1970 triumph tr25w 250cc

Transcription

REPLACEMENT
PARTS CATALOGUE
THtrtrFilY
TR25
258
W
25O c.c. (15 cu. ins.)
I97O MODELS
www.bsaunitsingles.com
REPLACEMENT
PA RTS
CATALOGUE
TR 25W
TRIUMPH ENGINEERING
COMPANY LIMITED
MERIDEN WO RKS ALLESLEY .COVENTRY
ENGLAND
TELEPHONE MERIDEN 33I
TELEX 3'305
TELEGRAMS "TRUSTY, COVENTRY'
P..t No. 99-0906
PU
BLISHED SEPIE MBER
1 9
69
TRIUMPH GUARANTEE
'1.
In this Guarantee the word "machine" refers to the motor cycle, scooter, motor cycle combination
or sidecar
as
the
case may be, purchased by
the Purchaser.
2.
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 sumcient, 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 offitting such new or repaired part or accessory.
.4
Any part considered to be defective must be sent to our Works, carriage paid, accompanied by the
following information :(a) Name of purchaser and his address;
(b) Date of purchase of machine;
(c) Name of dealer from whom the purchase was made;
(d)
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 petitions;
(c) Adaptation or alteration of any part or parts after leaving our Works;
(d) The attaching ofa sidecar in a manner not approved by us or to an unsuitable
motor cycle.
This Guarantee shall not extend to machines whose trade mark, name or manufacturing number has
been altered or removed, or in which has been used any part not supplied or approved by us, or to
tyres, saddles, chains, speedometers, revolution counters and electrical equipment or to parts supplied
to the order of the Purchaser and different from our standard specification.
6.
Our liability and that ofour dealer who sells the machine, whall be limited to that set out in this guarantee,
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 exctuded and no guarantee other than that expressly herein contained applies to
the machine to which this Guarantee relates or any accessory or part theregf.
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
MAN UFACTURER INVALIDATES THE GUARANTEE
REPAIRS GUARANTEE
1.
Whilst the highest standard of workmanship and materials is aimed at, we canno! accept liability for
any defects appearing more than three months after the machine, assembly or component has left our
Works after being repaired.
2.
We will repair or replace at our option free of charge any defective work, materials or parts relating
to the repairs carried out by us appearing within that time but shall not be under any further or other
liability for any other loss or damage whether direct or consequential and our liability shall be limited
to the cost of so making good. We do not undertake to bear the cost of fitting any replacement or
repaired part.
3.
We do not accept liability in respect of parts of proprietary manufacture, e.g. tyres, saddles, chains,
speedometers, revolution counters and electrical equipment which may be used by us in effecting a
repair. AII other conditions and warranties statutory or otherwise express or implied are hereby excluded.
t-
INDEX
Poge
AIR
...
FILTER
ALTERNATOR
OIL PUMP
OIL RELEASE VALVE
OIL TANK
...
.
...
PILLION
PROP STAND
... 33
... 9, 1'l
... 23
... 29
53
REAR PANELS
...
71
REAR WHEEL
49
RECTIFIER
...41,43
...53,55
49
REFLECTORS
59
... 15, 23
BATTERY CARRIER...
CARTON PACKS
CHAINGUARD
59
7
29
CHAINS
... 23, 41
CLUTCH
CONTACT BREAKER
CONTROL CABLES...
CONTROL LEVERS ...
...
...
...
...
...
CRANKCASE...
... 13, 15
cotL
...
...
...
CRAN KSHAFT
CYLINDER HEAD
EXHAUST
FE
FOOTRESTS
...
9,
11
...
31
PISTON
PRII'4ARY CHAINCASE
...
...
45
...
25
...
SPEEDOMETER
...
...
STEERING RACES
...
SPARK PLUGS
31
53
9,
11
51
35, 37
SUSPENSION UNITS
...
swtTcHEs
... 53, 5s
TACHOIVlETER
...
...
52
,,.
I)
29
...
FRONT FORKS
...35,37
FRONT WHEEL
...
39
TAIL LAMP
TII.lING GEARS
TIMING COVERS
47
...
GASKET SETS
GEARBOX
17, 't9,
HANDLEBARS
5'1
17,'t9,11
TWINSEAT
...
...
47
VALVES
...
9, 1'l
TOOLKIT
GAS TANK
MUFFLER
FOOTRESTS
9,11
3't
FRAME...
HEADLAMP
HORN...
13
23
PIPES
N DERS
15
15
...
...
...
CARBURETOR
Poge
7
57
11
49
...
...
52
53
31
WIRING HARNESS ...
()
ZENER DIODE
55
TROPHY 250 TECHNICAL
D
ATA
67 x 70 mm.
Bore and stroke ...
Capacity ...
249 c.c.
-..
9.6:1
Compression ratio
Champion N3
Sparking plug
Amal Concentric .928
28 mm.
Carburetor
Choke size
Main jet ...
Need le
Need le
160
jet
''106
Standard
No.
Throttle valve
15 teeth
Gearbox sprocket
52 teeth East Coast
49 teeth West Coast
Final Drive Sprocket
$ in. x
Front
Chains
;
I
Rear
Capacities
...
Fuel tank ...
Oil tank ...
Gearbox ...
...
Primary chaincase
Front forks (each
...
S
in. Duplex x 70 links
in. x I in. x 10'1 links East Coast
in. x + in. x 99 links Vy'est Coast
3.916 galls. U.S.
6 Pints
+ pint
leg)
I
...
Front and rear diameter
Brakes
Tyre size ...
3
pint
+ pint
7 in.
3.25
4.00
Front
Rear
x
18
x
18
TRIUMPH SPARES
HO\/V 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 assem bly and a n u m ber 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.
WHERE TO OBTAIN, Triumph Spare Parts can only be obtained from an authorised Triumph
Dealer, and we recommend our customers to place their orders with the Triumph Dealer in their district.
When parts not usually asked for are required, and for which the Dealer may have to write or obtain specially,
the postage or carriaSe 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 cycies 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.,
f4elksham,
Holdford
Wilts.
Road,
Witton,
Birmingham,6.
SPARKING PLUGS.
Champion Sparking Plug Co. Ltd.,
CHAINS.
Feltham,
Renold Ltd.,
Wythenshawe,
Manchester.
M
ELECTRICAL E@UIPMENT,
Messrs. J. Lucas Ltd.,
iddlesex.
SPEEDO M ETERS.
Messrs. Smiths lndustries Ltd.,
Cricklewood Works,
London, N.W.2.
Gt. Hampton Street,
Birmingham, lS.
TYRES.
Dun lop Rubber Co. Lto.,
Fort Dunlop,
Birmingham,24.
SUSPENSION UNITS.
Messrs. Girling Ltd.,
Birmingham Road,
West Bromwich,
Staffordshire.
HOW TO USE
THIS PARTS CATALOGUE
Consult the index on Page 3 for the parts or group of parts which you wish to locate.
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.
Proprietary components e.8. electrical equipment, carburetors, suspension units etc. are listed in the flrst
or 99-) wherever they are stocked at the
column under Triumph part numbers (prefixed either Dfactory. lf proprietary parts are listed only under manufacturers part numbers, they are not available from
the factory.
PLEASE NOTE
THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS
INCLUDED IN THAT ASSEI4BLY ARE INDENTED IN THE DESCRIPTION COLU14N, REVERTING
TO THE ORIGINAL ALIGNMENT WHEN THE ASSEI4BLY IS COMPLETE. TO ORDER THE COMPLETE
ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEIYBLY NUI'4BER. ANY COMPONENT
PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.
