REPLACEMENT PARTS
CATALOGUE No. 7
UNIT CONSTRUCTION 40 cu. ins. TWINS
TR6R TIGER 650
TR6C TROPHY 650
Tl2OR BONNEVILLE 120
From engine No. DU 85904
T R I U M P H E N G I N E E R I N G C O M P A N Y L I M I T E D
M E R I D E N W O R K S . A L L E S L E Y . C O V E N f R Y . E N G L A N D
T E L E P H O N E MERIDEN 331 TELEGRAMS "TRUSTY COVENTRY"
PUBLISHED SEPTEMBER 1960 REF. SPC.7.
TRIUMPH GUARANTEE 1. i n this Guarantee the w o r d "machine" refers t o t he mo to r cycle, scoorer, mo to r cycle combination
o r sidecar as t h e case may be, purchased by t he Purchaser.
2. I n o rde r t o obta in t he benefi t o f this Guarantee, the Purchaser must have correctly completed the
3 regist rat ion fo rm and returned it t o us w i t h i n fourteen days o f t he purchase.
1 3. W e w i l l supply, free o f charge, a new pa r t i n exchange for, or , i f w e consider repair sufficient, w i l l
repai r free o f charge any par t proved w i t h i n s ix months o f the date o f purchase of any new machine, ( three months overseas) o r w i th in th ree months o f i ts renewal o r repair i n the case o f a par t already renewed o r repaired, t o be defective by reason o f our faulty workmanship o r materials. W e do n o t undertake t o bear t he cost o f f i t t ing such new o r repaired par t or accessory.
4. A n y pa r t considered t o be defective must be sent t o ou r Worlcs, carriage paid, accompanied by the fo l lowing information:-
(a) Name o f purchaser and his address; (b) Date o f purchase o f machine; (c) Name o f dealer f rom whom the purchase was made;
'
(d) Engine number and model.
5. This Guarantee shall n o t extend t o defects o r damage appearing after misuse, neglect, abnormal stress or strain, o r the incorporation o r affixing o f unsuitable attachments o r parts and i n particular:-
(a) H i r i ng ou t ; (b) Racing and Compet i t ions; (c) Adaptat ion o r alterat ion o f any par t or parts after leaving ou r Works ; (d) The attaching o f a sidecar i n a manner n o t approved by us o r t o an unsuitable
m o t o r cycle. This Guarantee shall n o t extend t o machines whose trade mark, name o r manufacturing number has been altered o r removed, o r i n 'which has been used any par t no t supplied o r approved by us, o r t o ryres, saddles, chains, speedometers, revolut ion counters and electrical equipment o r t o parts supplied t o t he o rder of t he Purchaser and dif ferent f rom ou r standard specification.
6. O u r l iabi l i ty and that o f o u r dealer w h o sells t h e machine, shall be l imi ted t o that set ou t i n this guarantee, and no o ther claims including claims for consequential damage o r in ju ry t o person o r property, shall be admissible. A i l o ther conditions and warranties statutory o r otherwise and whether express o r impl ied are hereby excluded and no guarantee other than that expressly herein contained applies t o t he machine t o which this Guarantee relates o r any accessory o r par t thereof.
7. W e reserve the r igh t t o modify o r deviate f rom the Published Specification w i thou t notice,
REPAIRS G U A R A N T E E
1. W h i l s t the highest standard o f workmanship and maierials is aimed at, w e cannot accept l iabi l i ty for any defects appearing more than th ree months after the machine, assembly o r component has left o u r Wor lcs after being repaired.
2. W e wi l l repair o r replace a t o u r op t ion free o f charge any defective work , materials o r parts relating t o t he repairs carried o u t by us appearing w i th in that t ime bu t shall n o t be under any fur ther or other l iabi l i ty for any o ther loss o r damage whether d i rect o r consequential and ou r liability shall be l imited to the cost o f so making good. W e do n o t undertake t o bear the cost o f f i t t ing any replacement o r repaired part.
3. W e do no t accept l iabi l i ty i n respect o f parts of propr ietary manufacture, e.g. tyres, saddles, chains. speedometers, r?volut ion counters and electrical equipment which may be used by us i n effecting a repair. A l i o ther conditions and warranties statutory or otherwise expressed o r implied are hereby excluded.
TRIUMPH SPARES HOW TO ORDER. Every par t is indicated by number, and this should be quoted together w i t h
t h e description. In order t o assist customers, dimensions have been given i n many cases where parts are similar. Parts where possible have been listed i n o rder o f assembly and a number o f the il lustrations show t h e assembly o rde r also. W i t h these aids there should be no d i f i cu l ty i n identifying t he parts you require A l w a y s h e a d y o u r o r d e r w i t h t h e e n g i n e n u m b e r , s t a m p e d o n t h e l e f t s ide o f t h e c r a n k case u n d e r n e a t h t h e c y l i n d e r flange, t o g e t h e r with t h e p r e f i x le t ters.
W H E R E TO O B T A I N . Tr iumph Spare Parts can only be obtained from an authorized Tr iumph Dealer, and w e recommend ou r customers t o place the i r orders w i th the Tr iumph Dealer i n thei r district. W h e n par ts n o t usually asked for are required, and f o r which the Dealer may have t o w r i t e o r obtain specially, t h e postage o r carriage incurred becomes payable.
T r i u m p h Spares a r e n o t supp l i ed t o p r i v a t e o w n e r s d i r e c t f r o m t h e fac to ry . If d i f f i c u l t y i s e x p e r i e n c e d in o b t a i n i n g t h e r e q u i r e d par ts , t h e m a t t e r shou ld b e t a k e n u p d i r e c t l y with t h e T r i u m p h Spa res D e p a r t m e n t .
Customers are warned against t he r isk incurred by purchasing parts that are no t o f genuine Tr iumph manufacture. This r isk is eliminated i f parts are ordered as instructed f rom recognised Dealers.
P A T T E R N S A N D P A R T S F O R REPAIR. It is not necessary t o send patterns i f the par t number is quoted. T h e sending o f patterns often delays the order as parcel post o r rai l takes longer than let ter post.
Parts sent t o Coventry for repair, replacement, o r as patterns should bear the sender's name and address and clear instruct ions should accompany the parts. In your own interest send a copy o f the advice note under separate cover. A l l pans must be fowarded carriage paid and care should be taken t o ensure that a l l remittances are sent separately and n o t enclosed w i t h the parts. Fragile units such as cylinders, etc., should always be boxed t o avoid damage i n transit. Complete machines should have all f itments such as
windscreens, dr iv ing mirrors, tools, etc., removed by the sender before despatch, as it is impossible for us t o accept responsibil ity i n t he event o f loss i n transit. W e are always pleased t o give estimates for over- hauling and repairs, bu t should an estimate n o t be accepted, a charge w i l l be made covering cost of dismantling and re-assembling, i f carried out.
Communications relating t o Parts should be addressed t o the SPARES DEPARTMENT and for repairs. guarantee claims and technical advice t o the SERVICE DEPARTMENT. Tr iumph Engineering Co. Ltd., Meriden Works , Allesley, Coventry. In o rder t o facilitate quick reference, the quoting o f any number, invoice number o r reference f rom previous communications is essentizl. Accessories not o f ou r manufacture should be sent d i rect t o the actual makers, whose names and addresses appear below.
PROPRIETARY GROUP Ancil lary equipment which i s f i t ted t o ou r mo to r cycles i s o f the highest quality and is guaranteed by
t he manufacturer and no t by ourselves. Any repairs or claims should be made t o the actual makers o r the i r local agents w h o w i l l always give owners every possible assistance. The fol lowing are the addresses o f t he various manufacturers:-
CARBURETTERS SPARKING PLUGS Messrs. Ama l Lid., Champion Sparking Plug Co. Ltd.. Holdford Rd.. W i t t o n , Birmingham 6. Feltham. Middlesex.
CHAIFIS Renold Chains Ltd., Wythenshawe. Manchester.
ELECTRICAL EQUIPMENT Messrs. J. Lucas Ltd., Gt. Hampton St., Birmingham, 18
SPEEDOMETERS Messrs. Smiths Industries Ltd., Cricklewood Works. London. N.W.2.
SUSPENSION UNITS Messrs. Gir l ing Ltd., Birmingham Road, West Bromwich. Staffs,
TYRES Dunlop Rubber Co. Ltd.. Fo r t Dunlop. Birmingham, 24
INDEX
Page Page
AIR FILTER ... ... ... ... 57 ALTERNATOR ... ... ... ... 13 . 33
... AUTO-ADVANCE UNIT ... 23
. . . . . . BATTERY CARRIER ... 57 BRAKE SWITCHES . . . . . . ... 65
CAMSHAFT. INLET AND EXHAUST 13 CAPACITOR. IGNITION ... ... 75 CARBURETTER ... ... ... 69 . 71 CARTON PACKS ... ... ... 9 CENTRE STAND ... ... ... 35 CHAINS . . . . . . ... ... ... 33 CHAINCASE . . . . . . ... ... 33 CLUTCH ... ... ... ... 31 CLUTCH LEVER ASSEMBLY ... 29 COIL ... ... ... ... . . 77 CONDENSER PACK . . . . . . ... 77 CONNECTING RODS ... ... 13 CONTACT BREAKER . . . . . . ... 23 CONTROL CABLES . . . . . . ... 65 CONTROL LEVERS . . . . . . ... 63 CRANKCASE . . . . . . ... ... 15 CRANKCASE UNDERSHIELD ... 39 CRANKSHAFT . . . . . . ... ... 13 CYLINDERS ... ... ... ... 19. 21 CYLINDER HEAD ... ... ... 19. 21 ....
ENGINE PLATES ... ... ... 39 ENGINE TORQUE STAY ... . . . 39 EXHAUST PIPES ... ... ... 41.43 EXHAUST PIPE ADAPTOR . . . . . . 19.21
FENDERS ... ... ... ... 61 FOOTRESTS ... ... ... ... 39. 67 FRAME . . . . . . ... ... ... 35 FRONT BRAKE ... ... ... 49 FRONT FORKS ... ... ... 45 FRONT WHEEL ... ... ... 49 FUSE ASSEMBLY ... ... ... 57
GAS TANK ... ... ... ... 53 . . . . . . GASKET SET ... ... 9 ... GEARBOX ... ... 25. 27. 29
HANDLEBARS . . . . . . ... HANDLEBAR MOUNTINGS ... HEADLAMP ... ... ... HEAT SINK ... ... ... HORN . . . . . . ... ...
KICKSTARTER . . . . . . ...
MANIFOLD ... ... ... MUFFLERS ... ... ...
OIL PUMP ... ... ... OIL TANK ... ... ...
PISTONS ... ... ... PROP STAND . . . . . . ... PUSH RODS . . . . . . ...
REAR WHEEL . . . . . . ... RECTIFIER ... ... ... REFLECTORS . . . . . . ... ROCKERS ... ... ...
SIDE PANEL . . . . . . ... SPARKING PLUG ... ... SPEEDOMETER . . . . . . ... SPEEDOMETER GEARBOX ... STEERING DAMPER . . . . . . STEERING RACES ... ... SUSPENSION UNITS . . . . . . SWINGING FORK ... ... SWITCHES ... ... ...
TACHOMETER . . . . . . ... TACHOMETER GEARBOX ... TAIL LAMP ... ... ... TAPPETS ... ... ... TIMING GEARS ... ... TOOLKIT ... ... ... TWIN SEAT . . . . . . ...
