Discover 125 M & 100 M SPC - Mar 2014
Discover 125 M & 100 M SPC - Mar 2014
A: Add A: Add
REV. NO., PART SR. PAGE Reason for change REV. NO., PART SR. PAGE
SHORT DESCRIPTION QTY. D: Delete SHORT DESCRIPTION QTY. D: Delete Reason for change
MM YY NUMBER NO. NO. MM YY NUMBER NO. NO.
C: Change C: Change
Index Index
Plate No. Description Page No. Plate No. Description Page No.
1 Cover Cylinder Head 2 31 Front Hub (Drum brake) 62
2 Cylinder Head 4 32 Front Hub (Disc Brake) 64
3 Valve 6 33 Front Master Cylinder (Disc Brake) 66
4 Camshaft / Tensioner 8 34 Front Caliper Assembly (Disc Brake) 68
5 Cylinder and Piston 10 35 Rear Hub 70
6 Crankshaft 12 36 Rear Brake Pedal 72
7 Transmission 14 37 Handle Bar Assly 74-76
8 Change Drum / Shift Fork 16 38 Front Fork 78
9 Gear Change Mechanism 18 39 Painted Parts & Decals-D 100 M 80-82
10 Engine Assly / Crankcase RH 20 40 Painted Parts & Decals-D 125 M 84-88
11 Crankcase LH 22 41 Petrol Tank, Cap Tank & Gauge Fuel 90
12 Oil Pump 24 42 Fittings - Petrol Tank, Side Cover & Cover Seat 92
13 Kick Starter Mechanism 26 43 Meter Assly. 94
14 Cover Clutch 28 44 Control Cables 96
15 Cover Magneto 30 45 Chain Case 98
16 Clutch Assly 32 46 Head Lamp & Fairing 100
17 Carburettor Assembly (100M) 34 47 Indicator Light Assly. 102
18 Carburettor Assembly (125M) 36 48 Tail Lamp Assly. / Front No. Plate 104
19 Air Cleaner Complete 38 49 Electrical Equipments 106
20 Silencer Assly 40 50 Tool Kit 108
21 Starter Assly 42 51 Accessories / Grab Handle 110
22 Magneto, C.D.I. & H.T. Coil 44
23 Seat Assly / Seat Lock 46 Kits List 111-118
24 Engine Mountings 48
25 Frame and Frame Fitting 50 Part Index 119
26 Swing Arm/Rear Shock Absorber 52
27 Rider Foot Rest 54
28 Mudguard- Front & Rear 56
29 Stand Assembly 58
30 Tyre/ Tube / Rim 60
Pictorial Index Pictorial Index
PLATE NO. : 1 PAGE NO. PLATE NO. : 2 PAGE NO. PLATE NO. : 5 PAGE NO. PLATE NO. : 6 PAGE NO.
COVER CYLINDER HEAD 2 CYLINDER HEAD 4 CYLINDER & PISTON 10 CRANKSHAFT 12
PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
VALVE 6 CAMSHAFT / TENSIONER 8 TRANSMISSION 14 CHANGE DRUM / SHIFT FORK 16
Pictorial Index Pictorial Index
PLATE NO. : 9 PAGE NO. PLATE NO. : 10 PAGE NO. PLATE NO. : 13 PAGE NO. PLATE NO. : 14 PAGE NO.
GEAR CHANGE MECHANISM 18 ENGINE ASSLY & CRANKCASE RH 20 KICK STARTER MECHANISM 26 COVER CLUTCH 28
PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO. PLATE NO. : 15 PAGE NO. PLATE NO. : 16 PAGE NO.
CRANKCASE LH 22 OIL PUMP 24 COVER MAGNETO 30 CLUTCH ASSLY 32
Pictorial Index Pictorial Index
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
CARBURETTOR - 100 M 34 CARBURETTOR - 125 M 36 STARTER ASSLY 42 MAGNETO, C.D.I. & H.T. COIL 44
PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
AIR CLEANER COMPLETE 38 SILENCER ASSLY 40 SEAT ASSLY / SEAT LOCK 46 ENGINE MOUNTINGS 48
Pictorial Index Pictorial Index
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO. PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
FRAME AND FRAME FITTING 50 SWING ARM/REAR SHOCK ABSORBER 52 STAND ASSEMBLY 58 TYRE/ TUBE / RIM 60
PLATE NO. : 27 PAGE NO. PLATE NO. : 28 PAGE NO. PLATE NO. : 31 PAGE NO. PLATE NO. : 32 PAGE NO.
