Pulsar 220

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 authorized Bajaj Dealer for
the latest information on product improvements incorporated
after this manual was issued.
DOC. NO.: 71111247 REV. 01 MAR. 13

Brand ID: 001MC618
We have pleasure in presenting the Spare Parts Catalogue for ‘Pulsar 220 for full 1. How to Read the Catalogue : Open the catalogue and from the pictorial index
Fairing (F) & Small Fairing (S)’ Models. This catalogue has been specially designed 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
to assist you in selecting the correct parts for procurement to maintain 100%
the part you wish to order. Write down the part number against that particular
availability. figure number from the text.
The Bajaj spares are subjected to the stringent quality control standards to ensure 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
longer life of the vehicle. It is therefore necessary that only the Genuine Bajaj Spares and page number of the part you wish to order.
are used.
2. How to Order Spare Parts : The part number and the description of the part
In a continual effort to improve Performance and Efficiency of the vehicles, required should be invariably mentioned in the order as per the catalogue text.
Specifications, Diagrams, Illustrations and Part Numbers can change without notice. The latest part number as conveyed through our service circulars should only
Consequently, the description in this Spare Parts Catalogue cannot therefore be final appear on the order. In case of ordering painted components, colour shade of the
and binding on us. components should be mentioned.
The quantity shown against the part number is the quantity per vehicle for that
The modifications / alterations which are carried out after the issue of this catalogue, group so that particular quantity should be multiplied by the number of sets
will be conveyed to you through our Service Circulars. You are requested to make required.
necessary corrections in the Parts Catalogue as per the circulars so as to keep your
3. Part Number System: We have used 8 digit system for part numbers. The model
catalogue up-to-date. This will ensure the appropriate and speedy delivery of the or hardware item is indicated by first two digits or alphanumeric, the next two or
Spare Parts as the order placed will bear the latest part numbers. 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
In case, if you need any technical assistance contact the concerned Regional Office numbers will be indicated by 2-2-4 or 2-4-2 digit system. Understanding this
system will enable you to identify the spare parts easily.
or write to us on the following address :
4. Abbreviations : The following abbreviations are used in this catalogue.
Bajaj Auto Limited assly. Assembly V Volts
Service Department N.I. Not illustrated W Watts
Akurdi, Pune 411 035 India C'case Crankcase accl. Accelerator
Phone : 020-27406557
Fax : 020-27407385 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
Brand ID: 001MC618 Brand ID: 001MC618
INDEX PICTORIAL INDEX
Description Page Description Page

No. No.
No. No.
1 Cover Cylinder Head 1 36 Rear Disc Brake 42
2 Cylinder Head 2 37 Rear Master Cylinder 43
3 Valve 3 38 Rear Caliper 44
4 Camshaft / Tensioner 4 39 Rear Brake Pedal 45
5 Cylinder & Piston 5 40 Handle Bar 46&47
6 Crankshaft 6 41 Front Fork 48&49

7 Balancer & Balancer Idler Gear 7 42 Painted Parts & Decals (For S) 50-51
8 Transmission 8&9 43 Painted Parts & Decals (Exl. S) 52-53
9 Change Drum/ Shift Fork 10 44 Cap Tank & Gauge Fuel 54
10 Gear Change Mechanism 11 45 Fitting - Petrol Tank,
Side Cover & Cover seat 55
11 Engine Assly & Crankcase RH 12
12 Crankcase LH 13&14 46 Meter Assly. 56
13 Cover RH 15&16 47 Control Cables 57
14 Cover Magneto 17 48 Chain Case 58
15 Clutch 18&19 49 Head Lamp & Fairing 59
50 Indicator Light Assly. 60
16 Carburetor 20
17 Oil Coller Assly 21 51 Fearing & Mounting 61&62
18 Air Cleaner Comp. 22 52 Tail Lamp Assly / Front &
19 Silencer Assly 23 Rear No. Plate 63
20 Seat Assly. / Seat Lock 24 53 Electrical Equipments 64&65
54 Tool Kit 66
21 Oil Pump 25 55 Accessories / Grab Handle 67
22 Magneto/C.D.I./H.T.Coil 26&27
23 Starter Assly 28 Kits List 68&70
24 Engine Mountings 29 Amendment Sheet(Parts Added) 71
25 Frame & Frame fitting 30 Amendment Sheet(Parts Deleted) 72
Part Index 73
26 Swing Arm / Rear Shock Absorber 31
27 Rider Foot rest 32
28 Pillion Foot rest / Holder 33
29 Mudguard Front & Rear 34
30 Stand Assembly 35
31 Tyre/ Tube /Rim 36

32 Front Hub 37
33 Front Master Cylinder 38
34 Front Disc Brake 39
35 Rear Hub 40&41
PICTORIAL INDEX PICTORIAL INDEX
PICTORIAL INDEX Plate No. 1 : COVER CYLINDER HEAD
Qty/
No. Part No. Description Veh. Remarks
1 36 DK00 90 Kit Assly Cylinder Head with Cover 1 D-44 (Old P. No.-DK101607)
DK 1017 74 Head Cylinder with Cover 1 D-46 - 26.03.2012
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
10 DH 1012 72 Plug 2
11 31 1011 06 Gasket 2
1
Plate No. 2 : CYLINDER HEAD Plate No. 3 : VALVE
Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks
1 36 DK00 90 Kit Assly Cylinder Head with Cover 1 D-44 (Old P. No.-DK101607) 1 DS 1013 35 Rocker Arm Shaft - Intake 1 .
DK 1017 74 Head Cylinder with Cover 1 D-46 - 26.03.2012 DK 1017 48 Rocker Arm Shaft - Intake 1 D-44 - 02.12.2011.
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 D-44 - 02.12.2011
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 without roller 2 D-44 - 02.12.2011
4 DG 1010 29 Collet 4
6 DK 1210 82 Insulator 1 D-46 (Old P. No.-JC120018) 5 39 2017 19 Seal valve stem 2
7 DH 1211 42 Clamp for Insulator 2 D-46 (Old P. No.-DH121038)
8 39 1674 04 Hex. Bolt / Flange 2 (F) 6 DK 1013 26 Valve Repair Kit 1 Ref. page no. 68
9 DH 1110 12 Sleeve - Spark Plug 1 7 DK 1013 27 Valve Kit (inlet + exhaust) 1 Ref. page no. 68
10 39 2608 01 Grub Screw 1 For Sleeve Spark Plug 8 DS 1013 66 Wave washer 2
DH 1012 95 Wave washer 2 D-44 - 02.12.2011
11 36 DS10 01 Cyl. Head ‘O’ Ring Kit 1 Ref. page no. 68 9 59 1100 02 Plain washer 4
12 JC 1200 17 Manifold 1 39 2440 11 Plain washer 4 D-44 - 02.12.2011
13 39 1075 04 Hex bolt 1
14 DK 1015 03 Engine temperature sensor 1
15 39 2181 06 Dowel 2
16 39 1759 04 Bolt 1
2 3
Plate No. 4 : CAMSHAFT / TENSIONER Plate No. 5 : CYLINDER AND PISTON
Qty/ Qty/
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 1010 92 Piston Assly. Standard . 1 Not Serviceable
4 JC 1010 85 Bearing cam LH side 1 4 DK 1013 28 Ring Set Piston 1 Ref. page no. 68
5 DK 1013 30 Guide chain Kit 1 Ref. page no. 68 5 39 2132 17 Ring Snap 2
6 DS 1012 76 Sprocket cam Driven (32 T) 1 6 DK 1016 25 Cylinder Block / Piston Assly 1
7 DH 1014 12 Collar cam Sprocket 1 7 DH 1014 14 Damper 4
8 DH 1010 48 Special camshaft washer 1 8 DK 1015 92 Assembly Oil Pipe 1
9 DK 1013 86 Hex. Soc. Head cap Bolt 1 9 31 1210 06 Gasket 4
10 DK 1010 64 Cam Chain (100 link) 1 10 DD 1210 07 Bolt 2
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
Plate No. 6 : CRANK SHAFT Plate No. 7 : BALANCER & BALANCER IDLER GEAR
Qty/ Qty/
1 DK 1010 65 Crankshaft assly. comp. 1 1 DK 1017 76 Body Balancer Assly. 1 F-29 (Old P No.DK101416)
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 DJ 1011 33 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 13 59 2000 28 Bearing 1 F-29 (Old P No.39218520)
6 7
Plate No. 8 : TRANSMISSION Plate No. 8 : TRANSMISSION
Qty/ Qty/
1 DK 1014 71 Shaft input transmission 1 16 DH 1012 35 Circlip 1

2 39 2158 11 Washer plain 2 17 DK 1017 17 Gear 1st driven 1 D-41-29/07/2011 (Old-DK101118)
3 DK 1011 03 Gear 4th Drive 1 18 DK 1017 20 Gear 5th Driven 1 D-41-29/07/2011 (Old-DK101633)
4 DH 1010 79 Washer Spline 3 19 DH 1013 19 Bush 2nd driven 1
5 DH 1012 35 External Circlip 4 20 DK 1017 19 Gear 2nd Driven 1 D-41-29/07/2011 (Old-DH101333)
6 DK 1011 02 Gear 3rd Drive 1 21 DK 1012 45 Collar Sprocket 1

