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 ENGINEERING COMPANY LIMITED

MERIDEN WORKS . ALLESLEY . COVENfRY . ENGLAND
T E L E P H O N E M E R I D E N 331 TELEGRAMS "TRUSTY C O V E N T R Y "

PUBLISHED SEPTEMBER 1960 REF. SPC.7.

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 TRIUMPH GUARANTEE
1. i n this Guarantee t h e w o r d "machine" refers t o t h e m o t o r cycle, scoorer, m o t o r cycle combination
o r sidecar as t h e case may be, purchased by t h e Purchaser.

2. I n o r d e r t o obtain t h e benefit o f this Guarantee, t h e Purchaser must have correctly completed t h e

registration f o r m and returned it t o us w i t h i n fourteen days o f t h e purchase.
3
1
3. W e w i l l supply, free o f charge, a n e w p a r t i n exchange for, or, i f w e consider repair sufficient, w i l l
repair free o f charge any p a r t proved w i t h i n six months o f t h e date o f purchase of any new machine,
(three months overseas) o r w i t h i n t h r e e months o f its renewal o r repair i n t h e case o f a part already
renewed o r repaired, t o be defective by reason o f o u r faulty workmanship o r materials. W e d o n o t
undertake t o bear t h e cost o f fitting such n e w o r repaired part or accessory.

4. A n y p a r t considered t o be defective m u s t be sent t o o u r Worlcs, carriage paid, accompanied by t h e

following information:-
(a) N a m e o f purchaser and his address;
(b) Date o f purchase o f machine; '
(c) Name o f dealer f r o m w h o m t h e 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 t h e incorporation o r affixing o f unsuitable attachments o r parts and i n particular:-
(a) H i r i n g o u t ;
(b) Racing and Competitions;
(c) Adaptation o r alteration o f any part or parts after leaving o u r W o r k s ;
(d) T h e 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 part n o t supplied o r approved by us, o r t o
ryres, saddles, chains, speedometers, revolution counters and electrical equipment o r t o parts supplied
t o t h e o r d e r of t h e Purchaser and different from o u r standard specification.

6. O u r liability and that o f o u r dealer w h o sells t h e machine, shall be limited t o that set o u t i n this guarantee,
and n o o t h e r claims including claims for consequential damage o r i n j u r y t o person o r property, shall
b e admissible. A i l o t h e r conditions and warranties statutory o r otherwise and whether express o r
implied are hereby excluded and n o guarantee other than that expressly herein contained applies t o
t h e machine t o which this Guarantee relates o r any accessory o r p a r t thereof.

7. W e reserve the r i g h t t o modify o r deviate f r o m the Published Specification w i t h o u t notice,

REPAIRS G U A R A N T E E

1. W h i l s t t h e highest standard o f workmanship and maierials is aimed at, w e cannot accept liability for
any defects appearing m o r e than t h r e e months after t h e machine, assembly o r component has left o u r
Worlcs after being repaired.

2. W e w i l l repair o r replace a t o u r o p t i o n free o f charge any defective w o r k , materials o r parts relating

t o t h e repairs carried o u t by us appearing w i t h i n that t i m e b u t shall n o t be under any further or other
liability for any o t h e r loss o r damage w h e t h e r direct o r consequential and o u r liability shall be limited
t o t h e cost o f so making good. W e d o n o t undertake t o bear t h e cost o f fitting any replacement o r
repaired part.

3. W e d o n o t accept liability i n respect o f parts of proprietary manufacture, e.g. tyres, saddles, chains.
speedometers, r?volution counters and electrical equipment which may be used by us i n effecting a
repair. A l i o t h e r conditions and warranties statutory or otherwise expressed o r implied are hereby
excluded.

