Bajaj Auto Limited Service Department Akurdi, Pune India Phone : Fax :

Transcription

1 We have pleasure in presenting the Spare Parts Catalogue for Pulsar DTS-i 200cc 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 manufactured previously. Contact your authorized Bajaj Dealer for the latest information on product improvements incorporated after this manual was issued. DOC. NO.: REV. 00, SEP. 08 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 : Bajaj Auto Limited Service Department Akurdi, Pune India Phone : Fax : service@bajajauto.co.in

2 Instructions for using the Catalogue 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.. 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 or digit system. Understanding this system will enable you to identify the spare parts easily. 4. Abbreviations : The following abbreviations are used in this catalogue. assly. Assembly V Volts N.I. Not illustrated W Watts C'case Crankcase accl. Accelerator Cyl Cylinder Comp. Complete o/s. Over size Fr Front Std. Standard L Length A/t. Alternate Rr Rear R.H. Right hand Hex. Hexagonal L.H. Left hand AR As required INDEX Description Page 1 Cover Cylinder Head 1 2 Cylinder Head 2 Valve 4 Camshaft / Tensioner 4 5 Cylinder & Piston 5 6 Crankshaft 6 7 Balancer & Balancer Idler Gear 7 8 Transmission 8 & 9 9 Change Drum/ Shift Fork Gear Change Mechanism Engine Assly & Crankcase RH Crankcase LH 1&14 1 Cover RH 15&16 14 Cover Magneto Clutch Oil Cooler Assly Carburettor Air Cleaner Comp Silencer Assly Seat Assly. / Seat Lock 2 21 Oil Pump Magneto/C.D.I./H.T.Coil 25&26 2 Starter Assly (For Self Start) Engine Mountings Frame & Frame fitting Swing Arm / Rear Shock Absorber 0 27 Rider Foot rest 1 28 Pillion Foot rest / Holder 2 29 Mudguard Front & Rear 0 Stand Assembly 4 1 Tyre/ Tube /Rim 5 2 Front Hub 6 Front Master Cylinder 7 4 Front Disc Brake 8 Description Page 5 Rear Hub 9&40 6 Rear Brake Pedal 41 7 Handle Bar 42&4 8 Front Fork 44&45 9 Painted Parts & Decals 46,47,48 40 Petrol Cock, Cap Tank & Gauge Fuel Fitting - Petrol Tank, Side Cover & Cover seat Meter Assly Control Cables Chain Case 5 45 Head Lamp & Fairing Indicator Light Assly Tail Lamp Assly/Front & Rear Plate Electrical Equipments Tool Kit Accessories / Grab Handle 59 Kits List 60&61 Amendment Sheet (Part Added) 62 Amendment Sheet (Part Deleted) 6 Part Index 64

3 Pictorial Index PLATE NO. : 1 PLATE NO. : 2 COVER CYLINDER HEAD 1 CYLINDER HEAD 2 PLATE NO. : PLATE NO. : 4 VALVE CAMSHAFT / TENSIONER 4 PLATE NO. : 5 PLATE NO. : 6 CYLINDER AND PISTON 5 CRANK SHAFT 6

4 Pictorial Index Pictorial Index PLATE NO. : 7 PLATE NO. : 8 PLATE NO. : 1 PLATE NO. : 14 BALANCER & BALANCER IDLER GEAR 7 TRANSMISSION 8 & 9 COVER RH 15 & 16 COVER MAGNETO 17 PLATE NO. : 9 PLATE NO. : 10 PLATE NO. : 15 PLATE NO. : 16 CHANGE DRUM / SHIFT FORK 10 GEAR CHANGE MECHANISM 11 CLUTCH 18 OIL COOLER ASSEMBLY 19 PLATE NO. : 11 PLATE NO. : 12 PLATE NO. : 17 PLATE NO. : 18 ENGINE ASSLY. & CRANKCASE RH 12 CRANKCASE LH 1 & 14 CARBURETTOR 20 AIR CLEANER COMP 21

5 Pictorial Index Pictorial Index PLATE NO. : 19 PLATE NO. : 20 PLATE NO. : 25 PLATE NO. : 26 SILENCER ASSLY. 22 SEAT ASSLY / SEAT LOCK 2 FRAME & FRAME FITTINGS 29 SWING ARM / RR. SHOCK ABSORBER 0 PLATE NO. : 21 PLATE NO. : 22 PLATE NO. : 27 PLATE NO. : 28 OIL PUMP 24 MAGNETO / C.D.I. / H.T. COIL 25 & 26 RIDER FOOT REST 1 PILLION FOOT REST / HOLDER 2 PLATE NO. : 2 PLATE NO. : 24 PLATE NO. : 29 PLATE NO. : 0 STARTER ASSLY (FOR SELF START) 27 ENGINE MOUNTINGS 28 MUDGUARD FRONT & REAR STAND ASSEMBLY 4

