Plate No.

1 : COVER CYLINDER HEAD 180

6 8

2 4
9 7

11 2

10 3

10
11 1

Qty/
No. Part No. Description Veh. Remarks

1 DJ 1012 69 Head Cylinder with Cover 1

2 DJ 1012 17 Cover Tappet 2
3 36 DS10 01 ‘O’ Ring Kit for Cover Cyl. Head 1 Ref. Page No. 60
4 DS 1011 66 Silent Bush (V) 1
5 DS 1010 96 Camshaft Cap 1

6 39 2647 15 Dommed Cap Nut 4

7 DS 1010 84 Copper Washer 4
8 39 2532 04 Hex. Bolt with Flange 2
9 39 1075 04 Hex. Bolt / Flange 4
10 DH 1012 72 Plug 2

11 DG 1014 98 Washer 2 Alt. 31101106

1
Plate No. 2 : CYLINDER HEAD 180 Plate No. 3 : VALVE 180

9
4 8

2
10 9
1
11 1

6 3
12

2
2
6 9 5
5

3 7
8
7
8

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1012 69 Head Cylinder with Cover 1 1 DS 1013 35 Rocker Arm Shaft - Intake 1
2 39 1660 05 Stud (Exhaust) 2 2 DS 1013 36 Rocker Arm Shaft - Exhaust 1
3 DJ 1010 12 Gasket Cylinder Head 1 3 DS 1013 33 Rocker Arm with roller 2
4 DH 1015 08 Damper Cylinder Head 5 4 DG 1010 29 Cotter valve 4
5 DJ 1012 15 Intake Pipe 1 5 39 2017 19 Seal valve stem 2

6 39 2539 21 ‘O’ Ring (Intake Pipe) 1 6 36 DK00 05 Valve Repair Kit 1 Ref. Page No. 60
7 DJ 1210 22 Carburettor Insulator 1 7 36 DJ10 04 Valve Kit 1 Ref. Page No. 60
8 DH 1210 38 Clamp for Insulator 2 8 DS 1013 66 Wave washer 2
9 39 1674 04 Hex. Bolt / Flange 2 9 59 1100 02 Plain washer 4
10 DH 1110 12 Sleeve - Spark Plug 1

11 39 2608 01 Grub Screw 1 For Sleeve Spark Plug

12 36 DS10 01 ‘O’ Ring Kit for Cover Cyl. Head 1 Ref. Page No. 60

2 3 3
Plate No. 4 : CAMSHAFT / TENSIONER 180 Plate No. 5 : CYLINDER AND PISTON 180

2
6
4

3
11 3 7 6 8 9

1
4

16

10 13

12 1 7
14 5

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 CS 1011 28 Gasket Tensioner 1 1 DJ 1010 04 Gasket Cylinder 1

2 DH 1017 03 Camshaft assembly 1 2 39 2181 06 Pin dowel 4
3 39 2542 20 Bearing ball 15X42X13 1 3 DJ 1011 58 Piston Assly. Std. 1
JC 1010 86 Bearing ball 6302 RS1/C3H 1 4 DJ 1011 06 Ring Set Piston 1
4 39 1880 20 Bearing ball 15x32x9 (6002-C3) 1 5 39 2132 17 Ring Snap 2
JC 1010 85 Bearing ball 6002/C3H 1
5 36 DH10 03 Guide chain Kit 1 Ref. Page No.60
JC 1010 38 Guide chain kit 1 From Oct07 6 DJ 1013 27 Cylinder Block / Piston Assly. 1 From 26Apr08 (C5)
DJ 1013 71 Cylinder Block / Piston Assly. (CLS) 1 From 13Feb09 (C13)
6 DS 1012 76 Sprocket cam Driven 1
7 DH 1014 12 Collar cam Sprocket 1
8 DH 1010 48 Special camshaft washer 1
9 39 2198 04 Hex. Soc. Head cap Bolt 1
10 JC 1010 35 Cam Chain 1

11 DJ 1011 37 Decomp Assly. 1

12 DH 1010 11 Cam chain Tensioner pivot Bolt 1
13 DS 1012 77 Tensioner assly. 1
JC 1010 34 Tensioner assly. 1 From. Oct07
14 39 1673 04 Hex Bolt / Flange 2 From 26Apr08 (C5)
15 39 1013 21 “O”Ring 1 From 26Apr08 (C5) N.I
16 39 2669 21 “O”Ring 1
4 3 5
Plate No. 6 : CRANK SHAFT 180 Plate No. 7 : BALANCER & BALANCER IDLER GEAR 180

8 1
5

9
4 7 3
2 10
6
8

12 11
5
3
2 9 8
11 7

6
13 4
7
10 5 9

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1012 23 Crankshaft assly. comp. 1 1 DJ 1010 22 Body Balancer Assly. 1

2 39 2183 04 Bolt 1 2 DH 1010 72 Bearing stopper 1
3 39 2165 11 Plain washer 1 3 39 1672 04 Bolt 1
4 31 1011 73 Key woodruff 1 4 DJ 1011 34 Assly. Balancer Idler Gear comp. 1 Alt. DH101432
5 DS 1011 54 Square Key 1 5 39 2152 20 Needle roller bearing 2

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

7 DS 1012 75 Sprocket cam drive 1 7 39 2557 17 Circlip ext. 2
8 39 2203 07 Parallel pin 1 8 39 1686 06 Dowel Pin 2
9 36 DH40 06 Set primary driver & driven 1 9 39 1620 11 Thrust washer 2
10 DH 1010 64 Body centrifugal oil filter 1 10 52 DH01 77 Balancer Idler Holder 1

11 DH 1011 95 Nut 1 7mm. (Height) 11 39 1674 04 Bolt 3

12 DH 1010 65 Cover centrifugal oil filter 1
13 36 DK00 07 Kit centrifugal oil filter 1 Ref. Page No. 60

6 3 7
Plate No. 8 : TRANSMISSION 180 Plate No. 8 : TRANSMISSION 180

1 1
16 13 16 13
2 2
15 15
3 14 3 14
4 4
5 5
12 5 12 5
4 4
6 6
5 5
4 11 4 11
7 7
8 10 8 10
9 9
17 17

19 18 19 18

11 21 11 21
20 20
5 5
22 22
23 23
24 24

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1011 25 Shaft Input Transmission 1 16 DJ 1011 10 Gear 1st driven 1

