triumph 650 twins parts manual

REPLACEMENTPARTSCATALOGUEFOR 1972

BONNEVILLE T 12011 9 T 120RV

TIGER 650 TR6R, TR6RV

TROPHY 650 TR6C. TR6CV

TRIUMPH ENGINEERING COMPANY LIMITEDMERIDEN WORKS • ALLESLEY • COVENTRY CV5 9AU • ENGLAND

TELEPHONE COVENTRY 20221 TELEGRAMS "TRUSTY" COVENTRYMERIDEN 331 TELEX "TRUSTY" 31305

PUBLISHED AUGUST 1971 PUBLICATION PART No. 99-0953

FIRST AMENDMENT NOVEMBER 1971

ClassicBike.Biz

Don

Text Box

See Bookmarks

http://www.classicbike.biz

I NTRODUCTION

The Triumph Engineering Co. Ltd. point out that the information in this catalog was complete and correctat the time of printing. Distributors will be informed of any subsequent alterations.

A plastic binder, of the type used for Workshop Manuals, is available to enable this catalog and all other1971 season catalogs to be bound into one unit.

GUARANTEE

Please refer to your dealer or distributor for the latest terms of guarantee.

Eastern U.S.A. Distributor: Western U.S.A. Distributor:

Triumph Motorcycle Corporation,P.O. Box 6790,Towson,Baltimore 4,Maryland 21204.

Telex—Tricor Balt. 87728Telephone-301-252-1700

Triumph Motorcycle Corporation,P.O. Box 2765,East Huntington Drive,Duarte,California 91010.

Telex—Tricor Duarte 675469Telephone-213-359-3221

213-681-0255

ENGINE AND FRAME NUMBERS

The engine number is located on the left side of the engine, immediately below the cylinder barrel to

crankcase flange.

The frame number is located on the left side of the frame headlug, beneath the fork top lug and forwardof the gasoline tank.

Both the engine and frame number should be quoted in full in any correspondence relating to themachine.

2

ClassicBike.Biz


I NDEX

Page Page

AIR CLEANER ... ... ... ... 77 KICKSTARTER ... ... ... ... 47ALTERNATOR ... ... ... ... 11, 51AUTO-ADVANCE UNIT ... ... 39 MANIFOLD ... ... ... ... 17

MOTOR PLATES ... ... ... 57BATTERY CARRIER ... ... ... 93 MOTOR TORQUE STAY ... ... 57BRAKE SWITCH ... ... ... 57 MUFFLERS ... ... ... 59, 61, 63BREATHER PIPES ... ... ... 53

OILPUMP ... ... ... ... 17

CAMSHAFT, INLET AND EXHAUST 11 OIL PIPES ... ... ... ... 53

CARBURETOR ... ... 35, 37 OIL PRESSURE RELEASE VALVE ... 17

CARTON PACKS ... ... ... 7CENTRESTAND •.. ... ... 53 PISTONS ... ... ... ... 11CHAINS... ... ... ... ... 51 PROP STAND ... ... ... ... 53CHAINCASE ... ... ... ... 51 PUSH RODS ... 19,21,23,25,27,29,31,33CLUTCH ... ... ... ... 49CLUTCH LEVER ASSEMBLY .•• 47COIL ... ...... ... ... 89

REAR WHEEL ... ... ... ... 73RECTIFIER ... 89

CONDENSERPACK ... ... „_ 89 ... ... ...ROCKERS 19,21,23,25,27,29,31,33

CONNECTING RODS ... ... 11CONTACT BREAKER ... ... ... 39CONTROL CABLES ... ... ... 83 SIDE PANEL ... ... ... ... 77CONTROL LEVERS ... ... ... 81 SPARK PLUG ... ... ... ... 89CRANKCASE ... ... ... ... 13, 15 SPEEDOMETER ... ... 87CRANKCASE UNDERSHIELD ... 63 SPEEDOMETER GEARBOX ... ... 73CRANKSHAFT ... ... ... ... 11 STEERING DAMPER ... 69CYLINDERS ... 19,21,23,25,27,29,31,33 SUSPENSION UNITS ... ... ... 55CYLINDER HEAD 19,21,23,25,27,29,31,33 SWINGING FORK ... ... ... 55

SWITCHES ... ... ... ... 81, 91

EXHAUST PIPES ... ... 59, 61, 63

TABLE OF STANDARD HARDWARE 94,95FENDERS ... ... ... ... 79 TACHOMETER ... ... ... ... 87FIVE SPEED GEARBOX ... ... 45 TACHOMETER GEARBOX ... ... 87FLASHERS ... ... ... ... 89, 91 TAIL LAMP ... ... ... ... 79FOOTRESTS ... ... ... ... 57, 63 TAPPETS ... ... 17FRAME... ... ... ... ... 53 TIMING GEARS ... ... ... 11FRONT FORKS ... ... ... 65, 67 TOOLKIT ... ... ... 85FRONT WHEEL ... ... ... 71 TWIN SEAT ... ... 75

GAS TANK ... ... ... ... 75 VALVES ... ... 19,21,23,25,27,29,31,33GEARBOX ... ... ...41, 43, 45, 47 VALVE GUIDES 19,21,23,25,27,29,31,33

HANDLEBAR... ... ... ... 81HANDLEBAR MOUNTINGS ... ... 69

WIRING HARNESS . •••.... •.. 91

HEADLAMP... ... ... ... 91, 93HORN... ... ... ... ... 89 ZENER DIODE... ... ... ... 89

3

ClassicBike.Biz


TIGER 6 0 (TR 6 R) (TR 6 RV— SPEED) TECHNICAL DATA

71 x82 mm.2-79 x 3 .23 ins.

Capacity ... ... 649 c.c. (40 cu. ins.)

Compression ratio 9 : 1Spark plugs Champion N3

Carburetor Amal Concentric 930Main jet 230Needle jet ... 106Throttle valve ... No. 32

Gearbox sprocket 19 teethChains ... Front I" Duplex x 84 links

Rear ... Ex6 " x106 linksCapacities Gas Tank 3.6 U.S. galls.

Oil Tank 4.8 U.S. pints.Gearbox ... i pint (500 c.c.)Primary Chaincase 4 pint (150 c.c.)Primary Chaincase ... * pint (150 c.c.)Front Forks (each leg) ... i pint (190 c.c.)

Brakes Front, diameter... ... 8" (20 . 32 cm.)

Rear, diameter 7" (17 .78 cm.)

Tire size ... Front 3.25x19

Rear 4.00 x18

Bore and Stroke

4

ClassicBike.Biz


Bore and stroke...

Capacity ... ...

Compression ratio

Spark plugs ...

Carburetor ...

Gearbox sprocket

Chains ... ...

Capacities ...

Brakes ... ...

Tire size ... ...

Main jet ...Needle jet ...Throttle valve ...

... Front ... ...Rear ... ...

... Gas Tank ...Oil Tank ...Gearbox ...Primary ChaincaseFront Forks (each leg)

... Front, diameter...Rear, diameter

... Front ... ...Rear ... ...

5

TROPHY 650 (TR6C) (TR6CV-5 SPEED) TECHNICAL DATA

... ... 71 x 82 mm.2 . 79 x 3 . 23 ins.

... ... 649 c.c. (40 cu. ins.)

9:1

... ... Champion N3

... ... Amal Concentric 930230

... ... •106

... ... No. 32

... ... 18 teeth

" Duplex x 84 links... ... 8"xW'x106links

... ... 3.6 U.S. galls.... 4.8 U.S. pints

pint (500 c.c.)

4'- pint (150 c.c.)pint (190 c.c.)

8" (20 .32 cm.)... ... 7" (17 .78 cm.)

3.25x19... ... 4•00x18

ClassicBike.Biz


BONNEVILLE (T120R) (T120RV-5 SPEED) TECHNICAL DATA

71 x82 mm.2 .79 x 3 .23 ins.

Capacity ... 649 c.c. (40 cu. ins.)Compression ratio 9 : 1Spark plugs ... Champion N3Carburetors ... 2 Amal Concentric 930

Main jet 190Needle jet .. .106Throttle valve No. 3

Gearbox sprocket 19 teethChains ... Front 1" Duplex x 84 links

Rear ... 8"x8"x106 linksCapacities Gas Tank 3.6 U.S. galls.

Oil Tank 4.8 U.S. pints.Gearbox ... i pint (500 c.c.)Primary Chaincase ... 4 pint (150 c.c.)Front Forks (each leg) 1 pint (199 c.c.)

Brakes Front, diameter... 8" (20 . 32 cm.)

Rear, diameter 7" (17 .78 cm.)

Tire size Front 3.25x19

Rear 4.00x18

Bore and stroke...

6

ClassicBike.Biz


HOW TO USE THIS SPARE PARTS CATALOG

First consult the index on Page 3 for the parts or group of parts which you wish to locate. Whenyou have located the parts make sure from the end columns that the part you have located does apply toyour machine.

List the quantities required as single units; do not ask for "2 pairs" or "3 dozen".

In case of painted items always state the color required. Painted parts are available only in the colorsor alternatives specified for that model of that particular year.

CARTON PACK LIST

The following sub-assemblies are supplied in carton packs under the C.P. part number stated. Thecontents of these carton packs are preserved and will not deteriorate under adverse conditions.

Part No. Contents

Brake Lining

C. P.38/A. M.2

C.P.205 ... ...

2 ... ... NW243 ... ... ... Brake lining

16 ... ... ... W129 ... ... ... Rivet

2 ... ... ... W1734 ... ... ... Brake lining

16 ... ... ... W129 ... ... ... Rivet

Pistons (complete with rings, gudgeon pins and circlips)

E6895 ... ... ... ... ... ... 7 .5 : 1 C.R. ... ... For use with low grade fuel

E9488 ... ... ... ... ... ... 9 :1 C.R. ... ... Standard

E6867 ... ... ... ... ... ... 11 : 1 C.R. ... ... Competition use only

All the above pistons are available in oversizes of 0 . 010 ins., 0 . 020 ins., 0 .040 ins., (0 .25 mm., 0 . 5 mm., 1 mm.)

Valve Guides

C.P.97 ... ... ... 2 ... ... ... E2899 ... ... ... Inlet guide

(TR6) ... ... ... 2 ... ... ... E2900 ... ... ... Exhaust guide

7

ClassicBike.Biz


PLEASE NOTE

THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTSINCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN, REVERTINGTO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETEASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENTPARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.

SPECIAL WORKSHOP TOOLS

A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTINGYOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASESTHESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE, ANDTHEREFORE, IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS INORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCESIT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.

UNIFIED THREAD FORM

NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOG HAVE THE UNIFIEDFORM OF SCREW THREADS. THIS CHANGEOVER WILL BE CONTINUED AS AND WHEN NEW PARTSARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERSWILL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDSHAVING THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS INTHEIR HEADS, STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKINGCIRCLES ON THE SIDE.

COLOR

TIGER 650 (TR6R—TR6RV)

Petrol tank—Polychromatic blue and cold white, black lining.Petrol tank (44 U.S. gallon) optional—Polychromatic blue and cold white, black lining.Fenders —Polychromatic blue, cold white stripe, black lining.Side covers—Black, gold decal.

TROPHY 650 (TR6C—TR6CV)

Petrol tank—Polychromatic blue and cold white, black lining.Fenders —Chromium plated.Side covers—Black, gold decal.

BONNEVILLE (T120R—T120V)

Petrol tank—Tiger gold and cold white, black lining.Petrol tank (41 U.S. gallon) optional—Tiger gold, white stripes, black lining.

Fenders —Tiger gold, white centre stripe, black lining.Side covers—Black, gold decal.

N.B. It is important to state year and model of machine when ordering painted components.

ClassicBike.Biz


TRIUMPH SPARESHOW TO ORDER. Every part is indicated by a number, and this should be quoted together with

the description. In order to assist customers, dimensions have been given in many cases where partsare similar. Parts where possible have been listed in order of assembly and a number of the illustrationsshow the assembly order also. With these aids, there should be no difficulty in identifying the parts yourequire.

ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OFTHE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS.

WHERE TO OBTAIN. Triumph Spare Parts can only be obtained from an authorised TriumphDealer, and we recommend our customers to place their orders with the Triumph Dealer in their district.When parts not usually asked for are required, and for which the Dealer may have to write or obtainspecially, the postage or carriage incurred becomes payable.

TRIUMPH SPARES ARE NOT SUPPLIED TO PRIVATE OWNERS DIRECT FROM THE FACTORY.A LIST OF AUTHORISED DEALERS WHO STOCK TRIUMPH SPARES IS AVAILABLE ON REQUEST.IF DIFFICULTY IS EXPERIENCED IN OBTAINING THE REQUIRED PARTS, THE MATTER SHOULDBE TAKEN UP DIRECTLY WITH THE TRIUMPH SPARES DEPARTMENT.

Customers are warned against the risk incurred by purchasing parts that are not of genuine Triumphmanufacture. This risk is eliminated if parts are ordered as instructed from recognised Dealers.

PATTERNS AND PARTS FOR REPAIR. It is not necessary to send patterns if the part numberis quoted. The sending of patterns often delays the order as parcel post or rail takes longer than letter post.

Parts sent to Coventry for repair, replacement, or as patterns should bear the sender's Name andAddress and clear instructions should accompany the parts. In your own interest send a copy of the advicenote under separate cover. All parts must be forwarded carriage paid and care should be taken to ensurethat all remittances are sent separately and not enclosed with the parts. Fragile units such as cylinders,etc., should always be boxed to avoid damage in transit. Complete machines should have all fitments suchas windscreens, driving mirrors, tools, etc., removed by the sender before despatch, as it is impossible forus to accept responsibility in the event of loss in transit. We are always pleased to give estimates for over-hauling and repairs, but should an estimate not be accepted, a charge will be made covering cost of dismantlingand re-assembling, if carried out. Work cannot be accepted at the factory direct from private owners.

Communications relating to Parts should be addressed to the SPARES DEPARTMENT and for repairs,guarantee claims and technical advice to the SERVICE DEPARTMENT, Triumph Engineering Co. Ltd.,Meriden Works, Allesley, Coventry. In order to facilitate quick reference, the quoting of any number,invoice number or reference from previous communications is essential. Accessories not of our manu-facture should be sent direct to the actual makers, whose Names and Addresses appear below.

PROPRIETARY GROUPAncillary equipment which is fitted to our motor cycles is of the highest quality and is guaranteed by

the manufacturers and not by ourselves. Any repairs or claims should be directed to the actual makersor their local agents who will always give owners every possible assistance. The following are the addressesof the various manufacturers:—

CARBURETORS SPARK PLUGS.Messrs. Amal Ltd., Champion Sparking Plug Co. Ltd.,Holdford Road, TIRES. Feltham,Witton, Dunlop Rubber Co. Ltd., Middlesex.Birmingham, 6. Fort Dunlop,

Birmingham, 24. I NSTRUMENTS.CHAINS. Messrs. Smiths Industries Ltd.,Renold Chains Ltd., The Avon Rubber Co. Ltd., Cricklewood Works,Wythenshawe, Melksham, London, N.W.2.Manchester. Wilts.

SUSPENSION UNITS.ELECTRICAL EQUIPMENT. Messrs. Girling Ltd.,Messrs. J. Lucas Ltd., Birmingham Road,Gt. Hampton Street, West Bromwich,Birmingham, 18. Staffordshire.

9

ClassicBike.Biz


33 31 31 32 35

1 ?1

^ ^ 4 ._ Y

34 30

29 27 26

28 38

15

--16

18 17 -

-- 14

3

Fig. 1. CRANKSHAFT AND CONNECTING RODS

10

ClassicBike.Biz


Ref. No. Part No. DESCRIPTION QUANTITY REMARKS

CRANKSHAFT AND CONNECTING RODS

E13054 CRANKSHAFT AND FLYWHEEL ASSEMBLY (METRIC) 12 E13097 • • CRANKSHAFT C/W. OIL TUBE 13 E3903 Oil tube 14 E12800 Screwed plug 15 E12425 Flywheel ... 16 *E12799 Flywheel bolt 37 E11003 Washer ... 38 E3114 Crankshaft stud (11 in. 0.A.) ... 19 E9525 CONNECTING ROD ... 2

10 E1511 Small end bush ... 211 E6576 Connecting rod bolt 412 D3761 Self locking nut ... 413 E3586 Big end bearing (Available in —•010 in. and — . 020 in. undersizes) 414 E9488 PISTON COMPLETE 9 :1 C.R. 215 E6864 co qo Taper compression ring ... 416 E6865 ) Oil control ring ... ... 217 •••E6861 Gudgeon pin (short) ... 218 WE479 X- 6 ?‘? Circlip ... ... •••... 419 •••E3835 Main bearing, right (metric) ...20 •••El 2662 Motor sprocket, 29 teeth Duplex21 •••E4573 70-'19/Z Distance piece ...22 E10082 Rotor key ...23 542139015qWW(Rotor (99-0739)24 E3975 Tab washer ...25 E3977 Nut 126 E1580 Key ...27 E4564 Timing pinion28 E12877 Nut ...29 E6159 INTERMEDIATE WHEEL 130 E400 Intermediate wheel bush...31 E12719 Camshaft pinion... 232 E1558 Camshaft key ... 233 E11007 Inlet camshaft nut 134 E6523 Exhaust camshaft nut3536

E11063 Inlet camshaft, ... ...•••E9989 EXHAUST CAMSHAFT

37 •••E9988 Tachometer drive plug38 •••E3300 Clamping washer ...39 •••E2879 Main bearing, left (metric) 1Not illus. E12663 Spacer 1Not illus. E8038 Shim (0 .010 in.) -Engine sprocket As required (up to 4)Not illus. E12660 Shim (0 .030 in.) As required (up to 4)

* Use D524 Loctite Sealant

11

ClassicBike.Biz


52

Fig. 2. CRANKCASE

12

ClassicBike.Biz

57

___-.40 82

Fig. 2. CRANKCASE

12


123456789

10111213141516171819202122232425262728293031323334353637383940414243444546474849505152

CRAN KCASE

E11266 CRANKCASE DRIVE SIDE ... ... ... ... ... ... 1E10287 Camshaft bush ... ... ... ... ... ... ... 1E10287 Camshaft bush ... ... ... ... ... ... ... 1E5976 Chain tensioner abutment ... ... ... ... ... 1E13098 CRANKCASE TIMING SIDE ... ... ... ... ... 1E10286 Camshaft bush ... ... ... ... ... ... ... 2E4538 Scavenge pipe ... ... ... ... ... ... ... Reference onlyE6386 Locating peg (at oil pipes) ... ... ... Reference onlyT989 Hollow dowel ... ... ... ... ... ... ... 2T912 Locating peg (LAS at thrust washer) ... ... ... ... 1T1606 Needle roller bearing, layshaft ... ... ... ... ... 1E375 Intermediate wheel spindle ... ... ... ... ... 1E8751 Hollow dowel ... ... ... ... ... ... ... ... 1E3716 Hollow dowel ... ... ... ... ... ... ... ... 1 Not requiredS1873 Screw ... ... ••. ... ... ... ... ... ... 2 on later models14-1445 Stud ... ... ... ... ... ... ... ... ... 1S25-2(0-'24' Plain washer ... ... ... ... ... ... ... ... 214-0303 Nut ... ... ... ... ... ... ... ... ... 2E1532 Hollow dowel, tappet oil feed ... ... ... ... ... 2E9330 Oilway plug ... ... ... ... ... ... ... ... 1F1880 Copper washer ... ... ... ... ... ... ... ... 1S1871 Tachometer drive plug (L.H. thread) ... ... ... ... 1E8896 Fibre washer ... ... ... ... ... ... ... ... 251863 Oil pipe stud ... ... ... ... ... ... ... ... 151865 Cylinder stud ... ... ... ... ... ... ... ... 851872 Plug, timing hole ... ... ... ... ... ... ... 1S1870 Bolt ... ... ... ... ... ... ... ... ... 114-6220 Bolt ... ... ... ... ... ... ... ... ... 114-6223 Bolt ... •.. ... ... ... ... ... ... ... 114-0230 Bolt ... •.. ... ... ... ... ... ... ... 1S1823 Bolt ... ... ... ... ... ... ... ... ... 2 (TR6C 3 off)D2330 Plain washer ... ... ... ... ... ... ... ... 10 (TR6C 7 off)14-1302 Nut ... ... ... ... ... ... ... .. ... 5 (TR6C 4 off)E9336 Crankcase filter... ... ... ... ... ... ... ... 1E53157O- 72-Joint washer ... ... ... ... ... ... ... ... 1T2167 Drain plug (with level tube) ... ... ... ... ... ... 1T1257 Fibre washer ... ... ... ... ... ... ... ... 1S543 Level plug UN ... ... ... ... ... ... ... ... 1E2441G,O- 7/32 Copper washer ... ... ... ... ... ... ... ... 1T2259 Drain and adjuster plug ... ... ... ... ... ... 1T1738 Fibre washer ... ... ... ... ... ... ... ... 1T1 920 Blanking plug ... ... ... ... ... ... ... ... Reference onlyT2166 Filler plug UN ... ... ... ... ... ... ... ... 2E8782 "0" ring ... ... ... ... ... ... ... ... 214-6242 Bolt ... ... ... ... ... ... ... ... ... 1S669 Stud ... ... ... ... ... ... ... ... ... 1 (Except TR6C)E8892 Protection blade ... ... ... ... ... ... ... 1

