Platina 100ES - BS IV
Platina 100ES - BS IV
Platina 100ES - BS IV
We have pleasure in presenting the Spare Parts Catalogue for 1. How to Read the Catalogue : Open the catalogue and from the pictorial
‘PLATINA 100 ES (BS IV + AHO) & KS’ Motorcycle. This catalogue has been index locate the group in which the part you want to find is present.
Turn over to the concerned page number (as given by pictorial index).
specially designed to assist you in selecting the correct parts for procurement
Now find out the figure of the part you wish to order. Write down the
to maintain 100% availability. part number against that particular figure number from the text.
In case, if you have the part number and you need the other details, the
The Bajaj spares are subjected to the stringent quality control standards to part index can be used. The part index (at the end of the catalogue) will
ensure longer life of the vehicle. It is therefore necessary that only the give you the figure and page number of the part you wish to order.
Genuine Bajaj Spares are used.
2. How to Order Spare Parts : The part number and the description of the
part required should be invariably mentioned in the order as per the
In a continual effort to improve Performance and Efficiency of the vehicles, catalogue text.
Specifications, Diagrams, Illustrations and Part Numbers can change without
The latest part number as conveyed through our service circulars should
notice. Consequently, the description in this Spare Parts Catalogue cannot only appear on the order. In case of ordering painted components,
therefore be final and binding on us. colour shade of the components should be mentioned.
The quantity shown against the part number is the quantity per vehicle
The modifications / alterations which are carried out after the issue of this for that group so that particular quantity should be multiplied by the
catalogue, will be conveyed to you through our Service Circulars. You are number of sets required.
requested to make necessary corrections in the Parts Catalogue as per the
3. Part Number System : We have used 8 digit system for part numbers.
circulars so as to keep your catalogue up-to-date. This will ensure the The model or hardware item is indicated by first two digits or
appropriate and speedy delivery of the Spare Parts as the order placed will alphanumeric, the next two or four digits indicate main group and the last
bear the latest part numbers. four or two digits indicate serial number in main group or serial number
or subgroup of fastener respectively. Thus the part numbers will be
indicated by 2-2-4 or 2-4-2 digit system. Understanding this system will
In case, if you need any technical assistance contact the concerned Regional enable you to identify the spare parts easily.
Office or write to us on the following address :
4. Abbreviations : The following abbreviations are used in this catalogue.
Assly Assembly V Volts
Bajaj Auto Limited
N.I. Not illustrated W Watts
Service Department
C'case Crankcase Accl. Accelerator
Akurdi, Pune 411 035 India
Cyl Cylinder Comp. Complete
O/s Over size Fr. Front
Fax : 020-27407385 RR Rear Std. Standard
L Length A/t. Alternate
R.H. Right hand L.H. Left hand
Hex. Hexagonal AR As required
Revision No. & Change Details BS IV Revision No. & Change Details BS IV
A: Add A: Add
REV. NO., PART SR. PAGE D: Delete Reason for change REV. NO., PART SR. PAGE D: Delete Reason for change
SHORT DESCRIPTION QTY. SHORT DESCRIPTION QTY.
MM YY NUMBER NO. NO. C: Change MM YY NUMBER NO. NO. C: Change
01 JAN 15 DG121040 Clamp 1 8 2 C In place of DG121025 KADF0625 Bolt Hex 4 2 54 C Changed from LAD00113
LAJ00002 Stud 2 6 4 C In place of JA511028 KADF0610 Bolt Flanged 1 7 54 C Changed from KADA0610
39260801 O-Ring 1 4 4 C Qty changed from 3 to 1 31151021 Coupling Rubber 4 6 62 C Change in qty
PA521214 Snap Ring 2 6 10 C Changed from JB521211 PF151015 Handle Bar 1 2 66 C Changed from Jz151070
JA551008 Washer Thrust 1 15 14 C Changed from JA551208 DS141009 Cap Fuel Tank 1 1 72 C Changed from Jz171004
JA561002 Cam Drum Change 1 5 16 C Changed from JD561002 JZ171829 Tube Fuel 1 10 72 C Changed from Jl171035
BF561219 Bolt 1 4 18 C Changed from 39081715 DU161119 Screw 2 10 74 A Added
PA561207 Step Washer 1 7 18 D Deleted KBCC0514 Screw 1 5 78 A Added
39245304 Bolt 1 9 18 C Changed from BF561219 KADC0610 Bolt 2 3 80 C Changed from 39150811
JA541011 Needle Roller Bearing 1 3 20 C Changed from 39256220 39150811 Washer 2 6 80 A Added
52JA0027 Stud 1 10 20 D Deleted KCGD0606 Nut Hex 5 7 86 C Change in qty.
