User manual | re· place me nt parts catalogue

,

20-10107

C

RE · PLACE ME

NT

PARTS CATALOGUE

--

No. 4

From Engine No.

DU

24875

THUNDERBIRD 6T

TROPHY TR6

BON

.

NEVILL · E T120

British Only

MOTORCYLES AND PARTS INC.

32451 PARKLANE ST.

GARDEN CITY, MI 48135 USA

WWW.BRITISHONLY.COM

[email protected]

RETAIL: 1-800-278-6659 WHOLESALE: 1-800-852-9253 FAX: 1-734-422-9253

WORLDS LARGEST SELECTION OF FACTORY ORIGINAL NEW AND USED PARTS

45,000 SQ. FT. OF MOTORCYLE PARTS & ACCESSORIES FROM 1911 TO 1984 FOR ALL BRITISH MAKES!

CASH FOR ALL BRITISH BIKES, PARTS AND LITERATURE

SPECIALIZING IN

VINTAGE MOTORCYLCE PARTS

THE BIGGEST!

ENGINE REBUILDING PARTS

GASKET - SEALS - BEARINGS

BUSHINGS - PISTONS - RINGS

CLUTCHES - TUNE UP PARTS

SPEED EQUIPMENT

THE BEST!

STOCK AND CUSTOM PARTS

SEATS - HANDLEBARS - CHAINS

TIRES - TUBES - EXHAUST PIPES

MUFFLERS - GAS TANKS - FENDERS

RESTORATION PARTS

THE ONLY!

VELOCETTE ANDOVER NORTON TEC HAYNES P&P SEATING WASSELL MORGO

ALPHA BEARINGS M.A.C. PRODUCTS JOE HUNT MAGNETOS J.J. CABLES BUCHANAN’S

L.A. SLEEVE MEGACYCLE CAMS T.J. WASSELL LIMITED SUDCO INTERNATIONAL

ACE CLASSICS LONDON CLASSIC GASKETS BRITISH WIRING PBM ENGINEERING

TRI-COR ENGLAND LEAK PROOF SEALS MCA (ASTON) LIMITED GARDNER - WESTCOTT

WE ACCEPT VISA - MASTERCARD - DISCOVER - AMERICAN EXPRESS

PARTS SHIPPED WORDLWIDE !!!

VISIT OUR EBAY STORE http://stores.ebay.com/British-Only-Motorcycles-And-Parts

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 repair free of charge any part proved within six months of the date of purchase of any new machine,

(three months overseas) or within three months of its renewal or repair in the case of a part already renewed or repaired, to be defective by reason of our faulty workmanship or materials. We do not undertake to bear the cost of fitting such new or repaired part or access .

cry.

4. Any part considered to be defective must be sent to our Works, carriage paid, accompanied by the following information:-

(a) Name of purchaser and his address;

(b) Date of purchase of machine;

(c) Name of dealer from whom the purchase was made;

(d) Engine number and model.

5 . This Guarantee shall not extend to defects or damage appearing after misuse, neglect, abnormal stress or strain, or the incorporation or affixing of unsuitable attachments or parts and in particular:-

. (a) Hiring out;

(b) Racing and Competitions;

(c) Adaptation or alteration of any part or parts after leaving our Works;

(d) The attaching of a sidecar in a manner not approved by us or to an unsuitable motor cycle.

This Guarantee shall not extend to machines whose trade mark, name or manufacturing number has been altered or removed, or in which has been used any part not supplied or approved by us, or to tyres, saddles, chains, speedometers, revolution counters and electrical equipment or to parts supplied to the order of the Purchaser and different from our standard specification. ·

6. Our liability and that of our dealer who sells the machine, shall be limited to that set out in this guarantee, and no other claims including claims for consequential damage or injury to person or property, shall be admissible. All other conditions and warranties statutory or otherwise and whether express or

Implied are hereby excluded and no guarantee other than that expressly herein contained applies to the machine to which this Guarantee relates or any accessory or part thereof.

7. We reserve the right to modify or deviate from the Published Specification without notice .

REPAIRS GUARANTEE

1. Whilst the highest standard of workmanship and materials is aimed at, we cannot accept liability for any defects appearing more than three months after the machine, assembly or component has left our

Works after being repaired.

2. We will repair or replace at our option free of charge any defective work , materials or parts relating to the repairs carried out by us appearing within that time but shall not be under any further or other liability for any other loss or damage whether direct or consequential and our liability shall be limited to the cost of so making good. We do not undertake to bear the cost of fitting any replacement or repaired part.

3. We do not accept liability in respect of parts of proprietary manufacture, e.g. tyres, saddles, chains, speedometers, revolution counters and electrical equipment which may be used by us in effecting a repair. All other conditions and warranties statutory or otherwise expressed or implied are hereby excluded .

3

ILLUSTRATION INDEX

24

25

26

27

28

29

30

31

32

14

15

16

17

18

19

20

10

11

12

13

21

22

23

1

2

3

4

5

6

7

8

9

38

39

40

33

34

35

36

37

F

i

g

. No.

Descr

i

pt

ion

CRANKSHAFT AND CONNECTING RODS

CRANKCASE

OIL PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS

CYLINDER BLOCK AND HEAD, 6T AND TR6

CYLINDER BLOCK AND HEAD, T120

TIMING COVER AND CONTACT BREAKER

GEARBOX INNER COVER AND SELECTORS

GEARBOX SHAFTS AND GEARS

GEARBOX OUTER COVER

CLUTCH ...

CHAINCASE AND CHAINS

FRAME

SWINGING FORK AND SUSPENS I ON UNITS

ENG IN E UNIT FITIINGS AND FOOTRESTS

EXHAUST PIPES AND SILENCERS ...

EXHAUST PIPES AND MUFFLERS (U.S.A.)

TELESCOPIC FRONT FORKS, 6T

NACELLE HEADLAMP AND SWITCHES ...

TELESCOPIC FRONT FORK, TR6 AND T120

TELESCOPIC FRONT FORK , U.S.A. TR6C AND T120TI

FRONT WHEEL, 6T AND T120

FRONT WHEEL, TR6 AND U.S.A. T120

REAR WHEEL ...

QUICKLY DETACHABLE REAR WHEEL

PETROL (GAS) TANKS

OIL TANK

BATIERY CARRIER AND AIR FILTERS

PANEL AND TWINSEAT

MUDGUARDS (STANDARD ) ...

FENDERS (U.S.A.)

HANDLEBARS AND CONTROL LEVERS

CONTROL CABLES AND AMER I CAN HANDLEBARS

TOOLKIT , FRAME LOCK, PILLION FOOTRESTS AND LICE N CE HOLDER

AMAL .

CAR.BUR.ETIER, 6T

AMAL C}\RBUR.ETIER., TR6 AND T120

AMAL CAR.BUR.ETIER, T120TI

SPEEDOMETER AND TACHOMETER

A.C. MAGNETO IGNITION COILS AND DIRECT LIGHTING ...

D.C. IGNITION COILS, HORN, RECTIFIER. AND ZENER DIODE

HEADLAMP, WIRING HAR.NESS

, SW I TCHES AND TAIL LAMP

Page

No.

82

84

.

: >

~ ; 86

88

90

92

94

96

98

58

60

62

64

48

50

52

54

56

34

36

38

40

42

44

46

20

22

24

26

28

30

32

66

68

70

72

74

76

78

80

4

·'

· 1

..

. 1

AIR FI L TE R

A LTE R NAT O R .

.

.

B A TIER Y C A R RI ER

..

.

C ARBU RE TI ER

CAR T ON P ACKS

CENTR E S T AN D

CHAIN CAS E

CHAINS

CLU T C H

CO IL

C O N T AC T B R E AK E R

CO NTR O L CAB LE S

CON TR OL LE V E RS

C R ANKCAS E

...

CRANKSHA FT ...

CY LI N DE R H E AD

E NG INE PLA T ES

E X H A U S T P IP E S

FEN D E RS

F OO T R E STS

F RO NT F ORKS

F RO NT W HEEL

G A S T A N KS

G A S KET S ET S .

.

.

G E AR B OX

H A NDLEB ARS ...

H O RN

...

Page

73

... 2 1, 41

INDEX

MA N IFO L D

MUD GU ARDS

M U FFLE RS

73

N AC E LLE

87, 89, 91

1 6

43

4 1

41

3 9

..

. 95 , 97

3 1

83

8 1

23

21

... 27, 29

OI L P UMP

O IL T ANK

PET ROL T ANK

PI L LI ON F OOTR E STS

P I S T ONS

PROP S T AND

Q.

D . R E A R W HEE L

R E A R P ANEL

...

RE AR W H EE L ...

R E C TI FIER

4 7

..

. 49, 5 1

4 7

47

5 3, 57, 59

... 61 , 6 3

S I LENC E RS

SPARK P LUGS

SP EED OMET E R

S TEE R IN G RAC E S

S U S PE NS I ON U NI T S ..

.

SW IT C HE S

TIM I NG G E A R S

T OOLK I T

TW LN S E A T

69

1 7

33 ,3 5, 37

VALV E S ...

W IR ING H ARN E SS

..

. 81, 8 3

5 5 , 9 5, 97

ZENE R DI OD E

Page

25

77

51

49

97

93

43

4 5

... 55, 99

2 1

85

75

75

65

97

. .. 27 ; 29

5 5 , 95, 99

69

85

2 1

43

67

5 5

25

71

97

5

MODEL GROUPING CHART

Basic 650 c.c. (40 cub. in.) model

Parts common to all models are listed without comment in the "Remarks" column

I

6T

TR6

T120

Model specified in

"Remarks" column also includes sub-groups below.

U.S.A. 6T

(Eastern only)

I I

TR6R

' - - - - - - . . . l

Eastern

TR6C

Western

TR6C

T120R

I

T120TT

Parts unique to particular models are indicated by model number in the "Remarks" column.

6

I

;

T H U N D E R B I R D (6 T) T E C H N I CA L DAT A

Bore and stroke

Capacity ...

Compression ratio

Sparking plugs

Carburetter

Gearbox sprocket

Chains

Capacities

Brakes

Tyre size ...

Main jet

Needl e jet

Needle ...

Throttle valve

Pilot Jet .

..

Solo

Sidecar

Front

Rear

Fuel Tank

Oil Tank

Gearbo x

Primary Chaincase

Front Forks (each le g)

Front, diameter ...

Rear, diameter

Front

R ea r

Solo

Sidecar

7

71x82 mm.

2·79x3·23 ins .

649 c .

c . (40 cu. ins.)

7 .

5: 1

Champion N4

Amal Monobloc 376

230

· 106

Type C

376 / 4

25

20 teeth

18 teeth f'

Duplex x 84 lin ks j''xr'x 103 links j''xf' 'x 102 l i nks

4 galls. (18 litres)

5 pints (2 ·8 litre s ) t pint (500 c.c.) i pint (350 c.c

.

) r pint (190c.c.)

8 " (20·32 ems.)

7" (17 ·7 8 ems .)

3·25x18

3 ·50x18

U

.

S

.

A. THUNDERBIRD

(

6 T) TECHNICAL DAT A

Bore

and stroke

Capacity

...

Compression ratio

Sp

ark

plugs

Ca

r

bureter

Gearbox

sprocket

Chains

Capacities

Brakes

Tire size

Main jet

Needle jet

Need

l

e ...

T

hrott

l

e valve

Pilot Jet ..

.

Fr ont

Re ar

Gas

T

ank

Oil Tank

Gearbox

Primary Chaincase

F

ront Fo

r

ks (each leg)

Front, d iameter ..

.

Rear, diameter

Front

Rear

8

71 x

2·79 x

649 c.c

.

82 mm

.

3·23 ins.

(40 cu. ins.)

7.5: 1

Champion N4

Ama

l

Monobloc 376

270

· 106

Type C

376 / 4

25

1

8 teeth

·r

Duplex x 84 lin ks

i"

x f

"

x 102 links

3! U .S. galls. (16 litres)

6 U.S

.

pints (2

·

8 lit

r

es) t pint (500 c.c.)

i

pint (350 c.c.) t pint (190 c.c.)

8

11

(20

·32

ems.)

7" (17·78 ems.)

3·25

X

18

3·50

X

18

-

I ,

Bore and stroke

Capacity

...

Compression ratio

Sparking plugs

Carburetter

Gearbox sprocket

Chains

Capacities

Brakes

Tyre

size ...

T R O P H Y (T R 6) T E C H N I C A L D

A

T A

Ma i n jet

Needle jet

Needle ...

Throttle valve

Pilot Jet ...

Front

Rear

Fuel Tank

Oil

Tank

Gearbox

Primary Chaincas e

Front Forks (each leg)

Front, diameter ...

Rear, diamete r

Front

Rear

9

71 x 82 mm.

2 ·79 x 3·23 ins.

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

8·5:

1

Champion N4

Amal Monobloc 389

310

·106

Type D

389 / 3t

25

19 teeth r'

Duplex x 84 links i " xf'x103 links

4

galls. (18 litres)

5 pints (2·8 litres) t pint (500 c.c.) t pint (350 c.c.) t pint (190 c.c.)

8

in. (20·32 cm.)

7 in. (17·78 cm .)

3·25

X

19

4•00

X

18

U. S . A . T R O P H Y

( T R 6 R ) T E C H N I

C A L D AT A

Bor e a nd st roke .

..

Cap a ci t y ...

Compres si on rati o

Sp ark p l ugs

C a rbur e ter

Ge a rbo x sp r o c k e t

Cha i ns

Capacit i es

Br a kes

T i re size ..

.

Ma in jet

Needle jet

Needle

.

..

Throttle val v e

Pilot jet ...

Front

Rear

Gas Tan k

O il Tan k

Gearbox

Pr im ary Cha i ncase

Front Forks (each leg)

F r ont , diamete r ..

.

Rear. d i ameter

F ront

Rea r

71 x 82 mm .

2 · 79 x 3 · 23 ins.

649 c.c

. (4 0 cu. ins.)

8·5 : 1

Cham p ion N4

Amal Monobloc 389

310

· 106

Type D

389 / 3 t

25

19 teeth i " Duplex x 84 links f"xi " x103 links

3 !

U .

S . galls. (16 litres)

6 U.S

. pints (2·8 litres) t pint ( 5 00 c .

c .

) i pin t (350 c.c

.) t pint ( 1 90 c.c.)

8 " (20·32 cm.)

7"

(17·78 c m .

)

3 • 2 5

X

19

4 · 00

X

18

10

-·

-··--~ -· ·

--

·-·-·~ ·--·· · -·

-

-

--------·-·--------

_., i. t

I

E A ST E R N U. S. A. T R O P H Y (T R 6 C) T E C H N I C A L D AT A

Bore and stroke ..

.

Capacity ...

Compression ratio

Spark plugs

Carbureter

Gearbox sprocket

Chains

Capacities

Brakes

Tire size ..

.

Ma in jet

Needle jet

N eedle ...

Throttle valve

Pilot jet ..

.

Front

Rear

Gas Tank

Oil Tank

Gearbox

Primary Chaincase

Front Forks (each leg)

Front , diameter ...

Rear , diameter

Front

Rear

11

71 x

82 mm.

2 · 79 x 3·23 ins.

649 c .

c. (40 cu. ins.)

8·5 : 1

Champion N4

Amal Monobloc 389

310

· 106

Type D

389 / 3t

25

18 teeth

i

·

Duplex x 84 l i n ks

·

r

X f

"

X

103 links

2} U.S. galls. (11 litres)

6 U .S. pints (1·8 l it re s)

-k

pint (500 c .c.) i pint (350 c.c

.

) t pint (190 c.c.)

8 " (20·32 cm.)

7"

(17·78 cm.)

