T100 1971 - JRC Engineering, Inc.
Transcription
T100 1971 - JRC Engineering, Inc.
REPLACEMENT PARTS CATALOGUE FOR 1971 DAYTONA (T I OOR) TROPHY 500 (T I OOC) TRIUMPH ENGINEERING MERIDEN WORKS . ALLESLEY TELEPHONE COVENTRY 20221 MERIDEN 331 PUBLISHED JULY 1970 . COMPANY COVENTRY CVS 9AU LIMITED • ENGLAND TELEGRAMS "TRUSTY" COVENTR"Y TELEX "TRUSTY" 31305 PUBLICATION PART No. 99-01134 ADVANCE INFORMATION The Triumph Engineering Co. Ltd. point ou t that this catalogue is not complete, but at the time of going to press neither the infor mation nor time required to complete many of the illustrations was available. A complete catalogue will be issued as soon as possible. A plastic binder, of the t ype used for Workshop Manuals, is available to enable this catalogue and all other 1971 season catalogues to be bound into one un it . GUARANTEE Please refer to your local 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 Tel e phone-301-252- 1700 Telex-Tricor Duarte 675469 Telephone-213- 359-3221 213- 681 - 0255 ENGINE AND FRAME NUMBERS The engi ne number is located on the left side of t he engine, immediately below the cylind e r barrel to crankcase flange. The frame number is located on the left side of the frame head lug, 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 mach ine. .. .... 2 • ...... INDEX Page 67 AIR FILTER ALTERNATOR ... AUTO-ADVANCE UNIT BATTERY CARRIER BRAKE SWITCHES BREATHER PIPES Page HANDLEBARS HANDLEBAR MOUNTINGS ... HEADLAMP HEAT SINK HORN .. 25 000 69 000 9,35 000 77 77 o 67 45, 73 KICKSTARTER. 65 000 o 15 ... 37, 41 OIL PUMP OIL TANK OIL PIPES 13 65 65 PISTONS PROP STAND PUSH RODS 43 REAR. WHEEL .. RECTIFIER. REFLECTORS ROCKERS 0 31 000 MANIFOLD MUFFLERS CAMSHAFT, INLET AND EXHAUST 9 75 CAPACITOR, IGNITION CAPACITOR PACK 75 CARBURETOR 17,19 CARTON PACKS 7 43 CENTRE STAND CHAINS .. 35 CHAIN CASE 35 CLUTCH 33 CLUTCH LEVER ASSEMBLY 31 COIL 77 CONNECTING RODS 9 CONTACT BREAKER .. 25 CONTROL CABLES 73 CONTROL LEVERS .. 69 CRANKCASE .. 11 CRANKCASE UNDERSHIELD 41 CRANKSHAFT .. 9 CYLINDERS 21,23 CYLINDER HEAD 21.23 71 75, 79 9 ... 21' 23 55 0 77 .. . 57, 63 23 o SIDE PANEL SPARKING PLUG SPEEDOMETER .. SPEEDOMETER. GEARBOX STEERING DAMPER STEERING RACES SUSPENSION UNITS SWINGING ARM SWITCHES o 0 ENGINE PLATES ENGINE TORQUE STAY EXHAUST PIPES EXHAUST PIPE ADAPTOR FENDERS FLASHERS FOOTRESTS FRAME .. FRONT FORKS FRONT WHEEL FUSE ASS EM BL Y o GAS TANK GASKET SET GEARBOX 0 000 00 0 39 39 37, 41 21,23 71 43 45 45 000 TABLE OF STANDARD HARDWARE TACHOMETER ... TACHOMETER GEARBOX TAIL LAMP ... TAPPETS TIMING GEARS TOOLKIT TWIN SEAT 57 79 ... 41,43 43 ... 47, 49 51 . 53 0 77 81 55 0 000 00 61 69, 79 82 81 81 59 21, 23 9 67 61 00 67 VALVES .. VALVE GUIDES o 63 7 27, 29. 31 3 ... 21, 23 21' 23 000 WIRING HARNESS 79 ZENER DIODE 77 HOW TO USE THIS PARTS CATALOGUE 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 e nd 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 colour required. Painted parts are availab le only in the colours or alternatives specified for that model of that particular year. Model T100C T100R Colour }olympic Flame and Black 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 CATALOGUE 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. ...... 4 • ...... TIGER 100 (T100C) TECHNICAL DATA Bore and Stroke 2.716 x 2.578 ins. Capacity 30 cu. ins. Compression Ratio 9 :1 Spark Plugs Champion N4 Carburetor Amal Concentric 170 .106 Standard No.4 Main Jet Needle Jet Needle Throttle Valve Gearbox Sprocket 18 teeth Chains Front Rear ~in. Duplex x 78 link~ tin. x j in. x 102 links Capacities Gas Tank Oil Tank Gearbox Primary Chaincase (initial fill) Front Forks (each leg) 2i U.S. galls. 6 U.S. pints 2/3 pint (375 c.c.) -k pint (150 c.c.) t pint (200 c.c.) Brakes Front and Rear, diameter 7 in. (17.18 em.) Tire Size Front Rear 3.50 X 19 4.00 X 18 5 TIGER 100 (T100R) TECHNICAL DATA Bo re and St roke 2.716 x 2.578 ins. Capacity 30 cu. ins. Compression Rat io 9 :1 Spark Plugs Champion N4 Ca r bu retor Amal Co nce nt ric 150 .106 Standard No .3 Main Jet Needle Jet Needle Throttle Val ve Gearbox Sprocket 19 teeth j in. Duplex x 78 links Front Rear i Capacit ies Gas Tank O il Tank Ge arbox Primary Chaincase (In itial fill) Front Forks (e ach leg) 2~ U.S. Galls. 6 U.S. pints 2 /3 pint (375 c.c.) t pint (150 c.c.) t pint (200 c.c.) Brakes Front, diamete r Rear, diam eter 8 in. (20.32 em.) 7 in. (17.18 em.) Tire Size Front Rear 400 Chains in. x 3.~x 6 X ~in. 19 18 x 103 links CARTON PACK LIST ...... The following sub-assemblies are supplied in carton packs under the part number stated. The contents of these carton packs are preserved and will not deteriorate under adverse conditions. PISTONS (cfw rings, gudgeon pins and circlips) E.6906 7.0 : 1 C.R. 500 c.c. Low grade fuel E.6884 9 : 1 C.R. 500 c.c. T100R, T100C E.7603 7.5: 1 C.R. 500 c.c. Available All piston assemblies are available in 0.010 in., 0.020 in., 0.040 in., oversizes (0.25 mm., 0.5 mm., 1.0 mm.). BRAKE LININGS C.P.38fAM2 C.P.205 2 NW243 Brake lining 16 W129 Rivet 2 W1734 Brake lining 16 W129 Rivet 4 E5946 Inner valve spring 4 E4011 Outer valve spring H111 H439 H1018 570-3 Cup Cone Top cone Ball VALVE SPRI!"GS (all models) C.P.177 STEERING HEAD RACES C.P.156 2 1 1 40 GASKET SETS Decoke Overhaul 99-1164 99-1167 7 15 14 ~~ ll t-------7 16 ..... 17 Fig. 1. CRANKSHAFT AND CONNECTING RODS 8 19 20 21 • • • Ref No. Part No. DESCRIPTION QUANTITY REMARKS .... C R A N K s· H A F T 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 32 33 34 35 36 E9489 E9490 E3999 E9492 E5870 *S1913 E9915 E9914 52016 E3706 E6884 E6893 E6894 E6861 E6869 E9505 E3734 E3851 54213901 E3975 S1915 E1580 E1771 51914 E6160 E400 E4562 E1558 E11007 E6523 E11064 E9984 E9983 E9988 E9502 S2051 E9503 .. AND CONNECTING RO OS CRANKSHAFT AND FLYWHEEL ASSEMBLY Crankshaft ... Oil tube Screwed plug Flywheel ... Flywheel bolt (1# in. U.H.) CONNECTING ROD ... Connecting rod bolt Self-locking nut ... Big end bearing (available in -.010 and -.020 undersizes) PISTON COMPLETE C.R. 9.1 Taper compression ring ... Oil control ring Gudgeon pin Circlip Distance collar ... Engine sprocket, 26T Duplex Rotor key Rotor (99-0739) Tab washer Nut Key Timing pinion Nut INTERMEDIATE WHEEL Bush Camshaft wheel Camshaft key ... Inlet camshaft nut Exhaust camshaft nut In let camshaft ... EXHAUST CAMSHAFT EXHAUST CAMSHAFT Tachometer drive plug Retaining plate .. . Screw in. U.H.) Clamping washer m *Use D524 Loctite sealant 9 1 1 1 1 1 3 2 2 2 4 2 T100R, T100C 4 2 2 4 T100C, T100R T100C, T100R 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 4 1 T100R T100C 5- ' 35 - - 0 30 ~ 31 ~ 34-- - 9 33 _ _ Fig. 2. CRANKCASE 10 ~ '."" Ci 7 ~ Ref. No. Part No. DESCRIPTION .."" E11268 E4147 E3823 E3823 4 E11269 5 6 E9496 E1509 7 8 S1920 9 14-6102 10 E7430 11 T1606 12 E6386 13 E375 14 T912 E3716 15 16 $1926 17 14--0225 S1925 18 19 S1919 20 525-3 14-1302 21 22 S1852 23 51864 24 E9494 25 S1921 26 51922 27 E1534 28 E9493 29 T1257 E3724 30 31 E3722 E7431 32 33 E9501 34 E1577 S1927 35 36 T2167 37 E2441 38 $543 39 E8896 40 T2166 41 E8782 42 51871 E7431 43 44 S1872 E11079 45 E9335 46 47 E11460 E1107S 48 49 E11077 Not illus. E4707 1 2 3 • ~ - .. QUANTITY CRANKCASE CRANKCASE DRIVE SIDE Pivot pin ... Camshaft bush Camshaft bush CRANKCASE TIMING SIDE Oil scavenge pipe ... Clip··· Screw Bolt··· Tab washer Needle roller bearing Dowel at juncti on block ... Idler gea r spindle ... Peg (at thrust washer) Hollow dowel ... Screw n~ in. U.H.) Bolt Stud (3~ in. U.H .) Bolt Plain washer Nut Nut Oil pump stud (1-ft; in. O.A.) Right main bearing (ball journal) Cylinder base stud (1t in . O.A.) Cylinder base stud (1-f-k in. O.A.) Dowel Left main bearing (roller journal) Washer ... Filter spring Filter Sealing washer ... Filter cap Joint washer Stud (3-.'6 in. O.A.) Drain plug (with leve l tube) Fibre washer Level plug Fibre washer Filler plug "0" ring Blanking plug (L.H. thread) " 0 " ring Plug Cover plate Outlet stub-breather Joint washer Screw Screw Grommet, alternator leads ~- 11 Ref. only 1 1 2 2 1 2 1 3 2 1 2 6 2 2 1 2 2 2 1 1 1 1 1 1 1 2 1 1 (Not T100R) REMARKS 7-------1 ----~---6 - ASSY.1 - - - - - - - - - J - ------2 10-_..../ 13 14 ASSY.12 Fig. 3. OIL PUMP AND RELEASE VALVE '. " 12 • Ref. No. Part No . DESCRIPTION ... 