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 TRIUMPH SPARES
HOW TO O R D E R . Every p a r 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 w h e r e possible have been listed i n o r d e r o f assembly and a number o f t h e illustrations show
t h e assembly o r d e r also. W i t h these aids there should be no d i f i c u l t y i n identifying t h e 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 i d e 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 letters.
W H E R E TO O B T A I N . T r i u m p h Spare Parts can only be obtained from an authorized T r i u m p h
Dealer, and w e recommend o u r customers t o place t h e i r orders w i t h the T r i u m p h Dealer i n their district.
W h e n parts 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 s u p p l i e d 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 f a c t o r y . 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 parts, t h e m a t t e r s h o u l d 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 Spares Department.
Customers are warned against t h e risk incurred by purchasing parts that are n o t o f genuine T r i u m p h
manufacture. This risk is eliminated i f parts are ordered as instructed f r o m recognised Dealers.
P A T T E R N S A N D P A R T S F O R R E P A I R . It is not necessary t o send patterns i f t h e part number
is quoted. T h e sending o f patterns often delays t h e order as parcel post o r rail takes longer than letter post.
Parts sent t o Coventry for repair, replacement, o r as patterns should bear t h e sender's name and address
and clear instructions should accompany t h e parts. In your o w n 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 fitments such as
windscreens, driving mirrors, tools, etc., removed by t h e sender before despatch, as it is impossible for us
t o accept responsibility i n t h e event o f loss i n transit. W e are always pleased t o give estimates for over-
hauling and repairs, b u 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 t h e SERVICE DEPARTMENT. T r i u m p h Engineering Co. Ltd., Meriden
W o r k s , Allesley, Coventry. In o r d e r t o facilitate quick reference, the quoting o f any number, invoice
number o r reference from previous communications is essentizl. Accessories not o f o u r manufacture
should be sent direct t o t h e actual makers, whose names and addresses appear below.

PROPRIETARY GROUP
Ancillary equipment which i s fitted t o o u r m o t o r cycles i s o f the highest quality and is guaranteed by
t h e manufacturer and n o t by ourselves. Any repairs or claims should be made t o the actual makers o r t h e i r
local agents w h o w i l l always give owners every possible assistance. The following are t h e addresses o f t h e
various manufacturers:-
CARBURETTERS SPARKING PLUGS
Messrs. A m a l Lid., Champion Sparking Plug Co. Ltd..
Holdford Rd.. W i t t o n , Birmingham 6. Feltham. Middlesex.
CHAIFIS SPEEDOMETERS
Renold Chains Ltd., Messrs. Smiths Industries Ltd.,
Wythenshawe. Manchester. Cricklewood Works. London. N.W.2.
ELECTRICAL EQUIPMENT SUSPENSION UNITS
Messrs. J. Lucas Ltd., Messrs. Girling Ltd.,
Gt. H a m p t o n St., Birmingham, 18 Birmingham Road, W e s t Bromwich. Staffs,
TYRES
Dunlop R u b b e r Co. Ltd..
F o r t Dunlop. Birmingham, 24

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 INDEX
Page Page
AIR FILTER ... ... ... ... 57 HANDLEBARS . . . . . . ...
ALTERNATOR ... ... ... ... 13. 33 HANDLEBAR MOUNTINGS ...
AUTO-ADVANCE UNIT ... ... 23 HEADLAMP ... ... ...
HEAT SINK ... ... ...
HORN . . . . . . ... ...
BATTERY CARRIER ...... ... 57
BRAKE SWITCHES ...... ... 65
KICKSTARTER ...... ...
CAMSHAFT. INLET AND EXHAUST 13 MANIFOLD ... ... ...
CAPACITOR. IGNITION ... ... 75 MUFFLERS ... ... ...
CARBURETTER
CARTON PACKS
... ... ... 69 71
... ... ... 9
. OIL PUMP ... ... ...
CENTRE STAND ... ... ... 35 OIL TANK ... ... ...
CHAINS . . . . . . ... ... ... 33
CHAINCASE . . . . . . ... ... 33 PISTONS ... ... ...
CLUTCH ... ... ... ... 31 PROP STAND ...... ...
CLUTCH LEVER ASSEMBLY ... 29 PUSH RODS ...... ...
COIL ... ... ... ... . . 77
CONDENSER PACK . . . . . . ... 77 REAR WHEEL ...... ...
CONNECTING RODS ... ... 13 RECTIFIER ... ... ...
CONTACT BREAKER . . . . . . ... 23 REFLECTORS ...... ...
CONTROL CABLES . . . . . . ... 65 ROCKERS ... ... ...
CONTROL LEVERS . . . . . . ... 63
CRANKCASE . . . . . . ... ... 15 SIDE PANEL . . . . . . ...
CRANKCASE UNDERSHIELD ... 39 SPARKING PLUG ... ...
CRANKSHAFT . . . . . . ... ... 13 SPEEDOMETER . . . . . . ...
CYLINDERS ... ... ... ... 19. 21 SPEEDOMETER GEARBOX ...
CYLINDER HEAD
....
... ... ... 19. 21 STEERING DAMPER . . . . . .
STEERING RACES ... ...
SUSPENSION UNITS . . . . . .
ENGINE PLATES ... ... ... 39 SWINGING FORK ... ...
ENGINE TORQUE STAY ... ... 39 SWITCHES ... ... ...
EXHAUST PIPES ... ... ... 41.43
EXHAUST PIPE ADAPTOR . . . . . . 19.21
TACHOMETER . . . . . . ...
TACHOMETER GEARBOX ...
FENDERS ... ... ... ... 61 TAIL LAMP ... ... ...
FOOTRESTS ... ... ... ... 39. 67 TAPPETS ... ... ...
FRAME . . . . . . ... ... ... 35 TIMING GEARS ... ...
FRONT BRAKE ... ... ... 49 TOOLKIT ... ... ...
FRONT FORKS ... ... ... 45 TWIN SEAT . . . . . . ...
FRONT WHEEL ... ... ... 49
FUSE ASSEMBLY ... ... ... 57 VALVES . . . . . . ... ...
VALVE GUIDES ... ...
GAS TANK ... ... ... ... 53 WIRING HARNESS
GASKET SET ...... ... ... 9
GEARBOX ... ... ... 25. 27. 29 ZENER DIODE

