SPC_Pulsar DTSi UG III SPC (Black Tech, Tablero Digital y Cola Supersonic A)

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

Domed 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.

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 DS10 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 02 66 02

Description

180

Remarks

Ref. Page No. Ref. Page No.

For Sleeve Spark Plug Ref. Page No.

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 DH 1010 50

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.

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 6 7 8 9 10 11 12 13 14 15 16 17 18

DJ 1012 23 DH 1011 95 39 2200 11 36 DK00 04 DS 1012 75 DH 1010 64 DH 1010 65 DH 1012 34 39 2267 01 DH 1010 66 DH 1010 67 39 2199 08 31 1011 73 39 2203 07 39 2183 04 39 2165 11 39 2561 20 DS 1011 54

6

Description Crankshaft assly. comp. Nut Washer Set primary driver & driven Sprocket cam drive Body centrifugal oil filter Cover centrifugal oil filter Gasket centrifugal oil filter Oval Screw Joint Oil Delivery - B Spring Oil Delivery- B Pin Oil delivery joint - B Key woodruff Parallel pin Bolt Plain washer Bearing Ball Square Key

180

Qty/ Veh.

1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1

Remarks

7mm. (Height)

3

Plate No. 7 : BALANCER & BALANCER IDLER GEAR

Description

Qty/ Veh.

No.

Part No.

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

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

11

39 1674 04

Bolt

3

180

Remarks

Alt. DH 1013 59

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.

Part No.

1 2 3 4 5

DK DK DK DH DK

6 7 8 9 10

39 2437 04 39 2606 07 DK 1011 58 DH 1014 96 DK 1011 35

10

1011 1011 1011 1014 1011

59 60 35 93 57

Description

180

Qty/ Veh.

Remarks

Plate No. 10 : GEAR CHANGE MECHANISM

No.

Part No.

Description

180

Qty/ Veh.

Fork Gear Shift Input Fork Gear Shift output Shaft Gear Shift Fork Shaft Gear Shift Fork Drum comp. Gear Shift

1 2 1 1 1

1 2 3 4 5

DH 1017 05 DH 1017 14 DH 1011 44 DJ 1011 49 31 1011 08

Lever comp. Gear Shifter Spring arm reset Spring Gear Shifter return Lever comp. change Damper

1 1 1 1 1

Bolt Socket Parellel pin Guide Gear Shifter Spacer Bush fork gear shift

1 1 1 1 2

6 7 8 9 10

39 2453 04 DH 1010 13 DH 1015 03 DH 1015 02 DH 1012 25

Flanged Bolt Bolt Gear Shift drum Stopper Stopper gear shifter drum Spring gear shifter drum stopper Bolt shift change

1 1 1 1 1

3

Remarks

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 12 39 2531 05 DH 1012 26 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

Qty/ Veh.

No.

Part No.

16 17 18 19 20

DG 1014 98 31 2010 81 DH 1012 64 DH 1012 69 39 1414 02

Gasket (For Drain Bolt) Switch comp.(Neutral) Gasket Neutral Switch Baffle Self tapping Screw

1 1 1 1 1

21 22 23 24 25

39 1845 04 39 1677 04 39 2305 04 DH 1012 78 DH 1011 69

Flanged Bolt Bolt Bolt Plug Starter Motor Bush starter gear inner

1 8 1 1 1

26 27 28

DJ 2010 21 39 2448 11 DH 1014 22

Cable assly. (Battery to Earth) Plain Washer Damper

1 1 1

14

Description

180

Remarks

3

Plate No. 13 : COVER RH

No.

Part No.

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

DJ 1012 41 DH 1011 97 30 1011 42 39 1041 19 DH 1011 41 DH 1011 42 39 2202 07 DG 1014 18 DS 1012 15 39 1074 04 39 0999 06 DH 1010 18 DH 1011 54 DH 1210 15 DH 1210 11 DH 1210 12 DH 1012 81 39 2443 11 36 DH10 04 39 2208 04 DS 1012 52 DS 1012 01 36 DH10 05

Description Cover comp RH Grommet Breather Seal kick Shaft Seal clutch lever 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’ Spring torsion clutch lever Washer Set damper Flanged Bolt ‘bajaj’ Decal Bushing Set of Plate

180

Qty/ Veh.

