SPC Pulsar NS 200 BS IV - AS200 (2018 07 24)
SPC Pulsar NS 200 BS IV - AS200 (2018 07 24)
SPC Pulsar NS 200 BS IV - AS200 (2018 07 24)
REV. FEB 17
2. How to Order Spare Parts : The part number and the description of the
In a continual effort to improve Performance and Efficiency of the vehicles, part required should be invariably mentioned in the order as per the
Specifications, Diagrams, Illustrations and Part Numbers can change without catalogue text.
notice. Consequently, the description in this Spare Parts Catalogue cannot
The latest part number as conveyed through our service circulars should
therefore be final and binding on us. only appear on the order. In case of ordering painted components, colour
shade of the components should be mentioned.
The modifications / alterations which are carried out after the issue of this The quantity shown against the part number is the quantity per vehicle for
catalogue, will be conveyed to you through our Service Circulars. You are that group so that particular quantity should be multiplied by the number
requested to make necessary corrections in the Parts Catalogue as per the of sets required.
circulars so as to keep your catalogue up-to-date. This will ensure the 3. Part Number System : We have used 8 digit system for part numbers.
appropriate and speedy delivery of the Spare Parts as the order placed will The model or hardware item is indicated by first two digits or
bear the latest part numbers. alphanumeric, the next two or four digits indicate main group and the last
four or two digits indicate serial number in main group or serial number or
subgroup of fastener respectively. Thus the part numbers will be indicated
In case, if you need any technical assistance contact the concerned Regional by 2-2-4 or 2-4-2 digit system. Understanding this system will enable you
Office or write to us on the following address : to identify the spare parts easily.
55 Tail Lamp Assly / Front Number Plate Amendment Sheet 155 TO 158
Pulsar 200 AS 112
56 Electrical Equipments 114 Parts Index 159 TO 178
56A Electrical Equipments 116
57 Tool Kit 118
58 Accessories / Grab Handle 120
59 Painted Parts and Decals BS IV 122
59A Painted Parts and Decals BS IV 124
60 Painted Parts 126
60A Painted Parts 128
61 Painted Parts and Decals 130
61A Painted Parts and Decals 132
62 Painted Parts and Decals
(New Decal Scheme As Per Cir IB-166) 134
63 Painted Parts and Decals
(Old Decal Scheme Before Cir IB-166) 136
64 Painted Parts and Decals
(Old- up tp Oct. 2013_Refer Circular IB-82) 138
64A Painted Parts and Decals
(Old- up tp Oct. 2013_Refer Circular IB-82) 140
65 Painted Parts and Decals 142
65A Painted Parts and Decals 144
PLATE NO. : 1 PAGE NO. PLATE NO. : 2 PAGE NO. PLATE NO. : 5 PAGE NO. PLATE NO. : 6 PAGE NO.
COVER CYLINDER HEAD 1 SAI System 3 CAMSHAFT / TENSIONER 9 CYLINDER & PISTON 11
PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
CYLINDER HEAD 5 VALVE 7 CRANKSHAFT 13 TRANSMISSION 15
BS IV BS IV
Pictorial Index Pictorial Index
PLATE NO. : 9 PAGE NO. PLATE NO. : 10 PAGE NO. PLATE NO. : 13 PAGE NO. PLATE NO. : 14 PAGE NO.
CHANGE DRUM / SHIFT FORK 17 GEAR CHANGE MECHANISM 19 BALANCER IDLER GEAR/WATER PUMP 25 OIL PUMP 27
PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO. PLATE NO. : 16 PAGE NO.
PLATE NO. : 15 PAGE NO.
ENGINE ASSLY & CRANKCASE RH 21 CRANKCASE LH 23 COVER CLUTCH 31
RADIATOR 29
BS IV BS IV
Pictorial Index Pictorial Index
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
COVER MAGNETO 33 CLUTCH ASSEMBLY 35 EVAP MECHANISM 41 SILENCER ASSEMBLY 43
PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
CARBURETTOR 37 AIR CLEANER COMPLETE 39 STARTER ASSEMBLY 45 MAGNETO, CDI & H.T. COIL 47
BS IV BS IV
Pictorial Index Pictorial Index
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO.
PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
SEAT ASSEMBLY / SEAT LOCK 49 ENGINE MOUNTINGS 51
PILLION FOOT REST / HOLDER 57 MUD GUARD - FRONT & REAR 59
E
: US -4
ING T3
RN DO FROM
WA LY ID ER
ON FLU AIN
E NT P
AK G
BR ED CO CA VIN
AL LER
SE N FIL REMO
A EA
CL FORE
BE
PLATE NO. : 35 PAGE NO. PLATE NO. : 36 PAGE NO. PLATE NO. : 39 PAGE NO. PLATE NO. : 40 PAGE NO.
FRONT DISC BRAKE 69 REAR HUB 71 HANDLE BAR ASSEMBLY 77 FRONT FORK 79
x
Pictorial Index BS IV
Pictorial Index BS IV
PLATE NO. : 45
PLATE NO. : 40 A PAGE NO. PLATE NO. : 41 PAGE NO. PLATE NO. : 44 PAGE NO. PAGE NO.
FAIRING AND PETROL TANKK COVER
FRONT FORK 81 RADIATOR COVERS 83 FITTING SEAT COVER 89 91
5
6
TILL OCT 2014
22
17
AFTER OCT 2014
PLATE NO. : 56 PAGE NO. PLATE NO. : 56 A PAGE NO. PLATE NO. : 59 PAGE NO. PLATE NO. : 59 A PAGE NO.
ELECTRICAL EQUIPMENTS 113 ELECTRICAL EQUIPMENTS 115 GRAB HANDLE AND SAREE GUARD 121 GRAB HANDLE AND SAREE GUARD 123
1 2
Front Wheel Direction
Plate No.: 2
SAI System
Qty.
No. Part No. Description 200 200 Remarks
NS AS
5 6
Front Wheel Direction
Plate No.: 3A
BS IV
Cyl Head New Casting Circulars IB:303
Qty.
No. Part No. Description 200 200 Remarks
NS AS
1
1 36 Jl01 44 Kit Cyl Head(new Casting) 1 –
2 52 Jl12 66 Cyl Head (new Casting) 1 –
2
3 36 JL01 45 Kit Cyl Head(new Casting) 1 –
9
4 JL 5110 80 Cyl Head (new Casting) 1 –
5 5 JL 5112 41 Camshaft Assembly 1 –
10
6 JL 5112 49 Shaft Rocker Arm 2 –
6 7 JL 5112 54 Plate Stopper Rocker Shaft 1 –
11 8 JL 5111 12 Sleeve Spark Plug 1 –
9 KJ AC18 24 O-ring 1 –
7
12 10 JL 5112 50 Spacer Camshaft 1 –
11 39 0594 17 Internal Circlip 1 –
13 12 LA E000 14 Bolt Flanged 1 –
8
13 JG 5112 69 Bolt Flange 1 –
4
9
5
10
6
11
7
12
13
8
5A 6B
Front Wheel Direction
Plate No.: 4
BS IV
Valve
Qty.
8 No. Part No. Description Remarks
200 200
NS AS
10
3
3
7 8
Front Wheel Direction
Plate No.: 5
BS IV
Camshaft / Tensioner
Qty.
No. Part No. Description 200 200 Remarks
NS AS
15
9 10
Front Wheel Direction
Plate No.: 6
BS IV
Cylinder and Piston
Qty.
No. Part No. Description 200
Qty.
200 Remarks
NS AS
4 5
11 12
Front Wheel Direction
Plate No.: 7
BS IV
Crankshaft
Qty.
No. Part No. Description 200 200 Remarks
NS AS
13 14
Front Wheel Direction
Plate No.: 8
BS IV
Transmission
26 Qty.
No. Part No. Description 200 200 Remarks
NS AS
15 16
Front Wheel Direction
Plate No.: 9
BS IV
Change Drum / Shift Fork
Qty.
No. Part No. Description 200 200 Remarks
NS AS
4 7
5
9
6
17 18
Front Wheel Direction
Plate No.: 10
BS IV
Gear Change Mechanism
Qty.
No. Part No. Description 200 200 Remarks
NS AS
15 12
11 1 JL 5614 01 Assembly Lever Complete Change 1 1
10
JL 5612 05 Assembly Shift Lever- Ball Joint 1 1 From Dec’15
2 JL 5614 04 Assembly Lever Change Arm 1 1
JL 5612 06 Assembly Arm Change Ball Joint 1 1 From Dec’15
13
3 DH 1015 09 Damper 1 1
4 JL 5614 05 Rod Tie 1 1
52 JF00 62 Tie Rod With Nut Assly 1 1 From Dec’15
5 JD 5614 16 Washer - Nylon (Dia6.5Xd15X2.0) 2 2 Till Nov’ 15
6 39 0808 08 Pin - Split 2 2 Till Nov’ 15
7 JL 5614 07 Boot -Change Arm 1 1 Till Nov’ 15
8 JL 5614 08 Boot -Change Lever 1 1 Till Nov’ 15
9 39 1902 04 Bolt - Flange :- M6 1 1
Till Nov15 From Dec 15
9 10 JG 5612 00 Lever Gear Shift Assy Comp. 1 –
DT 5612 06 Lever Gear Shift Assy Comp. – 1
3 2 2a 11 JG 5612 15 Compression Spring 1 1
1
12 JG 5612 18 Torsion Spring 1 –
6
JG 5612 32 Torsion Spring – 1
13 JG 5612 17 Bush-Torsion Spring 1 1
5 14 JL 5614 09 Bolt Gear Change Lever 1 1
4 7 1a 4a 15 JL 5614 10 Washer - Steel 1 1
16 16 01 1009 05 ‘O’ Ring 2 2
14
5
8
19 20
Front Wheel Direction
Plate No.: 11
BS IV
Engine Assembly / Crankcase RH
Qty.
3 No. Part No. Description Remarks
200 200
NS AS
2 1 JL 5010 03 Assembly Engine 1 – N.I.
