8) PULSAR 180 UG-5 - SP - Catalogue - 10012017
8) PULSAR 180 UG-5 - SP - Catalogue - 10012017
PLATE NO. : 1 PAGE NO. PLATE NO. : 2 PAGE NO. PLATE NO. : 5 PAGE NO. PLATE NO. : 6 PAGE NO.
COVER CYLINDER HEAD 1&2 SAI UNIT 3&4 CAMSHAFT / TENSIONER 9 & 10 CYLINDER & PISTON 11 & 12
PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
CYLINDER HEAD 5&6 VALVE 7&8 CRANKSHAFT 13 & 14 Balancer & Balancer Idler Gear 15 & 16
Pictorial Index Pictorial Index
PLATE NO. : 9 PAGE NO. PLATE NO. : 10 PAGE NO. PLATE NO. : 13 PAGE NO. PLATE NO. : 14 PAGE NO.
Transmission 17 & 18 Change Drum / Shaft Fork 19 & 20 Crankcase LH 25 & 26 Cover RH 27 & 28
PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO. PLATE NO. : 15 PAGE NO. PLATE NO. : 16 PAGE NO.
Gear Change Mechanism 21 & 22 Engine Assly. & Crankcase RH 23 & 24 Cover Magneto 29 & 30 Clutch 31 & 32
Pictorial Index Pictorial Index
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
Carburettor 33 & 34 Air Cleaner Complete 35 & 36 Oil Pump 41 & 42 Magneto, CDI & H.T. Coil 43 & 44
PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
Silencer Assembly 37 & 38 Seat Assembly / Seat Lock 39 & 40 Starter Assembly (For Self Start) 45 & 46 Engine Mountings 47 & 48
Pictorial Index Pictorial Index
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO. PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
Frame Fittings 49 & 50 Swing Arm Assembly 51 & 52 Stand Assembly 57 & 58 Tube / Tyre / Rim 59 & 60
PLATE NO. : 27 PAGE NO. PLATE NO. : 28 PAGE NO. PLATE NO. : 31 PAGE NO. PLATE NO. : 32 PAGE NO.
Rider & Pillion Foot Rest / Holder 53 & 54 MUDGUARD FRONT & REAR 55 & 56 FRONT HUB 61 & 62 FRONT MASTER CYLINDER 63 & 64
Pictorial Index Pictorial Index
PLATE NO. : 33 PAGE NO. PLATE NO. : 34 PAGE NO. PLATE NO. : 37 PAGE NO. PLATE NO. : 37A PAGE NO.
Front Disc Brake Rear Hub 65 & 66 REAR HUB 67 & 68 Rear Brake Pedal 73 & 74 HANDLE BAR 75 to 78
PISTON SEAL
DUST SEAL
BLEEDER CAP
x
PROTECTION BOOT
INSULATOR
CALIPER PISTON
BLEEDER SCREW
PAD SPRING
PLATE NO. : 35 PAGE NO. PLATE NO. : 36 PAGE NO. PLATE NO. : 38 PAGE NO. PLATE NO. : 39 PAGE NO.
Rear Disc Brake 69 & 70 Rear Disc Brake Master Cylinder 71 & 72 Front Fork 77 & 78 Cap Tank & Gauge Fuel 79 & 80
Pictorial Index Pictorial Index
PLATE NO. : 40 PAGE NO. PLATE NO. : 41 PAGE NO. PLATE NO. : 44 PAGE NO. PLATE NO. : 45 PAGE NO.
CANISTER ASSEMBLY 81 & 82 Fittings P. Tank, Side Cover & Cover Seat 83 & 84 Chain Case 89 & 90 Head Lamp & Fairing 91 & 92
PLATE NO. : 42 PAGE NO. PLATE NO. : 43 PAGE NO. PLATE NO. : 46 PAGE NO. PLATE NO. : 47 PAGE NO.
