TRI PU 1960-62 - JRC Engineering

TRI PU 1960-62 - JRC Engineering
~
I
I
l
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REPLACEMENT PARTS
CATALOGUE No. 16
FOR
6T- THUNDERBIRD
TR6-TROPHY
T120- BONNEVILLE 120
From Eng No 029364 & D 101 onwards
Sept1960
TRIUMPH ENGINEERING CO. LTD., MERIDEN WORKS
ALLESLEY, COVENTRY, ENGLAND
ILLUSTRATION INDEX
Fig. No.
Page No.
1
Crankshaft and Connecting Rods
16
2
Crankcase
18
3
Oil pump and Release valve and Manifold
20
4
Cylinder block and head. 6T
22
5
Cylinder block and head. T110 and TR6
24
6
Cylinder block and head. T120
7
Gearbox and <asing
a
26
28
Gearbox shafts and gears
30
9
Gearbox selector mechanism
32
10
Clutch
34
11
Frame
12
Swinging fork and suspension units
36
38
13
Engine and gearbox fottings
40
14
Chai ncase and alternator
42
15
Exhaust pipes and silencers
44
16
Telescopic Front Fork, 6T and T110
46
17
Nacelle, head lamp and switches
48
18
Telescopic Front Fork. TR6 and T120
50
19
Front Wheel, 6T
52
20
Front Wheel, T110, TR6 and THO
54
21
Rear Wheel
56
12
Quickly detachable Rear Wheel
58
23
Petrol Tanks
60
24
Oil Tanks
62
25
Battery Carrier and Air Filter
64
26
Mudguards
66
27
Panels and Twinseats
68
28
Handlebars
70
29
Control Cables and American Handlebars
72
30
Tool Kit, Frame Lock, Pillion Footrest and licence Holder
74
31
Carburetter 6T. T110 and TR6
76
32
Bonneville 120 Carburetters
78
33
Bonneville 120 Float Chamber
80
34
Magneto with Automatic Advance and Retard
82
35
Magneto with Manual Control
84
36
Diotributor and Coil
86
37
Head lamp and Wiring Harness. TR6 and T120
88
38
Speedometer, Tail lamp and Rectifier
90
6
INDEX
Page No.
64
AIR FILTER
MAGNETO
Page No.
... 82, 84
ALTERNATOR
42
MUDGUARDS
66
BATTERY CARRIER ...
64
NACELLE
48
76,78,80
OIL PUMP
20
CARTON PACKS
12
OIL TANK
62
CENTRE STAND
36
CHAIN CASE ...
42
PETROL TANK
60
CHAINS
42
PILLION FOOTRESTS
H
CLUTCH
34
PISTONS
16
COIL
86
PROP STAND
36
CONTROL CABLES ...
n
CONTROL LEVERS
70
Q.D. REAR WHEEL ...
58
CRANKCASE ...
18
REAR PANELS
69
CRANKSHAFT
16
REAR WHEEL
56
RECTIFIER
90
SILENCERS
44
CARBURETTER
CYLINDER HEAD
22.24.26
86
DISTRIBUTOR
ENGINE PLATES
40
SPARKING PLUGS
ENGINE SPROCKET ...
16
SPEEDOMETER
EXHAUST PIPES
«
STEERING RACES
SUSPENSION UNITS
FOOTRESTS
...
40
FRONT FORKS
... 46,50
FRONT WHEEL
... 52,54
GASKET SETS
GEARBOX
SWITCHES
14
82,84,86
90
36,46,50
38
... 48,88
TIMING GEARS
16
TOOLKIT
H
TWINSEAT
69
28,30,32
HANDLEBARS
... 1o.n
HORN ...
. .. <18, 88
VALVES
22,24,26
WIRING HARNESS
... 48,88
SUPPLEMENT SHEETS WITH EFFECT FROM ENGINE No. D.m7
7
93
THUNDERBIRD (6T) TECHNICAL DATA
71 x 82 mm.
2·79 x 3·23 ins.
Bore and stroke
649 c.c. (40 cu. ins.)
Capacity ...
7:1
Compression ratio
Champion L7, K.LG. F.80 or lodge H.H
Sparking plugs ...
Carburetter
Main Jet
Needle jet
Needle ...
Throttle valve
Pilot Jet
Engine sprocket
Chains
Capacities
Amal Monobloc 376
270
·106S
TypeC
376/31:
25
23 teeth
Solo
Sidecar
20 teeth
j' X
Front
Rear
i'
FueiT~nk
011 Tank
Garbox
Primary Chalncase
Front Forks (each leg)
Brakes
Front and rar diameter
Tyre sin ...
Front
Rear
X
ft • X
70 links
j ' X 98 links
4 galls. (18 lltres)
5 pints (2·8 lltres)
l pint (400 c.c.)
i pint (150 c.c.)
i pint (150 c.c.)
1' (1N8cm•.)
3·25 X 18
3·50 X 18
8
TIGER 110 (T110) TECHNICAL DATA
71 X 82mm.
2·79 X 3·23 ins.
Bore and stroke
649 c.c. (40 cu. ins.)
Capacity ...
8 :1
Compression Ratio
Champion N3, K.L.G. FE.100 or Lodge HLN
Sparking Plugs
Amal Monobloc 376
Carburetter
Main Jet ...
Needle jet
Needle ...
Throttle valve
Pilot jet ...
1065
Type C
376/3!
25
Engine sprocket
Solo
Sidecar
23 teeth
20 teeth
Chains
Front
250
!" X f.. x 70 links
i • X i" X 98 links
Rear
Capacities
Fuel Tank
Oil Tank
Gearbox
Primary Chalncase
Front Forks (each leg)
4 galls. (18 litres)
5 pins (2·8 litres)
I pint (400 c.c.)
l pint (150 c. c.)
l pint (150 c.c.)
Brakes
Front diameter ...
Rear diameter
8 ln. (20·32 em.)
7 ln. (17·78 em.)
Tyre size ...
Front
Rear
3·25 X 18
HO x 18
9
TROPHY (TR6) TECHNICAL DATA
Bore and stroke
71 x 82 mm.
1·79 x 3·23 Ins.
Capacity ...
649 e.c. (40 cu. ins.)
Compression ratio
8 :1
Sparking plugs ...
Champion N3, K.L.G. FE.100 or Lodge HLN
Carburetter
Main jet ...
Needle jet
Needle ...
Throttle valve
Pilot jet ...
Engine sprocket
Amal Monobloc 376
250
·1065
Type C
376/3!
25
22 teeth
Chains
Front
Rea:r
i" X f.' X 70 links
i' x !' x 981inks
Capacities
Fuel Tank
Oil Tank
Gearbox
Primary Chaincase
Front Forks (each leg)
3 galls. (13·5 litres)
5 pints (2 ·8 lit res)
i pint (400 c. c.)
! pint (150 e.e.)
1 pint (150 c.c.)
Brakes
Front diameter ...
Rear diameter
Tyre size ...
Front
Rear
8 in. (20·32 em.)
7 in. (17·78 em.)
3·25 X 19
4·00 X 18
10
BONNEVILLE 120 (T120) TECHNICAL DATA
71 x 82 mm.
2·79 x 3·23 Ins.
Bore and stroke
649 c.c. (40 cu. Ins.)
Capacity ...
8·5 : 1
Compression ratio
Champion N3. K.L.G. FE.100 or Lodge HLN
Sparking plugs
Carburetters
Main jet ...
Needle jet
Needle
Th rattle valve
Pilot jet
Engine sprocket
Chains
22 teeth
!" x f. • x 70 links
i" X i" X 98 links
F-ront
Rear
Capacities
2 Amal Monobloc 376
240
·1065
Type
376/3!
25
Fuel Tank
Oil Tank
Gearbox
Primary Chai ncase
Front Forks (each leg)
Brakes
Front diameter ...
Rear diameter
Tyre si:z:e ...
Front
4 galls. (18 lit res)
5 pints (2·8 litres)
i pint (400 c.c.)
t pint (150 c.c.)
t pint 1150 c.c.)
8 in. (20·32 em.)
7 ln. (17·78 em.)
3·25
X 19
3·50 >: 19
Rear
11
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 deter5orate under ad¥erse conditions.
Part No.
Contents
Brake Linlns
C.P.38/A.M.l
2
16
C.P.66JA.M.2
... 2
16
Cranlcase Bearing
C.P.H4 ...
Fork Service Pack
C.P.168 ...
...
2
2
...
NWl-43
W129
Brake lining
Rivet
W1336
W129
Brake lining
Rivet
.. . E1591
..
H-420
H-430
2
2
H#l
2
H1062
2
H1168
~1
Standanl Ratio Gears (to conYert from Wide llatlo)
C.P.HS
1
T13112.
1
T916
1
1
1
T1063
T1065
T9H
Wide Ratio Gears (to convert from Standard Ratio)
C.P.9<4
1
T1384
1
T968
1
T971
1
T97<4
1
T97S
Clote Ratio Gears (to convert from Standard Ratio)
C.P.9S
1
T1177
1
T13B3
1
T1179
1
T9SS
1
T9S9
1
1'964
1
T963
1
1
T%1
T1ll7
12
...
Ball journal bearings.
Rubber washer
Fibre washer
Upper bearing
Lower bearing
Aluminium washer
Oil seal
Mainshaft high gear
Malnshaft >«ond gear
Layshaft and high gear
Layshaft second gear
Speedometer driven gear
Mainshaft high 11ear
Mainshaft second gear
Layshaft and high gear
Layshaft second gear
Speedometer driven gear
Matnshaft and low gear
Mainshaft high gear
Matnshaft third gear
Malnshaft second gear
Layshaft and high gear
Layshaft third gear
Layshaft second gear
Layshaft low ....,.
Blanking cap
C A R T 0 N P A C K' L I S T- continued
Contents
Klc:kstarter Ratchet Set
CP.27
1 ""'
1
1
T730
T731
T1250
T133B
T732
Klckstarter pinion
Klckstarter ratchet
Ratchet spring
Sleeve
Tab washer
E3611
E3049
E2898
WE203E ...
WE479 . ..
Piston C.R. 6·3 : 1
Compression ring
011 control ring
Gudgeon pin
Circllp
Pistons
C.P.15B
1
2
1
1
2
C.P.98 (6T only)
...
..
...
1
2
Piston C.R.7 : 1
E2891
E3049
E2898
WE203E ...
WE-479 ...
1
2
Compression ring
Oil control ring
Gudgeon pin
Circlip
C.P.98 Is also available In 0·010 in. and 0·020 ln. oversizes
1
2
1
1
2
C.P.159
E3612
E3049
E2898
WE203E ...
WE479 ...
Piston CR. 7·5 : 1
...
Compression ring
011 control ring
Gudgeon pin
Circlip
C.P.159 is also available In 0·010 in. and 0·020 in. overslzes
1
2
1
1
2
C.P.163
E3670
E3049
E2898
WE203E ...
WE479 ...
Piston C.R. 8 : 1
Compression ring
Oil control ring
Gudgeon pin
Clrdlp
C.P.163 Is also available In 0·010 in. and 0·020 ln. oversizes
1
2
1
1
2
C.P.157
...
E3610
E3049
E2898
WE203E ...
WE479 ...
Piston C.R. 8·5 : 1
Compression ring
011 control ring
Gudgeon pin
Cirdlp
C.P.157 Is also available in 0·010 ln. and 0·020 ln. overslzes
C.P.160
...
1
E3613
Piston C.R. 12 : 1
l
E3049
E2898
WE203E ...
WE479
Compression ring
on control ring
Gudgeon pin
Cirdlp
(Alcohol fuel)
1
1
2
13
C A R T 0 N P A C K L I S T - continued
Part No.
Contenu
Piston Rinp
4
C.P.99
Compression ring
Oil control ring
E3049
E2898
2
C.P.99 is also available In 0·010 in. and 0·020 ln. oversizes
Valves
C.P.96 (6T)
C.P.173
(T110. TR6, T120)
2
E2903
E2904
Inlet valve
Exhaust valve
2
2
E3310
E3927
Inlet valve
Exhaust valve
E2899
E2900
Inlet guide
Exhaust guide
2
Valve Guides
C.P.97
(6T, T110, TR6)
2
2
...
C.P.S
(6T. T110, TR6)
4
... EHS8
4
E1487
Inner spring
Outer spring
C.P.102
(T120)
4
4
E3001
E3002
Inner spring
Outer spring
2
1
1
40
H111
H439
H1018
$70-3
Cups
Cone
E4167
E2749
E3678
E3679
E3682
E3686
E3685
52091 !5
H1083
H1086
RC109
Cover
Valve Springs
Steering Races
C.P.156
...
Top cone and dust cover
Balls
Tachometer Drive (TR6 and T120)
C.P.181
1
1
2
1
1
1
...
1
1
2
1
Driven gear
Grub screw
Driving gear housing
Driven gear housing
Driving gear
Exhaust camshaft nut
Drive cable
Mounting bracket
Bolts
Tachometer head
GASKET SETS
6T
T110 and TR6
THO
GS. 6Tj56
GS. T110/S6
GS. T120/59
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.
15
Crankshaft and
flywheel aaembiJ
Ref. Ne>. t.
18
17
18
-----------------~
r-----------------9
44
II-I
12
33 33
34
-------e
37
---------14
\W:::J--13
4039-
+---------- 9
~~~
38
34~
8
31 --------=-30 --------'IIIJ
29-----__J
28 _________
____j
27
"-------- 5
19
20
FIG. t
16
21
22
23
24
25
26
CRANKSHAFT AND CONNECTING RODS
RJJf. No.
QUANTITY
DESCRIPTION
Pon No.