SPECIAL WORKSHOP TOOLS
A
COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING
YOUR DEALER OR APPLYING DIRECT TO THE DISTRIBUTOR. IN MOST CASES THESE TOOLS ARE
VERY COSTLY AS THEY ARE II4ADE ENTIRELY FOR WORKSHOP USE, AND THEREFORE, IT IS NOT
RECOI"II"lENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN ORDER TO AID SERVICING
THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUI,ISTANCES IT IS FAR MORE ECONOMICAL
TO GET IN TOUCH WITH A RECOGNISED DEALER.
UNIFIED TH READ FORM
NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOGUE HAVE THE UNIFIED
FORI4 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 MARKINGS. BOLTS HAVE A CIRCULAR RECESS IN THEIR HEADS,
STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING CIRCLES ON IHE
SIDE.
CARTO N PACK LIST
The following sub-assemblies are supplied in carron packs under the part numberstated. The contents
ofthese carton packs are preserved and will not deterlorate under adverse conditions.
PISTON (complete with rings, gudgeon pin and circlips). These are in effect,carton pack,
assemblies.
9.6 : I C.R.
9.6 : 1 C.R.
9.6 : 'l C.R.
E7998
E8277
E8773
OVERHAUL GASKET SET
DECOKE GASKET SET
STANDARD SIZE
0.020 in. oversize
0.040 in. oversize
99-0031
99-0040
PA RTS VARYING
FROM STANDARD SIZE
The following are the part numbers of piston rings to suit oversizes of +0.020 in. and +0.040
rings are no longer available in carton packs:
PISTON RINGS
(0.020 in. oversize)
PISTON RINGS
(0.040 in. oversize)
Big end bearing
1
1
1
1
1
1
undersizes
E8177
Top compression ring
E90'17
E9021
I'4idd le compression ring
Scraper ring
E8278
Top compression ring
E9018
lYidd Ie compression ring
Scraper ring
E9022
0.010 in.
0.020 in.
0.030 in.
Part Number E6068/10
in.
These
6t
un
68
/-':bN)'
.:ffi..
r.1q1Qlr, ).')tt'
)s\
,'-
\7O
39
"\F
94u\Z
>--.\
-4W
NN
o.. l,
tr
27
R
l\
,ua
40
\4@
S^,,N
Fig.
l.
CYLINDER HEAD, BARREL AND CRANKSHAFT
Ref.
No.
Port No.
DESCR/PflON
QUANTITY
'l
z
3
4
5
6
7
9
9
10
'11
12
E9848
E9849
E9906
E9907
E8036
E8032
E8033
E8037
E8038
E8039
E1580
E8144
CAMSHAFT AND FLYWHEEL ASSEMBLY
C ran
FLYWHEEL DRIVE SIDE
FLYWHEEL TII'4ING SIDE
Reference only
Reference only
Reference only
Screwed plug
Flywheel bolts (1$ in. U.H.)
Flywheel bolts (2 in. U.H.)
4
4
8
in.) ...
in.) ...
Crankshaft pinion key
A.R.
A.R.
e
...
...
14
E2922
15
E6068
Connecting rod big end bush (available
D911
0.010 in., 0.020 in.,0.030 in.)
Sparking plug N3
18
19
20
E8276
wE479
Circlip
23
E9263
24
E7728
25
25
26
E8053
30
E8197
E8228
32
E8229
33
E7996
34
E8010
E8080
E8227
E8725
35
36
37
37
37
38
38
38
39
40
41
42
E't1227
E1'1228
E8226
El1229
E',t1230
E8081
E8137
E8136
E7820
undersizes of
2 halves
'l
1
22
16
in
*PISTON COMPLETE
21
29
1
7
2
Plain compression ring
Taper compression ring
Oil control ring
Gudgeon pin
27
'l
Self locking nut
E6838
E6839
WE2O3E
E8055
E7739
E8008
E8196
E8215
1
Rotor key
CONNECTING ROD
Connecting rod bolt
13
E7998
1
r
Wash
Shim (0.0'10
Shim (0.015
E8836
E3705
'17
I
kshaft
1
1
2
Cylinder barrel
Cylinder base washer
Push rod (exhaust)
Push rod (in let)
1
1
1
1
Tappet
Cylinder
Stud nut
1
1
1i:*''::o
(2+"-in o:A)
CYLINDER HEAD
Stud (2+ in. O.A.)
Stud (3 in. O.A.)
Stud (3+ in. O.A.)
Dowel
Stud (21{ in. O.A.)
Carburetor stud (1$ in. O.A.)
ValYe gu ide (inlet)
Service size valve guide -f.002 in.
Service size valve guide +.015 in.
Valve gu ide (exhausr)
Service size valve guide +.002 in.
Service size valve guide f .0'15 in.
Cylinder head gasket
Carburetor stud nut
Carburetor flange washer"
Distance piece ,..
*Refer page 7 for oversizes.
7
2
2
7
1
7
2
3
2
2
7
1
1
1
1
1
1
I
2
1
1
63
65
€uo @uu
g
6)
se @^
vaz
\43
6a
6P
6\@
67R
€o@* g\
'1,flv
,' --70 ,'
,, "'
zs
%
u
34
28
@
'&
-G.
6)
NN
-l
,",U
42
@L
' -22
Fis.
l.
10
Ref,
No.
Port No.
DESCRIPflON
QUANI/IY
CYLIN DER HEAD, BARREL AND CRANKSHAFT
43
44
45
46
47
48
49
50
JI
52
53
54
55
55
57
58
59
60
61
62
63
64
65
66
67
68
69
70
E7911
E7858
E7787
E7790
E7791
E1483
E'!575
E1330
E8952
E808s
E8086
E11165
El1166
E8112
E7777
Dt002
14-0403
s25-2
E8952
E8085
E8087
spindle
EXHAUST ROCKER
Thrust
Thrust
washer ...
washer ..,
Screw
(]f
E8113
E8114
E811s
E81 10
...
...
...
...
...
...
...
Top collar
Split collet
lnlet valve
Exhaust valve
PIug cover
Locknut ...
Washer ...
lnspection cap
Washer ...
Nut
Nut
Clip...
Nipple
U nion nut ...
Bottom cup
spring-outer
spring-lnner
...
...
11
I
1
2
1
'l
2
2
2
1
1
z
7
4 halves
1
,1
1
...
2
...
...
...
...
7
...
...
...
...
...
...
...
...
...
...
I
...
Fibre washer
ROCKER FEED PIPE ASSEMBLY
Oil feed pipe (26f in. long)
Valve
Valve
...
...
...
...
...
...
..
...
...
...
...
in. U.H.)
Union
74
...
Gasket
E8082
E8083
E8105
E8107
...
lnspection coyer...
Washer
72
73
...
Ball end
E8072
E8106
...
INLET ROCKER
Washer ...
E8111
75
Rocker
E8088
E8089
71
76
Rocker box
Rocker box gasket
continued
z
2
1,
7
7
7
1
1
1
1
I
1
2
2
7
m'-.-.o
@'-31
90
57
t
54
6<T
47
@-:77
--78
@r
w--,o
fFt
q€&=68
*ffik^
ryffi-"
,r l&
\t7
18
66
65
Fig.2.
CRANKCASE
'12-
Ref.
No.
Port No.
DESCR'PI/ON
QUANIi
I}'
CRANKCASE
1
E11'119
2
E8006
3
4
5
s1889
s1890
2
2
2
E8009
Hollow dowel
,|
6
E8011
1+1401
8A
E8003
E9974
9
E8025
10
s1894
s1895
s1896
11
12
13
't4
15
't6
17
18
19
1
Cylinder securint stud
Crankcase top stud (2!| in. O.A.)
Crankcase rear stud (21{ in. O.A.)
