1968 triumph tr25w 250cc

REPLACEMENT
PARTS CATALOGUE
THEtrW
asE
TR25W
25 0 c.c. (15 cu. ins.)
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REPI.ACEMENT PARTS
CATALOGUE
TROPHY 250
TR.25.W.
g$otot C tle <tv *,ct,otet {t, rtcc,
n, r::..cetlc
Ul4ein czdgcnl 1ijt,.*Qr's,(. &
HAWTHORNE WORKS, FAf(K STRItl , TTJAHr
OXFORDSHIR$
Trlrphonc: IHA|,IE 271
TRIUMPH ENGINEERING
COMPANY LIMTTED
MERIDEN WORKS ALLESLEY
COVENTRY ENGLAND
TELEPHONE I.IERIDEN
I31
TELEGRAMS ..TRUSTY, COVENTRY''
REF. No. trC6
PWI.ISHED MAECH 1968
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TRIUMPH GUARANTEE
1.
ln 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.
ln 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 sufticient, will
repair tree of charge any part prove.d within six months of the date of purchase of any new machine,
(three months overseas) or within three months of its renewal or repaii 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 pait or accessory.
4.
Any part considered to be defective must be sent to our Works, carriage paid, accompanied by the
i nformatioHName of purchaser and his address;
(b) Date of purchase of machine;
(.) Name of dealer from whom the purchase was made;
followi ng
(d) Engine number and model.
5.
This Guarantee shall not extend to defects or damage appearing after misuse, neglect, abnormal stress
or strain, or the incorporation or affixing of unsuitable attachments or parts and ii particular:-
(")
Hiring out;
(.)
Racing and Competitions;
A.daptation or alteration of any part or parts after leaving our Works;
The attaching of a sidecar in a manner not approved by-us or to an unsuitable
(b)
(d)
This Guarantee shall
machines whose trade mark, name or manufacturing number has
""I:i:J#:'i
been altered or removed,
or in which has been used any part not supplied or approved- by us, or to
tyres, saddles, ch.ains, speedometers,_revolution counters and electrical'6quipmend br
to the order of the Purchaser and different from our standard specification.
to parts supplied
6.
Ou.r liability and.that of our dealer who sells the machine, shall be limited to that set out in this guarantee,
and not other claims including.claims for. consequential damage or injury to person or prop-erty, shall
be admissable. All other coiditions and warranties statutor:y or othelwise'and whetfier express or
implied .are hereby excluded and no guarantee other than that expressly herein contained aiplies 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.
THE FITTING OF ANY COMPONENTS WHICH ARE NOT APPROVED BY THE
MANUFACTURER INVALIDATES THE GUARANTEE
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 lefi our
Works after being repaired.
2.
We.will repair or re.place.at our option free of charge any.defective work, materials or parts relating
repairs carried out by us appearing within thaitime but shall nor be under any furiher or othei
!9.tlt.
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 uied'by us in effecting a
repair. All other conditions and warranties statutory or otherwise express or implied aie hereby excludEd.
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TROPHY 250 TECHNICAL DATA
67 x 70 mm.
Bore and stroke
249 c.c.
Capacity
10:1
Compression ratio
Champion N3
Sparking plug
Amal Concentric .928
Carburettor
Choke size
28 mm.
Main jet
Needle jet
.106
Need le
Th
170
Stan
d
No.
rottle valve
ard
3
5 teeth
Gearbox sprocket
1
Final Drive Sprocket
52 teeth
Chains
F
$ in.x $ in. Duplex x 70 links
j in. x 1f in. x 100 links
ront
Rear
Capacities
Fuel tank
Oil tank
Gearbox ...
Primary chaincase
Front forks (each leg)
Brakes
Front and rear diameter
Tyre size
F
3.916 galls. U.S.
6 pints
{ pint
f, pint
j pint
7 in. x
1j
in.
3.25 x 18
ront
4.00 x 18
Rear
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INDEX
Poge
AIR FILTER
ALTERNATOR
BATTERY CARRIER
CARBURETOR
CARTON PACKS
CHAINGUARD
47
15,43
Poge
HANDLEBARS
39
HORN
41
MUFFLER
27
OIL PUMP
13
OIL TANK
77
PILLION FOOTRESTS
29
23
47
7
2s
PISTON
CHAINS
PROP STAND
25
REAR PANELS
27
REAR WHEEL
35
RECTIFIER
4t
13
SPARK PLUGS
11
29
SPEEDOMETER
41
STEERING RACES
31
SUSPENSION UNITS
75
CLI-,'TCH
21
cotL
41
CONTACT BREAKER
43
CONTROL CABLES
39
CONTROL LEVERS
39
CRANKCASE
CRANKSHAFT
CYLINDER HEAD
EXHAUST
PIPES
27
FENDERS
37
FOOTRESTS
29
FRONT FORKS
31
FRONT WHEEL
33
GAS TANK
GASKET SETS
GEARBOX
9
21,35
39
swlTcHEs
41, 13
TIMING GEARS
19
TOOLKIT
45
TWINSEAT
39
VALVES
11
WIRING HARNESS
41
ZENER DIODE
43
7
17,19
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ILLUSTRATION INDEX
Poge No
Fig. No.
8&10
1
CYLINDER AND CRANKSHAFT
2
CRANKCASE
17 &14
3
GEAR CLUSTER
16 & 18
4
CLUTCH
5
FRAME COMPLETE
6
SWINGING ARM
7
OIL-TANK, PANELS AND EXHAUST
8
FOOTRESTS
9
TELESCOPIC FRO NT FORK
30
10
FRONT WHEEL
32
11
REAR WHEEL
34
12
FENDERS
36
13
GAS TANK,
14
ELECTRICAL EQUIPMENT
15
TOOL KIT
44
16
CARBURETTOR
46
20
72
74
26
SYSTEM
28
AND BRAKE LINKAGE
38
TWIN SEAT AND HANDLEBARS
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,10
& 42
TRIUMPH SPARES
HOYY TO ORDER. Every part is indicated by a number, and this should be quoted totether with
the description.. ln order to assist customers, dimensions have been given in many cises wheie parts are
similar. Partswherepossiblehavebeenlistedinorderofassemblyandinumberoftheillustrationsihowthe
assembly order also. With these aids, there should be no difficulty in identifying the parts you require.
ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OF
THE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS.
\ffHERE TO OBTAIN. Triumph Spare Parts can only be obtained from an authorised Triumph
Dealer, and we recommend our customers to place their ordeis with the Triumph Dealer in their distrii:t.
When parts not usually asked for are required, ind for which the Dealer may have io write or obtain specially,
the postage or carriage incurred becomes payable.
Customers are warned. against th-e risk incurred by purchasing parts that are not of genuine Triumph
manufacture. This risk is eliminated if parts are ordered is instrucied from recognised Deilers.
PROPRIETARY
G
ROUP
. Ancill-ary equipme.nt which is fitted to our motor cycles is of the highest quality and is guaranteed by
the manufacturers and not by ourselves. Any repairs or claims should-be diiected to rhe-actual makert
or their local agents-who will always give owners every possible assistance. The following are the addresses
of the various manufacturers:-
CARBURETTORS.
The Avon lndia Rubber Co. Ltd.,
Messrs. Amal Ltd.,
Melksham,
Holdford
Wilts,
Road,
Witton,
Birmingham, 6
SPARKING PLUGS.
Champion Sparking Plug Co. Ltd.,
CHAINS.
Fe
lt ham,
Reynold Chains Ltd.,
Wythenshawe,
Middlesex.
Manchester.
SPEEDOMETERS.
Messrs. Smiths lndustries Ltd.,
Cricklewood Works,
London, N.W.2.
ELECTRICAL EAUIPMENT.
Messrs. J. Lucas Ltd.,
Gt. Hampton Street.
Birmingham, 18.
TYRES.
Dunlop Rubber Co. Ltd.,
Fort Dunlop,
SUSPENSION UNITS.
Messrs. Girling Ltd.,
Birmingham Road,
West Bromwich,
Staffordshi re.
Birmingham, 24
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HOW TO USE THIS PARTS CATALOGUE
First check that the engine number of your machine is subsequent to that guoted on the
title
page.
Page 0 for the parts or group of parts which you w.ish to locate. When
slure from the end columns that the Part you have located does apply to
parts
make
the
you have located
your machine.
Next consult the index on
List the quantities required as single units; do not ask for "2 pairs" or "3 dozen".
Items marked "reference only" are not available from the factory.
ln case of painted items always state the colour. Painted parts are available only in the colours specified
for that model of that particular year.
Model
Colour
TR25W
Hi-Fi Scarlet
N.B. Hi-Fi Scarlet is a flamboyant finish applied over Gold
Paint is available only in Aerosol containers.
PLEASE NOTE
THROUGHOUT TH]S 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
CASES
Voun DEALER oR APPLYING DIREcT To THE TRIUMPH SERVICE DEPARTMENT. IN MOST
USE'
AND
WORKSHOP
FOR
ENTIRELY
MADE
ARE
THEY
COSTLY AS
THESE Tools ARE
RECoMMENDED THAT THE pRlvATE owNER PURCHASES THE Tools lN
rHEneronr, tr ts Noi
'ERY
ONOTN TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES
IT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.
UNIFIED THREAD FORM
NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOGUE HAVE THE UNIFIED
FORM OF SCREW THREADS. THIS CHANGEOVER WILL BE CONTINUED AS AND WHEN NEW PARTS
ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS
WILI- SE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS HAVING
THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS IN THEIR HEADS'
STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING CIRCLES ON THE
SIDE.
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CARTON PACK LIST
The following sub-assemblies are supplied in carton packs under the C.P. part number stated. The
contents ofthese carton packs are preserved and will not deteriorate under adveise conditions.
PISTON (complete
with rings, gudgeon pin and circlips). These are in effect'carton
assemblies.
E7998
E8772
10:1 C.R.
10:1 C.R.
E8273
'10:1 C.R.
STANDARD SIZE
0.020 in. oversize
0.040 in. oversize
PISTON RINGS
cP
211
(Standard size)
1
E8276
1
E8782
Top Compression Ring
Middle Compression Ring
1
E8779
Scraper Ring
PISTON RINGS
cP211120
(0.020 in.
oversize)
1
E8277
1
E8283
Top Compression Ring
Middle Compression Ring
1
E8280
Scraper Ring
1
1
1
E8278
E8284
Top Compression Ring
Middle Compression Ring
E8281
Scraper Ring
PISTON RINGS
cP211140
(0.040 in. oversize)
OVERHAUL GASKET SET
99-0031
DECOKE GASKET SET
99-0040
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CYLINDER AND CRANKSHAFT
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Ref. No
Port No.
DESCRIPT'ON
CYLINDER
QUANIIIY
AND CRANKSHAFT
1
E8031
2
88032
3
E8033
4
E8034
5
E8035
6
E8037
7
E8028
Flywheel d riveside
Flywheel bolts upper (1$ in. U.H.)
Flywheel bolts lower (2 in. U.H.)
FLYWHEEL TIMING SIDE
Flywheel screwed plug
Washer
Cran kshaft assy.
8
E8038
Shi m
A.R.
8
E8039
Shim
A.R.
9
E1
580
1
4
4
1
1
8
1
Cran kshaft pin ion key
1
10
E8144
Rotor key
1
11
E8836
17
E3705
CONNECTING ROD
Connecting rod bolt
2
'13
E7977
14
E,+003
15
E6068
16
E7998
17
E8044
'18
E8047
19
E8050
70
wE203E
21
wE479
22
El 895
73
E7728
74
E8053
24
E8055
25
E7739
76
E8008
27
E81
96
1
Self-locking nut
Small end bush (split)
Big end bush
PISTON COMPLETE
Plain compression ring
Taper compression ring
Oil control ring
Gudgeon pin
2
Circlip
Cylinder barrel ...
Cylinder base washer
Push rod (exhaust)
Push rod (inlec) ..
