Brand ID: 001MC618 Brand ID: 001MC618

PICTORIAL INDEX Plate No. 1 : COVER CYLINDER HEAD

PLATE NO. : 55 PAGE NO.:

ACCESSORIES / GRAB HANDLE 67

6 8

2 4
9 7

11 2

10 3

10
11 1

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No. Part No. Description Veh. Remarks

1 DK 1016 07 Head Cylinder with Cover 1

2 52 JN01 36 Cover Tappet 2
3 36 DS10 01 Cyl. Head ‘O’ Ring Kit 1 Ref. page no. 68
4 DS 1011 66 Silent Bush (V) 1
5 DS 1010 96 Camshaft Cap 1

6 39 2647 15 Domed Cap Nut 4

7 DS 1010 84 Copper gasket 4
8 59 0400 23 Hex. Bolt with Flange 2
9 39 1075 04 Hex. Bolt with Flange 4
10 DH 1012 72 Plug 2

11 DG 1014 98 Gasket 2

1
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 2 : CYLINDER HEAD Plate No. 3 : VALVE

9
4 8

2
9
9
1
10
1

11 6 3
16 15
2

2
5
5
4 12
8

6
7
3 7
14 7
13

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1016 07 Head Cylinder with Cover 1 1 DS 1013 35 Rocker Arm Shaft - Intake 1
36 DK00 90 Head Cylinder with Cover 1 (W/o NRB) from Eng. BUF67894 DK 1017 48 Rocker Arm Shaft - Intake 1 (W/o NRB) from Eng. BUF67894
2 59 0500 02 Stud (Exhaust) 2 2 DS 1013 36 Rocker Arm Shaft - Exhaust 1
3 DK 1010 03 Gasket Cylinder Head 1 DK 1017 51 Rocker Arm Shaft - Exhaust 1 (W/o NRB) from Eng. BUF67894
4 DH 1015 08 Damper Cylinder Head 5 3 DS 1013 33 Rocker Arm with roller 2
5 39 1283 21 ‘O’ Ring (Intake Pipe) 1
DK 1017 55 Rocker Arm 2 (W/o NRB) from Eng. BUF67894
6 JC 1200 18 Insulator 1 4 DG 1010 29 Collet 4
7 DH 1210 38 Clamp for Insulator 2 5 39 2017 19 Seal valve stem 2
8 39 1674 04 Hex. Bolt / Flange 2 (F)
9 DH 1110 12 Sleeve - Spark Plug 1 6 DK 1013 26 Valve Repair Kit 1 Ref. page no. 68
10 39 2608 01 Grub Screw 1 For Sleeve Spark Plug 7 DK 1013 27 Valve Kit (inlet + exhaust) 1 Ref. page no. 68
8 DS 1013 66 Wave washer 2
11 36 DS10 01 Cyl. Head ‘O’ Ring Kit 1 Ref. page no. 68 DH 1012 95 Wave washer 2 from Eng. BUF67894
12 JC 1200 17 Manifold 1 9 59 1100 02 Plain washer 4
13 39 1075 04 Hex bolt 1 39 2440 11 Plain washer 4 from Eng. BUF67894
14 DK 1015 03 Engine temperature sensor 1
15 39 2181 06 Dowel 2

16 39 1759 04 Bolt 1

2 3
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 4 : CAMSHAFT / TENSIONER Plate No. 5 : CYLINDER AND PISTON

2
5
4

3
3 7 6 8 9

2
6

1
3
8
15 8
1 9
4

5
8
10 12
14

11 4
13 7
8 9

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No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 39 2669 21 Ring ‘O’ 1 1 DK 1010 63 Gasket Cylinder 1

2 DK 1016 14 Camshaft Assembly 1 2 39 2181 06 Pin dowel 4
3 JC 1010 86 Bearing cam RH side 1 3 DK 1013 28 Ring Set Piston 1 Ref. page no. 68
4 JC 1010 85 Bearing cam LH side 1 4 39 2132 17 Ring Snap 2
5 DK 1013 30 Guide chain Kit 1 Ref. page no. 68 5 DK 1016 25 Cylinder Block / Piston Assly 1

6 DS 1012 76 Sprocket cam Driven (32 T) 1 6 DH 1014 14 Damper 4

7 DH 1014 12 Collar cam Sprocket 1 7 DK 1015 92 Assembly Oil Pipe 1
8 DH 1010 48 Special camshaft washer 1 8 31 1210 06 Gasket 4
9 DK 1013 86 Hex. Soc. Head cap Bolt 1 9 DD 1210 07 Bolt 2
10 DK 1010 64 Cam Chain (100 link) 1

11 DH 1013 92 Cam chain Tensioner pivot Bolt 1

12 JC 1010 34 Tensioner Assly 1
13 39 1673 04 Hex Bolt / Flange 2
14 CS 1011 28 Tensioner assly. gasket 1
15 DD 1010 62 Bolt Flange 1

4 3 5
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 6 : CRANK SHAFT Plate No. 7 : BALANCER & BALANCER IDLER GEAR

5 8

4 13
3
7
6 2 10
8

11 11
3 5
2
9 8
10 7

12
6

6
12 4
7 12
9 9
5

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1010 65 Crankshaft assly. comp. 1 1 DK 1014 16 Body Balancer Assly. 1

2 39 2183 04 Bolt primary drive lock 1 2 DH 1010 72 Bearing stopper 1
3 39 2165 11 Plain washer 1 3 39 1672 04 Bolt 1
4 31 1011 73 Key woodruff 1 4 DH 1014 32 Assly. Balancer Idler Gear comp. 1
5 DS 1011 54 Square Key 1 5 39 2152 20 Needle roller bearing 2

6 39 1931 20 Bearing Ball 1 6 DH 1014 24 Spring torsion Balancer Idler 2

7 DK 101248 Sprocket cam drive (16 T) 1 7 39 2557 17 Circlip ext. 2
8 39 2203 07 Parallel pin 1 8 39 1686 06 Dowel Pin 2
9 DH 1010 64 Body centrifugal oil filter 1 9 39 1620 11 Spring steel washer 2
10 DH 1011 95 Nut 1 10 52 DH01 77 Balancer Idler Holder 1

11 DH 1010 65 Cover centrifugal oil filter 1 11 39 1674 04 Hex bolt with flange 3
12 36 DK00 07 Kit centrifugal oil filter 1 Ref. page no. 68 12 DH 1013 73 Scissor balancer idler 2
13 DK 1012 41 Housing comp. clutch 1

6 7
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 8 : TRANSMISSION Plate No. 8 : TRANSMISSION

1 17 1 17
13 13

2 15 2 15
16 16
3 14 3 14
4 4
5 5
12 5 12 5
4 4
6 6
5 5
4 11 4 11
7 7
8 10 8 10
9 9
18 18

20 19 20 19

11 22 11 22
21 21
5 5
23 23
24 24
25 25

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1014 71 Shaft input transmission 1 16 DH 1012 35 Circlip 1