7
I
CRANKCASE
E8315
E8014
E8015
E6026
E8010
s1891
Solid dowel ...
...
Sum p stud ...
...
l4ain bearing (ball-journal)
Main bearing (roller bearing)
Oil seal left main bearint ...
...
Generator stud rear, short hexagon 1zg i".1
Generator stud front, long hexagon (2{i rn.)
Generator stud bottom (2{; in.)
Camshaft bush
Mainshaft bearing
Mainshaft oil seal ...
2
4
1
1
1
'l
'l
1
1
1
1
Oil seal circlip
Hollow dowel
Oil union stud ...
1
1
1
E8017
s1893
E8022
Scavenge pipe
1
Oil pump stud ...
2
Hollow dowel
2
s1857
Gearbox drain plug
1
73
12697
"O"
1
24
sl872
Timint hole plut...
'l
25
26
E8896
E9384
E8256
T1'150
Washer hole plug
'l
20
21
27
28
s1892
ring
Sealing plare
Sealing washer
1
...
Screw
Bolt (1+ in. U.H.)
Cylinder securing
...
1
2
29
30
14
31
E8135
Washer ...
32
14-0307
Nut
4
4
E8088
E8065
E9979
E8070
Washer ...
7
34
34A
36
0303
E807'1
14-1901
3
nut
...
4
Sump cover
1
Filter
1
Gasket
Plain washer
1
4
Nyloc nut
4
OIL
'l
E7590
VALVE...
Valve body ...
...
1
40
GS251
Piston
1
41
E6596
GS254
E11156
E9737
caP ...
1
38
39
42
43
44
45
46
E8124
47
48
s1898
D2133
H2704
RELEASE
Fibre washer
l'4ain
spring...
1
...
1
Joint washer
1
Non-return valve spring
'l
Valve ball... ...
Valve screw
Oil pressure switch
'l
1
Alternative
'13
kl*,."@
8B
.,g
,u..'u..
)@
IF\
\C\T
3A //
N\r
\$
41'
,-of43 >.\
oo
\-iS)
tw*nk",
A\v-
SP-ou
/ai
77
B7a
w70
&"'
q_
LqH
)[lil'
74
ryffi"
64
23-@
22
(g
\r--ll
Fig.2.
CRANKCASE
14
Ref. No.
Port No.
DESCR/PTiON
CRANKCASE
QUANI/TY
continued
49
50
D2045
Cover for oil switch
1
12695
Dipsrick ...
1
51
T948
Dipsticl( washer
52
E8147
E8148
E3789
E3832
53
54
55
56
57
58
59
60
61
62
53
64
...
Clip for alcernaror lead grommec
Alrernator lead grom met
Orl seal housing ...
...
1
1
1
1
ct
1
seal
1
G ask
E3833
Oil
E3821
Screw
Chain oiler
E8179
E8173
...
6
1
R: bber pipe
1
s1985
E8072
14-1901
Sru d
1
Washer ...
1
Nyloc nut
1
E8127
O'l pipcs and unron block
1
E8259
''O"
65
14-0302
Un
66
67
68
69
70
E8134
Serrated
E111 33
OIL PUI,IP COMPLETE
E11139
E11'147
Spind le housing
1
Spindle
1
E8094
Spind le gear
71
E8095
77
E1't143
E8097
gear-driven ...
Scavenge gear-driving
Scavenge gear-driven
73
ring ...
ion nut
..
2
1
washer...
...
1
1
1
Feed
...
1
'l
1
74
75
76
El1147
Driven gear spindle
'l
E8099
E8100
Bottom plate
1
77
78
79
80
E8071
Screw
Spindle gear nut
Spindle gear washer
F9041
4
1
1
82
E8104
E11276
Gasket
Hold ing nut
Washe r
Camshafc c/w pinion
83
E8041
Drive tear
84
E997s
E8040
Distance
Cran l<shaft pinion
1
E8043
Lockwasher
1
w1798
Nut
E8140
E8141
Distance piece C325 in. thick)...
Distance piece (3'10 in. thick)...
Distance piece (295 in. thick)..-
8t
85
86
87
88
88
88
89
90
E8103
1+190'.1
E8142
E8139
E8184
washer...
1
1
7
1
I
...
1
1
Engine sprocket
(23T) ...
...
...
A.R.
A.R.
A.R.
1
91
E8143
Chain tensioner
Distance piece
92
1+1901
Nut
93
E8072
Washer
94
95
99-0739
Rotor
E8274
E8146
Tab washer
1
Nut
1
96
...
1
...
1
3
...
3
(5421 3901)
1
15
37
J'u
[[w
34
\
6 {"-\
\,^\b
,
53.54
,/d,-=\
_..^
/<a ,.'
(.Y'
\J
\,2
I
&--.u
r
i
-99
/il .ru1OO
)k 7a
\E^
\/
27
--79
@r- ,.94
19
_*qD'
J-
23
(,
24
N.
A)
70J
/73
)?
a\
13iv\
/Y
72
\6
76
v
I
",i
15 30
I
+-97
2ts
104
107
v/d 106
P"EK.--"e xo /lo5
_^^
'o"=Y,i
(@
90
64
63
A
t-:r
tlr/
Ge
62
Fig.3. GEAR CLuSTER AND TIMING
't6
t-
103
COVERS
a3
Ref,
No.
Port No.
DESCR/PIlON
QUANTITY
GEAR CLUSTER AND TIMING COVERS
'l
2
3
r2661
r1391
MAINSHAFT COMPLETE WITH BUSH
I3872
HrGH GEAR (22T)
T275i
lligh gear bush
Mainshaft oil seal
5
E8015
6
E8014
7
7
7
8
9
T2678
12679
T2680
T3876
9
12664
r2:665
9
10
r2666
r2662
11
r7663
12
E8151
13
E8152
14
T2677
T2685
15
tb
't7
T2686
18
17671
r2667
'18
r2672
't9
E8005
20
T2668
21
n669
22
23
r3877
T3874
24
r2757
75
26
17670
T2733
27
28
29
30
r2750
31
T7699
Spacer (075
'l
LAYSHAFT
tOW
Tabwasher
11$4
Nut
T1164
Gear change pedal
T2435
T2106
42
T2105
43
44
T'1109
T3854
1
...
I
1
A.R.
1
1
'l
1
Qn\
1
1
'l
'l
1
1
1
T7701
rT07
...
Clutch push rod ...
Clutch lever complete ...
Gearbox sprocket (15T)
Gearbox sprocket (16T)
39
'l
Spacing shim
Thrust ball
40
'l
1
E801 9
T',t277
1
GEAR COMPLETE
Low gear bush
r2765
r2692
1
A.R.
A,R.
A.R.
Layshaft second gear (22T)
Layshaft circlip ...
Layshaft third gear (19T)
r2700
T2450
1
A.R.
A.R.
Spacer (080 in.) ...
Mainshaft third gear (24T)
Mainshaft low gear (16T)
l'4ainshaft bearing
Bearing circlip ...
...
Felt washer
Lockwasher
l'4ainshaft nut
Layshaft and high gear (14T)
Thrust washer (084 in.)
Thrust washer (079 in.)
Layshaft bearing ...
Clutch operaring rack ...
Clutch operating pin ion
12703
1
Spacer (070 in.) ...
r2766
r2707
41
I
2
in.)...
31
34
35
36
37
38
'l
Mainshaft bearing
Th rust washer (093 in.)
Th rust washer (098 in.)
Thrust washer (.103 in.)
Mainshaft second gear (21T) ...
31
32
1
Pushrod bush
Gearbox sprocket (1/
I
Alternat ive
I)
Alternative
1
1
1
Pedal rubber
Pedal bolt (+ in. U.H.)
