Caliber 115

1 FRONT WHEEL DIRECTION

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

PLATE NO.

DrumBrake

DiscBrake

PART NOS. SHOWN IN BOLD ARE FOR CALIBER 115 ONLYREMAINING PARTS ARE COMMON WITH CALIBER

1 : CYLINDER HEAD

1 36DF1001 O Ring Kit 1 1 (Set of A&B) Ref.Page No.622 DD101470 Tappet Cap 2 2 Granite Silver Painted3 39167304 Flanged bolt 6 64 31101008 Guide Valve 2 25 39102121 Ring O 2 2 Alt to 39 2384 21

6 DD101347 Bolt 2 27 DD101350 Stud 2 28 DD101349 Bolt 4 49 DD101439 Head Comp. Cylinder 1 1 Granite Silver Painted

10 DD101469 Cover (OHC) 1 1 Granite Silver Painted

11 DD101351 Bolt 2 212 39100006 Hollow Dowel Pin 2 213 DD101010 Gasket Head 1 114 39101721 Ring O 2 215 DD101444 Pipe Intake 1 1 Granite Silver Painted

16 39161211 Plain washer 4 417 31101175 Insulator 1 1

13

12

15

3 2

A

11

A2

9

6 8

10B

12

7 7

3

14

14

5

4

16

3

1

17

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

FRONT WHEEL DIRECTION

PLATE NO.

DrumBrake

DiscBrake


1 31101021 Shaft Rocker 2 22 DF101055 Screw 2 23 31101235 Rocker arm assembly 2 24 31101104 Stopper 1 15 39070201 Screw Pan Cros 2 2

6 31101018 Retainer Valve Spring 2 27 DD101440 Spring Stiffer 2 28 36311008 Valve Repair Kit 1 2 (Set of A,B & C) Ref.Page No.629 DD101134 Valve Intake 1 1

10 DD101135 Valve Exhaust 1 1

2 : VALVE

7

6

1

2

5

54

87

1

6

2

9

33

A

B

C

A

C

B

8

10



PLATE NO.

DrumBrake

DiscBrake


1 31101026 Guide Chain 1 12 39204021 Ring O 1 13 22150451 Screw 2 24 31101024 Sprocket (28 T) 1 15 DD101441 Camshaft Assembly 1 1

6 31101033 Chain 1 17 DD101463 Tensioner Assembly 1 1 Granite Silver Painted8 39107001 Hex. Screw 2 29 39073212 Washer Spring 2 2

10 39019811 Plain Washer 2 2

11 31101025 Guide Chain 1 112 39074801 Screw pan cross 2 213 39099906 Hollow Dowel pin 2 2

3 : CAMSHAFT / TENSIONER

89

10

6

5

7

1

2

3

3

4

131211

13

12



PLATE NO.

DrumBrake

DiscBrake


1 39100006 Hollow dowel Pin 2 22 DD101007 Gasket For Cyl.Block 1 1 Alt to DD1013053 DD101445 Piston assly std 1 14 DD101014 Piston ring set std. 1 15 39098517 Wire Circlip 2 2

6 DD101478 Cylinder Block Piston assly 1 1

4 : CYLINDER AND PISTON

5

3

5

4

1

12

6



PLATE NO.

DrumBrake

DiscBrake


1 39105515 Flanged Nut 1 12 01100610 Woodruff Key 1 13 DD101117 Crankshaft assly 1 14 31101173 Key Woodruff 2 25 31101076 Gear Primary, Helical (23 T) 1 1

6 31101075 Gear (21 T) 1 17 39105315 Flanged Nut 1 18 DD101447 Flywheel 1 19 DD101475 Special washer 1 1

5 : CRANK SHAFT

77

8

44

2

1

810

6

5

3



PLATE NO.

DrumBrake

DiscBrake


1 39099411 Plain washer 1 12 DD101092 Gear Transmission Spur(2nd) 1 13 31101079 Gear Transmission Spur(3rd) 1 14 39098717 Ring Snap (16 mm) 2 25 31101082 Gear Transmission Spur(Top) 1 1

6 31101219 Shaft Transmission Input(1st) 1 17 31101221 Gear Transmission Spur(Low) 1 18 31101084 Gear Transmission Spur(Top) 1 19 31101083 Gear Transmission Spur(3rd) 1 1

10 31101080 Shaft Transmission Output(2nd) 1 1

11 39098917 Ext.Circlip 1 112 DD101136 Sprocket Output 1 113 31101117 Collar (Steel) 1 1

31101216 Collar (Sintered) 1 1 Alt. to 31 10 111714 39101821 O Ring 1 1

6 : TRANSMISSION

1312

11

7

8

49

10

6

5

43

2

1

14



PLATE NO.

DrumBrake

DiscBrake


1 31101081 Fork Shift 1 131101191 Fork Shift 1 1 Alt. to 31 10 1081

2 31101051 Rod shift 2 23 31101168 Drum assly. change 1 14 36311002 Holder for Drum Kit 1 1 Ref.Page No.625 31101047 Fork shift 1 1

31101192 Fork shift 1 1 Alt. to 31 10 1047

7 : CHANGE DRUM / SHIFT FORK

1

2

4

2

5

3



PLATE NO.

DrumBrake

DiscBrake


1 DD101304 Lever 1 12 30101086 Bolt 1 13 31101055 Spring 1 14 31101105 Plate Position 1 15 39074601 Screw Pan Cross 2 2

6 DD101077 Lever Comp. Change Shaft 1 17 DD101106 Bolt 1 18 39247404 Flanged bolt 1 19 DD101071 Lever Change 1 1

10 31101108 Damper 1 1

11 DD101298 Spring 1 112 DG101129 Spacer 1 113 31101054 Spring 1 1

8 : GEAR CHANGE MECHANISM

9

10

6

3

7

5

4

2

5

1

8

11

13

12



PLATE NO.