VALVES . . . . . . ... ... VALVE GUIDES ... ...
WIRING HARNESS
ZENER DIODE
T I G E R 6 5 0 ( T R 6 R ) T E C H N I C A L D A T A
Bo re and s t roke . . . . . . . , . ... ... ... ... ... ... ... 71 x 82 rnrn.
2.79 x 3.23 ins.
Capacity . . . . . . ... ... ... ... ... ... ... ... ... 649 C.C. (40 cu. ins.)
Compress ion r a t i o
Spark plugs ...
Ca rbu re t t e r ...
Gearbox sprocket
Chains ... ...
Capacit ies ...
Brakes ... ...
T i r e size . . . . . .
. . ... ... ... ... Main jet ... ... Needle jet ... ... Throttle valve . . . . . .
Front ... ... ... Rear ... ... ...
... ... Gas Tank ... ... Oil Tank ... . . . Gearbox ... ... Primary Chaincase ... Front Forks (each leg)
... ... Front, diameter ... ... Rear, diameter ...
.. Front ... ... ... Rear ... ... ...
Champion N3
... ... ... Amal Concentric 930
... ... ... 230
... ... ... .I 06
... ... ... No. 3+
19 teeth
... ... ... +" Duplex x 84 links
... ... ... %" x x 104 links
... ... ... 3$ U.S. galls. (16 litres)
... . . . ... 6 U.S. pints (2.8 litres)
... ... ... $ pint (500 c.c.)
... ... ... 2 pint (350 c.c.)
... ... ... f pint (200 c.c.)
... ... ... 8" (20.32 cm.)
... ... ... 7" (17.78 cm.)
B o r e and s t roke ...
T R O P H Y 6 5 0 ( T R 6 C ) T E C H N I C A L D A T A
Capacity . . . . . .
Compression r a t i o
Spark plugs ...
Carbure t te r ...
Gearbox sprocket
Chains ... ...
Capacit ies ...
Brakes ... ...
T i r e s i z e . . . . . .
... ... ... ... Main jet ... ...
... Needle jet ...
. . . . . . Thrott le valve
Front ... ... ... Rear ... ... ...
Gas Tank ... ... Oi l Tank ... ... Gearbox ... . . , Primary Chaincase ... Front Forks (each leg)
... ... Front, diameter . . . . . . Rear, diameter . .
... Front ... ... ... Rear ... ... ...
71 x 82 mm. 2.79 x 3.23 ins.
... ... ... 649 C.C. (40 cu. ins.)
Champion N3
... ... ... Amal Concentric 930
... ... ... 230
... ... ... .I 06
... ... ... No. 3f
... ... ... +'' Duplex x 84 links
... ... ... $ " x + " x l 0 4 l i n k s
... ... ... 2$ U.S. galls. (11 litres)
... ... ... 6 U.S. pints (1.8 litres)
... ... ... pint (500 c.c.)
... ... ... $ pint (350 c.c.)
... ... ... f pint (200 c.c.)
... ... ... 8" (20.32 cm.)
... ... ... 7" (17.78 cm.)
B O N N E V I L L E ( T 1 2 O R ) T E C H N I C A L D A T A
... Bo re and s t roke
Capacity . . . . . .
Compression r a t i o
Spark plugs ...
Carbure t te rs ...
Gearbox sproclcet
Chains ... ...
Capacities
Brakes ... ...
T i r e Size . . . . . .
... ... ... ... Main jet ... ... Needle jet ... ... Throttle valve . . . . . .
... ... ... ... ... Front Rear ... ... ...
... Gas Tank ...
... Oi l Tank ... Gearbox ... ...
... Primary Chaincase Front Forks (each leg)
... Front, diameter . . . . . . Rear, diameter ...
Front ... ... ... ... Rear ... ...
... 71 x 82 mm. 2.79 x 3.23 ins.
... ... ... 649 C.C. (40 cu. ins.)
... ... ... 9 :I
Champion N3
... ... ... 2 Amal Concentric 930
... ... ... 190
... ... ... .I 06 ... ... ... No. 3
... ... ... 19 teeth
... ... ... +" Duplex x 84 links
... ... ... x x 104 links
... ... ... 2; U.5, galls. (11 litres)
... ... ... 5 U.5. pints (2.8 litres)
... ... ... + pint (500 LC.) ... ... ... 5 pint (350 c.c.)
... ... ... f pint (200 c.c.)
... ... ... 8" (20.32 cm.)
... ... ... 7" (17.78 cm.)
4 C A R T O N P A C K L I S T
1 The following sub-assemblies are supplied in carton packs under the C.P: part number stated. The contents o f these carton packs are preserved and wi l l not deteriorate under adverse conditions.
Part No. Contents
B rake L in ing
C.P.38/A.M.2 . . . . . . 2 . . . . . . ... NW243 . . . . . . ... Brake lining
16 . . . . . . ... W129 . . . . . . ... Rivet
Pistons (complete with rings, gudgeon pins and circlips). These are in effect "carton pack" assemblies.
E6868 . . . . . . ... ... ... ... 9 : 1 CR. ... ... Standard
E6867 . . . . . . ... ... ... ... 11 :I CR. ... ... Competition use only
Al l the above pistons are available in oversizes of 0.010 ins., 0.020 ins., 0.040 ins., (0.25 mm.,0.5 mm..lmm.)
De-coke Gasket Set Al l models . . . . . . ... ... ... ... DGS7
Ove rhau l Gasket Set Ail models . . . . . . ... ... ... ... GS/B/66/67
F o r k Service pack ... ... ... ... ... ... ... CP168,64T
Steer ing Race K i t
C.P.156 . . . . . . ... 2 . . . ... ... HI11 ... ... ... Cups
1 . . . . . . ... H439 ... ... ... Cone
1 . . . . . . ... HI018 . . . . . . ... Top cone
40 . . . . . . ... 570-3 ... ... ... Ball
HOW TO USE THIS PARTS CATALOGUE
First check tha t t he engine number o f you r machine is subsequent t o tha t quoted o n the t i t l e page.
N e x t consult t he index on Page 4 for the parts o r g roup o f parts which you wish t o locate. When you have located t he parts make sure from the end columns tha t the par t you have located does apply t o your machine.
List t h e quantities required as single units; do n o t ask for "2 pairs" o r "3 dozen". I .
Proprietary components e.g. electrical equipment, carburetters, suspension units etc. are listed i n the f i rs t c o l u m n ~ n d e r ~ r i u m ~ h par t numbers (prefixed either D-or99-) whereverthey are stocked a t t he factory. I f propr ietary par ts are listed only under manufacturers par t numbers, they are n o t available from,the factory.
In case o f painted items always state the colour required. Painted parts are available only in t he colours o r alternatives specified for that model o f that particular year.
Model
TR6 all cond~t ions
T12OR
Colour
Trophy Red/Silver
Olympic Flame/Silver
N.B. Trophy Red and Olympic Flame are bo th flamboyant finishes applied over Silver.
Paint is available only in Aerosol containers.
P L E A S E N O T E i
THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS INCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN, REVERTING TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENT PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.
S P E C I A L W O R K S H O P T O O L S
A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING YOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASES THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE. AND THEREFORE, IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES IT I S FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.
U N I F I E D T H R E A D F O R M
NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOGUE HAVE THE UNIFIED FORM OF SCREW THREADS. THIS CHANGEOVER WlLL BE CONTINUED AS AND WHEN NEW PARTS ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS WlLL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS HAVING THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS IN THEIR HEADS. STUDS A CIRCULAR GROOVE O N THE END. AND NUTS HAVE INTERLOCKING CIRCLES ON THE SIDE.
i I
41 19 io 21 22 23 24 2s
Fig. 1. CRANKSHAFT A N D C O N N E C T I N G RODS
Ref . No . I - Part No .
"E9686 E4643 E3903 E3905
"'E9687 *E9307
E3114 E9S25 El 51 1 E6576 5549 E3586 E6868 E6867 E6864 E6865 E6863 E6869 El 591 E3876 E5446 E4573 E3974 99-0739 E3975 E3977 El580 E4564 E4565 E6159 E400 E4562 El558 El 463 E4563 E l 0040 El 0041 i E4700
E5316 E2256 E3300 E2879
OESCRIP TlON QUANTITY REMARKS
C R A N K S H A F T A N D C O N N E C T I N G R O D S
CRANKSHAFT A N D FLYWHEEL ASSEMBLY . . . . . . ... 1 ... ... CRANKSHAFT C/W . OIL TUBE ... ... 1 ... ... ... ... ... O i l tube ... ... 1 ... ... ... ... ... Screwed plug ... 1 ... ... ... ... ... Flywheel . . . . . . ... 1 ... ... ... ... ... Flywheel bolt ... ... 3 ... ... Crankshaft stud ( I+ in . O.A.) . . . . . . ... 1 ... ... CONNECTING ROD . . . . . . ... ... ... 2 ... ... ... ... ... Small end bush ... ... 2 ... ... Connecting rod bolt ... ... ... ... 4 ... ... ... Self locking nut . . . . . . ... ... 4
Big end bearing (Available in -.010 in . and -.020 in . oversizes) 4 ... ... PISTON COMPLETE 9 : 1 C.R. ... ... ... 2 ... .... PISTON COMPLETE 11 : 1 C.R. . . . . . . ... 2
... ... ... Taper compression ring . . . . . . ... 4 ... ... ... ... O i l control ring . . . . . . ... 2 ... ... Gudgeon pin (long) ... ... ... ... 2
... ... ... Circlip ... ... ... ... ... 4 ... ... ... Main bearing. right ... ... ... ... 1 ... ... Oil seal ... ... ... ... ... ... ... 1 ... ... Engine sprocket, 29 teeth Duplex ... ... ... 1 ... ... Distance piece . . . . . . ... ... ... ... 1 ... ... ... Rotor key ... ... ... ... ... 1
... ... ... Rotor (54213901) ... ... ... ... 1 ... ... ... Tab washer ... ... ... ... ... 1 ... ... ... ... ... Nu t ... ... ... ... 1 ... ... Key ... ... ... ... ... ... ... 1
. . . . . . ... ... Timing pinion ... ... ... ... 1 ... ... Nut ... ... ... ... ... ... ... 1 ... ... ... INTERMEDIATE WHEEL ... . . . ... 1 ... ... Intermediate wheel bush . . . . . . ... ... 1 ... ... ... Camshaft wheel . . . . . . ... ... ... 2 ... ... ... ... ... Camshaft key ... ... ... 2 ... ... ... ... ... ... Inlet camshaft nut ... 1 ... ... ... Exhaust camshaft nut . . . . . . ... ... 1 ... ... ... ... Inlet camshaft. Racing type ... ... 1
EXHAUST CAMSHAFT. RACING TYPE . . . . . . ... ... 1 ... ... Tachometer drive thimble ... ... ... 1 ... ... ... Rotary breather valve . . . . . . ... ... 1 ... Breather valve spring . . . . . . ... ... ... .. 1
... ... ... Clamping washer ... ... ... ... 1
... ... ... ... ... Main bearing. left ... ... 1
' Use D524 Loctite Sealant ** For the commencement of the season. the previous 'light' type of crankshaft
assembly (Part N o . E7331) i s fitted . The flywheel only from this assembly bears Part N o . E7332
i. Use E7050 to replace without dismantling motor
Fig. 2. CRANKCASE
14
DESCRIPTION
C R A N K C A S E ... CRANKCASE DRIVE SIDE ...