14-1301 Self locknut UN ... ... ... ... ... ... ... 1

E7573 Rubber plug (for protection blade stud hole) ... ... ... 1

14-0402 Nut, exhaust ties ... ... ... ... ... ... -.. 2 (Except TR6C)

E11072 Breather cover plate assembly ... ... ... ... ... I

E11075 Screw ... ... ... ... ... ... ... ... ... 1

13

ClassicBike.Biz


CRANKCASE (continued)

5354555657585960

E9335 Outlet stub ... ...E11460 Joint washer ... ...E11077 Screw ... ... ...E11078 Tube, primary chain oilerE4705 Clip ... ... ...S26-2 600- %'2S0 Spring washer ... ...14-0101 Bolt (gib in. U.H.) ...E11345 Grommet, alternator leads-

... ... ... ... ... ... 1

... ... ... ... ... ... 1

... ... ... ... ... ... 2

... ... ... ... ... ... 1

... ... ... ... ... ... 1

... ... ... ... ... ... 1

... ... ... ... ... ... 1—external ... ... ... ... 1

15

ClassicBike.Biz

Bruce

Cross-Out

5

10

9

Assy 1

12

11

6

7

8

20

22

21

23

24

28

Fig. 3. OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS

16

ClassicBike.Biz


CRANKCASE (continued)

53 E9335 Outlet stub 000 000 000 000 ... 000 000 000 1 54 E11460 Joint washer ... 000 000 ... ... 000 . .. 000 1 55 E11077 Screw 000 ... . .. 000 ... ... . .. 000 000 2 56 E11078 Tube, primary chain oiler ... . .. ... . .. 000 000 1 57 E4705 Clip 000 ... 000 ... 000 000 000 000 ... 1 58 S26-2 ~- ti2SO Spring washer ... 000 ... ... 000 000 ... 000 1 59 14-0101 Bolt U6 in. U.H.) ... 000 ... ... 000 000 ... 1 60 E11345 Grommet, alternator leads-external ... 000 000 ... 1

15


OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS

1 E9421 OIL PUMP ... ... ... ... ... ... ... ... 12 Reference only Pump body... ... ... ... ... ... ... ... 13 E9269 Feed plunger ... ... ... ... ... ... ... 14 E6681 Scavenger plunger ... ... ... ... ... ... 15 E495 Drive block ... ... ... ... ... ... ... 16 S70-7 6 0-

2.363 Valve ball ( 3'—z in. dia.) ... ... ... ... 27 E403 Valve spring ... ... ... ... ... ... ... 28 E2360 Screwed plug ... ... ... ... ... ... ... 29 E11461 Joint washer ... ... ... ... ... ... ... ... 1

10 S1864 Oil pump stud ... ... ... ... ... ... ... ... 211 E3887 Serrated washer ... ... ... ... ... ... ... 212 S1906 Nut ... ... ... ... ... ... ... ... ... 213 E6595 Oil release valve ... ... ... ... ... ... ... 114 E167060 33Y5 Fibre washer ... ... ... ... ... ... ... ... 1Not Illus. E8754 Joint washer, release valve cap to body ... ... ... ... Available15 S1876 Stud ... ... ... ... ... ... ... ... ... 416 E5660 Joint washer ... ... ... ... ... ... ... ... 217 E9973 Inlet manifold ... ... ... ... ... ... ... ... 118 S25-136€ 4'2 %{8' Plain washer ... ... ... ... ... ... ... ... 419 S1877 Nut ... ... ... ... ... ... ... ... ... 4

TR620 S1996 Stud21 E9555 Cup ... ... ... ... ... ... ... ... ... 222 E9554 "0" ring ... ... ... ... ... ... ... ... 223 14-1301 Nut ... ... ... ... ... ... ... ... ... 224 E9352 Inlet tappet guide ... ... ... ... ... ... ... 125 E9353 Exhaust tappet guide ... ... ... ... ... ... ... 126 El 612 Copper washer ... ... ... ... ... ... ... ... 2

2728

H200 Set bolt ..E3059R Inlet tappet 70.- 3D /9 b. /. y ... ... ... ... ...

22

29 E8801 Exhaust tappet ... ... ... ... ... ... ... 2

30 E7563 '0' ring ... ... ... ... ... ... ... ... 2

7c-8g5 /A- --/ mFPe7 f,,Q /S G4r,'r

17

ClassicBike.Biz

17

16

15

14

1B4

Fig, 4, CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)

18

ClassicBike.Biz


OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS

1 E9421 OIL PUMP ... ... ... ... ... ... ... .. . 1

2 Reference only Pump body ... 3 E9269 Feed plunger ... ... ... ... ... .. . ... 1

4 E6681 Scavenger plunger ... ... ... ... ... .. . 1

5 E495 Drive block ... ... ... ... ... ... .. . 1 6 S70-7 GD- 2..363 Valve ball {J2 in. dia.) ... ... ... ... ... .. . 2

7 E403 Valve spring ... ... ... ... ... . .. ... 2

8 E2360 Screwed plug ... ... . .. . .. ... .. . ... 2

9 E11461 Joint washer ... ... . .. ... . .. ... . .. ... 1

10 S1864 Oil pump stud ... ... ... ... ... ... . .. ... 2

11 E3887 Serrated washer ... ... . .. . .. ... .. . ... 2

12 S1906 Nut ... ... .. . ... ... .. . . .. ... . .. 2

13 E6595 Oil release valve ... ... ... ... . .. ... ... 1

14 E167060-33S'5' Fibre washer ... ... . .. . .. ... . .. ... ... 1

Not lllus. E8754 Joint washer, release valve cap to body ... . .. . .. .. . Available

15 S1876 Stud ... ... . .. ... . .. . .. ... ... . .. 4

16 E5660 Joint washer ... . .. ... . .. ... ... . .. ... 2

17 E9973 Inlet manifold ... ... ... . .. ... . .. ... ... 1

18 S25-13b0- '12'18 Plain washer ... ... ... . .. ... . .. . .. ... 4

19 S1877 Nut ... ... ... ... ... .. . ... .. . ... ~ '> TR6 20 S1996 Stud ... ... ... ... .. . ... .. . ... ... 21 E9555 Cup ... ... . .. ... ... .. . ... . .. ... 2

22 E9554 "0" ring ... ... ... .. . ... . .. ... .. 2

23 14-1301 Nut ... ... . .. ... ... ... . .. ... ... 2

24 E9352 Inlet tappet guide ... ... ... ... ... .. . ... 1

25 E9353 Exhaust tappet guide ... ... ... ... .. . ... ... 1

26 E1612 Copper washer ... ... ... . .. ... . .. ... ... 2

27 H200 Set bolt ... ... ... 0 ... ... ... ... . .. ... 2

28 E3059R Inlet tappet 70::: 30 §:<f O.t.'( ... ... ... . .. ... 2

. 29 E8801 Exhaust tappet .. . .. . ... ... .. . ... ... 2

30 E7563 '0' ring ... ... ... . .. ... ... ... ... 2

70- gg>1S /IJ. + £ ;<'. II!'PPt!'l rc;l? ::# 15" CAm

17

1234566a789

10111213141516171819202122232425262728293031323334353637383940414243

84222

222224444844

2


CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)

E6309E6304S692E2620E12575E7310E11283E4547E12354

Cylinder base washCylinder block ...Cylinder base nutPush rodCover tube ..."0" ring, push rod"0" ring, push rodCylinder head gaskeCYLINDER HEAD

cover tube (bottom)cover tube (top)tc/w GUIDES

er

44

454647484950 E1288870-ve0 Bolt, cylinder head51 E1288974-9781 Bolt, rocker box

246664244444224446424244

•• • 4

• • • 4

E2899 7/-32?2 Inlet valve guide ...E2900 7/-3195 Exhaust valve guideE9516 Exhaust pipe adaptorE4603 Inlet valveE2904 Exhaust valveE6439 Bottom cup ... •••E4221 Inner valve spring (red spot) ... •••E7400 Outer valve spring (green spot) •••E1543 Top collar ... •••99-006271- 37g Split cotter ... •••E327 Cylinder head bolt •••F2184 Plain washer •••E4771 Bolt ... •••S25-3 -g2q7 Plain washer •••D3548 Sealing ring ... •••E12350 Inlet rocker box •••E12351 Exhaust rocker box •••E12599 Joint washer ... •••51875 Rocker box bolt •••1 301 Rocker box nut •••E3302 Plain washer ... •••1 1401 Rocker box stud •••S25-13 qZ4e Plain washer ... •••1 1435 Cylinder head stud (for torque stay) •••E4610 7/-174'q Inspection cap ... .••E3751 Joint washer ... •••E4609 Locking spring ... •••WE170 6o-q263 Fibre washer ... •••1 2203 Screw ... •••E1457 ROCKER (right exhaust, left inlet) ... •••E1458 ROCKER (left exhaust, right inlet) ... •••E10070 Rocker ball pin •••E1513 Rocker adjusting pin •••E470 Adjuster lock nut •••E1575 Thrust washer,

z in. •••E1574 Spring washer ... •••E1512 Rocker spindle ... •••E12361 Dowel, rocker box •••El 330 Thrust washer, in. •••

E12079 Access plug ... •••

E12080 Washer ... •••

19

ClassicBike.Biz

e-5837 x-57

- 56 34 3335 36

24 ^ / 51E31 27 32

q ^^ j;

45 23

43 ? 52 E3 29

48 49 I 0---28

50- 25 46

21 30

1 i22

42

41 -^

44 47 39 40 43

4

26

6A

1918

2017 ^^

g -16

15 8

12

1413

F1

^IiiNill

-- 11

10

7 6

53

54

2

3

1 ^ a

B4

Fig. 4. CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)

20

ClassicBike.Biz


CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)(continued)

52 E12598 Spacer ... ... ... ... ... ... ... ... ... 453 E4752 Sealing ring ... ... ... ... ... ... ... ... 254 E11707 Sleeve ... ... ... ... ... ... ... ... ... 255 D2332 Washer ... ... ... ... ... ... ... ... ... 456 E12597 Distance piece 257 D2331 Washer For torque stay ... ... ... ... ... 258 14-1303 Nut J ... ... ... ... 2

21

ClassicBike.Biz

5453

52

B4

Fig. S. CYLINDER BLOCK AND HEAD, TR6R, TR6C (LATER MODELS)

22

ClassicBike.Biz


52 53 54 55 56 57 58

CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS) (continued)

E12598 Spacer ... ... ... ... ... ... ... ... .. . 4 E4752 Sealing ring ... ... ... ... ... ... ... .. . 2 E11707 Sleeve ... ... ... ... ... ... ... . .. ... 2 D2332 Washer ... ... ... ... .. . ... ... .. . ... 4 E12597 Dlst'"<e plo<e} ... ... ... ... .. . 2 D2331 Washer For torque stay ... ... ... ... .. . 2 14-1303 Nut ... . .. ... ... .. . 2

21


CYLINDER BLOCK AND HEAD, TR6R, TR6C(LATER MODELS)

1 E6309 Cylinder base washer ... ... ... ... ... ... ... 12 E6304 Cylinder block ... ... ... ... ... ... ... ... 13 S692 Cylinder base nut ... ... ... ... ... ... ... 84 E2620 Push rod ... ... ... ... ... ... ... ... 45 E12575 Cover tube ... ... ... ... ... ... ... ... 26 E7310 "0" ring, push rod cover tube (bottom) ... ... ... ... 26a E11283 "0" ring, push rod cover tube (top) ... ... ... ... 27 E4547 Cylinder head gasket ... ... ... ... ... ... ... 18 E12806 CYLINDER HEAD c/w GUIDES ... ... ... ... ... 19 E2899 7/-3Z9Z Inlet valve guide ... ... ... ... ... ... ... 2

10 E29007/-3293 Exhaust valve guide ... ... ... ... ... ... 211 E4603 Inlet valve ... ... ... ... ... ... ... ... 212 E2904 Exhaust valve ... ... ... ... ... ... ... ... 213 E6439 Bottom cup ... ... ... ... ... ... ... ... 414 E4221 Inner valve spring (red spot) ... ... ... ... ... ... 415 E7400 Outer valve spring (green spot) ... ... ... ... ... 416 E1543 Top collar ... ... ... ... ... ... ... ... 417 99-00627/-374'8Split cotter ... ... ... ... ... ... ... ... 818 E327 Cylinder head bolt ... ... ... ... ... ... ... 419 F2184 Plain washer ... ... ... ... ... ... ... ... 420 E4771 Bolt ... ... ... ... ... ... ... ... ... 121 S25-360-'/Z'/7 Plain washer ... ... ... ... ... ... ... ... 122 D3548 Sealing ring ... ... ... ... ... ... ... ... 223 E12569 Inlet rocker box ... ... ... ... ... ... ... 124 E12570 Exhaust rocker box ... ... ... ... ... ... ... 125 E12599 Joint washer ... ... ... ... ... ... ... ... 226 51875 Rocker box bolt ... ... ... ... ... ... ... 427 14-0301 Rocker box nut... ... ... ... ... ... ... ... 628 E3302 Plain washer ... ... ... ... ... ... ... ... 629 14-1401 Rocker box stud ... ... ... ... ... ... ... 630 525-13(j0-1/2Vo0Plain washer ... ... ... ... ... ... ... ... 431 14-1435 Cylinder head stud (for torque stay) ... ... ... ... 232 E12572 Inspection cover ... ... ... ... ... ... ... 433 E12574 Joint washer ... ... ... ... ... ... ... ... 434 E1457 ROCKER (right exhaust, left inlet) ... ... ... ... ... 235 E1458 ROCKER (left exhaust, right inlet) ... ... ... ... ... 236 E10070 Rocker ball pin ... ... ... ... ... ... ... 437 E1513 Rocker adjusting pin ... ... ... ... ... ... ... 438 E470 Adjuster lock nut ... ... ... ... ... ... ... 439 E1575 Thrust washer, 2 in. ... ... ... ... ... ... ... 640 E1574 Spring washer ... ... ... ... ... ... ... ... 441 E1512 Rocker spindle ... ... ... ... ... ... ... ... 242 E12361 Dowel, rocker box ... ... ... ... ... ... ... 443 E1330 Thrust washer, e in. ... ... ... ... ... ... ... 244 E12079 Access plug ... ... ... ... ... ... ... ... 445 E12080 Washer ... 4

46 El288870-9700aBolt, cylinder head ... ... ... ... ... ... ... 4

47 E1 2889 70-9 78/ Bolt, rocker box ... ... ... ... ... ... ... 4

23

ClassicBike.Biz

5453

52

B4

Fig. S. CYLINDER BLOCK AND HEAD, TR6R, TR6C (LATER MODELS)

24

ClassicBike.Biz


CYLINDER BLOCK AND HEAD, TR6R, TR6C (LATER MODELS)

1 E6309 Cylinder base washer ... ... . .. . .. . .. . .. . .. 1 2 E6304 Cylinder block ... ... . .. . .. . .. . .. ... ... 1 3 S692 Cylinder base nut ... . .. . .. ... . .. . .. . .. 8

4 E2620 Push rod ... ... . .. . .. . .. . .. ... . .. 4 5 E12575 Cover tube ... ... . .. . .. ... . .. . .. . .. 2 6 E7310 "0" ring, push rod cover tube (bottom) ... ... . .. . .. 2 6a E11283 "0" ring, push rod cover tube (top) ... . .. . .. ... 2 7 E4547 Cylinder head gasket ... ... ... . .. ... ... . .. 1 8 E12806 CYLINDER HEAD cjw GUIDES ... ... . .. . .. . .. 1 9 E2899 71-3Zt!JZ. Inlet valve guide ... ... ... . .. . .. . .. ... 2

10 E2900 7t-?J2.,, Exhaust valve guide ... ... ... . .. . .. ... 2

11 E4603 Inlet valve ... ... . .. ... . .. ... . .. ... 2

12 E2904 Exhaust valve ... ... . .. . .. ... . .. . .. ... 2

13 E6439 Bottom cup ... . .. ... ... ... ... . .. ... 4

14 E4221 Inner valve spring (red spot) ... ... ... . .. ... . .. 4

15 E7400 Outer valve spring (green spot) ... . .. ... . .. ... 4

16 E1543 Top collar ... . .. ... . .. ... . .. ... . .. 4

17 99-00627/- 37q9Split cotter ... ... ... . .. ... . .. ... . .. 8

18 E327 Cylinder head bolt ... . .. ... ... . .. . .. ... 4

19 F2184 Plain washer ... ... . .. . .. ... . .. ... ... 4

20 E4771 Bolt ... ... . .. . .. ... ... . .. . .. ... 1

21 S25-3GO-tfZ.tl7 Plain washer ... . .. ... ... ... ... ... ... 1

22 D3548 Sealing ring ... ... . .. ... ... . .. ... ... 2

23 E12569 Inlet rocker box ... ... . .. ... ... . .. ... .1

24 E12570 Exhaust rocker box ... ... ... ... ... ... ... 1

25 E12599 Joint washer ... ... . .. ... ... . .. ... ... 2

26 S1875 Rocker box bolt ... ... . .. ... ... ... ... 4

27 14-0301 Rocker box nut ... ... . .. ... ... ... ... ... 6

28 E3302 Plain washer ... ... . .. ... ... . .. ... ... 6

29 14-1401 Rocker box stud ... . .. ... ... . .. ... ... 6

30 S25-136o-fi2YS'Piain washer ... ... . .. ... ... . .. ... ... 4

31 14-1435 Cylinder head stud (for torque stay) ... . .. ... ... 2

32 E12572 Inspection cover ... ... ... ... . .. ... ... 4

33 E12574 Joint washer ... . .. ... ... ... . .. ... ... 4

34 E1457 ROCKER (right exhaust, left inlet) ... ... ... ... ... 2

35 E1458 ROCKER (left exhaust, right inlet) ... ... ... ... ... 2

36 E10070 Rocker ball pin ... ... ... ... ... ... ... 4

37 E1513 Rocker adjusting pin ... ... ... ... . .. ... ... 4

38 E470 Adjuster lock nut ... ... ... ... ... ... ... 4

39 E1575 Thrust washer, t in. ... ... ... ... ... ... ... 6

40 E1574 Spring washer ... ... ... ... ... ... ... ... 4

41 E1512 Rocker spindle ... ... . .. ... ... . .. ... ... 2

42 E12361 Dowel, rocker box ... . .. ... ... ... ... ... 4

43 E1330 Thrust washer, i in. ... ... ... ... ... ... ... 2

44 E12079 Access plug ... . .. ... ... ... ... ... ... 4

45 E12080 Washer ... ... ... ... ... ... ... ... 4

46 E128887o-'f7R0Bolt, cylinder head ... ... ... ... ... ... ... 4

47 E12889 70·Cf74'/ Bolt, rocker box ... ... ... 4

23


CYLINDER BLOCK AND HEAD, TR6R, TR6C (LATER MODELS) (continued)

48 E12598 Spacer ... 449 E4752 Sealing ring ... 250 E11707 Sleeve ... 251 D2332 Washer ... 452 E12597 Distance piece 253 D2331 Washer For torque stay ... 254 14-1303 Nut 255 14-0103 Screw 856 D2329

}

Tappet inspection cover r 8

25

ClassicBike.Biz

06746 66

(5 --- 65

44 45

60 29

B5

Fig. 6. CYLINDER BLOCK AND HEAD, T12OR (EARLIER MODELS)

26ClassicBike.Biz


CYLINDER B L 0 C K AND HEAD, T R 6 R, T R 6 C (LATER MODELS) (continued)

48 E12598 Spacer ... 000 ... . .. 000 ... 000 000 ... 4 49 E4752 Sealing ring ... ... . .. 000 ... 000 000 ... 2 so E11707 Sleeve 000 ... 000 . .. 000 ... ... . .. . .. 2 51 D2332 Washer ... ... . .. . .. 000 ... . .. 000 ... 4 52 E12597 Dltto"'e ple<e } ... 000 000 00 000 2 53 D2331 Washer For torque stay ... 000 ... 000 000 2 54 14-1303 Nut ... 000 ... ... . .. 2 55 14-0103 Screw }T . . ... . .. ... . .. 8 56 D2329 W h appet mspect1on cover 8 as er ... ... . .. ...

