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Special Tools

Guide
(International Business)

Bajaj Auto Limited


International Marketing
Akurdi, Pune 411 035 India
Phone : 020-27472851
Fax : 020-27407395
E-mail : exports@bajajauto.co.in
Foreword
With introduction of 3-4 new products / vehicles every
year, more special tools are being added into our
workshop. Our efforts in bring down in number of special
tools is on going activity and some of the special tools are
made common for products.

With increase in special tools, we try to bring complete list


of special tools in one folder of all running models.

We try to make this booklet meaning full and easy to order


by referring booklet. As and when we add new products in
the market we will give you similar hard copies for filling.

Ashok Saxena
GM - Operations (International Business)

Bajaj Auto Limited


International Marketing
Akurdi, Pune 411 035 India
Phone : 020-27472851
Fax : 020-27407395
E-mail : exports@bajajauto.co.in
MODEL :

Tool Service Cam Sproket Tighten


Part No. : F41ZJZ47
FOB in $ : 5.43
Application : For holding sprocket during
removal / refitting of Cam
sprocket allen bolt.

Tool Rotor Tighten Disco M(Jb501002)


Part No. : F41ZJZ44
FOB in $ : 6.39
Application : To hold rotor while loosening
/ tightening its nut.

Magneto Rotor Puller


Part No. : F41ZJZ46
FOB in $ : 20.68
Application : To pull out the rotor from
crankshaft assembly.

Clutch & Primary Gear Holding Tool_Kg


Part No. : F41AJA11
FOB in $ : 7.47
Application : T o h o l d p r i m a r y a n d
secondary gear while
loosening/tightening the
primary gear nut & special
nut securing clutch.

1 Special Tools Guide


MODEL : MODEL :

Socket For Tightening Nut DH101195 Remover For Inlet Valve Rocker Pin
Part No. : 37 10DJ 43 Part No. : 37 10CS 22
FOB in $ : 3.43 FOB in $ : 0.79
Application : To loosen / tighten special Application : To remove Rocker Shaft
nut securing clutch. from cylinder head.

Note : Existing tool can be used by

Special Tool_Clutch Dismantling Bearing Puller


Part No. : F41AJA58 Part No. : 37 1030 48
FOB in $ : 5.71 FOB in $ : 18.53
Application : To dismantle & assembled Application : To Pull out main ball bearing
clutch of DISCOVER DTS-Si from crankshaft
kick start as well as self start
vehicle.

Socket Special For Spark Plug Adaptor - Valve Spring Comp.Assly /


Part No. : 37 1040 51 Valve Spring
FOB in $ : 2.89 Adaptor Part No. : 37 1031 08
Application : For removing and refitting Valve Spring Compressor : 37 1031 07
spark plug R.H. and L.H. FOB in $ : 0.99 + 3.81
side.
Application : To assemble / dismantle
intake, exhaust valve by
compressing spring in
cylinder head.

Special Tool For Tappet Adjustment Drift For Removal Of Piston Pin.
Part No. : F41ZJW33 Part No. : 37 1010 06
FOB in $ : 1.17 FOB in $ : 1.11
Application : To hold the Valve Tappet Application : To remove refit piston pin.
screw while adjusting tappet
clearance.

2 Special Tools Guide 3 Special Tools Guide


MODEL : MODEL :

Engine Sprocket Hold Bearing Puller


Part No. : 37 1030 53 Part No. : 37 1030 48
FOB in $ : 2.35 FOB in $ : 18.53
Application : To hold the output sprocket Application :
while removing sprocket allen To Pull out steering race from ' Fork Under
bolts. Holder bracket'

Tool For Pressing Drum Change Bush In Extractor - Bear. Race


C'
Part No. : 37 1805 06
Part No. : E6 1011 00 TE
FOB in $ : 5.65
FOB in $ : 3.81
Application :
Application : To assemble “Bushing with
To remove steering cones
PTFE Lining” at parent hole
from frame.
of crankcase RH for “Gear
Shift Drum” mounting.

Driver Set - Bearing Tool To Adjust Rear Shock Absorber


Part No. : 37 1030 61 Part No. : 37 00DS 01
FOB in $ : 25.44 FOB in $ : 2.32
Application : Common bearing driver set Application :
for fitting & removing
To adjust rear shock absorber spring tension
bearings from crankcase.
by adjusting the position of spring cam
between 1st to 5th notch position.

Assembler T-0021330 (Installer Upper &


Lower Bearing Race Frame)
Part No. : 37 1801 06
FOB in $ : 23.19
Application :
To install upper & lower steering races /
cones into their seats inside frame.

4 Special Tools Guide 5 Special Tools Guide


MODEL : MODEL :
150 / 180 / 200 / 220 150 / 180 / 200 / 220

Catcher To Hold Sprocket Chain (Pulsar U Puller For Magneto Rotor


Part No.: 37 10DH 36 Part No. : 37 10DJ 32
FOB IN $ : 1.45 FOB IN $ : 4.95
Application : Application :
For holding sprocket during removal / refitting Used to pull out the rotor from crankshaft
of Cam sprocket allen bolt. assembly. bearing from CVT shaft

Puller To Remove Brg (Big) From Cam Shaf Tool For Holding Whi
Part No. : 37 10DH 32 Part No. : 37 10DJ 28
FOB IN $ : 5.71 FOB IN $ : 3.05
Application : Application :
To remove bearing (Decompression assembly Use to hold primary gear while loosening /
side) of camshaft. tightening the clutch nut.

Puller To Remove Brg From Cam Shaft Assly Spl Tool For Bal Idler Gear
Part No. : 37 10DH 31 Part No. : 37 10DJ 63
FOB IN $ : 4.76 FOB IN $ : 7.43
Application : Application :
To remove small bearing of camshaft. Used to load the pre-tensioned scissor gears of
Assly balancer Idler gear.

Tool To Remove Rocker Arm Pin From Cyl H Socket For Tightening Nut
Part No. : 37 10DH 35 Part No. : 37 10DJ 43
FOB IN $ : 0.69 FOB IN $ : 3.43
Application : Application :
To remove rocker pin from cylinder head. Used to remove / fit of centrifugal oil filter nut.
Note : Existing tool can be used by reducing
diameter to 25.9 + 0.1 mm
Dia. = 25.9+0.1

Hand Tool To Remove Silent Bush From Cov Tool For Piston Assly Insertion
Part No. : 37 10DH 33 Part No. : 37 10DJ 30
FOB IN $ : 5.41 FOB IN $ : 4.57
Application : Application :
To remove silent bush from cylinder head Used for compressing the piston rings when
cover. assembly piston in the cylinder block.

6 Special Tools Guide 7 Special Tools Guide


MODEL : MODEL :
150 / 180 / 200 / 220 150 / 180 / 200 / 220

Bearing Puller For Holder Fork Under Dh1 Piston Pin Drift
Part No.: 37 00DJ 01 Part No. : 74 9309 89
FOB IN $ : 15.23 FOB IN $ : 0.76
Application : Application :
Used for removing the lower bearing race from To remove piston pin.
‘T’

Puller Bearing For C'Case LH Special Tool For Thrust Plate Fitment
Part No.: 37 10DJ 76 Part No. : T-1011168
FOB IN $ : 6.85 FOB IN $ : 6.46
Application : Application :
Used to extract the input shaft bearing from To align the clutch hub concentricity w.r.to
crankcase LH. clutch wheel, clutch housing and thrust plate

Puller Bearing For C'Case LH Crankshaft Bearing Extractor


Part No. : 37 10DJ 77 Part No. : 37 1001 14 / JC 1010 01
FOB IN $ : 7.04 FOB IN $ : 34.62
Application : Application :
Used to pull out the bearing for body balancer To remove bearing from crankshaft
from crankcase LH.

Valve Compressor Adopter / Valve Spring Engine Sprocket Hold


Part No. : 37 10DJ 78 / 37 1031 07 Part No. : 37 1030 53
FOB IN $ : 1.71 + 3.81 FOB IN $ : 2.35
Application : Application :
Used for assembling / dismantling inlet, exhaust To hold the output sprocket while removing
valves by compressing spring in cylinder head. sprocket bolt

Rotor Holder Driver Set - Bearing


Part No. : H6 0721 00 Part No. : 37 1030 61
FOB IN $ : 20.53 FOB IN $ : 25.44
Application : Application :
To hold rotor while loosening bolt. Common bearing driver set for fitting and
removing bearings from crankcase.