CRANKSHAFT AND CONNECTING RODS
2
3
4
5
6
7
8
9
10
11
12
13
14
14
14
15
16
17
18
19
20
21
21
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
37
37
38
38
39
40
41
42
43
44
45
46
47
E3893
E3894
E3903
E3905
E3906
E3907
Ell88
E31H
E3606
E1511
E2490A
E29ll
E3586
CF98
CP163
CP157
E3049
E2898
WE203E
WE479
E1591
H1168
E3108[23
E3108/20
E3108f22
E3116
E3974
413506
E3975
E3977
E3300
E1580
E1472
E398
E1471
E400
E1486A
E155S
E1463
E1492
E3275
E3325
E3134
E3275
E3325
Ell54
Ell56
E3123
E3125
E3126
47502
E2741
170104
E1330
CRANKSHAFT AND FLYWHEEL ASSEMBLY
CRANKSHAFT cjw OIL TUBE
Oil tube ...
Screwed plug
Flywheel
Flywheel bolt ...
Serrated washer
Crankshaft stud (1 f. • O.A.)
CONNECTING ROD
Small end bush ...
Connecting rod bolt
Self locking nut
Big end bearings
PISTON COMPLETE 7 : 1 C.R.
PISTON COMPLETE 8 : 1 C.R.
PISTON COMPLETE 8 · 5 : 1 C.R.
Taper compression ring
Oil control ring
Gudgeon pin
Circllp ...
Main bearing
Oil seal
Engine sprocket (solo)
Engine sprocket (sidecar)
Engine sprocket (solo)
Backing washer
Rotor key
Rotor
Tab washer
Nut
Clamping washer
Key
Timing pinion
Nut
INTERMEDIATE WHEEL
Intermediate wheel bush
Camshaft wheel
Camshaft key
Inlet camshaft nut
Exhaust camshaft nut
Inlet camshaft
Inlet camshaft
Inlet camshaft
Exhaust camshaft
Exhaust camshaft
Rotary breather valve
Breather valve spring
Distributor pinion
Pin
Circllp ...
Auto-advance unit
Magneto pinion
Magneto pinion nut ...
Plain washer
6T
1
1
1
1
1
3
3
1
2
2
4
4
4
T110
1
1
1
1
1
3
3
TR6
1
1
T120
1
1
1
1
1
3
3
1
2
2
4
4
4
3
3
1
2
2
4
4
4
2
2
4
4
2
2
4
2
1
2
2
4
4
4
2
4
2
2
4
2
1
1
A
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
4
2
1
1
A
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
4
2
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
17
15
31
l 3
24
23
~--------------27
ir------------26
~';#------28
----""""
~~-------------29
:.---3----------30
FIG. 2 CRANKCASE
18
Ref. No.
Port No.
DESCRIPTION
QUANTITY
CRANKCASE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
ll
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
E2892j2314
E6n
E3523
E1479
E1516
E2260
GS87
E2n4
E1508
E1509
E1645
E1579
E1534A
E1555
525-3
E1S40
E1532
E1535
E375
E2022
E1534A
E1647
T456
525-3
51-51
~487
E529
E486
E1612
F879
E3110
E378
E3585
E4016
0208-5
E2615
E1335
E3437
E3439
E3078
6T
1
6
2
2
CRANKCASE
Cylinder base stud (1t' O.A.)
Cylinder base stud (1 t• O.A.)
Camshaft bush ...
Camshaft bush ...
Camshaft breather bush
Breather disc ...
Breather pipe ...
Oil scavenge pipe
Scavenge pipe clip
Screw (it' U.H.)
1
1
1
1
1
1
1
1
Crankcase joint hollow aowel
Top rear bolt (1i' U.H.)
Plain washer
Oil filter stud (II' O.A.)
Oil junction block dowel
4
1
1
4
1
1
1
4
4
2
2
2
3
2
2
1
2
2
2
1
3
2
2
1
2
2
2
1
4
4
4
4
4
4
1
1
A
1
3
1
1
..
~
1
3
2
2
1
2
2
2
...
Serrated washer
Nut
TIMING COVER
Crankshaft oil feed bush
Crankshaft oil feed bush (0·020 in. undersize)
Patent plate ...
Patent plate rivet
Timing cover plug
Copper washer
Cover screw (U ln. U.H.) ...
Cover screw (1 f.' U.H.) ...
Breather extension rubber pipe
1
1
Timing cover dowel
Filter cover
T120
1
6
2
2
1
1
Crankcase joint dowel
Intermediate wheel spindle
Magneto stud (1 f< O.A.)
Cylinder base dowel
Crankcase joint screw
Bottom front stud (3£" O.A.)
Plain washer
Nut
Filter joint washer
Crankcase oil filter
T110 TR6
1
6
6
2
2
2
2
4
4
1
A
1
3
2
2
1
1
A
1
3
3
1
1
7
3
1
7
3
A
1
3
1
1
7
3
1
7
3
19
Oil Pump A•oembly
Ref. No. 1.
3------------~
+------------------2
12-------J
11-----~
_,r----------9
6----------~~
7--------~
8--------22
21
20
I
i~~
Release Valve
Assembly
Ref. No. tJ.
19
15
17
----24
30---------31---------.
29--------..
32---~
'-------26
33---_j
29
FIG. l
20
OIL PUMP AND RELEASE VALVE AND MANIFOLD
Ref. No.
Part No.
QUANTITY
DESCRIPTION
OIL PUMP AND RELEASE VALVE AND MANIFOLD
1
2
3
4
s
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
24
25
26
27
28
29
29
30
31
32
33
EJon
GS35
G$_153
E1476
E49S
570-7
E403
E2360
E1537
E1536
E1612
FB79
E2795
E2794
GS251
E2790
GS254
E27BB
E2789
E2791
E2793
E2792
E1670
E2920
E2973
E3334
E3304
525-13
W103
E1553
E2962
NA43A
E2968
525-3
51-51
...
OIL PUMP
Pump body
Feed plunger
Scavenge plunger
Drive block
Valve ball
Valve spring
Screwed plug
Joint washer
Oil pump stud (1l.r' O.A.)
Serrated wuhet
Nut
OIL RELEASE VALVE AND INDICATOR
Valve body
Piston
Cap
Fibre washer
Main spring
Auxiliary spring
Button and shaft
Sealing rubber ...
Shaft nut
Fibre washer
Stud (1 H in. O.A.) ...
Stud (11f in. O.A.) ...
Joint washer ...
Inlet manifold
Plain washer ...
Nut ...
Stud (1,& in. O.A.) ...
Stud (1 ,& in. O.A.) ...
Joint washer ...
Insulating block
Plain washer ...
Nut
...
...
6T
1
1
1
1
1
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
4
2
1
4
4
2
2
2
T110
1
1
1
1
1
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
TR6
1
1
1
1
1
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
4
2
4
4
4
2
1
4
4
2
1
1
2
2
2
1
1
2
2
1
T120
1
1
1
1
1
2
2
2
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
21
21---.
1 \ - - - - - - - 2<1
e-------25
43
46
15
14
12
13
,,
46
44
52
51
45
~e
41
FIG. 4 CYUNDEII BLOc:tt AND HEAD 6T
22
Ref. No.
DESCRIPTION
Part No.
QUANTITY
CYLINDER BLOCK AND HEAD, 6T
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
.....
45
46
47
48
49
so
51
52
E2894
E3332
W76
P0172A
EH77
HlOO
E1612
E3059
E3873
E2899
E2900
E2903
E2904
E1544
E1488
E1487
E1543
WE259A
E327
E3614
E1461T
E1462T
E1650
E1540
F879
E1545
SlS-13
E1484
E1596
GS308
E1564
E1577
E1457
E1458
E1483
E1513
E-470
E1330
E1575
E1574
E1512
E3253
E1693
E1505
EH96
E3547
GSln
GS273
E1601
E1335
E984
F1880
Cylinder base washer
Cylinder block
Inner cylinder base nut
Outer cylinder base nut
Tappet guide block ...
Tappet block screw(-,'." U.H.)
Serrated washer
Tappet
CYLINDER HEAD c/w GUIDES ...
Inlet valve guide
Exhaust valve guide
Inlet valve
Exhaust valve
Bottom cup ...
Inner valve spring
Outer valve spring
Top collar
Split cotter ...
Cylinder head bolt (3i" U.H.)
Cylinder head gasket
Inlet rocker box
Exhaust rocker box ...
Joint washer
Rocker box stud ( ti • O.A.)
Rocker box nut
Rocker box bolt (2" U.H.)
Plain washer
Cylinder head bolt (Sf' U.H.)
Cylinder head bolt (for torque stay)
Pial n washer
Inspection cap
Joint washer
ROCKER (right exhaust, left inlet)
ROCKER (left exhaust, right inlet)
Rocker ball pin
Rocker adjusting pin
Adjuster lock nut
Thrust washer, i"
Thrust washer, t •
Spring washer
Rocker spindle
Sealing rubber
Push rod
...
Cover tube ...
Bottom joint washer
Top joint washer
Rear drain pipe
Front drain pipe
Adaptor bolt
Copper washer
Adaptor bolt
Copper washer
6T
1
1
4
4
2
2
2
4
1
2
2
2
2
4
4
4
4
8
4
1
1
1
4
4
4
4
4
2
2
4
4
4
2
2
4
4
4
2
6
4
2
2
4
2
2
2
1
1
4
8
2
4
23
21--~.r
11.1>----21
32---ll
39
19~
45
IS~
·----\\---"
Jb
15
'
~\---1:3
@
[I
FIG. S CYLINDER BLOCK AND HEAD, T'IIO AND 1116
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CYLINDER BLOCK AND HEAD, T110 & TR6
1
2
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
E2894
E3332
E3332/TR6
W76
P01nA
EHn
H200
E1612
E3059
E3924
E2899
E2900
E3583
E3310
E3927
E1544
E1488
E1487
E1543
WE259A
E2873
F2184
E3614
E3550
E3551
E3552
E2980
F879
E3302
E2982
S25-13
E2874
E1596A
E1564
E1577
E1457
E1458
E1483
E1513
E470
E1330
E1575
E1574
E1512
E3253
E2620
E3646
E1496
E3547
Cylinder base washer
Cylinder block
Cylinder block
Inner cylinder base nut
Outer cylinder base nut
Tappet guide block ...
Tappet block screw h'." U.H.)
Serrated washer
Tappet
CYLINDER HEAD cfw GUIDES ...
Inlet valve guide
Exhaust valve guide
Exhaust pipe adaptor
Inlet valve
Exhaust valve
Bottom cup
...
Inner valve spring
Outer· valve spring
Top collar
Split cotter ...
Cylinder head bolt (3f" U.H.)
Plain washer
Cylinder head gasket
Inlet rocker box
Exhaust rocker box ...
Joint washer
Rocker box stud
Oi" O.A.)
Rocker box nut
Plain washer
Rocker box bolt (2/." U.H.)
Plain washer
Cylinder head bolt (5fi" U.H.)
Cylinder head bolt (for torque stay)
Inspection cap
Joint washer
ROCKER (right exhaust, left inlet)
ROCKER (left exhaust, right inlet)
Rocker bail pin
Rocker adjusting pin
Adjuster lock nut
Thrust washer, i"
Thrust washer, !"
Spring washer
Rocker spindle
Sealing rubber
Push rod
Cover tube ...
Bottom joint washer
Top joint washer
T110 TR6
1
1
1
4
4
4
4
2
2
2
2
2
2
4
4
1
2
2
2
2
2
2
2
2
2
2
4
4
4
4
4
4
4
4
8
8
4
4
8
8
1
1
1
2
2
6
6
6
6
6
6
4
4
4
4
2
2
2
2
4
4
4
4
2
2
2
2
4
4
4
4
4
4
2
2
6
6
4
4
2
2
2
2
4
4
2
2
2
2
2
2
25
23 ------<WI'
~---23
1----33
nr------- 28
~------30
'-------29
22_j~~~~~~-27
47
'
17-------"
14
llt--48
~
49
8--s
!-·
FIG. 6 CYLINDER BLOCK AND HEAD, TIZO
26
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CYLINDER BLOCK AND HEAD, TUO
T120
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
ll
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
E2894
E3332
W76
P0172A
E1477
H200
E1612
E3059
E4019
E3827
E3828
E3940
E3847
E3583
E3310
E3927
E1544
E3001
E300l
E1543
WE259A
E2873
F2184
E3614
E3550
E3551
E3552
E2980
F879
E3302
E2982
525-13
E2874
E1596A
E1564
E1577
E1457
E1458
E1483
E1513
E470
E1330
E1575
E1574
E1512
E3253
E2620
E3646
E1496
E3547
Cylinder base washer
Cylinder blo.:k
Inner cylinder base nut
Outer cylinder base nut
Tappet guide blo.:k ...
Tappet block screw(,'." U.H.)
Serrated washer
Tappet
CYLINDER HEAD cfw GUIDES ...
Inlet valve guide
Exhaust valve guide
Carburetter adaptor
Adaptor lock! ng nut
Exhaust pipe adaptor
Inlet valve
Exhaust valve
Bottom cup ...
Inner valve spring
Outer valve spring
Top collar
Split cotter " .
Cylinder head bolt (3f" U.H.)
Plain Washer
Cylinder head gasket
Inlet rocker box
Exhaust rocker box ...
Joint washer
Rocker box stud Hi-• O.A.)
Rocker box nut
Plain washer
Rocker box bolt {2,&" U.H.)
Plain washer
Cylinder head bolt (Slt • U.H.)
Cylinder head bolt (for torque stay)
Inspection cap
Joint washer
ROCKER (right exhaust, left inlet)
ROCKER (left exhaust, right inlet)
Rocker ball pin
Rocker adjusting pin
Adjuster lock nut
Thrust washer, ij •
Thrust washer,!"
Spring washer
Rocker spindle
Sealing rubber
Push rod
Cover tube ...
Bottom joint washer
Top jol nt washer
1
1
4
4
2
2
2
4
1
2
2
2
2
l
2
2
4
4
4
4
8
4
8
1
1
1
2
6
6
6
4
4
2
2
4
4
2
2
4
4
4
2
6
4
2
2
4
2
2
2
27
2
9
7
17
t-4
0
~
25
24
11
5
~
i12 '\,
27
3&--
35--
FIC. 7 CEARBOX AND CASINC
~
I&
15
6
Ref. No.
Port No.