6 Pictorial Index Pictorial Index PLATE NO. : 1 PLATE NO. : 2 PLATE NO. : 7 PLATE NO. : 8 TYRE / TUBE / RIM 5 FRONT HUB 6 HANDLE BAR 42 & 4 FRONT FORK 44 & 45 PLATE NO. : PLATE NO. : 4 PLATE NO. : 9 PLATE NO. : 40 FRONT MASTER CYLINDER 7 FRONT DISC BRAKE 8 PAINTED PARTS & DECALS 46, 47, 48 CAP TANK & GAUGE FUEL 49 PLATE NO. : 5 REAR HUB 9 & 40 PLATE NO. : 6 REAR BRAKE PADAL 41 PLATE NO. : 41 FITTINGS P. TANK, SIDE COVER & COVER SEAT 50 PLATE NO. : 42 METER ASSEMBLY 51

7 Pictorial Index Pictorial Index PLATE NO. : 4 PLATE NO. : 44 PLATE NO. : 49 PLATE NO. : 50 CONTROL CABLES 52 CHAIN COVER 5 TOOL KIT 58 ACCESSORIES / GRAB HANDLE 59 PLATE NO. : 45 PLATE NO. : 46 HEAD LAMP & FAIRING 54 INDICATOR LIGHT ASSEMBLY 55 PLATE NO. : 47 PLATE NO. : 48 TAIL LAMP ASSLY / FR & RR NO. PLATE 56 ELECTRICAL EQUIPMENTS 57

8 Plate 1 : COVER CYLINDER HEAD 1 JC Head Cylinder with Cover 1 2 DJ Cover Tappet 2 6 DS10 01 O Ring Kit for Cover Cyl. Head 1 Refer Page 60 4 DS Silent Bush (V) 1 5 DS Camshaft Cap Domed Cap Nut 4 7 DS Copper gasket Hex. Bolt with Flange Hex. Bolt with Flange 4 10 DH Plug Gasket 2 1

9 Plate 2 : CYLINDER HEAD Plate : VALVE 1 JC Head Cylinder with Cover Stud (Exhaust) 2 DK Gasket Cylinder Head 1 4 DH Damper Cylinder Head O Ring 1 6 JC Carburettor Insulator 1 7 DH Clamp for Insulator Hex. Bolt / Flange 2 9 DH Sleeve - Spark Plug Grub Screw 1 For Sleeve Spark Plug 1 DS Rocker Arm Shaft - Intake 1 2 DS Rocker Arm Shaft - Exhaust 1 DS 101 Rocker Arm with roller 2 4 DG Cotter valve Seal valve stem 2 6 DK Valve Repair Kit 1 Refer Page 60 7 DK Valve Kit 1 Refer Page 60 8 DS Wave washer Plain washer DS10 01 O Ring Kit for Cover Cyl. Head 1 Refer Page JC Manifold "O" ring insulator Hex bolt with flange 2 Manifold mtg. 15 AP Engine temperature sensor 1 2

10 Plate 4 : CAMSHAFT / TENSIONER Plate 5 : CYLINDER AND PISTON Ring O 1 2 JC Camshaft Assembly Bearing cam RH side Bearing cam LH side 1 5 JC Guide chain Kit 1 Refer Page 60 6 DS Sprocket cam Driven (2 T) 1 7 DH Collar cam Sprocket 1 8 DH Special camshaft washer Hex. Soc. Head cap Bolt 1 10 JC Cam Chain 1 1 DK Gasket Cylinder Pin dowel 4 JC Piston Assly. Std. 1 4 DK Ring Set Piston 1 Refer Page Ring Snap 2 6 JC Cylinder Block / Piston Assly 1 7 DK Banjo oil cooler pipe 1 8 DK Bolt special 2 9 DK Washer copper 4 10 DH Damper 6 11 DH Cam chain Tensioner pivot Bolt 1 12 JC Tensioner Assly Hex Bolt / Flange 2 14 CS Tensioner assly. gasket 1 15 DD Bolt 1 4 5

11 Plate 6 : CRANK SHAFT Plate 7 : BALANCER & BALANCER IDLER GEAR 1 JC Crankshaft assly. comp Bolt Plain washer Key woodruff 1 5 DS Parallel key Bearing Ball 1 7 DK Sprocket cam drive (16 T) Parallel pin DK00 29 Set primary driver driven 1 10 DH Body centrifugal oil filter 1 11 DH Nut primery drive 1 12 DH Cover centrifugal oil filter DK00 07 Kit centrifugal oil filter 1 Refer Page 60 1 DJ Body Balancer Assly. 1 2 DH Bearing stopper Bolt 1 4 DH Assly. Balancer Idler Gear comp Needle roller bearing 2 6 DJ 1011 Spring torsion Balancer Idler Circlip ext Dowel Pin Spring steel washer DH01 77 Balancer Idler Holder Hex bolt with flange 6 7