JA541235 Bolt 1 11 20 C Changed serial no. KADA0610 Bolt 2 18 86 C Added
JE541028 Pin 1 12 20 C Changed serial no. 39106204 Bolt - Earing cable 1 18 88 A Added
59040038 Bolt Flanged 8 12 22 C Change in qty. LAD00127 Bolt 1 19 88 A Added
59040038 Bolt Flanged 9 2 30 C Change in qty. KADF0816 Bolt 4 2 92 C Change in qty.
PF541251 Gear Shift Label 1 9 30 C Change in serial no. LAD00001 Bolt Flanged 1 3 92 D Deleted
JD551400 Spacer Clutch Assly 1 11 32 D Deleted LCG00001 Nut Hex 1 4 92 D Deleted
JA551420 Washer Plain 1 12 32 C Change in serial no. PF231413 Grab handle 1 9 92 D Deleted
39100120 Bearing Ball 1 13 32 C Change in serial no. KACA0822 Bolt 4 10 92 C Change in serial no.
JA531007 Nut Crankshaft 1 14 32 C Change in serial no. PF111092 Cap Tube End 2 8 48 A
JE551409 Washer 1 15 32 C Change in serial no. PF111096 Cap for Tube End 1 9 48 A
PF581052 Tube Connecting 1 6 36 C Changed from PF581050 JZ111292 Frame Tape 1 10 48 A
DG121040 Clip 1 11 36 C Changed from DG121025 02 APR 15 PF111060 Frame Assembly 1 1 48 C Changed from Pf111100
DG121025 Clip 1 13 36 C Changed from DG121040 PF161013 Pipe Throttle 1 22 66 D Deleted
LAD00001 Bolt Flanged 3 3 46 C Changed from LAD00002 PA621005 Gear Kick Pinion 1 7 26 C Changed from Pf621004
LAD00121 Bolt Flanged 1 4 46 C Changed from LAD00001 --- --- -- -- -- -- Addition of KS & Silver colour parts
30181011 Nut Fork 1 2 48 C Changed from DH181056 03 JUN 16 30141039 Packing Fuel Cock 1 19 72 A
39093915 Nut Hex 1 16 50 C Changed from Jk122008 Platina Upgrade Models Parts added.
KDCB0816 Washer Spring 2 6 52 C Change in qty. 04 JAN 17 BS IV + AHO Parts added
Index BS IV Index BS IV
Plate No. Description Page No. Plate No. Description Page No.
1 Cover Cylinder Head 2 31 Tyre/ Tube / Rim 62
2 SAI System 4 32 Front Hub 64
3 Cylinder Head 6 33 Rear Hub 66
4 Valve 8 34 Rear Brake Pedal 68
5 Camshaft / Tensioner 10 35 Handle Bar Assly 70-72
6 Cylinder and Piston 12 36 Front Fork 74
7 Crankshaft 14 37 Petrol Tank, Cap Tank & Gauge Fuel 76
8 Transmission 16 38 Fittings - Side Cover & Cover Seat 78
9 Change Drum / Shift Fork 18 39 Meter Assly 80
10 Gear Change Mechanism 20 40 Control Cables 82
11 Engine Assly / Crankcase RH 22 41 Chain Case 84
12 Crankcase LH 24 42 Head Lamp & Fairing 86
13 Oil Pump 26 43 Indicator Light Assly 88
14 Kick Starter Mechanism 28 44 Tail Lamp Assly / Front No. Plate 90
15 Cover Clutch 30 45 Electrical Equipments 92
16 Cover Magneto 32 46 Tool Kit 94
17 Clutch Assly 34 47 Accessories / Grab Handle 96
18 Carburettor Assembly 36 48 Painted Parts & Decals 98-102
19 Air Cleaner Complete 38
20 EVAP Mechanism 40 Kits List 103-107
21 Silencer Assly 42
22 Starter Assly 44 Part Index 108-120
23 Magneto, C.D.I. & H.T. Coil 46
24 Seat Assly / Seat Lock 48
25 Engine Mountings 50
26 Frame and Frame Fitting 52
27 Swing Arm/Rear Shock Absorber 54
28 Foot Rest - Rider / Pillion 56
29 Mudguard- Front & Rear 58
30 Stand Assembly 60
Pictorial Index BS IV Pictorial Index BS IV
PLATE NO. : 1 PAGE NO. PLATE NO. : 2 PAGE NO. PLATE NO. : 5 PAGE NO. PLATE NO. : 6 PAGE NO.
COVER CYLINDER HEAD 1 SAI SYSTEM 3 CAMSHAFT / TENSIONER 9 CYLINDER & PISTON 11
PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
CYLINDER HEAD 5 VALVE 7 CRANKSHAFT 13 TRANSMISSION 15
Pictorial Index BS IV Pictorial Index BS IV
PLATE NO. : 9 PAGE NO. PLATE NO. : 10 PAGE NO. PLATE NO. : 13 PAGE NO. PLATE NO. : 14 PAGE NO.
CHANGE DRUM / SHIFT FORK 17 GEAR CHANGE MECHANISM 19 OIL PUMP 25 KICK STARTER MECHANISM 27
PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO. PLATE NO. : 15 PAGE NO. PLATE NO. : 16 PAGE NO.
