Pulsar N-160 BS6 - SPC
Pulsar N-160 BS6 - SPC
COUNTRIES
All Information Contained In This Manual Is Based On The Latest We Have Pleasure In Presenting The Spare Parts Catalogue For ‘PULSAR
Product Information At The Time Of Publication. Bajaj Auto Limited N-160 BS6’ Motorcycle. This Catalogue Has Been Specially Designed To
Assist You In Selecting The Correct Parts For Procurement To Maintain 100%
Accepts No Liability For Any Inaccuracies Or Omissions In This
Availability.
Publication, Although Every Possible Care Has Been Taken To Make
It As Complete And Accurate As Possible. All Procedures And The Bajaj Spares Are Subjected To The Stringent Quality Control Standards
To Ensure Longer Life Of The Vehicle. It Is Therefore Necessary That Only
Specifications Subject To Change Without Prior Notice. The Right Is
The Genuine Bajaj Spares Are Used.
Reserved To Make Such Changes At Any Time Without Prior Notice
And Without Incurring An Obligation To Make Such Changes To In A Continual Effort To Improve Performance And Efficiency Of The Vehicles,
Product Manufactured Previously. Contact Your Authorized Bajaj Specifications, Diagrams, Illustrations And Part Numbers Can Change Without
Notice. Consequently, The Description In This Spare Parts Catalogue Cannot
Dealer For The Latest Information On Product Improvements
Therefore Be Final And Binding On Us.
Incorporated After This Manual Was Issued.
The Modifications / Alterations Which Are Carried Out After The Issue Of This
Catalogue, Will Be Conveyed To You Through Our Service Circulars. You Are
Requested To Make Necessary Corrections In The Parts Catalogue As Per
The Circulars So As To Keep Your Catalogue Up-to-date. This Will Ensure
The Appropriate And Speedy Delivery Of The Spare Parts As The Order
Placed Will Bear The Latest Part Numbers.
Revision 00 In Case, If You Need Any Technical Assistance Contact The Concerned
Regional Office Or Write To Us On The Following Address :
COUNTRIES
Instructions Index
1. How To Read The Catalogue : Open The Catalogue And From The Pictorial Plate No. Description Page No.
Index Locate The Group In Which The Part You Want To Find Is Present.
Turn Over To The Concerned Page Number (as Given By Pictorial Index).
Now Find Out The Figure Of The Part You Wish To Order. Write Down The 1 Cover Cylinder Head 2
Part Number Against That Particular Figure Number From The Text. 2 Cylinder Head 4
In Case, If You Have The Part Number And You Need The Other Details, 3 Valve 6,8
The Part Index Can Be Used. The Part Index (at The End Of The 4 Camshaft Assembly 10
Catalogue) Will Give You The Figure And Page Number Of The Part You 5 Cylinder And Piston 12
Wish To Order.
6 Crankshaft / Balancer Idler Gear 14
2. How To Order Spare Parts : The Part Number And The Description Of The 7 Transmission 16
Part Required Should Be Invariably Mentioned In The Order As Per The
8 Change Drum / Shift Fork 18
Catalogue Text.
9 Gear Change Mechanism 20
The Latest Part Number As Conveyed Through Our Service Circulars Should
Only Appear On The Order. In Case Of Ordering Painted Components,
10 Engine Assembly / Crankcase LH 22
Colour Shade Of The Components Should Be Mentioned. 11 Crankcase RH 24
The Quantity Shown Against The Part Number Is The Quantity Per Vehicle 12 Oil Pump 26
For That Group So That Particular Quantity Should Be Multiplied By The 13 Oil Cooler 28
Number Of Sets Required. 14 Cover Clutch 30
3. Part Number System : We Have Used 8 Digit System For Part Numbers. 15 Cover Magneto Assembly 32
The Model Or Hardware Item Is Indicated By First Two Digits Or 16 Clutch Assembly 34
Alphanumeric, The Next Two Or Four Digits Indicate Main Group And The 17 Throttle Body 36
Last Four Or Two Digits Indicate Serial Number In Main Group Or Serial
Number Or Subgroup Of Fastener Respectively. Thus The Part Numbers Will 18 Air Cleaner Complete 38
Be Indicated By 2-2-4 Or 2-4-2 Digit System. Understanding This System Will 19 EVAP Mechanism 40
Enable You To Identify The Spare Parts Easily. 20 Silencer Assembly 42
4. Abbreviations : The Following Abbreviations Are Used In This Catalogue. 21 Magneto & Starter Motor 44
Assly Assembly V Volts 22 H.T. Coil 46
N.I. Not Illustrated W Watts 23 Seat Assembly / Seat Lock 48
C'Case Crankcase Accl. Accelerator 24 Engine Mountings 50
Cyl Cylinder Comp. Complete 25 Frame And Frame Fittings 52
O/S Over Size FR. Front 26 Swing Arm / Rear Shock Absorber&Chain Case 54
RR. Rear Std. Standard
27 Foot Rest & Step Holder 56
L Length A/t. Alternate
28 Mudguard - Front & Rear 58
R.H. Right Hand L.H. Left Hand
Hex. Hexagonal AR As Required
29 Stand Assembly 60
30 Tube / Tyre / Rim 62
COUNTRIES
Index Index
Plate No. Description Page No. Plate No. Description Page No.
