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.
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.
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 :
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.
INDEX No. 1 2 3 4 5
Description Cover Cylinder Head Cylinder Head Valve Camshaft / Tensioner Cylinder & Piston
Page No.
No.
1 2 3 4 5
36 37 38 39 40
6 7 8 9 10
Crankshaft Balancer & Balancer Idler Gear Transmission Change Drum/ Shift Fork Gear Change Mechanism
6 7 8 & 9 10 11
11 12 13 14 15
Engine Assly & Crankcase RH Crankcase LH Cover RH Cover Magneto Clutch
12 13&14 15&16 17 18&19
16 17 18 19 20
Oil Cooler Assly. Carburettor Air Cleaner Comp. Silencer Assly Seat Assly. / Seat Lock & Tool Kit
Assembly
V
Volts
N.I.
Not illustrated
W
Watts
C'case
Crankcase
accl.
Accelerator
Cyl
Cylinder
Comp.
Complete
o/s.
Over size
Fr
Front
Std.
Standard
L
Length
A/t.
Alternate
Rr
Rear
R.H.
Right hand
Hex.
Hexagonal
L.H.
Left hand
AR
As required
42 43 44 45
46 20 21 22 23 24
4. Abbreviations : The following abbreviations are used in this catalogue. assly.
41
21 22 23 24 25
Oil Pump Magneto/C.D.I./H.T.Coil Starter Assly (For Self Start) Engine Mountings Frame & Frame fitting
26 27 28 29 30
Rider Foot rest Pillion Foot rest / Holder Mudguard Front & Rear Stand Assembly
31 32 33 34 35 35
Tyre/ Tube /Rim Front Hub Front Master Cylinder Front Disc Brake Rear Hub Rear Hub
Swing Arm / Rear Shock Absorber
25 26&27 28&29 30 31 32 33 34 35 36 37 38 39 40 41&42 41&42
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
52 53 54 55 56 57
Brand ID: 001MC625
Pictorial Index PLATE NO. : 1 COVER CYLINDER HEAD
PLATE NO. : 3 VALVE
PLATE NO. : 5 CYLINDER AND PISTON
PAGE NO.: 1
PAGE NO.: 3
PLATE NO. : 2 CYLINDER HEAD
PLATE NO. : 4 CAMSHAFT / TENSIONER
PAGE NO.: 2
PAGE NO.: 4
PAGE NO.:
PLATE NO. : 6
PAGE NO.:
5
CRANK SHAFT
6
Brand ID: 001MC625
Brand ID: 001MC625
Pictorial Index
Pictorial Index
PLATE NO. : 7 BALANCER & BALANCER IDLER GEAR
PLATE NO. : 8
PAGE NO.:
7
TRANSMISSION
8 & 9
PAGE NO.:
PLATE NO. : 10
PAGE NO.:
PLATE NO. : 13
PAGE NO.: 15 & 16
COVER RH
PLATE NO. : 14
PAGE NO.: 17
COVER MAGNETO
5 4 1 3 2 N
PAGE NO.:
PLATE NO. : 9 CHANGE DRUM / SHIFT FORK
10
GEAR CHANGE MECHANISM
11
PLATE NO. : 15
PAGE NO.:
CLUTCH
18 & 19
PLATE NO. : 16 OIL COOLER ASSEMBLY
PAGE NO.: 20
4
PLATE NO. : 11 ENGINE ASSLY. & CRANKCASE RH
PAGE NO.:
PLATE NO. : 12
PAGE NO.:
PLATE NO. : 17
PAGE NO.:
12
CRANKCASE LH
13 & 14
CARBURETTOR
21
PLATE NO. : 18 AIR CLEANER COMP
PAGE NO.: 22
Brand ID: 001MC625
Brand ID: 001MC625
Pictorial Index
Pictorial Index
PLATE NO. : 19 SILENCER ASSLY.
PLATE NO. : 21 OIL PUMP
PLATE NO. : 23 STARTER ASSLY (FOR SELF START)
PAGE NO.: 23
PAGE NO.: 25
PAGE NO.: 28 & 29
PLATE NO. : 20 SEAT ASSLY / SEAT LOCK & TOOL KIT
PLATE NO. : 22 MAGNETO / C.D.I. / H.T. COIL
PLATE NO. : 24 ENGINE MOUNTINGS
PAGE NO.: 24
PAGE NO.: 26 & 27
PAGE NO.: 30
PLATE NO. : 25 FRAME & FRAME FITTINGS
PLATE NO. : 27 RIDER FOOT REST
PLATE NO. : 29 MUDGUARD FRONT&REAR,COVER CHAIN
PAGE NO.: 31
PAGE NO.: 33
PAGE NO.: 35
PLATE NO. : 26 SWING ARM / RR. SHOCK ABSORBER
PLATE NO. : 28 PILLION FOOT REST / HOLDER
PLATE NO. : 30 STAND ASSEMBLY
PAGE NO.: 32
PAGE NO.: 34
PAGE NO.: 36
Brand ID: 001MC625
Brand ID: 001MC625
Pictorial Index
Pictorial Index
PLATE NO. : 31
PAGE NO.: 37
TYRE / TUBE / RIM
PLATE NO. : 32
PAGE NO.: 38
FRONT HUB
PLATE NO. : 37
PAGE NO.: 44 & 45
HANDLE BAR
PLATE NO. : 38
PAGE NO.: 46 & 47
FRONT FORK
EU
N E -R
I G N I T
FF O L O N
I
O
KE CHO
S
CK LO
PUS
R
OGRIP
PAS
H N TUR
EU
R
OGRIP
PLATE NO. : 33
PAGE NO.:
FRONT MASTER CYLINDER
39
PLATE NO. : 34
PAGE NO.:
FRONT DISC BRAKE
40
PLATE NO. : 39
PAGE NO.:
PLATE NO. : 40
PAINTED PARTS & DECALS
48, 49, 50
CAP TANK & GAUGE FUEL
PLATE NO. : 41 FITTINGS P. TANK, SIDE COVER & COVER SEAT
PAGE NO.:
PLATE NO. : 42
PAGE NO.: 51
PISTON SEAL
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
WA
BR A
SE
BLEEDER CAP x
PROTECTION BOOT
INSULATOR
CALIPER PISTON
BLEEDER SCREW
PAD SPRING
PLATE NO. : 35
PAGE NO.:
REAR HUB
41 & 42
PLATE NO. : 36 REAR BRAKE PADAL
PAGE NO.: 43
52
PAGE NO.:
METER ASSEMBLY & CONTROL CABLES
8
53
10
12 F
6 E
4
2
SIDE
1
4
km/h
x 1 0 0 rpm STAND
Brand ID: 001MC625
Pictorial Index PLATE NO. : 43 HEAD LAMP & FAIRING
PLATE NO. : 45 TAIL LAMP ASSLY / FR & RR NO. PLATE
PAGE NO.: 54
PAGE NO.: 56
PLATE NO. : 44
PAGE NO.:
INDICATOR LIGHT ASSEMBLY
55
PLATE NO. : 46
PAGE NO.:
ELECTRICAL EQUIPMENTS
57
8 7
1/2
4
3
13
11
14
12
10
5 6
Brand ID: 001MC625
Plate No. 1 : COVER CYLINDER HEAD
8
6
4
2 9
7 5
3
11
2
10
3 10 1
11
No.
Part No.
1 2 3 4 5
JC 1010 DJ 1012 36 DS10 DS 1011 DS 1010
6 7 8 9 10 11
36 17 01 66 96
Description
Qty/ Veh.
Head Cylinder with Cover Cover Tappet ‘O’ Ring Kit for Cover Cyl. Head Silent Bush (V) Camshaft Cap
1 2 1 1 1
39 2647 15 DS 1010 84 39 2532 04 39 1075 04 DH 1012 72
Domed Cap Nut Copper gasket Hex. Bolt with Flange Hex. Bolt with Flange Plug
4 4 2 4 2
31 1011 06
Washer
2
Remarks
Ref. page no. 60
Alt. DG101498
1
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 2 : CYLINDER HEAD
Plate No. 3 : VALVE
9 4
8 2 9
8
1
9 3
6 10 1 7
5
12 4 3
11
5
6 7
2 13
Part No.
