500s / 350s - ClassicBike.biz

Transcription

REPLACEMENT
PARTS
CATALOGUE No. 7
"C" RANGE MODELS
TWENTY-ONE (3TA)
SPEED TWIN (5TA)
TIGER 90 (T90)
TIGER 100 (T100)
from Engine No. H 40528
September 1965
See Bookmarks
TRIUMPH ENGINEERING COMPANY LIMITED
MERIDEN WORKS •
TELEPHONE MERIDEN 331
REF.
ALLESLEY •
COVENTRY •
ENGLAND
TELEGRAMS "TRUSTY COVENTRY"
PUBLISHED OCTOBER 1965
18167
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TRIUMPH GUARANTEE
1. In this Guarantee the word "machine" refers to the motor cycle, scooter, motor-cycle combination
or sidecar as the case may be, purchased by the Purchaser.
2. In order to obtain the benefit of this Guarantee, the Purchaser must have correctly completed the
registration form and returned it to us within fourteen days of the purchase.
3. We will supply, free of charge, a new part in exchange for, or, if we consider repair sufficient, will repair free of charge any part proved within six months of the date of purchase of any new machine, (3
months overseas) or within three months of its renewal or repair in the case of a part already renewed
or repaired, to be defective by reason of our faulty workmanship or materials. We do not undertake
to bear the cost of fitting such new or repaired part or accessory.
4. Any part considered to be defective must be sent to our Works, carriage paid, accompanied by the
following information:
(a) Name of purchaser and his address;
(b) Date of purchase of machine;
(c) Name of dealer from whom the purchase was made;
(d) Engine number and model
5. This Guarantee shall not extend to defect or damage appearing after misuse, neglect, abnormal stress
or strain, or the incorporation or affixing of unsuitable attachments or parts and in particular:—
(a) Hiring out;
Racing and Competitions;
(c) Adaptation or alteration of any part or parts after leaving our Works;
(d) The attaching of a sidecar in a manner not approved by us or to an unsuitable motor-cycle.
This Guarantee shall not extend to machines whose trade mark, name or manufacturing number has
been altered or removed, or in which has been used any part not supplied or approved by us, or to
tyres, saddles, chains, speedometers, revolution counters and electrical equipment or to parts supplied
to the order of the Purchaser and different from our standard specification.
6. Our liability and that of our dealer who sells the machine, shall be limited to that set out in this guarantee, and no other claims for consequential damage or injury to person or property, shall be admissible.
All other conditions and warranties statutory or otherwise and whether express or implied are hereby
excluded and no guarantee other than that expressly herein contained applies to the machine to which
this Guarantee relates or any accessory or part thereof.
7. We reserve the right to modify or deviate from the Published Specification without notice.
REPAIRS GUARANTEE
1.
Whilst the highest standard of workmanship and materials is aimed at, we cannot accept liability for
any defects appearing more than three months after the machine, assembly or component has left our
Works after being repaired.
2.
We will repair or replace at our option free of charge any defective work, materials or parts relating
to the repairs carried out by us appearing within that time but shall not be under any further, or other
liability for any other loss or damage whether direct or consequential and our liability shall be limited
to the cost of so making good. We do not undertake to bear the cost of fitting any replacement or
repaired part.
3.
We do not accept liability in respect of parts of proprietary manufacture, e.g. tyres, saddles, chains
speedometers, revolution counters and electrical equipment which may be used by us in effecting a
repair. All other conditions and waranties statutory or otherwise express or implied are hereby excluded.
2
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TRIUMPH SPARES
HOW TO ORDER. Every part is indicated by 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 crank case
underneath the cylinder flange, 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. 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.
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 manufacturer and not by ourselves. Any repairs or claims should be made 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:—
CARBURETTERS
Messrs. Amal Ltd.,
Holdford Rd., Witton, Birmingham 6.
SPARKING PLUGS
Champion Sparking Plug Co. Ltd.,
Feitham, Middlesex.
CHAINS
Renold Chains Ltd.,
Wythenshawe, Manchester.
SPEEDOMETERS
Messrs. Smiths Motor Accessories Ltd.,
Cricklewood Works, London, N.W.2.
ELECTRICAL EQUIPMENT
Messrs J. Lucas Ltd.,
Gt. Hampton St., Birmingham, 18.
SUSPENSION UNITS
Messrs. Girling Ltd.,
Birmingham Road, West Bromwich, Staffs.
TYRES
Dunlop Rubber Co. Ltd.,
Fort Dunlop,
Birmingham, 24.
ClassicBike.biz
ILLUSTRATION INDEX
Fig. No.
Description
Page No.
1
CRANKSHAFT AND CONNECTING RODS ...
16
2
CRANKCASE
18
3
OIL PUMP, RELEASE VALVE AND INLET MANIFOLD
20
4
CYLINDER BLOCK AND HEAD, 3TA AND T90 ...
5
CYLINDER BLOCK AND HEAD 5TA AND T100
6
TIMING COVER AND CONTACT BREAKER
...
28
7
GEARBOX SHAFTS, BEARINGS AND INNER COVER
30, 32
8
GEARBOX OUTER COVER AND LEVERS
34
9
CLUTCH
...
36
10
CHAINCASE AND CHAINS
38
11
ENGINE FITTINGS AND EXHAUST SYSTEM
12
EXHAUST PIPES, UNDERSHIELD AND FOOTPEGS 100C)
42
13
FRAME
44
14
SWINGING FORK, SUSPENSION UNITS AND CHAINGUARD
46
15
TELESCOPIC FRONT FORK, 3TA AND 5TA
48
16
NACELLE, HEADLAMP AND SWITCHES
50
17
TELESCOPIC FRONT FORK, T90 AND T100
52
18
TELESCOPIC FRONT FORK, U.S.A. EASTERN T100C
54
19
FRONT WHEEL
56
20
REAR WHEEL
21
QUICKLY DETACHABLE REAR WHEEL (NOT U.S.A.)
60
22
MUDGUARDS (STANDARD) ...
62
23
FENDERS (U.S.A.) ...
24
PANELS AND TWINSEAT
66
25
PETROL (GAS) TANKS ...
68
26
OIL TANK ...
22, 24
26
...
...
...
40
58
...
...
64
...
70
27
BATTERY, TOOLKIT AND AIR FILTER
72
28
HANDLEBARS AND CONTROL LEVERS
74
29
CONTROL CABLES
76
30
CARBURETTER, 3TA AND 5TA
78
31
CARBURETTER, T90 AND T100
80
32
A.C. MAGNETO IGNITION COILS, WIRING HARNESS AND
DIRECT LIGHTING ...
...
82
33
D.C. IGNITION
COILS, HORN, RECTIFIER AND ZENER DIODE
84
34
T90 AND T100 HEADLAMP, WIRING HARNESS, SWITCHES AND
TAIL LAMP ...
86
SPEEDOMETER AND TACHOMETER ...
88
35
...
4
ClassicBike.biz
I NDEX
Page
...
...
ALTERNATOR
...
...
BATTERY CARRIER
...
...
CARBURETTER
...
...
CARTON PACKS
...
...
...
CENTRE STAND
...
...
CHAINCASE...
...
...
AIR FILTER
...
...
73
17,39
...
...
21
MUDGUARDS ...
...
...
...
63
MUFFLERS
...
...
...
41
...
51
...
21
...
NACELLE
...
10
OIL PUMP
...
...
...
45
OIL TANK
...
...
...
...
71
...
39
...
...
...
69
PILLION FOOTRESTS ...
...
...
45
...
...
17
79,81
...
39
CLUTCH
...
37
...
83, 85
CONTACT BREAKE
MANIFOLD
73
CHAINS
COIL
Page
...
...
29
PETROL TANK
PISTONS
...
...
PROP STAND ...
45
Q.D. REAR WHEEL (NOT U.S.A.) ...
61
CONTROL CABLES
...
...
...
77
CONTROL LEVERS
...
...
...
75
CRANKCASE...
...
...
...
19
REAR PANELS
...
...
...
67
CRANKSHAFT
...
...
...
17
REAR WHEEL ...
...
...
...
59
CYLINDER HEAD
...
...
23, 25, 27
RECTIFIER
...
...
...
...
85
ENGINE PLATES
...
...
SILENCERS
...
...
...
...
41
EXHAUST PIPES
...
...
... 41, 43
SPARK PLUGS
...
...
...
85
SPEEDOMETER
...
...
...
89
STEERING RACES
...
...
...
45
SUSPENSION UNITS ...
...
...
47
...
...
... 51,87
...
...
...
17
41
FENDERS
...
...
...
...
FOOTRESTS
...
...
...
... 43, 45
FRONT FORKS
...
...
49, 53, 55
FRONT WHEEL
...
...
...
65
SWITCHES
...
57
TIMING GEARS
...
...
...
...
69
GASKET SETS ...
...
...
...
11
GEARBOX
...
...
...
31, 33, 35
HANDLEBARS...
...
...
...
HORN
...
...
... 83, 85
GASTANK
...
...
ClassicBike.biz
TOOLKIT
...
...
...
...
73
TWINSEAT
...
...
...
...
67
VALVES...
...
...
...
23, 25, 27
...
...
51, 83,85
75
WIRING HARNESS
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TW ENTY-ONE (3TA) TECHNICAL DATA
Bore and stroke
58.25 x 65.5 mm.
2.292 in. x 2.578 ins.
Capacity
348 c.c. (21.23 cu. ins.).
Compression Ratio
7.5 : 1
Sparking Plugs
Champion N4
Amal Monobloc 375
100
.106
Type B
375/31
25
Carburetter
Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
17 teeth
Gearbox Sprocket
Chains
Front
Rear
1 in. Duplex x 78 links
in. x 1 in. x 102 links
Capacities
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
31 galls. (16 litres)
6 pints (3.5 litres)
2/3 pint (375 c.c.)
pint (300 c.c.)
pint (190 c.c.)
Brakes
Front and Rear, diameter
7 in. (17.78 cm.)
Tyre Size
Front
Rear
3.25 x 18
3.50 x 18
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6
SPEED TWIN (5TA) TECHNICAL DATA
Bore and Stroke
69 x 65.5 mm.
2.716 x 2.578 ins.
Capacity
490 c.c. (29.8 cu. ins.)
Compression Ratio
7:1
Sparking Plugs
Champion N4
Carburetter
Amal Mono bloc 375
160
.105
Type B
375/3
25
Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Gearbox Sprocket
19 teeth
Chains
Front
Rear
Capacities
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
2/3 pint (375 c.c.)
1 pint (300 c.c.)
I pint (190 c.c.)
Brakes
7 in. (17.78 cm.)
Tyre Size
Front
Rear
3.25 x 18
3.50 x 18
ClassicBike.biz
in. Duplex x 78 links
in. x I in. x 103 links
7
TIGER 90 (T90) TECHNICAL DATA
Bore and Stroke
58.25 x 65.5 mm.
2.292 x 2.578 ins.
Capacity
348 c.c. (21.23 cu. ins.)
Compression Ratio
9:1
Champion N4
Sparking Plugs
Carburetter
Amal Monobloc
f"lain Jet
Main
Needle Jet
Needle
Throttle Valve
180
.106
Type C
376/32
376/3420
20
Pilot Jet
Gearbox Sprocket
Chains
17 teeth
Front
e in.
in. xx 8 in. x 102 links
Rear
Capacities
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
3'—z galls.
34galls.(16
(16 litres)
litres)
2/3 pint (375 c.c.)
z'— pint (300 c.c.)
'^ pint
4pint (190
(190 c.c.)
c.c.)
Brakes
Brakes'
7 in. (17.78
(17.78 cm.
cmJ
Tyre Size
Front
3.25 x 18
3.50 x 18
Rear
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8
TIGER 100 (T100) TECHNICAL DATA
Bore and Stroke
69 x 65.5 mm.
2.716 x 2.578 ins.
Capacity
490 c.c. (29.8 cu. ins.)
Compression Ratio
9:1
Sparking Plugs
Champion N4
Carburetter
Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Gearbox Sprocket
Amal Monobloc
190
.106
Type C
376/31
25
18 teeth
Chains
Front
Rear
I in. Duplex x 78 links
in. x in. x 102 links
Capacities
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
Brakes
2/3 pint (375 c.c.)
pint (300 c.c.)
pint (190 c.c.)