1 1 1 1 1 1 1 1 1 10 2 1 1 1 1 1 1 1 1 8 1 1 1

Remarks

Ref. Page No.63 Fitted on Cover comp.RH Ref. Page No.63

15

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 14 : COVER MAGNETO

Qty/ Veh.

No.

Part No.

1 2 3 4 5

DJ 1012 09 DH 1011 58 39 2197 21 DH 1011 59 39 1074 04

Cover Magneto Cap Timing Hole ‘O’ Ring Gasket Magneto cover Bolt

1 1 1 1 7

6 7 8 9 10

39 0999 06 DH 1011 57 39 1283 21 DJ 1012 10 36 DH10 06

Pin Dowel Cap Crank Center ‘O’ Ring Cover LH RR Set Damper

2 1 1 1 1

11 12 13 14

39 2208 04 DS 1012 53 36 DH10 07 DJ 1011 90

Flanged Bolt ‘bajaj’ Decal Set of Plate Cover LH with gear shifter sticker

6 1 1 1

16

Description

180

Remarks

Plate No. 15 : CLUTCH

No.

Alt to 39 2452 21 Ref. Page No.63 Fitted on Cover magneto Ref. Page No.63

3

Part No.

1 2 3 4 5

DH 1012 36 DK00 DK 1010 DK 1010 DK 1011

6 7 8 9 10

75 04 75 01 63

Description

180

Qty/ Veh.

Special Nut Set primary driver & driven Clutch Plate Assly Clutch Center Plate Clutch pressure

1 1 1 1 1

DK 1011 49 DK 1011 51 DH 1017 43 39 1674 04 DK 1011 54

Disc Clutch friction Plate Clutch Spring Clutch Capacity Bolt Bolt

5 4 6 1 4

11 12 13 14 15

39 1880 20 DK 1010 78 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

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

17

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 16 : KICK STARTER MECHANISM

No.

Part No.

1 2 3 4 5

DH 1012 DD 1010 36 DH10 DH 1015 DH 1015

6 7 8 9 10

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

11 12 13 14 15

DH DH DH DH DH

16 17 18 19

39 1672 04 39 2276 11 39 0738 17 DH 1015 39

18

1015 1015 1011 1013 1015

28 97 08 37 31

Description

180

36 48 25 21 38

Remarks

Plate No. 17 : CARBURETTOR

No.

Part No.

Description

180

Qty/ Veh.

Remarks Make : Ucal Mikuni Ref. Page No.63 Ref. Page No.64

1 2 3 4 5

DJ DJ DJ DJ DJ

1210 1210 1210 1210 1210

41 51 52 44 53

Carburettor Assly. BS 26 with TPS Vaccum Piston Kit Idling Screw Kit Jet needle(JN) “O” ring

1 1 1 1 1

1 1 1 1 1

6 7 8 9 10

DJ DJ DJ DJ DJ

1210 1210 1210 1110 2011

54 55 56 20 31

Screw Float assly. Jet Holder Kit Magnet Assly. Reed Switch Assly.

2 1 1 1 1

Guide Kick Bolt Flanged Spring Kick Starter Return Bolt flange Stopper

1 3 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

Bolt Flanged Washer Circlip Spindle kick shaft

1 2 2 1

Ref. Page No.63

3

Ref. Page No.63 TPS Assly. Parts

19

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 18 : AIR CLEANER COMP

No.

Part No.

Description

180

Qty/ Veh.

Remarks

Plate No. 19 : SILENCER ASSLY.

No.

Part No.

1 2 3 4 5

DK DK 01 39 DJ

1210 1011 1106 1698 1210

40 62 09 01 39

Air Cleaner comp Bracket Lock Plain Washer Screw Pan cross Connecting Tube

1 1 1 1 1

1 2 3 4 5

DJ DH DJ DH DJ

6 7 8 9 10

DK DK 39 31 39

1210 1210 1773 1210 0711

02 03 04 43 11

Element air filter (fine) Element air filter (coarse) Bolt Flanged Collar Plain Washer

1 1 4 3 3

6 7 8 9 10

11 12

39 1902 04 AA 1210 45

Flanged Bolt Clamp

3 1

11 12 13 14 15

20

3

1012 1013 1012 1013 1010

Qty/ Veh.

