PULSAR DTSi
PLATE NO. 1 : COVER CYLINDER HEAD
6
8
9 2
4 7
5 3
2
11 3
10 10
1 11
Fig. No.
Part No.
Description
1 2 3 4 5
DH 1015 29 DJ 1011 57 DS 1010 26 39 2391 21 DS 1011 66 DS 1010 96
Head Cylinder with Cover Head Cylinder with Cover Cover Tappet ‘O’ Ring (Cover Tappet) Silent Bush (V) Camshaft Cap
6 7 8 9 10
39 2647 15 DS 1010 84 39 2532 04 39 1075 04 DH 1012 72
11
DG 1014 98
150 ES
150 KS
-1 2 2 1 1
1 -2 2 1 1
1 -2 2 1 1
Dommed Cap Nut Copper Washer Hex. Bolt with Flange Hex. Bolt / Flange Plug
4 4 2 4 2
4 4 2 4 2
4 4 2 4 2
Gasket
2
2
2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
1
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 2 : CYLINDER HEAD
10 1
11 12 12
2 2 6
9
5
4
8 3
7 8
Fig. No.
Part No.
1
DH 1015 29 DJ 1011 57 39 1660 05 DJ 1010 12 DH 1010 33 DH 1015 08 DJ 1011 36 DH 1014 07
Head Cylinder with Cover Head Cylinder with Cover Stud (Exhaust) Gasket Cylinder Head Gasket Cylinder Head Damper Cylinder Head Intake Pipe Intake Pipe
8 9
39 2539 21 39 1283 21 DJ 1210 22 DH 1211 06 DH 1210 38 39 1674 04
10 11 12
DH 1110 12 39 2608 01 39 1283 21
2 3 4 5
6 7
Description
150 ES
150 KS
-1 2 1 -5 1 --
1 -2 -1 5 -1
1 -2 -1 5 -1
‘O’ Ring (Intake Pipe) ‘O’ Ring (Intake Pipe) Carburettor Insulator Carburettor Insulator Clamp for Insulator Hex. Bolt / Flange
1 -1 -2 2
-1 -1 2 2
-1 -1 2 2
Sleeve - Spark Plug Grub Screw ‘O’ Ring
1 1 2
1 1 2
1 1 2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
2
Remark
For Sleeve Spark Plug
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 3 : VALVE
15
4
14
6 5
2
7 15 8
1 3
9
10
11
12/13
Fig. No.
Part No.
Description
180
150 ES
150 KS
1 2 3 4 5
DH 1014 69 DS 1010 32 DS 1010 30 39 1024 01 39 0973 15
Rocker Arm Shaft - Intake Rocker Arm Shaft - Exhaust Rocker Arm Screw Nut
1 1 2 2 2
1 1 2 2 2
1 1 2 2 2
6 7 8 9 10
DG 1010 29 DS 1010 83 DH 1010 27 DH 1010 28 39 2017 19
Cotter valve Retainer valve spring Spring valve inner Spring valve outer Seal valve stem
4 2 2 2 2
4 2 2 2 2
4 2 2 2 2
11 12
DH 1010 26 DJ 1011 24 DS 1010 23 DJ 1011 25 DS 1010 24 DH 1012 95 39 2440 11
Seat valve spring Valve Intake Valve Intake Valve Exhaust Valve Exhaust Wave washer Plain washer
2 1 -1 -2 4
2 -1 -1 2 4
2 -1 -1 2 4
13 14 15
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
3
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 4 : CAMSHAFT / TENSIONER
6 9
8
4 3
7
15
16
2
5
1
13 10 11 12
Fig. No.
Part No.
1 2 3 4 5
39 2040 21 DH 1014 10 39 2542 20 39 2617 20 DH 1010 17
6 7 8 9 10
Description
180
150 ES
150 KS
Ring’O’ Camshaft assly. Bearing cam RH side Bearing cam LH side Guide chain (Tight)
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
DJ 1010 77 DH 1014 12 DH 1010 48 39 2198 04 DH 1010 50
Sprocket cam Driver Collar cam Sprocket Special camshaft washer Hex. Soc. Head cap Bolt Cam Chain
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
DH 1010 10 DH 1010 11 52 DH01 78 39 1674 04 DJ 1011 37
Guide Chain (slack) Cam chain Tensioner pivot Bolt Tensioner Assly Hex Bolt / Flange Decomp Assly.
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
16
DH 1014 11
Camshaft
1
1
1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
4
14
Remark
6302 - RS1/C3 6002 - C3
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 5 : CYLINDER AND PISTON
7 2
3
2 8 1 4
5 6
5
Fig. No.
Part No.
1
DJ 1010 04 DH 1010 16 39 2181 06 DJ 1011 58 DH 1015 30 DJ 1011 06 AA 1012 17 39 2132 17
Gasket Cylinder Gasket Cylinder Pin dowel Piston Assly. Std. Piston Assly. Std. Ring Set Piston Ring Set Piston Ring Snap
DJ 1010 17 DH 1012 70 DJ 1011 55 DH 1015 27 DH 1014 14
Pin Piston Pin Piston Cylinder Block / Piston Assly Cylinder Block / Piston Assly Damper - Cylinder Block
2 3 4 5 6 7 8
Description
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
5
150 ES
150 KS
1 -4 1 -1 -2
-1 4 -1 -1 2
-1 4 -1 -1 2
1 -1 -6
-1 -1 6
-1 -1 6
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 6 : CRANK SHAFT
14 4
13 5
9 1
16
12
15 10 11 7 2
3
8
6
Fig. No.
Part No.
1 2 3 4 5
DJ 1010 18 DH 1010 57 DH 1011 95 39 2200 11 DJ 1011 12 DH 1010 62
6 7 8 9 10
Description
180
150 ES
150 KS
Crankshaft assly. comp. Crankshaft assly. comp. Nut Washer Set primary driver & driven Sprocket cam drive
1 -1 1 1 1
-1 1 1 1 1
-1 1 1 1 1
DH 1010 64 DH 1010 65 DH 1012 34 39 2267 01 DH 1010 66
Body centrifugal oil filter Cover centrifugal oil filter Gasket centrifugal oil filter Oval Screw Joint Oil Delivery - B
1 1 1 3 1
1 1 1 3 1
1 1 1 3 1
11 12 13 14 15
DH 1010 67 39 2199 08 31 1011 73 39 2203 07 39 2183 04
Spring Oil Delivery- B Pin Oil delivery joint - B Key woodruff Parallel pin Bolt
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16
39 2165 11
Plain washer
1
1
1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
6
Remark
7mm. (Height)
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 7 : BALANCER & BALANCER IDLER GEAR
1
10
3 2
8
11
5 9
8
7 6
6 7 5
9 4
Fig. No.
Part No.
1
DJ 1010 22 DH 1010 69 DH 1010 72 39 1672 04 DJ 1011 34 DH 1014 32 39 2152 20
Body Balancer Assly. Body Balancer Assly. Bearing stopper Bolt Assly. Balancer Idler Gear comp. Assly. Balancer Idler Gear comp. Needle roller bearing
DJ 1011 33 DH 1014 24 39 2557 17 39 1686 06 39 1620 11 52 DH01 77 39 1674 04
Spring torsion Balancer Idler Spring torsion Balancer Idler Circlip ext. Dowel Pin Thrust washer Balancer Idler Holder Bolt
2 3 4 5 6 7 8 9 10 11
Description
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
7
150 ES
150 KS
Remark
1 -1 1 1 -2
-1 1 1 -1 2
-1 1 1 -1 2
2 -2 2 2 1 3
-2 2 2 2 1 3
-2 2 2 2 1 Alt. DH 1013 59 3
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 8 : TRANSMISSION
1
5 4
2 14
3
4
12 5
4
13
15
5
6 11 10
7
8
16
9
17 21 19
18
11 20 5 23
22
180
150 ES
150 KS
24
Fig. No.
Part No.
Description
1 2 3 4 5
DH 1015 19 39 2158 11 DH 1010 78 DH 1010 79 DH 1012 35
Shaft Input Transmission Washer thrust Gear 4th Drive Washer Spline External Circlip
1 1 1 3 4
1 1 1 3 4
1 1 1 3 4
6 7 8 9 10
DH 1010 80 DH 1010 82 DH 1010 84 39 2160 11 DH 1013 31
Gear 3rd Drive Gear 5th drive Gear 2nd drive Thrust washer Shaft output Transmission
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
DH 1013 36 DH 1011 08 39 2159 11 DH 1011 10 DH 1011 11
Washer Thrust Gear 3rd Driven Thrust Washer Gear 4th Driven Bush 1st driven
2 1 1 1 1
2 1 1 1 1
2 1 1 1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
8
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 8 : TRANSMISSION
1
5 4
16
2 14
3
4
12 5
15
5
6 11 10
7
8
4
13
9
17 21 19
18
11 20 5 23
22
150 ES
150 KS
24
Fig. No.
