TRI PU 1960-62 - JRC Engineering, Inc.
Transcription
TRI PU 1960-62 - JRC Engineering, Inc.
~ I I l ( REPLACEMENT PARTS CATALOGUE No. 16 FOR 6T- THUNDERBIRD TR6-TROPHY T120- BONNEVILLE 120 From Eng No 029364 & D 101 onwards Sept1960 TRIUMPH ENGINEERING CO. LTD., MERIDEN WORKS ALLESLEY, COVENTRY, ENGLAND ILLUSTRATION INDEX Fig. No. Page No. 1 Crankshaft and Connecting Rods 16 2 Crankcase 18 3 Oil pump and Release valve and Manifold 20 4 Cylinder block and head. 6T 22 5 Cylinder block and head. T110 and TR6 24 6 Cylinder block and head. T120 7 Gearbox and <asing a 26 28 Gearbox shafts and gears 30 9 Gearbox selector mechanism 32 10 Clutch 34 11 Frame 12 Swinging fork and suspension units 36 38 13 Engine and gearbox fottings 40 14 Chai ncase and alternator 42 15 Exhaust pipes and silencers 44 16 Telescopic Front Fork, 6T and T110 46 17 Nacelle, head lamp and switches 48 18 Telescopic Front Fork. TR6 and T120 50 19 Front Wheel, 6T 52 20 Front Wheel, T110, TR6 and THO 54 21 Rear Wheel 56 12 Quickly detachable Rear Wheel 58 23 Petrol Tanks 60 24 Oil Tanks 62 25 Battery Carrier and Air Filter 64 26 Mudguards 66 27 Panels and Twinseats 68 28 Handlebars 70 29 Control Cables and American Handlebars 72 30 Tool Kit, Frame Lock, Pillion Footrest and licence Holder 74 31 Carburetter 6T. T110 and TR6 76 32 Bonneville 120 Carburetters 78 33 Bonneville 120 Float Chamber 80 34 Magneto with Automatic Advance and Retard 82 35 Magneto with Manual Control 84 36 Diotributor and Coil 86 37 Head lamp and Wiring Harness. TR6 and T120 88 38 Speedometer, Tail lamp and Rectifier 90 6 INDEX Page No. 64 AIR FILTER MAGNETO Page No. ... 82, 84 ALTERNATOR 42 MUDGUARDS 66 BATTERY CARRIER ... 64 NACELLE 48 76,78,80 OIL PUMP 20 CARTON PACKS 12 OIL TANK 62 CENTRE STAND 36 CHAIN CASE ... 42 PETROL TANK 60 CHAINS 42 PILLION FOOTRESTS H CLUTCH 34 PISTONS 16 COIL 86 PROP STAND 36 CONTROL CABLES ... n CONTROL LEVERS 70 Q.D. REAR WHEEL ... 58 CRANKCASE ... 18 REAR PANELS 69 CRANKSHAFT 16 REAR WHEEL 56 RECTIFIER 90 SILENCERS 44 CARBURETTER CYLINDER HEAD 22.24.26 86 DISTRIBUTOR ENGINE PLATES 40 SPARKING PLUGS ENGINE SPROCKET ... 16 SPEEDOMETER EXHAUST PIPES « STEERING RACES SUSPENSION UNITS FOOTRESTS ... 40 FRONT FORKS ... 46,50 FRONT WHEEL ... 52,54 GASKET SETS GEARBOX SWITCHES 14 82,84,86 90 36,46,50 38 ... 48,88 TIMING GEARS 16 TOOLKIT H TWINSEAT 69 28,30,32 HANDLEBARS ... 1o.n HORN ... . .. <18, 88 VALVES 22,24,26 WIRING HARNESS ... 48,88 SUPPLEMENT SHEETS WITH EFFECT FROM ENGINE No. D.m7 7 93 THUNDERBIRD (6T) TECHNICAL DATA 71 x 82 mm. 2·79 x 3·23 ins. Bore and stroke 649 c.c. (40 cu. ins.) Capacity ... 7:1 Compression ratio Champion L7, K.LG. F.80 or lodge H.H Sparking plugs ... Carburetter Main Jet Needle jet Needle ... Throttle valve Pilot Jet Engine sprocket Chains Capacities Amal Monobloc 376 270 ·106S TypeC 376/31: 25 23 teeth Solo Sidecar 20 teeth j' X Front Rear i' FueiT~nk 011 Tank Garbox Primary Chalncase Front Forks (each leg) Brakes Front and rar diameter Tyre sin ... Front Rear X ft • X 70 links j ' X 98 links 4 galls. (18 lltres) 5 pints (2·8 lltres) l pint (400 c.c.) i pint (150 c.c.) i pint (150 c.c.) 1' (1N8cm•.) 3·25 X 18 3·50 X 18 8 TIGER 110 (T110) TECHNICAL DATA 71 X 82mm. 2·79 X 3·23 ins. Bore and stroke 649 c.c. (40 cu. ins.) Capacity ... 8 :1 Compression Ratio Champion N3, K.L.G. FE.100 or Lodge HLN Sparking Plugs Amal Monobloc 376 Carburetter Main Jet ... Needle jet Needle ... Throttle valve Pilot jet ... 1065 Type C 376/3! 25 Engine sprocket Solo Sidecar 23 teeth 20 teeth Chains Front 250 !" X f.. x 70 links i • X i" X 98 links Rear Capacities Fuel Tank Oil Tank Gearbox Primary Chalncase Front Forks (each leg) 4 galls. (18 litres) 5 pins (2·8 litres) I pint (400 c.c.) l pint (150 c. c.) l pint (150 c.c.) Brakes Front diameter ... Rear diameter 8 ln. (20·32 em.) 7 ln. (17·78 em.) Tyre size ... Front Rear 3·25 X 18 HO x 18 9 TROPHY (TR6) TECHNICAL DATA Bore and stroke 71 x 82 mm. 1·79 x 3·23 Ins. Capacity ... 649 e.c. (40 cu. ins.) Compression ratio 8 :1 Sparking plugs ... Champion N3, K.L.G. FE.100 or Lodge HLN Carburetter Main jet ... Needle jet Needle ... Throttle valve Pilot jet ... Engine sprocket Amal Monobloc 376 250 ·1065 Type C 376/3! 25 22 teeth Chains Front Rea:r i" X f.' X 70 links i' x !' x 981inks Capacities Fuel Tank Oil Tank Gearbox Primary Chaincase Front Forks (each leg) 3 galls. (13·5 litres) 5 pints (2 ·8 lit res) i pint (400 c. c.) ! pint (150 e.e.) 1 pint (150 c.c.) Brakes Front diameter ... Rear diameter Tyre size ... Front Rear 8 in. (20·32 em.) 7 in. (17·78 em.) 3·25 X 19 4·00 X 18 10 BONNEVILLE 120 (T120) TECHNICAL DATA 71 x 82 mm. 2·79 x 3·23 Ins. Bore and stroke 649 c.c. (40 cu. Ins.) Capacity ... 8·5 : 1 Compression ratio Champion N3. K.L.G. FE.100 or Lodge HLN Sparking plugs Carburetters Main jet ... Needle jet Needle Th rattle valve Pilot jet Engine sprocket Chains 22 teeth !" x f. • x 70 links i" X i" X 98 links F-ront Rear Capacities 2 Amal Monobloc 376 240 ·1065 Type 376/3! 25 Fuel Tank Oil Tank Gearbox Primary Chai ncase Front Forks (each leg) Brakes Front diameter ... Rear diameter Tyre si:z:e ... Front 4 galls. (18 lit res) 5 pints (2·8 litres) i pint (400 c.c.) t pint (150 c.c.) t pint 1150 c.c.) 8 in. (20·32 em.) 7 ln. (17·78 em.) 3·25 X 19 3·50 >: 19 Rear 11 CARTON PACK LIST The following sub-assemblies are supplied In carton packs under the C.P. part number stated. The contents of these carton packs are preserved and will not deter5orate under ad¥erse conditions. Part No. Contents Brake Linlns C.P.38/A.M.l 2 16 C.P.66JA.M.2 ... 2 16 Cranlcase Bearing C.P.H4 ... Fork Service Pack C.P.168 ... ... 2 2 ... NWl-43 W129 Brake lining Rivet W1336 W129 Brake lining Rivet .. . E1591 .. H-420 H-430 2 2 H#l 2 H1062 2 H1168 ~1 Standanl Ratio Gears (to conYert from Wide llatlo) C.P.HS 1 T13112. 1 T916 1 1 1 T1063 T1065 T9H Wide Ratio Gears (to convert from Standard Ratio) C.P.9<4 1 T1384 1 T968 1 T971 1 T97<4 1 T97S Clote Ratio Gears (to convert from Standard Ratio) C.P.9S 1 T1177 1 T13B3 1 T1179 1 T9SS 1 T9S9 1 1'964 1 T963 1 1 T%1 T1ll7 12 ... Ball journal bearings. Rubber washer Fibre washer Upper bearing Lower bearing Aluminium washer Oil seal Mainshaft high gear Malnshaft >«ond gear Layshaft and high gear Layshaft second gear Speedometer driven gear Mainshaft high 11ear Mainshaft second gear Layshaft and high gear Layshaft second gear Speedometer driven gear Matnshaft and low gear Mainshaft high gear Matnshaft third gear Malnshaft second gear Layshaft and high gear Layshaft third gear Layshaft second gear Layshaft low ....,. Blanking cap C A R T 0 N P A C K' L I S T- continued Contents Klc:kstarter Ratchet Set CP.27 1 ""' 1 1 T730 T731 T1250 T133B T732 Klckstarter pinion Klckstarter ratchet Ratchet spring Sleeve Tab washer E3611 E3049 E2898 WE203E ... WE479 . .. Piston C.R. 6·3 : 1 Compression ring 011 control ring Gudgeon pin Circllp Pistons C.P.15B 1 2 1 1 2 C.P.98 (6T only) ... .. ... 1 2 Piston C.R.7 : 1 E2891 E3049 E2898 WE203E ... WE-479 ... 1 2 Compression ring Oil control ring Gudgeon pin Circlip C.P.98 Is also available In 0·010 in. and 0·020 ln. oversizes 1 2 1 1 2 C.P.159 E3612 E3049 E2898 WE203E ... WE479 ... Piston CR. 7·5 : 1 ... Compression ring 011 control ring Gudgeon pin Circlip C.P.159 is also available In 0·010 in. and 0·020 in. overslzes 1 2 1 1 2 C.P.163 E3670 E3049 E2898 WE203E ... WE479 ... Piston C.R. 8 : 1 Compression ring Oil control ring Gudgeon pin Clrdlp C.P.163 Is also available In 0·010 in. and 0·020 ln. oversizes 1 2 1 1 2 C.P.157 ... E3610 E3049 E2898 WE203E ... WE479 ... Piston C.R. 8·5 : 1 Compression ring 011 control ring Gudgeon pin Cirdlp C.P.157 Is also available in 0·010 ln. and 0·020 ln. overslzes C.P.160 ... 1 E3613 Piston C.R. 12 : 1 l E3049 E2898 WE203E ... WE479 Compression ring on control ring Gudgeon pin Cirdlp (Alcohol fuel) 1 1 2 13 C A R T 0 N P A C K L I S T - continued Part No. Contenu Piston Rinp 4 C.P.99 Compression ring Oil control ring E3049 E2898 2 C.P.99 is also available In 0·010 in. and 0·020 ln. oversizes Valves C.P.96 (6T) C.P.173 (T110. TR6, T120) 2 E2903 E2904 Inlet valve Exhaust valve 2 2 E3310 E3927 Inlet valve Exhaust valve E2899 E2900 Inlet guide Exhaust guide 2 Valve Guides C.P.97 (6T, T110, TR6) 2 2 ... C.P.S (6T. T110, TR6) 4 ... EHS8 4 E1487 Inner spring Outer spring C.P.102 (T120) 4 4 E3001 E3002 Inner spring Outer spring 2 1 1 40 H111 H439 H1018 $70-3 Cups Cone E4167 E2749 E3678 E3679 E3682 E3686 E3685 52091 !5 H1083 H1086 RC109 Cover Valve Springs Steering Races C.P.156 ... Top cone and dust cover Balls Tachometer Drive (TR6 and T120) C.P.181 1 1 2 1 1 1 ... 