1
GEARCHANGE QUADRANT
Sprint rivet...
1
1
7
Keeper plate
Screw
Spring
Plu nger
Return spring
Selector fork-main shaft
1
1
2
2
1
1
17
I
34
\
,"^,
-Vt'**
@'s
_47-1
2;, tgt (
t( ),4
&---'-.u
auJ '
\4q
-56
,r\g--.loo
lk-1 a
Aat
ty2
2zl
\6
9A
-79
76
77
K,
,1
7.,l
/73
CIfl
62
Fig.3. GEAR CLUSTER AND TIMING
COVERS
18
T
)P
"Ku
/ \,i
is
I
15
g-97
30
Ref.
No.
DESCR/PTlON
Port No.
QUANTiIY
fork-lay
shaft
44
r2689
Selector
45
T3763
T2688
T3850
T1069
Anchor bolt
Selector spindle
Not illus.
D2.724
Split
49
50
51
r2691
r1749
r1076
Screw
52
T1180
Lockplate...
53
E8150
Camshaft
54
E3172
P"g
55
56
57
58
59
E8153
E8154
E8157
Camshaft oil seal
Crankshaft T/S oil seal ...
46
47
48
60
61
6Z
63
64
65
66
67
68
69
70
71
72
73
74
75
76
E8155
r2763
r2:/74
T2330
T1169
11167
H2704
...
...
...
...
bush ...
...
...
Camplate ...
Camplate spindle
pin ...
lndex spring
Spring backing
...
Oil seal circlip ...
...
Cable grommet ...
KICKSTART CRANK COMPLETE
Kickstart fold ing pedal
Pedal
rubber
Cotter Pin
Cotter washer
T2706
Cotter nut
r4070
KICKSTART SPINDLE...
Needle roller
Return spring
Anchor pin
Kickstart stop
Circlip
Kickstart ratchet
E8005
T2687
r37 64
17657
T2658
r2681
12682
...
Pinion
Spring
E8172
E8072
Washer ...
E8737
Contact breaker cover
81
E7882
Gasket
8Z
E7354
83
E8'165
Screw (+ in. U.H.)
Serrated washer
84
E9433
E8010
87
88
89
90
r2641
r7647
1+66't2
1+6611
1+6610
91
E8169
92
93
1+6606
't+6614
...
Bu sh
r7684
T2683
...
Steel ball
r2704
r2705
77
78
79
80
85
86
...
Pivot bolt (1 in. U.H.)
S pring
Contact breaker cliP
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 (f in. U.H.)
cover screw (f, in. U.H.)
cover screw (2| in. U.H.)
Outer
Outer
Outer
Outer
Outer
Outer
19
continued
45
50
3
34
/
\
,.^-
D1.*
C&' R
101
d
&----.u 35
I
\
V
_es
(/AL_ss
/r\Hloo
tk 7s
a
19
w*,"
24
I
73
a7
64
63
P
59
62
Fig.
3.
I
W
ao{
6R
\\
v
K^,1
'1 .,n
27
\6
77
23
*
@_rn
'ls
30
g-sz
Ref,
No.
Port No.
DESCR/PIlON
QUANI/TT
94
95
El1061
r1026
96
97
98
99
100
E8162
E9526
14 6608
101
E8'132
102
104
'F99 1056
D995
E7788
105
99 0072
106
14-0208
107
E8163
'108
47
E8164
E8166
103
109
110
14
66',t0
14-6606
E47
lnner timin8 cover
Breather tube
1
1
Screwed plug
Screwed plug (socket head)
lnner cover screw (1 in. U.H.)
lnner cover screw (1+ in. U.H.)
lnner cover screw
v nng
(;
in. U.H.)
1
1
1
4
2
'l
Auto-advance un it (54416405)
Condenser
Contact breaker
Points (54419827) ...
Contact breaker bolt ...
Washer ...
Clam p
continueo
1
1
1
...
pillar bolt
1
1
1
7
Washer ...
2
Contact breaker lead sleeve ...
1
*Spring set only 99-1011 (54417992)
21
l
\ 18
Fis.4. CLUTCH AND
PRIMA,RY CHAINCASE
22
Ref.
No.
Port No.
DESCR/PIlON
QUANI/T}'
CLUTCH AND PRIMARY CHAINCASE
1
r2166
2
E8782
"O" ring...
3
4
E11058
E9800
Filler plug
5
s2002
6
E7856
7
14-6611
I
14-6610
9
s'1951
10
Screwed plug
1
Primary chaincase cover
17
D951
Chaincase dowel
Primary chain (70L)
13
E8'17 6
lgnition pointer ...
16
17
18
E8955
E8178
Gasket
E8177
Screw
r2v3
19
20
T2714
T2715
17716
21
T27',t9
22
23
T2720
24
25
26
27
s1943
r2721
T2727
r2723
r2724
r2725
(f
Clutch spider
Sprocket and housing
Rolle r
ln ner retaining plate
Drain screw
Outer retaining plate
Screw (.i+ in. U.H.)
Shock absorber rubber drive and rebound
Centre
DriYen plate
Spring
T395'1
cuP
r2748
SprinS nut
Pressure plate
F879
36
T2730
37
38
r2731
39
40
40
40
41
42
r2732
99-1006
s1894
s1895
s1896
E8072
14-0901
'l
z
1
1
1
1
4
Clutch hub
Clutch hub key ...
JI
35
5
1
in. U.H.)
r2726
r2727
T4019
T7729
4
lnspection cover ...
28
29
30
33
1
1
Cover screw (1f in. U.H.;
Cover screw (1j in. U.H.)
Cover screw (1{ in. U.H.)
Washer ...
E8175
E8010
14
1
I
Level plug
Chaincase gasl<et
11
J5
2
Driving plate
1
1
1
'l
25
1
1
1
4
I
1
5
4
4
4
4
1
Adjuster...
Locknut ...
1
,|
Retaining nut
Plain washer
Lockwasher
1
1
Stator (47205)
Generator stud rear (2-j| in.) ...
Generator srud front (zti in.)
Generator stud bottom (2{{ in.)
Washer
1
I
1l Keler
, II I also
1)
3
Nut
3
Page 13
---
45
./.-.--'
a
(,'
\
o
\,1
e
(Ot
-
-_-->
-/
@-34
33
\tfi-
@N
.4t,<"
'12
o*
a_.-un
6
BK<Ys-'.
Dz', \lri
9
8/
\Y
@
-P6*,
50
53
Fig.
s.
FRAME COMPLETE
74
JJ
Ref.
No.
Port No.
DESCRIPflON
QUANTITY
FRAME
..,
I
F11607
Frame complete
2
F8994
3
F8995
F8996
F8819
Swinging arm spindle ...
Spindle nur
Spindle washer ...
...
4
...
1
...
...
'l
1
,|
Engine shield
(l
6
14-0113
Bolt
7
B
E8134
F9084
Washer ...
"P" clip ...
9
F9023
Bolt
Nut
'l
in. U.H.)
({f
7
2
1
,|
in. U.H.)
10
w1691
1'l
Washer ...
1).
13
E8088
F9745
F5535
14
15
I
1
Engine steady stay
I
Bolt (l-i in. U.H.)
3
s25-2
Plain washer
3
E8194
F8988
F8984
Nyloc nut
18
s1934
Bottom bolt (7i in. U.H.)
'l
't9
E8084
Spacer
2
70
Eq't94
Nyloc nut
'l
21
E8'l 33
Nut
22
E8134
Shakeproof washer
2
2
23
F8985
Rear stud
24
F8986
F8987
Spring washer
2
Nur
2
99-0719
D980
Battery (54027029) type PUZ5A
Battery vent pipe
Battery carrier ...