DrumBrake

DiscBrake


1 39186420 Bearing Ball 1 1 Alt. to 392293202 39099906 Hollow Dowel Pin 1 13 01170111 Ball Bearing 1 14 31121100 Oil Strainer 1 15 DG101498 Gasket 1 1

6 DD101275 Plug 1 17 01170110 Ball Bearing 1 18 DD101423 Engine Assly 1 1 N. I.9 DD101466 Crank case RH 1 1 Granite Silver Painted

9 : CRANKCASE RH / ENGINE ASSLY.

1 4

3

6

5

2

7

9

10



PLATE NO.

DrumBrake

DiscBrake


1 01170111 Ball Bearing 1 12 39105006 Hollow Dowel Pin 3 33 39106604 Bolt Flanged Small 3 34 39104319 Oil Seal 1 15 39108019 Seal Oil 1 1

6 39100820 Bearing Needle 1 17 39070201 Screw Pan Cros 2 28 31101056 Guide 1 19 31201081 Switch Comp. (Neutral) 1 1

10 39070311 Plain Washer * * * as required

11 39107504 Bolt Flanged Small 7 712 30101015 Gasket 1 113 DD101465 Crank case LH 1 1 Granite Silver Painted14 DM101052 Breather tube assly. 1 1

10 : CRANKCASE - L.H.

14

2

13

3

4

6

1210

8

9

5

7

7

11

1



PLATE NO.

DrumBrake

DiscBrake


11: PIPE OIL

1 DD121120 Pipe oil Assly. 1 12 DD121003 Pipe oil 1 13 39102304 Bolt 1 14 39106204 Bolt flanged small 1 15 39172711 Gasket 8 8

6 DD121009 Bolt 4 47 31121006 Gasket 2 2

3

4

6

5

2

5

5

5

5

6

1

5

77

12



PLATE NO.

DrumBrake

DiscBrake


1 31101062 Bolt 1 12 39101921 Ring O 1 13 DD101464 Cover Generator 1 1 Granite Silver Painted4 31101061 Plug 1 15 31101113 Gasket 1 1

6 DD101058 Gasket (Generator Cover) 1 17 39107404 Bolt Flanged Small 5 58 39099906 Hollow Dowel Pin 2 29 DD101424 Cover Chain (Engine) 1 1 Granite Silver Painted

10 39214704 Bolt Flanged Small 3 3

12 : COVER GENERATOR & COVER CHAIN

64

5

8

21

3

7

10

9



PLATE NO.

DrumBrake

DiscBrake


13: CLUTCH COVER

1 DD101459 Clutch cover assly./Decal 1 1 Granite Silver Painted2 DM101050 Label clutch cover 1 1 K-TEC3 DD101471 Clutch Cover Cap 1 1 Granite Silver Painted4 39167121 O ring 1 15 39167304 Flanged bolt 3 3

6 DD121006 Element oil filter 1 17 DD101057 Spring 1 18 DD121094 Rubber filter 1 19 DD101050 Plate position 1 1

10 39106204 Bolt flanged small 2 2

11 39104619 Seal oil 1 112 31101067 Guage 1 113 39104119 Seal oil 1 114 30101142 Seal oil 1 115 DD101325 Cap oil filler 1 1

16 39213421 O ring 1 117 DD101060 Gasket (Clutch cover) 1 118 39107504 Bolt flanged small 10 1019 39099906 Hollow Dowel Pin 2 2

3

5

47

6

215

16 18

19

119

10

17

1

14 13

12

19

8

14



PLATE NO.

DrumBrake

DiscBrake


1 DD101457 Housing Comp. Clutch 1 12 DD101449 Clutch Plate Assly. 1 13 39259311 Plain Washer 2 24 31101146 Collar 1 15 28101131 Wheel Clutch 1 1

6 DD101389 Plate Friction(Adlar) 5 57 28101134 Plate Clutch 4 48 28101132 Hub Clutch 1 19 28101214 Spring 6 6

10 39098004 Hex. Bolt 6 6

11 39105315 Flanged Nut 1 112 39240320 Ball Bearing 1 113 31101148 Rod Push 1 114 31101144 Lever Assly.Complete 1 1

14 : CLUTCH

11

7

6

7

6

10

10

8

9

9

6

76

7

6

5

14

3

1413

12

2

3



PLATE NO.

DrumBrake

DiscBrake


15 : KICK STARTER MECHANISM

1 39247404 Flanged bolt 1 12 39192001 Screw Pan Cros 2 23 DD101254 Guide Kick 1 14 DD101327 Lever Assly Kick 1 1 Alt to DD 1012 445 DD101097 Bush(Damper) 1 1

6 36311027 Boss Kick set A to E 1 1 Ref.Page No.627 36DF1003 Ratchet & Gear set K & L 1 1 Ref.Page No.628 36311020 Circlip & washer set F to H 1 1 Ref.Page No.629 31101124 Shaft Kick 1 1

10 31101040 Guide 1 1

11 31101041 Spring 1 112 39099311 Plain Washer 1 113 DD101330 Boss Kick 1 1

FGL

9G

FK

HG

F12

ECA B

1

D4

5

32

11

10

F

6

8

7

13

16



PLATE NO.

DrumBrake

DiscBrake


16 : CARBURETTOR

14

5

4

12

1315

1718

3

2

11

8

107

9

6

16

120

1 DD121142 Carburettor Assly. (Keihin FIE) 1 12 28121026 Insulator (Kehin Carburettor) 1 13 39101921 O ring 1 14 DD121164 Needle jet 1 15 DD121165 Holder- needle jet 1 1

6 DD121166 Main jet 1 17 DD121167 Slow Jet 1 18 DD121168 Valve Complete Float 1 19 DD121169 Float Complete 1 1

10 DD121170 Gasket - Float chamber 1 1

11 DD121171 Screw with washer 2 212 DD121172 Valve throttle 1 113 DD121173 Spring - Valve throttle 1 114 DD121174 Gasket top 1 115 DD121175 Screw Idling 1 1



PLATE NO.