12 Plate 8 : TRANSMISSION Plate 8 : TRANSMISSION 1 DK Shaft Input Transmission Washer plain 2 DK Gear 4th Drive 1 4 DH Washer Spline 5 DH External Circlip 4 6 DK Gear rd Drive 1 7 DK Gear 5th drive 1 8 DH Gear 2nd drive Plain washer 1 10 DK Shaft output Transmission 1 16 DK Gear 1st driven 1 17 DK Gear 5th Driven 1 18 DH Bush 2nd driven 1 19 DH 101 Gear 2nd Driven 1 20 DK Collar Sprocket O Ring Sprocket Coller 1 22 DV Sprocket Drive 1 2 DJ Plate Drive Sprocket Bolt flange 2 11 DH Washer Thrust 2 12 DK Gear rd Driven 1 1 DH Washer spline 2 14 DK Gear 4th Driven 1 15 DH Bush 1st driven 1 8 9

13 Plate 9 : CHANGE DRUM / SHIFT FORK Plate 10 : GEAR CHANGE MECHANISM 1 DK Fork Gear Shift Input 1 2 DK Fork Gear Shift output 2 DH Shaft Gear Shift Fork 1 4 DH Shaft Gear Fork Shift 1 5 DK Drum comp. Gear Shift Bolt Socket Parallel pin 1 8 DK Guide Gear Shifter 1 9 DH Spacer 1 10 DK Bush Fork Gear Shift 1 1 DH Lever comp. Gear Shifter 1 2 DH Spring Slider Arm Reset 1 DH Spring Gear Shifter Return 1 4 DK Lever gear shift assly 1 5 DH Damper Flanged Bolt 1 7 DH Bolt Gear Shift drum Stopper 1 8 DH Stopper Gear Shifter Drum 1 9 DK Spring Gear Shifter Drum Stopper 1 10 DH Bolt Shift Change Oil seal 2 12 DK Collar 1 1 DK Assembly tie rod 1 14 DK Washer pivot 1 15 DK Pivot bolt 1 16 DK Lever change arm

14 Plate 11 : ENGINE ASSLY. & CRANKCASE RH Plate 12 : CRANKCASE LH 1 JC Engine Assly. with starter motor 1 N I 2 JC Crankcase RH Stud 2 4 DH Bolt Flanged 1 5 DH Gasket Crankcase Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Dowel Pin NRB 1 10 DH Plate Stopper 1 1 JC Crankcase LH Stud 2 DK Guide starter assly Oil Seal O Ring 1 6 DK Damper C Sunk Head Screw Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Balancer LH Bearing Oil Seal (For Output shaft) Oil Seal (For Shift lever) 1 1 DH Breather pipe 1 14 DH Plug (Drain Bolt) Gasket (For Drain Bolt)

15 Plate 12 : CRANKCASE LH Plate 1 : COVER RH Switch comp.(neutral) 1 17 DH Gasket Neutral Switch Bolt Bolt 1 20 DJ Cable assly. (Battery to Earth) Plain Washer Hallow dowel pin Hallow dowel pin 2 1 JC Cover comp RH 1 2 DH Grommet Breather Oil Seal 1 4 DH Rack 1 5 DH Shaft clutch release 1 6 DK Parallel pin 1 7 DG Gauge 1 8 DS Wire circlip 1 9 DS Bolt Pin Dowel 2 11 DK Bracket Clutch Cable 1 12 DH Gasket cover RH 1 1 DH Plunger Oil 1 14 DH Plate Plunger Oil 1 15 DH Spring Joint A

16 Plate 1 : COVER RH Plate 14 : COVER MAGNETO 16 DH Spring torsion clutch lever Washer 1 18 DH Damper 1 19 DH Flanged Bolt 8 20 JC Bajaj Decal 1 Fitted on Cover comp. RH NRB 2 22 DH Plate 1 2 DK Spring relief valve Ball steel 1 25 DK Bold relief valve Integral circlip 1 1 DJ Cover Magneto 1 2 DV Gasket Magneto cover Bolt Pin Dowel 2 5 JC 1010 Cover LH RR DH10 06 Set Damper 1 Refer Page 60 7 DH Flanged Bolt DH10 07 Set of Plate 1 Refer Page 60 9 DJ Gear Shift Label 1 10 AP NR bearing 1 11 DH Cap crank center O ring 1 1 DH Decal cover magneto

