Spare Parts Catalogue Classic 500 & 350
Foreword We take pleasure in releasing CLASSIC 500 & 350 Spare Parts Catalogue. The Catalogue has been specially designed for selection of correct part number to maintain the vehicle, for its optimum performance, longer life and for enjoying the best running condition. The Royal Enfield Spares are manufactured under stringent quality control to ensure ultimate riding experience. It is therefore important to use only Royal Enfield Genuine Spares. Due to continuous improvement on performance and efficiency of the vehicle, since this catalogue was printed, it is possible some illustration, designs etc., found within this catalogue may differ from those found on the vehicle. Such modification will be conveyed through our Technical Service Bulletins, you are requested to update with the correct part numbers in this catalogue. SERVICE HEADQUARTERS : ROYAL ENFIELD (A Unit of Eicher Motors Limited) Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. India. Tel : +91-44-4204 3300, Fax : +91-44-4201 1719. Website : www.royalenfield.com E-mail : customerservice@royalenfield.com “ © Copyright 2006 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this Service technical manual shall be copied, distributed or otherwise dealt without the express permission in written from the Eicher Motors Limited, Royal Enfield Unit who remains the sole owner of this manual .”
1
For easy reference and quick identification, the parts are grouped into relevant categories. Details are given in the illustrated Group index. Tips on usage of this catalogue
ILLUSTRATION Helps in identifying the shape of the part in its relative assembly.
03-30 FUEL TANK Group No.
Alpha-Numeric Key No. for assy.
A1 Key Nos. 17, 18, 19
Key No. Which make up the assy.
Numeric Key No.
2
Part Number List
1
2
Key Part Number No. 500EFI 350cc
1.
3
4
Description
Qty.
5 Remarks
KEY NUMBER (KEY NO.) The numeric key number is provided to serve as the identification of the part with its part number. Serviceable assemblies or kits in a particular group are identified by alpha-numeric key numbers. e.g. A1, A2 etc. In such cases, key numbers of individual items or group number which make up such assembly / kit are given in illustration. 3
Part Number List 2. PART NUMBER The Part number of the individual item, kit OR the assembly is given in this column for unique identification. The parts for which part numbers are not given, are not individually serviced. 3. DESCRIPTION The description of the part assigned to the individual item kit / assembly is mentioned in this column. 4. QUANTITY The number of individual items, kits or assemblies required for one vehicle is mentioned here. Though quantity is indicated for oversize (O/S) or undersize (U/S) of some items, it is to be understood that for a vehicle the sizes only is applicable, depending upon the repair / matching requirements. 6. REMARKS For Reference purpose.
4
Group Index Group No. 01-10 01-15 01-20 01-25 01-30 01-45 02-10 02-20 02-30 02-40 03-10 03-20 03-30 03-40 03-50 03-50 03-60 03-60 04-10 04-20 04-30 05-10 05-20 05-30 05-40
Description
Page No.
ENGINE ..................................................................... CRANK CASE LH - COVER SIDE ............................. CRANK CASE RH - COVER SIDE ............................. CRANK CASE LH ...................................................... CRANK CASE RH...................................................... CYLINDER & HEAD ASSEMBLIES .......................... ENGINE COVER LH ................................................. ENGINE COVER RH ................................................. CLUTCH ..................................................................... GEAR TRAIN ASSEMBLY ........................................ SILENCER & EXHAUST PIPE .................................. EFI COMPONENTS IN CYLINDER HEAD................ TCI & IGNITION COMPONENTS .............................. CV CARBURETOR .................................................... FILTER BOX ASSEMBLY (CLASSIC 500)................. FILTER BOX ASSEMBLY (CLASSIC 350)................. FUEL TANK (CLASSIC 500) ..................................... FUEL TANK (CLASSIC 350) ..................................... FRAME & PAV COMPONENTS ................................ SEAT ASSEMBLY ...................................................... CENTER STAND ....................................................... HANDLE BAR & CONTROLS ................................... CONTROL CABLES ................................................... CALIPER ASSEMBLY ............................................... MASTER CYLINDER ASSEMBLY.............................
Group No.
13 15 19 25 27 31 35 37 41 43 45 47 49 51 55 57 59 61 63 69 71 73 75 77 79
06-10 06-20 06-30 06-40 07-10 07-20 07-30 08-10 08-20 09-10 10-10 10-20 11-10 11-20 11-30 11-40 11-50 11-60 12-10 12-20 12-20 12-30 13-10 14-10 5
Description
Page No.
HEAD LAMP CASING ............................................... 81 FRONT FORK ........................................................... 85 SWING ARM ASSEMBLY .......................................... 87 REAR SHOCK ABSORBER ....................................... 89 BRAKE PEDAL ......................................................... 91 REAR CHAIN ............................................................ 93 FOOT RESTS ............................................................. 95 FRONT WHEEL......................................................... 97 REAR WHEEL ........................................................... 99 REAR BRAKE ......................................................... 103 FRONT MUDGUARD .............................................. 105 REAR MUDGUARD ................................................. 107 BATTERY AND HARNESS ..................................... 111 SWITCHES, HORN & RELAYS ............................... 113 WARNING INDICATOR, AMMETER & SPEEDOMETER 115 HEAD LAMP ........................................................... 117 TAIL LAMP ............................................................. 119 TRAFFICATOR LIGHTS .......................................... 121 TOOL BOX (ELECTRICALS BOX) LH ..................... 123 UTILITY BOX .......................................................... 125 RESONATOR BOX & COVER ................................. 127 BATTERY CARRIER ............................................... 129 TOOL KIT ................................................................ 131 SPECIAL TOOLS LIST ............................................. 133
Group Index - Pictorial 01-15 CRANK CASE LH - COVER SIDE
01-10 ENGINE Page 12
01-25 CRANK CASE - LH
Page 14
01-30 CRANK CASE RH Page 24
02-10 ENGINE COVER - LH
01-20 CRANK CASE RH - COVER SIDE Page 18
01-45 CYLINDER & HEAD ASSEMBLIES Page 26
02-20 ENGINE COVER - RH Page 34
02-30 CLUTCH Page 36
6
Page 30
Page 40
Group Index - Pictorial 02-40 GEAR TRAIN ASSEMBLY
03-10 SILENCER & EXHAUST PIPE
Page 42
03-30 TCI & IGNITION COMPONENTS
Page 44
03-40 CV CARBURETOR
Page 48
03-50 FILTER BOX ASSY. (CLASSIC 350)
03-60 FUEL TANK (CLASSIC 500) Page 58
7
Page 46
03-50 FILTER BOX ASSY. (CLASSIC 500) Page 50
Page 56
03-20 EFI COMPONENTS IN CYL. HEAD
Page 54
03-60 FUEL TANK (CLASSIC 350) Page 60
Group Index - Pictorial 04-10 FRAME
04-20 SEAT ASSEMBLY Page 62
04-30 CENTER STAND Page 70
Page 68
05-10 HANDLE BAR & CONTROLS
05-20 CONTROL CABLES
Page 72
05-30 CALIPER ASSEMBLY Page 74
500
Page 76
350
05-40 MASTER CYLINDER ASSEMBLY
06-10 HEAD LAMP CASING
Page 78
06-20 FRONTFORK Page 80
8
Page 84
Group Index - Pictorial 06-30 SWING ARM ASSEMBLY
06-40 REAR SHOCK ABSORBER Page 86
07-20 REAR CHAIN
Page 90
Page 88
07-30 FOOT RESTS Page 92
08-20 REAR WHEEL
07-10 BRAKE PEDAL
08-10 FRONT WHEEL Page 94
09-10 REAR BRAKE Page 98
10-10 FRONT MUDGUARD Page 102
9
Page 96
Page 104
Group Index - Pictorial 10-20 REAR MUDGUARD
11-10 BATTERY AND HARNESS Page 106
11-30 WARNING INDICATOR, AMMETER & SPEEDOMETER
Page 110
11-40 HEAD LAMP
Page 114
11-60 TRAFFICATOR LIGHTS
11-20 SWITCHES, HORN & RELAYS Page 112
11-50 TAIL LAMP Page 116
12-10 TOOL BOX (ELE. BOX) LH Page 120
Page 122
10
Page 118
12-20 UTILITY BOX Page 124
Group Index - Pictorial 12-20 RESONATOR BOX & COVER
12-30 BATTERY CARRIER
Page 126
14-10 SPECIAL TOOLS LIST
13-10 TOOL KIT Page 128
14-10 SPECIAL TOOLS LIST Page 132
Page 134
DOL
11
Page 130
01-10 Engine
1
2
12
01-10 Engine Key 500 EFI Part 350CC Part No. Number Number 1 2
861040 859029
861309 859030
Description ENGINE (UCE 500 EFI) ENGINE (UCE 350) CRANK CASE LH & RH ASSEMBLY WITH BEARINGS
13
Qty. 1 1 1
Remarks
01-15 Crankcase LH - Cover Side
14
01-15 Crankcase LH - Cover Side Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
570153/e 570064 570063/c 570070/m 570073 570074/i 570032 500635/a 570007/f 570072/c 570071/d 570094/i 570016 861003/g 570298/a 591494/a 570249/g 571113 570465/c 560525/a 570442 570446/g 570090/d
570153/e 570064 570063/c 570070/m 570073 570074/i 570032 500635/a 570007/f 570072/c 570071/d 570094/i 570016 861003/g 570298/a 591494/a 570249/g 570443/c 570465/c 560525/a 570442 570446/g 570090/d
Description SPRAG CLUTCH ASSEMBLY HEX. HEAD SCREW WASHER ENGINE SPROCKET NEEDLE BEARING DISTANCE WASHER, SPRAG CLUTCH CIRCLIP KEY - JACK SHAFT GEAR, - JACK SHAFT SHAFT, DOUBLE GEAR DOUBLE GEAR - STARTER DRIVE HEX. SOCKET HEAD CAP SCREW, M5 X 25 HEX. SOCKET HEAD CAP SCREW, M5 X 45 HOUSING STARTER DRIVE DOWEL (6MM) NEUTRAL SWITCH WITH PACKING COLLAR, MAINSHAFT CLUTCH ASSEMBLY COMPLETE PLAIN WASHER NYLOCK NUT BALL BEARING 6001 CLUTCH PUSH PAD STUD M6 X 106 15
Qty. 1 1 1 1 1 1 1 1 1 1 1 1 3 1 2 1 1 1 1 1 1 1 1
Remarks
01-15 Crankcase LH - Cover Side
16
01-15 Crankcase LH - Cover Side Key 500 EFI Part 350CC Part No. Number Number 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
550086/a 570088/d 570089/d 570414/b 570030 570047/c 570295 570029/d 141246/c 140293 570095/d 570086/a 570024 570091/d 570130 560011/a 144636/a 141051 570025
550086/a 570088/d 570089/d 570414/b 570030 570047/c 570295 570029/d 141246/c 140293 570095/d 570086/a 570024 570091/d 570130 560011/a 144636/a 141051 570025
Description NUT M6X1, FLANGE NYLOC TYPE STUD M6 X 168 STUD M6 X 196 PRIMARY CHAIN HEX. SOCKET HEAD CAP SCREW, M6X20 AUTO CHAIN TENSIONER ASSEMBLY ‘O’ RING, CHAIN TENSIONER ASSEMBLY CHAIN TENSIONER PAD BUSH, CHAIN TENSIONER PAD PLAIN WASHER STUD, CHAIN TENSIONER PAD STUD M6 X 226 HEX. SOCKET HEAD CAP SCREW, M6 X 50 STUD M6 X 80 HEX. SOCKET HEAD CAP SCREW, M6X85 SPRAG CLUTCH BEARING COPPER WASHER NUT - TENSIONER PAD HEX. SOCKET HEAD CAP SCREW, M6 X 90
17
Qty. 20 1 2 1 2 1 1 1 1 1 1 2 2 1 1 1 1 1 4
Remarks
01-20 Crankcase RH - Cover Side A1 Key No’s 7,8,9,10,11 A2 Key No’s 22,23,24,25,26,27
A3 Key No’s 22,23,26,63,64,65
A4 Key No’s 50,51,52
18
01-20 Crankcase RH - Cover Side Key 500 EFI Part 350CC Part No. Number Number A1 A2 A3 A4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
570309/b 571047/d NA 570600 570044/j 570298/a 570421/a 570132/a 570100/b 570280/b 570105/f 570541/a 570108/f 570110/d 571165/a 570099/c 570039/c 570040 570041 571164/a 861034 570300/b 570246/e 570247/d
570309/b NA 570048/f 570600 570044/j 570298/a 570421/a 570132/a 570100/b 570280/b 570105/f 570541/a 570108/f 570110/d 571165/a 570099/c 570039/c 570040 570041 571164/a 861034 570300/b 570246/e 570247/d
Description
Qty.
