1969 triumph tr25w 250cc
Transcription
1969 triumph tr25w 250cc
REPLACEMENT PARTS CATALOGUE THEtrF{Y 2s@ TR2 5 W 25O c.c. (15 cu. ins.) 1969 MODEL BSA Unit Singles LLC REPLACEMENT PA RTS CATALOGUE TR25W TRIUMPH ENGINEERING COMPANY LIMITED MERIDEN WORKS TELEPHONE MERIDEN 33I ALLESLEY . COVE NTRY ENGLAND TELEGRAMS'TRUSTY, COVENTRY'' REF- Nd. SPC.I0 PUBLISHEO OCTOBER I968 BSA Unit Singles LLC TRIUMPH GUARANTEE 1. 2. 3. 4. 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. ln order to obtain the benefit of this Guarantee, the Purchaser must have correctl/ completed the registration form and returned it to us within fourteen days ofthe PUrchase. 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, (three 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. 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) 5. Engine number and model. This Guarantee shall not extend to defects or damage appearing after misuse, neglect, abnormal stress or strain, or the incorporation or afflxing of unsuitable attachments or parts and in Particular:- (a) Hiring out; (b) Racing and Com Petltions; (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 an/ 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. Ou r Iiability and that of ou r dealer who sells the machine, whall be lim ited to that set out in this Suarantee, and not other claims including claims for consequential damage or injury to Person or ProPerty, shall be admissable. 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 THE FITTING OF ANY COMPONENTS \/VHICH ARE NOT APPROVED BY THE MAN UFACTURER INVALIDATES THE GUARANTEE REPAIRS GUARANTEE 1. 7. 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. We will repair or replace at our option free of charge any defective work, materiais 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 liabilit/ shall be limited to the cost of so making good. We do not undertake to bear the cost of fittjng 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 warranties statutory or otherwise express or implied are hereby excluded- BSA Unit Singles LLC ,I INDEX Poge AIR ... FILTER ... ALTERNATOR 59 CHAING UARD CHAINS ...23,41 CARTON PACKS 59 7 29 CONTROL LEVERS ... ... ... ... ,,. ... CRANt(CAsE... ... 13, CLUTCH cotL CONTACT BREAKER CONTROL CABLES ... CRAN KSHAFT CYLINDER HEAD EXHAUST ... 31 OIL PUMP 15 OIL TANK ... ... ... CARBURETOR MUFFLER 15, 23 BATTERY CARRIER... I Poge ... ... 23 53 21 PROP STAND ... 33 ... 9, 11 ... 29 REAR PANELS ... REAR WHEEL ... RECTIFIER ... 53, 55 SPARK PLUGS SPEEDOMETER ... ... 51 STEERING RACES ... 35, 37 SUSPENSION UNITS ... SWITCHES ...53,55 PiLLION FOOTRESTS PISTON 49 15 9,11 9,11 PIPES 45 FOOTRESTS ... TIII4ING COVERS 35,37 FRONT WHEEL 39 GEARBOX TIMING GEARS 33 FRONT FORKS GASKET SETS 9,11 79 31 N DERS GAS TANK 4't , 43 49 TACHOMETER FE 31 TWINSEAT VALVES ... 17 47 7 , 't9, 21 WIRING HARNESS ... HANDLEBARS 49 HORN... 53 ZENER DIODE BSA Unit Singles LLC 51 15 't7, 19, ... ... TOOLKIT ... ... ... ... 21 57 47 9, 11 E 0 TROPHY 250 TECHNICAL DATA Bore and stroke -.. Capacity ... 67 x 70 mm. ... 249 c.c. Compression ratio 9.6 :1 Sparking plug Carbu 0 I Amal Concentric.92S 28 mm. Choke size Main jet ... Need le Need Ie 160 jet .106 Standard Throttle valve No.3 Gearbox sprocket 15 teeth ... Final Drive Sprocket Chains Rear ... Fuel 57 teeth East Coast 49 teeth West Coast ... I in. x * in. Duplex x 70 links ... I in. x j in. x 101 links East Coast Front ... I Cham pion N3 rettor Capacities 0 tank... 3 in. x + in. x 99 lin ks West Coast 3.916 galls. U.S. Oil tank ... Gearbox... 6 pints + pint Primary chaincase + pint + pint Front forks (each leg) Brakes ... Front and rear diameter Tyre size ... .., Front 7 in. 3.25 x 18 4.00 x 18 Rear BSA Unit Singles LLC TRIUMPH SPARES HOV/ TO ORDER. Every part is indicated by a number, and this should be quoted together with the description. ln order to assist customers, dimensions have been given in many cases where parts are similar. Parts where possible have been listed in order of assembly and a number of the illustrations show the assembly order also. With these aids, there should be no difficulty in identifying the parts you require. ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OF THE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS. \A/HERE TO OBTAIN, Triumph Spare Parts can only be obtalned 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 wrjte or obtain specially, the postage or carriage incurred becomes payable. Customers are warned against the risk incurred by purchasing parts that are not ofgenuine Triumph manufacture. This risk is eliminated if parts are ordered as instructed from recognised Dealers. PROPRIETARY GROUP Ancillary equipment which is fitted to our motor cycles is ofthe highest quality and is guaranteed by the manufacturers and not by ourselves. Any repairs or claims should be directed to the actual makers or their local agents who will always give owners every possible assistance. The following are the addresses of the various manufacturers:CARBURETORS. The Avon lndia Rubber co. Ltd., Messrs. Amal Ltd., lYe lks Holdford ham, Road, Birmingham,6. SPARKING