1969 triumph tr25w 250cc

Transcription

REPLACEMENT
PARTS CATALOGUE
THEtrF{Y
2s@
TR2
5 W 25O c.c. (15 cu. ins.)
1969 MODEL
BSA Unit Singles LLC
REPLACEMENT
PA RTS
CATALOGUE
TR25W
TRIUMPH ENGINEERING COMPANY LIMITED
MERIDEN WORKS
TELEPHONE MERIDEN
33I
ALLESLEY . COVE NTRY
ENGLAND
TELEGRAMS'TRUSTY, COVENTRY''
REF- Nd. SPC.I0
PUBLISHEO OCTOBER I968
TRIUMPH GUARANTEE
1.
2.
3.
4.
ln this Guarantee the word "machine" refers to the motor cycle, scooter, motor cycle combination
or sidecar as the case may be, purchased by the Purchaser.
ln order to obtain the benefit of this Guarantee, the Purchaser must have correctl/ completed the
registration form and returned it to us within fourteen days ofthe PUrchase.
We will supply, free of charge, a new Part in exchange for, or, if we consider repair sufficient, will
repair free of charge any part proved within six months of the date of purchase of any new machine,
(three months overseas) or within three months of its renewal or repair in the case of a part already
renewed or repaired, to be defective by reason of our faulty workmanship or materials We do not
undertake to bear the cost of fitting such new or repaired Part or accessory.
Any part considered to be defective must be sent to our Works, carriage paid, accompanied by the
following information :(a) Name of purchaser and his address;
(b) Date of purchase of machine;
(c) Name of dealer from whom the purchase was made;
(d)
5.
Engine number and model.
This Guarantee shall not extend to defects or damage appearing after misuse, neglect, abnormal stress
or strain, or the incorporation or afflxing of unsuitable attachments or parts and in Particular:-
(a) Hiring out;
(b) Racing and Com Petltions;
(c) Adaptation or alteration of any part or parts after leaving our Works;
(d) The attaching of a sidecar in a manner not approved by us or to an unsuitable
motor cYcle.
This Guarantee shall not extend to machines whose trade mark, name or manufacturing number has
been altered or removed, or in which has been used an/ Part not supplied or approved by us, or to
tyres, saddles, chains, speedometers, revolution counters and electrical equiPment or to Parts suPPlied
to the order of the Purchaser and different from our standard sPecification.
6.
Ou r Iiability and that of ou r dealer who sells the machine, whall be lim ited to that set out in this Suarantee,
and not other claims including claims for consequential damage or injury to Person or ProPerty, shall
be admissable. All other conditions and warranties statutory or otherwise and whether exPress or
implied are hereby excluded and no guarantee other than that expressly herein contained applies to
the machine to which this Guarantee relates or any accessory or Part thereof.
7.
We reserve the right to modify or deviate from the Published SPecification without notice
THE FITTING OF ANY COMPONENTS \/VHICH ARE NOT APPROVED BY THE
MAN UFACTURER INVALIDATES THE GUARANTEE
REPAIRS GUARANTEE
1.
7.
Whilst the highest standard of workmanship and materials is aimed at, we cannot accept liability for
any defects appearing more than three months after the machine, assembly or comPonent has left our
Works after being repaired.
We will repair or replace at our option free of charge any defective work, materiais or Parts relating
to the repairs carried out by us appearing within that time but shall not be under any further or other
liability for any other loss or damage whether direct or consequential and our liabilit/ shall be limited
to the cost of so making good. We do not undertake to bear the cost of fittjng any replacement or
repaired part.
3.
We do not accept liability in respect of parts of proprietary manufacture, e.g. tyres, saddles, chains,
speedometers, revolution counters and electrical equipment which may be used by us in effecting a
repair. All other conditions and warranties statutory or otherwise express or implied are hereby excluded-
,I
INDEX
Poge
AIR
...
FILTER
...
ALTERNATOR
59
CHAING UARD
CHAINS
...23,41
CARTON PACKS
59
7
29
CONTROL LEVERS ...
...
...
...
,,.
...
CRANt(CAsE...
... 13,
CLUTCH
cotL
CONTACT BREAKER
CONTROL CABLES ...
CRAN KSHAFT
CYLINDER HEAD
EXHAUST
...
31
OIL PUMP
15
OIL TANK
...
...
...
CARBURETOR
MUFFLER
15, 23
BATTERY CARRIER...
I
Poge
...
...
23
53
21
PROP STAND
... 33
... 9, 11
... 29
REAR PANELS
...
REAR WHEEL
...
RECTIFIER
... 53,
55
SPARK PLUGS
SPEEDOMETER
...
...
51
STEERING RACES
... 35, 37
SUSPENSION UNITS
...
SWITCHES
...53,55
PiLLION FOOTRESTS
PISTON
49
15
9,11
9,11
PIPES
45
FOOTRESTS ...
TIII4ING COVERS
35,37
FRONT WHEEL
39
GEARBOX
TIMING GEARS
33
FRONT FORKS
GASKET SETS
9,11
79
31
N DERS
GAS TANK
4't , 43
49
TACHOMETER
FE
31
TWINSEAT
VALVES
...
17
47
7
, 't9,
21
WIRING HARNESS ...
HANDLEBARS
49
HORN...
53
ZENER DIODE
51
15
't7, 19,
...
...
TOOLKIT
...
...
...
...
21
57
47
9,
11
E
0
TROPHY 250 TECHNICAL DATA
Bore and stroke -..
Capacity ...
67 x 70 mm.
...
249 c.c.
Compression ratio
9.6 :1
Sparking plug
Carbu
0
I
Amal Concentric.92S
28 mm.
Choke size
Main jet ...
Need le
Need Ie
160
jet
.106
Standard
Throttle valve
No.3
Gearbox sprocket
15 teeth
...
Final Drive Sprocket
Chains
Rear
...
Fuel
57 teeth East Coast
49 teeth West Coast
... I in. x * in. Duplex x 70 links
... I in. x j in. x 101 links East Coast
Front
...
I
Cham pion N3
rettor
Capacities
0
tank...
3 in. x + in. x 99 lin ks West Coast
3.916 galls. U.S.
Oil tank ...
Gearbox...
6 pints
+ pint
Primary chaincase
+ pint
+ pint
Front forks (each leg)
Brakes
...
Front and rear diameter
Tyre size ...
..,
Front
7 in.
3.25 x 18
4.00 x 18
Rear
TRIUMPH SPARES
HOV/ TO ORDER. Every part is indicated by a number, and this should be quoted together with
the description. ln 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.
\A/HERE
TO OBTAIN,
Triumph Spare Parts can only be obtalned 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 wrjte or obtain specially,
the postage or carriage incurred becomes payable.
Customers are warned against the risk incurred by purchasing parts that are not ofgenuine Triumph
manufacture. This risk is eliminated if parts are ordered as instructed from recognised Dealers.
PROPRIETARY GROUP
Ancillary equipment which is fitted to our motor cycles is ofthe 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.
The Avon lndia Rubber co. Ltd.,
Messrs. Amal Ltd.,
lYe lks
Holdford
ham,
Road,
Birmingham,6.
SPARKING PLUGS.
Champion Sparking Plug Co. Ltd.,
CHAINS.
Renold Ltd.,
Wythenshawe,
Manchester.
ELECTRICAL EQUIPMENT.
Messrs. J. Lucas Ltd.,
Feltham,
M idd lesex.
SPEEDOMETERS,
Messrs. Smiths lndustries Ltd.,
Cricklewood Works,
London, N.W.2.
Gt. Hampton Street,
Birmintham, 18.
SUSPENSION UNITS.
Messrs. Girling Ltd.,
TYRES.
Dunlop Rubber Co. Ltd.,
Fort Du nlop,
Birmintham,24.
Birmingham Road,
West Bromwich,
Staffordshire.