JL 5010 14 Assembly Engine 1 – for Argentina
JL 5010 40 Assembly Engine – 1
JL 5010 63 Assembly Engine 1 – BS IV (Nepal / B’Desh)
5 4 2 36 JL00 95 Kit Assly Cr. Case RH-New 1 1
6 3 39 1931 20 Ball Bearing 28 X 68 X 18 1 1
4 JG 5410 46 Balancer Bearing Stopper 1 1
JY 5410 47 Stopper I/P Shaft Bearing 1 – BS IV
5 LA D000 77 Bolt Flanged M6x16 1 1
6 36 Jl00 39 Special Shaft Seal Ring (oil) 2 2
8 7 LE B000 01 Circlip Internal 1 1
8 39 2602 20 Bearing - Ball 6202/HN3 1 1
9 AA 1014 37 Screw : Pre-coated 1 1
11 10 JG 5410 59 Plate Stopper Bearing Drum 1 1
11 39 2601 20 Bearing - Ball :- 61905 (25 X 42 X 9) 1 1
9 10 12 LB B000 06 Screw Pan head 3 3
13 JU 5410 05 Breather Plate 1 1
13 14 59 2000 28 Bearing Ball RH 1 1
15 JG 5612 04 Bolt Drum Stopper 1 1
16 JG 5612 05 Washer 1 1
12 17 JG 5610 09 Stopper Drum Complete 1 1
18 39 2005 11 Washer 1 1
19 JG 5612 26 Spring 1 1
20 39 2562 20 Bearing - Needle Roller :- 13X19X12 1 1
21 39 0746 01 Screw Pan Cross - M6 1 1
LB B000 07 Screw Pan Cross - M6 1 – BS IV
14 22 JG 5410 45 Input Shaft Bearing Stopper 1 1
23 DP 1011 91 Bolt Shifter 1 1
22 24 JG 5710 14 Oil Filter 1 1
21
25 JG 5710 16 O-Ring 1 1
26 JE 5412 18 Cap Oil Filter (MAGD3) 1 – Ref. Cir. IB-82
17 JL 5412 37 Cap Oil Filter – 1
18 56 JL1X 3V Cap Oil Filter (JL571001) “slate Grey” 1 – BS IV
15 6 27 KA DP05 16 Hexagonal Flange Bolt 2 2
7 KA EQ06 16 Bolt Flange Small 2 – BS IV
20
28 39 0594 17 Internal Circlip 1 –
19 29 JL 6010 10 Water Seal Double Lip 1 – BS IV
23 27
16
24 25 26
21 22
Front Wheel Direction
Plate No.: 12
BS IV
Crankcase LH
Qty.
No. Part No. Description 200 200 Remarks
NS AS
18
23 24
Front Wheel Direction
Plate No.: 13
BS IV
Balancer Idler Gear / Water Pump
Qty.
No. Part No. Description 200 200 Remarks
NS AS
25 26
Front Wheel Direction
Plate No.: 14
BS IV
Oil Pump
Qty.
No. Part No. Description 200 200 Remarks
NS AS
3
4
27 28
Front Wheel Direction
Plate No.: 15
BS IV
Radiator
Qty.
No. Part No. Description 200 200 Remarks
NS AS
25
1 JL 6012 10 Cowl Radiator 1 1
18 2 DJ 1810 65 Nut - Clip :- M6 3 3
1
5 4 3 3 JL 1812 56 Grommet For Radiator Cowl 3 3
4 JL 6012 31 Sleeve Cowl Mounting 3 3
2730 17 5 39 1944 04 Bolt-Flange Dia-06 L-12 3 3
31
15 29 20 6 JL 6010 00 Hose Thermostat To Radiator 1 1
7 JG 6012 34 Clamp Radiator Pipe 2 2
8 JG 6012 09 Clamp Radiator Pipe Dia 19.8 2 2
9 JL 6012 20 Coolant Hose Radiator To T 1 1
23
10 JL 6012 19 Hose By Pass To Pump 1 1
11 JL 6012 12 Clamp Radiator Dia 19 1 1
12 JL 6012 28 Coolant Pipe T Assembly 1 1
16 24
13 LJ A000 05 O-Ring Coolant Pipe 1 1
14 DJ 1013 02 Bolt - Hexagon Head 2 2 alternate
LA E000 41 Bolt Flange 2 - BS IV
15 JL 6012 00 Radiator Assly 1 1
19 16 JG 6012 37 Radiator Fan 1 1
6
22 17 JG 6012 35 Pressure Cap Radiator (Metallic) 1 1
18 JG 6012 11 Cap Expansion Tank 1 1
7 19 JL 6012 15 Clamp -Expansion Tank 2 2
11
21 20 JG 1710 29 Spring Band Clip 10 Mm 3 3
32 21 JL 6012 35 Expansion Tank Assly. 1 1
28 9 22 DJ 1810 65 Nut - Clip :- M6 2 2
23 KA DF06 16 Bolt - Flanged 2 2
26
24 JL 6012 27 Hose -Expansion Tank 1 1
8 25 JL 6012 14 Hose -Expansion Tank Top 1 1
26 LA D000 40 Bolt Flange M6 - 6L 3 3
27 39 2704 11 Washer Spring 4 4
11 28 JG 5810 14 Silent Block 4 4
10 12
14 29 JG 6012 30 O Ring Expansion Tank 1 1
30 39 2704 11 Plain Washer 4 4
31 JL 6012 16 Rubber Damper Radiator Mtg, 2 2
13 32 JL 6012 34 Radiator Core 1 1
29 30
Front Wheel Direction
Plate No.: 16
BS IV
Cover Clutch
Qty.
No. Part No. Description 200 200 Remarks
NS AS
31 32
Front Wheel Direction
Plate No.: 17
BS IV
Cover Magneto
Qty.
No. Part No. Description 200 200 Remarks
NS AS
6
8
9
10
6
6
33 34
Front Wheel Direction
Plate No.: 18
BS IV
Clutch Assly
Qty.
No. Part No. Description 200 200 Remarks
NS AS
14 1 JU 5514 04 Clutch Assy Comp 1 –
DT 5514 00 Clutch Assy Comp 1 1 BS IV
13
DT 5514 09 Clutch Assy Comp 1 1 From July 2017
12 2 JG 5514 27 Collared Bush 1 1
11 DT 5514 12 Collar 1 1 From July 2017
8 3 36 JL00 05 Kit Set Primary Drive & Driven Gear 1 1 N.I
10
9 36 DT00 33 Kit Gear Primary Drive & Driven 1 1
16 15 36 DT00 55 Kit Cl Housing & Primary Gear 1 1 From July 2017
17 4 JG 5514 28 Washer Clutch 1 1
5 JG 5514 49 Plate (Wheel Clutch) 1 –
DT 5514 02 Clutch Pressure Plate 1 1 BS IV
6 6 36 JU00 02 Kit Friction Plate 1 1 FOR JU551404
JG 5514 48 Friction Plate – 4 FOR DT551400 & DT551409
JG 5514 55 Friction Plate – 2 FOR DT551400 & DT551409
7 JG 5514 47 Pressure Plate 5 5
DT 5514 08 Pressure Plate 5 5 BS IV
8 JG 5514 43 Clutch Holder 1 –
5 DT 5514 01 Clutch Center 1 1 BS IV
9 JU 5514 06 Clutch Center_G2 1 1
7
10 JU 5514 02 Spring -Clutch 4 –
3 4
DT 5514 03 Spring -Clutch 4 4 BS IV
11 JG 5514 51 Bolt Sh 6*22 4 4
12 39 2200 11 Washer - Plain (Primary Drive Gear) 1 1
13 DH 1016 48 Nut Clutch Center Lock (Pre-coated) 1 1
2 14 JG 5514 23 Clutch Lifter Bearing 1 1
15 DP 1012 43 Plate Judder Spring 1 –
1 16 DP 1011 14 Spring Anti Judder 1 –
17 DP 1011 09 Plate Friction Reduced 1 –
35 36
Front Wheel Direction
BS IV
Plate No.: 19
Carburettor
Qty.
No. Part No. Description 200 200 Remarks
13 9 NS AS
1 JL 5812 01 Carburetor 1 1
5 JL 5812 15 Carburetor Assly EVAP Non TPS 1 - BS IV ( Nepal / B’Desh)
JL 5812 17 Carburetor Assly W/O EVAP & TPS 1 - BS IV
2 JL 5813 00 Clamp (Duct Carburetor) 1 1
3 JL 5110 16 Insulator Rubber 1 1
8 4 JL 5810 27 Clamp 1 1
5 36 JL00 19 Kit Jet P200 1 1
6 36 JL00 20 Kit VC Screw P200 1 1
7 36 JL00 21 Kit Idling Screw 1 1
18
6 8 36 JL00 22 Kit Piston Valve P200 1 1
9 36 JL00 24 Kit Jet Needle Hardware P200 1 1
10 36 JL00 23 Kit Gasket / O-ring P200 1 1
20 11 JA 5813 14 Drain Screw 1 1
16
12 CB 1210 42 Float Chamber Screw 2 2
13 DH 1210 64 Screw Needle Shaft 3 3
17 14 DH 1210 63 Float Needle 1 1
15 DK 1210 47 Needle Assly. 1 1
15 16 39 1780 01 Screw Pan - M5 2 2
2
3 4 17 JD 3518 00 TPS Assly. 1 1
5
18 JL 5812 04 Choke Lever 1 1
7
19 JL 5812 05 Tube Drain Carb. 1 1
14 20 JL 5812 06 Tube Breather 1 1
21 DK 1210 45 Float Assembly 1 1
21
22 22 36 JE00 22 Kit O Ring & Gasket 1 1
13
12 11
19
37 38
Front Wheel Direction
Plate No.: 20
BS IV
Air Cleaner Complete
Qty.
No. Part No. Description 200 200 Remarks
5
NS AS
18
14
10
12
12
13 11
39 40
Front Wheel Direction
Plate No.: 21
BS IV
EVAP Mechanism
Qty.