7 DK 1016 32 Gear 5th drive 1 22 DK 1013 52 ‘O’ Ring Sprocket Collar 1
8 DH 1010 84 Gear 2nd drive 1 23 DV 1010 48 Sprocket Drive 1
9 39 2160 11 Plain washer 1 24 DJ 1010 63 Plate Drive Sprocket 1
10 DK 1011 44 Shaft output transmission 1 25 DJ 1013 00 Bolt flange 2 For Crankcase with circlip
11 DH 1013 36 Washer Thrust 2

12 DK 1011 05 Gear 3rd Driven 1
13 DH 1010 79 Washer spline 2
14 DK 1017 18 Gear 4th Driven 1 D-41-29/07/2011 (Old-DK101106)
15 DH 1011 11 Bush 1st driven 1
8 9
Plate No. 9 : CHANGE DRUM / SHIFT FORK Plate No. 10 : GEAR CHANGE MECHANISM
Qty/ Qty/
1 DK 1011 59 Fork Gear Shift Input 1 1 DK 1017 33 Lever comp. Gear Shifter 1 D-41-29/07/2011(Old-DH101705)
2 DK 1011 60 Fork Gear Shift output 2 2 DH 1017 14 Spring Slider Arm Reset 1
3 DH 1011 46 Shaft Gear Shift Fork Input 1 3 DH 1011 44 Spring Gear Shifter Return 1
4 DH 1014 93 Shaft Gear Shift Fork Output 1 4 DK 1011 82 Lever gear shift 1
5 DK 1017 32 Drum comp. Gear Shift 1 D-41-29/07/2011 (Old-DK101382) 5 31 1011 08 Damper 1
6 39 2639 04 Bolt Socket 1 6 39 2453 04 Flanged Bolt 1

7 39 2606 07 Parallel pin 1 7 DH 1013 93 Bolt Gear Shift drum Stopper 1
8 DK 1013 61 Guide Gear Shifter 1 8 DK 1017 25 Stopper gear shifter drum 1 D-41-29/07/2011(Old-DH101503)
9 DH 1014 96 Spacer 1 9 DK 1012 53 Spring Gear Shifter Drum Stopper 1
10 DK 1011 35 Bush Fork Gear Shift 1 D-41-29/07/2011 (Deleted) 10 DH 1013 94 Bolt Shift Change 1
11 DK 1011 77 Lever change arm 1

12 DK 1011 80 Tie rod 1
10 11
Plate No. 11 : ENGINE ASSLY. & CRANKCASE RH Plate No. 12 : CRANKCASE LH
Qty/ Qty/
1 DK 1016 13 Engine Assly. with starter motor 1 N I (F) 1 DK 1015 81 Crankcase LH 1 with banjo
DK 1017 69 Engine Assly. with starter motor 1 N I (F) Metallic Covers 2 59 0500 02 Stud 2
2 JC 1010 29 Crankcase RH 1 3 DK 1010 94 Guide starter assly 1
3 59 0500 02 Stud 2 4 39 2188 19 Oil Seal 1
4 DJ 1013 02 Bolt Flanged 1 5 59 2100 06 ‘O’ Ring 1
5 DH 1018 96 Gasket Crankcase 1
6 DK 1010 97 Damper 1
6 39 2583 20 Bearing Ball (For Input shaft) 1 7 39 0752 01 ‘C’ Sunk Head Screw 3
7 59 2000 27 Bearing Ball (For Output shaft) 1 8 39 2603 20 Bearing Ball (For Input shaft) 1
8 39 2180 06 Dowel Pin 2 9 59 2000 06 Bearing Ball (For Output shaft) 1
9 39 2601 20 Needle Roller Bearing 1 (For Dr. Comp. Gear Shift) 10 59 2000 28 Bearing 1 F-29 (Old P No.39218520)
10 DH 1014 87 Plate Stopper 1
11 39 2189 19 Oil Seal (For Output shaft) 1
11 39 2181 06 Dowel Pin 2 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
Plate No. 12 : CRANKCASE LH Plate No. 13 : COVER RH
Qty/ Qty/
16 DH 1016 61 Plug (Drain Bolt) 1 1 52 DK02 04 Cover comp RH Flower type (MS) 1 D-43 (Old P No.36DK0064)
17 31 1011 06 Gasket (For Drain Bolt) 1 2 DH 1011 97 Grommet Breather 1
18 DK 1013 80 Switch comp. (Neutral) 1 3 39 1041 19 Seal clutch lever 1
19 39 1013 21 ‘O’ ring 1 4 DH 1011 41 Rack 1
20 39 1677 04 Bolt 8 5 DH 1011 42 Shaft clutch release 1
6 DK 1012 51 Parallel pin 1

21 DH 1013 90 Bolt 1
7 DG 1014 18 Gauge 1
22 DH 1011 69 Needle Roller Bearing 1
8 DS 1012 15 Wire circlip 1
23 DJ 2011 40 Cable assly. (Battery to Earth) 1 9 DS 1013 53 Bolt 10
24 39 2448 11 Plain Washer 1 10 39 0999 06 Pin Dowel 2
25 39 0849 14 Toothed Washer 1
11 DK 1012 52 Bracket Clutch Cable 1
26 DK 1015 77 Thermal Sensor with AL gasket 1 12 DH 1011 54 Gasket cover RH 1
27 39 1672 04 Flange Bolt 1 For Plastic neutral switch 13 DK 1014 80 Plunger Oil 1
28 KE BA37 15 Circlip (May 10) 1 For DKGBTB 50638 14 DH 1210 11 Plate Plunger Oil 1
15 DH 1210 12 Spring Joint ‘A’ 1
14 15
Plate No. 13 : COVER RH Plate No. 14 : COVER MAGNETO
Qty/ Qty/
16 DH 1015 44 Spring Torsion clutch lever 1 1 52 DH06 24 Assly Cover Magneto Flower Type 1 (For SF) D-40-02.05.2011
17 39 2443 11 Washer 1 52 DH06 86 Assly Cover Magneto (MS) 1 (For SF) D-43-03.10.2011
18 DK 1017 38 Decal clutch cover 1 52 DK01 72 Assly Cover Magneto Flower Type 1 (For F) D-40-02.05.2011
19 DK 1014 69 Assembly Relief Valve Complete 1 52 Dk02 03 Assly Cover Magneto (MS) 1 (For F) D-43-03.10.2011
20 DS 1010 71 Cap Oil Filler 1 2 DV 1010 42 Gasket Magneto cover 1
3 39 1074 04 Bolt 5 DS 1013 53
21 DH 1011 52 ‘O’ ring 1 4 39 0999 06 Pin Dowel 2
22 39 1990 20 Needle Roller Bearing 2 5 DK 1017 62 Cover LH Rear 1 D-43 (Old P No. Jc101033)
6 DH 1012 93 Plate Damper Cover LH Rear 1

7 DJ 1612 28 Gear Shift Label 1
8 AP 1010 43 Needle Roller Bearing 1
9 JE 5412 12 Decal DTS-i Magneto 1
16 17
Plate No. 15 : CLUTCH Plate No. 15 : CLUTCH
Qty/ Qty/
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 2617 20 Bearing Clutch lifter thrust 1