31 Front Hub 64
32 Rear Hub 66
33 Front Master Cylinder - Disc Brake 68
34 Front Caliper Assembly - Disc Brake 70
35 Rear Disc Brake Assembly 72
36 Rear Brake Pedal 74
37 ABS - Anti Lock Braking System 76
38 Handle Bar Assembly 78
39 Front Fork 80
40 Petrol Tank And Lock Set 82
41 Tank Flaps LH 84
42 Tank Flaps RH 86
43 Head Lamp & Front Fairing 88,90
44 Fittings - Side Covers & Cover Seat 92
45 Belly Pan Assembly 94
46 Speedometer Assembly 96
47 Control Cables 98
48 Indicator Lights & Tail Lamp 100
49 Rear Number Plate 102
50 Wiring Harness / ECU / Battery 104
51 Electrical Equipments 106
52 Tool Kit 108
53 Accessories / Grab Handle 110
54 Painted Parts And Decals 112,114
COUNTRIES
Pictorial Index Pictorial Index
PLATE NO. 1 PLATE NO. 2 PLATE NO. 5 CRANKSHAFT / BALANCER PLATE NO. 6
COVER CYLINDER HEAD CYLINDER HEAD CYLINDER AND PISTON
PAGE NO. 1 PAGE NO. 3 PAGE NO. 11 IDLER GEAR PAGE NO. 13
COUNTRIES
Pictorial Index Pictorial Index
COUNTRIES
Pictorial Index Pictorial Index
COUNTRIES
Pictorial Index Pictorial Index
COUNTRIES
Pictorial Index Pictorial Index
COUNTRIES
Pictorial Index Pictorial Index
HEAD LAMP & FRONT PLATE NO. 43 FITTINGS - SIDE COVERS AND PLATE NO. 44 PLATE NO. 47 INDICATOR LIGHTS AND PLATE NO. 48
CONTROL CABLES
FAIRING PAGE NO. 87,89 COVER SEAT PAGE NO. 91 PAGE NO. 97 TAIL LAMP PAGE NO. 99
COUNTRIES
Pictorial Index Pictorial Index
PLATE NO. 49 WIRING HARNESS / ECU / PLATE NO. 50 PLATE NO. 53 PLATE NO. 54
REAR NUMBER PLATE ACCESSORIES / GRAB HANDLE PAINTED PARTS & DECALS
PAGE NO. 101 BATTERY PAGE NO. 103 PAGE NO. 109 PAGE NO. 111,113
COUNTRIES
Cover Cylinder Head
1
No. Part No Description Qty Remarks
1 COUNTRIES
2
Cylinder Head
2
No. Part No Description Qty Remarks
1 36 JR01 02 Head Cylinder 1
2 PD 5111 72 Gasket Head Cylinder 1
3 PD 5814 32 Pipe Intake 1
4 39 2699 20 Ring O 1
5 JG 5814 07 Ring O 1
6 PD 3518 08 Sensor Temperature Engine 1
19 19 7 JE 3514 00 Switch Pressure Oil 1
12 8 PD 5112 05 Sleeve Spark Plug 1
9 52 PD16 21 Cover Sprocket 1
10 DK 1110 28 Plug Spark 2
9 11 39 1660 05 Stud-M8 2
13
12 LA D001 53 Bolt Flanged Step 4
14
13 DP 2010 31 Bolt Flanged M6x1 2
0 17 14 LD A000 08 Washer 4
10
15 KJ AB35 35 Ring O 1
8 16
15 16 39 1283 21 O Ring 1
18 17 KJ AC18 24 O Ring 1
7 18 39 2608 01 Grub Screw 1
4
6
19 LA E000 43 Bolt Flanged 2
11
3
1
17
0
5
3 COUNTRIES
4
Valve
3
No. Part No Description Qty Remarks
1 PD 5112 68 Seal Stem Valve Exhaust 2
6 2 36 JR01 01 Kit Valve 1
7 3 PD 5112 37 Rocker Arm Assembly 2
4 PD 5113 09 Shaft Rocker Arm 2
5
5 LD A000 48 Washer Plain 4
6 PD 5110 86 Washer Belleville 2
7 DP 2010 31 Bolt Flanged M6x1 2
3
8 PD 5110 85 Plug Shaft Rocker 2
12-63 4 9 CB 1010 22 Cotter Valve 4
10 36 JR01 10 Kit Valve Hardware 2
9 11 LJ A000 37 Ring O 2
11
12 36 JY00 29 Kit Shim 2 mm 1
8 13 36 JY00 30 Kit Shim 2.04 mm 1
14 36 JY00 31 Kit Shim 2.08 mm 1
15 36 JY00 32 Kit Shim 2.12 mm 1
16 36 JY00 33 Kit Shim 2.16 mm 1
10
17 36 JY00 34 Kit Shim 2.20 mm 1
18 36 JY00 35 Kit Shim 2.24 mm 1
19 36 JY00 36 Kit Shim 2.28 mm 1
1 20 36 JY00 56 Kit Shim 2.30 mm 1
21 36 JY00 37 Kit Shim 2.32 mm 1
22 36 JY00 57 Kit Shim 2.34 mm 1
23 36 JY00 38 Kit Shim 2.36 mm 1
24 36 JY00 58 Kit Shim 2.38 mm 1
2 25 36 JY00 39 Kit Shim 2.40 mm 1
26 36 JY00 59 Kit Shim 2.42 mm 1
27 36 JY00 40 Kit Shim 2.44 mm 1
28 36 JY00 60 Kit Shim 2.46 mm 1
29 36 JY00 41 Kit Shim 2.48 mm 1
30 36 JY00 61 Kit Shim 2.50 mm 1
31 36 JY00 42 Kit Shim 2.52 mm 1
32 36 JY00 62 Kit Shim 2.54 mm 1
5 COUNTRIES
6
Valve
3
No. Part No Description Qty Remarks