RIDER FOOT REST 54 MUDGUARD- FRONT & REAR 56 FRONT HUB (DRUM BRAKE) 62 FRONT HUB (DISC BRAKE) 64
Pictorial Index Pictorial Index
PLATE NO. : 33
PAGE NO. PLATE NO. : 34 PAGE NO. PLATE NO. : 37 PAGE NO. PLATE NO. : 38 PAGE NO.
FRONT MASTER CYLINDER
66 FRONT CALIPER ASSLY (DISC BRAKE) 68 HANDLE BAR ASSLY 74-76 FRONT FORK 78
(DISC BRAKE)
PLATE NO. : 40
PLATE NO. : 35 PAGE NO. PLATE NO. : 36 PAGE NO. PLATE NO. : 39 PAGE NO. PAGE NO.
PAINTED PARTS & DECALS-D100M
REAR HUB 70 REAR BRAKE PEDAL 72 PAINTED PARTS & DECALS-D100M 80-82 84-88
Pictorial Index Pictorial Index
PLATE NO. : 41 PLATE NO. : 42
PAGE NO. PAGE NO. PLATE NO. : 45 PAGE NO. PLATE NO. : 46 PAGE NO.
PETROL TANK, CAP TANK & GAUGE FITTINGS - PETROL TANK, SIDE
90 92 CHAIN CASE 98 HEAD LAMP & FAIRING 100
FUEL COVER & COVER SEAT.
2 4
11 PA 5812 05 Insulator 1 --
12 12 LJ A000 11 O-Ring 1 –
11
9A 13 PA 5812 25 Sleeve Carburettor – 1
14 AA 1210 71 Clamp Carburettor Duct – 1
13
1/2
8
11 CS 1011 28 Gasket 1 1
12 JE 5210 16 Chain Tensioner 1 1
13 JA 5210 19 Bolt 2 2
14 39 2669 21 Ring - ‘O’ (ID 10.15X1.5) 1 1
12
9 10 13
11
14
3
2
6 PA 5212 14 Circlip Piston 2 –
DP 1011 65 Pin Snap -- 2
7 JB 4022 02 Grommet - Thermal sensor 1 1
4 5
3 6
5 7 7 DS 1011 54 Key 1 1
8 JA 5310 12 Spring 1 1
6 9 JB 5310 21 Plunger Oil Crankshaft 1 1
9
8
2 4
4
10 11 PF 5512 04 Gear 3rd Driven 1 1
12 PA 5512 06 Gear 4th Driven 1 1
13 13 JZ 5512 05 Bush 1st Driven 1 1
8
12 14 PA 5512 05 Gear 1st Driven 1 1
15 JA 5510 08 Washer Thrust 1 1
20
19
11
10
12
6
6 DH 1013 80 Screw - Pan Pre-coated 1 1 (M6X12)-39
7 JA 5410 14 Bolt Shift Change 1 1
8 JA 5410 12 Guide Kick 1 1
7 9 39 1964 04 Bolt Flange 2 2
10 52 JA00 27 Stud (JA541015) Pre-coated 1 1
11 JA 5412 35 Bolt 2 2
3 9
8
12
5 JA 5410 05 Bush Bendix 1 1
11A
13
14
11
10
7 JZ 5412 14 Cap Filter 1 1
8 DD 1211 81 Element Oil Filter 1 1
1 9 PA 5514 05 Rod-Push 1 1
10 39 1041 19 Seal - Oil 1 1
19
5
4
3
2
1
N
10
11
1 17
7
11 JB 5812 60 Drain Screw 1 –
13 12 JB 5812 37 Adjuster Cable 1 –
8
9 13 JB 5812 58 Tube Air Vent 1 –
14 PA 5812 22 Solenoid Assembly 1 –
2 15 JB 5812 47 O-Ring Solenoid 1 –
10
1 20
11 DH 1210 59 Float Assly – 1
12 DH 1210 64 Screw Needle Shaft – 1
13 DH 1210 93 Needle Assly – 1
13 14 JE 5812 23 Pipe Overflow – 1
4 14A DH 1210 63 Pin – 1
9 15 DH 1210 41 Clip Drain Hose – 1 N.I.