7 in. (17.18 cm.)
Tyre Size
Front
Rear
3.25 x 18
3.50 x 18
ClassicBike.biz
9
U.S.A. TIGER 100 (EASTERN T1000) TECHNICAL DATA
Bore and Stroke
2.716 x 2.578 ins.
Capacity
29.8 cu. ins.
Compression Ratio
9:1
Sparking Plugs
Champion N4
Carburetter
Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Gearbox Sprocket
Amal Monobloc
190
.106
Type C
376/3425
18 teeth
Front
Rear
Capacities
Gas Tank
Oil Tank
Gearbox
Primary Chaincase
23 U.S. galls.
6 U.S. pints
2/3 pint (375 c.c.)
pint (300 c.c.)
3 pint (190 c.c.)
Brakes
7 in. (17.18 cm.)
Tyre Size
Front
Rear
3.25 x 19
4.00 x 18
Chains
ClassicBike.biz
in. x a in. x 102 links
10
U.S.A. TIGER 100 (WESTERN TINC) TECHNICAL DATA
Boe and Stroke
2.716 x 2.578 ins.
Capacity
29.8 cu. ins.
Compression Ratio
9:1
Sparking Plugs
Champion N4
Carburetter
Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Gearbox Sprocket
Amal Monobloc
190
.106
Type C
376/3f
25
18 teeth
Chains
Front
Rear
1 in. x in. x 102 links
Capacities
Gas Tank
Oil Tank
Gearbox
Primary Chaincase
21 U.S. galls.
6 U.S. pints
2/3 pint (375 c.c.)
+ pint (300 c.c.)
+ pint (190 c.c.)
Brakes
7 in. (17.18 cm.)
Tyre Size
Front
Rear
3.25 x 19
4.00 x 18
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11
U.S.A. TIGER 100 (T100R) TECHNICAL DATA
Bore and Stroke
2.716 x 2.578 ins.
Capacity
29.8 Cu. ins.
Compression Ratio
9:1
Sparking Plugs
Champion N4
Amal Monobloc
190
.106
Type C
376/3'—z
25
Carburetter
Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
19 teeth
Gearbox Sprocket
Chains
Front
Rear
8 in. x g in. x 102 links
Capacities
Gas Tank
Oil Tank
Gearbox
Primary Chaincase
28 U.S. Galls.
6 U.S. pints
2/3 pint (375 c.c.)
+ pint (300 c.c.)
pint (190 c.c.)
Brakes
Tyre Size
Front
Rear
7 in. (17.18 cm.)
3.25 x 19
4.00x18
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gin. Duplex x 78 links
12
HOW TO USE THIS PARTS CATALOGUE
First check that the engine number of your machine is subsequent to that quoted on the title page.
Next consult the Index on Page 5 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 colour required. Painted parts are available only in the colours
or alternatives specified for that model of that particular year.
Model
Colour
Suffix Letter to Part No,
3TA
PACIFIC BLUE/ALASKAN WHITE
PB/AW
5TA
BLACK/SILVER
W/V
T90
GRENADIER RED/ALASKAN WHITE
GR/AW
T100
SHERBOURNE GREEN/ALASKAN WHITE
SG/AW
N.B. Pacific Blue is a flamboyant finish applied over Silver Sheen.
Paint is available also in all colours in
4 pint or 1 gallon tins, or Aerosol containers.
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.
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13
CARTON PACK LIST
The following sub-assemblies are supplied in carton packs under the C.P. part number stated. The
contents of these carton packs are preserved and will not deteriorate under adverse conditions.
Contents
Part No.
Brake Lining
C.P. 38/AM2
Steering Races
C.P. 167
2 NW243
16 W129
Brake Lining
Rivet
1 H1110
1 H1140
2 H1130
48 S70-4
Cone
Cone and dust cover
Cup
Steel balls (3/16 in. diam.)
Pistons (350 c.c.)
C.P. 164
Piston C.R. 7.5 : 1
1 E3689
1 E3691
Compression ring (plain)
1 E3690
Compression ring (taper)
Oil control ring
1 E3692
Gudgeon pin
1 E1750
Circlips
2 E1767
C.P. 164 is also available in 0.010 in., 0.020 in. and 0.040 in. oversizes.
E4670
2 E3690
1 E3692
1 E1750
2 E1767
C.P. 198
1
Piston C.R. 9:1
Oil control ring
Gudgeon pin
Circlips
Piston Rings (350 c.c.)
C.P. 165
Compression ring (plain)
2 E3691
2 E3690
Oil control ring
2 E3692
Pistons (500 c.c.)
C.P. 174 1
E4004
2 E3829
1 E3831
1 WE203E
2 WE479
C.P. 174 is also available in 0.010 in. and 0.020 in. oversizes.
E4021
2 E3829
1 E3831
1 WE203E
2 WE479
C.P. 179
1
Piston C.R. 7 :1
Oil control ring
Gudgeon pin
Circlips
Piston C.R. 9 :1
Oil control ring
Gudgeon pin
Circlips
Piston Rings (500 c.c.)
4 E3829
2 E3831
C.P. 175
14
ClassicBike.biz
Oil control ring
CARTON PACK LIST— continued
Part
Contents
No.
C.P. 180
4 E4135
2 E4136
Oil control rings
C.P. 180 can only be fitted to E4021 Piston body, and should only be used for high-performance work.
Valve Guides (3TA, 5TA)
C.P. 170
Valves (3TA)
C.P. 166
Valves (500 c.c.)
C.P. 176
Valve Springs
C.P. 177
De-coke Gasket Set
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4 E3208
4 E3209
Valve guides
Valve guides circlip
2 E3738
2 E3739
Inlet valve
Exhaust valve
2 E4012
2 E4013
Inlet valve
Exhaust valve
4 E5946
4 E4011
Inner valve spring
Outer valve spring
Al! models
D/GS 6
15
13
14
15
12
18
19 40 21
AND CONNECTING RODS
Fig. 1. CRANKSHAFT
16
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22 28
Ref. No.
Part No
DESCRIPTION
QUANTITY
REMARKS
CRANKSHAFT AND CONNECTING RODS
1
E5869
2
E3998
E3999
3
E3711
4
E5870
5
*E3713
6
E3702
7
E4001T
7
E1762
8
E4003
8
E3705
9
E2922
10
E3706
11
CP 164
12
CP 174
12
CP
198
12
CP
179
12
E3691
13
E3829
13
E3690
14
E3829
14
E3692
15
E3831
15
E1750
16
WE
203E
16
E1767
17
WE 479
17
E4006
18
E4141
19
E3851
20
54213901
21
54215824
21
E3975
22
E3735
23
E1580
24
E1771
25
E398
26
E6160
27
E400
28
E1486 A
29
30
E1558
E1463
31
E4563
32
E6120
33
E4678
33
E5341
34
E4786
34
E4700
35
E5316
36
E2256
37
E3727
38
E3728
39
E4142
40
*Use D524 Loctite sealant
CRANKSHAFT AND FLYWHEEL ASSEMBLY
Crankshaft
...
...
...
...
Oil tube ...
...
...
...
...
Screwed plug
...
...
Flywheel ...
...
...
...
...
Flywheel bolt
...
...
...
...
CONNECTING ROD
...
...
...
CONNECTING ROD...
...
...
...
Small end bush ...
...
...
...
Small end bush ...
...
...
...
Connecting rod bolt
...
...
...
Self-locking nut ...
...
...
...
Big end bearing
...
...
...
...
PISTON COMPLETE C.R. 7.5:1
...
...
PISTON COMPLETE C.R. 7:1
...
...
...
...
...
...
Plain compression ring ...
...
...
Taper compression ring ...
...
...
...
...
...
...
Oil control ring ...
...
...
...
...
Oil control ring ...
...
...
Gudgeon pin
...
...
...
...
Gudgeon pin
...
...
...
...
Circlip
...
...
...
Circlip
...
...
...
...
...
Distance collar
...
...
...
...
Engine sprocket, 26T Duplex
...
...
Rotor key
...
...
...
...
...
Rotor, type RM 19
...
...
...
...
...
Rotor, type RM19... ...
...
...
Tab washer
...
...
...
...
...
Nut
...
...
...
...
...
...
Key
...
...
...
...
...
...
Timing pinion ...
...
...
...
...
...
Nut
...
...
...
...
...
...
...
INTERMEDIATE WHEEL
...
...
...
Bush
...
...
...
Camshaft wheel...
...
...
...
...
...
...
Camshaft key ...
...
...
Inlet camshaft nut
...
...
...
...
Exhaust camshaft nut ...
...
...
...
Inlet camshaft ...
...
...
...
...
...
...
...
...
Inlet camshaft ...
...
...
...
...
Exhaust camshaft
...
...
...
EXHAUST CAMSHAFT
...
...
Tachometer drive thimble
...
...
...
Rotary breather valve ...
...
...
...
Breather valve spring ...
...
...
...
...
Retaining plate ...
...
...
...
Screw (15/32 in. U.H.)
...
...
...
...
...
Dowel ...
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
3
2
2
2
2
2
2
4
2
2
2
2
2
2
2
2
2
2
2
2
4
4
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
2
4
1
3TA, T90
5TA, T100
3TA, T90
5TA, T100
3TA
5TA
T90
T100
3TA
STA, T100
3TA, T90 (4 off)
5TA, T100
3TA, T90
5TA, T100
3TA, T90
5TA, T100
3TA, T90
5TA, T100
A.C. ignition
3TA. (Use E3838)
5TA, T90, T100
3TA
STA, T90, T100
A.C. ignition
17
45 44
Fig. 2. CRANKCASE
18
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
R EMARKS
CRANKCASE
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
E5868/4645
E3716
E3859
E3804
E3803
E3799
S25-3
51-51
E1310
E3822
E3824
E3823
E2724
E6076
E6386
E4147
E3719
E1509
E1645
E3718
E375
E3717
E4322
E4139
E4140
E3820
E3819
E1534A
E3835
E3876
E3724
E3722
E3723
E1564
E1577
E3078
T1399
T1112
WE 170
T361
T1257
E732
NE507
E4587
E4593
E4706
CRANKCASE c/w STUDS AND RIGHT MAIN BEARING
Hollow dowel
...
Stud (3 in. O.A.) ...
Stud pi in. U.H.)
Bolt (11 in. U.H.) ...
Plain washer
Nut
Nut
...
Breather disc
...
Inlet camshaft bush
Exhaust camshaft bush
Breather pipe
...
Blanking plug
Dowel
...
...
Chain tensioner abutment
Oil scavenge pipe
Clip
...
...
Screw (17/64 in. U.N.) ...
Oil pump stud (1 in. O.A.)
Intermediate wheel spindle
Oil pipes stud (11 in. O.A.)
Right main bearing
...
Locating plate
...
Self-tapping screw
...
Cylinder stud (1i in. O.A.)
Cylinder stud (1 4 in. O.A.)
Dowel
Left main bearing (Ball-journal)
Oil seal ...
Filter spring
Filter
...
Sealing washer
Filter cap
Joint washer ...
Breather extension rubber pipe
Stud (3i.n. O.A.)
...
...
Drain plug (with level tube) ...
Fibre washer ...
Level plug
Fibre washer
Filler plug
...
Fibre washer ...
Distributor hole plug ...
Fibre washer ...
...
Tachometer drive plug
1
1
2
1
2
1
3
3
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
6
2
2
1
1
1
1
1
1
1
1
Not serviced
Not serviced
2
1
1
1
3
2
2
1
1
2
19
ClassicBike.biz
7v/
]
//% ®
i
8
ASSY.I
•I
K
I
3
O^
•• • 1
5
A
;iiiii;
13
rd
TI
I I
10
7
9
8
6
5
Fig. 3. OIL PUMP, RELEASE VALVE AND INLET MANIFOLD
20
ClassicBike.biz
DESCRIPTION
Ref. No. Part No.
QUANTITY
REMARKS
OIL PUMP AND RELEASE VALVE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
E3878
E3731
S70-7
E403
E2360
GS153
E1476
E495
E3730
E3887
E3732
E5896
E2794
GS251
E2304
GS254
E6062
El 670
...