33 36 JY00 43 Kit Shim 2.56 mm 1
6 34 36 JY00 63 Kit Shim 2.58 mm 1
7 35 36 JY00 44 Kit Shim 2.60 mm 1
36 36 JY00 64 Kit Shim 2.62 mm 1
5
37 36 JY00 45 Kit Shim 2.64 mm 1
38 36 JY00 46 Kit Shim 2.68 mm 1
39 36 JF00 89 Kit Shim 2.70 mm 1
3
40 36 JY00 47 Kit Shim 2.72 mm 1
12-63 4 41 36 JF00 90 Kit Shim 2.74 mm 1
42 36 JY00 48 Kit Shim 2.76 mm 1
9 43 36 JF00 91 Kit Shim 2.78 mm 1
11
44 36 JY00 49 Kit Shim 2.80 mm 1
8 45 36 JF00 92 Kit Shim 2.82 mm 1
46 36 JY00 50 Kit Shim 2.84 mm 1
47 36 JF0093 Kit Shim 2.86 mm 1
48 36 JY00 51 Kit Shim 2.88 mm 1
10
49 36 JF00 94 Kit Shim 2.90 mm 1
50 36 JY00 52 Kit Shim 2.92 mm 1
51 36 JF00 95 Kit Shim 2.94 mm 1
1 52 36 JY00 53 Kit Shim 2.96 mm 1
53 36 JF00 96 Kit Shim 2.98 mm 1
54 36 JY00 54 Kit Shim 3.00 mm 1
55 36 JF00 97 Kit Shim 3.02 mm 1
56 36 JY00 55 Kit Shim 3.04 mm 1
2 57 36 JF00 98 Kit Shim 3.06 mm 1
58 36 JF00 99 Kit Shim 3.08 mm 1
59 36 JF01 00 Kit Shim 3.10 mm 1
60 36 JF01 01 Kit Shim 3.12 mm 1
61 36 JF01 02 Kit Shim 3.14 mm 1
62 36 JF01 03 Kit Shim 3.16 mm 1
63 36 JF01 04 Kit Shim 3.18 mm 1
7 COUNTRIES
8
Camshaft Assembly
4
No. Part No Description Qty Remarks
1 PD 5112 35 Camshaft Assembly 1
2 JE 5112 34 Sprocket Camshaft 1
3 KE BB35 15 Circlip Internal 1
4 PD 5111 93 Spacer Camshaft 1
3 4 5 36 JR00 98 Kit Cam Chain Guide 1
7 6 PD 5110 84 Chain 1
7 LA D002 30 Bolt Special Flanged 1
8 DH 1013 92 Chain Guide Pivot Bolt 1
2
1
9 COUNTRIES
10
Cylinder And Piston
5
No. Part No Description Qty Remarks
3 1 36 JR00 99 Kit Block Piston 1
2 PD 5111 72 Gasket Head Cylinder 1
3 39 2181 06 Pin Dowel 4
2 4 36 PD00 96 Piston Ring Set 1
5 DH 1016 71 Circlip 2
6 PD 5210 05 Gasket Block Cylinder 1
7 JC 1010 34 Tensioner Assembly 1
8 KA ED06 20 Bolt Flange Small-m6 2
9 39 2669 21 O-Ring 1
10 JG 5112 70 Bolt Flanged M6x1 1
5 11 CS 1011 28 Gasket 1
4
1
3
11
8
9
6
10
11 COUNTRIES
12
Crankshaft / Balancer Idler Gear
6
No. Part No Description Qty Remarks
1 PD 5310 37 Crankshaft Assembly 1
2 LC G000 02 Nut Hex Fl-m16x1.5xht.10 1
3 PD 5310 52 Bolt Flanged M12x1.5 1
4 LD B000 91 Washer Plain 1
5 KF AB40 50 Key Woodruff 1
1 6 LF B000 01 Key Sunk 1
7 PD 5310 46 Sprocket Crankshaft 1
8 36 JR01 00 Kit Primary Drive & Clutch Housing 1
6 9 JY 5310 08 Washer Plain 1
4 3
10 PD 5312 39 Balancer Assembly 1
5
8 7
2 9
10
13 COUNTRIES
14
Transmission
7
No. Part No Description Qty Remarks
1 PD 5510 56 Shaft Assembly Input 1
8 2 PD 5512 57 Washer 1
7 3 PD 5512 64 Gear Fourth Drive 1
4 BF 5510 37 Ring Snap Output 2
6
5
5 PD 5512 63 Gear Third Drive 1
9
6 LD A000 30 Washer Spline 2
3
7 PD 5512 65 Gear Fifth Drive 1
8 PD 5512 62 Gear Second Drive 1
4
9 LD A000 56 Washer Plain 2
4 10 PD 5510 18 Shaft Output-Plug 1
6 11 PD 5512 68 Gear Third Driven 1
1 16 17 12 LD A000 30 Washer Spline 1
2
13 BF 5510 37 Ring Snap Output 1
14 14 PD 5512 69 Gear Fourth Driven 1
15 JL 5512 17 Bush First Driven 1
13 16 PD 5512 66 Gear First Driven 1
11 12
15 18 PD 5512 70 Gear Fifth Driven 1
18 17 PD 5512 67 Gear Second Driven 1
19 19 JL 5512 18 Bush Second Driven 1
17
20 LA E000 48 Bolt Flanged M6x1 2
21 JG 5510 21 Washer Plain-id 20.2xod30 1
22 DJ 1013 12 Plate - Drive Sprocket 1
23 DH 1011 17 Sprocket Drive 1
10
21
23
20
22
15 COUNTRIES
16
Change Drum / Shift Fork
8
No. Part No Description Qty Remarks
1 PD 5610 11 Drum Complete Gear Shift 1
2 EC 5610 23 Spring Gear Switch Indicator 1
3 JY 5410 39 Compression Spring 2
8 4 JY 5610 07 Shaft Output Fork Shift 1
5 PD 5610 12 Guide Gear Shift 1
6 DH 1013 89 Bolt Socket - M6 x 1 x 20L 1
9
7 PD 5610 13 Fork Gear Shift Input 1