14A
16 JE 5812 18 Drain Screw – 1
12
11 19 17 DP 1210 67 Screw Float Body – 4
21 18 DH 1211 76 Screw Diaphragm Cover – 2
19 DP 1210 59 Gasket Float Chamber – 1
17 5 20 DP 1210 18 Clamp – 1 Towards Air Filter
16
10
7
5
8 7
9
5
6 JA 6214 14 Body starter Clutch 1 1
7 DH 1013 82 Bolt 3 3
4
8 DH 1017 81 Plate Roller Clutch 1 1
9 36 JZ00 08 Starter Clutch Repair Kit 1 1 Refer Page No. 111
10 39 0849 14 Washer 3 3
8
6
10
9
6
4
5
7 2
5
2 6
1
3
3
3
4
11
2
7
1A
4 5
6
8 11 30 1510 69 Spring 2 2
12 30 1510 68 Shoe Brake 2 2
13 JB 1310 18 Plain Washer 1 1
5 10 13A JB 1310 22 Spacer + Dust Seal 1 1
9 20
24 14 JB 1310 19 U Nut (M12) 1 1
15 39 0840 01 Pan Headed Screw 1 1
13
4
9
11
12
RN D O ROM
WA NLY
T3
F
O FLUID AINE
AK
E
-4
T
ON AP
R 6 8 DJ 1910 58 Master Cylinder with lever 1 1
BR D C R C ING
V
ALE FILLE MO
SE N E
ER
9 DJ 2011 09 Switch 1 1
A A
CLE FOR
BE
4
10 DJ 1910 25 Washer - Copper 4 4
10
8 15
9
10
10
11
6 PISTON SEAL
DUST SEAL
BLEEDER CAP
PROTECTION BOOT
INSULATOR
CALIPER PISTON
BLEEDER SCREW
PAD SPRING
26 PA 1316 10 Sleeve 1 1
27 DX 1510 15 Plain Washer 1 1
16
8 6 21
7 13 22
10 13
14
16
9 17
15
26 18
20
23
9 11
9 11
8 7 10
16
11 JZ 1718 22 Pipe Fuel 1 1
12
12 39 0740 11 Washer (Non-Metallic) 2 2
8
10 13 DD 1412 27 Bolt - Flanged 2 2
13 14 DS 1410 12 Grommet Side Cover 2 2
15 DK 1410 41 Pipe Clip 2 2
11 5
14
16 30 1410 39 Packing 1 1
17 DZ 1410 75 4 Valve Washer 1 1 N.I.
15
18 DH 1410 48 Rotor - Cap Lock 1 1
7
6
5
11 KA DD06 14 Bolt M6 X 12 2 2
6A
12 39 0722 11 Plain Washer 2 2
7
8 13 PA 1812 95 Foam Seat Cowl LH 1 1
14 PA 1812 96 Foam Seat Cowl RH 1 1
15 LB U000 07 Screww Struss 2 2
16 DH 1612 31 Lock With Key Side Cover 1 1
14
10
13
11 12
3 2
1 JZ 4010 38 Indicator Fr RH / Rr LH 2 2
2 GH 2010 12 Lamp 12V-10W 4 4
3 LC A000 05 Nut Hex M10X1.25 2 2
4 JZ 4010 39 Indicator Fr LH / Rr RH 2 2
5 39 1225 15 Nut - Hexagon With Flange 2 2
4 1
3
4
1
5
9
JZ 1812 99 Bracket Number Plate Front 1 1 Disc Brake
5
6
8 6 39 1970 15 Nut 2 2
7 7 39 1907 01 Screw M5 4 4
8 YP A130 03 Tail Lamp W/O Bulb - D100M 1 1
9 DJ 1612 29 Clip Nut M5 4 4
20 10 DD 2010 02 Reflector - Reflex 1 1
10
11 39 2484 15 Nut - Flange : M5 1 1
12 JD 4010 07 Rear Number Plate Lamp 1 1
13 12 13 JZ 4010 42 Spacer Illumination Lamp 1 1
14 KB UA05 45 Screw Trus 2 2
15 39 2124 15 Nut - Hexagon With Flange 2 2
11
14
13
11 KA CA08 20 Bolt-Socket 4 4
10
11
6
8
7
1. 36PA0096 Kit Cylinder Head Assly PA511045 Cylinder Head Machined 1 10. JE541233 Assembly Cover Magneto JZ541210 Cover Magneto 1
31101064 Plug 1 JA541005 Bush Bendix 1
PA511236 Seat Valve 2 30101195 Ring - O 1
PA511237 Seat Valve 2 JA541233 Cap TDC Finder 1
JA511004 Guide Valve 4 JE541230 Label Magneto Cover 1
39262921 O Ring 1
39128321 Ring O 1 11. 36PA0145 Assly Crankcase RH PA541029 Crankcase RH 1
PF541018 Bushing Drum 1
2. 36PA0153 Kit Valve Repair-D100 4V 39201719 Seal - Oil 2 JA541011 Needle Roller Bearing Hk1212 1