DK 1014 71 Shaft Input Transmission (CLS) 1 From 13Feb09 (C13) 17 DH 1011 13 Gear 5th Driven 1
2 39 2158 11 Washer thrust 1 18 DH 1013 19 Bush 2nd driven 1
3 DH 1010 78 Gear 4th Drive 1 19 DH 1013 33 Gear 2nd Driven 1
4 DH 1010 79 Washer Spline 3 20 DH 1011 16 Collar Sprocket 1
5 DH 1012 35 External Circlip 4
21 30 1010 61 ‘O’ Ring Sprocket Collar 1
6 DH 1010 80 Gear 3rd Drive 1 22 DH 1011 17 Sprocket Drive 1
7 DH 1010 82 Gear 5th drive 1 23 DJ 1010 63 Plate Drive Sprocket 1
8 DH 1010 84 Gear 2nd drive 1 24 39 1062 04 Bolt Drive Sprocket 2
9 39 2160 11 Thrust washer 1
10 DH 1014 16 Shaft output Transmission 1

11 DH 1013 36 Washer Thrust 2

12 DH 1011 08 Gear 3rd Driven 1
13 39 2159 11 Thrust Washer 1
14 DH 1011 10 Gear 4th Driven 1
15 DH 1011 11 Bush 1st driven 1

8 3 9
Plate No. 9 : CHANGE DRUM / SHIFT FORK 180 Plate No. 10 : GEAR CHANGE MECHANISM 180

7 8 5
2 8
4
6

10
6

9
1

4
3
2
7
10
5
2
3

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 1011 59 Fork Gear Shift Input 1 1 DH 1017 05 Lever comp. Gear Shifter 1
2 DK 1011 60 Fork Gear Shift output 2 2 DH 1017 14 Spring arm reset 1 Alt. DH101134
3 DH 1011 46 Shaft Gear Shift Fork 1 3 DH 1011 44 Spring Gear Shifter return 1
4 DH 1014 93 Shaft Gear Shift Fork 1 4 DH 1011 65 Lever comp. change 1 Alt. DH101397
5 DK 1013 82 Drum comp. Gear Shift 1 From 14Jul08 (C7) 5 31 1011 08 Damper 1

6 39 2437 04 Bolt Socket 1 6 39 2453 04 Flanged Bolt 1

7 39 2606 07 Parellel pin 1 7 DH 1012 25 Bolt Gear Shift drum Stopper 1
8 DK 1013 61 Guide Gear Shifter 1 w.e.f. Mar. 07 8 DH 1015 03 Stopper gear shifter drum 1
9 DH 1014 96 Spacer 1 9 DH 1015 02 Spring gear shifter drum stopper 1
10 DK 1011 35 Bush fork gear shift 2 10 DH 1010 13 Bolt shift change 1

10 3 11
Plate No. 11 : ENGINE ASSLY. & CRANKCASE RH 180 Plate No. 12 : CRANKCASE LH 180

12 14
13
2
2
3 3 24
21
19 20
9
27
8 23 7
2
5
4
28

6 8
10
16
8
15 26
6
9 18
7
3 17 1
5
10 11
4
25

17c 17a 17b 22

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1012 31 Engine Assly. 1 N.I. 1 DJ 1013 20 Crankcase LH 1 plastic neutral switch

2 DJ 1012 13 Crankcase RH 1 DJ 1013 44 Crankcase LH (CLS) 1 From 13Feb09 (C13)
3 39 2531 05 Stud 2 2 39 2531 05 Stud 2
4 39 1074 04 Bolt Flanged 1 3 DH 1016 54 Guide starter Assly 1
5 DH 1010 06 Gasket Crankcase 1 4 39 2188 19 Oil Seal 1
5 DH 1014 23 O’ Ring 1
6 39 2583 20 Bearing Ball (For Input shaft) 1
7 39 2602 20 Bearing Ball (For Output shaft) 1 6 39 0752 01 C’ Sunk Head Screw 3
8 39 2180 06 Dowel Pin 2 7 39 2603 20 Bearing Ball (For Input shaft) 1
9 39 2601 20 Ball Bearing 1 (For Drum Comp. Gear Shift) 8 39 2583 20 Bearing Ball (For Output shaft) 1
10 DH 1014 87 Plate Stopper 1 9 39 2185 20 Balancer LH Bearing 1
10 39 2189 19 Oil Seal (For Output shaft) 1

11 39 2190 19 Oil Seal (For Shift lever) 1

12 DH 1012 03 Breather pipe 1
13 DH 1012 46 Rubber tube 1
14 28 1011 74 Spring Clip 1
15 DH 1012 72 Plug (Drain Bolt) 1

12 3 13
Plate No. 12 : CRANKCASE LH 180 Plate No. 13 : COVER RH 180

12 14
13 12
2 17
2 24 18
24 4
21 9 6
7
8 22
19 20 23
19
9
27 20
23 7
2
3
5
4 13 11
28 5
6 8
1
10
16 10

15 26
18
21
3 17 1
16
11 15
25 14

17c 17a 17b 22

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 DG 1014 98 Gasket (For Drain Bolt) 1 Alt. 31101106 1 52 DJ01 96 Cover comp RH 1
17 31 2010 81 Neutral switch 1 2 DH 1011 97 Grommet Breather 1
17a DK 1013 80 Neutral switch 1 From 14Jul08 (C7) 3 30 1011 42 Seal kick Shaft 1
17b DH 1013 85 Precoated Flanged bolt (M6x16) 1 17a part’s 4 39 1041 19 Seal clutch lever 1
17c 39 1013 21 O ring 1 17a part’s 5 DH 1011 41 Rack 1
18 DH 1012 64 Gasket Neutral Switch 1
DH 1017 84 Gasket Neutral Switch 1 From May 07 (deleted by 17a) 6 DH 1011 42 Shaft clutch release 1
19 DH 1012 69 Baffle 1 7 39 2202 07 Parallel pin 1
20 39 1414 02 Self tapping Screw 1 8 DG 1014 18 Gauge 1
9 DS 1012 15 Wire circlip 1
21 39 1845 04 Flanged Bolt 1 10 39 1074 04 Bolt 10
22 39 1677 04 Bolt 8
23 39 2305 04 Bolt 1 11 39 0999 06 Pin Dowel 2
24 DH 1012 78 Plug Starter Motor 1 12 DH 1010 18 Bracket Clutch Cable 1
25 59 2000 07 Needle bearing starter gear inner 1 13 DH 1011 54 Gasket cover RH 1
14 DH 1210 15 Plunger Oil 1
26 DJ 2010 21 Cable assly. (Battery to Earth) 1 15 DH 1210 11 Plate Plunger Oil 1
27 39 2448 11 Plain Washer 1
28 DH 1014 22 Damper 1

14 3 15
Plate No. 13 : COVER RH 180 Plate No. 14 : COVER MAGNETO 180

12
17
24 18
4
9 7 6
8 22
23
19
20

2
3

13 11
11
5 2
3
1
10
4 8
10 9

21

16 6
15
14 5 7

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 DH 1210 12 Spring Joint ‘A’ 1 1 DJ 1012 09 Cover Magneto 1

