boxer s spc_final

1 FRONT WHEEL DIRECTION

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

PLATE NO. Boxer S1 : CYLINDER HEAD

1 36 DU10 01 O Ring Kit 1 Ref. Page No.2 31 1010 06 Cap 23 39 1673 04 Flanged bolt 64 31 1010 08 Guide Valve 25 39 1021 21 O Ring 2

6 DD 1013 47 Bolt 27 DD 1013 50 Stud 28 DD 1013 49 Bolt 49 DU 1012 08 Head Comp. Cylinder 1

10 31 1010 07 Cover (OHC) 1

11 DD 1013 51 Bolt 212 39 1000 06 Hollow Dowel Pin 213 DD 1013 43 Gasket head 114 39 1017 21 O Ring 215 DD 1014 81 Damper Cylinder Head 4

13

12 16

17

3 2

1 11

2

9

6 8

10

12

7 7

3

14

14

5

4

18

3

15

2


PLATE NO. Boxer S

FRONT WHEEL DIRECTION

1 : CYLINDER HEAD

16 31 1011 75 Insulator (Head Side) 117 DU 1010 58 Pipe Intake 118 DD 1015 21 Plain washer 4

13

12 16

17

3 2

1 11

2

9

6 8

10

12

7 7

3

14

14

5

4

18

3

15



PLATE NO. Boxer S

1 DU 1011 91 Shaft Rocker 22 DF 1010 55 Screw 23 DU 1011 90 Rocker arm assembly 24 31 1011 04 Stopper 15 39 0702 01 Screw Pan Cros 2

6 31 1010 18 Retainer Valve Spring 27 DD 1014 40 Spring Stiffer 28 36 3110 08 Collet Seal Oil Kit 19 36 3110 28 Valve Kit 1

2 : VALVE

7

6

1

2

5

543

9

8

4


PLATE NO. Boxer S


1 36 3110 06 Chain Guide Kit 12 39 1017 21 O Ring 13 DU 1010 96 Hex. Soc.HD Screw 14 DU 1010 56 Sprocket (28 T) 15 DU 1010 78 Camshaft assly. 1 Alt. DU101078

6 31 1010 33 Chain 17 DD 1014 07 Tensioner Assly./O ring 1 Advik make

DD 1014 87 Tensioner Assly./O ring 1 Pricol make8 39 1959 04 Bolt Flanged Small 29 DD 1010 62 Bolt 1

10 39 0748 01 Screw Pan Cross 2

11 39 0999 06 Hollow Dowel Pin 212 DU Washer Spl. Cam Shaft 113 DU 1010 67 Collar Cam 114 39 1790 21 O Ring 1

3 : CAMSHAFT / TENSIONER

8

6

7

1

2

11

10

11

10

914

513

4123



PLATE NO. Boxer S

1 39 1000 06 Hollow dowel Pin 22 DD 1010 07 Gasket - Cyl. Block 13 DU 1010 94 Cylinder Block Piston assly 14 DD 1010 14 Piston ring set std. 15 39 0985 17 Wire Clip 2

6 DH 1014 30 Damper 3

4 : CYLINDER AND PISTON

5

5

4

1

12

3

6

6


PLATE NO. Boxer S


1 39 1055 15 Nut 12 01 1006 10 Woodruff Key 13 DU 1010 05 Crankshaft Assly. 14 28 1011 07 Key Woodruff 25 DX 1010 47 Gear Primary, Helical (23 T) 1

6 FA 1013 34 Gear 17 DU 1010 41 Cover 18 39 1699 01 Countersunk Screw 39 DH 1011 95 Nut 1

10 DX 1010 53 Body Centrifugal Oil Filter(C.I.) 1

11 DU 1010 10 Gasket Central Oil Filter 112 39 2200 11 Washer 113 DH 1010 66 Joint Oil Delivery 114 39 2199 08 Pin Snap 115 DH 1010 67 Spring Oil Delivery 1

16 28 1011 07 Key Woodruff 1 Alt. DU 1012 11

5 : CRANK SHAFT

11

91210

164

56

3

2

1

7

14

15

13

8



PLATE NO. Boxer S

1 DD 1013 09 Bushing Floating 12 DX 1010 45 Gear 2nd Input 13 DX 1010 48 Gear Transmission Spur(3rd) 14 39 0987 17 Ring Snap (16 mm) 25 DX 1010 49 Gear 4th Input 1

6 DU 1010 11 Shaft Transmission Input 17 DU 1010 80 Gear 1st Output 18 DX 1010 51 Gear 4th Output 19 DX 1010 50 Gear Transmission Spur(3rd) 1

10 DX 1010 46 Shaft Transmission Output 1

11 DM 1011 15 Plate For Sprocket Output 112 36 DU15 05 Chain Sprocket Kit 1 Ref. page No.13 DP 1011 55 Collar (Sintered) 114 DP 1011 68 ‘O’ Ring 115 39 1981 04 Bolt 2

16 DD 1014 75 Washer Special 1

6 : TRANSMISSION

1312

11

7

8

49

10

6

5

4

3

2

14

15

1

16

8


PLATE NO. Boxer S


1 31 10 1191 Fork Shift 12 31 10 1051 Rod shift 23 DU 1010 81 Drum assly. change 14 DM 1010 98 Cup Stopper 15 31 10 1192 Fork shift 1

6 39 0992 06 Pin Dowel 57 DP 1013 40 Bolt Soc. Head 18 DM 101099 Plate Spacer 19 DU 1010 83 Cam Drum Change 1