Silencer Assly. with CAT converter Seal Shield Muffler Shield Muffler Truss Screw Gasket Exhaust

1 2 1 2 1

39 1970 15 39 1850 04 39 2425 11 DD 1610 71 DH 1611 55

Flanged Nut Flanged Bolt Washer U Nut Damper silencer

2 1 2 1 1

DH DG DH DH DH

Tube silencer mounting Damper (Main Stand) Grommet shield Wire Shield Assly. Dommed Cap Nut

1 1 1 1 2

1611 1611 1014 1015 1015

43 01 46 02 64

Description

180

57 24 81 21 25

Remarks

21

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 20 : SEAT ASSLY. / SEAT LOCK

180

Plate No. 21 : OIL PUMP

180

12

No. 1 2 3 4

22

Part No. DJ DJ 39 DK

2110 2110 1902 2110

03 06 04 07

Description Seat Assly comp Lock Assly seat Flanged bolt Damper at a seat front

Qty/ Veh.

Remarks

1 1 2 1

3

Description

Qty/ Veh.

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

1 3 1 1 1

6

39 2194 21

‘O’ Ring

1

Remarks

23

Brand ID: 001MC607

Brand ID: 001MC607

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

No.

Part No.

1 2 3 4 5

DJ 1110 20 DJ 1110 21 39 1674 04 39 0761 01 DH 1011 99

Magneto Assly. Stator Assly. comp Hex. Bolt with Flange Pan Head Screw Stopper plate (wiring harness)

6 7 8 9 10

DJ 1110 22 39 0746 01 DG 1110 08 DJ 1110 23 DD 1110 11

11 12 13 14 15

DJ DH DH DD DH

24

2011 1110 1110 1110 1110

02 39 40 48 15

Description

180

Qty/ Veh.

Remarks

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

Description

180

Qty/ Veh.

No.

Part No.

1 1 2 2 1

16 17 18 19 20

DD 1110 12 DH 1110 13 DH 2010 18 31 2010 82 DD 2010 24

Grommet H.T. Cable Grommet Spark Plug Regulator Voltage Capacitor Flange Bolt

2 1 1 1 1

Rotor Assly. Screw Pan head Spark plug C.D.I. Assly. Grommet Spark Plug

1 1 2 1 1

21 22 23 24 25

39 0798 15 39 1902 04 DJ 1610 67 39 1680 04 DH 1110 16

Flange Nut Flange Bolt Bracket H.T. Coil Flange Bolt Grommet Sleeve Spark Plug

1 2 1 2 1

AC/DC Regulator H.T. Coil LH H.T. Coil RH Cap Spark Plug Cap Spark Plug

1 1 1 1 1

Remarks

With Aluminum bracket

3

25

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 23 : STARTER ASSEMBLY (FOR SELF START)

Part No.

1 2 3 4 5

DH 1015 78 DH 1011 86 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

6 7 8 9

DH 1011 71 DH 1011 72 DH 1011 88 39 2437 04

Shaft starter counter Collar starter counter Gear comp. starter counter assly. Bolt socket

1 1 1 3

10 11 12 13 14 15

DJ 1110 20 39 1074 04 DH 1013 72 39 2285 01 DH 1011 64 DJ 1011 09

Motor assly. starter Bolt Cover starter motor Slotted c’sunk screw Spring Bush For Spring Starter

1 2 1 1 5 5

16 17

DH 1011 63 DH 1015 33

Roller Bush Spring Starter Clutch

5 5

26

Description

Qty/ Veh.

No.

180

Remarks

For stopper plate

3

Plate No. 24 : ENGINE MOUNTINGS

Qty/ Veh.

No.

Part No.