Part No.
Description
16 17 18 19 20
DJ 1011 10 DH 1011 13 DH 1013 19 DH 1013 33 DH 1013 34
Gear 1st driven Gear 5th Driven Bush 2nd driven Gear 2nd Driven Collar Sprocket
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
21 22 23 24
30 1010 61 DH 1011 17 DJ 1010 63 39 1062 04
‘O’ Ring Sprocket Coller Sprocket Drive Plate Drive Sproket Bolt Drive Sprocket
1 1 1 2
1 1 1 2
1 1 1 2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
9
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 9 : CHANGE DRUM / SHIFT FORK
1
8
7
5
4 6
9
2
2
3
Fig. No.
Part No.
1 2 3 4 5
DH 1011 30 DH 1011 32 DH 1011 46 DH 1014 93 DJ 1011 47 DH 1014 91
Fork Gear Shift Input Fork Gear Shift output Shaft Gear Shift Fork Shaft Gear Shift Fork Drum comp. Gear Shift Drum comp. Gear Shift
6 7 8
39 2437 04 39 2606 07 DJ 1011 48 DH 1014 95 DH 1014 96
Bolt Socket Parellel pin Guide Gear Shifter Guide Gear Shifter Spacer
9
Description
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
10
150 ES
150 KS
1 2 1 1 1 --
1 2 1 1 -1
1 2 1 1 -1
1 1 1 -1
1 1 -1 1
1 1 -1 1
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 10 : GEAR CHANGE MECHANISM
10
9
2
11
7
1 3 8
4
5
6
6
Fig. No.
Part No.
Description
1 2 3 4 5
DH 1011 34 DH 1011 43 DH 1011 44 DJ 1011 49 DH 1011 65
Lever comp. Gear Shifter Spring Slider arm reset Spring Gear Shifter return Lever comp. change Lever comp. change
6 7 8 9 10
31 1011 08 39 2453 04 DH 1010 13 DH 1015 03 DH 1015 02
11
DH 1012 25
150 ES
150 KS
1 1 1 1 --
1 1 1 -1
1 1 1 -1
Damper Flanged Bolt Bolt Gear Shift drum Stopper Stopper gear shifter drum Spring gear shifter drum stopper
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Bolt shift change
1
1
1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
11
Remark
Alt. to DJ 1011 56
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 11 : ENGINE ASSLY & CRANKCASE RH
3 3
8 2
4
8 6 7
9
5 10 11
Fig. No.
Part No.
Description
150 ES
150 KS
1
2 3 4 5
DJ 1011 39 DH 1014 74 DH 1014 73 DH 1014 86 39 2531 05 39 2561 20 DH 1010 06
Engine Assly.(180cc) Engine Assly.(150cc, ES) Engine Assly.(150cc, KS) Crankcase RH Stud Bearing Ball (For Crankshaft) Gasket Crankcase
1 --1 2 1 1
-1 -1 2 1 1
--1 1 2 1 1
6 7 8 9 10
39 2583 20 39 2602 20 39 2180 06 39 2601 20 DH 1014 87
Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Dowel Pin Ball Bearing(For Drum Comp.Gear Shift) Plate Stopper
1 1 2 1 1
1 1 2 1 1
1 1 2 1 1
11
39 1062 04
Bolt Flanged
1
1
1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
12
Remark
N.I. N.I. N.I.
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 12 : CRANKCASE LH 14
2 12
13
2 24
21
19
20 9
27 23
7
5 4 6
8 10
16
26 15 1
18 3
17 11
25 22 Fig. No.
Part No.
Description
1 2 3 4 5
DH 1013 35 39 2531 05 DH 1012 26 DH 1012 99 39 2188 19 39 2462 21
Crankcase LH Stud Guide starter Assly Guide starter Assly Oil Seal O’ Ring
6 7 8 9 10
39 0752 01 39 2603 20 39 2583 20 39 2185 20 39 2189 19
11 12 13 14 15
39 2190 19 DH 1012 03 DH 1012 46 28 1011 74 DH 1012 72
150 ES
150 KS
1 2 1 -1 1
1 2 1 -1 1
1 2 -1 1 1
‘C’ Sunk Head Screw Bearing Ball (For Input shaft) Bearing Ball (For Output shaft) Balancer LH Bearing Oil Seal (For Output shaft)
3 1 1 1 1
3 1 1 1 1
3 1 1 1 1
Oil Seal (For Shift lever) Breather pipe Rubber tube Spring Clip Plug (Drain Bolt)
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
13
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 12 : CRANKCASE LH 14
2 12
13
2 24
21
19
20 9
27 23
7
5 4 6
8 10
16
26 15 1
18 3
17 11
25 22 Fig. No.
Part No.
16 17 18 19 20
DG 1014 98 31 2010 81 DH 1012 64 DH 1012 69 39 1414 02
21 22 23 24 25 26 27
Description
180
150 ES
150 KS
Gasket (For Drain Bolt) Switch comp.(Neutral) Gasket Neutral Switch Baffle Self tapping Screw
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
39 1845 04 39 1677 04 39 2305 04 DH 1012 78 DH 1011 69
Flanged Bolt Bolt Bolt Plug Starter Motor Bush starter gear inner
1 8 1 -1
1 8 1 -1
1 8 1 1 --
DJ 2010 21 39 2448 11
Cable assly. (Battery to Earth) Plain Washer
1 1
1 1
-1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
14
Remark
For W/O self start only
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 13 : COVER RH
12
17 18
4
8
6
7 19 9 20 2
3 11
13 5 1
10
21 16 15 14
Fig. No.
Part No.
1 2 3 4 5
DH 1011 49 DH 1011 97 30 1011 42 39 1041 19 DH 1011 41
6 7 8 9 10
Description
180
150 ES
150 KS
Cover comp RH Grommet Breather Seal kick Shaft Seal clutch lever Rack
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
DH 1011 42 39 2202 07 DH 1011 51 DH 1011 52 39 1074 04
Shaft clutch release Parallel pin Gauge Oil level ‘O’ ring Oil level Gauge Bolt
1 1 1 1 10
1 1 1 1 10
1 1 1 1 10
11 12 13 14 15
39 0999 06 DH 1010 18 DH 1011 54 DH 1210 15 DH 1210 11
Pin Dowel Bracket Clutch Cable Gasket cover RH Plunger Oil Plate Plunger Oil
2 1 1 1 1
2 1 1 1 1
2 1 1 1 1
16 17 18 19 20
DH 1210 12 DH 1012 81 39 2443 11 DH 1013 65 39 2208 04
Spring Joint ‘A’ Spring torsion clutch lever Washer Set damper A to D & Plate A to D Flanged Bolt
1 1 1 1 8
1 1 1 1 8
1 1 1 1 8
21
DH 1013 22
‘bajaj’ Decal
1
1
1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
15
Remark
Fitted on Cover comp.RH : FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 14 : COVER MAGNETO
11
2 3
4
5
6
15
8
10
12
1
7
9 14
Fig. No.
Part No.
1 2 3 4 5
DH 1011 55 DH 1011 58 39 2197 21 DH 1011 59 39 1074 04
6 7 8 9 10
11 12 13 14 15
13
Description
180
150 ES
150 KS
Cover Magneto Cap Timing Hole ‘O’ Ring Gasket Magneto cover Bolt
1 1 1 1 7
1 1 1 1 7
1 1 1 1 7
39 0999 06 DH 1011 57 39 1283 21 DH 1011 56 DH 1013 66
Pin Dowel Cap Crank Center ‘O’ Ring Cover LH RR Set Damper /plate for Cover LH & Cover LH RR
2 1 1 1 1
2 1 1 1 1
2 1 1 1 1
39 2208 04 39 2208 04 DJ 1610 12 DH 1612 09 DH 1013 23
Flanged Bolt Flanged Bolt Gear shift label Gear shift label ‘bajaj’ Decal
4 2 1 -1
4 2 -1 1
4 2 -1 1 Fitted on Cover magneto
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
16
Remark
Alt to 39 2452 21
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 15 : CLUTCH 6 7 2 6
4
7 6 10 7 12 8 9
1 5 14
16 6 17
13 11
3 15
Fig. No.
Part No.
1 2 3
5
DH 1012 75 DJ 1011 12 DJ 1011 50 DH 1015 01 DJ 1011 22 DH 1014 34 DH 1013 44
Special Nut Set primary driver & driven Clutch Plate Assly Clutch Plate Assly Clutch Center Clutch Center Plate Clutch pressure
6 7 8 9 10
DH 1014 99 DH 1010 98 DH 1014 83 39 1674 04 39 1553 04
11 12
39 2617 20 DH 1014 84
4
Description
150 ES
150 KS
1 1 1 -1 -1
1 1 -1 -1 1
1 1 -1 -1 1
Disc Clutch friction Adler (B type) Plate Clutch Spring Clutch Capacity Bolt Bolt
6 5 6 1 6
5 4 6 1 6
5 4 6 1 6
Bearing Clutch lifter thrust Holder Clutch
1 1
1 1
1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
17
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 15 : CLUTCH 6 7 2 6
4
7 6 10 7 12 8 9
1 5 14
16 6 17
13 11
3 15
Fig. No.
