Manual de Partes Pulsar 180 UG4

180 UG4
180 UG4
Bajaj Auto Limited
Akurdi Pune 411 035 India
Tel +91 20 27472851

Fax +91 20 27407385
www.bajajauto.com
Spare Parts Catalogue

(EXPORT)
Notice
All information contained in this manual is based on the latest
product information at the time of publication. Bajaj Auto Limited
accepts no liability for any inaccuracies or omissions in this
publication, although every possible care has been taken to
make it as complete and accurate as possible. All procedures
and specifications subject to change without prior notice. The
right is reserved to make such changes at any time without prior
notice and without incurring an obligation to make such changes
to product manufactured previously. Contact your authorized
Bajaj Dealer for the latest information on product improvements
incorporated after this manual was issued.
DOC. NO.: 71111553
REV. 01, MAR. 2012
Foreword
Instructions
We have pleasure in presenting the Spare Parts Catalogue for Pulsar 180
CC UG IV Motorcycle. This catalogue has been specially designed to assist
you in selecting the correct parts for procurement to maintain 100%
availability.
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.
The Bajaj spares are subjected to the stringent quality control standards to
ensure longer life of the vehicle. It is therefore necessary that only the
Genuine Bajaj Spares are used.
In a continual effort to improve Performance and Efficiency of the vehicles,
Specifications, Diagrams, Illustrations and Part Numbers can change without
notice. Consequently, the description in this Spare Parts Catalogue cannot
therefore be final and binding on us.
The modifications / alterations which are carried out after the issue of
catalogue, will be conveyed to you through our Service Circulars. You
requested to make necessary corrections in the Parts Catalogue as per
circulars so as to keep your catalogue up-to-date. This will ensure
appropriate and speedy delivery of the Spare Parts as the order placed
bear the latest part numbers.
this
are
the
the
will
In case, if you need any technical assistance contact the concerned Regional
Office or write to us on the following address :
Bajaj Auto Limited
International Business
Akurdi, Pune 411 035 India
Phone : 020-27472851
Fax : 020-27407395
Email : spdexports@bajajauto.co.in
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
Rr.
Rear
Std.
Standard
L
Length
A/t.
Alternate
R.H.
Right hand
L.H.
Left hand
Hex.
Hexagonal
AR
As required
Index
Plate No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
180
Description
Cover Cylinder Head
Cylinder Head
Valve
Camshaft / Tensioner
Cylinder & Piston
Crankshaft
Balancer & Balancer Idler Gear
Transmission
Change Drum / Shift Fork
Gear Change Mechanism
Engine Assly. & Crankcase RH
Crankcase LH
Cover RH
Cover Magneto
Clutch
Carburettor
Air Cleaner Comp
Silencer Assly.
Oil Pump
Starter Assly.
Magneto / C.D.I. /H.T. Coil
Seat Assembly / Seat Lock
Engine Mounting
Frame & Frame Fittings
Swing Arm / Rear Shock Absorber
Rider Foot Rest
Pillion Foot Rest / Holder
Mudguard - Front & Rear
Stand Assembly
Tube / Tyre / Rim
Front Hub (For Disc Brake System)
Page No.
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
Index
Plate No.
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
180
Description
Front Master Cylinder
Front Disc Brake
Rear Hub
Rear Brake Padal
Handle Bar
Front Fork
Painted Parts & Decals
Petrol Cock, Cap Tank & Gauge Fuel
Fitting Petrol Tank Spoiler, Side Cover,
Seat Cower
Meter Assly
Control Cables
Chain Cover
Head Lamp & Fairing
Indicator Light Assly
Tail Lamp Assly / Front & Rear No.Plate
Electrical Component
Tool Kit
Accessories / Grab Handle
Page No.
64
66
68
70
72
74
76, 78
80
82
84
86
88
90
92
94
96
98
100
Pictorial Index
180
Pictorial Index
180
PLATE NO. : 1
Cover Cylinder Head
PAGE NO.
1&2
PLATE NO. : 2
Cylinder Head
PAGE NO.
3&4
PLATE NO. : 5
CYLINDER & PISTON
PAGE NO.
9 & 10
PLATE NO. : 6
CRANKSHAFT
PAGE NO.
11 & 12
PLATE NO. : 3
VALVE
PAGE NO.
5&6
PLATE NO. : 4
PAGE NO.
7&8
PLATE NO. : 7
PAGE NO.
13 & 14
PLATE NO. : 8
CHANGE DRUM / SHIFT FORK
PAGE NO.
15 & 16
Pictorial Index
180
Pictorial Index
180
PLATE NO. : 9
PAGE NO.
17 & 18
PLATE NO. : 10
PAGE NO.
19 & 20
PLATE NO. : 13
Cover RH
PAGE NO.
25 & 26
PLATE NO. : 14
Cover Magneto
PAGE NO.
27 & 28
PLATE NO. : 11
PAGE NO.
21 & 22
PLATE NO. : 12
Crankcase LH
PAGE NO.
23 & 24
PLATE NO. : 15
CLUTCH
PAGE NO.
29 & 30
PLATE NO. : 16
Carburettor
PAGE NO.
31 & 32
Pictorial Index
180
Pictorial Index
180
PLATE NO. : 17
Air Cleaner Comp
PAGE NO.
33 & 34
PLATE NO. : 18
Silencer Assly.
PAGE NO.
35 & 36
PLATE NO. : 21
PAGE NO.
41 & 42
PLATE NO. : 22
PAGE NO.
43 & 44
PLATE NO. : 19
Oil Pump
PAGE NO.
37 & 38
PLATE NO. : 20
Starter Assly.
PAGE NO.
39 & 40
PLATE NO. : 23
Engine Mounting
PAGE NO.
45 & 46
PLATE NO. : 24
PAGE NO.
47 & 48
180
Pictorial Index
180
PAGE NO.
49 & 50
PLATE NO. : 26
Rider Foot Rest
PAGE NO.
51 & 52
PLATE NO. : 29
Stand Assembly
PAGE NO.
57 & 58
PLATE NO. : 30
Tube / Tyre / Rim
PLATE NO. : 27
PAGE NO.
53 & 54
PLATE NO. : 28
PAGE NO.
55 & 56
PLATE NO. : 31
PAGE NO.
61 & 62
PLATE NO. : 32
PAGE NO.
59 & 60
EU
PLATE NO. : 25
Pictorial Index
OGRIP
EU
PAGE NO.
63 & 64
OGRIP
Pictorial Index
PLATE NO. : 33
Front Disc Brake
180
PAGE NO.
65 & 66
PLATE NO. : 34
Rear Hub
PAGE NO.
67 & 68
Pictorial Index
PLATE NO. : 37
Front Fork
180
PAGE NO.
73 & 75
PLATE NO. : 38
PAGE NO.
75/76/77/78
180 DTS-i
PLATE NO. : 36
Handle Bar
PAGE NO.
71 & 72
E
-R
I G N I T
FF O
L O
N
CK
LO
PUS
PAGE NO.
69 & 70
PLATE NO. : 35
Rear Brake Padal
PLATE NO. : 39
PAGE NO.
79 & 80
PLATE NO. : 40
Fitting Petrol Tank Spoiler, Side
Cover, Seat Cower
PAGE NO.
81 & 82
Pictorial Index
180
PLATE NO. : 41
Meter Assly
PAGE NO.
83 & 84
PLATE NO. : 42
Control Cables
PAGE NO.
85 & 86
Pictorial Index
PLATE NO. : 45
PAGE NO.
91 & 92
PLATE NO. : 46
PAGE NO.
93 & 94
PAGE NO.
95 & 96
PLATE NO. : 48
Tool Kit
PAGE NO.
97 & 98
10
12
6
E
180
km/h
x 1 0 0 rpm
SIDE
PLATE NO. : 43
Chain Cover
STAND
PAGE NO.
87 & 88
PLATE NO. : 44
Head Lamp & Fairing
PAGE NO.
89 & 90
PLATE NO. : 47
Electrical Components
Pictorial Index
PLATE NO. : 49
180
PAGE NO.
99 & 100
Plate No.: 1
180
Brand ID: 001MC607
Cover Cylinder Head

No. Part No.
1
2
9
11
Qty.
/Veh. Remarks
DJ 1013 90
36 DJ40 34
Head Cylinder with Cover

Head Cylinder with Cover (W/o NRB)
1
1
2
3
4
5
DJ 1012 17
36 DS10 01
DS 1011 66
DS 1010 96
Cover Tappet
O Ring Kit for Cover Cyl. Head
Silent Bush
Camshaft Cap
2
1
1
1
6
7
8
9
10
39 2647 15
DS 1013 16
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
11
DG 1014 98
Gasket
Description
From Eng, No.

BUG20501
Ref. Page No. 101
10
3
10
11
Front Wheel Direction
Plate No.: 2
180
Brand ID: 001MC607
Cylinder Head
No. Part No.
10
11
Description
Qty.
/Veh. Remarks
1
2
3
4
5
36 DS10 01
39 1660 05
DJ 1010 12
DH 1015 08
DJ 1012 15
O Ring Kit for Cover Cyl. Head

Stud (Exhaust)
Gasket Cylinder Head
Damper Cylinder Head
Intake Pipe
1
2
1
5
1
6
7
8
9
10
39 2539 21
DJ 1210 22
DH 1210 38
39 1674 04
DH 1110 12
O Ring (Intake Pipe)

Carburettor Insulator
Clamp for Insulator
Hex. Bolt / Flange
Sleeve - Spark Plug
1
1
2
2
1
11
39 2608 01
Grub Screw
Ref. Page No.101
For Sleeve
Spark Plug
2
2
6
8
7
8
Plate No.: 3
180
Brand ID: 001MC607
Valve
No. Part No.
1
Qty.
/Veh. Remarks
DS 1013 35
DK 1017 48
Rocker Arm Shaft - Intake

Rocker Arm Shaft - Intake W/o NRB
1
1
DS 1013 36
DK 1017 51
Rocker Arm Shaft - Exhaust

Rocker Arm Shaft - Exhaust W/o NRB
1
1
DS 1013 33
DK 1017 55
Rocker Arm with roller

Rocker Arm
2
2
4
5
DG 1010 29
39 2017 19
Cotter valve
Seal valve stem
4
2
6
7
8
DK 1013 26
36 DJ10 04
DS 1013 66
DH 1012 95
Valve Repair Kit

Valve Kit
Wave washer
Wave washer
1
1
2
2
59 1100 02
39 2440 11
Plain washer
Plain Washer
4
4
9
4
Description
2
2
9
3
1
From Eng, No.

