66Triumph500cc Parts Manual[1]

User Manual: 66Triumph500ccPartsManual[1]

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REPLACEMENT
PARTS
CATALOGUE No. 7
"C" RANGE MODELS
TWENTY-ONE (3TA)
SPEED TWIN (5TA)
TIGER 90 (T90)
TIGER 100 (T100)
from Engine No. H 40528
September 1965
TRIUMPH ENGINEERING COMPANY LIMITED
MERIDEN WORKS
•
ALLESLEY
•
COVENTRY
•
ENGLAND
TELEPHONE MERIDEN 331
TELEGRAMS "TRUSTY COVENTRY"
REF.
18167
PUBLISHED OCTOBER 1965
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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.
2.
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 re-
pair free of charge any part proved within six months of the date of purchase of any new machine, (3
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 defect 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;
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 guaran-
tee, and no other 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 waranties statutory or otherwise express or implied are hereby ex-
cluded.
2
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TRIUMPH SPARES
HOW TO ORDER.
Every part is indicated by 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 crank case
underneath the cylinder flange, 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. 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 over-
hauling 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 names and addresses appear below.
PROPRIETARY GROUP
Ancillary equipment which is fitted to our motor cycles is of the highest quality and is guaranteed by
the manufacturer and not by ourselves. Any repairs or claims should be made 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 Rd., Witton, Birmingham 6.
CHAINS
Renold Chains Ltd.,
Wythenshawe, Manchester.
ELECTRICAL EQUIPMENT
Messrs J. Lucas Ltd.,
Gt. Hampton St., Birmingham, 18.
TYRES
Dunlop Rubber Co. Ltd.,
Fort Dunlop,
Birmingham, 24.
SPARKING PLUGS
Champion Sparking Plug Co. Ltd.,
Feitham, Middlesex.
SPEEDOMETERS
Messrs. Smiths Motor Accessories Ltd.,
Cricklewood Works, London, N.W.2.
SUSPENSION UNITS
Messrs. Girling Ltd.,
Birmingham Road, West Bromwich, Staffs.
ClassicBike.biz
ILLUSTRATION INDEX
Fig. No.
Description
Page No.
1
CRANKSHAFT AND CONNECTING RODS ...
16
2
CRANKCASE
18
3
OIL PUMP, RELEASE VALVE AND INLET MANIFOLD
20
4
CYLINDER BLOCK AND HEAD, 3TA AND T90 ...
22, 24
5
CYLINDER BLOCK AND HEAD 5TA AND T100
26
6
TIMING COVER AND CONTACT BREAKER
...
28
7
GEARBOX SHAFTS, BEARINGS AND INNER COVER
30, 32
8
GEARBOX OUTER COVER AND LEVERS
34
9
CLUTCH
...
36
10
CHAINCASE AND CHAINS
38
11
ENGINE FITTINGS AND EXHAUST SYSTEM
...
40
12
EXHAUST PIPES, UNDERSHIELD AND FOOTPEGS 100C)
42
13
FRAME
...
44
14
SWINGING FORK, SUSPENSION UNITS AND CHAINGUARD
46
15
TELESCOPIC FRONT FORK, 3TA AND 5TA
48
16
NACELLE, HEADLAMP AND SWITCHES
50
17
TELESCOPIC FRONT FORK, T90 AND T100
52
18
TELESCOPIC FRONT FORK, U.S.A. EASTERN T100C
54
19
FRONT WHEEL
56
20
REAR WHEEL
...
58
21
QUICKLY DETACHABLE REAR WHEEL (NOT U.S.A.)
60
22
MUDGUARDS (STANDARD) ...
...
62
23
FENDERS (U.S.A.) ...
...
64
24
PANELS AND TWINSEAT
66
25
PETROL (GAS) TANKS ...
68
26
OIL TANK ...
...
70
27
BATTERY, TOOLKIT AND AIR FILTER
72
28
HANDLEBARS AND CONTROL LEVERS
74
29
CONTROL CABLES
...
76
30
CARBURETTER, 3TA AND 5TA
78
31
CARBURETTER, T90 AND T100
80
32
A.C. MAGNETO IGNITION COILS, WIRING HARNESS AND
DIRECT LIGHTING ...
...
82
33
D.C. IGNITION
COILS,
HORN, RECTIFIER AND ZENER DIODE
84
34
T90 AND T100 HEADLAMP, WIRING HARNESS, SWITCHES AND
TAIL LAMP ...
86
35
SPEEDOMETER AND TACHOMETER ...
88
4
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I
NDEX
Page
Page
AIR FILTER
... ... ... ...
73
MANIFOLD
...
21
ALTERNATOR
... ...
17,39
MUDGUARDS ...
...
...
...
63
MUFFLERS
...
...
... ...
41
BATTERY CARRIER ...
...
...
73
NACELLE
... ...
51
CARBURETTER
... ...
79,81
CARTON PACKS ...
... ...
10
OIL PUMP
... ... ...
21
CENTRE STAND
... ... ...
45
OIL TANK
... ... ... ...
71
CHAINCASE...
... ... ...
39
PETROL TANK
...
... ...
69
CHAINS
...
39
PILLION FOOTRESTS
...
...
...
45
CLUTCH
...
37
PISTONS
... ... ... ...
17
COIL
...
83, 85
PROP STAND ...
45
CONTACT BREAKE
...
...
29
CONTROL CABLES
... ... ...
77
Q.D. REAR WHEEL (NOT
U.S.A.) ...
61
CONTROL LEVERS
...
...
...
75
CRANKCASE...
... ...
...
19
REAR PANELS
... ... ...
67
CRANKSHAFT
... ... ...
17
REAR WHEEL ...
...
... ...
59
CYLINDER HEAD
...
...
23, 25, 27
RECTIFIER
...
...
... ...
85
ENGINE PLATES
...
...
41
SILENCERS
...
... ... ...
41
EXHAUST PIPES
... ...
...
41, 43
SPARK PLUGS
... ... ...
85
SPEEDOMETER
...
... ...
89
FENDERS
... ... ...
...
65
STEERING RACES
...
...
...
45
FOOTRESTS
... ...
...
...
43, 45
SUSPENSION UNITS
...
... ...
47
FRONT FORKS
...
...
49, 53, 55
SWITCHES
... ... ...
...
51,87
FRONT WHEEL
...
...
...
57
TIMING GEARS
...
...
...
17
GASTANK
...
...
... ...
69
TOOLKIT
...
...
... ...
73
GASKET SETS ...
...
...
...
11
TWINSEAT
...
...
...
...
67
GEARBOX ... ...
...
31, 33, 35
VALVES...
... ...
...
23, 25, 27
HANDLEBARS...
...
...
...
75
HORN
...
...
... ... ...
83, 85
WIRING HARNESS
... ...
51, 83,85
I
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TW
ENTY-ONE (3TA) TECHNICAL DATA
Bore and stroke
Capacity
Compression Ratio
Sparking Plugs
Carburetter
Gearbox Sprocket
Chains
Capacities
Brakes
Tyre
Size
Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Front
Rear
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Front and Rear, diameter
Front
Rear
58.25 x 65.5 mm.
2.292 in. x 2.578 ins.
348 c.c. (21.23 cu. ins.).
7.5 : 1
Champion N4
Amal Monobloc 375
100
.106
Type B
375/31
25
17 teeth
1 in. Duplex x 78 links
in. x
1
in. x 102 links
31 galls. (16 litres)
6 pints (3.5 litres)
2/3 pint (375 c.c.)
pint (300 c.c.)
pint (190 c.c.)
7 in. (17.78 cm.)
3.25 x 18
3.50 x 18
6
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Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Front
Rear
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Front and Rear, diameter
Front
Rear
SPEED TWIN (5TA) TECHNICAL DATA
Bore and Stroke
Capacity
Compression Ratio
Sparking Plugs
Carburetter
Gearbox Sprocket
Chains
Capacities
Brakes
Tyre Size
69 x 65.5 mm.
2.716 x 2.578 ins.
490 c.c. (29.8 cu. ins.)
7 : 1
Champion N4
Amal Mono bloc 375
160
.105
Type B
375/3
25
19 teeth
in. Duplex x 78 links
in. x I in. x 103 links
31 galls. (16 litres)
6 pints (3.5 litres)
2/3 pint (375 c.c.)
1 pint (300 c.c.)
I pint (190 c.c.)
7 in. (17.78 cm.)
3.25 x 18
3.50 x 18
7
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Bore and StrokeBore and Stroke
58.25 x 65.5 mm.
2.292 x 2.578 ins.
58.25 x 65.5 mm.
2.292 x 2.578 ins.
TIGER 90 (T90) TECHNICAL DATATIGER 90 (T90) TECHNICAL DATA
Capacity
Compression Ratio
Sparking Plugs
Carburetter
Capacity
Compression Ratio
Sparking Plugs
Carburetter
Main Jet
f"lain Jet
Needle JetNeedle Jet
NeedleNeedle
Throttle ValveThrottle Valve
Pilot JetPilot Jet
Gearbox SprocketGearbox Sprocket
ChainsChains
FrontFront
RearRear
CapacitiesCapacities Fuel TankFuel Tank
Oil TankOil Tank
GearboxGearbox
Primary ChaincasePrimary Chaincase
Front Forks (each leg)Front Forks (each leg)
Brakes
Front and Rear, diameter
Brakes'
Front and Rear, diameter
Tyre SizeTyre Size
FrontFront
RearRear
348 c.c. (21.23 cu. ins.)
9:1
348 c.c. (21.23 cu. ins.)
9:1
Champion N4Champion N4
Amal Monobloc
180
.106
Type C
376/34-
20
Amal Monobloc
180
.106
Type C
376/32
20
17 teeth17 teeth
8 in. Duplex x 78 links
in. x 8 in. x 102 links
34- galls. (16 litres)
6 pints (3.5 litres)
2/3 pint (375 c.c.)
'—
z
pint (300 c.c.)
4-
pint (190 c.c.)
7 in. (17.78 cm.
3.25 x 18
3.50 x 18
8 in. Duplex x 78 links
e in. x 8 in. x 102 links
3'—
z
galls. (16 litres)
6 pints (3.5 litres)
2/3 pint (375 c.c.)
'—
z
pint (300 c.c.)
'^
pint (190 c.c.)
7 in. (17.78 cmJ
3.25 x 18
3.50 x 18
88
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Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Front
Rear
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Front and Rear, diameter
Front
Rear
TIGER 100 (T100) TECHNICAL DATA
Bore and Stroke
Capacity
Compression Ratio
Sparking Plugs
Carburetter
Gearbox Sprocket
Chains
Capacities
Brakes
Tyre Size
69 x 65.5 mm.
2.716 x 2.578 ins.
490 c.c. (29.8 cu. ins.)
9 : 1
Champion N4
Amal Monobloc
190
.106
Type C
376/31
25
18 teeth
I in. Duplex x 78 links
in. x
in. x 102 links
31 galls. (16 litres)
6 pints (3.5 litres)
2/3 pint (375 c.c.)
pint (300 c.c.)
pint (190 c.c.)
7 in. (17.18 cm.)
3.25 x 18
3.50 x 18
9
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U.S.A. TIGER 100 (EASTERN T1000) TECHNICAL DATA
Bore and Stroke
Capacity
Compression Ratio
Sparking Plugs
Carburetter
Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Gearbox Sprocket
Chains
Front
Rear
Capacities
Gas Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Brakes
Front and Rear, diameter
Tyre Size
Front
Rear
2.716 x 2.578 ins.
29.8 cu. ins.
9:1
Champion N4
Amal Monobloc
190
.106
Type C
376/34-
25
18 teeth
8
in. Duplex x 78 links
in. x a in. x 102 links
23 U.S. galls.
6 U.S. pints
2/3 pint (375 c.c.)
pint (300 c.c.)
3
pint (190 c.c.)
7 in. (17.18 cm.)
3.25 x 19
4.00 x 18
10
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Main Jet
Needle Jet
Needle
Throttle Valve
Pilot Jet
Front
Rear
Gas Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
Front and Rear, diameter
Front
Rear
U.S.A. TIGER 100 (WESTERN TINC) TECHNICAL DATA
Boe and Stroke
Capacity
Compression Ratio
Sparking Plugs
Carburetter
Gearbox Sprocket
Chains
Capacities
Brakes
Tyre Size
2.716 x 2.578 ins.
29.8 cu. ins.
9 : 1
Champion N4
Amal Monobloc
190
.106
Type C
376/3f
25
18 teeth
1 in. Duplex x 78 links
1 in. x
in. x 102 links
21 U.S. galls.
6 U.S. pints
2/3 pint (375 c.c.)
+ pint (300 c.c.)
+ pint (190 c.c.)
7 in. (17.18 cm.)
3.25 x 19
4.00 x 18
11
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U.S.A. TIGER 100 (T100R) TECHNICAL DATA
Bore
and Stroke
2.716 x 2.578 ins.
Capacity
29.8
Cu.
ins.
Compression Ratio
9 : 1
Sparking Plugs
Champion N4
Carburetter
Amal Monobloc
Main Jet
190
Needle Jet
.106
Needle
Type C
Throttle Valve
376/3'—
z
Pilot Jet
25
Gearbox Sprocket
19 teeth
Chains
Front
gin. Duplex x 78 links
Rear
8
in. x g in. x 102 links
Capacities
Gas Tank
28 U.S. Galls.
Oil Tank
6 U.S. pints
Gearbox 2/3 pint (375 c.c.)
Primary Chaincase
+ pint (300 c.c.)
Front Forks (each leg)
pint (190 c.c.)
Brakes
Front and Rear, diameter
7 in. (17.18 cm.)
Tyre Size
Front
3.25 x 19
Rear
4.00x18
12
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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.
Model
Colour
Suffix Letter to Part No,
3TA
PACIFIC BLUE/ALASKAN WHITE
PB/AW
5TA
BLACK/SILVER
W/V
T90
GRENADIER RED/ALASKAN WHITE
GR/AW
T100
SHERBOURNE GREEN/ALASKAN WHITE SG/AW
N.B. Pacific Blue is a flamboyant finish applied over Silver Sheen.
