Catalogo Royal Enfield PDF

Spare Parts Catalogue
Classic 500 & 350

Foreword
We take pleasure in releasing CLASSIC 500 & 350 Spare Parts Catalogue.
The Catalogue has been specially designed for selection of correct part number to maintain the vehicle, for its optimum performance,
longer life and for enjoying the best running condition.
The Royal Enfield Spares are manufactured under stringent quality control to ensure ultimate riding experience. It is therefore
important to use only Royal Enfield Genuine Spares.
Due to continuous improvement on performance and efficiency of the vehicle, since this catalogue was printed, it is possible some
illustration, designs etc., found within this catalogue may differ from those found on the vehicle.
Such modification will be conveyed through our Technical Service Bulletins, you are requested to update with the correct part
numbers in this catalogue.
SERVICE HEADQUARTERS :
ROYAL ENFIELD
(A Unit of Eicher Motors Limited)
Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. India.
Tel : +91-44-4204 3300, Fax : +91-44-4201 1719. Website : www.royalenfield.com
E-mail : customerservice@royalenfield.com
“ © Copyright 2006 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this Service technical manual shall be
copied, distributed or otherwise dealt without the express permission in written from the Eicher Motors Limited, Royal Enfield
Unit who remains the sole owner of this manual .”
1
For easy reference and quick identification, the parts are grouped into relevant categories. Details are given in the illustrated Group
index. Tips on usage of this catalogue
ILLUSTRATION
Helps in identifying the shape of the part in its relative assembly.
03-30 FUEL TANK

Group No.
Alpha-Numeric
Key No. for assy.
A1
Key Nos.
17, 18, 19
Key No. Which

make up the assy.
Numeric Key No.
2
Part Number List
1 2 3 4 5
Key Part Number
Description Qty. Remarks
No. 500EFI 350cc
1. KEY NUMBER (KEY NO.)

The numeric key number is provided to serve as the identification of the part with its part number.
Serviceable assemblies or kits in a particular group are identified by alpha-numeric key numbers. e.g. A1, A2 etc. In such cases,
key numbers of individual items or group number which make up such assembly / kit are given in illustration.
3
Part Number List
2. PART NUMBER
The Part number of the individual item, kit OR the assembly is given in this column for unique identification. The
parts for which part numbers are not given, are not individually serviced.
3. DESCRIPTION
The description of the part assigned to the individual item kit / assembly is mentioned in this column.
4. QUANTITY
The number of individual items, kits or assemblies required for one vehicle is mentioned here.
Though quantity is indicated for oversize (O/S) or undersize (U/S) of some items, it is to be understood that for a
vehicle the sizes only is applicable, depending upon the repair / matching requirements.
6. REMARKS
For Reference purpose.
4
Group Index
Group No. Description Page No. Group No. Description Page No.
01-10 ENGINE ..................................................................... 13 06-10 HEAD LAMP CASING ............................................... 81

01-15 CRANK CASE LH - COVER SIDE ............................. 15 06-20 FRONT FORK ........................................................... 85
01-20 CRANK CASE RH - COVER SIDE ............................. 19 06-30 SWING ARM ASSEMBLY .......................................... 87
01-25 CRANK CASE LH ...................................................... 25 06-40 REAR SHOCK ABSORBER ....................................... 89
01-30 CRANK CASE RH...................................................... 27 07-10 BRAKE PEDAL ......................................................... 91
01-45 CYLINDER & HEAD ASSEMBLIES .......................... 31 07-20 REAR CHAIN ............................................................ 93
02-10 ENGINE COVER LH ................................................. 35 07-30 FOOT RESTS ............................................................. 95
02-20 ENGINE COVER RH ................................................. 37 08-10 FRONT WHEEL......................................................... 97
02-30 CLUTCH ..................................................................... 41 08-20 REAR WHEEL ........................................................... 99
02-40 GEAR TRAIN ASSEMBLY ........................................ 43
09-10 REAR BRAKE ......................................................... 103
03-10 SILENCER & EXHAUST PIPE .................................. 45
10-10 FRONT MUDGUARD .............................................. 105
03-20 EFI COMPONENTS IN CYLINDER HEAD................ 47
10-20 REAR MUDGUARD ................................................. 107
03-30 TCI & IGNITION COMPONENTS .............................. 49
11-10 BATTERY AND HARNESS ..................................... 111
03-40 CV CARBURETOR .................................................... 51
11-20 SWITCHES, HORN & RELAYS ............................... 113
03-50 FILTER BOX ASSEMBLY (CLASSIC 500)................. 55
03-50 FILTER BOX ASSEMBLY (CLASSIC 350)................. 57 11-30 WARNING INDICATOR, AMMETER & SPEEDOMETER 115
03-60 FUEL TANK (CLASSIC 500) ..................................... 59 11-40 HEAD LAMP ........................................................... 117
03-60 FUEL TANK (CLASSIC 350) ..................................... 61 11-50 TAIL LAMP ............................................................. 119
04-10 FRAME & PAV COMPONENTS ................................ 63 11-60 TRAFFICATOR LIGHTS .......................................... 121
04-20 SEAT ASSEMBLY ...................................................... 69 12-10 TOOL BOX (ELECTRICALS BOX) LH ..................... 123
04-30 CENTER STAND ....................................................... 71 12-20 UTILITY BOX .......................................................... 125
05-10 HANDLE BAR & CONTROLS ................................... 73 12-20 RESONATOR BOX & COVER ................................. 127
05-20 CONTROL CABLES ................................................... 75 12-30 BATTERY CARRIER ............................................... 129
05-30 CALIPER ASSEMBLY ............................................... 77 13-10 TOOL KIT ................................................................ 131
05-40 MASTER CYLINDER ASSEMBLY............................. 79 14-10 SPECIAL TOOLS LIST ............................................. 133
5
Group Index - Pictorial
01-10 ENGINE 01-15 CRANK CASE LH - COVER SIDE 01-20 CRANK CASE RH - COVER SIDE
Page Page Page

12 14 18
01-25 CRANK CASE - LH 01-30 CRANK CASE RH 01-45 CYLINDER & HEAD ASSEMBLIES
Page Page Page

24 26 30
02-10 ENGINE COVER - LH 02-20 ENGINE COVER - RH 02-30 CLUTCH
Page Page Page

34 36 40
6
02-40 GEAR TRAIN ASSEMBLY 03-10 SILENCER & EXHAUST PIPE 03-20 EFI COMPONENTS IN CYL. HEAD
Page Page Page

42 44 46
03-30 TCI & IGNITION COMPONENTS 03-40 CV CARBURETOR 03-50 FILTER BOX ASSY. (CLASSIC 500)
Page Page Page

48 50 54
03-50 FILTER BOX ASSY. (CLASSIC 350) 03-60 FUEL TANK (CLASSIC 500) 03-60 FUEL TANK (CLASSIC 350)
Page Page Page

56 58 60
7
04-10 FRAME 04-20 SEAT ASSEMBLY 04-30 CENTER STAND
Page Page Page

62 68 70
05-10 HANDLE BAR & CONTROLS 05-20 CONTROL CABLES 05-30 CALIPER ASSEMBLY
Page 500 Page Page

72 74 76
350
05-40 MASTER CYLINDER ASSEMBLY 06-10 HEAD LAMP CASING 06-20 FRONTFORK
Page Page Page

78 80 84
8
06-30 SWING ARM ASSEMBLY 06-40 REAR SHOCK ABSORBER 07-10 BRAKE PEDAL
Page Page Page

86 88 90
07-20 REAR CHAIN 07-30 FOOT RESTS 08-10 FRONT WHEEL
Page Page Page

92 94 96
08-20 REAR WHEEL 09-10 REAR BRAKE 10-10 FRONT MUDGUARD
Page Page Page

98 102 104
9
10-20 REAR MUDGUARD 11-10 BATTERY AND HARNESS 11-20 SWITCHES, HORN & RELAYS
Page Page Page

106 110 112
11-30 WARNING INDICATOR, AMMETER & SPEEDOMETER 11-40 HEAD LAMP 11-50 TAIL LAMP
Page Page Page

114 116 118
11-60 TRAFFICATOR LIGHTS 12-10 TOOL BOX (ELE. BOX) LH 12-20 UTILITY BOX
Page Page Page
120 122 124
10
12-20 RESONATOR BOX & COVER 12-30 BATTERY CARRIER 13-10 TOOL KIT
Page Page Page
126 128 130
14-10 SPECIAL TOOLS LIST 14-10 SPECIAL TOOLS LIST

Page Page
132 134
DOL
11
01-10 Engine
12
01-10 Engine
Key 500 EFI Part 350CC Part Remarks

Description Qty.
No. Number Number
861040 ENGINE (UCE 500 EFI) 1
1
861309 ENGINE (UCE 350) 1
2 859029 859030 CRANK CASE LH & RH ASSEMBLY WITH BEARINGS 1
13
01-15 Crankcase LH - Cover Side
14

Description Qty.
No. Number Number
A1 570153/e 570153/e SPRAG CLUTCH ASSEMBLY 1
1 570064 570064 HEX. HEAD SCREW 1
2 570063/c 570063/c WASHER 1
3 570070/m 570070/m ENGINE SPROCKET 1
4 570073 570073 NEEDLE BEARING 1
5 570074/i 570074/i DISTANCE WASHER, SPRAG CLUTCH 1
6 570032 570032 CIRCLIP 1
7 500635/a 500635/a KEY - JACK SHAFT 1
8 570007/f 570007/f GEAR, - JACK SHAFT 1
9 570072/c 570072/c SHAFT, DOUBLE GEAR 1
10 570071/d 570071/d DOUBLE GEAR - STARTER DRIVE 1
11 570094/i 570094/i HEX. SOCKET HEAD CAP SCREW, M5 X 25 1
12 570016 570016 HEX. SOCKET HEAD CAP SCREW, M5 X 45 3
13 861003/g 861003/g HOUSING STARTER DRIVE 1
14 570298/a 570298/a DOWEL (6MM) 2
15 591494/a 591494/a NEUTRAL SWITCH WITH PACKING 1
16 570249/g 570249/g COLLAR, MAINSHAFT 1
17 571113 570443/c CLUTCH ASSEMBLY COMPLETE 1
18 570465/c 570465/c PLAIN WASHER 1
19 560525/a 560525/a NYLOCK NUT 1
20 570442 570442 BALL BEARING 6001 1
21 570446/g 570446/g CLUTCH PUSH PAD 1
22 570090/d 570090/d STUD M6 X 106 1
15
16