17 DH 1012 81 Spring torsion clutch lever 1 2 DV 1010 42 Gasket Magneto cover 1 From 14Jul08 (C7)
18 39 2443 11 Washer 1 3 39 1074 04 Bolt 7
19 36 DH10 04 Set damper 1 Ref. Page No. 60 4 39 0999 06 Pin Dowel 2
20 39 2208 04 Flanged Bolt 8 5 DH 1011 57 Cap Crank Center 1 Alt. 39245221

21 DS 1012 52 ‘Bajaj’ Decal 1 Fitted on Cover comp.RH 6 39 1283 21 ‘O’ Ring 1 Alt to 39 2452 21
22 DS 1012 01 Bushing 1 7 DJ 1012 68 Cover LH RR with sticker 1 w.e.f. Feb. 07
23 36 DH10 05 Set of Plate 1 Ref. Page No. 60 8 36 DH10 06 Set Damper 1 Ref. Page No. 60
24 DS 1012 63 Oil filler cap with "O" ring 1 9 39 2208 04 Flanged Bolt 6
10 DS 1012 53 ‘bajaj’ Decal 1 Fitted on Cover magneto

11 36 DH10 07 Set of Plate 1 Ref. Page No. 60

16 17
Plate No. 15 : CLUTCH 180 Plate No. 15 : CLUTCH 180

19 19
2 6 2 6

7 7

6 4 6 4

7 18 7 18
20 20

6 6

7 8 7 8
12 12
10 10

5 9 5 9
1 1

14 14
6 6
16 16
3 17 13 3 17 13
11 11

15 15

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DH 1012 75 Special Nut 1 11 39 1880 20 Bearing Clutch lifter thrust 1

2 36 DH40 06 Set primary driver & driven 1 1 12 DK 1013 38 Holder Clutch 1
3 DJ 1012 75 Clutch Plate Assly 1 DK 1015 73 Holder Clutch (CLS) 1 From 13Feb09 (C13)
DJ 1013 50 Clutch Plate Assly (CLS) 1 13 DH 1014 85 Rod Clutch lifter 1
4 DK 1010 01 Clutch Center 1 14 DK 1011 26 Spacer clutch 1
DK 1015 64 Clutch Center (CLS) 1 From 13Feb09 (C13) 15 DH 1015 20 Nut Primary drive lock 1 LH Thread
5 DK 1011 63 Plate Clutch pressure 1
DK 1015 69 Plate Clutch pressure (CLS) 1 From 13Feb09 (C13) 16 DH 1011 80 Lever Assly. Clutch 1
17 39 2200 11 Washer Primary Drive Gear 1
6 DK 1011 49 Disc Clutch friction 5 18 DK 1011 53 Seat Judder Spring 1
DK 1011 50 Disc Clutch friction 'B' type 1 DK 1015 70 Seat Judder Spring (CLS) 1 From 13Feb09 (C13)
DK 1015 68 Disc Clutch friction 'B' type (CLS) 1 From 13Feb09 (C13) 19 DK 1011 55 Spring Judder 1
DK 1012 55 Disc Clutch friction 'C' type 1 DK 1015 71 Spring Judder (CLS) 1 From 13Feb09 (C13)
DK 1015 67 Disc Clutch friction 'C' type (CLS) 1 From 13Feb09 (C13) 20 DK 1013 56 Friction clutch plate kit 1
7 DK 1011 51 Plate Clutch 4 DJ 1013 69 Friction clutch plate kit (CLS) 1 From 13Feb09 (C13)
DK 1015 65 Plate Clutch (CLS) 4 From 13Feb09 (C13)
8 DH 1017 43 Spring Clutch 4 21 DK 1015 74 Bolt (CLS) 5 From 13Feb09 (C13) N.I.
DH 1018 61 Spring Clutch (CLS) 5 From 13Feb09 (C13)
9 39 1674 04 Bolt 1
10 DK 1011 54 Bolt 4

18 19
Plate No. 16 : KICK STARTER MECHANISM 180 Plate No. 17 : CARBURETTOR 180

10
5 14
19
6

4
7
12
3
4 16 8 13
17
17 18 15 7
2 5
18
9 12
12 2
13 1
8
3 6 9
11
11 12 6

10
1
14

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DH 1015 45 Lever Kick Starter complete 1 1 DJ 1012 32 Carburettor Assly. 1

2 DD 1010 97 Damper 1 2 DJ 1210 51 Vaccum Piston Kit 1
3 36 DH10 08 Boss Kick set 1 Ref. Page No. 60 3 DJ 1210 52 Idling Screw Kit 1
4 DH 1015 37 Ratchet Kick Starter 1 4 DJ 1210 44 Jet needle(JN) 1
5 DH 1015 31 Gear Kick Idler 1 5 DJ 1210 53 “O” ring 1

6 DH 1015 40 Spindle Kick Starter Assly 1 6 DJ 1210 54 Screw 2

7 DH 1015 72 Pinion Kick Starter 1 7 DJ 1210 55 Float assly. 1
8 DH 1011 21 Spring for Kick Starter Ratchet 1 8 DJ 1210 56 Jet Holder Kit 1
9 39 0993 11 Washer Thrust 1 9 DH 1211 01 Magnet Assly. 1
10 39 2344 11 Plain Washer 1 10 DH 1211 02 Reed Switch Assly. 1
11 DH 1015 36 Guide Kick 1 11 39 0840 01 Pan Head Screw 2
12 DH 1015 48 Bolt Flanged 3 12 DJ 1210 57 Needle Assly. 1
13 DH 1011 25 Spring Kick Starter Return 1 13 DJ 1210 58 Set Adjuster(PS) 1
14 DH 1013 21 Bolt flange 1
14 DJ 1210 59 Set Plunger assly. 1
15 DH 1015 38 Stopper 1

16 39 1672 04 Bolt Flanged 1

17 39 2276 11 Washer 2
18 39 0738 17 Circlip 2
19 DH 1015 39 Spindle kick shaft 1

20 3 21
Plate No. 18 : AIR CLEANER COMP 180 Plate No. 19 : SILENCER ASSLY. 180

4 4
3
3

2 2
10
9
9
1

7 6
5
1

Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Qty/ Remarks
Veh.

