Pulsar 180 ug3

Brand ID: 001MC607
Foreword
180
We have pleasure in presenting the Spare Parts Catalogue for ‘Pulsar 180 cc UG III’
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
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 Office
or write to us on the following address :
manufactured previously. Contact your authorized Bajaj
Dealer for the latest information on product improvements
incorporated after this manual was issued.
Bajaj Auto Limited
Service Department
Akurdi, Pune 411 035 India
DOC. NO.: 71110426
REV.00 NOV . 07
Phone : 020-27406557
Fax : 020-27407385
E-mail : service@bajajauto.co.in
Brand ID: 001MC607
Brand ID: 001MC607
Instructions for using the Catalogue
180
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.
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
INDEX
Description
No.
1
2
3
4
5
6
7
8
9
10
180
Cover Cylinder Head
Cylinder Head
Valve
Camshaft / Tensioner
Cylinder & Piston
Crankshaft
Balancer & Balancer Idler Gear
Transmission
Change Drum/ Shift Fork
Gear Change Mechanism
Page
No.
1
2
3
4
5
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
Kick Starter Mechanism
Carburettor
Air Cleaner Comp.
Silencer Assly
Seat Assly. / Seat Lock
20&21
22
23
24
25
21
22
23
24
25
Oil Pump
Magneto/C.D.I./H.T.Coil
Starter Assly
Engine Mountings
Frame & Frame fitting
26
27&28
29
30
31
26
27
28
29
30
Swing Arm / Rear Shock Absorber
Rider Foot rest
Pillion Foot rest / Holder
Mudguard Front & Rear
Stand Assembly
32&33
34
35
36
37
31
32
33
34
Tyre/
Front
Front
Front
No.
Description
35
Rear Hub
42&43
36
37
38
39
40
Rear Brake Pedal
Handle Bar
Front Fork
Painted Parts & Decals
Petrol Cock, Cap Tank &
Gauge Fuel
44
45&46
47&48
49&50
41
42
43
44
45
46
47
48
49
50
Fitting - Petrol Tank,
Side Cover & Cover seat
Meter Assly.
Control Cables
Chain Case
Head Lamp & Fairing
Indicator Light Assly.
Tail Lamp Assly/Front &
Rear No.Plate
Electrical Equipments
Tool Kit
Accessories / Grab Handle
Kits List
Amendment Sheet (Parts Added)
Tube /Rim
Hub
Master Cylinder
Disc Brake
38
39
40
41
Page
No.
Part Index
51
52
53
54
55
56
57
58
59
60
61
62-64
65
66
Brand ID: 001MC607
PICTORIAL INDEX
PLATE NO. : 1
COVER CYLINDER HEAD
PLATE NO. : 3
VALVE
PLATE NO. : 5
CYLINDER AND PISTON
150
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
CARNKSHAFT
6
Brand ID: 001MC607
Brand ID: 001MC607
PICTORIAL INDEX
PLATE NO. : 7
BALANCER AND BALANCER
IDLER GEAR
PLATE NO. : 9
CHANGE DRUM / SHIFT FORK
PLATE NO. : 11
ENGINE ASSLY. & CRANKCASE RH
150
PAGE NO.:
PLATE NO. : 8
PAGE NO.:
7
TRANSMISSION
8 & 9
PAGE NO.:
PLATE NO. : 10
PAGE NO.:
10
GEAR CHANGE MECHANISM
11
PICTORIAL INDEX
PLATE NO. : 13
COVER RH
PLATE NO. : 15
CLUTCH
150
PAGE NO.:
15 & 16
PAGE NO.:
18 & 19
PAGE NO.:
PLATE NO. : 12
PAGE NO.:
PLATE NO. : 17
PAGE NO.:
12
CRANKCASE LH
13 & 14
CARBURETTOR
22
PLATE NO. : 14
COVER MAGNETO
PLATE NO. : 16
KICK STARTER MECHANISM
PLATE NO. : 18
AIR CLEANER COMP.
PAGE NO.:
17
PAGE NO.:
20 & 21
PAGE NO.:
23
Brand ID: 001MC607
Brand ID: 001MC607
PICTORIAL INDEX
PLATE NO. : 19
SILENCER ASSLY.
PLATE NO. : 21
OIL PUMP
PLATE NO. : 23
STARTER ASSLY. (FOR SELF START)
150
PAGE NO.:
24
PAGE NO.:
26
PAGE NO.:
29
PLATE NO. : 20
SEAT ASSLY. / SEAT LOCK
PLATE NO. : 22
MAGNETO / C.D.I./H.T. COIL
PLATE NO. : 24
ENGINE MOUNTINGS
PAGE NO.:
25
PAGE NO.:
27 & 28
PAGE NO.:
30
PICTORIAL INDEX
PLATE NO. : 25
FRAME & FRAME FITTINGS
PLATE NO. : 27
RIDDER FOOT REST
PLATE NO. : 29
MUDGUARD FRONT & REAR
150
PAGE NO.:
31
PAGE NO.:
33
PLATE NO. : 26
SWING ARM / REAR SHOCK ABSORBER
PLATE NO. : 28
PILLION FOOT REST / HOLDER
PAGE NO.:
32
PAGE NO.:
34
PAGE NO.:
PLATE NO. : 30
PAGE NO.:
35
STAND ASSLY.
36
Brand ID: 001MC607
Brand ID: 001MC607
PICTORIAL INDEX
PLATE NO. : 31
TYRE / TUBE / RIM
150
PAGE NO.:
38
PLATE NO. : 32
FRONT HUB (FOR DISC BRAKE)
PAGE NO.:
39
PLATE NO. : 33
FRONT MASTER CYLINDER
(FOR DISC BRAKE)
PAGE NO.:
PLATE NO. : 34
PAGE NO.:
40
FRONT BRAKE
41
PLATE NO. : 35
PAGE NO.:
PLATE NO. : 36
PAGE NO.:
REAER HUB
42 & 43
REAR BRAKE PEDAL
44
PICTORIAL INDEX
PLATE NO. : 37
HANDLE BAR
PLATE NO. : 39
PAINTED PARTS & DECALS
PLATE NO. : 41
PETROL TANK, SIDE COVER AND
COVER SEAT
150
PAGE NO.:
45 & 46
PAGE NO.:
49 & 50
PAGE NO.:
52
PLATE NO. : 38
FORK ASSEMBLY
PAGE NO.:
47 & 48
PLATE NO. : 40
PETROL COCK, CAP TANK AND
GAUGE FUEL
PAGE NO.:
PLATE NO. : 42
PAGE NO.:
METER ASSEMBLY
51
53
Brand ID: 001MC607
Brand ID: 001MC607
PICTORIAL INDEX
PLATE NO. : 43
CONTROL CABLES
PLATE NO. : 45
HEAD LAMP & FAIRING
PLATE NO. : 47
TAIL LAMP ASSEMBLY / FRONT
NUMBER PLATE
150
PAGE NO.:
54
PAGE NO.:
56
PAGE NO.:
58
PLATE NO. : 44
CHAIN CASE
PLATE NO. : 46
INDICATOR LIGHTS ASSLY.
PLATE NO. : 48
ELECTRICAL EQUIPMENTS
PAGE NO.:
55
PAGE NO.:
57
PAGE NO.:
59
PICTORIAL INDEX
PLATE NO. : 49
TOOL KIT
150
PAGE NO.:
60
PLATE NO. : 50
ACCESSORIES / GRAB HANDLE
PAGE NO.:
61
Brand ID: 001MC607
Plate No. 1 : COVER CYLINDER HEAD
No.