PLUGS. Champion Sparking Plug Co. Ltd., CHAINS. Renold Ltd., Wythenshawe, Manchester. ELECTRICAL EQUIPMENT. Messrs. J. Lucas Ltd., Feltham, M idd lesex. SPEEDOMETERS, Messrs. Smiths lndustries Ltd., Cricklewood Works, London, N.W.2. Gt. Hampton Street, Birmintham, 18. SUSPENSION UNITS. Messrs. Girling Ltd., TYRES. Dunlop Rubber Co. Ltd., Fort Du nlop, Birmintham,24. Birmingham Road, West Bromwich, Staffordshire. BSA Unit Singles LLC HOW TO USE THIS PARTS CATALOGUE Consult the index on Page 3 for the parrs or group of parts which you wish List the quantities required as single units; do not asl< !c t$, locate. for "2 pairs" or "3 dozen". Items marked "reference only" are not available from the factory. Proprietar/ components e.g. electrical equipment, carburetors, suspension units etc. are iisted in the flrst column under Triumph part numbers (prefixed either D-- or 99--) wherever they are stocl<ed ar rhe factory. lf proprietary parts are listed only under manufacturers part numbers, they are not available from the factory. PLEASE NOTE THROUGHOUT THIS LIST, ASSEIVIBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS INCLUDED IN THAT ASSEIYBLY ARE INDENTED IN THE DESCRIPTION COLUI.4N, REVERTING TO THE ORIGINAL ALIGNI'4ENT WHEN THE ASSEII4BLY IS COMPLETE. TO ORDER THE COMPLETE ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEI"IBLY NUMBER. ANY COMPONENT PARTS LISTED IYAY ALSO BE OBTAINED SEPARATELY IF REQUIRED. tl( SPECIAL WORKSHOP TOOLS A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITH ER CONTACTING YOUR DEALER OR APPLYING DIRECT TO THE DISTRIBUTOR. IN MOST CASES THESE TOOLS ARE VERY COSTLY AS THEY ARE I"IADE ENTIRELY FOR WORKSHOP USE, AND THEREFORE. IT IS NOT RECOI.4I.4ENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES IT IS FAR IYORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER. UNIFIED THREAD FORM NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOGUE H,\VE THE UNIFIED FORM OF SCREW THREADS. THIS CHANGEOVER WILL BE CONTINUED AS AND WHEN NEW PARTS ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS WILL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS HAVING THIS THREAD ARE IDENTIFIED BY MARI<INGS. BOLTS HAVE A CIRCULAR RECESS IN THEIR HEADS, STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING CIRCLES ON THE SIDE 0( BSA Unit Singles LLC CA RTO N PAC K 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 adverse conditions. PISTON (complete with rings, gudgeon pin and circlips). These are in effecr 'carton pack' assemblies. E7998 E8272 9.6 : 1 C.R. 9.6 : 1 C.R. 9.6 : I C.R. E8271 OVERHAUL GASKET SET DECOKE GASKET SET STANDARD SIZE 0.020 in. oversize 0.040 in. oversize 99-0031 99-0040 PA RTS VARYING FROM STA N DA RD SIZE The following are the part numbers of piston rings to suit oversizes of +0.020 in. and *0.040 in. These rints are no longer available in carton packs: PISTON RINGS (0.020 in. oversize) PISTON RINGS (0.040 in. oversize) Big end bearing 1 't 1 1 I 1 undersizes Top compression ring E8777 E9017 E9021 Middle compression ring Scraper ring E8278 Top compression E9018 Middle compression ring Scraper ring E907t 0.010 in. 0.020 in. 0.030 ln. Part Number E6068/10 Part Nu m ber E6068/20 Part Num ber E6068/30 BSA Unit Singles LLC rint rtlt ( 4 Y70 q) 2A |, @ s\\ lil"u ",ua 51 0( 53 ,fl\ 6) % 6 s^,, Fis. l. CYLINDER HEAD, BARREL AND CRANKSHAFT BSA Unit Singles LLC o( Ref No. Port No, DESCRIPT/ON QUANTITY CYLI NDER HEAD, BARREL AND CRANKSHAFT 6 7 E8032 E8033 CRANKSHAFT AND FLYWHEEL ASSEMBLY Crankshaft... ... FLYWHEEL DRIVE SIDE FLYWHEEL TIMING SIDE Screwed plug ... ... Flywheel bolts (1{ in. U.H.) Flywheel bolts (2 in. U.H.) 8 '10 E8037 E8038 E8039 E1580 Shim (0.010 in.) ... Shim (0.015 in.) ... Crankshaft pjnion key 't1 E8144 12 13 E8836 E3705 14 E2922 15 E6068 16 D911 E7998 'l 2 3 4 9 9 17 18 19 20 I 21 E8276 E6838 E6839 WE2O3E wE479 23 24 25 25 26 27 28 79 E9163 E7728 E8053 E8055 E7739 E8008 E8196 Washer 1 Reference only Reference only Reference only 1 4 4 8 ... A.R. A.R. ... 1 Rotor key CONNECTING ROD ... Connecting rod bolt 1 1 7 7 Self locking nut Big end bush (available in undersizes of 0 010 in., 0.020 in. 0.030 in.) Sparking plug N3 *PISTON COMPLETE ... ... 2 halves 'l 1 Piain compression ring Taper compression ring ... 1 1 Oil control ring 1 Gudgeon pin 1 Circlip Cylinder barrel ... ... Cylinder base washer ... Push rod (exhaust) Push rod (inlet) ... ... 2 1 1 1 1 Tappet 2 Cylinder barrel stud (2+ in. Stud nut ... Washer ... O.A.) ... 7 2 7 32 E821s E8197 E8228 E8229 JI E7996 34 E8010 Dowel 7 E8080 E8227 E8225 stud (2.1+ in. o.A.) Carburetor stud (13 in. O.A.) Valve guide (inlet) ... 2 E8226 Valve guide (exhaust) I 30 31 36 37 38 39 E8081 40 42 E8137 E8136 E7820 43 E79',t'l 44 E7858 E7787 41 I E9547 E8028 E9519 E8034 E8036 45 46 CYLINDER HEAD Stud (2+ in. O.A.) Stud (3 in. O.A.) ... Stud (3+ in. O.A.) 1 2 2 Cylinder head gasket ... Carburetor stud nut Carburetor flange washer z 1 1 7 1 piece ... 'l Rocker box Rocker box gasket 1 Distance Rocker spindle INLET ROCKER 47 E7790 E7791 48 E1483 Ball end 1 ... ... EXHAUST ROCKER ... 2 I ... 1 2 *Refer page 7 for oyersizes. BSA Unit Singles LLC {ro 6t-r,a )'?