650s - ClassicBike.biz

Transcription

REPLACEMENT
PARTS
CATALOGUE
FOR 1972
BONNEVILLE T 12011 9 T 120RV
TIGER 650 TR6R, TR6RV
TROPHY 650 TR6C. TR6CV
See Bookmarks
TRIUMPH ENGINEERING COMPANY LIMITED
MERIDEN WORKS • ALLESLEY • COVENTRY CV5 9AU • ENGLAND
TELEGRAMS "TRUSTY" COVENTRY
TELEX "TRUSTY" 31305
TELEPHONE COVENTRY 20221
MERIDEN 331
PUBLICATION PART No. 99-0953
PUBLISHED AUGUST 1971
FIRST AMENDMENT NOVEMBER 1971
ClassicBike.Biz
I NTRODUCTION
The Triumph Engineering Co. Ltd. point out that the information in this catalog was complete and correct
at the time of printing. Distributors will be informed of any subsequent alterations.
A plastic binder, of the type used for Workshop Manuals, is available to enable this catalog and all other
1971 season catalogs to be bound into one unit.
GUARANTEE
Please refer to your dealer or distributor for the latest terms of guarantee.
Eastern U.S.A. Distributor:
Western U.S.A. Distributor:
Triumph Motorcycle Corporation,
P.O. Box 6790,
Towson,
Baltimore 4,
Maryland 21204.
Triumph Motorcycle Corporation,
P.O. Box 2765,
East Huntington Drive,
Duarte,
California 91010.
Telex—Tricor Balt. 87728
Telephone-301-252-1700
Telex—Tricor Duarte 675469
Telephone-213-359-3221
213-681-0255
ENGINE AND FRAME NUMBERS
The engine number is located on the left side of the engine, immediately below the cylinder barrel to
crankcase flange.
The frame number is located on the left side of the frame headlug, beneath the fork top lug and forward
of the gasoline tank.
Both the engine and frame number should be quoted in full in any correspondence relating to the
machine.
2
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I NDEX
Page
AIR CLEANER ...
...
ALTERNATOR ...
...
AUTO-ADVANCE UNIT
...
...
...
...
77
... 11, 51
...
39
BATTERY CARRIER
BRAKE SWITCH
BREATHER PIPES
...
...
...
...
...
...
...
...
...
Page
KICKSTARTER ...
MANIFOLD
...
...
MOTOR PLATES
...
MOTOR TORQUE STAY
MUFFLERS
...
...
93
57
53
...
...
59, 61, 63
...
...
FENDERS
FIVE SPEED GEARBOX
...
...
FLASHERS
...
...
FOOTRESTS
...
...
FRAME...
...
FRONT FORKS
...
FRONT WHEEL
...
...
...
...
...
...
...
...
79
...
45
... 89, 91
... 57, 63
...
53
... 65, 67
...
71
GAS TANK
GEARBOX
...
...
...
...
...
...
...
...
...
47
17
...
...
57
...
57
59, 61, 63
...
...
...
17
53
17
PISTONS
...
PROP STAND ...
PUSH RODS
...
...
...
...
11
...
...
...
53
19,21,23,25,27,29,31,33
REAR WHEEL ...
RECTIFIER
...
ROCKERS
...
...
...
73
...
...
...
89
19,21,23,25,27,29,31,33
SIDE PANEL
...
...
...
SPARK PLUG ...
...
...
SPEEDOMETER ...
SPEEDOMETER GEARBOX ...
STEERING DAMPER
SUSPENSION UNITS ...
...
SWINGING FORK
...
...
SWITCHES
...
...
...
...
77
...
89
...
87
...
73
...
69
...
55
...
55
... 81, 91
TABLE OF STANDARD HARDWARE 94,95
TACHOMETER ...
...
...
...
87
TACHOMETER GEARBOX ...
...
87
TAIL LAMP
...
...
...
...
79
TAPPETS
...
...
17
TIMING GEARS
...
...
...
11
TOOLKIT
...
...
...
85
TWIN SEAT
...
...
75
...
...
75
...41, 43, 45, 47
...
...
HANDLEBAR...
HANDLEBAR MOUNTINGS ...
...
...
HEADLAMP...
...
...
...
HORN...
...
OILPUMP
...
...
...
OIL PIPES
...
...
...
OIL PRESSURE RELEASE VALVE
CAMSHAFT, INLET AND EXHAUST
11
...
... 35, 37
CARBURETOR
...
...
...
7
CARTON PACKS
•..
...
...
CENTRESTAND
53
...
...
...
51
...
CHAINS...
...
...
...
...
51
CHAINCASE
49
...
...
...
...
CLUTCH
.••
47
CLUTCH LEVER ASSEMBLY
...
...
89
...
...
...
COIL
89
„_
...
CONDENSERPACK ...
11
...
...
CONNECTING RODS
...
...
39
CONTACT BREAKER ...
...
...
...
83
CONTROL CABLES
...
...
81
CONTROL LEVERS ...
...
... 13, 15
...
CRANKCASE ...
...
63
CRANKCASE UNDERSHIELD
...
...
11
...
CRANKSHAFT ...
19,21,23,25,27,29,31,33
...
CYLINDERS
CYLINDER HEAD 19,21,23,25,27,29,31,33
EXHAUST PIPES
...
VALVES ...
...
VALVE GUIDES
81
...
...
69
... 91, 93
...
89
19,21,23,25,27,29,31,33
19,21,23,25,27,29,31,33
WIRING HARNESS
...
..
•••
•..
91
ZENER DIODE...
...
...
...
89
3
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TIGER 6 0 (TR 6 R) (TR 6 RV— SPEED) TECHNICAL DATA
Bore and Stroke
...
Capacity ...
Compression ratio
Spark plugs
Carburetor
Main jet
...
Needle jet
Throttle valve ...
Gearbox sprocket
...
Chains
Capacities
Brakes
Tire size ...
Front
Rear
...
Gas Tank
Oil Tank
...
Gearbox
Primary Chaincase
...
Primary Chaincase
Front Forks (each leg) ...
...
Front, diameter...
Rear, diameter
Front
Rear
4
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71 x82 mm.
2-79 x 3 . 23 ins.
649 c.c. (40 cu. ins.)
9:1
Champion N3
Amal Concentric 930
230
106
No. 32
19 teeth
I" Duplex x 84 links
Ex6 " x106 links
3.6 U.S. galls.
4.8 U.S. pints.
i pint (500 c.c.)
4 pint (150 c.c.)
* pint (150 c.c.)
i pint (190 c.c.)
8" (20 . 32 cm.)
7" (17 . 78 cm.)
3.25x19
4.00 x18
TROPHY 650 (TR6C) (TR6CV-5 SPEED) TECHNICAL DATA
Bore and stroke...
...
...
71 x 82 mm.
2 . 79 x 3 . 23 ins.
Capacity ...
...
...
649 c.c. (40 cu. ins.)
...
...
Champion N3
...
...
...
...
...
...
Amal Concentric 930
230
•106
No. 32
...
...
...
9:1
Compression ratio
Spark plugs
...
Carburetor
...
Main jet
...
Needle jet
...
Throttle valve ...
Gearbox sprocket
Chains
...
Capacities
Brakes
...
Tire size ...
...
...
Front
Rear
...
...
...
...
...
...
...
...
...
18 teeth
" Duplex x 84 links
8"xW'x106links
...
... Gas Tank
...
Oil Tank
...
Gearbox ...
Primary Chaincase
Front Forks (each leg)
...
... Front, diameter...
Rear, diameter
...
...
8" (20 . 32 cm.)
7" (17 . 78 cm.)
...
...
...
...
3.25x19
4•00x18
...
...
Front
Rear
...
...
5
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3.6 U.S. galls.
4.8 U.S. pints
pint (500 c.c.)
4'- pint (150 c.c.)
pint (190 c.c.)
BONNEVILLE (T120R) (T120RV-5 SPEED) TECHNICAL DATA
Bore and stroke...
...
Capacity
Compression ratio
...
Spark plugs
Carburetors
Gearbox sprocket
...
Chains
Capacities
Brakes
Tire size
...
Main jet
Needle jet
..
Throttle valve
Front
...
Rear
Gas Tank
Oil Tank
...
Gearbox
...
Primary Chaincase
Front Forks (each leg)
Front, diameter...
Rear, diameter
Front
Rear
6
ClassicBike.Biz
71 x82 mm.
2 . 79 x 3 . 23 ins.
649 c.c. (40 cu. ins.)
9:1
Champion N3
2 Amal Concentric 930
190
.106
No. 3
19 teeth
1" Duplex x 84 links
8"x8"x106 links
3.6 U.S. galls.
4.8 U.S. pints.
i pint (500 c.c.)
4 pint (150 c.c.)
1 pint (199 c.c.)
8" (20 . 32 cm.)
7" (17 . 78 cm.)
3.25x19
4.00x18
HOW TO USE THIS SPARE PARTS CATALOG
First consult the index on Page 3 for the parts or group of parts which you wish to locate. When
you have located the parts make sure from the end columns that the part you have located does apply to
your machine.
List the quantities required as single units; do not ask for "2 pairs" or "3 dozen".
In case of painted items always state the color required. Painted parts are available only in the colors
or alternatives specified for that model of that particular year.
CARTON PACK LIST
The following sub-assemblies are supplied in carton packs under the C.P. part number stated. The
contents of these carton packs are preserved and will not deteriorate under adverse conditions.
Part No.
Contents
Brake Lining
C. P.38/A. M.2
C.P.205 ...
...
2 ...
...
16
...
...
2
...
16
...
NW243 ...
...
...
Brake lining
...
W129
...
...
...
Rivet
...
...
W1734 ...
...
...
Brake lining
...
...
W129
...
...
...
Rivet
Pistons (complete with rings, gudgeon pins and circlips)
E6895
...
...
...
...
...
... 7 . 5 : 1 C.R.
...
...
For use with low grade fuel
E9488
...
...
...
...
...
...
9 :1 C.R.
...
...
Standard
E6867
...
...
...
...
...
...
11 : 1 C.R.
...
...
Competition use only
All the above pistons are available in oversizes of 0 . 010 ins., 0 . 020 ins., 0 . 040 ins., (0 . 25 mm., 0 . 5 mm., 1 mm.)
Valve Guides
C.P.97
...
...
...
2
...
...
...
E2899
...
...
...
Inlet guide
(TR6)
...
...
...
2 ...
...
...
E2900
...
...
...
Exhaust guide
7
ClassicBike.Biz
PLEASE NOTE
THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS
INCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN, REVERTING
TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE
ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENT
PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.
SPECIAL WORKSHOP TOOLS
A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING
YOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASES
THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE, AND
THEREFORE, IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN
ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES
IT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.
UNIFIED THREAD FORM
NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOG HAVE THE UNIFIED
FORM OF SCREW THREADS. THIS CHANGEOVER WILL BE CONTINUED AS AND WHEN NEW PARTS
ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS
WILL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS
HAVING THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS IN
THEIR HEADS, STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING
CIRCLES ON THE SIDE.
COLOR
TIGER 650 (TR6R—TR6RV)
Petrol tank—Polychromatic blue and cold white, black lining.
Petrol tank (44 U.S. gallon) optional—Polychromatic blue and cold white, black lining.
—Polychromatic blue, cold white stripe, black lining.
Fenders
Side covers—Black, gold decal.
TROPHY 650 (TR6C—TR6CV)
Petrol tank—Polychromatic blue and cold white, black lining.
—Chromium plated.
Fenders
BONNEVILLE (T120R—T120V)
Petrol tank—Tiger gold and cold white, black lining.
Petrol tank
(41 U.S. gallon) optional—Tiger gold, white stripes, black lining.
—Tiger gold, white centre stripe, black lining.
Fenders
N.B. It is important to state year and model of machine when ordering painted components.
ClassicBike.Biz
TRIUMPH SPARES
HOW TO ORDER. Every part is indicated by a number, and this should be quoted together with
the description. In order to assist customers, dimensions have been given in many cases where parts
are similar. Parts where possible have been listed in order of assembly and a number of the illustrations
show the assembly order also. With these aids, there should be no difficulty in identifying the parts you
require.
ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OF
THE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS.
WHERE TO OBTAIN. Triumph Spare Parts can only be obtained from an authorised Triumph
Dealer, and we recommend our customers to place their orders with the Triumph Dealer in their district.
When parts not usually asked for are required, and for which the Dealer may have to write or obtain
specially, the postage or carriage incurred becomes payable.
TRIUMPH SPARES ARE NOT SUPPLIED TO PRIVATE OWNERS DIRECT FROM THE FACTORY.
A LIST OF AUTHORISED DEALERS WHO STOCK TRIUMPH SPARES IS AVAILABLE ON REQUEST.
IF DIFFICULTY IS EXPERIENCED IN OBTAINING THE REQUIRED PARTS, THE MATTER SHOULD
BE TAKEN UP DIRECTLY WITH THE TRIUMPH SPARES DEPARTMENT.