No. Part No. Description 200 200 Remarks
NS AS
1 JY 1710 77 Canister 1 – BS IV
2 JZ 1710 55 Strap Canister 1 – BS IV
20 21 3 JL 1138 30 Bracket Canister Mounting 1 – BS IV
4 KA EA06 12 Bolt - Flanged - Small 1 – BS IV
5 JY 1710 70 Spring Band Clamp 9 x 8.4 2 – BS IV
13 6 JL 1718 37 Tube Y Connector To Canister 1 – BS IV
14 7 7 JY 1710 90 Spring Band Clamp 13 x 12 5 – BS IV
12
2 8 JY 1138 42 Connector Y Shape 1 – BS IV
15
11 9 JF 1716 07 Tube Connector To Plug 1 – BS IV
7
19 10 JY 1718 25 Plug Fuel Drain 1 – BS IV
11 JY 1710 69 Spring Band Clamp 15 x 10 1 – BS IV
7 12 JF 1718 04 Tube Canister To Connector 1 – BS IV
6
8 3 5 13 JF 1138 38 Bracket Purge Valve Mounting 1 – BS IV
1
17 14 JH 1710 48 Grommet Purge Valve 1 – BS IV
4 15 PD 1716 16 Valve Purge 1 – BS IV
7
16 JF 1718 07 Tube Canister Drain 1 – BS IV
2
18 16 17 JG 1710 29 Spring Band Clamp 11.5 x 8.4 2 – BS IV
18 JL 1716 07 Tube Purge Valve To Carb. 1 – BS IV
17 9
19 JF 1718 06 Tube Tank To Y Connector 1 – BS IV
20 JD 1710 59 Evap Cap Rubber Bush Sealing 1 – BS IV
21 DT 1138 49 Strap 1 -- BS IV
7
10
41 42
Front Wheel Direction
Plate No.: 22
BS IV
Silencer Assembly
Qty.
No. Part No. Description 200 200 Remarks
NS AS
4
5
3 12
43 44
Front Wheel Direction
Plate No.: 23
BS IV
Starter Assembly
1 Qty.
No. Part No. Description 200 200 Remarks
NS AS
19
45 46
Front Wheel Direction
Plate No.: 24
BS IV
Magneto, CDI & H.T. Coil
Qty.
No. Part No. Description 200 200 Remarks
7
4 NS AS
13 13
14 1 DK 1110 28 Spark Plug RG6HC 2 2
8 2 JG 3512 09 Ignition Spark Plug 1 1
JL 3512 18 Plug Spark 1 - BS IV
3 JL 3512 00 DC CDI With Sealed Coupler 1 –
JL 3512 41 DC CDI With Sealed Coupler – 1
13 JL 3512 46 CID Non Tps Assly 1 – BSIV EVAP & NON EVAP
13 4 DD 1110 12 Grommet For H. T. Cable 2 2
5 JD 3512 07 Spark Plug Cap 1 1
12 6 AN 1110 15 Spark Plug Cap 1 1
10 6 7 JL 3512 01 Ignition Coil with Cable LH 1 – Twin Output
9 JL 3512 32 Coil HT 1 1 BSIV EVAP & NON EVAP
5 9 8 JL 3512 02 Ignition Coil with Cable RH 1 –
JL 3512 30 Coil HT 1 1 BSIV EVAP & NON EVAP
9 DH 1110 13 Grommet - Spark Plug 2 2
11
2 10 DH 1110 16 Grommet - Sleeve Spark Plug 1 1
11 DD 1110 11 Grommet - Spark Plug Cap 1 1
1
1 12 DK 1110 11 Cap Spark Plug 1 1
13 39 1944 04 Bolt - Flanged 4 4
3 KA DF06 10 Bolt - Flanged 4 - BS IV
14 JL 4020 01 Regulator Assly 1 1
15 JL 4020 07 Regulator Assly 1 - BS IV
JL 4020 02 Regulator Assly 1 – For Argentina
15 JL 1138 36 Bracket Cdi Mtg Loose 1 1
16 JL 3512 19 Kit Ht Coil 1 - Model BS IV
47 48
Front Wheel Direction
Plate No.: 25
BS IV
Seat Assembly / Seat Lock
Qty.
No. Part No. Description 200 200 Remarks
3 NS AS
8 11
10
9
49 50
Front Wheel Direction
Plate No.: 26
BS IV
Engine Mountings
Qty.
No. Part No. Description 200 200 Remarks
NS AS
9
5
5
6 3
9
7
1
51 52
Front Wheel Direction
Plate No.: 27
BS IV
Frame and Frame Fittings
Qty.
No. Part No. Description 200 Remarks
10 200
NS AS
11 2 1 JL 1111 06 Frame Assly Complete 1 –
JL 1112 01 Frame Assly 1 – Ref. Cir. IB-140
5 JL 1111 83 Frame Assly – 1
JL 1112 33 Assly Frame EVAP 1 - BSIV EVAP & NON EVAP
2 JL 1111 03 Cap Tube End 2 2
4 1 3 JL 1110 81 Bracket Loose H.T. Coil 1 1 1
3 4 JL 1110 82 Bracket Loose H.T. Coil 2 1 1
7 5 39 1944 04 Bolt - Flanged 4 1
6 JL 1110 78 Bracket Horn Mtg LH 1 –
JL 1138 29 Bracket Horn Mtg LH – 1
7 36 JG00 11 Kit Steering head bearing 1 1
8 JG 5810 14 Silent Block 4 4
9 LA D000 40 Bolt Flange 2 2
10 PD 1510 06 Cup Steering 1 1
9 11 DK 1810 75 Nut Steering 1 1
6
12 DT 1813 22 Plug -1 1 - BS IV
13 DT 1138 55 Clamp 2 - BS IV
53 54
Front Wheel Direction
Plate No.: 28
BS IV
Swing Arm / Rear Shock Absorber
Qty.
No. Part No. Description 200 200 Remarks
NS AS
55 56
Front Wheel Direction
Plate No.: 29
BS IV
Pillion Foot Rest / Holder
8 Qty.
7 No. Part No. Description Remarks
200 200
NS AS
6
1
1 JL 1130 02 Holder Step RH 1 1
56 JL3Y 1Y Holder Step RH Slate Grey 1 – BSIV
2 52 JL01 59 Step Assy Main RH (MTL Color) 1 1
52 JL10 35 Step Assly Main RH Slate Grey 1 – BSIV
3 JL 1130 12 Spring Torsion 1 1
4 4 36 Jl00 41 Kit Main Step Hardware 2 2
20 3 5 JL 1130 36 Rubber Main Step Pillion 2 2
6 KA CA08 20 Bolt-Socket Dia-08 L-20 4 4
7 JL 1130 15 Step Holder - Pillion RH 1 1
23 56 JL4K 1Y Step Holder Pillion Rh Slate Grey 1 – BSIV
12 2 8 LA C000 16 Bolt Socket M8X35 4 4
LA C000 46 Bolt Socket 4 – BS IV
9 36 JL00 15 Kit Pillion Hardware 2 2
5 9 10 JL 1130 16 Step Pillion Assy Complete RH 1 1
56 JL02 01 Step Pillion Assy RH (Moon light silver) 1 1
56 JF19 1Y Step Pillion Rh Slate Grey 1 – BSIV
11 JL 1130 27 Flap Pillion Holder RH 1 1
13
10 56 JL4M 1Y Flap Holder Rh Slate Grey 1 – BSIV
11
12 KA DE06 10 Bolt - Flanged :- Small 4 4
13 DT 1130 15 Lock Plate RH 1 1
8 16 14 52 JL01 58 Step Assly Main LH(MTL Color) 1 1
52 JL10 24 Step Assly Main Lh Slate Grey 1 – BSIV
15 JL 1130 34 Holder Step LH 1 1
56 JL3X 1Y Holder Step Lh Slate Grey 1 – BSIV
16 JL 1130 13 Step Holder Pillion LH 1 1
56 JL4J 1Y Step Holder Pillion Slate Grey 1 – BSIV
17 56 JL01 01 Step Pillion Assy LH (moon light silver) 1 1 Ref. Cir IB-82
15 56 JF18 1Y Step Pillion Lh K10 Slate Grey 1 – BSIV
4 6
18 DT 1130 14 Lock Plate LH 1 1
19 JL 1130 26 Flap Pillion Holder LH 1 1
14 56 JL4L 1Y Flap Holder Lh Slate Grey 1 – BSIV
22 20 JL 1130 33 Bracket Rear Brake Switch 1 1
3 4 21 JL 1130 38 Step bolt 1 1
9 22 39 1055 15 Nut Hex. with flange- M10 1 1
23
23 JZ 1130 61 Rubber Pad Step 2 2
5
21 18 19
17
57 58
Front Wheel Direction
Plate No.: 30
BS IV
Mudguard - Front & Rear
11A Qty.
No. Part No. Description 200 200 Remarks
NS AS
59 60
Front Wheel Direction
Plate No.: 31
BS IV
Stand Assembly
Qty.
No. Part No. Description 200 200 Remarks
4 NS AS
9
14
15
16
61 62
Front Wheel Direction
Plate No.: 32
BS IV
Tube / Tyre / Rim
Qty.
No. Part No. Description 200 200 Remarks
NS AS
4 5
2
63 64
Front Wheel Direction
Plate No.: 33
BS IV
Front Hub
Qty.
No. Part No. Description 200 200 Remarks
NS AS
8
15
16
65 66
Front Wheel Direction
Plate No.: 34
BS IV
8 15
9
10
10
11
67 68
Front Wheel Direction
Plate No.: 35
BS IV
Front Disc Brake
Qty.
No. Part No. Description 200 200 Remarks
NS AS
6 2 PISTON SEAL
DUST SEAL
BLEEDER CAP
PROTECTION BOOT
INSULATOR
CALIPER PISTON
69 70
Front Wheel Direction
Plate No.: 36
BS IV
Rear Hub
Qty.
No. Part No. Description 200 200 Remarks
NS AS
1 3
1 DK 1510 36 Lock Set 1 1
2 36 JL00 09 Kit Chain Sprocket 1 1
5
16 3 39 2241 20 Bearing - Ball 1 –
17
4 KP BC62 02 Bearing - Ball – 1
4 39 2242 20 Bearing - Ball 1 –
KP BC63 02 Bearing - Ball – 1
5 JL 1312 16 Collar Bearing Assy 1 1
6 JL 1312 32 Coupling Rubber 1 1
2 7 JL 1312 25 Coupling 1 1
8 DK 1510 13 Bearing Coupling 1 1
9 DK 1510 12 Oil Seal 2 2
30 1510 82 Oil Seal 2 - BS IV
6
10 LA A000 19 D Bolt 6 6
11 JL 1312 26 Washer 6 Rubber 3 3
7
12 LC A000 09 Nut 6 6
9 8
19 13 JL 1312 03 Axle 1 1
18 14 DK 1510 15 Sleeve 1 1
15 JL 1312 11 Spacer for Coupling 1 1
10
16 JL 1312 18 Disc Rear 1 –
52 JL01 42 Disc Rear (Black) 1 1 Ref. Cir. IB-82
JL 1319 30 Disc Rear 1 1 From JUL'16
11 17 39 2038 04 Bolt Hex 6 6
12 18 LD B000 29 Washer 2 2
19 LC J000 02 Nut - U 1 1
13
20 DK 1510 81 Spacer I 1 1
21 DK 1510 82 Spacer II 1 1
71 72
Front Wheel Direction
Plate No.: 37
BS IV
Rear Disc Brake System
Qty.