1 1 2 1 Driven gear Grub screw Driving gear housing Driven gear housing Driving gear Exhaust camshaft nut Drive cable Mounting bracket Bolts Tachometer head GASKET SETS 6T T110 and TR6 THO GS. 6Tj56 GS. T110/S6 GS. T120/59 PLEASE NOTE THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS INCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN. REVERTING TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENT PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY. IF REQUIRED. SPECIAL WORKSHOP TOOLS A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING YOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASES THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE. AND THEREFORE. IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES IT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER. 15 Crankshaft and flywheel aaembiJ Ref. Ne>. t. 18 17 18 -----------------~ r-----------------9 44 II-I 12 33 33 34 -------e 37 ---------14 \W:::J--13 4039- +---------- 9 ~~~ 38 34~ 8 31 --------=-30 --------'IIIJ 29-----__J 28 _________ ____j 27 "-------- 5 19 20 FIG. t 16 21 22 23 24 25 26 CRANKSHAFT AND CONNECTING RODS RJJf. No. QUANTITY DESCRIPTION Pon No. CRANKSHAFT AND CONNECTING RODS 2 3 4 5 6 7 8 9 10 11 12 13 14 14 14 15 16 17 18 19 20 21 21 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 37 37 38 38 39 40 41 42 43 44 45 46 47 E3893 E3894 E3903 E3905 E3906 E3907 Ell88 E31H E3606 E1511 E2490A E29ll E3586 CF98 CP163 CP157 E3049 E2898 WE203E WE479 E1591 H1168 E3108[23 E3108/20 E3108f22 E3116 E3974 413506 E3975 E3977 E3300 E1580 E1472 E398 E1471 E400 E1486A E155S E1463 E1492 E3275 E3325 E3134 E3275 E3325 Ell54 Ell56 E3123 E3125 E3126 47502 E2741 170104 E1330 CRANKSHAFT AND FLYWHEEL ASSEMBLY CRANKSHAFT cjw OIL TUBE Oil tube ... Screwed plug Flywheel Flywheel bolt ... Serrated washer Crankshaft stud (1 f. • O.A.) CONNECTING ROD Small end bush ... Connecting rod bolt Self locking nut Big end bearings PISTON COMPLETE 7 : 1 C.R. PISTON COMPLETE 8 : 1 C.R. PISTON COMPLETE 8 · 5 : 1 C.R. Taper compression ring Oil control ring Gudgeon pin Circllp ... Main bearing Oil seal Engine sprocket (solo) Engine sprocket (sidecar) Engine sprocket (solo) Backing washer Rotor key Rotor Tab washer Nut Clamping washer Key Timing pinion Nut INTERMEDIATE WHEEL Intermediate wheel bush Camshaft wheel Camshaft key Inlet camshaft nut Exhaust camshaft nut Inlet camshaft Inlet camshaft Inlet camshaft Exhaust camshaft Exhaust camshaft Rotary breather valve Breather valve spring Distributor pinion Pin Circllp ... Auto-advance unit Magneto pinion Magneto pinion nut ... Plain washer 6T 1 1 1 1 1 3 3 1 2 2 4 4 4 T110 1 1 1 1 1 3 3 TR6 1 1 T120 1 1 1 1 1 3 3 1 2 2 4 4 4 3 3 1 2 2 4 4 4 2 2 4 4 2 2 4 2 1 2 2 4 4 4 2 4 2 2 4 2 1 1 A 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 2 4 2 1 1 A 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 4 2 2 4 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 17 15 31 l 3 24 23 ~--------------27 ir------------26 ~';#------28 ----"""" ~~-------------29 :.---3----------30 FIG. 2 CRANKCASE 18 Ref. No. Port No. DESCRIPTION QUANTITY CRANKCASE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ll 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 E2892j2314 E6n E3523 E1479 E1516 E2260 GS87 E2n4 E1508 E1509 E1645 E1579 E1534A E1555 525-3 E1S40 E1532 E1535 E375 E2022 E1534A E1647 T456 525-3 51-51 ~487 E529 E486 E1612 F879 E3110 E378 E3585 E4016 0208-5 E2615 E1335 E3437 E3439 E3078 6T 1 6 2 2 CRANKCASE Cylinder base stud (1t' O.A.) Cylinder base stud (1 t• O.A.) Camshaft bush ... Camshaft bush ... Camshaft breather bush Breather disc ... Breather pipe ... Oil scavenge pipe Scavenge pipe clip Screw (it' U.H.) 1 1 1 1 1 1 1 1 Crankcase joint hollow aowel Top rear bolt (1i' U.H.) Plain washer Oil filter stud (II' O.A.) Oil junction block dowel 4 1 1 4 1 1 1 4 4 2 2 2 3 2 2 1 2 2 2 1 3 2 2 1 2 2 2 1 4 4 4 4 4 4 1 1 A 1 3 1 1 .. ~ 1 3 2 2 1 2 2 2 ... Serrated washer Nut TIMING COVER Crankshaft oil feed bush Crankshaft oil feed bush (0·020 in. undersize) Patent plate ... Patent plate rivet Timing cover plug Copper washer Cover screw (U ln. U.H.) ... Cover screw (1 f.' U.H.) ... Breather extension rubber pipe 1 1 Timing cover dowel Filter cover T120 1 6 2 2 1 1 Crankcase joint dowel Intermediate wheel spindle Magneto stud (1 f< O.A.) Cylinder base dowel Crankcase joint screw Bottom front stud (3£" O.A.) Plain washer Nut Filter joint washer Crankcase oil filter T110 TR6 1 6 6 2 2 2 2 4 4 1 A 1 3 2 2 1 1 A 1 3 3 1 1 7 3 1 7 3 A 1 3 1 1 7 3 1 7 3 19 Oil Pump A•oembly Ref. No. 1. 3------------~ +------------------2 12-------J 11-----~ _,r----------9 6----------~~ 7--------~ 8--------22 21 20 I i~~ Release Valve Assembly Ref. No. tJ. 19 15 17 ----24 30---------31---------. 29--------.. 32---~ '-------26 33---_j 29 FIG. l 20 OIL PUMP AND RELEASE VALVE AND MANIFOLD Ref. No. Part No. QUANTITY DESCRIPTION OIL PUMP AND RELEASE VALVE AND MANIFOLD 1 2 3 4 s 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 25 26 27 28 29 29 30 31 32 33 EJon GS35 G$_153 E1476 E49S 570-7 E403 E2360 E1537 E1536 E1612 FB79 E2795 E2794 GS251 E2790 GS254 E27BB E2789 E2791 E2793 E2792 E1670 E2920 E2973 E3334 E3304 525-13 W103 E1553 E2962 NA43A E2968 525-3 51-51 ... OIL PUMP Pump body Feed plunger Scavenge plunger Drive block Valve ball Valve spring Screwed plug Joint washer Oil pump stud (1l.r' O.A.) Serrated wuhet Nut OIL RELEASE VALVE AND INDICATOR Valve body Piston Cap Fibre washer Main spring Auxiliary spring Button and shaft Sealing rubber ... Shaft nut Fibre washer Stud (1 H in. O.A.) ... Stud (11f in. O.A.) ... Joint washer ... Inlet manifold Plain washer ... Nut ... Stud (1,& in. O.A.) ... Stud (1 ,& in. O.A.) ... Joint washer ... Insulating block Plain washer ... Nut ... ... 6T 1 1 1 1 1 2 2 2 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 4 2 1 4 4 2 2 2 T110 1 1 1 1 1 2 2 2 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 TR6 1 1 1 1 1 2 2 2 1 2 2 2 1 1 1 1 1 1 1 1 1 1 4 2 4 4 4 2 1 4 4 2 1 1 2 2 2 1 1 2 2 1 T120 1 1 1 1 1 2 2 2 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 21 21---. 1 \ - - - - - - - 2<1 e-------25 43 46 15 14 12 13 ,, 46 44 52 51 45 ~e 41 FIG. 4 CYUNDEII BLOc:tt AND HEAD 6T 22 Ref. No. DESCRIPTION Part No. QUANTITY CYLINDER BLOCK AND HEAD, 6T 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 ..... 45 46 47 48 49 so 51 52 E2894 E3332 W76 P0172A EH77 HlOO E1612 E3059 E3873 E2899 E2900 E2903 E2904 E1544 E1488 E1487 E1543 WE259A E327 E3614 E1461T E1462T E1650 E1540 F879 E1545 SlS-13 E1484 E1596 GS308 E1564 E1577 E1457 E1458 E1483 E1513 E-470 E1330 E1575 E1574 E1512 E3253 E1693 E1505 EH96 E3547 GSln GS273 E1601 E1335 E984 F1880 Cylinder base washer Cylinder block Inner cylinder base nut Outer cylinder base nut Tappet guide block ... Tappet block screw(-,'." U.H.) Serrated washer Tappet CYLINDER HEAD c/w GUIDES ... Inlet valve guide Exhaust valve guide Inlet valve Exhaust valve Bottom cup ... Inner valve spring Outer valve spring Top collar Split cotter ... Cylinder head bolt (3i" U.H.) Cylinder head gasket Inlet rocker box Exhaust rocker box ... Joint washer Rocker box stud ( ti • O.A.) Rocker box nut Rocker box bolt (2" U.H.) Plain washer Cylinder head bolt (Sf' U.H.) Cylinder head bolt (for torque stay) Pial n washer Inspection cap Joint washer ROCKER (right exhaust, left inlet) ROCKER (left exhaust, right inlet) Rocker ball pin Rocker adjusting pin Adjuster lock nut Thrust washer, i" Thrust washer, t • Spring washer Rocker spindle Sealing rubber Push rod ... Cover tube ... Bottom joint washer Top joint washer Rear drain pipe Front drain pipe Adaptor bolt Copper washer Adaptor bolt Copper washer 6T 1 1 4 4 2 2 2 4 1 2 2 2 2 4 4 4 4 8 4 1 1 1 4 4 4 4 4 2 2 4 4 4 2 2 4 4 4 2 6 4 2 2 4 2 2 2 1 1 4 8 2 4 23 21--~.r 11.1>----21 32---ll 39 19~ 45 IS~ ·----\\---" Jb 15 ' ~\---1:3 @ [I FIG. S CYLINDER BLOCK AND HEAD, T'IIO AND 1116 Ref. No. Part No. DESCRIPTION QUANTITY CYLINDER BLOCK AND HEAD, T110 & TR6 1 2 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 E2894 E3332 E3332/TR6 W76 P01nA EHn H200 E1612 E3059 E3924 E2899 E2900 E3583 E3310 E3927 E1544 E1488 E1487 E1543 WE259A E2873 F2184 E3614 E3550 E3551 E3552 E2980 F879 E3302 E2982 S25-13 E2874 E1596A E1564 E1577 E1457 E1458 E1483 E1513 E470 E1330 E1575 E1574 E1512 E3253 E2620 E3646 E1496 E3547 Cylinder base washer Cylinder block Cylinder block Inner cylinder base nut Outer cylinder base nut Tappet guide block ... Tappet block screw h'." U.H.) Serrated washer Tappet CYLINDER HEAD cfw GUIDES ... Inlet valve guide Exhaust valve guide Exhaust pipe adaptor Inlet valve Exhaust valve Bottom cup ... Inner valve spring Outer· valve spring Top collar Split cotter ... Cylinder head bolt (3f" U.H.) Plain washer Cylinder head gasket Inlet rocker box Exhaust rocker box ... Joint washer Rocker box stud Oi" O.A.) Rocker box nut Plain washer Rocker box bolt (2/." U.H.) Plain washer Cylinder head bolt (5fi" U.H.) Cylinder head bolt (for torque stay) Inspection cap Joint washer ROCKER (right exhaust, left inlet) ROCKER (left exhaust, right inlet) Rocker bail pin Rocker adjusting pin Adjuster lock nut Thrust washer, i" Thrust washer, !" Spring washer Rocker spindle Sealing rubber Push rod Cover tube ... Bottom joint washer Top joint washer T110 TR6 1 1 1 4 4 4 4 2 2 2 2 2 2 4 4 1 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 8 8 4 4 8 8 1 1 1 2 2 6 6 6 6 6 6 4 4 4 4 2 2 2 2 4 4 4 4 2 2 2 2 4 4 4 4 4 4 2 2 6 6 4 4 2 2 2 2 4 4 2 2 2 2 2 2 25 23 ------<WI' ~---23 1----33 nr------- 28 ~------30 '-------29 22_j~~~~~~-27 47 ' 17-------" 14 llt--48 ~ 49 8--s !