.... ~ '19:%2 -MCDELS ~ .

, 4Ccu.1N. -[65Cc.c.J - ,,.,. - BONNEVILLE T'l20 R I T'l20 R ~ r

JIGER 650 TR SR, TR SRV TROPHV650 TR6C1TR6CV

U.S.A. EDITION - • * - • ... ---- - a~- -- * .,.. _____ __.

REPLACEMENT PARTS CATALOGUE FOR 1972

BONNEVILLE Tll0R, Tll0RV

TIGER650TR6R, TR6RV

TROPHY 650 TR6C, TR6CV

TRIUMPH ENGINEERING COMPANY LIMITE D

MERIDEN WORKS · ALLESLEY • COVENTRY CVS 9AU · EN GLAND

TELEPHON E COVENTRY 10lll MERIDE N 331

PUlltSHEO AUGUST 1971

ht; - == C

TELEGRAMS " T RUSTY" COVENT RY TELEX 0 T RUSTY" lUOS

AIR CLEANER .. . ALTERNATOR .. . AUTO-ADVANCE UNIT

BATTERY CARRIER ... BRAKE SWITCH BREATHER PIPES

Page

67 ... 11, 43

31

83 47 45

CAMSHAFT, INLET AND EXHAUST 11 CARBURETOR ... 27, 29 CARTON PACKS 7 CENTRE STAND 45 CHAINS. .. 43 CHAINCASE •3 CLUTCH •1 CLUTCH LEVER ASSEMBLY 39 COIL 79 CONDENSER PACK . .. 79 CONNECTING RODS 11 CONT ACT BREAKER . . . 31 CONTROL CABLES .. 73 CONTROL LEVERS .. . 71 CRANKCASE . .. . .. 13, 15 CRANKCASE UNDERSHIELD 53 CRANKSHAFT .•. 11 CYLINDERS . .. 19, 21, 23, 25 CYLINDER HEAD ... 19, 21, 23, 25

EXHAUST PIPES

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

GAS TANK GEARBOX

HANDLEBAR

... 51, 53

69 37

79, 81 . . •9, 53

45 55, 57

61

65 ... 33, 35, 37, 39

HANDLEBAR MOUNTINGS ... HEADLAMP

71 59

. .. 81, 83 79 HORN ...

INDEX

3

KICKSTARTER .. .

MANIFOLD MOTOR PLATES MOTOR TORQUE STAY MUFFLERS

•

Page

39

17 49

•9 .. 51, 53

OIL PU~ 17 OIL PIPES • ... 4S OIL PRESSURE RELEASE VALVE .. . 17

PISTONS PROP STANO PUSH RODS

REAR WHEEL ... RECTIFIER ROCKERS

11 45

. .. 19, 21, 23."2S

63 79

. 19, 21, 23, 25

SIDE PANEL 67 SPARK PLUG 79 SPEEDOMETER ... 77 SPEEDOMETER GEARBOX .. 63 STEERING DAMPER ... 59 SUSPENSION UNITS . 47 SWINGING FORK •7 SWITCHES 71, 81

TABLE OF STANDARD HARDWARE 84 TACHOMETER .. . 77 TACHOMETER GEARBOX .. 77 TAIL LAMP 69 TAPPETS 17 TIMING GEARS 11 TOOLKIT 75 TWIN SEAT 65

VALVES .. . VALVE GUIDES

WIRING HARNESS

ZENER DIODE ...

. .. 19, 21, 23, 25

.•. 19, 21, 23, 25

81

79

::,...a,_;;;-

T I G E R 6 5 0 (T R 6 R) (T R 6 R V - S S P E E D) T E C H N I C A L D A T A

Bore a nd Stroke

Capacity ... Compression ratio Spark plugs Carburet or

Gearbox sprocket Chains

Capacities

Brakes

Tire size

Main jet Needle Jet Throttle valve

Front Rear

... Gu Tank Oil Tank Gearbox Primary Chainc:ase Pn mary Chaincase Front Forks (each leg) ... Front. diameter ... Rear, diameter Front Rear

4

71 82 mm. 2-79 3·23 ins.

649 c.~. (40 cu. ins.) 9: 1

Champion N3 Amal Concentr ic 930

230 ·106

No. 3½ 19 teeth

1· Duplex 84 links ¼' i ' 106 links

3·6 U.S. galls. 4·8 U.S. pints.

t pi nt (500 c.c.) ¼ pint (150 c.c.)

¼ pint (1 SO c.c.) ½ pint (190 c.c.) 8" (20·32 cm.) 7" (17-78 cm.)

3-25 19 1-00 18

-

T II OP HY 6 5 0 (TR 6 C) ( T 116 C -5 S P E E D ) TE C H N IC AL DAT A

l!lco-e and stroke ...

Czpz •c, C = LQZ as.ion ratio

Gwboi sprod(et

Cu.ins

Brakes

Tires.in

Main 1e· Needle io,:

Thrott ~

Front Rear

Gas Tar. Oil Tani Gearbo,

Rear, d ... ~eur

Front Rear

s

71 x82 2-79 X) ?J

649 c.c. ('40 ca -.

9 t Cham N3

Amal Co•ra=ic ,30 2JZ -1:15

Ji 18(-1,

i " Dupk,< X 8-< -b rx1·x106 ks

3-6 U s.,.ri.. 4,8 US. p,=

t 500 c.c.) ¼ (150 c.c.) ½ pm (1~ Cc.)

e· (20-n an) 7" (17-78 cm.)

3·25x 19 ~00 X 18

BONNE VILL E T Ila: T110 RV - S SPEE D TECHNIC AL DATA

Bore and stroke

Capacity Compression ratio Spark plugs Carburetors

Gearbox sprocket Chains

Capacities

Brakes

Tire size

.. ... valve

- --~- Chalncase km& forks (each leg)

d ameter . .. .: ameter

6

.,.1 82 mm. 2 79 3·23 Ins.

6-'9 c.c. ('40 cu. ins.) 9 : 1

Champion N3 2 An a Concentric 930

190 ·106

No. 3 19~

i Duplex 8• links l i' 106 links

3·6 U.S. galls. 1·8 U.S. pints.

¾ pint (500 c.c.) ¼ pint (150 c.c.) ! pint (1 99 c.c.) 8. (20-32 cm.) 7' (17·78 cm.)

3.25 19 •·00 18

•

• HOW TO USE THIS SPARE PARTS CATALOG

consu t the index on Page 3 for located the parts make sure from

e

group of paru wh ch you w. Cllll,,mns that the part you have oat

':er ·•2 pairs'' or "3 doz.en".

--.o Painted paru are available only in the cc!ton

Liu the quantttles required as single

In case or pal nted Items always state t or alcernatives specified for that mod< ol -=.,.u·

Part Ne.

r:

2

16

2

16 ...

C A aTO

e with rings, gudgeon

a!looe p;su,ns are available In ove

Vahe C-s t

C P.97

(TR6)

2

2

•

• ...

P ACK LIST

7

~: <S under the C.P part number "•ted. The teriorate under adverse condJtions.

CA.

CA.

Brake lining

Rivet

Brake I 11ng

Rivet

.. For use .. t .,_

Standard

Compe,,r 0<1

0-020 Ins., 0·040 ins., (0·25

•

Inlet guld«

Exha,.,s:

1

•

14

33 31 31 32 35

- 11

9

I 34 30

36 13

29 27 26

~ 12

# 28

2

@ . li .,.~C ~ 5

8 39 . ' 20 21 22 23 24 25 8 1

Fi1. I. CRANKSHAFT AND CONNECTING RODS

10

Ref. No. Port No.

1 E1305• 2 E13097 3 E3903 4 E12800 5 E12425 6 •E12799 7 E11003 8 E311• 9 E9525

10 E1511 11 E6576 12 D3761 13 E3586 14 E9•88 15 E686• 16 E6865 17 E6861 18 E6869 19 E3835 20 E12662 21 E4573 22 E10082 23 5•213901 2• E3975 25 E39n 26 E1580 27 E4564 28 E128n 29 E6159 30 E•OO 31 E12719 32 E1558 33 E11007 34 E6523 35 E11063 36 E9989 37 E9988 38 E3300 39 E2879 Not illus. E12663 Not illus. E8038 Not illus. E12660

•

DESCRIPTION QUANTITY REMARKS

CRANKSHAFT AND C ONNECTING RODS

CRANKSHAFT AND FLYWHEEL ASS EMBLY (METRIC) CRANKSHAFT C{W. OIL TUBE

Oil tube Screwed plug

Flywheel .. . Flywheel bolt Washer Crankshaft stud (1i in. 0.A.)

CONNECTING e.oD ... ;; 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 (shore) Circllp

Main bearing, right (metric) .. . Motor sprocket, 29 teeth Duplex Distance piece .. . Rotor key Rotor (99-0739) Tab washer Nut Key Timing pinion ... Nut INTERMEDIATE WHEEL

Intermediate wheel bush ... Camshaft pinion .. . Camshaft key .. . Inlet camshaft nut Exhaust camshaft nut Inlet camshaft, . .. EXHAUST CAMSHAFT

Tachometer drive plug Clamping washer Main bearing, left (metric)

Spacer } Shim (0·010 in.) Engine sprocket Shim (0·030 in.)

1 1

1 1 3 3 1 2 2

• • 4 2 4 2 2 4 1 1 1 1 1 1 1 1 1 1 1 1 2 2

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

• Use DSH Loctite Sealant

N.B. Crankshaft main bearings and journals are graded "x" or "y". The appropriate grade bear, ng must be fitted onto a similarly marked crankshaft.

11

25

. r ·

54 53 55

42

/

50 ~

46- 25

19- ~

1p 14

30

4

40

41 B2

r Fig. 2 CRANKCASE

12

Re(. No. Part No. DESCRIPTION QUANTITY REMARK5

CR ANK C A SE - 1 E11266 CRANKCASE DRIVE SIDE 2 E10287 Camshaft bush 3 E10287 Camshaft bush ... 1 4 E5976 Chain tensioner abutment 1 5 E13098 CRANKCASE TIMING SIDE 1 6 E10286 Camshaft bush ... 2 7 E•538 Scavenge pipe Reference only 8 E6386 Locating peg (at oil pipes) ... Reference only 9 T989 Hollow dowel ... 2

10 T912 Locating peg (L/S at thrust washer) • .. ,.,. 1 11 T1606 Needle roller bearing, layshaft .. . ... 1 12 E375 Intermediate wheel spindle - 1 13 E8751 Hollow dowel ... 1 1• E3716 Hollow dowel 1 15 S1873 Screw 2 16 H -144S Stud 1 17 S25-2 Plain washer 2 18 1-4-0303 Nut ... 2 19 E1S32 Hollow dowel, tappet oil feed 2 20 E9330 Oilway plug 21 F1880 Copper washer .. . 22 S1871 Tachometer drive plug (L.H. thread) 23 E8896 Fibre washer 2 2• S1863 OIi pipe stud ... 1 - 25 S1865 Cyl inder stud ... 8 26 S1872 Plug, timing hole 1 27 S1870 Bolt 1 28 1•~220 Bolt 1 29 1•~223 Bolt 1 30 1•-0230 Bolt 1 31 S1823 Bolt 2 (TR6C 3 off) 32 02330 Plain washer ... 10 (TR6C 7 off) 33 14-1302 Nut s (TR6C 4 off) 3• E9336 Crankcase filter ... 35 ES315 Joint washer 1 36 TI167 Drain plug (with level tube) ... 1 37 T1257 fibre washer 1 38 SS43 Level plug UN ... 1 39 E2441 Copper washer .. . 1 40 T2259 Drain and adjuster plug 1 41 T1738 Fibre washer 1 42 T1920 Blanking plug 1 43 TI166 FIiier plug UN 2

• 44 E8782 "O' ' ring 2 45 1~242 Bolt 1 46 S669 Stud 1 (Except TR6C) 47 E8892 Protection blade 48 14-1301 Self locknut UN 1 49 E7573 Rubber plug (for protection blad~ stud hole) 1 ,-. so 14-0402 Nut, exhaust ties .. 2 (Except TR6C)

' 51 E11072 Breather cover plate assembly 1 ,.. 52 E1107S Screw 1

13

54 53

30

4

' 55

..., , ? ✓ / ,

, • ~

25

_ ,

~ 49

-~48

~~ 47

41 ~ 40

B2

Fig. l CRANKCASE

14

(

5

r-Re(. No. Port No. DESCRIPTION QUANTITY REMARKS

or P -- CRANKCASE (continued)

S3 E933S Out/et stub 1 S4 E11460 Joint washer 1 ss E11077 Screw 2

S6 E11078 Tube, primary chain oiler 1 S7 E4705 Clip 1 S8 S26-2 Spring washer ... 1

S9 14-0101 Bolt (-h In. U.H.) 1 60 E1H4S Grommet, alternator leads-external

• ~

,,.,.,...-....