1 2 3 4
39 1660 05 DK 1010 03 DH 1015 08 39 1283 21
Stud (Exhaust) Gasket Cylinder Head Damper Cylinder Head ‘O’ Ring
2 1 5 1
5 6 7 8 9
JC 1200 03 DH 1210 38 39 1674 04 DH 1110 12 39 2608 01
Carburettor Insulator Clamp for Insulator Hex. Bolt / Flange Sleeve - Spark Plug Grub Screw
1 2 2 1 1
10 11 12 13
36 DS10 JC 1200 59 2100 39 1674
‘O’ Ring Kit for Cover Cyl. Head Manifold "O" ring insulator Hex bolt with flange
1 1 1 2
2
01 01 08 04
Description
Qty/ Veh.
No.
Remarks
For Sleeve Spark Plug
Part No.
1 2 3 4 5
DS 1013 35 DS 1013 36 DS 1013 33 DG 1010 29 39 2017 19
Rocker Arm Shaft - Intake Rocker Arm Shaft - Exhaust Rocker Arm with roller Cotter valve Seal valve stem
1 1 2 4 2
6 7 8 9
DK DK DS 59
Valve Repair Kit Valve Kit Wave washer Plain washer
1 1 2 4
1013 26 1013 27 1013 66 1100 02
Description
Qty/ Veh.
No.
Remarks
Refer Page No.60
Ref. page no. 60
Manifold mtg.
3
3
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 4 : CAMSHAFT / TENSIONER
Plate No. 5 : CYLINDER AND PISTON 2
6
4 3 7
3
6
8
9
2 2
10 1
4 7 1
5 15
5 10
12 11
No. 1 2 3
Part No.
5 6 7 8 9 10
DS 1012 76 DH 1014 12 DH 1010 48 59 0400 31 JC 1010 35
Sprocket cam Driven (32 T) Collar cam Sprocket Special camshaft washer Hex. Soc. Head cap Bolt Cam Chain
1 1 1 1 1
11 12 13 14 15
DH 1013 92 JC 1010 34 39 1673 04 CS 1011 28 DD 1010 62
Cam chain Tensioner pivot Bolt Tensioner Assly Hex Bolt / Flange Tensioner assly. gasket Bolt
1 1 2 1 1
4
21 22 20 86 20 85 38
Qty/ Veh.
39 JC 39 JC 39 JC JC
4
2669 1010 2542 1010 1880 1010 1010
Description Ring ‘O’ Camshaft Assembly Bearing cam RH side Bearing cam RH side Bearing cam LH side Bearing cam LH side Guide chain Kit
1 1 1 1 1 1 1
14
9 5
13
8
Remarks
No.
From 24Nov08 (D13) From 24Nov08 (D13) Ref. page no. 60
3
Part No.
Description
Qty/ Veh.
1 2 3 4 5
DK 39 JC DK 39
1010 2181 1010 1013 2132
63 06 12 28 17
Gasket Cylinder Pin dowel Piston Assly. Std. Ring Set Piston Ring Snap
1 4 1 1 2
6 7 8 9 10
JC DK DD DK DH
1010 1012 1210 1012 1014
37 38 07 37 14
Cylinder Block & Piston Assly Assly. Oil Pipe BOLT M8x1.25PxL20L, Banjo Washer copper Damper
1 1 2 4 6
Remarks
5
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 6 : CRANK SHAFT
Plate No. 7 : BALANCER & BALANCER IDLER GEAR
1 8
5
9
4
7
3 2
6
10 8
1 12
11
3
5
2
9
11
8
7 6
6
13
4 7
10
No.
Part No.
1 2 3 4 5
JC 1010 39 2183 39 2165 31 1011 DS 1011
6 7 8 9 10 11 12 13
6
01 04 11 73 54
Description
5
Qty/ Veh.
Remarks
9
No.
Part No.
Description
Qty/ Veh.
Crankshaft assly. comp. Bolt Plain washer Key woodruff Parallel key
1 1 1 1 1
1 2 3 4 5
DJ 1010 22 DH 1010 72 39 1672 04 DJ 1011 34 39 2152 20
Body Balancer Assly. Bearing stopper Bolt Assly. Balancer Idler Gear comp. Needle roller bearing
1 1 1 1 2
39 1931 20 DK 1012 48 39 2203 07 36 DK00 29 DH 1010 64
Bearing ball 28x68x18 Sprocket cam drive (16 T) Parallel pin Set primary driver driven Body centrifugal oil filter
2 1 1 1 1
6 7 8 9 10
DJ 1011 33 39 2557 17 39 1686 06 39 1620 11 52 DH01 77
Spring torsion Balancer Idler Circlip ext. Dowel Pin Spring steel washer Balancer Idler Holder
2 2 2 2 1
DH 1011 95 DH 1010 65 36 DK00 07
Nut primery drive Cover centrifugal oil filter Kit centrifugal oil filter
1 1 1
11
39 1674 04
Hex bolt with flange
3
Ref. page no. 61
Remarks
Alt. DH101432
Ref. page no. 60
3
7
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 8 : TRANSMISSION
Plate No. 8 : TRANSMISSION
1
1 16
16
13
2 5
4
5
4
15
14
3 12
6
5
5
4
4
11
7
8
12
4
5
11 10 17
19
18
11
18
11
21
21
20 5
20 5
22
23
23
24
No. 1
Part No.
Description
Qty/ Veh.
2 3 4 5
1011 1014 2158 1011 1010 1012
25 71 11 03 79 35
Shaft Input Transmission Shaft Input Transmission Washer plain Gear 4th Drive Washer Spline External Circlip
1 1 2 1 3 4
6 7 8 9 10
DK DK DH 39 DK
1011 1011 1010 2160 1011
02 04 84 11 44
Gear Gear Gear Plain Shaft
1 1 1 1 1
11 12 13 14 15
DH DK DH DK DH
1013 1011 1010 1011 1011
36 05 79 06 11
Washer Thrust Gear 3rd Driven Washer spline Gear 4th Driven Bush 1st driven
8
22
24
DK DK 39 DK DH DH
3rd Drive 5th drive 2nd drive washer output Transmission Assly.
15
14
3
6
9
17 19
5
4
7
8
10
9
13
2
Remarks
No.
From 31Jan09 (D16)
Part No.
Description
Qty/ Veh.
16 17 18 19 20
DK DK DH DH DK
1011 1011 1013 1013 1012
18 07 19 33 45
Gear 1st driven Gear 5th Driven Bush 2nd driven Gear 2nd Driven Collar Sprocket
1 1 1 1 1
21 22 23 24
30 DV DJ 39
1010 1010 1010 1062
61 48 63 04
‘O’ Ring Sprocket Coller Sprocket Drive Plate Drive Sprocket Bolt flange
1 1 1 2
Remarks
2 1 2 1 1
3
9
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 9 : CHANGE DRUM / SHIFT FORK
Plate No. 10 : GEAR CHANGE MECHANISM
1
9 2 8 8
7
5
6
4
10 6
17
1
16 9
3
13
7 5
15
2
14
10
4
11
12 2
3
5 18
No. 1 2 3 4 5
6 7 8 9 10
10
Part No. DK DK DH DH DK DK
1011 1011 1011 1014 1011 1013
59 60 46 93 57 82
39 0972 04 39 2606 07 DK 1013 61 DH 1014 96 DK 1011 35
Description
Qty/ Veh.
Fork Gear Shift Input Fork Gear Shift output Shaft Gear Shift Fork Shaft Gear Shift Fork Drum comp. Gear Shift Drum comp. Gear Shift
1 2 1 1 1 1
Bolt Socket M6 Parallel pin Guide Gear Shifter Spacer Bush Fork Gear Shift
1 1 1 1 3
Remarks
From 15Apr09 (D18)
3
Description
Qty/ Veh.