25


CYLINDER BLOCK AND HEAD, T120R (EARLIER MODELS)

1 E6309 Cylinder base washer ... ... ... ... ... ... ... 12 E6304 Cylinder block ... ... ... ... ... ... ... ... 13 S692 Cylinder base nut ... ... ... ... ... ... ... 8

4 E2620 Push rod ... ... ... ... ... ... ... ... 4

5 E12575 Cover tube ... ... ... ... ... ... ... ... 26 E7310 "0" ring (bottom) ... ... ... ... ... ... ... 2

6A E11283 "0" ring (top) ... ... ... ... ... ... ... ... 2

7 E4547 Cylinder head gasket ... ... ... ... ... ... ... 1

8 E12356 CYLINDER HEAD c/w GUIDES ... ... ... ... ... 1

9 E5347 Sleeve for head bolts passing through inlet tracts ... ... Reference only

10 E3827 7/- 329y Inlet valve guide ... ... ... ... ... ... ... 2

11 E38287/- 3Z 9'.r Exhaust valve guide ... ... ... ... ... ... 2

12 E9550 Carburetor adaptor, left ... ... ... ... ... ... 1

13 E9551 Carburetor adaptor, right ... ... ... ... ... 1

14 E6916 Connector ... ... ... ... ... ... ... ... 2

15 E4792 Balance pipe ... ... ... ... ... ... ... 1

16 S1932 Adaptor locking nut ... ... ... ... ... ... 2

17 E9516 Exhaust pipe adaptor ... ... ... ... ... ... 2

18 14-1301 Self-locking nut ... ... ... ... ... ... ... 4

19 E9555 Cup ... ... ... ... ... ... ... ... ... 7

20 E9554 Insulating ring ... ... ... ... ... ... ... ... 4

21 E4603 Inlet valve ... ... ... ... ... ... ... ... 2

22 E2904 Exhaust valve ... ... ... ... ... ... ... ... 2

23 E6439 Bottom cup ... ... ... ... ... ... ... ... 4

24 E4221 Inner valve spring (Red spot) ... ... ... ... ... 4

25 E7400 Outer valve spring (green spot) ... ... ... ... ... 4

26 E1543 Top collar ... ... ... ... ... ... ... ... 4

27 99-00627/ 37Y(?Split cotter ... ... ... ... ... 828 E327 Cylinder head bolt ... ... ... ... ... ... ... 4

29 F2184 Plain washer ... ... ... ... ... ... ... ... 4

30 E4771 Bolt ... ... ... ... ... ... ... ... ... 1

31 S25-3 0-4v{7 Plain washer ... ... ... ... ... ... ... ... 1

32 D3548 Sealing ring ... ... ... ... ... ... ... ... 2

33 E12350 Inlet rocker box ... ... ... ... ... ... ... 1

34 E12351 Exhaust rocker box ... ... ... ... ... ... ... 1

35 E12599 Joint washer ... ... ... ... ... ... ... ... 2

36 S1875 Rocker box bolt ... ... ... ... ... ... ... 4

37 14-0301 Nut ... ... ... ... ... ... ... ... ... 6

38 E3302 Plain washer ... ... ... ... ... ... ... ... 6

39 14-1401 Rocker box stud ... ... ... ... ... ... ... 6

40 S25-1360-42q Plain washer ... ... ... ... ... ... ... ... 4

41 14-1435 Cylinder head stud (for torque stay) ... ... ... ... 2

42 E461070-Z7q/q Inspection cap ... ... ... ... ... ... ... ... 4

43 E3751 Joint washer ... ... ... ... ... ... ... ... 4

44 E4609 Locking spring ... ... ... ... ... ... ... ... 4

45 WE17060-qz 3Fibre washer ... ... ... ... ... ... ... ... 4

46 14-2203 Screw ... ... ... ... ... ... ... ... ... 4

47 E1457 ROCKER (right exhaust, left inlet) ... ... ... ... ... 2

48 E1458 ROCKER (left exhaust, right inlet) ... ... ... ... ... 2

49 E10070 Rocker ball pin ... ... ... ... ... ... ... 4

50 E1513 Rocker adjusting pin ... ... ... ... ... ... ... 4


52 E1575 Thrust washer, '-z in. •.. •.. ... 6

53 E1574 Spring washer ... ... ... ... ... ... ... ... 4

27

ClassicBike.Biz

1B5

Fig. 6. CYLINDER BLOCK AND HEAD, T12OR (EARLIER MODELS)

28

ClassicBike.Biz


CYLINDER BLOCK AND HEAD, T120R (EARLIER MODELS)

E6309 Cylinder base washer ... ... . .. . .. . .. . .. . .. 1 2 E6304 Cylinder block ... ... ... . .. . .. ... . .. . .. 1 3 S692 Cylinder base nut ... ... ... . .. ... . .. . .. 8

4 E2620 Push rod ... ... ... ... . .. ... . .. . .. 4

5 E12575 Cover tube ... ... ... ... ... . .. . .. . .. 2 6 E7310 "0" ring (bottom) ... ... ... . .. . .. . .. . .. 2

6A E11283 "0" . ( ) rmg top ... . .. ... . .. . .. ... . .. . .. 2

7 E4547 Cylinder head gasket ... ... ... ... ... . .. . .. 1 8 E12356 CYLINDER. HEAD cfw GUIDES ... ... . .. . .. . .. 1 9 E5347 Sleeve for head bolts passing through inlet tracts ... . .. Reference only

10 E3827 7/-32.'1'( Inlet valve guide ... ... ... ... . .. ... . .. 2 11 E3828 7/- 32 Cfj'"" Exhaust valve guide ... ... ... ... . .. . .. 2

12 E9550 Carburetor adaptor, left ... ... ... . .. ... . .. 1

13 E9551 Carburetor adaptor, right ... ... ... . .. . .. 1

14 E6916 Connector ... ... ... ... . .. ... . .. . .. 2

15 E4792 Balance pipe ... ... ... ... ... . .. . .. 1

16 S1932 Adaptor locking nut ... ... ... ... . .. . .. 2

17 E9516 Exhaust pipe adaptor ... ... ... ... ... . .. 2

18 14-1301 Self-locking nut ... ... ... ... . .. ... . .. 4

19 E9555 Cup ... ... ... ... ... ... . .. ... . .. 7

20 E9554 Insulating ring ... ... ... ... ... ... . .. . .. 4

21 E4603 Inlet valve ... ... ... ... . .. ... ... . .. 2

22 E2904 Exhaust valve ... ... ... ... ... ... ... . .. 2

23 E6439 Bottom cup ... ... ... ... ... ... ... . .. 4

24 E4221 Inner valve spring (R.ed spot) ... ... ... ... ... 4

25 E7400 Outer valve spring (green spot) ... ... ., ... . .. . .. 4

26 E1543 Top collar ... ... ... ... ... ... . .. ... 4

27 99-D0627/-37tf~Split cotter ... ... ... . .. ... ... ... . .. 8

28 E327 Cylinder head bolt ... ... . .. ... . .. ... . .. 4

29 F2184 Plain washer ... ... ... ... ... . .. ... ... 4

30 E4771 Bolt ... ... ... ... . .. ... . .. ... ... 1

31 S25-3~0-4Z.'/7 Plain washer ... ... ... . .. ... ... ... . .. 1

32 D3548 Sealing ring ... ... ... ... ... ... . .. ... 2


34 E12351 Exhaust rocker box ... ... . .. ... ... ... ... 1

35 E12599 Joint washer ... ... ... . .. ... ... ... ... 2

36 S1875 Rocker box bolt ... ... . .. ... . .. ... ... 4

37 14-0301 Nut ... ... ... ... . .. ... ... ... . .. 6

38 E3302 Plain washer ... ... ... . .. ... ... ... ... 6

39 14-1401 Rocker box stud ... ... ... ... ... ... . .. 6

40 S25-1360-'f2'f&'Piain washer ... ... ... ... ... ... ... . .. 4


42 E461070-Z7lf'/lnspection cap ... ... ... . .. ... ... ... . .. 4

43 E3751 Joint washer ... ... ... ... ... ... . .. . .. 4

44 E4609 Locking spring ... ... ... ... ... ... . .. ... 4

45 WE17060-lfU3Fibre washer ... ... ... . .. ... ... ... ... 4

46 14-2203 Screw ... ... ... ... . .. ... ... ... ... 4

47 E1457 ROCKER. (right exhaust, left inlet) ... ... ... ... ... 2

48 E1458 ROCKER. (left exhaust, right inlet) ... ... ... ... ... 2

49 E10070 Rocker ball pin ... ... ... ... ... ... ... 4



52 E1575 Thrust washer, t in. ... . ., . ... ... ... ... ... 6

53 E1574 Spring washer ... ... ... 4

27


CYLINDER BLOCK AND HEAD, MOR (EARLIER MODELS)(continued)

54 E1512 Rocker spindle ... 2

55 E12361 Dowel, rocker box 4

56 El 330 Thrust washer, a in. 2

57 E12079 Access plug ... 4

58 E12080 Washer ... 4

59 E128887o-9780 Bolt, cylinder head 4

60 E1288970 781 Bolt, rocker box 4

61 D2332 Washer ... 4

62 E12598 Spacer ... 4

63 E4752 Sealing ring 2

64 E11707 Sleeve ... 2

65 E12597 Distance piece 2

66 D2331 Washer For torque stay ... 2

67 14-1303 Nut 2

29

ClassicBike.Biz

^---64-63

(5---- 62

B5

Fig. 7. CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS)

30

ClassicBike.Biz


CYLINDER BLOCK AND HEAD, T120 R (EARLIER MODELS) (continued)

54 E1512 Rocker spindle ... ... . .. . .. ... . .. . .. . .. 2

55 E12361 Dowel, rocker box ... ... ... ... . .. . .. ... 4

56 E1330 Thrust washer, i in. ... . .. . .. ... . .. . .. ... 2 57 E12079 Access plug ... ... . .. ... ... . .. ... ... 4 58 E12080 Washer ... ... ... ... . .. ... ... . .. ... 4

59 E128887b-97B'O Bolt, cylinder head ... . .. ... ... ... . .. . .. 4

60 E1288970..&f781 Bolt, rocker box ... ... . .. ... ... ... . .. 4

61 D2332 Washer ... ... . .. ... ... ... ... . .. ... 4

62 E12598 Spacer ... . .. ... . .. ... . .. ... . .. ... 4

63 E4752 Sealing ring ... . .. ... ... ... ... . .. ... 2

64 E11707 Sleeve ... . .. ... ... ... ... ... ... ... 2

65 E12597 D;u•n<e p;e<e} ... ... ... ... . .. 2

66 D2331 Washer For torque stay ... ... ... ... ... 2

67 14-1303 Nut ... ... . .. ... 2

29


CYLINDER BLOCK AND HEAD, T120R(LATER MODELS)

1 E6309 Cylinder base washer ... ... ... ... ... ... ... 1

2 E6304 Cylinder block ... ... ... ... ... ... ... ... 1

3 S692 Cylinder base nut ... ... ... ... ... ... ... 8

4 E2620 Push rod ... ... ... ... ... ... ... ... 4

5 E12575 Cover tube ... ... ... ... ... ... ... ... 2

6 E7310 "0" ring (bottom) ... ... ... ... ... ... ... 2

6A E11283 "0" ring (top) ... ... ... ... ... ... ... 2

7 E4547 Cylinder head gasket ... ... ... ... ... ... ... 1

8 E12807 7/-3y9/(oCYLINDER HEAD c/w GUIDES ... ... ... ... ... 1

9 E5347 Sleeve for head bolts passing through inlet tracts ... ... Reference only

10 E3827 7/- 329'( Inlet valve guide ... ... ... ... ... ... ... 2

11 E38287/- 3295 Exhaust valve guide ... ... ... ... ... ... 2

12 E12811 Carburetor adaptor, left ... ... ... ... ... 1

13 E12812 Carburetor adaptor, right ... ... ... ... ... 1

14 E6916 Connector ... ... ... ... ... ... ... ... 2

15 E4792 Balance pipe ... ..• ... ... 1

16 E12813 Stud ... ... ... ... ... ... ... ... ... 4

17 E8771 7/- / %f/(p Gasket ... ... ... ... ... ... ... ... 2

18 14-1301 Self-locking nut ... ... ... ... ... ... ... 4

19 E9555 Cup ... ... ... ... ... ... ... ... ... 4

20 E9554 Insulating ring ... ... ... ... ... ... ... ... 4

21 E4603 Inlet valve ... ... ..• ..• ... 2

22 E2904 Exhaust valve ... ... ... ... ... ... ... ... 2

23 E6439 Bottom cup ... ... ... ... ... ... ... ... 4

24 E4221 Inner valve spring (Red spot) ... ... ... ... ... 4

25 E7400 Outer valve spring (green spot) ... ... _.. ... ... 4

26 El 543 Top collar ... ... ... ... ... ... ... ... 427 99-00627/-37`lrSplit cotter ... ... ... ... ... ... ... ... 8

28 E327 Cylinder head bolt ... ... ... ... ... ... ... 4

29 F2184 Plain washer ... ... ... ... ... ... ... ... 4

30 E4771 Bolt ... ... ... ... ... ... ... ... ...

31 S25-3 0-W-/7 Plain washer ... ... ... ... ... ... ... ... 1

32 D3548 Sealing ring ... ... ... ... ... ... ... ... 2


34 El 2570 Exhaust rocker box ... ... ... ... ... ... ... 1

35 E12599 Joint washer ... ... ... ... ... ... ... ... 2

36 S1875 Rocker box bolt ... ... ... ... ... ... .. 4

37 14-0301 Nut ... ... ... ... ... ... ... ... ... 6

38 E3302 Plain washer ... ... ... ... ... ... ... ... o

39 14-1401 Rocker box stud ... ... ... ... ... ... ... 6

40 S25-13f -gzq 'Plain washer ... ... ... ... ... ... ... ... 4


42 E12572 Inspection cover ... ... ... ... ... ... ... 4

43 E12574 Joint washer ... ... ... ... ... ... ... ... 4

44 Ell 457 ROCKER (right exhaust, left inlet) ... ... ... ... ... 2

45 Ell 458 ROCKER (left exhaust, right inlet) ... ... ... ... ... 2

46 El 0070 Rocker ball pin ... ... ... ... ... ... ... 4



49 El 575 Thrust washer, . In. ... ... ... ... ... ... 6450 El 574 Spring washer ... ... ... ... ... ... ... ...

31

ClassicBike.Biz

6463 62

57 29

41

65

4

6A

24

1B5

Fig. 7. CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS)

32

ClassicBike.Biz


CYLINDER B L 0 C K AND HEAD, T 1 2 0 R (LATER MODELS)

E6309 Cylinder base washer .. . . . . .. . .. . .. . .. . .. . 1 2 E6304 Cylinder block .. . . .. .. . .. . .. . .. . .. . .. . 1 3 S692 Cylinder base nut ... ... ... ... ... ... ... 8 4 E2620 Push rod .. . .. . . .. .. . .. . .. . . .. . .. 4 5 E12575 Cover tube ... . .. .. . .. . . .. . .. . .. ... 2 6 E7310 "0" ring (bottom) ... ... ... ... ... ... ... 2

6A E11283 "0" ring (top) ... ... ... ... ... ... ... 2 7 E4547 Cylinder head gasket ... ... ... ... ... ... ... 1 8 E12807 71-J9'y'~CYLINDER HEAD cjw GUIDES ... ... ... ... ... 1 9 E5347 Sleeve for head bolts passing through inlet tracts ... ... Reference only

10 E3827 7/- 32t:;'f_ Inlet valve guide ... ... ... ... ... ... ... 2 11 E3828 7/- 3 2. t:} > Exhaust valve guide .. . ... ... ... .. . . .. 2 12 E12811 Carburetor adaptor, left . .. .. . . .. . . . . . . 1 13 E12812 Carburetor adaptor, right .. . ... ... ... . . . 1 14 E6916 Connector... ... ... ... ... ... ... ... 2 15 E4792 Balance pipe . . . .. . . . . . . . . . . . . . . . . 1 16 E12813 Stud... ... ... ... ... ... ... ... ... 4 17 E8771 7/-1'1-/(i, Gasket ... ... ... ... ... ... ... ... 2 18 14-1301 Self-locking nut ... ... ... ... ... ... ... 4 19 E9555 Cup ... ... ... ... ... ... ... ... ... 4 20 E9554 Insulating ring ... ... ... ... ... ... ... . . . 4 21 E4603 Inlet valve ... . .. .. . .. . .. . ... .. . ... 2 22 E2904 Exhaust valve . . . . .. . . . .. . . . . . . . . . . . .. 2 23 E6439 Bottom cup ... ... ... ... ... . . . .. . ... 4 24 E4221 Inner valve spring (Red spot) . . . .. . .. . . . . . . . 4 25 E7400 Outer valve spring (green spot) ... ... -- ... ... 4 26 E1543 Top collar .. . .. . . .. . .. .. . .. . . . . .. . 4 27 99-0062 71-37'/?Split cotter . .. .. . . .. .. . .. . . .. . .. .. . 8 28 E327 Cylinder head bolt ... ... ... ... ... ... ... 4 29 F2184 Plain washer ... ... ... ... ... ... ... ... 4 30 E4771 Bolt .. . . .. .. . . .. .. . . .. . . . .. . .. . 1 31 S25-3 fOO-l/-l'/7 Plain washer ... ... ... ... ... ... ... ... 1 32 D3548 Sealing ring ... ... ... ... ... ... ... ... 2 33 E12569 Inlet rocker box . .. ... ... ... ... ... ... 1 34 E12570 Exhaust rocker box . .. . . . . .. .. . . .. .. . . .. 1 35 E12599 Joint washer . . . .. . .. . . . . . . . . . . . . . . . . 2 36 S1875 Rocker box bolt .. . .. . . . . . . . .. . .. . 4 37 14-0301 Nut ... ... ... ... ... ... ... ... ... €. 38 E3302 Plain washer ... . .. .. . ... . .. . . . . .. ... o 39 14-1401 Rocker box stud ... ... ... ... ... ... ... 6 40 S25-13YJ-l{Z.'If Plain washer .. . . .. ... ... ... ... ... .. . 4 41 14-1435 Cylinder head stud (for torque stay) ... ... ... ... 2 42 E12572 Inspection cover . . . ... ... ... .. . ... ... 4 43 E12574 Joint washer ... ... ... ... ... ... ... ... 4 44 E1457 ROCKER (right exhaust, left Inlet) ... ... ... ... ... 2 45 E1458 ROCKER (left exhaust, right inlet) ... ... ... ... ... 2 46 E10070 Rocker ball pin ... ... ... ... ... ... ... 4 47 E1513 Rocker adjusting pin .. . . .. ... ... ... ... .. · 4 48 E470 Adjuster lock nut ... ... ... ... ... ... ... 4 49 E1575 Thrust washer,! ln. ... ... ... ... ... ... ... 6 SO E1574 Spring washer ... -·· ··· ... 4

31

2424444

2

2For torque stay ...

} Tappet inspection cover


CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS) (continued)

51 E1512 Rocker spindle ...52 E12361 Dowel, rocker box53 E1330 Thrust washer, I in.54 E12079 Access plug ...

55 E12080 Washer ... ...56 E1288870-9762 Bolt, cylinder head57 E1288970/0/ Bolt, rocker box58 D2332 Washer59 E12598 Spacer ...60 E4752 Sealing ring61 E11707 Sleeve ...62 E12597 Distance piece63 D2331 Washer64 14-1303 Nut65 14-0103 Screw66 D2329 washer

... 8

33

ClassicBike.Biz

0

11

Fig. 8. AMAL CARBURETOR, TR6R, TR6C

34

ClassicBike.Biz


CYLINDER BLOCK AND HEAD, T 1 2 0 R (LATER MODELS) (continued)

51 E1512 Rocker spindle ... ... . .. . .. ... . .. . .. . .. 2 52 E12361 Dowel, rocker box ... . .. . .. ... ... . .. ... 4 53 E1330 Thrust washer, i in. ... ... . .. ... . .. . .. . .. 2 54 E12079 Access plug ... . .. . .. ... ... . .. . .. . .. 4

55 E12080 Washer ... ... ... . .. ... . .. . .. . .. 4 56 E1288870-9'7c9oBolt, cylinder head ... . .. . .. . .. . .. . .. ... 4 57 E1288970'17A'/ Bolt, rocker box ... . .. . .. ... . .. ... ... 4 58 D2332 Washer ... ... . .. . .. . .. ... . .. . .. ... 4 59 E12598 Spacer ... ... . .. . .. . .. . .. . .. ... . .. 4 60 E4752 Sealing ring ... . .. ... ... . .. . .. ... ... 2 61 E11707 Sleeve ... ... . .. . .. . .. ... . .. ... ... 2 62 E12597 Distance piece I ... ... . .. ... ... 2 63 D2331 Washer JFor torque stay ... . .. . .. ... ... 2 64 14-1303 Nut ... ... . .. ... ... 2

65 14-0103 Screw l T . . ... . .. ... ... 8 66 D2329

h J appet 1nspect1on cover 8 was er ... ... . .. ...

33

REMARKSRef. No. Part No. DESCRIPTION QUANTITY

1 D2183

AMAL CARBURETOR TR6R, TR6C

CARBURETOR (R930/60) less "0" ring ...

2 Mixing chamber (930/005) ... ...Rvfl wnly3 928/098 Mixing chamber top (99-1032) ... ...

4 622/086 Screw (99-0521) ...5 928/060 Throttle valve (3+ cutaway) (99-0527) ...6 622/131 Throttle return spring (99-1033) ...7 622/067 Needle clip (99-0510) ...8 622/124 Needle (99-1036) ... ...9 928/062 Air slide (99-0528) ... ...

10 622/129 Spring (99-1038) ... ...

11 928/103 Air valve guide sleeve (99-1037) ...

12 622/077 Throttle stop screw (99-0516) ... ...

13 622/076 Air adjusting screw (99-0515) ... ...

14 622/082 "0" ring (99-0520) ... ... 2

15 622/122 Needle jet (0 .106) (99-1035) ...

16 622/128 Jet holder (99-1034) ... ...

17 376/100 Main jet (230) (99-0450) ...

18 622/069 Float (99-0512) ... ...

19 622/071 Float spindle (99-0513) ... ... 1

20 622/055 Float chamber (99-0506) ... 1

21 622/073 Joint washer (99-0514) ... ... 1

22 622/068 Needle (99-0511) ... ... 1

23 376/093 Filter (99-0438) ... ...