12 DK 1015 73 Holder Clutch 1
18 19
PLATE NO. 16 : CARBURETTOR Plate No. 17 : OIL COOLER ASSEMBLY
Qty/ Qty/
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 Top 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
Plate No. 18 : AIR CLEANER COMP Plate No. 19 : SILENCER ASSLY.
Qty/ Qty/
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 0007 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 (Air Filter Top Mtg.) 3 D-39 - 22.02.2011
13 36 DH40 10 Kit Hardware Air Filter Cover 1
22 21
23
Plate No. 20 : SEAT ASSLY / SEAT LOCK Plate No. 21 : OIL PUMP
12
Qty/ Qty/
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
Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL
8
7
17
15 5
10
14
10
2
9 6
19
9
13
16
3
8
11 A B C
5 16
21 12 1 19
18
Qty/ Qty/
1 PD 3510 01 Stator assly. Comp. (For F) 1 D-48 (Old P. No. JC111026) 16 39 1680 04 Flange Bolt 2
DH 1110 81 Stator assly. comp. 1 (For S) 17 DH 1110 16 Grommet Sleeve Spark Plug 1
2 JC 1110 28 Rotor Assly. 1 (For F) 18 DK 1012 84 Hex bolt stator mounting 3
DH 1110 83 Rotor Assly. 1 (For S)
19 DH 1013 81 Pan head screw (Pick up coil mtg) 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 2011 39 Regulator Voltage (For F) 1 D-48 (Old P. No.DK201001 E 36 DK00 51 Starter Motor Repair kit 1 Refer page no. 69
DJ 2012 02 Regulator Voltage 1 (For S)
13 39 1955 04 Flange Bolt 1 D-48-17.08.2012
14 39 1902 04 Flange Bolt 2
15 DJ 1610 67 Bracket H.T. Coil 1
26 27
Plate No. 23 : STARTER ASSLY. Plate No. 24 : ENGINE MOUNTINGS
Qty/ Qty/
1 36 DK00 76 Kit body starter clutch 1 D-40 (Old P. No.DK101595) 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 Alt. 39 2311 04
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 D-43 (Old P. No.DJ101278) 14 39 2311 04 Bolt 1
14 DH 1013 89 Slotted c’sunk screw 1 15 39 2457 11 Washer 1
15 DK 1015 96 Spring Starter Clutch 5
16 DK 1612 22 Bracket engine hanger LH 1
16 DH 1011 63 Roller 5 17 DK 1612 23 Bracket engine hanger RH 1
17 59 2000 07 Needle roller bearing 1
28 29
Plate No. 25 : FRAME & FRAME FITTINGS Plate No. 26 : SWING ARM / RR. SHOCK ABSORBER
Qty/ Qty/
1 JC 1610 50 Frame Assly. Comp. 1 (For F) 1 JC 1710 03 Rear Shock Absorber 2 D-44 (Old P. No.DK171014)
JC 1610 49 Frame Assly. Comp. 1 (For S) 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 08 Bearing Cone Kit 1 F-27 (Old P No. 36DV0007)
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
Plate No. 27 : RIDER FOOT REST Plate No. 28 : PILLION FOOT REST / HOLDER
Qty/ Qty/
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 DK 1613 09 Holder LH step - Black 1 D-43 (Old P No. 52DK0167)
3 DJ 1611 27 Main step RH assly. comp. 1 2 DK 1611 38 Holder RH step - Silver 1
4 DH 1610 53 Rubber main step 2 DK 1613 08 Holder RH step - Black 1 D-43 (Old P No. 52DK0168)
5 DH 1611 94 Kick stopper 1 3 DJ 1611 28 Pillion step assly. comp. LH 1
4 DJ 1611 29 Pillion step assly. comp. RH 1
6 DX 1610 67 Plate lock pillion step 2 5 36 DK00 13 Kit hardware pillion 2 Ref. page no. 68
7 DH 1611 00 Spacer main step 2
8 39 2475 04 Bolt 2 6 39 1069 01 Hexagonal head screw 2
7 39 0292 15 Nut 1
8 39 1741 04 Flanged Bolt 2 Bolt Mtg. LH & RH Holder Step
9 DJ 1611 22 Pillion footrest rubber 2
32 33
Plate No. 29 : MUDGUARD FRONT & REAR Plate No. 30 : STAND ASSEMBLY
Qty/ Qty/
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
Plate No. 31 : TYRE / TUBE / RIM Plate No. 32 : FRONT HUB
Qty/ Qty/
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 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. 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
15 DK 2010 98 Sensor Speedometer 1
36 37
Plate No. 33 : FR. MASTER CYLINDER Plate No. 34 : FRONT DISC BRAKE
Qty/ Qty/
1 36 DH40 48 Major Kit - Master Cylinder 1 F-31 (Old P No.DE191043) 1 DK 1510 54 Caliper Assly. Front 1
2 DK 1510 57 Hose Brake Front 1 2 39 1769 04 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 6 DE 1510 37 Disc Pad Set 1

7 DJ 1910 28 Bolt 2 7 DE 1510 43 Insulator 1
8 DJ 1910 29 Bolt Front Brake Lever 1 8 DJ 1510 73 Protection Boot 1
9 DJ 1910 30 Nut Flanged 1 9 36 DK00 65 Minor kit caliper 1 F-31 (Old P No.DE151051)
10 DE 1910 30 Screw 2 10 36 DK00 66 Minor kit caliper 1 F-31 (Old P No.DE151052)
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
15 DE 1910 35 Oil Window Kit 1
38 39
3
Plate No. 35 : REAR HUB Plate No. 35 : REAR HUB
Qty/ Qty/
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 0787 08 Pin cotter 1
7 DK 1510 09 Axel rear 1 21 DK 1510 36 Drive chain lock 1
8 DH 1710 19 "U" nut 1
9 36 DK00 40 Chain sprocket kit 1 Ref. page no. 68
10 DJ 1510 88 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
Plate No. 36 : REAR DISC BRAKE Plate No. 37 : REAR MASTER CYLINDER
7 6
5
Piston
3 4
2/2A
Qty/ Qty/
1 DK 1510 59 Caliper assembly rear 1 1 DK 1510 31 Master Cylinder 1

2 DK 1510 32 Hose disc brake 1 2 36 DK00 69 Major kit caliper 1 F-31 (Old P No.DK151073)
3 DK 1510 33 Reservoir rear disc brake 1 2A 36 DK00 70 Minor kit caliper 1 F-31 (Old P No.DK151074)
4 DK 1510 34 Reservoir tube 1 3 DK 151078 Circlip 1
5 39 2310 04 Flange bolt 2 4 36 DK00 71 Push Rod 1 F-31 (Old P No.DK151043)
5 DK 1510 42 Boot 1
6 DK 1510 23 Caliper bracket 1
7 39 2481 04 Caliper bracket Bolt 2 6 DK 1510 76 Connector 1
8 DK 1510 45 Reservoir Wire cap 1 7 DK 1510 77 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 Modified 1
FLOATING TYPE CALIPER ASSLY
13 DK1510 83 Caliper Assly. 1
14 39 2310 04 Bolt 2
15 DK 1510 85 Rear brake pads 1
42 43
3
Plate No. 38 : REAR CALIPER Plate No. 39 : REAR BRAKE PADAL
Qty/ Qty/
1 DK 1510 59 Caliper assly. Rear 1 1 DK 1910 12 Lever Brake Pedal 1

2 DK 1510 68 Seal 2 2 DK 1011 84 Boss lever change 1
3 DK 1510 41 Spring Pad 1 3 DG 1013 39 Damper 1
4 DK 1510 64 Pin 1
5 DK 1510 65 Circlip 1 4 DK 1011 86 Bolt pivot lever change 1
5 DK 1011 85 Washer pivot bolt 1
6 DK 1510 67 Bleeder Screw 1
7 DK 1510 66 Bleeder cap 1 6 DK 1011 87 Collar pivot bolt 1
8 DK 1510 88 Piston Kit (major kit) floating caliper 1 Refer Page no. 69
9 DK 1510 89 Kit Piston Seal (Minor Kit) 1 Refer Page no. 69 7 DK 1910 13 Spring brake pedal 1
10 DK 1510 90 Insulator Kit floating caliper 1 Refer Page no. 69 8 DG 1013 39 Brake pedal rubber 1
11 DK 1510 71 Caliper Major Kit 1 (Includes Sr. No. 2.3.4.5)