DESCRIPTION
QUANTITY
GEARBOX AND CASING
1
1
1
1
1
1
1
1
1
2
3
4
s
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
T1S25
T1S28
T1S83
T1S26
T1S29
T1S84
T1S27
T1S30
T1S8S
T1201
T341
EH49
T1367
T912
T981
T989
E698
T1562
T1367
T912
T-412
T45
546-1S
PT104B
E732
NE507
E3436
E3437
T323A
T1534
T57
T23
T47
T-454
E3437
E3439
E3438
E3442
S1-51
S25-3
T1542
T1541
T1553
E1612
GEARBOX COMPLETE- STANDARD RATIO
GEARBOX COMPLETE- STANDARD RATIO
GEARBOX COMPLETE- STANDARD RATIO
GEARBOX COMPLETE- CLOSE RATIO
GEARBOX COMPLETE- CLOSE RATIO
GEARBOX COMPLETE- CLOSE RATIO
GEARBOX COMPLETE- WIDE RATIO
GEARBOX COMPLETE- WIDE RATIO
GEARBOX COMPLETE- WIDE RATIO
GEARBOX CASING
Camplate bush
Peg
Layshaft bush
Peg
Blanking disc
Dowel ...
Cover securing stud (2!' O.A.)
GEARBOX INNER COVER
Layshaft bush
Peg
Gearchange spindle bush
Kickstarter stop
Drain and level plug
Fibre washer
Filler plug
Fibre washer
Inner cover screw (1!' U.H.)
Inner cover screw (f!' U.H.)
Cover securing stud (1 fi' O.A.)
GEARBOX OUTER COVER
Gearchange spindle bush
Kickstarter spindle bush
Kickstarter spring anchor pin
Guide ?late stud (!' O.A.)
Cover screw (H' U.H.)
Cover screw (1.,'1," U.H.)
Cover screw (2-J'< U.H.)
Cover screw (3' U.H.)
Nut
Plain washer
Cover plate
Joint washer
Cover screw (i' U.H.)
Serrated washer
6T
1
T110 TR6
1
1
T120
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
1
3
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
1
3
1
1
1
1
3
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
1
3
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
2
1
4
2
4
2
4
2
1
1
1
4
2
1
1
1
3
3
1
1
2
2
1
3
3
1
1
2
2
1
3
3
1
1
2
2
1
3
3
1
1
2
2
29
j
4
j
2
23
~
j
3/
j
12~
24
:
-
j
II
j
13----A
14
j
15
16
j
9
FIG. 8 GeARBOX SHAFTS ANI:I GEAR$
I
j
Ref. No.
Part No.
DESCRIPTION
QUANTITY
GEARBOX SHAFTS AND GEARS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
ll
23
24
2S
26
27
28
29
30
31
3
4
6
9
11
12
13
14
1
2
3
4
5
6
7
a
9
10
11
T914
PT108B
T1382
T1370
T917
T916
T926
T928
T1065
T930
T1063
T924
T925
T934
T825
T933
T948
T448
E489
T946
T471A
T440
535-7
T280
T1338
T1250
T730
T731
T732
NT297
T1552
MAINSHAFT cfw LOW GEAR (16T)
Clutch rod bush ...
MAINSHAFT HIGH GEAR (26T)
High gear bush
Mainshaft third gear (24T)
Mainshaft second gear (lOT)
LA YSHAFT LOW GEAR (JOT)
Low gear bush
Layshaft second gear (26T) ...
Layshaft third gear (22T)
LAYSHAFT COMPLETE (lOT)
Speedometer drive pinion (1 OT)
Securing pin
Speedometer driven gear (16T)
Thrust washer ...
Speedometer drive bush
Rubber sealing ring
High gear bearing
Circlip ...
High gear oil seal
Gearbox sprocket (1ST)
Gearbox sprocket nut
Mainshaft bearing
Circlip ...
Kickstarter pinion sleeve
Kickstarter pinion spring
Kickstarter pinion
Kickstarter ratchet
Tab washer
Mainshaft nut ...
Clutch operating rod
T1384
T1370
T968
T974
T971
T973
T925
T975
To convert to Wide Ratio Gears use Gear Set C.P.94
MAINSHAFT HIGH GEAR (28T)
High gear bush ...
Mainshaft second gear (19T)
Layshaft second gear (27T)
LA YSHAFT COMPLETE (1ST)
Speedometer drive pinion (8T)
Securing pin
Speedometer driven gear (1ST) ...
T1177
PT108B
T1383
T1370
T1179
T955
T961
T928
T963
T964
T959
To Convert to Close Ratio Gears use Gear Set C.P.95
MAINSHAFT cfw LOW GEAR (1ST)
Clutch rod bush
MAINSHAFT HIGH GEAR (24T)
High gear bush ...
Mainshaft third gear (23T) ...
Mainshaft second gear (21T)
LA YSHAFT LOW GEAR (28T)
Low gear bush ...
Layshaft second gear (25T)
Lays haft third ge" (23T) ...
Layshaft cjw high gear (22T)
6T
1
1
1
1
1
1
1
1
1
T110 TR6
1
1
1
1
1
1
1
1
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
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
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
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
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
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
1
1
1
1
1
1
1
1
1
1
1
1
31
2b
24
29
m-6
,_,
39
i-s
38
~l
12
28
Jr43
o:::._44
46
45~ "i0)
40 41 42
FIG. 9 GEARBOX SEI..ECTOR MECHANISM
Ref. No.
Part No.
DESCRIPTION
QUANTITY
GEARBOX SELECTOR MECHANISM
6T
2
3
4
5
6
7
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
40
41
42
43
44
45
46
T260B
T913
NT261
T291
TSOO
T44
T373
T1604
T372
T397
T399
-fi"x1r'
T408/1540
E3309
T404
T406
T405
T407
F879
E1612
T1194
T1564
W932
T449
T25A
T31
T24A
T1512
T451
T1270
T1271
T1272
T1167
S70-3
T1273
F1814
T1222
T1539
*"Xi
T495
T402
T1536
T1538
E3412
T1554
E1612
T413
T453
Mainshaft selector fork
Layshaft selector fork ...
Selector fork roller
Selector fork rod
2
1
Serrated washer
Gearchange pedal
Heel-and-toe gearchange pedal
Pedal bolt (1" U.H.)
Pedal rubber
Kickstarter quadrant
Kickstarter return spring
Kickstarter axle
Split pin ...
Rubber cap
Clutch operating arm
CLUTCH OPERATING ARM
Roller
Roller fixing pin
Screwed peg
Serrated washer
Clutch rod adjuster pin
Adjuster pin nut
1
2
1
1
1
2
1
2
2
2
1
4
4
1
2
2
2
2
2
2
2
4
4
4
4
4
4
A
A
A
1
A
2
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
Kickstarter lever
Clutch operating lever
T120
1
1
1
2
Rubber sleeve
Kickstarter crank
FOLDING KICKSTARTER
Kickstarter pedal ...
Pedal locating spring
Pedal locating ball. ..
Pedal bolt (1·155' U.H.) ...
Pedal rubber
Cotter pin cfw nut and washer
TR6
1
1
2
1
1
Gear selector camplate
Camp'ate index plunger
Index plunger spring
Index plunger spring ...
Index plunger holder ...
Camplate operating quadrant
Quadrant spindle
Split pin ...
Gearchange quadrant
Rubber .. 0 .. ring
Quadrant return spring
Gearchange quadrant plunger
Plunger spring
Guide plate
Nut
T110
1
1
2
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
1
1
1
33
~---9:::
....
J:
u
:I
u
lQ
,..,~
N
!::!
S!
ci
ii:
Ref. No.
Part No.
QUANTITY
DESCRIPTION
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
T1548
T1586
T1549
T418
T394
T1039
T1038
T1041
T1472
T1473
T1044
T1040
T423A
T1362
T1363
T986
T422
T998
T999
T1560
T427
S66-1
T1045
T1046
T1047
CLUTCH COMPLETE
CLUTCH COMPLETE
Sprocket and housing
Hub
Rollers ...
Inner plate
Centre (Shock absorber body)
Shock absorber spider
Drive rubber (large) ...
Rebound rubber (small)
Outer plate
Countersunk screw (0-417" U.H.)
Screwed pin (Hi'" U.H.)
Driving plate (bonded)
Driven plate (plain)
PRESSURE PLATE
6T
1
T110
1
TR6
1
1
1
20
1
1
1
4
4
1
8
4
5
6
1
1
20
1
1
1
20
1
1
1
1
1
1
8
4
5
6
1
1
4
4
A
4
1
1
Spring cup
Spring ...
Spring (strong)
Brass nut
Key
Cupped washer
Tab washer ...
Clutch securing nut
4
4
A
4
1
1
1
1
1
20
1
1
.. .. ..
.. ..
4
1
8
4
5
6
1
1
Thrust button
T120
1
..
4
A
4
1
1
1
1
1
1
8
..
5
6
1
4
4
4
1
1
1
1
35
w
"'
33 32
14
10
1
...____2
18-----_j
FIG. 11
FRAME
Ref. No.
Port No.
DESCRIPTION
QUANTITY
FRAME
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
18
18
19
20
21
22
23
24
25
25
26
27
28
29
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
F-4608
H111
S70-3
H1018
DS55
TI24
DS57
NW100
WE170
E-4115
E-4164
S26-1
S1-52
F2603
E3181
S26-3
E1310
S1-51
F.,304
F4763
H49
F3619
F-4484
F2725
F4671
F4670
F4712
F3723
F3097
F3096
F2610
F4609
F4684
F2842
F4685
S26-1
S1-52
F3780
PCW73A
F4650
SCZ45
DS48
F-4647
S26-16
S25-2
S1-52
F1149
F879
Front frame
Steering race cup
Steel ball W diam.)
Top cone and dust cover
Steering stop bolt <fi" U.H.)
Nut ...
Plug screw(,'." U.H.)
Grease nipple
Fibre washer ...
Engine torque stay
Engine torque stay
Spring washer
Nut ...
Bolt (li' U.H.)
Bolt (2!' U.H.)
Spring washer
Nut ...
Nut ...
Centre stand ...
Centre stand
Pedal rubber ...
Pivot bolt (1]\" U.H.)
Tab washer ...
Nut
6T
1
2
-40
1
2
2
T110
2
-40
TR6
1
2
-40
T12C
1
2
-40
1
2
2
2
2
2
2
1
2
1
2
1
2
1
2
2
2
2
2
2
2
2
1
1
1
1
2
2
2
Rear frame
1
1
...
...
Stud (3!" O.A.)
Bolt (31t" U.H)
Spring washer
Nut ...
Bolt (1]\" U.H.)
Spring washer
Brake pedal spindle ...
Spring washer
Nut ...
Brake pedal ...
Spring washer
Plain washer
Nut ...
Pedal stop screw (-ji • U.H.)
Nut ...
1
2
2
2
1
1
1
2
2
2
1
1
2
2
2
1
Return spring
Rear frame
1
1
Return spring
Return spring link
PROP STAND COMPLETE
PROP STAND COMPLETE
Pivot bolt
Tab washer
1
1
1
1
1
1
1
2
2
4
4
2
2
1
4
4
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
2
2
1
1
1
3
3
2
2
1
1
1
1
1
1
1
37
....
00
l1
+--17
2
3
6
FIG. 12
SWINGING FORK AND SUSPENSION UNITS
f8
Ref. No.
Part No.
DESCRIPTION
QUANTITY
SWINGING FORK AND SUSPENSION UNITS
1
2
3
4
5
5
6
7
8
9
10
11
12
13
13
13
14
15
16
17
18
18
18
18
18
19
20
21
22
23
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
F4131
F3690
F3564
F3574
F3683
F3684
F3797
F3798
F3799
F3774
F3780
PCW73A
DS47
SB4/259
SB4{275
64054164
90541316A
9054/171
9054/151
9054/47
SA193j57
9054/63
9054/70
90541280
9054/69
E2113
S25-2
526-1
P0172A
F4130
F4138
DS57
526-2
F4134
F4135
F2277
S25-13
F879
F4140
F4136
S25-3
51-51
F3597
ra' X j'
W11
F4585
SWINGING FORK
Pivot bush
Spindle
Spacing washer
0·003" Shim ...
0·005" Shim ...
6T
1
2
1
1
}
Retainer rod .. ,
Cap
Nut ...
Brake torque stay ...
Bolt (1ra" U.H.)
Spring washer
Nut ...
SOLO SUSPENSION UNIT
SIDECAR SUSPENSION UNIT
SOLO SUSPENSION UNIT
Bonded bush
Spring retainer ...
Outer dirt shield
Inner dirt shield
Spring 150 lbs. (sidecar) Blue;Red
Spring 130 lbs. Red/Yellow
Spring 110 lbs. Purple/Blue
Spring 100 lbs. Green/Green
Spring 90 lbs. (road racing) Yellow/White ...
Unit fixing bolt (1 ~· U.H.)
Plain washer
Spring washer
Nut
Chainguard
Chalnguard
Bolt ...
Spring washer
Front bracket
Pivot bolt
Spring washer
Plain washer
Nut
Centre bracket
Stepped bolt ...
Plain washer
Nut ...
Brake operating rod
Split pin
Pivot pin
Adjuster nut ...
...
T110
1
2
1
1
TR6
1
2
1
1
T120
1
2
1
as required
1
2
1
1
1
2
2
2
2
1
2
1
1
1
2
2
2
1
1
2
1
1
1
2
2
1
2
1
1
2
2
2
4
4
2
2
A
A
A
2
A
4
2
4
4
1
1
4
4
2
2
A
A
A
4
4
A
4
2
4
4
1
2
2
A
A
A
2
A
4
2
4
4
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
4
4
2
2
A
A
A
2
A
4
2
4
4
1
3
3
1
1
1
2
3
1
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
39
30
2
12---------"
10
'------36
18
35
FIG. ll
ENGINE AND GI!!ARBOX FITTINGS
Ref. No.
Part No.