3·25

X

19

4·00

X

18

Brakes

Tire si z e

WESTERN U .

S .

A . TROPHY ( TR6C) TECHNICAL DATA

Bore and stroke ...

Capacity

...

Compression ratio

Spark plugs

Carbure t er

Gearbo x sprocket

Cha i ns

Capacities

Main jet

Nee d le jet

Needle ...

T hrottle va l ve

Pilot jet .

.

.

F ront

Rear

Gas T ank

Oi l T ank

Gea r box

Primary Chaincase

F r ont Forks (each leg)

Front, diameter ...

Rear , diamete r

Fr o n t

Rear

2 ·

71

79 x82 mm. x

649 c.c. (

3

4

8·5 :

· 23

0 cu

1 i ns

. i

. ns.)

Champion N4

Ama l Monob l oc 389

310

· 1 06

T ype D

389 / 3t

2 5

17 teeth j" Duplex x 84 l i nks i

"

x

% x 102 l inks

3 .} U .

S. gal l s. (16 l itres)

6 U .S. pints (2·8 litres) t p int ( 5 0 0 c .

c.)

i

p i nt (350 c.c.) t pint (190 c .

c .

) a ~

(20·32 cm.)

7 n

(17 ·78 cm .

)

3 ·2 5

X

1 9

4·00

X

18 t

'

'

I

..

. I

I

I

1

I r

!

I

B O N N E V I L L E 1

2 0

(T

1 2 0)

T E C H N I C A L D A T A

Bore and stroke

Capacity

.

..

Compression ratio

Sparking plugs

...

Carburetters

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, diameter ...

Rear, diameter

Front

Rear

13

71x82 mm.

2

· 79x3 · 23 ins.

649 c.c

.

(40 cu.

ins,)

9 : 1

Champion N4

2

Amal Monobloc

389

260

·106

Type D

389

/

3

25

19 teeth f"

Duple

x x

84

links f ' x f ' x

103 links

4 galls.

(18

I itres)

5

pints (2

·

8 litres)

f

pint (500

c.c

.) i pint

(350 c.c.)

r

pint (190

c.c.)

8 in.

(20·32 cm .

)

7

in.

(17 · 78

cm.)

3

•

25

X

18

3•50

X

18

U.S. A. BON NEV ILLE 120 (T 120 R) TECH NI CAL DAT A

Bore and stroke ...

Capacity ...

Compression ratio

Spark plugs

Carbureters

Gearbox sprocket

Chains

Capacities

Brakes

Tire size

.

..

Ma in jet

Needle j et

Needle ...

Throttle valve

Pilot jet ...

Front

Rear

Gas Tank

Oil Tank

Gearbox

Pr im ar y Chaincase

Front Forks (each leg)

Front , dia m eter ...

Rear , d ia meter

Front

Rear

14

71 x82 mm.

2·79 x 3·23 ins.

649 c.c. (40

9 : 1

cu :

i ns.)

Champion

2 Ama l Monob l oc 389

260

·106

Type D

389 / 3

25

19 teeth

t"

Duplex x 84 links t" x t

"

x 103 links

2j U.S. galls. (11 l i tres)

5 U.S. pints (2·8 litres) i pint (500 c.c.)

i

pint ( 350 c.c.) t pint (190 c.

c .

)

8 " (20·32 cm.)

7 " (17·78 cm.)

3·25

X

19

4 ·0 0

X

18

N4 i .

~

! •

U. S . A . B O N N E V I L L E 1 2 0 ( T 1 2 0 TT ) T E C H N I C A L D AT A

Bore and stroke ...

Capacity

...

Compression ratio

Spark plugs

Carbureters

Gearbox sprocket

Chains

C a pacities

Brakes

Tire size

.

.

.

Main jet

Nee d le jet

Needle ...

Th rottle va l ve

Pilot jet ...

Front

Rear

Gas T ank

O il Tank

Gearbox

Primary Chaincase

Fr o n t Forks (each leg)

Front, d iam ete r .

..

Rear, diameter

Front

R ear

15

71 x 82 mm .

2·79 x

3 · 23 ins.

649 c.c.

(40 cu. ins.)

11 :

1

Champion N58R

2 Amal Monobloc 389

330

· 10 6

Type

D

389 / 4

25

17 t eet h f

Duplex x 84 l inks

t"

x f' x

1 02 I i n ks

2&

U .

S . ga ll s.

(11 li tres)

6

U.S. pints (2·8 litres)

fr

pint ( 5 00 c.c.) i pint (350 c.

c.) t pint (190 c .c

.

)

8 " (20 ·32 cm.)

7" (17·78 cm.)

3·25

X

19

4 · 00x18

~'

i~

I.,'"""".,,_~~~ ~ ~-

Pa r t No.

CARTON PACK LIST

The followi n g sub assemblies a r e supplied in carton packs unde r the C.P

. part n u mber st _ The contents o f these carton packs are preserved and will not deteriorate u n der adverse conditi o ns .

Contents

B r ake Lining

C.

P .

38 / A.M.2 ...

C.P

.

205 ...

2

1 6

2

1 6

NW243

W129

W1734

W129

Br ake li n ing

Rivet

Brake lining

Rivet

P i s t ons

C.P.199 ... 1

2

1

1

E4899

E 3049

E2898

W E 203 E

2 W E 479 ...

C.

P .199 is also a v ailable in 0·010 in .

, 0·020 i n . and 0 · 040 i n . o v ersizes.

C.P.200 .

.. 1 E 5329

2

1

E3049

· E 2898

1

2

WE203E

WE479

...

C.

P. 200 is also available i n 0·010 In., 0 · 020 in. and 0 ·0 40 i n . oversizes.

C.P

.

206 ... 1 E6341

2

E3049

E2898

WE203E

1

2 WE479 ...

C.P.206 is also avai l able in 0·010 In.

, 0·020 in. and 0·040 in . oversizes .

C.P

.

202 ... 1

2

1

1

2

E 581 9

E 304 9

E2898

WE203E

W E 47 9

...

Piston Rings

C.

P. 99

..

.

4

2

.

.

.

...

.

.

.

E 3049

..

.

E 2898

C.P. 9 9 is also available in 0·0 1 0 in., 0 ·020 in. and 0·040 in. oversizes .

Piston C.R. 7 · 5 : 1

Compress i on ring

Oil c ontro l ring

Gudgeon pin

Circl i p

P i ston C.R. 8 · 5 :

1

Compression ring

Oil control ring

Gudgeon pin

Circlip

Piston C.R. 9: 1

Compression ring

Oil contro l ri n g

Gudgeon pin

C i rcl i p

Pisto n C.R. 1 1 : 1 (Alcoho l fue l )

Compress i on ring

Oil control r i ng

Gudgeon pin

Circl i p

Compress i on ring

Oil control ring

16

CA RT O N PAC K LI ST

continued

Part

No.

Valve springs

C.P.188 ...

4

4

Valves

C.P.173

(6T, TR6)

2

2

Valve Guides

C.P.97

(6T, TR6)

2

2

De-coke Gasket Set

All models ...

Contents

E4221

E4222

E3310

E3927

E2899

E2900

Inner spring (Red spot)

Outer spring (Red spot)

Inlet valve

Exhaust valve

Inlet guide

Exhaust guide

D / GS1

HOW TO USE THIS PARTS CATALOGUE

First check that the engine number of your machine is subsequent to that quoted on the title page.

Next cor.1sult the index on Pa ge 5 for the parts or g roup of parts which you wish to locate. When you have located the p arts make sure from the end columns that the part you have located does apply to your machine.

List the qu antit i es required as single units; do not ask for "2 pairs" or '.'3 dozen".

In case of painted ite ms always state the co l ou r required. Painted parts are available only in the colours or alternatives s pecifie d for that model of that particular yea r.

Model

Colour

6T

BL ACK / SILVER

U.S.A. 6T GRENADIER

RED / ALASKAN WHITE

TR6

PACIFIC BLUE /A LASKAN WHITE

T120

GRENADIER RED / ALASKAN WHITE

Suffix Letter

to

Part

No.

W

GR

PB

GR

/

/

/

/ V

AW

AW

AW

N.B. Pacific Blue Is a flamboyant finish applied over Silver Sheen.

Paint is available also in all colours in

! pint or 1 gallon tins, or Aerosol containers.

17

PLEASE NOTE

THROUGHOUT THI S LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS

INCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN, REVERTING

TO THE ORIGINA L 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 TR I UMPH SER.VICE DEPARTMENT. IN MOST CASES

THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE, AND

THEREFORE, I T IS NOT RECOMMENDED THAT THE PRIVATE OWNER. PURCHASES THE TOOLS IN

ORDER. TO AID SER.VICING THE MACH I NE ONCE OR TWICE ONLY . IN THESE CIRCUMSTANCES

IT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.

.

I

I

·

I

I

. I

1

·

i

11 i.l ti

!

\ i i

· 1

1

' l

~

1 8

TRIUMPH SPARES

HOW TO ORDER.

Every part is indicated by a number, and this should be quoted together with the description. In order to assist customers, dimensions have been given in many cases where parts are similar. Parts where p ossible have been listed in order of assembly and a number of the i llustrations show the assembly order also. With these aids, there should be no difficulty in identifying the parts you require .

ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OF

THE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETIERS.

WHERE TO OBTAIN.

Triumph Spare Parts can only be obtained from an authorised Triumph

Dealer, and we recommend our customers to place their orders with the Triumph Dealer in their district.

When parts not usually asked for are required, and for which the Dealer may have to write or obtain specially, the postage or carriage incurred becomes payable.

TRIUMPH SPARES ARE NOT SUPPLIED TO PRIVATE OWNERS DIRECT FROM THE FACTORY.

A LIST OF AUTHORISED DEALERS WHO STOCK TRIUMPH SPARES IS AVAILABLE ON REQUEST.

IF DIFFICULTY IS EXPERIENCED IN OBTAINING THE REQUIRED PARTS, THE MATTER SHOULD

BE TAKEN UP DIRECTLY WITH THE TRIUMPH SPARES DEPARTMENT.

Customers are warned against the risk incurred by purchasing parts that are not of genuine Triumph manufacture. This risk is eliminated if parts are ordered as instructed from recognised Dealers. .

PATTERNS AND PARTS FOR REPAIR.

It is not necessary to send patterns if the part number is quoted . The sending of patterns often delays the order as parcel post or rail takes longer than letter post .

Part s sent to Coventry for r epair, replacement , or as patterns should be a r the sender's Name and

Address and clear i nstr uctions should accompany the parts . In your own interest send a cop y of the advice note under separate cover. All parts must be forwarded carriage paid and care should be taken to ensure that all re m itta nces 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 shou ld have all fitments such as windscreens, driving mirrors, tools, etc., removed by the sender before despatch, as it is impossible for u s to accept responsib ility in the event of loss in transit. We are always pleased to give estimates for overhauling and repairs, but should an estimate not be accepted, a charge will be made covering cost of dismantling and re-assembling, if carried out.

Communications rel ati ng to Parts should be addressed to the SPARES DEPARTMENT and for repairs, guarant e e cla im s and technical advice t o the SERVICE DEPARTMENT , Tr iump h Engin ee ring Co. Ltd.,

M e;iden Works, Allesley, Coventry. In order to facilitate quick reference, the quoting of any number, in vo ice num ber or reference from pre v ious communications i s essential. Accessories not of our manufact ur e should be sent direct t o 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 th e manufacturers and not by ourselves . Any repairs or cl aims should be directed to th e actual makers or their local agents who will always · give owners every possible ass istan ce . The following are th e addresses of the var ious manufacturers:-

CARBURETTERS.

Messrs. Amal Ltd .,

Holdford Road,

Witten,

Birmingham , 6.

Th e Avon Indi a Rubber Co. Ltd .

,

Melksham,

Wilts.

CHAINS.

R en old Chains Ltd .,

Wythenshawe,

Manchester.

SPARKING PLUGS.

Champion Sparking Plug Co. Ltd .

,

Feltham,

Middlesex .

ELECTRICAL EQUIPMENT .

Messrs.

J .

Lucas Ltd.,

Gt . Hampton Street ,

Birmingham, 18.

SPEEDOMETERS.

Messrs. Smiths Motor Accessories Ltd.,

Cricklewood Works,

London, N.W.2.

TYRES.

Dunlop Rubber Co. Ltd .

,

Fort Dunlop,

Birmingham, 24 .

SUSPENSION UNITS .

Messrs. Girling Ltd ..

Birm i ngham Road,

West Bromwich ,

Staffordshire .