No. Part No. Description 200 200 Remarks
24 NS AS
5 23
20 1 DK 1510 83 Assembly Caliper 1 1
JL 1318 34 Assembly Caliper 1 - BS IV
6 2 DK 1510 31 Assembly Master Cyl. Rear 1 1
4
JL 1319 31 Cyl. Assly Master Rr. 1 - BS IV
19
3 JL 1318 03 Hose Disc Brake Rear 1 1
4 DK 1510 69 Banjo Bolt 2 2
2 22
5 JG 1318 21 Reservoir Rear Brake 1 1
6 JL 1312 20 Hose - Reservoir 1 1
7 DK 1510 63 Clip Reservoir 1 1 Cap Reservoir (N.I.)
3
8 DE 1910 10 Copper Washer 4 4 Banjo Bolt (N.I.)
9
10 9 DE 1510 47 Cap Bleeder Screw 1 1
14 12 4 10 DE 1510 46 Bleeder Screw 1 1
16 15
11 DK 1510 88 Caliper Piston Kit 1 1
1 12 DK 1510 89 Caliper Piston Seal Kit 1 1
PISTON SEAL 13 DK 1510 85 Set Disc Pad 1 1
14 30 1910 38 Pin 1 1
DUST SEAL
15 39 0198 11 Washer Plain 1 1
LD B000 18 Washer Plain 1 - BS IV
16 39 0808 08 Split Pin 1 1
17 DK 1510 73 Master Cyl. Major kit 1 1 N.I.
CALIPER PISTON 18 DK 1510 74 Master Cyl. Minor kit 1 1 N.I.
19 JL 1318 77 Clamp 1 1
20 DK 1510 45 Cap Reservoir Rear Brake 1 1
21 36 JG00 18 Reservoir with Cap Rear Brake 1 1 N.I.
22 JL 1318 41 Bracket Reservoir mounting 1 1
11 13 23 JL 1318 78 Bracket Reservoir Cap 1 1
24 39 1698 01 Screw 1 1
KB BA05 12 Screw Pan Cross 1 - BS IV
25 DK 1510 90 Insulator Kit 1 1 N.I
73 74
Front Wheel Direction
Plate No.: 38
BS IV
Rear Brake Pedal
Qty.
No. Part No. Description 200 200 Remarks
NS AS
6
3
5
7
75 76
Front Wheel Direction
Plate No.: 39
BS IV
Handle Bar Assly
Qty.
No. Part No. Description 200 200 Remarks
NS AS
22 1 JL 1510 21 Handle Bar Tube LH assly. 1 1
2 JL 1510 26 Holder Handle LH 1 –
56 JL31 5X Holder Handle LH (Stoic Black) 1 1 Ref. Cir. IB-82
21 20 2A JL 1510 38 O ring 4 4
21 3 39 1180 11 Washer - Plain 2 –
KD BA08 18 Washer - Plain – 2
4 LA C000 20 Bolt Socket M8X1.25Px55L 2 2
19 5 JL 1510 28 Plug Handle Holder 2 2
6 JL 1510 30 Holder Handle RH 1 –
56 JL32 5X Holder Handle RH (Stoic Black) 1 1 Ref. Cir. IB-82
3 7 JL 1510 34 Handlebar Tube Assy RH 1 1
8 DG 1810 08 Bolt - Socket 4 4
7 9 JL 1510 35 Handlebar Weight 2 2
11 4
2A 10 39 2427 04 Bolt - Hexagon Socket Head Cap:M6 2 2
12 11 DJ 1910 82 Lever & Support Holder Assly LH 1 –
JL 1610 15 Lever & Support Holder Assly LH – 1
10 JL 1610 13 Lever & Support Holder Assly 1 - BS IV
12 DJ 1910 83 Lever LH For New Clutch Switch 1 –
5 9 JG 1610 08 Lever LH For New Clutch Switch – 1
1
6 13 DJ 2012 46 Clutch Switch (6Amp Diode) 1 – N.I.
3
JL 4014 11 Clutch Switch – 1
15
14 JL 1610 03 Handle Grip LH 1 1
2A 2 15 JL 1610 08 Grip Hand Assy RH 1 –
8 DT 1610 05 Grip Hand Assy RH – 1
16 DH 1910 17 Pipe - Throttle 1 1 N.I.
17 JL 1510 23 Lock Set 3 In 1 1 – N.I.
17 DT 2326 01 Lock Set 3 In 1 – 1
JL 2326 05 Lock Set 3 In 1 +Tank Cap 1 – BS IV
14 18 18 JL 4014 03 Switch Ignition 1 – For JL151023
19 JL 4014 00 Switch Control LH 1 –
9 JL 4014 09 Switch Control LH – 1
10 23
20 JL 4014 01 Switch Control RH 1 –
JL 4014 10 Switch Control RH – 1
JL 4014 05 Switch Control RH AHO 1 – BS IV
21 JL 2316 01 Mirror Assly RH 1 1
22 JL 2316 00 Mirror Assly LH 1 1
23 DS 1910 52 Lever Boot LH 1 - BS IV
77 78
Front Wheel Direction
Plate No.: 40
BS IV
Front Fork
Qty.
No. Part No. Description 200 200 Remarks
NS AS
79 80
Front Wheel Direction
Plate No.: 40 A
BS IV
Front Fork
Qty.
No. Part No. Description 200 200 Remarks
NS AS
8 20
9
10 21
19
15 10
13
2/3
21
20
5
22
4
23
24
29
81 82
Front Wheel Direction
Plate No.: 41
BS IV
Radiator Covers
Qty.
No. Part No. Description 200 200 Remarks
NS AS
4
3 7
8
83 84
Front Wheel Direction
Plate No.: 42
BS IV
Petrol Tank, Cap Tank and Gauge Fuel
Qty.
3 No. Part No. Description Remarks
200 200
7 NS AS
85 86
Front Wheel Direction
Plate No.: 43
BS IV
Fittings - Petrol Tank Cover, Side Covers & Cover Seat
Qty.
No. Part No. Description 200 200 Remarks
7 6 4 4 5 6
8 3 7 NS AS
6 12
5 1 JL 1710 99 Bracket Side Cover Mtg RH 1 –
3 9 2 JL 1710 22 Bracket Side Cover Mtg LH 1 –
12 6 10 10 3 JL 1710 57 Damper 4 –
4 4 JL 1710 71 Tank Cover Mtg Sleeve 8 –
5 JL 1710 24 Damper Structure Mtg 2 –
1 6 JL 1710 70 Rubber Grommet 8 –
2 ‘ 7 LA C000 63 Bolt - Socket :- M6 2 –
4 8 JL 1710 62 Cover Mesh Rh 1 –
9 JL 1710 61 Cover Mesh LH 1 –
10 KA DB05 16 Bolt Flanged 2 –
RH Mounting LH Mounting 11 DJ 1612 29 Clip Nut M5 16 –
12 LA C000 22 Bolt Socket-Special Head 4 –
13 KB UB05 16 Screw Truss 8 –
14 KA DA05 12 Screw - Truss Cross : M5 2 –
15 JL 1710 78 Pad Tank Cover 1 –
17 16 JL 1111 02 Bracket Side cover Mtg 1 –
13 12 17 JL 1710 48 Tank Cover Central 1 –
11 18 LA C000 34 Bolt M6 X 20 2 –
13
11
15
16 18
14
87 88
Front Wheel Direction
Plate No.: 44
BS IV
Fittings - Cover Seat Pulsar 200 NS
Qty.
No. Part No. Description 200 200 Remarks
NS AS
11
89 90
Front Wheel Direction
Plate No.: 45
BS IV
Fittings - Fairing & Petrol Tank Cover - Pulsar 200 AS
Qty.
No. Part No. Description 200 200 Remarks
NS AS
4 15 14 1
1 JL 1814 49 Bracket Fairing Mounting LH – 1
2 JL 1814 47 Bracket Blinker Mounting LH – 1
3 JL 1814 48 Bracket Blinker Mounting RH – 1
4 JL 1814 50 Bracket Fairing Mounting RH – 1
5 39 1778 02 Screw – 12
6 KD AA04 08 Washer Plain – 12
7 LB R000 02 Screw Self Tapping – 6
8 KD BA05 12 Washer Plain – 6
12 9 JL 1814 56 Bracket Side Fairing Mtg LH – 1
12 11 10 JL 1814 57 Bracket Side Fairing Mtg RH – 1
11
6 11 LB U000 23 Screw Truss – 9
12 KD BA05 12 Washer Plain – 3
5 7 13 JL 1710 70 Tank Cover Grommet – 2
3 9 2 14 JL 1710 71 Tank Cover Mtg Sleeve – 2
10 6 15 JL 1710 24 Damper – 4 N.I
16 KA DA06 30 Bolt Flanged – 2
17 KA DA05 12 Bolt Flanged – 4
27 18 KD BB05 12 Washer – 2
26
19 LA C000 63 Bolt Socket – 2
20 LA C000 34 Bolt M6 – 2
5 6 21 LD B000 23 Washer Plain – 4 N.I
25 22 LA C000 22 Bolt Socket Head – 2
11 22 23 31 1610 78 Washer Nyloc – 2
19 24 JL 1710 78 Pad Tank Cover – 1
23 25 JL 1814 39 Cvr Tank Top Inner – 1
26 JL 1814 24 Sub Assly Side Fairing LH – 1
27 JL 1814 25 Sub Assly Side Fairing RH – 1
13
20
18 17
24
91 92
Plate No.: 46
BS IV
Fittings - Side Covers & Cover Seat Pulsar 200 AS
Qty.
No. Part No. Description 200 200 Remarks
NS AS
1 75 9 4
93 94
Front Wheel Direction
Plate No.: 47
BS IV
Meter Assembly
Qty.
No. Part No. Description 200 200 Remarks
NS AS
2
7
95 96
Front Wheel Direction
Plate No.: 48
BS IV
Control Cables
Qty.
No. Part No. Description 200 200 Remarks
NS AS
3
4
97 98
Front Wheel Direction
Plate No.: 49
BS IV
Chain Case and Hugger Assly
Qty.
