64Triumph650cc Parts Manual[1]
User Manual: 64Triumph650ccPartsManual[1]
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REPLACEMENT
PARTS
CATALOGUE No. 2
UNIT CONSTRUCTION 650 c.c. TWINS
6T THUNDERBIRD
TR6 TROPHY
T120 BONNEVILLE 120
From engine No. DU 5825
See Bookmarks
TRIUMPH ENGINEERING COMPANY LIMITED
MERIDEN WORKS • ALLESLEY • COVENTRY • ENGLAND
TELEPHONE MERIDEN 331
COVENTRY 20221
TELEGRAMS "TRUSTY COVENTRY"
PUBLICATION PART No. 99-0821
ClassicBike.biz
QO
BSz1
TRIUMPH GUARANTEE
1.
In this Guarantee the word "machine" refers to the motor cycle, scooter, motor cycle combination
or sidecar as the case may be, purchased by the Purchaser.
. In order to obtain the benefit of this Guarantee, the Purchaser must have correctly completed the
registration form and returned it to us within fourteen days of the purchase.
3. We will supply, free of charge, a new part in exchange for, or, if we consider repair sufficient, will
repair free of charge any part proved within six months of the date of purchase of any new machine,
(three months overseas) or within three months of its renewal or repair in the case of a part already
renewed or repaired, to be defective by reason of our faulty workmanship or materials. We do not
undertake to bear the cost of fitting such new or repaired part or accessory.
4.
Any part considered to be defective must be sent to our Works, carriage paid, accompanied by the
following information:
(a) Name of purchaser and his address;
(b) Date of purchase of machine;
(c) Name of dealer from whom the purchase was made;
(d) Engine number and model.
5. This Guarantee shall not extend to defects or damage appearing after misuse, neglect, abnormal stress
or strain, or the incorporation or affixing of unsuitable attachments or parts and in particular:
(a) Hiring out;
(b) Racing and Competitions;
(c) Adaptation or alteration of any part or parts after leaving our Works;
(d) The attaching of a sidecar in a manner not approved by us or to an unsuitable
motor cycle.
This Guarantee shall not extend to machines whOse trade mark, name or manufacturing number has
been altered or removed, or in which has been used any part not supplied or approved by us, or to
tyres, saddles, chains, speedometers, revolution counters and electrical equipment or to parts supplied
to the order of the Purchaser and different from our standard specification.
6.
Our liability and that of our dealer who sells the machine, shall be limited to that set out in this guarantee,
and no other claims including claims for consequential damage or injury to person or property, shall
be admissible. All other conditions and warranties statutory or otherwise and whether express or
implied are hereby excluded and no guarantee other than that expressly herein contained applies to
the machine to which this Guarantee relates or any accessory or part thereof.
7. We reserve the right to modify or deviate from the Published Specification without notice.
REPAIRS GUARANTEE
1.
Whilst the highest standard of workmanship and materials is aimed at, we cannot accept liability for
any defects appearing more than three months after the machine, assembly or component has left our
Works after being repaired.
2.
We will repair or replace at our option free of charge any defective work, materials or parts relating
to the repairs carried out by us appearing within that time but shall not be under any further or other
liability for any other loss or damage whether direct or consequential and our liability shall be limited
to the cost of so making good. We do not undertake to bear the cost of fitting any replacement or
repaired part.
3.
We do not accept liability in respect of parts of proprietary manufacture, e.g. tyres, saddles, chains,
speedometers, revolution counters and electrical equipment which may be used by us in effecting a
repair. All other conditions and warranties statutory or otherwise express or implied are hereby excluded.
3
ClassicBike.biz
ILLUSTRATION INDEX
Fig. No.
Description
Page No.
1
CRANKSHAFT AND CONNECTING RODS
...
...
...
...
...
...
12
2
CRANKCASE
...
...
...
...
...
...
14
3
OIL PUMP AND RELEASE VALVE AND MANIFOLD
...
...
...
...
...
16
4
CYLINDER BLOCK AND HEAD, 6T AND TR6
...
...
...
...
...
...
18
5
CYLINDER BLOCK AND HEAD, T120
...
...
...
...
...
...
20
6
TIMING COVER, CONTACT BREAKER AND COILS
...
...
...
...
...
22
7
GEARBOX INNER COVER AND SELECTORS
...
...
...
...
...
...
24
8
GEARBOX SHAFTS AND GEARS
...
...
...
...
...
...
...
...
26
9
GEARBOX OUTER COVER
...
...
...
...
...
...
...
...
...
28
...
...
...
...
...
...
...
30
...
...
...
...
...
CLUTCH
11
CHAINCASE AND CHAINS
...
...
...
...
...
...
...
...
...
32
12
FRAME
...
...
...
...
...
...
...
...
...
34
13
SWINGING FORK AND SUSPENSION UNITS
...
...
...
...
...
...
36
14
ENGINE UNIT FITTINGS AND FOOTRESTS
...
...
...
...
...
...
38
15
EXHAUST PIPES AND SILENCERS
...
...
...
...
...
...
...
...
40
16
TELESCOPIC FRONT FORKS, 6T
...
...
...
...
...
...
...
...
42
17
NACELLE HEADLAMP AND SWITCHES
...
...
...
...
...
.:.
...
44
18
TELESCOPIC FRONT FORK, TR6 AND T120
...
...
...
...
...
...
46
19
FRONT WHEEL ...
...
...
...
...
...
...
...
...
...
...
48
20
REAR WHEEL
...
...
...
...
...
...
...
...
...
...
50
21
QUICKLY DETACHABLE REAR WHEEL
...
...
...
...
...
...
...
52
22
PETROL TANKS ...
...
...
...
...
...
...
...
...
...
...
54
23
OIL TANK
...
...
...
...
...
...
...
...
...
...
56
24
BATTERY CARRIER AND AIR FILTER
...
...
...
...
...
...
...
58
25
PANELS AND TWINSEAT
...
...
...
...
...
...
...
...
...
60
26
MUDGUARDS
...
...
...
...
...
...
...
...
...
62
27
HANDLEBARS AND CONTROL LEVERS
...
...
...
...
...
...
...
64
28
CONTROL CABLES AND AMERICAN HANDLEBARS
...
...
...
...
...
66
29
TOOLKIT, FRAME LOCK, PILLION FOOTRESTS AND LICENCE HOLDER
...
68
30
AMAL CARBURETTER, 6T
31
AMAL CARBURETTER, TR6 AND T120
32
33
SPEEDOMETER, TACHOMETER AND TAIL LAMP
...
...
...
...
...
...
10
...
...
...
...
...
...
...
...
...
...
...
...
...
...
70
...
...
...
...
...
...
...
72
HEADLAMP, WIRING HARNESS, HORN AND RECTIFIER
...
...
...
...
