Brand ID: 001MC625

We have pleasure in presenting the Spare Parts Catalogue for ‘Pulsar DTS-i 200cc’ Motorcycle. This catalogue has been specially designed to assist you in selecting the correct parts for procurement to maintain 100% availability. The Bajaj spares are subjected to the stringent quality control standards to ensure longer life of the vehicle. It is therefore necessary that only the Genuine Bajaj Spares are used. In a continual effort to improve Performance and Efficiency of the vehicles, Specifications, Diagrams, Illustrations and Part Numbers can change without notice. Consequently, the description in this Spare Parts Catalogue cannot therefore be final and binding on us. The modifications / alterations which are carried out after the issue of this catalogue, will be conveyed to you through our Service Circulars. You are requested to make necessary corrections in the Parts Catalogue as per the circulars so as to keep your catalogue up-to-date. This will ensure the appropriate and speedy delivery of the Spare Parts as the order placed will bear the latest part numbers. In case, if you need any technical assistance contact the concerned Regional Team or write to us on the following address :

All information contained in this manual is based on the latest product information at the time of publication. Bajaj Auto Limited accepts no liability for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without prior notice. The right is reserved to make such changes at any time without prior notice and without incurring an obligation to make such changes to product manufactured previously. Contact your authorized Bajaj Dealer for the latest information on product improvements incorporated after this manual was issued.

REV.00 FEB.10.RB

Bajaj Auto Indonesia Menara Imperium Jakarta 12980 Indonesia Phone : 021-8281787 Fax : 021-8307615

Brand ID: 001MC625

Brand ID: 001MC625

Instructions for using the Catalogue
1. How to Read the Catalogue : Open the catalogue and from the pictorial index locate the group in which the part you want to find is present. Turn over to the concerned page number (as given by pictorial index). Now find out the figure of the part you wish to order. Write down the part number against that particular figure number from the text. In case, if you have the part number and you need the other details, the part index can be used. The part index (at the end of the catalogue) will give you the figure and page number of the part you wish to order. 2. How to Order Spare Parts : The part number and the description of the part required should be invariably mentioned in the order as per the catalogue text. The latest part number as conveyed through our service circulars should only appear on the order. In case of ordering painted components, colour shade of the components should be mentioned. The quantity shown against the part number is the quantity per vehicle for that group so that particular quantity should be multiplied by the number of sets required. 3. Part Number System: We have used 8 digit system for part numbers. The model or hardware item is indicated by first two digits or alphanumeric, the next two or four digits indicate main group and the last four or two digits indicate serial number in main group or serial number or subgroup of fastener respectively. Thus the part numbers will be indicated by 2-2-4 or 2-4-2 digit system. Understanding this system will enable you to identify the spare parts easily. 4. Abbreviations : The following abbreviations are used in this catalogue. assly. N.I. C'case Cyl o/s. Std. A/t. R.H. L.H. Assembly Not illustrated Crankcase Cylinder Over size Standard Alternate Right hand Left hand V W accl. Comp. Fr L Rr Hex. AR Volts Watts Accelerator Complete Front Length Rear Hexagonal As required

INDEX
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Description Cover Cylinder Head Cylinder Head Valve Camshaft / Tensioner Cylinder & Piston Crankshaft Balancer & Balancer Idler Gear Transmission Change Drum/ Shift Fork Gear Change Mechanism Engine Assly & Crankcase RH Crankcase LH Cover RH Cover Magneto Clutch Oil Cooler Assly. Carburettor Air Cleaner Comp. Silencer Assly Seat Assly. / Seat Lock & Tool Kit Oil Pump Magneto/C.D.I./H.T.Coil Starter Assly (For Self Start) Engine Mountings Frame & Frame fitting
Swing Arm / Rear Shock Absorber

Page No. 1 2 3 4 5 6 7 8 & 9 10 11 12 13&14 15&16 17 18&19 20 21 22 23 24 25 26&27 28&29 30 31 32 33 34 35 36 37 38 39 40 41&42 41&42

No. 36 37 38 39 40

Description Rear Brake Pedal Handle Bar Front Fork Painted Parts & Decals Petrol Cock, Cap Tank & Gauge Fuel Fitting - Petrol Tank, Side Cover & Cover seat Meter Assly.& control cables Head Lamp & Fairing Indicator Light Assly. Tail Lamp Assly/Front & Rear No.Plate Electrical Equipments

Page No. 43 44&45 46&47
48,49,50

51

41 42 43 44 45

52 53 54 55 56 57

46

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 35

Rider Foot rest Pillion Foot rest / Holder Mudguard Front & Rear Stand Assembly Tyre/ Tube /Rim Front Hub Front Master Cylinder Front Disc Brake Rear Hub Rear Hub

Brand ID: 001MC625

Pictorial Index
PLATE NO. : 1 COVER CYLINDER HEAD PAGE NO.: 1 PLATE NO. : 2 CYLINDER HEAD PAGE NO.: 2

PLATE NO. : 3 VALVE

PAGE NO.: 3

PLATE NO. : 4 CAMSHAFT / TENSIONER

PAGE NO.: 4

PLATE NO. : 5 CYLINDER AND PISTON

PAGE NO.: 5

PLATE NO. : 6 CRANK SHAFT

PAGE NO.: 6

Brand ID: 001MC625

Brand ID: 001MC625

Pictorial Index
PLATE NO. : 7 BALANCER & BALANCER IDLER GEAR PAGE NO.: 7 PLATE NO. : 8 TRANSMISSION PAGE NO.: 8 & 9

Pictorial Index
PLATE NO. : 13 COVER RH PAGE NO.: 15 & 16 PLATE NO. : 14 COVER MAGNETO PAGE NO.: 17

5 4 1 3 2 N

PLATE NO. : 9 CHANGE DRUM / SHIFT FORK

PAGE NO.: 10

PLATE NO. : 10 GEAR CHANGE MECHANISM

PAGE NO.: 11

PLATE NO. : 15 CLUTCH

PAGE NO.: 18 & 19

PLATE NO. : 16 OIL COOLER ASSEMBLY

PAGE NO.: 20

4

PLATE NO. : 11 ENGINE ASSLY. & CRANKCASE RH

PAGE NO.: 12

PLATE NO. : 12 CRANKCASE LH

PAGE NO.: 13 & 14

PLATE NO. : 17 CARBURETTOR

PAGE NO.: 21

PLATE NO. : 18 AIR CLEANER COMP

PAGE NO.: 22

Brand ID: 001MC625

Brand ID: 001MC625

Pictorial Index
PLATE NO. : 19 SILENCER ASSLY. PAGE NO.: 23 PLATE NO. : 20 SEAT ASSLY / SEAT LOCK & TOOL KIT PAGE NO.: 24

Pictorial Index
PLATE NO. : 25 FRAME & FRAME FITTINGS PAGE NO.: 31 PLATE NO. : 26 SWING ARM / RR. SHOCK ABSORBER PAGE NO.: 32

PLATE NO. : 21 OIL PUMP

PAGE NO.: 25

PLATE NO. : 22 MAGNETO / C.D.I. / H.T. COIL

PAGE NO.: 26 & 27

PLATE NO. : 27 RIDER FOOT REST

PAGE NO.: 33

PLATE NO. : 28 PILLION FOOT REST / HOLDER

PAGE NO.: 34

PLATE NO. : 23 STARTER ASSLY (FOR SELF START)

PAGE NO.: 28 & 29

PLATE NO. : 24 ENGINE MOUNTINGS

PAGE NO.: 30

PLATE NO. : 29 MUDGUARD FRONT&REAR,COVER CHAIN

PAGE NO.: 35

PLATE NO. : 30 STAND ASSEMBLY

PAGE NO.: 36

Brand ID: 001MC625

Brand ID: 001MC625

Pictorial Index
PLATE NO. : 31 TYRE / TUBE / RIM PAGE NO.: 37 PLATE NO. : 32 FRONT HUB PAGE NO.: 38

Pictorial Index
PLATE NO. : 37 HANDLE BAR PAGE NO.: 44 & 45 PLATE NO. : 38 FRONT FORK PAGE NO.: 46 & 47