Part No.
13 14 15
DH 1014 85 DH 1013 74 DH 1015 20
16 17
DH 1011 80 39 2200 11
Description
180
150 ES
150 KS
Rod Clutch lifter Guide Plate Clutch Pressure Nut Primary drive lock
1 1 1
1 1 1
1 1 1
Lever Assly. Clutch Washer Primary Drive Gear
1 1
1 1
1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
18
Remark
LH Thread
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 16 : KICK STARTER MECHANISM
6 5
10
7
2
11 8
9
12
4
13
16
3
15 14
1 Fig. No.
Part No.
Description
1 2 3 4 5
DH 1011 28 DD 1010 97 DH 1011 85 DH 1010 68 DH 1011 15
Lever Kick Starter complete Damper Spring Kick Starter Arm joint Ball steel Gear Kick Idler
6 7 8 9 10
DH 1011 19 DH 1013 67 DH 1013 68 39 0993 11 39 2344 11
11 12 13 14 15 16
150 ES
150 KS
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Spindle Kick Starter Assly Set Pinion & Ratchet Kick Starter Set Washer,Circlip & Spring Washer Thrust Plain Washer
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
DH 1011 27 39 1672 04 DH 1011 25 DH 1013 21 DH 1011 31
Guide Kick Bolt Flanged Spring Kick Starter Return Bolt flange Base kick lever
1 2 1 1 1
1 2 1 1 1
1 2 1 1 1
DH 1013 20
Hex. bolt with flange
1
1
1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
19
Remark
For Kick Starter Ratchet
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 17 : CARBURETTOR
14
4 9
12
10
11
8
3
2
16
13
7 15
5 1
17
6
19
6 18
Fig. No.
Part No.
Description
180
150 ES
150 KS
1
DJ 1210 20 DH 1210 97 DJ 1210 12 DH 1210 45 DJ 1210 13 DH 1210 46 DJ 1210 25 DH 1211 12 DH 1210 57
Carburettor Assly. BS 29 with TPS Carburettor Assly. BS 26 with TPS Piston valve assly. Piston valve assly. Spring (CO) Spring (CO) Jet needle(JN) Jet needle(JN) “O” ring
1 -1 -1 -1 -1
-1 -1 -1 -1 1
-1 -1 -1 -1 1
DH 1210 58 DH 1210 59 DJ 1210 23 DH 1211 10 DJ 1210 18 DH 1210 61 DH 1211 11 DJ 1210 24
Screw Float assly. Main jet Main jet Jet holder Jet holder Pilot Jet (PJ) Pilot Jet (PJ)
2 1 1 -1 --1
2 1 -1 -1 1 --
2 1 -1 -1 1 --
2 3 4 5 6 7 8 9 10
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
20
Remark
Make : Ucal Mikuni
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 17 : CARBURETTOR
14
4 9
12
10
11
8
3
2
16
13
7 15
5 17 1 6
19
6 18
Fig. No.
Part No.
Description
11 12 13 14 15
DH 1211 04 DH 1210 93 DH 1210 96 DH 1210 95 DH 1210 48
Spring (CO) Needle Assly. Set Adjuster(PS) Set Plunger assly. Diaphragm
16 17 18 19
DH 1210 78 DH 1211 01 DH 1211 02 39 1780 01
Adjust Screw Magnet Assly. Reed Switch Assly. Pan Head Screw
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
21
150 ES
150 KS
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 2
1 1 1 2
1 1 1 2
Remark
TPS Assly. Parts
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 18 : AIR CLEANER COMP
9 11 12
10 5
1 8
6 2 7 3 4 Fig. No.
Part No.
1 2 3 4 5
DH 1211 05 DH 1210 20 01 1106 09 39 1698 01 DJ 1210 21 DH 1210 98
6 7 8 9 10 11 12
Description
180
150 ES
150 KS
Air Cleaner comp Bracket Lock Plain Washer Screw Pan cross Connecting Tube Connecting Tube
1 1 1 1 1 --
1 1 1 1 -1
1 1 1 1 -1
DH 1210 37 DH 1210 22 39 1773 04 31 1210 43 39 1902 04
Cartridge Assly Element Air Filter Bolt Flanged Collar Flanged Bolt
1 1 4 3 3
1 1 4 3 3
1 1 4 3 3
39 0711 11 AA 1210 45
Plain Washer Clamp
3 1
3 1
3 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
22
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 19 : SILENCER ASSLY.
6 5
4
4 8
7 2 2 3
15
15 13
14
12
11
1
10 8 9
Fig. No.
Part No.
Description
1 2 3 4 5
DH 1014 36 DH 1013 01 DH 1014 68 DH 1013 02 DJ 1010 64
Silencer Assly Seal Shield Muffler Shield Muffler Truss Screw Gasket Exhaust
6 7 8 9 10
39 1970 15 39 1850 04 39 2425 11 DD 1610 71 DH 1611 55
11 12 13 14 15
DH 1611 57 DG 1611 24 DH 1014 81 DH 1015 21 DH 1015 25
150 ES
150 KS
1 2 1 2 1
1 2 1 2 1
1 2 1 2 1
Flanged Nut Flanged Bolt Washer U Nut Damper silencer
2 1 2 1 1
2 1 2 1 1
2 1 2 1 1
Tube silencer mounting Damper (Main Stand) Grommet shield Wire Shield Assly. Dommed Cap Nut
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
23
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 20 : SEAT ASSLY. / SEAT LOCK
1 6
2 5
4 3
Fig. No.
Part No.
1 2 3 4 5
DJ 2110 01 31 2110 04 DH 1610 46 DH 1612 33 39 1902 04
6
DH 2110 07
Description
180
150 ES
150 KS
Seat Assly comp Damper Lock Assly seat Reinforcement seat lock Flanged bolt
1 6 1 1 2
1 6 1 1 2
1 6 1 1 2
Damper
3
3
3
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
24
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 21 : OIL PUMP
4
2 1
6
3
5
Fig. No.
Part No.
Description
1 2 3 4 5
DH 1210 01 39 1674 04 DH 1210 10 39 1686 06 DH 1210 35
Oil Pump Assly Hex. Bolt with flange Mesh filter Oil pump Hollow dowel pin Clip Mesh Oil filter
6
39 2194 21
‘O’ Ring
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
25
150 ES
150 KS
1 3 1 1 1
1 3 1 1 1
1 3 1 1 1
1
1
1
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 22 : MAGNETO / C.D.I. / H.T.COIL
11
12 24
22 21
7
16
15 23 14
8 15
6 13
19
5 3 9 17 4
18
7 10
20 Fig. No.
Part No.
1
DJ 1110 07 DH 1110 24 DJ 1110 04 DH 1110 05 39 1674 04 39 0761 01 DH 1011 99
1
2 180
150 ES
150 KS
Magneto Assly. Magneto Assly. Stator Assly. comp Stator Assly. comp Hex. Bolt with Flange Pan Head Screw Stopper plate (wiring harness)
1 -1 -2 2 1
1 -1 -2 2 1
-1 -1 2 2 1
9 10
39 0746 01 DG 1110 08 DJ 1110 08 DH 1110 19 DD 1110 11 DJ 2010 16
Screw Pan head Spark plug C.D.I Assly C.D.I. Assly. Grommet Spark Plug AC/DC Regulator
1 2 1 -1 1
1 2 -1 1 1
1 2 -1 1 --
11 12 13 14 15
DH 1110 26 DH 1110 27 DD 1110 48 DH 1110 15 DD 1110 12
H.T. Coil LH H.T. Coil RH Cap Spark Plug Cap Spark Plug Grommet H.T. Cable
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
2 3 4 5 6 7 8
Description
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
26
Remark
With Aluminium bracket
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 22 : MAGNETO / C.D.I. / H.T.COIL
11
12 24
22 21
7
16
15 23 14
8 15
6 13
19
5 3 9 17 4
18
7 10
20
1
2
Fig. No.
Part No.