QUANTITY
DE.S CRIPT/ON
ENGINE AND GEARBOX FITTINGS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21
23
24
25
26
27
28
29
30
31
32
33
34
3$
36
F-4651
F4719
F471S
F3780
PCW73A
DS47
F3760
F3451
F3571
F1711
F4682
F839
F3665
F862
F4681
526-1
P0172A
$1-52
F3769
F3771
F3770
F3772
F4646
GS203
E1310
F-4669
S26·3
$1-51
F3592
T87
F987
F3593
SCZ45
DS48
NF704
F4695
Front engine plate
Engine plate cover
Screw ...
Bolt (1 }\-' U.H.)
Spring washer
Nut ...
Left rear engine plate
Right rear engine plate
Cover plate ...
Stud (4/<" O.A.)
Stud (7H"' O.A.)
Stud (4Jir' O.A.)
Stud (4!" O.A.)
Distance tube
Gearbox pivot bolt (8!" U.H.)
Spring washer
Nut
Nut ...
Gearbox top stud (4ft' O.A.)
Flanged nut ...
Clamping washer
Sleeve nut
Gearbox adjuster eyebolt
Plain washer
Nut ...
Abutment pin
Spring washer
Nut
Footrest hanger rod
Left distance piece
Left footrest
Right footrest
Spring washer
Nut ...
Pedal rubber ...
Crankcase undershield
6T
1
1
1
2
3
3
1
1
1
2
2
4
1
2
1
18
16
2
1
1
1
T110
1
1
1
2
TR6
1
T120
2
2
3
3
3
1
3
3
1
1
1
2
2
4
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
2
2
1
1
1
1
1
1
1
2
2
A
3
1
1
1
2
2
4
1
2
1
18
16
2
1
1
1
1
1
2
1
2
2
4
1
2
1
18
16
1
1
1
18
16
2
1
1
1
1
1
2
2
1
1
2
2
1
1
1
1
1
1
1
2
2
2
A
1
1
1
1
1
1
2
2
A
41
~~~~-----------------4
7----T,T:,
~~-nr-----------------3
6-------;IT~~-~
14
3
20
21
4
~-------18
~r---------17
14-----f
~--------------6
fiG. 14 CHAINCASE AND ALTERNATOR
41
Ref. No.
Pan No.
QUANTITY
DESCRIPTION
CHAIN CASE AND ALTERNATOR
1
2
2
3
4
5
6
7
8
9
9
10
11
12
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
T1477
T1603
T1600
T91
T177A
T1381
E3437
E3978
E3979
E3980
E4123
S25-3
E1310
469427
47134
T1059
T1226
T1237
T1601
T496
T497
NT316
NT367
NT376
PCE102F
WE170
E3449
E3440
D301
D438
Joint washer
INNER CHAINCASE
INNER CHAINCASE
Retainer plate
Rivet
Oil sealing plate
Screw (H" U.H.)
Adaptor ring
Flanged head bolt (1f." U.H.)
Stud (1f" O.A.)
Stud (1 H" O.A.)
Plain washer
Nut
Stator ...
6T
1
f
T110
1
1
1
1
11
1
3
3
3
3
1
Stator ...
Cable grommet
Joint washer
Outer chain case
Outer chain case
Oil restrictor screw
Spring
Footrest dowel
Filler plug
Leather washer
Drain plug
Fibre washer ...
Screw (2!" U.H.)
Screw (111" U.H.)
Primary chain (!" X ,a.• X 70L)
Rear chain (V x i • x 99L)
1
1
1
1
1
4
1
1
1
1
4
1
1
TR6
1
T120
1
1
1
1
11
1
3
1
1
1
1
11
1
3
1
1
1
11
1
3
3
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
4
1
1
1
1
4
1
1
4
1
1
4
1
1
t
7 6
2
23 26 25 28 29 30 27 2431 29 30
LJ
tr-----13
----14
'-----15
2 1 - -...
,
IZ
----12
C?n
5
3
7
6
8 II 9
16 1415
FIG. IS
i~T
10 811 9
EXHAUST PIPES AND SILENCERS
32
31 343536
Ref. No.
DE.SCRIPTION
Part No.
QUANTITY
EXHAUST PIPES AND SILENCERS
1
1
2
2
3
4
5
6
7
B
9
10
11
12
13
14
15
16
17
18
19
20
21
22
13
24
25
16
27
28
29
30
31
32
33
l4
35
36
E3426
E4133
E3350
E3632
E4125
E4130
E1269
E409
E410A
E3469
TE164E
TE164C
TE164D
F4707
DS57
$16-2
F879
F4265
F1369
E411B
E4119
E4107
H689
H745
E3767
F3430
E376B
E1310
E4110
F3641
Sl6-3
$1-51
H416
E413l
H622
F2694
Sl6-1
51-51
Left exhaust pipe
Left exhaust pipe
Right exhaust pipe
Right exhaust pipe
Left exhaust pipe
Right exhaust pipe
Finned cUp ...
Clip bolt (1f. • H.H.)
Spherical washer
Extension pipe and silencer clip
Clip bolt (1f." U.H.)
.. D" Nut
"D" Washer
Exhaust pipe bracket
Bracket bolt Ci." U.H.)
Spring washer
Nut ...
Pipe to frame clip
Clip bolt (I' U.H.) ...
Left silencer ...
Right silencer
Silencer mute
Screw W U.H.)
Nut
Silencer dip ...
Clip bolt (1!" U.H.)
.. D" Washer
Nut ...
Sflencer stay
Frame stud ...
Spring washer
Nut ...
Silencer hanger bolt (fl" U.H.)
Silencer
Silencer hanger bolt (1 !-6 • U.H.) ...
Distance piece
Spring washer
Nut
...
...
6T
1
T110
TR6
T120
1
1
1
1
1
1
l
2
l
l
2
2
2
2
l
2
2
2
2
2
l
2
2
2
2
l
1
1
l
2
2
l
2
4
2
1
1
3
3
2
2
2
2
l
2
2
1
1
1
1
1
1
2
2
2
2
2
4
2
2
2
1
1
2
2
1
2
2
4
2
2
1
3
3
2
2
1
3
3
2
1
1
1
1
1
45
a
41
7
Comlll- - l i l y
Ref. No. 1.
r----------34
-------35
14------~
39------i.
32
33
31
2324;1
~~20
30
~21
29
22
28
FIG. 16 TI!LESC:OI'IC: FRONT FORK, 6T AND TtiO
27
Ref. No.
Port No.
DESCRIPTION
QUANTITY
TELESCOPIC FRONT FORK, 6T 1r TffO
1
2
3
4
5
6
7
8
9
10
11
12
13
H
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
H1310
H1283
H439
H941
S25-2
E2412
H1141
H1108
F1760
H379
H1288
H1289
H420
H1123
H443
H1058
H519A
H1117
H1118
H1053
S26-3
H1070
H1071
H430
H1063
H1062
H1124
H1061
H1060
H1125
H1292
H1301
H1064
H1051
H106S
H1066
H1126
H441
H431
H1194
H1168
H1142
H565
H408
H1286
H9S
H1285
H43S
H660
S25-3
E1310
FORK ASSEMBLY ...
Middle lug and stem
Bottom cone
Pinch bolt (2!" U.H.) ...
Plain washer
Nut
Fork stem sleeve nut
Top lug ...
Pinch bolt (1 tl" U.H.)
Seated nut
Left nacelle cover
Right nacelle cover
Sponge rubber washer
STANCHION c/w BEARING
Lower bearing
Bearing nut
Oil filler plug (i'." U.H.)
LEFT BOTIOM MEMBER c/w CAP
RIGHT BOTIOM MEMBER c/w CAP
Spindle cap
Spring washer
Cap bolt (1 ,'." U.H.)
Drain plug
Fibre washer
Flanged bolt (H" U.H.)
Aluminium washer
RESTRICTOR ROD ASSEMBLY
Restrictor rod
Plain washer
Guide cube
Solo main spring (Black)
Sidecar main spring (Red/White)
CAP NUT ASSEMBLY
Guide tube
Cap nut
Pin ...
Damping sleeve
Top bearing
Plain washer
DUST EXCLUDER SLEEVE NUT
Oil seal
Steering damper rod c/w knob
Plain washer
6T
1
1
1
2
2
2
1
I
1
1
1
1
2
2
2
2
2
1
2
4
4
2
4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Plain washer
1
1
1
1
1
1
2
4
Nut
4
Adjuster sleeve
Locating pin
Spring plate
Anchor plate
Friction disc
Handlebar "U" bolt
T110
1
1
1
2
2
2
1
1
1
1
1
1
2
2
2
2
2
1
1
2
4
4
2
4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
2
4
4
47
29
la-28
~-------1
-------6
'
\
10 9
14
\
40
3b
FIG. 17 NACELLE, HEADLAHP AND SWITCHES
37 39 38
Ref. No.
OESCRJPTION
Part No.
QUANTITY
NACELLE, HEADLAMP AND SWITCHES
1
1
1
3
..
5
I
6
7
8
9
10
11
11
13
H
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
40
H11+4
H1198
H961
H669
H877
H878
H689
H688
H687
E1880
H691
H690
51860
553148
516812
50-4665
553267
534296
373
5S4601
988
554710
31+43
318323
318341
319333
a18346
318343
31784
36189
31071
H992
H993
GS299
F3799
H1172
70048
701851
1'42689
185051
54094162
54094163
Nacelletop ...
Nacelle top ...
Rubber grommet
Rubber grommet
Left motif
Right motif ...
Screw (l;' U.H.)
Screw (f." U.H.)
Screw W U.H.)
Serrated wa•her
Nut ...
Nut
HEADLAMP ...
Rim
Light unit
Fixing wire
Fixing ring
Screw and plate
Bulb (30/24W. L.H. dipping, Pre-focus)
Adaptor ...
Bulb (3W.M.C.c.)
Pilot bulbholder
LIGHTING AND IGNITION SWITCH (P.R.S.8)
Grommet
Key
Screw
Knob ...
Index plate
lighting $Witch (S.A.-41)
...
6T
1
3
1
1
1
1
3
1
1
1
2
2
2
2
~
4
..
..
...
..
..
2
2
1
1
1
1
1
6
1
1
1
1
1
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ammeter
Cut-out button (S.S.5)
Horn grille ".
Screw (0·540" U.H.)
Serrated washer
Nut
Horn bracket
Horn ...
Fixing plate ...
Screw ...
Spring washer
Wiring harness
Wiring harness
T110
2
2
2
1
1
2
2
2
1
2
2
2
1
1
2
2
2
1
8
7 9 10 II
45
Complete Attembly
Ref. No. 1.
12
13
46
15
3
4B
2
51
50
49
47
38
39
18
36
23
-37
35
:;1
~~24
34
F~
33
26
32
FIG. 18 TII!LESCOPIC FRONT FORK, TR6 ANO TI:IO
50
31
Ref. No.
Port No.
DESCRIPTION
QUANTITY
TELESCOPIC FRONT FORK, TR6 6 T110
46
H1311
H1283
H439
H941
S2S-2
E2412
H40S
H1287
HS06
S2S-3
H-436
F1760
H379
H963
H964
H420
H962
D340
H1299
H-443
H1058
H1117
H1118
H1053
S26-3
H1070
1-!1071
H430
H1063
H1062
H1124
H1061
H1060
H1125
H1300
H1305
H1064A
H1051
H1065A
H1066
H1126
H-441
H431
H1194
H1168
H1142
H565
47
H408
48
H1286
H95
H1285
H43S
1
2
3
4
s
6
7
8
9
10
11
12
13
14
1S
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
35
36
37
38
39
40
41
42
43
44
45
49
50
51
FORK ASSEMBLY ...
Middle lug and stem
Bottom cone
Pinch bolt (2!• U.H.) ...
Plain washer
Nut
Fork stem sleeve nut
TOP LUG cjw CAPS ...
Handlebar cap
Plain washer
Clamping bolt W U.H.)
Pinch bolt (111• U.H.)
Seated nut
Left nacelle cover
Right nacelle cover
Sponge rubber washer
Telescopic gaiter
Gaiter clip
STANCHION cjw BEARING
Lower bearing
Bearing nut
LEFT BOTIOM MEMBER cjw CAP
RIGHT BOTIOM MEMBER cjw CAP
Spindle cap
Spring washer
Cap bolt (1 i. • U.H.)
Drain plug
Fibre washer
Flanged bolt (ii" U.H.)
Aluminium washer
RESTRICTOR ROD ASSEMBLY
Restrictor rod
Plain washer
Guide tube
Solo main spring (Black/White)
Sidecar main spring (Black/Red)
CAP NUT ASSEMBLY
Guide tube
Cap nut
Pin ...
Damping sleeve
Top bearing
Plain washer
DUST EXCLUDER SLEEVE NUT
Oil seal
Steering damper rod cjw knob
Plain washer
Adjuster sleeve
Locating pin
Spring plate
Anchor plate
Friction disc
TR6
1
1
1
2
2
2
1
1
2
T120
1
1
1
2
2
2
1
1
2
1
1
1
1
2
2
2
2
2
2
1
1
2
1
1
1
1
2
2
2
2
2
2
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
... ...
.. ..
51
Compl- Aaclllly
Ref. No. I.
2
FIG. 19 FRONT WHEEL, 6T
Ref. No.
Port No.
DESCRIPTION
QUANTITY
FRONT WHEEL, 6T
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
2S
26
27
28
29
30
W1398
W1370
W1373
W1328
$79-2
W1231
W1239
W653
W1237
nao
W1238
W582
W1334
W1197
W1198
W1301
W1302
525-2
E1435
W93
W93
NW243
W129
W135
W1243
W1298X
51-52
S2S-6
W592
W1246
FRONT WHEEL COMPLETE
RIM, SPOKES AND HUB ASSEMBLY
Front wheel rim WM2-18
Spoke (8/10G x SJ*, straight) cfw nipple
Spoke nl pple
Hub and brake drum
Wheel spindle
Bearing ...
Dust cover
Clrcllp ...
Backing ring
Retaining ring
Cover plate
Balance weight, i oz. }
Balance weight, 1 oz.