8 Special Tools Guide 9 Special Tools Guide


MODEL : MODEL :
150 / 180 / 200 / 220 150 / 180 / 200 / 220

Tool For Oil Seal Pressing On Fork Front Holder For Fr. Fork
Part No.: 37 0040 03 Part No. : 37 1740 05
FOB IN $ : NA FOB IN $ : 6.02
Application : Application :
To fit fork oil seal on outer pipe Used for holding the fork piston from inside.

Diagnostic Tool
Part No. : NA
Tool To Adjust Rear Shock Absorber FOB IN $ : NA
Part No. : 37 00DH 14 Application :
FOB IN $ : 2.13 Used for diagnosing the electronic faults in the
Application : vehicle, CO% and idle rpm setting.
For adjusting the notch position of RSA to
achieve hard or soft rear suspension

Digital Diagnostic Instrument


Part No. : XXXXXX
FOB IN $ : NA
Application :
Extractor For Fork Pipe
Used for various electronic parts (Developed for
Part No. : 74 9310 15
like Wheel Sensor, Relay, Control 180 cc UG-III)
FOB IN $ : 20.18 Switches.
Application :
Used for removing front fork inner tube from
outer tube. Digital Diagnostic Instrument
Part No. : 37 2040 15
FOB IN $ : 128
Application :
Combined unit for 'Pulsar DTS-i' & 'Discover
Fork Oil Seal Fitment Punch DTS Si' M/c for checking various electrical &
electronic components / sub-assemblies.
Part No. : 74 9310 13
FOB IN $ : NA
Application : Load Unit
To fit fork oil seal on outer pipe
Part No. : 37 2040 17
FOB IN $ : 13
Application : Following tests can be carried
out on this unit along with load unit & DMU.
Pulsar DTSi - CDI unit for 150/180/220 /Auto
Tool For Extracting Inner From Outer choke for 220 / DC BCU (UG IV, All Models) /
Part No. : 37 1740 04
FOB IN $ : 24.09 DDI Master Unit
Application : Part No. : 37 2040 09
Used for removing front fork inner tube from FOB IN $ : 217
outer tube. Application : It is a common base unit for
various DDI for all models & is supplied to
you earlier. For more details refer its user
manual.

10 Special Tools Guide 11 Special Tools Guide


MODEL : MODEL :

Tool Service Cam Sproket Tighten Special Tool Rotor Dismantling


Part No. : F41ZJZ47 Part No. : F41AJA57
FOB IN $ : 5.43 FOB IN $ : 3.6
Application : For holding sprocket during Application : For removing magneto rotor
removal / refitting of Cam of DISCOVER DTS-Si kick
sprocket allen bolt. start vehicle.

Tool Rotor Tighten Disco M(JB501002) Special Tool_Clutch Dismantling


Part No. : F41ZJZ44 Part No. : F41AJA58
FOB IN $ : 6.39 FOB IN $ : 5.71
Application : To hold rotor while loosening Application : To dismantle & assembled
/ tightening its nut. clutch of DISCOVER DTS-Si
kick start as well as self start
vehicle.

Magneto Rotor Puller Socket Special For Spark Plug


Part No. : F41ZJZ46 Part No. : 37 1040 51
FOB IN $ : 20.68 FOB IN $ : 2.89
Application : To pull out the rotor from Application : For removing and refitting
crankshaft assembly. spark plug R.H. and L.H.
side.

Clutch & Primary Gear Holding Tool_Kg Socket For Kg Clutch Nut Tightening
Part No. : F41AJA11 Part No. : F4 1ZJA 54
FOB IN $ : 7.47
FOB IN $ : 5.04
Application : T o h o l d p r i m a r y a n d Application : To loosen / tighten special
secondary gear while nut securing clutch.
loosening/tightening the
primary gear nut & special

12 Special Tools Guide 13 Special Tools Guide


MODEL : MODEL :

Special Tool For Tappet Adjustment- Xcd Extractor For Fr.Fork Single Antifrictio
Part No. : F4 1ZJW 33 Application : 37 1041 95
FOB IN $ : 1.17 FOB IN $ : 13.49
Application : To hold the Valve Tappet To remove anti-friction & oil seal bush from
screw while adjusting tappet front fork outer pipe.
clearance.

Driver Seat
Part No. : 37 1830 07
Remover For Inlet Valve Rocker Pin FOB IN $ : 4.97
Part No. : 37 10CS 22 Application :
To fit fork oil seal in its seat provided at
FOB IN $ : 0.79
Application : To remove Rocker Shaft
from cylinder head.

Stem Bearing Driver


Part No. : 37 1830 05
FOB IN $ : NA
Application :

Bearing Puller To fit bearing race on fork under holder


bracket
Part No. : 37 1030 48
FOB IN $ : 18.53
Application : To Pull out main ball bearing Cyl Holder Handle fork
from crankshaft
Part No. : 37 1830 06
FOB IN $ : 3.24
Application :
To hold fork cylinder while loosening /
tightening fork allen head bolt at bottom.

Adaptor - Valve Spring Comp.Assly /


Valve Spring
Adaptor Part No. : 37 1031 08 Drift For Removal Of Piston Pin.
Valve Spring Compressor : 37 1031 07 Part No. : 37 1010 06
FOB IN $ : 0.99 + 3.81 FOB IN $ : 1.11
Application : To assemble / dismantle Application : To remove refit piston pin.
intake, exhaust valve by
compressing spring in
cylinder head.

14 Special Tools Guide 15 Special Tools Guide


MODEL : MODEL :

Engine Sprocket Hold Extractor - Bear. Race


Part No. : 37 1030 53 Part No. : 37 1805 06
FOB IN $ : 2.35 FOB IN $ : 5.65
Application : To hold the output sprocket Application :
while removing sprocket allen
To remove steering cones
bolts.
from frame.

Tool For Pressing Drum Change Bush In Tool To Adjust Rear Shock Absorber
C'
Part No. : 37 00DS 01
Part No. : E6 1011 00 TE
FOB IN $ : 2.32
FOB IN $ : 3.81 Application :
Application : To assemble “Bushing with
PTFE Lining” at parent hole To adjust rear shock absorber spring tension
of crankcase RH for “Gear by adjusting the position of spring cam
Shift Drum” mounting. between 1st to 5th notch position.

Driver Set - Bearing


Digital Diagnostic Instrument
Part No. : 37 1030 61 Part No. : 37 2040 15
FOB IN $ : 25.44 4 Special Tools Guide FOB IN $ : 128
Application : Common bearing driver set Application :
for fitting & removing Combined unit for 'Pulsar DTS-i' & 'Discover
bearings from crankcase. DTS Si' M/c for checking various electrical &
electronic components / sub-assemblies.

Assembler T-0021330 (Installer Upper &


Load Unit
Lower Bearing Race Frame)
Part No. : 37 1801 06 Part No. : 37 2040 17
FOB IN $ : 13
FOB IN $ : 23.19 Application : Following tests can be carried
Application : out on this unit along with load unit & DMU.
Discover DTS Si - CDI / Auto Choke / Starter
To install upper & lower steering races /
relay
cones into their seats inside frame.

Bearing Puller DDI Master Unit


Part No. : 37 1030 48 Part No. : 37 2040 09
FOB IN $ : 217
FOB IN $ : 18.53 Application : It is a common base unit for
Application : various DDI for all models & is supplied to
you earlier. For more details refer its user
To Pull out steering race from ' Fork Under
manual.
Holder bracket'

16 Special Tools Guide 17 Special Tools Guide


MODEL : MODEL :

Tool To Remove Bush From Cover Cyl Head Tool To Lock Gear Primary & Cl Hsg Gear
Part No. : 37 10DS 24 Part No. : 37 10DS 28
FOB IN $ : 3.3 FOB IN $ : 2.98
Application : Application :
To remove & Refit silent bush from Cover To lock primary gear & clutch housing gear
cylinder head. while tightening & loosening the special nut for
clutch / centrifugal filter

Tool To Adjust Rear Shock Absorber Tool To Remove Swing Arm Rubber Bush
Part No. : 37 00DS 01 Part No. : 37 00DS 02
FOB IN $ : 2.32 FOB IN $ : 22.02
Application : Application :
To adjust the rear shock absorber setting. Swing Arm Bush Puller to remove Rubber fitted
in chassis

Tool To Remove Nrb (O/P Sh) From C'C Lh


Part No. : 37 10DS 26
FOB IN $ : 5.56
Application :
To remove needle roller bearing of output shaft
from crank case RH.

