T120 TR6 1968 - JRC Engineering, Inc.

1968
REPLACEMENT
PARTS
CATALOGUE No. 6
UNIT CONSTRUCTION 40 cu. ins. TWINS
TR6!1. TROPHY SPECIAL
TR6C TROPHY SPORTS
T120R BONNEVILLE 120
From engine No. DU 66246
TRIUMPH ENGINEERING COMPANY LIMITED
MERIDEN WORKS • ALLESLEY
TELEPHONE M!R!DEN JJI
·
COVENTRY
•
ENGLAND
TELEGRAMS "TRUSTY COVENTRY"
ILLUSTRATION INDEX
Page No.
Description
Fig. No.
CRANKSHAFT AND CONNECTING RODS
12
2
CRANKCASE
14
3
OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS
16
4
5
6
CYLINDER BLOCK AND HEAD, TR6C, TR6R
18
CYLINDER BLOCK AND HEAD, T120R
...
20
TIMING COVER AND CONTACT BREAKER
22
7
GEARBOX INNER COVER AND SELECTORS
24
8
GEARBOX SHAFTS AND GEARS
26
9
GEARBOX OUTER COVER
28
10
CLUTCH ...
30
11
CHAINCASE AND CHAINS
32
12
FRAME
34
13
SWINGING FORK AND SUSPENSION UNITS
36
14
ENGINE UNIT FITTINGS AND FOOTRESTS
38
15
EXHAUST PIPES AND MUFFLERS TR6R, T120R ...
16
EXHAUST PIPES AND MUFFLERS TR6C
17
TELESCOPIC FRONT FORK
18
19
TELESCOPIC FRONT FORK AND STEERING DAMPER TR6C
20
REAR WHEEL
21
GAS TANKS
40
42
44
46
48
50
52
22
OIL TANK
54
23
BATTERY CARRIER AND AIR FILTERS
56
24
25
PANEL AND TWINSEAT
58
FENDERS ...
60
26
HANDLEBARS AND CONTROL LEVERS
62
27
28
CONTROL CABLES
TOOLKIT, FRAME LOCK, PILLION FOOTRESTS AND LICENCE HOLDER
39
AMAL CARBURETTER TR6R, TR6C ...
64
66
68
30
AMAL CARBURETTER, T120R ...
70
31
SPEEDOMETER AND TACHOMETER
...
...
FRONT WHEEL ...
32
IGNITION CAPACITOR AND HEADLAMP, TR6C
72
74
33
IGNITION COILS, HORN, RECTIFIER AND ZENER DIODE
76
34
HEADLAMP, WIRING HARNESS, SWITCHES AND TAIL LAMP
78
3
INDEX
Page
Page
57
AIR FILTER
ALTERN A TOR ...
BATTERY CARRIER
... 13, 32
MUFFLERS
... 41,43
OIL PUMP
17
OIL TANK
55
PILLION FOOTRESTS
67
PISTONS
13
PROP STAND
35
57
... 69, 71
CARBURETTER
17
MANIFOLD
CARTON PACKS
8
CENTRE STAND
35
CHAINCASE
35
CHAINS
35
CLUTCH
31
COIL
77
CONTACT BREAKER
23
REAR PANEL
...
59
CONTROL CABLES
65
REAR WHEEL ...
51
CONTROL LEVERS
63
RECTIFIER
77
SPARK PLUGS
77
SPEEDOMETER
73
STEERING RACES
35
SUSPENSION UNITS ...
36
...
15
CRANKSHAFT ...
13
CYLINDER HEAD
... 19, 21
CRANKCASE
ENGINE PLATES
39
EXHAUST PIPES
... 41, 43
... 75, 79
SWITCHES
FENDERS
61
FOOTRESTS
39
FRONT FORKS
... 45, 47
FRONT WHEEL
48
GAS TANKS
52
GASKET SETS
GEARBOX
TIMING GEARS
13
TOOLKIT
67
TWINSEAT
59
VALVES ...
... 19, 21
8
25,27,29
WIRING HARNESS
HANDLEBARS ...
HORN
...
...
... 75, 79
63
77
ZENER DIODE
77
U. S. A. T R 0 P H Y (T R 6 R) T E C H N I C A L D AT A
Bore and stroke ...
71 x 82 mm.
2·79 x 3·23 ins.
649 c.c. (40 cu. ins.)
Capacity ...
Compression ratio
9 :1
Champion N3
Spark plugs
Carburetter
Amal Concentric 930
230
·107
No.4
25
Main jet
Needle jet
Throttle valve
Pilot jet ...
Gearbox sprocket
Chains
19 teeth
~"Duplex
Front
Rear
-r x
Capacities
Gas Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Brakes
Front, diameter ...
Rear, diameter
Tire size ...
Front
Rear
~"
x 84 links
x 104 links
3i U.S. galls. (16 litres)
6 U.S. pints (2·8 litres)
i pint (500 c.c.)
i pint (350 c.c.)
t pint (200 c.c.)
8" (20·32 em.)
7" (17·78 em.)
3·25 X 19
4·00x18
5
TROPHY
(TR6C) TECHNICAL
Bore and stroke ...
DATA
71 x 82 mm.
2·79 x 3·23 ins.
Capacity ...
649 c.c. (40 cu. ins.)
Compression ratio
9 :1
Spark plugs
Champion N3
Carburetter
Amal Concentric 930
230
Main jet
Needle jet
Throttle valve
Pilot jet ...
·107
No.4
25
Gearbox sprocket
18 teeth
i" Duplex x 84 links
i" X in X 104 links
Chains
Front
Rear
Capacities
Gas Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Brakes
Front, diameter ...
Rear, diameter
Tire size ...
Front
Rear
2! U.S. galls. (11 Htres)
6 U.S. pints (1·8 litres)
i pint (500 c.c.)
i pint (350 c.c.)
t pint (200 c.c.)
8" (20·32 em.)
7" (17·78 em.)
3·50 X 19
4·00 X 18
6
B 0 N N E V I L L E 11 0 (T 1 l 0 R)
T E C H N I C A L D AT A
71 x 82 mm.
2·79 x 3·23 ins.
Bore and stroke ...
649 c.c. (40 cu. ins.)
Capacity ...
9 :1
Compression ratio
Champion N3
Spark plugs
2 Amal Concentric 930
220
·107
No.3
20
Carburetters
Main jet
Needle jet
Throttle valve
Pilot jet ...
Gearbox sprocket
19 teeth
i" Duplex x 84 links
·r x f" x 104 links
Chains
Front
Rear
Capacities
Gas Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Brakes
Front, diameter...
Rear, diameter
Tire Size ...
Front
Rear
2! U.S. galls. (11 litres)
5 U.S. pints (2·8 litres)
i pint (500 c.c.)
i pint (350 c.c.)
-! pint (200 c.c.)
8" (20·32 em.)
r (17·78 em.)
3·25 X 19
4·00 X 18
7
17
16
)7
~ ~~------------14
~--------14
D-----------15
--------------13
+-----------8
10----1
31 31
II
-----13
S
39 38 ...
35
~~ \\11\1
-b~
3l
~37
32~'S
7
29-------:=/
28 ----\"W~;
26 _ _ _ _ ____.
'----5
41
19
20
21
22
23
24
25
Fig. 1. CRANKSHAFT AND CONNECTING RODS
12
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
CRANKSHAFT AND CONNECTING RODS
1
2
3
4
5
6
7
8
9
10
11
12
13
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
E7331
E4643
E3903
E3905
E7332
*E6328
E3114
E3606T
E1511
E2490A
E2922
E3586
E6868
CRANKSHAFT AND FLYWHEEL ASSEMBLY
CRANKSHAFT CfW. OIL TUBE
Oil tube
Screwed plug
Flywheel ...
Flywheel bolt
Crankshaft stud (1i" O.A.)
CONNECTING ROD
Small end bush
Connecting rod bolt
Self locking nut ...
Big end bearing
PISTON COMPLETE 9 : 1 C.R.
E6867
E6864
E6865
E6863
E6869
E1591
E3876
E5446
E4573
E3974
54213901
E3975
E3977
E1580
E4564
E4565
E6159
E400
E4562
E1558
E1463
E4563
E4819
E5047
tE4700
E5316
E22S6
E3300
E2879
E4849
PISTON COMPLETE 11 :1 C.R.
