Вы находитесь на странице: 1из 85

REPLACEMENT

PARTS
CATALOGUE
FOR 1971

BONNEVILLE T120R
TIGER 650 TR6R
TRrPHY 650 TR6C
See Bookmarks

TRIUMPH ENGINEERING COMPANY LIMITED


MERIDEN WORKS ALLESLEY COVENTRY CV5 9AU ENGLAND
TELEGRAMS "TRUSTY" COVENTRY
TELEPHONE COVENTRY 20221
TELEX "TRUSTY" 31305
MERIDEN 331
PUBLICATION PART No. 99-0932

PUBLISHED FEBRUARY 1971

ClassicBike.biz

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.

TelexTricor Bait. 87728


Telephone-301-252-1700

TelexTricor 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.

ClassicBike.biz

I NDEX
Page

AIRCLEANER ...
...
ALTERNATOR ...
...
AUTO-ADVANCE UNIT

...
...
...

...
65
... 11, 41
31
...

BATTERY CARRIER
BRAKE SWITCHES
BREATHER PIPES

...
...
...

...
...
...

...
...
...

Page
KICKSTARTER...

MANIFOLD
...
...
MOTOR PLATES
...
MOTOR TORQUE STAY
MUFFLERS
...
...

81
45
43

...
67
...
84
... 77, 79
... 47, 51
43
...
... 53, 55
59
...
57
...

...
...

...
...

63
...
33, 35, 37

...
...
...
...

69
...
57
...
... 79, 81
77
...

GASTANK
GEARBOX

...
...

...
HANDLEBAR...
HANDLEBAR MOUNTINGS
...
HEADLAMP...
...
...
HORN...

...

37

...
...
...
...

...
...
...
... 49,

17
47
47
51

...
...
...

17
43
17

PISTONS
...
PROPSTAND ...
PUSH RODS
...

...
...
...

...
...
11
...
...
43
... 19, 21, 23, 25

REARWHEEL ...
RECTIFIER
...
ROCKERS
...

...
...
...

...
...
61
...
...
77
..19, 21, 23, 25

SIDEPANEL
...
...
SPARKPLUG ...
...
SPEEDOMETER ...
...
SPEEDOMETER GEARBOX
STEERING DAMPER ...
SUSPENSION UNITS ...
SWINGING FORK
...
SWITCHES
...
...

... 49, 51
...
...
EXHAUST PIPES
EXHAUST PIPE ADAPTOR ...19, 21, 23, 25
...
...
...
...
...
...
...
...

...

OILPUMP
...
...
...
OILPIPES
...
...
...
OIL PRESSURE RELEASE VALVE

CAMSHAFT, INLET AND EXHAUST


11
CARBURETOR
...
...
... 27, 29
CARTON PACKS
...
...
...
7
CENTRESTAND
...
...
...
43
CHAINS...
...
...
...
...
41
...
...
CHAINCASE...
...
41
...
...
...
...
39
CLUTCH
CLUTCH LEVER ASSEMBLY
...
37
...
...
...
...
...
77
COIL
CONDENSER PACK ...
...
...
77
CONNECTING RODS
...
...
11
...
...
31
CONTACT BREAKER ...
...
CONTROL CABLES ...
...
71
...
...
69
CONTROL LEVERS ...
...
... 13,15
...
CRANKCASE...
...
51
CRANKCASE UNDERSHIELD
...
...
...
11
CRANKSHAFT...
... 19, 21, 23, 25
...
...
CYLINDERS
...19, 21, 23, 25
CYLINDER HEAD
...

...
...
FENDERS
FIVE SPEED GEARBOX
...
...
FLASHERS
...
...
FOOTRESTS
...
...
FRAME...
...
FRONT FORKS
...
FRONT WHEEL
...
FUSE ASSEMBLY

...

...
...
...
...
...
...
...
...

...
65
...
77
...
75
...
61
...
57
...
45
...
45
... 69, 79

TABLE OF STANDARD HARDWARE 82


TACHOMETER...
...
...
75
...
TACHOMETER GEARBOX ...
75
...
TAILLAMP
67
...
...
...
...
TAPPETS
17
...
...
...
...
TIMING GEARS
...
...
...
11
...
...
...
...
73
TOOLKIT
...
63
TWINSEAT
...
...
...
VALVES ...
VALVE GUIDES

...
...

...19,21,23,25
...19,21,23,25

WIRING HARNESS ...

...

...

79

ZENERDIODE ...

...

...

77

ClassicBike.biz

...

TIGER 650 (TR6R) TECHNICAL DATA

Bore and stroke...

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

Capacity ...
...
Compression ratio
Spark plugs
...
Carburetor

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


9:1
Champion N3

...

Amal Concentric 930


230
106
No.31

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

Gearbox sprocket
Chains
...

19 teeth
Front
Rear

i" Duplex x 84 links


1" x i" x 106 links

...

Capacities

Gas Tank
Oil Tank
Gearbox
...
Primary Chaincase
Front Forks (each leg)

Brakes

Front, diameter...
Rear, diameter

Tire size ...

Front
Rear
4

ClassicBike.biz

3.6 U.S. galls.


4.8 U.S. pints
i pint (500 c.c.)
1 pint (150 c.c.)
pint (190 c.c.)
8" (20 . 32 cm.)
7" (17 . 78 cm.)
3.25 x 19
4.00 x 18

ClassicBike.biz

TROPHY 650 (TR6C) TECH N ICAL DATA

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

Bore and stroke...

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

Capacity ...

9:1

Compression ratio

Champion N3

Spark plugs
Carburetor
Main jet
Needle jet
Throttle valve ...

18 teeth

Gearbox sprocket
Chains

...

Amal Concentric 930


230
-106
No. 31

Front
Rear

i" Duplex x 84 links


1" x i" x 106 links

...

Capacities

Gas Tank
Oil Tank
Gearbox
...
Primary Chaincase
Front Forks (each leg)

Brakes

Front, diameter...
Rear, diameter

Tire size ...

Front
Rear

3.6 U.S. galls.


48 U.S. pints
i pint (500 c.c.)
a pint (150 c.c.)
1 pint (190 c.c.)
8" (20 . 32 cm.)
7" (17 . 78 cm.)
3 . 25 x 19
4 . 00 x 18

ClassicBike.biz

BONNEVILLE
Boreand stroke

...

(T120R)

TECHNICAL

DATA

...

...
...

...

...

...

...

...

...

...

...

9 : 1

...

...

...

...

...

...

...

...

...
...
...
...
...

...
...
...
...
...

...
...
...
...
...

...
...
...
...
...

Champion N3
2 Amal Concentric 930
190
106
No. 3

Gearboxsprocket

...

...

...

...

...

...

...

...

...

Chains

...

...

...

...

Front
Rear

...
...

...
...

...
...

...
...

...

...

e" x e" x 106 links

...

...

Gas Tank
...
OilTank
...
Gearbox
...
Primary Chaincase
Front Forks (each leg)

...
...
...
...

...
...
...
...
...

...
...
...
...
...

3.6 U.S. galls.


4.8 U.S. pints
8 pint (500 c.c.)
- pint (150 c.c.)
pint (190 c.c.)
8" (20 . 32 cm.)
7" (17 . 78 cm.)
325x19
4.00x18

Capacity...
Com

p
Sparkplugs
Carburetors

Ca

...

ressionratio

...

p acities

Brakes

...

...

...

...

...
...
...
...
Mainjet
Needlejet
Throttle valve

...

...

...

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

...

...

...

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

...

...

...

...

...

...

...

Front, diameter...
Rear, diameter

...
...

...
...

...
...

Tiresize ...

...

...

...

...

Front
Rear

...

...

...
...

...
...

...

ClassicBike.biz

19 teeth

8" Duplex x 84 links

'-3

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.
Contents

Part No.

Brake Lining
C.P.38/A.M.2

16 ...

C.P.205

2 ...
16

... Brake lining

NW243

...

...

W129

...

... W1734 ...


...

W129

...

...

Rivet

... Brake lining


...

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., 1mm.)

Valve Guides
C.P.97

E2899

... Inlet guide

(TR6)

E2900

... Exhaust guide

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)
TROPHY 650 (TR6C) J

Pacific Blue

BONNEVILLE (T120R)Tiger Gold


Paint is available in aerosol containers only.

ClassicBike.biz

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 end 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.

ClassicBike.biz

33

39

20

21

22

23

24

25

Fig. 1. CRANKSHAFT AND CONNECTING RODS

10

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

CRANKSHAFT AND CONNECTING RODS


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
Not illus.
Not illus.
Not illus.

E12600
E4643
E3903
E3905
El 2425
*E12601
E11003
E3114
E9525
E1511
E6576
S2016
E3586
E9488
E6864
E6865
E6861
E6869
E1591
E12662
E4573
El 00082
54213901
E3975
E3977
E1580
E4564
E4565
E6159
E400
E12719
E1558
E11007
E6523
E11063
E9989
E9988
E3300
E2879
E12663
E8038
E12660

CRANKSHAFT AND FLYWHEEL ASSEMBLY ...