Cam follower
Cylinder barrel stud
2
Stud
nut
1
2
4
1
1
1
1
1
1
1
1
2
7
...
2
78
E821 5
Washer
2
79
E8197
CYLINDER HEAD
1
30
E8228
Stud-short (2ft
31
E8229
Stud
32
E8079
Stud-long (3fr in. O.A.)
33
E801 0
34
E8080
35
E8777
36
E8225
37
88276
Dowel
Stud (2"1{ in. o.A.)
Carburettor stud (1$ in. O.A.)
Valve guide (inlet)
Valve guide (exhaust)
38
E8081
in
o.A.)
39
E8137
40
E81 36
Cylinder head gasket
Carburettor stud nut
Carburettor flange washer
41
E7820
Distance piece
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2
2
3
2
7
2
1
1
1
7
1
1
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CYLINDER AND CRANKSHAFT
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Ref.
No.
Port No.
DESCRIPT'ON
QUANI'TY
CYLINDER AND CRANKSHAFT
42
E7911
43
E7858
Rocker box
Rocket box gasket
1
44
E7787
Rocker spindle
2
45
E7790
INLET ROCKER
1
46
E1483
47
E7791
46
E1
48
El 575
49
E1
50
E8952
Ball end
EXHAUST ROCKER
Ball end
Thrust washer
Th rust washer
lnspection cover
51
E8085
Gasket
52
E8086
53
E8116
Screw (l{ in. U.H.)
Top collar
54
E8117
Split collet
55
D911
55
E81
57
D1002
58
1
59
E8084
SPARK PLUG (N3)
Washer
Plug cover
Lockn ut
Washer
60
E7958
60
E7959
60
E7960
483
330
38
4-0403
61
E1564
62
E1577
63
64
1
1
1
1
2
2
1
1
2
7
4 halves
1
1
1
2
2
Corrugated ring...
Corrugated ring...
Corrugated ring
A.R.
A.R.
A.R.
lnspection Cap
Washer
2
E8087
Nut
2
E8088
Washer
2
65
E8089
Nut
7
66
E8072
7
67
E8082
68
E8083
Washer
Union
Fibre washer
E81 05
OIL FEED
2
1
1
PIPE
1
69
E81
06
Rubber connection
70
E81
07
71
E8110
Nipple
Union nut
72
E8111
Clip
1
73
E8112
lnlet valve
1
74
E7777
Exhaust valve
1
75
E8113
Bottom cup
2
76
E8114
E811s
Valve spring-outer
Valve spring-inner
2
77
1
1
1
2
11
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72
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63
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66
1
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60
/61
78
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AJ
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8."t9(fl
-.\:-i,XJ po
35'
=,--{*-eNqy'p
--l)
lJn
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-35
Fig.
2
CRANKCASE
12
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Ref.
No.
Port No.
DESCRIPT/ON
QUANTITY
CRANKCASE
1
E8000
7
E8006
3
E8003
4
E8025
5
1
6
E81 35
7
CRANKCASE COMPLETE
Cylinder securing stud
Crankcase bearing
Crankcase
oil
seal
E8007
I
Cylinder securing nut
Washer
Crankcase stud-top (2{f in. O.A.)
E8008
Crankcase
9
E81 33
Nut
10
E8088
11
E8009
Washer
Dowel
17
E801 6
Cran kcase bolt
13
E801 0
Hollow dowel
14
E801
Solid dowel
15
E8012
16
E8017
4-0303
stud-rear (2j{ in. O.A.)
.
I
1
17
E8064
Sump stud
Scavenge pipe complete
Sump cover
18
E8070
Gasket
19
E8072
Plain washer
20
E8071
Nut
71
E801 3
22
E8127
Oil union stud (1{ in. O.A.)
Oil pipes and union block
'O' ring
32
23
E81
24
E81 33
25
E81
76
E8090
34
Union nut
Washer
OIL PUMP COMPLETE
27
E8092
Spindle housing
28
E8093
Spind le
79
E8094
Spindle gear
30
E8095
31
E8096
32
E8097
gear-driven
Scavenge gear-driving
Scavenge gear-d riven
33
E8098
Driven gear spindle
34
E8099
35
E81
36
E8071
37
F9041
Spindle gear nut
Spindle gear washer
38
E81 03
Gasket
39
E8A71
Holding nut
40
E8104
41
E8004
00
Feed
Bottom plate
Screw
Washer
Camshaft bush
42
E8059
Camshaft
43
E8060
Camshaft pinion
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*if {l;;, isdfg
l,tl.taitr *ttgcnt \C,,&,,;.8. #r "i"i' ,:'r""fq
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tolcphonc: TTIAME 2:rl -1g ()XFt)trDSHIRi.
:
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K
68
78
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41
az
,,43
l
\e
-36
s1-,,
ffi-,"
'&_,,
"$#t
55
56
5t
da
54- v
g\>
u.-@ F,,}
\2o
Fig.
2
CRANKCASE
14
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Ref.
No.
Port No.
DESCRIPT'ON
QUANT'TY
CRANKCASE
;45
E8051
Woodruff key
E8041
46
E8040
Drive gear
Crankshaft pinion
47
E8043
Lockwasher
44
48
E8042
Nut
49
E81 23
50
E8121
Pressure release valve plug
Plug washer
51
E81
57
E8122
53
T2696
54
T2697
'O' ring
55
E8179
56
E81 73
57
E81
58
E81 81
Chain oiler
Rubber pipe
Fibre washer
Bolt (1j in. U.H.)
59
E81
50
20
80
Spring
Ball
Gearbox drain plug
1
1
1
Generator lead grommet
1
E3789
Oil seal housing
1
48
61
E3832
Gasket
1
62
E3833
Oil
1
63
E3821
Screw
64
E8140
Distance plece
Distance piece
Distance piece
seal
6
A.R.
64
E8141
64
E8147
65
E81
66
E8144
67
E81 43
68
E7779
68
E7778
68
E8026
69
T2695
70
E8071
Generator stud-rear (2ii in.)
Generator stud-front (2if in.)
