PLATE NO.

1 : CYLINDER HEAD

Boxer S

2 18 7 7

4 5 10 2 3

15 12

14 1 12 14 16 11

13 17

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

36 DU10 01 31 1010 06 39 1673 04 31 1010 08 39 1021 21 DD 1013 47 DD 1013 50 DD 1013 49 DU 1012 08 31 1010 07 DD 1013 51 39 1000 06 DD 1013 43 39 1017 21 DD 1014 81

O Ring Kit Cap Flanged bolt Guide Valve O Ring Bolt Stud Bolt Head Comp. Cylinder Cover (OHC) Bolt Hollow Dowel Pin Gasket head O Ring Damper Cylinder Head

1 2 6 2 2 2 2 4 1 1 2 2 1 2 4

Ref. Page No.

FRONT WHEEL DIRECTION

PLATE NO. 1 : CYLINDER HEAD

Boxer S

2 18 7 7

4 5 10 2 3

15 12

14 1 12 14 16 11

13 17

Fig. No.

Part No.

Description

Qty / Veh.

Remark

16 17 18

31 1011 75 DU 1010 58 DD 1015 21

Insulator (Head Side) Pipe Intake Plain washer

1 1 4

FRONT WHEEL DIRECTION

PLATE NO. 2 : VALVE

Boxer S

2 3 5 4

6 8

5 1

9 Fig. No. Part No. Description Qty / Veh. Remark

1 2 3 4 5 6 7 8 9

DU 1011 91 DF 1010 55 DU 1011 90 31 1011 04 39 0702 01 31 1010 18 DD 1014 40 36 3110 08 36 3110 28

Shaft Rocker Screw Rocker arm assembly Stopper Screw Pan Cros Retainer Valve Spring Spring Stiffer Collet Seal Oil Kit Valve Kit

2 2 2 1 2 2 2 1 1

FRONT WHEEL DIRECTION

PLATE NO. 3 : CAMSHAFT / TENSIONER

Boxer S

13 3 12 4

5 10 6

1 11

10 11

8 2 7

14

9 Remark

Fig. No.

Part No.

Description

Qty / Veh.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

36 3110 06 39 1017 21 DU 1010 96 DU 1010 56 DU 1010 78 31 1010 33 DD 1014 07 DD 1014 87 39 1959 04 DD 1010 62 39 0748 01 39 0999 06 DU DU 1010 67 39 1790 21

Chain Guide Kit O Ring Hex. Soc.HD Screw Sprocket (28 T) Camshaft assly. Chain Tensioner Assly./O ring Tensioner Assly./O ring Bolt Flanged Small Bolt Screw Pan Cross Hollow Dowel Pin Washer Spl. Cam Shaft Collar Cam O Ring

1 1 1 1 1 1 1 1 2 1 2 2 1 1 1

Alt. DU101078

Advik make Pricol make

FRONT WHEEL DIRECTION

PLATE NO. 4 : CYLINDER AND PISTON

Boxer S
3

1 1 2

5 5

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6

39 1000 06 DD 1010 07 DU 1010 94 DD 1010 14 39 0985 17 DH 1014 30

Hollow dowel Pin Gasket - Cyl. Block Cylinder Block Piston assly Piston ring set std. Wire Clip Damper

2 1 1 1 2 3

FRONT WHEEL DIRECTION

PLATE NO. 5 : CRANK SHAFT

Boxer S
4 2 16

5 6 8 14 13

15 7 11 10 12 9

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

39 1055 15 01 1006 10 DU 1010 05 28 1011 07 DX 1010 47 FA 1013 34 DU 1010 41 39 1699 01 DH 1011 95 DX 1010 53 DU 1010 10 39 2200 11 DH 1010 66 39 2199 08 DH 1010 67 28 1011 07

Nut Woodruff Key Crankshaft Assly. Key Woodruff Gear Primary, Helical (23 T) Gear Cover Countersunk Screw Nut Body Centrifugal Oil Filter(C.I.) Gasket Central Oil Filter Washer Joint Oil Delivery Pin Snap Spring Oil Delivery Key Woodruff

1 1 1 2 1 1 1 3 1 1 1 1 1 1 1 1 Alt. DU 1012 11

FRONT WHEEL DIRECTION

PLATE NO. 6 : TRANSMISSION 6 5 4 3 2 16 9 4 8 7

Boxer S

10 12 11 13

14

15

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

DD 1013 09 DX 1010 45 DX 1010 48 39 0987 17 DX 1010 49 DU 1010 11 DU 1010 80 DX 1010 51 DX 1010 50 DX 1010 46 DM 1011 15 36 DU15 05 DP 1011 55 DP 1011 68 39 1981 04 DD 1014 75

Bushing Floating Gear 2nd Input Gear Transmission Spur(3rd) Ring Snap (16 mm) Gear 4th Input Shaft Transmission Input Gear 1st Output Gear 4th Output Gear Transmission Spur(3rd) Shaft Transmission Output Plate For Sprocket Output Chain Sprocket Kit Collar (Sintered) O Ring Bolt Washer Special

1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1

Ref. page No.

