Spare Parts Catalogue

Transcription

1 MOTORCYCLES Bajaj Auto Limited Akurdi Pune 0 India Spare s Catalogue

2 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.: REV. MARCH

3 Foreword Instructions We have pleasure in presenting the Spare s Catalogue for Pulsar DTS-I 0 BS IV Motorcycle. This catalogue has been specially designed to assist you in selecting the correct parts for procurement to maintain 00% availability.. 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 Numbers can change without notice. Consequently, the description in this Spare s 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 s Catalogue as per circulars so as to keep your catalogue up-to-date. This will ensure appropriate and speedy delivery of the Spare s 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 0 India 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.. How to Order Spare s : 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.. Number System : We have used 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 -- or -- digit system. Understanding this system will enable you to identify the spare parts easily.. 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

4 Index Plate Index Cover Cylinder Head SAI Unit Cylinder Head Valve Camshaft / Tensioner Cylinder & Piston Crankshaft Balancer & Balancer Idler Gear Transmission Change Drum / Shaft Fork Gear Change Mechanism Engine Assly. & Crankcase RH Crankcase LH Cover RH Cover Magneto Clutch Kick Starter Mechanism Carburettor Air Cleaner Complete Silencer Assembly Seat Assembly / Seat Lock Oil Pump Magneto, CDI & H.T. Coil Starter Assembly (For Self Start) Engine Mountings Frame and Frame Fittings Swing Arm / Rear Shock Absorber Rider Foot Rest Pillion Foot Rest / Holder Mudguard - Front & Rear Stand Assembly Page Plate Tube / Tyre / Rim Front Hub (For Drum Brake System) FR. Master Cylinder (For Disc Brake) Front Disc Brake Rear Hub Rear Brake Padal Handle Bar Front Fork Cap Tank & Gauge Fuel EVAP System Fittings P. Tank, Side Cover & Cover Seat Meter Assembly Control Cables Chain Case Head Lamp & Fairing Indicator Light Assembly Tail Lamp Assly / FR & RR Plate Tool Kit Electrical Equipments Accessories / Grab Handle Painted s & Decals Painted s & Decals Kit List SPC Updation Details s Index Page

5 Pictorial Index Pictorial Index PLATE NO. : COVER CYLINDER HEAD & PLATE NO. : SAI UNIT & PLATE NO. : CAMSHAFT / TENSIONER & 0 PLATE NO. : CYLINDER & PISTON & PLATE NO. : CYLINDER HEAD & PLATE NO. : VALVE & PLATE NO. : CRANKSHAFT & PLATE NO. : Balancer & Balancer Idler Gear &

6 Pictorial Index Pictorial Index PLATE NO. : Transmission & PLATE NO. : 0 PLATE NO. : & PLATE NO. : Gear Change Mechanism Change Drum / Shaft Fork Engine Assly. & Crankcase RH PLATE NO. : & 0 Crankcase LH & Cover Magneto PLATE NO. : & PLATE NO. : & 0 PLATE NO. : Cover RH Clutch Assly & &

7 Pictorial Index Pictorial Index PLATE NO. : Carburettor & PLATE NO. : Air Cleaner Complete & PLATE NO. : Oil Pump & PLATE NO. : Magneto, CDI & H.T. Coil & PLATE NO. : Silencer Assembly & PLATE NO. : 0 Seat Assembly / Seat Lock & 0 PLATE NO. : Starter Assembly (For Self Start) & PLATE NO. : Engine Mountings &

8 Pictorial Index Pictorial Index PLATE NO. : Frame Fittings & 0 PLATE NO. : Swing Arm Assembly & PLATE NO. : Stand Assembly & PLATE NO. : 0 Tube / Tyre / Rim & 0 PLATE NO. : Rider & Pillion Foot Rest / Holder & PLATE NO. : MUDGUARD FRONT & REAR & PLATE NO. : FRONT HUB & PLATE NO. : FRONT MASTER CYLINDER &

9 Pictorial Index PLATE NO. : Front Disc Brake Rear Hub Pictorial Index & PLATE NO. : REAR HUB & PLATE NO. : Rear Brake Pedal & PLATE NO. : Rear Disc Brake Master Cylinder & PLATE NO. : Front Fork & PLATE NO. : HANDLE BAR to PISTON SEAL DUST SEAL BLEEDER CAP x PROTECTION BOOT INSULATOR CALIPER PISTON BLEEDER SCREW PAD SPRING PLATE NO. : Rear Disc Brake & 0 PLATE NO. : 0 Cap Tank & Gauge Fuel & 0

10 Pictorial Index Pictorial Index PLATE NO. : EVAP System & PLATE NO. : Fittings P. Tank, Side Cover & Cover Seat & PLATE NO. : Meter Assembly & PLATE NO. : Control Cables & PLATE NO. : Chain Case PLATE NO. : Indicator Light Assembly & 0 & PLATE NO. : Head Lamp & Fairing & PLATE NO. : Tail Lamp Assly / FR & RR Plate &