Taper compression ring ...
Oil control ring ...
Gudgeon pin (long)
Circlip
Main bearing, right
Oil seal ...
Engine sprocket, 29 teeth Duplex
Distance piece ...
Rotor key
Rotor, type RM19
Tab washer
Nut
Key
Timing pinion
Nut
INTERMEDIATE WHEEL
Intermediate wheel bush ...
Camshaft wheel...
Camshaft key ...
Inlet camshaft nut
Exhaust camshaft nut
Inlet camshaft ...
EXHAUST CAMSHAFT
Tachometer drive thimble
Rotary breather valve .. .
Breather valve spring .. .
Clamping washer
Main bearing, left
Dowel pin for exhaust camshaft
* Use D524 Loctite Sealant
t Use E7050 to replace without dismantling motor
13
1
1
1
1
3
1
2
2
4
4
4
2
2
4
2
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1 (Not illustrated)
w
Ill
Ill:
u
="
z
~
u
«-4
.~
II.
o-
N\
.,.,
N
14
Ref. No.
DESCRIPTION
Port No.
QUANTITY
REMARKS
CRANKCASE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
E5871f7330
E3716
E5232
E4542
S25-2
P0172A
GS87
E2724
E2260
E1516
E1479
E1532
E6386
E4539
F1880
E4706
E8896
E5976
E375
E3717
E672
E3523
E1534A
E4541
E4540
E4098
E4856
E2888
$25-3
S1-51
E5312
E5315
E5375
T1112
T1257
T361
E2441
E6347
T1738
T1920
E732
NE507
E6929
E5963
E8892
CRANKCASE ...
Hollow Dowel
Screw
in. U.H.)
Stud (-ij- in. O.A.)
Plain washer
Nut
Breather disc
Breather pipe
Inlet camshaft bush
Exhaust camshaft bush
Camshaft bush
Hollow dowel, tappet oil feed
Locating peg
Oilway plug
.
Copper washer
Tachometer drive plug
Fibre washer
Chain tensioner abutment
Intermediate wheel spindle
Oil pipe stud (1t ln. O.A.)
Cylinder stud (1i in. O.A.)
Cylinder stud (1i ln. O.A.)
Hollow dowel
Bolt (2t in. U.H.)
Bolt (1! in. U.H.)
Bolt (1t in. U.H.)
Stud (5-fr in. O.A.)
Stud (3t in. O.A.)
Plain washer
Nut
Crankcase filter ...
Copper washer
Breather extension pipe
Drain plug (with level tube) ...
Fibre washer
Level plug
Copper washer
Drain and adjuster plug
Fibre washer
Blanking plug ...
Filler plug
Fibre washer ...
Bolt (4 in. U.H.)
Stud (4! in. O.A.)
Protection blade
Self lock nut
(it
15
1
1
2
1
2
2
1
1
1
1
2
1
1
1
1
3
3
1
1
1
6
2
2
1
1
1
1
2
11
8
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
Not serviced
(TR6C 3 off)
(except TR6C)
#P
~
$-
#
I0 t
5
4
:::::::,
~
::::::::
ASSY 1
3
~
:::::::,
§:
2
12
-
-
11
10
6
9
7
8
ASSY13
~
19
16
14
20
26
\
'1
.I
21
,j
22
Fig. J.
OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS
16
..
Ref. No.
DESCRIPTION
Part No.
OIL PUMP,
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
E6928
E6680
GS153
E6681 ·
E495
570-7
E403
E2360
E3730
E3718
E3887
E3732
E5896
E2794
GS251
E2304
GS254
E6062
E1670
E2973
E5660
E5512
S25-13
W103
E2962
NA43A
E4918
S25-3
E1310
E4676
E5861
E1612
H200
E3059R
E8801
E7563
RELEASE VALVE,
QUANTITY
REMARKS
MANIFOLD AND TAPPETS
1
1
1
1
1
2
2
OIL PUMP
Pump body ...
Feed plunger
Scavenge plunger ...
Drive block
Valve ball (if in. dia.)
Valve spring
Screwed plug
Joint washer
Oil pump stud (1-h in. U.H.)
Serrated washer
Nut
2
2
OIL RELEASE VALVE
1
Valve body
Piston
Cap ...
Fibre washer
Main spring
Fibre washer ...
Stud (1ft in. O.A.)
Joint washer
Inlet manifold
Plain washer
Nut
Stud (1 i2 in. O.A.)
Joint washer
Insulating block
Plain washer
Nut
Inlet tappet guide
Exhaust tappet guide
Serrated washer
Set bolt ...
Inlet tappet
Exhaust tappet ...
"0" ring
1
1
1
1
2
1
2
1
1
4
2
1
4
4
2
1
1
2
2
1
1
2
2
2
2
2
17
TR6R & TR6C
38---g
25
26 37-----st/il;l
~
36 ~~
...--.---
35
34
~ ~Q-48
•
~47
"
4446
28
®----
40
8-..
30
-----29
12
~a,
.\
\
i
I
I
11
16
15
14
l
!i
(f
4
3
--~..;:;.~~c
Fig.4. CY LINDER BLO CK AND HEAD, TR6
18
..
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CYLINDER BLOCK AND H E A D•tlf R 6 R, T R 6 C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
E6309
E6304
W76
P0172A
E2620
E6000
E4752
E4746
E7031
E2899
E2900
E3583
E4603
E2904
E6439
E4221
E7400
E1543
WE259A
E327
F2184
E4771
S25-3
E4547
E4550
E4551
E4549
E2980
F879
E3302
E2982
S25-13
E1596
E4610
E3751
E4609
WE170
T1553
E1457
E1458
E1483
E1513
E470
E1330
E1575
E1574
E1512
E3253
E3547
Cylinder base washer ...
Cylinder block ...
Inner cylinder base nut
Outer cylinder base nut
Push rod
Cover tube
Rubber washer ...
Bottom cup
CYLINDER HEAD cfw GUIDES
Inlet valve guide ...
Exhaust valve guide
Exhaust pipe adaptor
Inlet valve
Exhaust valve ...
Bottom cup
Inner valve spring (red spot) ...
Outer valve spring (green spot)
Top collar
Split cotter
Cylinder head bolt (31 in. U.H.)
Plain washer
Bolt (3 in. U.H.)
Plain washer
Cylinder head gasket
Inlet rocker box
Exhaust rocker box
Joint washer
Rocker box stud (tf ln. O.A.)
...
Rocker box nut ...
Plain washer
Rocker box bolt (2-/r ln. U.H.)
Plain washer
Cylinder head bolt (for torque stay)
Inspectlon cap ...
Joint washer
Locking spring ...
Fibre washer
Screw (i in. U.H.)
ROCKER (right exhaust, left inlet) ...
ROCKER (left exhaust, right Inlet) ...
Rocker ball pin
Rocker adJusting pin
Adjuster lock nut
Thrust washer, t in.
Thrust washer, ! ln.
Spring washer ...
Rocker spindle
Sealing rubber ...
Rubber washer ...
.
19
...~
1
1
4
4
4
2
2
2
1
2
2
2
2
2
4
4
4
4
8
4
8
1
1
1
1
1
2
6
6
6
4
4
4
4
4
4
4
4
2
2
4
4
4
2
6
4
2
2
2
REMARKS
48-47
i-------33
@e....___-----35
~--------34
\
29
..
\
Fig. 5. CYLINDER BLOCK AND HEAD, T110R
20
.•.
,
No.
Part No.
QUANTITY
DESCRIPTION
REMARKS
CYLINDER BLOCK AND HEAD, T120 R
1
2
3
4
s
•
6
7
8
9
10
11
12
13
\
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
E6309
E6304
W76
P0172A
E2620
E6000
E4752
E4746
E5727
E5347
E3827
E3828
E5351
E5352
E4791
E4792
E4608
E5914
E4603
E2904
E6439
E4221
E7400
E1543
WE259A
E327
F2184
E4771
525-3
E4547
E4550
E4551
E4549
E2980
F879
E3302
E2982
525-13
E1596
E4610
E3751
E4609
WE170
T1553
E1457
E1458
E1483
E1513
E470
E1330
E1575
E1574
E1512
E3253
E3547
Cylinder base washer ...