Brake anchor plate
Fulcrum pin
Plain washer
Domed nut
BRAKE SHOE cjw LINING
BRAKE SHOE cfw LINING
Brake lining
Brass rivet ...
Shoe return spring
Brake cam
Brake cam lever
Nut
Plain washer
Lever return spring
Anchor plate nut
6T
1
1
1
-40
-40
1
1
2
1
1
1
1
1
... as required
...
1
1
1
1
1
1
2
16
2
1
1
1
1
1
1
53
2
FIG. 10 FRONT WHEEL, T110, TR6 AND TllO
Ref. No.
Part No.
DESCRIPTION
QUANTITY
FRONT WHEEL, T110, TR6 & T110
1
1
2
2
3
3
4
4
s
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
W1399
W1323
W1371
W1324
W1374
W1230
W1275
W1328
579-2
W132S
W1239
W653
W1237
T280
W1238
W582
W1332
W1197
W1198
W1330
W1302
525-2
E143S
W1337
W1338
W1336
W129
W135
W1243
W1331X
S1-52
S25-6
W592
W1246
FRONT WHEEl COMPlETE
FRONT WHEEl COMPLETE
RIM, SPOKES AND HUB ASSEMBlY
RIM, SPOKES AND HUB ASSEMBLY
Front wheel rim (WMl-18)
Front wheel rim (WMl-19)
Spoke (8j10G x S!J", straight) cjw nipple
Spoke (8j10G x 5!", straight) cfw nipple
Spoke nipple
Hub and brake drum
Wheel spindle
Bearing ...
Dust cover
Circlip ...
Backing ring
Retaining ring
Cover plate
Balance weight, l oz. }
Balance weight, 1 oz.
Brake anchor plate
Fulcrum pin
Plain washer
Domed nut
lEADING BRAKE SHOE cJw LINING
TRAILING BRAKE SHOE cjw LINING
Brake lining
Brass rivet ...
Shoe return spring
Brake cam
Brake cam lever
Nut
Plain washer
lever return spring
Anchor plate nut
.
.;
T110 TR6
1
1
1
1
1
1
40
40
40
40
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
T120
1
1
1
40
40
1
1
2
1
1
1
1
1
as required
1
1
1
1
1
1
2
16
2
1
1
1
1
1
1
2
16
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
16
2
1
1
1
1
1
1
55
Compi-Aaembly
lief. No. t
2
34
22
31 32 33 29
28
24
21
30
23
26
252o1o
e
II
9
1b
27
FIG. 21
15 14
4
7
3
13 17
REAR WHEEL
35
14
5
b
12
19
18
34
31 32 33
Ref. No.
Port No.
QUANTITY
DESCRIPTION
REAR WHEEL
1
1
1
2
2
2
3
3
3
4
4
5
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
35
Wl-400
W1401
W1402
wnn
W1308
W1306
W1378
W1007
W79A
W1107
W1104
W1108
W1106
579-2
W1158
W1276
W62
51-51
W63
W1025
W10ll
W653
W1021
W1079
W1023
W583
W1026
W1024
W1112
F1747
W93
NW243
W129
W135
W1083
W1085
51-52
W1090
W1134
W1015
W1058
F1747
D106
WM3
REA~
WHEEL COMPLETE
REAR WHEEL COMPLETE
REAR WHEEL COMPLETE
RIM, SPOKES AND HUB ASSEMBLY
RIM, SPOKES AND HUB ASSEMBLY
RIM, SPOKES AND HUB ASSEMBLY
Rear wheel rim (WMl-18)
Rear wheel rim (WM3-18)
Rear wheel rim (WMl-19)
Spoke (8j10G x 7fo" 90°) cjw nipple ...
Spoke (8/10G x 8" 90°) cjw nipple
Spoke (8j10G x 7i" 90°) cjw nipple
Spoke (8j10G x Sf' 90°) cjw nipple
Spoke nipple
Hub
Sprocket and brake drum (43T)
Sprocket to hub bolt (H" U.H.)
Nut
Sprocket bolt lockplate
Wheel spindle ...
Backing ring
Bearing ...
RETAINING RING
Locking screw (f." U.H.)
Distance tube
Dust cover
Nut
Distance piece
Brake anchor plate
Nut
BRAKE SHOE cjw LINING
Brake lining
Brass rivet ...
Shoe return spring
6T
1
Nut
Chain adjuster
Adjuster end plate
Self-locking nut
Spindle nut ...
Tyre security bolt
Tyre security bolt
T120
1
1
1
1
1
1
1
1
20
20
20
20
20
20
40
1
1
8
8
8
1
1
2
1
1
1
1
1
40
1
1
8
8
8
1
1
2
1
1
1
1
1
1
1
1
2
2
16
2
1
40
20
1
2
2
16
2
Brake cam
Brake cam lever
Lever return spring
T110 TR6
1
1
1
1
2
2
2
2
1
1
1
2
2
2
2
1
1
8
8
8
1
1
2
1
1
1
1
1
1
1
1
2
2
16
2
1
1
1
1
2
2
2
2
20
40
1
1
8
8
8
1
1
2
1
1
1
1
1
1
1
1
2
2
16
2
1
1
1
1
2
2
2
2
1
1
57
~
Complete Assembly Ref. No.1.
2
33
24
31
25
26
27
17
18
20 40 21
7
3
4
5
9
13
15
34
I
37
38 39 30
32
25
28
29
FIG.
n
19
23
22 10 9 8
16 14
QUICKLY DETACHABLE REAR WHEEL
6
8
II
12
37
35 36
Re(. No.
Part No.
DESCRIPTION
QUANTITY
QUICKLY DETACHABLE REAR WHEEL
1
1
1
2
2
2
3
3
3
4
-4
5
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
14
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
4Q
4Q
W14QJ
W1404
W1405
W1375
W1099
W1098
W1378
W1007
W79A
W1107
W1104
W1108
W1106
S79-2
W1100
W1033
W1034
W1035
W1036
W1037
W1038
W1039
E398
W1091
W1376
W1143
W1041
W1042
W1043
W1044
W1045
W1121
W93
NW243
W129
W135
W1083
W1085
S1-52
W1090
W1052
W1053
W1170
W1055
W1135
W1015
W1058
D106
WM3
Q.D. REAR WHEEL COMPLETE
Q.D. REAR WHEEL COMPLETE
Q.D. REAR WHEEL COMPLETE
RIM, SPOKES AND HUB ASSEMBLY
RIM, SPOKES AND HUB ASSEMBLY
RIM, SPOKES AND HUB ASSEMBLY
Rear wheel rim (WM2-18)
Rear wheel rim (WMJ-18)
Rear wheel rim (WM2-19)
Spoke (Bj10G x 7f." 90") c/w nipple ...
Spoke (8j10G x B" 90°) cjw nipple
Spoke (8/10G x 7!" 90") cjw nipple
Spoke (8110G x Bi' 90") cjw nipple
Spoke nipple
Hub
Backing ring
Taper roller bearing complete
Dust cap
Felt washer
Distance piece
Dust cap
Bearing sleeve
Bearing adJuster nut ...
Rubber sealing ring
Sprocket and brake drum (-43T)
Grease retainer
Bearing ...
Felt washer
Bearing and felt retainer
Cirdip
Bearing sleeve ...
Brake anchor plate
BRAKE SHOE cfw LINING
Brake lining
Brass rivet .•.
Shoe return spring
Brake cam
Brake cam lever
Nut
Lever return spring
Nut
Inner distance piece
Outer distance piece
Spindle
Chain adjuster
Adjuster end plate
Self-locking nut
Tyre security bolt
Tyre security bolt
6T
1
1
T110 TR6
1
1
T120
1
1
1
1
1
1
1
20
20
20
20
20
20
20
20
4Q
1
2
4Q
4Q
4Q
1
1
2
2
1
1
1
1
1
2
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
2
16
2
1
1
1
1
1
1
1
1
2
2
2
1
1
1
2
2
16
2
1
1
1
1
1
1
2
2
2
1
2
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
2
16
2
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
1
1
1
2
2
16
2
1
1
1
1
1
1
1
1
2
2
2
1
1
59
~----------------~
,----44
'e.-----35
----45
~------46
--------37
.
•
-
--=--~----
•
7-&
20
38~-----1/
41---···-·-\
4o
31
,. - - - - 2 4
39
•
~'
I
26
.-r---23
'}---.u
a
~
42---~~-------11
..
34
I
'
13
I
14
I
4
FIG. 2l PETROL TANKS
60
32
I
15
Ref. No.
Port No.
DE.SCRIPTION
QUANTITY
PETROL TANKS
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
F-4640
F4148
F4766
F4129
F4665
F2551
F1953
F4551
F4767
F4667
F2552
F4700
F4235
F4127
F4236
F3915
525-13
T361
F1606
F4237
F4128
F4238
F3916
F1605
F3220
F3219
F4048
F1511
F3329
F1717
F3057
F3116
F4641
F4770
F4655
F4699
F4657
F4658
F4656
525-3
Petrol tank (4 gallons)
Styling strip (left, front)
Styling unit (left)
Styling unit screw (0·435" U.H.)
Styling strip (left, rear)
Knee grip (left)
Knee grip screw (i" U.H.)
Styling strip (right, front) ...
Styling unit (right) ...
Styling strip (right, rear)
Knee grip (right)
Petrol tank (3 gallons)
Styling strip (left, front)
Styling unit (left) ...
Styling strip (left, rear)
Knee grip plate (left)
-tlr" X!"
Split pin
Eyebolt
Self-locking nut
Rear bolt (1~" U.H.)
Spring washer
Nut ...
Parcel grid
Parcel grid screw
F4659
W1058
F2596
526-2
51-51
F3917
F2936
6T
1
1
1
4
1
1
4
1
1
1
1
Plain washer
Knee grip plate bolt (i" U.H.)
Kr.ee grip (left)
Styling strip (right, front) ...
Styling unit (right) ...
Styling strip (right, rear)
Knee grip plate (right)
Knee grip (right)
FILLER CAP
FILLER CAP c/w JACK CHAIN
Joint washer
Fibre washer ...
Blanking plug
Petrol tap
Petrol tap (left)
Petrol
1
1
2
1
1
3
1
1
1
1
3
1
1
1
1
1
3
2
1
1
1
1
1
1
4
1
1
1
3
2
1
1
1
1
1
1
4
tap with reserve tube
Mounting rubber
Steady rubber
Securing strap
Securing strap
Securing strap rubber
Front yoke ...
Yoke pin
Plain washer
T110 TR6
1
1
1
4
4
1
1
4
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
2
2
1
1
3
1
1
1
1
1
3
2
1
1
1
1
1
1
4
T120
1
1
1
4
1
1
4
1
1
1
1
1
1
2
2
3
1
1
1
1
3
2
1
1
1
1
1
1
4
61
32
31
9
26--
9------23
·~------22
20
FIG. 24 OIL TANKS
62
Ref. No.
Part No.
DESCRIPTION
QUANTITY
OIL TANKS
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
F4476A
F4477
F4478
F4702
F1792
PT104B
F3796
F3658
F4048
F4533
F3179
F1713
F3182
E4113
F3655
MF119f20
E3353
E3354
MF120
E4109
E3355
E1529
E4114
E1539
525-3
51-51
T1579
T1578
F1213
E2287
F2335
526-3
51-51
F3641
F1008
E3383
E4159
E1335
E1435
6T
1
1
1
Oil tank
FILLER CAP
Joint washer
T110 TR6
1
1
1
Oil tank
Drain plug
Fibre washer
FILLER CAP cjw JACK CHAIN
FILLER CAP
1
1
1
000
T120
1
1
1
Joint washer
Oil tank filter
Oil tank filter
1
Fibre washer ...
1
1
1
1
1
1
1
Union nut
Upper feed pipe
Upper feed pipe
1
2
Rubber connector
2
Rubber feed pipe
Rubber return pipe
Ferrule
Oil pipes and junction block
Oil pipes and junction block
oo•
1
Joint washer
Crankcase stud (1!" O.A.)
Crankcase stud (1ft O.A.)
Plain washer
Nut
Vent pipe
Vent pipe
Bolt (tl" U.H.)
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
4
2
1
2
2
1
1
1
1
4
2
oo·
Serrated washer
Bolt (tl" U.H.)
Spring washer
Nut
Stud (ti" O.A.)
Nut
000
1
1
1
2
1
1
3
3
2
1
1
3
3
4
2
1
1
4
2
000
Rubber connector
Rocker oil feed pipe
Copper washer
Domed nut
000
63
23--~
21---~~~k
24---
------16
9---
;-----6
llt-----33
lt------34
FIG. U
64
BAlTERY CARRIER AND AIR FILTER
Ref. No.
Port No.
DESCRIPTION
QUANTITY
BATTERY CARRIER AND AIR FILTER
1
2
3
4
5
6
7
8
9
9
10
11
12
13
14
15
16
17
18
29
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
F-4660
F-4661
F-4662
E3200
F1369
DS57
S25-1
F879
F4705
F4706
F3588
F1668
F1727
E534
E535
E536
F3874
F3875
F3227
F1213
F2335
S26-3
S1-51
F3641
F1008
F4673
F-4672
F3858
F3859
F4698
F3315E
F3376
E1612
MLZ9E
F4814
PU7E-9
Battery carrier
Top strap
Packing rubber
Screw Cit" U.H.)
Bolt (t' U.H.)
Bolt (tlr' U.H.)
Plain washer
Nut ...
BATTERY CASE AND TOOLBOX
BATTERY CASE AND TOOLBOX
Top strap
Side strap
Hinge pin
Plain swivel
Threaded swivel
Bolt (1 it R U.H.)
TOOLBOX LID
Lid fastener
Aluminium grommet
Bolt (fj' U.H.)
Bolt (it' U.H.)
Spring washer
Nut ...
Stud (fV O.A.)
Nut ...
Air filter
Rubber connector
Rubber connector
Clip , ..
AIR FILTER ...
Element only
Screw U ln. U.H.)