PA511223 Valve Spring 2 52JA0027 Stud (JA541015) Pre-coated 1
PA511210 Retainer Valve Spring 2 59200036 Bearing - Ball 6203 Hn3 C3 1
DG101029 Collet 4 31101064 Plug 1
PA511224 Seat Valve Spring 2 JA541014 Bolt Shift Change 1
3. 36PA0003 Kit Piston Ring Set JB521207 Ring Piston (Top) 1
12. 36DU1007 Boss Kick Set 30101233 Boss 1
JB521208 Ring Piston (Second) 1
30101234 Spring 1
JB521209 Ring Piston (Oil) 1
30101236 Ball - Steel 1
4. 36PA0093 Kit Block Piston PA521012 Block Cylinder 1 30101235 Pin 1
PA521216 Piston Assembly 1 39085517 Circlip : E-Type 1
5. 36PA0115 Kit Guide Cam Chain-D125T JE521019 Guide Cam Chain Tight D102C 1 14. 36PA0124 Kit Silencer W/O Shield
JE541030 Guide Cam Chain Slack Side 1
15. 36PA0123 Kit Chain Sprocket PA141011 Chain 120 Link 1
6. 36JE0024 Kit Friction Plate JE551410 Plate Friction D102C 5 PA141013 Sprocket Hub (43T) 1
JB551000 Sprocket Output (14T) 1
7. 36JZ0023 Kit Primary Drive & Driven JZ531006 Gear Primary Drive 1
PF551401 Clutch Hsg Assly Comp 1 16. 36PA0144 Kit Bearing Cone JZ151090 Bearing Cone 1
DH181024 Upper Bearing Race 1
8. 36JZ0008 Starter Clutch Repair Kit DH101163 Roller Clutch(Dia 12X10) 5 DH181025 Bearing Cone 1
DH101164 Spring Starter Clutch 5 DJ181115 Cage Bearing Steering 2
DJ101109 Bush For Spring Starter 5 36001052 Grease Lethon RR-3 - 10GM 1
JA621411 Bush Spring Starter Clutch 5
111 112
Kit List Kit List
17. 36PA0121 Cylinder Complete Fork 30181020 Piston Ring 1 24. 36PA0146 Assly C’case LH PA541032 C’case LH 1
JZ121013 Cap Oil Lock 1 39256220 Bearing - NRB 1
DM181008 Rebound Spring 1 39171519 Seal Oil 1
PA121041 Seat Pipe 1 59200036 Bearing Ball 1
JA541036 Plug Oil 1
18. 36PA0122 Kit Chain Case Upper+Lower PA181269 Chain Case Upper Assly 1 JZ541005 Nozzle Oil Jet 1
PA181272 Chain Case Lower Assly 1 JA541005 Bush Bendix 1
39219019 Seal Oil 1
19. 36PA0125 Kit Carb Jet D100 M PA581210 Jet Needle 1
25. 36DS1502 Speedo Gear Kit DL151014 Gear Speedometer 1
NA Needle Jet 1 30151041 Gear Screw 1
NA Holder Needle Jet 1
NA Jet Main # 108 1 26. 36DK0017 Kit Hardware Brake Rod 30191038 Pin 1
NA Jet Slow # 38 1 39021911 Washer Plain 1
NA Jet Comp # 38 X # 38 1 39080808 Split Pin 1
30191035 Spring 1
20. 36PA0126 Kit Carb Slow Jet D100 M NA Screw Adjuster 1 15191026 Pin 1
JB581240 ‘O’ - Ring 1 30191036 Nut Brake Adjuster 1
JB581244 Spring Compression Coil 1
JB581245 Plain Washer 1 27. 36PA0006 Kit Gear Set Primary Drive JB551401 Clutch Housing Complete 1
JB581246 ‘O’ - Ring 1 & Driven JA531010 Gear Primary Drive 1
113 114
Kit List Kit List
31. 36PA0154 Kit Piston Valve-D125M JE581213 Diaphragm 1 38. 36JE0002 Kit Piston Ring- 125ST JE521202 Top Ring Shriram 1
------------ Piston Valve Assembly 1 JE521203 Second Ring Shriram 1
------------ Spring 1 JE521204 Oil Ring Shriram 1
------------ Holder 1
JE581214 Spring 1 39. 36JZ0075 Kit Assly Cl Cover - 125ST JE541215 Cover Clutch D102A 1
Je581217 E-Ring 1 31101064 Plug 2