OIL PUMP
...
Pump body...
...
Valve ball
...
Valve spring
...
Screwed plug
...
Feed plunger
...
Scavenge plunger ...
...
Drive block
Joint washer ...
...
Serrated washer
...
...
Nut
...
...
OIL RELEASE VALVE
...
Valve body
...
...
Piston
Cap ...
...
...
...
Fibre washer
...
Main spring
...
Fibre washer ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
2
2
2
1
1
1
1
2
2
1
1
1
1
1
1
1
I NLET MANIFOLD
1
2
3
4
4
4
5
6
7
8
8
9
9
9
10
11
E3796
E3797
E2967
E3761
E4014
E4689
S25-13
W103
E3880
NA 43
NA 43A
E3834
E4504
E2968
S25-3
S1-51
Stud (1 17/32 in. O.A.)
Stud (2 in. O.A.)
...
...
Joint washer ...
...
Inlet manifold
...
Inlet manifold ...
...
Inlet manifold ...
...
Plain washer ...
...
...
Nut
...
Stud (1+ in. O.A.)
...
...
Joint washer ...
...
Joint washer ...
...
Insulating block
...
Insulating block
Insulating block
...
...
Plain washer ...
...
...
...
Nut
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
2
2
2
1
1
1
4
4
2
1
1
1
1
1
2
2
3TA
STA, T100
T90
3TA, 5TA
T90, 1100
3TA, 5TA
T90
T100
21
35 34
51
53
52
5
Fig. 4. CYLINDER BLOCK AND HEAD, 3TA AND T90
22
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, 3TA AND T90
1
2
3
4
5
6
7
8
9
9
10
10
11
12
13
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
,
t6
47
48
E3798
E3698
GS308
E2412
E4676
H2W
E1612
E3753
E5956
E4784
E3208
E6301
E3209
E2961
E3738
E4640
E3739
E3740
E5946
E4011
E3742
WE259A
E4456
F2184
E4674
E3745
E3744
E3743
E3858
E3302
F879
E3668
E3857
E3794
E3795
E3809
F1880
H400
E4610
E3751
E3749
E3750
E3222
E3223
GS662
E1330
E2534
E3224
E3748
E3253
E1335
Cylinder base washer
Cylinder block
...
Plain washer
Nut
...
...
...
Tappet guide block
...
Tappet block screw ( In. U.H.)
Serrated washer ...
...
Tappet
...
...
...
...
CYLINDER HEAD c/w GUIDES
Valve guide ...
Valve guide ...
Valve guide circlip
Exhaust pipe adaptor
Inlet valve
Inlet valve
Exhaust valve
Bottom cup
...
Inner valve spring
Outer valve spring
Top collar ...
Split cotter
Cylinder head bolt (2 25/32 in. U.H.)
...
...
Plain washer
Cylinder head gasket
Inlet rocker box
Exhaust rocker box
...
...
Joint washer
Rocker box stud (ff in. 0.A.)
...
Plain washer
Nut
Screw (+ in. U.H.)
...
...
...
Plain washer
Cylinder head bolt (5 i. n. U.H.)
Cylinder head torque stay bolt ...
Oil feed bolt
Copper washer
Domed nut
Inspection cap
Fibre washer
...
...
...
ROCKER (Right exhaust, left inlet)
ROCKER (Left exhaust, right inlet)
Rocker ball pin
Rocker adjusting pin
Adjuster lock nut
Thrust washer, in.
in.
Thrust washer,
Spring washer
Rocker spindle
Sealing rubber
Copper washer
(Continued)
•• •
i
...
•••
•••
•••
...
•••
1
1
8
8
2
2
2
4
1
1
.,.
4
4
4
2
2
2
2
4
4
4
4
8
4
8
1
1
1
2
4
4
4
4
4
2
2
2
6
2
4
4
2
2
4
4
4
2
3TA
T90
3TA
190
3TA
T90
6
4
2
2
2
23
ClassicBike.biz
45 39 44 41 42 45 44 23 31 21 32
35 34
37
36
47
46
50
53
51
53
52
5
8
Fig. 4. CYLINDER BLOCK AND HEAD, 3TA AND T90
24
ClassicBike.biz
Ref No.
Po rt No.
DESCRIP TION
QUANTITY
REMARKS
(Continued)
49
50
51
52
53
54
E1435
E3759
E4751
E4746
E4752
E4671
Domed nut
Push rod ...
Cover tube
Bottom cup
Rubber washer
Locking spring
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
2
4
2
2
4
4
25
ClassicBike.biz
45 39 44 41 42 45 44 23 31 21 32
35 34
50
53
13
Fig. S. CYLINDER BLOCK AND HEAD, 5TA AND T100
26
ClassicBike.biz
DESCRIPTION
Ref. No. Part No.
REMARKS
QUAN7ITY
1
2
3
4
5
6
7
8
9
10
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
54
E3798
E4000
GS308
E2412
E4676
H200
E1612
E3753
E4785
E3208
E6301
E3209
E2961
E4012
E4013
E3740
E5946
E4011
E3742
WE259A
E4456
F2184
E4675
E3745
E3744
E3743
E3858
E3302
F879
E3668
E3857
E3794
E3795
E3809
F1 880
E400
E4610
E3751
E3749
E3750
E3222
E3223
GS662
El 330
E2534
E3224
E3748
E3253
E1335
E1435
E4008
E4751
E4746
E4752
E4671
Cylinder base washer
...
...
Cylinder block
...
...
...
Plain washer
...
...
...
Nut
...
...
...
...
Tappet guide block
...
...
Tappet block screw ( 61 in. U.H.)
Serrated washer ...
...
Tappet
...
...
...
...
...
Valve guide ...
Valve guide ...
...
...
Valve guide circlip ...
...
Exhaust pipe adaptor
...
...
Inlet valve
...
...
...
Exhaust valve
...
...
...
...
Bottom cap
...
Inner valve spring
...
...
Outer valve spring
...
...
Top collar ...
...
...
...
...
Split cotter
...
...
Cylinder head bolt (225/32 in. U.H.)
...
Plain washer
...
...
...
Cylinder head gasket
...
Inlet rocker box
...
...
Exhaust rocker box
...
...
Joint washer
...
...
...
Rocker box stud (-6 in. O.A.)
...
...
...
Plain washer
Nut
...
...
...
...
...
Screw (+ in. U.H.)
...
Plain washer
...
...
...
Cylinder head bolt (5-h in. U.H.)
Cylinder head torque stay bolt ...
...
Oil feed bolt
...
...
...
Copper washer ...
...
...
...
...
Domed nut
...
...
Inspection cap
...
...
...
Fibre washer
...
ROCKER (right exhaust, left inlet)
ROCKER (left exhaust, right inlet)
...
Rocker ball pin
...
...
...
Rocker adjusting pin
...
Adjuster lock nut
...
...
Thrust washer, 8 in.
...
Thrust washer, ,-6 in.
...
...
...
...
...
Spring washer
...
...
...
Rocker spindle
...
...
Sealing rubber
...
...
...
Copper washer ...
...
...
...
Domed nut
...
...
...
Push rod ...
...
...
...
Cover tube
...
...
...
Bottom cup
...
...
Rubber washer ...
...
...
...
Locking spring
ClassicBike.biz
...
...
...
...
...
...
...
.,.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
8
8
2
2
2
4
I
4
4
4
2
2
2
4
4
4
4
8
4
8
1
1
1
2
4
4
4
4
4
2
2
2
6
2
4
4
2
2
4
4
4
4
6
2
2
2
2
2
4
2
2
4
4
5TA
1100
27
25
4
11
12
11
10
13
14
18
28
Fig. 6. TIMING COVER AND CONTACT BREAKER
28
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
TIMING COVER AND CONTACT BREAKER
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
8
27
29
11
29
13
14
15
E4630
E4016
D208-5
E4568
E3800
E3801
47605
425377
54441729
54415642
425359
54415751
425370
169194
54415803
E5451
S25-43
E4707
E4747
E6559
E4571
E5049
GS299
F4715
T989
47602
425377
54415473
54415641
425359
54415747
425370
169194
54415803
Timing cover ...
...
...
Patent plate
...
...
...
Hammer-drive screw ...
...
Oil seal ...
...
...
...
Screw ('—e in. U.H.)
...
...
Screw (18 in. U.H.)
...
...
CONTACT BREAKER, type 4CA
Condenser
...
...
Cam...
...
...
...
Spring set ...
...
...
Weight
...
...
...
Sleeve and action plate
ate
Base plate ...
...
...
Slotted nut...
...
...
Contact set
...
...
Bolt (2 in. U.H.)
...
...
Plain washer ...
...
...
Grommet
...
...
...
Pillar bolt
...
...
...
Plain washer ...
...
...
Cover ...
...
...
...
Joint washer ...
...
...
Serrated washer
...
...
...
Hollow dowel ...
...
...
CONTACT BREAKER, type 4CA
Condenser
...
...
Cam...
...
...
...
Spring set ...
Weight
...
...
...
Sleeve and action plate ...
Base plate ...
...
...
Slotted nut
...
...
Contact set
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
3
1
4
4
1
2
1
1
2
1
1
4
2-J
1
1
1
2
2
1
1
2
2
1
1
2
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1 A.C. Ignition
2
1
1
4
2J
I
gnition
29
ClassicBike.biz
42
33 48 45 46 47
Fig. 7. GEARBOX SHAFTS, BEARINGS AND INNER COVER
30
ClassicBike.biz
Ref. No. Port No.
DESCRIPTION
QUANTITY
REMARKS
GEARBOX SHAFTS, BEARINGS AND INNER COVER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
36
37
38
39
40
40
41
42
43
44
45
46
47
48
T665
T1478
W680
11367
T912
T981
T1606
T1607
T1947
T1405
T1948
T1391
T1922
T1411
T1965
T1949
T1839
T1950
T1393
T1426
T1471
T373
T1457
T1480
T1481
T1768
T1418
in. x I in.
T1416
i
H688
11448
T417
D208-5
T1 0
T1157
T1390
11 5
T1981
T1431
T1282
T1161
T1897
T1446
T1469
1280
T732
12009
T1464
T1 441
T1422
E3204
High gear bearing (ball journal)
Oil seal ...
Circlip ...
Layshaft bush ...
Peg
...
Blanking disc ...
Layshaft bearing
Thrust washer ...
...
MAINSHAFT HIGH GEAR (22T)
High gear bush ...
...
...
MAINSHAFT c/w THIRD AND LOW GEARS (16/24T)
Clutch rod bush ...
...
Mainshaft second gear (21T) ...
Mainshaft distance piece
...
...
...
Layshaft c/w second and high gears (15/23
Layshaft c/w second and high gears (15/23T)
Layshaft third gear (20T)
LAYSHAFT LOW GEAR (27T)
Low gear bush
Pawl retaining disc
Camplate index plunger
Index plunger spring ...
Selector fork spindle ...
Mainshaft selector fork
Layshaft selector fork
Gear selector cam plate
Camplate spindle
...
Split pin
...
...
Gear indicator pointer
Screw (* in. U.H.)
...
Inner cover
...
...
Gear indicator plate ...
Indicator plate rivet ...
Hollow dowel ...
...
Kickstarter stop plate ...
Stop plate and anchor screw
KICKSTARTER SPINDLE
KICKSTARTER SPINDLE
Kickstarter pawl ...
Plunger
...
Plunger spring
Bearing
...
Floating bush ...
...
Mainshaft bearing (Ball journal)
Circlip ...
Tab washer
Mainshaft nut
Distance piece ...
Kickstarter return spring
Return spring plate ...
...
Screw (1 in. U.H.)
ClassicBike.biz
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3TA, 5TA
3TA, 5TA
T90, TIN
T90, T100
3TA, 5TA
T90, T100
3TA, 5TA
T90, T100
T90, T100
3TA, 5TA
31
2
21
20
25
36
29 28
27 32
33 48 45 46 4/
Fig. 7. GEARBOX SHAFTS, BEARINGS AND INNER COVER
32
ClassicBike.biz
Ref No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
WIDE RATIO GEARS
(Can be fitted to T90 or T100)
9
11
13
15
16
17
11684
T1959
T1837
TI 960
11839
T1961
...
...