No. Part No. Description 200 200 Remarks
14 13
NS AS
1
1 JL 1812 05 Cover Assly Chain 1 1
3
2 JG 1220 28 Extruded Washer 2 2
3 39 1791 04 Bolt Flanged M6X8 2 2
2
4 JL 1814 09 Asly Hugger Rear 1 –
4a DT 1814 14 Asly Hugger Rear 1 –
5 JL 1810 06 Tube Rear Hugger Mtg 1 –
11 5a DT 1810 00 Tube Rear Hugger Mtg 1 –
9
10 6 JL 1814 07 Cover 1- Hugger Rear 1 –
6a DT 1814 15 Cover 1- Hugger Rear 1 –
8 5 7 JL 1814 08 Cover 2- Hugger Rear 1 –
4
7 8 KB UF04 08 Screw 6 –
TILL OCT 2014 9 LA C000 37 Bolt Soc-special Head 3 –
6
10 39 0265 12 Spring Washer 2 –
11 LA C000 54 Bolt Special Socket 2 –
12 JL1814 10 Collar Hugger Rear 2 –
13 JL 1812 53 Chain Cover RH Side 1 1
14 LA C000 08 Bolt Socket Head 2 –
LA C000 54 Bolt Socket Head 2 2
9 5a
4a 8
AFTER OCT 2014 6a
7
99 100
Front Wheel Direction
Plate No.: 50
BS IV
Belly Pan Mounting BS IV
Qty.
No. Part No. Description 200 200 Remarks
NS AS
2
2
3 3
2
1
2 4
2
3
101 102
Front Wheel Direction
Plate No.: 51
BS IV
Head Lamp & Fairing - Pulsar 200 NS
1
Qty.
No. Part No. Description 200 200 Remarks
5
4 NS AS
103 104
Front Wheel Direction
Plate No.: 52
BS IV
Head Lamp & Fairing - Pulsar 200 AS
Qty.
No. Part No. Description 200 200 Remarks
1 NS AS
17
16
9 10 15 14
13
105 106
Front Wheel Direction
Plate No.: 53
BS IV
Indicator Light Assembly
Qty.
No. Part No. Description 200 200 Remarks
NS AS
1 5
3
5
107 108
Front Wheel Direction
Plate No.: 54
BS IV
Tail Lamp Assly / Front Number Plate - Pulsar 200 NS
15 16 Qty.
No. Part No. Description 200 200 Remarks
1 NS AS
21
109 110
Front Wheel Direction
Plate No.: 55
BS IV
Tail Lamp Assly / Front Number Plate - Pulsar 200 AS
Qty.
No. Part No. Description 200 200 Remarks
NS AS
111 112
Front Wheel Direction
Plate No.: 56
BS IV
Electrical Equipments
Qty.
No. Part No. Description 200 200 Remarks
NS AS
10 16
12 11
17 18
15A
21
19
113 114
Front Wheel Direction
Plate No.: 56 A
BS IV
Electrical Equipments
Qty.
No. Part No. Description 200 200 Remarks
NS AS
4
13
8
15
23
12A 14
9 20
10 16
12 11
17 18 15A
21
19
115 116
Front Wheel Direction
Plate No.: 57
BS IV
Tool Kit
Qty.
No. Part No. Description 200 200 Remarks
NS AS
1 2
117 118
Front Wheel Direction
Plate No.: 58
BS IV
Accessories / Grab Handle
Qty.
No. Part No. Description 200 200 Remarks
8 NS AS
9 9
1 2 8 1 JL 2312 01 Guard Leg LH 1 1
1a JL 2312 13 Guard Leg LH 1 - From Jan.2018
2 JL 2312 03 Guard Leg Guard Rh 1 1
2a JL 2312 14 Guard Leg RH 1 - From Jan.2018
2b LA C000 29 Bolt Socket Head 1 1
3 JL 2314 04 Grab Handle Assy Lh 1 1
4 JL 2314 05 Grab Handle Assy Rh 1 1
5 LA C000 17 Bolt Socket M8 X 1.25 4 4
11
12 6 JL 2312 02 Guard Saree 1 –
15 14
JL 2312 11 Guard Saree – 1
7 KA CB06 22 Bolt Socket L-22 3 2
5
6 7A 39 2038 04 Hex Socket Bolt – 1
8
10 6 8 KD BE06 13 Washer 4 4
7
9 KA CA06 35 Bolt Socket 2 –
LA C000 48 Bolt Socket – 2
3 10 LA D000 40 Bolt Flanged M6-6L 1 –
LA C000 48 Bolt Socket – 1
11 JU 2312 07 Nut Nylock M8 x 1.25 1 –
39 2723 15 Hex Nut – 1
2a
12 JU 2312 05 Nut Leg Guard Mounting 1 1
1a
13 JL 2312 09 Plug Saree Guard 3 3
14 KD AA10 18 Washer Plain Small 1 - BS IV
15 LD C000 01 Washer Leg Guard 1 - BS IV
119 120
Front Wheel Direction
Plate No.:59
BS IV
Painted Parts and Decals BS IV
Qty.
No. Part No. Description 200 200 Remarks
NS AS
121 122
Front Wheel Direction
Plate No.:59 A
BS IV
Painted Parts and Decals BS IV
Qty.
8 7 No. Part No. Description Remarks
200 200
NS AS
123 124
Plate No.: 60
BS IV
Painted Parts
Qty.
No. Part No. Description 200 200 Remarks
NS AS
1
1 36 JL01 14 Kit Dcl Fairing Red-Black BS IV 1 –
36 JL01 18 Kit Fairing Dcl W-Gray BS IV 1 –
36 JL01 22 Kit Fairing Dcl Bl-Gray 1 –
36 JL01 31 Kit Fairing Dcl Yl-Gray BS IV 1 –
125 126
Plate No.: 60 A
BS IV
Painted Parts
Qty.
No. Part No. Description 200 200 Remarks
NS AS
10
11
12
127 128
Front Wheel Direction
Plate No.:61
BS IV
Painted Parts and Decals
10A Qty.
No. Part No. Description 200 200 Remarks
NS AS
13 10/11
1 56 JL22 X3 Tank Cover Top 1 – common for all
10B 56 JL22 5Y Tank Cover Top - Metallic White 1 – For Iran
12
2 52 JL02 18 Tank Cover Side LH - Saffire Blue 1 –
7 56 JL20 X3 Tank Cover Side LH - Black 1 –
52 JL02 20 Tank Cover Side LH - White 1 –
9
52 JL02 16 Tank Cover Side LH - Red 1 –
3 52 JL02 19 Tank Cover Side RH - Saffire Blue 1 –
56 JL21 X3 Tank Cover Side RH - Black 1 –
52 JL02 21 Tank Cover Side RH - White 1 –
1 52 JL02 17 Tank Cover Side RH - Red 1 –
17 4 52 JL01 96 Side Mask RH - Saffire Blue 1 –
8 52 JL01 92 Side Mask RH - Black 1 –
2
52 JL01 98 Side Mask RH - White 1 –
52 JL01 94 Side Mask RH - Red 1 –
5 52 JL01 95 Side Mask LH - Saffire Blue 1 –
3 52 JL01 91 Side Mask LH - Black 1 –
5
52 JL01 97 Side Mask LH - White 1 –
15 52 JL01 93 Side Mask LH - Red 1 –
6 52 JL01 89 Front Fender Blue 1 –
6 14 JL 7501 X3 Front Fender Black 1 –
52 JL01 90 Front Fender White 1 –
4 52 JL01 88 Front Fender Red 1 –
7 56 JL10 5N Seat Cowl Assy - Blue 1 –
56 JL10 X3 Seat Cowl Assy - Black 1 –
56 JL10 5Y Seat Cowl Assy - White 1 –
56 JL10 4R Seat Cowl Assy - Red 1 –
8 52 JL00 54 Cover Side LH Assly 1 –
9 52 JL00 55 Cover Side RH Assly 1 –
129 130
Front Wheel Direction
Plate No.: 61 A
BS IV
Painted Parts and Decals
10A Qty.
No. Part No. Description 200 200 Remarks
NS AS
13 10/11
10 JL 2330 04 3D Decal Tank RH 1 –
10B 10A JL 2331 85 3D Decal Tank LH/RH 1 – For Iran
12
10B JL 2330 17 3D Tank Decal Set Rouser 1 – For Argentina
7
11 JL 2330 03 3D Decal Tank LH 1 –
9
JL 2332 39 3D Decal Silver 2 – w.e.f May’16
12 JL 2330 02 ‘B’ Logo 1 –
13 36 JL00 48 Fairing DCL Upper - Blue 1 –
3
5
15
6 14
131 132
Front Wheel Direction
Plate No.: 62
BS IV
Painted Parts and Decals New Decal Scheme As Per Cir IB-166
Qty.
No. Part No. Description 200 200 Remarks
NS AS
133 134
Front Wheel Direction
Plate No.: 63
BS IV
Painted Parts and Decals Old Decal Scheme Before Cir IB-166
Qty.
No. Part No. Description 200 200 Remarks
NS AS
135 136
Front Wheel Direction
Plate No.: 64
BS IV
Painted Parts and Decals (Old- up tp Oct. 2013_Refer Circular IB-82)
10A Qty.
No. Part No. Description 200 200 Remarks
NS AS
13 10/11
1 JL 7401 5P Tank Cover Top - Saffire Blue 1 –
10B JL 7401 5N Tank Cover Top - Black 1 –
12 JL 7401 5Q Tank Cover Top - Yellow 1 –
JL 7401 5M Tank Cover Top - Red 1 –
7 2 JL 7301 5P Tank Cover Side LH - Saffire Blue 1 –
JL 1710 45 Tank Cover Side LH - Black 1 –
9 JL 1710 45 Tank Cover Side LH - Yellow 1 –
JL 7301 5M Tank Cover Side LH - Red 1 –
3 JL 7302 5P Tank Cover Side RH - Saffire Blue 1 –
JL 7302 5N Tank Cover Side RH - Black 1 –
JL 1710 46 Tank Cover Side RH - Yellow 1 –
JL 1710 46 Tank Cover Side RH - Red 1 –
1 4 JL 7602 5P Side Mask RH - Saffire Blue 1 –
16 JL 7602 5N Side Mask RH - Black 1 –
8 JL 1812 34 Side Mask RH - Yellow 1 –
2 JL 7602 5M Side Mask RH - Red 1 –
5 JL 7601 5P Side Mask LH - Saffire Blue 1 –
JL 7601 5N Side Mask LH - Black 1 –
JL 7602 5Q Side Mask LH - Yellow 1 –
JL 1812 33 Side Mask LH - Red 1 –
3 6 52 JL00 65 Front Fender - Blue 1 –
5
52 JL00 66 Front Fender - Black 1 –
15 52 JL00 67 Front Fender - Yellow 1 –
52 JL00 59 Front Fender - Red 1 –
7 JL 7801 5P Seat Cowl Assly - Blue 1 –
6 14 JL 7801 5N Seat Cowl Assly - Black 1 – N.S
JL 1810 05 Seat Cowl Assly - Yellow 1 –
4 JL 7801 5M Seat Cowl Assly - Red 1 –
137 138
Front Wheel Direction
Plate No.: 64 A
BS IV
Painted Parts and Decals (Old- up tp Oct. 2013_Refer Circular IB-82)
10A Qty.
