

6 8

3 2A
9
A 16
7
7

4
A
5 2
B 3
10

14

14A

1
12

12
11
3
13 15

Fig. Part No. Description Qty / Remark

No. Veh.
1 36 DF10 01 ‘O’ Ring Kit 1 (Set of A&B) Ref.Page No. 55
2 DD 1013 32 Cap intake side BSV 1
2A 31 1010 06 Cap 1
3 39 1673 04 Flanged bolt 6
4 31 1010 08 Guide Valve 2
5 39 1021 21 Ring ‘O’ 2 Alt to 39 2384 21

6 DD 1013 47 Bolt 2
7 DD 1013 50 Stud 2
8 DD 1013 49 Bolt 4
9 DM 1010 38 Head Comp. Cylinder (SAI) 1
10 31 1010 07 Cover (OHC) 1

11 DD 1013 51 Bolt 2
12 39 1000 06 Hollow Dowel Pin 2
13 DF 1010 24 Gasket Head 1
14 39 1017 21 Ring O 1
14A 39 1283 21 ‘O’ ring 1
15 DM 1010 46 Pipe Intake assly 1

16 39 1612 11 Plain washer 4

1 FRONT WHEEL DIRECTION

PLATE NO. 2 : VALVE BOXER AR

3
2
3

4 2
5

A
6 A
5
6

1
7
7 8
B

C B

8 C

10
9

Fig. Part No. Description Qty / Remark

No. Veh.

1 31 1010 21 Shaft Rocker 2

2 DF 1010 55 Screw 2
3 31 1012 35 Rocker arm assembly 2
4 31 1011 04 Stopper 1
5 39 0702 01 Screw Pan Cros 2

6 31 1010 18 Retainer Valve Spring 2

7 DD 1012 11 Spring Stiffer 2
8 36 3110 08 Collet Seal oil Kit 1 (Set of A,B & C) Ref.Page No. 55
9 DD 1011 34 Valve Intake 1
10 DD 1011 35 Valve Exhaust 1

2 FRONT WHEEL DIRECTION

PLATE NO. 3 : CAMSHAFT / TENSIONER BOXER AR

3
5

1
3 4
6

13
12
11

12

13

10
9
8

2
7

Fig. Part No. Description Qty / Remark

No. Veh.

1 31 1010 26 Guide Chain 1

2 39 2040 21 Ring O 1
3 DD 1014 06 Screw 2
4 31 1010 24 Sprocket (28 T) 1
5 DD 1010 63 Camshaft Comp. 1

6 31 1010 33 Chain 1
7 DD 1014 07 Tensioner Assembly 1
8 39 1070 01 Hex. Screw 2
9 39 0732 12 Washer Spring 2
10 39 0198 11 Plain Washer 2

11 31 1010 25 Guide Chain 1

12 39 0748 01 Screw Pan Cross 2
13 39 0999 06 Hollow Dowel Pin 2

3 FRONT WHEEL DIRECTION

PLATE NO. 4 : CYLINDER AND PISTON BOXER AR

1
2
1

4 3

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 1000 06 Hollow dowel Pin 2

2 DD 1010 07 Gasket 1
3 31 1011 82 Piston assly std 1 KHI Alt to 31 1013 07
4 31 1013 02 Piston ring set std. 1 KHI with chrome plated taper 2nd
piston ring
31 1012 49 Piston ring set std. 1
5 39 0985 17 Wire Circlip 2

6 31 1013 14 Cylinder Block Piston assly 1

4 FRONT WHEEL DIRECTION

PLATE NO. 5 : CRANK SHAFT BOXER AR

3 4
4

8
8
9
7
7

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 1055 15 Nut 1
2 01 1006 10 Woodruff Key 1
3 DD 1011 17 Crankshaft assly 1
4 31 1011 73 Key Woodruff 2
5 31 1010 76 Gear Primary, Helical (23 T) 1

6 31 1010 75 Gear (21 T) 1

7 39 1053 15 Nut 1
8 DM 1010 60 Flywheel 1
9 39 1046 19 Seal Oil 1

5 FRONT WHEEL DIRECTION

PLATE NO. 6 : TRANSMISSION BOXER AR

4 7
3

2 8
1

9 4

10 14

13
12

11

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 0994 11 Plain washer 1

2 DD 1010 92 Gear Transmission Spur(2nd) 1
3 31 1010 79 Gear Transmission Spur(3rd) 1
4 39 0987 17 Ring Snap (16 mm) 2
5 31 1010 82 Gear Transmission Spur(Top) 1

6 31 1012 19 Shaft Transmission Input(1st) 1

7 31 1012 21 Gear Transmission Spur(Low) 1
8 31 1010 84 Gear Transmission Spur(Top) 1
9 31 1010 83 Gear Transmission Spur(3rd) 1
10 31 1010 80 Shaft Transmission Output(2nd) 1

11 39 0989 17 Circlip 1
12 DD 1011 36 Sprocket Output 1
13 31 1011 17 Collar (Steel) 1
31 1012 16 Collar (Sintered) 1 Alt. to 31 10 1117
14 39 1018 21 ‘O’ Ring 1

6 FRONT WHEEL DIRECTION

PLATE NO. 7 : CHANGE DRUM / SHIFT FORK BOXER AR

4
1

Fig. Part No. Description Qty / Remark

No. Veh.

1 31 1010 81 Fork Shift 1

31 1011 91 Fork Shift 1 Alt. to 31 10 1081
2 DD 1013 00 Rod shift 2
3 31 1011 68 Drum assly. change 1
4 36 3110 02 Holder for Drum Kit 1 Ref.Page No. 55
5 31 1010 47 Fork shift 1
31 1011 92 Fork shift 1 Alt. to 31 10 1047

7 FRONT WHEEL DIRECTION

PLATE NO. 8 : GEAR CHANGE MECHANISM BOXER AR

11 4

1 2
12

7 6

13

9
8

10

Fig. Part No. Description Qty / Remark

No. Veh.