Description Qty.
No. Number Number
23 550086/a 550086/a NUT M6X1, FLANGE NYLOC TYPE 20
24 570088/d 570088/d STUD M6 X 168 1
25 570089/d 570089/d STUD M6 X 196 2
26 570414/b 570414/b PRIMARY CHAIN 1
27 570030 570030 HEX. SOCKET HEAD CAP SCREW, M6X20 2
28 570047/c 570047/c AUTO CHAIN TENSIONER ASSEMBLY 1
29 570295 570295 ‘O’ RING, CHAIN TENSIONER ASSEMBLY 1
30 570029/d 570029/d CHAIN TENSIONER PAD 1
31 141246/c 141246/c BUSH, CHAIN TENSIONER PAD 1
32 140293 140293 PLAIN WASHER 1
33 570095/d 570095/d STUD, CHAIN TENSIONER PAD 1
34 570086/a 570086/a STUD M6 X 226 2
36 570091/d 570091/d STUD M6 X 80 1
37 570130 570130 HEX. SOCKET HEAD CAP SCREW, M6X85 1
38 560011/a 560011/a SPRAG CLUTCH BEARING 1
39 144636/a 144636/a COPPER WASHER 1
40 141051 141051 NUT - TENSIONER PAD 1
17
01-20 Crankcase RH - Cover Side
A1
Key No’s
7,8,9,10,11
A2
Key No’s
22,23,24,25,26,27
A3
Key No’s
22,23,26,63,64,65
A4
Key No’s
50,51,52
18

Description Qty.
No. Number Number
A1 570309/b 570309/b CAM GEAR ASSEMBLY-EXHAUST WITH DECOMPRESSOR ASSY. 1
A2 571047/d NA OIL PUMP ASSEMBLY - 500CC 1
A3 NA 570048/f OIL PUMP ASSEMBLY - 350CC 1
A4 570600 570600 GEAR CHANGER ASSEMBLY 1
1 570044/j 570044/j CAM STEADY PLATE 1
2 570298/a 570298/a DOWEL 6 MM 2
3 570421/a 570421/a HEX. SOCKET HEAD CAP SCREW, M6 X 30 2
5 570100/b 570100/b NUT - CAM SPINDLE 2
6 570280/b 570280/b SHIM, CAM GEAR 2
7 570105/f 570105/f PIVOT 1
8 570541/a 570541/a FLY WEIGHT 1
9 570108/f 570108/f TORSION SPRING 1
10 570110/d 570110/d PIN ASSEMBLY 1
11 571165/a 571165/a CAM GEAR AUB ASSEMBLY - EXHAUST 1
12 570099/c 570099/c CAM SLEEVE 2
570039/c 570039/c CAM SPINDLE ADJUSTABLE 2
13 570040 570040 CAM SPINDLE ADJUSTABLE ( 0.1 OVERSIZE ) 2
570041 570041 CAM SPINDLE ADJUSTABLE ( 0.2 OVERSIZE ) 2
14 571164/a 571164/a CAM, GEAR - INLET 1
15 861034 861034 COVER, KICK START SHAFT 1
16 570300/b 570300/b HEX SOCKET PAN HEAD SCREW M5 X 12 4
17 570246/e 570246/e NUT, SLEEVE GEAR 1
18 570247/d 570247/d TAB WASHER 1
19
A1
Key No’s
7,8,9,10,11
A2
Key No’s
22,23,24,25,26,27
A3
Key No’s
22,23,26,63,64,65
A4
Key No’s
50,51,52
20

Description Qty.
No. Number Number
19 571032/b 570809/a FD SPROCKET 18 TEETH FOR 500CC & 16 TEETH FOR 350CC 1
20 570214/f 570214/f DISTANCE PIECE 1
21 570213 570213 OIL SEAL 1
22 570052 570052 CIRCLIP 1
23 571166 571166 PUMP DRIVE PINION 1
24 571155/a NA CSK SOCKET HEAD SCREW M6 X 30 3
25 571115/c NA GASKET, OIL PUMP 1
26 570293 570293 'O' RING, OIL PUMP OUTLET 1
27 570132/a NA HEX. SOCKET HEAD CAP SCREW M6 X 25 2
28 146031/a 146031/a 'O'- RING 1
29 570468/b 570468/b CAP, PIVOT PIN 1
30 144636/a 144636/a COPPER WASHER 1
31 570481 570481 HEX FLANGE BOLT M5 X 12 1
32 570303/a 570302/a HEX SOCKET HEAD CAP SCREW M6 X 60 2
33 560013 580306/c STARTER MOTOR ASSEMBLY 1
34 572012/a 570812/a COVER STARTER MOTOR 1
35 570300/b 570813/b HEX SOCKET, BUTTON HEAD SCREW, M5 X 12 1
36 570298/a 570298/a DOWEL PIN 2
37 861041 861040 TAPPET DOOR 1
38 570198/c 570198/c CSK SOCKET HEAD SCREW M5 X 12 4
39 572020/b 572125/a FLY WHEEL MAGNETO ASSEMBLY 1
40 502070/a 502070/a MAGNETO KEY 1
41 145708/a 145708/a PLAIN WASHER,
42 550025 550025 HEX. NUT M12 X 1.25 1
43 570219/f 570219/f ASSEMBLY, GEAR LEVER SHAFT 1
21
A1
Key No’s
7,8,9,10,11
A2
Key No’s
22,23,24,25,26,27
A3
Key No’s
22,23,26,63,64,65
A4
Key No’s
50,51,52
22

Description Qty.
No. Number Number
44 570184/b 570184/b SPACER - SHAFT, GEAR LEVER 1
46 570231/h 570231/h PIVOT BEARING, ROCKER SHAFT BOTTOM 1
47 570235/e 570235/e DOWEL, LOWER PIVOT BEARING 1
48 570229/d 570229/d STOP PIN 1
49 550256/a 550256/a 'O' RING 1
50 570222/e 570222/e ROCKER SHAFT ASSEMBLY 1
51 570226/e 570226/e STRIKER, GEAR CHANGE 1
52 570253/e 570253/e PIN, PIVOT 1
53 570230/f 570230/f SPRING, GEAR CHANGE STRIKER 1
55 570228/g 570228/g PIVOT BEARING, ROCKER SHAFT UPPER 1
56 570234 570234 'O' RING BLACK NITRILE RUBBER 1
57 570227/f 570227/f SPACER 1
58 550072/b 550072/b SPRING 1
59 570218/c 570218/c PIVOT, CAMPLATE 1
60 550108 550108 ‘O’ RING 1
61 146450/b 146450/b SPRING KICK 1
62 145090/a 145090/a HEX SCREW M6X16 1
63 NA 570294 ‘O’ RING - OIL PUMP 1
64 NA 570292 ‘O’ RING 1
65 NA 570051 HEX. SOCKET HD. CAP SCREW, M4 X 30 4
66 570102/d 570102/d PLUG 4
67 147058/a 592147/a STATOR AND PULSAR COIL ASSEMBLY 1
68 571062/b 147063/a ROTOR AND RELUCTOR ASSEMBLY 1
23
01-25 Crankcase LH
24
01-25 Crankcase LH

Description Qty.
No. Number Number
1 145867/a 145867/a FLANGE HEX NUT - M8 X 1.25 3
2 500104/b 500104/b STUD, M8 X 128 3
3 570008/f 570008/f JACK SHAFT 1
4 110037/3 110037/3 CIRCLIP 2
5 110050 110050 BALL BEARING 6305 C3 (25 X 62 X17) 1
6 570006/e 570006/e BEARING SPACER CRANKCASE LH 1
7 111887 111887 ROLLER BEARING NU 305 C4 (25 X 62 X 17) 1
8 570201/f 570201/f WASHER, THRUST 1
9 550032/a 550032/a NEEDLE BEARING 1
10 570013 570013 HEX SOCKET HEAD CAP SCREW, M5 X 16 2
11 570012/c 570012/c RETAINER PLATE, MAINSHAFT BEARING 1
12 570087/d 570087/d STUD M6 X 133 2
13 570011 570011 BALL BEARING 6006, C3 (G/B MAIN SHAFT) 1
14 570057/g 570005/c BEARING SPACER - LH CRANKSHAFT 1
25
01-30 Crankcase RH
43
26
01-30 Crankcase RH

Description Qty.
No. Number Number
1 570097/b 570097/b HYDRAULIC VALVE LIFTER ROLLER 2
2 570037 570037 BEARING NRB 1
3 570469/a 570469/a DEEP GROOVE BALL BEARING – SLEEVE GEAR 1
4 110037/3 110037/3 CIRCLIP 6.2 X 2N 1
5 550032/a 550032/a NEEDLE BEARING 1
6 570201/f 570201/f WASHER, THRUST 1
7 571172/b 571170/b CRANK SHAFT ASSEMBLY 1
8 570276/d 550108 OIL DRAIN BOLT WITH MAGNET 1
9 570206/j 570206/j SLEEVE GEAR 1
10 570207 570207 NEEDLE BEARING 1
11 570208 570208 NEEDLE BEARING 1
12 571116/b 570125 NEEDLE ROLLER 2
13 570141/d 570141/d BRACKET - PIN - HYDRAULIC - TAPPET 1
14 570232 570232 HEX. SOCKET HEAD CAP SCREW, M6 X12 1
15 570215/f 570215/f BOLT, PAWL 1
16 550083/b 570215/f SPRING 1
17 550082/c 550082/c PAWL, CAMPLATE 1
18 550087 550087 MACHINED WASHER 6.4 1
19 550086/a 550086/a NUT M6 X 1, FLANGE NYLOC TYPE 1
20 142257/b 142257/b STOP PLATE 1
21 146714/a 146714/a HEX SCREW M8 X 23 1
22 570239/c 570239/c OIL THROWER 1
23 570240 570240 HEX SOCKET HEAD CAP SCREW M5 X 35 3
27
01-30 Crankcase RH
43
28
01-30 Crankcase RH

Description Qty.
No. Number Number
24 570054/g 570054/g SUCTION FILTER ASY 1
25 570057/b 570057/b O RING-DRAIN CAP 1
26 570055/c 570055/c SUMP DRAIN CAP 1
27 570431 570431 HEX. FLANGE BOLT M5X16 2
28 144846/a 144846/a WASHER DRAIN PLUG 1
29 570176/d 570176/d DRAIN PLUG 1
30 570277 570277 MAGNET 1
31 120005/b 120005/b DOWEL - HOLLOW 2
32 500104/b 500104/b STUD, M8 X 128 3
33 145867/a 145867/a FLANGE NUT-M8 3
34 570236/h 570236/h KICK START SHAFT 1
35 140331/a 140331/a SPRING 1
36 140332/b 140332/b PLUNGER 1
37 140333/b 140333/b PAWL 1
38 550030/c 550030/c WASHER THRUST 2
39 570238/g 570238/g ASSY., KICK START GEAR 1
40 550039/c 550039/c BUSH 1
41 570209 570209 CIRCLIP 18N 1
42 570028 570028 LOCATING PIN,(PIVOT)-NRB 3 X 21.8 1
43 570278 570278 LOCTITE 5699 (ALTERNATE : LIQUID SEALANT 3702) 1
29
01-45 Cylinder & Head Assemblies
39
A1
Key No’s
7,8,9,10,11
A2
Key No’s
29,39
30