Breather disc ... ... ... Locating pin-at disc ... ... In let camshaft bush ... ... Exhaust camshaft bush . . . . . . Chain rensioner abutment ... Breather pipe (metal) ... ...
CRANKCASE T IM ING SIDE ... Camshaft bush ... ... ... Scavenge pipe ... ... ... Locating peg (at o i l pipes) ... H o l l o w dowel ... ... ... Locating peg (L/S at thrust washer) Needle ro l ler bearing. layshaft ... Intermediate wheel spindle ...
Ho l l ow dowel . . . . . . ... ... Ho l l ow dowel . . . . . . ... ... Screw (s i n . U.H.) ... ... ... Stud (4f i n . O.A.) ... ... ... Plain washer ... ... ... ... N u t ... ... ... ... ... Ho l l ow dowel. tappet o i l feed ... Oi lway plug ... ... ... ... Copper washer . . . . . . ... ... Tachometer dr ive plug (L.H. thread) Fibre washer ... ... ... ... O i l pipe stud ( I f i n . O.A.) . . . . . . Cyl inder stud (1: in . O.A.) . . . . . . Plug. t im ing hole ... ... ... Bol t (2f i n . U.H.) U N . . . . . . ... Bol t (1; i n . U.H.) U N . . . . . . ... Bol t (1; i n . U.H.) U N . . . . . . ... Stud ( 5 - h i n . O.A.) ... ... ... Stud (3; in . O.A.) ... ... ... Plain washer ... ... ... ... N u t ... ... ... ... ... Crankcase f i l ter U N . . . . . . ... Copper washer . . . . . . ... ... Breather extension pipe ... ... Drain plug ( w i t h level tube) U N ... F ~ b r e washer ... ... ... ... Level plug U N . . . . . . ... ... Copper washer . . . . . . ... ... Drain and adiuzter plug ... ... Fibre washer ... ... ... ... Biant ing plug ... ... ... ... Fi l ler plug U N . . . . . . ... ... Fibre washer ... ... ... ... Bo l t (4 i n . U.H.) U N . . . . . . ... Stud (4) i n . O.A.) ... ... ...
... Protect ion blade ... ... Self locknut U N ... ... ... Rubber plug (for protect ion blade stud I
QUANTITY REMARKS
... I
... 2
... Reference only
... Reference only
... 2
... 1
... 1 .... 1 ... 1 ... 1 ... 2 ... 1 ... 2 ... 2 ... 2
... I
... 2 (TR6C 3 off)
... 11
... 8
... 1
... 1
... I
... 1
... 1
... 2
... 2
... 1
... 1 (Except TR6C)
... 1
... 1
... 1 TR6R. T12OR
ASSY 13 16 24 18 23 20
21
22
Fig. 3. O I L PUMP. RELEASE VALVE, M A N I F O L D A N D TAPPETS
16
1 I Ref . No . Port No . DESCRIPTION QUANTITY REMARKS
1 O I L P U M P . R E L E A S E V A L V E . M A N I F O L D A N D T A P P E T S
E6928 Reference only GS153 E6681 E495 570-7 E403 E2360 E3730 51 864 E3887 51 906 E6595 E7590 GS251 E6596 GS254 E7591 E l 670 51 876 E5660 E5512 525-1 3 51 877 E2962 N A 4 3 A £491 8 525-3 El310 £9352 E9353 El612 HZ00 E3059R £8801 E7563
... ... ... ... O I L PUMP ... ... ... ... 1
... ... ... ... Pump body . . . . . . ... ... 1
... Feed plunger ... ... ... ... ... ... 1 ... ... ... Scavenge plunger ... ... ... ... 1
... ... ... ... ... ... D r i v e block ... 1 ... ... Valve ball (6 i n . dia.) ... ... ... ... 2 ... ... Valve spring ... ... ... ... ... 2
... ... ... ... ... Screwed plug ... ... 2
... ... ... ... Joint washer ... ... ... ... 1 ... ... Oil p u m p stud (I* i n . U.H.) ... ... ... 2
... ... ... ... ... ... Serrated washer ... 2
... ... ... ... ... ... ... N u t ... ... 2 . . . . O I L RELEASE VALVE ... ... ... ... ... 1
... ... Valve body ... ... ... ... ... 1 ... ... ... ... ... ... Piston ... ... 1
... ... Cap . . . . . . ... ... ... ... ... 1 ... ... Fibre washer ... ... ... ... ... 1
... ... ... Main spring ... ... ... ... 1 ... ... ... ... ... ... ... Fibre washer ... 1
... ... ... Stud (1E in . O.A.) . . . . . . ... ... 4 ... ... ... ... ... ... ... Joint washer ... 2 . . . . . . ... ... ... ... In let manifold ... ... ... ... Plain washer ... ... ... ...
... ... ... ... N u t ... ... ... ... ... ... ... Stud ( I& i n . O.A.) ... ... ...
... ... ... Joint washer ... ... ... ... ... ... ... ... ... ... ~6 1 & TR6C insulating bloclc ... ... 1
... ... ... Plain washer ... ... ... ... ... 2
... ... ... ... ... ... N u t ... ... ... 2 ... ... ... ... ... In let tappet guide ... ... 1
... ... Exhaust tappet guide . . . . . . ... ... ... 1
... ... ... ... Serrated washer ... ... ... 2
... ... ... ... ... Set bo l t . . . . . . ... ... 2
... ... ... ... In let tappet ... ... ... ... 2 . . . . . . ... ... Exhaust tappet ... ... ... ... 2
... ... ... ... " O - r i n g ... ... ... ... 2
Fig. 4. CYLINDER BLOCK A N D HEAD, TR6
18
i Ref. No . Part No . DESCRIPTION QUANTITY REMARKS
C Y L I N D E R B L O C K A N D H E A D . T R 6 R . T R 6 C
Cyl inder base washer . . . . . . ... . . . . . . Cyl inder block ... ...
Cyl inder base n u t ... ... ... ... ... Push r o d ... ...
Cover tube ... ... ... ... ... Rubber washer . . . . . . ...
Cyl inder head gasket . . . . . . ... ... CYLINDER H E A D c / w GUIDES
... In le t valve guide ... ... Exhaust valve guide ... ...
... Exhausr pipe adaptor ... ... ... Inlet valve ... ...
Exhausr valve . . . . . . ... . . . ... ... ... Botrom cup ...
. . . . . . Inner valve spring (red spot) ... Oure r valve spring (green spot)
... Top collar ... ... ... ... Split cotrer ... ... ...
. ... Cyl inder head bo l t ( 3 i i n U.H.) ... ... Plain washer ... ...
Bo l t (3 i n . U.H.) ... ... ... ... ... ... Plain washer ...
... Sealing r ing ... ... ... In let rocker box ... ... ... Exhausr rocker box ... ... ... Joint washer ... ... ... ...
. ... Rocker box stud (E i n O.A.) . . . . . . Rocker box n u t ... ...
Plain washer ... ... ... ... . ... Rocker box bol t (2& i n U.H.)
... Plain washer ... ... ... Cyl inder head bo l t ( lor t o rque stay)
... lnspeccion cap . . . . . . ... ... ... Joint washer ... ...
Locking spring . . . . . . ... ... ... Fibre washer ... ... ...
... Screw (i in . U.H.) ... ...
... ROCKER (r ight exhaust. l e l t inlet)
... ROCKER (lelt exhaust. r i gh t inlet)
... Rocker ball p in ... ... Rocker adjusting p in . . . . . . ...
... Adjuster lock n u t ... ... . . . . Thrust washer. $ i n ... ... . . . . Thrus t washer. + i n ... ...
Spring washer . . . . . . ... ... ... ... Rocker spindle ...
Fig. 5. CYLINDER BLOCK A N D HEAD, TIIOR
20
DESCRIPTION QUANTITY REMARKS
C Y L I N D E R B L O C K A N D H E A D . ' ~ 1 2 0 ~
Cylinder base washer . . . . . . ... ... ... ... ... 1 Cyl inder block . . . . . . . . . . . . ... ... ... ... 1 Cylinder base n u t ... . . . . . . ... ... ... ... 8
... ... ... ... ... Push rod ... ... ... 4 . . . . . . ... ... ... Cover tube ... ... ... 2
... ... ... ... Rubber washer . . . . . . ... ... 4 Cyl inder head gasket . . . . . . ... ... ... ... ... 1
... CYLINDER H E A D c /w GUIDES ... ... ... ... 1 ... Sleeve for head bolts passing th rough in le t tracts 2 Reference only ...
In let valve guide . . . . . . ... ... ... ... ... 2 Exhaust valve guide ... ... ... ... ... ... 2 Carburet ter adaptor. left ... ... ... ... ... 1 Carburet ter adaptor. r i gh t ... ... ... ... ... 1
... ... ... ... ... Connector . . . . . . ... 2
. . . ... ... ... Balance pipe ... ... . . . . 1 Adaptor locking n u t ... ... ... ... ... ... 2
... Exhaust pipe adaptor ... ... ... ... ... 2 ... ... ... ... ... ... ... In let valve ... 2
... ... ... ... Exhaust valve . . . . . . ... ... 2
... ... ... ... Bot tom cup ... ... ... ... 4 Inner valve spring (Red spot) ... ... ... ... ... 4
... O u t e r valve spring (green spot) ... ... ... ... 4 ... ... ... T o p collar ... ... ... ... ... 4 ... ... ... ... Split cot ter ... ... ... ... 8
Cyl inder head bo l t ( 3 t In . U.H.) ... ... ... ... ... 4 ... ... ... ... ... Plain washer ... ... ... 8 ... ... ... ... Bo l t (3 i n . U.H.) ... ... ... 1 ... ... ... ... ... Plain washer ... ... ... 1 ... ... ... ... ... ... Sealing r ing ... ... 2
... ... ... ... In let rocker box ... ... ... 1 ... ... Exhaust rocker box ... ... ... ... ... 1 ... ... ... ... Joint washer ... ... ... ... 2
... Rocker box stud (e In . O.A.) ... ... ... ... 6 ... ... ... ... ... ... N u t ... ... ... 6
... ... ... ... ... ... Plain washer ... ... 6
... Rocker box bol t (2& i n . U.H.) ... ... ... ... 4
... ... ... ... Plain washer ... ... ... ... 4 ... ... Cyl inder head bo l t ( for to rque stay) ... ... 4
. . . . . . ... ... Inspection cap ... ... ... ... 4 ... ... ... ... ... Joint washer ... ... ... 4
Locking spring . . . . . . ... ... ... ... ... ... 4 ... ... ... ... ... Fibre washer ... ... ... 4 ... Screw (+ i n . U.H.) ... ... ... ... ... ... 4
. . . . . . ROCKER (r ight exhaust. le f t inlet) ... ... ... 2 ... ROCKER (left exhaust. r i gh t inlet) . . . . . . ... ... 2
Rocker ball p in ... ... ... ... ... ... ... 4 Rocker adjusting pin . . . . . . ... ... ... ... ... 4
... Adluster lock n u t ... ... ... ... ... ... 4 Thrus t washer . $ i n . . . . ... ... ... ... ... ... 2 Thrus t washer. 4 i n . . . . ... ... ... ... ... ... 6
... ... Spring washer . . . . . . ... ... ... ... 4
... ... Rocker spindle . . . . . . ... ... ... ... 2
Fig. 6. T I M I N G COVER A N D C O N T A C T BREAKER
I Ref . No . Port No . DESCRIPTION QUANTITY REMARKS
T I M I N G C O V E R A N D C O N T A C T B R E A K E R
... ... ... ... Timing cover ... ... ... ... 1 ... ... ... Patent plate ... ... ... ... ... 1
. . . . . . ... ... ... Hammer-drive screw ... ... 3 ... ... ... ... ... O i l seal ... ... ... ... 2
O i l seal (0.020 i n undersize) . . . . . . ... ... ... ... 1 For reground crankshaft
... ... ... ... ... ... Circl ip ... ... ... 1 ... ... ... ... Hol low dowel . . . . . . ... ... 1
... ... Screw (Iff In . U.H.) ... ... ... ... ... 3 ... ... ... ... Screw (1 in . U.H.) ... ... ... 5
. . . . . . . ... ... ... Bolt (Zin U.H.) ... ... ... 1 ... ... ... ... ... ... Plain washer ... ... 1
... ... ... ... ... Rubber grommet ... ... 1 ... ... ... ... ... ... ... Pillar bo l t ... 2 ... ... ... ... ... Plain washer ... ... ... 2
... ... ... ... ... ... Cover . . . . . . 1 ... ... ... ... ... ... Joint washer ... ... 1
... ... ... ... ... Serrated washer ... ... 2 ... ... ... Screw (5 in . U.H.) ... ... ... ... 2
... A U T O ADVANCE U N I T (54419340) ... ... ... 1 ... ... ... ... ... Spring set (54415642) ... 1
. . . . . . CONTACT BREP.KER PLATE ASSEMBLY (54419097) 1 . . . . . . Contact set (54419827) ... ... ... ... 2
... ... ... Pin. adjustment (54419220) ... ... 2 Dowel pin lo r auto advance . . . . . . ... ... ... ... N o t illustrated
... ... ... ... ... O i l pressure switch ... ... 1 ... ... ... ... ... Cover pressure switch ... 1
Timing label l o r C.B. cover . . . . . . ... ... ... ... N o t illustrated
* E9526 Blanking plug available to replace oil switch i f required
23
Fig.7. GEARBOX I N N E R COVER A N D SELECTORS
24
i Ref . No . Port No . DESCRIPTION QUANTITY REMARKS
G E A R B O X I N N E R C O V E R A N D S E L E C T O R S
... ... Stud (3 in . O.A.) ... ... ... ... ... ... ... ... ... Hollow dowel . . . . . . ... ...