Part No.
1
2
3
4
5
DJ 1012
DS 1010
36 DS10
DS 1011
DS 1010
6
7
8
9
10
11
69
26
01
66
96
Description
180
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
Dommed Cap Nut
Copper Washer
Hex. Bolt with Flange
Hex. Bolt / Flange
Plug
4
4
2
4
2
DG 1014 98
Gasket
2
Remarks
Ref. Page No. 58
1
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 2 : CYLINDER HEAD
No.
Part No.
1
2
3
4
5
DJ 1012 69
39 1660 05
DJ 1010 12
DH 1015 08
DJ 1011 36
Head Cylinder with Cover
Stud (Exhaust)
Gasket Cylinder Head
Damper Cylinder Head
Intake Pipe
6
7
8
9
10
39 2539 21
DJ 1210 22
DH 1210 38
39 1674 04
DH 1110 12
11
12
39 2608 01
36 DS10 01
2
Description
180
Qty/
Veh.
Remarks
Plate No. 3 : VALVE
Qty/
Veh.
No.
Part No.
1
2
1
5
1
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
‘O’ Ring (Intake Pipe)
Carburettor Insulator
Clamp for Insulator
Hex. Bolt / Flange
Sleeve - Spark Plug
1
1
2
2
1
6
7
8
9
36 DK00
36 DJ10
DS 1013
59 1100
Valve Repair Kit
Valve Kit
Wave washer
Plain washer
1
1
2
4
Grub Screw
‘O’ Ring Kit for Cover Cyl. Head
1
1
05
04
66
02
Description
180
Remarks
Ref. Page No. 58
Ref. Page No. 58
For Sleeve Spark Plug
Ref. Page No.58
3
3
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 4 : CAMSHAFT / TENSIONER
Qty/
Veh.
No.
Part No.
1
2
3
4
5
39 2040 21
DH 1017 03
39 2542 20
39 1880 20
36 DH10 03
Ring’O’
Camshaft assembly
Bearing cam RH side
Bearing cam LH side
Guide chain Kit
1
1
1
1
1
6
7
8
9
10
DS 1012 76
DH 1014 12
DH 1010 48
39 2198 04
JC 1010 35
Sprocket cam Driven
Collar cam Sprocket
Special camshaft washer
Hex. Soc. Head cap Bolt
Cam Chain
1
1
1
1
1
11
12
13
14
DJ 1011 37
DH 1010 11
DS 1012 77
39 1674 04
Decomp Assly.
Cam chain Tensioner pivot Bolt
Tensioner Assly
Hex Bolt / Flange
1
1
1
2
4
Description
180
Remarks
Plate No. 5 : CYLINDER AND PISTON
No.
6302 - RS1/C3
6002 - C3
Ref. Page No.58
3
Part No.
1
2
3
4
5
DJ
39
DJ
DJ
39
1010
2181
1011
1011
2132
04
06
58
06
17
6
DJ 1012 22
Description
180
Qty/
Veh.
Gasket Cylinder
Pin dowel
Piston Assly. Std.
Ring Set Piston
Ring Snap
1
4
1
1
2
Cylinder Block / Piston Assly
1
Remarks
5
Brand ID: 001MC607
Brand ID: 001MC607
Plate No.
No. 6 : CRANK SHAFT
No.
Part No.
1
2
3
4
5
DJ
39
39
31
DS
6
7
8
9
10
11
12
13
6
1012
2183
2165
1011
1011
23
04
11
73
54
Description
180
Qty/
Veh.
Remarks
Plate No. 7 : BALANCER & BALANCER IDLER GEAR
No.
Part No.
Description
Qty/
Veh.
Crankshaft assly. comp.
Bolt
Plain washer
Key woodruff
Square 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 2561 20
DS 1012 75
39 2203 07
36 DH40 06
DH 1010 64
Bearing Ball
Sprocket cam drive
Parallel pin
Set primary driver & driven
Body centrifugal oil filter
1
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
Thrust washer
Balancer Idler Holder
2
2
2
2
1
DH 1011 95
DH 1010 65
36 DK00 07
Nut
Cover centrifugal oil filter
Kit centrifugal oil filter
1
1
1
11
39 1674 04
Bolt
3
Ref. Page No.58
7mm. (Height)
180
Remarks
Ref. Page No. 58
3
7
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 8 : TRANSMISSION
Qty/
Veh.
Remarks
Plate No. 8 : TRANSMISSION
No.
Part No.
1
2
3
4
5
DK 1011 25
39 2158 11
DH 1010 78
DH 1010 79
DH 1012 35
Shaft Input Transmission
Washer thrust
Gear 4th Drive
Washer Spline
External Circlip
1
1
1
3
4
16
17
18
19
20
DJ
DH
DH
DH
DH
6
7
8
9
10
DH 1010 80
DH 1010 82
DH 1010 84
39 2160 11
DH 1014 16
Gear 3rd Drive
Gear 5th drive
Gear 2nd drive
Thrust washer
Shaft output Transmission
1
1
1
1
1
21
22
23
24
30 1010 61
DH 1011 17
DJ 1010 63
39 1062 04
11
12
13
14
15
DH 1013 36
DH 1011 08
39 2159 11
DH 1011 10
DH 1011 11
Washer Thrust
Gear 3rd Driven
Thrust Washer
Gear 4th Driven
Bush 1st driven
2
1
1
1
1
8
Description
180
No.
3
Part No.
1011
1011
1013
1013
1011
10
13
19
33
16
Description
180
Qty/
Veh.
Gear 1st driven
Gear 5th Driven
Bush 2nd driven
Gear 2nd Driven
Collar Sprocket
1
1
1
1
1
‘O’ Ring Sprocket Collar
Sprocket Drive
Plate Drive Sprocket
Bolt Drive Sprocket
1
1
1
2
Remarks
9
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 9 : CHANGE DRUM / SHIFT FORK
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
1011
59
60
46
93
57
62
39 2437 04
39 2606 07
DJ 1012 30
DK 1011 58
DK 1011 61
DH 1014 96
DK 1011 35
Description
180
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
Parellel pin
Guide Gear Shifter
Guide Gear Shifter
Guide Gear Shifter
Spacer
Bush fork gear shift
1
1
1
1
1
1
2
Remarks
Plate No. 10 : GEAR CHANGE MECHANISM
Description
180
Qty/
Veh.
No.
Part No.
1
2
3
4
5
DH 1017 05
DH 1017 14
DH 1011 44
DH 1013 97
31 1011 08
Lever comp. Gear Shifter
Spring arm reset
Spring Gear Shifter return
Lever comp. change
Damper
1
1
1
1
1
6
7
8
9
10
39 2453 04
DH 1012 25
DH 1015 03
DH 1015 02
DH 1010 13
Flanged Bolt
Bolt Gear Shift drum Stopper
Stopper gear shifter drum
Spring gear shifter drum stopper
Bolt shift change
1
1
1
1
1
Remarks
From 1/03/07
Up to 28/02/07
From 1/03/07
3
11
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 11 : ENGINE ASSLY. & CRANKCASE RH
Qty/
Veh.
No.
Part No.
1
2
3
4
5
DJ 1012 31
DJ 1012 13
39 2531 05
39 1074 04
DH 1010 06
Engine Assly.
