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

Volts

N.I.

Not illustrated

Watts

C'case

Crankcase

accl.

Accelerator

Cyl

Cylinder

Comp.

Complete

o/s.

Over size

Fr

Front

Std.

Standard

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.:

CARNKSHAFT

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.:

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

Remarks

Ref. Page No. 58

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

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

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

RingO
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

Description

180

Remarks

Plate No. 5 : CYLINDER AND PISTON

No.

6302 - RS1/C3
6002 - C3
Ref. Page No.58

Part No.

1
2
3
4
5

DJ
39
DJ
DJ
39

1010
2181
1011
1011
2132

04
06
58
06
17

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

Remarks

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

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

Ref. Page No.58

7mm. (Height)

180

Remarks

Ref. Page No. 58

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

Description

180

No.

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

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

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)

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

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

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

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

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

25

Brand ID: 001MC607

Brand ID: 001MC607

Plate No. 21 : OIL PUMP

180

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

180

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

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

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

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

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 csunk 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

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

17

16

14
6
7
1

8/9
15

2
12

13

2
2

6
7

7
8

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

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

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

LH
LH
RH
RH

1
1
1
1
1
1
2
2

Remarks

56
57
28
13
29
15
22
17

DJ
DJ
DJ
DH
DJ
DH
DJ
DH

Qty/
Veh.

Description

1612
1612
1611
1613
1611
1613
1611
1613

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

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

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

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

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

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

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.

Part No.

Qty/
Veh.

Description

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

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

DK
DK
DK
DK
DK

7302
7302
7302
7302
7302

2T
2V
3A
3M
X3

Side
Side
Side
Side
Side

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.

DJ 7302 2T
DJ 7302 2V
DJ 7302 3A
DJ 7302 3M
DJ 7302 X3

Front
Front
Front
Front
Front

DH 1410 20

Seat tape

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

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.

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

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

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

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

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

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

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

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

61

Brand ID: 001MC607

Brand ID: 001MC607

KIT LIST
Sr.
Kit Part No. Kit Description
No.

36DS1001 Cyl.Head O Ring Kit

180
Consisting of Following Parts
Part No.

Description

Qty./Kit

39239121

O Ring (Cover tappet)

39128321

O ring

Valve Intake

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

36DJ1004 Valve Kit

DJ101124
DJ101125

Valve Exhaust

DH101302

Trust screw

36DK0005 Valve Repair Kit

DS101083

Retainer valve spring

DH101481

Grommet shield

DH101731

Spring valve inner

DH101730

Spring valve outer

39185004

Flange bolt

DH101026

Seat valve spring

DH101017

Guide chain (Tight)

DH101010

Guide Chain (slack)

DH101628

Gear primary drive

DK101127

Driven

xxxxxxxxx

Clutch Housing

39220011

Washer

DH101234

Gasket centrifugal oil filter

39226701

Oval screw

DH101066

Join oil dealivery

DH101067

Spring oil delivery

4
5

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

DH101284

Damper A

DH101285

Damper B

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

DD161071

U nut

DH161155

Damper silencer

DH161157

Tube silencer mounting

39231204

Bolt flange

39197015

Nut flange

39241304

Bolt flange

DH161245

U Nut

DH181025

Bearing cone

DH181026

Bearing race

DH181024

Upper bearing race

39071411

Plain washer

39071215

Dome cap nut

39073712

Spring washer

DJ161186

Plait side pillion stape

DH101286

Damper C

DH101287

Damper D

DH161061

Pin pillion set

DH101288

Plate A

30141031

"O" ring

DH101289

Plate B

39104011

Plain washer

39078408

Split pin

30151038

"O" ring

DH101290

Plate C

DH101291

Plate D

DH101282

Damper Cover Magneto

DD151009

Indicator

DH101292

Damper A Cover LH RR

DJ151059

Lever brake

DH101294

Damper B Cover LH RR

39244704

Lever brake

DH101283

Plate Damper

39079815

Nut

DH101293

Plate Damper Cover LH RR

DJ151086

Sprocket (43 teeth)

DH101185

Spring Kick Starter Arm

DJ151096

Chain

DH101068

Ball steel

DH101117

Sprocket Drive

DH101131

Base kick lever

39212104

Flange bolt

DH191013

Sprocket brake shifter assly

39153721

"O" ring

DH191023

Dust cap

DH101320

Hex. bolt with flange

DK101162

Bracket lock

01110609

Plain washer

39169801

Screw pan cross

39177304

Bolt flange

31121043

Coller

39071111

Plain washer

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

39021911

Plain washer

39080808

Split pin

30191035

Spring

15191026

Pin

30191036

Brake adjustment nut

39078912

Spring washer

3079415

Nut lock

39080708

Pin snap

39020111

Plain washer

30191024

Screw

30191017

Nut

39021911

Plain washer

39072504

Hex bolt

DJ181089

Seal dust

DJ181088

Ring snap

DS181072

Guide bush washer

DS181070

Guide bush

DH161158

Grommet side cover

DH161133

Grommet side cover rear

DH161259

Case chain upper assly

DH161262

Case chain lower assly

DJ181029

Coller faring mounting

DJ181064

Grommet fearing mounting

39021111

Plain washer

39155304

Flange bolt

DH161137

Hook leg guard

DH161139

Spacer leg guard

39227515

Dome cap nut

DH161255

Flange bolt

39078912

Spring washer

39008004

Bolt

59040013

Cap bolt

39029615

Hex nut

DH161144

Cap saree guard

DD221003

Plug

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
39074011
39074601
39075201
39076101
39078111
39078615
39078708
39078708
39078912
39079415
39080115
39084001
39089704
39099311
39099906
39099906