Description Qty.
No. Number Number
A1 859036 859034 CYLINDER HEAD ASSEMBLY 1
A2 805015 805016 CYLINDER PISTON ASSEMBLY 1
1 859037 859035 CYL. HEAD SUB ASSY. (CYL. HEAD, VALVE GUIDE, VALVE SEATS) 1
2 572025/a 500904/a SPARK PLUG - M 14 1
3 570298/a 570298/a DOWEL (6 MM) 8
4 500347/a 500347/a SEAT, SPRING 2
5 500322/a 500322/a VALVE STEM SEAL 2
6 500309/b 500309/b VALVE SPRING 2
7 500352/a 500352/a RETAINER, SPRING 2
8 500307/a 500307/a SPLIT COLLAR 4
9 570533/l 570533/l ROCKER BEARING SET-EXHAUST 1
10 570535/g 570535/g ROCKER ARM, EXHAUST 1
11 570536/g 570536/g ROCKER ARM - INLET 1
12 570532/e 570532/e ROCKER BEARING SET-INLET 1
14 572022/b 57022/b GASKET, ROCKER COVER EXHAUST 1
15 572021/b 572021/b GASKET, ROCKER COVER INLET 1
16 861016 861016 ROCKER COVER - EXHAUST 1
17 861017 861017 ROCKER COVER - INLET 1
18 571118/a 571118/a WASHER-SEAL 3
19 571117/c 571117/c HEX. HEAD SCREW-ROCKER COVER 3
20 570128/f 570128/f WASHER SEAL 1
21 570129/h 570129/h HEX. HEAD SCREW ROCKER COVER 1
31
39
A1
Key No’s
7,8,9,10,11
A2
Key No’s
29,39
32

Description Qty.
No. Number Number
22 571035/c 570164/d VALVE EXHAUST 1
23 571034/c 570163/d VALVE INLET 1
24 570480/b 570480/b DAMPER PAD - CYLINDER BARREL 3
25 570482/b 570482/b DAMPER PAD - CYLINDER BARREL TAPPER 6
26 570478/b 570478/b DAMPER PAD LH - CYLINDER HEAD 2
27 570479/b 570479/b DAMPER PAD RH - CYLINDER HEAD 4
28 570489/a 570489/a STUD, EXHAUST 2
29 805013 805014 CYL. BARREL ASSEMBLY 1
30 500116/a 500116/a DOWEL PIN 1
31 500123/a 500123/a DOWEL PIN 1
32 571043/b 570018/g GASKET 1
33 571039/a 570192/b MLS GASKET 1
34 570537/d 570537/d PUSH ROD ASSEMBLY, EXHAUST 1
35 570538/d 570538/d PUSH ROD ASSEMBLY, INLET 1
36 580395 580395 SPARK PLUG - M 10 - BOSCH (UR 5DC) 1
37 571119 500207/a CIRCLIP 2
38 571109 570273 RING SET STD 1
39 571108 570272 PISTON ASSEMBLY WITH RINGS STD 1
33
02-10 Engine Cover LH
A1
Key Nos.
1, 6, 10, 11, 12,
13, 14, 15, 16
A2
Key Nos.
10, 11, 12
34
02-10 Engine Cover LH

Description Qty.
No. Number Number
A1 861030 861030 LH COVER SUB ASSEMBLY 1
A2 570601 570601 CLUTCH OPERATING LEVER 1
1 861013 861013 COVER, LH 1
2 572015/a 572015/a HEX. FLANGE BOLT , M6 X 1 X 30 11
3 550095 550095 HEX SCREW M6 X 30 1
4 570244/b 570244/b GEAR PEDAL ASSEMBLY 1
5 550507/a 550507/a SLEEVE, GEAR LEVER 1
6 550661/a 550661/a OIL SEAL 14 X 20 X 3 1
7 502018/b 502018/b OIL FILLER PLUG 1
8 145835/a 145835/a ‘O’ - RING (PLUG) 1
9 571156/b 571156/b CLUTCH CABLE ASSEMBLY 1
10 570402/j 570402/j CLUTCH OPERATING LEVER ASSEMBLY 1
11 570406/d 570406/d PIN, CLUTCH OPERATING LEVER 1
12 570405/d 570405/d CABLE CLEVIS, CLUTCH OPERATING LEVER 1
13 570452/e 570452/e SPRING, CLUTCH OPERATING LEVER 1
14 570291/a 570291/a LOCK PIN SPRING, CLUTCH OPERATING MECH. 1
15 570407 570407 OIL SEAL INA G 12 X 18 X 5 1
16 550061/b 550061/b BUSH 1
35
02-20 Engine Cover RH
A1
Key No’s
1,2,3,4,8,9,10,11,12,
13,14,15,16,17,18,19,23,
24,25,26,27,28,29,32,43,
36

Description Qty.
No. Number Number
A1 861037 861037 RH COVER SUB ASSEMBLY 1
1 861036 861036 COVER RH 1
2 570426/h 570426/h GASKET, COVER PLATE 1
3 570424/d 570424/d COVER PLATE, BREATHER CHAMBER 1
4 570425 570425 HEX. SCREW, M5 X 12 6
5 570416/c 570416/c GASKET - COVER RH 1
6 550095 550095 ALLEN SCREW M6 X 30 3
7 570013 570013 HEX SOCKET HEAD CAP SCREW M5X16 2
8 550028 550028 CIRCLIP 24N 1
9 500622 500622 OIL SEAL, CRANK FEED 1
10 570183/a 570183/a JET, CRANKSHAFT RH 1
11 572011/a 572011/a HEX FLANGE BOLT M6 X 1 X 20 3
12 572005/b 572005/b CAP, OIL FILTER 1
13 572014/a 572014/a ‘O’ - RING, FILTER CAP 1
14 500637/b 500637/b SPRING 1
15 500617/a 500617/a WASHER 1
16 500619/a 500619/a ‘O’ - RING 1
17 500616/a 500616/a SPRING CAP 1
18 500621/a 500621/a ‘O’ - RING 1
19 500613/a 500613/a ELEMENT - OIL FILTER 1
20 572019/a 572019/a HEX. FLANGE BOLT, M6 X 1 X 45 2
37
A1
Key No’s
1,2,3,4,9,10,11,12,13,
14,15,16,17,18,19,20,
44,25,26,27,28,29,30
38

Description Qty.
No. Number Number
23 570059/c 570059/c OIL LEVEL WINDOW 1
24 144846/a 144846/a WASHER, INSPECTION SCREW 1
25 570176/d 570176/d INSPECTION SCREW, IGNITION TIMING 1
26 146459/a 146459/a ‘O’ - RING 1
27 570467/a 570467/a OIL FILLER CAP, METAL 1
28 570155 570155 SEALING WASHER 1
29 570444/a 570444/a BOLT BREATHER 1
30 146927/a 146927/a CLIP BREATHR PIPE 1
31 570286/c 500128/a BREATHER PIPE 1
32 570241 570241 OIL SEAL KICK START 2
33 570807/c 570807/c KICK START CRANK ASSEMBLY 1
34 570257/b 570257/b SPRING 1
35 570814/c 570814/c BOSS, KICK START CRANK 1
36 140201 140201 BALL DIA 6.35 1
37 570808/c 570808/c LEVER KICK START 1
38 145157/a 145157/a SLEEVE KICK START LEVER 1
39 PIN 1
40 570259/d 570259/d CIRCLIP 10 1
41 111914 111914 HEX BOLT M8X40 1
42 141051 141051 HEX NUT M8 1
43 571201/a 571201/a SCREW SPRING CAP 1
39
02-30 Clutch
11 12
9
10 3
6 7
5
4
1
2 3
350CC
A1
40
02-30 Clutch

Description Qty.
No. Number Number
A1 571113/a 570443/c CLUTCH ASSEMBLY COMPLETE 1
1 570440 570440 HEX. SCREW M6 6
2 570442 570442 BALL BEARING 6001 1
3 570447/b 570447/b BEARING CUP 1
4 570439/b 570439/b HOLDER, CLUTCH SPRING 1
5 570438/b 570438/b CLUTCH SPRING 6
6 570434/d 570434/d CLUTCH HUB / BACK PLATE 1
7 570436/c 570436/c CLUTCH FRICTION PLATE 7 For 350cc 6 nos.
8 570437/c 570437/c CLUTCH PLAIN PLATE 6 For 350cc 5 nos.
9 571100/a 570435/b WHEEL CLUTCH 1
10 570451/b 570451/b THRUST WASHER 1
11 570433/b 570433/b CLUTCH DRUM / SPROCKET 1
12 570441 570441 NEEDLE ROLLER BEARING SCE 228 1
41
02-40 Gear Train Assembly
42
02-40 Gear Train Assembly

Description Qty.
No. Number Number
A1 570157 570157 LAY SHAFT SUB ASSEMBLY 1
A2 570158/a 570158/a MAIN SHAFT SUB ASSEMBLY 1
1 570205/k 570205/k MAIN SHAFT 1
2 550008/b 550008/b MAIN SHAFT 2ND GEAR 1
3 550023/e 550023/e WASHER, THRUST 3
4 570823/a 570823/a MAIN SHAFT 4TH GEAR ASSEMBLY 1
5 550024 550024 CIRCLIP 1
6 570821/a 570821/a MAIN SHAFT 3RD GEAR ASSEMBLY 1
7 570204/h 570204/h MAIN SHAFT 1ST GEAR 1
8 550216/b 550216/b LAY SHAFT 1
9 570596/b 570596/b LAY SHAFT 2ND GEAR ASSY. WITH BUSH 1
10 550007/c 550007/c LAY SHAFT HIGH GEAR 1
11 550011/g 550011/g LAY SHAFT 3RD GEAR / 4TH DOUBLE GEAR 1
12 570202/e 570202/e LAY SHAFT 1ST GEAR ASSEMBLY 1
13 550090/c 550090/c SELECTOR FORK LH 1
14 550081/c 550081/c SELECTOR FORK CENTRE 1
15 550091/c 550091/c SELECTOR FORK RH 1
16 550078/a 50078/a SELECTOR FORK SHAFT 1
17 550141 550141 CIRCLIP 1
18 570216/e 570216/e CAM PLATE ASSEMBLY 1
19 550075/a 550075/a ROLLER 4
20 550030/c 550030/c WASHER THRUST 1
43
03-10 Silencer & Exhaust Pipe
350 cc
44
03-10 Silencer & Exhaust Pipe