2 39 2158 11 Washer plain 2 17 DK 1011 18 Gear 1st driven 1
3 DK 1011 03 Gear 4th Drive 1 DK 1017 17 Gear 1st driven 1 From Eng. No. BUC38650
4 DH 1010 79 Washer Spline 3 Ref. Cir. D-41
5 DH 1012 35 External Circlip 4 18 DK 1016 33 Gear 5th Driven 1
DK 1017 20 Gear 5th Driven 1 From Eng. No. BUC38650
6 DK 1011 02 Gear 3rd Drive 1 Ref. Cir. D-41
7 DK 1016 32 Gear 5th drive 1 19 DH 1013 19 Bush 2nd driven 1
8 DH 1010 84 Gear 2nd drive 1 20 DH 1013 33 Gear 2nd Driven 1
9 39 2160 11 Plain washer 1 DK 1017 19 Gear 2nd Driven 1 From Eng. No. BUC38650
10 DK 1011 44 Shaft output transmission 1 Ref. Cir. D-41
21 DK 1012 45 Collar Sprocket 1
11 39 2166 11 Washer Thrust 2 22 DK 1013 52 ‘O’ Ring Sprocket Collar 1
12 DK 1011 05 Gear 3rd Driven 1 23 DV 1010 48 Sprocket Drive 1
13 DH 1010 79 Washer spline 2 24 DJ 1010 63 Plate Drive Sprocket 1
14 DK 1011 06 Gear 4th Driven 1 25 DJ 1013 00 Bolt flange 2 For Crankcase with circlip
DK 1017 18 Gear 4th Driven 1 From Eng. No. BUC38650
Ref. Cir. D-41
15 DH 1011 11 Bush 1st driven 1

8 9
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 9 : CHANGE DRUM / SHIFT FORK Plate No. 10 : GEAR CHANGE MECHANISM

1
9

2
8

7 8 5
6
4
10
6

9
4

3
7

5
2
10
12
11
2
3

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1011 59 Fork Gear Shift Input 1 1 DK 1017 33 Lever comp. Gear Shifter 1
2 DK 1011 60 Fork Gear Shift output 2 2 DH 1011 43 Spring Slider Arm Reset 1
3 DH 1011 46 Shaft Gear Shift Fork 1 3 DH 1011 44 Spring Gear Shifter Return 1
4 DH 1014 93 Shaft Gear Shift Fork 1 4 DK 1011 82 Lever gear shift 1
5 DK 1013 82 Drum comp. Gear Shift 1 5 31 1011 08 Damper 1
DK 1017 32 Drum comp. Gear Shift 1 From Eng. No. BUC38650
6 39 1902 04 Flanged Bolt 1
Ref. Cir. D-41
7 DH 1013 93 Bolt Gear Shift drum Stopper 1
6 39 1197 04 Bolt Socket 1 8 DK 1017 25 Stopper Gear Shifter Drum 1
7 39 2606 07 Parallel pin 1 9 DK 1012 53 Spring Gear Shifter Drum Stopper 1
8 DK 1013 61 Guide Gear Shifter 1 10 DH 1013 94 Bolt Shift Change 1
9 DH 1014 96 Spacer 1
10 DK 1011 35 Bush Fork Gear Shift 1 11 DK 1011 77 Lever change arm 1
12 DK 1011 80 Tie rod 1

10 11
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 11 : ENGINE ASSLY. & CRANKCASE RH Plate No. 12 : CRANKCASE LH

13 15
14
2
2
3 3
21

10

8 21 8
2

6 5
4
24 9

7 28 11

17
11 16 23
6
26
7 9
19
3 18 1
5
25
27 12
4 10 22

20

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1016 13 Engine Assly. with starter motor 1 N I 1 DK 1015 81 Crankcase LH 1 with banjo
2 JC 1010 29 Crankcase RH 1 2 59 0500 02 Stud 2
3 59 0500 02 Stud 2 3 DK 1010 94 Guide starter assly 1
4 DJ 1013 02 Bolt Flanged 1 4 39 2188 19 Oil Seal 1
5 DH 1018 96 Gasket Crankcase 1 5 59 2100 06 ‘O’ Ring 1

6 39 2583 20 Bearing Ball (For Input shaft) 1 6 DK 1010 97 Damper 1

7 59 2000 27 Bearing Ball (For Output shaft) 1 7 39 0752 01 ‘C’ Sunk Head Screw 3
8 39 2180 06 Dowel Pin 2 8 39 2603 20 Bearing Ball (For Input shaft) 1
9 39 2601 20 Needle Roller Bearing 1 (For Dr. Comp. Gear Shift) 9 59 2000 06 Bearing Ball (For Output shaft) 1
10 DH 1014 87 Plate Stopper 1 10 39 2185 20 Bearing Balancer LH 1

11 39 2181 06 Dowel Pin 2 11 39 2189 19 Oil Seal (For Output shaft) 1

12 39 2190 19 Oil Seal (For Shift lever) 1
13 DH 1012 03 Breather 1
14 DH 1012 46 Rubber tube 1
15 28 1011 74 Spring Clip 1

12 13
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 12 : CRANKCASE LH Plate No. 13 : COVER RH

13 15
14 3 16
2 17
2 11
22
5
21 6
8
7
10

21 8 2

12 10
6 5
4 4
24 9

7 28 11 1
9
17
16 23 18
26
19
3 18 1
15 20
25 14 19
27 12
13 21
22

20

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 DH 1016 61 Plug (Drain Bolt) 1 1 36 DK00 64 Cover comp RH Flower type 1 Black Color
17 DG 1014 98 Gasket (For Drain Bolt) 1 52 DK02 04 Cover comp RH Flower type 1 Moon Light Silver
18 DK 1013 80 Switch comp. (Neutral) 1 2 DH 1011 97 Grommet Breather 1
19 39 1013 21 ‘O’ ring 1 3 39 1041 19 Seal clutch lever 1
20 39 1677 04 Bolt 8 4 DH 1011 41 Rack 1
5 DH 1011 42 Shaft clutch release 1

21 DH 1013 90 Bolt 1
6 DK 1012 51 Parallel pin 1
22 DH 1011 69 Needle Roller Bearing 1
7 DG 1014 18 Gauge 1
23 DJ 2011 40 Cable assly. (Battery to Earth) 1 8 DS 1012 15 Wire circlip 1
24 39 2448 11 Plain Washer 1 9 DS 1013 53 Bolt 10
25 39 0849 14 Toothed Washer 1 10 39 0999 06 Pin Dowel 2

26 DK 1015 77 Thermal Sensor with AL gasket 1 11 DK 1012 52 Bracket Clutch Cable 1

27 39 1672 04 Flange Bolt 1 For Plastic neutral switch 12 DH 1011 54 Gasket cover RH 1
28 KE BA37 15 Circlip (May 10) 1 For DKGBTB 50638 13 DK 1014 80 Plunger Oil 1
14 DH 1210 11 Plate Plunger Oil 1
15 DH 1210 12 Spring Joint ‘A’ 1
14 15
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 13 : COVER RH Plate No. 14 : COVER MAGNETO

3 16
11 17
22
5
6
8
7

12 10
4 2
3
1
9
6
18
9 4

1 5
15 20
14 19

5
4 3 2 N 1
13 21

7
8

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 DH 1015 44 Spring Torsion clutch lever 1 1 52 DH06 24 Cover Magneto Flower Type 1 Black Color (220 SF)
17 39 2443 11 Washer 1 52 DK01 72 Cover Magneto Flower Type 1 Black Color (220 F)
18 DK 1017 38 Decal clutch cover 1 52 DH06 86 Cover Magneto Flower Type 1 Moon Light Silver (220 SF)
19 DK 1014 69 Assembly Relief Valve Complete 1 52 DK02 03 Cover Magneto Flower Type 1 Moon Light Silver (220 F)
20 DS 1010 71 Cap Oil Filler 1 2 DV 1010 42 Gasket Magneto cover 1
3 DS 1013 53 Bolt 5
21 DH 1011 52 ‘O’ ring 1 4 39 0999 06 Pin Dowel 2
22 39 1990 20 Needle Roller Bearing 2 5 JC 1010 33 Cover LH Rear 1
DK 1017 62 Cover LH Rear 1 Moon Light Silver 220 F/SF