BUG20501
From Eng, No.
BUG20501
From Eng, No.
BUG20501
Ref. Page No. 101

Ref. Page No. 101
From Eng, No.
BUG20501
From Eng, No.
BUG20501
Plate No.: 4
180
Brand ID: 001MC607
No. Part No.
1
2
3
Description
Qty.
/Veh. Remarks
4
5
CS 1011 28
DJ 1013 72
JC 1010 86
39 2542 20
39 1880 20
36 DH40 30
Ring O
Camshaft Assembly
Bearing Ball 6302 RS1/C3H
Bearing - Ball-15X42X13
Bearing Ball :- 15 X 32 X 9 (6002-C3)
Guide Chain Kit
1
1
1
1
1
1
6
7
8
9
10
DS 1012 76
DH 1014 12
DH 1010 48
DK 1013 86
JC 1010 35
Sprocket cam Driven (32 T)

Collar cam Sprocket
Special camshaft washer
Pre Coated Socket Head Cap Bolt M8x40
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
3
1
15
5
10
12
11
14
13
Plate No.: 5
180
Brand ID: 001MC607
Cylinder and Piston

No. Part No.
1
2
3
4
5
DJ 1010
39 2181
DJ 1011
DJ 1011
39 2132
04
06
58
06
17
6
7
8
9
10
11
12
DJ 1013 71
DK 1015 92
DD 1210 07
31 1210 06
DH 1014 14
39 1689 04
39 2448 11
Description
Qty.
/Veh. Remarks
Gasket Cylinder
Pin dowel
Piston Assly. Std.
Ring Set Piston
Ring Snap
1
4
1
1
2
Cylinder Block / Piston Assly

Oil Pipe Assly
Bolt Special
Gasket
Damper
Bolt (dummy for Temp sensor)
Washer (dummy for Temp sensor)
1
1
2
4
6
1
1
6
12
3
11
10
1
8
4
7
9
5
10
Plate No.: 6
180
Brand ID: 001MC607
Crankshaft
No. Part No.
14
Description
Qty.
/Veh. Remarks
1
2
3
4
5
JC 1010 01
39 2183 04
39 2165 11
31 1011 73
DS 1011 54
Crankshaft assly. comp.

Bolt
Plain washer
Key woodruff
Square Key
1
1
1
1
1
6
7
8
9
10
39 1931 20
DK 1012 48
39 2203 07
36 DK00 38
DH 1010 64
Bearing Ball
Sprocket cam drive
Parallel pin
Set primary driver & driven
Body centrifugal oil filter
1
1
1
1
1
11
12
13
14
DH 1011
DH 1010
36 DH40
DK 1014
Nut
Cover centrifugal oil filter
Kit centrifugal oil filter
Oil plunger
1
1
1
1
Ref. Page No.101
1
12
95
65
19
80
7mm. (Height)z
Ref. Page No.101
3
2
11
13
10
11
12
Plate No.: 7
180
Brand ID: 001MC607

No. Part No.
1
3
2
10
8
Description
Qty.
/Veh. Remarks
DJ 9025 03
DJ 1016 89
Body Balancer Assly.

Body Balancer Assly.
1
1
2
3
4
5
DH 1010 72
39 1672 04
DH 1014 32
39 2152 20
Bearing stopper
Bolt
Assly. Balancer Idler Gear comp.
Needle roller bearing
1
1
1
2
6
7
8
9
10
DH 1014 24
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
12
39 1674 04
DH 1013 73
Bolt
Scissor Balancer Idler
3
2
from Eng.
DJZCCG36058
11
5
9
7
6
6
7
5
13
12
12
14
Plate No.: 8
180
Brand ID: 001MC607
Transmission
No. Part No.
1
16
13
2
5
15
14
3
12
11
10
9
17
19
18
11
21
20
5
23
22
24
15
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DK 1014 71
39 2158 11
DK 1011 03
DH 1010 79
DH 1012 35
Shaft Input Transmission

Washer Plain
Gear 4th Drive
Washer Spline
External Circlip
1
1
1
3
4
6
7
8
9
10
DK 1011 02
DK 1011 04
DH 1010 84
39 2160 11
DK 1011 44
Gear 3rd Drive

Gear 5th drive
Gear 2nd drive
Thrust washer
Shaft output Transmission
1
1
1
1
1
11
12
13
14
15
39 2166 11
DK 1011 05
39 2159 11
DK 1011 06
DH 1011 11
Washer Plain
Gear 3rd Driven
Thrust Washer
Gear 4th Driven
Bush 1st driven
2
1
1
1
1
16
17
18
19
20
DK
DK
DH
DH
DK
Gear 1st driven

Gear 5th Driven
Bush 2nd driven
Gear 2nd Driven
Collar Sprocket
1
1
1
1
1
21
22
23
24
DK 1013 52
DV 1010 48
DJ 1010 63
AA 1014 37
O Ring Sprocket Collar

Sprocket Drive
Plate Drive Sprocket
Screw Pre Coated
1
1
1
2
1011
1011
1013
1013
1012
18
07
19
33
45
16
Plate No.: 9
180
Brand ID: 001MC607

No. Part No.
7
4
DK
DK
DH
DH
DK
1011
1011
1011
1014
1013
59
60
46
93
82
6
7
8
9
10
39 2639 04
39 2606 07
DK 1013 61
DH 1014 96
DK 1011 35
Qty.
/Veh. Remarks
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
Bolt Socket
Parellel pin
Guide Gear Shifter
Spacer
Bush fork gear shift
1
1
1
1
3
10
17
1
2
3
4
5
Description
18
Plate No.: 10
180
Brand ID: 001MC607

No. Part No.
9
2
8
6
10
1
16
3
1
2
3
4
5
DH
DH
DH
DK
DH
6
7
8
9
10
1017
1011
1011
1011
1015
05
43
44
82
09
Description
Qty.
/Veh. Remarks
Lever comp. Gear Shifter

Spring Slider Arm Reset
Spring Gear Shifter Return
Lever gear shift
Damper
1
1
1
1
1
39 2453 04
DH 1013 93
DH 1015 03
DK 1012 53
DH 1013 94
Flanged Bolt
Bolt Gear Shift drum Stopper
Stopper Gear Shifter Drum
Spring Gear Shifter Drum Stopper
Bolt Shift Change
1
1
1
1
1
11
12
13
14
15
39 1998 19
DK 1011 87
DK 1011 80
DK 1011 85
DK 1011 86
Oil seal
Collar
Assembly tie rod
Washer pivot
Pivot bolt
2
1
1
1
1
16
17
DK 1011 77
39 2383 15
Assembly lever change arm

Flange Nut
1
1
13
7
5
15
14
4
5
11
12
17
19
20
Plate No.: 11
180
Brand ID: 001MC607

No. Part No.
1
3
11
8
2
Description
Qty.
/Veh. Remarks
2
3
4
5
DJ 1013 89
DJ 1016 72
JC 1010 29
59 0500 08
AA 1014 37
DH 1010 06
Engine Assly. with starter motor

Engine Assly. with Starter motor
Crankcase RH
Stud
Screw Pre Coated
Gasket Crankcase
1
1
1
2
1
1
6
7
8
9
39
59
39
39
Bearing Ball (For Input shaft)

Needle Roller Bearing (For Output shaft)
Dowel Pin
Ball Bearing
1
1
2
1
10
DH 1014 87
Plate Stopper
11
39 1845 04
Flange Bolt
2583
2000
2180
2601
20
27
06
20
N.I.
MLT Silver
(For Drum
Comp. Gear Shift)
8
6
9
7
5
4
21
10
22
Plate No.: 12
180
Brand ID: 001MC607
Crankcase LH
No. Part No.
12
2
14
13
2
19
Description
Qty.
/Veh. Remarks
1
2
3
4
5
JC 1010 45
59 0500 08
DK 1010 94
39 2188 19
59 2100 06
Crankcase LH
Stud
Guide starter Assly
Oil Seal
O Ring
1
2
1
1
1
6
7
8
9
39
39
59
39
59
C Sunk Head Screw

Bearing Ball (For Input shaft)
Bearing Ball (For Output shaft)
Balancer LH Bearing
Balancer LH Bearing
3
1
1
1
1
24
0752
2603
2000
2185
2000
01
20
06
20
28
23
6
10
16
21
15
17
11
10
DG 1014 56
Oil Seal (For Output shaft)
11
12
13
14
15
39 2190 19
DH 1012 03
DH 1012 46
28 1011 74
DH 1016 61
Oil Seal (For Shift lever)

Breather pipe
Rubber tube
Spring Clip
Plug (Drain Bolt)
1
1
1
1
1
16
17
18
19
20
DG 1014 98
DK 1013 80
39 2181 06
39 1677 04
DH 1013 90
Gasket (For Drain Bolt)

Switch comp. (Neutral)
Hollow dowel pin
Bolt
Bolt Flanged Pre Coated (M8 X 82)
1
1
2
8
1
21
22
23
24
DJ 2010 21
39 2448 11
DK 1010 97
39 2180 06
Cable assly. (Battery to Earth)

Plain Washer
Damper
Hollow dowel pin
1
1
1
2
from Eng. No.