2 8 PD 5610 14 Fork Gear Shift Output I 1
3 9 PD 5610 15 Fork Gear Shift Output II 1
10 JY 5610 04 Shaft Input Gear Shift Fork 1
10
6
4
17 COUNTRIES
18
Gear Change Mechanism
9
No. Part No Description Qty Remarks
15
7
14
8
13
11
12
10
19 COUNTRIES
20
Engine Assembly / Crankcase LH
10
No. Part No Description Qty Remarks
1 PD 5010 30 Engine Assembly 1
1A 36 JR01 04 Kit Crankcase LH 1
2 PD 3510 28 Sensor Assembly Pick Up 1
3 PD 5410 48 Guard Chain 1
4 52 PD16 22 Sensor Indicator Gear 1
2 5 KA ED06 70 Bolt Flanged M6x1 7
1A
5 6 KP AF60 04 Bearing Ball 1
13 7
7 KP BG62 01 Bearing Ball 1
6
8 PD 5510 71 Seal Oil 1
9 KE BA30 12 Circlip Internal 1
10 KJ AA20 24 O Ring 1
20 11 LA E000 42 Bolt Flanged-m6x1 2
4
12 LB B000 07 Screw Pan Cross M6x1 3
13 LA E000 10 Bolt Flanged M5x0.8 2
15 14 39 1043 19 Seal - Oil 1
16
18
21 15 JY 5710 30 Mesh Strainer Assly 1
16 LJ A000 04 Strainer O Ring 1
3 8 17 JA 5410 48 Strainer Cap With O-ring 1
18 JA 5410 21 Cap Strainer 1
14 19 59 2100 23 O-Ring 1
12
9 20 KA EQ06 35 Bolt Flange Small 7
10
11
21 COUNTRIES
22
Crankcase RH
11
No. Part No Description Qty Remarks
1 1 36 JR01 03 Kit Crankcase RH 1
2 KP BF62 03 Bearing-Ball-C3 Clearance-HN3 1
3 KP BG62 01 Bearing Ball ID 1
4 4 JG 5312 20 Balancer Bearing 1
5
5 JG 5410 59 Plate Stopper Bearing Drum 1
7 6 KA ED06 12 Bolt-Flanged-Small 2
7 PD 5410 49 Gasket Crankcase 1
6 8 PD 5612 15 Spring Torsion 1
9 LD B000 50 Washer Plain-ID 6xOD 1
10 PD 5612 37 Stopper Assembly Drum 1
11 LD A000 26 Washer Plain-ID10xOD 1
2 12 LA C000 84 Bolt Socket-M6x1xl 1
3 13 JG 5710 14 Oil Filter 1
14 LJ A000 22 Ring 1
15 52 PD16 63 Cap Oil Filter With O' Ring (PD571011) 1
16 KA ED06 16 Bolt Flanged 2
8
10
12 9
11 13
14
15
16
23 COUNTRIES
24
Oil Pump
12
No. Part No Description Qty Remarks
1 PD 5710 12 Oil Pump 1
2 LA E000 18 Bolt Flanged M6x1 3
3 39 0999 06 Pin Dowel-oil Pump 2
1 2
25 COUNTRIES
26
Oil Cooler
13
No. Part No Description Qty Remarks
8
9
11
11
10
27 COUNTRIES
28
Cover Clutch
14
No. Part No Description Qty Remarks
14
10
11
12 13
29 COUNTRIES
30
Cover Magneto Assembly
15
No. Part No Description Qty Remarks
6 8
31 COUNTRIES
32
Clutch Assembly
16
No. Part No Description Qty Remarks
10 11
12 13 14 15 6
7
33 COUNTRIES
34
Throttle Body
17
No. Part No Description Qty Remarks
5 4
35 COUNTRIES
36
Air Cleaner Complete
18
No. Part No Description Qty Remarks
5
4
8 7
9
9
12
11
9 7
10
37 COUNTRIES
38
EVAP Mechanism
19
No. Part No Description Qty Remarks
1 JR 1319 10 Strap 1
2 JY 1710 77 Canister 1
3 JG 6012 57 Strap-clip Swivel 1
1 4 JR 1718 15 Pipe Drain 1
5 JR 1718 16 Pipe Drain 1
6 JG 1710 30 Clamp 7
2 7 GL 1710 36 Connector For Breather & Vapor Tube 1
15 16
8 JR 1718 03 Pipe Fuel 1
6 9 BF 1722 15 Clamp Spacer Lpg Hose 1
12
14 3 10 JL 1318 77 Clamp Hose Reservoir 1
3 11 JR 1718 05 Pipe Fuel 1
17
13 8 4 12 33 1410 08 Clamp 4
19
13 JG 1710 86 Connector Tube Evap 1
12 14 JR 1718 07 Pipe Fuel 1
15 JU 1716 06 Valve Purge 1
9 7
16 KC GA06 06 Nut Hex Flanged M6x1 1
11 6 6 5
10 6 17 DP 1210 25 Clamp 1
18 JL 1710 37 Breather Tube 1
19 JR 1718 04 Pipe Fuel 1
18
39 COUNTRIES
40
Silencer Assembly
20
No. Part No Description Qty Remarks
41 COUNTRIES
42
Magneto & Starter Motor
21
No. Part No Description Qty Remarks
15
8
16
43 COUNTRIES
44
H.T. Coil
22
No. Part No Description Qty Remarks
4 7
8
5
5
45 COUNTRIES
46
Seat Assembly / Seat Lock
23
No. Part No Description Qty Remarks
10
5
11
12
10
47 COUNTRIES
48
Engine Mountings
24
No. Part No Description Qty Remarks
9
14 13 8
6
11 12
8 1
