Spare Parts Catalogue: (Export)

Bajaj Auto Limited
Akurdi Pune 411 035 India

Spare Parts Catalogue
Tel +91 20 27472851
Fax +91 20 27407385
www.bajajauto.com
(Export)
Notice
All information contained in this manual is based on the latest
product information at the time of publication. Bajaj Auto
Limited accepts no liability for any inaccuracies or omissions in
this publication, although every possible care has been taken to
make it as complete and accurate as possible. All procedures
and specifications subject to change without prior notice. The
right is reserved to make such changes at any time without
prior notice and without incurring an obligation to make such
changes to product manufactured previously. Contact your
authorized Bajaj Dealer for the latest information on product
improvements incorporated after this manual was issued.
DOC. NO.: 71111284 REV. 01, MAR. 12

Foreword Instructions
We have pleasure in presenting the Spare Parts Catalogue for ‘Discover 125 1. How to Read the Catalogue : Open the catalogue and from the pictorial
/ 150’ Motorcycle. This catalogue has been specially designed to assist you index locate the group in which the part you want to find is present.
Turn over to the concerned page number (as given by pictorial index).
in selecting the correct parts for procurement to maintain 100% availability.
Now find out the figure of the part you wish to order. Write down the
part number against that particular figure number from the text.
The Bajaj spares are subjected to the stringent quality control standards to
In case, if you have the part number and you need the other details, the
ensure longer life of the vehicle. It is therefore necessary that only the part index can be used. The part index (at the end of the catalogue) will
Genuine Bajaj Spares are used. give you the figure and page number of the part you wish to order.
2. How to Order Spare Parts : The part number and the description of the
In a continual effort to improve Performance and Efficiency of the vehicles, part required should be invariably mentioned in the order as per the
Specifications, Diagrams, Illustrations and Part Numbers can change without catalogue text.
notice. Consequently, the description in this Spare Parts Catalogue cannot
The latest part number as conveyed through our service circulars should
therefore be final and binding on us. only appear on the order. In case of ordering painted components,
colour shade of the components should be mentioned.
The modifications / alterations which are carried out after the issue of this The quantity shown against the part number is the quantity per vehicle
catalogue, will be conveyed to you through our Service Circulars. You are for that group so that particular quantity should be multiplied by the
requested to make necessary corrections in the Parts Catalogue as per the number of sets required.
circulars so as to keep your catalogue up-to-date. This will ensure the
3. Part Number System : We have used 8 digit system for part numbers.
appropriate and speedy delivery of the Spare Parts as the order placed will The model or hardware item is indicated by first two digits or
bear the latest part numbers. alphanumeric, the next two or four digits indicate main group and the last
four or two digits indicate serial number in main group or serial number
or subgroup of fastener respectively. Thus the part numbers will be
In case, if you need any technical assistance contact the concerned Regional
indicated by 2-2-4 or 2-4-2 digit system. Understanding this system will
Office or write to us on the following address : enable you to identify the spare parts easily.
4. Abbreviations : The following abbreviations are used in this catalogue.

Bajaj Auto Limited
Assly Assembly V Volts
Export Service Department
N.I. Not illustrated W Watts
Akurdi, Pune 411 035 India
C'case Crankcase Accl. Accelerator
Phone : 020-27406557 Cyl Cylinder Comp. Complete
Fax : 020-27407385 O/s Over size Fr. Front
Rr. Rear Std. Standard
L Length A/t. Alternate
R.H. Right hand L.H. Left hand
Hex. Hexagonal AR As required
Index Index
Plate No. Description Page No. Plate No. Description Page No.
1 Cover Cylinder Head 2 27 Pillion Foot Rest / Holder 54

2 Cylinder Head 4 28 Mudguard Front & Rear 56
3 Valve 6 29 Stand Assembly 58
4 Camshaft / Tensioner 8 30 Tyre / Tube / Rim 60
5 Cylinder & Piston 10 31 Front Hub (Disc Brake) 62
6 Crankshaft 12 32 Front Master Cylinder 64
7 Transmission 14 33 Front Disc Brake Caliper Assembly 66
8 Change Drum / Shift Fork 16 34 Front Hub (Drum Brake) 68, 70
9 Gear Change Mechanism 18 35 Rear Hub 72, 74
36 Rear Brake Pedal 76
10 Engine Assly & Crankcase RH 20
37 Handle Bar 78, 80
11 Crankcase LH 22
38 Front Fork 82
12 Cover RH 24
39 Painted Parts & Decals 84, 86
13 Cover Magneto 26
40 Petrol Tank, Cap Tank & Gauge Fuel 88
14 Clutch 28
41 Fittings - Petrol Tank, Side Cover & Cover Seat 90
15 Kick Starter Mechanism 30
42 Meter Assembly 92
16 Carburettor 32
43 Control Cables 94
17 Air Cleaner Complete 34
44 Chain Case 96
18 Silencer Assly 36 45 Head Lamp & Fairing 98, 100
19 Oil Pump 38 46 Indicator Light Assembly 102
20 Starter Assly 40 47 Tail Lamp Assembly / Front Number Plate 104
21 Magneto / C.D.I. / H.T. Coil 42 48 Electrical Equipments 106
22 Seat Assly / Seat Lock 44 49 Tool Kit 108
23 Engine Mountings 46 50 Accessories / Grab Handle 110
24 Frame & Frame Fitting 48 Kits List For Discover 150 111, 112, 113
25 Swing Arm / Rear Shock Absorber 50 Amendment Sheet (Parts Added & Deleted) 114, 115, 116
26 Rider Foot Rest 52 Part Index 117
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
VALVE 6 CAMSHAFT / TENSIONER 8 TRANSMISSION 14 CHANGE DRUM / SHIFT FORK 16
GEAR CHANGE MECHANISM 18 ENGINE ASSLY & CRANKCASE RH 20 COVER MAGNETO 26 CLUTCH 28
DT
S-i
CRANKCASE LH 22 COVER RH 24 KICK STARTER MECHANISM 30 CARBURETOR 32
Nozzle Oil Jet

(Press Fitted)
AIR CLEANER COMPLETE 34 SILENCER ASSLY 36 MAGNETO / C.D.I. / H.T. COIL 42 SEAT ASSLY / SEAT LOCK 44
OIL PUMP 38 STARTER ASSLY 40 ENGINE MOUNTINGS 46 FRAME & FRAME FITTINGS 48
SWING ARM / RR. SHOCK ABSORBER 50 RIDER FOOT REST 52 STAND ASSLY 58 TYRE / TUBE / RIM 60
PILLION FOOT REST / HOLDER 54 MUDGUARD FRONT & REAR 56 FRONT HUB 62, 64 FRONT MASTER CYLINDER 66, 68
8 WA LY
: USE 4
ING T3- M
RN DO
FRO R
ON FLUID INE
E NTA
AK CO CAP G
BR
LED LER VIN
SEA N FIL REMO
A EA E
CL OR
BEF
FRONT DISC BRAKE CALIPER ASSLY 70 REAR HUB 72, 74 HANDLE BAR 80,82,84 FRONT FORK 86
PISTON SEAL
DUST SEAL
BLEEDER CAP
PROTECTION BOOT
INSULATOR
CALIPER PISTON
BLEEDER SCREW
PAD SPRING
PLATE NO. : 40
PLATE NO. : 35 PAGE NO. PLATE NO. : 36 PAGE NO. PLATE NO. : 39 PAGE NO. PAGE NO.
PETROL TANK, CAP TANK AND
REAR HUB 72, 74 REAR BRAKE PEDAL 76, 78 PAINTED PARTS AND DECALS 88 90
GAUGE FUEL
PLATE NO. : 41
PAGE NO. PLATE NO. : 42 PAGE NO. PLATE NO. : 45 PAGE NO. PLATE NO. : 46 PAGE NO.
FITTINGS - PETROL TANK,
92 METER ASSEMBLY 94 HEAD LAMP & FAIRING 104 INDICATOR LIGHT ASSEMBLY 106, 108
SIDE COVERS & COVER SEAT
PLATE NO. : 47
PLATE NO. : 43 PAGE NO. PLATE NO. : 44 PAGE NO. PAGE NO. PLATE NO. : 48 PAGE NO.
TAIL LAMP ASSLY /
CONTROL CABLES 96,98,100 CHAIN CASE 102 110 ELECTRICAL EQUIPMENTS 112
FRONT NUMBER PLATE
5
Pictorial Index
PLATE NO. : 49 PAGE NO. PLATE NO. : 50 PAGE NO.

TOOL KIT 112 ACCESSORIES / GRAB HANDLE 94
Plate No.: 1 Brand ID: 001MC643
Cover Cylinder Head

DIS DIS DIS
No. Part No. Description 125 125 150 Remarks
DRUM DISC DISC
2
1 JZ 5110 21 Cover Cylinder Head 1 1 1
2 59 0400 38 Bolt Flange 4 4 4
1
3 JD 5110 10 Gasket Head Cover 1 1 1
4 JA 5110 08 Bolt Head Mounting 4 4 4
5 JZ 5110 20 Plate Cylinder Head 1 1 1
7
6 JZ 5810 04 Hose C’ case Breather 1 1 1

7 JA 5110 29 Clamp 2 2 2
6 8 59 0400 50 Flange Bolt 1 1 1 For Head Mtg.
5
4
1 2
Front Wheel Direction
Cylinder Head
DIS DIS DIS
DRUM DISC DISC
1 36 JZ00 10 Head Cylinder Complete -- -- 1 With studs &

36 JZ00 27 Head Cylinder Complete 1 1 -- Valve Guide
2 9
2 JA 5110 28 Stud 2 2 2
10 3 JZ 5110 16 Gasket Cylinder Head – -- 1
JD 5110 08 Gasket Cylinder Head 1 1 --
2 4 JZ 5814 02 Intake Manifold 1 1 1
12
11 5 JA 5814 06 Bolt Flange 2 2 2
1
6 JZ 5812 10 Sleeve (Carb - Duct Rubber) 1 1 1

7 DP 1011 98 Clamp (39mm) 1 1 1
8 39 1283 21 ‘O’ Ring (Intake Pipe) 1 1 1
9 JB 5110 18 Sleeve Spark Plug R.H 1 1 1
5 10 39 2608 01 Grub Screw 1 1 1
11 39 2629 21 ‘O’ Ring Sleeve 1 1 1

8
6 12 39 1283 21 ‘O’ Ring Sleeve 1 1 1
3
13
13 AA 1210 45 Clamp 1 1 1
4
7
3 4
Valve
DIS DIS DIS
DRUM DISC DISC
1 JA 5112 11 Shaft Rocker Arm Exhaust 2 2 2

2 JZ 5112 03 Rocker Arm with Roller 2 2 2
3 DG 1010 29 Cotter Valve (Collet) 4 4 4
3
4 36 JZ00 01 Valve Kit 1 1 1 Refer
Page No. 112
1
5 36 JZ00 04 Valve Repair Kit 1 1 1 Refer
Page No. 112
1
6 39 2017 19 Seal Valve Stem 2 2 2
5
2
5 6
Camshaft / Tensioner
DIS DIS DIS
DRUM DISC DISC
1 JZ 5110 04 Camshaft Complete 1 1 1

10
2 JA 5112 16 Spacer Cam Sprocket 1 1 1
3 DS 1012 76 Sprocket Cam Shaft 1 1 1
11
4 39 2198 04 Bolt Allen Bolt 1 1 1
8
DH 1013 87 Bolt Allen Bolt 1 1 1 Alt. For.39219804
13 5 DH 1010 48 Special Washer (’O’ Washer) 1 1 1
7
9 6 36 JE00 03 Guide Chain Kit 1 1 1 Refer
15
Page No. 112
7 DH 1013 92 Bolt Special 1 1 1
8 JA 5210 17 Adjuster Assly Chain 1 1 1
16
9 CS 1011 28 Gasket 1 1 1
10 JA 5210 18 Bolt 1 1 1
DD 1010 62 Bolt 1 1 1 Alt. For. Ja521018
14
11 JA 5210 19 Flange Bolt 2 2 2 Adjuster Assly

1 6 Mounting
39 1673 04 Flange Bolt 2 2 2 Alt. For.JA521019
12 39 0594 17 Circlip for Camshaft 1 1 1
12
13 39 2669 21 ‘O’ Ring (Tensioner) 1 1 1
5
2 14 DS 1099 05 Cam Chain (94 Link) 1 1 1
15 39 2683 20 Bearing Ball 1 1 1
3
4
16 39 1880 20 Bearing Ball 1 1 1
7 8
Cylinder and Piston

DIS DIS DIS
DRUM DISC DISC
1 JD 5210 02 Gasket Cylinder 1 1 1

2 39 1000 06 Dowel Pin 4 4 4
3 36 JZ00 05 Piston Ring Set -- -- 1 Refer
2 36 JE00 02 Piston Ring Set 1 1 -- Page No. 105
5 4 DP 1011 65 Wire Circlip 2 2 2
5 36 JZ00 02 Cylinder Block / Piston Assly. -- -- 1 Molycoat Piston
36 JZ00 24 Cylinder Block / Piston Assly. 1 1 --
6 JW 3514 00 Thermal Sensor 1 1 1

7 JB 4022 02 Grommet for Thermal Sensor 1 1 1
2
8 JA 5210 15 Damper 3 3 3
6
1
7 4
4
8
9 10
Crankshaft
DIS DIS DIS
DRUM DISC DISC
1 59 1500 14 Flange Nut 2 2 2

2A 59 1200 03 Belleville Washer 2 2 2
6 2B 59 1100 08 Plain Washer 1 1 1
4 3 31 1011 73 Woodruff Key 1 1 1
10 4 JZ 5310 03 Crank Shaft Assly -- -- 1 Alt. Ja531000
9 JZ 5310 07 Crank Shaft Assly 1 1 –--
8
JE 5310 00 Crank Shaft Assly 1 1 –-- Alt. For. JZ531003
3 5 JE 5310 01 Ball Bearing -- -- 2
11
39 1864 20 Ball Bearing 1 1 –--
1 1
6 DS 1011 54 Parallel Key 1 1 1
7 36 JZ00 14 Set Primary Drive / Driven -- -- 1 Refer page no.114
2A 36 JZ00 23 Set Primary Drive / Driven 1 1 – Refer page no.111
5
2A 8 JA 531012 Spring 1 1 1
2B
9 JA 5310 15 Parallel Pin 1 1 1
10 JB 5310 21 Plunger Oil 1 1 1
11 JD 5310 04 Spacer Crankshaft Clutch Side 1 1 1
11 12
Transmission
DIS DIS DIS
DRUM DISC DISC
1 JZ 5510 01 Shaft I/P Transmission -- -- 1