Cylinder block ...
Inner cylinder base nut
Outer cylinder base nut
Push rod
Cover tube
Rubber washer ...
Bottom cup
CYLINDER HEAD cjw GUIDES
Sleeve for head bolts passing through inlet tracts
Inlet valve guide ...
Exhaust valve guide
Carburetter adaptor, left
Carburetter adaptor, right
Connector ...
Balance pipe
Adaptor locking nut
Exhaust pipe adaptor
Inlet valve
Exhaust valve
Bottom cup
Inner valve spring (Red spot)
Outer valve spring (green spot)
Top collar
Split cotter
Cylinder head bolt (3i in. U.H.)
Plain washer
Bolt (3 in. U.H.)
Plain washer
Cylinder head gasket
Inlet rocker box
Exhaust rocker box
Joint washer
Rocker box stud (tf in. O.A.)
Nut
Plain washer
Rocker box bolt (2/,; in. U.H.)
Plain washer
Cylinder head bolt (for torque stay)
Inspection cap ...
Joint washer
Locking spring ...
Fibre washer
Screw (i in. U.H.)
ROCKER (right exhaust, left inlet) ...
ROCKER (left exhaust, right inlet) ...
Rocker ball pin
Rocker adjusting pin
Adjuster lock nut
Thrust washer, in.
Thrust washer, t ln.
Spring washer
Rocker spindle ...
Sealing rubber ...
Rubber washer ...
...
....
t
...
21
1
1
4
4
4
2
2
2
1
2 (Not illustrated)
2
2
1
1
2
1
2
2
2
2
4
4
4
4
8
4
8
1
1
1
1
1
2
6
6
6
4
4
4
4
4
4
4
4
2
2
4
4
4
2
6
4
2
2
2
10
9
o-4
~5
7
6
@cain
10
J·
8
~ ~"
9
Jl
' ~,'
21
25
AUTO-ADVANCE
UNIT No.20
22
Fig. 6. TIMING COVER AND CONTACT BREAKER
22
Ref. No.
Part No.
DESCRIPTION
TIMING
COVER
AND CONTACT
QUANTITY
BREAKER
1
2
3
4
4
E8797
E4016
0208-5
E4568
E6387
Timing cover ...
Patent plate
Hammer-drive screw
Oil seal ...
Oil seal (0·020 in undersize)
1
1
3
2
5
6
7
8
9
10
11
12
E4569
E2615
E1335
T989
E3668
E3204
E8828
S25-43
E4707
E7680
E6559
E8737
E5049
GS299
F7354
Circlip ...
Timing cover plug
Copper washer
Hollow dowel ...
Screw (1-h ln. U.H.)
Screw (1 ln. U.H.)
Bolt (2 in. U.H.) ...
Plain washer
Rubber grommet
Pillar bolt
Plain washer
Cover
joint washer
Serrated washer
Screw (# ln. U.H.)
1
1
1
AUTO ADVANCE UNIT
Cam
Spring set ...
Weight
Sleeve and action plate
1
1
1
23
24
54419340
54419338
54415642
42539
54419428
25
26
27
28
54419097
54419827
54419220
54933228
CONTACT BREAKER PLATE ASSEMBLY
Contact set
Pin, adjustment ...
Lead, contact set to coil ...
1
13
14
15
16
17
18
19
20
21
22
REMARKS
For reground
crankshaft
1
3
5
1
1
1
2
2
1
1
2
2
2
1
23
2
2
3
7.
~~
~
8
I
10
h
..,
17
18
8
t
;I·
,fi'
5
6
11
13
12
14
22
16
24
Fig. 7. GEARBOX INNER COVER AND SELECTORS
24
l
No.
DESCRIPTION
Part No.
QUANTITY
REMARKS
GEARBOX INNER COVER AND SELECTORS
1
2
3
4
5
5
6
E4535
T989
T3650
T44
T373
T1604
7
8
T372
T260B
T913
9
10
11
T291
T1606
12
13
14
15
16
17
18
19
20
21
22
23
24
NT261
T1607
T2112
T1614
T412
T45
T397
T1896
5
64
in.x1f in.
T1778
E3446
E3204
T1779
E3728
Stud (3 in. O.A.)
Hollow dowel ...
Gear selector camplate
Camplate index plunger
Index plunger spring ...
Strong index plunger spring ...
Index plunger holder ...
Mainshaft selector fork
Layshaft selector fork ...
Selector fork roller
Selector fork rod
Layshaft bearing
Thrust washer ...
GEARBOX INNER COVER
Layshaft bearing ...
Gearchange spindle bush ...
Kickstarter stop ...
Camplate operating quadrant ...
Quadrant spindle
Split pin ...
Bolt (1r in. U.H.)
Plain washer
Screw (1 ln. U.H.)
Socket screw (11 in. U.H.)
Countersunk screw Ht ln. U.H.)
25
2
4
1
1
1
as required
1
1
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
15
16
12
26 25
2
24 23
22
21
20
27
13
14
3
18·--~ ~~·~~~,:;s ~~~~:::=::::~--- 1
Fig. 8. GEAR80)( SHAFTS AND GEARS
4
Ref. No.
DESCRIPTION
Part No.
QUANTITY
REMARKS
GEARBOX SHAFTS AND GEARS
1
2
3
4
5
6
7
8
9
10
11
12
12
12
12
12
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
T2436
PT10SB
T2316
T1370
T917
T916
T926
T92S
T1065
T930
T2093
T1952
T1953
T1916
T1917
T191S
T1919
T2116
T440
T44S
E4S9
T946
535-7
TISO
T1962
T1963
T1250
T730
T731
T2240
S594
T1736
MAINSHAFT cfw LOW GEAR (16T)
Clutch rod bush ...
MAINSHAFT HIGH GEAR (26T) ...
High gear bush
Mainshaft third gear (24T)
Mainshaft second gear (20T)
LAYSHAFT LOW GEAR (30T)
Low gear bush
Layshaft second gear (26T)
Layshaft third gear (22T)
Layshaft cfw high gear (20T)
Gearbox sprocket (15 teeth) .. .
Gearbox sprocket (16 teeth) .. .
Gearbox sprocket (17 teeth) .. .
Gearbox sprocket (1S teeth) .. .
Gearbox sprocket (19 teeth) .. .
Gearbox sprocket (20 teeth) .. .
Tab washer
Gearbox sprocket nut
High gear bearing
Cirdip .. .
Oil seal .. .
Mainshaft bearing
Circlip ...
Plain washer
Pinion sleeve
Pinion spring
Kickstarter pinion
Kickstarter ratchet
Tab washer
Nut
Clutch operating rod
WIDE
3
6
9
11
T1912
T96S
T974
T1844
1
1
1
1
1
1
1
1
1
1
~}
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
RATIO GEARS
MAINSHAFT HIGH GEAR (2Sn
Mainshaft second gear (19T) .. .
Lays haft second gear (27T) .. .
Layshaft cfw high gear (1ST) .. .
1
1
1
CLOSE RATIO GEARS
3
5
6
7
9
10
11
T243S
T1910
T1179
T955
T961
T963
T964
T1846
MAINSHAFT cfw LOW GEAR (1ST)
MAINSHAFT HIGH GEAR (24T)
Mainshaft third gear (23T)
Mains haft second gear (21T) ...
LA YSHAFT LOW GEAR (28T)
Lays haft second gear (25T) ...
Layshaft third gear (23T)
Lays haft cfw high gear (22T) ...
27
1
1
1
1
1
1
1
See pages 5 to
s. for standard
SIZes
39
r
40
8
9
45
34
31
30
===------:--I
46
7
Fig. 9. G EARBOX OUTER COVER
1
---..
............
----~-------------------~~----
Ref. No.
Part No.
DESCRIPTION
QUANTITY
GEARBOX 0 UTER COVER
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
T3628
T57
T23
T47
T454
T1956
T1955
T408j9
E3309
T404
T406
T405
T407
E1612
F879
T25A
T31
T24A
T3629
T2191
T1710
T1771
T1711
T1712
GS127
6~ in. x tin.