49 COUNTRIES
50
Frame And Frame Fittings
25
No. Part No Description Qty Remarks
51 COUNTRIES
52
Swing Arm / Rear Shock Absorber & Chain Case
26
No. Part No Description Qty Remarks
10
53 COUNTRIES
54
Foot Rest & Step Holder
27
No. Part No Description Qty Remarks
29
1 56 JR4J 4X Holder Step Pillion LH(JR113048)Satin Blk 1
2 56 JR4S 4X Holder Step Pillion RH(JR113092)Satin Blk 1
3 56 JL19 4X Step Pillion RH (JL113016) Satin Black 1
13 27 4 56 JL18 4X Step Pillion LH (JL113014) Satin Black 1
14 5 GF 1611 43 Spring Pillion Footrest 2
30 6 KM AA08 00 Ball Steel 2
7 JL 1130 37 Pin Clevis Dia 8 2
8 JL 1130 36 Damper Step Pillion 2
28
27 26
9 DT 1130 14 Lock Plate LH 1
25 10 KH AE25 18 Pin Cotter 2
22 11 DT 1130 15 Lock Plate RH 1
24
12 LA C001 85 Bolt Socket M8x1.25 4
23 21
14 13 56 JR3X 4X Holder Step LH (JR113039) Satin Black 1
20 14 JR 1130 91 Pad Step 2
19
15 56 JR3S 4X Step Rider LH (JF113025) Satin Black 1
15 18 16 JL 1130 35 Bolt M6x1 2
17 2 17 LD B00 026 Washer Plain 2
1
18 KH AA25 20 Pin Cotter 2
19 KD AA08 16 Washer-kda-od/id/thk 2
16 3 20 30 1410 31 Ring O 2
21 DV 1610 50 Stopper Step 2
12 22 JF 1130 12 Spring Torsion - K10 2
7
23 LH E000 03 Pin Clevis With Hole 2
11 24 LA C001 04 Bolt Socket-M8 1
5
25 01 1009 05 Ring O 2
8 26 JL 5614 10 Washer Plain 1
6 27 LA C000 67 Bolt Socket-M8 2
9
10 28 LD A000 71 Washer Plain 1
4 29 56 JR3Y 4X Holder Step RH (JR113041) Satin Black 1
31 30 56 JR3T 4X Step Rider RH (JF113026) Satin Black 1
31 JR 1131 26 Spring Compression 2
55 COUNTRIES
56
Mudguard - Front & Rear
28
No. Part No Description Qty Remarks
11
12 0 0
57 COUNTRIES
58
Stand Assembly
29
No. Part No Description Qty Remarks
1 JR 1132 16 Stand Side 1
2 JR 1132 20 Bracket Holder Magnet 1
3 JG 1132 07 Bolt 1
6 4 LC H000 01 Nut Nyloc-m10x1.25xht 1
5 JZ 4036 01 Holder Magnet 1
6 JF 4014 15 Switch Stand Side 1
7 JL 1132 09 Spring Tension 1
8 DH 1611 46 Cover Spring Side Stand 1
9 JR 1132 15 Stand Center 1
3 10 LA C002 05 Bolt Socket M8x1.25 2
11 KD BC08 18 Washer Plain 2
5 12 JL 1132 10 Bush Main Stand LH 2
13 JD 4022 12 Band (Length 200mm) 3
14 PA 1132 04 Damper Center Stand 1
15 JL 1132 06 Spring Main Stand With Cover 1
16 JL 1132 12 Cover Spring Main Stand 1
1 2 4
7
8
9 15
11 12
10
16
14
59 COUNTRIES
60
Tube / Tyre / Rim
30
No. Part No Description Qty Remarks
4 5
2
61 COUNTRIES
62
Front Hub
31
No. Part No Description Qty Remarks
13
1
14
8
3
63 COUNTRIES
64
Rear Hub
32
No. Part No Description Qty Remarks
2 7
65 COUNTRIES
66
Front Master Cylinder - Disc Brake
33
No. Part No Description Qty Remarks
4
14 36 JF00 18 Major Kit M Cylinder - ABS 1
10
14A 36 JF00 19 Minor Kit M Cylinder - ABS 1
10
14
7
13
13
12
10
10
11
67 COUNTRIES
68
Front Caliper Assembly - Disc Brake
34
No. Part No Description Qty Remarks
5 2 PISTON SEAL
DUST SEAL
BLEEDER CAP
PROTECTION BOOT
INSULATOR
CALIPER PISTON
BLEEDER SCREW
PAD SPRING
69 COUNTRIES
70
Rear Disc Brake Assembly
35
No. Part No Description Qty Remarks
10 4
1 36 JR00 52 Reservoir Assembly Kit 1
2 JR 1318 83 Caliper Assembly Rear 1
3 JR 1318 97 Cylinder Assembly Master Rear 1
1 22 4 GL 1318 27 Bolt Banjo 2
5 LA D000 77 Bolt Flange-m6x1xl16 2
3 4 6 LH A000 01 Pin 1
7 KD AA06 11 Washer Plain 1
21
8 KH AA20 15 Pin Cotter 1
5 9 DJ 1510 70 Cap Bleeder Screw 1
10 KA DD06 14 Bolt Flanged 1
6 11 36 DH41 74 Pad Set Brake Rear 1
12 YJ R050 34 Bleeder Screw 1
8 7
15 13 36 JR00 50 Master Cyl Push Rod-Fork Kit 1
14 36 DH41 75 Kit Major Caliper 1
15 36 DH41 77 Kit Minor Caliper 1
2 16 36 JR00 49 Kit Major M Cylinder 1 N.I.