17 Plate 15 : CLUTCH Plate 16 : OIL COOLER ASSEMBLY 1 DH Special Nut 1 2 DK Clutch assembly comp. 1 DK Clutch Plate Assly 1 4 DK Clutch Center 1 5 DK Plate Clutch pressure 1 6 DK Disc Clutch friction 4 DK Disc Clutch friction (B type 1 DK Disc Clutch friction (C type 1 7 DK Plate Clutch 5 8 DK Spring Clutch Capacity 4 9 DK Bolt Bearing Clutch lifter thrust 1 11 DK Holder Clutch 1 12 DK Rod Clutch lifter 1 1 DK Spacer Clutch 1 14 DH Nut Primary drive lock 1 LH Thread 15 DK Lever Assly. Clutch Washer Primary Drive Gear 1 17 DK Judder spring 1 18 DK Spring 1 19 DK Friction clutch plate kit 1 1 DK Oil cooler assembly 1 2 DK Switch oil pressure O ring 1 4 DK Assembly oil cooler pipe Bolt 1 6 DK Pipe inlet oil cooler assly 1 7 DK Pipe outlet oil cooler assly Hexagon head screw 1 9 DK Banjo bolt 2 10 DK Gasket 2 11 DK Copper washer

18 Plate 17 : CARBURETTOR Plate 18 : AIR CLEANER COMP 1 JC Carburettor Assly. 1 2 DJ Vacuum Piston Kit 1 DJ Idling Screw Kit 1 4 JC Jet needle(jn) 1 5 DJ O ring 1 6 DJ Screw 2 7 DJ Float Assly. 1 8 JC Jet Holder 1 9 JC Main jet 1 10 JC Magnet Assly. 1 1 JC Air cleaner comp. 1 2 DK Assly element filter 1 DH Bracket lock Plain washer Hexagonal head screw 1 6 JC Connecting tube 1 7 CB Clamp 1 8 DK IR sensor 1 9 DK Intake air pump sensor 1 11 JC Reed Switch Assly Pan Head Screw 2 1 JC Needle Assly DJ Set Adjuster (PS) 1 15 DJ Set Plunger Assly JC Air jet 1 N.I

19 Plate 19 : SILENCER ASSLY. Plate 20 : SEAT ASSLY / SEAT LOCK JC Silencer Assly. 1 without shield 2 DH Silencer front shield 1 DH Truss screw 2 4 DJ Gasket exhaust 1 1 DK Seat Assly comp front 1 2 DP Damper 2 DH Lock Assly seat front 1 4 DK Seat assly comp rear 1 5 DK Lock assly seat rear Bolt flange

20 Plate 21 : OIL PUMP Plate 22 : MAGNETO / C.D.I. / H.T. COIL 1 DH Oil Pump Assly Hex. Bolt with flange DH Mesh filter Oil pump Hollow dowel pin 1 5 DH Clip Mesh Oil filter O Ring Spring dowel 1 N.I. 2 DJ Stator Assly. comp 1 DJ Rotor Assly Hex. Bolt with Flange Pan Head Screw 2 6 DH Stopper plate (wiring harness) Screw Pan head 1 8 DG Spark Plug 2 9 DH Grommet Spark Plug 2 10 DJ AC/DC Regulator 1 With Aluminum bracket 11 JC HT coil LH with cap 1 12 JC HT coil RH with cap 1 1 DH Cap Spark Plug 2 14 DD Grommet H.T. Cable Flange Bolt

21 Plate 22 : MAGNETO / C.D.I. / H.T. COIL Plate 2 : STARTER ASSLY 16 DJ Bracket H.T. Coil Flange Bolt 2 18 DH Grommet Sleeve Spark Plug 1 19 DJ CDI analog type 1 1 DH Body comp. starter clutch 1 2 DH Plate roller clutch 1 DH Gear starter clutch 1 4 DH Plate starter clutch gear return 1 5 DH Bolt 1 For stopper plate 6 DK Shaft starter counter 1 7 DH Collar starter motor 1 8 DH Gear comp. starter counter assly Needle roller bearing 1 10 DH Bolt socket 11 JC Motor assly. starter 1 12 DS Bolt 2 1 DJ Cover starter motor 1 14 DH Slotted c sunk screw 1 15 DH Spring 5 16 DJ Bush For Spring Starter 5 17 DH Roller 5 18 DH 1015 Bush Spring Starter Clutch

22 Plate 24 : ENGINE MOUNTINGS Plate 25 : FRAME & FRAME FITTINGS 1 DK Bkt. Assly. eng. mtg. front 1 2 DH Bkt. comp. LH eng. mtg. front 1 DH Bkt. comp. RH eng. mtg. front DK00 11 Kit hardware eng. mounting 1 Refer Page 60 5 DK Bkt. comp. LH eng. mtg. lower 1 6 DK Bkt. comp. RH eng. mtg. lower Bolt Flanged Bolt Flanged 1 Alt DH Bush in frame Bolt Hex. soc. hd. cap bolt 1 12 DK Bkt. comp. RH eng. rear Flanged bolt Bolt Washer 1 16 DK Bkt. Engine hanger LH 1 17 DK Bkt. Engine hanger RH JC Frame Assly. comp. 1 Incl. Bush, Races & Cup rear 2 DH Cup rear 2 DG Nut 1 4 DG Cup - Steering DV00 07 Bearing Cone Kit 1 Refer Page Ball steel Flanged bolt 2 8 DJ Cable Hook LH 1 9 DJ 1611 Cable Hook RH 1 10 DJ Hall sensor assly 1 11 DJ Magnet 1 N.I. 12 JC Guide clutch cable 1 N.I. 29