15

a = e __, , ,., '

4

Assy 1

12

11

6

7

8 -

20

22

I 21

23

24

28

..

% iP

I 0 I 5 ;&

3

-2

10

J

9

'-------------- 15

16

17

13

25

r, ~ 14

26 27 30

29

• I 83

Fis. 3. OIL PUMP, RELEASE VALVE, MANI FOLD ANO TAPPETS

16

Ref No. Part Na. DESCRIPTION QUANTITY REMARKS

~ 01 L PUMP , RELEA S E VALVE , MAN I FOLD AND TAPPET S

1 E9•21 OIL PUMP 1 2 Reference only Pump body ... ... 1 3 E9269 Feed plunger 1

• E6681 Scavenger plunger 5 E•95 Drive block 1 6 S70-7 Valve ball (n in. dia.)

' 2

7 E•03 Valve spring < 2 8 E2360 Screwed plug 2 9 E11•61 Joint washer • 1 ."' ...

10 S1684 Oil pump stud ... 2 11 E3887 Serrated washer -

' 2 ... 12 S1906 Nut

"i/-ii/o.: 2

13 •-El'2l~/-22/o Oil release valve 1 14 E1670 Fibre washer 1 15 S1876 Stud • 16 E5660 Joint washer 2 17 E9973 Inlet manifold 1 18 S25-13 Plain washer ... • 19 S1877 Nut 4

TR6 20 S1996 Stud 2 21 E9555 Cup ... 2 22 E955• "O" ring .. 2 23 14-1301 Nut 2 24 E9352 Inlet tappet guide 25 E9353 Exhaust tappet guide 1 26 E2#1 Copper washer ... 2 27 H200 Set bolt ... 2 28 E3059R Inlet tappet 2 29 E8801 Exhaust tappet 2 30 E7563 ·o· ring 2

• EARLIER MODELS USE THE FOLLOWING:-

E6595 Oil PRESSURE RELEASE VALVE E7590 Body 1 GS251 Piston 1 E7591 Spring 1 E6596 Cap ... 1 E9738 Joint washer (cap to body) 1

17 •

,

•

I ~ 1

r r 40 43 35 36 39 34

17

~! 16~

---\\-· 1--\ 13-----<G

23

1 -

Fis. •· CYLIND

46

~ 54 CS>-53 6--52

r 24 42

e-28 (C).. 27

~B4 ~-

ER BLOCK AND HEAD, TR6R, TR6C

32

56

l C>,---- 6A

~6

~.J-49 9-so

55

Ref. No. Port No. DESCRIPTION QUANTITY REMARKS

CYLINDER BLOCK AND HEAD, T R6R, TR6C

1 E6309 Cyll nder base washer .. 2 E6304 Cylinder block .. . 1 3 S692 Cylinder base nut 8 4 E2620 Push rod 4 5 E12575 Cover t ube 2 6 E7310 "O" ring, push rod cover tube (bottom) .. . 2 6a E11283 "O" r ing, push rod cover tube (top) .. , 2 7 E4547 Cylinder head gasket .. . 1 8 E12806 CYLINDER HEAD c/w GUIDES • 1 .. ... 9 - E2899 Inlet valve guide . .. 2

10 - E2900 Exhaust valve guide • 2 11 E4603 Inlet valve 2 _/A .. 12 E2904 Exhaust valve ... 2 13 E6439 Bottom cup 4 H em1 Inner valve spring (red spot) ... 4 \ 15 E7'400 Outer valve spring (green spot) 4 16 E1543 Top collar 4 17 99--0063 Split cotter 8 18 E327 Cylinder head bolt 4 19 F2184 Plain washer 4 20 E4771 Bolt ... 1 21 S25-3 Plain washer 1 22 03548 Sealing ring 2 23 E12569 Inlet rocker box 1 - 24 E12570 Exhaust rocker box 1 25 E12S99 Jo~ washer ... 2 26 S1875 , Rocker box bolt 4 ) 27 14-0301 Rocker box nut ... 6 28 E3302 Plain washer 6 29 1-4-1401 Rocker box stud 6 30 S25-13 Plain washer 4 31 14-1435 Cylinder head stud (for torque stay) 2 32 E12572 Inspection cover 4 33 E12574 Joint washer 4 34 EH57 ROCKER (right exhaust, left inlet) ... 2 35 EHSB ROCKER (left exhaust, right inlet) ... 2 36 E10070 Rocker ball pin ... 4 37 E1513 Rocker adjusting pin 4 38 E470 Adjuster lock nut 4 39 E157S Thrust washer, { In. 6 40 E1574 Spring washer ... 4 41 E1512 Rocker spindle .. 2 42 E12361 Dowel, rocker box 4 43 E1330 Thrust washer, t in. . ,. 2 44 E12079 Access plug 4 45 E12080 Washer ... 4 46 E12888 Bolt, cylinder head ... 4 47 E128~9 ~ Bolt, rocker box 4

19

-

~-~~~•1"'i

[a~ [~,. 39

Fig. 4.

46

e-s4 <S>-53 e-s2

7

1--~-· CYLINDER BL OCK AND HEAD • TR6R, TR6C

20

6A

5

-... _.. '

Ref. No. Port No. 0£SCRIPTION QUANTITY REMARKS

CYLINDER BLOCK AND HEAD , TR6R, TR6C (continu ed )

-48 E12598 Spacer ... 4 49 E4752 Sealing rl ng 2 50 E11707 Sleeve 2 51 D2332 Washer ... 4 52 E12597 OtStance piece } 2 53 D2331 Washer for torque stay 2 54 14-1303 Nm ... 2 55 14-0103 Screw } 8 56 D2329 W h Tappet Inspection cover

8 as er 1 • ..

•

r 21 --

23

2

1-

9- - 64 S- - 63 e)- --62

57 29

41

Fig, 5, CYLINDER BLOCK AND HEAD, Ttl0R

22

4

c::;) - 6A

- 5

•

BS

Ref. No. Port No . DESCRIPTION QUANTITY RE.MARKS

........ CYLINDER BLOCK AND HEAD , T 120 R

1 E6309 Cylinder base washer . .. 2 E630• Cylinder block .. . 1 3 S692 Cylinder base nut 8 • E2620 Push rod 4 5 E12575 Cover tube 2 6 E7310 " O" ring (bottom) 2

6A E11283 "O" ring (top) - 2 7 E45•7 Cylinder head gasket 8 E12807 CYLINDER HEAD c/w GUIDES , 1 9 E5347 Sleeve for head bolts passing through inlet tracts Reference only : • • • 10 E3827 Inlet valve guide ... ... .. . "· ... 2

11 E3828 Exhaust valve guide ... ... 2 12 - E12811 Carburetor adaptor, left 1 13 E12812 Carburetor adaptor, right 1 1• E6916 Connector ... 2

" 15 E4792 Balance pipe • 16 S2813 Stud .. . 4 17 E8771 Gasket 2 18 14-1301 Self-locking nut 4 19 E9555 Cup ... ........ _ • 20 E9554 Insulating ring . ..

4 ... 21 E•603 Inlet valve 2 22 E2904 Exhaust valve 2 23 E6439 Bottom cup • 2• E4221 Inner valve spring (Red spot) • 25 E7•00 Outer valve spring (green spot) 4 26 E15•3 Top collar 4 27 99-0062 Split cotter 8 28 E327 Cylinder head bolt 4 29 F218• Plain washer • 30 E4771 Bolt 1 31 S25- 3 Plain washer 1 32 D35•8 Sealing ring 2 3l. E12569 Inlet rocker box 1 r J4 E12570 Exhaust rocker box 1 35 E125'J9 Joint washer 2 36 S1875 Rocker box bolt • 37 1•-0301 Nut 6 38 E3302 • Plain washer 6 39 H-1401 Rocker box stud 6 40 S25-13 Plain washer • 41 14-1435 Cylinder head stud (for torque stay) 2 42 E12572 Inspection cover • 43 E12574 Joint washer 4 4• E1457 ROCKER (right exhaust, left Inlet) ... 2 45 E1458 ROCKER (left exhaust, right Inlet) 2 •6 E10070 Rocker ball pin • •7 E1513 Rocker adjusting pin 4 •8 E470 Adjuster lock nut • •9 E1575 Thrust washer, ½ In. 6

r4 50 E1574 Spring washer ... •

'"' 23

23

33

2

3-

1--

e- -64 <S> 63 el--62

57 29

41

Fis, S. CYLINDER BLOCK ANO H EA D, T120R

....

4 .

C) - 6A

5

85

Rt(. No. Port No. DESCRIPTION QUANTITY RE.MARKS

CYLINDER BLOCK AND HEAD , T 1 2 0 R ( cont i nued )

51 E1512 Rocker spindle ... 2

52 E12361 Dowel, rocker box .. " 53 E1330 Thrust washer, i in. 2

54 E12079 Access plug " 55 E12080 Washer .. . 4

56 E12888 Bolt, cylinder head 4

57 E12889 Bolt, rocker box 4-58 D2332 Washer ... 4

59 E12598 Spacer • 4 ... .. .,. 60 E4752 Sealing ring 2

61 E11707 Sleeve . 2

62 E12597 Distance piece} 2

63 D2331 Washer For torque stay 2

64 H-1303 Nut 2

65 H -0103 Screw } 8

66 D2329 h Tappet Inspection cover 8 was er

25

11~

2

f ig. 6,

9

5

AMAL c ARBURETOR

26

-4

7

29

8

BG

• TR6R, T R6C

Re(. No. Port No. DESCRIPTION QUANTITY REMARKS

AMAL CARBURETOR TR6R, TR6C

02183 CARBURETOR (R930/60) Jess "O" ring 1 2 Reference only Mixing chamber (930/005) 1 3 928/098 Mixing chamber top (99-1032) ... ... 1 4 622/086 Screw (99-0521 ) ... 4 5 928/060 Throttle valve (3½ cutaway) (99-0527) ... 1 6 622/131 Throttle return spring (99-1033) 1 7 622/067 Needle cl ip (99-0510) .. 1 8 622/124 Needle (99-1036) ... 9 928 062 Air slide (99-0528) ..