FF O L O N

KE CHO

N TUR

PLATE NO. : 33 FRONT MASTER CYLINDER

PAGE NO.: 39

PLATE NO. : 34 FRONT DISC BRAKE

PAGE NO.: 40

PLATE NO. : 39 PAINTED PARTS & DECALS

PISTON SEAL

WA

BR A

SE

E : US 4 ING T3- OM RN DO FR R ID LY INE ON FLU NTA P E AK CO CA G D LER VIN MO ALE FIL RE N EA RE CL FO BE

DUST SEAL BLEEDER CAP
x

PROTECTION BOOT

INSULATOR

CALIPER PISTON

BLEEDER SCREW

PAD SPRING

PLATE NO. : 35 REAR HUB

PAGE NO.: 41 & 42

PLATE NO. : 36 REAR BRAKE PADAL

PAGE NO.: 43

PLATE NO. : 41 FITTINGS P. TANK, SIDE COVER & COVER SEAT

4

CK LO

PUS

H

PAS

E -R

S

I G N I T

O

I

N

EU EU

R

OGRIP

R

OGRIP

PAGE NO.: 48, 49, 50

PLATE NO. : 40 CAP TANK & GAUGE FUEL

PAGE NO.: 51

PAGE NO.: 52

PLATE NO. : 42 METER ASSEMBLY & CONTROL CABLES

PAGE NO.: 53

8

10

12
F

6
E

km/h

4

x 1 0 0 rpm

2
1

STAND

SIDE

Brand ID: 001MC625

Pictorial Index
PLATE NO. : 43 HEAD LAMP & FAIRING PAGE NO.: 54 PLATE NO. : 44 INDICATOR LIGHT ASSEMBLY PAGE NO.: 55

PLATE NO. : 45 TAIL LAMP ASSLY / FR & RR NO. PLATE

PAGE NO.: 56

PLATE NO. : 46 ELECTRICAL EQUIPMENTS

PAGE NO.: 57

8
7

1/2

3

4

11

13 14

12 5 6

10

Brand ID: 001MC625

Plate No. 1 : COVER CYLINDER HEAD

6

8

2 9 7

4

5

3

11

2

10 10 11

3

1

No. 1 2 3 4 5 6 7 8 9 10 11

Part No. JC 1010 DJ 1012 36 DS10 DS 1011 DS 1010 36 17 01 66 96

Description Head Cylinder with Cover Cover Tappet ‘O’ Ring Kit for Cover Cyl. Head Silent Bush (V) Camshaft Cap Domed Cap Nut Copper gasket Hex. Bolt with Flange Hex. Bolt with Flange Plug Washer

Qty/ Veh.

Remarks

1 2 1 1 1 4 4 2 4 2 2

Ref. page no. 60

39 2647 15 DS 1010 84 39 2532 04 39 1075 04 DH 1012 72 31 1011 06

Alt. DG101498

1

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 2 : CYLINDER HEAD

Plate No. 3 : VALVE

9 4 8 2 8 9 6 10 1 7 12 4 3 11 5 3 9 1

5 2 13

6 7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Part No. 39 1660 05 DK 1010 03 DH 1015 08 39 1283 21 JC 1200 03 DH 1210 38 39 1674 04 DH 1110 12 39 2608 01 36 DS10 JC 1200 59 2100 39 1674 01 01 08 04

Description Stud (Exhaust) Gasket Cylinder Head Damper Cylinder Head ‘O’ Ring Carburettor Insulator Clamp for Insulator Hex. Bolt / Flange Sleeve - Spark Plug Grub Screw ‘O’ Ring Kit for Cover Cyl. Head Manifold "O" ring insulator Hex bolt with flange

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9

Part No. DS 1013 35 DS 1013 36 DS 1013 33 DG 1010 29 39 2017 19 DK DK DS 59 1013 26 1013 27 1013 66 1100 02

Description Rocker Arm Shaft - Intake Rocker Arm Shaft - Exhaust Rocker Arm with roller Cotter valve Seal valve stem Valve Repair Kit Valve Kit Wave washer Plain washer

Qty/ Veh.

Remarks

2 1 5 1 1 2 2 1 1 1 1 1 2

1 1 2 4 2 1 1 2 4 Refer Page No.60

For Sleeve Spark Plug Ref. page no. 60

Manifold mtg.

2

3

3

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 4 : CAMSHAFT / TENSIONER

Plate No. 5 : CYLINDER AND PISTON
2

6

4 3 3 2 2 7 6 8 9

10 1

4 7 1 15 5 10 11 12 13 5

14

9 5 8

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part No. 39 JC 39 JC 39 JC JC 2669 1010 2542 1010 1880 1010 1010 21 22 20 86 20 85 38

Description Ring ‘O’ Camshaft Assembly Bearing cam RH side Bearing cam RH side Bearing cam LH side Bearing cam LH side Guide chain Kit Sprocket cam Driven (32 T) Collar cam Sprocket Special camshaft washer Hex. Soc. Head cap Bolt Cam Chain Cam chain Tensioner pivot Bolt Tensioner Assly Hex Bolt / Flange Tensioner assly. gasket Bolt

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9 10

Part No. DK 39 JC DK 39 JC DK DD DK DH 1010 2181 1010 1013 2132 1010 1012 1210 1012 1014 63 06 12 28 17 37 38 07 37 14

Description Gasket Cylinder Pin dowel Piston Assly. Std. Ring Set Piston Ring Snap Cylinder Block & Piston Assly Assly. Oil Pipe BOLT M8x1.25PxL20L, Banjo Washer copper Damper

Qty/ Veh.

Remarks

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1

From 24Nov08 (D13) From 24Nov08 (D13) Ref. page no. 60

1 4 1 1 2 1 1 2 4 6

DS 1012 76 DH 1014 12 DH 1010 48 59 0400 31 JC 1010 35 DH 1013 92 JC 1010 34 39 1673 04 CS 1011 28 DD 1010 62

4

3

5

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 6 : CRANK SHAFT

Plate No. 7 : BALANCER & BALANCER IDLER GEAR

1 5 8

4

9 7 6 2 8 1 12 11 5 11 6 9 7 8 3 10

3 2

13 7 10 5 9

6 4

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Part No. JC 1010 39 2183 39 2165 31 1011 DS 1011 01 04 11 73 54

Description Crankshaft assly. comp. Bolt Plain washer Key woodruff Parallel key Bearing ball 28x68x18 Sprocket cam drive (16 T) Parallel pin Set primary driver driven Body centrifugal oil filter Nut primery drive Cover centrifugal oil filter Kit centrifugal oil filter

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9 10 11

Part No. DJ 1010 22 DH 1010 72 39 1672 04 DJ 1011 34 39 2152 20 DJ 1011 33 39 2557 17 39 1686 06 39 1620 11 52 DH01 77 39 1674 04

Description Body Balancer Assly. Bearing stopper Bolt Assly. Balancer Idler Gear comp. Needle roller bearing Spring torsion Balancer Idler Circlip ext. Dowel Pin Spring steel washer Balancer Idler Holder Hex bolt with flange

Qty/ Veh.

Remarks

1 1 1 1 1 2 1 1 1 1 1 1 1

1 1 1 1 2 2 2 2 2 1 3

Alt. DH101432

39 1931 20 DK 1012 48 39 2203 07 36 DK00 29 DH 1010 64 DH 1011 95 DH 1010 65 36 DK00 07

Ref. page no. 61

Ref. page no. 60

6

3

7

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 8 : TRANSMISSION

Plate No. 8 : TRANSMISSION

1 16 2 5 5 6 11 10 17 19 11 20 5 23 24 22 5 18 21 11 19 18 8 9 17 7 10 4 3 12 4 5 4 5 6 11 14 15 5 4 3 12 13 2

1 16 15 13

14 4 5

4 8 9 7

21 20 23 24 22

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part No. DK DK 39 DK DH DH DK DK DH 39 DK DH DK DH DK DH 1011 1014 2158 1011 1010 1012 1011 1011 1010 2160 1011 1013 1011 1010 1011 1011 25 71 11 03 79 35 02 04 84 11 44 36 05 79 06 11

Description Shaft Input Transmission Shaft Input Transmission Washer plain Gear 4th Drive Washer Spline External Circlip Gear Gear Gear Plain Shaft 3rd Drive 5th drive 2nd drive washer output Transmission Assly.