Customers are warned against the risk incurred by purchasing parts that are not of genuine Triumph
manufacture. This risk is eliminated if parts are ordered as instructed from recognised Dealers.
PATTERNS AND PARTS FOR REPAIR. It is not necessary to send patterns if the part number
is quoted. The sending of patterns often delays the order as parcel post or rail takes longer than letter post.
Parts sent to Coventry for repair, replacement, or as patterns should bear the sender's Name and
Address and clear instructions should accompany the parts. In your own interest send a copy of the advice
note under separate cover. All parts must be forwarded carriage paid and care should be taken to ensure
that all remittances are sent separately and not enclosed with the parts. Fragile units such as cylinders,
etc., should always be boxed to avoid damage in transit. Complete machines should have all fitments such
as windscreens, driving mirrors, tools, etc., removed by the sender before despatch, as it is impossible for
us to accept responsibility in the event of loss in transit. We are always pleased to give estimates for overhauling and repairs, but should an estimate not be accepted, a charge will be made covering cost of dismantling
and re-assembling, if carried out. Work cannot be accepted at the factory direct from private owners.
Communications relating to Parts should be addressed to the SPARES DEPARTMENT and for repairs,
guarantee claims and technical advice to the SERVICE DEPARTMENT, Triumph Engineering Co. Ltd.,
Meriden Works, Allesley, Coventry. In order to facilitate quick reference, the quoting of any number,
invoice number or reference from previous communications is essential. Accessories not of our manufacture should be sent direct to the actual makers, whose Names and Addresses appear below.
PROPRIETARY GROUP
Ancillary equipment which is fitted to our motor cycles is of the highest quality and is guaranteed by
the manufacturers and not by ourselves. Any repairs or claims should be directed to the actual makers
or their local agents who will always give owners every possible assistance. The following are the addresses
of the various manufacturers:—
CARBURETORS
Messrs. Amal Ltd.,
Holdford Road,
Witton,
Birmingham, 6.
CHAINS.
Renold Chains Ltd.,
Wythenshawe,
Manchester.
TIRES.
Dunlop Rubber Co. Ltd.,
Fort Dunlop,
Birmingham, 24.
The Avon Rubber Co. Ltd.,
Melksham,
Wilts.
SPARK PLUGS.
Champion Sparking Plug Co. Ltd.,
Feltham,
Middlesex.
I NSTRUMENTS.
Messrs. Smiths Industries Ltd.,
Cricklewood Works,
London, N.W.2.
SUSPENSION UNITS.
Messrs. Girling Ltd.,
Birmingham Road,
West Bromwich,
Staffordshire.
ELECTRICAL EQUIPMENT.
Messrs. J. Lucas Ltd.,
Gt. Hampton Street,
Birmingham, 18.
9
ClassicBike.Biz
15
--16
18
17
-- 14
3
33
^
31
31 32
^
1
4
35
._ Y
?1
34 30
29 27 26
28
38
Fig. 1. CRANKSHAFT AND CONNECTING RODS
10
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
CRANKSHAFT AND CONNECTING RODS
E13054
CRANKSHAFT AND FLYWHEEL ASSEMBLY (METRIC)
• •
E13097
CRANKSHAFT C/W. OIL TUBE
E3903
Oil tube
E12800
Screwed plug
E12425
Flywheel ...
*E12799
Flywheel bolt
E11003
Washer
...
E3114
Crankshaft stud (11 in. 0.A.) ...
E9525
CONNECTING ROD ...
Small end bush ...
E1511
E6576
Connecting rod bolt
Self locking nut ...
D3761
E3586
Big end bearing (Available in —•010 in. and — . 020 in. undersizes)
PISTON COMPLETE 9 :1 C.R.
E9488
Taper compression ring ...
E6864
co
Oil control ring ...
...
E6865 )
Gudgeon pin (short)
...
•••
E6861
...
•••
WE479 X- 6 ?‘? Circlip
...
...
•••
Main bearing, right (metric) ...
E3835
•••
Motor sprocket, 29 teeth Duplex
El 2662
•••
E4573 70-'19/Z Distance piece ...
Rotor key
...
22
E10082
542139015qWW(Rotor (99-0739)
23
...
Tab washer
24
E3975
Nut
E3977
25
Key
...
E1580
26
Timing pinion
27
E4564
Nut
...
E12877
28
INTERMEDIATE WHEEL
29
E6159
Intermediate wheel bush...
30
E400
Camshaft pinion...
E12719
31
Camshaft key ...
32
E1558
Inlet camshaft nut
33
E11007
Exhaust camshaft nut
34
E6523
...
Inlet camshaft, ...
E11063
35
•••
EXHAUST CAMSHAFT
E9989
36
•••
Tachometer drive plug
37
E9988
•••
...
Clamping washer
38
E3300
•••
Main
bearing,
left
(metric)
39
E2879
Spacer
Not illus. E12663
Shim (0 . 010 in.) -Engine sprocket
Not illus. E8038
Shim (0 . 030 in.)
Not illus. E12660
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
qo
* Use D524 Loctite Sealant
11
ClassicBike.Biz
1
1
1
1
1
3
3
1
2
2
4
4
4
2
4
2
2
4
1
1
2
2
1
1
1
As required (up to 4)
As required (up to 4)
52
Fig. 2. CRANKCASE
12
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
CRAN KCASE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
E11266
CRANKCASE DRIVE SIDE ...
...
...
E10287
Camshaft bush
...
...
...
...
E10287
Camshaft bush
...
...
...
...
E5976
Chain tensioner abutment
...
...
E13098
CRANKCASE TIMING SIDE
...
...
E10286
Camshaft bush
...
...
...
...
E4538
...
...
Scavenge pipe
...
...
E6386
Locating peg (at oil pipes)
...
...
T989
Hollow dowel
...
...
...
...
T912
Locating peg (LAS at thrust washer) ...
T1606
Needle roller bearing, layshaft ...
...
E375
Intermediate wheel spindle
...
...
E8751
...
...
...
...
Hollow dowel ...
E3716
...
...
...
Hollow dowel ...
...
S1873
...
...
...
...
Screw ...
••.
...
...
...
...
14-1445
...
...
Stud
...
...
...
...
S25-2(0-'24' Plain washer ...
...
...
...
14-0303
...
...
...
Nut
Hollow dowel, tappet oil feed
...
...
E1532
...
...
...
...
...
E9330
Oilway plug
...
...
...
...
F1880
Copper washer ...
...
S1871
Tachometer drive plug (L.H. thread)
...
...
...
...
E8896
Fibre washer ...
...
...
...
...
51863
Oil pipe stud ...
...
...
...
...
51865
Cylinder stud ...
...
...
...
...
Plug, timing hole
51872
...
...
...
...
...
...
S1870
Bolt
...
...
...
...
...
...
14-6220
Bolt
...
...
...
•..
...
...
14 -6223
Bolt
...
...
...
...
...
•..
14 -0230
Bolt
...
...
...
...
...
...
Bolt
S1823
...
...
...
...
Plain washer ...
D2330
...
...
...
...
...
...
14-1302
Nut
...
...
...
...
Crankcase filter...
E9336
...
...
...
...
E53157O- 72-Joint washer ...
...
...
Drain plug (with level tube) ...
T2167
...
...
...
...
Fibre washer ...
T1257
...
...
...
...
Level plug UN ...
S543
...
...
...
...
E2441G,O- 7/32 Copper washer ...
...
...
...
Drain and adjuster plug
T2259
...
...
...
...
Fibre washer ...
T1738
...
...
...
...
Blanking plug ...
T1 920
...
...
...
...
T2166
Filler plug UN ...
"0" ring
...
...
...
...
...
E8782
...
...
...
...
...
...
14-6242
Bolt
...
...
...
...
...
...
Stud
S669
...
...
...
...
Protection blade
E8892
...
...
...
...
Self locknut UN
14-1301
Rubber
plug
(for
protection
blade
stud
hole)
E7573
...
...
...
...
Nut, exhaust ties
14-0402
...
...
Breather
cover
plate
assembly
E11072
...
...
...
...
...
Screw ...
E11075
13
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
-..
...
...
1
1
1
1
1
2
Reference only
Reference only
2
1
1
1
1
1 Not required
2 on later models
1
2
2
2
1
1
1
2
1
8
1
1
1
1
1
2
(TR6C 3 off)
10
(TR6C 7 off)
(TR6C 4 off)
5
1
1
1
1
1
1
1
1
Reference only
2
2
1
(Except TR6C)
1
1
1
1
(Except TR6C)
2
I
1
Ref. No.
Part No.
DESCRIPTION
QUANTITY REMARKS
CRANKCASE (continued)
53
54
55
56
57
58
59
60
E9335
E11460
E11077
E11078
E4705
S26-2 6
0 0- %'2S0
14-0101
E11345
Outlet stub
...
...
...
...
Joint washer ...
...
...
...
Screw ...
...
...
...
...
Tube, primary chain oiler
...
...
Clip
...
...
...
...
...
Spring washer ...
...
...
...
Bolt (g
b
in.
U.H.)
...
...
...
i
Grommet, alternator leads- —external
15
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
2
1
1
1
1
1
5
Assy 1
12
11
10
6
7
9
8
20
22
21
23
24
28
Fig. 3. OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS
16
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Not Illus.
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
E9421
OIL PUMP
...
...
...
...
...
...
Reference only
Pump body...
...
Feed plunger
...
...
...
E9269
...
...
Scavenger plunger
E6681
...
...
Drive block
E495
...
2.
S70-7 6 0 - 363
Valve ball ( 3'—z in. dia.)
...
...
Valve spring
...
...
...
E403
Screwed plug
...
...
...
E2360
...
...
...
...
E11461
Joint washer
Oil pump stud ...
...
...
...
S1864
...
...
Serrated washer
...
E3887
...
...
...
...
Nut
...
S1906
...
...
...
Oil release valve
E6595
...
...
E167060 33Y5 Fibre washer ...
...
Joint washer, release valve cap to body
E8754
...
Stud
...
...
...
...
S1876
...
...
Joint washer ...
...
E5660
...
...
Inlet manifold ...
...
E9973
...
...
...
S25-136€ 4'2 %{8' Plain washer ...
...
...
...
Nut
...
...
S1877
Stud
S1996
...
...
...
...
Cup
...
E9555
...
...
...
...
"0" ring
E9554
...
...
...
...
Nut
...
14-1301
...
...
...
Inlet tappet guide
E9352
...
...
Exhaust tappet guide ...
E9353
...
...
Copper washer ...
...
El 612
Set bolt ..
H200
/9 b./. y ...
Inlet tappet 70.- 3D
E3059R
...
...
...
Exhaust tappet
E8801
...
...
...
...
'0' ring
E7563
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
2
...
...
...
...
...
...
...
...
2
2
7c-8g5 /A- -- / mF Pe 7 f,,Q /S G4r,'r
17
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
1
2
2
2
1
2
2
2
1
1
Available
4
2
1
4
4
TR6
... 2
... 2
... 2
... 1
... 1
... 2
2
17
16
15
14
1
B4
Fig, 4, CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)
18
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)
1
2
3
4
5
6
6a
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
E6309
Cylinder base wash er
E6304
Cylinder block ...
S692
Cylinder base nut
E2620
Push rod
E12575
Cover tube ...
E7310
"0" ring, push rod cover tube (bottom)
E11283
"0" ring, push rod cover tube (top)
E4547
Cylinder head gaske t
E12354
CYLINDER HEAD c/w GUIDES
E2899 7/-32?2
Inlet valve guide ...
E2900 7/-3195
Exhaust valve guide
E9516
Exhaust pipe adaptor
E4603
Inlet valve
E2904
Exhaust valve
E6439
Bottom cup
...
E4221
Inner valve spring (red spot) ...
E7400
Outer valve spring (green spot)
E1543
Top collar
...
99-006271- 37g Split cotter
...
E327
Cylinder head bolt
F2184
Plain washer
E4771
Bolt
...
S25-3
-g2q7 Plain washer
D3548
Sealing ring
...
E12350
Inlet rocker box
Exhaust rocker box
E12351
Joint washer ...
E12599
51875
Rocker box bolt
1
Rocker box nut
301
Plain washer ...
E3302
Rocker box stud
1 1401
S25-13
qZ4e Plain washer
...
1 1435
Cylinder head stud (for torque stay)
E4610 7/-174'q Inspection cap ...
Joint washer ...
E3751
E4609
Locking spring ...
WE170 6o-q263 Fibre washer ...
Screw ...
1 2203
E1457
ROCKER (right exhaust, left inlet) ...
ROCKER (left exhaust, right inlet) ...
E1458
E10070
Rocker ball pin
E1513
Rocker adjusting pin
E470
Adjuster lock nut
E1575
Thrust washer, z in.
Spring washer ...
E1574
Rocker spindle ...
E1512
Dowel, rocker box
E12361
Thrust washer, in.
El 330
Access plug
...
E12079
Washer ...