MAINSHAFT c/w THIRD & LOW GEAR (15/24T)
...
Mainshaft second gear (20T)
...
...
Layshaft c/w second & high gear (14/24T)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
11
1 1
1 L Standard on
1 Eastern T100 C
1
1J
CLOSE RATIO GEARS
(Can be fitted to T90 or T100)
9
11
13
15
16
17
11821
T1971
T1832
T1972
11842
11950
...
...
MAINSHAFT c/w THIRD & LOW GEAR (16/22T)
...
...
...
Mainshaft second gear (20T)
Layshaft c/w second and high gear (17/23T) ...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
1
1
33
ClassicBike.biz
35
25
26
34
32
24
33
30
A _
36
9
31
, 1
^i
8
A
J
7
10
6
2
3
23
39
22 ^
40
42
'^ I(
A
12
13
^\^
17
(q ^ O ,A ,
II
4
16
38
13
12
43
19
37
20
15
4'
Fig. $. GEARBOX OUTER COVER AND LEVERS
34
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
GEARBOX OUTER COVER AND 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
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
45
T1870
T1395
T1944
T1875
T1942
T1474
11436
11396
5/64 in. x in.
E3309
T1871
T1877
T1878
T1977
W103
T1876
T1874
T1880
T1771
11710
T1712
GS127
5/64 in. x 1 in.
T1945
T1946
11937
T1644
T2062
T2063
T1646
S1-51
S25-3
T1401
T1402
11435
T9
W932
T1677
11678
11272
S70-3
T1167
T1273
T1439
F1814
T1456
T1970
i
GEARBOX OUTER COVER
Gearchange spindle bush...
Stud (1 A in. O.A.)
...
Screw a in. O.A.)
...
GEARCHANGE QUADRANT
Spring retaining pin
Plunger spring
...
Selector plunger ...
Split pin ...
Sealing ring
...
Return spring housing
Return spring
Thrust button
Cover
...
Nut
Distance piece
Distance piece
Clutch lever
Ball, 1 in. diam.
Shaft
...
Spring ...
Plain washer
Split pin ...
Spoke ...
Connector
Nut
...
Abutment
Adaptor, short ...
...
...
Adaptor, long (For cable with short outer cover)...
Rubber cover ...
Nut
...
Plain washer ...
Screw (21 in. U.H.)
Screw (28 in. U.H.)
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 (1„ in. U.H.)
Pedal rubber ...
...
Clutch operating rod ...
Clutch operating rod ...
ClassicBike.biz
1
1
2
1
1
2
2
2
2
1
1
2
2
1
3
2
1
1
3
1
1
1
1
1
1
1
1
As required
As required
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
3TA
1
5TA, T90, T100
35
36
0
Z
}
W
U)
U
J
U
ClassicBike.biz
Co
N
10
in
00
O
`0
N
co
LO
Cl)
CN
(N
N
=
F-
U
U
w
o:
LL
Ref. No. Port No.
DESCRIPTION
QUANTITY
REMARKS
CLUTCH
1
2
3
4
5
5
6
6
7
8
9
10
11
12
13
13
14
15
16
17
18
19
19
20
20
21
22
23
24
25
T1933
T1935
T1751
T1735
T394
11442
11570
11718
T1719
TI 720
T1 040
11721
11722
T1723
T1 724
T423
T423A
T1 362
T1 363
T2156
T2159
13206/00/1
T1934
T1931
T1752
T1 560
T427
S66-1
T1045
T1046
T1047
...
...
CLUTCH COMPLETE
...
...
CLUTCH COMPLETE
...
...
...
Hub
...
...
...
...
Thrustwasher
...
...
...
Roller
...
...
...
Sprocket and housing
...
Sprocket and housing
...
Centre (Shock absorber body) ...
Centre (Shock absorber body) ...
...
...
Innerplate
...
Countersunk screw (0.417 in. U.H.)
...
Shock absorber spider ...
...
...
Driverubber (large)
Rebound rubber (small)
...
...
...
Outerplate
Screwed pin (1 19/32 in. U.H.) ...
Screwed pin (1 27/32 in. U.H.) ...
...
Driving plate (bonded) ...
...
...
Driven plate (plain)
...
...
...
Pressureplate
...
...
...
Adjusterpin
...
...
...
Nut
...
...
...
...
Springcup ...
...
...
...
Springcup ...
...
...
...
...
Spring
...
...
...
...
Spring
...
...
...
Brassnut ...
...
...
...
..
Key
...
...
...
...
Cuppedwasher
...
...
...
...
Tabwasher
...
...
...
...
...
Nut
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
20
1
1
1
1
1
6
1
3
3
1
3
3
5
5
1
1
1
3
3
3
3
3
1
1
1
3TA
5TA, T90, T100
3TA
STA, 190, T100
3TA
5TA, 190, T100
3TA
STA, T90, 1100
6 off 5TA, 190, T100
6 off STA, 190, T100
3TA
5TA, T90, T100
3TA
5TA, T90, 1100
1
37
ClassicBike.biz
1
ig. 10.
0. CHAINCASE
38
ClassicBike.biz
3
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
1
1
1
1
2
3
3
4
5
6
7
8
9
10
11
12
13
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
T1558
T1476
T1476/19
T1569
T1434
D444
D481
E3789
E3833
E3832
E3821
D358
E6283
E4152
E5977
E3811
47162
47188
E3810
S25-3
E5324
E4144
E5872
E1,509
T361
E4156
E4122
DS57
WE170
E732
NE507
E3802
E3668
E4153
E4154
T1738
T2056
E6186
T1553
E1612
E6226
Gearbox sprocket (17 teeth) ...
Gearbox sprocket nut
...
Rear chain, 1 in. x 1 in. x 102L
Rear chain, 1 in. x 1 in. x 103L
Cover plate
Oil seal ...
Joint washer ...
Countersunk screw (* in. U.H.)
Primary chain, 1 in. Duplex 78L
Chain tensioner blade ...
Tie rod
Trunnion
Stud (3* in. 0.A.)
Stator, RM 19
Stator, R.M.19
Distance piece
Plain washer
Nut
...
...
Rubber grommet
Sleeve nut
...
Clip
...
Bolt a in. U.H.)
Joint washer ...
Chaincase
...
Drain and level plug
Fibre washer
Filler plug
Fibre washer
Screw (21 in. U.H.)
Screw (1* in. U.H.)
Adjuster sleeve nut
Drain plug
Fibre washer
Tab washer
...
Crankcase protector
Screw (1 in. U.H.)
Serrated washer
Rubber plug
...
ClassicBike.biz
1
1
1
1
1
1
1
3TA, M
T100, T1
5TA, T100R
3TA, T%, T100
5TA
1
...
1
1
6
1
1
1
1
3
1
1
3
3
3
1
1
1
1
1
1
1
2
1
1
3
7
1
1
1
1
1
1
1
1
Coil Ignition
A.C. Ignition
T90, T100
3TA,5TA
39
5 4
pI
I
15
•
'I
14 7
23
13
24 25 26
34
u41 40 39 37 39 38
33
22
32
Fig. 11. ENGINE FITTINGS AND EXHAUST SYSTEM
40
ClassicBike.biz
QUANTITY
DESCRIPTION
Ref. No. Part No.
REMARKS
ENGINE FITTINGS AND EXHAUST SYSTEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
22
23
24
25
26
27
28
29
30
31
32
32
33
33
34
35
36
37
38
39
40
41
F4275
F4276
F2825
S26-1
P0172A
E3804
S26-3
S1-51
F4229
F4230
E3665
P0172A
E3695
S1-51
E4778
E5072
S1-52
F5532
E4165
E3812
F4197
E3992
E3994
E5325
E5327
E4947
E41OA
E409
F4707
F4283
DS57
E1612
F879
E3935
E4157
E3936
E4158
E4155
H689
H691
E2271
F3430
E3768
S26-3
E1310
Left front engine plate...
Right front engine plate
...
Stud (3+ in. O.A.)
...
Spring washer
...
...
...
Nut
...
Stud (3 in. O.A.)
...
Spring washer
...
...
Nut
...
Left rear engine plate
Right rear engine plate
...
Stud (44 in. O.A.)
...
...
...
Nut
...
Stud (4 61 in. O.A.)
...
...
...
Nut
...
Torque stay
...
Distance piece ...
...
...
Nut
...
...
Plain washer ...
...
Bolt (1-6 in. U.H.)
...
Stud (71-k in. O.A.)
...
Distance piece ...
...
Left exhaust pipe
...
Right exhaust pipe
...
Left exhaust pipe
...
Right exhaust pipe
...
Finned clip
...
Hemispherical washer ...
...
Bolt (1 6 in. U.H.)
...
Left bracket
...
Right bracket ...
...
...
Bolt ( 61 in. U.H.)
...
Serrated washer
Nut
...
...
...
...
Left silencer
...
Left muffler
...
...
Right silencer ...
...
Right muffler ...
...
Silencer mute ...
...
Screw (4 in. U.H.)
...
Nut
...
...
...
Clip
...
...
...
Bolt (1 2 in. U.H.)
...
"D" washer
...
...
Spring washer ...
...
Nut
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..•
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
8
2
3
8
3
1
1
1
4
2
5
2
2
2
2
1
1
2
5TA, T100
1
5TA, T100
1
3TA, T90
1
1
3TA, T90
2
2
2
1
1
2
2
2
1
T100R
1
1
I
T100R
As required
As required
As required
2
2
4
22
41
ClassicBike.biz
9
13
12
21
Fig. 12. EXHAUST PIPES, UNDERSHIELD AND FOOTPEGS (T100C)
42
ClassicBike.biz
10 11
Ref. No.
Port No.
DESCRIPTION
QUANTITY
REMARKS
EXHAUST PIPES, UNDERSHIELD AND FOOTPEGS (TIOOC)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E4513
E4514
E5874
F3430
E3768
S26-3
E1310
E3470
H426
S26-1
S1-51
F4852
F1700
F3078
F1369
S26-2
F879
F7018
F7019
F6411
F6655
Left Exhaust pipe ...
Right exhaust pipe
Clip
Bolt
...
"D" Washer
Spring Washer
...
Nut
Muffler
...
Bolt (H in. U.H.) ...
Spring washer
Nut
Undershield
Clip
Bracket
Bolt (I in. U.H.)
Spring washer
Nut
...
LEFT FOLDING FOOTPEG
RIGHT FOLDING FOOTPEG
...
Pedal ...
Pivot bolt
1
1
1
1
2
1
1
1
1
1
1
1
2
1
4
4
4
1
2
2
2
43
ClassicBike.biz
19
Fig. 13. FRAME
44
ClassicBike.biz
Ref No. Port No.
DESCRIPTION
REMARKS
QUANTITY
FRAME
1
2
3
4
5
6
7
8
9
10
11
12
13
13
14
15
16
17
18
19
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
F6912
H1130
S70-4
H1140
NW100
WE170
F6913
F2842
S26-1
S1-52
F3780
PCW73A
F4891
F5153
T449
F3619
F4484
F2725
F3617
F5539
F3723
F3097
F3096
F2610
F4214
F4215
NF704
F4369
F4370
DS47
F5087
F5088
DS58
S26-3
F1149
F879
F5552
F2268
F5535
S26-1
F1694
F2271
F2277
51-51
F1695
F4284
SCZ45
DS48
F4314
S26-16
S25-2
S1-52
Front frame
...
...
...
Steering race cup
...
...
Steel ball („ in. U.H.)
...
Top cone and dust cover
...
Grease nipple ...
...
...
Fibre washer ...
...
...
Rear frame
...
...
...
Stud (41 in. O.A.)
...
...
Spring washer
...
...
Nut
...
...
...
...
Bolt (1,!, in. U.H.)
...
...
Spring washer
...
...
Centre stand ...
...
...
Centre stand ...
...
...
Pedal rubber ...
...
...
Pivot bolt (1 a in. U.H.)
...
Tab washer
...
...
...
Nut
...
...
...
...
Return spring ...
...
...
Prop stand
...
...
...
Prop stand
...
...
...
Pivot bolt
...
...
...
Tab washer
...
...
...
...
...
Return spring ...
...
...
Left footrest ...
...
Right footrest ...
...
...
...
