Tvs Xl Super Catalogue 2l542

XL SUPER / HD / SPORT PARTS CATALOGUE

XL SUPER / HD / SPORT

ASSEMBLY INDEX 1. CYLINDER HEAD. CYLINDER BLOCK

15. REAR SUSPENSION ASSY.

2. CRANKCASE, REED VALVE

16. FRONT WHEEL ASSEMBLY

3. COVER CLUTCH SHIELD

17. REAR WHEEL ASSEMBLY

4. CRANKSHAFT, PISTON ASSEMBLY

17A.REAR WHEEL ASSY. - QD

5. CARBURETTOR ASSEMBLY

18. FRAME & STAND ASSEMBLY

6. AIR CLEANER ASSEMBLY

19. SEAT ASSEMBLY

7. EXHAUST SYSTEM ASSEMBLY

20. FUELTANK & TOOL BOX ASSY.

8. FAN AND COWL FAN ASSEMBLY

21. MUDGUARD, COVER FRAME & CHAIN GUARD

9. CLUTCH ASSEMBLY

22. HANDLE BAR, SPEEDOMETER ASSY.

10. GEAR ASSY. PRIMARY DRIVEN

23. CONTROL LEVER ASSY. LH

11. KICK STARTER ASSEMBLY

23A.CONTROL LEVER ASSY. RH

12. MAGNETO ASSY. & CDI UNIT

23B.CONTROL LEVER ASSY. LH,RH (SPORT)

13. FOOTREST ASSEMBLY

24. HEAD LAMP & TAIL LAMP ASSY.

14. FRONT SUSPENSION ASSEMBLY

24A.HEAD LAMP & TAIL LAMP ASSY. (SPORT)

14A.FRONT SUSPENSION ASSY. (HYDRALIC FORK)

25. TOOL KIT ASSY.

FIG.No. 01

CYLINDER HEAD, CYLINDER BLOCK

6

5

FIG.NO.01

NO. OFF REF

PART

NO.

NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

REMARKS

3 2

1

420307700

HEX NUT M7

4

4

4

4

4

2

420051000

SPRING WASHER

4

4

4

4

4

3

420002700

PUNCHED WASHER A7.6

4

4

4

4

4

4

A182390

SPARK PLUG BPR 7HS

1

1

1

1

1

5

T010230

HEAD, CYLINDER

1

1

1

1

1

6

P010430

GASKET CYLINDER HEAD

1

1

1

1

1

7

P1010120

CYLINDER BLOCK(VERTICAL FINS) 1

1

1

1

1

8

P180470

BASE GASKET

1

1

1

1

1

9

F200140

CYLINDER STUD

4

4

4

4

4

10 K010160

DAMPER ENGINE

13

13

13

11 P320740

GASKET KIT (OLD)

1

1

1

11A P321380

GASKET KIT (NEW)

1 10

3

4

9

2 1 8

9 7

11

11A

12 P1320280

CYLINDER BLOCK & PISTON KIT

1

1

13 P180340

ENGINE ASSY 70cc

1

1

13A J180030

ENGINE ASSY 70cc

CYLINDER HEAD, CYLINDER BLOCK ** - REF. KIT & KIT CONTENTS

1

1

** 1

1

**

1

1

**

1

1

CRANK CASE, REED VALVE ASSY.

FIG.No.02 12 11 6 7

NO. OFF REF NO.

9

FIG.NO. 02

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

REMARKS

10 8

9

2 5 4

1

P030190

CRANKCASE ASSY.

1

1

1

1

1

2

P030200

GASKET CRANKCASE

1

1

1

1

1

3

P200070

HARDENED PIN 8 X 30

2

2

2

2

2

4

K080460

RETAINER - OIL SEAL

1

1

1

1

1

5

K200260

CRR CSK SCREW M4 X 6

3

3

3

3

3

6

P200100

HEX BOLT M8 X 1.25 X 110

1

1

1

1

1

7

0332108

SCREW CRANKCASE PH M6x45

6

6

6

6

6

8

0330408

WAVE SPRING WASHER M6

6

6

6

6

6

9

404007000

INLET GASKET

2

2

2

2

2

10 P040430

REED VALVE ASSY.

1

1

1

1

1

11 P040640

PIPE INTAKE

1

1

1

1

1

12 P200210

CSK HD SCREW M6 X 25

2

2

2

2

2

13 420469700

HEX BOLT M8 X 65

2

2

2

2

2

14 0330318

WAVE SPRING WASHER M8

3

3

3

3

3

15 420316700

HEX NUT M8

3

3

3

3

3

16 P200170

STUD

2

2

2

2

2

17 K081100

RETAINER OIL SEAL

1

1

1

1

1

18 P080750

HOSE COMP. BREATHER

1

1

1

1

1

19 P3320160

KIT ENGINE BREATHER

1

1

1

1

1

3 13

14 15 16

1 17

CRANK CASE, REED VALVE

5

18

** ' - REF. KIT & KIT CONTENTS

**

FIG.No.03

COVER CLUTCH, SHIELD ASSY.

FIG.NO. 03

NO. OFF REF NO.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

P070120

COVER CLUTCH

1

1

1

1

1

2

0335876

RETAINER BEARING

1

1

1

1

1

3

M1200810

CRR PAN HD SCREW M6 x 12

2

2

2

2

2

4

P080420

GASKET COVER CLUTCH

1

1

1

1

1

5

0148010

PLUG OIL FILLER

1

1

1

1

1

6

N3140120

GASKET OIL LEVEL PLUG

1

1

1

1

1

7

0331688

HEX SCREW M6x8

1

1

1

1

1

8

F084010

GASKET RING OIL DRAIN

1

1

1

1

1

9

F085230

BOLT OIL DRAIN

1

1

1

1

1

10 P200260

CRR PAN HD SCREW M6 x 55

3

3

3

3

3

11 P200300

CRR PAN HD SCREW M6 x 85

2

2

2

2

2

12 P200290

CRR PAN HD SCREW M6 x 35

1

1

1

1

1

13 P080700

SPECIAL HEX NUT

2

2

2

2

2

14 P080510

SHIELD

1

1

1

1

1

15 P1200120

PUNCHED WASHER 6.5x13x01.0

2

2

2

2

2

16 0330408

WAVE SPRING WASHER

2

2

2

2

2

17 P200270

CRR PAN HD SCREW M6 x 12

2

2

2

2

2

18 0074010

PIN DOWEL

2

2

2

2

2

19 P1200430

OIL SEL 16X22X 4 (DOUBLE LIPS)

1

1

19A P081130

O RING

1

1

1

REMARKS

# *

COVER CLUTCH, SHIELD # - Replaces 420667000 * - APPLICABLE FOR THE VEHICLES PRODUCED BEFORE MAY 2005, REF.SIB REF No.SIB/MOPED/01/05-06 DATED 10.09.2006

FIG.No.04

CRANKSHAFT, PISTON ASSEMBLY

FIG.NO.04

NO. OFF REF NO.

PART NO.

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

REMARKS

1

K200630

OIL SEAL 20x30x6 (MAGNETO SIDE) 1

1

1

1

1

2

0339070

BALL BEARING 6204-C3

2

2

2

2

2

3

420702000

WOODRUFF KEY

2

2

2

2

2

4

P020010

CRANK SHAFT ASSY.

1

1

1

1

1

5

K200120

CIRCLIP

1

1

1

1

1

6

P200110

OIL SEAL 20x47x6 (CLUTCH SIDE)

1

1

1

1

1

7

420566000

NEEDLE CAGE

1

1

1

1

1

8

P010660

PISTON PIN

1

1

1

1

1

PISTON PIN NEW

1

1

1

1

1

WIRE CLIP

2

2

2

2

2

10 P010540

PISTON RING - STD

2

2

2

2

2

10A P320880

PISTON RING - I O/S

2

2

2

2

2

N.I

10B P320900

PISTON RING - II O/S

2

2

2

2

2

N.I

11 P010560

EXPANDER RING

1

1

1

1

1

12

---

PISTON STD

1

1

1

1

1

Ref. SNo.13

12A

---

PISTON - I O/S

1

1

1

1

1

Ref. SNo.13A

12B

---

PISTON - II O/S

1

1

1

1

1

Ref. SNo.13B

13 P320980

PISTON KIT STD

1

1

1

1

1

**

13A P321020

PISTON KIT I O/S

1

1

1

1

1

**

13B P321040

PISTON KIT II O/S

1

1

1

1

1

**

14 P321280

CRANKSHAFT KIT

1

1

1

1

1

**

15 P1320070

ENGINE OIL SEAL KIT

1

1

1

1

1

**

8A P010680 9

CRANKSHAFT, PISTON ASSEMBLY

DESCRIPTION

420950000

** - REF. KIT& KIT CONTETNS

N.I - NOT ILLUSTRATED

CARBURETTOR ASSEMBLY

FIG.No.05

FIG.NO. 05

NO. OFF REF NO.

1

CARBURETTOR ASSEMBLY

PART NO.

DESCRIPTION

P040560

CARBURETTOR ASSY.

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1

1

1A J040140

CARBURETTOR ASSY. (SPORT)

1B P1040080

CARBURETTOR ASSY.

1

1

1C P1040140

CARBURETTOR ASSY.

1

1

REMARKS

1

2

P320090

CAP

2

2

2

2

2

3

404037000

ADJUSTER

2

2

2

2

2

4

404049000

NUT

2

2

2

2

2

5

P320230

MIXING CHAMBER COVER

1

1

1

1

1

6

P320240

GASKET

1

1

1

1

1

7

P320250

SPRING

1

1

1

1

1

8

P320260

CABLE END SPINDLE

1

1

1

1

1

9

P320280

CIRCLIP

1

1

1

1

1

10 P320290

CONICAL NEEDLE TYPE Z - 3

1

1

1

1

1

10A P1320400

CONICAL NEEDLE, TYPE B - 2

1

1

11 P320270

THROTTLE VALVE, TYPE CA25

1

1

11A P1320410

THROTTLE VALVE, TYPE CA20

1

1

1

1

1

12 P320130

SEALING RING, DIA24xDIA18mm

1

1

1

1

1

13 P320140

ADAPTOR, DIA24x18mm

1

1

1

1

1

14 P320060

MIXURE CONTROLLER

1

1

1

1

1

15 P320070

SPRING

1

1

1

1

1

16 P320080

WASHER

1

1

1

1

1

17 D046090

O' RING

1

1

1

1

1

NEW

FIG.No.05

CARBURETTOR ASSEMBLY

FIG.NO. 05

NO. OFF REF NO.