CAM GEAR ASSEMBLY-EXHAUST WITH DECOMPRESSOR ASSY. OIL PUMP ASSEMBLY - 500CC OIL PUMP ASSEMBLY - 350CC GEAR CHANGER ASSEMBLY CAM STEADY PLATE DOWEL 6 MM HEX. SOCKET HEAD CAP SCREW, M6 X 30 HEX. SOCKET HEAD CAP SCREW, M6 X 25 NUT - CAM SPINDLE SHIM, CAM GEAR PIVOT FLY WEIGHT TORSION SPRING PIN ASSEMBLY CAM GEAR AUB ASSEMBLY - EXHAUST CAM SLEEVE CAM SPINDLE ADJUSTABLE CAM SPINDLE ADJUSTABLE ( 0.1 OVERSIZE ) CAM SPINDLE ADJUSTABLE ( 0.2 OVERSIZE ) CAM, GEAR - INLET COVER, KICK START SHAFT HEX SOCKET PAN HEAD SCREW M5 X 12 NUT, SLEEVE GEAR TAB WASHER
1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 2 2 2 2 1 1 4 1 1
19
Remarks
01-20 Crankcase RH - Cover Side A1 Key No’s 7,8,9,10,11 A2 Key No’s 22,23,24,25,26,27
A3 Key No’s 22,23,26,63,64,65
A4 Key No’s 50,51,52
20
01-20 Crankcase RH - Cover Side Key 500 EFI Part 350CC Part No. Number Number 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
571032/b 570214/f 570213 570052 571166 571155/a 571115/c 570293 570132/a 146031/a 570468/b 144636/a 570481 570303/a 560013 572012/a 570300/b 570298/a 861041 570198/c 572020/b 502070/a 145708/a 550025 570219/f
570809/a 570214/f 570213 570052 571166 NA NA 570293 NA 146031/a 570468/b 144636/a 570481 570302/a 580306/c 570812/a 570813/b 570298/a 861040 570198/c 572125/a 502070/a 145708/a 550025 570219/f
Description FD SPROCKET 18 TEETH FOR 500CC & 16 TEETH FOR 350CC DISTANCE PIECE OIL SEAL CIRCLIP PUMP DRIVE PINION CSK SOCKET HEAD SCREW M6 X 30 GASKET, OIL PUMP 'O' RING, OIL PUMP OUTLET HEX. SOCKET HEAD CAP SCREW M6 X 25 'O'- RING CAP, PIVOT PIN COPPER WASHER HEX FLANGE BOLT M5 X 12 HEX SOCKET HEAD CAP SCREW M6 X 60 STARTER MOTOR ASSEMBLY COVER STARTER MOTOR HEX SOCKET, BUTTON HEAD SCREW, M5 X 12 DOWEL PIN TAPPET DOOR CSK SOCKET HEAD SCREW M5 X 12 FLY WHEEL MAGNETO ASSEMBLY MAGNETO KEY PLAIN WASHER, HEX. NUT M12 X 1.25 ASSEMBLY, GEAR LEVER SHAFT 21
Qty. 1 1 1 1 1 3 1 1 2 1 1 1 1 2 1 1 1 2 1 4 1 1 1 1
Remarks
01-20 Crankcase RH - Cover Side A1 Key No’s 7,8,9,10,11 A2 Key No’s 22,23,24,25,26,27
A3 Key No’s 22,23,26,63,64,65
A4 Key No’s 50,51,52
22
01-20 Crankcase RH - Cover Side Key 500 EFI Part 350CC Part No. Number Number 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
570184/b 570233 570231/h 570235/e 570229/d 550256/a 570222/e 570226/e 570253/e 570230/f 570304/a 570228/g 570234 570227/f 550072/b 570218/c 550108 146450/b 145090/a NA NA NA 570102/d 147058/a 571062/b
570184/b 570233 570231/h 570235/e 570229/d 550256/a 570222/e 570226/e 570253/e 570230/f 570304/a 570228/g 570234 570227/f 550072/b 570218/c 550108 146450/b 145090/a 570294 570292 570051 570102/d 592147/a 147063/a
Description SPACER - SHAFT, GEAR LEVER HEX. SOCKET HEAD CAP SCREW, M5 X 40 PIVOT BEARING, ROCKER SHAFT BOTTOM DOWEL, LOWER PIVOT BEARING STOP PIN 'O' RING ROCKER SHAFT ASSEMBLY STRIKER, GEAR CHANGE PIN, PIVOT SPRING, GEAR CHANGE STRIKER HEX. SOCKET HEAD CAP SCREW, M6 X 12 PIVOT BEARING, ROCKER SHAFT UPPER 'O' RING BLACK NITRILE RUBBER SPACER SPRING PIVOT, CAMPLATE ‘O’ RING SPRING KICK HEX SCREW M6X16 ‘O’ RING - OIL PUMP ‘O’ RING HEX. SOCKET HD. CAP SCREW, M4 X 30 PLUG STATOR AND PULSAR COIL ASSEMBLY ROTOR AND RELUCTOR ASSEMBLY 23
Qty. 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 4 4 1 1
Remarks
01-25 Crankcase LH
24
01-25 Crankcase LH Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14
145867/a 500104/b 570008/f 110037/3 110050 570006/e 111887 570201/f 550032/a 570013 570012/c 570087/d 570011 570057/g
145867/a 500104/b 570008/f 110037/3 110050 570006/e 111887 570201/f 550032/a 570013 570012/c 570087/d 570011 570005/c
Description FLANGE HEX NUT - M8 X 1.25 STUD, M8 X 128 JACK SHAFT CIRCLIP BALL BEARING 6305 C3 (25 X 62 X17) BEARING SPACER CRANKCASE LH ROLLER BEARING NU 305 C4 (25 X 62 X 17) WASHER, THRUST NEEDLE BEARING HEX SOCKET HEAD CAP SCREW, M5 X 16 RETAINER PLATE, MAINSHAFT BEARING STUD M6 X 133 BALL BEARING 6006, C3 (G/B MAIN SHAFT) BEARING SPACER - LH CRANKSHAFT
25
Qty. 3 3 1 2 1 1 1 1 1 2 1 2 1 1
Remarks
01-30 Crankcase RH 43
7
26
01-30 Crankcase RH Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
570097/b 570037 570469/a 110037/3 550032/a 570201/f 571172/b 570276/d 570206/j 570207 570208 571116/b 570141/d 570232 570215/f 550083/b 550082/c 550087 550086/a 142257/b 146714/a 570239/c 570240
570097/b 570037 570469/a 110037/3 550032/a 570201/f 571170/b 550108 570206/j 570207 570208 570125 570141/d 570232 570215/f 570215/f 550082/c 550087 550086/a 142257/b 146714/a 570239/c 570240
Description HYDRAULIC VALVE LIFTER ROLLER BEARING NRB DEEP GROOVE BALL BEARING – SLEEVE GEAR CIRCLIP 6.2 X 2N NEEDLE BEARING WASHER, THRUST CRANK SHAFT ASSEMBLY OIL DRAIN BOLT WITH MAGNET SLEEVE GEAR NEEDLE BEARING NEEDLE BEARING NEEDLE ROLLER BRACKET - PIN - HYDRAULIC - TAPPET HEX. SOCKET HEAD CAP SCREW, M6 X12 BOLT, PAWL SPRING PAWL, CAMPLATE MACHINED WASHER 6.4 NUT M6 X 1, FLANGE NYLOC TYPE STOP PLATE HEX SCREW M8 X 23 OIL THROWER HEX SOCKET HEAD CAP SCREW M5 X 35 27
Qty. 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3
Remarks
01-30 Crankcase RH 43
28
01-30 Crankcase RH Key 500 EFI Part 350CC Part No. Number Number 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
570054/g 570057/b 570055/c 570431 144846/a 570176/d 570277 120005/b 500104/b 145867/a 570236/h 140331/a 140332/b 140333/b 550030/c 570238/g 550039/c 570209 570028 570278
570054/g 570057/b 570055/c 570431 144846/a 570176/d 570277 120005/b 500104/b 145867/a 570236/h 140331/a 140332/b 140333/b 550030/c 570238/g 550039/c 570209 570028 570278
Description SUCTION FILTER ASY O RING-DRAIN CAP SUMP DRAIN CAP HEX. FLANGE BOLT M5X16 WASHER DRAIN PLUG DRAIN PLUG MAGNET DOWEL - HOLLOW STUD, M8 X 128 FLANGE NUT-M8 KICK START SHAFT SPRING PLUNGER PAWL WASHER THRUST ASSY., KICK START GEAR BUSH CIRCLIP 18N LOCATING PIN,(PIVOT)-NRB 3 X 21.8 LOCTITE 5699 (ALTERNATE : LIQUID SEALANT 3702)
29
Qty. 1 1 1 2 1 1 1 2 3 3 1 1 1 1 2 1 1 1 1 1
Remarks
01-45 Cylinder & Head Assemblies
39
A1 Key No’s 7,8,9,10,11 A2 Key No’s 29,39 30
01-45 Cylinder & Head Assemblies Key 500 EFI Part 350CC Part No. Number Number A1 A2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
859036 805015 859037 572025/a 570298/a 500347/a 500322/a 500309/b 500352/a 500307/a 570533/l 570535/g 570536/g 570532/e 570131 572022/b 572021/b 861016 861017 571118/a 571117/c 570128/f 570129/h
859034 805016 859035 500904/a 570298/a 500347/a 500322/a 500309/b 500352/a 500307/a 570533/l 570535/g 570536/g 570532/e 570131 57022/b 572021/b 861016 861017 571118/a 571117/c 570128/f 570129/h
Description
Qty.
