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XL SUPER / HD / SPORT PARTS CATALOGUE

XL SUPER / HD / SPORT
1. CYLINDER HEAD. CYLINDER BLOCK
2. CRANKCASE, REED VALVE
3. COVER CLUTCH SHIELD
4. CRANKSHAFT, PISTON ASSEMBLY
5. CARBURETTOR ASSEMBLY
6. AIR CLEANER ASSEMBLY
7. EXHAUST SYSTEM ASSEMBLY
8. FAN AND COWL FAN ASSEMBLY
9. CLUTCH ASSEMBLY
10. GEAR ASSY. PRIMARY DRIVEN
11. KICK STARTER ASSEMBLY
12. MAGNETO ASSY. & CDI UNIT
13. FOOTREST ASSEMBLY
14. FRONT SUSPENSION ASSEMBLY
14A.FRONT SUSPENSION ASSY.
15. REAR SUSPENSION ASSY.
16. FRONT WHEEL ASSEMBLY
17. REAR WHEEL ASSEMBLY
17A.REAR WHEEL ASSY. - QD
18. FRAME & STAND ASSEMBLY
19. SEAT ASSEMBLY
20. FUELTANK & TOOL BOX ASSY.
21. MUDGUARD, COVER FRAME & CHAIN GUARD
22. HANDLE BAR, SPEEDOMETER ASSY.
23. CONTROL LEVER ASSY. LH
23A.CONTROL LEVER ASSY. RH
23B.CONTROL LEVER ASSY. LH,RH (SPORT)
24. HEAD LAMP & TAIL LAMP ASSY.
24A.HEAD LAMP & TAIL LAMP ASSY. (SPORT)
25. TOOL KIT ASSY.
(HYDRALIC FORK)
ASSEMBLY INDEX
CYLINDER HEAD, CYLINDER BLOCK FIG.NO.01
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
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 1 **
12 P1320280 CYLINDER BLOCK & PISTON KIT 1 1 1 1 1 **
13 P180340 ENGINE ASSY 70cc 1 1 1 1
13A J180030 ENGINE ASSY 70cc 1
** - REF. KIT & KIT CONTENTS
10
4
9
8
7
6
5
3
2
1
9
1
2
3
FIG.No. 01
CYLINDER HEAD, CYLINDER BLOCK
11 11A
CRANK CASE, REED VALVE ASSY. FIG.NO. 02
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
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 **
** ' - REF. KIT & KIT CONTENTS
6
7
8
9
10
11
12
5
4
3
2
1
9
18 17 5
14 15
16
13
FIG.No.02
CRANK CASE, REED VALVE
COVER CLUTCH, SHIELD ASSY. FIG.NO. 03
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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 *
# - 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.03
COVER CLUTCH, SHIELD

CRANKSHAFT, PISTON ASSEMBLY FIG.NO.04
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
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
8A P010680 PISTON PIN NEW 1 1 1 1 1
9 420950000 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 **
** - REF. KIT& KIT CONTETNS N.I - NOT ILLUSTRATED
FIG.No.04
CRANKSHAFT, PISTON ASSEMBLY
CARBURETTOR ASSEMBLY FIG.NO. 05
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P040560 CARBURETTOR ASSY. 1 1 1 1
1A J040140 CARBURETTOR ASSY. (SPORT) 1
1B P1040080 CARBURETTOR ASSY. 1 1
1C P1040140 CARBURETTOR ASSY. 1 1 NEW
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 1 1 1
11A P1320410 THROTTLE VALVE, TYPE CA20 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
FIG.No.05
CARBURETTOR ASSEMBLY

