Thunderbird 500 350 Parts Catalogue

1
Foreword
We take pleasure in releasing THUNDERBIRD 350 & THUNDERBIRD 500 Spare Parts
Catalogue.
The Catalogue has been specially designed for identification of correct part number
to help in ordering Spare Parts, Special Tools and Service Publications
from the company.
The Royal Enfield Spare Parts are manufactured under stringent quality control to
ensure ultimate riding experience. It is therefore important to use only
Royal Enfield Genuine Spares.
The illustration of the various parts are not to scale and is intended to serve
only as a means of identification of the component for its shape and relative
location in its respective assembly.
Due to continuous improvements in the motorcycle, the part nos and / or
illustrations are subject to change without prior notice. However the changes will
be intimated through technical Service Bulletin subsequently and periodically which
must be updated by you in the catalogue at your end.
The part numbers and description were correct at the time of printing. While
extreme care is taken in publishing this catalogue. We shall not be held
responsible for any errors/omissions or wrong interpretations and consequent loss
of any nature due to any of the above.as
For enquiry, suggestions or feedback may write to us ...
SERVICE HEADQUARTERS :
ROYAL ENFIELD
(A Unit of Eicher Motors Limited)
Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. India.
Tel : +91-44-4223 0400, Fax : +91-44-4201 1719. Website : www.royalenfield.com
E-mail : customerservice@royalenfield.com
“ © Copyright 2012 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 .”
Developed & Printed at Jiju Graphics  98400 57140
Part No. 888189/a , Version 1.01 / TRAB / Qty. 300 / Apr. 2013
2
00-00 General Information

For easy reference and quick identification, the parts are grouped into relevant
categories. Details are given in the illustrated Group index. Kindly follow
the below tips on usage of this catalogue

ILLUSTRATION
Illustration given with this catalogue helps in identifying the shape of part in
its relative assembly.
02-30 Air Filter (500cc)

Alpha-Numeric Key
No. for Assembly
Group No.
A1
10
A1
Key Nos.
1 to 14
A2
Key Nos.
2 to 5, 7, 8, 13,
(Qty. 4 Nos. 1)
A3
Key Nos.
4&5
Key No. Which make up

the Assembly
14
13
Numeric Key No.
6
3


PART NUMBER LIST

1
PART NUMBER
KEY
Thunderbird
Thunderbird
No.
350
1.
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
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.
4

2.
PART NUMBER
The Part number of the individual item, kit OR assembly is given in this column for
unique identification. The parts for which part numbers
are not given, are not individually serviced. The applicable part numbers are shown
as per Thunderbird 350 & 500 models. The numbers
which are mentioned in Remarks column are for reference only along with Service
Bulletin Index.
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.
5.
REFERENCE
Parts Revision / Modifications related to Technical Service Bulletin Number
mentioned in this column. The part numbers which are
displayed in this column are meant for reference only (Belongs to Kits Child Part
or Not Served Items).
6.
REMARKS
Updated / Modified or Child / alternate Part Numbers is mentioned for reference
purpose. However Service Bulletin are issued from
SHQ for updating the catalogue. Kindly note, this catalogue is updated upto SB /
Tech / 687.
7.
M.O.Q.
Number of Items Minimum Quantity to be ordered to our Spare Parts department (SPD).
So that they can serve you minimum packed /
ordered quantity. It may varies from item to item by Price, Size or Shape as
applicable.
5
Contents
Group No.
Description
Page No.
Group No.
Description
Page No.
00-00
GENERAL
INFORMATION .......................................................................
............... 2
05-00
REAR SHOCK ABSORBER & CENTER STAND ASSEMBLY ............................. 111
00-10
GROUP INDEX
PICTORIAL .........................................................................
........... 6
05-10
SWING ARM ASSEMBLY & REAR CHAIN GUARD ...........................................

113
01-10
ENGINE ............................................................................
.................................... 13
05-20
REAR
WHEEL .............................................................................
....................... 117
01-20
ENGINE COVER
RH ................................................................................
............. 15
05-30
REAR MASTER CYLINDER ASSEMBLY-

BBI .................................................... 121
01-30
CRANK CASE RH - COVER
SIDE ...................................................................... 21
05-40
REAR CALIPER ASSEMBLY-

BBI ...................................................................... 125
01-40
CYLINDER & HEAD

ASSEMBLY .........................................................................
29
05-50
CRADLE ASSEMBLY
RH ................................................................................
... 129
01-50
ENGINE COVER
LH ................................................................................
............. 35
05-60
REAR
MUDGUARD ..........................................................................
.................. 131
01-60
CRANK CASE LH - COVER

SIDE ........................................................................ 37
05-70
TAIL LAMP BRACKET, TRAFFICATOR & SAREE GUARD ............................... 133
01-70
CLUTCH ............................................................................
................................... 41
06-00
CRADLE ASSEMBLY LH & PILLION FOOT REST ASSEMBLY ......................... 135
01-80
CRANK CASE
LH ................................................................................
................ 43
06-10
SIDE PANEL LH &
RH ................................................................................
........ 139
01-90
CRANK CASE
RH ................................................................................
................ 45
06-20
SIDE DECOR LH &

RH ................................................................................
....... 143
01-100
GEAR TRAIN ASSEMBLY (OLD

TYPE) .............................................................. 51
06-30
FRAME .............................................................................
.................................. 145
01-110
GEAR TRAIN ASSEMBLY (ANTI SKIP MECHANISM) .........................................

55
07-00
BATTERY, BATTERY CARRIER AND HARNESS ..............................................

151
02-00
CV CARBURETOR (BS
29) ...............................................................................
. 59
07-10
HEAD
LAMP ..............................................................................
......................... 153
02-10
EFI COMPONENTS IN CYLINDER

HEAD ............................................................. 65
07-20
TAIL
LAMP ..............................................................................
........................... 155
02-20
AIR FILTER
(350CC) ...........................................................................
................. 69
07-30
INSTRUMENTAL
CLUSTER ...........................................................................
..... 157
02-30
AIR FILTER
(550CC) ...........................................................................
................. 71
07-40
SWITCHES, HORN &

RELAYS ..........................................................................
159
02-40
SILENCER & EXHAUST

PIPE ..............................................................................
. 73
07-50
TCI & EFI IGNITION

COMPONENTS ................................................................... 163
03-00
HANDLE BAR &

CONTROLS ..........................................................................
.... 75
07-60
TRAFFICATOR LIGHTS, TOOLS & FIRST AID

KIT ............................................ 167
03-10
CONTROL
CABLES ............................................................................
................. 79
08-00
SPECIAL TOOLS LIST - A

(COMMON) ............................................................. 169
03-20
FRONT MASTER CYLINDER ASSEMBLY -
BBI .................................................. 81
08-10
03-30
FRONT CALIPER ASSEMBLY -

BBI .................................................................... 85
SPECIAL TOOLS LIST - B (COMMON

& ........................................................... 171
(EXCL. FOR THUNDERBIRD 350 & 500 MODELS)
03-40
HEAD BRACKET & STEERING

STEM .................................................................. 89
09-00
WALL CHARTS LIST - A

(UCE) ........................................................................ 173
03-50
FRONT FORK (GIL - DIA

41) ...............................................................................
93
09-10
WALL CHARTS LIST - B

(DOMESTIC) ............................................................. 175
03-60
FRONT
MUDGUARD ..........................................................................
.................. 97
09-20
ALL UCE SERVICE PUBLICATION LIST - A (DOMESTIC) .................................

177
03-70
FRONT
WHEEL .............................................................................
....................... 99
09-30
ALL UCE SERVICE PUBLICATION LIST - B (DOMESTIC) ................................

179
04-00
FUEL
TANK ..............................................................................
.......................... 103
09-40
AFTER MARKET
PARTS .............................................................................
...... 181
04-10
SEAT
ASSEMBLY ..........................................................................
.................... 107
10-00
PART NUMBER
INDEX .............................................................................
.......... 184
04-20
SEAT SUB
FRAME .............................................................................
................ 109
11-00
SERVICE BULLETINS CHECKLIST FOR PARTS CATALOGUE UPDATE .......... 191

6
00-10 Group Index - Pictorial

01-10 Engine
01-30 Crankcase RH - Cover Side
01-20 Engine Cover RH

Page
12
01-40 Cylinder & Head assembly
Page
20
Page
14
01-60 Crankcase LH - Coverside
01-50 Engine Cover LH

Page
28
Page
34
Page
36
LOCTITE
01-70 Clutch
01-80 Crankcase LH
Page
40
01-90 Crankcase RH
Page
42
LOCTITE
Page
44
7

01-100 Gear Train Assembly (Old Type)
01-110 Gear Train Assembly (Anti Skip Mechanism)

Page
50
Page
54
03-10 Control Cables
03-00 Handle Bar & Controls

Page
72
Page
70
Page
68
Page
64
02-40 Silencer & Exhaust Pipe
Page
58
02-10 EFI Components in Cylinder Head
02-00 CV Carburetor (BS 29)
Page
74
Page
78
8

03-20 Front Master Cylinder Assembly (BBI)
03-30 Front Caliper Assembly (BBI)
03-40 Head Bracket & Steering Stem

Page
84
Page
80
03-60 Front Mudguard
03-50 Front Fork (GIL-Dia 41)
03-70 Front Wheel

Page
96
Page
92
04-10 Seat Assembly
04-00 Fuel Tank

Page
102
Page
88
Page
98
04-20 Seat Sub Frame

Page
106
Page
108
9

05-00 Rear Shock Absorber & Center Stand Assy.
05-10 Swing Arm Assembly & Rear Chain Guard
Page
110
Page
112
Page
120
05-60 Rear mudguard

Page
130
Page
116
05-50 Cradle Assembly RH
05-40 Rear Caliper Assembly
05-30 Rear Master Cylinder Assembly
05-20 Rear Wheel
Page
124
Page
128
05-70 Tail Lamp Bracket, Trafficator & Saree Guard
06-00 Cradle Assembly LH & Pillion Foot Rest Assy
Page
132
Page
134
10

06-30 Frame
06-20 Side Decor LH & RH
06-10 Side Panel LH & RH
07-20 Tail Lamp
07-10 Head Lamp
07-00 Battery, Battery Carrier & Harness
Page
152
Page
150
07-30 Instrumental Cluster
Page
154
07-50 TCI & EFI Ignition Components
07-40 Switches, Horn & Relays

Page
156
Page
144
Page
142
Page
138
Page
158
Page
162
11

07-60 Trafficator Lights, Tools & First Aid Kit
08-00 Special Tools List - A (Common)
Page
166
09-00 Wall Charts List - A (UCE)
Page
168
09-10 Wall Charts List - B (Domestic)

Page
172
09-30 All UCE Models Service Publication List - B

(Domestic)
Page
178
Page
174
09-40 After Market Parts
08-10 Special Tools List - B (Common &

(Exclusive for Thunderbird 350 & 500 Models)
Page
170
09-20 All UCE Models Service Publication List - A

(Domestic)
Page
176
10-00 Part Number Index

Page
180
Part Number Page No. Key No.
Page
184
11-00 SB Checklist for

Parts Catalogue Update
SB
NO.
Page
191
RECEIVED UPDATED DATE & SIGN OF

DATE
BY
PARTS
INCHARGE
12
01-10 Engine
5&6
3&4
2
13
01-10 Engine
PART NUMBER
KEY
Thunderbird Thunderbird
No.
350
500
1
869033
869032
888207
888208
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Unit Construction Engine with Electric Starter - 350
Matt Black-Powder Coated
Unit Construction Engine with Electric Starter - 500
Cr. Case Assy. Black LH & RH with Bearings - 350
Cr. Case Assy. Black LH & RH with Bearings - 350 (Anti Skip Mechanism)
Cr. Case Assy. Black LH & RH with Bearings - 500
1
1
Cr. Case Assy. Black LH & RH with Bearings - 500 (Anti Skip Mechanism)
390066
390066
15W 50 API SL Engine Oil (210 Ltrs.)
Recommended oil for replacement
390067
390067
15W 50 API SL Engine Oil (50 Ltrs.)
390068
390068
15W 50 API SL Engine Oil (2.50 Ltrs.)
10
390069
390069
15W 50 API SL Engine Oil (1.0 Ltr.)
Recommended oil for Top-up
20
1
14

44
A1
45
Key No’s
1
All Except 5, 6, 7,
32, 33 & 47
41
Key No’s
34 to 40
37
36
34 35
A3
(Qty. 3 Nos. 11),
(Qty. 2 Nos. 21 & 25),
(Qty. 7 Nos. 23)
22
33
32
A4
A5
Key No’s
12
13
14
15
16
17
48
48
Key No’s
18
28
30
10
12,13,14,15,16 & 17
29
31
A4
1, 44 & 45
40
39
38
A2
Key No’s
42
43
19
20
27
26
19
21
22
1
23
11
47
46
24
25
15

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
A1
869005
869005
RH Cover Assembly Complete - Black
A2
888101
888101
Kick Boss Repair Kit
A3
888112
888112
Bolt Reapir Kit RH Crankcase Cover
A4
888169
888169
Cap, Oil Filter Sub Assembly - Black
1
Black
A5
869006
869006
Cover RH Sub Assembly - Black
Served in Kit Ref. A5
Cover RH - Black
MOQ
Nos.
869007
570183/D
570183/D
Jet, Crankshaft RH
20
500622/B
500622/B
Oil Seal, Crank Feed 24 x 10 x 7
1
4
550028
550028
Circlip 24N
10
570013
570013
Pulser Coil Fixing Screw (Hex Socket Head Cap Screw M5X16)
20
550095
550095
Hex Socket Head Cap Screw M6X 30
10
570416/I
570416/I
Gasket - Cover RH
570425
570425
Hex. Screw, M5 X 12
6
50
570426/H
570426/H
Gasket, Cover Plate
10
570424/D
570424/D
Cover Plate, Breather Chamber
11
572011/A
572011/A
Hex Flange Bolt M6 X 1 X 20
40
Cap, Oil Filter (Matt Black-Powder Coated)
12
869008
13
572014/A
572014/A
‘O’ - Ring, Filter Cap
6
14
500637/B
500637/B
Spring
20
15
500617/A
500617/A
Washer
20
16
500621/A
500621/A
‘O’ - Ring
20
17
571201/A
571201/A
Screw Spring Cap
10
18
500616/A
500616/A
Spring Cap
1
10
16

44
A1
45
Key No’s
1
All Except 5, 6, 7,
32, 33 & 47
41
Key No’s
34 to 40
37
36
34 35
A3
(Qty. 3 Nos. 11),
(Qty. 2 Nos. 21 & 25),
(Qty. 7 Nos. 23)
22
33
32
A4
A5
Key No’s
12
13
14
15
16
17
48
48
Key No’s
18
28
30
10
12,13,14,15,16 & 17
29
31
A4
1, 44 & 45
40
39
38
A2
Key No’s
42
43
19
20
27
26
19
21
22
1
23
11
47
46
24
25
17

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
19
500619/A
500619/A
‘O’ - Ring
20
20
500613/A
500613/A
Element - Oil Filter
21
572019/A
572019/A
Hex. Flange Bolt M6X1X45
10
22
570241
570241
Oil Seal Kick Starter, g20 x 27 x 5 double lip
10
23
572017/A
572017/A
10
24
570059/C
570059/C
Oil Level Window
25
572016/A
572016/A
26
144846/A
144846/A
Washer, Inspection Screw
14
27
570176/D
570176/D
Inspection Screw, Ignition Timing
28
146459/A
146459/A
‘O’ - Ring
20
29
570467/A
570467/A
Oil Filler Cap, Metal
30
570155
570155
Sealing Washer
20
31
573968/A
573968/A
Bolt Breather
32
573964/A
573964/A
Clip Breather Pipe
20
Breather Pipe
581084/C
Breather Pipe
141051
Hex Nut M8
35
Circlip 10 - IS 3075
36
Ball Dia 6.35 (1/4”)
37
33
34
570286/C
141051
Served in Kit Ref. Key 43
40
570259/D
30
1
140201
50
Boss, Kick Start Crank
570814/C
38
Hex. Bolt M8X40
111914
Served in Kit Ref. Key 43
20
39
Spring - Kick Crank
570257/C
40
Pin - Kick Start Crank
570815/B

18

44
A1
45
Key No’s
1
All Except 5, 6, 7,
32, 33 & 47
41
Key No’s
34 to 40
37
36
34 35
A3
(Qty. 3 Nos. 11),
(Qty. 2 Nos. 21 & 25),
(Qty. 7 Nos. 23)
22
33
32
A4
A5
Key No’s
12
13
14
15
16
17
48
48
Key No’s
18
28
30
10
12,13,14,15,16 & 17
29
31
A4
1, 44 & 45
40
39
38
A2
Key No’s
42
43
19
20
27
26
19
21
22
1
23
11
47
46
24
25
19

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
41
570808/D
570808/D
Lever Kick Start Crank
Kit Ref. Key No. 43
42
145157/C
145157/C
Sleeve Kick Start Lever
Alt. No. 146642/A
43
570807/C
570807/C
Kick Start Crank Assembly
1
44
570723/A
570723/A
Plug Dummy
25
45
570182/B
570182/B
Plug ID 2.3 mm Restrictor - LEE Plug
20
46
144636/A
144636/A
Copper Washer
20
47
570604/A
570604/A
Circlip Oil Window
48
570298/A
570298/A
Dowel Pin
20
20

A1
350cc
A1 (350cc)
Key No’s
2, 3, 4, 5 & 6
0.
3
6
A1 (500cc)
Key No’s
2 to 4
A4
Key No’s
46 & 48
10
500cc
A1
51
56
3
49
52
0.
57
W
7K c c
0
5
3
40
45
46
44
47
43
11
10
53
50
W
9K c c
0
0
5
41
48
12
42
40
A5, A6, A7
13
14
15
54
55
16
37
Key No’s
Each Qty 2 Nos.
38, 39, 41 & 42
38
34
17
A2
39
19
26
27
18
20
36
35
A3
33
29
29
32
31 30
28
33
32
31
28
21
30
23
25
24
22
21

PART NUMBER
KEY
No.
350
500
A1
570048/F
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Oil Pump Assembly
571047/D
Oil Pump Assembly
A2
570309/B
570309/B
Cam Gear Assembly - Exhaust with Decompressor Assembly
Served in Kit Assy.
A3
570600/A
570600/A
Gear Changer Assembly
1
Served in Kit Assy.
A4
888170
888170
Cover Kick Start with Oil Seal
Black Colour
A5
888179
888179
Eccentric Cam Spindle Repair Kit - STD
A6
888180
888180
Eccentric Cam Spindle Repair Kit - 0.1mm oversize
A7
888181
888181
Eccentric Cam Spindle Repair Kit - 0.2mm oversize
Hex. Socket Head Cap Screw M4 X 30
4
20
571155/A
20
570051/A
570052
570052
Circlip - Oil Pump
14
571166/B
571166/B
Pump Drive Pinion
570293/A
570293/A
‘O’ Ring, Oil Pump Outlet
‘O’ Ring, Oil Pump Base
10
Gasket, Oil Pump
1
10
570292/A
‘O’ Ring, Oil Pump Inlet
10
573928/A
Cover Starter Motor (350cc) Black
Cover Starter Motor (500cc) Black
Button Head Screw M4 X 10-SS
50
Hex. Socket Button Head Screw M5 X 12
50
Mounting Allen Screw
14
Hex. Socket Head Cap Screw M6x60
10
5
6
7
570294/A
571115/C
573929/A
570813/A
570300/B
570302/A
570303/A
22

A1
350cc
A1 (350cc)
Key No’s
2, 3, 4, 5 & 6
0.
3
6
A1 (500cc)
Key No’s
2 to 4
A4
Key No’s
46 & 48
10
500cc
A1
51
56
3
49
52
0.
57
W
7K c c
0
5
3
40
45
46
44
47
43
11
10
53
50
W
9K c c
0
0
5
41
48
12
42
40
A5, A6, A7
13
14
15
54
55
16
37
Key No’s
Each Qty 2 Nos.
38, 39, 41 & 42
38
34
17
A2
39
19
26
27
18
20
36
35
A3
33
29
29
32
31 30
28
33
32
31
28
21
30
23
25
24
22
23

PART NUMBER
KEY
No.
350
500
QTY. REFERENCE
REMARKS
MOQ
Nos.
Starter Motor 0.7KW
573992/A
Starter Motor 0.9KW
570181/B
570181/B
Restrictor (Lee Plug 1.8 MM) - RCC
20
570102/D
570102/D
Plug dummy hole
25
570723/A
570723/A
Dummy Plug AVDEL Dia 7 X10 L
4
25
13
570304/B
570304/B
Hex. Socket Head Cap Screw, M6 X 12
50
14
869020
869020
Pivot Bearing, Rocker Shaft Upper Matt Black-Powder Coated
15
570234
570234
‘O’ Ring Black Nitrile Rubber
10
16
550072/B
550072/B
Spring
10
17
570227/F
570227/F
Spacer
5
18
550256/A
550256/A
‘O’ Ring
25
19
570229/D
570229/D
Stop Pin
25
20
570230/F
570230/F
Spring, Gear Change Striker
10
21
570235/E
570235/E
Dowel, Lower Pivot Bearing
50
22
570219/F
570219/F
Assembly, Gear Lever Shaft
1
1
23
570231/H
570231/H
Pivot Bearing, Rocker Shaft Bottom
24
570184/B
570184/B
Spacer - Shaft, Gear Lever
20
25
570233
570233
14
Tappet Door Matt Black-Powder Coated
Alt. No. 570817/B
869031
Tappet Door Matt Black-Powder Coated
Alt. No. 572305/B
570198/C
CSK Socket Head Screw M5 X 0.8 X 12

4
Fly Wheel Magneto Assembly (3 Phase TCI)
Dia M 5.5 MTG Holes
Fly Wheel Magneto Assembly (EFI)
Dia M 5.5 MTG Holes
10
11
12
26
27
28
573993/A
DESCRIPTION
869011
570198/C
570866/A
570862/A
Alt. No. 570228/G
20
24