Crankcase RH
Stud
Bolt Flanged
Gasket Crankcase
1
1
2
1
1
6
7
8
9
10
39 2583 20
39 2602 20
39 2180 06
39 2601 20
DH 1014 87
Bearing Ball (For Input shaft)
Bearing Ball (For Output shaft)
Dowel Pin
Ball Bearing
Plate Stopper
1
1
2
1
1
12
Description
180
Remarks
N.I.
(For Drum Comp. Gear Shift)
3
Plate No. 12 : CRANKCASE LH
Qty/
Veh.
No.
Part No.
1
2
3
4
5
DJ 1012 74
39 2531 05
DH 1016 54
39 2188 19
DH 1014 23
Crankcase LH
Stud
Guide starter Assly
Oil Seal
O’ Ring
1
2
1
1
1
6
7
8
9
10
39
39
39
39
39
C’ Sunk Head Screw
Bearing Ball (For Input shaft)
Bearing Ball (For Output shaft)
Balancer LH Bearing
Oil Seal (For Output shaft)
3
1
1
1
1
11
12
13
14
15
39 2190 19
DH 1012 03
DH 1012 46
28 1011 74
DH 1012 72
Oil Seal (For Shift lever)
Breather pipe
Rubber tube
Spring Clip
Plug (Drain Bolt)
1
1
1
1
1
0752
2603
2583
2185
2189
01
20
20
20
19
Description
180
Remarks
13
Brand ID: 001MC607
Brand ID: 001MC607
Plate No.
No. 12 : CRANKCASE LH
No.
Part No.
16
17
18
19
20
DG 1014 98
31 2010 81
DH 1017 84
DH 1012 69
39 1414 02
Gasket (For Drain Bolt)
Switch comp.(Neutral)
Gasket Neutral Switch
Baffle
Self tapping Screw
21
22
23
24
25
39 1845 04
39 1677 04
39 2305 04
DH 1012 78
DH 1011 69
26
27
28
DJ 2010 21
39 2448 11
DH 1014 22
14
Description
180
Qty/
Veh.
Remarks
Plate No. 13 : COVER RH
Qty/
Veh.
No.
Part No.
1
1
1
1
1
1
2
3
4
5
52 DJ01 96
DH 1011 97
30 1011 42
39 1041 19
DH 1011 41
Cover comp RH
Grommet Breather
Seal kick Shaft
Seal clutch lever
Rack
1
1
1
1
1
Flanged Bolt
Bolt
Bolt
Plug Starter Motor
Bush starter gear inner
1
8
1
1
1
6
7
8
9
10
DH 1011 42
39 2202 07
DG 1014 18
DS 1012 15
39 1074 04
Shaft clutch release
Parallel pin
Gauge
Wire circlip
Bolt
1
1
1
1
10
Cable assly. (Battery to Earth)
Plain Washer
Damper
1
1
1
11
12
13
14
15
39 0999 06
DH 1010 18
DH 1011 54
DH 1210 15
DH 1210 11
Pin Dowel
Bracket Clutch Cable
Gasket cover RH
Plunger Oil
Plate Plunger Oil
2
1
1
1
1
3
Description
180
Remarks
15
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 13 : COVER RH
Qty/
Veh.
No.
Part No.
16
17
18
19
20
DH 1210 12
DH 1012 81
39 2443 11
36 DH10 04
39 2208 04
Spring Joint ‘A’
Spring torsion clutch lever
Washer
Set damper
Flanged Bolt
1
1
1
1
8
21
22
23
DS 1012 52
DS 1012 01
36 DH10 05
‘Bajaj’ Decal
Bushing
Set of Plate
1
1
1
16
Description
180
Remarks
Ref. Page No. 58
Fitted on Cover comp.RH
Ref. Page No. 58
Plate No. 14 : COVER MAGNETO
Description
180
Qty/
Veh.
No.
Part No.
Remarks
1
2
3
4
5
DJ 1012 09
DH 1011 59
39 1074 04
39 0999 06
DH 1011 57
Cover Magneto
Gasket Magneto cover
Bolt
Pin Dowel
Cap Crank Center
1
1
7
2
1
6
7
8
9
10
39 1283 21
DJ 1012 68
36 DH10 06
39 2208 04
DS 1012 53
‘O’ Ring
Cover LH RR with sticker
Set Damper
Flanged Bolt
‘Bajaj’ Decal
1
1
1
6
1
Fitted on Cover magneto
11
36 DH10 07
Set of Plate
1
Ref. Page No.58
Alt to 39 2452 21
Ref. Page No.58
17
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 15 : CLUTCH
No.
Part No.
1
2
3
4
5
DH
DK
DJ
DK
DK
6
DK 1011 49
DK 1011 50
DK 1012 55
DK 1011 51
DH 1017 43
39 1674 04
DK 1011 54
7
8
9
10
18
1012
1013
1012
1010
1011
75
56
75
01
63
Description
180
Qty/
Veh.
Remarks
Plate No. 15 : CLUTCH
No.
Part No.
Description
180
Qty/
Veh.
Special Nut
Friction clutch plate kit
Clutch Plate Assly
Clutch Center
Plate Clutch pressure
1
1
1
1
1
11
12
13
14
15
39 1880 20
DK 1013 38
DH 1014 85
DK 1011 26
DH 1016 48
Bearing Clutch lifter thrust
Holder Clutch
Rod Clutch lifter
Spacer clutch
Nut Primary drive lock
1
1
1
1
1
Disc Clutch friction
Disc Clutch friction 'B' type
Disc Clutch friction 'C' type
Plate Clutch
Spring Clutch Capacity
Bolt
Bolt
5
1
4
5
4
1
4
16
17
18
19
DH 1011 80
39 2200 11
DK 1011 53
DK 1011 55
Lever Assly. Clutch
Washer Primary Drive Gear
Seat judder spring
Spring judder
1
1
1
1
Remarks
LH Thread
19
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 16 : KICK STARTER MECHANISM
No.
Part No.
1
2
3
4
5
DH 1015
DD 1010
36 DH10
DH 1015
DH 1015
6
7
8
9
10
11
12
13
14
15
20
Qty/
Veh.
Lever Kick Starter complete
Damper
Boss Kick set
Ratchet Kick Starter
Gear Kick Idler
1
1
1
1
1
DH 1015 40
DH 1015 72
DH 1011 21
39 0993 11
39 2344 11
Spindle Kick Starter Assly
Pinion Kick Starter
Spring for Kick Starter Ratchet
Washer Thrust
Plain Washer
1
1
1
1
1
DH
DH
DH
DH
DH
Guide Kick
Bolt Flanged
Spring Kick Starter Return
Bolt flange
Stopper
1
3
1
1
1
1015
1015
1011
1013
1015
45
97
08
37
31
Description
180
36
48
25
21
38
Remarks
Ref. Page No.58
3
Plate No. 16 : KICK STARTER MECHANISM
No.
Part No.
16
17
18
19
39 1672 04
39 2276 11
39 0738 17
DH 1015 39
Description
Bolt Flanged
Washer
Circlip
Spindle kick shaft
180
Qty/
Veh.
Remarks
1
2
2
1
21
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 17 : CARBURETTOR
No.
Part No.
Description
180
Qty/
Veh.
1
2
3
4
5
DJ
DJ
DJ
DJ
DJ
1012
1210
1210
1210
1210
32
51
52
44
53
Carburettor Assly.