Paint is available also in all colours in
4
pint or 1 gallon tins, or Aerosol containers.
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.
13
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Brake
Lining
C.P. 38/AM2
Steering Races
C.P. 167
Pistons (350 c.c.)
C.P. 164
Brake Lining
Rivet
Cone
Cone and dust cover
Cup
Steel balls (3/16 in. diam.)
Piston C.R. 7.5 : 1
Compression ring (plain)
Compression ring (taper)
Oil control ring
Gudgeon pin
Circlips
2 NW243
16 W129
1
H1110
1
H1140
2 H1130
48 S70-4
1
E3689
1
E3691
1
E3690
1
E3692
1
E1750
2 E1767
2 E3691
2 E3690
2 E3692
C.P. 165 is also available in 0.010 in., 0.020 in. and 0.040 in. oversizes.
Piston Rings (350 c.c.)
C.P. 165
Compression ring (plain)
Compression ring (taper)
Oil control ring
Piston C.R. 7 :1
Compression ring (taper)
Oil control ring
Gudgeon pin
Circlips
Piston C.R. 9 :1
Compression ring (taper)
Oil control ring
Gudgeon pin
Circlips
CARTON PACK LIST
The following sub-assemblies are supplied in carton packs under the C.P. part number stated. The
contents of these carton packs are preserved and will not deteriorate under adverse conditions.
Part No.
Contents
C.P. 164 is also available in 0.010 in., 0.020 in. and 0.040 in. oversizes.
C.P. 198
1 E4670
2 E3690
1
E3692
1
E1750
2 E1767
C.P. 198 is also available in 0.010 in., 0.020 in. and 0.040 in. oversizes.
Piston C.R. 9:1
Compression ring (taper)
Oil control ring
Gudgeon pin
Circlips
Pistons (500 c.c.)
C.P. 174
1 E4004
2 E3829
1
E3831
1
WE203E
2 WE479
C.P. 174 is also available in 0.010 in. and 0.020 in. oversizes.
C.P. 179
1 E4021
2 E3829
1
E3831
1
WE203E
2 WE479
C.P. 179 is also available in 0.010 in. and 0.020 in. oversizes.
Piston Rings
(500 c.c.)
C.P. 175
4 E3829
2 E3831
C.P. 175 is also available in 0.010 in. and 0.020 in. oversizes.
Compression ring (taper)
Oil control ring
14
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CARTON PACK LIST—
continued
Part
No.
Contents
C.P. 180
4 E4135
Compression ring (taper)
2 E4136
Oil control rings
C.P. 180 can only be fitted to E4021 Piston body, and should only be used for high-performance work.
Valve Guides (3TA, 5TA)
C.P. 170
4 E3208
Valve guides
4 E3209
Valve guides circlip
Valves (3TA)
C.P. 166
2 E3738
Inlet valve
2 E3739
Exhaust valve
Valves (500 c.c.)
C.P. 176
2 E4012
Inlet valve
2 E4013
Exhaust valve
Valve Springs
C.P. 177
4 E5946
Inner valve spring
4 E4011
Outer valve spring
De-coke Gasket Set
Al! models
D/GS 6
15
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12
13
14
15
18 19
40 21
22 28
Fig. 1. CRANKSHAFT
AND CONNECTING RODS
16
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Ref. No.
Part
No
DESCRIPTION
QUANTITY
REMARKS
CRANKSHAFT AND CONNECTING RODS
1
E5869
CRANKSHAFT AND FLYWHEEL ASSEMBLY
... ...
1
2
E3998
Crankshaft
...
...
...
... ...
...
1
3
E3999
Oil tube
... ...
...
...
...
4
E3711
Screwed plug
... ...
1
5
E5870
Flywheel
... ...
...
... ...
...
...
1
6
*E3713
Flywheel bolt
... ...
...
... ... ...
3
7
E3702
CONNECTING ROD
...
... ...
...
...
2
3TA, T90
7E4001T
CONNECTING ROD...
...
... ...
...
...
2
5TA, T100
8
E1762
Small end bush
...
...
...
...
...
...
2
3TA, T90
8
E4003
Small end bush
... ...
...
...
... ...
2
5TA, T100
9
E3705
Connecting rod bolt
...
...
...
... ...
2
10
E2922
Self-locking nut
...
...
...
...
... ...
2
11
E3706
Big end bearing
...
...
...
...
...
...
4
12
CP 164
PISTON COMPLETE C.R. 7.5:1
...
...
...
...
23TA
12
CP 174
PISTON COMPLETE C.R. 7:1
...
... ...
...
2
5TA
12
CP 198
PISTON COMPLETE C.R. 9:1
...
...
...
...
2
T90
12
CP 179
PISTON COMPLETE C.R. 9:1
...
...
...
...
2
T100
13
E3691
Plain compression ring ...
... ...
...
...
2
3TA
13
E3829
Taper compression ring ...
...
...
...
...
2
STA, T100
14
E3690
Taper compression ring ...
...
...
...
...
2
3TA, T90 (4 off)
14
E3829
Taper compression ring ...
...
...
...
...
2
5TA, T100
15
E3692
Oil control ring
...
...
...
...
...
...
2
3TA, T90
15
E3831
Oil control ring
...
...
...
...
...
...
2
5TA, T100
16 E1750
Gudgeon pin
... ... ...
... ... ...
2
3TA, T90
16
WE 203E
Gudgeon pin
...
...
...
...
... ...
2
5TA, T100
17 E1767
Circlip
... ... ...
4
3TA, T90
17
WE 479 Circlip
... ... ...
...
... ...
...
4
5TA, T100
18 E4006
Distance collar
... ...
...
...
...
...
1
19
E4141
Engine sprocket, 26T Duplex ...
... ... ...
1
20
E3851
Rotor key
...
... ...
...
...
...
...
1
21
54213901
Rotor, type RM 19 ...
...
...
...
...
...
1
21
54215824
Rotor, type RM19...
...
...
... ... ...
...
1
A.C. ignition
22
E3975
Tab washer ...
...
... ... ...
...
...
1
23 E3735
Nut
... ... ...
...
... ... ...
...
1
24
E1580
Key
... ... ... ... ... ... ...
...
1
25
E1771
Timing pinion
... ... ...
...
... ... ...
1
26
E398
Nut
...
...
...
...
... ...
...
...
1
27
E6160
INTERMEDIATE WHEEL
... ... ...
...
...
1
28
E400
Bush
... ...
...
... ... ... ...
1
29
E1486 A
Camshaft wheel...
...
...
... ... ... ...
2
30 E1558
Camshaft key
... ...
...
... ... ... ...
2
31
E1463
Inlet camshaft nut
...
...
... ... ... ...
1
32
E4563
Exhaust camshaft nut
...
...
... ... ...
...
1
33
E6120
Inlet camshaft
... ...
...
... ... ... ...
1
3TA. (Use E3838)
33
E4678
Inlet camshaft
...
...
...
... ...
...
...
1
5TA, T90, T100
34
E5341
Exhaust camshaft
... ...
...
... ...
...
1
3TA
34
E4786
EXHAUST CAMSHAFT
...
...
... ... ...
1
STA, T90, T100
35
E4700
Tachometer drive thimble
...
... ...
...
1
36
E5316
Rotary breather valve ...
...
...
... ... ...
1
37
E2256
Breather valve spring ...
...
...
...
...
...
1
38
E3727
Retaining plate ...
... ...
...
...
...
...
2
39
E3728
Screw (15/32 in. U.H.)
...
...
...
... ...
4
40
E4142
Dowel
...
...
...
...
...
...
...
...
1
A.C. ignition
*Use D524 Loctite sealant
17
ClassicBike.biz
45 44
Fig. 2. CRANKCASE
18
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
R
EMARKS
CRANKCASE
1
E5868/4645
CRANKCASE c/w STUDS AND RIGHT MAIN BEARING
1
2
E3716
Hollow dowel
...
1
3
E3859
Screw (21/32 in. U.H.)
2
4
E3804
Stud (3 in. O.A.) ...
1
5
E3803
Stud
pi
in. U.H.)
2
6
E3799
Bolt
(11
in. U.H.) ...
1
7
S25-3
Plain washer
3
8
51-51
Nut
3
9
E1310
Nut
...
1
10
E3822
Breather disc
...
1
11
E3824
Inlet camshaft bush
1
12
E3823
Exhaust camshaft bush
1
13
E2724
Breather pipe
...
1
14
E6076
Blanking plug
1
Not serviced
15 E6386
Dowel
... ...
1
Not serviced
16
E4147
Chain tensioner abutment
1
17 E3719
Oil scavenge pipe
1
18 E1509
Clip
...
...
1
19
E1645
Screw (17/64 in. U.N.)
...
1
20
E3718
Oil pump stud (1
in. O.A.)
2
21
E375
Intermediate wheel spindle
1
22
E3717
Oil pipes stud (11 in. O.A.)
1
23
E4322
Right main bearing
...
1
24
E4139
Locating plate ...
1
25
E4140
Self-tapping screw
...
1
26
E3820
Cylinder stud (1i in. O.A.)
6
27
E3819
Cylinder stud (1 4
in. O.A.)
2
28
E1534A
Dowel
2
29
E3835
Left main bearing (Ball-journal)
1
30
E3876
Oil seal
...
1
31
E3724
Filter spring
1
32 E3722
Filter
...
1
33
E3723
Sealing washer
1
34
E1564
Filter cap
1
35
E1577
Joint washer
...
1
36 E3078
Breather extension rubber pipe
1
37
T1399
Stud (3
.
in. O.A.)
...
...
2
38
T1112
Drain plug (with level tube) ...
1
39
WE 170
Fibre washer
...
1
40
T361
Level plug
1
41
T1257
Fibre washer
3
42
E732
Filler plug
2
43
NE507
Fibre washer
...
...
2
44
E4587
Distributor hole plug ...
1
45
E4593
Fibre washer
...
...
1
46
E4706
Tachometer drive plug
2
19
ClassicBike.biz
7v/
//%
®
8
]
i
ASSY.I
•
I
I
3
O^
5
K
•• • 1
A
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13
rd
TI
I
I
10
7 9 8 6 5
Fig. 3. OIL PUMP, RELEASE VALVE AND INLET MANIFOLD
20
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
OIL PUMP AND RELEASE VALVE
1
E3878
OIL PUMP
...
...
...
...
...
...
...
1
2
E3731
Pump body...
...
...
...
...
...
...
1
3
S70-7
Valve ball
...
...
...
...
...
...
2
4
E403
Valve spring
...
...
...
...
...
...
2
5
E2360
Screwed plug ...
...
...
...
...
...
2
6
GS153
Feed plunger ...
...
...
...
...
...
1
7
E1476
Scavenge plunger ...
...
...
...
...
...
1
8
E495
Drive block ...
...
...
...
...
...
1
9
E3730
Joint washer
...
...
...
...
...
...
...
1
10
E3887
Serrated washer
...
...
...
...
...
...
2
11
E3732
Nut
... ...
...
...
...
...
...
...
2
12 E5896
OIL RELEASE VALVE
...
...
...
...
...
1
13
E2794
Valve body
...
...
...
...
...
...
1
14
GS251
Piston
...
...
...
...
...
...
...
1
15
E2304
Cap ...
...
...
...
...
...
...
...
1
16
GS254
Fibre washer ...
...
...
...
...
...
1
17 E6062
Main spring
...
...
...
...
...
...
1
18
El 670
Fibre washer
...
...
...
...
...
...
...
1
I
NLET MANIFOLD
1
E3796
Stud (1 17/32 in. O.A.)
...
...
...
2
E3797
Stud (2 in. O.A.)
...
...
...
...
3
E2967
Joint washer
... ...
...
...
...
4
E3761
Inlet manifold
...
...
...
...
4
E4014
Inlet manifold
... ...
...
...
...
4
E4689
Inlet manifold
...
...
...
... ...
5
S25-13
Plain washer
...
...
...
... ...
6
W103
Nut
... ... ...
...
... ...
7
E3880
Stud (1+ in. O.A.)
...
...
... ...
8
NA 43
Joint washer
...
...
...
... ...
8
NA 43A
Joint washer
... ...
...
...
...
9
E3834
Insulating block
...
...
...
...
9
E4504
Insulating block
...
...
... ...
9
E2968
Insulating block
...
...
10
S25-3
Plain washer
... ...
...
...
...
11
S1-51
Nut
... ... ...
...
2
2
2
...
...
1
3TA
...
...
1
STA, T100
1
T90
4
4
2
...
...
1
3TA, 5TA
...
...
1
T90, 1100
...
...
1
3TA, 5TA
...
...
1
T90
...
...
1
T100
2
2
21
ClassicBike.biz
Fig. 4. CYLINDER BLOCK AND HEAD, 3TA AND T90
35 34
51
53
52
5
22
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, 3TA AND T90
1
E3798
Cylinder base washer
1
2
E3698
Cylinder block
...
...
1
3
GS308
Plain washer
••
•
•••
•••
•••
8
4
E2412
Nut
...
... ...
...
•••
8
5
E4676
Tappet guide block
...
2
6H2W
Tappet block screw (
In. U.H.)
2
7
E1612
Serrated washer
... ...
2
8 E3753
Tappet
...
...
... ...
4
9
E5956
CYLINDER HEAD c/w GUIDES
1
3TA
9
E4784
CYLINDER HEAD c/w GUIDES
1
T90
10
E3208
Valve guide
...
4
3TA
10
E6301
Valve guide
...
4
190
11 E3209
Valve guide circlip
4
12
E2961
Exhaust pipe adaptor
2
13
E3738
Inlet valve
.,.
2
3TA
13
E4640
Inlet valve
2T90
14
E3739
Exhaust valve
2
15 E3740
Bottom cup
...
4
16
E5946
Inner valve spring
4
17
E4011
Outer valve spring
4
18
E3742
Top collar ...