A1
350cc
A1 (350cc)
Key No’s
2, 3, 4, 5 & 6
0.
3
6
A1 (500cc)
Key No’s
2 to 4
A4
Key No’s
46 & 48
10
500cc
A1
51
56
3
49
52
0.
57
W
7K c c
0
5
3
40
45
46
44
47
43
11
10
53
50
W
9K c c
0
0
5
41
48
12
42
40
A5, A6, A7
13
14
15
54
55
16
37
Key No’s
Each Qty 2 Nos.
38, 39, 41 & 42
38
34
17
A2
39
19
26
27
18
20
36
35
A3
33
29
29
32
31 30
28
33
32
31
28
21
30
23
25
24
22
25

PART NUMBER
KEY
No.
350
500
29
30
592237/A
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
Rotor and Reluctor Assembly (Olive Green)
Rotor and Reluctor Assembly - 24T (Olive Green)
N.S.
Stator and Pulser Coil Assembly (ES) - 3 Phase - 350cc
Dia M5.5 MTG Holes
570863/A
Stator and Pulser Coil Assembly (ES) - 3 Phase - 500cc
Dia M5.5 MTG Holes
571062/B
570867/A
31
502070/A
502070/A
Magneto Key
32
586008/A
586008/A
Plain Washer
33
550025
550025
Hex. Nut M12 X 1.25
10
34
570421/A
570421/A
10
35
570132/A
570132/A
10
36
570044/J
570044/J
Cam Steady Plate
37
570298/A
570298/A
Dowel 6 mm
10
38
570100/B
570100/B
Nut - Cam Spindle
10
39
570280/B
570280/B
Shim, Cam Gear
20
40
570298/A
570298/A
Dowel Pin
10
570039/D
570039/D
Cam Spindle Adjustable (Standard Size)
Served in Kit, Ref. A5
570040/C
570040/C
Cam Spindle Adjustable (0.1 mm Over Size)
570041/C
570041/C
Cam Spindle Adjustable (0.2 mm Over Size)
42
570099/C
570099/C
Cam Sleeve
43
571164/A
571164/A
Cam, Gear - Inlet Sub Assembly
44
146450/B
146450/B
Spring Kick
45
145090
145090
Hex Screw M6 X 16
46
869019
869019
Cover, Kick Start Shaft - Matt Black Powder Coated
47
570300/B
570300/B
Hex Socket Pan Head Screw M5 X 12
41
20
Old No. 145708/A, 580344/A, 593023/B
14
20
1
50
26

A1
350cc
A1 (350cc)
Key No’s
2, 3, 4, 5 & 6
0.
3
6
A1 (500cc)
Key No’s
2 to 4
A4
Key No’s
46 & 48
10
500cc
A1
51
56
3
49
52
0.
57
W
7K c c
0
5
3
40
45
46
44
47
43
11
10
53
50
W
9K c c
0
0
5
41
48
12
42
40
A5, A6, A7
13
14
15
54
55
16
37
Key No’s
Each Qty 2 Nos.
38, 39, 41 & 42
38
34
17
A2
39
19
26
27
18
20
36
35
A3
33
29
29
32
31 30
28
33
32
31
28
21
30
23
25
24
22
27

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
48
570241
570241
Oil Seal Kick Starter G20 X 27 X 5 Double Lip
10
49
570246/E
570246/E
Nut, Sleeve Gear
50
570247/D
570247/D
Tab Washer
FD Sprocket 16 Teeth
1
1
571032/B
51
570809/A
52
570214/F
570214/F
Distance Piece
53
570213
570213
Oil Seal
54
144600/A
144600/A
Copper Washer
25
55
570713
570713
Hex. Socket Head Screw M8 X 1.25 X 14
1
10
570132/A
CSK Socket Head Screw M6 X 25
50
Grommet (Starter Motor Cover)
40
56
57
580286/A
28
01-40 Cylinder & Head Assembly

4
A1 (350cc)
Key No’s
(Qty. 4 Nos. 16), 15 to 19, 21,
22, (Qty. 2 Nos. 40), 41 & 42
23
43
28
6
25
A1 (500cc)
29
27
27
A2
A3
Key No’s
30 & 38
Key No’s
20 & 24
A4
A5
Key No’s
6&8
Key No’s
1&7
9
26
12
27
26
15
14
34
A10
33
16
10
15
16
13
Key No’s
(Qty. 2 Nos. 17, 18 & 40), (Qty.
4 Nos. 16), 21, 22, 41 & 42
A9
Key No’s
Key No’s Key No’s
10 & 12 13 & 14 (Qty. 2 Nos. 40),
41 & 42
30
17
11
35
18
17
A6 (350 & 500 cc)
A8
28
26
Key No’s
(A1 350cc), 43 & 44
A7
28
19
18
36
31
31
40
19
40
37
24
38
20
41
A10
Key No’s
30 & 32
42
22
21
A9
32
39
29

PART NUMBER
KEY
No.
350
500
A1
A2
A3
869046
869043
888171
888172
888003
888004
A4
888174
A5
888173
A6
888174
888173
888111
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
Cylinder Head Assembly with Valves - Black 350cc
Powder Coated
Cylinder Head Assembly with Valves - Black 500 cc
Powder Coated
1
Cylinder Barrel & Piston with Rings Assembly (350cc) - Black
Black
Cylinder Barrel & Piston with Rings Assembly (500cc) - Black
Black
Spark Plug Kit UCE 350cc Domestic
M14 & M10 Plugs
Spark Plug Kit UCE 500cc Domestic
M14 & M10 Plugs
Rocker Cover with Gasket - Exhaust - Black
Black
Rocker Cover with Gasket - Inlet - Black
Black
Valve Repair Major Kit UCE 350cc
888113
Valve Repair Major Kit UCE 500cc

1
A7
888109
888109
Rocker Bearing Set with Rocker Arm - Exhaust
A8
888110
888110
Rocker Bearing Set with Rocker Arm - Inlet
Cylinder Head Sub Assembly (Cyl. Head, Valve Guide, Valve Seats) 350cc
Cylinder Head Sub Assembly (Cyl. Head, Valve Guide, Valve Seats) 500cc
Piston Assembly with Rings (Std size) Kit 350cc
Piston Assembly with Rings (Std size) Kit 500cc
A9
A10
869047
869044
570272/A
869009
869009
Rocker Cover - Inlet - Black Powder Coated
Matt Black
573932/A
573932/A
Bolt Rocker Cover (white Passivation)
Old No. 570129/H
573906/A
573906/A
Washer Seal
573933/A
573933/A
Bolt Rocker Cover (white Passivation)
573907/A
573907/A
Washer Seal
3
869010
869010
Rocker Cover - Exhaust
572021/B
572021/B
Gasket, Rocker Cover - Inlet
572022/B
572022/B
Gasket, Rocker Cover - Exhaust
5
Old No. 571117/C
1
30
1
30

4
A1 (350cc)
Key No’s
(Qty. 4 Nos. 16), 15 to 19, 21,
22, (Qty. 2 Nos. 40), 41 & 42
23
43
28
6
25
A1 (500cc)
29
27
27
A2
A3
Key No’s
30 & 38
Key No’s
20 & 24
A4
A5
Key No’s
6&8
Key No’s
1&7
9
26
12
27
26
15
14
34
A10
33
16
10
15
16
13
Key No’s
(Qty. 2 Nos. 17, 18 & 40), (Qty.
4 Nos. 16), 21, 22, 41 & 42
A9
Key No’s
10 & 12 13 & 14 (Qty. 2 Nos. 40),
41 & 42
30
17
11
35
18
17
A6 (350 & 500 cc)
A8
28
26
Key No’s
(A1 350cc), 43 & 44
A7
28
19
18
36
31
31
40
19
40
37
24
38
20
41
A10
Key No’s
30 & 32
42
22
21
A9
32
39
31

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
570131/A
570131/A
Hex. Socket Head Cap Screw, M6 X 55 - Black
10
570533/B
570533/N
Rocker Bearing Set - Exhaust
11
570298/A
570298/A
Dowel (6 mm)
12
570535/G
570535/G
Rocker Arm - Exhaust
1
13
570536/G
570536/G
Rocker Arm - Inlet
14
570532/N
570532/N
Rocker Bearing Set-Inlet
15
500352/A
500352/A
Retainer, Spring
16
500307/A
500307/A
Split Collar
20
17
500309/B
500309/B
Valve Spring
18
500322/A
500322/A
Valve Stem Seal
19
500347/A
500347/A
Seat, Spring
20
Spark Plug (W5DC) M14
Spark Plug (WQR8DP) M14
Valve Exhaust - 350cc
Valve Exhaust - 500cc
Valve Inlet - 350cc

1
571034/C
Valve Inlet - 500cc
572318/A
Adaptor - Cylinder Head (PAV Connection)
20
21
22
500904/A
572339/A
570164/D
571035/C
570163/D
23
24
580395/A
20
1
10
Spark Plug (UR5DC) M10
572328/A
Spark Plug (UR6DC) M10
25
570478/B
570478/B
Damper Pad LH - Cylinder Head
10
26
570482/B
570482/B
Damper Pad - Cylinder Barrel Tapper
27
570480/B
570480/B
Damper Pad - Cylinder Barrel
28
570479/B
570479/B
Damper Pad RH - Cylinder Head
1
32

4
A1 (350cc)
Key No’s
(Qty. 4 Nos. 16), 15 to 19, 21,
22, (Qty. 2 Nos. 40), 41 & 42
23
43
28
6
25
A1 (500cc)
29
27
27
A2
A3
Key No’s
30 & 38
Key No’s
20 & 24
A4
A5
Key No’s
6&8
Key No’s
1&7
9
26
12
27
26
15
14
34
A10
33
16
10
15
16
13
Key No’s
(Qty. 2 Nos. 17, 18 & 40), (Qty.
4 Nos. 16), 21, 22, 41 & 42
A9
Key No’s
10 & 12 13 & 14 (Qty. 2 Nos. 40),
41 & 42
30
17
11
35
18
17
A6 (350 & 500 cc)
A8
28
26
Key No’s
(A1 350cc), 43 & 44
A7
28
19
18
36
31
31
40
19
40
37
24
38
20
41
A10
Key No’s
30 & 32
42
22
21
A9
32
39
33

PART NUMBER
KEY
No.
350
500
29
573931/A
30
31
32
573931/A
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Stud - Exhaust
10
Piston Assembly (Std size) Kit 350cc
Piston Assembly (Std size) Kit 500cc
Circlip (UCE 350)
20
Circlip 20 X 1 (UCE 500)
20
Piston Ring Set Std (350cc)

1
571109
Piston Ring Set Std (500cc)
571108
500207/A
571119/A
570273
33
570537/D
570537/D
Push Rod Assembly, Exhaust
34
570538/D
570538/D
Push Rod Assembly, Inlet
35
570192/C
MLS Gasket (Cylinder Head to Cylinder Barrel) (350cc)
571039/B
MLS Gasket (Cylinder Head to Cylinder Barrel) (500cc)
1
36
500123/A
500123/A
Dowel Pin, Inlet
10
37
500116/A
500116/A
Dowel Pin, Exhaust
20
Cylinder Barrel Assembly - 350cc
Cylinder Barrel Assembly - 500cc
Gasket (Crankcase to Cylinder Barrel)
571043/C
Gasket (Crankcase to Cylinder Barrel)
570165/C
Valve Guide UCE

2
Valve Seat Insert - Inlet (350cc)
10
Valve Seat Insert - Inlet (500cc)
10
Valve Seat Insert - Exhaust (350cc)
10
571037/B
Valve Seat Insert - Exhaust (500cc)
10
144844
Sealing Washer 16 X 20 (TC Feed Plug Washer)
38
39
40
41
42
43
869052
869049
570018/G
570165/C
570166/C
571036/B
500303/2
10
34

A1
Key Nos.
1, 3, 4,
(Qty. 11 Nos. 5),
6, 7, 8,
(Qty. 2 Nos. 12), 10
A2
11
A3
Key Nos.
3&4
10
12
A4
14
Key Nos.
6, (Qty. 11
Nos. 5)
A5
Key Nos.
3, 6, (Qty. 11
Nos. 5)
7
12
4
13
LOCT IT E
6
5
35

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
A1
869002
869002
LH Cover Assembly - Black
A2
573926/a
573926/A
Clutch Operating Lever Clevis and Lock Pin Spring Assembly
A3
869003
869003
LH Cover Sub Assembly
A4
888115
888115
Seal and Bolt Repair Kit LH Engine Cover
A5
888175
888175
Bolt, Bush & Seal Repair Kit LH Engine Cover
573925/A
573925/A
Clutch Operating Lever and Clevis Assembly
570291/A
570291/A
Lock Pin Spring, Clutch Operating Mech.
10
550061/B
550061/B
Bush
Cover, LH - Black
Powder Coated
MOQ
Nos.
1
1
869004
Served in Kit, Ref A3
572015/A
572015/A
Hex Flange Bolt M6 X 1 X 30
11
20
550661/A
550661/A
Oil Seal
502019/A
502019/A
‘O’ - Ring (Plug)
502018/B
502018/B
Oil Filler Plug
1
9
570409/F
570409/F
Clutch Cable Assembly
10
570407
570407
Oil Seal INA G 12 X 18 X 5, Clutch Operating Lever
11
570452/E
570452/E
Spring, Clutch Operating Lever
20
12
570298/A
570298/A
Dowel Pin
10
Liquid Gasket (Loctite 5699) - 30 ML (Liquid Sealent)
Gasket LH Cover
13
14
570410/F
570410/F
570278
Recommended Sealent
After Market usage
10
36
01-60 Crankcase LH - Cover Side

A1
2
4
Key No’s
31 & 32
5
6
40
26
6
39
22
36
38
37
34 35
6
33
32
A1
23
31
29
20
22
21
30
27
25
19
17
16
28
18
18
24
9
350cc
15
5
14
13
12
11
10
9
500cc
37

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
A1
592593/A
592593/A
Sprag Clutch Gear Set Assembly (Tsubaki)
570094
570094
20
570016
570016
10
869001
869001
Housing Starter Drive - Powder Coated Matt Black
570025
570025
Hex. Socket Head Cap Screw, M6 x 90
593090/C
593090/C
Nut M6 X 1, Flange Nyloc Type
22
570298/A
570298/A
Dowel (6mm)
591494/A
591494/A
Neutral Switch with Packing
Old Type
582510/A
582510/A
Neutral Switch with Packing
New Type
1
570249/G
570249/G
Collar, Mainshaft
Clutch Assembly Complete (6 Plates) - 350cc
571113/A
Clutch Assembly Complete (7 Plates) - 500cc
1
20
7
8
9
570443/C
Alt. No. 570017/K
1
10
Old No. 593090/A
30
10
10
570465/C
570465/C
Plain Washer
11
593038/D
593038/D
Hex. Nut with Nylock Insert M16 X 1.5

1
12
570442
570442
Ball Bearing 6001
13
570446/K
570446/K
Clutch Push Pad
14
570090/D
570090/D
Stud M6 X 106 L
25
15
570088/D
570088/D
Stud M6 X 168 L
10
16
144636/A
144636/A
Copper Washer (for Stud)

2
20
17
570089/D
570089/D
Stud M6 X 196 L
10
18
570030
570030
10
19
573918/A
573918/A
Auto Chain Tensioner Assembly - Pricol Powder Coated Matt Black
20
570295/A
570295/A
‘O’ Ring, Chain Tensioner Assembly
10
Old No. 560525/A
10
38

A1
2
4
Key No’s
31 & 32
5
6
40
26
6
39
22
36
38
37
34 35
6
33
32
A1
23
31
29
20
22
21
30
27
25
19
17
16
28
18
18
24
9
350cc
15
5
14
13
12
11
10
9
500cc
39

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
21
570086/D
570086/D
Stud M6 X 226 L
10
22
570024
570024
20
23
571221/A
571221/A
Stud, Chain Tensioner Pad
24
570029/D
570029/D
Chain Tensioner Pad
25
141246/C
141246/C
Bush, Chain Tensioner Pad
Gasket Neutral Switch
After Market
10
Alt. No. 141051, Old Type
20
26
27
586084/A
586084/A
Flanged U Nut M8 X 1.25
28
570414/B
570414/B
Primary Chain
29
571216/A
571216/A
Hex Flange Screw M12 X 1.25 X 25

1
30
570063/F
570063/F
Washer M12 Thick 5 MM
Engine Sprocket (Tsubaki)
31
Alt. No. 570095/e
20
1
Old No. 570064, Old Type
5
10
570551/C
Alt. No. 570070
N.S.
32
570073
570073
Needle Bearing
33
570074/I
570074/I
Distance Washer, Sprag Clutch
1
34
570130
570130
35
570091/D
570091/D
Stud M6 X 80 L
10
36
570007/F
570007/F
Gear - Jack Shaft
37
500635/A
500635/A
Key - Jack Shaft
20
38
570032
570032
Circlip 12 X 1N
1
20
39
570072/C
570072/C
Shaft, Double Gear
40
570570/C
570570/C
Double Gear - Starter Drive
With 2 bush
1
40
01-70 Clutch
A3 (500cc)
11
500CC
9
Key Nos.
(Qty. 7 Nos. 7),
(Qty. 6 Nos. 8)
7 Plate Clutch
12
10
6
A1
3
A1
6 Plate Clutch
11
9
6
350CC
1
4
2
10
12
5
3
A2 (350cc)
Key Nos.
(Qty. 6 Nos. 7),
(Qty. 5 Nos. 8)
41
01-70 Clutch
PART NUMBER
KEY
No.
350
500
A1
A2
570443/C
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Clutch Assembly Complete (6 Plates Kit) - 350cc
Clutch Assembly Complete (7 Plates Kit) - 500cc
Clutch Plates Kit - 350cc
888102
Clutch Plates Kit - 500cc
571113/A
597459
570440
570440
Hex. Screw M6
6
10
570442
570442
Ball Bearing 6001
570447/B
570447/B
Bearing Cup
570439/B
570439/B
Holder, Clutch Spring
570438/B
570438/B
Clutch Spring
570434/D
570434/D
Clutch Hub / Back Plate
Clutch Friction Plate - 350cc
Clutch Friction Plate - 500cc
Clutch Plain Plate - 350cc
Clutch Plain Plate - 500cc
Wheel Clutch - (6 Plates Type) - 350cc
571100/A
Wheel Clutch - (7 Plates Type) - 500cc
7
8
9
570436/C
570436/C
570437/C
570437/C
570435/B
10
570451/B
570451/B
Thrust Washer
11
570433/B
570433/B
Clutch Drum / Sprocket
12
570441
570441
Needle Roller Bearing - SCE 228
1
42
01-80 Crankcase LH
1
16
15
3
4
5
4
10
12
14
13
11
6
7
8
43
01-80 Crankcase LH
PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Old Type 593008/A, 145867/A
30
586005/A
586005/A
Flange Hex Nut - M8 X 1.25
500104/D
500104/D
Stud, M8 X 128L
570008/F
570008/F
Jack Shaft
4
110037/3
110037/3
Circlip 62 X 2N
110050
110050
Ball Bearing 6305 C3
570006/E
570006/E
Bearing Spacer Crankcase LH
10
570005/C
570005/C
Bearing Spacer - LH Crankshaft
10
571205/A
571205/A
NU 305E Cylinderical Roller Bearing with Cage, Single Row
570898/A
570898/A
NU 305, ECP Cylinderical Roller Bearing
1
1
570201/F
570201/F
Washer, Thrust
10
10
550032/A
550032/A
Needle Bearing Counter Shaft
11
570013
570013
20
12
570012/C
570012/C
Retainer Plate, Main Shaft Bearing
10
13
570087/D
570087/D
Stud M6 X 133 L
2
10
14
570011
570011
Ball Bearing 6006 C3
15
570715/A
570715/A
Copper Washer M8
16
570716/A
570716/A
Nut M8 -Cylinder Head (Cap Nut)
Alt. No. 110037/ 7
Polymide Cage
10
1
44
01-90 Crankcase RH
A1
A2
Key No’s
17 to 23
Key No’s
20 to 23
42
4
LOCT IT E
50
52
53
54
1
43
A3
Key No’s
21 to 23
52
45
46
44
49
55
40
47
48
51
9
6
7
8
10
9
11
13
12
14
25
15
24
16
19
41
21
22
23
A2
20
26
39
38
27
28
29
56
37
36
35
30
34
31
18
17 18
A1
32
33
45
01-90 Crankcase RH
PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
570804
570804
Kick Starter Shaft Assembly
A2
570805/B
570805/B
Kick Start Shaft Sub Assembly
A3
888182
888182
Kick Pawl, Plunger and Spring Kit
Conrod Kit (UCE 350 / 500)
1
1
1
A4
1
570097/B
570097/B
Hydraulic Valve Lifter Roller
586005/A
586005/A
Flange Hex Nut - M8 X 1.25
570716/A
570716/A
Nut M8 - Cylinder Head (Cap Nut)
570715/A
570715/A
Copper Washer M8
500104/D
500104/D
Stud, M8 X 128
2
6
570141/E
570141/E
Bracket - Pin - Hydraulic - Tappet
Hex Socket Head Cap Screw M6 X 16
10
10
Needle Roller -NRB-Type-BP-DIA 4 X 37 L
10
571116/B
Needle Roller - DIA. 4 X 29.8L (Lockpin Hydraulic Tappet)
10
7
8
500355
570232
570125
Old Type 593008/A, 145867/A
30
120005/B
120005/B
Dowel - Hallow (Centre Crankcase)
2
20
10
570037
570037
Bearing NRB (NBI 30 X 45 X 20)
11
570028
570028
Locating Pin, (Pivot) - NRB 3 X 21.8
10
12
550032/A
550032/A
Needle Bearing - Layshaft TS
13
570201/F
570201/F
Washer, Thrust
10
14
570208/B
570208/B
Needle Bearing
1
15
570206/J
570206/J
Sleeve Gear
16
570207
570207
Needle Bearing - INA HK 2012
17
570209
570209
Circlip 18N
20
46
01-90 Crankcase
RH RH
01-30
Crankcase
A1
A2
Key No’s
17 to 23
Key No’s
20 to 23
42
4
LOCT IT E
50
52
53
54
1
43
A3
Key No’s
21 to 23
52
45
46
44
49
55
40
47
48
51
9
6
8
10
9
11
13
12
14
25
15
24
16
19
41
21
22
23
A2
20
26
39
38
27
28
29
56
37
36
35
30
34
31
18
17 18
A1
32
33
47
01-90
RH RH
01-30Crankcase
Crankcase
PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
18
550030/C
550030/C
Washer Thrust
10
19
570248/D
570248/D
Kick Start Gear with Bush 35T
Kick Starter Shaft
20
570806/D
21
140333/B
140333/B
Pawl Kick
22
140332/B
140332/B
Plunger Kick Starter
10
23
140331/A
140331/A
Spring Kick
50
24
110037/3
110037/3
Circlip 62 x 2N
10
25
570469/A
570469/A
Deep Groove Ball Bearing - Sleeve Gear