Description
16 17 18 19 20
DH 1110 13 DH 2010 18 DD 2010 24 39 1913 04 39 0897 15
Grommet Spark Plug Regulator Voltage Capacitor Flange Bolt Flange Nut
1 --1 1
1 --1 1
1 1 1 Alt. to 31 2010 82 1 1
21 22 23 24
39 1902 04 DJ 1610 67 39 1680 04 DH 1110 16
Flange Bolt Bracket H.T.Coil Flange Bolt Grommet Sleeve Spark Plug
2 1 2 1
2 1 2 1
2 1 2 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
27
150 ES
150 KS
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 23 : STARTER ASSEMBLY ( FOR SELF START)
13 12 15
4 14
9 1 3
7
11 10 5
8
16
6
17 18
2
Fig. No.
Part No.
1 2 3 4 5
DH 1011 60 DH 1013 70 DH 1011 86 DH 1014 01 DH 1011 70
6 7 8 9 10
Description
180
150 ES
150 KS
Body comp.starter clutch Set roller, bush & spring Plate roller clutch Gear starter clutch Plate starter clutch gear return
1 5 1 1 1
1 5 1 1 1
------
39 1672 04 DH 1011 71 DH 1011 72 DH 1011 88 39 2152 20
Bolt Shaft starter counter Collar starter counter Gear comp.starter counter assly. Needle roller bearing
1 1 1 1 1
1 1 1 1 1
------
11 12 13 14 15
39 2437 04 DH 1110 02 39 1074 04 DH 1013 72 39 2285 01
Bolt socket Motor assly. starter Bolt Cover starter motor Slotted c’sunk screw
3 1 2 1 1
3 1 2 1 1
------
16 17 18
DH 1011 64 DJ 1011 09 DH 1011 63
Spring Bush For Spring Starter Roller
5 5 5
5 5 5
----
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
28
Remark
For starter clutch
Stopper plate For stopper plate
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 24 : ENGINE MOUNTINGS 5
20
12 19 17
5 1 4
5
3
15
15 18
5 2 10
16
15
5
14 8
7 11
9
8
6
Fig. No.
Part No.
Description
1 2 3 4 5
DH 1611 70 DH 1611 89 DH 1611 90 39 2312 04 39 1970 15
Bkt. Assly.eng.mtg.front Bkt. comp.LH eng.mtg.front Bkt. comp.RH eng.mtg.front Bolt Flanged Nut Flanged
6 7 8 9 10
DJ 1611 14 DJ 1611 15 39 2157 04 39 2412 04 39 2413 04
11 12 13 14 15
DJ 1611 20 39 1967 04 39 2414 04 DJ 1611 13 DH 1612 45
13 150 ES
150 KS
1 1 1 4 8
1 1 1 4 8
1 1 1 4 8
Bkt. comp. LH eng.mtg. lower Bkt. comp. RH eng.mtg. lower Bolt Flanged Bolt Flanged Bolt Flanged
1 1 3 1 1
1 1 3 1 1
1 1 3 1 1
Silent Bush LH Bolt Hex.soc.hd.cap bolt Bkt.comp.RH eng.rear ‘U’ Nut
1 1 1 1 3
1 1 1 1 3
1 1 1 1 3
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
29
Remark
Alt. 39 2311 04
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 24 : ENGINE MOUNTINGS 5
20
12 19 17
5 1 4
5
3
15
15 18
5 2 10
16
15
5
14 8
Part No.
16 17 18 19 20
39 2310 04 39 2311 04 39 2457 11 DJ 1610 88 DJ 1610 89
11
9
8
Fig. No.
7
6
Description
Flanged bolt Bolt Washer Bracket LH Engine Hanger Bracket RH Engine Hanger
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
30
13 180
150 ES
150 KS
2 1 1 1 1
2 1 1 1 1
2 1 1 1 1
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 25 : FRAME & FRAME FITTINGS
3 4 5 6 8 7 6
11
9/10 1
2 2
Fig. No.
Part No.
Description
180
150 ES
150 KS
1 2 3 4 5
DJ 1610 47 DH 1611 12 30 1810 11 DH 1810 14 DH 1810 25
Frame Assly. comp. Cup rear Nut Cup - Steering Bearing cone
1 2 1 1 1
1 2 1 1 1
6 7 8 9 10
30 1810 06 DH 1810 26 DH 1810 24 DJ 1611 32 DJ 1611 33
Ball steel Bearing race Upper bearing race Cable hook LH Cable hook RH
46 1 1 1 1
46 1 1 1 1
46 1 1 1 1
11
39 1680 04
Flanged bolt
2
2
2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
31
Remark
1 Incl. Bush, Races & Cup rear 2 1 1 1
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 26 : SWING ARM / REAR SHOCK ABSORBER
2
19
9 2
10 11
8
2
13
4
8
20
2
8 7
4
4
6
1
18
4 8 12
7
3 5 16 1
15
17 17
14 17 16
Fig. No.
Part No.
1 2 3 4 5
DG 1710 38 39 0714 11 DJ 1710 17 DH 1710 14 DJ 1710 07
6 7 8 9 10
Description
17
180
150 ES
150 KS
Bolt Precoated Plain washer Rear Shock Absorber Bush swing arm Swing arm assly.
2 8 2 4 1
2 8 2 4 1
2 8 2 4 1
35 1710 33 DH 1710 13 DH 1710 15 DJ 1710 08 39 0553 02
Grease nipple Collar swing arm Dust seal swing arm Chain slider Screw
2 2 4 1 2
2 2 4 1 2
2 2 4 1 2
11 12 13 14 15
39 0454 11 DH 1710 12 DH 1710 19 DJ 1510 36 DJ 1510 37
Plain washer Shaft swing arm ‘U’ nut swing arm Adjuster chain LH Adjuster chain RH
2 1 1 1 1
2 1 1 1 1
2 1 1 1 1
16 17 18 19 20
DJ 1510 47 39 0292 15 39 0740 11 39 0712 15 39 0737 12
Plate Chain Adjuster Hexagon nut Plain washer(Nylon) Domed Cap Nut Spring Washer
2 4 2 2 2
2 4 2 2 2
2 4 2 2 2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
32
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 27 : RIDER FOOT REST
4
9 8
7
2
6
10
2
5
2
3 2
10 1 4 8 9 6
7
Fig. No.
Part No.
Description
1 2 3 4 5
DJ 1611 30 39 2310 04 DJ 1611 31 DH 1610 53 DH 1611 94
Main step LH assly. comp. Flange bolt Main step RH assly. comp. Rubber main step Kick stopper
6 7 8 9 10
39 0963 15 39 0897 04 DH 1610 56 DH 1611 00 DJ 1610 90
Domed Cap nut Bolt Plate Comp. Lower Mounting Spacer Main Step Damper Footrest
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
33
150 ES
150 KS
1 4 1 2 1
1 4 1 2 1
1 4 1 2 1
2 2 2 2 2
2 2 2 2 2
2 2 2 2 2
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 28 : PILLION FOOT REST / HOLDER
5
4
7
9 2
6
10 8
1
12
13 7
11
6
10
8 9
5
Fig. No.
Part No.
1
DJ 1610 02 DJ 1611 11 DJ 1610 03 DJ 1611 12 DH 1612 27 DJ 1611 28 DH 1612 28 DJ 1611 29 DH 1610 59 DJ 1611 22
3
180
150 ES
150 KS
Holder LH step Holder LH step Holder RH step Holder RH step Pillion step assly. comp. LH Pillion step assly. comp. LH Pillion step assly. comp. RH Pillion step assly. comp. RH Rubber pillion step Rubber pillion step
1 1 1 1 1 1 1 1 2 2
1 1 1 1 1 1 1 1 2 2
1 1 1 1 1 1 1 1 2 2
7 8 9 10
DH 1610 60 DJ 1611 86 DH 1610 61 30 1410 31 39 1040 11 39 0784 08
Plate side pillion step Plate side pillion step Pin pillion step ‘O’ ring Plain washer Split pin
2 2 2 2 2 2
2 2 2 2 2 2
2 2 From Dec.2003 2 2 2 2
11 12 13
39 1069 01 39 0292 15 39 1741 04
Bolt Nut Flanged Bolt
1 1 2
1 1 2
1 1 2
2 3 4 5
6
Description
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
34
Remark
From Dec.2003 From Dec.2003 From Dec.2003 From Dec.2003 From Dec.2003
Stopper bolt Bottom Mtg. LH & RH Holder Step : FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 29 : MUDGUARD FRONT & REAR
17 4 5 1 2 8 7 4 3 11 16
6 9 7
14
10 15
12 15 13
Fig. No.
Part No.