-· FIG. 6 CYLINDER BLOCK AND HEAD, TIZO 26 Ref. No. Part No. DESCRIPTION QUANTITY CYLINDER BLOCK AND HEAD, TUO T120 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ll 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 E2894 E3332 W76 P0172A E1477 H200 E1612 E3059 E4019 E3827 E3828 E3940 E3847 E3583 E3310 E3927 E1544 E3001 E300l E1543 WE259A E2873 F2184 E3614 E3550 E3551 E3552 E2980 F879 E3302 E2982 525-13 E2874 E1596A E1564 E1577 E1457 E1458 E1483 E1513 E470 E1330 E1575 E1574 E1512 E3253 E2620 E3646 E1496 E3547 Cylinder base washer Cylinder blo.:k Inner cylinder base nut Outer cylinder base nut Tappet guide blo.:k ... Tappet block screw(,'." U.H.) Serrated washer Tappet CYLINDER HEAD cfw GUIDES ... Inlet valve guide Exhaust valve guide Carburetter adaptor Adaptor lock! ng nut Exhaust pipe adaptor Inlet valve Exhaust valve Bottom cup ... Inner valve spring Outer valve spring Top collar Split cotter " . Cylinder head bolt (3f" U.H.) Plain Washer Cylinder head gasket Inlet rocker box Exhaust rocker box ... Joint washer Rocker box stud Hi-• O.A.) Rocker box nut Plain washer Rocker box bolt {2,&" U.H.) Plain washer Cylinder head bolt (Slt • U.H.) Cylinder head bolt (for torque stay) Inspection cap Joint washer ROCKER (right exhaust, left inlet) ROCKER (left exhaust, right inlet) Rocker ball pin Rocker adjusting pin Adjuster lock nut Thrust washer, ij • Thrust washer,!" Spring washer Rocker spindle Sealing rubber Push rod Cover tube ... Bottom joint washer Top jol nt washer 1 1 4 4 2 2 2 4 1 2 2 2 2 l 2 2 4 4 4 4 8 4 8 1 1 1 2 6 6 6 4 4 2 2 4 4 2 2 4 4 4 2 6 4 2 2 4 2 2 2 27 2 9 7 17 t-4 0 ~ 25 24 11 5 ~ i12 '\, 27 3&-- 35-- FIC. 7 CEARBOX AND CASINC ~ I& 15 6 Ref. No. Port No. DESCRIPTION QUANTITY GEARBOX AND CASING 1 1 1 1 1 1 1 1 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 T1S25 T1S28 T1S83 T1S26 T1S29 T1S84 T1S27 T1S30 T1S8S T1201 T341 EH49 T1367 T912 T981 T989 E698 T1562 T1367 T912 T-412 T45 546-1S PT104B E732 NE507 E3436 E3437 T323A T1534 T57 T23 T47 T-454 E3437 E3439 E3438 E3442 S1-51 S25-3 T1542 T1541 T1553 E1612 GEARBOX COMPLETE- STANDARD RATIO GEARBOX COMPLETE- STANDARD RATIO GEARBOX COMPLETE- STANDARD RATIO GEARBOX COMPLETE- CLOSE RATIO GEARBOX COMPLETE- CLOSE RATIO GEARBOX COMPLETE- CLOSE RATIO GEARBOX COMPLETE- WIDE RATIO GEARBOX COMPLETE- WIDE RATIO GEARBOX COMPLETE- WIDE RATIO GEARBOX CASING Camplate bush Peg Layshaft bush Peg Blanking disc Dowel ... Cover securing stud (2!' O.A.) GEARBOX INNER COVER Layshaft bush Peg Gearchange spindle bush Kickstarter stop Drain and level plug Fibre washer Filler plug Fibre washer Inner cover screw (1!' U.H.) Inner cover screw (f!' U.H.) Cover securing stud (1 fi' O.A.) GEARBOX OUTER COVER Gearchange spindle bush Kickstarter spindle bush Kickstarter spring anchor pin Guide ?late stud (!' O.A.) Cover screw (H' U.H.) Cover screw (1.,'1," U.H.) Cover screw (2-J'< U.H.) Cover screw (3' U.H.) Nut Plain washer Cover plate Joint washer Cover screw (i' U.H.) Serrated washer 6T 1 T110 TR6 1 1 T120 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 2 1 1 1 3 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 2 1 1 1 3 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 2 1 1 1 3 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 2 1 4 2 4 2 4 2 1 1 1 4 2 1 1 1 3 3 1 1 2 2 1 3 3 1 1 2 2 1 3 3 1 1 2 2 1 3 3 1 1 2 2 29 j 4 j 2 23 ~ j 3/ j 12~ 24 : - j II j 13----A 14 j 15 16 j 9 FIG. 8 GeARBOX SHAFTS ANI:I GEAR$ I j Ref. No. Part No. DESCRIPTION QUANTITY GEARBOX SHAFTS AND GEARS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ll 23 24 2S 26 27 28 29 30 31 3 4 6 9 11 12 13 14 1 2 3 4 5 6 7 a 9 10 11 T914 PT108B T1382 T1370 T917 T916 T926 T928 T1065 T930 T1063 T924 T925 T934 T825 T933 T948 T448 E489 T946 T471A T440 535-7 T280 T1338 T1250 T730 T731 T732 NT297 T1552 MAINSHAFT cfw LOW GEAR (16T) Clutch rod bush ... MAINSHAFT HIGH GEAR (26T) High gear bush Mainshaft third gear (24T) Mainshaft second gear (lOT) LA YSHAFT LOW GEAR (JOT) Low gear bush Layshaft second gear (26T) ... Layshaft third gear (22T) LAYSHAFT COMPLETE (lOT) Speedometer drive pinion (1 OT) Securing pin Speedometer driven gear (16T) Thrust washer ... Speedometer drive bush Rubber sealing ring High gear bearing Circlip ... High gear oil seal Gearbox sprocket (1ST) Gearbox sprocket nut Mainshaft bearing Circlip ... Kickstarter pinion sleeve Kickstarter pinion spring Kickstarter pinion Kickstarter ratchet Tab washer Mainshaft nut ... Clutch operating rod T1384 T1370 T968 T974 T971 T973 T925 T975 To convert to Wide Ratio Gears use Gear Set C.P.94 MAINSHAFT HIGH GEAR (28T) High gear bush ... Mainshaft second gear (19T) Layshaft second gear (27T) LA YSHAFT COMPLETE (1ST) Speedometer drive pinion (8T) Securing pin Speedometer driven gear (1ST) ... T1177 PT108B T1383 T1370 T1179 T955 T961 T928 T963 T964 T959 To Convert to Close Ratio Gears use Gear Set C.P.95 MAINSHAFT cfw LOW GEAR (1ST) Clutch rod bush MAINSHAFT HIGH GEAR (24T) High gear bush ... Mainshaft third gear (23T) ... Mainshaft second gear (21T) LA YSHAFT LOW GEAR (28T) Low gear bush ... Layshaft second gear (25T) Lays haft third ge" (23T) ... Layshaft cjw high gear (22T) 6T 1 1 1 1 1 1 1 1 1 T110 TR6 1 1 1 1 1 1 1 1 T120 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 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 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 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 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 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 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 1 1 1 1 1 31 2b 24 29 m-6 ,_, 39 i-s 38 ~l 12 28 Jr43 o:::._44 46 45~ "i0) 40 41 42 FIG. 9 GEARBOX SEI..ECTOR MECHANISM Ref. No. Part No. DESCRIPTION QUANTITY GEARBOX SELECTOR MECHANISM 6T 2 3 4 5 6 7 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 40 41 42 43 44 45 46 T260B T913 NT261 T291 TSOO T44 T373 T1604 T372 T397 T399 -fi"x1r' T408/1540 E3309 T404 T406 T405 T407 F879 E1612 T1194 T1564 W932 T449 T25A T31 T24A T1512 T451 T1270 T1271 T1272 T1167 S70-3 T1273 F1814 T1222 T1539 *"Xi T495 T402 T1536 T1538 E3412 T1554 E1612 T413 T453 Mainshaft selector fork Layshaft selector fork ... Selector fork roller Selector fork rod 2 1 Serrated washer Gearchange pedal Heel-and-toe gearchange pedal Pedal bolt (1" U.H.) Pedal rubber Kickstarter quadrant Kickstarter return spring Kickstarter axle Split pin ... Rubber cap Clutch operating arm CLUTCH OPERATING ARM Roller Roller fixing pin Screwed peg Serrated washer Clutch rod adjuster pin Adjuster pin nut 1 2 1 1 1 2 1 2 2 2 1 4 4 1 2 2 2 2 2 2 2 4 4 4 4 4 4 A A A 1 A 2 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 Kickstarter lever Clutch operating lever T120 1 1 1 2 Rubber sleeve Kickstarter crank FOLDING KICKSTARTER Kickstarter pedal ... Pedal locating spring Pedal locating ball. .. Pedal bolt (1·155' U.H.) ... Pedal rubber Cotter pin cfw nut and washer TR6 1 1 2 1 1 Gear selector camplate Camp'ate index plunger Index plunger spring Index plunger spring ... Index plunger holder ... Camplate operating quadrant Quadrant spindle Split pin ... Gearchange quadrant Rubber .. 0 .. ring Quadrant return spring Gearchange quadrant plunger Plunger spring Guide plate Nut T110 1 1 2 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 1 1 1 1 1 1 33 ~---9::: .... J: u :I u lQ ,..,~ N !::! S! ci ii: Ref. No. Part No. QUANTITY DESCRIPTION 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 25 T1548 T1586 T1549 T418 T394 T1039 T1038 T1041 T1472 T1473 T1044 T1040 T423A T1362 T1363 T986 T422 T998 T999 T1560 T427 S66-1 T1045 T1046 T1047 CLUTCH COMPLETE CLUTCH COMPLETE Sprocket and housing Hub Rollers ... Inner plate Centre (Shock absorber body) Shock absorber spider Drive rubber (large) ... Rebound rubber (small) Outer plate Countersunk screw (0-417" U.H.) Screwed pin (Hi'" U.H.) Driving plate (bonded) Driven plate (plain) PRESSURE PLATE 6T 1 T110 1 TR6 1 1 1 20 1 1 1 4 4 1 8 4 5 6 1 1 20 1 1 1 20 1 1 1 1 1 1 8 4 5 6 1 1 4 4 A 4 1 1 Spring cup Spring ... Spring (strong) Brass nut Key Cupped washer Tab washer ... Clutch securing nut 4 4 A 4 1 1 1 1 1 20 1 1 .. .. .. .. .. 4 1 8 4 5 6 1 1 Thrust button T120 1 .. 4 A 4 1 1 1 1 1 1 8 .. 5 6 1 4 4 4 1 1 1 1 35 w "' 33 32 14 10 1 ...____2 18-----_j FIG. 11 FRAME Ref. No. Port No. DESCRIPTION QUANTITY FRAME 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 18 19 20 21 22 23 24 25 25 26 27 28 29 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 F-4608 H111 S70-3 H1018 DS55 TI24 DS57 NW100 WE170 E-4115 E-4164 S26-1 S1-52 F2603 E3181 S26-3 E1310 S1-51 F.,304 F4763 H49 F3619 F-4484 F2725 F4671 F4670 F4712 F3723 F3097 F3096 F2610 F4609 F4684 F2842 F4685 S26-1 S1-52 F3780 PCW73A F4650 SCZ45 DS48 F-4647 S26-16 S25-2 S1-52 F1149 F879 Front frame Steering race cup Steel ball W diam.) Top cone and dust cover Steering stop bolt <fi" U.H.) Nut ... Plug screw(,'." U.H.) Grease nipple Fibre washer ... Engine torque stay Engine torque stay Spring washer Nut ... Bolt (li' U.H.) Bolt (2!' U.H.) Spring washer Nut ... Nut ... Centre stand ... Centre stand Pedal rubber ... Pivot bolt (1]\" U.H.) Tab washer ... Nut 6T 1 2 -40 1 2 2 T110 2 -40 TR6 1 2 -40 T12C 1 2 -40 1 2 2 2 2 2 2 1 2 1 2 1 2 1 2 2 2 2 2 2 2 2 1 1 1 1 2 2 2 Rear frame 1 1 ... ... Stud (3!" O.A.) Bolt (31t" U.H) Spring washer Nut ... Bolt (1]\" U.H.) Spring washer Brake pedal spindle ... Spring washer Nut ... Brake pedal ... Spring washer Plain washer Nut ... Pedal stop screw (-ji • U.H.) Nut ... 1 2 2 2 1 1 1 2 2 2 1 1 2 2 2 1 Return spring Rear frame 1 1 Return spring Return spring link PROP STAND COMPLETE PROP STAND COMPLETE Pivot bolt Tab washer 1 1 1 1 1 1 1 2 2 4 4 2 2 1 4 4 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 2 2 1 1 1 3 3 2 2 1 1 1 1 1 1 1 37 .... 00 l1 +--17 2 3 6 FIG. 12 SWINGING FORK AND SUSPENSION UNITS f8 Ref. No. Part No. DESCRIPTION QUANTITY SWINGING FORK AND SUSPENSION UNITS 1 2 3 4 5 5 6 7 8 9 10 11 12 13 13 13 14 15 16 17 18 18 18 18 18 19 20 21 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 F4131 F3690 F3564 F3574 F3683 F3684 F3797 F3798 F3799 F3774 F3780 PCW73A DS47 SB4/259 SB4{275 64054164 90541316A 9054/171 9054/151 9054/47 SA193j57 9054/63 9054/70 90541280 9054/69 E2113 S25-2 526-1 P0172A F4130 F4138 DS57 526-2 F4134 F4135 F2277 S25-13 F879 F4140 F4136 S25-3 51-51 F3597 ra' X j' W11 F4585 SWINGING FORK Pivot bush Spindle Spacing washer 0·003" Shim ... 0·005" Shim ... 