No. Part No. Description 200 200 Remarks
NS AS
13 10/11
8 52 JL00 54 Cover Side LH Assly 1 –
10B 9 52 JL00 55 Cover Side RH Assly 1 –
12 10 JL 2330 04 3D Decal Tank RH 1 –
10A JL 2331 85 3D Decal Tank LH/RH 1 – For Iran
7 10B JL 2330 17 3D Tank Decal Set Rouser 1 – For Argentina
11 JL 2330 03 3D Decal Tank LH 1 –
9 JL 2332 39 3D Decal Silver 2 – w.e.f May’16
12 JL 2330 02 ‘B’ Logo 1 –
13 36 JL00 26 Fairing Decal 1 –
14 36 JL00 27 Fender Decal - Red 1 –
36 JL00 28 Fender Decal - Blue 1 –
36 JL00 29 Fender Decal - Black 1 –
1
36 JL00 30 Fender Decal - Yellow 1 –
16 15 JL 2330 05 Decal Side Cover ‘4 Valve’ 2 –
8 16 JL 2330 06 Decal Seat Cowl ‘200 NS’ 2 –
2
3
5
15
6 14
139 140
Front Wheel Direction
Plate No.: 65
BS IV
Painted Parts and Decals
Qty.
No. Part No. Description 200 200 Remarks
7 NS AS
6
1 56 JL22 4R Tank Cover Top – 1 Passion Red
3 56 JL22 5N Tank Cover Top – 1 Saffire Blue
56 JL22 X3 Tank Cover Top – 1 Ebony Black
2 2 52 JL03 52 Side Fairing Front LH Red – 1
15 52 JL03 53 Side Fairing Front LH Blue – 1
52 JL03 54 Side Fairing Front LH Black – 1
1
16 3 52 JL03 49 Side Fairing Front RH Red – 1
52 JL03 50 Side Fairing Front RH Blue – 1
52 JL03 51 Side Fairing Front RH Black – 1
4 4 JL 7501 5L Fender With Decal – 1 Passion Red
9
52 JL00 65 Fender With Decal – 1 Saffire Blue
JL 7501 X3 Fender With Decal – 1 Ebony Black
5 52 JL03 55 Seat Cowl – 1 Passion Red
52 JL03 56 Seat Cowl – 1 Saffire Blue
52 JL03 57 Seat Cowl – 1 Ebony Black
6 56 JL14 4R Side Mask LH – 1 Passion Red
56 JL14 5N Side Mask LH – 1 Saffire Blue
56 JL14 X3 Side Mask LH – 1 Ebony Black
5 7 56 JL15 4R Side Mask RH – 1 Passion Red
56 JL15 5N Side Mask RH – 1 Saffire Blue
8 56 JL15 X3 Side Mask RH – 1 Ebony Black
8 52 JL00 54 Cover Side LH Assly – 1
9 52 JL00 55 Cover Side RH Assly – 1
10A 10 JL 2330 03 3D Decal Tank – 2
10A JL 2331 85 3D Decal Tank – 2 For Iran
10 13 11 JL 2330 05 Decal Side Cover 4 Valve – 2
12 JL 2331 53 Decal Adventure – 2
12A 12A JL 2331 90 Decal Adventure – 2 For Iran
12 14 11
141 142
Front Wheel Direction
Plate No.: 65 A
BS IV
Painted Parts and Decals
Qty.
No. Part No. Description 200 200 Remarks
7 NS AS
6
13 36 JL00 28 Kit Decal Fender – 1 Blue
3 36 JL00 61 Kit Decal Fender – 1 Red
36 JL00 60 Kit Decal Fender – 1 Black
2 36 JL00 90 Kit Decal Fender – 1 White For Iran
15 14 JL 2331 55 Seat Cowl Decal – 2
15 56 JL66 4X Side Fairing RR RH – 1
1 16 56 JL67 4X Side Fairing RR LH – 1
16
4
9
10A
10 13
12A
12 14 11
143 144
BS IV BS IV
145 146
BS IV BS IV
Kit List Kit List
1. 36JL0009 Kit Chain Sprocket-P200 DV101048 Sprocket Output (14T) 1 7. 36JL0004 Assly C' Case RH-P200 JL541010 Crankcase RH Black 1
JL141000 Chain 1 BA102003 Plug - Oil Hole 3
JL131228 Sprocket 39T 1 39256220 Bearing - Needle Roller 1
JL541008 Pipe Breather Crankcase 1
2. 36JL0011 Kit Valve Repaire-P200 39201719 Seal - Oil 1
JF511215 Seat Valve Spring 1 8. 36JL0007 Block & Piston-P200 JL521200 Piston Assly Compl 1
JF511217 Valve Spring 1 JL521004 Cylinder Block With Nipple 1
JF511214 Retainer Valve Spring 1
DG101029 Collet 2 9. 36JL0010 Assly Cyl Head-P200 JL511019 Cylinder Head 1
39128321 Ring - O 1
3. 36JL0012 Kit Tank Damper-P200 JL171028 Damper Tank Cover Fr LH 1 JG511046 Stud (M8*1.25) 2
JL171029 Damper Tank Cover Fr RH 1
JL171030 Damper Tank Cover Center LH 1 10. 36JL0001 Chain Guide-P200 JL531004 Guide Chain (Slack Side) 1
JL171031 Damper Tank Cover Center RH 1
JL531005 Guide Chain (Tight Side) 1
JL171032 Damper Tank Cover Rear 1
JL171038 Beading Tank LH 1
11. 36JL0002 Asly Cl Cover-P200 JL541206 Clutch Cover P2011 1
JC101077 Plug Taper 1
4. 36JL0013 Kit Seat Damper-P200 JL191007 Damper For Seat 6
JL541218 Jet Oil Cover Clutch 1
DK211007 Damper Seat Front 1
JG541021 Oil Nozzle 2
39199020 Bearing - Needle 1
5. 36JL0014 Kit Engine Gasket-P200 JL541207 Gasket Clutch Cover 1
JL541208 Gasket Magneto Cover 1
JL521002 Gasket Cylinder Block 1 12. 36JU0001 Piston Ring-P200 JU521206 Ring Piston Top 1
JL511022 Gasket Cylinder Head 1 JU521207 Ring Piston Second 1
JG541041 Gasket Crankcase 1 JU521208 Ring Piston Oil 1
CS101128 Gasket 1
JL511001 Gasket Head Cover(rubber) 1 13. 36JU0002 Friction Plate-P200 JG551448 Friction Disk A 5
JG591070 Gasket Exhaust 1 JG551455 Disc C-Clutch Friction 1
DP101109 Plate - Friction 1
6. 36JL0003 Kit Assly C'case LH-P200 JL541009 Crankcase LH Black 1
JC101077 Plug Taper 2
JG541021 Oil Nozzle 1 14. 36JL0015 Pillion Hardware-P200 JD113019 Pin Foot Step 1
JG541015 Needle Bearing HK 1514 RS 1 30141031 Ring - O 1
39256220 Bearing - Needle Roller 1 39104011 Washer - Plain 1
JG541020 Jet Oil Crankcase RH 1 39078408 Pin - Split 1
147 148
BS IV BS IV
Kit List Kit List
16. 36JL0017 Wind Shield MtG-P200 01160508 Washer Lock 3 23. 36JL0031 Kit Tank Mtg Hardware JL171070 Tank Cover Grommet 4
JG181236 Well Nut - M5 X 16 L 2 JL171071 Tank Coover Mtg Sleeve 4
JG181235 Washer Special 2 39023911 Washer - Plain 4
JL181247 Grommet Wind Screen Mounting 2 LAC00034 Bolt M6 X 20 2
JL171057 Damper -Tank Side cover 2
DS141012 Grommet Side Cover Front 4 24 36JL0021 Kit Idling Screw – ----- – Screw Idling Adjustment 1
DH121163 Plain Washer 1
17. 36JL0019 Jet P200 -- ---- -- Jet Needle 1 DH121077 Spring 1
-- ---- -- Needle Jet 1
-- ---- -- Je Holder 1 25 36JL0026 Kit Fairing Decal - Black Jl233000 Decal Fairing LH 1
-- ---- -- Main Jet 1 Jl233001 Decal Fairing RH 1
DK121063 Pilot Jet 1
26 36JL0049 Kit Dcl Fairing-P Red Jl233077 Fairing Upper Decal LH 1
18. 36JL0020 VC Screw P200 -- ---- -- Screw Adjuster VC 1 Jl233078 Fairing Upper Decal RH 1
DH121130 O- Ring Screw VC 1 Jl233079 Fairing Lower Decal LH 1
DH121086 Spring Screw VC 1 Jl233080 Fairing Lower Decal RH 1
DH121087 Plain Washer 1
DH121088 O- Ring Screw VC 1 27 36JL0063 Kit Dcl Fairing-M White Jl233093 Fairing Upper Decal LH 1
Jl233094 Fairing Upper Decal RH 1
19 36JL0021 Idling Screw P200 -- ---- -- Screw Idling Adjustment 1 Jl233095 Fairing Lower Decal LH 1
DH121163 Plain Washer 1 Jl233096 Fairing Lower Decal RH 1
DH121077 Spring 1
28 36JL0048 Kit Dcl Fairing-S Blue Jl233109 Fairing Upper Decal LH 1
20. 36JL0022 Piston Valve P200 -- ---- -- Vacuum Piston Compl. 1 Jl233110 Fairing Upper Decal RH 1
DK121055 Diapragm 1 Jl233111 Fairing Lower Decal LH 1
DK121054 Spring 1 Jl233112 Fairing Lower Decal RH 1
21. 36JL0023 Gasket / ‘O’ ring P200 DK121058 O-Ring / Gasket Float Chamber 1 29 36JL0064 Kit Dcl Fender-E Black Jl233035 Fender Decal LH 1
DH121118 O-Ring - Drain Screw 1 Jl233036 Fender Decal RH 1
DH121088 O-Ring - VC Screw 1