4
19
WE259A
Split cotter
8
20
E4456
Cylinder head bolt (2 25/32 in. U.H.)
4
21
F2184
Plain washer
...
...
8
22
E4674
Cylinder head gasket
1
23
E3745
Inlet rocker box
1
24
E3744
Exhaust rocker box
1
25
E3743
Joint washer
...
...
2
26
E3858
Rocker box stud (ff in. 0.A.)
4
27
E3302
Plain washer
...
4
28
F879
Nut
4
29
E3668
Screw (+ in. U.H.)
...
4
30 E3857
Plain washer
... ...
4
31
E3794
Cylinder head bolt (5
.
in. U.H.)
2
32
E3795
Cylinder head torque stay bolt ...
2
33
E3809
Oil feed bolt
2
34
F1880
Copper washer
6
35
H400
Domed nut
2
36
E4610
Inspection cap
4
37
E3751
Fibre washer
...
...
...
4
38
E3749
ROCKER (Right exhaust, left inlet)
2
39 E3750
ROCKER (Left exhaust, right inlet)
2
40
E3222
Rocker ball pin
4
41
E3223
Rocker adjusting pin
4
42 GS662
Adjuster lock nut
4
43
E1330
Thrust washer,
i
in. 2
44
E2534
Thrust washer,
in.
6
,
t6
E3224
E3748
Spring washer
Rocker spindle
4
2
47
E3253
Sealing rubber
2
48
E1335
Copper washer
2
(Continued)
23
ClassicBike.biz
Fig. 4. CYLINDER BLOCK AND HEAD, 3TA AND T90
51
5
8
37
36
47
46
50
53
53
52
45 39 44 41 42 45 44
23
31 21 32
35 34
24
ClassicBike.biz
Ref No.
Po
rt
No.
DESCRIP
TION
QUANTITY
REMARKS
CYLINDER BLOCK AND HEAD, 3TA AND T90
(Continued)
49
E1435
Domed nut
...
...
...
... ...
...
2
50
E3759
Push rod
... ... ... ...
...
...
...
4
51
E4751
Cover tube
...
...
...
...
... ...
2
52
E4746
Bottom cup ... ...
...
...
...
...
2
53
E4752
Rubber washer
... ...
...
... ...
...
4
54
E4671
Locking spring
...
...
...
...
...
...
4
25
ClassicBike.biz
53
13
Fig. S. CYLINDER BLOCK AND HEAD, 5TA AND T100
45 39 44 41 42 45 44 23 31 21 32
35 34
50
26
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUAN7ITY
REMARKS
CYLINDER BLOCK AND HEAD, 5TA AND T100
1
E3798
Cylinder base washer
... ...
...
...
...
1
2
E4000
Cylinder block
... ... ...
... .,. ...
1
3
GS308
Plain washer
...
...
...
...
... ...
8
4
E2412
Nut
... ...
...
...
...
... ...
8
5
E4676
Tappet guide block
... ...
... ...
...
2
6
H200
Tappet block screw (
1
6 in. U.H.)
...
...
2
7
E1612
Serrated washer
...
2
8
E3753
Tappet ...
... ... ...
...
...
...
4
9
E4785
CYLINDER HEAD c/w GUIDES
...
... ...
I
10
E3208
Valve guide
... ... ...
...
...
...
4
5TA
10
E6301
Valve guide
... ...
... ...
...
...
4
1100
11
E3209
Valve guide circlip
...
...
...
...
...
4
12
E2961
Exhaust pipe adaptor
...
... ... ...
...
2
13
E4012
Inlet valve
... ... ... ...
...
...
2
14
E4013
Exhaust valve
...
...
... ... ...
2
15
E3740
Bottom cap
...
... ... ... ... ...
4
16
E5946
Inner valve spring
... ...
...
...
...
4
17
E4011
Outer valve spring
... ... ... ... ...
4
18
E3742
Top collar
...
...
... ... ...
...
...
4
19
WE259A
Split cotter
... ... ... ... ...
...
8
20
E4456
Cylinder head bolt (225/32 in. U.H.)
...
...
...
4
21
F2184
Plain washer
...
... ...
...
...
...
8
22
E4675
Cylinder head gasket
... ... ...
...
...
1
23
E3745
Inlet rocker box
...
...
...
...
...
1
24
E3744
Exhaust rocker box
...
...
...
...
...
1
25
E3743
Joint washer
...
...
...
...
...
...
2
26 E3858
Rocker box stud (-6 in. O.A.)
...
...
...
4
27
E3302
Plain washer
... ...
...
...
...
...
4
28
F879
Nut
... ... ...
...
...
...
...
4
29
E3668
Screw (+
in. U.H.)
... ... ...
... ...
4
30
E3857
Plain washer
... ... ... ... ... ...
4
31
E3794
Cylinder head bolt (5-h in. U.H.)
...
... ...
2
32
E3795
Cylinder head torque stay bolt ...
... ... ...
2
33
E3809
Oil feed
bolt
... ... ...
... ... ...
2
34
F1 880
Copper washer
... ...
...
... ...
...
6
35
E400
Domed nut
...
...
... ... ...
...
2
36
E4610
Inspection cap
...
...
... ...
... ...
4
37
E3751
Fibre washer ...
...
...
... ...
...
4
38
E3749
ROCKER (right exhaust, left inlet)
... ...
...
2
39
E3750
ROCKER (left exhaust, right inlet)
... ... ...
2
40
E3222
Rocker ball pin
...
...
... ...
...
4
41
E3223
Rocker adjusting pin
... ...
...
...
...
4
42
GS662
Adjuster lock nut
...
...
... ...
...
4
43
El 330
Thrust washer, 8 in.
...
...
...
...
...
4
44
E2534
Thrust washer,
,-
6
in.
...
...
... ... ...
6
45
E3224
Spring washer ... ...
...
...
...
...
2
46
E3748
Rocker spindle ... ...
...
...
... ...
2
47
E3253
Sealing rubber
...
...
... ...
...
...
2
48
E1335
Copper washer
...
...
...
...
...
...
2
49
E1435
Domed nut
...
... ... ...
...
2
50 E4008
Push rod
... ...
...
... ...
...
4
51
E4751
Cover tube
... ...
... ...
...
...
2
52
E4746
Bottom cup
... ...
...
...
... ...
2
53
E4752
Rubber washer ... ...
...
...
...
...
4
54
E4671
Locking spring
... ...
... ...
...
...
427
ClassicBike.biz
Fig. 6.
TIMING COVER AND CONTACT BREAKER
25
4
11
12
11
10
28
13
14
18
28
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
TIMING COVER AND CONTACT BREAKER
1
E4630
Timing cover
... ...
...
...
...
...
...
1
2
E4016
Patent plate
...
... ... ...
... ...
...
1
3
D208-5
Hammer-drive screw
... ... ...
...
...
...
3
4
E4568
Oil
seal
... ...
... ... ... ...
...
...
1
5
E3800
Screw ('—
e
in. U.H.)
...
... ... ...
...
...
4
6
E3801
Screw (18 in. U.H.)
...
... ...
...
...
...
4
7
47605
CONTACT BREAKER, type 4CA
...
... ... ...
1
8
425377
Condenser
...
... ...
...
...
...
2
9
54441729
Cam...
... ...
...
... ... ... ...
1
10
54415642
Spring set
...
... ... ... ...
...
...
1
11
425359
Weight
... ... ... ...
...
... ...
2
12 54415751
Sleeve and action plate
ate
I
gnition
1
13
425370
Base plate
...
... ...
...
... ... ...
1
14
169194
Slotted nut...
...
... ... ... ...
...
4
15
54415803
Contact set
... ...
...
...
...
...
2-J
16
E5451
Bolt (2 in. U.H.)
...
... ... ...
...
...
1
17
S25-43
Plain washer ... ...
...
...
...
...
...
1
18
E4707
Grommet
...
... ...
...
...
...
...
1
19 E4747
Pillar
bolt ... ... ... ...
...
...
...
2
20
E6559
Plain washer
...
...
...
...
...
...
...
2
21
E4571
Cover
...
...
... ... ... ... ... ...
1
22
E5049
Joint washer
... ... ...
...
... ... ...
1
23
GS299
Serrated washer
... ... ... ... ...
...
2
24
F4715
Screw (15/32 in. U.H.)
...
...
...
...
...
2
25
T989
Hollow dowel ...
...
...
...
...
...
...
1
26
47602
CONTACT BREAKER, type 4CA ...
...
... ...
1
8
425377
Condenser
...
...
...
... ... ...
2
27 54415473
Cam...
...
...
... ...
...
... ...
1
29
54415641
Spring set
1
11
425359
...
Weight
...
...
...
...
...
...
...
A.C. Ignition
2
29
54415747
Sleeve and action plate
... ...
...
...
...
1
13
425370
Base plate
...
...
... ... ... ... ...
1
14
169194
Slotted nut
... ...
...
...
... ...
4
15
54415803
Contact set
...
...
...
...
...
...
2J
29
ClassicBike.biz
42
33 48 45 46 47
Fig. 7. GEARBOX SHAFTS, BEARINGS AND INNER COVER
30
ClassicBike.biz
Ref. No.
Port
No.
DESCRIPTION QUANTITY
REMARKS
GEARBOX SHAFTS, BEARINGS AND INNER COVER
1
T665
High gear bearing (ball journal)
1
2
T1478
Oil seal
...
1
3
W680
Circlip
...
1
4
11367 Layshaft bush
...
1
3TA, 5TA
5
T912
Peg
...
1
6
T981
Blanking disc
...
1
3TA, 5TA
7
T1606
Layshaft bearing
1
T90, TIN
8
T1607
Thrust washer
...
...
1
T90, T100
9
T1947
MAINSHAFT HIGH GEAR (22T)
1
10
T1405
High gear bush
...
...
...
1
11
T1948
MAINSHAFT c/w THIRD AND LOW GEARS (16/24T)
1
12
T1391
Clutch rod bush
...
...
1
13
T1922
Mainshaft second gear (21T)
...
1
14
T1411
Mainshaft distance piece
... ... ...
1
15
T1965
Layshaft c/w second and high gears (15/23
1
3TA, 5TA
15
T1949
Layshaft c/w second and high gears (15/23T)
1
T90, T100
16
T1839
Layshaft third gear (20T)
1
17
T1950
LAYSHAFT LOW GEAR (27T)
1
18
T1393
Low gear bush
1
19
T1426
Pawl retaining disc
1
20
T1471
Camplate index plunger
1
21
T373
Index plunger spring
...
1
22
T1457
Selector fork spindle
...
1
23
T1480
Mainshaft selector fork
1
24
T1481
Layshaft selector fork
1
25
T1768
Gear selector cam plate
1
26
T1418
Camplate spindle
...
1
27
i
in. x I in.
Split pin
...
...
1
28
T1416
Gear indicator pointer
1
29
H688
Screw (* in. U.H.)
...
1
30
11448
Inner cover
...
...
1
31
T417
Gear indicator plate
...
1
32 D208-5
Indicator plate rivet
...
2
33
T1
0
Hollow dowel ...
...
2
34
T1157
Kickstarter stop plate ...
1
35
T1390
Stop plate and anchor screw
1
36 11
5
KICKSTARTER SPINDLE
1
3TA, 5TA
36
T1981
KICKSTARTER SPINDLE
1
T90, T100
37
T1431
Kickstarter pawl
...
1
38
T1282
Plunger
...
1
39
T1161
Plunger spring
1
40
T1897
Bearing
...
1
T90, T100
40
T1446
Floating bush
... ...
1
3TA, 5TA
41
T1469
Mainshaft bearing (Ball journal)
1
42
1280
Circlip
...
1
43
T732
Tab washer
1
44
12009
Mainshaft nut
1
45
T1464
Distance piece
...
1
46
T1
44
1
Kickstarter return spring
1
47
T1422
Return spring plate
...
1
48
E3204
Screw (1 in. U.H.)
...
2
31
ClassicBike.biz
2
21
20 25
29 28
36
27 32
33 48 45 46 4/
Fig. 7. GEARBOX SHAFTS, BEARINGS AND INNER COVER
32
ClassicBike.biz
Ref No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
WIDE RATIO GEARS
(Can
be fitted to T90 or T100)
9
11684
MAINSHAFT HIGH GEAR (23T)
... ... ... ... ...
11
11
T1959
MAINSHAFT c/w THIRD & LOW GEAR (15/24T)
...
...
1
1
13
T1837
Mainshaft second gear (20T)
...
...
...
...
...
...
1
L
Standard on
15
TI 960
Layshaft c/w second & high gear (14/24T) ... ... ... ...
1
Eastern T100 C
16
11839
Layshaft third gear (20T)
...
...
...
...
...
...
1
17
T1961
LAYSHAFT LOW GEAR (29T)
...
...
1
J
CLOSE RATIO GEARS
(Can
be fitted to T90 or T100)
9
11821
MAINSHAFT HIGH GEAR (20T)
...
... ... ... ...
1
11
T1971
MAINSHAFT c/w THIRD & LOW GEAR (16/22T)
...
...
1
13
T1832
Mainshaft second gear (20T)
...
... ... ... ... ...
1
15
T1972
Layshaft c/w second and high gear (17/23T)
...
... ... ...
1
16
11842
Layshaft third gear (21T)
...
...
...
...
...
...
1
17
11950
LAYSHAFT LOW GEAR (27T)
... ...
...
...
...
1
33
ClassicBike.biz
A
35
25
26
24
32
A
_
36
9
,
1
8
^i
7
J
1
0 6 2
3
23
39
40
22
^
A
'^
I(
12
13
^\^ 17
II
(q ^ O
,A ,
4
16
13
12
43
19
20
1
5
4'
34
33
30
31
42
38
37
Fig. $. GEARBOX OUTER COVER AND LEVERS
34
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
GEARBOX OUTER COVER AND LEVERS
1
T1870
GEARBOX OUTER COVER
1
2
T1395
Gearchange spindle bush...
1
3
T1944
Stud (1 A in. O.A.)
...
2
4
T1875
Screw a in. O.A.)