CARBURETTOR ASSEMBLY FIG.NO. 05
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
18 P320200 SCREW 1 1 1 1 1
18A
404377000
SCREW 1 1
19 P320220 VALVE CONTROLLER 1 1 1 1 1
19A P1320350 VALVE CONTROLLER 1 1
20 P320210 SPRING 1 1 1 1 1
20A P1320360 SPRING 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
33 P320190 FLOAT CHAMBER 1 1 1 1 1
33A P1320370 FLOAT CHAMBER 1 1
FIG.No.05
CARBURETTOR ASSEMBLY
CARBURETTOR ASSEMBLY FIG.NO. 05
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
33B P1320470 FLOAT BODY ASSY. 1 1
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 "
** - REF. KIT& KIT CONTETNS
FIG.No.05
CARBURETTOR ASSEMBLY
CARBURETTOR ASSEMBLY - NEW FIG.NO. 5A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P1040140 CARBURETTOR ASSY. 1 1
2 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
FIG.No.5A
CARBURETTOR ASSEMBLY NEW
CARBURETTOR ASSEMBLY - NEW FIG.NO. 5A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
20 P1320700 AIR ADJUSTER 1 1
21 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
FIG.No.5A
CARBURETTOR ASSEMBLY NEW
AIR CLEANER ASSEMBLY FIG.NO. 06
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P040700 AIR FILTER ASSEMBLY 1 1 1 1
1A P1040100 AIR FILTER ASSEMBLY 1 1
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
7A P1040110 COVER AIR - CLEANER 1 1
8 P040740 SEAL AIR CLEANER 1 1 1 1
9 P040750 SUPPORT 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 2 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 SUPPORT, 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
FIG.No.06
AIR CLEANER ASSEMBLY
SECONDARY AIR INJECTION ASSEMBLY FIG.NO. 06A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
FIG.No.06A
SECONDARY AIR INJECTION ASSEMBLY
EXHAUST SYSTEM ASSEMBLY FIG.NO. 07
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
FIG.No.07
EXHAUST SYSTEM ASSEMBLY
EXHAUST SYSTEM ASSEMBLY FIG.NO. 07
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
24 P5050300 GASKET EXHAUST 1 1 1 1 CAT
24A K5050689 GASKET EXHAUST 1 1 (LE VERSION)
25 P5050090 PIPE COMP. EXHAUST CAT 1 1
25A P5050560 PIPE COMP. EXHAUST CAT 1 1
25B P5050690 PIPE COMP. EXHAUST LE 1 1 *
26 K5050240 CATALYTIC CONVERTER COMP. 1 1 1 1
26A P5050680 CATALYTIC CONVERTER COMP. LE 1 1 *
27 P5050490 MUFFLER COMP CAT 1 1 1 1
27A P5050740 MUFFLER COMP. LE VERSION 1 1
28 P1200130 HEX SCREW M6x25 4.6 ZNG 2 2 2 2
29 P1320230 MUFFLER ASSY WITH GUARD LE 1 1 ** / *
**- REF. KIT & KIT CONTENTS
* - APPLICABLE FOR THE VEHICLES PRODUCED AFTER 01.04.2005
FIG.No.07
EXHAUST SYSTEM ASSEMBLY
EXHAUST SYSTEM ASSEMBLY FIG.NO. 07A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
CAT:- CATALYTIC
FIG.No.07A
EXHAUST SYSTEM ASSEMBLY
FAN AND COWL FAN ASSEMBLY FIG.NO. 08
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 0332275 CRR PAN HD SCREW M6x16 1
2 0335578 SPRING WASHER 6.5x13x1 4 4 5 4 4
3 7130140 WASHER 1
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
6A P1180060 COVER CARBURETTOR 1 1 *
6B J210100 DUMMY ENGINE COVER 1
7 P1180070 COWL FAN COMP. 1 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
10 P1320270 KIT COWL FAN 1 1 1 1 **
* - FOR DETAILS REFER SIB MOPED /02/06-07 DATED 17.01.2007
** - REF KIT & KIT CONTENTS
9
8
7
6
5
4
FIG.No.08
FAN AND COWL FAN ASSEMBLY
6A
3
1
2