6 DH 1012 93 Plate Damper Cover LH Rear 1

7 DJ 1612 28 Gear Shift Label 1
8 39 2240 20 Needle Roller Bearing 1
9 JE 5412 12 Decal DTS-i Magneto 1

16 17
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 15 : CLUTCH Plate No. 15 : CLUTCH

19 19

6 6
7 7
6 6
4 4
7 7
18 18
6 6

7 7
6 6

7 7
6 6
8 8
7 7
12 12
10 10
1 1

5 9 5 9
2 2

14 14

6 16 6 16
3 17 13 3 17 13
11 11

15 15

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1015 60 Clutch assembly comp. 1 13 DK 1010 72 Rod Clutch lifter 1

2 DH 1012 75 Nut 1 14 DK 1011 26 Spacer Clutch 1
3 DK 1015 63 Clutch Plate Assly 1 15 DH 1016 48 Nut Primary drive lock 1 LH Thread
4 DK 1015 64 Clutch Center 1
5 DK 1015 69 Plate Clutch pressure 1 16 DK 1016 36 Lever Assly. Clutch 1
17 39 2200 11 Washer Primary Drive Gear 1
6 DK 1015 66 Disc Clutch friction 4 18 DK 1015 70 Seat judder spring 1
DK 1015 68 Disc Clutch friction (B type) 1 DJ 1013 69 (Disc Clutch 19 DK 1015 71 Spring judder 1
DK 1015 67 Disc Clutch friction (C type) 1 Friction Kit)
7 DK 1015 65 Plate Clutch 5
8 DK 1015 72 Spring Clutch Capacity 5
9 39 1674 04 Bolt 1
10 DK 1015 74 Bolt 5

11 39 1880 20 Bearing Clutch lifter thrust 1

12 DK 1015 73 Holder Clutch 1

18 19
Brand ID: 001MC618 Brand ID: 001MC618
PLATE NO. 16 : CARBURETTOR Plate No. 17 : OIL COOLER ASSEMBLY
4

2
8
16 15
5

17 3

11 12
13
8 18
1 2
17 18
13
3
4 14
6
7
5 7 14/15
1

6 10
9 12
6
9
10
11

16

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 JC 1200 24 Carburettor Assly. 1 1 DK 1016 34 Oil cooler assembly 1

2 36 DK00 58 Piston valve assly. Kit 1 For BS III Carb. Refer Page 69 2 DK 1012 25 Switch oil pressure 1
3 DK 1210 41 Vaccum adjuster kit 1 Refer Page 69 3 DK 1013 40 ‘O’ ring Oval (oil cooler pipe) 1
4 DK 1610 81 Rubber Grommet 2
4 DK 1210 42 Jet needle (JN) 1 5 39 1672 04 Bolt 2
5 DK 1210 43 “O” ring 1 6 DK 1016 30 Pipe inlet oil cooler 1
6 DK 1210 44 Screw 2 7 DK 1016 31 Pipe outlet oil cooler 1
7 DK 1210 45 Float Assly. 1 8 39 2637 04 Hexagon head screw 2
9 DK 1013 66 Banjo bolt 2
8 36 DK00 59 Main jet Kit 1 Refer Page 70
10 DK 1012 37 Copper Washer (oil cooler) 4
9 36 DK00 60 Float Chamber body Kit 1 Refer Page 70
10 DH 1211 01 Magnet Assly. 1 11 DK 1611 88 Cap oil cooler LH 1
11 DJ 1210 70 Reed Switch Assly. 1 12 DK 1611 89 Cap oil cooler RH 1
12 39 1780 01 Pan Head Screw 2 13 DK 1016 35 Oil cooler jali 1
14 DK 1611 86 Oil cooler cap bracket LH 1
13 DK 1210 47 Needle Assly. 1
15 DK 1611 87 Oil cooler cap bracket RH 1
14 DK 1210 48 Pilot Screw Kit 1 Refer Page 69 16 DK 1012 79 Washer Cooler Pipe 1 At cover RH
15 36 DK00 62 Solenoid Kit for Auto choke 1 Refer Page 70 17 JB 4022 02 Grommet oil Pressure Switch 1
16 36 DK00 61 Tap Cap Assly. Kit 1 Refer Page 70 18 DK 1612 59 Decal Oil Cooler LH 1 Other than Orange (For S)
17 DH 1210 63 Screw Cover 4 DK 1612 63 Decal Oil Cooler RH 1 Other than Orange (For S)
DK 1612 60 Decal Oil Cooler LH 1 For Orange (For S)
18 DK 1210 51 Pilot Jet 1 DK 1612 64 Decal Oil Cooler RH 1 For Orange (For S)

20 21
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 18 : AIR CLEANER COMP Plate No. 19 : SILENCER ASSLY.

6 3
3
11
9

8 2

3
4
1 5

7 12 4
7 1
10
6

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1210 38 Air Cleaner comp 1 1 DK 1014 82 Silencer Assly. w/o shield 1

2 DK 1210 09 Assly element filter 1 2 DH 1016 08 Silencer front shield 1
3 DH 1210 20 Bracket lock 1 3 DH 1016 07 Truss screw 2
4 39 1765 11 Plain washer 1 4 DJ 1010 64 Gasket exhaust 1
5 39 1780 01 Hexagonal head screw 1 5 DK 1014 75 Silencer rear shield 1

6 AP 1210 64 Clamp 1 6 DK 9026 27 Nut 2

7 DK 1110 40 IR sensor 1 7 DK 1016 10 Resonator bolt 1
8 DK 1210 15 ‘O’ Ring 1
9 DK 1210 08 Filter element cover 1
10 DK 1210 22 Grommet IR sensor 1

11 DK 1210 39 Connecting Tube 1

12 DH 1613 77 Bolt Step 3

22 21
23
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 20 : SEAT ASSLY / SEAT LOCK Plate No. 21 : OIL PUMP

4
4
1
2

6
1

3/5

12

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 2110 01 Seat assly comp front 1 1 52 DH01 69 Oil Pump Assly 1

2 DS 2110 05 Damper 2 2 39 1674 04 Hex. Bolt with flange 3
3 DH 1610 46 Lock assly seat front 1 3 DH 1210 10 Mesh filter Oil pump 1
4 DK 2110 04 Seat assly comp rear 1 4 39 1686 06 Hollow dowel pin 1
5 DK 2110 08 Lock assly seat rear 1 5 DH 1210 35 Clip Mesh Oil filter 1

6 39 1902 04 Bolt flange 2 6 39 2194 21 ‘O’ Ring 1

24 25
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL

8 8
7 7

17 21 17 21
15 20 15 20
5 5
10 10

14 14
10 10
2 2
9 6 9 6

19 19
9 9
13 13
16 16
3 3
8 8
11 A 11 A
B C B C

4 4

5 16 5 16
21 12 1 19 21 12 1 19
18 18

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 JC 1110 26 Stator assly. comp. 1 (220 F) 16 39 1680 04 Flange Bolt 2