74
...
...
...
...
...
76
4
ClassicBike.biz
I NDEX
Page
AIR FILTER
ALTERNATOR ..
BATTERY CARRIER
CARBURETTER
MANIFOLD
... 13, 33
...
...
17
MUDGUARDS ...
63
NACELLE
45
OIL PUMP
17
OIL TANK
57
PETROL TANK
55
PILLION FOOTRESTS
69
PISTONS
13
PROP STAND ...
35
59
... 71, 73
CARTON PACKS
9
CENTRE STAND
35
CHAINCASE
33
CHAINS
33
CLUTCH
31
COIL
Page
59
...
23
Q.D. REAR WHEEL
...
53
CONTACT BREAKER
23
CONTROL CABLES
67
REAR PANELS
61
CONTROL LEVERS
65
REAR WHEEL ...
51
CRANKCASE
15
RECTIFIER
...
75
SILENCERS
...
41
CRANKSHAFT ...
...
13
CYLINDER HEAD
... 19, 21
ENGINE PLATES
39
EXHAUST PIPES
41
FOOTRESTS ......
...
FRONT FORKS
... 43, 47
FRONT WHEEL
...
SPARK PLUGS
23
SPEEDOMETER
77
STEERING RACES
35
SUSPENSION UNITS ...
...
SWITCHES
37, 45, 75
...
39
...
GEARBOX
25, 27, 29
13
TIMING GEARS
TOOLKIT
49
GASKET SETS ...
10
...
HORN
...
69
TWINSEAT
61
VALVES ...
... 19, 21
WIRING HARNESS
HANDLEBARS ..
37
...
... 45, 75
65
ZENER DIODE
45
5
ClassicBike.biz
45
THUNDERBIRD (6T) TECHNICAL DATA
...
...
...
...
...
...
...
, ...
...
71 x82 mm.
2 . 79x3 . 23 ins.
...
...
...
...
...
...
...
...
...
649 c.c. (40 Cu. ins.)
Compressionratio
...
...
...
...
...
...
...
...
...
7.5 : 1
Sparkingplugs ...
...
...
...
...
...
...
...
...
...
Champion N4
...
...
...
...
...
...
Mainjet
Needle jet
Needle...
Throttle valve
Pilotjet ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Amal Monobloc 376
230
•106
Type C
376/4
25
Gearboxsprocket
...
...
...
...
Solo
Sidecar...
...
...
...
...
...
...
...
...
20 teeth
18 teeth
...
...
...
...
Front
Rear
...
...
...
...
...
...
...
...
...
...
Fuel Tank
...
...
Oil Tank
...
...
Gearbox
...
Primary Chaincase
Front Forks (each leg)
...
...
...
...
...
...
...
...
...
...
4 galls. (18 litres)
5 pints (2 . 8 litres)
8 pint (500 c.c.)
8 pint (350 c.c.)
3 pint (190 c.c.)
...
...
...
...
...
Front, diameter...
Rear, diameter
...
...
...
...
...
...
8" (20 . 32 cms.)
7" (17 . 78 cros.)
Tyresize ...
...
...
...
Front
Rear
...
...
...
•.,
...
...
...
...
3.25x18
3.50x18
Boreand stroke
Capacity...
Carburetter
Chains
...
Capacities
B rakes
...
...
...
...
6
ClassicBike.biz
...
...
Solo
...
Sidecar ...
e" Duplexx84 links
1"xe"x103 links
1"x *"x102 links
TROPHY (TR6) TECHNICAL DATA
Boreand stroke
Ca
p
...
...
...
...
...
...
...
...
71 > 82 mm.
2 . 79;; 3 . 23 ins.
...
...
...
...
...
...
...
...
...
649 c.c. (40 Cu. ins.)
p ressionratio
...
...
...
...
...
...
...
...
...
8.5 : 1
lu
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
p acity
Com
S
...
arkin
...
gp
Carburetter
...
g
s
Mainjet
Needlejet
Needle...
Throttle valve
Pilotjet ...
Champion N4
Amal Monobloc 389
310
•106
Type D
389/3'-z
25
Gearbox sprocket
...
...
...
...
...
...
...
Solo
...
Sidecar ...
Chains
...
...
...
...
Front
Rear
...
...
...
...
...
...
...
Solo
Sidecar
...
...
...
e" Duplexx84links
8"x 8"x 103 links
' .: a"x 102 links
...
...
...
...
Fuel Tank
...
...
Oil Tank
...
...
Gearbox
Primary Chaincase
...
Front Forks (each leg)
...
...
...
...
...
...
...
...
4 galls. (18 litres)
5 pints (2 . 8 litres)
a pint (500 c.c.)
I pint (350 c.c.)
3 pint (190 c.c.)
...
Capacities
19 teeth
17 teeth
...
...
...
...
...
Front, diameter...
Rear, diameter
...
...
...
...
...
...
8 in. (20 . 32 cm.)
7 in. (17 . 78 cm.)
Tyresize ...
...
...
...
...
Front
Rear
...
...
...
...
...
...
...
...
325x19
400x18
Brakes
...
...
7
ClassicBike.biz
BONNEVILLE 120 (T 1 2 0) TECHNICAL DATA
71 x82 mm.
2 . 79x3 . 23 ins.
Bore and stroke
649 c.c. (40 cu. ins.)
Capacity ...
Compression ratio
8.5 : 1
Sparking plugs ...
Champion N4
2 Amal Monobloc 389
260
.106
Type D
389/3
25
Carburetters ...
Main jet
Needle jet
Needle ...
Throttle valve
Pilot jet ...
...
Gearbox sprocket
Chains
...
Front
Rear
Solo
Sidecar ...
... Solo
Sidecar ...
Capacities
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Brakes
Front, diameter...
Rear, diameter
Tyre size ...
Front
Rear
19 teeth
17 teeth
i" Duplexx 84 links
1"x8"x103 links
8"x8"x102 links
4 galls. (18 litres)
5 pints (2 . 8 litres)
pint (500 c.c.)
a pint (350 c.c.)
3 pint (190 c.c.)
8 in. (20 . 32 cm.)
7 in. (17 . 78 cm.)
3 . 25 x18
3 . 50 x 18
8
ClassicBike.biz
CARTON PACK LIST
The following sub-assemblies are supp€ied in carton packs under the C.P. part number stated. The
contents of these carton packs are preserved and will not deteriorate under adverse conditions.
Part No.
Contents
Brake Lining
C.P.38/A.M.2
C.P.184 ...
...
...
...
2
...
...
...
NW243 ...
16
...
...
...
W129
...
...
...
...
Brake lining
...
Rivet
2
...
...
...
W1414
...
...
...
Brake lining
16
...
...
...
W129
...
...
...
Rivet
1
...
...
...
E4899
...
...
...