24 622/078 Banjo bolt (99-0517) ... 1

25 376/092 Fibre washer (99-0437) ... ...

26 622/147 Drain plug (99-1152) ... ...

27 622/151 Washer (99-1153) ... 1

28 Fl 3507 Petrol pipe ... ...

29 E9711 "0" ring ... 1

35

ClassicBike.Biz

O

11

1i

I

6

8

Fig. 9. AMAL CARBURETOR, T12OR

36

ClassicBike.Biz

Ref No. Part No. DESCRIPTION QUANTITY REMARKS

123456789

1011121314151617181920212223242526272829

AMAL CARBURETOR T120R

D3492 CARBURETOR—L.H. (L930/67)"Less "0"

...ring

... 1

D3491 CARBURETOR—R.H. (R930/66)1

Reference only Mixing chamber (L930/005 and R930/005) ... .... ... 1

928/098 Mixing chamber top (99-1032) ... ... ... ... ... 1

622/086 Screw (99-0521) ... ... ... ... ... ... ... 4

928/060 Throttle valve (3 cutaway) (99-0527) ... ... ... ... 1

622/131 Throttle return spring (99-1033) ... ... ... ... 1622/067 Needle clip (99-0510) ... ... ... ... ... ... 1

622/124 Needle (99-1036) ... ... ... ... ... ... ... 1

928/062 Air slide (99-0528) ... ... ... ... ... ... 1

622/129 Spring (99-1038) ... ... ... ... ... ... ... 1

928/103 Air valve guide sleeve (99-1037) ... ... ... ... 1

622/077 Throttle stop screw (99-0516) ... ... ... ... ... 1

622/076 Air adjusting screw (99-0515) ... ... ... ... ... 1

622/082 "0" ring (99-0520) ... ... ... ... ... ... 2

622/122 Needle jet (0 . 106) (99-1035) ... ... ... ... ... 1

622/128 Jet holder (99-1034) ... ... ... ... ... ... 1

376/100 Main jet (190) (99-0446) ... ... ... ... ... ... 1

622/069 Float (99-0512) ... ... ... ... ... ... ... 1

622/071 Float spindle (99-0513) ... ... ... ... ... ... 1

622/055 Float chamber (99-0506) ... ... ... ... ... ... 1

622/073 Joint washer (99-0514) ... ... ... ... ... ... 1

622/068 Needle (99-0511) ... ... ... ... ... ... ... 1

376/093 Filter (99-0438) ... ... ... ... ... ... .. 1

622/078 Banjo bolt (99-0517) ... ... ... ... ... ... 1

376/092 Fibre washer (99-0437) ... ... ... ... ... .. 1

622/147 Drain plug (99-1152) ... ... ... ... ... ... 1

622/151 Washer (99-1153) ... ... ... ... ... ... 1

F13508 Petrol pipe ... ... ... ... ... ... ... ... 1E9711 "0" ring ... ... ... ... ... ... ... ... 2

Eachcarburetor

37

ClassicBike.Biz

e7

Fig. 10. TIMING COVER AND CONTACT BREAKER

38

ClassicBike.Biz

Ref. No. Part No.

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

D3492 D3491 Reference only 928/098 622/086 928/060 622/131 622/067 622/124 928f062 622/129 928f103 622/077 622/076 622/082 622/122 622/128 376/100 622/069 622/071 622/055 622/073 622/068 376/093 622/078 376f092 622/147 622/151 F13508 E9711

DESCRIPTION

AMAL CARBURETOR T120R

CARBURETOR-L.H. (L930f67) } L .. 0 .. . CARBURETOR-R.H. (R930f66) ess nng

Mixing chamber (L930f005 and R930f005) Mixing chamber top (99-1032) ... Screw (99-0521) ... Throttle valve (3 cutaway) (99-0527) Throttle return spring (99-1033) Needle clip (99-0510) Needle (99-1036) ... Air slide (99-0528) Spring (99-1038) ... Air valve guide sleeve (99-1037) Throttle stop screw (99-0516) Air adjusting screw (99-0515) "0" ring (99-0520) Needle jet (0·1 06) (99-1 035) Jet holder (99-1034) Main jet (190) (99-0446) ... Float (99-0512) Float spindle (99-0513) .. . Float chamber (99-0506) .. . Joint washer (99-0514) Needle (99-0511) .. . Filter (99-0438) .. . Banjo bolt (99-0517) Fibre washer (99-0437) Drain plug (99-1152) Washer (99-1153)

Petrol pipe "0" ring

37

QUANTITY REMARKS

1 1

~ l 4 1 1 1 1 1 1 1 1 1

r r 1 1

i J 2

Each carburetor


TIMING COVER AND CONTACT BREAKER

1 E9246 Timing cover ... ... ... ... ... ... ...2 E4016 Patent plate ... ... ... ... ... ... ...

3 D208-55p0-4'25^iHammer-drive screw ... ... ... ... ... ...

4 E4568 Oil seal ... ... ... ... ...4 E6387 Oil seal (0 . 020 in. undersize) ... .. ... ... ...

5 E4569 Circlip ... ... ... ... ... ... ... ...6 T989 Hollow dowel ... ... ... ... ... ... ...

7 14-6609 Screw ... ... ... ... ... ... ... .. .

8 14-6608 Screw ... ... ... ... ... ... ... ...9 14-0208 Bolt ... ... ... ... ... ... ... .. .

10 S25-437O-.'f3 Plain washer ... ... ... ... ... ... ...11 E4707 Rubber grommet ... ... ... ... ... ...12 E7680 Pillar bolt ... ... ... ... ... ... ...

13 E6559 Plain washer ... ... ... ... ... ... ...

14 E8737 Cover ... ... ... ... ... ... ... ...

15 E11462 Joint washer ... ... ... ... ... ... ...

16 GS2996o0-4' Z5 Serrated washer ... ... ... ... ... ...

17 E7354 Screw (4 in. U.H.) ... ... ... ... ... ...

18 54419340 AUTO ADVANCE UNIT (99-0771) ... ... ...

19 54415642 Spring set (99-0757) ... ... ... ... ...

20 54419097 CONTACT BREAKER PLATE ASSEMBLY (99-0768) ...

21 54419827 Contact set (99-0772) ... ... ... ... ...

22 54419220 Pin, adjustment (99-0769) ... ... ... ...

23 D21336p0 ;37/? Oil pressure switch ... ... ... ... ... ...

24 D2045 Cover pressure switch ... ... ... ... ...

Not illus. D2138 Timing label for C.B. cover ... ... ... ... ...

32

... For regroundcrankshaft

35

22

22

22

39

ClassicBike.Biz

b8

Fig. 9 GEARBOX INNER COVER AND SELECTORS

40

12

ClassicBike.Biz



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 Not illus.

E9246 Timing cover .. . E4016 Patent plate .. . 0208-.560-f/ZS"SHammer-drive screw E4568 Oil seal ... E6387 Oil seal (0·020 in. undersize) ...

E4569 T989

Circlip ... Hollow dowel

14-6609 Screw 14-6608 Screw 14-0208 Bolt S25-4370~~?/63 Plain washer E4707 Rubber grommet E7680 Pillar bolt E6559 Plain washer E8737 Cover ... E11462 Joint washer ... GS299,0-'{l~ Serrated washer E7354 Screw (t in. U.H.) 54419340 AUTO ADVANCE UNIT (99-0771) 54415642 Spring set (99-0757) 54419097 CONTACT BREAKER PLATE ASSEMBLY (99-0768) 54419827 Contact set (99-07n) 54419220 Pin, adjustment (99-0769) 021336/J-371'? Oil pressure switch 02045 Cover pressure switch 02138 Timing label for C.B. cover

39

1 1 3 2

1 1 3 5 1 1 1 2 2 1 1 2 2 1 1 1 2 2 1 1 1

For reground crankshaft


123456789

1011121314151617181920212223

GEARBOX INNER COVER AND SELECTORS

T4293 GEARBOX INNER COVER ... ... ... ... ... 1

T1614 Layshaft bearing ... ... ... ... ... ... ... 1

T412 Gearchange spindle bush... ... ... ... ... ... 1

T45 Kickstart stop ... ... ... ... ... ... ... 1

T1607 Thrust washer ... ... ... ... ... ... ... ... 2

T989 Hollow dowel ... ... ... ... ... ... ... ... 4

S2149 Stud ... ... ... ... ... ... ... ... ... 2

S1907 Bolt ... ... ... ... ... ... ... ... ... 1

E3446 Washer ... ... ... ... ... ... ... ... ... 1

14-6608 Screw ... ... ... ... ... ... ... ... ... 1

14-7023 Screw ... ... ... ... ... ... ... ... ... 1

T4055 Cam plate ... ... ... ... ... ... ... ... 1

T397 Operating quadrant ... ... ... ... ... ... ... 1

T1896 Quadrant spindle ... ... ... ... ... ... ... 1S p lit p in (64 in. x 18 in.) ... ... ... ... ... ... Ref. only

T4308 Mainshaft selector fork ... ... ... ... ... ... 1

T4307 Layshaft selector fork ... ... ... ... ... ... 1

T3989 Selector fork rod ... ... ... ... ... ... ... I

T4288 Leaf spring ... ... ... ... ... ... ... ... 1

T4289 Leaf spring support ... ... ... ... ... ... ... 1

T4290 Leaf spring top plate ... ... ... ... ... ... ... 1

T4291 Tab washer ... ... ... ... ... ... ... ... 1

F4771 Screw ... ... ... ... ... ... ... ... ... 2

41

ClassicBike.Biz



1 E9246 Timing cover ... ... ... ... ... ... ...

2 E4016 Patent plate ... ... ... ... ... ... ...

3 D208-55p0-4'25^iHammer-drive screw ... ... ... ... ... ...

4 E4568 Oil seal ... ... ... ... ...

4 E6387 Oil seal (0 . 020 in. undersize) ... .. ... ... ...

5 E4569 Circlip ... ... ... ... ... ... ... ...

6 T989 Hollow dowel ... ... ... ... ... ... ...

7 14-6609 Screw ... ... ... ... ... ... ... .. .

8 14-6608 Screw ... ... ... ... ... ... ... ...

9 14-0208 Bolt ... ... ... ... ... ... ... .. .

10 S25-437O-.'f3 Plain washer ... ... ... ... ... ... ...

11 E4707 Rubber grommet ... ... ... ... ... ...

12 E7680 Pillar bolt ... ... ... ... ... ... ...

13 E6559 Plain washer ... ... ... ... ... ... ...

14 E8737 Cover ... ... ... ... ... ... ... ...

15 E11462 Joint washer ... ... ... ... ... ... ...

16 GS2996o0-4' Z5 Serrated washer ... ... ... ... ... ...

17 E7354 Screw (4 in. U.H.) ... ... ... ... ... ...

18 54419340 AUTO ADVANCE UNIT (99-0771) ... ... ...

19 54415642 Spring set (99-0757) ... ... ... ... ...

20 54419097 CONTACT BREAKER PLATE ASSEMBLY (99-0768) ...

21 54419827 Contact set (99-0772) ... ... ... ... ...

22 54419220 Pin, adjustment (99-0769) ... ... ... ...

23 D21336p0 ;37/? Oil pressure switch ... ... ... ... ... ...

24 D2045 Cover pressure switch ... ... ... ... ...

Not illus. D2138 Timing label for C.B. cover ... ... ... ... ...

32

... For regroundcrankshaft

35

22

22

22

39

ClassicBike.Biz

Ref. N

o. P

art No.

DESCRIPTION

QU

ANTITY R

EM

AR

KS

GE

AR

BO

X S

HA

FT

S A

ND

GE

AR

S

1T4158

MAIN

SHAFT c/w

LOW

GEAR

(16T)...

......

...1

2T3988

Clutch rod bush...

......

......

......

13

T4332M

AINSHAFT HIGH G

EAR (25T)...

......

......

14

T1 370

High gear bush...

......

......

......

15

T3889

Mainshaft third gear (23T

)...

......

......

...1

6T

4335M

ainshaft second gear (20T)

......

......

......

17

T3862LAYSHAFT LO

W G

EAR (30T)...

......

......

18

T928Low gear bush

......

......

......

...1

9T3861

Layshaft second gear (26T

)...

......

......

...1

10T

3890L

ayshaft third gear (22T)

......

......

......

111

T4345L

ayshaft c/w high gear (19T

)...

......

......

112

T1 952

Gearbox sprocket (15 teeth) ...

......

......

...1

12T1 9

53


......

......

...1

See pages 4, 5 and

12T

1916 /O

/7G

earbox sprocket (17 teeth) ......

......

...1

6 for standard12

T1917/D

/ F'G

earbox sprocket (18 teeth) ...12

T1918/Q/I

Gearbox sprocket (19 teeth) ..

...siz

es

1

12TI919^010


......

......

...1

13T2116

Tab washer...

......

......

......

...1

14T440

Gearbox sprocket nut

......

......

......

115

D355657—

fy

'High gear bearing

......

......

......

...1

16E489

Circlip

......

......

......

......

...1

171946

Oil seal

......

......

......

......

...1

18D

3552M

ainshaft bearing...

......

......

......

119

T4113C

irclip...

......

......

......

......

120

T1962Plain washer

......

......

..._..

......

121

T1963

Pin

ion sle

eve

...

...

...

...

...

...

...

...

122

T1250Pinion spring

......

......

......

......

123

T730Kickstarter pinion

......

......

......

...1

24T731

Kickstarter ratchet...

......

......

......

125

T2240Tab washer

......

......

......

......

126

S594

Nut

......

......

......

......

...1

2711736

Clutch operating rod...

......

......

......

1

WID

E R

AT

IO G

EA

RS

3T3657

MAINSHAFT HIG

H GEAR (28T)

......

......

...1

614161

Mainshaft second gear (19T

)...

......

......

...1

9T

4160L

ayshaft second gear (27T)

......

......

......

1

11T

4159L


)...

......

......

1

CLO

SE

RA

TIO

GE

AR

S

1T4173

MAIN

SHAFT c/w

LOW

GEAR

(18T)...

......

...1

3T4172

MAIN

SHAFT H

IGH

GEAR

(24T)...

......

......

15

T4169

Mainshaft third gear (23T

)...

......

......

...1

6T

4167M

ainshaft second gear (21T)

......

......

......

1

7T4163

LAYSHAFT LO

W G

EAR (28T)

......

......

...1

9T

4166L

ayshaft second gear (25T)

......

......

......

1

10T

4168L

ayshaft third gear (23T)

......

......

......

1

11T

4162L


) ......

......

......

1

43

ClassicB

ike.Biz

ClassicBike.Biz

Ref. No. Part No. DESCRIPTION

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

3 6 9

11

1 3 5 6 7 9

10 11

GEARBOX SHAFTS AND GEARS

T4158 MAINSHAFT cfw LOW GEAR (16T) T3988 Clutch rod bush ... T4332 MAINSHAFT HIGH GEAR (25T) T1370 High gear bush T3889 Mainshaft third gear (23T) T4335 Mainshaft second gear (20T) T3862 LAYSHAFT LOW GEAR (30T) T928 Low gear bush T3861 Lays haft second gear (26T) ... T3890 Layshaft third gear (22T) T4345 Layshaft cfw high gear (19T) T1952 Gearbox sprocket (15 teeth) .. . T1953 Gearbox sprocket (16 teeth) .. . T1916/0I7 Gearbox sprocket (17 teeth) .. . T191i/OI t Gearbox sprocket (18 teeth) .. . T191S/G)Iq Gearbox sprocket (19 teeth) .. . T1919/0Z.0 Gearbox sprocket (20 teeth) .. . T2116 Tab washer T440 Gearbox sprocket nut D3556$?-0t/9'fHigh gear bearing ... E489 Circlip .. . T946 Oil seal .. . 03552 Mainshaft bearing T4113 Circlip ... T1962 Plain washer T1963 Pinion sleeve T1250 Pinion spring T730 Kickstarter pinion T731 Kickstarter ratchet T2240 Tab washer S594 Nut T1736 Clutch operating rod

WIDE RATIO GEARS

T3657 T4161 T4160 T4159

T4173 T4172 T4169 T4167 T4163 T4166 T4168 T416i

MAINSHAFT HIGH GEAR (28T) Mainshaft second gear (19T) .. . Lays haft second gear (27T) .. . Layshaft cfw high gear (18T)

CLOSE RATIO GEARS

MAINSHAFT cfw LOW GEAR (18T) MAINSHAFT HIGH GEAR (24T) Mainshaft third gear (23T) Mainshaft second gear (21T) ... LA YSHAFT LOW GEAR (28T) Lays haft second gear (25T) ... Layshaft third gear (23T) Layshaft cfw high gear (22T) ...

43

QUANTITY REMARKS

1 1 1 1 1 1 1 1 1 1 1 1 1 1 ~See pages 4, 5 and

1 6 for standard

1 sizes

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

Ref. N

o.P

art No.

DESC

RIPTIO

NQ

UA

NT

ITY

REM

ARKS

GE

AR

BO

X S

HA

FT

S A

ND

GE

AR

S (5

SP

EE

D)

1D

3500O

il seal, cover plate1

2E3789

Cover plate

...3

T436037—

w89 G

earbox cam plate

14

T4364

Selector fork— m

ainshaft 4th gear1

5T

4366Selector fork—

layshaft 3rd gear6

T4368

*Selector fork—

layshaft 1st gear...

7T

453657-q78/ MA

INS

HA

FT

HIG

H G

EA

R A

SS

EM

BL

Y (C

/W H

IGH

GE

AR

BEA

RIN

G)

...1

8D

3511N

eedle roller bearing2

9D

3500O

il seal, high gear1

1014432

MA

INSH

AFT

111

T3988B

ush1

12T4376

Mainshaft 4th gear

1

13T4377

MA

INSH

AFT

3rd GE

AR

1

14T

437957—q

57

CB

ushR

eference only

15T

4380M

ainshaft 1st and 2nd gear1

16T

454857—

q 0

° LA

YSH

AFT

......

1

17T

4550S7

— q/

00

Layshaft high gear...

Reference only

18T

438457— 4

900

Layshaft 4th gear ...

Reference only

19T

4387%L

ayshaft 3rd gear...

1

20T

4388L

AY

SHA

FT 2nd G

EA

R1

21T

439057—

qr7

7B

ush...

...1

22T4391

-(

LA

YSH

AFT

1st GE

AR

1

23T

43

93

57

-4'5

7e

Bush

1

24D

3494C

irclip...

1

25T

438

1*

Driving dog

1

26T4363

Quadrant

...1

T4402

Leaf spring

...1

T4374/408

Plunger quadrant

1

T4403

Plunger ...

2

Not

T4397G

earbox sprocket--19T1

Illus.T4396

Locknut

1

T4395L

ock washer

...1

D3512

Oil seal, gearbox

...1

U36

oppA

rE 9

% 3

8O

Z (a

sT

ue a

seo 4

5 ee)

45

ClassicB

ike.Biz

J

43

40

41

3g-_-

\\\3

m

34

30

8

46 31 47

36 191.1

37BO

Fig 14. GEARBOX OUTER COVER

46

ClassicBike.Biz


GEARBOX OUTER COVER

123456789

101112131415161718192021222324252627282930313233343536373839404142434445464748

T3760 GEARBOX OUTER COVER ... ... ... ... ... 1T23 Kickstarter spindle bush ... ... ... ... ... ... 1T57 Gearchange spindle bush ... ... ... ... ... 1T47 Kickstarter spring anchor pin ... ... ... ... ... 1S547 Guide plate stud ... ... ... ... ... ... ... 411956 Oil seal ... ... ... ... ... ... ... ... 1T1955 Oil seal housing ... ... ... ... ... ... ... 1T408/95?- 7OZ /Gearchange quadrant ... ... ... ... ... ... ... 1D3530 Rubber "0" ring ... ... ... ... ... ... ... 1T404 Quadrant return spring ... ... ... ... ... ... 2T406 Gearchange quadrant plunger ... ... ... ... ... 2

T405Plunger spring ... ... ... ... ... ... ... ... 2

T407 Guide plate ... ... ... ... ... ... ... ... IE1612 Serrated washer ... ... ... ... ... ... ... 414-0301 Nut ... ... ... ... ... ... ... ... ... 4T4117 Kickstarter quadrant ... ... ... ... ... ... ... 1T31 Kickstarter return spring ... ... ... ... ... ... 1T24A57 1{73 Kickstarter axle ... ... ... ... ... ... ... 1T362957- gS'87CLUTCH LEVER ASSEMBLY ... ... ... ... ... IT4441 Clutch lever ... ... ... ... ... ... ... 1T1710 Lever shaft ... ... ... ... ... ... ... 1D2368 Ball, fin. diam. ... ... ... ... ... ... ... 3T3761 Thrust plate ... ... ... ... ... ... ... 1T1712 Return spring ... ... ... ... ... ... ... 1

GS12757-3(073 Plain washer ... ... ... ... ... ... ... 1— GO- 2.70/ Split pin ( 64 in. x fin.) ... ... ... ... ... ... Reference only

S1879 Countersunk screw ... ... ... ... ... ... ... 2T1646 Rubber cover ... ... ... ... ... ... ... 1T3762 Abutment for clutch cable ... ... ... ... ... ... 1

S25-3 O-/2 y7 Plain washer ... ... ... ... ... ... ... ... 2

14-0302 Nut ... ... ... ... ... ... ... ... ... 1

S1878 Screw ... ... ... ... ... ... ... ... ... 2

14-6609 Screw ... ... ... ... ... ... ... ... ... 2

14-6608 Screw ... ... ... ... ... ... ... ... ... 1T375757- 70/0 Gearchange pedal ... ... ... ... ... ... ... 1

14-0201 Bolt ... ... ... ... ... ... .., ... ... 1T2450 Pedal rubber ... ... ... ... ... ... ... ... 1T3632$7-70/8 FOLDING KICKSTARTER ... ... ... ... ... ... 1T2173 37-2/73 Kickstarter lever ... ... ... ••. ... ... ... 1T1272 5']- 70/7 Kickstarter pedal ... ... ... ... ... ... ... 1T1167 Pedal locating spring ... ... ... ... ... ... 1S70-3 t 0 23 Steel ball, fin. diam. ... ... ... ... ... ... 1S541 Pedal bolt ... ... ... ... ... ... ... 1T2330 Pedal rubber ... ... ... ... ... ... ... ... 1T4356 Cotter pin c/w nut and washer ... ... ... ... ... 1

S544 Domed nut ... ... ... ... ... ... ... ... I

T2166 Filler plug ... ... ... ... ... ... ... ... 1

E8782 "O" ring ... ... ... ... ... ... ... ... 1

- iz- 'z9 7L1 %'c'$ /5 5C1B5r/7U7-SO / .v S?E6I2

47

ClassicBike.Biz

48

ClassicBike.Biz

Ref. No.