Description Qty.
No. Number Number
1 591824/d 592004/b EXHAUST PIPE ASSEMBLY 1
2 510804/a 500334/a GASKET, EXHAUST PIPE 1
3 145867/a 145867/a FLANGED HEX. NUT M8X1.25 2
4 591860/b 592082/a SILENCER ASSEMBLY 1
5 591865/a 591163/a SILENCER BRACKET FRONT 1
6 145872/a 145872/a FLANGE HEX BOLT M8X10 2
7 581158 581158 HEX SOCKET HEAD CAP SCREW M8X35 SS ,IS:2269 1
8 141044 141044 HEX BOLT M6X35 - IS :1364 (PART 1) 1
9 140129 140129 PLAIN WASHER 1
10 141060 141060 HEX. NUT M6 - IS ; 1364 (PART 3) - 8 - ZN.PL 1
11 141061/1 141061/1 PUNCHED WASHER 6.4, IS:2016,STEEL 1
12 591878/a NA GUARD – EXHAUST PIPE 1
13 591871/a NA GUARD – SILENCER ASSEMBLY 1
14 581122/a NA MUSHROOM HEAD SCREW, M6 X 8 X 1 5
15 NA 581091/a SILENCER GUARD 1
16 NA 581122/a MUSHROOM HEAD SCREW, M6 X 8 X 1 3
45
03-20 EFI Components in Cylinder Head
3
4
16 15 13 14 1
6
5
17
18
8
11
7
11
3
10
19
12
46
03-20 EFI Components in Cylinder Head

Description Qty.
No. Number Number
1 859037 NA CYLINDER HEAD 1
2 571055/a NA ENGINE TEMPERATURE SENSOR 1
3 521200/a NA ‘O’-RING 2
4 571079/d NA INSULATOR 1
5 144981/b NA ‘O’-RING 1
6 571080/g NA MANIFOLD-INLET 1
7 570132/a NA HEX. SOCKET HEAD CAP SCREW M6 X 25 2
8 145023 NA SEALING WASHER 6 X 10 4
9 571091 NA ADAPTOR 1
10 570030 NA HEX. SOCKET HEAD CAP SCREW M6 X 20 2
11 550086/a NA NYLOC NUT M6 3
12 571051/a NA THROTTLE BODY 1
13 571053/a NA INJECTOR 1
14 571090/a NA SEAL RING 1
15 571087/a NA ‘O’-RING, INJECTOR 1
16 571088/c NA CAP, INJECTOR ASSEMBLY 1
17 571110/b NA SPACER 1
18 570091/d NA STUD 1
19 140573 NA CLIP HOSE 1
47
03-30 TCI & Ignition Components 500cc EFI
48
03-30 TCI & Ignition Components

Description Qty.
No. Number Number
1 NA 147067/e TCI - UNIT (DIGITAL) 1
2 581024/c 581024/c R/R UNIT - 3 PHASE 1
3 NA 581027/b IGNITION COIL - PRIMARY 1
4 NA 147096/a IGNITION COIL - SECONDARY 1
5 NA 502071 HEX SCREW, IGNITION COIL MOUNTING 5
6 143498 143498 HEX SCREW RR MOUNTING M6 X 25 1
7 141061 141061 PLAIN WASHER 3
8 NA 580377/b BRACKET, IGNITION COIL 1
9 580397/a 580397/a CAP SPARK PLUG M10 1
10 500905/e 500905/e CAP SPARK PLUG M14 1
11 591837/b NA IGNITION COIL DUAL - WITH HT LEAD & SPARK PLUG CAPS 1
12 571056/a NA ELECTRONIC CONTROL UNIT 1
13 591370/c NA RUBBER STRAP 1
14 581054/b NA ROLL OVER SENSOR 1
15 141061 NA PUNCHED WASHER 6.4 1
16 570132 NA HEX. SOCKET HEAD CAP SCREW M6 X 25 1
49
03-40 CV Carburetor
50
03-40 CV Carburetor

Description Qty.
No. Number Number
1 NA 570282/b CARBURETOR ASSEMBLY 1
2 NA 500854 TOP COVER FIXING SCRREW 2
3 NA 500831 DIAPHRAGM TOP COVER 1
4 NA 50083 PISTON VALVE SPRING 1
5 NA 500848 JET NEEDLE PLATE FIXING SCREW 2
6 NA 500836 JET NEEDLE FIXING PLATE 1
7 NA 500837 JET NEEDLE RETAINER SPRING 1
8 NA 500839 JET NEEDLE WASHER 1
9 NA 500838 JET NEEDLE E-RING 1
10 NA 500864 JET NEEDLE 1
11 NA 500832 PISTON VALVE ASSEMBLY 1
12 NA 500835 DIAPHRAGM 1
13 NA 500834 DIAPHRAGM RETAINER RING 1
14 NA 500861 AIR VENT HOSE 1
15 NA 500865 NEEDLE JET 1
16 NA 500845 ‘O’ RING 1
17 NA 500844 MAIN JET HOLDER 1
18 NA 500863 MAIN JET 1
19 NA 500846 FLOAT PIN 1
20 NA 500847 FLOAT PIN FIXING SCREW 1
21 NA 500841 ‘O’ RING FLOAT CHAMBER COVER 1
22 NA 500843 FLOAT ASSEMBLY 1
51
03-40 CV Carburetor
52
03-40 CV Carburetor

Description Qty.
No. Number Number
23 NA 500860 FLOAT BODY ASSEMBLY 1
24 NA 141963 SPRING WASHER 2
25 NA 500842 SCREW 2
26 NA 500853 HOSE DRAIN 1
27 NA 500871 SCREW 1
28 NA 500857 IDLE ADJUSTER SCREW 1
29 NA 500820/a PACKING, IDLE ADJUSTING SCREW 1
30 NA 500855 SPRING, IDLE ADJUSTING 1
31 NA 500866 PIVOT PIN 1
32 NA 500867 PILOT AIR JET 1
33 NA 500874 CLIP 1
34 NA 500089 PLUNGER ASSEMBLY 1
35 NA 500870 ‘O’ RING PILOT SCREW 1
36 NA 500869 WASHER PILOT SCREW 1
37 NA 500862 SPRING PILOT SCREW 1
38 NA 14344/2 CLIP HOSE 2
39 NA 521262/a FLANGE 1
40 NA 521200/a O’ RING 1
41 500823/a BELLOWS 1
42 500355 HEX. SOCKET HEAD SCREW M6 X 16 2
43 144636/a SEALING WASHER 2
44 500873 CAP 1
53
03-50 Filter Box Assembly (Classic 500)
12
15
10
7
6
5 11
7
6
2 5
9
3 8
6
7
13
5
4
14
54

Description Qty.
No. Number Number
863043 NA AIR FILTER BOX ASSY., WITH STICKER,CLASSIC GREEN 1
1 866020 NA AIR FILTER BOX ASSY., WITH STICKER, BLACK 1
865054 NA AIR FILTER BOX ASSY., WITH STICKER, ROYAL MAROON 1
2 581007/a NA AIR FILTER ELEMENT 1
3 581008/a NA COVER FILTER ELEMENT 1
4 142182 NA HEX NYLOCK NUT 1
5 142274 NA HEX SCREW, M6 X 16 3
6 140129 NA LOCK WASHER,INTERNAL TEETH 3
7 141061 NA PUNCHED WASHER 3
8 140383/3 NA PLAIN WASHER 1
9 141060 NA HEX.NUT M6 1
10 591492/a NA INLET BELLOW 1
11 591493/a NA CLIP HOSE – INLET BELLOW 1
12 591470/a NA OUTLET BELLOW- AIR FILTER 1
13 500917/b NA STRAP 1
14 591875/a NA STICKER, FILTER BOX RH 1
15 142391 NA BEADING 1
55
12
56

Description Qty.
No. Number Number
NA 810610 AIR FILTER BOX ASSY., WITH STICKER, BLACK 1
1 NA 850041 AIR FILTER BOX ASSY., WITH STICKER, SILVER 1
NA 865043 AIR FILTER BOX ASSY., WITH STICKER, ROYAL MAROON 1
2 NA 143548/a AIR FILTER ELEMENT 1
3 NA 143477/b COVER FILTER ELEMENT 1
4 NA 141462/3 HEX.BOLT, M6 X 55 1
5 NA 142274/1 HEX SCREW, M6 X 16 4
6 NA 140129/3 LOCK WASHER,INTERNAL TEETH 3
7 NA 141061 PUNCHED WASHER 3
8 NA 140383/a PLAIN WASHER 1
9 NA 141060/a HEX.NUT M6 1
10 NA 147613/a CONNECTION TUBE 1
11 NA 500711 CLIP HOSE 1
12 NA 592021 STICKER- FILTER BOX RH 1
57
03-60 Fuel Tank (Classic 500)
58

Description Qty.
No. Number Number
863014 NA FUEL TANK ASSY., WITH STICKER, CLASSIC GREEN 1
1 801581 NA FUEL TANK ASSY., WITH STICKER, BLACK 1
865023 NA FUEL TANK ASSY., WITH STICKER, ROYAL MAROON 1
2 591060/a NA TANK STICKER LH 1
3 591071/a NA TANK STICKER RH 1
4 591182/a NA TANK STICKER TOP 1
5 591058/c NA THIGH PAD RH 1
6 591059/c NA THIGH PAD LH 1
7 110406/b NA SLEEVE 1
8 145869 NA TUBE 1
9 145860/a NA FLANGED HEX. BOLT M10 x 85 1
10 145876/a NA FLANGED HEX. BOLT M10 x75 1
11 591457/a NA STEADY BRACKET 1
12 140542 NA SLOTTED CH.HD.SCREW M4 X 12 (FUEL TANK CAP) 2
13 140508 NA WASHER 2
14 145868/a NA FLANGE HEX NUT M10 2
15 571063/a NA ‘O‘ RING – FUEL PUMP MODULE 1
16 571052/a NA FUEL PUMP MODULE 1
17 143496/a NA WASHER 5
18 144636/a NA COPPER WASHER 5
19 500355 NA M6 SCREW 5
20 581013/b NA FUEL HOSE 1
21 146318 NA CLIP 2
22 581053 NA LOW FUEL SENSOR 1
59
60

Description Qty.
No. Number Number
NA 866012 FUEL TANK ASSY., WITH STICKER,BLACK 1
1 NA 850037 FUEL TANK ASSY., WITH STICKER, SILVER 1
NA 865051 FUEL TANK ASSY., WITH STICKER, ROYAL MAROON 1
2 NA 591060/a TANK STICKER LH 1
3 NA 591071/a TANK STICKER RH 1
4 NA 5911821/a TANK STICKER TOP 1
5 NA 5910581/c THIGH PAD RH 1
6 NA 5910591/c THIGH PAD LH 1
7 NA 147371 SLEEVE 2
8 NA 147372 TUBE 1
9 NA 145860 FLANGED HEX. BOLT M10 X 85 1
10 NA 1458761/a FLANGED HEX. BOLT M10 X 60 1
11 NA 5925241/a STEADY BRACKET 1
12 NA 1458681/a FLANGE HEX NUT M10 2
13 NA 5702631/b SPACER 1
14 NA 5702991/a SPACER_STEADY BRACKET 1
15 NA 1458731/a FLANGED HEX. BOLT M8X90, BLACK PASSIVATION ,
240 HOURS NSS TEST, THICKNESS 10 MICRON MIN. 1
16 NA 142182 HEX NUT WITH NYLON INSERT, M8 - IS : 7002 -8 – ZN.PL 1
17 NA 1455751/a FUEL TAP 1
18 NA 500355 HEX BOLT M6X14 - IS :1364 (PART 1) 2
19 NA 1434961/a FIBER WASHER 4
20 NA 140143 PLAIN WASHER 2
21 NA 140542 SLOTTED CH. HD. SCREW M4X12 - IS :1366 - 4.8 -ZN.PL. 2
22 NA 140508 LOCK WASHER, INTERNAL TEETH B4.3 - IS :5371 2
61
04-10 Frame & PAV Components
CLASSIC 350
62

