T150 1968 - JRC Engineering, Inc.

0
45 cu. ins. (750 c.c.)
REPLACEMENT
PARTS
CATALOGUE
TRIUMPH
MERIDEN
ENGINEERING
LIMITED
WORKS· ALLESLEY ·COVENTRY • ENGLAND
TELEPHONE MERIDEN 331
PUBLISHED MAY 1968
COMPANY
TELEGRAMS '"TRUSTY COVENTRY""
REF. SPC.4
TRIUMPH GUARANTEE
1.
In th!s 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 obtaln 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 pan or accessory.
4.
Any part considered to be defective must be sent to our Works, carriage paid, accompanied by the
fallowing informat!on:(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;
•
(b) 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, saddtes, 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 guaran·
tee, 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 contamed applies to the machine to wllich
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 !eft 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 m~y be used by us in effecting a
repair. AU other conditions and warranties: statutory or otherwise express or lmpUed are hereby excluded,
2
ILLUSTRATION INDEX
Fig. Na.
1
2
3
4
5
6
7
B
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
Description
CRANKSHAFT AND CONNECTING RODS
CRANKCASES
OIL PUMP, RELEASE VALVE AND FILTER
CYLINDER HEAD AND ROCKER BOXES ...
CYLINDER BARREL, PUSH ROD AND TUBES, TAPPETS
TIMING COVER AND CONTACT BREAKER
MANIFOLD AND THROTTLE LINKAGE ..
GEARBOX OUTER COVER ...
GEARBOX INNER COVER AND SELECTORS
GEARBOX SHAFTS AND GEARS
CLUTCH AND CLUTCH OPERATION
INNER AND OUTER CHAINCASE
PRIMARY TRANSMISSION AND OIL PUMP DRIVE
FRAME
SWINGING FORK AND SUSPENSION UNITS
ENGINE UNIT FITTINGS AND FOOTRESTS
EXHAUST PIPES AND SILENCERS
TELESCOPIC FRONT FORK
HANDLEBAR MOUNTINGS AND STEERING DAMPER.
FRONT WHEEL .. .
REAR WHEEL .. .
OIL COOLER
PETROL (GAS) TANK
OIL TANK
BATTERY CARRIER AND AIR FILTER
PANELS AND TWINSEAT
MUDGUARDS (FENDERS)
HANDLEBARS, CONTROLS, BINNACLE AND OIL WARNING LIGHT
CQNTROL CABLES
TOOLKIT AND PILLION FOOTRESTS
AMAL CARBURETTER ...
SPEEDOMETER AND TACHOMETER
IGNITION COILS, HORNS, RECTIFIER AND ZENER DIODE ...
HEADLAMP, WIRING HARNESS, SWITCHES AND TAIL LAMP
3
Page No.
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
so
52
54
56
58
60
62
64
66
68
70
72
74
INDEX
Page
Page
AIR FILTER
57
MANIFOLD
21
ALTERNATOR.
19
MUFFLERS
41
BATTERY CARRIER
57
OIL COOLER
51
OIL PUMP
13
OIL TANK
55
OIL FILTER
13
67
CARBURETTER
69
CENTRE STAND
35
CHAINCASE
31
CHAINS
33
PILLION FOOTRESTS ..
CLUTCH
29
PISTONS
COIL
73
PROP STAND
CONTACT BREAKER
19
CONTROL CABLES
65
CONTROL LEVERS
63
CRANKCASE
"
'
CRANKSHAFT .
CYLINDER HEAD
"'
59
REAR WHEEL ".
49
RECTIFIER
73
SPARK PLUGS
73
SPEEDOMETER."
71
15
EXHAUST PIPES
41
FENDERS
61
FOOTRESTS
39
FRONT FORKS
43
FRONT WHEEL
47
STEERING RACES
'" 35, 43
SUSPENSION UNITS
37
SWITCHES
75
TIMING GEARS
53
9
TOOLKIT
67
TWIN SEAT
59
VALVES
15
..
23, 25, 27
HANDLEBARS
63
HORN
73
'"
'"
9
39
GEARBOX
35
•
REAR PANEL
11
ENGINE PLATES
GAS TANKS
9
4
WIRING HARNESS
75
ZENER DIODE
73
T RI D EN T
(T 1 S 0) T E C H N I C A L D A T A
Bore and stroke ...
67 x 70 mm.
2·67 x 2·751 ins.
741 c.c. (45 cu. ins.)
Capacity ...
Compression ratio
9·5: 1
Spark plugs
Champion N3
3 Amal Concentric 626
150
·106
No.3
Carburetors.,.
Main jet
Needle jet
Throttle valve
Gearbox sprocket
19 teeth
Chains
Front
Rear
Capacities
Gas Tank
Oil Tank
Gearbox ...
f." Triplex x 82 links
i" x 1." x 104 links
Primary Chaintase
Front Forks (each leg)
... 4j; U.S. galls. (15·94 litres)
5 U.S. pints (2·8 lit res)
1j; pints (700 c.c.)
j pint (350 c. c.)
t pint (200 c.c.)
Brakes
Front, diameter ...
Rear, diameter ...
8" (20·32 em.)
7" (17-78 em.)
Tire size ·--
Front
3·50 x 19 ins.
4·10x19 ins.
Rear
Aquamarine
Color
5
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 4 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 quantlties required as single units; do not ask for "2 pairs" or "3 dozen".
In case of painted items always state the color required. Painted parts are available only in the colours
or alternatives specified for that model of that particular year.
Model
Color
T150
Aquamarine
N.B. Aquamarine is a flamboyant finish applied over SHver.
Palnt is available only in Aerosol containers.
6
PISTON, PISTON lUNG AND BEARING OVERSIZES
AND GASKET SETS
PISTONS (Complete with rings, gudgeon pins and circlips)
These are in effect "carton pack" assemblies
Compression ratio 9·5 : 1
E8766 Std.
E9008 ~10
£9009720
E9010 40
J
l
PISTON RINGS
CP ~ {2 off E6838 Compression ring} S d
1 off E6839 Scraper ring
' ·
CPc {2 off E9016 Compression ring}
1 off E9020 Scraper ring
_
1
CP _ {2 off E9017 Compression ring\_
1 off E9021 Scraper ring
_
1 20
f
10
CPc {2 off E9018 Compression ring} ~40
1 off E9022 Scraper ring
'
BIG END BEARINGS SHELLS
E5998 Shell
E9023 Shell
E9024 Shell
E9025 Shell
E9026 Shell
Decoke Gasket Set
Overhaul Gasket Set
.
Std.
-10
-20
-30
-40
99-0039
99-0030
7
10----- - - - -
14
-
---c
I,
13
16
,- 'i
!;'If-
'
9----~
-
29
\
\
\
30
28
\_)
27
\
5
4
Fig. 1.
CRANKSHAFT AND CONNECTING RODS
\
14
Ref. No.
DESCRIPTION
Port No.
CRANK'S HAFT AND CONNECTING
1
2
3
4
5
6
7
a
9
10
11
1l
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
5548
E8763
E3975
E8777
E9630
5549
ES998
E8766
E6838
E6839
1:6836
E6840
E8765
E8764
E1558
E4562
E6523
E6029
E7650
E608S
E8768
E10037
E6524
E6173
E6030
SS<\7
14-0401
526-2
ES780
Rotor nut
Washer ...
CON ROD ASSEMBLY
Bolt con rod ...
Nut. con rod . , .
Bearing, big end
*PISTON ASSEMBLY
Taper piston ring
Scraper ring
Gudgeon pin
Circlip ...
Exhaust camshaft
Inlet camshaft ...
Key, camshaft ...
Pinion camshaft
N uc, camshaft ...
Intermediate timing gear
Needle roller bearing ...
Thrust washer ...
Circlip
...
Key-timing pinion and rotor
Timing pinion ...
Distance piece ...
Spindle, intermediate gear
Stud (i in. O.A.)
..
RODS
1
4
1
1
1
3
6
6
6
3
6
3
3
6
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
CRANKSHAFT ASSEMBLY
Oilway plug ...
Alternator stud (1! in.)
E8778
• E6577
QUANTITY
Nut. intermediate gear
Washer ...
Main bearing (roller) ...
*Available in oversizes of 0·010", 0·020", 0·040"
9
REMARKS
'
32
21
31
24
19
22
18
20
I
5 43
3
Fig. 2. C RANK CASES
10
4 •
Ref. No.
