dismantling - engine sub assemblies - team-bhp.com
TRANSCRIPT
Deale
r D
eve
lop
ment
Cente
r66
Cra
nk
ca
se
Clu
tch
Sid
e :
Usin
g S
pe
cia
l T
oo
l :
Be
ari
ng
Dri
ve
r se
t -
37
10
30
61
Re
mo
ve
:
•B
eari
ng
(A
) fo
r in
pu
t sh
aft
assem
bly
fro
m c
ran
kcase R
H
Usin
g
Sp
ec
ial
To
ol
: B
ea
rin
g
Extr
ac
tor
- 3
7 1
0D
J 7
7
Re
mo
ve
:
•B
earin
g
(B)
for
ou
tpu
t sh
aft
assem
bly
fro
m c
ran
kcase R
H
A
B
Cra
nk
ca
se
Ma
gn
eto
Sid
e :
Re
mo
ve
:
•O
il seal
Usin
g
Sp
ec
ial
To
ol
: B
ea
rin
g
Extr
ac
tor
- 3
7 1
0D
J 7
7
Re
mo
ve
:
•B
earin
g
(A)
for
ou
tpu
t sh
aft
assem
bly
fro
m c
ran
kcase L
H
Usin
g
Sp
ec
ial
To
ol
: B
ea
rin
g
Extr
ac
tor
- 3
7 1
0D
J 7
7
Re
mo
ve
:
•B
earin
g (A
) fo
r b
od
y b
ala
ncer
gear
bearin
g
fro
m
cra
nkcase
LH
Usin
g
Sp
ec
ial
To
ol
: B
ea
rin
g
Extr
ac
tor
- 3
7 1
0D
J 7
6
Re
mo
ve
:
•B
eari
ng
(A
) fo
r in
pu
t sh
aft
assem
bly
fro
m c
ran
kcase L
H
A
A
A
Dis
ma
ntl
ing
of
Oil S
ea
ls a
nd
Be
ari
ng
s :
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sD
eale
r D
eve
lop
ment
Cente
r65
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Re
mo
ve
:
•2
Co
tter
valv
e (
A)
•V
alv
e s
prin
g r
eta
iner
(B)
•S
prin
gs i
nn
er
(D)
•S
prin
g o
ute
r (C
)
•V
alv
e f
rom
belo
w (
E)
•W
ash
er
(F)
•V
alv
e s
team
seal
(G)
Sim
ila
rly
ca
rry
ou
t th
e
sa
me
p
roced
ure
to
d
ism
an
tle th
e o
ther
va
lve
fr
om
th
e
cylin
de
r h
ea
d
assem
bly
.
To
p E
nd
:
Cylin
de
r H
ea
d
Usin
g S
p.
To
ol
Va
lve
S
pri
ng
C
om
pre
sso
r 3
7 1
03
1 0
7 &
A
da
pte
r
37
10
DJ
78
A
B
D
C
F
E
Cylin
de
r H
ea
d C
ove
r
Us
ing
S
p.
To
ol
Ro
ck
er
Pin
rem
ove
r 3
7 1
0D
H 3
5
Re
mo
ve
:
•R
ocker
sh
aft
(A
)
•R
ocker
arm
•S
et
of
wash
ers
(1
w
ave
an
d
2 p
lan
e)
(B)
•R
olle
rs 2
0 n
os.
(C)
No
te
: S
imila
rly
rem
ove
the
oth
er
Ro
cker
shaft
&
R
ocker
Arm
fr
om
head
over
AB
C
Ma
gn
eto
Co
ve
rR
em
ove
:
•2
Ph
illip
s h
ead
scre
ws (
A)
of
pu
lsar
co
il (E
) m
ou
ntin
g.
•B
olts (
B)
of
sta
tor
assem
bly
.
•1
Ph
illip
s h
ead
scre
w (
C)
of
sto
pp
er.
•S
tato
r co
il assem
bly
(D
) alo
ng
with
pu
lsar
co
il.
A
E
DC
Re
mo
ve
:
•B
olt (A
)
•B
earin
g s
top
per
Usin
g
Sp
ec
ial
To
ol
: B
ea
rin
g
Dri
ve
r S
et
- 3
7 1
0B
A 6
1
Re
mo
ve
:
•B
earin
g
for
gear
dru
m
fro
m
RH
cra
nkcase
Dis
ma
ntl
ing
of
Su
ba
sse
mb
lie
s :
A
B
Dis
mantlin
g -
Eng
ine S
ub
Assem
blie
sD
ism
antlin
g -
Eng
ine S
ub
Assem
blie
s
Deale
r D
eve
lop
ment
Cente
r68
Deale
r D
eve
lop
ment
Cente
r67
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Ch
ain
Te
nsio
ne
r A
sse
mb
ly
Re
mo
ve
:
•C
irclip
(A
) fr
om
th
e b
od
y (
I)
•C
ap
(B
) alo
ng
with
scre
w i
nte
rnal
an
d s
cre
w e
xte
rnal
(C)
•S
prin
g (
D)
•T
hru
st
wash
er
(E)
•‘O
' rin
g (
F)
•B
olt (
G)
an
d ‘
O’
rin
g (
H)
AB
E
D
C
HG
F
I
Kic
k S
ha
ft A
sse
mb
ly
Re
mo
ve
:
•T
hru
st
wash
er
(A)
•W
ash
er
thru
st
(B)
•C
irclip
(C
) &
th
rust
wash
er
(D)
•S
prin
g k
ick s
tart
er
ratc
het
(E)
•R
atc
het
kic
k s
tart
er
(F)
•C
irclip
(G
)
•W
ash
er
(H)
•P
inio
n c
om
ple
te k
ick s
tart
er
(I)
Oil P
um
p
Re
mo
ve
:
•C
lip (
A)
•O
il str
ain
er
ele
men
t (B
) w
ith
‘O’
rin
g (
C)
Clu
tch
Asse
mb
ly
Re
mo
ve
:
•4
bo
lts (
A)
•H
old
er
clu
tch (
B)
•4
sp
rin
gs (
C)
•C
lutc
h c
en
ter
(D)
•P
lain
wash
er
•B
elli
velli
e w
ash
er
•D
isc c
lutc
h f
rictio
n (
E)
(Qty
. 6
fo
r 1
80
cc /
Qty
. 5
fo
r 1
50
cc)
•P
late
clu
tch
(F
)
•P
late
clu
tch
pre
ssu
re (
G)
(Wh
eel
clu
tch
)
•C
lutc
h h
ou
sin
g
•T
hru
st
wash
er
- co
nic
al
fro
m i
nn
er
ID
BC A
C
E
F
G
H
I
BA
D
2
14
17
1
16
9
8
12
10
5
7
6
7
6
7
6
4
6
15
11
13
3
Be
ari
ng
R
em
ova
l fr
om
A
ssly
B
ala
nc
er
Idle
r G
ea
r C
ove
r a
nd
Cra
nk
ca
se
RH
Usin
g S
p.
To
ol
: B
ea
rin
g E
xtr
ac
tor
- 3
7 1
0C
D 3
0
Re
mo
ve
:
•N
eed
le r
olle
r b
earin
g f
rom
RH
cra
nkcase.
Asse
mb
ly B
ala
nc
er
Idle
r G
ea
r
Re
mo
ve
:
•T
hru
st
wa
sh
ers
(A
)
•C
irclip
(B
) fr
om
an
y o
ne s
ide o
f th
e g
ear
•S
cis
so
r g
ear
(C)
•T
ors
ion
Sp
rin
g (
D)
Sim
ilarly
carr
y
ou
t th
e
sam
e
pro
ced
ure
o
n
oth
er
sid
e
of
the
gear
to d
ism
an
tle t
he i
dle
r g
ear
co
mp
lete
ly.
AC
BD
EC
BA
D
Ge
ar
Co
mp
lete
Sta
rte
r C
ou
nte
r A
sse
mb
ly
•P
lace
the
gear
co
mp
. sta
rter
co
un
ter
assly
o
n
the
arb
or
pre
ss
as s
ho
wn
in
th
e f
igu
re.
•U
sin
g B
earin
g d
river
set
(P.
No
. 3
7 1
03
0 6
1)
Re
mo
ve
:
•N
eed
le r
olle
r b
earin
g
Inp
ut
Sh
aft
Asse
mb
ly
•1
st
gear
is i
nte
gra
l w
ith
th
e s
haft
(A
)
•R
em
ove t
hru
st
wash
er
(B)
an
d s
lide o
ut
gear
2n
d d
rive (
C)
•R
em
ove
gear
5th
d
rive
(D)
an
d
co
llect
the
sp
lined
w
ash
er
(E)
beh
ind
it.
•R
em
ove c
irclip
(F
) an
d r
em
ove g
ear
3rd
drive (
G)
•R
em
ove c
irclip
(H
) an
d c
olle
ct
the s
plin
ed
wash
er
(I)
•R
em
ove g
ear
4th
(J
) an
d c
olle
ct
the t
hru
st
wash
er
(K)
beh
ind
it.
Ou
tpu
t S
ha
ft A
sse
mb
ly
•T
here
are
no
in
teg
ral g
ears
on
ou
tpu
t sh
aft
.