1 DM 1010 94 Lever 1
2 DM 1010 64 Bolt 1
3 31 1010 55 Spring 1
4 31 1011 05 Plate Position 1
5 39 0746 01 Screw Pan Cross 2

6 DD 1010 77 Lever Comp. Change Shaft 1

7 DD 1011 06 Bolt 1
8 39 2474 04 Flanged bolt 1
9 DD 1010 71 Lever Change 1
10 31 1011 08 Damper 1

11 31 1011 10 Spring 1
12 DG 1011 29 Spacer 1
13 31 1010 54 Spring 1

8 FRONT WHEEL DIRECTION

PLATE NO. 9 : CRANKCASE RH / ENGINE ASSLY. BOXER AR

2 7
3
1

5 8

1
11

2
4
13

2 9
3
10

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 1225 15 Nut 3
2 39 0248 11 Plain Washer 3
3 39 1068 04 Bolt 2
4 39 1056 04 Bolt 2
5 39 1864 20 Bearing Ball 1 Alt. to 39 2293 20

6 39 0999 06 Dowel Pin 5

7 01 1701 11 Bearing 1
8 31 1211 00 Oil Strainer 1
9 DG 1014 98 Gasket 1
10 DD 1012 75 Plug 1

11 01 1701 10 Bearing 1
12 DM 1010 33 Engine Assly 100 up with SAI 1 N. I.
13 DM 1010 63 Crank case RH 1

9 FRONT WHEEL DIRECTION

PLATE NO. 10 : CRANKCASE - L.H. BOXER AR

11
14

12
10
9 1

8
2
7
7
5

4 13

Fig. Part No. Description Qty / Remark

No. Veh.

1 01 1701 11 Ball Bearing 1

2 39 1050 06 Dowel Pin 3
3 39 1066 04 Bolt Flanged Small 1
4 39 1043 19 Oil Seal 1
5 39 1080 19 Seal Oil 1

6 39 1008 20 Bearing Needle 1

7 39 0702 01 Screw Pan Cros 2
8 31 1010 56 Guide 1
9 31 2010 81 Switch Comp. (Neutral) 1
10 39 0703 11 Plain Washer * * as required

11 39 1075 04 Bolt Flanged Small 7

12 30 1010 15 Gasket 1
13 DD 1011 01 Crank case LH 1
14 DD 1012 19 Tube rubber 1

10 FRONT WHEEL DIRECTION

PLATE NO. 11: PIPE OIL BOXER AR

3
3

7
5

6
1

6
6
6

Fig. Part No. Description Qty / Remark

No. Veh.

1 DD 1211 20 Pipe oil assly 1

2 DD 1210 03 Pipe oil 1
3 31 1210 06 Gasket 2
4 39 1023 04 Bolt 1
5 39 1062 04 Bolt flanged small 1

6 39 1727 11 Gasket 8
7 DD 1210 09 Bolt 4

11 FRONT WHEEL DIRECTION

PLATE NO. 12 : COVER GENERATOR & COVER CHAIN BOXER AR

6
4

1 2

10

Fig. Part No. Description Qty / Remark

No. Veh.

1 31 1010 62 Bolt 1
2 39 1019 21 Ring O 1
3 31 1012 95 Cover Generator 1
4 31 1010 61 Plug 1
5 31 1011 13 Gasket 1

6 DD 1010 58 Gasket 1
7 39 1074 04 Bolt Flanged Small 5
8 39 0999 06 Pin 2
9 DM 1010 55 Cover Chain 1
10 39 2147 04 Bolt Flanged Small 3

12 FRONT WHEEL DIRECTION

PLATE NO. 13: CLUTCH COVER BOXER AR

3
6
5

7 4
15 2

18
16
9
11
10 19
12

13
14
19
1

17

Fig. Part No. Description Qty / Remark

No. Veh.

1 DD 1011 14 Clutch cover assly 1

2 DM 1010 50 Decal clutch cover (K-Tec) 1
3 DD 1010 48 Cap 1
4 39 1671 21 ‘O’ ring 1
5 39 1673 04 Flanged bolt 3

6 DD 1210 06 Element oil filter 1

7 DD 1010 57 Spring 1
8 DD 1210 94 Rubber filter 1 N. I.
9 DD 1010 50 Plate position 1
10 39 1062 04 Bolt flanged small 2

11 39 1046 19 Seal oil 1

12 31 1010 67 Guage 1
13 39 1041 19 Seal oil 1
14 30 1011 42 Seal oil 1
15 DD 1013 25 Cap oil filler 1

16 39 2134 21 ‘O’ ring 1

17 DD 1010 60 Gasket (Clutch cover) 1
18 39 1075 04 Bolt flanged small 10
19 39 0999 06 Pin 2

13 FRONT WHEEL DIRECTION

PLATE NO. 14 : CLUTCH BOXER AR

4
3

10
2
9
6
5

14

8
9
7

13
12
11

Fig. Part No. Description Qty / Remark

No. Veh.