HOW TO USE
THIS PARTS CATALOGUE
Consult the index on Page 3 for the parrs or group of parts which you wish
List the quantities required as single units; do not
asl<
!c
t$,
locate.
for "2 pairs" or "3 dozen".
Items marked "reference only" are not available from the factory.
Proprietar/ components e.g. electrical equipment, carburetors, suspension units etc. are iisted in the flrst
column under Triumph part numbers (prefixed either D-- or 99--) wherever they are stocl<ed ar rhe
factory. lf proprietary parts are listed only under manufacturers part numbers, they are not available from
the factory.
PLEASE NOTE
THROUGHOUT THIS LIST, ASSEIVIBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS
INCLUDED IN THAT ASSEIYBLY ARE INDENTED IN THE DESCRIPTION COLUI.4N, REVERTING
TO THE ORIGINAL ALIGNI'4ENT WHEN THE ASSEII4BLY IS COMPLETE. TO ORDER THE COMPLETE
ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEI"IBLY NUMBER. ANY COMPONENT
PARTS LISTED IYAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.
tl(
SPECIAL WORKSHOP TOOLS
A
COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITH ER CONTACTING
YOUR DEALER OR APPLYING DIRECT TO THE DISTRIBUTOR. IN MOST CASES THESE TOOLS ARE
VERY COSTLY AS THEY ARE I"IADE ENTIRELY FOR WORKSHOP USE, AND THEREFORE. IT IS NOT
RECOI.4I.4ENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN ORDER TO AID SERVICING
THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES IT IS FAR IYORE ECONOMICAL
TO GET IN TOUCH WITH A RECOGNISED DEALER.
UNIFIED THREAD FORM
NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOGUE H,\VE 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 MARI<INGS. BOLTS HAVE A CIRCULAR RECESS IN THEIR HEADS,
STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING CIRCLES ON THE
SIDE
0(
CA RTO N PAC K LIST
The following sub-assemblies are supplied in carton packs under the C.P. part number stated. The
contents ofthese carton packs are preserved and
will not deteriorate under adverse conditions.
PISTON (complete with rings, gudgeon pin and circlips). These are in effecr 'carton pack'
assemblies.
E7998
E8272
9.6 : 1 C.R.
9.6 : 1 C.R.
9.6 : I C.R.
E8271
OVERHAUL GASKET SET
DECOKE GASKET SET
STANDARD SIZE
0.020 in. oversize
0.040 in. oversize
99-0031
99-0040
PA RTS VARYING
FROM STA N DA RD SIZE
The following are the part numbers of piston rings to suit oversizes of +0.020 in. and *0.040 in. These
rints are no longer available in carton packs:
PISTON RINGS
(0.020 in. oversize)
PISTON RINGS
(0.040 in. oversize)
Big end bearing
1
't
1
1
I
1
undersizes
Top compression ring
E8777
E9017
E9021
Middle compression ring
Scraper ring
E8278
Top compression
E9018
Middle compression ring
Scraper ring
E907t
0.010 in.
0.020 in.
0.030 ln.
Part Number E6068/10
Part Nu m ber E6068/20
Part Num ber E6068/30
rint
rtlt (
4
Y70
q)
2A
|,
@
s\\
lil"u
",ua
51
0(
53
,fl\
6)
%
6
s^,,
Fis.
l.
CYLINDER HEAD, BARREL AND CRANKSHAFT
o(
Ref No.
Port No,
DESCRIPT/ON
QUANTITY
CYLI NDER HEAD, BARREL AND CRANKSHAFT
6
7
E8032
E8033
CRANKSHAFT AND FLYWHEEL ASSEMBLY
Crankshaft... ...
FLYWHEEL DRIVE SIDE
FLYWHEEL TIMING SIDE
Screwed plug ...
...
Flywheel bolts (1{ in. U.H.)
Flywheel bolts (2 in. U.H.)
8
'10
E8037
E8038
E8039
E1580
Shim (0.010 in.) ...
Shim (0.015 in.) ...
Crankshaft pjnion key
't1
E8144
12
13
E8836
E3705
14
E2922
15
E6068
16
D911
E7998
'l
2
3
4
9
9
17
18
19
20
I
21
E8276
E6838
E6839
WE2O3E
wE479
23
24
25
25
26
27
28
79
E9163
E7728
E8053
E8055
E7739
E8008
E8196
Washer
1
Reference only
Reference only
Reference only
1
4
4
8
...
A.R.
A.R.
...
1
Rotor key
CONNECTING ROD ...
Connecting rod bolt
1
1
7
7
Self locking nut
Big end bush (available in undersizes of 0 010 in., 0.020 in.
0.030 in.)
Sparking plug N3
*PISTON COMPLETE
...
...
2 halves
'l
1
Piain compression ring
Taper compression ring ...
1
1
Oil control ring
1
Gudgeon pin
1
Circlip
Cylinder barrel ...
...
Cylinder base washer ...
Push rod (exhaust)
Push rod (inlet) ...
...
2
1
1
1
1
Tappet
2
Cylinder barrel stud (2+ in.
Stud nut ...
Washer ...
O.A.)
...
7
2
7
32
E821s
E8197
E8228
E8229
JI
E7996
34
E8010
Dowel
7
E8080
E8227
E8225
stud (2.1+ in. o.A.)
Carburetor stud (13 in. O.A.)
Valve guide (inlet) ...
2
E8226
Valve guide (exhaust)
I
30
31
36
37
38
39
E8081
40
42
E8137
E8136
E7820
43
E79',t'l
44
E7858
E7787
41
I
E9547
E8028
E9519
E8034
E8036
45
46
CYLINDER HEAD
Stud (2+ in. O.A.)
Stud (3 in. O.A.) ...
Stud (3+ in. O.A.)
1
2
2
Cylinder head gasket ...
Carburetor stud nut
Carburetor flange washer
z
1
1
7
1
piece ...
'l
Rocker box
Rocker box gasket
1
Distance
Rocker
spindle
INLET ROCKER
47
E7790
E7791
48
E1483
Ball end
1
...
...
EXHAUST ROCKER
...
2
I
...
1
2
*Refer page 7 for oyersizes.
{ro
6t-r,a
)'?-r: vZ
@,0
Olr--
{'l
o
o.
9@
6
s
*@-
Fig.
l.
'22
CYLINDER HEAD, BARREL AND CRANKSHAFT
10
lll a
Ref No.
Pdrt No-
DESCRIPT/ON
QUANI/IY
CYLINDER HEAD, BARREL AND CRANKSH A F T continued
E1330
E8952
Thrust washer ...
Thrust washer ...
lnspection cover...
E8085
Gasket
53
E8086
54
E81'16
E8117
Screw (lJ in. U.H.)
Top collar
Split collet
4
56
57
E8117
lnlet valve
'l
E7777
58
59
D1002
14-0403
s25-2
Exhaust valve
Plug cover
49
50
5'1
60
61
61
E157 5
E7958
E7959
...
2
7
...
1
,|
2
2
1
1
').
Locknut ...
Washer ...
Corrugated ring (0.024 in.)
Corrugated ring (0 027 in.)
Corrugated ring (0 030 in.)
7
A.R.
A.R.
A.R.
2
...
2
7
65
E7960
E1564
E1577
E8087
E8088
Washer ...
66
EBO89
Nut
67
68
69
70
E8072
Washer
7
7
7
E8082
EBO83
Union
Fibre washer
E8111
Oil feed pipe
71
72
E8107
E8110
73
E8113
Nipple
Union nut
Bottom cup
2
74
75
E8114
Valve spring-outer
Valve spring-inner
7
7
61
62
63
64
E8115
lnspection cap
Washe
r
Nut
..
halves
.
1
I
1
1
1
11
r-
z6
',
a@_
28'.
\@
tN\
h\s \lr
225
45
46
-._&
s)
r€\
B
73
'?4
W66
6*
t,o
lql
",-ffi
MA
t1l
i1-
q@
"'
,o
I
75
'48
1!-.--tt
{St
,(d*\oz
\iq.