No.
Part No.
1 2 3 4 5 6 7 8 9
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
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
1 1 1 1 1 1 1 1 1
10 11 12 13 14 15 16 17 18 19
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
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
1 2 1 1 1 1 1 1 1 1
Remarks
N.I.
11
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 11 : ENGINE ASSLY. & CRANKCASE RH
Plate No. 12 : CRANKCASE LH
13 3
28 27
2
3
2 18
10
23
8 2
19
4
21
8
6 5
7
9 16
8
11
6 9
7
20
16
14
15
3
5 4
17 12
Part No.
1 2 3 4 5
JC 1010 18 JC 1010 29 59 0500 08 DH 1013 83 DH 1010 06
Engine Assly. with starter motor Crankcase RH Stud Bolt Flanged Gasket Crankcase
1 1 2 1 1
6 7 8 9 10
39 2583 20 39 2601 20 39 2180 06 59 2000 27 DH 1014 87
Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Dowel Pin Bearing NRB HK 1516 (15x21x16) Plate Stopper
1 1 2 1 1
12
Description
Qty/ Veh.
No.
1
24
10
Remarks
No.
N I
1
3
Part No.
22
Description
Qty/ Veh.
2 3 4 5
JC JC 59 DK 39 59
1010 1010 0500 1010 2188 2100
16 45 08 94 19 06
Crankcase LH Crankcase LH Stud Guide starter assly Oil Seal O’ Ring
1 1 2 1 1 1
6 7 8 9 10
DK 39 39 59 39
1010 0752 2603 2000 2185
97 01 20 06 20
Damper C’ Sunk Head Screw Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Balancer LH Bearing
1 3 1 1 1
11 12 13 14 15
30 1010 14 39 2190 19 DH 1012 03 DH 1016 61 31 1011 06
Oil Seal (For Output shaft) Oil Seal (For Shift lever) Breather pipe Plug (Drain Bolt) Gasket (For Drain Bolt)
1 1 1 1 1
Remarks
From 15Apr09 (D18)
Alt. DG101498
13
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 12 : CRANKCASE LH
Plate No. 13 : COVER RH 3
28 13
16 17
11
27
21
2 2
27
8 7
22
5
6
18 18 19
10
23 19
21
2
8 10
12 4
4
6 5
1
7 11
15 14
20
16 3
16 17
DK 1011 24 DH 1017 84 39 1013 21 39 1677 04 39 2305 04 DJ 2010 21
Sensor thermal with gasket Gasket neutral switch 'O' ring (ID 9.8X1.9) Bolt Bolt Cable assly. (Battery to Earth)
1 1 1 8 1 1
25
39 39 39 31 DK 39
Plain Washer Hallow dowel pin Hallow dowel pin Switch Comp. (Neutral) Switch Comp. (Neutral) Flanged bolt (M6x16)
1 2 2 1 1 1
26 27 28
39 1013 21 DH 1012 46 28 1011 74
O Ring Rubber tube Spring clip
1 1 2
14
Description
Qty/ Veh.
Part No.
11 06 06 81 80 04
26
25
23
24
22
No.
2448 2180 2181 2010 1013 1672
14
1 13
12
21 22 23 24
20
15
17 24
18 19 20
9
9
Remarks
No.
From 15Apr09 (D18)
From 15Apr09 (D18) From 15Apr09 (D18) N.I. (For DK101380) N.I.
3
Part No.
1 2 3 4 5
JC 1010 DH 1011 39 1041 DH 1011 DH 1011
6 7 8 9 10 11 12 13 14 15
Qty/ Veh.
Cover comp RH Grommet Breather Oil Seal Rack Shaft clutch release
1 1 1 1 1
DK 1012 51 DG 1014 18 DS 1012 15 DS 1013 53 39 0999 06
Parallel pin Gauge Wire circlip Bolt Pin Dowel
1 1 1 10 2
DK DH DH DH DH
Bracket Clutch Cable Gasket cover RH Plunger Oil Plate Plunger Oil Spring Joint ‘A’
1 1 1 1 1
1012 1011 1210 1210 1210
30 97 19 41 42
Description
52 54 15 11 12
Remarks
15
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 13 : COVER RH
Plate No. 14 : COVER MAGNETO 3
16 17
11 21 27
8 7
22
7
5
6
18 19 2 10
12
8 2
4 10
3
1 9
6
4 13
20 5
15 14 13
26
25
23
5 4 1 3 2 N
12 11
24
9
No.
Part No.
16 17 18 19 20
DH 39 DH DH JC
21 22 23 24 25
26 27 28
16
1015 2443 1015 1013 1010
44 11 10 88 40
Description
Qty/ Veh.
Spring torsion clutch lever Washer Damper Flanged Bolt ‘bajaj’ Decal
1 1 1 8 1
39 1990 20 DH 1014 82 DK 1011 22 DK 1014 49 30 1012 36 DK 1011 23 DK 1014 65
NRB Plate Spring relief valve Spring relief valve Ball steel Pressure relief valve Pressure relief valve
2 1 1 1 1 1 1
39 2547 17 DS 1012 63 DK 1013 66
Intrigal circlip Oil Filler Cap with "O" ring Bolt Banjo Special Clutch Cover
1 1
Remarks
No.
Fitted on Cover comp. RH
From 31Jan09 (D16)
From 31Jan09 (D16) N.S.
3
Part No.
Description
Qty/ Veh.
1 2 3 4 5
DJ DV 39 39 JC
1012 1010 2183 0999 1010
09 42 04 06 33
Cover Magneto Gasket Magneto cover Bolt Pin Dowel Cover LH RR
1 1 7 2 1
6 7 8 9 10
36 DH10 DH 1013 36 DH10 DJ 1612 AP 1010
06 88 07 28 43
Set Damper Flanged Bolt Set of Plate Gear Shift Label NR bearing
1 4 1 1 1
11 12 13
DH 1011 57 39 2452 21 DH 1013 23
Cap crank center O ring Decal cover magneto
1 1 1
Remarks
Refer Page No.60 Refer Page No.60 White
Alt. 39128321
17
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 15 : CLUTCH
Plate No. 15 : CLUTCH
18
18 6a
6a 7
7 4
19
4
19
6
6
17
17 7
7
2
2
6
6 8
8 7
7
11
11 9
9
1
5
13
15 16
6b
12 10
3
1 2 3 4 5 6 6a 6b 7 8 9
18
Part No.
Description
12 10
3
21
14
14
No.
Qty/ Veh.
DH DK DK DK DK DK DK DK DK
1012 1010 1015 1010 1015 1010 1015 1011 1015
75 73 60 75 63 01 64 63 69
Special Nut Clutch assembly comp. Clutch assembly comp. Clutch Plate Assly Clutch Plate Assly Clutch Center Clutch Center Plate Clutch pressure Plate Clutch pressure
1 1 1 1 1 1 1
DK DK DK DK DK DK DK DK DK DK DK DK
1011 1015 1011 1015 1012 1015 1011 1015 1011 1015 1011 1015
49 66 50 68 55 67 51 65 52 72 54 74
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)
4 4 1 1 1 1 4 4 4 5 4 5
20
13
15 16
6b
1
5
Remarks
Part No.
10
39 1880 20
Bearing Clutch lifter thrust
1
From 31Jan09 (D16)
11
From 31Jan09 (D16)
12 13 14 15
DK DK DK DK DH DK DK
From 31Jan09 (D16) From 31Jan09 (D16)
Description
Qty/ Veh.
No.