Tool To Remove Nrb (I/P Sh) From C'C Lh


Part No. : 37 10DS 25
FOB IN $ : 5.56
Application :
To remove needle roller bearing of output shaft
from crank case LH.

Tool To Remove Pin Piston From Engine


Part No. : 37 10DS 27
FOB IN $ : 1.57
Application :
To remove piston pin from piston

18 Special Tools Guide 19 Special Tools Guide


MODEL : MODEL :

Tool Service Cam Sproket Tighten Socket For Tightening Nut Dh101195
Part No. : F41ZJZ47 Part No. : 3710DJ43
FOB IN $ : 5.43 FOB IN $ : 3.43
Application : For holding sprocket during Application : To loosen / tighten special
removal / refitting of Cam nut securing clutch.
sprocket allen bolt.
Note : Existing tool can be used by

Tool Rotor Tighten (Jb501002) Special Tool_Clutch Dismantling


Part No. : F41ZJZ44 Part No. : F41AJA58
FOB IN $ : 6.39 FOB IN $ : 5.71
Application : To hold rotor while loosening Application : To dismantle & assembled
/ tightening its nut. clutch of DISCOVER DTS-Si
kick start as well as self start
vehicle.

Magneto Rotor Puller Socket Special For Spark Plug


Part No. : F41ZJZ46 Part No. : 37104051
FOB IN $ : 20.68 FOB IN $ : 2.89
Application : To pull out the rotor from Application : For removing and refitting
crankshaft assembly. spark plug R.H. and L.H.
side.

Clutch & Primary Gear Holding Tool_Kg Special Tool For Tappet Adjustment
Part No. : F41AJA11 Part No. : F41ZJW33
FOB IN $ : 7.47 FOB IN $ : 1.17
Application : T o h o l d p r i m a r y a n d Application : To hold the Valve Tappet
secondary gear while screw while adjusting tappet
loosening/tightening the clearance.
primary gear nut & special
nut securing clutch.

20 Special Tools Guide 21 Special Tools Guide


MODEL : MODEL :

Remover For Inlet Valve Rocker Pin Engine Sprocket Hold


Part No. : 37 10CS 22 Part No. : 37 1030 53
FOB IN $ : 0.79 FOB IN $ : 2.35
Application : To remove Rocker Shaft from Application : To hold the output sprocket
cylinder head. while removing sprocket allen
bolts.

Bearing Puller Tool For Pressing Drum Change Bush In


Part No. : 37 1030 48 C'

FOB IN $ : 18.53 Part No. : E6101100TE


Application : To Pull out main ball bearing FOB IN $ : 3.81
from crankshaft Application : To assemble “Bushing with
PTFE Lining” at parent hole
of crankcase RH for “Gear
Shift Drum” mounting.

Adaptor - Valve Spring Comp.Assly / Driver Set - Bearing


Valve Spring Part No. : 37 1030 61
Adaptor Part No. : 37 1031 08 FOB IN $ : 25.44
Valve Spring Compressor : 37 1031 07 Application : Common bearing driver set
FOB IN $ : 0.99 + 3.81 for fitting & removing
bearings from crankcase.
Application : To assemble / dismantle
intake, exhaust valve by
compressing spring in

Drift For Removal Of Piston Pin. Special Tool to Remove Anti-Friction


Bush
Part No. : 37 1010 06
Part No. : XXXX
FOB IN $ : 1.11
FOB IN $ : NA
Application : To remove refit piston pin.
Application :
To remove anti-friction & oil seal bush from
front fork outer pipe.

22 Special Tools Guide 23 Special Tools Guide


MODEL : MODEL :

Driver Seat Bearing Puller


Part No. : 37 1830 07 Part No. : 37 1030 48
FOB IN $ : 4.97 FOB IN $ : 18.53
Application : Application :
To fit fork oil seal in its seat provided at To Pull out steering race from ' Fork Under
outer pipe ID. Holder bracket'

Stem Bearing Driver Extractor - Bear. Race


Part No. : 37 1830 05 Part No. : 37 1805 06
FOB IN $ : NA FOB IN $ : 5.65
Application : Application :
To fit bearing race on fork under holder To remove steering cones
bracket from frame.

Cyl Holder Handle fork Tool To Adjust Rear Shock Absorber


Part No. : 37 1830 06 Part No. : 37 00DS 01
FOB IN $ : 3.24 FOB IN $ : 2.32
Application : Application :
To hold fork cylinder while loosening / To adjust rear shock absorber spring tension
tightening fork allen head bolt at bottom. by adjusting the position of spring cam
between 1st to 5th notch position.

Assembler T-0021330 (Installer Upper &


Lower Bearing Race Frame)
Part No. : 37 1801 06
Application : 23.19
To install upper & lower steering races /
cones into their seats inside frame.

24 Special Tools Guide 25 Special Tools Guide


MODEL : MODEL :
180 cc / 180 cc /

Catcher To Hold Sprocket Chain (Pulsar U Puller For Magneto Rotor


Part No.: 37 10DH 36 Part No. : 37 10DJ 32
FOB IN $ : 1.45 FOB IN $ : 4.95
Application : Application :
For holding sprocket during removal / refitting Used to pull out the rotor from crankshaft
of Cam sprocket allen bolt. assembly. bearing from CVT shaft

Puller To Remove Brg (Big) From Cam Shaf Tool For Holding Whi
Part No. : 37 10DH 32 Part No. : 37 10DJ 28
FOB IN $ : 5.71 FOB IN $ : 3.05
Application : Application :
To remove bearing (Decompression assembly Use to hold primary gear while loosening /
side) of camshaft. tightening the clutch nut.

Puller To Remove Brg From Cam Shaft Assl Spl Tool For Bal Idler Gr. DH101074
Part No. : 37 10DH 31 Part No. : 37 10DJ 63
FOB IN $ : 4.76 FOB IN $ : 7.43
Application : Application :
To remove small bearing of camshaft. Used to load the pre-tensioned scissor gears of
Assly balancer Idler gear.

Tool To Remove Rocker Arm Pin From Cyl H Socket For Tightening Nut Dh101195
Part No. : 37 10DH 35 Part No. : 37 10DJ 43
FOB IN $ : 0.69 FOB IN $ : 3.43
Application : Application :
To remove rocker pin from cylinder head. Used to remove / fit of centrifugal oil filter nut.
Note : Existing tool can be used by reducing
diameter to 25.9 + 0.1 mm
Dia. = 25.9+0.1

Hand Tool To Remove Silent Bush From Cov Tool For Piston Assly Insertion
Part No. : 37 10DH 33 Part No. : 37 10DJ 30
FOB IN $ : 5.41 FOB IN $ : 4.57
Application : Application :
To remove silent bush from cylinder head Used for compressing the piston rings when
cover. assembly piston in the cylinder block.

26 Special Tools Guide 27 Special Tools Guide


MODEL : MODEL :
180 cc / 180 cc /

Bearing Puller For Holder Fork Under Dh1 Piston Pin Drift
Part No.: 37 00DJ 01 Part No. : 74 9309 89
FOB IN $ : 15.23 FOB IN $ : 0.76
Application : Application :
Used for removing the lower bearing race from To remove piston pin.
‘T’

Puller Bearing For C'Case LH Fork Oil Seal Driver


Part No. : 37 10DJ 76 Part No. : 74 9309 87
FOB IN $ : 6.85 FOB IN $ : 9.45
Application : Application :
Used to extract the input shaft bearing from Used for fitting fork oil seal on Front fork (New
crankcase LH. Tool Developed)

Puller Bearing For C'Case LH Bearing Remover Shaft With Head


Part No. : 37 10DJ 77 Part No. : E6 0690 00
FOB IN $ : 7.04 FOB IN $ : 5.81
Application : Application :
Used to pull out the bearing for body balancer Used for removing & fitment of bearing in
from crankcase LH. wheel.

Valve Compressor Adopter / Valve Spring Extractor For Fork Pipe


Part No. : 37 10DJ 78 / 37 1031 07 Part No. : 74 9310 15
FOB IN $ : 1.71 + 3.81 FOB IN $ : 20.18
Application : Application :
Used for assembling / dismantling inlet, exhaust Used for removing front fork inner tube from
valves by compressing spring in cylinder head. outer tube.