1 DD 1013 95 Housing Comp. Clutch 1

2 DD 1013 92 PlateClutch Assly. 1
3 39 1058 11 Plain Washer 1
4 31 1011 46 Collar 1
5 DD 1013 93 Wheel Clutch 1

6 DD 1013 89 Plate Friction 4

7 30 1010 96 Plate Clutch 3
8 DD 1013 94 Hub Clutch 1
9 30 1010 98 Spring 6 Alt to DD 1011 78
10 39 0980 04 Hex. Bolt 6

11 39 1053 15 Nut 1
12 39 1034 20 Bearing 1
13 31 1011 48 Rod Push 1
14 31 1011 44 Lever Complete 1

14 FRONT WHEEL DIRECTION

PLATE NO. 15 : KICK STARTER MECHANISM BOXER AR

4
D F
7
F
G
E L
13 C
B
A
9
G
6 F
K

H
G
F 10
12
11

2
3

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 2474 04 Flanged bolt 1

2 39 1920 01 Screw Pan Cros 2
3 DD 1012 54 Guide Kick 1
4 DD 1013 27 Lever Assly Kick 1 Alt DD 1012 44
5 30 1011 54 Bush (Damper) 1 Alt DD 1010 97

6 36 3110 27 Boss Kick set A to E 1 Ref.Page No. 55

7 36 DF10 03 Ratchet & Gear set K & L 1 Ref.Page No. 55
8 36 3110 20 Circlip & washer set F to H 1 Ref.Page No. 55
9 31 1011 24 Shaft Kick 1
10 31 1010 40 Guide 1

11 31 1010 41 Spring 1
12 39 0993 11 Washer 1
13 DD 1013 30 Boss Kick 1

15 FRONT WHEEL DIRECTION

PLATE NO. 16 : CARBURETTOR BOXER AR

20 1

17
14 18

13
15

16
8
12 9
5
7

6 10

11

Fig. Part No. Description Qty / Remark

No. Veh.

1 DM 1210 01 Carburettor Assly. (Keihin FIE) 1

2 DM 1010 06 Insulator 1
3 31 1210 80 ‘O’ ring 1
4 DM 1210 55 Needle jet 1
5 DM 1210 39 Holder- needle jet 1

6 DF 1210 08 Main jet 1

7 DM 1210 40 Slow Jet 1
8 DM 1210 44 Valve Complete 1
9 DM 1210 47 Float Complete 1
10 DM 1210 51 Gasket- Float chamber 1

11 DM 1210 52 Screw with washer 2

12 DM 1210 54 Valve throttle 1
13 DM 1210 56 Spring- Valve throttle 1
14 DM 1210 58 Gasket top 1
15 DM 1210 59 Screw Idling 1

16 FRONT WHEEL DIRECTION

PLATE NO. 16 : CARBURETTOR BOXER AR

20 1

17
14 18

13
15

16
8
12 9
5
7

6 10

11

Fig. Part No. Description Qty / Remark

No. Veh.

16 DM 1210 60 Spring- idling screw 1

17 DM 1210 61 Screw-VCS 1
18 DM 1210 62 Spring- Screw-VCS 1
19 DM 1210 63 Jet BSV 1 N.I.
20 39 1959 04 Flanged bolt 2 For mounting Carburettor

17 FRONT WHEEL DIRECTION

PLATE NO. 17 : AIR FILTER ASSLY AND BATTERY BOX BOXER AR

19 9

18 8

10

11
2

7
6
5

15 3
13 1
14
17

12 16

Fig. Part No. Description Qty / Remark

No. Veh.

1 DM 1210 02 Filter assly air 1

2 DM 1210 03 Case air filter 1
3 39 0986 08 Pin Cotter 1
4 DM 1210 06 Duct (Carburettor) 1
5 31 1210 29 Element air filter 1

6 DM 1210 07 ‘O’ ring air filter 1

7 DM 1210 04 Cap 1
8 01 1106 09 Plain washer 4
9 39 0830 01 Screw pan cross 4
10 DG 1611 66 Screw (Mounting air filter) 2

11 39 1789 24 Washer (Nylon) 2

12 DM 1210 10 Band (Battery) 1
13 31 1610 07 Damper battery 2
14 DM 1210 14 Tube oil drain 1
15 DM 1210 26 Clamp 1

16 39 1680 04 Flanged bolt (Battery) 1

17 DM 2210 01 Band - Tool kit 1
18 39 0711 11 Washer plain 2
19 39 2556 01 Screw Pan Cros 2

18 FRONT WHEEL DIRECTION

PLATE NO. 18 : SAI, BSV AND PCV. BOXER AR
8
7
11

6
4
5
11

9
1
2/3

7 9 8
16/17 12

15
13/14

Fig. Part No. Description Qty / Remark

No. Veh.

1 DD1013 55 Pipe with Flange (Cyl. head) 1

2 DM 1010 43 Gasket (SAI) 1 For Pipe With Flange
3 39 1673 04 Flanged bolt 2 For Mtg. Pipe With Flange
4 DM 1010 40 Tube assly (ASV to cyl. head) 1
5 DM 1210 27 Clamp 1

6 DG 1210 40 Clamp 1
7 DD 1013 33 By pass switch valve (BSV) 1
8 DM 1210 29 Tube BSV - IN to Air filter 1
9 DM 1210 28 Tube BSV - Out to Carburettor 1
10 DM 1210 70 Ring snap 6 N.I.

11 DM 1210 17 Air suction valve assly (ASV) 1

12 39 1552 04 Flanged bolt (For mtg. ASV) 2
13 DM 1210 19 Tube (Air Filter to ASV) 1
14 DM 1210 27 Clamp 2 For Tube (Air Filter to ASV)
15 DM 1210 30 Tube (ASV - manifold) 1

16 DM 1210 31 Tube (Carburettor to Air filter) 1

17 DM 1210 25 Clamp 1 For Tube (Carburettor to Air filter)

19 FRONT WHEEL DIRECTION

PLATE NO. 19 : MUFFLER BOXER AR

1
10

9
4
8 3
2

7 5

Fig. Part No. Description Qty / Remark

No. Veh.