Description Qty.
No. Number Number
A1 867005 NA PAV ASSY, BLACK 1
863053 NA PAV ASSY, CLASSIC GREEN
865059 NA PAV ASSY, ROYAL MAROON
1 863037 NA FRAME COMP,CLASSIC GREEN 1
801609 NA FRAME COMP, BLACK
865055 NA FRAME COMP, ROYAL MAROON
801609 FRAME COMP, BLACK
2 863016 NA ENGINE MOUNTING PLATE – LH,CLASSIC GREEN 1
801527 801527 ENGINE MOUNTING PLATE – LH,BLACK
865009 NA ENGINE MOUNTING PLATE – LH, ROYAL MAROON
3 863017 NA ENGINE MOUNTING PLATE – RH,CLASSIC GREEN 1
801528 801528 ENGINE MOUNTING PLATE – RH, BLACK
865010 NA ENGINE MOUNTING PLATE – RH, ROYAL MAROON
4 145856/b 145856/b FLANGED HEX. BOLT 1/2"x120 1
5 145708/a 145708/a PLAIN WASHER 1
6 142232/a 142232/a HEX NUT WITH NYLOC INSERT 1
7 145878/a 145878/a FLANGED HEX BOLT, M8X1120 1
8 145879/a 145879/a FLANGED HEX. BOLT M8x112 1
9 140080/2 140080/2 PLAIN WASHER 4
10 142182 142182 HEX NUT WITH NYLON INSERT, M8 4
11 863018 NA ENGINE MOUNTING PLATE, RH REAR,CLASSIC GREEN 1
801529 NA ENGINE MOUNTING PLATE,REAR,BLACK
865011 NA ENGINE MOUNTING PLATE,REAR,ROYAL MAROON
63
CLASSIC 350
64

Description Qty.
No. Number Number
12 591386/a 591386/a FLANGED HEX BOLT, M8X100 2
13 591388/a 591388/a HEX BOLT M12 X 226 1
14 145708/a 145708/a PLAIN WASHER 1
15 591389/a 591389/a HEX NUT WITH NYLOCK M12 1
16 580314 580314 BRACKET (PIECE MUDGUARD) 1
17 145868/a 145868/a FLANGED HEX. SERRATED NUT M10x1.25 1
18 145868/a 145868/a FLANGED HEX. NUT M10x1.25 1
19 591326/a 591326/a FLANGE HEX BOLT M10x1.25x288 1
20 591440/a 591440/a FLANGE HEX BOLT M10x1.25x260 1
21 591073/a 591073/a CAP – SWING PIVOT 2
22 863026 NA SIDE HANDLE ,CLASSIC GREEN 1
843087 843087 SIDE HANDLE ,BLACK 1
865001 NA SIDE HANDLE ,ROYAL MARON
23 145862/a 145862/a FLANGED HEX.BOLT, M8x20 1
24 591456 NA STIFFENER PLATE COMP 1
25 145880 NA FLANGED HEX.BOLT, M8x30 1
26 145867 145867 FLANGED HEX. NUT M8x1.25 1
27 143146 143146 HEX.SOCKET HD.CAP SCREW,M8 X 30 1
28 141044 NA HEX BOLT M6X35 2
29 147504 NA BUSH - PAV 2
30 147502 NA GROMMET 2
31 863045 NA ENGINE MOUNTING PLATE,REAR LH ,CLASSIC GREEN 1
867004 NA ENGINE MOUNTING PLATE,REAR LH ,BLACK
65
CLASSIC 350
66

Description Qty.
No. Number Number
865052 NA ENGINE MOUNTING PLATE,REAR LH ,ROYAL MAROON

32 510187 NA PULSE AIR VALVE 1
33 140129 NA LOCK WASHER 2
34 141060 NA HEX.NUT M6 2
35 572309 NA BRAIDED HOSE assy 1
36 146318 NA SS HOSE CLIP 1
37 572310 NA PAV HOSE-AIR FILTER 1
38 140573 NA CLIP, BREATHER BODY 2
39 572311 NA PAV TUBE ADAPTOR 1
40 147701 NA WIRE CLIP 2
41 NA 592121/b BRACKET ASSY, THROTTLE SWITCH 1
42 NA 145861/a FLANGED HEX BOLT M6X1X20 2
43 NA 801529 ENGINE MOUNTING PLATE,LH & RH REAR,BLACK 2
67
04-20 Seat Assembly
A1
2
1
14
3
17 5
16
4
6
22 12
4
9
11
10
20 18 4 4
19
5
7 8
13 8
15 21
7
17 20 5 4
19
16
68
04-20 Seat Assembly

Description Qty.
No. Number Number
A1 591524 591524 PILLION SEAT KIT SUB ASSEMBLY 1
1 591066/c 591066/c SPILT SEAT ASSEMBLY - RIDER 1
2 591030/c 591030/c COVER - SEAT RIDER 1
3 591423/a 591423/a SILENT BLOCK ASSEMBLY 1
4 142182 142182 HEX NUT WITH NYLON INSERT, M8 8
5 540042/c 540042/c SPRING BUSH 4
6 591029/e 591029/e SPRING STEEL 2
7 145881/a 145881/a FLANGED HEX.BOLT M8 2
8 110366/3 110366/3 WASHER 2
9 591418/b 591418/b SEAT HINGE MTG ASSEMBLY 1
10 591415/a 591415/a STUD - SEAT MTG. 1
12 210026 210026 SPRING WASHER 1
863022 - SUB FRAME CLASSIC GREEN 1
13 801575 - SUB FRAME ,BLACK
865014 - SUB FRAME ROYAL MAROON
801575 SUB FRAME ,BLACK 1
14 591077/c 591077/c SPLIT SEAT ASSEMBLY – PILLION 1
15 591197/a 591197/a PILLION HANDLE 1
16 591505/a 591505/a MUSHROOM HEAD SCREW -M6 X 26 2
17 591506/a 591506/a MUSHROOM HEAD SCREW -M6 X 35 2
18 591534/a 591534/a FLANGED HEX BOLT M8 X 16 2
19 140304/1 140304/1 PLAIN WASHER 2
20 141306/2 141306/2 NYLOCK NUT,M6 2
21 142182 142182 HEX NUT WITH NYLON INSERT, M8 - IS : 7002 -8 - Zn.pl 1
22 591401/a 591401/a FLANGED HEX BOLT M8 X 170 1
69
04-30 Center Stand
3
3 6
70
04-30 Center Stand

Description Qty.
No. Number Number
863025 - CENTER STAND COMPLETE CLASSIC GREEN 1
1 801580 - CENTER STAND COMPLETE BLACK 1
865020 - CENTER STAND COMPLETE ROYAL MAROON 1
- 592159/b CENTER STAND COMPLETE BLACK 1
2 591393/a 591393/a SPINDLE 1
3 141234 141234 WASHER 2
4 145186 145186 RUBBER STOP 1
5 144766/a 144766/a SPRING 2
6 141230/3 141230/3 SPLIT PIN 2
71
05-10 Handle Bar & Controls
A1
Key Nos.
6
All except 7 & 8
10
7
15
1
17
16
5
10
19
22
13 14 21
12
20
18
12 11
2 3
▲
72
05-10 Handle Bar & Controls

Description Qty.
No. Number Number
A1 591413/a 592118/b HANDLE BAR ASSY COMPLETE 1
1 591414/b 591414/b HANDLE BAR COMPLETE 1
2 581083/a 592150/a LEVER & HOLDER ASSYEMBLY, LH 1
3 581029/a 580441/a SWITCH MODULE LH 1
4 581097/a 560195/a SWITCH MODULE RH 1
5 528186 528186 HAND GRIP LH 1
6 581098 146044/a GRIP COMPLETE THROTLE RH 1
7 590250/b 590250/b REAR VIEW MIRROR LH 1
8 590251/b 590251/b REAR VIEW MIRROR RH 1
9 146197 146069 CLUTCH LEVER 1
10 521201/b 521201/b DAMPER WEIGHT 2
11 560632/a 560632/a CLUTCH SWITCH 1
12 560633/a 560633/a SCREW, CLUTCH SWITCH 2
13 147271/a 147271/a ADD ON LEAD,CLUTCH SWITCH 1
14 141460/a 141460/a LH LEVER BRACKET 1
15 145782/b 145782/b CABLE STRAP 6 INCH 4
16 591522/a 591522/a PAN HEAD SCREW M5X10 1
17 591521/a 591521/a ROTOR PLATE 1
18 591974 591974 NUT NYLOCK 1
19 591975 591975 STUD RELEASE LEVER 1
20 591973 591973 WASHER 1
21 591972 591972 SCREW 1
22 521202/a 521202/a HEX. SOCKET THREAD SCREW M8 X 50 2
73
05-20 Control Cables
500
1
1
350
2
3
2
3
74
05-20 Control Cables

Description Qty.
No. Number Number
1 581018/a 592113/b Throttle Cable Assembly (twin cable) 1
2 581032/ 581032/b BI Starter Cable 1
3 571156/b 571156/b Clutch Cable Assembly 1
75
05-30 Caliper Assembly
A1
10 4
1 2
4
5
3
12
13
12
11
13
6
8
9
15
76
05-30 Caliper Assembly

Description Qty.
No. Number Number
A1 146198 146198 Disc Brake Assembly 1
1 560585 560585 Body Caliper 1
2 560586 560586 Piston 2
3 560587 560587 Seal Piston 2
4 560588 560588 Dust Seal 2
5 560589 560589 Boot 1
6 560590 560590 Bellow 1
7 560583 560583 Pad Assembly Set 1
8 560591 560591 Bleed Screw 1
9 560592 560592 Cap 1
10 560593 560593 Spring Pad 1
11 560583 560583 Mounting Bracket Assembly 1
12 560594 560594 Pin bolt 2
13 560595 560595 Grub Screw 2
14 560534/a 560534/a Banjo Bolt 1
15 560597 560597 Washer (Copper) 2
77
05-40 Master Cylinder Assembly
6 12
13
7
10
11
4
5
1 3
A1
15
9
2 16
16
14 17 18 17
8 17 17
78
05-40 Master Cylinder Assembly