JZ 5510 06 Shaft I/P Transmission-Forged -- -- 1 From 21.11.2010
JZ 5510 10 Shaft I/P Gun hole 1 1 --
2 JZ 5512 02 Gear 4th Drive 1 1 1
3 39 0987 17 Ring Snap 1 1 5
4 JA 5510 02 Spline Washer 1 1 4
5 JZ 5512 01 Gear 3rd Drive 1 1 1
1 JE 5512 01 Gear 3rd Drive 1 1 1 from Eng no.
JZMBVA55392
15 5A JZ 5512 03 Gear 5th Drive -- -- 1 Upto 21.11.2010
JZ 5512 13 Gear 5th Drive 1 1 1
2
3 4 6 JZ 5512 00 Gear 2nd Drive 1 1 1
14
3 5 13 7 JA 5510 04 Washer Thrust 2nd Drive 1 1 1
4 12 8 JZ 5510 03 Shaft Output Transmission -- -- 1 Upto 21.11.2010
3
4 JZ 5510 08 Shaft O/P Transmission-Forged 1 1 1
5A 9 JZ 5512 10 Bush 2nd Driven 1 1 1
6 9A JZ 5512 06 Gear 2nd Driven 1 1 1
7 4 11
3 10 JZ 5512 09 Gear 5th Driven -- -- 1 Upto 21.11.2010
JZ 5512 11 Gear 5th Driven 1 1 1
3 10
8 11 JZ 5512 07 Gear 3rd Driven -- -- 1 Upto 21.11.2010
9A JZ 5512 12 Gear 3rd Driven 1 1 1
9 JE 5512 06 Gear 3rd Driven 1 1 1 from Eng no.
JZMBVA55392
16 12 JZ 5512 08 Gear 4th Driven 1 1 1
17 13 JZ 5512 05 Bush 1st Driven 1 1 1
19 18 14 JZ 5512 04 Gear 1st Driven 1 1 1
20
15 JA 5510 08 Washer Thrust 1st Driven 1 1 1
16 JA 5510 09 Collar Sprocket Drive 1 1 1

17 59 2100 24 ‘O’ Ring Collar Sprocket 1 1 1
18 JZ 5510 04 Sprocket Drive 1 1 1
19 DU 1012 13 Plate Lock Sprocket 1 1 1
20 39 1981 04 Socket Head Bolt 2 2 2
13 14
Change Drum / Shift Fork

DIS DIS DIS
DRUM DISC DISC
1 JZ 5610 00 Drum Complete Gear Shift 1 1 1

2 39 0992 06 Dowel (Pin Drum Change) 4 4 4
3 JD 5610 11 Special Bolt 1 1 1
4 JD 5610 06 Shaft Gear Shift Fork 2 2 2
5 5 JD 5610 04 Fork Gear Shift Output 2 2 2
5
6 JD 5610 02 Fork Gear Shift Input 1 1 1
7 JD 5610 02 Cam Drum Change 1 1 1
1
4
4
7
6
3
15 16
Gear Change Mechanism

DIS DIS DIS
DRUM DISC DISC
1 JW 5612 05 Lever Complete Gear Shift 1 1 1

52 Jz02 64 Lever Complete Gear Shift 1 1 1 Al.tFor. JW561205
2 JW 5612 06 Extension Spring 1 1 1
3 JW 5612 08 Spring Gear Shift Return 1 1 1
1
2 4 JD 5612 03 Inhibitor Complete Gear Shift 1 1 1
5 JD 5612 04 Spring Inhibitor 1 1 1
3 6 JA 5612 09 Step Washer (Collar) 1 1 1
8 7 39 2704 11 Plain Washer 1 1 1

8 39 0817 15 Nut 1 1 1
7
12 9 JZ 5614 01 Lever Complete Gear Shifter
4 (Gear Pedal) 1 1 1
6
10 DH 1015 09 Damper 1 1 1
5
11 DG 1013 39 Damper 1 1 1
12 JA 5612 11 Flange Bolt 1 1 1
9
10
11
17 18
Engine Assembly / Crankcase RH

DIS DIS DIS
DRUM DISC DISC
1 JZ 5010 01 Engine Assly 1 1 -- N.I.

JZ 5010 00 Engine Assly -- -- 1 N.I.
2 36 JZ00 29 Crankcase Clutch Side 1 1 -- NRB + Bush +
Stud
10 36 JZ00 09 Crankcase Clutch Side -- -- 1 NRB + Bush +
9 Stud
11
3 59 2000 36 Bearing Ball 1 1 1 For I/P Shaft.
4 JA 5410 11 Needle Roller Bearing 1 1 1 For O/P Shaft.
5 JA 5410 10 Stopper Plate 1 1 1
6 8
5
6 39 1000 06 Dowel Pin 2 2 2
3
12 7 DU 1010 85 Bushing 1 1 1
14 8 DH 1013 80 Screw 1 1 1
9 52 JA00 27 Stud Inhibitor Mounting 1 1 1
10 JA 5412 35 Bolt 2 2 2 Crankcase Mtg.
13
7 11 59 0400 38 Bolt Flange 1 1 1 Crankcase Mtg.

12 JA 5410 14 Bolt Shift Change 1 1 1
2 52 Ja00 29 Bolt Shift Change 1 1 1 Alt. For JA541014
13 JA 5410 12 Guide Kick 1 1 1
4 14 39 1964 04 Hexagon Bolt 2 2 2
19 20
Crankcase LH
DIS DIS DIS
DRUM DISC DISC
1 36 JZ00 11 Crankcase Magneto Side -- -- 1 NRB + Bush

Nozzle Oil Jet 36 JZ00 28 Crankcase Magneto Side 1 1 -- NRB + Bush
(Press Fitted)
2 39 2562 20 Needle Roller Bearing 1 1 1
3 59 2000 36 Ball Bearing 1 1 1
4 39 1715 19 Seal Oil 1 1 1 Output Shaft
5 31 2010 81 Neutral Switch 1 1 1
6 DH 1017 84 Gasket Neutral Switch 1 1 1

2 7 39 2190 19 Oil Seal 1 1 1 Shifter Shaft
8 19 8 JA 5410 05 Bush Starter Clutch 1 1 1 Starter Clutch
9 39 0747 01 Pan Head Screw 2 2 2
3 10 JA 5410 34 Stopper Gear Starter Clutch 1 1 1
11
11 39 1000 06 Hollow Dowel Pin 4 4 4
17
12 39 0999 06 Hollow Dowel Pin 4 4 4
10
13 JA 5410 19 Mesh Filter Oil strainer 1 1 1
1
9 14 59 2100 23 ‘O’ Ring Cap Strainer 1 1 1
15 JA 5410 21 Cap Strainer 1 1 1
20 18 5 6
13 7 12
16 59 0400 38 Bolt Flange 6 6 6 Crankcase Mtg.
14
15
17 39 1759 04 Bolt 1 1 1 Crankcase Mtg.
4
16 18 JA 5410 20 ‘O’ Ring Mesh Filter Oil Strainer 1 1 1
19 JD 5410 00 Damper Crankshaft 1 1 1
20 JA 5410 32 Strainer Assly. 1 1 1
JA 5410 19 Strainer Assly. 1 1 1 Alt. For.JA541032
21 22
Cover RH
DIS DIS DIS
DRUM DISC DISC
1 36 JZ00 13 Clutch Cover -- -- 1 With Decal +

36 JZ00 25 Clutch Cover 1 1 -- Gauge + Circlip
2 JE 5412 11 Decal Clutch Cover 1 1 1
19 20 21 22 3 39 1041 19 Oil Seal Clutch Lever 1 1 1
4 30 1011 42 Oil Seal (Kick Shaft) 1 1 1
5 JW 5410 05 Shaft Clutch Release 1 1 1
18 6 JE 5514 01 Rod Push -- -- 1

DP 1012 69 Rod Push 1 1 –--
10
11 7 DG 1014 18 Gauge 1 1 1 Oil Level Check
5
8 DS 1012 15 Wire Circilp 1 1 1
12 3 9 JA 5412 36 Plain Washer 1 1 1
9
10 JA 5412 37 Spring Torsion Clutch Lever 1 1 1
17
13 2
8 11 JA 5412 11 Cap Oil Filler 1 1 1
7
12 JA 5412 25 ‘O’ Ring Cap Oil Filler 1 1 1
15 13 JE 5412 09 Damper 1 1 1
4
14 14 JA 5412 16 Plate Damper 1 1 1
15 39 2208 04 Bolt Flange 3 3 3
17
16 JA 5412 12 Gasket Clutch Cover 1 1 1
17 59 0400 38 Bolt Flange 8 8 8 Clutch Cover to
Crankcase Mtg
6 18 JW 5410 00 Bracket Clutch Cable 1 1 1
1
19 DD 1211 81 Oil Filter Element 1 1 1
23
20 39 1671 21 ‘O’ Ring 1 1 1
16
24
21 JZ 5412 14 Cap Filter 1 1 1
22 JA 5210 19 Bolt Flange 3 3 3
39 1673 04 Bolt Flange 3 3 3 Alt. For JA521019
23 14 1510 33 Bearing Push Rod 1 1 1
24 39 0999 06 Pin Hollow Dowel 2 2 2
23 24
Cover Magneto
DIS DIS DIS
DRUM DISC DISC
7
1 36 JZ00 15 Cover Magneto 1 1 1 With Bush
2 JA 5410 44 Bolt Flange 8 8 8
3 JA 5412 05 Gasket Magneto Cover 1 1 1
8 4 59 0400 38 Bolt 2 2 2
5 JZ 5412 02 Cover LH Rear Complete 1 1 1 Without label
6
3
6 JE 5412 10 Damper Cover LH 1 1 1
7 DH 1013 88 Flanged Bolt 3 3 3
9 8 JA 5412 21 Plate Damper Cover LH 1 1 1
10
9 JA 5410 05 Bush 1 1 1 For Drive Gear
Assly
11
10 JA 5412 33 Threaded Cap TDC Finder 1 1 1
2 11 30 1011 95 ‘O’ Ring 1 1 1

12 12 JW 2330 00 Sticker Gear Shifting 1 1 1 N.S
DT 13 JE 5412 12 Decal Magneto Cover 1 1 1
S-i
13
13 1
4
5
12
25 26
Clutch
DIS DIS DIS
DRUM DISC DISC
1 JZ 5514 13 Clutch Complete 1 1 –

JZ 5514 09 Clutch Complete –-- –-- 1
2 JA 5514 06 Collar Clutch 1 1 1
3 39 2600 11 Washer 1 1 1
1. For Discover 125 1. For Discover 150 4 36 JE00 05 Friction Plate Kit -- -- 1 Ref. Page No.114
36 JZ00 37 Friction Plate 1 1 – Ref. Page No.111
5 DP 1011 07 Wheel Clutch -- -- 1
11 JB 5514 08 Wheel Clutch 1 1 –--
3 10
18 6 DP 1011 11 Plate Clutch -- -- 4 alt.Jg551447N.S
30 1010 96 Plate Clutch 4 4 –--
9
7 DP 1012 43 Plate Judder Spring –-- –-- 1
8 8 JE 5514 03 Hub Clutch -- -- 1
18 2
JB 5514 11 Hub Clutch 1 1 –--
17
9 JZ 5514 12 Compression Spring -- -- 4
7 JZ 5514 15 Compression Spring 6 6 –--
10 JE 5514 05 Holder Clutch -- -- 1 4 Hole
JB 5514 12 Holder Clutch 1 1 -- 6 Hole
JB 5514 06 Holder Clutch 1 1 -- Alt. For. Jb551412
11 DP 1011 16 Bolt Flange –-- –-- 4
39 1553 04 Bolt Flange –-- –-- 4 Alt.For. DP101116
6 39 0980 04 Bolt Flange 6 6 –--
12 39 2200 11 Belleville Washer –-- –-- 1
JA 5514 16 Belleville Washer 1 1 –--
5 13 39 0240 11 Plain Washer -- -- 1
12 JA 5514 20 Plain Washer 1 1 –--
4 13 14 DH 1016 48 Nut Special -- -- 1 L.H. Threads
15
14 JA 5310 07 Nut Special 1 1 -- L.H. Threads
52 Ja00 28 Nut Special 1 1 -- Alt. For.JA531007
15 14 1510 33 Bearing Clutch Lifter -- -- 1
39 1001 20 Bearing Clutch Lifter 1 1 –--
16 16 36 JZ00 14 Set Primary Drive & Driven -- -- 1 Refer Page 114
36 JZ00 23 Set Primary Drive & Driven 1 1 – Refer Page 111
17 DP 1011 14 Spring Anti Judder –-- –-- 1
18 JD 5514 00 Spacer Clutch Assly 1 1 1 ‘JD’ Mark for ID
27 28
Kick Starter Mechanism

DIS DIS DIS
DRUM DISC DISC
1 JA 6212 01 Lever Assly Kick 1 1 1

2 JA 6212 06 Bolt Special 1 1 1
6 3 36 DU10 07 Boss Kick Set 1 1 1 Refer page no 112
4 22 1502 41 Plain Washer 1 1 1
11
5 39 0993 11 Plain Washer Small 3 3 3
7
6 39 0738 17 Circlip Shaft 2 2 2
7 JD 6210 01 Shaft Kick 1 1 1
13 8 DS 1011 17 Spring Kick Starter 1 1 1
8 9 JA 6210 02 Ratchet 1 1 1
9 10 JZ 6210 00 Gear Spur Kick Starter 1 1 1
5
11 JA 6210 06 Washer Thrust 1 1 1

5 10 12 39 2408 17 Circlip 1 1 1
2 13 DD 1010 97 Kick Rubber 1 1 1
5 12 14 DH 1011 25 Spring Kick Starter Return 1 1 1
14
1
29 30
Carburettor
DIS DIS DIS
DRUM DISC DISC
2
1 JZ 5812 09 Carburettor Assly -- -- 1
19 JZ 5812 27 Carburettor Assly 1 1 --
14 2 36 JZ00 20 Adjuster Throttle Cable Kit 1 1 1 Refer Page 114
3 DH 1211 69 Pilot Screw Kit 1 1 1 Refer Page 112
9 20 4 36 JZ00 17 Jet Kit -- -- 1 Refer Page 112
36 JZ00 31 Jet Kit 1 1 – Refer Page 111
5
5 36 JZ00 16 Idling Screw Kit 1 1 1 Refer Page 113
10 9 6 JA 5812 21 Valve Complete Float 1 1 1