... ... ... ... ... Gear selector camplate ... ... Camplate index plunger ... ... ... ... ...
Index plunger spring . . . . . . ... ... ... ... ... ... ... Strong 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 ... ... Camplate operating quadrant . . . . . . ... ... ... ... Quadrant spindle ... ... ... ... ... ... ...
... ... ... Split pin . . . . . . ... ... ... ... Bolt (1; in . U.H.) ... ... ... ... ... ... ...
... ... Plain washer ... ... ... ... ... ... Screw (1 in . U.H.) ... ... ... ... ... ... ...
... Socket screw (1; in . U.H.) ... ... ... ... ... Countersunk screw (# in . U.H.) ... ... ... ... ...
as required 1
1 Ref. No . Port No . i
DESCRIPTION QUANTITY REMARKS
G E A R B O X S H A F T S A N D G E A R S
MAINSHAFT c/w L O W GEAR (16T) . . . . . . Clutch rod bush ...
... MAINSHAFT HlGH GEAR (26T) ... High gear bush ... ...
Mainshaft th ird gear (24T) ... ... . . . . . . Mainshaft second gear (20T)
... LAYSHAFT 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 sprocker (19 teeth) . . . . . . Gearbox sprocket (20 teeth) . . . . . .
... Tab washer ... ... ... Gearbox sprocket nut ... ...
... High gear bearing ... ...
... ... ... Circlip ... ... O i l seal . . . . . . ... ... ...
... Mainshaft bearing ... ... . . . . . . Circlip ... ... ...
... ... ... Plain washer ...
... Pinion sleeve ... ... ... ... ... Pinion spring ... ...
... Kickstarter pinion ... ... ... Kickstarter ratchet ... ...
... Tab washer ... ... ... ... ... ... Nu t ... ... . . . . . . Clutch operating rod ...
... ... ... See pages 5 t o ... ... ... 7 for standard ... ... ... ... 1
sizes ... ... ... ... 1 ... ... ... ... ;I 1
... ... ... ... 1 ... ... ... ... 1
... ... ... ... 1
W I D E R A T I O G E A R S
... MAINSHAFT HIGH GEAR (28T) . . . . . . ... ... 1
... Mainshafr second gear (19T) . . . . . . ... ... ... 1 ... ... Layshaft second gear (27T) . . . . . . ... ... 1
. . . . . . ... ... ... Layshaft c/w high gear (18T) ... 1
C L O S E R A T I O G E A R S
... ... MAINSHAFT c/w L O W GEAR (18T) ... ... 1 . . . . . . ... MAINSHAFT HIGH GEAR (24T) ... ... 1
... ... ... Mainshaft third gear (23T) ... ... ... 1 ... ... Mainshaft second gear (21T) . . . . . . ... ... 1
... ... ... LAYSHAFT L O W GEAR (28T) ... ... 1 ... ... ... Layshaft second gear (25T) . . . . . . ... 1
... ... ... ... ... Layshaft third gear (233 ... 1 ... ... ... Layshaft clw high gear (22T) . . . . . . ... 1
Fig. 9. G E A R B O X O U T E R COVER
28
I Ref . No . Port No . DESCRIPTION QUANTITY REMARKS
G E A R B O X O U T E R C O V E R
GEARBOX OUTER COVER ... Gearchange spindle bush
Kicltstarter spindle bush Kickstarter spring anchor p in Guide plate stud (i i n . O.A.) O i lsea l ... ... ... O i l seal housing . . . . . .
Gearchange quadrant . . . . . . Rubber "0" r ing ... ... Quadrant r e tu rn spring ... Gearchange quadrant plunger Plunger spring . . . . . . ... Guide plate ... ... ... Serrated washer ... ...
... ... N u t ... ... Kickstarter quadrant ... Kickstarter re tu rn spring ... Kickstarter axle ... ... C L U T C H LEVER ASSEMBLY
Clutch lever ... ... ... Lever shaft ...
Ball. i n d i m . . . ... Thrust plate ... ... Return spring ... ... Plain washer ... ... Sp l i t p i n ... ... ...
Countersunk screw (s i n . O.A.) Rubber cover . . . . . . ... Abutment f o r clutch cable ... Plain washer ... ... ... N u t ... ... ... ... Screw (23 in . U.H.) ... ... Screw (I& in . U.H.) . . . . . . Screw (1 in . U.H.) ... ... Gearchange pedal ... ... Bol t (1 i n . U.H.) ... ... Pedal rubber ... ... ... FOLDING KICKSTARTER ...
. . . . . . Kickstarter lever
. . . . . . Kickstarter pedal ... Pedal locating spring
. . . . . . Steel bail $ i n diam Pedal bo l t . . . . . . ...
... Pedal rubber ... ... Co t te r pin c/w n u t and washer
... Domed nu t ... ... Filler plug ... ... ... Fibre washer ... ... ...
I Ref. No . Port No . DESCRIPTION QUANTITY REMARKS
C L U T C H
... Clctch securing n u t ... ...
... ... ... H u b ... ... ... Thrust washer . . . . . . ...
... ... ... Roller ... ... Sprocket and housing (58 teeth Duplex) Centre . . . . . . ... ... ...
... Inner plate ... ... ... Countersunk screw (0.417 in . U.H.) Shock absorber spider ... ...
. . . . . . Dr ive rubber (large) ... ... Rebound rubber (small) ...
Ourer place ... ... ... ... . . . . . . . Screwed pin (1% in U.H.)
Dr iv ing place (bonded) ... ... Dr iven plate ... ... ... ... Pressure plate . . . . . . ... ... Adjuster pin ... ... ... ...
... ... ... N u t ... ... ... Spring cup ... ... ...
... ... ... Spring ... ... Pressure nu t ... ... ... ...
... ... ... Key ... ... Cupped washer ... ... ...
Ref . No . Part No . DESCRIPTION QUANTITY REMARKS
C H A I N C A S E A N D
Primary chain oi ler tube ... ... . . . . . . Cl ip ... ... ...
... Spring washer ... ... ...
... Bo l t (6 i n . U.H.) ... ... Rear chain, 5 i n . x i i n . x 104 links ...
... Joint washer ... ... ...
... Cover plate ... ... ...
... O i l seal . . . . . . ... ... Countersunlc screw (5 i n . U.H.) ... Chain tensioner abutment ... ... Chain tensioner blade . . . . . . ...
... T ie r o d . . . . . . ... ...
... Trunnion ... ... ...
... Adluster sleeve n u t ... ... Primary chain. i in . Dup lex x 84 links Stator stud (4% i n . O.A.) ... ... Stator stud ... ... ... ...
. . . . . . Stator. R M 2 l (47205) ... Sleeve nu t ... ... ... ...
... Rubber grommet ... ... Plastic sleeve ... ... ... ...
... Plain washer ... ... ... Self-locking n u t ... ... ...
... Joint washer ... ... ... Chaincase ... ... ... ... Rotor cover ... ... ... ... Joint washer ... ... ... ...
... Screw ... ... ... ...
... C v p e r washer ... ... ... Drain and adluster plug ...
Fibre washer ... ... ... ... Filler p lug ... ... ... ...
... ... Fibre washer ... ... ... . ... Screw (1 i n U.H.) ... ... . Screw ( s i n U.H.) ... ...
... ... Domed n u t ... ...
. . . . . . ... Copper washer ...
. . . . . . ... Timing pointer ... Level plug ... ... ... ...
C H A I N S
1 Ref . No . Port No . DESCRIPTION QUANTITY REMARKS !
F R A M E
F7843 H l l l 570-3 H I 0 1 8 F11267 R 3 3 1 51 978 F5679 F11270 14. 0404 F4671 F7849 R O 2 l 14-0703 F8392 F8036 51 801 526-1 14-0303 14-0251 F4370 14-0304 PCW73A 5588 F7155
Front Frame ... ... Steering race cup ... Steel ball ( $ i n . diam.) Top cone and dust cover Centre stand ... Pedalrubber . . . . . .
... Pivot bo l t ... Plain washer ... ... Tab washer ... ...
... N u t ... ... Return spring . . . . . .
... Prop stand ...
... Pivot bol t ... Self locking nu t ... Return spring . . . . . .
... Rear frame ... Stud (3; i n . O.A.) ...
... Spring washer ... N u t ... ... ... Bolt (244 in . U.H.) ... Plain washer ... ... N u t ... ... ...
. . . . . . Spring washer Bolt ( I& i n . U.H.) ... Steering srop ... ...