CLUTCH ASSEMBLY FIG.NO. 09
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
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 **
** - REF. KIT & KIT CONTENTS
6
8
9
10
1
2
1
3
4
5
7
6
FIG.No.09
CLUTCH ASSEMBLY
12
12
11
GEAR ASSY. PRIMARY DRIVEN FIG.NO.10
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 420602000 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 REF.Sl No.02
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
11A P081100 SPROCKET ENGINE NEW - 13T 1 1
12 P080180 LOCK WASHER SPROCKET 1 1 1
12A P081030 LOCK WASHER SPROCKET NEW 1 1
13 0334256 NUT ENGINE SPROCKET 1 1 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 1 1
15 P321420 CONNECTING LINK SET CHAIN 1 1 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) 1 1 ** (NEW)
** - REF. KIT & KIT CONTENTS
2
1
3 4
5
6
7
9
10
11,11A
12A
13
8
14
FIG.No.10
12
15
KICKSTARTER ASSEMBLY FIG.NO.11
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
3A P081260 SPRING GEAR K.S DRIVEN NEW 1 1
4 P080940 GEAR KICKSTARTER DRIVEN 1 1 1
4A P081340 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
15A J080190 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
1
2
3
6
8
17
16
18
16
12 13
10
11
14
9
15,15A
22
21 20
19
23
27
24
25
26
FIG.No.11
KICKSTARTER ASSEMBLY
5
4,4A
7
KICKSTARTER ASSEMBLY FIG.NO.11
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
19 P080410 STOPPER KICKSTARTER 1 1 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 **
28A P1320430 KICK STARTER KIT NEW 1 1 **
29 P321430 GEAR COMP. KICK START KIT 1 1 1 1 1 **
** - REF. KIT & KIT CONTENTS
1
2
3
6
8
17
16
18
16
12 13
10
11
14
9
15,15A
22
21 20
19
23
27
24
25
26
FIG.No.11
KICKSTARTER ASSEMBLY
5
4,4A
7
MAGNETO ASSY. & CDI UNIT FIG.NO. 12
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
FIG.No.12
MAGNETO ASSY. & CDI UNIT
FOOTREST ASSEMBLY FIG.NO.13
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.

1 P121560 RUBBER FOOTREST RH 1 1 1
1A 0258300 RUBBER FRONT FOOT REST 2 2
2 P3120120 BAR COMP. FOOTREST 1 1
2A J121030 BAR COMP. FOOTREST 1
2B P3120340 BAR COMP. FOOTREST 1 1
3 P121550 RUBBER FOOTREST LH 1 1 1
4 P121540 SPACER FOOTREST 2 2
5 P121660 RETAINER FOOTREST RUBBER 2 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
FIG.No.13
FOOTREST ASSEMBLY
FRONT SUSPENSION ASSY. FIG.NO.14
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 A200570 DOOMED CAP NUT 2 2 2
1A 0334218 HEX NUT M8 2 N.I.
2 420106000 UNDULATED WASHER B8 2 2 2 2
3 P1000800D CROWN PLATE TOP BLACK 1 1 1
3A J100320 BRACKET COMP. UPPER 1
4 P100190 FORK COMPLETE FRONT 1 1 *
4A J100520 FORK COMPLETE FRONT SILVER 1
4B P1100040 FORK COMPLETE FRONT 1 *
5 P100510 FORK TUBE COMP. INNER RH 1 1 1 *
5A J100130 FORK TUBE COMP. INNER RH 1 *
6 0334548 HEX NUT M8 2 2 2
7 0330318 WAVE SPRING WASHER M8 2 2 2
8 P100480 HOSE CLIP 2 2 2 2
9 J100200 DUST BELLOWS 2 2 2
9A J100280 DUST BELLOWS 2
10 410059000 CAP LOCK NUT 1 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
' * ' 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.
FRONT SUSPENSION ASSY. FIG.NO.14
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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 2
24 P100490 GUIDE BUSH HALF 4 4 4
24A P100610 GUIDE BUSH HALF LONG 4
25 P100500 FORK TUBE COMP. INNER LH 1 1 1 *
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 **
** -REF KIT & KIT CONTENTS
FIG.No.14
FRONT SUSPENSION ASSY.
FRONT SUSPENSION ASSY. (HYDRAULIC FORK) FIG.NO.14A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 J100520 FRONT SUSPENSION ASSY - SIL GR 1
1A P3320040 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 1
7A T4100050 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 1
20A T4100200 CROWN PLATE COMP. BOTTOM 1 1
N.I - NOT ILLUSTRATED
FIG.No.14A
FRONT SUSPENSION ASSY.(HYDRAULIC FORK)
FRONT SUSPENSION ASSY. (HYDRAULIC FORK) FIG.NO.14A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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 1
25A T4100080 FORK TUBE COMP. LOWER LH 1 1
26 410058700 STEERING LOCK NUT 1 1 1
27 410043700 SPECIAL WASHER 1 1 1
28 T41004400D CROWN PLATE TOP 1 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 1 N.I
37A P3320020 FORK LEG ASSY RH - SIL. GREY 1 1 N.I
38 J100540 FORK LEG ASSY LH - SIL GREY 1 N.I
38A P3320030 FORK LEG ASSY LH - SIL. GREY 1 1 N.I
39 P3320060 FRONT SUSPENSION KIT 1 1 1 **
** -REF KIT & KIT CONTENTS
FIG.No.14A
FRONT SUSPENSION ASSY.(HYDRAULIC FORK)