24121370 Ring Shim 1
DP121052 Washer 1 40. 36JE0019 Kit Float Chamber Body NA Float Body 1
------------ Jet Needle 1 DP121059 O-Ring 1
JE581218 Drain Screw 1
32. 36PA0155 Kit Pilot Screw-D125M ------------ Pilot Screw 1 DP121067 Screw 2
JE581208 Spring Adjuster 1 DH121118 O Ring Drain Screw 1
24121063 Washer 1
JE581209 O Ring 1
DH121130 O Ring 1 41. 36JE0020 Kit Top Cap NA Diaphragm Cover 1
DH121176 Screw 2
33. 36PA0156 Kit Jet D-125M ------------ Jet Needle 1
JZ581219 Jet Holder 1 42. 36JE0021 Kit Plunger Assly NA Screw 1
------------ Main Jet 1 DD121058 Spring 1
------------ Pilot Jet 1. NA Plunger Assly 1
NA Guide Holder 1
34. 36JZ0079 Kit Assly Cyl Head- 125ST JE511009 Cylinder Head Comp 1 NA O-Ring 1
31101064 Plug 1 NA Dust Cap 1
39128321 O Ring 1
39262921 O-Ring 1 43. 36JE0022 Kit Gasket/O-Ring-D125 DK121058 O Ring/Gasket Float Chamber 1
39166005 Stud M8X1.25X45L 2 DH121118 O-Ring - Drain Screw 1
DH121088 O-Ring - Vc Screw 1
35. 36JZ0102 Valve Kit JE511200 Valve Intake 1 DH121130 O-Ring - Vc Screw 1
JE511201 Valve Exhaust 1
44. Dk121041 Kit VC Screw D125 NA Screw Adjuster VC 1
36. 36JE0001 Kit Valve Repair- 125ST 39201719 Seal - Oil 2 DH121130 O- Ring Screw VC (Outside -
JD511203 Seat Valve Spring 2 Near The Head Of Vc Screw) 1
JD511204 Valve Spring 2 DH121086 Spring Screw VC 1
JD511205 Retainer Valve Spring 2 DH121087 Plain Washer 1
DG101029 Collet 4 DH121088 ‘O’ - Ring Screw VC
(Inside - At The Tip Of Air Screw) 1
37. 36JZ0074 Kit Block & Piston- 125ST JE521208 Piston Assembly D102C 1
JE521012 Cylinder Block D102C 1
115 116
Kit List Kit List
45. 36JZ0077 Kit Assly C' Case LH - 125ST JZ541021 Crankcase LH Exclusive Disco-H 1
JA541036 Plug (Oil Control) 2
JA541005 Bush Bendix 1
JZ541005 Nozzle Oil Jet 1
39256220 Needle Roller Brg. 1
117 118
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
119 120
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
121 122
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
123 124
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
125 126
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
127 128
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
129 130
Parts Index Parts Index
Figure Page Figure Page Figure Page Figure Page
Part Number Part Number Part Number Part Number
No. No. No. No. No. No. No. No.
131 132
Parts Index
Figure Page Figure Page
Part Number Part Number
No. No. No. No.
PF511021 6 2 YPA13022 16 94
PF541018 2 20 YPA15001 1 40
PF551003 8 14 YPA15002 8 94
PF551200 6 14 YPA15003 11 94
PF551201 5 14
PF551203 9 14
PF551204 11 14
PF551206 10 14
PF561002 2 16
PF561200 1 18
YPA13001 26 76
YPA13002 1 100
YPA13003 8 104
YPA13004 8 94
YPA13005 9 94
YPA13006 10 94
YPA13007 11 94
YPA13008 12 94
YPA13009 13 94
YPA13010 14 94
YPA13012 1 40
YPA13014 26 76
YPA13015 8 94
YPA13016 9 94
YPA13017 10 94
YPA13018 11 94
YPA13019 13 94
YPA13020 14 94
YPA13021 16 94
133