CYLINDER HEAD ASSEMBLY CYLINDER PISTON ASSEMBLY CYL. HEAD SUB ASSY. (CYL. HEAD, VALVE GUIDE, VALVE SEATS) SPARK PLUG - M 14 DOWEL (6 MM) SEAT, SPRING VALVE STEM SEAL VALVE SPRING RETAINER, SPRING SPLIT COLLAR ROCKER BEARING SET-EXHAUST ROCKER ARM, EXHAUST ROCKER ARM - INLET ROCKER BEARING SET-INLET HEX. SOCKET HEAD CAP SCREW, M6 X 55 GASKET, ROCKER COVER EXHAUST GASKET, ROCKER COVER INLET ROCKER COVER - EXHAUST ROCKER COVER - INLET WASHER-SEAL HEX. HEAD SCREW-ROCKER COVER WASHER SEAL HEX. HEAD SCREW ROCKER COVER
1 1 1 1 8 2 2 2 2 4 1 1 1 1 8 1 1 1 1 3 3 1 1
31
Remarks
01-45 Cylinder & Head Assemblies
39
A1 Key No’s 7,8,9,10,11 A2 Key No’s 29,39 32
01-45 Cylinder & Head Assemblies Key 500 EFI Part 350CC Part No. Number Number 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
571035/c 571034/c 570480/b 570482/b 570478/b 570479/b 570489/a 805013 500116/a 500123/a 571043/b 571039/a 570537/d 570538/d 580395 571119 571109 571108
570164/d 570163/d 570480/b 570482/b 570478/b 570479/b 570489/a 805014 500116/a 500123/a 570018/g 570192/b 570537/d 570538/d 580395 500207/a 570273 570272
Description VALVE EXHAUST VALVE INLET DAMPER PAD - CYLINDER BARREL DAMPER PAD - CYLINDER BARREL TAPPER DAMPER PAD LH - CYLINDER HEAD DAMPER PAD RH - CYLINDER HEAD STUD, EXHAUST CYL. BARREL ASSEMBLY DOWEL PIN DOWEL PIN GASKET MLS GASKET PUSH ROD ASSEMBLY, EXHAUST PUSH ROD ASSEMBLY, INLET SPARK PLUG - M 10 - BOSCH (UR 5DC) CIRCLIP RING SET STD PISTON ASSEMBLY WITH RINGS STD
33
Qty. 1 1 3 6 2 4 2 1 1 1 1 1 1 1 1 2 1 1
Remarks
02-10 Engine Cover LH
A1 Key Nos. 1, 6, 10, 11, 12, 13, 14, 15, 16 A2 Key Nos. 10, 11, 12
34
02-10 Engine Cover LH Key 500 EFI Part 350CC Part No. Number Number A1 A2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
861030 570601 861013 572015/a 550095 570244/b 550507/a 550661/a 502018/b 145835/a 571156/b 570402/j 570406/d 570405/d 570452/e 570291/a 570407 550061/b
861030 570601 861013 572015/a 550095 570244/b 550507/a 550661/a 502018/b 145835/a 571156/b 570402/j 570406/d 570405/d 570452/e 570291/a 570407 550061/b
Description LH COVER SUB ASSEMBLY CLUTCH OPERATING LEVER COVER, LH HEX. FLANGE BOLT , M6 X 1 X 30 HEX SCREW M6 X 30 GEAR PEDAL ASSEMBLY SLEEVE, GEAR LEVER OIL SEAL 14 X 20 X 3 OIL FILLER PLUG ‘O’ - RING (PLUG) CLUTCH CABLE ASSEMBLY CLUTCH OPERATING LEVER ASSEMBLY PIN, CLUTCH OPERATING LEVER CABLE CLEVIS, CLUTCH OPERATING LEVER SPRING, CLUTCH OPERATING LEVER LOCK PIN SPRING, CLUTCH OPERATING MECH. OIL SEAL INA G 12 X 18 X 5 BUSH
35
Qty. 1 1 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks
02-20 Engine Cover RH
A1 Key No’s 1,2,3,4,8,9,10,11,12, 13,14,15,16,17,18,19,23, 24,25,26,27,28,29,32,43,
36
02-20 Engine Cover RH Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
861037 861036 570426/h 570424/d 570425 570416/c 550095 570013 550028 500622 570183/a 572011/a 572005/b 572014/a 500637/b 500617/a 500619/a 500616/a 500621/a 500613/a 572019/a 572017/a 572016/a
861037 861036 570426/h 570424/d 570425 570416/c 550095 570013 550028 500622 570183/a 572011/a 572005/b 572014/a 500637/b 500617/a 500619/a 500616/a 500621/a 500613/a 572019/a 572017/a 572016/a
Description RH COVER SUB ASSEMBLY COVER RH GASKET, COVER PLATE COVER PLATE, BREATHER CHAMBER HEX. SCREW, M5 X 12 GASKET - COVER RH ALLEN SCREW M6 X 30 HEX SOCKET HEAD CAP SCREW M5X16 CIRCLIP 24N OIL SEAL, CRANK FEED JET, CRANKSHAFT RH HEX FLANGE BOLT M6 X 1 X 20 CAP, OIL FILTER ‘O’ - RING, FILTER CAP SPRING WASHER ‘O’ - RING SPRING CAP ‘O’ - RING ELEMENT - OIL FILTER HEX. FLANGE BOLT, M6 X 1 X 45 HEX. FLANGE BOLT, M6 X 1 X 70 HEX. FLANGE BOLT, M6 X 1 X 85 37
Qty. 1 1 1 1 6 1 3 2 1 1 1 3 1 1 1 1 1 1 1 1 2 7 2
Remarks
02-20 Engine Cover RH
A1 Key No’s 1,2,3,4,9,10,11,12,13, 14,15,16,17,18,19,20, 44,25,26,27,28,29,30
38
02-20 Engine Cover RH Key 500 EFI Part 350CC Part No. Number Number 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
570059/c 144846/a 570176/d 146459/a 570467/a 570155 570444/a 146927/a 570286/c 570241 570807/c 570257/b 570814/c 140201 570808/c 145157/a
570059/c 144846/a 570176/d 146459/a 570467/a 570155 570444/a 146927/a 500128/a 570241 570807/c 570257/b 570814/c 140201 570808/c 145157/a
570259/d 111914 141051 571201/a
570259/d 111914 141051 571201/a
Description OIL LEVEL WINDOW WASHER, INSPECTION SCREW INSPECTION SCREW, IGNITION TIMING ‘O’ - RING OIL FILLER CAP, METAL SEALING WASHER BOLT BREATHER CLIP BREATHR PIPE BREATHER PIPE OIL SEAL KICK START KICK START CRANK ASSEMBLY SPRING BOSS, KICK START CRANK BALL DIA 6.35 LEVER KICK START SLEEVE KICK START LEVER PIN CIRCLIP 10 HEX BOLT M8X40 HEX NUT M8 SCREW SPRING CAP
39
Qty. 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1
Remarks
02-30 Clutch 11
12
9 10
8 6
7
5 4 1 2 3
350CC
A1
40
3
02-30 Clutch Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7 8 9 10 11 12
571113/a 570440 570442 570447/b 570439/b 570438/b 570434/d 570436/c 570437/c 571100/a 570451/b 570433/b 570441
570443/c 570440 570442 570447/b 570439/b 570438/b 570434/d 570436/c 570437/c 570435/b 570451/b 570433/b 570441
Description CLUTCH ASSEMBLY COMPLETE HEX. SCREW M6 BALL BEARING 6001 BEARING CUP HOLDER, CLUTCH SPRING CLUTCH SPRING CLUTCH HUB / BACK PLATE CLUTCH FRICTION PLATE CLUTCH PLAIN PLATE WHEEL CLUTCH THRUST WASHER CLUTCH DRUM / SPROCKET NEEDLE ROLLER BEARING SCE 228
41
Qty.