Generator stud-bottom
Dipstick
Nyloc nut
71
E8077
Washer
3
72
99-0739
Rotor
1
73
E8224
Lockwasher
1
74
E8146
75
E8174
Nut
Non-return valve spri ng
76
E81
77
E8126
78
E7885
79
E81
80
E8288
81
E8022
82
T948
39
25
59
A.R.
A.R.
Engine sprocket (23T)
1
Chain tensioner
Distance piece
2
1
1
1
1
1
3
1
1
Valve ball
Valve screw
Sealing plug
Washer
Stud (21f in. O.A.)
Dowel
'O' Ring for dipstick
I
1
1
1
2
2
1
15
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16
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Ref.
No.
Port No.
DESCR/PflON
QUANrln/
GEAR CLUSTER
6
T2680
7
T2673
Mainshaft complete with bush
HIGH GEAR (22T)
High gear bush
Mainshaft oil seal
Mainshaft bearing
Thrust washer
Thrust washer
Thrust washer
Mainshaft second gear (21T)
8
r2664
I
I
Spacer
T2665
12666
Spacer
9
r2662
10
T2663
11
E81 51
12
E81
1
T2661
2
T2676
T2753
3
4
E801 5
5
6
4
T2678
T2679
6
E801
52
13
T2677
14
T2685
15
T2686
16
T2667
17
T2671
17
T2672
18
E8005
19
24
T2668
T2669
T7674
T2675
T2752
T2670
25
T2733
26
T1 391
20
21
22
23
1
1
2
1
1
A.R.
A.R.
A.R.
1
A.R.
A.R.
Spacer
Mainshaft third gear (24T)
Mainshaft Iow gear (16T)
Mainshaft bearing
Bearing circlip
Felt washer
Lockwasher
Mainshaft n ut
Layshaft and high gear (14T)
Thrust washer
Thrust washer
Layshaft bearing ...
Layshaft second gear (22T)
Layshaft circlip
Layshaft third gear (19T)
LAYSHAFT LOW GEAR COMPLETE (27T)
Low gear bush
A. R.
1
Spacing shim
Clutch push rod
Push rod bush
Clutch lever complete
77
T2750
28
T2699
29
T2700
Clutch operating rack
Clutch operating pinion
30
E801 9
Thrust ball
31
T2765
31
T2701
31
Gearbox sprocket (15T)
Gearbox sprocket (16T)
Gearbox sprocket (17T)
Alternative
Alternative
34
T2766
T2702
T1434
T1164
Gear change pedal
1
35
r2450
Pedal rubber
1
36
T2703
Pedal bolt
32
33
Lockwasher
1
Nut
1
(j{
in. U.H.)
1
17
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Ref. No.
Port No.
DESCR/PTlON
QUANIIIY
GEAR CLUSTER
37
T2692
T2693
38
39
T1277
T7107
40
r2435
r2106
41
42
43
44
45
46
47
48
49
50
51
52
T210s
T1109
T7689
T2659
T2588
GEARCHANGE QUADRANT COM PLETE
Spring rivet
Keeper plate
2
1
Screw
1
Spring
Pl u nger
2
7
Return spring
Selector fork
1
2
Anchor bolt
1
1
T2690
Cam plate
1
T1 069
Camplate spindle
lndex spring
1
T7691
T1749
T1076
T'1180
E81 50
54
E3172
1
Spring backing
1
Screw
2
Lockplate
1
Camshaft
1
P.g
Camshaft oil seal
Crankshaft T/S oil seal
55
E81 53
56
57
E81
E8157
Oil seal circlip
5B
E8'155
59
60
Cable grommet
KICKS1ART CRAN K
54
63
T2763
T2774
T2330
T1169
T1167
64
E81
61
1
Selector spinCle
53
62
1
Gearchange quadrant
1
1
cov pLiir
Kickstart folding pedal
Pedal rubber ...
Pivot bolt (1 in U.H.)
Spring
Steel ball
25
65
r2704
66
67
68
69
70
T27As
T2706
Cotter pin
Cotter washer
Cotter nut
r264.3
KICKSTART SPINDLE
E8005
T2687
Needle roller
Return spring
71
T2660
Anchor pin
72
Kickstart stoP
73
T2657
T2658
Circlip
74
E2681
K ic
75
E2682
T2683
Bush
1
Pin ion
Spri ng
1
E8172
E8072
Contact breaker clip
1
E7919
E81 60
E8161
lnner timing cover
ln ner cover screw-short
lnner cover screw-bottom front
OUTER TIMING COVER
76
77
78
79
80
81
82
T2684
E8232
E801 0
85
86
T2641
Kickstart oil
T2647
Bush
87
E8167
88
E81 58
89
90
E81 60
E8169
E81 70
E8171
E8737
93
94
95
96
E7882
E7354
E81
6s
1
1
1
I
1
1
1
1
1
Washer
84
92
1
kstart ratc h et
83
91
1
1
Dowel
1
5
2
1
2
seal
1
1
Outer cover screw
Outer cover screw
1
lnner cover screw
4
3
Outer cover screw ($ in. U.H.)
lnner cover screw (jf in. U.H.)
Outer cover screw (2$ in. U.H.)
3
1
1
Cover
1
Gas ket
Screw ({ in. U.H.)
S e r rated washer
2
2
1
19
www.bsaunitsingles.com
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CLUTCH
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Ref.
No.
Port No.
DESCRIPTION
QUANrtry
CLUTCH
1
2
3
4
,
E8231
Filler plug
NE507
Fibre washer
2
E8953
Primary chaincase cover
1
E7856
Chaincase gasket
1
5
6
E8168
E8160
Cover screw
Cover screw
7
F9174
E8174
lrrain nrrrDrain
plug
E8175
Washer
E801 0
Chaincase dowel
I
9
2
10
D951
Primary chain (701.)
11
E8176
lgnition pointer screw ...
12
E895s
lnspection cover
13
E8178
Gasket
14
E8177
Screw
15
19
T2713
T2714
T2715
T2716
T2719
20
r2720
21
Reference on ly
16
17
18
22
r2721
23
25
T2722
T2723
T2724
26
T272s
27
24
({ in. U.H.)