Piston C.R. 7 . 5 : 1
2
...
...
...
E3049
...
...
...
Compression ring
1
...
...
...
E2898
...
...
...
Oil control ring
1
...
...
...
WE203E
...
...
Gudgeon pin
2
...
...
...
WE479
...
...
Circlip
Pistons
C.P.199 ...
...
...
.
.
...
.
C.P.199 is also available in 0 010 in., 0 020 in. and 0 040 in. oversizes.
C.P.200 ...
...
...
1
...
...
...
E5329
...
...
...
Piston C.R. 8 . 5 : 1
2
...
...
...
E3049
...
...
...
Compression ring
1
...
...
...
E2898
...
...
...
Oil control ring
1
...
...
...
WE203E
...
...
Gudgeon pin
2
...
...
...
WE479
...
...
Circlip
...
.
C.P. 200 is also available in 0 010 in., 0 . 020 in. and 0 . 040 in. overseas.
C.P.201
...
...
...
1
...
...
...
E5317
...
...
...
Piston C.R. 11 : 1 (Alcohol fuel)
2
...
...
...
E3049
...
...
...
Compression ring
1
...
...
...
E2898
...
...
...
Oil control ring
1
...
...
...
WE203E
...
...
Gudgeon pin
...
...
...
Circlip
2
...
...
...
WE479
4
...
...
...
E3049
...
...
...
Compression ring
2
...
...
...
E2898
...
...
...
Oil control ring
Piston Rings
C.P. 99
...
...
...
.
.
.
C.P. 99 is also available in 0 010 in., 0 020 in. and 0 040 in. oversizes.
Valve springs
C.P.188 ...
...
...
4
...
...
...
E4221
...
...
...
Inner spring (Red spot)
( 6T )
...
...
4
...
...
...
E4222
...
...
...
Outer spring (Red spot)
...
4
...
...
...
E3001 ......
...
...
Inner spring (White spot)
...
...
Outer spring (White spot)
...
C.P.102 ...
(TR6, T120)
...
...
4
...
...
...
E3002
...
a
ClassicBike.biz
CARTON PACK LIST—continued
Part No.
Contents
Valves
C.P.173
(6T, TR6)
2
2
...
...
E3310
E3927
...
...
Inlet valve
Exhaust valve
Valve Guides
C.P.97
(6T, TR6)
2
2
...
E2899
E2900
...
...
Inlet guide
Exhaust guide
De-coke Gasket Set
All models
D/GS1
HOW TO USE THIS PARTS CATALOGUE
First check that the engine number of your machine is subsequent to that quoted on the title page.
Next consult the index on Page 5 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 colour required. Painted parts are available only in:the colours
or alternatives specified for that model of that particular year.
Colour
Suffix Letter to Part No.
BLACK
W
...
V
SILVER
ALASKAN WHITE/GOLD...
HI-Fl SCARLET
... AW/G
...
HF
N.B. Hi-Fi Scarlet is a flamboyant finish applied over Gold Sheen.
Paint is available also in all colours in
pint or 1 gallon tins.
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.
10
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 send patterns if the part number
is quoted. The sending of patterns often delays the order as parcel post or rail takes longer than letter post.
Parts sent to Coventry for repair, replacement, or as patterns should bear the sender's Name and
Address and clear instructions should accompany the parts. In your own interest send a copy of the advice
note under separate cover. All parts must be forwarded carriage paid and care should be taken to ensure
that all remittances are sent separately and not enclosed with the parts. Fragile units such as cylinders,
etc., should always be boxed to avoid damage in transit. Complete machines should have all fitments such
as windscreens, driving mirrors, tools, etc., removed by the sender before despatch, as it is impossible for
us to accept responsibility in the event of loss in transit. We are always pleased to give estimates for overhauling and repairs, but should an estimate not be accepted, a charge will be made covering cost of dismantling
and re-assembling, if carried out.
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 Name 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:—
CARBURETTERS.
Messrs. Amal Ltd.,
Holdford Road,
Witton,
Birmingham, 6.
CHAINS.
Renold Chains Ltd.,
Wythenshawe,
Manchester.
ELECTRICAL EQUIPMENT.
Messrs. J. Lucas Ltd.,
Gt. Hampton Street,
Birmingham, 18.
TYRES.
Dunlop Rubber Co. Ltd.,
Fort Dunlop,
Birmingham, 24.
The Avon India Rubber Co. Ltd.,
Melksham,
Wilts.
SPARKING PLUGS.
Champion Sparking Plug Co. Ltd.,
Feltham,
Middlesex.
SPEEDO METERS.
Messrs. Smiths Motor Accessories Ltd.,
Cricklewood Works,
London, N.W.2.
SUSPENSION UNITS.
Messrs. Girling Ltd.,
Kings Road,
Tyseley,
Birmingham, 11.
11
ClassicBike.biz
18
19
20
17
16
17
21
22
23
24
25
Fig. 1.
1. CRANKSHAFT
CRANKSHAFT AND
AND CONNECTING
CONNECTING RODS
RODS
12
ClassicBike.biz
Ref. No.
DESCRIPTION
Part No.
QUANTITY
CRANKSHAFT AND CONNECTING RODS
1
2
3
4
5
6
7
8
8
9
10
11
12
13
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
35
36
36
37
38
39
E464271-2caoo CRANKSHAFT AND FLYWHEEL ASSEMBLY
...
CRANKSHAFT C/W. OIL TUBE
E4643
...
...
...
...
Oil tube
E3903
...
...
...
Screwed
plug
E3905
-11 -Z4ZS
...
...
...
...
...
Flywheel
E4479
...
...
...
...
Flywheel bolt
*E3907
...
...
Crankshaft
stud
(1-&"
O.A.)
E3114
...
...
...
E3606 ,o-45ZSCONNECTING ROD
...
...
...
CONNECTING ROD
E3606P
...
...
...
...
Small end bush
E1511
o 001
1D
...
Connecting
rod
bolt
/
E2490A
...
...
...
Self locking nut ...
E2922
...
...
...
...
Big
end
bearing
E3586
...
PISTON COMPLETE 7 • 5:1 C.R.
CP199
D 94$$
...
•
5:1
C.R.
PISTON
COMPLETE
8
CP200, ...
...
Taper compression ring ...
E30491°- G1 -O`4'
...
...
...
E2898 -7 o - V`iL5 Oil control ring ...
o .
3
...
...
...
...
Gudgeon
pin
WE203El - $`
...
...
...
...
...
Circlip
WE4797o-VS(.`1
...
...
...
...
...
Main
bearing
E1591
...
...
...
...
...
Oil
seal
...
E3876
7
E5446`5 '^5 ° Engine sprocket, 29 teeth Duplex ...
...
...
...
...
Distance piece ...
E4573
...
...
...
...
...
