REPLACEMENT PARTS CATALOGUE FOR 1972
BONNEVILLE T 12011 9 T 120RV TIGER 650 TR6R, TR6RV TROPHY 650 TR6C. TR6CV See Bookmarks
TRIUMPH ENGINEERING COMPANY LIMITED MERIDEN WORKS • ALLESLEY • COVENTRY CV5 9AU • ENGLAND TELEGRAMS "TRUSTY" COVENTRY TELEX "TRUSTY" 31305
TELEPHONE COVENTRY 20221 MERIDEN 331
PUBLICATION PART No. 99-0953
PUBLISHED AUGUST 1971 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 correct at 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 other 1971 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.
Triumph Motorcycle Corporation, P.O. Box 2765, East Huntington Drive, Duarte, California 91010.
Telex—Tricor Balt. 87728 Telephone-301-252-1700
Telex—Tricor Duarte 675469 Telephone-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 forward of the gasoline tank. Both the engine and frame number should be quoted in full in any correspondence relating to the machine.
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I NDEX Page AIR CLEANER ... ... ALTERNATOR ... ... AUTO-ADVANCE UNIT
... ... ...
... 77 ... 11, 51 ... 39
BATTERY CARRIER BRAKE SWITCH BREATHER PIPES
... ... ...
... ... ...
... ... ...
Page KICKSTARTER ...
MANIFOLD ... ... MOTOR PLATES ... MOTOR TORQUE STAY MUFFLERS ... ...
93 57 53
...
...
59, 61, 63
... ... FENDERS FIVE SPEED GEARBOX ... ... FLASHERS ... ... FOOTRESTS ... ... FRAME... ... FRONT FORKS ... FRONT WHEEL
... ... ... ... ... ... ...
... 79 ... 45 ... 89, 91 ... 57, 63 ... 53 ... 65, 67 ... 71
GAS TANK GEARBOX
... ...
... ...
... ... ... ...
...
47
17 ... ... 57 ... 57 59, 61, 63 ... ... ...
17 53 17
PISTONS ... PROP STAND ... PUSH RODS ...
... ... ... 11 ... ... ... 53 19,21,23,25,27,29,31,33
REAR WHEEL ... RECTIFIER ... ROCKERS
... ... ... 73 ... ... ... 89 19,21,23,25,27,29,31,33
SIDE PANEL ... ... ... SPARK PLUG ... ... ... SPEEDOMETER ... SPEEDOMETER GEARBOX ... STEERING DAMPER SUSPENSION UNITS ... ... SWINGING FORK ... ... SWITCHES ... ... ...
... 77 ... 89 ... 87 ... 73 ... 69 ... 55 ... 55 ... 81, 91
TABLE OF STANDARD HARDWARE 94,95 TACHOMETER ... ... ... ... 87 TACHOMETER GEARBOX ... ... 87 TAIL LAMP ... ... ... ... 79 TAPPETS ... ... 17 TIMING GEARS ... ... ... 11 TOOLKIT ... ... ... 85 TWIN SEAT ... ... 75
... ... 75 ...41, 43, 45, 47
... ... HANDLEBAR... HANDLEBAR MOUNTINGS ... ... ... HEADLAMP... ... ... ... HORN...
...
OILPUMP ... ... ... OIL PIPES ... ... ... OIL PRESSURE RELEASE VALVE
CAMSHAFT, INLET AND EXHAUST 11 ... ... 35, 37 CARBURETOR ... ... ... 7 CARTON PACKS •.. ... ... CENTRESTAND 53 ... ... ... 51 ... CHAINS... ... ... ... ... 51 CHAINCASE 49 ... ... ... ... CLUTCH .•• 47 CLUTCH LEVER ASSEMBLY ... ... 89 ... ... ... COIL 89 „_ ... CONDENSERPACK ... 11 ... ... CONNECTING RODS ... ... 39 CONTACT BREAKER ... ... ... ... 83 CONTROL CABLES ... ... 81 CONTROL LEVERS ... ... ... 13, 15 ... CRANKCASE ... ... 63 CRANKCASE UNDERSHIELD ... ... 11 ... CRANKSHAFT ... 19,21,23,25,27,29,31,33 ... CYLINDERS CYLINDER HEAD 19,21,23,25,27,29,31,33 EXHAUST PIPES
...
VALVES ... ... VALVE GUIDES
81 ... ... 69 ... 91, 93 ... 89
19,21,23,25,27,29,31,33 19,21,23,25,27,29,31,33
WIRING HARNESS
... ..
•••
•..
91
ZENER DIODE...
...
...
...
89
3
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TIGER 6 0 (TR 6 R) (TR 6 RV— SPEED) TECHNICAL DATA Bore and Stroke ... Capacity ... Compression ratio Spark plugs Carburetor Main jet ... Needle jet Throttle valve ... Gearbox sprocket ... Chains Capacities
Brakes Tire size ...
Front Rear ... Gas Tank Oil Tank ... Gearbox Primary Chaincase ... Primary Chaincase Front Forks (each leg) ... ... Front, diameter... Rear, diameter Front Rear 4 ClassicBike.Biz
71 x82 mm. 2-79 x 3 . 23 ins. 649 c.c. (40 cu. ins.) 9:1 Champion N3 Amal Concentric 930 230 106 No. 32 19 teeth I" Duplex x 84 links Ex6 " x106 links 3.6 U.S. galls. 4.8 U.S. pints. i pint (500 c.c.) 4 pint (150 c.c.) * pint (150 c.c.) i pint (190 c.c.) 8" (20 . 32 cm.) 7" (17 . 78 cm.) 3.25x19 4.00 x18
TROPHY 650 (TR6C) (TR6CV-5 SPEED) TECHNICAL DATA
Bore and stroke...
...
...
71 x 82 mm. 2 . 79 x 3 . 23 ins.
Capacity ...
...
...
649 c.c. (40 cu. ins.)
...
...
Champion N3
...
...
... ...
... ...
Amal Concentric 930 230 •106 No. 32
...
...
...
9:1
Compression ratio Spark plugs
...
Carburetor
... Main jet ... Needle jet ... Throttle valve ...
Gearbox sprocket Chains
...
Capacities
Brakes
...
Tire size ...
...
...
Front Rear
... ...
... ...
...
...
...
... ...
18 teeth " Duplex x 84 links 8"xW'x106links
...
... Gas Tank ... Oil Tank ... Gearbox ... Primary Chaincase Front Forks (each leg)
...
... Front, diameter... Rear, diameter
...
...
8" (20 . 32 cm.) 7" (17 . 78 cm.)
... ...
...
...
3.25x19 4•00x18
...
...
Front Rear
... ...
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3.6 U.S. galls. 4.8 U.S. pints pint (500 c.c.) 4'- pint (150 c.c.) pint (190 c.c.)
BONNEVILLE (T120R) (T120RV-5 SPEED) TECHNICAL DATA
Bore and stroke... ... Capacity Compression ratio ... Spark plugs Carburetors
Gearbox sprocket ... Chains Capacities
Brakes Tire size
... Main jet Needle jet .. Throttle valve Front ... Rear Gas Tank Oil Tank ... Gearbox ... Primary Chaincase Front Forks (each leg) Front, diameter... Rear, diameter Front Rear 6 ClassicBike.Biz
71 x82 mm. 2 . 79 x 3 . 23 ins. 649 c.c. (40 cu. ins.) 9:1 Champion N3 2 Amal Concentric 930 190 .106 No. 3 19 teeth 1" Duplex x 84 links 8"x8"x106 links 3.6 U.S. galls. 4.8 U.S. pints. i pint (500 c.c.) 4 pint (150 c.c.) 1 pint (199 c.c.) 8" (20 . 32 cm.) 7" (17 . 78 cm.) 3.25x19 4.00x18
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. When you have located the parts make sure from the end columns that the part you have located does apply to your 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 colors or 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. The contents 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 ...
...
16
...
...
2
...
16
...
NW243 ...
...
...
Brake lining
...
W129
...
...
...
Rivet
...
...
W1734 ...
...
...
Brake lining
...
...
W129
...
...
...
Rivet
Pistons (complete with rings, gudgeon pins and circlips) E6895
...
...
...
...
...
... 7 . 5 : 1 C.R.
...
...
For use with low grade fuel
E9488
...
...
...
...
...
...
9 :1 C.R.
...
...
Standard
E6867
...
...
...
...
...
...
11 : 1 C.R.
...
...
Competition use only
All the above pistons are available in oversizes of 0 . 010 ins., 0 . 020 ins., 0 . 040 ins., (0 . 25 mm., 0 . 5 mm., 1 mm.)
Valve Guides C.P.97
...
...
...
2
...
...
...
E2899
...
...
...
Inlet guide
(TR6)
...
...
...
2 ...
...
...
E2900
...
...
...
Exhaust guide
7 ClassicBike.Biz
PLEASE NOTE THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS INCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN, REVERTING TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENT PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.
SPECIAL WORKSHOP TOOLS A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING YOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASES THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE, AND THEREFORE, IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES IT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.
UNIFIED THREAD FORM NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOG HAVE THE UNIFIED FORM OF SCREW THREADS. THIS CHANGEOVER WILL BE CONTINUED AS AND WHEN NEW PARTS ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS WILL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS HAVING THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS IN THEIR HEADS, STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING CIRCLES ON 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. —Polychromatic blue, cold white stripe, black lining. Fenders Side covers—Black, gold decal. TROPHY 650 (TR6C—TR6CV) Petrol tank—Polychromatic blue and cold white, black lining. —Chromium plated. Fenders 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.
—Tiger gold, white centre stripe, black lining. Fenders 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 SPARES HOW 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 parts are similar. Parts where possible have been listed in order of assembly and a number of the illustrations show the assembly order also. With these aids, there should be no difficulty in identifying the parts you require. ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OF THE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS. WHERE TO OBTAIN. Triumph Spare Parts can only be obtained from an authorised Triumph Dealer, and we recommend our customers to place their orders with the Triumph Dealer in their district. When parts not usually asked for are required, and for which the Dealer may have to write or obtain specially, the postage or 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 SHOULD BE TAKEN UP DIRECTLY WITH THE TRIUMPH SPARES DEPARTMENT. Customers are warned against the risk incurred by purchasing parts that are not of genuine Triumph manufacture. 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 number is 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 and Address and clear instructions should accompany the parts. In your own interest send a copy of the advice note under separate cover. All parts must be forwarded carriage paid and care should be taken to ensure that 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 such as windscreens, driving mirrors, tools, etc., removed by the sender before despatch, as it is impossible for us to accept responsibility in the event of loss in transit. We are always pleased to give estimates for overhauling and repairs, but should an estimate not be accepted, a charge will be made covering cost of dismantling and 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 manufacture should be sent direct to the actual makers, whose Names and Addresses appear below.
PROPRIETARY GROUP Ancillary 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 makers or their local agents who will always give owners every possible assistance. The following are the addresses of the various manufacturers:— CARBURETORS Messrs. Amal Ltd., Holdford Road, Witton, Birmingham, 6. CHAINS. Renold Chains Ltd., Wythenshawe, Manchester.
TIRES. Dunlop Rubber Co. Ltd., Fort Dunlop, Birmingham, 24. The Avon Rubber Co. Ltd., Melksham, Wilts.
SPARK PLUGS. Champion Sparking Plug Co. Ltd., Feltham, Middlesex. I NSTRUMENTS. Messrs. Smiths Industries Ltd., Cricklewood Works, London, N.W.2. SUSPENSION UNITS. Messrs. Girling Ltd., Birmingham Road, West Bromwich, Staffordshire.