...
1
5
T1942
GEARCHANGE QUADRANT
1
6
T1474
Spring retaining pin
2
7
11436
Plunger spring ...
2
8
11396
Selector plunger
...
2
9
5/64 in. x
i
in.
Split pin
...
2
10
E3309
Sealing ring
...
1
11
T1871
Return spring housing
1
12
T1877
Return spring
2
13
T1878
Thrust button
2
14
T1977
Cover
1
15
W103
Nut
...
3
16
T1876
Distance piece
2
17
T1874
Distance piece
1
18
T1880
Clutch lever
1
19 T1771
Ball, 1 in. diam.
3
20
11710
Shaft
...
1
21
T1712
Spring
...
1
22
GS127
Plain washer
1
23
5/64 in. x 1 in. Split pin ...
1
24
T1945
Spoke
...
1
25
T1946
Connector
1
26
11937
Nut
...
1
27
T1644
Abutment
1
28
T2062
Adaptor, short ...
... ... As required
28
T2063
Adaptor, long (For cable with short outer cover)...
As required
29
T1646
Rubber cover
...
1
30
S1-51
Nut
...
2
31
S25-3
Plain washer
...
2
32
T1401
Screw (21 in. U.H.)
2
33
T1402
Screw (28 in. U.H.)
2
34
11435
Gearchange lever
1
35
T9
Pedal rubber
...
1
36
W932
Bolt (1 in. U.H.)
...
1
37
T1677
KICKSTARTER LEVER COMPLETE...
1
38
11678
Kickstarter crank
1
39
11272
Kickstarter pedal ...
1
40
S70-3
Steel ball (+ in. diam.)
1
41
T1167
Index spring
1
42
T1273
Pivot bolt
...
1
43
T1439
Clamp bolt (1„ in. U.H.)
1
44
F1814
Pedal rubber
...
...
1
45
T1456
Clutch operating rod
...
1
3TA
45
T1970
Clutch operating rod
...
1
5TA, T90, T100
35
ClassicBike.biz
0
Z
}
W
U)
U
J
U
Co
N
1
0
in
=
U
F-
00
U
o:
w
LL
O
`0
N
co
LO
Cl)
CN
(N
N
36
ClassicBike.biz
Ref. No.
Port No.
DESCRIPTION
QUANTITY
REMARKS
CLUTCH
1
T1933
T1935
2
T1751
3
T1735
4
T394
5
11442
5
11570
6
11718
6
T1719
7
TI 720
8
T1 040
9
11721
10
11722
11
T1723
12
T1 724
13
T423
13
T423A
14
T1 362
15
T1 363
16
T2156
17
T2159
18
13206/00/1
19
T1934
19
T1931
20
T1752
20
T1 560
21
T427
22
S66-1
23
T1045
24
T1046
25
T1047
CLUTCH COMPLETE
...
...
... ... ...
1
3TA
CLUTCH COMPLETE
...
...
... ... ...
1
5TA, T90, T100
Hub
...
...
... ... ...
...
1
Thrustwasher
...
...
...
...
...
...
1
Roller
...
... ...
...
...
...
...
20
Sprocket and housing
...
...
...
...
...
1
3TA
Sprocket and housing
...
...
...
...
...
1
STA, 190, T100
Centre (Shock absorber body) ...
...
...
...
1
3TA
Centre (Shock absorber body) ...
...
... ...
1
5TA, 190, T100
Innerplate
...
...
...
...
... ...
1
Countersunk screw (0.417 in. U.H.)
... ... ...
6
Shock absorber spider
...
...
...
... ...
1
Driverubber (large)
...
...
...
...
...
3
Rebound rubber (small)
3
Outerplate
...
... ... ... ...
...
1
Screwed pin (1 19/32 in. U.H.) ...
...
...
...
3
3TA
Screwed pin (1 27/32 in. U.H.) ...
... ...
...
3
STA, T90, 1100
Driving plate (bonded)
...
...
...
...
...
5
6 off 5TA, 190, T100
Driven plate (plain)
... ... ...
...
...
5
6 off STA, 190, T100
Pressureplate
...
...
... ... ... ...
1
Adjusterpin
...
...
...
...
... ...
1
Nut
...
...
...
... ... ...
...
1
Springcup ...
...
...
...
...
...
...
3
3TA
Springcup ...
...
...
...
...
...
...
3
5TA, T90, T100
Spring
...
...
...
... ...
...
...
3
3TA
Spring
...
...
...
...
... ...
...
3
5TA, T90, 1100
Brassnut
...
... ... ...
... ...
...
3
Key
...
..
...
...
...
...
...
...
1
Cuppedwasher
...
...
... ...
...
...
1
Tabwasher
...
...
... ... ... ...
...
1
Nut
... ...
...
... ... ... ...
...
1
37
ClassicBike.biz
0. CHAINCASE AND CHAINS
ig. 10. CHAINCASE AND CHAINS
1
3
38
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
R
EM
ARKS
CHAINCASE AND CHAINS
1
T1558
Gearbox sprocket (17 teeth) ...
1
3TA,
M
1
T1476
Gearbox sprocket (18 teeth) ...
1
T100, T1
1
T1476/19
Gearbox sprocket (19 teeth) ...
1
5TA, T100R
1
T1569
Gearbox sprocket (20 teeth) ...
1
2
T1434
Gearbox sprocket nut
...
1
3
D444
Rear chain, 1 in. x 1 in. x 102L
1
3TA, T%,
T100
3
D481
Rear chain, 1 in. x 1 in. x 103L
1
5TA
4
E3789
Cover plate
1
5
E3833
Oil seal
...
1
6
E3832
Joint washer
...
1
7
E3821
Countersunk screw (* in. U.H.)
6
8
D358
Primary chain, 1 in. Duplex 78L
1
9
E6283
Chain tensioner blade ...
1
10
E4152
Tie rod
1
11
E5977
Trunnion
1
12
E3811
Stud (3* in. 0.A.)
3
13
47162
Stator, RM 19
1
Coil Ignition
13
47188
Stator, R.M.19
1
A.C. Ignition
14
E3810
Distance piece
3
15 S25-3
Plain washer
3
16 E5324
Nut
... ...
3
17
E4144
Rubber grommet
1
18
E5872
Sleeve nut
...
1
19
E1,509
Clip
...
1
20
T361
Bolt a in. U.H.)
1
21
E4156
Joint washer
...
1
22
E4122
Chaincase
...
1
23
DS57
Drain and level plug
1
24
WE170
Fibre washer
2
25
E732
Filler plug
1
26
NE507
Fibre washer
1
27
E3802
Screw (21 in. U.H.)
3
28
E3668
Screw (1* in. U.H.)
7
29
E4153
Adjuster sleeve nut
1
30
E4154
Drain plug
1
31
T1738
Fibre washer
1
32
T2056
Tab
washer
...
1
33
E6186
Crankcase protector
1
34
T1553
Screw (1 in. U.H.)
1
T90, T100
35
E1612
Serrated washer
...
1
36
E6226
Rubber plug
...
1
3TA,5TA
39
ClassicBike.biz
15
•
'I
5 4
I
pI
32
22
14 7
13
23
24 25 26
u41 40 39 37 39 38
34
33
Fig. 11. ENGINE FITTINGS AND EXHAUST SYSTEM
40
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
ENGINE FITTINGS AND EXHAUST SYSTEM
1
F4275
Left front engine plate...
...
...
...
...
...
1
2
F4276
Right front engine plate
... ...
... ...
...
1
3
F2825
Stud (3+ in. O.A.)
...
...
...
...
...
...
1
4
S26-1
Spring washer
...
... ...
...
...
...
8
5
P0172A
Nut
... ...
...
...
...
...
...
...
2
6
E3804
Stud (3 in. O.A.)
...
...
... ...
...
...
3
7
S26-3
Spring washer
...
...
... ...
...
...
8
8
S1-51
Nut
... ...
...
...
...
...
...
...
3
9
F4229
Left rear engine plate
... ... ...
...
...
1
10 F4230
Right rear engine plate
...
...
...
...
...
1
11
E3665
Stud (44 in. O.A.)
...
...
...
...
... ...
1
12
P0172A
Nut
... ... ...
... ...
...
... ...
4
13
E3695
Stud (4
1
6 in. O.A.)
...
...
...
...
...
...
2
14
S1-51
Nut
...
... ...
...
...
...
...
...
5
15
E4778
Torque stay
...
...
... ... ...
...
2
16
E5072
Distance piece
...
...
...
... ...
...
...
2
17
S1-52
Nut
...
... ...
...
...
...
...
...
2
18
F5532
Plain washer
...
...
...
... ... ...
...
2
19 E4165
Bolt (1-6 in. U.H.) ...
...
... ... ...
...
1
20
E3812
Stud
(71-k
in. O.A.)
...
...
...
...
...
...
1
21
F4197
Distance piece
...
... ... ... ...
...
...
2
22
E3992
Left exhaust pipe
...
...
...
...
...
...
1
5TA, T100
23
E3994
Right exhaust pipe
... ... ... ...
...
...
1
5TA, T100
22
E5325
Left exhaust pipe ...
...
... ...
...
...
1
3TA, T90
23
E5327
Right exhaust pipe
...
...
...
...
...
...
1
3TA, T90
24
E4947
Finned clip
...
... ... ... ...
...
...
2
25
E41OA
Hemispherical washer ... ...
...
...
...
...
2
26
E409
Bolt (1 6 in. U.H.)
... ... ... ...
...
...
2
27
F4707
Left bracket
... ... ...
... ...
...
...
1
28
F4283
Right bracket ... ...
...
... ...
...
...
1
29
DS57
Bolt (
1
6 in. U.H.)
...
...
...
...
...
...
2
30
E1612
Serrated washer
... ... ... ... ... ...
2
31
F879
Nut
...
...
...
...
... ... ...
...
2
32
E3935
Left silencer
...
...
... ... ...
...
...
1
32
E4157
Left muffler
...
...
..•
... ...
...
...
1
T100R
33
E3936
Right silencer
... ... ... ...
...
...
...
1
33
E4158
Right muffler
...
...
...
... ...
... ...
I
T100R
34
E4155
Silencer mute
...
... ...
... ... ... As required
35
H689
Screw (4 in. U.H.)
... ... ...
...
... ... As required
36
H691
Nut
...
...
... ... ... ... ... ...
As required
37
E2271
Clip
... ... ...
...
... ...
...
...
2
38
F3430
Bolt (1
2
in. U.H.)
...
...
2
39
E3768
"D" washer
...
...
...
...
...
...
...
4
40
S26-3
Spring washer
...
...
...
...
...
...
...
2-
41
E1310
Nut
... ...
...
... ... ... ...
...
2
41
ClassicBike.biz
9
10 11
13
1
2
21
Fig. 12. EXHAUST PIPES, UNDERSHIELD AND FOOTPEGS (T100C)
42
ClassicBike.biz
Ref. No.
Port No.
DESCRIPTION
QUANTITY
REMARKS
EXHAUST PIPES, UNDERSHIELD AND FOOTPEGS (TIOOC)
1
E4513
Left Exhaust pipe ...
1
2
E4514
Right exhaust pipe
1
3
E5874
Clip
1
4
F3430
Bolt
...
1
5
E3768
"D" Washer
2
6S26-3
Spring Washer
1
7
E1310
Nut
...
1
8
E3470
Muffler
...
1
9
H426
Bolt (H in. U.H.) ...
1
10
S26-1
Spring washer
1
11
S1-51
Nut
1
12 F4852
Undershield
1
13
F1700
Clip
2
14
F3078
Bracket
1
15
F1369
Bolt (I in. U.H.)
4
16 S26-2
Spring washer
4
17
F879
Nut
...
4
18
F7018
LEFT FOLDING FOOTPEG
1
19 F7019
RIGHT FOLDING FOOTPEG
2
20
F6411
Pedal
...
...
2
21
F6655
Pivot bolt
2
43
ClassicBike.biz
19
Fig. 13. FRAME
44
ClassicBike.biz
Ref No.
Port No.
DESCRIPTION
QUANTITY
REMARKS
FRAME
1
F6912
Front frame
... ... ... ... ... ...
1
2
H1130
Steering race cup
... ...
... ...
...
2
3
S70-4
Steel ball („ in. U.H.)
... ... ...
...
48
4
H1140
Top cone and dust cover
...
... ...
...
1
5
NW100
Grease nipple ... ...
...
... ...
...
1
6
WE170
Fibre washer
...
...
... ...
...
...
1
7
F6913
Rear frame ...
... ...
...
...
...
1
8
F2842
Stud (41 in. O.A.)
...
...
...
...
...
1
9
S26-1
Spring washer
... ... ... ...
...
2
10
S1-52
Nut
... ...
...
...
... ... ...
2
11
F3780
Bolt (1,
!
, in. U.H.)
...
...
...
...
...
2
12
PCW73A
Spring washer
... ...
...
...
...
2
13
F4891
Centre stand
...
...
...
...
...
...
1
13
F5153
Centre stand
...
...
...
...
...
...
1
14
T449
Pedal rubber
...
...
...
...
...
...
I
15
F3619
Pivot bolt (1 a in. U.H.)
...
...
...
...
2
16
F4484
Tab washer
... ...
...
...
... ...
2
17
F2725
Nut
...
...
...
...
...
...
...
2
18 F3617
Return spring
...
...
...
...
...
...
1
19
F5539
Prop stand
...
... ...
...
...
...
1
19
F3723
Prop stand
...
...
...
... ... ...
1
20 F3097
Pivot bolt
... ...
...
...
...
...
1
21
F3096
Tab washer
... ...
...
... ...
...
1
22
F2610
Return spring
... ...
...
... ...
...
1
23
F4214
Left footrest
...
...
...
... ...
...
1
24
F4215
Right footrest
...
...
...
...
...
...
1
25
NF704
Pedal rubber
...
...
...
...
...
...
2
26 F4369
Bolt (2-6 in. U.H.)
...
...
...
...
...
2
27
F4370
Plain washer
...