PART NO.

18 P320200 18A 404377000

CARBURETTOR ASSEMBLY

DESCRIPTION

SCREW

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

SCREW

19 P320220

VALVE CONTROLLER

19A P1320350

VALVE CONTROLLER

20 P320210

SPRING

20A P1320360

SPRING

1

1

1

1

1

1

21 P320100

HOUSING

1

1

1

1

1

22 P320110

SPRING

1

1

1

1

1

23 P320120

VALVE SPINDLE

1

1

1

1

1

24 P320480

PILOT JET NO.34

1

1

1

1

1

24A P1320420

PILOT JET NO.30

1

1

25 P320150

SPARY NOZZLE, TYPE 258

1

1

1

1

1

26 P320160

ATOMIZER, TYPE 03

1

1

1

1

1

27 404077000

MAIN JET No.52

1

1

1

1

1

28 404377000

NUT

1

1

1

1

1

29 404053000

PETROL STOP NEDDLE

1

1

1

1

1

30 P320320

FLOAT COMP. CARBURETTOR

1

1

1

1

1

31 P320310

SPINDLE

1

1

1

1

1

32 P320300

GASKET FLOAT BODY

1

1

1

1

1

32A P1320380

GASKET FLOAT BODY

1

1

1

1

1

1

33 P320190

FLOAT CHAMBER

33A P1320370

FLOAT CHAMBER

1

1

1

REMARKS

FIG.No.05

CARBURETTOR ASSEMBLY

FIG.NO. 05

NO. OFF REF NO.

PART NO.

33B P1320470

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

FLOAT BODY ASSY.

REMARKS

34 P320050

SCREW + SPRING WASHER

4

4

4

4

4

35 P320330

CLIP

1

1

1

1

1

36 P320340

RUBBER PIPE

1

1

1

1

1

37 N8300370

WASHER

1

1

38 P1320390

O RING

1

1

39 P1320340

CLIP CARB.

1

1

40 P321310

CARBURETTOR BUSH KIT

1

1

1

1

1

**

41 P321320

ADJUSTMENT KIT

1

1

1

1

1

"

42 P321330

MINOR KIT

1

1

1

1

1

"

43 P321340

MAJOR KIT

1

1

1

1

1

"

44 P321350

FLOAT KIT

1

1

1

1

1

"

45 P321360

THROTTLE VALVE KIT

1

1

1

1

1

"

46 P321370

DECARB GASKET KIT

1

1

1

1

1

"

CARBURETTOR ASSEMBLY

** - REF. KIT& KIT CONTETNS

FIG.No.5A

CARBURETTOR ASSEMBLY - NEW

FIG.NO. 5A

NO. OFF

CARBURETTOR ASSEMBLY NEW

REF NO.

PART NO.

1

P1040140

2

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

CARBURETTOR ASSY.

1

1

P1320730

RUBBER CAP

2

2

3

P1320500

MIXING CHAMBER COVER

1

1

4

P1320570

GASKET MCC

1

1

5

P1320510

SERVICE THROTTLE VALVE

1

1

6

P1320600

RETAINER DISC

1

1

7

P1320530

CIRCLIP

1

1

8

P1320540

JET NEEDLE TYPE B5

1

1

9

P1320520

THROTTLE VALVE TYPE 25

1

1

10

N8320930

HOUSING CHOCK

1

1

11

N8320730

O RING CHOCK

1

1

12

P320110

SPRING CHOCK

1

1

13

N8320950

VALVE SPINDLE CHOCK

1

1

14

P320330

TUBE CLIP

1

1

15

P1320720

RUBBER HOSE AV

1

1

16

P1320610

SQUARE NUT

1

1

17

N8320370

WASHER AIR ADJUSTER

1

1

18

N8320380

O RING AIR ADJUSTER

1

1

19

N8320360

SPRING AIR ADJUSTER

1

1

REMARKS

FIG.No.5A

CARBURETTOR ASSEMBLY - NEW

FIG.NO. 5A

NO. OFF

CARBURETTOR ASSEMBLY NEW

REF NO.

PART NO.

20

P1320700

21

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

AIR ADJUSTER

1

1

P1320590

ADAPTOR

1

1

22

P1320580

SEATING RINGS

1

1

23

P320200

CLAMBING BOLT

1

1

24

P1320560

VALVE CONTROLER

1

1

25

P1320550

SPRING VALVE

1

1

26

N8323590

PILOT JET 32

1

1

27

P1320710

MAIN JET 52

1

1

28

N8320500

FLOAT

1

1

29

P320050

SCREW WASHER

2

2

30

P1320490

NEEDLE JET TYPE 210

1

1

31

P1320480

NEEDLE JET HOLDER T06

1

1

32

N8320510

PETROL STOP NEEDLE

1

1

33

N8320490

ARM PIN FLOAT

1

1

34

P1320570

GASKET MCC

1

1

35

P1320470

FLOAT CHAMBER

1

1

REMARKS

FIG.No.06

AIR CLEANER ASSEMBLY

FIG.NO. 06 NO. OFF

REF NO. 1

PART NO. P040700

1A P1040100

AIR FILTER ASSEMBLY

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1

1

1

1

AIR FILTER ASSEMBLY

2

F200090

CRR PAN HD SCREW M5 X 70

6

6

6

6

3

420518700

CRR PAN HD SCREW M6 X 20

2

2

2

2

4

0330408

WAVE SPRING WASHER M6

2

2

2

2

5

0335928

PUNCHED WASER 6.5 X 18

2

2

2

2

6

P040260

SPACER

2

2

2

2

7

P040720

COVER AIR - CLEANER

1

1

1

1

1

1

7A P1040110

AIR CLEANER ASSEMBLY

DESCRIPTION

COVER AIR - CLEANER

8

P040740

SEAL AIR CLEANER

1

1

1

1

9

P040750

ELEMENT

2

2

2

2

10 P040730

ELEMENT AIR CLEANER

1

1

1

1

11 P040710

CASE AIR - CLEANER

1

1

1

1

11A P1040120

CASE AIR - CLEANER

1

1

12 8040300

SPRING CLIP

1

1

1

1

13 P040570

ADAPTOR CARBURETTOR

1

1

1

1

14 0086010

CLAMP

1

1

1

1

15 A182150

CRR PAN HD SCREW M5x35

2

16 0335558

PUNCHED WASHER

2

17 T040100

COVER, AIR CLEANER

2

18 T040140

SEAL, AIR CLEANER

1

19 T040120

, AIR CLEANER

1

20 T040110

ELEMENT, AIR CLEANER

1

21 T040130

AIR CLEANER ASSY

1

22 J040130

ADAPTOR CARBURETTOR

1

23 J040160

AIR INTAKE MANIFOLD

1

2

REMARKS

FIG.No.06A

SECONDARY AIR INJECTION ASSEMBLY

FIG.NO. 06A

NO. OFF REF NO.

SECONDARY AIR INJECTION ASSEMBLY

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

P1040160

HOSE SAI INLET

1

1

2

R2040400

HOSE CLIP

4

4

3

P1040200

HOSE AIR INLET

1

1

4

N9041670

AIR CLEANER SAI

1

1

5

P1040200

BOOT SAI AIR

1

1

6

M1200790

HEX SHOC HAD CAP SCR M6x16

1

1

7

P1040170

SEC AIR INJECTION VALVE ASSY.

1

1

8

N8040350

HOSE CLIP AIR INJECTION

2

2

9

R3040060

HOSE SAI INLET

1

1

10 P1040190

PIPE COMP. SAI

1

1

11 0330408

WAVE SPRING WASHER

2

2

12 M1200520

HEX FLANGE BOLT M6x16

2

2

REMARKS

FIG.No.07

EXHAUST SYSTEM ASSEMBLY

FIG.NO. 07 NO. OFF

REF NO.

EXHAUST SYSTEM ASSEMBLY

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

0332028

CRR PAN HD SCREW M5 x 8

2

2

0330308

WAVE SPRING WASHER M5

2

3

3

3

3

3

420010700

PUNCHED WASHER 5.5 x 10

2

3

3

3

3

4

P050640

GUARD EXHAUST

1

5

0334548

HEX NUT M8

2

2

2

2

2

6

0330318

WAVE SPRING WASHER M8

2

2

2

2

2

7

0333558

STUD M8 x 33

2

2

2

2

2

8

405138000

EXHAUST GASKET

1

1

1

1

1

9

420462700

HEX SCREW M6x20

2

10 P050610

PIPE COMP. EXHAUST

1

11 K200200

HEX SCREW M10x20

1

1

1

1

1

12 0330328

WAVE SPRING WASHER M10

1

1

1

1

1

13 420008700

PLAIN WASHER A11

1

1

1

1

1

14 P050090

MUFFLER COMP.

1

15 420305700

HEX NUT M6

2

16 0330408

WAVE SPRING WASHER M6

2

17 P050480

GASKET EXHAUST

1

18 P050270

O - RING

1

19 P050130

PIPE COMP BUFFLE

1

20 0330408

WAVE SPRING WASHER M6

2

1

1

1

1

21 0331688

HEX SCREW M6x8

2

1

1

1

1

22 K200520

CRR PAN HEAD SCREW M5

3

3

3

3

23 P5050290

GUARD EXHAUST CAT

1

1

1

1

CAT:- CATALYTIC

REMARKS

FIG.No.07

EXHAUST SYSTEM ASSEMBLY

FIG.NO. 07

NO. OFF REF NO.

PART NO.

DESCRIPTION

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1

1

CAT (LE VERSION)

24 P5050300

GASKET EXHAUST

24A K5050689

GASKET EXHAUST

1

1

25 P5050090

PIPE COMP. EXHAUST CAT

1

1

25A P5050560

PIPE COMP. EXHAUST CAT

1

1

25B P5050690

PIPE COMP. EXHAUST LE

1

1

1

1

1

1

1

1

1

1

2

2

1

1

26 K5050240 26A P5050680 27 P5050490 27A P5050740

CATALYTIC CONVERTER COMP.