-r: vZ @,0 Olr-- {'l o o. 9@ 6 s *@- Fig. l. '22 CYLINDER HEAD, BARREL AND CRANKSHAFT 10 BSA Unit Singles LLC lll a Ref No. Pdrt No- DESCRIPT/ON QUANI/IY CYLINDER HEAD, BARREL AND CRANKSH A F T continued E1330 E8952 Thrust washer ... Thrust washer ... lnspection cover... E8085 Gasket 53 E8086 54 E81'16 E8117 Screw (lJ in. U.H.) Top collar Split collet 4 56 57 E8117 lnlet valve 'l E7777 58 59 D1002 14-0403 s25-2 Exhaust valve Plug cover 49 50 5'1 60 61 61 E157 5 E7958 E7959 ... 2 7 ... 1 ,| 2 2 1 1 '). Locknut ... Washer ... Corrugated ring (0.024 in.) Corrugated ring (0 027 in.) Corrugated ring (0 030 in.) 7 A.R. A.R. A.R. 2 ... 2 7 65 E7960 E1564 E1577 E8087 E8088 Washer ... 66 EBO89 Nut 67 68 69 70 E8072 Washer 7 7 7 E8082 EBO83 Union Fibre washer E8111 Oil feed pipe 71 72 E8107 E8110 73 E8113 Nipple Union nut Bottom cup 2 74 75 E8114 Valve spring-outer Valve spring-inner 7 7 61 62 63 64 E8115 lnspection cap Washe r Nut .. halves . 1 I 1 1 1 11 BSA Unit Singles LLC r- z6 ', a@_ 28'. \@ tN\ h\s \lr 225 45 46 -._& s) r€\ B 73 '?4 W66 6* t,o lql ",-ffi MA t1l i1- q@ "' ,o I 75 '48 1!-.--tt {St ,(d*\oz \iq. \u., Fig.2. CRANKCASE flt 12 BSA Unit Singles LLC Ref. No. Port No. DESCRIPT'ON CRAN KCAS 'l 2 E9371 E8006 3 s'l889 4 s1890 5 E8009 6 7 E8011 't4-140'l 9 E8003 E8025 I 't0 1'l 12 IJ 14 IJ 16 17 18 19 z0 71 1 C/linder securing stud Crankcase top stud (2t| in. O.A.) Crankcase rear stud (21{ in. O.A.) Hollow dowel ... Solid dowel ... ... Sump stud ... Main bearing (ball-journal) Oil seal left main bearing ... ... Generator stud rear, short hexagon Generator stud front, long hexagon Generator stud bottom (2+; in.) 4 2 2 1 2 4 2 1 (2{! in.) (2]f in.) Camshafc bush l'4ainshaft bearing E8315 E80t 4 E8015 E8010 s1891 E8017 E CRANKCASE s1894 s1895 s1896 E6026 QUANI/IY Mainshaft oil 1 1 1 1 1 seal ... 'l Oil seal circlip Hollow dowel Oil union stud 1 1 1 Scavenge pipe 'l s1893 E8022 Oil pump stud ... 7 Hollow dowel z s1857 Gearbox drain plug 1 22 23 r2697 24 s1872 25 26 E8896 E9384 /7 E8256 78 29 T1150 s1892 14-0303 (J nng 1 Timing hole plug... Washer hole plug I Sealing plate Sealing washer ... 1 Screw 2 1 I Bolt (1t in. U.H.) Cylinder securing nut 3 31 E8135 32 1+0302 Nut 4 4 4 33 E8088 E8064 E8070 E8071 Washer .., 7 30 34 35 36 37 38 39 14-0901 40 s'|977 Sump cover Gasket Plain washer 1 1 4 4 Nyloc nut Pressure relief valve plug 1 1 E8120 Plug washer Spring 41 Eg't22 Ball 'l 42 43 E8124 Non-return Yalve sprint 1 s70-3 44 s1898 45 E7885 E81s9 Valve ball Valve screw Sealing plug 46 47 E8171 48 12695 T948 49 Eg',t47 50 E8148 1 1 1 'l Washer .,. Dipstick... 1 'l 'l Dipstick washer Clip for alternator lead grommet Alternator lead grom met '13 BSA Unit Singles LLC 1 1 @6 o^^ ,o& @aaA n,"o Q; -- tr \fu k'= _,](,) rz U/ "@ I 89 __ z' a5 51 32\33 26\2a N \4 49 _./__._ @*'Yr,,. \$ l/-, )t, i6\ \o) \rt 45 -€) s) 4a lr* rq 674 73 ffr I ffi66 r,?t 4e*) -t9 ao 57 ,e a1 60 6-' 17 u" n t## - "-.$ 70 zs@ ,r@ ,9,> tF su -az Fig. 2. CRANKCASE fi e 14 BSA Unit Singles LLC ,t Ref. No. Port No. DESCRIPIION CRAN KCASE QUANTITY continued 51 E3789 Oil seal housing 1 52 53 54 55 E3832 Gasket 1 E3833 Oil E3821 Screw 6 E8179 Chain oiler Rubber pipe Fibre washer Bolt (1i in. U.H.) Oil pipes and union block I 56 EB',t73 E8180 58 59 60 1+6203 E8127 E8259 1+0302 seal 1 1 1 'l 1 v flng Union nut Serrated 2 1 washer... 67 63 E81 64 E8092 Spindle housing 1 65 E8093 Spindle 1 66 67 68 69 70 E8094 E8095 E8096 E8097 E8098 Spindle gear 1 7',| E8099 E8100 Bottom plate 1 Screw 4 72 73 74 75 76 77 78 34 E8090 80 8t Scavenge E8042 E8140 84 E8139 E8184 E8143 E8141 E8147 1 1 1 1 Spind le gear nur Spind le gear washer 1 1 I Gasker Hold ing nut 14,0901 82 83 83 83 gear-driven Driven gear spindle E8'103 E8040 E8043 1 Feed gear-driven Scavenge gear-driving E8071 E8041 1 OIL PU14P COMPLETE F904'l E8104 E8058 ... 2 2 Washer cAt4sHAFT C/W PTN|ON Drive gear Crankshaft pinion 1 1 1 Lockwasher 'l Nut 1 Distance piece (.325 in. thick)... Distance piece (.310 in. thick) ... Distance piece (.295 in. thick)... Engine sprocket (23T) Chain tensioner Distance piece ... ... A.R. A.R. A.R. 1 ,| 86 87 88 89 14-0901 E8072 99 0739 Nut 3 Washer ... 3 Rotor 1 90 E8224 Tab washer 1 91 Eg',t46 Nut 1 (54213901) 15 BSA Unit Singles LLC 1 'fllfl \ a ,"u, -L.7.X (&-&-*e I '/Y|....-too [email protected] 96 27 \* 98 1 V) 76 77 4/ fla \ 'Tr 15 30 g-- s7 219 87 /lYs \ I 62 59 Fig.3. GEAR CLUSTER AND TIMING 't6 BSA Unit Singles LLC COVERS 0l Ref No. DE5CR/PIION Port No. QUANI/IT GEAR CLUSTER AND TIMING 1 2 r2661 4 Tt 391 T3872 12753 5 E8015 6 E8014 7 7 7 8 12678 12679 3 9 9 9 10 1'l T2680 13876 12664 r2665 r2666 r2667 12663 't2 E8151 13 E8152 14 15 12677 T2685 MAINSHAFT COMPLETE WITH BUSH Pushrod bush COVERS 1 1 H|GH GEAR (22T) 1 lligh gear bush It4ainshaft oil seal 2 1 Mainshaft bearing Thrust washer (.093 in.) Thrust washer (.098 in.) Thrust washer (.103 in.) Mainshaft second gear (21T) ... Spacer (.075 in.)... Spacer (.070 in.)... Spacer (.080 in.) ... f4ainshafr third gear (24T) Mainshaft low gear (16T) Mainshaft bearing .. Bearing circlip ... 