...
Battery tray rubber
25
26
77
28
29
30
31
33
34
35
36
38
39
40
4'l
F8285
F9003
F9004
F9005
F9006
F9007
F9008
E8137
F9086
F9007
F9087
F9010
E8'194
F9090
3
Ball head cup
Front engine fixing bolt
2
(3fr in. U.H.)
(2fr in. O.A.)
1
1
Hool<
1
1
1
1
1
Battery strap
Bolt (11f in. U.H.)
Mounting rubber
Washer ...
'l
2
4
2
Nut
Bolt (3 in. U.H.) ...
2.
I
Mounting rubber
2
Spacer
I
Washer ...
3
42
43
F909'l
Nyloc nut
Tool tray c/w clips
Plug fcr tool tray
Bolt (.641 in. U.H.)
F9092
Spacer
44
F8071
45
46
F9060
Nut
Bolt ($ in. U.H.) ...
E8072
Washer ...
'l
47
48
49
50
E8071
Nut
1
F9094
Bracker ...
I
F9093
Rubber buffer
Silencer mounting bracket
1
Not illus. F9't57
F994s
1
1
1
1
1
1
I
1
25
n,'
1u ou
*5
.gi'
"ufu""
V'"n F"
\ \.'. l/ .1,
o6 QYq=<f$=<
\F e-..
\r'
42\Eil
9--- 43
.3\
'44
l\
(<t
"'t%
52
/\
50
53
Fig.
5.
FRAME COMPLETE
2e
Ref.
No.
Port No.
DESCR/PIlON
FRAME
5'l
52
14-0115
Bol!
w2320
53
14-0302
54
F9ZZ2
Sprint washer ...
,..
Nut
Tank anti roll rubber ...
55
E8189
Steady stay bracket
QUANTITY
continued
z
2
z
...
2
1
p.-
5@
4
,@
7
Fig.6. S\iVINGING ARM AND SUSPENSION UNITS
28
Ref.
No.
Port No.
DESCR/PIION'
QUANI/TT
swt NGING ARM AND SUSPENSION UNITS
Swinging arm
Silentbloc
1
F9z',t0
7
F8993
3
D7067
99-1057
99-0107
99-o',tzt
99-1058
susPENstoN uNtT (64054927)
F8997
F8998
Unit fixing bolt (1* in. U.H.) ...
Plain washer
'10
2
s1-52
11
14-0903
Nut
Nut
2
2
7
4
5
6
7
8
Spring (64543626) ...
..
Spring retainer (90541171\
Bonded bush-top (64533645)
Bonded bush-bottom (64533654)
12
F8933
13
F
14
F3097
Swivel pin
IJ
F3096
Lockwasher
't6
F26'10
S
17
F9950
F9060
'18
t1606
1
Dust cover
Propstand leg
z
2
2
2
z
2
7
I
1
1
pring
1
Chainguard
1
(1jf in. U.H.)
19
20
14-0113
Bolt
Nut
Bolt
21
s25-2
Plain washer
1
22
1+1902
Nut
1
E8071
(1jf
I
1
in. U.H.)
1
29
"oBE
38
*-
\lE
27
14
29
4
t
@)
3
%
6^{1e@
w@
I
Fig.7. OIL TANK,
PANELS AND EXHAUST SYSTEM
30
Ref
No.
Port No.
DESCR/PTION
QUANI/IY
OIL TANK, PANELS AND EXHAUST SYSTEM
'l
uffle r
E11181
E2271
M
2
3
1+0219
4
E37
Bolt ('lf in. U.H.)
" D " washers
68
Fixing clip
5
s26-3
Washer ...
6
s1908
7
F9019
F9020
F879
Nut
Bolt
8
$
in. U.H.)...
Spring washer
Nut
10
E',t1121
Heat shield
'11
Et't722
El1223
Support strip
12
13
14
't5
16
17
18
19
z0
1+2206
't+2205
s25-43
D2338
E11178
F8976
F8977
F8978
F11648
Distance piece ...
...
Heat shield screw-rear
Heat shield screw
Heat shield washer
Backing washer-front ...
Exhaust pipe
Finned collar
Screw (-ff in. U.H.)
F9067
F9068
Nut
Oil tanl< ...
Bolt (1i in. U.H.)
Nut
24
F6039
Rubber sleeve
25
Fl1651
FTLLER
26
27
28
79
F907 6
30
F9146
Rubber connection
31
F907 3
32
F9224
33
35
36
37
E5473
E8106
E8111
F9127
F8614
Clip
Rubber connection
Clip
Rocker oil. feed pipe
Clip
Ru bber sleeve
38
D1006
21
27
23
34
39
40
CAP C/W D|PSTICK AND WASHER
Washer
F8874
Banjo
F9070
Fibre washer
F9071
Filter
D983
41
D2380
D2380
47
s771
Panel D/S
Oddie stud
Stud rubber
Panel motif D/S ...
Panel motif T/S ...
...
Oil tanl< botrom fixing bolt
26
@
2a
&P
24
*
a--.\i "
I
b,oA
&f
21
F
0 a,
to
37
re *l--b
,6{f"
32Y
/,
35
G
5
/P
@
)
6nr'
,,
%
11
9-,o
Fig.8.
FOOTRESTS
AND BRAKE LINKAGE
% d6^.
Ref,
No.
Port No.
DESCRiPTiON
QUANTITY
FOOTRESTS AND BRAKE LIN KAGE
F9031
Rear brake pedal
1
w2326
Grease nipple
1
2
F9032
Fulcrum pin
1
3
F9033
Nut
1
4
F9034
Spring washer
5
E8193
Bolt
Spring washer
Plain washer
Rear brake rod ...
1
6
s26-t
7
F9035
8
F9036
wF32
(f
1
in. U.H.) ...
'l
1
1
1
10A
F8072
D2683
Pivor pin ...
Washer ...
Split pin ...
1',|
F9958
Brake pedal srop
1
12
Swivel pin
1
14
15
16
F9038
F9039
F9040
F9041
...
Shakeproof washer
F9042
Nur
't7
F9043
18
F11426
19
20
F11428
Folding footresr ...
Foocrest hanger D/S
Footresr hanger T/S
F9044
Anchor bolt
2
21
E8084
Plain washer
7
22
F9045
Bolt (2j-f in. U.H.)
'l
23
F9046
F8986
F8987
Plain washer
9
10
13
74
1
1
1
Adjuster nur
Pedal stop
Spring
1
bolc
washer ...
Nyloc nut
Nyloc nut
Foorrest rubber...
Bolt (1| in. U.H.)
2
2
2
2
...
1
1
1
...
1
25
26
27
28
29
30
F9053
31
F9054
32
32
F9044
33
F9085
34
F9057
E8137
Boh (1| in. U.H.)
Nut
2
7
F9133
Pillion footrest support bracket T/S ..,
1
14-0116
14-0707
Bo
36
37
38
F9085
F9051
F9057
F8137
F9055
'l
2
2
...
2
7
7
Nut
Pillion footrest ...
Footrest rubber...
Anchor bolt T7S ...
...
...
z
...
1
Anchor bolt D/S
Nut
1
2.
lt
3
Nuc
3
33
43
24
-d\\
*-'-A)
42-'e
€
r;)
sa
60
ll-
g
41
s2{-)
sa
( <---.)
]H,
!,:33S
22,
d)-.-53
fa:A
gis__/$,,
36
10
35
34
L
11
dP
(o)
26
15
16
17
1a
t,@L
w
€--
6
Fis.
9.
TELESCoPIC FRONT FORK
&-,u
s
n2s
n
.l lE
30
l)(J.---:rz
sr
B
Ref.
No.