...
...
...
...
...
2
28
DS47
Nut
...
... ...
...
...
...
...
2
29
F5087
Left pillion footrest support
...
...
...
...
1
30
F5088
Right pillion footrest support
...
... ...
1
31
DS58
Bolt (j' in. U.H.)
...
...
...
...
...
4
32
S26-3
Spring washer
...
...
...
...
...
4
33
F1149
Pedal stop screw (r in. U.H.)
...
...
...
1
34
F879
Nut
...
...
...
...
...
...
...
1
35
F5552
PILLION FOOTREST ...
...
...
... ...
2
36
F2268
Footrest hanger
...
...
...
...
...
2
37
F5535
Bolt (ff in. U.H.) ...
...
...
...
...
2
38
S26-1
Spring washer
...
...
...
...
...
2
39
F1694
Pedal
...
.•.
.•.
...
...
...
2
40
F2271
Pivot bolt
...
...
...
...
...
...
2
41
F2277
Spring washer
... ...
...
...
...
2
42
51-51
Nut
...
...
...
...
...
...
2
43
F1695
Pedal rubber
...
...
...
...
...
2
44
F4284
Brake pedal spindle
...
...
...
...
...
1
45
SCZ45
Spring washer
...
...
...
...
...
1
46
DS48
Nut
... ...
...
...
... ... ...
1
47
F4314
Brake pedal
... ... ...
...
... ...
1
48
S26-16
Spring washer
...
...
...
... ...
1
49
S25-2
Plain washer
...
...
••.
••.
... ...
1
50
S1-52
Nut
...
...
...
...
... ...
...
I
T100R
T1000, T100R
45
ClassicBike.biz
•
0
w
4
3
0
Z
R
I
U
C
z
4
i
3
Z
0
Z
W
N
3
w
K
0
LL
0
Z
5
z
LL
46
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
SWINGING FORK, SUSPENSION UNITS AND CHAINGUARD
1
F6936
SWINGING FORK
...
... ...
...
...
1
2
F4076
Pivot bush ... ... ...
... ...
2
3
F4195
Spindle
... ...
...
...
...
... ...
1
4
F4078
Spacing washer ...
...
... ...
...
...
1
5
F4385
Shim 0.003 in.
... ...
... ...
... ...
as required
5
F4386
Shim 0.005 in.
...
... ...
... ... ...
as required
6
F3797
Retainer rod
...
...
...
... ...
...
1
7
F4196
Cap
...
...
...
... ... ...
...
2
8
F3799
Nut
... ...
...
...
... ... ...
2
9
64053946
SUSPENSION UNIT ... ... ...
...
...
2
9
64054164
SUSPENSION UNIT ...
...
...
... ...
2
T1000, T100R
10
9054/316A
Bonded bush ...
...
... ...
...
4
11
9054/171
Spring retainer
...
...
...
...
...
4
12
9054/151
Outer dirt shield
...
... ...
...
2
13
9054/47
Inner dirt shield
...
...
...
...
...
2
14
64539963
Spring, 130 lbs. Red/Orange
... ...
...
2
14
9054/277
Spring, 110 lbs. Red/Red
...
...
...
...
as required
14
SA253/5
Spring, 145 lbs. Blue/Yellow
...
...
...
...
as required
15
E2113
Unit fixing bolt (1 6 in. U.H.)
...
... ...
4
16
F2184
Plain washer ... ...
...
... ...
...
2
17
S26-1
Spring washer
...
... ...
...
...
2
18
P0172A
Nut
...
...
...
... ...
... ...
2
19
F5409
Upper chainguard
...
...
...
... ...
1
20
DS57
Bolt (, 6 in. U.H.)
...
...
...
...
...
1
21
S26-2
Spring washer
...
...
...
...
...
1
22
F4134
Front bracket
... ...
...
... ...
...
1
23
F4135
Pivot bolt
...
... ...
...
...
...
1
24
F2377
Spring washer
... ...
... ...
...
1
25
S25-13
Plain washer ... ... ...
...
...
...
2
26
E5269
Nut
... ...
..
...
...
... ...
1
27
F4136
Stepped bolt
...
...
...
...
...
...
1
28
S25-3
Plain washer
... ...
... ... ...
...
1
29
S1-51
Nut
...
... ...
... ... ...
...
1
30
F4199
Lower chainguard
...
... ... ...
...
1
3TA, 5TA
31
W840
Bolt (17/32 in. U.H.)
... ... ...
...
...
1
32
E2288
Serrated washer
...
...
...
...
...
1
33
DS47
Nut
...
...
...
...
... ...
...
1
34
PCW73A
Spring washer
...
...
... ...
...
1
35
F3597
Brake operating rod
... ...
...
... ...
1
36
,!, in. x e in.
Split
pin
... ...
...
...
... ...
1
37
F4585
Adjuster nut
...
... ... ...
...
...
1
38
F4201
Brake torque stay
... ... ...
...
...
1
T90, 1100
39
F6046
Front chainguard
...
... ...
...
...
1
40
31383
Stop lamp switch, type 22 B ...
...
...
1
41
T1076
Bolt (e in. U.H.)
... ...
... ...
...
3
42
F4717
Self locking nut
...
...
... ...
...
5
43
F5687
Lever
... ...
...
...
...
...
...
44 3/32in. x'— in.
Split
pin
... ...
...
...
...
...
1
45
F5413
"D" washer
...
...
...
...
...
...
1
47
ClassicBike.biz
12
10
39
Fig. 15. TELESCOPIC FRONT FORK, 3TA AND STA
FORK ASSEMBLY REF. N91
48
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
TELESCOPIC FRONT FORK, 3TA AND
5TA
1
H2014
FORK ASSEMBLY
...
1
2
H1328
Middle lug and stem
1
3
H1110
Bottom cone ...
...
1
4
H941
Pinch bolt (21 in. U.H.)
2
5
S25-2
Plain washer
2
6
H1335
Nut
(21
in. 0.A.)
...
2
7
H1667
Distance piece
...
1
8
H1141
Fork stem sleeve nut
1
9
H1108
Top lug
...
1
10 F1760
Pinch bolt (1* in. U.H.)
1
11
H379
Seated nut
...
...
1
12
H1290
Left nacelle cover
1
13
H1291
Right nacelle cover
1
14
F4047
Cork washer ...
2
15
H1916
Upper cover tube
2
16
H1745
Plain washer
2
17
H1891
Main spring (Yellow/Blue) ...
2
18
H1656
Plain washer ... ...
2
19
H1654
DUST EXCLUDER SLEEVE NUT
2
20 H1500
Oil seal
...
2
21
H431
Plain washer
2
22
H441
Top bearing
...
2
23
H1896
Damping sleeve
2
24
H1890
STANCHION c/w BEARING
2
25
H443
Lower bearing
... ...
2
26
H1058
Bearing nut
2
27 H1659
Cap nut
..
2
28 H519A
Oil filler plug (* in. U.H.)
...
2
29
H1842
LEFT BOTTOM MEMBER c/w CAP
1
30
H1843
RIGHT BOTTOM MEMBER c/w CAP
1
31
H1844
Spindle cap
...
2
32 S26-3
Spring washer
4
33
H1070
Cap bolt (1
1
6 in. U.H.)
4
34
H1071
Drain plug
...
2
35
H430
Fibre washer ...
4
36
H1499
Restrictor
... ...
2
37
H1063
Flanged bolt (23/32 in. U.H.)
2
38
H1062
Aluminium washer
...
2
39
H660
Handlebar "U" bolt
2
40
S25-3
Plain washer
...
4
41
E1310
Nut
4
49
ClassicBike.biz
31
•ir
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50
2
10
9 8
m
1
7
18 16
HEADLAMP
ASSEMBLY
84
7
,:
REF.Ne12
^,
m
19
20
I
I
I
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i
13
14
9
24
or
jLI
P!L
01
C
4
(r
Z7^
r
^'
Fig. 16. NACELLE, HEADLAMP AND SWITCHES
50
ClassicBike.biz
Ref.
No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
NACELLE, HEADLAMP AND SWITCHES
1
H1781
Nacelle top ...
...
...
...
... ...
1
2
H961
Rubber grommet ...
...
...
...
...
...
1
3
H669
Rubber grommet ...
...
...
... ... ...
2
4
H877
Left motif ...
... ...
...
...
...
...
1
5
H878
Right motif ... ...
... ...
... ...
1
6H689
Screw (+ in. U.H.) ...
... ... ... ...
4
7
H687
Screw (a in. U.H.)
...
... ... ... ...
2
8
H688
Screw (.
in. U.H.)
... ... ...
...
...
2
9
E2880
Serrated washer
...
... ... ... ...
...
4
10
H691
Nut
... ...
...
... ...
...
...
4
11
H690
Nut
... ... ...
...
... ...
...
12
59176
HEADLAMP
... ... ... ...
...
...
1
13
553248
Rim
...
... ... ... ...
...
...
1
14
516812
Light unit
... ...
...
...
...
...
1
15
504665
Fixing wire
...
...
... ...
...
...
6
16
553267
Fixing ring
... ...
... ... ... ...
1
17
144921
Screw ...
... ...
... ... ...
...
1
18
534296
Plate
...
...
...
...
...
...
1
19
414
Bulb (50/40 W. L.H. Dipping. Pre-focus) ...
...
...
1
20
554602
Adaptor
... ... ...
... ...
...
1
21
222
Bulb (4W.M.C.C.)
... ...
...
...
...
1
22
554710
Pilot bulbholder
... ...
...
... ...
1
23
34427
IGNITION SWITCH c/w KEY, type 88SA
...
...
1
24
54336176
Ignition key
... ...
...
... ...
1
25
54336178
Ignition switch cover ... ...
...
...
...
1
26
34289
Lighting switch, type 88SA
...
... ...
1
27 54330934
Knob c/w screw
...
...
...
... ...
1
28
54330576
Switch bezel plate ...
...
...
2
29
54930007
Replacement harness socket (Lighting) ...
...
as required
30
54930008
Replacement harness socket (Ignition)
...
...
as required
31
36296
Ammeter, type 2AR
... ...
1
32
H992
Horn grille ...
..
...
...
... ...
1
33
F4129
Screw (0.435 in. U.H.)
...
... ...
2
34 GS299
Serrated washer
...
...
...
...
4
35
F3799
Nut
... ... ...
2
36
H1420
Horn bracket
... ...
...
... ...
1
37
70164
Horn type 8H
... ...
1
38
F4771
Bolt (f
z
in. U.H.)
...
2
39
54938942
Wiring harness
..
...
1
40
F5983
Bracket
...
...
...
...
...
2
41
F5988
Rubber band
...
2
42 54942078
Lucar connector ...
...
...
...
...
2
43
54190042
Insulating cover
...
„_
2
44
900269
Snap connector terminal
...
... ...
...
as required
45
900288
Single snap connector
...
...
as required
46
850641
Double snap connector
... ... ... ...
as required
47
850844
Triple snap connector
...
...
as required
48
850832
Quintuple snap connector
... ...
...
as required
49
H1938
Blind grommet
...
... ...
..
2
50
H1421
Rubber grommet ...
...
...
1
51
ClassicBike.biz
Fig. 17. TELESCOPIC FRONT FORK, T90
AND T100
52
ClassicBike.biz
Ref.
No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
TELESCOPIC FRONT FORK, T90 AND T100
1
H1918
FORK ASSEMBLY
.. ..
...
...
...
1
incl. U.S.A. Western T1000
2
H1 328
Middle lug and stem
...
...
...
...
1
3
H1110
Bottom cone ...
...
...
...
...
...
1
4
H941
Pinch bolt (24 in. U.H.)
...
...
...
...
2
5
S25-2
Plain washer ... ...
...
...
...
2
6
H1335
Nut (28 in. O.A.)
...
...
...
... ...
2
7
H405
Fork stem sleeve nut
...
...
... ...
1
8
H1287
TOP LUG c/w CAPS
...
...
...
1
9
HSO6
Handlebar cap
...
...
...
... ...
2
10
S25-3
Plain washer ... ...
...
... ...
4
11
H1 340
Bolt (1'–
a
in. U.H.)
...
...
... ...
4
12
F1760
Pinch bolt (1 ;6 in. U.H.)
...
...
...
...
1
13
H379
Seated
nut
...
... ...
...
...
...
1
14
H1888
Left cover ...
... ...
...
...
...
1
15
H1 887
Right cover
... ... ...
...
... ...
1
16
F4047
Cork washer
...
...
...
...
...
2
17
H1657
Spring abutment
... ...
...
...
...
2
18
H1891
Main spring (Yellow/Blue) ...
...
...
2
19
H1656
Plain washer
...
...
...
...
...
2
20
H1645
Telescopic gaiter
... ...
...
...
...
2
21
D340
Clip
... ...
...
...
...
... ...
4
22 H1654
DUST EXCLUDER SLEEVE NUT
...
...
2
23
H1500
Oil
seal
... ... ...
... ... ...
2
24
H431
Plain washer
... ...
...
...
...
2
25
H441
Top bearing
... ...
...
...
...
...
2
26
H1896
Damping sleeve
...
... ... ...
...
2
27 H1889
STANCHION c/w BEARING
... ...
...
2
28 H443
Lower bearing
... ...
...
...
...
2
29
H1058
Bearing nut
...
... ...
...
...
2
30
H1658
Cap
nut
... ... ... ...
...
...
2
31
H1842
LEFT BOTTOM MEMBER c/w CAP
...
...
1
32
H1843
RIGHT BOTTOM MEMBER c/w CAP
... ...
1
33
H1 844
Spindle cap
...
...
...
...
...
2
34
S26-3
Spring washer ...
...
...
...
4
35
H1070 Bolt (1
-6 in. U.H.) ...
... ...
...
4
36
H1071
Drain
plug
...
...
...
... ...
...
2
37
H430
Fibre washer ...
...
...
... ... ...
2
38
H1499
Restrictor
...
...
...
...
... ...
2
39
H1063
Flanged bolt (23/32 in. U.H.)