1

1

CATALYTIC CONVERTER COMP. LE MUFFLER COMP CAT

1

1

MUFFLER COMP. LE VERSION

28 P1200130

HEX SCREW M6x25 4.6 ZNG

29 P1320230

MUFFLER ASSY WITH GUARD LE

REMARKS

XL

EXHAUST SYSTEM ASSEMBLY

**- REF. KIT & KIT CONTENTS * - APPLICABLE FOR THE VEHICLES PRODUCED AFTER 01.04.2005

2

2

*

*

** / *

FIG.No.07A

EXHAUST SYSTEM ASSEMBLY

FIG.NO. 07A NO. OFF

REF NO.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

0332028

CRR PAN HD SCREW M5 x 8

3

3

2

0330308

WAVE SPRING WASHER M5

3

3

3

420010700

PUNCHED WASHER 5.5 x 10

3

3

4

P050640

GUARD EXHAUST

1

1

5

405138000

GASKET EXHAUST

1

1

6

420305700

HEX NUT M6

2

2

7

0330408

WAVE SPRING WASHER

4

4

8

P5050709

PIPE COMP EXHAUST

1

1

9

K5050689

GASKET MUFFLER

1

1

10 0333558

STUD M8 x 33

2

2

11 0330318

WAVE SPRING WASHER M8

2

2

12 0334548

HEX NUT M8

2

2

13 P5050740

MUFFLER COMP.

1

1

14

END CAP

1

1

15 420463700

HEX SCREW M6x25

2

2

16 P050270

O RING

1

1

17 P5050540

PIPE COMP BAFFLE

1

1

18 4204528700

HEX SCREW M6x12

2

2

---

EXHAUST SYSTEM ASSEMBLY

CAT:- CATALYTIC

REMARKS

FIG.No.08 1

FAN AND COWL FAN ASSEMBLY

6A 2

3

NO. OFF REF NO.

4 5

FIG.NO. 08

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

4

4

1

0332275

CRR PAN HD SCREW M6x16

2

0335578

SPRING WASHER 6.5x13x1

3

7130140

WASHER

4

P200260

CRR PAN HD SCREW M6x55

4

4

4

4

4

5

0335578

WASHER 6.5 x 13 x 1.0

4

4

4

4

4

6

P180520

COVER CARBURETTOR

1

1

1

1

1

1

1

1

REMARKS

1 4

4

5

6 1

7 6A P1180060

COVER CARBURETTOR

6B J210100

DUMMY ENGINE COVER

7

P1180070

COWL FAN COMP.

*

1 1

1

1

Replaces

P180210 8

420515700

CRR PAN HD. SCREW M4x10

3

3

3

3

3

9

P180200

FAN

1

1

1

1

1

KIT COWL FAN

1

1

1

1

8 9

10 P1320270

FAN AND COWL FAN ASSEMBLY * - FOR DETAILS REFER SIB MOPED /02/06-07 DATED 17.01.2007 ** - REF KIT & KIT CONTENTS

**

FIG.No.09

CLUTCH ASSEMBLY 2

1

NO. OFF REF NO.

3

1

6

FIG.NO. 09

4

7

5

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

REMARKS

1

P070230

THRUST WASHER CLUTCH

2

2

2

2

2

2

P070540

DRUM COMP CLUTCH

1

1

1

1

1

3

P070430

CLUTCH ASSY.

1

1

1

1

1

4

420202000

MULTI TOOTH LOCK WASHER A10.5

1

1

1

1

1

5

P080220

RATCHET NUT KICKSTARTER

1

1

1

1

1

6

P200230

CIRCLIP 7.0

2

2

2

2

2

7

--

CLUTCH SHOE

2

2

2

2

2

Ref No. 03

8

--

DAMPER CLUTCH SHOE

2

2

2

2

2

"

9

--

SHOE CARRIER COMP.

1

1

1

1

1

"

10 P070320

SPRING CLUTCH

2

2

2

2

2

"

11 P1320020

DAMBER KIT (CLUTCH)

1

1

1

1

1

**

12 P070640

BUSH CLUTCH SHOE

2

2

2

2

2

13 P1320270

KIT CLUTCH BUSH

1

1

1

1

1

12 8 10

6 9

11

12

CLUTCH ASSEMBLY ** - REF. KIT & KIT CONTENTS

**

FIG.No.10

GEAR ASSY. PRIMARY DRIVEN

FIG.NO.10

NO. OFF REF NO.

2

1 3

4

5

6

7 8

PART NO.

15

11,11A 12A 12

13

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

BALL BEARING 12x32x10 (6201)

1

1

1

1

1

2

P080980

GEAR ASSY. PRIMARY DRIVEN

1

1

1

1

1

3

0330164

CIRCLIP 17x1.0

1

1

1

1

1

4

0335054

SHIM 17 x 29 x 1.5

1

1

1

1

1

5

---

GEAR PRIMARY DRIVEN

1

1

1

1

1

6

P080970

SHAFT GEAR PRIMARY DRIVEN

1

1

1

1

1

7

0339480

BEARING

1

1

1

1

1

8

F200230

OIL SEAL 24 x 35 x 6

1

1

1

1

1

9

0248010

O' RING ENGINE SPROCKET

1

1

1

1

1

10 P080950

SPACER ENGINE SPROCKET

1

1

1

1

1

11 F084398

SPROCKET ENGINE - 13T

1

1

1 1

1

1

1

1

1

1

1

1

1

12A P081030

14

XLSUPER

420602000

12 P080180

10

XL

1

11A P081100

9

DESCRIPTION

SPROCKET ENGINE NEW - 13T LOCK WASHER SPROCKET

1

1

REMARKS

REF.Sl No.02

1

LOCK WASHER SPROCKET NEW

13 0334256

NUT ENGINE SPROCKET

1

1

1

14 408019000

CHAIN ASSY. 112 LINKS

1

1

1

14A P081120

CHAIN ASSY. 112 LINKS

1

1

1

14B P1080010

CHAIN ASSY. NEW 110 LINKS

15 P321420

CONNECTING LINK SET CHAIN

1

1

1

16 P321390

CHAIN SPROCKET KIT

1

1

1

**

16A P320720

CHAIN SPROCKET KIT- (112 LINKS)

1

1

1

** (QD)

16B P1320250

CHAIN SPROCKET KIT (110 LINKS)

** - REF. KIT & KIT CONTENTS

1

1

** (NEW)

FIG.No.11 1

KICKSTARTER ASSEMBLY

FIG.NO.11 NO. OFF

2 REF NO.

3

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

M1200810

CRR PAN HEAD SCREW M6x10

1

1

1

1

1

2

0335876

SPECIAL WASHER

1

1

1

1

1

3

K080530

SPRING GEAR K.S DRIVEN

1

1

1

1

1

1

1

9 7

6

3A P081260

5

4

8

4,4A

P080940

4A P081340

10 11 17 12

16 18

13

14

16

15,15A

22

19

27

GEAR KICKSTARTER DRIVEN

1

1

1

GEAR KICKSTARTER DRIVEN NEW

1

1

1

1

1

5

P080920

BUSH KS DRIVEN

1

1

1

1

1

6

K080320

SHIM 8x16x0.5

2

2

2

2

2

7

P080460

GEAR COMP. KICKSTARTER DRIVE

1

1

1

1

1

8

P080140

SPRING KICKSTARTER

1

1

1

1

1

9

0258040

RUBBER KICKSTARTER PEDAL

1

1

1

1

1

10 0330208

CIRCLIP 8.0

1

1

1

1

1

11 F084100

WASHER LEVER KICKSTARTER

1

1

1

1

1

12 0339204

BALL KICKSTARTER LEVER

1

1

1

1

1

13 3030515

SPRING KICKSTARTER LEVER

1

1

1

1

1

14 F084088

PEDAL COMP. LEVER

1

1

1

1

1

15 P080680

LEVER ASSY. KICKSTARTER

1

1

1

LEVER ASSY. KICKSTARTER NEW

1

1

1

1

1

16 P080610

SHIM 11.2x18.5x0.5

2

2

2

2

2

17 P200150

CIRCLIP 11x 1.0

1

1

1

1

1

18 P080490

GEAR KICKSTARTER IDLER

1

1

1

18A P081290

GEAR KICKSTARTER IDLER

1

1

1

1

1

15A J080190

20

SPRING GEAR K.S DRIVEN NEW

21 26

24 23

25

KICKSTARTER ASSEMBLY

REMARKS

FIG.No.11 1

KICKSTARTER ASSEMBLY 2

FIG.NO.11 NO. OFF

3

REF NO.

9 7

6

5

8

4,4A 10 11

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

19 P080410

STOPPER KICKSTARTER

1

1

1

20 P081130

O RING KICKSTARTER

1

1

1

21 408003000

SHIM

1

1

1

1

1

22 P200030

CIRCLIP 16x1

1

1

1

1

1

23 420701700

COTTER PIN

1

1

1

1

1

24 420002700

PUNCHED WASHER

1

1

1

1

1

25 420051000

SPRING WASHER

1

1

1

1

1

26 420307700

HEX NUT M7 x 1

1

1

1

1

1

27 J080180

LEVER KICKSTARTER

1

1

1

1

1

28 P1320040

KICK STARTER KIT

1

1

1

REMARKS

17 12

16 18

13

14

16

15,15A

28A P1320430 29 P321430

22

19

20

KICK STARTER KIT NEW GEAR COMP. KICK START KIT

27

21 26

24 23

25

KICKSTARTER ASSEMBLY ** - REF. KIT & KIT CONTENTS

1

1

1

** 1

1

**

1

1

**

MAGNETO ASSY. & CDI UNIT

FIG.No.12

FIG.NO. 12 NO. OFF

REF NO.

MAGNETO ASSY. & CDI UNIT

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

P060090

MAGNETO ASSY 12V

1

1

1

1

1

2

P060120

STATOR ASSY.

1

1

1

1

1

3

406210000

SPECIAL WASHER

2

2

2

2

2

4

420957700

PHILIPS HD SCREW M4x15

2

2

2

2

2

5

K060090

GROMMET MAGNETO

1

1

1

1

1

6

F060190

STATOR PLATE

1

1

1

1

1

7

F060220

LIGHTING COIL

1

1

1

1

1

8

---

SPRING WASHER M4

5

5

5

5

5

9

---

REC PAN HD SCREW M4x25

3

3

3

3

3

10 P060110

ROTOR COMP.