Rotor Holder Needle Bearing Puller


Part No. : H6 0721 00 Part No. : 74 9309 93
FOB IN $ : 20.53 FOB IN $ : 27.68
Application : Application :
To hold rotor while loosening bolt. For removing & fitting needle roller bearing in
swing arm

28 Special Tools Guide 29 Special Tools Guide


MODEL : MODEL :

Reinforcement (Engine Support Stand) Cyl Holder Handle fork


Part No.: 37 0030 01 Part No. : 37 1830 06
FOB IN $ : 50.19 FOB IN $ : 3.24
Application : Application :
To be used for mounting engine assembly while Used for holding adaptor.
dismantling and assembling engine.

Bearing Driver Set Cyl Holder Adaptor / Adaptor Holder For


Part No. : 74 9309 94 Cylinder Fork
FOB IN $ : NA Part No. : 37 1830 08 / 37 1830 11
Application : FOB IN $ : 3.24 + 3.24
User for removal / fitting of various bearings & Application :
seals. Used in connection with front fork cylinder
holder handle.

Crankshaft alignment Spanner For Nipple Tightening.


Part No. : 37 1030 79 Part No. : 37 1530 18
FOB IN $ : 27.69 FOB IN $ : 0.79
Application : Application :
Used for supporting crankshaft assembly while Used for loosening & tightening of spokes as
checking its parameters. per required.

Valve Spring / Adaptor - Valve Spring Tool For Extracting


Comp.Assly Part No. : 37 10BA 61
FOB IN $ : 3.65
Part No. : 37 1031 07 / 37 1031 08
Application :
FOB IN $ : 3.81 + 0.99
User to remove input and output shaft bearing
Application :
from crankshaft RH and input shaft bearing
User for assembling / dismantling inlet exhaust from crankcase LH.
valves by compressing spring in cylinder head.

Extractor Extractor - Bear. Race


Part No. : 37 1703 04 Part No. : 37 1805 06
FOB IN $ : 1.99 FOB IN $ : 5.65
Application : Application :
Used to remove needle roller bearing from To be used for removal of bearing race from
clutch cover. chassis.

30 Special Tools Guide 31 Special Tools Guide


MODEL : MODEL :

Compr. Tester T T Spanner Size 8Mm / T Spanner Size 10Mm


Part No. : 69 7505 51 Part No. : 37 1031 65 / 37 1031 66
FOB IN $ : 26 FOB IN $ : 1.9 / 1.9
Application : Application :
User for checking compression pressure in the To be used for tightening / loosening nuts and
cylinder. bolts.

Plier - Inside Snapring Torque Wrench Avt300 / Torque Wrench Evt


Part No. : 37 1030 56 1200
FOB IN $ : 9.55 Part No. : 69 7505 26 / 69 7505 28
Application : FOB IN $ : 200.2 / 217.33
To be used for removing circlip. Application :
Used for tightening nuts and bolts to required
torques.

Circlip Plier Ot/S 37103057. Imp Screw Dirver


Part No. : 37 1030 57 Part No. : 73 2509 29
FOB IN $ : NA FOB IN $ : 5.2
Application : Application :
To be use for removing circlip. To be used for remove screws of different sizes
as required.

Instrument Multimeter Piston Pin Drift


Part No. : 37 1030 63 Part No. : 74 9309 89
FOB IN $ : 70.4 FOB IN $ : 0.76
Application : Application :
Used to check various electrical and valves. Used for removing the pin from piston.

Feeler Gauge Set 13 Blades 389Mm Rotor Puller


Part No. : 69 7502 51 Part No. : 74 9309 90
FOB IN $ : 1.58 FOB IN $ : NA
Application : Application :
Used for measuring gaps & clearances. For pulling the magneto rotor from crankshaft
assembly.

32 Special Tools Guide 33 Special Tools Guide


MODEL : MODEL :

Clutch Holder Output Shaft Bearing Extractor


Part No. : H6 0723 00 Part No. : 74 9309 91
FOB IN $ : NA FOB IN $ : NA
Application : Application :
To hold clutch hub for loosening & tightening For removing output shaft bearing from
the nut. crankcase.

Crank Case Bearing Extractor Pilot Screw Adjuster


Part No. : 74 9309 92 Part No. : E6 0687 00
FOB IN $ : NA FOB IN $ : NA
Application : Application :
For removing crankshaft bearing from For adjusting the pilot screw accurately.
crankcase.

Rotor Holder - For Eliminator. Fork Oil Seal Driver


Part No. : H6 0721 00 Part No. : 74 9309 87
FOB IN $ : 20.53 FOB IN $ : 9.45
Application : Application :
To hold rotor while removing magneto & To be used for installing oil seal for front fork.
balancer gear nuts.

Gear Holder Tdc Finder


Part No. : H6 0722 00 Part No. : 74 9533 54
FOB IN $ : NA FOB IN $ : NA
Application : Application :
To hold primary gear for loosening & tightening To be used to find the TDC position of piston
the primary gear nuts. A) Dial Gauge
B) TDC Finder

Crank Case Splitting Crankshaft Wedge


Part No. : E6 0691 00 Part No. : 74 9309 88
FOB IN $ : 15.58 FOB IN $ : NA
Application : Application :
To be use for splitting the crankcase halves. Used to maintain alignment at 2 crankshaft
webs, while pressing the crankshaft with
crankcase.

34 Special Tools Guide 35 Special Tools Guide


MODEL : MODEL :

Needle Bearing Puller Wrench Hook


Part No. : 74 9309 93 Part No. : 37 1801 01
FOB IN $ : 27.68 FOB IN $ : 2.48
Application : Application :
For removing & fitting bearing in swing arm. To be used for removing and fitting the ring
nut.

Assembler T-0021330 (Steering Column Stem Bearing Driver


Assembly Bush) Part No. : 37 1080 05
Part No. : 37 1801 06 (8) FOB IN $ : NA
FOB IN $ : 23.19 Application :
Application : Used for fitting the bearing race on steering
To be used for fitting upper & lower bearing stem.
races on chassis.

Extractor For Fork Pipe


Part No. : 74 9310 15
FOB IN $ : 20.18
Application :
Used for removing front fork inner tube from
outer tube.

Bearing Remover Shaft With Head


Part No. : E6 0690 00
FOB IN $ : 5.81
Application :
To be used for removing & fitment of needle
bearing in front wheel.

Valve Guide Arbor


Part No. : H6 0725 00
FOB IN $ : NA
Application :
Used for removing & fitting of valve guide from
cylinder head.

36 Special Tools Guide 37 Special Tools Guide


MODEL : MODEL :

Special Tool_Kg Cam Sprocket Holder Socket Special For Spark Plug
Part No. : F41AJA08 Part No. : 37 1040 51
FOB IN $ : 4.68 FOB IN $ : 2.89
Application : Application :
For holding sprocket during removal / refitting of For removing & refitting spark plug exhaust &
Cam sprocket allen bolt. Intake side.

Special Tool_Kg Magneto Rotor Holder Valve Adjusting Screw Holder


Part No. : F41AJA09 Part No. : 37 1031 53
FOB IN $ : 7.47 FOB IN $ : 0.78
Application : Application :
To hold rotor while loosening / tightening its To hold Valve Tappet screw while adjusting
nut. tappet clearance.

Special Tool_Kg Magneto Rotor Puller Puller To Remove Brg (Big) From Cam Shaf
Part No. : F41AJA10 Part No. : 37 10DH 32
FOB IN $ : 17.72 FOB IN $ : 5.71
Application : Application :
To pull out the rotor from crankshaft assembly. To remove big bearing from camshaft.

Clutch & Primary Gear Holding Tool_Kg Puller To Remove Brg From Cam Shaft Assl
Part No. : F41AJA11 Part No. : 37 10DH 31
FOB IN $ : 7.47 FOB IN $ : 4.76
Application : Application :
To hold primary & secondary gear while To remove small bearing of camshaft.
loosening / tightening the primary gear nut &
special nut securing clutch.

Socket For Kg Clutch Nut Tightening Remover For Inlet Valve Rocker Pin
Part No. : F41ZJA54 Part No. : 37 10CS 22
FOB IN $ : 5.04 FOB IN $ : 0.79
Application : Application :
To loosen / tighten special nut securing clutch. To remove Rocker Shaft from cylinder head.

38 Special Tools Guide 39 Special Tools Guide


MODEL : MODEL :

Bearing Puller Tool For Pressing Drum Change Bush In C'


Part No. : 37 1030 48 Part No. : E6101100TE
FOB IN $ : 18.53 FOB IN $ : 3.81
Application : Application :
To Pull out main ball bearing from crankshaft To assemble “Bushing with PTFE lining” at
parent hole of crankcase RH for “Gear Shift
Drum” mounting.