\u.,
Fig.2.
CRANKCASE
flt
12
Ref.
No.
Port No.
DESCRIPT'ON
CRAN KCAS
'l
2
E9371
E8006
3
s'l889
4
s1890
5
E8009
6
7
E8011
't4-140'l
9
E8003
E8025
I
't0
1'l
12
IJ
14
IJ
16
17
18
19
z0
71
1
C/linder securing stud
Crankcase top stud (2t| in. O.A.)
Crankcase rear stud (21{ in. O.A.)
Hollow dowel
...
Solid dowel ...
...
Sump stud ...
Main bearing (ball-journal)
Oil seal left main bearing ...
...
Generator stud rear, short hexagon
Generator stud front, long hexagon
Generator stud bottom (2+; in.)
4
2
2
1
2
4
2
1
(2{! in.)
(2]f in.)
Camshafc bush
l'4ainshaft bearing
E8315
E80t 4
E8015
E8010
s1891
E8017
E
CRANKCASE
s1894
s1895
s1896
E6026
QUANI/IY
Mainshaft oil
1
1
1
1
1
seal ...
'l
Oil seal circlip
Hollow dowel
Oil union stud
1
1
1
Scavenge pipe
'l
s1893
E8022
Oil pump stud ...
7
Hollow dowel
z
s1857
Gearbox drain plug
1
22
23
r2697
24
s1872
25
26
E8896
E9384
/7
E8256
78
29
T1150
s1892
14-0303
(J
nng
1
Timing hole plug...
Washer hole plug
I
Sealing plate
Sealing washer ...
1
Screw
2
1
I
Bolt (1t in. U.H.)
Cylinder securing nut
3
31
E8135
32
1+0302
Nut
4
4
4
33
E8088
E8064
E8070
E8071
Washer ..,
7
30
34
35
36
37
38
39
14-0901
40
s'|977
Sump cover
Gasket
Plain washer
1
1
4
4
Nyloc nut
Pressure relief valve plug
1
1
E8120
Plug washer
Spring
41
Eg't22
Ball
'l
42
43
E8124
Non-return Yalve sprint
1
s70-3
44
s1898
45
E7885
E81s9
Valve ball
Valve screw
Sealing plug
46
47
E8171
48
12695
T948
49
Eg',t47
50
E8148
1
1
1
'l
Washer .,.
Dipstick...
1
'l
'l
Dipstick washer
Clip for alternator lead grommet
Alternator lead grom met
'13
1
1
@6
o^^
,o&
@aaA
n,"o
Q; -- tr
\fu
k'=
_,](,) rz
U/
"@
I
89
__
z'
a5
51
32\33
26\2a
N
\4
49
_./__._
@*'Yr,,.
\$ l/-,
)t,
i6\
\o)
\rt
45
-€)
s)
4a
lr*
rq
674
73
ffr I
ffi66
r,?t
4e*)
-t9
ao
57 ,e
a1
60
6-'
17
u"
n
t## -
"-.$
70
zs@
,r@ ,9,>
tF
su
-az
Fig.
2. CRANKCASE
fi e
14
,t
Ref.
No.
Port No.
DESCRIPIION
CRAN KCASE
QUANTITY
continued
51
E3789
Oil seal housing
1
52
53
54
55
E3832
Gasket
1
E3833
Oil
E3821
Screw
6
E8179
Chain oiler
Rubber pipe
Fibre washer
Bolt (1i in. U.H.)
Oil pipes and union block
I
56
EB',t73
E8180
58
59
60
1+6203
E8127
E8259
1+0302
seal
1
1
1
'l
1
v
flng
Union nut
Serrated
2
1
washer...
67
63
E81
64
E8092
Spindle housing
1
65
E8093
Spindle
1
66
67
68
69
70
E8094
E8095
E8096
E8097
E8098
Spindle gear
1
7',|
E8099
E8100
Bottom plate
1
Screw
4
72
73
74
75
76
77
78
34
E8090
80
8t
Scavenge
E8042
E8140
84
E8139
E8184
E8143
E8141
E8147
1
1
1
1
Spind le gear nur
Spind le gear washer
1
1
I
Gasker
Hold ing nut
14,0901
82
83
83
83
gear-driven
Driven gear spindle
E8'103
E8040
E8043
1
Feed gear-driven
Scavenge gear-driving
E8071
E8041
1
OIL PU14P COMPLETE
F904'l
E8104
E8058
...
2
2
Washer
cAt4sHAFT C/W PTN|ON
Drive gear
Crankshaft pinion
1
1
1
Lockwasher
'l
Nut
1
Distance piece (.325 in. thick)...
Distance piece (.310 in. thick) ...
Distance piece (.295 in. thick)...
Engine sprocket (23T)
Chain tensioner
Distance piece ...
...
A.R.
A.R.
A.R.
1
,|
86
87
88
89
14-0901
E8072
99 0739
Nut
3
Washer ...
3
Rotor
1
90
E8224
Tab washer
1
91
Eg',t46
Nut
1
(54213901)
15
1
'fllfl
\
a
,"u,
-L.7.X
(&-&-*e
I
'/Y|....-too
t@.-rs
96
27
\*
98
1
V)
76
77
4/
fla
\
'Tr
15 30
g-- s7
219
87
/lYs
\
I
62
59
Fig.3. GEAR CLUSTER AND TIMING
't6
COVERS
0l
Ref
No.
DE5CR/PIION
Port No.
QUANI/IT
GEAR CLUSTER AND TIMING
1
2
r2661
4
Tt 391
T3872
12753
5
E8015
6
E8014
7
7
7
8
12678
12679
3
9
9
9
10
1'l
T2680
13876
12664
r2665
r2666
r2667
12663
't2
E8151
13
E8152
14
15
12677
T2685
MAINSHAFT COMPLETE WITH BUSH
Pushrod bush
COVERS
1
1
H|GH GEAR (22T)
1
lligh gear bush
It4ainshaft oil seal
2
1
Mainshaft bearing
Thrust washer (.093 in.)
Mainshaft second gear (21T) ...
Spacer (.075 in.)...
Spacer (.070 in.)...
Spacer (.080 in.) ...
f4ainshafr third gear (24T)
Mainshaft low gear (16T)
Mainshaft bearing
..
Bearing circlip ...
1
A.R.
A.R.
A.R.
1
A.R.
A.R.
A.R.
1
1
1
1
Felc washer
1
,|
17
18
T2667
T7671
18
19
70
r2672
71
r2669
r3877
Lockwasher
Mainshaft nut
Layshaft and high gear (14T)
Thrust washer ( 084 in.)
Thrusc washer (.079 in.)
Layshaftbearing... ...
Layshaft second gear (22T)
...
Layshaft cr rclip ...
Layshafr rhird gear ('19T)
r3874
r2757
LAYSHAFT LOW GEAR COMPLETE (271)
Low gear bush
17670
Spacing shim
76
r7733
27
r2750
Clutch push rod ...
Clutch Iever complete ...
28
29
30
r2699
r2700
Clutch operating rack ...
Clurch operarint pinion
E8019
Thrust ball
1
31
3t
r7766
Gearbox sprocket (15T)
1
31
r7765
r7701
T2686
72
23
74
EBOO5
r2,668
1
...
...
1
A.R.
A.R.
1
1
'l
1
1
1
1
1
1
1
1
Alte r native
Alternative
37
T7702
Tabwasher
'l
33
T',t434
Nut
'l
r1164
Gear change pedal
,|
T2450
Pedal rubber
Pedal bolt (j{ in. U.H.)
34
35
36
r2703
12692
r'1277
r2107
40
12435
T2106
Screw
T2105
T1109
T3854
PIu nge
42
43
44
1
GEARCHANGE QUADRANT
...
Spring rivet...