•R
em
ove t
hru
st
wash
er
(A)
an
d s
lide o
ff t
he g
ear1
st
driven
(B
) an
d
st
co
llect
the s
teel
bu
sh
(1
driven
gear
is m
ou
nte
d o
n s
teel
bu
sh
(C
) w
ith
sh
ou
lder
rin
g
•S
lide o
ff t
he g
ear
4th
driven
(D
).rd
•
Rem
ove circlip
(E
) an
d sp
line w
ash
er
(F).
R
em
ove th
e g
ear
3
driven
(G
).rd
•C
olle
ct
the t
hru
st
wash
er
(H)
beh
ind
th
e 3
gear
on
ou
tpu
t sh
aft
(I)
•R
em
ove c
irclip
(J
) an
d c
olle
ct
the w
ash
er
(K)
nd
•R
em
ove g
ear
2 d
riven
(L
) m
ou
nte
d o
n b
ush
(N
) w
ith
sh
ou
lder
rin
g
•S
lide o
ut
gear
5th
driven
(M
)
BC
D
EF
GH
J
IK
A
AB
C
D
EF
G
H
IJ
KLM
N
Dis
mantlin
g -
Eng
ine S
ub
Assem
blie
sD
ism
antlin
g -
Eng
ine S
ub
Assem
blie
s
Deale
r D
eve
lop
ment
Cente
r70
Deale
r D
eve
lop
ment
Cente
r69
Cra
nk
ca
se
Ma
gn
eto
Sid
e
Re
mo
ve
:
•3
Scre
ws (
A)
•G
uid
e s
tart
er
assem
bly
(B
) o
n w
hic
h o
il seal
is m
ou
nte
d.
•O
il seal
(C)
•D
am
per
(D)
Ge
ar
Sta
rte
r C
lutc
h
Re
mo
ve
:
•P
lace t
he g
ear
sta
rter
clu
tch
on
arb
or
pre
ss a
s s
ho
wn
in
ph
oto
•U
sin
g B
earin
g D
river
Set
(P.
No
.: 3
7 1
03
0 6
1)
Re
mo
ve
:
•N
eed
le r
olle
r b
earin
g
Clu
tch
Co
ve
r
Re
mo
ve
:
•P
ara
llel
Pin
(A
)
•C
lutc
h s
haft
rele
ase c
om
ple
tely
(B
) b
y s
ligh
tly r
ota
tin
g i
t so
,
•R
ack (
C)
•P
lun
ger
oil
(D)
•P
late
plu
ng
er
oil
(E)
•S
prin
g j
oin
t ‘A
’ (F
)
•O
il fille
r p
lug
(G
)
•O
il seal
kic
k s
haft
(H
)
•W
ire c
lip (
I)
•O
il in
sp
ectio
n w
ind
ow
•F
lan
ged
bo
lt (
8 N
os.) (
J)
•S
et
of
dam
per
(K)
•S
et
of
pla
te (
L)
•G
rom
met
(M)
Ca
msh
aft
Dis
ma
ntl
ing
Usin
g S
pe
cia
l T
oo
l :
Be
ari
ng
Pu
lle
rs:
37
10
DJ
74
fo
r B
ea
rin
g 3
92
27
02
0
37
10
DJ
75
fo
r B
ea
rin
g 3
91
48
52
0
Re
mo
ve
:
•B
igg
er
Bearin
g u
sin
g sp
. to
ol
fro
m c
am
sh
aft
assem
bly
(A)
•C
olla
r d
e-c
om
p (
B)
•D
eco
mp
ressio
n u
nit (
C)
•S
mall
Bearin
g (
E)
•L
ock w
ash
er
(D)
•P
ara
llel p
in (
F)
A
B
C
D
BG
FE
D
A
H
J
L
K
C
AB
C
D
E
F
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Dis
mantlin
g -
Eng
ine S
ub
Assem
blie
s
Deale
r D
eve
lop
ment
Cente
r72
Deale
r D
eve
lop
ment
Cente
r71
Part
s I
nsp
ectio
n P
ara
mete
rs
Rin
gs :
•N
o u
neven
wear
aro
un
d c
ircu
mfe
ren
ce /
bre
akag
e.
•D
isco
lora
tio
n a
t w
ork
ing
face.
•C
arb
on
bu
ilt u
p o
n i
nn
er
face i
f an
y.
•P
isto
n r
ing
en
d g
ap
-
As p
er
Serv
ice d
ata
•P
isto
n r
ing
wid
th (
thic
kn
ess)
- A
s p
er
Serv
ice d
ata
•F
ree r
ota
tio
n o
f R
ing
s i
n P
isto
n g
roo
ves -
No
stickyn
ess.
•P
ito
n r
ing
id
en
tificatio
n m
ark
To
p R
ing
: T
OP
1,
Se
co
nd
Rin
g :
TO
P 2
Sp
ark
Plu
g :
•T
yp
e /
Heat
valu
e -
RG
4 H
C/B
osh
UR
3D
C (
Resis
tive)
•G
ap
betw
een
ele
ctr
od
es -
0.7
to
0.8
mm
•E
lectr
od
e c
on
ditio
n -
No
err
osio
n
•C
olo
ur
at
the e
lectr
od
es t
ip -
Bro
wn
ish
•T
hre
ad
s o
f re
ach
po
rtio
n -
Ok /
No
dam
ag
e
Cylin
de
r H
ea
d :
•M
atin
g
su
rface
: N
o
warp
ag
e
/ N
o
scra
tch
es
(Serv
ice
limit
for
warp
ag
e:
0.0
5m
m)
•Id
en
tificatio
n m
ark
- D
J m
ark
em
bo
ssed
on
castin
g
•N
o f
ins b
reakag
e
•S
park
plu
g h
ole
th
read
s -
Ok /
No
dam
ag
e
•C
arb
on
bu
ilt u
p i
n c
om
bu
stio
n c
ham
ber
cavity-
Cle
an
it
•V
alv
e s
eat
: N
o p
ittin
g /
No
carb
on
dep
ositio
n
•P
rop
er
fitm
en
t o
f D
am
pers
(4
No
s)
•P
rop
er
fitm
en
t o
f ‘O
’rin
gs
•P
rop
er
fitm
en
t o
f valv
e s
tem
oil
seals
on
valv
e g
uid
e
•V
alv
e g
uid
e f
or
cra
ck i
f an
y
•S
ilen
cer
mo
un
tin
g s
tud
s t
hre
ad
s -
Ok /
No
dam
ag
e
Cylin
de
r B
loc
k :
•N
o f
ins b
reakag
e
•N
o S
co
rin
g m
ark
s
•N
o S
eiz
ure
mark
s
•O
k S
eatin
g –
matin
g s
urf
aces
•S
mo
oth
Ho
nin
g p
att
ern
•C
orr
ect
/ S
am
e g
rou
pin
g m
ark
w.r
.t.
pis
ton
(A
& B
gro
up
)
•In
ner
dia
mete
r o
f b
lock a
s m
en
tio
ned
in
serv
ice d
ata
.
•O
valit
y -
No
t m
ore
th
en
0.0
5 m
m.
•3
No
s.
of
dam
per
rub
bers
Pro
perly
fitt
ed
on
fin
s
•P
rop
er
fitm
en
t o
f ‘O
’ rin
g o
n b
ott
om
sid
e
Pis
ton
:
•G
rou
pin
g m
ark
with
resp
ect
to c
ylin
der
blo
ck m
ust
be s
am
e.
•D
iam
ete
r o
f th
e p
isto
n -
As m
en
tio
ned
in
serv
ice d
ata
•N
o s
co
rin
g m
ark
s o
n t
he s
kirt
•N
o b
low
by m
ark
s
•N
o s
eiz
ure
mark
s.
•M
an
ufa
ctu
rin
g /
Id
en
tificatio
n c
od
e a
nd
date
co
de
•P
isto
n p
in -
scra
tch
es d
en
t m
ark
s
Cra
nksh
aft
:
•B
ig e
nd
axia
l/ra
dia
l p
lay
:A
s p
er
Serv
ice d
ata
.
•R
un
ou
t:
As p
er
Serv
ice d
ata
.
•T
hre
ad
ing
co
nd
itio
n:
Ok /
No
dam
ag
es.
•K
ey w
ay c
on
ditio
n:
Ok /
No
dam
ag
es.
•B
ig e
nd
bearin
g:
Fre
e r
ota
tio
n /
Jam
•C
on
-ro
d:
No
ben
din
g /
tw
istin
g
•O
il p
assag
e:
No
blo
ckag
e.
•S
qu
are
slo
t key w
ay f
or
prim
ary
gear
Cra
nkc
ase
:
•M
atin
g s
urf
ace
:S
mo
oth
/ N
o s
cra
tch
es.
•N
o C
racks,
dam
ag
es,
bre
akag
e.
•B
earin
g seat,
o
il seal
seat
& p
rop
er
pre
ssin
g /
po
sitio
nin
g o
f o
il seals
, n
eed
le r
olle
r, b
all
bearin
gs f
reely
ro
tatin
g
•N
o B
low
ho
les i
n c
astin
g
•B
reath
er
pip
e /
ho
le:
No
clo
gg
ing
•O
il p
assag
e:
Cle
an
/ N
o c
log
gin
g
•T
hre
ad
s o
f h
ole
s &
stu
ds
:O
k /
No
dam
ag
es
•V
isib
le n
um
ber
pu
nch
ing
on
LH
Cra
nk C
ase
Be
ari
ng
s :
•A
xia
l p
lay
:O
k /
No
t excessiv
e
•R
ad
ial
pla
y:
Ok /
No
t e
xcessiv
e
•B
earin
g S
eat
:N
o s
ign
of
hig
h s
po
t o
n s
eatin
g a
rea.