1 31 1010 14 Gasket 1
2 39 0198 11 Plain Washer 2
3 39 0732 12 Spring washer 2
4 39 2145 15 Nut 2
5 DM 1010 09 Muffler 1

6 DD 1013 66 Flanged Bolt 1

7 DF 1010 19 Shield - silencer 1
8 30 1510 42 Washer A 2
9 39 0790 12 Spring washer 2
10 DD 1013 48 Hex screw 2

20 FRONT WHEEL DIRECTION

PLATE NO. 20 : OIL PUMP BOXER AR

1 2

4
5

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 1078 01 Screw Pan Cros 2 2

2 39 0753 01 Screw Pan Cros 1 1
3 DF 1210 03 Pump Assly. Oil without lug 1 1
4 39 0999 06 Pin dowel 1 1
5 39 1013 21 Ring ‘O’ 2 2

21 FRONT WHEEL DIRECTION

PLATE NO. 21 : MAGNETO ASSLY (INEL) BOXER AR

6
4 5

1 16

7 9
8

14
15
10

13 11

12

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 1110 07 Magneto assly/Brg. & Oil Seal 1

2 31 1110 01 Cap Assly. spark plug 1
3 31 1110 21 Stator assly 1
4 39 1042 19 Seal Oil (HTA make) 1
5 39 1003 20 Bearing ball 1

6 39 1028 21 Ring ‘O’ 1

7 39 1659 11 Plain washer 3
8 31 1110 22 C.D.I. 1
9 31 1110 34 Pulser Coil 1
10 39 1553 04 Flanged Bolt 2

11 DF 2011 21 Regulator/Rectifier (R/R) unit 1

12 DD 1110 18 Plug Spark 1
31 1110 30 Plug Spark UR2A 1
31 1110 27 Plug Spark UR2AS 1
13 TE 0066 02 Coil Ignition without cap 1
14 39 0745 01 Screw pan cross 2
15 DD 1013 18 Bolt 3

16 31 1110 33 Exciter coil 1

22 FRONT WHEEL DIRECTION

PLATE NO. 22 : MAGNETO ASSLY (VARROC) BOXER AR

6
4 5

1 16

7 9
8

14
15
10

13 11

12

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 1110 07 Magneto assly/Brg. & Oil Seal 1

2 31 1110 01 Cap spark plug 1
3 31 1110 55 Stator assly 1
4 39 1042 19 Seal Oil (HTA make) 1
5 39 1003 20 Bearing ball 1

6 39 1028 21 Ring ‘O’ 1

7 39 1659 11 Plain washer 3
8 31 1110 52 Ignitor assly (C.D.I.) 1
9 31 1110 58 Pulser coil assly 1
10 39 1553 04 Flanged Bolt 2

11 DF 2011 21 Regulator/Rectifier (R/R) unit 1

12 DD 1110 18 Plug Spark 1
31 1110 30 Plug Spark UR2A 1
31 1110 27 Plug Spark UR2AS 1
13 TE 0066 02 Coil Ignition without cap 1
14 39 0745 01 Screw pan cross 2
15 DD 1013 18 Bolt 3

16 31 1110 56 Exciter coil assly 1

23 FRONT WHEEL DIRECTION

PLATE NO. 23 : FRAME & GRIP FRAME BOXER AR

3
4
15
6
14

1 2
8
7

5
9

6
10

8 12

11

13

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 2473 04 Flanged Bolt 1

2 31 1910 02 Clamp 1
3 30 1810 11 Nut 1
4 DF 1810 52 Cap Steering 1
5 30 1810 08 Bearing Race 1

6 30 1810 06 Ball Steel 46

7 39 2470 04 Flanged Bolt 3
8 39 2479 15 Flanged nut 5
9 39 0876 04 Bolt 1
10 DM 1610 53 Frame Comp./Brg.races 1

11 39 2469 04 Flanged Bolt 2

12 DM 2210 02 Grip frame 1
13 39 2221 04 Flanged bolt 2
14 30 1810 74 Upper Bearing Race 1
15 30 1810 07 Bearing Cone 1

24 FRONT WHEEL DIRECTION

PLATE NO. 24 : SWING ARM/REAR SHOCK ABSORBER BOXER AR

A 3
3 B
1 2 3
17

19 5
18
4
24 A B

6 16 10
8
9
9
6 8
7
11

25
12

3 13
22/23 21
2 14
1 13 14
15 14
27
14
26
20

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 0712 15 Domed Cap Nut 4

2 39 0737 12 Washer Spring 4
3 39 0714 11 Washer Plain 8
4 DM 1710 01 Rear Shock Absorber 2
5 36 DF17 01 Rubber & Inner Bush Kit 1 (Set A & B) Ref.Page No. 55

6 39 0248 11 Plain Washer 2

7 31 1710 06 Shaft Swing Arm 1
8 39 0201 11 Plain Washer 2
9 30 1710 18 Bushing Rubber 2
10 39 0708 15 Nut Hex 1

11 31 1710 01 Arm Comp. Swing / Bush 1

12 31 1510 33 Adjuster Chain (RH) 1 Alt. to 15 1510 61
13 39 0711 11 Washer Plain 2
14 39 0292 15 Hex Nut 4
15 31 1510 32 Adjuster Chain (LH) 1 Alt. to 15 1510 62

25 FRONT WHEEL DIRECTION

PLATE NO. 24 : SWING ARM/REAR SHOCK ABSORBER BOXER AR

A 3
3 B
1 2 3
17

19 5
18
4
24 A B

6 16 10
8
9
9
6 8
7
11

25
12

3 13
22/23 21
2 14
1 13 14
15 14
27
14
26
20

Fig. Part No. Description Qty / Remark

No. Veh.