Keeper plate
39
41
1
S
1
'l
7
2
pring
r
Return spring
Selecror
1
2
fork-main
1
sh
aft
1
17
fii
o
>t*
QO' \t
34
\^
/"\ ,"
/---\
&'-.u
I
L,."
\/
/x
//, t_55
\\loo
7a
/4
{q AL
u/
-79
/,,
19
96
27
\4
%'"'nu76
I
/P
77
Q0n
\\
:'
r"
|
'18
\)
15 30
g--
97
29
..tou
=,ou
COVERS
ffr
;to7
d^
TIMING
1
_6
&^,
illt
a
Ref.
No.
Pdrt No.
DESCRiPT/ON
GEAR CLUSTER AND TIMING
44
45
46
47
48
T2688
T3850
T1069
D2774
12691
Selector
fork-lay
shaft
Anchor bolt
Selector spindle ...
Camplate ...
Cam plate spindle
r1249
pin ...
lndex spring
Spring backing
51
r1076
Screw
52
53
T1180
Lockplate...
E8150
Camshaft
s4
E3172
P"g
55
E8153
E8154
Camshaft oil seal
Crankshaft T/S oil seal
Not illus.
49
50
o
r2689
r3763
56
57
58
59
60
r2763
r7774
61
T2330
E8157
E8155
...
Split
...
...
...
bush ...
...
...
Kicl<start foldi ng pedal
Pedal
rubber
...
11169
Pivot bolt (1 in. U.H.)
63
T'1167
S
64
65
66
67
s70
r7705
r7706
Cotter pin
Cotter washer
Cotter nut
...
...
68
69
70
r2643
r2687
KICKSTART SPINDLE...
Need le roller
Return spring
71
r3764
Anchor pin
72
73
r2657
Kickstart stoP
74
T2658
12681
Circlip
Kickstart ratchet
75
r7682
Bu sh
76
77
78
r2683
Pin ion
r2684
S
E8005
E8172
E8072-
p
ring
Contact breaker clip
Washer ...
Contact breaker cover
80
E8737
81
E7887
Gasket
87
E7354
Screw
83
E8165
E9433
E8010
Serrated washer
84
85
86
87
r2641
r2642
88
89
90
14-6612
91
E8169
97
14-6606
93
14-66'14
14-6611
14-6609
...
p ring
Steel ball
3
r7704
...
...
Oil seal circlip ...
...
Cable grom met ...
KICKSTART CRANK COMPLETE
(] in. U.H.)
OUTER TIMING COVER
Hollow dowel
Kickstart oil seal ...
Bush
cover screw (2 in. U.H.)
cover screw (1f in. U.H.)
cover screw (1{ in. U.H.)
cover screw (* in. U.H.)
cover
screw (f in. U.H.)
lnner
cover
Outer
screw (2| in. U.H.)
Outer
Outer
Outer
Outer
19
QUANI/IY
COVERS
continued
r'1"
\&-o',ou
lfrl /'
(Eb<
-&@
o/
/'o oo
,,/ ,t,
138
o, ^l ,/
az I #-A'6
i I">' >\
,rw&" i4rul\
101
(t&' p
&--.u
d
/, !r.--1
lts
7A
v@.....=--zs
19
9a
76
$
77
i3/w
K^
1,o
I
u",
(
I
96
27
\4
\"
I
ld
fl,
I
1tl
o
\
15
30
g-s7
ao
/rA?'
"63
- a2
59
Fit.3.
GEAR CLUSTER AND TIMING COVERS
Ref.
No.
Port No.
DESCR/PIION
QUANTITY
GEAR CLUSTER AND TIMING COVERS
94
95
96
97
98
99
100
101
107
103
104
105
't 06
E9389
r1026
E8162
E9526
14-6608
14-6610
14 4606
E8158
99-.1056
D995
E7788
99-0077
109
E7831
E8163
E4747
E8164
110
E8166
'107
108
lnner timing cover
Breather tube
1
1
Screwed plug
Screwed plug (socket head)
lnner cover screw (1 in. U.H.)
lnner cover screw
lnner cover screw
"O" ring
continued
(l{
(t
in. U.H.)
in. U.H.)
1
1
1
1
1
1
Auto-adYance unit (5441 6405)
Condenser
Contact breaker
Points (54419827) ...
...
Contact breaker bolt ...
Washer ...
Clamp pillar bolt
Washer ...
Contact breaker lead sleeve ..,
21
1
1
1
1
1
1
2
2
1
M'
11
d
26
d
10
gE -zs
12
M
-
-D
\ 1a
Fig.4. CLUTCH AND
PRIMA,RY CHAINCASE
r
lo
Ref.
No.
DESCRIPIiON
Port No.
CLUTCH AND PRIMARY CHAINCASE
1
rv66
7
E8782
I
3
E9393
Primary chaincase cover
l
4
E9800
Filler
5
s1855
E7856
Level plug
6
Screwed plug
\J
n ng ...
pluS
Chaincase gasket
Cover screw (1f in. U.H.)
Cover screw (1 I in. U.H.)
Cover screw (1i in. U.H.)
Washer ...
7
14-6611
8
14-6610
9
11
s1951
E8175
E8010
12
D951
Chaincase dowel
Prrmary chain (701)
13
E817 6
lg n
14
E8955
lnspection cover ...
15
E8178
Eg't77
Screw
rzv3
Clutch hub
r7714
Clutch hub l.ey ...
Clutch sprde r
10
17
1l
QUANIiIY
ition pointer
...
...
Gasket
(, in. U.H.)
19
20
r2v5
rLv6
21
ra719
Rolle r
22
23
r2720
24
27
T2721
T2722
r27?,3
T2724
ner r craining plar€
Drain screw
Ou!er retaining plale ...
Screw ( i! in. U.H.)
Shock absorber rubber drive and rebound
Centre
z8
r2D5
29
30
T7726
T7777
31
T1't44
32
r7748
cuP
Spring nut
33
17728
Pressure glate
34
r2729
35
F879
Adjuster...
Locl(nut ...
36
r2730
Retaining nut
37
12731
Plain washe r
38
r2732
Lockwasher
39
99-1006
s1894
25
26
s1943
Sprocl<et and
housing ...
,n
Driven plate
Driving plate
Spring
41
s1896
E8072
Stator (47205)
Generator stud rear (2jf in.) ...
Generator stud front (2{} in.)
Generator stud bottom (2]f in.)
Washer ...
42
14-0901
Nut
40
40
40
s1895
o
..
..
..
..
...
..
..
...
..
..
..
..
..
..
..
..
..
..
..
._
..
..
..
..
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
'''
''
..
...
...
1
7
1
1
1
1
4
5
1
1
7
1
1
1
1
4
1
1
1
1
25
1
1
1
4
B
1
5
4
4
4
4
1
1
1
1
1
1
'l
1
-l
1!
*"r".
I f also
1)
3
3
Page 13
\"
q-1-7-2e
/..
((
r\r
\
fi-7ss -::
38-'vd
@=-sz @I l-32
*e,-"n
'6/
oo
Iiz
\,1
U
?
40 eYsE:><''z8
-\G
-E
-\!t==a_/
ao
533
V
@-34
42.\€i
@-
g---43
49
- 35
/+e
dM
@
\c+
*'-^(2"-"
/\
50\
51
Fig.
5.
FRAME COMPLETE
Ref. No.
Port No.
DESCRIPI'ON
QUANI'TY
FRAME
1
FgL',t4
Frame
2
F8994
3
F8995
4
5
F8996
F8819
6
14-0't13
SwinSing arm
Spindle nut
Spindle wash
Engine shield
Bolt (3 in.