6T 1 2 1 1 } Retainer rod .. , Cap Nut ... Brake torque stay ... Bolt (1ra" U.H.) Spring washer Nut ... SOLO SUSPENSION UNIT SIDECAR SUSPENSION UNIT SOLO SUSPENSION UNIT Bonded bush Spring retainer ... Outer dirt shield Inner dirt shield Spring 150 lbs. (sidecar) Blue;Red Spring 130 lbs. Red/Yellow Spring 110 lbs. Purple/Blue Spring 100 lbs. Green/Green Spring 90 lbs. (road racing) Yellow/White ... Unit fixing bolt (1 ~· U.H.) Plain washer Spring washer Nut Chainguard Chalnguard Bolt ... Spring washer Front bracket Pivot bolt Spring washer Plain washer Nut Centre bracket Stepped bolt ... Plain washer Nut ... Brake operating rod Split pin Pivot pin Adjuster nut ... ... T110 1 2 1 1 TR6 1 2 1 1 T120 1 2 1 as required 1 2 1 1 1 2 2 2 2 1 2 1 1 1 2 2 2 1 1 2 1 1 1 2 2 1 2 1 1 2 2 2 4 4 2 2 A A A 2 A 4 2 4 4 1 1 4 4 2 2 A A A 4 4 A 4 2 4 4 1 2 2 A A A 2 A 4 2 4 4 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 4 4 2 2 A A A 2 A 4 2 4 4 1 3 3 1 1 1 2 3 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 39 30 2 12---------" 10 '------36 18 35 FIG. ll ENGINE AND GI!!ARBOX FITTINGS Ref. No. Part No. QUANTITY DE.S CRIPT/ON ENGINE AND GEARBOX FITTINGS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 23 24 25 26 27 28 29 30 31 32 33 34 3$ 36 F-4651 F4719 F471S F3780 PCW73A DS47 F3760 F3451 F3571 F1711 F4682 F839 F3665 F862 F4681 526-1 P0172A $1-52 F3769 F3771 F3770 F3772 F4646 GS203 E1310 F-4669 S26·3 $1-51 F3592 T87 F987 F3593 SCZ45 DS48 NF704 F4695 Front engine plate Engine plate cover Screw ... Bolt (1 }\-' U.H.) Spring washer Nut ... Left rear engine plate Right rear engine plate Cover plate ... Stud (4/<" O.A.) Stud (7H"' O.A.) Stud (4Jir' O.A.) Stud (4!" O.A.) Distance tube Gearbox pivot bolt (8!" U.H.) Spring washer Nut Nut ... Gearbox top stud (4ft' O.A.) Flanged nut ... Clamping washer Sleeve nut Gearbox adjuster eyebolt Plain washer Nut ... Abutment pin Spring washer Nut Footrest hanger rod Left distance piece Left footrest Right footrest Spring washer Nut ... Pedal rubber ... Crankcase undershield 6T 1 1 1 2 3 3 1 1 1 2 2 4 1 2 1 18 16 2 1 1 1 T110 1 1 1 2 TR6 1 T120 2 2 3 3 3 1 3 3 1 1 1 2 2 4 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 2 1 1 1 1 1 1 1 2 2 A 3 1 1 1 2 2 4 1 2 1 18 16 2 1 1 1 1 1 2 1 2 2 4 1 2 1 18 16 1 1 1 18 16 2 1 1 1 1 1 2 2 1 1 2 2 1 1 1 1 1 1 1 2 2 2 A 1 1 1 1 1 1 2 2 A 41 ~~~~-----------------4 7----T,T:, ~~-nr-----------------3 6-------;IT~~-~ 14 3 20 21 4 ~-------18 ~r---------17 14-----f ~--------------6 fiG. 14 CHAINCASE AND ALTERNATOR 41 Ref. No. Pan No. QUANTITY DESCRIPTION CHAIN CASE AND ALTERNATOR 1 2 2 3 4 5 6 7 8 9 9 10 11 12 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 T1477 T1603 T1600 T91 T177A T1381 E3437 E3978 E3979 E3980 E4123 S25-3 E1310 469427 47134 T1059 T1226 T1237 T1601 T496 T497 NT316 NT367 NT376 PCE102F WE170 E3449 E3440 D301 D438 Joint washer INNER CHAINCASE INNER CHAINCASE Retainer plate Rivet Oil sealing plate Screw (H" U.H.) Adaptor ring Flanged head bolt (1f." U.H.) Stud (1f" O.A.) Stud (1 H" O.A.) Plain washer Nut Stator ... 6T 1 f T110 1 1 1 1 11 1 3 3 3 3 1 Stator ... Cable grommet Joint washer Outer chain case Outer chain case Oil restrictor screw Spring Footrest dowel Filler plug Leather washer Drain plug Fibre washer ... Screw (2!" U.H.) Screw (111" U.H.) Primary chain (!" X ,a.• X 70L) Rear chain (V x i • x 99L) 1 1 1 1 1 4 1 1 1 1 4 1 1 TR6 1 T120 1 1 1 1 11 1 3 1 1 1 1 11 1 3 1 1 1 11 1 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 4 1 1 1 1 4 1 1 4 1 1 4 1 1 t 7 6 2 23 26 25 28 29 30 27 2431 29 30 LJ tr-----13 ----14 '-----15 2 1 - -... , IZ ----12 C?n 5 3 7 6 8 II 9 16 1415 FIG. IS i~T 10 811 9 EXHAUST PIPES AND SILENCERS 32 31 343536 Ref. No. DE.SCRIPTION Part No. QUANTITY EXHAUST PIPES AND SILENCERS 1 1 2 2 3 4 5 6 7 B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 13 24 25 16 27 28 29 30 31 32 33 l4 35 36 E3426 E4133 E3350 E3632 E4125 E4130 E1269 E409 E410A E3469 TE164E TE164C TE164D F4707 DS57 $16-2 F879 F4265 F1369 E411B E4119 E4107 H689 H745 E3767 F3430 E376B E1310 E4110 F3641 Sl6-3 $1-51 H416 E413l H622 F2694 Sl6-1 51-51 Left exhaust pipe Left exhaust pipe Right exhaust pipe Right exhaust pipe Left exhaust pipe Right exhaust pipe Finned cUp ... Clip bolt (1f. • H.H.) Spherical washer Extension pipe and silencer clip Clip bolt (1f." U.H.) .. D" Nut "D" Washer Exhaust pipe bracket Bracket bolt Ci." U.H.) Spring washer Nut ... Pipe to frame clip Clip bolt (I' U.H.) ... Left silencer ... Right silencer Silencer mute Screw W U.H.) Nut Silencer dip ... Clip bolt (1!" U.H.) .. D" Washer Nut ... Sflencer stay Frame stud ... Spring washer Nut ... Silencer hanger bolt (fl" U.H.) Silencer Silencer hanger bolt (1 !-6 • U.H.) ... Distance piece Spring washer Nut ... ... 6T 1 T110 TR6 T120 1 1 1 1 1 1 l 2 l l 2 2 2 2 l 2 2 2 2 2 l 2 2 2 2 l 1 1 l 2 2 l 2 4 2 1 1 3 3 2 2 2 2 l 2 2 1 1 1 1 1 1 2 2 2 2 2 4 2 2 2 1 1 2 2 1 2 2 4 2 2 1 3 3 2 2 1 3 3 2 1 1 1 1 1 45 a 41 7 Comlll- - l i l y Ref. No. 1. r----------34 -------35 14------~ 39------i. 32 33 31 2324;1 ~~20 30 ~21 29 22 28 FIG. 16 TI!LESC:OI'IC: FRONT FORK, 6T AND TtiO 27 Ref. No. Port No. DESCRIPTION QUANTITY TELESCOPIC FRONT FORK, 6T 1r TffO 1 2 3 4 5 6 7 8 9 10 11 12 13 H 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 H1310 H1283 H439 H941 S25-2 E2412 H1141 H1108 F1760 H379 H1288 H1289 H420 H1123 H443 H1058 H519A H1117 H1118 H1053 S26-3 H1070 H1071 H430 H1063 H1062 H1124 H1061 H1060 H1125 H1292 H1301 H1064 H1051 H106S H1066 H1126 H441 H431 H1194 H1168 H1142 H565 H408 H1286 H9S H1285 H43S H660 S25-3 E1310 FORK ASSEMBLY ... Middle lug and stem Bottom cone Pinch bolt (2!" U.H.) ... Plain washer Nut Fork stem sleeve nut Top lug ... Pinch bolt (1 tl" U.H.) Seated nut Left nacelle cover Right nacelle cover Sponge rubber washer STANCHION c/w BEARING Lower bearing Bearing nut Oil filler plug (i'." U.H.) LEFT BOTIOM MEMBER c/w CAP RIGHT BOTIOM MEMBER c/w CAP Spindle cap Spring washer Cap bolt (1 ,'." U.H.) Drain plug Fibre washer Flanged bolt (H" U.H.) Aluminium washer RESTRICTOR ROD ASSEMBLY Restrictor rod Plain washer Guide cube Solo main spring (Black) Sidecar main spring (Red/White) CAP NUT ASSEMBLY Guide tube Cap nut Pin ... Damping sleeve Top bearing Plain washer DUST EXCLUDER SLEEVE NUT Oil seal Steering damper rod c/w knob Plain washer 6T 1 1 1 2 2 2 1 I 1 1 1 1 2 2 2 2 2 1 2 4 4 2 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Plain washer 1 1 1 1 1 1 2 4 Nut 4 Adjuster sleeve Locating pin Spring plate Anchor plate Friction disc Handlebar "U" bolt T110 1 1 1 2 2 2 1 1 1 1 1 1 2 2 2 2 2 1 1 2 4 4 2 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 2 4 4 47 29 la-28 ~-------1 -------6 ' \ 10 9 14 \ 40 3b FIG. 17 NACELLE, HEADLAHP AND SWITCHES 37 39 38 Ref. No. OESCRJPTION Part No. QUANTITY NACELLE, HEADLAMP AND SWITCHES 1 1 1 3 .. 5 I 6 7 8 9 10 11 11 13 H 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 40 H11+4 H1198 H961 H669 H877 H878 H689 H688 H687 E1880 H691 H690 51860 553148 516812 50-4665 553267 534296 373 5S4601 988 554710 31+43 318323 318341 319333 a18346 318343 31784 36189 31071 H992 H993 GS299 F3799 H1172 70048 701851 1'42689 185051 54094162 54094163 Nacelletop ... Nacelle top ... Rubber grommet Rubber grommet Left motif Right motif ... Screw (l;' U.H.) Screw (f." U.H.) Screw W U.H.) Serrated wa•her Nut ... Nut HEADLAMP ... Rim Light unit Fixing wire Fixing ring Screw and plate Bulb (30/24W. L.H. dipping, Pre-focus) Adaptor ... Bulb (3W.M.C.c.) Pilot bulbholder LIGHTING AND IGNITION SWITCH (P.R.S.8) Grommet Key Screw Knob ... Index plate lighting $Witch (S.A.-41) ... 6T 1 3 1 1 1 1 3 1 1 1 2 2 2 2 ~ 4 .. .. ... .. .. 2 2 1 1 1 1 1 6 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Ammeter Cut-out button (S.S.5) Horn grille ". Screw (0·540" U.H.) Serrated washer Nut Horn bracket Horn ... Fixing plate ... Screw ... Spring washer Wiring harness Wiring harness T110 2 2 2 1 1 2 2 2 1 2 2 2 1 1 2 2 2 1 8 7 9 10 II 45 Complete Attembly Ref. No. 1. 12 13 46 15 3 4B 2 51 50 49 47 38 39 18 36 23 -37 35 :;1 ~~24 34 F~ 33 26 32 FIG. 18 TII!LESCOPIC FRONT FORK, TR6 ANO TI:IO 50 31 Ref. No. Port No. DESCRIPTION QUANTITY TELESCOPIC FRONT FORK, TR6 6 T110 46 H1311 H1283 H439 H941 S2S-2 E2412 H40S H1287 HS06 S2S-3 H-436 F1760 H379 H963 H964 H420 H962 D340 H1299 H-443 H1058 H1117 H1118 H1053 S26-3 H1070 1-!1071 H430 H1063 H1062 H1124 H1061 H1060 H1125 H1300 H1305 H1064A H1051 H1065A H1066 H1126 H-441 H431 H1194 H1168 H1142 H565 47 H408 48 H1286 H95 H1285 H43S 1 2 3 4 s 6 7 8 9 10 11 12 13 14 1S 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 35 36 37 38 39 40 41 42 43 44 45 49 50 51 FORK ASSEMBLY ... Middle lug and stem Bottom cone Pinch bolt (2!• U.H.) ... Plain washer Nut Fork stem sleeve nut TOP LUG cjw CAPS ... Handlebar cap Plain washer Clamping bolt W U.H.) Pinch bolt (111• U.H.) Seated nut Left nacelle cover Right nacelle cover Sponge rubber washer Telescopic gaiter Gaiter clip STANCHION cjw BEARING Lower bearing Bearing nut LEFT BOTIOM MEMBER cjw CAP RIGHT BOTIOM MEMBER cjw CAP Spindle cap Spring washer Cap bolt (1 i. • U.H.) Drain plug Fibre washer Flanged bolt (ii" U.H.) Aluminium washer RESTRICTOR ROD ASSEMBLY Restrictor rod Plain washer Guide tube Solo main spring (Black/White) Sidecar main spring (Black/Red) CAP NUT ASSEMBLY Guide tube Cap nut Pin ... Damping sleeve Top bearing Plain washer DUST EXCLUDER SLEEVE NUT Oil seal Steering damper rod cjw knob Plain washer Adjuster sleeve Locating pin Spring plate Anchor plate Friction disc TR6 1 1 1 2 2 2 1 1 2 T120 1 1 1 2 2 2 1 1 2 1 1 1 1 2 2 2 2 2 2 1 1 2 1 1 1 1 2 2 2 2 2 2 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 ... ... .. .. 