16 39 0789 12 Spring Washer 1

17 31 1710 12 Damper for Swing arm 1
18 39 0454 11 Plain washer 2
19 39 0553 02 Self tapping Screw 2
20 15 1611 03 Rubber Sleeve 2

21 DF 1611 62 Step 2
22 DM 1610 25 Stay (Left) 1
23 DM 1610 26 Stay(Right) 1
24 39 2481 04 Flanged Bolt 2
25 DF 1611 63 Pin 2

26 39 0535 11 Plain Washer 2

27 39 0146 08 Split Pin 2

26 FRONT WHEEL DIRECTION

PLATE NO. 25 : STAND & HOLDER STEP BOXER AR

1
2

3 10

11
7
5

6 8
7
9

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 1611 29 Damper 2
2 DM 1610 54 Holder Step 1
3 39 1940 04 Flanged Bolt 4
4 DF 1611 02 Bolt 1
5 39 0422 15 Nyloc Nut 1

6 DM 1610 28 Stand Side 1

7 30 1611 58 Spring 2
8 30 1611 57 Shaft Stand 1
9 DM 1610 27 Stand Centre 1
10 39 0787 08 Pin Cotter 1

11 DG 1611 24 Damper 1

27 FRONT WHEEL DIRECTION

PLATE NO. 26 : FENDER - FRONT BOXER AR

2
4

3
5
1
1 6
8

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 2222 04 Flanged Bolt 4

2 39 2473 04 Flanged bolt 1
3 DF 1910 20 Clamp 1
4 30 1611 18 Fender Assly. Front 1
5 39 0197 11 Plain Washer 2

6 22 1504 35 Bolt 2
7 31 1612 78 Mud Flap Front 1
8 39 2484 15 Flanged nut 2

28 FRONT WHEEL DIRECTION

PLATE NO. 27 : FENDER - REAR BOXER AR

2
8

7
9

3
1 10

11
12

4
5

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 0817 15 Flanged Hex nut 4

2 39 2483 04 Hex head bolt 4
3 39 0711 11 Plain washer 4
4 CB 1611 06 Clip nut 2
5 DF 1611 53 Bolt flanged (Step) 2

6 39 1944 04 Bolt flanged 2

7 31 2010 21 Clamp 1
8 DM 1610 09 Fender Rear Front 1
9 DD 1610 51 Flap Fender Rear Fr. 1
10 DF 1611 04 Fender rear 1

11 30 2010 69 Reflector Reflex 1

12 39 2484 15 Hex Nut 1

29 FRONT WHEEL DIRECTION

PLATE NO. 28 : WHEEL RIM / SPOKES/ TYRE/ TUBE BOXER AR
1
3
2

7
4

8
9

5
3
1
2

Fig. Part No. Description Qty / Remark

No. Veh.

1 16 1510 66 Nipple Spoke 72

2 DF 1510 05 Spoke Inner 36
3 DF 1510 06 Spoke Outer 36
4 DM 1510 08 Wheel Rim (1.6 x 18) 1
5 DF 1510 10 Wheel Rim (1.85 x 18) 1

6 30 1510 18 Tyre Front 1

7 30 1510 19 Tube 1 Proprietory Parts
8 DM 1510 11 Tyre Rear 1 Not to Serviced
9 30 1511 08 Tube 1

30 FRONT WHEEL DIRECTION

PLATE NO. 29 : FRONT HUB BOXER AR

7 8
6
5
4
9
3
2

16
17
15
14 19

13 18

23
10 21

11 23
24 22
27 25
26 20
12

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 1006 20 Bearing Ball 1

2 DF 1510 03 Drum Front 1
3 31 1510 04 Collar 1
4 39 1004 20 Bearing Ball 1
5 14 1510 21 Oil Seal 1

6 31 1510 56 Collar Axle Assly. 1

7 39 0248 11 Plain Washer 1
8 39 0990 08 Pin Cotter 1
9 39 0981 15 Nut Castle 1
10 39 0775 04 Bolt 1

11 DD 1510 08 Lever Brake Cam 1

12 31 1510 36 Axle 1
13 30 1510 38 Ring O 1
14 31 1510 39 Panel Front Brake 1
15 31 1510 11 Cam Brake 1

31 FRONT WHEEL DIRECTION

PLATE NO. 29 : FRONT HUB BOXER AR

7 8
6
5
4
9
3
2

16
17
15
14 19

13 18

23
10 21

11 23
24 22
27 25
26 20
12

Fig. Part No. Description Qty / Remark

No. Veh.

16 31 1510 14 Oil Seal 1

17 30 1510 37 Spring 2
18 31 1510 60 Shoe Brake Assly. 2
19 DD 1510 05 Speedometer Gear (Plastic) 1
20 30 1511 18 Stopper for Bushing 1

21 30 1511 19 Bushing 1
22 39 1013 21 Ring 'O' 1
23 30 1510 42 Washer 'A' 2
24 30 1510 41 Gear Meter Screw 1
25 39 0900 12 Washer Spring 1

26 39 0840 01 Screw Pan Cross 1

27 39 0798 15 Nut 1

32 FRONT WHEEL DIRECTION

PLATE NO. 30 : REAR HUB BOXER AR

5 2
1

8
3
6
4
7

12

9
11
10

17 24
18
14
19
23
15

16
13

21 22
20

Fig. Part No. Description Qty / Remark

No. Veh.

