650s - ClassicBike.biz

REPLACEMENT
PARTS
CATALOGUE
FOR 1971
BONNEVILLE T120R
TIGER 650 TR6R
TRrPHY 650 TR6C
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TRIUMPH ENGINEERING COMPANY LIMITED
MERIDEN WORKS • ALLESLEY • COVENTRY CV5 9AU • ENGLAND
TELEGRAMS "TRUSTY" COVENTRY
TELEPHONE COVENTRY 20221
TELEX "TRUSTY" 31305
MERIDEN 331
PUBLICATION PART No. 99-0932
PUBLISHED FEBRUARY 1971
ClassicBike.biz
I NTRODUCTION
The Triumph Engineering Co. Ltd. point out that the information in this catalog was complete and correct
at the time of printing. Distributors will be informed of any subsequent alterations.
A plastic binder, of the type used for Workshop Manuals, is available to enable this catalog and all other
1971 season catalogs to be bound into one unit.
GUARANTEE
Please refer to your dealer or distributor for the latest terms of guarantee.
Eastern U.S.A. Distributor:
Western U.S.A. Distributor:
Triumph Motorcycle Corporation,
P.O. Box 6790,
Towson,
Baltimore 4,
Maryland 21204.
Triumph Motorcycle Corporation,
P.O. Box 2765,
East Huntington Drive,
Duarte,
California 91010.
Telex—Tricor Bait. 87728
Telephone-301-252-1700
Telex—Tricor Duarte 675469
Telephone-213-359-3221
213-681-0255
ENGINE AND FRAME NUMBERS
The engine number is located on the left side of the engine, immediately below the cylinder barrel to
crankcase flange.
The frame number is located on the left side of the frame headlug, beneath the fork top lug and forward
of the gasoline tank.
Both the engine and frame number should be quoted in full in any correspondence relating to the
machine.
2
ClassicBike.biz
I NDEX
Page
AIRCLEANER ...
...
ALTERNATOR ...
...
AUTO-ADVANCE UNIT
...
...
...
...
65
... 11, 41
31
...
BATTERY CARRIER
BRAKE SWITCHES
BREATHER PIPES
...
...
...
...
...
...
...
...
...
Page
KICKSTARTER...
MANIFOLD
...
...
MOTOR PLATES
...
MOTOR TORQUE STAY
MUFFLERS
...
...
81
45
43
...
67
...
84
... 77, 79
... 47, 51
43
...
... 53, 55
59
...
57
...
...
...
...
...
63
...
33, 35, 37
...
...
...
...
69
...
57
...
... 79, 81
77
...
GASTANK
GEARBOX
...
...
...
HANDLEBAR...
HANDLEBAR MOUNTINGS
...
HEADLAMP...
...
...
HORN...
...
37
...
...
...
...
...
...
...
... 49,
17
47
47
51
...
...
...
17
43
17
PISTONS
...
PROPSTAND ...
PUSH RODS
...
...
...
...
...
...
11
...
...
43
... 19, 21, 23, 25
REARWHEEL ...
RECTIFIER
...
ROCKERS
...
...
...
...
...
...
61
...
...
77
..19, 21, 23, 25
SIDEPANEL
...
...
SPARKPLUG ...
...
SPEEDOMETER ...
...
SPEEDOMETER GEARBOX
STEERING DAMPER ...
SUSPENSION UNITS ...
SWINGING FORK
...
SWITCHES
...
...
... 49, 51
...
...
EXHAUST PIPES
EXHAUST PIPE ADAPTOR ...19, 21, 23, 25
...
...
...
...
...
...
...
...
...
OILPUMP
...
...
...
OILPIPES
...
...
...
OIL PRESSURE RELEASE VALVE
CAMSHAFT, INLET AND EXHAUST
11
CARBURETOR
...
...
... 27, 29
CARTON PACKS
...
...
...
7
CENTRESTAND
...
...
...
43
CHAINS...
...
...
...
...
41
...
...
CHAINCASE...
...
41
...
...
...
...
39
CLUTCH
CLUTCH LEVER ASSEMBLY
...
37
...
...
...
...
...
77
COIL
CONDENSER PACK ...
...
...
77
CONNECTING RODS
...
...
11
...
...
31
CONTACT BREAKER ...
...
CONTROL CABLES ...
...
71
...
...
69
CONTROL LEVERS ...
...
... 13,15
...
CRANKCASE...
...
51
CRANKCASE UNDERSHIELD
...
...
...
11
CRANKSHAFT...
... 19, 21, 23, 25
...
...
CYLINDERS
...19, 21, 23, 25
CYLINDER HEAD
...
...
...
FENDERS
FIVE SPEED GEARBOX
...
...
FLASHERS
...
...
FOOTRESTS
...
...
FRAME...
...
FRONT FORKS
...
FRONT WHEEL
...
FUSE ASSEMBLY
...
...
...
...
...
...
...
...
...
...
65
...
77
...
75
...
61
...
57
...
45
...
45
... 69, 79
TABLE OF STANDARD HARDWARE 82
TACHOMETER...
...
...
75
...
TACHOMETER GEARBOX ...
75
...
TAILLAMP
67
...
...
...
...
TAPPETS
17
...
...
...
...
TIMING GEARS
...
...
...
11
...
...
...
...
73
TOOLKIT
...
63
TWINSEAT
...
...
...
VALVES ...
VALVE GUIDES
...
...
...19,21,23,25
...19,21,23,25
WIRING HARNESS ...
...
...
79
ZENERDIODE ...
...
...
77
3
ClassicBike.biz
...
TIGER 650 (TR6R) TECHNICAL DATA
Bore and stroke...
71 x 82 mm.
2 . 79 x 3 . 23 ins.
Capacity ...
...
Compression ratio
Spark plugs
...
Carburetor
649 c.c. (40 cu. ins.)
9:1
Champion N3
...
Amal Concentric 930
230
•106
No.31
Main jet
Needle jet
...
Throttle valve ...
Gearbox sprocket
Chains
...
19 teeth
Front
Rear
i" Duplex x 84 links
1" x i" x 106 links
...
Capacities
Gas Tank
Oil Tank
Gearbox
...
Primary Chaincase
Front Forks (each leg)
Brakes
Front, diameter...
Rear, diameter
Tire size ...
Front
Rear
4
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3.6 U.S. galls.
4.8 U.S. pints
i pint (500 c.c.)
1 pint (150 c.c.)
pint (190 c.c.)
8" (20 . 32 cm.)
7" (17 . 78 cm.)
3.25 x 19
4.00 x 18
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TROPHY 650 (TR6C) TECH N ICAL DATA
71 x 82 mm.
2 . 79 x 3 . 23 ins.
Bore and stroke...
649 c.c. (40 cu. ins.)
Capacity ...
9:1
Compression ratio
Champion N3
Spark plugs
Carburetor
Main jet
Needle jet
Throttle valve ...
18 teeth
Gearbox sprocket
Chains
...
Amal Concentric 930
230
-106
No. 31
Front
Rear
i" Duplex x 84 links
1" x i" x 106 links
...
Capacities
Gas Tank
Oil Tank
Gearbox
...
Primary Chaincase
Front Forks (each leg)
Brakes
Front, diameter...
Rear, diameter
Tire size ...
Front
Rear
3.6 U.S. galls.
48 U.S. pints
i pint (500 c.c.)
a pint (150 c.c.)
1 pint (190 c.c.)
8" (20 . 32 cm.)
7" (17 . 78 cm.)
3 . 25 x 19
4 . 00 x 18
5
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BONNEVILLE
Boreand stroke
...
(T120R)
TECHNICAL
DATA
...
...
...
...
...
...
...
...
...
...
...
9 : 1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Champion N3
2 Amal Concentric 930
190
•106
No. 3
Gearboxsprocket
...
...
...
...
...
...
...
...
...
Chains
...
...
...
...
Front
Rear
...
...
...
...
...
...
...
...
...
...
e" x e" x 106 links
...
...
Gas Tank
...
OilTank
...
Gearbox
...
Primary Chaincase
Front Forks (each leg)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
3.6 U.S. galls.
4.8 U.S. pints
8 pint (500 c.c.)
- pint (150 c.c.)
pint (190 c.c.)
8" (20 . 32 cm.)
7" (17 . 78 cm.)
325x19
4.00x18
Capacity...
Com
p
Sparkplugs
Carburetors
Ca
...
ressionratio
...
p acities
Brakes
...
...
...
...
...
...
...
...
Mainjet
Needlejet
Throttle valve
...
...
...
71 x 82 mm.
2 . 79 x 3 . 23 ins.
...
...
...
649 c.c. (40 cu. ins.)
...
...
...
...
...
...
...
Front, diameter...
Rear, diameter
...
...
...
...
...
...
Tiresize ...
...
...
...
...
Front
Rear
...
...
...
...
...
...
...
6
ClassicBike.biz
19 teeth
8" Duplex x 84 links
'-3
HOW TO USE THIS SPARE PARTS CATALOG
First consult the index on Page 3 for the parts or group of parts which you wish to locate. When
you have located the parts make sure from the end columns that the part you have located does apply to
your machine.
List the quantities required as single units; do not ask for "2 pairs" or "3 dozen".
In case of painted items always state the color required. Painted parts are available only in the colors
or alternatives specified for that model of that particular year.
CARTON PACK LIST
The following sub-assemblies are supplied in carton packs under the C.P. part number stated. The
contents of these carton packs are preserved and will not deteriorate under adverse conditions.
Contents
Part No.
Brake Lining
C.P.38/A.M.2
16 ...
C.P.205
2 ...
16
... Brake lining
NW243
2
...
...
W129
...
... W1734 ...
...
W129
...
...
Rivet
... Brake lining
...
Rivet
Pistons (complete with rings, gudgeon pins and circlips)
E6895
7.5 : 1 C.R.
For use with low grade fuel
E9488
9 :1 C.R.
Standard
E6867
11 : 1 C.R.
Competition use only
.
.
.
.
.
All the above pistons are available in oversizes of 0 010 ins., 0 020 ins., 0 040 ins., (0 25 mm., 0 5 mm., 1mm.)
Valve Guides
C.P.97
E2899
... Inlet guide
(TR6)
E2900
... Exhaust guide
7
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PLEASE NOTE
THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS
INCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN, REVERTING
TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE
ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENT
PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.
SPECIAL WORKSHOP TOOLS
A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING
YOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASES
THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE, AND
THEREFORE, IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN
ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES
IT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.
UNIFIED THREAD FORM
NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOG HAVE THE UNIFIED
FORM OF SCREW THREADS. THIS CHANGEOVER WILL BE CONTINUED AS AND WHEN NEW PARTS
ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS
WILL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS
HAVING THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS IN
THEIR HEADS, STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING
CIRCLES ON THE SIDE.
COLOR
TIGER 650 (TR6R)—
TROPHY 650 (TR6C)— J
Pacific Blue
BONNEVILLE (T120R)—Tiger Gold
Paint is available in aerosol containers only.
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TRIUMPH SPARES
HOW TO ORDER. Every part is indicated by a number, and this should be quoted together with
the description. In order to assist customers, dimensions have been given in many cases where parts
are similar. Parts where possible have been listed in order of assembly and a number of the illustrations
show the assembly order also. With these aids, there should be no difficulty in identifying the parts you
require.
ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OF
THE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS.
WHERE TO OBTAIN. Triumph Spare Parts can only be obtained from an authorised Triumph
Dealer, and we recommend our customers to place their orders with the Triumph Dealer in their district.
When parts not usually asked for are required, and for which the Dealer may have to write or obtain
specially, the postage or carriage incurred becomes payable.