...
... ...
2
40 H1062
Aluminium washer
... ...
...
...
...
2
41
H1142
Steering damper rod
...
...
... ...
1
42
H565
Plain washer
... ... ... ...
...
1
43
H408
Adjuster sleeve ... ...
...
... ...
1
44
H1286
Locating pin
... ... ...
...
... ...
1
45
H95
Spring plate
...
...
...
...
...
...
1
46
H1111A
Anchor plate
... ... ... ... ...
1
47
H435
Friction disc
...
... ... ... ...
....
1
48
H1618
Rubber sleeve
... ... ... ...
...
1
49
F3468
Bolt (2
,
'a in. U.H.) ...
...
...
...
... ...
1
50
S1-51
Nut
...
...
...
... ...
...
...
1
53
ClassicBike.biz
12
14
15
Fig. 18. TELESCOPIC FRONT FORK, U.S.A. EASTERN TING
54
ClassicBike.biz
Ref.
No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
TELESCOPIC FRONT FORK,
H2015
FORK ASSEMBLY
—
H1328
Middle lug and stem...
H1287
TOP LUG c/w CAPS
HSO6
Cap
... ,..
S25-3
Plain washer
...
H1340
Bolt (11 in. U.N.)
H1696
Top cover
...
...
H1892
Main spring (yellow/green)
H1913
DAMPER ASSEMBLY
H1893
Restrictor body...
H1897
Rod
H1764
Cup
H454
Pin
H452
Oil restrictor
F879
Nut
...
H1761
Restrictor body cap
T224
Nut
H1762
Cap nut
U.S.A.
EASTERN
..:
...
...
...
...
•••
...
...
...
•••
T100C
1
1
1
2
4
4
As required
2
2
2
2
2
2
2
2
2
4
2
All other parts as page 53.
55
ClassicBike.biz
^
O
N _
^\
0
z
W
J
x
W
N
00
U-
56
ClassicBike.biz
Ref.
No.
Part No.
DESCRIPTION
QUANTITY
R
EM
AR
KS
FRONT WHEEL
1
W1665
FRONT WHEEL COMPLETE
1
T100R, T1
1
W1
66
4
FRONT WHEEL COMPLETE
... ...
1
2
W1229
RIM, SPOKES AND HUB ASSEMBLY
1
T100R, T100C
2
W1370
RIM, SPOKES AND HUB ASSEMBLY
1
3
W1230
Front wheel rim (WM2-19)
1
T100R, T100C
3
W1373
Front wheel rim (WM2-18)
1
4
W1236
Spoke (8/10G x 6 in. straight) c/w nipple
40
T100R, T100C
4
W1497
Spoke (8/10G x 51 in. straight) c/w nipple
40
5
S79-2
Spoke nipple ...
...
40
6
W1231
Hub and brake drum
1
7
W1641
Wheel spindle
1
8
W653 Bearing
...
2
9
W1237
Dust cover
1
10
T280
Circlip
...
1
11
W1481
Grease retainer
...
...
1
12
W1474
Grease retainer (Brake side)
1
13
W1238
Backing ring
...
1
14
W582
Retaining ring
...
1
15
W1334
Cover plate
...
1
16
W1197
Balance weight,
+
oz.
as required
17
W1198
Balance weight, 1 oz.
as required
18
W1301
Brake anchor plate
1
19
W1639
Fulcrum pin
1
20
S25-2
Plain washer
1
21
S1-52
Nut
...
...
...
2
22
W1406
LEADING BRAKE SHOE C/W LINING
1
23
W1407
TRAILING BRAKE SHOE C/W LINING
1
24
NW243
Brake lining
...
2
25
W129
Brass rivet
...
16
26
W1415
Thrust pad
...
2
27
W135
Shoe return spring
2
28
W1243
Brake cam
...
1
29
W1331
Brake cam lever ...
1
30
S25-6
Plain washer
...
1
31
W592
Lever return spring
1
32
W1246
Anchor plate nut
1
33
W1640
Abutment (-- in. deep) ...
as required
33
W1711
Abutment (* in. deep)
...
as required
57
ClassicBike.biz
U.
Cl)
v
LO
58
ClassicBike.biz
Ref No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
REAR WHEEL
1
W1741
REAR WHEEL COMPLETE
... ...
...
...
...
1
1
W1742 REAR WHEEL COMPLETE
...
...
...
...
...
1
T100R, T1000
2
W1470
RIM, SPOKES AND HUB ASSEMBLY ...
...
...
1
2
W1486
RIM, SPOKES AND HUB ASSEMBLY ...
... ...
I
T100R, T1000
3
W1471
Rear wheel rim WM2-18
......
... ... ...
1
3
W1007
Rear wheel rim WM3-18 ...
... ... ...
1
T100R, T1000
4
W1107
Spoke (8/10G x 7,s in. 90
0
) c/w nipple
... ...
20
5
W1108
Spoke (8/10G x 78 in. 90°) c/w nipple ... ...
20
6
S79-2
Spoke nipple
... ...
... ...
... ...
40
7
W1472 Hub
...
...
...
...
... ... ...
1
8
W1499
Sprocket, 46T
...
...
... ... ...
...
1
9
W1500
Bolt
... ... ... ...
...
...
...
8
10
E1612
Serrated washer
...
... ... ...
...
8
11
W1498
Brake drum
...
... ...
...
...
...
1
12
W1690
Bolt (16 in. U.H.)
... ... ... ...
...
8
13
W1691
Self locking nut
...
...
... ...
...
8
14
W1281
Wheel spindle
...
...
...
...
...
...
1
15
W1474
Grease retainer (brake side) ...
... ...
...
1
16
W1654
Grease retainer
...
...
...
...
...
1
17
W1022
Backing ring
...
...
... ...
...
...
1
18
W653 Bearing
...
...
...
...
... ...
...
2
19
W1021
RETAINING RING
.
... ...
...
1
20
W1710
Locking screw (,6 in. U.H.)
... ...
...
1
21
W1278
Distance tube
... ...
...
... ...
...
1
22
W1024
Distance piece
...
... ...
... ...
...
1
23
W1112
Brake anchor plate
...
...
...
...
...
1
24
W1282
Nut
...
...
...
...
... ...
...
1
25
W1406
LEADING BRAKE SHOE C/W LINING
...
...
1
26
W1407
TRAILING BRAKE SHOE C/W LINING
...
...
1
27
NW243
Brake lining
... ... ... ...
...
2
28
W129
Brass rivet ...
...
...
...
...
...
16
29
W1415
Thrust pad
...
...
... ...
...
2
30
W135
Shoe return spring
...
...
... ...
...
2
31
W1083
Brake cam
...
...
...
...
...
...
1
32
W1466
Brake cam lever
...
...
...
...
...
1
33
W1467
Pivot
pin...
...
...
...
... ...
...
1
34
S25-6
Plain washer
...
...
...
... ...
...
1
35
SI-52
Nut
...
...
... ...
... ...
...
1
36
W1090
Lever return spring
... ...
...
..
...
1
37
W1635
Grease retainer
...
...
...
... ...
1
38
W1476
Speedometer adaptor
... ...
...
...
1
39
W1477
Distance piece
...
... ... ... ...
...
1
40
D373
Speedometer gearbox ...
...
... ...
...
1
41
W1280
Plain washer
...
...
...
...
... ...
1
42
W1134
Chain adjuster
...
...
...
...
... ...
2
43
W1015
Adjuster end plate
...
...
... ...
...
...
2
44
W1058
Self-locking nut
...
... ...
...
...
... ...
2
45
F1747
Spindle
nut
...
...
...
...
... ...
...
3
46
D106
Tyre security bolt...
... ...
...
... ...
...
2
46
WM3
Tyre security bolt...
...
... ...
...
...
...
2
T100R, T1000
59
ClassicBike.biz
N
0
0
r
1
*
.
0
14
4
1
....a
ti
p
o
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i
* 4,v
0
ClassicBike.biz
QUICKLY DETACHABLE REAR WHEEL (NOT U.S.A.)
1
W1746
Q.D. REAR WHEEL COMPLETE
...
1
1
W1745
Q.D. REAR WHEEL COMPLETE
...
...
1
T100R, T100C
2
W1747
RIM, SPOKES AND HUB ASSEMBLY
1
2
W1603
RIM, SPOKES AND HUB ASSEMBLY
1
T100R, T100C
3
W1471
Rear wheel rim WM2-18
...
1
3
W1007
Rear wheel rim WM3-18
...
...
1
T100R, T100C
4
W1107
Spoke (8/10G x 7* in.90°) c/w nipple
20
5
W1108
Spoke (8/10G x 78 in.90°) c/w nipple
20
6
S79-2
Spoke nipple ...
40
7
W1593 Hub
...
1
8
W1595
Grease retainer
2
9
W1509 Backing ring
2
10 S35-7
Bearing
...
2
11
W1596
Dust cap
...
1
12
W1614
Bearing sleeve
1
13
W1598
Distance piece (inner)
...
2
14
W1635
Grease retainer
...
1
15
W1599
Speedometer adaptor
1
16
W1477
Distance piece (outer)
1
17
W1280
Plain washer
1
18
W1282
Nut
1
19
W1040
Sprocket and brake drum 46T
1
20
W1143
Grease retainer
1
21
W1041
Bearing
...
1
22
W1042
Felt washer
1
23
W1043
Bearing and felt retainer
1
24
W1044
Circlip
...
1
25
W1045
Bearing sleeve
...
1
26 W1121
Brake anchor plate
1
27
W1406
LEADING BRAKE SHOE C/W LINING
1
28
W1407
TRAILING BRAKE SHOE C/W LINING
1
29
NW243
Brake lining
...
2
30
W129
Brass rivet
...
16
31
W1415
Thrust pad
...
2
32
W135
Shoe return spring
2
33
W1083
Brake cam
1
34
W1466
Brake cam lever
...
1
35
W1467
Pivot pin ...
1
36
S1-52
Nut
...
1
37
W1090
Lever return spring
1
38
W1052
Nut
...
...
1
39
W1392
Inner distance piece
1
40
W1170
Outer distance piece
1
41
W1055
Spindle
... ...
1
42
W1091
Rubber sealing ring
1
43
D373
Speedometer gearbox
1
44
W1135
Chain adjuster
...
2
45
W1015
Adjuster end plate
2
46
W1058
Self-locking nut
2
47
D106
Tyre security bolt
2
47
WM3
Tyre security bolt
2T100R, T100C
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
61
ClassicBike.biz
I
-
23
I
19
18
17
4
19 18 17
19 29
X36
34 38 17
19 36
30
^!
32
33
•
35
F7
3-
35
37
17
q
13
1
6
-;-
15
\1202314
o
=
21
od
i
31
_
^ al
12 11
39
--
C
o
®^
°
28
36
19
Fig. 22. MUDGUARDS (STANDARD)
5
6
2;
2^
62
ClassicBike.biz
Ref. No.
Part
No.
DESCRIPTION
QUANTITY
R
EMARKS
MUDGUARDS
(STANDARD)
1
H1901
Front mudguard
1
3TA, 5TA
2
F929
Bolt (I in. U.H.)
5
3
F4299
Plain washer
4
4
H1964
Front stay .:.
2
5
H1100
Bottom stay
1
3TA, 5TA
6
NS362
Spigot nut
1
7
H1675
Mudguard blade
1
T90, T1M
8
9
W62
S25-2
Bolt
...
...,
Plain washer
2
23TA, 5TA
3TA, 5TA
10
H1482
Bottom stay
1
11
H424
Bolt (39/64 in. U.H.)
2
flO, T1W
12
S25-71
Plain washer
...
...
2
13
H1681
Front stay ...
14 H1685
Bracket
•••
2
15
H1683
...
...
Mudguard bridge
•••
1
T90, T1W
16
WE170
Fibre washer
...
•••
2
17 DS57
Bolt (
in. U.H.)
•••
10
18
S25-1
...
Plain washer
...
•••
6
19
F879
Nut
17
20
T224
Nut
•••
2
190, T100
21
DS55
Bolt (+ in. U.H.)
•••
2
T90, T100
22
F1369
...
Bolt (I in. U.H.)
...
•••
2
3TA, 5TA
23
F6469
Number
plate
...
•••
1
3TA, 5TA
24
F6470
Number plate
...
•••
1
190, T100
25
H741
Clip assembly
...
2
26
H687
Screw (I in. U.H.)...
2
27 H745
Nut
...
2
28
F5984
Mudguard blade
...
1
29
F6915
Mudguard bridge
1
30
F5424
Lifting handle
1
31
F5994
Clip
...
1
32
F6031
Backing plate
1
33
S26-3
Spring washer
9
34
F6916
Bracket
...
1
35
S1-51
Nut
...
3
36
S26-2
Spring washer
10
37
F5924
Number plate
1
38 F6310
Plain washer
...
4
39
H590
Bolt (* in. U.H.) ...
2
63
ClassicBike.biz
1
•
•
9.
12
5
16
32
2
16
18
^
^
19
3
11
8
9
2ir
°
9
20
24
19
Fig. 23. FENDERS (U.S.A.)
64
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
FENDERS
(
U.S.A.)
1
H1677
Front fender
...
1
T100R, Eastern T100C
1
H1687
Front fender (aluminium)
1
Western T100C
2
H1681
Front stay
...
1
3
H1683
Centre bridge
1
4
H1678
Bottom stay
1
T100R, Eastern T100C
5
H1273
Bottom stay
1
Western T100C
6
H1685
Bracket
...
2
7
H1688
Bracket
...
2
Western T100C
8
F929
Bolt (1 in. U.H.)
...
5
9
F4299
Plain washer
...
5
10 DS55
Bolt (* in. U.H.) ...
2
11
T224
Nut
2
12
S1-51
Nut
4
13
NS362
Spigot nut
1
14
H424
Bolt
...
2
15 S25-71
Plain washer
2
16
DS57
Bolt (* in. U.H.) ...
10
17
WE170
Fibre washer
...
4
18
S25-1
Plain washer
13
19 F879
Nut
...