1 2 3 4 5

DH 1611 70 DH 1612 68 DH 1612 69 39 2312 04 39 1970 15

Bkt. Assly.eng.mtg.front Bkt. comp.LH eng.mtg.front Bkt. comp.RH eng.mtg.front Bolt Flanged Nut Flanged

1 1 1 4 8

6 7 8 9 10

DJ DJ 39 39 39

Bkt. Bkt. Bolt Bolt Bolt

1 1 3 1 1

11 12 13 14 15

DH 1612 73 39 1967 04 39 2414 04 DH 1613 01 DH 1612 45

1611 1611 2157 2412 2413

14 15 04 04 04

Description

180

comp. LH eng.mtg. lower comp. RH eng.mtg. lower Flanged Flanged Flanged

Bush in frame Bolt Hex.soc.hd.cap bolt Bkt.comp.RH eng.rear ‘U’ Nut

Remarks

Alt. 39 2311 04

1 1 1 1 3

27

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 24 : ENGINE MOUNTINGS

No. 16 17 18 19 20

28

Part No. 39 39 39 DJ DJ

2310 2311 2457 1610 1610

04 04 11 88 89

Description Flanged bolt Bolt Washer Bracket LH Engine Hanger Bracket RH Engine Hanger

180

Qty/ Veh.

Remarks

2 1 1 1 1

3

Plate No. 25 : FRAME & FRAME FITTINGS

Qty/ Veh.

No.

Part No.

1 2 3 4 5

DJ 1612 24 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

180

Remarks Incl. Bush, Races & Cup rear

Ref.Page No.64

29

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 26 : SWING ARM / REAR SHOCK ABSORBER

Part No.

1 2 3 4 5

DG 1710 38 39 0714 11 DJ 1710 19 DH 1710 14 DJ 1710 25

Bolt Precoated Plain washer Rear Shock Absorber Bush swing arm Swing arm assly.

2 8 2 4 1

6 7 8 9 10

35 1710 33 DH 1710 13 DH 1710 15 DJ 1710 08 39 0553 02

Grease nipple Collar swing arm Dust seal swing arm Chain slider Screw

2 2 4 1 2

11 12 13 14 15

39 0454 11 DJ 1710 32 DH 1710 19 DJ 1510 36 DJ 1510 37

Plain washer Shaft swing arm ‘U’ nut swing arm Adjuster chain LH Adjuster chain RH

2 1 1 1 1

16 17 18 19 20

DJ 39 39 39 39

Plate Chain Adjuster Hexagon nut Plain washer(Nylon) Domed Cap Nut Spring Washer

2 4 2 2 2

30

1510 0292 0740 0712 0737

47 15 11 15 12

Description

Qty/ Veh.

No.

180

Remarks

3

Plate No. 27 : RIDER FOOT REST

Description

180

Qty/ Veh.

No.

Part No.

1 2 3 4 5

DJ 1611 30 39 2310 04 DJ 1611 31 DH 1610 53 DH 1611 94

Main step LH assly. comp. Flange bolt Main step RH assly. comp. Rubber main step Kick stopper

1 4 1 2 1

6 7 8 9 10

39 0963 15 39 0897 04 DH 1610 56 DH 1611 00 DJ 1610 90

Domed Cap nut Bolt Plate Comp. Lower Mounting Spacer Main Step Damper Footrest

2 2 2 2 2

Remarks

31

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 28 : PILLION FOOT REST / HOLDER

No.

Part No.

1 2 3 4 5

DJ DJ DJ DJ DJ

6 7 8 9 10 11 12 13

32

1612 1612 1611 1611 1611

56 57 28 29 22

Description

180

Qty/ Veh.

Remarks

Plate No. 29 : MUDGUARD FRONT & REAR

No.

Part No.

Description

180

Qty/ Veh.