Vaccum Piston Kit
Idling Screw Kit
Jet needle(JN)
“O” ring
1
1
1
1
1
6
7
8
9
10
DJ
DJ
DJ
DH
DH
1210
1210
1210
1211
1210
54
55
56
01
02
Screw
Float assly.
Jet Holder Kit
Magnet Assly.
Reed Switch Assly.
2
1
1
1
1
11
12
13
14
39
DJ
DJ
DJ
1780
1210
1210
1210
01
57
58
59
Pan Head Screw
Needle Assly.
Set Adjuster(PS)
Set Plunger assly.
2
1
1
1
22
Remarks
Plate No. 18 : AIR CLEANER COMP
No.
Part No.
1
2
3
4
5
DJ 1210 40
36 DK00 08
DJ 1210 39
AA 1210 45
36 DK00 15
Description
Air Cleaner comp
Kit hardware air cleaner
ConKinecting Tube
Clamp
Kit element air filter
180
Qty/
Veh.
1
1
1
1
1
Remarks
Ref. Page No.58
(Fine & Coarse)
23
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 19 : SILENCER ASSLY.
180
Plate No. 20 : SEAT ASSLY. / SEAT LOCK
180
12
Part No.
1
2
3
4
5
DJ 1012 43
DJ 1011 61
DH 1014 68
36 DK00 10
DJ 1010 64
39 1970 15
Silencer Assly. with CAT converter
Silencer Assly. with CAT converter
Shield Muffler
Kit hardware shield
Gasket Exhaust
Flanged Nut
1
1
1
1
1
2
6
7
8
9
36 DK00
DG 1611
DH 1015
DH 1015
Kit hardware silencer
Damper (Main Stand)
Wire Shield Assly.
Dommed Cap Nut
1
1
1
2
24
09
24
21
25
Description
Qty/
Veh.
No.
Remarks
From 15/01/2007
Ref. Page No.59
No.
Part No.
1
2
3
4
DJ 2110 03
DJ 2110 06
39 1902 04
DK 2110 07
Description
Seat Assly comp
Lock Assly seat
Flanged bolt
Damper at a seat front
Qty/
Veh.
Remarks
1
1
2
1
Ref. Page No.59
3
25
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 21 : OIL PUMP
180
Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL
180
9
No.
Part No.
1
2
3
4
5
DH 1210 01
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
6
39 2194 21
‘O’ Ring
26
Description
Qty/
Veh.
Remarks
Part No.
1
3
1
1
1
1
2
3
4
5
59 1000 02
DJ 1110 59
39 1674 04
39 0761 01
DH 1011 99
Spring Dowel
Stator Assly. comp
Hex. Bolt with Flange
Pan Head Screw
Stopper plate (wiring harness)
1
1
2
2
1
1
6
7
8
10
DJ 1110 61
39 0746 01
DG 1110 08
DJ 1110 23
DD 1110 11
Rotor Assly.
Screw Pan head
Spark plug
C.D.I. Assly.
Grommet Spark Plug
1
1
2
1
1
11
12
13
14
15
DJ
DH
DH
DD
DH
AC/DC Regulator
H.T. Coil LH
H.T. Coil RH
Cap Spark Plug
Cap Spark Plug
1
1
1
1
1
3
2011
1110
1110
1110
1110
02
39
40
48
15
Description
Qty/
Veh.
No.
Remarks
N.I.
With Aluminum bracket
27
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL
No.
Part No.
16
17
18
19
20
DD 1110 12
DH 1110 13
39 1902 04
DJ 1610 67
39 1680 04
Grommet H.T. Cable
Grommet Spark Plug
Flange Bolt
Bracket H.T. Coil
Flange Bolt
21
DH 1110 16
Grommet Sleeve Spark Plug
28
Description
180
Qty/
Veh.
Remarks
Plate No. 23 : STARTER ASSEMBLY (FOR SELF START)
Part No.
2
1
2
1
2
1
2
3
4
5
DH 1017 82
DH 1017 81
DH 1016 58
DH 1015 81
39 1672 04
Body comp. starter clutch
Plate roller clutch
Gear starter clutch
Plate starter clutch gear return
Bolt
1
1
1
1
1
1
6
7
8
9
10
DK 1011 76
DH 1011 72
DH 1011 88
39 2437 04
DH 1110 58
Shaft starter counter
Collar starter counter
Gear comp. starter counter assly.
Bolt socket
Motor assly. starter
1
1
1
3
1
11
12
13
14
15
39 1074 04
DH 1013 72
39 2285 01
DH 1011 64
DJ 1011 09
Bolt
Cover starter motor
Slotted c’sunk screw
Spring
Bush For Spring Starter
2
1
1
5
5
16
17
DH 1011 63
DH 1015 33
Roller
Bush Spring Starter Clutch
5
5
3
Description
Qty/
Veh.
No.
180
Remarks
For stopper plate
29
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 24 : ENGINE MOUNTINGS
180
Plate No. 25 : FRAME & FRAME FITTINGS
180
3
4
10
6
17
16
5
14
6
7
1
4
8/9
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
DH 1611
DH 1611
DH 1611
36 DK00
DJ 1611
70
89
90
11
14
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
DJ 1611 15
39 2157 04
39 2412 04
DH 1612 73
39 1967 04
Bkt. comp. RH eng.mtg. lower
Bolt Flanged
Bolt Flanged
Bush in frame
Bolt
1
3
1
1
1
11
12
13
14
15
39 2414 04
DH 1613 01
39 2310 04
39 2311 04
39 2457 11
Hex.soc.hd.cap bolt
Bkt.comp.RH eng.rear
Flanged bolt
Bolt
Washer
1
1
2
1
1
16
17
DJ 1610 88
DJ 1610 89
Bracket LH Engine Hanger
Bracket RH Engine Hanger
1
1
30
Remarks
Ref. Page No.59
Alt. 39 2311 04
3
Part No.
1
2
3
4
5
DJ 1612 64
DH 1611 12
30 1810 11
DH 1810 14
36 DS18 02
Frame Assly. comp.
Cup rear
Nut
Cup - Steering
Bearing Cone Kit
1
2
1
1
1
6
7
8
9
30
39
DJ
DJ
Ball steel
Flanged bolt
Cable Hook LH
Cable Hook RH
46
2
1
1
1810
1680
1611
1611
06
04
32
33
Description
Qty/
Veh.
No.
Remarks
Incl. Bush, Races & Cup rear
Ref.Page No.59
31
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 26 : SWING ARM / REAR SHOCK ABSORBER
No.
Part No.
Description
Qty/
Veh.
1
2
3
4
5
DJ 1710
DG 1710
36 DK00
DJ 1710
DH 1710
19
38
12
32
14
Rear Shock Absorber
Bolt Pre-coated
Kit bush rear shock
Swing arm assly.
Bush swing arm
2
2
1
1
4
6
7
8
9
10
DH
DH
DH
DH
DJ
1710
1710
1710
1710
1710
13
15
19
12
08
Collar swing arm
Dust seal swing arm
‘U’ nut swing arm
Shaft swing arm
Chain slider
2
4
1
1
1
11
12
13
14
15
39
39
DJ
DJ
DJ
0553
0454
1510
1510
1510
02
11
36
37
47
Screw
Plain washer
Adjuster chain LH
Adjuster chain RH
Plate Chain Adjuster
2
2
1
1
2
32
180
Remarks
Ref. Page No.59
3
Plate No. 26 : SWING ARM / REAR SHOCK ABSORBER
No.
Part No.