1
26
550082/C
550082/C
Pawl, Cam Plate
27
550083/B
550083/B
Spring, Pawl
550087
550087
Machined Washer 6.4
Old Type
10
570664/A
570664/A
Washer Shift Cam Plate Stopper
Anti Skip Mechanism
10
29
570702/A
570702/A
Hex. Nut M6X1 ( U-type Nut)
5
30
570240
570240
Hex Socket Head Cap Screw M5 X 35
10
31
570239/C
570239/C
Oil Thrower
10
32
146714/A
146714/A
Hex Screw M8 X 23
10
33
142257/B
142257/B
Stop Plate (KSS)
34
570431
570431
Hex. Flange Bolt M5 X 16
2
20
35
869023
869023
Sump Drain Cap Assembly with Magnetic Tip, Matt Black-Powder Coated
36
570057/B
570057/B
‘O’ Ring - Drain Cap
10
37
570054/G
570054/G
Suction Filter Assembly
38
570276/D
570276/D
Magnetic Plug Assembly (Oil Drain Bolt)
28
Old Type
2
10
Alt. No. 570078/D
4
48
01-90 Crankcase RH
A1
A2
Key No’s
17 to 23
Key No’s
20 to 23
42
4
LOCT IT E
50
52
53
54
1
43
A3
Key No’s
21 to 23
52
45
46
44
49
55
40
47
48
51
9
6
7
8
10
9
11
13
12
14
25
15
24
16
19
41
21
22
23
A2
20
26
39
38
27
28
29
56
37
36
35
30
34
31
18
17 18
A1
32
33
49
01-90 Crankcase RH
PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
39
144846/A
144846/A
Washer Drain Plug (Inspection Screw Ignition Timing)
14
40
573983/A
573983/A
Bolt, Pawl ( White Passivation)
Crank Shaft Assembly (UCE 350)
Crank Shaft Assembly (UCE 500)
Loctite 5699 (Alternate : Liquid Sealent 5702) 30 ML
1
41
571170/C
571172/C
42
570278
Recommended Sealent
43
570481
570481
Hex Flange Bolt M5 X 12
20
44
144636/A
144636/A
Copper Washer
20
45
570468/B
570468/B
Cap, Pivot Pin
46
146031/A
146031/A
‘O’ Ring, Oil Pump Outlet
1
14
47
550108
550108
‘O’ Ring
20
48
570218/C
570218/C
Pivot, Cam Plate
49
570186/D
570186/D
Crank Pin
50
570185/B
570185/B
Connecting Rod Assembly
51
570193/B
570193/B
Bearing Needle Roller - Conrod
1
1
52
570187/B
570187/B
Thrust Washer - Conrod
10
53
572338/B
572338/B
Hex. Flange Bolt Anti Skip Plate M6 X 1 X 20
54
570666/A
570666/A
Copper Washer M6
20
55
570665/B
570665/B
Plate Anti Skip
56
570658/B
570658/B
Stopper Assy. Shift Cam Plate (Roller Type)
1
Alt No. 586042/A
Anti Skip Mechanism
10
1
50

A1
2
21
Key No’s
8 to 14
A3
22
A2
Key No’s
12 (2 Nos),
15 to 20
13
A3
14
Key No’s
1, 2 & 21
A1
12
11
10
A2
16
20
19
18 12
12
17
15
51

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
570157
570157
Lay Shaft Sub Assembly
A2
570158/B
570158/B
Main Shaft Sub Assembly
A3
570615
570615
Cam Plate, Neutral Pin with Rollers Complete UCE
550075/A
550075/A
Roller
12
Cam Plate Assembly
570216/E
550091/C
550091/C
Selector Fork Long RH
550081/C
550081/C
Selector Fork Short (Centre)
550090/C
550090/C
Selector Fork Middle LH
550078/A
550078/A
Selector Fork Shaft
550141
550141
Circlip (10N)
20
570202/E
570202/E
Lay Shaft 1st Gear Assembly (with Bush)
550030/C
550030/C
Washer Thrust
10
10
550011/C
550011/C
Lay Shaft 3rd Gear / 4th Double Gear
11
550216/D
550216/D
Lay Shaft
12
550023/E
550023/E
Washer, Thrust
13
570596/B
570596/B
Lay Shaft 2nd Gear Assembly (with Bush)
14
550007/C
550007/C
Lay Shaft High Gear
15
550008/B
550008/B
Main Shaft 2nd Gear
16
570205/N
570205/N
Main Shaft UCE 5S
17
570823/A
570823/A
Main Shaft 4th Gear Assembly (with Bush)
18
550024
550024
Circlip
14
19
570821/A
570821/A
Main Shaft 3rd Gear Assembly (with Bush)
20
570204/H
570204/H
Main Shaft 1st Gear
1
52

A1
2
21
Key No’s
8 to 14
A3
22
A2
Key No’s
12 (2 Nos),
15 to 20
13
A3
14
Key No’s
1, 2 & 21
A1
12
11
10
A2
16
20
19
18 12
12
17
15
53

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
21
550119/B
550119/B
Neutral Pin, Finder
10
22
572044/A
572044/A
Washer Special Cam Plate Assembly (Top Side)
5
54

A1
A3
1
Key No’s
8 to 14
21
22
A2
Key No’s
(Qty. 3 Nos. 12),
15 to 20
A1
A3
13
14
Key No’s
1, 2 & 21
12
11
10
A2
16
20
19
18 12
12
17
15
55

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
570157
570157
Lay Shaft Sub Assembly
A2
570158/B
570158/B
Main Shaft Sub Assembly
A3
570706/B
570706/B
Cam Plate, Neutral Pin with Rollers Complete UCE (Anti Skip Mechanism)
550075/A
550075/A
Roller
12
Cam Plate Assy. (Anti Skip Mechanism)
570707/B
New Type, Served in Kit, Ref.A3
550091/C
550091/C
Selector Fork Long
550081/C
550081/C
Selector Fork Short (Centre)
550090/C
550090/C
Selector Fork Middle (Length Cut)
550078/A
550078/A
Shaft, Selector Fork
550141
550141
Circlip 10 N
20
570202/E
570202/E
Assy., Layshaft 1st Gear
550030/C
550030/C
Washer, Thrust MS & L
10
10
550011/C
550011/C
Layshaft 3rd / 4th Gear
11
550216/D
550216/D
Layshaft
12
550023/E
550023/E
Washer, Thrust
13
570596/B
570596/B
Assy., Layshaft 2nd Gear
14
550007/C
550007/C
Layshaft High Gear
15
550008/B
550008/B
Mainshaft 2nd Gear
16
570205/N
570205/N
Mainshaft
17
570823/A
570823/A
Assy., 4th Gear Main Shaft
18
550024
550024
Circlip, Din:5108 Inv. External, Dia 24
14
19
570821/A
570821/A
Assy., 3rd Gear, Main Shaft
20
570204/H
570204/H
Main Shaft 1st Gear
1
56

A1
A3
1
Key No’s
8 to 14
21
22
A2
Key No’s
(Qty. 3 Nos. 12),
15 to 20
A1
A3
13
14
Key No’s
1, 2 & 21
12
11
10
A2
16
20
19
18 12
12
17
15
57

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
21
550119/B
550119/B
Pin, Neutral Finder
10
22
572044/A
572044/A
Washer - Cam Plate (Top Side)
1
58

A1
A2
A3
A4
A5
A6
A7
Key No’s
35, 36, 37, 43 & 44
Key No’s
27 & 45
Key No’s
11, 14, 26, 33
Key No’s
28, 29 & 30
Key No’s
12, 13 & 46
Key No’s
12, 16, 21, 35,
44, 45, 47 & 50
Key No’s
2, 5, 9, 10, 12, 15, 16, 18, 21,
31, 32, 35, 44, 45, 47 & 50
42
40
41
38
5
6
7
8
9
49
10
50
34
48
15
16
47
17
31
19
22
35 36
30
18
46
12
32
11
14
29
20
28
21
39
23
13
27
24
25
33
A5
26
45
37
43
44
59

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
888083
Mixture (Pilot) Screw Repair Kit CV Carb BS 29
A2
888084
Drain Screw Repair Kit CV Carb BS 29
A3
888085
Drain and Vent Pipe Kit CV Carb BS 29
A4
888086
Idle Screw Repair Kit CV Carb BS 29
2
A5
570944
Piston Valve and Diaphragm Assembly Kit - CV Carb. BS 29
A6
888224
Carburetor BS 29 Minor Kit
A7
888225
Carburetor BS 29 Major Kit
570282/K
Carburetor BS 29
570936
Top Cover Fixing Screw - CV Carb. (Shank Type)
570943
Diaphragm Top Cover - CV Carb. (PET Type - Single Piece)
570833/A
Piston Valve Spring - CV Carb.

1
500848
Jet Needle Plate Fixing Screw - CV Carb.
10
500836
Jet Needle Fixing Plate - CV Carb.
10
500837
Jet Needle Retainer Spring - CV Carb.
10
500839
Jet Needle Washer - CV Carb.
10
500838
Jet Needle “E” - Ring - CV Carb.
10
10
570834/A
Jet Needle - CV Carb. (4DHL42-2/3)
11
570874/A
Clip, Air Vent - CV Carb.
20
12
500835
Diaphragm - CV Carb.
Alt. No. Ref. A5 (N.S)
13
500834
Diaphragm Retainer Ring - CV Carb.
10
14
570873/A
Air Vent Hose - CV Carb.
Served in Kit, Ref. A3,

Alt. No. 570843
570282/H
New Type, Pilot Air Screw

Press Fit, > Apr. ‘12
1
10
Old No. 500831/A or 570831/A

New Type, > Mar. 2013
3
60

A1
A2
A3
A4
A5
A6
A7
Key No’s
35, 36, 37, 43 & 44
Key No’s
27 & 45
Key No’s
11, 14, 26, 33
Key No’s
28, 29 & 30
Key No’s
12, 13 & 46
Key No’s
12, 16, 21, 35,
44, 45, 47 & 50
Key No’s
2, 5, 9, 10, 12, 15, 16, 18, 21,
31, 32, 35, 44, 45, 47 & 50
42
40
41
38
5
6
7
8
9
49
10
50
34
48
15
16
47
17
31
19
22
35 36
30
18
46
12
32
11
14
29
20
28
21
39
23
13
27
24
25
33
A5
26
45
37
43
44
61

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
15
570835/A
Needle Jet - CV Carb. (P-2M-922)
16
500845
‘O’ Ring Jet Holder - CV Carb.
17
570838/A
Main Jet Holder - CV Carb.
18
570837/A
Main Jet (BS29-110)
19
500846
Float Pin - CV Carb.
20
500847
Float Pin Fixing Screw - CV Carb.
10
21
500841
‘O’ Ring Float Chamber Cover - CV Carb.
22
500843
Float Assembly - CV Carb.
23
570732/B
Float Body Assembly New Type - CV Carb.
24
141963
Spring Washer - CV Carb.
20
25
500842
Screw Bowl MTG with Washer - CV Carb.
10
26
570842/A
Hose Drain - CV Carb.
27
500871
Screw - Drain - CV Carb.
28
500857
Idle Adjuster Screw - CV Carb. (Yellow)
29
500856/A
Packing, Idle Adjusting Screw - CV Carb. (White Plastic)
20
30
500855
Spring, Idle Adjusting - CV Carb. (Yellow)
10
31
570840/A
Pilot (Slow) Jet (BS 29-12.5) - CV Carb.
32
570839/A
Pilot Air Jet - CV Carb. (Thread Type - ID 1.2)
Old Type < Apr’ 2012
33
500874
Clip Drain Hose - CV Carb.
10
34
570841/A
Plunger Assembly - CHOKE - CV Carb.
35
500870
‘O’ Ring Pilot Screw Front - CV Carb.
20
36
500869
Washer Pilot Screw - CV Carb.
20
Alt. No. 570845/A
OldNo.500860 With ‘O’ Ring type Drain Screw

and ‘L’ Type Bend, > Apr. ‘12
10
1
62

A1
A2
A3
A4
A5
A6
A7
Key No’s
35, 36, 37, 43 & 44
Key No’s
27 & 45
Key No’s
11, 14, 26, 33
Key No’s
28, 29 & 30
Key No’s
12, 13 & 46
Key No’s
12, 16, 21, 35,
44, 45, 47 & 50
Key No’s
2, 5, 9, 10, 12, 15, 16, 18, 21,
31, 32, 35, 44, 45, 47 & 50
42
40
41
38
5
6
7
8
9
49
10
50
34
48
15
16
47
17
31
19
22
35 36
30
18
46
12
32
11
14
29
20
28
21
39
23
13
27
24
25
33
A5
26
45
37
43
44
63

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
37
500862
Spring Pilot Screw - CV Carb.
20
38
143144/2
Clip Carb Flange - CV Carb.
Alt. No. 146882/A
39
570261/B
Flange (Carburetor to Cylinder Head) - CV Carb.
40
521200/A
‘O’ Ring Flange

1
41
571206/A
SS Hex Socket Head Cap Screw M6 X 25
42
144636/A
Sealing Washer
43
570844/B
Adjuster ‘E’ Pilot (Mixture) Screw - CV Carb.
Modified Taperness,
Alt. No. Ref. A1
44
570846/A
‘O’ Ring - Mixture / Pilot Screw Head - CV Carb.
20
45
570845/A
‘O’ Ring - Drain Screw - CV Carb.
20
46
570832/A
Piston C.V Carburetor (BS 29)
47
570836/B
Needle Assy. 1.5 - (BS 29)
48
500872
Cap Throttle Shaft
49
571253
Shim Jet Needle
50
570940/A
‘O’ Ring Plunger Assembly Choke
10
New Type
10
10
64

A1
A2
A3
A4
Key No’s
12, 13 & 14
Key No’s
3, 4 & 5
Key No’s
3&8
Key No’s
5, 6, 10, 12 to 17
15
14
12
13
3
10
23
17
22
24
10
16
21
10 9 7
20
18
11
9
19
6
1
65

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
571086
Injector Kit Assembly
A2
888183
Insulator Kit
A3
888192
Adaptor with PAV Connection & ‘O’ Ring Kit
A4
888176
Sub Assembly Manifold - Inlet, Thunderbird 500
1
Cylinder Head (500cc) Black
869045
571055/A
Engine Temperature Sensor with ‘O’ Ring
521200/A
‘O’ Ring for Insulator and Adaptor
571079/D
Insulator
144981/B
‘O’ Ring for Manifold
869025
Manifold - Inlet - Black
144636/A
Copper Washer M6
4
10
572304/A
Adaptor with PAV Connection
571206/A
10
10
593055/A
Hex. Nut with Nylon Insert M6
10
11
571051/B
Throttle Body Assy.
12
571053/A
Injector
13
571090/A
Seal Ring
1
10
14
571087/A
‘O’ Ring, Injector (I.D 7.47 X Wire Dia 3.6)
10
15
571088/C
Cap, Injector Assembly
16
573935/A
Spacer - EFI
17
571249/A
Stud Injector M6
18
143144/2
Clip Hose - Adaptor
19
572607/A
‘O’ Ring - Temperature Sensor
1
10
N.S., Ref. A2
10
N.S., Ref. A1
Alt. No. 573966/A, Old Type
1
66

A1
A2
A3
A4
Key No’s
12, 13 & 14
Key No’s
3, 4 & 5
Key No’s
3&8
Key No’s
5, 6, 10, 12 to 17
15
14
12
13
3
10
23
17
22
24
10
16
21
10 9 7
20
18
11
9
19
6
1
67

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
20
571226/A
Valve BI-Starter
21
571227/A
Spring Compression Valve BI-Starter
10
22
571228/A
Holder Cable Valve
23
571229/A
Guide Cable Valve
5
24
571230/A
Cap Cable Sealing
10
68

A1
Key Nos.
1 to 14
A2
14
Key Nos.
2, 4, 6, 8,
(Qty. 5 Nos. 9)
6
7
12
13
8
11
9
9
10
69

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
580559
Air Filter Assembly Complete
A2
521237
Air Filter Assembly
586025/A
Flange Hex Bolt M8 X 16
521238/B
Air Filter Body
3
141051
Hex Nut M8
521129/B
‘O’ Ring
521172/A
Air Filter Element (350cc)
521093/D
Cover, Filter Element
142065
Slotted Cheese Head Screw M5 X 20
40
521092/D
Lid - Air Filter
10
9
521125
Cross Recessed Pan Head Screw M5 X 25
40
10
141560
Air Polution Sticker
10
11
572611/A
Clip Hose
12
500823/B
Bellow Air Filter Outlet
13
147897/B
Hose Clip
14
586036/A
Washer
Old No. 591534/a
Alt. No. 500712/2

Old No. 140437/1, 593028/A, 140080/2
30
20
70
A1
Key Nos.
1 to 14
A1
10
A2
Key Nos.
2 to 5, 7, 8, 13
(Qty. 4 Nos. 1)
A3
Key Nos.
4&5
11
13
12
6
5
4
3
2
1
14
71

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
581114/A
Air Filter Assembly Complete
A2
581004/E
Air Filter Assembly
A3
888127
Air Filter with Cover
142095
Slotted Cheese Head Screw M5 X 18
20
2
581006/B
Air Filter - LID
586004/A
Hex Nut with Nylock Insert M8
581008/A
Cover - Filter Element
581007/A
Air Filter Element
586014/A
Flanged Hex. Bolt M8 X 1.25 X 10
581005/D
Air Filter Body
581044/C
Arrester Comp. – Air Filter
500712/A
Clip Hose
10
500823/B
Bellow (C.V. B)
11
111098/2
Washer, Plain
20
12
560506
‘O’ Ring
500917/B
Strap - White
Alt. No. 582511/A

10
582511/A
Strap - Black
Old No. 500917/B
10
13
14
Old No. 593030/A, 142182/A
Old No. 145872/A
581009/A
30
10
5
72

A1
16
15
Key Nos.
ALL
16
1
7
10
8
6
5
2
8
9
14
New Type
14
17
14
4
13
14
12
14
Old Type
11
73

PART NUMBER
KEY
No.
350
500
A1
A2
1
888210
888209
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
Exhaust Pipe Assembly Kit (350cc)
888211
Exhaust Pipe Assembly Kit (500cc)
888209
Silencer Assembly Kit TB 350 / 500 cc
Exhaust Pipe Assembly - 350cc
594076/B
Exhaust Pipe Assembly - 500cc
1
1
594191/B
594077/B
594077/B
Silencer Assembly
867072
867072
End Cone Silencer (Cup)
Dual Tone Colour
581122/A
581122/A
Mushroom Head Screw, M6 X 8 X 1
10
594079/B
594079/B
Bracket - Silencer Front Mounting
586038/A
586038/A
Spring Washer M8
Old No. 210026
50
586025/A
586025/A
Flange Hex Bolt M8 X 16
Old No. 591534/A
30
586032/A
586032/A
Plain Washer
Old No. 141061/ 1
50
591578/A
591578/A
Flanged Hex. Bolt, M6 X 1 X 35
10
586029/A
586029/A
Hex. Nut M6
1
Old No. 141060
40
11
594081/B
594081/B
Exhaust Guard (with Clip)
Old Type, < Feb. ‘13
12
500711/A
500711/A
Hose Clip
Old Type, < Feb. ‘13
13
594209/A
594209/A
Guard - Silencer
147896/A
147896/A
Philips Pan Head Screw M6 X 6
Old Type
10
147896/A
147896/A
Philips Pan Head Screw M6 X 6

5
New Type
10
15
582638/A
582638/A
Gasket - Exhaust Pipe (Copper Type)
Old No. 510804/A
10
16
586005/A
586005/A
Flanged Hex. Nut M8 X 1.25
Old Type 593008/A, 145867/A
17
594474/C
594474/C
Guard - Exhaust Pipe (without Clip)
New Type, > Mar. ‘13
14
10
1
74

A1
A2
Key Nos.
1, (Qty. 2 Nos. 2), 3, 4,
(Qty. 4 Nos. 5), 6, 7, 10,
11, 12, 14 & 23
Key Nos.
A3
Key Nos.
7, 13, (Qty. 2 Nos. 14)
8&9
A4
Key Nos.
18 & 21
6
21
18
19
13
14
22
20
17
16
23
15
14
(500cc)
12
Choke Lever
4
5
10
2
11
8
9
24
12
(350cc)
25
2
10
75

PART NUMBER
KEY
No.
350
500
A1
594397/A
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Handle Bar Assembly - 350cc
594004/A
Handle Bar Assembly - 500cc
A2
888193
888193
Mirror Set - Thunderbird (Black) 500cc
A3
888168
888168
Clutch Switch Repair Kit
1
A4
888128
888128
Clutch & Front Brake Lever Kit
594005/B
594005/B
Handle Bar Comp. (Classic)
580404/A
580404/A
Damper Weight (Nickle Plated)
Hand Grip Comp. (with Rotor) Throttle Assembly - 350cc
Grip Comp. Throttle RH (Twin Cable Type) - 500cc
Switch Module RH - 350cc
Single Hole Throttle Cable
581097/A
Switch Module RH - 500cc

1
Two Holes for Twin Cable
Alternate No. 560195/A
10
3
4
146044/A
581098/A
560195/A
Clear Coated
594425/A
594425/A
Cable Tie
581083/A
581083/A
Lever and Holder Assembly LH
560632/A
560632/A
Clutch Switch
594013/A
594013/A
Rear View Mirror - LH
594014/A
594014/A
Rear View Mirror - RH
10
594426/A
594426/A
Counter Weight Screw, M8 X 50 (White)
Old No. 521202/a
10
11
521186/A
521186/A
Grip LH FR Counter Weight
Switch Module LH - 350cc
581029/A
Switch Module LH - 500cc