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 T I G E R 6 5 0 (TR6R) T E C H N I C A L D A T A

B o r e a n d s t r o k e. ..... ., . ... ... ... ... ... ... ... 71 x 82 rnrn.

2.79 x 3.23 ins.

Capacity ...... ... ... ... ... ... ... ... ... ... 649 C.C. (40 cu. ins.)

Compression r a t i o

S p a r k plugs ... Champion N3

Carburetter ... .. ... ... ... ... ... ... ... Amal Concentric 930
Main jet ... ... ... ... ... 230
Needle jet ... ... ... ... ... .I06
Throttle valve ...... ... ... ... No. 3+

G e a r b o x sprocket 19 teeth

Chains ... ... Front ... ... ... ... ... ... +" Duplex x 84 links
Rear ... ... ... ... ... ... %" x x 104 links

Capacities ... ... ... Gas Tank ... ... ... ... ... 3$ U.S. galls. (16 litres)
Oil Tank ... ... ... ... ... 6 U.S. pints (2.8litres)
Gearbox ... ... ... ... ... $ pint (500 c.c.)
Primary Chaincase ... ... ... ... 2 pint (350c.c.)
Front Forks (each leg) ... ... ... f pint (200c.c.)
Brakes ... ... ... ... Front, diameter ... ... ... ... ... 8" (20.32cm.)
Rear, diameter ... ... ... ... 7" (17.78 cm.)

T i r e size ...... .. Front ... ... ...

Rear ... ... ...

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 T R O P H Y 650 (TR6C) T E C H N I C A L D A T A

B o r e and s t r o k e ... 71 x 82 mm.

2.79 x 3.23 ins.

Capacity ...... ... ... ... 649 C.C. (40cu. ins.)

Compression r a t i o

S p a r k plugs ... Champion N3

Carburetter ... ... ... ... ... ... ... ... Amal Concentric 930
Main jet ... ... ... ... ... 230
Needle jet ... ... ... ... ... .I
06
Throttle valve ...... ... ... ... No. 3f

Gearbox sprocket

Chains ... ... Front ... ... ... ... ... ... Duplex x 84 links
+''
Rear ... ... ... ... ... ... $"x+"xl04links

Capacities ... Gas Tank ... ... ... ... ... 2$ U.S. galls. (11 litres)
O i l Tank ... ... ... ... ... 6 U.S. pints (1.8 litres)
Gearbox ... .., ... ... ... pint (500 c.c.)
Primary Chaincase ... ... ... ... $ pint (350 c.c.)
Front Forks (each leg) ... ... ... f pint (200 c.c.)

Brakes ... ... ... ... Front, diameter . ..... ... ... ... 8" (20.32 cm.)
Rear, diameter .. ... ... ... 7" (17.78 cm.)

Tiresize ...... ... Front ... ... ...

Rear ... ... ...

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 B O N N E V I L L E (T12OR) T E C H N I C A L D A T A

B o r e a n d s t r o k e ... ... 71 x 82 mm.

2.79 x 3.23 ins.

Capacity ...... ... ... ... 649 C.C. (40 cu. ins.)