23 Plate 26 : SWING ARM / RR. SHOCK ABSORBER Plate 27 : RIDER FOOT REST 1 JC Rear Shock Absorber 2 2 DG Bolt Pre-coated 2 6 DK00 12 Kit bush rear shock 1 Refer Page 60 4 JC Swing arm assly. 1 5 DG Needle bearing 2 6 DK Collar swing arm 2 7 DG Oil seal 4 8 DH U nut swing arm 1 9 DK Shaft swing arm 1 10 DG Chain slider 1 1 DJ Main step LH assly. comp Flange bolt 4 DJ Main step RH assly. comp. 1 4 DH Rubber main step 2 5 DH Kick stopper 1 6 DX Plate lock pillion step 2 7 DH Spacer main step 2 11 DG Adjuster chain 2 12 DG Plate chain adjuster Hexagon nut 4 0 1

24 Plate 28 : PILLION FOOT REST / HOLDER Plate 29 : MUDGUARD FRONT & REAR 1 DK Holder LH step 1 2 JC Holder RH step 1 DJ Pillion step assly. comp. LH 1 4 DJ Pillion step assly. comp. RH DK00 1 Kit hardware pillion 2 Refer Page Hexagonal head screw Nut Flanged Bolt 2 Bott. Mtg. LH & RH Holder Step 1 DK Brace fender Step bolt 4 DK Fender rear front Plain washer Flange bolt 2 6 DK Fender rear 1 7 DK Mud flap front 1 2

25 Plate 0 : STAND ASSEMBLY Plate 1 : TYRE / TUBE / RIM 1 DK Stand main Shaft stand Pin cotter 1 4 DH Spring main stand 1 5 DH Cover spring main stand 1 1 JC Wheel rim front 1 2 DK Tubeless tyre front 1 Not serviceable JC Wheel rim rear 1 4 DK Tubeless tyre rear 1 Not serviceable 5 DK Valve for tubeless tyre 1 6 DK Stand side 1 7 DH Spring side stand 1 8 DH Cover spring side stand 1 9 DF Bolt Nut 1 11 DH Side stand switch 1 12 DH Magnet assly. 1 N.I. 4 5

26 Plate 2 : FRONT HUB Plate : FRONT MASTER CYLINDER Pin cotter Bearing ball 2 DK Spacer assly. 1 4 DG Seal oil 1 5 DE Plate drive 1 6 DE Seal oil 1 7 DK Disc Hex. slotted nut Plain washer 1 10 DG Hex. soc. hd. bolt 6 11 DK Sensor speedometer 1 12 DG Collar 1 1 DK Axle 1 1 DE Major Kit - Master Cylinder 1 2 DJ Hose Brake Front 1 DJ Lever Grip RH 1 4 DE Banjo Bolt 2 5 DE Washer Copper 4 6 DE Clamp Holder RH 1 7 DJ Bolt 1 8 DJ Bolt Front Brake Lever 1 9 DJ Nut Flanged 1 10 DJ Screw 2 11 DJ Cylinder Master 1 12 DJ Front brake switch 1 1 DJ Reservoir Cover 1 14 DJ Diaphragm DH19 02 Oil Window Kit 1 6 7

27 Plate 4 : FRONT DISC BRAKE Plate 5 : REAR HUB 1 DG Caliper Assly. Front Bolt Flanged 2 DJ Spring Pad 1 4 DJ Bleeder Screw 1 5 DJ Bleeder Cap 1 6 DJ Disc Pad Set 1 7 DJ Insulator 1 8 DJ Protection Boot 1 9 DJ Minor Kit - Caliper 1 10 DJ Major Kit - Caliper Bearing ball 1 2 DK Collar bearing 1 DJ Damper Bearing ball Spring Shoe brake assly. 1 7 JC Cam brake 1 8 JC Panel rear brake 1 9 DK Axle 1 10 JC Spacer panel side 1 11 JC Lever cam brake Hexagon head bolt Nut 1 14 JC Indicator "O" ring 1 8 9

28 Plate 5 : REAR HUB Plate 6 : REAR BRAKE PADAL 16 DH U nut Nut Plain washer 2 19 DK Spacer for coupling 1 20 DS Lock washer 21 DK Seal oil 1 22 DK Bearing ball 1 2 DK Coupling 1 24 DS Stud 6 25 DK Sleeve 1 1 JC Lever Brake Pedal 1 2 DK Bolt pivot lever change 1 DK Washer pivot bolt 1 4 JC Collar pivot bolt Flange nut 1 6 JC Spring brake pedal 1 7 JC Rod brake DK00 1 Kit hardware rod brake 1 Refer Page 61 9 JC Magnet rear brake switch 1 10 JC Rear brake switch magnet bolt Hex. lock nut 6 27 DK Drive Chain Lock JC00 02 Chain Sprocket kit 1 Refer Page