13
20
F6965
Rear fender
•••
1
T100R, Eastern T100C
20
F6966
Rear fender (aluminium)
•••
1
Western T100C
21
F6915
Fender bridge
•••
1
22
F5424
Lifting handle
•••
1
23
F6916
Bracket
...
1
24 S26-2
Spring washer
2
25
S26-3
Spring washer
5
26
H590
Bolt (* in. U.H.) ...
2
27
F5994
Clip
...
1
28
F6031
Backing place
1
29
F6310
Plain washer
...
1
30
F6847
Tail lamp adapter ...
1
31
F6849
Tail lamp plate
...
1
32
F6850
Number plate bracket
1
33
E2980
Stud (H- in. 0.A.) ...
1
34
F4715
Screw (AI in. U.H.)
3
65
ClassicBike.biz
3
13 12 10
8
11
15
14
6
9
30--
16
-19
23
24
7,,
lil
Il
^
lli
,
Fig. 24. PANELS AND TWINSEAT
1
7
28
27
66
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
PANELS AND TWINSEAT
1
F6964
Left panel
..
. . .
1
3TA, 5TA
2
F6947
Motif "Twenty-One" ...
2
2
F6948
Motif "Tiger 90" ...
...
2
2
F6949
Motif "Tiger 100"
...
2
2
F6950
Motif "Speed Twin" ...
2
3
F4317
Spire nut
..
...
4
4
E1612
Serrated washer
...
2
5
13104/00/2
Nut
..
...
2
6
15104/00/2
Self-locking nut
...
1
7
F6931
Switch p
ane
• •
...
1
T90, T100
8
F1369
Bolt (I in. U.H.)
...
1
9
F5466
Grommet
..
.••
2
10 F5976
Link
... ...
1
11
11104/06/2
Bolt (I in. U.H.)
...
1
12
S26-2
Spring washer
...
1
13
F879
Nut
... ...
1
14
S25-43
Washer
...
...
1
15
H961
Grommet
... ... ...
3
16
F4239
TWINSEAT (GREY TOP)
...
1
16
F4360A
TWINSEAT (BLACK TOP)
...
...
... ...
1
Eastern T100C
17
F4244
Twin seat cover c/w clips (GREY TOP) ...
...
1
17
F4244A
Twinseat cover c/w clips (BLACK TOP) ...
...
1
Eastern T100C
18
F4475
Clip
... As required
19
F4898
Rubber buffer
2
20 F4222
Hinge
... ...
2
21
DS57
Bolt (,s in. U.H.) ...
4
22
S26-2
Spring washer ...
4
23
D374
Check wire
...
1
24
F4483
Self tapping screw
1
25
F4226
Seat catch plunger
1
26
F4228
Spring
...
1
27
E1719A
Plain washer
...
1
28
*
in. x 1 in.
Split pin ...
1
29
F6659
Knob
...
1
30
F4361
Safety strap
...
1
Western T100C,T1OOR
31
F4365
Self tapping screw
4
67
ClassicBike.biz
13
g
16
12
11
^ -15
27
22
29
I
I/If
26
21
23
17
-
18
-^
..
19
-
2
20
E--3
8
9
l
,
1
,
•
;
O
69
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
PETROL
(
GAS)
TANKS
1
F7001
Petrol tank (3 gallons)
...
2
F6887
Styling unit (left)
3
F4129
Styling unit screw (0.435 in. U.H.)
4
F6888
Styling unit (right)
5
F5401
Left knee grip
...
6
F5402
Right knee grip ...
7
F6313
Centre styling strip
8
F4019
Serrated washer
9
H919
Nut
...
10
F1717
Petrol tap ...
11
F6143
Tank bracket
12
F6144
Saddle
13
F6145
'U' bolt
...
14
S26-3
Spring washer
15
S1-51
Nut
...
16 F6535
'T' head bolt
17
F5228
Rubber washer
18
F5229
Spigot rubber
19
F3814
Cup
20
F1808
Bolt
...
21
F3220
FILLER CAP ...
22
F3219
FILLER CAP c/w JACK CHAIN
23
F4048
Joint washer
24
F4971
Petrol tap (left)
25
F4972
Petrol tap with reserve tube
26
F1511
Fibre washer
...
...
27
F7002
Petrol tank (21 U.S. gallons)
28
F1606
Left knee grip
29
F1605
Right knee grip
30 F4108
Rubber washer
31
S26-2
Spring washer
32 F6958
Tank bracket
33
F3917
Parcel grid
34
F2936
Screw
...
...
35
F4384
Rubber blanking plug
1
1
4
3TA, 5TA
T90, T100
2J
1
1
4
4
2
4
4 3TA, 5TA, 190, T100
4
4
1
1
1
1
1
1
2
1
T100C, T100R
1
1
4
4
2-
1
1
A
•••
69
ClassicBike.biz
10
Fig. 26. OIL TANK
c
437 19 1
5
4
7
6
9
8
11
70
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY REMARKS
OIL TANK
1
F6877
Oil tank
...
1
2
F3216A
FILLER CAP ...
1
3
F4047
Joint washer
1
4F5343
Drain plug
...
1
S
PT104B
Fibre washer
...
1
6
F3179
Oil tank filter
...
1
7
F1713
Fibre washer
...
1
8
F6103
Upper feed pipe
1
9
F3182
Union nut
1
10
E3353
Flexible connector, long ...
2
11
E5473
Clip
... ...
4
12
E5434
Oil pipes and junction block
1
13
E3763
Joint washer
1
14
E3446
Plain washer
1
15
E1310
Nut
...
1
16
E6356
Vent pipe ...
1
17
E5370
"T" piece
...
...
1
18
E5376
Extension pipe
...
1
18
E5376
Extension pipe
1
19
F3098
Clip
...
2
20
F6892
Front strap
1
21
*F6894
Rear strap
1
22
F6673
Spigot rubber
4
23
F6968
Rubber washer
2
24
11104/06/2
Bolt (1 in. U.H.)
2
25
15104/00/2
Self locking nut
2
26
F6511
Metering screw
1
27
F6874
Coil spring
1
28
F6672
Screwed peg
2
29
S25-13
Plain washer
4
30
F879
Nut
...
...
2
31
E6353
Rubber connector
1
32
E6351
Rocker oil feed pipe
1
33
F6898
Bracket ...
1
34
F6039
Grommet
...
1
35
E6355
Flexible pipe
1
36
E6354
Chain oiler pipe
1
37
€6357
Flexible pipe
1
38
F6970
Clip
...
...
...
1
39
MF119
Flexible connector, short
...
1
* See page 73
71
ClassicBike.biz
D ^
35
34
32
33 "'
n ^1
22
6
9
^
1
0
b ^
rb}- 11
8
2
fD
5
4
1
37
16
14
j 18
1
7
r' 13
p
3
S
V
3
S r
26
24
23
21
20
19
^:
28
27
29
30
Fig. 27. BATTERY, TOOLKIT AND AIR FILTER
72
ClassicBike.biz
use MK E (2 off)
use F7083
use F7086
use F7085 (1 off)
use F7045 (3 off)
use F7046 (2 off)
use F7087
73
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
BATTERY, TOOLKIT AND AIR FILTER
1
*F6891
Battery carrier
1
2
*F6897
Retainer
2
3
*E6226
Rubber
4
4
525-1
Plain washer
3
5
F879
Nut
...
4
6
*PUZ5A
Battery
7
*F6969
Battery carrier lining
1
8
F6901
Tool tray
1
9
F1369
Bolt (e in. U.H.)
2
10
F7128
Plain washer
...
2
11
S25-13
Plain washer
...
•••
12
D
44
6
TOOL KIT
1
•••
...
13
D360
Open spanner,
e
in. x
in. whit.
•••
14
NA55
Open spanner,
a
in. x
*
in. whit.
•••
15
DA16
Open spanner, I in. x *in. whit.
16
D370
Ring spanner, *in. x
in. whit.
17
PA57
Ring spanner,
2
in. x
*
in. whit.
18
D311
Ring spanner, I in. x16 in. whit.
19
D87
Box spanner, spark plug ...
1
20
D363
Tyre lever and tommy bar
1
21
D364
Tyre lever and clutch key
1
22 D362
"C" spanner and tappet key
1
23
D336
Phillips No. 3 screwdriver
1
24 400935
Ignition screwdriver and feeler gauge
1
25
WA58
Tool roll
...
1
26
DA50/1
Clutch hub extractor ...
as required
27
D527
Fork spanner (for sleeve nut) as required
28
D220
Fork spanner (for cap nut)
...
as required
29
D484
Contact breaker extractor
...
as required
3Q
D486
Contact breaker assembly pilot
as required
31
D296
Tyre inflator
...
1
32
F5432
Inflator top bracket
1
33
F1369
Bolt (1 in. U.H.)
1
34
S25-43
Plain washer ...
1
35
S1-40
Nut
...
1
36 F5433
Inflator bottom bracket
1
37 S25-3
Plain washer
...
1
38
E5194
Adaptor ...
1
3TA, 5TA
38
F4812
Adaptor ...
4
T90, T100
39
F5625
Clip
...
1
40
F6430
AIR FILTER
1
41
F4811
Filter element (felt)
1
40
F6433
AIR FILTER
...
1
U.S.A. models
41
F5694
Filter element (paper)
1
U.S.A. models
•••
*Some
early models
...
have two 6 volt batteries.
These are interchangeable as a group but the following part numbers
apply to this condition (Not
Illustrated)
PUZ5A
Battery
F6891
Battery carrier
F6894
Rear strap
F6897
Retainer
E6226
Rubber
Rubber (between batteries)
F6969
Battery carrier lining
ClassicBike.biz
N 00
W
W
J
J
0
I-
F-
z
0
u
G
z
a
a
W
c
z
a
N
0_0
W
0'
N
to
M
10
(
N
N
N
v
N
1
N
i' N
N
rT
r
-
i^f
i
74
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
HANDLEBARS AND CONTROL LEVERS
1
H1871
Handlebar
1
3TA, STA
1
H1872
Handlebar
...
1
T90, T100
1
H1519
American handlebar
1
T100C
1
H1873
American handlebar
1
T100R
2
H1425
Packing piece ...
4
3
16/362
TWISTGRIP
...
1
4
16/328
Body top half
...
1
5
16/329
Body bottom half ...
1
6
16/091
Rotor
...
1
7
16/008
Friction spring
1
8
16/009
Friction spring screw
1
9
16/010
Nut
1
10
11/014
Screw
...
2
11
366/012
Handlebar grip
1
12
16/011
Cable stop
1
13
18/999
FRONT BRAKE LEVER ASSEMBLY
1
14
18/535
Brake lever
...
1
15
18/1013
Brake lever bracket
1
16
12/595
Clamp
...
1
17
11/014
Screw
...
2
18
18/087
Fulcrum screw
1
19
18/053
Self-locking nut
1
20 18/1005
Cable adjuster
1
21
18/1006
Thumb nut
...
1
22
18/1000
CLUTCH LEVER ASSEMBLY
1
23
18/528
Clutch lever
...
1
24 18/1009
Clutch lever bracket
1
25
12/595
Clamp
1
26
11/014
Screw
...
2
27
18/087
Fulcrum screw
1
28
18/053
Self-locking nut
1
29
18/1005
Cable adjuster
1
30
18/1006
Thumb nut
...
1
31
31563
Horn push and dip switch
1
32
380459
Backing rubber
...
1
33
H1876
Screw (1 in. U.H.)
...
2
34
366/011
Handlebar grip ...
...
1
...
...
...
35
18/951
FRONT BRAKE LEVER ASSEMBLY (Ball-end)
1
36
18/754
Brake lever (Ball-end)
1 1
37
18/777
Brake lever bracket
1
38
18/838
Cable adjuster
1
T100C,
T1OOR
39
18/839
Thumb nut
...
... ...
1
40
18/952
CLUTCH LEVER ASSEMBLY (Ball-end))
1
41
18/752
Clutch lever (Ball-end) ...
1
42
18/773
Clutch lever bracket
...
1_
75
ClassicBike.biz
w
W
J
Q
u
J
0
H
z
0
U
P
Co
LL
C
76
ClassicBike.biz
W.
No.
Port. No.
DESCRIPTION
QUANTITY
REMARKS
CONTROL CABLES
1
D495
THROTTLE CABLE ...
1
2
D101
Ferrule
3
3
D83
Nipple
1
4
D104
Adjuster
1
5
6/132A
Ferrule
1
6
NS191
Nipple
...
...
1
7
D561
FRONT BRAKE CABLE
1
3TA, 5TA
7D560
FRONT BRAKE CABLE
1
T90, T100
8
D103
Ferrule
2
9
D506
Nipple
1
10
W593
Fork end
1
11
WF32
Pivot pin...
1
12
*
in. x I in.
Split
pin ...
...
1
13
D566
CLUTCH CABLE
...
1
13
D565
AMERICAN CLUTCH CABLE
1
T100R, T1
14
D103
Ferrule
...
2
15
D506
Nipple
1
16
DS73
Nipple
1
17
XA69
Cable clip
As required
77
ClassicBike.biz
Fig. 30. CARBURETTER, 3TA AND 5TA
3
4
36
37
43
42
29
28
34
35
33
27
30
31
32
78
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION QUANTITY
REMARKS
CARBURETTER, 3TA AND 5TA
1
375/62
CARBURETTER, 25/32 in. choke
1
3TA
1
375/35
CARBURETTER,
f
in. choke ...
1
5TA
2375/003
Mixing chamber, 25/32 in. choke
1
3TA
2
375/005
Mixing chamber,
f
in. choke
1
5TA
3
375/057
Jet block, 25/32 in. choke
1
3TA
3
375/059
Jet block,
g
in. choke
1
5TA
4 375/067
Joint washer
1
5
376/070
Peg screw
...
...
1
6
375/102
AIR VALVE ASSEMBLY
1
7
375/065
Mixing chamber cap
1
8
375/071
Spring
...
1
9
4/241
Screw
...