1013 1015 1010 1011 1015 1010 1016
38 73 72 26 20 78 36
Plate Clutch Lifter (CLS) Plate Clutch Lifter (CLS) Rod Clutch lifter Spacer Clutch Nut Primary drive lock Lever Assly. Clutch Lever Assly. Clutch
1 1 1 1 1 1 1
11 53 70 55 71 56 69 04
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
1 1 1 1 1 1 1 1
Nut special
1
From 31Jan09 (D16)
16 17
From 31Jan09 (D16)
18
From 31Jan09 (D16)
19
From 31Jan09 (D16)
20
39 2200 DK 1011 DK 1015 DK 1011 DK 1015 DK 1013 DJ 1013 39 1674
From 31Jan09 (D16)
21
DH 1012 75
Remarks
From 31Jan09 (D16)
From 13Jul09 (D22)
From 31Jan09 (D16) From 31Jan09 (D16) without plate clutch From 31Jan09
From 31Jan09 (D16)
3
19
Plate No. 16 : OIL COOLER ASSEMBLY
Plate No. 17 : CARBURETTOR
8 5 15
3
1 11 2
4 12
8
13
9
14 3
13
7
7
5
6 2
10
6
12
6 11 9
10 1
No.
Part No.
Description
Qty/ Veh.
1 2 3 4 5
DK 1011 DK 1012 39 1661 DK 1012 39 1672
12 25 21 38 04
Oil cooler assembly Switch oil pressure O ring Assembly oil cooler pipe Bolt
1 1 1 1 1
6 7 8 9 10
DK DK 39 DK DK
75 76 04 66 37
Pipe inlet oil cooler Pipe outlet oil cooler Hexagon head screw Bolt Special Banjo Gasket oil cooler pipe
1 1 1 2 4
11 12 13
DK 1012 89 DK 1013 40 JC 1610 27
Cover Oil Cooler O Ring oil cooler Guide clutch cable
1 2 1
20
1012 1012 2637 1013 1012
Remarks Alt. 52DK0048 (with cover)
N.I.
Allen bolt
No.
Part No.
Description
Qty/ Veh.
1 2 3 4 5
JC DJ DJ JC DJ
1200 1210 1210 1200 1210
05 51 52 09 53
Carburettor Assly. Vacuum Piston Kit Idling Screw Kit Jet needle(JN) “O” ring
1 1 1 1 1
6 7 8 9 10
DJ 1210 DJ 1210 JC 1200 JC 1200 DH 1211
54 55 11 06 01
Screw Float Assly. Jet Holder Main jet Magnet Assly.
2 1 1 1 1
11 12 13 14 15
DH 1211 39 1780 JC 1200 DJ 1210 DJ 1210
02 01 10 58 59
Reed Switch Assly. Pan Head Screw Needle Jet (NJ)P3 Set Adjuster (PS) Set Plunger Assly.
1 2 1 1 1
16
JC 1200 07
Air jet
1
Remarks
Alt. 39084001
N.I.
21
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 18 : AIR CLEANER COMP
Plate No. 19 : SILENCER ASSLY.
6
7 3
9
2
1
3 4
4
5
8
1
2
Part No.
1 2 3 4 5
JC 1200 04 DK 1210 09 DH 1210 20 39 1765 11 39 0007 01
Air cleaner comp. Assly element filter Bracket lock Plain washer Hexagonal head screw
1 1 1 1 1
6 7 8
JC 1200 02 CB 1210 14 DK 1110 10
Connecting tube Clamp Sensor air filter
1 1 1
22
Description
Qty/ Veh.
No.
Remarks
No. 1
Alt. 39234501
3
Part No.
2 3 4 5
JC JC JC DH DH DJ DK
1010 1010 1010 1016 1016 1010 1014
14 39 83 08 07 64 75
6
DK 9026 27
Description
Qty/ Veh.
Remarks
Silencer Assly. Silencer Assly. (shield can’t replace) Silencer assly. (shield can replace) Silencer front shield Truss screw Gasket exhaust Silencer rear shield
1 1 1 1 2 1 1
without shield
N.I.
Nut for shield muffler
2
N.I.
From 20Aug08 (D10)
23
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 21 : OIL PUMP
Plate No. 20 : SEAT ASSLY / SEAT LOCK & TOOL KIT
4
4
1 2
2 1
6
6
8
7
3 3/5
5
No.
Part No.
1 2 3 4 5
DK DS DH DK DK
2110 2110 1610 2110 2110
01 05 46 04 08
6 7 8
39 1902 04 DJ 2210 06 DH 2110 05
Qty/ Veh.
Description Seat Assly Damper Lock Assly Seat assly Lock assly
comp front seat front comp rear seat rear
Bolt flange Tool Kit with Band Band Tool Kit
Remarks
1 2 1 1 1 2 1 2
Description
Qty/ Veh.
No.
Part No.
1 2 3 4 5
52 DH01 69 39 1674 04 DH 1210 10 39 1686 06 DH 1210 35
Oil Pump Assly Hex. Bolt with flange Mesh filter Oil pump Hollow dowel pin Clip Mesh Oil filter
1 3 1 1 1
6
39 2194 21
‘O’ Ring
1
Remarks Alt. DH121001
N.S.
24
24 19
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
12
11
11 18
16
18
16 8
15
8
15 14
14 17
17 3
9
13
3
9
13 14
14 19
19
7
13
7
13
6
6 4
9
4
9
5
5
10
8
10
2
8 2 20
20
No. 1 2
3 4 5
Part No. 59 DJ DJ DJ DJ 39 39
Description
Qty/ Veh.
1000 1110 1110 1110 1110 1674 0761
02 59 21 94 61 04 01
Spring dowel Stator Assly. comp Stator Assly. comp. Stator Assly. comp. Rotor Assly. Hex. Bolt with Flange Pan Head Screw
1 1 1 1 1 2 2
DH 1011 39 0746 DG 1110 DH 1110 DJ 2011 DJ 2011
99 01 08 13 02 64
Stopper plate (wiring harness) Screw Pan head Spark Plug Grommet Spark Plug AC/DC Regulator (Green) AC/DC Regulator (Brown)
1 1 2 2 1 1
JC 1110 JC 1110 DH 1110 DD 1110 39 1902
03 04 15 12 04
HT coil LH with cap HT coil RH with cap Cap Spark Plug Grommet H.T. Cable Flange Bolt
1 1 2 2 2
Remarks N.I. (Old) From 18Oct08 (D12) From 22Nov07 (D3)
No. 16 17 18 19 20
21 6 7 8 9 10
11 12 13 14 15
26
Part No. DJ 1610 39 1944 DH 1110 DJ 1110 DJ 1110 DJ 1110
67 04 16 23 62 93
JM 1000 45
Description
Qty/ Veh.
Remarks
Bracket H.T. Coil Flange Bolt Grommet Sleeve Spark Plug CDI analog type Magneto Assembly Magneto Assembly
1 2 1 1 1 1
From 18Oct08 (D12)
Bolt flanged (M6x28)
2
N.I.
N.I.
From 14Jun08 (D8)
27
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 23 : STARTER ASSLY
Plate No. 23 : STARTER ASSLY
12
12
11
11 14
14
3
3
13
7
9
13
1
7
2
6
9
1 2
6
10
10
4
4
8
8 15
15
17
17
5
5
18
18
16
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
28
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.
1 1 1 1 1 1 1 1
DK 1011 76 DH 1011 72 DH 1011 88 JC 1011 15 59 2000 07 DH 1013 82
Shaft starter counter Collar starter counter Gear comp. starter counter assly. Assly. Gear Starter Counter Needle roller bearing Bolt socket
1 1 1 1 1 3
JC DS DH DH DH DK
Motor assly. starter Bolt Cover starter motor Slotted c’sunk screw Spring Starter Clutch Spring Starter Clutch
1 2 1 1 5 5
1110 07 1013 53 1011 84 1013 89 1011 64 1015 96
16
Remarks include 2,15,16,17,18 From 15May09 (D19)
No.
Part No.
16 17 18
DJ 1011 09 DH 1011 63 DH 1015 33
Description Bush for spring starter Roller Bush for spring starter clutch
Qty/ Veh.