1 31 1510 82 Chain (114 links) 1

2 39 0978 04 ‘D’ bolt 4
3 31 1510 29 Washer 2
4 39 0794 15 Nut Hex. Fine 4
5 39 2240 20 Bearing Ball 1

6 30 1510 82 Seal Oil 1

7 DM 1510 03 Sprocket (47 T) 1
8 39 0988 15 Nut Hex. 1
9 39 2362 20 Bearing Ball 1
10 31 1510 21 Shock Damper 4

11 DF 1510 09 Drum Rear 1

12 39 2396 20 Bearing Ball 1
13 30 1510 69 Spring 2
14 31 1510 60 Shoe Brake Assly. 1
15 31 1510 22 Brake Cam assly 1

33 FRONT WHEEL DIRECTION

PLATE NO. 30 : REAR HUB BOXER AR

5 2
1

8
3
6
4
7

12

9
11
10

17 24
18
14
19
23
15

16
13

21 22
20

Fig. Part No. Description Qty / Remark

No. Veh.

16 31 1510 24 Panel Rear Brake 1

17 30 1510 38 Ring O 1
18 31 1510 37 Lever Brake 1
19 39 0775 04 Bolt 1
20 31 1510 01 Axle 1

21 39 0714 11 Washer Plain 1

22 39 0982 15 Nut Castle 1
23 39 0787 08 Pin Cotter 1
24 39 0798 15 Hex. nut 1

34 FRONT WHEEL DIRECTION

PLATE NO. 31 : BRAKE PEDAL BOXER AR

5 7

17 6

4
3
2
1

2
11 12
10
15
9

13

16 14

10
15 12 11

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 0808 08 Split pin 1

2 39 0198 11 Plain Washer 2
3 31 1910 16 Rod Brake 1
4 30 1910 38 Pin 1
5 DM 1910 01 Lever Brake 1

6 39 0805 11 Washer 1
7 39 0797 08 Pin Cotter 1
8 30 1910 31 Spring 1
9 30 1910 35 Spring 1
10 39 0807 08 Pin Snap 2

11 39 0708 15 Nut Hex. 2

12 39 0789 12 Washer Spring 2
13 15 1910 26 Pin 1 Alt to 30 1910 37
14 30 1910 36 Brake adjusting nut 1
15 30 1510 95 Bolt 2

16 DF 1510 16 Torque rod 1

17 DD 1610 78 Damper 1

35 FRONT WHEEL DIRECTION

PLATE NO. 32 : HANDLE BAR BOXER AR

10

7
12

3 11

7
4
8
2

6 5

1
8

Fig. Part No. Description Qty / Remark

No. Veh.

1 31 1810 54 Handle 1
2 30 1810 03 Holder Handle 2
3 39 1714 04 Flanged Bolt 4
4 DF 1910 45 Lever / Switch Assly.LH 1
5 DF 1910 13 Lever / Switch Assly.RH 1

6 DF 1910 12 Lever grip - Left 1

7 39 0830 01 Screw Pan Cross 2
8 39 1184 15 Nyloc nut 2
9 DF 1910 26 Grip - Left hand 1
10 DF 1910 14 Lever grip - Right 1

11 DF 1910 27 Grip assly RH 1

12 36 DF19 01 Cable adjuster kit 1 Ref.Page No. 55

36 FRONT WHEEL DIRECTION

PLATE NO. 33 : FORK FRONT BOXER AR

9
10
11
12

13
19

20 6 24

22

23
14/15

8
7

4 16
5
17
18
2/3

21

Fig. Part No. Description Qty / Remark

No. Veh.

1 DD 1811 02 Seal Oil 1

2 DD 1810 10 Pipe Left Fork Outer 1
3 DD 1810 14 Pipe Right Fork Outer 1
4 30 1810 26 Gasket 2
5 30 1810 25 Bolt 2

6 31 1810 15 Cyl. Complete Fork 2

7 DD 1810 06 Pipe Fork Inner 2
8 31 1810 17 Spring Front Fork 2
9 30 1810 44 Bolt 1
10 30 1810 30 Bolt Fork 2

11 30 1810 29 Ring ‘O’ 2

12 30 1810 28 Seat Fork Spring 2
13 30 1810 43 Holder Fork Upper 1
14 DM 1810 05 Cover Fork RH 1
15 DM 1810 04 Cover Fork LH 1

16 DL 1810 60 Holder Fork Under 1

17 39 0789 12 Washer Spring 2

37 FRONT WHEEL DIRECTION

PLATE NO. 33 : FORK FRONT BOXER AR

9
10
11
12

13
19

20 6 24

22

23
14/15

8
7

4 16
5
17
18
2/3

21

Fig. Part No. Description Qty / Remark

No. Veh.

18 39 1813 04 Bolt Hex. 2

19 DD 1810 11 Dust seal 2
20 30 1810 23 Ring snap 2

21 DM 1810 01 Front Fork 1

22 DD 1811 00 Boot 2
23 30 1810 09 Bearing cone 1
24 DD 1810 05 Band assly 2

38 FRONT WHEEL DIRECTION

PLATE NO. 34 : PAINTED PARTS BOXER AR

1 2/3

4/5

Fig. Part No. Description Qty / Remark

No. Veh.

1 DM 7101 22 Tank fuel with Decal 1 Jet Black

DM 7101 M5 Tank fuel with Decal 1 Wine Red

2 DM 1410 08 Tank Decal LH 1 Jet Black

DM 1410 11 Tank Decal LH 1 Wine Red

3 DM 1410 09 Tank Decal RH 1 Jet Black

DM 1410 12 Tank Decal RH 1 Wine Red

4 DM 1610 45 Cover Side LH with Decal 1 Jet Black

DM 1610 49 Cover Side LH with Decal 1 Wine Red

5 DM 1610 46 Cover Side RH with Decal 1 Jet Black

DM 1610 50 Cover Side RH with Decal 1 Wine Red

39 FRONT WHEEL DIRECTION

PLATE NO. 35 : FUEL TANK CAP & TAP ASSLY. BOXER AR

3
7 8

10

9
4

1 6

Fig. Part No. Description Qty / Remark

No. Veh.