7 : CHANGE DRUM / SHIFT FORK

1

2

4

2

5

3

8

6

9

7



PLATE NO. Boxer S

1 DU 1010 73 Stopper Comp.Gear Shifter 12 39 1994 04 Bolt 13 36 DU10 04 Gear Lever Spring Kit 1 Ref. Page No.4 DU 1010 74 Plate Position 15 39 0746 01 Screw Pan Cross 1

6 DU 1011 84 Lever Comp. Change Shaft 17 DD 1011 06 Bolt 18 39 2474 04 Flanged bolt 19 DU 1011 85 Lever Change / Damper 1

10 31 10 1108 Damper 1

11 31 1011 09 Collar 112 39 2704 11 Washer Spring Steel 113 DU 1011 13 Spacer 1

8 : GEAR CHANGE MECHANISM

910

6

7

11

83

1

2

12

4

5

13

10


PLATE NO. Boxer S


1 39 1225 15 Nut 32 39 0248 11 Plain Washer 33 39 1068 04 Bolt 24 39 1056 04 Bolt 15 39 1864 20 Bearing Ball 1 Alt. to 39229320

6 39 0999 06 Dowel Pin 57 01 1701 11 Bearing 18 DP 1014 52 Oil Strainer 19 DG 1014 98 Gasket 1

10 DD 10 1275 Plug (Drain) 1

11 01 1701 10 Bearing 112 DU 1010 75 Crankcase Comp. RH 113 DU 1010 85 Bushing 114 DU 1010 01 Engine Assembly 1 N.I.

9 : CRANKCASE RH / ENGINE ASSLY.

5

1

8

7

1

10

923

6

24

11

1

23

12

13



PLATE NO. Boxer S

1 01 1701 11 Ball Bearing 12 39 1050 06 Dowel Pin 13 39 1066 04 Bolt Flanged Small 34 39 1043 19 Oil Seal 15 39 1080 19 Seal Oil 1

6 39 1008 20 Bearing Needle 17 39 0702 01 Screw Pan Cros 28 31 1010 56 Guide 19 31 2010 81 Switch Comp. (Neutral) 1

10 39 0703 11 Plain Washer 1

11 39 1075 04 Bolt Flanged Small 712 30 1010 15 Gasket 1

DG 1014 98 Gasket 113 DD 1011 01 Crankcase LH 114 DD 1012 19 Tube rubber 115 30 1410 15 Clamp 1

DU 1210 29 Clamp 1

10 : CRANKCASE - L.H.

14

2

13

3

4

6

1210

8

9

5

7

7

11

1

15

12


PLATE NO. Boxer S


11: PIPE OIL

1 DU 1210 05 Pipe Oil 1 Use with Bkt.Engine Front RH DU161094DU 1210 10 Pipe Oil 1 Use with Bkt.Engine Front DD161052

2 31 1210 06 Gasket 43 39 1023 04 Bolt 24 39 1062 04 Bolt flanged small 2

3

2 4

22

3

2

1



PLATE NO. Boxer S

1 31 1010 62 Bolt 12 39 1019 21 Ring O 13 31 1012 95 Cover Generator 14 31 1010 61 Plug 15 31 1011 13 Gasket 1

6 DD 1010 58 Gasket - Generator Cover 17 39 1074 04 Bolt Flanged Small 58 39 0999 06 Pin 29 DM 1011 49 Cover Chain (Engine) 1

10 39 2147 04 Bolt Flanged Small 3

12 : COVER GENERATOR & COVER CHAIN

64

5

8

21

3

7

10

9

14


PLATE NO. Boxer S


13 : CLUTCH COVER

1 DU1012 10 Clutch cover/ Graphics/Gauge 12 DU 1011 88 Label “BAJAJ EXHAUSTEC” 13 39 0999 06 Dowel Pin 24 31 1010 67 Guage 15 39 1041 19 Seal oil 1

6 30 1011 42 Seal oil 17 DD 1013 25 Cap oil filler 18 39 2134 21 O ring 19 DD 1010 60 Gasket (Clutch cover) 1

10 39 1075 04 Bolt flanged small 10

119

7

10

1

4

56

3

8

2



PLATE NO. Boxer S

1 DX 1010 54 Housing Comp. clutch 12 28 1011 95 Holder 13 39 2600 11 Plain Washer 24 DU 1011 09 Collar 15 DD 1014 92 Wheel Clutch 1

6 DD 1014 80 Plate Friction 57 30 1010 96 Plate Clutch 48 DD 1014 93 Hub Clutch 19 28 1012 14 Spring 6

10 39 0980 04 Hex. Bolt 6

11 39 1053 15 Hex.Nut/Flange 112 39 2403 20 Bearing 113 31 10 1148 Rod Push 114 DX 1010 35 Lever Assly. Complete 1

14 : CLUTCH

56

9

1

4

3

10

98

7

14

1312

11 2

16


PLATE NO. Boxer S


15 : KICK STARTER MECHANISM

1 DP 1510 18 Flanged bolt 12 DD 1012 64 Screw Pan Cross 23 DD 1012 54 Guide Kick 14 DU 1010 50 Lever Assly Kick Comp. 15 30 1011 54 Bush(Damper) 1

6 36 DU10 07 Boss Kick Set 1 Ref. Page No.7 22 1502 41 Plain Washer 18 31 1010 41 Spring 19 39 0993 11 Plain Washer 1

10 31 1010 39 Coil Spring 1

11 31 1010 38 Ratchet 112 DU 1010 38 Gear Spur Kick Start 113 39 0995 11 Plain Washer 214 39 0738 17 External Circlip Type C 415 DU 1010 45 Shaft Kick 1

16 31 1010 40 Guide 1

1413

12

1513

1411

10

149

1

4

5

32

8

16

14

67



PLATE NO. Boxer S16 : CARBURETTOR

1 DU 1210 09 Carburettor Assly. (PB-16) 12 DU 1010 57 Insulator (Carburettor / Intake) 13 39 1283 21 O ring 14 36 DU12 06 Carburettor Holder / Jet Kit 1 Ref. Page No.5 36 DU12 04 Gasket O ring Kit for Carb. 1 Ref. Page No.