E12080
E1288870-ve0 Bolt, cylinder head
E1288974-9781 Bolt, rocker box
19
ClassicBike.Biz
8
4
2
2
2
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
.••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
2
2
2
2
2
4
4
4
4
8
4
4
2
2
4
6
6
6
4
2
4
4
4
4
4
2
2
4
4
4
6
4
2
4
2
4
4
•• •
4
•• •
4
e-58
x-57
56 3 4
37
35
33
36
24 ^ / 51
E31 27
32
42
41 -^
q
^^ j;
45 23
52
?
43
48 49
50-
44 47 39 40 43
18
29
25 46
21
1
E3
0---28
I
4
30
i22
26
19
6A
20
17 ^^
ÎiiNill
-
g
F1
16
11
--
10
8
15
12
7
14
13
6
53
54
2
3
^
1
a
B4
Fig. 4. CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)
20
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)
(continued)
52
53
54
55
56
57
58
E12598
E4752
E11707
D2332
E12597
D2331
14-1303
Spacer ...
Sealing ring
Sleeve ...
Washer ...
Distance piece
Washer
Nut
...
...
...
...
...
...
...
...
...
...
...
...
For torque stay
J
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
21
ClassicBike.Biz
...
...
...
4
2
2
4
2
2
2
54
53
52
B4
Fig. S. CYLINDER BLOCK AND HEAD, TR6R, TR6C (LATER MODELS)
22
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
CYLINDER BLOCK AND HEAD, TR6R, TR6C(LATER MODELS)
1
2
3
4
5
6
6a
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
E6309
Cylinder base washer ...
...
...
E6304
Cylinder block ...
...
...
...
S692
Cylinder base nut
...
...
...
E2620
Push rod
...
...
...
...
Cover tube
E12575
...
...
...
...
E7310
"0" ring, push rod cover tube (bottom)
E11283
"0" ring, push rod cover tube (top)
E4547
Cylinder head gasket ...
...
...
E12806
CYLINDER HEAD c/w GUIDES ...
E2899 7/-3Z9Z
...
...
E29007/ -3293
Exhaust valve guide
...
...
E4603
...
...
Inlet valve
...
...
E2904
Exhaust valve ...
...
...
...
E6439
Bottom cup
...
...
...
...
E4221
Inner valve spring (red spot) ...
...
E7400
...
E1543
Top collar
...
...
...
...
99-00627/-374'8Split cotter
...
...
...
...
E327
Cylinder head bolt
...
...
...
F2184
Plain washer ...
...
...
...
...
...
E4771
Bolt
...
...
...
S25-360 -'/Z'/7 Plain washer ...
...
...
...
Sealing ring
...
...
...
...
D3548
Inlet rocker box
...
...
...
E12569
Exhaust rocker box ...
...
...
E12570
Joint washer ...
...
...
...
E12599
...
...
...
Rocker box bolt
51875
Rocker box nut...
...
...
...
14-0301
Plain washer ...
...
...
...
E3302
Rocker box stud
...
...
...
14-1401
...
...
...
525-13(j0-1/2Vo0Plain washer ...
14-1435
...
Inspection cover
...
...
E12572
...
...
...
Joint washer ...
E12574
E1457
E1458
...
Rocker ball pin ...
...
E10070
...
Rocker adjusting pin ...
...
E1513
Adjuster lock nut
...
...
...
E470
...
...
Thrust washer, 2 in. ...
E1575
...
Spring washer ...
...
...
E1574
Rocker spindle ...
...
...
...
E1512
Dowel, rocker box
...
...
...
E12361
...
Thrust
washer,
e
in.
...
...
E1330
...
...
...
Access plug
...
E12079
Washer ...
E12080
...
...
...
El288870-9700aBolt, cylinder head
...
...
...
Bolt,
rocker
box
2889
70-9
78/
E1
23
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
8
4
2
2
2
1
1
2
2
2
2
4
4
4
4
8
4
4
1
1
2
1
1
2
4
6
6
6
4
2
4
4
2
2
4
4
4
6
4
2
4
2
4
4
... 4
... 4
54
53
52
B4
Fig. S. CYLINDER BLOCK AND HEAD, TR6R, TR6C (LATER MODELS)
24
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, TR6R, TR6C (LATER MODELS) (continued)
48
49
50
51
52
53
54
55
56
E12598
E4752
E11707
D2332
E12597
D2331
14-1303
14-0103
D2329
Spacer ...
Sealing ring
Sleeve ...
Washer ...
Distance piece
Washer
Nut
Screw
...
For torque stay
...
}
Tappet inspection cover
r
25
ClassicBike.Biz
4
2
2
4
2
2
2
8
8
067
66
(5 --- 65
46
45
44
60 29
B5
Fig. 6. CYLINDER BLOCK AND HEAD, T12OR (EARLIER MODELS)
26
ClassicBike.Biz
Ref. No. Part No.
QUANTITY
DESCRIPTION
REMARKS
CYLINDER BLOCK AND HEAD, T120R (EARLIER MODELS)
1
2
3
4
5
6
6A
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
...
...
E6309
...
...
...
Cylinder block ...
E6304
...
...
...
Cylinder base nut
S692
...
...
...
...
Push rod
E2620
...
...
...
...
Cover tube
E12575
...
...
...
"0" ring (bottom)
E7310
...
...
...
"0" ring (top) ...
E11283
...
...
Cylinder head gasket ...
E4547
...
CYLINDER HEAD c/w GUIDES
E12356
Sleeve for head bolts passing through
E5347
...
...
E3827 7/- 329y
...
...
E38287/- 3Z 9'.r Exhaust valve guide
...
Carburetor adaptor, left ...
E9550
...
Carburetor adaptor, right
E9551
...
...
...
Connector ...
E6916
...
...
...
Balance pipe
E4792
...
...
Adaptor locking nut
S1932
...
...
Exhaust pipe adaptor
E9516
...
...
...
Self-locking nut
14-1301
...
...
...
...
...
Cup
E9555
...
...
...
Insulating ring ...
E9554
...
...
...
...
Inlet valve
E4603
...
...
...
...
Exhaust valve
E2904
...
...
...
...
Bottom cup
E6439
...
Inner valve spring (Red spot)
E4221
...
E7400
...
...
...
...
Top collar
E1543
...
...
99-00627/ 37Y(?Split cotter
...
...
...
Cylinder head bolt
E327
...
...
...
Plain washer ...
F2184
...
...
...
...
...
Bolt
E4771
...
...
...
S25-3 0-4v{7 Plain washer ...
...
...
...
...
Sealing ring
D3548
...
...
...
Inlet rocker box
E12350
...
...
...
Exhaust rocker box
E12351
...
...
...
Joint washer ...
E12599
...
...
...
Rocker box bolt
S1875
...
...
...
...
...
Nut
14-0301
...
...
...
...
Plain washer
E3302
...
...
...
Rocker
box
stud
14-1401
...
...
...
...
Plain
washer
S25-1360-42q
Cylinder
head
stud
(for
torque
stay)
14-1435
...
...
...
E461070-Z7q/q Inspection cap ...
...
...
...
Joint washer ...
E3751
...
...
...
Locking spring ...
E4609
...
...
...
WE17060-qz 3Fibre washer ...
...
...
...
...
Screw ...
14-2203
E1457
E1458
...
...
Rocker ball pin ...
E10070
...
...
...
Rocker
adjusting
pin
E1513
...
...
...
Adjuster
lock
nut
E470
in.
Thrust
washer,
'z
E1575
...
...
...
Spring washer ...
E1574
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
inlet tracts
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
•..
...
...
27
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
•..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
8
4
2
2
2
1
1
Reference only
2
2
1
1
2
1
2
2
4
7
4
2
2
4
4
4
4
8
4
4
1
1
2
1
1
2
4
6
6
6
4
2
4
4
4
4
4
2
2
4
4
4
6
4
B5
1
Fig. 6. CYLINDER BLOCK AND HEAD, T12OR (EARLIER MODELS)
28
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
CYLINDER BLOCK AND HEAD, MOR
QUANTITY
(EARLIER MODELS)
(continued)
54
55
56
57
58
59
60
61
62
63
64
65
66
67
Rocker spindle ...
E1512
Dowel, rocker box
E12361
Thrust washer, a in.
El 330
...
Access plug
E12079
Washer ...
E12080
E128887o-9780 Bolt, cylinder head
E1288970 781 Bolt, rocker box
Washer ...
D2332
Spacer ...
E12598
Sealing ring
E4752
Sleeve ...
E11707
Distance piece
E12597
For torque stay
Washer
D2331
Nut
14-1303
...
29
ClassicBike.Biz
REMARKS
2
4
2
4
4
4
4
4
4
2
2
2
2
2
^---64
-63
(5---- 62
B5
Fig. 7. CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS)
30
ClassicBike.Biz
Ref. No. Part No.
QUANTITY REMARKS
DESCRIPTION
CYLINDER BLOCK AND HEAD, T120R(LATER MODELS)
1
2
3
4
5
6
6A
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
...
...
...
...
E6309
...
...
...
...
...
Cylinder block ...
E6304
...
...
...
...
...
Cylinder base nut
S692
...
...
...
...
...
...
Push rod
E2620
...
...
...
...
...
...
Cover tube
E12575
...
...
...
...
"0" ring (bottom) ...
E7310
...
...
...
...
...
"0"
ring
(top)
E11283
...
...
...
...
...
Cylinder
head
gasket
E4547
9/(oCYLINDER HEAD c/w GUIDES
...
...
...
E12807 7/-3y
Sleeve for head bolts passing through inlet tracts
E5347
...
...
...
...
E3827 7/- 329'( Inlet valve guide ...
...
...
...
...
E38287/- 3295 Exhaust valve guide
...
...
...
Carburetor adaptor, left
E12811
...
...
...
Carburetor
adaptor,
right
E12812
...
...
...
...
...
Connector ...
E6916
Balance pipe
...
..•
E4792
...
...
...
...
...
...
Stud ...
E12813
%
...
...
...
...
...
...
Gasket
E8771 7/- / f/(p
...
...
...
...
...
Self-locking nut
14-1301
...
...
...
...
...
...
...
Cup
E9555
...
...
...
...
...
Insulating ring ...
E9554
...
..•
...
Inlet valve
E4603
...
...
...
...
...
Exhaust valve ...
E2904
...
...
...
...
...
...
Bottom cup
E6439
...
...
...
Inner valve spring (Red spot)
E4221
...
_..
...
E7400
...
...
...
...
Top collar
...
...
El 543
...
...
...
...
...
...
99-00627/-37`lrSplit cotter
...
...
...
...
...
Cylinder head bolt
E327
...
...
...
...
...
...
Plain washer
F2184
...
...
...
...
...
...
...
Bolt
E4771
...
...
...
...
...
S25-3 0-W-/7 Plain washer ...
...
...
...
...
...
...
Sealing ring
D3548
...
...
...
...
...
Inlet rocker box
E12569
...
...
...
...
Exhaust rocker box ...
El 2570
...
...
...
...
...
Joint washer ...
E12599
...
...
...
...
...
Rocker box bolt
S1875
...
...
...
...
...
...
...
Nut
14-0301
...
...
...
...
...
Plain washer ...
E3302
...
...
...
...
...
Rocker box stud
14-1401
...
...
...
...
...
S25-13f -gzq 'Plain washer ...
...
...
14-1435
...
...
...
...
...
Inspection cover
E12572
...
...
...
...
...
Joint washer ...
E12574
...
...
ROCKER
(right
exhaust,
left
inlet)
...
Ell 457
...
...
ROCKER
(left
exhaust,
right
inlet)
...
Ell 458
...
...
...
...
...
Rocker ball pin
El 0070
...
...
...
...
...
Rocker adjusting pin
E1513
...
...
...
...
...
Adjuster lock nut
E470
...
...
...
...
In.
Thrust washer, .
El 575
...
...
...
...
...
...
Spring washer
El 574
31
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..•
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
8
4
2
2
2
1
1
Reference only
2
2
1
1
2
1
4
2
4
4
4
2
2
4
4
4
4
8
4
4
1
2
1
1
2
4
6
o
6
4
2
4
4
2
2
4
4
4
6
4
64
63
62
57 29
41
65
4
6A
24
B5
1
Fig. 7. CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS)
32
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS) (continued)
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
Rocker spindle ...
E1512
Dowel,
rocker box
E12361
Thrust
washer,
I in.
E1330
...
Access plug
E12079
...
Washer ...
E12080
E1288870-9762 Bolt, cylinder head
E1288970/0/ Bolt, rocker box
Washer
D2332
Spacer ...
E12598
Sealing ring
E4752
Sleeve ...
E11707
Distance piece
E12597
...
For torque stay
Washer
D2331
Nut
14-1303
Screw
14-0103
} Tappet inspection cover
washer
D2329
33
ClassicBike.Biz
2
4
2
4
4
4
4
2
2
...
8
0
11
Fig. 8. AMAL CARBURETOR, TR6R, TR6C
34
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
AMAL CARBURETOR TR6R, TR6C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
D2183
Rvfl
928/098
622/086
928/060
622/131
622/067
622/124
928/062
622/129
928/103
622/077
622/076
622/082
622/122
622/128
376/100
622/069
622/071
622/055
622/073
622/068
376/093
622/078
376/092
622/147
622/151
Fl 3507
E9711
wnly
CARBURETOR (R930/60) less "0" ring
...