...
...
CRANKSHAFT C/W. OIL TUBE
...
...
...
...
...
Oil tube
...
...
...
...
...
...
Screwed plug
...
...
...
...
...
...
Flywheel ...
...
...
...
...
...
...
...
Flywheel bolt
...
...
...
...
...
...
...
Washer
...
...
...
...
...
...
...
...
Crankshaft stud (18 in. O.A.) ...
...
...
...
...
CONNECTING ROD ...
...
...
...
...
...
...
Small end bush ...
...
...
...
...
...
...
Connecting rod bolt
...
...
...
...
...
...
Self locking nut ...
...
...
...
...
...
...
Big end bearing (Available in 010 in. and 020 in. undersizes)
PISTON COMPLETE 9 : 1 C.R. ...
...
...
...
...
Taper compression ring ...
...
...
...
...
...
Oil control ring ...
...
...
...
...
...
...
...
...
...
...
...
Gudgeon pin (short)
...
...
...
...
Circlip
...
...
...
...
...
Main bearing, right
...
...
...
...
...
...
...
...
...
Motor sprocket, 29 teeth Duplex ...
...
...
...
Distance piece ...
...
...
...
...
...
...
...
...
...
...
...
Rotor key
...
...
..
...
...
...
...
rotor (99-0739) ,S'J2A. 22 7 ...
...
...
...
...
...
...
...
Tab washer
...
...
...
...
...
...
...
...
...
...
Nut
...
...
...
...
...
...
...
...
...
Key
...
...
...
...
...
Timing pinion ...
...
...
...
...
...
...
...
...
...
...
...
Nut
...
...
...
...
...
...
INTERMEDIATE WHEEL
...
...
...
...
...
Intermediate wheel bush...
...
...
...
...
...
...
...
Camshaft wheel...
...
...
...
...
...
...
...
Camshaft key ...
...
...
...
...
...
...
...
Inlet camshaft nut
...
...
...
...
...
...
Exhaust camshaft nut ...
...
...
...
...
...
...
...
Inlet camshaft, ...
...
...
...
...
...
...
EXHAUST CAMSHAFT
...
...
...
...
...
Tachometer drive plug ...
...
...
...
...
...
...
...
Clamping washer
...
...
...
...
...
...
Main bearing, left
...
...
...
...
...
...
Spacer
...
...
...
...
Shim (0 . 010 in.) Engine sprocket ...
...
...
...
...
...
Shim (0 . 030 in.) J

* Use D524 Loctite Sealant

II
ClassicBike.biz

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

1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
As required (up to 4)
As required (up to 4)

Fig. 2. CRANKCASE

12

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

CRANKCASE

E11266
CRANKCASE DRIVE SIDE ...
E10287
Camshaft bush
...
E10287
Camshaft bush
...
E5976
Chain tensioner abutment
E12274
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-q1q6Plain washer
1 0303
Nut
...
E1532
Hollow dowel, tappet oil feed
E9330
Oilway plug
...
F1880
Copper washer ...
51871
Tachometer drive plug (L.H. thread)
E8896
Fibre washer ...
51863
Oil pipe stud ...
S1865
Cylinder stud ...
S1872
Plug, timing hole
51870
...
Bolt
14-6220
Bolt
14-6223
Bolt
14-0230
Bolt
S1823
Bolt
...
D2330
Plain washer
14-1302
Nut
...
E9336
Crankcase filter...
E5315 70-P g1 Joint washer ...
T2167
Drain plug (with level tube)
T1257
Fibre washer
S543
Level plug UN ...
E2160-7/32 Copper washer ...
T2259
Drain and adjuster plug
T1738
Fibre washer
T1920
Blanking plug ...
12166
Filler plug UN ...
E8782
"0" ring
...
14-6242
Bolt
...
S669
Stud
...
E8892
Protection blade
Self locknut UN
1 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
... 2

1
2
2
2
...
...

...

1
2
1
8

...

...
...
...
... 2
... 10
... 5
...
...
...
...
...
...
...
...

2
2
1
1
1
1
1

2
...
...

(TR6C 3 off)
(TR6C 7 off)
(TR6C 4 off)

1
1

(Except TR6C)

(Except TR6C)

Fig. 2 CRANKCASE

14

ClassicBike.biz

Ref. No.

Pprt No.

DESCRIPTION

QUANTITY REMARKS

CRANKCA^ iE (continued)
53
54

.55
56
57
58
59
60

...
...
...
...
E9335
Outlet stub
Joint washer ...
...
E11460
...
...
Screw ...
...
...
E11077
...
...
Tube, primary chain oiler
E11078
...
...
...
...
...
Clip
E4705
...
...
...
S26-260-g2S0 Spring washer ...
...
...
...
14-0101
Bolt(,'-6 in. U.H.)
Grommet, alternator leads. external
E11345

15

ClassicBike.biz

...

...

...

...

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...

1
1
2
1
1
1
1
1

11

6
7
8

19

18
15

16

17

-13

14

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
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

...
E9421
OIL PUMP
Reference only
Pump body...
...
E9269
Feed plunger
Scavenge plunger ...
E6681
Drive block
...
E495
Valve ball ( in. dia.)
570-7 0-2363
...
E403
Valve spring
Screwed plug
E2360
E11461
Joint washer
...
S1684
Oil pump stud ...
Serrated washer
E3887
S1906
Nut
...
E122107/-2369 Oil release valve
E1670 60-335 Fibre washer
Stud
...
51876
Joint washer
E5660
Inlet manifold
E9973
S25-136p0-12y$ Plain washer
Nut
51877
Stud
S1996
Cup
...
E9555
"0"
ring
E9554
Nut
...
...
1 1301
...
Inlet tappet guide
E9352
Exhaust tappet guide ...
E9353
Copper washer ...
E1612
...
...
...
Set bolt ...
H200
0
5.9/0.iy
7Q.7
3
Inlet
tappet
E3059R
Exhaust tappet
E8801
'0' Ring
E7563

...

17

ClassicBike.biz

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

TR6

e--58
E3--56 34 33

37
35
24
42

36
X

51

32

31 27

41
!,

45

p
43

52

48 49

44 47 39 40 43

x---29

28

25 46

5021

30
^'

22

= i

18

^_^ r^

19
20

26

Ili
^1111^^1

ffI1
8
14-

\\_

23

10

1
7

13

2
3

1
B4
o.,

Fig. 4. CYLINDER BLOCK AND HEAD, TR6R, TR6C

18
ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

CYLINDER BLOCK AND HEAD, TR6R, TR6C


I
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 washer ...
...
...
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 gasket ...
...
...
E12354
CYLINDER HEAD c/w GUIDES ...
E2899 71'-3292
Inlet valve guide ...
...
...
E2900 7/- 3293
Exhaust valve guide
...
...
E9516
Exhaust pipe adaptor
...
...
E4603
Inlet valve
...
...
...
...
E2904
Exhaust valve ...
...
...
...
Bottom cup
E6439
...
...
...
...
E4221
Inner valve spring (red spot) ...
...
E7400
Outer valve spring (green spot)
...
E1543
Top collar
...
...
...
...
99-00637/-37y8Split cotter
...
...
...
...
E327
Cylinder head bolt
...
...
...
Plain washer ...
...
...
F2184
...
E4771
Bolt
...
...
...
...
...
S25- 360-'/2Y7 Plain washer ...
...
...
...
...
E3253CO-3SY1Sealing ring
...
...
...
Inlet
rocker
box
...
...
...
E12350
Exhaust rocker box ...
...
...
E12351
...
...
...
Joint washer ...
E12599
...
...
...
Rocker box bolt
51875
...
...
...
Rocker
box
nut...
14-0301
...
...
...
Plain washer ...
E3302
...
...
...
Rocker
box
stud
14-1401
...
...
...
S25-1360-y2Y Plain washer ...
Cylinder
head
stud
(for
torque
stay)
14-1435
...
...
...
E46107/-27'1`1 Inspection cap ...
...
...
...
Joint
washer
...
E3751
...
...
...
...
Locking
spring
E4609
...
...
...
WE17000 - qf 263 Fibre 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
...
Thrust washer, fin. ...
...
E1575
...
...
Spring washer ...
...
E1574
...
...
...
Rocker spindle ...
E1512
...
...
...
Dowel, rocker box
E12361
...
...
Thrust washer, I in. ...
E1330
...
...
...
...
Access plug
E12079
...
...
...
...
Washer ...
E12080
...
...
...
Bolt, cylinder head
E12362
...
...
...
Bolt, rocker box
S588
19
ClassicBike.biz

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

1
1
8
4
2
2
2
1
1
2
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
4
4
4
2
2
4
4
4
6
4
2
4
2
4
4
4
4

REMARKS

58
57
56 3 4

33

17

16

15
14

1
B4

Fig. 4. CYLINDER BLOCK AND HEAD, TR6R, TR6C


20

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

CYLINDER BLOCK AND HEAD, TR6R, TR6C (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

...
...
...
...
...
...

...

21
ClassicBike.biz

...
...
...
...
...
...

...

...
...
...
...
...
...

...

...
...
...
...
...
...

...

...
...
...
...
...
...

...

4
2
2
4
2
2
2

REMARKS

^-

67

66

1
-

_65

B5

Fig. 5. CYLINDER BLOCK AND HEAD, T120R

22

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY REMARKS

CYLINDER BLOCK AND HEAD, T120R


1
2
3
4
.5
6
6A

7
8

E6309
E6304
S692

E2620
E12575
E7310
E11283
E4547
E12356

9
10

E5347
E3827 7/-

11
12
13

14
15
16
17
18
19

...
Cylinder base washer ...
...
...
Cylinder block ...
...
...
Cylinder base nut
...
...
...
Push rod
...
...
...
Cover tube
...
...
"0" ring (bottom)
...
...
"O" ring (top)
...
Cylinder head gasket ...
CYLINDER HEAD c/w GUIDES

3Z/

42
43
44

45
46
47
48
49
50
51
52

53

...