6 36 DU12 05 Carburettor Float pin Kit 1 Ref. Page No.7 36 DU12 02 Idling Screw kit 1 Ref. Page No.8 36 DU12 03 Air Control Screw Kit 1 Ref. Page No.9 39 1675 04 Flanged bolt 2 For mounting Carburettor

10 DU 1210 28 Seat for Jet Needle 1

11 DD 1211 71 Screw with washer 212 DU 1210 17 Valve throttle 113 DH 1211 01 Magnet Assly. 1 TPS Assly.14 DH 1211 02 Reed Switch Assly. 1 Parts15 39 1062 04 Bolt Flanged Small 1 TPS Mounting

4

12 7

8

3

2

11

6

5

19

15

14

13

10

18


PLATE NO. Boxer S


17 : AIR FILTER ASSLY AND BATTERY BOX

1 DF 1210 23 Filter assly air 12 DU 1210 04 Case air filter 13 39 0986 08 Pin Cotter 14 DU 1210 08 Duct (A/F to Carburettor) 15 31 1210 29 Element air filter 1

6 36 DU12 01 Air filter Kit 1 Ref. Page No.7 DH 1211 03 Duct (Inlet) 18 DM 2210 01 Band - Tool kit 19 39 1680 04 Flanged bolt (Battery) 1

10 39 2407 01 Screw (Mounting air filter) 2

11 39 1789 24 Washer (Nylon) 212 DM 1210 10 Band (Battery) 113 31 1610 07 Damper battery 214 DM 1210 14 Tube oil drain 115 DM 1210 26 Clamp 1

18

12/13

14

65

2

11

10

4

3

9

7

15



PLATE NO. Boxer S

1 31 10 1014 Gasket 12 39 0198 11 Plain Washer 23 39 0732 12 Spring washer 24 39 2145 15 Nut 25 DU 1011 96 Assembly Silencer Comp. 1 Exhaust-Tec

6 DD 1013 66 Flanged Bolt 1

18 : MUFFLER

5

1

23

4

6

7

20


PLATE NO. Boxer S


1 39 1078 01 Screw Pan Cros 22 39 0753 01 Screw Pan Cros 13 DF 1210 03 Pump Assly. Oil 14 39 0999 06 Pin dowel 15 39 1013 21 Ring O 2

19 : OIL PUMP

5

3

54

1

21



PLATE NO. Boxer S

1 DX 1110 03 Magneto assly/Brg. & Oil Seal 12 DD 1110 48 Cap Spark plug (R) 13 DF 1110 20 Stator assly 14 39 1042 19 Seal Oil (HTA make) 15 39 1003 20 Bearing ball 1

6 39 1028 21 Ring O 17 39 1659 11 Plain washer 38 DF 1110 17 Ignitor assly (C.D.I.) / Damper 19 31 1110 58 Pulser Coil 1

10 39 1553 04 Flanged Bolt 2

11 DU 2010 62 Regulator/Rectifier (R/R) unit 112 DD 1110 18 Plug Spark (P-RZ9HC) 1 Alt.DD 1110 3613 DF 1110 40 H. T. Coil 114 39 0745 01 Screw pan cross 115 DD 1013 18 Bolt 3

16 31 1110 56 Exciter coil 117 DD 1110 11 Grommet Spark plug Cap 118 DD 1110 12 Grommet H.T.Cable 1

20 : MAGNETO ASSEMBLY

1

3

4

16

9

13

7

65

15

8

1410

12 2

11

18

17

22


PLATE NO. Boxer S


1 39 2473 04 Flanged Bolt 12 31 1910 02 Clamp 13 DF 1810 90 Nut 14 DF 1810 52 Cap Steering 15 36 3118 03 Bearing cone kit 1 Ref. Page No.

6 30 18 1006 Ball Steel 467 DM 1611 20 Frame Comp./Brg.races 18 39 2222 04 Flange Bolt 49 39 1068 04 Hex.Bolt 1 Engine Mounting Rubber

10 39 2469 04 Flanged Bolt 1

11 39 2479 15 Flange Nut 512 DM 2210 08 Grip frame 113 DU 2210 07 Flanged bolt 2

14A DU 1610 93 Bracket Engine Front/Bush LH 114B DU 1610 94 Bracket Engine Front/Bush RH 115 DD 1612 03 Bracket Engine Upper LH 1

16 DD 1612 04 Bracket Engine Upper RH 117 39 2700 04 Flange Bolt 118 DF 1810 24 Lock Set (4 in 1) 1

21 : FRAME

11 7

6

34

5 6

1 2

10

11

1615

13

17

914A/14B

12



PLATE NO. Boxer S

1 39 0712 15 Domed Cap Nut 42 39 0737 12 Washer Spring 43 39 0714 11 Washer Plain 84 DM 1710 26 Rear Shock Absorber 25 36 DF17 01 Rubber Inner Bush kit 1 Ref. Page No.