0 I L 'PUMP AND 2 3 4 5 6 7 8 9 10 11 12 13 E6928 E6680 S70-7 E403 E2360 GS153 E6681 E495 E11461 E3887 $1906 EmllJ Et54'i E12211 QUANTITY RELEASE VALVE OIL PUMP Pump body ... Valve ball .. . Valve spring Screwed plug Feed plunger Scavenge plunger .. . Drive block Joint washer Serrated washer Nut Oil release valve Joint washer Refere nce only 2 2 2 1 1 1 1 2 2 • 13 REMARKS 1 16 15 17 ' 2 14 23 18 I I 13 19 12 fl_----21 \.._____ f•g. . 4. INLET MANIFOLDS _ _ __ 22 C6 • Ref. No. Part No . DESCRIPTION .."' INLET QUANTITY MANIFOLDS Single Carburetor Model (T100C) 1 2 3 4 5 6 7 8 9 10 11 E7578 E6772 525-3 5582 E11459 E2968 525-3 14-1302 14-7024 5648 14-6115 • Inlet manifold Joint washer Plain washer Stud (1 156 in. O.A.) Joint washer Insulating block Plain washer Self locking nut Socket head screw (2 in. U.H.) Spring washer ... Bolt 1 2 4 2 1 2 2 2 4 2 Twin Carburetor Model (T100R) 12 13 14 15 16 17 18 19 20 21 22 23 5582 14-1302 E6772 E11459 E2968 E7136 E7137 525-3 E6916 E6958 E5473 14-7019 .. Stud (1 156 in. U.H.) Self locking nut ... Joint washer, manifold ... Joint washer, insulating block Insulating block Left manifold Right manifold Plain washer Co nnector Balance pipe Clip Socket head screw(~ in . U.H.) 15 4 4 2 2 2 4 2 1 2 4 REMARKS 14 ' CIS ' Fig. 5. CARBURETOR T100C 16 '..... Ref. No. Part No. DESCRIPTION ..... ~ t 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 D2455 622J101 Reference only 622/097 622/086 622/060 622/065 622/077 622f076 622/082 622/128 376/100 622/122 622/124 622/067 622/134 622f069 622f071 622f073 622/055 622/068 376 f093 622/078 13/163 4f035 5/077 622/062 622/129 622/089 14/032 .... 622/147 622/151 F9269 QUANTITY REMARKS CARBURETOR, T1 OOC CARBURETOR R626J32 "0" ring seal (99-0522) Mixing chamber R626J005 Mixing chamber top (99-1049) ... Screw (99--0521) ... Thrott le valve (4 cutaway) (99-1050) Throttle return spring (copper plated) (99-0509) Throttle stop screw (99- 0516) Air adjusting screw (99- 0515) "0" ring (99--0520) Jet holder (99-1034) Main jet (99-1132) size 170 Needle jet (99-1035) size .106 Needle (99-1036) ... Needle cl ip (99-0510) Air valve guide sleeve (99-1051) Float (99-0512) Float spindle (99-0513) ... Joint washer (99-0514) ... Float chamber (99-1154) Float needle (99-0511) Filter (99-0438) ... Banjo bolt (99- 0517) Fibre washer (99- 1124) Cabl e adjuster Nut (99-0224) Air slide Air slide sprin~ (99-1038) Tickler pin Spring Drain plug (99- 1152) W asher (99-1153) Petrol pipe ... 17 1 4 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Referen ce 1 Refe rence 1 Reference Refe rence 1 1 only only only only ~16 2 f-------~-14 I CiS 9 8 ~~----- ------13 ' 31 .. Fig. 6. CARBURETOR, TfOOR 18 "' ' Ref. No. Part No. DESCRIPTION CARBURETOR, 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 02453 02454 622/101 Reference only 622/097 622j086 622/060 622/ 065 622/077 622(076 622/082 622/128 376/100 622/122 622/124 622/067 622/134 622/069 622f071 622/073 622/055 622/068 376/093 622/078 13/163 4/035 Sj077 622/062 622/129 622/089 .... 14(032 622/147 622/151 F9271 QUANTITY T100R CARBURETOR L626/34 CARBURETOR R626f33 "0" ring seal (99-0522) Mixing chamber ... Mixing chamber top (99-1049) ... Screw (99-0521) ... Throttle valve (3 cutaway) (99-1125) Throttle return spring (copper plated) (99-0509) Throttle stop screw (99-0516) Air adjusting screw (99-0515) "0" ring (99-0520) Jet holder (99-1 034) Main jet (99-1131) size 150 Needle jet (99-1 035) size .1 06 Needle (99-1036) ... Needle clip (99-0510) Air valve guide sleeve (99-1051) Float (99-0512) Float spindle (99-0513) ... Joint washer (99-0514) Float chamber (99-1154) Float needle (99-0511) Filter (99-0438) ... Banjo bolt (99-0517) Fibre washer (99-1124) Cable adjuster Nut (99-0224) Air slide Air slide spring (99-1038) Tickler pin Spring Drain plug (99-1152) Washer (99-1153) Petrol pipe 19 REMARKS 1 Left Right 11 1 1 4 1 1 2 1 1 1 1 Each carburetor 1 iJ Reference only 1 Each carburetor Reference only 1 Each carburetor Reference only Reference only 1 1 1 43 39 43 41 42 43 44 2,2 I I I I I ~,, I \ 34 35 32 6 .. ,~ ! .. ·-- ·- -------37 ~ .;~, 27 28 - -49 ' 19- . 18 ' \. ( j '"~ :-\ @>---·- · · - 52 " 11 15-----\ .. ··---·-50 ---10 ~Sf · - - - - -13 12- -- -- _ _.J .- 5 -·-5 4- f ----@ 7 C39 <. Fig. 7, "'" CYLINDER BLOCK AND HEAD, T100C 20 - -.- 3 8 ' ~ Ref. No. Port No. CYLINDER 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 49 50 51 52 53 E3798 E9719 E7563 S692 E9352 H200 E1612 E3753 E10277 E10229 E9510 E6853 E6854 E6855 E5946 E4011 E3742 99- 0062 E4456 F2184 E4675 E12075 E1 2076 E9511 14-0103 D241 7 E12079 E1 2080 14-6609 E3857 E3794 E3795 E3809 F1 880 H400 E4610 E3751 E3749 E3750 E7651 E3223 GS662 E2534 E3224 E3748 E3253 E1335 E1435 E4008 E9512 E7310 E11283 E4671 .. DESCRIPTION .. BLOC~ AND HEAD, T100C Cylinde r base gasket Cylinder block . .. " 0" r ing N ut (12 point) ... Tappet guide block Tappet block screw (-?-,; in. U. H.) Se rrated washe r Tappet ... C YLINDER HEAD cfw GUIDES Valve gu ide (cast iron) Ex haust pipe adaptor Inle t valve Exhaust valve ... Botto m C up Inne r valve sp ring O uter val ve spring To p collar Split cotter Cylinder head bo lt (2 25/ 32 in. U.H.) Pla in washe r Cyl inder head gas ket Inlet rocker box Ex haust rocker box Joint washe r Rocker box bo lt W as he r ... Plug, roc ke r box Jo int washer Screw Hi in. U.H.) Plain washe r Cylind e r head bo lt (Sir; in. U. H.) Cylinde r head t orque st ay bo lt O il feed bo lt Copper washer . .. Do med nut Inspectio n cap ... Fibre washer ROCK ER (r ight exhaust, left inlet ) ... ROCKER (l eft ex haust, right inlet ) ... Rocke r ball pin Rocke r adjusting pin Adjuste r lock nut Th rust washer, 176 in . Spring was he r .. . Rocke r spindle ... Seali ng r ubbe r ... Coppe r washer ... Domed nut Pus h rod Cover t ube "0" ring, p ush rod cove r tube (bottom) " 0" ri ng, pu sh rod cove r tube (t op) Locking spri ng ... 21 QUANTITY SINGLE REMARKS CARBURETOR 1 1 2 8 2 2 2 4 1 4 2 2 2 4 4 4 4 8 4 8 1 1 2 4 4 4 4 4 4 2 2 2 6 2 4 4 2 2 4 4 4 8 4 2 2 2 2 4 2 2 2 4 I 45 42 43 40 44 44 23 I i 33 I 36 35 l i ' I ~" 31 ~ 39 41 45 30 50 19~) 11 20 11 : ~~~ 16 - < 8 > - 53 9 -- ·- \ 51 15- - -@ < § > - - 52 13 - . &--- ' 5 2 3 8 2 Cl4 4 ~ '. Fig. 7. "'" CYLINDER BLOCK AND HEAD, TtOOR 22 ' Ref. No. Part No. CYLINDER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ~ t It 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 52 53 54 E3798 E9719 E7563 5692 E9352 H200 E1612 E4040 E9507 E6301 E3209 E9510 E6853 E6854 E6855 ES946 E4011 E3742 99-0062 E4456 F2184 E4675 E12075 E12076 E951 1 14-01 03 D241 7 E1 2079 E12080 14-6609 E3857 E3794 E3795 E3809 F1880 H400 E4610 E3751 E3749 E3750 E7651 E3223 GS662 E2534 E3224 E3748 E3253 E1335 E1435 E4008 E9512 E7310 E1 1283 E4671 QUANTITY DESCRIPTION BLOCK AND HEAD, T100R, "'" Cylinder ·base gasket .. Cyl inder block . .. " 0 " ring N ut (12 point) . .. Ta ppe t gui de bloc k Tappet block screw (,;. in . U. H.) Serrated washe r Ta ppet, Rac ing t ype CY LINDER HEAD cjw GUIDES Valve guid e Va lve g uide c irclip Ex haust pipe adapto r Inlet val ve Ex haust valve . . . Bott om cup Inne r val ve spring Oute r valve spring Top colla r Split cotter Cylinde r head bo lt (2-H in. U.H.) Plai n washe r Cylinder head gasket Inlet rocke r box Ex haust roc ker box Joint was her Rocke r box bolt Was he r ... Pl ug, rocke r box Jo int washer Scr ew (1;\- in. U.H.) Plai n wash e r Cylinde r head bo lt (5fi in. U.H.) Cyli nder head t orq ue stay bolt Oil feed bolt Coppe r was he r .. . Do med nut Ins pectio n cap .. . Fi bre washe r ROCKER (rig ht exhaust , left inle t) ROCKER (left ex haust, right inlet) Rocke r ball pin Rocke r adjust ing pin Ad juste r lock nut Thrust washer, -ft in. Sprin g washer .. . Rocke r spindle .. . "0" ring Cop pe r washe r .. . Do med nu t Pus h rod Cove r tu be " 0" ring, push rod cover tub e (bottom) "0" ring, push rod cover tu be (t o p) Locking s pri ng ... 