19

17 16 17

~ ~ -14

~~~

14

_,..,,,.;;;~ - - - - - - 1 5

' t - - - - - - - - - 1 3

31 31

10-f

- t - - - - - - - - 8

- - - 13

, ! - - - - 9

27 - - ----'

26 - - - - - '

41 19

2 0 21 22 23

24 2 5

Fig. 1. CRANKSHAFT AND CONNECTING RODS

20

..

,j,

' y

1

'

6

7

8

9

10

11

12

13

13

13

13

H

15

20

20

21

21

16

1 7

18

19

22

23

23

24

25

26

33

34

35

35

36

36

37

38

39

40

41

-42

27

28

29

30

31

32

1

2

3

4

5

Ref. No. Port No.

DESCRIPTION

QUANTITY REMARl<S

CRANKSHAFT AND CONNECTING RODS

E3049

E2898

WE203E

WE479

E1591

E3876

E5446

E5450

E4573

E4912

E3974

54213901

54215824

E3975

E3977

E1580

E4564

E4565

E6159

E400

E4562

E1558

E6326

E4643

E3903

E3905

E6327

* E6328

E3114

E3606T

E1511

E2490A

E2922

E3586

CP199

CP200

CP206

CP202

E1463

E4563

E4818

E4819

E4848

E4855

E4700

E5316

E2256

E3300

E2879

E4913

*

Use D524 L oct ite Sealant

CRANKSHAFT AND FLYWHEEL ASSEMBLY

CRANKSHAFT C / W. OIL TUBE

Oil tube

Screwed plug

Fly whee l ...

Flywheel bolt

Crankshaft stud (1f' O.A.)

CONNECTING ROD

Small end bush

Connecting rod bolt

Self locking nut ...

Big end bearing

PISTON COMPLETE 7·5 : 1 C.R.

PISTON COMPLETE 8·5 : 1 C.R.

PISTON COMPLETE 9 : 1 C.R.

PISTON COMPLETE 11 : 1 C.R.

Taper compression r ing ...

Oil control ring

Gudgeon pin

Circlip

Main bearing, right

Oil seal ...

Engine sprocket, 29 teeth Duplex

Engine sprocket, 29 teeth Duplex

Distanc e piece

Distance piece ...

Rotor ke y

Rotor, type RM19

Rotor, t ype RM19

.

.-i

Tab washer

Nut

Key

Timing pinion

Nut

INTERMEDIATE WHEEL

Intermediate wheel bush ..

.

Camshaft wheel .. ;

Camshaft key ...

Inlet camshaft nut

Exhaust camshaft nut

Inlet camshaft .

. .

Inlet camshaft .. .

E xhaus t camshaft

EXHAUST CAMSHAFT

Tachometer drive thimble

Rotary breather valve .. .

Breather valve spring .. .

Clamping washer

M ain bearing, left

Dowel ...

1

1

3

1

2

2

4

4

2

2

4

1

4

2

6T

2 TR6

2

T120

&

T12 0R

2

T120TT

4

1

1

1 A.C. Ignition

1

1

A.C. I gnition

1

1

1 A.C. I gnition

1

1

1

1

1

1

1

2

2

1

1

1 6T

TR6

&

T120

1 6T

TR6 & T120

1

1

1

1

1 A.C. Igniti on

21

"':"-:..:

..... ,.

..

~

18

F i g. 2 . CRANKCASE

~'Lr~

r f

~ s t

~

.

{

-

•

;

'

.

..

' i

! i

;

'

~!

'

...

: ·

•l

!

~

-,

;:' t,

· · t!

f.,;.

:,,

;,

i .

J,

L _ __

19

20

21

22

23

24

10

11

12

13

14

15

" 16

17

18

7

8

9

4

5

6

1

2

3

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

Ref. No. Part No.

DESCRIPTION

E4540

E4098

E4856

E2888

S25-3

S1-51

E5312

E5315

E5375

T1112

T1257

T361

E2441

E6347

T1738

T1920

E732

NE507

E5616

E6386

E4539

F1880

E4706

E697

E5976

E375

E3717

E672

E3523

E1534A

E4541

E5871 / 6303

E3716

E5232 ·

E4542

S25-2

P0172A

GS87

E2724

E2260

E1516

E1479

CRANKCASE

CRANKCASE

...

Hollow Dowel

Screw

(;1

In. U.H

.

)

Stud (4t in. O.A.)

Plain washer

Nut

Breather disc

Breather pipe

Inlet camshaft bush

Exhaust camshaft bush

Camshaft bush

Blanking plug

Locating peg

Oilway plug

Copper washer

Tachometer drive plug

Fibre washer

Chain tensioner abutment

Intermediate wheel spindle

Oil pipe stud (1t in . O.A.)

Cylinder stud (11 in. O.A.)

Cylinder stud (1i in . O.A.)

Hollow dow e l

Bolt (2t in . U.H

.

)

Bolt (1-! in . U.H.)

Bolt (1-j in. U.H.)

Stud (5-ft in. O.A.)

Stud (3-j in . O .

A.)

Plain washer

Nut

Crankcase filter ...

Copper washer

Breather e x tension pipe

Drain plug (with level tube) ..

.

Fibre washer

Level plug

Copper washer

Drain and adjuster · plug

Fibre washer

Blanking plug

Filler plug

Fibre washer

...

23

QUANTITY

REMARKS

1

1

1

1

1

3

11

8

1

1

1

2

2

1

1

1

1

1

6

1

1

2

2

2

2

1

1

1

1

1

1

1

2

2

2

1

2

1

1

1

2

Not serviced

6

7

8

4-

ASSY

1

12

11

ASSY13

16

26 - - - -

2 7 - --,.

2 5 - - - - . .

I

0

I

1 0

9

1 - - - - - - 1 9

5

3

9

;·l ,

~

I

I

+ - - - - -

21

- - - - - - - - 2 2

Fig . 3. OIL PUMP, RELEASE VALVE, MANIF<;)LD AND TAPPETS

24

I· i

I

I

I

I

1 ; j '.

"

I l

'

I

11

12

13

14

7

8

9

10

15

16

17

18

19

20

21

22

23

24

4

5

6

1

2

3

25

26

27

28

29

30

31

32

33

34

34

35

35

;·

Ref. No .

Part No. DESCRIPTION QUANTITY

REMARKS ·

01 L PUMP, RELEASE VALVE, MANIFOLD AND TAPPETS

E5896

E2794

GS251

E2304

GS254

E6062

E16 70

E2973

E3334

E3878

E3731

GS153

E1476

E495

S70-7

E403

E2360

E3730

E3718

E3887

E3732

E3304

S25-13

W103

E2962

NA43A

E2968

S25-3

S1-51

E4676

E5861

E1612

H200

E3059

E3059R

E6329

E6490

OIL PUMP

Pump body ...

Feed plunger

Scavenge plunger ...

Dri ve block

Valve ball {a7

Valve spring

2 in. dia.)

Screwed plug

Joint washer

Oil pump stud (1 i5

6

Serrated washer

Nut i n . U.H.)

OIL RELEASE VALVE

Valve body

Piston

Cap ...

Fibre washer

Main spring

Fibre washer

Stud (1ft in. O.A.)

Joint washer

Inlet manifold

Plain washer

Nut

Stud (1* in . O.A.)

Joint washer

Insulating block

Plain washer

Nut

Inlet tappet guide

E xhaust tappet guide

Serra t ed washer

Set bolt ...

Inlet tappet

Inlet tapp e t

E x haust tappet · ...

E x haust tappet ...

1

4

4

1

4

2

2

1

1

2

2

1

1

2

2

2

6T, TR6

2 T120

2

6T , TR6

2

T120

1

1

1

1

1

1

2

2

1

2

2

2

1

1

2

1

1

1

25

21-----< 1 1l:i

3 3 - ---

25

2

4

3

F ig.4. c

YLINDER ' BLOCK

AND HEAD

•

6T AND TR6

26

24

28

30

29

5 i

!

! l

!

!·

I

L

I

I

I

' l

I

I

I

1

2

3

4

5

6

7

8

9

10

11

40

41

42

43

44

45

46

47

48

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

15

16

17

18

19

20

21

22

23

24

12

13

14

15

Ref. No.

Part No.

-

DESCRIPTION QUANTITY REMARKS

E6309

E6304

W76 .

P0172A

E2620

E6000

E3547

E4746

E4552

E2899

E2900

E5914

E3310

E3927

E5008

E6439

E4221

E4222

E1543

WE259A

E327

F2184

E4771

S25-3

E4547

E4550

E4551

E4549

E2980

F879

E3302

E2982

S25-13

E1596

E4610

E3751

E4609

WE170

T1553

E1457

E1458

E1483

E1513

E470

E1330

E1575

E1574

E1512

E3253

CYLINDER BLOCK AND HEAD, 6T AND TR6

Cylinder base washer ...

Cylinder block ...

Inner cylinder base nut

Outer cylinder base nut

Push rod

Cover tube

Rubber washer ...

Bottom cup

CYLINDER HEAD c/w GUIDES

Inlet valve guide .

..

Exhaust valve guide

Exhaust pipe adaptor

Inlet valve

Exhaust valve

Bottom cup

Bottom cup

Inner valve spring (red spot) ...

Outer valve spring (red spot)

Top collar

Split cotter

Cylinder head bolt (3j- in. U .

H .

)

Plain washer

Bolt (3 in. U.H

.

)

Plain washer

Cylinder head gasket

Inlet rocker box

Exhaust rocker box

Joint washer

Rocker box stud

(-ft in. O.A

.

)

Rocker box nut ..

.

Plain washer

Rocker box bolt (2-fr in. U.H.)

Plain washer

Cylinder head bolt (for torque stay)

Inspection cap ...

Joint washer

Locking spring ...

Fibre washer

Screw (f in. U.H.)

ROCKER (right exhaust, left Inlet) .. .

ROCKER (left exhaust, right Inlet) .. .

Rocker ball pin

Rocker adjusting pin

Adjuster lock nut

Thrust washer, i in.

Thrust washer, t in.

Spring washer ...

Rocker spindle

Sealing rubber ...

4

4

4

4

4

4

2

6

4

4

4

4

2

2

4

2

2

6

4

4

8

4

8

1

1

1

2

6

4

4

2

2

2

4 6T

4

TR6

4

4

1

6

4

2

4

2

2

2

27

38

4 8 - -

47--..leJI

@)

45 l

5044 50 44 45

31

33

~

35

~ - - - - -

34

5

!i

!

r ii f (

!

I

Ii

t

i

;t

I } l

!

!1

l·

\ '

I it

I t

!':

'

. t i f '

1 :

1 ·

! :

I

1

!·

!

1 i t

I

, tr .

"

Ir

!,

,' f ~

6

29

~

~ 8 fig . 5. CYLINDER BLOCK AND HEAD , T120

28

Ref. No. Part No.

E6309

E6304

W76

P0172A

E2620

E6000

E3547

E4746

ES348

E3827

E3828

E5349

E5350

E4791

E4792

E4608

ES914

E4603

E2904

E6439

E4221

E4222

E1543

WE259A

E327

F2184

E4771

S25-3

E4547

E4550

E4551

E4549

E2980

F879

E3302

E2982

S25-13

E1596

E4610

E3751

E4609

WE170

T1553

E1457

E1458

E1483

E1513

E470

E1330

E1575

E1574

E1512

E3253

13

26

27

28

29

30

31

40

41

42

43

44

45

46

36

37

38

39

32

33

34

35

47

48

49

50

51

52

53

21

22

23

24

25

14

15

16

17

18

19

10

9

10

11

12

1

2

3

4

5

6

7

8

DESCRIPTION

CYLINDER BLOCK AND HEAD, T120

Cylinder base washer ...

Cylinder block ...

Inner cylinder base nut ·

Outer cylinder base nut

Push rod

Cover tube

Rubber washer ...

Bottom cup

CYLINDER HEAD c / w GUIDES

Inlet valve guide ...

Exhaust valve guide

Carburetter adaptor, left

Carburetter adaptor, right

Connector .

..

Balance pipe

Adaptor locking nut

Exhaust pipe adaptor

Inlet valve

Exhaust valve ...

Bottom c .

up

Inner valve spring (Red spot )

Outer val v e spring (Red spot)

Top collar

Split cotter

Cylinder head bolt (3j in. U.H.)

Plain washer

Bolt (3 in. U.H

.

)

Plain washer

Cylinder head gasket

Inlet rocker box

Exhaust rocker box

Joint washer

Rocker box stud ( }t In. 0.A.)

Nut

Plain washer

Rocker box bolt (2-h In. U.H.)

Plain washer

Cylinder head bolt (for torque stay}

Inspection cap ...

Joint washer

Locking spring ...

Fibre washer

Screw

(i in. U.H.)

ROCKER (right exhaust, left inlet)

ROCKER (left exhaust, right inlet) ...

Rocker ball pin

Rocker adjusting pin

Adjuster lock nut

Thrust washer,

Thrust washer, f in. t in.

Spring washer ...

Rocker spindle

Sealing rubber .

..

29

QUANTITY REMARKS

6

6

4

1

1

2

6

4

4

4

4

4

4

4

2

.

2

4

4

4

2

6

4

2

2

4

2

1

{Use E5727 for

T120TT

2

2

4

4

4

2

2

1

2

2

2

2

2

8

4

8

1

1

4

4

4

1 iUse E5351 for

T120T T

1

Use ES352 for

T120T T .

1.

- - -.

9

10

01-----4

27 28

17

CONTACT BREAKER

ASSEMBLY REF. NOll

14

~ - - - 2 2

,~20

17

. . . . - - 22

CONTACT BREAKER

ASSEMBLY REF . N03Q

32

24 23

Fig . 6 . TIMING COVER AND CONTACT BREAKER

3 0

,~20

I

I

I

I

I

I

~ - --···

8

9

10

5

6

7

1

2

3

4

11

12

13

14

15

16

17

18

19

33

17

1 8

19

29

30

12

31

32

15

20

21

22

23

24

25

26

27

28

Ref.

No.

Part No.

I

DESCRIPTION

·

QUANTITY REMARKS

E456 7

E4016

D208-s )

E4568 '

E4569

E2615

E1335

T989

E3668

E3204

47605

425377

54441729

54415642

425359

54415751

425370

169194

54415803

E5451

S25-43

E4707

E4747

E655 9

E4571

E5049

GS299

F4715

E6348

47602

425377

54415473

54415641

425359

54415747

425370

169194

54415803

/

i

.1

T IM ING COVER AND CONTACT

Timing cover

Patent plate

...

Hammer-drive screw

; Oil seal ...

I

/ Circlip ...

Timing cover plug

Copper washer

Hollow dowel

...

Screw (1

1

5

6 ln. U.H

Screw (1 in. U.H.)

.

)

CONT ACT BREAKER, type 4CA

Condenser

Cam ...

Spring set ...

Weight

Sleeve and action plate

Base pl ate .

.

.

Slotted nut ...

Contact set

Bolt (2 in. U .

H.)

Plain washer

Rubber grommet

Pillar bolt

Plain washer

Cover

Joint washer

Serrated washer

Screw

(# in . U .

H.)

Hollow metering dowel

CONT ACT BREAKER , type 4CA

Condenser

Cam ..

.

Spring set ...

Weight

Sleeve and action plate

Base plate .

..

Slotted nut .

.

.

Contact set

"'.

/

/

...

BREAKER

1

1

4

1

1

2

2

1

1

1

3

5

1

2

2

1

1

1

1

1

3

1

2

2

1

1

2

2

2

1

1

1

1

2

1

;J

Coil Ignit io n models

AC.

Ig nition model

31

13

22

16

8

10

7.

3

17

18

~

I

I

6

4 s

11

12

14

!

I i

I l

I

I i

I

1

·

i l i i

'

I

' i

\ I

, ,

!

\ i

I

I

:

I

24

20 21

Fig . 7 . GEARBOX INNER COVER AND SELECTORS

32

11

12

13

14

15

16

5

6

7

8

9

10

1

2

3

4

21

22

23

24

17

18

19

20

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

GEARBOX INN ER COVER AND SELECTORS

E4535

T989

TSOO

T44

T373

T372

T260B

T913

NT261

T291

T1606

T1607

T2112

T1614

T412

HS

T397

T1896

5 in . x 1i in.

6 4

T1778

E3446

E3204

T1779

E3728

Stud (3 In . O.A.)

Hollow dowel

...

Gear selector camplate

Camplate index plunger

Index plunger spring

...

Index plunger holder ..

.

Mainshaft selector fork

Layshaft selector fork ...

Selector fork roller

Selector fork rod

Layshaft bearing

Thrust washer ...

GEARBOX INNER COVER

Layshaft bearing

...

Gearchange spindle bush ...

Kickstarter stop

..

.

Cam plate operating quadrant ...

Quadrant spindle

\

Split pin ...

Bolt (1f in. U.H.)

Plain washer

Screw (1 in. U.H.)

Socket screw (1! in. U.H.)

Countersunk screw

(#

In. U.H.)

1

2

1

1

1

1

1

1

2

1

2

4

1

1

1

1

1

1

1

1

1

2

1

1

33

15 16 17

12

13 14

26 25 24 23

3

J8 -

2

~

<U:::1

~===

---

19 ~

8

7

Fig . 8 .

GEAR&ox

SHAFTS

A

No

GEARS

·.

c. c . .

. • · cc

·

.

-

.

.•

: ..c.

,

_,

· ~' '--c.

·.~

-

11

- ·· -- - · · · · · · •

--

• · "'." ··

-

=

-·

·

4

-.,

Ref.

No.

Part

No.

3

6

9

11

12

12

12

12

12

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

8

9

10

11

5

6

7

1

2

3

4

T1952

T1953

T1916

T1917

T1918

T1919

T2116

T440

T448

T489

T946

S35-7

T280

T1962

T1963

T1250

T730

T731

T732

NT297

T1736

T914

PT108B

T1914

T1370

T917

T916

T926

T928

T1065

T930

T1843

T1912

T968

T974

T1844

6

7