DJZCCG36058
24
22
19
18
20
23
24
Brand ID: 001MC607
Plate No.: 13
180
Cover RH
No. Part No.
6
12
9
8
23
1
1A
17
18
3
22
19
20
2
8
11
13
5
1
10
21
16
15
14
Description
Qty.
/Veh. Remarks
2
3
4
5
52 DJ03 90
36 DJ40 17
36 DJ40 26
DH 1011 97
DH 1011 42
39 1041 19
DH 1011 41
Clutch Cover with Tapper Plug DJ

Kit Assly Clutch Cover Flower Type
Kit Assly Clutch Cover Flower Type
Grommet Breather
Shaft clutch release
Seal clutch lever
Rack
1
1
1
1
1
1
1
6
7
8
9
10
DS 1012 63
DK 1012 51
DG 1014 18
DS 1012 15
DS 1013 53
Dip stick with O ring

Parallel pin
Gauge
Wire circlip
Bolt
1
1
1
1
10
11
12
13
14
15
39 0999 06
DH 1010 18
DH 1011 54
DK 1014 80
DH 1210 11
Pin Dowel
Bracket Clutch Cable
Gasket cover RH
Plunger Oil
Plate Plunger Oil
2
1
1
1
1
16
17
18
19
20
DH 1210 12
DH 1015 44
39 2443 11
36 DH10 04
DH 1013 88
Spring Joint A
Spring torsion clutch lever
Washer
Set damper
Flanged Bolt
1
1
1
1
5
21
JC 1010 40
Bajaj Decal
21A
22
23
24
25
DK 1017 38
39 1990 20
36 DH10 05
DH 1014 82
DH 1015 10
Decal Clutch Cover

Bushing
Set of Plate
Plate
Damper
1
1
1
1
1
21A
1A
25
Ref. Cir. C-31

MLT Silver
Ref. Page No. 101
Fitted on
Cover comp.RH
Ref Cir. C-31
Ref. Page No. 101
26
Plate No.: 14
180
Brand ID: 001MC607
Cover Magneto
No. Part No.
12
1
1A
2
3
4
5
6
7
11
2
3
10
6
5
8
9
10
Qty.
/Veh. Remarks
DJ 1012 71
52 DH06 24
52 DH06 86
DV 1010 42
DS 1013 53
39 0999 06
DH 1011 57
Cover Magneto
Magneto Cover Flower Design
Magneto Cover Flower Design
Gasket Magneto cover
Bolt
Pin Dowel
Cap Crank Center
1
1
1
1
5
2
1
39 1283 21
JC 1010 33
DK 1017 62
36 DH10 06
DH 1013 88
DH 1013 23
O Ring
Cover LH RR
Cover LH RR
Set Damper
Flanged Bolt
Bajaj Decal
1
1
1
1
6
1
Decal Magneto Comp.

Set of Plate
Bolt
Sticker
1
1
2
1
10A JE 5412 12
11 36 DH10 07
12 DS 1013 53
13 DJ 1612 28
Description
Ref. Cir. C-31

MLT Silver
MLT Silver
Ref.Page No.101
Fitted on Cover
magneto
Ref Cir. C-31
Ref. Page No.101
13
10A
1A
27
28
Plate No.: 15
180
Brand ID: 001MC607
Clutch
No. Part No.
2
7
4
7
17
7
11
9
5
1
15
16
Qty.
/Veh. Remarks
1
2
3
4
5
DH 1012 75
DK 1015 71
DJ 1013 50
DK 1015 64
DK 1015 69
Special Nut
Spring judder
Clutch Assly. Complete
Clutch Center
Plate Clutch Pressure
1
1
1
1
1
6
7
8
9
10
DJ 1013 69
DK 1015 65
DH 1018 61
DK 1015 74
39 1880 20
Friction Plate Kit

Plate Clutch
Spring Clutch Capacity
Bolt
Bearing Ball:- 15 X 32 X 9 (6002-C3)
1
5
4
5
1
11
12
13
14
15
DK
DK
DK
DH
DH
DK
Holder Clutch
Rod Clutch lifter
Spacer clutch
Nut Primary drive lock
Lever Assly. Clutch
Lever Assly. Clutch
1
1
1
1
1
1
Washer Primary Drive Gear

Seat judder spring
1
1
1015
1010
1011
1016
1011
1016
73
72
26
48
80
36
13
3
Description
16
17
39 2200 11
DK 1015 70
LH Thread
From Engine No.
DJGBSC54429
12
10
14
29
30
Plate No.: 16
180
Brand ID: 001MC607
Carburettor
No. Part No.
14
4
12
3
13
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DJ 1210
DJ 1210
DH 1211
DJ 1210
DJ 1210
41
51
49
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 1210
DJ 1210
DJ 1210
DH 1211
DJ 1210
54
55
56
01
70
Screw
Float assly.
Jet Holder Kit
Magnet Assly.
Reed Switch Assly.
2
1
1
1
1
11
12
13
14
39 1780 01
DJ 1210 57
DH 1211 50
DJ 1210 59
Pan Head Screw

Needle Assly.
Set Adjuster(PS)
Set Plunger assly.
2
1
1
1
7
5
2
1
6
6
11
10
31
32
Plate No.: 17
180
Brand ID: 001MC607
Air Cleaner Comp

No. Part No.
1
2
3
4
5
DJ 1210 71
36 DH40 10
DJ 1210 68
AA 1210 45
36 DK00 15
Description
Air Cleaner comp
Kit hardware air cleaner
Connecting Tube
Clamp
Kit element air filter
Qty.
/Veh. Remarks
1
1
1
1
1
Ref. Page No.101
(Fine & Coarse)

Ref. Page No.102
33
34
Plate No.: 18
180
Brand ID: 001MC607
Silencer Assly.
No. Part No.
1
5
4
Description
Qty.
/Veh. Remarks
2
3
4
5
DJ 1013 91
DJ 1014 20
DH 1014 68
36 DH40 11
DJ 1010 64
39 1970 15
Silencer W/O Shield

Silencer (Non Cat.)
Shield Muffler
Kit hardware shield
Gasket Exhaust
Flanged Nut
1
1
1
1
1
2
6
7
8
9
10
36 DK00
DG 1611
DH 1015
DH 1013
DH 1016
Kit hardware silencer

Damper (Main Stand)
Wire Shield Assly.
Screw
Silencer front (cat) shield
1
1
1
2
2
Ref. PageNo.102
10
9
09
24
21
02
08
Ref. Page No.102
6
1
35
36
Plate No.: 19
180
Brand ID: 001MC607
Oil Pump
No. Part No.
4
2
Description
Qty.
/Veh. Remarks
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
39 2194 21
O Ring
37
38
Plate No.: 20
180
Brand ID: 001MC607
Starter Assly.
No. Part No.
11
10
13
3
12
1
7
2
9
4
Qty.
/Veh. Remarks
Description
1
2
3
4
5
36 DK00 76
DK 1016 05
JC 1011 14
DH 1015 81
DH 1013 85
Body
Plate
Gear
Plate
Bolt
6
7
8
9
10
DK 1011 76
DH 1011 72
JC 1011 15
39 0972 04
DH 1110 84
Shaft starter counter

Collar starter counter
Gear comp. starter counter assly.
Bolt socket M6
Motor assly. starter clutch
1
1
1
3
1
11
12
DS 1013 53
52 DH01 53
DK 1017 70
DH 1013 89
36 DK00 77
DH 1011 63
59 2000 07
Bolt
Cover starter motor
Cover starter motor
Slotted csunk screw
Spring
Roller
Needle Roller Bearing
2
1
1
1
1
5
13
14
15
16
comp. starter clutch

roller clutch
starter clutch
starter clutch gear return
(For Gear Starter Clutch)
1
1
1
1
1
For stopper
Plate
MLT Silver
N.I.
8
14
15
39
40
Plate No.: 21
180
Brand ID: 001MC607

No. Part No.
18
Description
Qty.
/Veh. Remarks
1
2
3
4
5
59 1000 02
DH 1110 81
DH 1013 86
DH 1013 81
DH 1011 99
Spring Dowel
Stator Assly. comp
Hex. Bolt with Flange
Pan Head Screw
Stopper plate (wiring harness)
1
1
2
2
1
6
7
8
9
10
DH 1110 83
DH 1013 80
DG 1110 08
DJ 1110 92
DH 1110 13
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 2012 02
JC 1110 22
JC 1110 23
DD 1110 48
DH 1110 15
Regulator (With Bracket)

H.T. Coil LH with cable
H.T. Coil RH with cable
Cap Spark Plug
Cap Spark Plug
1
1
1
1
2
16
17
18
19
DD 1110 12
DH 1110 13
39 1944 04
DH 1110 16
Grommet H.T. Cable

Grommet Spark Plug
Flange Bolt
Grommet Sleeve Spark Plug
2
1
4
1
N.I.
12
13
19
16
15
17
16
14
5
3
10
18
4
8
11
41
42
Plate No.: 22
180
Brand ID: 001MC607

No. Part No.
7
4
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
DK 2110 07
DS 2110 04
Description
Qty.
/Veh. Remarks
Seat Assly comp front

Damper
Lock Assly seat front
Seat assly comp rear
Lock assly seat rear
1
6
1
1
1
Bolt flange
Damper Front
Damper
4
1
2
1
2
8
3/5
43
44
Plate No.: 23
180
Brand ID: 001MC607
Engine Mounting
No. Part No.
10
17
16
14
15
2
12
13
Description
Qty.
/Veh. Remarks
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
2
1
1
1
1
6
7
8
9
10
DK 1611 60
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
2
1
1
1
11
12
13
14
15
59 0400 43
DK 1611 61
39 2310 04
39 2412 04
39 1040 11
Hex. Soc. Hd. cap bolt

Bkt. Comp. RH eng. rear
Flanged bolt
Bolt Hex Head with Flange :- M8
Washer
1
1
2
1
1
16
17
DH 1611 89
DH 1611 90
Bracket LH Engine Hanger

Bracket RH Engine Hanger
1
1
Ref. Page No.102
6
7
7
8
5
11
45
46
Plate No.: 24
180
Brand ID: 001MC607

No. Part No.
Description
Qty.
/Veh. Remarks
1
2
3
4
5
JC 1610 31
DH 1611 12
DG 1810 48
DG 1810 42
36 DV00 07
Frame Assl. comp.

Cup rear
Nut
Cup - Steering
Bearing Cone Kit
1
2
1
1
1
6
7
36 3140 02
39 1680 04
DS 1612 24
DJ 1611 32
DJ 1611 33
JC 1610 15
JC 1610 14
Kit Ball Steel Steering (Set of 42)

Flanged bolt
Flanged bolt
Cable Hook LH
Cable Hook RH
Bkt. Engine Mounting Upper RH
Bkt. Engine Mounting Upper LH
1
2
2
1
1
1
1
Ref. Page No.102
3
4
6
8
9
10
11
6
7
Old
New 29.5.2010
N.I.
N.I.
8/9
2
2
47
48
Plate No.: 25
180
Brand ID: 001MC607

No. Part No.
10
7 7 5
5
Qty.
/Veh. Remarks
1
2
3
4
5
DK 1710 14
DG 1710 38
36 DK00 12
DJ 1710 35
DG 1710 18
Rear Shock Absorber Assly.