DH 1110 81 Stator assly. comp. 1 (220 SF) 17 DH 1110 16 Grommet Sleeve Spark Plug 1
2 JC 1110 28 Rotor Assly. 1 (220 F) 18 DK 1210 84 Hex bolt stator mounting 3
DH 1110 83 Rotor Assly. 1 (220 SF)
19 DH 1013 81 Pan head screw (Pick up coil mtg) 2
3 39 1674 04 Hex. Bolt with Flange 2
20 JC 1110 07 Motor assly. starter 1
4 39 0761 01 Pan Head Screw 2
5 DK 1110 28 Spark Plug 2
21 DS 1013 53 Bolt 2
6 DH 1011 13 Grommet Spark Plug 2 STARTER MOTOR SERVICEABLE
7 JC 1110 22 H.T. Coil LH 1 A DK 1110 16 Armature 1
8 JC 1110 23 H.T. Coil RH 1 B DK 1110 21 Tie Bolt 1
9 DH 1110 15 Cap Spark Plug 2
C JC 1110 10 Yoke 1
10 DD 1110 12 Grommet H.T. Cable 2
STARTER MOTOR KIT
11 DK 1110 72 CDI Unit 1 D 36 DK00 50 Starter Motor Repair kit 1 Refer page no. 69
12 DK 2010 01 Regulator Voltage 1 (220 F) E 36 DK00 51 Starter Motor Repair kit 1 Refer page no. 69
DJ 2012 02 Regulator Voltage 1 (220 SF)
13 DD 2010 24 Flange Bolt 1
14 39 1902 04 Flange Bolt 2
15 DJ 1610 67 Bracket H.T. Coil 1
26 27
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 23 : STARTER ASSLY. Plate No. 24 : ENGINE MOUNTINGS

14

10
3 17 16 17

14
13

9
7 1
1
2 4
6
10
4 15
8 3
12

15 2
13
5 12
16

6
11 Molykote
Grease
7 7
9
8 5

11

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 36 DK00 76 Kit comp. starter clutch 1 Ref. Cir. D-40 1 DK 1610 96 Bkt. Assly. eng. mtg. front 1
2 DK 1016 05 Plate roller clutch 1 2 DH 1611 89 Bkt. comp. LH eng. mtg. Front 1
3 JC 1011 12 Gear starter clutch 1 3 DH 1611 90 Bkt. comp. RH eng. mtg. Front 1
4 DH 1015 81 Plate starter clutch gear return 1 4 36 DK00 11 Kit hardware eng. mtg. 1 Ref. page no. 68
5 DH 1013 85 Bolt 1 For stopper plate 5 DK 1611 59 Bkt. comp. LH eng. mtg. lower 1

6 DK 1011 76 Shaft starter counter 1 6 DK 1611 60 Bkt. comp. RH eng. mtg. lower 1
7 DH 1011 72 Collar starter counter 1 7 39 2157 04 Bolt Flanged 3
8 JC 1011 15 Gear comp. starter counter assly. 1 8 39 2412 04 Bolt Flanged 1
9 DH 1612 73 Bush in frame 1
9 59 2000 07 Needle roller bearing 1
10 39 1967 04 Bolt 1
10 39 0972 04 Bolt Socket 3
11 59 0400 43 Hex. soc. hd. cap bolt 1
11 36 DK00 45 Grease Molykote (200 gm box) 1 For BSC Lubrication@ 5K Kms 12 DK 1611 61 Bkt. comp. RH eng. rear 1
12 39 0849 14 Star Washer Toothed 3 13 39 2310 04 Flanged bolt 2
13 DK 1017 70 Cover starter motor 1 14 39 2412 04 Bolt 1
14 DH 1013 89 Slotted c’sunk screw 1 15 39 2457 11 Washer 1
15 36 DK00 77 Kit For Starter Clutch Spring 1 Ref. Cir. No. D-40
16 DH 1011 63 Roller 5 16 DK 1612 22 Bracket engine hanger LH 1
17 59 2000 07 Needle roller bearing 1 17 DK 1612 23 Bracket engine hanger RH 1

28 29
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 25 : FRAME & FRAME FITTINGS Plate No. 26 : SWING ARM / RR. SHOCK ABSORBER

3 10
7 7 7 8 16
4 6

6 5
14
15 3
5

10
6
7 7 2
9
8/9

1 1
4

2
11
2
13
12
11

12 13

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 JC 1610 50 Frame Assly. Comp. 1 (220 F) 1 DK 1710 14 Rear Shock Absorber 2

JC 1610 49 Frame Assly. Comp. 1 (220 SF) 2 DG 1710 38 Bolt Pre-coated 2
2 DH 1611 12 Cup rear 2 3 36 DK00 12 Kit Bush Rear Shock Absorber 1 Ref. page no. 68
3 DK 1810 75 Nut 1 4 DK 1710 11 Swing arm assly. 1
4 DK 1810 76 Cup - Steering 1 5 DG 1710 18 Needle bearing 2
5 36 DV00 07 Bearing Cone Kit 1 Ref. page no. 68
6 DK 1710 06 Collar swing arm 2
6 DK 1810 50 Cage bearing upper 1 7 DG 1710 19 Dust seal swing arm 4
7 39 1680 04 Flanged bolt 2 8 DH 1710 19 ‘U’ nut swing arm 1
8 DJ 1611 32 Cable Hook LH 1 9 DK 1710 03 Shaft swing arm 1
9 DJ 1611 33 Cable Hook RH 1 10 DG 1710 34 Chain slider guard 1
10 DK 1810 51 Cage bearing lower 1
11 JM 1710 03 Adjuster chain 2
12 JM 1710 04 Cap Chain Adjuster 2
13 39 0292 15 Hexagon nut 4
14 35 1710 33 Grease nipple 2
15 39 0740 11 Plain washer (Nylon) 2

16 DJ 1710 34 Nitrox Screw Assly. 2 (1 Per RSA)

30 31
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 27 : RIDER FOOT REST Plate No. 28 : PILLION FOOT REST / HOLDER

4
4

2
2 2
5

2 7 6
3
8
2
4
1

6 9
5
7
8 3

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1611 26 Main step LH assly. comp. 1 1 DK 1611 37 Holder LH step - Silver 1

2 22 1504 51 Flange bolt 4 52 DK01 67 Holder LH step - Black 1
3 DJ 1611 27 Main step RH assly. comp. 1 DK 1613 08 Holder LH step - Moon Light Silver 1 Ref. Cir. IB-14; Aug-11
4 DH 1610 53 Rubber main step 2 2 DK 1611 38 Holder RH step - Silver 1
5 DH 1611 94 Kick stopper 1 52 DK01 68 Holder RH step - Black 1
DK 1613 09 Holder RH step - Moon Light Silver 1 Ref. Cir. IB-14; Aug-11
6 DX 1610 67 Plate lock pillion step 2 3 DJ 1611 28 Pillion step assly. comp. LH 1
7 DH 1611 00 Spacer main step 2 4 DJ 1611 29 Pillion step assly. comp. RH 1
8 39 2475 04 Bolt 2 5 36 DK00 13 Kit hardware pillion 2 Ref. page no. 68

6 39 1069 01 Hexagonal head screw 2

7 39 0292 15 Nut 1
8 39 2582 04 Flanged Bolt 2 Bolt Mtg. LH & RH Holder Step
9 DJ 1611 22 Pillion footrest rubber 2

32 33
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 29 : MUDGUARD FRONT & REAR Plate No. 30 : STAND ASSEMBLY

3 3

1 4

12
9
8
5
10
6
1
7 7
2 4
5 6

11

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1610 98 Brace fender 1 1 DK 1611 22 Stand main 1