6 39 0248 11 Plain Washer 27 31 1710 06 Shaft Swing Arm 18 39 0201 11 Plain Washer 29 30 1710 18 Bushing Rubber 2

10 39 1225 15 Nut Hex./ flange 1

11 DU 1710 18 Arm Comp. Swing / Bush 112 30 1710 24 Adjuster Chain (RH) 113 39 0711 11 Washer Plain 214 39 0292 15 Hex Nut 415 30 1710 23 Adjuster Chain (LH) 1

22 : SWING ARM/REAR SHOCK ABSORBER

1 2

105 5

16

3

33

9 8 6

15

1

12 1414

13 1414

132

3

986

7

11

4

1718

16

24


PLATE NO. Boxer S


1 2

105 5

16

3

33

9 8 6

15

1

12 1414

13 1414

13

2

3

986

711

4

1718

16

16 31 1710 12 Damper for Swing arm 117 39 0454 11 Plain washer 218 39 0553 02 Self tapping Screw 2

22 : SWING ARM/REAR SHOCK ABSORBER



PLATE NO. Boxer S

1 DF 1614 13 Damper (PVC) 2 Alt. DF1610962 DF 1614 25 Holder Step/Damper/Kick Stopper 1 Alt. DD1614173 39 1940 04 Flanged Bolt 44 DF 1611 02 Bolt 15 39 0422 15 Nyloc Nut 1

6 DL 1610 48 Stand Side 17 30 1611 58 Spring 28 30 1611 57 Shaft Stand 19 DU 1610 32 Stand Centre/Damper 1

10 39 0787 08 Pin Cotter 1

11 DG 1611 24 Damper 112 DU 1611 44 Stay LH / PVC Damper 113 DU 1611 45 Stay RH / PVC Damper 114 39 2481 04 Hex bolt flanged 215 DX 1610 56 Rubber Pillion Step (PVC) 2 Alt. DU161027

16 DH 1611 94 Kick Stopper 1

23 : STAND ,STEP AND STAY LH / RH

15

12/13

14

10

7

7

6

8

4

2

3

5

11

9

1

1

16

26


PLATE NO. Boxer S


1 39 2222 04 Flanged Bolt 42 30 1910 47 Clamp 1

DF 1910 20 Clamp 13 39 2483 04 Flanged Bolt 44 DD 1610 51 Flap 15 DF 1611 04 Fender Rear 1

6 DM 1610 09 Fender Rear Front 17 39 0711 11 Plain Washer 48 39 0817 15 Hex. Nut Flanged 49 39 2473 04 Flanged Bolt 1 N.I. for Clamp DF191020

10 DF 1612 45 Mudflap - Front 1

11 01 1106 09 Plain Washer 2 Alt. 3917111112 22 1504 35 Bolt 213 39 2484 15 Flange Nut 214 39 2473 04 Flange Bolt 1

24 : FENDER - FRONT & REAR

34

8

8

7 56

2

3

3

1

2

10

11 12

13

14



PLATE NO. Boxer S

1 16 1510 66 Nipple Spoke 722 DU 1510 25 Spoke Inner Front 183 DU 1510 26 Spoke Outer Front 184 DS 1510 46 Wheel Rim Front (1.6 x 17) 15 DM 1510 25 Tyre Front 1 Proprietory Parts

Not Serviced 6 DS 1510 49 Tube Front 1

7 DM 1510 28 Tyre Rear 18 DU 1510 18 Wheel Rim Rear(1.85 x 17) 19 DG 1510 22 Band Rim 1

10 DS 1510 09 Spoke Inner Rear 1811 DS 1510 10 Spoke Outer Rear 1812 DS 1510 53 Tube Rear 1

25 : WHEEL RIM / SPOKES/ TYRE/ TUBE

101

7

46

2

5

1

3

8 11

12

9

9

28


PLATE NO. Boxer S


1 39 2680 20 Ball Bearing 1 6300RS1/C32 DF 15 10 03 Drum Front 13 31 15 10 04 Collar 14 36 DU15 03 Gear Meter Screw Kit 1 Ref. Page No. (31151064)5 39 2681 20 Ball Bearing 1 6200RS1/C3

6 DU 1510 05 Collar Axle Assly. 17 39 0248 11 Plain Washer 18 DD 1510 09 Indicator Front 19 DZ 1510 40 Nut Hex. Slotted 1

10 39 0775 04 Bolt 1

11 DD 1510 08 Lever Brake Cam 112 DZ 1510 12 Axle 113 30 15 10 38 Ring O 114 31 15 10 39 Panel Front Brake 115 31 15 10 11 Cam Brake 1

26 : FRONT HUB

4

1517

18

2

3

67

9

13

141

10

24

19

16

12

11

8

5

20

21

22

27

26

23

2525



PLATE NO. Boxer S

16 39 0798 15 Flange Nut 117 30 15 1037 Spring 218 31 1510 13 Shoe Brake Assly. 219 39 1013 21 Ring 'O' 120 14 1510 21 Oil Seal 1

21 39 0990 08 Cotter Pin 122 31 1510 14 Oil Seal 123 30 1511 18 Stopper Fro bushing 124 JA 1316 06 Bushing 125 30 1510 42 Washer 2

26 39 0900 12 Spring Washer 127 39 0840 01 Screw pan Cross 1

26 : FRONT HUB

4

1517

18

2

3

67

9

13

141

10

24

19

16

12

11

8

5

20

21

22

27

26

23

2525

30


PLATE NO. Boxer S


1 36 DU15 05 Chain Sprocket Kit 1 Ref. Page No. (DU151013)2 39 0978 04 ‘D’ bolt 43 31 15 1029 Washer 24 39 0794 15 Nut Hex. Fine 45 30 1510 75 Bearing Ball 1

