BSVI

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

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
42
NO. NO. DRUM/DISC

1 M1200470 HEX FLANGE BOLT M6x30 3

2 K2010010 COVER CYL HD 1
2A K2010220 COVER CYL HD 1 BSVI
3 N3011730 PACKING SEAL, COVER CYLINDER 1
3A K2010190 PACKING SEAL, COVER CYLINDER 1 BSVI
44 4 N3012100 SPARK PLUG 1
4A 4 4A K6011090 SPARK PLUG BS4 1 BSVI
3A 5 S1010240 SCREW TAPPET ADJUSTING 3
6 S1010250 NUT TAPPET ADJUSTING 3
7 N4012400 ARM ROCKER VALVE ASSY INT 1
8 N8011740 COTTER VALVE 4.50 6
25A
9 N8011570 RETAINER VALVE SPRING 3
10 N4012000 SPRING VALVE 3
11 --- GUIDE VALVE 3
12 N3012080 SPRING ROCKER ARM 2
13 M1200510 HEX FLANGE BOLT M6x25 3
41 14 K2040030 PIPE INTAKE COMP 1
46 29A
43 15 M1010360 GASKET CYL HEAD NUT 1
16 N8041580 INSULATOR PAD 1 1
36A 17 N8011710 VALVE EXHAUST 4.50 1
18 N8011700 VALVE INTAKE 4.50 2
45
19 K2040050 INSULATOR PAD 1
20 K2040090 O-RING PIPE INTAKE 2
47 47A
21 N8011540 VALVE SEAT SPRING 3
22 R1010810 BOLT CAMCHAIN TENSIONER 3
23 N8200090 CRR CSK HEAD SCREW 1
24 P6010060 STOPPER CAMSHAFT 1
2A
25 K2010120 HEAD COMP CYLINDER 1
25A K2010180 CYLINDER HEAD COMP 1 BSVI
CYLINDER HEAD ASSEMBLY 26 N3200250 HEX SCREW M6 X 10 2
27 M1080500 WASHER,SPROCKET 1
FIG.NO.01 CYLINDER HEAD ASSEMBLY FIG.NO.01

NO.OFF
42 REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

28 R1010800 SPROCKET CAMSHAFT 1

29 K6010970 CAMSHAFT COMP 1
29A K2010240 CAMSHAFT COMP 1 BSVI
30 T4010760 SHAFT,ROCKER ARM 2
31 N4011100 SEAL VALVE STEM OIL 3
44 32 N4012310 ARM ROCKER VALVE (ROLLER) ASSY. EXH 1
4A 4
33 N3012090 STIFFENER HSG CAMSHAFT 1
3A
34 N9080750 UNION BREATHER 1
35 K2010070 GASKET PLATE BREATHER 1
36 K2180100 BEADING COWL TOP 1
25A
36A K2180350 BEADING COWL TOP R 1 BSVI
37 K2010060 PLATE BREATHER 1
38 0331708 CRPH SCR M5x12 6.8 ZNB 4
39 M1080370 GASKET OIL PIPE UNION 2
40 8200130 PUNCHED WASHER 6.5x11x1.6 2
41
46 29A 41 M1010490 PIN SPROCKET 1
43
42 N5040700CN O RING 1
43 M1200050 DOME CAP NUT 4
36A
44 F085230 BOLT OIL DRAIN 1
45 45 G2201140 STUD BOLT 2 BSVI
46 M1200060 PUNCHED WASHER 8.5x18x2.3 3
47 47A
47 K2010080 CYLINDER HEAD ASSY 1
47A K2010210 CYLINDER HEAD ASSY 1 BSVI

2A

CYLINDER HEAD ASSEMBLY

FIG.NO.01A INTAKE PIPE & THROTTLE BODY ASSY FIG.NO.01A

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC
12
1 K2040230 BODY THROTTLE ASSY 1 BSVI
2 N9041710 O-RING 31.70 2.40 2 BSVI
11 3 K2040300 INSULATOR PAD 1 BSVI
1 4 K2040310 PIPE INTAKE COMP 1 BSVI
10 5 K6060510 OXYGEN SENSOR 1 BSVI
6 R4060090 THERMAL SENSOR 1 BSVI
7 M1200510 HEX FLANGE BOLT M6x25 2
9 8 R4040220 COVER INJECTOR 1 BSVI
4 9 K2060100 EFI INJECTOR 1 BSVI
8 10 K2040320 CAP INJECTOR COMP 1 BSVI
11 N2200490 FLANGE BOLT M6x20 ZNG 1
12 A200050 HEX SOC HD CAP SCR M6x25 P 8.8 2 BSVI
7

2
3
2

INTAKE PIPE & THROTTLE BODY ASSY

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

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
8A NO. NO. DRUM/DISC

1 N3011900 GASKET CYL HEAD 1

3A 2 S1200270 TUBULAR DOWEL 2
3 N40125617D CYLINDER COMP 1
3A K2010160 CYLINDER COMP 1 BSVI
4 M1200510 HEX FLANGE BOLT M6x25 2
5 M7011370 ADJUSTER ASSY TENSIONER 1
6 N5010820 GASKET CYLINDER 1
7 N2200340 CIRCLIP PIN PISTON 2
8 N2010690 PISTON PIN 1
8A K6020330 PISTON PIN 1 BSVI
9 N3020110 PISTON KIT 53.50 STD 1
9A N3321950 PISTON KIT I O/S 1
9B N3321960 PISTON KIT II O/S 1
10 K6200290 BALL BEARING 25 62 17 1
11 420702000 WOODRUFF KEY 1
12 KL020010 CRANKSHAFT ASSY 1
13 KL010200 TENSIONER CAMCHAIN PLAS 1
14 M1200770 HEX FLANGE NUT M12x1.25 1
15 N9010450 CHAIN CAMSHAFT-94 LINKS 1
16 KL010190 GUIDE CAMCHAIN PLAS 1
17 M1200900 HEX FLANGE NUT M6 2
18 N8020310 RING SET STD 1
20A 18A N8020320 RING SET I O/S 1
18B N8020330 RING SET II O/S 1
19 K2320280 CYLINDER BLOCK PISTON KIT 1
20 KL180170 ENGINE ASSY. 125 ES VARIO 3V 1
20A K2180320 ENGINE ASSY. 125 ES VARIO 3V 1 RECE ED.
CYLINDER BLOCK & CRANK SHAFT ASSY. 20B K2180230 ENGINE ASSY 125 ES NTORQ BSVI 1 BSVI
21 K2200070 OIL SEAL 17 26 6 1
FIG.NO.03 CLUTCH & VARIAMATIC ASSEMBLY FIG.NO.03

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

1 K2070010 CVT SET DRIVEN 1

2 K2080370 COLLAR SPRING BOTTOM 1
3 K2080350 SPRING LH DRIVEN FACE 1
4 --- BALL BEARING 1
5 M1200730 CIRCLIP 3
6 K2070130 CLUTCH ASSY. 3
7 K2070150 SPRING CLUTCH 3
8 K2070160 DAMPER CLUTCH SHOE 3
9 --- PLATE ASSY. DRIVE 1
10 K2070080 NUT CLUTCH SHOE 1
11 K2070120 HOUSING CLUTCH COMP 1
12 R1200050 DISC SPRING 1
13 M1200770 HEX NUT M12x1.25 1
26A 14 --- NEEDLE ROLLER BEARING 1
29A 15 K2070050 FACE ASSY. DRIVE 1
16 K2080030 V BELT 1
17 K2070060 FACE COMP MOVABLE DRIVEN 1
18 K2070100 O RING PINION CAP 1
32 19 K2070090 OIL SEAL 34x39x3 2
20 K2070070 PIN ROLLER GUIDE 3
21 K2080340 ROLLER GUIDE 3
22 K2200060 HEX FL NUT M14 150 1
23 K2070110 O RING 38x2 1
24 K2070040 DAMPER MOVABLE DRIVE 3
25 K2070030 PLATE MOVABLE DRIVE 1
26 K2080170 ROLLER COMP MOVABLE DRIVE 6
CLUTCH & VARIAMATIC ASSEMBLY 26A K2070190 ROLLER MOVABLE DRIVE COMP 6 BSVI
27 K2080070 FACE COMP MOVABLE DRIVE 1
FIG.NO.03 CLUTCH & VARIAMATIC ASSEMBLY FIG.NO.03