Compression r a t i o ... ... ... 9 :I

Spark plugs ... Champion N3

Carburetters ... ... ... ... ... ... ... ... 2 Amal Concentric 930
Main jet ... ... ... ... ... 190
Needle jet ... ... ... ... ... .I
06
Throttle valve . . .... ... ... ... No. 3

G e a r b o x sproclcet ... ... ... 19 teeth

Chains ... ... ... ... Front ... ... ... ... ... ... +" Duplex x 84 links
Rear ... ... ... ... ... ... x x 104 links

Capacities Gas Tank ... ... ... ... ... 2; U.5, galls. (11 litres)
O i l Tank ... ... ... ... ... 5 U.5. pints (2.8 litres)
Gearbox ... ... ... ... ... +
pint (500 LC.)
Primary Chaincase ... ... ... ... 5 pint (350 c.c.)
Front Forks (each leg) ... ... ... f pint (200 c.c.)

Brakes ... ... ... Front, diameter . ..... ... ... ... 8" (20.32 cm.)
Rear, diameter ... ... ... ... 7" (17.78 cm.)

T i r e Size ...... Front ... ... ...

Rear ... ... ...

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 C A R T O N P A C K L I S T
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The following sub-assemblies are supplied i n carton packs under the C.P: part number stated. The
contents o f these carton packs are preserved and will not deteriorate under adverse conditions.

Part No. Contents

Brake Lining
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 :ICR. ... ... Competition use only
All 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 All models ...... ... ... ... ... DGS7
O v e r h a u l Gasket S e t Ail models ...... ... ... ... ... GS/B/66/67

F o r k Service pack ... ... ... ... ... ... ... CP168,64T

S t e e r i n g Race K i t
C.P.156 ...... ... 2 . . . ... ... HI11 ... ... ... Cups
1 ...... ... H439 ... ... ... Cone
1 ...... ... HI018 ...... ... Top cone
40 ...... ... 570-3 ... ... ... Ball

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 H O W TO USE THIS PARTS CATALOGUE
First check t h a t t h e engine number o f y o u r machine is subsequent t o t h a t quoted o n t h e t i t l e page.

N e x t consult t h e index o n Page 4 for t h e parts o r g r o u p o f parts which you wish t o locate. W h e n
you have located t h e parts make sure from t h e end columns t h a t t h e part you have located does apply t o
y o u r machine.

List t h e quantities required as single units; d o 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
first c o l u m n ~ n d e r ~ r i u mpart
~ h numbers (prefixed either D-or99-) whereverthey are stocked a t t h e factory.
If proprietary parts are listed only under manufacturers part numbers, they are n o t available from,the factory.

In case o f painted items always state t h e colour required. Painted parts are available only in t h e colours
o r alternatives specified for that model o f that particular year.

Model Colour

TR6 all cond~tions Trophy Red/Silver

T12OR Olympic Flame/Silver

N.B. T r o p h y Red and Olympic Flame are b o t h flamboyant finishes applied over Silver.

Paint is available only in Aerosol containers.

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 PLEASE N O T E
i
THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED I N CAPITALS AND THE COMPONENTS
INCLUDED I N THAT ASSEMBLY ARE INDENTED I N THE DESCRIPTION COLUMN, REVERTING
TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE
ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENT
PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.

SPECIAL 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. I N 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 I N
ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. I N THESE CIRCUMSTANCES
IT I S FAR MORE ECONOMICAL TO GET I N TOUCH WITH A RECOGNISED DEALER.

UNIFIED T H R E A D FORM

NEW PARTS HAVING THREADED FIXINGS INTRODUCED I N 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 I N
THEIR HEADS. STUDS A CIRCULAR GROOVE O N THE END. AND NUTS HAVE INTERLOCKING
CIRCLES O N THE SIDE.