Description
1 2 3 4 5
DJ 1610 19 DJ 1611 06 39 1557 04 DJ 1610 68 DH 1610 69
Clamp brake hose Brace fender Flange bolt Clamp Fender rear front
6 7 8 9 10
39 1672 04 39 0711 11 39 0798 15 DJ 1610 51 39 1680 04
11 12 13 14 15 16 17
150 ES
150 KS
1 1 4 2 1
1 1 4 2 1
1 1 4 2 1
Flange bolt Plain washer Flange nut Fender rear Flange bolt
2 4 2 1 2
2 4 2 1 2
2 4 2 1 2
DJ 1610 91 DH 1611 83 39 2420 01 39 0326 15 39 0242 11
Grommet Front Fender Mud flap rear Screw Nylock nut Plain washer
4 1 3 3 6
4 1 3 3 6
4 1 3 3 6
DJ 1610 92 DJ 1610 69
Sleeve Front Fender Nail for Cable Guide
4 2
4 2
4 2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
35
Remark
For disc brake hose Fender front mtg. For cables
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 30 : STAND ASSEMBLY
3
2
12
13 14 11 9 4
5 1
10
7 6
8
Fig. No.
Part No.
1 2 3 4 5
DJ 1610 53 30 1611 57 39 0787 08 DH 1611 21 DH 1611 45
6 7 8 9 10 11 12 13 14
Description
180
150 ES
150 KS
Stand comp. main Shaft stand Pin cotter Spring main stand Cover spring main stand
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
DH 1610 65 DH 1610 66 DH 1611 46 DF 1611 02 39 0422 15
Stand side Spring side stand Cover spring side stand Bolt Nut
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
DH 2010 15 DH 2010 26 39 0790 12 30 2010 64
Side stand switch Screw pan cross Spring washer Band
1 2 2 1
1 2 2 1
1 2 2 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
36
Remark
Alt. 39 1523 01 N.I.
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 31 : TYRE / TUBE / RIM / SPOKES 1 3
2
9
8
7
6
11 10
12
6 1
5
4
Fig. No.
Part No.
1 2 3 4 5
16 1510 66 DJ 1510 04 DJ 1510 05 DH 1510 24 DH 1510 25
Nipple spoke Spoke inner front Spoke outer front Spoke inner rear Spoke outer rear
72 18 18 18 18
72 18 18 18 18
72 18 18 18 18
6 7 8 9 10
30 1510 29 DJ 1510 21 DJ 1510 20 30 1510 19 DJ 1510 03 DH 1510 21
Band rim Wheel rim front Tyre front Tube front Wheel rim rear Wheel rim rear
2 1 1 1 1 --
2 1 1 1 -1
2 1 1 1 -1
Proprietory items not to service
11
DJ 1510 08 DH 1510 08 DJ 1510 09 30 1511 08
Tyre rear Tyre rear Tube rear Tube rear
1 -1 --
-1 -1
-1 -1
Proprietory items Not to service
12
Description
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
37
150 ES
150 KS
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 32 : FRONT HUB (FOR DISC BRAKE) 4
2 1
3
2
12
6
5
11 7
10
9
17
15
16
13 8
Fig. No.
Part No.
1 2 3 4 5
DJ 1510 30 39 2362 20 DE 1510 06 30 1510 33 DE 1510 12
6 7 8 9 10
Description
14
180
150 ES
150 KS
Drum front assly. Bearing ball Spacer assly. Seal oil Plate drive
1 2 1 1 1
1 2 1 1 1
1 2 1 1 1
DE 1510 08 DJ 1510 14 DJ 1510 39 39 2124 15 DH 1510 40
Seal oil Disc Adaptor Hex. nut / flange Hex. soc.hd. bolt
1 1 1 6 6
1 1 1 6 6
1 1 1 6 6
11 12 13 14 15
DJ 1510 43 DE 1510 11 DJ 1510 40 DJ 1510 41 39 0781 11
Case meter gear Speedometer gear Spacer Axle Plain washer
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16 17
39 0786 15 39 0787 08
Hex.slotted nut Pin cotter
1 1
1 1
1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
38
Remark
Alt. 39 2038 04
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 33 : FRONT MASTER CYLINDER (FOR DISC BRAKES) 8 3 10 4 13
5 5
9
14 18 19 20
12
15
11B 11A
2
1
17
16
21 7
22
6 11
5
5
4
Fig. No.
Part No.
Description
1 2 3 4 5
DE 1910 43 DH 1510 36 DJ 1910 06 DE 1910 11 DE 1910 10
Major Kit - Master Cylinder Hose Brake Front Lever Grip RH Banjo Bolt Washer Copper
6 7 8 9 10
DE 1910 33 DE 1910 34 DE 1910 31 DE 1910 32 DE 1910 30
11 12 13 14 15
DE 1910 12 DE 1910 24 DE 1910 29 DE 1910 28 DE 1910 27
150 ES
150 KS
1 1 1 2 4
1 1 1 2 4
1 1 1 2 4
Clamp Holder RH Bolt Bolt Front Brake Lever Nut Flanged Screw
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
Cylinder Master Circlip Reservoir Cover Diaphragm Cover seal Master cylinder (Boot)
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
39
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 33 : FRONT MASTER CYLINDER (FOR DISC BRAKES) 8 3 10 4 13
5 5
9
14 18 19 20
12
15
11B 11A
2
1
17
16
21 7
22
6 11
5
5
4
Fig. No.
Part No.
16 17 18 19 20
DE 2010 16 DE 1910 23 DE 1910 36 DE 1910 37 DE 1910 38
21 22 23
DE 1910 25 DE 1910 26 DH 0100 06
Description
180
150 ES
150 KS
Front brake switch Return spring Window 'O' ring Clip
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Push rod Conical spring Disc brake kit - KBX
1 1 1
1 1 1
1 1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
40
Remark
N.I.
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 34 : FRONT DISC BRAKE
6
7
11A 11A
10 11B 12A
11B 9
9
5 10
8
7 2
4
11 12A
3
6
1
Fig. No.
Part No.
1 2 3 4 5
DJ 1510 14 DG 1510 89 DH 1510 40 39 1769 04 DE 1510 48
Disc, Front Caliper Assly. Front Bolt, Disc Plate Bolt Flanged Spring Pad
6 7 8 9 10
DE 1510 46 DE 1510 47 DE 1510 37 DE 1510 43 DE 1510 45
11 12
DE 1510 51 DE 1510 52
12
Description
150 ES
150 KS
1 1 6 2 1
1 1 6 2 1
1 1 6 2 1
Bleeder Screw Bleeder Cap Disc Pad Set Insulator Dust cover
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Minor Kit - Caliper Major Kit - Caliper
1 1
1 1
1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
41
Remark
Alt. 39 2038 04
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 35 : REAR HUB 31 21 25
17
16
27 29
21 15
18 22 26
19 20
2 24 4 3
28
1 5 23
12
30 11
13 14 8
9
10
6
7 14 Fig. No.
Part No.
Description
180
150 ES
150 KS
1 2 3 4 5
30 1510 63 39 2241 20 39 2242 20 30 1510 75 30 1510 76
Drum rear Bearing ball Bearing ball Collar bearing Damper
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
6 7 8 9 10
30 1510 08 30 1510 12 30 1510 38 30 1510 05 DH 1510 15
Panel rear brake Cam brake Ring ‘O’ Indiactor Lever brake
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
39 2447 04 39 0798 15 30 1511 05 30 1510 69 DH 1510 10
Bolt Nut Shoe brake assly. Spring Coupling
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
42
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 35 : REAR HUB 31 21 25
17
16
27 29
21 15
18 22 26
19 20
2 24 28
1
4
5
3
23 12
30 11
13 14 8
9
10
6
7 14 Fig. No.
Part No.
Description
16 17 18 19 20
30 1011 92 39 2240 20 DJ 1510 33 30 1510 82 DJ 1510 18 30 1510 81
Bearing ball Bearing ball Sleeve Seal oil Sprocket Hub Lock washer
21 22 23 24 25
DJ 1510 48 39 0694 15 DJ 1510 32 DH 1710 19 DJ 1510 38
26 27 28 29 30 31
150 ES
150 KS
1 1 1 1 1 3
1 1 1 1 1 3
1 1 1 1 1 3
‘D’ Bolt Hex. lock nut Axle ‘U’ nut Chain
6 6 1 1 1
6 6 1 1 1
6 6 1 1 1
39 0801 15 DJ 1510 35 DJ 1510 34 39 2566 11 39 2567 11
Nut Collar Collar Plain washer Plain washer
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
DJ 1510 53
Drive Chain Lock
1
1
1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
43
Remark
‘IH’ mark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 36 : REAR BRAKE PEDAL
1 3
5 4 6 7 9
2
10 12 10
10
16 11
8 13
19
14
19 20 21 18 15 20
18 17
Fig. No.
Part No.