2 59 0400 40 Step bolt 4 2 30 1611 57 Shaft stand 1
3 DK 1610 86 Fender rear front 1 3 39 0787 08 Pin cotter 1
4 39 0711 11 Plain washer 4 4 DH 1611 21 Spring main stand 1
5 39 1680 04 Flange bolt 2 5 DH 1611 45 Cover spring main stand 1

6 DK 1610 85 Fender rear 1 6 JC 1610 17 Stand side 1

7 DS 1611 25 Cable guide 1 7 DH 1610 66 Spring side stand 1
8 DJ 1610 69 Nail Cable guide 1 8 DH 1611 46 Cover spring side stand 1
9 DF 1611 02 Bolt 1
10 39 0422 15 Nut 1

11 DJ 2011 06 Magnet assembly 1

12 DJ 1611 24 Main Stand Rubber 1

34 35
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 31 : TYRE / TUBE / RIM Plate No. 32 : FRONT HUB

4
2

2
5 2
5
6

11
1

EU
OGRIP
R
10

4 12
3 8
9
13
EU
R
OGRIP

14

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 JC 1510 13 Wheel rim front 1 1 39 0787 08 Pin cotter 1

2 DK 1510 39 Tubeless tyre front 1 Not serviceable 2 39 2241 20 Bearing ball 2
3 DK 1510 50 Wheel rim rear 1 3 DK 1510 28 Spacer assly. 1
4 DK 1510 40 Tubeless tyre rear 1 Not serviceable 4 DG 1510 05 Seal oil 1
5 DK 1510 26 Valve for tubeless tyre 2 5 DE 1510 12 Plate drive 1

6 Weights for Wheel Rim 1 6 DE 1510 08 Seal oil 1

7 DK 1510 27 Disc 1
8 DH 1710 19 U nut 1
9 DG 1510 08 Plain washer 1
10 DG 1510 49 Hex. soc. hd. bolt 6

11 JC 1510 20 Case meter assly. (W/o Sensor) 1 Applicable to all versions of

12 JC 2010 50 Hardware Kit 1 Pulsar 220 & 200
13 DG 1510 07 Collar 1
14 DK 1510 08 Axle 1

36 37
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 33 : FR. MASTER CYLINDER Plate No. 34 : FRONT DISC BRAKE

8 3
4

9
10
10
NG
E
: US -4
NI DOT3 OM
WAR NLY D FR R
O FLUI AINE
13 8
1
E NT
AK CO CAP
BR R VING
ED
AL FILLE MO
SE RE
A AN
CLE FORE
BE

15
9
5 10
7
5
4 x

14
3
7
7
2
6
11
12
6 2

5
4 1

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DE 1910 43 Major Kit - Master Cylinder 1 1 DK 1510 54 Caliper Assly. Front 1

2 DK 1510 57 Hose Brake Front 1 2 59 0400 48 Bolt Flanged 2
3 DJ 1910 06 Lever Grip RH 1 3 DE 1510 48 Spring Pad 1
4 DE 1910 11 Banjo Bolt 2 4 DE 1510 46 Bleeder Screw 1
5 DE 1910 10 Washer Copper 4 5 DE 1510 47 Bleeder Cap 1

6 DE 1910 33 Clamp Holder RH 1 (220 SF) 6 DE 1510 37 Disc Pad Set 1

6A DK 1810 52 Clamp Holder RH 1 (220 F) 7 DE 1510 43 Insulator 1
7 DJ 1910 28 Bolt 2 8 DJ 1510 73 Protection Boot 1
8 DJ 1910 29 Bolt Front Brake Lever 1 9 DE 1510 51 Minor kit caliper 1
9 DJ 1910 30 Nut Flanged 1 10 DE 1510 52 Major kit caliper 1
10 DE 1910 30 Screw 2

11 DJ 1910 32 Cylinder Master 1

12 DJ 2011 09 Front brake switch 1
13 DE 1910 29 Reservoir Cover 1
14 DK 1510 72 Diaphragm 1 Not Serviceable

38 39
3
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 35 : REAR HUB Plate No. 35 : REAR HUB

22 22
15 15
13 13
9 9
12 12
16 16
20 20
15 15
11 3 11 3
6 6

14 19 14 19

10 1 10 1

5 21 5 21
2 2
4 4

8 8
18 18
17 17

7 7
17B 17A 17B 17A

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1510 24 Rear disc 1 16 DK 1510 12 Oil Seal 1

2 39 2686 20 Ball bearing 1 17 DK 1510 17 Spacer 1
3 39 2687 20 Ball bearing 1 17A DK 1510 81 Spacer 1 For Floating Type Caliper assly.
4 30 1510 82 Seal oil 1 17B DK 1510 82 Spacer 1 For Floating Type Caliper assly.
5 DK 1510 22 Collar bearing assly. 1 18 DG 1510 08 Washer 1
19 DG 1510 49 Hex soc. HD bolt 6
6 39 1997 15 Nut hex small 6 20 39 2036 04 Bolt Socket 6
7 DK 1510 09 Axel rear 1
8 DH 1710 19 "U" nut 1 21 39 0787 08 Pin cotter 1
9 36 DK00 40 Chain sprocket kit 1 Ref. page no. 68 22 DK 1510 36 Drive chain lock 1
10 JG 1312 19 Coupling rubber 1

11 JC 1510 16 Coupling 1
12 DK 1510 13 Ball Bearing 1
13 DK 1510 15 Sleeve 1
14 DS 1510 74 Washer lock 6
15 DS 1510 73 Stud 2

40 41
3
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 36 : REAR DISC BRAKE Plate No. 37 : REAR MASTER CYLINDER

8
1
3 5
3

11
7 6
4
5
KBX
1/1A
10 9
Piston
6
7

3 4
2/2A

12/12A

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1510 59 Caliper assembly rear 1 1 DK 1510 31 Master Cylinder 1

1A DK1510 83 Caliper assembly rear 1 Floating Type (New) 2 DK 1510 73 Major Kit 1 (Includes Piston)
2 DK 1510 32 Hose disc brake 1 2A DK 1510 74 Major Kit 1 (Does not Includes Piston))
3 DK 1510 33 Reservoir rear disc brake 1 3 DK 151078 Circlip 1
4 DK 1510 34 Reservoir tube 1 4 DK 1510 43 Push Road 1
5 39 2310 04 Flange bolt 2 5 DK 1510 42 Boot 1

6 DK 1510 23 Caliper bracket 1 6 DK 1510 76 Connector 1

7 39 2481 04 Caliper bracket Bolt 2 7 DK 1510 77 Cap 1
8 DK 1510 45 Reservoir Wire cap 1
9 DK 1510 63 Clip for reservoir tube 2
10 DK 1510 69 Banjo Bolt 1

11 DE 1910 10 Copper Washer 1

12 DK 1510 38 Disc Pad 1
12A DK 1510 85 Disc Pad Modified 1 Floating Type (New)

42 43
3
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 38 : REAR CALIPER Plate No. 39 : REAR BRAKE PADAL

1 8

6
7 4 3 2
2 3 4
15 14
9B 2
10
9
9A

1 3

12 11 4

13 8

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1510 59 Caliper assly. Rear 1 1 DK 1910 12 Lever Brake Pedal 1