Adaptor - Valve Spring Comp.Assly Bearing Driver Set


Adaptor Part No.: 37 1031 08 Part No. : 37 1030 61
FOB IN $ : 0.99 FOB IN $ : 25.44
Valve Spring Compressor : 37 1031 07 Application :
FOB IN $ : 3.81 Common bearing driver set for fitting &
Application : removing bearings from crankcase.
To assemble / dismantle Intake, Exhaust valve
by compressing spring in cylinder head.

Drift For Removal Of Piston Pin.


Part No. : 37 1010 06
FOB IN $ : 1.11
Application :
To remove refit piston pin.

Special Tool For Thrust Plate Fitment


Part No. : T - 1011168
FOB IN $ : 6.46
Application :
To align the clutch hub concentricity w.r.t.
clutch housing & holder clutch.

Engine Sprocket Hold


Part No. : 37 1030 53
FOB IN $ : 2.35
Application :
To hold the output sprocket while removing
sprocket allen bolts.

40 Special Tools Guide 41 Special Tools Guide


MODEL : MODEL :

Special Tool_Kg Cam Sprocket Holder Puller To Remove Brg (Big) From Cam Shaf
Part No. : F41AJA08 Part No. : 37 10DH 32
FOB IN $ : 4.68 FOB IN $ : 5.71
Application: Application :
For holding sprocket during removal / refitting of To remove big bearing from camshaft.
Cam sprocket allen bolt.
22mm

Special Tool_Kg Magneto Rotor Holder Puller To Remove Brg From Cam Shaft Assl
Part No. : 37 10DH 31
Part No. : F41AJA09
FOB IN $ : 4.76
FOB IN $ : 7.47
Application :
Application :
To remove small bearing of camshaft.
To hold rotor while loosening / tightening its
nut.

Remover For Inlet Valve Rocker Pin


Special Tool_Kg Magneto Rotor Puller Part No. : 37 10CS 22
Part No. : F41AJA10 FOB IN $ : 0.79
FOB IN $ : 17.72 Application :
Application : To remove Rocker Shaft from cylinder head.
To pull out the rotor from crankshaft assembly.

Bearing Puller
Clutch & Primary Gear Holding Tool_Kg Part No. : 37 1030 48
Part No. : F41AJA11 FOB IN $ : 18.53
FOB IN $ : 7.47 Application :
Application : To Pull out main ball bearing from crankshaft
To hold primary & secondary gear while
loosening / tightening the primary gear nut &
special nut securing clutch.
Adaptor & valve Spring Compressor
Socket For Kg Clutch Nut Tightening Adaptor Part No. : 37 1031 08
Part No. : F41ZJA54 Valve Spring Compressor : 37 1031 07
FOB IN $ : 5.04 FOB IN $ : 0.99 + 3.81
Application : Application :
To loosen / tighten special nut securing clutch. To assemble / dismantle Intake, Exhaust valve

Drift For Removal Of Piston Pin.


Part No. : 37 1010 06
Special Tool For Tappet Adjustment- Xcd
FOB IN $ : 1.11
Part No. : F41ZJW33
Application :
FOB IN $ : 1.17
To remove refit piston pin.
Application :
To hold Valve Tappet screw while adjusting
tappet clearance.

42 Special Tools Guide 43 Special Tools Guide


MODEL : MODEL :

Special Tool For Thrust Plate Fitment Driver Seat


Part No. : T - 1011168 Part No. : 37 1830 07
FOB IN $ : 6.46 FOB IN $ : 4.97
Application : Application :
To align the clutch hub concentricity w.r.t. To fit fork oil seal in its seat provided at outer
clutch housing & holder clutch. pipe ID.

Stem Bearing Driver


Engine Sprocket Hold
Part No. : 37 1830 05
Part No. : 37 1030 53
FOB IN $ : NA
FOB IN $ : 2.35
Application :
Application :
To fit bearing race on fork under holder bracket
To hold the output sprocket while removing
sprocket allen bolts.

Cyl Holder Handle Fork


Tool For Pressing Drum Change Bush In C' Part No. : 37 1830 06
Part No. : E6101100TE FOB IN $ : 3.24
FOB IN $ : 3.81 Application :
Application : To hold fork cylinder while loosening /
To assemble “Bushing with PTFE lining” at tightening fork allen head bolt at bottom.
parent hole of crankcase RH for “Gear Shift
Drum” mounting. Assembler T-0021330 (Installer Upper &
Lower Bearing Race Frame)
Bearing Driver Set Part No. : 37 1801 06
Part No. : 37 1030 61 FOB IN $ : 23.19
FOB IN $ : 25.44 Application :
Application : To install upper & lower steering races / cones
Common bearing driver set for fitting & into their seats inside frame.
removing bearings from crankcase.
Bearing Puller
Part No. : 37 1030 48
Socket - For Blinker Nut (Xcd-135) FOB IN $ : 18.53
Part No. : 73 0904 31 Application :
FOB IN $ : 5.74 To Pull out steering race from ' Fork Under
Application: Holder bracket'
To remove & fit nut securing Indicator assembly.

Extractor - Bear. Race


Part No. : 37 1805 06
Extractor For Fr.Fork Single Antifrictio
FOB IN $ : 5.65
Application : 37 1041 95 Application:
FOB IN $ : 13.49 To remove steering
To remove anti-friction & oil seal bush from Cones from frame.
front fork outer pipe.

44 Special Tools Guide 45 Special Tools Guide


MODEL : MODEL :

Special Tool_Kg Cam Sprocket Holder Socket Special For Spark Plug -Gf

Part No. : F41AJA08 Part No. : 37 1040 51

FOB IN $ : 4.68 FOB IN $ : 2.89


Application: Application :
For holding sprocket during removal / For removing and refitting spark plug
refitting of Cam sprocket allen bolt. exhaust & Intake side.

Holder Fly Wheel Valve Adjusting Screw Holder


Part No. : 37103054 Part No. : 37103153
FOB IN $ : 4.76
Application : FOB IN $ : 0.78
To hold the rotor while removing & Application :
tightening the nut To hold the Valve Tappet screw while
adjusting tappet clearance.

Magneto Rotor Puller Puller To Remove Brg (Big) From Cam


Shaf
Part No. : F41ZJZ46
FOB IN $ : 20.68 Part No. : 37 10DH 32
Application : To pull out the rotor from FOB IN $ : 5.71
crankshaft assembly.
Application :
To remove big bearing from camshaft.

Clutch & Primary Gear Holding Puller To Remove Brg From Cam
Tool_Kg Shaft Assl
Part No. : F41AJA11 Part No. : 37 10DH 31
FOB IN $ : 7.47 FOB IN $ : 4.76
Application : Application :
To hold primary & secondary gear while To remove small bearing of camshaft.
loosening / tightening the primary gear
nut & special nut securing clutch.

Socket For Kg Clutch Nut Tightening Remover For Inlet Valve Rocker Pin

Part No. : F41ZJA54 Part No. : 37 10CS 22

FOB IN $ : 5.04 FOB IN $ : 0.79


Application : Application :
To loosen / tighten special nut securing To remove Rocker Shaft from cylinder
clutch. head.

46 Special Tools Guide 47 Special Tools Guide


MODEL : MODEL :

Bearing Puller Tool For Pressing Drum Change Bush


In C'
Part No. : 37 1030 48
Part No. : E6101100TE
FOB IN $ : 18.53
Application : FOB IN $ : 3.81
To Pull out main ball bearing from Application :
crankshaft To assemble “Bushing with PTFE lining”
at parent hole of crankcase RH for
“Gear Shift Drum” mounting.

Adaptor & valve Spring Compressor Bearing Driver Set


Adaptor Part No. : 37 1031 08 Part No. : 37 1030 61
Valve Spring Compressor : 37 1031 07
FOB IN $ : 25.44
FOB IN $ : 0.99 + 3.81 Application :
Application : Common bearing driver set for fitting &
To assemble / dismantle Intake, Exhaust removing bearings from crankcase.
valve by compressing spring in cylinder
head.

Drift For Removal Of Piston Pin.

Part No. : 37 1010 06

FOB IN $ : 1.11
Application :
To remove refit piston pin.

Special Tool_Clutch Dismantling


Part No. : F4 1AJA 58
FOB IN $ : 5.71
Application : To dismantle & assembled
clutch of PLATINA DTS-Si
kick start as well as self start
vehicle.

