Pulsar DTSi Parts List

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

2

Remark

For Sleeve Spark Plug


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


3

Remark


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


4

14

Remark

6302 - RS1/C3 6002 - C3


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

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


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


6

Remark

7mm. (Height)


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

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


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


8

Remark


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

9

Remark


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

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


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

11

Remark

Alt. to DJ 1011 56


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

12

Remark

N.I. N.I. N.I.


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

13

Remark


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


14

Remark

For W/O self start only


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


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


16

Remark

Alt to 39 2452 21


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

17

Remark


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


18

Remark

LH Thread


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

19

Remark

For Kick Starter Ratchet


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


20

Remark

Make : Ucal Mikuni


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

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


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


22

Remark


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

23

Remark


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


24

Remark


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

25

150 ES

150 KS

1 3 1 1 1

1 3 1 1 1

1 3 1 1 1

1

1

1

Remark


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


26

Remark

With Aluminium bracket


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

27

150 ES

150 KS

Remark


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

----


28

Remark

For starter clutch

Stopper plate For stopper plate


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

29

Remark

Alt. 39 2311 04


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


30

13 180

150 ES

150 KS

2 1 1 1 1

2 1 1 1 1

2 1 1 1 1

Remark


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


31

Remark

1 Incl. Bush, Races & Cup rear 2 1 1 1


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


32

Remark


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

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


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


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

35

Remark

For disc brake hose Fender front mtg. For cables


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


36

Remark

Alt. 39 1523 01 N.I.


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

37

150 ES

150 KS

Remark


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


38

Remark

Alt. 39 2038 04


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

39

Remark


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


40

Remark

N.I.


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

41

Remark

Alt. 39 2038 04


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


42

Remark


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

43

Remark

‘IH’ mark


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


44

Remark


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

45

Remark


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

--


46

Remark

Alt. 39 2427 04

For Self Start only


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

------


47

Remark


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


48

Remark


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

49

Remark


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


50

Remark


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


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


3


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



51


PULSAR DTSi


5

3 1

10/11

4 12 2

6/7 Fig. No.

Part No.

4


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



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


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


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



52


PULSAR DTSi


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


11

DJ 1410 29 DJ 1410 27

Pulsar decal / ‘B’ monogram RH Pulsar decal / ‘B’ monogram RH

1 1

1 1


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


53



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


54


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

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.


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


56

Remark


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

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


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


58

Remark

Rear side Mtg. Front side Mtg.


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

------


59

Remark


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

--


60

Remark

N.I.


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


61

Remark


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


62

Remark


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


63

Remark


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


64

Remark


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

65

Remark


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 ---


66

Remark


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


67

Remark

For reference only not to service separately


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


68

Remark


Pulsar DTSi Parts List

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