ENGINE ASSLY & CRANKCASE RH 21 CRANKCASE LH 23 COVER CLUTCH 29 COVER MAGNETO 31
N
1
2
3
4
Pictorial Index BS IV Pictorial Index BS IV
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
CLUTCH ASSLY 33 CARBURETTOR 35 SILENCER ASSLY 41 STARTER ASSLY 43
PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
AIR CLEANER COMPLETE 37 EVAP MECHANISM 39 MAGNETO, C.D.I. & H.T. COIL 45 SEAT ASSLY / SEAT LOCK 47
Pictorial Index BS IV Pictorial Index BS IV
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO. PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
ENGINE MOUNTINGS 49 FRAME & FRAME FITTINGS 51 MUDGUARD- FRONT & REAR 57 STAND ASSEMBLY 59
PLATE NO. : 27 PAGE NO. PLATE NO. : 28 PAGE NO. PLATE NO. : 31 PAGE NO. PLATE NO. : 32 PAGE NO.
SWING ARM/REAR SHOCK ABSORBER 53 FOOT REST - RIDER / PILLION 55 TYRE/ TUBE / RIM 61 FRONT HUB 63
Pictorial Index BS IV Pictorial Index BS IV
PLATE NO. : 38
PLATE NO. : 33 PAGE NO. PLATE NO. : 34 PAGE NO. PLATE NO. : 37 PAGE NO. PAGE NO.
FITTINGS - SIDE COVERS &
REAR HUB 65 REAR BRAKE PEDAL 67 P.TANK, CAP TANK & GAUGE FUEL 75 77
SEAT COWL
PLATE NO. : 35 PAGE NO. PLATE NO. : 36 PAGE NO. PLATE NO. : 39 PAGE NO. PLATE NO. : 40 PAGE NO.
HANDLE BAR ASSLY 69-71 FRONT FORK 73 METER ASSEMBLY 79 CABLES 81
Pictorial Index BS IV Pictorial Index BS IV
PLATE NO. : 41 PAGE NO. PLATE NO. : 42 PAGE NO. PLATE NO. : 45 PAGE NO. PLATE NO. : 46 PAGE NO.
CHAIN CASE 83 HEAD LAMP & FAIRING 85 ELECTRICAL EQUIPMENTS 91 TOOL KIT 93
PLATE NO. : 44
PLATE NO. : 43 PAGE NO. PAGE NO. PLATE NO. : 47 PAGE NO. PLATE NO. : 48 PAGE NO.
TAIL LAMP ASSEMBLY /
INDICATOR LIGHT ASSEMBLY 87 89 ACCESSORIES / GRAB HANDLE 95 PAINTED PARTS AND DECALS 97-101
NUMBER PLATE
BS IV Brand ID: 001MC667 Plate No.: 1
Cover Cylinder Head
Qty.
No. Part No. Description Remarks
(ES) (KS)
1
1 JV 5110 13 Cover Cylinder Head Complete 1 1 With Gasket
2 8
2 59 0400 38 Flanged Bolt 4 4
7 3 JV 5110 12 Gasket Cylinder Head Cover 1 1
4 JV 5110 11 Plate Cylinder Head 1 1
5 JB 5110 11 Bolt Head Mounting 4 4
1 2
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 2
SAI System
Qty.
No. Part No. Description Remarks
(ES) (KS)
12
13
10 12
14
3 4
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 3
Cylinder Head
Qty.
No. Part No. Description Remarks
(ES) (KS)
8 12
5 6
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 4
Valve
Qty.
No. Part No. Description Remarks
(ES) (KS)
7 8
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 5
Camshaft / Tensioner
Qty.
1 No. Part No. Description Remarks
(ES) (KS)
5
8 DS 1099 05 Cam Chain 94 Links 1 1
9 36 PF00 61 Kit Chain Guide 1 1 Refer Kit List
10 DH 1013 92 Tensioner Pivot Bolt 1 1
8
11 CS 1011 28 Gasket 1 1
12 JE 5210 16 Chain Tensioner 1 1
13 JA 5210 19 Bolt 2 2
14 39 2669 21 Ring - ‘O’ (ID 10.15X1.5) 1 1
12
9 10 13
11
14
3
9 10
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 6
Cylinder and Piston
Qty.
No. Part No. Description Remarks
(ES) (KS)
4 5
3 6
11 12
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 7
Crankshaft
Qty.
No. Part No. Description Remarks
(ES) (KS)
5 7
9
8
2 4
2
3
13 14
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 8
Transmission
Qty.
No. Part No. Description Remarks
(ES) (KS)
15 16
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 9
Change Drum / Shift Fork
Qty.
No. Part No. Description Remarks
(ES) (KS)
17 18
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 10
Gear Change Mechanism
Qty.
No. Part No. Description Remarks
(ES) (KS)
10
10
11 11
19 20
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 11
Engine Assembly / Crankcase RH
Qty.
No. Part No. Description Remarks
(ES) (KS)
10
1 PF 5010 37 Engine Assembly - ES 1 –
PF 5010 58 Engine Assembly - ES 1 -- Comfortec (June 16)
1A
2 PF 5010 45 Engine Assembly - ES 1 -- Model BS IV
PF 5010 40 Engine Assembly - KS – 1
PF 5010 71 Engine Assembly - KS -- 1 Comfortec (June 16)
5 1A PF 5410 31 Assembly C’Case RH 1 1 Refer Kit List
4
2 PF 5410 18 Bushing Drum 1 1
3 JA 5410 11 Needle Roller Bearing 1 1
4 59 2000 36 Bearing - Ball 6203 HN3 C3 1 1
5 JA 5410 10 Stopper plate input bearing 1 1
6
11
11 JE 5410 28 Pin 1 1
3
9
8
21 22
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 12
Crankcase LH
Qty.