Serrated washer
Battery cjw lid
Plastic vent pipe
Battery
6T
1
1
1
1
1
1
2
2
T110 TR6 T120
1
1
1
1
1
1
2
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
65
~21
19------
.~l
20
.~;~$'
:n
28
------35
31
30
FIG. :16 MUDGUARDS
Re(. No.
Port No.
Df.SCRII'TION
QUANTITY
MUDGUARDS
1
2
3
4
5
6
7
8
9
10
11
11
13
14
15
16
17
18
19
10
21
22
23
24
15
26
17
28
29
30
31
32
33
34
35
36
37
38
39
40
41
H1097
F929
F-'1299
H1100
W62
525-2
NS362
H1294
H1271
H129S
OSS7
SlS-1
F879
TlH
H412
H424
SlS-71
51-51
F2698
H2S1
F4332
S26-2
F879
F2996
H741
H687
H745
F-4674
OS57
S26-2
F4716
F4717
F-4687
F3599
F3896
F879
F-4690
F929
S26-3
51-51
F3363
Front mudguard
Bolt(!" U.H.)
Plain washer
Bottom stay ...
Bolt (it' U.H.)
Plain washer
Spigot nut
Mudguard blade
Front stay
Mudguard bridge
Bolt (}70 U.H.)
Plain washer
Nut ...
Nut ...
Bottom stay ...
Bolt (I£' U.H.)
Plain washer
Nut
Number plate
Plate beading
Packing piece
Spring washer
Nut ...
Number plate
Clip assembly
Screw (i" U.H.)
Nut ...
Rear mudguard
Bolt (i<' U.H.)
Spring washer
Screw (1i' U.H.)
Nut ...
Rear mudguard
Bracket
lifting handle
Nut ...
Clip ...
Bolt (f" U.H.)
Sprl ng washer
Nut ...
Number plate
6T
1
2
2
1
2
2
1
T110 TR6
1
2
2
2
1
2
2
1
1
1
1
1
T120
" "
2
1
1
1
1
"" ""
" "2
...
2
1
1
1
1
...
1
1
1
2
2
1
1
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
1
2
2
2
6
6
6
6
1
1
1
6
1
2
2
2
1
1
1
1
6
1
1
2
2
1
67
~_:3~~25
"---+-:!:-- 9
14
~nr~
1
II
\
l
101213
15 8
FIG. Z7 PANELS AND TWINSEAT
68
Ref. No.
Pan No.
DESCRIPTION
QUANTITY
PANELS AND TWINSEAT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
19
20
21
ll
23
24
25
26
27
28
29
30
31
32
F-4676
F46n
F4663
F4664
F4317
F4249
F4715
F4717
F#83
F4680
F2335
526-3
51-51
F4686
F1369
526-2
F879
F3098
F4239
F-4691
F4244
F4475
F42ll
DS57
526-2
0374
F4226
F4ll8
E1719A
/.' X
F4ll7
F4361
F4365
t'
Left panel
Right panel
Motif "Thunderbird"
Motif "Tiger 11 0"
Spire nut
Joint beading
Screw Ui' U.H.)
Nut
Self-tapping screw
Clip ...
Bolt (fl" U.H.)
Spring washer
Nut
Number plate
Bolt (t' U.H.)
Spring washer
Nut ...
Vent pipe dip
TWINSEAT ...
TWINSEAT cJw BRACKETS
Twlnseat cover cJw dips
Clip
Hinge
Bolt h\·' U.H.)
Spring washer
Check wire ...
Seat catch plunger
Spring
Plain washer ...
Split pin
Knob ...
Safety strap
Self-tapping screw
...
...
6T
1
1
2
6
2
T110 TR6
1
1
2
6
2
5
5
5
5
2
2
2
2
1
2
2
2
1
1
2
2
2
2
1
2
2
2
1
1
5
5
1
2
4
4
1
1
1
1
1
1
A
4
T120
1
1
1
as required
2
1
1
4
4
1
1
1
1
1
1
A
4
A
4
A
4
69
34
44
Complete
Ref. No.1
.,
, 2
.,
., 3
Assemblies
6T, T110.
TR6.
T120.
25
22
i9ASSY.
43-----_/
40 --------"-',y
42
FIG. 28
70
41
HANDLEBARS
5
Ref. No.
DESCRIPTION
Part No.
QUANTITY
HANDLEBARS
1
2
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
H1223
H1224
H1313
H1009
H811
H1003
H697
H698
H665
H685
H686
H234
H237
H700
H233
H232
H230
H230A
18j886
18j908
18f894
18f909
12/614
12/613
18/535
18/754
18/528
18j752
18/890
18/892
12/044
11/014
H668
61/004
18/087
18/053
18/838
18/839
18{880
12j556
12!014
12j607
12/606
12/033
31563
H689
HANDLEBAR cfw CONTROLS
HANDLEBAR cfw CONTROLS
HANDLEBAR cfw CONTROLS
Handlebar
Handlebar
Handlebar
TWISTGRIP ASSEMBLY
Twistgrip head assembly (Nos. 8-12)
Friction screw
Spring
Friction spring
Cable thimble
Grub screw
Sleeve
Retaining plate
Circlip
Rubber grip (and at left handlebar)
Left rubber grip
FRONT BRAKE lEVER ASSEMBLY
FRONT BRAKE LEVER ASSEMBLY (Ball-end)
ClUTCH lEVER ASSEMBLY
CLUTCH lEVER ASSEMBLY (Ball-end)
AIR lEVER ASSEMBlY
MAGNETO LEVER ASSEMBLY
Brake lever
Brake lever (Ball-end)
Clutch lever
Clutch lever (Ball-end)
Brake lever bracket
Clutch lever bracket
Clamp
Screw
Clamp
Screw
Fulcrum screw
Self-locking nut
Cable adjuster
Thumb nut
Barrel nipple
Air lever
.
"
6T
1
T110 TR6
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
2
2
2
1
1
1
1
1
2
2
2
2
2
2
...
Magneto lev-er
Centre bolt
Cap ...
Spring washer
Horn push and dip switch
Screw(!' U.H.)
T120
1
2
1
2
1
1
1
3
6
1
2
2
2
2
2
1
1
1
2
2
2
1
2
1
1
1
2
1
2
2
1
2
2
2
1
2
71
AIR CONTROl
CABLE
27 26
32
FIG. 29 CONTROL CABLES AND AMERICAN HANDLEBARS
n
ll.e(. No.
Pan No.
DESCRIPTION
QUANTITY
CONTROL CABLES AND AMERICAN HANDLEBARS
1
2
3
4
4
5
6
7
8
9
10
11
12
13
14
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
CLUTCH CABLE ...
Ferrule ..•
Nipple
FRONT BRAKE CABLE
FRONT BRAKE CABLE
Ferrule ...
Nipple
Fork end ...
Pivot pin
Split pin
g' Xi'
H1171
Clip
H916
Screw (/,' U.H.)
GS299
Serrated washer
H745
Nut ...
0224
THROTTLE CABLE
0439
THROTTLE CABLE
0421
THROTTLE CABLE
Twlstgrlp cable
0422
Junction box
244/104
Carburetter cable
0423
0101
Ferrule ...
H670
Guide tube
D83
Nipple
NS191
Nipple ...
D104
AdJuster
AIR CONTROL CABLE
0435
MAGNETO CONTROL CABLE
D100
D101
Ferrule
D83
Nipple
NS191
Nipple ...
Magneto cable end fittings supplied with magneto
AMERICAN HANDLEBAR cjw CONTROLS
H1246
AMERICAN HANDLEBAR cjw CONTROLS
H1228
AMERICAN HANDLEBAR cjw CONTROLS
HUH
American handlebar
H1247
American handlebar
H1179
0434
Clutch cable ...
0415
Front brake cable
0417
Front brake cable
D257
Th rotde cable
D+IO
Throttle cable
0424
THROTTLE CABLE
0425
Twistgrip cable
Magneto
control cable
0260
0432
0103
0368
0414
0416
0103
0368
W593
WF32
6T
1
2
2
1
...
2
...
...
...
1
1
1
1
1
1
1
1
1
T110 TR6
1
1
2
2
2
1
2
1
1
1
1
1
1
1
1
1
2
T120
1
2
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
...
...
1
2
1
3
1
1
1
1
1
1
3
1
1
1
...
3
1
1
1
1
1
1
4
2
1
10
1
1
s
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
73
I
7
3
4
17
z
FIG. l8 TOOL IUT, FRAME LOCit, PILLION FOOTREST AND LICENCE HOLDER
Ref. No.
1
2
l
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
Pan No.
DESCRIPTION
QUANTITY
TOOLKIT, FRAME LOCK, PILLION FOOTRESTS AND LICENCE HOLDER
6T T110 TR6
0365
TOOLKIT COMPLETE
1
1
1
WA58
Tool roll
1
1
1
0360
Open spanner, !" x .... Whit.
1
1
1
0361
1
Open spanner, t.• X !" Whit.
1
1
1
NA55
Open spanner, !" x -/ir Whit.
1
1
1
OA16
Open spanner, i" x -,1," Whit.
1
1
PA57
1
Ring spanner, i • x f. • Whit.
1
1
1
0311
1
Ring spanner, i" x fV Whit.
1
"C" Spanner and Tappet Key
1
0362
1
1
Plug spanner
1
087
1
1
1
0363
Tyre lever and screwdriver
1
1
1
0364
Tyre lever and clutch key
1
1
Phillips No. 3 Screwdriver
1
0336
1
1
Clutch Hub extractor oo•
1
1
OA50/1
1
1
400935
Screwdriver
415116
Spanner
1
1
0296
Tyre Inflator
1
1
1
A
0220
Fork spanner
A
A
1
FRAME LOCK cfw KEYS oo•
1
0402/3
1
1
0403
Key (state number)
1
1
2
F4327
PILLION FOOTREST
2
2
2
F1694
2
Pedal
2
2
F2268
Hanger oo•
2
2
2
F4309
Stud (11" O.A.)
2
2
2
F2271
Pivot bolt
2
2
2
F2277
Thackeray (Spring) Washer
2
2
2
51-51
Nut
2
2
2
526-1
Spring washer
2
2
2
Nut
2
51-52
2
2
F1695
Pedal rubber
2
2
0261
Licence holder
0557
Bolt (-,1,-" U.H.)
Serrated washer
E1612
F879
Nut
000
000
T120
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
A
1
2
2
2
2
2
2
2
2
2
2
1
75
13
'0?
12
~--------------------·~
19
~--------------42
--------------43
~---------------48
26----11
2
49
47
41
31
39
32
33
36
18
22
25
37
16
17
38
28
29
35
34
21
40
FIG 31 CARBURETTER, 6T, TffO AND TR6
76
Ref. No.
PanNa.
QUANTITY
DESCRIPTION
CARBURETTER 6T, T110 AND TR6
1
1
1
2
3
4
5
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
ll
23
23
H
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
376[156
376/255
376/40
376/003
376/174
376/065
29/307
4/276
4/241
30J064
376t107
376/062
4/046
6j047
6j132A
4/035
376j060
376/061
376/068
376/069
376/070
376/057
376/067
376/073
376/074
376/100
376/100
376/075
376/072
376/063
4/230
376/076
116/162
376/095
332/017
4/148
376j08S
376/083
376/094
376/078
376/077
376/079
376/088
376/089
376/093
376/091
376/092
376/086
376/087
343/011
244/1048
F4448
F4720
CARBURETTER
CARBURETTER
CARBURETTER
Mlxi ng chamber 11l • choke
AIR VALVE ASSEMBLY
Mixing chamber cap
Spring
Spring
Screw
Spring
Mixing chamber top
Air valve
Spring ...
Air valve guide ...
Throttle cable ferrule
Air cable adjuster
Throttle valve (3! cutaway)
Throttle return spring
Throttle stop screw ."
Stop screw spring
Peg screw
Jet block (1
Joint washer
Jet holder
Fibre washer
Main jet 270
Main jet 250
n' choke)
Cover nut
Needle jet (·1065)
Needle (Type C)
Needle dip
Pilot jet (25)
Fibre washer
Cover nut
Air adjusting screw
Spring ".
Float spindle
Float
Bush
Joint washer
Cover
."
Screw
Needle seating
Needle
Filter
Bolt
Fl bre washer
Tickler ...
Tickler spring
Tickler body
"0., ring seal
Petrol pipe assembly
Petrol pipe assembly
6T
1
T110 TR6
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
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
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
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
77
,.----6
8
?=~-7
4
5
3-----r'!~~
10-------<
23----'
~---------------14
9-----+
22-------1
2----------~---+
28----:::.\
27~
,r---"--30
----1(tp
II
12
29
24-i
25=:8
26
18
16
19
20
FIG. :11 IONNEYILLE 120 CARBURETTERS
78
Ref. No.
Port No.
DESCRIPTION
QUANTITY
BONNEVILLE 120 CARBURETTERS
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
376{233
376/16-4
376/107
376/065
4/276
4/241
4/137A
6/132A
376/060
376/132
376/068
376/069
~:'6/070
376/057
376/067
376/140
376/141
376/074
376/100
376/075
376ton
376/063
4{230
376/076
116/162
376/095
332/017
4/148
376/078
376/077
376/151
2-4-4/1048
376/066
F2603
525-3
526-3
51-51
MIXING CHAMBER ASSEMBLY
Mixing chamber (1 tlr" choke)
Mixing chamber top
Mixing chamber cap
Spring ...
Screw
Plug screw
Throttle cable ferrule
Throttle valve (3! cutaway)
Throttle return spring (light)
Throttle stop screw
Stop screw spring
Peg screw
Jet block (1 tlr' choke)
Joint washer
Jet holder
Inlet banjo
Fl bre washer
Main jet (240)
Cover nut
Needle jet (·1065)
Needle (Type C)
Needle clip
Pilot jet (25)
Fibre washer
Cover nut
Air adjusting screw
Spring ...
Joint washer
Cover
Screw
"0" ring seal
Air Intake tube ...
Bolt (1t' U.H.)
Plain washer
Spring washer
Nut ...