10 622/129 Spring (99-1038) ... ... 11 928/103 Air valve guide sleeve (99-1037) 12 622/077 Throttle stop screw (99-0516) 13 622/076 Air adjusting screw (99-0515) 1

r 14 6221082 "O" ring (99-0520) 2 15 622/122 Needle jet (0·106) (99-1035) 1 16 622/128 Jet holder (99-1034) 1 17 376/100 Main jet (230) (99-0441) 1 18 622/069 Float (99-0512) ... 1 19 622/071 Float spindle (99-0513) ... 1 20 622/055 Float chamber (99-0506) 1 21 622/073 Joint washer (99-0514) ... .. 1 22 622/068 Needle (99-0511) ... 1 23 376/093 filter (99-0438) ... 1 24 622/078 Banjo bolt (99-0517) ... 1 25 376/092 fibre washer (99-0437) 1 26 622/147 Drain plug (99-1152) ... 1 27 622/151 Washer (99-1153) 1 28 F13507 Petrol pipe .. . 1 29 E9711 "O" ring 1

27

4 - ~3

2-------< ' 29

14

13

12

~,__- - - - --1s

[1--- 4

_,,.._,-~28 ©--21

25---nll ~26

Fig. 7. AMAL CARBURETOR, T120R

28

•

---7

86

Ref. No. Port No.

1 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 H 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

DESCRIPTION

AMAL CARBURETOR T120R

CARBURETOR-L.H. (L930/67) } L "O" 1 CARBURETOR-R.H. (R930/66) OS$ r ng

Mixing chamber (L930/0QS 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 (99-0S28) Spring (99-1038) ... Air valve guide sleeve (99-1037) Throttle stop screw (99-0516) Air adjusting screw (99-0515) .. . "O" 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 "O" ring

29

• , ..

QUANTITY REMARKS

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

8

4

7 j ~ ~ 2

5

4 I

8 @©

14 15 ~ /

3 •, 1~

1 -~ ~

1 C ~~

' -~ 23 24

17

7

fj- 11

10

~ 9

~

87

Fis. 8. TIMING COVER AND CONT ACT BREAKER

30

R,(. No. Port No. DESCRIPTION QUANTITY REMARKS

Tl Ml NG COVER AND CONTACT BREAKER

1 E92•6 Timing cover .. 1 2 E-4016 Patent plate 1 3 0208-5 Hammer-drive screw 3 4 E•568 Oil seal .. 2

• E6387 Oil seal (0·020 In. underslze) . .. For reground crankshaft

5 E4569 Clrcllp ... 1 6 T989 Hollow dowel ... 1 7 1•~609 Screw ,, ... 3 8 1•~608 Screw ' 5 ... 9 1•-0208 Bolt 1

10 S25-43 Plain washer 1 11 E4707 Rubber grommet .. 1 12 E7680 Pillar bolt 2 13 E6559 Plain washer 2 1• E8737 Cover 1 15 E11 •62 Joint washer .. . 1 16 G~299 Serrated washer 2 17 E7354 Screw (½ In. U.H.) 2 18 544193•0 AUTO ADVANCE UNIT (99-0771) 1 19 54415642 Spring set (99-0757) 1 20 54419097 CONTACT BREAKER PLATE ASSEMBLY (99-0768) 1 21 54419827 Contact set (99-0m) 2

~ 22 54419220 Pin, adjustment (99-0769) 2 ..._ 23 02133 Oil pressure switch 1 24 020•5 Cover pressure switch 1 Not illus. 02138 Timing label for C.B. cover 1

--...

31

,,

1

13

3

8 9

1

14

BB

•

23

19 l!,>-- -r------22 1--.,£,;L----- --21

Fig. 9 GEARBOX INNER COVER AND SELECTORS

32

•

-

Re(. No. Port No. DE.SCRIPT/ON QUANTITY REMARKS

GEAR B OX INNER COVER AND SEL E CTO RS

1 T4293 GEARBOX INNER COVER 1 2 T1614 Lays haft bearing ... . .. 1 3 T412 Gearchange spindle bush .. . 1 4 T45 Kickstart stop 5 T1607 Thrust washer 2 6 T989 Hollow dowel 4 7 S2149 Stud 2 8 S1907 Bolt 9 E3446 Washer 11 , • •

10 14--6608 Screw ~ 1 11 14-7023 Screw 1 12 T-4055 Camplate 1 13 T397 Operating quadrant ... 1 14 T1896 Quadrant spindle 1 15 Spilt pin (-h in. x 1i in.) Ref. only 16 T4308 Mainshaft selector fork 1 • 17 T4307 Layshaft selector fork 18 T3989 Selector fork rod 19 T4288 Leaf spring 20 T4289 Leaf spring support 1 21 T4290 Leaf spring top plate 1 22 T4291 Tab washer ... 1 23 F4771

~ Screw 2

33

w ...

18

19-

) l~1

12 13 14

26 25 24 23 22 21

2 27

. @b~ I e:ffiF- ? - 1 .;•

11

7 10

Fig. 10 GEARBOX SHAFTS AND GEARS

) )

4

t

B9

-

Ref. No. Port No. DE.SCRIPT/ON QUANTITY REMARKS

G E A R B OX S H AF T S A ND GEA R S

1 T4158 MAINSHAFT c/w LOW GEAR. (16T) 1 2 1'3988 Clutch rod bush ... 1 3 T4332 MAINSHAFT HIGH GEAR. {~ oC7" ... 1 4 T4006 High gear bush 1 s T3889 Mainshaft th ird gear (23T) ... . .. 1 6 T4335 Mainshaft second gear (20T) 1 7 T3862 LAYSHAFT LOW GEAR. (30T) 1 8 T928 Low gear bush 1 9 T3861 Layshaft second gear (26T) ... 1

10 T3890- Layshaft third gear (22T) ~ 1 --.. 11 T4315 Layshaft c! w high gear (20T) . ...

12 T1952 Gearbox sprocket (15 teeth) . .. 1 12 T19S3 Gearbox sprocket (16 teeth) ... 1

See pages 4, 5 and

n 12 T1916 Gearbox sprocket (17 teeth) ... l 6 for standard

12 T1917 Gearbox sprocket (18 teeth) ... 1 12 T1918 Gearbox sprocket (19 teeth) ... 1

sizes ~

12 T1919 Gearbox sprocket (20 teeth) ... 1 13 TI116 Tab washer .. , 1 H T440 Gearbox sprocket nut 1 15 03556 High gear bearing 1 16 T489 Clrdlp ... 1 17 ~ T946 Oil seal ... 1

~ 18 03552 Mainshaft bearing 1 19 T4113 Clrcllp ... 1

~ 20 T1962 Plain washer 1 21 T1963 Pin ion sleeve 1 22 T1250 Pinion spring 1 23 T730 Kickstarter pinion 1 24 T731 ·- Kickstarter ratchet 1 2S TI240 Tab washer 1 26 S594 Nut 1 27 T1736 Clutch operating rod - 1

,. - I

WIDE RATI 0 G EAR S

3 T3657 MAINSHAFT HIGH GEAR. (28T) 1 6 T4161 Mainshaft second gear (19T) .. . 1 9 T4160 Layshafl second gear (27T) ... 1

11 T4159 Layshaft c w high gear (1 ST) 1

C L OSE R ATI 0 GEARS

1 T4173 MAINSHAFT c 'w LOW GEAR. (1ST) ... 1 3 H1n MAINSHAFT HIGH GEAR. (24T) 1 5 T4169 Mainshaft third gear (23T) ' .. . .. 1 6 T4167 Malnshaft second gear (21T) ... 1

~ 7 T4163 LA YSHAFT LOW GEAR. (28T) 1 9 T4166 Layshaft second gear (1ST) ... 1

10 T4168 Layshaft third gear (23T) 1 11 T4162 Layshaft c/w high gear (22T) ... 1

35

.~ ~ ~

l<>

~\1 ~ N

- ::,

~ ) ~

~ '

s "'

"

I' ~ "' .. "'

,;;- ~ e "' a: <

\ "' 0 Q z < "' t: < :c "' \

\\ 2-

X 0 .. 0: < "'

I

I~

. ~

I 0

~

~ I,~ -

·<\

~

M

.. l!!

( ' i

~-

.. • © r

I!!

r

N

36

Re(. No. Port No. DE.SCRIPT/ON QUANTITY RE.MARKS

GEARBOX SHAFTS AND GEARS (S S PEED )

1 D3500 011 seal, cover plate ... 1 2 E3789 Cover plate 1 3 T4360 Gearbox camplate 1

" T4364 Selector fork - mainshaft '4th gear .. 1

' s T4366 Selector fork - layshaft 3rd gear 1 6 T4368 Selector fork - layshaft 1st gear 1 7 T4S36 MAINSHAFT HIGH GEAR ASSEMBLY (C•W HIGH GEAR

BEARING} ... 1 8 D3S11 Needle roller bearing 2 9 D3500 Oil seal, high gear .

1 ··~ 10 T4432 MAINSHAFT ... 1 11 T3988 Bush 1 12 T4376 Malnshaft '4th gear 1 13 T43n MAINSHAFT 3rd GEAR 1 H T4379 Bush Re( only 1S T4380 / Mainshaft 1st and 2nd gear 1 16 T4371 Layshaft 1 17 T<\3831/ Layshaft high gear 1 18 T438-4 Layshaft 4th gear .. 1 19 D3'494/ Clrclip ... 1 20 T4387 / Layshaft 3rd gear 1 21 T4388 LA YSHAFT 2nd GEAR 1 22 T4390 Bush 1 23 T4391 / LA YSHAFT 1st GEAR 1 24 T4393 Bush 1 25 D3'49'4 Circlip ... •• · 1 26 T4381 Driving dog 1 27 T4363 Quadrant .. 1

T4402 Leaf spring 1 T4374 408 Plunger quadrant ... 1

Not T4403 Plunger . .. 2 Illus. T4397 Gearbox sprocket - 19T 1

T4396 Locknut 1 T4395 Lock washer 1

•

37

41

~o

39

30

31

42 /

Fis 11.

3 4 ~

3 7

V GU.~XO UTER COVER

38

,

16

15

21

20

1 e~

8

35

,

Ref. No. Port No. DESCRIPTION QUANTITY REMARKS

-r-, GEARBOX 0 UTER COVER

T3760 GEARBOX OUTER COVER 1

2 TI3 Kickstarter spindle bush ... 1

3 T57 Gearchange spindle bush 1 4 T47 Klckstarter spring anchor pin 1

5 S547 Guide plate stud 4

6 T1956 Oil seal 1 7 T1955 Oil seal housing 1

8 T408/9 Gearchange quadrant 1 . 9 D3530 Rubber "O" ring .,._ 1

10 T404 Quadrant return spring 2 11 T406 Gearchange quadrant plunger 2 12 T405 Plunger spring ... 2

13 T407 Guide plate 1 14 E1612 Serrated washer 4 15 14-0301 Nut 4 16 T4117 Kickstarter quadrant 1 17 T31 Klckstarter return spring 1 18 TI4A Kickstarter axle 1 19 T3629 CLUTCH LEVER ASSEMBLY 1

20 T4H1 Clutch lever ... 1 21 T1710 Lever shaft 1 22 D2368 Ball, i In. diam. 3 23 T3761 Thrust plate 1

--. 24 T1712 Return spring 1

25 GS127 Plain washer 1 26 Split pin (/. In. x tin.) Reference only

27 S1879 Countersunk screw 2

28 T1646 Rubber cover ... 1

29 T3762 Abutment for clutch cable 1

30 SlS-3 Plain washer 2 31 14-0302 Nut 1

32 S1878 Screw 2

33 14~609 Screw 2

34 1~608 Screw 35 T3757 Gearchange pedal 1

36 1-4-0201 Bolt 1

37 TI450 Pedal rubber 1

38 T3632 FOLDING KICKSTARTER 39 TI173 Klckstarter lever ... 1

40 T1272 Kickstarter pedal ... 1

41 T1167 Pedal locating spring 1

42 S70-3 Steel ball, ¼ in. diam. 1 43 SS-41 Pedal bolt 1

H T2330 Pedal rubber 1

45 T4356 Cotter pin c/w nut and washer 1

46 SSH Domed nut 1

47 TI166 Flier plug 1

48 E8782 "O" ring 1

• 39

;::; CD

0

"' a,

" ~

~

;! J: u t--:>

M ., a, .., u

"' ..;

"' .. ii:

!:?