Rotor
key
E3974
ozr R tor type RM19
...
...
...
...
5421 39015%z
o
,
...
...
...
...
...
washer
Tab
E3975
...
...
...
...
...
...
Nut
E3977
...
...
...
...
...
...
Key
E1580
...
...
...
...
...
Timing
pinion
E5447
...
...
...
...
...
...
Nut
E4565
...
...
...
E4566
' S`7INTERMEDIATE WHEEL
...
...
Intermediate
wheel
bush...
E400
...
...
...
...
Camshaft
wheel...
E4562
...
...
...
...
...
Camshaft
key
E1558
...
...
...
...
Inlet
camshaft
nut
E1463
...
...
...
...
Exhaust
camshaft
nut
E4563
...
...
...
...
...
camshaft
Inlet
E4818
E4819 11-Q ° Inlet camshaft ...
E4848
...
...
...
EXHAUST CAMSHAFT
E4855
...
...
Tachometer
dr°ve
thimble
E4700
...
...
...
Rota ry breather valve ...
E5316
...
...
...
Breather valve sp ri ng ...
E2256
Exhaust camshaft
...
...
. ..
* Use D524 Loctite Sealant
13
ClassicBike.biz
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.:.
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6T
1
1
1
1
1
3
1
2
2
4
4
4
2
4
2
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
TR6
1
1
1
1
1
3
1
2
2
4
4
4
2
4
2
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
-
1120
1
1
1
1
1
3
1
...
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1
-
-
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1
1
1
1
1
1
1
1
1
1
2
2
4
4
4
2
4
2
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
-
14
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CRANKCASE
1
2
3
4
5
6
7
8
9
10
11
12
13
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
1O r
_ q- ^53
1O
E4533/4
CRANKCASE ...
...
...
E3716
Hollow Dowel ...
...
E5232
...
Screw (32 in. U.H.)
E4542
Stud (4 ..
...
O.A.)
S25-2
...
...
Plain washer
P0172A` ° ° `ko1 Nut
...
GS87
...
...
Breather disc
E2724
...
...
Breather pipe
E2260 '►
Inlet camshaft bush
...
E1516 ^^" °^' $1 Exhaust camshaft bush ...
-► k
OZ
...
...
...
...
...
...
...
Chain oiler tube ...
...
Chain oiler jet ...
...
Blanking screw ...
...
...
Oilway plug
...
...
Fibre washer
Tachometer drive plug ...
...
...
T1 257
Fibre washer
E4147
Chain tensioner abutment
Intermediate wheel spindle
E375,
Oil pipe stud (1'-z in. O.A.)
E3717
Cylinder stud (18 in. O.A.)
E672
E3523^ 0 ' 3 i Z 4 Cylinder stud (18 in. O.A.)
...
•..
Hollow dowel
E1534A^o -' $ mss '
...
Bolt (22 in. U.H.) ...
E4541
...
Bolt (1 in. U.H.)
E4540
...
Bolt (18 in. U.H.)
E4098
...
Stud (5 .i6 in. O.A.)
E4856
...
Stud (3 in. O.A.)
E2888
c.
...
•..
S25-3 L• -' WL41 Plain washer
.
...
Nut
S1 -51 Z.t- ^
...
...
Crankcase filter...
E5312
1
I
...
...
E5315 ' ' -Copper washer
...
Breather extension pipe
E5375
Drain plug (with level tube) ...
T1112
...
...
Fibre washer ...
T1257
...
...
...
Level plug
T361
...
...
WE170bo`4 i.3Fibre washer ...
1
v5
...
Drain
and
adjuster
plug
'
E4922 °' * ...
...
...
Fibre
washer
T1738
...
...
Blanking plug ...
E4579
...
Fibre washer ...
T1 921
...
E732 S1 ' Z' 1OV Filler plug
...
...
%A-Fibre washer ...
NE507`to
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
El479
-
^^°
Camshaft bush
...
...
...
...
...
...
E4744
E3885
H689
E4539
GS439
E4706
•
•
...
...
...
...
...
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15
ClassicBike.biz
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. ...
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6T
1
1
2
2
2
2
1
1
1
1
2
TR6
• 1
1
2
2
2
2
1
1
1
1
2
T120
1
1
2
2
2
2
1
1
1
1
2
1
1
1
1
1
A
1
1
1
1
1
1
1
6
2
A
1
1
1
1
1
1
1
6
2
A
1
1
1
1
1
1
1
6
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
3
11
8
1
1
1
1
1
1
1
1
1
1
1
2
2
3
11
8
1
1
1
1
1
1
1
1
1
1
1
2
2
3
11
8
1
1
1
1
1
1
1
1
1
1
1
2
2
5
ASSY.I
12
11
6
7
8
22 18 17
23
24
Fig. 3. OIL PUMP AND RELEASE VALVE AND MANIFOLD
16
ClassicBike.biz
25
Ref. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Part No.
DESCRIPTION
QUANTITY
OIL PUMP AND RELEASE VALVE AND MANIFOLD
6T
E3878-ie"b"t"Lt OIL PUMP
...
...
...
...
...
...
...
1
E3731
Pump body...
...
...
...
...
...
...
...
1
GS153
...
Feed plunger
...
...
...
...
...
...
1
E1476
Scavenge plunger ...
...
...
...
...
...
...
1
E495
Drive block
...
...
...
...
...
...
...
1
570-7 tee- x-3'3 Valve ball ...
...
...
...
...
...
...
...
2
E403
Valve spring
...
...
...
...
...
...
...
2
E2360
...
Screwed plug
...
...
...
...
...
...
2
' Joint washer ...
E3730"tt-%
...
...
...
...
...
...
...
1
E3718
Oil pump stud ( 1 . in. U.H.)
...
...
...
...
...
2
E3887
Serrated washer
...
...
...
...
...
...
2
...
E3732
...
Nut...
...
...
...
...
...
...
...
2
1e
E4191'
-5$, t• OIL RELEASE VALVE AND INDICATOR
...
...
...
1
E2794
...
...
Valve body
...
...
...
...
...
1
...
...
GS251^ e -'4-1S -. Piston
...
...
...
...
...
...
1
E4192
...
...
...
Cap ...
...
...
...
...
...
1
E4193
Sealing ring
...
...
...
...
...
...
...
1
...
...
...
...
E4194
Cup
...
...
...
...
1
...
...
GS254 c
5* Fibre washer
...
...
1
...
...
...
...
...
Main spring
...
...
1
E2788
Auxiliary spring ...
...
...
...
...
...
...
1
E2789
Button and shaft ...
...
...
...
...
...
...
1
E2791
...
...
...
...
...
...
1
...
E2793
Sealing rubber
1
E2792
...
1
...
...
...
...
...
E1670 4 0- 33 55 Fibre washer ...