Bolt Pre-coated
Kit bush rear shock
Swing arm assly.
Swing arm bearing
2
2
1
1
4
6
7
8
9
10
DK
DG
DH
DK
DG
Collar swing arm

Oil seal swing arm
U nut swing arm
Shaft swing arm
Chain slider
2
4
1
1
1
11
DG 1710 21
JM 1710 03
DG 1710 20
JM 1710 04
39 1997 15
DG 1710 22
39 1224 11
Adjuster chain LH
Adjuster chain LH
Plate Chain Adjuster
Plate Chain Adjuster
Hexagon nut
Small nut
Washer
2
2
2
2
2
2
2
12
13
14
15
Description
1710
1710
1710
1710
1710
06
19
19
03
34
Ref. Page No.102
Old
Ref. Cir. C-31
Old
Ref. Cir. C-31
11
12
13
11
12
13
15 14
15 14
49
50
Plate No.: 26
180
Brand ID: 001MC607
Rider Foot Rest

No. Part No.
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DJ 1611 26
36 DK00 13
DJ 1611 27
DH 1610 53
39 1282 15
Main step LH assly.

Kit Hardware Main Step
Main step RH assly.
Rubber main step
Domed Cap Nut M-8
1
2
1
2
2
6
7
22 1504 51
DH 1610 56
Bold Hexagon Head

Plate Coml. Low M/Step
2
2
6
2
1
4
7
51
52
Plate No.: 27
180
Brand ID: 001MC607

No. Part No.
1
Qty.
/Veh. Remarks
3
4
5
DK 1611 37
DK 1613 08
JC 1610 02
DJ 1613 24
DJ 1611 28
DJ 1611 29
DJ 1611 22
Holder Step LH
Holder Step LH
Holder Step RH
Holder Step RH
Pillion step assly. comp. LH
Pillion step assly. comp. RH
Rubber pillion step
1
1
1
1
1
1
2
6
7
8
9
36 DK00 13
39 1069 01
39 0292 15
39 2582 04
Kit hardware pillion

Screw
Nut
Bolt Hex Head Flange : M8X1.25XL 35
(for LH & RH Holder Step Mtg.)
2
1
1
2
Ref. Page No.102

Stopper bolt
10
11
DJ 1611 86
DH 1611 00
Plate lock pillion step

Spacer main step
2
1
NI
NI
2
4
Description
MLT Silver
MLT Silver
11
8
53
54
Plate No.: 28
180
Brand ID: 001MC607

No. Part No.
5
2
11
Description
Qty.
/Veh. Remarks
1
2
3
DJ 1610 69
DK 1610 98
59 0400 40
Nail for Cable Guide

Brace fender
Step bolt
1
1
4
4
5
DS 1611 25
DK 1610 86
Clamp
Fender rear front
1
1
6
7
8
9
10
39 1672 04
39 0711 11
39 1680 04
DK 1610 85
DJ 1612 72
Flange Bolt M6
Plain washer
Flange bolt
Fender rear
Support assly for rear fender
2
2
2
1
1
11
39 0211 11
Plain washer
Fender front
mtg.
For cables
10
55
56
Plate No.: 29
180
Brand ID: 001MC607
Stand Assembly
No. Part No.
12
2
3
4
11
9
10
1
Description
Qty.
/Veh. Remarks
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
JC 2010 39
39 2060 04
DH 2010 65
DJ 2011 06
Side stand switch

Bolt
Magnet Assly.
Magnet Assly (Button Type)
1
2
1
1
7
6
8
13
57
58
Plate No.: 30
180
Brand ID: 001MC607
Tube / Tyre / Rim

No. Part No.
Description
Qty.
/Veh. Remarks
1
2
JC 1510 13
DK 1510 39
Wheel rim front (16 x 17 DC)

Tyre front
1
1
JC 1510 10
DK 1510 40
DK 1510 26
Wheel Rim Rear

Tyre rear
Valve for tubeless tyre
2
5
1
59
60
Plate No.: 31
180
Brand ID: 001MC607

No. Part No.
4
2
Description
Qty.
/Veh. Remarks
1
2
3
4
5
JC 1510 13
39 2241 20
DK 1510 28
DG 1510 05
39 0840 01
Wheel rim
Bearing ball
Spacer assly.
Seal oil
Screw
1
2
1
1
1
6
7
8
9
10
39 0900 12
DK 1510 27
DH 1710 19
DG 1510 08
DG 1510 49
Washer
Disc
U Nut
Plain washer
Hex. soc. hd. bolt
1
1
1
1
6
11
12
13
14
15
JC 1510 20
DG 1510 07
DK 1510 08
JC 2010 46
DE 1510 08
Case meter housing (W/o Speedo Sensor)

Coller
Front axle with head
Stopper plate
Seal Oil
1
1
1
1
1
2
15
11
10
7
14
6
5
8
9
1
12
13
61
62
Plate No.: 32
180
Brand ID: 001MC607

No. Part No.
10
10
E
US
G: 3-4 M
NIN DOT FRO
R
AR
W NLY UID INE
O
FL TA P
N A
E
AK CO C I NG
BR ED LER O V
AL FIL EM
R
SE N
A EA R E
L
O
C
F
BE
13
1
15
5
4
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DE 1910 43
DK 1510 57
DJ 1910 57
DE 1910 11
DE 1910 10
Major Kit - Master Cylinder

Hose Brake Front
Lever Grip RH
Banjo Bolt
Washer Copper
1
1
1
2
4
6
7
8
9
10
DJ
DJ
DJ
DJ
DJ
Clamp Holder RH
Bolt
Bolt Front Brake Lever
Nut Flanged
Screw
1
1
1
1
2
11
12
13
14
15
DJ 1910 56
DJ 2011 09
DJ 1910 34
DJ 1910 35
36 DH19 02
Cylinder Master
Front brake switch
Reservoir Cover
Diaphragm
Oil Window Kit
1
1
1
1
1
16
DJ 2011 08
Cable assly for switch
1910
1910
1910
1910
1910
27
28
29
30
31
BREMBO
BREMBO
BREMBO
14
7
2
11
12
7
6
5
5
16
63
64
Plate No.: 33
180
Brand ID: 001MC607
Front Disc Brake

No. Part No.
9
5
PISTON SEAL
DUST SEAL
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DK 1510 54
39 0400 48
DE 1510 48
DE 1510 46
DE 1510 47
Caliper Assly. Front

Bolt Flanged
Spring Pad
Bleeder Screw
Bleeder Cap
1
2
1
1
1
6
7
8
9
10
DE 1510 37
DE 1510 43
DE 1510 45
DJ 1510 74
DJ 1510 75
Disc Pad Set

Insulator
Protection Boot
Minor Kit - Caliper
Major Kit - Caliper
1
1
1
1
1
BLEEDER CAP
7
x
INSULATOR
CALIPER PISTON
2
4
PROTECTION BOOT
BLEEDER SCREW
PAD SPRING
10
65
66
Plate No.: 34
180
Brand ID: 001MC607
Rear Hub
No. Part No.
67
Description
Qty.
/Veh. Remarks
1
2
3
4
5
39 2686 20
DK 1510 22
JG 1312 19
39 2687 20
30 1510 69
Bearing ball
Collar bearing
Coupling Rubber
Bearing ball
Spring
1
1
1
1
2
6
7
8
9
10
30 1511 05
JN 1318 12
JC 1510 05
JC 1510 02
36 JC00 07
DK 1510 09
Shoe brake assly.

Shoe brake assly. (Non Asbestos)
Cam brake
Panel rear brake
Kit lever brake
Axle
1
1
1
1
1
1
11
12
13
14
15
16
17
18
19
20
DK 1510 14
39 1224 11
DH 1710 19
39 1997 15
39 2566 11
JC 1510 11
36 DK00 36
DS 1510 74
DK 1510 12
DK 1510 13
Spacer For Coupling

Plain washer
U nut
Nut
Plain washer
Spacer
Chain Sprocket Kit
Lock washer
Seal oil
Bearing ball
1
2
1
1
1
1
1
3
1
1
21
22
23
24
25
26
27
JC 1510 16
DS 1510 73
DK 1510 15
39 0794 15
DK 1510 36
39 0722 11
JC 1510 07
Coupling
Stud
Sleeve
Hex. lock nut
Drive Chain Lock
Washer Cam brake
Lever Brake
1
6
1
6
1
1
1
Ref. Page No.102
Ref. Page No.102
68
Plate No.: 35
180
Brand ID: 001MC607
Rear Brake Padal

No. Part No.
13
5
12
1
6
8
3
Description
Qty.
/Veh. Remarks
1
2
3
4
5
JC 1910 01
JC 1910 09
DK 1011 85
DK 1011 87
39 2383 15
Lever Brake Pedal

Bolt Brake Pedal
Washer pivot bolt
Collar pivot bolt
Flange nut
1
1
1
1
1
6
7
8
DK 1910 13
JC 1910 02
36 JC00 06
Spring brake pedal

Rod brake
Kit hardware rod brake
1
1
1
9
10
11
12
13
14
30 1510 95
DH 1510 29
JC 1510 08
36 DK00 34
JC 2010 04
36 DH 4015
Hex. bolt
Hex. bolt
Rod Torque
Brake Pedal Kit
Rear brake switch
Kit Hardware torque rod
1
1
1
1
1
1
N.I.
Refer Page No.102
Refer Page No.102
7
10
14
14
11
69
70
Plate No.: 36
180
Brand ID: 001MC607
Handle Bar
No. Part No.
31
Upper Bracket (Silver Color)

Upper Bracket (Black Color)
Kit Hall Sensor (Blinker Self Cancellation)
Holder Handle Assly RH
Holder handle RH (Silver Color)
Holder handle RH (Black Color)
Holder Handle Assly LH
Holder handle LH (Silver Color)
Holder handle LH (Black Color)
Socket bolt
1
1
1
1
1
1
1
1
1
4
10
JC
JC
DJ
DJ
DJ
DJ
DJ
DL
Control switch LH
Control switch RH
Lever & Support Holder Assly
Holder LH
Holder LH (Transil Diode Type Clutch Switch)
Lever LH
Lever LH (Transil Diode Type Clutch Switch)
Stud lever handle
1
1
1
1
1
1
1
1
11
12
12A
13
14
15
39 1184 15
36 DU19 01
39 1553 04
DH 1910 07
DH 1910 08
DS 1910 52
Nut Nyloc M5 x 0.8

Kit adjusting Screw
Bolt Flange M6
Grip LH
Grip RH
Boot for lever LH
1
1
1
1
1
1
16
17
18
19
DJ 1810 11
39 2427 04
DS 1910 52
JC 2010 45
Handle bar weight