40

Ref. No. Part No. DESCRIPTION QUANTITY REMARKS

C L U T C H , 1 S586 Clutch securing nut 1 2 T3929 Hub 1 3 T3931 Thrust washer ... 1 '4 T39'4 Roller . .. 20 5 T1570 Sprocket and housing (58 teeth Duplex) 1 6 T-4-438 Centre ... 7 T-4-436 Inner plate 8 S2157 Bolt 3 9 TIS38 Shock absorber spider 1 .

10 T1722 Drive rubber (large) ... "'· 3 11 T1723 Rebound rubber (small) 3 12 T-4-437 Outer plate • 1 13 T423A Screwed pin 3 H T1362 Driving plate (bonded) 6 15 T1363 Driven plate 6 16 TI156 Pressure plate 1 17 TI159 Adjuster pin 1 18 1-4-0-403 Nut 1 19 T1931 Spring cup 3 20 T1830 Spring ... 3 21 T2526 Pressure nut 3 22 S66-1 Key 23 TI279 Washer .. . -

•

..

'41

~

•

) ........ ~ 1

":uf\ " .'.I ,)

"- -V) ...___~

1S

12

) .

5 17 10

/

14 18 19 11 20 o 21

Fig. 1•. CHAINCASE AND CHAINS

l )

<

'-------31 ~-----32

........ -----24

23 22 812

i~ )

Ref. No. Part No. DESCRIPTION QUANTITY REMARKS

CHAINCASE AND CHAINS

1 D1915 Rear chain, tin. x t in. x 106 links 1 2 - E11419 Joint washer ... 1 3 E7037 Cover plate -4 E7565 Oil seal ... 5 E3821 Countersunk screw 6 6 E5976 Chain tensioner abutment {also listed with

crankcase group) 7 E6061 Chain tensioner blade ... 1

8 E4152 Tie rod ... • 1 9 E5977 Trunnion "' 1

10 E9703 Adjuster sleeve nut • 1 11 D477 Primary chain, i In. Duplex x 84 links 1 .. 12 S1866 Stator stud 2 13 S1867 Stator stud 1 14 47205 Stator, RM21 (99-1006) 1S E9360 Sleeve nut

16 H 1# Rubber grommet 17 ES-449 Plastic sleeve 1 18 S25-3 Plain washer .. 3 19 14-0702 Self-locking nut 3 20 _ E11463 Joint washer 21 E9245 Chaincase 22 TI#O Rotor cover - 23 E11457 Joint washer 1 H H 129 Screw 3 25 E2#1 Copper washer 1 26 T2166 filler plug 1 27 E8782 "O" ring 1

28 14-6608 Screw 6 29 14-6620 Screw 2 30 SS# Domed nut 2 31 F1880 Copper washer ... 2 32 TI-443 Timing pointer .. . 1 33 14-6101 Level plug

43

{ r p • "'I' ( - w. ... 1r 1r . , .i I

t 24

40

39

26 813 35

) )

4

~ 3 2

.16 34

Fla. 15. FRAME

1 )

.,.

6

11

10

6

s

SA

1

'

-~ -~ Ref. No. Port No. DESCRIPTION QUANTITY REMARKS •

FRAME

1 F12089 Frame • 2 E12744 Oil filler cap • 3 D3616 "O" ring 1

4 F13142 Dipstick , .. 1

5 F13642 Oil filter ... 1

SA F1318S Sump plate 1

6 F12829 Gasket "' 2

7 D2330 Washer} 4

8 S2109· Stud Sump plate to frame 4

9 14-1302 Nut • • o& 4

10 14-0113 Drain plug ~ 1

11 E12505 Joint washer 1

12 E6930 Oil junction block 1

13 E11458 Joint washer 1

14 S1908 Nut } ' 15 E3446

W h Junction block to crankcase as er

16 E12428 Rocker oil pipe

17 E1335 Washer ... 4

18 E1435 Nut ... 4

19 E12337 Rocker feed pipe 1

20 D3774 Clip-rocker feed pipe 2

21 E12345 Oil return pipe 1

22 E6848 Clip-feed and return pipes 4

23 E12347 Oil feed pipe 1

24 E12349 Oil vent pipe ... 1

25 E11149 Crankcase breather pipe-front 1

26 F11614 Crankcase breather pipe-rear 1

27 F11610 .. T" piece 1

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

29 D2252 Clip-breather pipe-rear 1

30 F11615 Clip-breather pipe to fender 4

31 H3894 Screw 4

32 F4717 Nut 4

33 F12627 Centre stand

34 F13793 Spring 1

35 S2077 Pivot bolt 2

36 14-1304 Nut 2

37 F11560 Prop stand 1

38 F7021 Bolt 1

39 14-1303 Nut 1

-40 F8382 Spring 1

Not illus. D3361 Transfer "Made in England" ... 1

Not illus. D2452 Transfer-Safety Standards 1

Not illus. 14-0114 Bolt} 1

Not Illus. 14-0402 Nut Prop stand stop 1

45

-

3 1

! ..

±17 Hr

t z . :, z 0 iii z .. L .. :, .. 0 z <( .. a:

f2 u z ;:; z i ..

{

f

I

C: #

Ref. No. Port No.

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

F12513 D1841 WE170 F12521 F12691 F12690 F12689 F12692 S2087 F12266 H-1307 F12656 H -1304 D2350 H-0133 W2330 14-1304 64052341 64052090 6-4533645 905-4/171 645-4-475-4 H-0235 S1997 D2331 H-1303 14-0234 D2321 H-1303 F12641 14-0206 D2H7 3-4815 D3550 H1388

OE.SCRIPT/ON QUANTITY RE.MARKS

SWINGING ARM AND SUSPENSION UNITS

SWINGING ARM Grease nipple Wa,her, grease nipple Bush, pivot arm ...

Sleeve, swinging arm pivot Distance piece R.H. Distance piece l.H. Dirt excluder ... Stud. swinging arm pivot Wa,her, swinging arm pivot .. . Nut, swinging arm pivot Brake torque stay Nut, torque stay to brake plate Washer, torque stay to brake plate .. . Bolt, torque stay to swinging arm .. . Washer. torque stay to swinging arm Nut, torque stay to swinging arm SUSPENSION UNIT (D2294)

Damper unit Bonded bush (99-0122) ... Spring retainer (99-0107) Spring, 110 lbs, chrome (99-1139)

Bolt damper-top Stud, damper-top l.H. Wa,her, damper-top Nut, damper-top Bolt, damper, lower .. . Washer dam per lower Nut damper lower Chalnguard Bolt, chainguard fixing-front Washer, chainguard fixing-front Stop lamp switch-118SA (99-1028) Screw Washer ...

47

11 ••·

~--

1 2 2 4 2

4 1 2 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) 2 2 2

1 1 2 2 I

i

,J;-

'{ t l

~

ct;

~ \ ;o •1 « •3

4Z

5

15

"'·

z

1Z 13

13 12 I

_./

14

ZZ Z,3

45 32 3•-31 \ _/\ ~") i;~~''"

16

"~;. ~ 36

~-- 37

I Z1

\ \ 35

38 39

Fis. 17. MOTOR UNIT FITTING AND FOOTRESTS

) ) )

ZS

6

46

- 48

- 47

~zg

,"\ ) \ :w

~

' )

)

}

n

'

_ ,.

Ref. No. Port No.

1 F12855 2 F12854 3 14-0259 4 02333 5 F9279 6 F12841 7 F9053 8 F13207 9 14-0217

10 F9089 11 14-1302 12 14-1303 13 F2184 14 F9054 15 F12666 16 14-0103 17 14-0301 18 S2045 19 14-1303 20 E8084 21 F12860 22 23 02393 24 F7387 25 F13024 26 F13023 27 14-0115 28 14-0116 29 14-1302 30 02330 31 14-0220 32 14-0221 33 14-1302 34 02321 35 F12846 36 F12847 37 S2112 38 14-1304 39 02332 40 F12848 41 F12849 42 14-0254 43 14-1304 44 02332 45 F13537 46 14-0126 47 14-1303 48 02331 Not illus S1933 Not illus 14- 1305 Not illus F13602

.,. ..._

--DESCRIPTION QUANTITY REMARKS

MOTOR UNIT FITTINGS AND FOOTRESTS

Footrest-L.H ... . Footrest-R.H ... . Bolt Washer ... Footrest rubber PILLION FOOTREST ...

Pedal

S~the:r blol:ootrest swivel

Nut Nut W h

Footresl to frame as er

Footrest rubber ... Rear brake pedal

Screw}s 1. h d . Nut top ,g ta justment

Pivot pin Nut Washer ... Rear brake operating rod Split pin hi, in. x f in.) Washer ... Adjuster nut-brake rod Rear motor plate R.H. Rear motor plate-L.H. Bolt Bolt Nut Washer Bolt Bolt Nut Washer

Rear motor plates to frame

Motor to motor plates

Distance plece-L.H. Distance plece-R.H.

.... '\Ii.

Stud Motor to frame centre bottom .. . Nut Washer OiStance piece-L.H. Distance piece-R.H. Bolt Motor fixing front Nul Washer Steady bracket motor to frame

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

Nut } Collar Footrest bolt

49

1 2 2 2 2 1 1 1 1 1 1

1 1

1 1 1

,. ,

Reference only 1 2 1 1 5 1 6 •

.. . 12 2

.. . 2 4

8 1 1 1 2 2

1 1 1 1 1 1 1 ~ (TR6c only)<f,, , .

2

•

I

I l

l

1

~ I

. . l;l

I I \ r •

\ I 'v

'

1 -~ '

.,_

... -..,

' -- .., ----

I -~

;.

- ....

50

"' a: .. .,J ~ ... ... :> I: Q z <(

"' .. .. ii: ... "' :> <( :t X ..

-

--

-

Ref. No. Port No. DESCRIPTION QUANTITY REMARKS

E ~ HA US T PIP ES A ND MU FFL E RS, TR6 R , T 120 R

1 E12636 Exhaust pipe-L.H . 2 E12637 Exhaust plpe-R.H. 1 3 E12•65 Finned clip

} Exhaust pipes to cylinder head 2

4 F8978 Washer 2 5 F8977 Bolt 2 6 E6857 Exhaust pipe stay 2 7 E6179 Screw 2 8 E7•71 Nut 2 9 E7512 cu, } 2

10 E3768 "O" washer . . .., . • 11 1•-0217

Bolt Exhaust pipes to coupling !'IP• 2 12 1•-1202 Nut - ' '

2 13 E9888 Coupling pipe ... 1 14 E2271

rn, } 2

15 E3768 "O" washer • 16 1•-0219 Bolt Exhaust pipes to mufflers " ' 2 17 S25-3 Washer 2 18 14-1302 Nut 2 19 E12382 Muffler ... 2 20 E12282 Hanger- muffler and pillion footrest 2 21 14-0101 Bolt} 4 22 1•-1301

Nut Muffler to hanger •

51

'° • Q)e,,,

u ,0 0: ...

~ .,; 0: .. ..J .. .. ::, \!!

:r 0 z < "' .. ... ~ ii:

~ :;, t; ::, < :r X .. \ ~

a ~ .. .., .., ii:

N .., ~ .., ::; :l

N

~~ 0

\ t

..,

.. $

•

I

52

Ref. No. Port No.