No. Part No. Description Remarks
(ES) (KS)
23 24
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 13
Oil Pump
Qty.
No. Part No. Description Remarks
(ES) (KS)
25 26
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 14
Kick Starter Mechanism
Qty.
No. Part No. Description Remarks
(ES) (KS)
1
1 PF 6210 03 Kick Shaft 1 1
2 JA 6210 06 Washer Thrust 1 1
3 39 0738 17 Circlip 2 2
4 DS 1011 17 Spring Kick Starter Ratchet 1 1
7 5 JA 6210 02 Ratchet 1 1
2
8
3
3 6 39 0993 11 Washer Plain 3 3
4 7 PA 6210 05 Gear Starter Pinion 1 1
5 8 39 2408 17 External Circlip 1 1
6
9 JE 6210 03 Spring Kick Return 1 1
6 12
6 9A JE 6210 04 Sleeve 1 1
10 JA 6212 01 Assembly Kick Lever 1 1
PF 6212 00 Assembly Kick Lever 1 1 Comfortec (June 16)
9A
11 14
27 28
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 15
Cover Clutch
Qty.
No. Part No. Description Remarks
7 (ES) (KS)
10
PF 5412 54 Cap Filter 1 1 Comfortec (June 16)
8 DD 1211 81 Element Oil Filter 1 1
1 9 PF 5514 07 Rod-Push 1 1
10 39 1041 19 Seal - Oil 1 1
29 30
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 16
Cover Magneto
Qty.
No. Part No. Description Remarks
(ES) (KS)
3
N
1
2
3
4
2
8
31 32
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 17
Clutch Assly
Qty.
No. Part No. Description Remarks
(ES) (KS)
33 34
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 18
Carburetor Assembly
Qty.
No. Part No. Description Remarks
(ES) (KS)
11
10
35 36
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 19
Air Cleaner Complete
Qty.
No. Part No. Description Remarks
(ES) (KS)
4 2
1 PF 5810 38 Assembly Air Filter 1 1
10 PF 5810 55 Assembly Air Filter With SAI 1 -- BS IV
2 PF 5810 45 Assly Catridge 1 1
3 PF 5810 44 Foam Element Air Filter 1 1
11 4 PF 5810 46 Arrester Flame 1 1
5 PF 5810 40 Cover Side 1 1
5
11 DG 1210 40 Clip 1 1
12 DS 1211 26 Pug 1 1
13 DG 1210 25 Clip 1 1
16
14 DH 1210 38 Clamp 1 1
8 15 PA 5810 53 Top Cove Screw 5 5
37 38
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 20
EVAP Mechanism
Qty.
No. Part No. Description Remarks
(ES) (KS)
1 JY 1710 77 Canister 1 --
2 JY 1710 90 Spring Band Clamp 13 x 12 6 --
3 PF 1710 35 Tube Inline To Purge Valve 1 --
4 JH 1710 48 Grommet Purge Valve 1 --
19
5 PD 1716 16 Valve Purge 1 --
13
2
6 JG 1710 29 Spring Band Clamp 11.5 x 8.4 1 --
2
4 3 7 PF 1710 36 Tube Purge Valve To Carburetor 1 --
5 12 8 JY 1710 70 Spring Band Clamp 9 x 8.4 3 --
6
9 PF 1710 34 Tube T Connector To Canister 1 --
7 2 8 9
10 JY 1138 42 Connector Y Shape 1 --
8
1
2 11
11 PF 1710 33 Tube Inline To T Connector 1 --
16
12 JG 1710 86 Connector Tube 1 --
10
8 13 PF 1710 32 Tube Tank To Inline Connector 1 --
17
2 14 JH 1710 19 Tube Drain 1 --
18 15 JY 1718 25 Plug Fuel Drain 1 --
14
20
16 JY 1710 69 Spring Band Clamp 15 x 10 1 --
2 17 JH 1710 24 Tube Breather Canister 1 --
18 JH 1710 25 Tube Canister Drain 1 --
15
19 JG 1710 29 Spring Band Clamp 11.5 X 8.4 1 --
20 JZ 1710 55 Strap Canister 1 --
39 40
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 21
Silencer Assembly
Qty.
No. Part No. Description Remarks
(ES) (KS)
8
9
41 42
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 22
Starter Assembly
Qty.
No. Part No. Description Remarks
(ES) (KS)
43 44
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 23
Magneto, CDI & H.T. Coil
Qty.
No. Part No. Description Remarks
2 5 1 3 (ES) (KS)
45 46
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 24
Seat Assembly / Seat Lock
Qty.
No. Part No. Description Remarks
(ES) (KS)
2 3
47 48
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 25
Engine Mountings
Qty.
No. Part No. Description Remarks
(ES) (KS)
5
2 6
5
1A
1
3
49 50
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 26
Frame and Frame Fittings
Qty.
No. Part No. Description Remarks
(ES) (KS)
3
7
10
6
9
51 52
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 27
Swing Arm / Rear Shock Absorber
Qty.