1

1

1

1

1

11

REC PAN HD SCREW M4x15

1

1

1

1

1

12 C063050

PULSER COIL

1

1

1

1

1

13 0258050

SEAL SPARK PLUG

1

1

14 D062020

SOURCE COIL

1

1

1

1

1

15 420008700

PUNCHED WASHER A11

1

1

1

1

1

16 0330328

WAVE SPRING WASHER M10

1

1

1

1

1

17 420308700

HEX NUT M10 x 1.0

1

1

1

1

1

18 420462700

HEX SCREW M6x20

1

1

1

19 0330408

WAVE SPRING WASHER M6

2

2

2

20 420001700

PUNCHED WASHER A6.6

2

2

2

21 K060200

IGNITION COIL ASSY

1

1

1

22 0331838

HEX SCREW M6 x 25

1

1

23 P060140

CDI UNIT

1

1

24 P060150

COMB. IGNITION COIL

1

1

1

1

1

25 F060250

SUPPRESSOR CAP ASSY.

1

1

1

25A C8060020

SUPPRESSOR CAP ASSY.

1

1

---

REMARKS

FIG.No.13

FOOTREST ASSEMBLY

FIG.NO.13 NO. OFF

REF NO. 1

PART NO. P121560

1A 0258300 2

FOOTREST ASSEMBLY

P3120120

DESCRIPTION

RUBBER FOOTREST RH

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1 2

2

1

1

RUBBER FRONT FOOT REST BAR COMP. FOOTREST

2A J121030

BAR COMP. FOOTREST

2B P3120340

BAR COMP. FOOTREST

1

1 1

3

P121550

RUBBER FOOTREST LH

1

1

1

4

P121540

SPACER FOOTREST

2

2

5

P121660

RETAINER FOOTREST RUBBER

2

2

6

420011700

WASHER

2

2

7

0330408

WAVE SPRING WASHER M6

2

2

2

8

420462700

HEX SCREW M6x20

2

2

2

9

0330318

WAVE SPRING WASHER M8

4

4

4

4

4

10 420454700

HEX SCREW M8 x 20

4

4

4

4

4

11 0335516

PUNCHED WASHER 8.5x16.0x1.2

4

4

4

2

REMARKS

FIG.No.14

FRONT SUSPENSION ASSY.

FIG.NO.14 NO. OFF

REF NO. 1

PART NO. A200570

1A 0334218

DOOMED CAP NUT

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

2

2

HEX NUT M8

420106000

UNDULATED WASHER B8

2

2

3

P1000800D

CROWN PLATE TOP BLACK

1

1

4

P100190

BRACKET COMP. UPPER FORK COMPLETE FRONT

4A J100520

FORK COMPLETE FRONT SILVER

4B P1100040

FORK COMPLETE FRONT

5

P100510

FORK TUBE COMP. INNER RH

5A J100130

FORK TUBE COMP. INNER RH

REMARKS

2 2

2

3A J100320

FRONT SUSPENSION ASSY.

DESCRIPTION

2

N.I. 2 1

1 1

1

* 1

1

1

1

*

1

*

1

*

6

0334548

HEX NUT M8

2

2

2

7

0330318

WAVE SPRING WASHER M8

2

2

2

8

P100480

HOSE CLIP

2

2

9

J100200

DUST BELLOWS

2

2

9A J100280

DUST BELLOWS

10 410059000

CAP LOCK NUT

1

1

11 410058700

LOCK NUT STEERING

1

1

1

1

12 410043700

SPECIAL WASHER

1

1

1

1

13 410055700 .

SHIM

1

1

1

1

14 410056700

SHIM

1

1

1

1

15 410013700

CONE TOP PLATED

1

1

1

1

16 420402000

BALLS 5/32" (DIA 3.9)

52

52

52

52

17 410113700

CUP TOP PLATED

1

1

1

1

2

2 2

2 1

' * ' ADD COLOR CODE. XL SUP/HD - 2L-BUS GREEN, OL-GREEN(XL), 0A-M RED, OD-BLACK, 0B-BLUE. XL SUPER UPGD - 0D -HG BLACK,8B -METALLIC BLUE, 7L - MOSS GREEN, SPORT - 2G-W RED, 1D-CH GREY, 6L-LIV GREEN.

FIG.No.14

FRONT SUSPENSION ASSY.

FIG.NO.14 NO. OFF

REF NO.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

18 410114700

CUP BOTTOM PLATED

1

1

1

1

19 410115700

CONE BOTTOM PLATED

1

1

1

1

20 410073000

TOLERANCE RING

1

1

1

1

21 P100130

BUMP STOPPER

2

2

2

2

22 P100140

SPRING ANCHOR

2

2

2

2

23 P100360

SPRING

2

2

2

23A P3100020

SPRING

24 P100490 24A P100610

GUIDE BUSH HALF

REMARKS

2 4

4

GUIDE BUSH HALF LONG

4 4

25 P100500

FORK TUBE COMP. INNER LH

25A J100140

FORK TUBE COMP. INNER LH

1

26 J100170

COVER FRONT FORK

2

27 P320710

GUIDE BUSH KIT

1

1

1

1

**

28 P321300

STEERING CONE KIT

1

1

1

1

**

FRONT SUSPENSION ASSY.

** -REF KIT & KIT CONTENTS

1

1

1

* *

FIG.No.14A

FRONT SUSPENSION ASSY. (HYDRAULIC FORK)

FIG.NO.14A

NO. OFF REF NO. 1

PART NO. J100520

1A P3320040

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

FRONT SUSPENSION ASSY - SIL GR

1

FRONT FORK SUSPENSION - SIL GR

1

1

2

T4100139

LOCK PLATE COMP. UPPER

2

2

2

3

T4100300

GUIDE BUSH

4

4

4

4

P100790

SPRING OIL FORK

2

2

2

5

T4100110

SPRING ANCHOR COMP.

2

2

2

6

T4100280

BUMP STOPPER

2

2

2

7

J100350

FORK TUBE COMP. LOWER RH

7A T4100050

FRONT SUSPENSION ASSY.(HYDRAULIC FORK)

DESCRIPTION

1

FORK TUBE COMP. LOWER RH

1

1

8

A054190

HOSE CLIP 35

2

2

2

9

M100200

BELLOW DUST

2

2

2

10 M100050

HOSE CLIP 48

2

2

2

11 1257281

SNAP RING

2

2

2

12 1257466

WASHER

2

2

2

13 1257290

OIL SEAL

2

2

2

14 7100610

SLIDE METAL

2

2

2

15 0334028

HEX NUT M8

2

2

2

16 T4100510

FORK TUBE COMP. UPPER

2

2

2

17 T4100290

SLIDER

4

4

4

18 410115700

CONE BOTTOM PLATED

1

1

1

19 410073000

TOLLERENCE RING

1

1

1

20 J100410

CROWN PLATE COMP. BOTTOM

20A T4100200

CROWN PLATE COMP. BOTTOM

N.I - NOT ILLUSTRATED

1 1

1

REMARKS

FIG.No.14A

FRONT SUSPENSION ASSY. (HYDRAULIC FORK)

FIG.NO.14A

NO. OFF REF NO.

FRONT SUSPENSION ASSY.(HYDRAULIC FORK)

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

21 T4100600

STRAP CABLE

1

1

1

22 0330318

WAVE SPRING WASHER M8

2

2

2

23 0334548

HEX NUT M8 8

4

4

4

24 420469700

HEX BOLT M8x65

2

2

2

25 J100340

FORK TUBE COMP. LOWER LH

25A T4100080

FORK TUBE COMP. LOWER LH

1

26 410058700

STEERING LOCK NUT

1

1

1

27 410043700

SPECIAL WASHER

1

1

1

28 T41004400D

CROWN PLATE TOP

1

28A P1000800D

CROWN PLATE TOP

1

1

29 410013700

CONE TOP PLATED

1

1

1

30 420402000

BALLS 5/32" (DIA 3.9)

52

52

52

31 K101430

CUP TOP

1

1

1

32 410055700

SHIM 26x32x1

1

1

1

33 410056700

SHIM

1

1

1

34 410114700

CUP BOTTOM PLATED

1

1

1

35 P3100100

BRKT COMP. HEAD LAMP MTG.

1

1

36 T4100550

PACKING

4

4

37 J100530

FORK LEG ASSY. RH - SIL GREY

37A P3320020

FORK LEG ASSY RH - SIL. GREY

38 J100540

FORK LEG ASSY LH - SIL GREY

38A P3320030

FORK LEG ASSY LH - SIL. GREY

1

FRONT SUSPENSION KIT

1

39 P3320060

** -REF KIT & KIT CONTENTS

REMARKS

1 1

1

1 1

N.I 1

1

1

N.I N.I

1

N.I

1

**

REAR SUSPENSION ASSEMBLY

FIG.No.15

FIG.NO.15

NO. OFF REF NO. 1

PART NO. K200500

HEX BOLT M10x45

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

4

2

NUT REAR SHOCK ABSORBER

3

1B P1200240

HEX NUT M10

1

409045000

2A 0334038 3

209261000

PUNCHED WASHER

12

4

PUNCHED WASHER 10.5x24 SHOCK ABSORBER

3A P3090010

SHOCK ABSORBER

3B T090030

SHOCK ABSORBER

3C P1090080

SHOCK ABSORBER

4

4

8 2 2

2 2 2

4

P3090240

PLATE COMP. FOOT REST RH

1

1

1

1

5

P3090210

PLATE COMP. FOOTREST LH

1

1

1

1

6

0330038

SPLIT PIN 2.0x18

4

7

0250028

BAR COMP. PILLION FOOTREST

2

8

0254028

PIN PILLION FOOTREST

2

9

0258100

RUBBER PILLION FOOTREST

2

10 0335728

PUNCHED WASHER 20x32x2

2

11 420476700

HEX SCREW M6x30

11A 0331248

2

HEX SCREW M6x33

2

2 2

N.I

12 420305700

HEX NUT M5

2

2

13 P090470

PAD CHAIN PROTECTION

1

1

1

1

1

14 K200230

HEX NUT M10x1.5

1

1

1

1

1

15 420053000

SPRING WASHER

1

1

1

1

1

16 P1320210

SWING ARM KIT

1

1

1

1

16A J090450

SWING ARM COMP.

** - REF KIT & KIT CONTENTS

REMARKS

2

1A 0334047

2

REAR SUSPENSION ASSY.