23 TWIN REMARKS CARBURETOR 1 1 2 8 2 2 2 4 1 4 4 2 2 2 4 4 4 4 8 4 8 1 1 2 4 4 4 4 4 4 2 2 2 6 2 4 4 2 2 4 4 4 6 2 2 2 2 2 4 2 2 2 4 ' 5 5 iP. 4 ~ere 22 23 1 6 (1-13 C2 1 Fig. 8. TIMING COVER AND CONTACT BREAKER .."'" 24 • Ref. No. Part No. TIMING ~OVER 1 2 3 4 ~ E9250 E4016 D2085 E4568 5 14-6607 6 S1916 7 T989 8 54419340 54415642 9 10 54419097 11 54419220 54419827 12 13 E4707 E7680 14 15 E6559 16 14-0208 17 S25-43 18 E8737 E1 1462 19 20 GS299 21 E7354 22 02133 23 D2045 E4569 24 Not illus. E4849 Not illus. D2138 Not illus. E9526 QUANTITY DESCRIPTION AND CO NT ACT BREAKER Timing cover ... Patent plate Hammer-drive screw Oil seal ... Screw (~ in. U.H.) Screw (1-b in . U.H.) Hollow dowel ... AUTO-ADVANCE UNIT (99- 0771) Spring set (99-0757) CONTACT BREAKER PLATE ASSEMBLY (99-0768) Pin adjustment (99-0769) Contact set (99-0772) Rubber grommet Pillar bolt Washer ... Bolt Washer ... Cover Joint washer Serrated washer Screw Oil pressure switch Cover pressure switch Circlip ... Dowel pin, auto advance to camshaft Timing label for C.B. cover ... Blanking plug (to replace oil pressure switch) 25 1 3 2 4 4 1 1 2 1 2 2 1 2 2 1 2 2 1 Available REMARKS 21 20 ~~ 25 36 22 33 23 41 34 35 33 4 45 Cl6 Fig. 9. G EARBOX SHAFTS, BEARINGS AND INNER COVER 26 Re(. No. DESCRIPTION Part No. GEAR B 0 X 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 T66S T1478 W680 14-6608 T1422 T912 T1606 T1607 T3991 T1405 T4039 T1391 T3994 T1411 T4041 T3997 T3999 T1393 T1426 T3660 T3661 T1457 T1480 T1481 T4218 T1418 T1416 H688 T4301-.. . T1417 D208-5 T1440 T1157 T1390 T1981 T1431 T1282 T1161 T1897 T1469 T4113 T732 S594 T1464 T1441 E4803 s).l AFT S, BEARINGS AND QUANTITY INNER C 0 V E R High gear bearing (ball journal) Oil seal Circl ip ... Screw Return spring plate Peg Layshaft bearing Thrust washer ... MAINSHAFT HIGH GEAR (22T) High gear bush MAINSHAFT cfw THIRD AND LOW GEARS (16f24T) Clutch rod bush ... Mains haft second gear (21T) ... Mainshaft distance piece Layshaft cjw second and high gears (15f23T) Layshaft third gear (20T) LAYSHAFT LOW GEAR (27T) Low ge ar bush Pawl retaining disc Camplate index plunger Index plunger spring .. . Selector fork spindle .. . Mainshaft selector fork Lays haft selector fork ... Gear selector camplate Camplate spindle Split pin (i in . x ~ in.) Gear indicator pointer Screw (-h in. U.H.) Inner cover Gear indicator plate Indicator plate rivet Hollow dowel ... Kickstarter stop plate ... Stop plate and anchor screw ... KICKSTARTER SPINDLE Kickstarter pawl Plunger Plunger spring Needle roller bearing Mainshaft bearing (Ball journal) Circlip ... Tab washer Mainshaft nut Distance piece Kickstarter return spring "0" ring 27 REMARKS 1 1 1 2 1 1 1 1 1 1 1 1 T100R and West Coast T1 OOC 1 1 1 1 1 1 1 1 1 Reference only 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 o--. !}- -- - - - -- ·- - 37 38 1-- - ~ -· -....39 i 19 Qrlh_ 21 I 20 I ~~ 25 36 22 23 41 34 35 42 33 Fig. 1 t. 4 45 46 ...... C l6 GEARBOX SHA FTS • BEARINGS AND INNER COVER 28 Ref. No. QUANTITY DESCRIPTION Part No. ..... " WIDE RATIO GEARS Standard on East Coast T100C 9 11 13 15 16 17 T4029 T4040 T4031 T4042 T3997 T4033 MAINSHAFT HIGH GEAR (23T) ... MAINSHAFT cf w THIRD AND LOW GEAR (15/24T) .. . Mains haft second gear (20T) ... Layshaft cfw second and high gear (14/HT) Layshaft third gear (20T) LAYSHAFT LOW GEAR (29T) CLOSE ~ •· RATIO 1 1 1 1 1 GEARS (Available if required) 9 11 13 15 16 17 T2532 T2276 T1B32 T1972 T1B42 T1950 MAINSHAFT HIGH GEAR (20T) ... MAINSHAFT cj w THIRD AND LOW GEAR (16J22T) ... Main shaft second gear (20T) ... Layshaft cjw second and high gear (17j23T) Layshaft third gear (21T) LAYSHAFT LOW GEAR (27T) 29 1 1 1 1 1 REMARKS ~--·--29 ~- ~l ~ --· 3.J - - · ----- ~ ~(y 28 ·-- 27 ~-~:: 34 / 32 36 . 5 ·-·- ::~ ~~A 21·~ \.'-:r 17 18--··-- '. " Fig. 12. GEARBOX OUTER COVER A NO LEVERS 30 ~ Ref. No. DESCRIPTION Part No. G E A li':B 0 X ~ 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 T3755 T1395 S1928 14-6505 T1942 T1474 T1436 T1396 E3309 T1871 T1877 T1878 T1977 $1877 T1876 T1874 T1880 T1771 T1710 T1712 GS127 0 UTER COVER AND LEVERS GEARBOX OUTER. COVER ... Gearchange spindle bush ... Stud (1ft in. O.A.) Screw GEARCHANGE QUADRANT Spring retaining pin Plunger spring Selector plunger ... Split pin (l4 in. x ~ in.) Sealing ring Return spring housing Return spring Thrust button Cover Nut Distance piece Distance piece Clutch lever Ball, i in . diam. Shaft Spring Plain washer Split pin (-h in. x in .) Spoke Connector Nut Abutment Adaptor, short Adaptor, long (For cable with short outer) Rubber cove r Nut Plain washer Screw Screw Gearchange lever Pedal rubber Bolt (1 in. U.H.) KICKSTARTER LEVER COMPLETE Kickstarter crank Kickstarter pedal . .. Steel ball ({- in. diam .) Index spring Pivot bolt . .. Clamp bolt (1fl; in. U.H.) Pedal rubbe r Clutch operating rod Oil seal ... Oil seal cover ... Serrated washer t T1945 T1946 T1937 T3784 T2062 T2063 T1646.. 14-1302 S25-3 S1918 $1917 T1435 T2450 W932 T3797 T3742 T1272 S?0-3 T1167 S541 S644 T2330 T1970 T2239 T2238 E1612 QUANTITY 31 1 2 1 1 2 2 2 Reference only 1 1 2 2 1 2 2 1 ., ~ 1 Refe rence on ly 1 1 1 1 As required As requ ired 1 2 2 2 2 1 1 1 1 1 1 1 2 REMARKS ...... v ().. ---------· II") - ;! :r u 1- ....~ 10 u ("") N ...; N 110 il: 0 .. "' 32 ---- N N N ' Ref. No. DESCRIPTION Part No. .. " 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 T1570 T3930 T3931 T394 5586 T1719 T1720 T1040 T2538 T1722 T1723 T1724 T423A T1362 T1363 T2156 T2159 14-0403 T1931 T1560 T2526 566-1 T2279 QUANTITY CLUTCH Sprocket and housing ... Hub Thrust washer Roller Nut Centre (Shock absorber body) Inner plate Countersunk screw (0.417 in. U.H.) Shock absorber spider Drive rubber (large) .. . Rebound rubber (small) Outer plate Screwed pin (1-H in. U.H.) Driving plate (bonded) Driven plate (plain) Pressure plate Adjuster pin Nut Spring cup Spring Nut Key Washer ... .. 33 1 1 1 20 1 1 1 6 1 3 3 1 3 6 6 1 3 3 3 1 1 REMARKS ff- -~ 38 4 . --5 '~34 ~3 J 22 ...... Fig. 14. CHAINCASE A ND CHAINS 34 CIO ~ t - Ref. No. DESCRIPTION Part No. QUANTITY tHAINCASE AND CHAINS 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 T1476f18 T1476/19 T1569 T2536 D-444 E7037 E7565 E11419 E3821 D358 E6283 E4152 E4148 E9495 47205 S25-3 14-0702 E4144 E9360 E1509 51920 E11456 E9249 T2440 E11457 F4139 T2537 14-6101 E2441 T2166 E8782 S1878 14-6609 E9703 T2259 T1738 T2056 E7571 14-1301 E7573 .. Gearbox sprocket (18 teeth) ... Gearbox sprocket (19 teeth) ... Gearbox sprocket (20 teeth) .. . Gearbox sprocket nut Rear chain,~ in. x fin. x 102L Cover plate Oil seal ... Joint washer Countersunk screw (f. in. U.H.) Primary chain, i in. Duplex 78L Chain tensioner blade ... Tie rod ... Trunnion Stud (3 156 in. O.A.) Stator, RM 21 (99-1006) Plain washer Nut Rubber grommet Sleeve nut Clip Setscrew Joint washer Chaincase Rotor cover Joint washer Screw Ignition pointer ... Level plug Copper washer .. . Fil ler plug "0" ring Screw (2! in . U.H.) Screw Adjuster sleeve nut Drain plug Fibre washer Tab washer Crankcase protector Self-locking nut Grommet 35 1 Avai labl e Avai lable 1 1 1 1 6 1 1 3 1 3 3 1 1 1 3 1 1 2 1 1 3 7 1 1 REMARKS '· ..... 