No. Part No. Description Remarks
(ES) (KS)
12
53 54
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 28
Foot Rest - Rider / Pillion
Qty.
1 2 Description
No. Part No. Remarks
(ES) (KS)
11
11 30 1710 22 Pin 2 2
12 39 0784 08 Pin Split 2 2
13 JK 1130 08 Rubber Pillion Step 2 2
14 DP 1611 70 Step (Pillion Footrest) 2 2
15 KA DD08 22 Bolt Flanged 2 2
13
10
12 16 PF 1130 33 Footrest Pillion RH 1 1 Comfortec (June 16)
17 PF 1130 32 Footrest Pillion LH 1 1 Comfortec (June 16)
16 / 17 12
23 21 22 18 PF 1130 44 Plate Pillion Footrest LH 1 1 Comfortec (June 16)
19 PF 1130 45 Plate Pillion Footrest RH 1 1 Comfortec (June 16)
8A / 9A 20 PF 1130 36 Pin Pillion Footrest 2 2 Comfortec (June 16)
20 21 PF 1130 46 Damper Hinge-1 2 2 Comfortec (June 16)
18 / 19 22 PF 1130 47 Damper Hinge-2 2 2 Comfortec (June 16)
23 GL 1810 99 Washer 2 2 Comfortec (June 16)
55 56
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 29
Mudguard - Front & Rear
Qty.
No. Part No. Description Remarks
(ES) (KS)
1
1 PF 1814 23 Fender Brace 1 1
2 KA DF06 25 Bolt Hex With Flange - M8x1.25 4 4
3 DS 1611 25 Guide - Cable 1 1
4 DJ 1610 69 Nail - Cable Guide 1 1
5 PF 1814 24 Fender Rear Front 1 1
PF 1814 29 Fender Rear Front 1 -- BS IV
2
6 PF 1814 22 Fender Rear RR 1 1
7 KA DF06 10 Bolt Flanged 1 1
8 KA DF06 14 Bolt Flanged 2 2
4
3 9 DS 1612 24 Bolt Stepped With Flange 2 2
10 DJ 2011 73 Grommet 2 2
5 8 6
10
9
57 58
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 30
Stand Assembly
Qty.
No. Part No. Description Remarks
(ES) (KS)
3
1 PF 1132 03 Stand Center 1 1
6 1A PF 1132 06 Stand Center 1 1 Comfortec (June 16)
2 JA 1132 02 Stand Side 1 1
PF 1132 07 Stand Side 1 1 Comfortec (June 16)
3 DG 1611 24 Damper Center Stand 1 1
4
4 30 1611 57 Shaft Center Stand 1 1
1 5 DH 1611 21 Spring M-Stand 1 1
JZ 1132 09 Spring Main Stand 1 -- BS IV
5
6 KH AA32 35 Pin - Cotter 1 1
7 DF 1611 02 Bolt For Side Stand Mtg. 1 1
1A
8 DH 1610 66 Spring Side Stand 1 1
9 39 0422 15 Nut - Nyloc 1 1
2
7
59 60
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 31
Tube / Tyre / Rim
Qty.
No. Part No. Description Remarks
(ES) (KS)
1 2
1 JK 1310 37 Wheel Fr 1.4X17 Dia 110 Blk 1 1
3 2 DM 1510 25 Tyre 2.75X17-Front 1 1
3 DS 1510 49 Tube 2.75 X 17 1 1
4 PA 1312 04 Wheel Rr 1.6X17-110 Dr Black 1 1
5 DM 1510 28 Tyre 3X17-Rear 1 1
4 5
6
61 62
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 32
Front Hub
Qty.
No. Part No. Description Remarks
(ES) (KS)
25 21 JA 1316 06 Bushing 1 1
22 JK 1310 16 Stopper For Bushing 1 1
23 39 1013 21 O Ring 1 1
24 JK 1310 19 Washer Spring 1 1
25 JK 1310 18 Screw Pan Cross 1 1
63 64
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 33
Rear Hub
Qty.
No. Part No. Description Remarks
3
(ES) (KS)
9
5 1 JD 1410 03 Drive Chain Lock 1 1
1 4
2 36 PA01 23 Kit Chain Sprocket 1 1 Refer Kit List
3 39 1364 20 Bearing ball C3 Clearance 1 1
4 39 2682 20 Bearing ball C3 Clearance 1 1
2 5 31 1510 18 Collar-Bearing 1 1
25
21 JB 1312 25 Hexagon Nut M18X1.5P 1 1
22 JB 1220 11 Washer Plain 1 1
23 JB 1310 19 Nut - U M12 1 1
11 24 PF 1312 37 Spacer Panel 1 1
25 PF 1312 36 Sleeve Coupling 1 1
26 JK 1312 03 Collar 1 1
65 66
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 34
Rear Brake Pedal
Qty.
No. Part No. Description Remarks
1 (ES) (KS)
2
2 JZ 1610 19 Pad Brake Pedal 1 1
3 DD 1610 78 Damper 1 1
5 4 KD BA08 18 Washer Plain 1 1
3 4
5 KA DF08 16 Bolt Flanged 1 1
12
6 JD 1610 02 Spring Brake Pedal 1 1
7 JD 1610 06 Sleeve Brake Return Spring 1 1
8 PF 1610 06 Brake Rod 1 1
9 30 1910 38 Pin Brake Rod 1 1
10 39 0198 11 Washer - Plain 1 1
13
67 68
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 35
Handle Bar Assly
Qty.