DESCRIPTION

1

N.I - NOT ILLUSTRATED

**

FIG.No.15

REAR SUSPENSION ASSEMBLY

FIG.NO.15

NO. OFF REF NO.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

17 P200450

HEX BOLT M10x160

1

1

1

1

1

18 F113620

BOLT CABLE ABUTMENT

1

1

1

1

1

19 0330318

WAVE SPRING WASHER

1

1

1

1

20 0334218

HEX NUT M8

1

2

1

1

21 P3090250

TORQUE LINK COMPLETE REAR

1

1

1

1

1

1

1

21A P3090290

1

1

TORQUE LINK COMP. REAR NEW

22 0336018

WASHER TORQUE LINK

1

1

1

23 3207018

SPRING (TORQUE)

1

1

1

24 J110270

ABUTMENT REAR BRAKE CABLE

1

1

1

REAR SUSPENSION ASSY.

SL. NO. 18 - 23 APPLICABLE FOR QD WHEEL XL SUPER

REMARKS

N.I - NOT ILLUSTRATED

N.I

FIG.No.16

FRONT WHEEL ASSEMBLY

FIG.NO.16 NO. OFF

1 2 4 19

5

3

6

REF NO.

PART NO.

1

411199000

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

TYRE FRONT 2.5x16

1

1

1

1

1

2

411341000

TUBE - BUTYL

1

1

1

1

1

3

411173000

RIM NUT

1

1

1

1

1

4

411016000

RIM TAPE

1

1

1

1

1

5

111048700

WHEEL RIM 1.5 - 16

1

1

1

1

1

6

411004000

SPOKE dia 2.98x159 LONG INNER

18

18

18

18

18

7

411209000

SPOKE dia 2.98 - 159 LONG OUTER

18

18

18

18

18

8

420313700

HEX NUT M12x1

1

1

1

1

1

9

0335538

PUNCHED WASHER A12.5x22x2.3

1

1

1

1

1

10 311325000

HUB DRIVE

1

1

1

1

1

11 420661000

SEALING RING

2

2

2

2

2

12 420602000

BALL BEARING 12x32x10

2

2

2

2

2

13 411257700

SPACER BUSH ASSY. FRONT

1

1

1

1

1

14 211204800

WHEEL HUB FRONT

1

1

1

1

1

15 A326340

BRAKE SHOE SET STD

1

1

1

1

1

15A A326330

BRAKE SHOE SET O/S

1

1

1

1

1

16 411187000

SPRING BRAKE SHOE

2

2

2

2

2

17 G11015

BRAKE PLATE ASSY. FRONT

1

1

17A P110410

BRAKE PLATE ASSY. FRONT

1

17B T4110030

BACKPLATE ASSY. FRONT NEW

1

1

1

REMARKS

7

8 9 10

12

11

11 12

13

17 15 14

16

18 11 8

17A

FRONT WHEEL ASSEMBLY

18 P110060

AXLE FRONT

1

1

1

1

1

19 411005000

NIPPLE SPOKE

36

36

36

36

36

20 A326070

SPOKE & NIPPLE ASSY INNER (SET)

1

1

1

1

1

**

21 A326080

SPOKE & NIPPLE ASSY OUTER (SET)

1

1

1

1

1

**

** - REF KIT & KIT CONTENTS

FIG.No.17

REAR WHEEL ASSEMBLY - OLD

FIG.NO. 17

NO. OFF REF NO.

REAR WHEEL ASSY. - OLD

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

420313700

HEX NUT M12X1

2

2

411190700

CHAIN TENSIONER CAM

2

3

413050000

NYLON LOCK NUT M8

1

4

D113518

PUNCHED WASHER 8.2x18

1

5

P110470

LEVER COMP REAR BRAKE

1

6

0178030

O - RING

1

7

P110350

BACK PLATE REAR

1

8

0234038

BRAKE CAM REAR

1

9

3171090

BRAKE SHOE SET 110 DIA

1

10 3230515

SPRING BRAKE SHOE

2

11 P110300

SHIELD WHEEL HUB REAR

1

12 420661000

SEALING RING WHEEL HUB

2

13 420602000

WHEEL BEARING 6201

2

14 J110010

HUB COMPLETE REAR WHEEL

1

15 J110110

CUSH DRIVE ELEMENT

1

16 P110680

THRUST PAD

1

17 J110030

DRUM SPROCKET

1

18 P081060

CHAIN WHEEL 50T

1

19 411295700

BUSH SPKT. CARRIER

4

20 J110060

LOCKING PLATE

1

21 0330408

WAVE SPRING WASHER M6

8

22 420476700

HEX SCREW M6x30

4

23 420462700

HEX SCREW M6x20

4

24 P110040

SPACER BUSH BEARING

1

25 411124700

END CAP

1

26 P110050

AXLE REAR

1

27 411161700

SPACER BUSH REAR

1

28 P110750

CUP CHAIN GUARD

1

REMARKS

REAR WHEEL ASSEMBLY - QD

FIG.No.17A 11

6 1

2

3

4

NO. OFF

10

9

5

FIG.NO.17A

8

13

REF NO.

14 15

7 19

12

21 16

22

23

17

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

0330048

SPLIT PIN 2x20

1

1

1

1

1

2

K200570

SLOTTED NUT M10x1.25

1

1

1

1

1

3

0335628

PUNCHED WASHER 10.5x24x2.3

1

1

1

1

1

4

0202118

ADJUSTER COMPLETE CHAIN RH

1

1

1

ADJUSTER ASSY CHAIN RH NEW

1

1

1

1

4A P1090210 5

P1200060

HEX NUT M6 ZNG

1

1

1

1

1

6

0331308

BOLT CHAIN ADJUSTER

2

2

2

2

2

7

0185028

SPACER REAR AXLE RH

1

1

1 1

1

18 24 20

7A P1110290

27

28 29

30

26

31

25 32

33

34 35 38

39

5

36

6

37

40 41

REAR WHEEL ASSY - QD

SPACER REAR AXLE RH

8

420305700

HEX NUT M6x1

1

1

1

1

1

9

0335578

PUNCHED WASHER

1

1

1

1

1

10 0182018

LEVER REAR BRAKE CAM

1

1

1

10A N3110420

LEVER REAR BRAKE CAM

1

1

11 0331248

HEX BOLT M6x33

1

1

1

1

1

12 3171043

COMP. RR BRAKE

1

1

1

1

1

13 0335698

WASHER

1

1

1

1

1

14 0178030

O - RING BRAKE CAM

1

1

1

1

1

15 0234038

CAM BRAKE

1

1

1

1

1

16 0339480

BEARING 20x42x12

1

1

1

1

1

17 3171090

BRAKE SHOE SET 110DIA

1

1

1

1

1

18 3230515

SPRING BRAKE SHOE

2

2

2

2

2

19 411018000

TYRE 2.50 - 16

1

1

1

1

1

20 411341000

TUBE - BUTYL

1

1

1

1

1

21 411016000

RIM TAPE

1

1

1

1

1

22 111255700

WHEEL RIM 1.5 x 16

1

1

1

WHEEL RIM 1.5 x 16 NEW

1

1

1

1

1

22A P3110080

** - REF KIT & KIT CONTENTS

REMARKS

**

REAR WHEEL ASSEMBLY - QD

FIG.No.17A 11

6 1

2

3

4

NO. OFF

10

9

5

FIG.NO.17A

8

13

REF NO.

14

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

NIPPLE DIA2.98

36

36

36

NIPPLE DIA3.5 NEW

36

36

36

36

36

SPOKE REAR WHEEL INNER

18

18

18

SPOKE REAR WHEEL INNER NEW

18

18

18

18

18

REMARKS

15

23 411005000

7

23A N3110200

19

24 F113178 24A P3110050

12

21 16

22

23

17 18 24 20

27

28 29

30

26

31

25 32

33

34 35 38

39

5

36

6

37

SPOKE REAR WHEEL OUTER

18

18

18

25A P3110060

25 F113188

SPOKE REAR WHEEL OUTER NEW

18

18

18

18

18

26 0181013

HUB COMPLETE REAR WHEEL M/C

1

1

1

1

1

27 P110650

SHOCK ABSORBER RR WHEEL HUB

1

1

1

1

1

28 0185018

SPACER REAR HUB BEARING

1

1

1

1

1

29 0339100

BEARING 12x32x10

1

1

1

1

1

30 0331318

BOLT REAR SPROCKET

4

4

4

4

4

31 3181043

DRUM REAR SPROCKET

1

1

1

1

1

32 3184038

SHAFT RR SPROCKET MTG DRUM

1

1

1

1

1

33 P081060

CHAIN WHEEL 50T

1

1

1

1

1

34 N3110470

WASHER REAR SPROCKET

2

2

2

2

2

35 0334548

HEX NUT M8x1.25

4

4

4

4

4

36 0339110

BEARING 12x37x12

1

1

1

1

1

37 0259520

OIL SEAL REAR SPROCKET DRUM

1

1

1

1

1

38 P1110300

SPACER REAR AXLE LH

1

1

1

1

1

39 3202318

ADJUSTER COMP. CHAIN LH

1

1

1

ADJUSTER ASSY. CHAIN LH NEW

1

1

40 J200030

HEX NUT M18

1

1

1

41 3184058

AXLE COMP. REAR

1

1

1

39A P1090200 40 41

REAR WHEEL ASSY - QD

41A P3110230

AXLE 12 x 244

** 1

1

1

1

1

1

42 P321250

HUB REAR WHEEL KIT

1

1

1

1

1

**

43 P3320070

SPOKE & NIPPLE KIT INNER

1

1

1

1

1

**

44 P3320080

SPOKE & NIPPLE KIT OUTER

1

1

1

1

1

**

**- REF KIT & KIT CONTENTS

FRAME & STAND ASSEMBLY

FIG.NO.18 NO. OFF

REF NO. 1

PART NO. P3120390

1A J120010

FRAME ASSY.

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1

1

FRAME ASSY.

1

2

409003000

SILENT BLOCK

2

2

2

2

2

3

8200120

RECESSED PAN HD. SCREW

2

2

2

2

2

4

0330308

WAVE SPRING WASHER

2

2

2

2

2

5

D128330

LOCK ASSY. STEERING

1

1

1

1

1

6

P3320019

BLANK KEY

1

1

1

1

1

7

P120380

STAND COMP.

1

1

1

7A P3120220

STAND COMP.

1

7B J120680

STAND COMP.