1 DJ 1210 40 Air Cleaner comp 1 1 DJ 1011 61 Silencer Assly. with CAT converter 1 From 15/01/2007
2 36 DK00 08 Kit hardware air cleaner 1 Ref. Page No. 60 2 DH 1014 68 Shield Muffler (Chrome) 1
3 DJ 1210 39 ConKinecting Tube 1 DH 1018 03 Shield Muffler (Silver) 1 From 14Jun08 (F2)
4 AA 1210 71 Clamp 1 Alt. AA121045 3 36 DK00 10 Kit hardware shield 1 Ref. Page No. 61
5 36 DK00 15 Kit element air filter 1 (Fine & Coarse) Ref. page no. 61 4 DJ 1010 64 Gasket Exhaust 1
5 39 1970 15 Flanged Nut 2

6 36 DK00 09 Kit hardware silencer 1 Ref. Page No. 61

7 DG 1611 24 Damper (Main Stand) 1
8 DH 1015 21 Wire Shield Assly (Chrome) 1
DH 1018 05 Wire Shield Assly (Silver) 1
9 DH 1015 25 Dommed Cap Nut 2
10 DH 1017 59 Shield Exhaust Tube (Chrome) 1 From 14Jun08 (F2)
DH 1018 04 Shield Exhaust Tube (Silver)

22 3 23
Plate No. 20 : SEAT ASSLY. / SEAT LOCK 180 Plate No. 21 : OIL PUMP 180

4 1

7
6
1

5 6

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 2110 03 Seat Assly comp 1 1 DH 1210 01 Oil Pump Assly 1 Alt. 52DH0169
2 DJ 2110 06 Lock Assly seat 1 2 39 1674 04 Hex. Bolt with flange 3
3 39 1902 04 Flanged bolt 2 3 DH 1210 10 Mesh filter Oil pump 1
4 DK 2110 07 Damper at a seat front 3 From 18Jun08 (C3) 4 39 1686 06 Hollow dowel pin 1
5 DH 2210 06 Tool Kit 1 5 DH 1210 35 Clip Mesh Oil filter 1

6 DH 2110 05 Band Tool Kit 2 6 39 2194 21 ‘O’ Ring 1

7 DJ 2110 07 Seat damper 9

24 3 25
Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL 180 Plate No. 22 : MAGNETO / C.D.I. / H.T. COIL 180

12 12
13 13

21 21
19 19
18 18
16 16

20 20

15 17 8 6 15 17 8 6

9 16 9 16

7 7
14 14
5 5
3 3
10 10

4 4

8 8
11 2 1 11 2 1

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1110 93 Magneto Assly. 1 From 26Dec08 (C11) 11 DJ 2011 02 AC/DC Regulator (Green) 1
2 DJ 1110 94 Stator Assly. comp 1 From 26Dec08 (C11) DJ 2011 64 AC/DC Regulator (Brown) 1 From 18Jun08 (C3&C6)
3 39 1674 04 Hex. Bolt with Flange 2 12 DH 1110 39 H.T. Coil LH 1
JM 1000 45 Bolt flange (M6x28) 2 From 26Dec08 (C11) 13 DH 1110 40 H.T. Coil RH 1
4 39 0761 01 Pan Head Screw 2 14 DD 1110 48 Cap Spark Plug 1
5 DH 1011 99 Stopper plate (wiring harness) 1 15 DH 1110 15 Cap Spark Plug 1

6 DJ 1110 61 Rotor Assly. 1 w.e.f. July 07 16 DD 1110 12 Grommet H.T. Cable 2

7 39 0746 01 Screw Pan head 1 17 DH 1110 13 Grommet Spark Plug 1
8 DG 1110 08 Spark plug 2 18 39 1902 04 Flange Bolt 2
9 DJ 1110 23 C.D.I. Assly. 1 19 DJ 1610 67 Bracket H.T. Coil 1
10 DD 1110 11 Grommet Spark Plug 1 20 39 1680 04 Flange Bolt 2

21 DH 1110 16 Grommet Sleeve Spark Plug 1

22 30 2010 64 Band 1 N.I. From 8Aug07 (C1)

26 3 27
Plate No. 23 : STARTER ASSEMBLY (FOR SELF START) 180 Plate No. 23 : STARTER ASSEMBLY (FOR SELF START) 180

11 11

10 10
13 13

3 3

12 12

7 1 7 1

2 2
6 6
9 9
4 4
8 8
14 14
15 15
16 16
5 5
17 17

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DH 1017 82 Body comp. starter clutch 1 16 DH 1011 63 Roller 5

2 DH 1017 81 Plate roller clutch 1 17 DH 1015 33 Bush Spring Starter Clutch 5
3 DH 1016 58 Gear starter clutch 1 18 DK 1110 19 ‘O’ Ring spigot (varroc) 1 From 2Dec08 (F7) N.I.
4 DH 1015 81 Plate starter clutch gear return 1 19 DJ 1110 71 ‘O’ Ring kit (varroc) 1 From 2Dec08 (F7) N.I.
5 39 1672 04 Bolt 1 For stopper plate 20 DJ 1110 70 Bush assly kit (varroc) 1 From 2Dec08 (F7) N.I.

6 DK 1011 76 Shaft starter counter 1 21 DS 1110 40 Carbon bush holder plate (varroc) 1 From 2Dec08 (F7) N.I.
7 DH 1011 72 Collar starter counter 1 22 DJ 1110 87 ‘O’ Ring spigot (flash) 1 From 2Dec08 (F7) N.I.
8 DH 1011 88 Gear comp. starter counter assly. 1 23 DJ 1110 88 ‘O’ Ring kit (flash) 1 From 2Dec08 (F7) N.I.
9 39 2437 04 Bolt socket 3 24 DJ 1110 90 Bush holder assly (+) (flash) 1 From 2Dec08 (F7) N.I.
10 DH 1110 58 Motor assly. starter (varroc) 1 25 DJ 1110 86 Bush holder assly (-) (flash) 1 From 2Dec08 (F7) N.I.
DJ 1110 63 Motor assly. starter (flash) 1

11 39 1074 04 Bolt 2
12 DH 1013 72 Cover starter motor 1 Alt. DH101184
13 39 2285 01 Slotted c’sunk screw 1
14 DH 1011 64 Spring 5
15 DJ 1011 09 Bush For Spring Starter 5

28 3 29
Plate No. 24 : ENGINE MOUNTINGS 180 Plate No. 25 : FRAME & FRAME FITTINGS 180