Pedal rubber ...
Bolt (2-6 in. U.H.)
...
...
...
Plain washer ...
...
...
Nut
...
...
...
Left pillion footrest support ...
Right pillion footrest support
...
...
Bolt (j' in. U.H.)
...
Spring washer
...
Pedal stop screw (r in. U.H.)
...
...
...
Nut
...
...
PILLION FOOTREST ...
...
Footrest hanger ...
...
Bolt (ff in. U.H.) ...
...
Spring washer
...
.•.
.•.
Pedal
...
...
...
Pivot bolt ...
...
...
Spring washer
...
...
...
Nut
...
...
Pedal rubber
...
Brake pedal spindle ...
...
...
Spring washer
...
...
...
Nut
...
...
...
...
Brake pedal
...
...
Spring washer
...
••.
Plain washer ...
...
...
...
...
Nut
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
••.
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
48
1
1
1
1
1
2
2
2
2
1
1
I
2
2
2
1
1
1
1
1
1
1
1
2
2
2
2
1
1
4
4
1
1
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
I
T100R
T1000, T100R
45
46
•
ClassicBike.biz
0
w
4
3
0
Z
R
I
U
C
z
4
i
3
Z
0
Z
W
N
3
w
K
0
LL
0
Z
z
5
LL
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
SWINGING FORK, SUSPENSION UNITS AND CHAINGUARD
1
2
3
4
5
5
6
7
8
9
9
10
11
12
13
14
14
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
F6936
F4076
F4195
F4078
F4385
F4386
F3797
F4196
F3799
64053946
64054164
9054/316A
9054/171
9054/151
9054/47
64539963
9054/277
SA253/5
E2113
F2184
S26-1
P0172A
F5409
DS57
S26-2
F4134
F4135
F2377
S25-13
E5269
F4136
S25-3
S1-51
F4199
W840
E2288
DS47
PCW73A
F3597
,!, in. x e in.
F4585
F4201
F6046
31383
T1076
F4717
F5687
3/32in. x'— in.
F5413
...
SWINGING FORK ...
...
...
Pivot bush
...
...
...
Spindle ...
...
...
Spacing washer ...
...
...
Shim 0.003 in. ...
...
...
Shim 0.005 in. ...
...
...
Retainer rod ...
...
...
...
Cap
...
...
...
...
Nut
...
...
SUSPENSION UNIT ...
...
SUSPENSION UNIT ...
...
...
Bonded bush
...
Spring retainer ...
...
Outer dirt shield
...
...
Inner dirt shield
Spring, 130 lbs. Red/Orange
...
Spring, 110 lbs. Red/Red
...
Spring, 145 lbs. Blue/Yellow
Unit fixing bolt (1 6 in. U.H.)
...
...
Plain washer
...
...
...
Spring washer
...
...
...
Nut
...
...
...
Upper chainguard
...
...
Bolt (, 6 in. U.H.)
...
...
Spring washer
...
...
Front bracket ...
...
...
...
Pivot bolt
...
...
Spring washer
...
...
Plain washer ...
...
..
...
...
Nut
...
...
Stepped bolt ...
...
...
Plain washer ...
...
...
...
...
Nut
...
...
Lower chainguard
...
Bolt (17/32 in. U.H.) ...
...
...
Serrated washer
...
...
...
...
Nut
...
...
Spring washer
...
Brake operating rod ...
...
...
...
Split pin
...
...
Adjuster nut ...
...
...
Brake torque stay
...
...
Front chainguard
Stop lamp switch, type 22 B
...
...
Bolt (e in. U.H.)
...
...
Self locking nut
...
...
...
...
Lever
...
...
...
Split pin
...
...
...
"D" washer
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
1
1
as required
as required
1
2
2
2
2
T1000, T100R
4
4
2
2
2
as required
as required
4
2
2
2
1
1
1
1
1
1
2
1
1
1
1
3TA, 5TA
1
1
1
1
1
1
1
1
T90, 1100
1
1
1
3
5
1
1
47
ClassicBike.biz
12
FORK ASSEMBLY REF. N91
Fig. 15. TELESCOPIC FRONT FORK, 3TA AND STA
48
ClassicBike.biz
10
39
Ref. No.
Part No.
DESCRIPTION
QUANTITY
TELESCOPIC FRONT FORK, 3TA AND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
H2014
H1328
H1110
H941
S25-2
H1335
H1667
H1141
H1108
F1760
H379
H1290
H1291
F4047
H1916
H1745
H1891
H1656
H1654
H1500
H431
H441
H1896
H1890
H443
H1058
H1659
H519A
H1842
H1843
H1844
S26-3
H1070
H1071
H430
H1499
H1063
H1062
H660
S25-3
E1310
FORK ASSEMBLY
...
Middle lug and stem
...
Bottom cone ...
Pinch bolt (21 in. U.H.)
Plain washer
Nut (21 in. 0.A.) ...
...
Distance piece
Fork stem sleeve nut
Top lug
...
Pinch bolt (1* in. U.H.)
...
Seated nut ...
Left nacelle cover
Right nacelle cover
Cork washer ...
Upper cover tube
Plain washer
Main spring (Yellow/Blue) ...
...
...
Plain washer
DUST EXCLUDER SLEEVE NUT
Oil seal ...
Plain washer
Top bearing ...
Damping sleeve
STANCHION c/w BEARING
...
Lower bearing ...
Bearing nut
Cap nut
..
...
Oil filler plug (* in. U.H.)
LEFT BOTTOM MEMBER c/w CAP
RIGHT BOTTOM MEMBER c/w CAP
...
Spindle cap
Spring washer
Cap bolt (1 61 in. U.H.)
Drain plug ...
Fibre washer ...
...
...
Restrictor
Flanged bolt (23/32 in. U.H.)
Aluminium washer ...
Handlebar "U" bolt
...
Plain washer
Nut
REMARKS
5TA
1
1
1
2
2
2
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
2
4
4
2
4
2
2
2
2
4
4
49
ClassicBike.biz
31
50
2
10
9
8
17
m
8
4
18
16
7
HEADLAMP
ASSEMBLY
,:
REF.Ne12
•ir
r^
^,
m
I
I
I
i
19
9
13
i
20
14
24
or
jLI
C
4
01
r^'
(r
Z7^
Fig. 16. NACELLE, HEADLAMP AND SWITCHES
50
ClassicBike.biz
P!L
Ref. No.
DESCRIPTION
Part No.
QUANTITY
REMARKS
NACELLE, HEADLAMP AND SWITCHES
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
H1781
H961
H669
H877
H878
H689
H687
H688
E2880
H691
H690
59176
553248
516812
504665
553267
144921
534296
414
554602
222
554710
34427
54336176
54336178
34289
54330934
54330576
54930007
54930008
36296
H992
F4129
GS299
F3799
H1420
70164
F4771
54938942
F5983
F5988
54942078
54190042
900269
900288
850641
850844
850832
H1938
H1421
Nacelle top
...
...
...
...
...
Rubber grommet ...
...
...
...
...
Rubber grommet ...
...
...
...
...
Left motif ...
...
...
...
...
...
Right motif
...
...
...
...
...
Screw (+ in. U.H.)
...
...
...
...
Screw (a in. U.H.)
...
...
...
...
Screw (. in. U.H.)
...
...
...
...
Serrated washer ...
...
...
...
...
Nut
...
...
...
...
...
...
Nut
...
...
...
...
...
...
HEADLAMP
...
...
...
...
...
Rim ...
...
...
...
...
...
Light unit
...
...
...
...
...
Fixing wire ...
...
...
...
...
Fixing ring ...
...
...
...
...
Screw ...
...
...
...
...
...
Plate ...
...
...
...
...
...
Bulb (50/40 W. L.H. Dipping. Pre-focus) ...
Adaptor
...
...
...
...
...
Bulb (4W.M.C.C.) ...
...
...
...
Pilot bulbholder
...
...
...
...
IGNITION SWITCH c/w KEY, type 88SA ...
Ignition key
...
...
...
...
Ignition switch cover
...
...
...
...
Lighting switch, type 88SA
...
...
Knob c/w screw ...
...
...
...
Switch bezel plate
...
...
Replacement harness socket (Lighting)
...
Replacement harness socket (Ignition)
...
Ammeter, type 2AR
...
Horn grille
...
..
...
...
...
Screw (0.435 in. U.H.) ...
...
Serrated washer ...
...
...
Nut
...
...
Horn bracket
...
...
...
...
...
Horn type 8H
...
Bolt (fz in. U.H.) ...
Wiring harness ..
Bracket
...
...
...
...
...
Rubber band
...
Lucar connector ...
...
...
...
Insulating cover ...
Snap connector terminal
...
...
...
Single snap connector ...
Double snap connector
...
...
...
Triple snap connector ...
Quintuple snap connector
...
...
Blind grommet ...
...
...
Rubber grommet ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
„_
...
...
...
...
...
..
...
1
1
2
1
1
4
2
2
4
4
1
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
2
as required
as required
1
1
2
4
2
1
1
2
1
2
2
2
2
as required
as required
as required
as required
as required
2
1
51
ClassicBike.biz
Fig. 17. TELESCOPIC FRONT FORK, T90
AND T100
52
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
TELESCOPIC FRONT FORK, T90 AND T100
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
H1918
H1 328
H1110
H941
S25-2
H1335
H405
H1287
HSO6
S25-3
H1 340
F1760
H379
H1888
H1 887
F4047
H1657
H1891
H1656
H1645
D340
H1654
H1500
H431
H441
H1896
H1889
H443
H1058
H1658
H1842
H1843
H1 844
S26-3
H1070
H1071
H430
H1499
H1063
H1062
H1142
H565
H408
H1286
H95
H1111A
H435
H1618
F3468
S1-51
FORK ASSEMBLY
..
..
...
Middle lug and stem
...
...
Bottom cone ...
...
...
...
...
Pinch bolt (24 in. U.H.)
...
Plain washer
...
...
...
...
...
Nut (28 in. O.A.) ...
...
...
Fork stem sleeve nut
...
TOP LUG c/w CAPS
Handlebar cap ...
...
...
...
...
Plain washer ...
...
...
Bolt (1'–a in. U.H.)
...
Pinch bolt (1 ;6 in. U.H.) ...
...
Seated nut ...
...
...
...
Left cover
...
...
...
...
...
Right cover ...
...
...
...
Cork washer
...
...
...
...
Spring abutment
...
Main spring (Yellow/Blue)
...
...
...
Plain washer
...
...
...
Telescopic gaiter
...
...
...
...
Clip ...
DUST EXCLUDER SLEEVE NUT
...
...
...
Oil seal ...
...
...
...
Plain washer
...
...
...
Top bearing ...
...
...
...
Damping sleeve
...
STANCHION c/w BEARING
...
...
Lower bearing ...
...
...
...
Bearing nut
...
...
...
Cap nut
...
LEFT BOTTOM MEMBER c/w CAP
RIGHT BOTTOM MEMBER c/w CAP
...
...
...
Spindle cap
...
...
Spring washer
...
...
Bolt (1 -6 in. U.H.)
...
...
...
Drain plug ...
...
...
...
Fibre washer ...
...
...
...
...
Restrictor
...
Flanged bolt (23/32 in. U.H.)
...
...
Aluminium washer ...
...
...
Steering damper rod
...
...
...
Plain washer
...
...
...
Adjuster sleeve
...
...
...
Locating pin ...
...
...
...
Spring plate ...
...
...
...
Anchor plate
...
...
...
Friction disc ...
...
...
...
Rubber sleeve
...
...
...
Bolt (2 ,'a in. U.H.) ...
...
...
...
...
...
Nut
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
....
...
...
...
1 incl. U.S.A. Western T1000
1
1
2
2
2
1
1
2
4
4
1
1
1
1
2
2
2
2
2
4
2
2
2
2
2
2
2
2
2
1
1
2
4
4
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
53
ClassicBike.biz
12
14
15
Fig. 18. TELESCOPIC FRONT FORK, U.S.A. EASTERN TING
54
ClassicBike.biz
Ref. No.
DESCRIPTION
Part No.
TELESCOPIC FRONT FORK,
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
H2015
H1328
H1287
HSO6
S25-3
H1340
H1696
H1892
H1913
H1893
H1897
H1764
H454
H452
F879
H1761
T224
H1762
FORK ASSEMBLY
—
Middle lug and stem...