5 5 5
Remarks For unit before 15May09 (D19) For unit before 15May09 (D19)
From 15May09 (D19) From Aug.09 For stopper plate
From Aug.09 Alt. 39097204 Ref. page no.61
From 15May09 (D19)
29
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 24 : ENGINE MOUNTINGS
Plate No. 25 : FRAME & FRAME FITTINGS
17
16
3 4
10
6
5
14 7 8 1
9&10
4 15
3
2 12
1
13 2 2
6 7
7 8
9
5 11
No.
Part No.
Description
Qty/ Veh.
1 2 3 4 5
DK 1610 DH 1611 DH 1611 36 DK00 DK 1611
96 89 90 11 59
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
1 1 1 1 1
6 7 8 9 10
DK 1611 60 39 2157 04 39 2412 04 DH 1612 73 39 1664 04
Bkt. comp. RH eng. mtg. lower Bolt Flanged Bolt Flanged Bush in frame Bolt - Hexagon M8x1.25
1 3 1 1 1
11 12 13 14 15 16 17
59 0400 DK 1611 39 2310 39 2311 39 2457 DK 1611 DK 1611
Bolt Hex Socket Head Bkt. comp. RH eng. rear Flanged bolt Bolt Washer Bkt. Engine hanger LH Bkt. Engine hanger RH
1 1 2 1 1 1 1
30
43 61 04 04 11 27 28
Remarks
No. 1 2 3
Qty/ Veh.
5
22 12 48 75 42 76 07
Frame Assly. comp. Cup rear Nut Nut Cup - Steering Cup - Steering Bearing Cone Kit with 4th Race
1 2 1 1 1 1 1
6 7 8 9 10
DK DK 39 DJ DJ
50 51 04 32 33
Cage Bearing Upper (19 ball) Cage Bearing Lower (20 ball) Flanged bolt Cable Hook LH Cable Hook RH
1 1 2 1 1
4
3
Description
JC 1610 DH 1611 DG 1810 DK 1810 DG 1810 DK 1810 36 DV00
Ref. page no. 60
Alt. 39 2311 04
Part No.
1810 1810 1680 1611 1611
Remarks Incl. Bush, Races & Cup rear
From Jul.09 From Jul.09 Ref. page no. 60 From 24Nov08 (D13) From 24Nov08 (D13)
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
7
9
3
5
6
7
6
2
7
1
10
4 2
12 11
Part No.
Description
13
Qty/ Veh.
1 2 3 4 5
JC 1710 DG 1710 36 DK00 JC 1710 DG 1710
03 38 12 02 18
Rear Shock Absorber Bolt Pre-coated Kit bush rear shock Swing arm assly. Needle bearing
2 2 1 1 4
6 7 8 9 10
DK DG DH DK DG
06 19 19 03 34
Collar swing arm Oil seal ‘U’ nut swing arm Shaft swing arm Chain slider
2 4 1 1 1
11 12 13 14 15
DG 1710 21 DG 1710 20 DG 1710 22 39 1997 15 35 1710 33 39 0740 11
Adjuster chain Cap Chain Adjuster Hexagon nut 14 Hexagon nut 12 Grease nipple Plain washer(Nylon)
2 2 2 2 2 2
16 17 18
39 1224 11 JC 1610 23 DJ 1710 34
Plain washer Instuction Lable Nitrox chamber screw assly
2 1 2
32
1710 1710 1710 1710 1710
3
13
16 12
No.
1
16
11
6
Remarks
No.
Ref. page no. 60
Part No.
1 2 3 4 5
DJ DJ DH DH DX
1611 26 1611 27 1610 53 1611 94 1610 67
6 7
22 1504 51 36 Dk00 13
Description
Qty/ Veh.
Main step LH assly. comp. Main step RH assly. comp. Rubber main step Kick stopper Plate lock pillion step
1 1 2 1 2
Bolt Kit hardware main step
2 2
Remarks
N.I. N.I. N.I.
Tyre Pressure decal (N.I.)
3
33
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 28 : PILLION FOOT REST / HOLDER
Plate No. 29 : MUDGUARD FRONT & REAR 4
5 14
6
3 2 1
1 12 7 7
8
6
8
10
2
6 15 4
5
5
16 5
No.
Part No.
1 2 3 4 5
DK 1611 JC 1610 DJ 1611 DJ 1611 36 DK00
6 7 8
39 1069 01 39 0292 15 39 1741 04
34
37 02 28 29 13
16
3
Description
16
Qty/ Veh.
Holder LH step Holder RH step Pillion step assly. comp. LH Pillion step assly. comp. RH Kit hardware pillion
1 1 1 1 2
Hexagonal head screw Nut Flanged Bolt
2 1 2
Remarks
No.
Ref. page no. 60
Alt. 39258204
3
Part No.
Description
Qty/ Veh.
1 2 3 4 5
DK 59 DK 39 39
1610 0400 1610 0711 1680
98 40 86 11 04
Brace fender Step bolt Fender rear front Plain washer Flange bolt
1 4 1 4 2
6 7 8 9 10
DK 1610 DK 1611 39 0242 39 0326 39 2420
85 98 11 15 01
Fender rear Mud flap front Washer plain Nut nylon M5x0.8 Screw pan head M5
1 1 6 3 3
11 12 13 14 15
52 DK00 DK 1610 DS 1611 DG 1810 DJ 1610 DK 1611
25 41 25 36 69 99
Rear fender complete Guide cable (steel) Guide cable (rubber) Bolt (for guide cable steel) Nail guide cable (rubber) Cover chain
1 1 1 1 1 1
16
DH 1612 83
Bolt
3
Remarks
Mud flap hardware Mud flap hardware Mud flap hardware
N.S. From 20Aug08 (D10) N.I. From 20Aug08 (D10)
35
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 30 : STAND ASSEMBLY
Plate No. 31 : TYRE / TUBE / RIM
2
3
2
12
5
11
4 EU
R
1
OGRIP
9 5
10 1 7 4
6 3
OGRIP
1 2 3 4 5
DK 1611 22 30 1611 57 39 0787 08 DH 1611 21 DH 1611 45
Stand main Shaft stand Pin cotter Spring main stand Cover spring main stand
1 1 1 1 1
6 7 8 9 10
JC 1610 17 DH 1610 66 DH 1611 46 DF 1611 02 39 0422 15
Stand side Spring side stand Cover spring side stand Bolt Nut
1 1 1 1 1
11 12 13 14
DH DH DJ DJ
Side stand switch Magnet Assly. Main Stand Pad Bottom Side Stand Pad Bottom
1 1 1 1
36
64 65 69 70
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.
R
Part No.
2010 2010 1612 1612
Description
Qty/ Veh.
No.
EU
8
Remarks
1 1 1 1 2
N.I. N.I.
3
37
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 32 : FRONT HUB
Plate No. 33 : FRONT MASTER CYLINDER 4 2 8
3
3
2 6
5
11
9
10
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 1 15
5
7 4
5 14
1
7
7
2
8 9
12
12
6
11
5
13 5 4 Qty/ Veh.
Part No.
Description
1 2 3 4 5
39 0787 08 39 2362 20 DK 1510 28 DG 1510 05 DE 1510 12
Pin cotter Bearing ball Spacer assly. Seal oil Plate drive
1 2 1 1 1
1 2 3 4 5
DE DJ DJ DE DE
1910 1510 1910 1910 1910
43 76 57 11 10
Major Kit - Master Cylinder Assly Hose Brake Front Lever Grip RH Banjo Bolt Washer Copper
1 1 1 2 4
6 7 8 9 10
DE DK DH DG DG
08 27 19 08 49
Seal oil Disc Hex. slotted nut Plain washer Hex. soc. hd. bolt
1 1 1 1 6
6 7 8 9 10
DE DJ DJ DJ DJ
1910 1910 1910 1910 1910
33 28 29 30 31
Clamp Holder RH Bolt Bolt Front Brake Lever Nut Flanged Screw
1 1 1 1 2
11
JC 1510 20
Case meter assly
1
12 13
JC 2010 50 DG 1510 07 DK 1510 08
Hardware kit speed sensor Collar Axle
1 1 1
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
Cylinder Master Front brake switch Reservoir Cover Diaphragm Oil Window Kit Clamp LH Clamp RH Clamp Rubber
1 1 1 1 1 1 1 1
38
1510 1510 1710 1510 1510
Remarks
From 15Jun09 (D21) Alt. JC151019 From 15Jun09 (D21)
No.