...

...

...

...

...

..

...

...

...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...

...

...

...

F2184

38
39
40
41

2
2
1

Carburetor adaptor, right

29

35
36
37

Reference only

...
...
...

E9551

...

E4792

S1932

Plain washer

...

...

...

..

...
...
...
...
...
Bolt
E4771
...
...
...
...
S25-36O-S/2g7 Plain washer
...
...
...
...
E3253 6pO-3S 1 'Sealing ring
...
...
...
Inlet rocker box
E12350
...
...
...
Exhaust rocker box
E12351
...
...
...
E123657/-2599 Joint washer ...
...
...
...
Rocker box bolt
51875
...
...
...
...
...
Nut
14-0301
...
...
...
...
Plain washer
E3302
...
...
...
Rocker box stud
14-1401
...
...
...
525 - I 36042 4'8' Plain washer
Cylinder
head
stud
(for
torque
stay)
14-1435
...
...
...
...
E4610 7I-2.7Y y Inspection cap
...
...
...
...
Joint washer
E3751
...
...
...
...
Locking
spring
E4609
...
...
...
WE17060"%263Fibre washer ...
...
...
...
...
...
Screw
14-2203
ROCKER
(right
exhaust,
left
inlet)
...
E1457
ROCKER (left exhaust, right inlet) ...
E1458
...
...
Rocker ball pin ...
Ell 0070
...
...
...
Rocker
adjusting
pin
E1513
...
...
...
Adjuster
lock
nut
E470
...
...
...
in.
Thrust
washer,
.
E1575

...
E1574

Spring washer

...

...

...

1
1
8
4
2
2
2
1
1

...

E3828 7/ - 3^9 S
E9550

...

...
...
...
...
...
...
...
...
...

...
...
...

...
...
...

Connector ...

...
...
...
...
...
...
...
...
...
...

...
...
...

E6916

...
...
...
...
...
...
...
...
...
...
...
...

...
Inlet valve guide ...
...
Exhaust valve guide
Carburetor adaptor, left

21
22
23
24
25
26
27
28
30
31
32
33
34

...
...
...
...
...
...
...
...
...

Sleeve for head bolts passing through inlet tracts

...
...
Balance pipe
...
Adaptor locking nut
...
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
...
El 543
...
...
...
99-00627/-375/BSplit cotter
...
...
Cylinder head bolt
E327

20

...
...
...
...
...
...
...
...
...

...

23

ClassicBike.biz

2
1
2
2
4
4
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

52
I
48 49 52 47 53

47 48 62

34 55

38
37

57 58
16

59

12

29
30

31

9s _
28

-17-

'-i

j- ,

29

B5

Fig. 5. CYLINDER BLOCK AND HEAD, MOB

24

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

CYLINDER BLOCK AND HEAD, MOR


54
55
56
57
58
59
60
61
62
63
64
65
66
67

E1512
E12361
El 330
E12079
E12080
E12362
S588
D2332
E12598
E4752
E11707
E12597
D2331
14-1303

Rocker spindle ...


Dowel, rocker box
Thrust washer, in. ...
...
Access plug
...
Washer ...
Bolt, cylinder head
Bolt, rocker box
Washer ...
Spacer ...
Sealing ring
Sleeve ...
Distance piece
For torque stay
Washer
Nut

(continued)
...

..
..
...

25

ClassicBike.biz

2
4
2
4
4
4
4
4
4
2
2
2
2
2

REMARKS

11
IiII-

Fig. 6. AMAL CARBURETOR, TR6R, TR6C

26

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION
AMAL CARBURETOR TR6R,

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
fly
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
F13507
E9711

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


Mixing chamber (930/005)
...
...
Mixing chamber top (99-1032) ...
...
Screw (99-0521) ...
...
...
...
Throttle valve (3z 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 (230) (99-0441) ...
...
...
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
...
...
...
...
...
' O" ring
...
...
...
...
...

5 F T/Q/

p,',

27
ClassicBike.biz

QUANTITY REMARKS
TR6C
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

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
1

Fig. 7.
Fig.
7. AMAL
AMAL CARBURETOR,
CARBURETOR, T12OR
T120R
28

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

AMAL CARBURETOR T12OR


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
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

CARBURETORL.H. (L930/67) }

Less 0 ring
CARBURETORR.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 (994506)...
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

asE Te/

P H fAr

29
ClassicBike.biz

1
4

1
1

1
1 ,
1
2

Each
carburetor

8
4

7
5
2

I^

ril

0
6

24

23
1

-- 11
19
10
9

6m ^

13

,^

12

22
B7

Fig. 8. TIMING COVER AND CONTACT BREAKER


30

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
...
...
...
D208-50 0-/2SSHammer-drive screw ...
...
E4568
Oil seal ...
...
...
...
E6387
Oil seal (0 . 020 in. undersize) ...

...
...
...
...
..

...
...
...
...
...

...
...
...
...
...

...
...
...
...
E4569
Circlip ...
...
...
...
...
...
...
...
T989
Hollow dowel ...
...
...
...
...
Screw ...
...
...
14-6609
...
...
...
...
...
...
14-6608
Screw ...
...
...
...
...
...
...
14-0208
Bolt
...
...
...
...
...
...
S25-4370-&/63 Plain washer ...
Rubber grommet
...
...
...
...
...
E4707
...
...
...
...
...
Pillar bolt
...
E7680
...
...
...
...
...
Plain washer ...
E6559
...
...
...
...
...
Cover ...
...
E8737
...
...
...
...
...
Joint washer ...
E11462
...
...
...
...
...
GS29960-qZr Serrated washer
...
...
...
...
...
Screw (4 in. U.H.)
E7354
...
...
AUTO ADVANCE UNIT (99-0771)
54419340
...
...
...
...
Spring set (99-0757)
54415642
CONTACT BREAKER PLATE ASSEMBLY (99-0768)
54419097
...
...
...
Contact set (99-0772) ...
54419827
...
...
...
Pin, adjustment (99-0769)
54419220
...
...
...
...
D213360-37/c/ Oil pressure switch ...
...
...
...
...
Cover pressure switch
D2045
...
...
...
Timing label for C.B. cover ...
D2138

31
ClassicBike.biz

...
...
...
...
...

...
...
...
...
...

1
1
3
2

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

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

For reground
crankshaft

12

17

18

13

14

B8
Fig. 9 GEARBOX INNER COVER AND SELECTORS

32

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

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
14-1427
S1907
E3446
14-6608
14-7023
T989
T1614
T1607
T412
T45
T4055
T397
11896

T4308
T4307
T3989
T4288
T4289
T4290
T4291
F4771

Gearbox inner cover


...
...
Stud
...
...
...
...
...
...
...
Bolt
Washer ...
...
...
...
...
...
...
...
Screw
...
...
...
Screw
...
Hollow dowel ...
...
...
...
...
Layshaft bearing
Thrust washer ...
...
...
Gearchange spindle bush
...
Kickstarter stop
...
...
...
Gear selector cam plate
Camplate operating quadrant...
...
Quadrant spindle
...
..
Split pin (64 in. x 18 in.)
...
Mainshaft selector fork
...
Layshaft selector fork
...
...
Selector fork rod
...
...
...
Leaf spring
...
...
Leaf spring support
Leaf
...
spring top plate ...
...
...
...
Tab washer
...
...
...
...
Screw

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

33

ClassicBike.biz

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

1
2
1
1
1
1
4
1
2
I
I
1
1

1
Reference only
1
1
1
1
1
1
1
2

34

ClassicBike.biz

U)

w
Q

0
0
z
4
w

LL

I
w
x
0
=
4
w
0
.
,
1. w

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

GEARBOX SHAFTS AND GEARS

1
2
3
4
5
6
7
8
9
10
11
12
12
12
12
12
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

T4158
MAINSHAFT c/w LOW GEAR (16D
T3988
Clutch rod bush ...
T4332
MAINSHAFT HIGH GEAR (26T)
High gear bush ...
T400657 1370
Mainshaft third gear (23T) ...
T3889
Mainshaft second gear (20T) ...
T4335
LAYSHAFT LOW GEAR (30T)
T3862
Low gear bush ...
T928
Layshaft second gear (26T) ...
T3861
T3890
Layshaft third gear (22T)
...
Layshaft c/w high gear (20T)
T4345
Gearbox sprocket (15 teeth)...
T1952
Gearbox sprocket (16 teeth)...
T1953
Gearbox sprocket (17 teeth)...
T1916/0/7
Gearbox sprocket (18 teeth)...
T1917/0It
Gearbox sprocket (19 teeth)...
T1918/0/9
Gearbox sprocket (20 teeth)...
T1919/020
Tab washer
T2116
Gearbox sprocket nut
T440
D3556 p-ovve High gear bearing
Circlip
T489
Oil seal ...
T946
Mainshaft bearing
D3552
Circlip
T4113
Plain washer
T1962
Pinion sleeve
T1963
Pinion spring ...
T1250
Kickstarter pinion
1730
Kickstarter ratchet
T731
Tab washer
...
T2240
Nut

5594
Clutch operating rod ...
T1736

See pages 4 to
5 for standard
sizes

WIDE RATIO GEARS

3
6
9
11

T3657
T4161
T4160
T4159

MAINSHAFT HIGH GEAR (28T)


Mainshaft second gear (19T) ...
Layshaft second gear (27T) ...
Layshaft c/w high gear (18T)

...