9

10

11

1

3

5

T1177

T1910

T1179

T955

T961

T963

T964

T1845

DESCRIPTION 'QUANTITY REMARKS

GEARBOX SHAFTS AND GEARS

MAINSHAFT c / w LOW GEAR (16T)

Clutch rod bush ...

MAINSHAFT HIGH GEAR (26T) ...

High gear bush

Mainshaft third gear (24T)

Mainshaft second gear (20T)

LA YSHAFT LOW GEAR (30T)

Low gear bush

Layshaft second gear (26T)

Layshaft third gear (22T)

Layshaft c / w high gear (20T)

Gearbox sprocket (15 teeth) .. .

Gearbox sprocket (16 teeth) .. .

Gearbox sprocket (17 teeth) .

..

Gearbox sprocket (18 teeth) .. .

Gearbox sprocket (19 teeth) .. .

Gearbox sprocket (20 teeth) .. .

Tab washer

Gearbox sprocket nut

High gear bearing

Circlip .. .

Oil seal .. .

Mainshaft bearing

Circlip ...

Plain washer

Pinion sleeve

Pinion spring

Kickstarter pinion

Kickstarter ratchet

Tab washer

Nut

Clutch operating rod

WIDE RATIO GEARS

MAINSHAFT HIGH GEAR (28T)

Mainshaft s econd gear (19T)

Layshaft second gear (27T) ...

Laysha ft c / w high gear (1ST)

CLOSE RATIO GEARS

MAINSHAFT c / w LOW GEAR (1ST)

MAINSHAFT HIGH GEAR (24T)

Mainshaft third gear (23T)

Mains haft second gear (21T) ..

.

L AYSHAFT LOW GEAR (28T)

Laysh a~ second gear (25T) ...

La yshaft third gear (23T)

Layshaft c / w high gear (22T)

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

~

I

~

See pages 7 to

1 .

s for standard

1

1 j sizes

1

1

1}

Standard on

Eastern TR6C

35

43

42

45

46

47

44

17

I

16 w

°'

49

18

38 ~ - - - ~ - - - - - - - ~ -lEI

35

34

50

(§)

~

~

36 7

Fig. 9 .

GEARBOX OUTER COVER

13

14 15 10

~ 1 1

0...~

12

I 8

' - - - - - - 10

- - 39

-

46

47

48

49 so

11

12

13

14

7

8

9

10

15

16

17

18

19

1

2

3

4

5

6

20

21

26

27

28

29

30

22

23

24

25

42

43

44

45

34

35

36

37

31

32

32

33

38

39

40

41

Ref. No.

Part

No.

DESCRIPTION

T1986

T57

T23

T47

T454

T1956

T1955

T408 / 9

E3309

T404

T406

T405

T407

E1612

F879

T25A

T31

T24A

T1707

T1708

T1710

T1771

T1711

T1712

GS127 s

64

I n .x

J.

2

.

T1713 m.

S1-51

E3802

E3668

E3204

T1750

W932

T449

T2113

T2095

T1272

T1714

T1937

T1946

T1644

T2062

T2063

T1646

S25-3

T1167

S70-3

T1273

F1814

T1222

H1531

GEARBOX

0 UTER COVER

GEARBOX OUTER COVER

Gearchange spindle bush ...

Kickstarter spindle bush

Kickstarter spring anchor pin

Guide plate stud

(! in. O.A.)

Oil seal

Oil seal housing

...

Gearchange quadrant ...

Rubber "O" ring

Quadrant return spring

Gearchange quadrant plunger

Plunger spring ...

..

,

Guide plate

Serrated washer

Nut

Klckstarter quad rant

Kickstarter return spring

Kickstarter axle

CLUTCH LEVER ASSEMBLY

Clutch lever

Lever shaft

Ball, f in. diam.

T hrust plate

Return spring

Plain washer

Split pin ...

Countersunk screw (t in. O.A.)

Spoke

Locknut

Connector

Abutment

Adaptor, short

Adaptor, long (For cable with short outer cover.)

Rubber cover

Plain washer

Nut

Screw (2! in. U.H.)

Screw (1-h in. U.H.)

Screw (1 in. U.H.)

Gearchange pedal

Bolt (1 in. U.H.)

Pedal rubber

FOLDING KICKSTARTER

Kickstarter lever ..

.

Kickstarter pedal ...

Pedal locating spring

Steel ball,

.t

In. diam.

Pedal bolt ...

Pedal rubber

Cotter pin c/w nut and washer

Domed nut

37

QUANTITY REMARKS

1

4

4

2

2

2

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

3

1

1

1

1

1

1

1

1

1

2

2

1

2

2

1

1 as required as required

1

CLUTCH AS SE MBLY

N<?

1

4

13

9

12 23 24 25

1 9 20

21

....,

CX)

22 2 3 5

8 7 6

10 11 8 14 15

Fi g. 10 .

CLUTCH

16

17 1 8

~

18

19

20

21

22

14

15

16

17

23

24

25

10

11

12

13

1

2

3

4

5

6

7

8

9

Ref. N o .

Part . No. DESCRIPTION

T1928

T1734

T1735 '

T394

T1570

T1719

T1720

T1040

T1721

T1722

T1723

T1724

T423A

T1362

T1363

T2156

T2159

13206 / 00 / 1

T1931

T1830

H27

S6f>-.1

T1045

T1046

T1047

CLUTCH

CLUTCH COMPLETE

Hub

Thrust washer

Roller

Sprocket and housing (58 teeth Duplex)

Centre

Inner plate

Countersunk screw (0 · 417 In. U.H.)

Shock absorber spider

.

..

Drive rubber (large)

Rebound rubber (small)

Outer plate

Screwed pin (1,H In . U.H

.

)

Driving plate (bonded)

Driven plate

Pressure plate

Adjuster pin

Nut

Spring cup ..

.

Spring

Brass nut .

..

Key

Cupped washer

Tab washer

Clutch securing nut

QUANTITY REMARKS

1

1

6

1

3

3

1

20

1

1

1

3

6

6

1

1

1

1

1

1

1

3

3

3

3 9

-I>,.

0

2 3

4

6

7 9

21 14

16

18 22 23

15

24

Fig.11. CHAINCASE AND CHAINS

25

.... -· ·

~·-

-··--· · · · - - - · ·· ·

..

· ·

·-

· ~

30 29 26

4

::

.

, _ .

_..,.

.

,s,y.

· • ..,....,dJ /'4t:!;

5

10

11

12

13

14

5

6

7

8

9

23

24

25

26

27

28

29

30

31

· JS

16

17

18

18

19

20

21

22

32

33

34

1

2

3

4

E4704

E4705

S26-2

DS57

D444

D481

E3832

E4577

E4578

E3821

E5976

E6061

E4152

E5977

E4153

D477

E4536

E4537

47162

47188

E5872

E4144

E5449

S25-3

E5324

T1770

T1727

E2441

E6347

T1738

E732

NE507

E3204

E4806

H1531

F1880

Ref. No. Part No.

DESCRIPTION

CHAINCASE AND CHAINS

Primary chain oiler tube

Clip

Spring washer ...

Bolt

(.7

6 in. U.H.)

Rear cha i n, i in. x tin . x 102 links

Rear chain, i in. x tin . x 103 links

Joint washer

Cover plate

Oil seal ...

. Countersunk screw (i\.

in. U.H

.

)

Chain tensioner abutment

Chain tensioner blade ..

.

Tie rod ...

Trunnion

Adjuster sleeve nut

Primary chain, tin. Duplex x

84 links

Stator stud

Stator stud

Stator, RM

19

Stator , RM

19

Sleeve nut

Rubber grommet

Plastic sleeve

Plain washer

Self-locking nut

Joint washer

Chaincase

Copper washer

Drain and adjuster plug

Fibre washer

Filler plug

Fibre washer

Screw (1 in . U.H.)

Screw

(ff in. U.H.)

Domed nut

Copper washer ...

QUANTITY REMARKS

1

1

6

1

1

2

6T, TR6C

1 (Western)

&

{ T120TI

1 TR6R, T120R

6

2

2

2

1

1

1

1

1

1

3

3

1

1

1

1

1

1

2

1

1 Coil Ignition

1 A.C. Ignition

41

~

6 / ~

Fig. 12. FRAME

· -----· · · · - - - ----. · ----

------- ----· -· -

-----------------------

~

'-,6~~

17 18

@ - 4

@ - 2

5

10

11

11

12

13

14

19

20

21

22

23

15

16

17

18

6

7

8

8A

9

2

3

4

5

F6903

H111

S70-3

H1018

F5928

F5932

T449

F5678

F5679

F4484

F2725

F4671

F4388

F6940

F3097

F3096

F2610

F6904

F2842

S26-1

S1-52

F4369

F4370

DS47

PCW 73A

F5605

Ref. No.

Part No .

DESCRIPTION

FRAME

Front frame

Steering race cup

Steel ball

(± in . diam .

)

Top cone and dust cover

Centre stand

Centre stand

Pedal rubber

Pivot bolt

Plain washer

Tab .washer

Nut

Return spring

PROP STAND COMPLETE (3 ·50 rear tyre)

PROP STAND COMPLETE (4·00 rear tyre)

Pivot bolt ...

Tab washer

Return spring

Rear frame

Stud

(3i

in. O.A.)

Spring washer ...

Nut

Bol t (2ft in. U.H

.

)

Plain washer

Nut

Spring washer

Bolt (1,\ in. U.H.)

QUANTITY

REMARKS

2

2

2

2

1

2

2

2

1

1

1

1

2

40

1

1 6T, T120

2

2

2

2

1

1

{ TR6 and all

U.S.A

. Models

1

43

.I>,.

.I>,.

45

24 21

, , _

' fl'.

27

17

/ ~

~~ ~

- -

qJ

•

-

~

37 t

36 35

~!-L ~

49 ~

30

~ 31 38 ~ 5038 . ,

!!!!,QJ

,_,,,/'

29 28

l.fj

~

~ ® ) ~

/ -

.._ 16

I ll

18

~-

·----

- - - - -

14 13

11

4

3 1 2

5

Fig.13

. SWINGING FORK AND SUSPENSION UNITS

5 7 8

.P- - - ··· ... -··· · · ·-

, ;:: ~

15

16

17

18

19

20

20

1

2

7

8

9

10

11

12

3

4

5

6

13

14

15

25

26

27

28

29

30

21

22

23

24

31

32

33

34

35

36

37

45

46

47

48

49

50

38

39

40

41

42

43

44

Ref. No.

Part No. DESCRIPTION

QUANTITY

REMARKS

t t

F6933

F6042

NW100

WE170

F6821

F5313

F6730

F6150

SWINGING

FORK

AND SUSPENSION UN ITS

SWINGING FORK

Pivot bush ...

Grease nipple

Fibre washer

Sleeve

.

.

.

Distance tube

End plate

F5944

NT297

Bolt (St in. U.H.)

Tab washer

Nut

F3774

F5315

PCW73A

DS47

64054506

Brake torque stay

Bolt

(H in . U.H.)

Spring washer ...

Nut

SUSPENSION UNIT

64054164

9054

9054/171

9054/151

9054/47

SA253

9054 /

/ 316A

/ 5

280

SUSPENSION UNIT

Bonded bush

Spring retainer

Outer dirt shield ...

Inner d irt shield

...

Spring, 145 lbs . Blue /

Spring, 100 lbs. Green

Yellow

/ Green

1

2

1

1

2

1

2

1

1

1

1

1

2

2

2 6T, T120

2{

TR6 and U.S.A.

T120

4

4

2

2

2 6T, T120

TR6 and U.S.A.

2{

T120

E2113

S25-2

S26-1

GS308

P0172 A

F 7 067

F5536

F4135

F2277

S25-13

Unit fixing bolt (1-h in. U.H.)

Plain washer

Spring washer

Plain washer

Nut

Chainguard

Grommet

Pivot bolt

Spring washer

Plain washer

\

4

2

2

3

4

1

1

1

.

..

1

2

E5269

F4136

F5413

315738

Self-locking nut

Stepped bolt

S25-3

F6070

31437

Plain washer

S1-51

F3808

F6663

F1369

Nut

Clip

Bracket

Bolt

(t in. U .

H.)

Spr.ing washer S26-2

F3597

Brake operating rod

+.-

In.

Xf

In. Split pin ...

W11

Pivot pin .

..

Adjuster nut

T1076

F4717

Stop lamp switch, type 22B

Screw

(i

In. U.H.)

Self locking nut

F5412

Switch lever

"D" washer

DS57

F879 f SB4 / 275

Spring (F .

3158)

Bolt

(n in. U.H.)

Nut

Sidecar suspension unit

1

1

1

2

1

1

1

3

5

1

1

1

1

1

1 No longer used

1

1

1

1 No longer used

1 as required

45

3 2

~

34

36

~5

38

1~

~

33 - - - - --

~

®i

.

@~~

~

5

~

19- -

24

23

@

@

26 28 11 12 bl~

14

•

,

44 1 - -..../

43 ~

39

41

32

29

Fig .

14. ENGINE UNIT FITTING AND . FOOTRESTS

23 25

- - • • · u •• •• - • o,

40(42)

23

24

~

Ref. No. Part No . DESCRIPTION

11

12

13

18

19

20

21

14

15

16

17

21

22

23

24

25

26

27

28

29

30

31

32

33

38

39

40

42

34

35

36

~

41

43

44

1

2

3

4

5

6

7

8

9

10

QUANTITY

REMARKS

F5469

PCW73A

DS47

F64~8

F5532

F6066

F5908

E4165

F5316

S25-3

S26-3

Sl-51

F6069

F5910

F5942

S25-6

S4-13

F5943

NF704

E3114

F1031

H426

F3248

S26-1

S1-52

P0172A

E4778

F 3 805

F3069

F6064

F1149

F879

F6449

F5472

F5788

S25-1

F879

F3771

F4370

F6653

F6654

F6409

F6410

F6411

F6655

ENGINE UN IT FITTINGS AND FOOTRESTS

Stud (3

1

5

6

In. O .

A.)

Spring washer ...

Nut

Stud

(7f in. O.A.)

Distance piece .

..

Left rear engine plate

Right rear engine plate

Bolt (1ft In. UJ:J.)

Bolt (1-k in. U.H.)

Plain washer

Spring washer

Nut

Left footrest

Right footrest

Stud (1 in. O.A.)

Plain washer

Nut

Peg

Footrest rubber

Stud (1f in. O.A.)

Bolt (:: in. U.H

.

)

Bolt

(H in. U .

H.)

Bolt (1

!

~

In . U .

H .

)

Spring was~er .

..

Nut

Nut

Engine torque stay

Bolt (1f. In . U .

H.)

Distance piece ..

.

Brake pedal lever

Bolt (:! in . U.H.)

Nut

Brake pedal

Crankcase undershield ..

.

Hook bolt

Pla i n wa s her

Nut

Nut

Plain washer

L.EFT FOOTREST ASS EMBLY

RIGHT FOOTREST ASSEMBLY

L e ft footrest

Right footrest

Footrest pedal

Pi v ot bolt

2

2

1

2

2

4

1

2

2

4

1

1

9

7

3

4

1

1

1

1

2

4

6

6

1

2

2

1

2

1

1

4

4

~} TR6

&

U.S

.

A .

2 TR6C

2

2

2 i

u

TR6 mon

&

4 7

5 4

3

10

11 9

11

12 13

21

12

2 0

18

I'

~ -

®

~

cl

20

12

19

16 - -

17 - - - -

15 14

F i g , 15 , EXHAUST PIPES AND SILENCERS

48 l

;

Re(. No. Pa r t No.

14

15

16

17

18

19

20

21

22

1

2

3

4

5

6

7

8

9

10

11

12

13

14

DESCRIPTION QUANT ITY REMARKS

E5866

E4951

S25-3

F929

E4711

F2335

Sl-51

DS 58

E5 676

E5957

E5958

E4501

E410A

E409

E6052

E6179

E3290

E2271

F3430

E3768

S26-3

E1310

E494 9

EXHAUST P I PES AND SILENCERS

(See also Page SO)

Left exhaust pipe

Right exhaust pipe

Finned clip

Hemispherical washer ...

Bolt (1-h In . U.H.)

Stay

Screw (i in. U.H.)

Self locking nut

Clip

Bolt (1! In. U.H.)

" D " washer

Spring washer

Nut

Silencer ...

Silencer (Muffler)

Bracket .

.

.

Plain washer

Bolt (t in . U.H.)

Pillion footrest support

Bolt

(ft

In. U.H

.

)

Nut

Bolt

(H

In . U.H

.)

Stay

1

2

2

1

1

2

2

2

2

2

4

8

2

2

4

2

2

6

2

2

{ U.S.A. 6T,

TR6R, T120R

2

4

1

I

I

I

49

17

-

~19i,--,s

- ~----'"":>.,,

20~

21,!'

- _

13

12

22 -

28

40

39 t

\~3 7

Fig. 16. EXHAUST PIPES A NO MUF FLERS ( U.S

.

A.

)

50

E 6374

F929

S26-3

E5959

E 5961

E 5963

S25-3

S1 51

E 5964

E 5965

F929

S26-3

E5966

T1439

F4299

S1 51

E4884

E4886

E4889

E4887

E4981

F929

S26-3

H590

E5874

F5087

F5088

E4132

E4176

H426

S26-1

S1 52

E4204

E4207

F4715

E2351

F3799

E6370

E6372

E6375

14

15

20

21

22

23

16

17

18

19

24

25

26

27

28

29

30

35

36

37

38

39

31

32

33

34

40

10

11

12

7

8

9

13

4

5

6

1

2

3

Ref. No . Part No.

DESCRIPTION

QUANTITY

REMARKS

E XHAU S T PIPES A

N D

M U FFL E RS

( U .S

.

A.)

Left exhau s t p i pe

Right exhaust pipe

Sleeve nut

Left stay

Right stay

Bo l t

(t in. U.H

.

)

Spring washer

Bolt

(nin. U.H.)

Clip

Left bracket

Right bracket

Left muffler

Right muffler

Bolt

(tf in. U.H.)

Spring washer

Nut

L e g guard

Clip

Screw

(,tt in. U.H.)

Plain washer

Self-loc kin g n u t

Left exhaust pipe

Right exhaust pipe

Sleeve nut

Stay

Bolt

(t in. U .

H .

)

Spring washer

Left e x haust p i pe

R i ght exhaust p i pe

Stud (.q in. O.A.)

Plain washer

Nut

Left stay

Right stay