1 A.R. A.R. A.R. 1 A.R. A.R. A.R. 1 1 1 1 Felc washer 1 ,| 17 18 T2667 T7671 18 19 70 r2672 71 r2669 r3877 Lockwasher Mainshaft nut Layshaft and high gear (14T) Thrust washer ( 084 in.) Thrusc washer (.079 in.) Layshaftbearing... ... Layshaft second gear (22T) ... Layshaft cr rclip ... Layshafr rhird gear ('19T) r3874 r2757 LAYSHAFT LOW GEAR COMPLETE (271) Low gear bush 17670 Spacing shim 76 r7733 27 r2750 Clutch push rod ... Clutch Iever complete ... 28 29 30 r2699 r2700 Clutch operating rack ... Clurch operarint pinion E8019 Thrust ball 1 31 3t r7766 Gearbox sprocket (15T) Gearbox sprocket (16T) Gearbox sprocket (17T) 1 31 r7765 r7701 T2686 72 23 74 EBOO5 r2,668 1 ... ... 1 A.R. A.R. 1 1 'l 1 1 1 1 1 1 1 1 Alte r native Alternative 37 T7702 Tabwasher 'l 33 T',t434 Nut 'l r1164 Gear change pedal ,| T2450 Pedal rubber Pedal bolt (j{ in. U.H.) 34 35 36 r2703 12692 r'1277 r2107 40 12435 T2106 Screw T2105 T1109 T3854 PIu nge 42 43 44 1 GEARCHANGE QUADRANT ... Spring rivet... Keeper plate 39 41 1 S 1 'l 7 2 pring r Return spring Selecror 1 2 fork-main 1 sh aft 1 17 BSA Unit Singles LLC fii o >t* QO' \t 34 \^ /"\ ," /---\ &'-.u I L,." \/ /x //, t_55 \\loo 7a /4 {q AL u/ -79 /,, 19 96 27 \4 %'"'nu76 I /P 77 Q0n \\ :' r" | '18 BSA Unit Singles LLC \) 15 30 g-- 97 29 ..tou =,ou COVERS ffr ;to7 d^ TIMING 1 _6 &^, illt a Ref. No. Pdrt No. DESCRiPT/ON GEAR CLUSTER AND TIMING 44 45 46 47 48 T2688 T3850 T1069 D2774 12691 Selector fork-lay shaft Anchor bolt Selector spindle ... Camplate ... Cam plate spindle r1249 pin ... lndex spring Spring backing 51 r1076 Screw 52 53 T1180 Lockplate... E8150 Camshaft s4 E3172 P"g 55 E8153 E8154 Camshaft oil seal Crankshaft T/S oil seal Not illus. 49 50 o r2689 r3763 56 57 58 59 60 r2763 r7774 61 T2330 E8157 E8155 ... Split ... ... ... bush ... ... ... Kicl<start foldi ng pedal Pedal rubber ... 11169 Pivot bolt (1 in. U.H.) 63 T'1167 S 64 65 66 67 s70 r7705 r7706 Cotter pin Cotter washer Cotter nut ... ... 68 69 70 r2643 r2687 KICKSTART SPINDLE... Need le roller Return spring 71 r3764 Anchor pin 72 73 r2657 Kickstart stoP 74 T2658 12681 Circlip Kickstart ratchet 75 r7682 Bu sh 76 77 78 r2683 Pin ion r2684 S E8005 E8172 E8072- p ring Contact breaker clip Washer ... Contact breaker cover 80 E8737 81 E7887 Gasket 87 E7354 Screw 83 E8165 E9433 E8010 Serrated washer 84 85 86 87 r2641 r2642 88 89 90 14-6612 91 E8169 97 14-6606 93 14-66'14 14-6611 14-6609 ... p ring Steel ball 3 r7704 ... ... Oil seal circlip ... ... Cable grom met ... KICKSTART CRANK COMPLETE (] in. U.H.) OUTER TIMING COVER Hollow dowel Kickstart oil seal ... Bush cover screw (2 in. U.H.) cover screw (1f in. U.H.) cover screw (1{ in. U.H.) cover screw (* in. U.H.) cover screw (f in. U.H.) lnner cover Outer screw (2| in. U.H.) Outer Outer Outer Outer 19 BSA Unit Singles LLC QUANI/IY COVERS continued r'1" \&-o',ou lfrl /' (Eb< -&@ o/ /'o oo ,,/ ,t, 138 o, ^l ,/ az I #-A'6 i I">' >\ ,rw&" i4rul\ 101 (t&' p &--.u d /, !r.--1 lts 7A v@.....=--zs 19 9a 76 $ 77 i3/w K^ 1,o I u", ( I 96 27 \4 \" I ld fl, I 1tl o \ 15 30 g-s7 ao /rA?' "63 - a2 59 Fit.3. GEAR CLUSTER AND TIMING COVERS BSA Unit Singles LLC Ref. No. Port No. DESCR/PIION QUANTITY GEAR CLUSTER AND TIMING COVERS 94 95 96 97 98 99 100 101 107 103 104 105 't 06 E9389 r1026 E8162 E9526 14-6608 14-6610 14 4606 E8158 99-.1056 D995 E7788 99-0077 109 E7831 E8163 E4747 E8164 110 E8166 '107 108 lnner timing cover Breather tube 1 1 Screwed plug Screwed plug (socket head) lnner cover screw (1 in. U.H.) lnner cover screw lnner cover screw "O" ring continued (l{ (t in. U.H.) in. U.H.) 1 1 1 1 1 1 Auto-adYance unit (5441 6405) Condenser Contact breaker Points (54419827) ... ... Contact breaker bolt ... Washer ... Clamp pillar bolt Washer ... Contact breaker lead sleeve .., 21 BSA Unit Singles LLC 1 1 1 1 1 1 2 2 1 M' 11 d 26 d 10 gE -zs 12 M - -D \ 1a Fig.4. CLUTCH AND PRIMA,RY CHAINCASE BSA Unit Singles LLC r lo Ref. No. DESCRIPIiON Port No. CLUTCH AND PRIMARY CHAINCASE 1 rv66 7 E8782 I 3 E9393 Primary chaincase cover l 4 E9800 Filler 5 s1855 E7856 Level plug 6 Screwed plug \J n ng ... pluS Chaincase gasket Cover screw (1f in. U.H.) Cover screw (1 I in. U.H.) Cover screw (1i in. U.H.) Washer ... 7 14-6611 8 14-6610 9 11 s1951 E8175 E8010 12 D951 Chaincase dowel Prrmary chain (701) 13 E817 6 lg n 14 E8955 lnspection cover ... 15 E8178 Eg't77 Screw rzv3 Clutch hub r7714 Clutch hub l.ey ... Clutch sprde r 10 17 1l QUANIiIY ition pointer ... ... Gasket (, in. U.H.) 19 20 r2v5 rLv6 21 ra719 Rolle r 22 23 r2720 24 27 T2721 T2722 r27?,3 T2724 ner r craining plar€ Drain screw Ou!er retaining plale ... Screw ( i! in. U.H.) Shock absorber rubber drive and rebound Centre z8 r2D5 29 30 T7726 T7777 31 T1't44 32 r7748 cuP Spring nut 33 17728 Pressure glate 34 r2729 35 F879 Adjuster... Locl(nut ... 36 r2730 Retaining nut 37 12731 Plain washe r 38 r2732 Lockwasher 39 99-1006 s1894 25 26 s1943 Sprocl<et and housing ... ,n Driven plate Driving plate Spring 41 s1896 E8072 Stator (47205) Generator stud rear (2jf in.) ... Generator stud front (2{} in.) Generator stud bottom (2]f in.) Washer ... 42 14-0901 Nut 40 40 40 s1895 o BSA Unit Singles LLC .. .. .. .. ... .. .. ... .. .. .. .. .. .. .. .. .. .. .. ._ .. .. .. .. .