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

Part No. DESCRIPTION

GEARBOX OUTER COVER

T3760 GEARBOX OUTER COVER T23 Kickstarter spindle bush ...

-~-

T57 Gearchange spindle bush T47 Kickstarter spring anchor pin

S547 Guide plate stud ... T1956 Oil seal T1955 Oil seal housing ...

*- T408J957-70l/Gearchange quadrant ... D3530 Rubber "0" ring T404 Quadrant return spring T406 Gearchange quadrant plunger T405 Plunger spring ... T407 Guide plate E1612 Serrated washer 14-0301 Nut T4117 Kickstarter quadrant T31 Kickstarter return spring T24AS7- '17s6 Kickstarter axle ... T3629.57-l/S"87CLUTCH LEVER ASSEMBLY T4441 Clutch lever T1710 Lever shaft D2368 Ball, i in. diam. T3761 Thrust plate T1712 Return spring

GS127 57-3"73 Plain washer

- (00-270/ Split pin u4 in. X t in.) S1879 Countersunk screw T1646 Rubber cover ... T3762 Abutment for clutch cable S25-3f00-lf2.'/7 Plain washer 14-0302 Nut S1878 Screw 14-6609 Screw 14-6608 Screw T3757 57- 7010 Gearchange pedal 14-0201 Bolt T2450 Pedal rubber ... T363257-7018 FOLDING KICKSTARTER

T217357-2173 Kickstarter lever ...

T1272 S7- 7017 Kickstarter pedal ... T1167 Pedal locating spring S70-3 /d)- 23~tf Steel ball, tin. diam. S541 Pedal bolt T2330 Pedal rubber ... T4356 Cotter pin cfw nut and washer S544 Domed nut

T2166 Filler plug E8782 "0'' ring

QUANTITY

1 1 1 1 4 1 1 1 1 2 2 2 1 4 4 1 1 1 1 1 1 3 1 1 1

REMARKS

Reference only 2 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

~ 2.1- Lf3 7L/ LftJ~ 15 SVBSTITV TEO j.A./ s- 5?6'£0.

47

Ref. N

o. Part N

o.

DE

SC

RIP

TION

QU

AN

TIT

YREM

ARK

S

CL

UT

CH

1S586

Clutch securing nut

12

T3929H

ub...

...1

3T3931

Thrust w

asher ...••. 1

4T

394R

oller...

... 20

5T

1570S

procket and housing (58 teeth Duplex)

1

6T

4438C

entre ...

1

7T

4436Inner plate

1

852157

Bolt

...3

9T

2538S

hock absorber spider1

10T

1722D

rive rubber (large) ...3

11T1723

Rebound rubber (sm

all)3

1214437

Outer plate

1

13T

423A57-417S

YS

crewed pin

••• 3

14T

13625763 D

riving plate (bonded)••• 6

15T1363

Driven plate

...••• 6

1612156

Pressure plate

••• 1

17T

2159A

djuster pin••• 1

1814-0403

Nut

...1

19T1931

Spring cup3

20T

1830S

prin

g ...

3

2112526

Pressure nut

3

22S66-1

Key

...1

23T2279

Wash

er ...1

49

ClassicB

ike.Biz

I-1

U)

c)

(Dr

N

U)T

N

N0 ZN Q

IU

TT z

QWHQ

Q) UT z

LQ

2co U

^ CGLL

NT

N Cl) M M-CM'

O NNm

N

NN

C.)N

50

ClassicBike.Biz


CLUTCH

5586 Clutch securing nut ... ... ... . .. ... . .. ... 1

2 T3929 Hub ... . .. ... ... . .. ... . .. ... ... 1

3 T3931 Thrust washer ... ... . .. ... ... ... . .. ... 1

4 T394 Roller ... ... ... ... ... . .. ... ... . .. 20

5 T1570 Sprocket and housing (58 teeth Duplex) ... ... ... ... 1

6 T4438 Centre ... ... ... . .. ... ... . .. ... ... 1

7 T4436 Inner plate ... ... ... . .. ... ... . .. ... 1

8 S2157 Bolt ... . .. ... ... ... ... ... ... ... 3

9 T2538 Shock absorber spider ... ... ... ... ... ... 1

10 T1722 Drive rubber (large) ... ... ... ... ... ... ... 3

11 T1723 Rebound rubber (small) ... ... ... ... ... ... 3

12 T4437 Outer plate ... ... ... . .. ... ... ... ... 1

13 T423A57-l/7S'/Screwed pin ... ... ... ... ... ... ... ... 3

14 T1362S7-'f763 Driving plate (bonded) ... ... ... ... ... ... 6

15 T1363 Driven plate ... ... ... ... ... ... ... ... 6

16 T2156 Pressure plate ... ... ... ... ... ... ... 1

17 T2159 Adjuster pin ... ... ... ... ... ... ... ... 1

18 14-0403 Nut ... ... ... ... ... ... ... ... ... 1

19 T1931 Spring cup ... ... ... ... ... ... ... ... 3

20 T1830 Spring ... ... ... ... ... ... ... ... ... 3

21 T2526 Pressure nut ... ... ... ... ... ... ... ... 3

22 S66-1 Key ... ... ... ... ... ... ... ... ... 1

23 T2279 Washer ... ... ... ... 1

49

Ref. No. Part N

o.DESCRIPTION

QU

ANTITY

RE

MA

RKS

123

D1915E11419E7037

CH

AIN

CA

SE

AN

D

Rear chain, a

in. xi in. x 106 links

Joint washer

Cover plate

CH

AIN

S

111N

ot 5 speed4

E7565O

il seal...

1 r models

5E3821

Countersu

nk screw

66

E597670-5087

Chain ten

sioner ab

utm

ent

1(also

listedw

ithcran

kcase group)

7E6061

Chain ten

sioner b

lade...

•• •

8E4152

Tie rod...

•• •9

E5977Trunnion

•• •10

E9703Adjuster sleeve nut

...•.•

111

D477P

rimary chain, f in. D

uplex x 84 links•••

1

1251866

Stator stud•••

2

1351867

Stator stud•••

1

1447205

Stator, RM

21 (99-1006)•••

1

15E9360

Sleev

e nut••••

1

16E4144

Ru

bb

er gromm

et•••

1

17E5449

Plastic sleeve•••

1

18525-3

-q2q7 Plain w

asher•••

3

191

0702S

elf-locking nut•••

3

20E11463

Joint washer

•••1

21E9245 7

/-q0

7Z

Chaincase

•••1

22T2440

Rotor cover

••.1

23E11457

Joint washer

••.1

24252627282930313233

F4129E244 1T2166E878214-660814-662055 44F1880T244 31

101

Screw...

Copper w

asherFiller plug"0

" ring

Screw...

Screw...

Do

med

nut...

Copper w

asher ...Tim

ing pointer ...L

evel plug...

•••3

.••1

•••1

•••1

•••6

•••2

•••2

•••2

•••1

•••1

51

ClassicB

ike.Biz

m

LL

52

ClassicBike.Biz


CHAIN CASE AND CHAINS

1 D1915 Rear chain, tin. x j- in. x 106 links .1/t.X'~(j:./;~.{p ... . .. 1

2 E11419 Joint washer ... ... ... . .. ... . .. ... . .. 1

3 E7037 Cover plate ... ... . .. ... ... . .. ... . .. 1 } Not 5 speed

4 E7565 Oil seal ... ... ... . .. ... ... . .. ... . .. 1 models

5 E3821 Countersunk screw ... ... ... ... ... ... .. . 6 6 E5976 70-!i087 Chain tensioner abutment ... ... ... ... .. . ... 1 (also listed with

crankcase group)

7 E6061 Chain tensioner blade ... ... ... ... ... ... .. . 1

8 E4152 Tie rod ... ... ... .. . ... ... ... ... .. . 1

9 E5977 Trunnion ... ... ... ... ... .. . ... .. . 1

10 E9703 Adjuster sleeve nut ... ... .. . ... .. . ... .. . 1

11 D477 Primary chain, i in. Duplex x 84 links ... ... ... .. . 1

12 S1866 Stator stud ... ... ... ... ... .. . ... .. . 2

13 S1867 Stator stud ... ... ... ... ... .. . ... .. . 1

14 47205 Stator, RM21 (99-1006) ... ... ... .. . ... .. . 1

15 E9360 Sleeve nut ... ... ... ... ... ... ... .. . 1

16 E4144 Rubber grommet ... ... ... ... ... ... .. . 1

17 E5449 Plastic sleeve ... ... ... ... ... .. . ... .. . 1

18 S25-3tp-'fl'l7 Plain washer ... ... ... ... ... ... ... .. . 3

19 14-0702 Self-locking nut ... ... ... ... ... ... .. . 3

20 E11463 Joint washer ... ... ... ... ... ... ... .. . 1

21 E9245 1/-t.{OlZ Chaincase ... ... ... ... .. ... ... .. . 1

22 TI440 Rotor cover ... ... .. ... ... ... ... .. . 1

23 E11457 Joint washer ... ... ... ... ... ... ... ... 1

24 F4129 Screw ... ... ... .. ... ... ... ... ... 3

25 E2441 Copper washer ... .. ... ... ... ... ... 1

26 TI166 Filler plug ... ... ... ... ... ... ... .. . 1

27 E8782 "0" ring ... ... ... ... ... ... ... .. . 1

28 14-6608 Screw ... ... ... ... ... ... ... ... . .. 6

29 14-6620 Screw ... ... ... ... ... ... ... ... . .. 2

30 S544 Domed nut ... ... ... ... ... ... ... ... 2

31 F1880 Copper washer ... ... .. ... ... ... ... ... 2

32 TI443 Timing pointer ... ... .. ... ... ... ... ... 1

33 14-6101 Level plug ... ... ... 1

51

Ref. N

o. Part N

o.

DESC

RIP

TION

QU

AN

TIT

Y R

EM

AR

KS

FR

AM

E

1F14283

Frame

......

......

...2

E1

27

44

7/Z

7' /O

il filler cap...

......

...3

D3616

"O" rin

g...

......

...4

F1 3142D

ipstick...

......

......

5F1 3642

Oil

filter...

......

...5A

F1 31 8 5 63-3 8 /, cS

ump plate

......

6F12829

Gasket

......

......

...7

D2330

Washer

...8

S2109Stud

Sum

p plate to frame

...9

14-1

30

2/q

-/Z0

2 N

ut

...10

14-0113D

rainplug

......

......

11E12505

Joint washer

......

......

12E

69307/ -7/7

0O

il junction block...

......

13X

444587/-375

Joint washer

......

......

14S1908

Nut

15E3446

Washer f

Junction block to crankcase

16E12428

Rocker oil pipe

......

...17

E1335W

asher...

......

......

18E1435

Nut

......

......

...19

E12337R

ocker feed pipe...

......

20D

3524C

lip—rocker feed pipe

......

21E12345

Oil return pipe

......

...22

E6848C

lip—feed and return pipes

......

23E12347

Oil feed

pipe...

......

...24

E12349O

il vent pipe...

......

...25

E11149C

rankcase breather pipe—front

...26

F11614C

rankcase breather pipe—rear

...27

F11610"T

" piece...

......

...28

D2253

Clip—

breather pipe—front

......

29D

2252C

lip—breather pipe—

rear...

...30

F11615C

lip—breather pipe to fender

...31

H3894

Screw...

......

......

32F4717

Nut

......

......

...33

F1262783-'/9y/ C

entre stand...

......

...34

F1 3793Spring

......

......

...35

S2077Pivot

bolt...

......

...36

14-1304N

ut...

......

......

37F11560

Prop stand

......

......

38F7021

Bolt

......

......

...39

14-1303N

ut...

......

......

40F8382

Spring...

......

......

Not illus.

D3361

-35

09

' Transfer "M

ade in England" ...

...N

ot illus.D

2452 P

-1-A

.T

ransfer—Safety Standards

......

Not illus.

14-0114B

olt1Prop stand stop

Not illus.

14-0402N

ut f

......

24444424

.1244422

.1

53

ClassicB

ike.Biz

11111111116 o

z

z0fAz

3

0z

0

z5z

OC

LL

54

ClassicBike.Biz


FRAME

1 F14283 Frame ... ... . .. . .. ... . .. . .. . .. ... 1

2 E127447/•l7'f~ Oil filler cap ... . .. ... ... ... . .. ... . .. 1 3 D3616 "0" ring ... ... ... . .. ... . .. ... . .. 1 4 F13142 Dipstick ... ... ... . .. ... ... ... . .. ... 1

5 F13642 Oil filter ... ... . .. ... ... . .. ... . .. 1

SA F1318S83-J8/S"Sump plate ... . .. ... ... ... ... . .. ... 1

6 F12829 Gasket ... . .. ... . .. ... . .. ... ... . .. 2

7 D2330 w .. h., } ... . .. ... ... . .. 4

8 S2109 Stud Sump plate to frame ... . .. ... ... . .. 4

9 14-1302/l{-/20Z Nut ... . .. ... ... . .. 4

10 14--0113 Drain plug ... . .. ... . .. ... ... . .. ... 1

11 E12505 Joint washer ... . .. ... ... . .. ... ... 1

12 E69307/-7/76 Oil junction block ... ... ... . .. ... ... . .. 1

13 f#HSB]/-37S'f Joint washer ... ... ... . .. 1

14 S1908 ~ut h }Junction block to crankcase 15 E3446 as er

16 E12428 Rocker oil pipe ... ... ... ... . .. ... ... 1

17 E1335 Washer ... ... ... ... ... ... ... ... ... 4

18 E1435 Nut ... ... ... ... ... ... ... ... ... 4

19 E12337 Rocker feed pipe ... ... ... ... ... ... ... 1

20 D3524 Clip-rocker feed pipe ... ... ... ... ... ... 2

21 E12345 Oil return pipe ... ... ... ... ... ... ... 1

22 E6848 Clip-feed and return pipes ... ... ... ... ... ... 4

23 E12347 Oil feed pipe ... ... . .. ... ... ... ... ... 1

24 E12349 Oil vent pipe ... ... ... ... ... ... ... ... 1

25 E11149 Crankcase breather pipe-front ... ... ... ... ... 1

26 F11614 Crankcase breather pipe-rear ... ... ... ... ... 1

27 F1161 0 "T" piece ... ... ... ... ... ... ... . ... 1

28 D2253 Clip-breather pipe-front ... ... ... ... ... ... 2

29 D2252 Clip-breather pipe-rear ... ... ... ... ... ... 1

30 F11615 Clip-breather pipe to fender ... ... ... ... ... 4

31 H3894 Screw ... ... ... ... ... ... ... ... ... 4

32 F4717 Nut ... ... ... ... ... ... ... ... ... 4

33 F1262783-'f'/'l/ Centre stand ... ... ... ... ... ... ... ... 1

34 F13793 Spring ... ... ... ... ... ... ... ... ... 1

35 52077 Pivot bolt ... ... ... ... ... ... ... ... 2

36 14-1304 Nut ... ... ... ... ... ... ... ... ... 2

37 F11560 Prop stand ... ... ... ... ... ... ... ... 1

38 F7021 Bolt ... ... ... ... ... ... ... ... ... 1

39 14-1303 Nut ... ... ... ... ... ... ... ... ... 1

40 F8382 Spring ... ... ... ... ... ... ... ... ... 1

Not illus. D336191-3S"tJ'f Transfer "Made in England" ... ... ... ... ... . .. 1

Not ill us. D2452 }/. t...A . Transfer-Safety Standards ... ... ... ... ... ... 1

Not illus. 14-0114 Bolt} ... ... ... ... ... ... 1

Not illus. 14-0402 Nut Prop stand stop ... ... 1

53

Ref. N

o.P

art No.

DE

SC

RIP

TION

QU

AN

TITYR

EM

AR

KS

123

SW

ING

ING

AR

M A

ND

SU

SP

EN

SIO

N U

NIT

S

F12513SW

ING

ING

AR

M1

D1841

Grease nipple

...2

WE

170 g3- 7221W

asher, grease nipple2

4F12521

Bush, pivot arm

...4

5F12691

Sleeve, sw

inging arm pivot

2

6F12690

Distance piece R

.H.

...1

7F12689

Distance piece L

.H.

...1

8F12692

Dirt excluder

......

4

9S2087

Stud, sw

inging arm pivot

...1

10F12266

Washer, sw

inging arm pivot

...2

1114-1307

Nut, sw

inging arm pivot

...1

12F12656

Brake torque stay

......

1

1314-1304

Nut, torque stay to brake plate

......

1

14D

2350W

asher, torque stay to brake plate ......

1

1514-0133

Bolt, torque stay to sw

inging arm...

...1

16W

2330W

asher, torque stay to swinging arm

...1

1714-1304

Nut, torque stay to sw

inging arm...

1

1864052341

SUSPE

NSIO

N U

NIT

(D2294)

2

1964052090

Dam

per unit...

..•R

eference only

2064533645

Bonded bush (99-0122)

...4

219054/171

Spring retainer (99-0107)

...4

2264544754

Spring, 110 lbs. chrom

e (99-1139)•••

2

2314-0235

Bolt, dam

per—top

...••.

2(1 off T

R6C

)

232425262728

51997S

tud, damper—

top L.H

.D

233

160-q

46W

asher, d

amper—

top

14-1303N

ut, damper—

top...

14-0234B

olt, damper, low

er...

D2321

Washer dam

per lower

14-1303N

ut damper low

er...

•• •

•••1

(TR6C

)2

(3 off TR

6C)

2(3 off T

R6C

)2221

29•• •

• • ••• •

F12641C

hainguardfixing—

front1

30••

14-0206B

olt, chainguard.

fixing—front

131323334

D2347

Washer, chainguard

. • •

34815S

top lamp sw

itch-118SA

(99-1028)

D35502 /- X

i0 Screw

...H

1388W

asher ...

122

55

ClassicB

ike.Biz

CDN

OM

e

L-'

D '

U,I-HW

I.-00U.

0zQ

z

U.

I_

zD

0,_M 0

W

O.

_O

U.

56

ClassicBike.Biz

Ref. N

o. Part N

o.

DE

SC

RIP

TION

QU

AN

TITYR

EM

AR

KS

MO

TO

R U

NIT

FIT

TIN

GS

AN

DF

OO

TR

ES

TS

1F1 2855 83

-7 o' bO Footrest—L.H

.......

......

......

......

12

F1285483-7Footrest—

R.H

.......

......

......

......

13

14-0259Bolt

......

......

......

......

...2

4D2333

Washer

......

......

......

......

...2

5F9279

Footrest rubber...

......

......

......

26

F12841PILLIO

N FO

OTR

EST ......

......

......

...2

7F9053

Pedal...

......

......

......

...1

8F1 3207

Hanger bolt

......

......

......

...1

914-0217

Bolt...

......

......

I10

F9089W

asherFootrest sw

ivel...

......

......

111

14_1302/q-/202.N

utJ

......

......

...1

1214-1303

Nut

Footrest to frame

"'...

......

...1

13F2184

Washer f

••••.•

••••••

•••1

14F9054

Footrest rubber...

......

......

......

115

F12666R

ear brake pedal...

......

......

......

116

14-0103Screw

Stop light adjustment

......

......

...11

1714-0301

Nut

•••...

......

...18

S2045Pivot pin

......

......

......

......

1

1914-1303

Nut

......

......

......

......

...1

20E8084 o

-412g6W

ash

er ...

......

......

......

......

1

21F1 2860

Rear brake operating rod

......

......

......

122

—S

plit pin (• i !6 in. x e in.)

......

......

......

Reference only

23F1 4277

Distance piece

......

......

......

...1

24F7387

Adjuster nut —

brake rod...

......

......

...2

25F13024

Rear m

otor plate R.H

....

......

......

...1

26F1 3023

Rear m

otor plate—L.H

....

......

......

...1

2714-0115

Bolt...

......

...5

2814-0116

Bolt•••

Rear m

otor plates to frame

••••••

•••16

2914-13 02/y-/202- N

ut•••

••••••

•••30

D2330W

asher...

......

...12

3114-0220

Bolt...