Part No.
Description
Qty/ Veh.
No.
Remarks KBX KBX
KBX
N.I. N.I. N.I.
39 3
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 34 : FRONT DISC BRAKE
Plate No. 35 : REAR HUB 20 24 29
4
21
9 5
17
18 19
24 26
PISTON SEAL
23
8
11
DUST SEAL
27 28
BLEEDER CAP
5 8
7 x
25
22
3
4
PROTECTION BOOT
16
INSULATOR
7 2 6
12
3
CALIPER PISTON
2
9
1
30 4
1
10
BLEEDER SCREW
13
3 6
PAD SPRING
10
12
5
14 7
8
5
Part No.
1 2 3 4 5
DG 1510 89 39 1769 04 DJ 1510 68 DJ 1510 69 DJ 1510 70
Caliper Assly. Front Bolt Flanged Spring Pad Bleeder Screw Bleeder Cap
1 2 1 1 1
6 7 8 9 10
DJ DJ DJ DJ DJ
Disc Pad Set Insulator Protection Boot Minor Kit - Caliper Major Kit - Caliper
1 1 1 1 1
11 12
DJ 1511 05 DJ 1511 06
Pad Spring Front Sp. Bolt Disc Pad Front
1 1
40
1510 1510 1510 1510 1510
71 72 73 74 75
Description
Qty/ Veh.
No.
Remarks
fitted on front fork
No. 1 2 3 4 5
Part No. 39 DK DJ 39 30 JC
2242 1510 1510 2241 1510 1910
6 7 8 9 10
30 JC JC DK JC
11 12 13 14 15
JC 39 39 JC 30
20 22 88 20 69 10
Description
11
Qty/ Veh.
Bearing ball Collar bearing Damper Bearing ball Spring Spring
1 1 1 1 2 2
1511 05 1510 05 1510 02 1510 09 1510 11
Shoe brake assly. Cam brake Panel rear brake Axle rear Spacer panel side
1 1 1 1 1
1510 0775 0798 1510 1510
Lever brake Hexagon head bolt Nut Indicator "O" ring
1 1 1 1 1
07 04 15 06 38
15
Remarks Alt. 39268720
From Oct 08
41 3
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 35 : REAR HUB
Plate No. 36 : REAR BRAKE PADAL
20 24 29
17
21
25
22
5
18 19
24 26
1
6
23
8
27
3 28
4 4 16 2
7
10
3
2
9
1
30
10
2 13 6
12
9
5
14 8
7
15
5
Qty/ Veh.
Remarks
15
Part No.
16 17 18 19 20
DH 1710 19 39 1997 15 39 1224 11 DK 1510 14 DS 1510 74
‘U’ nut Nut Plain washer Spacer for coupling Lock washer
1 2 2 1 2
1 2 3 4 5
JC 1910 36 DK00 DK 1011 JC 1910 39 2383
01 18 85 09 15
Lever Brake Pedal Kit hardware torque rod Washer pivot bolt Bolt Brake Pedal Flange nut
1 2 1 1 1
21 22 23 24 25
DK DK DK DS DK
1510 1510 1510 1510 1510
12 13 05 73 15
Seal oil Bearing ball Coupling Stud Sleeve
1 1 1 4 1
6 7 8 9 10
JC 1910 JC 1910 36 JC00 JC 1510 DH 1510
10 02 03 08 29
Spring brake pedal Rod brake Kit hardware rod brake Rod Torque Step Bolt Rod Torque
1 1 1 1 1
26 27 28 29 30
39 0794 DK 1510 36 JC00 JC 1510 DK 1510
15 36 02 14 10
Hex. lock nut Drive Chain Lock Chain Sprocket kit Sprocket 35T Chain 104 Link
4 1 1 1 1
11 12 13 14 15
39 39 39 39 30
11 15 12 08 95
Plain Washer Nut Hexagon Lock M8x1.25 Washer Spring Pin Snap Hexagon Bolt
1 2 2 2 1
Ref. page no. 60
No.
Part No.
1540 0694 0789 0807 1510
Description
Qty/ Veh.
No.
42
Description
11
Remarks
Ref. page no. 61
Ref. page no. 61
N.I. N.I. N.I. N.I.
43 3
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 37 : HANDLE BAR
Plate No. 37 : HANDLE BAR
20
3
20
3 18
18 2
19
2
19
5
5 16
16 22
I I G N I T
I
F L OF ON H
F L OF ON
E -R
N
O
I G N I T
PUS
E -R
1
E OK CH
SS PA
CK LO
CH
CK LO
PUS
SS PA
N
22
O
1
E OK
H
RN TU RN TU
21
4
14
9
15 17
13
7
11
11 23
12
15
23
12
17
17 10
10
6
Part No.
1 2 3 4 5
JC 1810 05 DH 1810 53 39 1714 04 DH 2010 48 DH 2010 49
Handle Bar Holder Handle Flanged bolt Control switch LH Control switch RH
1 1 4 1 1
6 7 8 9 10
DJ DJ DJ DD 39
Lever assly. grip LH Holder left hand Lever grip left Bolt Self locking nut
1 1 1 1 1
11 12 13 14 15
36 DK00 DH 1910 DH 1910 DH 1910 DJ 1810
Kit hardware holder LH Grip LH Grip Assly. RH Bolt for lever Handle bar weight
1 1 1 1 2
1910 09 1910 54 1910 55 1910 85 1184 15
Description
Qty/ Veh.
No.
Remarks
No.
19 07 16 19 11
Ref. page no. 61
Part No.
6
Description
Qty/ Veh.
16 17 18 19 20 21
30 39 DJ DJ DJ DS DJ
1910 2427 1810 2210 2210 1810 1811
48 04 39 03 04 22 10
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
2 2 1 1 1 1 1
22 23
39 DK DK DJ JC
1943 2010 2010 1910 1910
04 64 83 15 15
Flange bolt Clutch Switch with Diode Clutch Switch (6 amo Diode) Lever & Support Holder Assly LH. Lever & Support Holder Assly LH.
2 1 1 1 1
24
44
15 17
8
13
7
14
9
8
15
21
4
Remarks
Cable More Length (Old) From Aug.08 From Aug.09 (N.I.)
Ref. page no. 61
45 3
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 38 : FRONT FORK
Plate No. 38 : FRONT FORK
15
14
16
10
15
14 20
16
10
17 18
17 18 21
19
2 5
5 3 22
4
22
23
4
24 13
25 26
6/7
11
11 24
12 30
1 2 3 4 5
JC DG DG DG DG
1810 1810 1810 1810 1810
01 21 23 13 22
6 7 8 9 10
JC JC 30 31 DS
1810 11 1810 12 1810 26 1811 06 1810 77
11 12 13 14 15 16
Description
23
8
27
12
28
9
Part No.
24
23
8
46
13
26
16
23 24
25
6/7
No.
21
19
2
3
1
20
29
30
1
Qty/ Veh.
Remarks Without 20,21,22,23,24,25,26
Description
27
28
9 29
Qty/ Veh.
No.
Part No.
16 17 18 19 20
31 1811 02 31 1811 01 DS 1810 85 DG 1810 03 59 0400 05
‘O’ ring Seat fork spring Spacer Tube Washer Bolt with Washer M16*28L
2 2 2 2 1
Holder fork upper Socket Bolt Cushion Rubber Cover Trail B Lamp Shade Assly.