Meter Assembly 85 & 86 Control Cables 87 & 88 Indicator Light Assembly 93 & 94 Tail Lamp Assly / FR & RR No. Plate 95 & 96
Pictorial Index
10
8
1 DJ 1017 08 Head Cylinder Mach. With Cover 1
2 DJ 1012 17 Cover Tappet 2
2
3 39 2539 21 ‘O’ Ring Kit For Cover Cyl. Head 1
3 4 DS 1011 66 Silent Bush (V) 1
9 6 4 5 DH 1022 01 Camshaft Cap 1
5 6 39 2647 15 Domed Cap Nut 4
7 DS 1010 84 Copper Gasket 4
7 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 Gasket 2
11
10
1 2
Plate No.: 2
180 BS IV
SAI Unit
5
8
12
9
11 10
3 4
Plate No.: 3
180 BS IV
Cylinder Head
8
12 13
5 6
Plate No.: 4
180 BS IV
Valve
7 8
Plate No.: 5
180 BS IV
Camshaft / Tensioner
4 10
9 10
Plate No.: 6
180 BS IV
Cylinder and Piston
3
6
7
9
4
5
11 12
Plate No.: 7
180 BS IV
Crank shaft
13 14
Plate No.: 8
180 BS IV
Balancer & Balancer Idler Gear
12
1
6
4
9
5
15 16
Plate No.: 9
180 BS IV
Transmission
17 18
Plate No.: 10
180 BS IV
Change Drum / Shaft Fork
1
5
19 20
Plate No.: 11
180 BS IV
Gear Change Mechanism
7 6 5 2
21 22
Plate No.: 12
180 BS IV
Engine Assly. & Crankcase RH
10
6
8 7
22 24
Plate No.: 13
180 BS IV
Crankcase LH
1 JC 1010 45 Crankcase LH 1
2 59 0500 08 Stud M10 2
3 39 0752 01 Screw 3
4 DK 1010 94 Guide Starter Gear 1
2 5 59 2100 06 O Ring 1
6 DK 1010 97 Damper Crankshaft 1
7 39 2188 19 Oil Seal 1
8 DH 1015 81 Plate Starter Clutch Gear Return 1
20 9 DH 1013 85 Bolt Flange 1
1 10 DG 1014 98 Gasket 1
19 11 DH 1016 61 Plug Drain Magnetic 1
12 KJ AB10 19 O Ring 1
13 DK 1013 80 Neutral Switch Complete 1
14 DH 1013 85 Bolt Flange 1
4 5 6 15 39 2190 19 Oil Seal 1
7
3 16 39 1677 04 Flange Bolt 8
17 39 2583 20 Bearing Ball 1
18 39 2603 20 Bearing Ball 1
19 59 2000 29 Bearing Ball Balancer 1
20 DH 1012 03 Breather Pipe 1
9 18
21 DG 1014 56 Oil Seal 1
11 17
13 8
10
21
12
14
25 26
Plate No.: 14
180 BS IV
Cover RH
27 28
Plate No.: 15
180 BS IV
Cover Magneto
29 30
Plate No.: 16
180 BS IV
Clutch
31 32
Plate No.: 18
180 BS IV
Carburettor
6
6
9
11
10
33 34
Plate No.: 19
180 BS IV
Air Cleaner Complete
4
2 3 5
10
11
35 36
Plate No.: 20
180 BS IV
Silencer Assembly
8
9
37 38
Plate No.: 21
180 BS IV
Seat Assembly / Seat Lock
39 40
Plate No.: 22
180 BS IV
Oil Pump
41 42
Plate No.: 23
180 BS IV
Magneto, CDI & H.T. Coil
16
18
5
4
8
11
2/3
43 44
Plate No.: 24
180 BS IV
Starter Assembly
45 46
Plate No.: 25
180 BS IV
Engine Mountings
5
6
5
9 8
12
5
11
10
47 48
Plate No.: 26
180 BS IV
Frame and Frame Fittings
49 50
Plate No.: 27
180 BS IV
Swing Arm / Rear Shock Absorber
12
11
10
51 52
Plate No.: 28
180 BS IV
Rider, Pillion Foot Rest & Step Holder
54 Description
No. Part No. Qty/Veh. Remarks
RH 4
4
5
DJ 1611 27
36 DK00 13
Step Assembly - Main RH
Kit Hardware Pillion
1
2
5 6 DJ 1611 86 Plate Side Pillion Step 2
13 7 DJ 1611 28 Step Assly Complete - Pillion LH 1
15 8 DJ 1611 29 Step Assly Complete - Pillion RH 1