16
17
18
39 0292 15
35 1710 33
39 0740 11
Description
Hexagon nut
Grease nipple
Plain washer(Nylon)
Qty/
Veh.
180
Remarks
4
2
2
33
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 27 : RIDER FOOT REST
No.
Part No.
1
2
3
4
5
DJ 1611 30
39 2310 04
DJ 1611 31
DH 1610 53
DH 1611 94
Description
Main step LH assly. comp.
Flange bolt
Main step RH assly. comp.
Rubber main step
Kick stopper
180
Qty/
Veh.
Plate No. 28 : PILLION FOOT REST / HOLDER
No.
Remarks
1
4
1
2
1
1
2
3
Holder LH step
Holder RH step
Pillion step assly. comp.
Pillion step assly. comp.
Pillion step assly. comp.
Pillion step assly. comp.
Rubber pillion step
Rubber pillion step
6
7
8
9
10
36 DK00
39 1069
39 0292
39 1741
DX 1610
13
01
15
04
67
Kit hardware pillion
Bolt
Nut
Flanged Bolt
Plate lock pillion step
2
1
1
2
2
NI
11
12
DH 1611 00
22 1504 51
Spacer main step
Bolt cylinder securing
2
2
NI
NI
3
LH
LH
RH
RH
1
1
1
1
1
1
2
2
Remarks
56
57
28
13
29
15
22
17
4
DJ
DJ
DJ
DH
DJ
DH
DJ
DH
Qty/
Veh.
Description
1612
1612
1611
1613
1611
1613
1611
1613
5
34
Part No.
180
From Dec.2006
From Dec.2006
From Dec.2006
Ref. Page No.59
Stopper bolt
Bott. Mtg. LH & RH Holder Step
35
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 29 : MUDGUARD FRONT & REAR
No.
Part No.
Description
180
Qty/
Veh.
1
2
3
4
5
DJ
DH
DG
DJ
DJ
1610
1613
1810
1611
1612
69
04
08
25
55
Nail for Cable Guide
Brace fender
Socket bolt
Clamp
Fender rear front
1
1
4
1
1
6
7
8
9
10
11
DJ 1610
39 0711
39 1680
DJ 1612
36 DS40
DJ 1612
91
11
04
54
02
72
Grommet Front Fender
Plain washer
Flange bolt
Fender rear
Guard Kit
Support assly for rear fender
4
4
2
1
1
1
36
Remarks
Fender front mtg.
For cables
3
Plate No. 30 : STAND ASSEMBLY
Description
180
Qty/
Veh.
No.
Part No.
1
2
3
4
5
DJ 1612 14
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
DJ 1612 18
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
DH 2010 64
39 2060 04
DH 2010 65
Side stand switch
Bolt
Magnet Assly.
1
2
1
Remarks
N.I.
37
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 31 : TYRE / TUBE / RIM
No.
Part No.
1
2
3
4
5
DJ
DS
DS
DJ
DS
6
DS 1510 29
38
1510
1510
1510
1510
1510
77
48
49
87
31
Description
180
Qty/
Veh.
Remarks
Wheel rim front (16 x 17 DC)
Tyre front
Tube front
Wheel rim rear
Tyre rear
1
1
1
1
1
Proprietory items Not to
Tube rear
1
service
Proprietory items Not to
service
Plate No. 32 : FRONT HUB
No.
Part No.
1
2
3
4
5
39
39
DE
30
DE
6
7
0787
2362
1510
1510
1510
Qty/
Veh.
Pin cotter
Bearing ball
Spacer assly.
Seal oil
Plate drive
1
2
1
1
1
8
9
10
DE 1510 08
DJ 1510 14
DJ 1510 65
39 0786 15
39 0781 11
DD 1510 36
Seal oil
Disc
Disc
Hex. slotted nut
Plain washer
Hex. soc. hd. bolt
1
1
1
1
1
6
11
12
13
14
DH
DS
DJ
DJ
Case meter assly.
Spacer
Front Axle with head
Rotor Speedo
1
1
1
1
1510
1510
1510
1510
08
20
06
33
12
Description
180
62
58
41
94
Remarks
For KBX
For ETS
39
3
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 33 : FRONT MASTER CYLINDER
No.
1
2
3
Part No.
Description
180
Qty/
Veh.
4
5
DJ
DJ
DJ
DJ
DJ
DJ
1910
1510
1910
1910
1910
1910
23
76
59
57
25
26
Major Kit - Master Cylinder
Hose Brake Front
Lever Grip RH
Lever Grip RH
Banjo Bolt
Washer Copper
1
1
1
1
2
4
6
7
8
9
10
DJ
DJ
DJ
DJ
DJ
1910
1910
1910
1910
1910
27
28
29
30
31
Clamp Holder RH
Bolt
Bolt Front Brake Lever
Nut Flanged
Screw
1
1
1
1
2
11
12
13
14
15
DJ 1910
DJ 1910
DJ 2011
DJ 1910
DJ 1910
36 DH19
56
58
09
34
35
02
Cylinder Master
Cylinder Master
Front brake switch
Reservoir Cover
Diaphragm
Oil Window Kit
1
1
1
1
1
1
16
DJ 2011 08
Cable assly for switch
1
40
Remarks
For ETS
For KBX
For KBX
For ETS
Plate No. 34 : FRONT DISC BRAKE
No.
Part No.
Description
180
Qty/
Veh.
1
2
3
4
DJ
39
DJ
DJ
1510
1769
1510
1510
67
04
68
69
Caliper Assly. Front
Bolt Flanged
Spring Pad
Bleeder Screw
1
2
1
1
5
6
7
8
9
DJ
DJ
DJ
DJ
DJ
1510
1510
1510
1510
1510
70
71
72
73
74
Bleeder Cap
Disc Pad Set
Insulator
Protection Boot
Minor Kit - Caliper
1
1
1
1
1
10
DJ 1510 75
Major Kit - Caliper
1
Remarks
Ref. Page No. 60
41
3
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 35 : REAR HUB
No.
Part No.
Description
180
Qty/
Veh.
Remarks
Plate No. 35 : REAR HUB
No.
Part No.
Description
180
Qty/
Veh.
1
2
3
4
5
39
30
DJ
39
30
2442
1510
1510
2241
1510
20
75
88
20
69
Bearing ball
Collar bearing
Coupling Rubber
Bearing ball
Spring
1
1
1
1
2
16
17
18
19
20
DJ 1510
36 DJ40
DS 1510
30 1510
39 2240
35
05
74
82
20
Collar
Chain Sprocket Kit
Lock washer
Seal oil
Bearing ball
1
1
3
1
1
6
7
8
9
10
30 1511
30 1510
DJ 1510
36 DK00
DJ 1510
05
12
92
14
32
Shoe brake assly.
Cam brake
Panel rear brake
Kit lever brake
Axle
1
1
1
1
1
21
22
23
24
25
DS
DS
DJ
39
DJ
68
73
33
15
53
Coupling
‘D’ Bolt
Sleeve
Hex. lock nut
Drive Chain Lock
1
6
1
6
1
11
12
13
14
15
DJ 1510 34
39 2567 11
DH 1710 19
39 0801 15
39 2566 11
Collar
Plain washer
‘U’ nut
Nut
Plain washer
1
1
1
1
1
42
Ref. Page No.59
1510
1510
1510
0794
1510
Remarks
Ref. Page No.59
43
3
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 36 : REAR BRAKE PADAL
No.
Part No.