1 DM 1210 20 Tube Fuel 1

2 DD 1411 22 Rotor with key (Fuel tank) 1
DF 1810 43 Lock set assly (3 in 1) 1
3 DF 1411 20 Cap Assly. Tank 1
4 DF 1411 60 Tap assly 1
5 30 1410 39 Packing (For Tap) 1

6 DD 1410 16 Clamp Tube 2

7 30 1410 52 Packing 1
8 39 0761 01 Screw pan cross 2
9 DD 1410 22 Bolt flanged 2
10 30 1410 31 ‘O’ ring 2

40 FRONT WHEEL DIRECTION

PLATE NO. 36 : CHAIN CASE BOXER AR

3
8 2

4 3
6

Fig. Part No. Description Qty / Remark

No. Veh.

1 30 16 1271 Rubber Pad 1

2 DM 1610 12 Case Chain Upper 1
3 39 0219 11 Washer Plain 2
4 15 1610 69 Rubber Cap 1
5 39 2475 04 Flanged Bolt 2

6 39 2473 04 Flanged Bolt 2

7 DM 1610 15 Case Chain Lower 1
8 DL 1610 23 Trim case chain 1

41 FRONT WHEEL DIRECTION

PLATE NO. 37 : FITTINGS -PETROL TANK & SIDE COVER BOXER AR

4
3

5 9

2
A
C
1
B

Fig. Part No. Description Qty / Remark

No. Veh.

1 36 DF14 12 Damper Kit (Set A to C) 1 Ref.Page No. 55

2 30 1611 69 Grommet side cover mtg. 2
3 39 1789 24 Washer 1
4 DG 1611 21 Screw 1
5 31 1610 18 Damper 1

6 31 1611 71 Lock For Side Cover 1

7 DL 1410 35 Socket head bolt / flange 1
8 39 1054 11 Plain washer 1
9 30 2110 01 Damper - cover side 2

42 FRONT WHEEL DIRECTION

PLATE NO. 38 : METER ASSEMBLY BOXER AR

5
7

4
9

1
8
6
10
3

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 1910 48 Meter Assly/ Lamp 1

2 DL 1910 20 Lamp 12 V 3W W/out cap 4
3 39 0817 15 Nut 2
39 0292 15 Hex Nut 2 Alt to 39 0817 15
39 0849 14 Toothed Washer 2 Alt to 39 0817 15
4 DF 2010 92 Ignition switch / key 1
DF 1810 43 Lock set assly (3 in 1) 1
5 39 1943 04 Bolt flanged 2

6 DF 1910 40 Speedometer 1
7 DF 1910 41 Cover case upper 1
8 DF 1910 42 Cover case lower 1
9 DF 1910 43 Case inner (white) 1
10 DL 1910 37 Packing 1

43 FRONT WHEEL DIRECTION

PLATE NO. 39 : CONTROL CABLES BOXER AR

1 2
3
4
5

11

10 8
9

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 1910 10 Cable Brake (FR) 1

2 30 1910 70 Spring 1
3 30 1910 69 Dust Seal 1
4 30 1910 71 Rod End 1
5 30 1910 72 Adjusting Nut 1

6 DF 1910 09 Cable Clutch 1

7 31 1910 03 Cable Speedometer 1
8 30 1910 67 Oil Seal 1
9 31 1910 04 Inner Cable Speedo 1
10 DF 1910 19 Cable Throttle 1

11 DM 1910 02 Cable starter 1

44 FRONT WHEEL DIRECTION

PLATE NO. 40 : HEAD LAMP ASSLY BOXER AR

5/6
7
3

9
2

12
14
1

13 10
A B C 11
D

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 2011 24 Head light assly with lamp 1

2 DF 2010 03 Head Light / Rim 1
3 DF 2010 06 Lamp Holder Assly. 1
4 DF 2010 07 Head Light Housing 1
5 DF 2010 08 Damper Head Light 2

6 DF 2010 19 Cup Washer 2 For Rim mounting

7 39 0886 01 Screw (For Rim mounting) 2
8 36 DF20 02 Bkt.Head Light kit 1 (Set of A to E) Ref.Page No. 55
9 DF 2011 64 Lamp 12V - 35/35 W 1
10 DD 2010 09 Damper (H.L. Mounting) 2

11 DD 2010 10 Damper (H.L. Mounting) 2

12 DF 2010 09 Collar (H.L. Mounting) 2
12 39 0694 15 Hex Lock Nut (H.L. Mounting) 2
13 39 1394 04 Flange Bolt (H.L. Mounting) 2
14 DF 2011 58 Collar 1

45 FRONT WHEEL DIRECTION

PLATE NO. 41 : TURN SIGNAL LAMP BOXER AR

1/2/3/4

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 2011 75 Dir. ind. Front LH with Lamp 1

2 DF 2011 77 Dir. ind. Front RH with Lamp 1
3 DF 2011 79 Dir. ind. Rear LH with Lamp 1
4 DF 2011 81 Dir. ind. Rear RH with Lamp 1
5 06 2010 83 Bulb 12 V 10 W 4

6 DF 2011 83 Lens 4
7 39 1225 15 Hex Nut with flange 4
8 DG 2010 77 Screw 4

46 FRONT WHEEL DIRECTION

PLATE NO. 42 : FRONT AND REAR NUMBER PLATE BOXER AR

1
3

6 5

Fig. Part No. Description Qty / Remark

No. Veh.