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

28 K2080130 SAPCER MOVABLE DRIVE 1

29 K6081260 FACE COMP. FIXED DRIVE 1
29A K2080050 FACE FIXED DRIVE COMP 1 BSVI
30 K2080290 RATCHET KICK STARTER 1
31 K2080360 COLLAR SPRING TOP 1
32 K2070020 CVT SET DRIVE 1

26A
29A

32

CLUTCH & VARIAMATIC ASSEMBLY

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

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC
1 M1200780 STUD BOLT CYL HEAD 4
2 G4010040 STUD BOLT CYL HEAD 4
3 S1200270 TUBULAR DOWEL 2
4 R4200020 BALL BEARING 20 47 14 1
5 K2200010 BALL BEARING 12 37 12 HEAT TREATED 2
6 K2200020 BALL BEARING 17 40 12 HEAT TREATED 1
7 KL030010 CRANKCASE SC MC L 1
8 K3090380 SILENT BLOCK BUSH 1
9 S1101250 HEX BOLT M8*35 6.8ZNB 7
10 F085230 BOLT OIL DRAIN 2
11 N6200010 OILSEAL 30 20 6 1
12 M1080370 GASKET OIL PIPE UNION 2
13 0074010 DOWEL PIN 2
14 K2200050 OIL SEAL 25 40 6 1
15 N5200500 HEX SCREW M6x25 2
16 K2030120 COVER OILPUMP MC 1
31
17 M1200470 HEX FLANGE BOLT M6x30 8
18 K2030140 GASKET COVER OIL PUMP 1
19 S1090500 SILENT BLOC SHOCK ABSORBER 1
30
20 K4080150 PLUG OIL DRAIN 1
21 K3200730 O RING DRAIN PLUG 1
22 K2080280 OIL FILTER 1
23 K3081720 PIPE INLET OIL PUMP 1
24 R5080090 OILPUMP ASSY 1
25 K6030250 BUSH CENTER STAND 1
26 K6121720 HOOK STAND SPRING - WEGO 1
27 M1010090 PIN CYL HEAD COVER KNOCK 2
28 K200060 CIRCLIP 42x1.75 N IS:3075 1
CRANKCASE LH ASSEMBLY 29 KL080050 GEAR OILPUMP DRIVE 1
30 K3082170 BUSH KICK STARTER SUPPORT PLATE 1
31 M1010350 GASKET CYL HEAD COVER BOLT 1
FIG.NO.05 CRANKCASE RH ASSEMBLY FIG.NO.05
35 13A
34 NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC
2A
1 420518700 REC PAN HD SCREW M6x20 3
5A 2 K2180140 COVER FAN 1
2A K2180310 COVER FAN EFI 1 BSVI
3 K2180070 GROMMET SPARK PLUG 1
4 M1200470 HEX FLANGE BOLT M6x30 4
5 K2180040 HOUSING FAN 1
5A K2180290 HOUSING FAN EFI 1 BSVI
6 F200098 CRPH SCR M5x20 8.8 ZNB 3
7 P1200140 PUNCHED WASHER A5.5 ZNG (TSDS-0003) 3
8 K2180160 FAN ENGINE COOLING 1
9 P1200150 WAVE SPRING WASHERM5 3
10 0334640 NUT M20x1.5 1
36A
11 K3322200 ROTOR ASSEMBLY 1
27A 12 K3322190 STATOR ASSEMBLY 1
13 K2060010 MAGNETO ASSY BS4 - JUP/WEG 1
13A K2060170 MAGNETO ASSY EFI 1 BSVI
14 K2180120 BEADING COWL BOT R 1
15 K2180110 BEADING COWL BOT L 1
16 K2180060 GROMMET PIPE INTAKE 1
17 K2080210 GEAR STARTER CLUTCH 1
18 K2080310 ONE WAY CLUTCH SUB ASSY. 1
39 19 K6081450 DISC ONE WAY CLUTCH 1
20 KL060020 STARTER MOTOR 1
21 K3090380 SILENT BLOCK BUSH 1
38 22 K2030180 CRANKCASE KIT RH 1
23 K6030250 BUSH CENTER STAND 1
24 M1080400 O-RING 16.8x3.1 [M101 039 0] 1
25 K6081500 GAUGE OIL LEVEL 1
CRANKCASE RH ASSEMBLY 26 M1200770 HEX NUT M12x1.25 1
FIG.NO.05 CRANKCASE RH ASSEMBLY FIG.NO.05
35 13A
34
NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
2A NO. NO. DRUM/DISC

5A
27 K2180050 DEFLECTOR 1
27A K2180300 DEFLECTOR EFI 1 BSVI
28 0331708 CRPH SCREW M5x12 2
29 K6081460 LOCK WASHER 1
30 K2140130 GUIDE HOSE COMP 1
31 M1200170 NEEDLE ROLLER BEARING 22x28X16 1
32 R1080550 GEAR STARTER IDLE 1
33 M1080430 PIN MAGNETO COVER 1
34 K2180150 GROMMET TENSIONER ADJ 1
35 K2180180 MUDFLAP 1
36A 36 KL030070 COVER MAGNETO 1
36A K2030310 COVER MAGNETO MC 1 BSVI
27A
37 KL030120 GASKET MAGNETO COVER 1
38 K2180360 GROMMET PIPE INTAKE L 1 BSVI
39 K2180340 GROMMET PIPE INTAKE EFI 1 BSVI

39

38

CRANKCASE RH ASSEMBLY
FIG.NO.06 GEAR & GEAR CASE ASSEMBLY FIG.NO.06

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

1 K2060050 SPEED SENSOR 1

2 --- BUTTON STRAP 2
3 M1200530 HEX FLANGE BOLT M6x20 2
4 --- O RING SPEED SENSOR 2
5 K6030650 GASKET SENSOR 1
6 K2080110 SHAFT RR WHEEL COMP 1
7 KL200010 OIL SEAL 26 52 6 1
8 K2080250 SHAFT INTERMEDIATE 1
9 KL080010 SHAFT CLUTCH 1
10 K2080240 GEAR INTERMEDIATE 1
11 K2200010 BALL BEARING 12 37 12 HEAT TREATED 2
12 K2200030 BALL BEARING 25 52 15 S 2 1
13 S1200270 TUBULAR DOWEL 2
14 KL030130 GASKET GEARCASE 1
15 KL030100 GEARCASE COMP 1
16 M7040509 INSERT MAP HOSE 1

GEAR & GEAR CASE ASSEMBLY

FIG.NO.07 COVER VARIATOR & KICK STARTER ASSY. FIG.NO.07

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

1 0332248 REC CSK HD SCR M6x20 6.8 ZNB 5

2 KL070020 COVER FAN CVT 1
3 KL080090 GEAR KICKSTARTER DRIVE COMP 1
4 K3081530 SPRING KS SHAFT 1
5 K3082190 BUSH KICK STARTER SHAFT 1
6 KL0300507D COVER VARIATOR TITAN GREY PAINTED 1
7 0331268 HEX BOLT M8X1.25X25 8.8 ZNB 1
8 K3081320 GEAR COMP KS IDLER 1
9 P080610 SHIM 11.2x18.5x0.5 OILED 3
10 K3200380 BALL 7/3 KICK LEVER 1
11 K3081590 SPRING KS LEVER 1
12 K3082740 PEDAL KICK LEVER 1
13 KL080120 LEVER KICKSTARTER ASSY. 1
14 KH030020 CLAMP TUBE INLET 1
15 K6030620 INLET CVT COOLING 1
16 KA080020 HOLDER FILTER 2
17 K6081400 FOAM CVT FILTER 1
18 F084100 WASHER LEVER KICK STARTER 1
19 420919000 CIRCLIP 8.0 1
20 M1200470 HEX FLANGE BOLT M6x30 7
21 P200150 CIRCLIP 8.0 1
22 K2080300 GEAR COMP KICKSTARTER DRIVEN 1
23 KL200020 BALL BEARING 10x30x9 - 6200 2z 1
24 K3081500 SPRING KS DRIVEN GEAR 1
25 0332415 SCREW 1
COVER VARIATOR & KICK STARTER ASSY.
FIG.NO.07A COVER VARIATOR & KICK STARTER ASSY. - BSVI FIG.NO.07A