Remarks
1 6 1 1 1 6 1 7 For 350cc 6 nos. 6 For 350cc 5 nos. 1 1 1 1
02-40 Gear Train Assembly
42
02-40 Gear Train Assembly Key 500 EFI Part 350CC Part No. Number Number A1 A2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
570157 570158/a 570205/k 550008/b 550023/e 570823/a 550024 570821/a 570204/h 550216/b 570596/b 550007/c 550011/g 570202/e 550090/c 550081/c 550091/c 550078/a 550141 570216/e 550075/a 550030/c
570157 570158/a 570205/k 550008/b 550023/e 570823/a 550024 570821/a 570204/h 550216/b 570596/b 550007/c 550011/g 570202/e 550090/c 550081/c 550091/c 50078/a 550141 570216/e 550075/a 550030/c
Description LAY SHAFT SUB ASSEMBLY MAIN SHAFT SUB ASSEMBLY MAIN SHAFT MAIN SHAFT 2ND GEAR WASHER, THRUST MAIN SHAFT 4TH GEAR ASSEMBLY CIRCLIP MAIN SHAFT 3RD GEAR ASSEMBLY MAIN SHAFT 1ST GEAR LAY SHAFT LAY SHAFT 2ND GEAR ASSY. WITH BUSH LAY SHAFT HIGH GEAR LAY SHAFT 3RD GEAR / 4TH DOUBLE GEAR LAY SHAFT 1ST GEAR ASSEMBLY SELECTOR FORK LH SELECTOR FORK CENTRE SELECTOR FORK RH SELECTOR FORK SHAFT CIRCLIP CAM PLATE ASSEMBLY ROLLER WASHER THRUST
43
Qty. 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1
Remarks
03-10 Silencer & Exhaust Pipe
350 cc
44
03-10 Silencer & Exhaust Pipe Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
591824/d 510804/a 145867/a 591860/b 591865/a 145872/a 581158 141044 140129 141060 141061/1 591878/a 591871/a 581122/a NA NA
592004/b 500334/a 145867/a 592082/a 591163/a 145872/a 581158 141044 140129 141060 141061/1 NA NA NA 581091/a 581122/a
Description EXHAUST PIPE ASSEMBLY GASKET, EXHAUST PIPE FLANGED HEX. NUT M8X1.25 SILENCER ASSEMBLY SILENCER BRACKET FRONT FLANGE HEX BOLT M8X10 HEX SOCKET HEAD CAP SCREW M8X35 SS ,IS:2269 HEX BOLT M6X35 - IS :1364 (PART 1) PLAIN WASHER HEX. NUT M6 - IS ; 1364 (PART 3) - 8 - ZN.PL PUNCHED WASHER 6.4, IS:2016,STEEL GUARD – EXHAUST PIPE GUARD – SILENCER ASSEMBLY MUSHROOM HEAD SCREW, M6 X 8 X 1 SILENCER GUARD MUSHROOM HEAD SCREW, M6 X 8 X 1
45
Qty. 1 1 2 1 1 2 1 1 1 1 1 1 1 5 1 3
Remarks
03-20 EFI Components in Cylinder Head
3 4 16
15 13
14
1 6
2 5
17 18 8 11
7 11 3 9 10 19
12
46
03-20 EFI Components in Cylinder Head Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
859037 571055/a 521200/a 571079/d 144981/b 571080/g 570132/a 145023 571091 570030 550086/a 571051/a 571053/a 571090/a 571087/a 571088/c 571110/b 570091/d 140573
NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Description CYLINDER HEAD ENGINE TEMPERATURE SENSOR ‘O’-RING INSULATOR ‘O’-RING MANIFOLD-INLET HEX. SOCKET HEAD CAP SCREW M6 X 25 SEALING WASHER 6 X 10 ADAPTOR HEX. SOCKET HEAD CAP SCREW M6 X 20 NYLOC NUT M6 THROTTLE BODY INJECTOR SEAL RING ‘O’-RING, INJECTOR CAP, INJECTOR ASSEMBLY SPACER STUD CLIP HOSE
47
Qty. 1 1 2 1 1 1 2 4 1 2 3 1 1 1 1 1 1 1 1
Remarks
03-30 TCI & Ignition Components
500cc EFI
48
03-30 TCI & Ignition Components Key 500 EFI Part 350CC Part No. Number Number
Description
Qty.
1
NA
147067/e
TCI - UNIT (DIGITAL)
1
2
581024/c
581024/c
R/R UNIT - 3 PHASE
1
3
NA
581027/b
IGNITION COIL - PRIMARY
1
4
NA
147096/a
IGNITION COIL - SECONDARY
1
5
NA
502071
HEX SCREW, IGNITION COIL MOUNTING
5
6
143498
143498
HEX SCREW RR MOUNTING M6 X 25
1
7
141061
141061
PLAIN WASHER
3
8
NA
580377/b
BRACKET, IGNITION COIL
1
9
580397/a
580397/a
CAP SPARK PLUG M10
1
10
500905/e
500905/e
CAP SPARK PLUG M14
1
11
591837/b
NA
IGNITION COIL DUAL - WITH HT LEAD & SPARK PLUG CAPS
1
12
571056/a
NA
ELECTRONIC CONTROL UNIT
1
13
591370/c
NA
RUBBER STRAP
1
14
581054/b
NA
ROLL OVER SENSOR
1
15
141061
NA
PUNCHED WASHER 6.4
1
16
570132
NA
HEX. SOCKET HEAD CAP SCREW M6 X 25
1
49
Remarks
03-40 CV Carburetor
50
03-40 CV Carburetor Key 500 EFI Part 350CC Part No. Number Number
Description
Qty.
1
NA
570282/b
CARBURETOR ASSEMBLY
1
2
NA
500854
TOP COVER FIXING SCRREW
2
3
NA
500831
DIAPHRAGM TOP COVER
1
4
NA
50083
PISTON VALVE SPRING
1
5
NA
500848
JET NEEDLE PLATE FIXING SCREW
2
6
NA
500836
JET NEEDLE FIXING PLATE
1
7
NA
500837
JET NEEDLE RETAINER SPRING
1
8
NA
500839
JET NEEDLE WASHER
1
9
NA
500838
JET NEEDLE E-RING
1
10
NA
500864
JET NEEDLE
1
11
NA
500832
PISTON VALVE ASSEMBLY
1
12
NA
500835
DIAPHRAGM
1
13
NA
500834
DIAPHRAGM RETAINER RING
1
14
NA
500861
AIR VENT HOSE
1
15
NA
500865
NEEDLE JET
1
16
NA
500845
‘O’ RING
1
17
NA
500844
MAIN JET HOLDER
1
18
NA
500863
MAIN JET
1
19
NA
500846
FLOAT PIN
1
20
NA
500847
FLOAT PIN FIXING SCREW
1
21
NA
500841
‘O’ RING FLOAT CHAMBER COVER
1
22
NA
500843
FLOAT ASSEMBLY
1 51
Remarks
03-40 CV Carburetor
52
03-40 CV Carburetor Key 500 EFI Part 350CC Part No. Number Number
Description
Qty.
23
NA
500860
FLOAT BODY ASSEMBLY
1
24
NA
141963
SPRING WASHER
2
25
NA
500842
SCREW
2
26
NA
500853
HOSE DRAIN
1
27
NA
500871
SCREW
1
28
NA
500857
IDLE ADJUSTER SCREW
1
29
NA
500820/a
PACKING, IDLE ADJUSTING SCREW
1
30
NA
500855
SPRING, IDLE ADJUSTING
1
31
NA
500866
PIVOT PIN
1
32
NA
500867
PILOT AIR JET
1
33
NA
500874
CLIP
1
34
NA
500089
PLUNGER ASSEMBLY
1
35
NA
500870
‘O’ RING PILOT SCREW
1
36
NA
500869
WASHER PILOT SCREW
1
37
NA
500862
SPRING PILOT SCREW
1
38
NA
14344/2
CLIP HOSE
2
39
NA
521262/a
FLANGE
1
40
NA
521200/a
O’ RING
1
41
500823/a
BELLOWS
1
42
500355
HEX. SOCKET HEAD SCREW M6 X 16
2
43
144636/a
SEALING WASHER
2
44
500873
CAP
1 53
Remarks
03-50 Filter Box Assembly (Classic 500)
12 15 1 10 5
2
5
6
6
7 11
7
9 8 6 7 5
3
4 14
54
13
03-50 Filter Box Assembly (Classic 500) Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
863043 866020 865054 581007/a 581008/a 142182 142274 140129 141061 140383/3 141060 591492/a 591493/a 591470/a 500917/b 591875/a 142391
NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Description AIR FILTER BOX ASSY., WITH STICKER,CLASSIC GREEN AIR FILTER BOX ASSY., WITH STICKER, BLACK AIR FILTER BOX ASSY., WITH STICKER, ROYAL MAROON AIR FILTER ELEMENT COVER FILTER ELEMENT HEX NYLOCK NUT HEX SCREW, M6 X 16 LOCK WASHER,INTERNAL TEETH PUNCHED WASHER PLAIN WASHER HEX.NUT M6 INLET BELLOW CLIP HOSE – INLET BELLOW OUTLET BELLOW- AIR FILTER STRAP STICKER, FILTER BOX RH BEADING
55
Qty. 1 1 1 1 1 1 3 3 3 1 1 1 1 1 1 1 1
Remarks
03-50 Filter Box Assembly (Classic 350)
12
56
03-50 Filter Box Assembly (Classic 350) Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13
NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
810610 850041 865043 143548/a 143477/b 141462/3 142274/1 140129/3 141061 140383/a 141060/a 147613/a 500711 592021 142179
Description AIR FILTER BOX ASSY., WITH STICKER, BLACK AIR FILTER BOX ASSY., WITH STICKER, SILVER AIR FILTER BOX ASSY., WITH STICKER, ROYAL MAROON AIR FILTER ELEMENT COVER FILTER ELEMENT HEX.BOLT, M6 X 55 HEX SCREW, M6 X 16 LOCK WASHER,INTERNAL TEETH PUNCHED WASHER PLAIN WASHER HEX.NUT M6 CONNECTION TUBE CLIP HOSE STICKER- FILTER BOX RH CLIP HOSE
57
Qty. 1 1 1 1 1 1 4 3 3 1 1 1 1 1 1
Remarks
03-60 Fuel Tank (Classic 500)
3
2
4
58
03-60 Fuel Tank (Classic 500) Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
863014 801581 865023 591060/a 591071/a 591182/a 591058/c 591059/c 110406/b 145869 145860/a 145876/a 591457/a 140542 140508 145868/a 571063/a 571052/a 143496/a 144636/a 500355 581013/b 146318 581053
NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
Description FUEL TANK ASSY., WITH STICKER, CLASSIC GREEN FUEL TANK ASSY., WITH STICKER, BLACK FUEL TANK ASSY., WITH STICKER, ROYAL MAROON TANK STICKER LH TANK STICKER RH TANK STICKER TOP THIGH PAD RH THIGH PAD LH SLEEVE TUBE FLANGED HEX. BOLT M10 x 85 FLANGED HEX. BOLT M10 x75 STEADY BRACKET SLOTTED CH.HD.SCREW M4 X 12 (FUEL TANK CAP) WASHER FLANGE HEX NUT M10 ‘O‘ RING – FUEL PUMP MODULE FUEL PUMP MODULE WASHER COPPER WASHER M6 SCREW FUEL HOSE CLIP LOW FUEL SENSOR 59
Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 5 5 5 1 2 1
Remarks
03-60 Fuel Tank (Classic 350)
60
03-60 Fuel Tank (Classic 350) Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA
866012 850037 865051 591060/a 591071/a 5911821/a 5910581/c 5910591/c 147371 147372 145860 1458761/a 5925241/a 1458681/a 5702631/b 5702991/a 1458731/a 142182 1455751/a 500355 1434961/a 140143 140542 140508
Description FUEL TANK ASSY., WITH STICKER,BLACK FUEL TANK ASSY., WITH STICKER, SILVER FUEL TANK ASSY., WITH STICKER, ROYAL MAROON TANK STICKER LH TANK STICKER RH TANK STICKER TOP THIGH PAD RH THIGH PAD LH SLEEVE TUBE FLANGED HEX. BOLT M10 X 85 FLANGED HEX. BOLT M10 X 60 STEADY BRACKET FLANGE HEX NUT M10 SPACER SPACER_STEADY BRACKET FLANGED HEX. BOLT M8X90, BLACK PASSIVATION , 240 HOURS NSS TEST, THICKNESS 10 MICRON MIN. HEX NUT WITH NYLON INSERT, M8 - IS : 7002 -8 – ZN.PL FUEL TAP HEX BOLT M6X14 - IS :1364 (PART 1) FIBER WASHER PLAIN WASHER SLOTTED CH. HD. SCREW M4X12 - IS :1366 - 4.8 -ZN.PL. LOCK WASHER, INTERNAL TEETH B4.3 - IS :5371 61
Qty. 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 2 4 2 2 2
Remarks
04-10 Frame & PAV Components
CLASSIC 350
62
04-10 Frame & PAV Components Key 500 EFI Part 350CC Part No. Number Number A1 867005 863053 865059 1 863037 801609 865055 2
3
4 5 6 7 8 9 10 11
863016 801527 865009 863017 801528 865010 145856/b 145708/a 142232/a 145878/a 145879/a 140080/2 142182 863018 801529 865011
NA NA NA NA NA NA 801609 NA 801527 NA NA 801528 NA 145856/b 145708/a 142232/a 145878/a 145879/a 140080/2 142182 NA NA NA
Description PAV ASSY, BLACK PAV ASSY, CLASSIC GREEN PAV ASSY, ROYAL MAROON FRAME COMP,CLASSIC GREEN FRAME COMP, BLACK FRAME COMP, ROYAL MAROON FRAME COMP, BLACK ENGINE MOUNTING PLATE – LH,CLASSIC GREEN ENGINE MOUNTING PLATE – LH,BLACK ENGINE MOUNTING PLATE – LH, ROYAL MAROON ENGINE MOUNTING PLATE – RH,CLASSIC GREEN ENGINE MOUNTING PLATE – RH, BLACK ENGINE MOUNTING PLATE – RH, ROYAL MAROON FLANGED HEX. BOLT 1/2"x120 PLAIN WASHER HEX NUT WITH NYLOC INSERT FLANGED HEX BOLT, M8X1120 FLANGED HEX. BOLT M8x112 PLAIN WASHER HEX NUT WITH NYLON INSERT, M8 ENGINE MOUNTING PLATE, RH REAR,CLASSIC GREEN ENGINE MOUNTING PLATE,REAR,BLACK ENGINE MOUNTING PLATE,REAR,ROYAL MAROON 63
Qty. 1
1
1
1
1 1 1 1 1 4 4 1
Remarks
04-10 Frame & PAV Components
CLASSIC 350
64
04-10 Frame & PAV Components Key 500 EFI Part 350CC Part No. Number Number 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31
591386/a 591388/a 145708/a 591389/a 580314 145868/a 145868/a 591326/a 591440/a 591073/a 863026 843087 865001 145862/a 591456 145880 145867 143146 141044 147504 147502 863045 867004
591386/a 591388/a 145708/a 591389/a 580314 145868/a 145868/a 591326/a 591440/a 591073/a NA 843087 NA 145862/a NA NA 145867 143146 NA NA NA NA NA
Description FLANGED HEX BOLT, M8X100 HEX BOLT M12 X 226 PLAIN WASHER HEX NUT WITH NYLOCK M12 BRACKET (PIECE MUDGUARD) FLANGED HEX. SERRATED NUT M10x1.25 FLANGED HEX. NUT M10x1.25 FLANGE HEX BOLT M10x1.25x288 FLANGE HEX BOLT M10x1.25x260 CAP – SWING PIVOT SIDE HANDLE ,CLASSIC GREEN SIDE HANDLE ,BLACK SIDE HANDLE ,ROYAL MARON FLANGED HEX.BOLT, M8x20 STIFFENER PLATE COMP FLANGED HEX.BOLT, M8x30 FLANGED HEX. NUT M8x1.25 HEX.SOCKET HD.CAP SCREW,M8 X 30 HEX BOLT M6X35 BUSH - PAV GROMMET ENGINE MOUNTING PLATE,REAR LH ,CLASSIC GREEN ENGINE MOUNTING PLATE,REAR LH ,BLACK 65
Qty. 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 2 2 1
Remarks
04-10 Frame & PAV Components
CLASSIC 350
66
04-10 Frame & PAV Components Key 500 EFI Part 350CC Part No. Number Number 32 33 34 35 36 37 38 39 40 41 42 43
865052 510187 140129 141060 572309 146318 572310 140573 572311 147701 NA NA NA
NA NA NA NA NA NA NA NA NA NA 592121/b 145861/a 801529
Description ENGINE MOUNTING PLATE,REAR LH ,ROYAL MAROON PULSE AIR VALVE LOCK WASHER HEX.NUT M6 BRAIDED HOSE assy SS HOSE CLIP PAV HOSE-AIR FILTER CLIP, BREATHER BODY PAV TUBE ADAPTOR WIRE CLIP BRACKET ASSY, THROTTLE SWITCH FLANGED HEX BOLT M6X1X20 ENGINE MOUNTING PLATE,LH & RH REAR,BLACK
67
Qty.
1 2 2 1 1 1 2 1 2 1 2 2
Remarks
04-20 Seat Assembly A1
2 1
14
3 4 17
5
16
4
6
22
12 9 11 10
20
18
4
19
4 5
7 13
21
15
8 8 7
17
20 16
5
19
68
4
4
04-20 Seat Assembly Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22
591524 591066/c 591030/c 591423/a 142182 540042/c 591029/e 145881/a 110366/3 591418/b 591415/a 591450/a 210026 863022 801575 865014 591077/c 591197/a 591505/a 591506/a 591534/a 140304/1 141306/2 142182 591401/a
591524 591066/c 591030/c 591423/a 142182 540042/c 591029/e 145881/a 110366/3 591418/b 591415/a 591450/a 210026 801575 591077/c 591197/a 591505/a 591506/a 591534/a 140304/1 141306/2 142182 591401/a
Description PILLION SEAT KIT SUB ASSEMBLY SPILT SEAT ASSEMBLY - RIDER COVER - SEAT RIDER SILENT BLOCK ASSEMBLY HEX NUT WITH NYLON INSERT, M8 SPRING BUSH SPRING STEEL FLANGED HEX.BOLT M8 WASHER SEAT HINGE MTG ASSEMBLY STUD - SEAT MTG. FLANGED HEX.BOLT, M8x60 SPRING WASHER SUB FRAME CLASSIC GREEN SUB FRAME ,BLACK SUB FRAME ROYAL MAROON SUB FRAME ,BLACK SPLIT SEAT ASSEMBLY – PILLION PILLION HANDLE MUSHROOM HEAD SCREW -M6 X 26 MUSHROOM HEAD SCREW -M6 X 35 FLANGED HEX BOLT M8 X 16 PLAIN WASHER NYLOCK NUT,M6 HEX NUT WITH NYLON INSERT, M8 - IS : 7002 -8 - Zn.pl FLANGED HEX BOLT M8 X 170 69
Qty. 1 1 1 1 8 4 2 2 2 1 1 1 1 1
1 1 1 2 2 2 2 2 1 1
Remarks
04-30 Center Stand
5 3
6
3
6 2 4
1 5
70
04-30 Center Stand Key 500 EFI Part 350CC Part No. Number Number 1
2 3 4 5 6
863025 801580 865020 591393/a 141234 145186 144766/a 141230/3
592159/b 591393/a 141234 145186 144766/a 141230/3
Description CENTER STAND COMPLETE CLASSIC GREEN CENTER STAND COMPLETE BLACK CENTER STAND COMPLETE ROYAL MAROON CENTER STAND COMPLETE BLACK SPINDLE WASHER RUBBER STOP SPRING SPLIT PIN
71
Qty. 1 1 1 1 1 2 1 2 2
Remarks
05-10 Handle Bar & Controls A1 Key Nos. All except 7 & 8
6
10 7 8 15
4 1
17 16
5
19 13
22
14
12
21 20
18 9 11 2
â–²
12
72
10
3
05-10 Handle Bar & Controls Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
591413/a 591414/b 581083/a 581029/a 581097/a 528186 581098 590250/b 590251/b 146197 521201/b 560632/a 560633/a 147271/a 141460/a 145782/b 591522/a 591521/a 591974 591975 591973 591972 521202/a
592118/b 591414/b 592150/a 580441/a 560195/a 528186 146044/a 590250/b 590251/b 146069 521201/b 560632/a 560633/a 147271/a 141460/a 145782/b 591522/a 591521/a 591974 591975 591973 591972 521202/a
Description HANDLE BAR ASSY COMPLETE HANDLE BAR COMPLETE LEVER & HOLDER ASSYEMBLY, LH SWITCH MODULE LH SWITCH MODULE RH HAND GRIP LH GRIP COMPLETE THROTLE RH REAR VIEW MIRROR LH REAR VIEW MIRROR RH CLUTCH LEVER DAMPER WEIGHT CLUTCH SWITCH SCREW, CLUTCH SWITCH ADD ON LEAD,CLUTCH SWITCH LH LEVER BRACKET CABLE STRAP 6 INCH PAN HEAD SCREW M5X10 ROTOR PLATE NUT NYLOCK STUD RELEASE LEVER WASHER SCREW HEX. SOCKET THREAD SCREW M8 X 50 73
Qty. 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 4 1 1 1 1 1 1 2
Remarks
05-20 Control Cables
500
1
1
350
2 3
2 3
74
05-20 Control Cables Key 500 EFI Part 350CC Part No. Number Number 1 2 3
581018/a 581032/ 571156/b
592113/b 581032/b 571156/b
Description Throttle Cable Assembly (twin cable) BI Starter Cable Clutch Cable Assembly
75
Qty. 1 1 1
Remarks
05-30 Caliper Assembly
7
A1 10
4 3
2
1
4 5 3 2 12 13
12
11
13 6 8 15
9
76
05-30 Caliper Assembly Key 500 EFI Part 350CC Part No. Number Number A1 146198 1 560585
Description
Qty.