DESCR'PIiON
Port No.
QUANTITY
TELESCOPIC FRONT FORK
H3895
3
H2294
H2295
H1844
4
1+02'.t8
5
s26-3
6
H5t9
'l
7
7
8
9
10
1'l
H430
H3694
H3693
H
3638
FORK ASSEMBLY
D.S. BOTTOM MEMBER
T.S. BOTTOM
M EI4
BER
1
c/w
cAP
1
C1W:AP
1
z
Spindle cap
Cap bolt
Spring washer ...
4
4
2
...
Drain plug ...
Drain plug washer ...
Top cover T/S
Top cover D/S
Spring support
2
1
1
2
4
7
2
2
Sealing washer
Sealing washer
13
14
15
HZ63Z
H2633
H2513
H3678
H1656
't6
H'1500
17
H3639
Reference only
Oil seal
LOWER COVER TU BE eiseMgiv
Sleeve..,
17
18
Gaiter
...
Main spring ...
Spring support washer
2-
7
2
Not supplied
separately
z
lJ flng
19
20
H7119
H431
Outer washer
7
21
H441
Upper bearing
lnner sleeve
Top nut
Washer
2.
H3677
H2745
24
H2653
H3906
2,
2
2
Stanchion
2
2
H7',154
Lower bearing
Shuttle valve
H2091
Nut...
7
Circlip
2
Restrictor,...
7
31
H7127
H2090
H1062
Sealing washer
2-
37
H2126
Flanged bolt
Spacer
7
25
76
77
28
29
30
H443
H763'.|
34
36
38
39
40
41
42
43
z
2
7
H2630
s785
Washer
s25-2
Washer
2
1+0303
Nut
...
Middle lug and stem
Bottom cone
z
Top lug
1
Cable gulde bracket
7
H7526
H2648
H2525
H2658
H7659
H2645
H2646
Pinch bolt ...
z
...
1
I
.,.
Grommet ...
Bolt (1+ in. U.H.)
z
Nut
7
4
1
45
46
H2656
F8981
...
Bolt ...
Was he r
47
H265s
Handlebar clip
7
48
H2651
1
49
H2654
H2704
...
...
Steering head ball ...
44
50
4
nut ...
Cable guide ...
Sleeve
1
40
35
4E
x-_
46- u^ \
43fu
47
42.€
-.:'G)
a-a
41
6A
It-
58g
s4
d 17:-51
#B"
,/;
5' d4- 56
59
35
Jf
34
@
^fi-o'
@'"
s.
il^
-29
J L-"o
Er'
i9'--
ar
S=- ",
F.
ry
6
Fig.
9.
TELESCOPIC FRONT FORK
Ref, No.
Pdrt No-
DESCR/PrloN
TELESCOPIC
FRONT FORK
QUANI/IT
continued
52
H2647
H2650
53
H3746
54
55
56
14-0218
Top cone
Dust cap
Mounting bracker
Bolt
14-0707
Nut
'l
't4-6102
Bolt
1
s26-2
Spring washer
7
E8088
Spacer
H2237
Heat sink
H2775
H3926
Zener Diode sealing plug
1
Square nut
2
JI
57
58
59
60
61
1
1
1
1
1
...
I
...
37
Fig.
10. FRONTWHEEL
38
Ref.
No.
Port No.
DESCR/PTiON
QUANTITY
FRONT WHEEL
w3465
1
w7137
w1230
FRONT WHEEL COMPLETE
RII4, SPOKES AND HUB ASSEMBLY
Rim...
'l
1
1
3
w3325
w2137
3
w21 38
3
5
w2139
w2136
w653
Bearing
7
6
w1237
Dust cover
1
7
T280
Circlip
8
Wheel
11
w3582
w1481
w3443
w3337
17
w582
Bearingretainer...
13
w3429
Anchor plate
14
w3444
15
s1998
F235'l
Gauze
Screw
2
9
l0
16
17
w2026
w2001
't9
w3453
20
w3454
w7027
21
Hub
Spoke D/S 8 SWG x 6 in. straight
Spoke T/S 8 SWG x 51f in.76' ...
Spoke T/S 8 SWG x 5$ in. 100"
Spoke n ipple
spindle ...
G rease cap D/S ...
20
10
10
40
1
...
1
1
Cover plare
Bearing supporr ring
Washer
1
1
1
...
1
1
'l
3
..
3
.
Brake abutment pad
Brake cam
2
z
lever-front
Brake lever-rear
Washer ...
Bral<e
1
1
22
23
14-0403
Nut
2
2
w3522
Return spring
1
24
w3450
w200s
Brake rod
1
D2683
Fork end-threaded
Locknut ...
...
Pivot pin ...
Split pin ...
s1995
Nut
BRAKE SHOE C/W LINING...
3l
w3446
Rel on ly
37
Ref. on ly
33
w1
Rivet
Spring
34
34
w1't97
25
26
27
28
29
30
14-040'l
WF32
35
w1198
1
1
2
z
1
Lin ing
7
z
16
7
A.R.
A.R.
Balance weight + oz.
Balance weight 1 oz.
39
12
.14
Ag@,)
W
21
^v'^
^
(w*
\ :--\
a-(J
Fig.
tl.
REAR \^,HEEL
Ref. No.
Pdrt No-
DESCR/PIlON
QUANTITY
REAR WHEEL
w3581
w3452
,|
2
4
w2290
w2297
w2792
w2293
w2794
REAR WHEEL COMPLETE (LESS BRAKE AND TYRE)
REAR WHEEL COMPLETE (LESS BRAKE AND TYRE)
RII'4, HUB AND SPOKES ASSEMBLY
Hub com plete
Spoke D/S
Spoke T/S
Nrpple...
1
'l
1
20
70
40
w2291
w2309
w2339
w1015
Fixed spindle nut ...
Chain adjusrer
Chain adjuster end cap
7
7
E8137
E8088
Adjuster nu[
Adluster washer
2
2
11
w2335
Brake anchor strap
1
12
Bolt
1
13
w2336
w2337
Washer
1
14
F9085
Nut
1
15
w2325
16
w2324
17
18
19
20
w2323
Fulcrum pin nut
Fulcrum pin washer
Fulcrum pin
Brake anchor plate
BRAKE SHOE COMPLETE WITH LINING
5
6
7
8
9
10
w2372
w2327
Rim
(1{
'l
1
in. U.H.) ...
w2331
Brake lining ...
...
Bral(e rivet
Brake shoe spring ...
Brake cam lever
BRAKE CAM
Grease n ipple
Brake lever retu rn sprint
Plain washer
Shakeproof washer
w2332
Nut
30
w2317
31
31
D1028
D't023
Locking ring
Rear chain (t x
Rear chain (! x
32
w2314
33
w2312
34
w2311
35
w2315
w2316
w2308
w2305
71
22
23
24
25
26
27
28
29
36
37
38
39
40
41
42
43
44
45
46
46
47
Reference on ly
Reference only
w2328
w2329
w2226
w2326
w2334
w2330
w7798
w2299
..
1
1
1
1
2
2
'14
/
Nor serviced
\separately
7
1
'l
1
1
1
1
I
.
3
I
{
x 1011)
x 991)
...
...
...
...
Driving flanSe
Bearint sprint ring...
1
1
East coast
West coast
1
1
Bearing shim
Bolt ...
Nut ...
Fixed spind le
1
6
6
'l
Bearint retaining ring
1
Bear ing
z
Thrust washer
1
w2313
w2363
w2300
Washe r
1
w3468
w2318
w2354
Securrty bolt WM3 ..
Brake drum... ...
w2321
w2319
with 49 T sprocket
with 52 T sprocket
'1
Bearing
1
Sp.nd le sleeve
1
2
I
1
1
Chainwheel (52T) ...