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

1 K20302207D COVER VARIATOR GLOSSY TITAN GREY 1 BSVI

11 2 K080320 SHIM 8 X 16 X 0.5 1 BSVI
15 KA080130 GEAR COMP KICKSTARTER DRIVEN 1 BSVI
3
4 K3081500 SPRING KS DRIVEN GEAR 1
5 K6030620 INLET CVT COOLING 1
6 KH030020 CLAMP TUBE INLET 1
12 13 7 K6081400 FOAM CVT FILTER 1
14 10
16 20 8 KA080020 HOLDER FILTER 1
9 K2080410 GEAR KICKSTARTER DRIVE COMP 1 BSVI
10 R4080060 SPRING KICKSTARTER 1 BSVI
3 11 K2070170 COVER FAN CVT 1 BSVI
4 19 12 K3200880 SHIM 17x24x0.5 1 BSVI
7 13 KL200020 BALL BEARING 10x30x9 - 6200 2z 1
14 KA080150 BUSH KS DRIVE 1 BSVI
9 24
8 15 0332248 REC CSK HD SCR M6x20 6.8 ZNB 4
16 P200030 CIRCLIP 16x1.0 1 BSVI
5 2 KA080120 LEVER KICKSTARTER 1 BSVI
18 17
6 18 0331268 HEX BOLT M8X1.25X25 8.8 ZNB 1
23 22 19 420919000 CIRCLIP 1
17 20 K6081560 PEDAL LEVER 1 BSVI
1 21 M1200470 HEX FLANGE BOLT M6x30 7
22 K3200380 BALL 7/3 KICK LEVER 1
21 25 23 K3081590 SPRING KS LEVER 1
24 F084100 WASHER KICKSTARTER LEVER 1
25 KL080120 LEVER KICKSTARTER COMP 1

COVER VARIATOR & KICK STARTER ASSY. - BSVI

FIG.NO. 08 CARBURETTOR ASSEMBLY FIG.NO.08

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

1 K2040040 CARBURETTOR ASSY. 1

1A K2040240 CARBURETTOR ASSY. 1
2 K2320110 THROTTLE VALVE 1
3 K2320240 AUTO CHOKE KIT 1
4 --- CRR PAN SCREW WITH WASHER 1
5 K2320190 VENT HOSE 2
6 N8321730 HOSE CLIP 2
7 N8324900 PLATE NEEDLE CLIP 1
8 N8324990 CLIP BAR 1
9 K2320120 NEEDLE JET 1
10 K2040200 RUBBER CAP 1
11 K2320140 TOP CAP 1
12 K2320150 GASEKET TOP THROTTLE 1
13 K2320130 SPRING COMPR. 1
14 K2320170 MIXTURE CONTROLE SCREW 1
15 N8321560 O RING 3
16 N8321680 WASHER 1
17 N8321670 SPRING 1
18 N8321690 O RING 1
19 N8321510 PIN FLOAT VALVE 1
20 N8325000 VALVE COMP. FLOAT 1
21 N8321480 FLOAT COMP 1
22 N8321550 SCREW DRAIN 1
23 K2320100 GASKET FLOAT CHAMBER 1
24 K2320180 HOSE 1
25 K2320160 IDLE ADJUSTER SCREW 1
CARBURETTOR ASSEMBLY 26 NB321540 SCREW WASHER4x14 2
27 N8321740 O RING 24x25 1
FIG.NO. 08 CARBURETTOR ASSEMBLY FIG.NO.08

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

28 K2320270 BODY FLOAT CHAMBER 1

29 K2320090 JET SLOW 1
30 N8324850 HOLDER NEEDLE JET 1
31 K2320070 JET NEEDLE 1
32 K2320080 JET MAIN 1
33 K2320200 SPRING COMPR. 1

CARBURETTOR ASSEMBLY
FIG.NO. 09 AIRCLEANER ASSEMBLY FIG.NO.09

1A NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

3A
1 KL040020 AIRCLEANER ASSY. 1
1A K2040330 AIR CLEANER ASSY 1 BSVI
2 G4041110 CLAMP INTAKE PIPE 1
3 KL040080 TUBE OUTLET 1
3A K2040340 TUBE OUTLET 1 BSVI
4 --- CASE AIR CLEANER COMP 1
5 KL040070 TUBE INLET 1
6 R1040460 CLAMP BREATHER HOSE 1
7 KL040120 SEAL AIR CLEANER 1
8 K140820 HOSE CLIP 1
9 K4040200 DRAIN HOSE 1
10 P6040110 DRAIN PIPE 1
11 N2041150 HOSE CLIP NO.1 1
12 M1200660 CRPH SCR M5x16 ZNG 4
13 KL040040 COVER AIR CLEANER COMP 1
14 KL040050 FILTER HOLDER COMP 1
15 K2040120 FOAM AIR CLEANER 1
16 M1200470 HEX FLANGE BOLT M6x30 2
17 KL040100 HOSE BREATHER PCV 1
17A 17A K2040260 HOSE BREATHER PCV 1 BSVI
18 N4200130 HOSE CLAMP NP.090 1
19 KL040110 HOSE GEAR CRANKCASE 1
20 N8040350 HOSE CLIP AIR INJECTION 2

AIRCLEANER ASSEMBLY
FIG.NO. 10 SECONDARY AIRCLEANER ASSEMBLY FIG.NO.10

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

1 K140820 HOSE CLIP 2

2 K2040170 HOSE SAI INLET 1
3 K2040150 SAI VALVE SUB ASSY 1
4 M1200520 HEX FL BOLT M6x16 3
5 K2040190 BRKT SAI MTG 1
6 N2041670 CUSHION VALVE MOUNTING 2
7 N2200500 HEX FL BOLT M6x25 2
8 N3160220 SPACER R.C.LAMP MOUNTING 2
9 N8040350 HOSE CLIP AIR INJECTION 2
10 K6040340 HOSE SAI OUTLET 1
11 K2040160 PIPE COMP SAI 1
12 N8040340 O-RING AIR INJECTION 1
13 P1200050 WAVE SPRING 1
14 414147000 HOSE CLIP 1
15 N8040370 HOSE CLIP VACUUM 1
16 K2040180 HOSE AIR CUT VALVE 1
17 0335608 PUNCHED WASHER 6.5x16x1.2 2

SECONDARY AIRCLEANER ASSEMBLY

FIG.NO. 10A SECONDARY AIRCLEANER ASSEMBLY FIG.NO.10A

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
8 7
NO. NO. DRUM/DISC

12 9 1 K2040160 PIPE COMP SAI 1

2 K2040370 BRKT SAI MTG 1 BSVI
3 3 K2040400 BOOT ELECTRIC SAI VALVE 1 BSVI
2 4 K2040360 ELECTRIC-SAI 1 BSVI
5 K3041330 HOSE SAI OUTLET 1
6 N8040350 HOSE CLIP AIR INJECTION 2
4
7 K2040380 HOSE SAI INLET 1 BSVI
6
8 K140820 HOSE CLIP 1
9 R2040400 HOSE CLIP NP.054 1 BSVI
10 N8040340 O-RING AIR INJECTION 1
5
11 P1200050 WAVE SPRING WASHER 6.5 1
12 M1200520 HEX FL BOLT M6x16 2

10

11
12
SECONDARY AIRCLEANER ASSEMBLY
FIG.NO. 11 MUFFLER ASSEMBLY FIG.NO. 11

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

1 K2050100 MUFFLER SUB ASSY. 1

2 R1200280 CRR PAN HEAD SCREW M4X20 3
3 K2050080 GUARD EXHAUST REAR BOTTOM 1 DRUM
4 K2050040 MUFFLER COMP 1
5 P200480 HEX BOLT M10 X 45 2
6 N9053170 GASKET MUFFLER RTR 180 1
7 M1200890 U NUT M8x1.25 2
8 K6200310 PUNCHED WASHER 13x6.5x1.6 3
9 R1200220 SPL CRR PAN HEAD SCREW 3
10 K2050070 GUARD EXHAUST 1
11 K2050090 GUARD EXHAUST REAR TOP 1
12 K2050120 GUARD EXHAUST REAR L BOTTOM 1 DISC

MUFFLER ASSEMBLY
FIG.NO. 11A MUFFLER ASSEMBLY - BSVI FIG.NO. 11A
1

NO.OFF
12 REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

11
13
1 K2050210 MUFFLER SUB-ASSY 1 BSVI
7 2 N9053170 GASKET MUFFLER RTR 180 1
8
3 M1200890 U NUT M8x1.2 2
4 0335628 PUNCHED WASHER 10.5x24x2.3 ZNB 2
10 5 P200480 HEX BOLT M10x45 2
6 K2050220 MUFFLER COMP 1 BSVI
10 9 7 K2050270 GUARD EXHAUST REAR 1 BSVI
8 K2050090 GUARD EXHAUST REAR TOP 1 BSVI
9 K2050260 GUARD EXHAUST FRONT 1 BSVI
6
4 10 K6200310 PUNCHED WASHER 130 65 16 4
13
11 K2200080 TRUSS HEAD CAP SCREW M6 16 2 BSVI
5 12 K2220750 TAPESET 1 BSVI
13 R1200220 SPL SCREW PAN HEAD SCREW M6x12 4