Holder LH step Holder RH step Pillion step assly. comp. LH Pillion step assly. comp. RH Rubber pillion step

1 1 1 1 2

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

DJ 1611 86 DH 1610 61 30 1410 31 39 1040 11 39 0784 08

Plate side pillion step Pin pillion step ‘O’ ring Plain washer Split pin

2 2 2 2 2

6 7 8 9 10

39 39 39 DJ 39

1672 0711 0798 1612 1680

04 11 15 54 04

Flange bolt Plain washer Flange nut Fender rear Flange bolt

2 4 2 1 2

39 1069 01 39 0292 15 39 1741 04

Bolt Nut Flanged Bolt

1 1 2

11 12 13 14 15

DJ 1610 91 DH 1611 83 39 2420 01 39 0326 15 39 0242 11

Grommet Front Fender Mud flap rear Screw Nylock nut Plain washer

4 1 3 3 6

16

36 DS40 02

Guard Kit

1

Stopper bolt Bott. Mtg. LH & RH Holder Step

3

Remarks

Fender front mtg. For cables

33

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 30 : STAND ASSEMBLY

Qty/ Veh.

Remarks

Plate No. 31 : TYRE / TUBE / RIM

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

1 2 3 4 5

DJ DS DS DJ DS

6 7 8 9 10

DJ 1611 87 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

6

DS 1510 29

11 12 13 14 15

DH 2010 55 DH 2010 26 39 0790 12 30 2010 64 DH 1613 02

Side stand switch Screw pan cross Spring washer Band Bkt. Side stand switch

1 2 2 1 1

34

Description

180

No.

Part No. 1510 1510 1510 1510 1510

77 48 49 78 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

Alt. 39 1523 01

35 3

Brand ID: 001MC607 Plate No. 32 : FRONT HUB (FOR DISC BRAKE)

No.

Part No.

1 2 3 4 5

39 39 DE 30 DE

6 7 8 9 10 11 12 13 14

36

0787 2688 1510 1510 1510

Qty/ Veh.

Remarks

Plate No. 33 : FRONT MASTER CYLINDER

No.

Part No.

Description

180

(FOR DISC BRAKE)

Qty/ Veh.

Remarks

Pin cotter Bearing ball Spacer assly. Seal oil Plate drive

1 2 1 1 1

1 2 3 4 5

DJ DJ DJ DJ DJ

1910 1510 1910 1910 1910

23 76 24 25 26

Major Kit - Master Cylinder Hose Brake Front Lever Grip RH Banjo Bolt Washer Copper

1 1 1 2 4

DE 1510 08 DJ 1510 14 39 0786 15 39 0781 11 DD 1510 36

Seal oil Disc Hex. slotted nut Plain washer Hex. soc. hd. bolt

1 1 1 1 6

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

DH DJ DS DJ

Case meter gear Speedometer sensor Spacer Front Axle with head

1 1 1 1

11 12 13 14 15

DJ 1910 DJ 2011 DJ 1910 DJ 1910 36 DH19

32 09 34 35 02

Cylinder Master Front brake switch Reservoir Cover Diaphragm Oil Window Kit

1 1 1 1 1

Ref. Page No.64

16 17

DJ 0100 22 36 DH19 01

Disc brake kit - KBX Minor Kit

1 1

N.I. N.I.

1510 1510 1510 1510

08 20 06 33 12

Description

180

62 93 58 81

37 3

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 34 : FRONT DISC BRAKE

Qty/ Veh.

No.

Part No.

1 2 3 4 5

DJ 1510 65 DJ 1510 67 DH 1510 40 39 1769 04 DJ 1510 68

Disc, Front Caliper Assly. Front Bolt, Disc Plate Bolt Flanged Spring Pad

1 1 6 2 1

6 7 8 9 10

DJ DJ DJ DJ DJ

Bleeder Screw Bleeder Cap Disc Pad Set Insulator Protection Boot

11 12

DJ 1510 74 DJ 1510 75

Minor Kit - Caliper Major Kit - Caliper

38

1510 1510 1510 1510 1510

69 70 71 72 73

Description

180

Remarks

Plate No. 35 : REAR HUB

No.

Part No.

1 2 3 4 5

DJ 39 39 30 DJ

1 1 1 1 1

6 7 8 9 10

1 1

11 12 13 14 15

Alt. 39 2038 04

1510 2686 2687 1510 1510

Qty/ Veh.