•B
earin
g c
lass &
co
de
:A
s p
er
sp
ecific
atio
n n
um
bers
•B
earin
g R
ota
tio
n:
Fre
e R
ota
tio
n
Clu
tch
:
•C
lutc
h p
late
s /
Ste
el
pla
tes -
Th
ickn
ess a
s p
er
serv
ice d
ata
•W
arp
ag
e
as p
er
serv
ice d
ata
•N
o S
eiz
ure
/ D
am
ag
ed
bo
nd
ing
of
fric
tio
n m
ate
rial
•T
an
gs (
Lu
gs)
/ T
eeth
- N
o w
earin
g
•T
hru
st
pla
te c
racked
•N
o F
ore
ign
mate
rial
em
bed
ded
•C
olo
ur
ch
an
ge
/ S
ign
s o
f o
verh
eatin
g i
f an
y
•N
o u
neven
wear
patt
ern
•S
teel
pla
tes p
lan
ish
ing
•C
on
ical
face m
ach
inin
g f
or
sp
acer
clu
tch
Clu
tch
Ho
usin
g :
•N
o W
ear
mark
s o
n s
lots
.
•C
leara
nce
betw
een
clu
tch
p
late
ta
ng
s
an
d
slo
t in
th
e
clu
tch
h
ou
sin
g s
ho
uld
no
t b
e e
xcessiv
e
•F
ree m
ovem
en
t o
f p
late
s i
n c
lutc
h h
ou
sin
g
slo
ts.
•R
ivets
of
clu
tch
h
ou
sin
g
sh
ou
ld n
ot
be l
oo
se.
•F
ree r
ota
tio
n o
f h
ou
sin
g o
n I
np
ut
sh
aft
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Part
s I
nsp
ectio
n P
ara
mete
rs
Deale
r D
eve
lop
ment
Cente
r73
Deale
r D
eve
lop
ment
Cente
r74
Clu
tch
Hu
b /
Clu
tch
Wh
ee
l :
•C
on
tact
su
rface
for
fric
tio
n
pla
tes-s
ho
uld
n
ot
be
wo
rn
ou
t excessiv
ely
•P
ressu
re P
late
fre
e m
ovem
en
t in
clu
tch
hu
b s
plin
es
•H
ole
s f
or
lub
ricatio
n
•C
lutc
h h
ub
heig
ht
•S
mo
oth
ness i
n I
D o
f clu
tch
wh
eel
•S
pacer
free m
ovem
en
t o
n c
lutc
h w
heel
•P
resen
ce o
f p
lain
an
d w
ave w
ash
er
in 1
st
clu
tch
pla
te
Tra
nsm
issio
n :
•N
o T
eeth
bre
akag
e o
r cra
ck
•N
o W
ear
patt
ern
on
teeth
•N
o W
ear
of
do
g t
eeth
& d
og
ho
les o
n g
ear
•N
o S
eiz
ure
mark
on
gear
seat.
st
nd
rd•
Fre
e m
ovem
en
t o
f g
ears
on
th
e s
haft
(1
Ou
tpu
t,
2
Ou
tpu
t,
3
th
thO
utp
ut,
4
Inp
ut
an
d
5
inp
ut
gears
are
fr
ee
on
th
e
resp
ective
sh
aft
)
•F
ree m
ovem
en
t o
f F
ork
sh
ift
on
th
e f
ork
sh
aft
•G
ear
sh
ift
dru
m g
roo
ve p
rofile
- O
k /
No
dam
ag
e -
Wear
•F
ree m
ovem
en
t o
f F
ork
sh
ift
gu
ide r
olle
r in
th
e d
rum
gro
ove
Dru
m :
•P
resen
ce o
f N
eu
tral
rivet
on
th
e D
rum
•F
ree r
ota
tio
n o
f D
rum
in
LH
cra
nkcase p
are
nt
ho
le.
•In
ner
ho
llow
po
rtio
n m
ust
be f
ree f
rom
castin
g d
ust
/ b
urr
•G
roo
ve p
rofile
wid
th a
s p
er
Serv
ice D
ata
•H
ole
availa
ble
fo
r p
ara
llel
pin
•D
rum
pro
file
fre
e f
rom
Hi-
Sp
ot
for
free s
lidin
g o
f b
ush
Ca
rbu
rett
or
:
•F
loat
-N
o p
un
ctu
re
-A
lign
men
t w
.r.t
flo
at
pin
- O
k
-N
ot
to
uch
ing
to
bo
wl
walls
•N
eed
le V
alv
e
-N
o g
roo
ve f
orm
atio
n o
n t
he t
ip
-S
mo
oth
actio
n o
f sp
rin
g l
oad
ed
p
in,
-S
mo
oth
mo
vem
en
t in
its
seat.
•V
olu
me C
on
tro
l S
cre
w
-N
ot
ben
t /
Th
read
s
OK
. /
No
t ja
mm
ed
/
Pre
sen
ce
of
Sp
rin
g
Wash
er
an
d ‘
O’
rin
g.
•Jets
-C
orr
ect
siz
e,
No
wear
of
jet
ho
le,
No
clo
gg
ing
•P
isto
n V
alv
e
-S
mo
oth
fre
e s
lidin
g,
cle
ara
nce i
n i
ts s
eat,
no
excess w
ear
mark
.
•C
ho
ke O
pera
tio
n -
Sm
oo
th (
Pu
sh
an
d p
ull
typ
e)
Gu
ide
Kic
k :
•N
o p
resen
ce o
f an
y b
urr
& f
lash
es
•F
ace t
o f
ace f
itm
en
t o
n C
ran
kcase a
fter
tig
hte
nin
g.
•A
pp
licatio
n o
f lo
ctite
63
8 t
o s
ecu
rin
g a
llen
bo
lts
Ca
msh
aft
:
•P
resen
ce o
f lo
catin
g w
ash
er
•F
ree r
ota
tio
n o
f b
earin
g
•L
ob
e h
eig
ht
- as p
er
Serv
ice D
ata
•N
o c
ut
/ w
ear
mark
s o
n c
am
•D
e-c
om
p m
ech
an
ism
stickyn
ess
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
No
tes :
Part
s I
nsp
ectio
n P
ara
mete
rsP
art
s I
nsp
ectio
n P
ara
mete
rs
Serv
ice D
ata
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r75
Deale
r D
eve
lop
ment
Cente
r76
Serv
ice D
ata
- E
ng
ine
26.0
~ 1
0.0
Kg
/cm
Std
. L
imit
Se
rv.
Lim
it2
5.0
~ 1
0.0
Kg
/cm
Co
mp
ressio
n P
ressu
re
31.0
Inle
t
30.8
Std
. L
imit
Se
rv.
Lim
it
30.4
Exh
au
st
30.2
Ca
m H
eig
ht
4.4
8
Inle
t
4.4
0
Std
. L
imit
Se
rv.
Lim
it
4.4
6
Exh
au
st
4.4
1
Va
lve
Ste
m D
iam
ete
r
TIR
0.0
1S
td.
Lim
it
Se
rv.
Lim
itT
IR 0
.03
Va
lve
Ste
m B
en
d
0.5
Inle
t
0.3
Std
. L
imit
Se
rv.
Lim
it
0.8
Exh
au
st
0.6
Va
lve
He
ad
Th
ick
ne
ss
127.0
0 ~
127.2
0S
td.
Lim
it
Se
rv.
Lim
it128.0
Ca
msh
aft
Ch
ain
Lth
. 2
0 L
ink
s
20
-lin
k le
ng
th
1st
2n
d2
1st
ME
AS
UR
E T
HIS
LE
NG
TH
Se
rv.
Lim
it0.0
5
Cylin
de
r H
ea
d W
arp
Va
lve
Cle
ara
nc
e
0.0
5
Inle
t
0.0
5
Std
. L
imit
Se
rv.
Lim
it
0.1
0
Exh
au
st
0.1
5
Va
lve
Sp
rin
g F
ree
Le
ng
th
39.1
0
Inn
er
39.0
0
Std
. L
imit
Se
rv.
Lim
it
43.6
Ou
ter
42.6
Ca
m S
pro
ck
et
Dia
me
ter
61.4
8 ~
61.3
6S
td.
Lim
it
Se
rv.
Lim
it61.3
0
7.9
94 ~
8.0
Std
. L
imit
Se
rv.
Lim
it7.9
8
Ro
ck
er
Arm
Sh
aft
Dia
.
63.5
0 ~
63.5
08
Std
. L
imit
Se
rv.
Lim
it63.5
08 ~
63.5
15
Cylin
de
r In
sid
e D
iam
ete
r
10m
m
20m
m
40m
m
0.0
12 ~
0.0
30
Std
. L
imit
Se
rv.
Lim
it—
Pis
ton
/ C
ylin
de
r C
lea
ran
ce
Pis
ton
Dia
me
ter
7m
m
63.4
78 ~
63.4
88
Std
. L
imit
Se
rv.
Lim
it63.4
88 ~
63.4
98
Pis
ton
Rin
g /
Gro
ove
Cle
arn
.
0.0
2~
0.0
6
TO
P
0.1
6
Std
. L
imit
Se
rv.
Lim
it
0.0
1~
0.0
5
SE
CO
ND
0.1
5
Pis
ton
Rin
g E
nd
Ga
p
0.1
5~
0.3
0
TO
P
0.5
5
Std
. L
imit
Se
rv.