No. Part No. Description Remarks
(ES) (KS)
12
1 JB 4014 00 Control Switch LH 1 1
2 PF 1510 15 Handle Bar 1 1
11 3 39 1074 04 Bolt - Flanged 4 4
25
4 FD 1810 30 Holder Handle Upper 2 2
5
3 5 PF 4014 17 Control Switch RH-ES 1 --
DZ 2010 44 Control Switch RH-KS -- 1
4 25A JZ 4014 08 Control Switch RH-ES 1 -- BS IV
69 70
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 35
Handle Bar Assly
Qty.
No. Part No. Description Remarks
(ES) (KS)
12
21 PF 1610 07 Grip Assy RH 1 1
22 PF 1610 13 Pipe Throttle 1 1 Deleted
11 23 39 1912 04 Bolt Flange 2 2
25
24 JD 4022 17 Band 2 2
5
3 25 DX 1910 09 Lever Assembly RH 1 1
PF 1610 11 Assembly Lever Holder RH 1 1 Comfortec (June 16)
4 25A 25A DD 1911 42 Lever - Grip :- Right 1 1
7 13
10 22
13
14 21
16
24
17
9
15
26 18
20
23
71 72
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 36
Front Fork
Qty.
No. Part No. Description Remarks
(ES) (KS)
73 74
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 37
Petrol Tank, Cap Tank and Gauge Fuel
Qty.
No. Part No. Description Remarks
(ES) (KS)
1 2
1 DS 1410 09 Cap Fuel Tank 1 1
3 PF 1716 01 Cap Fuel Tank 1 -- BS IV
13 2 AP 1012 55 Screw Pan Cross - M5 2 2
14 18
3 39 2179 24 Washer 2 2
4 30 1410 32 Bolt 4 4
16 5 DZ 2010 02 Tank Unit 1 1
15 17
10
6 30 1410 28 Gasket 1 1
11
JH 1710 17
12 7 DZ 1410 40 Fuel Cock Assy 1 1
8 39 0740 11 Washer(Non Metallic) 2 2
9 DD 1412 27 Bolt - Flanged 2 2
10 JZ 1718 29 Tube Fuel (Tank) 1 1
20
21 11 33 1410 08 Clamp 2 2
22 12 DZ 1410 75 4 Hole Washer 1 1
13 DP 1410 20 Pad Seat Lab 1 1
9 14 DG 1410 19 Damper 1 1
15 30 2110 05 Collar 2 2
75 76
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 38
Fittings - Side Covers & Seat Cowl
Qty.
No. Part No. Description Remarks
(ES) (KS)
5 6 7
77 78
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 39
Meter Assembly
Qty.
No. Part No. Description Remarks
(ES) (KS)
2 1
1 PF 1812 14 Flap Speedometer 1 1
3 2 KB UA06 16 Screw Truss 3 3
3 KD BA06 13 Washer Plain 3 3
4 PF 4024 12 Speedometer Assembly 1 1
5 5 YP F080 10 Speedometer With Dial Minda 1 1
YP F080 17 Speedometer With Dial Pricol 1 1
13 14
Lamp
12
79 80
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 40
Cables
Qty.
No. Part No. Description Remarks
(ES) (KS)
81 82
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 41
Chain Case
Qty.
No. Part No. Description Remarks
(ES) (KS)
6 39 1508 11 Washer 2 2
6
3
6
3
83 84
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 42
Head Lamp & Fairing
Qty.
No. Part No. Description Remarks
(ES) (KS)
2A
11 PF 1812 39 Bracket Fork Side 1 1
2
12 PF 1812 36 Bracket Fairing Upper Pivot 1 1
3 13 CL 2010 23 Lamp 12V 35X35W 1 1
13 14 DU 2011 10 Cap Dust 1 1 N.I.
15 DU 2011 11 Clamp Wire For H/L 1 1 N.I.
4
11
6
6
6
85 86
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 43
Indicator Light Assembly
Qty.
No. Part No. Description Remarks
(ES) (KS)
7
1
87 88
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 44
Tail Lamp Assly / Number Plate
Qty.
No. Part No. Description Remarks
(ES) (KS)
3 6 DP 2010 44 Washer 3 3
14 7 KC GD06 06 Nut Hex Flanged 3 5
8 DJ 1610 72 Bracket-Rear Number Plate 1 1
13
9 DP 1611 45 Plate -No.:RR1 1 1
10 JZ 2328 05 Foam Rear Number Plate 1 1
18
10
89 90
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 45
Electrical Equipments
Qty.