PISTON SEAL
17 36 JF00 19 Kit Minor M Cylinder 1 N.I.
DUST SEAL 18 36 JR00 51 Master Cyl Seal Kit 1 N.I.
19 36 JR00 53 Filler Union O-Ring Kit 1 N.I.
BLEEDER CAP
9 20 36 JR00 54 Hose Tube-Clamp Kit 1 N.I.
PROTECTION BOOT 21 36 JR00 36 Kit Hose Brake Rear 1
22 30 1910 48 Band 1
INSULATOR
CALIPER PISTON
11
12 BLEEDER SCREW
PAD SPRING
14
71 COUNTRIES
72
Rear Brake Pedal
36
No. Part No Description Qty Remarks
11 8
5
4
9
10
10
5
13
73 COUNTRIES
74
ABS - Anti Lock Braking System
37
Part No Description Qty Remarks
5 4
5
9
11
12
75 COUNTRIES
76
Handle Bar Assembly
38
No. Part No Description Qty Remarks
77 COUNTRIES
78
Front Fork
39
No. Part No Description Qty Remarks
79 COUNTRIES
80
Petrol Tank And Lock Set
40
No. Part No Description Qty Remarks
14
10
11
12
15 9
5
13
81 COUNTRIES
82
Tank Flaps LH
41
No. Part No Description Qty Remarks
83 COUNTRIES
84
Tank Flaps RH
42
No. Part No Description Qty Remarks
4 10 7
16
3
8
2
5
85 COUNTRIES
86
Head Lamp & Front Fairing
43
No. Part No Description Qty Remarks
38
2 3 1 JR 1812 73 Carrier Mask 1
1
6 2 KA DF06 30 Bolt Flange-kad St-f Dia-06 L-30 2
3 JR 2328 09 Bracket Plate Number Front 1
5
4 JP 1812 80 Collar Head Lamp Holder Mtg 2
4 5 JP 1812 79 Grommet Front Fairing Assy 2
6 JY 1910 08 Damper 2
9
7 JR 1817 15 Pin Quick Release 1
13 9 KC GC06 06 Nut Hex Flanged 1
7 12 10 JR 4010 20 Lamp Position 1
11 YJ R030 01 Bush Head lamp 4
12 KD AA05 10 Washer Plain Small 5
10
13 KB RA42 13 Screw Tapping Pan Cross 5
14 JR 4010 17 Lamp Head 1
15 KA DF06 30 Bolt-flange-kad St-f Dia-06 L-30 2
12
16 JP 1812 80 Collar Head Lamp Holder Mtg 2
11 13 17 JP 1812 79 Grommet Front Fairing Assy 2
18 JG 1813 80 Nut Rivet 2
15 19 19 KA DA06 25 Bolt Flanged 1
16 37 20 JG 1710 20 Sleeve Tank Mounting 1
14
22 36 21 JG 1710 22 Grommet-tank Mounting Rear 1
18
20 22 JR 1813 42 Structure Lamp Head Front 1
21 23 JG 1710 20 Sleeve Tank Mounting 2
17 23
24 24 JR 1813 38 Structure Lamp Head Rear 1
28
25 JG 1710 22 Grommet-tank Mounting Rear 2
23
25 26 KB UA06 14 Screw Truss 1
29 27 LD B000 72 Washer Plain 1
27
31 30 28 DJ 1810 65 Nut - Clip :- M6 1
26
32 25 29 DJ 1810 65 Clip Nut M6 2
34 33
35
30 JY 1812 84 Washer Nylon 2
31 KB UA06 20 Screw Truss 2
32 JG 1812 43 Securing Clip-Piv Bolt-Mask Carr 2
87 COUNTRIES
88
Head Lamp & Front Fairing
43
No. Part No Description Qty Remarks
38
2 3 33 LD B000 83 Washer -Id 9xod 18xthk 2xblack 2
1
6 34 PA 1813 54 Grommet 2
35 PD 1812 39 Pin 2
5
36 AA 1612 90 Bracket Harness Clamp 1
4 37 KA DA05 16 Bolt Flanged M5X0.8 1
38 JR 4010 32 Lamp DRL 1
9
13
7 12
10
12
11 13
15 19
16 37
14
22 36
18
20
21
17 23
28 24
23
25
29
27
31 30 26
32 25
34 33
35
89 COUNTRIES
90
Fittings - Side Covers & Cover Seat
44
No. Part No Description Qty Remarks
10
3
13
12 11
91 COUNTRIES
92
Belly Pan Assembly
45
No. Part No Description Qty Remarks
13 7
9
4
10
3
93 COUNTRIES
94
Speedometer Assembly
46
No. Part No Description Qty Remarks
2
1 JR 4024 11 Speedometer 1
10
2 GL 1812 63 Bead Front Shield 6
3 JR 1813 57 Cover Flap Speedometer Front 1
4 JP 1812 29 Grommet Ignition Switch Cover 1
13 5 JR 1813 49 Bracket Assembly Speedometer 1
6 JP 1812 80 Collar Head Lamp Holder 2
7 JG 1812 38 Grommet Dashboard 3
8 LD B000 07 Washer Plain 2
12
2 9 KC AC05 04 Nut Hex Thick 2
10 LB U001 72 Bolt Soc-head Speedo Flap 2
11 JP 1812 79 Grommet Front Fairing Assy 2
3
12 JR 1813 56 Flap Speedometer 1
13 KD BB05 12 Washer Plain 2
7 11
8
10
95 COUNTRIES
96
Control Cables
47
No. Part No Description Qty Remarks
97 COUNTRIES