TOP LUG c/w CAPS
,..
Cap
...
Plain washer
...
Bolt (11 in. U.N.)
Top cover
...
...
Main spring (yellow/green)
DAMPER ASSEMBLY
Restrictor body...
Rod
Cup
Pin
Oil restrictor
Nut
...
Restrictor body cap
Nut
Cap nut
QUANTITY
REMARKS
U.S.A. EASTERN T100C
1
1
1
2
4
4
..:
As required
...
...
...
...
•••
...
...
...
•••
2
2
2
2
2
2
2
2
2
4
2
All other parts as page 53.
55
ClassicBike.biz
56
0
z
W
J
x
W
N
N _
ClassicBike.biz
^
^\
O
00
U-
Ref. No.
Part No.
DESCRIPTION
QUANTITY
R EM AR KS
FRONT WHEEL
1
1
2
2
3
3
4
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
33
W1665
W1 664
W1229
W1370
W1230
W1373
W1236
W1497
S79-2
W1231
W1641
W653
W1237
T280
W1481
W1474
W1238
W582
W1334
W1197
W1198
W1301
W1639
S25-2
S1-52
W1406
W1407
NW243
W129
W1415
W135
W1243
W1331
S25-6
W592
W1246
W1640
W1711
FRONT WHEEL COMPLETE
FRONT WHEEL COMPLETE
...
...
RIM, SPOKES AND HUB ASSEMBLY
Front wheel rim (WM2-19)
Front wheel rim (WM2-18)
Spoke (8/10G x 6 in. straight) c/w nipple
Spoke (8/10G x 51 in. straight) c/w nipple
Spoke nipple ...
...
Hub and brake drum
Wheel spindle
Bearing
...
Dust cover
Circlip
...
Grease retainer ...
...
Grease retainer (Brake side)
Backing ring
...
Retaining ring
...
Cover plate
...
Balance weight, + oz.
Balance weight, 1 oz.
Brake anchor plate
Fulcrum pin
Plain washer
...
...
Nut
...
LEADING BRAKE SHOE C/W LINING
TRAILING BRAKE SHOE C/W LINING
Brake lining ...
Brass rivet ...
Thrust pad ...
Shoe return spring
Brake cam
...
Brake cam lever ...
...
Plain washer
Lever return spring
Anchor plate nut
Abutment (-- in. deep) ...
Abutment (* in. deep) ...
1
T100R, T1
1
1
T100R, T100C
1
1
T100R, T100C
1
40
T100R, T100C
40
40
1
1
2
1
1
1
1
1
1
1
as required
as required
1
1
1
2
1
1
2
16
2
2
1
1
1
1
1
as required
as required
57
ClassicBike.biz
58
LO
Cl)
ClassicBike.biz
v
U.
Ref No. Part No.
DESCRIPTION
QUANTITY
REMARKS
REAR WHEEL
1
1
2
2
3
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
46
W1741
W1742
W1470
W1486
W1471
W1007
W1107
W1108
S79-2
W1472
W1499
W1500
E1612
W1498
W1690
W1691
W1281
W1474
W1654
W1022
W653
W1021
W1710
W1278
W1024
W1112
W1282
W1406
W1407
NW243
W129
W1415
W135
W1083
W1466
W1467
S25-6
SI-52
W1090
W1635
W1476
W1477
D373
W1280
W1134
W1015
W1058
F1747
D106
WM3
REAR WHEEL COMPLETE
...
...
...
REAR WHEEL COMPLETE
...
...
...
RIM, SPOKES AND HUB ASSEMBLY ...
RIM, SPOKES AND HUB ASSEMBLY ...
Rear wheel rim WM2-18 ......
...
Rear wheel rim WM3-18
...
...
0
Spoke (8/10G x 7,s in. 90 ) c/w nipple
Spoke (8/10G x 78 in. 90°) c/w nipple
Spoke nipple ...
...
...
...
Hub
...
...
...
...
...
Sprocket, 46T ...
...
...
...
Bolt
...
...
...
...
...
Serrated washer
...
...
...
Brake drum
...
...
...
...
Bolt (16 in. U.H.)
...
...
...
Self locking nut
...
...
...
Wheel spindle ...
...
...
...
Grease retainer (brake side) ...
...
Grease retainer
...
...
...
Backing ring
...
...
...
...
Bearing ...
...
...
...
...
RETAINING RING .
...
Locking screw (,6 in. U.H.)
...
Distance tube ...
...
...
...
Distance piece ...
...
...
...
Brake anchor plate
...
...
...
Nut
...
...
...
...
...
Brake lining
...
...
...
Brass rivet ...
...
...
...
Thrust pad
...
...
...
Shoe return spring
...
...
...
Brake cam
...
...
...
...
Brake cam lever
...
...
...
Pivot pin...
...
...
...
...
Plain washer ...
...
...
...
Nut
...
...
...
...
...
Lever return spring ...
...
...
Grease retainer
...
...
...
Speedometer adaptor
...
...
Distance piece ...
...
...
...
Speedometer gearbox ...
...
...
Plain washer
...
...
...
...
Chain adjuster
...
...
...
...
Adjuster end plate
...
...
...
...
Self-locking nut ...
...
...
...
...
...
Spindle nut
...
...
...
...
...
Tyre security bolt...
...
...
...
...
Tyre security bolt...
...
...
...
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
I
1
1
20
20
40
1
1
8
8
1
8
8
1
1
1
1
2
1
1
1
1
1
1
1
1
2
16
2
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
3
2
2
T100R, T1000
T100R, T1000
T100R, T1000
T100R, T1000
59
0
N
0
0
1
*
ClassicBike.biz
.
014
* 4,v
1
r
tipoiTi i ii4....a
Ref. No. Part No.
DESCRIPTION
REMARKS
QUANTITY
QUICKLY DETACHABLE REAR WHEEL (NOT U.S.A.)
1
1
2
2
3
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
47
W1746
W1745
W1747
W1603
W1471
W1007
W1107
W1108
S79-2
W1593
W1595
W1509
S35-7
W1596
W1614
W1598
W1635
W1599
W1477
W1280
W1282
W1040
W1143
W1041
W1042
W1043
W1044
W1045
W1121
W1406
W1407
NW243
W129
W1415
W135
W1083
W1466
W1467
S1-52
W1090
W1052
W1392
W1170
W1055
W1091
D373
W1135
W1015
W1058
D106
WM3
Q.D. REAR WHEEL COMPLETE ...
Q.D. REAR WHEEL COMPLETE ...
...
Rear wheel rim WM2-18 ...
Rear wheel rim WM3-18 ...
...
Spoke (8/10G x 7* in.90°) c/w nipple
Spoke (8/10G x 78 in.90°) c/w nipple
Spoke nipple ...
Hub ...
Grease retainer
Backing ring
Bearing
...
Dust cap ...
Bearing sleeve
Distance piece (inner) ...
Grease retainer ...
Speedometer adaptor
Distance piece (outer)
Plain washer
Nut
Sprocket and brake drum 46T
Grease retainer
...
Bearing
Felt washer
Bearing and felt retainer
Circlip
...
Bearing sleeve
...
Brake anchor plate
Brake lining ...
Brass rivet ...
Thrust pad ...
Shoe return spring
Brake cam
Brake cam lever ...
Pivot pin ...
Nut
...
Lever return spring
...
...
Nut
Inner distance piece
Outer distance piece
...
...
Spindle
Rubber sealing ring
Speedometer gearbox
Chain adjuster ...
Adjuster end plate
Self-locking nut
Tyre security bolt
Tyre security bolt
1
1
1
1
1
1
20
20
40
1
2
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
16
2
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
T100R, T100C
T100R, T100C
T100R, T100C
T100R, T100C
61
ClassicBike.biz
I-
23
19
I
18
17
4
5
6
2;
2^
q
19 18 17
13
16
19 29
X36
F7
34 38 17
15
-;-
\1202314
3-
o =
od
21
31
i
--
C
19 36
35
^
_
12 11
al
39
o
®^
30
^!
32
33
•
°
37
17
28 36
19
Fig. 22. MUDGUARDS (STANDARD)
62
ClassicBike.biz
35
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REM ARKS
MUDGUARDS (STANDARD)
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
H1901
F929
F4299
H1964
H1100
NS362
H1675
W62
S25-2
H1482
H424
S25-71
H1681
H1685
H1683
WE170
DS57
S25-1
F879
T224
DS55
F1369
F6469
F6470
H741
H687
H745
F5984
F6915
F5424
F5994
F6031
S26-3
F6916
S1-51
S26-2
F5924
F6310
H590
Front mudguard
Bolt (I in. U.H.)
Plain washer
Front stay .:.
Bottom stay
Spigot nut
Mudguard blade
Bolt
...
...,
Plain washer
Bottom stay
Bolt (39/64 in. U.H.)
Plain washer
...
Front stay ...
Bracket
...
...
Mudguard bridge
Fibre washer
...
Bolt ( in. U.H.) ...
Plain washer
...
Nut
Nut
Bolt (+ in. U.H.) ...
Bolt (I in. U.H.) ...
Number plate
...
Number plate
...
Clip assembly
...
Screw (I in. U.H.)...
Nut
...
Mudguard blade ...
Mudguard bridge
Lifting handle
Clip
...
Backing plate
Spring washer
Bracket
...
Nut
...
Spring washer
Number plate
...
Plain washer
Bolt (* in. U.H.) ...
...
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
1
5
4
2
1
1
1
2
2
1
2
2
2
1
2
10
6
17
2
2
2
1
1
2
2
2
1
1
1
1
1
9
1
3
10
3TA, 5TA
3TA, 5TA
T90, T1M
3TA, 5TA
3TA, 5TA
flO, T1W
T90, T1W
190, T100
T90, T100
3TA, 5TA
3TA, 5TA
190, T100
1
4
2
63
ClassicBike.biz
2
16
^
^
1
3
11 8
9.
12
•
•
2ir
9
°9
5
16
32
20 24
19
Fig. 23. FENDERS (U.S.A.)
64
ClassicBike.biz
18
19
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
FENDERS ( U.S.A.)
1
1
2
3
4
5
6
7
8
9
10
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
H1677
H1687
H1681
H1683
H1678
H1273
H1685
H1688
F929
F4299
DS55
T224
S1-51
NS362
H424
S25-71
DS57
WE170
S25-1
F879
F6965
F6966
F6915
F5424
F6916
S26-2
S26-3
H590
F5994
F6031
F6310
F6847
F6849
F6850
E2980
F4715
Front fender
...
Front fender (aluminium)
Front stay ...
Centre bridge
Bottom stay
Bottom stay
Bracket
...
Bracket
...
Bolt (1 in. U.H.) ...
Plain washer
...
Bolt (* in. U.H.) ...
Nut
Nut
Spigot nut
Bolt
...
Plain washer
Bolt (* in. U.H.) ...
Fibre washer
...
Plain washer
Nut
...
Rear fender
Rear fender (aluminium)
Fender bridge
Lifting handle
Bracket
...
Spring washer
Spring washer
Bolt (* in. U.H.) ...
Clip
...
Backing place
...
Plain washer
Tail lamp adapter ...
Tail lamp plate
...
Number plate bracket
Stud (H- in. 0.A.) ...
Screw (AI in. U.H.)
•••
•••
•••
•••
1
1
1
1
1
1
2
2
5
5
2
2
4
1
2
2
10
4
13
13
1
1
1
1
1
2
5
2
1
1
1
1
1
1
1
3
T100R, Eastern T100C
Western T100C
Western T100C
Western T100C
Western T100C
65
ClassicBike.biz
3
13 12 10
8
11
14
15
6
9
16
30--
-19
23
24
7,,
17
lil
Il
^ lli ,
28
27
Fig. 24. PANELS AND TWINSEAT
66
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
PANELS AND TWINSEAT
1
2
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
17
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
F6964
F6947
F6948
F6949
F6950
F4317
E1612
13104/00/2
15104/00/2
F6931
F1369
F5466
F5976
11104/06/2
S26-2
F879
S25-43
H961
F4239
F4360A
F4244
F4244A
F4475
F4898
F4222
DS57
S26-2
D374
F4483
F4226
F4228
E1719A
* in. x 1 in.