FRONT WHEEL DIRECTION

PLATE NO. 7 : CHANGE DRUM / SHIFT FORK

Boxer S

8 1 4 7

9 3 6 2

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9

31 10 1191 31 10 1051 DU 1010 81 DM 1010 98 31 10 1192 39 0992 06 DP 1013 40 DM 101099 DU 1010 83

Fork Shift Rod shift Drum assly. change Cup Stopper Fork shift Pin Dowel Bolt Soc. Head Plate Spacer Cam Drum Change

1 2 1 1 1 5 1 1 1

FRONT WHEEL DIRECTION

PLATE NO. 8 : GEAR CHANGE MECHANISM

Boxer S

7 4 12 13 11 3 5 2 6

9 10

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13

DU 1010 73 39 1994 04 36 DU10 04 DU 1010 74 39 0746 01 DU 1011 84 DD 1011 06 39 2474 04 DU 1011 85 31 10 1108 31 1011 09 39 2704 11 DU 1011 13

Stopper Comp.Gear Shifter Bolt Gear Lever Spring Kit Plate Position Screw Pan Cross Lever Comp. Change Shaft Bolt Flanged bolt Lever Change / Damper Damper Collar Washer Spring Steel Spacer

1 1 1 1 1 1 1 1 1 1 1 1 1

Ref. Page No.

FRONT WHEEL DIRECTION

PLATE NO. 9 : CRANKCASE RH / ENGINE ASSLY.

Boxer S

1 6 2 3 1 5 8 13 1 11 2 12 2 9 10 7

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14

39 1225 15 39 0248 11 39 1068 04 39 1056 04 39 1864 20 39 0999 06 01 1701 11 DP 1014 52 DG 1014 98 DD 10 1275 01 1701 10 DU 1010 75 DU 1010 85 DU 1010 01

Nut Plain Washer Bolt Bolt Bearing Ball Dowel Pin Bearing Oil Strainer Gasket Plug (Drain) Bearing Crankcase Comp. RH Bushing Engine Assembly

3 3 2 1 1 5 1 1 1 1 1 1 1 1

Alt. to 39229320

N.I.

10

FRONT WHEEL DIRECTION

PLATE NO. 10 : CRANKCASE - L.H.

Boxer S

15 11 14

10 9

12 1

8 2 7 7 5 6 4 3 13

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

01 1701 11 39 1050 06 39 1066 04 39 1043 19 39 1080 19 39 1008 20 39 0702 01 31 1010 56 31 2010 81 39 0703 11 39 1075 04 30 1010 15 DG 1014 98 DD 1011 01 DD 1012 19 30 1410 15 DU 1210 29

Ball Bearing Dowel Pin Bolt Flanged Small Oil Seal Seal Oil Bearing Needle Screw Pan Cros Guide Switch Comp. (Neutral) Plain Washer Bolt Flanged Small Gasket Gasket Crankcase LH Tube rubber Clamp Clamp

1 1 3 1 1 1 2 1 1 1 7 1 1 1 1 1 1

11

FRONT WHEEL DIRECTION

PLATE NO. 11: PIPE OIL

Boxer S

3 2 2 1 3 2 2 4

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4

DU 1210 05 DU 1210 10 31 1210 06 39 1023 04 39 1062 04

Pipe Oil Pipe Oil Gasket Bolt Bolt flanged small

1 1 4 2 2

Use with Bkt.Engine Front RH DU161094 Use with Bkt.Engine Front DD161052

12

FRONT WHEEL DIRECTION

PLATE NO. 12 : COVER GENERATOR & COVER CHAIN

Boxer S

6 4 5 1 2 8 3 7

10 9

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10

31 1010 62 39 1019 21 31 1012 95 31 1010 61 31 1011 13 DD 1010 58 39 1074 04 39 0999 06 DM 1011 49 39 2147 04

Bolt Ring O Cover Generator Plug Gasket Gasket - Generator Cover Bolt Flanged Small Pin Cover Chain (Engine) Bolt Flanged Small

1 1 1 1 1 1 5 2 1 3

13

FRONT WHEEL DIRECTION

PLATE NO. 13 : CLUTCH COVER

Boxer S

7 9 11 8 10 2 1 4

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10

DU1012 10 DU 1011 88 39 0999 06 31 1010 67 39 1041 19 30 1011 42 DD 1013 25 39 2134 21 DD 1010 60 39 1075 04

Clutch cover/ Graphics/Gauge Label BAJAJ EXHAUSTEC Dowel Pin Guage Seal oil Seal oil Cap oil filler O ring Gasket (Clutch cover) Bolt flanged small

1 1 2 1 1 1 1 1 1 10

14

FRONT WHEEL DIRECTION

PLATE NO. 14 : CLUTCH

Boxer S

4 3 10 6 9

14 8 7 9 12 11 2 13

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14

DX 1010 54 28 1011 95 39 2600 11 DU 1011 09 DD 1014 92 DD 1014 80 30 1010 96 DD 1014 93 28 1012 14 39 0980 04 39 1053 15 39 2403 20 31 10 1148 DX 1010 35

Housing Comp. clutch Holder Plain Washer Collar Wheel Clutch Plate Friction Plate Clutch Hub Clutch Spring Hex. Bolt Hex.Nut/Flange Bearing Rod Push Lever Assly. Complete

1 1 2 1 1 5 4 1 6 6 1 1 1 1

15

FRONT WHEEL DIRECTION

PLATE NO. 15 : KICK STARTER MECHANISM

Boxer S

5 1

4 14 13 6 7 15 13 11 10 9 14 8 16 14 12 14

2 3

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

DP 1510 18 DD 1012 64 DD 1012 54 DU 1010 50 30 1011 54 36 DU10 07 22 1502 41 31 1010 41 39 0993 11 31 1010 39 31 1010 38 DU 1010 38 39 0995 11 39 0738 17 DU 1010 45 31 1010 40

Flanged bolt Screw Pan Cross Guide Kick Lever Assly Kick Comp. Bush(Damper) Boss Kick Set Plain Washer Spring Plain Washer Coil Spring Ratchet Gear Spur Kick Start Plain Washer External Circlip Type C Shaft Kick Guide

1 2 1 1 1 1 1 1 1 1 1 1 2 4 1 1 Ref. Page No.