Bolt

(t i n . U.H.)

Spring washer ·

Clip

Bolt (1-fr in . U.H

.

)

Plain washer

Nut

1

2

1

1

2

4

2

2

1

1

Eastern U .

S .

A .

1

TRC

2

2

2

2

2

4

2

4

4

2

2

2

2

3

1

1

1

1

1

1

Western U.S

.

A.

1

3

T R6C

2

2

1

1 T120T T

2

51

ASSEMB

L y REF . No .

1

19 - - -

36 - -

45

- -

33

- - - - - 3 0

29

F i g . 17 . TELESCOPIC FRONT FORK , 6T

52

- - - -

31

32

- - -

42

Ref. No.

Part No.

H1890

H443

H1058

H1659

H519A

H1842

H1843

H1844

S26-3

H1070

H1071

H430

H1499

H1063

H1062

H1142

H565

H408

H1286

H95

H1797

H435

H1618

H1527

H1523

F1335

H1340

H1708

H1529

F3955

F1760

H1914

H1577

H439

H941

525-2

E2412

H1141

H1528

H379

H1290

H1291

F4047

H1745

H 1916

H1891

H1892

H1656

H1654

H1SOO

H431

H441

H1896

30

31

32

33

34

35

36

37

38

39

23

24

25

26

27

28

29

20

21

22

23

16

17

18

19

40

41

42

43

44

45

46

47

48

49

50

51

52

5

6

7

8

9

1

2

3

4

10

11

12

13

14

1 5

DESCRIPTION

TELESCOPIC FRONT FORK, 6T

FORK AS S E MBLY

Middle lug and stem

Bottom cone

P inch bolt (2! in. U.H.) ...

Plain washer

Nut

F ork s tem sleeve nut

TOP LUG ASS EMBLY

Bonded bush ..

.

Handlebar eyebolt

Plain washer

Bolt (1f in. U.H.)

Plain washer

Hemispherical washer

Self locking nut

...

P inch bolt (1-H- fn. U .

H .)

Seated nut ...

Left n a celle cover

Right nacelle cover

Cork washer

Plain washer

Upper cover tube

Solo main spring (Yellow / Blue) ..

.

Sidecar ma i n spring (Yellow / Gree n)

Pla in washer

DUST EXCLUDER SL EE V E NUT

O i l sea l

Plain washer

T op bear ing

Damp in g sleeve

STANCHION c / w BEARING

Lower bear i ng

Bearing nut

Cap nut

O il filler plug ("ft In.)

LEFT BOTTOM MEMBER c / w CAP

R I GHT BOTT OM M E MB ER c / w CAP

Spindle cap

...

Spring washer

Cap bolt (1,Z. in . U .

H .)

Drain plug ...

Fibre washer

Restr i ctor ...

Flanged bolt (,;} in. U.H

.)

Aluminium washe r

Steering damper rod c/w k nob ..

.

Plain w as her

Adjuster sleeve

Locating p in

Spring plate

Anchor plate

Friction disc

Rubber sleeve

53

QUANTITY REMARKS

1

1

2

2

2

1

2

1

4

2

2

2

2

4

2

2

2

2

2

2

2

2

2

1

1

1

1

1

1

1

2

2

2

2

2

2

1

1

2

2

2

2

2

1

2

2

2

2

~

5

1

Y:qb

3 1 ~

-111~

0 - - - - 2

' : : : ) 10 9 8

. ~

~o;ci

, - - - - - - 3

10 [email protected]

0

9

_ _ r

~\\\\\W~t\W'11,, , \ ~ ~ . :: :

,111,, \ \\1 \ ~

49

: 17 18 16

~

8 4 7

I

~

HEADLAMP

ASSEMBLY

REF . Nl212 l l

I

I i

~ 4 0 c:::?

---- -

41

Fig . 18 . NACELLE HEADLAMP AND SWITCHES

54

Ref. No. Part No.

1

2

3

4

5

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

6

7

8

9

10

2 6

27

28

33

34

35

36

37

29

30

31

32

38

39

40

45

46

47

48

49

41

42

43

44

H1781

H1971

H669

H877

H878

H689

H687

H688

E2880

H691

H690

59176

553248

516812

504665

553267

144921

534296

414

554602

222

554710

34427

54336176

54336178

34289

54330934

54330576

54930007

54930008

36296

H992

F4129

GS299

F3799

H1420

70164

F4771

54938942

F5983

F5988

54942078

54190042

900269

900288

850641

850844

850832

H1938

DESCRIPTION QUANTITY REMARKS

NACELLE HEADLAMP AND SWITCHES

Nacelle top

Plast i c grommet

Rubber grommet

Left motif

Right motif

Screw

(! in. U.H.)

Screw (t in. U.H.)

Screw

("f6 in. U.H

.

)

Serrated washer

Nut

Nut

HEADLAMP

Rim

Light unit

Fixing wire .

..

Fixing ring

Screw

P l ate

Bulb (50 / 40 W. L.H. dipping. Pre-focu s )

Adaptor

Bulb (4W.M.C.C.)

Pilot bulbholder

IGNITION SWITCH c / w KEY, type 88SA

Ignition key

Ignition switch cover

Lig h ting switch, type 88SA

Knob c / w screw

Switch bezel plate

Replacement harness socket (lighting)

Replacement harness socket (ignition)

Ammeter, t y pe 2AR ..

.

Horn grille

Screw (0·435 in. U.H.)

Serrated washer

Nut

Horn bracket ...

Horn, type 8H ...

Bolt

(t in. U.H.)

Wiring harness

Bracket ..

.

Rubber band

Lucar connector

Insulating cover .

..

Snap connector terminal

Single snap connector ...

Double snap connector

Triple snap connector ...

Quintuple snap connector

Blind grommet

2

1

2

A

A

4

2

2

4

4

2

1

6

2

4

2

2

1

2

2

2

2 as required as required as required as required as required

2

55

ASSEMBLY REF . No .

1

15 14

13 10 I ~

9

7

17

45

c-;~a._::: :..._

~ - - - 48

_ _ _ _ _

~ & - - - - - - 50

- - - - - - 49

- - - - - - - - 47

~ '--- - - - ~32

~ - - - - - --33

J--- - - - 42

Fig. 19. TELESCOPIC FRONT FORK, TR6 AND T120

56

I i

!

I

I

I

27

28

29

30

31

32

33

34

35

36

37

38

46

47

48

49

50

51

52

39

40

41

42

43

44

45

8

9

10

11

12

13

22

23

24

25

26

18

19

20

21

22

14

15

16

17

4

5

6

7

1

2

3

Ref. No. Part No.

H1142

H565

H408

H1286

H95

H1797

H435

H1618

H1896

H1889

H443

H1058

H1658

H1842

H1843

H1844

S26-3

H1070

H1071

H430

H1499

H1063

H1062

H1887

F4047

H1657

H1891

H1892

H1656

H1645

0340

H1654

H1500

H431

H441

H1527

H1523

F1335

H1340

H1708

H1529

F3955

F1760

H379

H1888

H1924

H1577

H439

H941

S25-2

E2412

H405

H1528A

DESCRIPTION

QUANTITY REMARKS

TELESCOPIC FRONT FORK, TR6 AND T120

FORK ASSEMBLY

Middle lug and stem

Bottom cone

Pinch bolt (2! In. U.H.)

Plain washer

Nut

Fork stem sleeve nut

TOP LUG ASS EMBLY

Bonded bush ...

Handlebar eyebolt

Plain washer

Bolt (1-k in. U.H.)

Plain washer

Hemispher i cal washer

Self-locking nut ...

Pinch bolt (1ft in. U.H.)

Seated nut ...

Left top cover

Right top cover

Cor k washer

Spring abutment

Solo main spring (Yellow / Blue)

Sidecar main spring (Yellow / Green)

Pla i n washer

Telescopic gaiter ...

Ga i ter clip ...

DUST EXCLUDER SLEEVE NUT

Oil seal t>lain washer

Top bearing

Damping sleeve

STANCHION c / w BEARING

Lower bear i ng

Bearing nut ...

Cap nut

LEFT BOTTOM MEMBER c / w CAP

RIGHT BOTTOM MEMBER c / w CAP

Spindle cap ...

Spring washer

Cap bo lt (1,Z,. in. U.

H.)

Drain plug ...

F i bre washer

Restrlctor ...

Flanged bolt (;} in. U.H.)

Aluminium washer

Steering damper rod c / w knob ...

Plain was h er

Adjuster slee v e

Locating pin

Spring plate

Anchor plate

Friction disc

Rubber sleeve

2

2

2

2

2

2

2

2

1

1

1

1

2

2

2

2

2

2

2

4

1

2

2

2

2

2

2

2

2

2

2

2

1

1

1

1

1

1

2

1

1

1

2

4

4

2

2

2

2

57

8

FORK ASSEMBLY REF NQ 1

11

2

12

~

14- ---, @

15

@

Fig. 20. TELESCOPIC FRONT FORK, U .

S .

A. TR6C AND T120TT

58

4

5 6

~

18

~ 1 6

10

9

I t f l

I

I t

I

!

I l

!

'

!

I

I

'

I

I

! t i

! i .

I

7

12

13

14

15

8

9 .

10

11

16

17

18

2

3

4

5

6

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

TELESCOPIC FRONT FORK, U .

S.A. TR6C AND T120TT

H1925

H1999

H1287

H506

S25 3

H1340

H1696

H1892

H1913

H1893

H1897

H1764

H454

H452

F879

H1761

T224

H1762

FORK ASSEMBLY

Middle lug and stem

TOP LUG c / w CAPS

Cap

Plain washer

Bolt (1-i\- in. U .

H.)

Top cover ..

.

Main spring (yellow / green)

DAMPER ASSEMBLY

Restr i ctor body

Rod

Cup

..

.

Pin

Oil restr i ctor ...

Nut

Restrictor body cap

Nut

Cap nut

1

1

2

4

4

2

2

4

2

2

2

2

2

2

2

2

{ Not Eastern

TR6C

2

All other parts are as listed on Page 57

5 9

0-

0

1 7 1 2

F i g . 21. FRONT WHEEL , 6T AND T120

w--

1 a w w w = w ~ ~

Ref. No. Part No.

8 .

9

10

11

12

13

14

15

16

17

18

19

20

21

22

32

33

34

35

35

28

29

30

31

23

24

25

26

27

1

2

3

4

5

6

7

W1739

W1729

W1374

W1275

W1730

W1731

S79-2

W1722

W1641

W653

W1237

T280

W1481

W1474

W1238

W582

W1332

W1197

W1198

. W1330

W1639

S25-2

S1 52

W1732

W1733

W1734

W129

W1415

W135

W1243

W1331X

S25-6

W592

W1246

W1640

W1711

DESCRIPTION

FRONT WHEEL, 6T AND T120

FRONT WHEEL COMPLETE

RIM , SPOKES AND HUB ASSEMBLY

Front wheel rim (WM2-18)

Spoke (8 / 10G x 5-h i n. straight ) c / w nipple

Spoke (8 / 10G x 4

1

5

6 i n. 78 ° ) c / w nip p le .

..

Spoke (8 / 10G x 4-h in. 100 ° ) c / w nipple ...

Spoke nipple ..

.

Hub and brake drum

Wheel spindle

Bearing

Dust cover

Circlip

Grease reta iner

Grease retainer (brake side)

Backing ring

Retain i ng ring

Cover plate

Balance weight, t oz.

Balance weight , 1 oz .

Brake anchor plate

Fulcrum pin

Plain w ash er

Nut

LEADING BRAKE SHOE c / w LIN IN G

TRAILING BRAKE SHOE c / w LINING

Bra k e lining

Br ass rivet

Pi vo t pad

Shoe return spring

Brake cam

Bra k e cam le v er ...

Plain washer

Lever return spring

Anchor plate nut

Abutment

(

1

9

6

Abutment in . deep)

(ft in . deep)

QUANTITY REMARKS

1

20

10

10

40

1

1

2

1

1

1

1

1

1

1 as requir ed as required

1

1

1

2

16

1

2

1

2

2

1

1

1

1

1 as required as requ i red

61

?j

1 7 1 2

11

F i g. 22 . FRONT WHEEL , TR6 AND U.S.A

. T120

- · - · - - - - - - ~ - · - - - - -.. - - - , . . - · - · · - - - - · - · - - - - - - . . - - - . Pl'

.

--

·"""~

Ref. No. Part No.

DESCRIPTION

1

2

3

4 s

6

7

18

19

20

21

22

23

24

29

30

31

32

33

34

35

35

25

26

27

28

8

9

10

11

12

13

14

15

16

17

W1197

W1198

W1330

W1639

S25-2

S1-52

W1732

W1733

W1734

W1720

W1721

W1230

W1328

W1708

W1709

S79-2

W1722

W1641

W653

W1237

T280

W1481

W1474

W1238

W582

W1332

W129

W1415

W135

W1243

.

W1331X

S25-6

WS92

W1246

W1640

W1711

FRONT WHEEL, TR6 AND U.S.A. T120

FRONT WHEEL COMPLETE

RIM, SPOKES AND HUB ASSEMBLY

Front wheel r i m (WM2-19)

Spoke (8 / 10G x

St in. straight) c / w nipple

Spoke (8 / 10G x

4 H in . 78 ° ) c / w nipple

Spoke (8 / 10G x4f in. 100 ° ) c / w nipple

Spoke nipple ...

Hub and brake drum

Wheel spindle

Bearing

Dust cover

Cirdip

Grease retainer

Grease retainer (brake side)

Backing ring

Retaining ring

Cover plate

Balance weight, t oz.

Balance weight, 1 oz.

Brake anchor plate

Fulcrum pin

Plain washer

Nut ...

LEADING BRAKE SHOE c / w LINING

TRAILING BRAKE SHOE c / w LINING

Brake lining

Brass rivet

P ivo t pad

Shoe return spring

Brake cam

Brake cam lever ...

Plain washer

Lever return spring

Anchor plate nut ...

Abutment (ft in. deep)

Abutment(# in. deep) ...

QUANTITY REMARKS

1

1

20

10

10

40

1

1

16

2

2

1

1

1

1

2

1

1

2

1

1

1

1

2

1

1

1 as required as required

1

1

1

1 as required as required

63

45 42 45

33 23

29

25 27 28 22 8 9 10 12 3 15 21

7

5 5 16 18

40 24 45 43

'

43 44 35 34 36 26 30 31 13 11 20 19 18 17

46

f i g . 23 . REAR WHEEL

4

6

4

14

37 38 39

41 42 44

, • • • - • · ·•-+ ,-W" " · • ...

..... -·• •• • • ~· - · ~ ., , , , , - . -~-_._., ........

. . ~ · - · ..

.

_ ,..,.

.

_,,_,a .. ~ ~-

·-~ , _ .

........, ~

-

.

-,y , , · ...... - - - · · ~ . - . - . , - - , . - - - - · - - - - • • , - • • - - - - · - · - ·

-

-

·

~

1

1

2

2

3

3

43

44

45

46

38

39

40

41

42

46

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

29

30

31

32

33

25

26

27

28

34

35

36

37

4

5

6

7

8

9

W1741

W1742

W1470

W1486

W147.1

W1007

W1635

W1476

W1477

D373

W1280

W1134

W1015

W1058

F1747

D106

WM3

W1654

W1022

W653

W1021

W1710

W1278

W1024

W1112

W1282

W1406

W1407

NW243

W129

W1415

W135

W1083

W1466

W1467

S25-6

S1-52

W1090

W1107

W1108

S79-2

W1472

W1499

W1500

E1612

W1498

W1690

W 1691

W1281

W1474

Ref. No. Part No. DESCRIPTION

REAR WHEEL

REAR WHEEL COMPLETE

REAR WHEEL COMPLETE

RIM, SPOKES AND HUB ASSEMBLY

RIM, SPOKES AND HUB ASSEMBLY

Rear wheel r i m WM2-18

Rear wheel rim WM3-18

Spoke (8 / 10G x 7

1

9

6 in. 90 ° ) c / w nipple

Spoke (8 / 1 0 G x 7f in. 90 ° ) c / w nipple

Spoke nipple ...

H ub ...

Sprocket, 46T

Bolt (# in. U.H.)

Serrated washer ...

Brake drum

Bolt

(ft in. U.H.) .. .

Self locking nut .. .

Wheel spindle

Grease retainer (brake side)

Grease retainer

Backing ring

Bearing

RETAINING RING

Loc king screw

(-h in. U.H.)

Distance tube

Distance piece

Brake anchor plate

Nut ...

LEADING BRAKE SHOE C / W LINING

TRAILING BRA KE SHOE C / W LINING

Br ake lining ...

Brass rivet

Thrust pad ...

Shoe return spring

Brake cam ...

Brake cam lever

Pivot pin ...

Plain washer

Nut ...

Lever return spring

Grease retainer ...

Speedometer adaptor

Distance piece

Speedometer gearbox

P lain washer

Chain adjuster ...

Adjuster end plate

Self-locking nut

Spindle nut

Tyre security bolt (WM2)

Tyre secu rit y bolt

65

QUANTITY REMARKS

1

1

1

1

1

1

1

1

1

2

16

2

2

1

1

1

2

2

2

3

2

6T & T120

2 TR6

&

U .

S.A.

T120

1

2

1

1

1

1

8

1

1

1

8

1

8

20

20

40

1

1

8

1 6T & T120

1 TR6

&

U.S.A.

T120

1 6T & T120

TR6

&

U.S.A.

T120

1 6T & T120

1 TR6

&

U.S.A.

T120

1

38

36 35 26

27 29 30 19 20 22

23 3 10 12 7 4 5 8

. . 31

15 13 41

40 45

46

I

44 45

34 37

28 32 33 21 25 24 11 8

47

Fig . 24. QUICKLY DETACHABLE REAR WHEEL

' '

'

6 9 10 16 43 17 18

39

44

46

.

' " "

,,.,

.•

.. ,..._ _ _ ~ - "' - ' ' • ~ · ·~ ..., . _ _ ,_ ..

.

..

.

. .., .

. ,,,.,cw.-.-..-.?:~•.,.,..,..~ _,.,.~ • · - - - ~ , . _ -... .

~ f~""""T'*_...,,......" .

, ii, ;Sil

7

8

9