Description Qty.
No. Number Number
A1 146199 146199 Master Cylinder Assembly 1
1 560567 560567 Piston Sub Assembly 1
2 560568 560568 Banjo – Bolt Kit 1
3 560571 560571 Cir Clip 1
4 560572 560572 Boot 1
5 560573 560573 Diaphragm 1
6 560574 560574 Csk. Philips Head Screw 2
7 560575 560575 Cover 1
8 560570 560570 Switch Assembly Kit 1
9 146336 146336 Clamp 1
10 146337 146337 Bolt Clamp 2
11 560579 560579 Nut – Lever 1
12 560609 560609 Screw - Lever 1
13 146586 146586 Lever 1
14 560511/b 560511/b Disc 1
15 560530/c 560530/c Socket Button Head Cap Screw 6
16 560534/a 560534/a Banjo Bolt 2
17 560535/a 560535/a Washer 4
18 560514/a 560514/a Brake Hose 1
79
06-10 Head Lamp Casing
18
15 17
16
A1 13 12
10 14
Key Nos. 14
2, 3 (38 Nos.), 11 16 18
19 17
4 (2 Nos), 5
1
A2
22
2 23
Key Nos.
21
1 (2 Nos.), 2, 3 20
32
3 (38 Nos), 4
4 (2 Nos), 5
1
27
24
4
3 25 24
5
25
6 26
26
30
8
7
8
7
28
29
31
9
80

Description Qty.
No. Number Number
A1 597010 597010 BALL RACE KIT 1
A2 597204 597204 BALL RACE KIT WITH COVER 1
1 145446/a 145446/a COVER 1
2 144583/e 144583/e BALL RACE,HEAD LAMP CASING 1
3 140201 140201 BALL DIA 6.35 38
4 144582/e 144582/e BALL RACE, FRAME 2
5 144581/e 144581/e BALL RACE,CROWN 1
6 801275 NA STEERING STEM ASSY,BLACK 1
865029 NA STEERING STEM ASSY,ROYAL MAROON 1
863030 NA STEERING STEM ASSY-CLASSIC GREEN 1
NA 801275 STEERING STEM ASSY,BLACK 1
7 145867/a 145867/a FLANGE HEX NUT M8 X 1.25 2
8 142182 142182 HEX.NUT WITH NYLOCK INSERT M8 2
9 591462/a 591462/a FLANGED HEX. BOLT M8 x 75 2
10 140558/b 140558/b PLUG SCREW 2
11 150254/b 150254/b ‘O’-RING 2
12 110116/b 110116/b STEM LOCK NUT 1
13 140189/3 140189/3 PLAIN WASHER 1
14 146610/a 146610/a WASHER 2
15 146032/a 146032/a M8 X 48 HEX SS BOLT (304 GRADE) 2
16 143818/1 143818/1 STUD, M8 X 32 2
17 140206/5 140206/5 PLAIN WASHER 2
18 143825/1 143825/1 NUT 2
81
18
15 17
16
A1 13 12
10 14
Key Nos. 14
2, 3 (38 Nos.), 11 16 18
19 17
4 (2 Nos), 5
1
A2
22
2 23
Key Nos.
21
1 (2 Nos.), 2, 3 20
32
3 (38 Nos), 4
4 (2 Nos), 5
1
27
24
4
3 25 24
5
25
6 26
26
30
8
7
8
7
28
29
31
9
82

Description Qty.
No. Number Number
19 140202/c 140202/c HANDLE BAR CLIP 1
20 140195 140195 SLEEVE 1
21 140196/d 140196/d SLEEVE, PLAIN 1
22 147560/a 147560/a HEX SOCKET HEAD CAP SCREW M10 X 1.5 X 35 1
23 500809/c 500809/c ADAPTOR 1
24 140193/b 140193/b RUBBER SPACER 2
25 143906/b 143906/b BUSH 2
26 863005 - COVER TUBE,CLASSIC GREEN 2
801006 COVER TUBE, BLACK 2
850032 COVER TUBE, SILVER 2
865006 COVER TUBE, ROYAL MAROON 2
27 863033 - HEAD LAMP CASING,CLASSIC GREEN 1
801600 801600 HEAD LAMP CASING, BLACK 1
850053 HEAD LAMP CASING, SILVER 1
865032 865032 HEAD LAMP CASING, ROYAL MAROON 1
28 863044 - RR COVER COMP WITH STICKER,CLASSIC GREEN 1
866008 866008 RR COVER COMP WITH STICKER,BLACK 1
850033 RR COVER COMP WITH STICKER, SILVER 1
865038 865038 RR COVER COMP WITH STICKER, ROYAL MAROON 1
29 845006 845006 FRONT NUMBER PLATE 1
30 145882/a 145882/a CROSS RECESSED PAN HEAD SCREW M6 x 14 2
31 581122/a 581122/a MUSHROOM HEAD SCREW M6X8X1 2
32 140872/b 140872/b GROMMET 2
83
06-20 Front Fork
15 6 20
A1
14
Key Nos. 5
All except 16,17,18, 19 7
4
13
A2
12
Key Nos.
All except 1, 2 & 3
10 3
16
9
17
18
11
18
19
2
8
1
84
06-20 Front Fork

Description Qty.
No. Number Number
A1 591012/a 591012/a FORK LH ASSY-DISC 1
A2 591021/a 591021/a FORK RH ASSY-DISC 1
1 147077/a 147077/a SOCKET HEADED BOLT 2
2 147074/a 147074/a COPPER PACKING 2
3 591002/a 591002/a FORK END LH – DISC 1
4 591828/a 591828/a OIL SEAL 2
5 591827/a 591827/a OIL SEAL STOPPER 2
6 147078/a 147078/a CAP OIL LOCK 2
7 591829/a 591829/a FORK PIPE SPINING 2
8 147090/a 147090/a REBOUND SPRING 2
9 147092/a 147092/a SEAT PIPE 2
10 147082/a 147082/a PISTON RING 2
11 591512/a 591512/a MAIN SPRING 2
12 591513/a 591513/a WASHER 2\
13 591514/a 591514/a SPACER TUBE 2
14 147081/a 147081/a O’-RING 2
15 591825/a 591825/a FORK BOLT 2
16 591001/a 591001/a FORK END RH 1
17 560564 560564 HEX HD.SCREW M6 X 65 1
18 141061/1 141061/1 PUNCHED WASHER 6.4 2
19 141306/2 141306/2 HEX.NUT WITH NYLON INSERT 1
20 591826/a 591826/a DUST SEAL 1
85
06-30 Swing Arm
6
A1 45
Key Nos.
2&7 3
1
2
7
A1
86
06-30 Swing Arm

Description Qty.
No. Number Number
A1 867006 867006 SWING ARM SUB ASSEMBLY BLACK 1
863054 NA SWING ARM SUB ASSEMBLY CLASSIC GREEN 1
865060 NA SWING ARM SUB ASSEMBLY MAROON 1
1 580347/a 580347/a HEX FLANGE BOLT 1
2 580038/c 580038/c BUSH 2
3 580037/f 580037/f SPACER 1
4 570547/b 570547/b PAD ASSEMBLY, REAR CHAIN 1
5 580344/a 580344/a WASHER 1
6 580343 580343 HEX. NYLOCK NUT 1
863007 NA SWING ARM, CLASSIC GREEN 1
7 801534 801534 SWING ARM BLACK 1
865022 NA SWING ARM ROYAL MAROON 1
87
06-40 Rear Shock Absorber
88
06-40 Rear Shock Absorber

Description Qty.
No. Number Number
863008 NA SHOCK ABSORBER, CLASSIC GREEN 1
1 843087 NA SHOCK ABSORBER, BLACK 1
865001 NA SHOCK ABSORBER, ROYAL MAROON 1
— 146347/b SHOCK ABSORBER 1
2 170399/a 170399/a HEX BOLT - 3/8"X45 (FOR RH SIDE ONLY) 1
3 111696/1 11696/1 HEX.BOLT, - 3/8" BSF x 2" (FOR LH SIDE ONLY) 1
4 140304/1 140304/1 PLAIN WASHER 6
5 143407 143407 SINGLE COIL SPRING LOCK WASHER 4
6 170352/1 170352/1 DOOMED NUT (3/8" B.S.F) 4
89
07-10 Brake Pedal
90
07-10 Brake Pedal

Description Qty.
No. Number Number
1 591074 591074 BRAKE PEDALCOMP 1
2 144886/c 144886/c BRAKE PEDAL RUBBER 1
3 580412/a 580412/a SUPPORT – BRAKE PEDAL 1
4 591385/a 591385/a WASHER 1
6 591469/e 591469/e BRAKE ROD ASSEMBLY 1
7 591390/a 591390/a PIN – BRAKE ROD 1
8 110298/2 110298/2 SPLIT PIN 1
9 144009/c 144009/c NUT,BRAKE ROD 1
10 591499/a 591499/a BRAKE LIGHT SWITCH ASSY 1
11 -- -- BRAKE LIGHT SWITCH SPRING 1
91
07-20 Rear Chain
A1
Key Nos.
3, 4, 5 & 6
92
07-20 Rear Chain

Description Qty.
No. Number Number
A1 597462 597463 CHAIN AND SPROCKET KIT 1
1 801535 801535 CHAIN GUARD ASSY 1
2 145872/b 145872/b FLANGE HEX.BOLT,M8x10 2
3 581085/a NA CHAIN, REAR, 102 PITCHES (‘ O’ Ring type ) - LGB 1
3 NA 580100/a CHAIN, REAR, 100 PITCHES (‘ O’ Ring type ) - LGB 1
4 145854 145854 CONNECTING LINK 1
5 571032/b 570809/a FD SPROCKET 1
6 801479 801479 REAR SPROCKET 1
93
07-30 Foot Rests
94
07-30 Foot Rests

Description Qty.
No. Number Number
863019 NA SIDESTAND MTG COMP.,CLASSIC GREEN 1
1 865012 NA SIDESTAND MTG COMP.,ROYAL MAROON
866001 866001 SIDESTAND MTG COMP.,BLACK
2 580294/b 580294/b SIDE STAND ASSY 1
3 580339 580339 PLAIN WASHER 1
4 521199 521199 HEX SOCKET HEAD SCREW M8X45 1
5 142182 142182 HEX NYLOCK NUT M8 1
6 147849 147849 SPRING 1
863020 NA FOOT REST ARM, LH CLASSIC GREEN 1
7 865013 NA FOOT REST ARM, LH ROYAL MAROON
801459 801459 FOOT REST ARM, LH BLACK
8 591425/a 591425/a SLEEVE-LH 1
9 145865 145865 FLANGED HEX. SERRATED NUT M10x1.5 1
10 145880/a 145880/a FLANGED HEX.BOLT M8 1
863031 NA FOOT REST ARM, RH CLASSIC GREEN 1
11 801460 801460 FOOT REST ARM, RH BLACK 1
865030 NA FOOT REST ARM, RH ROYAL MAROON
12 591428/b 591428/b SLEEVE-RH 1
13 147135/a 147135/a FOOT REST ASSY LH 1
14 591439/a 591439/a FOOT REST ASSY RH 1
95
08-10 Front Wheel
5 19
16 6
16
16
16
16
16
15
3 4
18 7 8
A1
18 9
Key Nos. 18
All 18
A2 17
18 18
Key Nos. 10 11 12
2 13 14
1
All Except
1,2,10,11,12,14
96
08-10 Front Wheel