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ''' '' .. ... ... 1 7 1 1 1 1 4 5 1 1 7 1 1 1 1 4 1 1 1 1 25 1 1 1 4 B 1 5 4 4 4 4 1 1 1 1 1 1 'l 1 -l 1! *"r". I f also 1) 3 3 Page 13 \" q-1-7-2e /.. (( r\r \ fi-7ss -:: 38-'vd @=-sz @I l-32 *e,-"n '6/ oo Iiz \,1 U ? 40 eYsE:><''z8 -\G -E -\!t==a_/ ao 533 V @-34 42.\€i @- g---43 49 - 35 /+e dM @ \c+ *'-^(2"-" /\ 50\ 51 Fig. 5. FRAME COMPLETE BSA Unit Singles LLC Ref. No. Port No. DESCRIPI'ON QUANI'TY FRAME 1 FgL',t4 Frame 2 F8994 3 F8995 4 5 F8996 F8819 6 14-0't13 SwinSing arm Spindle nut Spindle wash Engine shield Bolt (3 in. 7 E8134 F9084 I 9 F9023 10 w1691 11 12 E8088 F9745 '13 F5535 't4 15 16 17 18 19 'l Bolt Nut (+ Nyloc nut s1934 Bottom bolt 2',1 E8133 Nut 72 Shakeproof 25 76 34 F8985 F8986 F8987 99-07',t9 27 D980 78 F8285 79 F9003 30 F9004 F9005 F9006 F9007 F9008 34 35 36 37 38 39 bolt Front engi Nyloc nut 33 7 Ball head cu Spacer 32 'l (jf EB',t94 31 'l Engine steady Bolt in. Plain washer E8084 74 'l in 70 25 1 1 E8194 F8988 F8984 E81 spindle ... (3* 'il in. U.H.) Rear stud Spring wash Nut Battery (54077029\ Battery ve Battery carrier ... Battery tray rubber Nut Bolt (3 in. U.H.) ... E8137 F9086 F9007 F9087 Spacer l4ounting rubber F90'10 Washer ... 40 E8194 41 Nyloc nut Tool tray c/w clips Not illus. F9090 F9157 42 F9091 Plug fcr tool tray Bolt (641 in. U.H.) 43 F9092 Spacer 44 F8071 45 F9060 Nut Bolt 46 E8072 Washer ... 47 E8071 Nut 48 F9094 Bracket ... 49 F9093 Rubber buffer 50 F9945 Silencer mounting bracket (f in. U.H.)... 75 BSA Unit Singles LLC \* :\a --:=: ^ss sa*d @--gz ,a/ '.-(,( -e-"n 00 1iz \ ? ab zs 6L-32 I U QY*s<" -\e\ --) v(ei-r { -\lt=4--'l @ e-=>33 \.. 42-g @- 9.-- 4s q. 44 66 j6 t/ \f, @ ssA/ X\ l- h/u-5 /T 50\ 5t Fis. 5. FRAME COMPLETE BSA Unit Singles LLC Ref. No. DESCRiPT'ON Port No. FRAME QUANIi continued 14-0115 Bolt L w2320 Spring washer 53 '14-0307 Nut 7 7 54 55 F9272 Tank anti-roll ru bber ... Steady stay bracket 51 E8189 2 1 0 77 BSA Unit Singles LLC IY Flg.6. S}VINGING ARM AND SUSPENSION UNITS BSA Unit Singles LLC Ref. No. DESCRIPTION Port No. QUANTITY SWINGING ARM AND SUSPENSION UNITS Swinging arm S ile n tb loc 1 susPENsroN uNrT (640s4927) 5 D2067 99-1057 99-0107 6 99-0122 7 99-1058 8 F8997 F8998 Bonded bush-top (64533645) Bonded bush-bottom (64533654) Unit fixing bolt (1i in. U.H.) ... Plain washer 7 2 2 2 2 2 2 1 F9210 2 F8993 3 4 2 ... Spring (64543626) ... Spring retainer (90541171\ 9 10 s1-52 11 14-0903 Nut Nut 2 17 F8933 Washer .,. 2. 't3 F9766 Propstand leg 1 14 t3097 Swivel pin 'l 15 16 17 18 F3096 Lockwasher Spring 1 Chaingu ard 1 19 20 E8071 '14-011 3 Bolt +t in. U.H.) Nut Bolt (1j-i in. U.H.) 21 s25-2 Plain washer ,| 22 14-0902 Nut 'l FZ6',t0 F9950 F9060 2 1 (1 1 1 I r6 )4i 29 BSA Unit Singles LLC 1ra 13r HM <;v\ 1,4\t 6f* 14 4H 17 <-\-\.-\ ,tl o Y 34 %'ttt Fig.7. OIL TANK, PANELS AND EXHAUST SYSTEM BSA Unit Singles LLC o Ref No. Port No. DESCRIPIION QUANTITY OIL TANK, PANELS AND EXHAUST SYSTEM 1 2 3 4 s 6 7 8 9 10 11 ( I 114-0219 *1 I Muffler E8163 E9659 F8976 F8977 F8978 F9743 F9067 F9068 F6039 F9075 F9076 1 washer Spring washer sze-r 51832 1 "D" E3768 L S1e08 F9019 F9020 F879 E9679 1 FIXING CLIP Bolt (1+ in. U.H.) ... I Not illus. 1Z 13 14 15 '16 17 18 19 20 21 27 23 24 25 76 27 28 29 30 3',1 32 33 34 35 36 37 38 39 40 4t 42 E9653 E5A74 1 1 Locknut Bolt 1 (f in. U.H.)... Nut 7 2 7 Heat shield Screw z Washer ... 2 Spring washer 1 Exhaust pipe Finned collar 1 1 Screw (+* in. U.H.) 1 Nut Oil tank ... Bolt (1i in. U.H.) Nut 1 1 7 2 7 Rubber sleeve FTLLER CAP C/W D|PST|CK AND Washer F8874 F9070 Banjo F9071 Filter 1 F9146 Rubber connection 1 F9073 Clip 2 F9274 Rubber connection I E5473 E8106 Clip 2 Rocker oil feed pipe 1 E8'111 Clip 1 F9177 F9477 Rubber sleeve 1 F9478 D982 D1006 D983 D984 D1922 D1923 F10253 F8953 577'l Fibre washer 2 Panel D/S Panel T/S ... 1 1 Oddie stud-short Oddie stud-long Stud rubber (for long stud) Stud rubber (for short stud) ... Panel motif D/S ... Panel motif T/S ... ... Protective strip ... Grommet for T/S panel Oil tank bottom fixing bolt 1 3 3 1 'l 'l 2 1 1 *Later models use E2271 Fixing clip 14-0219 Bolt (1{ in. U.H.) 1 E3768 "D" 2 s26-3 Washer ... 1 s1908 Nut 1 1 washers 31 BSA Unit Singles LLC '!o 25 I @/h i' r 'i 6r-4." K.-@ @ ----".-----' ,"9e,Nil. .ry 22 \!'/ / \\---,, 37 6r^) W," ;^ /A."_.yF A\\ dr/i.P^" " F t-re)€^-i*-* "" 36 e I 39 fQ 27 'qo tt--^---,"^. "!" Fis.8. FOOTRESTS 3s / :-\ ---Z AND BRAKE LINKAGE ^O 32 BSA Unit Singles LLC Ref. No. 0 QUANIIIY FOOTRESTS AND BRAKE LIN KAGE 1A 7 w2376 Rear brake pedal Grease n ipple F9032 Fulcrum pin 1 1 F90ll 1 1 3 F9033 Nut 1 4 F9034 Spring washer 1 5 E8193 6 s26-l Bolt (t in. U.H.) ... Sprint washer 7 8 F9035 F9036 9 w2006 1 1 'l 10 F9958 't1 F9038 Plain washer Rear brake rod ... Toggle spring pin Brake pedal stop Swivel pin 17 F9039 F9040 Adjusrer nut Pedal stop bolt ... 7 t8979 F9041 Plain washer Shakeproof washer 2 2 13 14 15 ,!! DESCRIPIION Port No. F9047 Nut 11 F9043 Fold ing 18 F8448 Footrest bracket 't9 F9044 Anchor bolt 70 E8084 Plain washer 21 F9045 Bolt 22 F9046 F8986 F8987 74 25 1 1 1 'l 1 2. footrest (2i:;n. ... .2 ... 