DrumBrake

DiscBrake


16 : CARBURETTOR

16 DD121176 Spring- idling screw 1 117 DD121177 Screw-VCS 1 118 DD121178 Spring- Screw-VCS 1 119 DD121179 Jet BSV 1 1 N.I.20 39195904 Flanged bolt 2 2 For mounting Carburettor

14

5

4

12

1315

1718

3

2

11

8

107

9

6

16

120

18



PLATE NO.

DrumBrake

DiscBrake


17 : AIR FILTER ASSLY AND BATTERY BOX

1 DD121145 Filter assly air 1 12 DM121003 Case air filter 1 13 39098608 Pin Cotter 1 14 DM121006 Duct (Carburettor) 1 15 31121029 Element air filter 1 1

6 DM121007 O ring air filter 1 17 DM121004 Cap 1 18 01110609 Plain washer 4 49 39083001 Screw pan cross 4 4

10 DG161166 Screw (Mounting air filter) 2 2

11 39178924 Washer (Nylon) 2 212 DM121010 Band (Battery) 1 113 31161007 Damper battery 2 214 DM121014 Tube oil drain 1 115 DM121026 Clamp 1 1

16 39168004 Flanged bolt (Battery) 1 117 DM221001 Band - Tool kit 1 118 39071111 Washer plain 2 219 39074701 Screw Pan Cros 2 2

98

1

7

19

18

4

211

10

17

65

1612

14

15 313



PLATE NO.

DrumBrake

DiscBrake


1 31101014 Gasket 1 12 39019811 Plain Washer 2 23 39073212 Spring washer 2 24 39214515 Nut 2 25 DD101425 Muffler Assly.comp. 1 1

6 39185004 Flanged Bolt 1 17 DP101309 Cover Muffler Front 1 1 N.I.8 DD101428 Cover Muffler Rear 1 1 N.I.9 39258401 Screw SS 4 4 Cover Muffler Mtg.

10 DD211021 Seat assly comp. 1 1

11 DD161028 Lock Assly.Seat 1 112 39074301 Screw CSK Cross 2 213 DH161155 Damper Silencer 1 114 DH161157 Tube Silencer Mtg. 1 115 39242511 Plain washer 2 2

16 DD161071 U-Nut 1 1

18 : MUFFLER AND SEAT ASSLY.

16

11

12

5

1 2 34

615

14

1315

9

9

8

7

10

20



PLATE NO.

DrumBrake

DiscBrake


1 39107801 Screw Pan Cros 2 22 39075301 Screw Pan Cros 1 13 DF121003 Pump Assly. Oil without lug 1 14 39099906 Pin dowel 1 15 39101321 Ring O 2 2

19 : OIL PUMP

5

3

54

1

21



PLATE NO.

DrumBrake

DiscBrake


1 DD111039 Magneto assly /Brg./Oil Seal 1 12 31111001 Cap spark plug 1 13 DD111027 Stator assly 1 14 39104219 Seal Oil (HTA make) 1 15 39100320 Bearing ball 1 1

6 39102821 Ring O 1 17 39165911 Plain washer 3 38 DD111042 CDI assly with Damper 1 19 DD111006 Pulser Coil Assly. 1 1

10 39247304 Flanged Bolt 1 1

11 DD201001 Regulator/Rectifier (R/R) unit 1 1 Upto Apr. 03DD201157 Regulator/Rectifier (R/R) unit 1 1 From May 03

12 DD111018 Plug Spark 1 131111030 Plug Spark 1 1

13 TE006602 Coil Ignition without cap 1 114 39074501 Screw pan cross 2 215 DD101318 Bolt 3 3

16 DD111005 Exciter coil 1 1

20 : MAGNETO ASSLY.

1

34

16

9

13

7

65

15

8

14

10

12

2

11

22



PLATE NO.

DrumBrake

DiscBrake


1 39248104 Flanged Bolt 4 42 30181074 Upper Bearing race 1 13 30181007 Bearing Cone 1 14 30181008 Bearing Race 1 15 DF181090 Nut 1 1

6 DF181052 Cap - Steering 1 17 30181006 Ball Steel 46 468 DD161359 Frame Comp./Brg.races 1 19 DD221027 Grip Frame 1 1

21 : FRAME & GRIP FRAME

8

9

1

7

65

7

2

3

4



PLATE NO.

DrumBrake

DiscBrake


22 : ENGINE MOUNTING BRACKET

1 DD161344 Silent Bush 6 62 DD161356 Spacer Assly. 2 23 DD161351 Bracket Engine Front 2 24 39106804 Hex. Head Bolt 1 15 39024811 Plain Washer 4 4

6 39122515 Hex.Nut/Flange 4 47 DD161354 Bracket Engine upper LH 1 18 DD161355 Bracket Engine upper RH 1 19 39231104 Bolt Hex./Flange 2 2

10 DD161352 Bracket Engine Mounting LH 1 1

11 DD161353 Bracket Engine Mounting RH 1 112 39257104 Hex.Head Bolt 2 213 39247915 Flange Nut 3 314 39106804 Bolt 2 215 39247004 Flanged Bolt 1 1

16 39194004 Flange bolt 2 2 Leg guard Mtg.

12

12

8

6

34

9

7

10/11

1

2

513

13

11

14

5

14

5

6

16

15

24



PLATE NO.

DrumBrake

DiscBrake


1 39071215 Domed Cap Nut 4 42 39073712 Washer Spring 4 43 39071411 Washer Plain 8 84 DD171026 Rear Shock Absorber 2 25 DH161059 Rubber Pillion Step 2 2

6 39024811 Plain Washer 2 27 31171006 Shaft Swing Arm 1 18 39078912 Washer Spring 1 19 39020111 Plain Washer 2 2

10 30171018 Bushing Rubber 2 2

11 39070815 Nut Hex 1 112 DD171013 Arm Comp. Swing / Bush 1 113 DD161361 Stay (Left) 1 114 DD161360 Stay (Right) 1 115 39248104 Flanged Bolt 2 2

23 : SWING ARM / REAR SHOCK ABSORBER

1186

171622

19 2020

19

21

4

12333

2020

12

18

91010

3

21

5

13/14

96

15

7



PLATE NO.