T120
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
4
2
2
2
2
2
2
2
2
2
2
2
2
6
2
2
4
4
4
4
79
II
10
29--2
31-~,.t.~30~
32--.
f~
FIG. ll 80 NNEVILLE 120 FLO AT CHAMBER
Re(. No.
Port No.
DESCRIPTION
BONNEVILLE
'·
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
H
25
26
27
28
29
30
31
32
14/624
14/363
14,1219
14/336
14/385
14,1209
14/032
H/210
Hf289
H/017
14/355
161/054
376/093
376/135
376/092
14/384
14/383
81j027
E3987
E4054
E4053
T1017
F4722
F4525
F3353
F3337
E4035
F4725
F4726
F4526
F4356
E4035
no
FLOAT CHAMBER ...
Float chamber
Inlet union
Fibre washer
COVER cfw TICKLER
Tickler
Spring
Stop
Split pin
Float
Needle
Clip
Filter
Banjo
fibre washer
Bolt
Anchor stud
Nut
Flexible mounting
Screw (f. • U.H.)
Spring washer
Nut ...
PETROL PIPE
Rubber pipe
Obtuse elbow
Union nut
Clip
PETROL PIPE
Rubber pipe (long)
Rubber pipe (short)
"T" piece
Clip
QUANTITY
FLOAT CHAMBER
T1l0
1
...
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
2
2
2
2
"1
2
1
1
6
81
14
22 21
8
33 34
19
24
29 28 27
23
FIG. J4
MAGNETO WITH AUTOMATIC ADVANCE AND RETARD
Ref. No.
1
2
3
~
5
6
7
8
9
10
11
12
13
14
15
16
Part No.
-492856
49285-4
54440888
470537
459130
18
-493716
19
463932
20
21
ll
150509
185048
452907
45900-4
33
455361
458339
189294
1892#
459005
459002
-455191
455190
458675
525-3
34
F1008
24
25
26
27
28
29
30
31
32
QUANTITY
MAGNETO WITH AUTOMATIC ADVANCE AND RETARD
T110 TR6 T120
~23#
MAGNETO ...
1
1
~58876
PICK-UP
2
2
~51260
Brush and spring ...
2
2
Joint washer
~58877
2
2
~10600
Moulded nut
2
2
Rubber grommet ...
~58658
2
2
-4
-4
H50H
Fixing screw
~59269
1
1
CONTACT BREAKER COVER
459266
Moulded breather cap
1
1
459888
Terminal assembly
1
1
-455190
Brush and spring .. .
1
1
-457681
Rubber washer .. .
1
1
17
23
D<SC/I.II'TION
Contact breaker screw
CONTACT BREAKER
Contact and spring set
Earthing brush and spring
Cam
End plate
Insulating cup
Screw
Spring washer
Shim (0·005')
ARMATURE
Slip ring
Condenser
Contact breaker end bearing
Drive end bearing
Drive bearing insulating cup ...
Oil seal ...
EARTH BRUSH, SPRING AND HOLDER
Earth brush and spring
Sundry parts set
Plain washer ...
Nut ...
1
1
1
1
1
1
1
1
1
1
1
1
3
3
1
1
3
3
as required
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
3
3
3
t
470688
Some early Magnetos 423#D were fitted with
Contact breaker screw
}
CONTACT BREAKER
Contact set
Spring set ...
0297
D262
Sparking plug (Champion N3, K.l.N. F.E.100or lodge HLN)
Plug cover and suppressor
Plug cover
122160
470534
470609
35
36
36
Interchangeable
with the above as
an assembly only.
2
2
2
2
2
A
A
A
2
83
!>------! 17
ffi-18
2
14
252423
8
31
52
26
FIG. 35
MAGNETO WITH MANUAL CONTROL
Ref. No.
Port No.
DESCRIPTION
QUANTITY
MAGNETO WITH MANUAL CONTROL
T110 TR6
1
2
3
.
5
6
7
8
9
10
11
12
13
14
15
-42298
<458876
451260
<458877
410600
<458658
1<45074
459269
459266
459888
455190
<457681
492856
<492854
54440888
16
<470537
17
18
-492195
19
20
21
22
23
H
<455788
454<475
<458725
<459271
463932
150509
185048
25
<452907
26
-459004
-455361
27
28
<458339
29
30
189294
189244
31
-459005
-459002
32
33
<455191
<455190
3-4
35
-458675
36
525-3
37
F1008
MAGNETO ...
PICK-UP
Brush and spring ...
Joint washer
Moulded nut
Rubber grommet ...
Fixing screw
CONTACT BREAKER COVER
Moulded breather cap
Terminal assembly
Brush and spring ...
Rubber washer
Contact breaker screw
CONTACT BREAKER
Contact and spring set
Earthing brush and spring
CONTROl PARTS SET
Nipple
Rubber cover
Cam
End plate
Insulating cup
Screw
Spring washer
Shim (0·005•)
ARMATURE
Slip ring
Condenser
Contact breaker and bearing
Drive end bearing
Drive bearing insulating cup
Oil seal ...
EARTH BRUSH, SPRING AND HOLDER
Earth brush and •pring
Sundry, parts set
Plain W3$her
Nut
T120
1
2
2
2
2
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
as required
1
1
1
1
1
1
1
1
1
1
3
3
t
122160
-47053-4
-470609
-470688
Some early magnetos 42298C were fitted with
Contact breaker screw
}
CONTACT BREAKER
Contact set
Spring set
D297
0262
Sparking plug (Champion N3, K.LG. F.E.100 or lodge H. LN.)
Plu~: cover and suppressor ...
Plug cover
38
39
39
Interchangeable
with the above as
an assembly only.
2
2
2
2
2
2
A
A
A
85
4-----•
i
5-----~
2-----
15
lb
25
26
17
23
7
22
21
4----()
5----1?"
28
79
~~fl:i·
lP~- 36
~~30
32
41
---··-38
37
31 32
34
FIG. J6 DISTRIBUTOR AND COIL
86
Ref. N<J.
Part No.
DESCRIPTION
QUANTITY
DISTRIBUTOR AND COIL
1
40690
2
3
425049
4
5
421554
421863
6
4234l!6
7
423110
8
423108
9
10
423109
11
12
13
14
15
404435
54410U23
425219
423113
425284
425398
421056
16
17
425444
18
19
424158
20
2.1
22
23
425498
425243
188639
33
H
1
1
1
1
1
1
1
1
1
1
1
2
1
1
169160
422369
DS57
'"D .. washer
Bolt (ilr U.H.)
E1612
Serrated washer
Nut
Rubber cover
Sparking plug (Champion L7, K.l.G. F.BO or lodge H. H)
Plug cover and suppressor ...
Plug cover
112917
185051
173857
31
32
1
1
25
26
30
1
1
4
4
Distributor adaptor .. .
Plain washer ...
Nut
Clamping plate
Clamp bolt
Washer
Nut
Distributor sheath ...
Ignition coil (M.A.6)
Clip screw
Square nut ...
E3122
S25·3
S1·51
E4116
29
6T
1
.. .
24
27
28
DISTRIBUTOR (Type 18D2)
CAP ASSEMBLY
Brush and spring .. .
Rubber grommet .. .
Cable clip ...
Rotor
Shaped Insulating bush
Condenser connector
Insulating bush
Condenser
Contact set
Base plate
Cam
Spring set
Weight set
Shaft and action plate
Bearing bush
Retaining dip ...
Sundry parts set
E4117
45077
100104
35
36
37
236741
38
D297
38
D262
F879
Rubber .. 0 .. ring
3
3
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
A
87
4
5
FIG. '11 HIADLAMP AND WilliNG ...AIINISI, 1116 AND Tt21
88
Ref. No.
Part No.
DESCRIPTION
QUANTITY
HEAOLAMP ANO WIRING HARNESS. TR6 ANO Tf10
1
2
3
4
5
6
7
8
9
10
11
12
13
H
15
16
17
18
19
20
21
22
23
24
58556
553248
516798
504665
534296
312
554602
988
554710
36084
112201
137141
31784
F4696
F4697
E3798
E3221
H745
70048
701851
1'4771
GS299
H745
54944995
HEADLAMP COMPLETE
Rim
Light unit
Fixing wire
Screw and plate
Bulb (30f24W. Vert. dip, Pre-focus)
Adaptor·.··
Bulb (3W. M.C.C.)
Pilot bulbholder
Ammeter
Bolt
Plain washer
Lighting switch (SA.41)
Left switch bracket :..
Right switch bracket
Cap
Screw (1 i' U.H.)
Nut ...
Horn ...
Fixing plate
Bolt (!' U.H.)
Serrated wuher
Nut ...
Wiring harness
TR6 T120
1
1
1
1
1
1
6
6
1
1
1
1
1
2
2
1
1
1
2
1
1
1
4
2
2
2
1
1
1
1
1
2
2
1
1
1
2
1
1
1
4
2
2
2
1
89
10
~
12
23
FIG. l8 SPEEDOMETER, TAIL LAMP AND RECTIFIER
90
22
28
Ref. No.
Per! No.
QUANTITY
DE.SCRIPT/ON
SPEEDOMETER, TAIL LAMP AND RECTIFIER
1
1
1
1
1
2
3
4
5
6
7
8
9
10
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
SC3304f19
SC3304/20
SC5301j09
SC5301 /16
SC5301J18
P53279f1
P52305
P22469
15578!2
N1253
DS<40
DS57
S26-2
0245
D245A
53432
573839
575200
575208
575219
576002
575209
575207
573828
573825
384
838604
34279
F929
S26-3
$1-51
47132
F3600
F4813
H919
Speedometer head (12S m.p.h.)
Speedometer head (190 k.p.h.)
Speedometer head (125 m.p.h.)
Speedometer head (190 k.p.h.)
Speedometer head (2<40 k.p.h.)
BULB HOLDER cfw BULB
Bulb
Rubber ring ...
Clamp bar
Nut ...
Bracket
Bolt (ir' U.H.)
Spring washer
Speedometer drive cable (44' long)
Speedometer drive cable (44' long)
STOP AND TAIL LAMP (Type 564)
Lens
Window
Lens seating gasket
Sleeve nut
Base assembly ...
Bulbholder
Grommet
Contact Assembly
Grommet
Bulb (6f18W. Offset pin.)
Stop and tall lamp lead
Stop lamp switch (6SA)
Bolt (t" U.H.)
Spring washer
Nut ...
Rectifier
Self-locking nut
Screw (f.' U.H.)
Nut ...
6T
1
1
.. ,
1
1
1
1
2
T110 TR6
1
1
1
1
1
1
1
1
2
1
2
1
2
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
1
T120
1
1
1
1
2
1
2
2
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
91
6T
T110
R
TR6
c
T120
R
c
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
Page 17
CP159
CP157
E3108f22
E3108/21
E3325
E332S
PISTON COMPLETE 7·5 : 1 C.R.
PISTON COMPLETE 8·5 ; 1 C.R.
Engine Sprocket
Engine Sprocket
Inlet Camshaft
Exhaust Camshaft
...
...
...
...
...
...
Stock
Stock
Stock
Stock
Stock
Stock
13
E4191
16
E4192
E4193
E4194
E2973
E2962
NM3A
E2968
OIL RELEASE VALVE AND INDICATOR
Replaces
Cap
Replaces
...
Sealing ring
...
Cup
Stud (1H in. O.A.)
...
Stud (1j, ln. O.A.)
...
Joint Washer
...
Insulating block
...
E2795
E2790
NEW
NEW
Stock
Stock
Stock
Stock
14
14
21
21
37
38
2
2
1
1
1
1
Page 21
24
29
30
31
1
1
1
1
1
1
1
1
4
4
4
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
4
2
1
1
1
1
Page 23. For 6T read as for T!10 on page 25.
Page 29
1
1
T1583
2
5
T1605
T1606
T1607
T1612
T1614
T1607
GEARBOX COMPLETE- STANDARD RATIO
Replaces T152S
GEARBOX COMPLETE- STANDARD RATIO
Stock
GEARBOX CASING
... NEW
Layshaft bearing
... NEW
... NEW
Thrust washer ...
GEARBOX INNER COVER
... NEW
layshaft bearing
... NEW
Thrust wa>her ...
... NEW
Page 31
11
11
11
T1608
T1610
T1609
LAYSHAFT COMPLETE (20T)
LAYSHAFT COMPLETE (1ST)
Layshaft cjw high gear (22T)
Page 3l
29
40
T1270
T402
F-OLDING KICKSTARTER
Clutch operating arm
10
11
94
T1528
1
1
1
1
1
1
1
1
1
1
1
1
A
A
1
A
A
1
A
A
1
A
A
1
1
1
1
1
1
1
1
1
1
1
1
... NEW
... NEW
... NEW
1
A
A
A
A
... Stock
... Stock
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Pap 4t
20
28
S1-51
Flanged nut ...
Eyebolt
Plain washer
Nut
Abutment pin
Spring wuher
Nut
Pap.O
12
-47178
Stator ...
E4177
E4179
left exhaust pipe
...
Right exhaust pipe
...
left Bracket ...
...
Right bracket
...
Extended nut
...
Spring washer
...
Bolt (H ln. U.H.}
...
Exhaust leg guard
Replaces
•••
CUp ...
Screw (it ln. U.H.) ...
..•
Plain washer
...
.•.
Nut
left silencer ...
•..
Right silencer
••.
Silencer hanger bolt (1H ln. U.H.)
..•
Distance piece
...
Spring washer
...
Nut
••.
24
2S
26
27
1'4569
1'4716
GS203
E1310
1'4669
~3
...
...
...
..•
...
...
...
•..
..•
NEW
NEW
Stock
Stock
Stock
Stock
Stock
Replaces 471 ~
6T
T110
1
1
1
1
1
1
1
1
4
1
1
1
1
4
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
TR6
R
c
T120
R
c
. .. .. . ... ...
-
Pap -45
E2989
E2990
32
33
34
35
36
E4181
S26-1
W840
E4204
E-4207
F4715
E2351
F3799
E4132
E4176
H622
F2694
S26-1
S1-52
...