CLOSE RATIO GEARS

1
3
5
6
7
9
10
11

T4173
T4172
T4169
T4167
T4163
T4166
T4168
T4162

MAINSHAFT c/w LOW GEAR (18T)


MAINSHAFT HIGH GEAR (24T)
Mainshaft third gear (23T) ...
Mainshaft second gear (21D ...
LAYSHAFT LOW GEAR (28D
Layshaft second gear (25T) ...
...
Layshaft third gear (23T)
Layshaft c/w high gear (22T)...
35
ClassicBike.biz

15
14

21

27

^C
20

25.

24
26
O
2

^5

11

10,

\\\ \<:
45

W,

'
6

>
/^^ /7\3 v9

34

34
30

8
46

- \
31

1
47
36

BlO

Fig 11. GEARBOX OUTER COVER

36

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

GEARBOX OUTER COVER

37
38
39
40

GEARBOX OUTER COVER


...
Kickstarter spindle bush ...
...
...
Gearchange spindle bush
Kickstarter spring anchor pin ...
Guide plate stud ...
...
...
...
...
Oil seal
...
..,
T1 956
Oil seal housing .... 7_.Q0
T1 955
^i
Gearchange quadrant
T408/9
...
...
...
E330960-353 Rubber "0" ring
Quadrant return spring
...
...
T404
Gearchange quadrant plunger
...
T406
...
...
...
Plunger spring ...
T405
...
...
...
Guide plate
...
T407
...
Serrated washer
...
...
E1612
...
...
...
...
...
Nut
301
...
Kickstarter quadrant ...
...
T4117
Kickstarter return spring
...
...
T31
...
Kickstarter axle
...
...
T24A57-'17$
...
T3629$7- S'3W7 CLUTCH LEVER ASSEMBLY
...
...
Clutch
lever
...
12191 S7-', VY/
...
Lever
shaft
...
...
T1710
Ball,
8
in.
diam.
...
...
...
D2368
...
Thrust
plate
...
...
T3761
Return spring
...
...
...
T1712
6
Plain
washer
73
GS12757 3
...
Split pin (4
60.2701
6 in. x fin.) ...
...
Countersunk
screw
...
...
51879
...
...
..
Rubber
cover
...
T1646
...
Abutment
for
clutch
cable
...
T3762
...
...
...
S25-3 o-c{2g7 Plain washer ...
...
...
...
...
...
Nut
14-0302
...
...
...
...
Screw ...
51878
...
...
...
...
...
Screw
14-6609
...
...
...
...
...
Screw
14-6608
...
...
...
Gearchange
pedal
T3757 5-70/O
...
...
...
...
...
Bolt
14-0201
...
...
...
Pedal rubber ...
T2450
...
T3632 57-7018 FOLDING KICKSTARTER ...
7
...
...
Kickstarter lever ...
T2173 5 -W 3
...
...
Kickstarter pedal ...
T1 272 57-70/7

41

T1167

...

...

...

...

...

...

42
43
44
45
46
47

Steel ball, I in. diam.


...
S70-3t0 236Y
...
...
Pedal bolt
S541
Pedal rubber ...
...
...
T2330
Cotter pin c/w nut and washer
T4356
...
...
...
Domed nut
S544
...
...
...
Filler plug
T2166
<< O" ring
...
...
...
E8782

...
...
...
...
...
...
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...

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

1
2
3
4
5

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

48

T3760
T23
T57
T47
S547

14-0

Pedal locating spring

37

ClassicBike.biz

...
...
...
...
...
...
...
2
.. 9
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

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
Reference only
2
1
1
2
1
2
2
1

...

...

...

...

...
...
...
...
...

...
...
...
...
...

...
...
...
...
...

...
...
...
...
...

1
1
1
1
1
1

38

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

6
7

8
12

Clutch securing nut


5586
...
Hub
...
T3929
Thrust
washer
...
13931
...
Roller ...
T394
Sprocket
and
housing
(58
teeth
Duplex)
T1570
Centre ...
T1719
...
Inner plate
T1720
Countersunk screw ...
T1040
Shock absorber spider
T2538
Drive rubber (large) ...
T1722
Rebound rubber (small)
T1723
Outer
plate
T1724
...
T423A 57 n q7S qScrewed pin
T136257YiS3 Driving plate (bonded)
Driven plate
T1363
Pressure plate
T2156
Adjuster pin
T2159
Nut
...
14-0403
Spring cup
T1931
Spring ...
T1830
Pressure nut
T2526
...
S66-1 co-nr 3 Key
Cupped washer
T2279

14438
T4436
5644
T4437

LATER MODELS USE THE FOLLOWING:...


Centre (shock absorber body)
Inner plate
...
Bolt
Outer plate

39
ClassicBike.biz

...
...
...
..

1
1
1
20
1
1
1
6
1
3
3
1
3
6
6
1
1
1
3
3
3
1
I

1
1
3
1

REMARKS

rn

^^

az

ClassicBike.biz

M
M

N
N
n
N

o
M
MMN

N
("5
N

_N

O Z

N Q
0
z
Q
W
H

r
r

U
z

a
0)
r

O u

(V

Ref No. Part No.

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

DESCR IPTION

D1915 /OOOSG//Okear chain, I in. x in. x 106 links


...
...
Joint washer ...
E11419
...
...
...
Cover plate
E7037
...
...
...
Oil seal ...
E7565
...
Countersunk screw ...
E3821
E597670 -Sb87 Chain tensioner abutment ...

REMARKS

CHAINS

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

I
1
1
1
6
1

...
...
Chain tensioner blade...
E6061
...
...
...
...
...
Tie
rod
E4152
...
...
...
...
Trunnion
E5977
...
...
Adjuster sleeve nut ...
E9703
Primary chain, I in. Duplex x 84 links
D477
...
...
...
...
Stator stud
S1866
...
...
...
...
Stator stud
S1867
...
...
Stator, RM21 (99-1006)
47205
...
...
...
...
Sleeve nut
E9360
...
...
...
Rubber grommet
E4144
...
...
...
...
Plastic
sleeve
E5449
y7
q
...
...
...
525-340- {Z Plain washer ...
...
...
...
Self-locking nut
14-0702
...
...
...
...
Joint
washer
E11463
0 2
-...
...
...
...
4 7 Chaincase
E9245
...
...
..
...
Rotor cover
T2440
...
...
...
Joint washer ...
E11457
w
...
..
...
...
Scre ...
F4129
...
..
...
Copper washer
E2441
...
...
Filler plug
...
...
T2166
...
...
...
...
"0" ring
E8782
...
...
...
...
Screw ...
14-6608
...
...
...
...
Screw ...
14-6620
d
...
...
...
...
Dome nut
S544
r
...
..
...
Coppe washer ...
F1880
...
..
...
Timing pointer ...
T2443
...
Level plug
14-6101

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

I
1
1
I
1
2
1
1
1
1
1
3
3
1

7/

41
ClassicBike.biz

1
1
3
1
1
1
6
2
2
2
I

(also listed with


crankcase group)

42

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

FRAME
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
Not illus.
Not illus.
Not illus.
Not illus.

Fl 208983-4283 Frame ...


E127 44 7/-27 yy Oil filler cap
D3616
"0" ring
F13142
Dipstick ...
F12826
*Oil filter and sump plate
F12829
*Gasket
D2330
Washer
52109
Stud
Sump plate to frame
14-1302
Nut
S1945
*Drain plug
E12505
Joint washer
E6930 7/-7/7 6 Oil junction block
E11458
Joint washer ...
}
Nut
S1908
Junction block to crankcase
E3 44 6
Wash
Washer
E12428
Rocker oil pipe
El 335
Washer ...
E1435
Nut
E12337
Rocker feed pipe
...
E811160-3ny Cliprocker feed pipe
E12345
Oil return pipe
E6848
Clipfeed and return pipes
E12347
Oil feed pipe
E12349
Oil vent pipe ...
E11149
Crankcase breather pipefront
F11614
Crankcase breather piperear
F11610
"T" piece
D2253
Clipbreather pipefront ...
D2252
Clipbreather piperear ...
F11615
Clipbreather pipe to fender
H3894
Screw
F4717
Nut
...
F12627g3-qqq/ Centre stand
F13793
Spring ...
S2077
Pivot bolt
14-1304
Nut
...
Prop stand
F11560
F7021
Bolt
14-1303
Nut
F8382
Spring ...
D3361 ,-3m Transfer "Made in England"
D2452
TransferSafety Standards
Bolt }
14-0114
Prop stand stop
14-0402
Nut

1
1
1
4
4
4

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

* LATER MODELS USE THE FOLLOWING:


F13642
Oil filter assembly
F12829
Gasket ...
Drain plug
14-0113
F1364393-3/CSump plate

1
2

43
ClassicBike.biz

REMARKS

N
N

N^ \ (/ice

44

ClassicBike.biz

z
0
z
0
_
U,

z
W

0.
H

D
N

z
Q

0
LL
0

Z_

Z_
y
M

of

LL

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
35

F12513
...
...
...
SWINGING ARM
D1841
...
...
...
Grease nipple
WE170 M 7221
...
Washer, grease nipple ...
F1 2521
Bush, pivot arm ...
...
...
F12691
Sleeve, swinging arm pivot ...
...
Distance piece R.H. ...
...
...
F12690
F12689
...
Distance piece L.H. ...
...
F12692
...
...
...
Dirt excluder ...
S2087
Stud, swinging arm pivot
...
...
F12266
Washer, swinging arm pivot ...
...
14-1307
...
Nut, swinging arm pivot
...
...
F12656
Brake torque stay
...
...
...
14-1304
Nut, torque stay to brake plate
D2350
Washer, torque stay to brake plate ...
14-0133
Bolt, torque stay to swinging arm ...
Washer, torque stay to swinging arm
W2330
Nut, torque stay to swinging arm ...
14-1304
...
64052341
SUSPENSION UNIT (D2294)
...
...
64052090
Damper unit
...
Bonded bush (99-0122) ...
...
64533645
9054/171
Spring retainer (99-0107)
...
64544754
Spring, 110 lbs. chrome (99-1139)
Bolt, dampertop
...
...
...
14-0235
Stud, dampertop L.H.
...
S1997
...
...
D2332
Washer, dampertop
...
...
Nut, dampertop
...
14-1303
...
14-0234
Bolt, damper, lowerL.H.
...
Bolt, damper, lowerR.H.
14-2034
...
...
D2321
Washer damper lower
...
...
...
Nut damper lower
14-1303
...
...
...
...
F12641
Chainguard
Bolt,
chainguard
fixingfront
...
14-0206
Washer, chainguard fixingfront ...
D2347
Stop
lamp switch-118SA (99-4028)
34815
...
...
...
...
D35502/ 70/0 Screw ...
...
...
...
...
H1388
Washer ...