1
147270/A
12
13
580441/A
147270/A
With Choke Lever
Add on Lead Clutch Switch
14
Screw Clutch Switch
560633/A
15
Stud Release Lever
591975
10
10
76

A1
A2
Key Nos.
1, (Qty. 2 Nos. 2), 3, 4,
(Qty. 4 Nos. 5), 6, 7, 10,
11, 12, 14 & 23
Key Nos.
A3
Key Nos.
7, 13, (Qty. 2 Nos. 14)
8&9
A4
Key Nos.
18 & 21
6
21
18
19
13
14
22
20
17
16
23
15
14
(500cc)
12
Choke Lever
4
5
10
2
11
8
9
24
12
(350cc)
25
2
10
77

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
16
Screw
591972
10
17
Washer
591973
10
Lever Assy. LH - Clutch (P.U. Clear Coated)
19
Nut Nyloc
591974
20
Bracket LH Lever (Holder)
594683
Alt. No. 143332
21
Lever RH - Disc Brake (P.U. Clear Coated) - BBI
594621
Alt. No. 594551/A
Add On Lead (Disc Brake)
Mirror Thread Guard
18
22
594635/A
592857/B
594635/A
592857/B
23
24
591521/A
591521/A
Rotor Plate
25
591522/A
591522/A
Pan Head Screw M5 X 10
10
Alt. No. 418083

1
10
5
141460/A
N.S.
10
20
78

A1 (350cc)
Key Nos.
1&2
A1 (500cc)
Key Nos.
1, 2 & 3
500cc
350cc
1
1
3
2
3
2
79

PART NUMBER
KEY
No.
350
500
A1
1
2
3
888186
QTY. REFERENCE
REMARKS
MOQ
Nos.
Control Cable Kit Thunderbird - 350cc
Control Cable Kit Thunderbird - 500cc
Throttle Cable
594279/A
Throttle Cable Assembly (Twin Cable)
570409/E
Clutch Cable Assembly (350cc)
594278/A
Choke Cable Assembly
888187
580387/D
570409/E
DESCRIPTION
80
03-20 Front Master Cylinder Assembly - BBI

A1
A2
Key Nos.
All except
26 to 28
Key Nos.
26, (Qty. 2 Nos. 27)
(Qty. 4 Nos. 28)
16
A3
A4
Key Nos.
14, 15, 16,
(Qty. 2 Nos. 17)
Key Nos.
A5
A6
Key Nos.
Key Nos.
(Qty. 2 Nos. 27)
(Qty. 4 Nos. 28)
2 16 & 172to
A8
Key Nos.
2 to 8 & 31
Key Nos.
2,2 to 5 & 315
A9
A10
Key Nos.
18,19 & 202
Key Nos.
21 & 222
A12
Key Nos.
Key Nos.
14 & 152 9,11,12 & 31
24
30
23
11
23 & 24
A7
A11
17
17
27 28
28
10
9
15
12
14
26
25
22
13
A13
Key Nos.
All except
9, 26 to 28
6
29
19
18
21
20
22
27 28
28
81

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
Alt. No. 592825/A
MOQ
Nos.
A1
594631/A
594631/A
Master Cylinder Assembly with Brake Lever - (BBI)
A2
594704/A
594704/A
Front Brake Hose Assy. and Banjo Bolt Kit Front M/C
1
1
A3
888009
888009
Reservoir Cover Kit and Diaphragm Front M/C
A4
594710/A
594710/A
Switch Repair Kit Front Brake - (BBI)
A5
594712/A
594712/A
Reservoir Cover Kit Front M/C
A6
594721/A
594721/A
Banjo Bolt Kit
A7
594705/A
594705/A
Major Kit Front Master Cylinder Front M/C
A8
594706/A
594706/A
Minor Kit Front Master Cylinder Front M/C
A9
594707/A
594707/A
Oil Window Kit Front M/C
A10 594708/A
594708/A
Clamp Kit Front M/C
A11 594709/A
594709/A
Diaphragm Kit Front M/C
A12 594711/A
594711/A
Lever Brake Kit Front M/C - Buffed
Clear Coated
A13
Master Cylinder without Brake Lever
Common
Master Cylinder Body Front
594602/A
N.S., Served in Kit, Ref. A1
Piston - Front Master Cylinder
594603/A
N.S., Served in Kit, Ref. A7, A8
Primary Seal Disc
594604/A
Secondary Seal Disc
594605/A
Spring Disc
594606/A
Circlip Disc
594607/A
N.S., Served in Kit, Ref. A7,
Boot Disc
1
594608/A
Push Rod Disc
594609/A
Brake Lever (Clear Coated)
594621/A
10
Shim FR Disc
594610

82

A1
A2
Key Nos.
All except
26 to 28
Key Nos.
26, (Qty. 2 Nos. 27)
(Qty. 4 Nos. 28)
16
A3
A4
Key Nos.
14, 15, 16,
(Qty. 2 Nos. 17)
Key Nos.
A5
A6
Key Nos.
Key Nos.
(Qty. 2 Nos. 27)
(Qty. 4 Nos. 28)
2 16 & 172to
A8
Key Nos.
2 to 8 & 31
Key Nos.
2,2 to 5 & 315
A9
A10
Key Nos.
18,19 & 202
Key Nos.
21 & 222
A12
Key Nos.
Key Nos.
14 & 152 9,11,12 & 31
24
30
23
11
23 & 24
A7
A11
17
17
27 28
28
10
9
15
12
14
26
25
22
13
A13
Key Nos.
All except
9, 26 to 28
6
29
19
18
21
20
22
27 28
28
83

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
11
Bolt Handle Lever
594611/A
12
Hex. Nut Lever Disc
594612/A
13
Cap Sub Assembly Disc
594613/A
14
Diaphragm Front Disc
592257/A
15
Plate Diaphragm Disc

1
592258/A
16
Reservoir Cover Front Disc
594614/A
17
Reservoir Screw Disc
592260/A
N.S., Served in Kit, Ref. A3,A5
18
Window Assembly FR Disc
594615/A
19
‘O’ Ring FR Disc
594616/A
20
Clip FR Disc
594617/A
21
Clamp FR Disc
594618/A
22
Screw Clamp
594619/A
23
Switch Assembly Front
580892/A
24
Screw Switch FR M/C
594620/A
25
Thread Protector
26
Brake Hose Assembly - Black Trivalant
594622/A
27
Banjo Bolt Disc
2
594507/A
28
Copper Washer Disc
594508/A
29
Mirror Thread Guard
141460/A
Addon Lead Front Brake Switch - Disc (BBI)
Grease Pouch (Reference only)
30
31
582519/A
582519/A
MOQ
Nos.
10
N.S.
Alt. No. 592857/a

594728/A
N.S., Served in Kit,

Ref. A7,A8, A12
10
84
03-30 Front Caliper Assembly - BBI

A1
A2
A4
A3
Key Nos.
Key Nos.
Key Nos.
All Except 18 to 20, All Except 18 14 & 15
(A1, A2 in
Page No. 76)
A5
Key Nos.
19, (Qty. 2 Nos. 20)
Key Nos.
4, 10 & 21
A6
Key Nos.
2, 3, 4, 7, 8,
12, 13 & 21
A7
A8
Key Nos. Key Nos.

3, 4, 7, 8,
5&9
12, 13 & 21
14
15
18
22
16
13
12
1
19 20 20
Key Nos.
3, 11, 17, 21 & 22
6
18
A9
10
4
17
11
85

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594517/A
594517/A
Disc Brake System Assembly Kit Front - (BBI)
A2
147649/B
147649/B
Caliper Assembly - (BBI)
A3
594715/A
594715/A
Disc Pad Kit Front - (BBI)
A4
594721/A
594721/A
Banjo Bolt Kit (Disc Brake Caliper)
A5
594720/A
594720/A
Primary Pin Kit Front Caliper - (BBI) - Thunderbird
A6
594713/A
594713/A
Major Kit Front Caliper - (BBI)
A7
594714/A
594714/A
Minor Kit Front Caliper - (BBI)
A8
594717/A
594717/A
Pad Pin Kit Front Caliper - (BBI)
A9
594718/A
594718/A
Bracket Sub Assy. Front Caliper
Caliper Body Front Kit
594623/A
Piston - Front Caliper
594624/A
Insulator FR Disc
594625/A
N.S., Served in Kit, Ref. A6,A7,A9
Dust Cover FR Disc
594626/A
Pin Sub Assembly FR Disc
594627/A

Spring Pad FR Disc
Scrapper Ring FR Disc
594628/A
Seal FR Disc
594629/A
Clip Special FR Disc
594632/A
10
Primary Pin FR Disc
594737/A
11
Caliper Bracket Assembly Front Disc
594738/A
12
Bleeder Screw Front
1
594742/A
13
Bleeder Cap
594741/A
592256/A
592256/A
10
86

A1
A2
A4
A3
Key Nos.
Key Nos.
Key Nos.
All Except 18 to 20, All Except 18 14 & 15
(A1, A2 in
Page No. 76)
A5
Key Nos.
19, (Qty. 2 Nos. 20)
Key Nos.
4, 10 & 21
A6
Key Nos.
2, 3, 4, 7, 8,
12, 13 & 21
A7
A8
Key Nos. Key Nos.

3, 4, 7, 8,
5&9
12, 13 & 21
14
15
18
22
16
13
12
1
19 20 20
Key Nos.
3, 11, 17, 21 & 22
6
18
A9
10
4
17
11
87

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
14
Pad (Piston Side)
592254/A
15
Pad (Opposite Side)
592255/A
16
Thread Protector
N.S.
17
594630/A
594630/A
Wear Pad
18
586022/A
586022/A
Flange Hex. Bolt M8 X 1.25 X 45
19
Banjo Bolt
594507/A
20
Washer (Copper)
594508/A
21
Grease Pouch (Reference only)
594728/A
N.S., Served in Kit,

Ref. A5, A6, A7, A9
22
Secondary Pin FR Caliper
594740/A
MOQ
Nos.
5
10
88

A1
24
Key Nos.
2, 21, (Qty. 38 Nos. 3),
(Qty. 2 Nos. 22 & 27)
20
20
23
22
21
19
A2
Key Nos.
(Qty. 4 Nos. 6),
7&8
16
16
27
22
15
14
14
13
25 13
27
7
25
30
26
31
30
8
9
13
14
13
14
17
18
17
32
6 29
28
1
2
6
18
10
11
12
11
12
25
25
32
29
28
89

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
888133
888133
Ball Race Kit with Cover (Thunderbird 350 & 500)
A2
888134
888134
Rubber, Head Lamp Holder RH & LH Kit (Thunderbird 350 & 500)
859045
859045
Steering Assembly (Metalic Silver) - Bottom Yoke Assembly
Alt.No. 594218/C
2
144581/E
144581/E
Ball Race - Fork Crown
140201
140201
Ball Dia 6.35 (Dia 1/4”)
38
Top:19 + Bottom Race:19 Balls 38
845019
845019
Number Plate Assembly - Front (Milky White)
586042/A
586042/A
Flanged Hex. Bolt M6 X 20
Old No. 145861/A
10
140193/B
140193/B
Rubber Head Lamp Holder
Alt. No. 594503/B

10
594161/B
594161/B
Holder RH-Head Lamp Assembly Plated
594160/B
594160/B
Holder LH-Head Lamp Assembly Plated
594195/A
594195/A
Topyoke (Metalic Silver)
10
888056/A
888056/A
Ignition Switch cum Steering Lock Assembly with Keys
11
586031/A
586031/A
Lock Washer M6, Internal Teeth
12
570030
570030
10
13
594253/A
594253/A
Rubber Damper Sleeve Handle Bar
14
594252/B
594252/B
Cover - Bottom Raiser
15
859043
859043
Bottom Raiser (Metalic Silver)
16
594008/A
594008/A
Hex. Bolt M10X60
17
586008/A
586008/A
Washer
18
594009/B
594009/B
Hex. Nyloc Nut M10
19
859042
859042
Top Raiser - Handle Bar (Metalic Silver)
20
594356/B
594356/B
Domed Cap Bolt
21
594288/A
594288/A
Upper Ball Race - Topyoke
Alt. No. 859044
1
1
Old No. 140129
Alt. No. 594251/A
40
1
10
Old No. 145708/A, 580344/A, 593023/B
20
10
Alt. No. 594212/A
1
4

90

A1
24
Key Nos.
2, 21, (Qty. 38 Nos. 3),
(Qty. 2 Nos. 22 & 27)
20
20
23
22
21
19
A2
Key Nos.
(Qty. 4 Nos. 6),
7&8
16
16
27
22
15
14
14
13
25 13
27
7
25
30
26
31
30
8
9
13
14
13
14
17
18
17
32
6 29
28
1
2
6
18
10
11
12
11
12
25
25
32
29
28
91

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
22
145446/A
145446/A
Cover Ball Race
10
23
594287/A
594287/A
Ring Nut
24
594286/A
594286/A
Lock Nut
25
594215/A
594215/A
Hex. Allen Bolt M8 X 25
10
26
594121/A
594121/A
Head Lamp Stopper (Plated)
27
144581/E
144581/E
Ball Race Frame
28
591702/A
591702/A
Hex. Bolt M6 X 1 X 12
29
586032/A
586032/A
Plain Washer
Old No. 141061/1
20
30
586002/A
586002/A
Old No. 580349/A, 145862/A,

594310/A, 593927/A
31
586025/A
586025/A
32
586031/A
586031/A

20
10
Old No. 140129
50
92
03-50 Front Fork (GIL - Dia 41)

A1
A2
A3
A4
A5
A6
Key Nos.
Key Nos.
Key Nos.
Key Nos.
Key Nos.
Key Nos.
All Except 5 & 7
Each Qty. 2 Nos.

2, 4, 8, 12, 14 & 18
Qty. 2 Nos. 2, 8,
12, 14 & 18
Qty. 2 Nos. 15,

18 & 19
Key Nos.
All Except 10
2, 8, 9, 10,
12 & 14
2, 5, 7 to 9,
12 & 14
3 2
15
A7
10
1
16
7
9
18 19
4
11 12
17
13
14
93

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594018/A
594018/A
Front Fork Assembly LH
A2
594019/A
594019/A
Front Fork Assembly RH
A3
888135
888135
Fork Pipe Spining Replacement Kit
A4
888136
888136
Fork Oil Seal, ‘O’ Ring & Piston Ring Kit
A5
888137
888137
Main Spring Fork Major Kit
A6
888139
888139
Bottom Tube LH Sub Assembly Kit
A7
888138
888138
Bottom Tube RH Sub Assembly Kit
594403/A
594403/A
Piston - Front Fork
Piston Ring Dia 41
2
2
594552/A
Served in Kit, Ref. A3,A4,A6&A7
10
594553/A
594553/A
Spring 2 (Sub Spring) - Rebound Fork
594402/A
594402/A
Inner Tube Assembly with Bush
594419/A
594419/A
Allen Bolt M8 X 1.25 X 45
10
594409/A
594409/A
Spindle Tapper - Oil Lock Piece
594400/A
594400/A
Outer Tube RH Kit Dia 41
594410/A
594410/A
Gasket - Washer
20
594411/A
594411/A
Bolt M10 X 1
10
594401/A
594401/A
Outer Tube LH Kit Dia 41
11
594405/A
594405/A
Bush Washer
12
594406/A
594406/A
Oil Seal Dia 41

2
13
594407/A
594407/A
Circlip (Snap Ring) Dia 41
14
594408/A
594408/A
Dust Seal Dia 41
Spring - Main Dia 41
Washer Spring Top
15
16
594413/A
594413/A
2
10
1
10
2
10
594412/a
2
2
10
94

A1
A2
A3
A4
A5
A6
Key Nos.
Key Nos.
Key Nos.
Key Nos.
Key Nos.
Key Nos.
All Except 5 & 7
Each Qty. 2 Nos.

2, 4, 8, 12, 14 & 18
Qty. 2 Nos. 2, 8,
12, 14 & 18
Qty. 2 Nos. 15,

18 & 19
Key Nos.
All Except 10
2, 8, 9, 10,
12 & 14
2, 5, 7 to 9,
12 & 14
3 2
15
A7
10
1
16
7
9
18 19
4
11 12
17
13
14
95

PART NUMBER
KEY
No.
350
500
17
594414/A
594414/A
18
19
594415/A
594415/A
DESCRIPTION
QTY. REFERENCE
Spacer Dia 41
‘O’ Ring Dia 41
Bolt Cap (Special Square 38mm Head)
REMARKS
MOQ
Nos.
2
594416/A
Served in Kit, Ref. A3,A4 & A5
10
2
96

A1
1
Key Nos.
(Qty. 2 Nos. 4, 6, 8),
7, 9, 10,
(Qty. 4 Nos. 5)
2
3
10
3
4
6
9
5
7
6
5
4
8
97

PART NUMBER
KEY
No.
350
500
A1
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
888140
888140
Front Mudguard Extension & Clip Kit
874001
874001
Front Mudguard, Twilight
875001
Front Mudguard, Stone Black
879007
879007
Front Mudguard, Flicker
2
586002/A
586002/A
Flange Hex. Bolt M8 X 20
Old No. 580349/A, 145862/A,

594310/A, 593927/A, 593016/A
10
586038/A
586038/A
Spring Washer M8
Old No. 210026
20
145882/A
145882/A
Cross Recessed Pan Head Screw M6
586032/A
586032/A
Punched Washer 6.4
Old No. 141061/1
20
586021/A
586021/A
Hex. Nut with Nylon Insert

2
Old No. 141306/2
20
146797/A
146797/A
Mudguard Extension
10
591702/A
591702/A
20
594078/B
594078/B
Cable Guide - Speedo Cable (Metal)
10
594233/A
594233/A
Cable Guide (Metal)
1
20
98
03-70 Front Wheel
2
20
1
3
19
14
12
15
13
16
17 18
11 8
9
10
A1
A2
Key Nos.
1, 2,(Qty. 40 Nos. 5), (Qty. 20 Nos. 6 &
10), 7, (Qty. 2 Nos. 8), 9, 11, 12,
(Qty. 6 Nos. 13 & 15) 14, 19 & 20
Key Nos.
(Qty. 40 Nos. 5), (Qty. 20 Nos. 6 & 10),
7, (Qty. 2 Nos. 8), 9, 11, 12,
(Qty. 6 Nos. 13 & 15) 14, 19 & 20
A3
A4
Key Nos.
(Qty. 2 Nos. 8),
7, 9, & 11
Key Nos.
3, 17 & 18
A5
Key Nos.
(Qty. 2 Nos. 7
& 8)
A6
Key Nos.
1&2
A7
A8
Key Nos.
Key Nos.
(Qty. 20 Nos. 6 &
7, (Qty. 2 Nos. 8), 9,
10), (Qty. 40 Nos. 5) 11, 12, (Qty. 6 Nos. 13)
99
03-70 Front Wheel

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594006/A
594006/A
Front Wheel Assembly Adaptor Plate, Disc with Tyre and Tube
A2
888166
888166
Front Wheel Assembly Adaptor Plate, Disc without Tyre and Tube
A3
888141
888141
Front Hub Sub Assembly
A4
888142
888142
Front Spindle Kit
A5
888118
888118
Front Wheel Bearing and Seal Kit
A6
888051
888051
Front Wheel Tyre & Tube Kit - 90/90-19"
A7
888119
888119
Spokes & Nipple Kit Front Wheel 19”
A8
888143
888143
Hub Front Adaptor Plate and Bolt Kit
Tyre - Front 90/90-19"
1
591985/A
N.S., Ref. A6
Tube - Front 90/90-19"
591986/A
N.S., Ref. A6
2 Seals are packed in Common Kit
594421/A
594421/A
Spindle - Front Wheel
594238/A
594238/A
Wheel Speed Sensor Assembly
110349
110349
Nipple
40
40
560519/E
560519/E
Spokes Short (Outer)
20
20
141109/1
141109/1
Grease Seal, 25X40X7
150324/A
150324/A
Deep Groove Ball Bearing (6203 17 X 40 X 12)
10
859040
859040
Hub-Front Wheel (Metalic Silver)
10
560502/E
560502/E
Spokes Long (Inner)
20
20
11
560521/B
560521/B
Spacer Assembly
12
859041
859041
Adaptor Plate (Metalic Silver)
13
560546/A
560546/A
Hex. Flange Bolt M8X25
14
594071/A
594071/A
Disc, Front (Black)
15
560530/D
560530/D
Socket Button Head Cap Screw
Alt No. 594007/C
Alt. No. 560504/C
2
1
1
100
03-70 Front Wheel
2
20
1
3
19
14
12
15
13
16
17 18
6
A1
11 8
9
10
A2
Key Nos.
1, 2,(Qty. 40 Nos. 5), (Qty. 20 Nos. 6 &
10), 7, (Qty. 2 Nos. 8), 9, 11, 12,
(Qty. 6 Nos. 13 & 15) 14, 19 & 20
A3
A4
Key Nos.
(Qty. 2 Nos. 8),
7, 9, & 11
Key Nos.
3, 17 & 18
Key Nos.
(Qty. 40 Nos. 5), (Qty. 20 Nos. 6 & 10),
7, (Qty. 2 Nos. 8), 9, 11, 12,
(Qty. 6 Nos. 13 & 15) 14, 19 & 20
A5
Key Nos.
(Qty. 2 Nos. 7
& 8)
A6
Key Nos.
1&2
A7
A8
Key Nos.
Key Nos.
(Qty. 20 Nos. 6 &
7, (Qty. 2 Nos. 8), 9,
10), (Qty. 40 Nos. 5) 11, 12, (Qty. 6 Nos. 13)
101
03-70 Front Wheel

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
16
594422/A
594422/A
Spacer Disc Side
17
586070/A
586070/A
Plain Washer

Alt. No. 593005/A
Old No. 142835
10
18
593038/D
593038/D
Hex. Nut with Nyloc Insert M16X1.5

5
19
140355/B
140355/B
Rim Tape
20
147507/A
147507/A
Rim (1.85X19” - 1.5 THK)
1
102
04-00 Fuel Tank