Lim
it
0.3
0~
0.4
5
SE
CO
ND
0.7
0
Fri
cti
on
Pla
te T
hic
kn
ess
2.9
~ 3
.1S
td.
Lim
it
Se
rv.
Lim
it2.7
5
4.4
Std
. L
imit
Se
rv.
Lim
it4.2
Sh
ift
Fo
rk G
uid
e P
in D
ia.
Sh
ift
Dru
m G
roo
ve
Wid
th
Std
. L
imit
Se
rv.
Lim
it
7.1
5
7.0
Pre
ssu
re P
late
Wa
rp 0.2
Std
. L
imit
Se
rv.
Lim
it0.3
Clu
tch
Sp
rin
g F
ree
Le
ng
th
30.0
Std
. L
imit
Se
rv.
Lim
it29.0
Std
. L
imit
Se
rv.
Lim
it
0.0
2 M
ax.
0.0
5
Cra
nk
sh
aft
Ru
n O
ut
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Deale
r D
eve
lop
ment
Cente
r77
Deale
r D
eve
lop
ment
Cente
r78
Fro
nt
Bra
ke
Pa
d T
hic
kn
ess
7.4
Std
. L
imit
Se
rv.
Lim
it3.8
Axle
Ru
n O
ut
TIR
0.1
or
Less
Std
. L
imit
Se
rv.
Lim
itT
IR 0
.2
10
0 m
m
Dri
ve
Ch
ain
Sla
ck
25 ~
35
Std
. L
imit
Se
rv.
Lim
it40 ~
50
Dri
ve
Ch
ain
Le
ng
th
254.0
~ 2
54.6
Std
. L
imit
Se
rv.
Lim
it259.0
20
-lin
k le
ng
th
1st
2n
d2
1st
ME
AS
UR
E T
HIS
LE
NG
TH
Bra
ke
Pa
ne
l C
am
Ho
le D
ia.
12.0
0 ~
12.0
3S
td.
Lim
it
Se
rv.
Lim
it12.1
5
Bra
ke
Ca
m D
iam
ete
r
11.9
5 ~
11.9
8S
td.
Lim
it
Se
rv.
Lim
it11.8
8
Bra
ke
Dru
m I
nsid
e D
iam
ete
r
130 .
0 ~
130.1
6S
td.
Lim
it
Se
rv.
Lim
it130.7
5
Bra
ke
Sh
oe
Lin
ing
Th
ick
ne
ss
3.8
5 ~
4.1
5S
td.
Lim
it
Se
rv.
Lim
it2.0
Axia
l W
he
el
Ru
n O
ut
TIR
1.0
or
Less
Std
. L
imit
Se
rv.
Lim
itT
IR 2
.0
Ra
dia
l W
he
el
Ru
n O
ut
TIR
0.8
or
Less
Std
. L
imit
Se
rv.
Lim
itT
IR 2
.0
Re
ar
Sp
roc
ke
t W
arp
0.4
or
Less
Std
. L
imit
Se
rv.
Lim
it0.5
Tyre
Tre
ad
De
pth
Fro
nt:
5.0
R
ear:
6.8
Std
. L
imit
Se
rv.
Lim
itF
ron
t: 1
.0
Rear:
1.5
Fro
nt
Fo
rk S
pri
ng
Fre
e L
en
gth
398.5
0S
td.
Lim
it
Se
rv.
Lim
it391.0
0
Fre
e L
en
gth
Fro
nt
Fo
rk O
il
Gra
de
:S
AE
10
W2
0
Qu
an
tity
:16
5 m
l /
Fo
rk P
ipe
(Dra
in &
Re
fill)
Fork Oil Level
218 + 2.0 mm.
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
No
tes :
Serv
ice D
ata
- F
ram
eS
erv
ice D
ata
- F
ram
e
Deale
r D
eve
lop
ment
Cente
r79
Deale
r D
eve
lop
ment
Cente
r80
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Sh
aft
In
pu
t T
ran
sm
issio
n
DK
10
11
25
Ta
pe
r p
rovid
ed
on
sh
aft
ne
ar
clu
tch
mo
un
tin
g e
nd
.
Gu
ide
Ge
ar
Sh
ift
DK
10
11
58
Gu
ide
Ge
ar
wit
h 6
pin
s i
s m
esh
ed
wit
h g
ea
r
ch
an
ge
le
ve
r &
tra
nsm
its r
ec
ipro
ca
tin
g m
oti
on
in
to
rota
ry m
oti
on
& t
hu
s r
ota
tes d
rum
ch
an
ge
.
Fo
rk G
ea
r S
hif
t (I
np
ut
& O
utp
ut)
Inp
ut
: D
K 1
01
1 3
3
Ou
tpu
t :
DK
10
11
34
Th
e r
oller
in f
ork
gear
sh
ift
roll i
n t
he d
rum
pro
file
sm
oo
thly
as &
wh
en
dru
m r
ota
tes &
gu
ides t
o t
ran
sm
it T
o &
Fro
mo
tio
n t
o f
ork
gear
sh
ift
for
matc
hin
g r
esp
ecti
ve g
ears
.
• P
in d
iam
ete
r is
4.4
mm
• ‘
U’
ma
rk o
n f
ork
sh
ift.
Ge
ar
Dru
m C
ha
ng
e A
sse
mb
ly
DK
10
11
32
Pro
file
wid
th i
s 7
.15
mm
. It
ha
s a
sq
ua
re w
ind
ow
pa
ralle
l to
ne
utr
al
sto
pp
er
loc
ate
r.
Pa
rt N
o.
Be
tte
r c
lam
pin
g o
f c
lutc
h a
ssly
is e
nsu
red
on
Inp
ut
Sh
aft
fo
r e
ffe
cti
ve
to
rqu
e t
ran
sm
issio
n w
ith
this
ne
w c
lutc
h m
ec
ha
nis
m.
Gu
ide
Ge
ar
is h
avin
g 6
pin
s.
It h
as a
wid
e p
rofi
le (
gro
ove
) fo
r sm
oo
th r
ollin
g o
f
fork
ge
ar
sh
ift
rolle
r in
dru
m p
rofi
le f
or
sm
oo
th
sh
ifti
ng
of
ge
ar.
7.1
5
mmØ 4
.4
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-III
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-II
Se
lec
tor
leve
r o
pe
rate
s r
ad
ially.
Se
lec
tor
leve
r is
sh
ort
in
le
ng
th.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Le
ve
r C
om
p G
ea
r S
hif
t
DH
10
17
05
Le
ve
r c
om
p.
ge
ar
sh
ift
is m
esh
ed
wit
h g
uid
e g
ea
r
sh
ift
co
nsta
ntl
y.
Th
us h
elp
s i
n t
ran
sm
itti
ng
rec
ipro
ca
tin
g m
oti
on
to
gu
ide
ge
ar.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Sh
aft
In
pu
t T
ran
sm
issio
n
DH
10
15
19
No
Ta
pe
r p
rovid
ed
on
sh
aft
ne
ar
clu
tch
mo
un
tin
g e
nd
.
Gu
ide
Ge
ar
Sh
ift
DJ 1
01
1 4
8
Gu
ide
Ge
ar
wit
h 4
pin
s i
s m
esh
ed
wit
h g
ea
r c
ha
ng
e
leve
r &
tra
nsm
its r
ec
ipro
ca
tin
g m
oti
on
in
to r
ota
ry
mo
tio
n &
th
us r
ota
tes d
rum
ch
an
ge
.
Fo
rk G
ea
r S
hif
t (I
np
ut
& O
utp
ut)
DH
10
11
30
- I
np
ut
DH
10
11
32
- O
utp
ut
Th
e f
ork
ge
ar
sh
ift
pin
slid
es i
n t
he
dru
m p
rofi
le a
s
& w
he
n d
rum
ro
tate
s &
gu
ide
s t
o t
ran
sm
it T
o &
Fro
mo
tio
n t
o f
ork
ge
ar
sh
ift
for
ma
tch
ing
re
sp
ec
tive
ge
ar.
Pin
dia
. =
5 m
m.
I/P
sh
aft
fo
rk m
ark
= S
32
.
O/P
sh
aft
fo
rk m
ark
= S
95
& S
92
re
sp
ec
tive
ly.
Ge
ar
Dru
m C
ha
ng
e A
sse
mb
ly
DJ 1
01
1 4
6
Pro
file
wid
th i
s 5
mm
. It
ha
s a
od
d s
ha
pe
win
do
w
pa
ralle
l to
ne
utr
al
sto
pp
er
loc
ate
r.
Pa
rt N
o.
Eff
ec
tive
cla
mp
ing
of
clu
tch
asse
mb
ly i
s e
nsu
red
on
Inp
ut
Sh
aft
by u
sin
g g
uid
e p
late
clu
tch
in
be
twe
en
sh
aft
& c
lutc
h a
sse
mb
ly.
Gu
ide
Ge
ar
is h
avin
g 4
pin
s.
It h
as a
wid
e p
rofi
le (
gro
ove
) fo
r sm
oo
th s
lid
ing
of
fork
ge
ar
sh
ift
pin
in
dru
m p
rofi
le f
or
sh
ifti
ng
of
ge
ars
.