4
...
...
...
...
...
...
...
Stud (146-i in. O.A.)
E2973
i t
E3334
...
1
...
...
...
...
...
...
Inlet manifold ...
E3304
S25 - L - u %
...
...
...
...
...
...
...
...
...
W103
....
...
...
...
2
...
...
Stud (1,'—Z in. O.A.)
E2962
...
...
...
1
...
...
...
...
...
NA43A'%%-%'¼.. Joint washer
...
1
...
...
...
...
...
...
E2968-►o- O^^% Insulating block
o
...
2
...
...
...
...
S25 -3b -'l*-'k1 Plain washer
.....
2
...
...
...
...
...
...
...
...
S1-51 L'- °°°'/° ' Nut
Shaft
Jo n
13
ab
Q
4
nut
washer
Plain washer
. . .
...
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...
..
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...
. . .
...
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...
Nut
17
ClassicBike.biz
. . .
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. ..
...
2
TR6
1
1
1
1
1
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
4
T1 1
1
1
1
1
1
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
-
2
-
1
-
4
4
-
4
4
-
2
1
1
2
2
-
21
33
28
30
29
1
Fig. 4. CYLINDER BLOCK AND HEAD, 6T AND TR6
18
ClassicBike.biz
Ref. No.
QUANTITY
DESCRIPTION
Part No.
1
2
CYLINDER BLOCK AND HEAD, 6T AND TR6
...
...
...
...
...
...
E28941o^t.3o9 Cylinder base washer ...
...
...
...
...
...
...
...
E4546-1o'V3o4 Cylinder block ...
...
...
...
...
...
...
4
4
...
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. . .
.•.
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4
2
2
2
4
1
2
2
2
...
. ..
...
. . .
. . .
. . .
...
:
...
...
Exhaust valve ...
E3927
...
...
...
Bottom cup
E5008
...
...
...
Bottom cup
E1544
Inner valve spring (red spot) ...
E4221
E4222-16'1140° Outer-valve spring (red spot)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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•..
2
4
4
4
4
2
2
2
4
1
2
2
2
2
2
4
-
...
...
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4
8
4
4
4
8
...
...
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...
...
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...
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...
•...
...
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"'
...
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4
8
1
1
1
1
1
2
6
6
6
4
4
4
4
4
4
4
4
2
2
4
4
4
2
6
4
2
2
4
4
8
1
1
1
1
1
2
6
6
6
4
4
4
4
4
4
4
4
2
2
4
4
4
2
6
4
2
2
4
2
2
2
2
P0172A
El 477
H200
E1612
8
E3059 7/-70o?
Tappet...
9
10
11
12
13
E4552
E2899
E3583
CYLINDER HEAD caw GUIDES
...
Inlet valve guide ...
...
Exhaust valve guide
...
Exhaust pipe adaptor
E3310
I nlet valve
14
Inner valve spring (white spot)
Outer valve spring (white spot)
...
...
...
Top collar
...
...
...
44SpIit cotter
E29001
16
17
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
TR6
1
1
...
Inner cylinder base nut
W76
15
6T
1
1
- °*7 Outer cylinder base nut
...
Tappet guide block
Tappet block screw ...
...
Serrated washer
3
4
5
6
7
15
...
...
E3001
E3002
El 543
WE259A 1t
'-
...
. ..
...
...
Cylinder head bolt (38 in. U.H.)
...
...
...
Plain washer ...
...
...
...
Bolt (3 in. U.H.)
...
...
...
Plain washer ...
...
...
Cylinder head gasket ...
E4547
...
...
...
Inlet rocker box
E4550
...
...
Exhaust rocker box ...
E4551
...
...
...
E4549b^-S' b
'' Joint washer ...
...
Rocker box stud (-- . in. O.A.)
E2980
...
...
...
Rocker box nut...
F879
...
...
...
Plain washer ...
E3302
...
Rocker box bolt (232 in. U.H.)
E2982
...
...
...
...
S25-13 14 8 Plain washer
Cylinder head bolt (for torque stay)
E1596
...
...
...
E4610-it
44 Inspection cap ...
...
...
...
Joint washer ...
E3751
...
...
...
Locking spring ...
E4609
...
...
...
WE170LA0'^^''^Fibre washer ...
...
...
...
Screw (e in. U.H.)
T1 553
ROCKER (right exhaust, left inlet) ...
El 457
ROCKER (left exhaust, right inlet) ...
E1458
...
...
Rocker ball pin ...
El 483
...
...
Rocker adjusting pin ...
E1513
...
...
...
Adjuster lock nut
E470
...
...
Thrust washer, in. ...
E1330
...
...
Thrust washer, ! in.
El 575
...
Spring washer ...
El 574
Rocker spindle
E1512
+N8 Sealing rubber ...
E3253loo7
...
...
Push rod
E2620
..•
Cover
tube
"'
E3646
...
...
Bottom joint washer ...
E1496
...
•••
•••
To ) omt washer
Top
E3547
E327
F2184
E4771
19
ClassicBike.biz
...
••
...
...
...
...
...
...
"'
...
26
37 36 43 1
42
41
49 51 45 45044 50
44 45
1
Fig. 5. CYLINDER BLOCK AND HEAD, T120
20
ClassicBike.biz
40
39
53
52
Ref No.
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47
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49
50
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52
53
54
55
56
57
CYLINDER BLOCK AND HEAD, T120
E2894 7 '
Cylinder base washer ...
Cylinder
...
...
...
...
...
E4546 -10 -Is304 Cylinder block ...
...
...
...
...
...
...
W76
Inner cylinder base nut
...
...
...
...
...
P0172A
Outer cylinder base nut
...
...
...
...
...
E1477
Tappet guide block
...
...
...
...
...
...
H200
Tappet block screw ...
...
...
...
...
...
E1612
Serrated washer
...
...
...
...
...
...
Tappet ...
E3059
...
...
...
...
...
...
...
E5348,-57.' CYLINDER HEAD c/w GUIDES ...
...
...
...
E38277 ► - 3 z-S +
Inlet valve guide ...
3Z9S
E38287iExhaust valve guide
...
...
...
...
...
70.5351
E5349
Carburetter adaptor, left
...
...
...
...
10 -535ZE5350
Carburetter adaptor, right
...
E4791
Connector ...
...
...
...
...
...
...
E4792
...
...
Balance pipe
...
...
...
...
E4608
...
Adaptor locking nut
...
...
...
...
...
E3583
Exhaust pipe adaptor
...
...
...
...
...
...
...
E4603
Inlet valve
...
...
...
...
...
...
E2904
Exhaust valve ...
...
...
...
...
...
...
...
E1544
Bottom cup
...
...
...
...
...
Inner valve spring
...
...
...
E3001
...
...
...
...
...
...
E3002
Outer valve spring
...