Port No.
DESCRIPTION
QUANTITY
CRANKCASES
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
E9002
E1532
E6573
E6574
E8774
E6578
E8745
14-6113
E8776
E7423
S25-2
14-1203
E8755
E1523
S1931
E1534A
E8738
E1591
E6025
14-6218
14--6226
14--6220
14--6223
S25-3
E6023
E8748
E8746
T1150
E7505
T989
E8780
E6026
S678
14-1427
14--0302
T2167
E2441
S543
T1257
E8750
E6567
E6742
E6584
E6501
E6516
E6580
14--6103
S26-2
S1912
CRANKCASES
Dowel, oil pump to cranckcase
1
1
4
Oil return pipe stub
Oil feed pipe stud
Dowel D.S. and T.S.
Scavenge tube ...
Waisted stud, main bearing cap
Plug main bearing oilways
Washer ...
(t
in. U.H.)
Cap, main bearing
Washer ...
Nut
4
2
2
2
4
4
Plug, timing aperture ...
Washer, timing aperture
Stud, cylinder base (O.A.)
Dowel, cylinder base ...
Stud cylinder at dowel (1:
D.S. main bearing
~
in. O.A.)
4
2
2
2
2
9
2
Cirdip, main bearing ...
Clamping bolt (1i in. U.H.)
Clamping bolt (3t in. U.H.)
Clamping bolt (1~ in. U.H.)
Clamping bolt (2t in. U.H.)
Washer ...
Main Bearing Shell
Tappet oil feed pipe T.S.
Tappet oil feed pipe D.S.
9
4
Screw, pipe to bearing cap
•
Sealing rubber ...
Dowel
Main bearing T.S. (roller)
Circlip ...
Allen screw (4 in. U.H.)
Stud, T.S. cranckcase (3 in. O.A.)
Nut
Gearbox drain plug
4
2
1
2
Fibre washer
1
1
Level plug
2
2
Fibre washer
Non return valve ball (,;-in. dia.)
Spring
Joint washer
Plug
Scavenge filter
Gasket ...
1
2
Cover
Bolt
(~
in. U.H.)
Spring washer
Stud, cylinder base (1i ih. O.A.)
11
6
4
4
REMARKS
OIL PUMP COMPLETE No.8
7
2
\
\
\
11
\
\\
1
21
@
~
C)
~.
13
'25
27
16
23
30
23
Fl1 • 3. OIL PUMP, RELEASE VALVE AND FILTI!II
12
Ref No.
Part No.
0 IL
1
2
3
4
s
6
7
8
9
10
11
12
13
14
1S
16
17
18
19
20
21
22
23
24
2S
26
27
28
29
30
E6S9S
E7S90
GS2S1
E7S91
E6S96
GS2S4
E1670
E9001
E6430
E6S02
E64SS
E6889
E6038
E6039
E64S4
E6S2S
E64S9
SSS9
E8731
E72SO
E6S03
E10003
E9601
E8732
E6S70
E6S71
E6130
E6S82 .lllJI>
E6131-E /11)'1()
E8779
•
QUANTITY
DESCRIPTION
PUMP
RELEASE
VALVE
AND
01 L
REMARKS
FILTER
OIL PRESSURE RELEASE VALVE
Body
Piston
Spring
Cap ...
Joint washer (cap to body)
Fibre washer
OIL PUMP COMPLETE
Oil pump, body
Base plate ...
1
1
Not servic:::d
Drive feed gear
Drive scavenge gear
Driven feed gear ...
Driven scavenge gear
Driven gear spindle
Cover ... ...
Dowel, cover to body
Screw, cover to body (2 in. U.H.)
Washer, cover to pump screw ...
Screw, pinion to driven gear(~ in. U.H.)
Gasket, oil pump to crankcase
1
2
2
1
Screw, pump to crankcase (2! in. U.H.)
3
Screw, pump to crankcase at dowel ...
Washer, pump to crankcase
Seal, pump to crankcase
Oil filter element
3
2
1
Spring
Cap
Fibre washer
Filter seal
2
13
42
I
41
22
21
46
-15
14
20
- 44
45
7
6
~~
\\
'
1
4
9
I
3
2
'
',
5
.
-Fig, 4. CYLINDER HEAD AND ROCKER BOXES
14
Ref, No.
Part No.
DESCRIPTION
CYLINDER
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
E8781
E9510
E6420
E6422
E6423
£8787
E8788
E8720
E8789
WE259A
E6561
E6562
E8773
T2166
E8782
14-1401
14-0201
14-7004
E1335
E6018
·=~'9i'i~
E6466
E6465
E642S
E6426
E7651
£8783
14-0402
E1574 •
1:1575
E1330
E6564
HEAD AND
ROCKER BOXES
1
3
CYLINDER HEAD
Exhaust pipe adaptor
Valve guide
6
Inlet valve
Exhaust valve
Inner, valve spring
Outer valve spring
3
3
6
6
Top collar
6
6
12
Bottom cup
Split cotter
Inlet rocker box
Exhaust rocker box
Rocker box gasket
Rocker box cap
"0" ring cap
Stud, rocker box cover (1 in. O.A.) ...
Bolt, rocker box cover (1 in. U.H.) ...
2
4
4
4
4
Screw
Copper washer ...
Bush, T.S. for rocker spindle
"0" ring, D.S. bush __ _
Rocker spindle ...
Rocker lever, T.S. lnlet,icentre exhaust
Rocker lever. T.S. exhaustfcentre inlet
6
Rocker lever, exhaust D.S.
Rocker lever, inlet D.S.
Ball pin
Adjustmg pin
Locknut ...
Thackeray washer
Inspection cover, exterior
14-0303
Nut
F2184
E9274
Washer .,.
Rocker pipe
Connecting tube
Oil feed pipe
Dome nut
E8819
E6353
E9271
$550
2
2
2
2
1
1
6
6
6
6
E8818
E6565
E9237
E9239
525-1
E8820
E9240
14-6211
4
2
10
2
1
Plain washer
Plain washer
Inspection cover, interior
Gasket
Sleeve nut
Plain washer
Washer
Bolt, short rockerbox to barrel
Washer ...
Bolt, rocker box to head (3 in, U.H.)
Bolt, long rocker box co barrel
Bolt, torque stay, rocker box to barrel
E6563
QUANTITY
1
2
4
4
4
4
8
4
2
2
4
4
1
1
1
2
15
REMARKS
···--··········-13
•
11-----18
II----! 11---~8
6-----j
Fi 1 • S.
CYLINDER BARREL, PUSH ROD AND TUBES, TAPPETS
16
Ref. No.
DESCRIPTION
Port No.
CYLINDER BARREL, PUSH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
E6529
E8914
E8775
E6509
E6508
E9465
E8817
S686
E6560
5692
E6496
~t:J/133
E6506
E695S
E4752
E4746
E3237
E8917
E1532
REMARKS
RODS AND TUBES, TAPPET BLOCKS
CYLINDER BARREL CJW LINERS
Cylinder liner
Plug oil drillings
Tappet guide block T.S.
Tappet guide block D.S.
Dowel, tappet guide block ...
Pillar stud
Stud, barrel to head (4f" O.A.)
~o·
QUANTITY
ring
Base nut (12 point)
Base gasket
...
.. .
...
. ..
Cylinder head gasket /:1~14/./.yt"l.£..
Push rod
Push rod tube
Sealing rubber ...
Bottom cup
Top cup
Tappet
Dowel ...
17
1
3
Reference
Reference
Reference
Reference
8
4
4
10
1
6
4
8
4
4
6
6
only
only
only
only
29
27
30
CONTACT BREAKER ASSY. No. 24
28
'
25
<
ji
31
3,2
'
I
'
/
I
~
.
~~
~
~@
i
26
q
"
-·
I
.-
22
33
·20
\"''
-
)j
19
I
21
B
7
14
3
6-
I
4
15
2
5
12
12
Fl1 • 6.
1
TIMING COVER AND CONTACT BREAKER
16
Re(. No.
Port No.