1 2 2 4 1
Remarks
Fork front assy. Dust seal Oil seal Guide bush Ring snap
1 1 2 2 1
Outer Tube LH Outer Tube RH Gasket Bolt Cylinder comp. fork
1 1 2 2 2
21 22 23 24 25
JC 1810 DG 1810 JC 1810 JC 1810 52 JC00
JC 1810 21 DG 1810 11 JC 1810 17 DH 1810 09 DH 1810 15
Pipe comp. suspension inner Slide Bush Spring front fork Grommet Top Bolt fork
2 2 2 2 2
26 27 28 29 30
DG 1810 05 JC 1810 03 39 0789 12 39 1714 04 DK 1810 08
Bearing cone Holder fork under Spring washer Bolt Flaye Bolt
1 1 2 2 1
Pinels Bolt Outer Tube
DK 1810 08
Flange bolt
1
31
DG 1810 48
Nut Steering
1
N.I.
3
02 08 07 06 19
47
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 39 : PAINTED PARTS & DECALS
Plate No. 39 : PAINTED PARTS & DECALS
15 15 7
9
17
16
17
16
7
9
18
18 5
5 1 1
8
8
3
3
16 16 13
13
14
14
6 6
2 2
No.
Part No.
10/11
1
JC JC JC JC
7102 7102 7102 7102
2T 2V 3A X3
Fuel Fuel Fuel Fuel
Tank Tank Tank Tank
2
DK DK DK DK
7301 7301 7301 7301
2T 2V 3A X3
Side Side Side Side
cover cover cover cover
DK DK DK DK
7302 7302 7302 7302
2T 2V 3A X3
Side Side Side Side
DK DK DK DK
7303 7303 7303 7303
2T 2V 3A X3
Sear Sear Sear Sear
3
4
48
10/11
12
12
Qty/ Veh.
Description
4
4
Remarks
No.
1 1 1 1
FOR FOR FOR FOR
TITANIUM SILVER COCKTAIL WINE RED LONG BEACH BLUE EBONY BLACK
LH LH LH LH
1 1 1 1
FOR FOR FOR FOR
TITANIUM SILVER COCKTAIL WINE RED LONG BEACH BLUE EBONY BLACK
cover cover cover cover
RH RH RH RH
1 1 1 1
FOR FOR FOR FOR
TITANIUM SILVER COCKTAIL WINE RED LONG BEACH BLUE EBONY BLACK
Cowl Cowl Cowl Cowl
Assly. Assly. Assly. Assly.
1 1 1 1
FOR FOR FOR FOR
TITANIUM SILVER COCKTAIL WINE RED LONG BEACH BLUE EBONY BLACK
3
Part No. 7402 7402 7402 7402
2T 2V 3A X3
Description Front Front Front Front
Fender Fender Fender Fender
Qty/ Veh.
5
DK DK DK DK
6
DH 1410 20
Seat tape
1
7
DJ DJ DJ DJ
7401 7401 7401 7401
2T 2V 3A X3
Fairing Fairing Fairing Fairing
1 1 1 1
FOR TITANIUM SILVER FOR COCKTAIL WINE RED FOR LONG BEACH BLUE FOR EBONY BLACK
8
JC JC JC JC
7201 7201 7201 7201
2T 2V 3A X3
Tank Tank Tank Tank
1 1 1 1
FOR TITANIUM SILVER FOR COCKTAIL WINE RED FOR LONG BEACH BLUE FOR EBONY BLACK
flap flap flap flap
LH LH LH LH
1 1 1 1
Remarks FOR TITANIUM SILVER FOR COCKTAIL WINE RED FOR LONG BEACH BLUE FOR EBONY BLACK
49
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 39 : PAINTED PARTS & DECALS
Plate No. 40 : CAP TANK & GAUGE FUEL
15
3
17
16 7
1
9
5
18 2
5 1 8
3 4
6
16 13
14 15 8 7
6
4
14
10
13 9
2
No. 9
Part No.
10/11
Description
12
Qty/ Veh.
10
JC 7202 JC 7202 JC 7202 JC 7202 DK 1611
2T 2V 3A X3 23
Tank flap RH Tank flap RH Tank flap RH Tank flap RH Cover Side Mesh LH
1 1 1 1 1
11 12 13 14 15
DK 1611 59 0200 JC 1410 JC 1410 DK 1410
24 01 15 17 26
Cover Side Mesh RH Self tap screw Grommet tank flap Grommet tank flap “B” monogram on tank
1 6 2 4 2
16 17
DK JC JC JC JC
27 19 20 18 19
“Pulsar” Logo on tank Seat cowl decal LH Seat cowl decal RH Oil cooler decal LH Oil cooler decal RH
2 1 1 1 1
18
50
1410 1610 1610 1410 1410
12 11
Remarks FOR TITANIUM SILVER FOR COCKTAIL WINE RED FOR LONG BEACH BLUE FOR EBONY BLACK
fitted on fueltank fitted on tankflap
3
Description
Qty/ Veh.
No.
Part No.
1 2 3 4 5
DH 1410 50 39 0840 01 39 2381 04 JC 1410 20 DH 1410 48
Cap Assly. Tank Pan head screw Hex. Soc Hd. cap screw Tap Assly Rotor with key
1 1 7 1 1
6 7 8 9 10
30 1410 39 DD 1410 22 39 0740 11 DK 2010 65 39 2758 21
Packing Bolt flanged Plain Washer Gauge Fuel ‘O’Ring New Tank Fuel Guage
1 2 2 1 1
11 12 13 14 15
30 1410 32 DJ 1410 06 BA 1220 03 DH 1410 24 DG 1410 28
Bolt Tube fuel Pipe clip Drain tube Clamp
4 1 1 1 1
16 17 18
30 1410 38 30 1410 36 JC 1410 34
‘O’ Ring Packing Spring Drain tube
1 1 1
Remarks
Alt. 39 1780 01 Alt. DK141001
From 24Dec07 (D6)
N.I. N.I. From 31Mar09 (D17)
51
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 41 : FITTINGS P. TANK, SIDE COVER & COVER SEAT
Plate No. 42 : METER ASSEMBLY 2
9
3
7
4
4
8
8
10
12 F
6 E
4
SIDE
STAND
1
6
15 2
5
8
5
km/h
x 1 0 0 rpm
2
1
14 3
1 12
3a
13 10
7
4
Qty/ Veh.
Remarks
No.
Grommet Kit For side cover Tape tank inner Screw Washer Nylon Lock for side cover Damper Rear
1 2 2 2 1 1
Refer Page No. 61
1 2 3 4 5
JC 39 DJ DJ DJ
1910 1778 1811 2011 2011
DJ 1410 08 39 1556 04 39 2424 11 DK 1410 15 DH 1613 11
Damper front Flanged Bolt Plain Washer Tank pad Rubber seat cowl LH
2 1 1 1 1
6 7 8 9 10
DJ DJ DK JC JC
2011 82 1910 61 1910 11 1610 27 2010 48
11 12 13 14 15
DH 1613 12 DK 1410 17 DK 1611 47 DK 1611 48 39 2310 04
Rubber seat cowl RH Damper tank middle Grab handle LH Grab handle RH Bolt Flange
1 1 1 1 4
N.I.
16 17
DJ 1610 79 DJ 1610 80
Foam LH For grab Foam RH For grab
1 1
N.I. N.I.
No.
Part No.
1 2 3 3a 4 5
DK 1611 85 DH 1410 31 DG 1611 21 39 1789 24 DK 1810 34 DH 1410 23
6 7 8 9 10
52
Description
N.I.
3
Part No. 16 02 19 59 63
Description
Qty/ Veh.
Speedo meter with Breather Self Tapping Screw Cluster cover Speedo meter top cover Button push for tripmeter
1 4 1 1 1
Speedometer Gasket Control cable throttle Cable Clutch Guide Clutch Cable Speed sensor eith cable
1 1 1 1 1
Remarks From 15Jun09 (D21)
From 20Sep07 (D1)
From Aug.08 (Drawing require)
From Aug.09 (N.I.)