45
ClassicBike.biz

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

1
2
2
4
2
1

I
4
I
2
1
1
1
1
1
1
1
2
Reference only
4
4
2
2
(1 off TR6C)
1
(TR6C)
2
(3 off TR6C)
2
(3 off TR6C)
1
1
2
2
1
1
1
1
2
2

46

ClassicBike.biz

o
H
w
W
W

{^

0
0
LL
LL

0
o
Z
z
Q
4
I,
Z
z
P
F
F
LL
E

^_

Z
i

0
0
Z

0
F
0

^O
00
{L
E

Ref. No. Part No.

DESCRIPTION

QUANTITY

MOTOR UNIT FITTINGS 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
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

FOOTRESTS

F12855
F12854

Footrest L.H....

...

...

...

...

...

...

Footrest

...

...

...

...

...

...

14-0259
D2333
F9279

...
...
Bolt
...
...
...
Washer ...
...
...
Footrest rubber
...
...
PILLION FOOTREST ...
...
Pedal
...
...
...
Hanger bolt
...
...
Bolt
Washer Footrest swivel
Nut
J
Nut
Washer f Footrest to frame

...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...

...
Footrest rubber ...
...
...
Rear brake pedal
Screw
Stop light adjustment
Nut f
...
...
...
Pivot pin
...
...
...
...
Nut
...
...
...
Washer ...
...

F12841
F9053
F1 3207

14 -0217

F9089
14 -1302
14 -1303

F2184
F9054
F12666
14 -0103

14-0301
S2045

14-1303
E808460-%'Z'/
F12860

R.H.

...

Rear brake operating rod

...

...

...

...

...

... 1
1
... 2
... 2
... 2
... 2
... 1
... 1
... 1
... 1
... 1
... 1

...
...
...

...
...
...

...
...
...

...
...
...

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

...
...
...

...
...
...

...
...
...

...
...
...

... 1
... 1
... I

...

...

...

...

...

...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...

Reference only
1
2
1
1
5

...
...
...
...

...
...
...
...
...
...
...
...
...
...

...

...

...

... 4

...

...

...

...

...
...
...
...

...
...
...
...

...
"'

...
...
Split pin ( ^!6 in. x 8 in.)
-g27
D2393
...
...
...
...
Washer
...
7
93
...
...
F7387
Adjuster nutbrake rod
...
F1 3024
Rear motor plate R.H.
...
...
F1 3023
Rear motor plateL.H.
...
14 -0115
Bolt
I
14-0116
Bolt
Rear motor plates to frame
14 -1302
Nut
D2330
Washer
14 -0220
Bolt
14-0221
Bolt
pl
Motor to m oto r plates
14 -1302
Nut
D2321

F12846
F12847
S2112

14-0304
D2332
F1 2848

F12849
14-0254
14-1304
D2332

Washer J

'.

14-1303

...
...
...

D2321

Washer

...

...

14 -0126

...

Distance pieceL.H.
Distance pieceR.H.
Motor to frame centre bottom
Stud
Nut
Washer
J
...
Distance pieceL.H.
...
Distance piece R.H.
Motor fixing front
...
Bolt
...
Nut
...
Washer
J
Steady bracket motor to frame
...
Bolt
Bracket to frame ...
Nut

F1 3537

REMARKS

47

ClassicBike.biz

...

...

...

...

...

...

...

...
...

...
...

1
6
6
2
4

1
1
1
2
2
1
1
1
1
1

...

...

...
...
...

...

...
...

...
...
...

...
...

1
1

...

...

...

... 1

...

48

ClassicBike.biz

co

ob

LL

Ref. No.

Part No.

DESCRIPTION

EXHAUST PIPES AND


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

E12753
E12756
E10216
E8860
E6744
E6857
E6179
E7471
E7512
E3768
14-0217
14-1202

E9888
E2271
E3768
14-0219
S25-3
14-1302
E12382
E12282
14-0101
14-1301

MUFFLERS, TR6R, T12OR

Exhaust pipeL.H.
Exhaust pipeR.H.
Finned clip
Spherical washer Exhaust pipes to cylinder head
Bolt
Exhaust pipe stay
Screw
...
Nut
Clip
"D" washer
Exhaust pipes to coupling pipe
Bolt
...
Nut
Coupling pipe
Clip
"D" washer]
Exhaust pipes to mufflers
Bolt
q7 Washer
Nut
Muffler ...
Hangermuffler and pillion footrest
N ut

QUANTITY

Muffler to hanger

49

ClassicBike.biz

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

REMARKS

50

ClassicBike.biz

vi
oc
W
J
W
LL

bO
LL

Ref. No.

Part No.

DESCRIPTION

EXHAUST PIPES, MUFFLERS AND FOLDING


E11900
Exhaust pipelower
2
E11901
Exhaust pipeupper
3
E10216
Finned clip
4
E6744
Bolt
Exhaust pipe to cylinder head ...
5
E8860
Spherical washer
6
E6978
Exhaust pipe stay
7
14-0113
...
Bolt
8
S26-3
Spring washer
9
E7299
Clipupper
10
E5874
Cliplower
11
14-0116
Bolt
12
14-0219
Bolt
Exhaust pipes to connector
13
E3768
"D" washer
14
S26-3
Spring washer
15
14-1202
Nut
16
E9673
Connector
17
E2271
Clip
18
14-0219
Bolt
19
"D" washer
Connector to mufflers ...
E3768
20
S26-3
Spring washer
21
Nut
14-1302
Mufflerupper ...
22
E12019
Mufflerlower ...
23
E12020
Mufflerhanger
24
E12511
51822
Bolt
25
Mufflers to hanger
26
S26-3
4 Spring washer f

Bolt
27
14-0115
Hanger to frame ...
Spring washer
28
S26-3
51933
Spacer nut
29
Leg guard
E9680
30
Screw
51953
31
Washer
E9857
32
Leg guard attachment front
Clip
33
E9688
Bracket J
E9696
34
Screw
35
S1954
Washer . Leg guard attachment rear
E9857
36
Clip
37
E9688
38
E12851
-2F? 7 Crankcase undershield...
Hooked stud
39
52096
Nut
...
14-1301
40
Washer ...
41
D2320
FOLDING FOOTRESTR.H.
42
F13139
FOLDING FOOTRESTL.H.
42
F12856
Footrest hangerR.H.
43
F13140
Footrest hangerL.H.
43
F12858
...
Footrest pedal
44
F13092
...
Spring
45
F13095
Bolt
14-0216
46

Nut
14-1302
47
Footrest rubber
F9051
48
Bolt
51969
49
Footrest to frame
Washer
F8243
50

51

ClassicBike.biz

QUANTITY

REMARKS

FOOTRESTS, TR6C
1
1
2
. 2
2
1
3
3

1
2
2
4
2
2

1
2
2

1
1

1
1
2
2
2

2
2

6L41
3

q\\

X40

38

Lu

Fig. 19. TELESCOPIC FRONT FORK

52

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

TELESCOPIC FRONT FORK

1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
' 19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
42
42
42
43
44

45
46

H4080
FORK ASSEMBLY
H408q74080 FORK ASSEMBLY
Top Yoke ...
H4035
14-0234
Pinch Bolt ...
14-1303
Nut ...
...
E8084
Washer ...
F6738
Lock c/w 2 keys ...
D623 92-6738
Key (state serial No.)
S578
Grub screw
...
H2266
Sealing washer ...
H2270
Brake cable retainer
F8245
Starlock washer ...
H3682
Retaining bracket
Abutment ring ...
F12007
H4031
Taper roller bearing
Dust cover
...
H4028
Bottom yoke and stem
H4082
Pinch bolt
14-0238
Washer
E8084
Nut
14-1303
Stanchion
H4007
End plug
H4076
...
Main spring
H4087
H3954 v-fo8r Outer memberR.H.
H3952 q7- X033 Outer memberL.H.
Cap wheel spindle
H3947
Stud...
52102
Nut
14-0302
Washer
D2428
Drain plug ...
H3894
Washer ...
H3893
Damper tube and valve assembly
H4200/7"0" ringdamper valve
H4003
...
...
Recoil spring
H4009
Cap screw-damper tube
14-1019
Cap screw seal ...
H4004
Oil seal outer member ...
H4001
Scraper sleeve outer member
H4002
Top
cap nut
H4258
...
...
...
...
Washer
H4166
Steering stem nut (without steering damper)
H4029
...
Steering stem nut (with steering damper)
H4092
Headlamp bracketL.H.
H4058
Headlamp bracketR.H.
H4060
Headlamp bracketL.H.
H4088
Headlamp bracketR.H.
H4090
Nut
51809
Washer
D2338
Headlamp bracket top fixing
Bush
F12209
Spacer
F12211

Oaqe

gor

53
ClassicBike.biz

..