Hex. soc. hd. cap screw
Lever Boot for Clutch Switch
Switch assly. ignition
2
2
1
1
17
30
I
N
E
-R
I G N I T
F
L OF ON
20
CK
LO
PUS
26
16
27 28
19
6
7
8
8A
5
1
4
23
9
6
10
9
12
12A
16
13
8A
17
11
21
2
71
from Jun.11
from Jun.11
24
29
15
Qty.
/Veh. Remarks
DK 1810 27
DK 1810 63
36 DJ40 30
DK 1810 38
DK 1810 85
DK 1810 62
DK 1810 39
DK 1810 81
DK 1810 60
DG 1810 08
2
3
14
Description
2010
2010
1910
1910
1910
1910
1910
1910
17
18
82
54
81
55
83
14
from Chs. UCJ73042
N.I.
72
Plate No.: 36
180
Brand ID: 001MC607
Handle Bar
No. Part No.
31
20
21
17
14
30
20
N
E
-R
I G N I T
F
L OF ON
CK
LO
PUS
26
16
27 28
19
22
23
24
25
26
27
Flange bolt
Clutch Switch
Clutch Switch (Transil Diode)
Handle bar plug
Handle bar tube assly. LH
Handle bar tube assly. RH
Pipe throttle
2
1
1
2
1
1
1
N.I.
JC 1810 29
DK 1810 58
LA C000 20
1
2
2
from Jun11
2
2
1
1
28
29
30
39 1180 11
DK 1810 36
DJ 2210 03
31
DJ 2210 04
Mirror Assly. RH
29
5
1
15
23
Qty.
/Veh. Remarks
39 1680 04
DJ 2011 95
DJ 2012 46
DK 1810 36
DK 1810 82
DK 1810 86
DH 1910 17
Lock set 4 in 1
Bolt Handle Bar M8 X 40
Bolt Handle Bar Socket Head *
(Shank Height increased)
Washer
Handle Bar Plug
Mirror Assly. LH
24
Description
from Chs. UCJ73042
N.I.
10
Note - * The bolt (Sr. No. 27) Shank Length increased w.e.f. 15.05.2011
12
12A
16
The new bolt, Holder Handle, Handle Bar Assly are not individually interchangeable
with old one.
13
8A
17
11
21
71A
72A
Plate No.: 37
180
Brand ID: 001MC607
Front Fork
No. Part No.
21
Description
22
Qty.
/Veh. Remarks
23
18
14
8
15
16
17
31
19
32
20
33
28
24
4/5
9
11
22
21
6
7
10
30
25
26
27
73
DK
DK
DK
DK
DK
1810
1810
1810
1810
1810
72
21
19
56
57
Fork front
Inner Dust Seal
Oil seal
Outer Tube LH
Outer Tube RH
1
1
2
1
1
6
7
8
9
10
DK
DK
DK
DK
DK
1810
1810
1810
1810
1810
07
06
10
70
11
Copper Washer
Socket Headed Bolt M10 X 1.5 X 35
Seat Pipe
Pipe comp. suspension inner
Slide Bush
2
2
2
2
2
11
12
13
14
15
DK 1810 73
DH 1810 09
DK 1810 22
DK 1810 23
31 1811 01
Spring front fork

Grommet Top
Bolt fork
O ring
Seat fork spring
2
2
2
2
2
16
17
18
19
20
DK 1810 71
DK 1810 18
59 0400 05
DK 1810 27
DG 1810 08
Spacer Tube
Washer
Bolt
Holder fork upper
Socket Bolt
2
2
1
1
2
21
22
23
24
25
26
27
28
29
30
JC 1810 23
JC 1810 22
JC 1810 24
DG 1810 45
DK 1810 24
DK 1810 25
DK 1810 26
DK 1810 17
DK 1810 20
DK 1810 08
Cushion Rubber
Cover Trail B
Lamp Shade asly.
Bearing cone
Holder fork under
Spring washer
Bolt
Guide Bush
Oil Seal Stopper
Bolt
2
4
1
1
1
2
2
1
2
2
31
32
33
DK 1810 12
DK 1810 13
DK 1810 09
Piston Ring
Rebound Spring
Cap Oil Lock
2
2
2
13
12
2
29
1
2
3
4
5
74
Plate No.: 38
180
Brand ID: 001MC607

No. Part No.
1
DJ
DJ
DJ
DJ
DJ
DJ
DJ
7201
7201
7201
7201
7201
7107
7107
4M
2V
4K
4L
5C
5G
5F
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Tank
Tank
Tank
Tank
Tank
Tank
Tank
52
52
52
52
52
52
DH05
DH05
DH05
DH05
DH06
DH06
34
30
28
32
75
73
Side
Side
Side
Side
Side
Side
cover
cover
cover
cover
cover
cover
52
52
52
52
52
52
DH05
DH05
DH05
DH05
DH06
DH06
35
31
29
33
76
74
Side
Side
Side
Side
Side
Side
DH
DH
DH
DH
DH
7303
7303
7303
7303
7303
4M
2V
4K
4L
5L
DK
DK
DK
DK
7402
7304
7402
7402
2T
2V
3A
X3
DH 1410 20
11
12
2
6
Description
with Decal
with Decal
with Decal
with Decal
with Decal
With Dual Decal
With Dual Decal
Qty.
/Veh. Remarks
1
1
1
1
1
1
1
Midnight Black
Cocktail Wine Red
Plasma Blue
Misty Gray Silver
Orange Mica
Pl Blue
Cw Red
LH
LH
LH
LH
LH with Dual Decal
LH with Dual Decal
1
1
1
1
1
1
Midnight Black
Cocktail Wine Red
Plasma Blue
Misty Gray Silver
Blue Decal
Red Decal
cover
cover
cover
cover
cover
cover
RH
RH
RH
RH
RH with Dual Decal
RH with Dual Decal
1
1
1
1
1
1
Midnight Black
Cocktail Wine Red
Plasma Blue
Misty Gray Silver
Blue Decal
Red Decal
Seat
Seat
Seat
Seat
Seat
Cowl
Cowl
Cowl
Cowl
Cowl
Assly.
Assly.
Assly.
Assly.
Assly.
1
1
1
1
1
Midnight Black
Cocktail Wine Red
Plasma Blue
Misty Gray Silver
Orange Mica
Front
Front
Front
Front
Fender
Fender
Fender
Fender
1
1
1
1
Misty Gray Silver

Cocktail Wine Red
Plasma Blue
Ebony Black
180
10
75
Seat tape
76
Plate No.: 38
180
Brand ID: 001MC607

No. Part No.
DH 7401 4M
DJ 7401 2V
DH 7401 4K
DH 7401 4L
DH 7401 5C
52 DH06 83
52 DH06 82
Fairing
Fairing
Fairing
Fairing
Fairing
Fairing with Dual Decal
Fairing with Dual Decal
1
1
1
1
1
1
1
Midnight Black
Cocktail Wine Red
Plasma Blue
Misty Gray Silver
Orange Mica
Pl Blue
Cw Red
52
52
52
52
52
DJ03
DJ03
DJ03
DJ03
DJ04
63
57
59
61
08
Tank
Tank
Tank
Tank
Tank
Flap
Flap
Flap
Flap
Flap
LH
LH
LH
LH
LH
1
1
1
1
1
Midnight Black
Cocktail Wine Red
Plasma Blue
Misty Gray Silver
Orange Mica
52
52
52
52
52
DJ03
DJ03
DJ03
DJ03
DJ04
64
58
60
62
09
Tank
Tank
Tank
Tank
Tank
Flap
Flap
Flap
Flap
Flap
RH
RH
RH
RH
RH
1
1
1
1
1
Midnight Black
Cocktail Wine Red
Plasma Blue
Misty Gray Silver
Orange Mica
10
DJ
DJ
DJ
DJ
DJ
1613
1613
1613
1613
1613
07
04
05
06
13
Seat
Seat
Seat
Seat
Seat
Cowl
Cowl
Cowl
Cowl
Cowl
Decal
Decal
Decal
Decal
Decal
2
2
2
2
2
Black (Ref.Cir.C-20)
Red (Ref.Cir.C-20)
Blue (Ref.Cir.C-20)
Silver (Ref.Cir.C-20)
Ref. Cir. C-27
11
JC 1410 51
JC 1410 50
B Monogram Tank Black Chrome

B Monogram Tank Gray Chrome Decal
2
2
12
36 JC00 08
36 JC00 09
36 JC00 10
Decal Kit LH (Black Chrome)

Decal Kit RH(Black Chrome)
Decal Kit LH(Grey Chrome)
1
1
1
36 JC00 11
Decal Kit RH(Grey Chrome)
DJ 1410 61
Rubber Beading (On Flap)
For Silver Colour

For Black,Blue,
Red Colour
For Silver Colour
For Silver Colour
For Black,Blue,
Red Colour
For Black,Blue,
Red Colour
N.I.
11
Qty.
/Veh. Remarks
7
7
Description
12
2
6
180
10
13
77
78
Plate No.: 38A
180
Brand ID: 001MC607
Dual Color Decals

No. Part No.
Description
Qty.
/Veh. Remarks
36 DH40 35
36 DH40 38
Kit Fairing Decal Blue

Kit Fairing Decal Red
1
1
36 DH40 34
36 DH40 37
Kit Tank Decal Blue

Kit Tank Decal Red
1
1
36 DK00 84
36 DK00 88
Kit Side Cover Decal Blue

Kit Side Cover Decal Blue
1
1
36 DJ40 23
36 DJ40 24
Kit Seat Cowl Decal Blue

Kit Seat Cowl Decal Red
1
1
4
3
77A
Note - For Plasma Blue & Passion Red Dual Color Decal Vehicles The Seat Cowl & Side Cover - Black Color is common.
(to be used along with above Decal Set.)
78A
Plate No.: 39
180
Brand ID: 001MC607

No. Part No.
3
1
5
2
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DK 1410 14
30 1780 01
39 2381 04
DK 1410 01
DK 1410 13
Cap Assly. Tank

Pan head screw
Hex. Soc Hd. cap bolt
Tap Assly
Lock Cap Tank
1
1
7
1
1
6
7
8
9
10
30 1410 39
DD 1412 27
39 0740 11
DK 2010 65
39 2758 21
Packing
Bolt flanged
Plain Washer
Gauge Fuel
Gasket fuel Gauge
1
2
2
1
1
11
12
13
14
15
16
39 2484 15
52 DJ04 49
BA 1220 03
DH 1410 24
DG 1410 28
DH 141021
Nut Flange M-5