Qty/ Veh.

Remarks

No. 16 17 18 19 20 21 22 23 24

Part No. DK DK DH DH DK 30 DV DJ 39 1011 1011 1013 1013 1012 1010 1010 1010 1062 18 07 19 33 45 61 48 63 04

Description Gear 1st driven Gear 5th Driven Bush 2nd driven Gear 2nd Driven Collar Sprocket ‘O’ Ring Sprocket Coller Sprocket Drive Plate Drive Sprocket Bolt flange

Qty/ Veh.

Remarks

1 1 2 1 3 4 1 1 1 1 1 2 1 2 1 1

From 31Jan09 (D16)

1 1 1 1 1 1 1 1 2

Washer Thrust Gear 3rd Driven Washer spline Gear 4th Driven Bush 1st driven

8

3

9

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 9 : CHANGE DRUM / SHIFT FORK
1

Plate No. 10 : GEAR CHANGE MECHANISM

9 2 8
7 4 6 8 5

6 10 1 17

16
9

3 7 5
2 10

13

15 14 4 12 11

3

2

5 18

No. 1 2 3 4 5

Part No. DK DK DH DH DK DK 1011 1011 1011 1014 1011 1013 59 60 46 93 57 82

Description Fork Gear Shift Input Fork Gear Shift output Shaft Gear Shift Fork Shaft Gear Shift Fork Drum comp. Gear Shift Drum comp. Gear Shift Bolt Socket M6 Parallel pin Guide Gear Shifter Spacer Bush Fork Gear Shift

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Part No. DH 1017 05 DH 1017 14 DH 1011 44 DK 1011 82 DH 1015 09 39 2453 04 DH 1013 93 DH 1015 03 DK 1012 53 DH 1013 94 39 1998 19 DK 1011 87 DK 1011 80 DK 1011 85 DK 1011 86 DK 1011 77 DK 1011 84 39 2383 15 JC 1910 09

Description Lever comp. Gear Shifter Spring Slider Arm Reset Spring Gear Shifter Return Lever gear shift Damper Flanged Bolt Bolt Gear Shift drum Stopper Stopper Gear Shifter Drum Spring Gear Shifter Drum Stopper Bolt Shift Change Oil seal Collar Assembly tie rod Washer pivot Pivot bolt Assembly Lever Change Arm Boss lever change Flange nut Bolt Brake Pedal

Qty/ Veh.

Remarks

1 2 1 1 1 1 1 1 1 1 3

From 15Apr09 (D18)

6 7 8 9 10

39 0972 04 39 2606 07 DK 1013 61 DH 1014 96 DK 1011 35

1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1

N.I.

10

3

11

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 11 : ENGINE ASSLY. & CRANKCASE RH

Plate No. 12 : CRANKCASE LH

13 3 3 2 2 18

28 27

8 2

23 19 21

10 8

4 7 8 6 7 5 4 10 9 16 3 24

6 5

9 16 11 20 14 15 17 12 1 22

No. 1 2 3 4 5 6 7 8 9 10

Part No. JC 1010 18 JC 1010 29 59 0500 08 DH 1013 83 DH 1010 06 39 2583 20 39 2601 20 39 2180 06 59 2000 27 DH 1014 87

Description Engine Assly. with starter motor Crankcase RH Stud Bolt Flanged Gasket Crankcase Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Dowel Pin Bearing NRB HK 1516 (15x21x16) Plate Stopper

Qty/ Veh.

Remarks N I

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part No. JC JC 59 DK 39 59 DK 39 39 59 39 1010 1010 0500 1010 2188 2100 1010 0752 2603 2000 2185 16 45 08 94 19 06 97 01 20 06 20

Description Crankcase LH Crankcase LH Stud Guide starter assly Oil Seal O’ Ring Damper C’ Sunk Head Screw Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Balancer LH Bearing Oil Seal (For Output shaft) Oil Seal (For Shift lever) Breather pipe Plug (Drain Bolt) Gasket (For Drain Bolt)

Qty/ Veh.

Remarks

1 1 2 1 1 1 1 2 1 1

1 1 2 1 1 1 1 3 1 1 1 1 1 1 1 1

From 15Apr09 (D18)

30 1010 14 39 2190 19 DH 1012 03 DH 1016 61 31 1011 06

Alt. DG101498

12

3

13

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 12 : CRANKCASE LH
28
13 2 2

Plate No. 13 : COVER RH
3

27
8 7 18 27

11 21 6

16 17 5

22 18 19

23 19 21

10 8

2 12 10 4 1 9 9

4 7

6 5

15 14 16 3 24 12 22 17 1

11 20 20

15
14 13 26 25 23 24

No. 16 17 18 19 20 21 22 23 24 25 26 27 28

Part No. DK 1011 24 DH 1017 84 39 1013 21 39 1677 04 39 2305 04 DJ 2010 21 39 39 39 31 DK 39 2448 2180 2181 2010 1013 1672 11 06 06 81 80 04

Description Sensor thermal with gasket Gasket neutral switch 'O' ring (ID 9.8X1.9) Bolt Bolt Cable assly. (Battery to Earth) Plain Washer Hallow dowel pin Hallow dowel pin Switch Comp. (Neutral) Switch Comp. (Neutral) Flanged bolt (M6x16) O Ring Rubber tube Spring clip

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9 10

Part No. JC 1010 DH 1011 39 1041 DH 1011 DH 1011 30 97 19 41 42

Description Cover comp RH Grommet Breather Oil Seal Rack Shaft clutch release Parallel pin Gauge Wire circlip Bolt Pin Dowel Bracket Clutch Cable Gasket cover RH Plunger Oil Plate Plunger Oil Spring Joint ‘A’

Qty/ Veh.

Remarks

1 1 1 8 1 1 1 2 2 1 1 1 1 1 2

From 15Apr09 (D18)

1 1 1 1 1 1 1 1 10 2 1 1 1 1 1

DK 1012 51 DG 1014 18 DS 1012 15 DS 1013 53 39 0999 06 DK DH DH DH DH 1012 1011 1210 1210 1210 52 54 15 11 12

From 15Apr09 (D18) From 15Apr09 (D18) N.I. (For DK101380) N.I.

39 1013 21 DH 1012 46 28 1011 74

11 12 13 14 15

14

3

15

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 13 : COVER RH
3 11 21 8 7 18 19 2 12 4 1 9 10 27 6

Plate No. 14 : COVER MAGNETO

16 17 5

7

22

8 2 3 10 4 13 6

20 5

15
14 13 26 25 23 24 11

12

5 4 1 3 2 N

9

No. 16 17 18 19 20 21 22 23 24 25

Part No. DH 39 DH DH JC 1015 2443 1015 1013 1010 44 11 10 88 40

Description Spring torsion clutch lever Washer Damper Flanged Bolt ‘bajaj’ Decal NRB Plate Spring relief valve Spring relief valve Ball steel Pressure relief valve Pressure relief valve Intrigal circlip Oil Filler Cap with "O" ring Bolt Banjo Special Clutch Cover

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Part No. DJ DV 39 39 JC 1012 1010 2183 0999 1010 09 42 04 06 33 06 88 07 28 43

Description Cover Magneto Gasket Magneto cover Bolt Pin Dowel Cover LH RR Set Damper Flanged Bolt Set of Plate Gear Shift Label NR bearing Cap crank center O ring Decal cover magneto

Qty/ Veh.

Remarks

1 1 1 8 1 2 1 1 1 1 1 1 1 1

Fitted on Cover comp. RH

1 1 7 2 1 1 4 1 1 1 1 1 1 Refer Page No.60 Refer Page No.60 White

39 1990 20 DH 1014 82 DK 1011 22 DK 1014 49 30 1012 36 DK 1011 23 DK 1014 65 39 2547 17 DS 1012 63 DK 1013 66

From 31Jan09 (D16)

36 DH10 DH 1013 36 DH10 DJ 1612 AP 1010

From 31Jan09 (D16) N.S.