10

11

25

26

27

28

29

30

31

32

33

38

39

40

41

42

34

35

36

37

43

44

45

46

47

47

19

20

21

22

23

24

12

1 3

14

15

16

17

18

3

3

4

5

6

1

1

2

2

W1042

W1043

W1044

W1045

W1121

W1406

W1407

NW243

W129

W1415

W135

W1083

W1466

W1467

S1 -52

W1090

W1052

W 1392

W1170

W1055

W1091

D373

W1135

W1015

W1058

D106

WM3

W1746

W1745

W1747

W1603

W1471

W1007

W1107

W1108

S79-2

W1593

W1595

W1509

S35-7

W1596

W1614

W1598

W1635

W1599

W1477

W1280

W1282

W1040

W1143

W1041

Ref. No. Part No. DESCRIPTION QUANTITY REMARKS

QUICKLY DETACHABLE REAR WHEEL

Q.D. REAR WHEEL COMPLETE .. .

Q.D. REAR WHEEL COMPLETE .. .

RIM, SPOKES AND HUB ASS EMBL Y

RIM, SPOKES AND HUB ASSEMBLY

Rear wheel rim WM2-18 .. .

Rear wheel rim WM3-18 .. .

Spoke (8 / 10 x 7rt in . 90 ° ) c / w nipple

Spoke (8 / 10G x 7f in . 90 ° ) c / w nipp le

Spoke nipple ...

Hub ...

Grease reta i ner

Bac ki ng ring

Bear i ng

Dust cap ...

Bear ing sleeve

Distance piece (inner)

Grease retainer ...

Locking r ing

Distance piece (outer)

Plain washer

Nut

Sprocket and brake drum 46T

Grease reta i ner

Bearing

Felt washer

Bearing and felt retainer

Circlip

Bearing sleeve

Brake anchor p la te

LEADING BRAKE SHOE C / W LINING

TRAILING BRAKE SHOE C / W LINING

Brake lining

Brass rivet

Thrust pad

Shoe return spring

Brake cam

Brake cam lever

Pivot pin ...

Nut

Lever return spring

Nut

Inner distance piece

Outer distance piece

Spindle

Rubber sealing r i ng

Speedometer gearbox

Chain adjuster ..

.

Adjuster end plate

Self-locking n ut

Tyre secur i ty bolt, WM2

Tyre security bolt

1

1

1

1

2

1

2

1

1

1

1

1

1

1

6T, T120

T R6, U.S

.

A . T12 0

6T, T120

.. TR6, U.S.A. T120

1 6T, T120

1 TR6 , U.S.A. T120

20

20

40

1

1

1

1

2

16

2

2

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2 6T, T120

2 TR6 , U.S

.

A . T120

67

13

1 5

4

19

20

10

14

11

7

..

3

.

.

2 5

•

PETROL ( GAS ) TANKS

68

"

2-8

26

8

9

6

25

21

24

lfi:ie~-.

23

18

~

I

I i l

J

' i

I

I i

I

I

I i

I .

I

I r

I

I

I

I i r

I

I

I

I

~

!

I

I

11

22

23

24

25

26

2 7

28

16

17

18

19

20

21

12

13

14

15

8

9

10

5

6

7

1

2

3

4

F6728

F5229

F3814

F1808

F5336

F967

F533 7

F3917

F2936

F4384

F5564

F3220

F3219

F4048

F4971

F4972

F1511

F5228

F7004

F6887

F4129

F6888

F5401

F5402

F5398

F4019

H919

F7003

Ref. No. Part No . DESCRIPTION

PETROL

(GAS)

TAN KS

Petrol tank (4 gallons)

Sty l ing unit (left)

Styling unit screw (0 ·

435

in.

U.H.)

Styling un i t (right)

Left

knee grip ..

.

Right

knee grip

Centre

styling

strip

Serrated washer

Nut

Pet r ol tank (J} gal Ions )

Petrol

tank

(2t gallons )

Centre

styling strip

FILLER

CAP

...

FILLER

CAP c / w JACK CHAIN

Joint washer

Petrol tap (left) ..

.

Petrol

tap

w i th re s er v e tube ..

.

Fibre

washer

Rubber washer ...

Spigot rubber

..

.

Cup

Should e red bolt

Double spigot

rubber

Rubber washer ...

Bolt (1tf

in.

U.H

.

)

Parcel grid

S c rew

Rubber blanking plug ...

QUANTITY REMARK S

1

1

1

2

1

1

A

2

2

3

1

1

2

1

6T,

TR6

&

T120

1

4

1

1

1

1

6T,

TR6

&

T120

1

1

1

U .

S.A. 6T,

TR6R

1

{

TR6C

,

T120R

,

T120TI U

.

S.A.

1

1

1

TR.6C

,

T120TT

1

69

41

~

40

5

4

7

21

10

Fig. 26. OIL TANK

70

· - ~ - - - - - 2 2

20 l

32

''

~ i

34 33 33

' - - - - - - 3 6

"

37

I

I

I

I l

i

t i i

I

I

I i

1

I

!

'

I

!

,

Ref. No. Part No.

DESCRIPTION

F6877

F3216

F4047

F5343

PT104B

F3179

F1713

F3655

F3182

E4594

E5473

E4590

E3763

E3446

E1310

E6356

S25-13

F879

E6353

E6349

E1335

E1435

F6147

F6039

F929

E6355

E6354

E6357

F6970

E5370

E5376

F3098

F6892

* F6894

F6673

F6968

11104 / 06 / 2

15104 / 00 / 2

F6511

F6874

F6672

*

See Page 73

17

18

19

20

21

22

11

12

13

14

15

16

5

6

7

. 8

9

10

1

2

3

4

35

36

37

38

31

32

33

34

39

40

27

28

29

30

23

24

25

26

41

01 L

TANK

O i l tank ..

.

FILLER CAP

Joint washer

Drain plug

Fibre washer

Oil tank filter

Fibre washer

Upper feed pipe

Union nut

Flexible connector

Cl i p

Oil pipes and junction block ..

.

Joint washer

Plain washer

Nut

Vent pipe

"T" piece

Extens i on pipe ...

Clip

Front strap

Rear Strap

Spigot rubber

Rubber washer ..

.

Bolt

(t in. U .

H .

)

Se l f locking nut

Metering screw

Coil spring

Scre w ed peg

Plain washer

Nut

Rubber connector

Rocker oil feed pipe

Copper washer

Domed nut

Bracket ...

Grommet

Bolt

(t

In .

U.H

.

)

Flexible pipe

Cha i n oiler pipe

Flexible pipe

Clip

QUANTITY REMARKS

1

1

1

1

1

1

1

1

1

2

4

1

1

1

1

1

4

2

2

2

1

2

1

1

1

1

2

4

2

1

1

1

4

2

1

1

1

71

15

14

' I

8

10

3

2

® - 5

6

.l

7

~ :

°'lr;~/

~ 9

I

I

I

I

I

F ig . 27. BATTERY CARRIER AND AIR FILTERS

72

DESCRIPTION Ref. No.

Part No.

QUANT I TY REMARKS

BATTERY CAR R IER AND AIR F I L T ERS

15

12

13

14

15

14

1 5

16

17

18

19

20

21

22

23

24

25

1 1

12

1 3

14

15

14

6

7

8

9

10

1

2

3

4

5

*F6891

*F 6 897

* E 6226

S251

F8 79

*PUZ5A

*F6969

F 6901

F 1369

S25-13

F6883

E 4576

F562 5

F6430

F4811

F6433

F5694

F5958

F6074

F6431

F 5764

F6432

F 5694

E5262

E5267

F4810

E 5268

F6036

F5857

F4743

F606 1

DS57

S26 2

Battery carrier

Retainer .. .

Rubber .. .

Plain washer

N ut

B attery ..

.

Battery c arrier lining

T oo l tray

Bo l t (t in . U .

H .

)

Plai n washer

Inflater bracket

Adaptor sleeve

Clip

A I R FILTER

Filter element (felt)

AIR FILTER

Filter element (paper)

A d aptor sleeve ...

Clip

AIR FILTER

F ilter element (coarse felt)

A I R FILTER

Filter element (paper)

AIR FIL TE R

Filter element

Clip

Rubber con nectar

Clip

Cap

B olt (2f in. U.H.)

Bracket ...

Bolt

C\ in. U.H.)

Spring washer ...

1

2

4

3

7

3

2

2

1 6T

1

6T

6T

6T

U .

S.A. 6T

U .

S.A. 6T

~

} TR6

&

Eastern

1 T 1 20

1

1 U.S.A. TR6

1 U.S

.

A. TR6 n

*Some early models have two 6 volt batteries. These are interchangeable as a group but t he follow i ng part n u mbers ap pl y t o this condition (No t I llustrated)

P UZSA

F6891

F6894

F 6897

E6226

F6969

Battery

Battery carrier

Rear strap use

M

KZ9 E

(2 off ) use F7083 use F7086

R etainer

Rubber use F7085 ( 1 off ) use F7045 (3 off )

Rubber (between batteries) use F7046 (2 off )

Ba t tery carrier lining use F7087

73

74

(·

I

I

t

j f

.i

\

i

~

1

I

1

2

3

4

5

6

7

7

8

9

10

11

20

21

22

23

24

16

17

18

19

12

13

14

15

25

26

27

28

29

30

31

Ref. No. Part No . DESCRIPTION

F879

S25-43

F5466

F5239

F541 8

F4475

F4898

F4222

DS57

S26-2

0374

F4483

F4226

F4228

F6930

F6946

F4317

E1612

13104 / 00 / 2

15104 / 00 / 2

F6 931

F6 962

F1369

F5939

F5923

11104 / 06 / 2

S2~2

E1719A

-h

In. xt in.

F6659

F4361

F4365

PANEL AND TWINSEAT

Le ft panel

Motif " Th unde rb ird" ...

Spire nut

Serrated washer

Nut

Self-locking nut

Switch panel

Left panel

B olt

(i in. U.H.)

Fixing bracket ...

Link

Bolt (! in. U.H.)

Spring washer

Nut

Washer ...

Grommet

TWINSEAT

Twinseat cover c / w clips

Clip

Rubber buffer ..

.

Hinge

B o l t

(rt i n. U.H.)

Spring was he r ...

Check wire

Self tapp ing screw

Seat catch plunger

Spring ..

.

Pl ai n washer

Split pin ...

Knob

Saf ety strap

Self t apping screw

QUANTITY REMARKS

1 6T

1

6T

2 6T

2

2

TR6

&

T12 0

TR6C& T1 20 TI

1

1

1

1

1

1

1

1

3

1

1 as required

2

2

4

4

1

1 as requ i re d

4

75

1

6

2

7

- -

- - - - " "

2

5

.

__!:::::=1

~

19

18

17

4

l l

I

I

I

2

24

?r

~ :

1918 ~ 2

7

- - - -

I

3 -

6 f

1 0

37

- - -

-

- -

I

17 -

-

-

-

~ -"

28 36

19

Fig, 29 .

MU

DGUARDS ( STANDARD )

7

6

30

~ - ~ 32

35

9

10

11

6

7

8

12

13

14

1

2

3

4

5

21

22

23

24

25

26

27

28

29

30

31

32

15

16

17

18

19

20

33

34

35

36

37

38

S25 71

H1681

H1685

H1683

WE170

DSS7

S25-1

F879

T224

DS55

F1369

F6469

F6470

H741

H687

H745

F5984

F6915

F5424

FS994

F6031

S26-3

,F6851

S1-51

S26-2

F5 9 24

H590

H1901

F929

F4299

H1964

H1100

NS362

H1675

W62

S25-2

HH82

H424

Ref. No.

Part

No.

DESCRIPTION

M UD GUARD S

(STAN D ARD )

Front mudguard

Bolt

(t in. U.H.)

Plain washer

Front stay

Bottom stay

Spigot nut

Mudguard blade

Bolt

Plain wa sher

Bottom stay

Bolt

(ff in. U.H.)

Plain washer

Front stay

Bracket .

..

Mudguard bridge

Fibre washer

Bolt

(-h in. U .

H.)

Plain washer

Nut

Nut

Bolt

(# in. U .

H.)

Bolt

(t in. U.H.)

Number plate

Numb er plate

Clip assembly

...

...

Scr ew

(i in. U.H

.)

Nut

Mudguard blade

Mudguard bridge

Lifting handle

C:lip

Backing plate

Spring washer

B racket ...

N u t

Spring washer

Number plate

Bolt

(-/r

In. U .

H.)

QUANTITY REMARKS

3

10

1

2

1

9

1

1

1

1

1 6T

5

4

2

1

6T

1

1 TR6, T120

2 6T

2 6T

1 TR6 , T12 0

2

TR6, T120

2

TR6, T120

1 TR6, T 120

2

1

TR6, T12 0

2

10

6

17

2 T R6, T120

2

TR6, T120

2 6T

1 6T

1

TR6, T120

2

2

2

1

n

13

9 - - -

2

~ ~ - w - - - - - --16

~ - - - - - - - 18

------

- - - 1 9

3

11 8 9

1 ? le..!~

71

w-

15 14

6

G - 7

~

4 \ 35

34

36

37

5 - - - --l

23

21

I

I

I

I

34 31

22

28

25

12

20 24 19

F i g . 30 . FENDERS ( U .

S .

A .

)

78

,•

1

1

2

3

4

5

8

9

10

11

12

13

14

15

16

17

18

19

20

6

7

20

32

33

34

35

28

29

30

31

24

25

26

27

20

21

22

23

36

37

H1685

H1688

F929

F4 299

DSSS

T224

S1 51

NS362

W62

S26-3

DS57

WE170

S25-1

F879

F6965

FS955

F6967

F6915

FS424

F6851

S26-2

S26-3

H590

F5994

F6031

F6310

F6847

F6849

F6850

E2980

F4715

H1998

GS299

F3799

H1677

H1687

H1997

H1681

H1683

H1678

H1273

Ref No. Part No. DESCRIPTION

FENDERS ( U.S.A.

)

Front fender

Front fender (aluminiu.m)

Front fender (stainless steel) ...

Front stay

Centre bridge

Bottom sta y

Bottom sta y

Bracket

Brac k et

Bolt

(t i n. U.H

.

)

Plain washer

Bole

(-h in. U .

H .)

Nut

Nut

Spigot nut

Bolt

(ft in. U .

H.)

Spring washer

Bolt (.7

6 in . U.H

Fibre washer

Plain washer

.)

Nut

Rear fender

Rear fender (aluminium)

Rear fender (stainless steel)

Fender bridge

Lifting handle

Bracket .

..

Spring washer

Spring washer

.

B ol t

(-h in. U.H

.)

Clip

Backing plate

...

Pl ain washer

Tail lamp adapter

Tail lamp plate ...

Number plate bracket

Stud

(ft

In.

O.A.)

Screw

(H in. U .

H .

)

Backing strip

Serrated washer

Nut

79

QUANTITY REMARKS

6T, E a stern

TR6C , T R6R

1 Western TR6C,

T120TI

T120R

1

1

} 6T, Eastm

1 TR 6C, TR6R,

T120R

1 Western TR6C,

T120TT

1

6T, E astern

2 TR6C , TR6R, j

T12 0R

2 Western TR6C,

1

1

1

1

2

1

1

1

1

2

5

5

1

2

2

T 120TI

5

5

2

2

4

1

2

2

10

4

13

13

1 6T, Eastern

TR6C, TR6R

Western TR6C ,

, T120TI

1 T120R

1

1

31

17

.

1 3

~

25

~ 2 6

~

Ce)

24

27

14

3 to

0

46

6

• . i t . , . 1 : F - " ' ' 1 1 1 1 ~ ~ : - . W \ : 1 1 " ~ :

40

Fig . 31 . HANDLEBARS AND CONT R OL LEVERS

~ ~

.

.......

~

...

---.-

Ref. No. Part No . DESCRIPTION QUANTITY REMARKS

13

H

15

15

16

17

18

19

20

8

9

10

11

12

13

4

5

6

7

21

22

23

30

31

32

33

34

35

39

39

40

41

36

37

37

38

42

43

24

25

26

27

28

29

44

45

46

47

48

49

1

2

3

HANDLEBARS AND CONTROL LEVERS (SEE

ALSO PAGE 82)

H.1871

H .

1425

16 / 362

16 / 328

18 / 1005

18 / 1006

18 / 978

18 / 951

18 / 754

18 / 776

18 / 777

12 / 594

18 /8 38

18 / 839

11 / 013

18 / 087

18 / 053

18 / 1005

18 / 1006

12 / 556

12 / 607

12 / 606

12 / 033

18 / 1000

18 / 528

18 / 1009

1 2 / 595

11 / 014

18 / 087

18 / 053

16 / 329

16 / 091

16 / 008

16 / 009

16 / 010

11 / 013

366 / 012

16 / 011

18 / 1004

18 / 999

18 / 535

18 / 1014

18 / 1013

12 / 619

12 / 595

11 / 014

18 / 952

18 / 752

18 /773

366 / 011

31563

380459

H1994

Handleb a r

Packing piece ...

TWISTGRIP

Bod y top half

Body bottom half ..

.

Rotor

Frict ion s pring

Fri ction spring screw

Locknut

Screw

Grip

Cable stop ...

FRONT BRAKE AND AIR LEVER ASSEMBLY

FRONT BRAKE LEVER ASSEMBLY

Br ake lever

Le ve r bracket

Lever bracket

Control body

Clamp

· Screw

Screw

Fulcr um screw

Self locking nut

Cable adju s ter

Thumb nut

Lev er

Bolt

Cap ...

Spring washer

CLUTCH LEVER ASSEMBLY

Clutch lever

Clutch le ve r bracket

Clamp

Screw

Fu lcrum screw

Self locking nut

Cable adjuster

Thumb nut

FRONT BRAKE AND AIR LEVER ASSEMBLY

FRONT BRAKE LEVER ASSEMBLY

Brake lever (ball end)

Le ver bracket

Le ve r bracket

Control body

Cable adjuster

Thumb nut

CLUTCH LEVER ASSEMBLY

Clu tc h le ver (ba ll end)

Lever bracket

H andleba r grip ...

H o rn pu sh and dip switch

Backing rubb er

Self-tapping screw

(t in. U .

H.)

1

1

1

1

2

1 6T, TR6, T120

4

1 6T, TR6 , T120

1

1

1

2

1

1 6T

1 T120

1 6T

1 T12 0

1

1

6T

T120

1

1

1

1

1

1

1

1 6T, T120

1

1

1

2

1

1

1

1

TR6

T120R, T120TT

1

1 TR6

1 T120R, T120TT