Fuel Pipe with Clip E10
Pipe clip
Drain tube
Clamp
Seat Tape
4
1
1
1
1
1
15
8
7
14
10
13
9
12
11
79
80
Plate No.: 40
180
Brand ID: 001MC607
Fitting Petrol Tank Spoiler, Side Cover, Seat Cowl

No. Part No.
21
15
18
19
16
8
17
13
7
20
Description
Qty.
/Veh. Remarks
36 DH16 01
Grommet Kit For side cover
Ref. Page No.103
2
3
4
5
DH 1410 31
DG 1611 21
39 2424 11
JC 1810 29
Tape tank inner

Screw
Plain Washer
Lock Set (4 in 1) with Key
2
2
1
1
N.I.
6
7
8
9
10
DH 1410 23
DJ 1410 08
39 1902 04
DK 1611 23
DK 1611 24
Damper
Damper front
Flanged Bolt
Cover Side Mesh LH
Cover Side Mesh RH
1
2
1
1
1
11
12
13
14
15
59 0200 01
31 1610 18
JW 1710 07
JD 1710 18
JC 1410 15
Self Tap Screw

Damper
Dual Tape
Special Tape
Grommet
6
2
2
2
2
16
17
18
19
20
21
JC 1410 17
JC 1410 16
39 1556 04
39 2424 11
DK 1410 17
DK 1410 15
Grommet II
Collar
Flange Bolt
Plain Washer
Damper tank middle
Tank Pad
2
2
1
1
1
1
11
9/10
12
81
82
Plate No.: 41
180
Brand ID: 001MC607
Meter Assly
No. Part No.
1
2
3
4
5
DJ 1910
39 1778
DJ 1811
DJ 2011
DJ 2011
71
02
19
74
59
DK 1612 09
Description
Qty.
/Veh. Remarks
Meter Assly / Instrument Cluster

Self Tapping Screw
Back Cover
Trip Meter Knob
Speedo Meter Top Cover
1
4
1
1
1
Tape I
5
8
10
12
F
6
E
km/h
x 1 0 0 rpm
SIDE
STAND
83
84
Plate No.: 42
180
Brand ID: 001MC607
Control Cables
No. Part No.
1
2
3
4
5
DJ
JC
JC
59
30
1910
2010
1910
2100
1910
61
43
04
19
48
Description
Cable Accelerator
Vehicle Speedos Sensor ( Potted )
Cable Clutch
O ring
Band
Qty.
/Veh. Remarks
1
1
1
1
1
N.I.
85
86
Plate No.: 43
180
Brand ID: 001MC607
Chain Cover
No. Part No.
1
2
3
DK 1612 50
DH 1612 83
39 1680 04
Description
Cover Chain assly
Bolt (Small)
Bolt (Big)
Qty.
/Veh. Remarks
1
1
2
3
2
87
88
Plate No.: 44
180
Brand ID: 001MC607
Head Lamp & Fairing

No. Part No.
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DJ 2011 76
DJ 1811 20
DJ 1810 33
DF 1810 98
39 2141 24
Head Lamp Assly. without Bulb

Head Lamp Mask
Wind Shield
Bolt
Non Metallic Washer
1
1
1
4
4
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
11
12
13
14
15
16
17
36 DH40 20
DJ 1612 29
39 0716 01
39 1524 01
CL 2010 23
DJ 1810 69
DH 2010 40
Kit hardware mtg. bracket

Clip Nut
Screw pan cross
Screw pan cross
Lamp 12V 35/35W-HS1
Packing Fairing
Head Lamp Wiring Harness
1
4
2
2
1
1
1
6
8
7
1
13
11
14
10
12
17
Ref. Page No.103
9
9
15
17
89
90
Plate No.: 45
180
Brand ID: 001MC607

No. Part No.
1/2
1
2
3
4
5
DJ 2012
DJ 2012
DJ 2012
DJ 2012
36 DJ40
07
06
06
07
30
6
7
8
39 1225 15
GH 2010 12
39 2208 04
Description
Qty.
/Veh. Remarks
Blinker Front LH flexible

Blinker Front RH flexible
Blinker Rear LH flexible
Blinker Rear RH flexible
Kit Hall Sensor (Blinker Self Cancellation)
1
1
1
1
1
Hex. Nut With Flange

Lamp 12V 10W
Bolt
4
4
2
For Hall Sensor

Mounting (N.I.)
3/4
7
7
6
91
92
Plate No.: 46
180
Brand ID: 001MC607

No. Part No.
3 2
6
13
12
8
17
9
14
18
10
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DK 2010 03
DH 1612 93
DK 1611 53
59 0100 13
39 1907 01
Tail light Assly

Damper
Clip Nut
Screw pan cross
Truss Screw
1
2
4
4
2
6
7
8
9
10
39 1972 15
30 2010 29
JW 4010 11
DJ 1610 72
DP 1611 45
Nut flange
Lamp 12V-4W
No. Plate illumination
Rear No. plate bkt.
Number plate Rear
2
1
1
1
1
11
12
39 1680 04
39 1783 01
Hex Flanged Bolt

Truss Screw
2
2
13
14
15
16
17
18
19
DP 1611 44
JC 1810 26
39 1062 04
DH 1612 93
JC 1810 25
39 1943 04
DJ 1810 83
Number plate front

No. plate mounting bracket
Bolt flange
Damper front no. Plate
Front no. plate bracket
Bold Flange M6
Sleeve
1
1
2
1
1
2
2
For Front No.

Plate
No. Plate Bracket
11
15
93
94
Plate No.: 47
180
Brand ID: 001MC607
Electric Component
No. Part No.
13
8
Description
Qty.
/Veh. Remarks
1
2
3
4
5
DK 2010 37
DK 2010 38
39 1507 11
39 1956 04
DJ 2011 26
Horn LH Dia 70
Horn RH Dia 70
Plain Washer
Flange Bolt
Battery (12V-9A) mf Dry Charged
1
1
1
1
1
6
7
DJ 1612 47
DJ 2012 05
DJ 2012 48
Band Battery
Wiring Harness
Wiring Harness
1
1
1
1/2
N.I.
from Chassis No.
MD2A12DZ4CCC05651
8
9
10
JC 2010 04
DJ 2010 20
JC 2010 16
Rear Brake Switch

Cable assly. (Battery to St.Relay)
BCU
1
1
1
11
12
13
14
15
AL 2010 12
DJ 2010 28
39 1680 04
DK 2010 78
DJ 2011 40
30 2011 04
Kill switch relay

Relay (Interlocking)
Flange bolt
Starter Relay / Damper
Cable assly. (Battery to Earth)
Fuse box Assly.
1
1
1
1
1
1
16
17
18
30 2010 85
JC 2010 27
60 1114 15
Fuse
Cable Assly. St. Motor to St. Relay
Cable Tie Lock
1
1
4
14
18
11
7
12
15
Ref. Cir. C-19
N.I.
from Chassis No.
MD2A11CZ3CCC40192
10
16
95
96
Plate No.: 48
180
Brand ID: 001MC607
Tool Kit
No. Part No.
1
2
97
DK 2210 11
DK 2210 24
Description
Tool Kit
Band Tool Kit
Qty.
/Veh. Remarks
1
2
98
Plate No.: 49
180
Brand ID: 001MC607

No. Part No.
Description
Qty.
/Veh. Remarks
1
2
3
4
5
36 DK00 33
39 2310 04
DK 1611 76
36 DK00 23
DK 1611 47
Kit Leg Guard

Flange bolt
Sari Guard Assly.
Kit hardware sari guard
Grab handle LH
1
4
1
1
1
6
7
8
9
DK 1611 48
39 2310 04
DJ 1610 79
DJ 1610 80
Grab handle RH
Bolt Flange
Foam LH For grab
Foam RH For grab
1
4
1
1
8
9
3
4
99
100
Brand ID: 001MC606
Brand ID: 001MC606
KIT LIST
Sr.
Kit Part No.
No.
1
2
3
4
5
6
180
Kit Description
36DS1001 Cyl.Head O Ring Kit

36DJ1004 Valve Kit
DK101326 Valve Repair Kit
36DK0039 Guide Chain Kit

36DK0038 Set primary drive & driven
36DH4019 Kit centrifugal oil filter
36DH1004 Set Damper
36DH1005 Set of Plate
36DH1006 Set Damper
10 36DH1007 Set of Plate

11 36DH4010 Kit hardware air cleaner
101
Consisting of Following Parts

Part No.
Description
Qty./Kit
39239121
O Ring (Cover tappet)
39128321
O ring
DJ101124
Valve Intake
DJ101125
Valve Exhaust
DK101247
Retainer valve spring
DK101108
Spring valve inner
DK101110
Spring valve outer
DK101246
KIT LIST
Sr.
Kit Part No.
No.
180
Kit Description
Description
Qty./Kit
DK121002
Element air filter fine
DK121003
Element air filter coarse
DH101301
Seal shield muflar
DH101395
Trust screw
DH101481
Grommet shield
39185004
Flange bolt
39242511
Plain washer
Seat valve spring
DD161071
U nut
DH101017
Guide chain (Tight)
DH161155
Damper silencer
DK101059
Guide Chain (slack)
DH161157
Tube silencer mounting
DH101628
Gear primary drive
DK101561
Clutch Housing
39231204
Bolt flange
39220011
Washer
39197015
Nut flange
DH101234
Gasket centrifugal oil filter
39241304
Bolt flange
DH101640
Oval screw
DH161245
U Nut
DG181045
Bearing cone
DG181047
Bearing race
DG181046
Upper bearing race
39071411
Plain washer
Dh101066
Join oil dealivery
DH101067
Spring oil delivery
39219908
Pin oil delivery joint
12 36DK0015 Kit element air filter