......

...2

3214-0221

BoltM

otor to motor plates

......

2433

14-1302N

ut...

......

34D2321

Washer

. . ....

......

.8

35F12846

Distance piece—

L.H.

......

136

F12847D

istance piece—R

.H.

......

137

S2112Stud

Motor to fram

e centre bottom ...

...1

3814-1304

Nut

......

239

D2332W

asherJ

......

240

F1 2848D

istance piece—L.H

....

......

141

F12849D

istance piece—R

.H.

j...

......

142

14-0254Bolt

Motor fixing front

......

...1

4314-1304

Nut

I...

......

144

D2332W

asherJ

......

...1

45F1 3537

Steady bracket m

otor to frame

......

......

...1

4614-0126

Bolt...

..... •

.....

...1

4714-1303

Nut

Bracket to frame

......

......

......

1

48D2331

Washer

......

...E

xtended nut (used with 14-0220) ...

......

.....

......

...II (TR

6c only)N

ot illus51933

2N

ot illus14-1305

Nut

Footrest bolt.

.

..N

ot illusF13602

Collar

......

......

...

57

ClassicB

ike.Biz

0N

58

ClassicBike.Biz


MOTOR 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 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 Not illus Not illus Not illus

F12855 SJ~.it'¥0 Footrest-L.H ... . F1285483-70'f0 Footrest-R.H ... . 14-0259 Bolt D2333 Washer F9279 Footrest rubber F12841 PILLION FOOTREST ... F9053 Pedal F13207 Hanger bolt

14-0217 Bolt { F9089 Washer Footrest swivel 14-1302/tf-/202. Nut 14-1303 Nut F2184 Washer J Footrest to frame

F9054 Footrest rubber ... F12666 Rear brake pedal 14-01 03 Screw } 14_0301 Nut Stop light adjustment

S2045 Pivot pin 14-1303 Nut .. . E8084(j'J~'/-2.l/6washer .. . F12860 Rear brake operating rod

Split pin h~ in. xi in.) F14277 Distance piece F7387 Adjuster nut'-brake rod F13024 Rear motor plate R.H. F13023 Rear motor plate-L.H. 14-0115 Bolt 14-0116 Bolt 14-1302f'f-/202. Nut

Rear motor plates to frame

D2330 Washer 14-0220 Bolt 14-0221 Bolt l 14_1302 Nut f Motor to motor plates

D2321 Washer F12846 Distance piece-L.H.} ... F12847 Distance piece-R.H. . .. S2112 Stud Motor to frame centre bottom .. . 14-1304 Nut .. . D2332 Washer .. . F12848 Distance piece-L.H. } F12849 Distance piece-R.H. 14-0254 Bolt Motor fixing front 14-1304 Nut D2332 Washer F13537 Steady bracket motor to frame

14-0126 Bolt } .. . 14-1303 Nut Bracket to frame .. . D2331 Washer .. . S1933 Extended nut (used with 14-0220)

14-1305 Nut } Footrest bolt F13602 Collar

57

1 1 2 2 2 2 1 1 1 1 1 1

1 1 1 1 1 1 1 1 Reference only 1 2 1 1 5 1 6 12 2 2 4 8 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 (TR6c only) 2 2

Ref. N

o. Part N

o.

DESCRIPTIONQUANTITY

RE

MA

RK

S

EX

HA

US

T P

IPE

S A

ND

MU

FF

LE

RS

, TR

6R

, T12O

R

1E12636

Exhaust pipe—L.H.

...2

E12637Exhaust pipe—

R.H. ...E12465

clip4

F897W2^n7e W

asher1

F89778Z-g777 Bolt

Exhaust pipes to cylinder head2

52

3Finned

6E6857

Exhaust pipe stay... 2

7E6179

Screw... 2

8E7471

Nut

... 29

E7512Clip

... 210

E3768washer

"'... 4

Exhaust pipes to coupling pipe11

14-0217Bolt

...... 2

1214-1202

Nut

J... 2

13E9888

Coupling pipe14

E2271Clip

... 215

E3768"D

" washer

...... 4

1614-0219

BoltExhaust pipes to m

ufflers ...... 2

17S25-3

4'2q7 Washer

...... 2

1814-1302

Nut

... 219

E12382M

uffler ......

......

......

220

E12282Hanger—

muffler and pillion footrest

... 2

2214-1301

Nut

Bolt }M

uffler to hanger...

421

10101

"'4

*EARLIER MO

DELS USE THE FOLLO

WING

:—

1E12753

Exhaust pipe—L.H.

...1

2E12756

Exhaust pipe—R

.H. ...

13

E10216Finned Clip

24

E8860Spherical washer

25

E6744Bolt...

2

...1 2 Later m

odels

59

ClassicB

ike.Biz

U,IxWJLLLL

D

N

LL

60

ClassicBike.Biz


EXHAUST PIPES AND MUFFLERS, TR6R, T120R

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22

1 2 3 4 5

E12636 Exhaust pipe-L.H. ... . .. . .. . .. ... ... E12637 Exhaust pipe-R.H. ... ... . .. . .. . .. ... E12465 Finned clip

}Exh'"" pipe• to cylinde' head ...

F897882-9fl7&'Washer ... F89778Z.-'8177 Bolt ... E6857 Exhaust pipe stay ... . .. ... ... . .. ... E6179 Screw ... . .. ... . .. . .. ... . .. ... E7471 Nut ... ... ... . .. . .. ... ... ... E7512

CUp } ... ...

E3768 "D" washer ... . .. 14-0217

Bolt Exhaust pipes to coupling pipe ... ... 14-1202 Nut ... ... E9888 Coupling pipe ... ... ... ... . .. ... ... E2271 CUp } ... ... ... E3768 "D" washer ... ... ... 14-0219 Bolt Exhaust pipes to mufflers ... ... ... S25-3~'/2.'f7 Washer ... ... ... 14-1302 Nut ... ... ... E12382 Muffler ... ... ... ... . .. ... . .. ... E12282 Hanger-muffler and pillion footrest ... ... . .. 14-0101 Bolt} ... ... ... ... ... 14-1301

Nut Muffler to hanger --- --- --- ... ...

*EARLIER MODELS USE THE FOLLOWING:-

E12753 E12756 E10216 E8860 E6744

Exhaust pipe-L.H. Exhaust pipe-R.H. Finned Clip Spherical washer Bolt ...

59

. ..

. ..

. ..

. ..

...

. ..

. ..

. ..

. ..

...

. ..

. ..

. ..

. ..

. ..

. ..

. ..

. ..

. ..

. ..

. .. -··

i} Late' mode/,

2 2 2 2 4 2 2 1 2 4 2 2 2 2 2 4 4

1 1 2 2 2

Ref. N

o.P

art. No

DE

SC

RIP

TION

QU

AN

TIT

YREM

ARKS

EX

HA

US

T P

IPE

S, M

UF

FL

ER

S A

ND

FO

LD

ING

FO

OT

RE

ST

S, T

R6C

1E

123347/'&0

0 Exhaust pipe—

lower

2E

126327/ /90

/ Exhaust pipe—

upper1

3E12465

Finned clip2

Later models

4F897782-

777 BoltExhaust pipe to cylinder head ...

25

F89788Z- me W

asher2

6El 325070 -6978 Exhaust pipe stay

17

14-0113Bolt

...3

8S26-3 0-4i26

v Spring w

asher3

9E7299

Clip—

upper•••

110

E5874C

lip—low

er•••

111

14-0116Bolt

•••1

1214-0219

BoltExhaust pipes to connector

•••1

13E3768

"D" w

asher•••

214

S26-3-q

2Spring w

asher•••

115

14-1202N

ut•••

116

E9673C

onnector•••

117

E2271C

lip•••

218

14-0219Bolt

•••2

19E3768

"D" w

asherC

onnector to mufflers

•••4

20S26-

q260 Spring w

asher•••

221

14-1202N

ut•••

222

E12019M

uffler—upper ...

•••23

E12020M

uffler—low

er ...•••

124

E12511M

uffler—hanger

•••2526

S1822Bolt

Mufflers to hanger

S26-3-'z

Spring washer

•••22

2714-0115

Bolt•••

28S26-3

Spring washer

Hanger to fram

e...

29S1933

Spacer nut1

30E9680

Leg guard31

51953Screw

3233E9857

Washer

E9688C

lipLeg guard attachm

ent front1

34E9696

Bracket35

51954Screw

136

E9857W

asherLeg guard attachm

ent rear•••

37E9688

Clip

•••1

38E1285183

-2?5

1 Crankcase undershield...

•••1

39S2096

Hooked stud

•••2

4014-1301

Nut

...2

41D2320

Washer ...

2

61

ClassicB

ike.Biz

v;acWJLLLL

DE

NN

00LL

62

ClassicBike.Biz

Ref. No. Part. No DESCRIPTION

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

EXHAUST PIPES, MUFFLERS AND FOLDING E12334 71-/lfOO Exhaust pipe-lower .. . E126327/-/~0/ Exhaust pipe-upper .. . E12465 Finned clip } .. . F8977'f/l-3,77 Bolt Exhaust pipe to cylinder head .. . F8978g2-817cfwasher .. . E1325070 -6'178' Exhaust pipe stay ... ... ... ... . .. 14-0113 Bolt S26-3€/)~lf260 Spring washer E7299 Clip-upper E5874 Clip-lower 14-0116 Bolt 14-0219 Bolt ~ Exhaust pipes to connector E3768 "D" washer S26-36o-'/Zfo0 Spring washer 14-1202 Nut E9673 Connector

E2271 Clip } 14-0219 Bolt E3768 "D" washer Connector to mufflers S26-?/P0-'/2.60 Spring washer 14-1202 Nut E12019 Muffler-upper .. . E12020 Muffler-lower .. . E12511 Muffler-hanger

S1822 Bolt f /' /'1 11 Lr~ Mufflers to hanger S26-3~~,2.CP-' Spring washer 14-0115 Bolt ... S26-3 Spring washer Hanger to frame S1933 Spacer nut E9680 Leg guard S1953 Screw E9857 Washer L

Cl r- Leg guard attachment front E9688 ip E9696 Bracket S1954 Screw E9857 Washer ~Leg guard attachment rear E9688 Clip E1285183-2~5/ Crankcase undershield ... S2096 Hooked stud 14-1301 Nut 02320 Washer ...

61

QUANTITY REMARKS

FOOTRESTS, TR6C

11

H ~,.,model' 1 3 3 1 1 1 1 2 1 1 1 2 2 4 2 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2

Ref. N

o.P

art No.

DE

SC

RIP

TION

QU

AN

TIT

YR

EM

AR

KS

EX

HA

US

T P

IPE

S, M

UF

FL

ER

S A

ND

FO

LD

ING

FO

OT

RE

ST

S, T

R6C

42F13139

FO

LD

ING

FO

OT

RE

ST

—R

.H.

•••1

42F12856

FO

LD

ING

FO

OT

RE

ST

—L

.H.

•••1

43F13140

Fo

otrest h

anger—

R.H

....

•••1

43F12858

Footrest h

ang

er—L

.H.

•••1

44Fl 3092

Fo

otrest p

edal

•••1

45F13095

Spring

...•••

146

14-0216B

olt•••

147

14-1

30

2 /q

^/Z

OL

Nu

t•••

148

F9051F

ootrest ru

bber

•••1

49S1969

Bo

lt

50

}

Fo

otrest to

frame

F82432

EA

RL

IER

MO

DE

LS

US

E T

HE

FO

LL

OW

ING

:—

1E

11900E

xh

aust p

ipe—

low

er1

2E

11901E

xh

aust p

ipe—

upper

13

E10216

Finned clip

...2

4E

6744B

olt...

...2

5E

8860S

pherical w

asher

2

6E

6978E

xhau

st pip

e stay1

63

ClassicB

ike.Biz

Fig. 22. TELESCOPIC FRONT FORK

64

ClassicBike.Biz


EXHAUST PIPES, MUFFLERS AND FOLDING FOOTRESTS, TR6C

42 42 43 43 44 45 46 47 48 49 50

1 2 3 4 5 6

F13139 FOLDING FOOTREST-R.H. ... . .. ... . .. F12856 FOLDING FOOTREST-L.H. ... . .. ... . .. F13140 Footrest hanger-R.H. ... . .. . .. . .. . .. F12858 Footrest hanger-L.H. ... ... . .. . .. . .. F13092 Footrest pedal ... ... . .. ... ... . .. F13095 Spring ... . .. . .. . .. . .. ... . .. 14-0216 Bolt ... . .. ... . .. . .. ... . .. 14-1302 11./-/lOZ.. Nut ... ... . .. . .. . .. . .. ... F9051 Footrest rubber ... ... . .. . .. . .. . .. S1969 Bolt } F8243

W h Footrest to frame ... . .. ... . .. . .. as er

EARLIER MODELS USE THE FOLLOWING:-

E11900 E11901 E10216 E6744 E8860 E6978

Exhaust pipe-lower Exhaust pipe-upper Finned clip Bolt Spherical washer Exhaust pipe stay

63

. ..

. ..

. ..

. ..

. ..

...

. ..

. ..

...

. ..

1 1 1 1 1 1 1 1 1 2 2

1 1 2 2 2 1


1

TELESCOPIC FRONT FORK

H4080 FORK ASSEMBLY2 H4035 Top Yoke ...3 14-0234 Pinch Bolt ... 14 14-1303 Nut... 15 E8084 Washer ...6 F6738 Lock c/w 2 keys ...7 D623 F z- 6738 Key (state serial No.)8 5578 Grub screw9 H2266 Sealing washer ...

10 H2270 Brake cable retainer11 F8245 Starlock washer ...12 H3682 Retaining bracket13 F12007 Abutment ring ... 214 H4031 Taper roller bearing 215 H4028 Dust cover 216 H4315 Bottom yoke and stem17 14-0238 Pinch bolt ... 218 E8084 —qz#6 Washer 419 14-1303 Nut 220 H4007 Stanchion 221 H4076 End plug ... 222 H4087 Main spring ••• 223 H4343 OUTER MEMBER—R.H.24 H4342 OUTER MEMBER—L.H. 125 H3947 Cap wheel spindle 226 S2102 Stud 827 14-0302 Nut 828 D2428 Washer ... 829 H4001 Oil seal outer member 230 H3894 Drain plug ... 231 H3893 Washer ... 232 H4003 "0" ring—damper valve 233 H4009 Recoil spring 234 14-1019 Cap screw-damper tube 235 H4004 Cap screw seal 236 H4325 Damper tube and valve assembly 237 H4002 Scraper sleeve outer member 238 H4258 Top cap nut 239 H4166 Washer ... . •• 240 H4317 Steering stem nut (without steering damper)41 H431897— Z? Steering stem nut (with steering damper) ••4242

H4058 Headlamp bracket—L.H.H4060 Headlamp bracket—R.H. 1 TR6R, T12OR

42 H4088 Headlamp bracket—L.H. TR6C42 H4090 Headlamp bracket—R.H.43 51809 Nut 244 D2338 Washer 245 F12209 Bush Headlamp bracket top fixing ... 446 F12211 Spacer 2

65

ClassicBike.Biz

Fig. 22. TELESCOPIC FRONT FORK

66

ClassicBike.Biz

Ref No. Part No. DESCRIPTION

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 42 42 42 43 44 45 46


H4080 H4035

FORK ASSEMBLY

14-0234 14-1303 E8084 F6738 D623 ~Z-073~ S578 H2266 H2270 F8245 H3682 F12007 H4031 H4028 H4315 14-0238 E8084 €/)-tfZ.t/6 14-1303 H4007 H4076 H4087 H4343 H4342

Top Yoke .. . Pinch Bolt .. . Nut ... Washer Lock cfw 2 keys Key (state serial No.) Grub screw Sealing washer Brake cable retainer Star lock washer ... Retaining bracket Abutment ring Taper roller bearing Dust cover Bottom yoke and stem Pinch bolt ... Washer Nut Stanchion End plug Main spring OUTER MEMBER-R.H. OUTER MEMBER-L.H.

H3947 S2102

Cap wheel spindle Stud

14-0302 Nut

D2428 Washer H400~ Oil seal outer member H3894 Drain plug ... H3893 Washer H4003 "0" ring-damper valve H4009 Recoil spring 14-1019 Cap screw-damper tube H4004 Cap screw seal H432S Damper tube and valve assembly H4002 Scraper sleeve outer member H4258 Top cap nut H4166 Washer H4317 Steering stem nut (without steering dam per) H4318q7- t.fOZ.Cf Steering stem nut (with steering damper) H4058 Head lamp bracket-L.H. . . . . . . . .. H4060 Headlamp bracket-R.H. H4088 Headlamp bracket-L.H. H4090 Headlamp bracket-R.H.

S1809 Nut 1 D2338 Washer F12209 Bush Headlamp bracket top fixing

F12211 Spacer

65

QUANTITY REMARKS

1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 2 4 2 2 2 2 1 1 2 8 8 8 2 2 2 2 2 2 2 2 2 2 2 1 1

~ } TR6R, T120R

~} TR6C

2 2 4 2

Bruce

Callout

97-4342

Bruce

Callout

97-4343



47 S2062 Sleeve nut 24849

D2333D2630

WasherGrommet Headlamp bracket bottom fixing 2

250 F9046 Washer 251 H4012 Nut—damper valve ... 252 F12216 F3 2Z10 Clamp washer ••• 4

67

ClassicBike.Biz

3

6

8

L5

17-

10

Fig. 23. HANDLEBAR MOUNTINGS AND STEERING DAMPER

68

ClassicBike.Biz


HANDLEBAR MOUNTINGS AND STEERING DAMPER

1 H2291 Handlebar eyebolt 22 F1335 Washer ... 23 5589 Bolt ... ... 24 H1527 Metalastic bush 25 H1529 Hemispherical washer ... 46 H1581 Distance piece ... 27 H1580 Rubber washer ... 28 H2221 Cup 29 14-1303 Nut ... 2

10 H3875 Steering damper rod c/w knob 111 D2438 Spring washer ... ••• 112 H435 Friction disc ... ••• 113 H1797 Anchor plate ••• .•• 1 Available14 H95 Spring plate ... ••• 115 D2329 Washer ... ••• 116 H4102 Bottom nut ••• 117 — Split pin (K in. x 1 in.) Reference only

69

ClassicBike.Biz

NNNM TJ^ N /\

CoU.

70

ClassicBike.Biz

Ref. N

o.P

art No.

DESC

RIPTIO

NQ

UA

NTITY

RE

MA

RK

S

FR

ON

T W

HE

EL

1W

3845FR

ON

T W

HE

EL

CO

MPL

ET

E...

12

W3844

RIM

, SPOK

ES A

ND

HU

B A

SSEM

BL

Y1

3W

3818W

heel rim (W

M2-19)

...1

4W

3658B

rake drum and hub

1

5W

3820Spoke (R

.H.—

inner)10

6W

3819S

poke (R.H

.—outer)

107

W3821

Spoke (L.H

.)20

8W

2294N

ipple......

409

W3969

Balance w

eight (short)as required

10W

3970B

alance weight (long)

as required11

W653

Bearing

...2

12D

2632C

irclip—R

.H.

...1

13W

3797G

rease retainer—R

.H.

•••1

14W

3759L

ock ring—R

.H.

...•••

1

15W

1481G

rease cap inner—L

.H.

...•••

1

16W

1237G

rease cap outer—L

.H. ...

••.1

17T280

Circlip—

L.H

.1

18W

3932D

istance piece•••

1

19W

3796W

heel spindle...

•••1

20W

2058N

ut wheel spindle

•••1

21D

3669G

romm

et brake drum•••

1

2214-1303

Nut

Anchor plate to fork leg

1

23D

2340W

asher1

24W

3655B

rake anchor plate1

25W

3987B

rake lever front ...1

26W

3986B

rake lever rear...

1

27D

2639"0" ring brake cam

2

28W

3762T

appet brake cam•••

2

29W

3761"0

" ring b

rake tap

pet

•••2

30W

3713B

rake shoe complete

...•••

2

31W

3714R

eturn spring...

...•••

2

32W

3715C

age brake shoe adjuster2

33W

3716M

icram adjuster

...2

34W

3717A

butment pressing

......