Mixing chamber (930/005)
Mixing chamber top (99-1032) ...
Screw (99-0521) ...
Throttle valve (3+ cutaway) (99-0527)
Throttle return spring (99-1033)
...
Needle clip (99-0510)
Needle (99-1036) ...
...
Air slide (99-0528)
Spring (99-1038) ...
Air valve guide sleeve (99-1037)
Throttle stop screw (99-0516) ...
Air adjusting screw (99-0515) ...
...
"0" ring (99-0520)
.
106)
(99-1035)
Needle jet (0
...
Jet holder (99-1034)
Main jet (230) (99-0450)
...
Float (99-0512)
Float spindle (99-0513) ...
Float chamber (99-0506)
Joint washer (99-0514) ...
Needle (99-0511) ...
Filter (99-0438) ...
Banjo bolt (99-0517)
Fibre washer (99-0437) ...
...
Drain plug (99-1152)
Washer (99-1153)
...
Petrol pipe
"0" ring
35
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
2
1
1
1
1
1
1
1
REMARKS
O
11
I
1i
6
8
Fig. 9. AMAL CARBURETOR, T12OR
36
ClassicBike.Biz
Ref No. Part No.
QUANTITY REMARKS
DESCRIPTION
AMAL CARBURETOR T120R
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
D3492
D3491
Reference only
928/098
622/086
928/060
622/131
622/067
622/124
928/062
622/129
928/103
622/077
622/076
622/082
622/122
622/128
376/100
622/069
622/071
622/055
622/073
622/068
376/093
622/078
376/092
622/147
622/151
F13508
E9711
CARBURETOR—L.H. (L930/67)
Less""0" ring
CARBURETOR—R.H. (R930/66)
...
Mixing chamber (L930/005 and R930/005)
...
...
Mixing chamber top (99-1032) ...
...
...
...
...
...
Screw (99-0521)
...
...
Throttle valve (3 cutaway) (99-0527)
...
...
Throttle return spring (99-1033)
...
...
...
...
Needle clip (99-0510)
...
...
...
...
Needle (99-1036) ...
...
...
...
...
Air slide (99-0528)
...
...
...
...
...
Spring (99-1038)
...
...
Air valve guide sleeve (99-1037)
...
...
Throttle stop screw (99-0516) ...
...
...
Air adjusting screw (99-0515) ...
...
...
...
...
"0" ring (99-0520)
...
...
...
Needle jet (0 . 106) (99-1035)
...
...
...
...
Jet holder (99-1034)
...
...
...
Main jet (190) (99-0446) ...
...
...
...
...
Float (99-0512) ...
...
...
...
Float spindle (99-0513) ...
...
...
...
Float chamber (99-0506) ...
...
...
...
Joint washer (99-0514) ...
...
...
...
...
Needle (99-0511) ...
...
...
...
...
Filter (99-0438) ...
...
...
...
...
Banjo bolt (99-0517)
...
...
...
Fibre washer (99-0437) ...
...
...
...
...
Drain plug (99-1152)
...
...
...
...
Washer (99-1153)
...
...
...
...
...
...
Petrol pipe
"0" ring
...
...
...
...
...
...
37
ClassicBike.Biz
...
...
1
1
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
..
...
...
...
...
1
1
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Each
carburetor
e7
Fig. 10. TIMING COVER AND CONTACT BREAKER
38
ClassicBike.Biz
QUANTITY REMARKS
DESCRIPTION
Ref. No. Part No.
TIMING COVER AND CONTACT BREAKER
1
2
3
4
4
...
...
Timing cover ...
E9246
...
...
...
Patent plate
E4016
...
D208-55p0- 4'25îHammer-drive screw ...
Oil
seal
...
E4568
Oil seal (0 . 020 in. undersize) ...
E6387
E4569
T989
14-6609
7
14-6608
8
14-0208
9
S25-437O-.'f3
10
E4707
11
E7680
12
E6559
13
E8737
14
E11462
15
GS2996o0-4' Z5
16
E7354
17
54419340
18
54415642
19
54419097
20
54419827
21
54419220
22
D21336p0 ;37/?
23
D2045
24
Not illus. D2138
5
6
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Circlip ...
...
...
...
...
...
Hollow dowel ...
...
...
...
...
...
...
Screw ...
...
...
...
...
...
...
Screw ...
...
...
...
...
...
...
...
Bolt
...
...
...
...
...
Plain washer ...
...
...
...
...
...
Rubber grommet
...
...
...
...
...
...
Pillar bolt
...
...
...
...
...
...
Plain washer
...
...
...
...
...
...
Cover ...
...
...
...
...
...
Joint washer ...
...
...
...
...
...
Serrated washer
...
...
...
...
...
Screw ( 4in. U.H.)
...
...
AUTO ADVANCE UNIT (99-0771)
...
...
...
...
Spring set (99-0757)
CONTACT BREAKER PLATE ASSEMBLY (99-0768)
...
...
...
Contact set (99-0772) ...
...
...
...
Pin, adjustment (99-0769)
...
...
...
...
Oil pressure switch ...
...
...
...
...
Cover pressure switch
...
...
...
Timing label for C.B. cover ...
39
ClassicBike.Biz
...
...
...
...
...
...
...
.. .
...
.. .
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
3
2
For reground
crankshaft
...
3
5
2
2
2
2
2
2
12
b8
Fig. 9 GEARBOX INNER COVER AND SELECTORS
40
ClassicBike.Biz
Ref. No. Part No.
QUANTITY
DESCRIPTION
GEARBOX INNER COVER AND SELECTORS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
T4293
T1614
T412
T45
T1607
T989
S2149
S1907
E3446
14-6608
14-7023
T4055
T397
T1896
T4308
T4307
T3989
T4288
T4289
T4290
T4291
F4771
GEARBOX INNER COVER
...
Layshaft bearing ...
Gearchange spindle bush...
...
Kickstart stop
...
...
...
Thrust washer ...
...
...
Hollow dowel ...
...
...
...
Stud
...
...
...
...
...
Bolt
...
...
...
Washer ...
...
...
...
Screw ...
...
...
...
Screw ...
...
...
...
Cam plate
...
Operating quadrant ...
...
...
Quadrant spindle
S lit p in (6 in. x 18 in.)
...
4
p
...
Mainshaft selector fork
...
Layshaft selector fork
...
...
Selector fork rod
...
...
...
Leaf spring
...
...
Leaf spring support
...
Leaf spring top plate ...
...
...
...
Tab washer
...
...
...
Screw
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
41
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
2
4
2
1
1
1
1
1
1
1
Ref. only
1
1
I
1
1
1
1
2
REMARKS
DESCRIPTION
Ref. No. Part No.
QUANTITY REMARKS
TIMING COVER AND CONTACT BREAKER
1
2
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Not
Timing cover
E9246
Patent plate
E4016
D208-55p0- 4'25îHammer-drive
Oil seal ...
E4568
Oil seal (0 . 020
E6387
E4569
T989
14-6609
14-6608
14-0208
S25-437O-.'f3
E4707
E7680
E6559
E8737
E11462
GS2996o0-4' Z5
E7354
54419340
54415642
54419097
54419827
54419220
D21336p0 ;37/?
D2045
illus. D2138
...
...
...
...
screw ...
...
...
...
...
...
...
...
..
in. undersize) ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Circlip ...
...
...
...
...
...
Hollow dowel ...
...
...
...
...
...
...
Screw ...
...
...
...
...
...
...
Screw ...
...
...
...
...
...
...
...
Bolt
...
...
...
...
...
Plain washer ...
...
...
...
...
...
Rubber grommet
...
...
...
...
...
...
Pillar bolt
...
...
...
...
...
...
Plain washer
...
...
...
...
...
...
Cover ...
...
...
...
...
...
Joint washer ...
...
...
...
...
...
Serrated washer
...
...
...
...
...
Screw ( 4in. U.H.)
...
...
AUTO ADVANCE UNIT (99-0771)
...
...
...
...
Spring set (99-0757)
CONTACT BREAKER PLATE ASSEMBLY (99-0768)
...
...
...
Contact set (99-0772) ...
...
...
...
Pin, adjustment (99-0769)
...
...
...
...
Oil pressure switch ...
...
...
...
...
Cover pressure switch
...
...
...
Timing label for C.B. cover ...
39
ClassicBike.Biz
...
...
...
...
...
...
...
.. .
...
.. .
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
3
2
For reground
crankshaft
...
3
5
2
2
2
2
2
2
Ref. No.
Part
No.
DESCRIPTION
QUANTITY REMARKS
GEARBOX SHAFTS AND GEARS
T1 370
MAINSHAFT c/w LOW GEAR (16T)
...
...
Clutch rod bush ...
MAINSHAFT HIGH GEAR (25T) ...
...
...
High gear bush ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
T3889
T4335
Mainshaft third gear (23T) ...
Mainshaft second gear (20T) ...
...
...
...
...
...
...
...
...
...
...
1
1
7
8
T3862
T928
LAYSHAFT LOW GEAR (30T)
...
Low gear bush ...
...
...
...
...
...
...
...
...
... 1
... 1
9
10
11
T3861
T3890
T4345
Layshaft second gear (26T) ...
...
Layshaft third gear (22T)
Layshaft c/w high gear (19T)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
12
12
T1 952
T1 953
Gearbox sprocket (15 teeth) ...
...
...
...
...
...
...
...
...
... 1
... 1
12
12
T1916/O/7
T1917/D/ F'
...
...
...
...
12
12
13
14
T1918/Q/I
TI919^010
T2116
T440
Gearbox sprocket (19 teeth) ..
...
...
...
Tab washer
...
Gearbox sprocket nut
15
D355657—f
1
2
3
T4158
T3988
T4332
4
5
6
23
24
25
26
27
...
...
...
...
...
...
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 1
... 1
D3552
Mainshaft bearing
...
...
...
...
...
...
...
T4113
T1962
Circlip ...
Plain washer
...
...
...
...
...
...
...
...
...
...
...
_..
...
...
T1963
Pinion sleeve
...
...
...
...
...
...
...
T1250
T730
T731
T2240
Pinion spring ...
Kickstarter pinion
Kickstarter ratchet
...
Tab washer
...
...
Nut
Clutch operating rod
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... 1
... 1
1
... 1
... 1
... 1
... 1
... 1
... 1
E489
22
...
...
...
...
...
1946
19
...
...
...
...
S594
11736
'High gear bearing
Circlip ...
Oil seal ...
1
...
WIDE RATIO GEARS
3
6
9
11
T3657
14161
T4160
T4159
MAINSHAFT HIGH GEAR (28T)
...
...
...
...
... 1
Layshaft c/w high gear (18T)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
CLOSE RATIO GEARS
1
3
T4173
T4172
MAINSHAFT c/w LOW GEAR (18T)
MAINSHAFT HIGH GEAR (24T) ...
...
...
...
...
...
...
... 1
... 1
5
6
T4169
T4167
Mainshaft third gear (23T) ...
...
...
...
...
...
...
...
...
...
...
7
T4163
LAYSHAFT LOW GEAR (28T)
...
...
...
...
... 1
9
10
11
T4166
T4168
T4162
...
...
...
...
...
...
...
...
...
... 1
... 1
... 1
...
Layshaft third gear (23T)
Layshaft c/w high gear (22T) ...
See pages 4, 5 and
6 for standard
sizes
... 1
... 1
... 1
... 1
...
17
20
21
1
...
...
16
18
y
1
1
1
...
...
...
43
ClassicBike.Biz
1
1
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
GEARBOX SHAFTS AND GEARS (5 SPEED)
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
Not
Illus.
Oil seal, cover plate
D3500
...
Cover plate
E3789
T436037— w89 Gearbox cam plate
Selector fork— mainshaft 4th gear
T4364
Selector fork— layshaft 3rd gear
T4366
...
Selector fork— layshaft 1st gear
T4368*
T453657-q78/ MAINSHAFT HIGH GEAR ASSEMBLY (C/W HIGH GEAR
BEARING) ...
Needle roller bearing
D3511
Oil seal, high gear
D3500
MAINSHAFT
14432
Bush
T3988
Mainshaft 4th gear
T4376
MAINSHAFT 3rd GEAR
T4377
Bush
T437957— q57C
Mainshaft 1st and 2nd gear
T4380
...
...
T454857 —q 0° LAYSHAFT
— q 00
Layshaft
high
gear...
/
T4550S7
00
Layshaft 4th gear ...
T438457— 4 9
...
Layshaft
3rd gear
T4387%
LAYSHAFT
2nd
GEAR
T4388
...
Bush
...
T439057 — qr77
LAYSHAFT
1st
GEAR
T4391 -(
T439357-4'57e Bush
Circlip ...
D3494
Driving dog
T4381*
...
Quadrant
T4363
...
Leaf
spring
T4402
Plunger quadrant
T4374/408
Plunger ...