2 DK 1510 68 Seal 2 2 DG 1013 39 Damper 1
– DK 1510 71 Caliper Major Kit 1 (Includes Sr. No. 6,3,2,4) 3 DK 1011 86 Bolt pivot lever change 1
-- DK 1510 70 Caliper Minor Kit 1 (Includes Sr. No. 6,3,2)
3 Not Serviceable Scrapper Ring 2 4 DK 1011 85 Washer pivot bolt 1
4 Not Serviceable Piston 2 5 DK 1011 87 Collar pivot bolt 1
5 Not Serviceable Half Caliper without Mounting –
6 Not Serviceable ‘O’ Ring -- 6 DK 1910 13 Spring brake pedal 1
7 Not Serviceable Pad --
8 DK 1510 41 Spring Pad 1 7 DG 1013 39 Brake pedal rubber 1
9 Not Serviceable Pin Assly. --
9A DK 1510 64 Pin 1
9B Not Serviceable Fork --
10 DK 1510 65 Circlip 1

11 DK 1510 67 Bleeder Screw 1

12 DK 1510 66 Bleeder cap 1
13 Not Serviceable Thread Protector –
14 Not Serviceable Shim Mounting Side --
15 Not Serviceable Shim Wheel Side –
16 DK 1510 88 Piston Kit (major kit) floating caliper 1 Refer Page no. 69
17 DK 1510 89 Kit Piston Seal (Minor Kit) 1 Refer Page no. 69
18 DK 1510 90 Insulator Kit floating caliper 1 Refer Page no. 69

44 45
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 40 : HANDLE BAR Plate No. 40 : HANDLE BAR

17 17
14 16 14 16

N
O
19 N
O
19

I
L OF ON

L OF ON
I G N I T

I G N I T
F

F
E

E
7 7

-R

-R
H LO H LO
PUS PUS

21 21
CK CK

27 18 23 24 27 18 23 24
3 3

29 29

1 1
15 5 15 5
4 4
22 22

10 6 10 6

2 2
9 9
12 12
28 28
13 13
16 20 16 20
25/26 25/26
17 17
11 11
8 8

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1810 39 Upper Bracket 1 Silver colour 16 DH 1810 22 Handle bar weight 2 (220 F)
DK 1810 63 Upper Bracket 1 Black colour DJ 1810 11 Handle bar weight 2 (220 SF)
2 DK 2010 76 Hall sensor assly. 1 17 39 2427 04 Hex. soc. hd. cap screw 2
3 DK 1810 85 Holder handle RH 1 Silver colour 18 DK 2010 15 Switch assly. ignition 1 (220 F)
DK 1810 62 Holder handle RH 1 Black colour
JC 2010 45 Switch assly. ignition 1 (220 SF)
4 DK 1810 81 Holder handle LH 1 Silver colour
DK 1810 60 Holder handle LH 1 Black colour
19 39 1943 04 Flange bolt 2
5 DG 1810 08 Allen bolt 4
20 DK 2010 83 Clutch Switch 1 (220 F)
6 DK 2010 70 Control switch LH 1 (220 F) DJ 2011 95 Clutch Switch 1 (220 SF)
JC 2010 17 Control switch LH 1 (220 SF) DJ 2012 46 Clutch Switch (Transil Diode Type) 1 (220 SF & F)(from Chs. no. UCJ73042)
7 DK 2010 71 Control switch RH 1 (220 F) 21 DK 1810 36 Handle bar plug 2
JC 2010 18 Control switch RH 1 (220 SF) 22 DK 1810 82 Handle bar tube assly. LH 1
8 DJ 1910 09 Lever & Holder Assly LH 1 23 DK 1810 86 Handle bar tube assly. RH 1
DJ 1910 82 Lever & Holder Assly LH 1 (for Transil Diode Type Clutch Switch) 24 DH 1910 17 Pipe throttle 1
from Chs. no. UCJ73042) 25 DK 2210 22 Mirror holder LH 1 (220 F)
9 DJ 1910 55 Lever LH 1
DJ 1910 54 Mirror holder LH 1 (220 SF)
DJ 1910 83 Lever LH (from Chs. no. UCJ73042) 1 (for Transil Diode Type Clutch Switch
10 DL 1910 14 Stud lever handle 1
26 DK 2210 23 Mirror holder RH 1 (220 F)
11 39 1184 15 Self locking nut 1 DK 2210 15 Mirror holder RH 1 (220 SF)
12 36 DK00 19 Hardware Holder kit LH 1 Ref. page no. 69 27 DK 1810 34 Lock set 4-in-1 1 (220 F)
13 DH 1910 07 Grip LH 1 JC 1810 29 Lock set 4-in-1 1 (220 SF)
14 DH 1910 08 Grip RH 1 28 DK 2010 39 Magnet Hall Sensor 1
15 DH 1910 19 Boot for lever 1 29 LA C000 20 Handle Bar bolt 2

46 47
3
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 41 : FRONT FORK Plate No. 41 : FRONT FORK

18 18
19 19

28 20 28 20
7 7

29 29
26 26
17 17
2 2
15A 25 15A 25
11 11
10 10
12 12
13 13
3/4 14 21 3/4 14 21
16 16
8 8
18 18
15 19 15 19
5 22 5 22
9 9
6 23 6 23
24 24
1 27 1 27

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1810 72 Fork front 1 16 DK 1810 18 Washer 2

2 DK 1810 19 Oil seal 2 17 59 0400 05 Bolt 1
3 DK 1810 56 Outer Tube LH 1 18 JC 1810 23 Cushion Rubber 2
4 DK 1810 57 Outer Tube RH 1 19 JC 1810 22 Cover Trail B 4
5 DK 1810 07 Copper Washer 2 20 JC 1810 24 Lamp Shade asly. 1

6 DK 1810 06 Bolt 2 21 DG 1810 05 Bearing cone 1 Included in kit 36 DV00 07

7 DK 1810 10 Seat Pipe (Cylinder comp. fork) 2 22 DK 1810 24 Holder fork under 1
8 DK 1810 70 Pipe comp. suspension inner 2 23 DK 1810 25 Spring washer 2
9 DK 1810 11 Slide Bush 2
24 DK 1810 08 Flange Bolt 2
10 DK 1810 73 Spring front fork 2
25 DK 1810 17 Guide bush 1

11 DK 1810 22 Bolt fork 2

26 DK 1810 13 Rebound spring 2
12 DK 1810 23 ‘O’ ring 2
27 36 3140 04 Fork Oil Bottle 160 ml 1
13 31 1811 01 Seat fork spring 2
28 DK 1810 09 Cap Oil Lock 2
14 DK 1810 71 Spacer Tube 2
15 DK 1810 48 Clamp for brake hose lower 1 29 DK 1810 12 Piston Ring 2
15A DK 1810 37 Clamp for brake hose upper 1

48 49
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 42 : PAINTED PARTS & DECALS (FOR F) Plate No. 42 : PAINTED PARTS & DECALS (FOR F)

14 14
3 3
5 5
7 7

12 18 12 18
1 1

15 15
11 11

16 16

4 4

6 6
8/9 10 8/9 10

2 2

17 13 17 13

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 7103 2V Fuel Tank 1 FOR WINE RED 6 DH 1410 20 Seat tape 1