EXHAUST 1 E12334 2 E12632 3 E12465 4 E8977 5 E8978 6 E6978 7 14-0113 8 526-3 9 En99

10 E5874 11 14-0116 12 14-0219 13 E3768 H S26-3 15 H-1202 16 E9673 17 E2271 18 14-0219 19 E3768 20 526-3 21 14-1202 22 E12019 23 E12020 H E12511 25 51822 26 S26-3 27 14-0115 28 S26-3 29 S1933 30 E9680 31 S1953 32 E9857 33 E9688 34 E9696 35 S1954 36 E9857 37 E9688 38 E12851 39 S2096 40 14-1301 41 D2320 42 F13139 42 F12856 43 F13140 43 F12858 44 F13092 45 F13095 46 14-0216 47 14-1302 48 F9051 49 S1969 50 F8243

DESCRIPTION QUANTITY REMARKS

PIPES, MUFFLERS AND FOLDING FOOTRESTS , TR6C Exhaust pipe-lower .. . 1 Exhaust pipe-upper ... . .. 1 f inned clip } ... 2 Bolt Exhaust pipe to cylinder head ... 2 Washer .. . 2 Exhaust pipe stay 1 ~t 3 Spring washer 3 Clip-upper 1 Clip-lower 1 ~ ; 1 Bolt Exhaust pipes to connector 1 "O" washer 2 Spring washer 1 Nm 1 Connector

~}. washer } Connector to mufflers Sprl ng washer Nut Muffler-upper . . . Muffler-lower .. .

S~:l~er- hahnge}r Mufflers to hanger

prmg was er Bolt ... Spring washer Hanger to frame Spacer nut Leg guard Screw Washer Clip Leg guard attachment front

Bracket Screw Washer Leg guard attachment rear Clip Crankcase undershield ... Hooked stud Nut Washer .. . FOLDING FOOTREST- R.H. FOLDJNG FOOTREST - L.H.

Footrest hanger- R.H . Footrest hanger- L.H. Footrest pedal Spring Bolt Nut Footrest rubber

Bolt } Washer Footrest to frame .. .

53

1 2 2

.. . 4 2

. .. 2 1 1 1 2 2 1 1

.. 1 1

1 1 1

... 1 1 2

... 2 2 1

1 1 1 1 1 1 1 2 2

~ 38

~39

22

I 47

51

32

JJ

/ 35 34 818

fig. 20. TELE SCOPIC FRONT FORK

54

Ref. No. Part No. DE.SCRIPT/ON QUANTITY RE.MARKS

TELESCOPIC FRO NT FORK

1 H4080 FORK ASSEMBLY 1 2 H4035 Top Yoke ... 1 3 14-0234 Pinch Bolt ... 1 4 14-1303 Nut ... 1 5 E8084 Washer 1 6 F6738 Lock c/w 2 keys 7 D623 Key (state serial No.) 8 S578 Grub screw 9 Hll66 Sealing washer 1 ..

10 H2270 Brake cable retainer 1 11 F8245 Starlock washer ... 1 12 H3682 Reta I nl ng bracket 1

'>-13 F12007 J Abutment ring 2 14 H-4031 Taper roller bearing 2

:> 15 H-4028 Dust cover 2 16 H4315 Bottom yoke and stem 1 17 1•-0238 Pinch bolt ... 2 18 E8084 Washer 4 19 14-1303 Nut 2 20 H4007 Stanchion 2 21 H4076 End plug 2 22 H4087 Main spring 2 23 H4343 Outer member-R.H. ,--- 24 H4342 Outer member-L.H. 25 H3947 Cap wheel spindle 2 26 S2102 Stud ... 8 27 14~302 Nut 8 28 D2428 Washer 8 29 H3894 Drain plug ... 2 30 H3893 Washer 2 31 H4001 - Oil seal ouier member 2 32 H4003 "O" ring-damper valve 2 33 H4009 Recoil spring 2

3• 14-1019 Cap screw-damper tu be 2 35 H4004 Cap screw seal 2 36 H4325 Damper tu be and valve assembly 2 37 H4002 Scraper sleeve outer member 2 38 - H4258 Top cap nut • 2 39 H4166 Washer ... 2 '40 H4317 • Steering stem nut (without steering damper) 1 41 H4318.., Steering stem nut (with steering damper) 1 42 H-4058 Headlamp bracket-L.H.

:~"°' '"' 42 H4060 Headlamp bracket-R.H. 42 H-4088 Headlamp bracket-L.H. ~ TR6C 42 H•090 Headlamp bracket-R.H. .,,. 43 S1809

"" } 2 44 D2338 Washer 2 45 F12209 Bush Headlamp bracket tod fixing 4 46 F12211 Spacer 2

55

3

~38

~39

22

\

-...

51

~ 25

27

818

Fis. 20. TELESCOPIC FR ONT FORK

56

Ref. No. Part No. DESCRIPTION QUANTITY REMARKS

f'-) TELESCOPIC FRO NT FORK

47 S2062 "~~ ""'} 2

-48 D2333 Washer . 2

49 D2630 G Headlamp bracket bottom tixong 2 rommet

50 F9046 Washer ... 2

51 H-4012 Nut-damper valve ... 2

52 F12216 Clamp washer 4 /

. ~

57

~ 3

®--- 2

~ 5

~6

~7

@ - s ~ ~ - 14

~ - 5 @---9 16

17~ '

12

13

819

Fis, 21. HANDLEBAR MOUNTINGS ANO STEERING DAMPER

58

r ..

r ...

Ref. No. Port No . DESCRIPTION QUANTITY REMARKS

... HANDLEBAR MOUNTINGS AND STEERING DAMPER

' 1 H2291 Handlebar eyebolt ' 2 2 F1335 Washer .. 2 3 5S89 Bolt 2 4 H1527 Metalastlc bush 2 5 H1529 Hemispherical washer .. 4 6 H1581 Distance piece , .. 2 7 H1580 Rubber washer . 2 8 H2221 Cup 2 9 H-1303 Nut 2

10 H3875 Steering damper rod c /w knob 1 11 D2438 Spring washer ..... 1 12 H435 Friction disc 1 13 H1797 Anchor plate 1 Available 14 H95 Spring plate 1 15 D2329 Washer ... 1 16 H4102 Bollom nut 1 17 Split pin (fr in. x ½ in.) Reference only

,-

, '

,:

59

" \

~

~~ ""~. I

)

2

3 39

9

y l4

10 6

Fig. n. fl,ON T WHEEL

J

FRONT WHEEL COMPLETE Nol

~

24

25

,.

~~'( ~ --~W'f:> 'Q a W \i,Y-./ 20

~~- 22

l,)

2li

820

)\ )

Ref. No. Port No. DESCRIPTION QUANTITY REMARKS

_.,._ FRONT WHEEL

1 W38•5 FR.ONT WHEEL COMPLETE 1 2 W3844 RIM, SPOKES AND HUB ASSEMBLY 1 3 W3818 Wheel rim (WM2-19) 1

• W3658 Brake drum and hub 1 5 W3820 Spoke (R..H.-lnner) 10 6 W3819 Spoke (R..H.--outer) 10 7 W3821 Spoke (L.H .) ... 20 8 W229• Nipple ... ... •O 9 W3969 Balance weight (short) , as required ··~

10 W3970 Balance weight (long) ... as required 11 W653 Bearing ... .. 2 12 D2632 Circlip-R.H. 1 13 W3797 Grease retalner-R.H. 1

1• W3759 Lock ring-R.H. ... 1 15 W1•81 Grease cap inner-L.H. 1 16 W1237 Grease cap outer-L.H .... 1 17 TISO Circlip-L.H. 1 18 W3932 Distance piece 1 19 W3796 Wheel spindle 1 20 W2058 Nut wheel spindle 1 21 D3669 Grommet brake drum 1 22 14-1303 Nut } 23 D23•0

W h Anchor plate to fork leg 1 as er

r ... 24 W3655 Brake anchor plate 25 W3987 Brake lever front ... 1 26 W3986 Brake lever rear ... 1 27 D2639 " O" ring brake cam 2 28 W3762 Tappet brake cam 2 29 W3761 "O" ring brake tappet 2 30 W3713 Brake shoe complete 2 31 W3714 Return spring 2 32 W3715 Cage brake shoe adjuster 2 33 W3716 Micram adjuster ... 2

3• W3717 Abutment pressing 2 35 1•-1635 Stud-anchor plate torque reaction

..

61

~

39 40 38 I

I

36

4,

......

7

41

2

02,

Fi&, 23. REAR WHEEL

)

3 1 REAR WHffl. COMPlET£

9

i. 20

2,8

27

35

i. )

-

Re(. No. Part No.

1 2 3 4 5 6 7 8 9

10 11 12 13 H 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3• 35 36 37 38 39 •O •1 42 •3 •-•. 45 46 47

W3968 W3782 W3784 W3724 W3725 W3726 Wll94 W3773 W3468 W3749 W653 W3752 W3753 W1654 W3747 H-0207 02320 H-1301 W3856 W3872 W•03• 14-1303 D2331 W3870 14-0305 D2431 W3925 W3926 W2328 W•049 F12656 14-0133 W2330 1•-1304 W3965 W3750 03213 W3746 H-1307 F12266 W3751 F13082

W374u 1•-0107

I,_ 14-03 -r>1841

WE170

DESCRIPTION

REAR WHEEL

REAR WHEEL COMPLETE ... RIM SPOKES AND HUS ASSEMSL Y

RIM (Wm 3 x18) .. . Spoke (inner-L. H.) Spoke (outer-L.H.) Spoke-R.H .... Nipple . .. Hub and brake drum

Tyre security bolt ... Support rlng- L.H . Searing Locking ring- L.H. Spacer Grease retainer-R.H.

;!::::t}•:ptr:::et to hub

Nut Brake anchor plate Brake cam Brake lever Nut Washer Brake pivot

Nut } Washer Brake pivot to torque arm

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

~~her }wheel spindle

Speedometer drive ring Cover plate-swinging arm fork end Chain adjuster

~c~;w }chain adjuster

Grease nipple .~ Fibre washer

63

• ·'II>

QUANTITY REMARKS

1

1 10 10

... 20

... •O 1

. . . 2 1 2 1 1 1 1 5 5 5

1 1 1 1 1 1

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

•

19-

20

21

I ,J

1-Q

16 -

17 ~

ta -

~ 28 30 ~

'1>----29 0 13 14

r==u e--10

1}=~ - 11

W-12

~-~ ~~

~.::::.'

~

~ ~'::- ~ " ---

[]-s 622

ll-· Tl

Fie, 24. GAS TANKS AND TWINSEAT

---

•

,

.... "'

15

tr-· .r~

23

, i"'I.