REAR SUSPENSION ASSEMBLY FIG.NO.15
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 K200500 HEX BOLT M10x45 4 2 2
1A 0334047 NUT REAR SHOCK ABSORBER 3
1B P1200240 HEX NUT M10 1
2 409045000 PUNCHED WASHER 12 4 4 4
2A 0334038 PUNCHED WASHER 10.5x24 8
3 209261000 SHOCK ABSORBER 2
3A P3090010 SHOCK ABSORBER 2 2
3B T090030 SHOCK ABSORBER 2
3C P1090080 SHOCK ABSORBER 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 2
11A 0331248 HEX SCREW M6x33 2 2 N.I
12 420305700 HEX NUT M5 2 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. 1
** - REF KIT & KIT CONTENTS N.I - NOT ILLUSTRATED
FIG.No.15
REAR SUSPENSION ASSY.

REAR SUSPENSION ASSEMBLY FIG.NO.15
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
21A P3090290 TORQUE LINK COMP. REAR NEW 1 1
22 0336018 WASHER TORQUE LINK 1 1 1 1 1
23 3207018 SPRING (TORQUE) 1 1 1
24 J110270 ABUTMENT REAR BRAKE CABLE 1 1 1 1 1 N.I
SL. NO. 18 - 23 APPLICABLE FOR QD WHEEL XL SUPER N.I - NOT ILLUSTRATED
FIG.No.15
REAR SUSPENSION ASSY.
FRONT WHEEL ASSEMBLY FIG.NO.16
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 411199000 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
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
1
2
4
5
6
7
8
9
10 11
12 13
14
12
11
16
17
11
8
15
17A
FIG.No.16
FRONT WHEEL ASSEMBLY
3
18
19
REAR WHEEL ASSEMBLY - OLD FIG.NO. 17
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
FIG.No.17
REAR WHEEL ASSY. - OLD
REAR WHEEL ASSEMBLY - QD FIG.NO.17A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
4A P1090210 ADJUSTER ASSY CHAIN RH NEW 1 1 1 1 **
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

7A P1110290 SPACER REAR AXLE RH 1 1

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 PANEL 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
22A P3110080 WHEEL RIM 1.5 x 16 NEW 1 1 1 1 1
** - REF KIT & KIT CONTENTS
FIG.No.17A
REAR WHEEL ASSY - QD
13
14
15
2
4 5
6
7
3
11
10
12
27
29
28
37
30
31
33
34
35
38
32
39 5 6
41
8
9
1
16
20
19
22
21
23
26
24
25
36
40
17
18

REAR WHEEL ASSEMBLY - QD FIG.NO.17A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
23 411005000 NIPPLE DIA2.98 36 36 36
23A N3110200 NIPPLE DIA3.5 NEW 36 36 36 36 36
24 F113178 SPOKE REAR WHEEL INNER 18 18 18
24A P3110050 SPOKE REAR WHEEL INNER NEW 18 18 18 18 18
25 F113188 SPOKE REAR WHEEL OUTER 18 18 18
25A P3110060 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 **
39A P1090200 ADJUSTER ASSY. CHAIN LH NEW 1 1 1 1
40 J200030 HEX NUT M18 1 1 1 1 1
41 3184058 AXLE COMP. REAR 1 1 1
41A P3110230 AXLE 12 x 244 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
FIG.No.17A
REAR WHEEL ASSY - QD
13
14
15
2
4 5
6
7
3
11
10
12
27
29
28
37
30
31
33
34
35
38
32
39 5 6
41
8
9
1
16
20
19
22
21
23
26
24
25
36
40
17
18
FRAME & STAND ASSEMBLY FIG.NO.18
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P3120390 FRAME ASSY. 1 1 1 1 P1320200
1A J120010 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 1
7B J120680 STAND COMP. 1
8 409115000 STAND SPRING 1 1 1 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
11A F126650 CUSHION STAND 1 1 1
12 0330028 SPLIT PIN 1 1 1 1
13 P090370 SPACER SILENT BLOCK 1 1 1 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
FRAME & STAND ASSEMBLY
FRAME & STAND ASSEMBLY FIG.NO.18
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
21 P121630 LICENCE PLATE COMPLETE 1 1 1 1
21A D127420 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 1
36 P3120180 COVER COMP. FRAME 2 #
37 P3300500 PLOTFORM KIT 1 1 1 1
38 420462700 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
FRAME & STAND ASSEMBLY
SEAT ASSEMBLY FIG.NO.19

NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P130050 SEAT ASSY. 1 1
1A J130060 SEAT ASSY. 1

1B P3130130 SEAT COMP. FRONT 1 1
1C P3130020 SEAT COMP. REAR 1 1
2 P130079 REXIN ASSY. 1 1
2A J130079 REXIN ASSY. 1
2B P3130099 REXIN ASSY FRONT 1 1
2C P3130129 SEAT REXINE REAR 1 1
3 P130069 SEAT FOAM 1 1
3A -- SEAT FOAM 1 N.S
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 1
7B P3130010 SEAT BASE FRONT 1 1
7C P3130030 SEAT BASE REAR 1 1
8 0335578 WASHER 6.5x13x10 6 10 3 6 10
9 409047000 NYLON LOCK NUT 2 2
10 P120560 HANDLE COMP. PILLION 1 1
10A J120440 HANDLE COMP PILLION 1
10B P1120080 HANDLE COMP. PILLION NEW 1
11 420464700 HEX SCREW M6x16 2 6 2 2 6
N.S - NOT SERVICED
FIG.No.19
SEAT ASSYEMBLY
SEAT ASSEMBLY FIG.NO.19

NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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) 1 1 1

18 J130150 STOPPER COMP. SEAT 1
19 K130130 LATCH FOR SEAT LOCK 1 1 1
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
FIG.No.19
SEAT ASSYEMBLY
FUELTANK & TOOL BOX ASSEMBLY FIG.NO.20
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 --- TANK COMP. FUEL 1 1 1 1 Ref. P. No.
COLOUR MAT.
1A --- TANK COMP. FUEL 1 "
2 P140230 COVER FUEL TANK 1 1 1 1
3 -- SEALING RING 1 1 N.S
4 414004000 TANK CAP ASSY. 1 1
4A T140160 TANK CAP ASSY. 1 1 1
5 420001700 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 Ref P. No.
COLOUR MAT.
8A -- TAPE SET XL SUPER/ HD 1 1
"
8B -- TAP SET SPORT 1
"
9 P210040 COVER CONTROL CABLE 1 1 1 1
9A J210010 COVER CONTROL CABLE 1
10 7130140 WASHER 1 1 3 1 1
11 P200310 HEX SCREW M6x12 1 1 3 1 1
12 414074000 SEALING WASHER 1 1 1 1
13 P140080 FUEL COCK ASSY. (OLD) 1 1 1 1
13A P140320 FUEL COCK ASSY - M14 1 1 1 1 N.I
13B T140250 FUEL COCK ASSY. 1
14 P140100 KNOB FUEL COCK 1 1 1 1
14A T140240 KNOB FUEL COCK 1
15 P200390 CHEESE HD SCREW M3x30 1 1 1 1
15A T200050 SLOTTED CHEESE HD SCREW M3x10 1
16 3020516 CLAMP FUEL LINE 4 4 4 4 4
N.I - NOT ILLUSTRATED N.S - NOT SERVICE
SUPER
FIG.No.20
FUELTANK & TOOL BOX ASSY.
FUELTANK & TOOL BOX ASSEMBLY FIG.NO. 20
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
17 P140390 HOSE FUEL UPPER 335L 1 1 1 1
17A J140120 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 Ref P.No.
COLOUR MAT.
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
* 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.
SUPER
FIG.No.20
FUELTANK & TOOL BOX ASSY.
MUDGUARD, COVER FRAME & CHAIN GUARD FIG.NO. 21
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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 Ref P.No.
COLOUR MAT.
4 410019000 STABILISER PAD 1 1 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
9 --- FENDER FRONT 1 1 1 1 Ref P.No.
COLOUR MAT.
10 P100570 CABLE GUIDE SPEEDO 2 2 2 2
11 F300060 MUD FLAP 1 1 1 1
12 --- STAY MUDGUARD 1 1 1 1 Ref P.No.
COLOUR MAT.
13 P121060 PAD FENDER REAR 1 1 1 1
14 --- FENDER REAR 1 1 1 1 Ref P.No.
COLOUR MAT.
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 8 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 Ref P.No.
COLOUR MAT.
21A -- COVER FRAME RH NEW 1 1 "