146198 560585
Disc Brake Assembly Body Caliper
1 1
2
560586
560586
Piston
2
3
560587
560587
Seal Piston
2
4
560588
560588
Dust Seal
2
5
560589
560589
Boot
1
6
560590
560590
Bellow
1
7
560583
560583
Pad Assembly Set
1
8
560591
560591
Bleed Screw
1
9
560592
560592
Cap
1
10
560593
560593
Spring Pad
1
11
560583
560583
Mounting Bracket Assembly
1
12
560594
560594
Pin bolt
2
13
560595
560595
Grub Screw
2
14
560534/a
560534/a
Banjo Bolt
1
15
560597
560597
Washer (Copper)
2
77
Remarks
05-40 Master Cylinder Assembly
6
12 13
7
10 11 4 5 3
1
A1 15 9 2
16 16 14 8
17 17
78
18
17 17
05-40 Master Cylinder Assembly Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
146199 560567 560568 560571 560572 560573 560574 560575 560570 146336 146337 560579 560609 146586 560511/b 560530/c 560534/a 560535/a 560514/a
146199 560567 560568 560571 560572 560573 560574 560575 560570 146336 146337 560579 560609 146586 560511/b 560530/c 560534/a 560535/a 560514/a
Description Master Cylinder Assembly Piston Sub Assembly Banjo – Bolt Kit Cir Clip Boot Diaphragm Csk. Philips Head Screw Cover Switch Assembly Kit Clamp Bolt Clamp Nut – Lever Screw - Lever Lever Disc Socket Button Head Cap Screw Banjo Bolt Washer Brake Hose
Qty. 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 6 2 4 1
79
Remarks
06-10 Head Lamp Casing 15 A1 10
16
13 12
18
14
14
Key Nos. 2, 3 (38 Nos.), 4 (2 Nos), 5
17
11
16
17
19
18
1
A2
22
23
2
Key Nos. 1 (2 Nos.), 2, 3 (38 Nos), 4 (2 Nos), 5
3
32
4
20
21
1 27
24 4
24
25
3 5
25
26
6
26 30
8 7 8 7
28
29 31
9
80
06-10 Head Lamp Casing Key 500 EFI Part 350CC Part No. Number Number A1 A2 1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 17 18
597010 597204 145446/a 144583/e 140201 144582/e 144581/e 801275 865029 863030 NA 145867/a 142182 591462/a 140558/b 150254/b 110116/b 140189/3 146610/a 146032/a 143818/1 140206/5 143825/1
597010 597204 145446/a 144583/e 140201 144582/e 144581/e NA NA NA 801275 145867/a 142182 591462/a 140558/b 150254/b 110116/b 140189/3 146610/a 146032/a 143818/1 140206/5 143825/1
Description BALL RACE KIT BALL RACE KIT WITH COVER COVER BALL RACE,HEAD LAMP CASING BALL DIA 6.35 BALL RACE, FRAME BALL RACE,CROWN STEERING STEM ASSY,BLACK STEERING STEM ASSY,ROYAL MAROON STEERING STEM ASSY-CLASSIC GREEN STEERING STEM ASSY,BLACK FLANGE HEX NUT M8 X 1.25 HEX.NUT WITH NYLOCK INSERT M8 FLANGED HEX. BOLT M8 x 75 PLUG SCREW ‘O’-RING STEM LOCK NUT PLAIN WASHER WASHER M8 X 48 HEX SS BOLT (304 GRADE) STUD, M8 X 32 PLAIN WASHER NUT 81
Qty. 1 1 1 1 38 2 1 1 1 1 1 2 2 2 2 2 1 1 2 2 2 2 2
Remarks
06-10 Head Lamp Casing 15 A1 10
16
13 12
18
14
14
Key Nos. 2, 3 (38 Nos.), 4 (2 Nos), 5
17
11
16
17
19
18
1
A2
22
23
2
Key Nos. 1 (2 Nos.), 2, 3 (38 Nos), 4 (2 Nos), 5
3
32
4
20
21
1 27
24 4
24
25
3 5
25
26
6
26 30
8 7 8 7
28
29 31
9
82
06-10 Head Lamp Casing Key 500 EFI Part 350CC Part No. Number Number 19 20 21 22 23 24 25 26
140202/c 140195 140196/d 147560/a 500809/c 140193/b 143906/b 863005 801006
140202/c 140195 140196/d 147560/a 500809/c 140193/b 143906/b 850032
27
865006 863033 801600
28
865032 863044 866008
29 30 31 32
865038 845006 145882/a 581122/a 140872/b
801600 850053 865032 866008 850033 865038 845006 145882/a 581122/a 140872/b
Description HANDLE BAR CLIP SLEEVE SLEEVE, PLAIN HEX SOCKET HEAD CAP SCREW M10 X 1.5 X 35 ADAPTOR RUBBER SPACER BUSH COVER TUBE,CLASSIC GREEN COVER TUBE, BLACK COVER TUBE, SILVER COVER TUBE, ROYAL MAROON HEAD LAMP CASING,CLASSIC GREEN HEAD LAMP CASING, BLACK HEAD LAMP CASING, SILVER HEAD LAMP CASING, ROYAL MAROON RR COVER COMP WITH STICKER,CLASSIC GREEN RR COVER COMP WITH STICKER,BLACK RR COVER COMP WITH STICKER, SILVER RR COVER COMP WITH STICKER, ROYAL MAROON FRONT NUMBER PLATE CROSS RECESSED PAN HEAD SCREW M6 x 14 MUSHROOM HEAD SCREW M6X8X1 GROMMET 83
Qty. 1 1 1 1 1 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 2 2 2
Remarks
06-20 Front Fork
15
A1
6
20
14
Key Nos. All except 16,17,18, 19
5 7 4 13
A2 12
Key Nos. All except 1, 2 & 3 10
3 16
9
17 18 11 19 2 8 1
84
18
06-20 Front Fork Key 500 EFI Part 350CC Part No. Number Number A1 A2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
591012/a 591021/a 147077/a 147074/a 591002/a 591828/a 591827/a 147078/a 591829/a 147090/a 147092/a 147082/a 591512/a 591513/a 591514/a 147081/a 591825/a 591001/a 560564 141061/1 141306/2 591826/a
591012/a 591021/a 147077/a 147074/a 591002/a 591828/a 591827/a 147078/a 591829/a 147090/a 147092/a 147082/a 591512/a 591513/a 591514/a 147081/a 591825/a 591001/a 560564 141061/1 141306/2 591826/a
Description FORK LH ASSY-DISC FORK RH ASSY-DISC SOCKET HEADED BOLT COPPER PACKING FORK END LH – DISC OIL SEAL OIL SEAL STOPPER CAP OIL LOCK FORK PIPE SPINING REBOUND SPRING SEAT PIPE PISTON RING MAIN SPRING WASHER SPACER TUBE O’-RING FORK BOLT FORK END RH HEX HD.SCREW M6 X 65 PUNCHED WASHER 6.4 HEX.NUT WITH NYLON INSERT DUST SEAL
85
Qty. 1 1 2 2 1 2 2 2 2 2 2 2 2 2\ 2 2 2 1 1 2 1 1
Remarks
06-30 Swing Arm
45
A1 Key Nos. 2&7
3
2
1
2
7
A1
86
6
06-30 Swing Arm Key 500 EFI Part 350CC Part No. Number Number A1 867006 863054 865060 1 580347/a 2 580038/c 3 580037/f 4 570547/b 5 580344/a 6 580343 863007 7 801534 865022
867006 NA NA 580347/a 580038/c 580037/f 570547/b 580344/a 580343 NA 801534 NA
Description SWING ARM SUB ASSEMBLY BLACK SWING ARM SUB ASSEMBLY CLASSIC GREEN SWING ARM SUB ASSEMBLY MAROON HEX FLANGE BOLT BUSH SPACER PAD ASSEMBLY, REAR CHAIN WASHER HEX. NYLOCK NUT SWING ARM, CLASSIC GREEN SWING ARM BLACK SWING ARM ROYAL MAROON
87
Qty. 1 1 1 1 2 1 1 1 1 1 1 1
Remarks
06-40 Rear Shock Absorber
88
06-40 Rear Shock Absorber Key 500 EFI Part 350CC Part No. Number Number 1
2 3 4 5 6
863008 843087 865001 — 170399/a 111696/1 140304/1 143407 170352/1
NA NA NA 146347/b 170399/a 11696/1 140304/1 143407 170352/1
Description SHOCK ABSORBER, CLASSIC GREEN SHOCK ABSORBER, BLACK SHOCK ABSORBER, ROYAL MAROON SHOCK ABSORBER HEX BOLT - 3/8"X45 (FOR RH SIDE ONLY) HEX.BOLT, - 3/8" BSF x 2" (FOR LH SIDE ONLY) PLAIN WASHER SINGLE COIL SPRING LOCK WASHER DOOMED NUT (3/8" B.S.F)
89
Qty. 1 1 1 1 1 1 6 4 4
Remarks
07-10 Brake Pedal
90
07-10 Brake Pedal Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11
591074 144886/c 580412/a 591385/a 145862/a 591469/e 591390/a 110298/2 144009/c 591499/a --
591074 144886/c 580412/a 591385/a 145862/a 591469/e 591390/a 110298/2 144009/c 591499/a --
Description BRAKE PEDALCOMP BRAKE PEDAL RUBBER SUPPORT – BRAKE PEDAL WASHER FLANGED HEX.BOLT, M8x20 BRAKE ROD ASSEMBLY PIN – BRAKE ROD SPLIT PIN NUT,BRAKE ROD BRAKE LIGHT SWITCH ASSY BRAKE LIGHT SWITCH SPRING
91
Qty. 1 1 1 1 1 1 1 1 1 1 1
Remarks
07-20 Rear Chain
A1 Key Nos. 3, 4, 5 & 6
92
07-20 Rear Chain Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 3 4 5 6
597462 801535 145872/b 581085/a NA 145854 571032/b 801479
597463 801535 145872/b NA 580100/a 145854 570809/a 801479
Description CHAIN AND SPROCKET KIT CHAIN GUARD ASSY FLANGE HEX.BOLT,M8x10 CHAIN, REAR, 102 PITCHES (‘ O’ Ring type ) - LGB CHAIN, REAR, 100 PITCHES (‘ O’ Ring type ) - LGB CONNECTING LINK FD SPROCKET REAR SPROCKET
93
Qty. 1 1 2 1 1 1 1 1
Remarks
07-30 Foot Rests
94
07-30 Foot Rests Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14
863019 865012 866001 580294/b 580339 521199 142182 147849 863020 865013 801459 591425/a 145865 145880/a 863031 801460 865030 591428/b 147135/a 591439/a
NA NA 866001 580294/b 580339 521199 142182 147849 NA NA 801459 591425/a 145865 145880/a NA 801460 NA 591428/b 147135/a 591439/a
Description SIDESTAND MTG COMP.,CLASSIC GREEN SIDESTAND MTG COMP.,ROYAL MAROON SIDESTAND MTG COMP.,BLACK SIDE STAND ASSY PLAIN WASHER HEX SOCKET HEAD SCREW M8X45 HEX NYLOCK NUT M8 SPRING FOOT REST ARM, LH CLASSIC GREEN FOOT REST ARM, LH ROYAL MAROON FOOT REST ARM, LH BLACK SLEEVE-LH FLANGED HEX. SERRATED NUT M10x1.5 FLANGED HEX.BOLT M8 FOOT REST ARM, RH CLASSIC GREEN FOOT REST ARM, RH BLACK FOOT REST ARM, RH ROYAL MAROON SLEEVE-RH FOOT REST ASSY LH FOOT REST ASSY RH
95
Qty. 1
1 1 1 1 1 1
1 1 1 1 1 1 1 1
Remarks
08-10 Front Wheel
19
5
6
16 16
16 16 16 16
15 3
18 A1
A2
7
8
9
18
Key Nos. All
4
18
18 18
17
18 10
Key Nos.