36 DK00 68 Kit Caliper Major with Grease 1 F-31- 03.12.2012
12 DK 1510 70 Caliper Minor Kit 1 (Includes Sr. No. 2.3.4.5)
36 DK00 67 Kit Caliper Minor with Grease 1 F-31- 03.12.2012
13 Not Serviceable Scrapper Ring 2
14 Not Serviceable Piston 2
15 Not Serviceable ‘O’ Ring 2
44 45
Plate No. 40 : HANDLE BAR Plate No. 40 : HANDLE BAR
Qty/ Qty/
1 DK 1810 30 Holder handle 1 Silver colour 16 DH 1810 22 Handle bar weight 2 (For F)
DK 1810 63 Holder handle 1 Black colour DJ 1810 11 Handle bar weight 2 (For S)
2 DK 2010 76 Hall sensor assly. 1 17 DH 1810 40 Hex. soc. hd. cap screw 2
3 DK 1810 32 Holder handle RH 1 18 DK 2010 15 Switch assly. ignition 1 (For F)
DK 1810 85 Holder handle RH 1 Black, D-42 (Old-DK181062) JC 2010 45 Switch assly. ignition 1 (For S)
4 DK 1810 39 Holder handle LH 1 Black colour 19 39 1943 04 Flange bolt 2
DK 1810 81 Holder handle LH 1 Black, D-42 (Old-DK181060) 20 DK 2010 83 Clutch Switch 1 (For F)
5 DG 1810 08 Allen bolt 4 DJ 2011 95 Clutch Switch 1 (For S)
21 DK 1810 36 Handle bar plug 2
6 DK 2011 40 Control switch LH (For F) 1 D-48 (Old-DK201070) 22 DK 1810 82 Handle bar tube assly. LH 1 D-42 (Old-DK181046)
JC 2010 17 Control switch LH 1 (For S) 23 DK 1810 86 Handle bar tube assly. RH 1 D-42 (Old-DK181047)
7 DK 2011 41 Control switch RH (For F) 1 D-48 (Old-DK201071) 24 DH 1910 17 Pipe throttle 1
JC 2010 18 Control switch RH 1 (For S) 25 DK 2210 22 Mirror holder LH 1 (For F)
8 DJ 1910 09 Lever assly. grip LH 1 DK 2010 14 Mirror holder LH 1 (For S)
9 DJ 1910 55 Lever LH 1
10 DL 1910 14 Stud lever handle 1 26 DK 2210 23 Mirror holder RH 1 (For F)
DK 2210 15 Mirror holder RH 1 (For S)
11 39 1184 15 Self locking nut 1 27 DK 1810 34 Lock set 4-in-1 1 (For F)
12 36 DK00 19 Hardware Holder kit LH 1 Ref. page no. 69 JC 1810 29 Lock set 4-in-1 1 (For S)
13 DH 1910 07 Grip LH 1 28 36 DK00 91 Kit Magnet + Hall Sensor 1 (For F) D-46 - 26.03.2012
14 DH 1910 08 Grip RH 1 36 DJ40 30 Kit Magnet + Hall Sensor 1 (For S) D-46 - 26.03.2012
15 DH 1910 19 Boot for lever 1 29 LA C000 20 Handle Bar bolt kit 1 Old-36DK0052
46 47
3
Plate No. 41 : FRONT FORK Plate No. 41 : FRONT FORK
Qty/ Qty/
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 30 1810 28 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
Plate No. 42 : PAINTED PARTS & DECALS (FOR F) Plate No. 42 : PAINTED PARTS & DECALS (FOR F)
Qty/ Qty/
1 DK 7103 2V Fuel Tank 1 For Wine Red DK 7304 4M Front Fender 1 For Midnight Black
DK 7103 4K Fuel Tank 1 For Plasma Blue 6 DH 1410 20 Seat tape 1
DK 7103 4L Fuel Tank 1 For Grey Silver 7 DK 7401 2V Fairing 1 For Wine Red
DK 7103 4M Fuel Tank 1 For Midnight Black 52 DK02 00 Fairing (DK75042V) With Red Dcl 1 D-43 - 03.10.2011
DK 7103 5C Fuel Tank 1 For Orange Metallic DK 7401 4K Fairing 1 For Plasma Blue
2 52 DH05 30 Side cover LH (for F&S) 1 For Wine Red 52 DK02 01 Fairing (DK75044K) With Blue Dcl 1 D-43 - 03.10.2011
52 DH05 28 Side cover LH (for F&S) 1 For Plasma Blue DK 7401 4L Fairing 1 For Grey Silver
52 DH05 32 Side cover LH (for F&S) 1 For Grey Silver DK 7401 4M Fairing 1 For Midnight Black
52 DH05 34 Side cover LH (for F&S) 1 For Midnight Black DK 7401 5C Fairing 1 For Orange
3 52 DH05 31 Side cover RH (for F&S) 1 For Wine Red 8 DK 1611 23 Cover Side Mesh LH 1 (for F&s)
52 DH05 29 Side cover RH (for F&S) 1 For Plasma Blue 9 DK 1611 24 Cover Side Mesh RH 1 (for F&s)
52 DH05 33 Side cover RH (for F&S) 1 For Grey Silver 10 59 0200 01 Self tap screw 6 (for F&s)
52 DH05 35 Side cover RH (for F&S) 1 For Midnight Black 11 DK 1410 15 Tank Pad 1 (for F&s)
4 DH 7308 2V Seat Cowl Assly. (for F&S) 1 For Wine Red 12 DK 1612 10 Foam Tape II 16
DH 7303 4K Seat Cowl Assly. (for F&S) 1 For Plasma Blue 13 DK 1612 55 Decal for seat cowl 1 Common For All
DH 7303 4L Seat Cowl Assly. (for F&S) 1 For Grey Silver DK 1612 57 Decal for seat cowl 1 For Orange
DH 7303 4M Seat Cowl Assly. (for F&S) 1 For Midnight Black 14 DK 1810 74 Beading For Fairing 1
DH 7303 5C Seat Cowl Assly. (for F&S) 1 For Orange Metallic
5 DK 7304 2V Front Fender 1 For Wine Red 15 JC 1410 49 B Monogram 1 For Red Blue Black
JC 1410 53 B Monogram 1 For Silver
DK 7304 4K Front Fender 1 For Plasma Blue
16 JC 1410 39 Pulsar Tank Decal 1 For Red Blue Black
DK 7304 4L Front Fender 1 For Grey Silver JC 1410 40 Pulsar Tank Decal 1 For Silver
50 51
Plate No. 43 : PAINTED PARTS & DECALS (EXCLUSIVE FOR S) Plate No. 43 : PAINTED PARTS & DECALS (EXCLUSIVE FOR S)
Qty/ Qty/
1 DK 7105 2V Fuel Tank 1 For Wine Red 5 36 DH40 34 Kit Decal Tank 200SF Bl (LH&RH) 1 D-43 - 03.10.2011
DK 7105 4K Fuel Tank 1 For Plasma Blue 36 DH40 37 Kit Decal Tank 200SF Red 1 D-43 - 03.10.2011
DK 7105 4L Fuel Tank 1 For Grey Silver 36 DK00 82 Kit Decal Tank 220F Bl -- D-43 - 03.10.2011
DK 7105 4M Fuel Tank 1 For Midnight Black
36 DK00 86 Kit Decal Tank 220F Rd -- D-43 - 03.10.2011
DK 7105 5C Fuel Tank 1 For Orange
2 JC 7201 2V Tank Flap LH 1 For Wine Red
JC 7201 4K Tank Flap LH 1 For Plasma Blue 6 36 DK00 84 Kit Decal Sd Cover Blue 1 D-43 - 03.10.2011
JC 7201 4L Tank Flap LH 1 For Grey Silver 36 DK00 88 Kit Decal Sd Cover Red 1 D-43 - 03.10.2011
JC 7201 4M Tank Flap LH 1 For Midnight Black
JC 7201 5C Tank Flap LH 1 For Orange 7 36 DK00 85 Kit Decal Cowl 220F Blue -- D-43 - 03.10.2011
3 JC 7202 2V Tank Flap RH 1 For Wine Red 36 DK00 89 Kit Decal Cowl 220F Red -- D-43 - 03.10.2011
JC 7202 4K Tank Flap RH 1 For Plasma Blue
36 DH40 36 Kit Decal Cowl 200SF Bl 1 D-43 - 03.10.2011
JC 7202 4L Tank Flap RH 1 For Grey Silver
36 DH40 39 Kit Decal Cowl 200SF Rd 1 D-43 - 03.10.2011
JC 7202 4M Tank Flap RH 1 For Midnight Black
JC 7202 5C Tank Flap RH 1 For Orange
4 DH 7401 2V Fairing 1 For Wine Red 8 36 DK00 83 Kit Decal Fairing 220F Bl -- D-43 - 03.10.2011
DH 7401 4K Fairing 1 For Plasma Blue 36 DK00 87 Kit Decal Fairing 220F Rd -- D-43 - 03.10.2011
DH 7401 4L Fairing 1 For Grey Silver 36 DH40 35 Kit Decal Fairing 200SF Bl 1 D-43 - 03.10.2011
DH 7401 4M Fairing 1 For Midnight Black 36 DH40 38 Kit Decal Fairing 200SF Rd 1 D-43 - 03.10.2011
DH 7401 5C Fairing 1 For Orange
52 53
Plate No. 44 : CAP TANK & GAUGE FUEL Plate No. 45 : FITTINGS P. TANK, SIDE COVER & COVER SEAT
Qty/ Qty/
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 39 1607 01 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 DJ 1410 06 Tube fuel 1 Alt. 52 DJ03 13
13 BA 1220 03 Pipe clip 1
14 DH 1410 24 Drain tube 1
54 55
Plate No. 46 : METER ASSEMBLY Plate No. 47 : CONTROL CABLES
Qty/ Qty/
1 JC 1910 18 Meter Assly / Instrument Cluster 1 (For F) 1 JC 1910 19 Assembly Throttle 1

DK 1910 35 Meter Assly / Instrument Cluster 1 (For F) D-48-17.08.2012 2 JC 1910 04 Cable Clutch 1
JC 1910 14 Instrument Cluster 1 (For S) 3 DK 2010 98 Sensor speedometer cable 1 (F) With Sleeve
2 DJ 2011 59 Speedometer top cover 1 4 JC 2010 46 Stopper 1
3 DJ 2011 82 Speedo gasket 1 5 59 2100 19 O-Ring 1
4 39 1970 15 Nut Flange M8 (fairing Fit.) 2 (For F) D-48-17.08.2012 6 39 0900 12 Washer Spring 1
5 DK 1613 24 Sleeve Speedometer Support 2 (For F) D-48-17.08.2012 7 39 0840 01 Screw Pan Head 1
6 DK 1613 23 Bracket Speedometer Support 1 (For F) D-48-17.08.2012

7 DK 1610 81 Grommet Speedo Bkt 2 (For F) D-48-17.08.2012
8 39 1970 15 Nut Flange M8 2 (For F) D-48-17.08.2012
9 LA D000 77 Bolt Flanged (speedo Bkt Fit.) 2 (For F) D-48-17.08.2012
56 57
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/
1 DK 1612 50 Cover chain 1 1 DK 2010 56 Head Lamp assly. without bulb 1 (For F)
2 DS 1612 24 Bolt 2 1A DJ 2011 76 Head Lamp assly. without bulb 1 (For S)
2 DJ 1811 20 Back cover 1
3 DK 1610 69 Wind Shield 1 (For F)
DJ 1810 33 Wind Shield 1 (For S)
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 (For F)
JC 2010 09 Headlight bulb 1 (For S)
16 DK 2011 17 Wiring harness for HL 1 (For F)