TRIUMPH SPARES ARE NOT SUPPLIED TO PRIVATE OWNERS DIRECT FROM THE FACTORY.
A LIST OF AUTHORISED DEALERS WHO STOCK TRIUMPH SPARES IS AVAILABLE ON REQUEST.
IF DIFFICULTY IS EXPERIENCED IN OBTAINING THE REQUIRED PARTS, THE MATTER SHOULD
BE TAKEN UP DIRECTLY WITH THE TRIUMPH SPARES DEPARTMENT.
Customers are warned against the risk incurred by purchasing parts that are not of genuine Triumph
manufacture. This risk is eliminated if parts are ordered as instructed from recognised Dealers.
PATTERNS AND PARTS FOR REPAIR. It is not necessary to end patterns if the part number
is quoted. The sending of patterns often delays the order as parcel post or rail takes longer than letter post.
Parts sent to Coventry for repair, replacement, or as patterns should bear the sender's Name and
Address and clear instructions should accompany the parts. In your own interest send a copy of the advice
note under separate cover. All parts must be forwarded carriage paid and care should be taken to ensure
that all remittances are sent separately and not enclosed with the parts. Fragile units such as cylinders,
etc., should always be boxed to avoid damage in transit. Complete machines should have all fitments such
as windscreens, driving mirrors, tools, etc., removed by the sender before despatch, as it is impossible for
us to accept responsibility in the event of loss in transit. We are always pleased to give estimates for overhauling and repairs, but should an estimate not be accepted, a charge will be made covering cost of dismantling
and re-assembling, if carried out. Work cannot be accepted at the factory direct from private owners.
Communications relating to Parts should be addressed to the SPARES DEPARTMENT and for repairs,
guarantee claims and technical advice to the SERVICE DEPARTMENT, Triumph Engineering Co. Ltd.,
Meriden Works, Allesley, Coventry. In order to facilitate quick reference, the quoting of any number,
invoice number or reference from previous communications is essential. Accessories not of our manufacture should be sent direct to the actual makers, whose Names and Addresses appear below.
PROPRIETARY GROUP
Ancillary equipment which is fitted to our motor cycles is of the highest quality and is guaranteed by
the manufacturers and not by ourselves. Any repairs or claims should be directed to the actual makers
or their local agents who will always give owners every possible assistance. The following are the addresses
of the various manufacturers:
CARBURETORS
Messrs. Amal Ltd.,
Holdford Road,
Witton,
Birmingham, 6.
CHAINS.
Renold Chains Ltd.,
Wythenshawe,
Manchester.
TIRES.
Dunlop Rubber Co. Ltd.,
Fort Dunlop,
Birmingham, 24.
The Avon Rubber Co. Ltd.,
Melksham,
Wilts.
SPARK PLUGS.
Champion Sparking Plug Co. Ltd.,
Feltham,
Middlesex.
I NSTRUMENTS.
Messrs. Smiths Industries Ltd.,
Cricklewood Works,
London, N.W.2.
SUSPENSION UNITS.
Messrs. Girling Ltd.,
Birmingham Road,
West Bromwich,
Staffordshire.
ELECTRICAL EQUIPMENT.
Messrs. J. Lucas Ltd.,
Gt. Hampton Street,
Birmingham, 18.
ClassicBike.biz
33
39
20
21
22
23
24
25
Fig. 1. CRANKSHAFT AND CONNECTING RODS
10
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
CRANKSHAFT AND CONNECTING RODS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Not illus.
Not illus.
Not illus.
E12600
E4643
E3903
E3905
El 2425
*E12601
E11003
E3114
E9525
E1511
E6576
S2016
E3586
E9488
E6864
E6865
E6861
E6869
E1591
E12662
E4573
El 00082
54213901
E3975
E3977
E1580
E4564
E4565
E6159
E400
E12719
E1558
E11007
E6523
E11063
E9989
E9988
E3300
E2879
E12663
E8038
E12660
CRANKSHAFT AND FLYWHEEL ASSEMBLY ...
...
...
CRANKSHAFT C/W. OIL TUBE
...
...
...
...
...
Oil tube
...
...
...
...
...
...
Screwed plug
...
...
...
...
...
...
Flywheel ...
...
...
...
...
...
...
...
Flywheel bolt
...
...
...
...
...
...
...
Washer
...
...
...
...
...
...
...
...
Crankshaft stud (18 in. O.A.) ...
...
...
...
...
CONNECTING ROD ...
...
...
...
...
...
...
Small end bush ...
...
...
...
...
...
...
Connecting rod bolt
...
...
...
...
...
...
Self locking nut ...
...
...
...
...
...
...
Big end bearing (Available in —•010 in. and —•020 in. undersizes)
PISTON COMPLETE 9 : 1 C.R. ...
...
...
...
...
Taper compression ring ...
...
...
...
...
...
Oil control ring ...
...
...
...
...
...
...
...
...
...
...
...
Gudgeon pin (short)
...
...
...
...
Circlip
...
...
...
...
...
Main bearing, right
...
...
...
...
...
...
...
...
...
Motor sprocket, 29 teeth Duplex ...
...
...
...
Distance piece ...
...
...
...
...
...
...
...
...
...
...
...
Rotor key
...
...
..
...
...
...
...
rotor (99-0739) ,S'J2A. 22 7...
...
...
...
...
...
...
...
Tab washer
...
...
...
...
...
...
...
...
...
...
Nut
...
...
...
...
...
...
...
...
...
Key
...
...
...
...
...
Timing pinion ...
...
...
...
...
...
...
...
...
...
...
...
Nut
...
...
...
...
...
...
INTERMEDIATE WHEEL
...
...
...
...
...
Intermediate wheel bush...
...
...
...
...
...
...
...
Camshaft wheel...
...
...
...
...
...
...
...
Camshaft key ...
...
...
...
...
...
...
...
Inlet camshaft nut
...
...
...
...
...
...
Exhaust camshaft nut ...
...
...
...
...
...
...
...
Inlet camshaft, ...
...
...
...
...
...
...
EXHAUST CAMSHAFT
...
...
...
...
...
Tachometer drive plug ...
...
...
...
...
...
...
...
Clamping washer
...
...
...
...
...
...
Main bearing, left
...
...
...
...
...
...
Spacer
...
...
...
...
Shim (0 . 010 in.) Engine sprocket ...
...
...
...
...
...
Shim (0 . 030 in.) J
* Use D524 Loctite Sealant
II
ClassicBike.biz
1
1
1
1
1
3
3
1
2
2
4
4
4
2
4
2
2
4
1
1
1
I
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
As required (up to 4)
As required (up to 4)
Fig. 2. CRANKCASE
12
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
CRANKCASE
1
E11266
CRANKCASE DRIVE SIDE ...
E10287
Camshaft bush
...
E10287
Camshaft bush
...
E5976
Chain tensioner abutment
E12274
CRANKCASE TIMING SIDE
E10286
Camshaft bush
...
E4538
Scavenge pipe
...
E6386
Locating peg (at oil pipes)
T989
Hollow dowel
...
T912
Locating peg (LAS at thrust washer)
T1606
Needle roller bearing, layshaft
E375
Intermediate wheel spindle
E8751
Hollow dowel ...
E3716
Hollow dowel ...
S1873
Screw
14-1445
Stud
...
S25-2 0-q1q6Plain washer
1 0303
Nut
...
E1532
Hollow dowel, tappet oil feed
E9330
Oilway plug
...
F1880
Copper washer ...
51871
Tachometer drive plug (L.H. thread)
E8896
Fibre washer ...
51863
Oil pipe stud ...
S1865
Cylinder stud ...
S1872
Plug, timing hole
51870
...
Bolt
14-6220
Bolt
14-6223
Bolt
14-0230
Bolt
S1823
Bolt
...
D2330
Plain washer
14-1302
Nut
...
E9336
Crankcase filter...
E5315 70-P g1 Joint washer ...
T2167
Drain plug (with level tube)
T1257
Fibre washer
S543
Level plug UN ...
E2160-7/32 Copper washer ...
T2259
Drain and adjuster plug
T1738
Fibre washer
T1920
Blanking plug ...
12166
Filler plug UN ...
E8782
"0" ring
...
14-6242
Bolt
...
S669
Stud
...
E8892
Protection blade
Self locknut UN
1 1301
Rubber plug (for protection blade stud hole)
E7573
Nut, exhaust ties
14-0402
Breather cover plate assembly
E11072
Screw ...
E11075
13
ClassicBike.biz
•••
•••
•••
•••
1
1
1
1
1
2
Reference only
Reference only
2
... 1
... 1
... 1
... 1
... 1
... 2
1
2
2
2
...
...
•••
•••
•••
•••
...
1
2
1
8
...
...
...
...
... 2
... 10
... 5
...
...
...
...
...
...
...
...
•••
•••
.••
•••
2
2
1
1
1
1
1
2
...
...
(TR6C 3 off)
(TR6C 7 off)
(TR6C 4 off)
1
1
(Except TR6C)
(Except TR6C)
Fig. 2 CRANKCASE
14
ClassicBike.biz
Ref. No.
Pprt No.
DESCRIPTION
QUANTITY REMARKS
CRANKCA^ iE (continued)
53
54
.55
56
57
58
59
60
...
...
...
...
E9335
Outlet stub
Joint washer ...
...
E11460
...
...
Screw ...
...
...
E11077
...
...
Tube, primary chain oiler
E11078
...
...
...
...
...
Clip
E4705
...
...
...
S26-260-g2S0 Spring washer ...
...
...
...
14-0101
Bolt(,'-6 in. U.H.)
Grommet, alternator leads. —external
E11345
15
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
2
1
1
1
1
1
5
3
2
11
6
7
8
19
18
15
16
17
-13
14
Fig. 3. OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS
16
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
...
E9421
OIL PUMP
Reference only
Pump body...
...
E9269
Feed plunger
Scavenge plunger ...
E6681
Drive block
...
E495
Valve ball ( in. dia.)
570-7 0-2363
...
E403
Valve spring
Screwed plug
E2360
E11461
Joint washer
...
S1684
Oil pump stud ...
Serrated washer
E3887
S1906
Nut
...
E122107/-2369 Oil release valve
E1670 60-335 Fibre washer
Stud
...
51876
Joint washer
E5660
Inlet manifold
E9973
S25-136p0-12y$ Plain washer
Nut
51877
Stud
S1996
Cup
...
E9555
"0"
ring
E9554
Nut
...
...
1 1301
...
Inlet tappet guide
E9352
Exhaust tappet guide ...
E9353
Copper washer ...
E1612
...
...
...
Set bolt ...
H200
0
5.9/0.iy
7Q.7
3
Inlet
tappet
E3059R
Exhaust tappet
E8801
'0' Ring
E7563
...
17
ClassicBike.biz
1
1
1
1
1
2
2
2
1
2
2
2
1
1
4
2
1
4
4
2
2
2
2
1
1
2
2
2
2
2
TR6
e--58
E3--56 34 33
37
35
24
42
36
X
51
32
31 27
;
41
!,
45
p
43
52
48 49
44 47 39 40 43
x---29
I
28
25 46
5021
30
^'
4
22
= i
18
^_^ r^
19
20
26
Ili
^1111^^1
ffI1
8
14-
\\_
23
10
1
7
13
2
3
1
B4
o.,
Fig. 4. CYLINDER BLOCK AND HEAD, TR6R, TR6C
18
ClassicBike.biz
Ref. No. Part No.