3
4

10 6 5
16 17

14
6

7
1 8/9
4

3 15
1

2
13
12 2

2
6
7 7
9
8 5

11

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DH 1611 70 Bkt. Assly.eng.mtg.front 1 1 DJ 1612 64 Frame Assly. comp. 1 Incl. Bush, Races & Cup rear
2 DH 1611 89 Bkt. comp. LH eng. mtg. front 1 2 DH 1611 12 Cup rear 2
3 DH 1611 90 Bkt. comp. RH eng. mtg. front 1 3 30 1810 11 Nut 1
4 36 DK00 11 Kit hardware eng. mounting 1 Ref. Page No. 61 4 DH 1810 14 Cup - Steering 1
5 DJ 1611 14 Bkt. comp. LH eng. mtg. lower 1 5 36 DS18 02 Bearing Cone Kit 3 Alt. 36311803
Ref. Page No. 61
6 DJ 1611 15 Bkt. comp. RH eng. mtg. lower 1
7 39 2157 04 Bolt Flanged 3
6 36 3140 02 Ball steel 1 46 pcs
8 39 2412 04 Bolt Flanged 1 Alt. 39 2311 04
DJ 1811 15 Ball steel with cage 2 23 pcs
9 DH 1612 73 Bush in frame 1
7 39 1680 04 Flanged bolt 2
10 39 1967 04 Bolt 1
8 DJ 1611 32 Cable Hook LH 1
11 39 2414 04 Hex. soc. hd. cap bolt 1 9 DJ 1611 33 Cable Hook RH 1
12 DH 1613 01 Bkt. comp. RH eng. rear 1
13 39 2310 04 Flanged bolt 2
14 39 2311 04 Bolt 1
15 39 2457 11 Washer 1
16 DJ 1610 88 Bracket LH Engine Hanger 1
17 DJ 1610 89 Bracket RH Engine Hanger 1

30 3 31
Plate No. 26 : SWING ARM / REAR SHOCK ABSORBER 180 Plate No. 27 : RIDER FOOT REST 180

19

12
7 5 8 3
7 7
5 6
5
2 2
5
6 2
18

6 5
7 4 1
9
2 3
10
11 2

2 1
14
16 4
15
13
16
15

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1710 19 Rear Shock Absorber 2 1 DJ 1611 30 Main step LH assly. comp. 1

2 DG 1710 38 Bolt Pre-coated 2 2 39 2310 04 Flange bolt 4
3 36 DK00 12 Kit bush rear shock 1 Ref. Page No. 61 3 DJ 1611 31 Main step RH assly. comp. 1
4 DJ 1710 32 Swing arm assly. 1 4 DH 1610 53 Rubber main step 2
5 DH 1710 14 Bush swing arm 4 5 DH 1611 94 Kick stopper 1
6 DH 1710 13 Collar swing arm 2
7 DH 1710 15 Dust seal swing arm 4
8 DH 1710 19 ‘U’ nut swing arm 1
9 DH 1710 12 Shaft swing arm 1
10 DJ 1710 08 Chain slider 1

11 39 0553 02 Screw 2
12 39 0454 11 Plain washer 2
13 DJ 1510 36 Adjuster chain LH 1
14 DJ 1510 37 Adjuster chain RH 1
15 DJ 1510 47 Plate Chain Adjuster 2

16 39 0292 15 Hexagon nut 4

17 35 1710 33 Grease nipple 2
18 39 0740 11 Plain washer(Nylon) 2
19 DJ 1710 34 Nitrox chamber screw assly 2 From 26Dec08 (F4)
32 3 33
Plate No. 28 : PILLION FOOT REST / HOLDER 180 Plate No. 29 : MUDGUARD FRONT & REAR 180

4 5

5
2 2

6 4
1
3

8 7
9 9

7
8
12 12a
6
10

5 3

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1612 56 Holder LH step 1 1 DJ 1610 69 Nail for Cable Guide 1 From 26Dec08 (C10)
2 DJ 1612 57 Holder RH step 1 2 DH 1613 04 Brace fender 1
3 DH 1613 13 Pillion step assly. comp. LH 1 From Dec.2006 DH 1612 58 Brace fender 1 From 26Dec08 (C10)
4 DH 1613 15 Pillion step assly. comp. RH 1 From Dec.2006 3 DG 1810 08 Socket bolt 4 Fender front mtg.
5 DH 1613 17 Rubber pillion step 2 From Dec.2006 4 DS 1611 25 Cable guide 1 From 26Dec08 (C10)
5 DJ 1612 55 Fender rear front 1
6 36 DK00 13 Kit hardware pillion 2 Ref. Page No. 61
7 39 1069 01 Bolt 1 Stopper bolt 6 DJ 1610 91 Grommet Front Fender 4
8 39 0292 15 Nut 1 7 39 0711 11 Plain washer 4
9 39 1741 04 Flanged Bolt (Mtg holder step LH&RH) 2 Alt. 39258204 8 39 1680 04 Flange bolt 2
10 DX 1610 67 Plate lock pillion step 2 NI 9 DJ 1612 54 Fender rear 1
10 36 DS40 02 Guard Kit 1
11 DH 1611 00 Spacer main step 2 NI
12 22 1504 51 Bolt cylinder securing 2 NI 11 DJ 1612 72 Support Assly for Rear Fender 1 N.I.
12 DH 1613 03 Grommet Rear Fender 1
12a DJ 1612 91 Grommet Rear Fender 1 From 13Feb09 (C14)

34 3 35
Plate No. 30 : STAND ASSEMBLY 180 Plate No. 31 : TYRE / TUBE / RIM 180

12 3
2
14
13
15
3

4
11
1

9 4

5 10
1
7

6
2

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1612 14 Stand main 1 1 DJ 1510 77 Wheel rim front 1

2 30 1611 57 Shaft stand 1 2 DJ 1510 87 Wheel rim rear 1
3 39 0787 08 Pin cotter 1 3 DS 1510 47 Front tyre assly with tube 1
4 DH 1611 21 Spring main stand 1 4 DS 1510 30 Rear tyre assly with tube 1
5 DH 1611 45 Cover spring main stand 1

6 DJ 1612 18 Stand side 1

7 DH 1610 66 Spring side stand 1
8 DH 1611 46 Cover spring side stand 1
9 DF 1611 02 Bolt 1
10 39 0422 15 Nut 1

11 DH 2010 64 Side stand switch 1 From Mar.07

12 39 2060 04 Bolt 2
13 30 2010 64 Band 1
14 DJ 1611 88 Bkt. Side stand switch 1
15 DH 2010 65 Magnet assly. 1 From March 2007

36 3 37
Plate No. 32 : FRONT HUB (FOR DISC BRAKE) 180 Plate No. 33 : FRONT MASTER CYLINDER (FOR DISC BRAKE) 180

4
2
8 3
3

2
5 9
6 10
14 10
E

AR
NG
: US -4
NI DOT3 FRO
W NLY UID INER
M

13
11 O
E
FL TA
N AP
AK CO C NG
ER OVI

1
BR ED
AL FILL EM

10 A
SE AN
CLE FO
BE
RE
R

15
5
7
5
4
14
1
7
7
2
8
9 11 6
12
12

5
13
16
5
4

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 39 0787 08 Pin cotter 1 1 DJ 1910 23 Major Kit - Master Cylinder 1 ETS