MUFFLER ASSEMBLY - BSVI

FIG.NO. 12
40 HANDLEBAR ASSEMBLY - DRUM/DISC FIG.NO. 12

NO.OFF
46 REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

1 KA110010 MASTER CYLINDER ASSY FRONT 1 DISC

41
1A K2110300 MASTER CYLINDER ASSY FRONT 1 SBT
43
2 N3200180 HEX SOC HD CAP SCREW M8 x 35 2
3 R3150040 GRIP COMP THROTTLE 1
44 3A R4150240 GRIP COMP THROTTLE - DISC 1 BSVI

4 K3150570 CASE, THROTTLE UNDER 1

3A
5 K150420 GASE, THROTTLE UPPER 1
6 KL220490 MIRROR ASSY RH 1
7 P1200140 PUNCHED WASHER A5.5 2
19A
8 8200120 CRR FL PAN HD SCREW M5 x12 1
9 K2150260 CONTROL LEVER ASSY. LH 1 DISC

1A 10 P1200150 WAVE SPRING WASHER M5 1

11 K3200660 HEX FL BOLT M10 X1.25 x 45 1

47 12 S1150500 BUSH 1

48 13 N7160620 CABLE STRAP 2

14 420302700 HEX NUT M5 1
15 N3160340 CLAMP WIRING HARNESS BIG SIZE 1
.
16 KL220480 MIRROR ASSY LH 1
17 K2150110 HANDLE BAR COMP 1 DISC

18 K2150020 HANDLE BAR COMP 1 DRUM

42
19 R3150030 GRIP L 1
19A N9221070 GRIP L - DISC 1 BSVI

20 K2150130 DAMPER HANDLE BAR 2 DISC

21 K2150250 LOCK STOPPER 1

HANDLEBAR ASSEMBLY - DRUM/DISC 22 K2150270 HINGE PARKING 1 DISC
23 K3200420 PAN HEAD SCREW 1 DISC
FIG.NO. 12
40
HANDLEBAR ASSEMBLY - DRUM/DISC FIG.NO. 12

NO.OFF
46 REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

41 24 K3150270 CLAMP,LEVER BRAKE 1 DISC

25 K6150200 HOLDER CONTROL 1 DISC

43
26 K3150250 BRAKE LEVER LH 1 DISC

27 K200570 HEX FLANGE U NUT M10 x 1.25 1

44
28 P1200180 PUNCHED WASHER A11 1

3A 29 K160240 SWITCH STOP LEVER 1

30 409047000 HEX NUT M6 1
31 K6150249 SPRING PARKING BRAKE 1 DISC

19A 32 K2150210 CONTROL LEVER ASSY RH 1

33 K6150380 BRACKET LEVER R 1
34 K3150280 CLAMP LEVER BRAKE 1
1A 35 K4150130 CONTROL LEVER ASSY LH 1 DRUM

36 K4150150 BRACKET LEVER LH 1

47 37 K4150170 SUPPORT BRAKE LEVER 1
48 38 K6150450 SPECIAL SCREW 1
39 K6150570 CLAMP LEVER BRKT LH 1

. 40 K6321540 KIT PARKING BRAKE 1

41 K6150580 KIT BRAKE LEVER ASSY RR LH 1
42 S1200820 E CLIP 1
42 43 K2220140 GROMMET MIRROR RH 1
44 K2220130 GROMMET MIRROR RH 1

45 K2150220 CONTROL LEVER R 1

46 0332038 CRPH SCR M5x45 6.8 ZNB (TSDS-0203) 1
HANDLEBAR ASSEMBLY - DRUM/DISC 47 0330448 WAVE SPRING WASHER M4 1
48 420957700 PHILIPS HD SCREW M4X15 1
FIG.NO. 13 CABLE ASSEMBLY - DRUM/DISC FIG.NO. 13

NO.OFF

9A REF. PART DESCRIPTION NTORQ REMARKS

NO. NO. DRUM/DISC

16
1 KA170060 CABLE ASSY BRAKE FRONT R 1 DRUM
2 KA170050 CABLE ASSY BRAKE FRONT L 1 "
2A K2170040 CABLE ASSY BRAKE FRONT L 1 DISC SBT
2A 3 N2110680 DUST SEAL FRONT BRAKE CABLE 1 "
4 0254038 PIN FR.BR. LEVER - BREAK 2 "
5 K6111350 BRAKE ADJUSTER 2 "
7A
6 K6111390 SPRING BRAKE CABLE REAR 1
7 K6170230 CABLE ASSY. THROTTLE 1
7A K2170050 CABLE ASSY. THROTTLE 1 BSVI
8 8200120 CRPH TAPPING SCREW M5*12 1
9 KA170040 CABLE ASSY BRAKE REAR 1
9A K2170050 CABLE ASSY BRAKE REAR 1 BSVI
10 0334268 NUT FR.BR.CABLE ADJ.-BR 1
11 K6111340 SPRING BRAKE RETURN DRUM 1 DRUM
12 N2110690 SPRING FRONT BRAKE CABLE 1 "
13 K6170100 CABLE GUIDE REAR - WEGO 1
14 420464700 HEX SCREW M6X20 8.8 ZNB 1
15 P1200050 WAVE SPRING WASHER 6.5 1
16 0254096 PIECE THROTTLE CABLE END 1

CABLE ASSEMBLY - DRUM/DISC

FIG.NO. 14 FUEL TANK & AUTO FUEL COCK ASSY. FIG.NO. 14

NO.OFF
24
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

1 --- FUEL TANK ASSY. 1

2 K2140050 CAP FUEL TANK 1
3 R1200280 CRR PAN HEAD SCREW M4X20 3
4 K2140030 FUEL TANK COMP. 1
5 K2120390 BRKT FUEL TANK MTG RR 1
6 K140820 HOSE CLIP 1
7 R1140410 FUEL FILTER 1
8 R1140440 HOSE CLIP 1
9 N8040370 HOSE CLIP VACUUM 1
10 K2140120 AUTO FUEL COCK ASSY. 1
11 K2140080 HOSE ASSY. 1
11A K2140230 HOSE ASSY. 1 RACE EDITION

11A
12 M1200670 CRPH SCR M6x20 1
13 N2200490 FLANGE BOLT M6x20 1
14 K2140100 BRKT HOSE GUIDE 1
15 P1200050 WAVE SPRING WASHER 6.5 2
16 K2160030 FUEL SENDER ASSY. 1
26 17 R1200380 HEX FLANGE BOLT M5X14 4
18 N2200500 HEX FLANGE BOLT M6x25 ZNG 1
19 K4140040 HOSE FUEL TANK 1
20 K2140150 BRKT FUEL COCK MTG COMP 1
21 K2140130 GUIDE HOSE COMP 1
22 0335928 PUNCHED WASHER 6.5x18.0x1.6 ZNB 3
23 N2200490 FLANGE BOLT M6x20 2
24 K2320250 BODY COVER FUEL TANK 1
25 K2140190 HOSE VACUUM 1 RACE EDITION
FUEL TANK & AUTO FUEL COCK ASSY. 26 K3140260 SPRING VACUUM HOSE 1 RACE EDITION
FIG.NO. 14A FUEL TANK & AUTO FUEL COCK ASSY. - BSVI FIG.NO. 14A
12
NO.OFF
20 3
REF. PART DESCRIPTION NTORQ REMARKS
1 NO. NO. DRUM/DISC
2