51 Compl- Aaclllly Ref. No. I. 2 FIG. 19 FRONT WHEEL, 6T Ref. No. Port No. DESCRIPTION QUANTITY FRONT WHEEL, 6T 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2S 26 27 28 29 30 W1398 W1370 W1373 W1328 $79-2 W1231 W1239 W653 W1237 nao W1238 W582 W1334 W1197 W1198 W1301 W1302 525-2 E1435 W93 W93 NW243 W129 W135 W1243 W1298X 51-52 S2S-6 W592 W1246 FRONT WHEEL COMPLETE RIM, SPOKES AND HUB ASSEMBLY Front wheel rim WM2-18 Spoke (8/10G x SJ*, straight) cfw nipple Spoke nl pple Hub and brake drum Wheel spindle Bearing ... Dust cover Clrcllp ... Backing ring Retaining ring Cover plate Balance weight, i oz. } Balance weight, 1 oz. Brake anchor plate Fulcrum pin Plain washer Domed nut BRAKE SHOE cjw LINING BRAKE SHOE cfw LINING Brake lining Brass rivet ... Shoe return spring Brake cam Brake cam lever Nut Plain washer Lever return spring Anchor plate nut 6T 1 1 1 -40 -40 1 1 2 1 1 1 1 1 ... as required ... 1 1 1 1 1 1 2 16 2 1 1 1 1 1 1 53 2 FIG. 10 FRONT WHEEL, T110, TR6 AND TllO Ref. No. Part No. DESCRIPTION QUANTITY FRONT WHEEL, T110, TR6 & T110 1 1 2 2 3 3 4 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 W1399 W1323 W1371 W1324 W1374 W1230 W1275 W1328 579-2 W132S W1239 W653 W1237 T280 W1238 W582 W1332 W1197 W1198 W1330 W1302 525-2 E143S W1337 W1338 W1336 W129 W135 W1243 W1331X S1-52 S25-6 W592 W1246 FRONT WHEEl COMPlETE FRONT WHEEl COMPLETE RIM, SPOKES AND HUB ASSEMBlY RIM, SPOKES AND HUB ASSEMBLY Front wheel rim (WMl-18) Front wheel rim (WMl-19) Spoke (8j10G x S!J", straight) cjw nipple Spoke (8j10G x 5!", straight) cfw nipple Spoke nipple Hub and brake drum Wheel spindle Bearing ... Dust cover Circlip ... Backing ring Retaining ring Cover plate Balance weight, l oz. } Balance weight, 1 oz. Brake anchor plate Fulcrum pin Plain washer Domed nut lEADING BRAKE SHOE cJw LINING TRAILING BRAKE SHOE cjw LINING Brake lining Brass rivet ... Shoe return spring Brake cam Brake cam lever Nut Plain washer lever return spring Anchor plate nut . .; T110 TR6 1 1 1 1 1 1 40 40 40 40 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 T120 1 1 1 40 40 1 1 2 1 1 1 1 1 as required 1 1 1 1 1 1 2 16 2 1 1 1 1 1 1 2 16 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 16 2 1 1 1 1 1 1 55 Compi-Aaembly lief. No. t 2 34 22 31 32 33 29 28 24 21 30 23 26 252o1o e II 9 1b 27 FIG. 21 15 14 4 7 3 13 17 REAR WHEEL 35 14 5 b 12 19 18 34 31 32 33 Ref. No. Port No. QUANTITY DESCRIPTION REAR WHEEL 1 1 1 2 2 2 3 3 3 4 4 5 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 35 Wl-400 W1401 W1402 wnn W1308 W1306 W1378 W1007 W79A W1107 W1104 W1108 W1106 579-2 W1158 W1276 W62 51-51 W63 W1025 W10ll W653 W1021 W1079 W1023 W583 W1026 W1024 W1112 F1747 W93 NW243 W129 W135 W1083 W1085 51-52 W1090 W1134 W1015 W1058 F1747 D106 WM3 REA~ WHEEL COMPLETE REAR WHEEL COMPLETE REAR WHEEL COMPLETE RIM, SPOKES AND HUB ASSEMBLY RIM, SPOKES AND HUB ASSEMBLY RIM, SPOKES AND HUB ASSEMBLY Rear wheel rim (WMl-18) Rear wheel rim (WM3-18) Rear wheel rim (WMl-19) Spoke (8j10G x 7fo" 90°) cjw nipple ... Spoke (8/10G x 8" 90°) cjw nipple Spoke (8j10G x 7i" 90°) cjw nipple Spoke (8j10G x Sf' 90°) cjw nipple Spoke nipple Hub Sprocket and brake drum (43T) Sprocket to hub bolt (H" U.H.) Nut Sprocket bolt lockplate Wheel spindle ... Backing ring Bearing ... RETAINING RING Locking screw (f." U.H.) Distance tube Dust cover Nut Distance piece Brake anchor plate Nut BRAKE SHOE cjw LINING Brake lining Brass rivet ... Shoe return spring 6T 1 Nut Chain adjuster Adjuster end plate Self-locking nut Spindle nut ... Tyre security bolt Tyre security bolt T120 1 1 1 1 1 1 1 1 20 20 20 20 20 20 40 1 1 8 8 8 1 1 2 1 1 1 1 1 40 1 1 8 8 8 1 1 2 1 1 1 1 1 1 1 1 2 2 16 2 1 40 20 1 2 2 16 2 Brake cam Brake cam lever Lever return spring T110 TR6 1 1 1 1 2 2 2 2 1 1 1 2 2 2 2 1 1 8 8 8 1 1 2 1 1 1 1 1 1 1 1 2 2 16 2 1 1 1 1 2 2 2 2 20 40 1 1 8 8 8 1 1 2 1 1 1 1 1 1 1 1 2 2 16 2 1 1 1 1 2 2 2 2 1 1 57 ~ Complete Assembly Ref. No.1. 2 33 24 31 25 26 27 17 18 20 40 21 7 3 4 5 9 13 15 34 I 37 38 39 30 32 25 28 29 FIG. n 19 23 22 10 9 8 16 14 QUICKLY DETACHABLE REAR WHEEL 6 8 II 12 37 35 36 Re(. No. Part No. DESCRIPTION QUANTITY QUICKLY DETACHABLE REAR WHEEL 1 1 1 2 2 2 3 3 3 4 -4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 14 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 4Q 4Q W14QJ W1404 W1405 W1375 W1099 W1098 W1378 W1007 W79A W1107 W1104 W1108 W1106 S79-2 W1100 W1033 W1034 W1035 W1036 W1037 W1038 W1039 E398 W1091 W1376 W1143 W1041 W1042 W1043 W1044 W1045 W1121 W93 NW243 W129 W135 W1083 W1085 S1-52 W1090 W1052 W1053 W1170 W1055 W1135 W1015 W1058 D106 WM3 Q.D. REAR WHEEL COMPLETE Q.D. REAR WHEEL COMPLETE Q.D. REAR WHEEL COMPLETE RIM, SPOKES AND HUB ASSEMBLY RIM, SPOKES AND HUB ASSEMBLY RIM, SPOKES AND HUB ASSEMBLY Rear wheel rim (WM2-18) Rear wheel rim (WMJ-18) Rear wheel rim (WM2-19) Spoke (Bj10G x 7f." 90") c/w nipple ... Spoke (8j10G x B" 90°) cjw nipple Spoke (8/10G x 7!" 90") cjw nipple Spoke (8110G x Bi' 90") cjw nipple Spoke nipple Hub Backing ring Taper roller bearing complete Dust cap Felt washer Distance piece Dust cap Bearing sleeve Bearing adJuster nut ... Rubber sealing ring Sprocket and brake drum (-43T) Grease retainer Bearing ... Felt washer Bearing and felt retainer Cirdip Bearing sleeve ... Brake anchor plate BRAKE SHOE cfw LINING Brake lining Brass rivet .•. Shoe return spring Brake cam Brake cam lever Nut Lever return spring Nut Inner distance piece Outer distance piece Spindle Chain adjuster Adjuster end plate Self-locking nut Tyre security bolt Tyre security bolt 6T 1 1 T110 TR6 1 1 T120 1 1 1 1 1 1 1 20 20 20 20 20 20 20 20 4Q 1 2 4Q 4Q 4Q 1 1 2 2 1 1 1 1 1 2 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 16 2 1 1 1 1 1 1 1 1 2 2 2 1 1 1 2 2 16 2 1 1 1 1 1 1 2 2 2 1 2 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 2 16 2 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 2 2 16 2 1 1 1 1 1 1 1 1 2 2 2 1 1 59 ~----------------~ ,----44 'e.-----35 ----45 ~------46 --------37 . • - --=--~---- • 7-& 20 38~-----1/ 41---···-·-\ 4o 31 ,. - - - - 2 4 39 • ~' I 26 .-r---23 '}---.u a ~ 42---~~-------11 .. 34 I ' 13 I 14 I 4 FIG. 2l PETROL TANKS 60 32 I 15 Ref. No. Port No. DE.SCRIPTION QUANTITY PETROL 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 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 F-4640 F4148 F4766 F4129 F4665 F2551 F1953 F4551 F4767 F4667 F2552 F4700 F4235 F4127 F4236 F3915 525-13 T361 F1606 F4237 F4128 F4238 F3916 F1605 F3220 F3219 F4048 F1511 F3329 F1717 F3057 F3116 F4641 F4770 F4655 F4699 F4657 F4658 F4656 525-3 Petrol tank (4 gallons) Styling strip (left, front) Styling unit (left) Styling unit screw (0·435" U.H.) Styling strip (left, rear) Knee grip (left) Knee grip screw (i" U.H.) Styling strip (right, front) ... Styling unit (right) ... Styling strip (right, rear) Knee grip (right) Petrol tank (3 gallons) Styling strip (left, front) Styling unit (left) ... Styling strip (left, rear) Knee grip plate (left) -tlr" X!" Split pin Eyebolt Self-locking nut Rear bolt (1~" U.H.) Spring washer Nut ... Parcel grid Parcel grid screw F4659 W1058 F2596 526-2 51-51 F3917 F2936 6T 1 1 1 4 1 1 4 1 1 1 1 Plain washer Knee grip plate bolt (i" U.H.) Kr.ee grip (left) Styling strip (right, front) ... Styling unit (right) ... Styling strip (right, rear) Knee grip plate (right) Knee grip (right) FILLER CAP FILLER CAP c/w JACK CHAIN Joint washer Fibre washer ... Blanking plug Petrol tap Petrol tap (left) Petrol 1 1 2 1 1 3 1 1 1 1 3 1 1 1 1 1 3 2 1 1 1 1 1 1 4 1 1 1 3 2 1 1 1 1 1 1 4 tap with reserve tube Mounting rubber Steady rubber Securing strap Securing strap Securing strap rubber Front yoke ... Yoke pin Plain washer T110 TR6 1 1 1 4 4 1 1 4 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 2 2 1 1 3 1 1 1 1 1 3 2 1 1 1 1 1 1 4 T120 1 1 1 4 1 1 4 1 1 1 1 1 1 2 2 3 1 1 1 1 3 2 1 1 1 1 1 1 4 61 32 31 9 26-- 9------23 ·~------22 20 FIG. 24 OIL TANKS 62 Ref. No. Part No. DESCRIPTION QUANTITY OIL 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 31 32 33 34 35 36 37 38 39 F4476A F4477 F4478 F4702 F1792 PT104B F3796 F3658 F4048 F4533 F3179 F1713 F3182 E4113 F3655 MF119f20 E3353 E3354 MF120 E4109 E3355 E1529 E4114 E1539 525-3 51-51 T1579 T1578 F1213 E2287 F2335 526-3 51-51 F3641 F1008 E3383 E4159 E1335 E1435 6T 1 1 1 Oil tank FILLER CAP Joint washer T110 TR6 1 1 1 Oil tank Drain plug Fibre washer FILLER CAP cjw JACK CHAIN FILLER CAP 1 1 1 000 T120 1 1 1 Joint washer Oil tank filter Oil tank filter 1 Fibre washer ... 1 1 1 1 1 1 1 Union nut Upper feed pipe Upper feed pipe 1 2 Rubber connector 2 Rubber feed pipe Rubber return pipe Ferrule Oil pipes and junction block Oil pipes and junction block oo• 1 Joint washer Crankcase stud (1!" O.A.) Crankcase stud (1ft O.A.) Plain washer Nut Vent pipe Vent pipe Bolt (tl" U.H.) 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 4 2 1 2 2 1 1 1 1 4 2 oo· Serrated washer Bolt (tl" U.H.) Spring washer Nut Stud (ti" O.A.) Nut 000 1 1 1 2 1 1 3 3 2 1 1 3 3 4 2 1 1 4 2 000 Rubber connector Rocker oil feed pipe Copper washer Domed nut 000 63 23--~ 21---~~~k 24--- ------16 9--- ;-----6 llt-----33 lt------34 FIG. U 64 BAlTERY CARRIER AND AIR FILTER Ref. No. Port No. DESCRIPTION QUANTITY BATTERY CARRIER AND AIR FILTER 1 2 3 4 5 6 7 8 9 9 10 11 12 13 14 15 16 17 18 29 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 F-4660 F-4661 F-4662 E3200 F1369 DS57 S25-1 F879 F4705 F4706 F3588 F1668 F1727 E534 E535 E536 F3874 F3875 F3227 F1213 F2335 S26-3 S1-51 F3641 F1008 F4673 F-4672 F3858 F3859 F4698 F3315E F3376 E1612 MLZ9E F4814 PU7E-9 Battery carrier Top strap Packing rubber Screw Cit" U.H.) Bolt (t' U.H.) Bolt (tlr' U.H.) Plain washer Nut ... BATTERY CASE AND TOOLBOX BATTERY CASE AND TOOLBOX Top strap Side strap Hinge pin Plain swivel Threaded swivel Bolt (1 it R U.H.) TOOLBOX LID Lid fastener Aluminium grommet Bolt (fj' U.H.) Bolt (it' U.H.) Spring washer Nut ... Stud (fV O.A.) Nut ... Air filter Rubber connector Rubber connector Clip , .. AIR FILTER ... Element only Screw U ln. U.H.) Serrated washer Battery cjw lid Plastic vent pipe Battery 6T 1 1 1 1 1 1 2 2 T110 TR6 T120 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 65 ~21 19------ .