500cc
350cc
12
27
A2
18
27
11
2
7
A1
13
4
1, (Qty. 2 Nos. 2)
11, 18 & 27
32
33
14
15
16
9
10
34
19
22
20
21
A1
Key Nos.
15
30
31
26
25
24
23
13
A1
Key Nos.
14
1
A2
11
12
A1
Key Nos.
12
7
12
18
A2
29
28
9
31
17
16
8
8
9
8
9
10
1, (Qty. 2 Nos. 2)
A2
Key Nos.
18 & 27
103
04-00 Fuel Tank

PART NUMBER
KEY
No.
350
500
874002
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
874002
Fuel Tank with Sticker, Twilight
875002
Fuel Tank with Sticker, Stone
879006
879006
Fuel Tank with Sticker, Flicker
A2
888057
888057
Cap Assembly Fuel Filler with Key
A3
594816/A
Fuel Hose and Clip Assembly Set (L 150mm)
594002/A
Cover - Fuel Tap, Silver Ash
594208/A
594208/A
Sticker
594264/B
594264/B
Rear Damper Tank
10
571063/A
571063/A
‘O’ Ring – Fuel Pump Module
10
571052/A
Fuel Pump Module
1
10
A1
Alt. No. 855013
Alt. No. 813044
594538/A
594538/A
Washer - Tank
586042/A
586042/A
Flanged Hex. Bolt M6 X 1 X 20
143496/A
143496/A
Washer
10
144636/A
144636/A
Copper Washer
20
10
500355
500355
M6 Screw
10
11
594513/A
594513/A
Ring - Fuel Cap, Metallic Silver
12
594514/A
594514/A
CSK Screw - M4
13
594222/A
594222/A
‘O’ Ring - Fuel Guage
14
594244/A
594244/A
Fuel Gauge Unit
15
586032/A
586032/A
Plain Washer - Fuel Gauge MTG
4
Old No. 141061/1
50
16
586048/A
586048/A
Hex. Screw, M6 X 10
Old No. 141093
20
17
594470/A
594470/A
Drain Hose - Tank
Fuel Tank Cap Filler
18
Old No. 145861/A
Alt. No. 859048
10
2
20
Alt. No. 170374
5
1
2
594131/B

104
04-00 Fuel Tank

500cc
350cc
12
27
A2
18
27
11
2
7
A1
13
4
1, (Qty. 2 Nos. 2)
11, 18 & 27
32
33
14
15
16
9
10
34
19
22
20
21
A1
Key Nos.
15
30
31
26
25
24
23
13
A1
Key Nos.
14
1
A2
11
12
A1
Key Nos.
12
7
12
18
A2
29
28
9
31
17
16
8
8
9
8
9
10
1, (Qty. 2 Nos. 2)
A2
Key Nos.
18 & 27
105
04-00 Fuel Tank

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
19
594165/A
Fuel Tap
20
143496/A
Washer
20
21
500355
Hex. Bolt M6 X 14
10
22
570262/F
Steady Bracket - Cylinder Head Engine
5
23
586004/A
Hex. Nut with Nylon Insert M8
24
570263/B
Spacer
25
586056/A
Spacer Steady Bracket
26
594210/B
27
594231/B
594231/B
Key Complete - Blank
10
28
594089/B
Fuel Hose
10
29
146318/A
Clip Fuel Hose
50
Fuel Pipe (L 150mm)
594815/A
10
Clip Fuel Pipe
594814/A
50
30
141454
31
Old No. 593030/A, 142182/A
10
5
Old No. 570299/a
20
32
594092/B
594092/B
Tank Decor Plate RH
Alt. No. 867037
33
594091/B
594091/B
Tank Decor Plate LH

1
Alt. No. 867036
34
147870/A
Joint Packing Fuel Tap
20
106
04-10 Seat Assembly
14
8
A2
9
8
16
9
13
9
5
5
10
2
A1
2
12
15
4
3
17
17
11
5
6
5
107
04-10 Seat Assembly

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
A1
594094/A
594094/A
Seat Assembly - Rider
A2
594298/A
594298/A
Seat Assembly - Pillion
594281/B
594281/B
Seat - Cover Rider Rexine
594284/A
594284/A
Rubber Boot - Rider Seat
580290/A
580290/A
Rubber - Support
594655/A
594655/A
Grommet Rear - Rider Seat
594660/A
594660/A
CSK Screw M6 X 20
594102/A
594102/A
Rider Seat Lock (Latch) with Cable
594305/A
594305/A
Seat - Cover Pillion Rexine
594453/A
594453/A
Rubber Boot - Pillion Seat
594306/A
594306/A
Grommet Rear - Pillion Seat
10
594106/A
594106/A
Pillion Seat Lock (Latch) with Cable
11
594681/A
594681/A
Cable, Rider Seat Latch
10
12
594682/A
594682/A
Cable, Pillion Seat Latch
10
13
Seat Cushion Rider
594280/B
N.S.
14
Seat Cushion Pillion
594299/A
N.S.
Alternate No. 594096/B
15
594275/C
594275/C
Seat Pan Assembly Rider
16
594300/A
594300/A
Seat Pan Assembly Pillion
1
17
592030/A
592030/A
Plug (Rubber) Cable Seat Latch
20
108

A1
14
Key Nos.
2, 3, 5, (Qty 2 Nos. 6)
11
11
10
13
1
12
9
2
4
4
6
109

PART NUMBER
KEY
No.
350
500
A1
DESCRIPTION
QTY. REFERENCE
Pillion Gabriel and Back Rest Kit
REMARKS
594097/A
MOQ
Nos.
1
594125/B
594125/B
Sub Frame (Black Powder Coated)
Alt. No. 867045
859049
859049
Pillion Grab Rail - LH (Metalic Silver)
Alt. No. 594099/A
859050
859050
Pillion Grab Rail - RH (Metalic Silver)
Alt. No. 594100/A
586002/A
586002/A
Flanged Hex. Bolt, M8 X 20
Old No. 580349/A, 145862/A,

594310/A, 593927/A, 593016/A
10
594097/A
594097/A
Back Rest - Pillion
586002/A
586002/A
Hex. Socket Head Screw M8 X 1.25 X 20
145882/A
145882/A
Cross Recessed Pan Head Screw M6 X 14
586032/A
586032/A
Punched Washer 6.4
Old No. 141061/A
50
586021/A
586021/A
Hex. Nut with Nylon Insert B M6
Old No. 141306/2
40
10
594108/B
594108/B
Luggage Carrier Plate (Black Powder Coated)
Alt. No. 867039
11
594046/A
594046/A
10
12
580431/E
580431/E
Side Handle LH
1
2
13
594601/A
594601/A
Side Handle RH
14
594680/A
594680/A
Rexine Back Rest
1
Old No. 580349/A, 145862/A,
594310/A, 593927/A, 593016/A
10
20
110
05-00 Rear Shock Absorbers & Center Stand Assembly

LH
RH
13
4
14
1
9
12
11
8
9
12
10
11
5
A1
Key Nos.
(Qty. 2 Nos. 4 & 5),
(Qty. 3 Nos. 3 & 6),
(Qty. 7 Nos. 2)
2 3
2
6 3
2
7
A2
Key Nos.
(Qty. 2 Nos. 9, 11 & 12),
7, 8, 10
111
05-00 Rear Shock Absorbers & Center Stand Assembly

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
888195
888195
Bolt, Washer & Nut Kit Rear Shocks (Thunderbird 350 & 500)
A2
888146
888146
Center Stand and Spindle Kit
146347/B
146347/B
Shock Absorber - Gas Filled
593046/A
593046/A
Plain Washer
593109/A
593109/A
Single Coil Spring Lock Washer M10
594492/A
594492/A
Domed Bolt - 3/8"X60
10
594491/A
594491/A
Domed Bolt - 3/8"X45
10
594493/B
594493/B
Hex. Nut 3/8” BSF
20
867003
867003
Center Stand, Black-Powder Coated
Alt. No. 592159/B
586015/A
586015/A
Spindle Main (Center) Stand
Old No. 580295/C
586016/A
586016/A
Washer Plain - Center Stand
Old No. 141234
40
10
145186/C
145186/C
Rubber Stop Center Stand Main
11
144766/A
144766/A
Spring New
2
10
12
586012/A
586012/A
Split Pin Rear Spindle
13
594601/A
594601/A
Side Handle RH
14
580431/E
580431/E
Side Handle LH
Old No. 580361/A
20
112

A4
Key Nos.
(Qty. 2 Nos. 2 & 3), 4

9
A1
19
17
12
11
18
11
2
3
7
20
6
10
14
15
13
16
15
16
16
16
A2
A3
113

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
867034
867034
Swing Arm Sub Assembly Black (Powder Coated)
A2
888147
888147
Chain Adjuster Kit (RH & LH)
Chain and Sprocket Kit (350cc)
16T (102 Pitches ‘O’ Ring Type)
888149
Chain and Sprocket Kit (500cc)
18T (102 Pitches ‘O’ Ring Type)

1
A3
888148
A4
888079
888079
Swing Arm End Cap, Bush and Spacer Kit
594028/B
594028/B
Swing Arm Complete, Black-Powder Coated
580038/E
580038/E
Bush - Celcon
580749/D
580749/D
End Cup
580037/H
580037/H
Spacer - Chain Stay
580347/A
580347/A
Flanged Hex. Bolt 1/2 X 16 TPI X 235
586008/A
586008/A
Washer - Shake Proof M12
Old No. 145708/A, 580344/A, 593023/A
10
593050/C
593050/C
Hex Nylock nut
Old No. 580343/A, 593050/B
10
594540/A
594540/A
Chain Pad
9
146435/A
146435/A
CSK Screw M6 X 12
Alt. No. 594660/A
20
10
594484/B
594484/B
Bracket Complete - Chain Guard, Black-Powder Coated
Alt. No. 867035
11
593108/A
593108/A
Flange Bolt with Collar - M6 X 1
10
12
591667/B
591667/B
Chain Guard
13
594533/A
594533/A
Chain Tensioner RH
1
10
14
594216/B
594216/B
Chain Tensioner LH
10
15
594365/A
594365/A
Plate-Chain Adjuster
20
16
586005/A
586005/A
Old Type 593008/A, 145867/A
20
17
581085/B
581085/B
Chain - Rear (102 Pitches ‘O’ Ring Type LGB)

1
18
145854
145854
Connecting Link
1
114

A4
Key Nos.
(Qty. 2 Nos. 2 & 3), 4

9
A1
19
17
12
11
18
11
2
3
7
20
6
10
14
15
13
16
15
16
16
16
A2
A3
115

PART NUMBER
KEY
No.
350
500
19
20
570809/A
594048/B
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
571032/B
594048/B
Sprocket Rear Drive 38T
1
116
05-20 Rear Wheel

A1
A2
Key Nos.
1, 2, 3, (Qty. 2 Nos. 4),
5, 6, 7, (Qty. 20 Nos. 8
& 9), (Qty. 40 Nos. 10),
(Qty. 6 Nos. 15),
11, 14 & 16
Key Nos.
3, (Qty. 2 Nos. 4),
5, 6, 7, (Qty. 20 Nos. 8
& 9), (Qty. 40 Nos. 10),
(Qty. 6 Nos. 15),
11, 14 & 16
A3
2
21
17
18
14
19
22 25 28
27
13
20
22
12
24
15
Key Nos.
3, (Qty. 2 Nos.
4), 5, 6
26
27 23
15
A4
Key Nos.
(Qty. 2 Nos. 4), 6
A5
A6
A7
Key Nos.
Key Nos.
Key Nos.
1&2
(Qty. 2 Nos. 4), (Qty. 20 Nos.8

6, 18 & 20
& 9), (Qty. 40
Nos. 10)
A8
A9
Key Nos.
Key Nos.
17, 18, 20
25 & 28
11
8
3
16
4
A10
Key Nos.
12, 13, 26,
(Qty. 2 Nos. 27)
10
9
117
05-20 Rear Wheel

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594042/A
594042/A
Rear Wheel Assembly with Tyre & Tube
A2
888167
888167
Rear Wheel Sub Assembly without Tyre & Tube
A3
594043/C
594043/C
Rear Hub Assembly
A4
888150
888150
Rear Wheel Bearing Kit
A5
888050
888050
Rear Wheel Tyre & Tube Kit - 120/ 80 - 18”
A6
888151
888151
Bearing and Seal Kit Rear Wheel TB 350 & 500cc
A7
888152
888152
Wheel Spokes and Nipple Kit - Thunderbird 500
A8
888153
888153
Adaptor Rear Sprocket Sub Assembly Kit
A9
888154
888154
Short Spindle and Nut Kit
A10 888178
888178
Rear Spindle, Washer and Nut Kit
Tube, Rear 120/ 80 - 18”
591984/A
N.S., Ref. A5
Tyre, Rear 120/ 80 - 18” Zapper C
591983/A
N.S., Ref. A5
2 Seals are packed in Kit
859046
859046
Centre Hub, Rear (Metalic Silver)
150324/A
150324/A
Deep Groove Ball Bearing 6203 (17 X 40 X 12)
10
146499/A
146499/A
Rear Hub Spacer Assembly
Served in Kit, Ref. A3,

Old No. 141105/C
141109/1
141109/1
Grease Seal, 25 X 40 X 7
10
591210/A
591210/A
Rim - Rear
594427/A
594427/A
Spokes Inner, Rear (Long)
20

20
594428/A
594428/A
Spokes Outer, Rear (Short)
20
20
10
110349
110349
Nipple
40
40
11
140355/B
140355/B
Rim Tape
12
586010/A
586010/A
Hex. Castle Nut, M16 x 1.5
Old No. 593043/2
10
1
118
05-20 Rear Wheel

A1
A2
Key Nos.
1, 2, 3, (Qty. 2 Nos. 4),
5, 6, 7, (Qty. 20 Nos. 8
& 9), (Qty. 40 Nos. 10),
(Qty. 6 Nos. 15),
11, 14 & 16
Key Nos.
3, (Qty. 2 Nos. 4),
5, 6, 7, (Qty. 20 Nos. 8
& 9), (Qty. 40 Nos. 10),
(Qty. 6 Nos. 15),
11, 14 & 16
A3
2
21
17
18
14
19
22 25 28
27
13
20
22
12
24
15
Key Nos.
3, (Qty. 2 Nos.
4), 5, 6
26
27 23
15
A4
Key Nos.
(Qty. 2 Nos. 4), 6
A5
A6
A7
Key Nos.
Key Nos.
Key Nos.
1&2
(Qty. 2 Nos. 4), (Qty. 20 Nos.8

6, 18 & 20
& 9), (Qty. 40
Nos. 10)
A8
A9
Key Nos.
Key Nos.
17, 18, 20
25 & 28
11
8
3
16
4
A10
Key Nos.
12, 13, 26,
(Qty. 2 Nos. 27)
10
9
119
05-20 Rear Wheel

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
Alt. No. 593044/A
MOQ
Nos.
13
586012/A
586012/A
Split Pin
50
14
594045/A
594045/A
Rear Disc Plate
15
590906/B
590906/B
Hex. Socket Head Screw M6 X 1 X 14
16
144471/A
144471/A
Cushion Rubber
4
17
859047
859047
Adaptor - RD Sprocket (Metalic Silver)
18
145553/B
145553/B
Bearing 6005 (25 X 47 X12) (double side rubber sealed)
19
594054/A
594054/A
Rear Caliper Assembly
20
594562/A
594562/A
Dust Seal - RD Sprocket
21
594048/B
594048/B
Sprocket - Rear Drive
1
22
560530/D
560530/D
Socket Button Head Cap Screw
23
594050/A
594050/A
Spacer - Disc Side
24
594051/A
594051/A
Spacer - Sprocket Side
25
594087/A
594087/A
Spindle Short
26
594088/A
594088/A
Spindle Long

5
27
593095/A
593095/A
Plain Washer
10
28
586009/A
586009/A
Hex. Nut, M22X1.5
Old No. 593042/B
10
1
Alt. No. 594046/A, Old Type
10
5
1
10
120
05-30 Rear Master Cylinder Assembly - BBI

A1
14
Key Nos.
1 to 15
11
12
A2
10
13
2
3 4 5
10A
10D 10C
15
Key Nos.
16, (Qty. 2 Nos. 17),
(Qty. 4 Nos. 18)
A3
18
17
Key Nos.
24 & 25
A4
A1
16
A7
Key Nos.
19 to 23, (Qty. 2
Nos. 24), 25
Key Nos.
2 to 9 & 10E
A5
A8
Key Nos.
20, 21 & 22
Key Nos.
12 & 13
A6
A9
Key Nos.
2 to 5, 8 & 9
Key Nos.
17, (Qty. 2 Nos. 18)
A1
17
19
20
18
24
21
25
22
24
23
26
10B
121

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594055/A
594055/A
Rear Master Cylinder Assembly
A2
594688/A
594688/A
Rear Brake Hose Assembly Kit with Banjo Bolt - BBI
A3
594695/A
594695/A
Reservoir Tube Kit Rear M/C
A4
888157
888157
Rear Reservoir Kit
A5
594694/A
594694/A
Reservoir Kit Rear M/C Threaded
A6
594690/A
594690/A
Minor Kit Rear M/C
A7
594689/A
594689/A
Major Kit Rear M/C
A8
594693/A
594693/A
Connector Kit Rear M/C
A9
594721/A
594721/A
Banjo Bolt Kit (Disc Brake)
Master Cylinder M/C - Rear Body
Spring Rear M/C
594595/A
(N.S.) Served in Kit, Ref.A6, A7
Spring Guide Rear M/C
594594/A
Primary Seal Rear M/C
594593/A
Primary Washer
594592/A
Piston - Rear Master Cylinder

1
594591/A
(N.S.) Served in Kit, Ref. A7
Seal (‘O’ Ring) Rear M/C
594590/A
Spacer Rear M/C
594722/A
Circlip Rear M/C
594510/A
Push Rod Assembly Kit Rear M/C
10A
Push Rod Rear M/C
594723/A
(N.S.) Served in Kit, Ref. Key 10
10B
Fork Push Rod Rear M/C
594724/A

10C
Lock Nut Rear M/C
594725/A
10D
Push Rod Assembly Rear M/C
594509/A
10
594691/A
594691/A
N.S., Ref. A1
(N.S.) Served in Kit
5
122

A1
14
Key Nos.
1 to 15
11
12
A2
10
13
2
3 4 5
10A
10D 10C
15
Key Nos.
16, (Qty. 2 Nos. 17),
(Qty. 4 Nos. 18)
A3
18
Key Nos.
24 & 25
A4
A7
Key Nos.
19 to 23, (Qty. 2
Nos. 24), 25
Key Nos.
2 to 9 & 10E
A5
A8
Key Nos.
20, 21 & 22
Key Nos.
12 & 13
A6
A1
16
17
A1
17
19
20
18
24
21
25
22
24
Key Nos.
2 to 5, 8 & 9
23
26
10B
123

PART NUMBER
KEY
No.
350
500
10E
DESCRIPTION
REMARKS
QTY. REFERENCE
Grease Pouch (Reference Only)
Boot Rear M/C
12
Bush Rear M/C
594726/A
13
Connector Rear M/C
594586/A
14
Cap
N.S.
15
Thread Protector
1
N.S.
16
Brake Hose Rear
594056/A
17
Banjo Bolt (Black Tri-Valent)
594507/A
(N.S.) Served in Kit, Ref. A2, A9
18
Copper Washer Disc
594508/A
20
Reservoir Rear (Threaded)
594057/A
21
Diaphragm Rear Disc Reservoir
594504/A
22
Lid Reservoir Threaded

1
594633/A
Cover Reservoir
24
Clip (Reservoir)
594727/A
25
Rubber Tube - Rear Disc
594059/A
Cable Strap 8” (Black)
11
19
23
26
594511/A
594046/A
594518/A
582511/A
594511/A
594046/A
594518/A
582511/A
594728/A
MOQ
Nos.
(N.S.) Served in Kit, Ref. A7, 10

Figure not shown
10
10
20
124
05-40 Rear Caliper Assembly - BBI

A8
A1
A2
A3
A4
A5
A6
A7
Key Nos.
A2,
(In Page No. 116 A1, 16, (Qty. 2 Nos. 17 & 24),
(Qty. 4 Nos. 18), 20 to 23 & 25)
Key Nos.
Key Nos.
Key Nos.
8,
(Qty. 2 Nos. 9)
Key Nos.
6&7
Key Nos.
2, 3, 10, 12,
13, 14 & 21
Key Nos.
1 to 20
Key Nos.
2, 3, 4, 10, 12,
13, 14 & 21
11, 12 & 21
10, 15, 17, 18,

19 & 21
5
20
15
9
8
10
16
14
13
6
11
19
17
12
18
125

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594053/A
594053/A
Disc Brake Assembly Rear - BBI
A2
594054/A
594054/A
Caliper Assembly Rear - BBI
A3
594698/A
594698/A
Disc Pad Kit Rear Caliper - BBI
A4
594696/A
594696/A
Major Kit Rear Caliper
A5
594697/A
594697/A
Minor Kit Rear Caliper
A6
594700/A
594700/A
Pad Pin Kit Rear Caliper
A7
594703/A
594703/A
Primary Pin Kit Rear Caliper
A8
594701/A
594701/A
Bracket Sub Assembly Rear Caliper
Caliper Body
1
Piston Seal Rear Caliper
594432/A
(N.S.) Served in Kit,Ref. A4, A5
Scrapper Ring Rear Caliper
594433/A
Piston - Rear Caliper
594431/A
(N.S.) Served in Kit,Ref. A4
Pad Spring Rear Caliper
Pad (Piston Side) Rear Caliper
594430/A
Pad (Opposite Piston Side) Rear Caliper
594429/A
8
Pad Pin Rear Caliper
594730
Clip Hanger Rear Caliper
594600/A
10
Insulator Rubber Rear Caliper
594599/A
(N.S.) Served in Kit,Ref.A4,A5,A8
11
Primary Pin Rear Caliper
594598/A
12
Dust Cover Rear Caliper
594597/A
(N.S.) Served in Kit, Ref.A4,A5,A7
13
Bleeder Screw Rear Caliper
594435/A
14
Bleeder Cap Rear Caliper
594434/A
15
Bracket Sub Assembly Rear Caliper
594731/A
594729/A
594729/A
10
126