Engine Sprocket Hold

Part No. : 37 1030 53

FOB IN $ : 2.35
Application :
To hold the output sprocket while
removing sprocket allen bolts.

48 Special Tools Guide 49 Special Tools Guide


MODEL : BOXER / CALIBER / CT 100 MODEL : BOXER / CALIBER / CT 100

Valve Adjusting Screw Holder Arbor Val Guide


Part No.: 37 1031 53 Part No. : 37 1031 05
FOB IN $ : 0.78 FOB IN $ : 0.79
Application : Application :
To be used for holding the screw for valve To remove and fitment of valve guide inside the
adjustment through its screw head. cylinder head.

Compr. Tester T / Adaptor Guide For Holder Cutter


Compression Gauge Part No. : 37 1031 06
Part No. : 69 7505 51 / 37 1031 11 FOB IN $ : 1.13
FOB IN $ : 26 + 0.95 Application :
Application : These tools are to be used for valve seat
Used to Compression pressure of the engine repairs.
with 5 sharp kicks and throttle valve full open.

Valve spring compressor assembly with Split Tool Assy Cc Ase


adapter Part No. : 37 1030 12
Part No. : 37 1031 07 / 37 1031 08 FOB IN $ : 4.76
FOB IN $ : 3.81 + 0.99 Application :
Application : Used for removing splitting and removal of
crankcase.

Clutch Holder For Engine Assly. Puller F/W Magneto


Part No. : 37 1031 52 Part No. : 37 1030 34
FOB IN $ : 4.33 FOB IN $ : 3.24
Application : Application :
To be used for holding clutch assembly To be used while pulling magneto rotor out.
loosening or tightening clutch nut.

Reamer Vl Guide Holder Fly Wheel


Part No. : 37 1031 12 Part No. : 37 1030 54
FOB IN $ : 6.2 FOB IN $ : 4.76
Application : Application :
To be used to clear up the burr or any To be used for holding magneto rotor while its
unevenness at inner surface of valve guide. removal or assembly.

50 Special Tools Guide 51 Special Tools Guide


MODEL : BOXER / CALIBER / CT 100 MODEL : BOXER / CALIBER / CT 100

Plier - Inside Snapring Crankshaft Alignment


Part No.: 37 1030 56 Part No. : 37 1030 79
FOB IN $ : 9.55 FOB IN $ : 27.69
Application : Application :
To be used for removal and fitment of circlip This tool is to be used for the inspection of
mounted on inner diameters. crankshaft run out.

Circlip Plier Ot/S 37103057. Tool - Tightening Filter


Part No. : 37 1030 57 Part No. : 37 1031 51
FOB IN $ : NA FOB IN $ : 3.86
Application : Application :
To be used for removal and fitment of circlip The centrifugal oil filter is mounted on
mounted on inner diameters. crankshaft at clutch side in 4S Champion &
Boxer only. While tightening as well as
loosening this nut it is necessary to hold the oil
filter.

Wrench Spring Plug Gauge - Check Height 20+/-1


Part No. : 37 1031 13 Part No. : 37 1031 64
FOB IN $ : 3.62 FOB IN $ : 3.03
Application : Application :
This is useful for removal and fitment of This height gauge can be used with its higher
sparkplug. level (HL = 21) and lower level (LL = 19).

Bearing Driver Sets Reinforcement


Part No. : 37 1030 61 Part No.: 37 0030 01
FOB IN $ : 25.44 FOB IN $ : 50.19
Application : Application :
To be used for remove and fitment of bearing To be used for mounting engine assembly while
from its seat. dismantling and assembling engine.

Wedge For Crankshaft Alignment Tool For Removing Shaft Rocker


Part No. : 37 1030 65 Part No. : 37 1031 68
FOB IN $ : NA FOB IN $ : 2.28
Application : Application :
Wedge is to be put in between the two crank The rocker arm shaft is slide fit into the cylinder
webs while putting crankshaft into crankcase. head. While removing, if it is tight and difficult
to remove then this tool is to be used.

52 Special Tools Guide 53 Special Tools Guide


MODEL : BOXER / CALIBER / CT 100 MODEL : BOXER / CALIBER / CT 100

Cyl Holder Handlefork / Cyl Holder Adaptor / Stem Bearing Driver


Adaptor Holder For Cylinder Fork Part No. : 37 1830 05
Part No. : 37 1830 06 / 37 1830 08 / 11 FOB IN $ : NA
Application :
FOB IN $ : 3.24 + 3.24 + 3.24
The stem bearing driver is used for fitment of
Application : the lower inner bearing race on steering stem.
The adapter 37-1830-11 to be used along with 1 2 3 4 5
its handle 37-1830-06 for holding the piston
cylinder unit in front fork assembly while 1. Allen key
removal and fitment of its allen head bolt at 2. Allen bolt
bottom.
3. Piston/cylinder unit Assembler T-0021330
The adapter 37-1830-08 is to be used along 4. Adaptor (37-1830-11) Part No. : 37 1801 06
with its handle 37-1830-06 while fitment of the 5. Front fork cylinder holder handle (37-1830-06) FOB IN $ : 23.19
disc nut P.No. 30-1810-28 at top of front
suspension spring. Application :
This tool is useful for installing upper and lower
bearing races on chassis.

Driver Seat (Front Fork Oil Seal Driver) Kick Shaft Oil seal
Part No. : 37 1830 07 Part No. : 37 1030 55
FOB IN $ : 4.97 FOB IN $ : 1.56
Application : Application :
In between inner tube of the front fork and the This oil seal guide is to be put on the oil seal
outer tube an oil seal is fitted. The inner tube due to which its lips gets protected; from
while sliding in the outer tube rubs against this getting damaged by kick shaft.
oil seal.For installation of this oil seal this tool is
to be used.

Stem Nut Wrench Instrument Multimeter


Part No. : 37 1630 04 Part No. : 37 1030 63
FOB IN $ : 0.93 FOB IN $ : 70.4
Application : Application :
A stem nut has been provided on the steering Used to check various electrical and valves.
stem. For tightening as well as loosening the
nut, this tool is useful

Bearing Puller
Part No. : 37 1030 48
FOB IN $ : 18.53
Application :
This tool is useful for removal of the steering
stem bearing race from the steering stem P.No.
31-18-1009 of the steering.

54 Special Tools Guide 55 Special Tools Guide


MODEL : MODEL :

Special Tool_Kg Cam Sprocket Holder Socket Special For Spark Plug
Part No. : F4 1AJA 08 Part No. : 37 1040 51
FOB IN $ : 4.68 FOB IN $ : 2.89
Application : Application :
For holding sprocket during removal / For Removing & Refitting Spark Pulg.
refitting of cam sprocket allen bolt.

Valve Adjusting Screw Holder


Part No. : 37 1031 53
Special Tool_Kg Magneto Rotor Holder FOB IN $ : 0.78
Part No. : F4 A1JA 09 Application :
FOB IN $ : 7.47 To hold the valve tappet screw while adjusting
Application :
To hold Rotor while loosening / tightening its
nut.
Puller To Remove Brg (Big) From Cam Shaf
Part No. : 37 10DH 32
FOB IN $ : 5.71
Application :
Magneto Rotor Puller To remove big bearing from camshaft.
Part No. : F4 1ZJZ 46
FOB IN $ : 20.68
Application : Puller To Remove Brg From Cam Shaft Assl
To Pull out the rotor from crackshaft assembly. Part No. : 37 10DH 31
FOB IN $ : 4.76
Application :
To remove small bearing of Camshaft.

Clutch & Primary Gear Holding Tool_Kg


Part No. : F4 1AJA 11 Remover For Inlet Valve Rocker Pin
FOB IN $ : 7.47 Part No. : 37 10CS 22
Application : FOB IN $ : 0.79
To hold primary & secondary gear Application :
while loosening / tightening the primary To remove rocker shaft from cylinder head.
gear nut & special nut securing clutch.

Socket For Kg Clutch Nut Tightening Bearing Puller


Part No. : F4 1ZJA 54 Part No. : 37 1030 48
FOB IN $ : 5.04 FOB IN $ : 18.53
Application: Application:
To loosen / tighten special nut securing clutch. To pull out main ball bearing from crankshaft.

56 Special Tools Guide 57 Special Tools Guide


MODEL : MODEL :

Adapter & Valve Spring Compressor Extractor For Fr.Fork Single Antifriction
Part No. : 37 1031 08 (Adapter)
Application : 37 1041 95
37 1031 07 (Valve Spring Comp.)
FOB IN $ : 13.49
FOB IN $ : 0.99 + 3.81
To remove anti-friction & oil seal bush from
Application :
front fork outer pipe.
To assemble / dismantle Intake / Exhaust valve
by compressing spring in cylinder head.