11 Pictorial Index PLATE NO. : Tool Kit Pictorial Index & PLATE NO. : 0 Electrical Equipment & 00 0 PLATE NO. : Accessories / Grab Handle 0 & 0 PLATE NO. : Painted s 0 & 0 PLATE NO. : Painted s & Decals 0 & 0

12 Plate : 0 BS IV Cover Cylinder Head 0 DJ 0 DJ 0 DS 0 DH 0 0 DS DH 0 DG 0 Cylinder Head With Cover Cover Tappet O Ring Kit For Cover Cyl. Head Silent Bush (V) Camshaft Cap Domed Cap Nut Copper Gasket Hex. Bolt With Flange Hex. Bolt / Flange Plug Gasket 0

13 Plate : 0 BS IV SAI System 0 PD 00 JL JL 0 DJ 0 DK 0 DH 0 DH 0 DH 0 0 KA EG0 JD JD KA DF0 0 KC GF0 0 SAI Unit Clamp SAI Pipe Clamp Clamp Hose SAI Tube SAI Air Filter Hose SAI Unit To Manifold Metal Pipe With Flange SAI Hose SAI Unit To SAI Pipe Gasket Metal Pipe With Flange SAI Flanged Bolt Grommet SAI Unit Sleeve SAI Unit Bolt Flanged Nut Hex Flanged. 0 Front Wheel Direction

14 Plate : 0 BS IV Cylinder Head DJ 00 DH 0 0 DJ 0 0 DJ 0 DH 0 0 DH DS0 0 KA EG0 DH 0 0 Stud (exhaust) Gasket Cylinder Head Damper Cylinder Head Intake Manifold O Ring (intake Pipe) Carburetor Insulator Clamp For Insulator Hex. Bolt / Flange Sleeve - Spark Plug Grub Screw O Ring Kit For Cover Cyl. Head Bolt Flange Gasket /Veh. N.I N.I

15 Plate : 0 BS IV Valve DK 0 DK 0 DK 0 DG 00 0 DK 0 DJ0 0 DH 0 0 Rocker Arm Shaft - Intake Rocker Arm Shaft - Exhaust Rocker Arm Assembly Cotter valve Seal valve stem Valve Repair Kit Valve Kit Wave washer Plain washer /Veh.

16 Plate : 0 BS IV Camshaft / Tensioner 0 DJ 0 JC 00 JC 00 Dh0 0 PD DH 0 DH 00 DH 0 JC 00 DH 0 JC 00 0 CS 0 DD 00 Camshaft Assembly Bearing Ball -XX Bearing Ball 00 C Guide chain Kit Sprocket cam Driven Collar cam Sprocket Special camshaft washer Hex. Soc.Head cap Bolt Cam Chain Cam chain Tensioner pivot Bolt Tensioner Assly Hex Bolt / Flange Tensioner assly. gasket Ring O Tension assly Bolt /Veh. 0 0

17 Plate : 0 BS IV Cylinder and Piston /Veh. DJ DJ 0 DK 0 DJ 0 DK DD 0 0 Gasket Cylinder Pin Dowel Piston Assly. Std. Ring Set Piston Ring Snap Cylinder Block / Piston Assly Assembly Oil Pipe Gasket Bolt

18 Plate : 0 BS IV Crank shaft 0 0 JC 00 0 DH 0 0 DS 0 0 DK DK00 DH 0 DH 0 DH 0 PD 0 Crankshaft assly. comp. Bolt Plain washer Key woodruff Parallel key Bearing Ball Kit centrifugal over screw oil filter Parallel pin Kit Gear Primary Drive & Driven Body centrifugal oil filter Nut primary drive Cover centrifugal oil filter Sprocket Crankshaft /Veh. N.I

19 Plate : 0 BS IV Balancer & Balancer Idler Gear 0 0 DJ 0 DH 00 DH 0 DH 00 0 DH DH Body Balancer Assly. Bearing stopper Bolt stopper Gear Complete Balancer Idler Needle roller bearing Spring torsion Balancer Idler Circlip ext. Dowel Pin Spring steel washer Balancer Idler Holder Hex bolt with flange Bearing Balancer /Veh.

20 Plate : 0 BS IV Transmission DK 0 DK 0 0 DH 00 DH 0 DK 0 0 DK 0 0 DH 00 0 DK 0 DH 0 DK 0 DK 0 0 DK 0 DH 0 DK 0 DK 0 DK 0 DH 0 DV 00 DJ 00 AA 0 Shaft Input Transmission Plain Washer Gear th Drive Washer Spline Circlip Ext Gear rd Drive Gear th Drive Gear nd Drive Plain Washer Plain Washer Gera st Driven Bush st Driven Gear th Driven Gear rd Driven Washer plain Gear th Driven Bush nd Driven Gear nd Driven Shaft Output Transmission O Ring sprocket Collar Collar sprocket Sprocket Drive Plate Drive Sprocket Bolt Flanged Small /Veh.