DrumBrake

DiscBrake


16 39055302 Screw 2 217 39045411 Plain Washer 2 218 30171023 Adjuster Chain (LH) 1 119 39071111 Washer Plain 2 220 39029215 Hex Nut 4 4

21 30171024 Adjuster Chain (RH) 1 122 31171012 Damper for swing arm 1 1

23 : SWING ARM/REAR SHOCK ABSORBER

1186

171622

19 2020

19

21

4

12333

2020

12

18

91010

3

21

5

13/14

96

15

7

26



PLATE NO.

DrumBrake

DiscBrake


1 DF161096 Damper - Step Front 2 22 DF161249 Holder Step 1 13 39194004 Flanged Bolt 4 44 DF161102 Bolt 1 15 39042215 Nylock Nut 1 1

6 DD161063 Stand Side 1 17 DD161380 Spring 2 28 30161157 Shaft Stand 1 19 DD161338 Stand Centre with Damper 1 1

10 39078708 Pin Cotter 1 1

11 DG161124 Damper 1 1

24 : STAND & HOLDER STEP

10

7

7

6

8

4

2

35

119

1 1



PLATE NO.

DrumBrake

DiscBrake


1 39222204 Flanged Bolt 4 42 DD161013 Grommet 1 13 39021111 Plain Washer 4 44 39248304 Flanged Bolt 6 65 DD161038 Clamp for Front Fender 1 1

6 DD161051 Flap 1 17 31201021 Clamp 1 18 DM161009 Fender Rear Front 1 19 39071111 Plain Washer 2 2

10 39081715 Hex. Nut Flanged 4 4

11 DD161329 Fender Rear 1 112 DD161011 Brace fender 1 1

25 : FENDER (MUDGUARD)

4610

10

93

11

7

8

2

4

412

5

1

3

28



PLATE NO.

DrumBrake

DiscBrake


1 16151066 Nipple Spoke 72 722 DD151026 Spoke Inner (3.5 Dia.) 18 --

DP151019 Spoke Inner (3.5 Dia.) -- 183 DD151027 Spoke Outer (3.5 Dia) 18 --

DP151020 Spoke Outer (3.5 Dia) -- 184 DD151025 Wheel Rim (1.6 x 18) 1 --

DE151030 Wheel Rim (1.6 x 18) -- 15 30151028 Wheel Rim (1.85 x 18) 1 1

6 DJ151020 Tyre Front 1 1 Alt. DH 1510 04 7 30151019 Tube 1 1 Proprietory Parts

8 DH151008 Tyre Rear 1 1 Not to Serviced9 30151108 Tube 1 1

26 : WHEEL RIM / SPOKES/ TYRE/ TUBE

21

8

47

2

6

13

5 3

9



PLATE NO.

DrumBrake

DiscBrake


1 39236220 Bearing Ball 2 22 DD151024 Drum Front 1 13 30151032 Collar Bearing 1 14 39079815 Flanged Nut 1 15 30151033 Oil Seal 1 1

6 30151122 Collar Axle Assly. 1 17 39078111 Plain Washer 1 18 39078708 Pin Cotter 1 19 39078615 Nut Castle 1 1

10 30151046 Axle 1 1

11 39077504 Bolt 1 112 DD151008 Lever Brake Cam 1 113 DD151009 Indicator Front 1 114 30151038 Ring O 1 115 DD151013 Panel Front Brake 1 1

27 : FRONT BRAKE DRUM (FOR DRUM BRAKE)

18 19

17

1413

11

7

9

865

1

3

2

1

4

26

15

25 2125 23

24

20

27

12

1618

10

22

30



PLATE NO.

DrumBrake

DiscBrake


16 30151004 Cam Brake Assly. 1 117 30151035 Oil Seal 1 118 30151069 Spring 2 219 30151105 Shoe Brake Assly. 2 220 30151116 Speedometer Gear 1 1

21 30151041 Gear Meter Screw 1 122 30151118 Stopper for Bushing 1 123 30151119 Bushing 1 124 39101321 Ring 'O' 1 125 30151042 Washer 'A' 2 2

26 39090012 Washer Spring 1 127 39084001 Screw Pan Cross 1 1

27 : FRONT BRAKE DRUM (FOR DRUM BRAKE)

18 19

17

1413

11

7

9

865

1

3

2

1

4

26

15

25 2125 23

24

20

27

12

1618

10

22



PLATE NO.

DrumBrake

DiscBrake


1 DP151003 Drum Front -- 12 39236220 Bearing ball -- 23 39078708 Pin cotter -- 14 30151032 Collar bearing -- 15 30151033 Seal oil -- 1

6 DP151015 Plate Meter Gear -- 17 DP151004 Seal oil -- 18 DP151012 Disc -- 19 DG151049 Bolt socket -- 4

10 DE151010 Case meter gear -- 1

11 DE151011 Speedometer gear -- 112 30151041 Gear meter screw -- 113 30151119 Bushing -- 114 30151118 Stopper for bushing -- 115 39101321 O ring -- 1

28 : FRONT HUB (FOR DISC BRAKE)

20

8

9

1315

18

12

1814

1617

52

41

26

711

10

3

2221

19

32



PLATE NO.

DrumBrake

DiscBrake


16 39090012 Spring washer -- 117 39084001 Screw pan cross -- 118 30151042 Washer A -- 219 DP151005 Coller (Sleeve) -- 120 DP151021 Axle - Front -- 1

21 39078111 Plain washer -- 122 39078615 Nut castle -- 1

28 : FRONT HUB (FOR DISC BRAKE)

20

8

9

1315

18

12

1814

1617

52

41

26

711

10

3

2221

19



PLATE NO.