Fig. 13. S W I N I G N G FORK A N D S U S P E N S I O N UNITS
Ref . No . Part No . DESCRIPTION QUANTITY REMARKS
1
S W I N G I N G F O R K A N D S U S P E N S I O N - U N I T S
F10045 F6042 NW100 WE170 F6821 F5313 F7848 5620 F5944 5545 F7365 51 802 PCW73A 14-0304 F8090 D2024 Reference only 09-0122 99-01 07 99-1 048 99-1 047 14-0235 525-2 526-1 GS308 14-0303 F7067 F5536 14-01 13 F7364 525-1 3 14-0702 F9387 525-3 14-0302 F3808 F879 F1369 526-2 F7386 & in . x $ i n . F7387 99-0725 TI 076 F4717 F5412 F5413 F3158
... SWINGING FORK . . . . . . ... ... . . . . . . Pivot bush ... ... ... ...
... ... Grease nipple . . . . . . ... ... ... ... ... Fibre washer ... ... ... ... ... ... Sleeve ... ... ... ...
Distance tube . . . . . . ... ... ... ... ... ... ... Flanged washer ... ...
Bolt (85 in . U.H.) ... ... ... ... ... Tab washer ... ... ... ... ... ...
... ... N u t ... ... ... ... ...
... ... Brake torque stay ... ... ... Bolt (j+ In . U.H.) ... ... ... ... ...
... Spring washer . . . . . . ... ... ... N u t ... ... ... ... ... ... ... "0" ring ... ... ... ... ... ...
... SUSPENSION UNIT (64052107) ... ... Damper unit ... ... ... ... ... Bonded bush (64533645) . . . . . . ... ...
... Sprinz retainer (9054,'171) ... ... ... . Spring 100 ibs chrome (64543708) ...
Spring . 145 lbs . chrome hexdy duty (64544234) Uni t fixing bolt (1& i t 4 . U.H.) ... ... ...
... ... ... Plain washer ... ... ... Spring washer . . . . . . ... ... ... ...
... ... ... Plain washer ... ... ... N u t ... ... ... ... ... ... ...
... ... ... Chainguard ... ... ...
... ... ... ... Grommet ... ... ... ... Bolt ( In . H ) ... ... ... ... ... Rubber tube ... ... ... ... ... ... Plain washer ... ... ... ... ... ... Self-locking nut ... ... ...
... ... ... ... Stepped bolt ... ... ... ... Plain washer ... ... ... ... ... ... N u t ... ... ... ... ... ... Clip ... ... ... ... ... ... ... ... ... ... N u t ... ... ...
... ... ... Bolt (;in . U.H.) ... ... ... Spring washer ... ... ... ... ... ... Brake operating rod ... ... ...
... ... ... ... Split pin . . . . . . ... ... Adluster nut ... ... ... ... ...
Stop lamp switch . type 228 (54033234) ... ... Screw (+ in . U.H.) ... ... ... ... ...
... ... ... ... Self locking nut ...
... ... Switch lever ... ... ... ... ... ... ... ... "D" washer ... ...
... ... Spring (315738) ... ... ...
1 2 1 1 2 1 2 1 1 1 1 1 2 2 2 2 2 4 4 2 Available 4 2 2 3 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 5 1 1 1
Fig. 14. E N G I N E U N I T F I T T I N G A N D FOOTRESTS
38
Ref. No . - Port No . DESCRIPTION QUANTITY REMARKS
E N G I N E U N I T F I T T I N G S A N D F O O T R E S T S
Stud (3& l n . O.A.) ... ... Sprlngwaher . . . . . . ... Nu t ... ... ... ... Stud (8& in . O.A.) ... ... Distance plece ... ... ... Left rear engine plate ...
... Rlght rear engine plate Bolt (I# in . U.H.) ... ... Bolt (2 in . U.H.) ... ... Plaln washer ... ... ... Spring washer . . . . . . ... Nut ... ... ... ... Extended nut . . . . . . ... Left footrest ... ... ... Right footrest ... ... ... Stud (I& in . O.A.) ... ... Plain washer ... ... ... Nu t ... ... ... ... Peg ... ... ... ... Footrest rubber ... ... Stud (1: in . O.A.) ... ... Nu t ... ... ... ... Bolt (a in . U.H.) ... ... Bolt (19 in . U.H.) ... ... Spring washer . . . . . . ... Nut ... ... ... ... Nut ... ... ... ... Nu t ... ... ... ... Engine torque stay ... ... B i t 1 in . U . ) ... ... Nut ... ... ... ... Distance piece . . . . . . ... Brake pedal lever ... ... Bolt (E in . U.H.) ... ...
... Nut ... ... ... Brake pedal ... ... ... Crankcase undershield . . . . . . Hook bolt ... ... ...
... Plain washer ... ... Nu t ... ... ... ... Nu t ... ... ... ...
... Plain washer ... ... LEFT FOOTREST ASSEMBLY RIGHT FOOTREST ASSEMBLY
Left footrest ... ... ... Right footrest ...
Footrest pedal ... ... Pivot bolt . . . . . . ...
... ... ... ... ... 2 ... ... ... ... ... 4
... ... ... ... ... 6 ... ... ... ... ... 4 (3 on TR6C)
... ... ... ... ... 1 (TR6C only)
Fig.15. E X H A U S T PIPES A N D MUFFLERS TIZOR, TR6R
I Ref . No . Port N o . DESCRIPTION QUANTITY REMARKS
I E X H A U S T P I P E S A N D M U F F L E R S . T 1 2 0 R . T R ~ R (Seealso Page43)
. . . . . . ... ... EXHAUST PIPE D.S. ... ... ... ... ... ... EXHAUST PIPE T.S. . . . . . . ... ...
... ... ... ... Coupling pipe . . . . . . ... ...
... ... ... Clip ... ... ... ... ... ... ... ... ... ... Cap ... ... ... ... ... ... . ... ... ... Bolt. coupling pipe ( 1 i in U.H.) ...
... Nut. coupling pipe ... ... ... ... ... ... Clip. exhaust pipe to head ... ... ... ... ... ...
... Spherical washer clip bolt ... ... ... ... ... ... Bolt (for clip) . . . . . . ... ... ... ... ...
... ... ... ... ... ... Exhaust pipe tie ... . . . . . . ... ... ... ... Spring washer ... ...
... Screw. stay to exhaust pipe . . . . . . ... ... ... ... Nut. stay t o exhaust pipe ... ... ... . . . . . . .
... ... ... ... ... ... Silencer (muffler) ... ... ... Bracket. silencer bracket ... ... ... ...
. . . . . . ... ... ... Spring washer ... ... ... ... ... ... Bolt. bracket to silencer (i in . U.H.) ...
... ... ... Hanger. frame for silencer ... ... ... Bolt. silencer hanger t o frame (i in . U.H.) . . . . . . ... ...
... Nut ... ... ... ... ... ... ... ... ... ... ... Spring washer . . . . . . ... ... ...
... Eolt. silencer to frame ($ in . U.H.) . . . . . . ... ... . . . . . . ... Spring washer ... ... ... ... ...
... Nu t ... ... ... ... ... ... ... ...
... Clip. silencer to exhaust pipe ... ... ... ... Stay. DS and TS silencers ... ... ... ... ... ...
... "DM washer ... ... ... ... ... ... ... . ... ... ... ... ... Bolt (If in U.H.) ... ...
. . . . . . ... Spring washer ... ... ... ... ... Nu t ... ... ... ... ... ... ... ... ...
. . . . . . ... ... ... Coupling pipe ... ... ... ... ... ... Clip ... ... ... ... ... ... ... ... ... "D" washer ... ... ... ... ...
... Bolt ... ... ... ... ... ... ... ... ... ... Nu t ... ... ... ... ... ... ...
2 I Alternative pariz
Fig. 16. E X H A U S T PIPES A N D MUFFLERS (TR6C)
42
/ Ref . No . Port No . DESCRIPTION QUANTITY REMARKS
E X H A U S T P I P E S A N D M U F F L E R S T R 6 C
Exhaust pipe D.S. lower ... ... ... ... ... ... 1 Exhaust pipe T.S. upper ... ... ... ... ... ... 1 Exhaust pipe stay ... ... ... ... ... ... ... 1 5 in . bolt ... ... ... ... ... ... ... ... 3
... Spring washer ... ... ... ... ... ... ... 3 Silencer. upper . . . . . . ... ... ... ... ... ... 1 Silencer. lower . . . . . . ... ... ... ... ... ... 1
... ... ... ... ... Connector ... ... ... 1 Bolt ... ... ... ... ... ... ... ... ... 2
... ... Spring washer . . . . . . ... ... ... ... 3 Silencer bracket ... ... ... ... ... ... ... 1 Clip ... ... ... ... ... ... ... ... ... 1
... ... Bolt (for clip) . . . . . . ... ... ... ... 1 Nu t (for clip) ... ... ... ... ... ... ... .... 2
... Bolt hanger t o frame . . . . . . ... ... ... ... 4 ... ... ... Spring washer . . . . . . ... ... ... 4
Clip ... ... ... ... ... ... ... ... ... 2 ... "D" washer ... ... ... ... ... ... ... 6
Bolt washer ... ... ... ... ... ... ... ... 3 Spring washer . . . . . . ... ... ... ... ... ... 3
... ... ... Nut ... ... ... ... ... ... 3 Clip ... ... ... ... ... ... ... ... ... 1
... ... Bolt ... ... ... ... ... ... ... 1 Clip ... ... ... ... ... ... ... ... ... 1
... ... Leg guard ... ... ... ... ... ... 1 Clip ... ... ... ... ... ... ... ... ... 2
... ... Bracket . . . . . . ... ... ... ... ... 1 ... ... ... ... ... Screw (short) . . . . . . ... 1
... ... Screw (long) I $ in . U.H. ... ... ... ... 1 ... ... ... Washer (for lines 28 and 29) . . . . . . ... 2 No t illustrated
ASSEMBLY REF. No.1
Fig. 17. TELESCOPIC F R O N T FORK
44
I Ref . No . Part No . DESCRIPTION
T E L E S C O P I C F R O N T F O R K T R 6 R .
FORK ASSEMBLY ... ... FORK ASSEMBLY ... ...
Middle lug and stem ... Middle lug and stem ...
... Bo t t om cone ... Pinch bo l t (2f i n . U.H.) ...
... Plain washer ... Cieveloc nu t ... ... Fork stem sleeve nu t (blind) Top lug ... ... ...
... Bondedbush ... Lock c /w 2 keys ... ... Key (stare serial number)
... ... G r u b screw ... ... ... ... ... Sealing washer ...
... Locating pin ... ... ...
... Pinch bol t ( I+ i n . U.H.) ...
... Seated n u t . . . . . . ... ... ... ... Left top cover ... ... . . . . . . ... Right top cover ...
... C o r k washer ... ... ...
... Spring abutment . . . . . . ... Solo main spring (Yellow/Blue) ... Extra strong main spring (Yellow/Green)
... ... Plain washer ... ... ... ... ... Telescopic gaiter ...
... DUST EXCLUDER SLEEVE N U T
... ... ... O i l seal ... . . . . . . ... ... "0" r ing ...
... ... Plain washer ... ...
... ... ... T o p bearing ... ... Damping sleeve . . . . . . ...
. . . . . . ... ... Stanchion ... ... ... ... Lower bearing ... ... ... ... Bearing n u t ...
... ... ... Cap nu t ... ... LEFT BOTTOM MEMBER c / w CAP ... RIGHT BOTTOM MEMBER c /w CAP
... Spindlecap . . . . . . ... ... ... Spring washer ...
... . Cap bol t (I& in U.H.) ...
... ... Drain plug . . . . . . ...