T2525
T1646
T2540
S25-3
S1-51
E3802
E3668
E3204
T1750
W932
T2450
T2113
T2095
T12n
T1167
S70-3
T1273
T2330
T1222
H1531
E732
NE507
GEARBOX OUTER COVER
Gearchange spindle bush ...
Kickstarter spindle bush
Kickstarter spring anchor pin
Guide plate stud (i in. O.A.)
Oil seal
Oil seal housing ...
Gearchange quadrant ...
Rubber "0" ring
Quadrant return spring
Gearchange quadrant plunger
Plunger spring ...
Guide plate
Serrated washer
Nut
Kickstarter quadrant
Kickstarter return spring
Kickstarter axle
CLUTCH LEVER ASSEMBLY
Clutch lever
Lever shaft
Ball, l in. diam.
Thrust plate
Return spring
Plain washer
Split pin
Countersunk screw (i in. O.A.)
Rubber cover ...
Abutment for clutch cable
Plain washer
Nut
Screw (2! in. U.H.)
Screw (1 156 in. U.H.)
Screw (1 in. U.H.)
Gearchange pedal
Bolt (1 in. U.H.)
Pedal rubber
FOLDING KICKSTARTER
Kickstarter lever ...
Kickstarter pedal ...
Pedal locating spring
Steel ball, i in. diam.
Pedal bolt ...
Pedal rubber
Cotter pin cfw nut and washer
Domed nut
Filler plug
Fibre washer
29
4
1
2
2
2
4
4
1
1
3
1
1
1
1
2
1
1
2
1
2
2
1
1
2
1
1
REMARKS
CLUTCH ASSEMBLY NC?
1
9
4
12
23
24
8
14
21
19
w
0
22 2
3
5
8 7
6
10
11
15
Fig. 10. CLUTCH
16
17
18
e:-
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CLUTCH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
T1928
T1734
T1735
T394
T1570
T1719
T1720
T1040
T2538
T1722
T1723
T1724
T423A
T1362
T1363
T2156
T2159
14·0403JOOO
T1931
T1830
T2526
S66-1
T2279
S586
CLUTCH COMPLETE
Hub
Thrust washer
Roller
Sprocket and housing (58 teeth Duplex)
Centre
Inner plate
Countersunk screw (0·417 in. U.H.)
Shock absorber spider ...
Drive rubber (large)
Rebound rubber (small)
Outer plate
Screwed pin (11t ln. U.H.)
Driving plate (bonded)
Driven plate
Pressure plate
Adjuster pin
Nut
Spring cup ...
Spring
Pressure nut
Key
.(. 0 4-2
Cupped washer
Clutch securing nut ...
s. :s
31
1
1
1
20
1
1
1
6
1
3
3
1
3
6
6
1
1
1
3
3
3
1
1
1
REMARKS
5
6
7
9
21
14
1
27
16
18
22
23
15
24
Fig. 11. CHAINCASE AND CHAINS
25
26
.,
'I
\
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CHAIN CASE AND CHAINS
1
2
3
4
5
E4704
E4705
S26-2
DS57
D530
Primary chain oiler tube
Clip
Spring washer ...
Bolt (f. in. U.H.)
Rear chain, i in. x l in. x 104 links
1
1
1
2
1
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
E3832
E7037
E7565
E3821
E5976
E6061
E4152
E5977
E4153
D477
E4536
E4537
47162
E58n
E4144
E5449
S25-3
E5324
T1770
T2439
T2440
T2442
F4129
E2441
E6347
T1738
E732
NE507
E3204
E4806
H1531
F1880
T2443
Joint washer
Cover plate
Oil seal ...
Countersunk screw (,\ in. U.H.)
Chain tensioner abutment
Chain tensioner blade ...
Tie rod ...
Trunnion
Adjuster sleeve nut
Primary chain, l in. Duplex x 84 links
Stator stud
Stator stud
Stator, RM 19
Sleeve nut
Rubber grommet
Plastic sleeve ...
Plain washer
Self-locking nut
Joint washer
Chain case
Rotor cover
Joint washer
Screw
Copper washer
Drain and adjuster plug
Fibre washer
Filler plug
Fibre washer
Screw (1 ln. U.H.)
Screw (ft in. U.H.)
Domed nut
Copper washer ...
Timing pointer ...
1
1
1
6
1
1
1
1
1
1
2
1
1
1
1
1
3
3
1
1
1
1
3
1
1
1
1
1
6
2
33
l
l
1
REMARKS
w
....
Fig. 12. FRAME
35
i
li
24
21
26
18
41
2 5
F;g.
n.
4 3
1
SWINIGNG FORK AND SUSPENSION UN ITS
8
Ref. No.
Part No.
DESCRIPTION
QUANTITY
RE.MARKS
SWINGING FORK AND SUSPENSION UNITS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
F7845
<r.;2.f6042
NW100
WE170
F6821
F5313
~ 2..F7848
%15620 '2.1 C:i.Z<.'
"?Z.F5944
5545 '21 0$4- 5'
F7365
F5315
PCW73A
DS47
64054164
64054465
9054/316A
9054/171
9054/151
9054/47
9054/280
E2113
525-2
S26-1
GS308
25
P0172A
26
27
28
29
30
F7067
F5536
H590
F7364
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
..,
48
S25-13
W1691
F4136
525-3
51-51
F3808
F879
F1369
526-2
F7386
-h ln. xf ln.
F7387
31437
T1076
F4717
F5412
F5413
F3158
'iSZ. F8090
SWINGING FORK
1
Pivot bush ...
Grease nipple
Fibre washer
Sleeve ...
Distance tube
Flanged washer
Bolt (Bi in. U.H.)
Tab washer
Nut
Brake torque stay
Bolt (it ln. U.H.)
Spring washer ...
Nut
2
1
1
2
1
2
1
1
1
1
1
2
2
2
SUSPENSION UNIT
Damper unit
Bonded bush
Spring retainer
Outer dirt shield .. .
Inner dirt shield .. .
Spring, 100 lbs. Green/Green
Unit fixing bolt (1,\ ln. U.H.)
Plain washer
Spring washer
Plain washer
Nut
Chain guard
Grommet
Bolt (,\ in. U.H.)
Rubber tube
Plain washer
Self-locking nut
Stepped bolt
Plain washer
Nut
Clip
Nut
Bolt (i in. U.H.)
Spring washer
Brake operating rod
Split pin ...
Adjuster nut
Stop lamp switch, type 22B
Screw (f ln. U.H.)
Self locking nut
Switch lever
"D" washer
Spring
"0" ring
37
2
4
4
2
2
2
4
2
2
3
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
5
1
1
1
2
(Not illustrated}
3 2
1
26
24--@
23
@
28
11
12
bb~
40(42}
~21
::---<i>j
J.--------23
[...__-----24
2----3---~---=-------7
cg@----~
.....
Q)
--------22
16
39
29
Fig.14.
ENGINE UNIT FITTING AND FOOTRESTS
23
25
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
ENGINE UNIT FITTINGS AND FOOTRESTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
F5469
PCW73A
DS47
F6498
F5532
F6066
F5908
E4165
F5316
S25-3
S26-3
S1-51
t--!J(F6069
•b'ZF5910
F5942
525-6
S4-13
F5943
NF704
S548
F1031
H426
F3248
526-1
51-52
P0172A
E4778
F3805
F3069
F6064
F1149
F879
F6449
F5472
F5788
525-1
F879
F7389
F4370
F6653
F6654
F6409
F6410
F6411
F6655
Stud (3,\ ln. O.A.)
Spring washer ...
Nut
Stud (7-t ln. O.A.)
Distance piece ...
Left rear engine plate
Right rear engine plate
Bolt (1ft in. U.H.)
Bolt (1} in. U.H.)
Plain washer
Spring washer
Nut
Left footrest
Right footrest
Stud (1,\ in. O.A.)
Plain washer
Nut
Peg
Footrest rubber
Stud (1 i in. O.A.)
Bolt (tf in. U.H.)
Bolt (H ln. U.H.)
Bolt (1tf in. U.H.)