26 27 28

DH 1011 57 39 2452 21 DH 1013 23

Alt. 39128321

16

3

17

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 15 : CLUTCH

Plate No. 15 : CLUTCH

18
6a 7 7 4 6 6a

18

19 17
7

19
6

4

17
7

2
7

6 8 11 9

2
7

6 8 11 9

5

1

5

1

20

13 6b 3 14 16 10 12

15

13 6b 3 14 16 10 12

15

21

No. 1 2 3 4 5 6 6a 6b 7 8 9

Part No. DH DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK 1012 1010 1015 1010 1015 1010 1015 1011 1015 1011 1015 1011 1015 1012 1015 1011 1015 1011 1015 1011 1015 75 73 60 75 63 01 64 63 69 49 66 50 68 55 67 51 65 52 72 54 74

Description Special Nut Clutch assembly comp. Clutch assembly comp. Clutch Plate Assly Clutch Plate Assly Clutch Center Clutch Center Plate Clutch pressure Plate Clutch pressure Disc Clutch friction Disc Clutch friction Disc Clutch friction (B type) Disc Clutch friction (B type) Disc Clutch friction (C type) Disc Clutch friction (C type) Plate Clutch Plate Clutch Spring Clutch Capacity Spring Clutch Capacity Bolt M6X25 (CLS) Bolt M6X25 (CLS)

Qty/ Veh.

Remarks

No. 10

Part No. 39 1880 20 DK DK DK DK DH DK DK 1013 1015 1010 1011 1015 1010 1016 38 73 72 26 20 78 36 11 53 70 55 71 56 69 04

Description Bearing Clutch lifter thrust Plate Clutch Lifter (CLS) Plate Clutch Lifter (CLS) Rod Clutch lifter Spacer Clutch Nut Primary drive lock Lever Assly. Clutch Lever Assly. Clutch Washer Primary Drive Gear Seat Judder spring Seat Judder spring Spring Judder Spring Judder Friction clutch plate kit Friction clutch plate kit Bolt flange M6x25 Nut special

Qty/ Veh.

Remarks

1 1 1 1 1 1 1 4 4 1 1 1 1 4 4 4 5 4 5

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 From 31Jan09 (D16)

From 31Jan09 (D16) From 31Jan09 (D16) From 31Jan09 (D16) From 31Jan09 (D16) From 31Jan09 (D16) From 31Jan09 (D16) From 31Jan09 (D16) From 31Jan09 (D16) From 31Jan09 (D16) From 31Jan09 (D16)

11 12 13 14 15 16 17 18 19 20 21

From 13Jul09 (D22)

39 2200 DK 1011 DK 1015 DK 1011 DK 1015 DK 1013 DJ 1013 39 1674

From 31Jan09 (D16) From 31Jan09 (D16) without plate clutch From 31Jan09

DH 1012 75

18

3

19

Plate No. 16 : OIL COOLER ASSEMBLY

Plate No. 17 : CARBURETTOR

8 5 3 15

1 11 2 12 4 13 8 9 13 6 2 6 6 11 9 10 1 10 7 5 14 3

7

12

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Part No. DK 1011 DK 1012 39 1661 DK 1012 39 1672 DK DK 39 DK DK 1012 1012 2637 1013 1012 12 25 21 38 04 75 76 04 66 37

Description Oil cooler assembly Switch oil pressure O ring Assembly oil cooler pipe Bolt Pipe inlet oil cooler Pipe outlet oil cooler Hexagon head screw Bolt Special Banjo Gasket oil cooler pipe Cover Oil Cooler O Ring oil cooler Guide clutch cable

Qty/ Veh.

Remarks Alt. 52DK0048 (with cover)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part No. JC DJ DJ JC DJ 1200 1210 1210 1200 1210 05 51 52 09 53 54 55 11 06 01 02 01 10 58 59

Description Carburettor Assly. Vacuum Piston Kit Idling Screw Kit Jet needle(JN) “O” ring Screw Float Assly. Jet Holder Main jet Magnet Assly. Reed Switch Assly. Pan Head Screw Needle Jet (NJ)P3 Set Adjuster (PS) Set Plunger Assly. Air jet

Qty/ Veh.

Remarks

1 1 1 1 1 1 1 1 2 4 1 2 1

N.I.

1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1

Allen bolt

DJ 1210 DJ 1210 JC 1200 JC 1200 DH 1211 DH 1211 39 1780 JC 1200 DJ 1210 DJ 1210

DK 1012 89 DK 1013 40 JC 1610 27

Alt. 39084001

JC 1200 07

N.I.

20

21

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 18 : AIR CLEANER COMP

Plate No. 19 : SILENCER ASSLY.

6

7 9 3

2

1 8

3 4 5 4 1

2

No. 1 2 3 4 5 6 7 8

Part No. JC 1200 04 DK 1210 09 DH 1210 20 39 1765 11 39 0007 01 JC 1200 02 CB 1210 14 DK 1110 10

Description Air cleaner comp. Assly element filter Bracket lock Plain washer Hexagonal head screw Connecting tube Clamp Sensor air filter

Qty/ Veh.

Remarks

No. 1

Part No. JC JC JC DH DH DJ DK 1010 1010 1010 1016 1016 1010 1014 14 39 83 08 07 64 75

Description Silencer Assly. Silencer Assly. (shield can’t replace) Silencer assly. (shield can replace) Silencer front shield Truss screw Gasket exhaust Silencer rear shield Nut for shield muffler

Qty/ Veh.

Remarks without shield From 20Aug08 (D10)

1 1 1 1 1 1 1 1

Alt. 39234501

2 3 4 5 6

1 1 1 1 2 1 1 2

N.I. N.I.

DK 9026 27

22

3

23

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 20 : SEAT ASSLY / SEAT LOCK & TOOL KIT

Plate No. 21 : OIL PUMP

4 1

4

2

2 1 6 6

7

8
3 3/5

5

No. 1 2 3 4 5 6 7 8

Part No. DK DS DH DK DK 2110 2110 1610 2110 2110 01 05 46 04 08

Description Seat Assly Damper Lock Assly Seat assly Lock assly comp front seat front comp rear seat rear

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6

Part No. 52 DH01 69 39 1674 04 DH 1210 10 39 1686 06 DH 1210 35 39 2194 21

Description Oil Pump Assly Hex. Bolt with flange Mesh filter Oil pump Hollow dowel pin Clip Mesh Oil filter ‘O’ Ring

Qty/ Veh.

Remarks Alt. DH121001

1 2 1 1 1 2 1 2

1 3 1 1 1 1

39 1902 04 DJ 2210 06 DH 2110 05

Bolt flange Tool Kit with Band Band Tool Kit

N.S.

24 19

24

25

Brand ID: 001MC625

Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL

Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL

12 11 16 15 14 17 13 14 19 13 19 9 3 14 17 18 8 16 15

12 11 18 8 14

13

9

3

7 6

13 4

7 6

9

9

4

5 8 2 20 8 2

5

10

10

20

No. 1 2

Part No. 59 DJ DJ DJ DJ 39 39 1000 1110 1110 1110 1110 1674 0761 02 59 21 94 61 04 01 99 01 08 13 02 64 03 04 15 12 04

Description Spring dowel Stator Assly. comp Stator Assly. comp. Stator Assly. comp. Rotor Assly. Hex. Bolt with Flange Pan Head Screw Stopper plate (wiring harness) Screw Pan head Spark Plug Grommet Spark Plug AC/DC Regulator (Green) AC/DC Regulator (Brown) HT coil LH with cap HT coil RH with cap Cap Spark Plug Grommet H.T. Cable Flange Bolt

Qty/ Veh.

Remarks N.I. (Old) From 18Oct08 (D12) From 22Nov07 (D3)

No. 16 17 18 19 20

Part No. DJ 1610 39 1944 DH 1110 DJ 1110 DJ 1110 DJ 1110 67 04 16 23 62 93

Description Bracket H.T. Coil Flange Bolt Grommet Sleeve Spark Plug CDI analog type Magneto Assembly Magneto Assembly Bolt flanged (M6x28)

Qty/ Veh.