16

FRONT WHEEL DIRECTION

PLATE NO. 16 : CARBURETTOR 9 2 1

Boxer S

8 3

12

10

13 15

4 11 14

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DU 1210 09 DU 1010 57 39 1283 21 36 DU12 06 36 DU12 04 36 DU12 05 36 DU12 02 36 DU12 03 39 1675 04 DU 1210 28 DD 1211 71 DU 1210 17 DH 1211 01 DH 1211 02 39 1062 04

Carburettor Assly. (PB-16) Insulator (Carburettor / Intake) O ring Carburettor Holder / Jet Kit Gasket O ring Kit for Carb. Carburettor Float pin Kit Idling Screw kit Air Control Screw Kit Flanged bolt Seat for Jet Needle Screw with washer Valve throttle Magnet Assly. Reed Switch Assly. Bolt Flanged Small

1 1 1 1 1 1 1 1 2 1 2 1 1 1 1

Ref. Page No. Ref. Page No. Ref. Page No. Ref. Page No. Ref. Page No. For mounting Carburettor

TPS Assly. Parts TPS Mounting

17

FRONT WHEEL DIRECTION

PLATE NO. 17 : AIR FILTER ASSLY AND BATTERY BOX

Boxer S

3 12/13 9 10 11 8 14 15 1 5 6

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DF 1210 23 DU 1210 04 39 0986 08 DU 1210 08 31 1210 29 36 DU12 01 DH 1211 03 DM 2210 01 39 1680 04 39 2407 01 39 1789 24 DM 1210 10 31 1610 07 DM 1210 14 DM 1210 26

Filter assly air Case air filter Pin Cotter Duct (A/F to Carburettor) Element air filter Air filter Kit Duct (Inlet) Band - Tool kit Flanged bolt (Battery) Screw (Mounting air filter) Washer (Nylon) Band (Battery) Damper battery Tube oil drain Clamp

1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 Ref. Page No.

18

FRONT WHEEL DIRECTION

PLATE NO. 18 : MUFFLER

Boxer S

3 2

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6

31 10 1014 39 0198 11 39 0732 12 39 2145 15 DU 1011 96 DD 1013 66

Gasket Plain Washer Spring washer Nut Assembly Silencer Comp. Flanged Bolt

1 2 2 2 1 1

Exhaust-Tec

19

FRONT WHEEL DIRECTION

PLATE NO. 19 : OIL PUMP

Boxer S
1 2

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5

39 1078 01 39 0753 01 DF 1210 03 39 0999 06 39 1013 21

Screw Pan Cros Screw Pan Cros Pump Assly. Oil Pin dowel Ring O

2 1 1 1 2

20

FRONT WHEEL DIRECTION

PLATE NO. 20 : MAGNETO ASSEMBLY

Boxer S

4 3

1 7 9

16

15 13 14 10 18 11

12 17

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

DX 1110 03 DD 1110 48 DF 1110 20 39 1042 19 39 1003 20 39 1028 21 39 1659 11 DF 1110 17 31 1110 58 39 1553 04 DU 2010 62 DD 1110 18 DF 1110 40 39 0745 01 DD 1013 18 31 1110 56 DD 1110 11 DD 1110 12

Magneto assly/Brg. & Oil Seal Cap Spark plug (R) Stator assly Seal Oil (HTA make) Bearing ball Ring O Plain washer Ignitor assly (C.D.I.) / Damper Pulser Coil Flanged Bolt Regulator/Rectifier (R/R) unit Plug Spark (P-RZ9HC) H. T. Coil Screw pan cross Bolt Exciter coil Grommet Spark plug Cap Grommet H.T.Cable

1 1 1 1 1 1 3 1 1 2 1 1 1 1 3 1 1 1

Alt.DD 1110 36

21

FRONT WHEEL DIRECTION

PLATE NO. 21 : FRAME

Boxer S
3 4 6 15 16

5 1 2

11 6

10

11

13 17 14A/14B 9

12 Fig. No. Part No. Description Qty / Veh. Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14A 14B 15 16 17 18

39 2473 04 31 1910 02 DF 1810 90 DF 1810 52 36 3118 03 30 18 1006 DM 1611 20 39 2222 04 39 1068 04 39 2469 04 39 2479 15 DM 2210 08 DU 2210 07 DU 1610 93 DU 1610 94 DD 1612 03 DD 1612 04 39 2700 04 DF 1810 24

Flanged Bolt Clamp Nut Cap Steering Bearing cone kit Ball Steel Frame Comp./Brg.races Flange Bolt Hex.Bolt Flanged Bolt Flange Nut Grip frame Flanged bolt Bracket Engine Front/Bush LH Bracket Engine Front/Bush RH Bracket Engine Upper LH Bracket Engine Upper RH Flange Bolt Lock Set (4 in 1)

1 1 1 1 1 46 1 4 1 1 5 1 2 1 1 1 1 1 1

Ref. Page No.