Spring washer
Nut
Nut
Engine torque stay
Bolt (1-ft in. U.H.)
Distance piece ...
Brake pedal lever
Bolt (tf in. U.H.)
Nut
Brake pedal
Crankcase undershield ...
Hook bolt
Plain washer
Nut
Nut
Plain washer
LEFT FOOTREST ASSEMBLY
RIGHT FOOTREST ASSEMBLY'
Left footrest
Right footrest
Footrest pedal
Pivot bolt ...
39
1
4
4
2
1
1
2
2
4
6
6
1
TR6R & T120R
2
2
2
.
2
2
1
1
2
9
7
3
4
2
4
I
II
1
\
I
1
1
n
n
u
TR6C
2
2
TR6C
10
5
21
12
20
18
4
~
11
9
3
®
't ~
20
12
19
463
15
Fig. 15.
14
EXHAUST PIPES AND MUFFLERS T120R, TR6R
40
11 12 13
~
-
No.
Part No.
DESCRIPTION
REMARKS
EXHAUST PIPES AND MUFFLERS, T120R, TR6R (See also Page 43)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
E5957
E59S8
E4501
E410A
E409
E6857
E6179
E7471
E2271
F3430
E3768
S26-3
E1310
E5866
E4951
525-3
F929
E4711
F2335
Sl-51
DS58
E5676
Left exhaust pipe
Right exhaust pipe
Finned clip
Hemispherical washer ...
Bolt (1,\ in. U.H.)
Stay
Screw (i in. U.H.)
Self locking nut
Clip
Bolt (1! in. U.H.)
"D" washer
Spring washer
Nut
Muffler ...
Bracket ...
Plain washer
Bolt (! ln. U.H.)
Pillion footrest support
Bolt (# in. U.H.)
Nut
Bolt (if in. U.H.)
Stay
1
1
2
2
2
2
2
2
2
2
4
8
2
2
2
4
4
2
2
6
2
1
-----.
~~
~
~1
I
!
41
11
5
6
150-14
7
~i\
11
1
a
Fig. 16. EXHAUST PIPES AND MUFFLERS (TR6C)
6
12
"
Ref. No.
DESCRIPTION
Part No.
QUANTITY
EXHAUST PIPES AND MUFFLERS TR6C
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
E7024
E7026
E4889
E6978
H590
S26-3
E6974
E6975
F7549
E8724
F2335
S1-51
E4204
E4207
F4715
E2351
F3799
Left exhaust pipe
Right exhaust pipe
Sleeve nut
Stay
Bolt ( 196 in. U.H.)
Spring washer
Upper muffler
Lower muffler
Clip
Stay
Bolt (ft in. U.H.)
Nut
Leg guard
Clip
Screw
Plain washer
Self locking nut
1
2
1
4
6
1
1
2
1
2
2
2
4
4
4
4
43
REMARKS
T
ASSEMBLY REF. No.1
16
18
2
4
'---33
39 40
LJ
30
36----~
3 7 --~'-Sat!
38----j
1-43
!l--.-44
L_45
Fig.17. TELESCOPIC FRONT FORK
No.
DESCRIPTION
Part No.
QUANTITY
REMARKS
TELESCOPIC FRONT FORK TR6R, T120R
1
1
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
H2283
H2285
H2278
H2280
H439
H941
S25-2
E2412
H2263
H2100
H1527
F6738
D623
S578
H2266
H2083
F1760
H379
H2161
H2162
F4047
H1657
H1891
H1892
H1656
H1645
H1654
H1500
H2119
H431
H441
H1896
c17 H2092 use.
H443
H2091
H2245
H1842
H1843
H1844
S26-3
H1070
D519
H430
H21S4
H2127
H2090
H2126
H1062
H2107
FORK ASSEMBLY
FORK ASSEMBLY
Middle lug and stem
Middle lug and stem
Bottom cone
Pinch bolt (2! ln. U.H.) ...
Plain washer
Nut
Fork stem sleeve nut (blind)
Top lug
Bonded bush
Lock cfw 2 keys
Key (state serial number)
3~o
4
Grub screw
Sealing washer
Gaiter clip ...
Pinch bolt (1tt ln. U.H.)
Seated nut ...
Left top cover
Right top cover
Cork washer
Spring abutment
Solo main spring (Yellow JBiue)
Extra strong main spring (Yellow/Green)
Plain washer
Telescopic gaiter ...
DUST EXCLUDER SLEEVE NUT
011 seal
"0" ring ...
Plain washer
Top bearing
Damping sleeve
Stanchion ...
Lower bearing
Bearing nut
Cap nut
LEFT BOTTOM MEMBER cjw CAP
RIGHT BOTTOM MEMBER cjw CAP
Spindle cap ...
Spring washer
Cap bolt (1-fr ln. U.H.)
Drain plug ...
Fibre washer
Shuttle valve
Cirdip
Restrictor ...
Flanged bolt
Aluminium washer
Locating pin
1
1
1
1
1
TR6R
T120R
TR6R
T120R
2
2
2
1
2
2
1
Key Nos. run
from EJR1 to
EJR50
1
4
1
1
1
1
2
2
2
Available
2
2
2
2
2
2
2
2
2*
2
2*
2*
1
1
2
4
4
2
2
2
2
2
2
2
1
* Between engine numbers DU66246 and DU68363 the following parts are fitted and should only
as a set: H1658 Cap nut, H3605 Stanchion, H2224 Bearing nut.
45
be replaced
FORK ASSEMBLY REF. N2 1
4
11--18
~17
f
24~
~
16
~19
tl!--22
~21
23
®--19
20
@)
Fi1 • tB. TELESCOPIC FRONT FORK, TR6C
5
6
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
TELESCOPIC FRONT FORK AND STEERING DAMPER TR6C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
H2284
H2280
H2101
H722
S25-3
S589
H1142
HS65
H408
H95
H1797
H2108
H1618
H435
H1892
FORK ASSEMBlY
Middle lug and stem
Top lug
Cap ...
Plain washer
Bolt (11- in. U.H.) ...
Steering damper rod cfw knob ...
Plain washer
Adjuster sleeve
Spring plate
Anchor plate
Fork stem sleeve nut
Rubber sleeve
Friction disc
Main spring (yellow/green)
1
1
1
2
4
4
'I
1
1
1
1
1
1
2
All other parts are as listed on Page 45
HANDLEBAR
16
17
18
19
20
21
22
23
24
H1523
F1335
H1340
H1529
F3955
H1580
H1581
F3814
H1616
MOUNTINGS
Handlebar eyebolt
Plain washer
Bolt (1t in. U.H.)
Hemispherical washer ...
Self-locking nut
Steady rubber
Distance piece ...
Cup
Solid bush (for handlebar-mounted windscreen)
47
2
2
2
4
TR6R, T120R
2
2
2
2
as required
2
18
\
12
40 37 31 37
I
7
5
6
19 20 14
15
Fig. 19.
10 16
FRONT WHEEL
33 32
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
FRONT WHEEL
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
W2050
W1994
W1230
W1328
W1708
W2023
S79-2
W1995
W1641
W653
W1237
T280
W1481
W1474
W1238
W582
W1992
S064
W1197
W1198
W1990
W1996
W1998
W2059
W2026
W135
W2001
W2000
14·0302/001
W1999
W2003
W2005
14·0401/001
W592
W1246
WF32
S25-6
W1991
S650
FRONT WHEEL COMPLETE
RIM, SPOKES AND HUB ASSEMBLY
Front wheel rim (WM2-19)
Spoke (8/10G x Sf in. straight) cfw nipple
Spoke (8f10G x 4-H in. 78°) cfw nipple
Spoke (8f10G x .q in. 100°) cfw nipple
Spoke nipple ...
Hub and brake drum
Wheel spindle
Bearing
Dust cover
Cirdip
Grease retainer
Grease retainer (brake side)
Backing ring
Retaining ring
Cover plate
Fixing screw
Balance weight, ! oz.
Balance weight, 1 oz.
Brake anchor plate
BRAKE SHOE cfw LINING
Brake lining ...
Brass rivet
Abutment pad
Shoe return spring
Brake cam
Brake cam lever (front)
Nut ...
Brake cam lever (rear)
Rod ...