6 39 0798 15 Hex. nut 17 36 DU15 06 Rear Wheel Bearing Kit 1 Ref. Page No.8 39 0988 15 Nut Hex. 19 31 1510 26 Collar 1

10 30 1510 76 Shock Damper 4

11 30 1510 63 Drum Rear 1 Alt.DF15100912 31 1510 18 Collar Assly. 113 30 15 1069 Spring 214 30 1511 05 Shoe Brake Assly. 1

31 1510 60 Shoe Brake Assly. 1 For Bangladesh version15 30 1510 11 Brake Cam assly 1

27 : REAR HUB

19

186

23

711

8

1

4

5

3

2

13

14

16

15

17

21 22

20

24

25

2627

12

9



PLATE NO. Boxer S

16 31 1510 08 Panel Rear Brake 117 30 1510 38 Ring O 118 31 1510 37 Lever Brake 119 39 0775 04 Bolt 120 DM 1510 32 Axle 1

21 39 0714 11 Washer Plain 122 39 0982 15 Nut Castle 123 39 0787 08 Pin Cotter 124 30 1510 05 Indicator 125 DU 1510 06 Collar 1

26 30 1510 78 Coupling 127 30 1510 79 Sleeve 1

27 : REAR HUB

19

186

23

711

8

1

4

5

3

2

13

14

16

15

17

21 22

20

24

25

2627

12

9

32


PLATE NO. Boxer S


1 39 0808 08 Split pin 12 DF 1910 67 Plain Washer 23 DM 1910 10 Rod Brake 14 30 19 1038 Pin 15 DM 1910 16 Lever Brake Tubular 1

6 39 0805 11 Washer Plain 17 39 0797 08 Pin Cotter 18 30 19 1031 Spring 19 30 1910 35 Spring 1

10 39 0807 08 Pin Snap 2

11 39 0708 15 Nut Hex. 212 DF 1910 67 Washer Spring 213 30 1910 38 Pin 114 30 1910 36 Brake adjusting nut 115 30 1510 95 Bolt 2

16 DF 1510 16 Torque rod 117 DD 1610 78 Damper 1

28 : BRAKE PEDAL

11 12

14

13

1

23

4

8

5

6

7

10

101112

2

915

15

17

16



PLATE NO. Boxer S

1 DF 1811 17 Handle 12 FD 1810 30 Holder Handle Upper 23 39 1074 04 Flanged Bolt 44 DF 2010 53 Control Switch RH 15 DU 1910 34 Control Switch LH 1

6 DL 1910 12 Holder Left hand 17 DX 1010 30 Lever grip - Left 1 DU 1910 358 DL 1910 14 Stud Lever handle 29 39 1184 15 Nyloc nut 2

10 DF 1910 26 Grip - Left hand 1

11 DD 1911 41 Holder Right hand 112 DF 1910 66 Lever grip - Right 113 DD 2011 70 Front brake switch 114 DF 1910 28 Grip - Right hand 115 DM 1911 14 Boot For Lever LH 1

29 : HANDLE BAR

8

6

9

10

7

16

8

15

9

2524

28

14

12

25

249

13

11

16

26

27

21

3

2320

22

2119

18

5

4

17

34


PLATE NO. Boxer S


16 36 DU19 01 Cable Adjuster kit 1 Ref. Page No.17 DU 2010 46 Plunger with Spring 118 FD 1810 31 Holder Handle Lower 219 DF 1810 91 Damper Handle Upper 220 DF 1810 92 Damper Handle Lower 2

21 FD 1810 19 Washer Plain Upper 222 FD 1810 20 Washer Plain Lower 223 39 1184 15 Nylock Nut 224 39 0725 04 Hex.Bolt 225 39 0198 11 Plain Washer 2

26 DM 1910 15 Boot For Lever RH 127 DM 1910 13 Lever Assly. grip RH 128 DM 1910 12 Lever Assly. grip LH 1

29 : HANDLE BAR

8

6

9

10

7

16

8

15

9

2524

28

14

12

25

249

13

11

16

26

27

21

3

2320

22

2119

18

5

4

17



PLATE NO. Boxer S

1 DL 1810 80 Seal Oil 12 DD 1810 10 Pipe Left Fork Outer 13 DD 1810 14 Pipe Right Fork Outer 14 30 1810 26 Gasket 25 30 1810 25 Bolt 2

6 31 1810 15 Cyl. Complete Fork 27 DM 1810 36 Pipe Comp.Susp.Inner 28 DM 1810 08 Spring Front Fork 29 FD 1810 12 Cap Special Nut 1

10 30 1810 44 Bolt Fork 2

11 30 1810 29 Ring ‘O’ 212 DF 1810 85 Seat Fork Spring 213 DF 1810 77 Holder Fork Upper 114 DM 1810 32 Cover Fork RH 115 DM 1810 31 Cover Fork LH 1

16 DD 1810 83 Holder Fork Under 117 39 0789 12 Washer Spring 2

30 : FORK FRONT

21

18

16

9

10

11

12

13

87

5

4

2/3

1

20

19

6

22

17

21/22

14/15

25

27

26

36


PLATE NO. Boxer S


18 39 1813 04 Bolt Hex. 219 DD 1810 11 Dust seal 220 30 1810 23 Ring snap 2

21 DM 1810 28 Front Fork 122 36 3118 03 Bearing cone Kit 1 Ref.page No.23 DM 1810 29 Damper Assly.LH 124 DM 1810 30 Damper Assly.RH 125 DD 1810 91 Cover Trail Top 2