Drive Chain Lock Bearing ball Bearing ball Collar bearing Damper

1 1 1 1 1

DJ 1510 85 30 1510 12 30 1510 38 DD 1510 09 DJ 1510 59

Panel rear brake Cam brake Ring ‘O’ Indicator Lever brake

1 1 1 1 1

39 39 30 30 DS

Bolt Nut Shoe brake assly. Spring Coupling

1 1 1 2 1

2447 0798 1511 1510 1510

53 20 20 75 88

Description

180

04 15 05 69 68

Remarks

39 3

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 35 : REAR BRAKE

No.

Part No.

16 17 18 19 20

39 2240 DJ 1510 30 1510 36 DJ40 DS 1510

21 22 23 24 25 26 27 28 29

40

Qty/ Veh.

Bearing ball Sleeve Seal oil Chain Sprocket Kit Lock washer

1 1 1 1 3

DS 1510 73 39 0794 15 DJ 1510 32 DH 1710 19 39 0801 15

‘D’ Bolt Hex. lock nut Axle ‘U’ nut Nut

6 6 1 1 1

DJ DJ 39 39

Collar Collar Plain washer Plain washer

1 1 1 1

1510 1510 2566 2567

20 33 82 05 74

Description

180

35 34 11 11

Remarks

3

Plate No. 36 : REAR BRAKE PADAL

No.

Part No.

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

DH 1910 01 DJ 1910 21 39 2121 04 DH 1910 13 DH 1910 06 39 1537 21 DH 1910 23 DJ 1910 10 30 1910 38 39 0219 11 39 0808 08 30 1910 35 15 1910 26 30 1910 36 DJ 1510 42 DH 1510 29 30 1510 95 39 0789 12 39 0794 15 39 0807 08 39 0201 11

Description Brake Pedal Shaft assly. brake Pedal Flange bolt Spacer brake shaft assly. Spring ‘O’ Ring Dust Cap Rod assly. brake Pin Plain washer Split pin Spring Pin Brake adjuster nut Rod torque Hex. bolt Hex. bolt Spring washer Nut hex. Pin snap Plain Washer

180

Qty/ Veh.

Remarks

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

41

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 37 : HANDLE BAR

Qty/ Veh.

Remarks

Plate No. 37 : HANDLE BAR

No.

Description

Qty/ Veh.

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

16 17 18 19 20

DH DH DH DH DJ

1910 1910 1810 1810 1810

17 19 11 40 39

Grip Assly. RH Boot for lever Handle bar weight Hex. soc.hd. cap screw Pad Holder Handle

1 1 2 2 1

6 7 8 9 10

DJ 1910 09 DJ 1910 04 DH 1910 02 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

21 22 23 24 25

DJ DJ 30 DS 39

2210 2210 1910 1810 1943

03 04 48 22 04

Mirror assly. LH Mirror assly. RH Band Switch assly.ignition Flange bolt

1 1 4 1 2

11 12 13 14 15

30 1910 24 30 1910 17 39 0219 11 39 0725 04 DH 1910 07

Screw Nut Plain washer Hex. bolt Grip LH

1 1 1 1 1

26

DJ 2010 90

Clutch Switch

1

3

Part No.

180

No.

42

Description

180

Remarks

Alt. 39 2427 04

43

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 38 : FRONT FORK

No.

Part No.

Description

180

Qty/ Veh.

Remarks

Plate No. 38 : FRONT FORK

No.

Part No.

Description

180

Qty/ Veh.