3
11
7 24 1213 65 Float Complete 1 1 1
13 8 CB 1210 42 Screw Washers Bowl M4x14 -- -- 2
12 CB 1210 39 Screw Washers Bowl M4x14 2 2 --
1
9 JA 5812 33 Screw TPS & Solenoid Choke 2 2 2
6 10 JA 5812 39 Solenoid Choke Assly 1 1 1
7
11 JA 5812 40 "O" Ring Solenoid Choke 1 1 1
16 12 JB 5812 02 Throttle Position Sensor 1 1 1
13 JB 5812 04 "O" Ring (TPS) 1 1 1
4
14 36 JZ00 19 Throttle Valve Kit -- -- 1 Refer Page 113
36 JZ00 32 Throttle Valve Kit 1 1 – Refer Page 111
15 36 JZ00 21 Carburetor Gasket ‘O’ Ring 1 1 1 Refer Page 113
16 24 1210 69 Arm Pin Float 1 1 1

8
17 JA 5813 14 Drain Screw 1 1 1
17
18 JZ 5812 20 Hose Drain 1 1 1
18
19 JZ 5812 16 Spring 1 1 1
20 JZ 5812 22 Jet Needle -- -- 1
31 32
Air Cleaner Complete

DIS DIS DIS
DRUM DISC DISC
1 JZ 5810 07 Air Filter Assly 1 1 1

2 DS 1211 16 Air Filter Duct 1 1 1 Intake
3 JZ 5810 10 Assly Catridge Air filter 1 1 1
10
4 JZ 5810 11 Element Air Filter 1 1 1
1 5 DX 1210 11 Flame Arrester 1 1 1
11
15 6 JZ 5810 12 Tube Drain 1 1 1

16 13 7 DS 1211 26 Plug 1 1 1
8 DG 1210 02 Clamp 1 1 1
5 9 JZ 5810 04 Hose Breather 1 1 1 N.I.
17 10 39 1797 01 Hex Head Screw 3 3 3
11 39 1765 11 Washer 3 3 3
4 12 DH 1210 38 Clamp 1 1 1 N.I.
14 13 DS 1610 69 Bracket Side Cover Mtg. 1 1 1
6 14 JZ 5810 06 Connecting Tube 1 1 1
2 3
15 39 1779 02 Self Tapping Screw 2 2 2
8
7 16 JZ 5810 09 Filter Air Cover 1 1 1
17 DX 1210 06 ‘O’ Ring -- -- 1 Upto 15.04.2011
JZ 5810 29 ‘O’ Ring -- -- 1 Alt For Dx121006
JZ 5810 29 ‘O’ Ring 1 1 1
18 JA 5210 19 Flange Bolt 2 2 2 For Filter Mtg
19 39 1677 04 Flange Bolt 1 1 1 For Filter Mtg
33 34
Silencer Assembly
DIS DIS DIS
DRUM DISC DISC
1 36 JZ00 12 Silencer Assly without Shield -- –-- 1

36 JZ00 30 Silencer Assly without Shield 1 1 –--
2 CB 1011 14 Gasket Exhaust Mounting 1 1 1
3 3 JA 5910 40 Flange Nut 2 2 2
2
39 2295 15 Flange Nut 2 2 2 Alt. For JA591040
4 JZ 5910 43 Shield Silencer 1 1 1
5 5 JW 5910 28 Truss Screw 2 2 2
5
4 6 JB 5910 59 Grommet Shield 2 2 2

7 39 2754 04 Bolt Hex with Flange M5 1 1 1
7 8 39 2492 11 Plain Washer 1 1 1
9 9 39 2722 04 Bolt M10 x 1.25 1 1 1
8 10 10 JB 1130 05 Washer 2 2 2
6 11 36 DK00 09 Hardware Kit 1 1 1
1
12 DD 1610 71 U Nut M10 x 1.25 1 1 1
12 11
35 36
Oil Pump
DIS DIS DIS
DRUM DISC DISC
1 JZ 5710 00 Oil Pump Assly 1 1 1

2 JA 5410 16 Gasket Case Oil Pump 1 1 1
3 39 0753 01 Pan Head Screw 3 3 3
4 39 0999 06 Dowel 2 2 2
5 JZ 5710 01 Gear Driven + Shaft 1 1 1
1
4
3
37 38
Starter Assembly
DIS DIS DIS
4 DRUM DISC DISC
3 1 JA 6214 14 Body Complete Starter Clutch 1 1 1

2 DH 1017 81 Plate Roller Clutch 1 1 1
7
5 3 JA 6214 10 Gear Starter Clutch 1 1 1
4 JA 6214 02 Washer 2 2 2
1 5 JA 6214 06 Drive Assly 1 1 1
2
6 6 36 JZ00 08 Starter Clutch Repair Kit 1 1 1 Refer
7 Page No. 114
7 JA 3516 00 Motor Assly 1 1 1
8 JA 3516 04 ‘O’ Ring for Tie Bolt (Flash) 1 1 1 N.S
9 JA 3516 06 Sealing Ring (Flash) 1 1 1
JA 3516 26 Sealing Ring (Lucas-TVS) 1 1 1
10 LA D000 11 Hange Bolt 2 2 2 Motor Mounting
12
11 JA 3516 02 ‘O’ Ring for Spigot (Flash) 1 1 1
JA 3516 27 ‘O’ Ring for Spigot (Lucas-TVS) 1 1 1
12 JA 3516 08 +ve Brush Holder Assly (Flash) 1 1 1
13 JA 3516 09 -ve Brush Holder Assly (Flash) 1 1 1
16
14 JA 3516 18 Brush & Earth Plate Assly 1 1 1 N.I. (Lucas-TVS)
10 13
15 JA 3516 24 Brush Spring (Lucas-TVS) 1 1 1 N.I.
16 JA 3516 19 Terminal Assly (Lucas-TVS) 1 1 1

8
10
11 9
39 40
Magneto, CDI & H.T. Coil

DIS DIS DIS
DRUM DISC DISC
1 JE 3510 02 Rotor Assly –-- –-- 1

JZ 3510 01 Rotor Assly 1 1 –--
2 JP 3510 07 Stater Assly Complete 1 1 1
3 39 1675 04 Bolt Flange 2 2 2
5 39 1674 04 Bolt Flange 2 2 2 Alt. For. 39167504
6
4 39 0746 01 Pan Head Screw -- -- 3 For Lock Plate &
DH 1013 60 Pan Head Screw 1 1 -- Pick Up Coil Mtg
8 DH 1014 32 Pan Head Screw 1 1 –- Alt.For. DH101360
11 16
5 JE 3512 03 H. T. Coil LH -- -- 1
7 PA 3512 01 H. T. Coil LH 1 1 –--
9
6 JE 3512 04 H. T. Coil RH -- -- 1
PA 3512 02 H. T. Coil RH 1 1 –--
11
4 7 JZ 3512 05 C.D.I. Assly -- -- 1 Red Colour
9
JZ 3512 06 C.D.I. Assly 1 1 --
12 14
3 8 DD 1110 18 Spark Plug PRZ9 HC 2 2 2
10A / B 1
9 DD 1110 48 Spark Plug Cap LH 1 1 1
4
DH 1110 15 Spark Plug Cap RH 1 1 1
10A DD 1110 11 Grommet Spark Plug Cap LH 1 1 1
8
10B DH 1110 13 Grommet Spark - Plug Cap RH 1 1 1
13
2
11 DD 1110 12 Grommet for HT Cable 2 2 2

12 39 1943 04 Bolt Flange 2 2 2
13 JK 4020 00 DC Regulator With Capacitor 1 1 1
14 JA 5410 28 Lock Plate 1 1 1
15 59 0400 14 Bolt Flange (N.I.) 4 4 4 For HT Coil Mtg
41 42
Seat Assembly / Seat Lock

DIS DIS DIS
DRUM DISC DISC
1 JN 1910 00 Seat Assly Comp -- -- 1 Up to 10.03.2011

JZ 1910 06 Seat Assly Comp 1 1 1
2 36 DS21 01 Seat Damper Kit 1 1 1 Ref.Page No. 106
3 DS 2110 06 Lock Assly Seat 1 1 1
4 39 1902 04 Flanged Bolt 2 2 2
4
2
43 44
Engine Mountings
DIS DIS DIS
DRUM DISC DISC
1 JA 1134 03 Flange Bolt M10 x 110 2 2 2

2 39 2723 15 Flanged Nut 2 2 2
3
3 39 1556 04 Bolt Flanged 8 8 8
4 LA D000 52 Bolt Flange 1 1 1
5 39 1970 15 Nut Flanged 4 4 4
11/12 6 JA 1134 02 Bolt Flanged 2 2 2

7 LA D000 41 Bolt Flanged 1 1 1
8 JZ 1134 00 BKT Comp LH Engine Front 1 1 1
4/5
9 JZ 1134 03 BKT Comp RH Engine Front 1 1 1
10 JZ 1134 02 Engine Mtg. BKT Rear Top 2 2 2
3
11 JZ 1134 05 Bracket Comp LH Top 1 1 1
7/5
10 12 JZ 1134 07 Bracket Comp RH Top 1 1 1
5/6
1/2
8/9
5/6
45 46
Frame and Frame Fittings

DIS DIS DIS
DRUM DISC DISC
1 JZ 1110 29 Frame Assly Complete 1 1 1

2 DS 1810 18 Nut Fork 1 1 1
3 DH 1810 14 Cup - Steering 1 1 1
4 4 36 DS18 02 Bearing Cone Kit 1 1 1 Refer

2 Page No. 106
3 5 36 3140 02 Ball Steel Kit 1 1 1
1
5 6 PA 4010 00 Side Reflector 2 2 2

7 DP 1710 06 Silent Bush 2 2 2
8 DP 1612 60 End Cap 2 2 2
9 PA 1138 00 Hook Clutch Cable 1 1 1
8 10 39 2060 04 Bolt M5 1 1 1
5
11
6 11 59 0400 34 Bolt D Head M6 1 1 1
9
10
47 48
Swing Arm / Rear Shock Absorber

DIS DIS DIS
DRUM DISC DISC
1 JB 1220 16 Hex Bolt / Flange - M10 2 2 2 For RSA

8 7
2A JB 1220 11 Plain Washer 4 4 4 For RSA
2B
2B JB 1220 10 Plain Washer 4 4 4
3 JN 1220 00 Rear Shock Absorber 2 2 2
2A
2B 4 39 0258 11 Plain Washer 2 2 2 For Mud Flap
18 17
5 JN 1220 06 Swing Arm Assly 1 1 1
9 4 2A
6 6 DS 1710 15 Cap Swing Arm 2 2 2
10
11 13 7 JB 1220 09 Domed Cap Nut 2 2 2
8 39 2726 12 Spring Washer 2 2 2
9 DS 1710 07 Chain Slider 1 1 1
1
10 39 0553 02 Screw 2 2 2 For Chain Sider
11 39 0454 11 Plain Washer 2 2 2 For Chain Sider

6
3 12 DS 1710 13 Shaft Swing Arm 1 1 1
5
13 39 1358 15 Flanged Nut 1 1 1
12
14 DJ 1510 36 Adjuster Chain LH 1 1 1
15 DJ 1510 37 Adjuster Chain RH 1 1 1
1
15
16 39 0292 15 Hexagon Nut 4 4 4
16
14 16 17 DS 1710 14 Mud Flap 1 1 1
19 18 39 2060 04 Flange Bolt 2 2 2 For Mud Flap
19 DJ 1510 47 Plate Chain Adjuster 2 2 2
20 DJ 1710 34 Nitrox Chamber Screw Assly 1 1 1 N.I.
49 50
Rider Foot Rest

DIS DIS DIS
DRUM DISC DISC
1 JZ 1130 01 Main Step LH 1 1 1

2 39 2310 04 Flange Bolt 4 4 4
2 4 3 JZ 1130 11 Main Step RH 1 1 1
4 DF 1614 13 Rubber Main Step 2 2 2
5 DH 1611 94 Damper 1 1 1 For Kick stopper
3 2
2 5
4 1
2
51 52
Pillion Foot Rest / Holder

DIS DIS DIS
DRUM DISC DISC
1 JZ 1130 15 Holder LH Step 1 1 1

5 4
2 JZ 1130 17 Holder RH Step 1 1 1
3 DJ 1611 29 Step Assembly RH 1 1 1
3 4 DJ 1611 22 Rubber Pillion Step 2 2 2
8 5 DD 1613 81 Pin Pillion Step 2 2 2
9 10
6
6 DH 1611 00 Spacer 2 2 2 For Rear Footrest
7 39 0784 08 Split Pin 2 2 2
7 8 39 2722 04 Soc. Head Bolt 4 4 4
8
1
9 30 1410 31 ‘O’ Ring 2 2 2
8 10 39 1040 11 Washer Plain 2 2 2
11 DJ 1611 28 Step Assembly LH 1 1 1
5
9
11
10
4 7
6
53 54
Mudguard - Front & Rear

DIS DIS DIS
DRUM DISC DISC
1 DS 1611 25 Cable Guide 1 1 1

2 JB 1814 21 Brace Fender -- 1 1
JB 1814 16 Brace Fender 1 – –--
3 JB 1814 12 Flange Bolt 4 4 4 Fender Front Mtg
39 1075 04 Flange Bolt 4 4 4 Alt. For.JB181412
4 JZ 1814 02 Fender Rear Front 1 1 1
2 11 5 DS1612 87 Flange Bolt 2 2 2
16
15 15
6 39 0798 15 Flange Nut 2 2 2

6 14
12 18 7 39 0211 11 Plain Washer 2 2 2
8 JZ 1814 01 Fender Rear 1 1 1
10
5 9 39 1943 04 Flange Bolt 2 2 2
1 7 9
10 DJ 1610 69 Nail for Cable Guide 1 1 1
3
11 39 0326 15 Nyloc Nut 3 3 3
12 JB 1814 03 Flap Front Fender 1 1 1
4 13 13 DL 1610 15 Grommet 2 2 2
8 14 JZ 1814 06 Grommet Saree Guard 1 1 1
15 39 0242 11 Washer 6 6 6
16 39 2420 01 Screw 3 3 3
39 1698 01 Screw 3 3 3 Alt. For. 39242001
55 56
Stand Assembly
DIS DIS DIS
DRUM DISC DISC
1 DS 1611 13 Center Stand 1 1 1