•

:t: :;I •

,-..,. Ref. No. Port No. DESCRIPTION QUANTITY RE.MARKS

-r .1 GA S TANK AND TWINSEAT

1 f12996 •Gas tank (3 gall.) 1 •For color see

page 8 2 F9062 Steady rubber 2 3 F13021 Mounting rubber 2

• S1823 Centre fixing bolt 1 5 F13133 Distance tube ... 1 6 F10260 Mounting rubber .... 1

7 F13320 Washer ... 1 8 F13321 Rubber washer ... ' 1 .. ~ 9 F13319 Mounting ring 1

10 S1999 Nut 1 11 D2330 Washer ... 1 12 F13318 Beading holder .. . 1

..--.. 13 F13068 Grommet 1 H F13134 Styling striJ>-front 1 15 F13135 Styling strip-rear 1 16 F9700 Tank motif-L.H. 1 16 F9701 Tank motif-RH. 17 F11339 Screw-front-tank motif 2 18 F7888 Screw-rear-tank motif 2 19 F13875 filler cap 20 F-4048 Joint waser ... 1 21 F3217 Jack chain 1 TR6C --..., 22 F3221 Clip 1 TR6C 23 F12800 Gas tap ... 23 F12801 Gas tap-reserve ... 1

2• E7351 Tap seal 2 25 F10002 Washer ... 2 26 F13634 Twlnseat 1 27 F13637 Twinseat cover 1 28 F12867 Hinge 2 29 14-0101

~I: h } Hinge to twinseat • 30 D2417 pr ng was er • 31 F9093 Rubber buffer ... 5 32 F13061 Catch assembly 1 33 F12597 Sprlng-<:atch assembly 1

3• 1-4060• Screw} . 1 35 14-1301 Nut Twinseat catch fixing 1 36 02087 Check wire 1 37 D2381 Screw-self tapping 1

*F12881 Petrol tank (4¼ gall.) Available

65

--- \

t (

'

. ' \e I

66

• -

.., \

•

- -

g ,/;

..

--

~ "' z < ... "' 0 ;;; 0 z < "' .. "' z < "' ... V .. <i

•

Ref. No. Part No. DESCRIPTION QUANTITY REMARKS [

AIR CLEANER AND SIDE PANELS

F13789 AIR CLEANER ASSEMBL Y-L.H. ... F13790 AIR CLEANER ASSEMBL Y-R.H.

1 F12749 Body- L.H. 1 Twin Carb 1 F12750 Body-R.H. 1 T120R 2 F13850 Cover-L.H. 1 2 F13851 Cover- R.H. 1

F13791 AIR CLEANER ASSEMBL Y-L.H. ... F13792 AIR CLEANER ASS EM BL Y-R.H.

1 F12798 Body-L.H. 1 SI ngle ca,b. 1 F12797 Body-R.H. • 1 TR6R, TR6C -~ 2 F13864 Cover-L.H. 1 2 F13865 Cover-R.H. 1 3 D3072 Element 2 4 14-0221 ~· } 2 5 FB245 Retainer 2 6 D2438 Washer Cover to body . . . . .. 2 All models 7 H-0302 Nut . .. . .. 2

.

8 03539 Screw } L H R H ... 2 9 S501 N . . assy. to . . assy.

2 Ut ...

10 14-0218 ~I; h }Air cleaner to frame

2 11 D2-418 pr ng was er 2 12 F12626 Connector pipe 2 T120R 13 F12625 Connector pipe TR6C, TR6R 14 E11860 Carburetor adaptor 1 or 2 i

~ 15 D3S36 Clip-Jubilee type 1 or 2 16 F13859 Side panel-L.H. 1 17 F13860 Side panel-R.H. 1 18 F6673 Panel grommet ... 2 19 H-0201

Bolt } 4 20 02329 Washer Side panel to air cleaner 4 21 14-1301 Nut 4 Not illus. 03722 Transfer .. . 2 T120R Not illus. 03724 Transfer ... 2 TR6C Not illus. 03723 Transfer ... 2 TR6R Not illus. F9196 Spacer (use with 14--0218) 2

67

, IP ..

l ~

' I,,

~· ~

~ .

)=

"""' 36 38

31

19

34 ..A.

\; 37

€[,

21 22 23

~-

' 20

•

)

,,,.

24

Jr Ii

I 0

-~ 27

~ 26

I el 29 ~ 28

6

17 16

Fie, 26. FENDERS AND TAIL LAMP

)' )

•.

13 10

11

S 4

•

2

..

14 12

9 B

~ B

7

t

~

L

- • • . ' q; '

Rt( No. Port No. DESCRIPTION

I 1 1 2 3 • 5 6

¥ 8 9

10 11 12 13 1• 15 16 17 19 1S 20 21

2"--:---.: 22

23 2• 25 26 27 28 29 30 31 32 33 3• 35 36 37 38

Not Ill. Not Ill.

NOTE:

FENDERS AIIO TAIL LAMP H4271/114 Front renclcr T l20

H4271/l 15 Front fender TRGR .. . H•270 Front fender TR6C .. .

H•Ol2 Bracket } H•021 Rubber bush 1•--0l 03 Bolt Stay to fork leg

D2427 Spring washer F l3566/lll Rea r fende r Tl20

f i~~gg/llG ~g~~ f~nJ~~~ tffg~ (chrome) 1•--01. 4 Bolt .. . D2330 Washer Fender fixing front . . . 1•-1302 Nut .. . 1•--0101 Bolt 1•-0103 Bolt F3069 Spacer D2329 Washer } 1•- 1301 Nut Fender fixing top and rear

f12768 Lifting handle . .. 1•--0101 Bolt } . . 02329

Washer Lifting handle to frame

1•-1301 Nut f12727 Rear number plate bracket-L.H. F12728 Rear number plate bracket-R.H. 1•-0102 Bolt } .. . D2329 Washer Number plate bracket to fender .. . 1•-1301 Nut .. . f12786 Tail lamp support

r {t~~2 ~~t~::;nu;ail lamp support front fixing

1•-0101 Bolt . . 02427

Washer Tail lamp support. rear fixing

F13213 Rubber beading strip .. . 57079 Reflector red (99-1162) D2391 Washer ... F•717 Nut 53973 STOP AND TAIL LAMP 679 (99-0S97) S4577109 Lens (99-10•6) 144921 Screw (99-1189) ... 5-4525286 Lamp base assembly 380 Bulb (99-0S42) 97-440 3 Front Fender stay kit F 13419 U -bracket, support to fende r

Parts added for low frame models: F 14 600 Bridge - r e ar fe nder

14-010 2 Bolt D2329 Washer - bridge to fe nde r

14-1301 Nut

----

.•.

[ QUANTITY REMARKS

/\rTJ:R I:NCINC NO. GGS0 -114 USE:

1 1

• • • •

2

• 2 2 1 1 3

" 3 1

.. l •• 2

2 .. 1

1

• • -4 1 1 1 1 2 2 2 2 2 2 1 1 1

F 14594

Reference only 1 Available

1

1 2 4 2

Tl20 TR6R TR6C

[

t

t

r '

--

\ ~ ~ ~ = ~~ ) y ;t

0 .., ~

•N

~ .. N

N

~

/

' ~~\

70

:: )

"' a: .. > .., .. .J .J 0 a: I-z 0 u 0 z ~ < a: < .. .. .J 0 z ...... <

·- J: N

:::i , ,;, iI

- ::?

r

...

Re(. No. Port No.

1 2 3 4 5 6 7 8 9

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

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

H4252 H1425 16 364 16 328 16 329 16 008 16 009 16 010 99-0244 11 013 H958 16 011 H2124 12 608 12 556 12 607 12 606 12 033 12 /040 11 014 03583 03648 03657 03144 S2048 14-1201 D3585 D3586 39595 54033666 54340882 54115246 39596 54033667 54340883 54115246

-

•

DESCRIPTION QUANTITY REMARKS

HANDLEBAR S AND CONTROL LEVERS

Handlebar Sleeve, handlebar mounting TWISTGRIP (99-0248)

Body, top half (99-0245) BODY, BOTTOM HALF (99-0246)

Friction spring Screw ... Locknut

Rotor Screw (99-0225) Grip

Cable stop (99-0241) Grip AIR CONTROL LEVER (D3246)

Lever Bolt Cap ... Spring washer Clamp Screw

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

71

.. ~

4

1 1 Reference only Reference only Reference only 1 2

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

.. 4

• \

J

I \

\

0

•

s---CJ

4

24

- 25

19 18

FiJ, 28. CONTROL CABL.ES

n

,...., Ref. No. Port No. DESCRIPTION QUANTITY REMARKS

CON TRO L C A BLES

1 01819 Throttle cable 2 T120R 1 01806 Throttle cable 1 TR6C, TR6R 2 03079 Clutch cable 3 03557 Front brake cable

• W3996 Bush-brake cable stop 5 W3997 Bush-brake cable 1 6 E12500 Washer ... 2 7 W•01• Cable sprl ng 1 8 01807 Air control cable ' 1 TR6C, TR6R ···, 9 03•85 AIR CONTROL CABLE 1 T120R

10 01818 Cable, lever to Junction box -~ -11 2•• /10• Junction box (0685) 1 12 03486 Cable, junction box co carburetor 2 13 313113 TWIN ROTOR TWISTGRIP (99-0347) T120R 1• 18108• Screw (99-0251) ... 2 15 313 /020 Body, top half (99-03•8) 1 ' 16 313 /021 BODY, BOTTOM HALF (99-0349) ... 1 17 16/008 Friction spring Reference only 18 210/007 Screw ... ... Reference only 19 S/077 Nut Reference only 20 313 /00• Rotor (99-03••) 1 21 210 /008 Rotor stop screw (99-0338) 22 51077 Nut-rotor stop screw (99-022•) 1 r--- 23 H2125 Grip 1 2• 0343/3 Cable clip 2 25 0343/7 Cable clip 6 26 H•112 Handlebar clip ... •

LATER MODELS USE THE FOLLOWING:-3 03815 Front brake cable ... 1

-73

827

Fis. 29. TOOLKIT ' 74

Ref. No. Part No. DESCRIPTION QUANTITY REMAAKS

TOOL KIT

D2112 TOOLKIT COMPLETE 1 1 D291 Tool roll .. 1 2 D218• Damper unot •~ M" 1 3 D1911 Tommy bar ... 1

• D2084 Spanner-open e cef! 1 5 D971 Box spanner 1 6 D9n Ring spanner 1 7 D97• Tyre valve key 1 8 D767 Screw driver , 1 9 F13292 Tool tray

.... 1

10 14--0101 Bolt 1 11 D2329 Washer ... 1

75

;;!

20

•• ' . • 1

'

2, 4

3

\\ \}

()(~,-__

10 9

8 TACHOMETER GEARBOX COMPLETE

) ·n ti

s

7

6

21

0

11

~~oo~ I I ~ 11

12 14

Fis. JO. SPEEDOMETER AN O TACH O METER

(1)

22

'I

"

16

17 ., . 19 ~

18 LI m

23

tJ E) 24

15

828 w f.·

Ref No. Port No. DESCRIPTION QUANTITY REMARKS

SPEEDOMETER AND TAC HO M ETER

SSMS007 00 Speedometer head (02394) 1 2 41-148-203-10 Trip control (99--0176) ... 1 3 54959626 Bulb holder Reference only 4 643 Bulb (3W. MES) Reference only 5 D3249 Speedometer cable 1

6 H4026 Mounting bracket {! TR6C, T120R, TR6R

7 D2600 Rubber cup TR6C, T120R, TR6R .

Not illus. 02391 Washer ... . .... 2 or 4 8 E9331 TACHO METE R GEARBOX (E5758 Body)-L.H. thread, 1 9 E9332 Securing screw-L.H. thread, U.N. 1

10 Reference only Bush ... 1 ..... 11 Reference only Flanged bush ... 1 12 E5157 Drlvl ng gear 1 13 E5759 End cap 1 14 E6300 "O" ring . .. 1 15 E5578 Driven gear 1 16 E12875 Driven gear housing 1 TR6R 17 06299 "O" ring 1 T120R 18 Reference only Bush 19 D3530 "O" r ing 20 E5881 Set screw 1

"'---21 03282 Tachometer cable 1 22 RSM3003 13 Tachometer (02396) 1 23 31-371-398 Spade (99--0173) 1 24 0 494 Circlip ... 1 25 E7351 Sealing washer .. . Not illus. D546 Blanking plug (replaces tacho bulb holder) 1

77

29

•

I

30 31 32

6

5

l •

,,-, '\

0

C)

- 21

7

25

11

~ ' ,,-,

8

28 ~

~

26 27

24

17 - 18

19 16

15

19 20

€3. - 19

- 9 20

~ 2 23

3 4

22

14

B29

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

78 --

-

.:,,-,L, -

Ref, No. Port No. DESCRIPTION QUANTITY l COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HOII.N

..,_J\f!!....:.T~J:R~Ec,..:Nc,,G:..:.l:..:.N.!!E_·.;..:: 0"'-'-• ..:::G==.!... ~

1 F12571 14-0101 D2329 14-1301 F9561 45223 •9072 F5338

~t 11,n}g platforn,----dcancal co

Washer Platform ,

poncnts ...