1
All Except 1,2,10,11,12,14 96
2
13
14
11 12
08-10 Front Wheel Key 500 EFI Part 350CC Part No. Number Number A1 A2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
591855 592041 560524/b 560523/e 141109/1 145552/b 591206 110349 592078 592079 861012 591195/b 142835 560525/a 560521/b 560522/e 560511/b 560530/c 560504/f 560546/a 140355/b 592006 592007
592005 592146 560524/b 560523/e 141109/1 145552/b 141133/a 110349 560519 560502 861012 591195/b 142835 560525/a 560521/b 560522/e 560511/b 560530/c 560504/f 560546/a 140355/b 110280 110278
Description FRONT WHEEL FRONT WHEEL ASSY SPEEDO DRIVE ASSY SPACER GREASE SEAL, 25X40X7 BEARING, 6203.RS1-C3 RIM, FRONT NIPPLE FRONT SPOKES SHORT FRONT SPOKES LONG HUB, FRONT SPINDLE PLAIN WASHER HEX. NUT WITH NYLOCK INSERT M16x1.5, SPACER ASSEMBLY SPACER, DISC SIDE DISC PLATE SOCKET BUTTON HEAD SCREW ADAPTOR PLATE HEX. FLANGE BOLT M8X25 RIM TAPE TUBE, FRONT TYRE, FRONT 97
Qty.
Remarks
1 1 1 1 2 2 1 40 20 20 1 1 1 1 1 1 1 6 1 6 1 1 Fig. not Shown 1 Fig. not Shown
08-20 Rear Wheel
A1 Key Nos. 1, 2, 8, 9, 12, 17, 18, 19, 20, 21, 24, 25, 26, 27, 28, 30, 31
98
08-20 Rear Wheel Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
592040 170547 144471/a 141114/b 145553 801479 580311/b 141115/b 804005 124539/1 591816/a 580309/a 591210/a 580308/b 141127/4 141128/2 141129/1 592013/a 110349 140355/b 592003/a 592002/a 144386/a
592040 170547 144471/a 141114/b 145553 801479 580311/b 141115/b 804005 124539/1 591816/a 580309/a 591210/a 580308/b 141127/4 141128/2 141129/1 592013/a 110349 140355/b 592003/a 592002/a 144386/a
Description REAR WHEEL ASSEMBLY REAR HUB ASSEMBLY CUSHION RUBBER SPINDLE SHORT BEARING 6005 C3 SPROCKET DRUM SPACER DISTANCE PIECE DUST COVER SLOTTED CHEESE HEAD SCREW M5 X 10 COVER PLATE ASSEMBLY COMP SPACER COVER PLATE RIM, REAR SPINDLE LONG HEX. LOCK NUT, M22x1.5 HEX. CASTLE NUT, M16 SPLIT PIN SPOKES OUTER, REAR NIPPLE RIM TAPE TYRE, REAR TUBE, REAR ADJUSTER LH 99
Qty. 1 1 4 1 1 1 1 1 1 2 1 1 1 1 1 1 1 20 40 1 1 1 1
Remarks
08-20 Rear Wheel
A1 Key Nos. All in group 08-20, 09-10 Except 3 and 13 in group 9-10
100
08-20 Rear Wheel Key 500 EFI Part 350CC Part No. Number Number 23 24 25 26 27 28 29 30 31
144387/a 861011 592012/a 146499/a 145552/b 141109/1 141119/b 146256/a 141113/1
144387/a 861011 592012/a 146499/a 145552/b 141109/1 141119/b 146256/a 141113/1
Description ADJUSTER RH CENTRE HUB, REAR SPOKES INNER, REAR SPACER ASSEMBLY BEARING, 6203.RS1-C3 GREASE SEAL, 25X40X7 DISTANCE COLLAR ‘O’ RING GREASE SEAL 25 X 47 X 7
Qty. 1 1 20 1 2 1 1 1 1
101
Remarks
09-10 Rear Brake
A1 Key Nos. All in Group 09 - 10
102
09-10 Rear Brake Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
591816 801540 580362/a 580310/a 145088/b 145090/a 145089/b 145091 144570/d 147151/a 147150/a 591451/a 140376/2 146434 580367 580368/b 580139/c
591816 801540 580362/a 580310/a 145088/b 145090/a 145089/b 145091 144570/d 147151/a 147150/a 591451/a 140376/2 146434 580367 580368/b 580139/c
Description COVER PLATE ASSY COMP COVER PLATE ASSY SHOE PIN LOCK NUT BUSH HEX.SCREW M6X25 SCREW M6X1X16 HEX.THIN NUT M6 BRAKE SHOE ASSEMBLY OPERATING CAM SPRING BRAKE SHOE LEVER ASSEMBLY SINGLE COIL SPR.LOCK WASHER NUT WASHER HEX.NUT M12X1.25 SPRING REAR BRAKE
103
Qty. 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 1 1
Remarks
10-10 Front Mudguard
104
10-10 Front Mudguard Key 500 EFI Part 350CC Part No. Number Number 1
2
3
4
5 6 7 8 9 10 11 12 13 14
863001 801568 NA 865002 863002 801569 NA 865003 863003 801570 NA 865004 863004 801571 NA 865005 153355/4 140129 140056/3 145862/a 210026 142532/b 560516/a NA NA NA
NA 866004 850028 865034 NA 866005 850029 865035 NA 866006 850030 865036 NA 866007 850031 865037 153355/4 140129 140056/3 145862/a 210026 142532/b 560516/a 145882/a 141061/1 141060
Description MUDGUARD FRONT,CLASSIC GREEN MUDGUARD FRONT, BLACK MUDGUARD FRONT, SILVER MUDGUARD FRONT, ROYAL MAROON STAY FRONT – CLASSIC GREEN STAY FRONT – BLACK STAY FRONT – SILVER STAY FRONT – ROYAL MAROON STAY CENTER – CLASSIC GREEN STAY CENTER – BLACK STAY CENTER – SILVER STAY CENTER – ROYAL MAROON STAY REAR – CLASSIC GREEN STAY REAR – BLACK STAY REAR – SILVER STAY REAR – ROYAL MAROON SCREW LOCK WASHER HEX NUT WITH NYLOCK INSERT FLANGED HEX. BOLT M8x20 SPRING WASHER M8 CABLE GUIDE WIRE CLAMP CROSS RECESSED PAN HEAD SCREW M6 X 14 PLAIN WASHER M6 HEX.NUT M6 - IS ; 1364 (PART 3) - 8 – ZN.PL 105
Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 6 6 6 6 1 1 1 1 1
Remarks
10-20 Rear Mudguard
8
6 23 22
3 7
1
24 25
21 4 5 9 18
10
2
4 27 26 11 12
7
8
5 4
13 19 14 18 4
15 16 17
6 9 20
106
10-20 Rear Mudguard Key 500 EFI Part 350CC Part No. Number Number 1
2
3
4 5 6 7 8 9 10 11 12 13 14
863040 801602 NA 865056 863046 866014 865045 863051 866022 NA 865057 141061/1 142274 592141/a 142182 145881/a 592030/a 170242/a 591023/a 801562 845007 591099/a
NA NA 850040 865056 NA 866014 850039 865045 NA 866022 850038 865057 141061/1 142274 592141/a 142182 145881/a 592030/a 170242/a 591023/a 801562 845007 591099/a
Description REAR MUDGUARD COMP., WITH STICKER,CLASSIC GREEN REAR MUDGUARD COMP., WITH STICKER,BLACK REAR MUDGUARD COMP., WITH STICKER,SILVER REAR MUDGUARD COMP., WITH STICKER,ROYAL MAROON SAREE GUARD LH, CLASSIC GREEN SAREE GUARD LH, BLACK SAREE GUARD LH, SILVER SAREE GUARD LH, ROYAL MAROON MUDGUARD CARRIER RH ASSY, CLASSIC GREEN MUDGUARD CARRIER RH ASSY, BLACK MUDGUARD CARRIER RH ASSY, SILVER MUDGUARD CARRIER RH ASSY, ROYAL MAROON PLAIN WASHER HEX.SCREW, M6x16 HEX_SOCKET HEAD SCREW M8x40 HEX NYLOCK NUT FLANGED HEX. BOLT M8 X 45 PLUG GROMMET BEADING NUMBER PLATE HOLDER COMP TAIL LAMP BKT COMP BEADING 107
Qty. 1
1
1
4 4 2 2 2 2 1 1 1 1 1
Remarks
10-20 Rear Mudguard
8
6 23 22
3 7
1
24 25
21 4 5 9 18
10
2
4 27 26 11 12
7
8
5 4
13 19 14 18 4
15 16 17
6 9 20
108
10-20 Rear Mudguard Key 500 EFI Part 350CC Part No. Number Number 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
592140/b 581122/a 143275/a 141306/2 145880/a 591180/a 591556/a 140090/1 143498 140383/3 141060 140129 141306/2 863055 865061 860028 NA
592140/b 581122/a 143275/a 141306/2 145880/a 591180/a 591556/a 140090/1 143498 140383/3 141060 140129 141306/2 NA 865061 860028 850052
Description BRACKET-REFLECTOR MUSHROOM HEAD SCREW M6X8 REFLECTOR ASSEMBLY HEX NYLOCK NUT FLANGED HEX.BOLT, M8x20 STICKER, REAR MUDGUARD PIECE MUDGUARD WASHER HEX SCREW M6X25 WASHER HEX NUT M6 LOCK WASHER HEX NYLOCK NUT MUDGUARD CARRIER LH CLASSIC GREEN MUDGUARD CARRIER LH ROYAL MAROON MUDGUARD CARRIER LH BLACK MUDGUARD CARRIER LH SILVER
109
Qty. 1 1 1 4 1 1 1 2 2 2 2 8 1 1 1 1 1
Remarks
11-10 Battery & Harness
110
11-10 Battery & Harness Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11
146134/c 591877/a 591560/a 591156/b 591353 591567 NA NA 591838/a 141162/c 141161/c
146134/c 592168/a 591560/a 591156/b NA NA 146451 146418 NA 141162/c 141161/c