I
DESCRIPTION
QUANTITY
CYLINDER BLOCK AND HEAD, TR6R, TR6C
I
2
3
4
5
6
6a
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
E6309
Cylinder base washer ...
...
...
E6304
...
Cylinder block ...
...
...
S692
Cylinder base nut
...
...
...
E2620
Push rod
...
...
...
...
E12575
Cover tube
...
...
...
...
E7310
"0" ring, push rod cover tube (bottom)
E11283
"0" ring, push rod cover tube (top)
E4547
Cylinder head gasket ...
...
...
E12354
CYLINDER HEAD c/w GUIDES ...
E2899 71'-3292
Inlet valve guide ...
...
...
E2900 7/- 3293
Exhaust valve guide
...
...
E9516
Exhaust pipe adaptor
...
...
E4603
Inlet valve
...
...
...
...
E2904
Exhaust valve ...
...
...
...
Bottom cup
E6439
...
...
...
...
E4221
Inner valve spring (red spot) ...
...
E7400
Outer valve spring (green spot)
...
E1543
Top collar
...
...
...
...
99-00637/-37y8Split cotter
...
...
...
...
E327
Cylinder head bolt
...
...
...
Plain washer ...
...
...
F2184
...
E4771
Bolt
...
...
...
...
...
S25- 360-'/2Y7 Plain washer ...
...
...
...
...
E3253CO-3SY1Sealing ring
...
...
...
Inlet
rocker
box
...
...
...
E12350
Exhaust rocker box ...
...
...
E12351
...
...
...
Joint washer ...
E12599
...
...
...
Rocker box bolt
51875
...
...
...
Rocker
box
nut...
14-0301
...
...
...
Plain washer ...
E3302
...
...
...
Rocker
box
stud
14-1401
...
...
...
S25-1360-y2Y Plain washer ...
Cylinder
head
stud
(for
torque
stay)
14-1435
...
...
...
E46107/-27'1`1 Inspection cap ...
...
...
...
Joint
washer
...
E3751
...
...
...
...
Locking
spring
E4609
...
...
...
WE17000 - qf 263 Fibre washer ...
...
...
...
...
Screw ...
14-2203
ROCKER (right exhaust, left inlet) ...
E1457
ROCKER (left exhaust, right inlet) ...
E1458
...
...
Rocker ball pin ...
E10070
...
...
Rocker adjusting pin ...
E1513
Adjuster lock nut
...
...
...
E470
...
Thrust washer, fin. ...
...
E1575
...
...
Spring washer ...
...
E1574
...
...
...
Rocker spindle ...
E1512
...
...
...
Dowel, rocker box
E12361
...
...
Thrust washer, I in. ...
E1330
...
...
...
...
Access plug
E12079
...
...
...
...
Washer ...
E12080
...
...
...
Bolt, cylinder head
E12362
...
...
...
Bolt, rocker box
S588
19
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
8
4
2
2
2
1
1
2
2
2
2
2
4
4
4
4
8
4
4
1
1
2
1
1
2
4
6
6
6
4
2
4
4
4
4
4
2
2
4
4
4
6
4
2
4
2
4
4
4
4
REMARKS
58
57
56 3 4
33
17
16
15
14
1
B4
Fig. 4. CYLINDER BLOCK AND HEAD, TR6R, TR6C
20
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
CYLINDER BLOCK AND HEAD, TR6R, TR6C (continued)
52
53
54
55
56
57
58
E12598
E4752
E11707
D2332
E12597
D2331
14-1303
Spacer ...
Sealing ring
Sleeve ...
Washer ...
Distance piece
Washer
Nut
...
...
...
...
...
...
...
...
...
...
...
...
For torque stay
J
...
...
...
...
...
...
...
21
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
4
2
2
4
2
2
2
REMARKS
^-
67
66
1
-
_65
B5
Fig. 5. CYLINDER BLOCK AND HEAD, T120R
22
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY REMARKS
CYLINDER BLOCK AND HEAD, T120R
1
2
3
4
.5
6
6A
7
8
E6309
E6304
S692
E2620
E12575
E7310
E11283
E4547
E12356
9
10
E5347
E3827 7/-
11
12
13
14
15
16
17
18
19
...
Cylinder base washer ...
...
...
Cylinder block ...
...
...
Cylinder base nut
...
...
...
Push rod
...
...
...
Cover tube
...
...
"0" ring (bottom)
...
...
"O" ring (top)
...
Cylinder head gasket ...
CYLINDER HEAD c/w GUIDES
3Z/
42
43
44
45
46
47
48
49
50
51
52
53
...
...
...
...
1
...
...
•..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
F2184
38
39
40
41
2
2
1
Carburetor adaptor, right
29
35
36
37
Reference only
...
...
...
E9551
...
E4792
S1932
Plain washer
...
...
...
..•
...
...
...
...
...
Bolt
E4771
...
...
...
...
S25-36O-S/2g7 Plain washer
...
...
...
...
E3253 6pO-3S 1 'Sealing ring
...
...
...
Inlet rocker box
E12350
...
...
...
Exhaust rocker box
E12351
...
...
...
E123657/-2599 Joint washer ...
...
...
...
Rocker box bolt
51875
...
...
...
...
...
Nut
14-0301
...
...
...
...
Plain washer
E3302
...
...
...
Rocker box stud
14-1401
...
...
...
525 - I 36042 4'8' Plain washer
Cylinder
head
stud
(for
torque
stay)
14-1435
...
...
...
...
E4610 7I-2.7Y y Inspection cap
...
...
...
...
Joint washer
E3751
...
...
...
...
Locking
spring
E4609
...
...
...
WE17060"%263Fibre washer ...
...
...
...
...
...
Screw
14-2203
ROCKER
(right
exhaust,
left
inlet)
...
E1457
ROCKER (left exhaust, right inlet) ...
E1458
...
...
Rocker ball pin ...
Ell 0070
...
...
...
Rocker
adjusting
pin
E1513
...
...
...
Adjuster
lock
nut
E470
...
...
...
in.
Thrust
washer,
.
E1575
•
...
E1574
Spring washer
...
...
...
1
1
8
4
2
2
2
1
1
...
E3828 7/ - 3^9 S
E9550
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Connector ...
...
...
...
...
...
...
...
...
...
...
...
...
...
E6916
...
...
...
...
...
...
...
...
...
...
...
...
...
Inlet valve guide ...
...
Exhaust valve guide
Carburetor adaptor, left
21
22
23
24
25
26
27
28
30
31
32
33
34
...
...
...
...
...
...
...
...
...
Sleeve for head bolts passing through inlet tracts
...
...
Balance pipe
...
Adaptor locking nut
...
Exhaust pipe adaptor
E9516
...
...
Self-locking nut
14-1301
...
...
...
...
Cup
E9555
...
...
Insulating ring ...
E9554
...
...
...
Inlet valve
E4603
...
...
Exhaust valve ...
E2904
...
...
...
Bottom cup
E6439
Inner valve spring (Red spot)
E4221
Outer valve spring (green spot)
E7400
...
...
Top collar
...
El 543
...
...
...
99-00627/-375/BSplit cotter
...
...
Cylinder head bolt
E327
20
...
...
...
...
...
...
...
...
...
...
23
ClassicBike.biz
2
1
2
2
4
4
4
2
2
4
4
4
4
8
4
4
1
1
2
1
1
2
4
6
6
6
4
2
4
4
4
4
4
2
2
4
4
4
6
4
52
I
48 49 52 47 53
47 48 62
34 55
38
37
57 58
16
59
12
29
30
31
9s _
28
-17-
'-i
4
j- ,
29
B5
1
Fig. 5. CYLINDER BLOCK AND HEAD, MOB
24
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
CYLINDER BLOCK AND HEAD, MOR
54
55
56
57
58
59
60
61
62
63
64
65
66
67
E1512
E12361
El 330
E12079
E12080
E12362
S588
D2332
E12598
E4752
E11707
E12597
D2331
14-1303
Rocker spindle ...
Dowel, rocker box
Thrust washer, in. ...
...
Access plug
...
Washer ...
Bolt, cylinder head
Bolt, rocker box
Washer ...
Spacer ...
Sealing ring
Sleeve ...
Distance piece
For torque stay
Washer
Nut
•••
•••
(continued)
...
•••
i
•••
•••
•••
•••
•••
•••
..•
..•
...
25
ClassicBike.biz
2
4
2
4
4
4
4
4
4
2
2
2
2
2
REMARKS
11
Ii•II-
Fig. 6. AMAL CARBURETOR, TR6R, TR6C
26
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
AMAL CARBURETOR TR6R,
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
D2183
fly
928/098
622/086
928/060
622/131
622/067
622/124
928/062
622/129
928/103
622/077
622/076
622/082
622/122
622/128
376/100
622/069
622/071
622/055
622/073
622/068
376/093
622/078
376/092
622/147
622/151
F13507
E9711
CARBURETOR (R930/60) less "0" ring ...
Mixing chamber (930/005)
...
...
Mixing chamber top (99-1032) ...
...
Screw (99-0521) ...
...
...
...
Throttle valve (3z cutaway) (99-0527)...
Throttle return spring (99-1033)
...
Needle clip (99-0510) ...
...
...
Needle (99-1036) ...
...
...
...
Air slide (99-0528)
...
...
...
Spring (99-1038) ...
...
...
...
Air valve guide sleeve (99-1037)
...
Throttle stop screw (99-0516) ...
...
Air adjusting screw (99-0515) ...
...
"0" ring (99-0520)
...
...
...
Needle jet (0 . 106) (99-1035) ...
...
Jet holder (99-1034)
...
...
...
Main jet (230) (99-0441) ...
...
...
Float (99-0512) ...
...
...
...
Float spindle (99-0513) ...
...
...
Float chamber (99-0506)...
...
...
Joint washer (99-0514) ...
...
...
Needle (99-0511) ...
...
...
...
Filter (99-0438) ...
...
...
...
Banjo bolt (99-0517)
...
...
...
Fibre washer (99-0437) ...
...
...
Drain plug (99-1152)
...
...
...
Washer (99-1153)...
...
...
...
Petrol pipe
...
...
...
...
...
' • O" ring
...
...
...
...
...
5 F T/Q/
p,',
r
27
ClassicBike.biz
QUANTITY REMARKS
TR6C
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..•
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Fig. 7.
Fig.
7. AMAL
AMAL CARBURETOR,
CARBURETOR, T12OR
T120R
28
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
AMAL CARBURETOR T12OR
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
D3492
D3491
928/098
622/086
928/060
622/131
622/067
622/124
928/062
622/129
928/103
622/077
622/076
622/082
622/122
622/128
376/100
622/069
622/071
622/055
622/073
622/068
376/093
622/078
376/092
622/147
622/151
F13508
E9711
CARBURETOR—L.H. (L930/67) }
„ „
Less 0 ring
CARBURETOR—R.H. (R930/66)
Mixing chamber (L930/005 and R930/005)
Mixing chamber top (99-1032) ...
Screw (99-0521) ...
Throttle valve (3 cutaway) (99-0527) ...
Throttle return spring (99-1033)
Needle clip (99-0510)
...
Needle (99-1036) ...
Air slide (99-0528)
...
Spring (99-1038) ...
Air valve guide sleeve (99-1037)
Throttle stop screw (99-0516) ...
Air adjusting screw (99-0515) ...
"0” ring (99-0520)
...
Needle jet (0 . 106) (99-1035)
...
Jet holder (99-1034)
Main jet (190) (99-0446)
Float (99-0512) ...
Float spindle (99-0513) ...
Float chamber (994506)...
Joint washer (99-0514) ...
Needle (99-0511) ...