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 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

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 Ref . N o. Part No. OESCRIP TlON QUANTITY REMARKS
I -
CRANKSHAFT A N D C O N N E C T I N G RODS

"E9686 CRANKSHAFT A N D FLYWHEEL ASSEMBLY . . . . . . ... 1

E4643 .
CRANKSHAFT C/W OIL TUBE ... ... ... ... 1
E3903 O i l tube ... ... ... ... ... ... ... 1
E3905 Screwed plug ... ... ... ... ... ... 1
"'E9687 Flywheel . . . . . . ... ... ... ... ... ... 1
*E9307 Flywheel bolt ... ... ... ... ... ... ... 3
E3114 Crankshaft stud ( I + in . O.A.) . . . . . . ... ... ... 1
E9S25 CONNECTING R O D . . . . . . ... ... ... ... ... 2
El 511 Small end bush ... ... ... ... ... ... ... 2
E6576 Connecting rod bolt ... ... ... ... ... ... 4
5549 Self locking nut . . . . . . ... ... ... ... ... 4
E3586 Big end bearing (Available in -.010 in . and -.020 in . oversizes) 4
E6868 PISTON COMPLETE 9 : 1 C.R. ... ... ... ... ... 2
E6867 PISTON COMPLETE 11 : 1 C.R. . . . . . . ... ... .... 2
E6864 Taper compression ring . . . . . . ... ... ... ... 4
E6865 O i l control ring . . . . . . ... ... ... ... ... 2
E6863 Gudgeon pin (long) ... ... ... ... ... ... 2
E6869 Circlip ... ... ... ... ... ... ... ... 4
El 591 Main bearing. right ... ... ... ... ... ... ... 1
E3876 Oil seal ... ... ... ... ... ... ... ... ... 1
E5446 Engine sprocket, 29 teeth Duplex ... ... ... ... ... 1
E4573 Distance piece . . . . . . ... ... ... ... ... ... 1
E3974 Rotor key ... ... ... ... ... ... ... ... 1
99-0739 Rotor (54213901) ... ... ... ... ... ... ... 1
E3975 Tab washer ... ... ... ... ... ... ... ... 1
E3977 Nut ... ... ... ... ... ... ... ... ... 1
El580 Key ... ... ... ... ... ... ... ... ... 1
E4564 Timing pinion . . . . . . ... ... ... ... ... ... 1
E4565 Nut ... ... ... ... ... ... ... ... ... 1
E6159 INTERMEDIATE WHEEL ... ... ... ... ... ... 1
E400 Intermediate wheel bush . . . . . . ... ... ... ... 1
E4562 Camshaft wheel . . . . . . ... ... ... ... ... ... 2
El558 Camshaft key ... ... ... ... ... ... ... ... 2
El 463 Inlet camshaft nut ... ... ... ... ... ... ... 1
E4563 Exhaust camshaft nut . . . . . . ... ... ... ... ... 1
E l 0040 Inlet camshaft. Racing type ... ... ... ... ... ... 1
El 0041 EXHAUST CAMSHAFT. RACING TYPE . . . . . . ... ... 1
iE4700 Tachometer drive thimble ... ... ... ... ... 1
E5316 Rotary breather valve . . . . . . ... ... ... ... ... 1
E2256 Breather valve spring . . . . . . ... ... ... ... .. 1
E3300 Clamping washer ... ... ... ... ... ... ... 1
E2879 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

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 Fig. 2. CRANKCASE

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 DESCRIPTION QUANTITY REMARKS

CRANKCASE
C R A N K C A S E DRIVE SIDE ... ...
Breather disc ... ... ...
Locating pin-at disc ... ...
Inlet camshaft bush ... ...
Exhaust camshaft bush . . . . . .
Chain rensioner abutment ...
Breather pipe (metal) ... ...
C R A N K C A S E T I M I N G SIDE ... ... I
Camshaft bush ... ... ... ... 2
Scavenge pipe ... ... ... ... Reference only
Locating peg (at o i l pipes) ... ... Reference only
H o l l o w dowel ... ... ... ... 2
Locating peg (L/S at thrust washer) ... 1
Needle roller bearing. layshaft ... ... 1
Intermediate wheel spindle ... .... 1
H o l l o w dowel . . . . . . ... ... ... 1
H o l l o w dowel . . . . . . ... ... ... 1
Screw (s . i n U.H.) ... ... ... ... 2
Stud (4f i n . O.A.) ... ... ... ... 1
Plain washer ... ... ... ... ... 2
Nut ... ... ... ... ... ... 2
H o l l o w dowel. tappet o i l feed ... ... 2
Oilway plug ... ... ... ...
Copper washer . . . . . . ... ...
Tachometer drive plug (L.H. thread)
Fibre washer ... ... ... ...
O i l pipe stud ( I f i n . O.A.) ......
Cylinder stud (1: in . O.A.) . . . . . .
Plug. t i m i n g hole ... ... ...
Bolt (2f i n . U.H.) U N . . . . . . ...
Bolt (1; i n . U.H.) U N . . . . . . ...
Bolt (1; i n . U.H.) U N . . . . . . ...
Stud ( 5 - h i n . O.A.) ... ... ... ... I
Stud (3; in. O.A.) ... ... ... ... 2 (TR6C 3 off)
Plain washer ... ... ... ... ... 11
Nut ... ... ... ... ... ... 8
Crankcase filter U N . . . . . . ... ... 1
Copper washer . . . . . . ... ... ... 1
Breather extension pipe ... ...
Drain plug ( w i t h level tube) U N ...
F ~ b r ewasher ... ... ... ...
Level plug U N . . . . . . ... ...
Copper washer . . . . . . ... ...
Drain and adiuzter plug ... ... ... I
Fibre washer ... ... ... ... ... 1
Bianting plug ... ... ... ... ... 1
Filler plug U N . . . . . . ... ... ... 2
Fibre washer ... ... ... ... ... 2
B o l t (4 i n . U.H.) U N . . . . . . ... ... 1
Stud (4) i n . O.A.) ... ... ... ... 1 (Except TR6C)
Protection blade ... ... ... ... 1
Self l o c k n u t U N ... ... ... ... 1
Rubber plug (for protection blade stud I ... 1 TR6R. T12OR