Clutch hub
Clutch hub key ...
1
Clutch spider
Sprocket and housing
Roller
INNER RETAINING PLATE
Spring stud
1
1
25
1
4
Outer retaining plafe
1
4
Shock absorber-drive and rebound
Centre
I
1
T2726
Driven plate
Driving plate
4
28
T2727
Spring
r1144
4
29
4
30
Pressure plate
1
32
T2748
T2728
T2729
cuP
Spring nut
Adjuster...
1
33
F879
Lockn ut
1
34
T2730
35
T2731
36
T2732
Retaining nut
Plain washer
Lockwasher
31
5
4
1
1
1
21
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FRAME COMPLETE
11
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Ref.
No.
Port No.
DESCR/PTlON
QUANr/Ty
FRAME COMPLETE
1
2
F8451
F8994
3
Reference only
4
F8995
F8996
5
6
7
F881 9
F9029
34
Frame
SWINGING ARM SPINDLE
Spindle locking plate
Spindle nut
Shakeproof washer
Engine shield
Bolt
(l in. u.H.)
U.
(j
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Shakeproof
eproof washer
was
Front engine fixing bolt
2
2
8
E81
9
F8984
10
15
16
E8084
E8194
F8985
F8987
F8986
E81 89
F5535
17
s25-2
18
881 34
19
20
E81 33
Nut
Engine steady stay
22
F9745
F5535
E8084
73
E8194
Nut
24
25
26
27
78
29
E81 91
Shakeproof washer
F8988
Steering race cup
F9094
Bracket
F9093
F9090
Rubber buffer
Tool tray
1
Fastener clip
6
11
17
13
14
21
S
Nut
Rear stud (21| in. O.A.)
Rear nut
Washer
Steady bracket
Bolt
Washer
Shakeproof washer
F9091
Pop rivet
Bolt (.641 in. U.H.)
37
33
F9097
Spacer
E8071
F9060
Nut
Bolt ($ in. U.H.)
E8072
Washer
E8071
F8989
F8285
Nut
Bottom bolt
40
41
42
43
44
45
46
47
48
49
F9004
F9005
F9006
F9007
F9008
E8137
F9086
F9007
F901 0
1
1
1
2
2
1
3
3
3
30
F9003
3
2
1
1
12
1
Battery carrier
Battery tray rubber
Hook
Battery strap
Bolt
Mou
1
2
Plain washer
3'1
35
35
37
38
39
1
2
7
2
Bolt
Reference only
Reference on ly
34
(3fr in. U.H.)
pacer
nting
ru bber
Washer
Nut
Bolt (3 in. U.H.)
Mounting rubber
Washer
E8194
Nut
50
F9087
S
51
F9227
Tank anti-roll rubber
52
F9084
53
F9023
54
w1691
'P'clip
Bolt (j{ in. U.H.)
Nut
55
E8088
Washer
pace
r
23
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Fis.
6
SWINGING ARM
24
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*---**
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Ref.
No.
Port No.
DESCR'PflON
SW I N G I N G A
I
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QUANTITY
RM
1
F8992
Swinging arm
1
7
F8993
Silentbloc
2
3
F8876
Suspension unit
2
4
F8997
Unit fixing bolt
2
5
F8998
Plain washer
2
6
F8999
F9085
Nut
Nut
2
7
8
F9766
Propstand
1
9
F3097
Swivel pin
1
2
10
F3096
11
F2610
Lockwasher
Spring
12
F9059
Chai nguard
1
13
F9060
Bolt
1
1
1
14
E8071
Nut
1
15
w2336
Bolt
1
16
E8084
Plain washer
1
17
F908s
Nut
1
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25
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OIL-TANK, PANELS AND EXHAUST
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SYSTEM
Ref
No.
Port No.
DESCR'PT'ON
QUANT'N'
olL TANK, pANELS AND EXHAUST SYSTEM
,
1
F9241
2
F8975
Muffler
FIXING CLIP
3
F9128
Pin
4
F9179
Swivel
5
s5102
6
Bolt
7
14-0114
14-0707
8
F8981
9
E9514
Plain washer
Exhaust pipe
Finned clip
Screw (ff in. U.H.)
Nut
Nut
10
F8976
11
F8977
12
F8978
13
F9743
14
F9067
15
F9068
Nut
Oil tank
Bolt (1f in. U.H.)
Nut
16
F6039
Rubber sleeve
17
F9075
18
F9076
Filler cap c/w dipstick
Filler cap washer
19
F8874
Banjo
20
F9070
Fibre washer
21
F9071
Filter
22
F9146
Rubber connection
23
F9073
Clip
24
F9124
Rubber connection
25
E5473
Clip
26
t't927
Sleeve
27
D1922
Panel motif D/S
78
F9477
Panel D/S
29
D1923
Panel motif T/S
30
Panel T/S
31
F9478
D1006
32
D982
33
D893
33
D984
34
Reference only
Reference only
35
.
.
Oddie stud-long
Oddie stud-standard
Stud rubber
Stud rubber
Fastener clip
2
Rivet
4
1
3
1
27
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FOOTRESTS
AND BRAKE LINKAGE
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30
Ref.
No.
Port No.
DESCRIPTION
QUANT'T)'
FOOTRESTS AN D BRAKE LI N KAGE
1
F9031
2
F9032
Rear brake pedal
Fulcrum pin
3
F9033
Nut
1
4
F9034
Washer
1
(f
5
E81 93
Bolt
6
s26-1
7
F9035
Spring Washer
Plain washer
Rear brake rod
Toggle spring pin
Bnake pedal stop
I
F9036
9
w2006
10
F9037
11
F9038
12
F9039
13
F9040
14
15
1
1
in. U.H.) ...