DJ 2012 30 Wiring harness for HL 1 (For S)
58 59
Plate No. 50 : INDICATOR LIGHT ASSEMBLY Plate No. 51 : FAIRING & MOUNTING (FOR F)
Qty/ Qty/
1 DJ 2012 08 Indicator front LH 1 1 DK 1613 17 Faring mtg. structure 1 D-48 (Old P. No.52DK0144)
2 DJ 2012 09 Indicator front RH 1 2 39 1957 04 Flange bolt 2
3 DJ 2012 06 Indicator rear LH 1 39 1956 04 Flange bolt 2
4 DJ 2012 07 Indicator rear RH 1 3 DK 1610 81 Rubber grommet Fairing mtg. 4
5 GH 2010 12 Lamp 1 4 DK 1610 82 Sleeve Fairing 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 1611 76 Fairing mesh LH 1
15 DK 1610 77 Fairing mesh RH 1
60 61
Plate No. 51 : FAIRING & MOUNTING (FOR F) Plate No. 52 : TAIL LAMP ASSLY / FR & RR NO. PLATE
Qty/ Qty/
16 39 1918 24 Washer 6 1 DK 2010 03 Tail light with Lamp 1

17 DK 2210 14 Mirror assly. LH 1 (For F) 2 DH 1612 93 Damper 2
DJ 2210 03 Mirror assly. LH 1 (For S) 3 DK 1611 53 Clip Nut 4
18 DK 2210 15 Mirror assly. RH 1 (For F) 4 59 0100 13 Screw pan cross 4
DJ 2210 04 Mirror assly. RH 1 (For S) 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 (For F)
JC 1810 25 No. plate mounting bracket 1 (For S)
14 39 1773 04 Bolt flange 2
15 DK 1611 64 Blinker mounting bracket 1
62 63
Plate No. 53 : ELECTRICAL EQUIPMENTS Plate No. 53 : ELECTRICAL EQUIPMENTS
Qty/ Qty/
1 DK 2011 14 Horn LH stay 1 (For F) 14 JC 2010 27 Cable assly. (Battery to St. Relay) 1
DK 2010 37 Horn LH stay 1 (For S) 15 DJ 2011 40 Cable assly. (Battery to Earth) 1
2 DK 2011 15 Horn RH stay 1 (For F)
DK 2010 38 Horn RH stay 1 (For S) 16 AL 2010 12 Main relay 1
3 39 1507 11 Plain Washer 1 17 JC 2010 40 B.C.U. 1 (For F)
4 39 1956 04 Flange Bolt 1 JC 2010 16 B.C.U. 1 (For S)
5 DK 2011 38 Wiring Harness (For F) 1 D-48 (Old P. No.JC201041) 18 JD 4018 06 Battery Drain Pipe 1
JC 2010 37 Wiring Harness 1 (For S)
6 31 2010 79 Rear Brake Switch 1 Alt. DS 2010 29

7 DK 1910 14 Spring Brake Switch 1
8 DH 2010 19 Grommet Rear Brake Switch 1
9 DJ 2011 25 Battery (12V-9A) 1 N.S.
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
Plate No. 54 : TOOL KIT Plate No. 55 : ACCESSORIES / GRAB HANDLE
Qty/ Qty/
1 DK 2210 11 Tool Kit 1 1 36 DK00 33 Leg Guard Kit 1

* DF 2010 43 Tool Driver 1 Not service separately 2 39 2310 04 Flange bolt 4
* DJ 2210 13 Tool Bag 1 Not service separately 3 DK 1611 76 Sari Guard Assly. 1
* DJ 2210 12 Tool bar 1 Not service separately 4 36 DK00 23 Kit hardware sari guard 1 Ref. page no. 69
* DG 2210 10 Tool wrench 1 Not service separately 5 DK 1611 47 Grab handle LH 1
DK 1612 17 Grab handle LH 1 Black color
2 DK 2210 24 "O" ring for tool kit 2
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
KIT LIST KIT LIST
Sr. Consisting of Following Parts Consisting of Following Parts

Kit Part No. Kit Description Kit Part No. Kit Description
No. Part No. Description Qty./Kit Part No. Description Qty./Kit
1 36DS1001 Cyl. Head O Ring Kit 39239121 O Ring (Cover tappet) 2 14 36DK0019 Hardware holder kit LH 30191024 Screw 1
39128321 O ring 2 30191017 Nut 1
39021911 Plain washer 1
2 DK101327 Valve Kit DK101052 Valve Intake 1 39072504 Hex bolt 1
DK101011 Valve Exhaust 1
15 36DK0021 Kit hardware mtg. bracket DJ181029 Collar fearing mtg. 1
3 DK101326 Valve Repair Kit DK101247 Retainer valve spring 2
DK101108 Spring valve inner 2 DJ181036 Grommet fearing structure 1
DK101110 Spring valve outer 2 39021111 Plain washer 1
DK101246 Seat valve spring 2 39155304 Flange bolt 1
4 DK101330 Guide Chain Kit DK101611 Guide chain (Tight) 1 16 DK161185 Grommet kit for side cover DH161158 Grommet side cover front 2
DK101059 Guide Chain (slack) 1 DH161133 Grommet side cover rear 2
5 DK101328 Ring set piston DK101049 Ring piston top 1 17 36DK0023 Kit hardware saree guard DH161255 Bolt special 1
DK101050 Ring piston second 1 39078912 Washer spring 1
DK101051 Ring piston oil 1
39008004 Bolt hexagaon 1
6 36DK0007 Kit centrifugal oil filter 39220011 Washer 1 59040013 Bolt hex socket 1
DH101234 Gasket centrifugal oil filter 1 39029615 Hexagaon nut 1
DH101640 Oval screw 3 DH161144 Cap saree guard 1
DH101066 Join oil delivery 1 DD221003 Plug 1
DH101067 Spring oil delivery 1
39219908 Pin oil delivery joint 1 18 36DK0050 St. Mtr. Repair Kit DK111017 Brush assly. kit 1
DK111019 ‘O’ ring for spigot 1
7 DK101334 Set Damper (cover magneto) DK101191 Damper Cover Magneto 1 DK111020 Oil Seal for yoke 1
DH101292 Damper A Cover LH RR 1
DH101294 Damper B Cover LH RR 1
19 36JC0015 Starter Motor Repair kit JC111018 Drive end bracket 1
8 DK101333 Set of Plate (cover magneto) DK101192 Plate Damper 1 JC111019 Bracket rear end 1
DH101293 Plate Damper Cover LH RR 1
20 36DK0058 Piston valve assly. Kit Piston valve assly. 1
9 36DK0011 Kit hardware engine mounting 39231204 Bolt flange 4 Spring (CO) 1
39197015 Nut flange 8 Diaphragm 1
39241304 Bolt flange 1 Holder 1
DH161245 U Nut 3 Spring 1
E Spring 1
10 36DV0007 Bearing cone kit DG181045 Bearing cone 1 Ring 1
DG181046 Bearing race 1
Jet Needle 1
DG181047 Upper bearing race 1
DG181005 Lower bearing race 1 Ring 1
Washer 1
11 36DK0012 Kit bush rear shock absorber 39071411 Plain washer 8
39071215 Dome cap nut 2 21 DK121048 Pilot screw kit O ring 1
39073712 Spring washer 2 Adjuster 1
Spring 1
12 36DK0013 Kit hardware pillion DJ161186 Plait side pillion step 2 Washer 1
DH161061 Pin pillion set 2 O ring 1
30141031 "O" ring 2
39104011 Plain washer 2
22 DK161241 Vacuum Adjuster kit Spring 1
39078408 Split pin 2
Adjust Screw 1
13 36DK0040 Chain sprocket kit DV101048 Sprocket drive 1 Packing 1
DK151010 Sprocket 1
DK151060 Chain 1
68 69
3
Consisting of Following Parts Amendment Sheet (Parts Added)

Kit Part No. Kit Description
Part No. Description Qty./Kit
Sr.No. Part No. Description Qty. Page No. Fig.No.
23 36DK0059 Main Jet kit Needle jet 1
Main jet 1
Jet holder 1
O ring 1
Pilot Jet 1
24 36DK0060 Float chamber body kit O ring 1

Float body assly. 1
Assly. Screw 4
Drain Screw 1
O ring
25 36DK0061 Tap Cap assly. Kit Diaphragm cover 1

Screw 4
26 36DK0062 Solenoid assly. Kit JC120026 Solenoid assly. 1

39178001 Screw 2
‘O’ ring 1
27 DK151088 Piston Kit Piston 1

Piston Seal 1
Scraper Ring 1
28 DK151089 Kit Piston Seal Piston Seal 1

Scraper Ring 1
29 DK151090 Insulator Kit Dust Cover 1

Insulator 1
30 36DK0050 Starter Motor repair kit DK111017 Brush Assly Kit 1

DK111019 ‘O’ ring for spigot 1
Dk111020 Oil seal for yoke 1
31 36DK0051 Starter Motor Cover kit DK101014 Drive end bracket 1

DK101015 Bracket Rear end 1
70 71
PART INDEX
Amendment Sheet (Parts Deleted) Figure Page Figure Page