1
10
30/064
Spring
...
...
...
1
11
375/060
Throttle valve (32 cutaway)
1
3TA
11
375/060
Throttle valve (3 cutaway) ...
1
5TA
12
375/079
Throttle return spring
1
13
375/063
Needle (Type B)
1
14
4/230
Needle clip
...
1
15
376/072
Needle jet (.106)
1
16
376/100
Main jet (100)
1
3TA
16
376/100
Main jet (160)
1
5TA
17
376/073
Jet holder
...
1
18
376/074
Fibre washer ...
1
19
376/075
Cover nut
...
1
20
376/076
Pilot jet (25)
...
1
21
116/162
Fibre washer ...
1
22
376/095
Cover nut
... ...
1
23
332/017
Air adjusting screw
1
24
4/148
Spring
... ...
1
25
376/068
Throttle stop screw ...
1
26
376/069
Spring
...
1
27
376/085
Float spindle
1
28
376/083
Float
...
1
29
376/094
Bush
... ...
1
30
376/078
Joint washer
1
31
376/077
Cover ...
1
32
376/079
Screw ...
3
33
376/088
Needle seating
1
34
376/089
Needle
1
35
376/093
Filter
...
1
36
376/091
Bolt
...
•••
1
37
376/092
Fibre washer ...
1
38
376/086
Tickler
•..
1
39
376/087
Spring
...
1
40
343/011
Tickler body
1
41
244/765
"0" ring seal...
1
42
229/048
Air intake tube
...
As required
43
F4308
Petrol pipe
...
1
79
ClassicBike.biz
4•
•
•
•
•
33
32
38
21
39
37
31
34
35
36
20
23
11
14
6
oe.
13
^=1°
IJ
,
-
If.-
8
9
CARBURETTER COMPLETE
REF. No.
I
7
10
(i!.
17
2
Fig. 31. CARBURETTER, T90 AND T100
80
ClassicBike.biz
Ref. No.
Part
No.
DESCRIPTION
QUANTITY REMARKS
CARBURETTER, T90 AND T100
1
376/300
CARBURETTER,
+
in. choke ...
1
190
1
376/273
CARBURETTER, 1 in. choke
...
1
T100
2
376/001
Mixing chamber,
*
in. choke
1
190
2
376/002
Mixing chamber, 1 in. choke
1
T100
3
376/055
Jet block, .f
in. choke
1
T90
3
376/056
Jet block, 1 in. choke
1
T100
4
376/067
Joint washer
1
5
376/070
Peg screw
...
1
6
376/158
Mixing chamber top
1
7
376/197
Air valve
...
...
—
1
8
376/402
Control rod and lever
1
9
376/109
Return spring
1
10
376/409
Friction washer
1
11
30/064
Click spring
...
1
12
376/065
Mixing chamber cap
1
13
29/308
Spring
1
14
4/241
Screw
•••
1
15
376/060
Throttle valve (3 cutaway) ...
1
190
15
376/060
Throttle valve (32 cutaway)
1
T100
16 376/061
Throttle return spring
1
17 376/063
Needle (Type C)
1
18
4/230
Needle clip
...
1
19
376/072
Needle jet (.106)
1
20 376/100
Main jet (180)
1
T90
20
376/100
Main jet (190)
1
See Pages 9 to 12
21
376/073
Jet holder
...
1
22
376/074
Fibre washer ...
1
23
376/075
Cover nut
...
1
24 376/076
Pilot jet (20)
1
190
24 376/076
Pilot jet (25)
1
T100
25
116/162
Fibre washer ...
1
26
376/095
Cover nut
...
...
1
27 332/017
Air adjusting screw
1
28
4/148
Spring
...
...
1
29
376/068
Throttle stop screw
1
30
376/069
Spring
...
1
31
376/085
Float spindle
1
32
376/083
Float
...
1
33
376/094
Bush
... ...
1
34 376/078
Joint washer
1
35
376/077
Cover
1
36
376/079
Screw ...
3
37
376/088
Needle seating
1
38
376/089
Needle
...
1
39
376/093
Filter
...
1
40
376/091
Bolt
...
...
1
41
376/092
Fibre washer ...
1
42
376/086
Tickler
...
1
43
376/087
Spring
...
1
44
343/011
Tickler body
1
45
2/1048
"0" ring seal...
1
46
F4308
Petrol pipe
...
1
47 376/066
Air intake tube ...
A
81
ClassicBike.biz
8
10
14
13
15
15
31
32 33 34
KIi]
5
4
e
2
6
a
3
/
7
4
per
-5
18
16
_=
17
19
III
-f
1
-
IPJ
Fig. 32. A.C. MAGNETO IGNITION COILS, WIRING HARNESS AND DIRECT LIGHTING
82
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY REMARKS
A.C. MAGNETO IGNITION COILS, WIRING HARNESS
AND DIRECT LIGHTING
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
36 and
F6112
F4366
F6122
E1612
F879
W932
F6125
F6136
45149
54441582
54190108
54937097
31071
H1669
Ht670
H687
H745
58395
534343
54520452
504665
166
554602
112201
137499
31356
31620
144921
534296
D552
11104/06/2
F4366
E1612
15104/00/2
D553
53972
384
F3069
37 not illustrated.
Coil bracket
...
Distance piece
...
Bolt (1
A
in. U.H.)
Serrated washer
Nut
...
Bolt (1
in. U.H.)
Retainer
Retainer ...
Ignition coil, type 3ET
Condenser
...
Lucar terminal
...
Wiring harness ...
...
Cut-out button, type SS5
Cup
Clip
...
Bolt
(i
in. U.H.)
Nut
... ... ...
HEADLAMP ASSEMBLY, MCH 66 ...
Rim
...
Light unit
...
Fixing wire...
...
...
Bulb (24/24W. Pre-focus, Vertical Dip)
Adaptor
Bolt
Washer
...
Lighting switch
Dip switch ...
Screw
...
Plate
...
Horn, clear hooters AC5855G
Bolt
Distance piece
Serrated washer
Horn push, clear hooters No. 10
STOP AND TAIL LAMP, Type 679
Bulb (6/18
W.
Offset pin)
Distance piece
...
...
...
••;
...
4
2
2
6
6
..
4
2
..
2
.. 2
2
2
1
1
1
2
1
1
1
1
1
6
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
"Kill button"
Except for bulb
See Page 87
83
ClassicBike.biz
I!
13
^
15
--z'Ja
9
_^
154
^ 2
345
10
-^
'# I
Q
r
7
6
38 37
I
20
19 21. 22
m
m m
I -^.
31
32
J
32
e m
34
30
33
L4
Fig. 33. D.C. IGNITION COILS, HORN, RECTIFIER AND ZENER DIODE
ra Q
35
23
11
12
4u
-.c,
1
10
8
11
12
29
84
ClassicBike.biz
Ref. No.
fart
No.
DESCRIPTION
QUANTITY
REMARKS
D.C. IGNITION
COILS,
HORN,
RECTIFIER AND ZENER DIODE
1
45110
IGNITION COIL. Type MAl2
2
2
54190108
Lucar terminal
...
...
4
3
131023
Plain washer (E2351)
...
4
4
188330
Serrated washer (GS299)...
4
5
166043
Nut (F3799)
...
...
4
6
421554
Rubber grommet ...
...
2
7
421863
Cable clip
...
...
2
8
100104
Screw
...
...
2
9
169160
Square nut
2
10
422369
"D" washer
4
11
54942078
Lucar connector ...
as required
12
54190042
Insulating cover...
...
as required
13
F3809
Bolt (11 in. U.H.)
...
2
14
F5466
Rubber grommet
...
2
15
F5467
Distance piece
...
4
16
E3290
Self locking nut
...
...
...
2
17
—
Sparking plug (Champion N4)
...
2
18
D262
Plug cover
... ...
2
U.S.A.
19
F6632
Horn bracket
...
...
1
20 H426
Bolt (n in. U.H.)
1
21
S26-1
Spring washer
1
22
S1-52
Nut
... ...
1
23
F6900
Mounting plate ...
1
24 49345
Zener diode
...
1
25
DS57
Bolt (
.
j in. U.H.)
2
26
S25-1
Washer ...
2
27
54441582
Condenser
...
2
U.S.A.
28
54937976
H.T. lead complete (resistive)
2
29 842183
H.T. lead (7 m.m. cable)
2
U.S.A.
30
35601
Cut-out button, type SS5
1
"Kill button"
31
H1669
Cup ...
•••
1
32
H1670
Clip
...
---
2
33
H687
Bolt (8 in. U.H.)
•-•
1
34
H745
Nut
...
...
...
1
35
70164
Horn, type 8H
...
1
36
F4771
Screw (I in. U.H.)
2
37 F3799
Nut
...
...
2
38
GS299
Serrated washer
...
2
39
49072
Rectifier, type 2DS 506
1
40
F5338
Nut (156 596)
...
1
41
F6896
Bracket
...
1
42
F879
Nut
...
2
85
ClassicBike.biz
41
40
37
25
^ ^' 20
21
f1
19
18
- 33
27 28
29
30
31
32
5
6
11
1
17
\
-4
I
I
rr
10
^----
26
J 14 13
12
49
1
47
46
Fig. 34. HEADLAMP, WIRING HARNESS, SWITCHES AND TAIL LAMP
86
ClassicBike.biz
Ref.
No.
Part
No.
DESCRIPTION
QUANTITY
REMARKS
HEADLAMP, WIRING HARNESS, SWITCHES
AND TAIL LAMP
1
59579
HEADLAMP COMPLETE
1
2
553248
Rim ...
1
3
516798
Light unit
...
1
4
504665
Fixing wire...
6
5
144921
Screw ...
1
6
534296
Plate
...
...
...
1
7
446
Bulb (50/40 W. Vert dip. Pre-focus)
1
8
554602
Main bulbholder
...
1
9
988
Bulb (3W. M.C.C.)
1
10
554710
Pilot bulbholder
...
1
11
36296
Ammeter type 2AR
1
12
862217
Grommet
... ...
...
1
13
112201
Bolt
...
2
14 137499
Plain washer
...
...
2
15
38189
Ignition warning light body
...
1
16
281
Bulb (2W. BA7S)
...
1
17
H1932
Headlamp spacer
...
2
18
F6981
Ignition lock c/w two keys
1
19
31899
Ignition switch, type S45
1
20
34289
Lighting switch, type 88SA
1
21
54330934
Knob c/w screw
1
22
F5983
Bracket
...
...
1
23
F5988
Rubber band
...
1
24
54330576
Switch bezel plate
1
25
54930007
Replacement harness socket (Lighting)
1
26
54938941
Wiring harness ...
...
1
27
900269
Snap connector terminal as required
28
900288
Single snap connector ... as required
29
850641
Double snap connector as required
30
850844
Triple snap connector ...
as required
31
850832
Quintuple snap connector
...
as required
32
53454
STOP AND TAIL LAMP, Type 564
1
33
573839
Lens
...
1
34
575200
Window
...
...
1
35
575208
Lens seating gasket
1
36
575219
Sleeve nut
•••
2
37
576002
Base assembly
...
1
3TA, 5TA
38
575209
Bulbholder
...
1
1
T90, T100
39
575207
Grommet
...
...
1
40
573828
Contact assembly ...
1
41
573625
Grommet
... ... ...
1
42
380
Bulb (6/21 W. Offset pin)
...
1 J
43
44
53973
54572932
STOP AND TAIL LAMP, Type L679
Lens...
...
11
i
45
572289
Screw
...
...
2
46
54574348
Bulb holder with reflector
1
T1OOR
47
573828
Contact assembly ...
1
48
380
Bulb (6/21 W. Offset pin)
1
49
54571677
Gasket
... ...
1
50
127684
Screw
...
...
2J
51
838604
Stop and tail lamp lead
1
87
ClassicBike.biz
//
5
w
1
3
^^
2
tW3
0
c
I
6
1413 12 10
Fig. 35. SPEEDOMETER AND TACHOMETER
88
ClassicBike.biz
Ref. No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
SPEEDOMETER AND TACHOMETER
1
1
1
1
SSM5002/00
SSM5002/01
SSM5001/00
SS M 5001/01
Speedometer head MPH
Speedometer head KPH
Speedometer head MPH
Speedometer head KPH
1
3TA, 5TA
Alternative 3TA, 5TA
1
T90, T100
Alternative T90,T100
2
554734
Bulb holder ...
1
3
987
Bulb, 3.W. M.E.S.
1
4
41-118-127-72
Trip control
1
5
31-753-778
Rubber ring
1
6
31-674-188-01
Fixing strap
1
3TA, 5TA
7 30-283-014-11
Washer ...
2
8
30-277-023-11
Nut
...
2
9
41-148-203-10
Trip control
10 H1702
Distance piece
2
11
H1701
Sleeve nut
2
T90, T100
12 H1668
Bracket
...
1
13
DS57
Bolt
in. U.H.)
2
14
15
S26-2
D609
Spring washer
Speedometer cable (65 ins. long)
2,
1
Smiths DF9110/00
16
E5755
TACHOMETER GEARBOX ...
1)
17
E5153
Securing screw
...
1
18
E5156
Bush
...
19 E5155
Flanged bush ...
1
20
E5157
Driving gear
...
21
E5759
End cap
...
22
E6300
"0" ring
...
1
23
E5578
Driven gear ...
24
E6122
Driven gear housing
1
25
E6299
"0" ring
1
26
E6124
Bush
...
...
1
T1WR
27
E3309
"0" ring
...
28
E5881
Set screw
29 D578
Tachometer cable (28 in. long)
...
1
30
RSM3003/01
Tachometer
...
31
H19
46
MOUNTING BRACKET
•••
1
32
H1929 Metal lasti k Bush
•••
2
33
3
282-01411
Washer
•••
2
34
30-276-037-11
...
Nut
...
•••
2
35
H1086
Bolt (1
* in. U.H.)
36
H1698
Cable bracket
...
37
D493
Spade
...
...
1
38
D494
Circlip
89
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ClassicBike.biz

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