16 1 --- FUEL TANK ASSY EFI 1 BSVI

6
4 BSVI
2 K2140240 CAP FUEL TANK ASSY 1
3 R1200280 CRR PAN HEAD SCREW M4X20 3
4 K2120700 BRKT FUEL TANK MTG RR 1 BSVI
7 5 K2140180 FUEL TANK COMP EFI 1 BSVI
10 5 6 K2320250 BODY COVER FUEL TANK 1
19 7 K2140350 BRKT FUEL TANK COMP 1 BSVI
23 8 K2140270 GUIDE HOSE 2 BSVI
14 BSVI
9 K2140250 HOSE ASSY 1
17 BSVI
10 R3200010 O-RING 6260 350 1
13 11 K2160310 FUEL SENDER ASSY 1 BSVI
12 N8200060 HEX FLANGE BOLT M6x10 6
13 N2200490 FLANGE BOLT M6x20 ZNG 1
11
14 N2200500 HEX FLANGE BOLT M6x25 ZNG 1
15 0332068 CRPH SCR M6x12 6.8 ZNB 2
16 K6140690 FUEL PUMP MODULE 1 BSVI
15 18
17 P1200050 WAVE SPRING WASHER 6.5 2
8 15
18 7130140 WASHER CUP ZnK 2
19 0335928 PUNCHED WASHER 6.5x18.0x1.6 ZNB 2
9 20 K6140400 FLANGE TOP FUEL PUMP MTG 1 BSVI
21 K2140260 PLATE GUIDE COMP 1 BSVI
22 M7200720 HEX FL. BOLT M6x16 2
23 R1200380 HEX FLANGE BOLT M5X14 4
22
21
FUEL TANK & AUTO FUEL COCK ASSY. - BSVI
FIG.NO. 14B FUEL TANK CANISTER ASSEMBLY - BSVI FIG.NO. 14B

NO.OFF
13 REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

11
14 1 K2140300 BOOT CANISTER 1 BSVI
2 K4140140 CANISTER COMP 1 BSVI
10
3 K2140340 HOSE PURGE VALVE 1
4 N9141650 HOSE AIR INLET 1
3 6 5 K2140320 HOSE DRAIN CANISTER 1 BSVI
6 R1040460 CLAMP BREATHER HOSE 2
7 R2040400 HOSE CLIP NP.054 1
1 8 N8040370 HOSE CLIP VACUUM 2
9 N9142340 CUSHION 1
8 10 K6060520 VALVE CANISTER PURGE 1 BSVI
2 11 K2140290 HOSE CANISTER 1 BSVI
12 K2140310 HOSE INDUCTION 1 BSVI
13 414147000 HOSE CLIP 2
7 14 P1200060 HEX NUT M6 ZNG (TSDS-0304) 1
4
12
9
5

13

FUEL TANK CANISTER ASSEMBLY - BSVI

FIG.NO. 15 HEADLAMP & PANEL FRONT ASSEMBLY FIG.NO. 15

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

1 0331708 CRPH SCR M5x12 6.8 ZNB 2

2 K3200830 RETAINER CLIP M5 2
3 N8220460 CLIP HEAD LAMP ASSY 3
4 KL220099 PANEL BOTTOM CTR 1 BLACK
5 KL220400 HEADLAMP ASSY. 1
5A K2220910 HEADLAMP ASSY. 1 RACE EDITION
6 M7160190 BULB HEAD LAMP 12V 35/35W 1
7 --- PANEL FRONT 1 REF. COLOUR
8 M1200660 CRPH SCR M5x16 ZNG 4
9 K2320210 DUST CAP 1
10 F200058 CRPH SCREW M5x35 2
11 K4220920 BRKT LICENCE PLATE 1
12 KL220060 PANEL FRONT TOP 1
13 KL220050 GRILL PANEL FRONT 1
14 K200320 SCREW SELF TAPPING 4.2x16 3
15 K2220030 BRKT PANEL FRONT 1
16 N8160350 HEX FLANGE BOLT M4x12 2
17 R1122340 CUSHION 9*20*2 2
18 0332275 SCREW - CRPH M6x16 6.8 ZNK 2

HEADLAMP & PANEL FRONT ASSEMBLY

FIG.NO. 16 SEAT ASSEMBLY FIG.NO. 16

NO.OFF
1A REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

1 KL130050 SEAT ASSY N15 1

1A K2130040 SEAT ASSY 1 BSVI
2 KL130030 COVER COMP. SEAT 1
3 KL130020 SEAT FOAM 1
3A K2130030 SEAT FOAM 1 BSVI
4 KL130010 SEAT BASE 1
4A K2130020 SEAT BASE 1 BSVI
3A 5 K6130100 CUSHION SEAT REAR 2
6 K210800 O RING 1
7 K2130010 PACKING SEAT BASE FRONT 1
8 M1200900 HEX FL. NUT M6x1 2
4A 9 R1130100 HINGE COMP, SEAT 1
10 R1130090 BOLT PLATE COMP. SEAT 1
11 R1130110 HEX SCREW M6 1
12 K4160190 MAGNET 1
13 KL130060 PACKING SEAT BASE 1
14 K2130060 ADAPTOR SEAT CUSHION 1 BSVI

14

SEAT ASSEMBLY
FIG.NO. 17 FRAME & FOOTREST ASSEMBLY FIG.NO. 17
42
NO.OFF
40
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC

1 N3200220 HEX FL. BOLT M6x1.25x16 9

2 M1200530 FLANGE BOLT M6x20 2
13A 3 N9051860 CUP WASHER 3
4 K2150170 BLANK KEY 1
5 K2150090 IGNITION LOCK 1
6 K2120580 BATTERY BOX TOP 1
7 N9101470 CUP BOTTOM 1
8 N3200270 FLANGE BOLT M6x30 2
9 P1200050 WAVE SPRING WASHER M6 2
41 10 0335608 PUNCHED WASHER 6.5x16x1.2 2
11 K2120330 PILLION FOOTREST RH 1
12 K6122300 SAPCER PILLION FOOTREST 2
39 13 K2120010 FRAME, SCOOTER COMP 1
13A K2120680 FRAME, SCOOTER COMP 1 BSVI
14 0331708 CRR PAN HEAD SCREW M5x12 2
15 P1200140 PUNCHED WASHER A5.5 2
16 K6210100 SEAT LATCH ASSY. 1
34A 26A
17 R1122340 CUSHION 9x20x2 14
18 N8220400 CUSHION FUELTANK 2
38A 19 N9200030 HEX FLANGE BOLT M8x45 2
20 K6121490 FOOTREST COMP PILLION 2
21 K3122800 SPRING FOOTREST FOLDABLE 1
22 K3122850 COTTER PIN FOOTREST FOLDABLE 1
23 K3122840 COTTER PIN FOOTREST FOLDABLE 1
24 K3122830 PIN FOOTREST FOLDABLE 1
FRAME & FOOTREST ASSEMBLY 25 K3122820 PIN FOOTREST FOLDABLE 1
FIG.NO. 17
42
FRAME & FOOTREST ASSEMBLY FIG.NO. 17

40 NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC
26 K3123140 PAD FOOTREST FOLDABLE 1
26A K31231407D PAD FOOTREST FOLDABLE 1
27 3030515 SPRING 2
13A
28 0339204 BALL 2
29 K2120320 PILLION FOOTREST LH 1
30 N8121890 SPRING PROP STAND 1
31 KA120270 PROP STAND COMP 1
32 N9200010 HEX BOLT M8x1.25x30 1
33 K2120490 BRKT BATTERY HOLDER COMP 1
34 K2120570 BATTERY BOX BOT 1
41
34A K2120750 BATTERY HOLDER BOTTOM 1 BSVI
35 K3100590 CUP BOTTOM 1
36 0334548 HEXAGONAL NUT M8 1
39 37 G5200400 PUNCHED WASHER 8.5 x 20 x 2 2
38 K61214807D FOOTREST ASSY PILLION JUPITER/WEGO T GRY 1
38A K6121480 FOOTREST ASSY PILLION 1 BSVI
39 P200310 HEX SCREW M6x12 2
40 K2120820 BRKT CANISTER MTG COMP 1 BSVI
34A 26A 41 K2120760 BRKT ECU MTG 1 BSVI
42 420452700 HEX SCREW M6X12 8.8 ZNB 1

38A

FRAME & FOOTREST ASSEMBLY

FIG.NO. 18 TOGGLE LINK & CENTER STAND ASSY. FIG.NO. 18

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

1 K4090070 STOPPER TOGGLE LINK 1

2 K4090060 ARRESTOR PLATE 1
3 K6090510 BUMP STOPPER TOGGLE LINK - WEGO 1
4 K6090680 SILENT BLOC - WEGO 2
5 K6090700 TOGGLE LINK ASSY 1
6 K6090590 SPACER ASSY TOGGLE LINK - WEGO 1
7 0330318 WAVE SPRING WASHER M8 ZNB 3
8 K2090020 SHOCK ABSORBER REAR RED 1 DISC
9 0330328 WAVE SPRING WASHER M10 ZNG 1
10 420496700 HEX BOLT M10X40 8.8 ZNB 1
11 K6200080 CLEVIS PIN CENTER STAND - WEGO 2
12 K6123310 CENTER STAND COMP 1
13 K6170090 CABLE GUIDE FRONT - WEGO 1
14 P200530 HEX NUT M10 8 ZNB (TSDS-0304) 2
15 0335528 PUNCHED WASHER 10.5x18x1.6 4
16 K6200060 HEX BOLT M10X1.25X250 1
17 0330028 SPLIT PIN 3.2x25 ZNB 3
18 K6123420 LEVER CENTER STAND COMP 1
19 K3200210 BOLT COMP M10 X 312 1
20 420496700 HEX SCREW M8X40 8.8 ZNB 1