DESCRIPTION
QUANTITY
TIMING COVER AND CONTACT BREAKER
1
2
3
4
5
6
7
B
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
E6432
EB762
EB761
E10007
E10006
E9266
E4568
E6519
E6572
F4715
GS299
14-6612
14-6608
99-1012
99-1016
E6522
5677
525-3
E8760
E4144
E8757
E8756
H916
99-1013
99-1014
99-0769
99-1015
99-0757
E6521 "
E6559
14-0208;001
525-43
E8756
Timing cover
Cover, timing aperture
Joint washer
1
1
1
Screw
Pointer screw
Washer ...
Oil seal ...
C:B. cover
Gasket C:B. cover
Screw
Washer ...
Screw (2" U.H.)
Screw (1" U.H.)
Rotor 54210937
Stator 47209
2
1
3
1
1
1
3
3
Stud, alternator mounting
Nut, alternator mounting
Washer ...
Cable seal nut
Grommet
Cover, alternator leads
Rubber ferrule
Screw. lead cover to crankcase
CONTACT BREAKER 7CA 54419327
Contact set 54419828
Adjusting screw 54419220 ...
AUTO ADVANCE UNIT 54419867 ...
Spring 54415642
Pillar bolt
Washer
Bolt C. B. cam to camshaft (2f' U.H.)
Washer ,.
Grommet
19
3
6
1
1
3
3
3
1
1
1
1
1
1
3
3
1
2
1
1
1
1
1
REMARKS
3
t1
12
i
I
6
20
,~("').,.
2
!'------~
I
I
18
22
•
1
Fig. 7..
13
MANIFOLD AND TROTTLE LINKAGE
I
14
15
Ref. No.
DESCRIPTION
Part No.
QUANTITY
MAN !'FOLD AND THROTTLE LINKAGE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E7633
E9073
E9242
5774*
E9251
E9255
E9267
525~3
E9241
E9243
E9252
E9254
E9060
D707
EB981
5673
ADAPTOR cfw BUSHES
Bush ...
Support arm
1
2
1
2
1
2
1
2
1
4
1
1
3
6
3
6
6
6
3
3
6
Screw
Spindle ...
Circlip ...
Return spring
Washer ...
Operating arm
Trunnion
Screw
Spring
Rubber sleeve
Jubl1ee type clip
Insulating block
Stud carburetter (1f' O.A.)
525~3
Washer ...
n
14-0302
E9057
E8784
S557
14-0301
23
525~13
Nut, carburetter fixing
Stub, cylinder head
Joint washer, stub to head
Stud (1-fi" O.A.)
Nut, cylinder head
Washer ...
6
6
*Early models use 51930 Screw 2 off E9534 Packing piece 1 off
21
REMARKS
13 -
~
...
10-
33---
i
16
15 -·-·····
28---·
·-
27
I
29
5
F,'I· 8. GEARB OX OUTER COVER
1
I
35
Ref. No.
Part No.
DESCRIPTION
GEARBOX
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
T3750
T47
S547
E3309
T1955
T1956
E3759
T57
T408;9
T405
T406
T404
T407
E1612
14-0302
T24A
T2169
T31
T3632
T2173
T1167
S70-3
T1272
S541
T2330
T1222
S544
S25-3
S1815
14-66~
14-6610
14-6608
T3751
14-0201
T2450
0 UTER
GEARBOX OUTER COVER
COVER
1
1
4
Kickstart anchor peg
Stud guide plate
Sealing Ring
QUANTITY
(i in.)
Housing, oil seal
Oil seal
Bush (F/C Spindle)
Bush (K/S Spindle)
Quadrant
Spring
Plunger
Spring
Guide plate
Washer
Nut
2
2
2
4
Kickstart axle shaft
Kickstart quadrant
Kickstart return spring
FOLDING KICKSTART COMPLETE
Crank
Spring
Ball,~ in. dia.
Pedal
Pivot bolt
Rubber
Cotter pin c/w nut and washer
Domed nut outer cover
Washer
Screw, outer cover long
Screw, outer cover (1f'
Screw, outer cover (1t''
Screw, outer cover long
Footchange pedal
Pinch bolt (1f in. U.H.)
Rubber
(4t" U.H.) ...
U.H.)
U.H.)
(1" U.H.)
23
2
1
1
2
1
1
1
1
REMARKS
23
17
rn------19
. 16
15
F;g, 9.
GEARBOX INNER COVER AND SELECTORS
24
Ref. No.
Part No.
DESCRIPTION
GEARBOX INNER COVER 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
12137
T1614
T3727
T412
T1606
T1607
T912
T989
T397
T1896
D1928
14-7101
14-6121
E3446
14-6614
14-1431
T3650
NT261
T44
T373
T2172
T291
T260B
T913
T2166
E8782
INNER COVER
Layshaft bearing
Klckstart stop
Bush (F/C spindle)
Layshaft, needle roller bearing
Thrust washer , ..
Peg, LiS thrust washer
Dowel, inner to outer cover ...
Quadrant
Quadrant spindle
Split pin, f. in. x 1i in.
Socket screw
Bolt, inner cover to crankcase (2} in. U.H.)
Washer, inner cover to crankcase ' "
Screw inner cover to crankcase (2! in. U.H.)
Stud, gearbox cover
Cam plate
Camplate roller
Plunger ...
Plunger spring ...
Plunger acorn sleeve nut
Selector spindle
Selector fork mainshaft
Selector fork lays haft
Filler cap
"0" ring
25
QUANTITY
SELECTORS
1
1
1
1
2
1
2
1
1
1
1
1
2
2
1
2
1
1
1
1
1
1
1
1
REMARKS
25
12
13
I
11
I
24
23
22
16
21
I
5
19
I
'
26
27
18
i
I
10
I
9
I
7
17
8
I
6
Fig. 10. GEARBOX SHAFTS AND GEARS
Ref. No.
Pan No.
DESCRIPTION
QUANTITY
GE'ARBOX SHAFTS AND GEARS
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
2S
26
27
28
29
T2174
T3857
T3858
T2176
T3785
T3864
T3860
T3861
T3862
T928
T2153
T3642
T2165
14-6610
T1918
T2116
5542
T1962
T1963
T1250
T2170
T731
T732
5594
T448
T280
T3621
S681
566-1
•
MAINSHAFT CJW LOW GEAR
MAINSHAFT 2ND GEAR
MAINSHAFT 3RD GEAR
MAINSHAFT HIGH GEAR
High gear bush
LAYSHAFT CjW HIGH GEAR
LA YSHAFT 3RD GEAR
LAYSHAFT 2ND GEAR
LAYSHAFT LOW GEAR
Low gear bush
Housing, high gear oil seal
Oil seal high gear oil seal
Gasket, high gear oil seal
Fixing screw (i in. U.H.)
Gearbox sprocket 19T
Tab washer
Locknut sprocket
Kickstart pihion washer
Kickstart pinion sleeve
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
Kickstarc pinion spring
Kickstart pinion
Kickstart ratchet
Tab washer mainshaft nut
Nut, washer
High gear bearing
Bearing cirdip ...
Mainshaft bearing
1
Nut, clutch hub to mainshaft
Key
1
27
REMARKS
2
7
6
5
I
12
11
v
33
fig, 11.
32
v
31
22
CLUTC H AND CLUTCH OPERATION
i
8
9
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CLUTCH AND CLUTCH OPERATION
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
Clutch cover
T2554
T2556
T2555
T3756
14-6510
S680
T2557
14-6610
T3642
T2479
T3642
T2562
T3705
T3709
T3708
T3715
T3717
T3718
T3719
T3720
Joint washer
Cover, breather duct
Adaptor ...
Screw, long, cover to crankcase (4 in. U.H.)
Screw short cover to crankcase (i in.)
Tube
Screw cover to crankcase (1f in.)
Oil seal cover to mainshaft
Sleeve, shaft oil seal
Oil seal dutch shaft
CLUTCH ASSEMBLY
End cover, assembly
Driven plate assembly
Drive ring
Pressure plate
Thrust bearing
Diaphram spring
Bolt end cover to housing
Tab washer. end cover to housing
nsao
T2552
T3640
T2465
570-3
T2547
T3647
T2553
14-0402
T2473
T3638
T2474
14-6102
Clutch hub
Pull rod dutch release
Peg, outer chaincase (for clutch operation)
Thrust plate inner
Ball, in. dia.
Clutch lever complete
Bearing, outer thrust plate
t
Sleeve nut
•
Locknut ..
Spring, outer thrust plate
Distance piece, outer thrust plate
Tab washer
Bolt (t in. U.H.)