1 2 3 4 5
DH 1910 01 DH 1910 04 39 2121 04 DH 1910 13 DH 1910 06
6 7 8 9 10
Description
180
150 ES
150 KS
Lever brake Shaft assly.brake lever Flange bolt Spacer brake shaft assly. Spring
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
39 1537 21 DH 1910 23 DJ 1910 10 30 1910 38 39 0198 11
‘O’ Ring Dust Cap Rod assly. brake Pin Plain washer
1 1 1 1 3
1 1 1 1 3
1 1 1 1 3
11 12 13 14 15
39 0808 08 30 1910 35 15 1910 26 30 1910 36 DJ 1510 42
Split pin Spring Pin Brake adjuster nut Rod torque
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16 17 18 19 20 21
DH 1510 29 30 1510 95 39 0789 12 39 0794 15 39 0807 08 39 0201 11
Hex. bolt Hex. bolt Spring washer Nut hex. Pin snap Plain Washer
1 1 2 2 2 1
1 1 2 2 2 1
1 1 2 2 2 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
44
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 37 : HANDLE BAR 22 3 21 2 20 5 23 25
1 24
4 9 8
17 12 11
19 18
16 7 18
13
15 19 10
14
Fig. No.
Part No.
1
DJ 1810 67 DJ 1810 68 DJ 1810 84 39 1714 04 DJ 2010 24 DJ 2010 12 DH 2010 16
Handle Handle Holder handle Assly. Flanged bolt Control switch LH Control switch RH Control switch RH
8 9 10
DJ 1910 09 DH 1910 15 DJ 1910 04 DH 1910 34 DH 1910 02 DD 1910 85 39 1184 15
11 12 13 14 15
30 1910 24 30 1910 17 39 0198 11 39 0725 04 DH 1910 07
2 3 4 5
6 7
26 6
Description
150 ES
150 KS
1 -1 4 1 1 --
-1 1 4 1 1 --
-1 1 4 1 -1
Lever assly.grip LH Lever assly.grip LH Holder left hand Holder left hand Lever grip left Bolt Self locking nut
1 -1 -1 1 1
1 -1 -1 1 1
-1 -1 1 1 1
Screw Nut Plain washer Hex. bolt Grip LH
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
45
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 37 : HANDLE BAR
22 3 21 2 20 5 23 25
1 24
4 9 8
17 12 11
19 16
18
7 18
13
15
19 10
Fig. No.
Part No.
16 17 18 19 20
DH 1910 14 DH 1910 19 DJ 1810 11 DH 1810 22 DH 1810 40 DJ 1810 39
21 22 23 24 25 26
14
26 6
Description
180
150 ES
150 KS
Grip Assly. RH Boot for lever Handle bar weight Handle bar weight Hex. soc.hd. cap screw Pad Holder Handle
1 1 2 -2 1
1 1 -2 2 1
1 1 -2 2 1
DJ 2210 03 DJ 2210 04 30 1910 48 DJ 2010 23 39 1943 04
Mirror assly. LH Mirror assly. RH Band Switch assly.ignition Flange bolt
1 1 4 1 2
1 1 4 1 2
1 1 4 1 2
DJ 2010 34
Clutch Switch
1
1
--
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
46
Remark
Alt. 39 2427 04
For Self Start only
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 38 : FRONT FORK 12
16
8
15
17 18 19
1 9 2
28
26
20
3
27
10 25 4/5 11 13 14 20 26
6
22
23
7
24
21
Fig. No.
Part No.
Description
180
150 ES
150 KS
1 2 3 4 5
DJ 1810 89 DJ 1810 88 DJ 1810 87 DJ 1810 61 DJ1810 62
Seal dust Ring snap Oil seal Outer Tube LH Outer Tube RH
2 2 2 1 1
2 2 2 1 1
------
6 7 8 9 10
30 1810 26 30 1810 25 30 1810 53 DJ 1810 45 DJ 1810 44
Gasket Bolt Cylinder comp.fork Clamp for Bellow Bellow
2 2 2 2 2
2 2 2 2 2
------
11 12 13 14 15
DJ 1810 70 DH 1810 09 DJ 1810 86 DE 1810 07 30 1810 44
Clamp Hose Pipe Grommet Top Pipe comp.suspension inner Spring front fork Bolt
1 2 2 2 1
1 2 2 2 1
------
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
47
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 38 : FRONT FORK
12
16
8
15
17 18 19
1 9 2
28
26 20
3
27
10 25 4/5 11 13 14 20 26
6
22
23
7
24
21
Fig. No.
Part No.
16 17 18 19 20
DH 1810 15 30 1810 29 30 1810 28 DJ 1810 17 DJ 1810 52
21 22 23 24 25 26 27 28
Description
180
150 ES
150 KS
Bolt fork ‘O’ ring Seat fork spring Holder fork upper Cover Trail B
2 2 2 1 4
2 2 2 1 4
------
DJ 1810 48 DJ 1810 41 39 0789 12 39 1813 04 DH 1810 23
Fork front Holder fork under Spring washer Bolt Bearing cone
1 1 2 2 1
1 1 2 2 1
------
DJ 1810 85 DJ 1810 66 DG 1810 08
Cushion Rubber Lamp Shade asly. Socket Bolt
2 1 2
2 1 2
--2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
48
Remark
: FRONT WHEEL DIRECTION
PLATE NO. 38A : FRONT FORK ( FOR PULSAR 150 KICK START ONLY) 12
PULSAR DTSi 16
8
15
17 18 19
1 9 2
30 27
3 10
29 4/5
25 28
11
13 14 20 26
6
22
23
7
24
21
Fig. No.
Part No.
Description
1 2 3 4 5
DJ 1810 89 DJ 1810 88 DJ 1810 87 DJ 1810 61 DJ1810 62
Seal dust Ring snap Oil seal Outer Tube LH Outer Tube RH
6 7 8 9 10
30 1810 26 30 1810 25 30 1810 53 DJ 1810 45 DJ 1810 44
11 12 13 14 15
DJ 1810 70 DH 1810 09 DJ 1810 86 DE 1810 07 30 1810 44
150 ES
150 KS
------
------
2 2 2 1 1
Gasket Bolt Cylinder comp.fork Clamp for Bellow Bellow
------
------
2 2 2 2 2
Clamp Hose Pipe Grommet Top Pipe comp.suspension inner Spring front fork Bolt
------
------
1 2 2 2 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
49
Remark
: FRONT WHEEL DIRECTION
PLATE NO. 38A : FRONT FORK ( FOR PULSAR 150 KICK START ONLY) 12
PULSAR DTSi 16
8
15
17 18 19
1 9 2
30 27
3 10
29 4/5
25 28
11
13 14 20 26
6
22
23
7
24
21
Fig. No.
Part No.
16 17 18 19 20
DH 1810 15 30 1810 29 30 1810 28 DJ 1810 17 DJ 1810 43
21 22 23 24 25 26 27 28 29 30
Description
180
150 ES
150 KS
Bolt fork ‘O’ ring Seat fork spring Holder fork upper Cover Trail B
------
------
2 2 2 1 2
DJ 1810 47 DJ 1810 41 39 0789 12 39 1813 04 DH 1810 23
Front Fork Holder fork under Spring washer Bolt Bearing cone
------
------
1 1 2 2 1
DJ 1810 85 DJ 1810 42 DJ 1810 74 DJ 1810 75 DG 1810 08
Cushion Rubber Cover Trail A Cover Fork LH Cover Fork RH Socket Bolt
------
------
2 2 1 1 2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
50
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 39 : PAINTED PARTS & DECALS 13
5
3 1
10/11
4 12 2
6/7 Fig. No.
Part No.
Description
180
8/9 150 ES
150 KS
Remark
1
DH 7101 X4 DH 7101 X6 DH 7101 T8 DH 7101 X3 DH 7101 W1 DH 7101 1C
Fuel Tank with Decal Fuel Tank with Decal Fuel Tank with Decal Fuel Tank with Decal Fuel Tank with Decal Fuel Tank with Decal
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
FOR RED COLOUR FOR BLUE COLOUR FOR SILVER COLOUR FOR BLACK COLOUR FOR PURPLE COLOUR FOR MAGIC SILVER COLOUR
2
DH 7301 X4 DH 7301 X6 DH 7301 T8 DH 7301 X3 DH 7301 W1 DH 7301 1C
Side Side Side Side Side Side
cover cover cover cover cover cover
LH LH LH LH LH LH
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
FOR RED COLOUR FOR BLUE COLOUR FOR SILVER COLOUR FOR BLACK COLOUR FOR PURPLE COLOUR FOR MAGIC SILVER COLOUR
3
DH 7302 X4 DH 7302 X6 DH 7302 T8 DH 7302 X3 DH 7302 W1 DH 7302 1C
Side Side Side Side Side Side
cover cover cover cover cover cover
RH RH RH RH RH RH
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
FOR RED COLOUR FOR BLUE COLOUR FOR SILVER COLOUR FOR BLACK COLOUR FOR PURPLE COLOUR FOR MAGIC SILVER COLOUR
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
51
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 39 : PAINTED PARTS & DECALS 13
5
3 1
10/11
4 12 2
6/7 Fig. No.
Part No.