36 Ref. No. Part No. DESCRIPTION QUANTITY .. ,EXHAUST SYSTEM (T1 OOR) ~ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 E12037 E12038 E4947 E409 E410A 14-0102 14-1301 E9888 E7512 E3768 14-0217 14-1302 E4157 E4158 E2711 E3768 14-0219 S25-3 14-1302 Exhaust pipe-D.S. Exhaust pipe-T.S. Finned clip Bolt } Exhaust pi pes to Washer cylinder head Bolt Exhaust pipes Nut to brackets Coupling pipe ... 1 1 2 2 2 2 2 1 2 4 2 2 1 l J 1 s Clip "D" washer Coupling Bolt pipe Nut Muffler-D.S. .. . Muffier-T.S. ... CBp 1 1 "D " washer Bolt Mufflers to exhaust pipes Washer Nut j I 37 2 4 2 2 2 REMARKS 25 24 18 20 19 21 33 26 31 C45 . 16 17 Fig. 16. ~ ...... MOTOR FITTINGS Ref. No. DESCRIPTION Part No. .." 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 F7333 F7334 14-0239 S25-2 14-1303 S2006 S25-3 14-1302 S2083 S25-3 14-0302 14-1302 E7641 E7642 14-0225 S25- 3 14-1302 E4778 S25- 1 14-1302 14-0220 E7119 E3434 S25- 3 14-1302 F4229 F4230 14-0242 S25- 2 14-130J. 14-0228 S25-3 14-1302 MOTOR FITTINGS Front motor plate-D.S. Front motor plate-T.S. Bolt Front motor plates to frame . .. Washer Nut (Cleveloc) Stud (3k in. O.A.) Top-front motor plates Washer Nut (Cleveloc) Stud (4-k in. O .A.) Middle-front Washer Nut (plain) motor plates Nut (Cieveloc) Exhaust bracket-D.S. Exhaust-bracket-T.S . ... Bolt } Washer Bottom-front motor plates Nut (Cieveloc) Torque stay Washer }Torque stay to Nut (Cleveloc) rocker box studs Bolt 1 Distance piece-D.S. Distance piece-T.S. Torque stay to frame Washer Nut (Cieveloc) Rear motor plate-D.S. Rear motor plate- T.S. Bolt Washer Rear motor plates to crankcase .. . Nut (Cieve loc) Bolt Washer Rear motor plates to frame Nut (Cleveloc) J ' ' QUANTITY 39 1 1 1 1 1 2 2 1 2 2 2 (Not T100C) (Not T100C) (Not T100C) 1 1 1 2 1 2 2 2 1 1 2 2 2 (2 T100C) (2 T100C) REMARKS 34 ~ / ~ ~- ">-::' ' / 33 ' / 35 30 c 29 Fig. 17. '.,, EXH AU ST PIPES, UNDERSHIELD AND FO O TPEGS (T1DOC) 40 ' Ref. No. Part No. DESCRIPTION EXHAUST E10019 E10017 E6981 4 14-0114 525-3 5 14-0302 6 7 F7705 E9669 8 9 E9670 E9673 10 E7299 11 14-0116 12 E2271 13 14 E5874 E3768 15 14-0219 16 14-1302 17 18 E9691 F929 19 20 525-3 21 F7550 14-0114 22 23 14-1302 E9680 24 E9688 25 26 E9696 51954 27 28 51953 F11590 29 30 F11591 31 F6411 51971 32 33 F11279 F1700 34 F3078 35 14-0102 36 S25-1 37 38 14-1301 Not illus. E9857 1 2 3 .. . PIPES\ UNDERSHIELD AND Exhaust pipe D.S. lower Exhaust pipe T.S. upper Stay Bolt Washer Nut Abutment Silencer upper Silencer lower Connector Clip Bolt Clip Clip "D" washer Bolt Nut Bracket (silencer to frame) Bolt Washer ... Cl ip, bracket to frame Bolt, clip to bracket Nut Leg guard Clip Bracket .. . Short screw Long screw (1! in. U.H.) LEFT FOLDING FOOTPEG RIGHT FOLDING FOOTPEG Pedal Pivot bolt ... Undershield Clip, undershield Bracket . .. Bolt Washer ... Nut Washer (for lines 27 and 28) ... 41 QUANTITY FOOTPEG 1 2 3 1 1 1 1 1 1 1 2 6 3 3 1 2 1 1 1 2 1 1 1 1 1 2 2 1 2 4 4 4 2 (T100C) REMARKS 21 50 f 1 51 4 3 ·-·2 I ~ ..,~ ·· 22 20 ~ 49 ------~--- ~;~, 48 47 , __ ' _/~ ., ' f' - ·46 44 7 / , . ..- - - - ~- - - -- - 15 5 ·- 16 ·- --13 18 Fig. t8, FRAME .. ~ 42 C37 t ' ' . Ref. No. DESCRIPTION Part No. ..... 1 2 3 .. F10034 H111 S7~3 H1018 F5679 F7155 F8038 14-0241 $25-2 14-1303 14-0115 99-0046 12 13 F7693 14 TI331 F5678 15 F4484 16 F2725 17 18 F3617 19 F11560 20 F7021 14-0703 21 F8382 22 F4214 23 F4215 24 25 NF704 14- 0251 26 27 F-4370 14-1304 28 F5087 29 FS088 _ 30 14-0115 31 32 S25-3 F7705 33 14-0302 34 35 F9369 F9370 36 37 51910 $26-1 38 F1694 39 40 F9371 S25-3 41 42 14-1302 F1695 43 44 F7706 14-1305 45 F7703 46 47 S26-16 48 $25-2 49 14-0403 so 14-0216 14--0402 51 Not illus. 02452 5 6 7 8 9 10 11 . QUANTITY FRAME 1 2 40 Front frame Steering race cup Steel ball (t in. dia.) Top cone and dust cover Washer ... Steering stops Rear frame Bolt Washer ... Nut Bolt Spring washer Centre stand Pedal rubber Pivot bolt Tab washer Nut Return spring Prop stand Pivot bolt Self-locking nut Return spring Left footrest Right footrest Pedal rubber Bolt Plain washer Nut Left pillion footrest support Right pillion footrest support Bolt (-it in . U.H.) Washer ... Pedal stop screw Nut PILLION FOOTREST ... Footrest hanger Bolt ... Washer Pedal Pivot bolt Washer Nut ... Pedal rubber Brake pedal spindle Nut Brake pedal Spring washer Plain washer Nut Bolt Nut Transfer, 'Safety Standards' 1 2 2 1 1 1 1 2 2 T100R only 1l H 1 I T100R ooly 1 1 1 1 1 1 2 2 2 2 1 4 4 1 2 2 2 2 2 2 2 2 6 2 1 1 1 1 1 1 1 1 1 43 REMARKS 34 \r ® ~~-=--=--=== - ~· ?~ ()' ., ZJ:u. d: n_ 45 12 ~ - -~ ,, ~ ~33 t 32--! ~ ~~ ~-37 23~. 7 (6'-44 ' i l - -38 21 • c-··;'>---39 "® ' t'@-6 -~~40 - - -- ' - ~~ ~-~ .. - 12 ~ 19 48 16 - - - g ~ r 46~/Jd - I; 49 21 22 I I 14 13 ,. I ' I 2 3 4 Fl• • 19. SWINGING ARM, SUSP£NSION UNITS AND CHAINGUARO ..... - C31 - ' Ref. No. Part No. SWINGING 1 2 3 4 5 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 49 F7375 F4076 F7342 F72JO F4385 F4386 F10037 S580 5579 64052107 64533645 9054/171 64543708 14-0235 S25-2 14-1303 F7707 DS57 525-1 F4134 14-0113 F7343 NW100 14-0702 F9387 S2>-3 14-1302 14-0128 14-1303 DS47 99-oo4l' . F7386 F7387 F11780 99-0046 14-1304 F6046 14-0101 S25-1 14-1301 54033234 F3158 T1076 F4717 F5687 F5413 F7774 14-0702 F4078 DESCRIPTION ARM:'; SUSPENSION UN ITS SWINGING ARM Pivot bush . .. Spindle ... Gaiter ... Shim 0.003 in. Shim 0.005 in. Left distance piece Left bolt ... Right bolt SUSPENSION UNIT (02024) Bonded bush (99-0122) Spring retainer (99-0107) Spring, 100 lbs. chrome (99-1048) Unit fixing bolt Plain washer Nut Chainguard Bolt (.16 in. U.H .) Washer . .. Front bracket Bolt Tab washer Lubricator Self-locking nut Stepped bolt Plain washer Nut Bolt Nut Nut Spring washer Brake operating rod Split pin (14 in. x tin.) Adjuster nut Brake torque stay Torque stay washer Torque stay nut Front chai nguard Bolt Washer ... Nut Stop lamp switch (99-0725) Spring (315738) Bolt (i in. U.H.) Self-locking nut Lever " D" washer Right distance piece Nut Thrust washer ... 45 QUANTITY AND REMARKS CHAINGUARD 1 2 1 2 As required As required 1 1 1 2 4 4 2 4 8 4 1 1 1 1 2 1 1 1 1 1 Reference only 1 1 1 1 1 1 1 1 1 3 5 1 ASSEM8l y REF. No. I 10 12 11 ---=- 1. 7~-------("::), 8 <3r 53 - . · 22 3,9 40 l~/ .. - - 29 -- 25 26 ''• 27 c Fig. 20. TELESCOPIC FRONT FORK 46 " ' 38 - ' ' Ref. No. Part No. :rELESCOPIC 1 2 3 4 5 6 7A 7 8 9 10 H4120 H4119 H2288 H439 H2290 525-2 14-1303 H2108 H2263 H3662 F6738 0623 11 12 13 14 15 16 17 18 19 20 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 S578 H2266 H2107 5684 S685 H2198 H2199 F4047 H1657 H1892 H1891 03273 H3635 H4167 D3274 H2119 H431 H441 H1896 H3904 H443 H2091 H2245 H3921 H3922 H1844 E3446 S2024 14-1202 H3894 H3893 H2154 H2127 H2090 H1062 H2126 H3682 H2270 F8245 .. QUANTITY DESCRIPTION FRO NT FORK ASSEMBLY FORK ASSEMBLY Middle lug and stem Bottom cone Pinch bolt (2t in. U.H.) ... Plain washer Cleveloc nut Fork stem sleeve nut Fork stem sleeve nut Top lug Lock cfw 2 keys ... Key (state serial number) Grub screw Sealing washer Locating pin Pinch bolt (1i in. U.H.) Seated nut ... Left top cover Right top cover Cork washer Spring abutment Main spring (YellowfGreen) Main spring (Yellow/Blue) Plain washer Telescopic gaiter ... DUST EXCLUDER SLEEVE NUT Oil seal "0" ring .. . Plain washer Top bearing Damping sleeve STANCHION Lower bearing Bearing nut Cap nut LEFT BOTTOM MEMBER cfw CAP RIGHT BOTTOM MEMBER cjw CAP Spindle cap . .. Plain washer .. . Stud .. . Nut, self locking Drain plug ... Sealing washer Shuttle valve Cirdip Restrictor ... Aluminium washer Flanged bolt Bracket Cable retainer Starlock washer 47 REMARKS FORK 1 1 1 1 2 3 2 1 1 2 T100R T100C T100C T100R 1 1 Key no's run from EJR 1 to EJR 50 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 4 4 4 2 2 2 2 2 2 2 T100C T100R ASSEMBLY REF·No.1 10 12 11 - --C> 19 1-----~---w 01' ---13 · 22 .._ 29 35 37 36 ~-~-~ . -~ 38 26 ·· ····· 27 @ -~ 28 " 33 .. Fig.lO. TELESCOPIC FR ONT FORK 48 ~ C 3F ' Ref. No. Part No. TEL C:S C 0 PI C 49 F R 0 NT FORK 51 52 53 H3926 H722 S25- 3 S589 H1696 Square nut Cap ... Plain washer Bolt (1! in. U.H.) ... Top cover ... 