Remarks

3 4 5 6 7 8 9 10

1 1 1 1 1 2 2 1 1 2 2 1 1 1 1 2 2 2

1 2 1 1 1 1 2

N.I. From 18Oct08 (D12) N.I.

21 DH 1011 39 0746 DG 1110 DH 1110 DJ 2011 DJ 2011 JC 1110 JC 1110 DH 1110 DD 1110 39 1902

JM 1000 45

From 14Jun08 (D8)

11 12 13 14 15

26

27

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 23 : STARTER ASSLY

Plate No. 23 : STARTER ASSLY

12 11 14 11

12

14

3 13 9 2 10 4 8 15 17 18 16 16 5 17 18 8 15 1 6 9 2 10 1 13

3

7 6

7

4

5

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part No. DH DK DH DK DH JC DH DH 1017 82 1015 95 1017 81 1016 05 1016 59 1011 14 1015 81 1013 85

Description Body Body Plate Plate Gear Gear Plate Bolt comp. starter clutch comp. starter clutch Roller Clutch Roller Cutch starter clutch assly. Starter Clutch Assly. starter clutch gear return

Qty/ Veh.

Remarks include 2,15,16,17,18 From 15May09 (D19) From 15May09 (D19) From Aug.09 For stopper plate

No. 16 17 18

Part No. DJ 1011 09 DH 1011 63 DH 1015 33

Description Bush for spring starter Roller Bush for spring starter clutch

Qty/ Veh.

Remarks For unit before 15May09 (D19) For unit before 15May09 (D19)

1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 2 1 1 5 5

5 5 5

DK 1011 76 DH 1011 72 DH 1011 88 JC 1011 15 59 2000 07 DH 1013 82 JC DS DH DH DH DK 1110 07 1013 53 1011 84 1013 89 1011 64 1015 96

Shaft starter counter Collar starter counter Gear comp. starter counter assly. Assly. Gear Starter Counter Needle roller bearing Bolt socket Motor assly. starter Bolt Cover starter motor Slotted c’sunk screw Spring Starter Clutch Spring Starter Clutch

From Aug.09 Alt. 39097204 Ref. page no.61

From 15May09 (D19)

28

29

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 24 : ENGINE MOUNTINGS

Plate No. 25 : FRAME & FRAME FITTINGS

16

17 3 4

10

6 14 7 8 1

5

4 3 15

9&10

1

2 12 6 7 7 8 5 11
Qty/ Veh.

13 2 2

9

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part No. DK 1610 DH 1611 DH 1611 36 DK00 DK 1611 96 89 90 11 59

Description Bkt. Assly. eng. mtg. front Bkt. comp. LH eng. mtg. front Bkt. comp. RH eng. mtg. front Kit hardware eng. mounting Bkt. comp. LH eng. mtg. lower Bkt. comp. RH eng. mtg. lower Bolt Flanged Bolt Flanged Bush in frame Bolt - Hexagon M8x1.25 Bolt Hex Socket Head Bkt. comp. RH eng. rear Flanged bolt Bolt Washer Bkt. Engine hanger LH Bkt. Engine hanger RH

Remarks

No. 1 2 3

Part No. JC 1610 DH 1611 DG 1810 DK 1810 DG 1810 DK 1810 36 DV00 DK DK 39 DJ DJ 1810 1810 1680 1611 1611 22 12 48 75 42 76 07 50 51 04 32 33

Description Frame Assly. comp. Cup rear Nut Nut Cup - Steering Cup - Steering Bearing Cone Kit with 4th Race Cage Bearing Upper (19 ball) Cage Bearing Lower (20 ball) Flanged bolt Cable Hook LH Cable Hook RH

Qty/ Veh.

Remarks Incl. Bush, Races & Cup rear

1 1 1 1 1 1 3 1 1 1 1 1 2 1 1 1 1

Ref. page no. 60 4 5 Alt. 39 2311 04 6 7 8 9 10

DK 1611 60 39 2157 04 39 2412 04 DH 1612 73 39 1664 04 59 0400 DK 1611 39 2310 39 2311 39 2457 DK 1611 DK 1611 43 61 04 04 11 27 28

1 2 1 1 1 1 1 1 1 2 1 1

From Jul.09 From Jul.09 Ref. page no. 60 From 24Nov08 (D13) From 24Nov08 (D13)

30

3

31

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 26 : SWING ARM / RR. SHOCK ABSORBER

Plate No. 27 : RIDER FOOT REST

3 7 7 14 6 7 8

18

15
14 15 5 3

6

9

7

6

7 2

10

1 4

7 2

11 12 11 12 16 13

16 13 3

1

6

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Part No. JC 1710 DG 1710 36 DK00 JC 1710 DG 1710 DK DG DH DK DG 1710 1710 1710 1710 1710 03 38 12 02 18 06 19 19 03 34

Description Rear Shock Absorber Bolt Pre-coated Kit bush rear shock Swing arm assly. Needle bearing Collar swing arm Oil seal ‘U’ nut swing arm Shaft swing arm Chain slider Adjuster chain Cap Chain Adjuster Hexagon nut 14 Hexagon nut 12 Grease nipple Plain washer(Nylon) Plain washer Instuction Lable Nitrox chamber screw assly

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7

Part No. DJ DJ DH DH DX 1611 26 1611 27 1610 53 1611 94 1610 67

Description Main step LH assly. comp. Main step RH assly. comp. Rubber main step Kick stopper Plate lock pillion step Bolt Kit hardware main step

Qty/ Veh.

Remarks

2 2 1 1 4 2 4 1 1 1 2 2 2 2 2 2 2 1 2

Ref. page no. 60

1 1 2 1 2 2 2

N.I. N.I. N.I.

22 1504 51 36 Dk00 13

DG 1710 21 DG 1710 20 DG 1710 22 39 1997 15 35 1710 33 39 0740 11 39 1224 11 JC 1610 23 DJ 1710 34

Tyre Pressure decal (N.I.)

32

3

33

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 28 : PILLION FOOT REST / HOLDER
4 5

Plate No. 29 : MUDGUARD FRONT & REAR

14 6

3 2 1

1 12 7 7 8 6 2 8 10 15 4 5 16 5 6

16 5 3 16

No. 1 2 3 4 5 6 7 8

Part No. DK 1611 JC 1610 DJ 1611 DJ 1611 36 DK00 37 02 28 29 13

Description Holder LH step Holder RH step Pillion step assly. comp. LH Pillion step assly. comp. RH Kit hardware pillion Hexagonal head screw Nut Flanged Bolt

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part No. DK 59 DK 39 39 1610 0400 1610 0711 1680 98 40 86 11 04 85 98 11 15 01 25 41 25 36 69 99

Description Brace fender Step bolt Fender rear front Plain washer Flange bolt Fender rear Mud flap front Washer plain Nut nylon M5x0.8 Screw pan head M5 Rear fender complete Guide cable (steel) Guide cable (rubber) Bolt (for guide cable steel) Nail guide cable (rubber) Cover chain Bolt

Qty/ Veh.

Remarks

1 1 1 1 2 2 1 2

Ref. page no. 60

1 4 1 4 2 1 1 6 3 3 1 1 1 1 1 1 3

39 1069 01 39 0292 15 39 1741 04

Alt. 39258204

DK 1610 DK 1611 39 0242 39 0326 39 2420 52 DK00 DK 1610 DS 1611 DG 1810 DJ 1610 DK 1611

Mud flap hardware Mud flap hardware Mud flap hardware

N.S. From 20Aug08 (D10) N.I. From 20Aug08 (D10)

DH 1612 83

34

3

35

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 30 : STAND ASSEMBLY

Plate No. 31 : TYRE / TUBE / RIM

2

3

2

12
4

11

5

9 5 1 7 6 3 4 10

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part No. DK 1611 22 30 1611 57 39 0787 08 DH 1611 21 DH 1611 45 JC 1610 17 DH 1610 66 DH 1611 46 DF 1611 02 39 0422 15 DH DH DJ DJ 2010 2010 1612 1612 64 65 69 70

Description Stand main Shaft stand Pin cotter Spring main stand Cover spring main stand Stand side Spring side stand Cover spring side stand Bolt Nut Side stand switch Magnet Assly. Main Stand Pad Bottom Side Stand Pad Bottom

Qty/ Veh.