21 Plate : 0 0 BS IV Change Drum / Shaft Fork 0 DK 0 DK 0 0 DH 0 DH 0 DK DH 0 DH 0 DK 0 Fork Gear Shift Input Fork Gear Shift Output Shift Gear Shift Fork Shaft Gear Fork Shift Drum Comp. Gear Shift Bolt Socket Parallel Pin Guide Gear Shift Spacer Bush Fork Gear Shift /Veh. 0

22 Plate : 0 BS IV Gear Change Mechanism 0 DK 0 DK 0 DH 0 DK 0 DK 0 DK 0 DH DK 0 0 DK 0 DK 0 DK 0 DH 0 Assly Lever Shaft Spring Shift Return Bolt Gear shift Drum Stopper Spring Stopper Drum Stopper Drum Assembly Lever Complete Change Damper Bolt - Flange :- M Assembly Tie Rod Bolt Pivot Lever Change Washer Pivot Bolt Collar Pivot Bolt Seal - Oil Nut - Hexagon With Flange - M Spring arm reset /Veh. N.I. N.I. 0

23 Plate : 0 BS IV Engine Assly. & Crankcase RH 0 DJ 0 JC 00 DH DH 0 AA 0 0 DH 0 Engine Assly. BS IV SAI Crankcase RH Gasket Crankcase Bearing Ball (For Input Shaft) Bearing Ball (For Output Shaft) Ball Bearing Plate Stopper Bolt Flanged Small Needle Roller Bearing Bolt Shift Change /Veh. N.I 0

24 Plate : 0 BS IV Crankcase LH JC DK DK 00 DH 0 DH 0 DG 0 DH 0 KJ AB0 DK 0 0 DH DH 0 0 DG 0 DH Crankcase LH Stud M0 Screw Guide Starter Gear O Ring Damper Crankshaft Oil Seal Plate Starter Clutch Gear Return Bolt Flange Gasket Plug Drain Magnetic O Ring Neutral Switch Complete Bolt Flange Oil Seal Flange Bolt Bearing Ball Bearing Ball Bearing Ball Balancer Breather Pipe Oil Seal Breather Pipe Assly NRB /Veh.

25 Plate : 0 BS IV Cover RH 0 /Veh DJ0 DH 0 0 DH 0 DH 0 DK 0 DG 0 DS 0 DS DH 00 DH 0 DK 0 0 DH 0 DH 0 DH 0 0 DK 0 DH 0 DK 0 0 DH 0 DS 00 DK 0 0 Kit Assly Cl Cover Grommet Breather Oil Seal Rack Shaft clutch release Parallel pin Gauge Wire circlip Bolt Pin Dowel Bracket Clutch Cable Gasket cover RH Plunger Oil Plate Plunger Oil Spring Joint A Spring torsion clutch lever Washer Seal Oil Decal Clutch Cover Nut Special Lever Assly Flange Bolt O Ring Cap Oil Filter Cover Starter Motor 0

26 Plate : 0 BS IV Cover Magneto DH0 DG 0 DV 00 DK 0 AP 00 JE DS 0 DJ 0 Magneto Cover Gauge Gasket Assly Cvr LH RR Moon Light Bearing Needle Bendix Decal Magneto Cover Bolt Flanged Grear Shift Label ES KS /Veh. N.I. 0

27 Plate : 0 BS IV Clutch 0 0 DH 0 DJ 0 DJ 0 0 DK 0 DK 0 PD00 0 DK 0 PD 0 DK DK 0 DK 00 DK 0 DH 0 DK 0 00 DK 0 0 DK 0 Special Nut Friction Clutch Plate Kit Clutch Plate Assly. Complete Clutch Center Plate Clutch Pressure Clutch Friction Plate Kit Plate Clutch Spring Clutch Capacity Bolt Bolt Bearing Clutch Lifter Thrust Holder Clutch Rod Clutch Lifter Spacer Clutch Nut Primary Drive Lock Lever Assly. Clutch Washer Primary Drive Gear Seat Judder Spring Spring Judder /Veh.

28 Plate : 0 BS IV Carburettor 0 DJ 0 DJ 0 DH DH DJ 0 DJ 0 DJ 0 DJ 0 DJ 0 DH 0 DJ DJ 0 DH DJ 0 /Veh. Carburettor Assembly Carburettor Assembly Vacuum Piston Kit Set Adjuster (PS) Jet Needle (JN) O Ring Screw Float Assembly Jet Holder Kit Magnet Assembly Reed Switch Assembly Pan Head Screw Needle Assembly Idling Screw Kit Set Plunger Assembly EVAP Non EVAP 0

29 Plate : 0 BS IV Air Cleaner Complete 0 DJ 0 KB BA0 DJ 0 DK 0 DK 0 0 DH 0 DJ 0 DH 0 DS DG 0 0 DS AA 0 DH 0 0 DS Assly Air Filter for SAI Screw Pan Cross Cartridge Assemblly O Ring Assly Element Filter Breather Pipe Clip Assly Tube Connecting Clip Band Tube Drain Clamp Plug Spring Band Clip Bracket Lock Screw Pan M Duct /Veh. N.I. 0

30 Plate : 0 BS IV Silencer Assembly 0 YD J00 0 DJ 0 0 DH 0 JW 0 DJ 00 0 DK 0 00 DH DD 0 DG DH 0 DH 0 0 JB 0 Silencer Assly. W/O Shileld (With Cat) Silencer Assly. W/O Cat Shield Muffler Screw Truss Gasket Exhaust Flanged Nut Bolt socket Head Wahser Damper Silencer U Nut Damper (main Stand) Wire Shield Assly. Truss Screw Washer Nylon Shield /Veh.