1
2
3
4
5
DH 1910
DJ 1910
36 DK00
DH 1910
DJ 1910
6
7
8
9
10
36 DK00 17
36 DK00 18
30 1510 95
DJ 1510 42
DH 1510 29
44
01
21
16
06
10
Description
180
Qty/
Veh.
Lever Brake Pedal
Shaft assly. brake Pedal
Kit hardware brake pedal
Spring
Rod assly. brake
1
1
1
1
1
Kit hardware rod brake
Kit hardware rod torque
Hex. bolt
Rod torque
Hex. bolt
1
1
1
1
1
Remarks
Ref. Page No.59
Ref. Page No.60
Ref. Page No.60
3
Plate No. 37 : HANDLE BAR
Qty/
Veh.
No.
Part No.
1
2
3
4
5
DH 1810 55
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 1910 09
DJ 1910 54
DJ 1910 55
DD 1910 85
39 1184 15
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
DH 1810
Kit hardware holder kit
Grip LH
Grip assly.RH
Boot for lever
Handle bar weight
1
1
1
1
2
19
07
17
19
22
Description
180
Remarks
Ref.pageno.60
45
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 37 : HANDLE BAR
No.
Part No.
16
17
18
19
20
DH
DJ
DJ
DJ
DS
21
22
39 1943 04
DJ 2010 35
46
1810
1810
2210
2210
1810
40
39
03
04
22
Description
180
Qty/
Veh.
Hex. soc.hd. cap screw
Pad Holder Handle
Mirror assly. LH
Mirror assly. RH
Switch assly.ignition
2
1
1
1
1
Flange bolt
Clutch Switch
2
1
Remarks
Alt. 39 2427 04
Plate No. 38 : FRONT FORK
No.
Part No.
Description
180
Qty/
Veh.
1
2
3
4
5
DJ 1811
36 DK00
DJ 1810
DJ 1811
DJ 1811
00
20
87
01
02
Fork front
Kit outer tube
Oil seal
Outer Tube LH
Outer Tube RH
1
1
2
1
1
6
7
8
9
10
30
30
DS
DJ
DS
1810
1810
1810
1811
1810
26
25
77
03
71
Gasket
Bolt
Cylinder comp. fork
Pipe comp. suspension inner
Slide Bush
2
2
2
2
2
11
12
13
14
15
DJ
DJ
DJ
DH
DH
1810
1810
1811
1810
1810
45
44
04
09
15
Clamp for Bellow
Bellow
Spring front fork
Grommet Top
Bolt fork
2
2
2
2
2
Remarks
Ref. Page No.60
47
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 38 : FRONT FORK
Qty/
Veh.
No.
Part No.
16
17
18
19
20
30 1810 29
30 1810 28
DS 1810 85
DM 1810 10
30 1810 44
‘O’ ring
Seat fork spring
Spacer Tube
Washer
Bolt
2
2
2
2
1
21
22
23
24
25
DH
DG
DJ
DJ
DH
56
08
85
52
48
Holder fork upper
Socket Bolt
Cushion Rubber
Cover Trail B
Lamp Shade asly.
1
2
2
4
1
26
27
28
29
DH 1810 23
DJ 1810 41
39 0789 12
39 1813 04
Bearing cone
Holder fork under
Spring washer
Bolt
1
1
2
2
48
1810
1810
1810
1810
1810
Description
180
Remarks
Plate No. 39 : PAINTED PARTS & DECALS
No.
3
Part No.
Qty/
Veh.
Description
1
DH
DH
DH
DH
DH
7102
7102
7102
7102
7102
2T
2V
3A
3M
X3
Fuel
Fuel
Fuel
Fuel
Fuel
Tank
Tank
Tank
Tank
Tank
with
with
with
with
with
2
DK
DK
DK
DK
DK
7301
7301
7301
7301
7301
2T
2V
3A
3M
X3
Side
Side
Side
Side
Side
cover
cover
cover
cover
cover
3
DK
DK
DK
DK
DK
7302
7302
7302
7302
7302
2T
2V
3A
3M
X3
Side
Side
Side
Side
Side
4
DK
DK
DK
DK
DK
7303
7303
7303
7303
7303
2T
2V
3A
3M
X3
Seat
Seat
Seat
Seat
Seat
180
Decal
Decal
Decal
Decal
Decal
Remarks
1
1
1
1
FOR
FOR
FOR
FOR
FOR
TITANIUM SILVER
COCKTAIL WINE RED
LONG BEACH BLUE
MICA ORANGE
EBONY BLACK (MET)
LH
LH
LH
LH
LH
1
1
1
1
1
FOR
FOR
FOR
FOR
FOR
TITANIUM SILVER
COCKTAIL WINE RED
LONG BEACH BLUE
MICA ORANGE
EBONY BLACK
cover
cover
cover
cover
cover
RH
RH
RH
RH
RH
1
1
1
1
1
FOR
FOR
FOR
FOR
FOR
TITANIUM SILVER
COCKTAIL WINE RED
LONG BEACH BLUE
MICA ORANGE
EBONY BLACK
Cowl
Cowl
Cowl
Cowl
Cowl
Assly.
Assly.
Assly.
Assly.
Assly.
1
1
1
1
1
FOR
FOR
FOR
FOR
FOR
TITANIUM SILVER
COCKTAIL WINE RED
LONG BEACH BLUE
MICA ORANGE
EBONY BLACK
49
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 39 : PAINTED PARTS & DECALS
Qty/
Veh.
No.
Part No.
5
DJ 7302 2T
DJ 7302 2V
DJ 7302 3A
DJ 7302 3M
DJ 7302 X3
Front
Front
Front
Front
Front
6
DH 1410 20
Seat tape
1
7
DJ
DJ
DJ
DJ
DJ
Fairing
Fairing
Fairing
Fairing
Fairing
1
1
1
1
1
8
9
10
52 DJ01 10
DH 1613 10
DK 1611 23
DK 1611 24
Tank Decal Set
Seat Cowl Decal
Cover Side Mesh LH
Cover Side Mesh RH
1
1
1
1
11
59 0200 01
Self tap screw
6
50
7401
7401
7401
7401
7401
2T
2V
3A
3M
X3
Description
180
Fender
Fender
Fender
Fender
Fender
1
1
1
1
1
Remarks
FOR
FOR
FOR
FOR
FOR
TITANIUM SILVER
COCKTAIL WINE RED
LONG BEACH BLUE
MICA ORANGE
EBONY BLACK
FOR
FOR
FOR
FOR
FOR
TITANIUM SILVER
COCKTAIL WINE RED
LONG BEACH BLUE
MICA ORANGE
EBONY BLACK
Plate No. 40 : PETROL COCK, CAP TANK & GAUGE FUEL
Description
Qty/
Veh.
No.
Part No.
1
2
3
4
5
DH 1410 50
39 0840 01
39 2381 04
DK 1410 01
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
DH 2010 62
30 1410 28
Packing
Bolt flanged
Plain Washer
Gauge Fuel
Gasket fuel Gauge
1
2
2
1
1
11
12
13
14
15
30 1410 32
DJ 1410 06
30 1410 15
DH 1410 24
DJ 1410 02
Bolt
Tube fuel
Pipe clip
Drain tube
Clamp
4
1
1
1
1
180
Remarks
Alt. 39 1780 01
51
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 41 : FITTINGS PET. TANK SI. COVER & COVER SEAT
180
Plate No. 42 : METER ASSEMBLY
180
5
4
Part No.