Description BATTERY 12V -14AH MF-A 2 HARNESS MAIN CABLE WIRING HARNESS, TAIL LIGHT BATTERY CABLE -VE BLADE FUSE 20 AMPS FUSE BOX ASSEMBLY FUSE 10 AMPS FUSE 15 AMPS POWER RELAY ADD-ON CABLE STRAP 8 INCH CABLE STRAP 6 INCH
111
Qty. 1 1 1 1 6 1 2 2 1 3 2
Remarks
11-20 Switches, Horn & Relays
5 1 7
2
6
10
11
4
12
3 8 9
112
11-20 Switches, Horn & Relays Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9 10 11 12
591880 580396/a 146168/b 591561/a 145143 571060 571059 145862/a 143407 581234/a --------
592177/a 580396/a 146168/b 591561/a 145143 NA NA 145862/a 143407 NA ------
Description COMMON KEY SET FLASHER UNIT HORN RELAY STARTER STEERING LOCK MOUNTING SCREW (M6 × 12) POWER RELAY FOR IGNITION RELAY - (FUEL PUMP & INJECTOR) BOLT FOR HORN MOUNTING SPRING WASHER RUBBER HOLDER FOR RELAY BOLT FOR RELAY STARTER WASHER - RELAY STARTER MOUNTING
113
Qty. 1 1 1 1 2 1 1 1 1 1 2 2
Remarks
11-30 Warning Indicator, Ammeter & Speedometer
7 4
6
8
9
5
114
11-30 Warning Indicator, Ammeter & Speedometer Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8 9
591009 140193/b 141715 591434 591904 145980/b 110179 591219
NA 141715 NA 592099 145980/b 110179
592173
Description MALFUNTION INDICATOR ASSEMBLY (MIL) RUBBER RING, WARNING INDICATOR BULB, 12V - 2W BULB, 12V - 4W SPEEDOMETER ASSEMBLY (KMPH) SPEEDOMETER CABLE RUBBER RING, SPEEDOMETER BULB HOLDER COMPLETE MIL INNER CABLE SPEEDOMETER AMMETER
115
Qty. 1 1 1 3 1 1 1 1 1 1
Remarks
11-40 Head Lamp
A1 6
1
4
2
7
3
6 A1
5
116
11-40 Head Lamp Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5 6 7
591873/a 141632 591905/b 591442 141634 146456 141715 147726/B
591873/a 141632 591905/b 591442 141634 146456 141715 147726/b
Description PILOT LAMP WITH BULB HEAD LIGHT RIM HEAD LAMP ASSEMBLY WITH HALOGEN BULB BULB 12V - 60/55W HALOGEN (HEAD LAMP) RIM FIXING (HEAD LAMP FIXING RIM) BULB 12V - 4W BA 7S CAP BULB 12V - 2W BA 7S CAP ADDON LEAD
117
Qty. 2 1 1 1 1 1 2 1
Remarks
11-50 Tail Lamp
A1 Key No’s All
A1
118
11-50 Tail Lamp Key 500 EFI Part 350CC Part No. Number Number A1 1 2 3 4 5
591011/d 591216 561215 591214 145882 141061/1
591011/d 591216 561215 591214 145882 141061/1
Description TAIL LAMP ASSEMBLY LENS & BASE SEALED BULB HOLDER COMPLETE BULB 12V - 21/ 5W MUSHROOM HEAD SCREW M6 X 1 X 10 PLAIN WASHER
119
Qty. 1 1 1 1 3 6
Remarks
11-60 Trafficator Lights
6
5
5
7
3,4
1,2
8
120
11-60 Trafficator Lights Key 500 EFI Part 350CC Part No. Number Number 1 2 3 4 5 6 7 8
592171/a 592169/a 592172/a 592170/a 146348 540097/b 540098/b 142182
592171/a 592169/a 592172/a 592170/a 146348 540097/b 540098/b 142182
Description TRAFFICATOR ASSEMBLY TRAFFICATOR ASSEMBLY TRAFFICATOR ASSEMBLY TRAFFICATOR ASSEMBLY BULB 12V 10W BRACKET LH, FRONT BRACKET RH, FRONT NUT, NYLOCK M8
RH FRONT RH REAR LH FRONT LH REAR
121
Qty. 1 1 1 1 1 1 1 2
Remarks
12-10 Tool Box (Electricals Box) LH
2
5
6
3
7
1
8
3 5 4
3 7
5
4 122
3
5
4
9
12-10 Tool Box (Electricals Box) LH Key 500 EFI Part 350CC Part No. Number Number 1
863042 866019
2 3 4 5 6 7 8 9
865053 141093 142274/a 141061/1 140383/3 140129 141060 591352/a 591876
NA 866009 850044 865046 141093 142274/a 141061/1 140383/3 140129 141060 591352/a 592020/a
Description TOOL BOX, ELECTRICAL WITH STICKER,CLASSIC GREEN TOOL BOX, ELECTRICAL WITH STICKER, BLACK TOOL BOX, ELECTRICAL WITH STICKER,SILVER TOOL BOX, ELECTRICAL WITH STICKER,ROYAL MAROON HEX SCREW, M6 X 10 HEX SCREW, M6 X 16 PUNCHED WASHER PLAIN WASHER LOCK WASHER,INTERNAL TEETH HEX.NUT M6 GROMMET-ELECTRICAL BOX STICKER, TOOL BOX
123
Qty. 1 1 1 1 1 3 4 1 3 2 1 1
Remarks
12-20 Utility Box
124
12-20 Utility Box Key 500 EFI Part 350CC Part No. Number Number 1
2 3 4 5
863029 801578 865018 863028 801577 865017 521088/b 142274 140383/3
NA NA NA NA NA NA NA NA NA
Description BODY COMP.TOOLBOX, CLASSIC GREEN BODY COMP.TOOLBOX, BLACK BODY COMP.TOOLBOX ,ROYAL MAROON LID ASSY, TOOL BOX.CLASSIC GREEN LID ASSY, TOOL BOX. BLACK LID ASSY, TOOL BOX. ROYAL MAROON GROMMET HEX SCREW, M6 X 16 PLAIN WASHER
125
Qty. 1 1 1 1 1 1 2 2 2
Remarks
12-20 Resonator Box & Cover
126
12-20 Resonator Box & Cover Key 500 EFI Part 350CC Part No. Number Number 1
2 3 4 5 6 7 8
NA NA NA NA NA NA NA NA NA NA
801607 850042 865044 147521/b 521088/b 142274 592109/a 142169 592132/b 145861/a
Description LID COVER ASSEMBLY BLACK LID COVER ASSEMBLY SILVER LID COVER ASSEMBLY MAROON RESONATOR BOX GROOMET HEX. SCREW M6 X 16 RUBBER BELLOW CLIP HOSE BRACKET RESONATOR BOX FLANGED HEX. BOLT M6 X 1 X 20
127
Qty. 1 1 1 1 2 2 1 1 1 2
Remarks
12-30 Battery Carrier
128
12-30 Battery Carrier Key 500 EFI Part 350CC Part No. Number Number 1 2
3 4 5
801209 863024 801476 865016 142258 560100 560058/b
801209 801476 850034 865016 142258 560100 560058/b
Description BACK PLATE ASSEMBLY, COVER – BATTERY CLASSIC GREEN COVER – BATTERY BLACK COVER – BATTERY SILVER COVER – BATTERY ROYAL MAROON HEX BOLT M8X16 HEX BOLT M8 X 45 STRAP
129
Qty. 1 1 1 1 1 1 1 2
Remarks
13-10 Tool Kit
1
2
3
4
11
A1 Key Nos. 1 to 10
130
5
6
7
8
9
10
13-10 Tool Kit Key 500 EFI Part 350CC Part No. Number Number A1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
570828/a 521150/a 570827/a 570826/a
570828/a 521150/a 570827/a 570826/a
521104/a
521104/a
580695/a 142631 521097/a
580695/a 142631 521097/a
Description TOOL KIT TOOL WALLET TOMMY BAR WITH 8MM ALLEN KEY HEAD PLUG SPANNER (16 X 8MM) TUBULAR SPANNER (12 X 13MM) EYELET SPANNER 17MM SCREW DRIVER DOUBLE END SPANNER (3/8” X 5/16”) DOUBLE END SPANNER (10 X 13MM) DOUBLE END SPANNER (10 X 12MM) TUBULAR SPANNER (21 X 24MM) FIRST AID KIT
131
Qty. 1 1 1 1 1 1 1 1 1 2 1 1
Remarks
14-10 Special Tools List
1
4
7
2
3
5
6
9
8
132
14-10 Special Tools List Key 500 EFI Part No. Number
350CC Part Number
Description
Qty.
1
ST-25118 - 4
CYLINDER HEAD NUT TIGHTENING TOOL
1
2
ST-25123 - 1
VALVE SPRING COMPRESSOR
1
3
ST-25612-4
ROTOR TIGHTENING & LOOSENING TOOL
1
4
ST-25128 - 2
PULLER FOR MAGNETO ROTOR
1
5
ST-25592-4
CONNECTING ROD LOCKING TOOL
1
6
ST-25151-4
PULLER FOR CHAIN CASE OUTER
1
7
ST-25591-4
SPROCKET & CLUTCH TIGHTENING TOOL
1
8
ST-25594-4
CLUTCH PLATE TIGHTENING TOOL
1
9
ST-25153 - 4
EXTRACTOR FOR GEAR BOX ROCKER PIVOT PIN
1
133
Remarks
14-10 Special Tools List
10
13
11
12
14
15
DOL TOOL
16
17
134
14-10 Special Tools List Key 500 EFI Part No. Number
350CC Part Number
Description
Qty.
10
ST-25835-2
FD SPROCKET REMOVING TOOL
1
11
ST-25834-2
FRONT FORK DISMANTLING TOOL
1
12
ST-25114-4
EXTRACTOR FOR FORK OIL SEAL
1
13
ST-25113 - 4
MANDREL FOR OIL SEAL
1
14
ST-25112-4
EXPANDER FOR FRONT FORK OIL SEAL
1
15
ST-25110-3
GAUGE PLATE FOR TIGHTENING CHAIN STAY
1
16
ST-25244 - 4
SPECIAL SPANNER ADJUSTER
1
17
CR0060
DOL TOOL FOR EFI DIAGNOSIS
1
135
Remarks
Spare Parts Catalogue Classic 500 & 350
KEEP IT
REAL USE ONLY GENUINE ROYAL ENFIELD SPARE PARTS
Royal Enfield (A Unit of Eicher Motors Ltd.) Tiruvottiyur High Road, Tiruvottiyur, Chennai - 600 019. Tel: +91 44 4223 0400. Fax : +91 44 4204 3019 Website : www.royalenfield.com