22 -- COVER FRAME LH 1 1
22A -- COVER FRAME LH NEW 1 1
23 P090120 CHAIN COVER 1 1
23A P3090270 CHAIN COVER NEW 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
MUDGUARD, COVER FRAME & CHAIN GUARD FIG.NO.21
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
24 7130140 WASHER 4 4 4 4
25 0332275 CRR PAN HEAD SCREW M6x16 8
26 7130140 WASHER 8
27 --- COVER FRAME COMP. RH 1 Ref P.No.
COLOUR MAT.
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 Ref P.No.
COLOUR MAT.
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
* 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
HANDLE BAR, SPEEDOMETER ASSY. FIG.NO.22
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P150380 SPEEDOMETER ASSY. 1 1
1A P1150030 SPEEDOMETER ASSY. 1 1
2 5227360 SPEEDOMETER BULB 12V, 3.4W 1 1 2 2
2A 419113000 HOLDER SPEEDOMETER BULB 1 1
3 P150110 HOUSING INSTRUMENT PANEL 1 1
3A P1150050 HOUSING INSTRUMENT PANEL NEW 1 1
4 P150120 COVER INSTRUMENT PANEL 1 1
4A B1150099 COVER INSTRUMENT PANEL 1 1
5 F160610 ASSY. SWITCH IGNITION 1
5A P3160060 ASSY. SWITCH IGNITION 1 1
5B P1160130 ASSY. SWITCH IGNITION (2 WAY ) 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
9A P1150090 HANDLE BAR NEW 1 1
9B J150260 HANDLE BAR COMP. 1
10 P150250 CLAMP BOLT 2 2 2 2
11 415005700 SUPPORT 2 2 2 2
12 P150310 BRKT SPEEDO MOUNTING 1 1
12A P1150010 BRKT SPEEDO PANEL MTG. 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
HANDLE BAR, SPEEDOMETER ASSY.
HANDLE BAR, SPEEDOMETER ASSY. FIG.NO. 22
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
20 P170090 INNER FRONT BRAKE CABLE 1 1 1 1
20A J170040 INNER BRAKE FRONT CABLE 1
21 P170070 CABLE ASSY. BRAKE FRONT 1 1
21A J170030 CABLE ASSY. BRAKE FRONT 1
21B P170120 CABLE ASSY. BRAKE FRONT 1 1
22 432009000 NIPPLE BRAKE ASSY. 1 1 1 1 1
23 P170020 CABLE ASSY. BRAKE REAR 1 1 1 1
23A J170130 CABLE ASSY. BRAKE REAR 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 1
27B P1170040 CABLE ASSY. CHOKE 1 1
28 P320590 INNER SPEEDO CABLE 1 1 1 1
28A J320010 INNER SPEEDO CABLE 1
29 P170080 CABLE ASSY. SPEEDO 1 1 1 1
29A J170120 CABLE ASSY. SPEEDO 1
30 419136000 CLIP CABLE 2 2 2 2
31 J150180 SPEEDOMETER ASSY. 1
32 J200080 PUNCHED WASHER 12.5x36.8x2 2
33 J150280 CUSHION UPPER 2
HANDLE BAR, SPEEDOMETER ASSY.
HANDLE BAR, SPEEDOMETER ASSY. FIG.NO. 22
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
HANDLE BAR, SPEEDOMETER ASSY.
CONTROL LEVER ASSEMBLY LH FIG.NO. 23
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P150100 LEVER ASSY. CONTROL LH 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
2 P150400 CASE UPPER LH 1 1
2A P1150130 CASE UPPER LH 1 1
3 P150410 CASE UNDER LH 1 1 1 1
3A P1150160 CASE UNDER LH 1 1
4 P150450 BRAKE LEVER LH - NEW 1 1
4A P1150070 BRAKE LEVER LH 1 1
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
10 3160725 SET SCREW CHOKE LEVER 1 1
11 0332458 SCREW 1 1 1 1
12 P160420 CORD SET 1
12A P1160140 CORD SET 1 1 1
13 P150330 GRIP LH 1 1 1 1
14 K321000 SET, BRAKE LIGHT SWITCH FR 1 1
14A P1160150 SWITCH ASSY. FRONT STOP LAMP 1 1 N.I
15 1324570 SWITCH REPAIR KIT LH 1 1 N.I
N.I - NOT ILLUSTRATED