29
1
1
1
3
1
3
1
1
1
1
1
12
6
1
1
1
1
3
1
1
1
2
2
1
2
REMARKS
8
!
11
12
23.--24
30
17
..
28
w
0
ll
18
19
"~
~I
I
11
32~
31~ ~
I
22
'1
,,
I
21
33
Fig. 12.
INNER AND OUTER CHAINCASE
10
!
Ref. No.
Part No.
DESCRIPTION
QUANTITY
I N'N E R AND OUTER CHAIN CASE
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
TI460
S536
E402
E8786
E4705
14-6101
$1819
S25-3
TI581
TI558
14-6608
14-7006
51820
$25-3
T2461
TI166
E5782
T3619
T3620
T2551
T3639
14-6605
TI220
T1645
T3733
S567
T1646
14-6611
14-6613
14-66fs
14-6504
14-6510
14-6610
T2244
T989
Inner primary chaincase
Drain plug
Washer ...
Tube, chain oiler
Clip-tube
Bolt, clip
Bolt, long (4i ln. U.H.)
Washer ...
Joint washer inner to outer chaincase
Gasket inner case to <:haincase
Screw, short (1 in. U.H.)
Internal screw (1 in. U.H.)
Bolt (4i in. U.H.)
Washer .. ,
Outer primary chaincase
Filler plug
"0" ring
Tensioner, adjusting plug
"0" ring
Inspection cover
Inspection cover gasket
Screw, inspection cover (i in. U.H.)
Clutch cable abutment
Adaptor ...
Sealing Ring
Locknut ...
Rubber cap
Screw, outer to inner chaincase (1! in. U.H.)
Screw, long outer to inner chaincase (2! in.)
Screw, outer to inner chaincase (3 ln. U.H.)
Screw, short countersunk (~ in. U.H.)
Screw, longer countersunk (2 ln. U.H.)
Screw, short, chaincase (1! ln. U.H.)
Joint washer
Dowel
31
1
1
1
1
1
1
1
1
1
1
2
7
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
7
2
1
2
1
1
1
2
REMARKS
30
28
29
22
27
!
I
I
i
~©
13
14
~ck
21
j
33
32
~-31
,,
10
I
6
I
3
5
2
7
8
'
Fig, I •·
4
TRANSMISSION A ND OIL PUMP DAIV
PAIMAAY
E
Ref No.
Part No.
DESCRIPTION
PRIMARY tRANSMISSION
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
not illus.
T3610
E6061
T361S
T3618
T9257
T9258
E9256
E5977
T3614
T3617
T2245
T2471
T2250
T2251
T2252
T1150
T2215
T3646
T2478
T2480
T3644
T7248
E6881
E7246
E6885
E7248
D699
E6890
E8785
S585 •
D1915
T3643
T2214
E9634
AND
QUANTITY
0 I L PUMP
T ensioner blade
Tensioner blade
Tie rod '"'
Spring
Saddle wasner (rear)
Saddle washer (adjuster end)
Trunnion
REMARKS
DRIVE
1
1
1
Trunnion
Pivot pin
Adjuster nut
Clutcn sprocket
Spider
Drive rubber
Rebound rubber
Retaining plate ,
Screw. retaining plate.
Outer thrust washer, dutch shaft
Thrust race
Spacer, shock absorber nut
Nut
Oil seal . "'
Driven gear
Spindle, intermediate gear
Intermediate gear c/w bush
Bush, intermediate gear
Oil pump, driving gear
Primary chain, Triplex 82 links
Engine sprocket
Tab wasner
Nut, engine sprocket
Rear chain, 106 links
Needle race
Thrust washer, inner
Shim for engine sprocket (0·010 in. thick) "''
33
1
1
2
1
1
1
1
6
6
1
6
1
1
1
1
1
1
1
1
1
1
1
2
1
as required
5
23
'
22
\
/
/
QJ@
6'
17
10
24
15
19
is
Ref. No.
Part No.
DESCRIPTION
QUANTITY
FRAME
1
2
3
4
5
6
7
a
9
10
11
12
13
14
15
16
17
18
19
lO
?.1
22
23
24
25
26
27
28
29
30
31
F9329
F7159
14-0126
S16-1
F9330
F9380
S1805
526--3
14-0402
F9365
T2331
F4671
F9368
F5679
F4484
14-0405
F7849
F7021
14-0703
F8392
51801
526-1
14-0303
PCW73A
5588
14-0251
14-0304
F4370
H111
570-3 ..
H1018
Front Frame
Front D.S. engine plate
Bolt
Spring washer
Rear frame
Mounting bracket, petrol tank
Bolt (2t in. U.H.)
Washer
Nut
Centre stand
Pedal rubber
Spring
Pivot bolt
Washer ...
Tab washer
Nut
Prop stand
Swivel pin
Nut, swivel pin
Spring
Stud, top rear to front frame (3f in.)
Washer, frame ...
Nut
Spring Washer ...
Bolt, bottom rear to front frame
Bolt, front rear to front frame (1! in.)
Nut
Washer ...
Cup, top and bottom steering race .
Ball, top and bottom
Top cone
35
1
1
2
2
1
2
2
2
2
1
1
1
2
2
2
2
1
1
1
1
1
2
2
4
2
2
2
2
2
40
1
REMARKS
~~
16
I
27
36
24
22
18
/--------~
/
/
"-;0
~
r
I
I
-1 9
I
J
c.,-
17
c~:.
21
c.:-.-:.
~
33 32
\
)
®@
20
i
311
5
9
\
7
I
~
11
Fig. 1S. SWINGING FORK AND SUSPENSION UNITS
No.
Part No.
DESCRIPTION
SWINGING
1
F1 0045
2
F6042
3
4
NW100
WE170
5
F6821
6
7
8
9
10
11
12
13
F5313
14-0304
14
S1802
15
22
PCW73A
D2021
99-0122
99-0107
99-0106
99-0103
99-0109
14-0235
23
525-3
24
GS308
526-1
14-0303
F9383
14-0113
14-0702
F~>87 •
526-3
14-0302
14-6131
16
17
18
19
20
21
25
26
27
28
29
30
31
32
33
34
35
36
FORK AND SUSPENSION
SWINGING FORK
Bush
Grease nipple
Bobbin
Distance tube
1
Sfarm bolt
Tab washer
$545
Nut
F8090
F7848
"0" ring
Upped washer
Torque stay
F7532
1
2
1
1
FS944
F7364
14-1303
UNITS
Fibre washer
S620
F7365
REMARKS
2
1
1
1
Nut
Bolt
Spring washer
SUSPENSION UNIT (SB4 x 133)
Bonded bush 64533645
Spring retainer 9054/171 .
Outer dirt shield 9054:151
Inner dirt shield 9054/47
Spring 9054/280 ...
Bolt, top and bottom (2 in. U.H.)
Washer, hottom bolt
Wash~r. top bolt
Spring washer, bottom bolt
Nut
Rear chai nguard
Front pivot bolt (fin. U.H.)
Self-locking nut
Bolt, rear chainguard to fork (¥,-in.)
Washer
Nut
Bolt
Long chain oiler pipe .. .
Short chain oiler pipe .. .
Nut
37
2
2
1
1
1
1
2
4
4
2
2
2
4
2
2
2
2
1
1
1
1
1
1
1
2
32
I
1
2
\
3
I
I
I
\I~
~~
33
34
/
4
7
w
<X>
I
28
29
I
46
Fig. 16.
ENGINE UNIT FITTINGS A ND FOOTRESTS
~
49
Re( No.
ENGINf:
1
2
3
5571
14-0804
PCW73A
4
5
5572
6
PCW73A
7
F5532
F9623
F9624
FS943
51800
14-0305
S25-6
F9279
F9630
F9627
F9629
F7157
14-0222
14-0221
S25-3
526-3
14-1302
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
so
14-0304
S548
F7389
14-0126
14-0234
S26-1
14-1303
14-0;\03
F9379
F9378
S26-1
14-0303
14-0236
526-1
14-0303
F9635
F6064
526-1
14-0303
14-0106
14-0401
14-0103
14-0401
F7386
S25-13
UNIT,
FITTINGS AND
FOOTRESTS
Stud, front engine to frame (3t in. O.A.)
Nut, stud
Spring washer
Stud (bottom) engine to frame (1Qt in. O.A.)