T4403
Gearbox sprocket--19T
T4397
Locknut
T4396
Lock washer ...
T4395
...
Oil seal, gearbox
D3512
U36
oppArE 9% 38OZ (asT
45
ClassicBike.Biz
1
1
1
1
2
1
1
1
1
1
Reference only
1
1
Reference only
Reference only
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
ue aseo 45 ee)
43
40
41
3 g -_-
\\\3
m
34
J
30
8
46
31
47
191.1
36
37
Fig 14. GEARBOX OUTER COVER
46
ClassicBike.Biz
BO
Ref. No. Part No.
QUANTITY
DESCRIPTION
REMARKS
GEARBOX OUTER COVER
T3760
GEARBOX OUTER COVER
T23
Kickstarter spindle bush ...
T57
Gearchange spindle bush
T47
Kickstarter spring anchor pin
S547
Guide plate stud ...
...
11956
Oil seal
...
...
...
T1955
Oil seal housing ...
...
T408/95?- 7OZ /Gearchange quadrant ...
...
Rubber "0" ring
D3530
...
...
T404
Quadrant return spring
...
Gearchange quadrant plunger
T406
Plun er
g spring ...
...
...
T405
Guide plate
T407
...
...
...
Serrated washer
E1612
...
...
Nut
...
...
...
14-0301
...
Kickstarter quadrant ...
T4117
...
Kickstarter return spring
T31
...
T24A57 1{73 Kickstarter axle
...
...
T362957- gS'87CLUTCH LEVER ASSEMBLY
Clutch lever
...
...
T4441
Lever shaft
T1710
...
...
Ball, fin. diam. ...
...
D2368
Thrust
plate
...
...
T3761
Return
spring
...
...
T1712
...
...
GS12757 -3(073 Plain washer
— GO- 2.70/
Split pin ( 6 in. x fin.) ...
Countersunk screw ...
...
S1879
Rubber
cover
...
...
...
T1646
Abutment for clutch cable ...
T3762
y
...
...
S25-3 O-/2 7 Plain washer ...
Nut
...
...
...
...
14-0302
...
...
...
Screw
...
S1878
...
...
...
Screw
...
14-6609
Screw ...
...
...
...
14-6608
...
...
T375757- 70/0 Gearchange pedal
Bolt
...
...
...
...
14-0201
Pedal rubber ...
...
...
T2450
T3632$7-70/8 FOLDING KICKSTARTER ...
Kickstarter lever ...
...
T2173 37-2/73
...
T1272 5']- 70/7 Kickstarter pedal ...
Pedal locating spring
...
T1167
Steel ball, fin. diam.
...
S70-3 t 0 23
Pedal bolt
...
...
S541
Pedal rubber ...
T2330
...
...
Cotter pin c/w nut and washer
T4356
...
...
...
Domed nut
S544
...
Filler plug
...
...
T2166
...
...
...
"O" ring
E8782
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
4
-
iz- 'z9 7L1 %'c'$ /5 5
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
C1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
••.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..,
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
B5r/7U7-SO
47
ClassicBike.Biz
/
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.v
1
1
1
1
4
1
1
1
1
2
2
2
I
4
4
1
1
1
I
1
1
3
1
1
1
Reference only
2
1
1
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
I
1
1
S?E6I2
48
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
CLUTCH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Clutch securing nut
S586
...
...
Hub
T3929
Thrust
washer
...
T3931
Roller ...
T394
Sprocket and housing (58 teeth Duplex)
T1570
Centre ...
T4438
Inner plate
T4436
...
Bolt
52157
Shock
absorber
spider
T2538
Drive
rubber
(large)
...
T1722
Rebound
rubber
(small)
T1723
Outer plate
14437
T423A57-417SYScrewed pin
763 Driving plate (bonded)
T13625
Driven plate ...
T1363
Pressure plate
12156
Adjuster
pin
T2159
...
Nut
14-0403
Spring
cup
T1931
Spring ...
T1830
Pressure nut
12526
...
Key
S66-1
Washer
...
T2279
49
ClassicBike.Biz
1
1
••. 1
... 20
1
1
1
3
1
3
3
1
••• 3
••• 6
••• 6
••• 1
••• 1
1
3
3
3
1
1
REMARKS
N
Cl)
O
M
-CM'
M
N
N
m
N
N
N
C.)
N
N
N
0
N Z
Q
I1
I
U
T
T
U)
z
Q
W
H
Q
c)
Q)
T
U
z
LQ
co
2
U
^
CG
LL
(D
r
N
U)
T
N
T
50
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
CHAINCASE AND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
QUANTITY REMAR KS
CHAINS
1
1
1 Not 5 speed
1 r models
6
(also listed with
1
crankcase group)
Rear chain, a in. xi in. x 106 links
D1915
Joint
washer
E11419
Cover
plate
E7037
...
Oil
seal
E7565
Countersunk screw
E3821
E597670-5087 Chain tensioner abutment
Chain tensioner blade...
E6061
Tie
rod ...
E4152
Trunnion
E5977
Adjuster sleeve nut ...
E9703
Primary chain, f in. Duplex x 84 links
D477
Stator
stud
51866
Stator
stud
51867
Stator, RM21 (99-1006)
47205
Sleeve nut
E9360
Rubber grommet
E4144
Plastic sleeve
E5449
-q2q7
Plain
washer
525-3
nut
Self-locking
1 0702
Joint
washer
E11463
E9245 7/-q07Z Chaincase
Rotor cover
T2440
Joint
washer
E11457
...
Screw
F4129
Copper
washer
E2 441
Filler plug
T2166
"0" ring
E8782
...
Screw
14-6608
...
Screw
14-6620
...
nut
Domed
55 44
Copper
washer
...
F1880
Timing
pointer
...
T2 44 3
...
Level plug
1 101
51
ClassicBike.Biz
• ••
• ••
• ••
•••
•••
•••
•••
••••
•••
•••
•••
•••
•••
•••
••.
••.
•••
.••
•••
•••
•••
•••
•••
•••
•••
1
1
2
1
1
1
1
1
3
3
1
1
1
1
3
1
1
1
6
2
2
2
1
• ••
1
•.•
m
LL
52
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
FRAME
1
F14283
Frame ...
...
...
...
...
2
E127447/Z7' /Oil filler cap
...
...
...
...
3
D3616
"O" ring
...
...
...
...
4
F1 3142
Dipstick ...
...
...
...
...
F1 3642
5
Oil filter
...
...
...
...
- 8 cSump plate
5A
F1 31 8 5
...
...
/,
F12829
6
Gasket ...
...
...
...
...
7
D2330
Washer
...
8
S2109
Stud
Sump plate to frame
...
9
14-1302/q-/Z02 Nut
...
10
14-0113
...
Drain plug
...
...
...
11
E12505
Joint washer ...
...
...
...
12
E69307/ -7/70 Oil junction block
...
...
...
X444587/ -375 Joint washer ...
...
...
13
...
14
S1908
Nut
Junction block to crankcase
Washer f
15
E3446
...
...
...
Rocker oil pipe
E12428
16
...
...
...
...
Washer ...
17
E1335
...
...
...
...
Nut
...
E1435
18
...
...
...
Rocker feed pipe
E12337
19
...
...
Clip—rocker feed pipe
D3524
20
...
...
...
Oil return pipe
E12345
21
...
...
Clip—feed
and
return
pipes
22
E6848
...
...
...
Oil feed pipe ...
E12347
23
...
...
...
...
Oil
vent
pipe
E12349
24
...
Crankcase
breather
pipe—front
E11149
25
...
Crankcase
breather
pipe—rear
F11614
26
...
...
...
...
"T" piece
F11610
27
...
...
Clip—breather
pipe—front
D2253
28
...
Clip—breather pipe—rear ...
D2252
29
...
Clip—breather
pipe
to
fender
F11615
30
...
...
...
...
...
Screw
H3894
31
...
...
...
...
...
Nut
F4717
32
...
...
...
...
Centre
stand
F1262783- '/9y/
33
...
...
...
...
...
Spring
F1 3793
34
...
...
...
...
bolt
Pivot
S2077
35
...
...
...
...
...
Nut
14-1304
36
...
...
...
...
Prop
stand
F11560
37
...
...
...
...
...
Bolt
F7021
38
...
...
...
...
...
Nut
14-1303
39
...
...
...
...
Spring ...
F8382
40
...
-3509' Transfer "Made in England" ...
Not illus. D3361
...
Not illus. D2452 P-1-A. Transfer—Safety Standards ...
Not illus. 14-0114
Bolt1Prop stand stop
Nut f
...
...
Not illus. 14-0402
63 3
53
ClassicBike.Biz
2
4
4
4
4
4
2
4
.
1
2
4
4
4
2
2
.
1
11111111116
o
z
z
0
fA
z
3
0
z
0
z
5
z
OC
LL
54
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
SWINGING ARM AND SUSPENSION UNITS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
23
24
25
26
27
28
29
30
31
32
33
34
SWINGING ARM
F12513
...
Grease nipple
D1841
WE170 g3- 7221 Washer, grease nipple
Bush, pivot arm ...
F12521
Sleeve,
swinging arm pivot
F12691
Distance
piece R.H.
F12690
Distance
piece
L.H.
F12689
...
Dirt
excluder
F12692
Stud,
swinging
arm
pivot
S2087
Washer,
swinging
arm
pivot
F12266
Nut,
swinging
arm
pivot
14-1307
...
Brake torque stay
F12656
...
Nut,
torque
stay
to
brake
plate
14-1304
Washer,
torque
stay
to
brake
plate
...
D2350
Bolt, torque stay to swinging arm ...
14-0133
Washer,
torque stay to swinging arm
W2330
Nut,
torque
stay to swinging arm ...
14-1304
SUSPENSION
UNIT (D2294)
64052341
..•
...
Damper
unit
64052090
...
Bonded
bush
(99-0122)
64533645
...
Spring retainer (99-0107)
9054/171
Spring,
110
lbs.
chrome
(99-1139)
64544754
...
Bolt, damper—top
14-0235
Stud,
damper—top
L.H.
51997
D233160-q46Washer, damper—top
...
Nut, damper—top
14-1303
...
Bolt,
damper,
lower
14-0234
Washer
damper
lower
D2321
...
Nut damper lower
14-1303
•••
•• •
•
•
•
Chainguard
F12641
.••
fixing—front
Bolt,
chainguard
14-0206
.••
fixing—front
Washer,
chainguard
D2347
Stop
lamp
switch-118SA
(99-1028)
34815
D35502 /- Xi0 Screw ...
Washer ...
H1388
55
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
•••
••.
• ••
•••
1
2
2
4
2
1
1
4
1
2
1
1
1
1
1
1
1
2
Reference only
4
4
2
(1 off TR6C)
2
(TR6C)
1
(3 off TR6C)
2
(3 off TR6C)
2
2
2
2
1
1
1
1
2
2
CD
N
O
M
e
D
'
U,
IH
W
I.-
0
0
U.
0
z
Q
z
U.
I_
z
D
0
,_
L-'
M
0
W
O.
_O
U.
56
ClassicBike.Biz
DESCRIPTION
Ref. No. Part No.
MOTOR UNIT FITTINGS AND
o
QUANTITY
FOOTRESTS
bO
...
...
...
...
...
...
F1 2855 83 7 ' Footrest—L.H....
1
...
...
...
...
...
...
Footrest—R.H....
F1285483-7
2
...
...
...
...
...
...
...
...
Bolt
14-0259
3
...
...
...
...
...
...
...
...
Washer
D2333
4
...
...
...
...
...
...
Footrest
rubber
F9279
5
...
...
...
...
...
PILLION
FOOTREST
...
F12841
6
...
...
...
...
...
...
...
Pedal
F9053
7
...
...
...
...
...
...
Hanger
bolt
F1 3207
8
Bolt
...
...
...
...
14-0217
9
...
...
...
...
Footrest
swivel
Washer
F9089
10
...
...
...
...
14_1302/q-/202. Nut
11
J
Nut
14-1303
...
...
12
...
Footrest to frame "'
•.•
•••
•••
•••
Washer
F2184
13
...
...
...
...
...
...
Footrest
rubber
F9054
14
...
...
...
...
...
...
Rear
brake
pedal
F12666
15
...
Screw
...
14-0103
16
...
...
Stop light adjustment
•••
...
Nut
...
...
14-0301
17
...
...
...
...
...
...
...
Pivot
pin
S2045
18
...
...
...
...
...
...
...
...
Nut
14-1303
19
...
...
...
...
...
...
...
o-412g6Washer
...
E8084
20
...
...
...
...
...
Rear
brake
operating
rod
F1 2860
21
...
...
...
...
...
in.
x
e
in.)
Split pin (•!
22
—
i 6
...
...
...
...
...
...
Distance
piece
F1 4277
23
...
...
...
...
...
Adjuster nut — brake rod
F7387
24
...
...
...
...
...
Rear
motor
plate
R.H.
F13024
25
...
...
...
...
...
Rear
motor
plate—L.H.
F1 3023
26
...
...
...