A8
A1
A2
A3
A4
A5
A6
A7
Key Nos.
A2,
(In Page No. 116 A1, 16, (Qty. 2 Nos. 17 & 24),
(Qty. 4 Nos. 18), 20 to 23 & 25)
Key Nos.
Key Nos.
Key Nos.
8,
(Qty. 2 Nos. 9)
Key Nos.
6&7
Key Nos.
2, 3, 10, 12,
13, 14 & 21
Key Nos.
1 to 20
Key Nos.
2, 3, 4, 10, 12,
13, 14 & 21
11, 12 & 21
10, 15, 17, 18,

19 & 21
5
20
15
9
8
10
16
14
13
6
11
19
17
12
18
127

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
16
Thread Protector
N.S., Ref. A2
17
Wear Pad Rear Caliper
594733/a
18
Bracket Machined Rear Caliper
594732/a
19
Secondary Pin Rear Caliper
594734/a
20
Pad Spacer
1
21
Grease Pouch ( Reference Only)
N.S., Ref. A2
594728/a
(N.S.) Served in Kit,Ref. A4,A5,A7,A8
MOQ
Nos.
128
18 18
16
17
6
4
5
1
3
13
15
12
14 11 10
A1
A2
A3
A4
Key Nos.
Key Nos.
Key Nos.
Key Nos.
(Qty. 4 Nos. 17),

(Qty. 8 Nos. 18)
2, (Qty. 2 Nos. 3),

4, 5, 6 & 7
12 & 16
All 1 to 18
129

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
888164
888164
Foot Rest Rubber Kit
A2
888162
888162
Foot Rest Assembly RH with Holder Kit
A3
888197
888197
Rear Brake Pedal with Rubber
A4
594220/A
594220/A
Cradle Tube Sub Assembly RH
594116/B
594116/B
Cradle Tube Complete - RH Black (Powder Coated)
Alt. No. 867043
594358/B
594358/B
Foot Rest Holder - RH, Metalic Silver
Alt. No. 859052
586002/A
586002/A
Old No. 580349/A, 145862/A,

594310/A, 593927/A, 593016/A
594118/A
594118/A
Foot Rest Assembly - RH

1
594334/B
594334/B
Spring - Rider Foot Rest
20
5943702/B
594372/B
Lock Pin - Foot Rest
20
550141
550141
Circlip 10 X 1N
20
594055/A
594055/A
Master Cylinder Assembly
586042/A
586042/A
10
594067/A
594067/A
Spring - Pedal Return
40
11
594393/A
594393/A
Brake Light Switch with Spring
12
594526/A
594526/A
Rear Brake Pedal
13
594537/A
594537/A
Pin Master Cylinder
10
14
594066/A
594066/A
Split Pin
1
40
15
586032/A
586032/A
Punched Washer 6.4
16
144886/C
144886/C
Brake Pedal Rubber
17
594351/A
594351/A
Foot Rest Rubber Large
18
594350/A
594350/A
Foot Rest Rubber Small
10
1
Old No. 145861/A
Old No. 593004/A, 141061/A

10
20
130
05-60 Rear Mudguard

8
1
8
10
9
12
11
6
5
3
4
6
5
131
05-60 Rear Mudguard

PART NUMBER
KEY
No.
350
500
874007
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
874007
Rear Mudguard Assembly, Twilight
875005
Rear Mudguard Assembly, Stone
879001
879001
Rear Mudguard Assembly, Flicker
586052/A
586052/A
Hex. Screw M6 X 16
Old No. 142274
40
3
586051/A
586051/A
Hex. Screw M6 X 20
Old No. 111846
50
586035/A
586035/A
Plain Washer
Old No. 140383/A
50
140090/1
140090/1
Star Washer
586029/A
586029/A
Hex. Nut M6
Old No. 141060
40
586021/A
586021/A
Hex. Nut with Nylon Insert B M6
Old No. 141306/2
40
586042/A
586042/A
Old No. 145861/A
10
586025/A
586025/A
Old No. 591534/A
30
10
594214/A
594214/A
Reflex Reflector
11
580811/B
580811/B
Piece Mudguard Assembly
1
12
586035/A
586035/A
Plain Washer M6
50
132

A1
Key No’s
10, 11,
(Qty. 2 Nos. 12)
13
10
11
2
7
4
1
5
12
12
133

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
888159
888159
Saree Guard Complete Kit
594101/B
594101/B
Bracket Assembly - Tail Lamp Plated
586028/A
586028/A
Hex. Nut M12
502006/A
502006/A
Spring Washer M12
50
594015/A
594015/A
Trafficator Assembly LH
146375
146375
Hex. Screw M6 X 14
845020
845020
Number Plate - Rear, Milky White
581122/A
581122/A
Mushroom Head Screw M6X8
10
594016/A
594016/A
Trafficator Assembly RH
594036/A
594036/A
Tail Lamp Led
10
867070
867070
Saree Guard (Powder Coating Black)
11
867071
867071
Saree Guard - Add On (Powder Coating Black)
12
594046/A
594046/A
20
13
591023/A
591023/A
Beading
Old No. 580368/B
868037
10
1
134
06-00 Cradle Assembly LH & Pillion Foot Rest Assembly

A3
RH
A1
Key No’s
16, 17, 21,
(Qty. 2 Nos. 22 & 23)
19
16
24
27
18
17
26
20
Key No’s
24, 26 to 30
28
21
23 22
29
5
7
32
30
23 22
LH
26
4
31
25 25
15
10
11
9
A4
Key No’s
2, (Qty. 2 Nos. 3)
4, 5, 6 & 7
A5
Key No’s
(Qty. 8 Nos. 25)
(Qty. 4 Nos. 31)
14
27
28
15
13
12
A6
A2
Key No’s
1 to 23
Key No’s
4, 26 to 30
29
30
135

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594047/A
594047/A
Gear Shifter Assembly without Rubber
A2
594221/A
594221/A
Pillion Foot Rest Sub Assembly LH
A3
594371/A
594371/A
Pillion Foot Rest Sub Assembly RH
A4
888163
888163
Foot Rest Assembly LH with Holder Kit
A5
888164
888164
Foot Rest Rubber Kit
A6
594063/A
594063/A
Cradle Tube Sub Assembly LH
594117/B
594117/B
Cradle Tube Complete LH - Black-Powder Coated
Alt. No. 867041
594120/B
594120/B
Foot Rest Holder - LH, Metalic Silver
Alt. No. 859051
1
3
586002/A
586002/A
Old No. 580349/A, 145862/A,

594310/A, 593927/A, 593016/A
594119/A
594119/A
Foot Rest Assembly - LH
Old No. 594521/B
594334/C
594334/C
Spring Rider Foot Rest
594372/B
594372/B
20
550141
550141
Circlip 10 X 1N
20
594122/B
594122/B
Side Stand Mounting Complete, Black-Powder Coated
591713/C
591713/C
Side Stand Assembly
10
521199
521199
Hex. Socket Head Screw M8 X 45
11
586036/A
586036/A
Washer
Old No. 140437/1, 593028/A, 140080/2
5
12
586004/A
586004/A
Hex. Nut with Nylon Insert, M8
Old No. 593030/A, 142182/A
13
591992/B
591992/B
Spring
Old No. 147849/A
14
581738/A
581738/A
Switch, Side Stand
Alt. No. 146147/C
15
500632
500632
Hex. Screw Head Cap Screw M5 X 20
16
594177/B
594177/B
Gear Lever (Shifter Complete)

1
867042
10
N.S. Ref. A1
1
136

A3
RH
A1
Key No’s
16, 17, 21,
(Qty. 2 Nos. 22 & 23)
19
16
24
27
18
17
26
20
Key No’s
24, 26 to 30
28
21
23 22
29
5
7
32
30
23 22
LH
26
4
31
25 25
15
10
11
9
A4
Key No’s
2, (Qty. 2 Nos. 3)
4, 5, 6 & 7
A5
Key No’s
(Qty. 8 Nos. 25)
(Qty. 4 Nos. 31)
14
27
28
15
13
12
A6
A2
Key No’s
1 to 23
Key No’s
4, 26 to 30
29
30
137

PART NUMBER
KEY
No.
350
500
17
DESCRIPTION
QTY. REFERENCE
Actuator Complete
594452/A
REMARKS
MOQ
Nos.
18
594065/A
594065/A
Pivot Pin
19
550507/A
550507/A
Gear Lever Rubber (Sleeve)
20
572015/A
572015/A
Hex. Socket Head Cap Screw M6X 30

1
10
21
Link Rod
594235/B
22
Punched Washer 6.4
594641/B
20
594066/B
20
Old No. 594522/B
23
593019/B
593019/B
Split Pin 4 X 32
24
594118/A
594118/A
Foot Rest Assembly Pillion / Rider - RH
1
25
594350/A
594350/A
Foot Rest Rubber Small
26
594372/B
594372/B
Served in Kit Ref. A3, A4
20
27
580381/D
580381/D
Spring Pillion Foot Rest
20
28
594447/B
594447/B
Bracket Assembly - Pillion Foot Rest
29
580380/A
580380/A
Ball

50
30
550141
550141
Circlip 10 X 1- Foot Rest
50
31
594351/A
594351/A
Foot Rest Rubber Large
32
586003/A
586003/A
Hex. Flange Bolt M8 X 1.25 X 30
10
594448/B
5
Old No. 593014/A
138

A1
Key No’s
6&7
A2
Key No’s
8&9
A3
Key No’s
3, 10 &
(Qty. 4 Nos. 4)
10
A4
Key No’s
6&7
9
139

PART NUMBER
KEY
No.
350
500
A1
A2
888058
888058
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Side Panel Lock Assembly with Key Kit
Sticker Side Panel RH and LH Kit 350cc
888161
Sticker Side Panel RH and LH Kit 500cc
888160
A3
888198
888198
Side Panel Grommet, Washer and Boot Repair Kit
1
A4
888058
888058
Side Panel Lock with Key
879004
Side Panel RH (with Sticker), Flicker
874004
Side Panel RH (with Sticker), Twilight
874003
Side Panel RH (with Sticker), Twilight
875003
Side Panel RH (with Sticker), Stone Black
879005
Side Panel RH (with Sticker), Flicker
879002
Side Panel LH (with Sticker), Flicker
1
874006
Side Panel LH (with Sticker), Twilight
874005
Side Panel LH (with Sticker), Twilight
875004
Side Panel LH (with Sticker), Stone Black
879003
Side Panel LH (with Sticker), Flicker
594500/A
594500/A
Washer Side Panel
10
521112/B
521112/B
Grommet
4
10
594501/A
594501/A
Side Panel Screw M6 (Special)
20
Side Panel Lock
Key Set Blank
Sticker RH - 350cc
Sticker RH - 500cc
6
7
8
594231/B
594231/B
594109/A
594138/A
594473/A
1
140

A1
Key No’s
6&7
A2
Key No’s
8&9
A3
Key No’s
3, 10 &
(Qty. 4 Nos. 4)
10
A4
Key No’s
6&7
9
141

PART NUMBER
KEY
No.
350
500
9
10
594110/A
521066/B
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Sticker LH - 350cc
594136/A
Sticker LH - 500cc
521066/B
Side Panel Boot
10
142
1
7
2
7
6
3
11
13
12
10
13
12
3
3
9
9
8
143

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
594543/A
594543/A
Back Plate Assembly LH Black (Powder Coated) )
Alt. No. 801526
594144/A
594144/A
Back Plate Assembly RH Black (Powder Coated) )
Alt. No. 867038
586031/A
586031/A
Old No. 140129

50
586032/A
586032/A
Plain Washer
Old No. 141061/1
10
586052/A
586052/A
Hex. Screw, M6 X 16
Old No. 142274
40
860009
860009
Side Decor - LH (Chrome Plated)
521088/B
521088/B
Grommet
14
580447/A
580447/A
Beading
10
147559/A
147559/A
Mushroom Head Screw M5
20
10
521089/B
521089/B
Strap Rubber
11
147098/C
147098/C
R/R Unit - 3 Phase
12
591702/A
591702/A
50
13
586032/A
586032/A
Plain Washer
Old No. 141061/1
50
144
06-30 Frame
3
52 53 54
51
50
49
7
1
61
65
64
63
46
62
61
45
59
60
57
47
12
48
9 11
4
7
28
27
29
16
17
16
17
19
21
22
67
18
13
14
15
20
31
41
40
38
14
32
34
33
31
39
42
30
30
26
17 34
33
32
35
16
10
16
43
41
40
17
59
58
56
55
44
57
24
25
39
37
66
37
23
145
06-30 Frame
PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
Alternate No. 594115/C
MOQ
Nos.
867040
867040
Frame Assembly - Black (Powder Coated)
144582/E
144582/E
Ball Race Frame
140201
140201
Ball, Dia 1/4” (6.35 MM)
19
38
145446/A
145446/A
Cover Ball Race
20
594091/B
594091/B
Tank Decor - Plate LH - Black (Powder Coated)
Alt. No. 867036
594092/B
594092/B
Tank Decor - Plate RH - Black (Powder Coated)
Alt. No. 867037
147896/A
147896/A
Philips Pan Head Screw, M5 X 6
594202/B
594202/B
Engine Mounting Bracket - LH, Black-Powder Coated
Alt. No. 867031

1
594469/B
594469/B
Engine Mounting Bracket - RH, Black-Powder Coated
Alt. No. 867032
10
593049/C
593049/C
Flanged Hex. Bolt 1/2"x120
11
586008/A
586008/A
Plain Washer M12
12
593050/C
593050/C
Hex. Nut with Nyloc Insert
13
593060/C
593060/C
10
14
593061/C
593061/C
10
15
594420/A
594420/A
Hex. Flange Bolt M8 X 1.25 X 176
10
16
586036/A
586036/A
Plain Washer
Old No. 140437/1, 593028/A, 140080/2
17
586004/A
586004/A
Old No. 593030/A, 142182/A
18
594389/A
594389/A
Engine Mounting Plate Rear Complete - LH, Black Matt , Black-Powder Coated
Alt. No. 867033
19
801529
801529
Engine Mounting Plate Rear “R”
20
593022/C
593022/C
Hex. Bolt M12 X 266
21
586008/A
586008/A
Plain Washer M12
22
593024/D
593024/D
Hex. Nut with Nyloc M12
10
23
594330/A
594330/A
Flanged Hex. Bolt M10
10
50
5
Old No. 145708/A, 580344/A, 593023/A
Old No. 145708/A, 580344/A, 593023/A
5
146
06-30 Frame
3
52 53 54
51
50
49
7
1
61
65
64
63
46
62
61
45
59
60
57
47
12
48
9 11
4
7
28
27
29
16
17
16
17
19
21
22
67
18
13
14
15
20
31
41
40
38
14
32
34
33
31
39
42
30
30
26
17 34
33
32
35
16
10
16
43
41
40
17
59
58
56
55
44
57
24
25
39
37
66
37
23
147
06-30 Frame
PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
24
593011/C
593011/C
Flanged Hex. Nut M10x1.25
25
580203/D
580203/D
Cap Swing Pivot
26
867044
867044
Spacer - Cradle Tube, Black-Powder Coated
27
593010/C
593010/C
Steady Bracket
1
581048/B
Steady Bracket
28
570262/F
Old No. 593011/B
MOQ
Nos.
5
2
Alt. No. 594333
Old No. 593011/B
29
593011/C
593011/C
30
142258
142258
Hex. Screw M8 X 16
31
586046/A
586046/A
Washer Faced Hex. Nut 3/8”

2
Old No. 140402/C
14
32
586047/A
586047/A
Stud 3/8” X 26” TPI
Old No. 146143/B
33
586070/A
586070/A
Plain Washer
Old No. 142835
20
34
586057/A
586057/A
Hex. Nut
Old No. 140302/3
10
35
594545/A
594545/A
1
10
36
593011/C
593011/C
37
594009/B
594009/B
Hex. Nyloc Nut M10 X 1.5
10
38
586052/A
586052/A
Hex. Screw M6 X 16
Old No. 142274
40
39
586035/A
586035/A
Plain Washer
Old No. 140383/A
50
40
140090/1
140090/1
Star Washer
41
586029/A
586029/A
Hex. Nut M6
Old No. 141060
40
42
586051/A
586051/A
Hex. Screw M6 X 20
Old No. 111846
50
43
801530
801530
Bracket (Piece Mudguard), Black-Powder Coated
Alt. No. 580314/A
44
581019/B
ECU Carrier Assembly, Black-Powder Coated
Alt. No. 801538
1
45
571056/A
ECU Unit
50
50
1
148
06-30 Frame
3
52 53 54
51
50
49
7
1
61
65
64
63
46
62
61
45
59
60
57
47
12
48
9 11
4
7
28
27
29
16
17
16
17
19
21
22
67
18
13
14
15
20
31
41
40
38
14
32
34
33
31
39
42
30
30
26
17 34
33
32
35
16
10
16
43
41
40
17
59
58
56
55
44
57
24
25
39
37
66
37
23
149
06-30 Frame
PART NUMBER
KEY
No.
350
500
46
QTY. REFERENCE
REMARKS
MOQ
Nos.
Strap
593144/A
586004/A
49
591578/A
50
147504/A
Bush - PAV
2
51
147502/A
Grommet - PAV
50
52
510187/B
Pulse Air Valve - Ucal
53
586031/A
Old No. 140129
50
54
586029/A
Hex. Nut M6
Old No. 141060
40
55
573986/A
Braided Hose Assembly
56
146318/A
SS Hose Clip
57
140573/B
Clip - PAV
40
58
573984/A
PAV Hose - Air Filter
59
147701/A
Wire Clip
50
60
573985/A
PAV Tube Adaptor
594268/B
Front Damper Tank
Bracket Filter Box Mounting, Black-Powder Coated - 350cc
Alt. No. 867046

1
47
48
521089/B
DESCRIPTION
594210/B
586004/A
61
594268/B
62
594158/A
Old No. 593030/A, 142182/A
5
10
N.S., Old No. 573977/A
63
586032/A
Punched Washer
Old. No. 141061/1
50
64
586031/A
Old No. 140129
50
65
586052/A
Hex. Screw M6 X 16
2
Old No. 142274
40
Alt. No. 801630
66
580314/A
580314/A
Bracket Piece Mudguard
67
586001/A
586001/A
5
150
07-00 Battery, Battery Carrier and Harness

1
350-TCI
500-EFI
11
5
6
15
14
13
17
12
10
16
18
19
9
151
07-00 Battery, Battery Carrier and Harness

PART NUMBER
KEY
No.
350
500
1
594440/A
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Harness Main Cable - 350 TCI
594038/A
Harness Main Cable - 500 EFI
592212/A
592212/A
Battery, 12V-14 AH MF14-A2
Alt. No. 146134/C
521204/F
521204/F
Battery Carrier Complete (ES)
1
Alt. No. 801541
594104/B
594104/B
Cover Battery
521204/F
521204/F
Back Plate Assembly
142258
142258
Hex. Bolt M8 X 16
50
141162/C
141162/C
Cable Strap - Long 8”
40
141161/C
141161/C
Cable Strap - Small 6”
5
40
582511/A
582511/A
Strap (White)
Old No. 500917/B
30
10
594542/A
594542/A
Cable - Battery Negative
Alt. No.147956/A
11
594173/A
594173/A
Wiring Harness - Tail Light
12
594525/A
Mini Blade Fuse 10 Amps (Red Colour) (4+1)
10
13
594524/A
Mini Blade Fuse 15 Amps (Blue Colour) (2+1)
4
10
1
Alt. No. 801292
14
582512/A
Blade Fuse 10 Amps (Red Colour) (1+1)
10
15
582513/A
Blade Fuse 15 Amps (Blue Colour) (1+1)
10
16
594744/A
Rubber Holder Fuse Carrier
10
17
573993/A
Starter Motor 0.7KW
573992/A
Starter Motor 0.9KW
591494/A
Neutral Switch with Gasket

1
18
19
591494/A
152
07-10 Head Lamp

A1
Key Nos.
All
A2
4
5
4
1
6
A3
2
6
153
07-10 Head Lamp

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594029/A
594029/A
Head Lamp Assembly with Bulb
A2
594579/A
594579/A
Lens & Inner Housing Sealed Body with Bulb
A3
594580/A
594580/A
Lens & Inner Housing Sealed Body without Bulb
594573/A
594573/A
Outer Housing Chrome Plating
594574/A
594574/A
Rim Chrome Plating
594575/A
594575/A
HL Installation (Addon Lead - Head Lamp)
594576/A
594576/A
Mounting Grommet
10
594577/A
594577/A
Bulb H7 12V 55W
594578/A
594578/A
Bolt M6 HL (NT)
20
154
07-20 Tail Lamp

A1
Key Nos.
All
A2
4
2
155
07-20 Tail Lamp

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594036/A
594036/A
Tail Lamp LED Assembly Complete
A2
594572/A
594572/A
Lens & Inner House Sealed Body Tail Lamp
594570/A
594570/A
Outer Housing Chrome Plating
594571/A
594571/A
Screw 8 X 19 mm (Mask & Housing)
20
Cover-LH Chrome Plating
Cover-RH Chrome Plating
2
156
07-30 Instrument Cluster
A1
500cc
MIL
A2
350cc
6
2
4
1
157
07-30 Instrument Cluster

PART NUMBER
KEY
No.
350
500
A1
594030/A
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Instrument Cluster Assembly, TB 500cc (EFI)
Instrument Cluster Assembly, TB 350cc (TCI)
A2
594634/A
594652/A
594652/A
Rubber Grommet Bulb Window
10
594650/A
594650/A
Mounting Bracket - Instrument Cluster Bracket
1
1
594656/A
594656/A
Grommet - Instrument Cluster Bracket
10
594657/A
594657/A
Nut - Instrument Cluster Bracket
20
594658/A
594658/A
Washer - Instrument Cluster
20
594651/A
594651/A
Bulb 12V, 1.4W (Neutral and Side Stand)
10
158
A1
5
3
11
A2
A3
A4
Key Nos.
1&2
Key Nos.
1&5
Key Nos.
1&4
12
10
13
4
16
20
15
14
17
18
19
7
21
15
22
14
159