Engine Mounting Rubber

22

FRONT WHEEL DIRECTION

PLATE NO. 22 : SWING ARM/REAR SHOCK ABSORBER

Boxer S

3 16 1 2 3 3

18 17 4 5 9 7 6 8 9 11 8 6 16 10 5

15 3 1 2 12 13 14 14 13 14 14

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

39 0712 15 39 0737 12 39 0714 11 DM 1710 26 36 DF17 01 39 0248 11 31 1710 06 39 0201 11 30 1710 18 39 1225 15 DU 1710 18 30 1710 24 39 0711 11 39 0292 15 30 1710 23

Domed Cap Nut Washer Spring Washer Plain Rear Shock Absorber Rubber Inner Bush kit Plain Washer Shaft Swing Arm Plain Washer Bushing Rubber Nut Hex./ flange Arm Comp. Swing / Bush Adjuster Chain (RH) Washer Plain Hex Nut Adjuster Chain (LH)

4 4 8 2 1 2 1 2 2 1 1 1 2 4 1

Ref. Page No.

23

FRONT WHEEL DIRECTION

PLATE NO. 22 : SWING ARM/REAR SHOCK ABSORBER

Boxer S

3 16 1 2 3 3

18 17 4 5 9 7 6 8 9 11 8 6 16 10 5

15 3 1 2 12 13 14 14 13 14 14

Fig. No.

Part No.

Description

Qty / Veh.

Remark

16 17 18

31 1710 12 39 0454 11 39 0553 02

Damper for Swing arm Plain washer Self tapping Screw

1 2 2

24

FRONT WHEEL DIRECTION

PLATE NO. 23 : STAND ,STEP AND STAY LH / RH

Boxer S

2 1 1 16

5 3 10

14 7 6

7 12/13

11

9 15

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

DF 1614 13 DF 1614 25 39 1940 04 DF 1611 02 39 0422 15 DL 1610 48 30 1611 58 30 1611 57 DU 1610 32 39 0787 08 DG 1611 24 DU 1611 44 DU 1611 45 39 2481 04 DX 1610 56 DH 1611 94

Damper (PVC)
Holder Step/Damper/Kick Stopper

Flanged Bolt Bolt Nyloc Nut Stand Side Spring Shaft Stand Stand Centre/Damper Pin Cotter Damper Stay LH / PVC Damper Stay RH / PVC Damper Hex bolt flanged Rubber Pillion Step (PVC) Kick Stopper

2 1 4 1 1 1 2 1 1 1 1 1 1 2 2 1

Alt. DF161096 Alt. DD161417

Alt. DU161027

25

FRONT WHEEL DIRECTION

PLATE NO. 24 : FENDER - FRONT & REAR

Boxer S

2 14 1 11 12 3 2

13 3 10

6 7 8 8 4 3 5

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14

39 2222 04 30 1910 47 DF 1910 20 39 2483 04 DD 1610 51 DF 1611 04 DM 1610 09 39 0711 11 39 0817 15 39 2473 04 DF 1612 45 01 1106 09 22 1504 35 39 2484 15 39 2473 04

Flanged Bolt Clamp Clamp Flanged Bolt Flap Fender Rear Fender Rear Front Plain Washer Hex. Nut Flanged Flanged Bolt Mudflap - Front Plain Washer Bolt Flange Nut Flange Bolt

4 1 1 4 1 1 1 4 4 1 1 2 2 2 1

N.I. for Clamp DF191020

Alt. 39171111

26

FRONT WHEEL DIRECTION

PLATE NO. 25 : WHEEL RIM / SPOKES/ TYRE/ TUBE 1 2 3

Boxer S

9 4

12 9 8 1 10 Fig. No. Part No. Description Qty / Veh. 11

Remark

1 2 3 4 5 6 7 8 9 10 11 12

16 1510 66 DU 1510 25 DU 1510 26 DS 1510 46 DM 1510 25 DS 1510 49 DM 1510 28 DU 1510 18 DG 1510 22 DS 1510 09 DS 1510 10 DS 1510 53

Nipple Spoke Spoke Inner Front Spoke Outer Front Wheel Rim Front (1.6 x 17) Tyre Front Tube Front Tyre Rear Wheel Rim Rear(1.85 x 17) Band Rim Spoke Inner Rear Spoke Outer Rear Tube Rear

72 18 18 1 1 1 1 1 1 18 18 1

Proprietory Parts Not Serviced

27

FRONT WHEEL DIRECTION

PLATE NO. 26 : FRONT HUB 7 6 9 3 2 20 5 21

Boxer S

22 17 15 1 13 8 10 11 16 26 27 23 12 25 25 24 4 19 14 18

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

39 2680 20 DF 15 10 03 31 15 10 04 36 DU15 03 39 2681 20 DU 1510 05 39 0248 11 DD 1510 09 DZ 1510 40 39 0775 04 DD 1510 08 DZ 1510 12 30 15 10 38 31 15 10 39 31 15 10 11

Ball Bearing Drum Front Collar Gear Meter Screw Kit Ball Bearing Collar Axle Assly. Plain Washer Indicator Front Nut Hex. Slotted Bolt Lever Brake Cam Axle Ring O Panel Front Brake Cam Brake

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

6300RS1/C3

Ref. Page No. 6200RS1/C3

(31151064)

28

FRONT WHEEL DIRECTION

PLATE NO. 26 : FRONT HUB

Boxer S
7 6 9 3 2 20 5 21

22 17 15 1 13 8 10 11 16 26 27 23 12 25 25 24 4 19 14 18

Fig. No.

Part No.

Description

Qty / Veh.