1

1

1 1

8

409115000

STAND SPRING

1

1

9

420015700

PUNCHED WASHER 12.5x20x1.2

2

2

2

2

10 F123718

PIVOT PIN - STAND

1

1

1

1

11 412069000

TANK REST CUSHION

1

1 1

1

1

1

1

1

11A F126650

FRAME & STAND ASSEMBLY

DESCRIPTION

CUSHION STAND

1

1

12 0330028

SPLIT PIN

1

1

13 P090370

SPACER SILENT BLOCK

1

1

14 420462700

HEX SCREW M6x20

2

2

2

2

15 420011700

WASHER A6.4

2

2

2

2

16 P3120160

BRKT COMP. TURN SIGNAL LAMP

1

1

1

1

17 0330408

WAVE SPRING WASHER

2

2

2

2

18 P1200060

HEX NUT M6

2

2

2

2

19 420001700

PUNCHED WASHER A6.6

2

2

2

2

20 420464700

HEX SCREW M6x16

2

2

2

2

1

REMARKS

P1320200

FRAME & STAND ASSEMBLY

FIG.NO.18 NO. OFF

REF NO.

PART NO.

21 P121630 21A D127420

FRAME & STAND ASSEMBLY

DESCRIPTION

LICENCE PLATE COMPLETE

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1

1

LICENCE PLATE REAR

1

22 420001700

PUNCHED WASHER A6.6

2

23 0332275

CRR PAN HD SCREW M6x16

2

24 J120960

CUP SPRING

1

25 3207018

SPRING

1

26 J130130

PLATE SEAT SPRING

1

27 0331298

BOLT CENTER STAND M10

1

28 0204048

SPACER CENTER STAND

1

29 0330328

WAVE SPRING WASHER

1

30 0334038

HEX NUT M10

1

31 J140100

CUSHION FUEL TANK COMP.

2

32 0331708

CRR PAN HD SCREW

2

33 0330308

WAVE SPRING WASHER M5

2

34 K130160

GUIDE SEAT LATCH

1

35 K130110

ASSY. SEAT LOCK

1

36 P3120180

COVER COMP. FRAME

37 P3300500

PLOTFORM KIT

38 420462700

1

2 1

# 1

1

HEX SCREW M6x20

4

4

39 P1200120

PUNCHED WASHER A6.6

4

4

40 P1200500

WAVE SPRING WASHER M6

4

4

41 P300050

MUD-FLAP FRONT

1

1

# - OPTIONAL

1

REMARKS

FIG.No.19

SEAT ASSEMBLY

FIG.NO.19 NO. OFF

REF NO. 1

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

P130050

SEAT ASSY.

1A J130060

SEAT ASSY.

1B P3130130

SEAT COMP. FRONT

1

1

1C P3130020

SEAT COMP. REAR

1

1

2

1 1

REXIN ASSY.

2A J130079

REXIN ASSY.

2B P3130099

REXIN ASSY FRONT

1

1

2C P3130129

SEAT REXINE REAR

1

1

3A

P130069

SEAT FOAM

--

SEAT FOAM

1

1 1

1

1

N.S

1

3B P3130040

SEAT FOAM FRONT

1

1

3C P3130150

SEAT FOAM REAR

1

1

4

P130200

REINFORCEMENT COMP. REAR

1

1

5

P130190

REINFORCEMENT COMP. REAR

1

1

6

P130160

REINFORCEMENT COMP. FRONT

1

1

7

P130029

BASE SEAT

1

1

7A J130010

BASE SEAT

7B P3130010

SEAT BASE FRONT

1

1

7C P3130030

SEAT BASE REAR

1

1

1

8

0335578

WASHER 6.5x13x10

6

9

409047000

NYLON LOCK NUT

2

2

10 P120560

HANDLE COMP. PILLION

1

1

10A J120440

HANDLE COMP PILLION

10B P1120080

HANDLE COMP. PILLION NEW

11 420464700

HEX SCREW M6x16

N.S - NOT SERVICED

REMARKS

1

P130079

3

SEAT ASSYEMBLY

PART NO.

10

3

6

10

1 1 2

6

2

2

6

FIG.No.19

SEAT ASSEMBLY

FIG.NO.19 NO. OFF

REF NO.

SEAT ASSYEMBLY

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

12 0330408

WAVE SPRING WASHER M6

2

10

2

2

10

13 420305700

HEX NUT M6

2

10

8

2

10

14 K130150

BOLT PLATE COMP.

1

15 420302700

HEX NUT M5

1

16 420010700

PUNCHED WASHER

1

17 K130100

BOLT PLATE COMP. (REAR)

18 J130150

STOPPER COMP. SEAT

19 K130130

LATCH FOR SEAT LOCK

20 S1130160

CUSHION SEAT

1

21 K130220

CLEVIS PIN SEAT

1

22 J130120

BRKT. SEAT HINGE

1

23 0138010

CUSHION

3

3

24 K130200

LOCATOR SEAT COMP.

1

1

25 0138050

CUSHION, COVER FRAME

1

1

26 0331708

CRR PAN HD SCREW M5x12

2

2

27 0330308

WAVE SPRING WASHER

2

2

28 P3120030

CARRIER COMP.

1

1

29 K130110

ASSY. SEAT LOCK

1

1

30 P3120100

BRKT SEAT MTG. FRONT

1

1

1

1

1

1 1

1

1

REMARKS

FIG.No.20

FUELTANK & TOOL BOX ASSEMBLY

FIG.NO.20

NO. OFF REF NO.

PART NO.

1

---

TANK COMP. FUEL

1A

---

TANK COMP. FUEL

2

P140230

COVER FUEL TANK

1

1

3

--

SEALING RING

1

1

TANK CAP ASSY.

1

1

4

414004000

4A T140160

SUPER

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1

1

TANK CAP ASSY.

1

N.S

1

1

1

PUNCHED WASHER A6.6

4

4

4

4

4

6

0330408

WAVE SPRING WASHER

4

4

4

4

4

7

0332068

CRR PAN HEAD SCREW M6x12

4

4

4

4

4

8

--

TAP SET XL SUPER/ HD

1

1

8A

--

TAPE SET XL SUPER/ HD

8B

--

TAP SET SPORT

COVER CONTROL CABLE

10 7130140

WASHER

1

1

11 P200310

HEX SCREW M6x12

1

1

12 414074000

SEALING WASHER

1

13 P140080

FUEL COCK ASSY. (OLD)

13A P140320

FUEL COCK ASSY - M14

13B T140250

FUEL COCK ASSY.

14 P140100

KNOB FUEL COCK

14A T140240

KNOB FUEL COCK

15A T200050 16 3020516

CHEESE HD SCREW M3x30

1

1

N.I - NOT ILLUSTRATED

" "

1

1

3

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4

4

1

1 1

1 1

1

1

SLOTTED CHEESE HD SCREW M3x10 CLAMP FUEL LINE

1

1

9A J210010

15 P200390

Ref P. No. COLOUR MAT.

1

COVER CONTROL CABLE

Ref. P. No. COLOUR MAT.

1

420001700

P210040

REMARKS

"

1

5

9

FUELTANK & TOOL BOX ASSY.

DESCRIPTION

1 4

4

4

N.S - NOT SERVICE

N.I

FIG.No.20

FUELTANK & TOOL BOX ASSEMBLY

FIG.NO. 20

NO. OFF REF NO.

PART NO.

17 P140390 17A J140120

DESCRIPTION

HOSE FUEL UPPER 335L

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

1

1

HOSE FUEL 310L

1

18 D143100

FILTER, FUEL

1

1

1

1

1

19 P140260

HOSE FUEL 40L

1

1

1

1

1

20

TOOL BOX COMPLETE

1

1

1

1

---

REMARKS

Ref P.No. COLOUR MAT.

SUPER

21 P120310

COVER TOOL BOX REAR

1

1

1

1

22 420464700

HEX SCREW M6x16

4

4

4

4

23 420305700

HEX NUT M6

4

4

4

4

24 P120320

LID TOOL BOX

1

1

1

1

25 D046200

LOCK ASSY. TOOL BOX

1

1

1

1

26 P210500

CUSHION

2

2

2

2

FUELTANK & TOOL BOX ASSY. * ADD COLOR CODE. XL SUP/HD - 2L-BUS GREEN, OL-GREEN(XL), 0A-M RED, OD-BLACK, 0B-BLUE. XL SUPER UPGD - 0D -HG BLACK,8B -METALLIC BLUE, 7L - MOSS GREEN

SPORT - 2G-W RED, 1D-CH GREY, 6L-LIV GREEN.

MUDGUARD, COVER FRAME & CHAIN GUARD

FIG.NO. 21

NO. OFF REF NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

420464700

HEX SCREW M6x16

14

14

14

14

2

P100310

BRACKET STABILISER

1

1

1

1

3

---

STABILISER TUBE

1

1

1

1

1

1

4

410019000

STABILISER PAD

1

1

5

420452700

HEX SCREW M6x12

8

8

8

8

8

6

0330408

WAVE SPRING WASHER

24

24

24

24

24

7

420305700

HEX NUT M6

14

14

14

14

14

8

420010700

PUNCHED WASHER A6.6

14

14

14

14

14

FENDER FRONT

1

1

1

1

10 P100570

CABLE GUIDE SPEEDO

2

2

2

2

11 F300060

MUD FLAP

1

1

1

1

12

STAY MUDGUARD

1

1

1

1

13 P121060

PAD FENDER REAR

1

1

1

1

14

FENDER REAR

1

1

1

1

15 412092000

PAD MUDGUARD

1

1

1

1

16 P300010

MUD FLAP REAR

1

1

1

1

17 0332275

CRR PAN HD. SCREW M6x16

2

2

2

2

18 A128730

FLOOR MAT BUTTON

6

6

6

6

19 P1120060

MAT FLOOR PLASTIC

1

1

1

1

20 420011700

WASHER

4

4

21

--

COVER FRAME RH

1

1

21A

--

COVER FRAME RH NEW

22

--

COVER FRAME LH

22A

--

COVER FRAME LH NEW

9

MUDGUARD, COVER FRAME & CHAIN GUARD

PART NO.

---

---

---

23 P090120 23A P3090270

CHAIN COVER CHAIN COVER NEW

1

1

8

REMARKS

Ref P.No. COLOUR MAT.

Ref P.No. COLOUR MAT.

Ref P.No. COLOUR MAT.

Ref P.No. COLOUR MAT.

Ref P.No. COLOUR MAT.