2

3514-1635

Stud-anchor plate torque reaction

1

71

ClassicB

ike.Biz

N

LL

72

ClassicBike.Biz


FRONT WHEEL

1 W3845 FRONT WHEEL COMPLETE ... . .. . .. ... . .. 1 2 W3844 RIM, SPOKES AND HUB ASSEMBLY ... . .. ... 1

3 W3818 Wheel rim (WM2-19) ... ... . .. ... . .. 1

4 W3658 Brake drum and hub ... ... . .. ... . .. 1

5 W3820 Spoke (R.H.-inner) ... . .. ... ... . .. 10 6 W3819 Spoke (R.H.-outer) ... ... ... ... . .. 10 7 W3821 Spoke (L.H.) ... ... . .. . .. ... . .. 20 8 W2294 Nipple ... ... ... . .. . .. ... ... . .. 40 9 W3969 Balance weight (short) ... . .. ... . .. ... . .. as required

10 W3970 Balance weight (long) ... . .. . .. ... ... ... as required

11 W653 Bearing ... ... ... . .. . .. ... . .. ... 2

12 D2632 Circlip-R.H. ... . .. ... ... . .. . .. ... 1

13 W3797 Grease retainer-R.H. ... . .. ... . .. ... . .. 1

14 W3759 Lock ring-R.H. . .. ... . .. ... . .. ... . .. 1

15 W1481 Grease cap inner-L.H. . .. ... . .. ... ... ... 1

16 W1237 Grease cap outer-L.H .... ... ... . .. ... ... 1

17 TI80 Circlip-L.H. ... ... ... ... . .. ... . .. 1

18 W3932 Distance piece ... ... ... ... . .. ... ... 1

19 W3796 Wheel spindle ... ... . .. ... . .. ... ... 1

20 W2058 Nut wheel spindle ... . .. ... . .. ... ... 1

21 D3669 Grommet brake drum ... ... ... ... ... . .. 1

22 14-1303 Nut } 1

23 D2340 W h Anchor plate to fork leg ... ... ... ...

1 as er 24 W3655 Brake anchor plate ... ... . .. ... ... . .. 1

25 W3987 Brake lever front ... ... ... . .. ... ... . .. 1

26 W3986 Brake lever rear ... ... ... ... ... . .. ... 1

27 D2639 "0" ring brake cam ... ... ... ... ... ... 2

28 W3762 Tappet brake cam ... ... . .. ... ... ... 2

29 W3761 "0" ring brake tappet ... . .. ... ... ... 2

30 W3713 Brake shoe complete ... ... ... ... ... ... 2

31 W3714 Return spring ... ... ... . .. ... ... ... 2

32 W3715 Cage brake shoe adjuster ... ... ... ... ... 2

33 W3716 Micram adjuster ... ... ... ... ... ... ... 2

34 W3717 Abutment pressing ... ... ... ... . .. ... 2

35 14-1635 Stud-anchor plate torque reaction --- --- --- ... 1

71

••••••2

••••••2

Ref. N

o. Part N

o.

DESC

RIPTIO

NQ

UAN

TITYREM

ARKS

RE

AR

WH

EE

L

1W

3968R

EA

R W

HE

EL

CO

MP

LE

TE

......

2W

3782R

IM SPO

KE

S AN

D H

UB

ASSE

MB

LY

3W

3784R

IM (W

m 3 x 18) ...

4W

3724Spoke (inner—

L.H

.)

5W

3725S

poke (outer—L

.H.)

6W

3726S

poke—R

.H....

7W

2294N

ipple......

...8

W3773

Hub and brake drum

9W

3468T

yre security bolt...10

W3749

Support ring—

L.H

.11

W653

Bearing

......

12W

3752L

ocking ring—L

.H.

13W

3753Spacer

......

14W

1654G

rease retainer—R

.H.

15W

3747S

procket 47 teeth16

14-0207B

olt17

D2320

Wash

er .S

procket to hub

1814-1301

Nut

19W

3856B

rake anchor plate

20W

3872B

rake cam21

W4034

Brake lever

2214-1303

Nut

23D

2331W

asher...

24W

3870B

rake pivot25

14-0305N

utB

rake pivot to torque arm26

D2431

Washer

27W

3925B

rake shoe complete (leading) ...

28W

3926B

rake shoe complete (trailing) ...

29W

2328R

eturn spring (brake shoe)...

30W

4049R

eturn spring (brake lever)

31F12656

Brake torque arm

3214-0133

Bolt

33W

2330W

asher T

orq

ue arm

to fram

e

3414-1304

Nut

35W

3965W

heel spindle

36W

3750D

istance piece inner...

37D

3213S

peedometer drive gearbox

38W

3746D

istance piece outer...

40F12266

Wash

er

sp

ind

le

r

3914-1307

Nut

41W

3751S

peedometer drive ring

...

42Fl 3082

Cover plate-sw

inging arm fork end

43W

3742C

hain adjuster44

14-0107S

cre

w C

hain

ad

juste

r —45

14-0301N

ut I

...

46D

1841G

rease nipple

47W

E170 83-722 ) F

ibre washer

•••

73

ClassicB

ike.Biz

18 --

16

17

B22

-- I- q__--3413

19 14 10

1520 ®--11

2112

22 ^-

2 T

Fig. 26. GAS TANKS AND TWINSEAT

74

x--2425̂

23 i

23

ClassicBike.Biz


1

GAS TANK AND TWINSEAT

F1299683-42Gas tank (3 gall.) ... 1 *For color seepage 8

2 F9062 Steady rubber ... 23 Fl 3021 Mounting rubber ... 24 51823 Centre fixing bolt ... 15 F13133 Distance tube ... ... 16 F10260 Mounting rubber ... 17 F13320 Washer ... ... 18 F13321 Rubber washer ... ... 19 F13319 Mounting ring ... ... 1

10 S1999 Nut ... ... 1

11 D2330 Washer ... ... 1

12 F13318 Beading holder ... ... 1

13 F13068 Grommet ... ... 1

14 F13134 Styling strip-front ... 1

15 F13135 Styling strip-rear ... 1

16 F9700 Tank motif—L.H. ... 1

16 F9701 Tank motif—RH. ... 1

17 F11339 Screw—front—tank motif ... 2

18 F7888 Screw—rear—tank motif ... 2

192021222323242526272829

F13875F4048F3217F3221 NF12800F12801E7351F10002F14288F14291F1286714-0101

L, A .

Filler capJoint waserJack chainClip ...Gas tap ...Gas tap—reserveTap sealWasher ...Twinseat

Twinseat coverHinge ...Bolt to twinseat}Hinge

...

...

...

...

...

...

...

...

...

...

...

•••

1111112211244

TR6CTR6C

30313233

D2417F9093F13061F12597

Spring washerRubber buffer ... •••Catch assemblySpring—catch assembly

...

...

...

511

34 1-40604 Screw Twinseat catch fixing •••353637

14-1301D2087D2381

NutCheck wire ...Screw—self tapping ...

...

...

*F1288183-y4gg Petrol tank (44 gall.) ... ... Available

75

ClassicBike.Biz

00

LL

M_fV

7

76

ClassicBike.Biz


GAS TANK AND TWINSEAT

F1299633-tf'l~Gas tank (3 gall.) ... . .. . .. ... . .. ... . .. 1 *For color see page 8

2 F9062 Steady rubber ... ... . .. ... . .. ... . .. 2

3 F13021 Mounting rubber ... ... . .. ... . .. ... ... 2

4 S1823 Centre fixing bolt ... ... . .. ... . .. ... . .. 1

5 F13133 Distance tube ... ... ... . .. ... ... . .. ... 1

6 F10260 Mounting rubber ... ... . .. ... . .. ... . .. 1

7 F13320 Washer ... ... ... ... .. . ... . .. ... ... 1

8 F13321 Rubber washer ... ... ... . .. ... ... ... .. . 1

9 F13319 Mounting ring ... ... ... ... ... ... ... . .. 1

10 S1999 Nut ... ... ... ... ... ... ... ... ... 1

11 D2330 Washer ... ... ... ... ... ... ... ... . .. 1

12 F13318 Beading holder ... ... ... ... ... ... . .. ... 1

13 F13068 Grommet ... ... ... ... . .. ... ... . .. 1

14 F13134 Styling strip-front ... ... ... ... ... ... . .. 1

15 F13135 Styling strip-rear ... ... ... ... ... ... . .. 1

16 F9700 Tank motif-L.H. ... ... ... ... ... ... ... 1

16 F9701 Tank motif-RH. ... . .. ... ... ... ... ... 1

17 F11339 Screw-front-tank motif ... ... ... ... ... ... 2

18 F7888 Screw-rear-tank motif ... ... ... ... ... ... 2

19 F13875 Filler cap ... ... ... ... ... ... ... ... 1

20 F4048 Joint waser ... ... ... ... ... ... ... ... 1

21 F3217 Jack chain ... ... ... ... ... ... ... ... 1 TR6C

22 F3221 !/. L.., A· Clip ... ... ... ... ... ... ... ... ... 1 TR6C

23 F12800 Gas tap ... ... ... ... ... ... ... ... ... 1

23 F12801 Gas tap-reserve ... ... ... ... ... ... ... 1

24 E7351 Tap seal ... ... ... ... ... ... ... ... 2

25 F10002 Washer ... ... ... ... ... ... ... ... ... 2

26 F14288 Twin seat ... ... ... ... ... ... ... ... 1

27 F14291 Twinseat cover ... ... ... ... ... ... ... 1

28 F12867 Hinge ... ... ... ... ... ... ... ... ... 2

29 14-0101 Bolt \._H. . 4 . h J mge to twmseat ... ... ... ... . ..

4 30 D2417 Sprmg was er

31 F9093 Rubber buffer ... ... ... ... ... ... ... ... 5

32 F13061 Catch assembly ... ... ... ... ... ... ... 1

33 F12597 Spring-catch assembly ... ... ... ... ... ... 1

34 1-40604 Screw}T. hfi. 1

wmseat catc 1xmg ... ... ... ... ... 1

35 14-1301 Nut

36 D2087 Check wire ... ... ... ... ... ... ... ... 1

37 D2381 Screw-self tapping --- ... ... 1

*F128818J-tf6Jf Petrol tank (4~ gall.) --- ... ... Available

75

Ref. N

o.P

art No.

DE

SC

RIP

TION

QUANTITY

REM

ARKS

AIR

CL

EA

NE

R A

ND

SID

E P

AN

EL

S

F13789 N• 1• A

•A

IR C

LE

AN

ER

ASSEMBLY—

L.H.1

F13790* 4.4

.AIR

CLEAN

ER ASSEM

BLY—R

.H.

11

F12749Body—

L.H.

1Tw

in Carb

1F12750

Body—R

.H.

1T12OR

2F13850$3-

V C

over—L.H

.1

2F13851

Cover—

R.H

....

...1

F13791N.L

,A-

AIR C

LEANER

ASSEMBLY—

L.H.

1F13792M

"• AIR

CLE

AN

ER

AS

SE

MB

LY—

R.H

.1

1F12798

Body—L.H

.1

Single carb.1

F12797Body—

R.H

.•••

1TR

6R, TR

6C2

Fl 3864C

over—L.H

.•••

12

F13865C

over—R

.H.

•••1

3D

307260- '/165

Ele

ment

...•••

24

14-0221Bolt

25

F8245R

etainerC

over2

67

to bodyD2438

Washer

14-0302N

ut22

All models

8D3539

Screw2

95501

Nut

L. H. assy. to R

. H. assy.

21011

14-0218Bolt

}Air cleaner to fram

eD2418

Spring washer

2212

Fl 26267/- Pt/ C

onnector pipe2

T12OR13

F12625C

onnector pipe...

1TR

6C, TR

6R14

E11860C

arburetor adaptor1 or 2

15D3536

Clip—

Jubilee type1 or 2

16F1385983-073 S

ide panel—L.H

.1

17F138608•

-7C

Side panel—R

.H.

18F6673

Panel gromm

et ...2

19• ••

14-0201Bolt

420

D2329W

asher .Side panel to air cleaner

...4

2114-1301

Nut

4N

ot illus.D3722

Transfer ...2

T12ORN

ot illus.D3724

Transfer ...2

TR6C

Not illus.

D3723Transfer ...

2TR6R

Not illus.

F9196Spacer (use w

ith 14-0218)2

77

ClassicB

ike.Biz

nc.GaJ

J_

QI-0z4HWGzWU-

^Nby

LL

co

N

N ea97 ,.. ,.

r —

0

a M

78

ClassicBike.Biz

Ref. N

o. P

art No.

DE

SC

RIP

TION

QU

AN

TIT

Y

REM

AR

KS

FE

ND

ER

S A

ND

TA

IL L

AM

P

1H4271,4/1-A.

*Front fender

......

......

......

......

1T

R6R

, T120R

1H

4270*F

ront fender...

......

......

......

...1

TR

6C

2H

4022B

racket...

......

......

43

H4021

Rubber bush

I•••

......

Stay to fork leg

......

44

14-0103B

olt4

5D

2427S

pring washer

......

......

...4

6F13566

*Rear fender

......

......

......

......

1T

R6R

, T120R

6F13565

*Rear fender

......

......

......

......

1T

R6C

714-0114

Bolt

......

......

...2

8D

2330W

asherF

ender fixing front...

......

......

4

914-1302/1/-/202 N

utJ

......

......

...2

1014-0101

Bolt

......

......

......

......

...2

1114-0103

Bolt

......

......

......

......

...1

12F

30

69

82'9

O'Z

Spacer

......

......

......

......

...1

13D

2329W

ashe r...

...F

ender fixing top and rear...

...33

1414-1301

Nu

t•••

••••••

••15

F12768L

ifting handle...

......

......

......

...1

1614-0101

Bolt

• • •...

..L

ifting handle to frame

..

•....

2217

D2329

••••.•

Washer

•••

1914-1301

Nut

......

......

......

......

...21

18F12727

Rear num

ber plate bracket—L

.H.

......

......

...

20F12728

Rear num

ber plate bracket—R

.H.

......

......

...1

2114-0102

Bolt

......

......

4422

D2329

Washer

Num

ber plate bracket to fender......

......

2314-1301

Nut

J...

...

...

...

4124

F12786T

ail lamp support

......

......

......

...1

25D

3313C

aptive nut...

......

......

...

2614-6102

Bolt

Tail lam

p support front fixing"

"'27

S25-160-^f 2

h/S W

asher...

......

...

2814-0101

Bolt

Tail lam

p support rear fixing...

......

2229

D2427

Washer

......

230

F13213R

ubberg

stripbeading stri

......

......

•.....

...2

3157079

Reflector red (99-1162)

......

.. •...

......

32D

2391W

asher...

......

......

•.....

...22

...33

F4717N

ut...

......

•..

ST

OP

AN

D T

AIL

LA

MP

679 (99-0597)...

.........

...1

3453973

135

54577109L

ens (99-1046)...

......

......

...1

36144921

Screw (99-1189)

......

......

......

...R

eferenceonly

3754525286

Lam

p base assembly

......

......

......

38380

Bulb

(99-

05

42

)...

...

...

...

...

...

*For color see page 8.

79

ClassicB

ike.Biz

80

ClassicBike.Biz


1 1 2 3 4 5 6 6 7 8 9

10 11 12 13 14 15 16 17 19 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

FENDERS AND TAIL LAMP

H4271 A/. /..A . H4270 H4022

*Front fender *Front fender

H4021 Rubber bush Bracket }

14_0103 Bolt Stay to fork leg

02427 Spring washer F13566 *Rear fender F13565 *Rear fender

14-0114 Bolt } 02330 Washer Fender fixing front 14-1302/'I-IZOZ Nut 14-0101 Bolt 14-01 03 Bolt F306982-f3JO'!Z Spacer 02329 Washer} 14-1301 Nut Fender fixing top and rear

F12768 Lifting handle ... 14-0101 Bolt } 02329 Washer Lifting handle to frame

14-1301 Nut F12727 Rear number plate bracket-L.H. F12728 Rear number plate bracket-R.H.

14-0102 Bolt } .. . 02329 Washer Number plate bracket to fender .. . 14-1301 Nut .. . F12786 Tail lamp support 03313 Captive nut 14-6102 Bolt } 0 •

S25_1GO-lfZ'/S"Washer Tail lamp support front fixmg

14-0101 Bolt } 0 0

02427 Washer Tail lamp support rear fixmg

F13213 Rubber beading strip ... 57079 Reflector red (99-1162) 02391 Washer ... F4717 Nut 53973 STOP AND TAIL LAMP 679 (99-0597) 54577109 Lens (99-1046) 144921 Screw (99-1189) ... 54525286 Lamp base assembly 380 Bulb (99-0542)

*For color see page 8.

79

QUANTITY REMARKS

1 TR6R, T120R 1 TR6C 4 4 4 4 1 TR6R, T120R 1 TR6C 2 4 2 2 1 1 3 3 1 2 2 2 1 1 4 4 4 1 1 1 1 2 2 2 2 2 2 1 1 1 Reference only 1

Ref. No. P

art No.

DESCRIPTION

QU

AN

TIT

YREM

ARKS

HA

ND

LE

BA

RS

AN

D C

ON

TR

OL L

EV

ER

S

1H

4252q7-7OO

/ Handlebar

......

......

......

......

12

H1425Sleeve, handlebar m

ounting...

......

......

...4

316136460-7

0Y

q TW

ISTGR

IP (99-0248)...

......

......

...1

416/328

Body, top half (99 -0245)

......

......

...1

516/329

BO

DY

, BO

TTOM

HA

LF (99-0246)

......

......

16

16/008F

riction spring...

......

......

...R

eference only7

16/009 ri Z2

./09

9'

Screw

...•••

••••••

•--...

......

Reference only

816/010

Locknut

......

......

......

...R

eference only9

99-0244R

otor...

......

......

......

...I

1011/013

Screw

(9^,^

25)

......

......

......

...2

11H

9589'7

- 2/2

SG

rip...

......

......

......

...1

1216/011

Cable stop (99-0241)

......

......

......

...1

13H

212497- 2./4'2. Grip

......

......

......

......

...1

1412/60

-3c6

7 A

IR C

ON

TR

OL

LE

VE

R (D

3246)...

......

......

115

12/556- 0

22

1r

Lever

......

......

......

......

Reference only

1612/607

Bolt

......

......

......

......

Reference only

1712/606

Cap ...

......

......

......

......

Reference only

1812/033

Spring w

asher...

......

......

......

Reference only

1912/040

Clam

p...

......

......

......

...R

eference only20

11 /014 9'9- c'ZZ

Screw...

Reference only

21D

3583F

ront brake lever (alloy)...

......

......

...1

22D

3657C

lutch lever (alloy)...

......

......

......

123

S2048P

ivot pin......

......

......

......

...2

24

14-1201N

ut...

......

......

......

......

225

D3585

Adjuster

......

......

......

......

22

6D

3586L

ockring...

......

......

......

...2

2739595

HA

ND

LE

BA

R SW

ITC

H—

L.H

....

......

......

Reference only

2854033666

Switch half

......

......

......

...R

eference only29

54340882L

ever half (99-1187)...

......

......

...1

3054115246

Screw (99-1188)

......

......

......

...4

3139596

HA

ND

LE

BA

R SW

ITC

H—

R.H

....

......

......

Reference only

3254033667

Switch half

......

......

......

...R

eference only33

54340883L

ever half (99-1215)...

......

......

...1

3454115246

Screw (99-1188)

......

......

......

...4

81

ClassicB

ike.Biz

Fig. 30. CONTROL CABLES

B26

13

4

7

25

82

ClassicBike.Biz


CONTROL CABLES

1123456789

1011121314151617181920212223242526

3

D1819 Throttle cable ... ... ... ...D1 806 Throttle cable ... ... ... ...D3079 Clutch cable ... ... ... ... ...D3557 Front brake cable ... ... ... ...W3996 Bush—brake cable stop ... ... ...W3997 Bush—brake cable ... ... ... ...E12500 Washer ... ... ... ... ... ...W4014 Cable spring ... ... ... ... ...D1 807 Air control cable ... ... ... ...D3485 AIR CONTROL CABLE ... ... ...D1 818 Cable, lever to junction box ... ...244/10460-068

JS Junction box (99-0341) ... ... ...

D3486 Cable, junction box to carburetor ...313/13 TWIN ROTOR TWISTGRIP (99-0347) ...18/084 Screw ... ... ... ... ...313/020 Body, top half ... ... ... ...313/021 BODY, BOTTOM HALF ... ...16/008 Friction spring ... ... ...210/007 Screw ... ... ... ... ...5/077 T9- 70 ?7 Nut ... ... ... ... ...313/004 Rotor ... ... ... ... ...210/008 Rotor stop screw ... ... ... ...5/0779- 7097 Nut—rotor stop screw ... ... ...H2125 Grip ... ... ... ... ...D343/3 Cable clip ... ... ... ... ...D343/7 Cable clip ... ... ... ... ...H4112 Handlebar clip ... ... ... ... ...

LATER MODELS USE THE FOLLOWING:D3815O-35j7Front brake cable ... ... ...

... ... ... 2 T120R

... ... ... 1 TR6C, TR6R

21

... ... ... 1 TR6C, TR6R

... ... ... 1 T120R

2... ... ... 1 T120R... ... ... Reference only... ... ... Reference only... ... ... Reference only... ... ... Reference only... ... ... Reference only... ... ... Reference only... ... ... Reference only... ... ... Reference only... ... ... Reference only

1264

1

83

ClassicBike.Biz

ClassicBike.Biz


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

3

CONTROL CABLES

D1819 D1806 D3079 D3557 W3996 W3997 E12500 W4014 D1807 D3485

Throttle cable Throttle cable Clutch cable Front brake cable Bush-brake cable stop Bush-brake cable Washer ... Cable spring Air control cable AIR CONTROL CABLE

D1818 Cable, lever to junction box 244/10460- o6eS" Junction box (99-0341) ... D3486 Cable, junction box to carburetor 313/13 TWIN ROTOR TWISTGRIP (99-0347) 18/084 Screw 313/020 Body, top half 313/021 BODY, BOTTOM HALF 16/008 Friction spring 210/007 Screw .. . 5f077 Cf'f- 70 97 Nut .. . 313/004 Rotor 210/008 Rotor stop screw ... 5f077o/9-70Cf7 Nut-rotor stop screw H2125 Grip D343f3 Cable clip D343f7 Cable clip H4112 Handlebar clip ...

