500s / 350s - ClassicBike.biz
Transcription
500s / 350s - ClassicBike.biz
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 ClassicBike.biz 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 ClassicBike.biz 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 ClassicBike.biz ClassicBike.biz ClassicBike.biz ClassicBike.biz 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 ClassicBike.biz 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 Front Forks (each leg) 31 galls. (16 litres) 6 pints (3.5 litres) 2/3 pint (375 c.c.) 1 pint (300 c.c.) I 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 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 8 in. Duplex x 78 links 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) 6 pints (3.5 litres) Front Forks (each leg) 2/3 pint (375 c.c.) z'— pint (300 c.c.) '^ pint 4pint (190 (190 c.c.) c.c.) Brakes Brakes' Front and Rear, diameter 7 in. (17.78 (17.78 cm. cmJ Tyre Size Front 3.25 x 18 3.50 x 18 Rear ClassicBike.biz 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 Front Forks (each leg) Brakes Front and Rear, diameter 31 galls. (16 litres) 6 pints (3.5 litres) 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 8 in. Duplex x 78 links Capacities Gas Tank Oil Tank Gearbox Primary Chaincase Front Forks (each leg) 23 U.S. galls. 6 U.S. pints 2/3 pint (375 c.c.) pint (300 c.c.) 3 pint (190 c.c.) Brakes Front and Rear, diameter 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. Duplex x 78 links 1 in. x in. x 102 links Capacities Gas Tank Oil Tank Gearbox Primary Chaincase Front Forks (each leg) 21 U.S. galls. 6 U.S. pints 2/3 pint (375 c.c.) + pint (300 c.c.) + pint (190 c.c.) Brakes Front and Rear, diameter 7 in. (17.18 cm.) Tyre Size Front Rear 3.25 x 19 4.00 x 18 ClassicBike.biz 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 Front Forks (each leg) 28 U.S. Galls. 6 U.S. pints 2/3 pint (375 c.c.) + pint (300 c.c.) pint (190 c.c.) Brakes Front and Rear, diameter Tyre Size Front Rear 7 in. (17.18 cm.) 3.25 x 19 4.00x18 ClassicBike.biz 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. ClassicBike.biz 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 is also available in 0.010 in., 0.020 in. and 0.040 in. oversizes. C.P. 198 1 Piston C.R. 9:1 Compression ring (taper) Oil control ring Gudgeon pin Circlips Piston Rings (350 c.c.) C.P. 165 Compression ring (plain) 2 E3691 Compression ring (taper) 2 E3690 Oil control ring 2 E3692 C.P. 165 is also available in 0.010 in., 0.020 in. and 0.040 in. oversizes. 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 is also available in 0.010 in. and 0.020 in. oversizes. C.P. 179 1 Piston C.R. 7 :1 Compression ring (taper) Oil control ring Gudgeon pin Circlips Piston C.R. 9 :1 Compression ring (taper) Oil control ring Gudgeon pin Circlips Piston Rings (500 c.c.) 4 E3829 2 E3831 C.P. 175 is also available in 0.010 in. and 0.020 in. oversizes. C.P. 175 14 ClassicBike.biz Compression ring (taper) Oil control ring CARTON PACK LIST— continued Part Contents No. C.P. 180 4 E4135 2 E4136 Compression ring (taper) 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 ClassicBike.biz 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 ClassicBike.biz 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 ... ... PISTON COMPLETE C.R. 9:1 ... ... PISTON COMPLETE C.R. 9:1 ... ... Plain compression ring ... ... ... Taper compression ring ... ... ... Taper 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 ... Screw (21/32 in. U.H.) 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 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 CYLINDER BLOCK AND HEAD, 3TA AND T90 (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 CYLINDER BLOCK AND HEAD, 5TA AND T100 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 ... ... ... CYLINDER HEAD c/w GUIDES ... ... 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 ... ... Screw (15/32 in. U.H.) ... 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 HIGH GEAR (23T) ... ... MAINSHAFT c/w THIRD & LOW GEAR (15/24T) ... Mainshaft second gear (20T) ... ... Layshaft c/w second & high gear (14/24T) ... ... ... ... Layshaft third gear (20T) ... LAYSHAFT LOW GEAR (29T) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 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 HIGH GEAR (20T) MAINSHAFT c/w THIRD & LOW GEAR (16/22T) ... ... ... Mainshaft second gear (20T) Layshaft c/w second and high gear (17/23T) ... ... ... ... Layshaft third gear (21T) ... ... LAYSHAFT LOW GEAR (27T) ... ... ... ... ... 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 CHAINCASE AND CHAINS 38 ClassicBike.biz 3 Ref. No. Part No. DESCRIPTION QUANTITY REMARKS CHAINCASE AND CHAINS 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 (18 teeth) ... Gearbox sprocket (19 teeth) ... Gearbox sprocket (20 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 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 ... ... ... ... ... 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 ... ... ... 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 ... ... RIM, SPOKES AND HUB ASSEMBLY RIM, SPOKES AND HUB ASSEMBLY 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 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 ... 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 T100R, Eastern T100C Western T100C Western T100C T100R, Eastern 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 ... ... ... Bulb (6/21 W. Offset pin) ... STOP AND TAIL LAMP, Type L679 Lens... ... Screw ... ... Bulb holder with reflector Contact assembly ... Bulb (6/21 W. Offset pin) ... ... 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 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 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 ... 1 1 1 ... 1 ••• ••• ••• ••• 1 2 2 2 ... 1 T1WR 89 ClassicBike.biz ClassicBike.biz
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