1

1

1

1

1

1

"

1

1

* ADD COLOR CODE. XL SUP/HD - 2L-BUS GREEN, OL-GREEN(XL), 0A-M RED, OD-BLACK, 0B-BLUE. XL SUPER UPGD - 0D -HG BLACK,8B -METALLIC BLUE, 7L - MOSS GREEN 'SPORT -2G-W RED, 1D-CH GREY, 6L-LIV GREEN.

MUDGUARD, COVER FRAME & CHAIN GUARD

FIG.NO.21

NO. OFF REF NO.

MUDGUARD, COVER FRAME & CHAIN GUARD

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

4

4

4

4

REMARKS

24 7130140

WASHER

25 0332275

CRR PAN HEAD SCREW M6x16

8

26 7130140

WASHER

8

27

COVER FRAME COMP. RH

1

28 T120550

COVER FRONT

1

29 T120660

COVER

1

Ref P.No. COLOUR MAT.

30

COVER FRAME COMP. LH

1

"

31 J140060

COVER FUEL TANK

1

32 420464700

HEX SCREW

4

33 J210460

COVER FRAME COMP. RH

1

34 T100290

FENDER ASSY. FRONT

1

35 J100150

CABLE GUIDE SPEEDO

2

36 0332275

CRR PAN HD SCREW M6x16

3

37 8200140

WAVE SPRING WASHER

4

38 P200270

CRR PAN HD SCREW M6x12

6

39 J100260

MUD - FLAP, FRONT

1

40 J100290

BRACE FENDER COMP.

1

41

COVER SIDE LH

1

42 J120380

FENDER REAR

1

43 J120850

BRACKET TURN SIGNAL LAMP

1

44 J120410

MUDGUARD

1

45 8160020

REFLEX REFLECTOR

1

46 T300010

MUDFLAP REAR

1

47 J090140

CHAIN CASE COMP UPPER

1

48 J090170

CHAIN CASE COMP LOWER

1

49 J090260

DUMMY CHAIN COVER

1

---

---

--

Ref P.No. COLOUR MAT.

*

Ref P.No. COLOUR MAT.

* ADD COLOR CODE. XL SUP/HD - 2L-BUS GREEN, OL-GREEN(XL), 0A-M RED, OD-BLACK, 0B-BLUE. XL SUPER UPGD - 0D -HG BLACK,8B -METALLIC BLUE, 7L - MOSS GREEN 'SPORT -2G-W RED, 1D-CH GREY, 6L-LIV GREEN.

HANDLE BAR, SPEEDOMETER ASSY.

FIG.NO.22

NO. OFF REF NO. 1

PART NO. P150380

1A P1150030 2

5227360

2A 419113000 3

P150110

3A P1150050 4

P150120

4A B1150099 5

HANDLE BAR, SPEEDOMETER ASSY.

F160610

DESCRIPTION

SPEEDOMETER ASSY.

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1 1

1

2

2

1

1

1

1

SPEEDOMETER ASSY. SPEEDOMETER BULB 12V, 3.4W

1

1

HOLDER SPEEDOMETER BULB

1

1

HOUSING INSTRUMENT

1

1

HOUSING INSTRUMENT NEW COVER INSTRUMENT

1

1

COVER INSTRUMENT ASSY. SWITCH IGNITION

5A P3160060

ASSY. SWITCH IGNITION

5B P1160130

ASSY. SWITCH IGNITION (2 WAY )

1 1

1 1

1

6

420010700

PUNCHED WASHER A5.5

2

2

2

2

7

0330308

WAVE SPRING WASHER A5

2

2

2

2

8

420465700

SLOTTED CS HD SCREW M5x16

2

2

2

2

9

P150150

HANDLE BAR

1

1 1

1

9A P1150090

HANDLE BAR NEW

9B J150260

HANDLE BAR COMP.

10 P150250

CLAMP BOLT

2

2

2

2

11 415005700



2

2

2

2

12 P150310

BRKT SPEEDO MOUNTING

1

1

12A P1150010

BRKT SPEEDO MTG.

1

1

1

13 P150260

DAMPER RUBBER UPPER

4

4

4

4

14 P150280

SPACER BUSH

4

4

4

4

15 P150270

DAMPER RUBBER LOWER

4

4

4

4

16 P150290

WASHER

4

4

4

4

17 0330408

WAVE SPRING WASHER

4

4

4

4

REMARKS

HANDLE BAR, SPEEDOMETER ASSY.

FIG.NO. 22

NO. OFF REF NO.

HANDLE BAR, SPEEDOMETER ASSY.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

18 420305700

HEX NUT M6

4

4

4

4

19 P170050

CABLE ASSY. THROTTLE

1

1

1

1

19A J170010

CABLE ASSY. THROTTLE

1

1

1

1

1

1

1

1

20 P170090

INNER FRONT BRAKE CABLE

20A J170040

INNER BRAKE FRONT CABLE

21 P170070

CABLE ASSY. BRAKE FRONT

21A J170030

CABLE ASSY. BRAKE FRONT

21B P170120

CABLE ASSY. BRAKE FRONT

1 1

1 1

1

1 1

22 432009000

NIPPLE BRAKE ASSY.

1

1

23 P170020

CABLE ASSY. BRAKE REAR

1

1

23A J170130

CABLE ASSY. BRAKE REAR

1

1

24 N3110360

BRAKE RELEASE SPRING

1

1

1

1

1

25 S1111940

PIN REAR BRAKE ROD LEVER

1

1

1

1

1

26 0334268

NUT REAR BRAKE ROD ADJUSTER

1

1

1

1

1

27 P170060

CABLE ASSY. CHOKE

1

1

1

1

27A J170020

CABLE ASSY. CHOKE

27B P1170040

CABLE ASSY. CHOKE

1

1

1

1

1

1

2

2

28 P320590

INNER SPEEDO CABLE

28A J320010

INNER SPEEDO CABLE

29 P170080

CABLE ASSY. SPEEDO

29A J170120

CABLE ASSY. SPEEDO

1

1

1 1

1

1 1

30 419136000

CLIP CABLE

2

2

31 J150180

SPEEDOMETER ASSY.

1

32 J200080

PUNCHED WASHER 12.5x36.8x2

2

33 J150280

CUSHION UPPER

2

REMARKS

HANDLE BAR, SPEEDOMETER ASSY.

FIG.NO. 22

NO. OFF REF NO.

HANDLE BAR, SPEEDOMETER ASSY.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

34 J100320

BRKT UPPER COMP.

2

35 J150290

CUSHION BOTTOM

2

36 J200070

PUNCHED WASHER 10.3x36.8x2

2

37 K200570

HEX FLANGE U NUT M10x1.25

2

38 P1160100

INDICATOR ASSY. TS LAMP

1

1

39 P1160090

INDICATOR ASSY. HI BEAM

1

1

40 P1320060

HANDLE BAR DAMPER KIT

1

1

1

1

REMARKS

FIG.No.23

CONTROL LEVER ASSEMBLY LH

FIG.NO. 23

NO. OFF REF NO. 1

PART NO. P150100

DESCRIPTION

LEVER ASSY. CONTROL LH

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

REMARKS

1

1A P3150010

LEVER ASSY. CONTROL LH

1

1B P1150060

LEVER ASSY. CONTROL LH

1

1

1C P1150100

LEVER ASSY. CONTROL LH NEW

1

1

1

1

1

1

1

1

1

1

HO RN

2

P150400

2A P1150130 3

P150410

3A P1150160 HO

4

RN

P150450

4A P1150070

HO RN

1

1

CASE UPPER LH CASE UNDER LH

1

1

CASE UNDER LH BRAKE LEVER LH - NEW

1

1

BRAKE LEVER LH

5

3160268

LEVER SET SCREW

1

1

1

1

6

3160278

U NUT

1

1

1

1

7

3168610

BODY CHOCK LEVER

1

1

1

1

8

3160424

ADJUSTER WASHER

1

1

1

1

9

3168600

LEVER STARTER

1

1 1

1

1

1

1

1

1

1

1

1

1

1

10 3160725

SET SCREW CHOKE LEVER

11 0332458

SCREW

1

12 P160420

CORD SET

1

12A P1160140

CORD SET

13 P150330

GRIP LH

1

1

14 K321000

SET, BRAKE LIGHT SWITCH FR

1

1

14A P1160150

CONTROL LEVER ASSY. LH

CASE UPPER LH

15 1324570

SWITCH ASSY. FRONT STOP LAMP SWITCH REPAIR KIT LH

N.I - NOT ILLUSTRATED

1

1

N.I N.I

FIG.No.23A

CONTROL LEVER ASSEMBLY RH

FIG.NO. 23A

NO. OFF REF NO. 1

PART NO.

DESCRIPTION

P150020

LEVER ASSY. CONTROL RH

1A P150430

LEVER ASSY. CONTROL RH

1B P1150110

LEVER ASSY. CONTROL RH

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

1

REMARKS

1 1 REPLACES P3150080

2

P150040

CASE UPPER RH

2A 1166050

CASE UPPER RH

2B P1150120

CASE RH UPPER

3

P150050

CASE UNDER CON. LEVER RH

3A 1166060

CASE UNDER CON. LEVER RH

3B P1150170

CASE UNDER RH

1 1 1

1

1 1

4

0254096

PIECE THROTTLE CABLE END

1

1

5

1166010

LEVER BRAKE RH

1

1

5A P1150080

N.I

LEVER BRAKE RH

N.I 1

1

1

1

1

1

6

P150320

GRIP COMP. THROTTLE

1

1

1

1

7

3160268

LEVER SET SCREW

1

1

1

1

8

0332458

SCREW

2

2

2

2

9

3160278

U NUT

1

1

1

1

10 K321000

SET, BRAKE LIGHT SWITCH FRONT

1

1

1

1

10A P1160150

SWITCH ASSY. FRONT STOP LAMP

1

1

11 P3160050

CARD SET SWITCH ASSY. RH

12 1324560

SWITCH REPAIR KIT RH

CONTROL LEVER ASSY. RH N.I - NOT ILLUSTRATED

1 1

1

N.I

CONTROL LEVER ASSY LH, RH (SPORT)

FIG.NO.23B

NO. OFF REF NO.