Nut, stud
Spring washer ...
Spacer, bottom engine fixing ...
Drive side footrest
Timing side footrest
Peg
Stud, footrest (1 ,', in. O.A.) ...
Nut, stud footrest
Washer. stud footrest .
Footrest rubber T.5.
Footrest rubber D.S. . .
Rear engine plate T.S.
Rear eng>ne plate 0.5.
Spacer D.S. rear engine plate
Bolt, D.S. rear engine plate to engine (2.!: in. U.H.)
Bolt. T.S. rear engine plate to engine (2 in. U.H.)
Washer, rear englne plate to engine
Spring washer
Nut
Stud, D.S. and T.S. pivot lug to engine plate (1% in. O.A.)
Nut stud
Bolt, upper rear engine plate to frame(! in. U.H.)
Bolt, lower rear engine plate to frame (1;f in. U.H.)
Spring washer
Nut
Nut
Torque stay engine R.H.
Torque stay engine L.H.
Spring washer ...
Nut
Bolt, torque stay to frame (2t in. U.H.)
Spring washer
Nut
Rear brake pedal
Lever
Spring washer
Nut
Stop bolt (1 in. U.f-'.) .
Locknut .
Adjuster. stoplamp switch
Nut, adjuster
Brake rod
Washer
Split pin,
F7387
F9529
QUANTITY
DESCRIPTION
Part No.
in.
xi in.
Adjuster nut
Oil pipe retaining strap
39
1
2
2
1
2
2
1
1
1
4
2
2
2
1
1
2
2
2
4
4
4
2
2
2
2
4
2
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
REMARKS
17
19
18
16
I
22
24 23
20
21
1
2
5
11
10
Fig. 17.
~XHAUST PIPES AND SILENCERS
12'
13
No.
DESCRIPTION
Part No.
REMARKS
EXHAUST PIPES AND MANIFOLDS
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
E7597
E6743
E410A
E6744
EB900
E8901
14-0205
14-0701
526-3
E9036
E9037
E7512
E3768
14-0119
14-1302
F9440
14-0101
14-0301
E4711
14-0115
525-3
14-1302
14-0114
525-3
14-1302
E8902
51822
525-13
F9947
..
Exhaust manifold
Finned dip
1
3
Hemispherical washer.,
3
Bolt
Exhaust pipe D.S.
Exhaust pipe T.S.
Bolt, exhaust pipe to manifold (1;\c in.)
Nut, Philidas exhaust pipe to manifold
Spring washer
Silencer D.S.
Silencer T.S.
Clip
'D' washer
Bolt
Nut, Cleveloc
Strut
Screw, strut top and bottom
Nut (Cieveloc) ...
Hanger, frame from silencer T.S.-D.S.
Bolt (~ in. U.H.)
Plain washer
Nut
Bolt, silencer to frame (i in. U.H.)
Spring washer
Nut
Bracket D.S. and T.S. silencer
Bolt, bracket to silencer (! in. U.H.)
Washer ...
Centre stand stop plate
3
1
1
2
2
41
4
1
1
2
4
2
2
2
4
4
2
4
3
4
2
2
2
2
4
4
Not iII ustrated
FORK ASSEMBLY No.1
11
~
13~
12--
-~
18~--
47
.. 23
.. -
39 40
I i
6.,1@
30
Fig. 18. TELESCOPIC FRONT FORK
42
33
Ref. No.
Part No.
DESCRIPTION
TELESCOPIC
1
2
3
4
5
6
7
8
9
10
11
H2287
H2288
H439
H2290
SlS-2
14--1303
H2108
H2293
H1527
F6738
D623
12
S578
13
Hll66
14
H2083
15
S684
S685
16
17
H2300
18
H2301
19
F4047
20
H1657
21
H1892
22
H1656
23
H1645
24
H1654
25
H1500
26
H2119
17
H431
28
H441
29
H1896
30
H209l.
31
H443
32
H2091
33
H2245
34
H2294
35
H2295
H1B44
36
37
$26-3
14--0218
38
39
HS19
40
H430
41
H2090
42
H2126
43
H1062
H2154
44
45
H2127
46
F3098
47
H2107
Not ill us. H3682
QUANTITY
FRO NT FORK
FORK-ASSEMBLY
Middle lug and stem
Bottom cone
Pinch bolt (2;1: in. U.H.)
Pial n washer
Nut
Fork stem sleeve nut
Top lug
Bonded bush
Lock cfw 2 keys
Key (state serial number)
Grub screw
Sealing washer
Gaiter dip ...
Pinch bolt (1Jt in. U.H.)
Seated nut ...
Left top cover
Right top cover
Cork washer
Spring abutment
Main spring (yellow/green)
Plain washer
Telescopic gaiter ...
DUST EXCLUDER SLEEVE NUT
Oil seal
·'Q"
1
1
1
2
2
2
1
2
2
1
1
1
4
1
1
1
1
2
2
ring
Plain washer
Top bearing
Damping sleeve . . .
. ..
.. .
STANCHION cjw BEARING LJR
.. .
Lower bearing
Bearing nut ...
Cap nut
LEFT BOTTOM MEMBER cjw CAP
RIGHT BOTTOM MEMBER cfw CAP
Spindle cap ...
Spring washer
Cap bolt (1 f. in. U.H.)
Drain plug.
Fibre washer
Restrktor , ..
Flanged bolt (if in. U.H.)
Aluminium washer
Shuttle valve
Cirdip
Clip, front brake cable
Locating pin
Brake cable retaining bracket
43
,._ .
If J.i J l:< ..
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
2
4
4
2
2
2
2
2
2
2
1
1
1
REMARKS
7
~13
Fig. 19.
HANDLEBAR MOUNTINGS AND STEERING DAMPER
Ref. No.
DESCRIPTION
Part No
HANDLEBAR
1
2
3
4
5
6
7
8
9
10
11
12
13
H
15
16
17
18
Hll91
F1335
5589
H2221
H1529
14--0903
H1616
H435
H1618
H3602
H565
H3601
H95
H1797
H2108
H3604
H1581
H1580
MOUNTINGS
AND STEERING
Handlebar eyebolt
Plain washer
Bolt (1t in. U.H.)
Cup
Hemispherical washer ...
Self-locking nut
Sold bush for handlebar mounted windscreen
Friction disc
Rubber sleeve ...
Steering damper rod cjw knob
Plain washer
Adjuster sle•ve
Spring plate
Anchor plate
Sleeve nut
Nameplate
Distance piece
Rubber ...
45
QUANTITY
DAMPER
2
2
2
2
2
2
available
1
1
1
1
1
1
1
1
1
1
2
REMARKS
4
13
2
23
22
27
21
39
I
17
11
i
30 38 29 34
I
I I
9
~j}r~
~~,JM2l
I
I
l
l
i
I
I
\
5
I
7
I
27
I
I
6
26
I
25
I
19
';;)[36
''>'''"'/,
/&f~
l
4~
Fig. 20
FRONT WHEEL
I
I
37
I
31
l
l
I
!
l
'"f'
:
I
37 33 32
Ref. No.
Part No.
DESCRIPTION
FRO NT
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
QUANTITY
REMARKS
WHEEL
W3509
W1994
W270A
W1328
W1708
W1709
S79-2
W1995
W2057
W653
W1237
T280
W1481
W3337
WS82
W1992
W2092
F2351
W1197
W1198
W3462
W1996
W1998
W2059
W2026
W135
W2001
W3453
14--0303
FRONT WHEEL COMPLETE
RIM SPOKES AND HUB ASSEMBLY
Front wheel rim (WM2-19)
Spoke (8(10G x 5t in.) straight cjw nipple
Spoke (8(10G x 4:~ in. 78c) c w nipple
Spoke (8j10G x 4i in. 100"') c w nipple
Spoke nipple
Hub and brake drum
Wheel spindle
W34~
Brake cam lever rear
W2003
W2005
14--0401
W592
W2058
WF32
D2683
W2027
W1991
S650
D2687
Rod assembly ...
Fork end threaded
20
10
10
40
2
Bearing
Dust cover
Circlip
Grease retainer
Bearing support ring
Retaining ring
Cover plate
Screw
Washer
3
3
Balance weight t oz.
Balance weight 1 oz.