Description Qty.
No. Number Number
A1 591855 592005 FRONT WHEEL 1
A2 592041 592146 FRONT WHEEL ASSY 1
1 560524/b 560524/b SPEEDO DRIVE ASSY 1
2 560523/e 560523/e SPACER 1
3 141109/1 141109/1 GREASE SEAL, 25X40X7 2
4 145552/b 145552/b BEARING, 6203.RS1-C3 2
5 591206 141133/a RIM, FRONT 1
6 110349 110349 NIPPLE 40
7 592078 560519 FRONT SPOKES SHORT 20
8 592079 560502 FRONT SPOKES LONG 20
9 861012 861012 HUB, FRONT 1
10 591195/b 591195/b SPINDLE 1
11 142835 142835 PLAIN WASHER 1
12 560525/a 560525/a HEX. NUT WITH NYLOCK INSERT M16x1.5, 1
13 560521/b 560521/b SPACER ASSEMBLY 1
14 560522/e 560522/e SPACER, DISC SIDE 1
15 560511/b 560511/b DISC PLATE 1
16 560530/c 560530/c SOCKET BUTTON HEAD SCREW 6
17 560504/f 560504/f ADAPTOR PLATE 1
18 560546/a 560546/a HEX. FLANGE BOLT M8X25 6
19 140355/b 140355/b RIM TAPE 1
20 592006 110280 TUBE, FRONT 1 Fig. not Shown
21 592007 110278 TYRE, FRONT 1 Fig. not Shown
97
08-20 Rear Wheel
A1
Key Nos.
1, 2, 8, 9, 12, 17, 18, 19, 20,
21, 24, 25, 26, 27, 28, 30, 31
98
08-20 Rear Wheel

Description Qty.
No. Number Number
A1 592040 592040 REAR WHEEL ASSEMBLY 1
1 170547 170547 REAR HUB ASSEMBLY 1
2 144471/a 144471/a CUSHION RUBBER 4
3 141114/b 141114/b SPINDLE SHORT 1
4 145553 145553 BEARING 6005 C3 1
5 801479 801479 SPROCKET DRUM 1
6 580311/b 580311/b SPACER 1
7 141115/b 141115/b DISTANCE PIECE 1
8 804005 804005 DUST COVER 1
9 124539/1 124539/1 SLOTTED CHEESE HEAD SCREW M5 X 10 2
10 591816/a 591816/a COVER PLATE ASSEMBLY COMP 1
11 580309/a 580309/a SPACER COVER PLATE 1
12 591210/a 591210/a RIM, REAR 1
13 580308/b 580308/b SPINDLE LONG 1
14 141127/4 141127/4 HEX. LOCK NUT, M22x1.5 1
15 141128/2 141128/2 HEX. CASTLE NUT, M16 1
16 141129/1 141129/1 SPLIT PIN 1
17 592013/a 592013/a SPOKES OUTER, REAR 20
18 110349 110349 NIPPLE 40
19 140355/b 140355/b RIM TAPE 1
20 592003/a 592003/a TYRE, REAR 1
21 592002/a 592002/a TUBE, REAR 1
22 144386/a 144386/a ADJUSTER LH 1
99
08-20 Rear Wheel
A1
Key Nos.
All in group
08-20, 09-10
Except 3 and 13
in group 9-10
100
08-20 Rear Wheel

Description Qty.
No. Number Number
23 144387/a 144387/a ADJUSTER RH 1
24 861011 861011 CENTRE HUB, REAR 1
25 592012/a 592012/a SPOKES INNER, REAR 20
26 146499/a 146499/a SPACER ASSEMBLY 1
27 145552/b 145552/b BEARING, 6203.RS1-C3 2
28 141109/1 141109/1 GREASE SEAL, 25X40X7 1
29 141119/b 141119/b DISTANCE COLLAR 1
30 146256/a 146256/a ‘O’ RING 1
31 141113/1 141113/1 GREASE SEAL 25 X 47 X 7 1
101
09-10 Rear Brake
A1
Key Nos.
All in Group
09 - 10
102
09-10 Rear Brake

Description Qty.
No. Number Number
A1 591816 591816 COVER PLATE ASSY COMP 1
1 801540 801540 COVER PLATE ASSY 1
2 580362/a 580362/a SHOE PIN 1
3 580310/a 580310/a LOCK NUT 1
4 145088/b 145088/b BUSH 1
5 145090/a 145090/a HEX.SCREW M6X25 1
6 145089/b 145089/b SCREW M6X1X16 1
7 145091 145091 HEX.THIN NUT M6 2
8 144570/d 144570/d BRAKE SHOE ASSEMBLY 2
9 147151/a 147151/a OPERATING CAM 1
10 147150/a 147150/a SPRING BRAKE SHOE 2
11 591451/a 591451/a LEVER ASSEMBLY 1
12 140376/2 140376/2 SINGLE COIL SPR.LOCK WASHER 1
13 146434 146434 NUT 1
14 580367 580367 WASHER 1
15 580368/b 580368/b HEX.NUT M12X1.25 1
16 580139/c 580139/c SPRING REAR BRAKE 1
103
10-10 Front Mudguard
104
10-10 Front Mudguard

Description Qty.
No. Number Number
1 863001 NA MUDGUARD FRONT,CLASSIC GREEN 1
801568 866004 MUDGUARD FRONT, BLACK 1
NA 850028 MUDGUARD FRONT, SILVER 1
865002 865034 MUDGUARD FRONT, ROYAL MAROON 1
2 863002 NA STAY FRONT – CLASSIC GREEN 1
801569 866005 STAY FRONT – BLACK 1
NA 850029 STAY FRONT – SILVER 1
865003 865035 STAY FRONT – ROYAL MAROON 1
3 863003 NA STAY CENTER – CLASSIC GREEN 1
801570 866006 STAY CENTER – BLACK 1
NA 850030 STAY CENTER – SILVER 1
865004 865036 STAY CENTER – ROYAL MAROON 1
4 863004 NA STAY REAR – CLASSIC GREEN 1
801571 866007 STAY REAR – BLACK 1
NA 850031 STAY REAR – SILVER 1
865005 865037 STAY REAR – ROYAL MAROON 1
5 153355/4 153355/4 SCREW 6
6 140129 140129 LOCK WASHER 6
7 140056/3 140056/3 HEX NUT WITH NYLOCK INSERT 6
8 145862/a 145862/a FLANGED HEX. BOLT M8x20 6
9 210026 210026 SPRING WASHER M8 6
10 142532/b 142532/b CABLE GUIDE 1
11 560516/a 560516/a WIRE CLAMP 1
12 NA 145882/a CROSS RECESSED PAN HEAD SCREW M6 X 14 1
13 NA 141061/1 PLAIN WASHER M6 1
14 NA 141060 HEX.NUT M6 - IS ; 1364 (PART 3) - 8 – ZN.PL 1
105
10-20 Rear Mudguard
8
6
23
3 22
7
1
21 24
25
4
5
9
18
10 4 27
2 26
11
12
5 13
7 4 19
8
14
18
4 15
6 16
17
9
20
106
10-20 Rear Mudguard

Description Qty.
No. Number Number
1 863040 NA REAR MUDGUARD COMP., WITH STICKER,CLASSIC GREEN 1
801602 NA REAR MUDGUARD COMP., WITH STICKER,BLACK
NA 850040 REAR MUDGUARD COMP., WITH STICKER,SILVER
865056 865056 REAR MUDGUARD COMP., WITH STICKER,ROYAL MAROON
2 863046 NA SAREE GUARD LH, CLASSIC GREEN 1
866014 866014 SAREE GUARD LH, BLACK
850039 SAREE GUARD LH, SILVER
865045 865045 SAREE GUARD LH, ROYAL MAROON
3 863051 NA MUDGUARD CARRIER RH ASSY, CLASSIC GREEN 1
866022 866022 MUDGUARD CARRIER RH ASSY, BLACK
NA 850038 MUDGUARD CARRIER RH ASSY, SILVER
865057 865057 MUDGUARD CARRIER RH ASSY, ROYAL MAROON
4 141061/1 141061/1 PLAIN WASHER 4
5 142274 142274 HEX.SCREW, M6x16 4
6 592141/a 592141/a HEX_SOCKET HEAD SCREW M8x40 2
7 142182 142182 HEX NYLOCK NUT 2
8 145881/a 145881/a FLANGED HEX. BOLT M8 X 45 2
9 592030/a 592030/a PLUG 2
10 170242/a 170242/a GROMMET 1
11 591023/a 591023/a BEADING 1
12 801562 801562 NUMBER PLATE HOLDER COMP 1
13 845007 845007 TAIL LAMP BKT COMP 1
14 591099/a 591099/a BEADING 1
107
10-20 Rear Mudguard
8
6
23
3 22
7
1
21 24
25
4
5
9
18
10 4 27
2 26
11
12
5 13
7 4 19
8
14
18
4 15
6 16
17
9
20
108
10-20 Rear Mudguard

Description Qty.
No. Number Number
15 592140/b 592140/b BRACKET-REFLECTOR 1
16 581122/a 581122/a MUSHROOM HEAD SCREW M6X8 1
17 143275/a 143275/a REFLECTOR ASSEMBLY 1
18 141306/2 141306/2 HEX NYLOCK NUT 4
20 591180/a 591180/a STICKER, REAR MUDGUARD 1
21 591556/a 591556/a PIECE MUDGUARD 1
22 140090/1 140090/1 WASHER 2
23 143498 143498 HEX SCREW M6X25 2
24 140383/3 140383/3 WASHER 2
25 141060 141060 HEX NUT M6 2
26 140129 140129 LOCK WASHER 8
27 141306/2 141306/2 HEX NYLOCK NUT 1
28 863055 NA MUDGUARD CARRIER LH CLASSIC GREEN 1
29 865061 865061 MUDGUARD CARRIER LH ROYAL MAROON 1
30 860028 860028 MUDGUARD CARRIER LH BLACK 1
31 NA 850052 MUDGUARD CARRIER LH SILVER 1
109
11-10 Battery & Harness
110
11-10 Battery & Harness

Description Qty.
No. Number Number
1 146134/c 146134/c BATTERY 12V -14AH MF-A 2 1
2 591877/a 592168/a HARNESS MAIN CABLE 1
3 591560/a 591560/a WIRING HARNESS, TAIL LIGHT 1
4 591156/b 591156/b BATTERY CABLE -VE 1
5 591353 NA BLADE FUSE 20 AMPS 6
6 591567 NA FUSE BOX ASSEMBLY 1
7 NA 146451 FUSE 10 AMPS 2
8 NA 146418 FUSE 15 AMPS 2
9 591838/a NA POWER RELAY ADD-ON 1
10 141162/c 141162/c CABLE STRAP 8 INCH 3
11 141161/c 141161/c CABLE STRAP 6 INCH 2
111
11-20 Switches, Horn & Relays
1
7 6
2
10
11 4
12 3
8
9
112
11-20 Switches, Horn & Relays