DrumBrake

DiscBrake


1 DP151012 Disc Front -- 12 DG151089 Caliper Assly. Front -- 13 DG151049 Bolt Socket -- 44 DP151018 Bolt Flanged -- 25 DE151048 Spring Pad -- 1

6 DE151046 Bleeder Screw -- 17 DE151047 Bleeder Cap -- 18 DE151037 Disc Pad Set -- 19 DE151043 Insulator -- 1

10 DE151045 Dust cover -- 1

11 DE151051 Minor Kit Caliper -- 112 DE151052 Major Kit Caliper -- 1

29 : FRONT DISC BRAKE

7

1011A

11B12 A

58

24

11

12

6

6

12A

7

10

9

11B

11A

9

3

1

SEAL

SCRAPING RING

INSULATOR

DUST COVER

BLEEDER CAP

BLEEDER SCREW

PISTON

34



PLATE NO.

DrumBrake

DiscBrake


16

2019

18

17

7

6

22

21

11A

11B12 15

9

8

3 11A

11B

15

11

55

4

10

13

14

5

4

5

2 1

2324

1 DE191043 Major Kit Master Cylinder -- 12 DP191009 Hose Brake Front -- 13 DD191080 Lever Grip RH -- 14 DE191011 Banjo Bolt -- 25 DE191010 Washer Copper -- 4

6 DE191033 Clamp Holder RH -- 17 DE191034 Screw - Clamp RH -- 18 DE191031 Bolt Front Brake Lever -- 19 DE191032 Nut Flanged -- 1

10 DE191030 Screw -- 2

11 DE191042 Minor Kit Master Cylinder -- 112 DE191024 Circlip -- 113 DE191029 Reservoir Cover -- 114 DE191028 Diaphragm -- 115 DE191027 Boot -- 1

30 : FRONT MASTER CYLINDER (FOR DISC BRAKE)



PLATE NO.

DrumBrake

DiscBrake


16

2019

18

17

7

6

22

21

11A

11B12 15

9

8

3 11A

11B

15

11

55

4

10

13

14

5

4

5

2 1

2324

16 DE201016 Front brake switch -- 117 DE191023 Return spring -- 118 DE191036 Window - Master Cylinder -- 119 DE191037 'O' ring -- 120 DE191038 Clip -- 1

21 DE191025 Push rod -- 122 DE191026 Conical spring -- 123 DD191109 Master Cylinder Assly. -- 124 DE201017 Cable assly. front brake switch -- 1

30 : FRONT MASTER CYLINDER (FOR DISC BRAKE)

36



PLATE NO.

DrumBrake

DiscBrake


1 DD151019 Chain (116 Links) 1 12 DP151028 Bolt (Square) 6 63 30151081 Washer Lock 3 34 39069415 Hex. Lock Nut 4 45 39224020 Bearing Ball 1 1

6 30151082 Seal Oil 1 17 DP151011 Sprocket (43T) 1 18 39080115 Nut Hex 1 19 39224120 Bearing Ball 1 1

10 DP151027 Damper - Coupling 1 1

11 30151063 Drum Rear 1 112 39224220 Bearing Ball 1 113 30151105 Shoe Brake Assly. 2 214 30151069 Spring 2 215 30151011 Brake Cam Assly. 1 1

31 : REAR HUB

20

14

13

9

1211

10

2

2

34

5

7

6

8

1

2122

23 24

1917

16

1514

18



PLATE NO.

DrumBrake

DiscBrake


16 30151008 Panel Rear Brake 1 117 30151038 Ring O 1 118 DD151015 Lever Brake (Forged) 1 119 39009204 Bolt 1 1

20 30151071 Axle 1 121 30151073 Collar 1 122 39071111 Washer Plain 1 123 39080015 Nut Castle 1 124 39078708 Pin Cotter 1 1

31 : REAR HUB

20

14

13

9

1211

10

2

2

34

5

7

6

8

1

2122

23 24

1917

16

1514

18

38



PLATE NO.

DrumBrake

DiscBrake


1 39080808 Split pin 1 12 39019811 Plain Washer 2 23 DD191043 Rod Brake 1 14 30191038 Pin 1 15 DD191012 Lever Brake 1 1

6 39080511 Washer 1 17 39079708 Pin Cotter 1 18 30191031 Spring 1 19 30191035 Spring 1 1

10 15191026 Pin 1 130191037 Pin 1 1 Alt. to 15 19 1026

11 30191036 Brake Adjusting Nut 1 112 39080708 Pin Snap 2 213 39070815 Nut Hex. 2 214 39078912 Washer Spring 2 215 DD151014 Rod Torque 1 1

32 : BRAKE PEDAL

12

13

15

1412

13 1

2 3

84

7

65

11

109

14

2



PLATE NO.

DrumBrake

DiscBrake


1 DD191056 Grip LH 1 12 DL191015 Lever Assly. Grip, RH 1 --3 39107404 Bolt 4 44 FD181030 Holder Handle Upper 2 25 DD181104 Handle 1 1

6 DD201155 Control Switch LH 1 17 DL191017 Lever Grip, Right 1 --8 DD191057 Grip Assly, RH 1 19 30191048 Band 2 2

10 DD201103 Control Switch RH 1 1

11 DL191016 Holder Right Hand 1 --12 39224915 Nylock Nut 2 213 DL191011 Lever Assly Grip LH 1 --

DD191106 Lever Assly Grip LH -- 114 DL191013 Lever Grip, Left 1 115 DL191014 Stud Lever Handle 2 2

33 : HANDLE BAR

15

18

9

1

14

B15

27

21

2019 13

8

7

20

192117

11AB

27

2

45

3

A

16

16

122426

2523

22

6

10

40



PLATE NO.