ELECTRICAL EQUIPMENT. Messrs. J. Lucas Ltd., Gt. Hampton Street, Birmingham, 18. 9
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15
--16
18
17
-- 14
3
33
^
31
31 32
^
1
4
35
._ Y
?1
34 30
29 27 26
28
38
Fig. 1. CRANKSHAFT AND CONNECTING RODS 10
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
CRANKSHAFT AND CONNECTING RODS E13054 CRANKSHAFT AND FLYWHEEL ASSEMBLY (METRIC) • • E13097 CRANKSHAFT C/W. OIL TUBE E3903 Oil tube E12800 Screwed plug E12425 Flywheel ... *E12799 Flywheel bolt E11003 Washer ... E3114 Crankshaft stud (11 in. 0.A.) ... E9525 CONNECTING ROD ... Small end bush ... E1511 E6576 Connecting rod bolt Self locking nut ... D3761 E3586 Big end bearing (Available in —•010 in. and — . 020 in. undersizes) PISTON COMPLETE 9 :1 C.R. E9488 Taper compression ring ... E6864 co Oil control ring ... ... E6865 ) Gudgeon pin (short) ... ••• E6861 ... ••• WE479 X- 6 ?‘? Circlip ... ... ••• Main bearing, right (metric) ... E3835 ••• Motor sprocket, 29 teeth Duplex El 2662 ••• E4573 70-'19/Z Distance piece ... Rotor key ... 22 E10082 542139015qWW(Rotor (99-0739) 23 ... Tab washer 24 E3975 Nut E3977 25 Key ... E1580 26 Timing pinion 27 E4564 Nut ... E12877 28 INTERMEDIATE WHEEL 29 E6159 Intermediate wheel bush... 30 E400 Camshaft pinion... E12719 31 Camshaft key ... 32 E1558 Inlet camshaft nut 33 E11007 Exhaust camshaft nut 34 E6523 ... Inlet camshaft, ... E11063 35 ••• EXHAUST CAMSHAFT E9989 36 ••• Tachometer drive plug 37 E9988 ••• ... Clamping washer 38 E3300 ••• Main bearing, left (metric) 39 E2879 Spacer Not illus. E12663 Shim (0 . 010 in.) -Engine sprocket Not illus. E8038 Shim (0 . 030 in.) Not illus. E12660 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
qo
* Use D524 Loctite Sealant
11 ClassicBike.Biz
1 1 1 1 1 3 3 1 2 2 4 4 4 2 4 2 2 4
1
1 2 2 1
1 1 As required (up to 4) As required (up to 4)
52
Fig. 2. CRANKCASE
12
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
CRAN KCASE 1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
E11266 CRANKCASE DRIVE SIDE ... ... ... E10287 Camshaft bush ... ... ... ... E10287 Camshaft bush ... ... ... ... E5976 Chain tensioner abutment ... ... E13098 CRANKCASE TIMING SIDE ... ... E10286 Camshaft bush ... ... ... ... E4538 ... ... Scavenge pipe ... ... E6386 Locating peg (at oil pipes) ... ... T989 Hollow dowel ... ... ... ... T912 Locating peg (LAS at thrust washer) ... T1606 Needle roller bearing, layshaft ... ... E375 Intermediate wheel spindle ... ... E8751 ... ... ... ... Hollow dowel ... E3716 ... ... ... Hollow dowel ... ... S1873 ... ... ... ... Screw ... ••. ... ... ... ... 14-1445 ... ... Stud ... ... ... ... S25-2(0-'24' Plain washer ... ... ... ... 14-0303 ... ... ... Nut Hollow dowel, tappet oil feed ... ... E1532 ... ... ... ... ... E9330 Oilway plug ... ... ... ... F1880 Copper washer ... ... S1871 Tachometer drive plug (L.H. thread) ... ... ... ... E8896 Fibre washer ... ... ... ... ... 51863 Oil pipe stud ... ... ... ... ... 51865 Cylinder stud ... ... ... ... ... Plug, timing hole 51872 ... ... ... ... ... ... S1870 Bolt ... ... ... ... ... ... 14-6220 Bolt ... ... ... •.. ... ... 14 -6223 Bolt ... ... ... ... ... •.. 14 -0230 Bolt ... ... ... ... ... ... Bolt S1823 ... ... ... ... Plain washer ... D2330 ... ... ... ... ... ... 14-1302 Nut ... ... ... ... Crankcase filter... E9336 ... ... ... ... E53157O- 72-Joint washer ... ... ... Drain plug (with level tube) ... T2167 ... ... ... ... Fibre washer ... T1257 ... ... ... ... Level plug UN ... S543 ... ... ... ... E2441G,O- 7/32 Copper washer ... ... ... ... Drain and adjuster plug T2259 ... ... ... ... Fibre washer ... T1738 ... ... ... ... Blanking plug ... T1 920 ... ... ... ... T2166 Filler plug UN ... "0" ring ... ... ... ... ... E8782 ... ... ... ... ... ... 14-6242 Bolt ... ... ... ... ... ... Stud S669 ... ... ... ... Protection blade E8892 ... ... ... ... Self locknut UN 14-1301 Rubber plug (for protection blade stud hole) E7573 ... ... ... ... Nut, exhaust ties 14-0402 ... ... Breather cover plate assembly E11072 ... ... ... ... ... Screw ... E11075 13 ClassicBike.Biz
... ... ... ... ... ... ...
... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... -.. ... ...
1 1 1 1 1 2 Reference only Reference only 2 1 1 1 1 1 Not required 2 on later models 1 2 2 2 1 1 1 2 1 8 1 1 1 1 1 2 (TR6C 3 off) 10 (TR6C 7 off) (TR6C 4 off) 5 1 1 1 1 1 1 1 1 Reference only 2 2 1 (Except TR6C) 1 1 1 1 (Except TR6C) 2 I 1
Ref. No.
Part No.
DESCRIPTION
QUANTITY REMARKS
CRANKCASE (continued) 53 54 55 56 57 58 59 60
E9335 E11460 E11077 E11078 E4705 S26-2 6 0 0- %'2S0 14-0101 E11345
Outlet stub ... ... ... ... Joint washer ... ... ... ... Screw ... ... ... ... ... Tube, primary chain oiler ... ... Clip ... ... ... ... ... Spring washer ... ... ... ... Bolt (g b in. U.H.) ... ... ... i Grommet, alternator leads- —external
15 ClassicBike.Biz
... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ...
1 1 2 1 1 1 1 1
5
Assy 1 12
11 10 6 7
9
8
20 22 21 23
24
28
Fig. 3. OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS 16
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Not Illus. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
E9421 OIL PUMP ... ... ... ... ... ... Reference only Pump body... ... Feed plunger ... ... ... E9269 ... ... Scavenger plunger E6681 ... ... Drive block E495 ... 2. S70-7 6 0 - 363 Valve ball ( 3'—z in. dia.) ... ... Valve spring ... ... ... E403 Screwed plug ... ... ... E2360 ... ... ... ... E11461 Joint washer Oil pump stud ... ... ... ... S1864 ... ... Serrated washer ... E3887 ... ... ... ... Nut ... S1906 ... ... ... Oil release valve E6595 ... ... E167060 33Y5 Fibre washer ... ... Joint washer, release valve cap to body E8754 ... Stud ... ... ... ... S1876 ... ... Joint washer ... ... E5660 ... ... Inlet manifold ... ... E9973 ... ... ... S25-136€ 4'2 %{8' Plain washer ... ... ... ... Nut ... ... S1877 Stud S1996 ... ... ... ... Cup ... E9555 ... ... ... ... "0" ring E9554 ... ... ... ... Nut ... 14-1301 ... ... ... Inlet tappet guide E9352 ... ... Exhaust tappet guide ... E9353 ... ... Copper washer ... ... El 612 Set bolt .. H200 /9 b./. y ... Inlet tappet 70.- 3D E3059R ... ... ... Exhaust tappet E8801 ... ... ... ... '0' ring E7563
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ...
... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
...
...
...
...
2
... ...
... ...
... ...
... ...
2 2
7c-8g5 /A- -- / mF Pe 7 f,,Q /S G4r,'r
17 ClassicBike.Biz
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
1 1 1 1 1 2 2 2 1 2 2 2 1 1 Available 4 2 1 4 4 TR6
... 2 ... 2 ... 2 ... 1 ... 1 ... 2 2
17
16
15 14
1 B4
Fig, 4, CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)
18
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, TR6R, TR6C (EARLIER MODELS)
1 2 3 4 5 6 6a 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
45 46 47 48 49 50 51
E6309 Cylinder base wash er E6304 Cylinder block ... S692 Cylinder base nut E2620 Push rod E12575 Cover tube ... E7310 "0" ring, push rod cover tube (bottom) E11283 "0" ring, push rod cover tube (top) E4547 Cylinder head gaske t E12354 CYLINDER HEAD c/w GUIDES E2899 7/-32?2 Inlet valve guide ... E2900 7/-3195 Exhaust valve guide E9516 Exhaust pipe adaptor E4603 Inlet valve E2904 Exhaust valve E6439 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 Exhaust rocker box E12351 Joint washer ... E12599 51875 Rocker box bolt 1 Rocker box nut 301 Plain washer ... E3302 Rocker box stud 1 1401 S25-13 qZ4e Plain washer ... 1 1435 Cylinder head stud (for torque stay) E4610 7/-174'q Inspection cap ... Joint washer ... E3751 E4609 Locking spring ... WE170 6o-q263 Fibre washer ... Screw ... 1 2203 E1457 ROCKER (right exhaust, left inlet) ... ROCKER (left exhaust, right inlet) ... E1458 E10070 Rocker ball pin E1513 Rocker adjusting pin E470 Adjuster lock nut E1575 Thrust washer, z in. Spring washer ... E1574 Rocker spindle ... E1512 Dowel, rocker box E12361 Thrust washer, in. El 330 Access plug ... E12079 Washer ... E12080 E1288870-ve0 Bolt, cylinder head E1288974-9781 Bolt, rocker box 19 ClassicBike.Biz
8 4 2 2 2
••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• .•• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• •••
2 2 2 2 2 4 4 4 4 8 4 4
2
2 4 6 6 6 4 2 4 4 4 4 4 2 2 4 4 4 6 4 2 4 2 4 4
•• •
4
•• •
4
e-58 x-57 56 3 4
37
35
33
36
24 ^ / 51 E31 27
32
42 41 -^
q
^^ j; 45 23 52
?
43
48 49 50-
44 47 39 40 43
18
29
25 46
21
1
E3
0---28
I
4
30
i22 26
19
6A
20 17 ^^
^IiiNill
-
g
F1
16 11
--
10
8
15 12
7
14 13
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 53 54 55 56 57 58
E12598 E4752 E11707 D2332 E12597 D2331 14-1303
Spacer ... Sealing ring Sleeve ... Washer ... Distance piece Washer Nut
... ... ... ...
... ... ... ...
... ... ... ...
For torque stay
J
... ... ... ...
... ... ... ...
... ... ... ...
... ... ... ...
... ... ... ...
...
...
...
...
...
...
21
ClassicBike.Biz
...
...
...