3 2 DS 1611 12 Shaft Stand 1 1 1
2 3 39 0797 08 Pin Cotter 1 1 1
4 DH 1611 21 Spring Main Stand 1 1 1
5 DH 1611 45 Cover Spring Main Stand 1 1 1
8 6 DS 1610 77 Stand Side 1 1 1
4
7 DH 1612 40 Spring Side Stand with Cover 1 1 1
10 8 DF 1611 02 Bolt 1 1 1
9 39 0422 15 Nut 1 1 1
10 JN 1132 00 Damper Main Stand 1 1 1
5 11 DH 1611 46 Cover Side Stand Spring 1 1 1

1 9
11
57 58
Tube / Tyre / Rim

DIS DIS DIS
2 No. Part No. Description 125 125 150 Remarks
DRUM DISC DISC
3
1 JD 1310 02 Wheel Rim Front –-- –-- 1
1
JD 1310 00 Wheel Rim Front -- -- 1 Alt.For. JD131002
JZ 1310 12 Wheel Rim Front -- -- 1 w.e.f. Jan 2013
JZ 1310 14 Wheel Rim Front -- 1 –--
JZ 1310 11 Wheel Rim Front 1 –-- –--
2 DS 1510 48 Tyre Front 1 1 1 N.S
3 DS 1510 49 Tube Front 1 1 1 N.S
4 JW 1312 10 Wheel Rim Rear -- -- 1
JW 1312 05 Wheel Rim Rear -- -- 1 Alt.For. JW131210
JZ 1312 13 Wheel Rim Rear 1 1 –--
5 DS 1510 31 Tyre Rear -- -- 1 N.S
DS 1510 52 Tyre Rear 1 1 –-- N.S
6 DS 1510 29 Tube Rear -- -- 1 N.S

DS 1510 53 Tube Rear 1 1 –-- N.S
6 5
59 60
Front Hub (Disc Brake)

DIS DIS DIS
DRUM DISC DISC
1 30 1510 33 Seal Oil -- 1 1

1
2 2 39 2688 20 Bearing Ball -- 2 2
3 DE 1510 06 Spacer Assly -- 1 1
3
4 DE 1510 12 Plate Drive -- 1 1
5 DE 1510 08 Seal Oil -- 1 1
2
4
5 14 6 30 1510 41 Meter Gear -- 1 1
7 7 DS 1510 38 Speedo Gear -- 1 1
18 8 JD 1318 11 Hex. Soc. Head Bolt –-- –-- 5
LA C000 02 Hex. Soc. Head Bolt -- 1 –--
8 9 JD 1318 10 Disc (240 mm Dia) –-- –-- 1
JW 1318 06 Disc (200 mm Dia) -- 1 –--
10 JB 1310 18 Plain Washer -- 1 1
9
11 JN 1310 03 Spacer -- 1 1
DS 1510 58 Spacer -- 1 1 Alt. For.JN131003
17
6 12 JB 1310 17 Axle -- 1 1
13 JB 1310 19 ‘U’ Nut -- 1 1
59 1500 03 ‘U’ Nut -- 1 1 Alt. ForJB131019
13 14 JN 1812 06 Cover Disc –-- –-- 1
10 JW 1812 41 Cover Disc -- 1 –--
11 15 JN 1812 11 Clip Nut (Cover Disc Mtg -- 1 1 N.I.
12 16 LB U000 06 Truss Screw (Cover Disc Mtg) -- -- 1 N.I.

LB U000 05 Truss Screw (Cover Disc Mtg) -- 1 -- N.I.
17 36 DU15 04 Front Hub Bushing Kit -- 1 1
18 DJ 151057 Case Meter Assly -- -- 1 Up to 30.11.2010
JZ 1316 01 Case Meter Assly- Screw Mtg -- 1 1
61 62
Front Master Cylinder

DIS DIS DIS
DRUM DISC DISC
1 DJ 1910 23 Major Kit - Master Cylinder -- 1 1

2 JN 1318 00 Hose Brake Front -- –-- 1
8 3 JW 1318 05 Hose Brake Front -- 1 –--
3 DD 1911 42 Lever Grip RH -- 1 1
4 DE 1910 11 Banjo Bolt -- 2 2
5 DE 1910 10 Washer Copper -- 4 4
9
10 6 DE 1910 33 Clamp Holder RH -- 1 1
10
IN
USE
G: T3-4
RN DO RO
WA NLY ID F ER
M
13 7 DE 1910 34 Bolt -- 2 2
O FLU IN
E TA
AK ON AP
BR D C R C ING
8 DE 1910 31 Bolt Front Brake Lever -- 1 1

V
A LE ILLE O
SE N F REM
A A E
LE
C FO R
BE
15 9 DE 1910 32 Nut Flanged -- 1 1

5 10 DE 1910 30 Screw -- 2 2
5
4 11 DE 1510 15 Cylinder Master with Lever -- 1 1
1
14 12 DE 2010 16 Front Brake Switch -- 1 1
DJ 2011 00 Front Brake Switch -- 1 1 Alt. ForDE201016
7
7 13 DE 1910 29 Reservoir Cover -- 1 1
2
14 DE 1910 28 Diaphragm -- 1 1
6
15 DE 1910 35 ‘O’ Ring Master Cylinder Kit -- 1 1
12
5 16 DJ 2011 08 Cable Assly for Switch -- 1 1 N.I.

17 JN 1318 04 Clamp Hose Pipe - Upper -- 1 1 N.I.
5
4 11
63 64
Front Disc Brake Caliper Assly

DIS DIS DIS
DRUM DISC DISC
1 JD 1318 13 Caliper Assly Front -- -- 1

JW 1318 01 Caliper Assly Front -- 1 –--
4
2 DJ 1612 80 Bolt Flanged Caliper Mounting -- 2 2
5
DH 1510 39 Bolt Flanged Caliper Mounting -- 2 2 Alt. For DJ161280
3 DE 1510 48 Spring Pad -- 1 1
8
4 DE 1510 46 Bleeder Screw -- 1 1
5 DE 1510 47 Bleeder Cap -- 1 1
7
x 11
9 6 DE 1510 37 Disc Pad Set -- -- 1
3 JW 1318 07 Disc Pad Set -- 1 –--
7 DJ 1510 72 Insulator -- –-- 1
6 PISTON SEAL DE 1510 43 Insulator -- 1 –--
2
8 DJ 1510 73 Protection Boot -- -- 1
DUST SEAL DE 1510 45 Protection Boot -- 1 –--
1
BLEEDER CAP 9 DJ 1510 74 Minor Kit - Caliper -- -- 1
5 JW 1318 09 Minor Kit - Caliper -- 1 –--
8 PROTECTION BOOT
10 DJ 1510 75 Major Kit - Caliper -- 1 1
INSULATOR
7
11 JW 1318 10 Anchor Pin Kit -- 1 1
CALIPER PISTON
4 BLEEDER SCREW
3
PAD SPRING
10
65 66
Front Hub (Drum Brake)

DIS DIS DIS
DRUM DISC DISC
3 2 1 JB 1310 19 U Nut (M12) 1 –-- –--
5A
1 59 1500 03 U Nut (M12) 1 –-- –- Alt.For JB131019-
5
1A JB 1310 17 Axle Front Wheel 1 –-- –--
2 JB 1310 18 Plain Washer 1 –-- –--
4 3 DS 1510 56 Dust Seal 1 -- -- N.S.
4 JB 1310 22 Spacer + Dust Seal (Assembly) 1 -- -- (N.I.)
5 39 2680 20 Bearing Ball 1 –-- –--
6
5A PA 1310 03 Oil Seal 1 –-- –--
7 6 PA 1316 00 Collar Bearing 1 –-- –--

10
7 39 2681 20 Ball Bearing 1 –-- –--
11
8
8 30 1511 05 Shoe Brake 2 –-- –--
15 12 9
13 JN 1318 12 Shoe Brake Assly 1 1 1 (Non Asbestos)
14
9 30 1510 69 Spring 2 –-- –--
10 14 1510 21 Oil Seal 1 –-- –--
22
16 21 11 DS 1510 89 Cam Brake Assly. 1 –-- –--
17 12 DS 1510 87 Panel Front Brake 1 –-- –--
24 23 13 30 1510 38 Ring ‘O’ 1 –-- –--
24 25
26 14 DS 1510 91 Indicator 1 –-- –--
1A 15 DS 1510 95 Bolt 1 –-- –-- N.S
16 DS 1510 92 Lever Brake Cam 1 –-- –--
20
17 DS 1510 94 Nut 1 –-- –--
19
18 39 0840 01 Pan Headed Screw 1 –-- –--
18
19 39 0263 12 Washer Spring 1 –-- –--
39 0732 12 Washer Spring 1 –-- –-- Alt. For39026312
20 30 1511 18 Stopper for Bushing 1 –-- –--
67 68
Front Hub (Drum Brake)

DIS DIS DIS
DRUM DISC DISC
3 2 21 LB D000 01 Screw 1 -- -- To Secure Speedo
5A
5
1 Cable
22 36 DS 15 02 Speedometer Gear Kit 1 -- –--
23 30 1510 35 Seal Oil 1 -- –--
4 24 30 1510 42 Washer Plain 2 -- -- For Gear Meter
Screw
6 39 0242 11 Washer Plain 2 –-- –-- Alt. For30151042
25 39 1013 21 ‘O’ Ring 1 -- –--
7
10
26 JA 1316 06 Bushing Speedo Gear 1 -- –--
11
15 12 9 8
13
14
22
16 21
17
24 23
24 25
26
1A
20
19
18
69 70
Rear Hub
DIS DIS DIS
DRUM DISC DISC
8
11 1 DJ 1510 53 Drive Chain Lock 1 1 1
9
2 6 2 36 JZ00 07 Chain Sprocket Kit –-- –-- 1
36 JZ00 26 Chain Sprocket Kit 1 1 –--
5 3 LC A000 01 Nut 1 1 1
4
39 0801 15 Nut 1 1 1 Alt. For LCA00001
7 4 LD B000 02 Plain Washer 1 1 1
39 2567 11 Plain Washer 1 1 1 Alt. For LDB00002
3 5 DJ 1510 35 Collar Assly 1 1 1
6 39 2240 20 Bearing Ball 1 1 1
10
7 DS 1510 68 Coupling 1 1 1
15 8 DS 1510 73 ‘D’ Bolt 4 4 4
9 39 0794 15 Hex Lock Nut 4 4 4
10 DS 1510 74 Washer 2 2 2
13
14 11 DJ 1510 33 Sleeve 1 1 1
27 12 39 2686 20 Bearing Ball 1 1 1

12
13 30 1510 75 Collar Bearing 1 1 1
25
14 DJ 1510 88 Damper 1 1 1
24 15 39 2687 20 Bearing Ball 1 1 1
26 16 30 1510 69 Spring 2 2 2
28
23 17 30 1511 05 Shoe Brake Assly 1 1 1
17 JN 1318 12 Shoe Brake Assly 1 1 1 (Non Asbestos)
16 18 DJ 1510 92 Panel Rear Brake 1 1 1
20 21 22 19 30 1510 12 Cam Brake 1 1 1
19 19A 18 30 1510 11 Cam Brake 1 1 1 Alt For 30151012
16 19A 39 0722 11 Plain Washer 1 1 1
20 30 1510 38 Ring ‘O’ 1 1 1
71 72
Rear Hub
DIS DIS DIS
DRUM DISC DISC
8
11 21 DS 1510 90 Indicator 1 1 1
9
2 6 22 JZ 1318 03 Lever Brake 1 1 1
23 JB 1312 24 Bolt 1 1 1 N.S
5 24 JN 1312 11 Axle 1 1 1
4
25 DX 1510 22 Collar 1 1 1
7
26 LD B000 01 Plain Washer 1 1 1

3 27 DJ 1710 33 ‘U’ Nut 1 1 1
10 28 DS 1510 94 Nut M6 1 1 1
15
14
13
12 27
25
24
28 26
23
17
16
20 21 22
19 19A 18
16
73 74
Rear Brake Pedal

DIS DIS DIS
DRUM DISC DISC
1 JA 1610 03 Pad Lever Brake 1 1 1

2 JZ 1610 02 Brake Pedal 1 1 1
1 3 39 1680 04 Hex. Bolt 1 1 1
4 DG 1910 45 Washer 1 1 1
2 20
5 DS 1910 11 Brake Pedal Spring 1 1 1
8 6 JZ 1610 04 Rod Brake 1 1 1

3 10 7 30 1910 38 Pin 1 1 1
5
7 11 8 39 0198 11 Plain Washer 2 2 2
4 9 39 0808 08 Split Pin 1 1 1
10 30 1910 35 Spring 1 1 1
8 11 15 1910 26 Pin 1 1 1
14 12 12 30 1910 36 Brake Adjuster Nut 1 1 1
9 13 DS 1510 25 Rod Torque 1 1 1
6
14 DH 1510 29 Step Bolt 1 1 1
16 15 39 0789 12 Spring Washer 2 2 2
16
17 16 39 0694 15 Nut Hex. Lock 2 2 2

19
17 39 0807 08 Pin Snap 2 2 2
15 18 30 1510 96 Hex. Bolt 1 1 1
13 19 39 1540 11 Plain Washer 1 1 1
17 15
20 JZ 1610 06 Sleeve Brake Return Spring 1 1 1
18 21 39 1672 04 Bolt M - 6 1 1 1 For Brake Pedal

Adjuster
22 39 0292 15 Hex Nut M-6 1 1 1 For Brake Pedal
Adjuster
23 36 DH40 14 Brake Adjusting Kit 1 1 1 Include
Sr. No. 7 to 11
75 76
Handle Bar
DIS DIS DIS
DRUM DISC DISC
1 DS 1810 44 Handle Bar 1 1 1