No. Part No. Description Remarks
5 (ES) (KS)
6
1 JZ 4016 00 DC Horn 1 1
2 KA DD08 14 Bolt Flanged 1 1
3 PA 4018 10 Battery 3Ah VRLA 1 -- Not Supplied in spares
7 31 2010 27 Battery -- 1
4 DS 2010 25 Assy D C Flasher 1 1
2 4A JL 4020 04 Light Control Module 1 -- BS IV (AHO)
4A 5 JN 3516 04 Starter Relay-with Grommet 1 1
1
4
6 PF 4022 24 Cable Assy St Relay-Motor 1 1
7 PF 4022 23 Cable Assy Battery-Earth 1 1
8 8 PF 4022 20 Harness Wiring - ES 1 --
PF 4022 29 Harness Wiring - ES 1 -- Comfortec (June 16)
PF 4022 18 Harness Wiring - KS -- 1
11 10
9 / 10 PF 4022 37 Harness Wiring - ES 1 -- BS IV (AHO)
9 60 1114 05 Cable Tie Lk-Rlsbl 1 1
10 JD 4022 17 Band (L 150) 2 2
91 92
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 46
Tool Kit
Qty.
No. Part No. Description Remarks
(ES) (KS)
93 94
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 47
Accessories / Grab Handle
Qty.
No. Part No. Description Remarks
(ES) (KS)
6 39 1540 11 Washer 1 1
7 KA CA08 22 Bolt Master KAC 4 4
8 PF 2312 05 Pad Saree Gaurd 1 1 Comfortec (June 16)
3
3A
6
3
4
95 96
Front Wheel Direction
BS IV Brand ID: 001MC667 Plate No.: 48
Painted Parts and Decals
Qty.
No. Part No. Description Remarks
(ES) (KS)
97 98
BS IV Brand ID: 001MC667 Plate No.: 48
Painted Parts and Decals
Qty.
No. Part No. Description Remarks
(ES) (KS)
99 100
BS IV Brand ID: 001MC667 Plate No.: 48
Painted Parts and Decals
Qty.
No. Part No. Description Remarks
(ES) (KS)
101 102
Kit List BS IV Kit List BS IV
1. 36PF0044 Kit Asly Cyl Head-Pl B104D PF511054 Cylinder Head Complete B104D 1 PF511205 Valve Exhaust B104D 1
JA511028 Stud M8X1.25X45L 1
39262921 O-Ring 1 9. 36PF0062 Piston Ring Set JB521207 Ring Compresion Top 1
39128321 O Ring 2 PF521215 Ring Compresion 2Nd 1
PF521204 Ring Oil Control 1
2. 36PF0045 Kit Block Piston B104D PF521022 Cylinder Block B104D 1
PF521210 Assembly Piston B104D 1 10. 36PF0049 Kit Fairing Dcl-C Red PF233027 Fairing Decal Lh Candy Red 1
PF233028 Fairing Decal Rh Candy Red 1
3. 36PF0046 Clutch Cover-B104D PF541219 Cover Clutch B104D 1
31101064 Plug 2 11. 36PF0050 Kit Fairing Dcl-El Blue PF233029 Fairing Decal Lh El Blue 1
JB541201 Jet Clutch Cover Disco M 1 PF233030 Fairing Decal Rh El Blue 1
BA102004 Plug 1
12. 36PF0051 Kit Fairing Dcl-E Black PF233031 Fairing Decal Lh Ebony Black 1
4. 36PF0061 Cam Chain Guide JE521019 Guide Cam Chain Tight D102C 1 PF233032 Fairing Decal Rh Ebony Black 1
JE541016 Guide Cam Chain Slack Side D102C 1
13. 36PF0052 Kit Tank Dcl-C Red PF233033 Tank Decal Lh Candy Red 1
5. 36PF0042 Kit Jet Platina-B104D JB581225 Jet Needle 1 PF233034 Tank Decal Rh Candy Red 1
JB581282 Needle Jet New Seting Disco-M 1
JB581280 Holder Jn New Seting Disco-M 1 14. 36PF0053 Kit Tank Dcl-El Blue PF233035 Tank Decal Lh El Blue 1
Jet Main # 80 1 PF233036 Tank Decal Rh El Blue 1
JB581281 Jet Comp New Seting Disco-M 1
15. 36PF0054 Kit Tank Dcl-E Black PF233037 Tank Decal Lh Ebony Black 1
6. 36PF0043 Kit Chain Case-Pl B104D PF181217 Case Chain Upper 1 PF233038 Tank Decal Rh Ebony Black 1
PF181218 Chain Case Lower 1
PF181219 Rubber Cap 1 16. 36PF0055 Kit S Cover Dcl-C Red PF233039 Cover Side Decal Lh Candy Red 1
PF233040 Cover Side Decal Rh Candy Red 1
7. 36PF0047 Valve Repair Kit B104D JD511203 Seat Valve Spring 2
39201719 Seal Valve Stem 2 17. 36PF0056 Kit S Cover Dcl-El Blue PF233041 Cover Side Decal Lh El Blue 1
JE511240 Spring Valve D106A 2 PF233042 Cover Side Decal Rh El Blue 1
JD511205 Retainer Valve Spring 2
DG101029 Cotter Valve 4 18. 36PF0057 Kit S Cover Dcl-E Black PF233043 Cover Side Decal Lh Ebony Black 1