Remarks

No. 1 2 3 4 5

Part No. JC DK JC DK DK 1510 1510 1510 1510 1510 13 39 10 40 26

Description Wheel rim front Tubeless tyre front Wheel rim rear Tubeless tyre rear Valve for tubeless tyre

Qty/ Veh.

1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 2

N.I. N.I.

36

3

R

OGRIP

8

R

OGRIP

1

EU

EU

Remarks

37

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 32 : FRONT HUB
4 2 3

Plate No. 33 : FRONT MASTER CYLINDER

8

3

2 6 11 10 5 4 1 5 14 7 8 9 12 13 5 4
Qty/ Veh. Qty/ Veh.

5 10
E : US -4 M NG NI DOT3 FRO AR W NLY UID INER O FL TA N AP E AK CO C NG ER OVI BR ED AL FILL EM R SE AN A RE CLE FO BE

10 13

9

1 15

7

2 12 5 11

7 6

No. 1 2 3 4 5 6 7 8 9 10 11

Part No. 39 0787 08 39 2362 20 DK 1510 28 DG 1510 05 DE 1510 12 DE DK DH DG DG 1510 1510 1710 1510 1510 08 27 19 08 49

Description Pin cotter Bearing ball Spacer assly. Seal oil Plate drive Seal oil Disc Hex. slotted nut Plain washer Hex. soc. hd. bolt Case meter assly Hardware kit speed sensor Collar Axle

Remarks

No. 1 2 3 4 5 6 7 8 9 10

Part No. DE DJ DJ DE DE DE DJ DJ DJ DJ 1910 1510 1910 1910 1910 1910 1910 1910 1910 1910 43 76 57 11 10 33 28 29 30 31

Description Major Kit - Master Cylinder Assly Hose Brake Front Lever Grip RH Banjo Bolt Washer Copper Clamp Holder RH Bolt Bolt Front Brake Lever Nut Flanged Screw Cylinder Master Front brake switch Reservoir Cover Diaphragm Oil Window Kit Clamp LH Clamp RH Clamp Rubber

Remarks KBX KBX

1 2 1 1 1 1 1 1 1 6 1 1 1 1 From 15Jun09 (D21) Alt. JC151019 From 15Jun09 (D21)

1 1 1 2 4 1 1 1 1 2 1 1 1 1 1 1 1 1

JC 1510 20 JC 2010 50 DG 1510 07 DK 1510 08

12 13

11 12 13 14 15 16 17 18

DJ 1910 56 DJ 2011 00 DJ 1910 34 DJ 1910 35 36 DH19 02 DK 1810 48 DK 1810 49 DG 1810 34

KBX

N.I. N.I. N.I.

38

39 3

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 34 : FRONT DISC BRAKE

Plate No. 35 : REAR HUB
20 24 29 21 22 24 26 27 28 4 16 2 3 9 10 23 25

4 5

9 17
PISTON SEAL

18 19

11

8
DUST SEAL BLEEDER CAP

7
x

3

5 8 7

PROTECTION BOOT

INSULATOR

12 1

6

2 4 3

CALIPER PISTON

30
BLEEDER SCREW

1 13

PAD SPRING

6 5 7 5 8 15 11

12 14

10

No. 1 2 3 4 5 6 7 8 9 10 11 12

Part No. DG 1510 89 39 1769 04 DJ 1510 68 DJ 1510 69 DJ 1510 70 DJ DJ DJ DJ DJ 1510 1510 1510 1510 1510 71 72 73 74 75

Description Caliper Assly. Front Bolt Flanged Spring Pad Bleeder Screw Bleeder Cap Disc Pad Set Insulator Protection Boot Minor Kit - Caliper Major Kit - Caliper Pad Spring Front Sp. Bolt Disc Pad Front

Qty/ Veh.

Remarks

No. 1 2 3 4 5

Part No. 39 DK DJ 39 30 JC 30 JC JC DK JC JC 39 39 JC 30 2242 1510 1510 2241 1510 1910 20 22 88 20 69 10

Description Bearing ball Collar bearing Damper Bearing ball Spring Spring Shoe brake assly. Cam brake Panel rear brake Axle rear Spacer panel side Lever brake Hexagon head bolt Nut Indicator "O" ring

Qty/ Veh.

Remarks Alt. 39268720

1 2 1 1 1 1 1 1 1 1 1 1

fitted on front fork

1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1

From Oct 08

6 7 8 9 10 11 12 13 14 15

1511 05 1510 05 1510 02 1510 09 1510 11 1510 0775 0798 1510 1510 07 04 15 06 38

DJ 1511 05 DJ 1511 06

40

41 3

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 35 : REAR HUB

Plate No. 36 : REAR BRAKE PADAL

20 24 29 18 19 26 27 28 4 4 16 2 30 1 13 6 5 7 5 8 15 11 15
Qty/ Veh.

25 5 24 1

21

22

17

23

6 8 3

10 7 2 2

3 9

10

12

9
14

No. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Part No. DH 1710 19 39 1997 15 39 1224 11 DK 1510 14 DS 1510 74 DK DK DK DS DK 1510 1510 1510 1510 1510 12 13 05 73 15 15 36 02 14 10

Description ‘U’ nut Nut Plain washer Spacer for coupling Lock washer Seal oil Bearing ball Coupling Stud Sleeve Hex. lock nut Drive Chain Lock Chain Sprocket kit Sprocket 35T Chain 104 Link

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part No. JC 1910 36 DK00 DK 1011 JC 1910 39 2383 JC 1910 JC 1910 36 JC00 JC 1510 DH 1510 39 39 39 39 30 1540 0694 0789 0807 1510 01 18 85 09 15 10 02 03 08 29 11 15 12 08 95

Description Lever Brake Pedal Kit hardware torque rod Washer pivot bolt Bolt Brake Pedal Flange nut Spring brake pedal Rod brake Kit hardware rod brake Rod Torque Step Bolt Rod Torque Plain Washer Nut Hexagon Lock M8x1.25 Washer Spring Pin Snap Hexagon Bolt

Remarks

1 2 2 1 2 1 1 1 4 1 4 1 1 1 1

1 2 1 1 1 1 1 1 1 1 1 2 2 2 1

Ref. page no. 61

Ref. page no. 61

39 0794 DK 1510 36 JC00 JC 1510 DK 1510

Ref. page no. 60

N.I. N.I. N.I. N.I.

42

43 3

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 37 : HANDLE BAR

Plate No. 37 : HANDLE BAR

3 18 19 2

20

3 18 19 2

20

5 16
F L OF ON
E OK CH

5 16
SS PA

F L OF ON

E OK CH

I G N I T

SS PA

RN TU

4 9

8 7 12 11 23

15 17

10

6

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part No. JC 1810 05 DH 1810 53 39 1714 04 DH 2010 48 DH 2010 49 DJ DJ DJ DD 39 1910 09 1910 54 1910 55 1910 85 1184 15 19 07 16 19 11

Description Handle Bar Holder Handle Flanged bolt Control switch LH Control switch RH Lever assly. grip LH Holder left hand Lever grip left Bolt Self locking nut Kit hardware holder LH Grip LH Grip Assly. RH Bolt for lever Handle bar weight

36 DK00 DH 1910 DH 1910 DH 1910 DJ 1810

44

CK LO

PUS

H

E -R

RN TU

21 14 15 17 13

4 9

8 7 12 11 23

15 17

10

6

Qty/ Veh.

Remarks

No. 16 17 18 19 20 21

Part No. 30 39 DJ DJ DJ DS DJ 39 DK DK DJ JC 1910 2427 1810 2210 2210 1810 1811 1943 2010 2010 1910 1910 48 04 39 03 04 22 10 04 64 83 15 15

Description Band handle bar Hex. soc. hd. cap screw Pad Holder Handle Mirror assly. LH Mirror assly. RH Switch assly. ignition Lock set 4 in 1 Flange bolt Clutch Switch with Diode Clutch Switch (6 amo Diode) Lever & Support Holder Assly LH. Lever & Support Holder Assly LH.

