Triumph 650 Twins Parts Manual
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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
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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.
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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
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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
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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 ... ...
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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
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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...
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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
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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.
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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.
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33 31 31 32 35
1 ?1
^ ^ 4 ._ Y
34 30
29 27 26
28 38
15
--16
18 17 -
-- 14
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Fig. 1. CRANKSHAFT AND CONNECTING RODS
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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
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Fig. 2. CRANKCASE
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___-.40 82
Fig. 2. CRANKCASE
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Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
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Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
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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
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Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
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Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
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15
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1B4
Fig, 4, CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)
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Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
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84222
222224444844
2
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
51 E470 Adjuster lock nut ... ... ... ... ... ... ... 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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
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-'f2'f&'Piain washer ... ... ... ... ... ... ... . .. 4
41 14-1435 Cylinder head stud (for torque stay) ... ... ... ... 2
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
50 E1513 Rocker adjusting pin ... ... ... ... ... ... ... 4
51 E470 Adjuster lock nut ... ... ... ... ... ... ... 4
52 E1575 Thrust washer, t in. ... . ., . ... ... ... ... ... 6
53 E1574 Spring washer ... ... ... 4
27
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
33 E12569 Inlet rocker box ... ... ... ... ... ... ... 1
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
41 14-1435 Cylinder head stud (for torque stay) ... ... ... ... 2
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
47 E1513 Rocker adjusting pin ... ... ... ... ... ... ... 4
48 E470 Adjuster lock nut ... ... ... ... ... ... ... 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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
TIMING COVER AND CONTACT BREAKER
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
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
Gearbox sprocket (16 teeth) ...
......
......
...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
Gearbox sprocket (20 teeth) ...
......
......
...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
ayshaft c/w high gear (18T
)...
......
......
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
ayshaft c/w high gear (22T
) ......
......
......
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
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c)
(Dr
N
U)T
N
N0 ZN Q
IU
TT z
QWHQ
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2co U
^ CGLL
NT
N Cl) M M-CM'
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N
NN
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50
ClassicBike.Biz
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
TELESCOPIC FRONT FORK
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
TELESCOPIC FRONT FORK
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION
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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
85
ClassicBike.Biz
86
ClassicBike.Biz
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION
~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
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
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
Ref. No. Part No. DESCRIPTION
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
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