27 21 S1125310 CUSHION 1
22 K6123300 CENTER STAND ASSY 1
23 K3122140 SPRING CENTER STAND 1
24 K6170100 CABLE GUIDE REAR - WEGO 1
24 25 KL220470 MUDGUARD REAR 1
28 26 K20900202D SHOCK ABSORBER REAR BLACK 1 DRUM
27 P1200050 WAVE SPRING WASHER 6.5 1
TOGGLE LINK & CENTER STAND ASSY. 28 420462700 HEX SCREW M6X20 8.8 ZNB 1
FIG.NO. 19 FRONT FORK ASSEMBLY FIG.NO. 19

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

1 K2100200 LEG ASSY RH 30 40400 1 DRUM

2 K2100160 INNER TUBE ASSY. 2
3 U1100120 SPINDLE TAPER 2
4 K2100150 FORK TUBE OUTER RH 2
5 N8101220 PACKING 2
6 N8101230 BOLT 2
7 K6100960 NUT FRONT FORK 2
8 7100300 O RING 2
9 N3102410 DUST SEAL FRONT FORK 2
10 N3100290 CIRCLIP FRONT FORK 2
11 N3102420 OIL SEAL FRONT FORK 2
12 K2100240 SPRING FR FORK 2
13 N3100330 PISTON RING (FRONT FORK) 2
14 K2100250 DAMPER PISTON FRONT FORK 2
15 K6320560 REBOUND SPRING FR FORK 2
16 K2100290 DUST SEAL UPPER 1
17 410058700 LOCK NUT STEERING 1
41
18 K2100270 ARRESTER STEERING STEM TOP 1
19 N9101530 LOCK WASHER ARRESTOR STEERING 1
20 N9101600 CONE TOP 1
21 K3200450 BALL DIA 6.35 38
22 P1210980 BEECHAM PREMIUM GREASE 1
23 K3100600 CONE BOTTOM 1
24 K3100800 ARRESTOR STEERING STEM 1
25 K4100110 DUST SEAL LOWER 1
26 K6101040 CAP, LOCKNUT 1
FRONT FORK ASSEMBLY 27 K2100100 LOWER BRKT COMP 1
FIG.NO. 19 FRONT FORK ASSEMBLY FIG.NO. 19

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

21 28 --- HEX WELD NUT M6 P 3

29 K2100140 FORK TUBE OUTER LH 1
24 30 R1200260 CUP WASHER 5
31 N3200220 HEX FL BOLT M6x16 ZNG 5
32 K6170130 CABLE GUIDE FRONT L 1
33 P1200050 WAVE SPRING WASHER 6.5 1
34 420452700 HEX SCREW M6X12 8.8 ZNB 1
35 420001700 PUNCHED WASHER A6.6 ZNB 1
36 R1200160 HEX FL BOLT M10X1.25X40 4
37 KL100030 LEG ASSY LH 30 42400 1 DISC
38 KL100040 LEG ASSY RH 30 42400 1 DISC
39 K2100190 LEG ASSY LH 30 40400 1 DRUM
40 KL100050 FORK TUBE OUTER LH 1 DISC
41 KL100060 FORK TUBE OUTER R 1 DISC

41

FRONT FORK ASSEMBLY

FIG.NO. 20 FRONT WHEEL ASSEMBLY - DRUM FIG.NO. 20

NO.OFF
REF. PART DESCRIPTION NTORQ 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 0339100 BALL BEARING 6201 2
5 K2110040 WHEEL ASSY. FRONT 1
6 K2110020 TYRE TUBE LESS 90/90-12 1
7 K2110030 ALLOY WHEEL FRONT 1.85*12 1
8 K2110010 SPACER COMP. FRONT HUB 1
9 N2110130 CAM BRAKE 1
10 K6111320 PANEL SUB ASSY. FRONT BRAKE 1
11 1112620 SET BRAKE SHOE ASSY. D130 1
12 3230515 SPRING BRAKE SHOE 2
13 K6111310 PANEL COMP. FRONT BRAKE 1
14 0331248 HEX BOLT M6X1.0X33 4.8 1
15 420001700 PUNCHED WASHER A6.6 1
16 0178030 O RING BRAKE CAM-BR 1
17 0335698 PUNCHED WASHER 14.5x22x1.6 1
18 420305700 HEX NUT M6 8 ZNB 1
19 K6111330 LEVER FRONT CAM BRAKE 1
20 R1110570 AXLE FRONT 12x240 1
21 K4110140 VALVE TUBELESS TYRE 1
22 K2220240 TAPESET WHEEL RIM 1

FRONT WHEEL ASSEMBLY

FIG.NO. 21 FRONT WHEEL ASSEMBLY - DISC FIG.NO. 21

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

1 K2110020 TYRE FRONT TUBELESS 1

2 K6111290 SPACER COMP FR AXLE 1 DISC
3 0339100L BALL BEARING 2
4 K2110120 ALLOY WHEEL 1 DISC
5 K4110140 VALVE TUBELESS 1
6 K2110010 SPACER COMP 1
7 K6110830 SPACER COMP FR AXLE - WEGO 1
8 R1110570 AXLE 12 x 240 1
9 K2110170 DISC FRONT BRAKE 1 DISC
10 M7110280 HEXAGONAL FLANGE 4 DISC
11 K2110130 WHEEL ASSY DISC TUBELESS FRONT 1 DISC
12 0334158 NUT REAR SWING ARM PIVOT 1
13 0335538 PUNCHED WASHER 12.522x2.3 1
14 K2220240 TAPESET WHEEL RIM 1

FRONT WHEEL ASSEMBLY - DISC

FIG.NO. 22 REAR WHEEL ASSEMBLY FIG.NO. 22

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

1 S1200910 FLANGE U NUT M16x1.5 1

2 S1111430 PUNCHED WASHER 16.5x33.2x3.15 ZNB 1
3 K2110060 TYRE TUBELESS 12 11000 REAR 1
4 K2110070 ALLOY WHEEL 12 275 5 DRUM REAR 1
5 420001700 PUNCHED WASHER 16.5x33.2x3.15 ZNB 1
6 0331248 HEX BOLT M6 X 1 X33 1
7 0334268 NUT FRONT BRAKE CABLE ADJUSTER 1
8 0254038L PIN FRONT BRAKE LEVER 1
9 K2110230 LEVER COMP BRAKE REAR 1
10 K6111390 SPRING BRAKE CABLE REAR 1
11 K2110080 WHEEL ASSY. REAR ALLOY TUBELESS 1
12 K4110140 VALVE TUBELESS TYRE JUPITER 1
13 0178030 O RING BRAKE CAM-BR 1
14 0335698 PUNCHED WASHER 14.5x22x1.6 ZNB 1
15 K6110840 BRAKE CAM REAR - WEGO 1
16 1110020 SET SHOE BRAKE ASSM 1
17 K2220240 TAPESET WHEEL RIM 1