Drift For Removal Of Piston Pin.


Part No. : 37 1010 06
FOB IN $ : 1.11
Application :
To remove / refit Piston Pin. Driver Seal (Fork Oil Seal Driver)
Part No. : 37 1830 07
FOB IN $ : 4.97
Application :
Special Tool_Clutch Dismantling To fit fork oil seal in its seat provided at
Part No. : F4 1AJA 58 outer pipe ID.
FOB IN $ : 5.71
Application :
To dismantle / Assemble Clutch.

Engine Sprocket Hold


Part No. : 37 1030 53
FOB IN $ : 2.35
Application :
To hold the output sprocket while removing
sprocket allen bolts.

Tool For Pressing Drum Change Bush In C'


Part No. : E6- 10 1100 TE
FOB IN $ : 3.81
Application:
To assemble 'Bushing with PTFE Lining' at parent
hole of crankcase RH for 'Gear Shift Drum'

Bearing Drive Set


Part No. : 37 1030 61
FOB IN $ : 25.44
Application:
Common bearing driver set for fitting & removing
bearings from crankcase.

58 Special Tools Guide 59 Special Tools Guide


MODEL : MODEL :

Socket Special For Spark Plug -Gf Extractor Rear CVT Assembly
Part No. : 37 1040 51 Part No. : xxxxx
FOB IN $ : 2.89 FOB IN $ : NA
Application : Application :
For removing & fitting of spark plug LH & RH For removing Rear CVT Assembly from Rear
CVT Shaft

Sleeve For Cshaft Lh Side Special Toothed Tool For Oil Window In C
Part No. : 37 1040 44 Part No. : 37 10CS 04
FOB IN $ : NA FOB IN $ : 4.81
Application : Application :
To split crankcase halves To remove & fitting oil window nut

Sleeve For Cshaft Lh Side Sub Assly Fixture For Fitting The Spring
Part No. : 37 1040 44 Part No. : 74 0106 46
FOB IN $ : NA FOB IN $ : 2.56
Application : Application :
To push out crankshaft from LH crankcase To fit return spring on kick shaft

Sleeve For Cshaft Lh Side Oil Seal Fitment Tool For Cs,Cu Engines.
Part No. : 37 1040 37 Part No. : 37 10CS 02
FOB IN $ : NA FOB IN $ : NA
Application : Application :
To guide oil seal while fitting crankshaft in Fitting tool for Oil seal in crankcase for CVT
crankcase LH shaft and sleeve to guide oil seal.

Extractor For Removing Cvt Brg Sleeve For Cvt Rear Fixed Pulley
Part No. : 37 1040 54 Part No. : 37 10CS 14
FOB IN $ : NA FOB IN $ : NA
Application : Application :
To be used for extracting needle roller bearing To guide oil seal while fitting rear CVT sliding
from fixed rear CVT pulley pulley with fix pulley

60 Special Tools Guide 61 Special Tools Guide


MODEL :

Cvt Shaft Removing Puller


Part No. : 37 10CS 15
FOB IN $ : NA
Application :
To remove Rear CVT shaft with bearing from
crankcase LH. also to be used for removing
bearing from CVT shaft

Cvt Shaft Fitment Tool


Part No. : 37 10CS 20
FOB IN $ : NA
Application :
To fit bearing on rear CVT shaft

Extractor For Cvt Bearing Removal From T


Part No. : 37 10CS 21
FOB IN $ : NA
Application :
To remove ball bearing from transmission cover
for CVT shaft.

C'Case Bush Remover & Bush Fitment Tool


Part No. : 37 10CS 18
FOB IN $ : NA
Application :
To remove & fit crank case bush for engine
hanger

C'Case Small Bush Remover & Fitment Tool


Part No. : 37 10CS 19
FOB IN $ : NA
Application :
To remove 6 fit crankcase bush for RSA

62 Special Tools Guide


SPECIAL TOOL INDEX : SPECIAL TOOL INDEX :

PART NO Description FOB in US $ P-135 P-150 P-180 P-200 P-220 DIS-100 DIS-135 DIS-150 AVG-180 AVG-200 ELEMINATOR XCD-125 XCD-135 BM-125 CT-100 BOXER CALIBER PLATINA-125 KRISTAL
E6101100 TOOL FOR PRESSING DRUM CHANGE BUSH IN C' 3.81 
3710DH32 PULLER TO REMOVE BRG (BIG) FROM CAM SHAF 5.71 
37003001 REINFORCEMENT 50.19    
37004003 TOOL FOR OIL SEAL PRESSING ON FORK FRONT #/N/A    
3700DH14 TOOL TO ADJUST REAR SHOCK ABSORBER 2.13    
3700DJ01 BEARING PULLER FOR HOLDER FORK UNDER DH1 15.23      
3700DS01 TOOL TO ADJUST REAR SHOCK ABSORBER 2.32    
3700DS02 TOOL TO REMOVE SWING ARM RUBBER BUSH 22.02 
37100114 CRANK SHAFT BEARING EXTRACTOR 34.62    
37101006 DRIFT FOR REMOVAL OF PISTON PIN. 1.11       
37183006 CYL HOLDER HANDLEFORK 3.24 
37183007 DRIVER SEAT 4.97 
37103012 SPLIT TOOL ASSY CC ASE 4.76   
37103034 PULLER F/W MAGNETO 3.24   
37103048 BEARING PULLER 18.53          
37103053 ENGINE SPROCKET HOLD 2.35           
37103054 HOLDER FLY WHEEL 4.76    
37103055 KICK SHAFT OILSEAL 1.56   
37103056 PLIER - INSIDE SNAPRING 9.55    
37103057 CIRCLIP PLIER OT/S 37103057. #/N/A    
37103061 DRIVER SET - BEAR. 25.44              
37103063 INSTRUMENT MULTIMETER 70.4    
37103065 WEDGE FOR CRANKSHAFT ALIGNMENT #/N/A   
37103079 CS ALIGNMENT 27.69    
37103105 ARBOR VAL GUIDE 0.79   

63 Special Tools Guide 64 Special Tools Guide


SPECIAL TOOL INDEX : SPECIAL TOOL INDEX :

PART NO Description FOB in US $ P-135 P-150 P-180 P-200 P-220 DIS-100 DIS-135 DIS-150 AVG-180 AVG-200 ELEMINATOR XCD-125 XCD-135 BM-125 CT-100 BOXER CALIBER PLATINA-125 KRISTAL
37103106 HOLDER CUTTER 1.13   
37103107 VALVE SPRING 3.81                
37103108 ADAPTOR - VALVE SPRING COMP.ASSLY 0.99           
37103111 ADAPTOR GUIDE FOR COMPRESSION GAUGE 0.95   
37103112 REAMER VL GUIDE 6.2   
37103113 WRENCH SPRING PLUG 3.62   
37103151 TOOL - TIGHTENING FILTER 3.86   
37103152 CLUTCH HOLDER FOR ENGINE ASSLY. 4.33   
37103153 VALVE ADJUSTING SCREW HOLDER 0.78      
37103164 GAUGE - CHECK HEIGHT 20+/-1 3.03   
37103165 T SPANNER SIZE 8MM 1.9 
37103166 T SPANNER SIZE 10MM 1.9 
37103168 TOOL FOR REMOVING SHAFT ROCKER 2.28   
37104037 SLEEVE FOR CSHAFT LH SIDE #/N/A 
37104044 SLEEVE FOR CSHAFT LH SIDE #/N/A 
37104051 SOCKET SPECIAL FOR SPARK PLUG -GF 2.89       
37104054 EXTRACTOR FOR REMOVING CVT BRG #/N/A 
37104195 Extractor for Fr.Fork single antifrictio 13.49   
37108005 STEM BEARING DRIVER #/N/A 
3710BA61 TOOL FOR EXTRACTING 3.65 
3710CS02 OIL SEAL FITMENT TOOL FOR CS,CU ENGINES. #/N/A 
3710CS04 SPECIAL TOOTHED TOOL FOR OIL WINDOW IN C 4.81 
3710CS14 SLEEVE FOR CVT REAR FIXED PULLEY #/N/A 
3710CS15 CVT SHAFT REMOVING PULLER #/N/A 
3710CS18 C'CASE BUSH REMOVER & BUSH FITMENT TOOL #/N/A 