...
El543
...
...
...
...
Top collar
...
...
...
...
...
WE259A-7L-37 41 Split cotter
...
...
...
...
...
...
E327
Cylinder head bolt (38 in. U.H.)
...
...
...
...
...
...
Plain washer ...
...
F2184
...
...
...
...
...
...
...
E4771
Bolt (3 in. U.H.)
...
...
...
...
...
...
S25-3 u e, -4 ' 7Plain washer
...
...
...
...
Cylinder head gasket ...
...
E4547
...
...
...
...
...
...
Inlet rocker box
...
...
E4550
...
...
••.
Exhaust rocker box ...
...
E4551
...
...
E4549'10-93 4% Joint washer ...
...
...
Rocker box stud (16 i.i. O.A.)
...
E2980
...
...
...
...
.••
F879
Nut
...
...
...
...
...
Plain washer ...
...
...
E3302
...
...
...
Rocker box bolt (2,A in. U.H.)
...
E2982
c `{241
...
...
...
...
...
Plain washer
...
...
S25-13ta ...
Cylinder head bolt (for torque stay)
...
...
E1596
...
...
...
...
...
...
E4610 7-'' 4Inspection cap ...
...
...
...
...
...
Joint washer ...
...
E3751
...
...
....
...
Locking spring ...
...
...
E4609
o
...
...
...
...
...
...
WE170ia -'f ..3Fibre washer ...
...
...
...
...
...
Screw (8 in. U.H.)
...
T1553
...
ROCKER (right exhaust, left inlet) ...
...
...
E1457
...
...
ROCKER (left exhaust, right inlet) ...
...
E1458
...
...
...
...
...
Rocker ball pin ...
E1483
...
...
...
...
...
Rocker adjusting pin ...
E1513
...
...
...
...
...
...
Adjuster lock nut
E470
...
...
...
...
...
Thrust washer, e in. ...
E1330
...
...
...
...
...
Thrust washer,. in. ...
E1575
...
...
...
...
...
...
Spring washer ...
E1574
...
...
...
...
...
...
Rocker spindle
E1512
...
...
...
...
...
...
E3253 0 35'4BSealing rubber ...
...
...
...
...
...
...
...
Push rod
E2620
Cover
...
...
...
...
...
...
...
tube
E3646
...
...
...
...
...
Bottom joint washer ...
E1496
...
...
..•
...
Top joint washer
E3547
21
DESCRIPTION
ClassicBike.biz
QUANTITY
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
T120
1
1
4
4
2
2
2
4
1
2
2
1
1
2
1
2
2
2
2
4
4
4
4
8
4
8
I
1
I
1
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
6
6
6
4
4
4
4
4
4
4
4
2
2
4
4
4
2
6
4
2
2
4
2
2
2
16
22
15
20
39
37
38
40
44
46
34
45
35
29
38 36
Fig. 6. TIMING COVER, CONTACT BREAKER AND COILS
22
ClassicBike.biz
Ref. No.
1
2
3
4
5
6
7
8
9
10
11
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14
15
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17
18
19
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29
30
31
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33
34
35
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37
38
39
40
41
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43
44
45
46
46
Part No.
DESCRIPTION
QUANTITY
TIMING COVER, CONTACT BREAKER AND COILS
6T
E4567
Timing cover ...
...
...
...
...
...
...
...
1
E4016
Patent plate
...
...
...
...
...
...
...
...
1
1SS
0
D208-510 -4
Hammer-drive screw ...
...
...
...
...
...
...
3
Oil seal ...
E4568
...
...
...
...
...
...
...
...
2
E4569
Circlip ...
...
...
...
...
...
...
...
...
1
E2615
Timing cover plug
...
...
...
...
...
...
...
1
El335
Copper washer
...
...
...
...
...
...
...
1
T989
Hollow dowel ...
...
...
...
...
...
...
...
2
E3668
Screw (1 1 in. U.H.) ...
...
...
...
...
...
...
3
E3204
Screw (1 in. U.H.)
...
...
...
...
...
...
...
5
47605 N .1-•A .CONTACT BREAKER, type 4CA ...
...
1
425377
Condenser
...
...
...
...
...
...
...
2
54441729
Cam...
...
...
...
...
...
...
...
...
1
54415642 C:x
Spring set ...
...
...
...
...
...
...
...
1
425379
Weight
...
...
...
...
...
...
...
...
2
54415751'S 444tS,11 Sleeve and action plate ...
...
...
...
...
...
1
425370
Base plate ...
...
...
...
...
...
...
...
1
169194
Slotted nut...
...
...
...
...
...
...
...
4
54415803
Contact set
...
...
...
...
...
...
...
2
E5451
Bolt (2 in. U.H.)
...
...
...
...
...
...
...
1
LL.3
S25-43-,o -%
Plain washer
...
...
1
E4707
Rubber grommet
...
...
...
...
...
...
...
1
E4747
Pillar bolt
...
...
...
...
...
...
...
...
2
E2351
Plain washer
...
...
...
...
...
...
...
...
2
E4571'7 0- 1 ' 3 ' Cover ...
...
1
E50497 1 - "''02' Joint washer ...
...
...
...
...
...
...
...
1
14
GS299(ao } -'
Serrated washer
...
...
2
F4715
Screw (32 in. U.H.)
2
45110
IGNITION COIL, type MAl2
...
...
...
...
...
2
45152
...
...
...
...
...
IGNITION COIL, type MA6
54190108
...
...
Lucar terminal
...
...
...
...
...
4
131023
...
...
...
...
4
Plain washer (E2351)
...
...
188330
...
...
...
...
...
4
Serrated washer (GS299)
166043
Nut (F3799)
...
...
...
...
...
...
4
...
421554 S4RS3 r•Z$ Rubber grommet ...
...
...
...
...
...
...
2
421863
...
...
...
Cable clip ...
2
...
...
...
...
btsc.
100104
...
Screw
...
...
...
...
2
169160
...
...
...
...
Square nut
...
...
...
2
422369 Dtk
...
...
...
...
...
"D" washer
...
...
4
54942078544 " .1s%Lucar connector
...
...
...
...
...
...
...
4
54190042
Insulating cover...
...
...
...
...
...
...
...
4
F4744
Bolt (1 in. U.H.)
...
...
...
...
...
...
...
2
F5466
...
Rubber grommet
...
...
...
...
...
...
2
F4366
...
Distance piece ...
...
...
...
...
...
...
4
...
...
...
...
2
...
E3290
Self locking nut
...
...
...
...
... 2
...
...
Sparking plug (Champion N4)
—
2
...
...
...
...
Plug cover and suppressor ...
D297
...
A
...
...
...
...
...
...
Plug cover
...