1 1 4 1 1 1 1 1 1 1 1 1 1 1 2 Ref. page no. 61 Ref. page no. 61

22 23 24

CK LO

PUS

H

E -R

I G N I T

I

O

I

N

O

N

1

22

1

22 21 14 15 17 13

Qty/ Veh.

Remarks

2 2 1 1 1 1 1 2 1 1 1 1

Cable More Length (Old) From Aug.08 From Aug.09 (N.I.)

45 3

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 38 : FRONT FORK

Plate No. 38 : FRONT FORK

14 10 17 18 2 5 3 22 4 13 24 19

15 16 20 10

14

15 16 17 18 20

21

2 5 3

19

21

23 25 26 6/7

22 4 13 24

23 25 26

6/7 11 24 8 12 9 1 30 29 28 23

16

11 24 27 8 12 9 1 30 29 28 23 27

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part No. JC DG DG DG DG JC JC 30 31 DS 1810 1810 1810 1810 1810 01 21 23 13 22

Description Fork front assy. Dust seal Oil seal Guide bush Ring snap Outer Tube LH Outer Tube RH Gasket Bolt Cylinder comp. fork Pipe comp. suspension inner Slide Bush Spring front fork Grommet Top Bolt fork Flange bolt

Qty/ Veh.

Remarks Without 20,21,22,23,24,25,26

No. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Part No. 31 1811 02 31 1811 01 DS 1810 85 DG 1810 03 59 0400 05 JC 1810 DG 1810 JC 1810 JC 1810 52 JC00 02 08 07 06 19

Description ‘O’ ring Seat fork spring Spacer Tube Washer Bolt with Washer M16*28L Holder fork upper Socket Bolt Cushion Rubber Cover Trail B Lamp Shade Assly. Bearing cone Holder fork under Spring washer Bolt Flaye Bolt Nut Steering

Qty/ Veh.

Remarks

1 1 2 2 1 1 1 2 2 2 2 2 2 2 2 1

2 2 2 2 1 1 2 2 4 1 1 1 2 2 1 1

1810 11 1810 12 1810 26 1811 06 1810 77

JC 1810 21 DG 1810 11 JC 1810 17 DH 1810 09 DH 1810 15 DK 1810 08

DG 1810 05 JC 1810 03 39 0789 12 39 1714 04 DK 1810 08 DG 1810 48

Pinels Bolt Outer Tube N.I.

46

3

47

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 39 : PAINTED PARTS & DECALS

Plate No. 39 : PAINTED PARTS & DECALS

15 15 16 7 9 17 18 5 5 1 1 8 3 8 3 16 7 9

17 18

16 16 13 14 13 14

6 6 4 2 2 10/11 12 10/11 12

4

No. 1

Part No. JC JC JC JC DK DK DK DK DK DK DK DK DK DK DK DK 7102 7102 7102 7102 7301 7301 7301 7301 7302 7302 7302 7302 7303 7303 7303 7303 2T 2V 3A X3 2T 2V 3A X3 2T 2V 3A X3 2T 2V 3A X3

Description Fuel Fuel Fuel Fuel Side Side Side Side Side Side Side Side Sear Sear Sear Sear Tank Tank Tank Tank cover cover cover cover cover cover cover cover Cowl Cowl Cowl Cowl LH LH LH LH RH RH RH RH Assly. Assly. Assly. Assly.

Qty/ Veh.

Remarks FOR FOR FOR FOR FOR FOR FOR FOR FOR FOR FOR FOR FOR FOR FOR FOR TITANIUM SILVER COCKTAIL WINE RED LONG BEACH BLUE EBONY BLACK TITANIUM SILVER COCKTAIL WINE RED LONG BEACH BLUE EBONY BLACK TITANIUM SILVER COCKTAIL WINE RED LONG BEACH BLUE EBONY BLACK TITANIUM SILVER COCKTAIL WINE RED LONG BEACH BLUE EBONY BLACK

No. 5

Part No. DK DK DK DK 7402 7402 7402 7402 2T 2V 3A X3

Description Front Front Front Front Fender Fender Fender Fender

Qty/ Veh.

Remarks FOR TITANIUM SILVER FOR COCKTAIL WINE RED FOR LONG BEACH BLUE FOR EBONY BLACK

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

2

6 7

DH 1410 20 DJ DJ DJ DJ JC JC JC JC 7401 7401 7401 7401 7201 7201 7201 7201 2T 2V 3A X3 2T 2V 3A X3

Seat tape Fairing Fairing Fairing Fairing Tank Tank Tank Tank flap flap flap flap LH LH LH LH

FOR TITANIUM SILVER FOR COCKTAIL WINE RED FOR LONG BEACH BLUE FOR EBONY BLACK FOR TITANIUM SILVER FOR COCKTAIL WINE RED FOR LONG BEACH BLUE FOR EBONY BLACK

3

8

1 1 1 1

4

48

3

49

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 39 : PAINTED PARTS & DECALS

Plate No. 40 : CAP TANK & GAUGE FUEL

15 16 7 9

17 1 18 2

3 5

5 1 8 3 4

6

16 13 14 15 8 7 4 13 9 2 10/11 12 12 11 14 10

6

No. 9

Part No. JC 7202 JC 7202 JC 7202 JC 7202 DK 1611 DK 1611 59 0200 JC 1410 JC 1410 DK 1410 DK JC JC JC JC 1410 1610 1610 1410 1410 2T 2V 3A X3 23 24 01 15 17 26 27 19 20 18 19

Description Tank flap RH Tank flap RH Tank flap RH Tank flap RH Cover Side Mesh LH Cover Side Mesh RH Self tap screw Grommet tank flap Grommet tank flap “B” monogram on tank “Pulsar” Logo on tank Seat cowl decal LH Seat cowl decal RH Oil cooler decal LH Oil cooler decal RH

Qty/ Veh.

Remarks FOR TITANIUM SILVER FOR COCKTAIL WINE RED FOR LONG BEACH BLUE FOR EBONY BLACK

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Part No. DH 1410 50 39 0840 01 39 2381 04 JC 1410 20 DH 1410 48 30 1410 39 DD 1410 22 39 0740 11 DK 2010 65 39 2758 21 30 1410 32 DJ 1410 06 BA 1220 03 DH 1410 24 DG 1410 28 30 1410 38 30 1410 36 JC 1410 34

Description Cap Assly. Tank Pan head screw Hex. Soc Hd. cap screw Tap Assly Rotor with key Packing Bolt flanged Plain Washer Gauge Fuel ‘O’Ring New Tank Fuel Guage Bolt Tube fuel Pipe clip Drain tube Clamp ‘O’ Ring Packing Spring Drain tube

Qty/ Veh.

Remarks

10 11 12 13 14 15 16 17 18

1 1 1 1 1 1 6 2 4 2 2 1 1 1 1

1 1 7 1 1 1 2 2 1 1 4 1 1 1 1 1 1 1

Alt. 39 1780 01 Alt. DK141001

fitted on fueltank fitted on tankflap

From 24Dec07 (D6)

N.I. N.I. From 31Mar09 (D17)

50

3

51

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 41 : FITTINGS P. TANK, SIDE COVER & COVER SEAT

Plate No. 42 : METER ASSEMBLY
2 3

9

7 8 4
8

4
10

12
F

6
E

km/h

4

5
STAND

x 1 0 0 rpm

2
1

SIDE

6
2 5

15 14
3

8

1

1 12

3a

13
10

4

7

No. 1 2 3 3a 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part No. DK 1611 85 DH 1410 31 DG 1611 21 39 1789 24 DK 1810 34 DH 1410 23 DJ 1410 08 39 1556 04 39 2424 11 DK 1410 15 DH 1613 11 DH 1613 12 DK 1410 17 DK 1611 47 DK 1611 48 39 2310 04 DJ 1610 79 DJ 1610 80

Description Grommet Kit For side cover Tape tank inner Screw Washer Nylon Lock for side cover Damper Rear Damper front Flanged Bolt Plain Washer Tank pad Rubber seat cowl LH Rubber seat cowl RH Damper tank middle Grab handle LH Grab handle RH Bolt Flange Foam LH For grab Foam RH For grab

Qty/ Veh.