Filter (99-0438) ...
Banjo bolt (99-0517)
...
Fibre washer (99-0437) ...
Drain plug (99-1152)
...
Washer (99-1153)
Petrol pipe
...
"0" ring
asE Te/
P H fAr
29
ClassicBike.biz
1
4
•••
•••
•••
•••
1
1
2
•••
•••
1
•••
•••
•••
1
•••
1
1 ,
1
2
Each
carburetor
8
4
7
5
2
I^
4
1
8
ril
0
6
Y
24
23
1
©-- 11
19
10
9
0
\
6m ^
13
,^
12
22
B7
Fig. 8. TIMING COVER AND CONTACT BREAKER
30
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
TIMING COVER AND CONTACT BREAKER
1
2
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Not illus.
E9246
Timing cover ...
...
...
E4016
Patent plate
...
...
...
D208-50 0-/2SSHammer-drive screw ...
...
E4568
Oil seal ...
...
...
...
E6387
Oil seal (0 . 020 in. undersize) ...
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
E4569
Circlip ...
...
...
...
...
...
...
...
T989
Hollow dowel ...
...
...
...
...
Screw ...
...
...
14-6609
...
...
...
...
...
...
14-6608
Screw ...
...
...
...
...
...
...
14-0208
Bolt
...
...
...
...
...
...
S25-4370-&/63 Plain washer ...
Rubber grommet
...
...
...
...
...
E4707
...
...
...
...
...
Pillar bolt
...
E7680
...
...
...
...
...
Plain washer ...
E6559
...
...
...
...
...
Cover ...
...
E8737
...
...
...
...
...
Joint washer ...
E11462
...
...
...
...
...
GS29960-qZr Serrated washer
...
...
...
...
...
Screw (4 in. U.H.)
E7354
...
...
AUTO ADVANCE UNIT (99-0771)
54419340
...
...
...
...
Spring set (99-0757)
54415642
CONTACT BREAKER PLATE ASSEMBLY (99-0768)
54419097
...
...
...
Contact set (99-0772) ...
54419827
...
...
...
Pin, adjustment (99-0769)
54419220
...
...
...
...
D213360-37/c/ Oil pressure switch ...
...
...
...
...
Cover pressure switch
D2045
...
...
...
Timing label for C.B. cover ...
D2138
31
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
1
1
3
2
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
3
5
I
1
1
2
2
1
1
2
2
1
1
1
2
2
1
I
1
For reground
crankshaft
12
17
18
13
14
B8
Fig. 9 GEARBOX INNER COVER AND SELECTORS
32
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
GEARBOX INNER COVER AND SELECTORS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
T4293
14-1427
S1907
E3446
14-6608
14-7023
T989
T1614
T1607
T412
T45
T4055
T397
11896
—
T4308
T4307
T3989
T4288
T4289
T4290
T4291
F4771
Gearbox inner cover
...
...
Stud
...
...
...
...
...
...
...
Bolt
Washer ...
...
...
...
...
...
...
...
Screw
...
...
...
Screw
...
Hollow dowel ...
...
...
...
...
Layshaft bearing
Thrust washer ...
...
...
Gearchange spindle bush
...
Kickstarter stop
...
...
...
Gear selector cam plate
Camplate operating quadrant...
...
Quadrant spindle
...
..
Split pin (64 in. x 18 in.)
...
Mainshaft selector fork
...
Layshaft selector fork
...
...
Selector fork rod
...
...
...
Leaf spring
...
...
Leaf spring support
Leaf
...
spring top plate ...
...
...
...
Tab washer
...
...
...
...
Screw
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
33
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
1
1
1
1
4
1
2
I
I
1
1
1
Reference only
1
1
1
1
1
1
1
2
34
ClassicBike.biz
U)
w
Q
0
0
z
4
w
LL
I
w
x
0
=
4
w
0
.
,
1. w
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
GEARBOX SHAFTS AND GEARS
1
2
3
4
5
6
7
8
9
10
11
12
12
12
12
12
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
T4158
MAINSHAFT c/w LOW GEAR (16D
T3988
Clutch rod bush ...
T4332
MAINSHAFT HIGH GEAR (26T)
High gear bush ...
T400657— 1370
Mainshaft third gear (23T) ...
T3889
Mainshaft second gear (20T) ...
T4335
LAYSHAFT LOW GEAR (30T)
T3862
Low gear bush ...
T928
Layshaft second gear (26T) ...
T3861
T3890
Layshaft third gear (22T)
...
Layshaft c/w high gear (20T)
T4345
Gearbox sprocket (15 teeth)...
T1952
Gearbox sprocket (16 teeth)...
T1953
Gearbox sprocket (17 teeth)...
T1916/0/7
Gearbox sprocket (18 teeth)...
T1917/0It
Gearbox sprocket (19 teeth)...
T1918/0/9
Gearbox sprocket (20 teeth)...
T1919/020
Tab washer
T2116
Gearbox sprocket nut
T440
D3556 p-ovve High gear bearing
Circlip
T489
Oil seal ...
T946
Mainshaft bearing
D3552
Circlip
T4113
Plain washer
T1962
Pinion sleeve
T1963
Pinion spring ...
T1250
Kickstarter pinion
1730
Kickstarter ratchet
T731
Tab washer
...
T2240
Nut
•••
5594
Clutch operating rod ...
T1736
•••
•••
•••
•••
•••
•••
See pages 4 to
5 for standard
sizes
•••
•••
•••
•••
•••
•••
•••
•••
•••
WIDE RATIO GEARS
3
6
9
11
T3657
T4161
T4160
T4159
MAINSHAFT HIGH GEAR (28T)
Mainshaft second gear (19T) ...
Layshaft second gear (27T) ...
Layshaft c/w high gear (18T)
...
CLOSE RATIO GEARS
1
3
5
6
7
9
10
11
T4173
T4172
T4169
T4167
T4163
T4166
T4168
T4162
MAINSHAFT c/w LOW GEAR (18T)
MAINSHAFT HIGH GEAR (24T)
Mainshaft third gear (23T) ...
Mainshaft second gear (21D ...
LAYSHAFT LOW GEAR (28D
Layshaft second gear (25T) ...
...
Layshaft third gear (23T)
Layshaft c/w high gear (22T)...
35
ClassicBike.biz
1
15
14
21
27
4
^C
20
25.
24
26
O
2
^5
11
10,
\\\ \<:
45
W,
'
6
>
/^^ /7\3 v9
34
7
34
30
8
46
- \
31
1
47
36
BlO
Fig 11. GEARBOX OUTER COVER
36
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
GEARBOX OUTER COVER
37
38
39
40
GEARBOX OUTER COVER
...
Kickstarter spindle bush ...
...
...
Gearchange spindle bush
Kickstarter spring anchor pin ...
Guide plate stud ...
...
...
...
...
Oil seal
...
..,
T1 956
Oil seal housing .... 7_.Q0
T1 955
^i
Gearchange quadrant
T408/9
...
...
...
E330960-353° Rubber "0" ring
Quadrant return spring
...
...
T404
Gearchange quadrant plunger
...
T406
...
...
...
Plunger spring ...
T405
...
...
...
Guide plate
...
T407
...
Serrated washer
...
...
E1612
...
...
...
...
...
Nut
301
...
Kickstarter quadrant ...
...
T4117
Kickstarter return spring
...
...
T31
...
Kickstarter axle
...
...
T24A57-'17$
...
T3629$7- S'3W7 CLUTCH LEVER ASSEMBLY
...
...
Clutch
lever
...
12191 S7-', VY/
...
Lever
shaft
...
...
T1710
Ball,
8
in.
diam.
...
...
...
D2368
...
Thrust
plate
...
...
T3761
Return spring
...
...
...
T1712
6
Plain
washer
73
GS12757 3
...
Split pin (4
— 60.2701
6 in. x fin.) ...
...
Countersunk
screw
...
...
51879
...
...
..
Rubber
cover
...
T1646
...
Abutment
for
clutch
cable
...
T3762
...
...
...
S25-3 o-c{2g7 Plain washer ...
...
...
...
...
...
Nut
14-0302
...
...
...
...
Screw ...
51878
...
...
...
...
...
Screw
14-6609
...
...
...
...
...
Screw
14-6608
...
...
...
Gearchange
pedal
T3757 5-70/O
...
...
...
...
...
Bolt
14-0201
...
...
...
Pedal rubber ...
T2450
...
T3632 57-7018 FOLDING KICKSTARTER ...
7
...
...
Kickstarter lever ...
T2173 5 -W 3
...
...
Kickstarter pedal ...
T1 272 57-70/7
41
T1167
...
...
...
...
...
...
42
43
44
45
46
47
Steel ball, I in. diam.
...
S70-3t0 236Y
...
...
Pedal bolt
S541
Pedal rubber ...
...
...
T2330
Cotter pin c/w nut and washer
T4356
...
...
...
Domed nut
S544
...
...
...
Filler plug
T2166
<< O" ring
...
...
...
E8782
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 1
... 1
... 1
... 1
... 1
... 1
... 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
48
T3760
T23
T57
T47
S547
14-0
Pedal locating spring
37
ClassicBike.biz
...
...
...
...
...
...
...
2
.. 9
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
4
1
1
1
1
2
2
2
1
4
4
1
1
1
1
1
1
3
1
1
1
Reference only
2
1
1
2
1
2
2
1
...
...
...
...
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
1
1
38
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CLUTCH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
6
7
8
12
Clutch securing nut
5586
...
Hub
...
T3929
Thrust
washer
...
13931
...
Roller ...
T394
Sprocket
and
housing
(58
teeth
Duplex)
T1570
Centre ...
T1719
...
Inner plate
T1720
Countersunk screw ...
T1040
Shock absorber spider
T2538
Drive rubber (large) ...
T1722
Rebound rubber (small)
T1723
Outer
plate
T1724
...
T423A 57 n q7S qScrewed pin
T136257—YiS3 Driving plate (bonded)
Driven plate
T1363
Pressure plate
T2156
Adjuster pin
T2159
Nut
...
14-0403
Spring cup
T1931
Spring ...
T1830
Pressure nut
T2526
...
S66-1 co-nr 3 Key
Cupped washer
T2279
14438
T4436
5644
T4437
LATER MODELS USE THE FOLLOWING:...
Centre (shock absorber body)
Inner plate
...
Bolt
Outer plate
39
ClassicBike.biz
...
...
...
..•
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
••
1
1
1
20
1
1
1
6
1
3
3
1
3
6
6
1
1
1
3
3
3
1
I
1
1
3
1
REMARKS
T
rn
N
^^
az
ClassicBike.biz
M
M
N
N
n
N
o
M
MMN
N
N
("5
N
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m
N
N
O Z
I
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0
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Q
W
H
U
r
r
U
z
a
a
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r
W
M
O u
(V
T
Ref No. Part No.
CHAINCASE AND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
QUANTITY
DESCR IPTION
D1915 /OOOSG//Okear chain, I in. x in. x 106 links
...
...
Joint washer ...
E11419
...
...
...
Cover plate
E7037
...
...
...
Oil seal ...
E7565
...
Countersunk screw ...
E3821
E597670 -Sb87 Chain tensioner abutment ...
REMARKS
CHAINS
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
I
1
1
1
6
1
...
...
Chain tensioner blade...
E6061
...
...
...
...
...
Tie
rod
E4152
...
...
...
...
Trunnion
E5977
...
...
Adjuster sleeve nut ...
E9703
Primary chain, I in. Duplex x 84 links
D477
...
...
...
...
Stator stud
S1866
...
...
...
...