1
1
1
1
1
1
F8979
Swivel pin
Adjuster nut
Adjuster bolt
Washer
2
F9041
Shakeproof washer
,t
16
F9042
Nut
2
17
F9043
18
F8448
Folding footrest
Footrest bracket
7
''9
F9044
20
F9045
21
F9046
22
F8986
23
F8987
24
F9085
25
19047
26
F9048
27
F9049
Stud (2 in. O.,A.)
Locking plate
Washer
28
F9050
Nut
29
F9034
3o
F9051
2
31
F9057
Spring washer
Footrest rubber
Bolt
32
E8137
Nut
2
Pillion footrest
2
1
1
2
2
Anchor bolt
Bolt (2jf in. U.H.)
2
1
Plain washer
Spring washer
1
1
Nut
Nut
1
2
1
1
1
1
1
2
33
F9053
34
F9054
Ru
35
t9044
35
F9055
Anchor bolt O/S
Anchor bolt N/S
36
E8084
Plain washer
2
37
F9085
2
38
t9057
39
.{0
E8137
F91 33
Nut
Bolt (1{ in. U.H.)
Nut
Pillion footrest support bracket O/S
41
F8991
Bolt
3
42
E81
37
Nut
4
bber
7
1
1
29
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TELESCOPIC FRONT FORK
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Ref.
No.
Port No.
DESCR'PT/ON
QUANflT)',
FRONT FORKS
2
H3610
H2679
3
F8980
Spring washer
4
4
Sleeve complete N/S
Sleeve complete O/S
6
H3652
H3653
H2513
H2630
7
l-12631
7
4
2
2
2
1
5
FORK ASSEMBLY COMPLETE
(1ft in. U.H.)
Bolt
H2633
H2634
Drain plug
11
H263s
12
H2636
13
H2637
H2638
Fibre washer
Stanchion
Top bearing
14
15
16
17
18
19
H2632
H2639
H2640
H7514
H2641
2
2
Oil seal holder
Oil seal
Oil seal holder
2
2
21
H2536
22
H2s7s
H2645
H2646
Top Lug
H2647
H2650
H2651
Top cone
Bottom cone
Steering head ball
Dust cap ...
Sleeve nut
H2652
Nut
75
26
27
28
29
30
H2648
E8125
and bearing spacer
Main spring
Gaiter ring
2
1
1
1
H2653
Plain washer
l-12526
33
34
s785
14-0303
Middle lug and stem
Pinch bolt
35
H2654
36
37
H2655
38
F8981
39
40
Cable guide bracket
Gronnmet
Damper Tube
47
H26s8
H2659
H2660
H7661
43
H2662
Circlip
44
H2688
Bolt
45
46
H2664
H2665
H2666
Valve collar
t12667
Valve seating
E8071
Nut
H2668
H766e
Washer
51
52
E81 33
Nut
53
H7670
Sealing.washer
54
112671
55
56
H7237
H3625
Retainer
Heat slnk
Bracket
57
144217
58
14{702
Bolt
59
60
1+6102
s2l12
Bolt
Washer
61
E8088
Spacer
48
49
50
2
Special nut
32
47
2
2
2
Bolt
31
41
2
Shaft plug
Plug washer
H2643
H3678
24
2
Bottom bearing ...
20
23
1
2
Washer
9
10
I
1
Gaiter
Spacer
Sealing washer
Sealing washer
1
4
4
1
1
40
1
1
2
2
1
2
Nut
2
Cable guide
Handlebar clamp
1
2
H2656
4
4
2
2
2
2
Bush
2
2
2
2
2
Circlip
Valve
2
7
2
2
2
2
Damper rod
2
1
1
1
Nut
1
1
2
1
31
www.bsaunitsingles.com
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22
FRONT WHEEL
32
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Ref. No.
Port No.
DESCRIPI/ON
QUANTTTv
FRONT WHEEL
w3424
FRONT WHEEL COMPLETE (LESS BRAKE AND TYRE)
FRONT WHEEL RIM, HUB AND SPOKES ASSEMBLY
2
w3323
w1230
w3325
3
w1236
3
w3329
3
w330
Spoke T/S
Spoke T/S
4
s79-7
N
5
8
w653
w1237
w1238
w1641
9
w1481
1
6
7
10
w2710
1
1
Rim
1
Hub
Spoke D/S
ipple
1
20
10
10
40
Beari ng
7
Dust cover
Circlip
1
Spind le
1
Grease cap D/S
Cover plate
1
1
1
11
w3337
12
w582
Bearing support ring
Bearing retainer
1
1
13
w1301
Anchor plate
14
w1639
15
E8084
16
E8999
Fulcrum pin
Fulcrum pin washer
Fulcrum pin nut
17
w7069
Brake cam
18
w492
Lever return sPnnS
19
20
w2000
w2027
71
14-0403
Brake cam
Brake cam washer
Brake cam nut
22
w1197
w1198
Balance weight short
Balance weight long
w1246
w1406
Spindle nut
LEADING BRAKE SHOE
TRAILING BRAKE SHOE
Brake shoe
Brake lining
22
23
w1407
76
Reference only
Reference only
Reference only
77
w141s
28
w13s
w'I640
24
25
29
1
1
1
1
Brass rivet
Pivot
1
pad
Brake shoe spring
Cable abutment
www.bsaunitsingles.com
1
1
1
1
A.R.
A.R.
1
1
1
2l
Not
2 lServiced
1
6J Separately
2
7
1
M
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31
W
19
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REAR WHEEL
34
www.bsaunitsingles.com
Ref. No.
Port No.
DESCRIPTION
QUANfln',
REAR \^/HEEL
1
7
3
4
w2789
w2290
w2297
REAR WHEEL COMPLETE (LESS BRAKE AND TYRE)
RIM, HUB AND SPOKES ASSEMBLY
w2291
6
7
8
9
10
w2309
1
Hub complete
w2297
w2293
w2294
5
1
1
Spoke N/S
Spoke O/S
N ipple
20
20
40
Rim
1
w101s
Fixed spindle nut
Chain adjuster
Chain adjuster end cap ...
E8137
E8088
Ad
Adjuster nut
juster washer
2
2
2
2
11
w2335
Torque stay
1
17
w2335
w2337
Bolt (1..| in. U.H.)