F6659
F4361
F4365
Left panel ..
Motif "Twenty-One"
Motif "Tiger 90" ...
Motif "Tiger 100"
Motif "Speed Twin"
Spire nut ..
Serrated washer
Nut
..
Self-locking nut
Switch p ane
Bolt (I in. U.H.)
Grommet ..
Link
...
Bolt (I in. U.H.)
Spring washer
Nut
...
Washer
...
Grommet ...
...
TWINSEAT (GREY TOP)
TWINSEAT (BLACK TOP)
...
...
...
Twin seat cover c/w clips (GREY TOP) ...
Twinseat cover c/w clips (BLACK TOP) ...
Clip ...
Rubber buffer
Hinge
...
...
Bolt (,s in. U.H.) ...
Spring washer
...
Check wire
...
Self tapping screw
Seat catch plunger
Spring
...
Plain washer
Split pin
Knob
Safety strap
Self tapping screw
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
••
...
.••
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
2
2
4
2
2
1
1
1
2
1
1
1
1
1
3
1
1
1
1
3TA, 5TA
T90, T100
Eastern T100C
Eastern T100C
As required
2
2
4
4
1
1
1
1
1
1
1
1
Western T100C,T1OOR
4
67
21
23
8
9
1
•
,
l
17 -
18 -^
,
;O
..
2
19 -
20
E--3
22
13
29
g
12
I
16
11
I/If
^ -15
27
69
ClassicBike.biz
26
Ref. No.
DESCRIPTION
Part No.
QUANTITY
REMARKS
PETROL ( GAS) TANKS
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
F7001
F6887
F4129
F6888
F5401
F5402
F6313
F4019
H919
F1717
F6143
F6144
F6145
S26-3
S1-51
F6535
F5228
F5229
F3814
F1808
F3220
F3219
F4048
F4971
F4972
F1511
F7002
F1606
F1605
F4108
S26-2
F6958
F3917
F2936
F4384
Petrol tank (3 gallons) ...
Styling unit (left)
•••
Styling unit screw (0.435 in. U.H.)
Styling unit (right)
Left knee grip
...
Right knee grip ...
Centre styling strip
Serrated washer
Nut
...
Petrol tap ...
Tank bracket
Saddle
'U' bolt ...
Spring washer
Nut
...
'T' head bolt
Rubber washer
Spigot rubber
Cup
Bolt
...
FILLER CAP
...
FILLER CAP c/w JACK CHAIN
Joint washer
Petrol tap (left)
Petrol tap with reserve tube
Fibre washer
...
...
Petrol tank (21 U.S. gallons)
Left knee grip
Right knee grip
Rubber washer
Spring washer
Tank bracket
Parcel grid
Screw
...
...
Rubber blanking plug
1
1
4
3TA, 5TA
T90, T100
2J
1
1
4
4
2
4
4 3TA, 5TA, 190, T100
4
4
1
1
11
1
1
2
1 T100C, T100R
1
1
4
4
21
1
A
69
ClassicBike.biz
c
437 19 1
5
4
7
6
9
8
11
10
Fig. 26. OIL TANK
70
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
OIL TANK
1
2
3
4
S
6
7
8
9
10
11
12
13
14
15
16
17
18
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
F6877
F3216A
F4047
F5343
PT104B
F3179
F1713
F6103
F3182
E3353
E5473
E5434
E3763
E3446
E1310
E6356
E5370
E5376
E5376
F3098
F6892
*F6894
F6673
F6968
11104/06/2
15104/00/2
F6511
F6874
F6672
S25-13
F879
E6353
E6351
F6898
F6039
E6355
E6354
€6357
F6970
MF119
Oil tank
...
FILLER CAP
...
Joint washer
Drain plug
Fibre washer
Oil tank filter
Fibre washer
Upper feed pipe
Union nut
Flexible connector, long ...
Clip
...
...
Oil pipes and junction block
Joint washer
Plain washer
Nut
Vent pipe
"T" piece ...
Extension pipe
Extension pipe
Clip
...
Front strap
Rear strap
Spigot rubber
Rubber washer
Bolt (1 in. U.H.)
Self locking nut
Metering screw
Coil spring
Screwed peg
Plain washer
Nut
...
...
Rubber connector
Rocker oil feed pipe
Bracket
...
Grommet ...
Flexible pipe
Chain oiler pipe
Flexible pipe
...
...
...
Clip
Flexible connector, short
...
...
...
...
...
...
...
...
...
1
1
1
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
2
1
1
4
2
2
2
1
1
2
4
2
1
1
1
1
1
1
1
1
1
* See page 73
71
ClassicBike.biz
8
b
2
fD
9
10
^
^
5
rb}- 11
4
6
D
35
^
34
32
33 "'
n ^1
j
18
17
3
V
p
S
r' 13
16
14
3
S
r
26
23
21
24
20
19
28
^:
27
29
30
Fig. 27. BATTERY, TOOLKIT AND AIR FILTER
72
ClassicBike.biz
1
37
22
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
BATTERY, TOOLKIT AND AIR FILTER
1
Battery carrier
1
*F6891
2
Retainer
2
*F6897
4
Rubber
*E6226
3
3
Plain
washer
4
525-1
4
Nut
...
5
F879
Battery
6
*PUZ5A
1
Battery carrier lining
7
*F6969
1
Tool tray
8
F6901
2
Bolt (e in. U.H.)
9
F1369
2
...
Plain washer
10
F7128
•••
Plain washer
...
11
S25-13
••• 1
...
TOOL KIT
12
D 44 6
•••
in. whit.
Open spanner, e in. x
D360
13
•••
Open spanner, a in. x in. whit.
14
NA55
Open spanner, I in. x *in. whit.
15
DA16
Ring spanner, *in. x in. whit.
16
D370
Ring spanner, 2 in. x in. whit.
PA57
17
Ring spanner, I in. x16 in. whit.
D311
18
1
Box spanner, spark plug ...
D87
19
1
Tyre lever and tommy bar
20
D363
1
Tyre lever and clutch key
D364
21
1
"C" spanner and tappet key
22
D362
1
Phillips No. 3 screwdriver
23
D336
1
Ignition screwdriver and feeler gauge
400935
24
1
Tool roll ...
WA58
25
as required
Clutch hub extractor ...
DA50/1
26
as required
Fork spanner (for sleeve nut)
D527
27
as required
Fork spanner (for cap nut) ...
D220
28
as required
Contact breaker extractor ...
D484
29
as required
Contact breaker assembly pilot
D486
3Q
1
Tyre inflator ...
D296
31
1
Inflator top bracket
F5432
32
1
Bolt (1 in. U.H.)
F1369
33
1
...
Plain washer
S25-43
34
1
Nut
...
S1-40
35
1
Inflator bottom bracket
F5433
36
1
...
Plain washer
S25-3
37
3TA, 5TA
1
Adaptor ...
E5194
38
T90,
T100
4
Adaptor ...
F4812
38
1
...
F5625
Clip
39
1
AIR FILTER
F6430
40
1
Filter element (felt)
F4811
41
1 U.S.A. models
...
AIR FILTER
F6433
40
1 U.S.A. models
•••
...
Filter
element
(paper)
F5694
41
These
are
interchangeable
as
a
group
but
the
following
part numbers
have
two
6
volt
batteries.
*Some early models
Illustrated)
apply to this condition (Not
use MK E (2 off)
Battery
PUZ5A
use F7083
Battery carrier
F6891
use F7086
Rear strap
F6894
use F7085 (1 off)
Retainer
F6897
use F7045 (3 off)
Rubber
E6226
Rubber (between batteries) use F7046 (2 off)
use F7087
Battery carrier lining
F6969
73
*
*
ClassicBike.biz
N
N
74
10
N
N
N
(
v
1
N
i' N
r
rT
i^f
ClassicBike.biz
-
i
N 00
N
to
M
0'
W
W
J
J
0
IFz
0
u
G
z
a
a
W
c
z
a
0_0
N
W
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
HANDLEBARS AND CONTROL LEVERS
1
1
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
H1871
H1872
H1519
Handlebar
Handlebar
...
American handlebar
H1873
H1425
16/362
16/328
16/329
16/091
16/008
16/009
16/010
11/014
366/012
16/011
18/999
18/535
18/1013
12/595
11/014
18/087
18/053
18/1005
18/1006
18/1000
18/528
18/1009
12/595
11/014
18/087
18/053
18/1005
18/1006
31563
380459
H1876
366/011
18/951
18/754
18/777
18/838
18/839
18/952
18/752
18/773
American handlebar
Packing piece ...
TWISTGRIP ...
Body top half
...
Body bottom half ...
Rotor
...
Friction spring
Friction spring screw
Nut
Screw
...
Handlebar grip
Cable stop
FRONT BRAKE LEVER ASSEMBLY
Brake lever
...
Brake lever bracket
Clamp
...
Screw
...
Fulcrum screw
Self-locking nut
Cable adjuster
Thumb nut
...
CLUTCH LEVER ASSEMBLY
Clutch lever
...
Clutch lever bracket
Clamp
...
Screw
Fulcrum screw
Self-locking nut
Cable adjuster
Thumb nut
...
Horn push and dip switch
Backing rubber
...
Screw (1 in. U.H.)
...
...
Handlebar grip ...
...
...
...
FRONT BRAKE LEVER ASSEMBLY (Ball-end)
Brake lever (Ball-end)
Brake lever bracket
Cable adjuster
Thumb nut
...
...
...
CLUTCH LEVER ASSEMBLY (Ball-end))
Clutch lever (Ball-end) ...
Clutch lever bracket ...
1
1
1
1
3TA, STA
T90, T100
T100C
T100R
4
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
11 1
1
1 T100C,
T1OOR
1
1
1
1_
75
ClassicBike.biz
C
76
ClassicBike.biz
w
W
J
Q
u
J
0
H
z
0
U
Co
P
LL
W.
No.
Port. No.
DESCRIPTION
QUANTITY
REMARKS
CONTROL CABLES
1
2
3
4
5
6
7
7
8
9
10
11
12
13
13
14
15
16
17
D495
D101
D83
D104
6/132A
NS191
D561
D560
D103
D506
W593
WF32
in. x I in.
D566
D565
D103
D506
DS73
XA69
*
THROTTLE CABLE ...
Ferrule
Nipple
Adjuster
Ferrule
...
...
Nipple
FRONT BRAKE CABLE
FRONT BRAKE CABLE
Ferrule
Nipple
Fork end
Pivot pin...
...
Split pin ...
...
CLUTCH CABLE
AMERICAN CLUTCH CABLE
Ferrule
...
Nipple
Nipple
Cable clip
1
3
1
1
1
1
1
3TA, 5TA
T90, T100
1
2
1
1
1
1
1
T100R, T1
1
2
1
1
As required
77
ClassicBike.biz
3
4
36
37
43
42
35
33
27
30
31
32
29
28
34
Fig. 30. CARBURETTER, 3TA AND 5TA
78
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
CARBURETTER, 3TA AND 5TA
1
1
2
2
3
3
4
5
6
7
8
9
10
11
11
12
13
14
15
16
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
375/62
375/35
375/003
375/005
375/057
375/059
375/067
376/070
375/102
375/065
375/071
4/241
30/064
375/060
375/060
375/079
375/063
4/230
376/072
376/100
376/100
376/073
376/074
376/075
376/076
116/162
376/095
332/017
4/148
376/068
376/069
376/085
376/083
376/094
376/078
376/077
376/079
376/088
376/089
376/093
376/091
376/092
376/086
376/087
343/011
244/765
229/048
F4308
CARBURETTER, 25/32 in. choke
CARBURETTER, f in. choke ...
Mixing chamber, 25/32 in. choke
Mixing chamber, f in. choke
Jet block, 25/32 in. choke
Jet block, g in. choke
Joint washer
...
...
Peg screw
AIR VALVE ASSEMBLY
Mixing chamber cap
Spring ...
Screw ...
...
...
Spring ...
Throttle valve (32 cutaway)
Throttle valve (3 cutaway) ...
Throttle return spring
Needle (Type B)
Needle clip ...