D262
6
23
ClassicBike.biz
TR6
1
1
3
2
1
1
1
2
3
5
1
2
1
1
2
1
1
4
2
1
1
1
2
2
1
1
2
2
2
4
4
4
4
2
2
2
2
4
4
4
2
2
4
2
2
2
A
1120
1
1
3
2
1
1
1
2
3
5
1
2
1
1
2
1
1
4
2
1
1
1
2
2
1
1
2
2
2
4
4
4
4
2
2
2
2
4
4
4
2
2
4
2
2
2
A
8
4
10
6
17
24
18
21
20
Fig. 7. GEARBOX INNER COVER AND SELECTORS
24
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
GEARBOX INNER COVER AND SELECTORS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
20
21
22
23
24
E4535
Stud (3 in. 0.A.)
...
T989
Hollow dowel ...
...
T500 51-4 06 9 Gear selector camplate
T44 7-36‘0 Camplate index plunger
T373
Index plunger spring ...
T372
Index plunger holder ...
T260B's? - 2SS lo
selector fork
T913 V-4 501Layshaft selector fork ...
NT2611/- L51 CSelector fork roller
...
1291
Selector fork rod
T1606
Layshaft bearing
T1607
Thrust washer ...
...
11703
GEARBOX INNER COVER
T1614
Layshaft bearing ...
...
T412
Gearchange spindle bush...
T45
Kickstarter stop ...
...
T397
Camplate operating quadrant...
T1896
Quadrant spindle
in
x1
in.
Split
pin ...
...
64
'
T1778
Bolt (1i in. U.H.)
E3446
Plain washer ...
E3204
Screw (1 in. U.H.)
.
Socket screw (11 in. U.H.) ...
T1779
Countersunk screw (*in. U.H.)
E3728
25
ClassicBike.biz
...
..
...
...
..
6T
2
4
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
TR6
2
4
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
T120
2
4
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
N
0
N
u
H
M
26
IIII
M
N
ClassicBike.biz
T
W
Z
c
=
x
0
W
0
00
co
LL
Ref. No.
Part No.
DESCRIPTION
QUANTITY
GEARBOX SHAFTS AND GEARS
1
2
3
1914 5
'
"
PT108B"5^' ' S$
11914
MAINSHAFT c/w LOW GEAR (16T)
Clutch rod bush ...
...
...
MAINSHAFT HIGH GEAR (26T) ...
High gear bush ...
...
...
T120
...
...
...
1
1
1
1
1
1
1
1
1
...
...
...
1
1
1
1
1
1
...
...
...
...
1
1
1
...
...
1
1
1
1
1
1
1
1
1
...
...
...
...
...
...
...
...
1
A
1
1
A
1
1
1
1
A
1
1
A
1
1
1
1
A
1
1
A
1
1
1
1
1
1
...
...
...
1
1
1
1
...
...
...
...
...
...
LAYSHAFT LOW GEAR (30T)
Low gear bush ...
...
...
...
...
...
...
...
...
T1 370
5
6
T917T7-3SSS Mainshaft third gear (24T) ...
T916 57- 3$5 7
' Mainshaft second gear (20T) ...
57 - 1 (-
TR6
...
...
...
4
7
1T
...
...
...
...
8
T926
T928
9
10
11
T1065
T930
T1843
12
12
13
14
14
15
16
17
Layshaft second gear (26T) ...
Layshaft third gear (22T)
...
Layshaft c/w high gear (20T)
TI 744
T1747
...
...
...
T948
Speedometer pinion, solo (10T)
Speedometer pinion, sidecar (9T)
Securing pin ...
...
...
Speedometer gear, solo (15T)
Speedometer gear, sidecar (1ST)
Thrust washer ...
...
...
Speedometer drive bush
...
Rubber sealing ring ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
18
T448
High gear bearing
.:.
...
...
...
...
...
...
...
...
...
...
...
1
1
1
-
1
1
...
A
-
A
A
1
1
1
1
1
1
...
...
...
...
...
...
1
1
1
1
1
1
1
1
1
1
1
1
...
1
1
1
1
1
1
1
1
1
1925
T1 745
TI 748
T825
1933
...
...
21
21
21
T489 °°%
Circlip
Circlip ...
...
T946
Oil seal ...
...
...
...
...
T191957-X1"1!°" Gearbox sprocket (20 teeth) solo ...
T191857-t " " Gearbox sprocket (19 teeth) solo
T1917 Sh"/ 0lSGearbox sprocket (18 teeth) side-car
21
T19161-1.1'%'^''^° Gearbox sprocket (17 teeth) side-car
...
22
T440
23
S35-7Cob-3S52-Mainshaft bearing
24
25
26
27
28
29
30
31
Circlip ...
...
T1338
-3 Pinion sleeve ...
T1250
Pinion spring ...
1730
Kickstarter pinion
1731
Kickstarter ratchet
1732
...
Tab washer
NT29799 - 35 4 2 ut
...
...
11736
Clutch operating rod
19
20
1280
Gearbox sprocket nut
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
27
ClassicBike.biz
...
1
28
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
GEARBOX OUTER COVER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
T1986
GEARBOX OUTER COVER
T57
Gearchange spindle bush...
T23
Kickstarter spindle bush
T47
Kickstarter spring anchor pin
T454
Guide plate stud (I in. O.A.)
T1956
Oil seal
...
T1955
Oil seal housing ...
T408/9
°"t'earchange quadrant ...
E3309 - 353 ° Rubber "0" ring
...
T404
Quadrant return spring
T406
Gearchange quadrant plunger
T405
Plunger spring ...
1407
...
Guide plate
E1612
Serrated washer
F879
Nut
...
y
5
ji 7 ...
T25A 51
/°tIckstarter quadrant
T31
Kickstarter return spring
I
T24AS "
Kickstarter axle
57—
T1707
CLUTCH LEVER ASSEMBLY
11708
Clutch lever
T1710
Lever shaft
6°'Z3to4
T1771
Ball, I in. diam.
T1711 5 7 - 4 "
Thrust plate
•••
T1712
Return spring
GS127
Plain washer
Split
pin ...
5
in
40-Z10/
64 in • • •
Countersunk screw (I in. O.A.)
T1713
T1714
Spoke ...
T1937
Locknut
T1946
Connector
T1644
Abutment
T1645
Adaptor ...
T1646
Rubber cover
525-3u e-q41 Plain washer
1 051
/
S1-51
...
Nut
Screw (21 in. U.H.)
E3802
Screw (1* in. U.H.)
E3668
E3204
Screw (1 in. U.H.)
T1750 57- 7010 Gearchange pedal
W932 /Y- 02° IBolt (1 in. U.H.)
T9 51 - 45 ° Pedal rubber ...
T193857- 3‘ 3 FOLDING KICKSTARTER 5.7— 7Plr
T193951'
Kickstarter lever
Kickstarter pedal ...