1 DP 1611 44 Front Number plate 1

2 DF 1810 97 Bracket Front No. Plate 1
3 39 1783 01 Truss Screw 2
4 39 1553 04 Flanged bolt 2
5 DP 1611 45 Number plate Rear 1

6 DF 1612 48 Bracket No. Plate 1

7 39 2476 04 Hex head bolt / Flange 2
8 39 2475 04 Flanged Bolt 2

47 FRONT WHEEL DIRECTION

PLATE NO. 43 : TAIL LAMP ASSLY. BOXER AR

8
2
5

4 1

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 2011 86 Tail Light / Lamp 1

2 30 2010 06 Lamp 12V 21/5 W 1
3 DF 2011 88 Lens 1
4 30 2010 11 Damper 2
5 30 2010 10 Collar 2

6 30 2010 03 Gasket 1
7 39 0718 01 Screw Pan cross 2
8 39 1063 01 Hex. Screw 2

48 FRONT WHEEL DIRECTION

PLATE NO. 44 : ELECTRICAL EQUIPMENT BOXER AR
1

10

11
3

5 14

8
7

Fig. Part No. Description Qty / Remark

No. Veh.

1 39 1940 04 Flanged Bolt 1

2 DF 2011 40 Horn 1
3 31 2010 79 Switch Rear Brake 1
4 30 2010 74 Spring Brake Switch 1 Alt. DD 1910 13
5 DF 2011 85 Wiring Harness 1

6 31 2010 27 Battery 1
7 30 2010 60 Fuse - Assly. 1
8 30 2010 85 Fuse, 15A 1
9 DF 2011 32 Assly. DC Flasher 1 Alt. to DF 2011 31
10 31 2010 82 Capacitor 1

11 39 2473 04 Hex Bolt Flanged 1

49 FRONT WHEEL DIRECTION

PLATE NO. 45 : SEAT ASSLY. BOXER AR

2
5

Fig. Part No. Description Qty / Remark

No. Veh.

1 DM 2110 06 Seat assly comp. with Damper 1

2 39 1945 04 Bolt Flanged 2
3 31 2110 04 Damper 6
4 DF 2110 36 Bracket Seat 1
5 39 2124 15 Hex Nut /Flange 4

50 FRONT WHEEL DIRECTION

PLATE NO. 46 : ACCESSORIES (LEG GUARD, SAREE GUARD & MIRRORS) BOXER AR
4

3
2 5

Fig. Part No. Description Qty / Remark

No. Veh.

1 DF 2210 33 Leg guard 1

2 DF 2210 07 Mirror assly RH 1
3 DF 2210 37 Mirror assly LH 1
4 39 1940 04 Flanged Bolt 2 For mounting Leg guard
5 DF 2210 04 Saree Guard 1

6 DF 2210 06 Plug For Sari Guard 1

7 39 1608 04 Hex.soc.hd.bolt 1
8 39 1556 04 Bolt Flanged 2 For Sari Guard mounting

51 FRONT WHEEL DIRECTION

PLATE NO. 47 : TOOL KIT BOXER AR

Fig. Part No. Description Qty / Remark

No. Veh.

1 31 2210 01 Tool Kit 1

* 31 2210 03 Tool Wrench (Box, 16 mm) 1
* 30 2210 33 Tool Wrench (Open End 10 x 13) 1

* 30 2210 04 Tool Driver (Philips & slot) 1

* 30 2210 11 Tool Wrench (Open End 14 x 17) 1 For reference only not
to service separately
* 30 2210 02 Tool Bag 1
* 30 2210 09 Tool bar 1
* 30 2210 10 Tool Plier 1
* 31 2210 04 Tool wrench (24 A/F) 1
* 30 2210 03 Tool Driver 1

52 FRONT WHEEL DIRECTION

 BOXER A R
Amendment Sheet (Parts Added)

Sr.No. Part No. Description Qty. Page No.

Fig.No.

53
 BOXER A R
Amendment Sheet (Parts Deleted)

Sr.No. Part No. Description Qty. Page No.

Fig.No.

54
 BOXER A R

KITS LIST FOR BOXER AR

SNo. Kit Part No. Kit Description Consisting of Following Parts

Part No. Description Qty./Kit

1 36DF1001 ‘O’ RING KIT FOR 39102021 RING ‘O’ 2

COVER 39101621 RING ‘O’ 1

2 36311008 COLLET SEAL OIL 31101019 COLLET 4

KIT 39103519 SEAL OIL 2
31101045 SEAT SPRING 2

3 36311002 HOLDER FOR DRUM 39070201 SCREW PAN CROS 1

KIT 31101048 HOLDER 1
39099206 PIN DOWEL 6

4 36311027 BOSS KIT 31101044 PIN 2

SET ‘A’ TO ‘E’ 30101234 SPRING 2
30201236 BALL STEEL 1
DD101330 BOSS KICK 1
39085517 CIRCLIP 1

5 36311020 CIRCLIP WASHER 39073817 CIRCLIP TYPE C 4

SET ‘F’ TO ‘H’ 31101039 COIL SPRING 1
39099511 WASHER 3

6 36DF1003 RATCHET & GEAR 31101038 RATCHET 1

SET ‘K’ & ‘L’ 31101218 GEAR SPUR 1

7 36DF1701 RUBBER & INNER 30171030 RUBBER BUSH 4

BUSH KIT 30171031 INNER BUSH 4

8 36DF1901 CABLE ADJUSTER 30191017 NUT 2

ASSLY.KIT 30191024 SCREW 2

9 36DF1412 DAMPER KIT FOR 31141005 DAMPER 1

FUEL TA N K 31141009 DAMPER 2
31141037 DAMPER (FUEL TANK) 1

10 36DF2002 BRACKET HEAD DD201045 SCREW 1

LIGHT KIT DD201046 SPRING - ADJUSTER 1
DD201047 WASHER 1
DD201048 NUT (NYLON) 1
DF201064 BRACKET HEAD LIGHT 1

55