Remark

16 17 18 19 20 21 22 23 24 25 26 27

39 0798 15 30 15 1037 31 1510 13 39 1013 21 14 1510 21 39 0990 08 31 1510 14 30 1511 18 JA 1316 06 30 1510 42 39 0900 12 39 0840 01

Flange Nut Spring Shoe Brake Assly. Ring 'O' Oil Seal Cotter Pin Oil Seal Stopper Fro bushing Bushing Washer Spring Washer Screw pan Cross

1 2 2 1 1 1 1 1 1 2 1 1

29

FRONT WHEEL DIRECTION

PLATE NO. 27 : REAR HUB

Boxer S

8 1 4 25

27 3

26

7 11

12 14 15 13

17

6 18 19 24 9 16 21 22 20 23

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

36 DU15 05 39 0978 04 31 15 1029 39 0794 15 30 1510 75 39 0798 15 36 DU15 06 39 0988 15 31 1510 26 30 1510 76 30 1510 63 31 1510 18 30 15 1069 30 1511 05 31 1510 60 30 1510 11

Chain Sprocket Kit D bolt Washer Nut Hex. Fine Bearing Ball Hex. nut Rear Wheel Bearing Kit Nut Hex. Collar Shock Damper Drum Rear Collar Assly. Spring Shoe Brake Assly. Shoe Brake Assly. Brake Cam assly

1 4 2 4 1 1 1 1 1 4 1 1 2 1 1 1

Ref. Page No.

(DU151013)

Ref. Page No.

Alt.DF151009

For Bangladesh version

30

FRONT WHEEL DIRECTION

PLATE NO. 27 : REAR HUB

Boxer S
2

8 1 4 25

27 3

26

7 11

12 14 15 13

17

6 18 19 24 9 16 21 22 20 23

Fig. No.

Part No.

Description

Qty / Veh.

Remark

16 17 18 19 20 21 22 23 24 25 26 27

31 1510 08 30 1510 38 31 1510 37 39 0775 04 DM 1510 32 39 0714 11 39 0982 15 39 0787 08 30 1510 05 DU 1510 06 30 1510 78 30 1510 79

Panel Rear Brake Ring O Lever Brake Bolt Axle Washer Plain Nut Castle Pin Cotter Indicator Collar Coupling Sleeve

1 1 1 1 1 1 1 1 1 1 1 1

31

FRONT WHEEL DIRECTION

PLATE NO. 28 : BRAKE PEDAL

Boxer S

5 17 6

4 2 1 8 2 11 12 10 15 9 3

13 16 14

15

12 11

10

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

39 0808 08 DF 1910 67 DM 1910 10 30 19 1038 DM 1910 16 39 0805 11 39 0797 08 30 19 1031 30 1910 35 39 0807 08 39 0708 15 DF 1910 67 30 1910 38 30 1910 36 30 1510 95 DF 1510 16 DD 1610 78

Split pin Plain Washer Rod Brake Pin Lever Brake Tubular Washer Plain Pin Cotter Spring Spring Pin Snap Nut Hex. Washer Spring Pin Brake adjusting nut Bolt Torque rod Damper

1 2 1 1 1 1 1 1 1 2 2 2 1 1 2 1 1

32

FRONT WHEEL DIRECTION

PLATE NO. 29 : HANDLE BAR 3 4 2 1 9 17

Boxer S

18 21 5 20 15 8 16 13 16 9 24 7 10 6 25 24 28 27 11 25 22 23 12 26 19 8

14

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DF 1811 17 FD 1810 30 39 1074 04 DF 2010 53 DU 1910 34 DL 1910 12 DX 1010 30 DL 1910 14 39 1184 15 DF 1910 26 DD 1911 41 DF 1910 66 DD 2011 70 DF 1910 28 DM 1911 14

Handle Holder Handle Upper Flanged Bolt Control Switch RH Control Switch LH Holder Left hand Lever grip - Left Stud Lever handle Nyloc nut Grip - Left hand Holder Right hand Lever grip - Right Front brake switch Grip - Right hand Boot For Lever LH

1 2 4 1 1 1 1 2 2 1 1 1 1 1 1

DU 1910 35

33

FRONT WHEEL DIRECTION

PLATE NO. 29 : HANDLE BAR

Boxer S
3 4

2 1 9 17

18 21 5 20 15 8 16 13 16 9 24 7 10 6 25 24 28 27 11 25 22 23 12 26 19 8

14

Fig. No.

Part No.

Description

Qty / Veh.

Remark

16 17 18 19 20 21 22 23 24 25 26 27 28

36 DU19 01 DU 2010 46 FD 1810 31 DF 1810 91 DF 1810 92 FD 1810 19 FD 1810 20 39 1184 15 39 0725 04 39 0198 11 DM 1910 15 DM 1910 13 DM 1910 12

Cable Adjuster kit Plunger with Spring Holder Handle Lower Damper Handle Upper Damper Handle Lower Washer Plain Upper Washer Plain Lower Nylock Nut Hex.Bolt Plain Washer Boot For Lever RH Lever Assly. grip RH Lever Assly. grip LH

1 1 2 2 2 2 2 2 2 2 1 1 1

Ref. Page No.