Stator stud
S1867
...
...
Stator, RM21 (99-1006)
47205
...
...
...
...
Sleeve nut
E9360
...
...
...
Rubber grommet
E4144
...
...
...
...
Plastic
sleeve
E5449
y7
q
...
...
...
525-340- {Z Plain washer ...
...
...
...
Self-locking nut
14-0702
...
...
...
...
Joint
washer
E11463
0 2
-...
...
...
...
4 7 Chaincase
E9245
...
...
..
...
Rotor cover
T2440
...
...
...
Joint washer ...
E11457
w
...
..
...
...
Scre ...
F4129
...
..
...
Copper washer
E2441
...
...
Filler plug
...
...
T2166
...
...
...
...
"0" ring
E8782
...
...
...
...
Screw ...
14-6608
...
...
...
...
Screw ...
14-6620
d
...
...
...
...
Dome nut
S544
r
...
..
...
Coppe washer ...
F1880
...
..
...
Timing pointer ...
T2443
...
Level plug
14-6101
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..•
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
I
1
1
I
1
2
1
1
1
1
1
3
3
1
7/
41
ClassicBike.biz
I
1
1
3
1
1
1
6
2
2
2
I
(also listed with
crankcase group)
42
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
FRAME
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Not illus.
Not illus.
Not illus.
Not illus.
Fl 208983-4283 Frame ...
E127 44 7/-27 yy Oil filler cap
D3616
"0" ring
F13142
Dipstick ...
F12826
*Oil filter and sump plate
F12829
*Gasket
D2330
Washer
52109
Stud
Sump plate to frame
14-1302
Nut
S1945
*Drain plug
E12505
Joint washer
E6930 7/-7/7 6 Oil junction block
E11458
Joint washer ...
}
Nut
S1908
Junction block to crankcase
E3 44 6
Wash
Washer
E12428
Rocker oil pipe
El 335
Washer ...
E1435
Nut
E12337
Rocker feed pipe
...
E811160-3ny Clip—rocker feed pipe
E12345
Oil return pipe
E6848
Clip—feed and return pipes
E12347
Oil feed pipe
E12349
Oil vent pipe ...
E11149
Crankcase breather pipe—front
F11614
Crankcase breather pipe—rear
F11610
"T" piece
D2253
Clip—breather pipe—front ...
D2252
Clip—breather pipe—rear ...
F11615
Clip—breather pipe to fender
H3894
Screw
F4717
Nut
...
F12627g3-qqq/ Centre stand
F13793
Spring ...
S2077
Pivot bolt
14-1304
Nut
...
Prop stand
F11560
F7021
Bolt
14-1303
Nut
F8382
Spring ...
D3361 ,-3m Transfer "Made in England"
D2452
Transfer—Safety Standards
Bolt }
14-0114
Prop stand stop
14-0402
Nut
1
1
1
4
4
4
•••
•.•
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
1
4
4
1
2
1
4
1
1
1
1
1
2
1
4
4
4
1
1
2
2
1
1
1
1
1
1
1
1
* LATER MODELS USE THE FOLLOWING:—
F13642
Oil filter assembly
F12829
Gasket ...
Drain plug
14-0113
F1364393-3/CSump plate
1
2
43
ClassicBike.biz
REMARKS
N
N
N
N^ \ (/ice
44
ClassicBike.biz
m
H
z
0
z
0
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W
0.
H
D
N
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Q
0
LL
0
Z_
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Z_
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LL
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
SWINGING ARM AND SUSPENSION UNITS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
23
24
25
26
27
28
29
30
31
32
33
34
35
F12513
...
...
...
SWINGING ARM
D1841
...
...
...
Grease nipple
WE170 M 7221
...
Washer, grease nipple ...
F1 2521
Bush, pivot arm ...
...
...
F12691
Sleeve, swinging arm pivot ...
...
Distance piece R.H. ...
...
...
F12690
F12689
...
Distance piece L.H. ...
...
F12692
...
...
...
Dirt excluder ...
S2087
Stud, swinging arm pivot
...
...
F12266
Washer, swinging arm pivot ...
...
14-1307
...
Nut, swinging arm pivot
...
...
F12656
Brake torque stay
...
...
...
14-1304
Nut, torque stay to brake plate
D2350
Washer, torque stay to brake plate ...
14-0133
Bolt, torque stay to swinging arm ...
Washer, torque stay to swinging arm
W2330
Nut, torque stay to swinging arm ...
14-1304
...
64052341
SUSPENSION UNIT (D2294)
...
...
64052090
Damper unit
...
Bonded bush (99-0122) ...
...
64533645
9054/171
Spring retainer (99-0107)
...
64544754
Spring, 110 lbs. chrome (99-1139)
Bolt, damper—top
...
...
...
14-0235
Stud, damper—top L.H.
...
S1997
...
...
D2332
Washer, damper—top
...
...
Nut, damper—top
...
14-1303
...
14-0234
Bolt, damper, lower—L.H.
...
Bolt, damper, lower—R.H.
14-2034
...
...
D2321
Washer damper lower
...
...
...
Nut damper lower
14-1303
...
...
...
...
F12641
Chainguard
Bolt,
chainguard
fixing—front
...
14-0206
Washer, chainguard fixing—front ...
D2347
Stop
lamp switch-118SA (99-4028)
34815
...
...
...
...
D35502/ 70/0 Screw ...
...
...
...
...
H1388
Washer ...
45
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
4
2
1
I
4
I
2
1
1
1
1
1
1
1
2
Reference only
4
4
2
2
(1 off TR6C)
1
(TR6C)
2
(3 off TR6C)
2
(3 off TR6C)
1
1
2
2
1
1
1
1
2
2
46
ClassicBike.biz
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W
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LL
LL
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Z
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Ref. No. Part No.
DESCRIPTION
QUANTITY
MOTOR UNIT FITTINGS AND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
FOOTRESTS
F12855
F12854
Footrest L.H....
...
...
...
...
...
...
Footrest
...
...
...
...
...
...
14-0259
D2333
F9279
...
...
Bolt
...
...
...
Washer ...
...
...
Footrest rubber
...
...
PILLION FOOTREST ...
...
Pedal
...
...
...
Hanger bolt
...
...
Bolt
Washer Footrest swivel
Nut
J
Nut
Washer f Footrest to frame
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Footrest rubber ...
...
...
Rear brake pedal
Screw
Stop light adjustment
Nut f
...
...
...
Pivot pin
...
...
...
...
Nut
...
...
...
Washer ...
...
F12841
F9053
F1 3207
14 -0217
F9089
14 -1302
14 -1303
F2184
F9054
F12666
14 -0103
14-0301
S2045
14-1303
E808460-%'Z'/
F12860
—
—
R.H.
...
Rear brake operating rod
...
...
...
...
...
... 1
1
... 2
... 2
... 2
... 2
... 1
... 1
... 1
... 1
... 1
... 1
...
...
...
...
...
...
...
...
...
...
...
...
... 1
... 1
... 1
...
...
...
...
...
...
...
...
...
...
...
...
... 1
... 1
... I
...
...
...
...
...
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Reference only
1
2
1
1
5
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 4
...
...
...
...
...
...
...
...
...
...
...
...
...
"'
...
...
Split pin (• ^!6in. x 8 in.)
-g27
D2393
...
...
...
...
Washer
...
7
93
...
...
F7387
Adjuster nut—brake rod
...
F1 3024
Rear motor plate R.H.
...
...
F1 3023
Rear motor plate—L.H.
...
14 -0115
Bolt
I
14-0116
Bolt
Rear motor plates to frame
14 -1302
Nut
D2330
Washer
14 -0220
Bolt
14-0221
Bolt
pl
Motor to m oto r plates
14 -1302
Nut
D2321
F12846
F12847
S2112
14-0304
D2332
F1 2848
F12849
14-0254
14-1304
D2332
Washer J
'.
14-1303
...
...
...
D2321
Washer
...
...
14 -0126
...
Distance piece—L.H.
Distance piece—R.H.
Motor to frame centre bottom
Stud
Nut
Washer
J
...
Distance piece—L.H.
...
Distance piece — R.H.
Motor fixing front
...
Bolt
...
Nut
...
Washer
J
Steady bracket motor to frame
...
Bolt
Bracket to frame ...
Nut
F1 3537
REMARKS
47
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
1
6
6
2
4
1
1
1
2
2
1
1
1
1
1
...
...
...
...
...
...
1
...
...
...
...
...
...
...
1
1
...
...
...
... 1
...
48
ClassicBike.biz
co
ob
LL
Ref. No.
Part No.
DESCRIPTION
EXHAUST PIPES AND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
E12753
E12756
E10216
E8860
E6744
E6857
E6179
E7471
E7512
E3768
14-0217
14-1202
E9888
E2271
E3768
14-0219
S25-3
14-1302
E12382
E12282
14-0101
14-1301
MUFFLERS, TR6R, T12OR
Exhaust pipe—L.H.
Exhaust pipe—R.H.
Finned clip
Spherical washer Exhaust pipes to cylinder head
Bolt
Exhaust pipe stay
Screw
...
Nut
Clip
"D" washer
Exhaust pipes to coupling pipe •••
Bolt
...
Nut
Coupling pipe
Clip
"D" washer]
Exhaust pipes to mufflers
Bolt
q7 Washer
Nut
Muffler ...
Hanger—muffler and pillion footrest
N ut
QUANTITY
Muffler to hanger
49
ClassicBike.biz
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
••.
•••
•••
•••
•••
•••
1
1
2
2
2
2
2
2
2
4
2
2
1
2
4
2
2
2
2
2
4
4
REMARKS
50
ClassicBike.biz
vi
oc
W
J
W
LL
bO
LL
Ref. No.
Part No.
DESCRIPTION
EXHAUST PIPES, MUFFLERS AND FOLDING
E11900
Exhaust pipe—lower
2
E11901
Exhaust pipe—upper
3
E10216
Finned clip
4
E6744
Bolt
Exhaust pipe to cylinder head ...
5
E8860
Spherical washer
6
E6978
Exhaust pipe stay
7
14-0113
...
Bolt
8
S26-3
Spring washer
9
E7299
Clip—upper
10
E5874
Clip—lower
11
14-0116
Bolt
12
14-0219
Bolt
Exhaust pipes to connector
13
E3768
"D" washer
14
S26-3
Spring washer
15
14-1202
Nut
16
E9673
Connector
17
E2271
Clip
18
14-0219
Bolt
19
"D" washer
Connector to mufflers ...
E3768
20
S26-3
Spring washer
21
Nut
14-1302
Muffler—upper ...
22
E12019
Muffler—lower ...
23
E12020
Muffler—hanger
24
E12511
51822
Bolt
25
Mufflers to hanger
26
S26-3
4° Spring washer f
•••
Bolt
27
14-0115
Hanger to frame ...
Spring washer
28
S26-3
51933
Spacer nut
29
Leg guard
E9680
30
Screw
51953
31
Washer
E9857
32
Leg guard attachment front
Clip
33
E9688
Bracket J
E9696
34
Screw
35
S1954
Washer . Leg guard attachment rear
E9857
36
Clip
37
E9688
38
E12851
-2F? 7 Crankcase undershield...
Hooked stud
39
52096
Nut
...
14-1301
40
Washer ...
41
D2320
FOLDING FOOTREST—R.H.
42
F13139
FOLDING FOOTREST—L.H.
42
F12856
Footrest hanger—R.H.
43
F13140
Footrest hanger—L.H.
43
F12858
...
Footrest pedal
44
F13092
...