Needle jet (.106)
Main jet (100)
Main jet (160)
Jet holder
...
Fibre washer ...
Cover nut
...
Pilot jet (25) ...
Fibre washer ...
Cover nut ...
...
Air adjusting screw
Spring
...
...
Throttle stop screw ...
Spring
...
Float spindle
Float ...
Bush ...
...
Joint washer
Cover ...
Screw ...
Needle seating
Needle
Filter ...
Bolt ...
•••
Fibre washer ...
Tickler
•..
Spring
...
Tickler body
"0" ring seal...
Air intake tube ...
Petrol pipe
...
1
1
1
1
1
1
1
1
3TA
5TA
3TA
5TA
3TA
5TA
1
1
1
1
1
3TA
1
1
5TA
1
1
1
1
1
3TA
1
5TA
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
As required
1
79
ClassicBike.biz
11
14
6
8
oe.
13
9
^=1°
CARBURETTER COMPLETE
REF. No. I
IJ,7
If.-
10
(i!.
17
2
39
37
31
4•
34
•
35
•
36
•
33
•
32
21
38
20
23
Fig. 31. CARBURETTER, T90 AND T100
80
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REM ARKS
CARBURETTER, T90 AND T100
1
1
2
2
3
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16
17
18
19
20
20
21
22
23
24
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
376/300
376/273
376/001
376/002
376/055
376/056
376/067
376/070
376/158
376/197
376/402
376/109
376/409
30/064
376/065
29/308
4/241
376/060
376/060
376/061
376/063
4/230
376/072
376/100
376/100
376/073
376/074
376/075
376/076
376/076
116/162
376/095
332/017
4/148
376/068
376/069
376/085
376/083
376/094
376/078
376/077
376/079
376/088
376/089
376/093
376/091
376/092
376/086
376/087
343/011
2/1048
F4308
376/066
CARBURETTER, + in. choke ...
CARBURETTER, 1 in. choke ...
Mixing chamber, * in. choke
Mixing chamber, 1 in. choke
Jet block, .f in. choke
Jet block, 1 in. choke
Joint washer
Peg screw
...
Mixing chamber top
Air valve
...
...
Control rod and lever
Return spring
Friction washer
Click spring ...
Mixing chamber cap
Spring
Screw
•••
Throttle valve (3 cutaway) ...
Throttle valve (32 cutaway)
Throttle return spring
Needle (Type C)
Needle clip ...
Needle jet (.106)
Main jet (180)
Main jet (190)
Jet holder ...
Fibre washer ...
Cover nut ...
Pilot jet (20)
Pilot jet (25)
Fibre washer ...
Cover nut ...
...
Air adjusting screw
Spring
...
...
Throttle stop screw
Spring
...
Float spindle
Float ...
Bush ...
...
Joint washer
Cover
Screw ...
Needle seating
Needle
...
Filter ...
...
Bolt ...
Fibre washer ...
Tickler
...
Spring
...
Tickler body
"0" ring seal...
Petrol pipe
...
Air intake tube ...
—
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
A
190
T100
190
T100
T90
T100
190
T100
T90
See Pages 9 to 12
190
T100
81
ClassicBike.biz
8
5
4
2
e
10
6
a
3
/
7
4
14
per-5
13
15
18
15
_=
16
19
III
-f
1-
31
32 33 34
KIi]
IPJ
Fig. 32. A.C. MAGNETO IGNITION COILS, WIRING HARNESS AND DIRECT LIGHTING
82
ClassicBike.biz
17
Ref. No.
DESCRIPTION
Part No.
QUANTITY REMARKS
A.C. MAGNETO IGNITION COILS, WIRING HARNESS
AND DIRECT LIGHTING
F6112
1
2
F4366
3
F6122
E1612
4
5
F879
6
W932
7
F6125
F6136
8
9
45149
54441582
10
11
54190108
12
54937097
31071
13
14
H1669
Ht670
15
H687
16
17
H745
58395
18
534343
19
20
54520452
21
504665
22
166
23
554602
112201
24
137499
25
31356
26
31620
27
144921
28
534296
29
D552
30
11104/06/2
31
F4366
32
E1612
33
15104/00/2
34
35
D553
53972
36
384
37
F3069
38
36 and 37 not illustrated.
Coil bracket
...
Distance piece ...
Bolt (1 A in. U.H.)
Serrated washer
Nut
...
Bolt (1 in. U.H.)
Retainer
Retainer ...
Ignition coil, type 3ET
Condenser
...
Lucar terminal ...
Wiring harness ...
...
Cut-out button, type SS5
Cup
Clip
...
Bolt (i in. U.H.)
Nut
...
...
...
HEADLAMP ASSEMBLY, MCH 66 ...
Rim
...
Light unit ...
...
Fixing wire...
...
Bulb (24/24W. Pre-focus, Vertical Dip)
Adaptor
Bolt
Washer
...
Lighting switch
Dip switch ...
Screw
...
Plate
...
Horn, clear hooters AC5855G
Bolt
Distance piece
Serrated washer
Horn push, clear hooters No. 10
STOP AND TAIL LAMP, Type 679
Bulb (6/18 W. Offset pin)
...
...
Distance piece ...
ClassicBike.biz
..
...
..
..
••;
4
2
2
6
6
4
2
2
2
2
2
1
1
1
2
1
1
1
1
1
6
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
"Kill button"
Except for bulb
See Page 87
83
13 ^
15 --z'Ja
9
_^ 154 ^
'#
10 -^
2
345
I!
11
12
I
Q
r
29
7
1
10
6
8
I -^.
20
31
19 21. 22
32
32
m
J
e m
m
34
30
m
38 37
33
I
ra Q
35
23
11
12
L4
4u -.c,
Fig. 33. D.C. IGNITION COILS, HORN, RECTIFIER AND ZENER DIODE
84
ClassicBike.biz
Ref. No.
fart No.
DESCRIPTION
D.C. 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
35
36
37
38
39
40
41
42
45110
54190108
131023
188330
166043
421554
421863
100104
169160
422369
54942078
54190042
F3809
F5466
F5467
E3290
—
D262
F6632
H426
S26-1
S1-52
F6900
49345
DS57
S25-1
54441582
54937976
842183
35601
H1669
H1670
H687
H745
70164
F4771
F3799
GS299
49072
F5338
F6896
F879
COILS,
HORN,
IGNITION COIL. Type MAl2
Lucar terminal
...
...
Plain washer (E2351)
...
Serrated washer (GS299)...
Nut (F3799)
...
Rubber grommet ...
Cable clip ...
Screw
...
Square nut
"D" washer
Lucar connector
...
Insulating cover...
...
Bolt (11 in. U.H.)
...
Rubber grommet
...
Distance piece ...
Self locking nut
...
...
Sparking plug (Champion N4)
Plug cover
...
Horn bracket ...
Bolt (n in. U.H.)
Spring washer
Nut
...
...
Mounting plate ...
Zener diode
...
Bolt ( .j in. U.H.)
Washer ...
Condenser
...
H.T. lead complete (resistive)
H.T. lead (7 m.m. cable)
Cut-out button, type SS5
Cup
...
Clip
...
Bolt (8 in. U.H.)
Nut
...
...
Horn, type 8H
Screw (I in. U.H.)
Nut
...
...
Serrated washer
...
Rectifier, type 2DS 506
Nut (156 596) ...
Bracket ...
Nut
...
QUANTITY
REMARKS
RECTIFIER AND ZENER DIODE
...
...
...
...
...
...
...
...
•••
--•-•
...
...
2
4
4
4
4
2
2
2
2
4
as required
as required
2
2
4
2
2
2 U.S.A.
1
1
1
1
1
1
2
2
2 U.S.A.
2
2 U.S.A.
1 "Kill button"
1
2
1
1
1
2
2
2
1
1
1
2
85
ClassicBike.biz
5
11 -4
6
\
rr
^----
27 28
29
31
30
I
12
26
25
^
^'
20
41
40
37
19
- 33
1
47
46
Fig. 34. HEADLAMP, WIRING HARNESS, SWITCHES AND TAIL LAMP
ClassicBike.biz
I
10
f1
86
17
J 14 13
32
49
1
18
21
Ref. No.
Part No.
DESCRIPTION
HEADLAMP, WIRING HARNESS, SWITCHES
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
59579
553248
516798
504665
144921
534296
446
554602
988
554710
36296
862217
112201
137499
38189
281
H1932
F6981
31899
34289
54330934
F5983
F5988
54330576
54930007
54938941
900269
900288
850641
850844
850832
53454
573839
575200
575208
575219
576002
575209
575207
573828
573625
380
53973
54572932
572289
54574348
573828
380
54571677
127684
838604
HEADLAMP COMPLETE
Rim ...
Light unit ...
Fixing wire...
Screw
...
Plate
...
...
...
Bulb (50/40 W. Vert dip. Pre-focus)
Main bulbholder
...
Bulb (3W. M.C.C.)
Pilot bulbholder ...
Ammeter type 2AR
Grommet ...
...
Bolt
Plain washer
...
Ignition warning light body
Bulb (2W. BA7S)
Headlamp spacer
...
Ignition lock c/w two keys
Ignition switch, type S45
Lighting switch, type 88SA
Knob c/w screw
Bracket ...
...
Rubber band ...
Switch bezel plate
Replacement harness socket (Lighting)
Wiring harness ...
...
Snap connector terminal
Single snap connector ...
Double snap connector
Triple snap connector ...
Quintuple snap connector
...
STOP AND TAIL LAMP, Type 564
Lens
...
Window ...
...
Lens seating gasket
Sleeve nut
Base assembly
Bulbholder
Grommet ...
Contact assembly ...
Grommet ...
...
...
...
STOP AND TAIL LAMP, Type L679
Lens...
...
Screw
...
...
Bulb holder with reflector
Contact assembly ...
...
...
Gasket
...
...
Screw
Stop and tail lamp lead
QUANTITY
REMARKS
AND TAIL LAMP
...
...
...
...
...
•••
...
...
...
1
1
1
6
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
as required
as required
as required
as required
as required
1
1
1
1
2
1 3TA, 5TA
1 1 T90, T100
1
1
1
1J
11 i
2
1 T1OOR
1
1
1
2J
1
87
ClassicBike.biz
//
tW3
5
w
0
1
3
c
I
^^
2
6
1413 12 10
Fig. 35. SPEEDOMETER AND TACHOMETER
88
ClassicBike.biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
SPEEDOMETER AND TACHOMETER
1
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SSM5002/00
SSM5002/01
SSM5001/00
SS M 5001/01
554734
987
41-118-127-72
31-753-778
31-674-188-01
30-283-014-11
30-277-023-11
41-148-203-10
H1702
H1701
H1668
DS57
S26-2
D609
E5755
E5153
E5156
E5155
E5157
E5759
E6300
E5578
E6122
E6299
E6124
E3309
E5881
D578
RSM3003/01
H19 46
H1929
3 282-01411
30-276-037-11
H1086
H1698
D493
D494
Speedometer head MPH
Speedometer head KPH
Speedometer head MPH
Speedometer head KPH
Bulb holder
...
Bulb, 3.W. M.E.S.
Trip control
Rubber ring
Fixing strap
Washer ...
Nut
...
Trip control
Distance piece
Sleeve nut
Bracket ...
in. U.H.)
Bolt
Spring washer
Speedometer cable (65 ins. long)
TACHOMETER GEARBOX ...
Securing screw ...
Bush ...
Flanged bush ...
Driving gear
...
End cap
...
"0" ring ...
Driven gear
...
Driven gear housing
"0" ring
Bush ...
"0" ring ...
Set screw
Tachometer cable (28 in. long)
Tachometer
...
MOUNTING BRACKET
Metal lasti k Bush
Washer ...
Nut
...
Bolt (1 * in. U.H.)
Cable bracket ...
Spade
...
Circlip
1 3TA, 5TA
Alternative 3TA, 5TA
1 T90, T100
Alternative T90,T100
1
1
1
1
1 3TA, 5TA
2
2
2
2 T90, T100
1
2
2,
1 Smiths DF9110/00
1)
1
1
1
...
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1
...
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T1WR
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ClassicBike.biz
ClassicBike.biz

500s / 350s - ClassicBike.biz

Transcription

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