26 30 1810 45 Cushion 227 DD 1810 90 Cover Trail Bottom 2

30 : FORK FRONT

21

18

16

9

10

11

12

13

87

5

4

2/3

1

20

19

6

22

17

21/22

14/15

25

27

26



PLATE NO. Boxer S

1 DU 7101 22 Tank fuel with Decal 1 Jet BlackDU 7101 X4 Tank fuel with Decal 1 Flame RedDU 7101 Y7 Tank fuel with Decal 1 Star BlueDU 7101 W1 Tank fuel with Decal 1 Damson Purple

2 36 DF14 44 Decal Set 1 Jet Black36 DF14 45 Decal Set 1 Flame Red Ref. Page No.36 DF14 46 Decal Set 1 Star Blue36 DF14 4 Decal Set 1 Damson Purple

3 DU 7301 22 Cover Side LH with Decal 1 Jet BlackDU 7305 22 Cover Side LH with Decal 1 Jet Black(Full Painted)DU 7301 X4 Cover Side LH with Decal 1 Flame RedDU 7305 X4 Cover Side LH with Decal 1 Flame Red(Full Painted)DU 7301 Y7 Cover Side LH with Decal 1 Star BlueDU 7305 Y7 Cover Side LH with Decal 1 Star Blue(Full Painted)DU 7301 W1 Cover Side LH with Decal 1 Damson Purple

31 : PAINTED PARTS

4

1

3

2

38


PLATE NO. Boxer S


4 DU 7302 22 Cover Side RH with Decal 1 Jet BlackDU 7306 22 Cover Side RH with Decal 1 Jet Black(Full Painted)DU 7302 X4 Cover Side RH with Decal 1 Flame RedDU 7306 X4 Cover Side RH with Decal 1 Flame Red(Full Painted)DU 7302 Y7 Cover Side RH with Decal 1 Star BlueDU 7306 Y7 Cover Side RH with Decal 1 Star Blue(Full Painted)DU 7302 W1 Cover Side RH with Decal 1 Damson Purple

31 : PAINTED PARTS

4

1

3

2



PLATE NO. Boxer S

1 DU 1410 41 Tube Fuel 12 DU 1810 34 Lock set Assly. (3 IN 1) 1 (N.I.)3 DF 1411 20 Cap Assly. Tank 14 DF 1411 66 Tap Assly. 1

DU 1410 40 Tap Assly. 1 ADVIK MAKEDU 1410 45 Tap Assly. 1 PAVNA MAKE

5 30 1410 39 Packing For Tap 1

6 DD 1410 16 Clamp Tube 27 30 1410 52 Packing (For Cap) 18 39 0761 01 Screw Pan Cross 29 DD 1412 27 Bolt Flanged 2

10 30 1410 31 O Ring 2

32 : FUEL TANK CAP,TAP ASSLY.

7

4

5

1

6

6

9

83

10

6

40


PLATE NO. Boxer S


1 30 16 1271 Rubber Pad 12 36 DU16 01 Case Chain Kit 1 (DM161144 upper case chain assly)3 DF 1614 15 Trim case chain 14 DF1614 16 Rubber Cap 15 39 2475 04 Flanged Bolt 2

6 39 2473 04 Flanged Bolt 2

33 : CHAIN CASE

1

5

46

2

3



PLATE NO. Boxer S

1 DF 1411 29 Damper 12 30 1611 69 Damper side cover mtg. 23 39 1789 24 Washer Nylon 14 DG 1611 21 Screw 15 DU 1610 02 Damper 1

6 DF 1810 24 Lock set (4 in 1) 1 N.I.7 DL 1410 35 Flange Bolt 18 39 1054 11 Plain Washer 19 DL 1610 17 Damper - cover side 2

34 : FITTINGS -PETROL TANK & SIDE COVER

4

3

5

7

8

1

9

6

4

2

42


PLATE NO. Boxer S


1 31 1910 12 Meter Assly/ Lamp 12 31 1910 21 Cover Meter Lower Black 13 31 1910 18 Speedometer 14 30 2010 29 Lamp 12V 4W 15 30 2011 29 Lamp 12V 2W 2

6 30 2011 28 Lamp 12V 4W 17 39 0292 15 Toothed washer 18 39 0292 15 Nut 19 DF 2010 32 Ignition switch/ key 1

10 31 1910 17 Cover meter case upper 1

11 31 1910 20 Cover (white) 112 31 1910 14 Bracket Meter 1

35 : METER ASSEMBLY

4/65

3

7

8

1

9

10

2

11

12



PLATE NO. Boxer S

1 DU1910 41 Cable Brake (FR) 12 30 19 1070 Spring 13 30 19 1069 Dust Seal 14 30 19 1071 Rod End 15 30 19 1072 Adjusting Nut 1

6 DM 1910 17 Cable Clutch 17 DZ 1910 14 Cable Speedometer 18 30 1910 67 Oil Seal 19 31 1910 04 Inner Cable Speedo 1

10 DM 1910 05 Cable Throttle 1

11 DM 1910 02 Cable starter 1

36 : CONTROL CABLES

2

3

45

8

9

6

10

1

7

11

44


PLATE NO. Boxer S


1 DM 2010 22 Head light assly with lamp 12 DD 2010 17 Bracket Head Light 13 DU 2010 57 Head Light Housing 14 DJ 2010 46 Head Light Rim 15 DJ 2010 51 Reflector with Lens 1

6 DU 2010 29 Special Screw 27 DU 2010 60 Collar 28 DD 2010 47 Washer 19 DD 2010 10 Damper 2

10 DD 2010 09 Damper 2

11 39 1684 12 Spring Washer 212 39 1683 04 Flange Bolt 213 39 2479 15 Flange Nut 214 DF 2011 64 Lamp 12 V 35/35 W 115 DL 1910 20 Lamp 12 V 3W 1

37 : HEAD LAMP ASSLY.