... ... Fibre washer ... ... ... ... Shutt le valve ... ...
... ... Circ l ip ... ... ... Restr ictor . . . . . . ... ... ...
... Aluminium washer ... ...
... Flanged bo l t ... ... ...
... ... Brake cable bracket ... ... . . . . . . ... ... Cable retainer ...
... ... ... Starlock washer ...
45
QUANTITY REMARKS
1 TR6R 1 t120r 1 TR6R 1 t120r 1 2 2 2 1 1 2 1 1 Key Nos . run
f rom E l k1 t o EJRSO
1 1
... ... I
... ... 1
... ... 1
... ... 1
... ... 2
... ... 2
... ... 2
... ... Available
... ... 2 ... ... 2
... ... 2
... ... 2 ... ... 2
... ... 2
... ... 2
... ... 2
... ... 2
... ... 2
... 2 ...
FORK ASSEMBLY REF. NP 1
15
@-- 21
&Zk--- 23
@?- 19
L 20 Fig. 18. TRbC F O R K P A R T S A N D S T E E R I N G D A M P E R
46
Ref. No . Port No . DESCRlPTlON QUANTITY REMARKS
T R 6 C F O R K P A R T S A N D S T E E R I N G D A M P E R
... ... ... FORK ASSEMBLY ... ... ... ... 1 ... ... Middle lug and stem ... ... ... ... 1
... ... Top lug ... ... ... ... ... ... 1
... ... ... Cap . . . . . . ... ... ... ... 2 Plain washer ... . . . . . . . ... ... ... ... 4
... ... ... ... ... Bolt (1$ in . U.H.) ... ... 4 ... ... ... Steering damper rod c/w knob ... ... 1
... ... ... ... ... Plain washer ... ... 1 ... ... ... Adjuster sleeve ... ... ... ... 1
... ... ... ... ... Spring plate ... ... 1 ... ... ... ... ... ... Anchor plate ... 1
Fork stem sleeve nut ... ... ... ... ... ... 1 ... ... ... Rubber sleeve ... ... ... ... 1
... ... ... Friction disc ... ... ... .... 1 Main spring (yellowlgreen) ... ... ... ... ... 2
All other parts are as listed on Page 45
H A N D L E B A R M O U N T I N G S
... ... Handlebar eyebolt ... ... ... ... Plain washer ... ... ... ... ... ... ...
... Bolt ( I$ in . U.H.) ... ... ... ... ... Hemispherical washer . . . . . . ... ... ... ...
i! ... 1 Self-locking nut ... ... ... ... ... ... 2
TR6R. T12OR
... ... ... Steady rubber . . . . . . ... ... ... 2 Distance piece . . . . . . ... ... ... ... ... ... 2
... Cup ... ... ... ... ... ... ... ... 2 Solid bush (lor handlebar-mounted windscreen) . . . . . . ... as required
I Ref. No . Porf No . DESCRIPTION QUANTITY REMARKS
F R O N T W H E E L
... ... ... ... ... W3458 FROEJT WHEEL COMPLETE 1 ... ... ... W1721 RIM . SPOKES A N D HUB ASSEMBLY 1
... ... ... ... W1230 Front wheel r im (WM2-19) 1
... . ... ... ... W1328 Spoke (8/10G x 55 in straight) 20
.... ... ... . ... W1708 Spoke (8/10G x 4 W in 78'j 10
... . ... ... ... W1709 Spoke (8/10G xG in 100") 10 . . . . . . ... ... ... ... ... 579-2 Spoke nipple 40
... ... ... ... ... W1693 Hub and brake drum 1 ... ... ... ... ... ... ... W2057 Wheel spindle 1
... ... ... ... ... ... ... W653 Bearing .... 2 ... ... ... ... ... ... W1237 Dust cover ... 1
... ... ... ... ... ... T280 Circlip ... ... 1
... ... ... ... ... ... W3337 Bearing support r ing 1 ... ... ... ... ... W1481 Grease retainer ... . 1 ... ... ... ... ... ... W582 Retaining ring ... 1
... ... ... ... ... W3460 Cover plate ... ... 1 ... ... . . . . ... ... ... W1197 Balance weight. f oz as required ... . . . . ... ... ... ... W1198 Balance weight. 1 oz as required
... ... ... ... ... ... W3462 Brake anchor plate 1 ... ... ... ... ... W1996 BRAKE SHOE c/w LINING 2
... ... ... ... ... Reference only Brake lining . . . . . . 2 ... ... ... ... ... Reference only Brass rivet ... ... 16 ... ... ... ... ... ... W2026 Abutment pad 2 ... ... ... ... ... W135 Shoe return spring ... 2 ... ... ... ... ... W200l Brake cam ... ... 2
. . . . . . ... ... ... ... W3453 Brake cam lever (front) 1 ... ... ... ... ... ... ... 140302 Nu t . . . . . . 2
. . . . . . ... ... ... ... W3454 Brake cam lever (rear) 1 ... ... ... ... ... ... ... W2003 Rod . . . . . . 1
... ... ... ... ... ... W2005 Fork end. threaded 1 ... ... ... ... ... ... ... ... 140401 Locknut 1
... ... ... ... ... ... W3522 Lever return spring 1 . . . . . . ... ... ... ... ... W2058 Anchor plate nut 1
... ... ... ... ... ... WF32 Pivot pin . . . . . . 2 ... - Splic pin ... ... ... ... ... ... ... 2
... ... ... ... ... ... W2027 Plain washer ... 2 ... ... ... ... W1991 Anchor plate gauze (for a i r scoop) 1
... ... ... ... ... ... 5650 Taptite screw ... 3 ... ... ... ... ... ... F2351 Plain washer ... 3
/ Ref . No . Pon No . DESCRIPTION QUANTITY REMARKS
R E A R W H E E L
W2102 W1486 W1007 W1107 W3402 W l l 0 8 579-2 W1472 W1499 W 1 500 El612 W1498 W1690 W1691 W1281 W1474 W1654 W l 0 2 2 W653 W1021 W1710 W1278 W1024 W l l l 2 W3426
" W1406 W1407 Reference only Reference only W1415 W135 W1083 W2015 525-6 51-52 W1090 W163S W1476 W1477 D637 W1280 W2089 W1015 14-1 902 F1747 WM3 W3425 W1467
. . . . . . REAR WHEEL COMPLETE ... RIM . SPOKES A N D HUB ASSEMBLY
. . . . . . Rear wheel r im WM3-18 Spoke (8/10G x7-& i n . 90") ...
. ... Spoke (8/1OG x7-& In 110") . . . . . . . Spoke (8/1OG x 79 i n 90")
. . . . . . ... Spoke nipple ... ... Hub . . . . . . ... ...
... ... Sprocket. 46T ... ... Bolt ( # i n . U.H.) ... ... ... Serrated washer . . . . . . ... ...
... ... ... Brake drum ... . . . . . . . ... Bolt (+In U.H.) ...
. . . . . . ... Self locicing nut ...
... ... ... Wheel spindle ... Grease retainer (brake side) ... ...
. . . . . . Grease retainer ... ... ... Backing ring ... ... ...
... ... Bearing ... ... ... ... ... RETAINING RING ...
... . Locking screw (& in U.H.) ... ... Distance tube ... ...
... Distance piece ... ... ... ... Bralce anchor plate ... ...
... ... ... N u t . . . . . . ... 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 . . . . . . ...
... ... Plain washer ... ... ... ... ... N u t . . . . . . ...
Lever return spring ... ... ... Grease retainer . . . . . . ... ...
... ... Speedometer adaptor ... ... ... ... Distance piece ...
. . . . . . Speedometer gearbox ... ... ... ... Plain washer ...
... ... Chain adjuster . . . . . . ... ... ... Adjuster end plate ... ...
... ... Self-locking nut ... ... ... ... ... ... Spindle nut ...
... ... ... Tire security bolt ... ... ... ... N u t inner D.S. ...
... ... ... ... Pivot pin ...
Fig. 22. GAS TANKS
52
Ref . No . Port No . I
DESCRIPTION QUANTITY REMARKS
G A S T A N K S
... ... Gas tank (3f gallons) ... ... Gas tank (24 gallons) . . . . . . ... ...
... ... Gas tank (2f gallons) ... ... ... Styling uni t (left) ... . . . . . . .
... ... Styling uni t (right) ... ... ... Styling uni t screw (front) ... ...
... Styling unit screw (rear) ... ... ... Left knee gr ip ... ... ... ...
... ... Right knee grip ... ... ... Centre styling strip ... ... ...
... ... Hook screw ... ... ... Serrated washer ... ... ... ...
... ... ... ... Nu t ... ... . . . . . . ... ... FILLER CAP ...
... FILLER CAP c/w CHAIN ... ... ... ... Joint washer '... ...
... ... ... Petrol tap (left) ... Petrol tap with reserve tube . . . . . . ...
. . . . . . ... ... Petrol tap nut ... ... ... Petrol tap seal . . . . . . ...
... Steel washer ... ... ... ... ... ... Rubber washer . . . . . . ...
... Spigot rubber . . . . . . ... ... ... ... Cup ... ... ... ...
... ... ... Shouldered stud ... ... ... N u t ... ... ... ...
. . . . . . Double spigot rubber ... ... ... Rubber washer . . . . . . ... ...
Bolt 1 i n H . ) ... ... ... ... ... ... Reflector bracket ... ...
Reflector . Amber (57161) ... ... ... ... ... Decal-Bonneville ... ...
... ... Decal-Trophy 650 ... ... ... ... Decal-Trophy Sports ...
... Decal-Made in England ... ...
10
Fig. 23. OIL TANK
54
Ref. No . Port No . DESCRIPTION QUANTITY REMARKS
O I L T A N K
Oi l tank ... ... ... ... ... ... FILLER CAP . . . . . . ... ... ...
Joint washer ... ... ... ... ... Drain plug ... ... ... ... ... ... Fibre washer ... ... ...
Oi l tank f i l ter . . . . . . ... ... ... ... ... Fibre washer ... ... ...
Upper feed pipe ... ... ... ... ... ... ... Union nut ... ...
Flexible connector ... ... ... ... Clip ... ... ... ... ... ... O i l pipes and junction block . . . . . . ...
... Joint washer ... ... ... ... ... ... ... Plain washer ... ...
N u t ... ... ... ... ... ... ... Vent pipe ... ... ... ... ... "T" piece ... ... ... ...
Extension pipe . . . . . . ... ... ... Clip ... ... ... ... ... ...
... Front strap ... ... ... ...
... Rear Strap ... ... ... ...
. . . . . . Spigot rubber ... ... ... Rubber washer . . . . . . ... ... ... Bolt ($ in . U.H.) ... ... ... ... Self locking nut ... ... ... ... Metering screw ... ... ... ... Coil spring ... ... ... ... ... Screwed peg ... ... ... ... ...
... Plain washer ... ... ... ... Nut ... ... ... ... ... ...
... Rubber connector ... ... ... Rocker oil feed pipe . . . . . . ... ... Copper washer ... ... ... ...
... Domed nut ... ... ... ... Bracket . . . . . . ... ... . . . . . .
... ... Grommet ... ... ... Bolt (f in . U.H.) ... ... ... ...
... Flexible pipe ... ... ... ... Clip ... ... ... ... ... ... Sleeve nut ... ... ... ... ... Grouped transfer "Drain and ref i l l " e t c . . . .