LATER MODELS USE THE FOLLOWING:

D3815{1J-355/Front brake cable

83

QUANTITY REMARKS

2 T120R 1 TR6C, TR6R 1 1 1 1 2 1 1 TR6C, TR6R 1 T120R 1 1 2 1 T120R Reference only Reference only Reference only Reference only Reference only Reference only Reference only Reference only Reference only 1 2 6 4

... 1

TOOLKIT

D2112 TOOLKIT COMPLETED291 Tool roll ... ... ...D2184 Damper unit spanner ... ... ...

D1911 Tommy bar ... ... ... ...D2084 Spanner—open ended ... ... ...D971 Box spanner ... ... ... ...D972 Ring spanner ... ... ... ...D974 Tyre valve key ... ... ... ...D767 Screw driver ... ... ... ...F13292 Tool tray ... .. ... ... ...14-0101 Bolt ... ... ... ... ... ...D2329 Washer ... ... .. ... ... ...

123456789

1011

1


85

ClassicBike.Biz

86

ClassicBike.Biz


TOOLKIT

02112 TOOLKIT COMPLETE 1 1 0291 Tool roll ... 000 ... ... . .. . .. . .. . .. 1 2 02184 Damper unit spanner ... . .. ... . .. . .. . .. 1 3 01911 Tommy bar ... ... . .. ... . .. . .. . .. 1 4 02084 Spanner-open ended ... . .. . .. . .. . .. . .. 1 5 0971 Box spanner ... ... . .. . .. . .. . .. . .. 1 6 0972 Ring spanner ... ... . .. . .. . .. . .. . .. 1 7 0974 Tyre valve key ... ... . .. . .. . .. . .. . .. 1 8 0767 Screw driver ... . .. ... ... . .. . .. . .. 1 9 F13292 Tool tray ... .. ... . .. . .. . .. . .. . .. 1

10 14-0101 Bolt ... ... . .. . .. . .. . .. . .. . .. . .. 1 11 02329 Washer ... ... . .. . .. . .. ... . .. . .. . .. 1

85

VE

ED

OM

ET

ER

AN

D T

AC

HO

ME

TE

R

1lSpeedom

eter head (D2394) ...

...T

rip control (99-0

176)..6

04.7

0//.

Bulb

holder...

......

......

Bulb (3W

. ME

S)..

Speed

om

eter cable O

f 9/.,1

0 Q

.,Z C

...

Mounting

bracket ...

......

...

Rubber

cup...

......

......

Wash

er...

......

......

...T

AC

HO

ME

TE

R G

EA

RB

OX

(E5758 B

ody)—L

.H. thread

Securing screw

—L

.H. thread, U

.N.

...B

ush......

......

...F

langedbush ...

......

...

Drivinggear

......

......

Endcap .

..

......

......

"0"

ring ...

......

......

Driven

gear ...

......

...D

riven gear housing...

......

"0'' rin

g...

......

...B

ush

......

......

..."0

" ring

......

......

Set screw

.....

Tachom

eter cable.J^

F .9

'///,48.

...T

achom

eter (D23

96) ... O

- 7/ 7.1...

...S

pade(99-0173)

......

......

...C

irclip...

......

......

......

Sealingw

asher ......

......

......

Blanking plug (replaces tacho bulb holder)

...

87

1S

SM

5007/00^ ,...

12

41-148-203-10...

13

54959626...

Reference only

4643

Reference only

5D3249

...1

6H4026

f 1TR6C,

2T120R, TR6R

7D2600

12TR6C,T120R, TR6R

Not illus.

D23912 or 4

8E

93317/-L//3...

19

E9332...

I10

Reference only

...1

11R

eference only...

112

E5157...

113

E5759...

114

E6300...

115

E5578...

116

E12875...

1TR6R

17E6299

...1

T120R18

Reference only

...1

19D3530

...1

20

E5881

D328211

2122RSM

3003/13......

123

31-371-398...

124

D494...

125

E7351...

1N

ot illus.D546

...1

Ref. N

o. Part N

o.

DESCRIPTIONQ

UA

NT

ITY

REMARKS

ClassicB

ike.Biz

Fig. 33. COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN

88

ClassicBike.Biz


~cf E E D 0 M E T E R A N D T A C H 0 M E T E R (_/\ .. ,,~

1 2 3 4 5

SSM5007J00{J' Speedometer head (02394) . . . . .. 41-148-203-10 Trip control (99-0176) .. 60-:]01/. 54959626 Bulb holder 643 Bulb (3W. MES) ... ··· f'Jh.. ··· D3249 Speedometer cable Or 9.11~ a 2. c ...

6 H4026 Mounting bracket

7 D2600 Rubber cup

Not ill us. D2391 Washer ... 8 E9331 7/-'f/36 TACHOMETER GEARBOX (E5758 Body)-L.H. thread 9 E9332 Securing screw-L.H. thread, U.N.

10 Reference only Bush ... 11 Reference only Flanged bush ... 12 E5157 Driving gear 13 E5759 End cap 14 E6300 "0" ring ... 15 E5578 Driven gear 16 E12875 Driven gear housing 17 E6299 "0" ring 18 Reference only Bush 19 D3530 "0" ring 20 E5881 Set screw 21 D3282 Tachometer cable 22 RSM3003J13 Tachometer (02396) 23 31-371-398 Spade (99-0173) 24 D494 Circlip ... 25 E7351 Sealing washer ...

:i;r ?!1111~'18. ... 60::·. 71 7../ ...

Not illus. D546 Blanking plug (replaces tacho bulb holder)

87

QUANTITY REMARKS

1 1 Reference only Reference only 1

f1 }~ l_2

2 or 4 1 1 1 1 1 1 1 1

TR6C, T120R, TR6R TR6C, T120R, TR6R

1 I TR6R 1 ( T120R 1 1 1 1 1 1 1 1 1


COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN

1 F12571 Mounting platform—electrical components... ... ... ... 12 14-0101 Bolt .•. ... ... ... ... 1

3 D2329 Washer Platform to mudguard ... ... ... ... ... 1

4 14-1301 Nut J ... ... ... ... ... I5 F9561 Grommet—coil mounting ... ... ... ... ... ... 26 45223 Ignition coil (17-M-12) D2206 tD

t2- 1203... ... ... 27 49072 Rectifier (99O589) tP - Q7c. ... ... ... ... 18 F5338 Nut ... ... ... ... ... ... ... ... ... 19 47638 CAPACITOR PACK-2CP ... ... ... ... ... ... Reference only

10 54420128 Capacitor (994$43) ... ... ... ... ... ... 211 54418528 Cover (99-077) ... ... ... ... ... ... ... 112 54418526 Base plate (99-1160) ... ... ... ... ... ... 113

9S207

} ...Capacitor pack to platformNw

... ... ... 214 S778 Nut15 35048 Flasher unit (99-1201 ) ... ... ... ... ... ... ... 116 54385091 Clip, flasher unit (99-1204) ... ... ... ... ... ... 1

17 D3614 Spring ... ... ... ... ... 1

18 S2079 Screw I

Flasher unit to platform "• ... ... ... ... 219 D2391 Washer ••• ••. ••• ••• ••• 220 S778 Nut ••. ... ... ... 221 49345 Zener Diode (99-0590) Cv '-0957.. ... ... ... 1

22 N3 Sparking plug ... ... ... ... ... ... ... ... Reference only

23 D262 Plug cover (Champion WC200) ... ... ... ... ... 1

24 70228 Horn-6H (99-1245) ... ... ... ... ... ... ... 1

25 14-0103 Bolt 226 D2347 Washer Horn to frame ... ... ... ... ... ... 4

27 14-1301 Nut J ... ... ... ... ... ... 228 54190038 Lucar blade terminal ... ... ... ... ... ... ... Reference only

29 57183 Reflector-amber (99-1161 ) ... ... ... ... ... ... 2

30 D2391 Washer ••• ... ... ... 231 F4717 Nut .Reflector mounting ... ... ... ... 2

32 F13522 Mounting rubber J ... ... ... ... 2Not illus. D3161 Grommet (horn mounting) ... ... ... ... ... ... 2

89

ClassicBike.Biz

90

ClassicBike.Biz

Ref No. Part No. DESCRIPTION QUANTITY REMARKS

COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN

1 F12571 2 14-0101 3 D2329 4 14-1301 5 F9561 6 45223 7 49072 8 F5338 9 47638

10 54420128 11 54418528 12 54418526 13 52079 14 5778 15 35048 16 54385091 17 D3614 18 S2079 19 D2391 20 5778 21 49345 22 N3 23 0262 24 70228 25 14-0103 26 02347 27 14-1301 28 54190038 29 57183 30 02391 31 F4717 32 F13522 Not illus. 03161

Mounting platform-electrical components ...

Washer Platform to mudguard Bolt }

Nut Grommet-coil mounting ... ... ... . .. Ignition coil (17-M-12) 102206) fi>C?..- 2.'?.0 .3 ... Rectifier (99 Oa89) 6.0 ~ 0..75'~. . .. . .. Nut CAPACITOR PACK-2CP

Capacitor (~3) Cover (99 9r67) ... Base plate (99 1160)

Screw } Nut Capacitor pack to platform

Flasher unit (99-1201) ... Clip, flasher unit (~)

Spring } Screw W h Flasher unit to platform

as er Nut ... . .. Zener Diode (99-0590) t;C?.~09..f? 7. .. Sparking plug ... Plug cover (Champion WC200) Horn-6H (99-121.5) ...

Bolt } Washer Horn to frame Nut Lucar blade terminal ... Reflector-amber(~)

Washer I Nut ~Reflector mounting Mounting rubber J Grommet (horn mounting)

89

1 1 1 1 2 2 1 1 Reference only 2 1 1 2 2 1 1 1 2 2 2 1 Reference only 1 1 2 4 2 Reference only 2 2 2 2 2

Ref. N

o. Part N

o.D

ES

CR

IPTIO

NQ

UA

NTITY

REMA

RKS

HE

AD

LA

MP

AN

D F

LA

SH

ER

LA

MP

S

160260

HE

AD

LA

MP C

OM

PLE

TE

MC

H 69 (

21)...

......

IT

R6R

, T120R

2553248

Rim

(99-0692)...

......

......

......

13

516801L

ight unit (99-1156)...

......

......

...1

4504665

Fixing wire (99-0683)

......

......

......

65

144921Screw

......

......

......

......

Reference only

6534296

Plate...

......

......

......

...R

eference only7

370M

ain bulb (45/35W) (99-1214)

......

......

...1

8554602

Bulbholder

......

......

......

...R

eference only9

989P

ilot bulb (99-0548)...

......

......

...1

1054573590

Pilot bulbholder (99-1213)

......

......

...1

1154363454

Warning light (R

ed) (99-1208)...

......

...1

1254363455

Warning light (G

reen) (99-1209)...

......

...1

1354363453

Warning light (A

mber) (99-1207)

......

......

114

54140331Sealing w

asher (99-1210)...

......

...3

1531276

Light sw

itch (99-1211)...

......

......

...1

1654525212

Shield, w

arning light...

......

......

...R

eference only17

281B

ulb, warning linglt (99-0537)

......

......

...3

1854115106

Screw, headlam

p fixinhgk9^

23) 9'70/.

Z...

...2

19143086

Washer, headlam

p fixing 99-1224)...

......

...2

Not illus.

54959629W

iring harness (99 122-i)...

......

......

...1

2039565

IGN

ITIO

N SW

ITC

H (T

YP

E 149 SA

) (99-1200)...

...1

2154130041

Nut ...

......

......

......

...R

eference only22

F6981S

Y335/6q IG

NIT

ION

LO

CK

C/W

KE

Y8

2.'9

8/

......

...1

23D

6225*0

35/6

9K

ey (state serial number)

......

......

...A

s required24

H2262

Cover, ignition sw

itch...

......

......

...1

2556147

FLA

SHE

R L

AM

P (99-1190)...

......

......

...4

2654581638

Lens (99-119

.1)...

......

......

......

127

54580300G

asket...

......

......

......

...R

eference only28

554548B

ulbholder...

......

......

......

Reference only

29473832

Interior assembly ...

......

......

......

Reference only

30382

Bulb (99-1192)

......

......

......

...1

3154123401

Screw (99-1193)

......

......

......

...2

3260600092

Stanchion, flasher lamp (99-1246)

......

......

4

91

ClassicB

ike.Biz

4

0Q

UI

m

0Z4

mW

4m

M

92

ClassicBike.Biz


2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 Not illus 20 21 22 23 24 25 26 27 28 29 30 31 32

HEADLAMP AND FLASHER LAMPS

60260 553248 516801 504665 144921

HEADLAMP COMPLETE MCH 69 (~9 122~)

Rim (99-0692) Light unit (99-1156) Fixing wire (99-0683) Screw

534296 Plate 370 Main bulb (45j35W) (99-1214) 554602 Bulbholder 989 Pilot bulb (99-0548) 54573590 Pilot bulbholder (99-1213) 54363454 Warning light (Red) (99-1208) 54363455 Warning light (Green) (99-1209) 54363453 Warning light (Amber) (99-1207) 54140331 Sealing washer (99-1210) 31276 Light switch (99-1211) ... 54525212 Shield, warning light 281 Bulb, warning lihg!t (99-0537) 54115106 Screw, headlamp fixinhg ~23) 9l:f.~ 70./.Z 143086 Washer, headlamp fixing 99-1224) 54959629 Wiring harness (~~ 122'2.) 39565 IGNITION SWITCH (TYPE 149 SA) (99 12Q~) 54130041 Nut... .. . F69815'(335/6'/IGNITION LOCK CJW KEY 8 2..-:: tD9',$: I 0622~'/335"/0, Key (state serial number) ... ... H2262 Cover, ignition switch 56147 FLASHER LAMP (99-1190) 54581638 Lens (99 1191) 54580300 Gasket 554548 Bulbholder 473832 Interior assembly ... 382 Bulb (99-1192) 54123401 Screw (99-1193) ... 60600092 Stanchion, flasher lamp (99-1246)

91

QUANTITY REMARKS

1 TR6R, T120R 1 1 6 Reference only Reference only 1 Reference only 1 1 1 1 1 3 1 Reference only 3 2 2 1 1 Reference only 1 As required 1 4 1 Reference only Reference only Reference only 1 2 4

Ref. N

o. Part N

o.

DESC

RIPTIO

NQ

UA

NT

ITY

REM

AR

KS

BA

TT

ER

Y A

ND

TR

6C

HE

AD

LA

MP

1F1 2

512

Battery carrier

......

......

......

...1

2F8091

Carrier tray

......

......

......

......

13

F8255P

rotective strip...

......

......

......

24

F9353R

etaining strap ......

......

......

......

15

F1 3849

Buckle

......

......

......

......

...1

6F1 3

295

Protective strip

......

......

......

...11

7F12508

Shoulder screw

......

...3

8F6039

Rubber bush

Battery carrier m

ounting...

......

39

14-1301N

u...

......

110

54027029B

attery—PU

Z5A

(99-O9)

.'25'$

......

...1

1160262

HE

AD

LA

MP A

SSEM

BL

Y M

CH

66 (995)

......

...1

12534343

Rim

(99

--O69^)

...

...

...

...

...

...

...

113

54525272L

ight unit (99-1-21-2)...

......

......

114

504665Fixing w

ire (99-9683)...

......

......

...6

15370

Bulb (45/35W

vertical dip, pre-focus 99-1214)...

...1

1654573590

Bulbholder, pilot (99-0695)

......

......

...1

17989

Bulb (3W

.M.C

.C. 99-0548)

......

......

...1

18554602

Adaptor c/w

leads (99-1003)...

......

......

2N

ot illus.54115106

Screw, lam

p fixing (99=1157)...

......

......

2N

ot illus.143086

Washer (99-1224)

......

......

......

219

31272L

ighting switch (99-6563)

......

......

...1

20153631

Nut for lighting sw

itch...

......

......

...R

eference only21

144921Screw

......

......

......

Reference only

22534296

Plate (99-0690).6

0 7

0 9

'7

......

......

1

2354363454

Warning light, red (99-1

.208)...

......

......

124

281B

ulb (2W.B

A75) (99-0537)

......

......

...2

2554363455

Warning light, green (99-1209)

......

......

126

54140331Sealing w

asher (99-1210)...

......

......

327

54363453W

arning light amber (99-1207)

......

......

128

54525212W

arning light shield...

......

......

...R

eference only29

14-0404N

ut...

......

......

......

......

230

H4247

Support bracket

......

......

......

...1

93

ClassicB

ike.Biz

STANDARD HARDWARE SPECIFICATIONBOLTS

Length under

head+,,

1 3,,1 6

n"1 31

”

6

21,,

f"1"8f"k"1"24"1f"lk"li"11"3"4" 7,,

W

0.563"11" 1"24" 1" 0.563"3" 1" 0.563"34" 1" 0.563"4" 1" 0.563"21" 1+" 0.625"1” 0.438"87”W 0.500"

N U TSPart No. Material Thd. dia. Hexagon A.F. Thickness Remarks

ClevelocPhilidas

PlainPlainPlainPlainPlainPlainPlainPlainLockLockLockPhilidasPhilidasPhilidasStiffnutStiffnutStiffnutStiffnutStiffnutStiffnutStiffnutNylocNyloc

1 02 34

Part No. Material Thd. dia.21-1822 Steel *" UNF21-1910 f f A" UNF821-121-1919 II , 6 " UNC21-2010 f f 1" UNF41 0101 t f k" UNF1 0102 t I k" UNF1 0103 PP I" UNF4

1 0113 II *" UNF1 0114 It *" UNF1 0115 It *" UNF1 0128 1 t 1" UNF1 0208 f t I" UNF41 216 f P 16 UNF1 0217 PP " UNF1 0219 tI *" UNF1 0220 PP UNF14-0225 f f 1 6 " UNF1 0228 IP *" UNF

2 f a " UNF81 0236 tt i" UNF1 0239 0 , A" UNF81 0240 /I A" UNF81 0242 tl A" UNF81 0251 IP " UNF1 6102 ., k" UNC1 6115 Of *" UNC

77821-0778 Steel No. 10 UNF 0.375" 0.225"21-1852 I f " UNF* 0.437" 0.330"21-1906 It I" UNF4 0.348" 0.188"21-190 If 1 6 " UNF 0.438" 0.313"21-1914 A" UNEF4 1.125" 0.250"21-2012 f " UNEF 1.313" 0.438 "21-2013 l' UNEF 1.313" 0.313"21-2014 f" UNEF 1.313" 0.438"

030114-0301 1 " UNF4 0.438" 0.224"1 030 1 6 UNF 0.500" 0.271"1 0401 k" UNF 0.438" 0.1 61"1 0402 *" UNF 0.500" 0.192"1 0403 " 1" UNF "0.563 "0.2241 0701 " k" UNF "0.438 "0.2031 702 " UNF 0.500" "0.2461 0703 U "I UNF 0.563" 0.296"1 1201 k" UNF 0.438" 0.285"1 1202 f 0

*" UNF 0.500" 0.335"

1 1301 f Pk" UNF 0.438" 0.245"

1 1302 ,, A" UNF 0.500" 0.290"

1 1303 tIf" UNF 0.563" 0.320"

1 1304 IP" UNF 0.688" 0.375"

1 1305 t t1 " UNF2

0.750" 0.435"

1 1902 tt 1 6 UNF 0.500" 0.361"

1 1903 " 1" UNF 0.563" 0.375"

Min. length

of thread Hexagon A.F.ft" 0.500"

1 31 6” 0.565"7,,w 0.500"3"I 0.375"

0.438"0.438"0.438"0.500"0.500"0.500"0.563"

I" 0.438"2”8 0.500"7,,

W

i"0.500"0.500"

7"w 0.500"7"w 0.500"

94

ClassicBike.Biz

SCREWS

Part No. Type of head Material Thd. dia. Length under head Type of drive21-1916 Cheese head Steel 4" UNC 18" Cross recess21-1917 Cheese head 4" UNC 28" Cross recess21-1918 Cheese head 4" UNC 28" Cross recess21-1920 Hex. head „ 4" UNC

111-1929 Countersunk (82°)2

64

„ -," UNC '^Z'" Slot21-2079 Cheese head „ No. 10 UNF ' " Pozidrive14-0604 Cheese head 4" UNF '-z" Cross recess14-6505 Countersunk (82°) „ 4" UN e" Cross recess14-6607 Cheese head 4" UNC 8" Cross recess14-6608 Cheese head „ 4" UNC 1" Cross recess14-6609 Cheese head 4" UNC 1,'-" Cross recess14-7019 Socket head 6" UN -g'" Hex. socket14-7024 Socket head " UNC 2" Hex. socket

WASH ERS—PLAI N

Part No. Material i/dia. o/dia. Thickness60-4245 Steel 0.273" 0.563" 0.048"60-4246 Steel 0.398" 0.750" 0.063"60-4247 Steel 0.336" 0.625" 0.063"37-2027 Steel 0.531" 1.031" 0.092"60-4248 Steel 0.266" 0.469" 0.064"

WASHERS—SPRING

Part No. Material 1/dia. o/dia. o/a height Thickness

60-4259 Spring Steel e" clearance ;Z" T" 0.104"60-4250 ,, , clearancea'-" '3—z" T. 0.064"60-3541 „ „ z" e" 0.040**

21-0648 6" clearance z" 32

** Double coil.

95

ClassicBike.Biz

Printed in England by

WARWICK PRINTING COMPANY LIMITEDWARWICK

ClassicBike.Biz

ClassicBike.Biz

triumph 650 twins parts manual

Documents