22
2 JB 4014 00 Control Switch LH 1 1 1
10 3 JB 4014 01 Control Switch RH 1 1 1
13 4 PA 4014 00 Holder LH Assly 1 1 1
21
9 3 4A DJ 1910 54 Holder LH 1 1 1
1 24
5 DS 1910 15 Grip LH 1 1 1
20
11 6 DJ 1910 55 Lever LH 1 1 1
7 PA 4014 01 Clutch Switch with
14
15 Sealed Coupler 1 1 1
23 12
2 8 DS 1910 52 Boot for Lever LH 1 1 1
26
19 16 9 DJ 2210 03 Mirror Assly. LH 1 1 1
17 30
18 10 DJ 2210 04 Mirror Assly. RH 1 1 1
6 12
25 28
11 36 DS18 01 Kit Holder Handle 2 2 2
31
12 DS 1910 18 Boot for Lever RH 1 1 1
4A 13 39 2582 04 Flange Bolt -- -- 4
7 39 1714 04 Flange Bolt 4 4 –--
27
29
4
14 DS 1810 07 Washer Handle Upper 2 2 2
5 15 DS 1810 08 Damper Handle Upper 2 2 2
28
16 DS 1810 09 Damper Handle Lower 2 2 2
17 DS 1810 10 Washer Handle Lower 2 2 2
27 18 39 0422 15 Nylock Nut 2 2 2
19 DL 1910 14 Stud LH (R.H) -- -- 1
39 2249 15 Stud LH (R.H.) 1 1 –- N.S
77 78
Handle Bar
DIS DIS DIS
DRUM DISC DISC
20 30 1910 48 Band 2 2 2
22
21 JZ 2326 00 3 in One Lock Set 1 1 1
10 22 39 1912 04 Flange Bolt 2 2 2 For Ignition
13 Switch
21 39 2453 04 Flange Bolt 2 2 2 Alt. For 39191204
9 3
1 24 23 JZ 1510 23 Holder Fork Upper 1 1 1
20 PA 1510 07 Holder Fork upper 1 1 1 Alternate
11
24 DU 2010 46 Plunger With Spring 1 1 1 Part of Ride
14 Control Switch
15
23 12 25 DX 1910 01 Throttle Pipe 1 1 1
2
26
19 16 17 30
18
26 DS 1910 16 Hand Grip RH 1 1 1
6 12 27 DH 1810 22 Handel Bar Weight 2 2 2
25 28 28 39 2427 04 Socket Bolt 2 2 2
31 29 DS 1910 38 Holder Assly RH 1 -- –--
4A 30 DD 1911 42 Lever RH 1 -- –--

7 31 DD 2011 70 Front Brake Switch 1 – –--
27
29
PA 4014 03 Front Brake Switch 1 – –--
4
28
27
79 80
Front Fork
DIS DIS DIS
DRUM DISC DISC
1 JZ 1510 00 Fork Front -- -- 1

JZ 1510 43 Fork Front 1 – –
JZ 1510 57 Fork Front -- 1 –--
1 JZ 1510 73 Fork Front -- 1 1 For Colombia
2 36 Dz00 20 Front Fork Seal Kit 1 1 1
7 3 30 1810 26 Gasket 2 2 2
8 4 30 1810 25 Bolt 2 2 2
21 15 5 JA 1510 13 Fork Pipe Inner 2 2 2
23/24 19 22 6 DJ 1811 04 Spring Front Fork 2 2 2
7 59 0400 06 Bolt Fork 2 2 2 With Washer
10 8 DS 1810 15 Cap Nut Fork 1 1 1
2
9 DS 1810 16 Plain Washer 1 1 1 For Cap Nut
10 JZ 1510 23 Holder Fork upper 1 1 1
PA 1510 07 Holder Fork upper 1 1 1 Alternate N.S
20 18 11 DH 1810 23 Bearing Cone 1 1 1
30 1810 09 Bearing Cone 1 1 1 Alt For Dh181023
6 11
12 JZ 1510 36 Under Bracket Fork 1 1 1
5
13 39 0789 12 Spring Washer 2 2 2
16/17 14 39 1181 01 Bolt 2 2 2
15 DS 1810 16 Washer 2 2 2
16 JZ 1510 04 Outer Tube LH -- -- 1
JZ 1510 61 Outer Tube LH -- 1 –--
3
JW 1510 05 Outer Tube LH 1 –-- –--
12 17 JZ 1510 06 Outer Tube RH -- -- 1
4
JZ 1510 59 Outer Tube RH -- 1 –--
13
14 JW 1510 07 Outer Tube RH 1 –-- –--
18 JK 1210 07 Anti Friction Bush 2 2 2
19 JW 1510 23 Cylinder Complete Fork 2 2 2
20 JK 1210 09 Washer Anti Friction Bush 2 2 2
21 DS 1810 12 Bolt Fork 2 2 2

22 31 1811 02 ‘O’ Ring 2 2 2
81 82
Painted Parts and Decals

DIS DIS DIS
DRUM DISC DISC
1 JZ 7101 3B Fuel Tank Black with Decal -- -- 1 Blue Decals

JZ 7101 3C Fuel Tank Black with Decal -- -- 1 Red Decals
JZ 7101 5A Fuel Tank Black with Decal 1 1 1 Blue2 Decals
6 JZ 7101 5B Fuel Tank Black with Decal 1 1 1 Red2 Decals
JZ 7101 5D Fuel Tank Black with Decal 1 1 1 Green / Gold
JZ 7101 5E Fuel Tank Black with Decal 1 1 1 Magenta Red
JZ 7101 3F Fuel Tank Black with Decal 1 1 1 Flame Red/Gold
1
2 52 JZ00 20 Side Cover Black LH -- -- 1 Blue Decals
52 JZ00 14 Side Cover Black LH -- -- 1 Red Decals
3 52 JZ00 51 Side Cover Black LH 1 1 1 Blue2 Decals
52 JZ00 53 Side Cover Black LH 1 1 1 Red2 Decals
52 JZ00 97 Side Cover Black LH 1 1 1 Green / Gold
5
52 JZ01 15 Side Cover Black LH 1 1 1 Magenta Red
52 JZ02 36 Side Cover Black LH 1 1 1 Flame Red/Gold
3 52 JZ00 21 Side Cover Black RH -- -- 1 Blue Decals

4
2 52 JZ00 15 Side Cover Black RH -- -- 1 Red Decals
52 JZ00 50 Side Cover Black RH 1 1 1 Blue2 Decals
8 52 Jz00 52 Side Cover Black RH 1 1 1 Red2 Decals
52 JZ00 98 Side Cover Black RH 1 1 1 Green / Gold
52 JZ01 16 Side Cover Black RH 1 1 1 Magenta Red
52 JZ02 37 Side Cover Black RH 1 1 1 Flame Red/Gold
4 JZ 7303 3B Seat Cowl Black Assembly -- -- 1 Blue Decals

JZ 7303 3C Seat Cowl Black Assembly -- -- 1 Red Decals
JZ 7303 5A Seat Cowl Black Assembly -- -- 1 Blue2 Decals
JZ 7303 5B Seat Cowl Black Assembly -- -- 1 Red2 Decals
7 52 JZ00 99 Seat Cowl Black Assembly -- -- 1 Green / Gold
JZ 7303 5E Seat Cowl Black Assembly -- -- 1 Magenta Red
JZ 7303 3F Seat Cowl Red Assembly -- -- 1 Flame Red/Gold
JZ 7304 5D Seat Cowl Black Assembly 1 1 -- Green / Gold
JZ 7304 5E Seat Cowl Black Assembly 1 1 -- Magenta Red
JZ 7304 5A Seat Cowl Black Assembly 1 1 -- Blue Decals
JZ 7304 5B Seat Cowl Black Assembly 1 1 -- Red Decals
83 84
Painted Parts and Decals

DIS DIS DIS
DRUM DISC DISC
JZ 7304 3F Seat Cowl Red Assembly 1 1 -- Flame Red/Gold
5 JZ 7304 3B Fender Front Black 1 1 1

6 6 52 JZ00 23 Head Lamp Black Cowling -- -- 1 Blue Decals
52 JZ00 18 Head Lamp Black Cowling -- -- 1 Red Decals
52 JZ00 54 Head Lamp Black Cowling 1 1 1 Blue2 Decals
52 JZ00 55 Head Lamp Black Cowling 1 1 1 Red2 Decals
1
52 JZ01 00 Head Lamp Black Cowling 1 1 1 Green / Gold
52 JZ01 18 Head Lamp Black Cowling 1 1 1 Magenta Red
3 52 Jz00 18 Head Lamp Black Cowling 1 1 1 Alt For 52JZ0118
52 JZ02 41 Head Lamp Red Cowling 1 1 1 Flame Red/Gold
7 JZ 2330 00 Tank Decal Set -- -- 1 Blue Decals
5 JZ 2330 12 Tank Decal Set -- -- 1 Red Decals
JZ 2330 24 Tank Decal Set 1 1 1 Blue2 Decals
4 JZ 2330 36 Tank Decal Set 1 1 1 Red2 Decals
2 JZ 2330 70 Tank Decal Set 1 1 1 Green / Gold
JZ 2330 86 Tank Decal Set 1 1 1 Magenta Red
8
36 JZ00 84 Tank Decal Set 1 1 1 Flame Red/Gold
8 JZ 2330 05 Kit Decal Blue -- -- 1

JZ 2330 29 Kit Decal Blue2 1 1 1 (Seat Cowl,
Side Cover
JZ 2330 17 Kit Decal Red -- -- 1
LH / RH,
11 JZ 2330 41 Kit Decal Red2 1 1 1 Head lamp
9 10
JZ 2330 75 Kit Decal Gold / Green 1 1 1 cowling)
JZ 2330 91 Kit Decal Magenta Red 1 1 1
9 36 JZ00 86 Kit Fairing Decal 1 1 1 Flame Red/Gold

7 10 36 JZ00 85 Kit Side Cover Decal 1 1 1 Flame Red/Gold
11 36 JZ00 87 Kit Side Cover Decal 1 1 -- Flame Red/Gold
36 JZ00 88 Kit Side Cover Decal -- -- 1 Flame Red/Gold
85 86
Petrol Tank Cap and Gauge Fuel

DIS DIS DIS
DRUM DISC DISC
1 DS 1410 09 Cap Assly. Tank 1 1 1

2 39 0761 01 Screw Pan Cross 2 2 2
5 3 39 2179 24 Washer 2 2 2
2 3A 30 1410 31 ‘O’ Ring 2 2 2
1 3 4 DS 1410 18 Fuel Tap Assly 1 1 1
JZ 1718 09 Fuel Tap Assly 1 1 – from 02 Jul.2013
3A
5 JZ 2326 00 3 In 1 Lock Set with Key 1 1 1
9
4
6 DD 1410 22 Bolt Flanged 2 2 2 For Petrol Cock
DD 1412 27 Bolt Flanged 2 2 2 Alt. For Dd141022
8A 7 39 0740 11 Washer (Non-Metallic) 2 2 2 For Petrol Cock

8 DS 2010 79 Fuel Gauge - Tank Unit 1 1 1 With ‘O’ Ring
8A 39 2758 21 ‘O’ Ring 1 1 1 For Tank Unit
DK 1410 28 ‘O’ Ring 1 1 1 Alt. For 39275821
9 DS 1410 13 Seat Tape 1 1 1 Pasted on Tank
7 8A
6
10 39 2484 15 Flanged Nut 4 4 4
12
11 JB 1718 02 Tube Fuel 1 1 1 Cock to
8 Carburettor
11
12 30 1410 15 Pipe Clip 2 2 2
10
DK 1410 41 Pipe Clip 2 2 2 Alt For. 30141015
13 DZ 1410 75 4 Hole Washer 1 1 1 For Pavna make
Fuel Cock
14 36 Jz00 22 Kit fuel cock seal -Advik 1 1 1 For Advik make
Fuel Cock
87 88
Fittings - Petrol Tank, Side Covers & Cover Seat

DIS DIS DIS
DRUM DISC DISC
1 36 DS14 01 Grommet Kit for Side Cover 1 1 1 Refer

Page No. 114
8
2 DG 1611 21 Screw 1 1 1
3 39 1943 04 Flanged Bolt 2 2 2
6 4 JN 1710 00 Damper Rear 1 1 1 For Tank
5 39 1789 24 Washer Nylon 3 3 3
7 6 39 0983 08 Pin Snap 1 1 1

7 39 1054 11 Plain Washer 1 1 1
1 2
8 DJ 1410 08 Damper Front 2 2 2 For Tank Mtg
8
9 31 1610 18 Damper 1 1 1
4
3
5
89 90
Meter Assembly
DIS DIS DIS
DRUM DISC DISC
1 PA 4024 00 Speedometer Assly. -- -- 1 Up to 10.03.2011

2 JZ 4024 03 Speedometer Assly. 1 1 1
2 JZ 1812 00 Flap Cowling 1 1 1
1 3 PA 4024 01 Speedo Machine With Dial Pricol -- -- 1 Up to 10.03.2011
PA 4024 21 Speedo Machine With Dial Minda -- -- 1 Up to 10.03.2011
JZ 4024 06 Speedo Machine With Dial Minda 1 1 1 Minda
36 JZ00 39 Speedo Machine With Dial Pricol 1 1 1 Pricol
13 4 PA 4024 02 Fuelgauge Machine with Pricol -- -- 1 Up to 10.03.2011
14
PA 4024 20 Fuelgauge Machine with Minda -- -- 1 Up to 10.03.2011
4
JZ 4024 07 Fuelgauge Machine with Minda 1 1 1
36 JZ00 38 Fuelgauge Machine with Minda 1 1 1
5 PA 4024 03 Speedo meter Top Cover 1 1 1 PA402419-Minda
8 15
5 6 PA 4024 04 Speedometer wiring harness 1 1 1 PA402420-Minda
16 3
7 CL 2010 42 Bulb 12V - 1.2 W 4 4 4
7 10
8 DL 1910 20 Bulb 12V - 3 W 2 2 2
DH 1910 37 Bulb 12V - 3 W 2 2 2 Alt. For DL191037
9 39 0798 15 Flanged Nut 2 2 2
8 10 PA 4024 05 Speedometer Bracket 1 1 1
11 JN 1810 14 Foam Speedo Flap 2 2 2 N.I.