4 2 2 4 2 2 2
54 53 52
B4
Fig. S. CYLINDER BLOCK AND HEAD, TR6R, TR6C (LATER MODELS)
22
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
CYLINDER BLOCK AND HEAD, TR6R, TR6C(LATER MODELS) 1 2 3 4 5 6 6a 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
E6309 Cylinder base washer ... ... ... E6304 Cylinder block ... ... ... ... S692 Cylinder base nut ... ... ... E2620 Push rod ... ... ... ... Cover tube E12575 ... ... ... ... E7310 "0" ring, push rod cover tube (bottom) E11283 "0" ring, push rod cover tube (top) E4547 Cylinder head gasket ... ... ... E12806 CYLINDER HEAD c/w GUIDES ... E2899 7/-3Z9Z Inlet valve guide ... ... ... E29007/ -3293 Exhaust valve guide ... ... E4603 ... ... Inlet valve ... ... E2904 Exhaust valve ... ... ... ... E6439 Bottom cup ... ... ... ... E4221 Inner valve spring (red spot) ... ... E7400 Outer valve spring (green spot) ... E1543 Top collar ... ... ... ... 99-00627/-374'8Split cotter ... ... ... ... E327 Cylinder head bolt ... ... ... F2184 Plain washer ... ... ... ... ... ... E4771 Bolt ... ... ... S25-360 -'/Z'/7 Plain washer ... ... ... ... Sealing ring ... ... ... ... D3548 Inlet rocker box ... ... ... E12569 Exhaust rocker box ... ... ... E12570 Joint washer ... ... ... ... E12599 ... ... ... Rocker box bolt 51875 Rocker box nut... ... ... ... 14-0301 Plain washer ... ... ... ... E3302 Rocker box stud ... ... ... 14-1401 ... ... ... 525-13(j0-1/2Vo0Plain washer ... Cylinder head stud (for torque stay) 14-1435 ... Inspection cover ... ... E12572 ... ... ... Joint washer ... E12574 ROCKER (right exhaust, left inlet) ... E1457 ROCKER (left exhaust, right inlet) ... E1458 ... Rocker ball pin ... ... E10070 ... Rocker adjusting pin ... ... E1513 Adjuster lock nut ... ... ... E470 ... ... Thrust washer, 2 in. ... E1575 ... Spring washer ... ... ... E1574 Rocker spindle ... ... ... ... E1512 Dowel, rocker box ... ... ... E12361 ... Thrust washer, e in. ... ... E1330 ... ... ... Access plug ... E12079 Washer ... E12080 ... ... ... El288870-9700aBolt, cylinder head ... ... ... Bolt, rocker box 2889 70-9 78/ E1
23 ClassicBike.Biz
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ...
... ...
... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
1 1 8 4 2 2 2 1 1 2 2 2 2 4 4 4 4 8 4 4 1 1 2 1 1 2 4 6 6 6 4 2 4 4 2 2 4 4 4 6 4 2 4 2 4 4 ... 4 ... 4
54 53 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) (continued) 48 49 50 51 52 53 54 55 56
E12598 E4752 E11707 D2332 E12597 D2331 14-1303 14-0103 D2329
Spacer ... Sealing ring Sleeve ... Washer ... Distance piece Washer Nut Screw
...
For torque stay
...
}
Tappet inspection cover r
25
ClassicBike.Biz
4 2 2 4 2 2 2 8 8
067 66 (5 --- 65
46 45
44
60 29
B5
Fig. 6. CYLINDER BLOCK AND HEAD, T12OR (EARLIER MODELS)
26
ClassicBike.Biz
Ref. No. Part No.
QUANTITY
DESCRIPTION
REMARKS
CYLINDER BLOCK AND HEAD, T120R (EARLIER MODELS) 1 2 3 4 5 6 6A 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53
... ... Cylinder base washer ... E6309 ... ... ... Cylinder block ... E6304 ... ... ... Cylinder base nut S692 ... ... ... ... Push rod E2620 ... ... ... ... Cover tube E12575 ... ... ... "0" ring (bottom) E7310 ... ... ... "0" ring (top) ... E11283 ... ... Cylinder head gasket ... E4547 ... CYLINDER HEAD c/w GUIDES E12356 Sleeve for head bolts passing through E5347 ... ... Inlet valve guide ... E3827 7/- 329y ... ... E38287/- 3Z 9'.r Exhaust valve guide ... Carburetor adaptor, left ... E9550 ... Carburetor adaptor, right E9551 ... ... ... Connector ... E6916 ... ... ... Balance pipe E4792 ... ... Adaptor locking nut S1932 ... ... Exhaust pipe adaptor E9516 ... ... ... Self-locking nut 14-1301 ... ... ... ... ... Cup E9555 ... ... ... Insulating ring ... E9554 ... ... ... ... Inlet valve E4603 ... ... ... ... Exhaust valve E2904 ... ... ... ... Bottom cup E6439 ... Inner valve spring (Red spot) E4221 ... Outer valve spring (green spot) E7400 ... ... ... ... Top collar E1543 ... ... 99-00627/ 37Y(?Split cotter ... ... ... Cylinder head bolt E327 ... ... ... Plain washer ... F2184 ... ... ... ... ... Bolt E4771 ... ... ... S25-3 0-4v{7 Plain washer ... ... ... ... ... Sealing ring D3548 ... ... ... Inlet rocker box E12350 ... ... ... Exhaust rocker box E12351 ... ... ... Joint washer ... E12599 ... ... ... Rocker box bolt S1875 ... ... ... ... ... Nut 14-0301 ... ... ... ... Plain washer E3302 ... ... ... Rocker box stud 14-1401 ... ... ... ... Plain washer S25-1360-42q Cylinder head stud (for torque stay) 14-1435 ... ... ... E461070-Z7q/q Inspection cap ... ... ... ... Joint washer ... E3751 ... ... ... Locking spring ... E4609 ... ... ... WE17060-qz 3Fibre washer ... ... ... ... ... Screw ... 14-2203 ROCKER (right exhaust, left inlet) ... E1457 ROCKER (left exhaust, right inlet) ... E1458 ... ... Rocker ball pin ... E10070 ... ... ... Rocker adjusting pin E1513 ... ... ... Adjuster lock nut E470 in. Thrust washer, 'z E1575 ... ... ... Spring washer ... E1574
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... inlet tracts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... •.. ... ...
27
ClassicBike.Biz
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... •.. ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
1 1 8 4 2 2 2 1 1 Reference only 2 2 1 1 2 1 2 2 4 7 4 2 2 4 4 4 4 8 4 4 1 1 2 1 1 2 4 6 6 6 4 2 4 4 4 4 4 2 2 4 4 4 6 4
B5
1
Fig. 6. CYLINDER BLOCK AND HEAD, T12OR (EARLIER MODELS)
28
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
CYLINDER BLOCK AND HEAD, MOR
QUANTITY
(EARLIER MODELS)
(continued) 54 55 56 57 58 59 60 61 62 63 64 65 66 67
Rocker spindle ... E1512 Dowel, rocker box E12361 Thrust washer, a in. El 330 ... Access plug E12079 Washer ... E12080 E128887o-9780 Bolt, cylinder head E1288970 781 Bolt, rocker box Washer ... D2332 Spacer ... E12598 Sealing ring E4752 Sleeve ... E11707 Distance piece E12597 For torque stay Washer D2331 Nut 14-1303
...
29 ClassicBike.Biz
REMARKS
2 4 2 4 4 4 4 4 4 2 2 2 2 2
^---64 -63 (5---- 62
B5
Fig. 7. CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS)
30
ClassicBike.Biz
Ref. No. Part No.
QUANTITY REMARKS
DESCRIPTION
CYLINDER BLOCK AND HEAD, T120R(LATER MODELS) 1 2 3 4 5 6 6A 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
... ... ... ... Cylinder base washer ... E6309 ... ... ... ... ... Cylinder block ... E6304 ... ... ... ... ... Cylinder base nut S692 ... ... ... ... ... ... Push rod E2620 ... ... ... ... ... ... Cover tube E12575 ... ... ... ... "0" ring (bottom) ... E7310 ... ... ... ... ... "0" ring (top) E11283 ... ... ... ... ... Cylinder head gasket E4547 9/(oCYLINDER HEAD c/w GUIDES ... ... ... E12807 7/-3y Sleeve for head bolts passing through inlet tracts E5347 ... ... ... ... E3827 7/- 329'( Inlet valve guide ... ... ... ... ... E38287/- 3295 Exhaust valve guide ... ... ... Carburetor adaptor, left E12811 ... ... ... Carburetor adaptor, right E12812 ... ... ... ... ... Connector ... E6916 Balance pipe ... ..• E4792 ... ... ... ... ... ... Stud ... E12813 % ... ... ... ... ... ... Gasket E8771 7/- / f/(p ... ... ... ... ... Self-locking nut 14-1301 ... ... ... ... ... ... ... Cup E9555 ... ... ... ... ... Insulating ring ... E9554 ... ..• ... Inlet valve E4603 ... ... ... ... ... Exhaust valve ... E2904 ... ... ... ... ... ... Bottom cup E6439 ... ... ... Inner valve spring (Red spot) E4221 ... _.. ... Outer valve spring (green spot) E7400 ... ... ... ... Top collar ... ... El 543 ... ... ... ... ... ... 99-00627/-37`lrSplit cotter ... ... ... ... ... Cylinder head bolt E327 ... ... ... ... ... ... Plain washer F2184 ... ... ... ... ... ... ... Bolt E4771 ... ... ... ... ... S25-3 0-W-/7 Plain washer ... ... ... ... ... ... ... Sealing ring D3548 ... ... ... ... ... Inlet rocker box E12569 ... ... ... ... Exhaust rocker box ... El 2570 ... ... ... ... ... Joint washer ... E12599 ... ... ... ... ... Rocker box bolt S1875 ... ... ... ... ... ... ... Nut 14-0301 ... ... ... ... ... Plain washer ... E3302 ... ... ... ... ... Rocker box stud 14-1401 ... ... ... ... ... S25-13f -gzq 'Plain washer ... ... ... Cylinder head stud (for torque stay) 14-1435 ... ... ... ... ... Inspection cover E12572 ... ... ... ... ... Joint washer ... E12574 ... ... ROCKER (right exhaust, left inlet) ... Ell 457 ... ... ROCKER (left exhaust, right inlet) ... Ell 458 ... ... ... ... ... Rocker ball pin El 0070 ... ... ... ... ... Rocker adjusting pin E1513 ... ... ... ... ... Adjuster lock nut E470 ... ... ... ... In. Thrust washer, . El 575 ... ... ... ... ... ... Spring washer El 574
31
ClassicBike.Biz
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..• ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... ... ... ... ... ...
1 1 8 4 2 2 2 1 1 Reference only 2 2 1 1 2 1 4 2 4 4 4 2 2 4 4 4 4 8 4 4 1 2 1 1 2 4 6 o 6 4 2 4 4 2 2 4 4 4 6 4
64
63 62 57 29 41
65
4
6A
24
B5 1
Fig. 7. CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS)
32
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, T12OR (LATER MODELS) (continued) 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
Rocker spindle ... E1512 Dowel, rocker box E12361 Thrust washer, I in. E1330 ... Access plug E12079 ... Washer ... E12080 E1288870-9762 Bolt, cylinder head E1288970/0/ Bolt, rocker box Washer D2332 Spacer ... E12598 Sealing ring E4752 Sleeve ... E11707 Distance piece E12597 ... For torque stay Washer D2331 Nut 14-1303 Screw 14-0103 } Tappet inspection cover washer D2329
33
ClassicBike.Biz
2 4 2 4 4 4 4
2 2
...
8
0 11
Fig. 8. AMAL CARBURETOR, TR6R, TR6C
34
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
AMAL CARBURETOR TR6R, TR6C 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
D2183 Rvfl 928/098 622/086 928/060 622/131 622/067 622/124 928/062 622/129 928/103 622/077 622/076 622/082 622/122 622/128 376/100 622/069 622/071 622/055 622/073 622/068 376/093 622/078 376/092 622/147 622/151 Fl 3507 E9711
wnly
CARBURETOR (R930/60) less "0" ring ... Mixing chamber (930/005) 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) . 106) (99-1035) Needle jet (0 ... Jet holder (99-1034) Main jet (230) (99-0450) ... 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
35
ClassicBike.Biz
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
2
1 1 1 1 1
1 1
REMARKS
O 11
I
1i
6
8
Fig. 9. AMAL CARBURETOR, T12OR 36
ClassicBike.Biz
Ref No. Part No.
QUANTITY REMARKS
DESCRIPTION
AMAL CARBURETOR T120R
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 928/098 622/086 928/060 622/131 622/067 622/124 928/062 622/129 928/103 622/077 622/076 622/082 622/122 622/128 376/100 622/069 622/071 622/055 622/073 622/068 376/093 622/078 376/092 622/147 622/151 F13508 E9711
CARBURETOR—L.H. (L930/67) Less""0" ring CARBURETOR—R.H. (R930/66) ... Mixing chamber (L930/005 and R930/005) ... ... 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 . 106) (99-1035) ... ... ... ... 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 ClassicBike.Biz
...
...
1 1
.... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... .. ... ... ... ...