Part No. Part No.
No. No. No. No.
Sr.No. Part No. Description Qty. Page No. Fig.No.
22 1504 51 2 32 36 DK00 62 15 20
28 1011 74 15 13 36 DK00 65 9 39
30 1410 32 11 54 36 DK00 66 10 39
30 1410 36 6 54 36 DK00 67 12 44
30 1510 82 4 40 36 DK00 68 11 44
30 1611 57 2 35 36 DK00 69 2 43
30 1810 28 13 48 36 DK00 70 2 43
31 1011 06 11 1 36 DK00 71 4 43
31 1011 06 17 14 36 DK00 76 1 28
31 1011 08 5 11 36 DK00 82 5 53
31 1011 73 4 6 36 DK00 83 8 53
31 1210 06 9 5 36 DK00 84 6 53
31 2010 79 6 64 36 DK00 85 7 53
35 1710 33 14 31 36 DK00 86 5 53
36 3140 04 27 49 36 DK00 87 8 53
36 DH40 10 13 22 36 DK00 88 6 53
36 DH40 34 5 53 36 DK00 89 7 53
36 DH40 35 8 53 36 DK00 90 1 2
36 DH40 36 7 53 36 DK00 91 28 47
36 DH40 37 5 53 36 DS10 01 3 1
36 DH40 38 8 53 36 DS10 01 11 2
36 DH40 39 7 53 36 DV00 08 5 30
36 DH40 48 1 38 39 2443 11 17 16
36 DJ40 30 28 47 39 0007 01 5 22
36 DK00 07 12 6 39 0292 15 13 31
36 DK00 11 4 29 39 0292 15 7 33
36 DK00 12 3 31 39 0422 15 10 35
36 DK00 13 5 33 39 0705 01 5 63
36 DK00 19 12 46 39 0711 11 4 34
36 DK00 21 11 59 39 0716 01 13 59
36 DK00 23 4 67 39 0740 11 15 31
36 DK00 33 1 67 39 0740 11 8 54
36 DK00 40 9 40 39 0752 01 7 13
36 DK00 45 11 28 39 0761 01 4 26
36 DK00 50 21 27 39 0787 08 3 35
36 DK00 51 21 27 39 0787 08 1 37
36 DK00 58 2 20 39 0787 08 20 41
36 DK00 59 8 20 39 0840 01 2 54
36 DK00 60 9 20 39 0840 01 7 57
36 DK00 61 16 20 39 0849 14 25 14
72 3 73
PART INDEX PART INDEX
Figure Page Figure Page Figure Page Figure Page

Part No. Part No. Part No. Part No.
No. No. No. No. No. No. No. No.
39 0849 14 12 28 39 1778 02 11 61 39 2203 07 8 6 52 DH05 35 3 50

39 0900 12 6 57 39 1780 01 12 20 39 2241 20 2 37 52 DH06 24 1 17
39 0972 04 10 28 39 1783 01 11 63 39 2310 04 13 29 52 DH06 86 1 17
39 0999 06 10 15 39 1902 04 6 24 39 2310 04 5 42 52 DK01 72 1 17
39 0999 06 4 17 39 1902 04 14 26 39 2310 04 14 42 52 DK02 00 7 51
39 1013 21 19 14 39 1907 01 8 59 39 2310 04 2 67 52 DK02 01 7 51
39 1041 19 3 15 39 1907 01 13 61 39 2310 04 7 67 52 Dk02 03 1 17
39 1069 01 6 33 39 1918 24 16 62 39 2311 04 14 29 52 DK02 04 1 15
39 1074 04 3 17 39 1931 20 6 6 39 2381 04 3 54 52 JN01 36 2 1
39 1075 04 9 1 39 1943 04 19 47 39 2412 04 8 29 59 0100 13 4 63
39 1075 04 13 2 39 1955 04 13 26 39 2424 11 4 55 59 0200 01 10 51
39 1184 15 11 46 39 1956 04 61 39 2440 11 9 3 59 0200 01 9 61
39 1283 21 5 2 39 1956 04 4 64 39 2448 11 24 14 59 0200 01 20 62
39 1507 11 3 64 39 1957 04 2 61 39 2453 04 6 11 59 0400 05 17 49
39 1524 01 14 59 39 1967 04 10 29 39 2457 11 15 29 59 0400 23 8 1
39 1551 04 11 64 39 1970 15 4 56 39 2475 04 8 32 59 0400 40 2 34
39 1556 04 7 55 39 1970 15 8 56 39 2481 04 7 42 59 0400 43 11 29
39 1607 01 3 55 39 1970 15 6 60 39 2557 17 7 7 59 0500 02 2 2
39 1620 11 9 7 39 1972 15 6 63 39 2583 20 6 12 59 0500 02 3 12
39 1672 04 3 7 39 1990 20 22 16 39 2601 20 9 12 59 0500 02 2 13
39 1672 04 27 14 39 1997 15 6 40 39 2603 20 8 13 59 1100 02 9 3
39 1672 04 5 21 39 2017 19 5 3 39 2606 07 7 10 59 2000 07 9 28
39 1673 04 13 4 39 2132 17 5 5 39 2608 01 10 2 59 2000 06 9 13
39 1674 04 8 2 39 2141 24 5 59 39 2617 20 11 18 59 2000 07 17 28
39 1674 04 11 7 39 2152 20 5 7 39 2637 04 8 21 59 2000 27 7 12
39 1674 04 9 18 39 2157 04 7 29 39 2639 04 6 10 59 2000 28 13 7
39 1674 04 2 25 39 2158 11 2 8 39 2647 15 6 1 59 2100 06 5 13
39 1674 04 3 26 39 2160 11 9 8 39 2669 21 1 4 59 2100 19 5 57
39 1677 04 20 14 39 2165 11 3 6 39 2686 20 2 40 AL 2010 12 16 65
39 1680 04 16 27 39 2180 06 8 12 39 2687 20 3 40 AP 1010 43 8 17
39 1680 04 7 30 39 2181 06 15 2 39 2758 21 10 54 AP 1210 64 6 22
39 1680 04 5 34 39 2181 06 2 5 52 DH01 69 1 25 BA 1220 03 13 54
39 1680 04 10 63 39 2181 06 11 12 52 DH01 77 10 7 CS 1011 28 14 4
39 1686 06 8 7 39 2183 04 2 6 52 DH05 28 2 50 DD 1010 62 15 4
39 1686 06 4 25 39 2185 20 10 13 52 DH05 29 3 50 DD 1110 12 10 26
39 1741 04 8 33 39 2188 19 4 13 52 DH05 30 2 50 DD 1210 07 10 5
39 1759 04 16 2 39 2189 19 11 13 52 DH05 31 3 50 DD 1410 22 7 54
39 1765 11 4 22 39 2190 19 12 13 52 DH05 32 2 50 DE 1510 08 6 37
39 1769 04 2 39 39 2194 21 6 25 52 DH05 33 3 50 DE 1510 12 5 37
39 1773 04 14 63 39 2200 11 17 19 52 DH05 34 2 50 DE 1510 37 6 39
74 3 75