Bolt
14-0115
27
Bolt
•••
•••
•••
14-0116
28
Rear motor plates to frame
•••
•••
•••
14-13 02/y-/202- Nut
29
...
...
...
Washer
D2330
30
Bolt
...
...
...
14-0220
31
Bolt
14-0221
32
Motor to motor plates ...
...
...
Nut
...
14-1302
33
.
.
.
...
...
...
Washer
D2321
34
...
Distance
piece—L.H.
F12846
35
...
Distance piece—R.H.
F12847
36
Motor
to
frame
centre
bottom
...
Stud
S2112
37
Nut
...
14-1304
38
...
Washer
D2332
39
J
...
...
Distance
piece—L.H.
F1
2848
40
...
...
Distance piece—R.H . j
F12849
41
...
...
Motor fixing front
Bolt
14-0254
42
Nut
...
...
14-1304
43
I
...
...
Washer
44
D2332
J
...
...
...
...
Steady bracket motor to frame
F1 3537
45
...
.. •
..
...
Bolt
...
14-0126
46
...
...
...
...
...
Bracket
to
frame
Nut
14-1303
47
...
...
...
...
...
Washer
D2331
48
...
...
...
Extended
nut
(used
with
14-0220)
...
Not illus 51933
Nut
Not illus 14-1305
Footrest bolt
...
...
... .
...
Collar
F13602
Not illus
...
f
57
ClassicBike.Biz
REMARKS
...
...
...
...
...
...
...
...
...
...
...
1
1
2
2
2
2
1
1
I
1
1
...
•••
...
...
1
1
1
1
...
...
...
...
...
...
...
...
...
...
...
...
•••
•••
...
...
...
1
1
1
1
1
1
Reference only
1
2
1
1
5
61
12
2
2
4
8
.
... 1
... 1
... 1
... 2
... 2
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
.. I
... I (TR6c only)
. 2
..
0
N
58
ClassicBike.Biz
DESCRIPTION
Ref. No. Part No.
QUANTITY
REMARKS
EXHAUST PIPES AND MUFFLERS, TR6R, T12OR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
E12636
Exhaust pipe—L.H. ...
E12637
Exhaust pipe—R.H. ...
E12465
Finned clip
1
F897W2^n7e Washer
Exhaust pipes to cylinder head
F89778Z-g777 Bolt
E6857
Exhaust pipe stay
E6179
Screw
E7471
Nut
E7512
Clip
E3768
washer
Exhaust pipes to coupling pipe "'
14-0217
Bolt
...
14-1202
Nut
J
E9888
Coupling pipe
E2271
Clip
E3768
"D" washer
...
14-0219
Bolt
Exhaust pipes to mufflers ...
S25-3 4'2q7 Washer
...
14-1302
Nut
Muffler ...
E12382
...
...
...
...
E12282
Hanger—muffler and pillion footrest
Bolt }
1 0101
Nut Muffler to hanger
14-1301
2 Later models
2
2
... 2
... 2
... 2
... 2
.. . 4
... 2
... 2
... 1
... 2
... 4
... 2
... 2
... 2
... 2
... 2
"' 4
... 4
*EARLIER MODELS USE THE FOLLOWING:—
1
2
3
4
5
E12753
E12756
E10216
E8860
E6744
Exhaust pipe—L.H. ...
Exhaust pipe—R.H. ...
Finned Clip
Spherical washer
Bolt...
1
1
2
2
2
59
ClassicBike.Biz
U,
Ix
W
J
LL
LL
D
N
LL
60
ClassicBike.Biz
Ref. No.
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
Part. No
DESCRIPTION
EX HAUST PIPES, MUFFLERS AND FOLDING
00
E123347/'&
Exhaust pipe—lower
E126327/ /90/ Exhaust pipe—upper
E12465
Finned clip
F897782- 777 Bolt
Exhaust pipe to cylinder head ...
F89788ZWasher
El 325070 -6978 Exhaust pipe stay
14-0113
Bolt
...
S26-30-4i26 v Spring washer
E7299
Clip—upper
E5874
Clip—lower
14-0116
Bolt
Bolt
Exhaust pipes to connector
14-0219
"D" washer
E3768
Spring washer
S26-3 -q2
Nut
14-1202
Connector
E9673
Clip
E2271
Bolt
14-0219
"D" washer
Connector to mufflers
E3768
q260 Spring washer
S26Nut
14-1202
Muffler—upper ...
E12019
Muffler—lower ...
E12020
Muffler—hanger
E12511
Bolt
S1822
Mufflers to hanger
Spring washer
S26-3 -'z
•••
Bolt
14-0115
Spring washer Hanger to frame ...
S26-3
Spacer nut
S1933
Leg guard
E9680
Screw
51953
Washer
E9857
Leg guard attachment front
Clip
E9688
Bracket
E9696
Screw
51954
Washer Leg guard attachment rear
E9857
Clip
E9688
E1285183 -2?51 Crankcase undershield...
Hooked stud
S2096
...
Nut
14-1301
Washer ...
D2320
me
61
ClassicBike.Biz
QUANTITY
REMARKS
FOOTRESTS, TR6C
1
2
2
2
1
3
3
1
1
1
1
2
1
1
1
2
2
4
2
2
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
••• 1
•••
••• 2
2
1
1
1
•••
••• 1
••• 1
••• 2
2
2
Later models
v;
ac
W
J
LL
LL
D
E
NN
00
LL
62
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
EXHAUST PIPES, MUFFLERS AND FOLDING FOOTRESTS, TR6C
42
42
43
43
44
45
46
47
48
49
50
F13139
FOLDING FOOTREST—R.H.
F12856
FOLDING FOOTREST—L.H.
F13140
Footrest hanger—R.H. ...
F12858
Footrest hanger—L.H.
Fl 3092
Footrest pedal
F13095
Spring
...
14-0216
Bolt
14-1302 /q^/ZOL Nut
F9051
Footrest rubber
Bolt
}
S1969
Footrest to frame
F8243
•••
•••
•••
•••
•••
•••
•••
•••
•••
1
1
1
1
1
1
1
1
1
2
EARLIER MODELS USE THE FOLLOWING:—
1
2
3
4
5
6
E11900
E11901
E10216
E6744
E8860
E6978
1
1
2
2
2
1
Exhaust pipe—lower
Exhaust pipe—upper
...
Finned clip
Bolt
...
...
Spherical washer
Exhaust pipe stay
63
ClassicBike.Biz
Fig. 22. TELESCOPIC FRONT FORK
64
ClassicBike.Biz
Ref. No.
Part
No.
DESCRIPTION
QUANTITY
REMARKS
TELESCOPIC FRONT FORK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
42
42
42
43
44
45
46
H4080
FORK ASSEMBLY
H4035
Top Yoke ...
14-0234
Pinch Bolt ...
14-1303
Nut...
Washer ...
E8084
F6738
Lock c/w 2 keys ...
D623 F z- 6738 Key (state serial No.)
Grub screw
5578
H2266
Sealing washer ...
H2270
Brake cable retainer
F8245
Starlock washer ...
Retaining bracket
H3682
Abutment ring ...
F12007
H4031
Taper roller bearing
H4028
Dust cover
Bottom yoke and stem
H4315
14-0238
Pinch bolt ...
E8084
—qz#6 Washer
14-1303
Nut
Stanchion
H4007
End plug ...
H4076
Main spring
•••
H4087
OUTER MEMBER—R.H.
H4343
OUTER MEMBER—L.H.
H4342
Cap wheel spindle
H3947
Stud
S2102
Nut
14-0302
Washer ...
D2428
Oil seal outer member
H4001
Drain plug ...
H3894
Washer ...
H3893
"0" ring—damper valve
H4003
Recoil spring
H4009
Cap screw-damper tube
14-1019
Cap screw seal
H4004
Damper tube and valve assembly
H4325
Scraper sleeve outer member
H4002
Top cap nut
H4258
. ••
Washer ...
H4166
Steering stem nut (without steering damper)
H4317
H431897—
Z? Steering stem nut (with steering damper) ••
Headlamp bracket—L.H.
H4058
Headlamp bracket—R.H.
H4060
Headlamp bracket—L.H.
H4088
Headlamp bracket—R.H.
H4090
Nut
51809
Washer
D2338
Headlamp bracket top fixing ...
Bush
F12209
Spacer
F12211
65
ClassicBike.Biz
1
1
2
2
2
2
4
2
2
2
2
1
2
8
8
8
2
2
2
2
2
2
2
2
2
2
2
1
TR6R, T12OR
TR6C
2
2
4
2
Fig. 22. TELESCOPIC FRONT FORK
66
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
TELESCOPIC FRONT FORK
47
48
49
50
51
52
S2062
D2333
D2630
F9046
H4012
F12216 F3 2Z10
Sleeve nut
Washer
Headlamp bracket bottom fixing
Grommet
Washer
Nut—damper valve ...
Clamp washer
•••
67
ClassicBike.Biz
2
2
2
2
2
4
REMARKS
3
10
6
8
L5
17-
Fig. 23. HANDLEBAR MOUNTINGS AND STEERING DAMPER
68
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
HANDLEBAR MOUNTINGS AND STEERING DAMPER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
H2291
F1335
5589
H1527
H1529
H1581
H1580
H2221
14-1303
H3875
D2438
H435
H1797
H95
D2329
H4102
—
Handlebar eyebolt
Washer ...
Bolt
...
...
Metalastic bush
Hemispherical washer ...
Distance piece ...
Rubber washer ...
Cup
Nut
...
Steering damper rod c/w knob
Spring washer ...
Friction disc
...
Anchor plate •••
Spring plate
...
Washer ...
Bottom nut
Split pin (K in. x 1 in.)
69
ClassicBike.Biz
•••
•••
.••
•••
•••
•••
2
2
2
2
4
2
2
2
2
1
1
1
1 Available
1
1
1
Reference only
M
^
NNN
/\
N
TJ
Co
U.
70
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
FRONT WHEEL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
W3845
W3844
W3818
W3658
W3820
W3819
W3821
W2294
W3969
W3970
W653
D2632
W3797
W3759
W1481
W1237
T280
W3932
W3796
W2058
D3669
14-1303
D2340
W3655
W3987
W3986
D2639
W3762
W3761
W3713
W3714
W3715
W3716
W3717
14-1635
...
FRONT WHEEL COMPLETE
RIM, SPOKES AND HUB ASSEMBLY
...
Wheel rim (WM2-19)
Brake drum and hub
Spoke (R.H.—inner)
Spoke (R.H.—outer)
Spoke (L.H.)
Nipple...
...
Balance weight (short)
Balance weight (long)
...
Bearing
...
Circlip—R.H.
Grease retainer—R.H.
Lock ring—R.H. ...
Grease cap inner—L.H. ...
Grease cap outer—L.H. ...
Circlip—L.H.
Distance piece
...
Wheel spindle
Nut wheel spindle
Grommet brake drum
Nut
Anchor plate to fork leg
Washer
Brake anchor plate
Brake lever front ...
Brake lever rear ...
"0" ring brake cam
Tappet brake cam
"0" ring brake tappet
...
Brake shoe complete
...
...
Return spring
Cage brake shoe adjuster
Micram adjuster ...
...
...
Abutment pressing
Stud-anchor plate torque reaction
71
ClassicBike.Biz
•••
•••
•••
••.
•••
•••
•••
•••
•••
•••
•••
•••
1
1
1
1
10
10
20
40
as required
as required
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
1
N
LL
72
ClassicBike.Biz
DESCRIPTION
Ref. No. Part No.
QUANTITY
REAR WHEEL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
W3968
W3782
W3784
W3724
W3725
W3726
W2294
W3773
W3468
W3749
W653
W3752
W3753
W1654
W3747
14-0207
D2320
14-1301
W3856
W3872
W4034
14-1303
D2331
W3870
14-0305
D2431
W3925
W3926
W2328
W4049
F12656
14-0133
W2330
14-1304
W3965
W3750
D3213
W3746
14-1307
F12266
W3751
Fl 3082
W3742
14-0107
14-0301
D1841
WE170
...
REAR WHEEL COMPLETE ...
RIM SPOKES AND HUB ASSEMBLY
RIM (Wm 3 x 18) ...
Spoke (inner—L.H.)
Spoke (outer—L.H.)
Spoke—R.H....
...
...
Nipple...
Hub and brake drum
Tyre security bolt...
Support ring—L.H.
...
...
Bearing
Locking ring—L.H.
...
...
Spacer
Grease retainer—R.H.
Sprocket 47 teeth
Bolt
Washer . Sprocket to hub
Nut
Brake anchor plate
Brake cam
Brake lever
Nut
...
Washer
Brake pivot
Nut
Brake pivot to torque arm
Washer
Brake shoe complete (leading) ...
Brake shoe complete (trailing) ...
...
Return spring (brake shoe)
Return spring (brake lever)
Brake torque arm
Bolt
Washer Torque arm to frame
Nut
Wheel spindle
...
Distance piece inner
Speedometer drive gearbox
...
Distance piece outer
Nut
spindle
•••
•••
•••
•••
Washerr
83-722 )
...