29 Plate 7 : HANDLE BAR Plate 7 : HANDLE BAR 1 JC Handle Bar 1 2 DH Holder Handle Flanged bolt 4 4 DH Control switch LH 1 5 DH Control switch RH 1 6 DJ Lever assly. grip LH 1 7 DJ Holder left hand 1 8 DJ Lever grip left 1 9 DD Bolt Self locking nut 1 16 DH Hex. soc. hd. cap screw 2 Alt DJ Pad Holder Handle 1 18 DJ Mirror assly. LH 1 19 DJ Mirror assly. RH 1 20 DS Switch assly. ignition Flange bolt 2 22 DK Clutch Switch 1 DK Clutch Switch (6 Amp.) 1 For solenoid relay July DK00 19 Kit hardware holder LH 1 Refer Page DH Grip LH 1 1 DH Grip Assly. RH 1 14 DH Boot for lever 1 15 DJ Handle bar weight

30 Plate 8 : FRONT FORK Plate 8 : FRONT FORK 1 JC Fork front 1 2 DG Dust seal 1 DG Oil seal 2 4 DG Guide bush 2 5 DG Ring snap 1 6 JC Outer Tube LH 1 7 JC Outer Tube RH Gasket Bolt 2 10 DS Cylinder comp. fork 2 11 JC Pipe comp. suspension inner 2 12 DG Slide Bush 2 1 JC Spring front fork 2 14 DH Grommet Top 2 15 DH Bolt fork O ring Seat fork spring 2 18 DS Spacer Tube 2 19 DG Washer Bolt 1 21 JC Holder fork upper 1 22 DG Socket Bolt 2 2 JC Cushion Rubber 2 24 JC Cover Trail B JC00 19 Lamp Shade asly DG Bearing cone 1 27 JC Holder fork under Spring washer Bolt

31 Plate 9 : PAINTED PARTS & DECALS Plate 9 : PAINTED PARTS & DECALS 1 JC T Fuel Tank 1 FOR TITANIUM SILVER JC V Fuel Tank 1 FOR COCKTAIL WINE RED JC 7101 A Fuel Tank 1 FOR LONG BEACH BLUE JC 7101 X Fuel Tank 1 FOR EBONY BLACK 2 DK 701 2T Side cover LH 1 FOR TITANIUM SILVER DK 701 2V Side cover LH 1 FOR COCKTAIL WINE RED DH 701 A Side cover LH 1 FOR LONG BEACH BLUE DH 701 X Side cover LH 1 FOR EBONY BLACK DK 702 2T Side cover RH 1 FOR TITANIUM SILVER DK 702 2V Side cover RH 1 FOR COCKTAIL WINE RED DK 702 A Side cover RH 1 FOR LONG BEACH BLUE DK 702 X Side cover RH 1 FOR EBONY BLACK 4 DK 70 2T Sear Cowl Assly. 1 FOR TITANIUM SILVER DK 70 2V Sear Cowl Assly. 1 FOR COCKTAIL WINE RED DK 70 A Sear Cowl Assly. 1 FOR LONG BEACH BLUE DK 70 X Sear Cowl Assly. 1 FOR EBONY BLACK 5 DK T Front Fender 1 FOR TITANIUM SILVER DK V Front Fender 1 FOR COCKTAIL WINE RED DK 7402 A Front Fender 1 FOR LONG BEACH BLUE DK 7402 X Front Fender 1 FOR EBONY BLACK 6 DH Seat tape 1 7 DJ T Fairing 1 FOR TITANIUM SILVER DJ V Fairing 1 FOR COCKTAIL WINE RED DJ 7401 A Fairing 1 FOR LONG BEACH BLUE DJ 7401 X Fairing 1 FOR EBONY BLACK 8 JC T Tank flap LH 1 FOR TITANIUM SILVER JC V Tank flap LH 1 FOR COCKTAIL WINE RED JC 7201 A Tank flap LH 1 FOR LONG BEACH BLUE JC 7201 X Tank flap LH 1 FOR EBONY BLACK 46 47