4
DH 7303 X4 DH 7303 X6 DH 7303 T8 DH 7303 X3 DH 7303 W1 DH 7303 1C
5
Description
8/9
180
150 ES
150 KS
Remark
Seat Cowl W/o Decal Seat Cowl W/o Decal Seat Cowl W/o Decal Seat Cowl W/o Decal Seat Cowl W/o Decal Seat Cowl W/o Decal
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
FOR RED COLOUR FOR BLUE COLOUR FOR SILVER COLOUR FOR BLACK COLOUR FOR PURPLE COLOUR FOR MAGIC SILVER COLOUR
DH 7304 X4 DH 7304 X6 DH 7304 T8 DH 7304 X3 DH 7304 W1 DH 7304 1C
Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
FOR RED COLOUR FOR BLUE COLOUR FOR SILVER COLOUR FOR BLACK COLOUR FOR PURPLE COLOUR FOR MAGIC SILVER COLOUR
6
DJ 1611 80 DJ 1611 78
Decal 150 LH (For Seat Cowl) Decal 150 LH (For Seat Cowl)
1 1
1 1
1 1
FOR RED & SILVER FOR BLUE,BLACK,PURPLE
7
DJ 1611 81 DJ 1611 79
Decal 150 RH (For Seat Cowl) Decal 150 RH (For Seat Cowl)
1 1
1 1
1 1
FOR RED & SILVER FOR BLUE,BLACK,PURPLE
8
DJ 1611 84 DJ 1611 82
Decal 180 LH (For Seat Cowl) Decal 180 LH (For Seat Cowl)
1 1
1 1
1 1
FOR RED & SILVER FOR BLUE,BLACK,PURPLE
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
52
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 39 : PAINTED PARTS & DECALS 13
5
3 1
10/11
4 12 2
6/7 Fig. No.
Part No.
Description
8/9
180
150 ES
150 KS
Remark
9
DJ 1611 85 DJ 1611 83
Decal 180 RH (For Seat Cowl) Decal 180 RH (For Seat Cowl)
1 1
1 1
1 FOR RED , SILVER 1 FOR BLUE,BLACK,PURPLE
10
DJ 1410 28 DJ 1410 26
Pulsar decal / ‘B’ monogram LH Pulsar decal / ‘B’ monogram LH
1 1
1 1
1 FOR RED , SILVER 1 FOR BLUE,BLACK,PURPLE
11
DJ 1410 29 DJ 1410 27
Pulsar decal / ‘B’ monogram RH Pulsar decal / ‘B’ monogram RH
1 1
1 1
1 FOR RED , SILVER 1 FOR BLUE,BLACK,PURPLE
12
DH 1410 20
Seat tape
1
1
1
13
DJ 7401 X4 DJ 7401 X6 DJ 7401 T8 DJ 7401 X3 DJ 7401 W1 DJ 7401 1C
Fairing Fairing Fairing Fairing Fairing Fairing
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
53
FOR RED COLOUR FOR BLUE COLOUR FOR SILVER COLOUR FOR BLACK COLOUR FOR PURPLE COLOUR FOR MAGIC SILVER COLOUR
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 40 : PETROL COCK, CAP TANK & GAUGE FUEL
3 1
5
2
4
6
15 14
8
10
7 13 9 12 11
Fig. No.
Part No.
Description
180
150 ES
150 KS
Remark
1 2 3 4 5
DH 1410 50 39 0840 01 39 2381 04 DK 1410 01 DH 1410 48 DH 1810 44
Cap Assly. Tank Pan head screw Hex. Soc Hd. cap screw Tap Assly Rotor with key 4 In 1 Lock set With Key
1 1 7 1 1 1
1 1 7 1 1 1
1 1 Alt. 39 1780 01 7 1 1 1
6 7 8 9 10
30 1410 39 DD 1410 22 39 0740 11 DH 201013 30 1410 28
Packing Bolt flanged Plain Washer Gauge Fuel Gasket fuel Gauge
1 2 2 1 1
1 2 2 1 1
1 2 2 1 1
11 12 13 14 15
30 1410 32 DJ 1410 06 30 1410 15 DH 1410 24 DJ 1410 02
Bolt Tube fuel Pipe clip Drain tube Clamp
4 1 1 1 1
4 1 1 1 1
4 1 1 1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
54
: FRONT WHEEL DIRECTION
PLATE NO. 41 : FITTINGS - PETROL TANK, SIDE COVER & COVER SEAT
PULSAR DTSi
8
9 4
7 2 1
6 10 3
1 2 4
Fig. No.
Part No.
Description
1 2 3 4 5
DH 1611 58 DH 1611 33 39 1607 01 DH 1612 31 DH 1810 44
Grommet side cover Grommet side cover Rear Screw Lock for side cover with key Lock Set (4 in 1) with Key
6 7 8 9 10
DH 1410 23 DJ 1410 08 39 1556 04 39 2424 11 DH 1410 31
Damper Damper front Flanged Bolt Plain Washer Tape tank inner
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
55
150 ES
150 KS
4 2 2 2 1
4 2 2 2 1
4 2 2 2 1
1 2 1 1 2
1 2 1 1 2
1 2 1 1 2
Remark
Alt. DG 1611 21 N.I.
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 42 : METER ASSLY.
2 7
4
5 3
10
12
8 13 11 6
9 1
Fig. No.
Part No.
1 2 3 4 5
DJ 1910 16 DH 1910 25 DJ 1910 18 DJ 1910 17 DH 1910 28
6 7 8 9 10 11 12 13 14
Description
180
150 ES
150 KS
Meter Assly Cover Meter case Upper (Black) Speedometer Techo meter Meter fuel
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
DH 1910 29 DH 1910 30 DH 1910 31 DH 1910 37 DH 1910 33
Lamp 12 V-1.4W Cover meter lower (Black) Bracket meter Lamp 12V - 3W Cover (White)
4 1 1 3 1
4 1 1 3 1
4 1 1 3 1
DD 1910 31 DD 1911 33 DG 1910 98 39 0798 15
Grommet special Knob for tripmeter Screw for ‘Tripmeter Knob’ Nut
2 1 1 2
2 1 1 2
2 1 1 2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
56
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 43 : CONTROL CABLES
2
3
6
1 5
Fig. No.
Part No.
1
4 5
DJ 1910 14 DJ 1910 13 DJ 1910 15 DH 1910 41 DJ 1910 12 DJ 1910 11 DJ 1910 05 30 1910 67
Cable Throttle Cable Throttle Cable Clutch Cable Clutch Cable Starter (Choke) Cable Starter (Choke) Cable Speedometer Oil Seal
6
DD 1910 10
Inner cable Speedometer
2 3
Description
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
57
150 ES
150 KS
1 -1 -1 -1 1
-1 -1 -1 1 1
-1 -1 -1 1 1
1
1
1
4
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 44 : CHAIN CASE
7 1 6 7
5 3
7 2
4
6 8
7 5
Fig. No.
Part No.
1 2 3 4 5
DJ 1610 56 DJ 1610 59 28 1611 47 DH 1610 73 39 0897 04
6 7 8
39 2475 04 39 0711 11 15 1610 69
Description
180
150 ES
150 KS
Case Chain Upper Assly Case Chain Lower Assly Rubber Plug A Instruction Label Bolt
1 1 4 1 2
1 1 4 1 2
1 1 4 1 2
Bolt Plain Washer Rubber Cap
2 4 1
2 4 1
2 4 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
58
Remark
Rear side Mtg. Front side Mtg.
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 45 : HEAD LAMP & FAIRING 8 10 7 9
16
2 12 13 6
3
15
1 18 17 21 19
11
5 18
3
5
19
4
14
13
Fig. No.
17 21
Part No.
Description
180
150 ES
150 KS
1 2 3 4 5
DJ 2010 54 39 1778 02 DJ 1810 77 DD 2011 60 DJ 2010 72
Head Lamp Self Tapping Screw Special Bolt Fairing Mounting Lamp 12V 35/35W-HS1 Lamp 12V 5W
1 4 2 1 2
1 4 2 1 2
------
6 7 8 9 10
DJ 1810 69 DJ 1810 33 DF 1810 98 DL 1810 10 39 2141 24
Packing Fairing Wind Shield Bolt Well Nut Non Metallic Washer
1 1 4 4 4
1 1 4 4 4
------
11 12 13 14 15
DJ 1810 34 DJ 1810 35 DJ 1810 36 39 0705 01 DJ 1810 26
Side Flap LH Side Flap RH Plug Side Flap Mashroom Head Bolt Fairing mounting upper bracket
1 1 2 2 1
1 1 2 2 1
------
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
59
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 45 : HEAD LAMP & FAIRING 8 10 7 9
16
2 12 13 6
3
15
1 18 17 21 19
11
5 18
3 13
Fig. No.
Part No.