DH121130 O-Ring - VC Screw 1 30 36JL0061 Kit Dcl Fender-P Red Jl233091 Decal Fender LH 1
Jl233092 Decal Fender RH 1
22. 36JL0024 Jet Needle Hardware P200 DD121056 Holder For Jet Needle 1
DD121050 Spring-Jet Needle 1 31 36JL0065 Kit Dcl Fender-M White Jl233107 Decal Fender LH 1
DD121052 Washer-Jet Needle 1 Jl233108 Decal Fender RH 1
Dd121054 E-Clip 1
149 150
BS IV BS IV
Kit List Kit List
32 36JL0060 Kit Dcl Fender-S Blue Jl233123 Decal Fender LH 1 40 36JL0068 Kit Dcl Tank Lower-M White Jl233097 Tank Lower Decal LH 1
Jl233124 Decal Fender RH 1 Jl233098 Tank Lower Decal RH 1
33 36JL0058 Kit Dcl S Cowl-P Red Jl233087 Seat Cowl Upper Decal LH 1 41 36JL0052 Kit Dcl Tank Lower-S Blue Jl233113 Tank Lower Decal LH 1
Jl233088 Seat Cowl Upper Decal RH 1 Jl233114 Tank Lower Decal RH 1
Jl233089 Seat Cowl Lower Decal LH 1
Jl233090 Seat Cowl Lower Decal RH 1 42 36JL0078 Kit New Dcl S Cowl - P Red Jl233181 Seat Cowl Dcl Upper LH 1
Jl233182 Seat Cowl Dcl Upper RH 1
34 36JL0066 Kit Dcl S Cowl-M White Jl233103 Seat Cowl Upper Decal LH 1 Jl233183 Seat Cowl Dcl Lower LH 1
Jl233104 Seat Cowl Upper Decal RH 1 Jl233184 Seat Cowl Dcl Lower RH 1
Jl233105 Seat Cowl Lower Decal LH 1
Jl233106 Seat Cowl Lower Decal RH 1 43 36JL0079 Kit New Dcl S Cowl - M White Jl233167 Seat Cowl Dcl Upper LH 1
Jl233168 Seat Cowl Dcl Upper RH 1
35 36JL0057 Kit Dcl S Cowl-S Blue Jl233119 Seat Cowl Upper Decal LH 1 Jl233169 Seat Cowl Dcl Lower LH 1
Jl233120 Seat Cowl Upper Decal RH 1 Jl233170 Seat Cowl Dcl Lower RH 1
Jl233121 Seat Cowl Lower Decal LH 1
Jl233122 Seat Cowl Lower Decal RH 1 44 36JL0080 Kit New Dcl S Cowl - S Blue Jl233171 Seat Cowl Dcl Upper LH 1
Jl233172 Seat Cowl Dcl Upper RH 1
Jl233173 Seat Cowl Dcl Lower LH 1
36 36JL0054 Kit Dcl Spoiler-P Red Jl233083 Spoiler Upper Decal LH 1
Jl233174 Seat Cowl Dcl Lower RH 1
Jl233084 Spoiler Upper Decal RH 1
Jl233085 Spoiler Lower Decal LH 1
44 36JL0081 Kit New Dcl Spoiler - P Red Jl233083 Spoiler Dcl Upper LH 1
Jl233086 Spoiler Lower Decal RH 1
Jl233084 Spoiler Dcl Upper RH 1
Jl233175 Spoiler Dcl Lower LH 1
37 36JL0067 Kit Dcl Spoiler-M White Jl233099 Spoiler Upper Decal LH 1
Jl233176 Spoiler Dcl Lower RH 1
Jl233100 Spoiler Upper Decal RH 1
Jl233101 Spoiler Lower Decal LH 1
45 36JL0082 Kit New Dcl Spoiler - M White Jl233099 Spoiler Dcl Upper LH 1
Jl233102 Spoiler Lower Decal RH 1
Jl233100 Spoiler Dcl Upper RH 1
Jl233177 Spoiler Dcl Lower LH 1
38 36JL0055 Kit Dcl Spoiler-S Blue Jl233115 Spoiler Upper Decal LH 1
Jl233178 Spoiler Dcl Lower RH 1
Jl233116 Spoiler Upper Decal RH 1
Jl233117 Spoiler Lower Decal LH 1
46 36JL0083 Kit New Dcl Spoiler -S Blue Jl233115 Spoiler Dcl Upper LH 1
Jl233118 Spoiler Lower Decal RH 1
Jl233116 Spoiler Dcl Upper RH 1
Jl233179 Spoiler Dcl Lower LH 1
39 36JL0053 Kit Dcl Tank Lower-P Red Jl233081 Tank Lower Decal LH 1
Jl233180 Spoiler Dcl Lower RH 1
Jl233082 Tank Lower Decal RH 1
47 36JL0084 Kit Dcl Necked Sport Jl233165 Necked Sport Dcl LH 1
Jl233166 Necked Sport Dcl RH 1
151 152
BS IV BS IV
Kit List Kit List
48 36JL0117 Kit Dcl Fender Red-Blk BS IV JL233253 Decal Fender Front LH Red-Black 1 61 36JL0127 Kit Dcl Side CVR Blk-Gry BSIV JL233292 Decal Side Cover LH Black-Gray 1
JL233254 Decal Fender Front RH Red-Black 1 JL233293 Decal Side Cover RH Black-Gray 1
36JL0114 Kit Dcl Fairing Red-Blk BS IV JL233243 Decal Fairing LH Red-Black 1 36JL0124 Kit Dcl Seat Cowl Blk-Gry BSIV JL233294 Decal Cowl Seat LH Black-Gray 1
JL233244 Decal Fairing RH Red-Black 1 JL233295 Decal Cowl Seat RH Black-Gray 1
36JL0115 Kit Dcl CVR Tank Red-blk BSIV JL233245 Decal Cover Tank Up LH Red-Blk 1 36JL0130 Kit Fender Fr Dcl YL-Gry BSIV JL233308 Decal Fender Front LH Yellow-Gry 1
JL233246 Decal Cover Tank Up RH Red-Blk 1 Jl233309 Decal Fender Front RH Yellow-Gry 1
36JL0108 Kit Dcl Side CVR R-Blk BS IV JL233249 Decal Side Cover LH Red-Black 1 36JL0131 Kit Fairing Dcl YL-GRAY BSIV JL233300 Decal Fairing LH Yellow-Gray 1
JL233250 Decal Side Cover RH Red-Black 1 JL233301 Decal Fairing RH Yellow-Gray 1
36JL0116 Kit Dcl Seat Cowl R-Blk BSIV JL233251 Decal Cowl Seat LH Red-Black 1 36JL0132 Kit Cvr Tank Dcl YL-Gray BSIV JL233302 Decal CVR Tank Top LH Ylw-Gray 1
JL233252 Decal Cowl Seat RH Red-Black 1 JL233303 Decal CVR Tank Top RH Ylw-Gray 1
36JL0121 Kit Dcl Fender White-Blk BSIV JL233267 Decal Fender Front LH White-Gray 1 36JL0133 Kit Dcl Side Cvr YL-GRY BSIV JL233304 Decal Side Cover LH Yellow-Gray 1
JL233268 Decal Fender Front RH White-Gray 1 JL233305 Decal Side Cover RH Yellow-Gray 1
36JL0118 Kit Dcl Fairing Wht-blk BSIV JL233257 Decal Fairing LH White-Gray 1 36JL0134 Kit Dcl Seat Cowl YL-Gry BSIV JL233306 Decal Cowl Seat LH Yellow-Gray 1
JL233258 Decal Fairing RH White-Gray 1 JL233307 Decal Cowl Seat RH Yellow-Gray 1
36JL0119 Kit Dcl CVR Tank Wht-blk BSIV JL233259 Decal Tank Upper LH White-Gray 1 36JL0135 KIT TANK CVR DCL NS200 JL233327 Decal Cover Tank LH-200 1
JL233260 Decal Tank Upper RH White-Gray 1 JL233328 Decal Cover Tank RH-200 1
36JL0110 Kit Dcl Side CVR Wht-blk BSIV JL233263 Decal Side Cover LH White-Gray 1 63 36DT0033 KIT GEAR PRIMARY DRIVE & DRIVEN JG551216 GEAR PRIMARY DRIVE 22T 1
JL233264 Decal Side Cover RH White-Gray 1 DT551407 HOUSING CLUTCH ASSY COMP 1
36JL0120 Kit Dcl Seat Cowl Wht-blk BSIV Jl233265 Decal Cowl Seat LH White-Gray 1
JL233266 Decal Cowl Seat RH White-Gray 1
36JL0125 Kit Fender Front Dcl BL-Gray JL233296 Decal Fender Front LH Black-Gray 1
JL233297 Decal Fender Front RH Black-Gray 1
36JL0123 Kit Cover Tank Dcl BL-Gray JL233290 Decal Cover Tank Top LH Blk-Gray 1
JL233291 Decal Cover Tank Top RH Blk-Gray 1
153 154
BS IV BS IV
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
54 24 N/A 36JL0041 KIT MAIN STEP` 16.08.13 CORRECTION (MAIL DATED:16.08.13) 53 3 JL122014 JL122013 SWING ARM 13.10.15 CHILD PART SERVICED
86 1 N/A JL171081 TANK ASSLY 03.10.13 REF. CIRULAR IB-73 32 1 52JL0145 JL541243 MAGNETO CVR ASSLY 05.11.15 CONFIRMATION FROM BUYERS
86 6 N/A JL402602 SENSOR FUEL LEVEL 03.10.13 REF. CIRULAR IB-73 32 2 JA541233 JL541245 CAP TCD FINDER 05.11.15 CONFIRMATION FROM BUYERS
86 25 JL171096 30141039 SEALING RING 03.10.13 ALTERNATE 32 10 JL541238 JL541223 DECAL BAJAJ LOGO 05.11.15 CONFIRMATION FROM BUYERS
86 26 N/A JL171073 DAMPER TANK 03.10.13 REF. CIRULAR IB-73 108 1 JL402203 JL402229 HARNESS WIRING 10.12.15 REF. CIR. IB-194
42 8 LDB00010 39216511 PLAIN WASHER 25.10.13 CORRECTION 108 1A JL402220 JL402228 WIRIRNG HARNESS 21.01.16 ECR NO. N15JLELA0226