Brake anchor plate
as required
as required
BRAKE SHOE ciw LINING
Brake lining
Brass rivet
Abutment pad
Shoe return spring
Brake cam
1
2
2 } Not supplied
14
separately
2
2
2
Brake cam lever front .
Nut
2
Locknut ...
Lever return spring
1
2
2
Anchor plate nut
Pivot pin ..
Split pin (-H; in.
Plain washer
xi in.
long)
Gauze
3
Taptite screw
Split pin
(16- in. xi
in. long)
47
38
36
'
14
REAR WHEEL COMPLETE
NQ1
I
40
'
\
''
'
5
RIM, WHEEl & SPOKES ASSEMBLY
NQ2
27
28
I
\
1
'
18
16
29
11
i
8
I
26
!
I
41
i
42
Fig. ll.
REAR WHEEL
37
39
46
I
44
I
I
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
REAR WHEEL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
39
40
41
42
43
44
45
46
47
W3427
W3428
W270A
W1104
W1106
579-2
W1472
W3411
W1500
E1612
W1498
W1690
W1691
W1281
W1474
W1654
W1022
W653
W1021
W1710
W1278
W1024
W1112
W3426
W1406
W1407
NW243
W129
W1415
W13S.
W1083
W2015
S25-6
S1-52
W1090
W163S
W1476
W1477
D373
D637
W1280
W2089
W1015
14-0802
F1717
W3468
W3425
W1467
REAR WHEEL COMPLETE ...
RIM, SPOKES AND HUB ASSEMBLY
Rear wheel rim W,3-19
Spoke D.S.
Spoke T.S.
Spoke nipple ...
Hub
Sprocket S2T
Bolt (+tin. U.H.)
Serrated washer
Brake drum
Bolt ft in. U.H.)
Self locking nut
Wheel spindle
Grease retainer (brake side)
Grease retainer
Backing ring
Bearing
RETAINING RING
Locking screw (f. ln. U.H.)
Distance tube
Distance piece
Brake anchor plate
Nut
LEADING BRAKE SHOE CfW LINING
TRAILING BRAKE SHOE CfW LINING
Brake lining ...
Brass rivet
Thrust pad
Shoe return spring
Brake cam
Brake cam lever
Plain washer
Nut
Lever return spring
Grease retainer
Speedometer adaptor
Distance piece
Speedometer gearbox (KPH HEAD)
Speedometer gearbox (MPH HEAD)
Plain washer
Rear wheel adjuster
Adjuster end plate
Self locking nut
Spindle nut T.S.
Tyre security bolt WM3
Inner nut D.S.
Pivot pin ...
49
1
1
1
20
20
40
1
1
8
8
1
8
8
1
1
1
1
2
1
1
1
1
1
1
1
2 } Not serviced
16
separately
2
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
1
1
12
1
I'
'
3
I
ti:n
--
4-
I
I
'
i
I
I
5
Fig.
22.
Ref. No.
Port No.
DESCRIPTION
QUANTITY
OIL COOLER GROUP
1
2
3
4
5
6
7
s
9
10
11
12
F9315
F9907
F9573
99·1017
D1990
F9316
F9322
F9321
F9323
E2351
F4717
D702
Oil cooler, including unions
Reflector rubber and plate
Reflector out
1
2
4
4
2
2
...
Reflector screw 51940
Reflector (57160)
Support strap ...
Corner packing
Rubber bush
Clamp bolt
Washer ...
Nut
Clip
s
4
2
2
2
2
51
REMARKS
14
I
B
tj----16---{j
~17~
®--24-®
®--25--@
@)-~18----§
4--19-11
21
Fig.ll.
PETROL (GAS) TANK
52
Ref. No.
DESCRIPTION
Port No.
QUANTITY
PETROL (GAS) TANK
1
not illus.
not iiJus.
2
3
4
5
6
7
7
8
a
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
F9307
AS6
A61
F3ll0
51804
F9381
F7388
F4715
F9372
F9373
F9360
F9361
F9449
H919
F4019
S1804
E2351
F9450
F9451
F5228
F9543
F3814
F9446
F5336
F4971
F4972
F9436
E7351
F10002
F3814
F967
•
PETROL TANK
Transfer "World Record Holder
Transfer "Made in England"
Filler Cap
Screw, tank motif clip (;j- in. U.H.)
Spring dip motif
Bolt for rear
Screw, motif (it in. U.H.)
Knee grip D.S ....
Knee grip T.S ....
Tank motif D.S.
Tank motifT.S.
T ensioner (for band) ."
Nut
Washer ...
Screw
Washer ..
Centre band
Centre band beading
Top rubber (front support)
Spiggoted rubber (front support)
Bottom cup (front support) ...
Bolt (front support) (1,Z. in.)
Rubber rear mounting ...
Petrol tap (reserve)
Petrol tap (main) R.H.
Petrol pipe (assembly)
Tap seal ...
Steel washer
..
1
1
1
1
4
2
4
1
1
1
1
1
2
2
2
2
1
2
2
2
1
2
2
1
1
1
2
2
Cup for rear mounting
1
Washer for rear tank fixing
53
REMARKS
13
14
11
I
I
I'
•I
I
1
,
I
10I
12
'
®@~~
~
25
26
23
I
'
5,,
~···
-15
I
26
76
··-l
"18
24
28
21
I
27
Fig. 24. OIL TANK
54
26
Ref, No.
Part No.
DESCRIPTION
TANK
OIL
F9308
Not illus, A40 (D778)
Not illus. A44 (D44)
Not illus. A3
F9659
2
F4047
3
F5343
4
PT104B
5
F9430
6
7
F1713
F9435
8
9
F6874
10
F9664
11
F6673
12
F7510
14-0301
13
14
525-13
F6039
15
16
51822
S26-3
17
18
F9588
19
F36SS
10
F3182
21
E8904
E6848
22
23
E8905
24
E8906
25
E8907
D702
26
27
F9530,.
28
F9531
29
F9526
Not lllus. F9918
QUANTITY
Oil tank ,.,
Transfer (gilt)
Transfer (gilt)
Transfer (gilt)
Filler cap
1
1
1
1
1
1
1
1
1
1
Joint washer
Drain plug
Fibre washer
Filter
Fibre washer
Metering screw
Metering screw spring
Extension pipe, froth tower
1
Spiggoted rubber
Peg, tank to frame
2
2
2
2
1
1
1
1
Nut, tank to frame
Washer, tank to frame
Bottom grommet
Bottom bole (t in. U.H.)
Washer ,,
Bottom bracket
Oil feed pipe top half
1
Union nut
Oil pipe flex tank to engine
Oil pipe clip
Oil pipe engine to oil cooler , .
Rocker to oil cooler plpe flex
1
2
1
1
Cooler to oil tank pipe flex
Clip oil return pipe
4
Feed pipe protection spring
Scavenge pipe spring ' "
Rear chain oiler pipe ,. '
Clip. oil pipes to frame
55
REMARKS
16
-······~···~
~~
~·"'II
14
'i
5
.Ii
12
13
6
11
\
5
2
\
1----_J.
\\
\
\.
~
\\ ~@~
\ ~
~·
15---__(
Fig. 15.
BATTERY CARRIER AND AIR FILTER
56
••
Ref. No.
Port No.
BATTERY
1
2
3
4
5
6
7
•
F9343
F9351
F9349
14--0221
525-3
14--0302
F9350
a
F9352
9
F4299
10
14--0228
14--0302
11
F9354
12
F9355
13
F9353
14
15
F8091
Not illus. A 52
16
99-0719
17
F7431
F7892
18
F9074
19
20
F9562
21
E9586
14--0213
22
F9563
23
QUANTITY
DESCRIPTION
CARRIER AND
FILTER
1
Battery carrier
4
Spiggoted rubber bush
Top distance tube
Top bolt (2 in, U.H.)
Washer
Nut
Bottom distance tube . ,
Rubber washer ...
Washer ...
Bolt (4 in. U.H.)
Nut
Strap buckle top
Strap buckle bottom
Retaining strap, ..
Rubber battery tray
AIR
...
Transfer, positive earth
Battery PUZ5A 54027029
Battery vent pipe
Cirdip ...
Air cleaner complete (Element E9138)
Grommet
Sleeve
Bolt (3t in. U.H.)
Connector hose
57
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
1
1
1
3
3
2
1
REMARKS
i
2
34
13
I
21
'
I
-~
i
20
i
19
23
Fig. 16.