34

FRONT WHEEL DIRECTION

PLATE NO. 30 : FORK FRONT

Boxer S

10 9 6 21/22 19 13 20 1 25 7 8 21 2/3 14/15 26 4 5 18 17 27 16 22 11 12

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

DL 1810 80 DD 1810 10 DD 1810 14 30 1810 26 30 1810 25 31 1810 15 DM 1810 36 DM 1810 08 FD 1810 12 30 1810 44 30 1810 29 DF 1810 85 DF 1810 77 DM 1810 32 DM 1810 31 DD 1810 83 39 0789 12

Seal Oil Pipe Left Fork Outer Pipe Right Fork Outer Gasket Bolt Cyl. Complete Fork Pipe Comp.Susp.Inner Spring Front Fork Cap Special Nut Bolt Fork Ring O Seat Fork Spring Holder Fork Upper Cover Fork RH Cover Fork LH Holder Fork Under Washer Spring

1 1 1 2 2 2 2 2 1 2 2 2 1 1 1 1 2

35

FRONT WHEEL DIRECTION

PLATE NO. 30 : FORK FRONT

Boxer S

10 9 6 21/22 19 13 20 1 25 7 8 21 2/3 14/15 26 4 5 18 Fig. No. Part No. Description Qty / Veh. 17 27 16 22 11 12

Remark

18 19 20 21 22 23 24 25 26 27

39 1813 04 DD 1810 11 30 1810 23 DM 1810 28 36 3118 03 DM 1810 29 DM 1810 30 DD 1810 91 30 1810 45 DD 1810 90

Bolt Hex. Dust seal Ring snap Front Fork Bearing cone Kit Damper Assly.LH Damper Assly.RH Cover Trail Top Cushion Cover Trail Bottom

2 2 2 1 1 1 1 2 2 2

Ref.page No.

36

FRONT WHEEL DIRECTION

PLATE NO. 31 : PAINTED PARTS

Boxer S
4

Fig. No.

Part No.

Description

Qty / Veh.

Remark

DU 7101 22 DU 7101 X4 DU 7101 Y7 DU 7101 W1 36 DF14 44 36 DF14 45 36 DF14 46 36 DF14 4 DU 7301 22 DU 7305 22 DU 7301 X4 DU 7305 X4 DU 7301 Y7 DU 7305 Y7 DU 7301 W1

Tank fuel with Decal Tank fuel with Decal Tank fuel with Decal Tank fuel with Decal Decal Decal Decal Decal Set Set Set Set

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Jet Black Flame Red Star Blue Damson Purple Jet Black Flame Red Ref. Page No. Star Blue Damson Purple Jet Black Jet Black(Full Painted) Flame Red Flame Red(Full Painted) Star Blue Star Blue(Full Painted) Damson Purple

Cover Side LH with Decal Cover Side LH with Decal Cover Side LH with Decal Cover Side LH with Decal Cover Side LH with Decal Cover Side LH with Decal Cover Side LH with Decal

37

FRONT WHEEL DIRECTION

PLATE NO. 31 : PAINTED PARTS 4

Boxer S

Fig. No.

Part No.

Description

Qty / Veh.

Remark

DU 7302 22 DU 7306 22 DU 7302 X4 DU 7306 X4 DU 7302 Y7 DU 7306 Y7 DU 7302 W1

Cover Side RH with Decal Cover Side RH with Decal Cover Side RH with Decal Cover Side RH with Decal Cover Side RH with Decal Cover Side RH with Decal Cover Side RH with Decal

1 1 1 1 1 1 1

Jet Black Jet Black(Full Painted) Flame Red Flame Red(Full Painted) Star Blue Star Blue(Full Painted) Damson Purple

38

FRONT WHEEL DIRECTION

PLATE NO. 32 : FUEL TANK CAP,TAP ASSLY. 7 8 10

Boxer S
3

9 6 6 4 Fig. No. Part No. Description 1 6 Qty / Veh. Remark

1 2 3 4

5 6 7 8 9 10

DU 1410 41 DU 1810 34 DF 1411 20 DF 1411 66 DU 1410 40 DU 1410 45 30 1410 39 DD 1410 16 30 1410 52 39 0761 01 DD 1412 27 30 1410 31

Tube Fuel Lock set Assly. (3 IN 1) Cap Assly. Tank Tap Assly. Tap Assly. Tap Assly. Packing For Tap Clamp Tube Packing (For Cap) Screw Pan Cross Bolt Flanged O Ring

1 1 1 1 1 1 1 2 1 2 2 2

(N.I.)

ADVIK MAKE PAVNA MAKE

39

FRONT WHEEL DIRECTION

PLATE NO. 33 : CHAIN CASE

Boxer S

3 5 2

4 6

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6

30 16 1271 36 DU16 01 DF 1614 15 DF1614 16 39 2475 04 39 2473 04

Rubber Pad Case Chain Kit Trim case chain Rubber Cap Flanged Bolt Flanged Bolt

1 1 1 1 2 2

(DM161144 upper case chain assly)

40

FRONT WHEEL DIRECTION

PLATE NO. 34 : FITTINGS -PETROL TANK & SIDE COVER

Boxer S

3 6 5 7 8

1 4

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9

DF 1411 29 30 1611 69 39 1789 24 DG 1611 21 DU 1610 02 DF 1810 24 DL 1410 35 39 1054 11 DL 1610 17

Damper Damper side cover mtg. Washer Nylon Screw Damper Lock set (4 in 1) Flange Bolt Plain Washer Damper - cover side

1 2 1 1 1 1 1 1 2 N.I.