1

2

2

TR6 , T120TT

81

11

THROTTLE

CABLE

16

5

CLUTCH

CABLE

18

FRONT

BRAKE

CABLE

8

16

AIR CONTROL

CABLE

BONNEVILLE

THROTTLE

CABLE NO

1

25

19

31

34 fl

35 33

Fig .

32.

2 1

36

82

ANDLEBARS

10

11

11

11

12

1 3

5

6

7

8

9

2

3

4

5

30

31

32

3 3

26

27

28

29

34

35

36

21

21

21

22

23

24

25

18

19

20

20

14

15

16

17

Ref. No.

Pa

.

r

t

No

.

DESCRIPTION

QUANTITY REMARKS

CON T ROL CABLE S

ANO AMERIC

A N HANDL E BARS

D565

D103

D506

DS73

0558

D559

D103

D506

W593

WF32 rrin .

X f'

.

D495

0519

0528

0499

0500

244 / 104

0423

D101

083

NS191

0104

0435

0507

H 1869

H18 70

H1511

313 / 8

313 / 008

313 / 009

313 / 013

4 / 048

16 / 008

2 1 0 / 007

210 / 008

210 / 009

366 / 012

16 / 011

H1S80

H1581

F3814

H1616

CLUTCH CABLE

Ferrule

Nipple (Handlebar end)

Nipp l e

FRONT B RAKE CABLE

FRONT BRAKE CABLE

Ferrul e

Nipple (H and leb ar end)

Fork end

P ivot pin ...

Spli t pin ...

T HROTI L E CABLE

THROTI L E CABLE

Throttle c a ble .

.

.

THROTILE CABLE

Twistgrip cable

Junction block

Carburetter cable

Ferrule

Nipple

Nipple

Adjuster

Air co n tro l cable

Air control cable

American handlebar

American handlebar

American handlebar

TWIN ROTOR TW I STGR I P

Body top hal f

Bod y bottom half ...

Rotor

Bolt

Friction spring

A djuster scre w

Rotor stop

N ut ...

Gr i p

C a ble stop .

..

Steady rubber ...

Distance piece ..

.

Cup

Solid bush (for handlebar-mounted w indscreen)

2

2

2

2

4

1

1

2

1

2

1

1

1

2

1

1

1

1 All U.S.A. models

1

1

1 6T

1

TR6

2 T 120R, T120TI

1 T120

1

T120

1

2 T120

1

1

1

2

3

5

1

3

1 6T

1 TR6

1 U .

S .

A. 6T

1

TR6R , T120R

1

TR6C , T12 0 TT

1

T120R , T120TT

83

7

5

17

I

2

~ 1

/9

27"@

29

2 4

cak

23

~

2 6 ~

22

28

II

30 3 1

Fig , lJ ,

TOOLKIT , FRAME LOCK , PILLION FOOTRESTS ANO LICENCE HOLDER

84

!

I l

I

.I

l f l

I

I

f

'

I

I

•

I

I

.

,

I

10

11

12

7

8

9

4

5

6

1

2

3

17

18

19

20

21

22

13

14

15

16

23

24

25

26

27

28

29

30

31

32

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

TOOLKIT, FRAME LOCK, PILLION FOOTRESTS AND

LICENCE HOLDER

D363

D364

D336

400935

D496

DAS0 / 1

D296

D220

D402 / 3

D403

F5552

F1694

F2268

F5535

F2271

F2277

S1-51

F1695

D261

E1612

F879

D527

D365

WASS

D360

D361

NASS

DA16

PAS?

D311

D362

D87

TOOLKIT COMPLETE

Tool roll ..

.

Open spanner, tx-h in. Wh i t .

Open spanner,

1

3

6 xf in. Whit .

.. .

Open spanner, f x

1

5

6

In. Whit ... .

Open spanner, txn in. Whit ... .

Ring span ner, tx

1

9

6

Ring spanner, in . Whit. f x# in. Whit.

"C" spanner and tappet key

Plug spanner

Tyre lever and screwdriver

Tyre lever and clutch key

Phillips No. 3 screwdriver

Screwdriver

Screwdri v er for chain tens i oner

Clutch hub extractor ...

Tyre inflater

Fork spanner (for cap nut)

FRAME LOCK c / w KEYS

Key (state number )

PILLION FOOTREST ...

Pedal

Hanger

B olt

(ft in. U.H.)

Pivot bolt .

.

.

Thackeray (spring) washer

Nut

Pedal rubber

Licence holde r ..

.

Serrated washer

Nut

Fork spanner (for sleeve nut)

1

1

1

1

1

1

1

1

1

1

1

1 as require d

1 as required

1

2

2

2

2

2

2

2

2

1

1 as required

85

13---'-

25-----11

CARBURETTER COMPLETE

REF. N21

10

9

, - - - - - - - - - - - - - 1 8

, r - - - - - - - - - - - - - - - 1 9

- - - - - - - - - 4 1

- - - - : - - - - - - - - 4 2

- - - - - - ~ - - 4 6

1 5 1 - - - - S

16---.,,,._f;E

7-------

2

~a - - -

9 · - - - - -

- - - - - - - - - 4 0

- - - - - - - - - - - 3 8

- - - - - - - - - - - 3 2

/--.

,,;;, ,-. ~--:==----35

;-----36

'-------===----34

' - - - - - - - - - - - - - 3 3

' - - - - - - - - - - - - - - 3 9

2 3 - - - ' - -

Fig . 34 . AMAL CARBURETTER , 6T

86

Ref.

No . Part No.

22

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

27

28

29

30

31

23

24

25

26

1

5

6

7

8

9

2

3

4

10

11

12

13

14

15

16

17

18

19

20

21

376 / 303

376 / 003

244 / 1048

376 / 065

29 / 307

4 / 241

376 / 107

376 / 062

4 / 046

6 / 047

6 / 132A

4 / 035

376 / 060

376 / 061

376 / 068

376 / 069

376 / 070

376 / 057

376 / 067

376 / 073

376 / 074

376 / 100

376 / 075

376 / 072

376 / 063

4 / 230

376 / 076

116 / 017

376 / 095

332 / 017

4 / 148

376 / 085

376 / 083

376 / 094

376 / 078

376 / on

376 / 079

376 / 088

376 / 089

376 / 093

376 / 091

376 / 092

376 / 086

376 / 087

343 / 011

F5339

DESCRIPTION

AMAL CARBURETTER 6T

CAR.BUR.ETTER

Mixing chamber, 117 in. choke

"O" r ing seal

Mixing chamber cap

Spring

Screw

Mi xing chamber top

Air valve ...

Spring

Air valve guide

Throttle cable ferrule

Air cable adaptor ...

Throttle v alve (state cuta way)

Throttle return s pring

Throttle stop screw

Stop screw spring

Peg screw ...

Jet block (1-n in. choke)

Joint washer

Jet holder ...

Fibre washer

Main Jet (state size)

Co ver nut ...

Needle jet (0 .1

06) ...

Needle (Type

C) ...

Needle clip

Pilot jet (state size)

Fibre washer

Cover nut ...

Air adjusting screw

Spring

Float spindle

Float

Bush

Joint washer

Cover

Screw

Needle seating

Needle

Filter

Bolt

Fibre washer

Tickler

Tickler spring

Tickler body

Petrol p i pe

QUANTITY REMARK S

1

1

1

1

1 / 4 std .

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

{ 230 std.,

270 U .

S.A.

1

1

1

1

1

1

1

1

25 std.

87

CARBURETTER

REFERENCE N<?l COMPLETE

1 2 - - ~

14

21 - ~

2 3 -

2 4 - - -

Fig. 35 .

AMA L CARBURETTER

, TR6 AND T120

8 8

19

20

42

43

53

52

4 1

39

33

36

35

34

40

2

I

I n

I

I i i

I

I

I

I

I

I

I

I

I i i

I i

I

· I

I

I

I

42

43

44

45

46

47

48

49

50

51

52

53

24

25

26

27

28

29

30

31

32

33

38

38

39

40

41

34

35

36

37

6

7

8

9

10

11

1

1

2

3

4

5

20

21

22

23

16

17

18

19

12

13

14

15

Ref

No. Part No.

DESCRIPTION

376 / 095

332 / 017

4 / 148

376 / 085

376 / 083

376 / 094

376 / 078

376 / 077

376 / 079

376 / 151

376 / 070

389 / 109

376 / 067

376 / 073

376 / 074

376 / 100

376 / 075

376 / 072

389 / 063

4 / 230

376 / 076

116 / 162

389 / 97

389/203

389 / 002

244 / 1048

389 / 065

29/307

4 / 241

4 / 137A

389 / 107

389 / 062

4 / 046

29 / 057

6 / 132A

4 / 035

389 / 060

389 / 061

376 / 068

376 / 069

376 / 088

376 / 089

3 76 / 093

3 76 / 091

376 / 092

376 / 086

376 / 087

343 / 011

E2968

NA43A

F 2603

S25-3

T224

F5339

F5462

AMAL CARBURETTER, TR6

&

T120

CAR.BU RETTER.

CAR.BUR.ETTER.

Mixing chamber (1f in. choke) .

..

"O" ring seal

M ix ing chamber cap

Spring

Screw

Plug screw

Mixing chamber top

Air valve

...

Spring

Air valve guide

Thrott le cable f errule

Air cable adjuster

Thr ottle valve (state cutaway)

Throttle return spring

Thr ottle stop screw

Stop screw spr i ng

Peg screw ...

Jet block (1f in . c hoke)

Joint washer

Jet holder ...

Fibre washer

Main jet (state size)

Cover nut .

.

.

Needle jet (0.106) ..

.

Need l e (Type D) ...

Needle clip

Pilot jet (state size)

Fibre washer

Cover nut

Air adjusting screw

Spring

Fl oat spindle

Float

Bush

Joint washer

Cover

Screw

Screw

N eedle seating

Needle

Filter

B ol t

Fibre washer

Tickler

Ti ck ler spring

Tickler body

I nsulating b l ock

Joint washer

Bolt

Ht in. U.H.)

Pl ain washer

Nut

Petrol pipe

Petrol pipe

89

.

.

.

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

QUANTITY

T120 &

TR.6 T120R

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

REMARKS

2

2

4

4

2

2

2

2 See Pag e s 7 to 1 5

2

2

2

2

2 For T120 u se 389 / 0 56

2

2

2

2 See Pages 7 to 15

2

2

2

2

6

2

2

2

2

2

2

2

2

6

2

2

2

2

2

2 See Pages 7 to 1 5

2

2

CARBURETTER

R EF ER EN CE N':ll COMPLE T E

9 - ··

10

12

13

1 7 -

19 - -

20 - - -

F ig . 36 . AMAL C ARBURETTER

T120T T

90

3 1

30

36

2

49

3 7

35

2 9

3 2

15

1 6

38

39

48

.f f i

•

I

!

:

I i

I

.

,

I

Ref. No. Part No.

14

15

20

21

22

23

16

17

18

19

24

25

26

27

28

29

30

31

32

33

34

35

36

37

5

6

7

8

1

2

3

4

9

10

11

12

13

38

39

40

41

42

43

44

45

46

47

48

49

389 / 063

4 / 230

376 / 076

116 / 162

376 / 095

332 / 017

4 / 148

376 / 085

376 / 083

376 / 094

376 / 078

376 / 077

376 / 151

376 / 088

376 / 089

376 / 093

376 / 091

3 76 / 092

376 / 086

376 / 087

343 / 011

E4 918

E4919

F2603

S25-3

T224

F5 462

389 /06 6

389 / 95

389 / 030

244 / 1048

389 / 065

29 / 307

4 / 241

4 / 137A

389 / 107

6 / 132A

389 / 060

376 / 132

376 / 068

37 6 / 069

3 76 / 070

389 / 058

376 / 067

376 / 073

376 / 074

376 / 100

376 / 075

376 / 072

DESCRIPTION

AMAL CARBURETTER, T120TT

CARBURETIER

M i xing chamber (1-hin. choke)

"O" ring seal

Mixing chamber cap

Spring

Screw

Plug screw ..

.

Mixing chamber top

T h rottle cable ferru l e

Throttle valve (4 cutawa y)

Throttle return spring

Throttle stop screw

Stop screw spring

Peg screw ..

.

J et block (1

3

1 6

Joint washer

Jet holder ...

Fibre washer i n . choke)

Main jet (330)

Cover nut .

..

Need le jet (0 .1

06 )

Needle (Type

D) ...

Needle clip

Pilot jet (25)

F ibre washer

Co ve r nut

Air adjusting screw

Spring

Float spindle

Float

Bush

Jo int washer

Co ve r

Screw

Needle seating

Needle

Filter

Bolt

Fibre washer

Tic kler

Tickler spring

T i ckler body

Insu latin g bloc k

Jo i nt washer

Bolt

(ft in. U.H.)

Plain washer

Nut

P etrol pipe

Air intake tu b e

QUANTITY REMARKS

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

6

2

2

2

2

2

2

2

2

3

4

1

2

2

2

2

2

2

2

2

2

2

91

9

~ . . - - ; ; - - + - - 3

r-"Ti--i--

2

+---

6

......---

7

'----

8

·

- - 4

3 6 ~

!-11

24

25

--c.>

2 6 ~

28

16

18 17 19

Fig . 37 . SPEEDOMETER AND TACHOMETER

92

, 22 21

!

!

' !

I

_ I

,

I

I

I

I

I

I

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

2

3

4

5

6

7

.

8

9

10

11

12

13

14

15

1

1

1

1

Ref. No. Pa rt No.

DESCRIPTION

SPEEDOMETER AND TACHOMETER

SSM5002 / 00

SSM5002 / 01

SSM5001 / 00

SSM5001 / 01

Speedometer head MPH

Speedometer head KPH

Speedometer head MPH

Speedometer head KPH

554734

Bulb holder

987

Bulb, 3.W. M.E.S.

41-118-127-72

Trip control

31-753-778

Rubber ring

31-674-188-01

Fixing strap

30-283-014-11

Washer .

.

.

30-277--023-11

Nut

41-148-203-10

Trip control

H1702

Distance piece

H1701

H1668

DS57

Sleeve nut

Brack et ...

Bolt

(n; in. U.H.)

S26-2

D609

Spring washer ...

Speedometer cable (65 ins. lorig)

E5756

TACHOMETER GEARBOX

E5153

E5156

E5155

Securing screw

Bush

..

.

Flanged bush ...

E5157

Driving gear

E5759

E63 00

End cap

"O" ring ...

E5578

Driven gear

E6122

E6299

E6124

Driven gear housing

"O" ring

Bush

E33 09

"O" ring ...

E5881

Set screw ...

D578

Tachometer cable (28 in. long)

RSM3003 / 01

Tachometer

H1946

H1929

H1086

H1698

MOUNTING

30-282-014-11

Washer ..

.

30-276-037-11

Nut

BRACKET

Metalastik bush

Bolt (1-h in. U.H.)

Cable bracket

..

.

QUANTITY

REMARKS

1

1

6T

Alternative 6T

TR6, T120

Alternative

TR6, T120

U·T

1

1

1

1

1

2

2 TR6, T120

1

2

2

Smiths

DF9110 / 00

2

2

2

2

1

1

1

1

1

1

1

1

1

1

1

TR6 .

R, T120R ,

T120TT

93

19

8

()

()

()

2

~ i - - - - - 5

~

4

, - - - - - 10

20 21

22

18

&=

:

@--s

13 , - -..,.

1 ---i

16

@

Olli ii

----<l9

23

17

26

27

''

·,:·

1 \ ff'

11

! f

!

\

' / \

~

,

' l\l

~\~

,,

'

31~~~ ~ ~

3 3 34

35

Fig. 3 8 . A .

C . MAGN E TO I GNI TI ON COILS A N D DIR E C T LIGHTING

94

Ref. No. Port No.

DESCRIPTION

QUANTITY R EMARKS

A.C

. MAGNETO IGNITION COILS AND DIRECT LIGHTING

534343

54520452

5 04665

166

554602

112201

137499

31356

3 1 620

144921

534296

D552

11104 / 06 / 2

F43 66

E 1612

15104 / 00 / 2

D553

53972

384

F694 3

F6944

F1369

E1612

S1 -40

W932

F6125

F6136

45149

54441582

54190108

549 37097

31071

H1669

H1670

H687

H745

58395

36 and 37 not illustrated.

6

7

8

9

1

2

3

4

5

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

10

11

12

13

14

15

31

32

33

34

35

36

37

L eft coil bracket

Right coil bracket

B o lt

(i in . U.H.

)

Ser rated washer

Nut

B olt ( 1 in. U.H.)

Retainer .. .

Retainer .. .

Ign i tion coil, type 3ET

Condenser

Lucas ter mina l .. .

Wiring harness .. .

Cut-out button , t ype SS5

Cup

Clip

B olt

(i in. U.H

.

)

Nut

HEADLAMP ASSEMBLY, MCH 66 ..

.

Rim ...

Light unit ...

Fi xing wire

Bu lb (24f24W. Pr e-focus, Vert i cal Dip)

Adaptor

Bo l t

Washer

Lighting switch

Dip switch ..

.

Screw

Pl ate

Horn, clear hooters AC585SG

Bolt

Distance piece ...

Serrated wa sher

Nut

Horn push, clear h ooters No. 10

STOP AND TAIL LAMP , T ype 679

Bulb (6 / 18W. Offset pin)

1

1

2

2

2

2

1

4

2

2

1

2

6

6

TR6C &

T12 0TT

"K il l b u tto n "

1

6

1

2

2

2

1

Eastern TR6C

1

1

1

1

1

1

1

1

1

E xcept for bulb

See Page 99

95

27

25

1 3 - /

14

1 5 ~

~

9 cD1s~&

10

~

:.,.-----;,,::t1..._~-::::,

!III

11