1
2
3
4
5
36 DH16 01
DH 1410 31
39 1606 01
39 2424 11
DJ 1811 10
Grommet Kit For side cover
Tape tank inner
Screw
Plain Washer
Lock Set (4 in 1) with Key
1
2
2
1
1
6
7
8
DH 1410 23
DJ 1410 08
39 1556 04
Damper
Damper front
Flanged Bolt
1
2
1
52
Description
Qty/
Veh.
No.
Remarks
No.
Ref. Page No. 60
1
2
3
4
5
Alt. DG 1611 21
N.I.
3
Part No.
DJ
39
DJ
DJ
DJ
1910
1778
1811
2011
2011
60
02
19
74
59
Description
Meter Assly / Instrument Cluster
Self Tapping Screw
Back Cover
Trip Meter Knob
Speedo Meter Top Cover
Qty/
Veh.
Remarks
1
4
1
1
1
53
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 43 : CONTROL CABLES
No.
1
2
3
4
54
Part No.
DJ
DJ
DJ
JC
1910
2011
1910
2010
61
44
15
15
Description
Cable Accelerator
Assly. Speedo Sensor with cable
Cable Clutch
Pig Tail
180
Qty/
Veh.
1
1
1
1
Remarks
N. I. For Clutch Switch
3
Plate No. 44 : CHAIN CASE
Description
180
Qty/
Veh.
No.
Part No.
1
2
3
4
5
52 DJ01 66
DH 1612 84
15 1610 69
DH 1610 73
39 0897 04
Case Chain Kit
Rubber Pad
Rubber Cap
Instruction Label
Bolt
1
2
1
1
2
6
7
39 2475 04
39 0711 11
Bolt
Plain Washer
2
4
Remarks
Ref. Page No. 60
Rear side Mtg.
Front side Mtg.
55
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 45 : HEAD LAMP & FAIRING
180
Plate No. 46 : INDICATOR LIGHT ASSEMBLY
180
1/2
3/4
6
No.
Part No.
Qty/
Veh.
Remarks
No.
Part No.
1
2
3
4
5
DJ
DJ
DJ
DF
39
32
20
33
98
24
Head Lamp assly. without bulb
Back cover
Wind Shield
Bolt
Non Metallic Washer
1
1
1
4
4
1
2
3
4
5
DJ
DJ
DJ
DJ
DJ
6
7
8
9
10
DL 1810 10
DJ 1810 37
39 1907 01
DJ 2010 72
DH 1810 52
Well Nut
Decal Wind Shield
M5 x 15L mushroom HD
Pilot Bulb
Fairing mounting upper bracket
4
1
2
2
1
6
7
39 1970 15
CL 2010 23
11
12
13
14
15
36 DK00 21
DJ 1810 65
39 0716 01
39 1524 01
GH 2010 12
Kit hardware mtg. bracket
Clip Nut
Screw pan cross
Screw pan cross
Lamp 12V 35/35W-HS1
1
4
2
2
1
56
2011
1811
1810
1810
2141
Description
2011
2011
2011
2011
2011
48
49
46
47
30
7
Description
Qty/
Veh.
Blinker Front LH flexible
Blinker Front RH flexible
Blinker Rear LH flexible
Blinker Rear RH flexible
Mgt. assly. blinker self cancellation
1
1
1
1
1
Hex. nut with flange
Lens for blinker
4
2
Remarks
N.I.
Ref. Page No.60
3
57
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 47 : TAIL LAMP ASSLY/ FRONT & REAR NO. PLATE
Part No.
1
2
3
4
5
DK 2010 03
DH 1612 93
DK 1611 53
39 2592 01
39 0705 01
Tail light with Lamp
Damper
Clip Nut
Screw pan cross
Truss Screw
1
2
4
4
2
6
7
8
9
10
39
30
DK
DJ
DP
Bolt flange
Lamp 12V-4W
No. Plate illumination
Rear No. plate bkt.
Number plate Rear
2
1
1
1
1
11
12
13
14
15
39 1680 04
39 1783 01
DP 1611 44
DH 1612 92
39 1773 04
Hex Flanged Bolt
Truss Screw
Number plate front
No. plate mounting bracket
Bolt flange
2
2
1
1
2
58
1972
2010
2010
1610
1611
15
29
24
72
45
Description
Qty/
Veh.
No.
180
Remarks
For Front No. Plate
3
Plate No. 48 : ELECTRICAL EQUIPMENTS
Description
180
Qty/
Veh.
No.
Part No.
1
2
3
4
5
DH 2010 11
DH 2010 14
39 1507 11
39 1956 04
DJ 2011 25
Horn with LH stay
Horn with RH stay
Plain Washer
Flange Bolt
Battery (12V-9A) mf wet
1
1
1
1
1
6
7
8
9
10
DJ 1612 47
DJ 2011 53
31 2010 29
DH 1910 12
DH 2010 19
Band Battery
Wiring Harness
Rear Brake Switch
Spring Brake Switch
Grommet Rear Brake Switch
1
1
1
1
1
11
12
13
14
15
DS
39
DK
DJ
30
2010
1680
2010
2010
2011
25
04
16
28
04
Assly DC flasher / damper
Flange bolt
Starter Relay / Damper
Relay for Interlock
Fuse box Assly.
1
1
1
1
1
16
17
18
19
30
DJ
DJ
DJ
2010
2011
2010
2011
85
40
20
41
Fuse
Cable assly. (Battery to Earth)
Cable assly. (Battery to St.Relay)
Switch control unit
1
1
1
1
Remarks
N.S.
N.I.
59
Brand ID: 001MC607
Brand ID: 001MC607
Plate No. 49 : TOOL KIT
1
180
180
2
Description
Qty/
Veh.
No.
Part No.
1
*
*
*
*
DJ 2210 06
30 2210 04
CB 2210 03
30 2210 33
30 2210 11
Tool
Tool
Tool
Tool
Tool
Kit
Driver
Wrench (Box 16 mm)
Wrench (10 X 13)
Wrench (14 X 17)
1
1
1
1
1
*
*
*
*
*
*
30 2210 10
DH 2210 03
30 2210 05
30 2210 06
30 2210 09
DG 2210 40
Plier
Tool
Tool
Tool
Tool
Tool
Bag
wrench (27 A/F)
wrench (22 A/F)
bar
wrench
1
1
1
1
1
1
2
DH 2110 05
Band Tool Kit
60
Plate No. 50 : ACCESSORIES / GRAB HANDLE
Remarks
For reference only not
to service separately
Description
Qty/
Veh.
No.
Part No.
1
2
3
4
5
DJ 1612 26
DH 1613 05
36 DK00 23
DJ 1612 58
39 2310 04
Leg Guard with hardware
Sari Guard Assly.
Kit hardware sari guard
Grab Handle
Bolt Flange
1
1
1
1
4
6
7
8
DH 1613 03
DJ 1610 79
DJ 1610 80
Boot Sari Guard
Foam LH For grab
Foam RH For grab
1
1
1
Remarks
Ref. Page No.60
2
3
61
Brand ID: 001MC607
Brand ID: 001MC607
KIT LIST
Sr.
Kit Part No. Kit Description
No.
1
36DS1001 Cyl.Head O Ring Kit
180
Consisting of Following Parts
Part No.
Description
Qty./Kit
39239121
O Ring (Cover tappet)
2
39128321
O ring
2
Valve Intake
1
KIT LIST
Kit Part No. Kit Description
13 36DK0015 Kit element air filter
180
Consisting of Following Parts
Part No.