2 7 2 'l U.H.) Plain washer 1 Sprlng washer Nyloc nut Nyloc nut Special srud (2 ln. O.A.) Locking plate Washer ... 1 1 2 78 29 30 F9085 F9047 F9048 F9049 F9050 F9034 JI F9051 Footrest 37 F9057 F8137 Bolt Nut 34 35 36 F9053 Pillion F9054 Ru F9044 36 F9055 F9085 F9133 Anchor bolt T/S ... Anchor bolt D/S Nut Bolt (11 in. U.H.) Nut Pillion footrest support bracket T/S 41 14-0116 Bolt 3 47 '14-0702 Nut 3 77 33 37 38 39 40 F9057 E8137 I 1 1 Nut 1 I Spring washer ('1 f rubber... ... 7 2 7 ... 2 in. U.H.) foorrest ... 7 bber t 33 BSA Unit Singles LLC ,1 1 7 2 z 'l - 43=6-*\@ '1 0 42'@ <s :a- E44 41 -@p. 59 34 b P.o g sr€-no # dA\ \=\9-39 3g "i --10 \bo 11 13 'lo G'-49 15 16 17 'ia ry 6 €-,, a.\ n -29 il JL"" p fJ- sr V--.\ 32 Ae € d-* Fig. 9. TELESCOPIC FRONT FORK BSA Unit Singles LLC TO Ref. No. Port No. DESCR/PIlON QUANIIIY TELESCOPIC FRONT FORK 0 H3671 I H7294 2 H2295 3 H',t844 4 14-0218 5 s26-3 5 H519 H430 H3694 H3693 7 8 9 10 H 't1 17 H2632 13 14 15 16 17 18 3638 H2633 H2513 H3678 H1656 FORK ASSEMBLY D.S. BOTTOM MEMBER C/W CAP ... T.S. BOTTOM MEI"IBER C/W CAP Spindle cap Cap bolt Spring washer ... 1 1 'l 7 4 4 7 ... Drain plug ... Drain plug washer ... Top cover T/S Top cover D/S Spring su pport 2 1 1 2 Sealing washer Sealing washer 4 Gaiter 2 l.1ain spring... 2 ... 2 Spring support washer 7 1 H'1500 Oil H3639 Reference only LOWER COVER TUBE ASSEMBLY Sleeve ... 2 H7119 "O" 7 7 7 seal Not supplied separately ,rll 19 20 H431 71 H441 ring Outer washer LJpper bearing 22 H3672 H2245 lnner sleeve 2 Top nut 7 Washer Stanchion 2 2 24 25 76 28 H2653 H3637 H443 H2154 Lower bearing 2. 5huttle valve 2 Nut '). ... H2091 HZ127 Circlip H2090 Restrictor 3t H 1062 37 H7126 33 H1631 H2630 s785 Sealing washer Flanged bolt Spacer 29 30 34 35 36 37 38 39 40 s25 2 14-0303 H7526 H2648 42 H2525 H2658 H2659 43 H7645 44 H?,646 45 46 H2656 47 H2655 H2651 41 48 49 50 F898't H2654 s70-3 z ... ... 7 7 2 2 2 Washer Pinch bolt ... ... Washer Nut ... M idd le lug and stem Bottom cone Top lug Cable guide bracket G rom met ... ... Bolt (1+ in. U.H.) Nut ... Bolt ... 7 7 7 1 1 1 2 2 'l 7 4 4 Washer Hand lebar clip z nut ... Cable gu ide ... ... ... Steering head ball ... Sleeve 1 1 40 35 BSA Unit Singles LLC 43_@:::@ "&S 1t a 1l a 42-_€ E44 U- g sc 51 50 39 ;,9.-; # 35 26 <_/49 <r 7 €-,, a\ n -20 il J L.-* \a !s>- --31 f7 H=.- 32 tr@ I6 F" Fig. 9. TELESCOPIC FRONT FORK BSA Unit Singles LLC l)lo Ref, No. Port No. DESCRIPIION TELESCOPIC FRONT FORK 51 52 H2647 H2650 53 H3746 54 't+0218 1+0702 Top cone Dust cap Mounting bracket Bolt Nut 55 56 1+61m Bolt 57 s26:2 Spring 58 59 60 E8088 Spacer washer ... sink... H2737 Heat H7275 Zener Diode sealing plug ... BSA Unit Singles LLC QUANflTY conrinued $t 11r Fia. 10, FRONTWHEEL 38 BSA Unit Singles LLC I fla Ref No. Port No. D€SCR/PTlON t FRONT vl/HEEL w3465 w2132 7 w1230 w3325 3 wz't37 1 FRONT WHEEL COM PLETE RI14, SPOKES 1 AND HUB ASSEMBLY I Hub ... 1 6 w2136 w653 w1237 7 wl238 Circlr p w2057 Wheel 3 4 5 I 9 w2138 w2139 w1481 10 w3443 't1 w3337 12 13 14 15 16 w582 w3429 w3444 17 18 19 w3453 z0 1 Rim... Spoke D/S 8 SWG x 6 in. straight Spoke T/S 8 SWG x 5fr in. 76" ... Spoke T/S 8 SWG x 5g in. 100' Spoke nr pple Bearing ... Dust cover 3 !i QUANTITY 20 10 10 40 a 1 1 spindle ... Grease cap D/S ... ... 1 ,| Cover place Bearing supporr ring Bearrngretainer... 1 1 ... 1 Anchor plate 1 s650 Gauze Screw 3 F2351 Washer ... w2026 2. w3454 Brake abutmenr pad Brake cam Brake lever-front Brake lever-rear 21 w7077 Washer ... 2 22 14-0403 Nut 2 23 24 w3522 Return spring I w3450 w2005 Brake rod 26 27 28 29 30 3l 32 33 34 34 w2001 1 3 7 1 1 1 D2683 Fork end-threaded Lockn ut ... Pivot pin ... Split pin ... 7 w2058 Nut 1 w3446 BRAKE SHOE C/W 2 Ref. only Ref. on ly Lining Rivet S p ring 7 14-040'l WF32 w135 w1197 w1198 1 1 2 't6 7 A.R. A.R. Balance weight j ozBalance weight 1 oz. I 39 BSA Unit Singles LLC /a( 12 @ .11 @ tt 15 16 d-d fi I w B -/F\ a-(J Fig. ll. REAR WHEEL 40 BSA Unit Singles LLC flo Ref. No. Port No. DESCRIPT'ON QUANIIIY REAR WHEEL w3581 'l 7 3 4 5 w3452 w2290 w2297 w2297 w2293 w2294 w7291 REAR WHEEL COMPLETE (LESs BRAKE AND TYRE) REAR WHEEL COMPLETE (LESS BRAKE AND TYRE) RIM, HUB AND SPOKES ASSEMBLY... Hub complete Spoke D/S Spoke T/S Nipple... 1 with 49 T sprocket I 1 40 Rim 1 I w2309 w2339 w1015 Fixed spindle nut ... Chain adjuster Chain adjuster end cap z z 9 10 E8137 E8088 Adjuster nut Adjuster washer 2 2 11 w2335 Brake anchor strap I 12 w2336 Bolt (11f in. U.H.) ... 1 IJ v't7337 Washer 1 14 15 16 F9085 Nut 1 w2325 Fulcrum pin nut Fulcrum pin washer Fulcrum pin Brake anchor plate BRAKE SHOE COMPLETE WITH LINING Brake lining ... ... w2323 18 19 w2322 w7327 20 Reference only Reference only 21 22 73 24 25 26 27 w2328 w2329 w2226 w2326 w2334 w2330 1 Brake rivet Brake shoe sprint ... Brake cam lever BRAKE CAM Grease nipple Brake lever return spring Plain washer Shakeproof washer 1 1 1 1 7 2 fNot 14 'l 1 1 1 31 D1026 31 D1028 3/ w2314 Rear chain (f x Rear chain (i x Drivint flange 33 w23t2 Bearint spring ring... 'l 34 w231'1 Bearing shim 'l 35 w2315 w2316 w2308 w2305 Bolt ... 