1
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

TR6C

Not TR6C
TR6C
2
2
4
2

X38
6

^o

,^ L
43

39

(^'

X13

45

46

X14

15

15
18

/ CMS

\\

48 42 49

50 19 1 8

^51
24

30
d

2^^
26

28
27^ 25

--35

BIB

---34
Fig.19. TELESCOPIC FRONT FORK

54

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

TELESCOPIC FRONT FORK


47
48
49
50
51
52

52062
Sleeve nut 1
D2333
Washer
(._
Headlamp bracket bottom fixing
D2630
Grommet r
F9046
Washer j
Nutdamper valve
H4012
F12216 g3-12/0 Clamp washer ...

55
ClassicBike.biz

2
2
2
2
2
4

10

4
I

77

Fig. 20. HANDLEBAR MOUNTINGS AND STEERING DAMPER

56

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
S589
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 (h x 1)

ClassicBike.biz

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

^
z

u,

58

ClassicBike.biz

O
N

N
N

z
0
Ix

U.

00
LL

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
D2594
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
...
Circli
R.H.
Grease retainerR.H.
Lock ringR.H. ...
Grease cap innerL.H.
Grease cap outerL.H.
L.H.
Circli
...
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

59
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

60

ClassicBike.biz

bO

LL

Ref. No.

Part No.

DESCRIPTION

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
REAR WHEEL COMPLETE ...

W3782
RIM SPOKES AND HUB ASSEMBLY
W3784
RIM (Wm 3 x 18) ...
W3724
Spoke (innerL.H.)
W3725
Spoke (outerL.H.)
W3726
SpokeR.H....
W2294
...
Nipple...
W3773
Hub and brake drum
W3468
Tyre security bolt...
W3749
Support ringL.H.
W653
...
Bearing
W3752
Locking ringL.H.
W3753
...
Spacer
W1654
Grease retainerR.H.
W3747
Sprocket 47 teeth
14-0207
Bolt
D2320
Washer . Sprocket to hub
14-1301
Nut
W3856
Brake anchor plate
W3872
Brake cam
W3877
Brake lever
14-1303
Nut
...
D2331
Washer
W3870
Brake pivot
Nut
}
14-0305
Brake pivot to torque arm
D2431
Washer
W3925
Brake shoe complete (leading) ...
W3926
Brake shoe complete (trailing) ...
...
W2328
Return spring (brake shoe)
W3880
Return spring (brake lever)
F12656
Brake torque arm
14-0133
Bolt
W2330
Washer Torque arm to frame
14-1304
Nut
...
Wheel spindle
W3965
...
W3750
Distance piece inner
D3213
Speedometer drive gearbox
...
W3746
Distance piece outer
14-1307
Nut
Wheel spindle
Fl 2266
Washer
W3751
Speedometer drive ring
Cover plate-swinging arm fork end
Fl 3082
W3742
...
Chain adjuster
Screw
14-0107
Chain adjuster
14-0301
Nut
D1841
Grease nipple
Fibre washer
WE170 83-n21

61
ClassicBike.biz

1
1
1
10
10
20
40

1
2

1
1

1
5
5
5

1
1
1

1
2

1
1
1
2

1
1
1
1
1
1
1
2
2
2
2

REMARKS

28

ri

16

17 -

--24
25^
f
B22

23

18 -f--^

4
23

Fig. 23. GAS TANKS AND TWINSEAT


62

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

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

F12996 g3F9062
F13021
51823
F13133
F10260
F13320
F13321
F13319
51999
D2330
F13318
F13068
F13134
F13135
F9700
F9701
F11339
F7888
F3220 83
F4048
F3217
F3221
F12800
F12801
E7351
F10002
F13634
F13637
F12867
14-0101
01
D2417
F9093
F13061
F12597
14-0604
14-1301
D2087
D2381

3 Gas tank (3 gall.)


Steady rubber
Mounting rubber
Centre fixing bolt
Distance tube ...
Mounting rubber
Washer ...
Rubber washer ...
Mounting ring ...
Nut
...
Washer ...
Beading holder
...
Grommet
Styling strip-front
Styling strip-rear
Tank motifL.H.
Tank motifR.H.
Screwfronttank motif
Screwreartank motif
cap
Joint washer
Jack chain
Clip
...
Gas tap ...
Gas tapreserve
Tap seal
Washer ...
Twinseat
Twinseat cover
Hinge ...
Bolt
}Hinge to twinseat
Spring washer

Rubber buffer

Catch assembly
Springcatch assembly
Screw

Twinseat catch fixing


Nut
Check wire
...
Screwself tapping ...

63
ClassicBike.biz

..
.

1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
2
2
1
1
2
4
4
5
1
1
1
1
1
1

TR6C
TR6C

64

ClassicBike.biz

H
J
W
z

0
U)

0
z
4
N
ac
W
z

W
J

4
N
00
LL

Ref. No.

Part No.

DESCRIPTION

QUANTITY REMARKS.

AIR CLEANER AND SIDE PANELS


Fl 3789
AIR CLEANER ASSEMBLYL.H. ...
F13790
AIR CLEANER ASSEMBLYR.H. ...
1
F12749
BodyL.H.
1
F1275
BodyR.H.
2
F12751
CoverL.H.
2
F12752
CoverR.H.
F13791
AIR CLEANER ASSEMBLYL.H. ...
F13792
AIR CLEANER ASSEMBLYR.H. ...
1
F12798
BodyL.H.
1
F12797
BodyR.H.
2
F12839
CoverL.H.
F12840
2
CoverR.H.
3
D3072
Element ...
4
14-0221
Bolt
5
F12799
Circlip
Cover to body
6
D2438
Washer
7
14-0302
Nut
8
D3539
Screw }
L. H. assy. to R. H. assy.
9
S501
Nut
1
0
14-0217
Bolt
}Air cleaner to frame
11
D2418
Spring washer
12
F12626
Connector pipe
13
F12625
Connector pipe
14
E11860
Carburetor adaptor
15
D3536
ClipJubilee type
16
F12502n-1673 Side panelL.H.
17
F1250483
7ide panelR.H.
18
F6673
Panel grommet ...

19
14-0201
Bolt
20
D2329
Washer . Side panel to air cleaner .
21
14-1301
Nut
Not illus. D2103
Transfer ...
Not illus. D2104
Transfer ...
Not illus. D2102
Transfer ...

5
10

F8245
14-0218
F9196

LATER MODELS USE THE FOLLOWING:Retainer ...


Bolt
...
Spacer (use with 14-0218)
...

65
ClassicBike.biz

... 1
... 1 1 Twin Carb
T12OR
1

1
1
1
1
1
2

Single carb.
TR6R, TR6C

2
2
All models
2
2
2
2
2
2 T12OR
... 1
TR6C, TR6R
1 or 2
1 or 2
1
1
2
4
...

4
2 T12OR
... 2
TR6C
TR6R
... 2

Ref. No. Part No.

DESCRIPTION

QUANTITY

REMARKS

FENDERS AND TAIL LAMP


I

1
2

3
4

5
6
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

1
1

H4260
...
...
A LA. Front fender
...
H4065 97 _g27o Front fender ...
...
...
H4022
Bracket
1
H4021
Rubber bush
Stay to fork leg
14-0103
Bolt
D2427
Spring washer
F13566
Rear fender
...
...
...
F13565
Rear fender
...
...
...
14-0114
Bolt
...
...
...
...
D2330
Washer ...
...
...
...
14-1302
Nut
...
...
...
...
14-0101
Bolt

...
...

...

...

...

...

...

...

...

...

...

"'
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

D2329
14-1301
F12768
14-0101
D2329
14-1301
F12727
F12728
14-0102
D2329
14-1301
F12786
D3313
14-6101
D2320
14-0101
D2427
F13213
57079
D2391
F4717
53973
54577109
144921
54525286
380

Washer Fender to fixing top and rear


Nut
Lifting handle ...
...
...
...
Bolt
Lifting handle to frame
Washer
...
Nut
...
...
...
...
...
Rear number plate'bracketL.H. ...
Rear number plate bracketR.H.
Bolt
Washer Number plate bracket to fender
Nut
Tail lamp support
...
...
...
Captive nut
...
...
...
...
Bol
support front fixing
Washer
Bolt
rail lamp support rear fixing
Washer f
Rubber beading strip ...
...
...
Reflector red (99-1162)
...
...
...
...
...
Washer ...
...
...
...
...
...
Nut
...
STOP AND TAIL LAMP 679 (99-0597)
Lens (99-1046)
...
...
...
Screw (99-1189) ...
...
...
Lamp base assembly
...
...
Bulb (99-0542) ...
...
...

H4270
H4271 N^G^

LATER MODELS USE THE FOLLOWING:Front fender


...
...
...
...
...
Front fender
...
...
...
...
...

67

ClassicBike.biz

...

...

1
1
4
44
4
I

1
2
2
2
3

...

...

...

...

...

...

...

...

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

...
... 2
... 2
... 2
... 1
... 1
... 4
... 4

...
...
...
"'
...
...

...
...