Description
Qty./Kit
DK121002
Element air filter fine
DK121003
Element air filter coarse
1
1
DH101301
Seal shield muflar
2
2
2
36DJ1004 Valve Kit
DJ101124
DJ101125
Valve Exhaust
1
DH101302
Trust screw
3
36DK0005 Valve Repair Kit
DS101083
Retainer valve spring
2
DH101481
Grommet shield
1
DH101731
Spring valve inner
2
DH101730
Spring valve outer
2
39185004
Flange bolt
1
DH101026
Seat valve spring
2
DH101017
Guide chain (Tight)
1
DH101010
Guide Chain (slack)
1
DH101628
Gear primary drive
1
DK101127
Driven
1
xxxxxxxxx
Clutch Housing
1
39220011
Washer
1
DH101234
Gasket centrifugal oil filter
1
39226701
Oval screw
1
DH101066
Join oil dealivery
1
DH101067
Spring oil delivery
1
4
5
6
7
8
9
36DH1003 Guide Chain Kit
36DH4006 Set primary drive & driven
36DK0007 Kit centrifugal oil filter
36DH1004 Set Damper
36DH1005 Set of Plate
36DH1006 Set Damper
10 36DH1007 Set of Plate
11 36DH1008 Boss Kick Set
12 36DK0008 Kit hardware air cleaner
62
39219908
Pin oil delivery joint
1
DH101284
Damper A
1
DH101285
Damper B
1
14 36DK0010 Kit hardware shield
15 36DK0009 Kit hardware silencer
16 36DK0011 Kit hardware engine mounting
17 36DS1802 Bearing cone kit
18 36DK0012 Kit bush rear shock absorber
19 36DK0013 Kit hardware pillion
39242511
Plain washer
1
DD161071
U nut
1
DH161155
Damper silencer
1
DH161157
Tube silencer mounting
1
39231204
Bolt flange
4
39197015
Nut flange
8
39241304
Bolt flange
1
DH161245
U Nut
3
DH181025
Bearing cone
1
DH181026
Bearing race
1
DH181024
Upper bearing race
1
39071411
Plain washer
8
39071215
Dome cap nut
2
39073712
Spring washer
2
DJ161186
Plait side pillion stape
2
DH101286
Damper C
1
DH101287
Damper D
1
DH161061
Pin pillion set
2
DH101288
Plate A
1
30141031
"O" ring
2
DH101289
Plate B
1
39104011
Plain washer
2
39078408
Split pin
2
30151038
"O" ring
1
DH101290
Plate C
1
DH101291
Plate D
1
DH101282
Damper Cover Magneto
1
DD151009
Indicator
1
DH101292
Damper A Cover LH RR
1
DJ151059
Lever brake
1
DH101294
Damper B Cover LH RR
1
39244704
Lever brake
1
DH101283
Plate Damper
1
39079815
Nut
1
DH101293
Plate Damper Cover LH RR
1
DJ151086
Sprocket (43 teeth)
1
DH101185
Spring Kick Starter Arm
1
DJ151096
Chain
1
DH101068
Ball steel
1
DH101117
Sprocket Drive
1
DH101131
Base kick lever
1
39212104
Flange bolt
1
DH191013
Sprocket brake shifter assly
1
39153721
"O" ring
1
DH191023
Dust cap
1
DH101320
Hex. bolt with flange
1
DK101162
Bracket lock
1
01110609
Plain washer
1
39169801
Screw pan cross
1
39177304
Bolt flange
4
31121043
Coller
3
39071111
Plain washer
3
3
20 36DK0014 Kit lever brake
21 36DJ4005 Chain sprocket kit
22 36DK0016 Kit hardware bracket pedal
63
Brand ID: 001MC607
Brand ID: 001MC607
KIT LIST
Kit Part No. Kit Description
23 36DK0017 Kit hardware rod bracket
24 36DK0018 Kit hardware rod torque
25 36DK0019 Kit hardware holder LH
26 36DK0020 Kit outer tube
27 36DH1601 Grommet kit for side cover
28 36DJ4001 Chin case kit
29 36DK0021 Kit hardware mounting bracket
30 36DK0022 Kit hardware leg guard
31 36DK0023 Kit hardware saree guard
64
180
180
Consisting of Following Parts
Part No.
Description
Qty./Kit
30191038
Pin
1
39021911
Plain washer
1
39080808
Split pin
1
30191035
Spring
1
15191026
Pin
1
30191036
Brake adjustment nut
1
39078912
Spring washer
2
3079415
Nut lock
2
39080708
Pin snap
2
39020111
Plain washer
1
30191024
Screw
1
30191017
Nut
1
39021911
Plain washer
1
39072504
Hex bolt
1
DJ181089
Seal dust
2
DJ181088
Ring snap
2
DS181072
Guide bush washer
2
DS181070
Guide bush
2
DH161158
Grommet side cover
4
DH161133
Grommet side cover rear
2
DH161259
Case chain upper assly
1
DH161262
Case chain lower assly
1
DJ181029
Coller faring mounting
6
DJ181064
Grommet fearing mounting
6
39021111
Plain washer
4
39155304
Flange bolt
4
DH161137
Hook leg guard
2
DH161139
Spacer leg guard
2
39227515
Dome cap nut
4
DH161255
Flange bolt
1
39078912
Spring washer
1
39008004
Bolt
1
59040013
Cap bolt
1
39029615
Hex nut
1
DH161144
Cap saree guard
1
DD221003
Plug
1
3
Amendment Sheet (Parts Added)
Sr.No.
Part No.
Description
Qty.
Page No. Fig.No.
65
Brand ID: 001MC607
Brand ID: 001MC607
180
180
66
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
15161069
22150451
28101174
30101061
30101142
30141015
30141028
30141032
30141039
30151012
30151033
30151069
30151075
30151082
30151095
30151105
30161157
30181006
30181011
30181025
30181026
30181028
30181029
30181044
30201029
30201085
30201104
30221004
30221005
30221006
30221009
30221010
30221011
30221033
31101108
31101173
31201029
31201081
35171033
36DH1003
36DH1004
36DH1005
36DH1006
36DH1007
36DH1008
36DH1601
36DH1902
36DH4006
36DJ1004
36DJ4005
3
12
14
21
3
13
10
11
6
7
4
5
2
19
8
6
2
6
3
7
6
17
16
20
7
16
15
1
1
1
1
1
1
1
5
4
8
17
17
5
19
23
8
11
3
1
15
9
7
17
55
35
13
9
15
51
51
51
51
42
39
42
42
43
44
42
37
31
31
47
47
48
48
48
58
59
59
60
60
60
60
60
60
60
11
6
59
14
33
4
16
16
17
17
20
52
40
6
3
43
36DK0005
36DK0007
36DK0008
36DK0009
36DK0010
36DK0011
36DK0012
36DK0013
36DK0014
36DK0015
36DK0016
36DK0017
36DK0018
36DK0019
36DK0020
36DK0021
36DK0023
36DS1001
36DS1001
36DS1802
36DS4002
39188020
39213217
39029215
39029215
39042215
39045411
39055302
39070501
39071111
39071111
39071601
39073817
39074011
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Brand ID: 001MC607
Brand ID: 001MC607
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DH161112
DH161121
DH161145
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DH161170
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DH161194
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Brand ID: 001MC607
Brand ID: 001MC607
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71
Brand ID: 001MC607
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