65 Special Tools Guide 66 Special Tools Guide


SPECIAL TOOL INDEX : SPECIAL TOOL INDEX :

PART NO Description FOB in US $ P-135 P-150 P-180 P-200 P-220 DIS-100 DIS-135 DIS-150 AVG-180 AVG-200 ELEMINATOR XCD-125 XCD-135 BM-125 CT-100 BOXER CALIBER PLATINA-125 KRISTAL
3710CS19 C'CASE SMALL BUSH REMOVER & FITMENT TOOL #/N/A 
3710CS20 CVT SHAFT FITMENT TOOL #/N/A 
3710CS21 EXTRACTOR FOR CVT BEARING REMOVAL FROM T #/N/A 
3710CS22 REMOVER FOR INLET VALVE ROCKER PIN 0.79       
3710DH31 PULLER TO REMOVE BRG FROM CAM SHAFT ASSL 4.76          
3710DH32 PULLER TO REMOVE BRG (BIG) FROM CAM SHAF 5.71         
3710DH33 HAND TOOL TO REMOVE SILENT BUSH FROM COV 5.41      
3710DH35 TOOL TO REMOVE ROCKER ARM PIN FROM CYL H 0.69      
3710DH36 CATCHER TO HOLD SPROCKET CHAIN (PULSAR U 1.45      
3710DJ28 TOOL FOR HOLDING WHI 3.05      
3710DJ30 TOOL FOR PISTON ASSLY INSERTION 4.57      
3710DJ32 PULLER FOR MAGNETO ROTOR 4.95      
3710DJ43 SOCKET FOR TIGHTENING NUT DH101195 3.43        
3710DJ63 SPL TOOL FOR BAL IDLER GR. DH101074 7.43      
3710DJ76 PULLER BEARING FOR C'CASE LH DH101003 6.85      
3710DJ77 PULLER BEARING FOR C'CASE LH DH101003 7.04      
3710DJ78 VALVE COMPRESSOR ADOPTER 1.71      
3710DS24 TOOL TO REMOVE BUSH FROM COVER CYL HEAD 3.3 
3710DS25 TOOL TO REMOVE NRB (I/P SH) FROM C'C LH 5.56 
3710DS26 TOOL TO REMOVE NRB (O/P SH) FROM C'C LH 5.56 
3710DS27 TOOL TO REMOVE PIN PISTON FROM ENGINE 1.57 
3710DS28 TOOL TO LOCK GEAR PRIMARY & CL HSG GEAR 2.98 
37153018 SPANNER FOR NIPPLE TIGHTENING. 0.79 
37163004 STEM NUT WRENCH 0.93   
37170304 EXTRACTOR 1.99 

67 Special Tools Guide 68 Special Tools Guide


SPECIAL TOOL INDEX : SPECIAL TOOL INDEX :

PART NO Description FOB in US $ P-135 P-150 P-180 P-200 P-220 DIS-100 DIS-135 DIS-150 AVG-180 AVG-200 ELEMINATOR XCD-125 XCD-135 BM-125 CT-100 BOXER CALIBER PLATINA-125 KRISTAL
37174004 TOOL FOR EXTRACTING INNER FROM OUTER 24.09    
37174005 HOLDER FOR FR. FORK 6.02    
37180101 WRENCH HOOK 2.48 
37180106 ASSEMBLER T-0021330 23.19        
37180506 EXTRACTOR - BEAR. RACE 5.65     
37183005 STEM BEARING DRIVER #/N/A      
37183006 CYL HOLDER HANDLEFORK 3.24      
37183007 DRIVER SEAT 4.97      
37183008 CYL HLDER ADAPTOR 3.24    
37183011 ADAPTOR HOLDER FOR CYLINDER FORK 3.24    
37204009 TOOL DDI MASTER UNIT (DMU) 217.7 
37204015 DDI for Pulsar UG 4 128 
37204017 Load Unit Pulsar UG4 13 
69750251 FEELER GAUGE SET 13 BLADES 389MM 1.58 
69750526 TORQUE WRENCH AVT300 200.2 
69750528 TORQUE WRENCH EVT 1200 217.33 
69750551 COMPR. TESTER T 26    
73090431 SOCKET - FOR BLINKER NUT (XCD-135) 5.74 
73250929 IMP SCREW DIRVER 5.2 
74010646 SUB ASSLY FIXTURE FOR FITTING THE SPRING 2.56 
74930987 FORK OIL SEAL DRIVER 9.45   
74930988 CRANKSHAFT WEDGE #/N/A 
74930989 PISTON PIN DRIFT 0.76       
74930990 ROTOR PULLER #/N/A 
74930991 OUTPUT SHAFT BEARING EXTRACTOR #/N/A 

69 Special Tools Guide 70 Special Tools Guide


SPECIAL TOOL INDEX : SPECIAL TOOL INDEX :

PART NO Description FOB in US $ P-135 P-150 P-180 P-200 P-220 DIS-100 DIS-135 DIS-150 AVG-180 AVG-200 ELEMINATOR XCD-125 XCD-135 BM-125 CT-100 BOXER CALIBER PLATINA-125 KRISTAL
74930992 CRANK CASE BEARING EXTRACTOR #/N/A 
74930993 NEEDLE BEARING PULLER 27.68   
74930994 BEARING DRVIER SET #/N/A 
74931013 FORK OIL SEAL FITMENT PUNCH #/N/A    
74931015 EXTRACTOR FOR FORK PIPE 20.18       
74953354 TDC Finder #/N/A 
E6068700 PILOT SCREW ADJUSTER #/N/A 
E6069000 BEARING REMOVER SHAFT WITH HEAD 5.81   
E6069100 CRANK CASE SPLITTING 15.58 
E6101100 TOOL FOR PRESSING DRUM CHANGE BUSH IN C' 3.81      
F41AJA08 SPECIAL TOOL_KG CAM SPROCKET HOLDER 4.68 
F41AJA08 SPECIAL TOOL_KG CAM SPROCKET HOLDER 4.68   
F41AJA09 SPECIAL TOOL_KG MAGNETO ROTOR HOLDER 7.47  
F41AJA10 SPECIAL TOOL_KG MAGNETO ROTOR PULLER 17.72  
F41AJA11 CLUTCH & PRIMARY GEAR HOLDING TOOL_KG 7.47       
F41AJA54 HOLDER_ROTOR TIGHTEN_DC TOOL_KICK ST._KG #/N/A 
F41AJA57 SPECIAL TOOL_ROTOR DISMANTLING XCD KS 3.6 
F41AJA58 SPECIAL TOOL_CLUTCH DISMANTLING_XCD KS 5.71     
F41AJA09 SPECIAL TOOL_KG MAGNETO ROTOR HOLDER 7.47 
F41ZJA54 SOCKET FOR KG CLUTCH NUT TIGHTENING 5.04    
F41ZJW33 SPECIAL TOOL FOR TAPPET ADJUSTMENT- XCD 1.17    
F41ZJZ44 TOOL ROTOR TIGHTEN DISCO M(JB501002) 6.39   
F41ZJZ46 Magneto Rotor Puller 20.68     
F41ZJZ47 TOOL SERVICE CAM SPROKET TIGHTEN DISCO M 5.43   
H6072100 ROTOR HOLDER - FOR ELIMINATOR. 20.53       

71 Special Tools Guide 72 Special Tools Guide


SPECIAL TOOL INDEX : SPECIAL TOOL INDEX :

PART NO Description FOB in US $ P-135 P-150 P-180 P-200 P-220 DIS-100 DIS-135 DIS-150 AVG-180 AVG-200 ELEMINATOR XCD-125 XCD-135 BM-125 CT-100 BOXER CALIBER PLATINA-125 KRISTAL
H6072200 GEAR HOLDER #/N/A 
H6072300 CLUTCH HOLDER #/N/A 
H6072500 VALVE GUIDE ARBOR #/N/A 
XXXXXX DIGITAL DIAGNOSTIC INSTRUMENT #/N/A     
T1011168 SPECIAL TOOL FOR THRUST PLATE FITMENT 6.46      
XXXX SPECIAL TOOL TO REMOVE ANTI-FRICTION BUSH #/N/A 
xxxxxx EXTRACTOR REAR CVT ASSLY. #/N/A 
37204009 TOOL DDI MASTER UNIT (DMU) 217.7     
37204015 DDI for Pulsar UG 4 128     
37204017 Load Unit Pulsar UG4 13     

73 Special Tools Guide 74 Special Tools Guide

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