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 ASSY 13 16 24 18 23
20

21

22

Fig. 3. O I L P U M P . RELEASE VALVE, M A N I F O L D A N D TAPPETS

16
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1 Ref . No. Port No. DESCRIPTION QUANTITY REMARKS
I
1 O I L PUMP. RELEASE VALVE. MANIFOLD A N D TAPPETS

E6928 O I L PUMP ... ... ... ... ... ... ... ... 1
Reference only Pump body . . . . . . ... ... ... ... ... ... 1
GS153 Feed plunger ... ... ... ... ... ... ... 1
E6681 Scavenge plunger ... ... ... ... ... ... ... 1
E495 D r i v e block ... ... ... ... ... ... ... 1
570-7 Valve ball (6i n . dia.) ... ... ... ... ... ... 2
E403 Valve spring ... ... ... ... ... ... ... 2
E2360 Screwed plug ... ... ... ... ... ... ... 2
E3730 Joint washer ... ... ... ... ... ... ... ... 1
51 864 Oil p u m p stud (I*i n. U.H.) ... ... ... ... ... 2
E3887 Serrated washer ... ... ... ... ... ... ... 2
51 906 Nut ... ... ... ... ... ... ... ... ... 2
E6595 O I L RELEASE VALVE ... ... ... ... ... . . . . 1
E7590 Valve body ... ... ... ... ... ... ... 1
GS251 Piston ... ... ... ... ... ... ... ... 1
E6596 Cap . . . . . . ... ... ... ... ... ... ... 1
GS254 Fibre washer ... ... ... ... ... ... ... 1
E7591 Main spring ... ... ... ... ... ... ... 1
E l 670 Fibre washer ... ... ... ... ... ... ... ... 1
51 876 Stud (1Ei n . O.A.) ...... ... ... ... ... ... 4
E5660 Joint washer ... ... ... ... ... ... ... ... 2
E5512 Inlet manifold . . . . . . ... ... ... ... ...
525-1 3 Plain washer ... ... ... ... ... ... ...
51 877 Nut ... ... ... ... ... ... ... ...
E2962 Stud ( I & i n . O.A.) ... ... ... ... ... ...
NA43A Joint washer ... ... ... ... ... ... ... ... ~6
1 & TR6C
£491 8 insulating bloclc ... ... 1
525-3 Plain washer ... ... ... ... ... ... ... ... 2
El310 Nut ... ... ... ... ... ... ... ... ... 2
£9352 Inlet tappet guide ... ... ... ... ... ... ... 1
E9353 Exhaust tappet guide . . . . . . ... ... ... ... ... 1
El612 Serrated washer ... ... ... ... ... ... ... 2
HZ00 Set b o l t . . . . . . ... ... ... ... ... ... ... 2
E3059R Inlet tappet ... ... ... ... ... ... ... ... 2
£8801 Exhaust tappet . . . . . . ... ... ... ... ... ... 2
E7563 "O-ring ... ... ... ... ... ... ... ... 2

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 Fig. 4. CYLINDER BLOCK A N D H E A D , TR6

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 Ref. No. Part No.
i DESCRIPTION QUANTITY REMARKS

CYLINDER BLOCK A N D H E A D . TR6R. TR6C

Cylinder base washer . . . . . . ...