Speedometer drive ring
Cover plate-swinging arm fork end
Chain adjuster
Screw
Chain adjuster —
...
Nut I
Grease nipple
Fibre washer
73
ClassicBike.Biz
•••
2
2
REMARKS
--
I-
q__--34
13
19
14
10
15
20
®--11
12
21
22
^-
T
2
x--24
25^
16
B22
i
23
17
23
18 --
Fig. 26. GAS TANKS AND TWINSEAT
74
ClassicBike.Biz
Ref. No.
DESCRIPTION
Part No.
QUANTITY
REMARKS
GAS TANK AND TWINSEAT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
17
18
19
20
21
22
23
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
F1299683-42Gas tank (3 gall.)
Steady rubber
F9062
Mounting rubber
Fl 3021
Centre
fixing bolt
51823
Distance
tube ...
F13133
Mounting
rubber
F10260
Washer
...
F13320
Rubber washer ...
F13321
Mounting ring ...
F13319
...
Nut
S1999
Washer
...
D2330
Beading holder ...
F13318
...
Grommet
F13068
Styling
strip-front
F13134
Styling strip-rear
F13135
Tank
motif—L.H.
F9700
Tank
motif—RH.
F9701
Screw—front—tank
motif
F11339
Screw—rear—tank
motif
F7888
Filler cap
F13875
Joint
waser
F4048
Jack
chain
F3217
...
F3221 N L, A . Clip
...
Gas
tap
F12800
Gas
tap—reserve
F12801
Tap seal
E7351
Washer ...
F10002
Twinseat
F14288
Twinseat cover
F14291
...
Hinge
F12867
Bolt
14-0101
}Hinge to twinseat
Spring washer
D2417
•••
Rubber buffer ...
F9093
Catch
assembly
F13061
Spring—catch assembly
F12597
Screw Twinseat catch fixing
1-40604
Nut
14-1301
...
Check
wire
D2087
Screw—self tapping ...
D2381
... 1 *For color see
page 8
... 2
... 2
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 2
... 2
... 1
... 1
TR6C
... 1
TR6C
1
...
... 1
... 1
... 2
... 2
... 1
... 1
... 2
4
••• 4
... 5
... 1
... 1
•••
...
...
... Available
*F1288183-y4gg Petrol tank (44 gall.) ...
75
ClassicBike.Biz
M_
fV
7
00
LL
76
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
AIR CLEANER AND SIDE PANELS
1
1
2
2
1
1
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Not illus.
Not illus.
Not illus.
Not illus.
F13789 N• 1 • A• AIR CLEANER ASSEMBLY—L.H.
F13790* 4.4. AIR CLEANER ASSEMBLY—R.H.
F12749
Body—L.H.
F12750
Body—R.H.
F13850$3V Cover—L.H.
...
...
F13851
Cover—R.H.
F13791 N.L,A- AIR CLEANER ASSEMBLY—L.H.
F13792M "• AIR CLEANER ASSEMBLY—R.H.
F12798
Body—L.H.
F12797
Body—R.H.
Fl 3864
Cover—L.H.
F13865
Cover—R.H.
D307260- '/165Element ...
14-0221
Bolt
F8245
Retainer
Cover to body
D2438
Washer
14-0302
Nut
D3539
Screw
L. H. assy. to R. H. assy.
Nut
5501
14-0218
Bolt
}Air cleaner to frame
D2418
Spring washer
Fl 26267/- Pt/ Connector pipe
F12625
Connector pipe
E11860
Carburetor adaptor
Clip—Jubilee type
D3536
F1385983-073 Side panel—L.H.
F138608• - 7CSide panel—R.H.
Panel grommet ...
F6673
• ••
14-0201
Bolt
Washer .Side panel to air cleaner ...
D2329
14-1301
Nut
Transfer ...
D3722
Transfer ...
D3724
Transfer ...
D3723
Spacer (use with 14-0218)
F9196
77
ClassicBike.Biz
1
1
1
1
1
1
1
1
1
••• 1
••• 1
••• 1
••• 2
2
2
2
2
2
2
2
2
2
... 1
1 or 2
1 or 2
1
2
4
4
4
2
2
2
2
Twin Carb
T12OR
Single carb.
TR6R, TR6C
All models
T12OR
TR6C, TR6R
T12OR
TR6C
TR6R
co
N
nc.
G
aJ
J_
Q
I0
z
4
H
W
G
zW
U-
^
N
by
LL
N
ea97
,.. ,.
—
r
M
a
78
ClassicBike.Biz
0
Ref. No.
QUANTITY
DESCRIPTION
Part No.
REMARKS
FENDERS AND TAIL LAMP
1
1
2
3
4
5
6
6
7
8
9
10
11
12
13
14
15
16
17
19
18
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
...
...
...
...
*Front fender ...
...
...
...
...
*Front fender ...
H4270
...
...
Bracket
H4022
•••
...
Rubber bush
H4021
Stay to fork leg
Bolt
14-0103
...
...
Spring washer
D2427
...
...
...
...
...
*Rear fender
F13566
...
...
...
...
...
*Rear fender
F13565
Bolt
...
...
14-0114
...
...
Fender fixing front
Washer
D2330
...
...
14-1302/1/-/202 Nut
J
...
...
...
...
...
...
Bolt
14-0101
...
...
...
...
...
...
Bolt
14-0103
...
...
...
...
...
F306982'9O 'Z Spacer ...
...
Washe r Fender fixing top and rear
D2329
•••
14-1301
Nut
...
...
...
...
Lifting handle ...
F12768
...
Bolt
14-0101
Lifting handle to frame • • •
•••
•.•
Washer
D2329
...
...
...
...
...
...
Nut
14-1301
...
...
Rear number plate bracket—L.H.
F12727
...
...
Rear number plate bracket—R.H.
F12728
...
Bolt
14-0102
Washer Number plate bracket to fender...
D2329
H4271,4/1-A.
I
...
...
...
...
...
...
...
...
1
1
...
...
...
...
...
...
...
...
...
...
•••
...
...
...
...
...
...
...
...
...
...
...
...
...
4
1
1
...
•••
...
...
••
...
33
..
•••
...
...
...
. .
•.
...
...
...
...
22
...
...
...
...
J
...
...
...
Tail lamp support
F12786
...
...
Captive nut
D3313
Bolt
14-6102
Tail lamp support front fixing
S25-160-^f 2 /S Washer
Bolt
14-0101
Tail lamp support rear fixing
Washer
D2427
...
...
stri ...
Rubber beading
g strip
F13213
...
...
Reflector red (99-1162)
57079
...
...
...
Washer ...
D2391
...
...
Nut
F4717
STOP
AND
TAIL
LAMP
679
(99-0597)
53973
...
...
Lens (99-1046)
54577109
...
...
...
Screw
(99-1189)
144921
...
...
Lamp
base
assembly
54525286
h
380
Bulb (99
-
05
42
)
...
...
*For color see page 8.
79
ClassicBike.Biz
...
...
...
...
...
...
"
...
"'
...
...
...
...
.. •
...
...
...
...
...
...
...
...
•..
...
•..
•..
...
...
...
...
...
...
4
4
4
1
... 2
... 1
... 1
... 4
... 4
...
...
...
...
4
1
1
...
...
2
...
...
2
...
...
...
...
...
...
...
...
... 2
... 2
... 2
... 2
... 1
... 1
... 1
... Reference only
...
...
TR6R, T120R
TR6C
... 2
... 4
... 2
... 2
... 1
... 1
...
Nut
14-1301
TR6R, T120R
TR6C
...
...
...
...
80
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTIO N
QUANTITY
REMARKS
HANDLEBARS AND CONTROL LEVERS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
H4252q7-7OO/ Handlebar
...
...
...
...
H1425
Sleeve, handlebar mounting ...
...
16136460-70Yq TWISTGRIP (99-0248)
...
...
16/328
Body, top half (99 -0245)
...
16/329
BODY, BOTTOM HALF (99 -0246)
...
...
...
...
...
16/008
Friction spring
...
16/009 ri Z2./099'
Screw ...
•••
•••
16/010
Locknut
...
...
99-0244
Rotor
...
...
...
11/013
Screw (9^,^25) ...
...
H9589'7- 2/2 S Grip
...
...
...
16/011
Cable stop ( 99-0241) ...
...
H212497- 2./4'2. Grip
...
...
...
...
12/60
-3c67 AIR CONTROL LEVER (D3246)
12/556 - 0221r Lever
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
4
1
1
1
...
•••
...
...
...
•-...
...
...
...
...
...
...
...
...
...
...
...
...
...
Reference only
Reference only
Reference only
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
2
1
1
1
1
Reference only
...
...
...
...
...
...
...
...
...
...
...
...
Reference only
Reference only
Spring washer
...
...
Clamp
...
...
...
c'ZZ Screw
...
Front brake lever (alloy)
...
Clutch lever (alloy)
...
...
...
...
Pivot pin...
...
...
...
Nut
...
...
Adjuster
...
...
...
Lockring
...
...
...
HANDLEBAR SWITCH—L.H.
Switch half
...
...
Lever half (99-1187)
...
Screw (99-1188) ...
...
HANDLEBAR SWITCH—R.H.
Switch half
...
...
Lever half (99-1215)
...
Screw (99-1188) ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
12/607
12/606
12/033
12/040
11 /014 9'9D3583
D3657
S2048
14-1201
D3585
D3586
39595
54033666
54340882
54115246
39596
54033667
54340883
54115246
Bolt
Cap ...
...
...
...
...
81
ClassicBike.Biz
I
Reference only
Reference only
Reference only
... 1
... 1
... 2
... 2
... 2
... 2
... Reference only
... Reference only
... 1
... 4
... Reference only
... Reference only
... 1
... 4
7
4
25
13
B26
Fig. 30. CONTROL CABLES
82
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CONTROL CABLES
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
3
D1819
D1 806
D3079
D3557
W3996
W3997
E12500
W4014
D1 807
D3485
D1 818
Throttle cable
...
...
...
Throttle cable
...
...
...
Clutch cable ...
...
...
...
Front brake cable
...
...
...
Bush—brake cable stop
...
...
Bush—brake cable
...
...
...
...
Washer ...
...
...
...
Cable spring ...
...
...
...
Air control cable
...
...
...
AIR CONTROL CABLE
...
...
Cable,
lever
to
junction
box
...
8S
244/10460-06 J Junction box (99-0341) ...
...
D3486
Cable, junction box to carburetor
313/13
TWIN ROTOR TWISTGRIP (99-0347)
...
Screw
...
...
...
18/084
Body, top half ...
...
...
313/020
BODY, BOTTOM HALF
...
313/021
...
Friction spring
...
16/008
...
Screw ...
...
...
210/007
...
...
...
Nut ...
5/077 T9- 70 ?7
...
...
...
...
Rotor
313/004
...
...
Rotor stop screw ...
210/008
...
5/0779- 7097 Nut—rotor stop screw ...
...
...
...
...
Grip
H2125
...
...
...
...
Cable
clip
D343/3
...
...
...
...
Cable clip
D343/7
...
...
...
...
Handlebar clip
H4112
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
LATER MODELS USE THE FOLLOWING:
...
...
...
D3815 O-35j7Front brake cable
83
ClassicBike.Biz
...
...
...
...
... 2
... 1
T120R
TR6C, TR6R
...
...
...
...
2
1
... 1
... 1
TR6C, TR6R
T120R
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
2
1 T120R
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
1
2
6
4
1
ClassicBike.Biz
Ref. No. Part No.
QUANTITY
DESCRIPTION
TOOLKIT
1
2
3
4
5
6
7
8
9
10
11
D2112
D291
D2184
D1911
D2084
D971
D972
D974
D767
F13292
14-0101
D2329
TOOLKIT COMPLETE
...
Tool roll ...
Damper unit spanner
...
Tommy bar
Spanner—open ended
...
Box spanner
...
Ring spanner
...
Tyre valve key
...
Screw driver
..
Tool tray
...
Bolt
...
...
...
...
..
Washer ...
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
85
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
REMARKS
86
ClassicBike.Biz
DESCRIPTION
Ref. No. Part No.
QUANTITY
1
2
3
4
5
EEDOMETER AND TACHOMETER
,1l V
SSM5007/00^ Speedometer head (D2394) ...
...
41-148-203-10 Trip control (99-0176)..604.70//.
54959626
Bulb holder
...
...
...
...
...
643
Bulb (3W. MES)
..
D3249
Speedometer cable Of 9/.,10 Q.,Z C ...
6
H4026
Mounting bracket...
...
...
...
7
D2600
Rubber cup...
...
...
...
...
...
...
...
...
...
Not illus.
8
9
10
11
12
13
14
15
16
17
18
19
D2391
E93317/-L//3
E9332
Reference only
Reference only
E5157
E5759
E6300
E5578
E12875
E6299
Reference only
D3530
20
E5881
21
22
23
24
25
Not illus.
D3282
RSM3003/13
31-371-398
D494
E7351
D546
Washer...
TACHOMETER GEARBOX (E5758 Body)—L.H. thread
Securing screw—L.H. thread, U.N.