7
E8134
F9084
I
9
F9023
10
w1691
11
12
E8088
F9745
'13
F5535
't4
15
16
17
18
19
'l
Bolt
Nut
(+
Nyloc nut
s1934
Bottom bolt
2',1
E8133
Nut
72
Shakeproof
25
76
34
F8985
F8986
F8987
99-07',t9
27
D980
78
F8285
79
F9003
30
F9004
F9005
F9006
F9007
F9008
34
35
36
37
38
39
bolt
Front engi
Nyloc nut
33
7
Ball head cu
Spacer
32
'l
(jf
EB',t94
31
'l
Engine steady
Bolt
in.
Plain washer
E8084
74
'l
in
70
25
1
1
E8194
F8988
F8984
E81
spindle ...
(3*
'il
in. U.H.)
Rear stud
Spring wash
Nut
Battery (54077029\
Battery ve
Battery carrier ...
Battery tray rubber
Nut
Bolt (3 in. U.H.) ...
E8137
F9086
F9007
F9087
Spacer
l4ounting rubber
F90'10
Washer ...
40
E8194
41
Nyloc nut
Tool tray c/w clips
Not illus.
F9090
F9157
42
F9091
Plug fcr tool tray
Bolt (641 in. U.H.)
43
F9092
Spacer
44
F8071
45
F9060
Nut
Bolt
46
E8072
Washer ...
47
E8071
Nut
48
F9094
Bracket ...
49
F9093
Rubber buffer
50
F9945
Silencer mounting bracket
(f
in. U.H.)...
75
\*
:\a --:=:
^ss
sa*d
@--gz
,a/
'.-(,(
-e-"n
00
1iz
\
?
ab
zs
6L-32
I
U
QY*s<"
-\e\
--)
v(ei-r {
-\lt=4--'l
@
e-=>33
\..
42-g
@-
9.-- 4s
q.
44
66
j6
t/
\f,
@
ssA/
X\
l-
h/u-5
/T
50\
5t
Fis.
5.
FRAME COMPLETE
Ref. No.
DESCRiPT'ON
Port No.
FRAME
QUANIi
continued
14-0115
Bolt
L
w2320
Spring washer
53
'14-0307
Nut
7
7
54
55
F9272
Tank anti-roll ru bber ...
Steady stay bracket
51
E8189
2
1
0
77
IY
Flg.6. S}VINGING ARM AND SUSPENSION UNITS
Ref.
No.
DESCRIPTION
Port No.
QUANTITY
SWINGING ARM AND SUSPENSION UNITS
Swinging arm
S ile n tb loc
1
susPENsroN uNrT (640s4927)
5
D2067
99-1057
99-0107
6
99-0122
7
99-1058
8
F8997
F8998
Bonded bush-top (64533645)
Bonded bush-bottom (64533654)
Unit fixing bolt (1i in. U.H.) ...
Plain washer
7
2
2
2
2
2
2
1
F9210
2
F8993
3
4
2
...
Spring (64543626) ...
Spring retainer (90541171\
9
10
s1-52
11
14-0903
Nut
Nut
2
17
F8933
Washer .,.
2.
't3
F9766
Propstand leg
1
14
t3097
Swivel pin
'l
15
16
17
18
F3096
Lockwasher
Spring
1
Chaingu ard
1
19
20
E8071
'14-011 3
Bolt +t in. U.H.)
Nut
Bolt (1j-i in. U.H.)
21
s25-2
Plain washer
,|
22
14-0902
Nut
'l
FZ6',t0
F9950
F9060
2
1
(1
1
1
I
r6
)4i
29
1ra
13r
HM
<;v\
1,4\t
6f*
14
4H
17
<-\-\.-\
,tl
o
Y
34
%'ttt
Fig.7. OIL TANK,
PANELS AND EXHAUST SYSTEM
o
Ref No.
Port No.
DESCRIPIION
QUANTITY
OIL TANK, PANELS AND EXHAUST SYSTEM
1
2
3
4
s
6
7
8
9
10
11
(
I
114-0219
*1
I
Muffler
E8163
E9659
F8976
F8977
F8978
F9743
F9067
F9068
F6039
F9075
F9076
1
washer
Spring washer
sze-r
51832
1
"D"
E3768
L S1e08
F9019
F9020
F879
E9679
1
FIXING CLIP
Bolt (1+ in. U.H.) ...
I
Not illus.
1Z
13
14
15
'16
17
18
19
20
21
27
23
24
25
76
27
28
29
30
3',1
32
33
34
35
36
37
38
39
40
4t
42
E9653
E5A74
1
1
Locknut
Bolt
1
(f in. U.H.)...
Nut
7
2
7
Heat shield
Screw
z
Washer ...
2
Spring washer
1
Exhaust pipe
Finned collar
1
1
Screw (+* in. U.H.)
1
Nut
Oil tank ...
Bolt (1i in. U.H.)
Nut
1
1
7
2
7
Rubber sleeve
FTLLER
CAP C/W D|PST|CK AND
Washer
F8874
F9070
Banjo
F9071
Filter
1
F9146
Rubber connection
1
F9073
Clip
2
F9274
Rubber connection
I
E5473
E8106
Clip
2
Rocker oil feed pipe
1
E8'111
Clip
1
F9177
F9477
Rubber sleeve
1
F9478
D982
D1006
D983
D984
D1922
D1923
F10253
F8953
577'l
Fibre washer
2
Panel D/S
Panel T/S ...
1
1
Oddie stud-short
Oddie stud-long
Stud rubber (for long stud)
Stud rubber (for short stud) ...
Panel motif D/S ...
Panel motif T/S ...
...
Protective strip ...
Grommet for T/S panel
Oil tank bottom fixing bolt
1
3
3
1
'l
'l
2
1
1
*Later models
use
E2271
Fixing clip
14-0219
Bolt (1{ in. U.H.)
1
E3768
"D"
2
s26-3
Washer ...
1
s1908
Nut
1
1
washers
31
'!o
25
I
@/h
i'
r
'i
6r-4." K.-@
@ ----".-----'
,"9e,Nil.
.ry
22
\!'/
/
\\---,,
37
6r^) W,"
;^
/A."_.yF A\\
dr/i.P^"
"
F
t-re)€^-i*-*
""
36
e
I
39
fQ
27
'qo
tt--^---,"^.
"!"
Fis.8.
FOOTRESTS
3s
/
:-\
---Z
AND BRAKE LINKAGE
^O
32
Ref. No.
0
QUANIIIY
FOOTRESTS AND BRAKE LIN KAGE
1A
7
w2376
Rear brake pedal
Grease n ipple
F9032
Fulcrum pin
1
1
F90ll
1
1
3
F9033
Nut
1
4
F9034
Spring washer
1
5
E8193
6
s26-l
Bolt (t in. U.H.) ...
Sprint washer
7
8
F9035
F9036
9
w2006
1
1
'l
10
F9958
't1
F9038
Plain washer
Rear brake rod ...
Toggle spring pin
Brake pedal stop
Swivel pin
17
F9039
F9040
Adjusrer nut
Pedal stop bolt ...
7
t8979
F9041
Plain washer
Shakeproof washer
2
2
13
14
15
,!!
DESCRIPIION
Port No.
F9047
Nut
11
F9043
Fold ing
18
F8448
Footrest bracket
't9
F9044
Anchor bolt
70
E8084
Plain washer
21
F9045
Bolt
22
F9046
F8986
F8987
74
25
1
1
1
'l
1
2.
footrest
(2i:;n.
...
.2
...
2
7
2
'l
U.H.)
Plain washer
1
Sprlng washer
Nyloc nut
Nyloc nut
Special srud (2 ln. O.A.)
Locking plate
Washer ...
1
1
2
78
29
30
F9085
F9047
F9048
F9049
F9050
F9034
JI
F9051
Footrest
37
F9057
F8137
Bolt
Nut
34
35
36
F9053
Pillion
F9054
Ru
F9044
36
F9055
F9085
F9133
Anchor bolt T/S ...
Anchor bolt D/S
Nut
Bolt (11 in. U.H.)