Cylinder block . . . . . . ... ...
Cylinder base n u t ... ... ...
Push r o d ... ... ... ...
Cover t u b e ... ... ... ...
Rubber washer . . . . . . ... ...
Cylinder head gasket . . . . . . ...
CYLINDER H E A D c / w GUIDES ...
I n l e t valve guide ... ... ...
Exhaust valve guide ... ...
Exhausr pipe adaptor ... ...
Inlet valve ... ... ... ...
Exhausr valve . . . . . . ... .. .
Botrom cup ... ... ... ...
Inner valve spring (red spot) . . . . . .
O u r e r valve spring (green spot) ...
T o p collar ... ... ... ...
Split cotrer ... ... ... ...
.
Cylinder head b o l t ( 3 i i n U.H.) ...
Plain washer ... ... ... ...
B o l t (3 i n . U.H.) ... ... ...
Plain washer ... ... ... ...
Sealing ring ... ... ... ...
Inlet rocker b o x ... ... ...
Exhausr rocker b o x ... ... ...
Joint washer ... ... ... ...
Rocker b o x stud (E . i n O.A.) ...
Rocker box n u t . . . . . . ... ...
Plain washer ... ... ... ...
Rocker b o x bolt (2& i n . U.H.) ...
Plain washer ... ... ... ...
Cylinder head b o l t (lor t o r q u e stay)
lnspeccion cap . . . . . . ... ...
Joint washer ... ... ... ...
Locking spring . . . . . . ... ...
Fibre washer ... ... ... ...
Screw ( n . U.H.)
ii ... ... ...
ROCKER (right exhaust. l e l t inlet) ...
ROCKER (lelt exhaust. r i g h t inlet) ...
Rocker ball p i n ... ... ...
Rocker adjusting p i n . . . . . . ...
Adjuster lock n u t ... ... ...
Thrust washer. $ i n . . . . ... ...
+
T h r u s t washer. i n .... ... ...
Spring washer . . . . . . ... ...
Rocker spindle ... ... ...

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 Fig. 5. C Y L I N D E R B L O C K A N D H E A D , TIIOR

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 DESCRIPTION QUANTITY REMARKS

CYLINDER BLOCK A N D HEAD. ' ~ 1 2 0 ~

Cylinder base washer ...... ... ... ... ... ... 1
Cylinder block . . . . . . ...... ... ... ... ... 1
Cylinder base n u t ... . . . . . . ... ... ... ... 8
Push r o d ... ... ... ... ... ... ... ... 4
Cover tube ... ... . . . . . . ... ... ... ... 2
Rubber washer . . . . . . ... ... ... ... ... ... 4
Cylinder head gasket . . . . . . ... ... ... ... ... 1
CYLINDER H E A D c / w GUIDES ... ... ... ... ... 1
Sleeve for head bolts passing t h r o u g h i n l e t tracts ... ... 2 Reference only
Inlet valve guide . . . . . . ... ... ... ... ... 2
Exhaust valve guide ... ... ... ... ... ... 2
Carburetter adaptor. left ... ... ... ... ... 1
Carburetter adaptor. r i g h t ... ... ... ... ... 1
Connector . . . . . . ... ... ... ... ... ... 2
Balance pipe ... ... ... ... ... ... . . . . 1
Adaptor locking n u t ... ... ... ... ... ... 2
Exhaust pipe adaptor ... ... ... ... ... ... 2
Inlet valve ... ... ... ... ... ... ... ... 2
Exhaust valve . . . . . . ... ... ... ... ... ... 2
B o t t o m cup ... ... ... ... ... ... ... ... 4
Inner valve spring (Red spot) ... ... ... ... ... 4
O u t e r valve spring (green spot) ... ... ... ... ... 4
T o p collar ... ... ... ... ... ... ... ... 4
Split cotter ... ... ... ... ... ... ... ... 8
Cylinder head b o l t ( 3 t In. U.H.) ... ... ... ... ... 4
Plain washer ... ... ... ... ... ... ... ... 8
B o l t (3 i n . U.H.) ... ... ... ... ... ... ... 1
Plain washer ... ... ... ... ... ... ... ... 1
Sealing ring ... ... ... ... ... ... ... ... 2
Inlet rocker b o x ... ... ... ... ... ... ... 1
Exhaust rocker b o x ... ... ... ... ... ... ... 1
Joint washer ... ... ... ... ... ... ... ... 2
Rocker b o x stud (e In . O.A.) ... ... ... ... ... 6
Nut ... ... ... ... ... ... ... ... ... 6
Plain washer ... ... ... ... ... ... ... ... 6
Rocker box bolt (2& i n . U.H.) ... ... ... ... ... 4
Plain washer ... ... ... ... ... ... ... ... 4
Cylinder head b o l t (for t o r q u e stay) ... ... ... ... 4
Inspection cap . . . . . . ... ... ... ... ... ... 4
Joint washer ... ... ... ... ... ... ... ... 4
Locking spring . . . . . . ... ... ... ... ... ... 4
Fibre washer ... ... ... ... ... ... ... ... 4
Screw (+ i n . U.H.) ... ... ... ... ... ... ... 4
ROCKER (right exhaust. left inlet) . . . . . . ... ... ... 2
ROCKER (left exhaust. r i g h t inlet) . . . . . . ... ... ... 2
Rocker ball p i n ... ... ... ... ... ... ... 4
Rocker adjusting pin . . . . . . ... ... ... ... ... 4
Adluster lock n u t ... ... ... ... ... ... ... 4
.
T h r u s t washer $ i n....
T h r u s t washer. 4 i n . . . .
... ... ... ...
... ... ... ...
...
...
...
...
2
6
Spring washer . . . . . . ... ... ... ... ... ... 4
Rocker spindle . . . . . . ... ... ... ... ... ... 2