6
12 JN 1814 06 Beading Speedo Flap 4 4 4 N.I.
9 13 PA 4024 10 Cover Speedo Black 1 1 1 PA402414-Minda
14 PA 4024 11 Assly Speedo Case 1 1 1 PA402415-Minda
15 PA 4024 12 Trip Meter Knob 1 1 1 PA402416-Minda
16 PA 4024 13 Screw Trip Meter Knob 1 1 1 PA402417-Minda
91 92
Control Cables
DIS DIS DIS
DRUM DISC DISC
1 JZ 1612 02 Cable Accelerator 1 1 1

2 JZ 1612 03 Cable Clutch 1 1 1
3 JZ 1612 04 Cable Speedometer-Screw Mtg -- -- 1
JZ 1612 10 Cable Speedometer-Screw Mtg -- 1 1 From 01.12.2010
DS 1910 53 Speedo Cable 1 -- --
4 DS 1910 54 Brake Cable 1 -- --
2
93 94
Chain Case
DIS DIS DIS
DRUM DISC DISC
1 36 DS40 20 Chain Case Assly Kit 1 1 1 Refer

36 JZ00 06 Chain Case Assly Kit 1 1 -- Page No. 106
2 15 1610 69 Rubber Cap 1 1 1
3 JB 1812 39 Bolt 4 4 4 Front & Rear
Side Mtg
DH 1612 83 Bolt 4 4 4 Alt. For JB181239
4 DX 1610 52 Beading Chain Case 1 1 1 N.I.
1
3
3
2 3
95 96
Head Lamp & Fairing

DIS DIS DIS
2 Description
No. Part No. 125 125 150 Remarks
3 DRUM DISC DISC
1 JN 1810 01 Wind Shield 1 1 1

2 JZ 1812 06 Screw S.S. 4 4 4
3 39 2141 24 Non Metallic Washer 4 4 4
4 JZ 1810 03 Well Nut 4 4 4
8
5 JN 1810 10 Bush-1 for Well Nut 2 2 2
6 JN 1810 11 Bush-2 for Well Nut 2 2 2
1
4 5
6 35 1610 60 Clip Nut 5 5 5
11 7 39 2238 01 Screw M.S. 2 2 2
10
12 8 JZ 4010 12 Head Lamp Assly 1 1 1 Without Bulb
13 7 9 39 0454 11 Washer Metallic 6 6 6
9
9 10 39 1778 02 Screw Tapping 2 2 2
30
11 JN 1810 05 Bracket Head Lamp Mounting 1 1 1 For Bracket
19
H/L Mtg
16 18 12 CL 2010 23 Lamp 12V 35/35W-HS1 1 1 1
30
15 13 DS 2010 36 Head Lamp Bulb Clip 1 1 1
14 JN 1810 19 Foam 1 1 1 Between Fairing
20 24 & Windshield
21 9 22 25 31
15 JZ 4010 15 Head Lamp Harness Branch 1 1 1
33
17 23 32 16 JN 1810 03 Bracket Fairing Top 1 1 1
19 27 28
17 JN 1810 17 Bracket Flap Support LH 1 1 1
26
18 JN 1810 18 Bracket Flap Support RH 1 1 1
29 19 JN 1810 21 Bolt Flange 2 2 2 Fairing Top
32
27A
20 39 1943 04 Bolt Flange 2 2 2
97 98
Head Lamp & Fairing

DIS DIS DIS
2 Description
No. Part No. 125 125 150 Remarks
3 DRUM DISC DISC
21 JN 1810 23 Bracket H/L Mtg Lower LH 1 1 1

22 JN 1810 24 Bracket H/L Mtg Lower RH 1 1 1
23 59 0100 05 Screw Mushroom Head 2 2 2
24 JN 1810 04 Bracket Cowling 1 1 1
8
25 39 0219 11 Washer 2 2 2 For Bracket
6 Cowling Mounting
1
4 5
26 39 2060 04 Bolt Hex 2 2 2 For Bracket
Cowling Mounting
11
10 27 JZ 1812 08 Bracket Cowling Lower 1 1 1
12
13 28 39 1943 04 Bolt Flange 2 2 2
7
9 29 39 1961 04 Bolt Hex Flange 1 1 1
9
30 39 1907 01 Mushroom Head Screw 4 4 4
30
19 31 39 2141 24 Washer Non-Metallic 4 4 4

16 18 32 39 1508 11 Washer for H/L Adjustment Bolt 2 2 2 N.S
30
15 33 39 0798 15 Hex Flange Nut 1 1 1
34 JZ 1810 02 Damper Assly (N.I.) 1 1 1 On Fairing
20 24 JZ 1810 06 Damper Assly (N.I.) 1 1 1 Alt. For JZ181002
21 9 22 25 31
35 39 1508 11 Washer for H/L Adjustment Bolt 2 2 2 N.I. N.S
33 36 JN 1810 19 Foam (N.I.) 1 1 1 Between Fairing
17 23 32 & Wind Shield
19 27 28 37 JZ 1810 04 Foam on Head Lamp 5 5 5 N.I.
26
29
32
27A
99 100
Indicator Light Assembly

DIS DIS DIS
DRUM DISC DISC
6
1 JZ 4010 00 Indicator Assly Front LH 1 1 1
2 JZ 4010 01 Indicator Assly Front RH 1 1 1
3 DJ 2012 06 Indicator Assly Rear LH 1 1 1
3/4 4 DJ 2012 07 Indicator Assly Rear RH 1 1 1
5 GH 2010 12 Lamp 12 V - 10W 4 4 4 N.I.
6 39 1225 15 Hex Nut with Flange 2 2 2 N.I.

7 31 2010 01 Collar 2 2 2
8 LA D000 26 Bolt Flange 2 2 2
9 JZ 1510 24 Blinker Mounting Bracket 1 1 1 Mounted on
Bracket Cowling
Lower
10 39 1943 04 Flange Bolts 2 2 2 For Blinker
Mounting Bracket
7
7 8
10
1/2
101 102
Tail Lamp Assly / Front Number Plate

DIS DIS DIS
DRUM DISC DISC
1 JZ 4010 06 LED Tail Lamp 1 1 1

18 17
JZ 4010 41 Tail Lamp with Bulb 1 1 1 from Chs. no.
VWB33928 (Cir. A-20)
2 DD 2010 11 Damper 2 2 2 For Front
No. Plate
3 31 2010 01 Collar 2 2 2 For Front
No. Plate
4 39 2124 15 Flange Nut 1 1 1
5 DJ 1610 72 Bracket Rear No. Plate 1 1 1 For Front
No. Plate
6 39 1553 04 Bolt Flange 2 2 2 For Front

No. Plate
19 7 DP 1611 45 Number Plate Rear 1 1 1
1
8 39 2476 04 Hex Flanged Bolt 2 2 2 For Front
No. Plate
4 4 9 DP 1611 44 Number Plate Front 1 1 1
13
10 JN 2328 01 Front No. Plate Mtg Bracket 1 1 1
12
14 11 39 1783 01 Truss Screw Front No. Plate 2 2 2

15
12 JW 4010 11 No. Plate Lamp with 1 1 1
2 Point Coupler
13 DJ 2010 72 Bulb 12V/ 5W 1 1 1 Rear No.
11 5 Plate Lamp
10 14 39 0705 01 Screw 2 2 2 Rear No.
9 Plate Lamp
7 15 39 0711 11 Plain Washer 2 2 2
2
3 8 16 39 1211 11 Washer 2 2 2
16 17 39 0740 11 Washer (Non Metallic) 4 4 4 For LED
6 Tail Lamp
18 39 0746 01 Screw For LED Tail Lamp 4 4 4
39 0817 15 Hex Nut – Tail Lamp
19 JZ 1810 04 Foam Strip 1 1 1
103 104
Electrical Equipments
DIS DIS DIS
DRUM DISC DISC
1 JZ 4016 00 Horn LH with Stay 1 1 1
2 39 1945 04 Flange Bolt 1 1 1 N.S
3 PA 4022 11 Wiring Harness 1 1 1
4 DS 2010 29 Rear Brake Switch 1 1 1
31 2010 79 Rear Brake Switch 1 1 1 Alt. For Ds201029
5 DS 1910 07 Spring Brake Switch 1 1 1
1 13 16 6 JB 4010 13 Head Lamp Control Unit or 1 1 1

JZ 4010 13 Head Lamp Control Unit 1 1 1
7 DS 2010 82 Battery MF Dry Charged 5 AH 1 1 –--
JZ 4018 02 Battery MF Dry Charged 7 AH -- -- 1
17 7 8 JZ 4018 00 Base Battery 1 1 1
9 JZ 4018 01 Band Battery 1 1 1
2 10 DX 1610 45 Battery Arrester 1 1 1 N.S
6
4 11 DS 2010 25 Assly DC Flasher 1 1 1
5
11 12 39 2208 04 Bolt Flange 2 2 2
9 13 JK 3516 00 Starter Relay 1 1 1 With Grommet
10 14 30 2011 04 Fuse Box Assly 2 2 2 For Light &
14 Main Fuse
3 12 15 GF 2010 53 Fuse 2 2 2 Light &
15
Main Fuse
9 16 DS 2010 22 Cable Assly 1 1 1 (Battery to
Starter Relay)
8 17 PA 4022 03 Starter Relay to Motor Relay 1 1 1
12 18 JZ 4022 02 Cable Assly. (Battery to Earth) -- -- 1 N.I.
JV 4022 05 Cable Assly. (Battery to Earth) 1 1 -- N.I.
19
19 30 1910 48 Band (Harness) 5 5 5 Length 123 mm
20 20 30 2010 64 Band (Harness) 3 3 3 Length 149 mm
21 JD 4018 03 Adapter Vent Tube 1 1 1 N.I.

22 39 1942 04 Bolt Flanged 1 1 1 N.I.
23 60 1114 15 Cable Tie Lock 1 1 1 N.I. (Fairing Mtg BKT)
24 60 1114 17 Clip Positive Lock 1 1 1 N.I. (Frame)
105 106
Tool Kit
DIS DIS DIS
DRUM DISC DISC
1 JN 2310 00 Tool Kit 1 1 1 For Reference

Only
DJ 2210 19 Tool Kit 1 1 1 Alt. For Jn231000
2 DP 2210 24 Band Tool Kit 1 1 1 Not Serviced
1 2 Separately
DP 2210 11 Band Tool Kit 1 1 1 Alt. For DP221024
107 108
Accessories / Grab Handle

DIS DIS DIS
3 DRUM DISC DISC
3
1 JZ 2312 01 Leg Guard 1 1 1
5
2 JZ 2312 02 Saree Guard 1 1 1
7 3 39 1556 04 Bolt Flange 2 2 2
1 4 DS 1611 88 Grab Handle with Foam 1 1 1
5 39 1681 04 Flange Bolt 4 4 4 For Mtg Grab
Handle
6 DJ 1610 79 Foam LH 1 1 1
7 DJ 1610 80 Foam RH 1 1 1
4
11 8 JZ 2312 04 Small Saree Guard 1 1 1
9 39 2495 04 Socket Head Bolt 1 1 1
10 JA 1134 04 Flange Bolt 1 1 1
10
6
11 39 197015 Hex Nut 1 1 1
12
12 39 2731 04 Bolt Flange 1 1 1
109 110
Kit List Discover 125 Kit List Discover 150
Sr Kit Consisting of Following Parts Sr Kit Consisting of Following Parts

Kit Description Kit Description
No Part No. Part No. Description Qty/Kit No Part No. Part No. Description Qty/Kit
1 36JE0002 Piston Ring Set JE521202 Ring Piston Top 1 1 36JZ0001 Valve Kit JZ511200 Valve Intake 1
JE521203 Ring Piston Second 1 JZ511201 Valve Exhaust 1
JE521204 Ring Piston Oil 1
2 36JZ0004 Valve Repair Kit 39201719 Seat Valve Stem 2
2 36JZ0023 Set Primary Drive & Driven PF551401 Housing Complete Clutch 1 DG101029 Cotter Valve 2
JZ531006 Gear Primary Drive 1 JA511203 Retainer Valve Spring 2
28101129 Seat Valve Spring 2
3 36JZ0031 Jet Kit JZ581234 Needle Jet 1 JZ511202 Spring Washer 2
JZ581230 Holder Needle Jet 1
JZ581231 Jet Main 1 3 36JE0003 Kit Guide Cam Chain JW541012 Guide Cam Chain (Slack Side) 1
JZ581233 Jet Pilot 1 JA521002 Guide Cam Chain (Tight Side) 1
4 36JZ0032 Throttle Valve Kit JZ581232 Valve Piston 1 4 36JZ0005 Piston Ring Set JZ521204 Ring Piston Top 1
DD121054 E-Ring 1 JZ521205 Ring Piston Second 1
JZ581211 Holder 1 JZ521206 Ring Piston Oil 1
DD121055 Spring Compression 1
JZ581223 Packing 1 5 36DU1007 Boss Kick Set 30101233 Boss Kit 1
JZ581222 Jet Needle 1 30101234 Spring 1
24121370 Ring 1 30101236 Ball Steel 1
30101235 Pin 1
39085517 E - Type Clip 1
5 36JZ0026 Chain Sprocket Kit Disco 125 DJ151086 Sprocket Hub (43T) 1
JZ551004 Sprocket Drive (14T) 1
6 36JZ0017 Jet Kit Jz581213 Needle Jet 1
JZ141003 Chain 120 Link - 420 Series 1
JZ581219 Holder Needle Jet 1
JZ581218 Jet Main 1
6 36JZ0037 Kit Friction Plate Disco 125 Jz551416 Plate Friction 5
JZ 581214 Jet Pilot 1
7 DH121169 Pilot Screw Kit DH121131 Screw Adjuster 1

DH121130 ‘O’ - Ring 1
DH121186 Spring Compr Coil 1
DH121187 Plain Washer 1
DH121188 ‘O’ - Ring 1
111 112
Kit List Discover 150 Kit List Discover 150
Sr Kit Consisting of Following Parts Sr Kit Consisting of Following Parts

Kit Description Kit Description
No Part No. Part No. Description Qty/Kit No Part No. Part No. Description Qty/Kit
8 36JZ0016 Idling Screw Kit JZ581217 Screw Stop 1 17 36JZ0007 Chain Sprocket Kit DJ151086 Sprocket Hub (43T) 1
DH121130 ‘O’ - Ring 1 JZ551004 Sprocket Drive (14T) 1
CB121044 Spring Compression DS151082 Chain 120 Link - 420 Series 1
9 36DS2101 Seat Damper Kit DS211004 Damper Seat - I 7 18 36JZ0014 Set Primary Drive & Driven JZ551410 Housing Complete Clutch 1
DS211005 Damper Seat - II 2 JZ531006 Gear Primary Drive 1
10 36DS1802 Bearing Cone Kit DH181025 Bearing cone 1

19 36JZ0008 Starter Clutch Repair Kit JA621411 Bush Spring Starter Clutch 5
DH181026 Bearing race 1
DH101163 Roller Clutch 5
DH181024 Upper bearing race 1
DH101164 Spring 5
DS211004 Seat Damper 1
DJ101109 Bush For Spring Starter Clutch 5
11 36DS1801 Holder Handle Set DS181019 Holder Handle 2
DS181006 Holder Handle 2 20 36JZ0020 Cable Adjuster Kit JA581315 Nut 1
JA581261 Cable Adjuster 1
12 36DS1401 Grommet Kit - Side Cover DS141012 Grommet Side Cover Front 2 JZ531215 Mixing Cap Assembly 1
DS161082 Grommet Side Cover Rear 2
21 36JE0005 Friction Plate Kit DP101110 Plate Friction 4
14 36DS4020 Case Chain Kit DS161269 Case Chain Upper Assly. 1
DP101109 Plate Friction 1
DS161270 Case Chain Lower Assly. 1
15 36JZ0019 Throttle Valve Kit JZ581221 Valve Piston 1