2 3 4

5 6 7, 8 9

10 11 12 13 1• 15 16 17 18 19 20 21 21 23 24

,--25 26 17 28 29 30 31 32

Ref. Only 5+120·28 5+118528 5+118526 52079 $778 350-48 54385091 D3614 S2079 D2391 S778 •9345 N-3-MC D262

- 70218 1•-0103 D2347 H-1301 $•190038 57163 D2391 F-017 F13Sll

Nut Gromme:t-coil mount , Ignition coil (17-M-12 (D22:l Rectifier (99-0589) Nut CAPACITOR PACK-2CP

Capacitor (99-10-431 Cover (99-0767) ... Base plate (99-1160) •

Screw } Nut Capacitor pack to p.~

Flasher unit (99-1201) ... Clip, flasher unit (99-120•) .. Spring } Screw , W h

Flasher unit to plat'o·:n as er

Nut Zener Diode (99-0590) Sparking plug ... Plug cover (Champion WC200) Horn--{)H (99-1245) ...

Bolt } Washer Horn to frame Nut Lucar blade terminal ... Reflector-amber (99-1161)

Washer } Nut Reflector mount ng

Mount •g rub~r

Not I u<.. D3161 Grommet (li"orr. mo,.,r.tinz)

Not i!L 5~683262 Horn Bracket

NOTE: Parts added for low frame models: D2391 Washer - capact:or bracket Fl 4520 Mounting bracket - capacitor D242 7 Washer - mounting platform 14-0301 Nut - front falririg Fl 4677 Rubber strip - tool tray F6784 Grommet - coil tray

., .

• ...

1 f l4 1 14-01 2 1 D2329 1 2 2 1 1 Reference only 2 54441582 ~ Delete - not fitted to f low frame models

~ ( 1 1 l

l l

.. 2

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

1 1 2 2 1 2

Re(. No. Part No. DE5CRIPTION QUANTITY REMARKS

~ C OIL , CAPACITOR PA C K , F L AS H E R UNIT , ZENER DIODE AND HORN

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

10 54420128 11 54418528 12 54418526 13 S2079 14 S778 15 350-48 16 54385091 17 03614 18 S2079 19 02391 20 S778 21 49345 22 N3 23 0262 2-4 70228 25 14--0103 26 D2347 27 14-1301 28 54190038 29 57183 30 D2391 31 F4717 32 F13522 Not illus. D3161

Mounting platform-electrical components ...

Bolt } Washer Platform to mudguard Nut Grommet-coil mounting Ignition coil (17-M-12) (02206) Rectifier (99--0589) Nut CAPACITOR PACK-2CP

Capacitor (99-10-43) Cover (99--0767) ... Base plate (99-1160)

Screw } . Nut Capamor pack to platform

Flasher unit (99-1201) ... Clip, flasher unit (99-1204)

Spring } Screw . W h

Flasher unit to platform as er

Nut Zener Diode (99--0590) Sparking plug .. . Plug cover (Champion WC200) Hom-6H (99-1245) ...

Bolt } Washer Horn to frame Nut Lucar blade terminal ... Reflector-amber (99-1161)

Washer } Nut Reflector mounting Mounting rubber Grommet (horn mounting) ...

79

' ... '

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

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

.. . Referenc~ only 2 2 2 2 2

.. \

[

30

26

\ ,/

31

I 2

Q) 0

t ,~ (

\,, '

. . ._a

.,,_,._

' 25 27

28 ~ 1 HEADLAMP COMPU TE

34

~ ",

2~

3

4

6 0'1

Q ........._ ..... -....___ __,,,,,. ;/ . , ~ tf. .

g I 23 10

j ' ' /

v"' r

Fis, 31. HEADLAMP AND FLASHER LAMPS

) ,. J.~ I ., ) ...

12 16

13 I

) ~ -/ii~

~ff/' ri i4 ~~

II

24

O.JO

/Ii [ ~

( t

)

Ref- No. Part Na

1 2 3

' s

'

31 n n

l16 54S2.S212

54 15106 -0086

54959619 39565 54130041 F6981 0622 Hll62 56H7 -54581638 5-4580300 SS45'48 •73832 382 s-4123'401 H-1248 1'13525 143086 1981n1

-cJESCRIPTION

HEADLAMP A D FL A S HER LAM PS

'=AOLAMP COMP~ETE R,m (99-06921 _ ght unit (99-121 F , ng wire (99-G612:i Screw ?ue Main bulb (•5 35Wl & bholder Pi ot bu I b (99-0548)

'9 99-1221)

P ot bulbholder (99-1213 Wirnlng light (Red) (99-120E) Warning light (Green) (99-1 ~ W.rning light (Amber) (99-12 Sea ng washer (99-1210)

ght switch (99-1211) .. etd, warning light

& b. warning lihgtt (99-0537) Screw, headlamp fixinhg (99-1223

,, headlamp fixing 99-122•) ,i harness (99-1222)

ON SWITCH (TYPE 149 SA) (99-1200) t

ON LOCK C W KEY Key (slate serial number)

gnition switch .:.ASHER LAMP (99-1190)

u-s (99-1191) Gas«t II; bholder merior assembly ..

Be b (99-1192) Screw (99-1193) ..

<)n, flasher lamp front ... Samduon, flasher lamp rear .. w...i- (99 1196) ..000---"1: (99 1195)

81 •

QUANT/

1 TR6R, T120P. 1 1 6 Reference only Reference only 1 Reference only

. . 1

1 1 3

'

2 2 ? 2 8

I

...

J

'

=

-

82

.. I: :5 0

~ :i: u ~ l-

o z < >­a: .. ~ .,

Ref. No. Part No. DESCRI PT/ON QUANTITY REMARKS

AfTCR J:NGINC NO. BA TTERY AND TR6C HEAD LAMP CGS0414 usr::

1 F12512 Battery earner 1 Fl4610 2 F8091 Carrier tray 1 3 F7380 Protective strip 2 4 F9353 Retaining strap ... 1 5 F13849 Buckle ... 1 F9355 6 F7380 Protective strip 4 7 F12508 Shoulder screw} 3 8 F6039 Rubber bush Battery carrier mounting 3 9 1•-1301 Nut

' 1 10 PUZ5A Bmcry-PUZ5A (99-0719) "- 1 ... 11 60262 HEADLAMP ASSEMBLY MCH 66 (91-1205) ... .. ... 1 12 534343 Rim (99-0691) 1 13 5'4525272 Light unit (99-1212) 1 1• 504665 Fixing wire (99-0683) 6 15 3J0 Bulb (45/35W vertical dip, pre-locus 99-121 •) 1 16 5'4573590 Bulbholder, pilot (99-0695) 1 17 989 Bulb {3W.M.C.C. 99-0548) 1 18 554602 Adaptor c/w leads (99-1003) 2 Not illus. 54115106 Screw, lamp fixing (99-1157) 2 Not illus. 143086 Washer (99-1224) 2 19 31356 Lighting switch (99-0563) 1 20 153631 Nut for lighting switch (pack of 10) 1 21 144921 Screw (pack of 10) 1 - 22 534296 Plate (99-0690) ... 1 23 54363454 Warning light, red (99-1208) 1 24 281 Bulb (2W.BA75) (99-0537) 2 25 54363455 Warning light, green (99-1209) 1 26 54140331 Sealing washer (99-1210) 3 27 54363'453 Warning light amber (99-1207) 1 28 54525212 Warning light shield 2 29 1-4-0404 Nut 2 30 H4247 Support bracket 1

' •

..

•

• .. Ref. No. Port No OOCRIPTION QUA

BATTER Y ... D T R6C HEADLAMP

1 fH5 _ Battery carrier 1

£ 2 F8091 Carrier t ray 1

3 F8255 Protective strip 2

4 ~353 Retaining strap ... 1

5 f13&49 Buckle ... 6 F13295 Protective strip . .. 11

7 ,12508 Shoulder screw} 3

8 "6039 Rubbe• bush Battery ca 3

9 H-1301 Nut 1

10 54027029 Ba tery-PJZ5A (99-0719) • 1

11 60262 HEADL,.MP ASSEMBLY MCH 1

12 534343 Ri ,99-0691) 1

13 545252TI . (99-041) ... • l ,,-.... 14 504665 wore (99-0683) 6

15 370 B; o 45 35W vertical dip, p

16 54573590 oholder, pilot (99-0695)

17 989 !! b 13W.M.C.C. 99-0548)

18 554602 ,t.,captor c w leads (99-1003)

Not illus. 54115106 San,, lamp fixing (99-1157)

Not illus. 143086 Washer (99-1224)

19 31272 og switch (99-0563)

20 153631 for lighting switch ... 21 H4921 Screw

............ ll 534296 99-0690)

'---23 54363454 g light, red (99-1208)

24 281 :W.BA75) (99-0537)

25 54363455 g light, green (99-1209)

26 54140331 .. asher (99-1210)

27 54363453 1,ghc amber (99-1207)

28 54525212 & ight shield

[ 29 14 0404

30 H4247 et

t

I f)

B3

• ... -

( -.,_., _.,,....

' STANDARD HARDWARE SPECIFICATION BOLTS

lengt,, Md, length

Part No. Mater/al Tbd. d a. l>eoC o(t!i,.,,d Hexagon A.F.

S1822 Steel /. UNF ½' ii" 0.500•

S1910 " i UNF it • 0.565'

S1919 ,\-'UNC 11 • 0.500•

S2010 t UNF -H' 0.375 '

1'4-0101 ¾' UNF i 0.-438·

1'4-0102 ¼' UNF I 0.438 '

1'4-0103 .. ¼' UNF l 0.438'

14-0113 /r'UNF I 0,500•

1'4-01H -rr• UNF I 0.500• • 1'4-0115 /r' UNF l '

o.500'

1'4-0128 t• UNF .... 0.563'

14-0208 ¼' UNF .. l 0.-438"

1'4-0216 n• UNF ,

o.soo· • { 1'4-0217 n ' UNF

, 0.500' •

1'4-0219 -rr' UNF • i' o.soo· (

I 14-0220 /r'UNF l

,. 0.500" • 14-0225 n• UNF 7 • 0.5QO' • 1'4-0228 /r'UNF 4 •• 0500•

14-023• t• UNF • 1· ..563"

14-0236 t • UNF ... 1· 0..56.)'

1'4-0239 t• UNF r 1· o.5c.3.

14-02•0 t • UNF • 1· 5'.3'

14-02•2 t• UNF .. 1· 8.563'

14-0251 n• UNF ... 1¼' 0-.QS'

14-6102 ¼' UNC I tlSI

14-6115 " /r"UNC II

NUTS

Part No. Material Thd. dla. Thickness rb

sn8 Steel No. 10 UNF 0.225 CkYeloc S1852 .. /r' UNF 0.330 ..