98
Indicator Lights & Tail Lamp
48
No. Part No Description Qty Remarks
17
12
99 COUNTRIES
100
Rear Number Plate
49
No. Part No Description Qty Remarks
12 4
7
5 1
101 COUNTRIES
102
Wiring Harness / ECU / Battery
50
No. Part No Description Qty Remarks
18
103 COUNTRIES
104
Electrical Equipments
51
No. Part No Description Qty Remarks
1 JR 4016 05 Horn 1
2 JL 4032 01 Unit Termination 1
3 JF 4030 00 Relay Interlock 4
1 4 JP 4030 00 Relay Starter 1
9 2 17 5 JP 4030 02 Damper Relay Starter 1
6 JF 4020 06 Unit Regulator 1
10 7 JR 1138 58 Bracket Sensor Roll Over 1
3 8 JY 4036 04 Sensor Roll Over 1
9 KA DF08 14 Bolt Flange 1
10 LB U001 55 Screw 1
11 KA DD06 22 Bolt Flanged 1
8
4 12 GL 1138 11 Collar 1
13 GL 1138 12 Grommet 1
14 KA CA06 22 Bolt Socket 2
15 JR 4034 01 Socket Charger 1
6 16 39 2484 15 Nut - Flange :- M5 2
0 5
12 11 17 JR 1138 80 Bracket Can Unit Termination 1
13
7
14
15
16
105 COUNTRIES
106
Tool Kit
52
No. Part No Description Qty Remarks
1 JR 2310 10 Strap 1
107 COUNTRIES
108
Accessories / Grab Handle
53
No. Part No Description Qty Remarks
10
11
13
12
109 COUNTRIES
110
Painted Parts and Decals
54
No. Part No Description Qty Remarks
7/8 5/6 1 12/13 2/3 4 1 52 JR03 30 Tank Glossy Brklyn Black+ Decal 1
37
2 52 JR03 34 Fairing Front LH Glos Brklyn Blk+Decal 1
3 52 JR03 35 Fairing Front RH Glos Brklyn Blk+Decal 1
4 52 JR03 32 Front Fender Top Glos Brklyn Blk+Decal 1
5 52 JR03 29 Side Cover LH Assly S Blk_Matt Blk 1
6 52 JR04 51 Side Cover RH Assly S Blk_Matt Blk 1
7 52 JR04 46 Seat Cowl RH Glos Bklyn Blk_Red Decal 1
8 52 JR04 45 Seat Cowl LH Glos Bklyn Blk_Red Decal 1
9 52 JR03 40 Belly Pan Top LH Gloss Brkyn.Blk+Decal 1
10 52 JR03 41 Belly Pan Top RH Gloss Brkyn Blk+Decal 1
11 56 JRA9 X3 Carrier Mask Glossy Black 1
12 52 JR03 43 Flap Tank LH Glos Brkln Blk+Decal 1
13 52 JR03 46 Flap Tank RH Glos Brkln Blk+Decal 1
14/15 14 52 JR03 44 Shroud LH Glos Brkln Blk+Decal 1
9/10 15 52 JR03 47 Shroud RH Glos Brkln Blk+Decal 1
16 JR 2333 07 Decal Fender B Black G LH 1
17 JR 2333 09 Decal Fender B Black G RH 1
25 18 JR 2333 08 Decal Fender B Black G Middle 1
19 JR 2333 19 Decal Belly Pan B Black G LH 1
20 JR 2333 20 Decal Belly Pan B Black G RH 1
33/34 28 31/32 29/30 21 JR 2333 21 Decal Wheel B Black Glossy LH 2
22 JR 2333 22 Decal Wheel B Black Glossy RH 2
23 JR 2333 42 Decal Shroud Tank B Black G LH 1
24 JR 2333 43 Decal Shroud Tank B Black G RH 1
25 JR 2333 06 Decal Pulsar 2
26 JR 2334 32 Decal Cover Magneto 1
27 JR 2332 41 Decal Cover Clutch 1
28 36 JR00 91 Kit Tank Dcl Black Glossy 1
29 JR 2333 97 Decal N160 B Black Glossy LH 1
30 JR 2333 98 Decal N160 B Black Glossy RH 1
18 19/20 24 21/22 23/24 31 JR 2333 29 Decal Fairing Front B Black G LH 1
32 JR 2333 30 Decal Fairing Front B Black G RH 1
111 COUNTRIES
112
Painted Parts And Decals
54
No. Part No Description Qty Remarks
7/8 5/6 1 12/13 2/3 4 33 36 JR00 92 Kit Dcl Flap LH Black Glossy 1
37
34 36 JR00 93 Kit Dcl Flap RH Black Glossy 1
35 JR 1812 96 Belly Pan LH 1
36 JR 1812 97 Belly Pan RH 1
37 JR 1810 10 Cowl Seat Middle 1
14/15
9/10
25
113 COUNTRIES
114
Kit List Kit List
1 36JR0098 CHAIN GUIDE KIT PD511239 GUIDE CHAIN SLACK SIDE 1 JG541021 NOZZLE JET OIL 1
PD511240 GUIDE CHAIN TIGHT SIDE 1
12 36JR0104 KIT ASSLY CRANKCASE LH PD541076 CRANKCASE ASSEMBLY LH 1 1
2 36JR0099 KIT BLOCK PISTON ASSLY PD521012 BLOCK CYLINDER 1 KPBG6201 BEARING BALL ID12XOD32XT10XC3 1
PD521204 PISTON ASSEMBLY 1 JG531220 BALANCER BEARING(6202/HN3C3D8) 1