FRONT WHEEL ASSEMBLY - DISC

FIG.NO. 23 COVER HANDLEBAR ASSY. FIG.NO. 23

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
14A 14B 14C 12A NO. NO. DRUM/DISC
1 KL220030 VISOR HEADLAMP 1
2 K2220740 TAPESET VISOR 1
3 K2220310 COVER HANDLE FR BOTTOM 1
4 KL220410 TURN SIGNAL LAMP LH 1
5 K3200830 RETAINER CLIP M5 2
6 N3200340 CRR FLA. PAN HD TAP SCREW ST4.2x13 13
7 K200320 SCREW SELF TAPPING 4.2x16 7
8 --- COVER HANDLE FRONT 1 REF. COLOUR
9 R1200380 HEX FLANGE BOLT M5X14 2
10 K2160060 SWITCH ASSY LH 1 DISC
11 P3200010 CRPH SCR M6x12 6.8 1
12 K2160250 DIGITAL SPEEDOMETER ASSY 1
12A K2160380 DIGITAL SPEEDOMETER ASSY BSVI 1 BSVI
13 K2220190 TAPSET COVER HANDLE REAR 1
14 K2160070 SWITCH ASSY RH 1 DISC
14A K2160300 SWITCH ASSY RH 1 RACE ED.
14B K2160330 SWITCH ASSY R EFI 1 BSVI RACE ED.
14C K2160430 SWITCH ASSY R EFI 1 BSVI
15 P1200140 PUNCHED WASHER A5.5 2
16 N5120820 GROMMET HEADLAMP 3
17 N8122610 CUP WASHER 3
18 N2200490 FLANGE BOLT M6x20 3
19 KL220420 TURN SIGNAL LAMP RH 1
20 KL220010 COVER HANDLE REAR 1
21 R1200280 CRR PAN HEAD SCREW M4X20 2
22 K2160100 SWITCH ASSY R BASIC 1 DRUM
23 K2160200 SWITCH ASSY L BASIC 1 "
24 N9162650 BULB 12V 10W 2
25 K2160170 CORDSET TSL FRONT R 1
COVER HANDLEBAR ASSY. 26 K2160160 CORDSET TSL FRONT L 1
27 K2220800 CAP COVER HANDLE REAR L 1
28 K2220810 CAP COVER HANDLE REAR R 1
FIG.NO. 24 FRONT FENDER & PANEL REAR ASSY. FIG.NO. 24

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

1 K200320 SCREW SELF TAPPING 4.2x16 24

9A
2 ---- FENDER FRONT LH 1 REF. COLOUR
3 KL220139 PANEL FR BOT 1 BLACK
14A
4 M1200660 CRR PAN HEAD SCREW M5x16 2
5 N2200490 FLANGE BOLT M6x20 ZNG 4
6 KL220170 FLOOR BOARD 1
7 ---- COVER FRONT BTM L 1
8 K2200080 TRUSS HEAD CAP SCREW M6 16 4
9 ---- COVER FRONT MATTE 1 REF. COLOUR
9A K2220620 COVER FR 1
10 ---- PANEL BOT R 1 REF. COLOUR
11 KL220160 PANEL REAR 1
12 KA220500 BAG HOOK ASSY. FR 1
13 M1200660 CRPH SCR M5x16 ZNG 14
14 ---- SIDE TRIM FLOOR R 1 REF. COLOUR
14A K2220960 SIDE TRIM FLOOR RH 1
15 R1200260 CUP WASHER 5
16 KL220150 GRILL PANEL BOT R 1
17 N8220400 CUSHION FUEL TANK 4
18 N7201600 CLIP NUT 3 10
19 ---- FENDER FRONT R 1 REF. COLOUR
22A
20 ---- COVER FRONT BTM R 1 "
21 ---- PANEL BOT L 1 "
22 ---- SIDE TRIM FLOOR L 1 "
22A K2220950 SIDE TRIM FLOOR LH 1
23 KL220460 COVER BOT FLOOR 1
24 ---- FRONT FENDER CENTER 1 REF. COLOUR
SIDE PANEL LH RH & FRONT FENDER ASSY. 25 KL220140 GRILL PANEL BOT L 1
FIG.NO. 24 FRONT FENDER & PANEL REAR ASSY. FIG.NO. 24

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

26 K2220160 RETAINER HINGE 1

9A
27 0335608 PUNCHED WASHER 6.5x16x1.2 5
28 0331708 CRPH SCR M5x16 ZNG 4
14A 29 N7201300 SNAP RIVET 7
30 KL220210 SIDE TRIM FLOOR REAR R 1
31 KL220200 SIDE TRIM FLOOR REAR L 1
32 P3200010 CRPH SCREW M6x12 2
33 0332275 CRPH SCREW M6x16 2
34 0335928 PUNCHED WASHER 6.5x18x1.6 3
35 KA220710 BAG HOOK ASSY. REAR 1
36 8200320 CIRCLIP 5.0 1
37 N3200220 HEX FLANGE BOLT M6x1.25x16 3
38 KA220740 HOLDER UTILITY BOX 1

22A

FRONT FENDER & PANEL REAR ASSY.

FIG.NO. 25 PANEL SIDE LH,RH & REAR ASSY. FIG.NO. 25
7A 26
NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC
1 --- SIDE PANEL R 1 REF. COLOUR
2 --- PILLION HANDLE TITAN GREY 1 "
3 --- COVER TAIL CENTER MATTE BLACK 1 "
4 --- SIDE PANEL TOP R MATTE BLACK 1 "
5 N2200500 HEX FLANGE BOLT M6x25 ZNG 4
6 N9227200 REFLEX REFLECTOR 2
7 KL220340 FENDER REAR INNER 1
7A K2221010 FENDER REAR OUTER 1 BSVI
8 KL220350 FENDER REAR OUTER 1
9 P1200060 HEX NUT M6 ZNG (TSDS-0304) 2
10 K200320 SCREW SELF TAPPING 4.2x16 9
11 --- SIDE PANEL L 1 REF. COLOUR
12 K2220300 BRACKET TAIL LAMP 1
12A
12A K2221030 BRACKET CAM SEAT LOCK 1 BSVI
13 K2150200 BRACKET CAM SEAT LOCK 1
14 N3200220 HEX FL BOLT M6x16 ZNG 5
15 K3200840 RETAINER CLIP NUT M6 12
16 M1200060 PUNCHED WASHER 8.5x18x2.3 2
17 --- SIDE PANEL TOP L MATTE BLACK 1 REF. COLOUR
18 420001700 PUNCHED WASHER A6.6 ZNB 2
19 0335928L PUNCHED WASHER 6.5x18x1.6 4
20A 20 KL220360 UTILITY BOX 1
20A K2221020 UTILITY BOX 1 BSVI
21 M1200480 HEX FLANGE BOLT M8x25 2
22 N3200340 CRR FLANGED PAN HD TAP SCREW ST4.2x13 1
23 KL220380 LID UTILITY BOX 1
24 7130020 CLIP NUT ST4 1
PANEL SIDE LH,RH & REAR ASSY. 25 KA220740 HOLDER UTILITY BOX 1
26 N4221270 RUBBER TOOL BOX 1
FIG.NO. 26 COVER & TAIL LAMP ASSEMBLY FIG.NO. 26

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC
1 K2220730 DEFLECTOR FUEL TANK 1
2 K200320 SCREW SELF TAPPING 4.2x16 4
3 K2160150 CORD SET LAMP LIC PLATE 1
4 KL220310 COVER TAIL LAMP 1
5 KL220430 TURN SIGNAL LAMP REAR R 1
6 0330328 WAVE SPRING WASHER M10 2
7 0334038 HEX NUT M10 8 ZNB 2
8 K3200840 RETAINER CLIP NUT M6 6
9 420302700 HEX NUT M5 8 ZNB 3
10 0335528 PUNCHED WASHER 10.5x18x1.6 2
11 N4160320 BULB 1
12 KL220450 TAIL LAMP ASSY. 1
13 K2220120 NUMBER PLATE LAMP 1
14 M7160120 REFLEX REFLECTOR 1
15 0332275 SCREW CRPH M6x16 4
16 KL220440 TURN SIGNAL LAMP REAR L 1
17 0335608 PUNCHED WASHER 6.5x16x1.2 3
18 N7201300 SNAP REVIT PALSTIC 2
19 N9162650 BULB 12V 10W 2
20 K2150190 CORD SET RH TSL 1
21 K2160180 CORD SET LH TSL 1
22 K6170160 CABLE SEAT LOCK 1
23 K2170030 CABLE FUEL TANK 1
24 R3320350 CAM SEAT LOCK KIT 1
29 25 K2150240 SEAT LOCK ASSY. 1
26 N7160620 CABLE STRAP 1
27 N4221120 PAD CUSHION 86 * 20 1
TAIL LAMP & REAR FENDER ASSY 28 R3220650 CUSHION RC LAMP 3
29 K6222470 LOGO TVS 3D 2
FIG.NO. 27 WIRING HARNESS & ELECTRICAL ASSY. FIG.NO. 27