54 55 55 56 57 58 Not illus. H2208 H4121 H4123 H2209 H2210 52095 F6784 Rubber mounting, headlamp bracket Headlamp bracket-D.S. Headlamp bracket-T.S.... Rubber buffer Washer, headlamp bracket Attachment bolt ... Cable grommet (right lop cover) so ' ' ' QUANTITY DESCRIPTION 49 REMARKS (continued) 2 2 4 4 Available for use where headlam p removed 2 1 1 4 4 4 1 16 10 14 4 8 Front wheel complete NO 1 ' V'l 0 4 38 Fig. 21. & . .N Cll 29 35 31 30 FRONT WHEEL T100R ~ ~ Ref. No. Part No. .... .,fRONT WHEEl 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 W3458 W1721 W1230 W1328 W1708 W1709 $79-2 W1722 W3582 W653 W1237 T280 W3337 W1481 W582 W3460 W1197 W1198 W3461 W1996 Reference only Reference only W2026 W135 W2001 W3453 14-1303 W3454 W2003 W2005 ·~ 14-0401 W3522 S1995 WF32 $25-6 W1 991 S1998 E2351 QUANTITY DESCRIPTION (T100R) FR.ONT WHEEL COMPLETE R.IM, SPOKES AND HUB ASSEMBLY Front wheel rim (WM2-19) Spoke (8f10G x 5~ in. straight) cfw nipple Spoke (8j10G x 4~~ in. 78°) cfw nipple Spoke (8f10G x 4k in. 100o) cfw nipple Spoke nipple ... Hub and brake drum Wheel spindle Bearing Dust cover Circlip Bearing support ring Grease retainer Retaining ring Cover plate Balance weight, t oz. Balance weight, 1 oz. BRAKE ANCHOR. PLATE ASSEMBLY BRAKE SHOE cfw LINING Brake lining Brass rivet Thrust pad Shoe return spring Brake cam Brake cam lever (front) Nut Brake cam lever (rear) Rod assembly Fork end, threaded Locknut Lever return spring Anchor plate nut Pivot pin ... Split pin (-kin. x tin. lo ng) Plain washer Anchor plate gauze {fo r air scoop) Taptite screw Washer for taptite screws 51 1 1 20 10 10 40 1 1 2 As required As required 1 2 ~}Each shoe 2 2 1 1 2 1 1 1 1 1 1 2 Refe rence only 2 1 3 3 REMARKS 16 10 14 4 8 Front wheel complete NO 1 " 1.1'1 t-J 38 Fii· 22. ~· ~. FRONT WHEEL T100C ~ Cl l 29 35 31 30 ' ' ' Ref. No. Part No. DESCRIPTION •' • 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 36 37 38 39 W 3430 W 2132 W1230 W213 7 W2138 W2139 W2136 W 3325 W3582 W653 W1237 T280 W3337 W 1481 WS82 W 3443 W 1197 W 11 98 W34SS W3446 Reference only Reference only W2026 W 135 W 2001 W 3453 14-1 303 W3454 W34SO W2005 14-0401 W3522 S1995 WF32 .. 525-6 W1991 51998 E2351 QUANTITY (TfOOC) FRO NT WHEEL COMPLETE RIM SPO KES AND HUB ASSEMBLY Front wheel ri m (WM2-1 9) Spoke D.S. Spoke T.S. Spoke T.S. Spoke n ipple ... Hub and brake d r um W heel spind le Wheel bearing Dust cover C ircl ip Bearing support ring G rease retai ner Retaining ring Cover plat e Balance weight t oz. Balance weig ht 1 oz. BRAKE AN CHOR PLATE ASSEM BLY BRAKE SHOE cfw LINING Brake lini ng Brass rivet Thrust pad ... Shoe re~ urn spri ng Brake cam ... Brake cam lever (fro nt) Nut Brake cam lever (rear) Rod assembly Fo rk e nd, th readed Lockn ut Lever retu rn spr ing Anchor plate nut ... Pivo t pin .. . Split pin (-IT in. x fin. long) Plain washer Anchor plate gauze (for ai r scoop) Tapti te screw Was her fo r ta ptite screws 53 1 1 20 10 10 40 1 1 2 1 1 1 1 As requi red As required 1 2 ~}Each shoe 2 2 2 1 1 1 1 1 2 Refere nce on ly 2 1 3 3 REMAR KS 45 42 41 47 23 29 25 27 28 22 8 9 10 12 3 15 21 5 7 16 39 18 24 45 43 ~ 43 44 34 33 35 30 31 13 11 20 19 18 Fig. 32. ~ ... 17 46 .• 4 6 a 37 40 42 44 259 REAR WHEEL llfltr ,.,.. - ' Ref. No. Part No. DESCRIPTION "' 1 2 3 4 4A 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 W3607 W3610 W1007 W1107 W3402 W1108 S79-2 W3586 W1499 S2010 E1612 W3585 S2011 14-1202 W3589 W1474 W1654 W1022 W653 W3587 W1710 W1278 W1024 W3590 S2013 W'\.406 W1407 Reference only Reference o nly W1415 ._ W135 W3592 W2014 525-6 W2027 W1488 W1635 W3588 W1477 D373 W1280 52014 W2089 W1015 14-1902 5585 WM3 W11 REAR QUANTITY WHEEL REAR WHEEL COMPLETE RIM, SPOKES AND HUB ASSEMBLY Rear wheel rim WM3-18 ... Spoke (8(10G x 7 196 in. 90°) Spoke (B/10G x 7 196 in.110°) Spoke (8(10G x 7k in. 90°) ... Spoke nipple ... Hub ... Sprocket, 46T Bolt Serrated washer Brake drum Bolt (ft in. U.H.) Self-locking nut ... Wheel spindle Grease retainer (brake side) Grease retainer Backing ring Bearing RETAINING RING Locking screw in. U.H.) Distance tube Distance piece Brake anchor plate Nut LEADING BRAKE SHOE C(W LINING TRAILING BRAKE SHOE C(W LINING Brake lining Brass rivet Thrust pad Sho e return spring Brake cam Brake cam lever Plain washer Nut Lever return spring Grease retainer ... Speedometer adaptor Distance piece Speedometer gearbox Plain washer Nut D.S. inner Chain adjuster . .. Adjuster end plate Self-locking nut Spindle nut Tyre security bolt WM3 Pivot pin 1 1 1 10 10 20 40 1 1 8 8 1 8 8 1 1 1 1 2 (n 55 1 1 1 1 2 16 2 2 1 1 1 1 1 1 1 1 2 2 2 2 2 REMARKS 23 34 2.7 26 17 ~ 32 -o/a 3 q - 0 0 0 'I 0 19 20 ~ ~ "36 ~ ~ 2 ~5 ·-· 2 18 33 ·~ / r V'l 12. \ '\ a- /j ~ · ~ 11 1 I I ~ (; 29 -- - ( ] 1E) 15 41 7 6 ~\ 9a 10 ff. @(@ 8 12 13 14 )!;)~ \ 0 ~ I 40 39 ' •' I,,\ 38 - .-... 5 8 Fig. 24. FENDERS 4 ~ ~ ' ' Ref. No. Part No. DESCRIPTION ..' 1 2 2 3 3 4 4 5 6 7 8 9 9A 10 11 12 13 14 15 16 17 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 H3884 H3882 H3663 H1 681 H3664 H1683 H3886 H3885 14-0101 525-1 14-1201 H1 685 14-0113 H4071 D3025 14-011 5 F4299 14-1302 14-0115 $25-3 14-0702 F12995 F12876 F6916 14-0101 F6310 526-2 14-1201 F691 5 14-0104 F6310 525- 1 14-1201 F12879 14-0102 525- 1 14-1201 F5994 F6031 14-0113 525- 3 14-1302 F7826 14-0102 525-1 14-1201 57079 D2391 F4717 QUANTITY FENDERS Fro nt fender (stainless) Front fender Fro nt stay (chrome) .. . Fro nt stay Centre stay (chrome) ... Centre stay Bottom stay (c hrome) .. . Bo ttom stay Bol t } Was her Stays to fe nd er Nut (Cieveloc) Bracket D.S. and T.S. fork leg to p stays Bolt } Tab washe r Brackets to fork leg W asher Bo lt l_ To p and cent re stays W asher to bracket N ut (Cievelo c) 1 Bolt } Bottom " ' Y t o Was her fork leg Nut Rear fend er (stai nl ess) Rear fe nder Bracket ... J Bo lt } Washer Bracket to Washer fender Nut (Cieveloc) Bridge Bo lt Was her Bd dg' t o Washer fende r N ut (C ieveloc) Lifting handle ... 1 J Bolt } W asher Lift ing handle to fender N ut (Cieveloc) Cli p Back ing plate Bolt } Washe r Cli p to fend er Nut (Cieveloc) W iring protector Bolt 1Wir ing protector to Was her N ut (Cieveloc) j Reflector- red (99-1162) Washer ... Nut 57 fend·~~ 1 1 1 1 1 1 1 1 6 6 6 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 2 2 2 T1 00C T1 00R T1 00C T1 00R T1 00C T100R T100C T100R T100C T100R REMARKS _9 15 10 __, 14 16 1 ~, 11 ~.... -···· ··?-.:..:'-=·-~· / 12 I {\ ~ ~ \) ~=- Vl (X) ~-. . /. ~~~~t /~fi / ;' ,·~ ' ~ .· 4' (; / ~ 5 1 / ,. _/' ----· Fig. 25. TAIL LAMP AND SUPPORT / .3 ' 2 ___. { .· .-· .. 