Se
lec
tor
leve
r o
pe
rate
s T
o &
Fro
. S
ele
cto
r le
ve
r
is m
ore
in
le
ng
th.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Le
ve
r C
om
p G
ea
r S
hif
t
DH
10
11
34
Le
ve
r c
om
p.
ge
ar
sh
ift
is m
esh
ed
wit
h g
uid
e g
ea
r
sh
ift
co
nsta
ntl
y.
Th
us h
elp
s i
n t
ran
sm
itti
ng
rec
ipro
ca
tin
g m
oti
on
to
gu
ide
ge
ar.
Ø 5
mm
5 m
m
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r81
Deale
r D
eve
lop
ment
Cente
r82
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Clu
tch
Co
ve
r
DJ 1
01
2 4
1
Clu
tch
co
ve
r h
as E
ng
ine
oil i
nsp
ec
tio
n w
ind
ow
.
Ho
lde
r C
lutc
h (
Th
rust
Pla
te)
DK
10
10
78
Ho
lde
r c
lutc
h h
old
s t
he
clu
tch
be
ari
ng
& p
lun
ge
r.
Clu
tch
Sp
rin
g
DH
10
17
43
Clu
tch
sp
rin
g h
elp
s s
mo
oth
en
ga
gin
g &
dis
en
ga
gin
g
the
clu
tch
me
ch
an
ism
.
Clu
tch
sp
rin
g h
eig
ht
is 3
0.8
mm
.
Clu
tch
Ce
nte
r
DK
10
10
01
Ste
p f
or
sp
ac
er
is p
rovid
ed
. C
lutc
h c
en
ter
he
igh
t is
26
mm
.
Pa
rt N
o.
It h
ou
se
s t
he
en
trir
e c
lutc
h s
ide
asse
mb
lie
s.
Ho
lde
r c
lutc
h h
as 4
ho
les f
or
mo
un
tin
g.
Clu
tch
ce
nte
r h
old
s t
he
se
t o
f c
lutc
h p
late
&
pre
ssu
re p
late
.
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-III
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-II
Clu
tch
wh
ee
l h
as 4
le
gs f
or
mo
un
tin
g
clu
tch
sp
rin
gs.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Clu
tch
Wh
ee
l
DK
10
11
63
Clu
tch
wh
ee
l h
old
s t
he
se
t o
f c
lutc
h p
late
&
pre
ssu
re p
late
.
26 m
m
H
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Clu
tch
Co
ve
r
DH
10
11
49
Clu
tch
co
ve
r d
oe
s n
ot
ha
ve
En
gin
e o
il
insp
ec
tio
n w
ind
ow
.
Ho
lde
r C
lutc
h (
Th
rust
Pla
te)
DH
10
14
84
Ho
lde
r c
lutc
h h
old
s t
he
clu
tch
be
ari
ng
& p
lun
ge
r.
Clu
tch
Sp
rin
g
DH
10
14
83
Clu
tch
sp
rin
g h
elp
s s
mo
oth
en
ga
gin
g &
dis
en
ga
gin
g
the
clu
tch
me
ch
an
ism
.
Clu
tch
sp
rin
g h
eig
ht
is 2
9.3
mm
.
Clu
tch
Ce
nte
r
DJ 1
01
1 7
9
No
ste
p f
or
gu
ide
pla
te p
rovid
ed
. C
lutc
h c
en
ter
he
igh
t is
30
mm
.
Pa
rt N
o.
It h
ou
se
s t
he
en
tire
clu
tch
sid
e a
sse
mb
lie
s.
Ho
lde
r c
lutc
h h
as 6
ho
les f
or
mo
un
tin
g.
Clu
tch
ce
nte
r h
old
s t
he
se
t o
f c
lutc
h p
late
&
pre
ssu
re p
late
.
Clu
tch
wh
ee
l h
as 6
le
gs f
or
mo
un
tin
g
clu
tch
sp
rin
gs.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Clu
tch
Wh
ee
l
DH
10
13
44
Clu
tch
wh
ee
l h
old
s t
he
se
t o
f c
lutc
h p
late
&
pre
ssu
re p
late
.
30 m
m
HPart
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r83
Deale
r D
eve
lop
ment
Cente
r84
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Clu
tch
Pla
in W
ash
er
Pla
in w
ash
er
wit
h n
o I
de
nti
fic
ati
on
Ma
rk.
Clu
tch
Be
lle
ville
Wa
sh
er
Ne
w p
art
ad
de
d f
or
pre
ve
nti
ng
clu
tch
ju
dd
er.
Dis
c C
lutc
h F
ric
tio
n P
late
DK
10
11
49
Clu
tch
pla
te I
D i
s s
malle
r th
an
reg
ula
r clu
tch
pla
te b
ecau
se t
o
acco
mm
od
ate
th
e p
lain
wash
er
& w
ave w
ash
er
of
an
ti j
ud
der
mech
an
ism
. T
his
pla
te i
s f
itte
d f
acin
g t
he c
lutc
h h
ub
sid
e.
• I
nte
rna
l d
iam
ete
r is
10
9.5
mm
.
• F
ric
tio
n m
ate
ria
l c
ub
s a
re 4
8 n
os.
Clu
tch
Pla
te P
ressu
re
DK
10
11
63
Fri
cti
on
ma
teri
al
cu
bs =
40
no
s.
Clu
tch
pla
te
ap
pe
ars
to
be
in
Bro
wn
ish
co
lou
r.
Pa
rt N
o.
Ne
w p
art
ad
de
d f
or
pre
ve
nti
ng
clu
tch
ju
dd
er.
Clu
tch
Be
lle
ville
Wa
sh
er
is c
on
ca
ve
in
sh
ap
e.
Ne
w p
art
ad
de
d.
Th
is p
late
is f
itte
d f
ac
ing
th
e
clu
tch
wh
ee
l sid
e.
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-III
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-II
Fri
cti
on
ma
teri
al
cu
bs 3
6 n
os.
Clu
tch
pla
te a
pp
ea
rs
to b
e i
n G
ree
nis
h c
olo
ur.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Clu
tch
Pla
te (
4 N
os.)
DK
10
11
51
Ne
w p
art
ad
de
d.
4 c
lutc
h p
late
s o
f sa
me
sp
ec
ific
ati
on
s a
re s
an
dw
ich
ed
in
be
twe
en
LH
& R
H
clu
tch
pla
tes f
or
torq
ue
tra
nsm
issio
n.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
NA
NA
NA
NA
NA
Clu
tch
Pla
te P
ressu
re (
6 C
lutc
h P
late
s)
DH
10
13
44
All c
lutc
h p
late
s a
re B
row
n i
n c
olo
ur.
Pa
rt N
o.
To
tal
6 c
lutc
h p
late
s o
f sa
me
sp
ec
ific
ati
on
s a
re
ho
use
d i
n c
lutc
h a
sse
mb
ly f
or
torq
ue
tra
nsm
issio
n.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
39
21
67
12
39
21
61
11
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r85
Deale
r D
eve
lop
ment
Cente
r86
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pla
te C
lutc
h (
Pre
ssu
re P
late
)
Pre
ssu
re p
late
is m
ore
wid
e.
Pre
ssu
re p
late
wid
th =
17
mm
.
Sp
ac
er
Ne
w p
art
ad
de
d f
or
ad
din
g i
s b
ett
er
fac
e c
lam
pin
g
of
clu
tch
asse
mb
ly o
n I
np
ut
Sh
aft
.
Clu
tch
Ho
usin
g
DK
10
10
74
Clu
tch
ho
usin
g h
old
s t
he
en
tire
clu
tch
asse
mb
ly &
the
slo
ts h
elp
s f
or
eff
ec
tive
lu
bri
ca
tio
n.
Slo
ts p
rovid
ed
in
clu
tch
ho
usin
g.
He
ad
Co
ve
r
Cylin
de
r h
ea
d c
ove
r is
a p
art
of
Cylin
de
r H
ea
d C
om
p
‘U’
ma
rk e
mb
osse
d i
n c
asti
ng
.
Pa
rt N
o.
Pre
ssu
re p
late
are
ho
use
d i
n b
etw
ee
n c
lutc
h p
late
s.
Inte
rna
l d
iam
ete
r (I
D)
is i
n c
on
ica
l sh
ap
e.
He
ad
co
ve
r h
ou
se
s t
he
co
mp
lete
OH
C s
yste
m.
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-III
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-II
‘DJ’
ma
rk a
lon
g w
ith
‘U
’ m
ark
em
bo
sse
d i
n c
asti
ng
.
Va
lve
sp
rin
gs f
itm
en
t g
roo
ve
is d
ee
p.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Cylin
de
r H
ea
d C
om
p
DJ 1
01
2 6
9
Cylin
de
r h
ea
d c
om
p h
ou
se
s t
he
co
mp
lete
OH
C
syste
m w
ith
va
lve
tra
in.
ID
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pla
te C
lutc
h (
Pre
ssu
re P
late
)
Gu
ide
pla
te c
lutc
h h
elp
s i
n b
ett
er
cla
mp
ing
of
clu
tch
assly
. o
n I
np
ut
sh
aft
.
Clu
tch
Ho
usin
g
Clu
tch
ho
usin
g h
old
s t
he e
nti
re c
lutc
h a
ssem
bly
.
No
slo
ts i
n c
lutc
h h
ou
sin
g.
He
ad
Co
ve
r
Cylin
de
r h
ea
d c
ove
r is
a p
art
of
Cylin
de
r H
ea
d C
om
p
‘DJ’
ma
rk e
mb
osse
d i
n c
asti
ng
.