41

FRONT WHEEL DIRECTION

PLATE NO. 35 : METER ASSEMBLY

Boxer S

10

1 3

4/6

11 12

7 9 8

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12

31 1910 12 31 1910 21 31 1910 18 30 2010 29 30 2011 29 30 2011 28 39 0292 15 39 0292 15 DF 2010 32 31 1910 17 31 1910 20 31 1910 14

Meter Assly/ Lamp Cover Meter Lower Black Speedometer Lamp 12V 4W Lamp 12V 2W Lamp 12V 4W Toothed washer Nut Ignition switch/ key Cover meter case upper Cover (white) Bracket Meter

1 1 1 1 2 1 1 1 1 1 1 1

42

FRONT WHEEL DIRECTION

PLATE NO. 36 : CONTROL CABLES

Boxer S
1 2 3 4 5 6

9 10 8

11

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11

DU1910 41 30 19 1070 30 19 1069 30 19 1071 30 19 1072 DM 1910 17 DZ 1910 14 30 1910 67 31 1910 04 DM 1910 05 DM 1910 02

Cable Brake (FR) Spring Dust Seal Rod End Adjusting Nut Cable Clutch Cable Speedometer Oil Seal Inner Cable Speedo Cable Throttle Cable starter

1 1 1 1 1 1 1 1 1 1 1

43

FRONT WHEEL DIRECTION

PLATE NO. 37 : HEAD LAMP ASSLY.

Boxer S

14

17

6 15 5

13 7 10 11 1 18 19 12 2 8 16 3

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DM 2010 22 DD 2010 17 DU 2010 57 DJ 2010 46 DJ 2010 51 DU 2010 29 DU 2010 60 DD 2010 47 DD 2010 10 DD 2010 09 39 1684 12 39 1683 04 39 2479 15 DF 2011 64 DL 1910 20

Head light assly with lamp Bracket Head Light Head Light Housing Head Light Rim Reflector with Lens Special Screw Collar Washer Damper Damper Spring Washer Flange Bolt Flange Nut Lamp 12 V 35/35 W Lamp 12 V 3W

1 1 1 1 1 2 2 1 2 2 2 2 2 1 1

44

FRONT WHEEL DIRECTION

PLATE NO. 37 : HEAD LAMP ASSLY.

Boxer S

14

17

6 15 5

13 7 10 11 1 18 19 12 2 8 16 3

Fig. No.

Part No.

Description

Qty / Veh.

Remark

16 17 18 19

DD 2010 48 DF 2010 58 DD 2010 46 DD 2010 45

Nut (Nylon) Lamp Holder (Socket) Assly. Spring for Adjustment Screw

1 1 1 1

45

FRONT WHEEL DIRECTION

PLATE NO. 38 : TURN SIGNAL LAMP

Boxer S

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10

DM 2010 27 DM 2010 28 DM 2010 29 DM 2010 30 06 2010 83 DU 2010 16 DD 1811 92 39 1225 15 DU 2010 42 DU 2010 43

Dir. ind. Front LH with Lamp Dir. ind. Front RH with Lamp Dir. ind. Rear LH with Lamp Dir. ind. Rear RH with Lamp Lamp 12 V 10 W Lens Bracket Signal Hex. Nut Adopter LH Adopter RH

1 1 1 1 4 4 1 4 1 1

N.I. N.I.

46

FRONT WHEEL DIRECTION

PLATE NO. 39 : FRONT AND REAR NUMBER PLATE

Boxer S

4 10 9 7 8

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10

DP 1611 44 DF 1810 97 39 1783 01 39 2473 04 DP 1611 45 DF 1612 48 39 2476 04 39 2475 04 30 2010 69 39 2484 15

Front Number plate Bracket Front No. Plate Truss Screw Flanged bolt Number plate Rear Bracket No. Plate Hex head bolt / Flange Hex.bolt/Flange Reflector Reflex Flanged Nut

1 1 2 2 1 1 2 2 1 1

47

FRONT WHEEL DIRECTION

PLATE NO. 40 : TAIL LAMP ASSLY.

Boxer S

7 6 4 5 1

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7

DF 2011 38 30 2010 06 DF 2011 41 DD 2010 11 30 2110 05 39 2429 11 39 2430 15

Tail Light Assly. with lamp Lamp 12 V, 21/5W Lens Tail Light Damper Collar Plain Washer Hex Nut. / Flange

1 1 1 2 2 For Mtg. Tail light 2 2

48

FRONT WHEEL DIRECTION

PLATE NO. 41 : ELECTRICAL EQUIPMENT

Boxer S

2 10 11 3

8 7 9

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7 8 9 10 11

39 1940 04 DF 2012 52 31 2010 79 30 2010 74 DM 2010 15 31 2010 27 DF 2011 29 30 2010 85 31 2010 03 DU 2010 63 39 2473 04

Flanged Bolt Horn Switch Rear Brake Spring Brake Switch Wiring Harness Battery Fuse - Assly. Fuse, 15A Relay assly. Capacitor Electrolytic Hex Head Bolt / Flange

1 1 1 1 1 1 1 1 1 1 1

49

FRONT WHEEL DIRECTION

PLATE NO. 42 : TOOL KIT

Boxer S

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 * * * * * *

DD 2210 30 DF 2210 47 DD 2210 31 DF 2210 43 DF 2210 48 DD 2210 32 DF 2210 49

Tool Kit Tool Wrench 17 A/F Tool Wrench 22 A/F (PATTI) Tool Driver Box Spanner 16 x 14 Tool Bag Tool bar

1 1 1 1 1 1 1

Not Serviceable

50

FRONT WHEEL DIRECTION

PLATE NO. 43 : SEAT ASSLY.

Boxer S

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2

DM 2110 18 39 1802 04

Seat assly. Hex. Soc. Hd.Bolt

1 2

51

FRONT WHEEL DIRECTION

PLATE NO. 44 : ACCESSORIES (LEG GUARD, SAREE GUARD & MIRRORS)

Boxer S

3 4 7 6

Fig. No.