6 14
9 39 1069 01 Screw - Hexagon Head 2
8 10 DK 1013 14 Bolt Socket Head M10x50 1
12 11 DH 1611 55 Damper Silencer 1
11 12 DH 1611 57 Tube Silencer Mounting 1
10 13 DD 1610 71 Nut -U M10 X 1.25 X Height 6.5 1
14 39 0963 15 Nut - Domed Cap :- M6 2
15 DH 1611 00 Spacer - Main Step 2
9 1
5
LH
14 15 6
7
5
53 54
Plate No.: 29
180 BS IV
Mudguard - Front & Rear
5 7 6
55 56
Plate No.: 30
180 BS IV
Stand Assembly
10
9
12
7 13
8
6 11
57 58
Plate No.: 31
180 BS IV
Tube / Tyre / Rim
59 60
Plate No.: 32
180 BS IV
Front Hub
6
2
5
3
61 62
Plate No.: 33
180 BS IV
FR. Master Cylinder
13
ON FLU
1
LE E V
EA FILL EMO
A S AN E R
LE
C FO R
BE
7
7
2
11 6
12
5
4
63 64
Plate No.: 34
180 BS IV
Front Disc Brake
9B BLEEDER CAP
10A 5
x
7
PROTECTION BOOT
8
3 INSULATOR
7
1
3
PAD SPRING
10
65 66
Plate No.: 35
180 BS IV
Rear Hub
67 68
Plate No.: 36
180 BS IV
Rear Disc Brake System
4 5
69 70
Plate No.: 37
180 BS IV
Rear Disc Brake - Master Cylinder & Caliper
11 10
12 9
71 72
Plate No.: 38
180 BS IV
Rear Brake Padal
6 1
3
73 74
Plate No.: 39
180 BS IV
Handle Bar
75 76
Plate No.: 40
180 BS IV
Front Fork
77 78
Plate No.: 41
180 BS IV
Cap Tank & Gauge Fuel
11
10
7
8
9 6
12
5 3
4
13
14
15
79 80
Plate No.: 42
180 BS IV
Canister Assembly
1 JY 1710 77 Canister 1
2 DJ 1410 72 Tube Tank To T Connector 1
3 DJ 1410 73 Tube T Connector To Canister 1
4 DJ 1410 77 Tube Connector To Purge Valve 1
5 DJ 1410 71 Tube Purge Valve To Carburetor 1
9 6 DH 1410 75 Tube Drain 1
8 7 DJ 1410 74 Tube Canister Breather 1
4 12 11
5 8 JH 1710 38 Valve Purge 1
9 PD 1716 16 Grommet Purge Valve 1
3 10 GL 1710 36 Connector Breather & Vapor Tube 1
12 11 JY 1710 69 Spring Band Clamp 11.5 X 8.4 1
12 JG 1710 29 Spring Band Clamp 13x12 5
13 2 13 JY 1710 70 Spring Band Clamp 9 X8.4 3
1 14 DG 1210 40 Clamp 1
10 12 15 JY 1718 25 Plug Fuel Drain 1
16 16 DH 1614 29 Strap Canister 2
17 DH 1410 73 Tube Canister Drain 1
6
12
13 7
17
15
81 82
Plate No.: 43
180 BS IV
Fittings P. Tank, Side Cover & Cover Seat
54 2
3
No. Part No. Description Qty/Veh. Remarks
6
1 36 DH16 01 Grommet Kit For Side Cover 1 Ref. Page No. 103
2 JC 1410 17 Grommet II 2
3 JC 1410 15 Grommet 2
4 JC 1410 16 Collar 2
5 39 1902 04 Flanged Bolt 2
6 DJ 1410 08 Damper Front 2
7 39 1556 04 Flange Bolt 1
10 8 39 2424 11 Plain Washer 1
9 DK 1611 23 Cover Side Mesh LH 1
8 7
10 DK 1611 24 Cover Side Mesh RH 1
11 11 59 0200 01 Self Tap Screw 6
13 1 12 DJ 1810 65 Clip Nut 2
13 DG 1611 21 Screw 3
14 DH 1611 58 Grommet Side Cover RR 1
9 12 1
13
14
83 84
Plate No.: 44
180 BS IV
Meter Assembly
2 1
85 86
Plate No.: 45
180 BS IV
Control Cables
87 88
Plate No.: 46
180 BS IV
Chain Case
89 90
Plate No.: 47
180 BS IV
Head Lamp & Fairing
11
91 92
Plate No.: 48
180 BS IV
Indicator Light Assembly
4 4
2 1
93 94
Plate No.: 49
180 BS IV