KPAF6004 BEARING BALL-ORD CLEARANCE 1
3 36JR0100 KIT PRIMARY GEAR+ CL HSG PD531044 GEAR PRIMARY DRIVE 1 PD551071 SEAL OIL 1
PD551434 HOUSING ASSEMBLY CLUTCH 1 KEBA3012 CIRCLIP INTERNAL-OD 32.1XTHK 1.2 1
JY541038 BUSH 1
4 36JR0101 KIT VALVE INTAKE+EXHAUST PD511233 VALVE INTAKE 1 39104319 SEAL - OIL 1
PD511234 VALVE EXHAUST 1
13 36PD0096 PISTON RING SET DH101666 RING PISTON TOP 1
5 36JR0110 KIT VALVE REPAIR DK102028 SPRING VALVE 2 PD521233 RING PISTON SECOND 1
PD511231 SEAT SPRING VALVE 2 PD521234 RING PISTON OIL 1
PD511268 SEAL STEM VALVE 2
PD511208 RETAINER SPRING VALVE 2 14 36JR0035 KIT HOSE CYL MSTR-UNIT ABS JR131812 HOSE CYLINDER MASTER-UNIT ABS 1
CB101022 COTTER VALVE 4 DJ191026 COPPER WASHER 4
GL131827 BOLT BANJO 2
6 36JR0112 KIT FRICTION PLATE YJR06009 DISC A CLUTCH FRICTION 2
YJR06011 DISC C CLUTCH FRICTION 2 15 36JR0085 ABS UNIT TO FR CLIPR HS KIT JR131849 HOSE UNIT ABS-CALIPER FRONT 1
DJ191026 COPPER WASHER 4
7 36JR0114 KIT CLUTCH COVER MATTE PD541253 COVER CLUTCH-PLUG 1 GL131827 BOLT BANJO 2
JH541236 JET OIL COVER CLUTCH 1
JZ541268 WINDOW GAUGE OIL 1 16 36JG0011 KIT STEERING HEAD BEARING 52DG0370 KIT BEARING RACE & CONE 1
JZ541269 CIRCLIP 1 DK181050 CAGE BEARING STEERING TOP 1
39199020 BEARING - NEEDLE 1 DK181051 CAGE BEARING STEERING BOTTOM 1
39104119 SEAL - OIL 1 JG151024 WASHER 1
PD541316 PLUG 1 DG181004 SEAL - OIL 1
8 36JR0113 KIT CLUTCH PLATE STEEL YJR06008 PLATE CLUTCH 3 17 36JR0052 RESERVOIR ASSEMBLY KIT YJR05052 RESERVOIR CAP SCREW 1
YJR05053 RESERVOIR CAP 1
9 36JR0109 KIT CHAIN SPROCKET JR131256 SPROCKET 1 YJR05049 RESERVOIR BODY 1
JR141003 CHAIN 1 YJR05051 SEAL CAP 1
DH101117 SPROCKET DRIVE 1 36JR0044 DAIPHRAM RESERVOIR-ETL 1
10 36JR0102 KIT ASSLY CYL HEAD PD511081 HEAD CYLINDER 1 18 36JR0050 MASTER CYL P ROD-FORK KIT YJR05048 HEXAGONAL LOCK NUT M6X1 1
JH541236 JET OIL COVER CLUTCH 1 YJR05046 SEAL WASHER M6X1 1
JE511052 NOZZLE 1 YJR05047 PUSH ROD FORK 1
YJR05045 PUSH ROD M6X1 1
11 36JR0103 KIT ASSLY CRANKCASE RH PD541079 CRANKCASE ASSEMBLY RH 1
KPBF6203 BEARING-BALL-C3 CLEARANCE-HN3 1 19 36JR0036 KIT HOSE BRAKE REAR GL131827 BOLT BANJO 2
KPBG6201 BEARING BALL ID12XOD32XT10XC3 1 JR131831 HOSE BRAKE REAR 1
JG531220 BALANCER BEARING (6202/HN3C3D8) 1 DJ191026 COPPER WASHER 4
JY541038 BUSH 1
115 COUNTRIES
116
Kit List Kit List
21 36JR0053 FILLER UNION , O-RING KIT YJR05056 CIRCLIP FOR FILLER UNION 1
YJR05054 FILEER UNION 1
YJR05055 O RING FOR FILLER UNION 1
YJR05027 GREASE SYNTHESO GLEP-1 1
25 36JR0091 KIT TANK DCL BLACK GLOSSY JR233331 DECAL TANK TOP B BLACK G LH 1
JR233333 DECAL TANK TOP B BLACK G RH 1
JR233334 DECAL TANK SIDE B BLACK G LH 1
JR233335 DECAL TANK SIDE B BLACK G RH 1
26 36JR0092 KIT DCL FLAP LH BLACK GLSS JR233336 DECAL FLAP TANK UPP B BLK G LH 1
JR233338 DECAL FLAP TANK SD FRT BB G LH 1
JR233340 DECAL FLAP TANK SD RR BB G LH 1
27 36JR0093 KIT DCL FLAP RH BLACK GLSS JR233337 DECAL FLAP TANK UPP B BLK G RH 1
JR233339 DECAL FLAP TANK SD FRT BB G RH 1
JR233341 DECAL FLAP TANK SD RR BB G RH 1
117 COUNTRIES
118
Amendment Sheet Amendment Sheet
Page Fig. Old part New part Description Updation Remarks Page Fig. Old part New part Description
Updation Remarks
no. no. no. no. date no. no. no. no. date
119 COUNTRIES
120
Part Index Part Index
121 COUNTRIES
122
Part Index Part Index
123 COUNTRIES
124
Part Index Part Index
125 COUNTRIES
126
Part Index Part Index
127 COUNTRIES
128
Part Index Part Index
129 COUNTRIES
130
Part Index Part Index
131 COUNTRIES
132
Part Index Part Index
133 COUNTRIES
134