6 Nut... 6 Fixed spindle Bearing retaining ring I w2298 w2299 Bearing 2 38 39 40 1 Nut... 1 Locking ring I i x 101L) x 991) ... ... 3 ... ... 1 '1 1 Thrust washer Was he r 1 42 43 w2300 Spindle sleeve 1 44 w2295 w2318 Security bolt WM3... 7 w2354 Chainwheel (52T) ... Chainwheel (49T) ... Chainwheel bolt 45 46 46 47 w2321 w2319 East coast y'est coast \ 1 w2313 w2363 41 \separately 1 w2331 36 serviced 7 28 29 30 w2332 w73't7 52 T sprocket 20 1n 6 7 w2324 with 1 1 I Bearing Brake drum... 1 I '1 10 41 BSA Unit Singles LLC East coast West coast ,$l 12 trfr{?n 14 W w rll)o -€\ 4-(-i/ Fig. ll. REAR WHEEL 42 BSA Unit Singles LLC fillo Ref. No. Port No. DESCRIPflON REAR WHEEL QUANTITY continued w2320 w2302 Spring washer 10 49 lnner retainer 1 50 w2301 Felt washer 1 51 w2303 Outer retainer 1 52 vv2304 53 D1026 54 w2306 w2307 Hub end cover Speedometer gearbox (BG5330i31) 2 :1 Distance collar inner O/S ... Distance collar outer O/S Hub spindle 48 55 56 w2333 BSA Unit Singles LLC 1 1 1 1 1 w', ft, - . 'w '%:,, ?*"' ,, ) ebEb '11 4 oQ Kd-s7 s)e *-e % Fig. 12. FENDERS BSA Unit Singles LLC o,, -Ref. No. DESCR/PTION Port No. FENDERS c 4 F9016 H3619 H3671 H3685 6 F9019 F9068 1 2 3 7 8 9 10 F9029 E8088 w1691 F9017 F9088 1'l 12 13 14 15 16 wl691 Bridge stay Bottom stay Bolt (+ in. U.H.) ... Nyloc nut Bolt Washer ... Nut Bolt (J in. U.H.)... Bolt (1 * in. U.H.) Nut 14 0114 Bolt s25 Plain Washe r 3 GS299 Washer ... 14-0707 Nut Rear fender 1F9165 F9019 F9077 F9020 Special 71 t879 27 F9023 Nut Bolt 23 E8088 E8137 Washer 75 26 F9028 Wiring grom met 27 *Ft0270 28 E2980 29 30 37 F9132 s25-1 F9030 F9068 33 F9198 Rear 34 F9019 Bolt (+ in. U.H.)... 35 s25-1 Washer ... 36 E8071 Nut 38 39 H3669 H3680 s1822 Bracket O/S Bracket N/S 40 F4299 Washer ... 41 F4715 Screw 47 s5161 Nut F11 335 3t 'r {t Front fender Front stay... 17 18 19 20 74 0-.t QUANI/IY F81 39 tF9s05 Bolt (+ in. U.H.) ... Spring Washer Washer (l{ ... ... ... ... in. U.H.) ... Nut Rear fender support rail Tail lam p support Stud (jf in. o.A.) Support plate Washer ... Spacer Nut Bo nu m ber plate bracket lt Tail lamp support fitted to later models Rear guard fitted to later models I I I 45 BSA Unit Singles LLC I @'",, r 17 Fig. 13. GAS TANK AND T\i/IN SEAT f{ll]o BSA Unit Singles LLC Ref No. Pdrt No. 0 GAS TANK AND T\^r'IN SEAT tank ... Mounting rubber-rear F9479 F9690 Gas 2 lnlounting rubber-front Bolt (1+ in. U.H.) Distance tube Distance tube 1 3 F9134 4 fl0a59 5 F9063 6 F10250 F10260 F9065 7 8 Mounting rubber Plain washer E8196 F9480 F4715 Nut Trim strip 124 H430 H430 Washer ... Washer ... 13 F9700 13 F9701 Styling unit T/S ... Styling unit D/S 14 15 F8197 Knee F8193 Knee grip T/S 16 17 18 19 19 20 F8946 F7888 Styling unit screw-front 20A 23 Fl 0002 F10267 F9744 F9196 24 s5662 Bolt E8088 26 17 28 29 w2320 9 10 11 12 D DESCR/PTiON 21 2t 69 F4971 F97 F4972 E7351 Screw (:; in. U.H.) grip D/S ... Styli ng unit screw-rear Gas line -.. Gas tap ... Gas tap-with Teserve -.. Gas tap washer (Stat-o-seal) ... Steel washer Filler cap Tie bar piece ... Distance (N F9020 Plain washer Spring washer Twin seat (cover F9504) Rear flxing bracket Sprint washer 30 E8101 Nut 31 Plain washer 32 s602 F'l1304 33 F9023 Bolt 34 E8088 Washer ... 35 w1691 Nut F9477 F9476 Hand rail (li ... in. U.H.) ... ... in. U.H.) [n BSA Unit Singles LLC QUANTITY fl zs'/ @ I ... oX 1104 \z\ d'--. #\ 4r'' k WqY-' 6.Y --.-u /* YN\'' 9 \N. M @,} \o iI t Fig. 14. HANDLEBARS, CONTROL LEVERS AND CABLES ,l BSA Unit Singles LLC fr I fI( qZ Ref. No. P.rrt No. QUANI/IT HAN DLEBARS, CONTROL LEVERS AND CABLES 0 1 z 3 4 5 6 7 I 9 l0 11 17 13 14 15 16 17 18 19 H2678 99-0248 D958 99-0245 99-0746 99-0744 99-0738 99-0239 99-0740 99-0226 99-0241 D959 D2090 99-0267 99-0A62 99-0230 99-0226 99-0250 99-0252 99-1031 99-'1059 D2074 tl) DESCR/PTlON 70 99-0265 21 99-026',1 22 23 99-0230 99-0752 99-0226 99-0250 99-1031 24 25 /t) 27 28 79 30 3l 99-'1059 D967 *D2050 D2085 D2086 D638 33 w2006 34 D2083 Hand lebar-Western cype rwrsTGRrP (161364) ... 1 1 I Handlebar grrp Body top half (16/328) Body bottom half (16/329) Rotor (16/091) Fnct ion sprint I 1 1 (16/008) ... 1 Friction spring screw (16'0091 1 Nut (16/010) 1 Screw (11 /014) Cable stop (16/011) 2 ,| Dummy grip FRONT BRAKE LEVER (ball end) (18/951) Lever bracket (18,777) Lever ('18/754) 1 1 1 I Control clip (12/595) Clamp bolt (11 /014) Fulcrum pin nut (18/053) Fulcrum pin (18,087) 1 2off ,| 'l Cable adluscer (18i1708) ... 1 Thumb nut (18/1709) 1 CLUTCH LEVER (ball end) 18/952) Bracket (18/773) Lever (18/752) ... ... ... ... 1 'l ,| Cont rol clip (121595) 'l Fulcrum pin ('18/087) 1 Clamp bolt 7 (11 /014) Fulcrum pin nut (18/053) Cable adjuster (18/1708) ... Thumb nut (18/1709) THROTTLE CABLE FRONT BRAKE CABLE Front stop switch ... Rubber cover 1 1 1 I 1 'l 1 Fork end Pivot pin (spring fix) 1 1 CLUTCH CABLE 1 I r[, 1,D2034 FRONT BRAKE CABLE fitted to later models I 49 BSA Unit Singles LLC t' na @\ ,t 1\ ]I lJ ,.-q 5 I 0 25 -_@ 20' -@ 4ra a\2 16 ,, ," ;s /ff)'" I -L,z"' N@K"', \7 Fig. '15. SPEEDOMETER AND TACHOMETER BSA Unit Singles LLC (o ) Ref. No. 0 QUANI/IY ,| D't022 Tachometer (R.S.M. 3003/06) 2 Dz123 Cable 3 4 H3689 F9170 Mounting plate ... Mounting rubber 5 F917'l Screw 6 F9172 Washer 7 F9173 Nut F9174 Bu sh 't1 E9428 E9517 E938'l E9382 TACHOMETER GEARBOX COMPLETE Drive body ... ... Drive shafr ... ... Drive gear ... ... 