2 39 2688 20 Bearing ball 2 Alt. 39236220 DE 1910 43 Major Kit - Master Cylinder 1 KBX
3 DE 1510 06 Spacer assly. 1 2 DJ 1510 76 Hose Brake Front 1
4 30 1510 33 Seal oil 1 3 DJ 1910 59 Lever Grip RH (ETS) 1
5 DE 1510 12 Plate drive 1 DJ 1910 57 Lever Grip RH (KBX) 1
4 DJ 1910 25 Banjo Bolt 2
5 DJ 1910 26 Washer Copper 4
6 DE 1510 08 Seal oil 1
7 DJ 1510 14 Disc (KBX) 1 Alt. DE151013 6 DJ 1910 27 Clamp Holder RH 1
DJ 1510 65 Disc (ETS) 1 7 DJ 1910 28 Bolt 1
8 39 0786 15 Hex. slotted nut 1 8 DJ 1910 29 Bolt Front Brake Lever 1
9 39 0781 11 Plain washer 1 9 DJ 1910 30 Nut Flanged 1
10 DD 1510 36 Hex. soc. hd. bolt 6 10 DJ 1910 31 Screw 2

11 DH 1510 62 Case meter assly. 1 11 DJ 1910 56 Cylinder Master (KBX) 1

12 DS 1510 58 Spacer 1 DJ 1910 58 Cylinder Master (ETS) 1
13 DJ 1510 41 Front Axle with head 1 12 DJ 2011 09 Front brake switch 1
13 DJ 1910 34 Reservoir Cover 1
14 DJ 1510 94 Rotor Speedo 1
14 DJ 1910 35 Diaphragm 1
15 36 DH19 02 Oil Window Kit 1
16 DJ 2011 08 Cable assly for switch 1
17 36 DH19 01 Minor Kit 1 N.I.
38 39
3
Plate No. 34 : FRONT DISC BRAKE 180 Plate No. 35 : REAR HUB 180

4 22
23
5 27
17 20
PISTON SEAL 19
8
DUST SEAL 15 16 22
25 14
BLEEDER CAP 21
7 5 24
x

8 PROTECTION BOOT
26
3 INSULATOR
7 18 4
CALIPER PISTON
6 2 9
13
4 BLEEDER SCREW

1 3 11
3 PAD SPRING
2
1 10
12
10
6

5
7 8

5 9

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1510 67 Caliper Assly. Front 1 1 39 2442 20 Bearing ball 1

2 39 1769 04 Bolt Flanged 2 2 30 1510 75 Collar bearing 1
3 DJ 1510 68 Spring Pad 1 3 DJ 1510 88 Damper 1
4 DJ 1510 69 Bleeder Screw 1 4 39 2686 20 Bearing ball 1 Alt. 39224120
5 DJ 1510 70 Bleeder Cap 1 5 30 1510 69 Spring 2

6 DJ 1510 71 Disc Pad Set 1 6 30 1511 05 Shoe brake assly. 1

7 DJ 1510 72 Insulator 1 7 30 1510 11 Cam brake 1
8 DJ 1510 73 Protection Boot 1 8 DJ 1510 92 Panel rear brake 1
9 DJ 1510 74 Minor Kit - Caliper 1 9 36 DK00 14 Kit lever brake 1 Ref. Page No. 61
10 DJ 1510 75 Major Kit - Caliper 1 10 DJ 1510 32 Axle 1

11 DJ 1510 34 Collar 1
12 39 2567 11 Plain washer 1
13 DH 1710 19 ‘U’ nut 1
14 39 0801 15 Nut 1
15 39 2566 11 Plain washer 1

40 41
3
Plate No. 35 : REAR HUB 180 Plate No. 36 : REAR BRAKE PADAL 180

22
23
27
17 20
19 1

15 16 22
25 14 4
21
24
3
26

18 4 6
2

13

3 11
2
10 10
1 5
12
7
6 7

5
8 9
7
5 9
8

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

16 DJ 1510 35 Collar 1 1 DH 1910 01 Lever Brake Pedal 1

17 36 DJ40 13 Chain Sprocket Kit 1 Alt. 36DJ4005 2 DJ 1910 21 Shaft assly. brake Pedal 1
Ref. Page No. 61 3 36 DK00 16 Kit hardware brake pedal 1 Ref. Page No. 61
18 DS 1510 74 Lock washer 3 4 DH 1910 06 Spring 1
19 30 1510 82 Seal oil 2 5 DJ 1910 10 Rod assly. brake 1
20 39 2240 20 Bearing ball 1
6 36 DK00 17 Kit hardware rod brake 1 Ref. Page No. 62
21 DS 1510 68 Coupling 1 7 36 DK00 18 Kit hardware rod torque 1 Ref. Page No. 62
22 DS 1510 73 ‘D’ Bolt 4 8 30 1510 95 Hex. bolt 1
23 DJ 1510 33 Sleeve 1 9 DJ 1510 42 Rod torque 1
24 39 0794 15 Hex. lock nut 4 10 DH 1510 29 Hex. bolt 1
25 DJ 1510 53 Drive Chain Lock 1

26 DJ 1510 86 Sprocket 43 T - 4 Rubber 1

27 DJ 1510 96 Chain 124 L - Solid Bush 1

42 43
3
Plate No. 37 : HANDLE BAR 180 Plate No. 37 : HANDLE BAR 180

19 19
3 3

17 17
18 2 18 2

5 5

1 N
O
21 1 N
O
21
I

I
N

N
I G N I T

I G N I T
E FF O

FF O
E
OK OK
CH CH
L O

L O
E

E
SS SS
-R

-R
PA H LO PA H LO
PUS CK PUS CK

RN RN
TU TU

20 20
4 4

9 14 9 14

16 16
13 15 13 15
8 8
7 7
11 11
22 22
12 12
15 15
16 16
10 10
6 6

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DH 1810 55 Handle Bar 1 16 DH 1810 40 Hex. soc.hd. cap screw 2 Alt. 39 2427 04
2 DH 1810 53 Holder Handle 1 17 DJ 1810 39 Pad Holder Handle 1
3 39 1714 04 Flanged bolt 4 18 DJ 2210 03 Mirror assly. LH 1
4 DH 2010 48 Control switch LH 1 19 DJ 2210 04 Mirror assly. RH 1
5 DH 2010 49 Control switch RH 1 20 DS 1810 22 Switch assly.ignition 1

6 DJ 1910 09 Lever assly. grip LH 1 21 39 1943 04 Flange bolt 2

7 DJ 1910 54 Holder left hand 1 22 DJ 2010 35 Clutch Switch 1
8 DJ 1910 55 Lever grip left 1 DJ 2011 95 Clutch Switch 1 From 26Dec08 (C11)
9 DD 1910 85 Bolt 1
10 39 1184 15 Self locking nut 1