Fork end, threaded
Locknut
Lever return spring
Anchor plate nut ...
Pivot pin ...
Split pin
Plain washer
Anchor plate gauze (for air scoop)
Taptite screw
49
1
1
20
10
10
40
1
1
2
1
1
1
1
1
1
1
3
as required
as required
1
2
2
16
2
2
1
1
2
1
1
1
1
1
1
2
2
2
1
3
44
27
44
22
9
5
12
1
16
18
24
VI
,0
42 43
34 33 35
26
31
45
11
Fig. 20.
REAR WHEEL
4
6
14
36 37
40
41
Ref. No.
Part No.
DESCRIPTION
REAR
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
W1742
W1486
W1007
W1107
W1108
S79-2
W1472
W1499
W1500
E1612
W1498
W1690
W1691
W1281
W1474
W1654
W1022
W653
W1021
W1710
W1278
W1024
W1112
W1282
W1406
W1407
NW243
W129
W1415
W135
W1083
W2015
S25-6
S1-52
W1090
W1635
W1476
W1477
D637
W1280
W1134
W1015
W1058
F1747
WM3
QUANTITY
WHEEL
REAR WHEEL COMPLETE ...
RIM, SPOKES AND HUB ASSEMBLY
Rear wheel rim WM3-18 ...
Spoke (8f10G x 7-f!6 in. 90°) cfw nipple
Spoke (8f10G x 7-k in. 90°) cfw nipple
Spoke nipple ..
Hub ...
Sprocket, 46T
Bolt (ft ln. U.H.)
Serrated washer ...
Brake drum
Bolt (ft in. U.H.) ...
Self locking nut ...
Wheel spindle
Grease retainer (brake side)
Grease retainer
Backing ring
Bearing
RETAINING RING
Locking screw {-ft in. U.H.)
Distance tube
Distance piece
Brake anchor plate
Nut ...
LEADING BRAKE SHOE CJW LINING
TRAILING BRAKE SHOE CfW LINING
Brake lining ...
Brass rivet
Thrust pad ...
Shoe return spring
Brake cam ...
Brake cam lever
Plain washer
Nut ...
Lever return spring
Grease retainer ...
Speedometer adaptor
Distance piece
Speedometer gearbox
Plain washer
Chain adjuster ...
Adjuster end plate
Self-locking nut
Spindle nut
Tire security bolt
51
1
1
1
20
20
40
1
1
8
8
1
8
8
1
1
1
1
2
1
1
1
1
1
1
1
2
16
2
2
1
1
1
1
1
1
2
2
2
3
2
REMARKS
9
12
14
10
---11
6
8
24
1
18
19
7
4-l
2
28~
Fig. 21.
GAS TANKS
52
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
GAS TANKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
F7003
F6728
~z F6887
F4129
F7888
<:t'Z.F6888
F8192
F8193
F5398
F4019
H919
F3220
F3219
F4048
F4971
F4972
F8198
F5228
F5229
F3814
F1808
F5336
F967
F7388
F3917
F2936
F4384
F8194
57161
D680
D1920
D1918
F10002
F10006
Petrol tank (4! gallons)
Petrol tank (2t gallons)
Styling unit (left)
Styling unit screw (front)
Styling unit screw (rear)
Styling unit (right)
Left knee grip ...
Right knee grip
Centre styling strip
Serrated washer
Nut
FILLER CAP ...
FILLER CAP cjw JACK CHAIN
Joint washer
Petrol tap (left)...
..S.S
Petrol tap with reserve tube ... ~ 3.Z 'S":9:U
Tap seal
Rubber washer ...
Spigot rubber ...
Cup
Shouldered bolt
Double spigot rubber
Rubber washer ...
Bolt (1-H in. U.H.)
Parcel grid
Screw
Rubber blanking plug ...
Reflector bracket
Reflector, AMBER
D~cai-BONNEVILLE .. .
Decal-TROPHY 650 .. .
Decal-TIGER 650
Steel washer
Nut for petrol tap
z..s--o..(
TR6R
TR6C, T120R
1
2
2
1
1
1
1
1
1
1
1
1
1
1
2
2
2
3
2*
1
1
1
1
TR6C
TR6R
as required
2
2
1
TR6C
1
1
TR6R
2
2 not illustrated
* Later machines replace bolt F1808 with: F9298 Stud 2off 14-1302/001 Self-lock nut 2 off
53
TR6R
21
22
26~~
32
!1---27
-----36
5
4
35
7
6
9
10
8
11
10
Fig. 23.
OIL TANK
54
No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
0 I L TANK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
F7836
F3216
F4047
F5343
PT104B
F3179
F1713
F3655
F3182
E4594
E6848
E6930
E3763
E3446
E1310
E6356
E5370
F7353
F3098
F9255
F8028
F6673
F6968
14·01 03/001
15104/00/2
F6511
F6874
F6672
S25-13
F879
E6353
E6349
E1335
E1435
F6147
F6039
14·0113/001
F7352
E6849
F8034
Oil tank ...
FILLER CAP
Joint washer
Drain plug
Fibre washer
Oil tank filter
Fibre washer
Upper feed pipe
Union nut
Flexible connector
Clip
Oil pipes and junction block ...
Joint washer
Plain washer
Nut
Vent pipe
"T" piece
Extension pipe ...
Clip
Front strap
Rear Strap
Spigot rubber
Rubber washer ...
Bolt (! in. U.H.)
Self locking nut
Metering screw
Coil spring
Screwed peg
Plain washer
Nut
Rubber connector
Rocker oil feed pipe
Copper washer
Domed nut
Bracket ...
Grommet
Bolt (i in. U.H.)
Flexible pipe
Clip
Sleeve nut
1
1
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
2
1
1
4
2
2
2
1
1
2
4
2
1
1
4
2
1
1
1
1
1
•
,
1-;
.f
55
...,-,-~~,~..,....---·-
6
U1
o-
,_)?
~- + - - 8
rJij•
Jli!L__ _ _ _
~
13
5
2
Fig. 24. BATTERY CARRIER AND AIR FILTERS
.
-·
~
~
I
I
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
BATTERY CARRIER AND AIR FILTERS
1
2
3
4
5
6
7
8
9
10
11
12
11
12
13
F8024
F8091
F8033
F8032
F8031
A52
F7431
F7892
PUZSA
F7632
0177/9
F6432
F5694
F8196
F6866
54938986
Battery carrier
Battery carrier rubber tray
Battery carrier strap ...
Battery strap anchorage
Battery carrier rubber strip
Transfer positive earth
Vent pipe
Circlip, vent pipe
Battery
Adaptor ...
Clip
AIR FILTER
Filter element (Paper)
AIR FILTER
Filter element (Cloth)
Fuse assembly ...
1
1
1
TR6R, TR6C
1
1
t
57
T120R
17--llifL....
19~
Fig. 25.
PANEL AND TWINSEAT
58
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
PANEL AND TWINSEAT
1
,
l
""
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
F8042
(;,c D1918
Left panel and tool box
Decal-TIGER 650
tc D1920
Decal-TROPHY 650 ...
,00680
Decal-BONNEVILLE ...
1
TWINSEAT (black top)
Twinseat cover (black top)
Trim strip
Trim strip sprag
Rubber buffer
Hinge-front ...
Hinge-rear
Bolt (t in. U.H.)
Spring washer
Check wire
Self tapping screw
Seat catch plunger
Spring ...
Plain washer
Split pin ...
Panel nut
Panel knob
Washer
Panel grommet ...
Safety strap
Self tapping screw
1
1
1
4
1
1
1
4
4
1
1
F8204
F7489
D696
D697
F7835
F8026
F7862
14·01 01/001
S26-2
D374
F4483
F7560
F4228
E1719A
h in. xf in.
S653
F8044
F8132
F6673
F7553
F4365
59
TR6R
(Not illustrated)
TR6C
(Not illustrated)
T120R
(Not illustrated)
1
1
1
1
1
1
1
2
!}
Alternative
2
~ili:l\-e;r--------14
~~-------------16
--------------17
1----------1
7---
~12
~11
21
37
29
28
--------26
~-----------23
....___ _ _ _ _36
30--
18
22
Fig. 26. FENDERS
60
17
~
Ref. No.