32 Plate 9 : PAINTED PARTS & DECALS Plate 40 : CAP TANK & GAUGE FUEL 9 JC T Tank flap RH 1 FOR TITANIUM SILVER JC V Tank flap RH 1 FOR COCKTAIL WINE RED JC 7202 A Tank flap RH 1 FOR LONG BEACH BLUE JC 7202 X Tank flap RH 1 FOR EBONY BLACK 10 DK Cover Side Mesh LH 1 11 DK Cover Side Mesh RH Self tap screw 6 1 JC Grommet 2 14 JC Grommet JC00 01 Decal set 1 Refer page DK 'B' monogram for tank 2 17 DK Pulsar monogram for tank 2 18 JC Seat cowl decal 2 19 JC Oil cooler decal 2 20 DJ Nail guide cable 1 N.I. (From June 08) 21 DK Foam Tape I 4 22 DK Foam Tape II 2 1 DH Cap Assly. Tank Pan head screw 1 Alt Hex. Soc Hd. cap screw 7 4 DJ Tap Assly 1 5 DH Rotor with key Packing 1 7 DD Bolt flanged Plain Washer 2 9 DK Gauge Fuel 1 DK Gauge Fuel 1 Short length December Gasket fuel Gauge Bolt 4 12 DJ Tube fuel 1 1 BA Pipe clip 1 14 DH Drain tube 1 15 DG Clamp

33 Plate 41 : FITTINGS P. TANK, SIDE COVER & COVER SEAT Plate 42 : METER ASSEMBLY 1 DK Grommet Kit For side cover 1 Refer Page 61 2 DH Tape tank inner 2 DG Screw 2 4 DK Lock for side cover with key 2 5 DH Damper Rear 1 6 DJ Damper front Flanged Bolt Plain Washer 1 9 DK Tank pad 1 1 JC Meter Assly / Instrument Cluster 1 JC Meter Assly / Instrument Cluster 1 From December Self Tapping Screw 4 DJ Cluster cover 1 4 DJ Speedo meter top cover (Varroc) 1 5 DJ Button push for trip meter 1 6 DJ Gasket (Varroc)

34 Plate 4 : CONTROL CABLES Plate 44 : CHAIN COVER 1 DK Control cable throttle 1 2 DK Cable Clutch 1 JC Speedo sensor with cable 1 1 DK Cover Chain 1 DK Cover chain 1 For point mounting 2 DH Bolt

35 Plate 45 : HEAD LAMP & FAIRING Plate 46 : INDICATOR LIGHT ASSEMBLY 1 JC Head Lamp assly. 1 2 DJ Mask 1 DJ 1810 Wind Shield 1 4 DF Bolt Non Metallic Washer 4 6 DL Well Nut 4 7 DJ Decal Wind Shield M5 x 15L mushroom HD 2 9 DJ Packing Fairing 1 10 DH Fairing mounting upper bracket 1 1 DJ Blinker Front LH Flexible 1 2 DJ Blinker Front RH Flexible 1 DJ Blinker RR LH Flexible 1 4 DJ Blinker RR RH Flexible 1 5 GH Lamp 12V / 10W Hex Nut Flange 4 7 DJ Magnet assly blinker self cancellation DK00 21 Kit hardware mtg. bracket 1 Refer Page DJ Clip Nut Screw pan cross Screw pan cross 2 15 JC Lamp 12V 5/5W-HS DK Watt bulb white output

36 Plate 47 : TAIL LAMP ASSLY / FR & RR NO. PLATE Plate 48 : ELECTRICAL EQUIPMENTS 1 DK Tail light with Lamp 1 2 DH Damper 2 DK Clip Nut Screw pan cross Truss Screw Bolt flange 2 7 DK Plate illumination 1 8 DJ Rear plate bkt. 1 9 DP Number plate Rear Hex Flanged Bolt Truss Screw 2 For Front Plate 12 DP Number plate front 1 1 DH plate mounting bracket Bolt flange DH Horn with LH stay 1 2 DH Horn with RH stay Plain Washer Flange Bolt 1 5 DJ Battery (12V-9A) mf wet 1 N.S. 6 DJ Band Battery 1 7 JC Wiring Harness 1 JC Wiring harness 1 For below seat JC Wiring harness 1 For Solenoid Relay July 08 8 JC Rear Brake Switch 1 9 DH Spring Brake Switch 1 10 DH Grommet Rear Brake Switch Flange bolt 1 12 DK Starter Relay 1 DK Starter Relay 1 For Solenoid Relay July Fuse box Assly Fuse 1 15 DJ Cable assly. (Battery to Earth) 1 16 DJ Cable assly. (Battery to St. Relay) 1 17 DJ BCU 1 DJ BCU 1 For Solenoid Relay July 08 57

37 Plate 49 : TOOL KIT Plate 50 : ACCESSORIES / GRAB HANDLE 1 DH Tool Kit 1 * Tool Driver 1 * DH Tool Wrench (Box 16 mm) 1 * Tool Wrench (10 X 1) 1 * Tool Wrench (14 X 17) 1 * Plier 1 For reference only not * DH Tool Bag 1 to service separately * DJ Tool wrench (27/22 A/F) 1 * Tool bar 1 * DG Tool wrench 1 * DK "O" ring for tool kit 2 1 DK Leg Guard LH 1 DK Leg Guard RH Flange bolt 4 DK Sari Guard Assly DK00 2 Kit hardware sari guard 1 Refer Page 61 5 DK Grab handle LH 1 6 DK Grab handle RH Bolt Flange 4 8 DJ Foam LH For grab 1 9 DJ Foam RH For grab