Part No.

Description

Qty / Veh.

Remark

1 2 3 4 5 6 7

DU 2210 03 39 1814 04 DF 2210 07 DF 2210 37 39 1940 04 DF 2210 54 39 1608 04

Leg guard Bolt Flanged Mirror assly RH Mirror assly LH Flanged Bolt Saree Guard Hex.soc.hd.bolt

1 1 1 1 2 1 2

For mounting Leg guard

52

FRONT WHEEL DIRECTION

Amendment Sheet (Parts Added)

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

53

Amendment Sheet (Parts Deleted)

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

54

KITS LIST FOR Boxer S

SNo. Kit Part No.

Kit Description Part No.

Consisting of Following Parts Description

O Ring O Ring Collet Oil Seal Seat Spring Valve Intake Valve Exhaust Guide Chain RH Guide Chain LH Spring Spring Spring Boss Kick Spring Ball Steel Pin E - Type Circlip O Ring for Air Filter Cap Plain Washer Screw Pan cross Bolt Steeped Flanged Bearing Cone Bearing race Upper Bearing Race Bearing Cone Rubber Bush Inner Bush Case Chain Upper Assly. Case Chain Lower Assly. Speedo Gear (22T) Gear Meter Screw Chain (112 Links) Sprocket (47 T) Sprocket 0/P Ball Bearing (6301RS1/C3) Ball Bearing (6201RS1/C3) Nut Screw Screw Idling (Stop Screw) Spring - Idling Screw

Qty./Kit
2 1 4 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 2 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 2 2 1 1

36DU1001

O Ring Kit

39102021 39256921

36311008

Collet Seal Oil Kit

31101019 39103519 31101045 DD101134 DD101135 31101026 31101025 31101055 31101054 DU101084 30101233 30101234 30101236 30101235 39085517 DM121007 DM121004 01110609 39083001 DF161426 DH181025 30181026 30181024 30181023 30171030 30171031 DM161150 DM161151 31151064 30151041 DF151023 DM151009 DX101052 39268220 39136420 30191017 DD191147 DU121024 DD121176

36311028

Valve Kit

36311006

Chain Guide Kit

36DU1004

Gear Lever Spring Kit

36DU1007

Boss Kick Kit

36DU1201

Air Filter Kit

36311803

Bearing Cone kit

36DF1701

Rubber - Inner Bush Kit

10

36DU1601

Chain Case Kit

11

36DU1503

Gear Meter Screw Kit

12

36DU1505

Chain Sprocket Kit

13

36DU1506

Rear Wheel Bearing Kit

14

36DU1901

Cable Adjuster Kit

15

36DU1202

Idling Screw Kit

55

SNo. Kit Part No.

Kit Description Part No.

Consisting of Following Parts Description

Screw - Air (Adjust) Spring - Screw Air Gasket - Float Chamber Gasket Top Valve complete Float Float Complete Needle Jet Holder - Needle Jet Main Jet Slow Jet complete Spring - Valve throttle Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Cowling Decal - LH Cowling Decal - RH Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Cowling Decal - LH Cowling Decal - RH

Qty./Kit
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

16

36DU1203

Air Control Screw Kit

DU121025 DD121178 DD121170 DU121023 DD121168 DU121015 DU121018 DU121012 DU121013 DU121014 DU121021 DU141015 DU141016 DU161049 DU161050 DU161035 DU161036 DU141017 DU141018 DU161051 DU161052 DU161039 DU161040 DU141019 DU141020 DU161053 DU161054 DU161043 DU161044 DU141063 DU141064 DU161108 DU161109 DU161110 DU161111 DU141015 DU141016 DU161049 DU161050 DU161035 DU161036 DU181033 DU181034 DU141017 DU141018 DU161051 DU161052 DU161039 DU161040 DU181035 DU181036

17

36DU1204

Gasket O ring Kit for Carb.

18

36DU1205

Carburettor Float Pin Kit

19

36DU1206

Carburettor Holder/Jet Kit

20

36DF1444

Decal Set - Jet Black

21

36DF1445

Decal Set - Flame Red

22

36DF1446

Decal Set - Star Blue

23

36DF144

Decal Set - Damson Purple

24

36DU1401

Decal Set - Jet Black

25

36DU1402

Decal Set - Flame Red

56

SNo. Kit Part No.

Kit Description Part No.

Consisting of Following Parts Description

Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Cowling Decal - LH Cowling Decal - RH Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Cowling Decal - LH Cowling Decal - RH Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Cowling Decal - LH Cowling Decal - RH Tank Decal - LH Tank Decal - RH Cover Side Decal - LH Cover Side Decal - RH Cover Seat Decal - LH Cover Seat Decal - RH Cowling Decal - LH Cowling Decal - RH

Qty./Kit
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

27

36DU1403

Decal Set - Star Blue

DU141019 DU141020 DU161053 DU161054 DU161043 DU161044 DU181037 DU181038 DU141030 DU141031 DU161087 DU161088 DU161089 DU161090 DU181043 DU181044 DU141028 DU141029 DU161083 DU161084 DU161085 DU161086 DU181041 DU181042 DU141063 DU141064 DU161108 DU161109 DU161110 DU161111 DU181063 DU181064

28

36DU1404

Decal Set - Olive Green

29

36DU1405

Decal Set - Brownish grey

30

36DU1407

Decal Set - Damson Purple

57