PF233044 Cover Side Decal Rh Ebony Black 1
8. 36PF0048 Valve Kit B104D PF511204 Valve Intake B104D 1
103 104
Kit List BS IV Kit List BS IV
19. 36PF0058 Kit S Cowl Dcl-C Red PF233045 Cowl Seat Up Decal Lh Candy Red 1 26. PF541237 Assembly Magneto Cover PF541238 Cover Magneto B104D 1
PF233046 Cowl Seat Up Decal Rh Candy Red 1 JA541005 Bush Bendix 1
PF233047 Cowl Seat Lr Decal Lh Candy Red 1 PF541249 Label Magneto Cover B104D 1
PF233048 Cowl Seat Lr Decal Rh Candy Red 1
27. PF232603 Lock Kit DU201056 Switch - Ignition 1
20. 36PF0059 Kit S Cowl Dcl-El Blue PF233049 Cowl Seat Up Decal Lh El Blue 1 DF201246 Key Set 1
PF233050 Cowl Seat Up Decal Rh El Blue 1 30141050 Rotor 1
PF233051 Cowl Seat Lr Decal Lh El Blue 1 31161171 Lock For Side Cover 1
PF233052 Cowl Seat Lr Decal Rh El Blue 1
28. PF541029 Assembly Crankcase Lh 39171519 Oil Seal 22X35X7 1
21. 36PF0060 Kit Cowl Dcl-E Black PF233053 Cowl Seat Up Decal Lh Ebn Black 1 39256220 Needle Roller Brg. 1
PF233054 Cowl Seat Up Decal Rh Ebn Black 1 PF541030 Crankcase Lh B104D 1
PF233055 Cowl Seat Lr Decal Lh Ebn Black 1 PF541044 Insert Crankcase Lh B104D 1
PF233056 Cowl Seat Lr Decal Rh Ebn Black 1 59200036 6203 Hn3 C3 Ball Bearing 1
JA541036 Plug (Oil Control) 1
22. 36JB0022 Kit Air Screw ( Mod ) JB581275 Screw Adjuster 1
DH101264 Gasket Neutral Switch( T1.5 ) 1
JB581240 O-Ring 1
31201081 Switch Complete 1
JB581244 Sping Compr Coil 1
JA541005 Bush Bendix 1
JB581245 Plain Washer 1
39219019 Oil Seal 1
JB581246 O- Ring 1
23. 36PA0013 Idling Screw Kit JB581241 Screw Stop 1 29. PF541031 Assembly Crankcase Rh PF541018 Bushing Drum Bm150 4 Spd 1
JB581240 O-Ring 1 DH101380 Screw Pan Head(M6X12) 1
JB581242 Spring Compr 1 JA541014 Bolt Shift Change 1
JA541011 Needle Roller Bearing Hk1212 1
24. 36PA0014 Throttle Valve Kit JB581265 Valve Throttle 1 PF541032 Crankcase Rh B104D 1
JB581235 Bar Clip 1 PF541045 Insert Crankcase Rh B104D 1
JZ581206 Collar Magnet Holder 1 JA541015 Stud Inhibitor Mounting 1
JB581249 Spring Compr 1 59200036 6203 Hn3 C3 Ball Bearing 1
JA541010 Stopper Plate Input Bearing 1
25. 36PA0108 Carb. Gasket-'O' Ring Kit PA581220 Gasket Float Chamber 1 31101064 Plug 1
JB581239 Top Gasket 1 JA541012 Guide Kick 1
JB581240 O-Ring 3 39196404 Bolt-Flanged-Small 2
JB581269 O-Ring 24X26 (Eng Side) 1 JE541028 Pin K11 1
105 106
Kit List BS IV Part Index BS IV
30. 36JE0024 Kit Friction Plate JE551410 Plate Clutch Friction - D102C 5 40. 36PF0113 FORK CYL COMPLETE PF121082 SEAT PIPE 1
30181020 PISTON RING 1
31. 36PA0123 Chain Sprocket Kit PA141013 Sprocket Hub (43T) 1 JZ121013 CAP OIL LOCK 1
JB551000 Sprocket Output(14T) 1 DM181008 REBOUND SPRING 1
PA141011 Chain 120 Link - 420 Series 1
41. 36PF0112 ASSLY CYL HEAD + STUD PF511056 CYLINDER HEAD 1
32. 36JZ0132 Starter Clutch Repair DJ101109 Bush For Spring Starter 5 39262921 O-RING 1
DH101163 Roller Clutch(Dia 12X10) 5 LAJ00002 BOLT STUD-M8 2
39128321 RING - O 1
33. 36DK0077 Kit For Starter Clutch DK101596 Spring Starter Clutch 5
35. 36JZ0023 Kit Primary Drive&Driven PF551401 Clutch Hsg Assly Comp (Bm100) 1
JZ531006 Gear Primary Drive 1
36. 36JZ0103 Clutch Plate Kit 30101096 Plate - Clutch 4
107 108
Parts Index BS IV Parts Index BS IV
109 110
Parts Index BS IV Parts Index BS IV
111 112
Parts Index BS IV Parts Index BS IV
113 114
Parts Index BS IV Parts Index BS IV
115 116
Parts Index BS IV Parts Index BS IV
117 118
Parts Index BS IV Parts Index BS IV
119 120
Parts Index BS IV Parts Index BS IV
121 122