DK 7103 4K Fuel Tank 1 FOR PLASMA BLUE 7 DJ 7401 2V Fairing 1 FOR WINE RED
DK 7103 4L Fuel Tank 1 FOR GREY SILVER DK 7401 4K Fairing 1 FOR PLASMA BLUE
DK 7103 4M Fuel Tank 1 FOR MIDNIGHT BLACK DK 7401 4L Fairing 1 FOR GREY SILVER
DK 7103 5C Fuel Tank 1 FOR ORANGE METALLIC DK 7401 4M Fairing 1 FOR MIDNIGHT BLACK
2 52 DH05 30 Side cover LH (for F&S) 1 FOR WINE RED DK 7401 5C Fairing 1 FOR ORANGE
52 DH05 28 Side cover LH (for F&S) 1 FOR PLASMA BLUE 8 DK 1611 23 Cover Side Mesh LH 1 (For F&S)
52 DH05 32 Side cover LH (for F&S) 1 FOR GREY SILVER 9 DK 1611 24 Cover Side Mesh RH 1 (For F&S)
52 DH05 34 Side cover LH (for F&S) 1 FOR MIDNIGHT BLACK 10 59 0200 01 Self tap screw 6 (For F&S)
3 52 DH05 31 Side cover RH (for F&S) 1 FOR WINE RED 11 DK 1410 15 Tank Pad 1 (For F&S)
52 DH05 29 Side cover RH (for F&S) 1 FOR PLASMA BLUE 12 DS 1611 25 Guide cable 1
52 DH05 33 Side cover RH (for F&S) 1 FOR GREY SILVER 13 DK 1612 55 Decal for seat cowl 1 Common for all
52 DH05 35 Side cover RH (for F&S) 1 FOR MIDNIGHT BLACK DK 1612 57 Decal for seat cowl 1 FOR ORANGE
4 DK 7303 2V Seat Cowl Assly. (for F&S) 1 FOR WINE RED 14 DJ 1610 69 Nail guide cable 1
DH 7303 4K Seat Cowl Assly. (for F&S) 1 FOR PLASMA BLUE
DH 7303 4L Seat Cowl Assly. (for F&S) 1 FOR GREY SILVER 15 JC 1410 49 B Monogram 1
DH 7303 4M Seat Cowl Assly. (for F&S) 1 FOR MIDNIGHT BLACK
DH 7303 5C Seat Cowl Assly. (for F&S) 1 FOR ORANGE METALLIC 16 JC 1410 39 Pulsar Tank Decal 1 For Red Blue Black
5 DK 7304 2V Front Fender 1 FOR WINE RED JC 1410 40 Pulsar Tank Decal 1 For Silver
DK 7304 4K Front Fender 1 FOR PLASMA BLUE 17 DK 1612 10 Foam Tape II 16
DK 7304 4L Front Fender 1 FOR GREY SILVER 18 DK 1810 74 Beading For Fairing 1
DK 7304 4M Front Fender 1 FOR MIDNIGHT BLACK

50 51
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 43 : PAINTED PARTS & DECALS (EXCLUSIVE FOR S) Plate No. 43 : PAINTED PARTS & DECALS (EXCLUSIVE FOR S)

5 5
1 1

4 4

2/3 2/3

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 7105 2V Fuel Tank 1 FOR WINE RED 5 DH 7401 2V Fairing 1 FOR WINE RED
DK 7105 4K Fuel Tank 1 FOR PLASMA BLUE DH 7401 4K Fairing 1 FOR PLASMA BLUE
DK 7105 4L Fuel Tank 1 FOR GREY SILVER DH 7401 4L Fairing 1 FOR GREY SILVER
DK 7105 4M Fuel Tank 1 FOR MIDNIGHT BLACK DH 7401 4M Fairing 1 FOR MIDNIGHT BLACK
DK 7105 5C Fuel Tank 1 FOR ORANGE DH 7401 5C Fairing 1 FOR ORANGE
2 JC 7201 2V Tank Flap LH 1 FOR WINE RED
JC 7201 4K Tank Flap LH 1 FOR PLASMA BLUE
JC 7201 4L Tank Flap LH 1 FOR GREY SILVER
JC 7201 4M Tank Flap LH 1 FOR MIDNIGHT BLACK
JC 7201 5C Tank Flap LH 1 FOR ORANGE
3 JC 7202 2V Tank Flap RH 1 FOR WINE RED
JC 7202 4K Tank Flap RH 1 FOR PLASMA BLUE
JC 7202 4L Tank Flap RH 1 FOR GREY SILVER
JC 7202 4M Tank Flap RH 1 FOR MIDNIGHT BLACK
JC 7202 5C Tank Flap RH 1 FOR ORANGE
4 DK 7304 2V Front Fender 1 FOR WINE RED
DK 7304 4K Front Fender 1 FOR PLASMA BLUE
DK 7304 4L Front Fender 1 FOR GREY SILVER
DK 7304 4M Front Fender 1 FOR MIDNIGHT BLACK

52 53
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 43A : PAINTED PARTS & DUAL COLOR DECALS Plate No. :

5 5

1 1

7/8 7/8
2 2

3 3

6 6
4 4

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 36 DK00 82 Kit Decal Tank 220 F Blue 1 220 F 7 JC 1410 18 Decal Oil Cooled LHS 1
36 DK00 86 Kit Decal Tank 220 F Red 1 220 F 8 JC 1410 19 Decal Oil Cooled RHS 1
36 DH40 34 Kit Decal Tank Pulsar Blue 1 220 SF
36 DH40 37 Kit Decal Tank Pulsar Red 1 220 SF

2 36 DK00 83 Kit Decal Fairing 220 F Blue 1 220 F

36 DK00 87 Kit Decal Fairing 220 F Red 1 220 F

3 36 DK00 84 Kit Decal Side Cover Blue 1 220 F / SF

36 DK00 88 Kit Decal Side Cover Red 1 220 F / SF

4 36 DK00 85 Kit Decal Cowling 220 F Blue 1 220 F

36 DK00 89 Kit Decal Cowling 220 F Red 1 220 F

36 DH40 36 Kit Decal Cowling Pulsar Blue 1 220 SF

36 DH40 39 Kit Decal Cowling Pulsar Red 1 220 SF

5 52 DK02 01 Fairing 220 F with Decal Blue 1 220 F

52 DK02 00 Fairing 220 F with Decal Red 1 220 F

6 36 DH40 35 Kit Decal Fairing Pulsar Blue 1 220 SF

36 DH40 38 Kit Decal Fairing Pulsar Red 1 220 SF

53A 51
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 44 : CAP TANK & GAUGE FUEL Plate No. 45 : FITTINGS P. TANK, SIDE COVER & COVER SEAT

3
1
7

4
2

4
6 2 5

6
1
13 3
8 14 10
7
5
13
9
12
11

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1410 14 Cap Assly. Tank 1 1 DK 1611 85 Grommet Kit For side cover 1 Ref. Page No. 69
2 39 0840 01 Pan head screw 1 2 DH 1410 31 Tape tank inner 2
3 39 2381 04 Hex. Soc Hd. cap screw 7 3 DG 1611 21 Screw 2
4 DK 1410 01 Tap Assly 1 4 39 2424 11 Plain Washer 1
5 JC 1410 34 Spring drain tube 1 5 DH 1410 23 Damper Rear 1

6 30 1410 36 Packing 1 6 DJ 1410 08 Damper front 2

7 DD 1410 22 Bolt flanged 2 7 39 1556 04 Flanged Bolt 1
8 39 0740 11 Plain Washer 2
9 DK 2010 65 Gauge Fuel (Tank Unit) 1
10 39 2758 21 Gasket fuel Gauge 1

11 30 1410 32 Bolt 4
12 52 DJ03 13 Tube fuel 1
13 BA 1220 03 Pipe clip 1
14 DH 1410 24 Drain tube 1

54 55
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 46 : METER ASSEMBLY Plate No. 47 : CONTROL CABLES

10
8 12

2
F
6
E km/h
4 x 1 0 0 rpm

2 SIDE
STAND
1

4 1

1
4

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 JC 1910 18 Meter Assly / Instrument Cluster 1 (220 F) 1 JC 1910 19 Assembly Throttle 1