Nut
Pillion footrest support bracket T/S
41
14-0116
Bolt
3
47
'14-0702
Nut
3
77
33
37
38
39
40
F9057
E8137
I
1
1
Nut
1
I
Spring washer
('1
f
rubber...
...
7
2
7
...
2
in. U.H.)
foorrest ...
7
bber
t
33
,1
1
7
2
z
'l
-
43=6-*\@
'1
0
42'@
<s
:a-
E44
41
-@p.
59
34
b
P.o
g
sr€-no
#
dA\
\=\9-39
3g "i
--10
\bo
11
13
'lo
G'-49
15
16
17
'ia
ry
6
€-,,
a.\
n -29
il
JL""
p
fJ- sr
V--.\ 32
Ae
€
d-*
Fig.
9.
TELESCOPIC FRONT FORK
TO
Ref.
No.
Port No.
DESCR/PIlON
QUANIIIY
0
H3671
I
H7294
2
H2295
3
H',t844
4
14-0218
5
s26-3
5
H519
H430
H3694
H3693
7
8
9
10
H
't1
17
H2632
13
14
15
16
17
18
3638
H2633
H2513
H3678
H1656
FORK ASSEMBLY
D.S. BOTTOM MEMBER C/W CAP ...
T.S. BOTTOM MEI"IBER C/W CAP
Spindle cap
Cap bolt
Spring washer ...
1
1
'l
7
4
4
7
...
Drain plug ...
Drain plug washer ...
Top cover T/S
Top cover D/S
Spring su pport
2
1
1
2
Sealing washer
Sealing washer
4
Gaiter
2
l.1ain
spring...
2
...
2
Spring support washer
7
1
H'1500
Oil
H3639
Reference only
LOWER COVER TUBE ASSEMBLY
Sleeve ...
2
H7119
"O"
7
7
7
seal
Not supplied
separately
,rll
19
20
H431
71
H441
ring
Outer washer
LJpper bearing
22
H3672
H2245
lnner sleeve
2
Top nut
7
Washer
Stanchion
2
2
24
25
76
28
H2653
H3637
H443
H2154
Lower bearing
2.
5huttle valve
2
Nut
').
...
H2091
HZ127
Circlip
H2090
Restrictor
3t
H 1062
37
H7126
33
H1631
H2630
s785
Sealing washer
Flanged bolt
Spacer
29
30
34
35
36
37
38
39
40
s25 2
14-0303
H7526
H2648
42
H2525
H2658
H2659
43
H7645
44
H?,646
45
46
H2656
47
H2655
H2651
41
48
49
50
F898't
H2654
s70-3
z
...
...
7
7
2
2
2
Washer
Pinch bolt ...
...
Washer
Nut ...
M idd le lug and stem
Bottom cone
Top lug
Cable guide bracket
G rom met ...
...
Bolt (1+ in. U.H.)
Nut ...
Bolt ...
7
7
7
1
1
1
2
2
'l
7
4
4
Washer
Hand lebar clip
z
nut ...
Cable gu ide ...
...
...
Steering head ball ...
Sleeve
1
1
40
35
43_@:::@
"&S
1t
a
1l
a
42-_€
E44
U-
g
sc
51
50
39
;,9.-;
#
35
26
<_/49
<r
7
€-,,
a\
n -20
il
J L.-*
\a
!s>- --31
f7
H=.-
32
tr@
I6
F"
Fig.
9.
l)lo
Ref,
No.
Port No.
DESCRIPIION
51
52
H2647
H2650
53
H3746
54
't+0218
1+0702
Top cone
Dust cap
Mounting bracket
Bolt
Nut
55
56
1+61m
Bolt
57
s26:2
Spring
58
59
60
E8088
Spacer
washer ...
sink...
H2737
Heat
H7275
Zener Diode sealing plug
...
QUANflTY
conrinued
$t
11r
Fia. 10, FRONTWHEEL
38
I
fla
Ref
No.
Port No.
D€SCR/PTlON
t
FRONT vl/HEEL
w3465
w2132
7
w1230
w3325
3
wz't37
1
FRONT WHEEL COM PLETE
RI14, SPOKES
1
AND HUB
ASSEMBLY
I
Hub ...
1
6
w2136
w653
w1237
7
wl238
Circlr p
w2057
Wheel
3
4
5
I
9
w2138
w2139
w1481
10
w3443
't1
w3337
12
13
14
15
16
w582
w3429
w3444
17
18
19
w3453
z0
1
Rim...
Spoke D/S 8 SWG x 6 in. straight
Spoke T/S 8 SWG x 5fr in. 76" ...
Spoke T/S 8 SWG x 5g in. 100'
Spoke nr pple
Bearing ...
Dust cover
3
!i
QUANTITY
20
10
10
40
a
1
1
spindle ...
Grease cap D/S ...
...
1
,|
Cover place
Bearing supporr ring
Bearrngretainer...
1
1
...
1
Anchor plate
1
s650
Gauze
Screw
3
F2351
Washer ...
w2026
2.
w3454
Brake abutmenr pad
Brake cam
Brake lever-front
Brake lever-rear
21
w7077
Washer ...
2
22
14-0403
Nut
2
23
24
w3522
Return spring
I
w3450
w2005
Brake rod
26
27
28
29
30
3l
32
33
34
34
w2001
1
3
7
1
1
1
D2683
Fork end-threaded
Lockn ut ...
Pivot pin ...
Split pin ...
7
w2058
Nut
1
w3446
BRAKE SHOE C/W
2
Ref. only
Ref. on ly
Lining
Rivet
S p ring
7
14-040'l
WF32
w135
w1197
w1198
1
1
2
't6
7
A.R.
A.R.
Balance weight j ozBalance weight 1 oz.
I
39
/a(
12
@
.11
@
tt
15
16
d-d
fi I
w
B
-/F\
a-(J
Fig.
ll.
REAR WHEEL
40
flo
Ref.
No.
Port No.
DESCRIPT'ON
QUANIIIY
REAR WHEEL
w3581
'l
7
3
4
5
w3452
w2290
w2297
w2297
w2293
w2294
w7291
REAR WHEEL COMPLETE (LESs BRAKE AND TYRE)
REAR WHEEL COMPLETE (LESS BRAKE AND TYRE)
RIM, HUB AND SPOKES ASSEMBLY...
Hub complete
Spoke D/S
Spoke T/S
Nipple...
1 with 49 T sprocket
I
1
40
Rim
1
I
w2309
w2339
w1015
Fixed spindle nut ...
Chain adjuster
Chain adjuster end cap
z
z
9
10
E8137
E8088
Adjuster nut
Adjuster washer
2
2
11
w2335
Brake anchor strap
I
12
w2336
Bolt (11f in. U.H.) ...
1
IJ
v't7337
Washer
1
14
15
16
F9085
Nut
1
w2325
Fulcrum pin nut
Fulcrum pin washer
Fulcrum pin
Brake anchor plate
BRAKE SHOE COMPLETE WITH LINING
Brake lining ...
...
w2323
18
19
w2322
w7327
20
Reference only
Reference only
21
22
73
24
25
26
27
w2328
w2329
w2226
w2326
w2334
w2330
1
Brake rivet
Brake shoe sprint ...
Brake cam lever
BRAKE CAM
Grease nipple
Brake lever return spring
Plain washer
Shakeproof washer
1
1
1
1
7
2 fNot
14
'l
1
1
1
31
D1026
31
D1028
3/
w2314
Rear chain (f x
Rear chain (i x
Drivint flange
33
w23t2
Bearint spring ring...
'l
34
w231'1
Bearing shim
'l
35
w2315
w2316
w2308
w2305
Bolt ...
6
Nut...
6
Fixed spindle
Bearing retaining ring
I
w2298
w2299
Bearing
2
38
39
40
1
Nut...
1
Locking ring
I
i
x 101L)
x 991)
...
...
3
...
...