Description Qty.
No. Number Number
1 591880 592177/a COMMON KEY SET 1
2 580396/a 580396/a FLASHER UNIT 1
3 146168/b 146168/b HORN 1
4 591561/a 591561/a RELAY STARTER 1
5 145143 145143 STEERING LOCK MOUNTING SCREW (M6 × 12) 2
6 571060 NA POWER RELAY FOR IGNITION 1
7 571059 NA RELAY - (FUEL PUMP & INJECTOR) 1
8 145862/a 145862/a BOLT FOR HORN MOUNTING 1
9 143407 143407 SPRING WASHER 1
10 581234/a NA RUBBER HOLDER FOR RELAY 1
11 ---- --- BOLT FOR RELAY STARTER 2
12 ----- ---- WASHER - RELAY STARTER MOUNTING 2
113
11-30 Warning Indicator, Ammeter & Speedometer
6 4
8
114
11-30 Warning Indicator, Ammeter & Speedometer

Description Qty.
No. Number Number
1 591009 NA MALFUNTION INDICATOR ASSEMBLY (MIL) 1
2 140193/b RUBBER RING, WARNING INDICATOR 1
3 141715 141715 BULB, 12V - 2W 1
591434 NA BULB, 12V - 4W 3
4 591904 592099 SPEEDOMETER ASSEMBLY (KMPH) 1
5 145980/b 145980/b SPEEDOMETER CABLE 1
6 110179 110179 RUBBER RING, SPEEDOMETER 1
7 591219 BULB HOLDER COMPLETE MIL 1
8 INNER CABLE SPEEDOMETER 1
9 592173 AMMETER 1
115
11-40 Head Lamp
A1
6
4
1 2
3 7
A1
5
116
11-40 Head Lamp

Description Qty.
No. Number Number
A1 591873/a 591873/a PILOT LAMP WITH BULB 2
1 141632 141632 HEAD LIGHT RIM 1
2 591905/b 591905/b HEAD LAMP ASSEMBLY WITH HALOGEN BULB 1
3 591442 591442 BULB 12V - 60/55W HALOGEN (HEAD LAMP) 1
4 141634 141634 RIM FIXING (HEAD LAMP FIXING RIM) 1
5 146456 146456 BULB 12V - 4W BA 7S CAP 1
6 141715 141715 BULB 12V - 2W BA 7S CAP 2
7 147726/B 147726/b ADDON LEAD 1
117
11-50 Tail Lamp
A1
Key No’s
All
A1
118
11-50 Tail Lamp

Description Qty.
No. Number Number
A1 591011/d 591011/d TAIL LAMP ASSEMBLY 1
1 591216 591216 LENS & BASE SEALED 1
2 561215 561215 BULB HOLDER COMPLETE 1
3 591214 591214 BULB 12V - 21/ 5W 1
4 145882 145882 MUSHROOM HEAD SCREW M6 X 1 X 10 3
5 141061/1 141061/1 PLAIN WASHER 6
119
11-60 Trafficator Lights
5
7 5
1,2 3,4
120
11-60 Trafficator Lights

Description Qty.
No. Number Number
1 592171/a 592171/a TRAFFICATOR ASSEMBLY RH FRONT 1
2 592169/a 592169/a TRAFFICATOR ASSEMBLY RH REAR 1
3 592172/a 592172/a TRAFFICATOR ASSEMBLY LH FRONT 1
4 592170/a 592170/a TRAFFICATOR ASSEMBLY LH REAR 1
5 146348 146348 BULB 12V 10W 1
6 540097/b 540097/b BRACKET LH, FRONT 1
7 540098/b 540098/b BRACKET RH, FRONT 1
8 142182 142182 NUT, NYLOCK M8 2
121
12-10 Tool Box (Electricals Box) LH
3 7
6
5
2
3
5
4 9
3 5
3 4
4
7 5
122
12-10 Tool Box (Electricals Box) LH

Description Qty.
No. Number Number
863042 NA TOOL BOX, ELECTRICAL WITH STICKER,CLASSIC GREEN 1
1 866019 866009 TOOL BOX, ELECTRICAL WITH STICKER, BLACK 1
850044 TOOL BOX, ELECTRICAL WITH STICKER,SILVER 1
865053 865046 TOOL BOX, ELECTRICAL WITH STICKER,ROYAL MAROON 1
2 141093 141093 HEX SCREW, M6 X 10 1
3 142274/a 142274/a HEX SCREW, M6 X 16 3
4 141061/1 141061/1 PUNCHED WASHER 4
5 140383/3 140383/3 PLAIN WASHER 1
6 140129 140129 LOCK WASHER,INTERNAL TEETH 3
7 141060 141060 HEX.NUT M6 2
8 591352/a 591352/a GROMMET-ELECTRICAL BOX 1
9 591876 592020/a STICKER, TOOL BOX 1
123
12-20 Utility Box
124
12-20 Utility Box

Description Qty.
No. Number Number
863029 NA BODY COMP.TOOLBOX, CLASSIC GREEN 1
1 801578 NA BODY COMP.TOOLBOX, BLACK 1
865018 NA BODY COMP.TOOLBOX ,ROYAL MAROON 1
863028 NA LID ASSY, TOOL BOX.CLASSIC GREEN 1
2 801577 NA LID ASSY, TOOL BOX. BLACK 1
865017 NA LID ASSY, TOOL BOX. ROYAL MAROON 1
3 521088/b NA GROMMET 2
4 142274 NA HEX SCREW, M6 X 16 2
5 140383/3 NA PLAIN WASHER 2
125
12-20 Resonator Box & Cover
126
12-20 Resonator Box & Cover

Description Qty.
No. Number Number
1 NA 801607 LID COVER ASSEMBLY BLACK 1
NA 850042 LID COVER ASSEMBLY SILVER 1
NA 865044 LID COVER ASSEMBLY MAROON 1
2 NA 147521/b RESONATOR BOX 1
3 NA 521088/b GROOMET 2
4 NA 142274 HEX. SCREW M6 X 16 2
5 NA 592109/a RUBBER BELLOW 1
7 NA 592132/b BRACKET RESONATOR BOX 1
8 NA 145861/a FLANGED HEX. BOLT M6 X 1 X 20 2
127
12-30 Battery Carrier
128
12-30 Battery Carrier

Description Qty.
No. Number Number
1 801209 801209 BACK PLATE ASSEMBLY, 1
2 863024 - COVER – BATTERY CLASSIC GREEN 1
801476 801476 COVER – BATTERY BLACK 1
850034 COVER – BATTERY SILVER 1
865016 865016 COVER – BATTERY ROYAL MAROON 1
3 142258 142258 HEX BOLT M8X16 1
4 560100 560100 HEX BOLT M8 X 45 1
5 560058/b 560058/b STRAP 2
129
13-10 Tool Kit
1 2 3 4 5 6 7 8 9 10
11
A1
Key Nos.
1 to 10
130
13-10 Tool Kit

Description Qty.
No. Number Number
A1 570828/a 570828/a TOOL KIT 1
1. 521150/a 521150/a TOOL WALLET 1
2. 570827/a 570827/a TOMMY BAR WITH 8MM ALLEN KEY HEAD 1
3. 570826/a 570826/a PLUG SPANNER (16 X 8MM) 1
4. TUBULAR SPANNER (12 X 13MM) 1
5. EYELET SPANNER 17MM 1
6. 521104/a 521104/a SCREW DRIVER 1
7. DOUBLE END SPANNER (3/8” X 5/16”) 1
8. DOUBLE END SPANNER (10 X 13MM) 1
9. 580695/a 580695/a DOUBLE END SPANNER (10 X 12MM) 2
10. 142631 142631 TUBULAR SPANNER (21 X 24MM) 1
11. 521097/a 521097/a FIRST AID KIT 1
131
14-10 Special Tools List
2
1 3
5 6
4
9
7 8
132

Description Qty.
No. Number Number
1 ST-25118 - 4 CYLINDER HEAD NUT TIGHTENING TOOL 1
2 ST-25123 - 1 VALVE SPRING COMPRESSOR 1
3 ST-25612-4 ROTOR TIGHTENING & LOOSENING TOOL 1
4 ST-25128 - 2 PULLER FOR MAGNETO ROTOR 1
5 ST-25592-4 CONNECTING ROD LOCKING TOOL 1
6 ST-25151-4 PULLER FOR CHAIN CASE OUTER 1
7 ST-25591-4 SPROCKET & CLUTCH TIGHTENING TOOL 1
8 ST-25594-4 CLUTCH PLATE TIGHTENING TOOL 1
9 ST-25153 - 4 EXTRACTOR FOR GEAR BOX ROCKER PIVOT PIN 1
133
11
10 12
14 15
13
DOL TOOL
16 17
134

Description Qty.
No. Number Number
10 ST-25835-2 FD SPROCKET REMOVING TOOL 1
11 ST-25834-2 FRONT FORK DISMANTLING TOOL 1
12 ST-25114-4 EXTRACTOR FOR FORK OIL SEAL 1
13 ST-25113 - 4 MANDREL FOR OIL SEAL 1
14 ST-25112-4 EXPANDER FOR FRONT FORK OIL SEAL 1
15 ST-25110-3 GAUGE PLATE FOR TIGHTENING CHAIN STAY 1
16 ST-25244 - 4 SPECIAL SPANNER ADJUSTER 1
17 CR0060 DOL TOOL FOR EFI DIAGNOSIS 1
135
Spare Parts Catalogue
Classic 500 & 350
KEEP IT
REAL
USE ONLY GENUINE
ROYAL ENFIELD
SPARE PARTS
Royal Enfield (A Unit of Eicher Motors Ltd.)

Tiruvottiyur High Road, Tiruvottiyur, Chennai - 600 019.
Tel: +91 44 4223 0400. Fax : +91 44 4204 3019 Website : www.royalenfield.com

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Spare Parts Catalogue

Classic 500 & 350

03-30 FUEL TANK

Key No. Which

Numeric Key No.

1. KEY NUMBER (KEY NO.)

01-10 ENGINE ..................................................................... 13 06-10 HEAD LAMP CASING ............................................... 81

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02-10 ENGINE COVER - LH 02-20 ENGINE COVER - RH 02-30 CLUTCH

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04-10 FRAME 04-20 SEAT ASSEMBLY 04-30 CENTER STAND

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Page 500 Page Page

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07-20 REAR CHAIN 07-30 FOOT RESTS 08-10 FRONT WHEEL

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08-20 REAR WHEEL 09-10 REAR BRAKE 10-10 FRONT MUDGUARD

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14-10 SPECIAL TOOLS LIST 14-10 SPECIAL TOOLS LIST

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

865052 NA ENGINE MOUNTING PLATE,REAR LH ,ROYAL MAROON

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks

Key 500 EFI Part 350CC Part Remarks