8 ' ' ' Ref. No. DESCRIPTION Part No. ,. T'A I L LAMP AND SUPPORT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 F12877 14--0101 02426 F12727 F12728 14-0101 02338 14-1301 H961 53973 54577109 144921 573828 54571677 110714 380 Tail lamp support Bolt h } Tail. lamp support-rear fixing W as er Rear number plate bracket-L.H. Rear number plate bracket-R.H. Bolt Washer JNumber plate bracket to fender ... Nut . .. Grommet-tail lamp lead STOP AND TAIL LAMP-679 (99-0597) Lens (19-1 065) Screw (19-1 066) Bulbholder Gasket Screw Bulb (99-0542) I ' ' QUANTITY 59 2 2 1 4 4 4 1 1 2 Reference only Reference only Reference only REMARKS \ ~/ 9 @ I r~C4 I 13 Fig. 26. 14 i 15 PANELS AND TWINSEAT 60 18·· 19 20 ~ 21 Ref. No. Part No. DESCRIPTION QUANTITY ;';pANELS AND TWINSEAT 1 2 3 4 F8042 F11357 F11377 F12874 14-1303 5 6 F6673 F11 573 7 F9715 8 Not illus. AS2 9 0696 10 0697 F4898 11 12 F7835 13 F8026 14 F7862 15 S26-2 16 14-0101 17 0374 18 D2381 19 E1719A 20 F4228 21 22 F7560 Not } 02105 ill us. 02106 1 Left panel and toolbox Toolbox screw .. . Washer ... Nut, tool box knob Nut, tool box knob Grommet TWINSEAT Twinseat cover Transfer, positive earth Trim strip (bright) Sprag Buffer front Buffer rear Hinge front Hinge rear Spring washer Bolt ( 176 in . U.H .) Check wire Self tapping screw Washer ... Spring Split pin (-ft in. x t in.) Seat knob and pi unger Transfer Trophy 500 Transfer Daytona 1 2 1 1 4 2 2 1 1 4 4 1 2 1 Reference onl y 1 1 T100C T100R 1 61 REMARKS 8 I 21 22 ? -9 5 --- e- -10 7 I 3 i 4 ~-- 16 ~§- --- 17 - 18 o--19 ® - - - 20 30--6 Fig. 27. GAS TANK 62 .. ." '3----- 11 ' ' ' Ref. No. Part No. DESCRIPTION ,. " 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 No t ill us. F11804 F11803 F9701 F11339 F7888 F9700 F8192 F8193 F10007 F10008 F4019 H919 F7388 F5336 F967 F3814 F5228 FS229 F3814 S1883 14-1302 F3220 F4048 F3217 F12801 F12800 E73516 F1000 F1000 F12903 57183 D2391 F4717 .. { A56 A61 D2105 02106 QUANTITY GAS TANKS Petrol tank Petrol tank Styling unit (left) Styling unit screw (27(64 in. O.A.) front Styling unit screw (35/64 in. O.A.) rear Styling unit (right) Left knee grip .. . Right knee grip Centre styling strip Hook, screw Serrated washer Nut Rear bolt Double spigot rubber ... Rubber washer ... Cup Rubber washer ... Spigot rubber ... Cup Stud Nut FILLER CAP Joint washer Jack chain Petrol tap-D.S. Petrol tap-T.S. Petrol tap seal Steel washer Tap nut Reflector bracket Reflector, amber (99- 1161) Washer (front reflectors) Nut (front reflectors) ... Transfer, World Speed Record Transfer, Made in England Transfer, Trophy 500 Transfer, Daytona 63 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 1 1 1 2 2 2 2 2 2 2 T100R T100C REMARKS 19 - --- - -- - - - ~·----- --20 ·-1& 22 16 5 4 31 7 6 1 C41 10 .. Fig. 28. OIL TANK 64 ~ 65 4 13 --- - 1 12 7 6 - 5 15 16 17 18 20 19 21 I 23 I C28 Fig. 29. BATTERY, TOOLKIT AND AIR FILTER •~• 66 t ~ Ref. No. Part No. DESCRIPTION ' BATTE«.Y, TOOLKIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 54027029 F7431 F8033 F8032 F8024 F8031 F8091 54938986 F11609 F6866 F4810 E4576 D177 /8 D2110 D291 D2251 D370 D2084 DA16 D2184 D218S D87 D767 D1911 AND Battery PUZSA (99-0719) Vent pipe Battery retaining strap Battery strap anchorage Battery carrier ... Battery carrier rubber Battery carrier tray Fuse assembly ... AIR FILTER Filter element (Filter cloth and gauze) Clip for cover Adaptor Clip TOOL KIT Tool roll Ring spanner 1-k in. x 1-f6 in. AF. Ring spanner 136 in. x ±in. WHIT ... Open end spanner tin. x 176 in. AF. Open end spanner i in. x -h in. WHIT C spanner Tappet spanner Box spanner for sparking pi ug Screwdriver cfw blade Tommy bar ... 67 QUANTITY AIR FILTER 1 1 •·· 1 1 1 1 1 or or or or 1 1 1 1 1 1 1 1 1 2 2 2 2 REMARKS ~-- - 23 ( -6-· .. _____Q) · 22 -24 26 \ a Jl. 1 2,5 17 . - ~6) 15~ 14-! :.... ··~···· .·• il18- W,~ "" " 28 ~ 19 29 -~ 120-··- 27 32\ '\ _ o- 00 I 13 cS) _r;!;) (; '2·· •• Fig. 30. 3;. . 4 HANDLEBAR AND CONTROL LEVERS .-. ' l' t Ref. No. Part No. HAND:'LEBAR AND 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 QUANTITY DESCRIPTION H1484 H1511 H1425 16/364 16/328 16/329 16/008 16/009 16/010 99-0244 11 /013 H2125 16/011 H2124 12/608 12/556 12/607 12/606 12/033 12 /040 11 J014 02628 03143 D2627 03144 52048 14-1301 02071 02072 39595 54033666 54340881 54115246 39596 54033667 54340881 54115246 .. CONTROL Handlebar Handlebar (Western) Sleeve, handlebar mounting TWISTGRIP (99-0248) Body, top half (99-0245) ... BODY, BOTTOM HALF (99-0246) Friction spring Screw ... Locknut Rotor Screw (99-0225) Grip Cable stop (99-0241) Grip AIR CONTROL LEVER (03246) Leve r Bolt .. . Cap ... Spring washer Clamp Screw Front brake leve r (alloy) Front brake lever (steel) Clutch lever (alloy) Clutch lever (steel) Pivot pin Nut Adjuster ... Lockring HANDLEBAR SWITCH-l.H . Switch half ... Lever half (19{1335) Screw (19{1336) ... HANDLEBAR SWITCH-R.H. Switch half ... Lever half (19/1335) Screw (19/1336) .. . 69 LEVERS 1 Avai lable 4 1 T100C 1 Refere nce only Reference only Reference only 2 ... 1 1 1 Refe rence only Reference only Reference only Reference only Reference only Reference only 1 1 T100C 1 1 T100C 2 2 2 2 Reference only Refe re nce only 1 4 Refe rence only Reference only 1 4 REMARKS -·- 1 -------15 ~------- s (j__ --------16 -- -- - -10 ---8 ~- --n ® - - -4 @5)------s ~ v--------- 6 A--- - ---11 ~ ~ ------13 IJ - --- .._____ _ 9 12 - C42 Fig. 30. STEERING DAMPER . .' .. 70 t l' Ref. No. Part No. H A N D L E 8 A R ::M 0 U N T I N G S AND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 H2291 F1335 S589 H2221 H1529 14-1903 H1616 H435 H1618 H3602 H565 H3601 H95 H1797 H2108 H1581 H1580 QUANTITY DESCRIPTION STEERING Handlebar eyebolt Plain washer Bolt (1! in . U.H.) Cup Hemispherical washer ... Self-locking nut Solid bush for handlebar mounted windscreen Friction disc Rubber sleeve ... Steering damper rod cfw knob Plain washer Adjuster sleeve ... Spring plate Anchor plate Sleeve nut Distance piece Rubber ... 71 DAMPER 2 2 2 2 4 2 Available 1 1 1 1 1 1 2 2 REMARKS 6 5 14 16 23 19 27 22 21 .., . Fig. 32. CONTROL CABLES 72 C2 4 t ~ Ref. No. Part No. DESCRIPTION "' 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 D1823 D1822 D1994 D2076 D2086 WF32 CONTROL ... 73 REMARKS CABLES Throttle cable Throttle cable Clutch cable Front brake cable Cover, stop switch Pivot pin Split pin ... Air control cable AIR CONTROL CABLE Cable, lever to junction box Junction box (D685) Cable, junction box to carburetor Clip, metal Clip, rubber Clip, metal Cable clip TWIN ROTOR TWISTGRIP (99-0347) Screw (99-0251} ... Body, top half (99-0348) ... Body, bottom half (99-0349) Friction spring Screw ... Nut Rot o r (99-0344) Rotor stop (99-0338) Nut (99-0224) Grip Cable stop (99-0241) D3270 D3271 D3272 244/104 D745 XA69 D343f7 F9918 H4112 313/13 18/084 313/020 313 /021 16/008 210/007 5/077 313/004 210(008 Sj077 H2125 16/011 QUANTITY T100C 2 T100R 1 1 1 1 Reference only 1 T100C 1 T100R 1 1 2 } As required 4 1 2 1 T100R }Refmooe ooly 1 1 2 a I .,20 . . 2~ 3 ,... .. 4 . ' 5 14 I )~<SJ __,. ~ 18 ~-~'A~~ <ffl-~v -15 // \ 17 C20 . .' .. Fig. ll. T100C IGNITION CAPACITOR AND HEADLAMP 74 ' ~ Ref. No. Part No. T1 OOC 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 QUANTITY DESCRIPTION 54170009 54483156 54052982 553343 54525272 504665 370 54573590 989 554602 31276 144921 534296 54363454 281 54363455 54363453 54140331 54525212 47638 54420128 54418528 54418526 F8082 E4638 F10033 G5299 F3799 862217 ... ' I0 N I G N t'T CAPACITOR Ignition capacitor (99-0737) .. . Mounting spring (99-0778) HEADLAMP COMPLETE-MCH66 .. . Rim (19/1082) Light unit (19/1088) Fixing wire (99-0683) Main bulb (40/27 W) (19/1091) ... Bulbholder, pilot (99-0695) Pilot bulb (99-0548) Bulbholder, main ... Lighting switch (19/1087) ... Screw Plate Warning light, red (19/1084) Bulb (99-0537) Warning light, green (19/1085) .. . Warning light , amber (19/1083) ... Sealing washer (19/1086) ... Warning light shield CAPACITOR PACK-2CP (99-0588) Capacitor (99-1043) Cover (99-0767) ... Base plate (99-1160) Capacitor pack bracket Scre w, bracket to fram e Bolt, bracket to bolt Shake proof washer Nut Grommet 75 AND HEADLAMP Available Available 1 6 1 Reference only 1 Reference only Refere nce on ly 1 3 1 3 Reference o nly 1 2 1 1 1 2 2 2 2 Reference only REMARKS 9 7 8 18 17 ' ~ ®\~ 31 15 32 23 \\ ~~··· ~ ~ 'Y ~· , ~~ ~ 24 28 13 .... 