1 1 4 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2
Each carburetor
e7
Fig. 10. TIMING COVER AND CONTACT BREAKER
38
ClassicBike.Biz
QUANTITY REMARKS
DESCRIPTION
Ref. No. Part No.
TIMING COVER AND CONTACT BREAKER 1 2 3 4 4
... ... Timing cover ... E9246 ... ... ... Patent plate E4016 ... D208-55p0- 4'25^iHammer-drive screw ... Oil seal ... E4568 Oil seal (0 . 020 in. undersize) ... E6387
E4569 T989 14-6609 7 14-6608 8 14-0208 9 S25-437O-.'f3 10 E4707 11 E7680 12 E6559 13 E8737 14 E11462 15 GS2996o0-4' Z5 16 E7354 17 54419340 18 54415642 19 54419097 20 54419827 21 54419220 22 D21336p0 ;37/? 23 D2045 24 Not illus. D2138 5
6
... ... ... ... ..
... ... ... ... ...
... ... ... ... ...
... ... ... ... ... ... Circlip ... ... ... ... ... ... Hollow dowel ... ... ... ... ... ... ... Screw ... ... ... ... ... ... ... Screw ... ... ... ... ... ... ... ... Bolt ... ... ... ... ... Plain washer ... ... ... ... ... ... Rubber grommet ... ... ... ... ... ... Pillar bolt ... ... ... ... ... ... Plain washer ... ... ... ... ... ... Cover ... ... ... ... ... ... Joint washer ... ... ... ... ... ... Serrated washer ... ... ... ... ... Screw ( 4 in. U.H.) ... ... AUTO ADVANCE UNIT (99-0771) ... ... ... ... Spring set (99-0757) CONTACT BREAKER PLATE ASSEMBLY (99-0768) ... ... ... Contact set (99-0772) ... ... ... ... Pin, adjustment (99-0769) ... ... ... ... Oil pressure switch ... ... ... ... ... Cover pressure switch ... ... ... Timing label for C.B. cover ...
39
ClassicBike.Biz
... ... ... ... ... ... ... .. . ... .. . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
3 2 For reground crankshaft
...
3 5
2 2
2 2
2 2
12
b8
Fig. 9 GEARBOX INNER COVER AND SELECTORS
40
ClassicBike.Biz
Ref. No. Part No.
QUANTITY
DESCRIPTION
GEARBOX INNER COVER AND SELECTORS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
T4293 T1614 T412 T45 T1607 T989 S2149 S1907 E3446 14-6608 14-7023 T4055 T397 T1896 T4308 T4307 T3989 T4288 T4289 T4290 T4291 F4771
GEARBOX INNER COVER ... Layshaft bearing ... Gearchange spindle bush... ... Kickstart stop ... ... ... Thrust washer ... ... ... Hollow dowel ... ... ... ... Stud ... ... ... ... ... Bolt ... ... ... Washer ... ... ... ... Screw ... ... ... ... Screw ... ... ... ... Cam plate ... Operating quadrant ... ... ... Quadrant spindle S lit p in (6 in. x 18 in.) ... 4 p ... Mainshaft selector fork ... Layshaft selector fork ... ... Selector fork rod ... ... ... Leaf spring ... ... Leaf spring support ... Leaf spring top plate ... ... ... ... Tab washer ... ... ... Screw ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
41
ClassicBike.Biz
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
1 1 1 1 2 4 2 1 1 1 1 1 1
1 Ref. only 1 1 I 1 1 1 1 2
REMARKS
DESCRIPTION
Ref. No. Part No.
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
Timing cover E9246 Patent plate E4016 D208-55p0- 4'25^iHammer-drive Oil seal ... E4568 Oil seal (0 . 020 E6387 E4569 T989 14-6609 14-6608 14-0208 S25-437O-.'f3 E4707 E7680 E6559 E8737 E11462 GS2996o0-4' Z5 E7354 54419340 54415642 54419097 54419827 54419220 D21336p0 ;37/? D2045 illus. D2138
... ... ... ... screw ...
... ... ...
... ... ... ... ..
in. undersize) ...
... ... ... ... ...
... ... ... ... ...
... ... ... ... ... ... Circlip ... ... ... ... ... ... Hollow dowel ... ... ... ... ... ... ... Screw ... ... ... ... ... ... ... Screw ... ... ... ... ... ... ... ... Bolt ... ... ... ... ... Plain washer ... ... ... ... ... ... Rubber grommet ... ... ... ... ... ... Pillar bolt ... ... ... ... ... ... Plain washer ... ... ... ... ... ... Cover ... ... ... ... ... ... Joint washer ... ... ... ... ... ... Serrated washer ... ... ... ... ... Screw ( 4 in. U.H.) ... ... AUTO ADVANCE UNIT (99-0771) ... ... ... ... Spring set (99-0757) CONTACT BREAKER PLATE ASSEMBLY (99-0768) ... ... ... Contact set (99-0772) ... ... ... ... Pin, adjustment (99-0769) ... ... ... ... Oil pressure switch ... ... ... ... ... Cover pressure switch ... ... ... Timing label for C.B. cover ...
39
ClassicBike.Biz
... ... ... ... ... ... ... .. . ... .. . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
3 2 For reground crankshaft
...
3 5
2 2
2 2
2 2
Ref. No.
Part
No.
DESCRIPTION
QUANTITY REMARKS
GEARBOX SHAFTS AND GEARS
T1 370
MAINSHAFT c/w LOW GEAR (16T) ... ... Clutch rod bush ... MAINSHAFT HIGH GEAR (25T) ... ... ... High gear bush ...
... ... ... ...
... ... ... ...
... ... ... ...
... ... ... ...
1 1 1 1
T3889 T4335
Mainshaft third gear (23T) ... Mainshaft second gear (20T) ...
... ...
... ...
... ...
... ...
... ...
1 1
7 8
T3862 T928
LAYSHAFT LOW GEAR (30T) ... Low gear bush ...
... ...
... ...
... ...
... ...
... 1 ... 1
9 10 11
T3861 T3890 T4345
Layshaft second gear (26T) ... ... Layshaft third gear (22T) Layshaft c/w high gear (19T)
... ... ...
... ... ...
... ... ...
... ... ...
... ... ...
12 12
T1 952 T1 953
Gearbox sprocket (15 teeth) ... Gearbox sprocket (16 teeth) ...
... ...
... ...
... ...
... ...
... 1 ... 1
12 12
T1916/O/7 T1917/D/ F'
Gearbox sprocket (17 teeth) ... Gearbox sprocket (18 teeth) ...
...
...
...
...
12 12 13 14
T1918/Q/I TI919^010 T2116 T440
Gearbox sprocket (19 teeth) .. Gearbox sprocket (20 teeth) ... ... ... ... Tab washer ... Gearbox sprocket nut
15
D355657—f
1 2 3
T4158 T3988 T4332
4 5 6
23 24 25 26 27
... ... ...
... ... ...
1
...
...
...
...
...
... ...
... ...
... ...
... ...
... ...
... 1 ... 1
D3552
Mainshaft bearing
...
...
...
...
...
...
...
T4113 T1962
Circlip ... Plain washer
... ...
... ...
... ...
... ...
... ...
... _..
... ...
T1963
Pinion sleeve
...
...
...
...
...
...
...
T1250 T730 T731 T2240
Pinion spring ... Kickstarter pinion Kickstarter ratchet ... Tab washer ... ... Nut Clutch operating rod
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
... 1 ... 1 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1
E489
22
... ... ...
... ...
1946
19
... ... ...
...
S594
11736
'High gear bearing
Circlip ... Oil seal ...
1
...
WIDE RATIO GEARS 3 6 9 11
T3657 14161 T4160 T4159
MAINSHAFT HIGH GEAR (28T)
...
...
...
...
... 1
Mainshaft second gear (19T) ... Layshaft second gear (27T) ... Layshaft c/w high gear (18T)
... ... ...
... ... ...
... ... ...
... ... ...
... ... ...
1 1 1
CLOSE RATIO GEARS 1 3
T4173 T4172
MAINSHAFT c/w LOW GEAR (18T) MAINSHAFT HIGH GEAR (24T) ...
... ...
... ...
... ...
... 1 ... 1
5 6
T4169 T4167
Mainshaft third gear (23T) ... Mainshaft second gear (21T) ...
... ...
... ...
... ...
... ...
... ...
7
T4163
LAYSHAFT LOW GEAR (28T)
...
...
...
...
... 1
9 10 11
T4166 T4168 T4162
... ... ...
... ... ...
... ... ...
... 1 ... 1 ... 1
Layshaft second gear (25T) ... ... Layshaft third gear (23T) Layshaft c/w high gear (22T) ...
See pages 4, 5 and 6 for standard sizes
... 1 ... 1 ... 1 ... 1
...
17 20 21
1
... ...
16
18
y
1 1 1
... ... ...
43
ClassicBike.Biz
1 1
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
GEARBOX SHAFTS AND GEARS (5 SPEED) 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
Not Illus.
Oil seal, cover plate D3500 ... Cover plate E3789 T436037— w89 Gearbox cam plate Selector fork— mainshaft 4th gear T4364 Selector fork— layshaft 3rd gear T4366 ... Selector fork— layshaft 1st gear T4368* T453657-q78/ MAINSHAFT HIGH GEAR ASSEMBLY (C/W HIGH GEAR BEARING) ... Needle roller bearing D3511 Oil seal, high gear D3500 MAINSHAFT 14432 Bush T3988 Mainshaft 4th gear T4376 MAINSHAFT 3rd GEAR T4377 Bush T437957— q57C Mainshaft 1st and 2nd gear T4380 ... ... T454857 —q 0° LAYSHAFT — q 00 Layshaft high gear... / T4550S7 00 Layshaft 4th gear ... T438457— 4 9 ... Layshaft 3rd gear T4387% LAYSHAFT 2nd GEAR T4388 ... Bush ... T439057 — qr77 LAYSHAFT 1st GEAR T4391 -( T439357-4'57e Bush Circlip ... D3494 Driving dog T4381* ... Quadrant T4363 ... Leaf spring T4402 Plunger quadrant T4374/408 Plunger ... T4403 Gearbox sprocket--19T T4397 Locknut T4396 Lock washer ... T4395 ... Oil seal, gearbox D3512
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45
ClassicBike.Biz
1 1 1
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Fig 14. GEARBOX OUTER COVER
46 ClassicBike.Biz
BO
Ref. No. Part No.