DE 1510 43 7 39 DH 1011 41 4 15 DH 1016 07 3 23 DH 1710 19 8 40

DE 1510 46 4 39 DH 1011 42 5 15 DH 1016 08 2 23 DH 1810 22 16 47
DE 1510 47 5 39 DH 1011 44 3 11 DH 1016 48 15 19 DH 1810 40 17 47
DE 1510 48 3 39 DH 1011 46 3 10 DH 1016 61 16 14 DH 1810 52 10 59
DE 1910 10 5 38 DH 1011 52 21 16 DH 1017 05 1 11 DH 1910 07 13 46
DE 1910 10 11 42 DH 1011 54 12 15 DH 1017 14 2 11 DH 1910 08 14 46
DE 1910 11 4 38 DH 1011 63 16 28 DH 1018 96 5 12 DH 1910 17 24 47
DE 1910 29 13 38 DH 1011 69 22 14 DH 1110 12 9 2 DH 1910 19 15 46
DE 1910 30 10 38 DH 1011 72 7 28 DH 1110 15 9 26 DH 2010 19 8 64
DE 1910 33 6 38 DH 1011 95 10 6 DH 1110 16 17 27 DH 7303 4K 4 50
DE 1910 35 15 38 DH 1011 97 2 15 DH 1110 81 1 26 DH 7303 4L 4 50
DF 1611 02 9 35 DH 1012 03 13 13 DH 1110 83 2 26 DH 7303 4M 4 50
DF 1810 98 4 59 DH 1012 35 5 8 DH 1210 10 3 25 DH 7303 5C 4 50
DF 2010 43 1 66 DH 1012 35 16 9 DH 1210 11 14 15 DH 7308 2V 4 50
DG 1010 29 4 3 DH 1012 46 14 13 DH 1210 12 15 15 DH 7401 2V 4 52
DG 1013 39 3 45 DH 1012 72 10 1 DH 1210 20 3 22 DH 7401 4K 4 52
DG 1013 39 8 45 DH 1012 75 2 18 DH 1210 35 5 25 DH 7401 4L 4 52
DG 1014 18 7 15 DH 1012 93 6 17 DH 1210 63 17 20 DH 7401 4M 4 52
DG 1510 05 4 37 DH 1012 95 8 3 DH 1211 01 10 20 DH 7401 5C 4 52
DG 1510 07 13 37 DH 1013 19 19 9 DH 1211 42 7 2 DJ 1010 63 24 9
DG 1510 08 9 37 DH 1013 33 20 9 DH 1410 20 6 51 DJ 1010 64 4 23
DG 1510 08 18 41 DH 1013 36 11 8 DH 1410 23 5 55 DJ 1011 33 6 7
DG 1510 49 10 37 DH 1013 73 12 7 DH 1410 24 14 54 DJ 1013 00 25 9
DG 1510 49 19 41 DH 1013 81 19 27 DH 1410 31 2 55 DJ 1013 02 4 12
DG 1710 18 5 31 DH 1013 85 5 28 DH 1610 46 3 24 DJ 1210 70 11 20
DG 1710 19 7 31 DH 1013 89 14 28 DH 1610 53 4 32 DJ 1410 06 12 54
DG 1710 34 10 31 DH 1013 90 21 14 DH 1610 66 7 35 DJ 1410 08 6 55
DG 1710 38 2 31 DH 1013 92 11 4 DH 1611 00 7 32 DJ 1510 73 8 39
DG 1810 05 21 49 DH 1013 93 7 11 DH 1611 12 2 30 DJ 1510 88 10 40
DG 1810 08 5 46 DH 1013 94 10 11 DH 1611 21 4 35 DJ 1610 67 15 26
DG 2210 10 1 66 DH 1014 12 7 4 DH 1611 45 5 35 DJ 1610 69 8 34
DH 1010 48 8 4 DH 1014 14 7 5 DH 1611 46 8 35 DJ 1610 72 8 63
DH 1010 64 9 6 DH 1014 32 4 7 DH 1611 89 2 29 DJ 1610 79 8 67
DH 1010 65 11 6 DH 1014 87 10 12 DH 1611 90 3 29 DJ 1610 80 9 67
DH 1010 72 2 7 DH 1014 93 4 10 DH 1611 94 5 32 DJ 1611 22 9 33
DH 1010 79 4 8 DH 1014 96 9 10 DH 1612 73 9 29 DJ 1611 24 12 35
DH 1010 79 13 8 DH 1015 03 8 11 DH 1612 93 2 63 DJ 1611 26 1 32
DH 1010 84 8 8 DH 1015 08 4 2 DH 1613 77 12 22 DJ 1611 27 3 32
DH 1011 11 15 8 DH 1015 44 16 16 DH 1710 19 8 31 DJ 1611 28 3 33
DH 1011 13 6 26 DH 1015 81 4 28 DH 1710 19 8 37 DJ 1611 29 4 33
76 3 77

DJ 1611 32 8 30 DK 1010 64 10 4 DK 1013 61 8 10 DK 1016 36 16 19

DJ 1611 33 9 30 DK 1010 65 1 6 DK 1013 66 9 21 DK 1017 17 17 9
DJ 1612 28 7 17 DK 1010 72 13 19 DK 1013 80 18 14 DK 1017 18 14 8
DJ 1612 29 12 61 DK 1010 92 3 5 DK 1013 82 5 10 DK 1017 19 20 9
DJ 1612 47 10 64 DK 1010 94 3 13 DK 1013 86 9 4 DK 1017 20 18 9
DJ 1710 34 16 31 DK 1010 97 6 13 DK 1014 69 19 16 DK 1017 25 8 11
DJ 1810 11 16 47 DK 1011 02 6 8 DK 1014 71 1 8 DK 1017 32 5 10
DJ 1810 33 3 59 DK 1011 03 3 8 DK 1014 75 5 23 DK 1017 33 1 11
DJ 1810 65 12 59 DK 1011 05 12 8 DK 1014 80 13 15 DK 1017 38 18 16
DJ 1810 65 13 64 DK 1011 06 14 8 DK 1014 82 1 23 DK 1017 48 1 3
DJ 1811 20 2 59 DK 1011 18 17 9 DK 1015 03 14 2 DK 1017 51 2 3
DJ 1910 06 3 38 DK 1011 26 14 19 DK 1015 60 1 18 DK 1017 55 3 3
DJ 1910 09 8 46 DK 1011 35 10 10 DK 1015 63 3 18 DK 1017 62 5 17
DJ 1910 28 7 38 DK 1011 44 10 8 DK 1015 64 4 18 DK 1017 69 1 12
DJ 1910 29 8 38 DK 1011 59 1 10 DK 1015 65 7 18 DK 1017 70 13 28
DJ 1910 30 9 38 DK 1011 60 2 10 DK 1015 66 6 18 DK 1017 74 1 2
DJ 1910 32 11 38 DK 1011 76 6 28 DK 1015 67 6 18 DK 1017 76 1 7
DJ 1910 55 9 46 DK 1011 77 11 11 DK 1015 68 6 18 DK 1110 16 21 27
DJ 2011 06 11 35 DK 1011 80 12 11 DK 1015 69 5 18 DK 1110 21 21 27
DJ 2011 09 12 38 DK 1011 82 4 11 DK 1015 70 18 19 DK 1110 28 5 26
DJ 2011 25 9 64 DK 1011 84 2 45 DK 1015 71 19 19 DK 1110 40 7 22
DJ 2011 40 23 14 DK 1011 85 5 45 DK 1015 72 8 18 DK 1110 72 11 26
DJ 2011 40 15 65 DK 1011 86 4 45 DK 1015 73 12 18 DK 1210 08 9 22
DJ 2011 59 2 56 DK 1011 87 6 45 DK 1015 74 10 18 DK 1210 09 2 22
DJ 2011 76 1 59 DK 1012 25 2 21 DK 1015 77 26 14 DK 1210 15 8 22
DJ 2011 82 3 56 DK 1012 37 10 21 DK 1015 81 1 13 DK 1210 22 10 22
DJ 2011 95 20 47 DK 1012 41 13 6 DK 1015 92 8 5 DK 1210 38 1 22
DJ 2012 02 12 26 DK 1012 45 21 9 DK 1015 96 15 28 DK 1210 39 11 22
DJ 2012 06 3 60 DK 1012 51 6 15 DK 1016 05 2 28 DK 1210 41 3 20
DJ 2012 07 4 60 DK 1012 52 11 15 DK 1016 07 1 1 DK 1210 42 4 20
DJ 2012 08 1 60 DK 1012 53 9 11 DK 1016 10 7 23 DK 1210 43 5 20
DJ 2012 09 2 60 DK 1012 79 16 21 DK 1016 13 1 12 DK 1210 44 6 20
DJ 2012 30 16 59 DK 1012 84 18 27 DK 1016 14 2 4 DK 1210 45 7 20
DJ 2210 03 17 62 DK 101248 7 6 DK 1016 25 6 5 DK 1210 47 13 20
DJ 2210 04 18 62 DK 1013 26 6 3 DK 1016 30 6 21 DK 1210 48 14 20
DJ 2210 12 1 66 DK 1013 27 7 3 DK 1016 31 7 21 DK 1210 51 18 20
DJ 2210 13 1 66 DK 1013 28 4 5 DK 1016 32 7 8 DK 1210 82 6 2
DK 1510 64 4 44 DK 1013 30 5 4 DK 1016 33 18 9 DK 1410 01 4 54
DK 1010 03 3 2 DK 1013 40 3 21 DK 1016 34 1 21 DK 1410 14 1 54
DK 1010 63 1 5 DK 1013 52 22 9 DK 1016 35 13 21 DK 1410 15 11 51
78 3 79
Brand ID: 001MC618
PART INDEX