Spring
45
F13095
Bolt
14-0216
46
•••
Nut
14-1302
47
Footrest rubber
F9051
48
Bolt
51969
49
Footrest to frame
Washer
F8243
50
1
51
ClassicBike.biz
QUANTITY
REMARKS
FOOTRESTS, TR6C
••• 1
••• 1
••• 2
.•• 2
••• 2
••• 1
••• 3
••• 3
•••
•.•
2
1
2
2
4
2
2
1
2
2
1
1
1
1
1
2
2
2
•••
•••
•••
•••
•••
•••
1
2
2
6L41
3
s—
q\\
a
X40
^
38
Lu
Fig. 19. TELESCOPIC FRONT FORK
52
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
TELESCOPIC FRONT FORK
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
' 19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
42
42
42
43
44
45
46
H4080
FORK ASSEMBLY
H408q74080 FORK ASSEMBLY
Top Yoke ...
H4035
14-0234
Pinch Bolt ...
14-1303
Nut ...
...
E8084
Washer ...
F6738
Lock c/w 2 keys ...
D623 92-6738
Key (state serial No.)
S578
Grub screw
...
H2266
Sealing washer ...
H2270
Brake cable retainer
F8245
Starlock washer ...
H3682
Retaining bracket
Abutment ring ...
F12007
H4031
Taper roller bearing
Dust cover
...
H4028
Bottom yoke and stem
H4082
Pinch bolt
14-0238
Washer
E8084
Nut
14-1303
Stanchion
H4007
End plug
H4076
...
Main spring
H4087
H3954 v-fo8r Outer member—R.H.
H3952 q7- X033 Outer member—L.H.
Cap wheel spindle
H3947
Stud...
52102
Nut
14-0302
Washer
D2428
Drain plug ...
H3894
Washer ...
H3893
Damper tube and valve assembly
H4200/7"0" ring—damper valve
H4003
...
...
Recoil spring
H4009
Cap screw-damper tube
14-1019
Cap screw seal ...
H4004
Oil seal outer member ...
H4001
Scraper sleeve outer member
H4002
Top
cap nut
H4258
...
...
...
...
Washer
H4166
Steering stem nut (without steering damper)
H4029
...
Steering stem nut (with steering damper)
H4092
Headlamp bracket—L.H.
H4058
Headlamp bracket—R.H.
H4060
Headlamp bracket—L.H.
H4088
Headlamp bracket—R.H.
H4090
Nut
51809
Washer
D2338
Headlamp bracket top fixing
Bush
F12209
Spacer
F12211
Oaqe
gor
53
ClassicBike.biz
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
••.
•••
•.•
•••
•••
•••
•••
•••
•••
.••
•••
•••
•••
•••
•••
..•
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
2
4
2
2
2
2
1
1
2
8
8
8
2
2
2
2
2
2
2
2
2
2
2
TR6C
Not TR6C
TR6C
2
2
4
2
a
^
X38
6
^o
,^ L
—43
39
(^'
X13
45
46
X14
5
15
15
18
/ CMS
\
\\
48 42 49
50 19 1 8
^51
24
30
d
2^^
26
28
27^® —25
® --35
BIB
---34
Fig.19. TELESCOPIC FRONT FORK
54
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
TELESCOPIC FRONT FORK
47
48
49
50
51
52
52062
Sleeve nut 1
D2333
Washer
(._
Headlamp bracket bottom fixing
D2630
Grommet r
F9046
Washer j
Nut—damper valve
H4012
F12216 g3-12/0 Clamp washer ...
55
ClassicBike.biz
2
2
2
2
2
4
3
10
4
I
a
77
Fig. 20. HANDLEBAR MOUNTINGS AND STEERING DAMPER
56
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
HANDLEBAR MOUNTINGS AND STEERING DAMPER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
H2291
F1335
S589
H1527
H1529
H1581
H1580
H2221
14-1303
H3875
D2438
H435
H1797
H95
D2329
H4102
—
Handlebar eyebolt
Washer ...
Bolt
...
...
Metalastic bush
...
Hemispherical washer ...
Distance piece ...
Rubber washer ...
Cup
...
Nut
...
Steering damper rod c/w knob
Spring washer
Friction disc
Anchor plate
Spring plate
Washer ...
Bottom nut
Split pin (h x 1)
ClassicBike.biz
2
2
2
2
4
2
2
2
2
1
1
1 Available
1
1
1
Reference only
^
z
N
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^
58
ClassicBike.biz
O
N
N
N
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0
Ix
U.
00
LL
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
FRONT WHEEL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
W3845
W3844
W3818
W3658
W3820
W3819
W3821
W2294
W3969
W3970
W653
D2632
W3797
W3759
W1481
W1237
T280
W3932
W3796
W2058
D2594
14-1303
D2340
W3655
W3987
W3986
D2639 W3762
W3761
W3713
W3714
W3715
W3716
W3717
14-1635
...
FRONT WHEEL COMPLETE
...
RIM, SPOKES AND HUB ASSEMBLY
Wheel rim (WM2-19)
Brake drum and hub
Spoke (R.H.—inner)
Spoke (R.H.—outer)
Spoke (L.H.)
...
Nipple...
Balance weight (short)
Balance weight (long)
...
Bearing
...
Circli
R.H.
Grease retainer—R.H.
Lock ring—R.H. ...
Grease cap inner—L.H.
Grease cap outer—L.H.
L.H.
Circli
...
Distance piece
...
Wheel spindle
Nut wheel spindle
Grommet brake drum
Nut
Anchor plate to fork leg
Washer
Brake anchor plate
Brake lever front ...
Brake lever rear ...
"0" ring brake cam
Tappet brake cam
"0" ring brake tappet
Brake shoe complete
...
...
Return spring
Cage brake shoe adjuster
Micram adjuster ...
...
...
Abutment pressing
Stud-anchor plate torque reaction
59
ClassicBike.biz
1
1
1
... 1
... 10
... 10
... 20
... 40
... as required
... as required
••• 2
••• 1
1
1
1
1
1
1
1
1
1
1
1
1
••• 1
••• 1
••• 2
••• 2
••• 2
2
2
2
2
2
1
60
ClassicBike.biz
bO
LL
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REAR WHEEL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
W3968
REAR WHEEL COMPLETE ...
•••
W3782
RIM SPOKES AND HUB ASSEMBLY
W3784
RIM (Wm 3 x 18) ...
W3724
Spoke (inner—L.H.)
W3725
Spoke (outer—L.H.)
W3726
Spoke—R.H....
W2294
...
Nipple...
W3773
Hub and brake drum
W3468
Tyre security bolt...
W3749
Support ring—L.H.
W653
...
Bearing
W3752
Locking ring—L.H.
W3753
...
Spacer
W1654
Grease retainer—R.H.
W3747
Sprocket 47 teeth
14-0207
Bolt
D2320
Washer . Sprocket to hub
14-1301
Nut
W3856
Brake anchor plate
W3872
Brake cam
W3877
Brake lever
14-1303
Nut
...
D2331
Washer
W3870
Brake pivot
Nut
}
14-0305
Brake pivot to torque arm
D2431
Washer
W3925
Brake shoe complete (leading) ...
W3926
Brake shoe complete (trailing) ...
...
W2328
Return spring (brake shoe)
W3880
Return spring (brake lever)
F12656
Brake torque arm
14-0133
Bolt
W2330
Washer Torque arm to frame
14-1304
Nut
...
Wheel spindle
W3965
...
W3750
Distance piece inner
D3213
Speedometer drive gearbox
...
W3746
Distance piece outer
14-1307
Nut
Wheel spindle
Fl 2266
Washer
W3751
Speedometer drive ring
Cover plate-swinging arm fork end
Fl 3082
W3742
...
Chain adjuster
Screw
14-0107
Chain adjuster
14-0301
Nut
D1841
Grease nipple
Fibre washer
WE170 83-n21
61
ClassicBike.biz
1
••• 1
••• 1
••• 10
••• 10
20
40
1
2
1
2
•••
••• 1
••• 1
•••
••• 1
••• 5
5
5
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
2
2
2
2
REMARKS
28
ri
3
16
17 -
®--24
25^
f
B22
23
18 •-f--^
4
23
Fig. 23. GAS TANKS AND TWINSEAT
62
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
GAS TANK AND TWINSEAT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
17
18
19
20
21
22
23
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
F12996 g3F9062
F13021
51823
F13133
F10260
F13320
F13321
F13319
51999
D2330
F13318
F13068
F13134
F13135
F9700
F9701
F11339
F7888
F3220 83
F4048
F3217
F3221
F12800
F12801
E7351
F10002
F13634
F13637
F12867
14-0101
01
D2417
F9093
F13061
F12597
14-0604
14-1301
D2087
D2381
3 Gas tank (3 gall.)
Steady rubber
Mounting rubber
Centre fixing bolt
Distance tube ...
Mounting rubber
Washer ...
Rubber washer ...
Mounting ring ...
Nut
...
Washer ...
Beading holder
...
Grommet
Styling strip-front
Styling strip-rear
Tank motif—L.H.
Tank motif—R.H.
Screw—front—tank motif
Screw—rear—tank motif
cap
Joint washer
Jack chain
Clip
...
Gas tap ...
Gas tap—reserve
Tap seal
Washer ...
Twinseat
Twinseat cover
Hinge ...
Bolt
}Hinge to twinseat
Spring washer
Rubber buffer
•••
Catch assembly
Spring—catch assembly
Screw
Twinseat catch fixing
Nut
Check wire
...
Screw—self tapping ...
63
ClassicBike.biz
•••
•••
•••
•••
•••
•••
..•
.••
•••
•••
•••
.••
•••
•••
•••
•••
•••
•••
•••
•••
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
2
2
1
1
2
4
4
5
1
1
1
1
1
1
TR6C
TR6C
N
64
ClassicBike.biz
H
J
W
z
4
d
W
0
U)
0
z
4
N
ac
W
z
4
W
J
u
4
N
00
LL
Ref. No.
Part No.
DESCRIPTION
QUANTITY REMARKS.
AIR CLEANER AND SIDE PANELS
Fl 3789
AIR CLEANER ASSEMBLY—L.H. ...
F13790
AIR CLEANER ASSEMBLY—R.H. ...
1
F12749
Body—L.H.
1
F1275
Body—R.H.
2
F12751
Cover—L.H.
2
F12752
Cover—R.H.
F13791
AIR CLEANER ASSEMBLY—L.H. ...
F13792
AIR CLEANER ASSEMBLY—R.H. ...
1
F12798
Body—L.H.
1
F12797
Body—R.H.
2
F12839
Cover—L.H.
F12840
2
Cover—R.H.
3
D3072
Element ...
4
14-0221
Bolt
5
F12799
Circlip
Cover to body
6
D2438
Washer
7
14-0302
Nut
8
D3539
Screw }
L. H. assy. to R. H. assy.
9
S501
Nut
1
0
14-0217
Bolt
}Air cleaner to frame
11
D2418
Spring washer
12
F12626
Connector pipe
13
F12625
Connector pipe
14
E11860
Carburetor adaptor
15
D3536
Clip—Jubilee type
16
F12502n-1673 Side panel—L.H.
17
F1250483
7ide panel—R.H.
18
F6673
Panel grommet ...
•• •
19
14-0201
Bolt
20
D2329
Washer . Side panel to air cleaner .
21
14-1301
Nut
Not illus. D2103
Transfer ...
Not illus. D2104
Transfer ...
Not illus. D2102
Transfer ...
5
10
F8245
14-0218
F9196
LATER MODELS USE THE FOLLOWING:Retainer ...
Bolt
...
Spacer (use with 14-0218)
...