...
...
...

...

...
...
...
...
...
...
...
...
...

...

...

...

...

TR6R, T120R
TR6C

TR6R, T120R
TR6C

3
2
1

...

...

...
...
...
...
...
.:

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

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

...
...

...
...

...
...

"'

1
1
1
1
2
2

1
1

TR6C
TR6R, T120R

Ref. No.

DESCRIPTION

Part No.

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
21
22
22
23
24
25
26
27
28
29
30
31
32
33
34

...
...
H425297-700/ Handlebar
Sleeve, handlebar mounting ...
H1425
16/364 &70 / q TWISTGRIP (99-0248)
...
Body, top half (22-0245)
16/328
BODY, BOTTOM HALF (22 7QW)
16/329
Friction spring
16/008
Screw ...
16/009 62Z/0
Locknut
16/010
Rotor
99-0244
Screw
) ...
11/013
...
...
Grip
H95897-2 ar
Cable stop (99-0241) ...
16/011
...
...
...
...
H2124g72/YZ Grip
12/60860-3567 AIR CONTROL LEVER (D3246)
...
12/55 /-022e Lever
Bolt
12/607
Cap ...
12/606
Spring washer
12/033
Clamp
12/040
Screw
11 /01
126
...
D26286p 35n Front brake lever (alloy)
Front brake lever (steel)
D31430-3583
D26270-3657 Clutch lever (alloy)
D31440-36S7 Clutch lever (steel)
Pivot pin...
52048
...
Nut
14-1201
Adjuster
D3585
...
Lockring
D3586
HANDLEBAR SWITCHL.H.
39595
...
...
Switch half
54033666
...
Lever half (99-1215)
54340883
...
Screw (99-1188) ...
54115246
HANDLEBAR SWITCHR.H.
39596
...
...
Switch half
54033667
...
Lever half (99-1187)
54340882
Screw (99-1188) ...
54115246

21

D3583
D3648

21

83

LATER MODELS USE THE FOLLOWING:...


Front brake lever (alloy)
...
Front brake lever (steel)

69
ClassicBike.biz

1
4
1
1
1
Reference only
Reference only
Reference only
1
2
1
1
1
1
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
1
1
(TR6R)
1
1
(TR6R)
2
2
2
2
Reference only
Reference only
1

4
Reference only
Reference only
1

1
1

Ref. No. Part No.

DESCRIPTION

QUANTITY

REMARKS

CONTROL CABLES

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

3
4
5

Throttle cable
...
...
...
...
Throttle cable
...
...
...
...
...
...
Clutch cable
...
...
...
D30756O-3557 Front brake cable
...
...
W386737_399 Bushbrake cable stop
...
...
...
W386a37_3997Bush brake cable
...
...
...
...
Washer ...
E12500
...
...
...
...
Cable spring
W4014
...
...
...
Air control cable
D1 807
...
AIR CONTROL CABLE
...
D3485
...
Cable, lever to junction box
D1 818
...
...
Junction box (D685)
244/104
Cable, junction box to carburetor
D3486
TWIN ROTOR TWISTGRIP (99-0347)
313/13
...
...
Screw (99-0251) ...
18/084
...
Body, top half (99-0348)
313/020
BODY, BOTTOM HALF (99-0349)
313/021
...
...
Friction spring
16/008
...
...
...
Screw ...
210/007
...
...
...
Nut ...
5/077
...
...
Rotor (99-0344) ...
313/004
...
Rotor stop screw (99-0338)
210/008
Nutrotor stop screw (99-0224)
5/077
...
...
...
...
Grip
H2125
...
Cable clip
D978
Cable clip (pD-.0353 e Q.7
D343/7
...
Cover, front brake stop switch
D2086
...
...
...
Handlebar clip ...
H4112
D1 819
D1 806
D3079

D3557
W3996
W3997

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...

LATER MODELS USE THE FOLLOWING:


...
...
...
...
Front brake cable
...
...
...
Bushbrake cable stop
...
...
...
...
Bushbrake cable

71
ClassicBike.biz

...
...

...
...

...
...

2,
1

T120R
TR6C, TR6R

...

...

1
... 1

...

...

...

...

...

...

2
1
2

...
...
...

...
...
...

...
...
..

Reference only
Reference only
Reference only

6
6
1
4

TR6C, TR6R
T120R

T120R

Fig. 28. TOOLKIT, PILLION FOOTRESTS AND LICENCE HOLDER

72

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

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
...
Spanneropen ended
Box spanner
...
Ring spanner
...
Tyre valve key
...
Screwdriver
...
Tool tray
...
...
Bolt
...
...
...
Washer ...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

73
ClassicBike.biz

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
..

...
...
...
...
...
...
...
...
...
...
...
..

1
1
I

1
1
1
1
1
1
1
1
1

REMARKS

74

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

SPEEDOMETER AND TACHOMETER


1
2
3
4
5

SSM5007/00^i0ht
41-148-203-10
54959626
643
D3249

eedometer head (D2394) ...


...
Trip control (99-0176)...(0 0.-. 7011.
Bulb holder
...
...
...
...
Bulb (3W. MES)
...
Speedometer cable D F 9lld "O2

H4026

Mounting bracket

D2600

Rubber cu p

...

...

...

...
...

...

...

...
..

...
...

...
...
...

22
23
24
25

"'
D2391
Washer ...
...
...
...
...
...
E93317,-W3(p TACHOMETER GEARBOX (E5758 Body)L.H.
E9332
Securing screwL.H. thread, U.N.
...
Reference only
Bush ...
...
...
...
...
Reference only
Flanged bush ...
...
...
...
E5157
Driving gear
...
...
...
...
E5759
End cap
...
...
...
...
...
E6300
"O" ring ...
...
...
...
...
E5578
Driven gear
...
...
...
...
E6122
Driven gear housing
...
...
...
E6299
"0" ring
...
...
...
.,.
Reference only
Bush ...
...
...
...
...
"0" ring
...
...
...
...
E330960-3530
E5881
Set screw
...
...
D3282
Tachometer cable
D.eF 1&/ /O. yf 3 ...
RSM3003/13
Tachometer (D2396) 6
...
..7/7/...
...
...
...
...
31-371-398
Spade (99 -0173
D494
Circlip ...
...
...
...
...
...
Sealing washer ...
...
...
...
...
E7351

...
...
...
..
...
...
...
...

...
...
...
...
...
...
...
...

1
1
Reference only
... Reference only
... 1
f1 TR6C,
2 T120R, TR6R
1 TR6C,
2 T120R, TR6R
2 or 4
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1
TR6R,
... 1
T120R
... 1
... 1
... 1
... 1
... 1
... 1
... 1
... 1

Not illus.

D546

...

...

...

Not illus.

8
9
10
11
12
13
14
15
16
17
18
19
20
21

G ..

Blanking plug (replaces tacho bulb holder)

75

ClassicBike.biz

...
...
thread
...
...
...
...
...
...
...
...
...
...
...
...
...
...

Fig. 30. COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORD

76

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

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


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

F12571
14-0101

Mounting platformelectrical components...


...
...
Bolt
...
...
D2329
Washer Platform to mudguard
Nut
14 -1301
...
...
Grommetcoil mounting
F9561'
2
Ignition coil (17-M-12 (D2206 g5Q'Z ,03
45223
...
Rectifier (99-0589)
D.-O7o ...
49072
...
...
...
...
...
...
Nut
F5338
...
...
...
CAPACITOR
PACK-2CP
47638
...
...
...
Capacitor
(99-4043)
54420128
...
...
Cover
(99677)
54418528
...
...
...
Base
plate
(99-4466)54418526
Bolt
F10033
GS2996O-423'6 Shakeproof washer Capacitor pack to platform
Nut
F3799
...
...
...
Flasher unit (99-120 ...
35048
...
...
Clip, flasher unit (99-1204 ...
54385091
...
...
Spring
D3614
I
Bolt
F10033
...
Flasher unit to platform ...
Washer
..

E2251
Nut
F4717
...
Zener Diode (99-0590) 6O O?87.
49345
...
...
...
...
Sparking plug ...
N3
...
...
Plug cover (Champion WC200)
D262
...
...
...
Horn-6H (99-4246) ...
70216
Bolt
...
...
...
14-0102
...
...
...
D239383 -9277 Washer Horn to frame
Nut
14-1301
...
...
...
Lucar black terminal ...
54190038
...
...
Reflector-amber (99-1161) ...
57183
Washer
.
D2391
...
Reflector mounting
Nut
F4717
...
Mounting rubber J
F13522

...

...

...

...

...

"A
ClassicBike.biz

...

...
...
...

...
...
...

...
...
...

1
1

1
1
2
2

...

...

...

...

...

...

...

...

... 1

...
...
...
...
...
..
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...

...
..
...

...
...
...

...
...
...

...
...

...
...

...
...

...

...

...
...

...

...

...

...

...

...
...

2
2
2
1

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

...
...
...
...
...

...
...
...
...
...

...

...

...

...
...
...
...
...

...
...
...
...
...

...
...
...
...
...

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

78

ClassicBike.biz

U.

4
I

4
LL

Ref. No. Part No.