T1272 5 7—
Pedal locating spring
T1167
°,Zito
S7 3
4 Steel ball, a in. diam.
Pedal bolt ...
T1273
3
•••
...
...
F1814 51- " ° Pedal rubber
pin
c/w
nut
and
washer
T122251-q356Cotter
...
...
Domed nut
H1531
29
ClassicBike.biz
6T
1
1
1
1
4
1
1
1
1
2
2
2
1
4
4
1
1
1
1
1
1
3
•••
• ••
•••
• ••
TR6
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
1
1
1
1
1
2
1
1
1
2
1
1
I
1
1
1
I
1
1
2
1
2
2
1
1
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1120
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
1
2
1
1
1
I
1
1
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
eb
U.
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W
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J
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N
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30
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
24
25
...
...
...
CLUTCH COMPLETE
T1928
...
...
...
...
Hub
...
T1734
...
...
...
...
Thrust washer
T1735
...
...
...
...
...
Roller
T394
Sprocket and housing (58 teeth Duplex)
TI 570
...
...
...
...
...
Centre
T1719
...
...
...
...
Inner plate
T1720
Countersunk screw (0 . 417 in. U.H.) ...
11040
...
...
Shock absorber spider ...
11721
...
...
...
Drive rubber (large)
T1722
...
...
Rebound rubber (small)
11723
...
...
...
...
Outer plate
T1724
S
...
...
Screwed pin (1 2 in. U.H.)
7 -47 `
T423A 'S...
...
Driving plate (bonded) ...
1136257-4763
...
...
...
...
Driven plate
T1363
L5
...
Pressure-plate
T1929
...
...
...
...
Adjuster pin
T1256
0
...
...
...
...
...
GS662(- - 42d. q- Nut
...
...
...
...
Spring cup ...
T1931
...
...
...
...
...
Spring
T1830
...
...
...
...
Brass nut ...
T427
...
...
...
...
...
...
'tVS 3 Key
566-1 t
...
...
...
...
Cupped washer
11045
...
...
...
...
...
Tab washer
T1 046
...
...
...
Clutch securing nut ...
T1047
31
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
6T
...
1
1
...
1
...
... 20
1
...
...
1
...
1
...
6
...
1
3
...
3
...
...
1
...
3
6
...
...
6
...
1
1
...
...
1
...
3
...
3
3
.•.
...
1
1
...
1
1
...
TR6
1
1
1
20
1
1
1 -
6
1
3
3
1
3
6
6
1
1
1
3
3
3
1
1
1
1
T120
1
1
1
20
1
1
1
6
1
3
3
1
3
6
6
1
1
1
3
3
3
1
1
1
1
M
O
N
\
O
M
N
A
N
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32
ClassicBike.biz
M
N
N
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N
Q
2
C
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4
W
U
z
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I
U
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LL
Ref. No.
Port No.
DESCRIPTION
QUANTITY
CHAINCASE AND CHAINS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
E4704
Primary chain oiler tube
E4705
Clip
.
6•
S2 2 6 4 250 Spring washer ...
DS57
- 9611 Bolt (* in. U.H.)
...
...
D481
Rear chain, 1 in. x i in. x 103 links
L
E383211 4 9 Joint washer
E4577
Cover plate
E4578
Oil seal ...
...
...
E3821
Countersunk screw (A in. U.N.)
E4147 73087 Chain tensioner abutment
E4149
Chain tensicner blade
E4152
Tie rod ...
E4145
Trunnion
...
E4153,0'"°3 Adjuster sl2eve nut
...
D477
Primary chain, 1 in. Duplex x 84 links
E4536
Stator stud
...
E4537
Stator stud
47162 4.j7x
Stator, RM 19 ...
47164 41111
Stator, RM 19 ...
E4772
Sleeve nut
...
E4144
Rubber grommet
E5449
Plastic sleeve ...
7
6
S25-3 °'4 L4 Plain washer
E5324
Self-locking nut
T1770ni-143 Joint washer
T1727 11-461
Chaincase
...
E2441
Copper washer
E4922n*4, Drain and adjuster plug
T1738
Fibre washer
1- 1 6 6 Filler plug
E732
NE5071b-S72 Fibre washer ...
E4805
Screw (H in. U.H.)
Screw (1 in. U.H.)
E3204
H1531
Domed nut
...
Copper washer ...
F1880
33
ClassicBike.biz
...
...
...
...
...
...
...
...
...
...
•.•
•••
•••
•••
6T
1
1
1
2
1
1
1
6
1
1
1
1
1
1
2
1
TR6
1
1
1
2
1
1
1
1
6
1
1
1
1
1
1
2
1
1
-
1
1
1
3
3
1
1
1
1
1
1
1
2
6
2
2
1
1
1
1
3
3
1
1
1
1
1
1
1
2
6
2
2
T120
1
1
1
2
1
1
1
1
6
1
1
1
1
1
1
2
1
1
1
1
1
3
3
1
1
1
1
1
1
1
.2
6
2
2
v cl)
®^o
bO
U-
34
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
FRAME
...
...
...
...
...
6T
1
2
40
...
...
...
1
1
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
—
1
2
2
2
1
1
—
1
1
1
1
1
—
2
2
2
2
2
2
2
—
1
1
2
2
2
1
—
1
1
1
1
1
—
1
2
2
2
2
2
2
2
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
F5448
Front frame
...
...
H111i - t- 41o3 Steering race cup
...
S70-3 °o ' -LS - %L Steel ball (I in. diam.)
...
...
...
...
...
...
...
...
...
...
4
H1018
...
...
...
5
5
6
7
F5928
...
Centre stand (3 . 50 rear tyre)...
...
...
...
F5932
Centre stand (4 . 00 rear tyre)...
b
T449 5-1 ...
...
...
Pedal rubber ...
...
...
...
...
...
F5678
Pivot bolt
...
...
...
...
F5679
Plain washer ...
...
...
Nut
...
...
...
...
F2725
...
...
...
...
F4671
Return spring ...
'357 PROP STAND COMPLETE (3 . 50 rear tyre)
F4388
73'3
PROP STAND COMPLETE (4 . 00 rear tyre)
F4712 t'
...
...
...
...
F3097
Pivot bolt ...
...
...
...
...
Tab washer
F3096
...
...
...
...
Return spring
F2610
...
F54494sZ''443 Rear frame
...
...
...
...
Stud (e in. O.A.) (when panels are fitted)
F4510
...
...
...
...
Stud (3'— in. O.A.)
F2842
S5
0
...
...
...
...
Spring washer ...
S26-1 L '4
i
...
...
...
...
...
Nut
S1-52(,O-^-P
...
...
...
...
Bolt (3 in. U.H.)
F5411
...
...
...
...
...
' Plain washer
S25-63
...
DS47
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