~l 20 .~;~$' :n 28 ------35 31 30 FIG. :16 MUDGUARDS Re(. No. Port No. Df.SCRII'TION QUANTITY MUDGUARDS 1 2 3 4 5 6 7 8 9 10 11 11 13 14 15 16 17 18 19 10 21 22 23 24 15 26 17 28 29 30 31 32 33 34 35 36 37 38 39 40 41 H1097 F929 F-'1299 H1100 W62 525-2 NS362 H1294 H1271 H129S OSS7 SlS-1 F879 TlH H412 H424 SlS-71 51-51 F2698 H2S1 F4332 S26-2 F879 F2996 H741 H687 H745 F-4674 OS57 S26-2 F4716 F4717 F-4687 F3599 F3896 F879 F-4690 F929 S26-3 51-51 F3363 Front mudguard Bolt(!" U.H.) Plain washer Bottom stay ... Bolt (it' U.H.) Plain washer Spigot nut Mudguard blade Front stay Mudguard bridge Bolt (}70 U.H.) Plain washer Nut ... Nut ... Bottom stay ... Bolt (I£' U.H.) Plain washer Nut Number plate Plate beading Packing piece Spring washer Nut ... Number plate Clip assembly Screw (i" U.H.) Nut ... Rear mudguard Bolt (i<' U.H.) Spring washer Screw (1i' U.H.) Nut ... Rear mudguard Bracket lifting handle Nut ... Clip ... Bolt (f" U.H.) Sprl ng washer Nut ... Number plate 6T 1 2 2 1 2 2 1 T110 TR6 1 2 2 2 1 2 2 1 1 1 1 1 T120 " " 2 1 1 1 1 "" "" " "2 ... 2 1 1 1 1 ... 1 1 1 2 2 1 1 1 1 1 1 2 2 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 2 2 2 6 6 6 6 1 1 1 6 1 2 2 2 1 1 1 1 6 1 1 2 2 1 67 ~_:3~~25 "---+-:!:-- 9 14 ~nr~ 1 II \ l 101213 15 8 FIG. Z7 PANELS AND TWINSEAT 68 Ref. No. Pan No. DESCRIPTION QUANTITY PANELS AND TWINSEAT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 20 21 ll 23 24 25 26 27 28 29 30 31 32 F-4676 F46n F4663 F4664 F4317 F4249 F4715 F4717 F#83 F4680 F2335 526-3 51-51 F4686 F1369 526-2 F879 F3098 F4239 F-4691 F4244 F4475 F42ll DS57 526-2 0374 F4226 F4ll8 E1719A /.' X F4ll7 F4361 F4365 t' Left panel Right panel Motif "Thunderbird" Motif "Tiger 11 0" Spire nut Joint beading Screw Ui' U.H.) Nut Self-tapping screw Clip ... Bolt (fl" U.H.) Spring washer Nut Number plate Bolt (t' U.H.) Spring washer Nut ... Vent pipe dip TWINSEAT ... TWINSEAT cJw BRACKETS Twlnseat cover cJw dips Clip Hinge Bolt h\·' U.H.) Spring washer Check wire ... Seat catch plunger Spring Plain washer ... Split pin Knob ... Safety strap Self-tapping screw ... ... 6T 1 1 2 6 2 T110 TR6 1 1 2 6 2 5 5 5 5 2 2 2 2 1 2 2 2 1 1 2 2 2 2 1 2 2 2 1 1 5 5 1 2 4 4 1 1 1 1 1 1 A 4 T120 1 1 1 as required 2 1 1 4 4 1 1 1 1 1 1 A 4 A 4 A 4 69 34 44 Complete Ref. No.1 ., , 2 ., ., 3 Assemblies 6T, T110. TR6. T120. 25 22 i9ASSY. 43-----_/ 40 --------"-',y 42 FIG. 28 70 41 HANDLEBARS 5 Ref. No. DESCRIPTION Part No. QUANTITY HANDLEBARS 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 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 H1223 H1224 H1313 H1009 H811 H1003 H697 H698 H665 H685 H686 H234 H237 H700 H233 H232 H230 H230A 18j886 18j908 18f894 18f909 12/614 12/613 18/535 18/754 18/528 18j752 18/890 18/892 12/044 11/014 H668 61/004 18/087 18/053 18/838 18/839 18{880 12j556 12!014 12j607 12/606 12/033 31563 H689 HANDLEBAR cfw CONTROLS HANDLEBAR cfw CONTROLS HANDLEBAR cfw CONTROLS Handlebar Handlebar Handlebar TWISTGRIP ASSEMBLY Twistgrip head assembly (Nos. 8-12) Friction screw Spring Friction spring Cable thimble Grub screw Sleeve Retaining plate Circlip Rubber grip (and at left handlebar) Left rubber grip FRONT BRAKE lEVER ASSEMBLY FRONT BRAKE LEVER ASSEMBLY (Ball-end) ClUTCH lEVER ASSEMBLY CLUTCH lEVER ASSEMBLY (Ball-end) AIR lEVER ASSEMBlY MAGNETO LEVER ASSEMBLY Brake lever Brake lever (Ball-end) Clutch lever Clutch lever (Ball-end) Brake lever bracket Clutch lever bracket Clamp Screw Clamp Screw Fulcrum screw Self-locking nut Cable adjuster Thumb nut Barrel nipple Air lever . " 6T 1 T110 TR6 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 2 1 1 1 1 1 2 2 2 2 2 2 ... Magneto lev-er Centre bolt Cap ... Spring washer Horn push and dip switch Screw(!' U.H.) T120 1 2 1 2 1 1 1 3 6 1 2 2 2 2 2 1 1 1 2 2 2 1 2 1 1 1 2 1 2 2 1 2 2 2 1 2 71 AIR CONTROl CABLE 27 26 32 FIG. 29 CONTROL CABLES AND AMERICAN HANDLEBARS n ll.e(. No. Pan No. DESCRIPTION QUANTITY CONTROL CABLES AND AMERICAN HANDLEBARS 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 35 36 36 37 38 39 CLUTCH CABLE ... Ferrule ..• Nipple FRONT BRAKE CABLE FRONT BRAKE CABLE Ferrule ... Nipple Fork end ... Pivot pin Split pin g' Xi' H1171 Clip H916 Screw (/,' U.H.) GS299 Serrated washer H745 Nut ... 0224 THROTTLE CABLE 0439 THROTTLE CABLE 0421 THROTTLE CABLE Twlstgrlp cable 0422 Junction box 244/104 Carburetter cable 0423 0101 Ferrule ... H670 Guide tube D83 Nipple NS191 Nipple ... D104 AdJuster AIR CONTROL CABLE 0435 MAGNETO CONTROL CABLE D100 D101 Ferrule D83 Nipple NS191 Nipple ... Magneto cable end fittings supplied with magneto AMERICAN HANDLEBAR cjw CONTROLS H1246 AMERICAN HANDLEBAR cjw CONTROLS H1228 AMERICAN HANDLEBAR cjw CONTROLS HUH American handlebar H1247 American handlebar H1179 0434 Clutch cable ... 0415 Front brake cable 0417 Front brake cable D257 Th rotde cable D+IO Throttle cable 0424 THROTTLE CABLE 0425 Twistgrip cable Magneto control cable 0260 0432 0103 0368 0414 0416 0103 0368 W593 WF32 6T 1 2 2 1 ... 2 ... ... ... 1 1 1 1 1 1 1 1 1 T110 TR6 1 1 2 2 2 1 2 1 1 1 1 1 1 1 1 1 2 T120 1 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 ... ... 1 2 1 3 1 1 1 1 1 1 3 1 1 1 ... 3 1 1 1 1 1 1 4 2 1 10 1 1 s 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 73 I 7 3 4 17 z FIG. l8 TOOL IUT, FRAME LOCit, PILLION FOOTREST AND LICENCE HOLDER Ref. No. 1 2 l 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 Pan No. DESCRIPTION QUANTITY TOOLKIT, FRAME LOCK, PILLION FOOTRESTS AND LICENCE HOLDER 6T T110 TR6 0365 TOOLKIT COMPLETE 1 1 1 WA58 Tool roll 1 1 1 0360 Open spanner, !" x .... Whit. 1 1 1 0361 1 Open spanner, t.• X !" Whit. 1 1 1 NA55 Open spanner, !" x -/ir Whit. 1 1 1 OA16 Open spanner, i" x -,1," Whit. 1 1 PA57 1 Ring spanner, i • x f. • Whit. 1 1 1 0311 1 Ring spanner, i" x fV Whit. 1 "C" Spanner and Tappet Key 1 0362 1 1 Plug spanner 1 087 1 1 1 0363 Tyre lever and screwdriver 1 1 1 0364 Tyre lever and clutch key 1 1 Phillips No. 3 Screwdriver 1 0336 1 1 Clutch Hub extractor oo• 1 1 OA50/1 1 1 400935 Screwdriver 415116 Spanner 1 1 0296 Tyre Inflator 1 1 1 A 0220 Fork spanner A A 1 FRAME LOCK cfw KEYS oo• 1 0402/3 1 1 0403 Key (state number) 1 1 2 F4327 PILLION FOOTREST 2 2 2 F1694 2 Pedal 2 2 F2268 Hanger oo• 2 2 2 F4309 Stud (11" O.A.) 2 2 2 F2271 Pivot bolt 2 2 2 F2277 Thackeray (Spring) Washer 2 2 2 51-51 Nut 2 2 2 526-1 Spring washer 2 2 2 Nut 2 51-52 2 2 F1695 Pedal rubber 2 2 0261 Licence holder 0557 Bolt (-,1,-" U.H.) Serrated washer E1612 F879 Nut 000 000 T120 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 A 1 2 2 2 2 2 2 2 2 2 2 1 75 13 '0? 12 ~--------------------·~ 19 ~--------------42 --------------43 ~---------------48 26----11 2 49 47 41 31 39 32 33 36 18 22 25 37 16 17 38 28 29 35 34 21 40 FIG 31 CARBURETTER, 6T, TffO AND TR6 76 Ref. No. PanNa. QUANTITY DESCRIPTION CARBURETTER 6T, T110 AND TR6 1 1 1 2 3 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ll 23 23 H 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 376[156 376/255 376/40 376/003 376/174 376/065 29/307 4/276 4/241 30J064 376t107 376/062 4/046 6j047 6j132A 4/035 376j060 376/061 376/068 376/069 376/070 376/057 376/067 376/073 376/074 376/100 376/100 376/075 376/072 376/063 4/230 376/076 116/162 376/095 332/017 4/148 376j08S 376/083 376/094 376/078 376/077 376/079 376/088 376/089 376/093 376/091 376/092 376/086 376/087 343/011 244/1048 F4448 F4720 CARBURETTER CARBURETTER CARBURETTER Mlxi ng chamber 11l • choke AIR VALVE ASSEMBLY Mixing chamber cap Spring Spring Screw Spring Mixing chamber top Air valve Spring ... Air valve guide ... Throttle cable ferrule Air cable adjuster Throttle valve (3! cutaway) Throttle return spring Throttle stop screw ." Stop screw spring Peg screw Jet block (1 Joint washer Jet holder Fibre washer Main jet 270 Main jet 250 n' choke) Cover nut Needle jet (·1065) Needle (Type C) Needle dip Pilot jet (25) Fibre washer Cover nut Air adjusting screw Spring ". Float spindle Float Bush Joint washer Cover ." Screw Needle seating Needle Filter Bolt Fl bre washer Tickler ... Tickler spring Tickler body "0., ring seal Petrol pipe assembly Petrol pipe assembly 6T 1 T110 TR6 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 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 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 77 ,.----6 8 ?=~-7 4 5 3-----r'!~~ 10-------< 23----' ~---------------14 9-----+ 22-------1 2----------~---+ 28----:::.\ 27~ ,r---"--30 ----1(tp II 12 29 24-i 25=:8 26 18 16 19 20 FIG. :11 IONNEYILLE 120 CARBURETTERS 78 Ref. No. Port No. DESCRIPTION QUANTITY BONNEVILLE 120 CARBURETTERS 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 37 376{233 376/16-4 376/107 376/065 4/276 4/241 4/137A 6/132A 376/060 376/132 376/068 376/069 ~:'6/070 376/057 376/067 376/140 376/141 376/074 376/100 376/075 376ton 376/063 4{230 376/076 116/162 376/095 332/017 4/148 376/078 376/077 376/151 2-4-4/1048 376/066 F2603 525-3 526-3 51-51 MIXING CHAMBER ASSEMBLY Mixing chamber (1 tlr" choke) Mixing chamber top Mixing chamber cap Spring ... Screw Plug screw Throttle cable ferrule Throttle valve (3! cutaway) Throttle return spring (light) Throttle stop screw Stop screw spring Peg screw Jet block (1 tlr' choke) Joint washer Jet holder Inlet banjo Fl bre washer Main jet (240) Cover nut Needle jet (·1065) Needle (Type C) Needle clip Pilot jet (25) Fibre washer Cover nut Air adjusting screw Spring ... Joint washer Cover Screw "0" ring seal Air Intake tube ... Bolt (1t' U.H.) Plain washer Spring washer Nut ... T120 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 2 2 2 2 2 2 2 2 2 2 6 2 2 4 4 4 4 79 II 10 29--2 31-~,.t.