1
Washer
1
13
w2339
14
F9085
Nut
15
w2325
16
17
18
19
20
w2324
Fulcrum pin nut...
Fulcrum pin washer
Fulcrum pin
Brake anchor plate
21
22
23
24
75
76
77
28
79
w2323
w2327
w2327
Reference only
Reference on ly
w2328
w7329
w2276
w2326
w2334
w2330
w2331
1
1
1
1
1
1
BRAKE SHOE COMPLETE WITH LINING
Brake lining
Brass rivet
2
1
Brake shoe spring
Brake cam lever ..
BRAKE CAM
Grease nipple
Brake lever return spring
Plain washer
Shakeproof washer
2l
NotServiced
4-,;l
Separately
2
1
1
1
1
1
Nut
32
33
w2332
w2317
D1 02st
w2314
w2317
34
w2311
Bearing circlip
Bearing Shim
35
36
37
38
w231s
w2316
w2308
39
40
w2298
w2299
Beari ng
7
Thrust washer
1
41
w2313
Washer
1
42
w2310
w2300
Beari ng
Spind le sleeve
w229s
w2318
w2354*
w2319
w2320
w2302
Secu
30
31
43
44
45
46
47
48
49
50
w2305
51
w2301
w2303
52
w2304
53
D1026
54
55
w2306
w2307
55
w2333
1
Locking plate
Rear Chain
Driving
(f
x
j
x
3
rozlj
1
Flange
1
1
1
Bolt
6
6
Nut
Fixed spind le
Bearing retainer
1
1
1
1
rity bolt
2
Brake drum
Chainwheel (52T)
Chainwheel bolt
1
1
10
10
Spring washer
lnner retainer
Felt washer
Outer retainer
Hub end cover
1
1
1
1
Speedometer gearbox
Distance collar inner O/S
Distance collar outer O/S
Hub spindle
1
1
1
1
*Early editions have 49T chainwheel 41-6091
tEarly editions have 99 Link chain D1023
35
www.bsaunitsingles.com
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Fis.12
FENDERS
36
www.bsaunitsingles.com
6
11
.t3
%
Ref.
No.
Port No.
DESCR'PTION
QUANTITY
FENDERS
1
F9016
2
H3619
3
H3621
4
H3523
5
F9019
6
F9068
Front fender
Front stay
Bridge stay
Bottom Stay
Bolt (j in. U.H.) ...
Nut
7
F9029
Bolt
8
E8088
Washer
9
w1691
Nut
Bolt ($ in. U.H.)
Bolt (1$ in. U.H.)
Nut
10
F9017
F9088
11
12
13
r
W1691
t8991
14
E8088
15
E81 34
Plain washer
Spring washer
't6
F9026
Nut
17
F9506
Rear fender
18
F901 9
Bolt ({ in. U.H.)
19
F9027
Special washer
20
F9020
Spring washer
21
F879
22
F9023
Nut
Bolt
23
E8088
Washer
24
E81 37
Nut
25
F9028
26
F9481
27
(ff
in. U.H.)
F9023
Wiring grommet
Rear fender support rail
Bolt (ff in. U.H.)
28
E8088
Washer
29
w'l691
30
F81 39
Nut
Tail lamp support
Stud (jf in. o.A.)
Support plate
31
E2980
32
F9132
33
s25-1
Washer
34
F9030
Spacer
35
F9068
Nut
36
F9198
Rear number plate bracket
37
F9019
Bolt
38
s25-1
Washer
39
E8071
Nut
(|
in. U.H.)
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37
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7
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-5
-4
6
2
)fu" #
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31
29
30
Fis.13
GAS TANK,
TWIN SEAT AND HANDLEBARS
www.bsaunitsingles.com
F.
Ref.
No.
Port No.
DESCRIPI/ON
QUANI'TY
GAS TANK, TvvtN SEAT AND HANDLEBARS
5
F9063
Gas tank
Mounting rubber-rear
Mounting rubber-front
Bolt
Distance tube
6
E8088
Plain washer
7
F9064
Mounting rubber
8
F9065
Plain washer
9
1
1
F9479
2
F9061
3
F9134
4
s1 824
4-0302
Nut
Trim strip
10
F9480
11
F4715
Screw
1Z
H430
13
F6888
't3
F6887
Washer
Styling unit TiS
Styling unit D/S
14
F8192
15
F81 93
7
'l
1
Knee grip D/S
Knee grip T/S
1
1
16
F4179
17
F7888
18
F9769
Styling unit screw-front
Styling unit screw-rear
Gas pipe ...
19
F4971
Gas
19
F4972
Gas
20
E7351
Gas tap washer
2
2t
F9226
F9744
Filler cap
Tie bar
I
23
F9196
Spacer
2
24
s5662
Bolt
2
25
E8088
2
26
w2320
Plain washer
Spring washer
27
F9472
28
F9476
Twin seat
Rear fixing bracket
29
F9020
Spring washer
2
30
E81 01
Nut
2
31
s602
Plain washer
2
37
H2628
33
D957
lebar-Western type
Throttle twist grip
34
D959
35
D960
36
D961
37
D962
38
D862
Throttle cable
Front brake cable
39
D963
Cable toggle
'l
40
D964
Screw
1
41
F9020
Spring washer
1
42
D965
43
D966
Nut
Clutch cable
72
tap-Short
tap-long
2
2
1
1
1
I
7
1
1
Hand
Dummy grip
Front brake control
Clutch control
1
1
1
1
1
1
1
1
1
39
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Fig.14
ELECTRICALEQUIPMENT
www.bsaunitsingles.com
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I
20
Ref.
No.
Port No.
DESCRIPT/ON
QUANTITY
ELECTRICAL EQUIPMENT
I
i
I
D1926
D962
H3626
Speedometer head-M. P.H.