Part No.
13 36DH4011 Kit hardware shield
14 36DK0009 Kit hardware silencer
15 36DK0011 Kit hardware engine mounting
16 36DV0007 Bearing cone kit
17 36DK0012 Kit bush rear shock absorber
DH101284
Damper A
DH101285
Damper B
39071215
Dome cap nut
DH101286
Damper C
39073712
Spring washer
DH101287
Damper D
DJ161186
Plait side pillion stape
DH101288
Plate A
DH161061
Pin pillion set
DH101289
Plate B
30141031
"O" ring
DH101290
Plate C
39104011
Plain washer
39078408
Split pin
01170122
"O" ring
DH101291
Plate D
DH101282
Damper Cover Magneto
18 36DK0013 Kit hardware pillion
19 36JC0007 Kit lever brake
DH101292
Damper A Cover LH RR
JC151006
Indicator
DH101294
Damper B Cover LH RR
JC151007
Lever brake
DH101283
Plate Damper
39244704
Hex. head bold
DH101293
Plate Damper Cover LH RR
39079815
Nut
DH121020
Bracket lock
DJ151110
Sprocket (36 teeth)
01110609
Plain washer
DK151010
Chain
39178001
Screw pan cross
DV101048
Sprocket Drive
39177304
Bolt flange
DK101186
Bolt pivot lever change
31121043
Coller
DK101185
Washer pivot bolt
39071111
Plain washer
DK101187
Collar pivot bolt
39199819
Oil Seal
39238315
Flange nut
DK191014
Spring ear brake switch
Dk191013
Springr brake peddle
20 36DK0036 Chain sprocket kit
21 36DK0034 Kit hardware brake pedal
102
Brand ID: 001MC606
Brand ID: 001MC606

KIT LIST
Sr.
Kit Part No.
No.
180
Kit Description
23 36JC0006 Kit hardware rod bracket
24 36DK0018 Kit hardware rod torque
25 36DK0019 Kit hardware holder LH
26 36DK0025 Kit outer tube
27 36DH1601 Grommet kit for side cover

28 36DH4020 Kit hardware mounting bracket
29 36DH4030 Cam Chain Guide Kit
30 36DJ4017 Kit Assly Clutch Cover
103
Notes
180

Part No.
Description
Qty./Kit
30191038
Pin
39019811
Plain washer
39080808
Split pin
JC191008
Spring
JC191006
Pin
JC191007
Brake adjustment nut
39078912
Spring washer
3079415
Nut lock
39080708
Pin snap
39154011
Plain washer
30191024
Screw
30191017
Nut
39021911
Plain washer
39072504
Hex bold
DK181021
Seal dust
DK181019
Seal oil
DG181088
Ring snap
DK181017
Guide bush
DH161158
Grommet side cover
DH161133
Grommet side cover rear
DJ181029
Coller faring mounting
DJ181064
Grommet fearing mounting
39021111
Plain washer
39155204
Flange bold
JM171003
Drive Chain Adjuster
JM171004
Cap Drive Chain Adjuster
39199020
Bearing Needle
CB101220
Plug - Taper :- 6 X 7
39104119
Seal -Oil
31101060
Plug
DH101152
Ring - O :- Oil Level Guage
DG101418
Gauge
DS101215
Clip - Wire
DJ101657
Clutch Cover P2010
DK101738
Decal Cover RH
104
102
180
SPC Updation Details

Page Fig. Old part New part
Description
no. no.
no.
no.
68
3 DJ151088 JG131219 Coupling Rubber
180
SPC Updation Details

Updation
Remarks
date
30.01.12 Modified for Improvement
68
---------
JN131812 Shoe Brake Assly
30.01.12 Non Asbestos implementation
72
21
--------
DJ201246 Clutch Switch
30.01.12 Transil Diode Type
72
--------
DJ191083 Clutch Lever
30.01.12 For Transil Diode Type Clutch Switch
--------
36DJ4028 Cyl. Head with Cover
31.01.12 W/o NRB from Eng. no. BUG20501
--------
DK101748 Rocker Shaft Intake
--------
DK101751 Rocker Shaft Exhaust
--------
DK101755 Rocker Arm
--------
DH101295 Wave Washer
--------
39244011 Plain Washer
72
23 DK181046 DK181082 H/bar tube assly LH
02.02.12
72
24 DK181047 DK181086 H/bar tube assly RH
02.02.12
Page Fig. Old part New part