11 36 DK00 19 Kit hardware holder kit 1 Ref. page no. 62

12 DH 1910 07 Grip LH 1
13 DH 1910 16 Grip assly.RH 1 Ref. page no. 62
14 DH 1910 19 Boot for lever 1
15 DH 1810 22 Handle bar weight 2

44 3 45
Plate No. 38 : FRONT FORK 180 Plate No. 38 : FRONT FORK 180

14 15 14 15
16 20 16 20
8 8
17 17 21
21
18 18
19 19
11 11
3 2 3 2

12 22 23 12 22 23
24 24
25 25

4/5 26 4/5 26

9 13 9 13
24 24
23 23
6 27 6 27
10 10
7 28 7 28
29 29
1 1

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1811 00 Fork front 1 without 20,21,22,23,24,25,26 16 31 1811 02 ‘O’ ring 2

DJ 1811 36 Fork front (without bellow) 1 From 20Aug08 (C9) 17 31 1811 01 Seat fork spring 2
2 36 DK00 20 Kit outer tube 1 Ref. Page No. 62 18 DS 1810 85 Spacer Tube 2
3 DJ 1810 87 Oil seal 2 19 DM 1810 10 Washer 2
4 DJ 1811 01 Outer Tube LH 1 20 31 1811 20 Bolt 1
DJ 1811 32 Outer Tube LH (without bellow) 1 From 20Aug08 (C9)
5 DJ 1811 02 Outer Tube RH 1 21 DH 1810 56 Holder fork upper 1
DJ 1811 33 Outer Tube RH (without bellow) 1 From 20Aug08 (C9) 22 DG 1810 08 Socket Bolt 2
23 DJ 1810 85 Cushion Rubber 2
6 30 1810 26 Gasket 2 24 DJ 1810 52 Cover Trail B 4
7 31 1811 06 Bolt 2 25 DH 1810 48 Lamp Shade asly. 1
8 DS 1810 77 Cylinder comp. fork 2
9 DJ 1811 03 Pipe comp. suspension inner 2 26 30 1810 09 Bearing cone 1
10 DS 1810 71 Slide Bush 2 27 DJ 1810 41 Holder fork under 1
28 39 0789 12 Spring washer 2
11 DJ 1810 45 Clamp for Bellow 2 N.S. (Deleted by C9) 29 39 1813 04 Bolt 2
12 DJ 1810 44 Bellow 2 Deleted by C9
13 DJ 1811 04 Spring front fork 2
14 DH 1810 09 Grommet Top 2
15 DH 1810 15 Bolt fork 2

46 47
Plate No. 39 : PAINTED PARTS & DECALS 180 Plate No. 39 : PAINTED PARTS & DECALS 180

5 5
6 6

3 3
1 1

11 11

4 4

7 7

2 2 8/9
8/9 10 10
180 D 180 D
TS-i TS-i

13 12 13 12

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DH 7102 X3 Fuel Tank with Decal 1 FOR EBONY BLACK 5 DJ 7302 X3 Front Fender 1 FOR EBONY BLACK
DH 7102 3A Fuel Tank with Decal 1 FOR LONG BEACH BLUE DJ 7302 3A Front Fender 1 FOR LONG BEACH BLUE
DH 7102 2T Fuel Tank with Decal 1 FOR TIT SILVER DJ 7302 2T Front Fender 1 FOR TIT SILVER
DH 7102 2V Fuel Tank with Decal 1 FOR COCKTAIL WINE RED DJ 7302 2V Front Fender 1 FOR COCKTAIL WINE RED

6 DJ 7401 X3 Fairing 1 FOR EBONY BLACK

2 DK 7301 X3 Side cover LH 1 FOR EBONY BLACK
DJ 7401 3A Fairing 1 FOR LONG BEACH BLUE
DK 7301 3A Side cover LH 1 FOR LONG BEACH BLUE
DJ 7401 2T Fairing 1 FOR TITANIUM SILVER
DK 7301 2T Side cover LH 1 FOR TIT SILVER DJ 7401 2V Fairing 1 FOR COCKTAIL WINE RED
DK 7301 2V Side cover LH 1 FOR COCKTAIL WINE RED
7 DH 1410 20 Seat tape 1
3 DK 7302 X3 Side cover RH 1 FOR EBONY BLACK 8 DK 1611 23 Cover Side Mesh LH 1
DK 7302 3A Side cover RH 1 FOR LONG BEACH BLUE 9 DK 1611 24 Cover Side Mesh RH 1
DK 7302 2T Side cover RH 1 FOR TIT SILVER 10 59 0200 01 Self tap screw 6
DK 7302 2V Side cover RH 1 FOR COCKTAIL WINE RED
11 52 DJ01 10 Tank Decal Set 1
4 DK 7303 X3 Seat Cowl Assly. 1 FOR EBONY BLACK 12 DH 1613 10 Seat Cowl Decal 2
DK 7303 3A Seat Cowl Assly. 1 FOR LONG BEACH BLUE 13 36 DK00 06 Decal Set 1
DK 7303 2T Seat Cowl Assly. 1 FOR TIT SILVER
DK 7303 2V Seat Cowl Assly. 1 FOR COCKTAIL WINE RED

48 3 49
Plate No. 40 : PETROL COCK, CAP TANK & GAUGE FUEL 180 Plate No. 41 : FITTINGS PET. TANK SI. COVER & COVER SEAT 180

3
1
5
8
4
2 9

4 13
6
2 6
11

1
15 3
8 14 10 10
7 12

13
9
12
11 4

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DH 1410 50 Cap Assly. Tank 1 1 36 DH16 01 Grommet Kit For side cover 1 Ref. Page No. 62
2 39 0840 01 Pan head screw 1 Alt. 39 1780 01 2 DH 1410 31 Tape tank inner 2
3 39 2381 04 Hex. Soc Hd. cap screw 7 3 DG 1611 21 Screw 2
4 DK 1410 01 Tap Assly 1 4 DH 1612 31 Lock for side cover with key 2
5 DJ 1811 10 4 in 1 Lock set With Key 1 5 DJ 1811 10 Lock Set (4 in 1) with Key 1 N.I.
DH 1410 48 Rotor with key 1
6 DH 1410 23 Damper 1
6 30 1410 39 Packing 1 7 DJ 1410 08 Damper front 2
7 DD 1410 22 Bolt flanged 2 8 39 1556 04 Flanged Bolt 1
8 39 0740 11 Plain Washer 2 9 39 2424 11 Plain Washer 1
9 DH 2010 38 Gauge Fuel 1 10 DJ 1612 58 Grab Handle 1 Alt. DJ161263
DH 2010 62 Gauge Fuel 1 From 2Jul07 (C1)
10 30 1410 28 Gasket fuel Gauge 1 11 39 2310 04 Bolt Flange 4
12 DJ 1610 79 Foam LH For grab 1
11 30 1410 32 Bolt 4 13 DJ 1610 80 Foam RH For grab 1
12 DJ 1410 06 Tube fuel 1
13 30 1410 15 Pipe clip 1
14 DH 1410 24 Drain tube 1
15 DJ 1410 02 Clamp 1