DK 1510 08 14 37 DK 1510 82 17 41 DK 1611 88 11 21 DK 1810 32 3 46

DK 1510 09 7 40 DK 1510 85 15 42 DK 1611 89 12 21 DK 1810 34 27 47
DK 1510 12 16 41 DK 1510 88 8 44 DK 1612 08 7 59 DK 1810 36 21 47
DK 1510 13 12 40 DK 1510 89 9 44 DK 1612 10 12 51 DK 1810 37 15 48
DK 1510 15 13 40 DK 1510 90 10 44 DK 1612 10 21 62 DK 1810 39 4 46
DK 1510 17 17 41 DK 151078 3 43 DK 1612 17 5 67 DK 1810 48 15 48
DK 1510 22 5 40 DK 1610 69 3 59 DK 1612 18 6 67 DK 1810 50 6 30
DK 1510 23 6 42 DK 1610 70 6 61 DK 1612 22 16 29 DK 1810 51 10 30
DK 1510 24 1 40 Dk 1610 71 7 61 DK 1612 23 17 29 DK 1810 56 3 48
DK 1510 26 5 36 DK 1610 72 8 61 DK 1612 50 1 58 DK 1810 57 4 48
DK 1510 27 7 37 DK 1610 73 10 61 DK 1612 55 13 51 DK 1810 63 1 46
DK 1510 28 3 37 DK 1610 77 15 61 DK 1612 57 13 51 DK 1810 70 8 48
DK 1510 31 1 43 DK 1610 81 4 21 DK 1612 59 18 21 DK 1810 71 14 48
DK 1510 32 2 42 DK 1610 81 7 56 DK 1612 60 18 21 DK 1810 72 1 48
DK 1510 33 3 42 DK 1610 81 3 61 DK 1612 63 18 21 DK 1810 73 10 48
DK 1510 34 4 42 DK 1610 82 4 61 DK 1612 64 18 21 DK 1810 74 14 51
DK 1510 36 21 41 DK 1610 85 6 34 DK 1613 08 2 33 DK 1810 75 3 30
DK 1510 38 12 42 DK 1610 86 3 34 DK 1613 09 1 33 DK 1810 76 4 30
DK 1510 39 2 36 DK 1610 96 1 29 DK 1613 17 1 61 DK 1810 81 4 46
DK 1510 40 4 36 DK 1610 98 1 34 DK 1613 23 6 56 DK 1810 82 22 47
DK 1510 41 3 44 DK 1611 22 1 35 DK 1613 24 5 56 DK 1810 85 3 46
DK 1510 42 5 43 DK 1611 23 8 51 DK 1710 03 9 31 DK 1810 86 23 47
DK 1510 45 8 42 DK 1611 24 9 51 DK 1710 06 6 31 DK 1910 12 1 45
DK 1510 50 3 36 DK 1611 25 24 62 DK 1710 11 4 31 DK 1910 13 7 45
DK 1510 54 1 39 DK 1611 26 5 61 DK 1810 06 6 48 DK 1910 14 7 64
DK 1510 57 2 38 DK 1611 37 1 33 DK 1810 07 5 48 DK 1910 35 1 56
DK 1510 59 1 42 DK 1611 38 2 33 DK 1810 08 24 49 DK 2010 03 1 63
DK 1510 59 1 44 DK 1611 47 5 67 DK 1810 09 28 49 DK 2010 14 25 47
DK 1510 63 9 42 DK 1611 48 6 67 DK 1810 10 7 48 DK 2010 15 18 47
DK 1510 65 5 44 DK 1611 52 23 62 DK 1810 11 9 48 DK 2010 37 1 64
DK 1510 66 7 44 DK 1611 53 3 63 DK 1810 12 29 49 DK 2010 38 2 64
DK 1510 67 6 44 DK 1611 59 5 29 DK 1810 13 26 49 DK 2010 43 15 59
DK 1510 68 2 44 DK 1611 60 6 29 DK 1810 17 25 49 DK 2010 44 9 59
DK 1510 69 10 42 DK 1611 61 12 29 DK 1810 18 16 49 DK 2010 56 1 59
DK 1510 70 12 44 DK 1611 64 15 63 DK 1810 19 2 48 DK 2010 65 9 54
DK 1510 71 11 44 DK 1611 76 14 61 DK 1810 22 11 48 DK 2010 76 2 46
DK 1510 72 14 38 DK 1611 76 3 67 DK 1810 23 12 48 DK 2010 78 12 64
DK 1510 76 6 43 DK 1611 85 1 55 DK 1810 24 22 49 DK 2010 83 20 47
DK 1510 77 7 43 DK 1611 86 14 21 DK 1810 25 23 49 DK 2010 98 15 37
DK 1510 81 17 41 DK 1611 87 15 21 DK 1810 30 1 46 DK 2010 98 3 57
80 3 81
Brand ID: 001MC618
PART INDEX

DK 2011 14 1 64 DL 1910 14 10 46 JC 1410 34 5 54 JC 7202 5C 3 52

DK 2011 15 2 64 DP 1611 44 12 63 JC 1410 39 16 51 JD 4018 06 18 65
DK 2011 17 16 59 DP 1611 45 9 63 JC 1410 40 16 51 JE 5412 12 9 17
DK 2011 38 5 64 DS 1010 71 20 16 JC 1410 49 15 51 JM 1710 03 11 31
DK 2011 39 12 26 DS 1010 84 7 1 JC 1410 53 15 51 JM 1710 04 12 31
DK 2011 40 6 46 DS 1010 96 5 1 JC 1510 13 1 36 JN 1814 06 22 62
DK 2011 41 7 46 DS 1011 54 5 6 JC 1510 16 11 40 JW 4010 11 7 63
DK 2110 01 1 24 DS 1011 66 4 1 JC 1510 20 11 37 KE BA37 15 28 14
DK 2110 04 4 24 DS 1012 15 8 15 JC 1610 17 6 35 LA C000 20 29 47
DK 2110 08 5 24 DS 1012 76 6 4 JC 1610 49 1 30 LA D000 77 9 56
DK 2210 01 19 62 DS 1013 33 3 3 JC 1610 50 1 30 Not Serviceable 14 44
DK 2210 15 26 47 DS 1013 53 9 15 JC 1810 23 18 49 PD 3510 01 1 26
DK 2210 15 18 62 DS 1013 53 21 27 JC 1810 24 20 49
DK 2210 22 25 47 DS 1013 66 8 3 JC 1810 25 13 63
DK 2210 23 26 47 DS 1510 73 15 40 JC 1810 29 27 47
DK 2210 24 2 66 DS 1510 74 14 40 JC 1910 04 2 57
DK 7103 2V 1 50 DS 1611 25 7 34 JC 1910 14 1 56
DK 7103 4K 1 50 DS 1612 24 2 58 JC 1910 18 1 56
DK 7103 4L 1 50 DS 1810 26 13 63 JC 1910 19 1 57
DK 7103 4M 1 50 DS 2110 05 2 24 JC 2010 09 15 59
DK 7103 5C 1 50 DV 1010 42 2 17 JC 2010 16 17 65
DK 7105 2V 1 52 DV 1010 48 23 9 JC 2010 17 6 46
DK 7105 4K 1 52 DX 1610 67 6 32 JC 2010 18 7 46
DK 7105 4L 1 52 GH 2010 12 5 60 JC 2010 27 14 65
DK 7105 4M 1 52 JB 4022 02 17 21 JC 2010 37 5 64
DK 7105 5C 1 52 JC 1010 29 2 12 JC 2010 40 17 65
DK 7304 2V 5 50 JC 1010 34 12 4 JC 2010 45 18 47
DK 7304 4K 5 50 JC 1010 85 4 4 JC 2010 46 4 57
DK 7304 4L 5 50 JC 1010 86 3 4 JC 2010 50 12 37
DK 7304 4M 51 JC 1011 12 3 28 JC 7201 2V 2 52
DK 7401 2V 7 51 JC 1011 15 8 28 JC 7201 4K 2 52
DK 7401 4K 7 51 JC 1110 07 20 27 JC 7201 4L 2 52
DK 7401 4L 7 51 JC 1110 10 21 27 JC 7201 4M 2 52
DK 7401 4M 7 51 JC 1110 22 7 26 JC 7201 5C 2 52
DK 7401 5C 7 51 JC 1110 23 8 26 JC 7202 2V 3 52
DK 9026 27 6 23 JC 1110 28 2 26 JC 7202 4K 3 52
DK1510 83 13 42 JC 1200 17 12 2 JC 7202 4L 3 52
DL 1810 10 6 59 JC 1200 24 1 20 JC 7202 4M 3 52
80 3 81

Pulsar 220

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All information contained in this manual is based on the

latest product information at the time of publication. Bajaj

DOC. NO.: 71111247 REV. 01 MAR. 13

Description Page Description Page

6 Crankshaft 6 41 Front Fork 48&49

31 Tyre/ Tube /Rim 36

6 39 2647 15 Domed Cap Nut 4

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

11 DH 1013 92 Cam chain Tensioner pivot Bolt 1

6 39 1931 20 Bearing Ball 1 6 DJ 1011 33 Spring torsion Balancer Idler 2

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

6 DK 1011 02 Gear 3rd Drive 1 21 DK 1012 45 Collar Sprocket 1

11 DH 1013 36 Washer Thrust 2

6 39 2639 04 Bolt Socket 1 6 39 2453 04 Flanged Bolt 1

11 DK 1011 77 Lever change arm 1

6 DK 1012 51 Parallel pin 1

6 DH 1012 93 Plate Damper Cover LH Rear 1

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

11 39 2617 20 Bearing Clutch lifter thrust 1

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

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

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

11 DK 1210 39 Connecting Tube 1

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

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

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

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

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

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

11 DJ 2011 06 Magnet assembly 1

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

6 DE 1510 08 Seal oil 1

11 JC 1510 20 Case meter assly. 1 Applicable to all versions of

6 DE 1910 33 Clamp Holder RH 1 6 DE 1510 37 Disc Pad Set 1

11 DJ 1910 32 Cylinder Master 1

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

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

11 DE 1910 10 Copper Washer 1

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

11 DK 1510 71 Caliper Major Kit 1 (Includes Sr. No. 2.3.4.5)

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

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

11 DK 1810 22 Bolt fork 2

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

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

6 DK 1613 23 Bracket Speedometer Support 1 (For F) D-48-17.08.2012

6 DL 1810 10 Well Nut 4

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

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

11 39 1778 02 Self tapping screw for speedo 1

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

6 31 2010 79 Rear Brake Switch 1 Alt. DS 2010 29

11 39 1551 04 Flange Bolt 1

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

Sr. Consisting of Following Parts Consisting of Following Parts

Consisting of Following Parts Amendment Sheet (Parts Added)

24 36DK0060 Float chamber body kit O ring 1

25 36DK0061 Tap Cap assly. Kit Diaphragm cover 1

26 36DK0062 Solenoid assly. Kit JC120026 Solenoid assly. 1

27 DK151088 Piston Kit Piston 1