PANELS AND TWINSEAT
58
I
12
\
Ref. No.
Part No.
DESCRIPTION
,
1
2
3
4
5
6
7
8
9
10
11
12
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
F9362
F9363
F9591
F9592
F8631
F6673
S1833
525-71
F9442
F9445
S1832
D1905
D1906
F9523
F7489
F7560
F4228
E1719
-h in. X tin.
D696
D697
F4898
F8026
F7862
F7835
14-0101
526-2
D2087
F4483
F9650 •
14-0502
14-0101
14-0401
F9770
F9749
QUANTITY
PANELS AND TWIN SEAT
1
D.S. Panel
T.S. Panel
Beading D.S.
Beading T.S.
Clip
... 1
1
6
2
1
1
1
1
3
1
1
1
Grommet
Nut
Washer ...
Rubber spacer
Release knob
Screw T.S. to oil tank ...
Transfer 'Trident' D.S.
Transfer 'Trident' T.S ....
TWINSEAT
1
Twins.eat cover
Knob
Spring ...
Washer ...
Split pin ...
1
1
1
1
...
Trim strip
Sprag
Buffer
1
4
1
Front hinge
Rear hinge
Buffer
Bolt, hinge H ln. U.H.)
Spring washer
Check wire
Self tapping screw
Toolbox ...
Screw, toolbox to battery carrier
Bolt
Nut
Panel buffer
Toolroll strap
59
...
1
1
1
4
4
1
1
1
1
2
3
2
REMARK$
----5
1~-
17
19
I
'FG d@-_-I
~<Q,'
6
I
r
\
_,
19
\
"'lv20
•
16
26
10'
31
'-
30
I
3
21~-
•
35
34
\
\
43
28
42
•
-55
•
- Q
33------1)
1!..,/
36
~/37
54
38--
41//
40
Fla. 21.
MUDGUARD
60
5 (FENDERS)
~
3g'
•
'
Ref. No.
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
H2677
H2270
H2271
H1681
H1683
H3683
14-0101
525-1
14-0201
14-0115
14-0702
525-3
51822
S25-3
14-1302
H1685
51822
14-0115
F4299
14-1302
F9310
F6915
14-0102
F6310
525-1
14-1201
F6851
S1822
525-1
14-0101
F6310 ~
14-1201
F6031
F5994
51822
525-3
14-1302
F9356
14-0114
F1335
14-0702
F9327
F6849
F6850
5547
F4715
DESCRIPTION
MUDGUARDS
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
55
GS299
55161
14-0102
525-1
14-1301
F8140
F8195
F8873
F7862
QUANTITY
(FENDERS)
Front mudguard
Brake cable retainer
Sleeve
Front stay
Centre stay
Bottom stay
Bolt (tin. U.H.)
Washer
Nut
Bolt (bottom stay to fork) (t in. U.H.)
Nut (bottom stay to fork)
Washer, bottom stay to fork
Bolt (bottom stay to guard) (tin. U.H.)
Washer
Nut, bottom scay to guard
Bracket, stays to fork leg
Bolt, stays to fork leg (t in. U.H.)
Bolt, stays to bracket (J: in. U.H.)
Washer, stays to bracket
Nut, stays to bracket
Rear mudguard
Bridge ...
Bolt, bridge (tin. U.H.)
Washer. bridge
Washer ...
Nut
Bracket (bottom front)
Bolt bracket (bracket to pivot lug) (t in. U.H.)
Plain washer
Bolt (bracket to guard) (!in. U.H.) ...
Washer
Nut
Backing plate
Top clip (guard to frame rail)
Bolt (tin. U.H.)
Washer ...
Nut
lifting handle ...
Bolt (t in. U.H.)
Plain washer
Nut
Tail lamp support
Tail lamp support plate
Number plate bracket
Stud (t in. U.H.)
Screw, plate to support
Shake proof washer
Nut
Bolt (lamp bracket to guard) (tin. U.H.)
Washer ...
Nut
Rubber mat. reflector ...
Push fix ...
Red refiector (57111)
Wiring protector
61
1
1
1
1
1
1
4
4
4
2
2
2
1
1
2
2
2
2
2
1
1
2
2
1
2
1
2
4
1
1
1
1
1
2
2
2
1
2
2
2
1
1
2
1
3
1
1
4
5
5
2
4
2
1
REMARKS
- - - - - - --35
----- 41-~-{]
42
ft--44
®~­
- -36
®-----
37
---45
43--
A.
v-----<t---
46
CLUTCH ASSEMBLY No.16
P----20
21--~
17
e'
19
34
TWISTGRIP ASSEMBLY No. 24
1
Fig. 18.
HANDLEBARS. CONTROLS, BINNACLE AND OIL WARNING LIGHT
62
•
Ref. No.
Port No.
DESCRIPTION
HANDLEBAR, BINNACLE, CONTROL
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
H1870
H1425
D788
99-0262
99-0267
99-0226
99-0225
99-0252
99-0250
99-0270
99-0129
99-0228
12/607
12/606
12/033
99-0283
99-0261
99-0265
99-0230
99-0226
99-0252
99-0250
99-0291
02017
99-0245
89-0246
99-0244
99-0238
99-0239
99-0240"
99-0225
H2125
99-0241
D2017
H2297
525-1
14-1201 :001
99-0555
99-0630
H1994
99-0568
99-0537
D1992
D1943
QUANTITY
LEVERS, OIL WARNING LIGHT
Handlebar
Packing piece
FRONT BRAKE LEVER ASSEMBLY (18,1978)
Front lever (ball end) 18/754
Lever bracket 18/777
Screw 11/014
Screw 11/013
Fukrum screw 18/087
Self locking nut 18{053 ...
Cable adjuster and nut 18/838/839
Control body 12/594
Lever 12/556
Bolt 12/607
Cap 12.1606
Spring washer 12;'033
Clutch lever assembly 18(952
Clutch lever (ball end) 18/752
Clutch lever bracket 18/773
Clamp 12/595
Screw 11 /014
Fulcrum screw 18f087
Self locking nut 18/053
Cable adjuster and nut 18J1005/839 ...
TWISTGRIP (16/364) ...
Body top half 16/328
Body bottom half 16/329 ...
Rotor 16J091
Friction spring 16/008 ...
Friction spnng screw 16/009
Locknut 16/010
Screw 11/013
Grip (black)
Cable stop 16/011
Grip (black)
1
4
1
1
1
1
1
1
1
1
Reference only
Reference only
Reference only
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
Binnacle
Plain washer
Nut
Dip switch 31563 ...
Mounting pad 380459
Screw
Warning light body (red) 38189
Bulb (2W. BA7S) 281
Warning bulb holder 54945043 ...
Warning light body (blue) 54361250
Ammeter type 2AR 36421
Oil Warning light switch (5307 j05) ...
63
REMARKS
4
4
1
1
2
1
1
1
1
1
l-
CLUTCH
CABLE
N91
13
I
~-~7
FRONT
BRAKE
CABLE
N9 5
22
10~----
11 -------J;
14---15 7--:--~----b/"
12--~~
THROTTLE
CABLE
N910
20
23
F;g. 29. CONTROL CABLES
•
I
20
CHOKE
CABLE
N\> 16
No.
Port No.
DESCRIPTION
REMARKS
CONTROL CABLES
1
2
3
"
•
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
10
21
12
13
24
15
D1946
D103
D506
D573
D2050
D103
D506
D638
W2006
D890
D101
D83
D2019
D1018
E9153
D1983
D1968
D2062
D2061
D1060
99-1018
D101
D83
NS191
D104
1
2
CLUTCH CABLE
Ferrule
Nipple. handlebar end
Nipple, dutch end
FRONT BRAKE CABLE
Ferrule
Nipple. handlebar end
Fork end, cable
Spring fix ...
THROTILE CABLE
Ferrule
Nipple
Nipple
Adjuster
Locknut
CHOKE CABLE COMPLETE...
Cable lever to junction box
Cable, junction box to lever, short
Cable~ junction box to lever, medium ."'
Cable, junction box to lever, long
Junction box complete 144/2080
Ferrule
Nipple at handlebar
Nipple at junction box and carburetter
Adjuster complete
65
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
10
1
7
1
-
3
4
5
6
•
7
~
/
/;
e
p
8
j,_
----~"
10
-
-11
2---
----
Fig. 30. TOOLKIT AND PILLION FO
66
OTREST
•
Ref. No.