4qt . . ··· [7?::, ~ / I I 29 22 30 -e e- 26 ~ r}!----25 21 Fig. 34. IGNITION COILS HO ,. ' RN, RECTIFIER A ND -.. ZENER DIODE 76 ~ • ~ Ref No. Part No. IGNITION 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 45223 02207 F11533 14-0103 525-1 14-1301 14-0114 525-3 14-1302 131023 188330 166043 54942078 54190042 N4 F7552 F4771 F3799 G5299 49072 F5338 H2237 49345 H2365 14- 6102 S26-2 14-0113 S26- 3 H2275 54190000 . 35048 54384768 83-2906 83- 2569 DESCRIPTION C 0 I L S•' ; H 0 RN • RECTIFIER AND Ignition coil (02206) Lucas type 17 M12 H.T. cable cfw clip and grommet non-resistive Coil bracket Bolt (Coil to bracket) ... Washer ... Nut Bolt (Coil bracket to frame) . .. Washer ... Nut Plain washer E2351 Serrated washer (GS299) Nut (F3799) Lucar connector Insulating cover ... Champion sparking plug Horn (Ciearhooter 27899) Screw (i in. U.H.) Nut Serrated washer Rectifier, type 205 506 (99-0589) Nut Heat sink Zener Diode (99-0590) Heat sink bracket Bolt Washer . .. Bolt, bracket to fork lug Washer ... Plug, heatsi nk .. . Earth blade, rectifier (99-1159) Flasher unit (19{1079) ... Clip , flasher unit (1 9/1081 ) Bracket, flasher unit ... Grommet, flasher unit 77 QUANTITY ZENER DIODE 2 2 2 4 4 4 2 2 2 4 4 4 As requ ired As requ ired 2 1 2 3 3 1 1 1 1 1 REMARK 1 -- - - · ·---·-··--------__)\__________ 4 3 2 5-- ! I 15 - ·· - · - · · · · - - - - - - - ·,, ( i ~ 6 7 8 ' 9 33 10 () ~ If _· .16 "13 23 21 I 31 .. ... Fig. 35. 29 24 HEADLAMP, WIRING HARNESS, SWITCHES AND TAIL LAMP 78 - Ref. No. ~ DESCRIPTION ' AMP AND HE A Dt. 60263 553248 516801 504665 14492 534296 370 54520540 989 54573590 54363454 54363455 12 13 54363453 14 54140331 35710 15 16 54525212 17 281 No t ill us. 54959628 18 31899 54130041 19 20 F6981 21 0622 H2262 22 23 56147 24 54581638 54580300 25 26 554548 573832 27 28 382 54123401-... 29 30 54582415 30 54582414 31 143086 32 1981721 33 862217 2 3 4 5 6 7 8 9 10 11 ' Part No. FLASHER HEADLAMP COMPLETE 55700P (99- 1155) Rim (99- 0692) Light un it (99-1156) Fi xing wire (99-0683) Screw Plate Main bulb (S0f40W) (19/1091 ) Bulbho lder Pilot bul b (99-0548) Pilot bulbholde r (19/1089) Wa rnin g light (Red) (19/1084) W arning light (G ree n) (1 9/1085) Warning light (Ambe r) (19/1083) Seali ng washer (19/1086) .. . Light switc h (57S A) (99-0563) Shield , warni ng light Bulb, warn ing light (99-0537) Wiring ha rness (99-11 58) IGN ITION SWITCH (TYPE 545) (99-0558) Nut .. . IG NITION LOCK CfW KEY Key (state serial nu mber) Cover, ig nit io n swit ch FLAS HER LAMP (19/1067) Le ns (19/1068) Gasket Bulbho lder Interio r asse mbl y .. . Bul b (19/1069) Screw (19/1 070) ... Stanch io n, flashe r lamp- fro nt (19/1071) Stanch ion, flasher la mp-rear (19/1072) Washer (19/1074) Lock nut (19/1073) Grommet 79 QUANTITY LAMPS 1 T100R 6 Reference on ly Reference only 1 Re fe re nce on ly 1 1 1 1 3 1 Refere nce only 3 1 1 Refe re nce only 1 As r eq uire d 1 4 1 Refe re nce o nly Refe re nce only Refe ren ce on ly 1 2 2 2 4 4 Refere nce only REMARKS 3- 1 _, 9 / 2- - - -- 8 - 7 - - - 11 15 27- \--:_--31 ®-----~- ~2 33 16 18 17 19 20 •• Fig. 36. SPEEDOMETER A ND TACHOM E~ER 80 - 32 21 C9 Ref. No. DES CR/PTION Part No. S P E E D~O M E T E R A N D 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 • ' SSM5007j02 SSM5007 j03 54953387 643 H1946 H1929 30-282-014-11 30-276-037-11 S590 41-148-203 H1702 H1701 H1668 14·0103 S26-2 D692 E9438 E9332 Reference only Reference only E5157 ES759 E6300 E5578 E6122 E6299 Reference only E3309 E5881 D648 _ RSM3003 j13 31-371-398 D494 E7351 F4366 . QUANTITY T A C H 0 M ET ER Speedometer head MPH (D2402) Speedometer head KPH (D2403) Bulb holder Bulb, 3.W. M.E.S. MOUNTING BRACKET Metalasti k bush Washer ... Nut Bolt (1 136 in. U. H.) Trip control Distance piece Sleeve nut Bracket ... Bolt(! in. U.H.) Spring washer ... Speedometer cable (63 ins. long) (D692W inner only) TACHOMETER GEARBOX (Body E5757) Securing screw (Left hand thread) UNF Bush ... Flanged bush . .. Driving gear End cap "0" ring ... Driven gear Driven gear housing " 0" ring Bush "0" ring .. . Set screw .. . Tachometer cable (26t in. long) Tachometer (D2396) Spade (99-0173) Circlip ... Sealing washer ... Spacer ... 81 REMARKS 1 Alternative 1 1 1 ~ ;J T100R (Coo be fittod to T100C) n 1 T100C 1 Smiths DF9110/00 1j 1 1 1 1 2 T100R (Can be fitte d to T100C) STANDARD HARDWARE SPECIFICATION BOLTS Part No. 51822 51910 51919 52010 14-0101 14-0102 14-0103 14-0113 14-0114 14-0115 14-0128 14-0208 14-0216 14-0217 14-0219 14-0220 14-0225 14-0228 14-0236 14-0239 14-0242 14-0242 14-0251 14- 6102 14-6115 Material Steel Length under head Thd. dia. -r\-" UNF f" UNF -f." UNC f ' UNF f ' UNF ! " UNF f ' UNF 156 " UNF -r\-" UNF -f." UNF f" UNF f' UNF f6" UNF -r\-" UNF -ft" UNF -f6" UNF -ft" UNF !\" UNF -}" UNF i " UNF i " UNF f" UNF T-6" UNF ! " UNC 156 " UNC Min. length of thread 2 7 ,, I " 2 I 3 64 tr II T6 1~ " 8 8 il" ~" 8 7" 16 I " 2 5" 8 3" 4 5" 8 3 f/ 4 7" 8 1" 2.L" 4 1.L" 8 1.L" 4 1t" ~" 4 7" if 7" 8 7" 8 7 ., 1~ " 8 4 3" 4" 2.L" 4 3" 4" 4" 7" 8 7" 8 1" 1" 1" 1" 1.L" 4 2~ " 4 5" 8 7" 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 " 0.625 '' 0.438 " 0.500" NUTS Part No. 5778 51852 51906 51908 51914 52012 52013 52014 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 14-1903 Material Steel Thd. dia. No. 10 UNF -ft" UNF f ' UNF ls6 " UNF t " UNEF i" UNEF f' UNEF f ' UNEF f ' UNF -ft'' UNF f ' UNF 156 '' UNF i " UNF ! " UNF 156 " UNF i " UNF f' UNF -ft" UNF f ' UNF -r\-" UNF t " UNF T-6" UNF f ' UNF -ft" UNF t" 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 ,.... 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 5tiffnut Stiffnut Stiffnut Stiffnut Stiffnut Stiffnut Stiffnut Nyloc Nyloc SCREWS Port No. S1916 S1917 S1918 S1920 S1929 S2079 14-0604 14-6505 14-6607 14-6608 14-6609 14-7019 14-7024 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 Steel Thd. dia. f ' UNC f' UNC ! " UNC f ' UNC ! " UNC No. 10 UNF f' UNF t " UNC f ' UNC f ' UNC t /1 UNC f6" UNC f6" UNC Length under head 1f' 2i" 2f" Type o( drive Cross recess Cross recess Cross recess lj ll 64 #" t• t /1 7" l 7" 8 1" 1f' ...7• 2" Slot Pozidrive Cross recess Cross recess Cross recess Cross recess Cross recess Hex. socket Hex. socket WASHERS-PLAIN Part No. S25-1 S25-2 S25-3 S25-6 S25-13 Material Steel Steel Steel Steel Steel ifdia. 0.273" 0.398" 0.336" 0.531 " 0.266" ofdia. 0.563 " 0.750" 0.625 " 1.031 " 0.469" Thickness 0.048 " 0.063 " 0.063" 0.092" 0.064" WASHERS-SPRING Part No. S26-1 S26-2 S26-16 S648 ** Double coil. Material Spring Steel ifdio. r clearance t " clearance ofdia . ofo height H" 13 i·/ -f." II TI '" 2'" 17 " 'i TI f6" clearance • • ' 83 7 • TI -n· Thickness 0.104" 0.064" 0.040** 0.080 " '•. .' SUPPLEMENT REPLACEMENT PARTS CATALOGUE FOR ~97~MODELS 500c.c. DAYTONA T'IDD R TROPHY 500 T'IDD C . U.K. & GENERAL EXPORT '•. T100R DAYTONA TECHNICAL DATA Bore and Stroke T100C 69 x 65.5 mm . 