Fig.14. BATTERY CARRIER A N D AIR FILTERS
/ Ref. No . Part No . DESCRIPTION QUANTITY REMARKS
... ... ... Battery carr ier ... Battery carr ier rubber t ray . . . . . . ...
... Battery carr ier strap . . . . . . ...
... Bat tery strap anchorage ... ... . . . . . . Battery carr ier rubber s t r ip ...
... ... Transfer positive earth ... ... ... Vent pipe ... ... ...
... ... Circl ip. ven t pipe ... ... ... ... Battery (PUZSA) 54027029 ...
... ... ... ... AIR CLEANER ... Air cleaner element (f i l ter cloth &gauze)
... ... ... ... AIR CLEANER ... A i r cleaner element (filter c loth & gauze)
... ... Fuse assembly . . . . . . ...
... Cl ip for a i r cleaner cover ... ...
T120R
Reference only 1 Not il lustrated
1 Ref. No . Port No . DESCRIPTION QUANTITY REMARKS
P A N E L A N D T W I N S E A T
Side panel and toolbox Decal-TIGER 650 ... Decal-TROPHY 650 ... Decal-BONNEVILLE ... Panel knob . . . . . . Washer . . . . . . . . . Panel nut . . . . . . Panel grommet . . . . . . TWINSEAT ... ...
... Twinsear cover T r im strip . . . . . .
... Tr im strip sprag Rubber buffer . . . . . . Hinge-front . . . . . . Hinge-rear ... ... Spring washer . . . . . . Bolt (+ In . U.H.) ... Check wire . . . . . . Self tapping screw ... Washer . . . . . . . . .
... Spring ... ... Split pin . . . . . . ... Seat catch plunger ... Seat ra i l . . . . . . ... Bolt (% in . U.H.) ... Spring washer . . . . . .
Fig. 26. FENDERS
60
9ef. No . Part No . DESCRIPTION OUANTITY REMARKS
F E N D E R S
Front fender (painted) ... Front fender (stainless steel) ... Front stay ... ... ... Front stay ... ... ... Centre stay ... ... ... Centre stay ... ... ... Bottom stay ... ... ... Bottom stay ... ... ... Bracket ... ... ... ... Rear fender ... ... ... Rear fender ... ... ... Bridge . . . . . . ... ... Lifting handle . . . . . . ... Bracket . . . . . . ... ...
... Clip ... ... ... Backing plate . . . . . . ... Tail lamp adaptor ... ... Tail lamp plate . . . . . . ... Number plate bracket ... Reflector red (57111) . . . . . . Push fix . . . . . . ... ... Rubbermat ... ... ... Wir ing protector ... ...
... Tail lamp lead grommet Bolt (i, in . U.H.) ... ... Plain washer ... ... ...
... ... Nut ... ... Bolt (& i n . U.H.) ... ...
... ... Nu t ... ... Bolt (f in . U.H.) ... ... Plain washer ... ... ... Washer . . . . . . ... ...
... ... Nu t ... ... Self-locking nut ... ...
... Plain washer ... ... Bolt (2 in . U.H.) ... ... Bolt ( i n . U.H.) ... ...
. . . . . . Spring washer ... Spring washer . . . . . . ...
... ... Screw ... ... Washer . . . . . . ... ...
... ... Nu t ... ... Stud (+ in . O.A.) ... ...
... ... Nu t ... ...
... 1
... 1
... 1
... 1
... 2
... 4
... 2
... 1
... Reference only
... 5
... 12
... 13
... 4
... 2
... 3
... 2
... 3
... 3
Fig. 27. HANDLEBARS A N D C O N T R O L LEVERS
Ref. No . Pan No . DESCRIPTION OUANTITY REMARKS
H A N D L E B A R S A N D C O N T R O L L E V E R S ( S E E A L S O P A G E 6 5 )
H1870 HI 425 99-0248 99-0245 99-0246 99-0244 99-0238 99-0239 99-0240 99-022s Reference only 99-0241 D2073 99-0262 99-0266 99-0234 99-0226 99-0225 99-0252 99-0250 99-1031 99-0228 121607 121606 121033 D2074 99-0261 99-0265 99-0230 99-0226 99-0252 99-0250 99-1031 Reference only 99-0555 99-0630 H1994
... Handlebar ... . . . . . . ... ... ... ... Packing piece . . . . . . ... ... ... ... ... M I S T G R I P (161364) . . . . . . ... ... ...
Body top half (161328) . . . . :. ... ... ... ... Body bottom half (161329) ... ... ...
Rotor (161091) ... . . . . . . ... ... ... . . . . . . ... Friction spring (161008) ... ...
Friction spring screw (161009) . . . . . . ... ... ... Locknut (161010) . . . . . . ... ... ...
... ... Screw (111013) . . . . . . ... ... Grip ... ... ... ... ... ... ...
... ... Cable stop (161011) ... ... ... FRONT BRAKE A N D AIR LEVER ASSEMBLY (181978)
... Brake lever (ball end) (181754) ... ... Lever bracket (181776) . . . . . . ... ... ...
... Control body (121619) . . . . . . ... ... . . . . . . ... ... Screw ('11/014) ... ...
Screw (111013) ... ... ... ... ... ... ... Fulcrum screw (181087) . . . . . . ... ...
Self locking nut (181053) ... ... ... ... Cable adjuster and nut (18/1708/1709) ... ... Lever (121556) ... ... ... ... ... ... Bolt ... ... ... ... ... ... ... Cap . . . . . . ... ... ... ... ... ... Spring washer ... ... ... ... ... ...
CLUTCH LEVER ASSEMBLE 181952 ... ... ... Clutch lever (ball end) (181752) . . . . . . ... ... Clutch lever bracket (181773) . . . . . . ... ...
... Clamp (121595) . . . . . . ... ... ... Screw (11/014) . . . . . . ... ... ... ... Fulcrum screw (181087) . . . . . . ... ... ... Self locking nut (181053) ... ... ... ... Cable adjuster and nut (18/1708/1709) ... ...
Handlebar grip . . . . . . ... ... ... ... ... Horn push and dip switch (31563) . . . . . . ... ... Backing rubber (380459) ... ... ... ... ... Self-tapping screw (o in . U.H.) ... ... ... ...
23 25
TROPHY
24 25
24
Fig. 28. C O N T R O L CABLES
?ef. No . Part No . DESCRIPTION QUANnTY REMARKS
C O N T R O L C A B L E S A N D T 1 2 0 R T W I S T C R I P
... ... ... ... ... CLUTCH CABLE ... ... ... . . . . . . . . . ... ... Ferrule ... ...
Nipple (Handlebar end) ... ... ... ... ... ... ... ... Nipple ... ... . . . . . . ...
. . . . . . ... ... Adjuster . . . . . . ... ... ... ... ... N u t ...... ... . . . . . . ...
FRONT BRAKE CABLE . . . . . . ... ... ... ... Front stop switch . . . . . . ... ... ... ... ... Cover for switch . . . . . . . . . ... ... ... ...
... ... ... ... ... Ferrule ... ... ... Nipple (Handlebar end) ... ... ... ... ...
... ... ... ... ... Fork end . . . . . . ... Pivot pin (spring-fix) . . . . . . ... ... ... ... ... T H R O T L E CABLE . . . . . . ... ... ... ... ... THROTTLE CABLE . . . . . . ... ... ... ... ...
... ... ... ... Ferrule ... ... ... ...
... ... ... ... ... Nipple ... ... ...
... ... Nipple ... ... ... ... ... ... ... ... ... ... ... ... Adjuster ... ...
... AIR CONTROL CABLE ... ... ... ... ... AIR CABLE ASSEMBLY ... ... ... ... ... ...
... ... ... ... ... ... Lever cable ...
... ... ... ... Carburetter cable ... ... . . . . . . ... Junction box (2441104) ... ... ...
Nipple (Handlebar end) ... ... ... ... ... Ferrule ... ... ... ... ... ... ... ...
... ... ... ... Nipple ... ... ... ...
... ... ... ... ... Clip. rubber ... ... ... ... ... TWIN ROTOR TWISTGRIP (313113) ... ...
Body top half (313/008) . . . . . . ... ... ... ... ... Body bocrom half (3131009) ... ... ... ...
. . . . . . Rotor (3131013) ... ... ... ... ... ... ... ... ... ... Bolt (41048) ... ...
... ... Friction spring (161008) ... ... ... ... Adjuster screw (2101007) ... ... ... ... ...
... Rotor stop (2101008) ... ... ... ... ... ... ... ... N u t (210/009) ... ... ... ...
... ... ... ... ... Grip ... ... ... Cable stop (16/011) ... ... ... ... ... ...
... ... ... ... ... Cable clip (metal) ... ...
1 2 i 1 1 1 1 1 1 2 1 1 1 1 TR6R. TR6C 1 t120r 8 1 1 1 1 TR6. TR6C 1 t120 1 2 1 1 6 3 as required 1 t120r 1 1 1 2 1 1 1 2 1 2 as required
Fig.29. TOOLKIT A N D PILLION FOOTRESTS
Ref. No . Port N o . DESCRIPTION QUANTITY REMARKS
T O O L K I T A N D P I L L I O N F O O T R E S T S
TOOLKIT COMPLETE ... ... Tool rol l . . . . . . ... ... Open spanner + x 6 in . Whi r .... Open spanner + xiri; in . Wh i t .:.. Ring spanner 5 x 9 in . Wh i t . . . .
... "C" spanner and tappet key Screwdriver for chain tensioner
... Tyre lever . . . . . . ...
... Tyre lever and tomrny bar
... Screwdriver ... ... . . . . . Ring spanner & x + in W h i t
. . . . . . Clutch hub extractor ...
... ... PILLION FOOTREST ...
... ... Pedal ... ... ... Hanger ... ... ...
... . Bolt (E in U.H.) ... ... . . . . . . ... Pivot bolt ...
... Thrackeray (spring) washer ... ... Nu t . . . . . . ...
... Pedal rubber ... ...
... ... ... ... I
... ... ... ... As required
Fig. 30. A M A L CARBURETTER, TR6R TR6C
68
I Ref. No . Part No . DESCRIPTION
D770 Reference only 99-0552 99-1 032 99-0521 99-0527 99-1 033 99-051 6 99-0515 99-0520 99-1 034 99-0441 99-1035 99-1036 99-051 0 99-1037 99-051 2 99-051 3 99-051 4 99-0506 99-051 1 99-0438 99-0517 99-0437 61132A 99-0528 99-1038 F9271
A M A L C A R B U R E T T E R T R 6 R . T R 6 C
. . . . . . CARBURElTER (R930123) . . . . . . Mixing chamber ...
... "0" ring seal (622/101) ... .... Mixing chamber top (9281098)
Screw (622/086) . . . . . . ... Thrortle valve (4 cutaway) (9281060) Thrott le return spring (622/131) Thrott le stop screw (6221077)
... A i r adjusting screw (6221076) ... "0" ring (6221082) .... ... Je t holder (67.21128) ...
Main jet (230) (3761100) ... Needle jet (0.107) (6221122) ... Needle (6221124) ... ...
... Needle clip (6221067) ... Air valve guide sleeve (9281103) Float (6221069) . . . . . . ... Float spindle (6221071) . . . . . . Joint washer (6221073) . . . . . . Float chamber (6221050) . . . . . . Needle (6221068) ... ...