DD121054 E-Ring 1
JZ581222 Holder 1
DD121055 Spring Compression 1
JZ581215 Packing 1
JZ581222 Jet Needle 1
24121370 Ring 1
16 36JZ0021 Carb. Gasket- 'O' Ring Kit JA581232 Gasket Float Chamber 1
DH121130 ‘O’ - Ring Idling Screw 2
JA581240 ‘O’ - Ring Auto Choke 1
DH121118 ‘O’ Ring Drain screw 1
JA581238 ‘O’ Ring TPS 1
113 114
SPC Updation Details
Page Fig. Old part New part Updation Remarks Page Fig. Old part New part Updation Remarks
no. no. no. no. Description date no. no. no. no. Description date
106 3 JZ402200 PA402211 Wiring Harness 13.02.12 Rationalization of Wiring Harness 68 19 39026312 39073212 WasherSpring 25.0314 Alternate
106 3 JZ402209 PA402211 Wiring Harness 13.02.12 ----------"do"-------------- 68 1 Jb131019 59150003 UNut(M12) 25.0314 Alternate
70 24 30151042 39024211 WasherPlain 25.0314 Alternate
106 23 -------- 60111415 Guide Tie Lock 13.02.12 ----------"do"-------------- 72 19 30151012 30151011 CamBrake 25.0314 Alternate
106 24 -------- 60111417 Clip Positive Lock 13.02.12 ----------"do"-------------- 72 3 LCA00001 39080115 Nut 25.0314 Alternate
80 23 Jz151023 Pa151007 Holder fork Upper 27.08.13 Alternate 72 4 LDB00002 39256711 PlainWasher 25.0314 Alternate
78 13 39171404 39258204 FlangeBolt 25.0314 Alternate
82 10 Jz151023 Pa151007 Holder fork Upper 27.08.13 Alternate
80 22 39191204 39245304 FlangeBolt 25.0314 Alternate
8 11 Ja521019 39167304 FlangeBolt 25.03.14 Alternate 82 11 Dh181023 30181009 BearingCone 25.0314 Alternate
8 10 Ja521018 Dd101062 Bolt 25.03.14 Alternate 86 6 52JZ0055 52JZ0018 HeadLampBlackCowling 25.0314 Alternate
8 4 39219804 Dh101387 BoltAllenBolt 25.0314 Alternate 88 6 Dd141022 Dd141227 BoltFlanged 25.0314 Alternate
88 8a 39275821 Dk141028 ‘O’Ring 25.0314 Alternate
12 4 Jz531003 Je531000 CrankShaftAssly 25.0314 Alternate 88 12 30141015 Dk141041 PipeClip 25.0314 Alternate
14 18 Jz551004 36JZ0007 SprocketDrive 25.0314 Alternate 88 4 Ds141018 Jz171809 FuelTapAssly 25.0314 Alternate
18 12 Ja561211 39190204 FlangeBolt 25.0314 Alternate 92 8 Dl191020 Dh191037 Bulb12V-3W 25.0314 Alternate
96 3 Jb181239 Dh161283 Bolt 25.0314 Alternate
18 1 Jw561205 52JZ0264 LeverCompleteGearShift25.0314 Alternate 100 34 Jz181002 Jz181006 DamperAssly(N.I.) 25.0314 Alternate
20 12 Ja541014 52JA0029 BoltShiftChange 25.0314 Alternate 106 4 Ds201029 31201079 RearBrakeSwitch 25.0314 Alternate
22 20 Ja541032 Ja541019 StrainerAssly. 25.0314 Alternate 106 6 Jb401013 Jz401013 HeadLampControlUnitor 25.0314 Alternate
108 1 Jn231000 Dj221019 ToolKit 25.0314 Alternate
24 22 Ja521019 39167304 BoltFlange 25.0314 Alternate
108 2 Dp221024 Dp221011 BandToolKit 25.0314 Alternate
24 1 36JZ0013 36JZ0025 ClutchCover 25.0314 Alternate 82 1 N/A Jz151073 Front Fork 05.06.14 updation
28 11 Dp101116 39155304 BoltFlange 25.0314 Alternate
28 14 Ja531007 52JA0028 NutSpecial 25.0314 Alternate
28 10 Jb551412 Jb551406 HolderClutch 25.0314 Alternate
34 18 Ja521019 39167304 FlangeBolt 25.0314 Alternate
34 17 Dx121006 Jz581029 ‘O’Ring 25.0314 Alternate
36 3 Ja591040 39229515 FlangeNut 25.0314 Alternate
42 3 39167504 39167404 BoltFlange 25.0314 Alternate
42 4 Dh101360 Dh101432 PanHeadScrew 25.0314 Alternate
56 3 Jb181412 39107504 FlangeBolt 25.0314 Alternate
56 16 39242001 39169801 Screw 25.0314 Alternate
60 1 Jd131002 Jd131000 WheelRimFront 25.0314 Alternate
60 4 Jw131210 Jw131205 WheelRimRear 25.0314 Alternate
62 13 Jb131019 59150003 ‘U’Nut 25.0314 Alternate
62 11 Jn131003 Ds151058 Spacer 25.0314 Alternate
64 12 De201016 Dj201100 FrontBrakeSwitch 25.0314 Alternate
66 2 Dj161280 Dh151039 BoltFlangedCaliperMounting25.0314Alternate
115 116
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.
14151021 10 68 30151069 16 72 36DH4014 23 76 36JZ0011 1 22

14151033 23 24 30151075 13 72 36DK0009 11 36 36JZ0012 1 36
14151033 15 28 30151096 18 76 36DS1401 1 90 36JZ0013 1 24
15161069 2 96 30151011 19 72 36DS1502 22 70 36JZ0014 7 12
15191026 11 76 30151118 20 68 36DS1801 11 78 36JZ0014 16 28
22150241 4 30 30181009 11 82 36DS1802 4 48 36JZ0015 1 26
24121069 16 32 30181025 4 82 36DS2101 2 44 36JZ0016 5 32
24121365 7 32 30181026 3 82 36DS4020 1 96 36JZ0017 4 32
30101096 6 28 30191035 10 76 36DU1007 3 30 36JZ0019 14 32
30101142 4 24 30191036 12 76 36DU1504 18 62 36JZ0020 2 32
30101195 11 26 30191038 7 76 36Dz0020 2 82 36JZ0021 15 32
30141015 12 88 30191048 20 80 36JE0002 3 10 36Jz0022 14 88
30141031 9 54 30191048 19 106 36JE0003 6 8 36JZ0023 7 12
30141031 3A 88 30201064 20 106 36JE0005 4 28 36JZ0023 16 28
30151005 17 72 30201104 14 106 36JZ0001 4 6 36JZ0024 5 10
30151012 19 72 31101173 3 12 36JZ0002 5 10 36JZ0025 1 24
30151033 1 62 31161018 9 90 36JZ0004 5 6 36JZ0026 2 72
30151035 23 70 31181102 22 82 36JZ0005 3 10 36JZ0027 1 4
30151038 13 68 31201001 7 102 36JZ0006 1 96 36JZ0028 1 22
30151038 20 72 31201001 3 104 36JZ0007 18 14 36JZ0029 2 20
30151041 6 62 31201079 4 106 36JZ0007 2 72 36JZ0030 1 36
30151042 24 70 31201081 5 22 36JZ0008 6 40 36JZ0031 4 32
30151068 8 68 35161060 6 98 36JZ0009 2 20 36JZ0032 14 32
30151069 9 68 36314002 5 48 36JZ0010 1 4 36JZ0037 4 28
119 120
36JZ0038 4 92 39073817 6 30 39098717 3 14 39155304 6 104

36JZ0039 3 92 39074011 7 88 39099206 2 16 39155604 3 46
39019811 8 76 39074011 17 104 39099311 5 30 39155604 3 110
39021111 7 56 39074601 4 42 39099906 12 22 39167121 20 24
39021911 25 100 39074601 18 104 39099906 24 24 39167204 21 76
39024011 13 28 39074701 9 22 39099906 4 38 39167304 11 8
39024211 15 56 39075301 3 38 39100006 2 10 39167304 22 24
39024211 24 70 39076101 2 88 39100006 6 20 39167304 18 34
39025811 4 50 39078408 7 54 39100006 11 22 39167404 3 42
39026312 19 68 39078912 15 76 39100120 15 28 39167504 3 42
39029215 16 50 39078912 13 82 39101321 25 70 39167704 19 34
39029215 22 76 39079415 9 72 39104011 10 54 39168004 3 76
39032615 11 56 39079708 3 58 39104119 3 24 39168104 5 110
39042215 9 58 39079815 6 56 39105411 7 90 39169801 16 56
39042215 18 78 39079815 9 92 39118101 14 82 39171404 13 78
39045411 11 50 39079815 33 100 39121111 16 104 39171519 4 22
39045411 9 98 39080708 17 76 39122515 6 102 39175904 17 22
39055302 10 50 39080115 3 72 39128321 8 4 39176511 11 34
39059417 12 8 39080808 9 76 39128321 12 4 39177802 10 98
39069415 16 76 39081715 8 18 39135815 13 50 39177902 15 34
39070501 14 104 39081715 18 104 39150811 32 100 39178301 11 104
39071111 15 104 39084001 18 68 39150811 35 100 39178924 5 90
39072211 19A 72 39098004 11 28 39154011 19 76 39179701 10 34
39073212 19 68 39098308 6 90 39155304 11 28 39186420 5 12
119 120
39188020 16 8 39219019 7 22 39266921 13 8 52JZ0050 3 84

39190204 4 44 39219804 4 8 39268020 5 68 52JZ0051 2 84
39190204 12 18 39220011 12 28 39268120 7 68 52Jz0052 3 84
39190701 30 100 39220804 15 24 39268320 15 8 52JZ0053 2 84
39191204 22 80 39220804 12 106 39268620 12 72 52JZ0054 6 86
39194304 12 42 39223801 7 98 39268720 15 72 52JZ0055 6 86
39194304 9 56 39224020 6 72 39268820 2 62 52JZ0097 2 84
39194304 3 90 39224915 19 78 39270411 7 18 52JZ0098 3 84
39194304 20 98 39229515 3 36 39272204 9 36 52JZ0099 4 84
39194304 28 100 39231004 2 52 39272204 8 54 52JZ0100 6 86
39194304 10 102 39240817 12 30 39272315 2 46 52JZ0115 2 84
39194504 2 106 39242001 16 56 39272612 8 50 52JZ0116 3 84
39196104 29 100 39242704 28 80 39273104 12 110 52JZ0118 6 86
39196404 14 20 39247604 8 104 39275404 7 36 52JZ0264 1 18
39197015 5 46 39248415 10 88 39275821 8A 88 59010005 23 100
39197015 11 110 39249211 8 36 52JA0027 9 20 59040006 7 82
39201719 6 6 39249504 9 110 52JA0028 14 28 59040014 15 42
39206004 10 48 39245304 22 80 52JA0029 12 20 59040038 2 2
39206004 18 50 39256220 2 22 52JZ0014 2 84 59040038 11 20
39206004 26 100 39256711 4 72 52JZ0015 3 84 59040038 16 22
39212415 4 104 39258204 13 78 52JZ0018 6 86 59040038 17 24
39214124 3 98 39260011 3 28 52JZ0020 2 84 59040038 4 26
39214124 31 100 39260801 10 4 52JZ0021 3 84 59040050 8 2
39217924 3 88 39262921 11 4 52JZ0023 6 86 59110008 2B 12
121 122
59120003 2A 12 DD161071 12 36 DE191034 7 64 DH111015 9 42

59150003 13 62 DD161381 5 54 DE191035 15 64 DH121038 12 34
59150003 1 68 DD191142 3 64 DE201016 12 64 DH121169 3 32
59150014 1 12 DD191142 30 80 DF161102 8 58 DH151029 14 76
59200036 3 20 DD201011 2 104 DF161413 4 52 Dh151039 2 66
59200036 3 22 DD201170 31 80 DG101029 3 6 DH161100 6 54
59210023 14 22 DE151006 3 62 DG101339 11 18 DH161121 4 58
59210024 17 14 DE151008 5 62 DG101418 7 24 DH161145 5 58
AA121045 13 4 DE151012 4 62 DG121002 8 34 DH161146 11 58
CB101114 2 36 DE151015 11 64 DG161121 2 90 DH161194 5 52
CB121039 8 32 DE151037 6 66 DG191045 4 76 DH161240 7 58
CB121042 8 32 DE151043 7 66 DH101048 5 8 Dh161283 3 96
CL201023 12 98 DE151045 8 66 DH101125 14 30 DH181014 3 48
CL201042 7 92 DE151046 4 66 DH101360 4 42 DH181022 27 80
CS101128 9 8 DE151047 5 66 DH101380 8 20 DH181023 11 82
Dd101062 10 8 DE151048 3 66 Dh101387 4 8 Dh191037 8 92
DD101097 13 30 DE191010 5 64 DH101388 7 26 DJ141008 8 90
DD111011 10A 42 DE191011 4 64 DH101392 7 8 DJ151033 11 72
DD111012 11 42 DE191028 14 64 Dh101432 4 42 DJ151035 5 72
DD111018 8 42 DE191029 13 64 DH101509 10 18 DJ151036 14 50
DD111048 9 42 DE191030 10 64 DH101648 14 28 DJ151037 15 50
DD121181 19 24 DE191031 8 64 DH101781 2 40 DJ151047 19 50
DD141022 6 88 DE191032 9 64 DH101784 6 22 DJ151053 1 72
Dd141227 6 88 DE191033 6 64 DH111013 10B 42 DJ151057 19 62
123 124
DJ151072 7 66 DJ201207 4 102 DS101117 8 30 DS151089 11 68