DrumBrake

DiscBrake


16 36DF1901 Screw & Nut kit (Set A & B) 2 1 Ref.Page No.6217 31201078 Switch Front Brake 1 --18 DL191012 Holder Left Hand 1 119 39072504 Hex Bolt 2 120 39019811 Washer Plain 2 1

21 39118415 Self Locking Nut 2 122 FD181031 Holder Handle lower 2 223 DF181091 Damper Handle Upper 2 224 DF181092 Damper Handle Lower 2 225 FD181019 Washer Plain Upper 2 2

26 FD181020 Washer Plain Lower 2 227 DD191072 Boot for Lever 2 1

33 : HANDLE BAR

15

18

9

1

14

B15

27

21

2019 13

8

7

20

192117

11AB

27

2

45

3

A

16

16

122426

2523

22

6

10



PLATE NO.

DrumBrake

DiscBrake


1 DL181080 Seal oil 2 22 DD181067 Pipe Left Fork Outer 1 --

DE181016 Pipe Left Fork Outer -- 13 DD181069 Pipe Right Fork Outer 1 --

DE181019 Pipe Right Fork Outer -- 14 30181016 Gasket 2 25 39077804 Bolt 2 2

6 31181015 Cyl. Complete Fork 2 27 DD181006 Pipe. Comp. suspension Inner 2 28 DM181008 Spring Front Fork 2 29 FD181012 Cap Nut Special 1 1

10 30181044 Bolt Fork 2 2

11 30181029 Ring O 2 212 DF181085 Seat Fork Spring 2 213 DD181205 Holder Fork Upper 1 114 DD181207 Holder Fork Under 1 115 39078912 Washer Spring 2 2

34 : FORK FRONT

17

16

14

910

1112

13

87

5

4

2/3

1

20

19

6

18

15

21/22

42



PLATE NO.

DrumBrake

DiscBrake


16 39181304 Bolt Small Fine 2 217 DD181202 Fork Front 1 --

DD181216 Fork Front -- 118 30181009 Bearing Cone 1 119 DD181011 Dust Seal 2 220 30181023 Ring Snap 2 2

21 DD181203 Damper assly.LH 1 --DD181217 Damper assly.LH -- 1

22 DD181204 Damper assly.RH 1 --DD181218 Damper assly.RH -- 1

34 : FORK FRONT

17

16

14

910

1112

13

87

5

4

2/3

1

20

19

6

18

15

21/22



PLATE NO.

DrumBrake

DiscBrake


1 DD141185 Tank fuel with Decal 1 1 Pearl Mica Jet BlackDD141191 Tank fuel with Decal 1 1 Flame RedDD7101Y7 Tank fuel with Decal 1 1 Star BlueDD141205 Tank fuel with Decal 1 1 GreenDD71011A Tank fuel with Decal 1 1 Ash Black (with Golden Red Decal)DD71011B Tank fuel with Decal 1 1 Ash Black (with Silver Green Decal)DD7101Y5 Tank fuel with Decal 1 1 Gun Metal Blue

2 DD141186 Tank Decal LH 1 1 Pearl Mica Jet BlackDD141192 Tank Decal LH 1 1 Flame RedDD141198 Tank Decal LH 1 1 Star BlueDD141206 Tank Decal LH 1 1 GreenDD141186 Tank Decal LH 1 1 Ash Black (with Golden Red Decal)DD141220 Tank Decal LH 1 1 Ash Black (with Silver Green Decal)DD141213 Tank Decal LH 1 1 Gun Metal Blue

3 DD141187 Tank Decal RH 1 1 Pearl Mica Jet BlackDD141193 Tank Decal RH 1 1 FlameRedDD141199 Tank Decal RH 1 1 Star BlueDD141207 Tank Decal RH 1 1 Green

35 : PAINTED PARTS

8

4/5

2/3

1

9

1013

14

6/7

11/12

44



PLATE NO.

DrumBrake

DiscBrake


DD141187 Tank Decal RH 1 1 Ash Black (with Golden Red Decal)DD141221 Tank Decal RH 1 1 Ash Black (with Silver Green Decal)DD141214 Tank Decal RH 1 1 Gun Metal Blue

4 DD161330 Cover Side Left with Decal 1 1 Pearl Mica Jet BlackDD161362 Cover Side Left with Decal 1 1 Flame RedDD7302Y7 Cover Side Left with Decal 1 1 Star BlueDD161382 Cover Side Left with Decal 1 1 GreenDD73021A Cover Side Left with Decal 1 1 Ash Black (with Golden Red Decal)DD73021B Cover Side Left with Decal 1 1 Ash Black (with Silver Green Decal)DD7302Y5 Cover Side Left with Decal 1 1 Gun Metal Blue

5 DD161332 Cover Side Right with Decal 1 1 Pearl Mica Jet BlackDD161364 Cover Side Right with Decal 1 1 Flame RedDD7303Y7 Cover Side Right with Decal 1 1 Star BlueDD161384 Cover Side Right with Decal 1 1 GreenDD73031A Cover Side Right with Decal 1 1 Ash Black (with Golden Red Decal)DD73011B Cover Side Right with Decal 1 1 Ash Black (with Silver Green Decal)DD7303Y5 Cover Side Right with Decal 1 1 Gun Metal Blue

8

4/5

2/3

1

9

1013

14

6/7

35 : PAINTED PARTS

11/12



PLATE NO.

DrumBrake

DiscBrake


6 DD161331 Cover Side Decal LH 1 1 Pearl Mica Jet BlackDD161363 Cover Side Decal LH 1 1 Flame RedDD161371 Cover Side Decal LH 1 1 Star BlueDD161383 Cover Side Decal LH 1 1 GreenDD161331 Cover Side Decal LH 1 1 Ash Black (with Golden Red Decal)DD161402 Cover Side Decal LH 1 1 Ash Black (with Silver Green Decal)DD161394 Cover Side Decal LH 1 1 Gun Metal Blue

7 DD161333 Cover Side Decal RH 1 1 Pearl Mica Jet BlackDD161365 Cover Side Decal RH 1 1 Flame RedDD161373 Cover Side Decal RH 1 1 Star BlueDD161385 Cover Side Decal RH 1 1 GreenDD161333 Cover Side Decal RH 1 1 Ash Black (with Golden Red Decal)DD161404 Cover Side Decal RH 1 1 Ash Black (with Silver Green Decal)DD161396 Cover Side Decal RH 1 1 Gun Metal Blue

8 DD161334 Cover Seat with Decal 1 1 Pearl Mica Jet BlackDD161366 Cover Seat with Decal 1 1 Flame RedDD7304Y7 Cover Seat with Decal 1 1 Star BlueDD161386 Cover Seat with Decal 1 1 Green

35 : PAINTED PARTS

8

4/5

2/3

1

9

1013

14

6/7

11/12

46



PLATE NO.