Chainwheel (49T) ...
Chainwheel bolc
10
41
East coast
West coast
12
M
,14
W
^i.n
(w"
\
o-€
Fig.
tt.
REAR wHEEL
Ref No.
DESCRIPTION
Port No.
REAR WHEEL
QUANTiIY
continued
48
49
w2320
w2302
Sprint washer
lnner retainer
50
w2301
Felc washer
1
51
w2303
Outer retainer
1
52
53
w2304
1
54
55
56
w2306
w2307
w2333
Hub end cover
Speedometer gearbox (BG5330/31) 2 : 1
Disrance collar inner O/S... ...
Distance collar outer O/S
Hub spindle
D1026
10
I
1
1
1
'l
%^*-.,o
1s
ffwt" 'eb
)iu
6)
p
),)
tle)
'oKT-----,,-
(y ,d'"
/(r, /
24
d
6
wqq"
Fig.
12.
',
.
I \}/
'-"n4
*0
o,,
FENDERS
44
I
Ref.
No.
Pcrt No.
DESCR/PTlON
FENDERS
1
H1674
2
H1681
3
H1683
H3683
4
F9019
6
8
F9068
F9079
E8088
9
w1691
7
10
F9017
11
w1591
14-0114
s25-3
12
13
14
15
16
17
18
19
Front fender
Front stay
Bridge stay
Bottom stay
Bolt (+ in. U.H.) ...
Nyloc nut
Bo
lt
Washer
...
Nut
Bolt ({ in. U.H.) ...
Nut
Bo
lt
GS299
Plain washer
Washer ...
1+0702
Nut
Rear fender
20
F9506
F9019
F9027
F9020
F879
21
F9023
22
E8088
E8137
F9028
F11 335
Washer ...
F8'139
Tail lam p support
Stud (lf ln. o.A.)
Support plate
Washer ...
23
24
25
26
27
28
29
30
31
E2980
F9132
s25-1
F9030
T3638
Bolt
(] in. U.H.) ...
Special
Spring
Nur
Bolt
washer ...
washer ...
(j{
...
...
in. U.H.)
Nut
Wiring grommet
Rear fender support rail
Spacer
Spacer
F9068
Nut
Rear number plate bracket
34
F11529
F9019
35
s25-'l
Washer ...
33
Bolt
(j
in. U.H.)...
36
E8071
Nut
37
38
H1685
s1822
Bracket ...
10
F4299
F4715
s5161
Washer ...
40
41
Bo
lt
Screw
Nut
QUANTITY
7
21
G,
-4
22
2oA-€)
(g)
20
18
/\\
wr
\t/'
ll
,<'%.'"
(6&/
ll .,'
3
24
-25
23
-"
16
T
't9
17
$
m-F
2A
Fis. 13. cAS TANK AND
T\r/IN
SEAT
Ref
No.
Port No.
DE5CR/PIlON
QUANI/IY
GAS TANK AND TWIN SEAT
tank ...
Mounting rubber-rear
1
F9479
Gas
2
3
t9690
t9't34
l'4ounting
4
F10759
Bolt (1* in. U.H.)
5
F9063
6
Fl0250
Distance tube
Distance tube
7
F10260
Mounting rubber
1
8
F9065
Plain washer
2
9
10
E8196
F9480
Nut
Trim strip
1
1'l
t4715
Screw
17
H430
H430
(-jf in. U.H.)
Washer ...
Washer ...
F9700
F970'l
Styling unit T/S ...
Styling unit D/S
F8192
F8193
Knee grip D/S ...
Knee grip T/S
F8946
Styling
F7888
F9769
F4971
Gas
124
't3
13
14
15
16
17
't8
19
19
20
20A
21
27
F4972
E735',1
F10002
F3220
1
1
rubber-front
1
1
z
1
1
2
2
7
1
1
1
1
it screw-front
StylinS unit screw-rear
Gas
Gas
7
7
un
line
tap
...
...
1
1
tap-with
reserve ...
Gas tap washer (Stat-o-seal)
1
Steel washer
),
Filler cap
Tie bar
Bolt (; in. U.H.)...
1
2
23
F9744
s5662
24
E8088
Spacer
75
26
77
28
w2320
F9472
Spring washe_r
Twin seat (cover F9504)
F11527
Trim strip
1
Sprags
As
29
D697
F9476
Rear fixing bracket
I
30
F9020
Spring washer
7
31
E8101
Nut
2
32
s602
Plain washer
7
33
Ft't304
34
F9023
Handrail ...
Bolt (+* in. U.H.)
35
E8088
Washer
36
w1691
Nut
1
7
4
2
1
1
2
2
2
...
47
req
uired
\N-tf
g
E'
Ntav
P
G)\
33
w
.17
ffi-'1a
@
Fig.
14. HANDLEBARS, CONTROL
LEVERS
's
\.
AND CABLES
Ref, No.
Port No.
DESCR/PIlON
QUANTITY
HANDLEBARS, CONTROL LEVE RS AND CABLES
1
H7628
99-0248
7
D958
3
99-0245
99-0246
99-0744
99-0238
99-0239
99-0240
99-0726
4
5
6
7
I
9
10
11
1Z
't3
14
15
16
'17
18
't9
20
21
22
23
24
25
26
27
28
29
99-0241
D959
D2243
99-0767
99-0262
99-0252
99-0250
99-0226
99-0230
99-1031
99-1059
D2742
99-1176
99-0261
99-0230
99-0252
99-0276
99-0250
99-1031
99-1059
D962
37
D2034
D2085
D2086
D963
33
D964
34
D965
D2083
30
31
35
Handlebar-Western type
'l
TWTSTGRTP (161364) ...
Handlebar gr ip
Body top half (16/328)
Body bottom half (161329)
Rotor
...
'l
1
1
(16/09'1)
1
Friction sprint (6/008) ...
Friction spring screw (16/009)
I
...
...
Nut (16l010)
1
'l
Screw (1 I /014)
Cable stop (16/011)
Dummy grip
FRONT BRAKE LEVER (ball end) (19/1098)
Lever bracket (19/003)
Lever (12l754)
Fulcrum prn (181087)
Fulcrum pin nut (18/053)
Clamp bolt (11/014)
2
'l
1
1
'l
1
1
...
...
Control clip (12/595)
1
2
1
Cable ad1uster (18/1708) ...
Cable adjuster locknut (18/1709)
cLUTCH LEVER (ball end) (18/9s2)
Bracket (19/002) ...
...
Lever (18/752)
'l
1
1
1
1
Control clip ('12/595)
Fulcrum pin (18/087)
Clamp bolt
'l
1
1
(11
/014)
Fulcrum pin nut (18/053)
Cable adjuster (18/1708) ...
Cable adjuster locknut (18/1709)
IHROTTLE CABLE
FRONT BRAKE CABLE
2
1
1
1
'l
'l
Front srop switch .,.
Rubber cover
Cable toggle end ...
Toggle end screw ...
Toggle end nut
CLUTCH CABLE
I
1
1
'l
1
1
49
.lL
,u.-€
26
@\
I\
V
ll
tl
u
@_r"
@-""
u--@
,-@
tg
\.
'o '--eb
--=;>>'-
6tt\_
,12
Fis. 15. SPEEDOMETER AND TACHOMETER
Reji
No.
Port No.
DESCRIPIION
QUANTITY
SPEEDOMETER AND TACHOMETER
Tachometer (R.S.M. 3003/01)
3
D1949
D2173
H3689
4
F10281
Mounting plate ...
Mounting rubber
5
F9't71
Screw
6
t9177
Washer
7
F9173
1
2
Ca
...
...