DJ151073 8 66 DJ221003 9 78 DS101154 6 12 DS151090 21 74
DJ151074 9 66 DJ221004 10 78 DS101215 8 24 DS151091 14 68
DJ151075 10 66 Dj221019 1 108 DS101276 3 8 DS151092 16 68
DJ151088 14 72 Dk141028 8A 88 DS109905 14 8 DS151094 17 68
DJ151092 18 72 Dk141041 12 88 DS121116 2 34 DS151094 28 74
DJ161069 10 56 DK201078 13 106 DS121126 7 34 DS151095 15 68
DJ161072 5 104 DL161015 13 56 DS141009 1 88 DS161069 13 34
DJ161079 6 110 DL191014 19 78 DS141013 9 88 DS161077 6 58
DJ161080 7 110 DL191020 8 92 DS141018 4 88 DS161112 2 58
DJ161122 4 54 DP101107 5 28 DS151025 13 76 DS161113 1 58
DJ161128 11 54 DP101111 6 28 DS151029 6 60 DS161125 1 56
DJ161129 3 54 DP101114 17 28 DS151031 5 60 DS161188 4 110
DJ161280 2 66 DP101116 11 28 DS151038 7 62 DS161287 5 56
DJ171033 27 74 DP101165 4 10 DS151048 2 60 DS171007 9 50
DJ171034 20 50 DP101198 7 4 DS151049 3 60 DS171013 12 50
DJ181104 6 82 DP101243 7 28 DS151052 5 60 DS171014 17 50
DJ191023 1 64 DP101269 6 24 DS151053 6 60 DS171015 6 50
DJ191054 4A 78 DP161144 9 104 DS151056 3 68 DS181007 14 78
DJ191055 6 78 DP161145 7 104 Ds151058 11 62 DS181008 15 78
DJ201072 13 104 DP161260 8 48 DS151068 7 72 DS181009 16 78
Dj201100 12 64 DP171006 7 48 DS151073 8 72 DS181010 17 78
DJ201108 16 64 DP221024 2 108 DS151074 10 72 DS181012 21 82
DJ201206 3 102 Dp221011 0 102 DS151087 12 68 DS181015 8 82
125 126
DS181016 9 82 DX121011 5 34 JA351627 11 40 Ja541019 20 22

DS181016 15 82 DX151022 25 74 JA511008 4 2 JA541020 18 22
DS181018 2 48 DX161045 10 106 JA511028 2 4 JA541021 15 22
DS181044 1 78 DX161052 4 96 JA511029 7 2 JA541028 14 42
DS191007 5 106 DX191001 25 80 JA511211 1 6 JA541032 20 22
DS191011 5 76 DZ141075 13 88 JA511216 2 8 JA541034 10 22
DS191015 5 78 GF201053 15 106 JA521015 8 10 JA541044 2 26
DS191016 26 80 GH201012 5 102 JA521017 8 8 JA541205 3 26
DS191018 12 78 JA113402 6 46 JA521018 10 8 JA541211 11 24
DS191038 29 80 JA113403 1 46 JA521019 11 8 JA541212 16 24
DS191052 8 78 JA113404 10 110 JA521019 22 24 JA541216 14 24
DS191053 3 94 JA131606 26 70 JA521019 18 34 JA541221 8 26
DS191054 4 94 JA151013 5 82 Ja5310004 4 12 JA541225 12 24
DS201022 16 106 JA161003 1 76 JA531007 14 28 JA541233 10 26
DS201025 11 106 JA351600 7 40 JA531012 8 12 JA541235 10 20
DS201029 4 106 JA351602 11 40 JA531015 9 12 JA541236 9 24
DS201036 13 98 JA351604 8 40 JA541005 8 22 JA541237 10 24
DS201079 8 88 JA351606 9 40 JA541005 9 26 JA551002 4 14
DS201082 7 106 JA351608 12 40 JA541010 5 20 JA551004 7 14
DS211006 3 44 JA351609 13 40 JA541011 4 20 JA551008 15 14
DU101085 7 20 JA351618 14 40 JA541012 13 20 JA551009 16 14
DU101213 19 14 JA351619 16 40 JA541014 12 20 JA551406 2 28
DU201046 24 80 JA351624 15 40 JA541016 2 38 JA551416 12 28
DX121006 17 34 JA351626 9 40 JA541019 13 22 JA551420 13 28
127 128
JA561209 6 18 JB131018 10 62 JB591059 6 36 JE531001 5 12

JA561211 12 18 JB131018 2 68 JD131002 1 60 JE541209 13 24
JA581221 6 32 JB131019 13 62 JD131810 9 62 JE541210 6 26
JA581233 9 32 JB131019 1 68 JD131811 8 62 JE541211 2 24
JA581239 10 32 JB131022 4 68 JD131813 1 66 JE541212 13 26
JA581240 11 32 JB131224 23 74 JD351206 16 42 JE551201 5 14
JA581314 17 32 JB171802 11 88 JD401803 21 106 JE551206 11 14
JA581406 5 4 JB181239 3 96 JD511008 3 4 JE551401 6 24
JA591040 3 36 JB181403 12 56 JD511010 3 2 JE551403 8 28
JA621002 9 30 JB181412 3 56 JD521002 1 10 JE551405 10 28
JA621006 11 30 JB181416 2 56 JD531004 11 12 JK121007 18 82
JA621201 1 30 JB181421 2 56 JD541000 19 22 JK121009 20 82
JA621206 2 30 JB401013 6 106 JD551400 18 28 JK402000 13 42
JA621402 4 40 JB401400 2 78 JD561002 6 16 JN113200 10 58
JA621406 5 40 JB401401 3 78 JD561002 7 16 JN122000 3 50
JA621410 3 40 JB402202 7 10 JD561004 5 16 JN122006 5 50
JA621414 1 40 JB511018 9 4 JD561006 4 16 JN131003 11 62
JB113005 10 36 JB531021 10 12 JD561011 3 16 JN131211 24 74
JB122009 7 50 Jb551406 10 28 JD561203 4 18 JN131800 2 64
JB122010 2B 50 JB551408 5 28 JD561204 5 18 JN131804 17 64
JB122011 2A 50 JB551411 8 28 JD621001 7 30 JN171000 4 90
JB122016 1 50 JB551412 10 28 JE351002 1 42 JN181001 1 98
JB131017 12 62 JB581202 12 32 JE351203 5 42 JN181003 16 98
JB131017 1A 68 JB581204 13 32 JE351204 6 42 JN181004 24 100
129 130
JN181005 11 98 JW131809 9 66 JZ113407 12 46 JZ161204 3 94

JN181010 5 98 JW131810 11 66 JZ131011 1 60 JZ161210 3 94
JN181011 5 98 JW151005 16 82 JZ131012 1 60 JZ181002 34 100
JN181014 11 92 JW151007 17 82 JZ131014 1 60 JZ181003 4 98
JN181017 17 98 JW151023 19 82 JZ131213 4 60 JZ181004 37 100
JN181018 18 98 JW181241 14 62 JZ131601 19 62 JZ181004 19 104
JN181019 14 98 JW233000 12 26 JZ131803 22 74 JZ181200 2 92
JN181019 36 100 JW351400 6 10 JZ151000 1 82 JZ181206 2 98
JN181021 19 98 JW401011 12 104 JZ151004 16 82 JZ181208 27 100
JN181023 21 100 JW541000 18 24 JZ151006 17 82 JZ181401 8 56
JN181024 22 100 JW541005 5 24 JZ151023 23 80 JZ181402 4 56
JN181206 14 62 JW561205 1 18 JZ151023 10 82 JZ181406 14 56
JN181211 15 62 JW561206 2 18 JZ151024 9 102 JZ191006 1 44
JN181406 12 92 JW561208 3 18 JZ151036 12 82 JZ231201 1 110
JN191000 1 44 JW591028 5 36 JZ151043 1 82 JZ231202 2 110
JN231000 1 108 JZ111029 1 48 JZ151057 1 82 Jz231204 8 110
JN232801 10 104 JZ113001 1 52 JZ151059 17 82 JZ232600 21 80
JP351007 2 42 JZ113011 3 52 Jz151061 16 82 JZ232600 5 88
JV402205 18 106 JZ113015 1 54 Jz151073 1 82 JZ233000 7 86
JW131210 4 60 JZ113017 2 54 JZ161002 2 76 JZ233005 8 86
JW131801 1 66 JZ113400 8 46 JZ161004 6 76 JZ233012 7 86
JW131805 2 64 JZ113402 10 46 JZ161006 20 76 JZ233017 8 86
JW131806 9 62 JZ113403 9 46 JZ161202 1 94 JZ233024 7 86
JW131807 6 66 JZ113405 11 46 JZ161203 2 94 JZ233029 8 86
131 132
JZ233036 7 86 JZ501000 1 20 JZ551207 11 14 JZ581209 1 32

JZ233041 8 86 JZ501001 1 20 JZ551208 12 14 JZ581210 6 4
JZ233070 7 86 JZ511004 1 8 JZ551209 10 14 JZ581216 19 32
JZ233075 8 86 JZ511016 3 4 JZ551210 9 14 JZ581220 18 32
JZ233086 7 86 JZ511020 5 2 JZ551211 10 14 JZ581222 20 32
JZ233091 8 86 JZ511021 1 2 JZ551212 11 14 JZ581227 1 32
JZ351001 1 42 JZ511203 2 6 JZ551213 5A 14 JZ581402 4 4
JZ351205 7 42 JZ531003 4 12 JZ551409 1 28 JZ591043 4 36
JZ351206 7 42 JZ531007 4 12 JZ551412 9 28 JZ621000 10 30
JZ401000 1 102 JZ541202 5 26 JZ551413 1 28 JZ71013B 1 84
JZ401001 2 102 JZ541214 21 24 JZ551415 9 28 JZ71013C 1 84
JZ401006 1 104 JZ551001 1 14 JZ561000 1 16 JZ71015A 1 84
JZ401012 8 98 JZ551003 8 14 JZ561401 9 18 JZ71015B 1 84
JZ401013 6 106 JZ551004 18 14 JZ571000 1 38 JZ71015D 1 84
JZ401015 15 98 JZ551006 1 14 JZ571001 5 38 JZ71015E 1 84
JZ401600 1 106 JZ551008 8 14 JZ581004 6 2 JZ73033B 4 84
JZ401800 8 106 JZ551010 1 14 JZ581004 9 34 JZ73033C 4 84
JZ401801 9 106 JZ551200 6 14 JZ581006 14 34 JZ73035A 4 84
JZ402200 3 106 JZ551201 5 14 JZ581007 1 34 JZ73035B 4 84
JZ402202 18 106 JZ551202 2 14 JZ581009 16 34 JZ73035E 4 84
JZ402209 3 106 JZ551203 5A 14 JZ581010 3 34 JZ73043B 5 84
JZ402403 1 92 JZ551204 14 14 JZ581011 4 34 JZ73045A 4 84
JZ402406 3 92 JZ551205 13 14 JZ581012 6 34 JZ73045B 4 84
JZ402407 4 92 JZ551206 9A 14 JZ581029 17 34 JZ73045D 4 84
133 134
JZ73045E 4 84 PA402401 3 92
LAC00002 8 62 PA402402 4 92
LAD00011 10 40 PA402403 5 92
LAD00026 8 102 PA402404 6 92
LAD00041 7 46 PA402405 10 92
LAD00052 4 46 PA402410 13 92
LBD00001 21 70 PA402411 14 92
LBU00004 16 62 PA402412 15 92
LBU00005 17 62 PA402413 16 92
LBU00006 17 62 PA402420 4 92
LCA00001 3 72 PA402421 3 92
LDB00001 26 74
LDB00002 4 72
PA113800 9 48
PA131003 5A 68
PA131600 6 68
PA351201 5 42
PA351202 6 42
PA401000 6 48
PA401400 4 78
PA401401 7 78
Pa401403 31 80
PA402203 17 106
PA402400 1 92
135 136

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Bajaj Auto Limited

Akurdi Pune 411 035 India

DOC. NO.: 71111284 REV. 01, MAR. 12

4. Abbreviations : The following abbreviations are used in this catalogue.

1 Cover Cylinder Head 2 27 Pillion Foot Rest / Holder 54

Nozzle Oil Jet

PLATE NO. : 49 PAGE NO. PLATE NO. : 50 PAGE NO.

Cover Cylinder Head

6 JZ 5810 04 Hose C’ case Breather 1 1 1

1 36 JZ00 10 Head Cylinder Complete -- -- 1 With studs &

6 JZ 5812 10 Sleeve (Carb - Duct Rubber) 1 1 1

11 39 2629 21 ‘O’ Ring Sleeve 1 1 1

1 JA 5112 11 Shaft Rocker Arm Exhaust 2 2 2

1 JZ 5110 04 Camshaft Complete 1 1 1

11 JA 5210 19 Flange Bolt 2 2 2 Adjuster Assly

Cylinder and Piston

1 JD 5210 02 Gasket Cylinder 1 1 1

6 JW 3514 00 Thermal Sensor 1 1 1

1 59 1500 14 Flange Nut 2 2 2

11 JD 5310 04 Spacer Crankshaft Clutch Side 1 1 1

1 JZ 5510 01 Shaft I/P Transmission -- -- 1

16 JA 5510 09 Collar Sprocket Drive 1 1 1

Change Drum / Shift Fork

1 JZ 5610 00 Drum Complete Gear Shift 1 1 1

Gear Change Mechanism

1 JW 5612 05 Lever Complete Gear Shift 1 1 1

3 6 JA 5612 09 Step Washer (Collar) 1 1 1

8 7 39 2704 11 Plain Washer 1 1 1

Engine Assembly / Crankcase RH

1 JZ 5010 01 Engine Assly 1 1 -- N.I.

7 11 59 0400 38 Bolt Flange 1 1 1 Crankcase Mtg.

1 36 JZ00 11 Crankcase Magneto Side -- -- 1 NRB + Bush

6 DH 1017 84 Gasket Neutral Switch 1 1 1

1 36 JZ00 13 Clutch Cover -- -- 1 With Decal +

18 6 JE 5514 01 Rod Push -- -- 1

2 11 30 1011 95 ‘O’ Ring 1 1 1

1 JZ 5514 13 Clutch Complete 1 1 –

Kick Starter Mechanism

1 JA 6212 01 Lever Assly Kick 1 1 1

11 JA 6210 06 Washer Thrust 1 1 1

10 9 6 JA 5812 21 Valve Complete Float 1 1 1

16 24 1210 69 Arm Pin Float 1 1 1

Air Cleaner Complete

1 JZ 5810 07 Air Filter Assly 1 1 1

15 6 JZ 5810 12 Tube Drain 1 1 1

1 36 JZ00 12 Silencer Assly without Shield -- –-- 1

4 6 JB 5910 59 Grommet Shield 2 2 2

1 JZ 5710 00 Oil Pump Assly 1 1 1

3 1 JA 6214 14 Body Complete Starter Clutch 1 1 1

16 JA 3516 19 Terminal Assly (Lucas-TVS) 1 1 1

Magneto, CDI & H.T. Coil

1 JE 3510 02 Rotor Assly –-- –-- 1

11 DD 1110 12 Grommet for HT Cable 2 2 2

Seat Assembly / Seat Lock

1 JN 1910 00 Seat Assly Comp -- -- 1 Up to 10.03.2011

1 JA 1134 03 Flange Bolt M10 x 110 2 2 2

11/12 6 JA 1134 02 Bolt Flanged 2 2 2

Frame and Frame Fittings