3

144

6

5

1

16818

219

13

15

7

10

9

12

17

11



PLATE NO. Boxer S

16 DD 2010 48 Nut (Nylon) 117 DF 2010 58 Lamp Holder (Socket) Assly. 118 DD 2010 46 Spring for Adjustment 119 DD 2010 45 Screw 1

37 : HEAD LAMP ASSLY.

3

144

6

5

1

16818

219

13

15

7

10

9

12

17

11

46


PLATE NO. Boxer S


1 DM 2010 27 Dir. ind. Front LH with Lamp 12 DM 2010 28 Dir. ind. Front RH with Lamp 13 DM 2010 29 Dir. ind. Rear LH with Lamp 14 DM 2010 30 Dir. ind. Rear RH with Lamp 15 06 2010 83 Lamp 12 V 10 W 4

6 DU 2010 16 Lens 47 DD 1811 92 Bracket Signal 18 39 1225 15 Hex. Nut 49 DU 2010 42 Adopter LH 1 N.I.

10 DU 2010 43 Adopter RH 1 N.I.

38 : TURN SIGNAL LAMP

6

55

6

3 4

1

2

7



PLATE NO. Boxer S

1 DP 1611 44 Front Number plate 12 DF 1810 97 Bracket Front No. Plate 13 39 1783 01 Truss Screw 24 39 2473 04 Flanged bolt 25 DP 1611 45 Number plate Rear 1

6 DF 1612 48 Bracket No. Plate 17 39 2476 04 Hex head bolt / Flange 28 39 2475 04 Hex.bolt/Flange 29 30 2010 69 Reflector Reflex 1

10 39 2484 15 Flanged Nut 1

39 : FRONT AND REAR NUMBER PLATE

8

7

56

4

31

2

910

48


PLATE NO. Boxer S


1 DF 2011 38 Tail Light Assly. with lamp 12 30 2010 06 Lamp 12 V, 21/5W 13 DF 2011 41 Lens Tail Light 14 DD 2010 11 Damper 25 30 2110 05 Collar 2

For Mtg. Tail light6 39 2429 11 Plain Washer 27 39 2430 15 Hex Nut. / Flange 2

40 : TAIL LAMP ASSLY.

5

4

6

7

3

2

1



PLATE NO. Boxer S

1 39 1940 04 Flanged Bolt 12 DF 2012 52 Horn 13 31 2010 79 Switch Rear Brake 14 30 2010 74 Spring Brake Switch 15 DM 2010 15 Wiring Harness 1

6 31 2010 27 Battery 17 DF 2011 29 Fuse - Assly. 18 30 2010 85 Fuse, 15A 19 31 2010 03 Relay assly. 1

10 DU 2010 63 Capacitor Electrolytic 1

11 39 2473 04 Hex Head Bolt / Flange 1

41 : ELECTRICAL EQUIPMENT

9

8

5

4

3

2

1

7

10

11

50


PLATE NO. Boxer S


1 DD 2210 30 Tool Kit 1* DF 2210 47 Tool Wrench 17 A/F 1* DD 2210 31 Tool Wrench 22 A/F (PATTI) 1* DF 2210 43 Tool Driver 1 Not* DF 2210 48 Box Spanner 16 x 14 1 Serviceable* DD 2210 32 Tool Bag 1* DF 2210 49 Tool bar 1

42 : TOOL KIT

1



PLATE NO. Boxer S43 : SEAT ASSLY.

1 DM 2110 18 Seat assly. 12 39 1802 04 Hex. Soc. Hd.Bolt 2

2

52


PLATE NO. Boxer S


44 : ACCESSORIES (LEG GUARD, SAREE GUARD & MIRRORS)

1 DU 2210 03 Leg guard 12 39 1814 04 Bolt Flanged 13 DF 2210 07 Mirror assly RH 14 DF 2210 37 Mirror assly LH 15 39 1940 04 Flanged Bolt 2 For mounting Leg guard

6 DF 2210 54 Saree Guard 17 39 1608 04 Hex.soc.hd.bolt 2

67

2

4

3

5

1

5

7

53

Amendment Sheet (Parts Added)

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

54

Amendment Sheet (Parts Deleted)

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

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

Part No. Description Qty./Kit

KITS LIST FOR Boxer S

55

1 36DU1001 O Ring Kit 39102021 O Ring 239256921 O Ring 1

2 36311008 Collet Seal Oil Kit 31101019 Collet 439103519 Oil Seal 231101045 Seat Spring 2

3 36311028 Valve Kit DD101134 Valve Intake 1DD101135 Valve Exhaust 1

4 36311006 Chain Guide Kit 31101026 Guide Chain RH 131101025 Guide Chain LH 1

5 36DU1004 Gear Lever Spring Kit 31101055 Spring 131101054 Spring 1DU101084 Spring 1

6 36DU1007 Boss Kick Kit 30101233 Boss Kick 130101234 Spring 130101236 Ball Steel 130101235 Pin 139085517 E - Type Circlip 1

7 36DU1201 Air Filter Kit DM121007 O Ring for Air Filter 1DM121004 Cap 101110609 Plain Washer 439083001 Screw Pan cross 4DF161426 Bolt Steeped Flanged 2