...
NEW
NEW
Stock
Stock
NEW
Stock
Stock
E-40n
NEW
Stock
Stock
Stock
Stock
NEW
Stock
Stock
Stock
Stock
1
1
1
1
1
1
1
2
-
1
1
1
1
1
1
1
2
..
....
4
4
..
1
1
2
2
2
2
1
1
2
2
2
2
Paze 53. For 6T read as for Tl10 on p&le 55.
Paee 55
20
21
22
W1410
Wl-411
W141-4
lEADING BRAKE SHOE ...
Tl\AIUNG BRAKE SHOE ...
Brake lining
Replaces W1337
Replaces W1338
... NEW
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Pa.. 57. For T1l0 r...t as for TR6.
95
6T
TR6
T110
R
Page 57
23
23
W1406
W1-4Q7
Page 59.
For T120 read as for TR6.
Page 59
25
25
W1-4Q6
W1407
Page 61.
For T120 read as for TR6.
Page 61
35
31
32
F4893
F3057
Fl116
Securing strap
Petrol tap
376f255
3761257
F4720
F4841
F4842
Carburetter
Carburetter
Petrol pipe
Petrol pipe (short)
Petrol pipe (long)
SC3304 124
Speedometer head (125 m.p.h.)
Replaces SC3304 /19
Speedometer head (190 k.p.h.)
Replaces SC3304j20
... Stock
Speedometer head (125 m.p.h.)
... Stock
Speedometer head (190 k.p.h.)
... NEW
Speedometer head (1-4Q m.p.h.)
... Stock
Speedometer head (2-4Q k.p.h.)
Replaces
34279
Stop lamp switch
...
NEW
Crinkle washer (rectifier leads}
Page 77
1
1
49
Page 91
1
1
SC3304j25
1
1
SC5301 f09
SC5301j16
SC5301 /26
SCS301/18
34181
F4844
1
1
23
96
LEADING BRAKE SHOE }
TRAILING BRAKE SHOE
LEADING BRAKE SHOE }
TRAILING BRAKE SHOE
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
2
1
2
1
1
2
2
1
1
1
1
In pairs
replace W93
1
1
1
Stock
NEW
Stock
NEW
NEW
c
1
1
...
...
...
...
...
R
1
1
1
In pairs
replace W93
... Replaces F-4655 and F4699
... Stock
...
... Stock
Petrol tap with reserve tube
T120
c
1
1
1
1
1
A
A
1
A
1
3
1
3
1
3
1
A
1
1
A
A
1
3
1
1
3
3
1962 REPLACEMENT PARTS CATALOGUE
1962 Season's machines were basically as specified in the No. 16 Replacement Parts Catalogue for 1960,'61 season's
models, w!th the following amendments, These changes apply to machines from Engine No. D15789 except where
otherwise stated.
Page 12
CARTON PACK LIST
CLOSE RATIO GEARS (To convert from Standard Ratio)
(Needle roller layshaft bearing condition- Engine No. D7727 onwards)
CP193
1
1
1
1
1
1
1
Page 14
T1177
T1383
T1179
T955
T1609
T964
T963
T961
T1227
Mainshaft and low gear (18T)
Mainshaft high gear (24T)
Mainshaft third gear (23T)
Mainshaft second gear (21T)
Layshaft c;w high gear (22T)
layshaft chi rd gear (23T)
layshaft second gear (25T)
layshaft low gear (28T)
Blanking plug
CARTON PACK LIST
VALVE SPRINGS
E4221
Inner valve spring (red)
CP188
4
4
E4222
Outer valve spring (red)
6T (Engine No. D11193 onwards)
Page 17
CRANKSHAFT AND CONNECTING RODS
E4492
E4493
E4479
CP159
CP157
E3108/22
E3108j21
54213901
E4220
E3134
E1486R
Page 21
Engine sprocket
(
Engine sprocket
Rotor RM19
Camshaft (D11193 onwards)
Inlet camshaft
Camwheel (3 keyway)
(
II
H
6T
1
TR6
1
1
1
1
1
2
2
T120
1
1
1
2
)
)
1
1
2
2
1
1
2
1
2
OIL PUMP AND RELEASE VALVE AND MANIFOLD (D7727 onwards)
E4191
E4192
E4193
E4194
E2973
E2962
NA43A
E2968
Page l3
CRANKSHAFT AND FlYWHEEL ASSEMBLY
Crankshaft c/w oil tube
Flywheel
PISTON COMPLETE 7.5 : 1 C.R. (D7727 onwards)
PISTON COMPLETE 8,5 : 1 C.R. (
" )
Oil release valve and ind!calor
Cap .. ,
Sealing ring
Cup
Stud (1·1~ in. O.A.)
Stud (1 3~ in. OA)
Joint washer
Insulating block ...
CYLINDER BLOCK AND HEAD 6T-Delete and read as for T110 and
TR6 (on Page 25) with the follow·
ing alterations. (D7727 onwards)
2
1
1
1
4
2
1
1
1
1
4
1
2
Page 25
CYLINDER BLOCK AND HEAD T110 & TR6
E4221
E4222
E3001
E3002
Page 29
T120
4
4
GEARBOX COMPLETE- STANDARD RATIO
GEARBOX CASING
Layshaft bearing
Thrust washer
GEARBOX INNER COVER
Layshaft bearing
Thrust washer
1
1
1
1
1
1
1
1
1
1
LAYSHAFT COMPLETE (20T- Std.) ...
LAYSHAFT COMPLETE (18T- W.R.)
LAYSHAFT COMPLETE (22T- CR.)
N"B.-To convert to dose ratio from standard ratio use CP193
1
A
A
1
A
A
1
A
A
Gearchange quadrant
FOLDING KICKSTARTER
Clutch operating arm
1
1
Clutch spring (strong)
4
...
FRAME
F4846
Page 41
TR6
CLUTCH
T1560
Page 37
6T
4
4
GEARBOX SELECTOR MECHANISM
T408j9
T1270
T402
Page 35
inner (red) (D11193 onwards)
outer (red) (D11193 onwards) ...
1nner (white)
outer (white)
GEARBOX SHAFTS AND GEARS {D7727 onwards)
T1608
T1610
T1609
Page 33
spring
spring
spring
spring
GEARBOX AND CASING (D7727 onwards)
T1583
T1605
T1606
T1607
T1612
T1614
T1607
Page 31
Valve
Valve
Valve
Valve
Front frame
1
1
ENGINE AND GEARBOX FITTINGS
F4569
F4746
GS203
E1310
F4669
526-3
S1-51
F3599
F5049
F2335
526-3
S1-51
Flanged nut
Eye bolt
(D7727 onwards)
( "
)
Plain washer ( "
)
Nut ...
( "
)
Abutment pin ( "
)
Spring washer (
)
"
Nut ...
( "
)
Bracket- Rear engine plate to mudguard
Bracket- Rear engine plate to oil tank
Bolt
Spring washer
Nut. ..
3
1
4
4
2
2
2
4
4
2
2
2
1
1
1
1
2
2
2
2
2
4
4
2
2
2
2
Page 43
Page 45
CHAINCASE AND ALTERNATOR
6T
47164
47162
47183
E4123
T1651
E3440
E3444
0433
1
1
A
1
1
Left-hand exhaust pipe ...
Right-hand exhaust pipe
Clip
"D" washer
Bolt (1 ,1, in. UH)
"D" nut
Silencer
Left silencer
Right silencer
Mute
Screw
Nut ...
1
2
2
2
2
1
1
2
2
2
2
1
1
1
1
2
2
2
1
1
2
1
1
1
2
1
1
1
2
1
1
2
2
1
1
2
1
I
I
FRONT FORK ASSEMBLY (SIDECAR)
LEFT BOTTOM MEMBER CjW CAP
RIGHT BOTTOM MEMBER CfW CAP ...
Spacing bobbins
Stud ...
A
2
2
NACELLE, HEADLAMP AND SWITCHES
70163
HH20
F4771
GS299
F3799
54094328
1
1
2
2
2
Horn
Horn bracket
Bolt H in. U.H.)
Serrated washer
Nut ...
Wiring harness
Page 53
FRONT WHEEL 6T -Read asforT110 on Page 55 with the undermentioned
amendments.
Page 55
FRONT WHEEL T110, TR6 & T120 (D7727 onwards)
W1410
W1411
W1414
W1415
Page 57
1
A
TELESCOPIC FORKS 6T
H1422
H1322
H1323
H1325
H1326
Page 49
3
1
4
4
1
T120
EXHAUST PIPES AND SILENCERS
E4409
E4410
E2271
TE164D
TE164E
TE164C
E4413
E4174
E4175
E4107
H689
H691
Page 47
Stator RM19
Stator RM19
Stator RM19 (U.S. Models)
Stud (1 :,J 1n. O.A.) for Stator
Outer chaincase ...
Screw (1 /6 10. U.H.)
Screw (2l in. U.H.)
Rear chain (~ in. · ~ in. " 98 L)
TR6
LEADING BRAKE SHOE
TRAILING BRAKE SHOE
Brake lining
Pivot pad
REAR WHEEL-For T120 read as for TR6 (07727 onwards)
W1406
W1407
W1415
LEADING BRAKE SHOE } In pairs
TRAILING BRAKE SHOE
replace
Pivot pad
W93
4
I
I
Page 59
QUICKLY DETACHABLE REAR WHEEL -For T120 read as for TR6 (D7727 onwards)
W1406
W1407
W1415
Page 61
I
LEADING BRAKE SHOE
In pairs
TRAILING BRAKE SHOE /- replace
Pivot pad
) W93
6T
1
1
TR6
T120
1
1
1
2
1
PETROL TANKS
Note: T120 Models were fitted with either 3 or 4 gallon tanks as required.
F3220
F4971
F4972
F4916
F4917
F4918
F4919
Filler cap ...
Petrol tap ...
1
Petrol tap with reserve tube
Tank securing strap (3 Gal.) (D16693 onwards)
Tank securing strap (4 Gal.)
Tank strap sleeve
Tank strap sleeve
I
I
Page 63
1
1
2
1
1
1
2
2
1
2
1
OIL TANK
F5067
FS066
F4985
F5051
F5049
F2335
S26-3
S1-51
F4110
F967
F3815
F4111
Oil tank
Oil tank
FILLER CAP
Stud
1
1
1
Bracket
Bolt
Spring washer
Nut ...
Cap ...
Rubber
Spigoted rubber
Bolt
2
FSOSO
T224
F3814
F967
F4108
W1058
Page 69
Stud
Nut ...
Cup
Rubber
Spigoted rubber
Self-lock nut
BATTERY CARRIER AND TOOL BOX
F4905
BATTERY CASE AND TOOL BOX (D9660 onwards)
PANELS AND TWINSEAT
F4897
F4715
F4717
Reinforcing strip, lower panel ftxing
Philips screw- reinforcing strip
Self-locking nut
2
3
3
2
2
1
2
2
1
as required
1
1
1
1
3
3
2
2
2
2
2
2
Locking wire
Page 65
1
1
1
1
2
...
5
1
2
2
Page 73
CONTROL CABLES
0416
F5203
E3220
GS299
H745
Page 77
TR6
T120
2
1
1
1
CARBURETTER (011193 onwards)
CARBURETTER
Main jet 220 (011193 onwards)
Tilronle valve (4 cutaway) (011193 onwards)
Petrol pipe assembly
Petrol pipe
2
1
1
1
1
DISTRIBUTOR AND COIL
54441582
Page 89
6T
1
CARBURETTER 6T, T110, TR6
376(285
376/257
376!1 00
376;060
F5039
F4720
Page 87
FRONT BRAKE CABLE
Throttle cable junction box clip to frame
Clip screw ...
Clip screw washer
CHp screw nut
External replacement condenser
(Coil bracket co C.B. terminal)
A
HEADLAMP AND WIRING HARNESS TR6 & T120
E4515
34289
F5020
F5021
54930007
54930000
58878
36296
E3050
H1413
58934
862217
54931221
70163
F4771
GS299
F3799
Switch cover (for 41 SA switch)
Lighting switch (88 SA)
left switch bracket
Right switch bracket
Replacement harness socket (Lighting)
(To convert from 41 SA switch to 88 SA type)
Harness (incorporating head lamp plug and 88 SA switch socket
with Lucas stop switch connectors)
Headlamp with 2 AR ammeter and socket connection
Ammeter 2 AR
Ammeter rubber sealing ring (lucas 523968)
Ammeter blanking disc ...
Headlamp complete (with 2 AR ammeter)
Headlamp rubber grommet, cable entry
Harness (to suit 58934 Head lamp, 88 SA switch, 49072 rectifier
and 34381 stop lamp switch) deleting plug and socket at
headlamp 018419 onwards ...
A
1
A
A
1
1
1
A
1
1
1
1
1
1
1
A
A
1
A
A
1
1
1
Serrated washer
2
1
2
2
Nut. horn foxing bolt
2
2
Horn, type 8H
Horn fixmg bolt
2
6
Page 91
SPEEDOMETER, TAIL LAMP AND RECTIFIER
6T
SC3304:24
SC3304;25
SC5301j09
SC5301;16
SC5301i26
SC5301:1a
Speedometer
Speedometer
Speedometer
Speedometer
Speedometer
Speedometer
34381
F4844
49072
F533B
54942078
54190042
Stop lamp switch (Lucar connectors)
Crinkle washer (Rectifier leads- for 47132 rectifier)
Silicon rectifier (D18419 onwards)
Rectifier fixing nut (Lucas 156596)
head
head
head
head
head
head
(125
(190
(125
(190
(140
(240
m.p.h.)
k.p.h.)
m.p.h.)
k.p.h.)
m.p.h.)
k.p.h.)
(D7727 onwards)
)
(
(
)
(
)
(
)
"
(
)
T120
A
1
A
..
1
A
.
1
3
1
1
Lucar Terminal (service conversion)
3
Lucar Terminal cover (service conversion)
3
7
TR6
1
1
3
1
1
3
3
1
3
1
1
3
3
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