2.716 x 2.578 ins. T100R 69 x 65.5 mm. 2.716 x 2.578 ins. Capacity 490 c.c. (30 cu. ins.) 490 c.c. (30 cu. ins.) Compression Ratio 9 :1 9 :1 Sparking Plugs Champion N4 Champion N4 Amal Conce ntric 170 .106 Middle No.4 Amal Co ncentric 170 .106 Top No. 3! 18 teeth 18 teeth Front Rear f j in. x i in. x 102 links i t Fue l Tank Oil Tank Gearbox Primary Chaincase {initial fill) Front Forks (each leg) 3 galls. (13.5 litres) 5! pints (3 .125 litres) 1 pint (375 c.c.) {-pint (150 c.c.) pint (200 c.c.) t 3 galls. (13.5 litres) 5! pints (3.125 litres) pint (375 c.c.) {- pint (150 c.c.) pint (200 c.c.) Brakes Front diameter Rear 7 in. (17.18 em.) 7 in. (17.18 em.) 8 in. (20.32 em.) 7 in. {17.18 c.m) Tyre Size Front Rear 3.25 4.00 Carburetter Main Jet N eedle Jet Nee dle Position Throttle Valve Gearbox Sprocket Chains Capacities 3 in . Duplex x 78 links X X 19 18 in. Duplex x 78 links in. x j in. x 102 links t t 3.25 4.00 X X 19 18 ~ - ~ . . ~~~-m r~ \... - 2 _/ --------y---- 1 r--- 4 _ . A _ -· -· · 7 ' 8 ! q ; ,;: ,:~ 0 F. 11 I( 5/ \~~ 1\ ~ ( (; ,; ' f ', . . _ ~- Vi=::::= ~\"\ ( 'li ~ ( - THIS SUPPLEMENT SHOULD BE READ IN CONJUNCTION WITH 1971 500 C.C. REPLACEMENT PARTS CATALOGUE .... Ref. No. 1 1 2 3 3 03382 03381 99-1132 F9268 F9269 CARBU RETTER-L.H. (L626j38) CARBURETTER-R.H. (R626f37) Main jet (376/100) Petrol pipe Petrol pipe 4 F12252 AIR CLEANER ASSEMBLY 5 6 6 7 8 9 10 11 11 F12255 F12250 F13354 F13353 F12248 !:3327 T1076 GS299 E11956 E12165 AIR CLEANER ASSEMBLY Body Carburetter plate (F12255 assembly) Carburette r plate (F12252 assemnly) Element Grommet .. . Bolt ... Serrated washer Induct ion pipe Induction pipe 12 03310 Clip 13 E12399 Backing ring 14 F9562 Grommet 15 E12398 Screwed flange ... 4 - DESCRIPTION Port No . QUANTITY 2 1 1 {~ 1 2 1 2 2 6 6 1 2 1 2 2 1 2 1 2 .. - .... 5 REMARKS T100C T100R T100C T100R T100R T100C T100R T100C T100R T100C T100R T100C T100R T100C T100R - on l' \ I \, / :I' .jr I .:· ,f.:,:··:'.' It) \ ' •. i" 0 I I I I I I I I ! I : I I '' ... ' c:> 6 . ~ - THIS SUPPLEMENT SHOULD BE READ IN CONJUNCTION WITH 1971 500 C.C. REPLACEMENT PARTS CATALOGUE .' Ref. No. - Part No. 1 E12013 2 E12014 F9759 3 Not illus. H4118 Not illus. H4174 02403 4 5 02599 6 F10216 7 H4126 8 525-1 9 14--1301 10 S2079 11 5778 F12726 12 13 14--0604 02320 14 15 14--0301 16 E12037 17 E12038 18 E11710 19 14--0101 20 14--1201 Not illus. 02209 DESCRIPTION Bracket-silencer and pillion footrest-L.H . Bracket-silencer and pillion footrest-R.H. Petrol tank (3 galls.) ... Telescopic fork assembly Telescop ic fork assembly Speedometer (190 K.P.H.) (S5M5007f03) Licence holder ... Front number plate CHp Washer } Nut Number plate attachment Screw Nut Rear number plate QUANTITY 1 1 1 1 1 1 2 2 2 2 2 4 Smw } Washer Rear number plate attachment Nut Exhaust pipe-L.H. Exhaust pipe-R.H. Silencer ... 4 4 2 4 Bolt} Nut Sile ncer to bracket H.T. cable-resistive (54956466) - 7 REMARKS 4 2 T100R T100C '•. D .·: ~:1 r····~:',·\ '···~· \_ - ·.".t. i t..-..1 i. . \. ·: r.~. ·· ··· '" ··-~.. j -~ i___ ··... . ._..~ {~,.... ~-:~..-:: _:~- ~~~ ~.... ... .oi (:':""3 ,. . - ·· ··''~~ '- ''···--~ .. ~__.......- ,- '•. / /' ( ;· ( ' \ \ .... .' ""( ··. \ \ ·, ·'\ ._. .· 1 .,' ../ I I J -:'.• T11JOR DAYTONA TECHNIC:'\L DATA T100R 69 x 65.5 mm. 2.716 x 2.578 in; . . Bore and Stroke 490 c.c . (30 cu. ins.) Capacity 9 :1 Compression Ratio C hampion N4 Sparking Plugs Amal Conce nt r k.- Carburetter Main Jet ... Needle Jet Needle P..:;sit if'> n Throttle Val ve .. . Capac'tics .106 To p N o . 3~ 18 teeth Gearbox Sprocket Chai ns 170 j in. D uplex x 78 l :nks Fro nt Rear t i:l. Xi in. X 102 li 1 ks 3 galls. (1 3.5 !it rcs) Fuel Tank Oil T?nk (lcar bvx Prima ry C haincase (initial f!l l) Front Fo rks (each leg) ... 5-f pi nts (3.125 li tres) t pint (375 c.c.) ~- p in t (150 c..:.) -} pint (200 c.c.) 8 in. (20.32 CPl . ) 7 in. (17.18 c.m) Brakes F,·ont diamete r ... Rear Tyrc Size Fro nt 3.25 R~ ;~ r 4.00 x1 8 3 X 19 - - -~---- ·-· - N - - ~ - Re(. No. 1 1 2 3 4 4 5 6 6 7 8 9 10 11 ,- 12 13 14 15 / Port No. 03679 03680 99-1132 F9269 F12252 F1 2255 F12250 F13354 F13353 F12248 E3327 T1 076 GS299 E121 65 0331 0 E12399 F9562 E1 2398 DESCRIPTION CAR BURETTER-L.H. (l626/34) CARBL' REITER- R.H. (R626f33) Main jet (376/100) Petrol pipe AIR CLEA NER ASSEMBLY AIR CLEANER ASSEMBLY ·s ody Carburetter plate (F12255 assembly) Carburetter plate (F12252 assem bly) Element Grom met .. . Bolt .. . Se rrated washer Induction pipe Clip Backi ng ri ng Grom met Screwed fl ange ... ' 5· QUANTITY 1 1 2 1 1 1 2 1 1 2 2 6 6 2 ") 2 2 2 REMARKS \ ., \:_ r .... N ! ,'~> \'-~ on ..... ...co.--- 10 ;:1 . :~ .:·n~ .. . \j G> I r-- co I a. I .. / ~0® ~ ~ "-o ~ . " Ref. No. Part No. E1 2013 2 E1 2014 3 F11806 Not illus. H411 8 0 2403 4 I' 02599 :.J 6 F10216 H41 26 7 $25- 1 8 9 14-1 301 S2079 10 S778 11 12 F12726 13 14-0604 14 0 23:20 14-0301 15 16 E1 2622 17 E1 2623 18 E11 710 19 14-01 01 20 14-1201 Not illus. 02209 Not illus. F1 3794 Not illus. S2125 Not illus. F1 717 Not ill us. F1511 DESCRIPTION Bracket-sil ence r and pillion footrest-L.H. Bracket-;">:-silencer and pillion foot rest-R.H. Pet rol t ank (3 galls .) ... Telescopic for k assem bly S;:>eedometer (190 K. P.H.) (SSM5007j03) Licence ho lder .. . Fro nt numbe r plate CBp W asher } N ut Nu mbe r plate attachment Screw N ut Rear nu mber plate Sm w } W as her Rear nu mbe r plat e attachme nt Nut Exhaust pipe-l.H. Exhau st pi re- ~.H. Sile ncer ... Bolt} . ncer to bracket N ut Sile QUANTI TY 1 1 1 1 1 1 1 2 2 2 2 2 1 4 4 4 1 1 2 4 4 H.T. cable- resistive (54956466) Distance piece} Bol t Petrol tank rear mounting Petrol t ap Ta p seal ... 2 1 1 1 2 Special ex port req uire men ts F1 4251 F14l 86 F141 87-. D3891 Rea r mudguard-- tong .. . Rea r numb e r plate bracket- L. H. Rea r numbe r plate bracket-R .H. Sparking plug cap (fully screened) 7 REMARKS 1 1 1 2 T100R T1 00R ______..,__ I I 1:,1 " "" 0'~ :"1. ~ !• ·v1}··T" "::l "'~ _ ._...J~:1 _.; \..,~ _ :' J(' "''To··· l J cu. 11.~) . ) , :~ J. ~B 1 3 :1 ~3 ~3 ~3 !7 }1 )1 S7 57 57 )7 ..1 +1 ·~1 ~.3 !..9 '*-9 4-9 51 53 57 57 57 59 59 63 63 65 69 69 69 69 75 75 75 75 75 75 75 75 75 77 77 77 77 79 79 79 79 79 79 79 81 J .' \ r,nm 16 3 50 26 27 55 10 19 40 1 2 13 14 8 9 19 3 55 59 60 19 19 JlJf- 8 11 12 6 7 37 29 30 33 34 3 4 5 7 11 14 16 17 18 31 32 33 31+ 10 23 24 28 29 30 .32 3 q ) ) : \J PI..R'l1 ~Ill c .. 2 · - ----~ ·..._ __ ______ J ti~?J. ACT; : ,i.F':; :T .. p _.·~ n:i' ~; C _r.T ~\.I ,OG UJ~ NlL~D!~l1 c~:I :.;.~~E Dcletc(l s70--, J~9512 11+-0103 D21 17 14- 0.301 T1 lt-05 T1771 370-3 E120.37 E12038 Eh157 E4158 E9669 E9670 F929 S70-3 H4123 H4201 Hh202 \'13461 W3h.55 H3886 H3885 H1688 19-1 065 19-1 066 F8192 F8193 F12817 19-1 335 19- 1336 19-1 335 19-1 336 54052982 553343 19-1 088 19- 1091 .31 276 19-1 084 19-1 085 19-1 08.3 19-1 086 19-1 079 19-1 081 83- 2906 83- 2569 19-1 089 19-1 067 19-1 068 19-1 069 19-1070 19-1 072 19-1 073 643 no'!i reads JJ2363 E1257G " II 141/._01 " E3302 " " N'ut added nmv reads Tlj.007 II " D2368 II If It D2.36l+ E9666 E9667 "II E12017 " II E'12018 11 II E12019 II II E12020 II II S1822 " " D2364 It II 114203 Stiffening strip - L.H. - Added II II - R.H. " now r eads W3h.62 " " " II " II II II II " " W31~9 H4046 II II H4044 Added - T1 00C II 99- 1046 II 99-11 89 Del eted Deleted Now reads F11 614 II II 99- 1215 Lucas 54340883 II II 99- 11 88 II II 99-1 187 Lucas 54340882 II 99- 1188 " II 60261 " 53J+3J+3 " " II 991212 " II "II 99- 1214 3571 0 "II "II 99-1 208 99-1 209 " 11 99- 1207 ,," 991210 " 99-1 201 " " 991204. " " " F13600 " Delet ed now r eads 99- 1213 90 " " 99-11 991191 "II "II 99-11 92 " " II " " 99~1193 99-11 94 99-11 95 987
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