1 2 3 4 5

DJ DJ DJ DJ DJ

1810 1810 1810 1811 1811

89 88 87 01 02

Seal dust Ring snap Oil seal Outer Tube LH Outer Tube RH

2 2 2 1 1

16 17 18 19 20

DH 1810 15 30 1810 29 30 1810 28 DH 1810 56 DJ 1810 52

Bolt fork ‘O’ ring Seat fork spring Holder fork upper Cover Trail B

2 2 2 1 4

6 7 8 9 10

30 30 DS DJ DJ

1810 1810 1810 1810 1810

26 25 77 45 44

Gasket Bolt Cylinder comp.fork Clamp for Bellow Bellow

2 2 2 2 2

21 22 23 24 25

DJ 1811 00 DJ 1810 41 39 0789 12 39 1813 04 DH 1810 23

Fork front Holder fork under Spring washer Bolt Bearing cone

1 1 2 2 1

11 12 13 14 15

DJ 1810 70 DH 1810 09 DJ 1811 03 DJ 1811 04 30 1810 44

Clamp Hose Pipe Grommet Top Pipe comp.suspension inner Spring front fork Bolt

1 2 2 2 1

26 27 28 29 30

DJ DJ DG DS DS

Cushion Rubber Lamp Shade asly. Socket Bolt Guide Bush Washer Guide Bush

2 1 2 2 2

31 32 33

DS 1810 71 DM 1810 10 DS 1810 85

Slide Bush Washer Spacer Tube

2 2 2

44

3

1810 1811 1810 1810 1810

85 48 08 72 70

Remarks

45

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 39 : PAINTED PARTS & DECALS

Qty/ Veh.

No.

Part No.

1

DH 7102 X3 DH 7102 X4 DH 7102 X6

Fuel Tank with Decal Fuel Tank with Decal Fuel Tank with Decal

1 1 1

FOR BLACK COLOUR FOR RED COLOUR FOR BLUE COLOUR

2

DK 7301 X3 DK 7301 X4 DK 7301 X6

Side cover LH Side cover LH Side cover LH

1 1 1

FOR EBONY BLACK FOR FLAME RED FOR M BLUE

3

DK 7302 X3 DK 7302 X4 DK 7302 X6

Side cover RH Side cover RH Side cover RH

1 1 1

FOR EBONY BLACK FOR FLAME RED FOR M BLUE

46

Description

180

Remarks

Plate No. 39 : PAINTED PARTS & DECALS

Description

180

Qty/ Veh.

No.

Part No.

Remarks

4

DK 7303 X3 DK 7303 X4 DK 7303 X6

Seat Cowl Assly. Seat Cowl Assly. Seat Cowl Assly.

1 1 1

FOR EBONY BLACK FOR FLAME RED FOR M BLUE

5

DJ 7302 X3 DJ 7302 X4 DJ 7302 X6

Front Fender Front Fender Front Fender

1 1 1

FOR EBONY BLACK FOR FLAME RED FOR MET.BLUE

6

DH 1410 20

Seat tape

1

7

DJ 7401 X4 DJ 7401 X6 DJ 7401 X3

Fairing Fairing Fairing

1 1 1

8 9 10

36 DK00 06 DK 1011 23 DK 1011 24

Decal Set Cover Side Mesh LH Cover Side Mesh RH

1 1 1

11

59 0200 01

Self tap screw

6

FOR RED COLOUR FOR BLUE COLOUR FOR BLACK COLOUR

47

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 40 : PETROL COCK, CAP TANK & GAUGE FUEL

Part No.

1 2 3 4 5

DH 1410 50 39 0840 01 39 2381 04 DJ 1410 07 DJ 1811 40

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 201013 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

48

Description

Qty/ Veh.

No.

180

Remarks

Alt. 39 1780 01

3

Plate No. 41 : FITTINGS PET. TANK SI. COVER & COVER SEAT

Description

Qty/ Veh.

No.

Part No.

1 2 3 4 5

36 DH16 01 DH 1410 31 39 1607 01 DH 1612 21 DJ 1811 10

Grommet Kit For side cover Tape tank inner Screw Lock for side cover with key Lock Set (4 in 1) with Key

1 2 2 2 1

6 7 8 9

DH 1410 23 DJ 1410 08 39 1556 04 39 2424 11

Damper Damper front Flanged Bolt Plain Washer

1 2 1 1

180

Remarks Ref. Page No.64 Alt. DG 1611 21 N.I.

49

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 42 : METER ASSEMBLY

No.

Part No.

1 2 3

DJ 1910 60 39 1778 02 DJ 2011 37

50

Description Meter Assly / Instrument Cluster Self Tapping Screw Dust Cover Electronic Cluster

180

Qty/ Veh.

Remarks

Plate No. 43 : CONTROL CABLES

No.

1 4 1

3

Part No.