DESCRIPTION

QUANTITY

REMARKS

HEADLAMP AND FLASHER LAMPS

...
wire (99-0683)
Screw
...
144921
5
Plate
534296
6
Main bulb (45/35W) (99-1214) ...
370
7
Bulbholder
554602
8
Pilot bulb (99-0548)
989
9
...
Pilot bulbholder (99-1213)
10
54573590
Warning
light
(Red)
(99-1208)
54363454
11
Warning light (Green) (99-1209)
12
54363455
Warning light (Amber) (99-1207)
54363453
13
...
Sealing washer (99-1210)
54140331
14
...
Light
switch
(99-1211)
31276
15
...
...
...
Shield, warning light
54525212
16
...
Bulb, warning light (99-0537) ...
281
17
Screw, headlamp fixing (99-1223) q7az
54115106
18
...
Washer, headlamp fixing (99-1224)
143086
19
...
...
...
1222)
Wiring harness
Not illus. 54959629
IGNITION SWITCH (TYPE 149 SA) (99-1200)
39565
20
...
..
...
Nut ...
54130041
21
2'698/...
IGNITION
LOCK
C/W
KEY
F6981
5V33V69
22
Key (state serial number)
D622 $y335/69
23
...
Cover,
ignition switch
H2262
24
FLASHER
LAMP
(99-1190)
56147
25
1) ...
Lens (
54581638
26
...
Gasket
54580300
27
...
Bulbholder
554548
28
Interior
assembly
...
473832
29
...
Bulb (99-1192)
382
30
...
...
Screw
(99-1193)
...
54123401
31
)
...
Stanchion,
flasher
lamp(
54582414
32
...
Washer (99--4446)
143086
33
...
)
Locknut
(
1981721
34

H4247
H42486
F13525
14-0404

LATER MODELS USE THE FOLLOWING:


Flasher mounting bracket
ZFront stanchion
2Rear stanchion ...
Nut (inside headlamp)

79
ClassicBike.biz

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
2
8

1
2
2
2

N^

cc

/1

^O'

r--

N/

i^

7:

\C

80

ClassicBike.biz

t2

N
N

0
I

U
IF

z
W
H
H

00
LL

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

BATTERY AND TR6C HEADLAMP


1
2
3
4
5
6
7
8
9
10

F12512
F8091
F8255
F9353
F13849
F13295
F12508
F6039
14-1301
54027029
11
60262
534343
12
54525272
13
504665
14
370
15
54573590
16
989
17
554602
18
Not illus. 54115106
Not illus. 143086
31272
19
153631
20
144921
21
534296
22
54363454
23
281
24
54363455
25
54140331
26
54363453
27
54525212
28

Battery carrier
...
Carrier tray
Protective strip
Retaining strap ...
Buckle ...
Protective strip
Shoulder screw
...
Battery carrier mounting
Rubber bush
Nut
...
) GP- ??. re...
BatteryPUZ5A (
1 )
HEADLAMP ASSEMBLY MCH 66 (
...
Rim (99-0691)
...
Light unit (99 011} ...
...
Fixing wire (99-0683) ...
Bulb (45/35W vertical dip, pre-focus 99-1214)
...
Bulbholder, pilot ( -0695)
...
Bulb (3W.M.C.C. 99-0548)
Adaptor caw leads (99-1003) ...
...
Screw, lamp fixing
...
Washer (99-1224)...
Lighting switch (.=-063}
Nut for lighting switch ...
...
...
...
Screw
8.7
Plate (99-0690)
Warning light, red (99 1200)
...
Bulb (2W.BA75) (99-0537)
Warning light, green (99-1209)
Sealing washer (99-1210)
Warning light amber (99-1207)
...
Warning light shield

81
ClassicBike.biz

...

1
2
1
1
11
3
3
1

1
1
1
6
1
1
1
2
2
2
1
Reference only
Reference only
1
1
2
1
3
1
Reference only

STANDARD HARDWARE SPECIFICATION


BOLTS
Part No.
S1822
S1910
S1919
S2010
14-0101
14-0102
14-0103
14-0113
14-011
14-0115
14-0128
14-0208
14-0216
14-0217
14-0219
14-0220
14-0225
14-0228
14-0234
14-0236
14-0239
14-0240
14-0242
14-0251
14-6102
14-6115

Material
Steel

Length under
head
-z'

Thd. dia.
6" UNF
e" UNF
6" UNC
4 " UNF
4" UNF
4" UNF
4" UNF
16" UNF
6"
UNF
1
6" UNF
8" UNF
4" UNF
16" UNF
16" UNF
16" UNF
16" UNF
16" UNF
16" UNF
8" UNF
UNF
8" UNF
8" UNF
e" UNF
" UNF
4" UNC
6" UNC

Min. length
of thread

64"

-6"
18"

e"

""
16

g'"

2"
8"
;"

8"
4"
8"
1"
24"
18"

14"
12"
14"
3"
4"
14"
24"
3"
34"
4"
24-"

."

8"
8"
8"
8"
8"
8"
1"
1"
1"
1"
1"
14 "

8"
8"

Hexagon A.F.
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"
0.500"
0.563"
0.563"
0.563"
0.563"
0.563"
0.625"
0.438"
0.500"

NUTS
Part No.
S778
S1852
S1906
S1908
51914
S2012
S2013
S2014
14-0301
14-0302
14-0401
14-0402
14-0403
14-0701
14-0702
14-0703
14-1201
14-1202
14-1301
14-1302
14-1303
14-1304
14-1305
14-1902
1 4-1903

Material
Steel

Thd. dia.
No. 10 UNF
16" UNF
a'-" UNF
- " UNF
4" UNEF
-g4-" UNEF
4" UNEF
4" UNEF
,'-" UNF
6" UNF
4" UNF
16 "UNF
8" UNF
a'-" UNF
6" UNF
e" UNF
4" UNF
16" UNF
4" UNF
6" UNF
e" UNF
6" UNF
'-z" UNF
. " UNF
a" UNF

Hexagon A.F.
0.375"
0.437"
0.438"
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"
82

ClassicBike.biz

Thickness
0.225"
0.330"
0.188"
0.313"
0.250"
0.438"
0.313"
0.438"
0.224"
0.271"
0.161"
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"

Remarks
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.

S1916
51917
S1918
S1920
S1929
S2079

1
1
1
1
1
1
1

0604
6505
607
6608
609
7019
7024

Type of head
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

Material

Thd. dia.

Steel

1" UNC
1"
4 UNC
4 UNC
i" UNC
4 " UNC
No. 10 UNF
1"
4 UNF
4 UNC
1"
4 UNC
k" UNC
k" UNC
*" UNC
6 UNC
4

i"

/9

i"

It

71

,t

"

Length under head

1f"
21"
28"
624"
1 70
32

1
2

III

8
ill

1"

w
f"
2"

Type of drive
Cross recess
Cross recess
Cross recess
Slot
Pozidrive
Cross recess
Cross recess
Cross recess
Cross recess
Cross recess
Hex. socket
Hex. socket

WASHERSPLAIN
Part No.

Material

i/dia.

o/dia.

Thickness

525-1
S25-2
S25-3
S2
S25-13

Steel
Steel
Steel
Steel
Steel

0.273"
0.398"
0.336"
0.531"
0.266"

0.563"
0.750"
0.625"
1.031"
0.469"

0.048"
0.063"
0.063"
0.092"
0.064"

WASHERSSPRING
Part No.

Material

i/dia.

S26-1
S26-2
S26-16
S648

Spring Steel

1" clearance

o/dia.

H"
13
32

1"
4 clearance
/,

211

1 70
32

8
1
2

*" clearance

** Double coil.

83
ClassicBike.biz

o/a height
7 II
3
32
3 /I
16
7N
32
50
3-1

Thickness

0.104"
0.064"
0.040**
0.080"

Ref. No.

DESCRIPTION

Part No.

QUANTITY

PARTS REQUIRED FOR 5 SPEED GEARBOXOPTIONAL


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

...
Crankcasetiming side
E12791
...
...
...
Oil seal ...
D3500
...
...
...
Cover plate
E3789
...
...
High gear bearing
D3493
...
...
...
Oil seal ...
D3512
...
...
Gearbox cam plate
T4360 57 7
Selector forkM/S 4th gear ...
T4364
Selector forkL/S 3rd gear ...
T4366
Selector forkL/S 1st gear ...
T4368...
...
T437237 St7i M/S High gear ...
...
Needle roller bearing ...
D3511
...
...
...
Oil seal ...
D3500
...
...
...
Main shaft
T4432
...
...
M/S 4th gear ...
T4376
...
...
M/S 3rd gear ...
T4377
...
M/S 1st and 2nd gear ...
T4380
y
...
...
...
Layshaft ...
T4371 ,S7 ?

...
...
...
O0 L/S 4th gear
T43845
...
...
...
Circlip ...
D3494
...
...
T4383 5?a47 L/S high gear ...
...
...
...
L/S 3rd gear
T4387'
...
...
...
L/S 2nd gear
T4388*
...
...
...
L/S 1st gear
T4391-'
Q Circlip
...
...
...
...
D3494 57 ?9
...
...
...
Driving dog
T43813
...
Gearbox inner cover ...
T4407
...
...
...
Leaf spring
T4402
uadrant
...
...
...
Q
T4363
...
...
Plunger quadrant
T4374Y0$'
...
...
...
Plunger ...
T4403
...
Gearbox sprocket-19T
T4397
...
Gearbox sprocket-18T
T4398
Locknut
...
...
...
...
T4396
...
T4395 74o Locking washer

(7

USN CI? Q, TI

England by
Printed
Warwickin Printing Co. Ltd., Warwick

9'?- 3

'0

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

2 (otvsr &-

84
ClassicBike.biz

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

1
1
I
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
I
1
I
1
1
1
1
1
1
2
1
1
1
1

t'& O ,45 K'%)

REMARKS