QUANTITY
DESCRIPTION
REMARKS
GEARBOX OUTER COVER T3760 GEARBOX OUTER COVER T23 Kickstarter spindle bush ... T57 Gearchange spindle bush T47 Kickstarter spring anchor pin S547 Guide plate stud ... ... 11956 Oil seal ... ... ... T1955 Oil seal housing ... ... T408/95?- 7OZ /Gearchange quadrant ... ... Rubber "0" ring D3530 ... ... T404 Quadrant return spring ... Gearchange quadrant plunger T406 Plun er g spring ... ... ... T405 Guide plate T407 ... ... ... Serrated washer E1612 ... ... Nut ... ... ... 14-0301 ... Kickstarter quadrant ... T4117 ... Kickstarter return spring T31 ... T24A57 1{73 Kickstarter axle ... ... T362957- gS'87CLUTCH LEVER ASSEMBLY Clutch lever ... ... T4441 Lever shaft T1710 ... ... Ball, fin. diam. ... ... D2368 Thrust plate ... ... T3761 Return spring ... ... T1712 ... ... GS12757 -3(073 Plain washer — GO- 2.70/ Split pin ( 6 in. x fin.) ... Countersunk screw ... ... S1879 Rubber cover ... ... ... T1646 Abutment for clutch cable ... T3762 y ... ... S25-3 O-/2 7 Plain washer ... Nut ... ... ... ... 14-0302 ... ... ... Screw ... S1878 ... ... ... Screw ... 14-6609 Screw ... ... ... ... 14-6608 ... ... T375757- 70/0 Gearchange pedal Bolt ... ... ... ... 14-0201 Pedal rubber ... ... ... T2450 T3632$7-70/8 FOLDING KICKSTARTER ... Kickstarter lever ... ... T2173 37-2/73 ... T1272 5']- 70/7 Kickstarter pedal ... Pedal locating spring ... T1167 Steel ball, fin. diam. ... S70-3 t 0 23 Pedal bolt ... ... S541 Pedal rubber ... T2330 ... ... Cotter pin c/w nut and washer T4356 ... ... ... Domed nut S544 ... Filler plug ... ... T2166 ... ... ... "O" ring E8782
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
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... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .., ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
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47 ClassicBike.Biz
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... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .v
1 1 1 1 4 1 1 1 1 2 2 2 I 4 4 1 1 1 I 1 1 3 1 1 1 Reference only 2 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 I 1 1 S?E6I2
48
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
CLUTCH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Clutch securing nut S586 ... ... Hub T3929 Thrust washer ... T3931 Roller ... T394 Sprocket and housing (58 teeth Duplex) T1570 Centre ... T4438 Inner plate T4436 ... Bolt 52157 Shock absorber spider T2538 Drive rubber (large) ... T1722 Rebound rubber (small) T1723 Outer plate 14437 T423A57-417SYScrewed pin 763 Driving plate (bonded) T13625 Driven plate ... T1363 Pressure plate 12156 Adjuster pin T2159 ... Nut 14-0403 Spring cup T1931 Spring ... T1830 Pressure nut 12526 ... Key S66-1 Washer ... T2279
49 ClassicBike.Biz
1 1 ••. 1 ... 20 1 1 1 3 1 3 3 1 ••• 3 ••• 6 ••• 6 ••• 1 ••• 1 1 3 3 3 1 1
REMARKS
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ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
CHAINCASE AND
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
QUANTITY REMAR KS
CHAINS
1 1 1 Not 5 speed 1 r models 6 (also listed with 1 crankcase group)
Rear chain, a in. xi in. x 106 links D1915 Joint washer E11419 Cover plate E7037 ... Oil seal E7565 Countersunk screw E3821 E597670-5087 Chain tensioner abutment Chain tensioner blade... E6061 Tie rod ... E4152 Trunnion E5977 Adjuster sleeve nut ... E9703 Primary chain, f in. Duplex x 84 links D477 Stator stud 51866 Stator stud 51867 Stator, RM21 (99-1006) 47205 Sleeve nut E9360 Rubber grommet E4144 Plastic sleeve E5449 -q2q7 Plain washer 525-3 nut Self-locking 1 0702 Joint washer E11463 E9245 7/-q07Z Chaincase Rotor cover T2440 Joint washer E11457 ... Screw F4129 Copper washer E2 441 Filler plug T2166 "0" ring E8782 ... Screw 14-6608 ... Screw 14-6620 ... nut Domed 55 44 Copper washer ... F1880 Timing pointer ... T2 44 3 ... Level plug 1 101
51 ClassicBike.Biz
• ••
• •• • •• ••• ••• ••• ••• •••• ••• ••• ••• ••• ••• ••• ••. ••. ••• .•• ••• ••• ••• ••• ••• ••• •••
1 1 2 1 1 1 1 1 3 3 1 1 1 1 3 1 1 1 6 2 2 2 1
• ••
1
•.•
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52
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY REMARKS
FRAME 1 F14283 Frame ... ... ... ... ... 2 E127447/Z7' /Oil filler cap ... ... ... ... 3 D3616 "O" ring ... ... ... ... 4 F1 3142 Dipstick ... ... ... ... ... F1 3642 5 Oil filter ... ... ... ... - 8 cSump plate 5A F1 31 8 5 ... ... /, F12829 6 Gasket ... ... ... ... ... 7 D2330 Washer ... 8 S2109 Stud Sump plate to frame ... 9 14-1302/q-/Z02 Nut ... 10 14-0113 ... Drain plug ... ... ... 11 E12505 Joint washer ... ... ... ... 12 E69307/ -7/70 Oil junction block ... ... ... X444587/ -375 Joint washer ... ... ... 13 ... 14 S1908 Nut Junction block to crankcase Washer f 15 E3446 ... ... ... Rocker oil pipe E12428 16 ... ... ... ... Washer ... 17 E1335 ... ... ... ... Nut ... E1435 18 ... ... ... Rocker feed pipe E12337 19 ... ... Clip—rocker feed pipe D3524 20 ... ... ... Oil return pipe E12345 21 ... ... Clip—feed and return pipes 22 E6848 ... ... ... Oil feed pipe ... E12347 23 ... ... ... ... Oil vent pipe E12349 24 ... Crankcase breather pipe—front E11149 25 ... Crankcase breather pipe—rear F11614 26 ... ... ... ... "T" piece F11610 27 ... ... Clip—breather pipe—front D2253 28 ... Clip—breather pipe—rear ... D2252 29 ... Clip—breather pipe to fender F11615 30 ... ... ... ... ... Screw H3894 31 ... ... ... ... ... Nut F4717 32 ... ... ... ... Centre stand F1262783- '/9y/ 33 ... ... ... ... ... Spring F1 3793 34 ... ... ... ... bolt Pivot S2077 35 ... ... ... ... ... Nut 14-1304 36 ... ... ... ... Prop stand F11560 37 ... ... ... ... ... Bolt F7021 38 ... ... ... ... ... Nut 14-1303 39 ... ... ... ... Spring ... F8382 40 ... -3509' Transfer "Made in England" ... Not illus. D3361 ... Not illus. D2452 P-1-A. Transfer—Safety Standards ... Not illus. 14-0114 Bolt1Prop stand stop Nut f ... ... Not illus. 14-0402
63 3
53 ClassicBike.Biz
2 4 4 4
4 4 2 4
.
1 2 4 4 4
2 2
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1
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54
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
SWINGING ARM AND SUSPENSION UNITS 1 2 3 4
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 25 26 27 28 29 30 31 32 33 34
SWINGING ARM F12513 ... Grease nipple D1841 WE170 g3- 7221 Washer, grease nipple Bush, pivot arm ... F12521 Sleeve, swinging arm pivot F12691 Distance piece R.H. F12690 Distance piece L.H. F12689 ... Dirt excluder F12692 Stud, swinging arm pivot S2087 Washer, swinging arm pivot F12266 Nut, swinging arm pivot 14-1307 ... Brake torque stay F12656 ... Nut, torque stay to brake plate 14-1304 Washer, torque stay to brake plate ... D2350 Bolt, torque stay to swinging arm ... 14-0133 Washer, torque stay to swinging arm W2330 Nut, torque stay to swinging arm ... 14-1304 SUSPENSION UNIT (D2294) 64052341 ..• ... Damper unit 64052090 ... Bonded bush (99-0122) 64533645 ... Spring retainer (99-0107) 9054/171 Spring, 110 lbs. chrome (99-1139) 64544754 ... Bolt, damper—top 14-0235 Stud, damper—top L.H. 51997 D233160-q46Washer, damper—top ... Nut, damper—top 14-1303 ... Bolt, damper, lower 14-0234 Washer damper lower D2321 ... Nut damper lower 14-1303 ••• •• • • • • Chainguard F12641 .•• fixing—front Bolt, chainguard 14-0206 .•• fixing—front Washer, chainguard D2347 Stop lamp switch-118SA (99-1028) 34815 D35502 /- Xi0 Screw ... Washer ... H1388
55 ClassicBike.Biz
... ... ... ... ... ... ... ... ... ... ...
••• ••. • ••
•••
1 2 2 4 2 1 1 4 1 2 1 1 1 1 1 1 1 2 Reference only 4 4 2 (1 off TR6C) 2 (TR6C) 1 (3 off TR6C) 2 (3 off TR6C) 2 2 2 2 1 1 1 1 2 2
CD N O M
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ClassicBike.Biz
DESCRIPTION
Ref. No. Part No.
MOTOR UNIT FITTINGS AND o
QUANTITY
FOOTRESTS
bO ... ... ... ... ... ... F1 2855 83 7 ' Footrest—L.H.... 1 ... ... ... ... ... ... Footrest—R.H.... F1285483-7 2 ... ... ... ... ... ... ... ... Bolt 14-0259 3 ... ... ... ... ... ... ... ... Washer D2333 4 ... ... ... ... ... ... Footrest rubber F9279 5 ... ... ... ... ... PILLION FOOTREST ... F12841 6 ... ... ... ... ... ... ... Pedal F9053 7 ... ... ... ... ... ... Hanger bolt F1 3207 8 Bolt ... ... ... ... 14-0217 9 ... ... ... ... Footrest swivel Washer F9089 10 ... ... ... ... 14_1302/q-/202. Nut 11 J Nut 14-1303 ... ... 12 ... Footrest to frame "' •.• ••• ••• ••• Washer F2184 13 ... ... ... ... ... ... Footrest rubber F9054 14 ... ... ... ... ... ... Rear brake pedal F12666 15 ... Screw ... 14-0103 16 ... ... Stop light adjustment ••• ... Nut ... ... 14-0301 17 ... ... ... ... ... ... ... Pivot pin S2045 18 ... ... ... ... ... ... ... ... Nut 14-1303 19 ... ... ... ... ... ... ... o-412g6Washer ... E8084 20 ... ... ... ... ... Rear brake operating rod F1 2860 21 ... ... ... ... ... in. x e in.) Split pin (•! 22 — i 6 ... ... ... ... ... ... Distance piece F1 4277 23 ... ... ... ... ... Adjuster nut — brake rod F7387 24 ... ... ... ... ... Rear motor plate R.H. F13024 25 ... ... ... ... ... Rear motor plate—L.H. F1 3023 26 ... ... ... Bolt 14-0115 27 Bolt ••• ••• ••• 14-0116 28 Rear motor plates to frame ••• ••• ••• 14-13 02/y-/202- Nut 29 ... ... ... Washer D2330 30 Bolt ... ... ... 14-0220 31 Bolt 14-0221 32 Motor to motor plates ... ... ... Nut ... 14-1302 33 . . . ... ... ... Washer D2321 34 ... Distance piece—L.H. F12846 35 ... Distance piece—R.H. F12847 36 Motor to frame centre bottom ... Stud S2112 37 Nut ... 14-1304 38 ... Washer D2332 39 J ... ... Distance piece—L.H. F1 2848 40 ... ... Distance piece—R.H . j F12849 41 ... ... Motor fixing front Bolt 14-0254 42 Nut ... ... 14-1304 43 I ... ... Washer 44 D2332 J ... ... ... ... Steady bracket motor to frame F1 3537 45 ... .. • .. ... Bolt ... 14-0126 46 ... ... ... ... ... Bracket to frame Nut 14-1303 47 ... ... ... ... ... Washer D2331 48 ... ... ... Extended nut (used with 14-0220) ... Not illus 51933 Nut Not illus 14-1305 Footrest bolt ... ... ... . ... Collar F13602 Not illus ...
f
57 ClassicBike.Biz
REMARKS
... ... ... ... ... ... ... ... ... ... ...
1 1 2 2 2 2 1 1 I 1 1
... ••• ... ...
1 1 1 1
... ... ... ... ... ... ... ... ... ... ... ... ••• ••• ... ... ...
1 1 1 1 1 1 Reference only 1 2 1 1 5 61 12 2 2 4 8 . ... 1 ... 1 ... 1 ... 2 ... 2 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 .. I ... I (TR6c only) . 2 ..
0 N
58
ClassicBike.Biz
DESCRIPTION
Ref. No. Part No.