1 2 3 4 5

DJ DJ DJ DJ DJ

1910 2011 1910 1910 2011

61 44 15 12 29

6 7

30 1910 67 DJ 2011 44

Description Cable Assly. Cable Cable Cable

Accelerator Speedo Sensor with cable Clutch Starter (Choke) Speedometer

Oil Seal Inner cable Speedometer

180

Qty/ Veh.

Remarks

1 1 1 1 1 1 1

51

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 44 : CHAIN CASE

Qty/ Veh.

No.

Part No.

1 2 3 4 5

36 DJ40 04 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

52

Description

180

Plate No. 45 : HEAD LAMP & FAIRING

Remarks

No.

Part No.

Ref. Page No.

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

DJ 2011 32 DJ 1811 19 DJ 1810 33 DF 1810 98 39 2141 24 DL 1810 10 DJ 1810 37 39 1907 01 DJ 1810 69 DH 1810 52 DJ 1810 29 DJ 1810 64 39 0211 11 39 1553 04 DJ 1810 65 39 0716 01 39 1524 01 DD 2011 60 GH 2010 12 DJ 1811 16

Rear side Mtg. Front side Mtg.

3

Description Head Lamp assly. without bulb Back cover Wind Shield Bolt Non Metallic Washer Well Nut Decal Wind Shield M5 x 15L mashroom HD Packing Fairing Fairing mounting upper bracket Collar Fairing Mounting Grommet Fairing Mounting Plain Washer Hex. Flanged Bolt Clip Nut Screw pan cross Screw pan cross Lamp 12V 35/35W-HS1 Amber bulb Fairing Assly.

180

Qty/ Veh.

Remarks

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

53

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 46 : INDICATOR LIGHT ASSEMBLY

No.

Part No.

1 2 3 4 5

DJ DJ DJ DJ DJ

6 7 8

39 1907 01 DJ 2011 51 DJ 2011 50

54

2011 2011 2011 2011 2011

15 16 13 14 30

Description

180

Qty/ Veh.

Remarks

Plate No. 47 : TAIL LAMP ASSLY/ FRONT & REAR NO. PLATE

No.

Part No.

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

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

Hex. nut with flange Lens for blinker Amber Bulb

4 1 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

3

1972 2010 2010 1610 1611

15 29 24 72 45

180

Remarks

For Front No. Plate

55

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 48 : ELECTRICAL EQUIPMENTS

180

Plate No. 49 : ELECTRICAL EQUIPMENTS 1

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 DJ DJ DH DH

1611 2011 2010 1910 2010

47 27 29 12 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 DK DJ 30 30

2010 2010 2010 2011 2010

25 16 28 04 85

Assly DC flasher / damper Starter Relay / Damper Relay for Interlock Fuse box Assly. Fuse

1 1 1 1 1

16 17

DJ 2011 40 DJ 2010 20

Cable assly. (Battery to Earth) Cable assly. (Battery to St.Relay)

1 1

56

Description

Qty/ Veh.

No.

Remarks

N.S.

3

180

2

Description

Qty/ Veh.

No.

Part No.

1 * * * *

DH 2210 04 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

Remarks

For reference only not to service separately

2

57

Brand ID: 001MC607 Plate No. 50 : ACCESSORIES / GRAB HANDLE

Qty/ Veh.

No.

Part No.

1 2 3 4 5 6 6 7 8 9 10

DJ 1612 26 DH 1611 37 DH 1611 39 39 2275 15 DH 1612 94 DH 1613 03 DH 1612 55 39 0789 12 39 0080 04 59 0400 13 39 0296 15

Leg Guard Hook leg guard Spacer leg guard Domed cap nut Sari Guard Assly Grommet Sari Guard Flange Bolt Spring Washer Bolt Cap Bolt Hex Nut

1 2 2 4 1 1 1 1 1 1 1

11 12 13 14 15 16 17

DH 1611 44 DJ 1612 58 39 2310 04 DD 2210 03 DH 1613 02 DJ 1610 79 DJ 1610 80

Cap Sari Guard Grab Handle Bolt Flange Plug Boot Sari Guard Foam LH For grab Foam RH For grab

1 1 4 2 1 1 1

58

Description

180

Remarks

3