FIG.No.23
CONTROL LEVER ASSY. LH
HORN
HORN
HORN
CONTROL LEVER ASSEMBLY RH FIG.NO. 23A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P150020 LEVER ASSY. CONTROL RH 1
1A P150430 LEVER ASSY. CONTROL RH 1
1B P1150110 LEVER ASSY. CONTROL RH 1 1
REPLACES
P3150080
2 P150040 CASE UPPER RH 1
2A 1166050 CASE UPPER RH 1 N.I
2B P1150120 CASE RH UPPER 1 1
3 P150050 CASE UNDER CON. LEVER RH 1
3A 1166060 CASE UNDER CON. LEVER RH 1 N.I
3B P1150170 CASE UNDER RH 1 1
4 0254096 PIECE THROTTLE CABLE END 1 1 1 1
5 1166010 LEVER BRAKE RH 1 1
5A P1150080 LEVER BRAKE RH 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 1
12 1324560 SWITCH REPAIR KIT RH 1 1 N.I
N.I - NOT ILLUSTRATED
FIG.No.23A
CONTROL LEVER ASSY. RH
CONTROL LEVER ASSY LH, RH (SPORT) FIG.NO.23B
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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
CONTROL LEVER ASSY LH,RH (SPORT)
CONTROL LEVER ASSY LH, RH (SPORT) FIG.NO.23B
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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 N.I
N.I - NOT ILLUSTRATED
CONTROL LEVER ASSY LH,RH (SPORT)
HEAD LAMP & TAIL LAMP ASSY. FIG.NO.24
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 P160440 HEAD LAMP ASSY. 12V 1
1A P3160030 HEAD LAMP ASSY. 12V 1 1 1 1 REPLACES
P1160030
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
6 --- RUBBER BUSH ASSY. 2 2
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
22A P160520 COMBINED REGULATOR 1 1
23 P160390 WIRING HARNESS 1
N .I - NOT ILLUSTRATED
HEAD LAMP & TAIL LAMP ASSY.
HEAD LAMP & TAIL LAMP ASSY. FIG.NO. 24
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
23A P160480 WIRING HARNESS - HD 1 N.I
23B P1160070 WIRING HARNESS 1 1 "
23C P1160120 WIRING HARNESS 1 1 "
24 P160350 LAMP ASSY REAR COMP. 12V 1 1
24A P1160040 LAMP ASSY. REAR COMP. 12V 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.
HEAD LAMP & TAIL LAMP ASSY. FIG.NO. 24
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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 N.I
43A P3210010 LOCK SET ASSY. 1 "
43B P1210630 LOCK SET ASSY. 1 "
43C P3210160 LOCK SET ASSY. 1 "
43D P3210220 LOCK SET ASSY. (2 STEP INGITION) 1 "
43E P3210210 LOCK SET ASSY. (2 STEP INGITION) 1 "
HEAD LAMP & TAIL LAMP ASSY.
HEAD LAMP & TAIL LAMP ASSY. (SPORT) FIG.NO. 24A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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 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.
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)
HEAD LAMP & TAIL LAMP ASSY. (SPORT) FIG.NO.24A
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. 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 N.I
52 J160250 REFLECTOR TURN SIGNAL LH, RH 2
N.I - NOT ILLUSTRATED
HEAD LAMP & TAIL LAMP ASSY (SPORT)
TOOL KIT FIG.NO. 25
NO. OFF
REF PART DESCRIPTION XL XLSUPER TVS XLSUPER XLSUPER REMARKS
NO. NO. SUPER HD SPORT UPG. HD UPG.
1 J210130 TOOL KIT SET 1 1 1 1 1
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
DATE : 03.03.2010
TOOL KIT

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