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
NO. NO. DRUM/DISC
1 K3160190 BEEPER 1
9A 9B
2 K3200900 CRR PAN HEAD TAPPING SCREW ST4.2x32 1
3 K6160340 MAINTENANCE FREE BATTERY CHARGED 1
4 N9160380 ELECTRONIC FLASHER UNIT 1
5 R2160100 RELAY STARTER MOTOR 1
6 G5200400 PUNCHED WASHER 8.5 x 20 x 2 1
18A 7 G5200380 HEX SCREW M8x 20 1
8 K2160210 HORN ASSY 1
9 K2160040 WIRING HARNESS 1 DISC
9A K2160090 WIRING HARNESS BASIC 1 DRUM
9B K2160280 WIRING HARNESS 1 RACE ED.
10 K2060030 COMBINED IDI & IGNITION COIL 1
11 N7202070 HOLE CLIP 6 1
12 N7160740 CLAMP WIRING HARNESS 1
13 N7160620 CABLE STRAP 8
14 K4160200 NON CONTACT SWITCH UTILITY BOX 1
15 N3200340 CRR FLANGED PAN HD TAP SCREW ST4.2x13 2
30 16 K4160180 UTILITY BOX LIGHT CUM CHARGER 1
17 M1200520 HEX FL BOLT M6x16 1
18 R4060030 REGULATOR CUM RECTIFIER 1
18A K2060070 REGULATOR CUM RECTIFIER 1 RACE ED.
19 M1200510 HEX FLANGE BOLT M6x25 1
20 420001700 PUNCHED WASHER A6.6 1
21 S1125320 CLAMP OIL HOSE No.2 1
22 K3160710 SENSOR LEAD WIRE 1
23 K2150100 LOCK SET 1
24 K2150170 KEY BLANK 1
25 K3060260 THERMAL SENSOR 1
26 N3060150 SUPPRESSOR CAP 1
WIRING HARNESS & ELECTRICAL ASSY. 27 R1060200 SEAL HT CORD 1
28 K2060040 GROMMET SPARK PLUG 1
29 N3060410 SEAL SPARK PLUG 1
30 KA160340 CONTROL UNIT PLUS 1 RACE ED.
FIG.NO. 27A WIRING HARNESS & ELECTRICAL ASSY. - BSVI FIG.NO. 27A

NO.OFF
REF PART DESCRIPTION NTORQ
17
NO. NO. DRUM/DISC
22
21 1 K2160350 WIRING HARNESS EFI 1 BSVI
15 12
16 1A K2160370 WIRING HARNESS 1 BSVI, RACE ED.
13 2 --- MAINTENANCE FREE BATTERY CHARGED 1
25
3 K2060110 IGNITION COIL ASSY 1 BSVI
10
4 0332275 SCREW - CRPH M6x16 6.8 ZNK 2
18 11 5 K2160210 HORN ASSY 1
14
9 6 G5200400 PUNCHED WASHER 8.5 x 20 x 2 1
7 G5200380 HEX SCREW M8x 20 1
7 8 K3160190 BEEPER 1
9 K3200900 CRR PAN HEAD TAPPING SCREW ST4.2x32 1
5 10 K2060130 ECU UNIT BASIC 1 BSVI
6
8 11 KA160410 BOOT ECU 1 BSVI
12 KA160420 BOOT CONTROL RELAY 1 BSVI
15A
13 NF160590 CONTROL RELAY EFI 1 BSVI
19 14 R2160100 RELAY STARTER MOTOR 1
1A 15 K2060120 REGULATOR CUM RECTIFIER EFI 1 BSVI
2 15A K2060150 REGULATOR CUM RECTIFIER LED 1 BSVI, RACE ED.
1
16 M1200520 HEX FL BOLT M6x16 2
17 K6161230 CORD SET DIAGNOST COUPLER 1 BSVI
4
18 N9160380 ELECTRONIC FLASHER UNIT 1
19 N7160620 CABLE STRAP 19
20
20 N7202070 HOLE CLIP 6 16
3 21 K4160180 UTILITY BOX LIGHT CUM CHARGER 1
22 K4160200 NON CONTACT SWITCH UTILITY BOX 1
23 K2150100 LOCK SET 1
24 K2150170 KEY BLANK 1
WIRING HARNESS & ELECTRICAL ASSY. 25 N3200340 CRR PAN HD TAP SCREW ST4.2x13 2 BSVI
FIG.NO. 28 DISC BRAKE ASSEMBLY FRONT FIG.NO. 28
2A 5A 7A 8A
4A 10A
NO.OFF
35A
REF. PART DESCRIPTION NTORQ REMARKS
37A 40A
NO. NO. DRUM/DISC REF. KIT

1A 34A 38A 1 --- LEVER COMP 1 R1320240

1A --- LEVER COMP 1 K6322350 - SBT
36A 2 --- BOOT PISTON 1 K6322010
2A --- BOOT PISTON 1 K6322330 - SBT
3 --- CIRCLIP 1 "
4 --- S CUP 1 K6322010
45 12A 11A
4A --- S CUP (SBT) 1 K6322330 - SBT

15A
5 --- GUAGE COMP LEVEL 1 K6322020
44
43 5A --- GUAGE COMP LEVEL (SBT) 1 K6322340 - SBT
6 --- O RING 1 "
41 42 7 --- HAND LEVER BOLT 1 R1320240
7A --- HAND LEVER BOLT (SBT) 1 K6322350 - SBT
8 --- SCREW RESERVOIR CAP 2 K6321980
8A --- SCREW RESERVOIR CAP (SBT) 2 K6322300 - SBT
9 --- DIAPHRAGM 1 "
10 --- HOLDER BOLT 2 K6322000
10A --- HOLDER BOLT (SBT) 2 K6322320 - SBT
11 --- HOLDER 1 K6322000
11A --- HOLDER 1 K6322320 - SBT
12 --- SWITCH 1 K6321990
12A --- SWITCH (SBT) 1 K6322310 - SBT
13 --- SUB HARNESS 1 "
14 --- SCREW & WASHER 1 "
15 --- FLANGE NUT 1 R1320240
15A --- FLANGE NUT (SBT) 1 K6322350 - SBT
16 --- PIN BOLT A 1 K6321880
17 --- BRKT COMP FRONT 1 "
18 --- COTTER PIN 2 K6321860
DISC BRAKE ASSEMBLY FRONT 19 --- SPRING WASHER 1 K6321880
20 --- PAD COMP. OUTER 1 K6321900
FIG.NO. 28 DISC BRAKE ASSEMBLY FRONT FIG.NO. 28

NO.OFF
REF. PART DESCRIPTION NTORQ REMARKS
5A 7A 8A NO. NO. DRUM/DISC REF. KIT
2A
4A 10A
35A
21 --- PAD COMP. INNER 1 "
22 --- PLUG PIN 1 K6321880
37A 40A
23 --- SPRING PLATE 1 K6321860

1A 34A 38A 24 --- BUSH BOOT PIN 1 K6321890

25 --- PAD SPRING 1 K6321860
36A 26 --- BLEEDER 1 K6321910
27 --- CAP BLEEDER 1 "
28 --- PIN HANGER 1 K6321860

11A
29 --- BOOT B 1 K6321890
12A
30 --- DUST SEAL 1 K6321870
45 44 15A 31 --- SEAL PISTON 1 "
43 32 --- PIN BOLT B 1 K6321880

42 33 --- PISTON CALIPER 1 K6321860

41
34 --- SPRING 1 K6322020
34A --- SPRING 1 K6322340 - SBT
35 --- RESERVOIR CAP 1 K6321980
35A --- RESERVOIR CAP 1 K6322300 - SBT
36 --- PISTON M/C FRONT 1 K6322020
36A --- PISTON M/C FRONT 1 K6322300 - SBT
K6322340
37 --- P CUP 1 K6322010
37A --- P CUP 1 K6322330 - SBT
38 KA110010 MASTER CYLINDER ASSY. 1
38A K2110300 MASTER CYLINDER ASSY. 1 SBT
39 M7110330 BANJO BOLT 2
40 --- PROTECTOR 1 K6322020
40A --- PROTECTOR 1 K6322340 - SBT
41 K6111470 CALIPER DISC BRAKE ASSY. 1
42 K2110180 HOSE COMP BRAKE 1
DISC BRAKE ASSEMBLY FRONT 43 N9111330 WASHER BANJO 4
44 K6322380 KIT LEVER SPRING COMP 1 SBT
45 U2200010 HEX FLANGED BOLT M8x27 1 "
FIG.NO. 29 TOOLKIT ASSEMBLY FIG.NO. 29

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

1 K6210090 TOOL KIT - WEGO/JUPITER 1

2 --- TOOL BAG 1
3 --- BIT (+) ( - ) 1
4 --- GRIP DRIVER 1
5 --- RING SPANNER 1

6 K2320260 PARTS CATALOGUE NTORQ 1

TOOLKIT ASSEMBLY