12 E9429 IJ E9383 14 15 16 E9430 E9431 E9432 Retaining pin-drive gear Thrust washer (J nng Locating pin Joint washer 17 D1926 SPEEDOMETER (SSM2001 /02) 18 3',t 't9 30-283-01 4-11 30-271 -0't 4-11 9 10 20 Nut Cable 22. ')? F909',| Bo 24 E8072 25 26 27 643 99-0695 Not illus. H E8102 3700 Mou ... ... 1 1 .. ,| 1 4 4 4 4 . Fixing strap... Serrated washer -647 -187 -01 D697 H3626 21 0 DESCR'PIION SPEEDOMETER AND TACHOMETER I ) Port No. ... 1 1 1 1 1 1 1 1 1 1 Rel only Rel only ... Ref. only 1 ntint plate ... 1 lt 2 7 2 Spring washer Bulb 7 Bulb holder (554710) Wire clip for speedometer cable 2 0t 51 BSA Unit Singles LLC 1 F ea 3 \t4 \u@) l" @.. 8," &-,o "*:t/ ffi G5," ./) =--\- \ss-\ r(# 23'iw 26 /S A \\ i" ' ,/", 0a 1 25 ,-\ , 34 /ul 39 ffi 'ov {J "":P " "o s"" 43 42 6da' j, uu m, 'M'(-'"' U-* ffi m -'-D>N,", \!--+4 \K( *d." ) gffi." ."{tT. Affi \ou -tt" ^" Fig. 16. ELECTRICAL EGrUIPMENT 52 BSA Unit Singles LLC flo Ref. No. Port No. DESCRIPT'ON QUANTITY ELECTRICAL EAU IP MENT *99-1040 2 99-0691 99-1041 3 99-0683 4 99-1042 1 HEADLAMP ASSE|.4 BLY (60037) Rim (s34343) I 1 Litht unir (54524526) Fixing wire (504665) 1 6 5 99-1003 Bulb (40/27W pre-fodrs) (464) ... Adaptor C/W leads (54520540) 6 7 8 9 10 99-'t004 Bolt (112201) z H1932 Spacer Screw 2 11 99-0556 99-0568 99-0537 99-0803 99-0548 99-0695 54190108 99- 1053 Bulb (2wBA.7s) (281) Warning bulbholder (54945043) Pilot bulb (989) Pilot bulbholder (55471 0) Double Lucar blade Harness (54955718) ... Reference on ly Scop-tail lead Rectifier C/W securing nut sTop AND TA|L LAMP ASSEMBLY (53973) 22 99-0589 99-0597 99-0781 99-0698 73 99-0542 24 54574348 25 26 54578213 573828 Contact assembly ... 27 28 99-0780 F4715 Gasket (54571677) Screw 29 30 GS299 F8307 F8286 12 13 14 l( 16 18 19 20 21 't44921 1 1 Ref. only Ref. only Plate ... 55408 99-0563 Lighting swirch (3571 0) Dip switch (31620) 1 'l Warning light (Red) I 2 Ref. only 1 'l Ref. only 1 1 1 'l Lens (54572932) 1 Screw (572289) 2 Bulb (6/21W cffset pin) (380) Bulbholder with refl ector 1 Ref. only Ref. only Ref. only Bracket 1 7 2 Washer Stop and tail lamp lead tube Front reflector C/W bracket Horn push (76204) ... ... 'l ... 33 F8273' 34 F8140 35 F8195 Push-Fix... 2 2 7 7 4 36 D997 Ho rn I F5535 Bolt 38 39 40 ::.tr Washer ... spring washer ... E8194 Nut 41 99-0574 coil 42 423947'' 43 F9131 Coil support clip... Bolt (t in. U.H.) 44 s602 F4374 Washer ... Distance piece ... 31 32 45 1D994 *D2166 fF8318 , Rear reflector Rubber washer ... ... 'l 1 ... ::. .:: 1 1 (45110) 1 'l 1 1 ... 'l Head lamp 54052910 fitted to later models. Ducon horn push (WIPAC 16714) fltted to late! models and dip switch 53 BSA Unit Singles LLC I I f( fll Fis. 15. ELECTRICAL EOUIPMENT 54 BSA Unit Singles LLC flO Ref. No. Port No. DESCR/PIlON QUANTITY ELECTRICAL EQ U IPME NT 46 47 48 49 50 51 52 53 54 55 56 E8071 Reference only 99-0590 F6981 99-0558 99-1000 D990 Nut H.T. continued 1 lead Zener I iode (49345) Itnition lock C/W keys lSnition switch (31899) d 1 1 'l IGNI'IION SWITCH NUT (s4130041) Stop switch (34815) F9't91 Bolt F8979 E9'172 Spring washer ... ... Cable slip (stop switch) D999 H.T. lead grommet ... ... 1 1 2 2 1 I 55 BSA Unit Singles LLC f,^ € lo 4 re I TOOL KIT BSA Unit Singles LLC I Ref. No. Port No. DESCR/PIION QUANTITY J 1 TOOL KIT D7113 2 D291 D968 3 D801 4 D87 5 D767 D2084 D971 1 6 7 o 9 10 D972 NA'I4A 1'l D974 D978 12 XA69 '13 D1029 '14 H2654 TOOLROLL COMPLETE WITH I .1 TOOLS ... Toolroll Suspension unit spanner Combined tyre lever and tomm)' Plug spanner bar Screwdriver set Spanner Box spanner Ring spanner Tyre lever ... Tyre valve key ... Cable clip-rubber Cable clip Cable clip Cable clip-wire 57 BSA Unit Singles LLC ... R v @ t-5 )€ lo )O)o 4 $€ € a----. --5 ! H il ll--" il U @L il o^oo ! Fis. 18. CARBURETOR BSA Unit Singles LLC ^'o Ref, No. DESCRiPIION Port No. CARBURETOR 0 D2021 CARBURETOR COMPLETE (R928/4) 1 99-0521 Screw and washer (622/086) 4 2 99-0271 Plug screw (411 37A) 1 3 99-0531 Top cap (928,097) 4 Th 10 99-0507 99-0510 99-0529 99-0527 Reference on ly 99-0445 99-0516 11 99-0515 12 13 14 99-0520 5 6 7 I 9 16 17 I QUANTITY 1 ... ... rottle sprint (622/051) ... 1 1 ... Circlip (6221067) ... ... Need le (928/063) ... Th rortle valve (3) (928/060) 1 Body ... lYain jet ('160 c.c.) (376/100) 'l 1 ,| 1 rottle stop suew (6721077\ Prloc air screw (6221076) ... ''O" ring (6221082) "O ' ring (6221101) ... Gasket (622/073) ... Need le jet (6221079) JeL hold er $22/080) 'l (62?/069) spind le (522/071) 1 99-051'l 99-0506 Floar Float Float Float needle (6221068) chamber (622/050) ... 1 61093 Filter 99-0527 99-0514 99-0518 99-0519 99-0512 18 19 20 99-0513 71 37 72 73 99-0517 D1053 24 t9194 Th 1 2 1 1 1 1 1 1 1 Banjo bolt (6221078) 1 AIR CLEANER COMPLETE Air cleaner element ... ... l,r 59 BSA Unit Singles LLC 1 'l Ptinted in Englond by WARWICK PRINTING COI4PANY LIMITED WARWICK BSA Unit Singles LLC
Similar documents
1968 triumph tr25w 250cc
Generator stud-rear (2ii in.) Generator stud-front (2if in.)
More information