~~~: e1'f

6 r\

9

~

10 8

20

26 - -'

29

31

32 ril

~ r

21 22 23

30 33 38 37 i

!

36 ~

~ 1 8

17

32

1 - - - - 42

35 - - t

39 41

43

Fig , 39. D.C. IGNITI ON COILS , HORN , RECTIFIER AND ZENER DIODE

96

r _ • •

1

Ref. No. Part

No.

DESCRIPTION

QUANTITY REMARKS

38

39

40

41

34

35

36

37

42

43

44

45

28

29

30

31

32

33

18

19

20

21

22

23

24

25

26

27

7

8

9

10

11

12

13

14

15

16

17

1

2

3

4

5

6

D262

F6943

F6944

F1369

E1612

S1--40

F879

E6388

E6389

54441582

F3799

GS299

49072

F5338

F6896

F6900

49345

DS57

S25-1

54937976

842183

35601

H1669

H1670

H687

H745

70164

F4771

D .

C . IGNITION COILS, HORN, RECTIFIER AND ZENER DIODE

45110

54190108

131023

188330

166043

421554

421863

100104

169160

422369

54942078

54190042

F4744

F5466

F4366

E3290

IGNITION COIL, Type MA12

Lucar terminal

Plain washer (E2351)

Serrated washer (GS299)

Nut (F3799)

Rubber grommet ...

Cable clip ...

Screw

Square nut

"D" washer

Lu car connector

Insulat i ng cover

Bolt (1

1

5

6 in. U.H

Rubber grommet

.

)

Distance piece ...

Self loc k ing nut

Sparking plug (Champion N4)

Plug cover

Left coil bracket

Right coil bracket

Bolt (tin . U .

H.)

Serrated washer

Nut

Nut

Ignition coil, Siba 32,000

Cl i p, Siba 32 , 000 / 1

Condens e r

H.T. lead complete (resist i ve)

H.T

. lead (7 m.m. cable)

Cut-out button, type SSS

Cup

Clip

Bolt

(t in. U.H

.

)

Nut

Horn, type 8H ..

.

Screw (t in. U .

H.)

Nut

Serrated washer

Rectifier, type 2DS 506

Nut(156596) ...

Bracket .

..

Mounting plate ...

Zener diode

Bolt

(fr

In. U.H

.

)

Washer .

.

.

2

J6T , TR6, TR6R

2

2

2

1

1

1

1

2

2

2

2

1

1

1

1

2 n

&

T120

4 as required as required

2

2

.

'

1

1

2

2

6

2

2

2

1

1

6

2

4

2

2 N58R for

T120TT

2

T120R

2

2

TR6, TR6R ,

T120 , T120R

TR6, T120

TR6R , T120R

"Kill button"

.

97

f

27 28

29 30 f~

31

7

5

.~

6 1 1 ~

17

'

' ~ > '1f

JIF

(!,

;~~

14 13

~ 1 2

24

25

23 22

Gl

20

21

33

19

~ 34

\.-- 3 6

18

49

47

Fig . 40. HEADLAMP, WIRING HARNESS, SWITCHES AND TAIL LAMP

98

19

20

21

22

23

24

25

26

27

36

37

38

39

40

41

4 2

32

33

34

35

28

29

30

31

7

8

9

10

11

12

13

14

15

16

17

18

4

5

" 6

1

2

3

43

44

45

46

47

48

49 so

51

Ref. No. Part No.

DESCRIPTION

QUANTIT Y REMARKS

HEADLAMP, WIRING HARNESS, SWITCHES AND TAIL LAMP

850832

53454

573839

575200

575208

575219

576002

575209

575207

573828

573825

380

5 3973

54572932

572289

54.574348

573828

380 .

54571677

127684

838604

112201

137499

38189

281

H1932

F6981

31899

34289

54330934

F5983

F5988

54330576

54930007

54938941

900269

900288

850641

850844

595 7 9

553248

516798

504665

14-4921

534296

446

554602

988

554710

36296

86TI17

. HEADLAM P COMPLETE

R i m ...

Light unit .. .

Fixing wire .. .

Screw

Plate

Bulb .

(50 / 40 W. Vert dip . Pre-focus)

Main bulbholder ...

_ (3W. M .C.

C.

)

Pilot bulbhol.der .

.

.

Ammeter, type 2AR

Grommet ...

Bolt

Plain washer

Ignition warn i ng light body

Bulb (2W. BA7S) .

..

Headlamp spacer

Ignition lock c / w two keys

Ign i tion switch , type S45

Lighting switch, t y pe 8&SA

Knob c / w screw

Bra c ket ...

Rubber band

Switch bezel plate

Replacement harness so cket (Lighti ng )

Wiring harness ..

.

Snap connector terminal

Sing le snap con nectar ...

Double snap connector

Triple snap connector ...

Quintuple snap connector

STOP AND TAIL LAMP , Type 564

Lens

Window ...

Lens seating gasket

Sleeve nut .

.

.

Base assembly

Bulbholder

Grommet ...

Contact assembly ...

Gromme1; ..

.

.

Bulb (6 / 21 W . Offset pin)

STOP AND TAIL LAMP. Type L6 79

Lens

Screw

Bulb holder with reflector

Contact assembly .

.

.

Buib (6f21W. Offset p i n)

Gasket

Screw

Stop and tail lamp lead

...

1

2

1

1

1

1

2

1

1

1

2

6

1

1

1

1

1

1

1

2

2

1

1

2

1

1

1

1

1 as requ i red as r equired as required as required as require d

1

1 TR6, T120

1

1

1

1

TR6R, T120R

99

.

.

.

, ·

.

.

.

• :

...

.

.

.

.

~

..

.

...

.

,

.

..

· '-·

'

.

,·.

British Only

MOTORCYLES AND PARTS INC.

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MOTORCYCLES AND PARTS INC.

32451 PARKLANE ST

GARDEN CITY, Ml 48135 USA

PHONE: 800-278-6659

FAX: 734-422-9253

Quantity Part #

Year:

Engine #

Frame #

Make: Model:

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Michigan Residents

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Amount

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MOTORCYCLES AND PARTS INC.

32451 PARKLANE ST

GARDEN CITY, Ml 48135 USA

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