31 Plate : 0 0 BS IV Seat Assembly / Seat Lock DK 0 DH 0 DK 0 DK DS 0 0 /Veh. Seat Assly comp front Lock Assly seat front Seat assly comp rear Lock assly seat rear Bolt flange Damper N.I N.I N.I 0

32 Plate : 0 BS IV Oil Pump DH0 0 DH DH 0 /Veh. Oil Pump Assly Hex. Bolt With Flange Mesh Filter Oil Pump Hollow Dowel Pin Clip Mesh Oil Filter O Ring

33 Plate : 0 BS IV Magneto, CDI & H.T. Coil DH 0 DH 0 DH 0 DH 0 DH 0 DH 0 0 DG 0 0 DJ 0 0 DJ 0 0 JC 0 JC 0 DH 0 DD 0 DH 0 DH 0 0 Spring Dowel Sleeve Stator Assly Rotor Assly. Hex. Bolt With Flange Pan Head Screw Stopper Plate (wiring Harness) Screw Pan Head Spark Plug C.D.I. Assly. Flange Bolt DC Regulator With Capacitor H.T. Coil LH With Cable H.T. Coil RH With Cable Cap Spark Plug Grommet H.T. Cable Grommet Spark Plug Cape Grommet Sleeve Spark Plug Flange Bolt /Veh. N.I. /

34 Plate : 0 BS IV Starter Assembly 0 DK00 DK 0 0 JC 0 DH 0 DH 0 DK 0 DH 0 JC DH 0 DS 0 DK 0 0 DH 0 DK 0 DH 0 Kit Body Comp. Starter Clutch Plate Roller Clutch Gear Starter Clutch(T) Plate Starter Clutch Gear Return Bolt Shaft Starter Counter Collar Starter Counter Gear Comp. Starter Counter Assly. Needle Roller Bearing Bolt Socket Motor Assly. Starter Bolt Cover Starter Motor (MLT Silver) Slotted C sunk Screw Spring Roller /Veh. N.I. 0

35 Plate : 0 BS IV Engine Mountings 0 DK DK DK DH DH 0 DJ 0 0 DT 0 Assembly Engine Mtg Bkt Top LH Assembly Engine Mtg Bkt Top RH Bolt Hex Hd Bolt Flanged - M Nut - Hexagon With Flange Bracket Complete Rh Engine Rear Flange Bolt Hex Hd Bolt/flang Bolt - Hexagon With Flange :- M Hex Hd Bolt/flang-m Bracket Complete - Engine LH FR Bracket Complete - Engine RH FR Damper Front Bracket Assly Engine Mtg FR /Veh. N.I. 0

36 Plate : 0 BS IV Frame and Frame Fittings DJ 00 DK 0 PD 0 0 JG00 DK 0 0 DK 0 Frame Assly Nut Steering Cap Steering Bearing Cone Kit Cage steering bearing top Cage steering bearing bottom /Veh. 0

37 Plate : 0 BS IV Swing Arm / Rear Shock Absorber /Veh. Swing Arm Assembly Shaft Swing Arm Seal-oil Sleeve For Swing Arm Bearing-needle Guard U Nut Swing Arm Small nut Hexagon Nut Plain Washer Cap Chain Adjuster Adjuster Chain Rear Shock Abs Asly Flanged Bolt Washer Plain Spring Washer Domed Cap Nut - M 0 DK 0 DK 0 0 DG 0 DK 0 0 DG 0 DG 0 DH 0 DG 0 JM 0 0 DJ 0 DK 0 DG 0 0 0

38 Plate : 0 BS IV Rider, Pillion Foot Rest & Step Holder 0 RH 0 DJ0 DJ0 DJ DJ DK00 DJ DJ DJ 0 0 DK 0 DH DH DD 0 0 DH 00 Holder Step LH Holder Step RH Step Assembly - Main LH Step Assembly - Main RH Kit Hardware Pillion Plate Side Pillion Step Step Assly Complete - Pillion LH Step Assly Complete - Pillion RH Screw - Hexagon Head Bolt Socket Head M0x0 Damper Silencer Tube Silencer Mounting Nut -U M0 X. X Height. Nut - Domed Cap :- M Spacer - Main Step /Veh. LH

39 Plate : 0 BS IV Mudguard - Front & Rear DK 0 DG 0 0 DS DJ 0 DK 0 0 DK 0 /Veh. Brace Fender Socket Bolt Cable Guide Nail For Cable Guide Fender Rear Front Plain Washer Flange Bolt Fender Rear

40 Plate : 0 BS IV Stand Assembly 0 DK DH DH JC 0 DH 0 DH DF 0 0 JC 00 DF 0 DH 00 Stand Main Shaft Stand Pin Cotter Spring Main Stand Cover Spring Main Stand Stand Side Spring Side Stand Cover Spring Side Stand Bolt Nut Side Stand Switch Bolt Magnet Holder /Veh. N.I 0