Pa
rt N
o.
Pre
ssu
re p
late
are
ho
use
d i
n b
etw
ee
n c
lutc
h p
late
s.
Gu
ide
Pla
te c
lutc
h h
as a
sta
inle
ss s
tee
l fi
nis
h w
ith
inte
rna
l sp
lin
es.
He
ad
co
ve
r h
ou
se
s t
he
co
mp
lete
OH
C s
yste
m.
‘DJ’
ma
rk e
mb
osse
d i
n c
asti
ng
. V
alv
e s
pri
ng
s
fitm
en
t g
roo
ve
is n
ot
de
ep
.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Cylin
de
r H
ea
d C
om
p
DH
10
16
00
Cylin
de
r h
ea
d c
om
p h
ou
se
s t
he
co
mp
lete
OH
C s
yste
m w
ith
va
lve
tra
in.
Pre
ssu
re p
late
is n
ot
wid
e a
s c
om
pa
red
wit
h r
eg
ula
r.
Wid
th =
14
mm
.
Gu
ide
Pla
te C
lutc
h
DK
10
11
63
DK
10
11
26
DH
10
15
57
DH
10
13
74
DH
10
15
58
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r87
Deale
r D
eve
lop
ment
Cente
r88
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ca
msh
aft
Asse
mb
ly
Ca
m (
tra
ck)
wid
th i
s l
ess.
Tra
ck w
idth
= 9
.6 m
m.
Va
lve
Sp
rin
g O
ute
r
Va
lve
sp
rin
g h
elp
s i
n s
mo
oth
clo
sin
g o
f va
lve
s
wit
ho
ut
an
y n
ois
e a
s p
er
en
ha
nc
ed
va
lve
tim
ing
.
Va
lve
Sp
rin
g I
nn
er
DH
10
17
31
Va
lve
sp
rin
g h
elp
s i
n s
mo
oth
clo
sin
g o
f va
lve
s
wit
ho
ut
an
y n
ois
e a
s p
er
en
han
ce
d v
alv
e t
imin
g.
It i
s m
ore
in
le
ng
th.
Le
ng
th =
39
.1 m
m.
Sp
rin
g i
s
ma
rke
d w
ith
Wh
ite
oil p
ain
t.
Sta
tor
Pla
te
DJ 1
11
0 2
1
Sta
tor
pla
te h
arn
ess n
eu
tra
l c
ou
ple
r is
ha
vin
g
sq
ua
re s
ha
pe
.
Pa
rt N
o.
Ca
msh
aft
assly
is h
ou
se
d i
n b
etw
ee
n c
ylin
de
r h
ea
d
co
ve
r &
cyl. h
ea
d c
om
p.
It d
rive
s t
he
en
tire
va
lve
tra
in a
ssly
as p
er
en
ha
nc
ed
va
lve
tim
ing
.
It i
s m
ore
in
le
ng
th.
Le
ng
th =
43
.6 m
m.
Sp
rin
g i
s
ma
rke
d w
ith
Wh
ite
oil p
ain
t.
All E
lec
tric
al
co
ils l
ike
Pic
k-u
p,
Exc
ite
r, L
igh
tin
g,
Ba
tte
ry c
ha
rgin
g c
oils w
ith
en
ha
nc
ed
ig
nit
ion
tim
ing
va
lue
s a
re f
itte
d o
n t
his
pla
te.
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-III
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-II
UG
-3 m
ark
em
bo
sse
d o
n t
he
bo
dy v
iew
ed
fro
m t
ail s
ide
.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ma
gn
eto
Asse
mb
ly (
Ro
tor)
DJ 1
11
0 2
0
Ma
gn
eto
asse
mb
ly r
oto
r is
ha
vin
g a
na
log
ig
nit
ion
tim
ing
fo
r in
itia
l sta
rtin
g f
or
avo
idin
g b
ac
k k
ickin
g.
9.6
m
m
DH
10
17
03
DH
10
17
30
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ca
msh
aft
Asse
mb
ly
Ca
m (
tra
ck)
wid
th i
s m
ore
. T
rac
k w
idth
= 1
2.6
mm
.
Va
lve
Sp
rin
g O
ute
r
Va
lve
sp
rin
g h
elp
s i
n s
mo
oth
clo
sin
g o
f va
lve
s
wit
ho
ut
an
y n
ois
e.
Va
lve
Sp
rin
g I
nn
er
DS
10
11
10
Va
lve
sp
rin
g h
elp
s i
n s
mo
oth
clo
sin
g o
f va
lve
s
wit
ho
ut
an
y n
ois
e.
It i
s s
ho
rt i
n l
en
gth
. L
en
gth
= 3
8 m
m.
Sp
rin
g i
s
ma
rke
d w
ith
Blu
e o
il p
ain
t.
Sta
tor
Pla
te
DJ 1
11
0 0
4
Sta
tor
pla
te h
arn
ess n
eu
tra
l c
ou
ple
r is
ha
vin
g b
ulle
t
typ
e t
erm
ina
l.
Pa
rt N
o.
Ca
msh
aft
assly
is h
ou
se
d i
n b
etw
ee
n c
ylin
de
r h
ea
d
co
ve
r &
cyl. h
ea
d c
om
p.
It d
rive
s t
he
en
tire
va
lve
tra
in a
ssly
.
It i
s s
ho
rt i
n l
en
gth
. L
en
gth
= 4
2 m
m.
Sp
rin
g i
s
ma
rke
d w
ith
Blu
e o
il p
ain
t.
All E
lec
tric
al
co
ils l
ike
Pic
k-u
p,
Exc
ite
r, L
igh
tin
g,
Ba
tte
ry c
ha
rgin
g c
oils a
re f
itte
d o
n t
his
pla
te.
‘E’
& ‘
M’
ma
rk e
mb
osse
d o
n t
he
bo
dy v
iew
ed
fro
m
tail s
ide
.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ma
gn
eto
Asse
mb
ly (
Ro
tor)
DJ 1
11
0 5
7
Ma
gn
eto
assly
ro
tor
is h
avin
g o
nly
Dig
ita
l Ig
nit
ion
Tim
ing
.
DH
10
16
17
DS
10
11
11
.m
12
6
m
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r89
Deale
r D
eve
lop
ment
Cente
r90
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ce
ntr
ifu
ga
l O
il F
ilte
r
Th
e c
en
trif
ug
al
oil f
ilte
r h
as a
cu
t m
ark
on
ta
il e
nd
.
Pa
rt N
o.
Th
e c
en
trif
ug
al
oil f
ilte
r b
od
y w
all t
hic
kn
ess h
as
be
en
in
cre
ase
d b
y r
ed
uc
ing
th
e i
nte
rna
l d
iam
ete
r
for
ge
ttin
g b
ett
er
str
en
gth
.
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-III
Pa
rts I
de
nti
fic
ati
on
- E
ng
ine
UG
-II
DH
10
10
64
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ce
ntr
ifu
ga
l O
il F
ilte
r
Th
e c
en
trif
ug
al
oil f
ilte
r d
oe
s n
ot
ha
ve
cu
t m
ark
on
ta
il e
nd
.
Pa
rt N
o.
Th
e c
en
trif
ug
al
oil f
ilte
r b
od
y i
nte
rna
l d
iam
ete
r is
mo
re a
s c
om
pa
red
to
UG
-III
filte
r.
DH
10
10
64
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ca
rbu
rett
or
Asse
mb
ly
On
RH
sid
e o
f C
arb
ure
tto
r b
od
y B
S-2
9,
DJ-U
3
ma
rk i
s e
mb
osse
d.
Air
Filte
r A
sse
mb
ly
Th
e n
ew
la
rge
vo
lum
e a
ir f
ilte
r w
ith
fin
e &
co
rse
filt
er
foa
m i
s i
nc
orp
ora
ted
to
pro
vid
e t
orq
ue
on
de
ma
nd
wit
h o
pti
mis
ed
in
take
syste
m.
Sile
nc
er
Asse
mb
ly
DJ 1
01
2 4
3
Th
e s
ile
nc
er
ha
s b
ee
n f
urt
he
r o
pti
mis
ed
to
ma
tch
the
ch
an
ge
s d
on
e i
nc
orp
ora
tin
g t
he
ne
w c
am
sh
aft
& a
ir f
ilte
r a
sse
mb
ly.
Fla
ng
ed
bo
lt o
n E
xh
au
sT
EC
is f
ac
ing
on
LH
sid
e.
He
ad
Lig
ht
Asse
mb
ly
DJ 2
01
1 3
2
Pa
rkin
g l
am
ps a
re p
roje
cte
d o
ut.
Pro
vis
ion
fo
r
ma
sk f
itm
en
t.
Pa
rt N
o.
Wit
h e
nh
an
ce
d v
alv
e t
imin
g &
to
ac
hie
ve
be
tte
r
en
gin
e p
erf
orm
an
ce
th
e c
arb
ure
tto
r a
sse
mb
ly
is r
etu
ne
d.
Dra
in t
ub
e i
s p
rovid
ed
on
bo
tto
m s
ide
to
dis
ch
arg
e
the
co
nd
en
se
d e
ng
ine
oil.
Th
e p
ark
ing
la
mp
s a
re p
roje
cte
d o
ut
wit
h a
ne
w a
gg
ressiv
e
loo
k &
to
ge
the
r w
ith
th
e m
ask t
ha
t g
ive
s a
re
al
‘Ph
an
tom
’
loo
k.