Remarks Refer Page No. 61

No. 1 2 3 4 5 6 7 8 9 10

Part No. JC 39 DJ DJ DJ DJ DJ DK JC JC 1910 1778 1811 2011 2011 16 02 19 59 63

Description Speedo meter with Breather Self Tapping Screw Cluster cover Speedo meter top cover Button push for tripmeter Speedometer Gasket Control cable throttle Cable Clutch Guide Clutch Cable Speed sensor eith cable

Qty/ Veh.

Remarks From 15Jun09 (D21)

1 2 2 2 1 1 2 1 1 1 1 1 1 1 1 4 1 1

1 4 1 1 1 1 1 1 1 1

From 20Sep07 (D1)

N.I. N.I.

2011 82 1910 61 1910 11 1610 27 2010 48

From Aug.08 (Drawing require)

From Aug.09 (N.I.)

N.I. N.I.

52

3

53

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 45 : HEAD LAMP & FAIRING
3 4 5 6 8 7 2 9 1 13 11 10 12 14

Plate No. 46 : INDICATOR LIGHT ASSEMBLY

1/2

3/4 5

16 17 16 15

6

8 7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part No. JC DJ DJ DF 39 2010 1811 1810 1810 2141 08 20 33 98 24

Description Head Lamp assly. Mask Wind Shield Bolt Non Metallic Washer Well Nut Decal Wind Shield M5 x 15L mushroom HD Packing Fairing Fairing mounting upper bracket Kit hardware mtg. bracket Clip Nut Screw pan cross Screw pan cross Lamp 12V 35/35W-HS1 5 Watt bulb white output BCU (Black) BCU (Brown)

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8

Part No. DJ DJ DJ DJ GH 2011 48 2011 49 2011 46 2011 47 2010 12

Description Blinker Front LH Flexible Blinker Front RH Flexible Blinker RR LH Flexible Blinker RR RH Flexible Lamp 12V / 10W Hex Nut Flange
Magnet assly blinker self cancellation

Qty/ Veh.

Remarks

1 1 1 4 4 4 1 2 1 1 1 4 2 2 1 2 1 1 Ref. page no. 61

1 1 1 1 4 4 1 1 N.I. From 20Aug08 (D10) From 20Aug08 (D10)

DL 1810 10 DJ 1810 37 39 1907 01 DJ 1810 69 DH 1810 52 36 DK00 DJ 1810 39 0716 39 1524 JC 2010 21 65 01 01 09

39 1970 15 DJ 2011 81 DJ 2011 80

Assy hall sensor

DK 2010 44 DJ 2011 41 DJ 2011 65

From 14Jun08 (D8)

54

3

55

Brand ID: 001MC625

Brand ID: 001MC625

Plate No. 47 : TAIL LAMP ASSLY / FR & RR NO. PLATE

Plate No. 48 : ELECTRICAL EQUIPMENTS

4

3 2

8
7

5

16 6 1 16 11 7

1/2

12

3

4

11 13 8 12 9 5

13 14

14

10

10

6

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part No. DK 2010 03 DH 1612 93 DK 1611 53 59 0100 13 39 0705 01 39 1972 DK 2010 DJ 1610 DP 1611 39 1680 15 24 72 45 04

Description Tail light with Lamp Damper Clip Nut Screw pan cross Truss Screw Bolt flange No. Plate illumination Rear No. plate bkt. Number plate Rear Hex Flanged Bolt Truss Screw Number plate front No. plate mounting bracket Bolt flange Grommet for Number plate mtg. Rear blinker mtg. plate

Qty/ Veh.

Remarks

No. 1 2 3 4 5 6 7 8 9 10

Part No. DH 2010 11 DH 2010 14 39 1507 11 39 1956 04 DJ 2011 26 DJ JC JC JC 39 DK DK 30 30 DJ DJ JC 1612 2010 2010 2010 1680 2010 2010 2011 2010 2011 2010 2010 47 13 29 05 04 16 78 04 85 40 20 06

Description Horn with LH stay Horn with RH stay Plain Washer Flange Bolt Battery (12V-9A) Dry Band Battery Wiring Harness For below seat Wiring Harness (St.RelaySol.Type) Rear Brake Switch Flange bolt Starter Relay Starter Relay Fuse box Assly. Fuse Cable assly. (Battery to Earth) Cable assly. (Battery to St. Relay) Magnet Rear Brake Switch

Qty/ Veh.

Remarks

1 2 4 4 2 2 1 1 1 2 2 1 1 2 2 1 For Front No. Plate

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Old From Aug.08

39 1783 01 DP 1611 44 DH 1612 92 39 1773 04 DH 1612 93 DK 1611 64

N.I.

11 12 13 14 15

N.I.

56

3

57

Brand ID: 001MC625

Brand ID: 001MC625

KIT LIST
Sr. Kit Part No. No.
Kit Description Consisting of Following Parts Part No. Description Qty./Kit

KIT LIST
Sr. No. Kit Part No.
Kit Description Consisting of Following Parts Part No. Description Qty./Kit

1

36DS1001 Cyl.Head O Ring Kit

39239121 39128321 DK101247 DK101108 DK101110 DK101246 DH101017 DK101059 39220011 DH101234 39226701 DH101066 DH101067 39219908 DH101282 DH101292 DH101294 DH101283 DH101293 39154011 39069415 39078912 39080708 39231204 39197015 39241304 DH161245 DG181045 DG181046 DG181047 39071411 39071215 39073712 DJ161186 DH161061 30141031 39104011 39078408 DV101048 JC151014 DK151010

O Ring (Cover tappet) O ring Retainer valve spring Spring valve inner Spring valve outer Seat valve spring Guide chain (Tight) Guide Chain (slack) Washer Gasket centrifugal oil filter Oval screw Join oil delivery Spring oil delivery Pin oil delivery joint Damper Cover Magneto Damper A Cover LH RR Damper B Cover LH RR Plate Damper Plate Damper Cover LH RR Plain washer Hex lock nut Washer spring Pin snap Bolt flange Nut flange Bolt flange U Nut Bearing cone Bearing race Upper bearing race Plain washer Dome cap nut Spring washer Plait side pillion stape Pin pillion set "O" ring Plain washer Split pin Sprocket drive Sprocket hub Chain

2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 8 1 3 1 1 1 8 2 2 2 2 2 2 2 1 1 1

13 36JC0003 Kit hardware rod Brake

2

DK101326 Valve Repair Kit

30191038 39021911 39080808 30191035 15191026 JC191007 30191024 30191017 39021911 39072504 DH161158 DH161133 DJ181029 DJ181064 39021111 39155304 DK101241 DK101561 DK101242 DK101243 DK101128 DK 1110 16 DK 1110 21 JC 1110 10 DK 1110 17 DK 1110 19 DK 1110 20 DH191017 DH191008

Pin Plain washer Split pin Spring Pin Brake adjustment nut Screw Nut Plain washer Bolt hex Grommet side cover front Grommet side cover rear Collar Grommet Plain washer Bolt flange Housing comp clutch Housing comp clutch. 31Jan09(D16) Gear comp prim driven Gear prim driven Bush prim driven. 31Jan09(D16) Armature Assembly Tie bolt Yoke Assembly Bush Assly Kit “O” Ring for spigot Oil seal for yoke Pipe throttle Grip hand RH

1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

14 36DK0019 Kit hardware holder LH

3 4

JC101038 Guide Chain Kit 36DK0007 Kit centrifugal oil filter

15 DK161185 Grommet kit for side cover 16 36DK0021 Kit hardware mtg. bkt.

5

36DH1006 Set Damper (cover magneto)

17 36DK0029 Kit primary drive and driven

6 7

36DH1007 Set of Plate (cover magneto) 36DH0018 Kit hardware torque rod

18 JC111007 Motor assly starter

8

36DK0011 Kit hardware engine mounting

9

36DV0007 Bearing cone kit

19 DH191016 Grip assly RH

10 36DK0012 Kit bush rear shock absorber

11 36DK0013 Kit hardware pillion

12

36JC0002 Chain sprocket kit

60

3

61