41 Plate : 0 0 BS IV Tube / Tyre / Rim JC 0 DK 0 DK 0 DK 0 0 DK 0 0 Wheel Rim Front (. X DC) Tyre Front Tubeless Valve Tubeless tyre Wheel Rim Rear Tyre Rear Tubless /Veh. 0

42 Plate : 0 BS IV Front Hub 0 0 DK 0 JC 0 KB BA JC 00 KP BC 0 DK 0 DG 0 0 DG 0 0 DK 0 PD 0 DG 0 0 DH 0 Front Axle Vehicle Speed Sensor Assly(pot Screw Pan Cross Washer Spring Thin Stopper plate Bearing-ball-c Clearance Spacer Front Wheel Seal-oil Collar Disc Front Bolt Washer U Nut Swing Arm /Veh.

43 Plate : 0 BS IV FR. Master Cylinder 0 0 USE G: - NIN OT OM D WAR LY ID FR R E ON FLU IN TA E AK ON AP BR D C R C ING E V LE EA FILL EMO A S AN E R LE R C FO BE 0 DE 0 DJ DJ 0 DK 0 DE 0 0 DE 0 DJ 0 DJ 0 DJ 0 0 DE 0 0 DJ 0 DJ 0 0 DE 0 DE 0 DE 0 Major Kit - Master Cylinder Hose Brake Front Lever Grip RH Banjo Bolt Washer Copper Clamp Holder RH Bolt Bolt Front Brake Lever Nut Flanged Screw Cylinder Master Front Brake Switch Reservoir Cover Diaphragm Oil Window Kit /Veh.

44 Plate : 0 BS IV Front Disc Brake A B 0A A PISTON SEAL B DUST SEAL 0 JF DE 0 DE 0 DE 0 DE 0 DE 0 DJ 0 DJ 0 DJ 0 /Veh. Caliper Assly. Front Bolt Flanged Spring Pad Bleeder Screw Bleeder Cap Disc Pad Set Insulator Protection Boot Minor Kit - Caliper Major Kit - Caliper BLEEDER CAP x INSULATOR 0A PROTECTION BOOT CALIPER PISTON BLEEDER SCREW PAD SPRING 0

45 Plate : 0 BS IV Rear Hub DK 0 0 DG 0 0 DK 0 LC A000 0 DS 0 DK00 KP AC0 0 DS 0 JC 0 JG DK 0 KP BC 0 DK 0 DK KP BC DK 0 DK 0 DH 0 Axle Rear Washer Seal Oil Nut Hex Thin M0x.x Washer Four Rubber Chain sprocket Kit Bearing Ball Ordinary Clearance Stud M0x.p Four Rubber Coupling Coupling Rubber Sleeve Bearing-ball-c Clearance Collar Bearing Assly Disc Rear Hexagon Socket Head Bolt-m Bearing-ball-c Clearance Seal Oil Spacer II Spacer I U Nut Swing Arm /Veh.

46 Plate : 0 BS IV Rear Disc Brake System DK 0 DK DK 0 0 DK 0 DK 0 DE 0 0 DK 0 Reservoir Rear Disc Brake Reservoir Tube Rear Disc Flange Bolt Reservoir Cap Bolt Hexagon Head With Flange M Clip For Reservoir Tube Banjo Bolt Copper Washer Hose Brake Rear /Veh. 0

47 Plate : 0 BS IV Rear Disc Brake - Master Cylinder & Caliper A DK 0 DK00 DK00 DK 0 DK00 DK 0 DK 0 DK 0 DK 0 DK 0 DE 0 DE 0 DK 0 DK 0 DK 0 DK 0 DK Master Cylinder Major kit caliper Minor kit caliper Circlip Push Rod Boot Connector Cap Caliper Assembly. Rear Spring Pad Bleeder Screw Bleeder cap Disc Pad Set Piston Kit (major kit) floating caliper Kit Piston Seal (Minor Kit) Insulator Kit floating caliper Kit Rear Caliper Major /Veh. 0 A 0

48 Plate : 0 BS IV Rear Brake Padal DK 0 DG 0 DK 0 DK 0 DK 0 DK 0 DK 00 0 Lever Brake Damper Bolt Pivot Lever Change Washer Pivot Bolt Collar Pivot Bolt Spring Rear Brake Switch Bkt. Rear Brake Switch Rear Brake Switch Hex. Head Bolt/flange M /Veh. N.I N.I

49 Plate : 0 BS IV Handle Bar A 0 A 0 0 DK 0 DK 0 DK 0 0 DK 0 JF 0 00 JD 0 00 DJ 0 DJ 0 DJ 0 DL 0 0 DU 0 DH 0 0 DH 0 DS 0 DK 0 0 JB DJ 0 DK 0. Upper Bracket (Black) Holder Handle RH (Black) Holder Handle LH (Black) Socket Bolt Control Switch LH Control Switch RH Lever & Support Holder Assly Holder LH Lever LH Stud Lever Handle Bolt Flange M Kit Adjusting Screw Grip LH Grip RH Boot for lever LH Handle bar weight Hex. Soc. Hd. Cap Screw Nut Nyloc M x 0. Switch Assly. Ignition Flange Bolt Clutch Switch (Transil Diode) Handle bar tube assly. LH N.I N.I N.I DK 0 Handle bar tube assly. RH DH 0 Pipe throttle DH Lock set in Non EVAP Lock Set EVAP LA C000 0 Bolt Socket Head * 0 Washer DK 0 Rubber Plug DH 0