~30~ 32--. f~ FIG. ll 80 NNEVILLE 120 FLO AT CHAMBER Re(. No. Port No. DESCRIPTION BONNEVILLE '· 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 H 25 26 27 28 29 30 31 32 14/624 14/363 14,1219 14/336 14/385 14,1209 14/032 H/210 Hf289 H/017 14/355 161/054 376/093 376/135 376/092 14/384 14/383 81j027 E3987 E4054 E4053 T1017 F4722 F4525 F3353 F3337 E4035 F4725 F4726 F4526 F4356 E4035 no FLOAT CHAMBER ... Float chamber Inlet union Fibre washer COVER cfw TICKLER Tickler Spring Stop Split pin Float Needle Clip Filter Banjo fibre washer Bolt Anchor stud Nut Flexible mounting Screw (f. • U.H.) Spring washer Nut ... PETROL PIPE Rubber pipe Obtuse elbow Union nut Clip PETROL PIPE Rubber pipe (long) Rubber pipe (short) "T" piece Clip QUANTITY FLOAT CHAMBER T1l0 1 ... 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 2 2 "1 2 1 1 6 81 14 22 21 8 33 34 19 24 29 28 27 23 FIG. J4 MAGNETO WITH AUTOMATIC ADVANCE AND RETARD Ref. No. 1 2 3 ~ 5 6 7 8 9 10 11 12 13 14 15 16 Part No. -492856 49285-4 54440888 470537 459130 18 -493716 19 463932 20 21 ll 150509 185048 452907 45900-4 33 455361 458339 189294 1892# 459005 459002 -455191 455190 458675 525-3 34 F1008 24 25 26 27 28 29 30 31 32 QUANTITY MAGNETO WITH AUTOMATIC ADVANCE AND RETARD T110 TR6 T120 ~23# MAGNETO ... 1 1 ~58876 PICK-UP 2 2 ~51260 Brush and spring ... 2 2 Joint washer ~58877 2 2 ~10600 Moulded nut 2 2 Rubber grommet ... ~58658 2 2 -4 -4 H50H Fixing screw ~59269 1 1 CONTACT BREAKER COVER 459266 Moulded breather cap 1 1 459888 Terminal assembly 1 1 -455190 Brush and spring .. . 1 1 -457681 Rubber washer .. . 1 1 17 23 D<SC/I.II'TION Contact breaker screw CONTACT BREAKER Contact and spring set Earthing brush and spring Cam End plate Insulating cup Screw Spring washer Shim (0·005') ARMATURE Slip ring Condenser Contact breaker end bearing Drive end bearing Drive bearing insulating cup ... Oil seal ... EARTH BRUSH, SPRING AND HOLDER Earth brush and spring Sundry parts set Plain washer ... Nut ... 1 1 1 1 1 1 1 1 1 1 1 1 3 3 1 1 3 3 as required 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 3 3 3 t 470688 Some early Magnetos 423#D were fitted with Contact breaker screw } CONTACT BREAKER Contact set Spring set ... 0297 D262 Sparking plug (Champion N3, K.l.N. F.E.100or lodge HLN) Plug cover and suppressor Plug cover 122160 470534 470609 35 36 36 Interchangeable with the above as an assembly only. 2 2 2 2 2 A A A 2 83 !>------! 17 ffi-18 2 14 252423 8 31 52 26 FIG. 35 MAGNETO WITH MANUAL CONTROL Ref. No. Port No. DESCRIPTION QUANTITY MAGNETO WITH MANUAL CONTROL T110 TR6 1 2 3 . 5 6 7 8 9 10 11 12 13 14 15 -42298 <458876 451260 <458877 410600 <458658 1<45074 459269 459266 459888 455190 <457681 492856 <492854 54440888 16 <470537 17 18 -492195 19 20 21 22 23 H <455788 454<475 <458725 <459271 463932 150509 185048 25 <452907 26 -459004 -455361 27 28 <458339 29 30 189294 189244 31 -459005 -459002 32 33 <455191 <455190 3-4 35 -458675 36 525-3 37 F1008 MAGNETO ... PICK-UP Brush and spring ... Joint washer Moulded nut Rubber grommet ... Fixing screw CONTACT BREAKER COVER Moulded breather cap Terminal assembly Brush and spring ... Rubber washer Contact breaker screw CONTACT BREAKER Contact and spring set Earthing brush and spring CONTROl PARTS SET Nipple Rubber cover Cam End plate Insulating cup Screw Spring washer Shim (0·005•) ARMATURE Slip ring Condenser Contact breaker and bearing Drive end bearing Drive bearing insulating cup Oil seal ... EARTH BRUSH, SPRING AND HOLDER Earth brush and •pring Sundry, parts set Plain W3$her Nut T120 1 2 2 2 2 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 as required 1 1 1 1 1 1 1 1 1 1 3 3 t 122160 -47053-4 -470609 -470688 Some early magnetos 42298C were fitted with Contact breaker screw } CONTACT BREAKER Contact set Spring set D297 0262 Sparking plug (Champion N3, K.LG. F.E.100 or lodge H. LN.) Plu~: cover and suppressor ... Plug cover 38 39 39 Interchangeable with the above as an assembly only. 2 2 2 2 2 2 A A A 85 4-----• i 5-----~ 2----- 15 lb 25 26 17 23 7 22 21 4----() 5----1?" 28 79 ~~fl:i· lP~- 36 ~~30 32 41 ---··-38 37 31 32 34 FIG. J6 DISTRIBUTOR AND COIL 86 Ref. N<J. Part No. DESCRIPTION QUANTITY DISTRIBUTOR AND COIL 1 40690 2 3 425049 4 5 421554 421863 6 4234l!6 7 423110 8 423108 9 10 423109 11 12 13 14 15 404435 54410U23 425219 423113 425284 425398 421056 16 17 425444 18 19 424158 20 2.1 22 23 425498 425243 188639 33 H 1 1 1 1 1 1 1 1 1 1 1 2 1 1 169160 422369 DS57 '"D .. washer Bolt (ilr U.H.) E1612 Serrated washer Nut Rubber cover Sparking plug (Champion L7, K.l.G. F.BO or lodge H. H) Plug cover and suppressor ... Plug cover 112917 185051 173857 31 32 1 1 25 26 30 1 1 4 4 Distributor adaptor .. . Plain washer ... Nut Clamping plate Clamp bolt Washer Nut Distributor sheath ... Ignition coil (M.A.6) Clip screw Square nut ... E3122 S25·3 S1·51 E4116 29 6T 1 .. . 24 27 28 DISTRIBUTOR (Type 18D2) CAP ASSEMBLY Brush and spring .. . Rubber grommet .. . Cable clip ... Rotor Shaped Insulating bush Condenser connector Insulating bush Condenser Contact set Base plate Cam Spring set Weight set Shaft and action plate Bearing bush Retaining dip ... Sundry parts set E4117 45077 100104 35 36 37 236741 38 D297 38 D262 F879 Rubber .. 0 .. ring 3 3 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 A 87 4 5 FIG. '11 HIADLAMP AND WilliNG ...AIINISI, 1116 AND Tt21 88 Ref. No. Part No. DESCRIPTION QUANTITY HEAOLAMP ANO WIRING HARNESS. TR6 ANO Tf10 1 2 3 4 5 6 7 8 9 10 11 12 13 H 15 16 17 18 19 20 21 22 23 24 58556 553248 516798 504665 534296 312 554602 988 554710 36084 112201 137141 31784 F4696 F4697 E3798 E3221 H745 70048 701851 1'4771 GS299 H745 54944995 HEADLAMP COMPLETE Rim Light unit Fixing wire Screw and plate Bulb (30f24W. Vert. dip, Pre-focus) Adaptor·.·· Bulb (3W. M.C.C.) Pilot bulbholder Ammeter Bolt Plain washer Lighting switch (SA.41) Left switch bracket :.. Right switch bracket Cap Screw (1 i' U.H.) Nut ... Horn ... Fixing plate Bolt (!' U.H.) Serrated wuher Nut ... Wiring harness TR6 T120 1 1 1 1 1 1 6 6 1 1 1 1 1 2 2 1 1 1 2 1 1 1 4 2 2 2 1 1 1 1 1 2 2 1 1 1 2 1 1 1 4 2 2 2 1 89 10 ~ 12 23 FIG. l8 SPEEDOMETER, TAIL LAMP AND RECTIFIER 90 22 28 Ref. No. Per! No. QUANTITY DE.SCRIPT/ON SPEEDOMETER, TAIL LAMP AND RECTIFIER 1 1 1 1 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 SC3304f19 SC3304/20 SC5301j09 SC5301 /16 SC5301J18 P53279f1 P52305 P22469 15578!2 N1253 DS<40 DS57 S26-2 0245 D245A 53432 573839 575200 575208 575219 576002 575209 575207 573828 573825 384 838604 34279 F929 S26-3 $1-51 47132 F3600 F4813 H919 Speedometer head (12S m.p.h.) Speedometer head (190 k.p.h.) Speedometer head (125 m.p.h.) Speedometer head (190 k.p.h.) Speedometer head (2<40 k.p.h.) BULB HOLDER cfw BULB Bulb Rubber ring ... Clamp bar Nut ... Bracket Bolt (ir' U.H.) Spring washer Speedometer drive cable (44' long) Speedometer drive cable (44' long) STOP AND TAIL LAMP (Type 564) Lens Window Lens seating gasket Sleeve nut Base assembly ... Bulbholder Grommet Contact Assembly Grommet Bulb (6f18W. Offset pin.) Stop and tall lamp lead Stop lamp switch (6SA) Bolt (t" U.H.) Spring washer Nut ... Rectifier Self-locking nut Screw (f.' U.H.) Nut ... 6T 1 1 .. , 1 1 1 1 2 T110 TR6 1 1 1 1 1 1 1 1 2 1 2 1 2 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 1 T120 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 1 1 1 1 1 1 1 1 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 91 6T T110 R TR6 c T120 R c 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 Page 17 CP159 CP157 E3108f22 E3108/21 E3325 E332S PISTON COMPLETE 7·5 : 1 C.R. PISTON COMPLETE 8·5 ; 1 C.R. Engine Sprocket Engine Sprocket Inlet Camshaft Exhaust Camshaft ... ... ... ... ... ... Stock Stock Stock Stock Stock Stock 13 E4191 16 E4192 E4193 E4194 E2973 E2962 NM3A E2968 OIL RELEASE VALVE AND INDICATOR Replaces Cap Replaces ... Sealing ring ... Cup Stud (1H in. O.A.) ... Stud (1j, ln. O.A.) ... Joint Washer ... Insulating block ... E2795 E2790 NEW NEW Stock Stock Stock Stock 14 14 21 21 37 38 2 2 1 1 1 1 Page 21 24 29 30 31 1 1 1 1 1 1 1 1 4 4 4 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 4 2 1 1 1 1 Page 23. For 6T read as for T!10 on page 25. Page 29 1 1 T1583 2 5 T1605 T1606 T1607 T1612 T1614 T1607 GEARBOX COMPLETE- STANDARD RATIO Replaces T152S GEARBOX COMPLETE- STANDARD RATIO Stock GEARBOX CASING ... NEW Layshaft bearing ... NEW ... NEW Thrust washer ... GEARBOX INNER COVER ... NEW layshaft bearing ... NEW Thrust wa>her ... ... NEW Page 31 11 11 11 T1608 T1610 T1609 LAYSHAFT COMPLETE (20T) LAYSHAFT COMPLETE (1ST) Layshaft cjw high gear (22T) Page 3l 29 40 T1270 T402 F-OLDING KICKSTARTER Clutch operating arm 10 11 94 T1528 1 1 1 1 1 1 1 1 1 1 1 1 A A 1 A A 1 A A 1 A A 1 1 1 1 1 1 1 1 1 1 1 1 ... NEW ... NEW ... NEW 1 A A A A ... Stock ... Stock 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Pap 4t 20 28 S1-51 Flanged nut ... Eyebolt Plain washer Nut Abutment pin Spring wuher Nut Pap.O 12 -47178 Stator ... E4177 E4179 left exhaust pipe ... Right exhaust pipe ... left Bracket ... ... Right bracket ... Extended nut ... Spring washer ... Bolt (H ln. U.H.} ... Exhaust leg guard Replaces ••• CUp ... Screw (it ln. U.H.) ... ..• Plain washer ... .•. Nut left silencer ... •.. Right silencer ••. Silencer hanger bolt (1H ln. U.H.) ..• Distance piece ... Spring washer ... Nut ••. 