CONTROL LEVER ASSY LH,RH (SPORT)

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

J150170

CONTROL LEVER ASSY. LH

1

2

P1200130

HEX SCREW M6x25

2

3

0330408

WAVE SPRING WASHER

2

4

3160268

LEVER SET SCREW

2

5

J150240

GRIP LH

1

6

J200080

PUNCHED WASHER

2

7

M1150450

DAMPER HANDLE BAR

2

8

M1201060

CSK HD SCREW M6x63

2

9

J150160

BRKT LEVER LH

1

10 31603424

ADJUSTER WASHER

1

11 3168610

BODY CHOKE LEVER

1

12 3168600

LEVER STARTER

1

13 0335558

PUNCHED WASHER 5.5x12x1

1

14 0330308

WAVE SPRING WASHER

1

15 F200098

CRR PAN HEAD SCREW M5x20

1

16 P150450

BRAKE LEVER LH

1

17 J150130

CONTROL LEVER ASSY. RH

1

18 J150230

GRIP COMP THROTTLE

1

19 0335558

CRR PAN HD SCREW M4x15

1

20 420010700

PUNCHED WASHER 5.5x12x1

2

21 K150420

CASE THROTTLE UPPER

1

22 K150430

CASE THROTTLE UNDER

1

23 A200170

WAVE SPRING WASHER

1

24 420521700

CRR PAN HD SCREW M4x15

1

REMARKS

CONTROL LEVER ASSY LH, RH (SPORT)

FIG.NO.23B

NO. OFF REF NO.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

25 0330308

WAVE SPRING WASHER

1

26 420302700

HEX NUT M5

1

27 K200520

CRR PAN HEAD SCREW M5x10

1

28 1166010

BRAKE LEVER - RH

1

29 J150120

BRKT LEVER - RH

1

30 3160278

U' NUT

2

31 J160320

CORD SET STOP LAMP

2

32 J300070

MIRROR ASSY. SPORT LH/RH

2

CONTROL LEVER ASSY LH,RH (SPORT)

N.I - NOT ILLUSTRATED

REMARKS

N.I

HEAD LAMP & TAIL LAMP ASSY.

FIG.NO.24

NO. OFF REF NO. 1

PART NO. P160440

1A P3160030

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

HEAD LAMP ASSY. 12V

1

HEAD LAMP ASSY. 12V

1

1

1

1

2

P1320650

RIM HEADLAMP

1

1

1

1

3

P1320640

REFLECTOR UNIT

1

1

1

1

4

P160460

BULB HEADLAMP 12V

1

1

1

1

5

P3160020

BULB HOLDER ASSY.

1

1

1

1

RUBBER BUSH ASSY.

2

2

6

---

7

0335516

WASHER

4

4

4

4

8

0330318

WAVE SPRING WASHER

2

2

2

2

9

8200080

BOLT H.L. HOUSING M8x30

2

2

2

2

10 0334548

HEX NUT M8

2

2

2

2

11 0330308

WAVE SPRING WASHER

2

2

2

2

12 420465700

SCH SCREW M5x16

2

2

2

2

13 P160160

HORN ASSY 12V

1

1

1

13A P160500

HORN ASSY. AC

1

14 0332738

SLOTTED CH. SCREW 4BAx9.5

2

2

2

2

15 P160430

HORN MOUNTING BRKT

1

1

1

1

16 A200320

SPRING WASHER

2

2

2

2

17 420320700

HEX NUT 4BA

2

2

2

2

18 0330408

WAVE SPRING WASHER M6

2

2

2

2

19 420452700

HEX SCREW M6x12

2

2

2

2

20 P120060

PLAIN WASHER

1

1

1

1

21 P120070

SCREW M6x16

1

1

1

1

22 1166090

AC REGULATOR 12V

1

1 1

1

22A P160520

HEAD LAMP & TAIL LAMP ASSY.

DESCRIPTION

23 P160390

COMBINED REGULATOR WIRING HARNESS

1 N .I - NOT ILLUSTRATED

REMARKS

REPLACES P1160030

HEAD LAMP & TAIL LAMP ASSY.

FIG.NO. 24

NO. OFF REF NO.

HEAD LAMP & TAIL LAMP ASSY.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

REMARKS

N.I

23A P160480

WIRING HARNESS - HD

23B P1160070

WIRING HARNESS

1

1

"

23C P1160120

WIRING HARNESS

1

1

"

1

1

24 P160350

LAMP ASSY REAR COMP. 12V

24A P1160040

LAMP ASSY. REAR COMP. 12V

1

1

1

25 5227350

BULB 12V 10/5W

1

1

1

1

26 420305700

HEX NUT M6

2

2

2

2

27 420201000

MULTI TOOTH LOCK WASHER M6

2

2

2

2

28 0335578

WASHER 6.5

2

2

2

2

29 1228880

CUSHION RC LAMP

2

2

2

2

30 1222286

SPACER RC LAMP

2

2

2

2

31 416089000

BULLET CONNECTOR

1

1

1

1

32 419019000

CABLE STRAPPING

9

9

9

9

33 419020000

STUD CABLE STRAPPING

9

9

9

9

34 P160470

RELAY ASSY 12V

1

1

35 T1160010

LAMP ASSY. TURN SIGNAL

4

4

35A B1160180

TURN SIGNAL LAMP ASSY. FR. LH

1

1

N.I

35B B1160150

TURN SIGNAL LAMP ASSY. REAR LH

1

1

"

35C B1160190

TURN SIGNAL LAMP ASSY. FR. RH

1

1

"

35D B1160080

TURN SIGNAL LAMP ASSY. REAR RH

1

1

"

36 N3160210

BULB 12V 5W

4

4

4

4

37 0332068

CRR PAN HEAD SCREW M6x12

4

4

4

4

38 0330408

WAVE SPRING WASHER M6

4

4

4

4

N.I - NOT ILLUSTRATED

HEAD LAMP & TAIL LAMP ASSY.

FIG.NO. 24 NO. OFF

REF NO.

HEAD LAMP & TAIL LAMP ASSY.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

39 0335578

WASHER 6.5x13x1

4

4

4

4

40 P320550

LENS R.C. LAMP

1

1

1

1

41 P320580

HEX SCREW M4x25

2

2

2

2

43 P210070

LOCK SET ASSY.

1

43A P3210010

LOCK SET ASSY.

43B P1210630

LOCK SET ASSY.

43C P3210160

LOCK SET ASSY.

43D P3210220

LOCK SET ASSY. (2 STEP INGITION)

43E P3210210

LOCK SET ASSY. (2 STEP INGITION)

REMARKS

N.I 1

" 1

" 1

1

" "

1

"

HEAD LAMP & TAIL LAMP ASSY. (SPORT)

FIG.NO. 24A

NO. OFF REF NO.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

1

J160150

HEAD LAMP ASSY

1

2

J160170

LENS FRONT TURN SIGNAL RH

1

3

F160490

BULB RC LAMP 12V-5W

2

4

J160310

HOLDER SET FRONT

2

5

---

HEAD LAMP HOUSING FRONT

1

REMARKS

Ref P.No. COLOUR MAT.

6

J150160

HEAD LAMP

1

7

S1160200

WASHER

4

8

S1160190

GROMMET HEADLAMP

2

9

420001700

PUNCHED WASHER

2

10 K200810

CRR PAN HD TAPPING SCREW 3x25

2

11 J150050

BRACKET HEADLAMP

1

12 0330308

WAVE SPRING WASHER M5

1

13 0331708

CRR PAN HD SCREW M5x12

1

14 S1160150

BULB 12V

1

15

BULB HOLDER

1

16 K160900

BOOT HEADLAMP

1

17 K160500

SWITCH BEAM CONTROL

1

18 0336088

PUNCHED WASHER 4.3x9x1

4

19 0331728

CRR PAN HD SCREW M5x30

4

20

HEADLAMP HOUSING REAR

1

---

---

Ref P.No. COLOUR MAT.

21

---

COVER HEAD LAMP HOUSING REAR

1

Ref P.No. COLOUR MAT.

HEAD LAMP & TAIL LAMP ASSY (SPORT)

22 P3200010

CRR TRUSS HD SCREW M6x12

2

23 7130140

WASHER

2

24 K160510

SWITCH LIGHTING

1

25 S1160360

SWITCH TRAFICATOR

1

26 J160340

SWITCH HORN

1

27 J160160

LENS FRONT TURN SIGNAL LH

1

HEAD LAMP & TAIL LAMP ASSY. (SPORT)

FIG.NO.24A

NO. OFF REF NO.

HEAD LAMP & TAIL LAMP ASSY (SPORT)

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

28 K200240

CRR PAN HD TAP SCR ST 3.5x13

2

29 419019000

CABLE STRAPING

1

30 419020000

STUD CABLE STRAPPING

1

31 F160430

RELAY TURN SIGNAL

1

32 0332068

CRR PAN HD SCREW M6x12

1

33 420001700

PUNCHED WASHER A6.6

1

34 7130140

WASHER

1

35 0332275

CRR PAN HD SCREW M6x16

1

36 J160180

WIRING HARNESS

1

37 P160160

HORN ASSY. 12V

1

38 420492700

SLOTTED CHEES HD. SCREW 4x9.5

2

39

CRR PAN HD SCREW

2

40 J160020

TAIL LAMP ASSY.

1

41 T1160010

LAMP ASSY TURN SIGNAL

2

42 F160490

BULB 12V

2

43 0334038

HEX NUT M10

2

44 1166090

AC REGULATOR 12V

1

45 420464700

HEX SCREW M6x10

1

46 420001700

PLAIN WASHER A6.6

1

47

TAIL LAMP LENS

1

48 5227350

BULB RC LAMP 12V-10/5W

1

49 420305700

HEX NUT M6-6

2

50 0330408

WAVE SPRING WASHER

2

51 J210110

LOCK SET

1

52 J160250

REFLECTOR TURN SIGNAL LH, RH

2

---

---

N.I - NOT ILLUSTRATED

REMARKS

N.I

TOOL KIT

FIG.NO. 25 NO. OFF

REF NO.

PART NO.

DESCRIPTION

XL

XLSUPER

TVS

XLSUPER

XLSUPER

SUPER

HD

SPORT

UPG.

HD UPG.

TOOL KIT SET

1

1

1

1

1

1

J210130

2

---

TOOL BAG

1

1

1

1

1

3

---

GRIP DRIVER

1

1

1

1

1

4

---

BIT STAR + NORMAL SCREW DRIVER

1

1

1

1

1

5

---

DOUBLE ENDED SPANNER 10x12

1

1

1

1

1

6

---

SPANNER DOUBLE END OPEN JAW

1

1

1

1

1

7

---

SOCKET SPANNER 19x21

1

1

1

1

1

REMARKS

TOOL KIT

DATE : 03.03.2010