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
594129/B
594129/B
Common Key Set
A2
888056
888056
Switch Assembly Combination and Key
A3
888057
888057
Cap Assembly Fuel Filler and Key
A4
888058
888058
Side Panel Lock and Key
594231/B
594231/B
Key Complete - Blank
Ignition Switch cum Steering Lock Assembly
594130/B
Cap Assembly Fuel Tank
594131/B
Side Panel Lock
594473/A
Alt. No. 859048
2
5
594513/A
594513/A
Ring Fuel Cap, Metalic Silver
594102/A
594102/A
Rider Seat Latch with Cable
594106/A
594106/A
Pillion Seat Latch with Cable
147955/B
147955/B
Relay Starter
Holder (For Relay Starter)
571059/A
Relay
2
1
9
10
11
594228/B
594228/B
Bracket LH Assembly - Horn MTG, Black-Powder Coated
Alt. No. 867047
12
594332/B
594332/B
Bracket RH Assembly - Horn MTG, Black-Powder Coated
Alt. No. 867048
13
591980/A
591980/A
Horn LT
14
586038/A
586038/A
Spring Washer M8
Old No. 210026
50
15
586002/A
586002/A
Flanged Hex. Bolt M8X20
Old No. 580349/A, 145862/A,

594310/A, 593927/A, 593016/A
20
16
580397/A
580397/A
Suppressor Cap, M10 (Spark Plug)
17
500905/C
500905/C
Suppressor Cap, M14 (Spark Plug)
18
594541/A
594541/A
Electronic Flasher Unit - 40W
Alt. No. 594437/A
1
160
A1
5
3
11
A2
A3
A4
Key Nos.
1&2
Key Nos.
1&5
Key Nos.
1&4
12
10
13
4
16
20
15
14
17
18
19
7
21
15
22
14
161

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
19
591981/A
591981/A
Horn HT
20
594681/A
594681/A
Cable, Rider Seat Latch
10
21
594682/A
594682/A
Cable, Pillion Seat Latch
10
22
144519
Flashet Bracket AC/DC
10
162

EFI System
3
20
1
7
8
2
10
21
22
11
23
16
19
15
16 15
18
18
A1
13
17
19
12
24
24
16
15
25
Key Nos.
23, (16 & 17 in
Page No. 158)
A2
Key Nos.
14
5
6
23, 25, (Qty. 2

Nos. 24)
163

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
A1
591837/A
Dual Ignition Coil Assembly with Spark Plug Caps
A2
591879/A
Dual Ignition Coil Assy. C5
147098/C
147098/C
R/R Unit - 3 Phase
591702/A
591702/A
Hex. Bolt M6 X 12
2
50
586032/A
586032/A
Plain Washer
581054/B
Roll Over Sensor
141061
Punched Washer 6.4
20
586053/A
Hex. Screw M6 x 25
Old No. 141061/1
Old No. 143498
50
10
592238/A
Digital TCI - Unit
1
8
586052/A
Hex. Screw M6 X 16
Old No. 142274
40
586031/A
Old No. 140129
50
10
586032/A
Plain Washer
Old No. 141061/1
50
11
502026/B
Bracket - TCI Unit
10
12
147096/A
Primary Ignition Coil without Bracket
13
581027/B
Secondary Ignition Coil with Resistive Cable
14
580377/B
Bracket, Ignition Coil
15
142606
Lock Washer Internal Teeth
40
16
502071
Hex. Screw M5
50
17
580288/D
Throttle Position Switch
18
142606
Lock Washer Internal Teeth
40
19
502071
Hex. Screw M5
20
20
521089/B
Strap - Rubber (Thunderbird)
21
592861/B
Electronic Control Unit - ECU 500 EFI - Domestic
1
164

EFI System
3
20
1
7
8
2
10
21
22
11
23
16
19
15
16 15
18
18
A1
13
17
19
12
24
24
16
15
25
Key Nos.
23, (16 & 17 in
Page No. 158)
A2
Key Nos.
14
5
6
23, 25, (Qty. 2

Nos. 24)
165

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
22
592862/B
Sticker - ECU
10
23
591837/B
Dual Ignition Coil without Bracket
24
500632
Hex. Screw Head Cap Screw M5
20
25
591874/A
Bracket, Dual Ignition Coil
1
166
07-60 Trafficator Lights & Tools, First Aid Kit

Front LH
A2
Front RH
A3
Key Nos.
1, 3, 4 & 6
A2
A3
3
A2
A1
Key Nos.
2, 3, 4 & 5
Rear LH Rear RH
6
RH
A3
A2
A4
7
4
A3
9 10 11
A4
12
Key Nos.
7 to 13
13
15
3
2
14
5
LH
167
07-60 Trafficator Lights, Tools & First Aid Kit

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
A1
888199
888199
Trafficator Kit - Thunderbird
A2
594016/A
594016/A
Trafficator Assembly RH
A3
594015/A
594015/A
Trafficator Assembly LH
A4
570828/B
570828/B
Tool Kit Assembly
594583/A
594583/A
Lens & REF Sealed Body FLH / RRH
594584/A
594584/A
Lens & REF Sealed Body FRH / RLH
594581/A
594581/A
Bulb 12V R10W
Screw M2, 9 X 13 Trafficator
Alt. No. 146348 or 142721

594582/a
10
20
594404/A
594404/A
TSL Gum Arm FLH / RRH
594418/A
594418/A
TSL Gum Arm FRH / RLH
Tool Bag
521150/B
N.S., Ref. A1
Screw Driver
521104/A
N.S., Ref. A1
Tommy Bar
570827/B
N.S., Ref. A1
10
Box Spanner 20.9X24
142631
N.S., Ref. A1
11
Tool Spark Plug
570826/B
N.S., Ref. A1
12
Double End Spanner 10 X 12mm
580695/A
N.S., Ref. A1
13
Double End Spanner 1/4” X 5/16”
140501
N.S., Ref. A1
Allen Key 4mm
First Aid Kit
14
15
595008/A
595008/A
10
521097/A
N.S.
1
168
10
11
12
169

PART NUMBER
KEY
No.
350
500
DESCRIPTION
REMARKS
QTY. REFERENCE
MOQ
Nos.
ST 26199-3
ST 26199-3
Cylinder Head Nut Tightening Tool (UCE models)
Old No.ST-25118/4, N.S.

(New Design, Common)
ST 25123-1
ST 25123-1
Valve Spring Compressor
Common
ST 25128-2
ST 25128-2
Puller for Magneto Rotor
Common
1
ST 25151-4
ST 25151-4
Puller for Chaincase Outer
Common
ST 25153-4
ST 25153-4
Extractor for Gear Box Rocker Pivot Pin - 5 Speed
Common
ST 25110-3
ST 25110-3
Gauge Plate for Tightening Chain Stay
Common
Mandrel for Oil Seal Pressing
Reference only, ST 25113-4
Expander for Front Fork Oil Seal

1
Extractor for Fork Oil Seal
10
ST-25244-4
ST-25244-4
Special Spanner Adjuster Rear Shox
Common
11
ST-25612-4
ST-25612-4
Rotor Tightening & Loosening Tool
Common
12
ST-25592-4
ST-25592-4
Connecting Rod Locking Tool
Common
1
170
08-10 Special Tools List - B (Common & Exclusive for Thunderbird 350 & 500 Models)
13
14
17
18
19
20
15
21
16
171
08-10 Special Tools List - B (Common & Exclusive for Thunderbird 350 & 500 Models)
PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
13
ST-25591-4
ST-25591-4
Sprocket & Clutch Tightening Tool
14
ST-25594-4
ST-25594-4
Clutch Plate Tightening Tool
15
ST-25835-2
ST-25835-2
FD Sprocket Removing Tool
16
NA
NA
Front Fork Dismantling Tool
Reference only, ST-25834-2
17
NA
NA
Front Fork Tool 1/2” SD
Reference only, ST-25833-4
18
NA
CR0060
DOL Tool for EFI Diagnosis, ECU
19
ST-26461-2 ST-26461-2
Front Fork Assembling & Dismantling Tool Dia 41mm
20
ST-26455-4
ST-26455-4
Steering Ring Nut “C” Spanner
21
ST-26485-3
ST-26485-3
Front Fork Oil Seal Driver Dia 41mm
1
172
09-00 Wall Charts - A (UCE)

A1
Key Nos.
1 to 5
8
173
09-00 Wall Charts - A (UCE)

PART NUMBER
KEY
No.
350
500
A1
888081
888081
DESCRIPTION
QTY. REFERENCE
UCE Bike Wiring Diagram & Torque Value Wall Charts 8 Kit
REMARKS
Reference only, 888081
consists of Sl. No.1 to 8
NA
NA
Complete Wiring Diagram - Bullet 350 UCE - KS
Served in Kit
Reference only, 888092, Ref. A1
NA
NA
Complete Wiring Diagram - Electra 350 UCE - ES
Served in Kit
NA
NA
Complete Wiring Diagram - Classic 350 (Version 2.0)
Served in Kit
NA
Complete Wiring Diagram - Thunderbird 350 (Version 1.0)
888090
NA
Served in Kit
Complete Wiring Diagram - Thunderbird 500 (Version 1.0)
888089
Torque Value Chart - Thunderbird 350 & 500
888188
Torque Value Chart - Electra
Served in Kit
4
5
NA
6
NA
7
8
NA
NA
MOQ
Nos.
1
174
09-10 Wall Charts - B (Domestic)

A1
Key Nos.
1 to 9
9
175
09-10 Wall Charts - B (Domestic)

PART NUMBER
KEY
No.
350
500
A1
597473
QTY. REFERENCE
REMARKS
Classic Model Blow up Charts Kit
Crankcase RH 500 - Exploded View
597464
From Sl. No. 1 to 9 are

Crankcase RH 350 - Exploded View
597465
Served in kit, Ref. A1
Cylinder & Head 500 & 350 - Exploded View
597466
Crankcase LH 500 & 350 - Exploded View
597467
5
Cover LH & RH 500 & 350 - Exploded View
597468
Crankcase LH & RH 500 & 350 - Exploded View
597469
EFI Components - Exploded View
597470
597473
DESCRIPTION
NA
NA

consists of Sl. No.1 to 9
NA
NA
NA
9
NA
NA
MOQ
Nos.
1
176
09-20 All UCE Models Service Publication List - A (Domestic)
5
177
09-20 All UCE Models Service Publication List - A (Domestic)

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Owner’s Manual Thunderbird 350
594069
Owner’s Manual Thunderbird 500
594132
Spare Parts Catalogue Thunderbird 500 & 350 - Book
Spare Parts Catalogue Thunderbird 500 & 350 (+TBTS) DVD
Service Manual Thunderbird 500 & 350
888189
888189
1
888190
1
1
178
09-30 All UCE Models Service Publication List - B (Domestic)
6-a
10
6-b
11
12
13
179
09-30 All UCE Models Service Publication List - B (Domestic)

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
NA
NA
Bullet 350 UCE Owner’s Manual
Reference only, 592814/B
NA
NA
Electra 350 UCE Owner’s Manual
Reference only, 592579/A
NA
NA
Classic 350 Owner’s Manual
Reference only, 592025/A

1
NA
NA
Classic 500 Owner’s Manual
Dealer’s Directory
New Layout, Jan. 13 Version
581677/A
NA
NA
DVD Spare Parts Catalogue & Service Manual - Classic models
NA
NA
DVD Parts Catalogue - Electra & Bu 350UCE
Self Learning UCE Service Module DVD
1
8
888002
888002
NA
NA
Thunderbird Twinspark Parts Catalogue (2012 Revision 2.0)
10
NA
NA
Thunderbird Twinspark Service Manual
11
NA
NA
TBTS Owner’s Manual
12
NA
NA
Combined UCE Models Spare Parts Catalogue

1
13
NA
NA
Combined UCE & Retired Models Spare Parts Catalogue DVD
1
180
4
5
4
5
1
6
6
181

PART NUMBER
KEY
No.
350
500
A1
QTY. REFERENCE
REMARKS
MOQ
Nos.
888216
888216
Off Road Silencer Kit (TB 350 & 500)
320050
320050
Touch Up Paint Aerosal, Black (440 ML)
320051
320051
Touch Up Paint Aerosal, Black (180 ML)
320038
320038
Touch Up Paint Aerosal, PU Clear (Lacquer) 440 ML
1
320118
320118
Touch Up Paint Spray, Twilight (440 ML)
320119
320119
Touch Up Paint Spray, RJ 1580 Silver (400 ML) Thunderbird
321010
321010
NA
DESCRIPTION
AW Black
Apply vehicle body

painted sheet metal parts
Apply NT/VT powder coating parts
Touch Up Paint Spray, Dead Matt Black (440 ML)
Apply engine black parts like crankcase, covers, cylinder & head etc.
Touch Up Paint Aerosol, Stone
Touch Up Paint Aerosal, Flicker
NA
NA
Touch Up Paint Aerosal, Royal Maroon C5 (440 ML)
Reference Only, 320040
NA
NA
Touch Up Paint Aerosal, Classic Green C5 (440 ML)
NA
NA
Touch Up Paint Aerosal, Classic Green C5 (180 ML)
NA
NA
Touch Up Paint Aerosal, Desert Storm (180 ML)
NA
NA
Touch Up Paint Aerosal, Rivera Red
1
NA
NA
Touch Up Paint Aerosal, Magic Black
NA
NA
Touch Up Paint Aerosal, Dark Silver
NA
NA
Touch Up Paint Aerosol, Olive Green (180 ML)
NA
NA
Touch Up Paint Aerosol, PO Red
NA
NA
Touch Up Paint Spray, Desert Storm (440 ML)
1
Off Road Silencer
595549/B
1
182
4
5
4
5
1
6
6
183

PART NUMBER
KEY
No.
350
500
DESCRIPTION
QTY. REFERENCE
REMARKS
MOQ
Nos.
Heat Shield
595230/B
Flange Hex. Bolt M8 X 16
586025/A
Old No. 591534/A
50
Spring Washer M8
586038/A
Old No. 210026
50
Phillips Pan Head Screw M6 X 6
2
147896/A
50
Bracket Silencer Mounting (Off Road)
595244/A
1
184

Part No.
110050
110349
110349
140201
140201
141051
141051
141061
141963
142065
142095
142258
142258
142606
142606
144519
145854
146375
144844
110037/3
110037/3
111098/2
120005/B
140090/1
140090/1
140193/B
140331/A
140332/B
140333/B
140355/B
Page Key
No. No.
43
99
117
89
145
17
69
163
61
69
71
147
151
163
163
161
113
133
33
43
47
71
45
131
147
89
47
47
47
101
5
5
10
3
3
34
3
5
24
7
1
30
6
15
18
22
18
5
43
4
24
11
9
5
40
6
23
22
21
19
Part No.
140355/B
140573/B
141109/1
141109/1
141161/C
141162/C
141246/C
141560
142257/B
143144/2
143144/2
143496/A
143496/A
144471/A
144581/E
144581/E
144582/E
144600/A
144636/A
144636/A
144636/A
144636/A
144636/A
144636/A
144766/A
144846/A
144846/A
144886/C
144981/B
145090
Page Key
No. No.
117
149
99
117
151
151
39
69
47
63
65
103
105
119
89
91
145
27
19
37
49
63
65
103
111
17
49
129
65
25
11
57
7
6
8
7
25
10
33
38
18
8
20
16
2
27
2
54
46
16
44
42
7
9
11
26
39
16
5
45
Part No.
145157/C
145186/C
145446/A
145446/A
145553/B
145882/A
145882/A
146031/A
146044/A
146318/A
146318/A
146347/B
146435/A
146450/B
146459/A
146499/A
146714/A
146797/A
147096/A
147098/C
147098/C
147270/A
147502/A
147504/A
147507/A
147559/A
147649/B
147701/A
147870/A
147896/A
Page Key
No. No.
19
111
91
145
119
97
109
49
75
105
149
111
113
25
17
117
47
97
163
143
163
75
149
149
101
143
85
149
105
73
42
10
22
4
18
4
7
46
3
29
56
1
9
44
28
5
32
7
12
11
1
13
51
50
20
9
A2
59
34
14
Part No.
147896/A
147896/A
147897/B
147955/B
150324/A
150324/A
320038
320050
320051
320118
320119
321010
390066
390067
390068
390069
500355
500355
500355
500632
500632
500834
500835
500836
500837
500838
500839
500841
500842
500843
Page Key
No. No.
73
145
69
159
99
117
181
181
181
181
181
181
13
13
13
13
45
103
105
135
165
59
59
59
59
59
59
61
61
61
14
7
13
8
8
4
1
1
1
1
1
1
3
4
5
6
7
10
21
15
24
13
12
6
7
9
8
21
25
22
Part No.
500845
500846
500847
500848
500855
500857
500862
500869
500870
500871
500872
500874
502071
502071
521125
521199
521237
550024
550024
550025
550028
550087
550095
550108
550141
550141
550141
550141
550141
560506
Page Key
No. No.
61
61
61
59
61
61
63
61
61
61
63
61
163
163
69
135
69
51
55
25
15
47
15
49
51
55
129
135
137
71
16
19
20
5
30
28
37
36
35
27
48
33
16
19
9
10
A2
18
18
33
4
28
6
47
7
7
7
7
30
12
Part No.
570011
570013
570013
570016
570024
570025
570028
570030
570030
570032
570037
570052
570073
570094
570125
570130
570155
570157
570157
570207
570209
570213
570232
570233
570234
570240
570241
570241
570273
570407
Page Key
No. No.
43
15
43
37
39
37
45
37
89
39
45
21
39
37
45
39
17
51
55
45
45
27
45
23
23
47
17
27
33
35
14
5
11
2
22
4
11
18
12
38
10
2
32
1
8
34
30
A1
A1
16
17
53
7
25
15
30
22
48
32
10
185

Part No.
570425
570431
570440
570441
570442
570442
570481
570615
570804
570936
570943
570944
571086
571109
571253
580559
597459
597473
500104/D
500104/D
500116/A
500123/A
500207/A
500303/2
500307/A
500309/B
500322/A
500347/A
500352/A
500613/A
Page Key
No. No.
15
47
41
41
37
41
49
51
45
59
59
59
65
33
63
69
41
175
43
45
33
33
33
33
31
31
31
31
31
17
8
34
1
12
12
2
43
A3
A1
2
3
A5
A1
32
49
A1
A2
A1
2
5
37
36
31
42
16
17
18
19
15
20
Part No.
500616/A
500617/A
500619/A
500621/A
500622/B
500635/A
500637/B
500711/A
500712/A
500823/B
500823/B
500856/A
500904/A
500905/C
500917/B
502006/A
502018/B
502019/A
502026/B
502070/A
510187/B
521066/B
521088/B
521089/B
521089/B
521089/B
521092/D
521093/D
521112/B
521129/B
Page Key
No. No.
15
15
17
15
15
39
15
73
71
69
71
61
31
159
71
133
35
35
163
25
149
141
143
143
149
163
69
69
139
69
18
15
19
16
3
37
14
12
9
12
10
29
20
17
14
3
8
7
11
31
52
10
7
10
46
20
8
6
4
4
Part No.
521172/A
521186/A
521200/A
521200/A
521204/F
521204/F
521238/B
550007/C
550007/C
550008/B
550008/B
550011/C
550011/C
550023/E
550023/E
550030/C
550030/C
550030/C
550032/A
550032/A
550061/B
550072/B
550075/A
550075/A
550078/A
550078/A
550081/C
550081/C
550082/C
550083/B
Page Key
No. No.
69
75
63
65
151
151
69
51
55
51
55
51
55
51
55
47
51
55
43
45
35
23
51
55
51
55
51
55
47
47
5
11
40
3
3
5
2
14
14
15
15
10
10
12
12
18
9
9
10
12
3
16
1
1
6
6
4
4
26
27
Part No.
550090/C
550090/C
550091/C
550091/C
550119/B
550119/B
550216/D
550216/D
550256/A
550507/A
550661/A
560195/A
560502/E
560519/E
560521/B
560530/D
560530/D
560546/A
560632/A
570005/C
570006/E
570007/F
570008/F
570012/C
570018/G
570029/D
570039/D
570040/C
570041/C
570044/J
Page Key
No. No.
51
55
51
55
53
57
51
55
23
137
35
75
99
99
99
99
119
99
75
43
43
39
43
43
33
39
25
25
25
25
5
5
3
3
21
21
11
11
18
19
6
4
10
6
11
15
22
13
7
7
6
36
3
12
39
24
41
41
41
36
Part No.
570048/F
570051/A
570054/G
570057/B
570059/C
570063/F
570072/C
570074/I
570086/D
570087/D
570088/D
570089/D
570090/D
570091/D
570097/B
570099/C
570100/B
570102/D
570131/A
570132/A
570132/A
570141/E
570158/B
570158/B
570163/D
570164/D
570165/C
570166/C
570176/D
570181/B
Page Key
No. No.
21
21
47
47
17
39
39
39
39
43
37
37
37
39
45
25
25
23
31
25
27
45
51
55
31
31
33
33
17
23
A1
1
37
36
24
30
39
33
21
13
15
17
14
35
1
42
38
12
9
35
56
6
A2
A2
22
21
40
41
27
11
Part No.
570182/B
570183/D
570184/B
570185/B
570186/D
570187/B
570192/C
570193/B
570198/C
570201/F
570201/F
570202/E
570202/E
570204/H
570204/H
570205/N
570205/N
570206/J
570208/B
570214/F
570218/C
570219/F
570227/F
570229/D
570230/F
570231/H
570235/E
570239/C
570246/E
570247/D
Page Key
No. No.
19
15
23
49
49
49
33
49
23
43
45
51
55
51
55
51
55
45
45
27
49
23
23
23
23
23
23
47
27
27
45
2
24
50
49
52
35
51
27
9
13
8
8
20
20
16
16
15
14
52
48
22
17
19
20
23
21
31
49
50
186