QUANTITY
REMARKS
EXHAUST PIPES AND MUFFLERS, TR6R, T12OR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
E12636 Exhaust pipe—L.H. ... E12637 Exhaust pipe—R.H. ... E12465 Finned clip 1 F897W2^n7e Washer Exhaust pipes to cylinder head F89778Z-g777 Bolt E6857 Exhaust pipe stay E6179 Screw E7471 Nut E7512 Clip E3768 washer Exhaust pipes to coupling pipe "' 14-0217 Bolt ... 14-1202 Nut J E9888 Coupling pipe E2271 Clip E3768 "D" washer ... 14-0219 Bolt Exhaust pipes to mufflers ... S25-3 4'2q7 Washer ... 14-1302 Nut Muffler ... E12382 ... ... ... ... E12282 Hanger—muffler and pillion footrest Bolt } 1 0101 Nut Muffler to hanger 14-1301
2 Later models 2 2 ... 2 ... 2 ... 2 ... 2 .. . 4 ... 2 ... 2 ... 1 ... 2 ... 4 ... 2 ... 2 ... 2 ... 2 ... 2 "' 4 ... 4
*EARLIER MODELS USE THE FOLLOWING:— 1 2 3 4 5
E12753 E12756 E10216 E8860 E6744
Exhaust pipe—L.H. ... Exhaust pipe—R.H. ... Finned Clip Spherical washer Bolt...
1 1 2 2 2
59 ClassicBike.Biz
U, Ix
W J LL LL
D
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60
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
Part. No
DESCRIPTION
EX HAUST PIPES, MUFFLERS AND FOLDING 00
E123347/'& Exhaust pipe—lower E126327/ /90/ Exhaust pipe—upper E12465 Finned clip F897782- 777 Bolt Exhaust pipe to cylinder head ... F89788ZWasher El 325070 -6978 Exhaust pipe stay 14-0113 Bolt ... S26-30-4i26 v Spring washer E7299 Clip—upper E5874 Clip—lower 14-0116 Bolt Bolt Exhaust pipes to connector 14-0219 "D" washer E3768 Spring washer S26-3 -q2 Nut 14-1202 Connector E9673 Clip E2271 Bolt 14-0219 "D" washer Connector to mufflers E3768 q260 Spring washer S26Nut 14-1202 Muffler—upper ... E12019 Muffler—lower ... E12020 Muffler—hanger E12511 Bolt S1822 Mufflers to hanger Spring washer S26-3 -'z ••• Bolt 14-0115 Spring washer Hanger to frame ... S26-3 Spacer nut S1933 Leg guard E9680 Screw 51953 Washer E9857 Leg guard attachment front Clip E9688 Bracket E9696 Screw 51954 Washer Leg guard attachment rear E9857 Clip E9688 E1285183 -2?51 Crankcase undershield... Hooked stud S2096 ... Nut 14-1301 Washer ... D2320
me
61 ClassicBike.Biz
QUANTITY
REMARKS
FOOTRESTS, TR6C
1 2 2 2 1 3 3 1 1 1 1 2 1 1 1 2 2 4 2 2
••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• 1 ••• ••• 2 2
1
1 1 ••• ••• 1 ••• 1 ••• 2 2 2
Later models
v; ac W J LL LL
D E
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62
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
F13139 FOLDING FOOTREST—R.H. F12856 FOLDING FOOTREST—L.H. F13140 Footrest hanger—R.H. ... F12858 Footrest hanger—L.H. Fl 3092 Footrest pedal F13095 Spring ... 14-0216 Bolt 14-1302 /q^/ZOL Nut F9051 Footrest rubber Bolt } S1969 Footrest to frame F8243
••• ••• ••• ••• ••• ••• ••• ••• •••
1 1 1 1 1 1 1 1 1 2
EARLIER MODELS USE THE FOLLOWING:— 1 2 3 4 5 6
E11900 E11901 E10216 E6744 E8860 E6978
1 1 2 2 2 1
Exhaust pipe—lower Exhaust pipe—upper ... Finned clip Bolt ... ... Spherical washer Exhaust pipe stay
63
ClassicBike.Biz
Fig. 22. TELESCOPIC FRONT FORK
64
ClassicBike.Biz
Ref. No.
Part
No.
DESCRIPTION
QUANTITY
REMARKS
TELESCOPIC FRONT FORK 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 42 42 42 43 44 45 46
H4080 FORK ASSEMBLY H4035 Top Yoke ... 14-0234 Pinch Bolt ... 14-1303 Nut... Washer ... E8084 F6738 Lock c/w 2 keys ... D623 F z- 6738 Key (state serial No.) Grub screw 5578 H2266 Sealing washer ... H2270 Brake cable retainer F8245 Starlock washer ... Retaining bracket H3682 Abutment ring ... F12007 H4031 Taper roller bearing H4028 Dust cover Bottom yoke and stem H4315 14-0238 Pinch bolt ... E8084 —qz#6 Washer 14-1303 Nut Stanchion H4007 End plug ... H4076 Main spring ••• H4087 OUTER MEMBER—R.H. H4343 OUTER MEMBER—L.H. H4342 Cap wheel spindle H3947 Stud S2102 Nut 14-0302 Washer ... D2428 Oil seal outer member H4001 Drain plug ... H3894 Washer ... H3893 "0" ring—damper valve H4003 Recoil spring H4009 Cap screw-damper tube 14-1019 Cap screw seal H4004 Damper tube and valve assembly H4325 Scraper sleeve outer member H4002 Top cap nut H4258 . •• Washer ... H4166 Steering stem nut (without steering damper) H4317 H431897— Z? Steering stem nut (with steering damper) •• Headlamp bracket—L.H. H4058 Headlamp bracket—R.H. H4060 Headlamp bracket—L.H. H4088 Headlamp bracket—R.H. H4090 Nut 51809 Washer D2338 Headlamp bracket top fixing ... Bush F12209 Spacer F12211
65 ClassicBike.Biz
1 1
2 2 2 2 4 2 2 2 2
1 2 8 8 8 2 2 2 2 2 2 2 2 2 2 2
1
TR6R, T12OR TR6C
2 2 4 2
Fig. 22. TELESCOPIC FRONT FORK
66
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
TELESCOPIC FRONT FORK 47 48 49 50 51 52
S2062 D2333 D2630 F9046 H4012 F12216 F3 2Z10
Sleeve nut Washer Headlamp bracket bottom fixing Grommet Washer Nut—damper valve ... Clamp washer •••
67 ClassicBike.Biz
2 2 2 2 2 4
REMARKS
3
10 6
8
L5
17-
Fig. 23. HANDLEBAR MOUNTINGS AND STEERING DAMPER
68
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
HANDLEBAR MOUNTINGS AND STEERING DAMPER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
H2291 F1335 5589 H1527 H1529 H1581 H1580 H2221 14-1303 H3875 D2438 H435 H1797 H95 D2329 H4102 —
Handlebar eyebolt Washer ... Bolt ... ... Metalastic bush Hemispherical washer ... Distance piece ... Rubber washer ... Cup Nut ... Steering damper rod c/w knob Spring washer ... Friction disc ... Anchor plate ••• Spring plate ... Washer ... Bottom nut Split pin (K in. x 1 in.)
69 ClassicBike.Biz
••• ••• .•• ••• ••• •••
2 2 2 2 4 2 2 2 2 1 1 1 1 Available 1 1 1 Reference only
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70
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
FRONT WHEEL 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
W3845 W3844 W3818 W3658 W3820 W3819 W3821 W2294 W3969 W3970 W653 D2632 W3797 W3759 W1481 W1237
T280 W3932 W3796 W2058 D3669 14-1303 D2340 W3655 W3987 W3986 D2639 W3762 W3761 W3713 W3714 W3715 W3716 W3717 14-1635
... FRONT WHEEL COMPLETE RIM, SPOKES AND HUB ASSEMBLY ... Wheel rim (WM2-19) Brake drum and hub Spoke (R.H.—inner) Spoke (R.H.—outer) Spoke (L.H.) Nipple... ... Balance weight (short) Balance weight (long) ... Bearing ... Circlip—R.H. Grease retainer—R.H. Lock ring—R.H. ... Grease cap inner—L.H. ... Grease cap outer—L.H. ... Circlip—L.H. Distance piece ... Wheel spindle Nut wheel spindle Grommet brake drum Nut Anchor plate to fork leg Washer Brake anchor plate Brake lever front ... Brake lever rear ... "0" ring brake cam Tappet brake cam "0" ring brake tappet ... Brake shoe complete ... ... Return spring Cage brake shoe adjuster Micram adjuster ... ... ... Abutment pressing Stud-anchor plate torque reaction
71 ClassicBike.Biz
••• ••• ••• ••. ••• ••• ••• •••
••• ••• ••• •••
1 1 1 1 10 10 20 40 as required as required 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 1
N LL
72
ClassicBike.Biz
DESCRIPTION
Ref. No. Part No.
QUANTITY
REAR WHEEL 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
W3968 W3782 W3784 W3724 W3725 W3726 W2294 W3773 W3468 W3749 W653 W3752 W3753 W1654 W3747 14-0207 D2320 14-1301 W3856 W3872 W4034 14-1303 D2331 W3870 14-0305 D2431 W3925 W3926 W2328 W4049 F12656 14-0133 W2330 14-1304 W3965 W3750 D3213 W3746 14-1307 F12266 W3751 Fl 3082 W3742 14-0107 14-0301 D1841 WE170
... REAR WHEEL COMPLETE ... RIM SPOKES AND HUB ASSEMBLY RIM (Wm 3 x 18) ... Spoke (inner—L.H.) Spoke (outer—L.H.) Spoke—R.H.... ... ... Nipple... Hub and brake drum Tyre security bolt... Support ring—L.H. ... ... Bearing Locking ring—L.H. ... ... Spacer Grease retainer—R.H. Sprocket 47 teeth Bolt Washer . Sprocket to hub Nut Brake anchor plate Brake cam Brake lever Nut ... Washer Brake pivot Nut Brake pivot to torque arm Washer Brake shoe complete (leading) ... Brake shoe complete (trailing) ... ... Return spring (brake shoe) Return spring (brake lever) Brake torque arm Bolt Washer Torque arm to frame Nut Wheel spindle ... Distance piece inner Speedometer drive gearbox ... Distance piece outer Nut spindle
••• ••• ••• •••
Washerr
83-722 )
... Speedometer drive ring Cover plate-swinging arm fork end Chain adjuster Screw Chain adjuster — ... Nut I Grease nipple Fibre washer
73 ClassicBike.Biz
•••
2 2
REMARKS
--
I-
q__--34
13
19
14
10 15
20
®--11 12
21
22
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2
x--24 25^ 16
B22
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17
23
18 --
Fig. 26. GAS TANKS AND TWINSEAT
74
ClassicBike.Biz
Ref. No.
DESCRIPTION
Part No.
QUANTITY
REMARKS
GAS TANK AND TWINSEAT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 20 21 22 23 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
F1299683-42Gas tank (3 gall.) Steady rubber F9062 Mounting rubber Fl 3021 Centre fixing bolt 51823 Distance tube ... F13133 Mounting rubber F10260 Washer ... F13320 Rubber washer ... F13321 Mounting ring ... F13319 ... Nut S1999 Washer ... D2330 Beading holder ... F13318 ... Grommet F13068 Styling strip-front F13134 Styling strip-rear F13135 Tank motif—L.H. F9700 Tank motif—RH. F9701 Screw—front—tank motif F11339 Screw—rear—tank motif F7888 Filler cap F13875 Joint waser F4048 Jack chain F3217 ... F3221 N L, A . Clip ... Gas tap F12800 Gas tap—reserve F12801 Tap seal E7351 Washer ... F10002 Twinseat F14288 Twinseat cover F14291 ... Hinge F12867 Bolt 14-0101 }Hinge to twinseat Spring washer D2417 ••• Rubber buffer ... F9093 Catch assembly F13061 Spring—catch assembly F12597 Screw Twinseat catch fixing 1-40604 Nut 14-1301 ... Check wire D2087 Screw—self tapping ... D2381
... 1 *For color see page 8 ... 2 ... 2 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 2 ... 2 ... 1 ... 1 TR6C ... 1 TR6C 1 ... ... 1 ... 1 ... 2 ... 2 ... 1 ... 1 ... 2 4 ••• 4 ... 5 ... 1 ... 1 •••
... ... ... Available
*F1288183-y4gg Petrol tank (44 gall.) ...