65
ClassicBike.biz
... 1
... 1 1 Twin Carb
T12OR
1
•• •
1
••• 1
••• 1
••• 1
••• 1
••• 2
Single carb.
TR6R, TR6C
2
2
All models
2
2
2
2
2
2 T12OR
... 1
TR6C, TR6R
1 or 2
1 or 2
1
1
2
4
...
4
2 T12OR
... 2
TR6C
TR6R
... 2
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
FENDERS AND TAIL LAMP
I
1
2
3
4
5
6
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1
1
H4260
...
...
A LA. Front fender
...
H4065 97 _g27o Front fender ...
...
...
H4022
Bracket
1
H4021
Rubber bush
Stay to fork leg
14-0103
Bolt
D2427
Spring washer
F13566
Rear fender
...
...
...
F13565
Rear fender
...
...
...
14-0114
Bolt
...
...
...
...
D2330
Washer ...
...
...
...
14-1302
Nut
...
...
...
...
14-0101
Bolt
...
...
...
...
...
...
...
...
...
...
...
"'
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
D2329
14-1301
F12768
14-0101
D2329
14-1301
F12727
F12728
14-0102
D2329
14-1301
F12786
D3313
14-6101
D2320
14-0101
D2427
F13213
57079
D2391
F4717
53973
54577109
144921
54525286
380
Washer Fender to fixing top and rear
Nut
Lifting handle ...
...
...
...
Bolt
Lifting handle to frame
Washer
...
Nut
...
...
...
...
...
Rear number plate'bracket—L.H. ...
Rear number plate bracket—R.H.
Bolt
Washer Number plate bracket to fender
Nut
Tail lamp support
...
...
...
Captive nut
...
...
...
...
Bol
support front fixing
Washer
Bolt
rail lamp support rear fixing
Washer f
Rubber beading strip ...
...
...
Reflector red (99-1162)
...
...
...
...
...
Washer ...
...
...
...
...
...
Nut
...
STOP AND TAIL LAMP 679 (99-0597)
Lens (99-1046)
...
...
...
Screw (99-1189) ...
...
...
Lamp base assembly
...
...
Bulb (99-0542) ...
...
...
H4270
H4271 N^G^
LATER MODELS USE THE FOLLOWING:Front fender
...
...
...
...
...
Front fender
...
...
...
...
...
J
J
67
ClassicBike.biz
...
...
1
1
4
44
4
I
1
2
2
2
3
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 2
... 2
... 2
... 1
... 1
... 4
... 4
...
...
...
"'
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
TR6R, T120R
TR6C
TR6R, T120R
TR6C
3
2
1
...
...
...
...
...
...
...
.:
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 2
... 2
... 2
... 2
... 1
... 1
... 1
... Reference only
... 1
...
...
...
...
...
...
"'
1
1
1
1
2
2
1
1
TR6C
TR6R, T120R
Ref. No.
DESCRIPTION
Part No.
QUANTITY
REMARKS
HANDLEBARS AND CONTROL LEVERS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21
22
22
23
24
25
26
27
28
29
30
31
32
33
34
...
...
H425297-700/ Handlebar
Sleeve, handlebar mounting ...
H1425
16/364 &70 / q TWISTGRIP (99-0248)
...
Body, top half (22-0245)
16/328
BODY, BOTTOM HALF (22 7QW)
16/329
Friction spring
16/008
Screw ...
16/009 62Z/0
Locknut
16/010
Rotor
99-0244
Screw
) ...
11/013
...
...
Grip
H95897-2 ar
Cable stop (99-0241) ...
16/011
...
...
...
...
H2124g72/YZ Grip
12/60860-3567 AIR CONTROL LEVER (D3246)
...
12/55 /-022e Lever
Bolt
12/607
Cap ...
12/606
Spring washer
12/033
Clamp
12/040
Screw
11 /01
126
...
D26286p 35n Front brake lever (alloy)
Front brake lever (steel)
D31430-3583
D26270-3657 Clutch lever (alloy)
D31440-36S7 Clutch lever (steel)
Pivot pin...
52048
...
Nut
14-1201
Adjuster
D3585
...
Lockring
D3586
HANDLEBAR SWITCH—L.H.
39595
...
...
Switch half
54033666
...
Lever half (99-1215)
54340883
...
Screw (99-1188) ...
54115246
HANDLEBAR SWITCH—R.H.
39596
...
...
Switch half
54033667
...
Lever half (99-1187)
54340882
Screw (99-1188) ...
54115246
21
D3583
D3648
21
83
LATER MODELS USE THE FOLLOWING:...
Front brake lever (alloy)
...
Front brake lever (steel)
69
ClassicBike.biz
•••
•••
•••
•.•
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
1
4
1
1
1
Reference only
Reference only
Reference only
1
2
1
1
1
1
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
1
1
(TR6R)
1
1
(TR6R)
2
2
2
2
Reference only
Reference only
1
4
Reference only
Reference only
1
4
•••
•••
1
1
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CONTROL CABLES
2
3
4'
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
3
4
5
Throttle cable
...
...
...
...
Throttle cable
...
...
...
...
...
...
Clutch cable
...
...
...
D30756O-3557 Front brake cable
...
...
W386737_399 Bush—brake cable stop
...
...
...
W386a37_3997Bush —brake cable
...
...
...
...
Washer ...
E12500
...
...
...
...
Cable spring
W4014
...
...
...
Air control cable
D1 807
...
AIR CONTROL CABLE
...
D3485
...
Cable, lever to junction box
D1 818
...
...
Junction box (D685)
244/104
Cable, junction box to carburetor
D3486
TWIN ROTOR TWISTGRIP (99-0347)
313/13
...
...
Screw (99-0251) ...
18/084
...
Body, top half (99-0348)
313/020
BODY, BOTTOM HALF (99-0349)
313/021
...
...
Friction spring
16/008
...
...
...
Screw ...
210/007
...
...
...
Nut ...
5/077
...
...
Rotor (99-0344) ...
313/004
...
Rotor stop screw (99-0338)
210/008
Nut—rotor stop screw (99-0224)
5/077
...
...
...
...
Grip
H2125
...
Cable clip
D978
Cable clip (pD-.0353 e Q.7 •••
D343/7
...
Cover, front brake stop switch
D2086
...
...
...
Handlebar clip ...
H4112
D1 819
D1 806
D3079
D3557
W3996
W3997
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
•••
...
...
LATER MODELS USE THE FOLLOWING:
...
...
...
...
Front brake cable
...
...
...
Bush—brake cable stop
...
...
...
...
Bush—brake cable
71
ClassicBike.biz
...
...
...
...
...
...
2,
1
T120R
TR6C, TR6R
2
...
...
1
... 1
...
...
...
1
...
...
...
2
1
2
...
...
...
...
...
...
...
...
•..
Reference only
Reference only
Reference only
6
6
1
4
TR6C, TR6R
T120R
T120R
Fig. 28. TOOLKIT, PILLION FOOTRESTS AND LICENCE HOLDER
72
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
TOOLKIT
1
2
3
4
5
6
7
8
9
10
11
D2112
D291
D2184
D1911
D2084
D971
D972
D974
D767
F13292
14-0101
D2329
TOOLKIT COMPLETE
Tool roll ...
...
Damper unit spanner
Tommy bar
...
Spanner—open ended
Box spanner
...
Ring spanner
...
Tyre valve key
...
Screwdriver
...
Tool tray
...
...
Bolt
...
...
...
Washer ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
73
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
..
1
1
I
1
1
1
1
1
1
1
1
1
REMARKS
74
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
SPEEDOMETER AND TACHOMETER
1
2
3
4
5
SSM5007/00^i0ht
41-148-203-10
54959626
643
D3249
eedometer head (D2394) ...
...
Trip control (99-0176)...(0 0.-. 7011.
Bulb holder
...
...
...
...
Bulb (3W. MES)
...
Speedometer cable D F 9lld "O2
6
H4026
Mounting bracket
7
D2600
Rubber cu p
...
...
...
...
...
...
...
...
..
...
...
...
...
...
22
23
24
25
"'
D2391
Washer ...
...
...
...
...
...
E93317,-W3(p TACHOMETER GEARBOX (E5758 Body)—L.H.
E9332
Securing screw—L.H. thread, U.N.
...
Reference only
Bush ...
...
...
...
...
Reference only
Flanged bush ...
...
...
...
E5157
Driving gear
...
...
...
...
E5759
End cap
...
...
...
...
...
E6300
"O" ring ...
...
...
...
...
E5578
Driven gear
...
...
...
...
E6122
Driven gear housing
...
...
...
E6299
"0" ring
...
...
...
.,.
Reference only
Bush ...
...
...
...
...
"0" ring
...
...
...
...
E330960-3530
E5881
Set screw
...
...
D3282
Tachometer cable
D.eF 1&/ /O. yf 3 ...
RSM3003/13
Tachometer (D2396) 6
...
..7/7/...
...
...
...
...
31-371-398
Spade (99 -0173
D494
Circlip ...
...
...
...
...
...
Sealing washer ...
...
...
...
...
E7351
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
...
1
1
Reference only
... Reference only
... 1
f1 TR6C,
2 T120R, TR6R
1 TR6C,
2 T120R, TR6R
2 or 4
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
TR6R,
... 1
T120R
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
Not illus.
D546
...
...
...
Not illus.
8
9
10
11
12
13
14
15
16
17
18
19
20
21
G ..
Blanking plug (replaces tacho bulb holder)
75
ClassicBike.biz
...
...
thread
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
Fig. 30. COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORD
76
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
F12571
14-0101
Mounting platform—electrical components...
...
...
Bolt
...
...
D2329
Washer Platform to mudguard
Nut
14 -1301
...
...
Grommet—coil mounting
F9561'
2
Ignition coil (17-M-12 (D2206 g5Q'Z ,03
45223
...
Rectifier (99-0589)
D.-O7o ...
49072
...
...
...
...
...
...
Nut
F5338
...
...
...
CAPACITOR
PACK-2CP
47638
...
...
...
Capacitor
(99-4043)
54420128
...
...
Cover
(99677)
54418528
...
...
...
Base
plate
(99-4466)54418526
Bolt
F10033
GS2996O-423'6 Shakeproof washer Capacitor pack to platform
Nut
F3799
...
...
...
Flasher unit (99-120 ...
35048
...
...
Clip, flasher unit (99-1204 ...
54385091
...
...
Spring
D3614
I
Bolt
F10033
...
Flasher unit to platform ...
Washer
..•
•••
E2251
Nut
F4717
...
Zener Diode (99-0590) 6O O?87.
49345
...
...
...
...
Sparking plug ...
N3
...
...
Plug cover (Champion WC200)
D262
...
...
...
Horn-6H (99-4246) ...
70216
Bolt
...
...
...
14-0102
...
...
...
D239383 -9277 Washer Horn to frame
Nut
14-1301
...
...
...
Lucar black terminal ...
54190038
...
...
Reflector-amber (99-1161) ...
57183
Washer
••.
D2391
...
Reflector mounting
Nut
F4717
...
Mounting rubber J
F13522
...
J
...
J
J
J
...
...
...
"A
ClassicBike.biz
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•..
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..
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...
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...
...
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...
...
...
...
...
...
2
2
2
1
Reference only
1
1
2
4
2
... Reference only
... 2
... 2
... 2
... 2
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...
...
...
...
...
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...
...
...
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...
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...
1
Reference only
2
1
1
2
2
2
1
1
1
78
ClassicBike.biz
4
U.
z
4
I
4
4
LL
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
HEADLAMP AND FLASHER LAMPS
...
wire (99-0683)
Screw
...