42 9 LAD00055 DH101396 BOL HEX 25.10.13 CORRECTION 108 7 DT402006 DS201025 FLASHER 21.01.16 ECR NO. N15JLELA0226
42 10 DK101595 JG351019 BODY COMP. ST. CLUTCH 25.10.13 CORRECTION 18 1A JL561401 JL561205 ASLY SHIFT LEVER- BALL JOINT 11.03.16 FROM DEC’15
42 11 DK101163 JY551402 CLUTCH ONE WAY ASSLY. 25.10.13 CORRECTION 18 2A JL561404 JL561206 ASSLY LEVER CHANGE ARM 11.03.16 FROM DEC’15
42 12 DK101596 N/A SPRING ST. CLUTCH 25.10.13 DELETED (CORRECTION) 18 4A JL561405 52JF0062 TIE ROD WITH NUT ASSLY 11.03.16 FROM DEC’15
42 12 N/A 39084914 TOOTHED LOCK WASHER 25.10.13 NEW PART ADDED (CORRECTION) 126 5 56JL224R 52JL0355 TANK CVR TOP PASSION RED 22.03.16 ALTERNATE
42 13 DK101605 N/A PLATE ROLLER CLUTCH 25.10.13 DELETED (CORRECTION) 126 5 56JL225N 52JL0356 TANK CVR TOP SAFFIRE BLUE 22.03.16 ALTERNATE
42 13 N/A DH101389 PRE-COATED SCREW 25.10.13 NEW PART ADDED (CORRECTION) 126 5 56JL22X3 52JL0357 TANK CVR TOP EBONY BLACK 22.03.16 ALTERNATE
42 13 DK101605 N/A PLATE ROLLER CLUTCH 25.10.13 DELETED (CORRECTION) 24 1A JU531214 JL531204 BALANCER INTEGRAL 23.03.16 REF. CIR. IB-214
42 13 N/A DH101389 PRE-COATED SCREW 25.10.13 NEW PART ADDED (CORRECTION) 24 3A JG531228 JL531203 SLEEVE BALANCER DRIVEN 23.03.16 REF. CIR. IB-214
42 14 DK101382 N/A PRE-COATED SCREW 25.10.13 DELETED (CORRECTION) 100 10 EC401030 DK201043 BULB- H7 CATEGORY 12V 55W 01.04.16 BULB CHANGED FOR 200 AS
42 15 SHIFTED TO SR. NO. 12 88 25 -------- JL181439 CVR TANK TOP INNER 14.04.16 ADDITION
42 16 59100002 N/A SPRING DOWEL 25.10.13 DELETED (CORRECTION) 32 1 JL541224 JL541244 MAGNETO COVER 20.05.16 UPDATION
42 17 SHIFTED TO SR. NO. 14 39 11 56JL083G -------- FLAP MOON LIGHT SILVER RH 20.05.16 DELETION
43 21 JL232808 BRACKET-RR NO. PLATE 12.03.14 ADDED NEW PART 39 19 56JL073G -------- FLAP MOON LIGHT SILVER LH 20.05.16 DELETION
90 1 JL402400 JL402405 SPEEDOMETER 19.03.14 DELETED (CORRECTION) 6 4 DT511242 DT511261 ASSLY ROCKER ARM INTAKE 27.07.16 ALTERNATE
4 72 N/A JL5110294 COVER THERMOSTAT 20.03.14 NEW PART ADDED (CORRECTION) 6 5 DT511243 DT511262 ASSLY ROCKER ARM EXHAUST 27.07.16 ALTERNATE
24 12 JG601011 JL601005 COVER WATER PUMP 27.03.14 DELETED (CORRECTION) 80 8 JL181226 JL181017 SHROUD ASSY LH 09.08.16 ALTERNATE
28 16 JG601400 JG601237 RADIATOR FAN 20.06.14 ALTERNATE ADDED 80 8 JL181451 JL181017 SHROUD ASSY LH 09.08.16 ALTERNATE
22 20 -------- JG541074 OIL NOZZLE 09.07.14 NEW PART ADDED (CORRECTION) 70 25 -------- DK151090 INSULATOR KIT 27.08.16 ADDITION
28 21 JL601209 JL601235 EXPANSION TANK ASSY 17.09.14 REF. CIR. IB-124 68 13 52JL0142 JL131930 DISC REAR 31.08.16 EC NO.-A16JLCHA1069
28 25 JL601214 – HOSE-EXP. TANK TOP 17.09.14 REF. CIR. IB-124 84 16 -------- JL111102 BRACKET SIDE COVER MTG 19.09.16 ADDITION
88 2 JL171023 JL171099 BRKT SIDE CVR MTG. RH 17.09.14 REF. CIR. IB-124 88 26 -------- JL181424 SUB ASSLY SIDE FAIRING LH 27.09.16 ADDITION
50 1 JL111106 JL111201 FRAME ASSLY 30.12.14 REF. CIR. IB-140 88 27 -------- JL181425 SUB ASSLY SIDE FAIRING RH 27.09.16 ADDITION
66 9 — JL131825 SPRING PAD 17.02.15 CORRECTION (MAIL DATED : 17.02.15) 6 4 JL511006 DT511261 ASSLY ROCKER ARM INTAKE 05.10.16 ALTERNATE
52 17 DG171015 JL122026 SHAFT SWING ARM 18.08.15 REF. CIR. IB-173 6 5 JL511007 DT511262 ASSLY ROCKER ARM EXHAUST 05.10.16 ALTERNATE
52 18 JL111109 DT113848 CAP 18.08.15 REF. CIR. IB-173 126 1 52JL0355 56JL224R TANK COVER TOP P RED 06.10.16 CORRECTION
28 32 -------- JL601234 RADIATOR CORE 24.08.15 ADDITION 126 1 52JL0356 56JL225N TANK COVER TOP S BLUE 06.10.16 CORRECTION
155 156
BS IV BS IV
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
126 1 52JL0357 56JL22X3 TANK COVER TOP E BLACK 06.10.16 CORRECTION 82 29 ----------- JL113835 Clamp Brake Hose 15.11.17 Addition
84 17 -------- JL171048 TANK COVER CENTRAL 10.11.16 ADDITION 6 4 -------- 36Jl0144 Kit Cyl Head(new Casting) 27.11.17 Ref. Cir IB:303
6 4 -------- 36JL0145 Kit Cyl Head(new Casting) 27.11.17 Ref. Cir IB:303
44 15 -------- JL113836 BRACKET CDI MTG LOOSE 15.11.16 ADDITION
6 4a -------- 52JL1266 Cyl Head (new Casting) 27.11.17 Ref. Cir IB:303
84 18 -------- LAC00034 BOLT M6 25.11.16 ADDITION
6 4b -------- JL511080 Cyl Head (new Casting) 27.11.17 Ref. Cir IB:303
108 21 -------- JL401805 BATTERY LID CAP 28.11.16 ADDITION 6 7 -------- JL511112 Sleeve Spark Plug 27.11.17 Ref. Cir IB:303
56 7 JL181402 JL181464 BRACKET BRACE FENDER 28.12.16 REF. CIR. IB-266 6 9 -------- KJAC1824 O-RING 27.11.17 Ref. Cir IB:303
56 9 JL181411 DT181434 CUP WASHER FRONT FENDER MTG 28.12.16 REF. CIR. IB-266 8 6 -------- JL511249 Shaft Rocker Arm 27.11.17 Ref. Cir IB:303
8 7 -------- JL511254 Plate Stopper Rocker Shaft 27.11.17 Ref. Cir IB:303
56 10 KACH0616 KACA0520 BOLT SOCKET HEAD 28.12.16 REF. CIR. IB-266
10 1 -------- JL511241 Camshaft Assembly 27.11.17 Ref. Cir IB:303
56 13 -------- JL181468 COLLAR FR FENDER 28.12.16 REF. CIR. IB-266
10 5 -------- JL511250 Spacer Camshaft 27.11.17 Ref. Cir IB:303
56 14 -------- DJ161091 GROMMET FRONT FENDER 28.12.16 REF. CIR. IB-266
110 2 -------- 56JL6F1Y JL Bkt. RR Blinker Mounting Slate Gray 12.12.17 Addition
56 15 -------- DT181435 GROMMET FRONT FENDER 28.12.16 REF. CIR. IB-266 4 20 –----- JL511056 Gasket Copper for Sai 04.01.18 Addition
76 1 JL151024 JL121005 FORK ASSLY- FRONT 28.12.16 REF. CIR. IB-266 4 1 JL511058 JL511059 Assly Sai Pipe with Hose & Clamp 11.01.18 Correction
124 8 52JL0996 52JL1055 Asly Side Cvr RH Satin Blk+Re 07.07.17 ALTERNATE 40 9 KAEM0622 KAED0622 Bolt-Flange 08.03.18 Alternate
100 8 KBUB0410 KBUF0408 Screw 08.03.18 Alternate
124 8 52JL0998 52JL1063 Asly Side Cvr RH Satin Blk + Wh 07.07.17 ALTERNATE
36 6 ------- JG551448 Friction Plate 28.3.18 Addition
124 8 52JL0997 52JL1059 Asly Side Cvr RH Satin Blk + Bl 07.07.17 ALTERNATE
36 6 ------- JG551455 Friction Plate 28.3.18 Addition
124 8 52JL0999 52JL1067 Asly Side Cvr RH Satin Blk + Ye 07.07.17 ALTERNATE
120 1a -------- JL231213 Guard Leg LH 17.07.18 ( Add)From Jan.2018
26 1 JU531215 JL531205 Balancer Assy 2.8.17 ALTERNATE
120 2a -------- JL231214 Guard Leg RH 17.07.18 (Add) From Jan.2018
56 18 JL111109 DT113848 Cap -Swing Arm Pivot 2.8.17 ALTERNATE
4 1 JL511060 JL511058 Assly SAI Pipe With Hose & Clamp 2.8.17 ALTERNATE
36 1 DT551400 DT551409 Clutch Assy Comp 15.09.17 (ALT) From July 2017 (IB-288)
36 3 36DT0033 36DT0033 Kit Gear Primary Drive & Driven 15.09.17 (ALT) From July 2017 (IB-288)
22 26 Jl571001 56JL1X3V CAP OIL FILTER (JL571001) “SLATE GREY” 30.10.17 UPDATION
157 158
BS IV BS IV
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.