50 Plate : 0 BS IV Front Fork 0 / DK 0 DK 0 DK 0 DK 0 0 DK 0 DK 0 0 DK 0 0 DK 0 0 DK 0 DK 0 DK 0 DK 0 DK 0 DK 0 DK DK 0 DG 0 0 JC 0 JC 0 JC 0 DG 0 DK 0 DK 0 DK 0 DK 0 0 DK 0 Fork Assembly Front Inner Dust Seal Oil seal Outer Tube LH Outer Tube RH Copper Washer Bolt Seat Pipe Fork Pipe Spinning Slide Bush Spring Main Spring Bolt fork O ring Spacer Tube Washer Seal Bolt Upper Bracket Socket Bolt Cushion Rubber Cover Trail B Lamp Shade asly. Bearing cone Upper Under Bracket Sub Assembly Spring washer Bolt Oil Seal Stopper Guide Bush /Veh.

51 Plate : 0 0 BS IV Cap Tank & Gauge Fuel /Veh. 0 DH 0 DH 0 0 KA CA0 DH 0 JG 0 JG 0 DJ 0 JG 0 DH DH 0 DD DK 00 DK 0 KC GA0 0 DJ0 Cap Assly. with CAP Cap Tank Bolt Socket Damper Rear Connector EVAP Spring Band Clamp Tube Tank To Inline Connector Spring Band Clip Grommet Side Cover RR Tank Assly Complete Bolt Flange Washer Plain Clamp Tank Unit O Ring Nut Fuel Pipe With Clamp EVAP Non EVAP 0 0

52 Plate : 0 BS IV EVAP System 0 0 JY 0 DJ 0 DJ 0 DJ 0 DJ 0 DH 0 DJ 0 JH 0 PD GL 0 JY 0 JG 0 JY 0 0 DG 0 0 JY DH DH 0 Canister Tube Tank To T Connector Tube T Connector To Canister Tube Connector To Purge Valve Tube Purge Valve To Carburetor Tube Drain Tube Canister Breather Valve Purge Grommet Purge Valve Connector Breather & Vapor Tube Spring Band Clamp. X. Spring Band Clamp x Spring Band Clamp X. Clamp Plug Fuel Drain Strap Canister Tube Canister Drain /Veh.

53 Plate : 0 BS IV Fittings P. Tank, Side Cover & Cover Seat 0 0 DH JC 0 JC 0 JC DJ DK DK DJ 0 DG DH DK DK Grommet Side Cover Rear Grommet II Grommet Collar Flanged Bolt Damper Front Flange Bolt Plain Washer Cover Side Mesh LH Cover Side Mesh RH Self Tap Screw Clip Nut Screw Grommet Side Cover RR Rubber Flap LH for Seat Cowl Rubber Flap RH for Seat Cowl /Veh.

54 Plate : 0 BS IV Meter Assembly DJ DJ DJ YD H0 0 Speedometer Assly Self Tapping Screw Dust Cover Electronic Cluster Mushroom Head Screw Speedo Meter Cover Top Cover With Sealing Ring /Veh. N.I. N.I.

55 Plate : 0 BS IV Control Cables DJ JC JC Cable Accelerator Speedo Sensor With Cable O Ring Cable Clutch O Ring /Veh.

56 Plate : 0 BS IV Chain Case DK 0 JC /Veh. Cover Chain Integral Instruction Label Bolt N.I 0

57 Plate : 0 BS IV Head Lamp & Fairing 0 0 JC 00 DJ 0 DF 0 DL 0 0 DJ 0 DH 0 DH0 0 DJ KC BA0 0 JC 0 CL 00 DJ 00 DJ 0 Head Lamp Assly. Wind Shield Bolt M- Non Metallic Washer Well Nut Decal Wind Shield Fairing Mounting Upper Bracket Kit Hardware Mtg. Bracket Clip Nut Nut Hex Thin Lamp Shade Assembly Lamp V /W-HS Lamp Position V/ / W Head Lamp Mask /Veh. N.I N.I.

58 Plate : 0 BS IV Indicator Light Assembly DJ 0 0 DJ 0 0 GH 00 DK Blinker FR LH / RR RH Blinker FR RH / RR LH Lamp V / 0W Hex Nut Flange Indicator Mtg Bkt Rear /Veh. N.I.