Speedometer cable
4
D195'1
5
F9091
6
E8077
7
E81
Speedometer lead
Bolt
Washer
Spring washer
8
D986
9
F9123
10
F91 31
11
s602
12
F4374
Washer
Distance piece
13
E8071
Nut
14
D980
15
D981
16
D997
17
D989
Battery vent pipe
Vent pipe clip
H.T. lead
lgnition switch
18
D1000
t9
21
99- r 000
D994
D992
2i
E-q1e1
Washer
23
F5535
24
E8084
Bolt
Washer
25
E8194
Nut
76
D996
27
F8273
28
F81
Double Lucar blade
Rear reflector
Rubber washer
29
F81 95
Push-on fix
30
F8286
Front reflector
2
31
F8349
7
32
D1950
Reflector bracket
Rectifier
33
D990
Stop switch
1
34
F9t9t
Screw
2
35
F8979
Washer
7
35
99-r00r
Harness (54953550)
I
99-1002
HEADLAMP ASSEMBLY (5988r)
1
2
3
70
Mounting cup
02
Coil (451 l0)
Coil support clip
Bolt ($ in. U.H.) ...
40
37
99-069
38
99-0688
99-0683
99-0545
99- I 003
99- I 004
99- r 005
39
40
4t
42
43
I
lgnition lock
lgnition switch nut
Horn push
(54130041)
Horn
1
Rim (534343)
Lig
ht
un
it
I
I
(5 I 6828)
I
Fixing wire (504665)
Bulb (446)
6
Adaptor c/w leads (54520540)
Bolt (ll220l)
7
Washer (137498)
7
41
www.bsaunitsingles.com
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-d':r
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&N
-T
.19
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20
E-_2
t- ll-/
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31 e
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rc/'
(
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32
2a
/*
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o*d
,"/
f-o
o^ ,n-r6)
-91
\
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L/
t\Y"/
ril
,RIU
36
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..-tr/
33- -{V34
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/u
35
37
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42
www.bsaunitsingles.com
-.l
Ref.
No.
Port No.
DESCRIPT'ON
QUANflrv
ELECTRICAL EQUIPMENT
44
99-0563
45
99-0556
Lighting switch (35710)
Dip switch (31620)
46
144921
Screw
Reference only
47
Plate
Reference only
48
s5408
99-0568
49
5494s043
50
99-0537
51
99-0569
57
99-0695
53
99-0548
1
1
Warning light (Red)
Warning bulbholder
Bulb (2W BAT5) (281)
Warning light (Green) (38191)
Pilot bulbholder (554710) ...
Pilot bulb (989)
1
Reference only
2
1
1
1
54
F831
55
D988
56
99-1 005
57
D987
Stop-tail lead
Battery
Stator (47205)
Zener diode
58
99-1 008
CoNTACT B REAKER (54419645)
59
60
99-0077
99-0769
61
99-1007
62
99-1011
63
E7831
Adlusting pin (54419220)
AUTO ADVANCE UN|T (5441
Spring set (54417992)
Contact breaker bolt
64
E81 63
Washer
1
65
E4747
Pillar bolt
2
66
E81
64
Washer
2
67
E81
66
Contact breaker lead sleeve
58
D995
Con den
D991
sToP AND TAtL LAMP ASSEMBLY
4
Reference only
1
1
1
1
Points set (54419827)
se
2
e6s3) ... ... ..
2
...
1
1
1
I
r
1
(53973)
1
69
99-0781
Lens (54572932)
1
70
99-0698
Screw (572289)
2
71
54s74348
Bulbholder with reflector
72
573828
contact
Reference only
Reference only
73
99-0542
99-0780
Bulb (6/21W offser pin) (380)
Gasket (54571677)
1
75
F4715
Screw
2
76
G5299
Washer
2
77
F8307
Stop and tail lamp lead tube
1
78
F4715
Screw
2
79
G5299
Washer
2
74
assy.
43
www.bsaunitsingles.com
1
\
=P
10
H
TOOL KIT
www.bsaunitsingles.com
Ref.
No.
Port No.
DESCR'PT'ON
QUANflT)',
TOOL KIT
D967
1
D969
D968
TOOLROLL COMPLETE WITH TOOLS
Toolroll
1
"l
3
D801
Damper unit and rear chain ajuster spanner
Combined tyre lever and tommy bar
4
D970
Plug spanner
1
5.
D767
Screwdriver set
1
6
D975
7
D97',\
I
Screwd river
Box spanner
D972
9
D973
10
D974
'11
D977
17
D978
13
XA69
2
1
1
1
1
Ring spanner
Tyre lever
Tyre valve key
Rubber cable clip
Alum. cable clip
Alum. cable clip
1
1
1
9
4
3
45
www.bsaunitsingles.com
Q
5
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'WW{w"
E-- 1s
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.t"t:i
Fig.16
CARBURETTOR
www.bsaunitsingles.com
Ref,
No.
Port No.
DESCR'PflON
QUANTITY
CARBURETTOR
99-001 9
cARBU RETTOR COMPLETE (R92814)
1
1
994521
2
99-0221
3
99-0531
4
99-0507
Top cap (928497)
Throttle spring (622-061)
.5
99-051 0
Circlip (622-067)
1
6
994529
Needle (928-063)
1
7
99-0527
Throttle valve (3) (928-060)
1
8
99-1 01 0
9
376-1 00
'10
99-051 6
11
Body (Re28/00s)
Main jet (170)
Throttle stop screw (622-077)
Pilot air screw (622-076)
1
1
Screw and washer (622-086)
Plug screw (4-137A)
4
1
1
1
1
1
1
12
99-05't5
99-0520
13
994572
'O'-ring (622482)
'O' ring (622-101)
14
622-073
Gasket
15.
1
99-051 8
Needle jet (.106) (99-0518)
1
1
16
99-051 9
Jet holder (622-080)
17
99-0512
18
99-051 3
19
99-0511
20
21
99-0506
376-093
Float
Float
Float
Float
22
994517
23
F9000
24
F9194
25
F9001
2
(622-069)
spind lb (622-071)
needle (622-068)
chamber (622-050)
1
1
1
1
Filter
1
Banjo bolt (622478)
1
AIR CLEANER COMPLETE
1
Air cleaner element
'O'ring
1
1
47
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