Part No.
DESCRIPTION
"*
QUANTITY
REMARKS
FENDERS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
H2276
H2268
H1681
H1683
H1678
H1685
F929
F4299
DS55
T224
NS362
DS55
GS203
W1691
DS57
WE170
$25-1
F879
F8143
F8144
F6915
F7860
F6851
S26-2
S26-3
H590
~'LF5994
?>'Zf6031
F6310
F8139
F6849
F6850
E2980
57111
F8195
F8140
14·0113 /001
$1-51
F4715
Front fender (stainless steel) ...
Front fender (painted)
Front stay
Centre bridge . . .
. ..
. ..
.. .
.t..15t£ ... '7 7 .. (£- t'/,.?Bottom stay
Bracket ...
Bolt (t in. U.H.)
Plain washer
Bolt (-(;; in. U.H.)
Nut
Spigot nut
Bolt (tt in. U.H.)
Plain washer
Nut, self locking
Bolt (-fi in. U.H.)
Fibre washer
Plain washer
Nut
Rear fender
Rear fender (stainless steel)
Fender bridge
Lifting handle
Bracket ...
Spring washer
Spring washer
Bolt (fi in. U.H.)
Clip
Backing plate ...
Plain washer
Tail lamp adaptor
Tail lamp plate
Number plate bracket
Stud (ft in. O.A.)
Reflecter
Push fix ...
Rubber mat
Bolt bracket to pivot lug
Nut
Screw
61
1
1
1
1
1
2
5
5
2
2
T120R, TR6C
TR6R
1
2
2
2
10
4
13
13
1
1
il
l
TR6R
T120R, TR6C
1
1
2
5
2
1
1
1
1
1
1
1
2
4
2
2
2
3
.l
26
t
28
ao--#
~24
23
\
22
29
Fig. 27.
21
HANDLEBARS A ND CON TROL LEVERS
14
No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
HANDLEBARS AND CONTROL LEVERS (SEE ALSO PAGE 6 s)
+
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
H1870
H1511
H1425
16/364
16/328
16/329
16/091
16/008
16/009
16{010
11{013
H2125
16{011
18/978
18/754
18/777
12/594
11/014
11/013
18/087
18{053
18/838/839
12/556
12{607
12/606
12/033
18/952
18/752
18/773
12/595
11/014
18{087
18/053
18/838/839
H2142
31563
380459
H1994
Handlebar
Handlebar
Packing piece
TWIST GRIP
Body top half
Body bottom half ...
Rotor
Friction spring
Friction spring screw
locknut
Screw
Grip
Cable stop ...
FRONT BRAKE AND AIR LEVER ASSEMBLY
Brake lever (ball end)
lever bracket
Control body
Screw
Screw
Fulcrum screw
Self locking nut
Cable adjuster and nut
lever
Bolt
Cap ...
Spring washer
CLUTCH LEVER ASSEMBLY
Clutch lever (ball end)
Clutch lever bracket
Clamp
Screw
Fulcrum screw
Self locking nut
Cable adjuster and nut
Handlebar grip ...
Horn push and dip switch
Backing rubber
Self-tapping screw (t in. U.H.)
63
1
1
4
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
TR6R, T120R
TR6C
TR6R, T120R
TR6C, TR6R
25
2
26
16
30f----
13------"
14,-----'
Fig. 28. CONTROL CABLES
64
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
CONTROL CABLES AND T120R TWISTGRIP
1
2
3
4
5
6
7
8
9
10
11
12
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
0667
0103
0506
0573
0668
5672
0665
0103
0506
0638
W2006
0746
0660
0101
083
NS191
0104
0747
0682
0683
0684
0685
083
0101
NS191
0343/7
313{13
313/008
313/009
313/013
4/048
16/008
210/007
210/008
210/009
H2125
16/011
CLUTCH CABLE
Ferrule
Nipple (Handlebar end)
Nipple
Adjuster ...
Nut ... ...
FRONT BRAKE CABLE
Ferrule
Nipple (Handlebar end)
Fork end ...
Pivot pin (spring-fix)
THROTTLE CABLE
THROTTLE CABLE
Ferrule
Nipple
Nipple
Adjuster
AIR CONTROL CABLE
AIR CABLE ASSEMBLY
Lever cable
Carburetter cable
Junction box
Nipple (Handlebar end)
Ferrule
Nipple
Clip, rubber
TWIN ROTOR TWISTGRIP
Body top half
Body bottom half ...
Rotor
Bolt
Friction spring
Adjuster screw
Rotor stop
Nut ...
Grip
Cable stop ...
1
2
1
1
1
1
1
2
1
1
1
1 TR6R, TR6C
1 T120R
2
1
1
1
1 TR6, TR6C
1 T120
1
2
1
1
6
3
as required
1 T120R
1
1
1
2
1
1
1
2
1
2
65
24
3
5
4
11
6
21
10
13
Fig. 29.
TOOLKIT, PILLION FOOTRESTS AND LICENCE HOLDER
66
Ref. No.
Part No.
TOOLKIT.
1
"'
/
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
0698
0291
NASS
OA16
OA311
0362
087
0496
0662/3
0296
0220
F5552
F1694
F2268
F5535
F2271
F2277
$1-51
F1695
0261
NA14A
0801
0767
0370
DESCRIPTION
PILLION
FOOTRESTS AND LICENCE
TOOLKIT COMPLETE
Tool roll ...
Open spanner, ixfi ln. Whit ....
Open spanner, ix-h in. Whit....
Ring spanner, ix+t in. Whit. ...
"C" spanner and tappet key ...
Plug spanner
Screwdriver for chain tensloner
Clutch hub extractor ...
Tyre inflator
Fork spanner (for cap nut)
PILLION FOOTREST ...
Pedal
Hanger
Bolt (ft in. U.H.)
Pivot bolt ...
Thackeray (spring) washer
Nut
Pedal rubber
Licence holder ...
Tyre lever
Tyre lever and tommy bar
Screwdriver
Ring spanner, ,\-xi ins. Whit.
67
QUANTITY
REMARKS
HOLDER
1
1
1
1
1
1
1
1
as required
as required
as required
2
2
2
2
2
2
2
2
as required
1
1
1
1
29
4
~15
3
19----~~~~~~
24----~~"""2rf"""-
9
16---'
8
~~------------13
,..------23
1-----24
Fig. 30. AMAL CARBURETTER, TR6R TR6C
68
Ref. No.
Part No.
DESCRIPTION
QUANTITY
RE.MARKS
AMAL CARBURETTER TR6R, TR6C
1
2
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
930/23
As above
244/1048
928/064
928/097
622/086
928/060
622/061
622/077
622/076
622/082
622/080
376/100
622/079
922/063
622/067
124/026
622/069
622/071
622/073
622/050
622/068
376/093
622/078
376/092
F9271
4/035
5f077
6/132A
928/062
622/065
CARBURETTER
Mixing chamber
"0" ring seal
Mixing chamber top
Mixing chamber top (for adjuster and ferrule)
Screw
Throttle valve (4 cutaway)
Throttle return spring
Throttle stop screw
Air adjusting screw
"0" ring
Jet holder ...
Main jet (230)
Needle jet (0.107)
Needle
Needle clip
Pilot jet (25)
Float
Float spindle
Joint washer
Float chamber
Needle
Filter
Banjo bolt
Fibre washer
Petrol pipe
Adjuster ...
Locknut, adjuster
Cable ferrule
Air slide
Spring
69
1
1
1 Available
4
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Available
Avaliable
2
1
1
4
~15
14
70
No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
AMAL CARBURETTER T120R
do'
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
R930f10
R930f9
As above
244/1048
928/097
622/086
928/060
622/061
622/077
622/076
622/082
622/080
376/100
622/079
922/063
622/067
124/026
622/069
622/071
622/073
622/050
622/068
376/093
622/078
376/092
F8133
4/035
5f077
6j132A
928/062
622/065
E2968
NA43A
F2603
S25-3
TI24
928/066
CARBURETTER-L.H.
CARBURETTER-R.H.
Mixing chamber ...