59 Plate : 0 BS IV Tail Lamp Assly / FR & RR Plate /Veh. 0 0 DK 00 0 DK DJ 00 JW 00 DJ 0 DP DP JC DH LED Tail Lamp Assly Clip Nut Screw Pan Cross Truss Screw Bolt Flange Lamp V-W Plate Illumination Rear Plate Bkt. Number Plate Rear Hex Flanged Bolt Truss Screw Number Plate Front Plate Mounting Bracket Bolt Flange Grommet For Number Plate Mtg Collar Bolt Flange

60 Plate : 0 BS IV Tool Kit DJ 0 Tool Kit /Veh.

61 Plate : 0 0 BS IV Electrical Equipments 0 / DK 00 DK DJ 0 DJ 0 DH JG DK 00 DJ 0 0 GF DJ DS 00 DJ 0 Horn Horn Plain Washer Flange Bolt Wiring Harness Battery V Ah Dry Band Battery Bkt. Foam Battery Bracket Flange Bolt Starter Relay Cable Assly. (Battery To Earth) Fuse Box Assly. Fuse - a Cable Assly. (Battery To St. Relay) Cable Tie Lock DC Flasher Bkt LCM Mtg Bolt for BKT Mtg (UG-) /Veh. N.I N.I N.I N.I 0 00

62 Plate : 0 BS IV Accessories / Grab Handle A A 0 DJ 0 0 DJ 0 0 DJ 0 0 DJ 0 KA DA0 DK DK 0 DK Mirror Assembly - LH Mirror Assembly - RH Leg Guard LH Leg Guard RH Bolt Flanged Grab Handle LH Grab Handle RH Bolt Flange Saree Guard Hex Socket Head Bolt Nut /Veh

63 Plate : Painted s & Decals a DJ0 0 DJ0 DJ0 0 DJ0 0 DJ0 DJ0 DJ0 DJ0 DJ0 0 DJ0 DJ0 DJ0 0 DJ0 DJ0 DH DJ0 DJ0 DH DJ0 0 DJ0 DH 0 DJ0 0 DJ0 DJ0 0 DJ0 DJ0 DJ0 DJ DJ DJ DH 0 0 DJ 0 Fuel Tank Eb Blk + Dcl Fuel Tank Royal Blue + Dcl Fuel Tank Assly FL Red + Dcl Fuel Tank EB Black + Dcl Fuel Tank Royal Blue + Dcl Fuel Tank Assly FL Red + Dcl Tank Flap Assly LH Eb Blk + Dcl Tank Flap Assly LH Royal Blue + Dcl Tank Flap Assly LH FL Red + Dcl Tank Flap Assly RH Eb Blk + Dcl Tank Flap Assly Rh Royal Blue + Dcl Tank Flap Assly RH FL Red + Dcl Assly Cover Side LH Eb Blk Assly Cover Side LH Royal Blue Assly Cover Side LH FL Red Assly Cover Side RH Eb Blk Assly Cover Side RH Royal Blue Assly Cover Side RH FL Red Fairing Ebony Black With Dcl Fairing Royal Blue + Dcl Fairing FL Red + Dcl Seat Cowl Ebony Black With Dcl Seat Cowl Royal Blue + Dcl Seat Cowl FL Red + Dcl Front Fender Assly Ebony Black Front Fender Assly Royal Blue Front Fender Assly FL Red Tank D Dcl Pulsar Tank D Dcl Rouser Tank D Dcl Pulse Seat Tape Decal Windshield EVAP EVAP EVAP Non EVAP Non EVAP Non EVAP N.I N.I 0

64 Plate : Painted s & Decals a /a / DJ0 DJ0 DH 0 DJ0 DJ0 DH DH 00 0 DH 00 0 DH 00 DH 00 0 DH 00 DH 00 DJ0 DH DH 0 DJ0 DH DH 0 DJ0 DJ0 DJ0 DH 00 0 DH 00 DH 00 DH 00 DH 00 DH 00 Kit Fairing Decal Red (E Black) Kit Fairing Decal Royal Blue Kit Dcl Fairing Fl Red Kit Tank Decal Red (E Black) Kit Tank Decal Royal Blue Kit Dcl Tank F Red Decal Tank Spoiler Upper Black LH Decal Flap Tank Upper LH Blue Decal Flap Tank Upper LH Red Decal Tank Spoiler Upper Black RH Decal Flap Tank Upper RH Blue Decal Flap Tank Upper RH Red Kit LH Side Cover Decal Red(E Black) Kit LH Side Cover Decal Royal Blue Kit Dcl S Cover LH F Red Kit RH Side Cover Decal Red(E Black) Kit RH Side Cover Decal Royal Blue Kit Dcl S Cover RH F Red Kit Seat Cowl Decal Red(E Black) Kit Seat Cowl Royal Blue Kit Dcl Seat Cowl F Red P0 Decal Wheel LH-Red Decal Wheel LH-Blue Decal Wheel Lh Red Decal Wheel RH-Red Decal Wheel RH-Blue Decal Wheel RH Red / / 0 0

65 Kit List Sr. Kit Kit List Kit Consisting of Following s./kit Sr. Consisting of Following s Kit Kit./Kit

66 Kit List Sr. Kit Kit List Kit Consisting of Following s./kit Sr. Consisting of Following s Kit Kit./Kit

67 SPC Updation Details Page Fig. no. no. Old part no. New part no. SPC Updation Details Updation date Page Fig. no. no. Old part no. New part no. Updation date