1
'1
1
Thrust washer
Was he r
1
42
43
w2300
Spindle sleeve
1
44
w2295
w2318
Security bolt WM3...
7
w2354
Chainwheel (52T) ...
Chainwheel (49T) ...
Chainwheel bolt
45
46
46
47
w2321
w2319
East coast
y'est coast
\
1
w2313
w2363
41
\separately
1
w2331
36
serviced
7
28
29
30
w2332
w73't7
52 T sprocket
20
1n
6
7
w2324
with
1
1
I
Bearing
Brake drum...
1
I
'1
10
41
East coast
West coast
,$l
12
trfr{?n
14
W
w
rll)o
-€\
4-(-i/
Fig.
ll.
REAR WHEEL
42
fillo
Ref.
No.
Port No.
DESCRIPflON
REAR WHEEL
QUANTITY
continued
w2320
w2302
Spring washer
10
49
lnner retainer
1
50
w2301
Felt washer
1
51
w2303
Outer retainer
1
52
vv2304
53
D1026
54
w2306
w2307
Hub end cover
Speedometer gearbox (BG5330i31) 2 :1
Distance collar inner O/S ...
Distance collar outer O/S
Hub spindle
48
55
56
w2333
1
1
1
1
1
w',
ft,
-
.
'w
'%:,,
?*"'
,, )
ebEb
'11
4
oQ
Kd-s7
s)e
*-e
%
Fig.
12.
FENDERS
o,,
-Ref. No.
DESCR/PTION
Port No.
FENDERS
c
4
F9016
H3619
H3671
H3685
6
F9019
F9068
1
2
3
7
8
9
10
F9029
E8088
w1691
F9017
F9088
1'l
12
13
14
15
16
wl691
Bridge stay
Bottom stay
Bolt (+ in. U.H.) ...
Nyloc nut
Bolt
Washer ...
Nut
Bolt (J in. U.H.)...
Bolt (1 * in. U.H.)
Nut
14 0114
Bolt
s25
Plain Washe r
3
GS299
Washer ...
14-0707
Nut
Rear fender
1F9165
F9019
F9077
F9020
Special
71
t879
27
F9023
Nut
Bolt
23
E8088
E8137
Washer
75
26
F9028
Wiring grom met
27
*Ft0270
28
E2980
29
30
37
F9132
s25-1
F9030
F9068
33
F9198
Rear
34
F9019
Bolt (+ in. U.H.)...
35
s25-1
Washer ...
36
E8071
Nut
38
39
H3669
H3680
s1822
Bracket O/S
Bracket N/S
40
F4299
Washer ...
41
F4715
Screw
47
s5161
Nut
F11 335
3t
'r
{t
Front fender
Front stay...
17
18
19
20
74
0-.t
QUANI/IY
F81
39
tF9s05
Bolt (+ in. U.H.) ...
Spring
Washer
Washer
(l{
...
...
...
...
in. U.H.)
...
Nut
Rear fender support rail
Tail
lam p support
Stud (jf in. o.A.)
Support plate
Washer ...
Spacer
Nut
Bo
nu m
ber plate bracket
lt
Tail lamp support fitted to later models
Rear guard fitted to later models
I
I
I
45
I
@'",,
r
17
Fig. 13. GAS TANK AND
T\i/IN
SEAT
f{ll]o
Ref
No.
Pdrt No.
0
GAS TANK AND T\^r'IN SEAT
tank ...
Mounting rubber-rear
F9479
F9690
Gas
2
lnlounting rubber-front
Bolt (1+ in. U.H.)
Distance tube
Distance tube
1
3
F9134
4
fl0a59
5
F9063
6
F10250
F10260
F9065
7
8
Mounting rubber
Plain washer
E8196
F9480
F4715
Nut
Trim strip
124
H430
H430
Washer ...
Washer ...
13
F9700
13
F9701
Styling unit T/S ...
Styling unit D/S
14
15
F8197
Knee
F8193
Knee grip T/S
16
17
18
19
19
20
F8946
F7888
Styling unit screw-front
20A
23
Fl 0002
F10267
F9744
F9196
24
s5662
Bolt
E8088
26
17
28
29
w2320
9
10
11
12
D
DESCR/PTiON
21
2t
69
F4971
F97
F4972
E7351
Screw
(:;
in. U.H.)
grip
D/S
...
Styli ng unit screw-rear
Gas line -..
Gas tap ...
Gas tap-with Teserve -..
Gas tap washer (Stat-o-seal) ...
Steel washer
Filler cap
Tie bar
piece ...
Distance
(N
F9020
Plain washer
Spring washer
Twin seat (cover F9504)
Rear flxing bracket
Sprint washer
30
E8101
Nut
31
Plain washer
32
s602
F'l1304
33
F9023
Bolt
34
E8088
Washer ...
35
w1691
Nut
F9477
F9476
Hand
rail
(li
...
in. U.H.) ...
...
in. U.H.)
[n
QUANTITY
fl
zs'/
@
I
...
oX
1104
\z\ d'--.
#\
4r''
k WqY-'
6.Y
--.-u
/*
YN\''
9
\N.
M
@,}
\o
iI
t
Fig.
14. HANDLEBARS, CONTROL
LEVERS AND CABLES
,l
fr
I
fI(
qZ
Ref. No.
P.rrt No.
QUANI/IT
HAN DLEBARS, CONTROL LEVERS AND CABLES
0
1
z
3
4
5
6
7
I
9
l0
11
17
13
14
15
16
17
18
19
H2678
99-0248
D958
99-0245
99-0746
99-0744
99-0738
99-0239
99-0740
99-0226
99-0241
D959
D2090
99-0267
99-0A62
99-0230
99-0226
99-0250
99-0252
99-1031
99-'1059
D2074
tl)
DESCR/PTlON
70
99-0265
21
99-026',1
22
23
99-0230
99-0752
99-0226
99-0250
99-1031
24
25
/t)
27
28
79
30
3l
99-'1059
D967
*D2050
D2085
D2086
D638
33
w2006
34
D2083
Hand lebar-Western cype
rwrsTGRrP (161364) ...
1
1
I
Handlebar grrp
Body top half (16/328)
Body bottom half (16/329)
Rotor (16/091)
Fnct ion sprint
I
1
1
(16/008) ...
1
Friction spring screw (16'0091
1
Nut (16/010)
1
Screw (11 /014)
Cable stop (16/011)
2
,|
Dummy grip
FRONT BRAKE LEVER (ball end) (18/951)
Lever bracket (18,777)
Lever ('18/754)
1
1
1
I
Control clip (12/595)
Clamp bolt (11 /014)
Fulcrum pin nut (18/053)
Fulcrum pin (18,087)
1
2off
,|
'l
Cable adluscer (18i1708) ...
1
Thumb nut (18/1709)
1
CLUTCH LEVER (ball end) 18/952)
Bracket (18/773)
Lever (18/752)
...
...
...
...
1
'l
,|
Cont rol clip (121595)
'l
Fulcrum pin ('18/087)
1
Clamp bolt
7
(11
/014)
Fulcrum pin nut (18/053)
Cable adjuster (18/1708) ...
Thumb nut (18/1709)
THROTTLE CABLE
FRONT BRAKE CABLE
Front stop switch ...
Rubber cover
1
1
1
I
1
'l
1
Fork end
Pivot pin (spring fix)
1
1
CLUTCH CABLE
1
I
r[,
1,D2034
FRONT BRAKE CABLE fitted to later models
I
49
t'
na
@\
,t 1\
]I
lJ ,.-q
5
I
0
25 -_@
20' -@
4ra
a\2
16 ,,
," ;s
/ff)'"
I -L,z"'
N@K"',
\7
Fig. '15. SPEEDOMETER AND TACHOMETER
(o
)
Ref.
No.
0
QUANI/IY
,|
D't022
Tachometer (R.S.M. 3003/06)
2
Dz123
Cable
3
4
H3689
F9170
Mounting plate ...