"0" ring seal
Mixing chamber top
Screw
Throttle valve (3 cutaway)
Throttle return spring
Throttle stop screw
Air adjusting screw
"0" ring
Jet holder ...
Main jet (220)
Needle jet (0.107)
Needle
Needle dip
Pilot jet (20)
Float
Float spindle
Joint washer
Float chamber
Needle
Filter
Banjo bolt
Fibre washer
Petrol pipe
Adjuster ...
Locknut
Cable ferrule
Air slide ...
Spring
Insulating block
Joint washer
Bolt Ht in. U.H.)
Plain washer
Nut
Air intake tube
71
1
1
2
2
2
8
2
2
2
2
4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
4
8
4
as required
2
3
::~
28
I
~31
32
~
22
'f.~ If@~
33
i
29
,
I
18
17
I
I
I
19
20
• 33 • SPEEDOMETER AND TACHOMETER
F1g.
72
21
No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
SPEEDOMETER AND TACHOMETER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
SSM5001j06
31-315-135
554734
987
H1946
H1929
30--282-014-11
30--276-037-11
S590
41-148-203-10
H1702
H1701
H2138
14•01 01/001
S26-2
D609
Speedometer head MPH
Brass fitting at cable connection
Bulb holder
Bulb, 3.W. M.E.S.
MOUNTING BRACKET
Metalastik bush
Washer ...
Nut
Bolt {1-f.in. U.H.)
Trip control
Distance piece ...
Sleeve nut
Bracket ...
Bolt {!in. U.H.)
Spring washer ...
Speedometer cable {65 ins. long)
E5756
E5153
E5156
E5155
E5157
E5759
E6300
E5578
E6122
E6299
E6124
E3309
E5881
D578
RSM3003f01
31-371-398
D494
E6961
D546
TACHOMETER GEARBOX
Securing screw
Bush ...
Flanged bush ...
Driving gear
End cap
"0" ring ...
Driven gear
Driven gear housing
"0" ring
Bush
"0" ring ...
Set screw ...
Tachometer cable {28 in. long)
Tachometer
Spade
Cirdip ...
Sealing washer ...
Blanking plug (replaces tacho bulb holder)
73
Not illustrated
1
1
1
~
TR6R, T120R
2J
11
Hmc
2
I
2J
1
Smiths
DF9110f00
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TR6R, T120R,
J
Not illustrated
e-2
1
5--~
7
--7
10
9---~
.,,_.....,,,,:L_ ···8
~-----------------------_/~------------------~--~-~···---11
12
13
14
-----26
r1j
28
Fig. 34. IGNITION CAPACITOR AND HEADLAMP TR6C
74
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
IGNITION CAPACITOR AND HEADLAMP, TR6C
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
54170009
54483156
F9274
54953455
Ignition capacitor (type 2MC)
Capacitor mounting spring ...
Cap, wiring harness terminal ...
Sub harness-to connect capacitor
54953440
35835
H2259
H2034
H687
H745
59882
534343
516828
504665
446
554710
989
554602
112201
13749
35710
31620
144921
534296
38189
54945043
281
38191
D553
Wiring harness
Kill button, type 151SA
Cup
Clip
Bolt (tin. U.H.)
Nut
HEADLAMP ASSEMBLY, MCH 66 ...
Rim ...
Light unit ...
Fixing wire
Bulb (50/40W. Vertical Dip, Pre-focus)
Bulbholder, pilot
Bulb (3W. M.C.C.)
Adaptor
Bolt
Washer
Lighting switch
Dip switch ...
Screw
Plate
Warning light, red
Warning bulbholder
Bulb (2W. BA75)
Warning light, green
Horn push, Clear Hooters No. 10
75
Available
Available
Available
Available TR6R,
T120R
(Standard on TR6C)
TR6C
1
1
1
2
1
1
1
1
1
6
1
1
1
2
2
2
1
1
1
1
1
1
2
1
1
50
1
I\
11
8
,,g
7
21
9
ill
26
22 23 24
32
@It,
~~
b~
42
12~
g----44
4 9 _______.
&--
13---4?
45
47----' 4----46
I
I
Fig. 35.
IGNITION COILS,. HORN, RECTIFIER AND ZENER DIODE
76
Ref. No.
IGNITION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
45110
423947
54190108
131023
188330
166043
421554
421863
54100776
169160
422369
54942078
54190042
F4744
F5466
F4366
E3290
D262
F6943
F6944
F1369
E1612
S1-40
F879
E6388
E6389
47638
54418527
54418528
F8082
F4771
S683
GS299
F3799
70197
F4771
F3799
GS299
49072
F5338
H2237
49345
H2236
526-2
14·61 02/001
14·0113/001
H2275
$26-3
842183
QUANTITY
DESCRIPTION
Part No.
COILS,
HORN,
RECTIFIER
IGNITION COIL, Type MA12
Bracket
lucar terminal
Plain washer (E2351)
Serrated washer (GS299)
Nut (F3799)
Rubber grommet ...
Cable clip ...
Screw
Square nut
"D" washer
lucar connector
Insulating cover
Bolt (11\ in. U.H.)
Rubber grommet
Distance piece ...
Self locking nut
Sparking plug (Champion N3)
Plug cover
left coil bracket
Right coil bracket
Bolt (i in. U.H.)
Serrated washer
Nut
Nut
Ignition coil, Siba 32,000
Clip, Siba 32,000/1
CONDENSER PACK 2CP
Condenser
Cover
Condenser pack bracket
Bolt, bracket to frame
Bolt, pack to bracket
Shakeproof washer
Nut
Horn, type 6H ...
Screw (i in. U.H).
Nut
Serrated washer
Rectifier, type 2DS 506
Nut (156 596)
Heat sink
Zener diode
Bracket .. .
Washer .. .
Bolt (bracket to heat sink)
Bolt (bracket to fork) ...
Plug heat sink ...
Washer ...
High tension lead
77
AND
ZENER
REMARKS
DIODE
2
I
2
4
4
4
f~
TR6R
J
4
as required
as required
2
2
4
2
2
2
1
1
4
2
2
6
2
2j
1
2
1
1
2
2
2
2
1
2
3
3
1
1
1
1
1
1
1
1
1
T120R
4
8~
7
I
11---r::t;
I
I
I
~·
2
17
15
21
/~~#42
1W
11
I
I
!
~
I
I
'
22
23
24
I
35
I
37
I
39
I
I
25
26
~
~,
36
33
31
32
Fig. 36.
HEADLAMP, WIRING HARNESS, SWITCHES AND TAIL LAMP
78
38
Ref. No.
Part No.
DESCRIPTION
HEADLAMP, WIRING
.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
59883
54523508
553248
516798
504665
144921
534296
446
54520540
989
554710
36403
862217
112201
137498
38189
281
38191
54945043
35710
H1932
54953443
900269
900288
850641
850844
850832
53973
54572932
572289
54574348
573828
380
54571677
127684
838604
31899
54130041
F6981
D662
H2262
QUANTITY
REMARKS
HARNESS, SWITCHES AND TAlL LAMP
HEADLAMP COMPLETE TYPE SS700P
Shell only ...
Rim ...
Light unit ...
Fixing wire ...
Screw
Plate
Bulb (50/40 W. Vert dip. Pre-focus)
Main bulbholder cfw leads
Bulb (3W. M.C.C.)
Pilot bulbholder ...
Ammeter, type 2AR
Grommet ...
Bolt
Plain washer
Warning light body (Red)
Bulb (2W. BA7S) ...
Warning light body (Green)
Warning bulbholder
Lighting switch
Distance piece ...
Wiring harness ...
Snap connector terminal
Single snap connector ...
Double snap connector
Triple snap connector ...
Quintuple snap connector
STOP AND TAIL LAMP, Type L679
Lens
...
Screw
Bulb holder with reflector
Contact assembly ...
Bulb (6/21W. Offset pin)
Gasket
Screw
Stop and tail lamp lead
Ignition switch, type S45
Nut
IGNITION LOCK cfw KEYS
Ignition key (state serial number)
Ignition switch cover ...
79
1
1
1
1
6
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
1
as
as
as
as
as
1
1
2
1
1
1
1
2
1
1
1
1
as
1
required
required
required
required
required
TR6R, T120R
required