16 17 18 19 20
DJ 1810 37 DJ 1810 64 DJ 1810 29 39 1553 04 DJ 1810 65
21
39 0211 11
17 21
5
19
4
14
Description
180
150 ES
150 KS
Decal Wind Shield Grommet Fairing Mounting Collar Fairing Mounting Hex.Flanged Bolt Clip Nut
1 6 6 4 4
1 6 6 4 4
------
Plain Washer
4
4
--
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
60
Remark
N.I.
: FRONT WHEEL DIRECTION
PLATE NO. 46 : HEAD LAMP ( FOR PULSAR 150 KICK START ONLY)
PULSAR DTSi
18 14
4
17
11 6
7
15 5 16
13 8
3
10 1 20
9 19
22
16
21
2
12
Fig. No.
Part No.
Description
180
150 ES
150 KS
1 2 3 4 5
DJ 2010 37 DH 2010 02 DH 2010 03 DJ 2010 46 DJ 2010 51
Head light assly complete Bracket Head light Head light housing Rim head light Reflector with lens
------
------
1 1 1 1 1
6 7 8 9 10
DD 2010 06 DD 2010 07 DD 2010 08 DJ 2010 71 DD 2010 09
Screw Collar Collar Damper Head Lamp Damper
------
------
2 2 2 2 2
11 12 13 14 15
39 1684 12 39 1682 04 39 0694 15 20 2010 24 DH 1910 37
Spring Washer Flange Bolt Nut Lamp 12 V 35/35 W Lamp 12 V 3W
------
------
2 2 2 1 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
61
Remark
: FRONT WHEEL DIRECTION
PLATE NO. 46 : HEAD LAMP ( FOR PULSAR 150 KICK START ONLY)
PULSAR DTSi
18 14
4
17
11 6
7
15 5 16
13 8
3
10 1 20
9 19
22
16
21
2
12
Fig. No.
Part No.
16 17 18 19 20
DD 2010 48 DF 2010 58 DD 2010 40 DD 2010 45 DD 2010 46
21 22
DD 2010 47 DJ 2010 69
Description
180
150 ES
150 KS
Nut (Nylon) Lamp Holder Assly. Screw Screw Spring for Adjustment
------
------
1 1 3 1 1
Washer Collar Head Lamp
---
---
1 2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
62
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 47 : INDIACATOR LIGHT ASSLY.
1/2
7/8
5
3/4
6
Fig. No.
1
Part No.
Description
180
150 ES
150 KS
3 4 5
DJ 2010 38 DJ 2010 58 DJ 2010 39 DJ 2010 59 DJ 2010 40 DJ 2010 41 06 2010 83
Light Assly. Signal Fr. LH/Lamp Light Assly. Signal Fr. LH/Lamp Light Assly. Signal Fr. RH/Lamp Light Assly. Signal Fr. RH/Lamp Light Assly. Signal Rr. LH/Lamp Light Assly. Signal Rr. RH/Lamp Lamp 12 V - 10W
1 -1 -1 1 4
1 -1 -1 1 4
-1 -1 1 1 4
6 7 8
39 1970 15 DJ 2010 49 DJ 2010 50
Hex. nut with flange Blinker Lens (LH) Blinker Lens (RH)
4 2 2
4 2 2
4 2 2
2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
63
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 48 : TAIL LAMP ASSLY. / FRONT NO. PLATE
6
5 4
7 9 2 8 17
14 3 15
18
1 16
11
10
12
Fig. No.
Part No.
1 2 3 4 5
DJ 2010 61 DJ 2010 74 20 2010 29 DD 2010 11 31 2010 01
6 7 8 9 10
13
Description
180
150 ES
150 KS
Tail light with Lamp Lens tail light Lamp 12 V 21/5 W Damper Collar
1 1 1 3 3
1 1 1 3 3
1 1 1 3 3
39 0211 11 39 2124 15 39 1972 15 39 0705 01 DJ 1610 72
Plain Washer Nut Flange Nut Screw Bracket Rear No. Plate
3 3 2 2 1
3 3 2 2 1
3 3 2 2 Assly. Light No. Plate Mtg. 1
11 12 13 14 15
39 1773 04 DP 1611 45 39 1680 04 DP 1611 44 DJ 1810 24
Bolt flange Number plate Rear Hex Flanged Bolt Number plate front Front No. Plate Mounting Bracket
2 1 2 1 1
2 1 2 1 1
2 1 2 1 1
16 17 18
DJ 2010 56 39 1783 01 30 2010 29
Assly. Light No. Plate Truss Screw (For Front No. Plate) Lamp 12V-4W
1 2 1
1 2 1
1 2 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
64
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 49 : ELECTRICAL EQUIPMENTS
23 1/2 24 12 4 3
11
8
18
13 10
9
14
20 17
7
16 21
22
19
5 15 6 Fig. No.
Part No.
1
DH 2010 11 DH 2010 14 DH 2010 20 39 1507 11 39 1956 04 30 1910 48
Horn with LH stay Horn with RH stay Horn Plain Washer Flange Bolt Band
30 2010 64 DH 2010 29 DJ 2010 60 DH 2010 31 31 2010 79 DH 1910 12 DH 2010 19 DJ 2010 33 DH 2010 17 DJ 1610 06 DH 1611 35 DJ 1610 07 DH 1611 36
2 3 4 5 6 7
8 9 10 11 12 13
Description
150 ES
150 KS
1 1 -1 1 5
--1 1 1 5
--1 2 2 5
Band Wiring Harness Wiring Harness Wiring Harness Rear Brake Switch Spring Brake Switch Grommet Rear Brake Switch
3 -1 -1 1 1
3 --1 1 1 1
3 1 --1 1 1
Battery (12V-9A) Battery (12V-2.5A) Rubber pad I Battery Bkt. Rubber pad I Battery Bkt. Rubber pad II Battery Bkt. Rubber pad II Battery Bkt.
1 -1 -2 --
1 -1 -2 --
-1 -2 -1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
180
65
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 49 : ELECTRICAL EQUIPMENTS
23 1/2 24 12
4 3
11
8
18
13 10
9
14
20 17
7
16 21
22
19
5 15 6 Fig. No.
Part No.
14 15
DJ 1610 08 DH 1611 19
16 17 18 19 20 21 22 23 24
Description
180
150 ES
150 KS
Rubber pad III Battery Bkt. Band Battery Bkt.
1 1
1 1
---
29 2010 66 39 1680 04 DJ 2010 19 DH 1611 26 DJ 2010 28
Assly DC flasher / damper Flange Bolt Starter Relay / Damper Bracket battery Relay for Interlock
1 -1 -1
1 -1 -1
1 3 -1 --
30 2011 04 30 2010 85 DJ 2010 20 DJ 2010 21
Fuse box Assly. Fuse Cable assly. (Battery to St.Relay) Cable assly. (Battery to Earth)
1 1 1 1
1 1 1 1
1 1 ---
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
66
Remark
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 50 : TOOL KIT
1
Fig. No.
Part No.
2
Description
180
150 ES
150 KS
1 * * * *
DH 2210 04 30 2210 04 CB 2210 03 30 2210 33 30 2210 11
Tool Kit Tool Driver Tool Wrench (Box 16 mm) Tool Wrench (10 X 13) Tool Wrench (14 X 17)
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
* * * * *
30 2210 10 DH 2210 03 30 2210 05 30 2210 06 30 2210 09
Plier Tool Bag Tool wrench (27 A/F) Tool wrench (22 A/F) Tool bar
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
2
DH 2110 05
Band Tool Kit
2
2
2
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
67
Remark
For reference only not to service separately
: FRONT WHEEL DIRECTION
PULSAR DTSi
PLATE NO. 51 : ACCESSORIES / GRAB HANDLE 4
13 1 3 2
12
6
14 15 7 8 10 5
9
11
Fig. No.
Part No.
1 2 3 4 5
DH 1610 75 DH 1611 37 DH 1611 39 39 2275 15 DH 1610 74
6 7 8 9 10 11 12 13 14 15
Description
180
150 ES
150 KS
Leg Guard Hook leg guard Spacer leg guard Domed cap nut Sari Guard Assly
1 2 2 4 1
1 2 2 4 1
1 2 2 4 1
DH 1612 55 39 0789 12 39 0080 04 39 1608 04 39 0296 15
Flange Bolt Spring Washer Bolt Cap Bolt Hex Nut
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
DH 1611 44 DH 1610 47 39 2310 04 DD 2210 03 DH 1611 99
Cap Sari Guard Grab Rail Bolt Flange Plug Boot Sari Guard
1 1 4 2 1
1 1 4 2 1
1 1 4 2 1
180 = 180 cc with Electric Start 150 ES = 150 cc with Electric Start 150 KS = 150 cc Kick Start
68
Remark
: FRONT WHEEL DIRECTION