Mounting rubber
5
F917'l
Screw
6
F9172
Washer
7
F9173
Nut
F9174
Bu sh
't1
E9428
E9517
E938'l
E9382
TACHOMETER GEARBOX COMPLETE
Drive body ...
...
Drive shafr ...
...
Drive gear ...
...
12
E9429
IJ
E9383
14
15
16
E9430
E9431
E9432
Retaining pin-drive gear
Thrust washer
(J nng
Locating pin
Joint washer
17
D1926
SPEEDOMETER (SSM2001 /02)
18
3',t
't9
30-283-01 4-11
30-271 -0't 4-11
9
10
20
Nut
Cable
22.
')?
F909',|
Bo
24
E8072
25
26
27
643
99-0695
Not illus.
H
E8102
3700
Mou
...
...
1
1
..
,|
1
4
4
4
4
.
Fixing strap...
Serrated washer
-647 -187 -01
D697
H3626
21
0
DESCR'PIION
SPEEDOMETER AND TACHOMETER
I
)
Port No.
...
1
1
1
1
1
1
1
1
1
1
Rel only
Rel only
...
Ref. only
1
ntint plate ...
1
lt
2
7
2
Spring washer
Bulb
7
Bulb holder (554710)
Wire clip for speedometer cable
2
0t
51
1
F
ea
3
\t4
\u@)
l"
@..
8,"
&-,o
"*:t/
ffi
G5,"
./)
=--\-
\ss-\
r(#
23'iw
26
/S
A \\
i" ' ,/",
0a
1
25
,-\
,
34
/ul
39
ffi 'ov {J
"":P
"
"o
s""
43
42
6da'
j,
uu
m,
'M'(-'"'
U-* ffi
m
-'-D>N,",
\!--+4
\K(
*d."
) gffi." ."{tT.
Affi
\ou
-tt"
^"
Fig.
16. ELECTRICAL EGrUIPMENT
52
flo
Ref.
No.
Port No.
DESCRIPT'ON
QUANTITY
ELECTRICAL EAU IP MENT
*99-1040
2
99-0691
99-1041
3
99-0683
4
99-1042
1
HEADLAMP ASSE|.4 BLY (60037)
Rim (s34343)
I
1
Litht unir (54524526)
Fixing wire (504665)
1
6
5
99-1003
Bulb (40/27W pre-fodrs) (464) ...
Adaptor C/W leads (54520540)
6
7
8
9
10
99-'t004
Bolt (112201)
z
H1932
Spacer
Screw
2
11
99-0556
99-0568
99-0537
99-0803
99-0548
99-0695
54190108
99- 1053
Bulb (2wBA.7s) (281)
Warning bulbholder (54945043)
Pilot bulb (989)
Pilot bulbholder (55471 0)
Double Lucar blade
Harness (54955718) ...
Reference on ly
Scop-tail lead
Rectifier C/W securing nut
sTop AND TA|L LAMP ASSEMBLY (53973)
22
99-0589
99-0597
99-0781
99-0698
73
99-0542
24
54574348
25
26
54578213
573828
Contact assembly ...
27
28
99-0780
F4715
Gasket (54571677)
Screw
29
30
GS299
F8307
F8286
12
13
14
l(
16
18
19
20
21
't44921
1
1
Ref. only
Ref. only
Plate ...
55408
99-0563
Lighting swirch (3571 0)
Dip switch (31620)
1
'l
Warning light (Red)
I
2
Ref. only
1
'l
Ref. only
1
1
1
'l
Lens (54572932)
1
Screw (572289)
2
Bulb (6/21W cffset pin) (380)
Bulbholder with refl ector
1
Ref. only
Ref. only
Ref. only
Bracket
1
7
2
Washer
Stop and tail lamp lead
tube
Front reflector C/W bracket
Horn push (76204)
...
...
'l
...
33
F8273'
34
F8140
35
F8195
Push-Fix...
2
2
7
7
4
36
D997
Ho rn
I
F5535
Bolt
38
39
40
::.tr
Washer ...
spring washer ...
E8194
Nut
41
99-0574
coil
42
423947''
43
F9131
Coil support clip...
Bolt (t in. U.H.)
44
s602
F4374
Washer ...
Distance piece ...
31
32
45
1D994
*D2166
fF8318
,
Rear reflector
Rubber washer
...
...
'l
1
...
::.
.::
1
1
(45110)
1
'l
1
1
...
'l
Head lamp 54052910 fitted to later models.
Ducon horn push (WIPAC 16714) fltted to late! models and
dip switch
53
I
I
f(
fll
Fis.
15. ELECTRICAL EOUIPMENT
54
flO
Ref.
No.
Port No.
DESCR/PIlON
QUANTITY
ELECTRICAL EQ U IPME NT
46
47
48
49
50
51
52
53
54
55
56
E8071
Reference only
99-0590
F6981
99-0558
99-1000
D990
Nut
H.T.
continued
1
lead
Zener
I
iode (49345)
Itnition lock C/W keys
lSnition switch (31899)
d
1
1
'l
IGNI'IION SWITCH NUT (s4130041)
Stop switch (34815)
F9't91
Bolt
F8979
E9'172
Spring washer ...
...
Cable slip (stop switch)
D999
H.T. lead grommet
...
...
1
1
2
2
1
I
55
f,^
€
lo
4
re
I
TOOL KIT
I
Ref.
No.
Port No.
DESCR/PIION
QUANTITY
J
1
TOOL KIT
D7113
2
D291
D968
3
D801
4
D87
5
D767
D2084
D971
1
6
7
o
9
10
D972
NA'I4A
1'l
D974
D978
12
XA69
'13
D1029
'14
H2654
TOOLROLL COMPLETE WITH
I
.1
TOOLS ...
Toolroll
Suspension unit spanner
Combined tyre lever and tomm)'
Plug spanner
bar
Screwdriver set
Spanner
Box spanner
Ring spanner
Tyre lever ...
Tyre valve key
...
Cable clip-rubber
Cable clip
Cable clip
Cable clip-wire
57
...
R
v
@
t-5
)€
lo
)O)o
4
$€
€
a----.
--5
!
H
il
ll--"
il
U
@L
il
o^oo
!
Fis. 18. CARBURETOR
^'o
Ref, No.
DESCRiPIION
Port No.
CARBURETOR
0
D2021
CARBURETOR COMPLETE (R928/4)
1
99-0521
Screw and washer (622/086)
4
2
99-0271
Plug screw (411 37A)
1
3
99-0531
Top cap (928,097)
4
Th
10
99-0507
99-0510
99-0529
99-0527
Reference on ly
99-0445
99-0516
11
99-0515
12
13
14
99-0520
5
6
7
I
9
16
17
I
QUANTITY
1
...
...
rottle sprint (622/051) ...
1
1
...
Circlip (6221067) ...
...
Need le (928/063) ...
Th rortle valve (3) (928/060)
1
Body ...
lYain jet ('160 c.c.) (376/100)
'l
1
,|
1
rottle stop suew (6721077\
Prloc air screw (6221076) ...
''O" ring (6221082)
"O ' ring (6221101)
...
Gasket (622/073) ...
Need le jet (6221079)
JeL hold er $22/080)
'l
(62?/069)
spind le (522/071)
1
99-051'l
99-0506
Floar
Float
Float
Float
needle (6221068)
chamber (622/050) ...
1
61093
Filter
99-0527
99-0514
99-0518
99-0519
99-0512
18
19
20
99-0513
71
37
72
73
99-0517
D1053
24
t9194
Th
1
2
1
1
1
1
1
1
1
Banjo bolt (6221078)
1
AIR CLEANER COMPLETE
Air cleaner element
...
...
l,r
59
1
'l
Ptinted in Englond by
WARWICK PRINTING COI4PANY LIMITED
WARWICK

1969 triumph tr25w 250cc

Transcription

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