68 s Index s Index Figure Page Figure Page Figure Page DH0 DH00 DH00 DH0 DH0 DH0 DH DJ00 DJ0 DJ0 Figure Page

69 s Index DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DK000 DK00 DK00 DK00 DK00 DK000 DK00 DK00 DK0 DK0 DS00 DU0 JG00 PD000 DH0 DH0 DH DH DH0 DJ0 DJ00 DJ00 DJ00 DJ0 DJ0 DJ0 s Index Figure Page A DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ00 DJ00 DJ00 DJ00 DJ0 DJ00 DJ0 DJ0 DJ0 DJ0 AA0 AA0 AA0 AP00 BA0 CL00 CS0 DD00 DD0 DD00 DD DD0 DD0 DE0 DE0 DE0 Figure Page a a a DE0 DE0 DE0 DE0 DE00 DE00 DE0 DE0 DE00 DE0 DE0 DE0 DF0 DF0 DF0 DG00 DG0 DG0 DG0 DG0 DG0 DG0 DG00 DG00 DG00 DG00 DG00 DG00 DG00 DG DG DG0 DG0 DG0 DG0 Figure Page DG0 DG00 DG00 DG0 DH000 DH000 DH000 DH00 DH000 DH00 DH00 DH00 DH00 DH00 DH00 DH00 DH00 DH00 DH00 DH00 DH00 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH00 DH0 DH0 Figure Page a a a

70 s Index DH0 DH0 DH0 DH0 DH00 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH00 DH00 DH0 DH0 DH0 DH00 DH0 DH0 DH0 DH0 DH0 DH00 DH0 s Index Figure Page DH0 DH0 DH0 DH0 DH00 DH00 DH0 DH00 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH0 DH00 DH0 DH0 DH0 DH0 DH0 DH DH DH DH0 DH00 DH0 DH00 DH0 DH0 DH0 DH0 Figure Page DH0 DH0 DH00 DH DH DH DH DH DH DH DH DH DH0 DH DH DH DH DH0 DH0 DH0 DH0 DH DH0 DH0 DH00 DH00 DJ000 DJ00 DJ00 DJ00 DJ0 DJ0 DJ00 DJ0 DJ0 Figure Page DJ0 DJ00 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ00 DJ0 DJ0 DJ0 DJ0 DJ0 DJ00 DJ0 DJ00 DJ00 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ DJ0 DJ0 DJ Figure Page

71 s Index DJ DJ DJ DJ DJ DJ DJ00 DJ DJ DJ DJ0 DJ0 DJ0 DJ0 DJ0 DJ DJ DJ0 DJ0 DJ0 DJ00 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ0 DJ00 DJ00 DJ00 DJ0 DJ0 DJ00 s Index Figure Page 0 A DJ00 DJ00 DJ00 DJ00 DJ0 DJ0 DJ00 DJ00 DJ0 DJ00 DJ0 DK00 DK00 DK00 DK00 DK00 DK00 DK00 DK0 DK0 DK0 DH0 DK0 DK00 DK0 DK00 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 Figure Page DK0 DK0 DK0 DK0 DK00 DK0 DK00 DK0 DK0 DK0 DK00 DK0 DK0 DK0 DK0 DK0 DK00 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK00 DK00 DK00 Figure Page DK0 DK0 DK0 DK00 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK00 DK0 DK0 DK0 DK00 DK0 DK0 DK0 DK00 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK0 Figure Page

72 s Index DK00 DK0 DK0 DK0 DK DK DK DK DK DK DK DK DK DK DK0 DK DK DK DK00 DK00 DK0 DK0 DK00 DK00 DK00 DK0 DK0 DK0 DK0 DK0 DK00 DK0 DK0 DK0 DK0 s Index Figure Page 0 A DK0 DK0 DK0 DK0 DK0 DK0 DK0 DK00 DK0 DK00 DK0 DK0 DK0 DK0 DK0 DK0 DK00 DK0 DK0 DK0 DK0 DK0 DK000 DK00 DK00 DK00 DK00 DK00 DK0 DK0 DL00 DL0 DP DP DS00 Figure Page DS00 DS0 DS0 DS0 DS0 DS0 DS0 DS DS DS DS0 DS0 DS DS0 DS00 DS00 DT0 DV00 DV00 GF00 GH00 GL0 JB00 JB0 JC000 JC00 JC00 JC00 JC00 JC00 JC0 JC0 JC0 JC0 JC0 Figure Page JC0 JC0 JC0 JC0 JC0 JC0 JC0 JC0 JC0 JC0 JC0 JC0 JC00 JC00 JC00 JC00 JC00 JD JD JD000 JE JF0 JF000 JG JG0 JG0 JG0 JG0 JG00 JH0 JL0 JL0 JM00 JW00 JW0 Figure Page

73 s Index JY0 JY00 JY0 JY KACA0 KADA0 KAEG0 KAEG0 KBBA00 KBBA0 KCBA00 KCGA KJAB0 KPAC00 KPBC0 KPBC0 KPBC0 LAC0000 LCA0000 PD0 PD00 PD PD PD0 PD PD00 YDH00 YDJ000 s Index Figure Page Figure Page Figure Page Figure Page