8 36311803 Bearing Cone kit DH181025 Bearing Cone 130181026 Bearing race 130181024 Upper Bearing Race 130181023 Bearing Cone 1

9 36DF1701 Rubber - Inner Bush Kit 30171030 Rubber Bush 430171031 Inner Bush 4

10 36DU1601 Chain Case Kit DM161150 Case Chain Upper Assly. 1DM161151 Case Chain Lower Assly. 1

11 36DU1503 Gear Meter Screw Kit 31151064 Speedo Gear (22T) 130151041 Gear Meter Screw 1

12 36DU1505 Chain Sprocket Kit DF151023 Chain (112 Links) 1DM151009 Sprocket (47 T) 1DX101052 Sprocket 0/P 1

13 36DU1506 Rear Wheel Bearing Kit 39268220 Ball Bearing (6301RS1/C3) 139136420 Ball Bearing (6201RS1/C3) 1

14 36DU1901 Cable Adjuster Kit 30191017 Nut 2DD191147 Screw 2

15 36DU1202 Idling Screw Kit DU121024 Screw Idling (Stop Screw) 1DD121176 Spring - Idling Screw 1

16 36DU1203 Air Control Screw Kit DU121025 Screw - Air (Adjust) 1DD121178 Spring - Screw Air 1

17 36DU1204 Gasket O ring Kit for Carb. DD121170 Gasket - Float Chamber 1DU121023 Gasket Top 1

18 36DU1205 Carburettor Float Pin Kit DD121168 Valve complete Float 1DU121015 Float Complete 1

19 36DU1206 Carburettor Holder/Jet Kit DU121018 Needle Jet 1DU121012 Holder - Needle Jet 1DU121013 Main Jet 1DU121014 Slow Jet complete 1DU121021 Spring - Valve throttle 1

20 36DF1444 Decal Set - Jet Black DU141015 Tank Decal - LH 1DU141016 Tank Decal - RH 1DU161049 Cover Side Decal - LH 1DU161050 Cover Side Decal - RH 1DU161035 Cover Seat Decal - LH 1DU161036 Cover Seat Decal - RH 1

21 36DF1445 Decal Set - Flame Red DU141017 Tank Decal - LH 1DU141018 Tank Decal - RH 1DU161051 Cover Side Decal - LH 1DU161052 Cover Side Decal - RH 1DU161039 Cover Seat Decal - LH 1DU161040 Cover Seat Decal - RH 1

22 36DF1446 Decal Set - Star Blue DU141019 Tank Decal - LH 1DU141020 Tank Decal - RH 1DU161053 Cover Side Decal - LH 1DU161054 Cover Side Decal - RH 1DU161043 Cover Seat Decal - LH 1DU161044 Cover Seat Decal - RH 1

23 36DF144 Decal Set - Damson Purple DU141063 Tank Decal - LH 1DU141064 Tank Decal - RH 1DU161108 Cover Side Decal - LH 1DU161109 Cover Side Decal - RH 1DU161110 Cover Seat Decal - LH 1DU161111 Cover Seat Decal - RH 1

24 36DU1401 Decal Set - Jet Black DU141015 Tank Decal - LH 1DU141016 Tank Decal - RH 1DU161049 Cover Side Decal - LH 1DU161050 Cover Side Decal - RH 1DU161035 Cover Seat Decal - LH 1DU161036 Cover Seat Decal - RH 1DU181033 Cowling Decal - LH 1DU181034 Cowling Decal - RH 1

25 36DU1402 Decal Set - Flame Red DU141017 Tank Decal - LH 1DU141018 Tank Decal - RH 1DU161051 Cover Side Decal - LH 1DU161052 Cover Side Decal - RH 1DU161039 Cover Seat Decal - LH 1DU161040 Cover Seat Decal - RH 1DU181035 Cowling Decal - LH 1DU181036 Cowling Decal - RH 1



56



27 36DU1403 Decal Set - Star Blue DU141019 Tank Decal - LH 1DU141020 Tank Decal - RH 1DU161053 Cover Side Decal - LH 1DU161054 Cover Side Decal - RH 1DU161043 Cover Seat Decal - LH 1DU161044 Cover Seat Decal - RH 1DU181037 Cowling Decal - LH 1DU181038 Cowling Decal - RH 1

28 36DU1404 Decal Set - Olive Green DU141030 Tank Decal - LH 1DU141031 Tank Decal - RH 1DU161087 Cover Side Decal - LH 1DU161088 Cover Side Decal - RH 1DU161089 Cover Seat Decal - LH 1DU161090 Cover Seat Decal - RH 1DU181043 Cowling Decal - LH 1DU181044 Cowling Decal - RH 1

29 36DU1405 Decal Set - Brownish grey DU141028 Tank Decal - LH 1DU141029 Tank Decal - RH 1DU161083 Cover Side Decal - LH 1DU161084 Cover Side Decal - RH 1DU161085 Cover Seat Decal - LH 1DU161086 Cover Seat Decal - RH 1DU181041 Cowling Decal - LH 1DU181042 Cowling Decal - RH 1

30 36DU1407 Decal Set - Damson Purple DU141063 Tank Decal - LH 1DU141064 Tank Decal - RH 1DU161108 Cover Side Decal - LH 1DU161109 Cover Side Decal - RH 1DU161110 Cover Seat Decal - LH 1DU161111 Cover Seat Decal - RH 1DU181063 Cowling Decal - LH 1DU181064 Cowling Decal - RH 1

57

boxer s spc_final

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