6
13
2
6
3
4
3
6
9
5
3
6
7
11
2
11
3
3
12
5
10
4
5
16
8
10
12
11
5
7
7
13
18
18
8
7
6
4
9
8
3
1
28
24
14
2
5
9
11
4

3
6
23
24
24
30
32
35
42
23
44
44
44
45
47
56
61
1
2
31
36
4
5
33
35
37
32
32
58
36
55
56
21
33
51
27
13
27
39
39
37
39
48
43
42
51
55
20
15
17

39104119
39106204
39106901
39107404
39107404
39107404
39107404
39107504
39118415
39128321
39141402
39150711
39152401
39155604
39160601
39162011
39166005
39167204
39167204
39167204
39167404
39167404
39167404
39167404
39167404
39167404
39167704
39168004
39168004
39168004
39168004
39168004
39168606
39168606
39171404
39174104
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Brand ID: 001MC607

Brand ID: 001MC607

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39253105
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DD111012
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DD141022
DD151036
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DE151008
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DG101418
DG101498
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DG181008
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DG221040

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DH101011
DH101013
DH101018
DH101048
DH101064
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DH101072
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DH101079
DH101080
DH101082
DH101084
DH101108
DH101110
DH101111
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DH101116
DH101117
DH101121
DH101125
DH101141
DH101142
DH101144
DH101146
DH101154
DH101157
DH101159
DH101163
DH101164
DH101169
DH101172
DH101180
DH101188
DH101195
DH101197
DH101199
DH101203
DH101225
DH101235
DH101246
DH101269
DH101272
DH101272
DH101275
DH101278
DH101281
DH101319
DH101321
DH101333

5
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DH101336
DH101372
DH101397
DH101412
DH101416
DH101422
DH101423
DH101468
DH101485
DH101487
DH101493
DH101496
DH101502
DH101503
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DH101521
DH101525
DH101531
DH101533
DH101536
DH101537
DH101538
DH101539
DH101540
DH101545
DH101548
DH101572
DH101581
DH101648
DH101654
DH101658
DH101703
DH101705
DH101714
DH101743
DH101781
DH101782
DH101784
DH111012
DH111013
DH111015
DH111016
DH111039
DH111040
DH111058
DH121001
DH121002
DH121010
DH121011
DH121012

11
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DH121015
DH121035
DH121038
DH121101
DH141020
DH141023
DH141024
DH141031
DH141048
DH141050
DH151029
DH151062
DH161053
DH161066
DH161073
DH161100
DH161112
DH161121
DH161145
DH161146
DH161170
DH161189
DH161190
DH161194
DH161273
DH161284
DH161292
DH161293
DH161301
DH161303
DH161304
DH161305
DH161310
DH161313
DH161315
DH161317
DH171012
DH171013
DH171014
DH171015
DH171019
DH171019
DH181009
DH181014
DH181015
DH181022
DH181023
DH181040
DH181048
DH181052

14
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69

Brand ID: 001MC607

Brand ID: 001MC607

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DH181053
DH181055
DH181056
DH191001
DH191006
DH191007
DH191012
DH191017
DH191019
DH201011
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DH201019
DH201048
DH201049
DH201062
DH201064
DH201065
DH211005
DH221003
DH71022T
DH71022V
DH71023A
DH71023M
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DJ201109
DJ101004
DJ101012
DJ101022
DJ101063
DJ101064
DJ101106
DJ101109
DJ101110
DJ101133
DJ101134
DJ101136
DJ101137
DJ101158
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DJ101213
DJ101222
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DJ101230
DJ101231
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DJ121040
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1
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9
7
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DJ191054
DJ191055
DJ191056
DJ191057
DJ191058
DJ191059
DJ191060
DJ191061
DJ201020
DJ201021
DJ201028
DJ201035
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DJ201108
DJ201125
DJ201130
DJ201132
DJ201140
DJ201141
DJ201144
DJ201146
DJ201147
DJ201148
DJ201149
DJ201153
DJ201159
DJ201174
DJ211003
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DJ221003
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DJ73022V
DJ73023A
DJ73023M
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3
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DJ74012T
DJ74012V
DJ74013A
DJ74013M
DJ7401X3
DK101001
DK101125
DK101126
DK101135
DK101149
DK101150
DK101151
DK101153
DK101154
DK101155
DK101157
DK101158
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DK101160
DK101161
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DK101163
DK101176
DK101255
DK101338
DK101356
DK141001
DK161123
DK161124
DK161153
DK201003
DK201016
DK201024
DK211007
DK73012T
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7
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DM181010
DP161144
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DS101026
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DS101201
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DS101275
DS101276
DS101277
DS101333
DS101335
DS101336
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DS151029
DS151031
DS151048
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DS151058
DS151068
DS151073
DS151074
DS181022
DS181071
DS181077
DS181085
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19
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