( S1906 " ¼" UNF 0.188 Pb:

S1908 n• UNF 0.313 l'lat,i

( S191-4 I' UNEF 0.250 i"\a;a

S2012 t• UNEF 0.-438 Fb:n r

S2013 I" UNEF 0.313' ffaln S10H i' UNEF 0.-438' '='.a n

1'4-0301 ¼' UNF 0.22• "loin

1'4-0302 n• UNF Q.500' 0.271' ?ta,n

14-0•01 ¼' UNF •JS 0.161 !.ock

14-0•02 'fr 'UNF Ci.5l1T 0.192 lock

14-0•03 t• UNF CU,J' 0.22, 1..ock

1'4-0701 ¼' UNF • .;J8' 0.203 ?liilldas

1'4-0702 n• UNF .soo· 0.246 Phllldas

1'4-0703 t• UNF · 563" 0.291,• Phllidas

14-1201 ¼' UNF 0.-438" 0.215' Stiffnut

14-1202 -r.•UNF 0.500• 0.335' Stlffnut

14-1301 ¾" UNF 0.438" 0.2,5• Stiff nut

14-1302 n• UNF 0.500• o.m· Stlffnut

14-1303 t• UNF 0.563' 0.320' Stiff nut

14-130-4 n' UNF 0.688' 0J75' Stiff nut

14-1305 t" UNF 0.750' 0,,35. Stlffnut

14-1902 /.'UNF 0,500• 03'1' Nyloc

• 14-1903 f' UNF 0.563' 0J75' Nyloc

i • -"'" ---

- -........,

SCREWS ,....._ ,. Port No. T ,r,e a( bead Mater/of Length under hta:J •

S1916 Cbttse head Steel 1,·

' S1917 ChffSehud 21·

S1918 C ees~ 1ead 21·

S1920 He head 1•• •• S1929 Countersunk (82 ) t½' Slot

S2079 Cheese head ,. Pozidrive y

14-060'4 Cheese head ½' Cross recess

14--6505 Countersunk (82 ·) t· I; C ,. Cross recess •

14--6607 Cheese head t• UNC .. Cross recess • 14--6608 Cheese head ¾' UNC , 1· Cross recess

14--6609 Cheese head t • UNC .... Cross recess • H-7019 Socket head -rr• UNC •• Hex. socket

• 14-7024 Socket head -f.' UNC Hex. socket

WA S HER S- PLA IN \

Port No. Material 1/dia. o/dlo. Tcl=s

S2S-1 Steel 0.273" 0.563 ' 0.048

S2S-2 Steel 0.398" 0.750" 0.063

S25-3 Steel 0.336' 0.625" 0.063

SlS-o Steel 0.531 ' 1.031 • 0.092

S25-13 Steel 0.266" 0.469' 0.06'4"

- ~ WASHER S-SP RING

Port No. Mot.tr a Os o d,a. o o height

S26-1 S?r ng Steel t· cearar,ce n· , . n

S26-2 ¼' durance it" ,1.· 0 C6-'

526-16 -H" t· n· 0040' ·

56'48 ..i.-• clearance ½' ir' ooao·

• •• Double coil.

85

Re( No. Port No. DESCRIPTION QUA"nTY ~m

---.__ FRAME

~ 1 F1•283 Frame 1

" 2 E12744 Oil filler cap 1 3 D3616 ·•ott ring 1 4 F131•2 Dipstick .. , 1 s F13642 011 filter 1 SA F13185 Sump plate 1 6 F12829 Gasket ... 2 7 D2330 Washer} 4 8 S2109 Stud Sump plate to frame 4 9 H-1302 Nut • 4

10 14--0113 Drain plug " 1 11 E12505 Joint washer 1 12 E6930 Oil Junction block 1 13 E11458 Joint washer 1 14 51908

~ut h }Junction block to crankcase 1 15 E3446 as er 16 E12428 Rocker oll pipe l 17 E1335 Washer . .. 4

18 E1435 Nut 4

19 E12337 Rocker feed pipe 1 20 D3524 Clip-rocker feed pipe 2 21 E1234S Oil return pipe 22 E6848 Clip-feed and return pipes 4

-r-.. 23 E12347 Oil feed pipe ... 24 E12349 Oil vent pipe ... 1 25 E11149 Crankcase breather pipe-front 1 26 F1161• Crankcase breather pipe-rear 1 27 F11610 "'T"' piece 1 28 D2253 Clop-breather pipe-front ... : 29 D2252 Clip-breather pipe-rear 1 30 F11615 Clip-breather pipe to fender 4

31 H3894 Screw 4

32 F4717 Nut 4

33 F12627 Centre stand 1 f l 4£15 34 F13793 Spring ... ., . 1

35 s2on Pivot bolt .. , "'

2. 36 14-1304 Nut .,. 2. 37 F11560 Prop stand 1 38 F7021 Bolt .. , 1 39 14-1303 Nut ., ' 1

40 ..... F8382 Spring 1 Not illus. D3361 Tran,fer "Made 1n England" .. . 1 Not illus. D2452 T ran,fer-Sa!ety Standards 1 Not illus. 14-0114 Bolt} 1

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

C

--R•f. No. Port No. DESCRIPTION QUANTITY REMARKS \

SW I NGING ARM ANO SUSPENSION UNITS /IJ'Tf.R ENG!Nl: NO . .....-... GGS0414 usr.: _ .,

2 3 4 5 6 7 8 9

10 11 12 13 H 15 16 17 18 19 20 21 22 23 23

-.... 24 25 26 27 28 29 30 31 32 33 34

F12513 0 1841 WE170 F12521 F12691 F12690 F12689 F12692 S2087 F12266 H-1307 F12656 H -1304 02350 14--0133 W2330 1'4-1304 64052341 64052090 64533645 9054/171 64544754 14-0235 S1997 02331 1'4-1303 14-0234 D2321 1'4-1303 F12641 14-0206 02347 3-4815 03550 H1388

SWINGING ARM Grc•se nipple Wosher. grease nipple Bush. pivot arm .. .

Sleeve, swinging arm pivot .. Distance piece R.H. Distance piece L.H. Dort e)(claJer ... Stud, swinging arm pivot W asher, swinging arm pivot ... Nut, swinging arm pivot Brake torque stay Nut, torque stay to brake plate Washer, torque stay to brake plate .. . Bolt, torque stay to swinging arm .. . Washer, torque stay to swinging arm Nut, torque stay to swinging arm SUSPENSION UNIT (D229~

Damper unit Bonded bush (99--0122 .. Spring retainer (99-0107) Sprong, 110 lbs. chrome (99-1'39)

Bolt, damper-top Stud, damper-top L.H. Washer, damper-top Nut, damper-top Bolt, damper, lower ... Washer damper lower Nut d•mper lower Chalnguard Bolt, chalnguard fixing-front Washer, ch•inguard fj)(ing-front Stop l•mp swltch-1f8SA (99-1028) Screw Washer ...

• ... ...

...

1 2 2 4 2 1 1 4 1 2 1 1 1 1 1 1 1 2 2564 1 2563 4 4 2 64543708 (100 lbs) 2 (1 off TR6C) 1 (TR6C) l (3 off TR6C) 2 (3 off TR6C) 2 2 2 1 1 1 1 2 2

Ref. No. Port No. DESCRIPTION

GAS TAN AND TW I NSEAT

1 l

*Fl4629 *fl4631

G~s t~0nk (3 ?,all.) Tl 20

TR6R 2 F9062 Steady rubber 3 F13021 Mounting rubber 4 S1823 Centre fixing bolt 5 F13133 Distance tube ... 6 F10260 Mounting rubber 7 F13320 Washer ... 8 F13321 Rubber washer .. . 9 F13319 Mounting ring .. .

10 S1999 Nut 11 02330 Washer ... 12 F13318 Beading holder ... 13 F13068 Grommet 14 F13134 Styling strip-front 15 F13135 Styling strip-rear 16 F9700 Tank motif-L.H. 16 F9701 Tank motif-RH. 17 F11339 Screw-front-tank motif 18 F7888 Screw-rear-tank motif 19 F13875 Filler cap 20 F•048 Joint waser

• 21 F3217 Jack chain -----.J.2 F3221 Clip

_ J F12800 Gas tap ... 23 F12801 Gas tap-reserve 24 E7351 Tap seal 25 F10002 Washer .. 26 F1•288 Twinseat 27 F1•291 Twinseat cover 28 F12867 Hinge 29 14-0101 Bolt } 30 02417 S

. L Hinge to twin seat ... pring was,,er 31 F9'093 Rubber buffer ... 32 F13061 , Catch assembly 33 F17597 Spring-catch assembly 34 1-40604 Screw } 35 14-1301 Nut Twlnseat catch fixing

36 02087 Check wire 37 02381 Screw-self tapping

Not Illus. Fl 3364 Seat trim strip (black) " F 14638 Petrol tank (4¾ gall.) Tl 20 .. " Fl4639 Petrol tank (4 3/4 gal.) TR6 " Fl4636 Slimline tank (2 gal.) Tl 20 " Fl4637 Slimline tank (2 gal.) TR6

--

, .....

**NOTE: Parts for seat latch after Engine Number GG50414: S25-3 Washer - side panel F7560 Seat catch plunger F4228 Spring 3/32xl/2 Split pin El 719A Washer

QUANTITY REMARKS

1 l 2 2

AFTCR ENGINE NO. GG50414 USE:

1 Fl4GG7 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 TR6C 1 TR6C 1 1 2 2 1 Fl4599 1 2 4 4 5

n Delete-not fittea to low frame models: see below**

1 1 1 l Available

l " l " l "

2 1 1 1 1

- , ' tr ' - .. --

_Re..:.(_: N_o_. __ Po_,_r _N_o. ____________ D_ES_C;_R_IP_T_IO_N _ ______ QUANTITY RCMARKS

AIR CLEANER AND SIDE PA N ELS

F13789 AIR CLEANER ASSEMBLY-L.H F13790 AIR CLEANER ASSEMBLY-R.H.

F127•9 Body- L.H. 1 F12750 Body- R.H.

2 F1)850 Cover-L.H.

2 F13851 Cover-R.H. F13791 AIR CLEANER ASSEMBLY-L.H. F13792 AIR CLEANER ASSEMBLY-R.H.

1 F12798 Body-L.H. 1 F12797 Body-R.H.

. ...... 2 F1386• Cover-L.H.

2 F13865 Covcr- R.H.

3 03072 Element

• 1•-0221 ~, } 5 F8HS Retainer

6 D2438 W h Cover 10 body as er ..

7 1•-0302 N~ ..

8 03539 Screw } 9 S501

Nut L. H. assy. to R.H. assy.

10 «218 Bolt } 11 18

S . h Air cleaner to frame prong was er

12 F12626 Connector pipe

13 F12625 Connector pipe

1• E11860 Carburetor adaptor 15 D3536 Clip-Jubilee ty;. s

16 F13859 Side panel-L.H. 17 F13860 Side panel-R.H.

18 F6673 Panel grommet ...

19 14-0201 Bolt } 20 02329 Washer Side panel to air cleaner

21 1-4--1301 Nut Not illus. 03722 Transfer ... Not illus. D3724 Transfer ...

Not illus. 03723 Transfer ...

Not illus. 1'9196 Spacer (use with 1-4--0218)

Not Illus. D3748 Transfer (5-speed)

•

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 1 2 ...

./\l'TCR CNGI N I: NO . GG5041 4 USE:

Twin Carb f'l4606 T120R 1'14 607

Single carb . Fl 4608 TR6R, TR6C Fl4 609

All models

T120R

Fl46ll TR6C, TR6R

..., Fl4673 Fl4675

14-0102 ... ~ Delete - not fitted to

• low frame models 2 T120R 2 TR6C 2 TR6R 2