1
ble
1
'l
1
Nut
4
4
4
F9174
Bush
4
TACHOMETER GEARBOX COMPLETE
9
E9428
E9517
10
E9381
11
E9382
E9429
I
..
.
Drive body
Drive shafr
Drive gear
...
...
...
1
...
...
...
1
1
1
Retaining pin-drive gear
I
E9383
Thrust washer
1
14
E9430
'15
E943',1
16
17
18
E9432
ring
Locating pin
Joint washer
12
13
D2296
"O"
1
1
1
SPEEDOMETER 12s r.4PH (SSM s00/03)
1
...
'19
F10281
Speedometer mounting plare assembly
Speedometer mou nting cup
20
F917'l
Screw
4
21
F9174
F9172
Bush...
Sprint washer
4
Nut
4
22
23
24
F8283
F9173
D692
...
...
1
1
643
Cable
Bulb
7
99-0695
Bulb holder (554710)
1
'l
51
Optional
100
12
li
/'R / \'1,
t/\\ I
\ uuR
t)F
\\)t\
\Y4 \'/
c?
,l+r
_
.=-J
5
dF,,
25
Eow
ffi
162*
.6
9..-""
43
*"b
"i-- d ----,afF" ))2
m) (
41
s6
(
m*
\--=-z
\({
)5
^l:i.(.)
w,"
4 5
\+u
Fig.
t6.
ELECTRICAL EOUIPMENT
17
&
Ref
No.
Part No.
DESCRIPT'ON
QUANTITY
ELECTRICAL EAUIPMENT
D2261
HEADLAMP ASSEMBLY (s4052910)
Rim (534343)
I
99-0691
2
Light unit (54524526\
3
99-'t041
99-0683
4
99-1047
5
99-1003
Bulb (40/27W pre-focus)
Adaptor c/w leads (54520540)
6
99-1004
Bolt
7
H't932
8
144921
55408
Spacer
Screw
9
Fixing wire
(504665)
...
(464) .
I
...
6
1
1
Ref. only
Ref. on ly
Plate ...
12
13
99-0568
99-0537
Warning light (Red)
14
99-0803
15
16
17
18
19
20
99-0548
21
1
2
Lighting switch (35710) ...
Dip switch (31620)
1
1
1
lb (2w BAT5) (281)
Warning bulbholder (54945043)
Pilot bu lb (989)
Pilot bulbholder (554710)
z
Bu
99-0695
54190108
Double Lucar blade
99-1053
Reference only
Harness
99-0597
99-0781
1
2.
99-0563
99-0556
99-0589
...
(112201)
't'l
10
...
Rel only
1
1
Ref. only
(54955718) ...
1
Stop-tail lead
Rectifier c/w securing nut
sToP AND TArL LAMP ASSETT4BLY (53973)
1
1
1
Lens (54572932)
1
Screw (572289)
2
73
99-0698
99-0542
24
54574348
Bulb (5/2lW offset pin) (380)
Bulbholder with refl ector
75
76
54578213
Bracker
573828
Contact assembly
77
99-0780
Gasket (54571677)
1
28
19
F4715
Screw
2
Washer
2
22
...
1
Ref. on ly
Ref. on ly
Ref. on ly
...
30
GS299
F8307
31
F8972
32
F8318
Stop and tail lamp lead tube ...
Front reflector c/w bracker
Ducon horn push (WIPAC '16714)
1
2
2
t8273
Rear reflector
2
34
35
F8140
F8195
Rubber washer
2
4
36
37
38
39
D992
E8084
Spring washer
1
40
E8194
Nut
1
41
D7240
coil
42
F11603
43
1+0204
Coil support clip
Bolt ('1t in. U.H.)
44
s602
45
F
F5535
Push-Fix ...
I
Horn
Bolt
1
I
E8'191
t1578
(4s221)
Washer ...
Distance piece
1
..,
1
1
...
...
53
1
1
-//
t-/
@
,ll|',\y
&,,
te\
'//
M:,^
t/
^20
-J/ftl
"==:r/
CD
2l
X5:*=
2(
a:={
-
2a
'""$wcl(
AP'n A
nM
\-P \J'tr- "-<v-
T\9:
25
oo
"Lr-+ 33
"9
34
'V-/ft
\-,/
""ffi*'
\,/
43
42
.ob
\eS
m)
\e)
4l
(^---\Sa")P
\,---=--
(s
r^ ,/
r\
,x),#^
frd\
(i).J
ral":A45
52
\ls
-,P"e
s4 53
I
Fit 16,
ELECTRICAL EOUIPMENT
54
An
l-Ref.
No.
Port No.
DESCR/PTiON
ELECTRICAL
Nut
H.T.
47
48
49
50
14-0801
Reference on ly
99-0590
D1000
99-0558
51
99-1000
52
D990
Rear stop swicch (34815)
53
F9191
Bo
54
F8979
56
E9122
D999
Spring washer
Cable slip (stop switch)
H.T. lead grom met
46
E
QU lP MENT
QUANI/IY
continued
1
lead
1
Zener diode (49345)
lgnition lock C/W keys
lgn ition switch (3'1899)
1
I
1
rGNrTroN swrTcH NUT (54130041)...
1
1
lt
7
2
1
I
55
f.
F
10
H
Fig. 17.
TOoL KIT
Ref.
No.
Port No.
DESCR/PflON
TOOL
2
D2113
D291
D968
3
D801
4
6
D87
D767
D2084
7
D97',|
1
5
I
1
1
1
Plug span ner
'l
Screwdriver set
1
Span
ner
1
D972
NA144
Tyre lever
Tyre valve key
11
D974
D978
12
X469
13
D1079
14
H2654
10
KIT
TOOLROLL COMPLETE WITH TOOLS
Toolroll
Suspension unit spanner ...
...
Combined tyre lever and tommy bar
Box spanner
Ring spanner
I
QUANIIIY
...
1
1
...
1
'l
Cable clip-rubber
Cable clip
Cable clip
Cable clip-wire
3
5
I
57
.-
K
{9
\l-,
6,--g,
o
Ft--M
1a
\
ruT
@r.'---'-l
v
Fig.'18. CARBURETOR
58
T
I
I
Ref. No.
DESCR/PIlON
Pdrt No.
QUANIIIY
CARBURETOR
D70ZZ
CARBURETOR COMPLETE (R928/4)
1
Screw and washer (622/086)
4
7
99-0521
99,0221
Plug screw (41137A)
1
3
99-0531
Top cap (928/097)
1
4
99-0507
99-0510
99-0529
99-0527
Reference only
99-0444
99-0516
99-0515
99-0520
...
Th rorrle sprint $271061) ...
...
Circlip (6221067) ...
...
Need le (928/063) ...
Throule valve (3) (928/060)
Body ...
1
5
6
7
I
9
10
11
12
13
14
15
16
17
18
99-0522
'19
23
99-0511
99-0506
99-0438
99-0517
D1053
24
F9194
20
21
27
99-0514
99-0518
99-0519
99-0517
99-0513
...
I
1
1
1
1
jet (160 c.c.) (376/100)
Throttle stop screw (6771077) ...
lYain
Pilot air screw (6221076) ...
''O"
''O"
1
1
z
ring (6221082)
ring (622110'l)
1
Gasket (6221073) ...
Need le jet (6221079)
...
1
1
holder
(6221080)
Float (6221069)
Jec
1
1
1
Floar spindle (6221071 )
Floar needle (6221068)
Float chamber (622/050) ...
1
1
1
Filcer (376/093)
I
Banjo bok (6221078)
1
AIR CLEANER COI'4PLETE
Air cleaner element
...
...
59
1
1

1970 triumph tr25w 250cc

Transcription

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