75 ClassicBike.Biz
M_ fV 7
00
LL
76
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
AIR CLEANER AND SIDE PANELS
1 1 2 2 1 1 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Not illus. Not illus. Not illus. Not illus.
F13789 N• 1 • A• AIR CLEANER ASSEMBLY—L.H. F13790* 4.4. AIR CLEANER ASSEMBLY—R.H. F12749 Body—L.H. F12750 Body—R.H. F13850$3V Cover—L.H. ... ... F13851 Cover—R.H. F13791 N.L,A- AIR CLEANER ASSEMBLY—L.H. F13792M "• AIR CLEANER ASSEMBLY—R.H. F12798 Body—L.H. F12797 Body—R.H. Fl 3864 Cover—L.H. F13865 Cover—R.H. D307260- '/165 Element ... 14-0221 Bolt F8245 Retainer Cover to body D2438 Washer 14-0302 Nut D3539 Screw L. H. assy. to R. H. assy. Nut 5501 14-0218 Bolt }Air cleaner to frame D2418 Spring washer Fl 26267/- Pt/ Connector pipe F12625 Connector pipe E11860 Carburetor adaptor Clip—Jubilee type D3536 F1385983-073 Side panel—L.H. F138608• - 7CSide panel—R.H. Panel grommet ... F6673 • •• 14-0201 Bolt Washer .Side panel to air cleaner ... D2329 14-1301 Nut Transfer ... D3722 Transfer ... D3724 Transfer ... D3723 Spacer (use with 14-0218) F9196
77 ClassicBike.Biz
1 1 1 1 1 1 1 1 1 ••• 1 ••• 1 ••• 1 ••• 2 2 2 2 2 2 2 2 2 2 ... 1 1 or 2 1 or 2 1 2 4 4 4 2 2 2 2
Twin Carb T12OR
Single carb. TR6R, TR6C
All models
T12OR TR6C, TR6R
T12OR TR6C TR6R
co
N
nc. G
aJ
J_ Q
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78
ClassicBike.Biz
0
Ref. No.
QUANTITY
DESCRIPTION
Part No.
REMARKS
FENDERS AND TAIL LAMP 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
... ... ... ... *Front fender ... ... ... ... ... *Front fender ... H4270 ... ... Bracket H4022 ••• ... Rubber bush H4021 Stay to fork leg Bolt 14-0103 ... ... Spring washer D2427 ... ... ... ... ... *Rear fender F13566 ... ... ... ... ... *Rear fender F13565 Bolt ... ... 14-0114 ... ... Fender fixing front Washer D2330 ... ... 14-1302/1/-/202 Nut J ... ... ... ... ... ... Bolt 14-0101 ... ... ... ... ... ... Bolt 14-0103 ... ... ... ... ... F306982'9O 'Z Spacer ... ... Washe r Fender fixing top and rear D2329 ••• 14-1301 Nut ... ... ... ... Lifting handle ... F12768 ... Bolt 14-0101 Lifting handle to frame • • • ••• •.• Washer D2329 ... ... ... ... ... ... Nut 14-1301 ... ... Rear number plate bracket—L.H. F12727 ... ... Rear number plate bracket—R.H. F12728 ... Bolt 14-0102 Washer Number plate bracket to fender... D2329 H4271,4/1-A.
I
... ... ... ...
... ... ... ...
1 1
... ... ... ... ... ... ... ... ... ... ••• ...
... ... ... ... ... ... ... ... ...
... ... ...
4 1 1
... ••• ...
... •• ...
33
.. ••• ... ... ...
. . •. ... ... ...
...
22
... ...
... ...
J
... ... ... Tail lamp support F12786 ... ... Captive nut D3313 Bolt 14-6102 Tail lamp support front fixing S25-160-^f 2 /S Washer Bolt 14-0101 Tail lamp support rear fixing Washer D2427 ... ... stri ... Rubber beading g strip F13213 ... ... Reflector red (99-1162) 57079 ... ... ... Washer ... D2391 ... ... Nut F4717 STOP AND TAIL LAMP 679 (99-0597) 53973 ... ... Lens (99-1046) 54577109 ... ... ... Screw (99-1189) 144921 ... ... Lamp base assembly 54525286 h
380
Bulb (99
-
05
42
)
...
...
*For color see page 8.
79
ClassicBike.Biz
...
...
... ...
... ...
" ...
"' ...
... ... ... .. • ... ... ... ... ... ...
... ... •.. ... •.. •.. ... ... ... ...
...
...
4 4 4
1
... 2 ... 1 ... 1 ... 4 ... 4
... ...
... ...
4 1 1
...
...
2
...
...
2
... ... ... ... ... ... ... ...
... 2 ... 2 ... 2 ... 2 ... 1 ... 1 ... 1 ... Reference only ...
...
TR6R, T120R TR6C
... 2 ... 4 ... 2 ... 2 ... 1 ... 1
... Nut
14-1301
TR6R, T120R TR6C
... ... ... ...
80
ClassicBike.Biz
Ref. No.
Part No.
DESCRIPTIO N
QUANTITY
REMARKS
HANDLEBARS AND CONTROL LEVERS 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
H4252q7-7OO/ Handlebar ... ... ... ... H1425 Sleeve, handlebar mounting ... ... 16136460-70Yq TWISTGRIP (99-0248) ... ... 16/328 Body, top half (99 -0245) ... 16/329 BODY, BOTTOM HALF (99 -0246)
... ... ... ... ...
16/008 Friction spring ... 16/009 ri Z2./099' Screw ... ••• ••• 16/010 Locknut ... ... 99-0244 Rotor ... ... ... 11/013 Screw (9^,^25) ... ... H9589'7- 2/2 S Grip ... ... ... 16/011 Cable stop ( 99-0241) ... ... H212497- 2./4'2. Grip ... ... ... ... 12/60 -3c67 AIR CONTROL LEVER (D3246) 12/556 - 0221r Lever ... ... ...
... ... ... ... ...
... ... ... ... ...
... ... ... ... ...
1 4 1 1 1
... ••• ... ...
... •-... ...
... ... ... ...
... ... ... ...
... ... ... ...
Reference only Reference only Reference only
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... ... ...
... ... ...
... ... ...
... ... ...
... ... ...
2 1 1 1 1 Reference only
... ...
... ...
... ...
... ...
... ...
... ...
Reference only Reference only
Spring washer ... ... Clamp ... ... ... c'ZZ Screw ... Front brake lever (alloy) ... Clutch lever (alloy) ... ... ... ... Pivot pin... ... ... ... Nut ... ... Adjuster ... ... ... Lockring ... ... ... HANDLEBAR SWITCH—L.H. Switch half ... ... Lever half (99-1187) ... Screw (99-1188) ... ... HANDLEBAR SWITCH—R.H. Switch half ... ... Lever half (99-1215) ... Screw (99-1188) ... ...
... ...
... ...
... ...
... ...
... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ... ... ... ... ...
12/607 12/606 12/033 12/040 11 /014 9'9D3583 D3657 S2048 14-1201 D3585 D3586 39595 54033666 54340882 54115246 39596 54033667 54340883 54115246
Bolt Cap ...
... ...
... ...
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Reference only Reference only Reference only ... 1 ... 1 ... 2 ... 2 ... 2 ... 2 ... Reference only ... Reference only ... 1 ... 4 ... Reference only ... Reference only ... 1 ... 4
7
4
25
13
B26
Fig. 30. CONTROL CABLES
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Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
CONTROL CABLES 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
D1819 D1 806 D3079 D3557 W3996 W3997 E12500 W4014 D1 807 D3485 D1 818
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 ... ... Cable, lever to junction box ... 8S 244/10460-06 J Junction box (99-0341) ... ... D3486 Cable, junction box to carburetor 313/13 TWIN ROTOR TWISTGRIP (99-0347) ... Screw ... ... ... 18/084 Body, top half ... ... ... 313/020 BODY, BOTTOM HALF ... 313/021 ... Friction spring ... 16/008 ... Screw ... ... ... 210/007 ... ... ... Nut ... 5/077 T9- 70 ?7 ... ... ... ... Rotor 313/004 ... ... Rotor stop screw ... 210/008 ... 5/0779- 7097 Nut—rotor stop screw ... ... ... ... ... Grip H2125 ... ... ... ... Cable clip D343/3 ... ... ... ... Cable clip D343/7 ... ... ... ... Handlebar clip H4112
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
LATER MODELS USE THE FOLLOWING: ... ... ... D3815 O-35j7Front brake cable
83 ClassicBike.Biz
... ...
... ...
... 2 ... 1
T120R TR6C, TR6R
... ...
... ...
2 1 ... 1 ... 1
TR6C, TR6R T120R
... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ...
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
ClassicBike.Biz
Ref. No. Part No.
QUANTITY
DESCRIPTION
TOOLKIT
1 2 3 4 5 6 7 8 9 10 11
D2112 D291 D2184 D1911 D2084 D971 D972 D974 D767 F13292 14-0101 D2329
TOOLKIT COMPLETE ... Tool roll ... Damper unit spanner ... Tommy bar Spanner—open ended ... Box spanner ... Ring spanner ... Tyre valve key ... Screw driver .. Tool tray ... Bolt ... ... ... ... .. Washer ...
1 ... ... ... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ... ...
85
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... ... ... ... ... ... ... ... ... ...
REMARKS
86
ClassicBike.Biz
DESCRIPTION
Ref. No. Part No.
QUANTITY
1 2 3 4 5
EEDOMETER AND TACHOMETER ,1l V SSM5007/00^ Speedometer head (D2394) ... ... 41-148-203-10 Trip control (99-0176)..604.70//. 54959626 Bulb holder ... ... ... ... ... 643 Bulb (3W. MES) .. D3249 Speedometer cable Of 9/.,10 Q.,Z C ...
6
H4026
Mounting bracket ...
...
...
...
7
D2600
Rubber cup ...
...
...
...
...
...
...
...
...
...
Not illus. 8 9 10 11 12 13 14 15 16 17 18 19
D2391 E93317/-L//3 E9332 Reference only Reference only E5157 E5759 E6300 E5578 E12875 E6299 Reference only D3530
20
E5881
21 22 23 24 25 Not illus.
D3282 RSM3003/13 31-371-398 D494 E7351 D546
Washer...
TACHOMETER GEARBOX (E5758 Body)—L.H. thread Securing screw—L.H. thread, U.N. ...
Bush...
...
...
...
...
Flanged bush ...
...
...
...
...
...
...
...
...
...
...
...
ring ... ... Driven gear ... Driven gear housing "0'' ring ...
...
...
...
...
...
...
... ...
... ...
... ...
...
...
...
Drivinggear
End cap ... "0"
Bush...
...
... ... "0" ring ... .. Set screw .J^F .9'///,4 Tachometer cable Tachometer (D2396) ... O- 7/ 7.1 ... ... ... Spade (99-0173)
... ...
8.
...
... ...
... ...
...
...
...
...
...
...
Sealing washer ...
...
...
...
...
...
Circlip
...
Blanking plug (replaces tacho bulb holder)
87
ClassicBike.Biz
...
REMARKS
... 1 ... 1 ... Reference only Reference only ... 1 TR6C, f 12 T120R, TR6R 1 TR6C, 2 T120R, TR6R 2 or 4 ... 1 ... I ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 TR6R ... 1 T120R ... 1 ... 1 1
... ... ... ... ... ...
1 1 1 1 1 1
Fig. 33. COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN
88
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN 1 2
F12571 14-0101
3 4
D2329 14-1301
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 Not illus.
F9561 45223 49072 F5338 47638 54420128 54418528 54418526 S207 S778 9 35048 54385091 D3614 S2079 D2391 S778 49345 N3 D262 70228 14-0103 D2347 14-1301 54190038 57183 D2391 F4717 F13522 D3161
Mounting platform—electrical components... ... ... Bolt .•. ... Washer Platform to mudguard ... ... ... Nut ... ... Grommet—coil mounting ... ... t Ignition coil (17-M-12) D2206 tD 2- 1 203... Rectifier (99O589) ... ... ... ... ... ... ... Nut ... ... CAPACITOR PACK-2CP ... ... Capacitor (994$43) ... ... ... ... ... ... Cover (99-077) ... ... ... ... ... Base plate (99-1160) ... ...