144921
5
Plate
534296
6
Main bulb (45/35W) (99-1214) ...
370
7
Bulbholder
554602
8
Pilot bulb (99-0548)
989
9
...
Pilot bulbholder (99-1213)
10
54573590
Warning
light
(Red)
(99-1208)
54363454
11
Warning light (Green) (99-1209)
12
54363455
Warning light (Amber) (99-1207)
54363453
13
...
Sealing washer (99-1210)
54140331
14
...
Light
switch
(99-1211)
31276
15
...
...
...
Shield, warning light
54525212
16
...
Bulb, warning light (99-0537) ...
281
17
Screw, headlamp fixing (99-1223) q7az
54115106
18
...
Washer, headlamp fixing (99-1224)
143086
19
...
...
...
1222)
Wiring harness
Not illus. 54959629
IGNITION SWITCH (TYPE 149 SA) (99-1200)
39565
20
...
..•
...
Nut ...
54130041
21
2'698/...
IGNITION
LOCK
C/W
KEY
F6981
5V33V69
22
Key (state serial number)
D622 $y335/69
23
...
Cover,
ignition switch
H2262
24
FLASHER
LAMP
(99-1190)
56147
25
1) ...
Lens (
54581638
26
...
Gasket
54580300
27
...
Bulbholder
554548
28
Interior
assembly
...
473832
29
...
Bulb (99-1192)
382
30
...
...
Screw
(99-1193)
...
54123401
31
)
...
Stanchion,
flasher
lamp—(
54582414
32
...
Washer (99--4446)
143086
33
...
)
Locknut
(
1981721
34
H4247
H42486
F13525
14-0404
LATER MODELS USE THE FOLLOWING:—
Flasher mounting bracket
ZFront stanchion
2Rear stanchion ...
Nut (inside headlamp)
79
ClassicBike.biz
6
Reference only
Reference only
1
Reference only
1
1
1
••• 1
••• 1
••• 3
••• 1
Reference only
3
••• 2
••• 2
••• 1
••• 1
••• Reference only
1
•••
••• As required
••• 1
••• 4
••• 1
••• Reference only
••• Reference only
••• Reference only
••• 1
2
4
2
8
•••
•••
•••
•••
•••
•••
•••
1
2
2
2
N^
N
\
cc
/1
N
^O'
r--
N/
i^
l
N
/
7:
\
N
^
J
C
\C
80
ClassicBike.biz
N
t2
m
z
d
N
N
0
I
W
U
IF
z
W
H
H
00
LL
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
BATTERY AND TR6C HEADLAMP
1
2
3
4
5
6
7
8
9
10
F12512
F8091
F8255
F9353
F13849
F13295
F12508
F6039
14-1301
54027029
11
60262
534343
12
54525272
13
504665
14
370
15
54573590
16
989
17
554602
18
Not illus. 54115106
Not illus. 143086
31272
19
153631
20
144921
21
534296
22
54363454
23
281
24
54363455
25
54140331
26
54363453
27
54525212
28
Battery carrier
...
Carrier tray
Protective strip
Retaining strap ...
Buckle ...
Protective strip
Shoulder screw
...
Battery carrier mounting
Rubber bush
Nut
...
) GP- ??. re...
Battery—PUZ5A (
1 )
HEADLAMP ASSEMBLY MCH 66 (
...
Rim (99-0691)
...
Light unit (99 011} ...
...
Fixing wire (99-0683) ...
Bulb (45/35W vertical dip, pre-focus 99-1214)
...
Bulbholder, pilot ( -0695)
...
Bulb (3W.M.C.C. 99-0548)
Adaptor caw leads (99-1003) ...
...
Screw, lamp fixing
...
Washer (99-1224)...
Lighting switch (.=-063}
Nut for lighting switch ...
...
...
...
Screw
8.7
Plate (99-0690)
Warning light, red (99 1200)
...
Bulb (2W.BA75) (99-0537)
Warning light, green (99-1209)
Sealing washer (99-1210)
Warning light amber (99-1207)
...
Warning light shield
81
ClassicBike.biz
I
...
•••
•••
•••
1
2
1
1
11
3
3
1
•••
1
•••
1
1
1
6
1
1
1
••• 2
••• 2
••• 2
••• 1
Reference only
••• Reference only
••• 1
••• 1
••• 2
1
3
1
Reference only
STANDARD HARDWARE SPECIFICATION
BOLTS
Part No.
S1822
S1910
S1919
S2010
14-0101
14-0102
14-0103
14-0113
14-011
14-0115
14-0128
14-0208
14-0216
14-0217
14-0219
14-0220
14-0225
14-0228
14-0234
14-0236
14-0239
14-0240
14-0242
14-0251
14-6102
14-6115
Material
Steel
„
„
„
„
„
„
„
„
„
„
Length under
head
-z'
Thd. dia.
6" UNF
e" UNF
6" UNC
4 " UNF
4" UNF
4" UNF
4" UNF
16" UNF
6"
UNF
1
6" UNF
8" UNF
4" UNF
16" UNF
•16" UNF
16" UNF
16" UNF
16" UNF
16" UNF
8" UNF
UNF
8" UNF
8" UNF
e" UNF
" UNF
4" UNC
6" UNC
Min. length
of thread
64"
•-6"
18"
e"
""
16
g'"
2"
8"
;"
8"
4"
8"
1"
24"
18"
14"
12"
14"
3"
4"
14"
24"
3"
34"
4"
24-"
."
8"
8"
8"
8"
8"
8"
1"
1"
1"
1"
1"
14 "
8"
8"
Hexagon A.F.
0.500"
0.565"
0.500"
0.375"
0.438"
0.438"
0.438"
0.500"
0.500"
0.500"
0.563"
0.438"
0.500"
0.500"
0.500"
0.500"
0.500"
0.500"
0.563"
0.563"
0.563"
0.563"
0.563"
0.625"
0.438"
0.500"
NUTS
Part No.
S778
S1852
S1906
S1908
51914
S2012
S2013
S2014
14-0301
14-0302
14-0401
14-0402
14-0403
14-0701
14-0702
14-0703
14-1201
14-1202
14-1301
14-1302
14-1303
14-1304
14-1305
14-1902
1 4-1903
Material
Steel
„
„
„
„
„
„
„
Thd. dia.
No. 10 UNF
16" UNF
a'-" UNF
- " UNF
4" UNEF
-g4-" UNEF
4" UNEF
4" UNEF
,'-" UNF
6" UNF
4" UNF
16 "UNF
8" UNF
a'-" UNF
6" UNF
e" UNF
4" UNF
16" UNF
4" UNF
6" UNF
e" UNF
6" UNF
'-z" UNF
. " UNF
a" UNF
Hexagon A.F.
0.375"
0.437"
0.438"
0.438"
1.125"
1.313"
1.313"
1.313"
0.438"
0.500"
0.438"
0.500"
0.563"
0.438"
0.500"
0.563"
0.438"
0.500"
0.438"
0.500"
0.563"
0.688"
0.750"
0.500"
0.563"
82
ClassicBike.biz
Thickness
0.225"
0.330"
0.188"
0.313"
0.250"
0.438"
0.313"
0.438"
0.224"
0.271"
0.161"
0.192"
0.224"
0.203"
0.246"
0.296"
0.285"
0.335"
0.245"
0.290"
0.320"
0.375"
0.435"
0.361"
0.375"
Remarks
Cleveloc
Philidas
Plain
Plain
Plain
Plain
Plain
Plain
Plain
Plain
Lock
Lock
Lock
Philidas
Philidas
Philidas
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Nyloc
Nyloc
SCREWS
Part No.
S1916
51917
S1918
S1920
S1929
S2079
1
1
1
1
1
1
1
0604
6505
607
6608
609
7019
7024
Type of head
Cheese head
Cheese head
Cheese head
Hex. head
Countersunk (82°)
Cheese head
Cheese head
Countersunk (82°)
Cheese head
Cheese head
Cheese head
Socket head
Socket head
Material
Thd. dia.
Steel
1" UNC
1"
4 UNC
4 UNC
i" UNC
4 " UNC
No. 10 UNF
1"
4 UNF
4 UNC
1"
4 UNC
k" UNC
k" UNC
*" UNC
6 UNC
4
i"
/9
1
i"
It
„
71
,t
"
7
Length under head
1f"
21"
28"
624"
1 70
32
T
1”
2
III
8
ill
1"
w
f"
2"
Type of drive
Cross recess
Cross recess
Cross recess
Slot
Pozidrive
Cross recess
Cross recess
Cross recess
Cross recess
Cross recess
Hex. socket
Hex. socket
WASHERS—PLAIN
Part No.
Material
i/dia.
o/dia.
Thickness
525-1
S25-2
S25-3
S2
S25-13
Steel
Steel
Steel
Steel
Steel
0.273"
0.398"
0.336"
0.531"
0.266"
0.563"
0.750"
0.625"
1.031"
0.469"
0.048"
0.063"
0.063"
0.092"
0.064"
WASHERS—SPRING
Part No.
Material
i/dia.
S26-1
S26-2
S26-16
S648
Spring Steel
1" clearance
o/dia.
H"
13
32
1"
4 clearance
/,
,
211
1 70
32
8
1
2
*" clearance
,
** Double coil.
83
ClassicBike.biz
o/a height
7 II
3
32
3 /I
16
7N
32
50
3-1
Thickness
0.104"
0.064"
0.040**
0.080"
Ref. No.
DESCRIPTION
Part No.
QUANTITY
PARTS REQUIRED FOR 5 SPEED GEARBOX—OPTIONAL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
...
Crankcase—timing side
E12791
...
...
...
Oil seal ...
D3500
...
...
...
Cover plate
E3789
...
...
High gear bearing
D3493
...
...
...
Oil seal ...
D3512
...
...
Gearbox cam plate
T4360 57— 7
Selector fork—M/S 4th gear ...
T4364
Selector fork—L/S 3rd gear ...
T4366
Selector fork—L/S 1st gear ...
T4368...
...
T437237 — St7iM/S High gear ...
...
Needle roller bearing ...
D3511
...
...
...
Oil seal ...
D3500
...
...
...
Main shaft
T4432
...
...
M/S 4th gear ...
T4376
...
...
M/S 3rd gear ...
T4377
...
M/S 1st and 2nd gear ...
T4380
y
...
...
...
Layshaft ...
T4371 ,S7 ?
—
...
...
...
O0 L/S 4th gear
T43845
...
...
...
Circlip ...
D3494
...
...
T4383 5?a47 L/S high gear ...
...
...
...
L/S 3rd gear
T4387'
...
...
...
L/S 2nd gear
T4388*
...
...
...
L/S 1st gear
T4391-'
Q Circlip
...
...
...
...
D3494 57 ?9
...
...
...
Driving dog
T43813
...
Gearbox inner cover ...
T4407
...
...
...
Leaf spring
T4402
uadrant
...
...
...
Q
T4363
...
...
Plunger quadrant
T4374Y0$'
...
...
...
Plunger ...
T4403
...
Gearbox sprocket-19T
T4397
...
Gearbox sprocket-18T
T4398
Locknut
...
...
...
...
T4396
...
T4395 74o Locking washer
(7
USN CI? Q, TI
England by
Printed
Warwickin Printing Co. Ltd., Warwick
9'?- 3
'0
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
2 (otvsr &-
84
ClassicBike.biz
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...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
•..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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...
...
1
1
I
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
I
1
I
1
1
1
1
1
1
2
1
1
1
1
t'& O ,45 K'%)
REMARKS