Part No.
570248/D
570249/G
570261/B
570262/F
570262/F
570263/B
570272/A
570276/D
570280/B
570282/K
570286/C
570291/A
570292/A
570293/A
570294/A
570295/A
570298/A
570298/A
570298/A
570298/A
570298/A
570298/A
570300/B
570300/B
570302/A
570303/A
570304/B
570309/B
570409/E
570409/F
Page Key
No. No.
47
37
63
105
147
105
29
47
25
59
17
35
21
21
21
37
19
25
25
31
35
37
21
25
21
21
23
21
79
35
19
8
39
22
28
24
A10
38
39
1
33
2
6
4
5
20
48
37
40
11
12
6
8
47
9
9
13
A2
2
9
Part No.
570410/F
570414/B
570416/I
570421/A
570424/D
570426/H
570433/B
570434/D
570435/B
570436/C
570437/C
570438/B
570439/B
570443/C
570443/C
570446/K
570447/B
570451/B
570452/E
570465/C
570467/A
570468/B
570469/A
570478/B
570479/B
570480/B
570482/B
570532/N
570533/N
570535/G
Page Key
No. No.
35
39
15
25
15
15
41
41
41
41
41
41
41
37
41
37
41
41
35
37
17
49
47
31
31
31
31
31
31
31
14
28
7
34
10
9
11
6
9
7
8
5
4
9
A1
13
3
10
11
10
29
45
25
25
28
27
26
14
10
12
Part No.
570536/G
570537/D
570538/D
570570/C
570596/B
570596/B
570600/A
570604/A
570658/B
570664/A
570665/B
570666/A
570702/A
570706/B
570713
570715/A
570715/A
570716/A
570716/A
570723/A
570723/A
570732/B
570805/B
570807/C
570808/D
570809/A
570809/A
570813/A
570821/A
570821/A
Page Key
No. No.
31
33
33
39
51
55
21
19
49
47
49
49
47
55
27
43
45
43
45
19
23
61
19
19
27
115
21
51
55
13
33
34
40
13
13
A3
47
56
28
55
54
29
A3
55
15
4
16
3
44
12
23
A2
43
41
51
19
8
19
19
Part No.
570823/A
570823/A
570828/B
570832/A
570833/A
570834/A
570835/A
570836/B
570837/A
570838/A
570839/A
570840/A
570841/A
570842/A
570844/B
570845/A
570846/A
570862/A
570863/A
570866/A
570867/A
570873/A
570874/A
570898/A
570940/A
571032/B
571032/B
571034/C
571035/C
571036/B
Page Key
No. No.
51
55
167
63
59
59
61
63
61
61
61
61
61
61
63
63
63
23
25
23
25
59
59
43
63
27
115
31
31
33
17
17
A4
46
4
10
15
47
18
17
32
31
34
26
43
45
44
28
30
28
30
14
11
8
50
51
19
22
21
41
Part No.
571037/B
571039/B
571043/C
571047/D
571051/B
571052/A
571053/A
571055/A
571056/A
571059/A
571062/B
571063/A
571079/D
571087/A
571088/C
571090/A
571100/A
571108
571113/A
571113/A
571115/C
571116/B
571119/A
571155/A
571164/A
571166/B
571170/C
571172/C
571201/A
571205/A
Page Key
No. No.
33
33
33
21
65
103
65
65
147
159
25
103
65
65
65
65
41
33
37
41
21
45
33
21
25
21
49
49
15
43
42
35
39
A1
11
5
12
2
45
10
29
4
4
14
15
13
9
30
9
A1
5
8
31
1
43
3
41
41
17
8
Part No.
571206/A
571206/A
571216/A
571221/A
571226/A
571227/A
571228/A
571229/A
571230/A
571249/A
572011/A
572014/A
572015/A
572015/A
572016/A
572017/A
572019/A
572021/B
572022/B
572044/A
572044/A
572304/A
572318/A
572328/A
572338/B
572339/A
572607/A
572611/A
573906/A
573907/A
Page Key
No. No.
63
65
39
39
67
67
67
67
67
65
15
15
35
137
17
17
17
29
29
53
57
65
31
31
49
31
65
69
29
29
41
9
29
23
20
21
22
23
24
17
11
13
5
20
25
23
21
7
8
22
22
8
23
24
53
20
19
11
3
5
187

Part No.
573918/A
573925/A
573926/A
573928/A
573929/A
573931/A
573932/A
573933/A
573935/A
573964/A
573968/A
573983/A
573984/A
573985/A
573986/A
573992/A
573992/A
573993/A
573993/A
580037/H
580038/E
580203/D
580286/A
580288/D
580290/A
580314/A
580347/A
580377/B
580380/A
580381/D
Page Key
No. No.
37
35
35
21
21
33
29
29
65
17
17
49
149
149
149
23
151
23
151
113
113
147
27
163
107
149
113
163
137
137
19
1
A2
7
7
29
2
4
16
32
31
40
58
60
55
10
18
10
17
4
2
25
57
17
3
66
5
14
29
27
Part No.
580387/D
580395/A
580397/A
580404/A
580431/E
580431/E
580441/A
580447/A
580749/D
580811/B
581004/E
581005/D
581006/B
581007/A
581008/A
581019/B
581027/B
581029/A
581044/C
581048/B
581054/B
581083/A
581084/C
581085/B
581097/A
581098/A
581114/A
582511/A
581122/A
581122/A
Page Key
No. No.
79
31
159
75
109
111
75
143
113
131
71
71
71
71
71
147
163
75
71
147
163
75
17
113
75
75
71
71
73
133
1
24
16
2
12
14
12
8
3
11
A2
7
2
5
4
44
13
12
8
28
4
6
33
17
4
3
A1
14
4
7
Part No.
581738/A
582510/A
582511/A
582511/A
582512/A
582513/A
582519/A
582638/A
586001/A
586002/A
586002/A
586002/A
586002/A
586002/A
586002/A
586002/A
586003/A
586004/A
586004/A
586004/A
586004/A
586004/A
586005/A
586005/A
586005/A
586005/A
586008/A
586008/A
586008/A
586008/A
Page Key
No. No.
135
37
123
151
151
151
83
73
149
91
97
109
109
129
135
159
137
71
105
135
145
149
43
45
73
113
25
89
113
145
14
7
26
9
14
15
30
15
67
30
2
4
6
3
3
15
32
3
23
12
17
48
1
2
16
16
32
17
6
11
Part No.
586008/A
586009/A
586010/A
586012/A
586012/A
586014/A
586015/A
586016/A
586021/A
586021/A
586021/A
586022/A
586025/A
586025/A
586025/A
586025/A
586028/A
586029/A
586029/A
586029/A
586029/A
586031/A
586031/A
586031/A
586031/A
586031/A
586031/A
586032/A
586032/A
586032/A
Page Key
No. No.
145
119
117
111
119
71
111
111
97
109
131
87
69
73
91
131
133
73
131
147
149
149
149
89
91
143
163
73
91
97
21
28
12
12
13
6
8
9
6
9
7
18
1
7
31
9
2
10
6
41
54
53
64
11
32
3
9
8
29
5
Part No.
586032/A
586032/A
586032/A
586032/A
586032/A
586032/A
586032/A
586032/A
586035/A
586035/A
586035/A
586036/A
586036/A
586036/A
586038/A
586038/A
586038/A
586042/A
586042/A
586042/A
586042/A
586046/A
586047/A
586048/A
586051/A
586051/A
586052/A
586052/A
586052/A
586052/A
Page Key
No. No.
103
109
129
143
143
149
163
163
131
131
147
69
135
145
73
97
159
89
103
129
131
147
147
103
131
147
131
143
147
149
15
8
15
4
13
63
3
10
4
12
39
14
11
16
6
3
14
5
7
9
8
31
32
16
3
42
2
5
38
65
Part No.
586052/A
586053/A
586056/A
586057/A
586070/A
586070/A
586084/A
590906/B
591023/A
591210/A
591494/A
591494/A
591521/A
591522/A
591578/A
591578/A
591667/B
591702/A
591702/A
591702/A
591702/A
591713/C
591837/A
591837/B
591874/A
591879/A
591980/A
591981/A
591992/B
592030/A
Page Key
No. No.
163
163
105
147
101
147
39
119
133
117
37
151
77
77
73
149
113
91
97
143
163
135
163
165
165
163
159
161
135
107
8
6
25
34
17
33
27
15
13
7
7
19
24
25
9
49
12
28
8
12
2
9
A1
23
25
A2
13
19
13
17
188

Part No.
592212/A
592237/A
592238/A
592256/A
592593/A
592857/B
592861/B
592862/B
593010/C
593011/C
593011/C
593011/C
593022/C
593024/D
593038/D
593038/D
593046/A
593049/C
593050/C
593050/C
593055/A
593060/C
593061/C
593090/C
593095/A
593108/A
593109/A
593144/A
594002/A
594004/A
Page Key
No. No.
151
25
163
85
37
77
163
165
147
147
147
147
145
145
37
101
111
145
113
145
65
145
145
37
119
113
111
149
103
75
2
29
7
6
A1
22
21
22
27
24
29
36
20
22
11
18
2
10
7
12
10
13
14
5
27
11
3
47
1
A1
Part No.
594005/B
594006/A
594008/A
594009/B
594009/B
594013/A
594014/A
594015/A
594015/A
594016/A
594016/A
594018/A
594019/A
594028/B
594029/A
594030/A
594036/A
594036/A
594038/A
594042/A
594043/C
594045/A
594046/A
594046/A
594046/A
594047/A
594048/B
594048/B
594050/A
594051/A
Page Key
No. No.
75
99
89
89
147
75
75
133
167
133
167
93
93
113
153
157
133
155
151
117
117
119
109
123
133
135
115
119
119
119
1
A1
16
18
37
8
9
4
A3
8
A2
A1
A2
1
A1
A1
9
A1
1
A1
A3
14
11
19
12
A1
20
21
23
24
Part No.
594053/A
594054/A
594054/A
594055/A
594055/A
594063/A
594065/A
594066/A
594067/A
594071/A
594076/B
594077/B
594078/B
594079/B
594081/B
594087/A
594088/A
594089/B
594091/B
594091/B
594092/B
594092/B
594094/A
594097/A
594101/B
594102/A
594102/A
594104/B
594106/A
594106/A
Page Key
No. No.
125
119
125
121
129
135
137
129
129
99
73
73
97
73
73
119
119
105
105
145
105
145
107
109
133
107
159
151
107
159
A1
19
A2
A1
8
A6
18
14
10
14
1
2
9
5
11
25
26
28
33
5
32
6
A1
5
1
6
6
4
10
7
Part No.
594108/B
594109/A
594110/A
594116/B
594117/B
594118/A
594118/A
594119/A
594120/B
594121/A
594125/B
594129/B
594136/A
594138/A
594144/A
594158/A
594160/B
594161/B
594165/A
594173/A
594177/B
594191/B
594195/A
594202/B
594208/A
594209/A
594210/B
594210/B
594214/A
594215/A
Page Key
No. No.
109
139
141
129
135
129
137
135
135
91
109
159
141
139
143
149
89
89
105
151
135
73
89
145
103
73
105
149
131
91
10
8
9
1
1
4
24
4
2
26
1
A1
9
8
2
62
8
7
19
11
16
1
9
8
2
13
26
47
10
25
Part No.
594216/B
594220/A
594221/A
594222/A
594228/B
594231/B
594231/B
594231/B
594233/A
594238/A
594244/A
594252/B
594253/A
594264/B
594268/B
594275/C
594278/A
594279/A
594281/B
594284/A
594286/A
594287/A
594288/A
594298/A
594300/A
594305/A
594306/A
594330/A
594332/B
594334/B
Page Key
No. No.
113
129
135
103
159
105
139
159
97
99
103
89
89
103
149
107
79
79
107
107
91
91
89
107
107
107
107
145
159
129
14
A4
A2
13
11
27
7
1
10
4
14
14
13
3
61
15
3
1
1
2
24
23
21
A2
16
7
9
23
12
5
Part No.
594334/C
594350/A
594350/A
594351/A
594351/A
594356/B
594358/B
594365/A
5943702/B
594371/A
594372/B
594372/B
594389/A
594393/A
594397/A
594400/A
594401/A
594402/A
594403/A
594404/A
594405/A
594406/A
594407/A
594408/A
594409/A
594410/A
594411/A
594413/A
594414/A
594415/A
Page Key
No. No.
135
129
137
129
137
89
129
113
129
135
135
137
145
129
75
93
93
93
93
167
93
93
93
93
93
93
93
93
95
95
5
18
25
17
31
20
2
15
6
A3
6
26
18
11
A1
7
10
4
1
5
11
12
13
14
6
8
9
16
17
19
189

Part No.
594418/A
594419/A
594420/A
594421/A
594422/A
594425/A
594426/A
594427/A
594428/A
594440/A
594453/A
594469/B
594470/A
594474/C
594484/B
594491/A
594492/A
594493/B
594500/A
594501/A
594511/A
594513/A
594513/A
594514/A
594517/A
594518/A
594524/A
594525/A
594526/A
594533/A
Page Key
No. No.
167
93
145
99
101
75
75
117
117
151
107
145
103
73
113
111
111
111
139
139
123
103
159
103
85
123
151
151
129
113
6
5
15
3
16
5
10
8
9
1
8
9
17
17
10
5
4
6
3
5
11
11
5
12
A1
23
13
12
12
13
Part No.
594537/A
594538/A
594540/A
594541/A
594542/A
594543/A
594545/A
594553/A
594562/A
594570/A
594571/A
594572/A
594573/A
594574/A
594575/A
594576/A
594577/A
594578/A
594579/A
594580/A
594581/A
594583/A
594584/A
594601/A
594601/A
594630/A
594631/A
594634/A
594635/A
594650/A
Page Key
No. No.
129
103
113
159
151
143
147
93
119
155
155
155
153
153
153
153
153
153
153
153
167
167
167
109
111
87
81
157
77
157
13
6
8
18
10
1
35
3
20
1
2
A2
1
2
3
4
5
6
A2
A3
3
1
2
13
13
17
A1
A2
18
2
Part No.
594651/A
594652/A
594655/A
594656/A
594657/A
594658/A
594660/A
594680/A
594681/A
594681/A
594682/A
594682/A
594688/A
594689/A
594690/A
594691/A
594693/A
594694/A
594695/A
594696/A
594697/A
594698/A
594700/A
594701/A
594703/A
594704/A
594705/A
594706/A
594707/A
594708/A
Page Key
No. No.
157
157
107
157
157
157
107
109
107
161
107
161
121
121
121
121
121
121
121
125
125
125
125
125
125
81
81
81
81
81
6
1
4
3
4
5
5
14
11
20
12
21
A2
A7
A6
10
A8
A5
A3
A4
A5
A3
A6
A8
A7
A2
A7
A8
A9
A10
Part No.
594709/A
594710/A
594711/A
594712/A
594713/A
594714/A
594715/A
594717/A
594718/A
594720/A
594721/A
594721/A
594721/A
594729/A
594744/A
594816/A
595008/A
801529
801530
845019
845020
859040
859041
859042
859043
859045
859046
859047
859049
859050
Page Key
No. No.
81
81
81
81
85
85
85
85
85
85
81
85
121
125
151
103
167
145
147
89
133
99
99
89
89
89
117
119
109
109
A11
A4
A12
A5
A6
A7
A3
A8
A9
A5
A6
A4
A9
5
16
A3
14
19
43
4
6
9
12
19
15
1
3
17
2
3
Part No.
860009
867003
867034
867040
867044
867071
867072
869001
869002
869003
869005
869006
869009
869010
869011
869019
869020
869023
869025
869031
869032
869033
869043
869044
869046
869047
869049
869052
874001
874002
Page Key
No. No.
143
111
113
145
147
133
73
37
35
35
15
15
29
29
23
25
23
47
65
23
13
13
29
29
29
29
33
33
97
103
6
7
A1
1
26
11
3
3
A1
A3
A1
A5
1
6
26
46
14
35
6
26
1
1
A1
A9
A1
A9
38
38
1
A1
Part No.
874003
874004
874005
874006
874007
875001
875002
875003
875004
875005
879001
879002
879003
879004
879005
879006
879007
888002
888003
888004
888009
888050
888051
888056
888057
888057
888058
888058
888058
888079
Page Key
No. No.
139
139
139
139
131
97
103
139
139
131
131
139
139
139
139
103
97
179
29
29
81
117
99
159
103
159
139
139
159
113
1
1
2
2
1
1
A1
1
2
1
1
2
2
1
1
A1
1
8
A3
A3
A3
A5
A6
A2
A2
A3
A1
A4
A4
A4
190

Part No.
888081
888083
888084
888085
888086
888101
888102
888109
888110
888111
888112
888113
888115
888118
888119
888127
888128
888133
888134
888135
888136
888137
888138
888139
888140
888141
888142
888143
888146
888147
Page Key
No. No.
173
59
59
59
59
15
41
29
29
29
15
29
35
99
99
71
75
89
89
93
93
93
93
93
97
99
99
99
111
113
A1
A1
A2
A3
A4
A2
A2
A7
A8
A6
A3
A6
A4
A5
A7
A3
A4
A1
A2
A3
A4
A5
A7
A6
A1
A3
A4
A8
A2
A2
Part No.
888148
888149
888150
888151
888152
888153
888154
888157
888159
888160
888161
888162
888163
888164
888164
888166
888167
888168
888169
888170
888171
888172
888173
888174
888175
888176
888178
888179
888180
888181
Page Key
No. No.
113
113
117
117
117
117
117
121
133
139
139
129
135
129
135
99
117
75
15
21
29
29
29
29
35
65
117
21
21
21
A3
A3
A4
A6
A7
A8
A9
A4
A1
A2
A2
A2
A4
A1
A5
A2
A2
A3
A4
A4
A2
A2
A5
A4
A5
A4
A10
A5
A6
A7
Part No.
888182
888183
888186
888187
888189
888192
888193
888195
888197
888198
888199
888207
888208
888209
888210
888211
888216
888224
888225
888056/A
NA
NA
CR0060
NA
NA
NA
NA
NA
NA
NA
Page Key
No. No.
45
65
79
79
177
65
75
111
129
139
167
13
13
73
73
73
181
59
59
89
171
171
171
173
173
173
173
173
175
175
A3
A2
A1
A1
3
A3
A2
A1
A3
A3
A1
2
2
A2
A1
A1
A1
A6
A7
10
16
17
18
1
2
3
5
8
8
9
Part No.
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
ST 25110-3
ST 25123-1
ST 25128-2
ST 25151-4
ST 25153-4
ST 26199-3
ST-25244-4
ST-25591-4
Page Key
No. No.
179
179
179
179
179
179
179
179
179
179
179
181
181
181
181
181
181
181
181
181
181
181
169
169
169
169
169
169
169
171
1
2
3
4
6
7
9
10
11
12
13
1
1
1
1
1
1
1
1
1
1
1
6
2
3
4
5
1
10
13
Part No.
ST-25592-4
ST-25594-4
ST-25612-4
ST-25835-2
ST-26455-4
ST-26461-2
ST-26485-3
Page Key
No. No.
169
171
169
171
171
171
171
13
13
29
33
39
45
81
83
87
121
123
123
125
127
127
155
155
159
171
171
171
181
181
12
14
11
15
20
19
21
2
2
A10
30
26
A4
A13
25
16
1
14
15
1
16
20
3
4
9
7
8
9
5
1
Part No.
Page Key
No. No.
191
11-00 Service Bulletins Checklist for Parts Catalogue Update

SB NO.
SB - 687
SB - 688
SB - 689
SB - 690
RECEIVED DATE
UPDATED BY
DATE & SIGN OF PARTS INCHARGE
Last SB No. 687 had been updated in this parts catalogue
SB NO.
RECEIVED DATE
UPDATED BY

192

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

193

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

194

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

195

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

196

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

197

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

198

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

199

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

200

SB NO.
RECEIVED DATE
UPDATED BY
SB NO.
RECEIVED DATE
UPDATED BY

Thunderbird 500 350 Parts Catalogue

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1

00-00 General Information

02-30 Air Filter (500cc)

Key No. Which make up

00-00 General Information

PART NUMBER LIST

KEY NUMBER (KEY NO.)

00-00 General Information

REAR SHOCK ABSORBER & CENTER STAND ASSEMBLY ............................. 111

SWING ARM ASSEMBLY & REAR CHAIN GUARD ...........................................

REAR MASTER CYLINDER ASSEMBLY-

REAR CALIPER ASSEMBLY-

CYLINDER & HEAD

CRANK CASE LH - COVER

TAIL LAMP BRACKET, TRAFFICATOR & SAREE GUARD ............................... 133

CRADLE ASSEMBLY LH & PILLION FOOT REST ASSEMBLY ......................... 135

SIDE DECOR LH &

GEAR TRAIN ASSEMBLY (OLD

GEAR TRAIN ASSEMBLY (ANTI SKIP MECHANISM) .........................................

BATTERY, BATTERY CARRIER AND HARNESS ..............................................

EFI COMPONENTS IN CYLINDER

SWITCHES, HORN &

SILENCER & EXHAUST

TCI & EFI IGNITION

HANDLE BAR &

TRAFFICATOR LIGHTS, TOOLS & FIRST AID

SPECIAL TOOLS LIST - A

FRONT CALIPER ASSEMBLY -

SPECIAL TOOLS LIST - B (COMMON

HEAD BRACKET & STEERING

WALL CHARTS LIST - A

FRONT FORK (GIL - DIA

WALL CHARTS LIST - B

ALL UCE SERVICE PUBLICATION LIST - A (DOMESTIC) .................................

ALL UCE SERVICE PUBLICATION LIST - B (DOMESTIC) ................................

SERVICE BULLETINS CHECKLIST FOR PARTS CATALOGUE UPDATE .......... 191

00-10 Group Index - Pictorial

01-30 Crankcase RH - Cover Side

01-20 Engine Cover RH

01-40 Cylinder & Head assembly

01-60 Crankcase LH - Coverside

01-50 Engine Cover LH

00-10 Group Index - Pictorial

01-110 Gear Train Assembly (Anti Skip Mechanism)

03-10 Control Cables

03-00 Handle Bar & Controls

02-40 Silencer & Exhaust Pipe

02-30 Air Filter (500cc)

02-20 Air Filter (350cc)

02-10 EFI Components in Cylinder Head

02-00 CV Carburetor (BS 29)

00-10 Group Index - Pictorial

03-30 Front Caliper Assembly (BBI)

03-40 Head Bracket & Steering Stem

03-60 Front Mudguard

03-50 Front Fork (GIL-Dia 41)

03-70 Front Wheel

04-10 Seat Assembly

04-00 Fuel Tank

04-20 Seat Sub Frame

00-10 Group Index - Pictorial

05-10 Swing Arm Assembly & Rear Chain Guard

05-60 Rear mudguard