H/L
fa
cin
g h
as b
ee
n l
ow
ere
d t
o g
ive
ba
lan
ce
d l
oo
ks.
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-III
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-II
He
igh
t o
f h
an
dle
ho
lde
r is
mo
re i
.e.
31
.5 m
m.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ha
nd
le H
old
er
Asse
mb
ly
DH
18
10
53
Ha
nd
le h
old
er
asse
mb
ly h
eig
ht
ha
s b
ee
n i
nc
rea
se
d
to a
cc
om
mo
da
te n
ew
sp
ee
do
co
nso
le.
DJ 1
01
2 3
2
DJ 1
21
0 4
0
Dra
inT
ub
e
H
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ca
rbu
rett
or
Asse
mb
ly
On
RH
sid
e o
f C
arb
ure
tto
r b
od
y B
S-2
9,
DJ-U
2
ma
rk i
s e
mb
osse
d.
Air
Filte
r A
sse
mb
ly
A l
arg
e v
olu
me
air
filte
r is
in
tro
du
ce
d t
o p
rovid
e
torq
ue
on
de
ma
nd
wit
h o
pti
mis
ed
in
take
syste
m.
Sile
nc
er
Asse
mb
ly
DJ 1
01
1 6
1
Th
e s
ile
nc
er
ha
s b
ee
n o
pti
mis
ed
to
me
et
the
pe
rfo
rma
nc
e o
f P
uls
ar
UG
-II
wit
h E
xh
au
sT
EC
intr
od
uc
tio
n.
Fla
ng
ed
bo
lt o
n E
xh
au
sT
EC
fo
r m
ea
su
rin
g C
O%
is
fac
ing
pe
rpe
nd
icu
lar
to s
tee
rin
g.
He
ad
Lig
ht
Asse
mb
ly
DJ 2
01
1 0
4
Pa
rkin
g l
am
ps a
re i
nlin
e w
ith
he
ad
lig
ht
bo
dy.
No
pro
vis
ion
fo
r m
ask f
itm
en
t.
Pa
rt N
o.
To
me
et
the
re
qu
ire
me
nt
of
UG
-II
en
gin
e
sp
ec
ific
ati
on
s t
he
ca
rbu
rett
or
is t
un
ed
.
No
dra
in t
ub
e i
s p
rovid
ed
on
bo
tto
m s
ide
to
dis
ch
arg
e t
he
co
nd
en
se
d e
ng
. o
il.
Th
e p
ark
ing
la
mp
s a
re i
n l
ine
wit
h t
he
he
ad
lig
ht
bo
dy l
ine
.
He
igh
t o
f h
an
dle
ho
lde
r is
le
ss i
.e.
18
.5 m
m.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ha
nd
le H
old
er
Asse
mb
ly
DJ 1
81
0 3
8
Ha
nd
le h
old
er
asse
mb
ly h
eig
ht
is b
ee
n d
esig
ne
d
low
to
ac
co
mm
od
ate
tw
in p
od
sp
ee
do
co
nso
le.
DJ 1
21
0 2
0
DJ 1
21
1 0
5
H
Deale
r D
eve
lop
ment
Cente
r91
Deale
r D
eve
lop
ment
Cente
r92
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r93
Deale
r D
eve
lop
ment
Cente
r94
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ho
lde
r F
ork
Up
pe
r
No
bra
cke
t fo
r h
old
ing
sp
ee
do
co
nso
le.
Bra
ce
Fe
nd
er
Bra
ce
fe
nd
er
giv
es r
ein
forc
em
en
t to
mu
d g
ua
rd &
als
o g
uid
es t
he
wir
e /
ho
se
go
ing
to
wh
ee
l se
nso
r
& c
alip
er
asse
mb
ly r
esp
ec
tive
ly.
Fro
nt
Nu
mb
er
Pla
te B
rac
ke
t
DH
16
12
92
Th
e f
ron
t n
um
be
r p
late
bra
cke
t h
old
s t
he
nu
mb
er
pla
te &
fo
r fi
rm f
itm
en
t 3
po
int
mo
un
tin
g i
s g
ive
n.
• 3
ho
les f
or
mo
un
tin
g o
n l
ow
er
‘T’.
• 1
ho
le i
s o
blo
ng
.
Sp
ee
do
me
ter
Asse
mb
ly
DJ 2
01
1 4
4
Dig
ita
l sp
ee
do
me
ter
wit
h a
na
log
ue
typ
e t
ac
ho
me
ter.
Pa
rt N
o.
Ho
lde
r fo
rk u
pp
er
co
ve
r c
lam
ps t
he
fo
rk p
ipe
s &
ha
nd
le h
old
er.
2 n
os.
of
bra
cke
ts p
rovid
ed
fo
r
a)
Sp
ee
do
me
ter
wir
e.
b)
Fo
r d
isc
bra
ke
ho
se
.
Easy t
o r
ead
dig
ital
sp
eed
om
ete
r d
isp
layin
g s
peed
in
km
ph
, o
do
mete
r d
isp
layin
g d
ista
nce c
overe
d &
tri
p m
ete
r
dis
pla
yin
g d
ista
nce c
overe
d p
er
trip
wit
h r
esett
ing
facilit
y.
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-III
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-II
NIL
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Wh
ee
l S
en
so
r U
nit
DK
10
11
63
Ne
w p
art
ad
de
d.
It i
s a
se
nso
r se
nsin
g t
he
ve
hic
le
sp
ee
d a
nd
is a
no
n c
on
tac
t ty
pe
wh
ee
l se
nso
r.
DH
18
10
56
DH
16
13
04
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ho
lde
r F
ork
Up
pe
r
To
mo
un
t th
e t
win
po
d s
pe
ed
o c
on
so
le t
he
re i
s a
bra
cke
t p
rovid
ed
.
Bra
ce
Fe
nd
er
Bra
ce
fe
nd
er
giv
es r
ein
forc
em
en
t to
mu
d g
ua
rd &
als
o g
uid
es t
he
bra
ke
ho
se
go
ing
to
wa
rds
ca
lip
er
asse
mb
ly.
Fro
nt
Nu
mb
er
Pla
te B
rac
ke
t
DJ 1
81
1 1
1
Th
e f
ron
t n
um
be
r p
late
bra
cke
t h
old
s t
he
nu
mb
er
pla
te &
is m
ou
nte
d w
ith
2 p
oin
t m
ou
nti
ng
.
• 2
ho
les f
or
mo
un
tin
g o
n l
ow
er
‘T’.
Sp
ee
do
me
ter
Asse
mb
ly
DJ 1
91
0 4
8
Tw
in p
od
an
alo
gu
e t
yp
e s
pe
ed
om
ete
r.
Pa
rt N
o.
Ho
lde
r fo
rk u
pp
er
co
ve
r c
lam
ps t
he
fo
rk p
ipe
s,
ha
nd
le h
old
er
& t
win
po
d s
pe
ed
om
ete
r a
sse
mb
ly.
No
bra
cke
t p
rovid
ed
fo
r d
isc
bra
ke
ho
se
/
sp
ee
do
ca
ble
.
Tw
in p
od
an
alo
gu
e t
yp
e s
pe
ed
om
ete
r d
isp
layin
g
ve
hic
le s
pe
ed
, e
ng
ine
rp
m,
od
om
ete
r &
tri
p m
ete
r.
Wit
h t
rip
me
ter
ad
justm
en
t fa
cilit
y.
Pro
vis
ion
fo
r m
ou
nti
ng
pin
ion
ge
ar
&
sp
ee
do
me
ter
ge
ar.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ca
se
Me
ter
DJ 1
51
0 5
7
Ca
se
me
ter
assly
ho
use
s t
he
sp
ee
do
me
ter
wo
rm
ge
ar
& t
he
pin
ion
ge
ar
assly
to
dri
ve
sp
ee
do
me
ter.
DJ 1
81
0 1
7
DH
16
12
58
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r95
Deale
r D
eve
lop
ment
Cente
r96
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-III
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-II
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Co
ntr
ol
Sw
itc
h L
H
Co
up
ler
co
lou
r is
Wh
ite
.
Co
ntr
ol
Sw
itc
h R
H
Th
e s
wit
ch
es o
pe
rate
wit
ho
ut
an
y p
hysic
al
co
nta
ct
&th
us h
as n
o w
ea
r &
te
ar
of
pa
rts.
Als
o t
he
se
ha
ve
illu
min
ati
on
of
tell-t
ale
ic
on
s t
hro
ug
h L
ED
's w
hic
hg
low
s B
luis
h-W
hit
e d
uri
ng
nig
ht
dri
vin
g.
Ba
tte
ry
DJ 2
01
1 2
5
A l
ow
ma
inte
na
nc
e b
att
ery
wit
h a
un
iqu
e v
en
tm
ec
ha
nis
m t
ha
t a
llo
ws o
nly
ga
s /
va
po
urs
to
esc
ap
e &
no
t th
e e
lec
tro
lyte
. H
en
ce
ele
ctr
oly
te l
eve
lin
sp
ec
tio
n i
nte
rva
l is
le
ss.
Ba
tte
ry t
op
sid
e m
ou
ld h
as o
ran
ge
co
lou
r.
Ba
tte
ry h
as v
en
t va
lve
on
RH
sid
e.
CD
I U
nit
DJ 1
11
0 2
3
Tw
o g
ree
n c
olo
ur
do
t m
ark
s o
n C
DI
un
it.