no.
no. no.
no.
Description
Updation
date
Remarks
Parts Index
113
180
Parts Index
180
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
22150451
52
39097204
40
39168004
20
72A
39213217
10
28101174
14
24
39099906
11
26
39168004
88
39214124
90
30141039
80
39099906
28
39168004
11
94
39215220
14
30151069
68
39104011
15
46
39168004
12
96
39215704
46
30151095
70
39104119
26
39168606
14
39215811
16
30151105
68
39106204
15
94
39168606
38
39215911
13
16
30161157
58
39106901
54
39168904
11
10
39216011
16
30178001
80
39107504
39177802
84
39216511
12
30191048
86
39118011
28
72A
39178001
11
32
39216611
11
16
30201029
94
39118415
11
72
39178301
12
94
39218006
22
30201085
16
96
39122411
15
50
39184504
11
22
39218006
24
24
30201104
15
96
39122411
12
68
39188020
39218106
10
31101173
12
39122515
92
39188020
10
30
39218106
18
24
31121006
10
39128215
52
39190204
44
39218304
12
31161018
12
82
39128321
28
39190204
82
39218520
24
31181101
15
74
39150711
96
39190701
90
39218819
24
36314002
48
39152401
14
90
39190701
94
39219019
11
24
39021111
11
56
39155304
12A
72
39193120
12
39219421
38
39029215
54
39155604
18
82
39194304
18
94
39220011
16
30
39040048
66
39162011
14
39194404
18
42
39220307
12
39042215
10
58
39166005
39195604
96
39220804
92
39071111
56
39167204
14
39196704
10
46
39224120
62
39071601
13
90
39167204
56
39197015
36
39231004
13
46
39072211
26
68
39167304
13
39197215
94
39231004
100
39074011
80
39167404
39199020
22
26
39231004
100
39075201
24
39167404
11
14
39199715
13
50
39238104
80
39078708
58
39167404
38
39199715
14
68
39238315
17
20
39079415
24
68
39167704
19
24
39199819
11
20
39238315
70
39084001
62
39168004
48
39201719
39241204
46
39090012
62
39168004
56
39206004
12
58
39241204
14
46
114
Parts Index
113
180
Parts Index
180
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
Figure
No.
Page
No.
39242411
82
59050008
22
36DJ4030
72
52DH0177
10
14
39242411
19
82
59050008
24
36DJ4030
92
52DH0528
76
39242704
17
72
59100002
42
36DJ4034
39244011
59110002
36DK0009
52DH0529
76
36
52DH0530
76
39244311
18
26
59200006
24
36DK0011
46
52DH0531
76
39244811
12
10
59200007
16
40
36DK0012
50
52DH0532
76
39244811
22
24
59200027
39245304
20
59210006
22
36DK0013
52
52DH0533
76
24
36DK0013
54
52DH0534
76
39248415
11
80
59210019
86
36DK0015
34
52DH0535
76
39253204
36DH1004
19
26
36DK0023
100
52DH0624
1A
28
39253921
39254220
36DH1005
23
26
36DK0033
100
52DH0673
76
36DH1006
28
36DK0034
12
70
52DH0674
76
39255717
14
36DH1007
11
28
36DK0036
17
68
52DH0675
76
39256611
15
68
36DH1601
82
36DK0038
12
52DH0676
76
39258204
54
36DH1902
15
64
36DK0076
40
52DH0682
78
39258320
22
36DH4010
34
36DK0077
14
40
52DH0683
78
39260120
22
36DH4011
36
36DK0084
78A
52DH0686
28
39260320
24
36DH4015
14
70
36DK0088
78A
52DJ0357
78
39260607
18
36DH4019
13
12
36DS1001
52DJ0358
78
39260801
11
36DH4020
11
90
36DS1001
52DJ0359
78
39263904
18
36DH4030
36DU1901
12
72
52DJ0360
78
39264715
36DH4034
78A
36DV0007
48
52DJ0361
78
39268620
68
36DH4035
78A
36JC0006
70
52DJ0362
78
39268720
68
36DH4037
78A
36JC0007
68
52DJ0363
78
39275821
10
80
36DH4038
78A
36JC0008
12
78
52DJ0364
78
59010013
94
36DJ1004
36JC0009
12
78
52DJ0390
26
59020001
11
82
36DJ4017
1A
26
36JC0010
12
78
52DJ0408
78
59040005
18
74
36DJ4023
78A
36JC0011
12
78
52DJ0409
78
59040040
56
36DJ4024
78A
52DH0153
12
40
52DJ0449
12
80
59040043
11
46
36DJ4026
26
52DH0169
38
59200028
24
Part No.
114
Parts Index
113
180
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
60111415
18
96
DG101498
16
24
AA101437
24
16
DG111008
AA101437
22
DG141028
AA121045
34
DG151005
AL201012
11
96
BA122003
13
CL201023
CS101128
Parts Index
180
Figure
No.
Page
No.
Figure
No.
Page
No.
DH101141
26
DH101389
13
40
42
DH101142
26
DH101390
20
24
15
80
DH101143
62
DH101144
20
DH101392
11
20
DH101393
20
DG151007
12
62
DH101146
18
DH101394
10
20
80
DG151008
62
DH101154
13
26
DH101412
15
90
DG151049
DG161121
10
62
DH101157
28
DH101414
10
10
82
DH101163
15
40
DH101424
14
CS101128
14
DG161124
36
DH101172
40
DH101432
14
DD101062
15
DG171018
50
DH101180
15
30
DH101468
36
DD111012
DD111048
16
42
DG171019
50
DH101195
11
12
DH101482
24
26
14
42
DG171020
12
50
DH101197
26
DH101487
10
22
DD121007
10
DG171021
11
50
DH101199
42
DH101493
18
DD141227
80
DG171022
14
50
DH101203
12
24
DH101496
18
DE151008
15
62
DG171034
10
50
DH101235
16
DH101503
20
DE151037
66
DG171038
50
DH101246
13
24
DH101508
DE151043
66
DG181008
72
DH101272
10
DH101509
20
DE151045
66
DG181008
20
74
DH101275
30
DH101510
25
26
DE151046
66
DG181042
48
DH101295
DH101521
36
DE151047
66
DG181045
24
74
DH101302
36
DH101544
17
26
DE151048
66
DG181048
48
DH101319
18
16
DH101581
40
DE191010
64
DH101006
22
DH101323
10
28
DH101608
10
36
DE191011
64
DH101018
12
26
DH101333
19
16
DH101648
14
30
DE191043
64
DH101048
DH101373
12
14
DH101661
15
24
DF161102
58
DH101064
10
12
DH101380
42
DH101705
20
DF181098
90
DH101065
12
12
DH101381
42
DH101861
30
DG101029
DH101072
14
DH101385
40
DH111012
10
DG101418
26
DH101079
16
DH101386
42
DH111013
10
42
DG101456
10
24
DH101084
16
DH101388
20
26
DH111013
17
42
DG101498
11
DH101111
15
16
DH101388
28
DH111015
15
42
Part No.
Part No.
114
Parts Index
113
180
Parts Index
180
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
DH111016
19
42
DH161190
17
46
DJ101215
DJ151075
10
66
DH111081
42
DH161273
46
DJ101217
DJ161069
56
DH111083
42
DH161283
88
DJ101271
28
DJ161072
94
DH111084
10
40
DH161293
94
DJ101350
30
DJ161079
100
DH121010
38
DH161293
16
94
DJ101369
30
DJ161080
100
DH121011
15
26
DH171019
50
DJ101371
10
DJ161122
54
DH121012
16
26
DH171019
62
DJ101372
DJ161126
52
DH121035
38
DH171019
13
68
DJ101389
22
DJ161127
52
DH121038
DH181009
12
74
DJ101390
DJ161128
54
DH121101
32
DH181052
10
90
DJ101391
36
DJ161129
54
DH121149
32
DH191007
13
72
DJ101420
36
DJ161132
48
DH121150
13
32
DH191008
14
72
DJ101672
22
DJ161133
48
DH141020
76
DH191017
25
72A
DJ101689
14
DJ161186
10
54
DH141021
16
80
DH201040
17
90
DJ111092
42
DJ161228
13
28
DH141023
82
DH201065
13
58
DJ121022
DJ161229
12
90
DH141024
14
80
DH73032V
76
DJ121041
32
DJ161247
96
DH141031
82
DH73034K
76
DJ121044
32
DJ161272
10
56
DH151029
10
70
DH73034L
76
DJ121051
32
DJ161304
10
78
DH161046
44
DH73034M
76
DJ121053
32
DJ161305
10
78
DH161053
52
DH73035L
76
DJ121054
32
DJ161306
10
78
DH161056
52
DH74014K
78
DJ121055
32
DJ161307
10
78
DH161066
58
DH74014L
78
DJ121056
32
DJ161313
10
78
DH161100
11
54
DH74014M
78
DJ121057
12
32
DJ161324
54
DH161112
48
DH74015C
78
DJ121059
14
32
DJ171035
50
DH161121
58
DJ101004
10
DJ121068
34
DJ181011
16
72
DH161145
58
DJ101012
DJ121070
10
32
DJ181033
90
DH161146
58
DJ101063
23
16
DJ121071
34
DJ181037
90
DH161189
46
DJ101064
36
DJ141008
82
DJ181069
16
90
DH161189
16
46
DJ101106
10
DJ141061
13
78
DJ181083
19
94
DH161190
46
DJ101158
10
DJ151074
66
DJ181119
84
114
Parts Index
113
180
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
DJ181120
90
DJ201176
90
DJ191027
64
DJ201181
DJ191028
64
DJ201195
DJ191029
64
DJ201202
DJ191030
64
DJ191031
10
DJ191034
DJ191035
Parts Index
180
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
DK101107
17
16
DK101565
30
92
DK101118
16
16
DK101569
30
21
72A
DK101126
13
30
DK101570
17
30
11
42
DK101135
10
18
DK101571
30
DJ201205
96
DK101144
10
16
DK101573
11
30
64
DJ201206
92
DK101159
18
DK101574
30
13
64
DJ201206
92
DK101160
18
DK101592
10
14
64
DJ201207
92
DK101176
40
DK101605
40
DJ191054
8A
72
DJ201207
92
DK101177
16
20
DK101636
15
30
DJ191055
72
DJ201246
21
72A
DK101180
13
20
DK101738
21A
26
DJ191056
11
64
DJ201248
96
DK101182
20
DK101748
DJ191057
64
DJ221003
30
72A
DK101185
14
20
DK101751
DJ191061
86
DJ221004
31
72A
DK101185
70
DK101755
DJ191071
84
DJ71075F
76
DK101186
15
20
DK101762
28
DJ191081
8A
72
DJ71075G
76
DK101187
12
20
DK101770
12
40
DJ191082
72
DJ72012V
76
DK101187
70
DK141001
80
DJ191083
72
DJ72014K
76
DK101245
20
16
DK141013
80
DJ201020
96
DJ72014L
76
DK101248
12
DK141014
80
DJ201021
21
24
DJ72014M
76
DK101251
26
DK141015
21
82
DJ201028
11
96
DJ72015C
76
DK101253
20
DK141017
20
82
DJ201049
92
DJ74012V
78
DK101326
DK151008
13
62
DJ201050
92
DJ902503
14
DK101352
21
16
DK151009
10
68
DJ201072
90
DK101072
12
30
DK101361
18
DK151012
19
68
DJ201106
13
58
DK101094
24
DK101380
17
24
DK151013
20
68
DJ201108
16
64
DK101097
23
24
DK101382
18
DK151014
11
68
DJ201109
12
64
DK101102
16
DK101386
DK151015
23
68
DJ201126
96
DK101103
16
DK101471
16
DK151022
68
DJ201140
14
96
DK101104
16
DK101480
14
12
DK151026
60
DJ201159
84
DK101105
12
16
DK101480
14
26
DK151027
62
DJ201174
84
DK101106
14
16
DK101564
30
DK151028
62
Part No.
114
Parts Index
113
180
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
DK151036
25
68
DK181010
74
DK151039
60
DK181011
10
DK151040
60
DK181012
DK151054
66
DK181013
DK151057
64
DK161085
DK161086
DK161096
Parts Index
180
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
DK181081
72
DS101316
74
DK181082
23
72A
DS101333
31
74
DK181085
72
DS101335
32
74
DK181086
24
72A
DS101336
DK181017
28
74
DK191013
70
DS101353
10
26
56
DK181018
17
74
DK201003
94
DS101353
28
56
DK181019
74
DK201037
96
DS101353
12
28
46
DK181020
29
74
DK201038
96
DS101353
11
40
DK161098
56
DK181021
74
DK201065
80
DS101366
DK161122
58
DK181022
13
74
DK201078
13
96
DS151073
22
68
DK161123
82
DK181023
14
74
DK211001
44
DS151074
18
68
DK161124
10
82
DK181024
25
74
DK211004
44
DS161125
56
DK161137
54
DK181025
26
74
DK211007
44
DS161224
48
DK161147
100
DK181026
27
74
DK211008
44
DS191052
15
72
DK161148
100
DK181027
72
DK221011
98
DS191052
18
72
DK161153
94
DK181027
19
74
DK221024
98
DS211004
44
DK161159
46
DK181036
22
72A
DK73042V
76
DS211005
44
DK161160
46
DK181036
29
72A
DK74022T
76
DV101042
28
DK161161
12
46
DK181038
72
DK74023A
76
DV101048
22
16
DK161176
100
DK181039
72
DK7402X3
76
GH201012
92
DK161209
84
DK181056
74
DL181010
90
JC101001
12
DK161250
88
DK181057
74
DL191014
10
72
JC101029
22
DK161308
54
DK181058
27
72A
DP161144
13
94
JC101033
28
DK171003
50
DK181060
72
DP161145
10
94
JC101034
12
DK171006
50
DK181062
72
DS101096
JC101035
10
DK171014
50
DK181063
72
DS101154
12
JC101040
21
26
DK181006
74
DK181070
74
DS101166
JC101045
24
DK181007
74
DK181071
16
74
DS101215
26
JC101086
DK181008
30
74
DK181072
74
DS101263
26
JC101114
40
DK181009
33
74
DK181073
11
74
DS101276
JC101115
40
Part No.
114
Parts Index
113
180
Part No.
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
JC111022
12
42
JC191002
70
JC111023
13
42
JC191004
86
JC141015
15
82
JC191009
70
JC141016
17
82
JC201004
13
70
JC141017
16
82
JC201004
96
JC141050
11
78
JC201016
10
96
JC141051
11
78
JC201017
72
JC151002
68
JC201018
72
JC151005
68
JC201027
17
96
JC151007
27
68
JC201039
11
58
JC151008
11
70
JC201043
86
JC151010
60
JC201045
19
72
JC151011
16
68
JC201046
14
62
JC151013
60
JD171018
14
82
JC151013
62
JE541212
10A
28
JC151016
21
68
JG131219
68
JC151020
11
62
JM171003
11
50
JC161002
54
JM171004
12
50
JC161014
11
48
JN131812
68
JC161015
10
48
JW171007
13
82
JC161017
58
JW401011
94
JC161031
48
LAC00020
27
72A
JC181022
22
74
JC181023
21
74
JC181024
23
74
JC181025
17
94
JC181026
14
94
JC181029
26
72A
JC181029
82
JC191001
70
Parts Index
Part No.
180
Figure
No.
Page
No.
Part No.
Figure
No.
Page
No.
114

Manual de Partes Pulsar 180 UG4

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180 UG4

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Spare Parts Catalogue

DOC. NO.: 71111553

REV. 01, MAR. 2012

Brand ID: 001MC607

Cover Cylinder Head

Head Cylinder with Cover

Domed Cap Nut

From Eng, No.

Front Wheel Direction

Brand ID: 001MC607

O Ring Kit for Cover Cyl. Head

O Ring (Intake Pipe)

Ref. Page No.101

Front Wheel Direction

Brand ID: 001MC607

Rocker Arm Shaft - Intake

Rocker Arm Shaft - Exhaust

Rocker Arm with roller

Valve Repair Kit

From Eng, No.

Ref. Page No. 101

Front Wheel Direction

Brand ID: 001MC607

Sprocket cam Driven (32 T)

Cam chain Tensioner pivot Bolt

Front Wheel Direction

Brand ID: 001MC607

Cylinder and Piston

Cylinder Block / Piston Assly

Front Wheel Direction

Brand ID: 001MC607

Crankshaft assly. comp.

Ref. Page No.101

Front Wheel Direction

Brand ID: 001MC607

Balancer & Balancer Idler Gear

Body Balancer Assly.

Spring torsion Balancer Idler

Front Wheel Direction

Brand ID: 001MC607

Front Wheel Direction

Shaft Input Transmission

Gear 3rd Drive

Gear 1st driven

O Ring Sprocket Collar

Brand ID: 001MC607

Change Drum / Shift Fork

Fork Gear Shift Input

Front Wheel Direction

Brand ID: 001MC607

Gear Change Mechanism

Lever comp. Gear Shifter

Assembly lever change arm

Front Wheel Direction

Brand ID: 001MC607

Engine Assly. & Crankcase RH

Engine Assly. with starter motor

Bearing Ball (For Input shaft)

Front Wheel Direction

Brand ID: 001MC607

C Sunk Head Screw