. . . . . . Filter (3761093) ... Banjo bolt (622/078) ... ... Fibre washer (3761092) . . . . . . Cable ferrule ... ... ...
... Air slide (9281062) ... Spring (6221129) . . . . . . ...
Petrol pipe ... ... ... ...
Ref . No . Part No . DESCRIPTION
D771 D772 Reference only 99-0552 99-1 032 99-0521 99-0527 99-1 033 99-051 6 99-051 5 99-0520 99-1 034 99-0441 99-1 035 99-1036 99-051 0 99-1037 99-0512 99-051 3 99-051 4 99-0506 99-051 1 99-0438 99-0517 99-0437 611 32A 99-0528 99-1 038 F8133 99-0530 NA43A E2968 Reference only S1932 E9555 E9554
A M A L C A R B U R E T T E R T12OR
... CARBURETTER-L.H. (L930110)
... CARBURETTER-R.H. (R930/9) . . . . . . Mixing chamber ...
"0" r ing seal (622/101) . . . . . . . ... Mixing chamber top (9281098)
. . . . . . Screw (6221086) ... Throttle valve (3 cutaway) (9281060) Throttle return spring (6221131) Throttle stop screw (6221077)
... A i r adjusting screw (6221076) ... "0" ring (6221082) ... ... Jet holder (6221128) ... . . . . . . Main jet (220) (3761100)
... Needle jet (0.107) (6221122) Needle (6221124) . . . . . . ... Needle clip (6221067) ... ... Air valve guide sleeve (9281103) Float (6221069) . . . . . . ...
. . . . . . Float spindle (6221071)
... Joint washer (6221073) ...
. . . . . . Float chamber (6221050) . . . . . . Needle (6221068) ... . . . . . . Filter (3761093) ...
... Banjo bolt (6221078) ...
. . . . . . Fibre washer (3761092) Cable ferrule ... ... ...
... A i r slide (9281062) ... Spring (6221129) . . . . . . ...
... ... Petrol pipe ... ...
... Air intake tube (9281066) ... Joint washer ... ... ... ...
... ... Insulating block ...
... ... Stude 1 in . . . . ... ... ... ... Self-lock nut ...
Cup ... ... ... ... ... Insulating ring . . . . . . ... ...
QUANTITY REMARKS
... L
... 1
... Available
... 1
... 1
... 4
... 4
... 4
... 4
Fig. 33. SPEEDOMETER A N D T A C H O M E T E R
Ref. No. Part No. DESCRIPTION QUANTITY REMARKS
E9331 E9332 Reierence only E5155 E5157 E5759 E6300 E5578 E6122 E6299 Reference only E3309 E5881 D578 99-01 66 31-371-398 D494 E6961 D546
... ... Speedometer head MPH (SSM5001/06) ...
... ... Brass f i t t ing at cable connection ... ... ... ... ... ... Bulb3W.MES . . . . . . ... ... ... ... ... Bulb ho lder (554710) . . . . . . ... ... ... ... M O U N T I N G BRACKET ... ... ... ... ... Metalastik bush . . . . . .
... ... ... ... ... Washer . . . . . . ... ... ... ... ... ... ... N u t ... ...
... ... ... ... ... Bo l t (l+in. U.H.) ...
... ... ... ... ... T r i p contro l ... ...
... ... ... ... Distance piece . . . . . . ... ... ... ... ... ... Sleeve n u t ... ... ... ... ... ... . . . . . . ... Bracket ...
... ... ... ... Bol t ( f i n . U.H.) ... ... ... ... ... ... ... Spring washer . . . . . . ... Speedometer cable (65 ins. long) (D609W inner only)
... ... TACHOMETER GEARBOX (E5758 Body) ... ... ... ... Securing screw ... ... ... ... ... ... Bush . . . . . . ... ... ... Flanged bush . . . . . . ... ... ... ... ... ... ... Dr iv ing gear ...
... ... ... ... ... End cap ... ... ... ... ... ... . . . . . . "0" r ing ...
... ... ... ... ... Dr iven gear ... ... ... ... ... Dr iven gear housing ...
... ... ... ... " 0 " r i n g ... ... ... ... ... ... Bush . . . . . . ...
... ... ... "0" r ing . . . . . . ... , . . ... ... ... ... Set screw . . . . . . ... ... Tachometer cable (28 in. long) (D578W inner only) ... ... ... ... Tachometer (RSM3003/01) ... ... ... ... ... ... Spade ... ... ,.. ... ... ... ... Circl ip . . . . . . ... .,. ... . . . . . . ... ... ... Sealing washer ... ... ... Blanking plug (replaces tacho bulb holder)
... 1
... 1 Not il lustrated
...
... 1 "' : J
. 1 Not il lustrated
Fig.34. I G N I T I O N CAPACITOR A N D HEADLAMP TR6C
3ef. No . Port No . DESCRIPTION QUANTITY REMARKS
I G N I T I O N C A P A C I T O R A N D H E A D L A M P . T R 6 C
... Ignition capacitor (type 2MC) (54170009) ... Capacitor mounting spring (54483156) ... ...
... Cap. wiring harness terminal ... ...
... Wiring harness (54955719) . . . . . . ...
... Kill button . type 151SA (35835) ... ...
... ... ... ... ... Cup ... ...
... ... ... ... Clip ... ... ...
... ... ... ... Bolt (+ in . U.H.) ...
... ... ... ... ... ... Nut ...
... HEADLAMP ASSEMBLY. MCH 66 (60087)
... ... ... ... Shell ... ...
... ... ... Rim (534343) ... ...
... Light unit (54524526) . . . . . . . ...
... Fixing wire (504665) ... ... ... Bulb (40127 W . Vertical Dip. Pre-focus) (464)
... Bulbholder . pilot (554710) ... ...
... Bulb (3W . M.C.C.) (989) ... ... ... ... ... Adaptor c/w leads ...
... ... ... ... Bolt ... ... ... ... ... ... ... Washer ...
... Lighting swirch (35710) . . . . . . ... ... ... ... Dip switch (31620) ...
... ... ... ... Screw ... ... ... ... ... ... Plate (534296) ...
... ... Warning light. red (38189) ... Warning bubholder (54945043) ... ...
... ... Bulb (2W . BA75) (181) . . . . . . ... Warning light. green (38191) . . . . . . ... Horn push. Clear Hooters No . 10 ... ... Nut for lighting switch . . . . . . ...
... ... Serrated washer (for H745) . . . . . .
Available Available Available
TR6C
1
Fig.35. I G N I T I O N COILS, H O R N , RECTIFIER A N D ZENER D I O D E
Ref. No. Port No. DESCRIPTION OUANTITY REMARKS
I G N I T I O N C O I L S , H O R N , R E C T I F I E R A N D Z E N E R D I O D E
I G N I T I O N COIL, Type MA12 (45110) Bracket ... ... ... ... Lucar terminal ... ... Plain washer ( ~ 2 3 5 i j ... Serrated washer (~5299 ) " ' ...
... N u t (F3799) ... ... Rubber g rommet . . . . . . ...
... Cable cl ip . . . . . . ...
as required as reouired
Screw ... ... ... Square n u t ... "D" washer (422369) ...
Lucar connector ... ... Insulating cover Bo l t ( I & in. U.H.) Rubber g rommet Distance piece ... Self locking n u t Sparking p lug (Cha Plug cover ... Left coi l bracket Right coi l bracket Bo l t (5 in. U.H.) Serrated washer Bo l t ... ...
... ...
... ... ... ...
... ...
... ... mpion N3)
... ... ... ...
... ...
... ... ... ...
... ... N u t ... ... ... ... Ignit ion coil, ~ib;'32,000 ... ... Clip. Sib3 32,000/1 ... ... CONDENSER PACK CP . . . . . .
Condenser (47638) ... ... Cover (54420128) ... ...
Condenser pack bracket (51418528) ... Bolt, bracket to frame ... ... Bolt, oack to bracltet ~ h a k & r o o f washcr ... ... N u t ... ... Horn , type 6 H i?0197j" ... Scrcw [a in. U.H.) ... ... ," N u t ... ... ... ... Serratcd washer Rcctificr, t ypc 2DS 506'(49072)' N u t ... Heat sink ... ... ... Zcner diode (49345) . . . . . . Brsclcet . . . . . . ... ... Washer . . . . . . ... Bo l t (bracket t o heat sink) Bo l t (bracket to fork) ... Plug heat s ink . . . . . . Washer . . . . . . ... H igh tension lead ... H o r n R.H. ... ... H o r n L.H. ... H o r n relay (33188) ... Bol t ... ... ... Washer . . . . . . ...
... Nut ... ... ...
... Bracltet . . . . . . ... Relay stay ... ... ...
Fig. 36. HEADLAMP, WIRING HARNESS, SWITCHES A N D TAIL LAMP
78
Ref. No . Port No . DESCRIPTION QUANTITY REMARKS
H E A D L A M P . W I R I N G H A R N E S S . S W I T C H E S A N D T A I L L A M P
TR6R. T12OR
HEADLAMP COMPLETE TYPE SS700P (59883) . . . . . . . ... 1 Shell only ... ... ... ... ... ... ... ... 1 Rim (553248) ... ... ... ... ... ... ... 1 Light un i t (516798) ... ... ... ... ... ... 1 Fixing wi re (504665) ... ... ... ... ... ... 6 Screw ... ... ... ... ... ... ... ... 1 Plate (534296) ... ... ... ... ... ... ... 1 Bulb (50/40W vert dip pre focus) (446) . . . . . . . ... 1 Main bulbholder (54520540) ... ... ... ... ... 1 Eu lb (6WMCC) (989) ... ... ... ... ... ... 1 Pilot bulbholder (554710) ... ... ... ... ... 1 Ammeter. type 2AR (36403) ... ... ... ... ... 1 Grommet ... ... ... ... ... ... ... ... 1 Bolt ... ... ... ... ... ... ... ... 2 Plain washer ... ... ... ... ... ... ... 2 Lighting switch (35710) . . . . . . ... ... ... ... 1 Warning l ight body (red) (38189) ... ... ... ... 1 Bulb (1W BA7S) (281) . . . . . . ... ... ... ... 1 Warning l ight body (green) (38191) . . . . . . ... ... 1 Warning bulbholder (54945043) ... ... ... ... 1
Distance piece . . . . . . ... ... ... ... ... ... 1 Wir ing harness (54955257) . . . . . . ... ... ... ... I Stop and ta i l lamp. type L679 (53973) ... ... ... ... 1
. . . . . . Lcns (54577109) ... ... ... ... ... 1 Screw ... ... ... ... ... ... ... ... 2 Bulb holder w i th reflector (54574348) . . . . . . ... ... 1 Contact assembly (573818) ... ... ... ... ... 1 Bulb (6/12W offset pin) (380) . . . . . . ... ... ... 1 Gasket (51571677) ... ... ... ... ... ... 1 Screw ... ... ... ... ... ... ... ... 1
Ignition zvditch . type 545 (31899) ... ... ... ... ... 1 N u t ... ... ... ... ... ... ... ... ... 1
Ignition loci< c /w keys . . . . . . ... ... ... ... ... 1 Ignition key (state serial No.) . . . . . . ... ... ... As required
Ignition switch cover . . . . . . ... ... ... ... ... 1 Ignition rubber cable clip (rear lamp) ... ... ... ... 1
Printed In Englond by
WARWICK PRINTING COMPANY LIMITED
WARWICK