Tail Lamp Assly / FR & RR No. Plate
11 12
13
14
15
16
95 96
Plate No.: 50
180 BS IV
Tool Kit
97 98
Plate No.: 51
180 BS IV
Electrical Equipments
1 DK 2010 37 Horn 1
2 DK 2010 38 Horn 1
1/2
3 39 1507 11 Plain Washer 1
4 4 39 2208 04 Flange Bolt 1
3
5 DJ 2012 60 Wiring Harness 1
6 DJ 2011 26 Battery 12V 7Ah Dry 1
7 DH 1614 29 Band Battery Bkt. 1
8 JG 4018 08 Foam Battery Bracket 3
9 39 1944 04 Flange Bolt 1
10 DK 2010 78 Starter Relay 1
11 DJ 2011 40 Cable Assly. (Battery To Earth) 1 N.I
12 GF 2010 36 Fuse Box Assly. 1
5 13 30 2010 85 Fuse - 15a 2 N.I
14 DJ 2011 40 Cable Assly. (Battery To St. Relay) 1 N.I
15 30 1910 48 Cable Tie Lock 4 N.I
16 DS 2010 25 DC Flasher 1
17 DJ 1613 27 Bkt LCM Mtg 1
18 39 1944 04 Bolt for BKT Mtg (UG-5) 1
18 17
9
7
10
16
99 100
Plate No.: 52
180 BS IV
Accessories / Grab Handle
9
10
12
11
101 102
Plate No.: 53
Painted Parts & Decals
9/10
103 104
Plate No.: 54
Painted Parts & Decals
7/8
105 106
Kit List Kit List
1 36DS1001 Cyl.Head O Ring Kit 39239121 O Ring (Cover tappet) 2 10 36DH1601 Grommet kit for side cover Dh161158 Grommet side cover 4
39128321 O ring 2 DH161133 Grommet side cover rear 2
2 36DJ1004 Valve Kit DJ101124 Valve Intake 1 11 36DH4020 Kit hardware fairing mounting DJ181029 Coller faring mounting 6
DJ101125 Valve Exhaust 1 DJ181064 Grommet fearing mounting 6
3 DK101326 Valve Repair Kit DK101247 Retainer valve spring 2 39021111 Plain washer 4
DK101108 Spring valve inner 2 39155204 Flange bolt 4
DK101110 Spring valve outer 2 12 36DH4030 Kit Cam Chain Guide JM171003 Drive Chain Adjuster 2
DK101246 Seat valve spring 2 JM171004 Cap Drive Chain Adjuster 1
4 36DH4030 Guide Chain Kit DH101923 Guide chain (Tight) 1
DK101059 Guide Chain (slack) 1
5 36DK0038 Set primary drive & driven DH101628 Gear primary drive 1
DK101561 Clutch Housing com. 1
6 36DK0007 Kit centrifugal oil filter 39220011 Washer 1
DH101234 Gasket centrifugal oil filter 1
39226701 Screw 1
DH101066 Join oil dealivery 1
DH101067 Spring oil delivery 1
39219908 Pin oil delivery joint 1
7 36DH1008 Boss Kick Set DH101185 Spring Kick Starter Arm 1
DH101068 Ball steel 1
DH101547 Base kick lever 1
DH101548 Hex. bolt with flange 1
DH101320 Bolt 1
8 36DK0013 Kit hardware pillion DJ161186 Plait side pillion stape 2
DH161061 Pin pillion set 2
30141031 O ring 2
39104011 Plain washer 2
39078408 Split pin 2
9 36DK0036 Chain sprocket kit DJ151110 Sprocket (39 teeth) 1
DK151010 Chain 1
DV101048 Sprocket Drive 1
SPC Updation Details SPC Updation Details
Page Fig. Old part New part Updation Remarks Page Fig. Old part New part Updation Remarks
no. no. no. no. Description date no. no. no. no. Description date
Parts Index Parts Index
LAC00020 25 80
LCA00002 4 72
PD131803 11 66
PD151006 3 54
PD171616 9 86
PD511229 5 10
PD531029 13 14
PD551427 8 32
PD582200 1 4