DrumBrake

DiscBrake


DD73041A Cover Seat with Decal 1 1 Ash Black (with Golden Red Decal)DD73041B Cover Seat with Decal 1 1 Ash Black (with Silver Green Decal)DD7304Y5 Cover Seat with Decal 1 1 Gun Metal Blue

9 DD161337 Fender Front 1 1 Pearl Mica Jet BlackDD161369 Fender Front 1 1 Flame RedDD7301Y7 Fender Front 1 1 Star BlueDD161389 Fender Front 1 1 GreenDD7301Y4 Fender Front 1 1 Ash Black (with Golden Red Decal)

and Silver Green Decal)DD7301Y5 Fender Front 1 1 Gun Metal Blue

10 DD181197 Cowling/Decal 1 1 Pearl Mica Jet BlackDD181208 Cowling/Decal 1 1 Flame RedDD7305Y7 Cowling/Decal 1 1 Star BlueDD181219 Cowling/Decal 1 1 GreenDD73051A Cowling/Decal 1 1 Ash Black (with Golden Red Decal)DD73051B Cowling/Decal 1 1 Ash Black (with Silver Green Decal)DD7305Y5 Cowling/Decal 1 1 Gun Metal Blue

11 DD181198 Cowling Decal LH 1 1 Pearl Mica Jet BlackDD181209 Cowling Decal LH 1 1 Flame Red

35 : PAINTED PARTS

8

4/5

2/3

1

9

1013

14

6/7

11/12



PLATE NO.

DrumBrake

DiscBrake


DD181214 Cowling Decal LH 1 1 Star BlueDD181220 Cowling Decal LH 1 1 GreenDD181198 Cowling Decal LH 1 1 Ash Black (with Golden Red Decal)DD181226 Cowling Decal LH 1 1 Ash Black (with Silver Green Decal)DD181223 Cowling Decal LH 1 1 Gun Metal Blue

12 DD181199 Cowling Decal RH 1 1 Pearl Mica Jet BlackDD181210 Cowling Decal RH 1 1 Flame RedDD181215 Cowling Decal RH 1 1 Star BlueDD181221 Cowling Decal RH 1 1 GreenDD181199 Cowling Decal RH 1 1 Ash Black (with Golden Red Decal)DD181227 Cowling Decal RH 1 1 Ash Black (with Silver Green Decal)DD181224 Cowling Decal RH 1 1 Gun Metal Blue

13 DD181196 Label B Kawasaki 1 114 DD141211 Seatlab 1 1

8

4/5

2/3

1

9

1013

14

6/7

11/12

35 : PAINTED PARTS

48



PLATE NO.

DrumBrake

DiscBrake


1 DD141024 Cap Tank 1 12 DD141122 Rotor with key 1 13 39076101 Screw Pan Cros 2 24 39217924 Washer 2 25 30141031 Ring O 2 2

6 30141052 Packing 1 17 DF141160 Fuel Tap Assly. 1 18 30141039 Packing 1 19 30141036 Packing 1 1

10 DD141016 Clamp 3 3

11 DD121163 Tube Fuel 1 112 DD201021 Gauge Fuel 1 113 DD141026 Tube Rubber 1 114 30141032 Bolt 4 415 30141028 Gasket For Gauge Fuel 1 1

36 : FUEL TANK CAP & TAP ASSLY.

6

7

8

11 10

10

1410

12

2

54

3 1

15

13



PLATE NO.

DrumBrake

DiscBrake


1 30161271 Rubber Pad 1 12 DD161378 Case Chain Upper Assly. 1 1 Granite Silver Painted3 39021911 Washer Plain 2 24 15161069 Rubber Cap 1 15 39247504 Flanged Bolt 2 2

6 39247304 Flanged Bolt 2 27 DD161379 Case Chain Lower Assly. 1 1 Granite Silver Painted8 DL161023 Trim case chain 1 1

37 : CHAIN CASE

1

5

3

4

7

36

28

50



PLATE NO.

DrumBrake

DiscBrake


1 DD161022 Damper 2 2 To fit Side Cover on Frame2 30161169 Grommet 2 2 To fit Side Cover on Petrol Tank3 39178924 Washer (Nylon) 3 34 DG161121 Screw 3 35 31161171 Lock for side cover with keys 1 1

6 DD161078 Damper 2 2 For Cover Seat7 DD161085 Pad Seat Cover 2 28 39098308 Pin Snap 1 19 39105411 Plain Washer 1 1

10 DF141129 Damper 1 1

11 DF141128 Damper 2 2

38 : FITTINGS -PETROL TANK & SIDE COVER

6

7

5

1

11

3

4

10

9

84

3

2



PLATE NO.

DrumBrake

DiscBrake


1 DD191129 Speedo assly with lamp 1 12 DD191134 Speedometer 1 13 DD191136 Meter fuel 1 14 DD191137 Cover meter case upper 1 15 DD191094 Cover meter case lower(Black) 1 1

6 DD191135 Tacho Meter 1 17 39194304 Flange bolt 2 28 DG201040 Lamp 12V 3.4W (W/o cap) 7 79 DD191133 Trip Meter Knob 1 1

10 DD201095 Ignition Switch / key 1 1

11 DD181162 Flap Cowling 1 112 35161060 Clip Nut 5 513 39258701 Screw SS 5 514 39214124 Washer Non-metallic 5 515 DD181185 Bracket cowling Upper 1 1

16 DD181186 Collar 2 217 39258501 Screw 2 2

39 : METER ASSEMBLY

7

17

13

14

16

2

43

6

1

5

9

10

1511

12

8

52



PLATE NO.