38 KIT LIST Sr. 60 Kit Part Kit Description Consisting of Following Parts Part Description Qty./Kit 1 6DS1001 Cyl. Head 'O' Ring Kit O Ring (Cover tappet) O ring 2 2 DK10127 Valve Kit DK Valve Intake 1 DK Valve Exhaust 1 DK10126 Valve Repair Kit DK Retainer valve spring 2 DK Spring valve inner 2 DK Spring valve outer 2 DK Seat valve spring 2 4 JC10108 Guide Chain Kit DH Guide chain (Tight) 1 DK Guide Chain (slack) 1 5 6DK0007 Kit centrifugal oil filter Washer 1 DH10124 Gasket centrifugal oil filter Oval screw 1 DH Join oil delivery 1 DH Spring oil delivery Pin oil delivery joint 1 6 6DH1006 Set Damper (cover magneto) DH Damper Cover Magneto 1 DH Damper A Cover LH RR 1 DH Damper B Cover LH RR 1 7 6DH1007 Set of Plate (cover magneto) DH10128 Plate Damper 1 DH10129 Plate Damper Cover LH RR 1 8 DK10128 Ring set piston DK Ring piston top 1 DK Ring piston second 1 DK Ring piston oil 1 9 6DK0011 Kit hardware engine mounting Bolt flange Nut flange Bolt flange 1 DH U Nut 10 6DV0007 Bearing cone kit DG Bearing cone 1 DG Bearing race 1 DG Upper bearing race 1 DG Lower bearing race DK0012 Kit bush rear shock absorber Plain washer Dome cap nut Spring washer DK001 Kit hardware pillion DJ Plait side pillion step 2 DH Pin pillion set "O" ring Plain washer Split pin 2 1 6JC0002 Chain sprocket kit DV Sprocket drive 1 JC Sprocket hub 1 DK Chain 1 KIT LIST Kit Part Kit Description Consisting of Following Parts Part Description Qty./Kit 14 6DK001 Kit hardware rod bracket Pin Plain washer Split pin Spring Pin 1 JC Brake adjustment nut DK0019 Kit hardware holder LH Screw Nut Plain washer Bolt hex 1 16 DK Grommet kit for side cover DH Grommet side cover front 2 DH1611 Grommet side cover rear JC0001 Decal Set JC Decal oil cooler LH 1 JC Decal oil cooler RH 1 JC Decal seat cowl LH 1 JC Decal seat cowl RH 1 DJ Decal tank LH 1 DJ Decal tank RH DK0021 Kit hardware mtg. bkt. DJ Collar 1 DJ Grommet Plain washer Bolt flange DK002 Kit hardware saree guard DH Bolt special Spring washer Bolt hexagon Bolt hex socket Nut hexagon 1 DH Cap 1 DD22100 Plug 1 61

39 KIT LIST KIT LIST Amendment Sheet (Parts Added) Sr. Qty. Page Fig. Amendment Sheet (Parts Deleted) Sr. Qty. Page Fig. 62 6

40 Part Index Part Index Part Figure Page Part Figure Page Part Figure Page Part Figure Page DH DH DH DK DK DK DK DK DK DK DK DK DS DS DV JC JC

41 Part Index Part Index Part Figure Page Part Figure Page Part Figure Page Part Figure Page DH JC AP AP BA CB CS DD DD DD DD DE DE DE DE DE DF DF DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DG DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH

42 Part Index Part Index Part Figure Page Part Figure Page Part Figure Page Part Figure Page DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH DH701A 2 46 DH701X 2 46 DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ DJ74012T 7 47 DJ74012V 7 47 DJ7401A 7 47 DJ7401X 7 47 DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK

43 Part Index Part Index Part Figure Page Part Figure Page Part Figure Page Part Figure Page DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK7012T 2 46 DK7012V 2 46 DK7022T 46 DK7022V 46 DK702A 46 DK702X 46 DK702T 4 46 DK702V 4 46 DK70A 4 46 DK70X 4 46 DK74022T 5 47 DK74022V 5 47 DK7402A 5 47 DK7402X 5 47 DL DP DP DS DS DS DS DS DS DS DS101 DS DS DS DS DS DS DS DS DS DS DS DV DV DX GH JC JC JC JC JC JC JC

44 Part Index Part Figure Page Part Figure Page 72 JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC JC71012T 1 46 JC71012V 1 46 JC7101A 1 46 JC7101X 1 46 JC72012T 8 47 JC72012V 8 47 JC7201A 8 47 JC7201X 8 47 JC72022T 9 48 JC72022V 9 48 JC7202A 9 48 JC7202X 9 48