50 51
Plate No. 42 : METER ASSEMBLY 180 Plate No. 43 : CHAIN CASE 180

3 7

6
10
5
8 12
F
7
6

4 x 1 0 0 rpm
E km/h
4
2 SIDE
STAND
1

5 1

9 1
7
7

6
6 4
3 7
5

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 1910 70 Speedometer Assly. For Export 1 With Breather 1 52 DJ01 66 Case Chain Kit 1 Ref. Page No. 62
2 39 1778 02 Self Tapping Screw 4 2 DH 1612 84 Rubber Pad 2
3 DJ 1811 19 Back Cover 1 3 15 1610 69 Rubber Cap 1
4 DJ 2011 74 Trip Meter Knob 1 4 DH 1610 73 Instruction Label 1
5 DJ 2011 59 Speedo Meter Top Cover 1 5 39 0897 04 Bolt 2 Rear side Mtg.
DJ 2011 69 Housing With Gasket 1 Varroc
DJ 2011 90 Housing With Gasket 1 Pricol 6 39 2475 04 Bolt 2 Front side Mtg.
7 39 0711 11 Plain Washer 4
6 DJ 1910 61 Cable Accelerator 1
7 DJ 1910 15 Cable Clutch 1
8 JC 2010 15 Pig Tail 1 N.I.
9 DJ 2011 83 Assly. Speedo Sensor with cable 1 From 26Dec08 (C10)

52 3 53
Plate No. 44 : HEAD LAMP & FAIRING 180 Plate No. 45 : INDICATOR LIGHT ASSEMBLY 180

4 5

6
8
7 9 1/2

2
13
11
10 14
12
1

3/4
7
16 5

16
8 6

15

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DJ 2011 32 Head Lamp assly. without bulb 1 1 DJ 2011 48 Blinker Front LH flexible 1
2 DJ 1811 20 Back cover 1 2 DJ 2011 49 Blinker Front RH flexible 1
3 DJ 1810 33 Wind Shield 1 3 DJ 2011 46 Blinker Rear LH flexible 1
4 DF 1810 98 Bolt 4 4 DJ 2011 47 Blinker Rear RH flexible 1
5 39 2141 24 Non Metallic Washer 4 5 DJ 2011 30 Mgt. assly. blinker self cancellation 1 N.I.
DJ 2011 81 Mgt. assly. blinker self cancellation
6 DL 1810 10 Well Nut 4
7 DJ 1810 37 Decal Wind Shield 1 6 39 1970 15 Hex. nut with flange 4
8 39 1907 01 M5 x 15L mushroom HD 2 7 GH 2010 12 Amber Bulb 4
9 DJ 1810 69 Packing Fairing 1
8 DJ 2011 43 Hall Sensor Assly. 1
10 DH 1810 52 Fairing mounting upper bracket 1
DJ 2011 80 Hall Sensor Assly. 1 From 26Jul08 (C8)
11 36 DK00 21 Kit hardware mtg. bracket 1 Ref. Page No. 62
12 DJ 1810 65 Clip Nut 4
13 39 0716 01 Screw pan cross 2
14 39 1524 01 Screw pan cross 2
15 CL 2010 23 Lamp 12V 35/35W-HS1 1

16 DJ 2010 72 Pilot Bulb 2

54 3 55
Plate No. 46 : TAIL LAMP ASSLY/ FRONT & REAR NO. PLATE 180 Plate No. 47 ELECTRICAL PARTS 180

4
3 2 8
1/2
11 7
5
9 10
4
3
6

13 1
7

17
12
8

14
13
9 6
15 5
16
14
15 10 11
12 12a

Qty/ Qty/
No. Part No. Description Veh. Remarks No. Part No. Description Veh. Remarks

1 DK 2010 03 Tail light with Lamp 1 1 DH 2010 11 Horn with LH stay 1

2 DH 1612 93 Damper 2 DJ 2011 84 Horn with LH stay 1 From 13Mar09 (C15)
3 DK 1611 53 Clip Nut 4 2 DH 2010 14 Horn with RH stay 1
4 39 2592 01 Screw pan cross 4 DJ 2011 85 Horn with RH stay 1 From 13Mar09 (C15)
5 39 0705 01 Truss Screw 2 3 39 1507 11 Plain Washer 1
4 39 1956 04 Flange Bolt 1
5 DJ 2011 26 Battery (12V-9A) mf dry 1 For export only
6 39 1972 15 Bolt flange 2
7 30 2010 29 Lamp 12V-4W 1 6 DJ 1612 47 Band Battery 1
8 DK 2010 24 No. Plate illumination 1 7 DJ 2011 07 Wiring Harness 1 For spoke wheel
9 DJ 1610 72 Rear No. plate bkt. 1 DJ 2011 53 Wiring Harness 1 From 8Aug07 (C1)
10 DJ 1610 73 Number plate Rear black 1 DJ 2011 86 Wiring Harness 1 From 26Dec08 (C11)
8 DS 2010 29 Rear Brake Switch 1 Alt. 31201079
11 39 1680 04 Hex Flanged Bolt 2 9 DH 1910 12 Spring Brake Switch 1
12 39 1783 01 Truss Screw 2 For Front No. Plate 10 DH 2010 19 Grommet Rear Brake Switch 1 N.S.
13 DJ 1811 13 Number plate front black 1
14 DH 1612 92 No. plate mounting bracket 1 11 39 1680 04 Flange Bolt 1
15 39 1773 04 Bolt flange 2 12 DK 2010 16 Starter Relay / Damper 1
12a DK 2010 78 Starter Relay 1 From 26Dec08 (C11)
13 30 2011 04 Fuse Box Assly. 1
14 30 2010 85 Fuse 1
15 DJ 2011 40 Cable assly. (Battery to Earth) 1
56 3 57
Plate No. 47 : ELECTRICAL EQUIPMENTS 180

1/2 8

11 7

9 10
4
3

17 6

13

15 6
14 16
5

12 12a

Qty/
No. Part No. Description Veh. Remarks

16 DJ 2010 20 Cable assly. (Battery to St.Relay) 1

17 DJ 2011 41 Body Control Unit (BCU) Black 1 Black
DJ 2011 65 Body Control Unit (BCU) Black 1 From 18Jun08 (C3)
DJ 2011 94 Body Control Unit (BCU) Brown 1 From 7jul08 (C6)
18 JC 2010 27 Cable Starter Relay to Stater Motor 1 From 26Dec08 (C11) N.I.

58