Pa
rt N
o.
Th
e s
wit
ch
es o
pe
rate
wit
ho
ut
an
y p
hysic
al
co
nta
ct
&th
us h
as n
o w
ea
r &
te
ar
of
pa
rts.
Als
o t
he
se
ha
ve
illu
min
ati
on
of
tell-t
ale
ic
on
s t
hro
ug
h L
ED
's w
hic
hg
low
s B
luis
h-W
hit
e d
uri
ng
nig
ht
dri
vin
g.
Pro
vis
ion
of
en
gin
e k
ill
sw
itc
h.
Fo
r e
asy k
ick s
tart
ing
th
e i
gn
itio
n t
imin
g h
as b
ee
n
op
tim
ise
d b
y i
ntr
od
uc
ing
an
alo
gu
e s
ign
alin
g t
o C
DI
un
it t
ill
30
00
rp
m &
th
ere
aft
er
dig
ita
l sig
na
lin
g.
Sid
e s
tan
d s
wit
ch
ca
ble
le
ng
th i
s m
ore
.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Sid
e S
tan
d S
wit
ch
DH
20
10
55
Sid
e s
tan
d s
wit
ch
asse
mb
ly c
ou
ple
r m
ou
nti
ng
po
sit
ion
sh
ifte
d h
en
ce
ca
ble
is l
on
ge
r in
le
ng
th.
DH
20
10
48
DH
20
10
49
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Co
ntr
ol
Sw
itc
h L
H
Co
up
ler
co
lou
r is
Re
d.
Co
ntr
ol
Sw
itc
h R
H
Th
ese
are
co
nve
nti
on
al
sw
itc
he
s &
op
era
te o
n
ph
ysic
al
ma
ke
& b
rake
typ
e m
ec
ha
nis
m c
au
sin
g
mo
re w
ea
r &
te
ar
of
pa
rts.
Ba
tte
ry
DJ 2
01
0 3
6
Co
nve
nti
on
al
typ
e o
f b
att
ery
wit
h o
ve
rflo
w t
ub
e
me
ch
an
ism
. E
lec
tro
lyte
le
ve
l in
sp
ec
tio
n i
nte
rva
l is
mo
re a
s c
om
pa
red
to
lo
w m
ain
ten
an
ce
ba
tte
ry.
Ba
tte
ry t
op
sid
e m
ou
ld h
as b
lac
k c
olo
ur.
Ba
tte
ry h
ave
a v
en
t p
lug
on
RH
sid
e.
CD
I U
nit
DJ 1
11
0 1
7
On
e g
ree
n c
olo
ur
do
t m
ark
s o
n C
DI
un
it.
Pa
rt N
o.
Th
ese
are
co
nve
nti
on
al
sw
itc
he
s &
op
era
te o
n
ph
ysic
al
ma
ke
& b
rake
me
ch
an
ism
ca
usin
g m
ore
we
ar
& t
ea
r o
f p
art
s.
No
en
gin
e k
ill
sw
itc
h a
va
ila
ble
.
CD
I u
nit
ha
s o
nly
dig
ita
l sig
na
lin
g.
Sid
e s
tan
d s
wit
ch
ca
ble
le
ng
th i
s l
ess.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Sid
e S
tan
d S
wit
ch
DJ 2
01
1 0
5
NIL
DJ 2
01
0 2
4
DJ 2
01
0 1
2
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r97
Deale
r D
eve
lop
ment
Cente
r98
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Sid
e S
tan
d M
ag
ne
t
Sid
e s
tan
d m
ag
ne
t b
od
y h
as g
ree
n p
assiv
ati
on
.
Se
at
Asse
mb
ly
Fo
r p
rop
er
loc
kin
g &
pro
pe
r fi
tme
nt
of
too
l kit
th
e
se
at
asse
mb
ly i
s r
ed
esig
ne
d.
Se
at
Lo
ck
Asse
mb
ly
DJ 2
11
0 0
6
Sin
ce
se
at
loc
k i
s s
hif
ted
to
ta
il e
nd
of
the
se
at.
Se
at
loc
k c
ab
le l
en
gth
is m
ore
.
Ge
ar
Ch
an
ge
Pe
da
l
Ge
ar
pe
da
l h
as m
ore
cu
rve
d s
ha
pe
.
Pa
rt N
o.
NIL
No
rib
at
too
l kit
mo
un
tin
g a
rea
. S
ea
t lo
ckin
g s
tud
is l
oc
ate
d a
t e
xtr
em
e t
ail e
nd
.
Th
e g
ea
r c
ha
ng
e p
ed
al
ha
s m
ore
cu
rve
d s
ha
pe
fo
r
pro
pe
r p
lac
ing
of
foo
t &
to
avo
id f
oo
t fo
ulin
g
wit
h s
tep
ho
lde
r.
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-III
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-II
Ad
dit
ion
al
pro
jec
ted
ste
p i
s p
rovid
ed
fo
r b
ett
er
ae
sth
eti
c l
oo
k.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ho
lde
r R
H S
tep
& L
H S
tep
DJ 1
61
2 5
7 &
DJ 1
61
2 5
6
Ho
lde
r ste
p p
rovid
ed
fo
r re
sti
ng
pillio
n r
ide
r's f
oo
t.
DJ 2
11
0 0
3
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Sid
e S
tan
d M
ag
ne
t
Sid
e s
tan
d m
ag
ne
t b
od
y i
s b
lac
k i
n c
olo
ur.
Se
at
Asse
mb
ly
NIL
Se
at
Lo
ck
Asse
mb
ly
DH
16
10
46
Th
e s
ea
t lo
ck i
s l
oc
ate
d a
t c
en
ter
of
the
se
at.
Se
at
loc
k c
ab
le l
en
gth
is s
ho
rt a
s c
om
pa
red
to
UG
-III
ca
ble
.
Ge
ar
Ch
an
ge
Pe
da
l
Ge
ar
pe
da
l h
as l
ess c
urv
ed
sh
ap
e.
Pa
rt N
o.
NIL
Rib
at
too
l kit
mo
un
tin
g a
rea
. S
ea
t lo
ckin
g s
tud
is
loc
ate
d i
n c
en
tra
l p
art
of
se
at
assly
.
NIL
No
ad
dit
ion
al
pro
jec
ted
ste
p i
s p
rovid
ed
.
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Ho
lde
r R
H S
tep
& L
H S
tep
DJ 1
61
1 1
2 &
DJ 1
61
1 1
1
Ho
lde
r ste
p p
rovid
ed
fo
r re
sti
ng
pillio
n r
ide
r's f
oo
t.
DJ 2
11
0 0
1
DJ 1
01
1 4
9D
H 1
01
1 4
9
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n
Deale
r D
eve
lop
ment
Cente
r99
Deale
r D
eve
lop
ment
Cente
r100
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Re
ar
Fe
nd
er
On
re
ar
fen
de
r a
ste
p i
s p
rovid
ed
at
rea
r e
nd
RH
sid
e.
Sa
ree
Gu
ard
Sa
ree
gu
ard
is m
ou
nte
d o
n c
ha
ssis
as a
sa
fety
fea
ture
fo
r a
rre
sti
ng
th
e p
ossib
ilit
y o
f sa
ree
ge
ttin
g
en
tan
gle
d i
nto
re
ar
wh
ee
l w
hile
rid
ing
th
e b
ike
.
Pa
rt N
o.
Th
e r
ea
r fe
nd
er
is l
oc
ate
d b
elo
w t
he
rid
er
se
at
for
arr
esti
ng
du
st
/ d
irt
& w
ate
r sp
lash
ing
on
.
Sa
ree
gu
ard
ha
s a
le
ss c
urv
e s
ha
pe
ne
ar
lad
ies
foo
t ste
p a
s c
om
pa
red
to
UG
-II.
Sa
ree
gu
ard
mo
un
tin
g a
lle
n b
olt
is s
ho
rt i
n l
en
gth
.
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-III
Pa
rts I
de
nti
fic
ati
on
- C
ha
ssis
UG
-II
DJ 1
61
2 5
4
DH
16
12
94
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Pa
rt N
o.
Pa
rt N
am
e
De
sc
rip
tio
n
Ide
nti
fic
ati
on
Ma
rk
Re
ar
Fe
nd
er
On
re
ar
fen
de
r n
o s
tep
is p
rovid
ed
.
Sa
ree
Gu
ard
Sa
ree
gu
ard
is m
ou
nte
d o
n c
ha
ssis
as a
sa
fety
fea
ture
fo
r a
rre
sti
ng
th
e p
ossib
ilit
y o
f sa
ree
ge
ttin
g
en
tan
gle
d i
nto
re
ar
wh
ee
l w
hile
rid
ing
th
e b
ike
.
Pa
rt N
o.
Th
e r
ea
r fe
nd
er
is l
oc
ate
d b
elo
w t
he
rid
er
se
at
for
arr
esti
ng
du
st
/ d
irt
& w
ash
er
sp
lash
ing
on
.
Sa
ree
gu
ard
ha
s m
ore
cu
rve
sh
ap
e n
ea
r la
die
s f
oo
t
ste
p a
s c
om
pa
red
wit
h P
uls
ar
UG
-III
. S
are
e g
ua
rd
mo
un
tin
g a
lle
n b
olt
is m
ore
in
le
ng
th.
DJ 1
61
0 5
1
DJ 1
61
2 1
5
Part
s I
dentific
atio
nP
art
s I
dentific
atio
n