JC 1910 14 Instrument Cluster 1 (220 SF) 2 JC 1910 04 Cable Clutch 1
2 DJ 2011 59 Speedometer top cover 1 3 DK 2010 98 Sensor speedometer cable 1 (F) With Sleeve
3 DJ 2011 82 Speedo gasket 1 N.I. 4 JC 2010 46 Stopper 1
4 DJ 1811 19 Speedometer Back Cover Fairing 1 (220 SF)

56 57
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 48 : CHAIN COVER Plate No. 49 : HEAD LAMP & FAIRING

4 5

6
8
7

1A
2
1
2 13
11
10 14
12

2
9

1 15
16

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1612 50 Cover chain 1 1 DK 2010 56 Head Lamp assly. without bulb 1 (220 F)
2 DS 1612 24 Bolt 2 1A DJ 2011 76 Head Lamp assly. without bulb 1 (220 SF)
2 DJ 1811 20 Back cover 1
3 DK 1610 69 Wind Shield 1 (220 F)
DJ 1810 33 Wind Shield 1 (220 SF)
4 DF 1810 98 Bolt 4
5 39 2141 24 Non Metallic Washer 4

6 DL 1810 10 Well Nut 4

7 DK 1612 08 Decal Wind Shield 1
8 39 1907 01 M5 x 15L mushroom HD 2
9 DK 2010 44 Bulb 2
10 DH 1810 52 Fairing mounting upper bracket 1

11 36 DK00 21 Kit hardware mtg. bracket 1 Ref. page no. 69

12 DJ 1810 65 Clip Nut 4
13 39 0716 01 Screw pan cross 2
14 39 1524 01 Screw pan cross 2
15 DK 2010 43 Headlight bulb 2 (220 F)
JC 2010 09 Headlight bulb 1 (220 SF)

16 DK 2011 17 Wiring harness for HL 1 (220 F)

DJ 2012 30 Wiring harness for HL 1 (220 SF)

58 59
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 50 : INDICATOR LIGHT ASSEMBLY Plate No. 51 : FAIRING & MOUNTING (FOR F)

16
18

9
14

3
1/2 24 2
7
19

5
15

20 8 21

2
4
17
4

3/4 6 1
5
13 10
11
22
6 12

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 2012 07 Indicator front LH 1 1 52 DK01 44 Faring mtg. structure 1

2 DJ 2012 06 Indicator front RH 1 2 39 1956 04 Flange bolt 2
3 DJ 2012 06 Indicator rear LH 1 3 DK 1610 81 Rubber grommet Fairing mtg. 4
4 DJ 2012 07 Indicator rear RH 1 4 DK 1610 82 Sleeve Fairing 1
5 GH 2010 12 Lamp 1 5 DK 1611 26 Damper for fairing 4

6 39 1970 15 Hex Nut Flange 4 6 DK 1610 70 Fairing air intake LH 1

7 Dk 1610 71 Fairing air intake RH 1
8 DK 1610 72 Fairing under cover 1
9 59 0200 01 Self tapping screw 4
10 DK 1610 73 Fairing back cover assly. 1

11 39 1778 02 Self tapping screw for speedo 1

12 DJ 1612 29 Clip nut 1
13 39 1907 01 Screw 12
14 DK 1610 76 Fairing mesh LH 1
15 DK 1610 77 Fairing mesh RH 1

60 61
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 51 : FAIRING & MOUNTING (FOR F) Plate No. 52 : TAIL LAMP ASSLY / FR & RR NO. PLATE

16
18 4
3 2
9
14
5
3
24 2
7
19
6
5
15
12 1
20 8 21
6

2
4

17 11
4
7
6 1
13
13 10
11
22 8
12

14 9 10

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 39 1918 24 Washer 6 1 DK 2010 03 Tail light with Lamp 1

17 DK 2210 14 Mirror assly. LH 1 (220 F) 2 DH 1612 93 Damper 2
DJ 2210 03 Mirror assly. LH 1 (220 SF) 3 DK 1611 53 Clip Nut 4
18 DK 2210 15 Mirror assly. RH 1 (220 F) 4 59 0100 13 Screw pan cross 4
DJ 2210 04 Mirror assly. RH 1 (220 SF) 5 39 0705 01 Truss Screw 2
19 DK 2210 01 Nut for mirror 1
6 39 1972 15 Bolt flange 2
20 59 0200 01 Screw (self tapping) 6
7 JW 4010 11 No. Plate illumination 1
8 DJ 1610 72 Rear No. plate bkt. 1
21 DK 1612 10 Tape 16 9 DP 1611 45 Number plate Rear 1
22 JN 1814 06 Beading 1 10 39 1680 04 Hex Flanged Bolt 2
23 DK 1611 52 Nylon bush for fairing 2
24 DK 1611 25 Rubber for mirror 2 11 39 1783 01 Truss Screw 2 For Front No. Plate
12 DP 1611 44 Number plate front 1
13 DS 1810 26 No. plate mounting bracket 1 (220 F)
JC 1610 26 No. plate mounting bracket 1 (220 SF)
14 39 1773 04 Bolt flange 2
15 DK 1611 64 Blinker mounting bracket 1

62 63
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 53 : ELECTRICAL EQUIPMENTS Plate No. 53 : ELECTRICAL EQUIPMENTS

6 6
1/2 1/2

7 8 7 8
9 9
4 4
3 14 3 14

15 15

13 18 13 18

5 5
11 11
12 12

16 16

17 17
10 10

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 2010 37 Horn LH stay 1 14 JC 2010 27 Cable assly. (Battery to St. Relay) 1

2 DK 2010 38 Horn RH stay 1 15 DJ 2011 40 Cable assly. (Battery to Earth) 1
3 39 1507 11 Plain Washer 1
4 39 1956 04 Flange Bolt 1 16 AL 2010 12 Main relay 1
5 JC 2010 41 Wiring Harness 1 (220 F) 17 JC 2010 40 B.C.U. 1 (220 F)
JC 2010 37 Wiring Harness 1 (220 SF) JC 2010 16 B.C.U. 1 (220 SF)
18 JD 4018 06 Battery Drain Pipe 1
6 31 2010 79 Rear Brake Switch 1
7 DK 1910 14 Spring Brake Switch 1
8 DH 2010 19 Grommet Rear Brake Switch 1
9 DJ 2011 26 Dry Battery (12V-9A) 1
10 DJ 1612 47 Band Battery 1

11 39 1551 04 Flange Bolt 1

12 DK 2010 78 Starter Relay / Damper 1
13 DJ 1810 65 Clip Nut 4

64 65
3
Brand ID: 001MC618 Brand ID: 001MC618
Plate No. 54 : TOOL KIT Plate No. 55 : ACCESSORIES / GRAB HANDLE

1 7

5
2

4 8/9

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 2210 11 Tool Kit 1 1 36 DK00 33 Leg Guard Kit 1

2 39 2310 04 Flange bolt 4
2 DK 2210 24 Band tool kit 2 N.I. 3 DK 1611 76 Sari Guard Assly. 1
4 36 DK00 23 Kit hardware sari guard 1 Ref. page no. 69
5 DK 1611 47 Grab handle LH 1
DK 1612 17 Grab handle LH 1 Black color

6 DK 1611 48 Grab handle RH 1

DK 1612 18 Grab handle RH 1 Black color
7 39 2310 04 Bolt Flange 4
8 DJ 1610 79 Foam LH For grab 1
9 DJ 1610 80 Foam RH For grab 1

66 3 67