...
Bush...
...
...
...
...
Flanged bush ...
...
...
...
...
...
...
...
...
...
...
...
ring ...
...
Driven gear...
Driven gear housing
"0'' ring
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Drivinggear
End cap...
"0"
Bush...
...
...
...
"0" ring
...
..
Set screw
.J^F .9'///,4
Tachometer cable
Tachometer (D2396) ... O- 7/ 7.1
...
...
...
Spade (99-0173)
...
...
8.
...
...
...
...
...
...
...
...
...
...
...
Sealing washer ...
...
...
...
...
...
Circlip
...
Blanking plug (replaces tacho bulb holder)
87
ClassicBike.Biz
...
REMARKS
... 1
... 1
... Reference only
Reference only
... 1
TR6C,
f 12 T120R, TR6R
1 TR6C,
2 T120R, TR6R
2 or 4
... 1
... I
... 1
... 1
... 1
... 1
... 1
... 1
... 1 TR6R
... 1 T120R
... 1
... 1
1
...
...
...
...
...
...
1
1
1
1
1
1
Fig. 33. COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN
88
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN
1
2
F12571
14-0101
3
4
D2329
14-1301
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
Not illus.
F9561
45223
49072
F5338
47638
54420128
54418528
54418526
S207
S778 9
35048
54385091
D3614
S2079
D2391
S778
49345
N3
D262
70228
14-0103
D2347
14-1301
54190038
57183
D2391
F4717
F13522
D3161
Mounting platform—electrical components...
...
...
Bolt
.•.
...
Washer Platform to mudguard
...
...
...
Nut
...
...
Grommet—coil mounting
...
...
t
Ignition coil (17-M-12) D2206 tD 2- 1 203...
Rectifier (99O589)
...
...
...
...
...
...
...
Nut
...
...
CAPACITOR PACK-2CP ...
...
Capacitor (994$43)
...
...
...
...
...
...
Cover (99-077) ...
...
...
...
...
Base plate (99-1160)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
Reference only
2
1
1
Capacitor pack to platform
...
Nut
Nw }
...
...
...
Flasher unit ( 99-1201 ) ...
...
1204) ...
...
Clip, flasher unit ( 99...
...
Spring
Screw I
Flasher unit to platform "•
...
•••
••.
Washer
Nut
••.
Zener Diode (99-0590) Cv ' - 0 957..
...
...
...
...
Sparking plug ...
...
...
Plug cover (Champion WC200)
...
...
...
Horn-6H (9 9-124 5) ...
Bolt
...
...
...
Washer Horn to frame
Nut
...
...
...
Lucar blade terminal ...
...
...
Reflector-amber ( 99-1161 ) ...
Washer
•••
...
.Reflector mounting
Nut
Mounting rubber
...
...
Grommet (horn mounting) ...
...
...
...
2
...
...
...
...
...
...
...
...
...
•••
...
...
...
•••
...
1
1
1
...
•••
...
2
2
2
...
...
...
...
...
...
...
...
...
...
...
...
...
J
tP - Q7c.
...
J
...
J
...
...
...
...
89
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
I
2
2
1
1
Reference only
1
1
2
4
2
Reference only
2
2
2
2
2
90
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
HEADLAMP AND FLASHER LAMPS
1
2
3
4
5
60260
HEADLAMP COMPLETE MCH 69 (
21)
...
...
553248
Rim (99-0692)
...
...
...
...
...
...
516801
Light unit (99-1156)
...
...
...
...
...
504665
Fixing wire (99-0683)
...
...
...
...
...
144921
Screw
...
...
...
...
...
...
...
6
534296
Plate
...
...
...
...
...
...
...
7
370
Main bulb (45/35W) (99-1214) ...
...
...
...
8
554602
Bulbholder
...
...
...
...
...
...
9
989
Pilot bulb (99-0548)
...
...
...
...
...
10
54573590
Pilot bulbholder (99-1213)
...
...
...
...
11
54363454
Warning light (Red) (99-1208)
...
...
...
12
54363455
Warning light (Green) (99-1209)
...
...
...
13
54363453
Warning light (Amber) (99-1207)
...
...
...
14
54140331
Sealing washer (99-1210)
...
...
...
15
31276
Light switch (99-1211) ...
...
...
...
...
16
54525212
Shield, warning light
...
...
...
...
...
17
281
Bulb, warning linglt (99-0537) ...
...
...
...
18
54115106
Screw, headlamp fixinhg k9
23)
70/. Z...
19
Washer, headlamp fixing 99-1224)
143086
...
...
...
...
Not illus. 54959629
Wiring harness (99 122-i)
...
...
...
...
39565
IGNITION SWITCH (TYPE 149 SA) (99-1200)
...
20
Nut ...
...
...
...
...
...
...
54130041
21
...
F6981SY335/6q IGNITION LOCK C/W KEY 8 2. ' 98/ ...
22
Key
(state
serial
number)
...
...
...
...
23
D6225*035/69
...
...
...
...
...
Cover, ignition switch
H2262
24
...
...
...
...
...
FLASHER
LAMP
(99-1190)
56147
25
.
...
...
Lens
(99-119
1)
...
...
...
...
26
54581638
...
...
...
...
...
...
...
Gasket
54580300
27
...
...
...
...
...
...
Bulbholder
554548
28
...
...
...
...
...
Interior assembly ...
473832
29
...
...
...
...
...
Bulb
(99-1192)
...
382
30
...
...
...
...
...
...
Screw
(99-1193)
54123401
31
...
...
...
Stanchion,
flasher
lamp
(99-1246)
60600092
32
^
9'
91
ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
I TR6R, T120R
1
1
6
Reference only
Reference only
1
Reference only
1
1
1
1
1
3
1
Reference only
3
...
2
... 2
... 1
... 1
... Reference only
... 1
... As required
... 1
... 4
... 1
... Reference only
... Reference only
... Reference only
... 1
... 2
... 4
4
0
Q
I
U
m
0
Z
4
m
W
4
m
M
92
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
BATTERY AND TR6C HEADLAMP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
F1 2512
F8091
F8255
F9353
F1 3849
F1 3295
F12508
F6039
14-1301
54027029
60262
534343
54525272
504665
370
54573590
989
17
554602
18
Not illus. 54115106
Not illus. 143086
19
31272
153631
20
21
144921
534296
22
23
54363454
24
281
54363455
25
54140331
26
54363453
27
54525212
28
14-0404
29
H4247
30
Battery carrier
...
...
...
...
Carrier tray
...
...
...
...
...
Protective strip
...
...
...
...
Retaining strap ...
...
...
...
...
Buckle ...
...
...
...
...
...
Protective strip
...
...
...
...
Shoulder screw
Rubber bush
Battery carrier mounting
Nu
Battery—PUZ5A (99-O 9)
HEADLAMP ASSEMBLY MCH 66 (9
95)
.'
25'$
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... ...
O69^)
...
...
...
...
Light unit (99-1-21-2)
...
...
...
...
Fixing wire (99-9683)
...
...
...
...
Bulb (45/35W vertical dip, pre-focus 99-1214)
Bulbholder, pilot (99-0695)
...
...
...
...
...
Bulb (3W.M.C.C. 99-0548)
...
Adaptor c/w leads (99-1003) ...
...
...
Screw, lamp fixing (99=1157) ...
...
...
Washer (99-1224)
...
...
...
...
Lighting switch (99-6563)
...
...
...
Nut for lighting switch ...
...
...
...
...
...
...
...
Screw
...
Plate (99-0690) .6 0 7 0 9' 7 ...
Warning light, red (99-1 .208) ...
...
...
...
...
...
Bulb (2W.BA75) (99-0537)
...
Warning light, green (99-1209)
...
...
...
...
Sealing washer (99-1210)
...
Warning light amber (99-1207)
...
...
Warning light shield
...
...
...
...
...
...
...
...
...
Nut
...
...
...
...
...
Support bracket
...
93
ClassicBike.Biz
1
...
...
...
...
...
...
...
...
...
...
1
1
... 1
... 6
... 1
... 1
... 1
... 2
... 2
... 2
... 1
... Reference only
... Reference only
...
...
...
...
...
...
...
...
...
...
... 1
... 2
... 1
... 3
... 1
... Reference only
... 2
... 1
-Rim (99
1
1
2
1
1
11
3
3
1
...
1
STANDARD HARDWARE SPECIFICATION
BOLTS
Material
Thd. dia.
21-1822
21-1910
21-1919
21-1
21-2010
1 0101
1 0102
1 0103
1 0113
1 0114
1 0115
1 0128
1 0208
216
1
1 0217
1 0219
1 0220
14-0225
1 0228
1 02 4
1 0236
1 0239
1 0240
1 0242
1 0251
1 6102
1 6115
Steel
Of
*" UNF
A"
8 UNF
6 " UNC
1"
4 UNF
k" UNF
k" UNF
I"
UNF
4
*" UNF
*" UNF
*" UNF
1" UNF
I"
4 UNF
16 UNF
UNF
*" UNF
UNF
1 6 " UNF
*" UNF
a8 " UNF
i" UNF
A"
8 UNF
A"
8 UNF
A"
8 UNF
UNF
k" UNC
*" UNC
Part No.
Material
Thd. dia.
21-0778
778
21-1852
21-1906
21-190
21-1914
21-2012
21-2013
21-2014
14-0301
0301
1 030
1 0401
1 0402
1 0403
1 0701
702
1
1 0703
Steel
Part No.
1
ff
II
+,,
1 3,,
1 6
n"”
,
ff
tf
tI
PP
II
It
It
1t
ft
fP
tI
PP
ff
IP
2f
tt
0,
/I
tl
1,,
.,
If
It
If
"
"
0
P
,,
tI
IP
tt
tt
"
Min. length
of thread
ft"
1 3
1 6”
7,,
w
3"
I
2
f"
1"
8
f"
k"
1"
24"
1f"
lk"
li"
11"
3"
4"
11"
24"
3"
34"
4"
21"
1”
8
"
IP
f
f
1 3
1 6
"
PP
1201
1 1202
1 1301
1 1302
1 1303
1 1304
1 1305
1 1902
1 1903
Length under
head
I"
2”
8
7,,
W
i"
7"
w
7"
w
W
1"
1"
1"
1"
1"
1+"
7”
No. 10 UNF
" UNF
I"
4 UNF
1 6 " UNF
A"
4 UNEF
f " UNEF
l' UNEF
f" UNEF
14 " UNF
UNF
1 6
k" UNF
*" UNF
1" UNF
k" UNF
" UNF
I" U
UNF
k" UNF
UNF
k" UNF
A" UNF
f" UNF
UNF
1
"
UNF
2
UNF
1 6
1" UNF
0.375"
0.437"
0.348"
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"
*
*"
"
94
ClassicBike.Biz
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"
7,,
W
N U TS
Hexagon A.F.
Hexagon A.F.
0.563"3
0.563"
0.563"
0.563"
0.563"
0.625"
0.438"
0.500"
Thickness
Remarks
0.225"
0.330"
0.188"
0.313"
0.250"
0.438 "
0.313"
0.438"
0.224"
0.271"
0.1 61"
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"
Cleveloc
Philidas
Plain
Plain
Plain
Plain
Plain
Plain
Plain
Plain
Lock
Lock
Lock
Philidas
Philidas
Philidas
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Nyloc
Nyloc
SCREWS
Part No.
21-1916
21-1917
21-1918
21-1920
2 1-1929
21-2079
14-0604
14-6505
14-6607
14-6608
14-6609
14-7019
14-7024
Type of head
Material
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
Thd. dia.
Steel
4" UNC
4" UNC
4" UNC
4" UNC
-," UNC
No. 10 UNF
4" UNF
4" UN
4" UNC
4" UNC
4" UNC
6" UN
" UNC
„
„
„
„
„
Length under head
18"
28"
28"
Type of drive
Cross recess
Cross recess
Cross recess
64
11
'^Z'"
' "
-z"
'
e"
8"
1"
1,'-"
-g'"
2"
Slot
Pozidrive
Cross recess
Cross recess
Cross recess
Cross recess
Cross recess
Hex. socket
Hex. socket
WASH ERS—PLAI N
Part No.
Material
i/dia.
o/dia.
Thickness
60-4245
60-4246
Steel
Steel
0.273"
0.398"
0.563"
0.750"
60-4247
37-2027
Steel
Steel
Steel
0.336"
0.531"
0.266"
0.625"
1.031"
0.469"
0.048"
0.063"
0.063"
0.092"
60-4248
0.064"
WASHERS—SPRING
Part No.
Material
1/dia.
o/dia.
o/a height
Thickness
60-4259
60-4250
Spring Steel
,,
,
e" clearance
a'-" clearance
;Z"
'3—z"
T"
0.104"
0.064"
60-3541
21-0648
„
„
z"
e"
6" clearance
z"
** Double coil.
95
ClassicBike.Biz
T.
0.040**
32
Printed in England by
WARWICK PRINTING COMPANY LIMITED
WARWICK
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ClassicBike.Biz

650s - ClassicBike.biz

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