DrumBrake

DiscBrake


1 DD191073 Cable Brake (FR) 1 --2 30191070 Spring 1 --3 30191069 Dust Seal 1 --4 DD191042 Rod End 1 --5 30191072 Adjusting Nut 1 --

6 DD191131 Cable Clutch 1 17 DD191075 Cable Speedometer 1 18 30191067 Oil Seal 1 19 DD191076 Inner Cable Speedo 1 1

10 DD191132 Cable Throttle 1 1

11 DD191125 Cable starter 1 1

40 : CONTROL CABLES

23

45

8

9

6

10

1

7

11



PLATE NO.

DrumBrake

DiscBrake


1 DD201141 Head Light With Lamp-HS1 1 12 39081302 Cr.Res.Pan hd.Taping Screw 4 43 CL201023 Lamp (12 V, 35/35 W)-HS1 1 14 39196104 Bolt Flanged Small 1 15 39081715 Nut Hex/Flanged 1 1

6 DD181161 Wind shield 1 17 DF181099 Nut well 4 48 39258701 Screw 4 49 39214124 Washer Non-metallic 4 4

10 DD181183 Bracket Cowling Lower 1 1

11 39074501 Screw Pan Cross 2 212 DD181184 Bracket Fork Lower 1 113 39247304 Hex.Bolt / Flange 2 214 30201029 Lamp 12V-4W 1 1

41 : HEAD LAMP ASSLY

12

6

7

5

13

9

8

1

2

14

3

11

4

10

54



PLATE NO.

DrumBrake

DiscBrake


1 DD201146 Lamp Assly Sig.FR.LH/Lamp 1 12 DD201148 Lamp Assly Sig.FR.RH/Lamp 1 13 06201083 Lamp (12 V, 10 W) 4 44 DD181192 Bracket Signal 1 15 39122515 Hex.Nut/Flange 4 4

6 FD201033 Lens Side Indicator 4 47 DD201135 Lamp Assly Sig.RE.LH/Lamp 1 18 DD201137 Lamp Assly Sig.RE.RH/Lamp 1 19 DD201139 Adapter RE - LH 1 1 N.I.

10 DD201140 Adapter RE - RH 1 1 N.I.

42 : TURN SIGNAL LAMP

1/2

7/8

5

4

6

3

5

6

3



PLATE NO.

DrumBrake

DiscBrake


1 DP161144 Front Number plate 1 12 DD181187 Bracket Front No. Plate 1 13 39178301 Truss Screw 2 14 39247304 Flanged bolt 2 25 DP161145 Number plate Rear 1 1

6 DF161248 Bracket No. Plate 1 17 39247604 Hex head bolt/Flange 2 28 39247504 Hex.bolt/flange 2 29 DP161100 Bracket (Fender Rear) 1 1

43 : FRONT AND REAR NUMBER PLATE

8

7

56

3

1

24

9

56



PLATE NO.

DrumBrake

DiscBrake


1 39081715 Flanged Nut 3 32 39021111 Plain Wahser 3 33 31201001 Collar 3 34 DD201011 Damper 3 35 DD201122 Tail Light With Lamp 1 1

6 31201028 Lamp 12 V, 10/5W 1 17 DD201156 Lens Tail Light 1 18 DD201034 Screw For Lens(Tail Light) 2 29 39248415 Flange Nut 1 1

10 30201069 Reflector Reflex 1 1

44 : TAIL LAMP ASSLY.

2

8

7

6

510

9

4

3

1



PLATE NO.

DrumBrake

DiscBrake


1 39194004 Flanged Bolt 1 12 DF201140 Horn 12V DC 1 13 31201079 Switch Rear Brake 1 14 DD191013 Spring Brake Switch 1 15 DD201150 Wiring Harness 1 1 Upto Apr. 03

DD201158 Wiring Harness 1 1 From May 03

6 31201027 Battery 1 17 30201104 Fuse box with damper 1 18 30201085 Fuse, 15A 2 29 DF201131 Assly. DC Flasher S.S. 1 1

10 31201082 Capacitor Electrolytic 1 1

11 39247304 Hex. bolt / flange 1 112 DD181188 Lock Assly. (3 in 1) 1 1 N.I.13 DD111046 TPS Assly. 1 114 39106204 Bolt Flanged 1 1

45 : ELECTRICAL EQUIPMENT/TPS Assly.

10

5

118

7

6

3

4

2

1

9

13

14

58



PLATE NO.

DrumBrake

DiscBrake


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

523

6

7

1 DD221029 Leg guard 1 12 DD221008 Mirror assly RH 1 13 DD221007 Mirror assly LH 1 14 39194004 Flanged Bolt 2 2 For Upper mounting of Leg guard5 DD221017 Saree Guard 1 1

6 39160804 Hex.soc.hd.bolt 2 2 Alt 391906047 39181404 Bolt Flanged 1 1

4

1



PLATE NO.

DrumBrake

DiscBrake


47 : TOOL KIT

1

2

1 DD221019 Tool Kit 1 1* 31221003 Tool Wrench (Box, 16 mm) 1 1* 30221033 Tool Wrench (Open End 10x13) 1 1* 30221003 Tool Driver 1 1* 30221004 Tool Driver (2 philips & slot) 1 1* 30221011 Tool Wrench(Open End 14 x17) 1 1* 30221009 Tool Bar 1 1 For Reference only* 30221002 Tool Bag 1 1 Not to service

Separately* 30221010 Tool Pliers 1 1* 30221005 Tool Wrench - 27 A/F 1 1* 30221006 Tool Wrench - 22 A/F 1 1

2 DM221001 Band tool kit 1 1

Documents

Caliber 115