... ... ...
... ... ...
...
...
...
...
... ... ... ... ...
... ... ... ... ...
1 Reference only 2 1 1
Capacitor pack to platform ... Nut Nw } ... ... ... Flasher unit ( 99-1201 ) ... ... 1204) ... ... Clip, flasher unit ( 99... ... Spring Screw I Flasher unit to platform "• ... ••• ••. Washer Nut ••. Zener Diode (99-0590) Cv ' - 0 957.. ... ... ... ... Sparking plug ... ... ... Plug cover (Champion WC200) ... ... ... Horn-6H (9 9-124 5) ... Bolt ... ... ... Washer Horn to frame Nut ... ... ... Lucar blade terminal ... ... ... Reflector-amber ( 99-1161 ) ... Washer ••• ... .Reflector mounting Nut Mounting rubber ... ... Grommet (horn mounting) ...
...
...
...
2
... ...
... ...
... ...
...
...
... ••• ...
... ... ••• ...
1 1 1
... ••• ...
2 2 2
... ...
... ...
... ...
...
...
...
...
...
...
...
J
tP - Q7c.
...
J
...
J
...
...
...
...
89 ClassicBike.Biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... ...
... ...
... ...
...
...
...
...
...
...
...
1 1 1
I 2 2 1
1
Reference only 1 1 2 4 2 Reference only 2 2 2 2 2
90
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
HEADLAMP AND FLASHER LAMPS 1 2 3 4 5
60260 HEADLAMP COMPLETE MCH 69 ( 21) ... ... 553248 Rim (99-0692) ... ... ... ... ... ... 516801 Light unit (99-1156) ... ... ... ... ... 504665 Fixing wire (99-0683) ... ... ... ... ... 144921 Screw ... ... ... ... ... ... ... 6 534296 Plate ... ... ... ... ... ... ... 7 370 Main bulb (45/35W) (99-1214) ... ... ... ... 8 554602 Bulbholder ... ... ... ... ... ... 9 989 Pilot bulb (99-0548) ... ... ... ... ... 10 54573590 Pilot bulbholder (99-1213) ... ... ... ... 11 54363454 Warning light (Red) (99-1208) ... ... ... 12 54363455 Warning light (Green) (99-1209) ... ... ... 13 54363453 Warning light (Amber) (99-1207) ... ... ... 14 54140331 Sealing washer (99-1210) ... ... ... 15 31276 Light switch (99-1211) ... ... ... ... ... 16 54525212 Shield, warning light ... ... ... ... ... 17 281 Bulb, warning linglt (99-0537) ... ... ... ... 18 54115106 Screw, headlamp fixinhg k9 23) 70/. Z ... 19 Washer, headlamp fixing 99-1224) 143086 ... ... ... ... Not illus. 54959629 Wiring harness (99 122-i) ... ... ... ... 39565 IGNITION SWITCH (TYPE 149 SA) (99-1200) ... 20 Nut ... ... ... ... ... ... ... 54130041 21 ... F6981SY335/6q IGNITION LOCK C/W KEY 8 2. ' 98/ ... 22 Key (state serial number) ... ... ... ... 23 D6225*035/69 ... ... ... ... ... Cover, ignition switch H2262 24 ... ... ... ... ... FLASHER LAMP (99-1190) 56147 25 . ... ... Lens (99-119 1) ... ... ... ... 26 54581638 ... ... ... ... ... ... ... Gasket 54580300 27 ... ... ... ... ... ... Bulbholder 554548 28 ... ... ... ... ... Interior assembly ... 473832 29 ... ... ... ... ... Bulb (99-1192) ... 382 30 ... ... ... ... ... ... Screw (99-1193) 54123401 31 ... ... ... Stanchion, flasher lamp (99-1246) 60600092 32
^
9'
91
ClassicBike.Biz
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
I 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
4 0 Q I
U m 0 Z 4 m W 4 m M
92
ClassicBike.Biz
Ref. No. Part No.
DESCRIPTION
QUANTITY
REMARKS
BATTERY AND TR6C HEADLAMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
F1 2512
F8091 F8255 F9353 F1 3849 F1 3295
F12508 F6039 14-1301 54027029 60262 534343
54525272 504665 370 54573590 989 17 554602 18 Not illus. 54115106 Not illus. 143086 19 31272 153631 20 21 144921 534296 22 23 54363454 24 281 54363455 25 54140331 26 54363453 27 54525212 28 14-0404 29 H4247 30
Battery carrier ... ... ... ... Carrier tray ... ... ... ... ... Protective strip ... ... ... ... Retaining strap ... ... ... ... ... Buckle ... ... ... ... ... ... Protective strip ... ... ... ... Shoulder screw Rubber bush Battery carrier mounting Nu Battery—PUZ5A (99-O 9) HEADLAMP ASSEMBLY MCH 66 (9 95)
.'
25'$
... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ...
... ... ... ... ... ... ... ... ...
...
...
...
...
...
...
... ...
O69^)
...
...
...
...
Light unit (99-1-21-2) ... ... ... ... Fixing wire (99-9683) ... ... ... ... Bulb (45/35W vertical dip, pre-focus 99-1214) Bulbholder, pilot (99-0695) ... ... ... ... ... Bulb (3W.M.C.C. 99-0548) ... Adaptor c/w leads (99-1003) ... ... ... Screw, lamp fixing (99=1157) ... ... ... Washer (99-1224) ... ... ... ... Lighting switch (99-6563) ... ... ... Nut for lighting switch ... ... ... ... ... ... ... ... Screw ... Plate (99-0690) .6 0 7 0 9' 7 ... Warning light, red (99-1 .208) ... ... ... ... ... ... Bulb (2W.BA75) (99-0537) ... Warning light, green (99-1209) ... ... ... ... Sealing washer (99-1210) ... Warning light amber (99-1207) ... ... Warning light shield ... ... ... ... ... ... ... ... ... Nut ... ... ... ... ... Support bracket ...
93
ClassicBike.Biz
1
... ... ... ... ... ... ... ... ... ...
1 1 ... 1 ... 6 ... 1 ... 1 ... 1 ... 2 ... 2 ... 2 ... 1 ... Reference only ... Reference only
...
...
... ... ... ... ... ... ... ...
... 1 ... 2 ... 1 ... 3 ... 1 ... Reference only ... 2 ... 1
-Rim (99
1 1 2 1 1 11 3 3 1
...
1
STANDARD HARDWARE SPECIFICATION BOLTS Material
Thd. dia.
21-1822 21-1910 21-1919 21-1 21-2010 1 0101 1 0102 1 0103 1 0113 1 0114 1 0115 1 0128 1 0208 216 1 1 0217 1 0219 1 0220 14-0225 1 0228 1 02 4 1 0236 1 0239 1 0240 1 0242 1 0251 1 6102 1 6115
Steel
Of
*" UNF A" 8 UNF 6 " UNC 1" 4 UNF k" UNF k" UNF I" UNF 4 *" UNF *" UNF *" UNF 1" UNF I" 4 UNF 16 UNF UNF *" UNF UNF 1 6 " UNF *" UNF a8 " UNF i" UNF A" 8 UNF A" 8 UNF A" 8 UNF UNF k" UNC *" UNC
Part No.
Material
Thd. dia.
21-0778 778 21-1852 21-1906 21-190 21-1914 21-2012 21-2013 21-2014 14-0301 0301 1 030 1 0401 1 0402 1 0403 1 0701 702 1 1 0703
Steel
Part No.
1
ff II
+,,
1 3,, 1 6
n"”
,
ff tf tI PP
II
It
It
1t ft fP tI
PP
ff IP
2f tt
0, /I tl
1,,
.,
If It If
" "
0
P
,, tI
IP
tt tt
"
Min. length of thread
ft" 1 3 1 6”
7,,
w
3" I
2
f" 1" 8 f" k" 1" 24" 1f" lk" li" 11" 3" 4"
11"
24" 3" 34" 4" 21" 1” 8
"
IP
f f
1 3 1 6
"
PP
1201
1 1202 1 1301 1 1302 1 1303 1 1304 1 1305 1 1902 1 1903
Length under head
I" 2” 8 7,, W
i" 7"
w
7"
w W
1" 1" 1" 1" 1" 1+"
7”
No. 10 UNF " UNF I" 4 UNF 1 6 " UNF A" 4 UNEF f " UNEF l' UNEF f" UNEF 14 " UNF UNF 1 6 k" UNF *" UNF 1" UNF k" UNF " UNF I" U UNF k" UNF UNF k" UNF A" UNF f" UNF UNF 1 " UNF 2 UNF 1 6 1" UNF
0.375" 0.437" 0.348" 0.438" 1.125" 1.313" 1.313" 1.313" 0.438" 0.500" 0.438" 0.500" 0.563 " 0.438 " 0.500" 0.563" 0.438" 0.500" 0.438" 0.500" 0.563" 0.688" 0.750" 0.500" 0.563"
*
*"
"
94 ClassicBike.Biz
0.500" 0.565" 0.500" 0.375" 0.438" 0.438" 0.438" 0.500" 0.500" 0.500" 0.563" 0.438" 0.500" 0.500" 0.500" 0.500" 0.500"
7,,
W
N U TS Hexagon A.F.
Hexagon A.F.
0.563"3 0.563" 0.563" 0.563" 0.563" 0.625" 0.438" 0.500"
Thickness
Remarks
0.225" 0.330" 0.188" 0.313" 0.250" 0.438 " 0.313" 0.438" 0.224" 0.271" 0.1 61" 0.192" 0.224 " 0.203 " 0.246 " 0.296" 0.285" 0.335" 0.245" 0.290" 0.320" 0.375" 0.435" 0.361" 0.375"
Cleveloc Philidas Plain Plain Plain Plain Plain Plain Plain Plain Lock Lock Lock Philidas Philidas Philidas Stiffnut Stiffnut Stiffnut Stiffnut Stiffnut Stiffnut Stiffnut Nyloc Nyloc
SCREWS Part No.
21-1916 21-1917 21-1918 21-1920 2 1-1929 21-2079 14-0604 14-6505 14-6607 14-6608 14-6609 14-7019 14-7024
Type of head
Material
Cheese head Cheese head Cheese head Hex. head Countersunk (82°) Cheese head Cheese head Countersunk (82°) Cheese head Cheese head Cheese head Socket head Socket head
Thd. dia.
Steel
4" UNC 4" UNC 4" UNC 4" UNC -," UNC No. 10 UNF 4" UNF 4" UN 4" UNC 4" UNC 4" UNC 6" UN " UNC
„ „ „ „ „
Length under head
18" 28" 28"
Type of drive
Cross recess Cross recess Cross recess
64 11
'^Z'" ' "
-z" ' e" 8" 1" 1,'-" -g'" 2"
Slot Pozidrive Cross recess Cross recess Cross recess Cross recess Cross recess Hex. socket Hex. socket
WASH ERS—PLAI N Part No.
Material
i/dia.
o/dia.
Thickness
60-4245 60-4246
Steel Steel
0.273" 0.398"
0.563" 0.750"
60-4247 37-2027
Steel Steel Steel
0.336" 0.531" 0.266"
0.625" 1.031" 0.469"
0.048" 0.063" 0.063" 0.092"
60-4248
0.064"
WASHERS—SPRING Part No.
Material
1/dia.
o/dia.
o/a height
Thickness
60-4259 60-4250
Spring Steel ,, ,
e" clearance a'-" clearance
;Z" '3—z"
T"
0.104" 0.064"
60-3541 21-0648
„
„
z"
e"
6" clearance
z"
** Double coil.
95
ClassicBike.Biz
T.
0.040** 32
Printed in England by
WARWICK PRINTING COMPANY LIMITED WARWICK
ClassicBike.Biz
ClassicBike.Biz