DESCRIPTION
Part No.
TOO L'KIT AND
1
2
3
4
5
..
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
01912
0291
01907
0362
01908
01909
01910
0767
01911
02020
02084
F9369
F1694
F1695
F9370
F9371
F2277
14-0302
14-0127
526-1
PILLION
QUANTITY
FOOTRESTS
Toolkit complete
Tool roll
Ring spanner (-f,; in. x t in. HEX.)
"C" spanner
Box spanner (1.j- in. x 1-f. in.)
Box spanner (i in. x +tin.)
Plug spanner
Screwdriver complete
Tommy bar
Tappet spanner ...
Spanner! in. x ?6 in. open ended
PILLION FOOTREST ASSEMBLY
Pedal
Rubber
Hanger
Pivot bolt
Thackeray washer
locknut
Bolt (rest to silencer hanger) (tin. U.H.)
Spring washer
67
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
REMARKS
10-~
s------~-------~----~-1
31-·
·-~-3
~··~····--6
1--------------------4
-~---7
C(
8
- - ·26
27'
•
25··- ·---··--------------{
24 ---· . ------------~,~
FIJ. lf. AMAL CARBURETTER AND AIR CLEANER CONNECTIONS
68
•
•
Ref. No.
DESCRIPTION
QUANTITY
AMAL CARBURETTERS
1
1
2
3
4
5
6
7
8
9
10
11
12
~
Part No.
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
D1957
D1985
D1986
99-0522
99-1019
99-0521
99-0506
D1959
D1960
D1987
D1984
E9253
99-0516
99-0515
99-0520
99-0519
99-1020
99-0518
99-0508
99-0512
99-0513
99-0514
99-0506
99-0511
99-0438
99-0517
99-0437
99-1021
99-0509
99-1024
99-0224
99-1022
99-1023
Carburetter type 626 R.H. (Amal 626/14)
Carburetter centre (Amal 626/15)
Carburetter L.H. (Amal 626/16)
'0' ring seal 622/101
Mixing chamber top 622f097 ' "
Screw 622/086
Throttle valve (No.3) 622/060 ...
Top spring abutment
Spring
Bottom s.pring abutment
~
Throttle rod assembly
Locknut
Throttle stop screw 622/077
Pilot air screw 622/076 ...
Friction ·o· ring 622/082
Jet holder 622/080
Main jet (150) 376/100 "'
Needle jet (·106) 622/079
Needle (Standard) 622/063
Float 622/069
Float spindle 622;071
Joint washer 622/073
Float chamber 622(050
Float needle 6221068
F1lter (376/093) ' "
Banjo bolt (622/078)
Fibre washer 376/092
Air slide 622J062 ...
Spring 622/065
Cable adjuster 4/035
Locknut 5(077
Clip 622/125
Sealing rubber 622/126
69
1
1
1
3
3
12
3
3
3
3
3
3
3
3
6
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
REMARKS
1
...
4-
I
3---lj
2~~
{]
®-----18
J!--17
!Q
--~·-12
ii.J
\cs
15
16
I
··············-~--·····-10
•
ah
···--8
Fig. ll. SPEEDOMETER AND TACHOMETER
70
•
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
S P E 'E 0 0 M E T E R A N D TACHOMETER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
D1930
554734
99-0546
99-0176
D1963
01949
01903
E8739
E8740
E8741
E8742
E6124
E3309
E6299
E8744
14-6605
H3632
GS308
Speedometer head MPH (SSM5001f06)
Bulb holder 554734
Bulb 3w. M.E.S. 987 ...
Trip control 41-148-203-10
Speedometer cable 68 in. long
Tachometer head (RSM 3003/01)
Tachometer cable (DF911JOO)
Joint washer. tacho drive
Housing tacho driven gear
Driven gear
Tacho bearing housing
Bush
'0' ring housing
·o· ring. driven gear
Locating screw. housing
Screw, housing to cfcase (if in. U.H.)
Sleeve nut, speedometer ftxing
Washer ...
71
1
reference only
1
1
1
1
1
1
1
1
1
1
1
1
3
4
4
8
7
I
4
3
----28
40--@l
41---®
39----
•
15
I
~
41-
I
24
I
23
~--17
19 -~~-·(~'!
@
21
18--·-~ ~~~--20
22
Fig. ll. IGNITION COILS, HORNS, RECTIFIER AND ZENER DIODE
72
•
Ref. No,
Part No.
DESCRIPTION
QUANTITY
REMARKS
IGNITION COILS, HORNS, RECTIFIER ZENER DIODE
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
0756
F5228
99-0799
99-0738
E6388
54190108
842189
99-0644
01935
99-0766
99-0767
F10033
F3799
G5299
99-0590
H2237
H2236
14-6102
526-2
14-0113
526-3
H2275
01900
01901
14-0103
525-1
14-1201
01964
0911
01937*
H2259
H2034
H687
H745
99-1022
F9564
F9561
F9565
14-0101
526-2
14-0301
02068
Rectifier (49072)
Nut
Lucar connector 54942078
Insulating cover 54190042
Ignition coil, Siba 32000
Lucar blade 54190108 ...
H.T. lead (7 m.m. cable) 842189
H.T. lead clip 421863 ...
Condenser pack 3CP (47637)
Capacitor 54418527
Cover 54418528 ...
Screw pack to plate
Nut
Shakeproof washer
Zener diode 49345
Heat sink
Bracket (sink to fork leg)
Bolt (bracket to heat sink) (i in. U.H.)
Washer ...
Bolt (bracket j in. U.H.)
Washer
Plug, heat sink ...
Horn, R.H. Windtone (Ciearhooter P201) ...
Horn, L.H. Windtone (Ciearhooter P101)
Bolt, horn to bracket (;\in. U.H.) ...
Washer ...
Nut
Spark pi ug cover
Spark pi ug N3 ...
Cut out switch type 151SA (35835)
Cup
Clip
Screw
1
1
as required
as required
3
Reference only
Reference only
3
1
3
1
4
4
4
1
1
1
1
1
1
1
1
4
4
4
3
3
1
1
2
1
Nut
Horn relay 33188
Platform
1
Grommet
3
Platform stay
Bolt
4
Washer
4
Nut
Lucar blade-condenser earth 54190038
4
1
1
1
73
1
-----~-------
••
2
16--
•.
18
31
32
33
•
~,;;®;;,;-------22
Fig. 34.
HEADLAMP, WIRING HARNESSSWITCHES AND TAIL LAMP
74
•
No.
Part No.
DESCRIPTION
.
HEADLAMP, WIRING
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
99-1029
54524099
99-0692
99-0686
99-0683
144921
99-0690
99-0545
99-0694
99-0548
99-0695
99-1026
112201
137498
H1932
99-0563
F9692
99-1025
99-1028
F4715
E2351
199001
99-0597
99-0781
99-0698
99-0783
99-0701
99-0542
99-0780
127684 ..
99-0558
F6981
0622
REMARKS
HARNESS, SWITCHES AND TAIL LAMP
HEADLAMP COMPLETE MCH69 (59892)
Shell 54524099
Rim 553248
Light unit 516798 .
Fixing wire 504665
Screw 144921
Plate 534296
Bulb (50j40W. vertical dip pre focus) 446
Main bulbholder 554602 .. .
Bulb (3W. M.C.c.) 989 .. .
Pilot bulb holder 554710 .. .
Rubber cover 54524048
Bolt 112201
Plain washer 137498
1
6
Reference only
1
1
1
1
1
Reference only
Reference only
2
Distance piece
Ltghting switch type 57SA 35710
Switch rubber cover
1
Reference only
1
...
Wiring harness 54954246
Stoplamp switch 118SA 34815
Screw, switch to engine plate
Washer, switch to engine palte
Rubber grommet (tail lead at guard) 199001
STOP AND TAIL LAMP, type L697 53973
Lens 545n932
Screw 572289
Bulb holder with reflector 54574348
Contact assembly 573828
Bulb (6r21W. offset pin) 380
Gasket 54571677 ...
Screw 127684
Ignition switch, type 545 31899
IGNITION LOCK CJW KEYS
Ignition key (state serial number)
75
1
1
1
1
1
Reference only
1
1
2
1
1
1
Reference only
1
2