24 2S 26 27 1'4569 1'4716 GS203 E1310 1'4669 ~3 ... ... ... ..• ... ... ... •.. ..• NEW NEW Stock Stock Stock Stock Stock Replaces 471 ~ 6T T110 1 1 1 1 1 1 1 1 4 1 1 1 1 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 TR6 R c T120 R c . .. .. . ... ... - Pap -45 E2989 E2990 32 33 34 35 36 E4181 S26-1 W840 E4204 E-4207 F4715 E2351 F3799 E4132 E4176 H622 F2694 S26-1 S1-52 ... ... NEW NEW Stock Stock NEW Stock Stock E-40n NEW Stock Stock Stock Stock NEW Stock Stock Stock Stock 1 1 1 1 1 1 1 2 - 1 1 1 1 1 1 1 2 .. .... 4 4 .. 1 1 2 2 2 2 1 1 2 2 2 2 Paze 53. For 6T read as for Tl10 on p&le 55. Paee 55 20 21 22 W1410 Wl-411 W141-4 lEADING BRAKE SHOE ... Tl\AIUNG BRAKE SHOE ... Brake lining Replaces W1337 Replaces W1338 ... NEW 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Pa.. 57. For T1l0 r...t as for TR6. 95 6T TR6 T110 R Page 57 23 23 W1406 W1-4Q7 Page 59. For T120 read as for TR6. Page 59 25 25 W1-4Q6 W1407 Page 61. For T120 read as for TR6. Page 61 35 31 32 F4893 F3057 Fl116 Securing strap Petrol tap 376f255 3761257 F4720 F4841 F4842 Carburetter Carburetter Petrol pipe Petrol pipe (short) Petrol pipe (long) SC3304 124 Speedometer head (125 m.p.h.) Replaces SC3304 /19 Speedometer head (190 k.p.h.) Replaces SC3304j20 ... Stock Speedometer head (125 m.p.h.) ... Stock Speedometer head (190 k.p.h.) ... NEW Speedometer head (1-4Q m.p.h.) ... Stock Speedometer head (2-4Q k.p.h.) Replaces 34279 Stop lamp switch ... NEW Crinkle washer (rectifier leads} Page 77 1 1 49 Page 91 1 1 SC3304j25 1 1 SC5301 f09 SC5301j16 SC5301 /26 SCS301/18 34181 F4844 1 1 23 96 LEADING BRAKE SHOE } TRAILING BRAKE SHOE LEADING BRAKE SHOE } TRAILING BRAKE SHOE 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 1 2 1 2 1 1 2 2 1 1 1 1 In pairs replace W93 1 1 1 Stock NEW Stock NEW NEW c 1 1 ... ... ... ... ... R 1 1 1 In pairs replace W93 ... Replaces F-4655 and F4699 ... Stock ... ... Stock Petrol tap with reserve tube T120 c 1 1 1 1 1 A A 1 A 1 3 1 3 1 3 1 A 1 1 A A 1 3 1 1 3 3 1962 REPLACEMENT PARTS CATALOGUE 1962 Season's machines were basically as specified in the No. 16 Replacement Parts Catalogue for 1960,'61 season's models, w!th the following amendments, These changes apply to machines from Engine No. D15789 except where otherwise stated. Page 12 CARTON PACK LIST CLOSE RATIO GEARS (To convert from Standard Ratio) (Needle roller layshaft bearing condition- Engine No. D7727 onwards) CP193 1 1 1 1 1 1 1 Page 14 T1177 T1383 T1179 T955 T1609 T964 T963 T961 T1227 Mainshaft and low gear (18T) Mainshaft high gear (24T) Mainshaft third gear (23T) Mainshaft second gear (21T) Layshaft c;w high gear (22T) layshaft chi rd gear (23T) layshaft second gear (25T) layshaft low gear (28T) Blanking plug CARTON PACK LIST VALVE SPRINGS E4221 Inner valve spring (red) CP188 4 4 E4222 Outer valve spring (red) 6T (Engine No. D11193 onwards) Page 17 CRANKSHAFT AND CONNECTING RODS E4492 E4493 E4479 CP159 CP157 E3108/22 E3108j21 54213901 E4220 E3134 E1486R Page 21 Engine sprocket ( Engine sprocket Rotor RM19 Camshaft (D11193 onwards) Inlet camshaft Camwheel (3 keyway) ( II H 6T 1 TR6 1 1 1 1 1 2 2 T120 1 1 1 2 ) ) 1 1 2 2 1 1 2 1 2 OIL PUMP AND RELEASE VALVE AND MANIFOLD (D7727 onwards) E4191 E4192 E4193 E4194 E2973 E2962 NA43A E2968 Page l3 CRANKSHAFT AND FlYWHEEL ASSEMBLY Crankshaft c/w oil tube Flywheel PISTON COMPLETE 7.5 : 1 C.R. (D7727 onwards) PISTON COMPLETE 8,5 : 1 C.R. ( " ) Oil release valve and ind!calor Cap .. , Sealing ring Cup Stud (1·1~ in. O.A.) Stud (1 3~ in. OA) Joint washer Insulating block ... CYLINDER BLOCK AND HEAD 6T-Delete and read as for T110 and TR6 (on Page 25) with the follow· ing alterations. (D7727 onwards) 2 1 1 1 4 2 1 1 1 1 4 1 2 Page 25 CYLINDER BLOCK AND HEAD T110 & TR6 E4221 E4222 E3001 E3002 Page 29 T120 4 4 GEARBOX COMPLETE- STANDARD RATIO GEARBOX CASING Layshaft bearing Thrust washer GEARBOX INNER COVER Layshaft bearing Thrust washer 1 1 1 1 1 1 1 1 1 1 LAYSHAFT COMPLETE (20T- Std.) ... LAYSHAFT COMPLETE (18T- W.R.) LAYSHAFT COMPLETE (22T- CR.) N"B.-To convert to dose ratio from standard ratio use CP193 1 A A 1 A A 1 A A Gearchange quadrant FOLDING KICKSTARTER Clutch operating arm 1 1 Clutch spring (strong) 4 ... FRAME F4846 Page 41 TR6 CLUTCH T1560 Page 37 6T 4 4 GEARBOX SELECTOR MECHANISM T408j9 T1270 T402 Page 35 inner (red) (D11193 onwards) outer (red) (D11193 onwards) ... 1nner (white) outer (white) GEARBOX SHAFTS AND GEARS {D7727 onwards) T1608 T1610 T1609 Page 33 spring spring spring spring GEARBOX AND CASING (D7727 onwards) T1583 T1605 T1606 T1607 T1612 T1614 T1607 Page 31 Valve Valve Valve Valve Front frame 1 1 ENGINE AND GEARBOX FITTINGS F4569 F4746 GS203 E1310 F4669 526-3 S1-51 F3599 F5049 F2335 526-3 S1-51 Flanged nut Eye bolt (D7727 onwards) ( " ) Plain washer ( " ) Nut ... ( " ) Abutment pin ( " ) Spring washer ( ) " Nut ... ( " ) Bracket- Rear engine plate to mudguard Bracket- Rear engine plate to oil tank Bolt Spring washer Nut. .. 3 1 4 4 2 2 2 4 4 2 2 2 1 1 1 1 2 2 2 2 2 4 4 2 2 2 2 Page 43 Page 45 CHAINCASE AND ALTERNATOR 6T 47164 47162 47183 E4123 T1651 E3440 E3444 0433 1 1 A 1 1 Left-hand exhaust pipe ... Right-hand exhaust pipe Clip "D" washer Bolt (1 ,1, in. UH) "D" nut Silencer Left silencer Right silencer Mute Screw Nut ... 1 2 2 2 2 1 1 2 2 2 2 1 1 1 1 2 2 2 1 1 2 1 1 1 2 1 1 1 2 1 1 2 2 1 1 2 1 I I FRONT FORK ASSEMBLY (SIDECAR) LEFT BOTTOM MEMBER CjW CAP RIGHT BOTTOM MEMBER CfW CAP ... Spacing bobbins Stud ... A 2 2 NACELLE, HEADLAMP AND SWITCHES 70163 HH20 F4771 GS299 F3799 54094328 1 1 2 2 2 Horn Horn bracket Bolt H in. U.H.) Serrated washer Nut ... Wiring harness Page 53 FRONT WHEEL 6T -Read asforT110 on Page 55 with the undermentioned amendments. Page 55 FRONT WHEEL T110, TR6 & T120 (D7727 onwards) W1410 W1411 W1414 W1415 Page 57 1 A TELESCOPIC FORKS 6T H1422 H1322 H1323 H1325 H1326 Page 49 3 1 4 4 1 T120 EXHAUST PIPES AND SILENCERS E4409 E4410 E2271 TE164D TE164E TE164C E4413 E4174 E4175 E4107 H689 H691 Page 47 Stator RM19 Stator RM19 Stator RM19 (U.S. Models) Stud (1 :,J 1n. O.A.) for Stator Outer chaincase ... Screw (1 /6 10. U.H.) Screw (2l in. U.H.) Rear chain (~ in. · ~ in. " 98 L) TR6 LEADING BRAKE SHOE TRAILING BRAKE SHOE Brake lining Pivot pad REAR WHEEL-For T120 read as for TR6 (07727 onwards) W1406 W1407 W1415 LEADING BRAKE SHOE } In pairs TRAILING BRAKE SHOE replace Pivot pad W93 4 I I Page 59 QUICKLY DETACHABLE REAR WHEEL -For T120 read as for TR6 (D7727 onwards) W1406 W1407 W1415 Page 61 I LEADING BRAKE SHOE In pairs TRAILING BRAKE SHOE /- replace Pivot pad ) W93 6T 1 1 TR6 T120 1 1 1 2 1 PETROL TANKS Note: T120 Models were fitted with either 3 or 4 gallon tanks as required. F3220 F4971 F4972 F4916 F4917 F4918 F4919 Filler cap ... Petrol tap ... 1 Petrol tap with reserve tube Tank securing strap (3 Gal.) (D16693 onwards) Tank securing strap (4 Gal.) Tank strap sleeve Tank strap sleeve I I Page 63 1 1 2 1 1 1 2 2 1 2 1 OIL TANK F5067 FS066 F4985 F5051 F5049 F2335 S26-3 S1-51 F4110 F967 F3815 F4111 Oil tank Oil tank FILLER CAP Stud 1 1 1 Bracket Bolt Spring washer Nut ... Cap ... Rubber Spigoted rubber Bolt 2 FSOSO T224 F3814 F967 F4108 W1058 Page 69 Stud Nut ... Cup Rubber Spigoted rubber Self-lock nut BATTERY CARRIER AND TOOL BOX F4905 BATTERY CASE AND TOOL BOX (D9660 onwards) PANELS AND TWINSEAT F4897 F4715 F4717 Reinforcing strip, lower panel ftxing Philips screw- reinforcing strip Self-locking nut 2 3 3 2 2 1 2 2 1 as required 1 1 1 1 3 3 2 2 2 2 2 2 Locking wire Page 65 1 1 1 1 2 ... 5 1 2 2 Page 73 CONTROL CABLES 0416 F5203 E3220 GS299 H745 Page 77 TR6 T120 2 1 1 1 CARBURETTER (011193 onwards) CARBURETTER Main jet 220 (011193 onwards) Tilronle valve (4 cutaway) (011193 onwards) Petrol pipe assembly Petrol pipe 2 1 1 1 1 DISTRIBUTOR AND COIL 54441582 Page 89 6T 1 CARBURETTER 6T, T110, TR6 376(285 376/257 376!1 00 376;060 F5039 F4720 Page 87 FRONT BRAKE CABLE Throttle cable junction box clip to frame Clip screw ... Clip screw washer CHp screw nut External replacement condenser (Coil bracket co C.B. terminal) A HEADLAMP AND WIRING HARNESS TR6 & T120 E4515 34289 F5020 F5021 54930007 54930000 58878 36296 E3050 H1413 58934 862217 54931221 70163 F4771 GS299 F3799 Switch cover (for 41 SA switch) Lighting switch (88 SA) left switch bracket Right switch bracket Replacement harness socket (Lighting) (To convert from 41 SA switch to 88 SA type) Harness (incorporating head lamp plug and 88 SA switch socket with Lucas stop switch connectors) Headlamp with 2 AR ammeter and socket connection Ammeter 2 AR Ammeter rubber sealing ring (lucas 523968) Ammeter blanking disc ... Headlamp complete (with 2 AR ammeter) Headlamp rubber grommet, cable entry Harness (to suit 58934 Head lamp, 88 SA switch, 49072 rectifier and 34381 stop lamp switch) deleting plug and socket at headlamp 018419 onwards ... A 1 A A 1 1 1 A 1 1 1 1 1 1 1 A A 1 A A 1 1 1 Serrated washer 2 1 2 2 Nut. horn foxing bolt 2 2 Horn, type 8H Horn fixmg bolt 2 6 Page 91 SPEEDOMETER, TAIL LAMP AND RECTIFIER 6T SC3304:24 SC3304;25 SC5301j09 SC5301;16 SC5301i26 SC5301:1a Speedometer Speedometer Speedometer Speedometer Speedometer Speedometer 34381 F4844 49072 F533B 54942078 54190042 Stop lamp switch (Lucar connectors) Crinkle washer (Rectifier leads- for 47132 rectifier) Silicon rectifier (D18419 onwards) Rectifier fixing nut (Lucas 156596) head head head head head head (125 (190 (125 (190 (140 (240 m.p.h.) k.p.h.) m.p.h.) k.p.h.) m.p.h.) k.p.h.) (D7727 onwards) ) ( ( ) ( ) ( ) " ( ) T120 A 1 A .. 1 A . 1 3 1 1 Lucar Terminal (service conversion) 3 Lucar Terminal cover (service conversion) 3 7 TR6 1 1 3 1 1 3 3 1 3 1 1 3 3
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