53
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 45 : HEAD LAMP & FAIRING
Plate No. 46 : INDICATOR LIGHT ASSEMBLY
3 5
4
1/2
6 8 7
9 1
2
13 11 14
10 12
3/4 5
6
16 17 16 15
8 7
No.
Part No.
1 2 3 4 5
JC DJ DJ DF 39
6 7 8 9 10
08 20 33 98 24
Qty/ Veh.
Remarks
No.
Part No.
Head Lamp assly. Mask Wind Shield Bolt Non Metallic Washer
1 1 1 4 4
1 2 3 4 5
DJ DJ DJ DJ GH
DL 1810 10 DJ 1810 37 39 1907 01 DJ 1810 69 DH 1810 52
Well Nut Decal Wind Shield M5 x 15L mushroom HD Packing Fairing Fairing mounting upper bracket
4 1 2 1 1
6 7 8
39 1970 15 DJ 2011 81 DJ 2011 80
11 12 13 14 15
36 DK00 DJ 1810 39 0716 39 1524 JC 2010
Kit hardware mtg. bracket Clip Nut Screw pan cross Screw pan cross Lamp 12V 35/35W-HS1
1 4 2 2 1
16 17
DK 2010 44 DJ 2011 41 DJ 2011 65
5 Watt bulb white output BCU (Black) BCU (Brown)
2 1 1
54
2010 1811 1810 1810 2141
Description
21 65 01 01 09
2011 48 2011 49 2011 46 2011 47 2010 12
Description
Qty/ Veh.
Blinker Front LH Flexible Blinker Front RH Flexible Blinker RR LH Flexible Blinker RR RH Flexible Lamp 12V / 10W
1 1 1 1 4
Hex Nut Flange
4 1 1
Magnet assly blinker self cancellation
Assy hall sensor
Remarks
N.I. From 20Aug08 (D10) From 20Aug08 (D10)
Ref. page no. 61
From 14Jun08 (D8)
3
55
Brand ID: 001MC625
Brand ID: 001MC625
Plate No. 48 : ELECTRICAL EQUIPMENTS
Plate No. 47 : TAIL LAMP ASSLY / FR & RR NO. PLATE
4
3 2
8
5
7
16
1/2 6 1
12
4
3
16 11 7
13
11
14
13 8 12
14
9
10
5
10
6
1 2 4 4 2
1 2 3 4 5
DH 2010 11 DH 2010 14 39 1507 11 39 1956 04 DJ 2011 26
Horn with LH stay Horn with RH stay Plain Washer Flange Bolt Battery (12V-9A) Dry
1 1 1 1 1
Bolt flange No. Plate illumination Rear No. plate bkt. Number plate Rear Hex Flanged Bolt
2 1 1 1 2
6 7
DJ JC JC JC 39 DK DK
1612 2010 2010 2010 1680 2010 2010
47 13 29 05 04 16 78
Band Battery Wiring Harness For below seat Wiring Harness (St.RelaySol.Type) Rear Brake Switch Flange bolt Starter Relay Starter Relay
1 1 1 1 1 1 1
39 1783 01 DP 1611 44 DH 1612 92 39 1773 04 DH 1612 93
Truss Screw Number plate front No. plate mounting bracket Bolt flange Grommet for Number plate mtg.
2 1 1 2 2
30 30 DJ DJ JC
2011 2010 2011 2010 2010
04 85 40 20 06
Fuse box Assly. Fuse Cable assly. (Battery to Earth) Cable assly. (Battery to St. Relay) Magnet Rear Brake Switch
1 1 1 1 1
DK 1611 64
Rear blinker mtg. plate
1
1 2 3 4 5
DK 2010 03 DH 1612 93 DK 1611 53 59 0100 13 39 0705 01
Tail light with Lamp Damper Clip Nut Screw pan cross Truss Screw
6 7 8 9 10
39 1972 DK 2010 DJ 1610 DP 1611 39 1680
11 12 13 14 15 16
15 24 72 45 04
Description
Remarks
8 9 10
Description
Qty/ Veh.
Part No.
Part No.
56
Qty/ Veh.
No.
No.
Remarks
Old From Aug.08
For Front No. Plate 11 12 13 14 15
N.I.
3
N.I.
57
Brand ID: 001MC625
Brand ID: 001MC625
KIT LIST Sr. Kit Part No. No.
KIT LIST Kit Description
Consisting of Following Parts Part No.
Description
Qty./Kit
1
36DS1001 Cyl.Head O Ring Kit
39239121 39128321
O Ring (Cover tappet) O ring
2 2
2
DK101326 Valve Repair Kit
DK101247 DK101108 DK101110 DK101246
Retainer valve spring Spring valve inner Spring valve outer Seat valve spring
2 2 2 2
3
JC101038 Guide Chain Kit
DH101017 DK101059
Guide chain (Tight) Guide Chain (slack)
1 1
4
36DK0007 Kit centrifugal oil filter
39220011 DH101234 39226701 DH101066 DH101067 39219908
Washer Gasket centrifugal oil filter Oval screw Join oil delivery Spring oil delivery Pin oil delivery joint
1 1 1 1 1 1
DH101282 DH101292 DH101294
Damper Cover Magneto Damper A Cover LH RR Damper B Cover LH RR
1 1 1
5
36DH1006 Set Damper (cover magneto)
6
36DH1007 Set of Plate (cover magneto)
DH101283 DH101293
Plate Damper Plate Damper Cover LH RR
1 1
7
36DH0018 Kit hardware torque rod
39154011 39069415 39078912 39080708 39231204 39197015 39241304 DH161245
Plain washer Hex lock nut Washer spring Pin snap Bolt flange Nut flange Bolt flange U Nut
1 1 1 1 4 8 1 3
DG181045 DG181046 DG181047
Bearing cone Bearing race Upper bearing race
1 1 1
10 36DK0012 Kit bush rear shock absorber
39071411 39071215 39073712
Plain washer Dome cap nut Spring washer
8 2 2
11 36DK0013 Kit hardware pillion
DJ161186 DH161061 30141031 39104011 39078408
Plait side pillion stape Pin pillion set "O" ring Plain washer Split pin
2 2 2 2 2
12
DV101048 JC151014 DK151010
Sprocket drive Sprocket hub Chain
1 1 1
8
36DK0011 Kit hardware engine mounting
9
36DV0007 Bearing cone kit
60
36JC0002 Chain sprocket kit
3
Sr. No. Kit Part No.
Kit Description
Consisting of Following Parts Part No.
Description
Qty./Kit
13 36JC0003 Kit hardware rod Brake
30191038 39021911 39080808 30191035 15191026 JC191007
Pin Plain washer Split pin Spring Pin Brake adjustment nut
1 1 1 1 1 1
14 36DK0019 Kit hardware holder LH
30191024 30191017 39021911 39072504
Screw Nut Plain washer Bolt hex
1 1 1 1
15 DK161185 Grommet kit for side cover
DH161158 DH161133
Grommet side cover front Grommet side cover rear
2 2
16 36DK0021 Kit hardware mtg. bkt.
DJ181029 DJ181064 39021111 39155304
Collar Grommet Plain washer Bolt flange
1 1 1 1
17 36DK0029 Kit primary drive and driven
DK101241 DK101561 DK101242 DK101243 DK101128
Housing comp clutch Housing comp clutch. 31Jan09(D16) Gear comp prim driven Gear prim driven Bush prim driven. 31Jan09(D16)
1 1 1 1 1
18 JC111007 Motor assly starter
DK 1110 16 DK 1110 21 JC 1110 10 DK 1110 17 DK 1110 19 DK 1110 20
Armature Assembly Tie bolt Yoke Assembly Bush Assly Kit “O” Ring for spigot Oil seal for yoke
1 1 1 1 1 1
19 DH191016 Grip assly RH
DH191017
Pipe throttle
1
DH191008
Grip hand RH
1
61