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 Fig. 6. T I M I N G C O V E R A N D C O N T A C T BREAKER

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I Ref . No. Port No. DESCRIPTION QUANTITY REMARKS

T I M I N G COVER A N D CONTACT BREAKER

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
Circlip ... ... ... ... ... ... ... ... ... 1
H o l l o w dowel . . . . . . ... ... ... ... ... ... 1
Screw f f I( .
In U.H.) ... ... ... ... ... ... ... 3
Screw (1 in . U.H.) ... ... ... ... ... ... ... 5
.
Bolt (Zin U.H.) . . . . . . ... ... ... ... ... ... 1
Plain washer ... ... ... ... ... ... ... ... 1
Rubber grommet ... ...
... ... ... ... ... 1
Pillar b o 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
C O N T A C T BREP.KER PLATE ASSEMBLY (54419097) . . .... 1
Contact set (54419827) . . . . . . ... ... ... ... 2
Pin. adjustment (54419220) ... ... ... ... ... 2
Dowel pin l o 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 t o replace oil switch i f required

23
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 Fig.7. G E A R B O X I N N E R C O V E R A N D SELECTORS

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 Ref . No. Port No. DESCRIPTION QUANTITY REMARKS
i
G E A R B O X I N N E R COVER A N D SELECTORS

Stud (3 in. O.A.) ... ... ... ... ... ... ...
Hollow dowel . . . . . . ... ... ... ... ... ...
Gear selector camplate ... ... ... ... ... ...
Camplate index plunger ... ... ... ... ... ...
Index plunger spring . . . . . . ... ... ... ... ...
Strong index plunger spring . . . . . . ... ... ... ... as required
Index plunger holder . . . . . . ... ... ... ... ... 1
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; i n . U.H.) ... ... ... ... ... ...
.
Countersunk screw (# in U.H.) ... ... ... ... ...

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1 Ref. No . Port No . DESCRIPTION QUANTITY REMARKS
i
GEARBOX SHAFTS AND GEARS

MAINSHAFT c/w L O W GEAR (16T)

Clutch rod bush . . . . . . ...
MAINSHAFT HlGH GEAR (26T) ...
High gear bush ... ... ...
Mainshaft third gear (24T) ... ...
Mainshaft second gear (20T) . . . . . .
LAYSHAFT L O W 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) . . . . . . ... ... ...

;I
See pages 5 t o
Gearbox sprocket (18 teeth) . . . . . . ... ... ... 7 for standard
Gearbox sprocker (19 teeth) . . . . . . ... ... ... ... 1
sizes
Gearbox sprocket (20 teeth) . . . . . . ... ... ... ... 1
Tab washer ... ... ... ... ... ... ... ... 1
Gearbox sprocket nut ... ... ... ... ... ... 1
High gear bearing ... ... ... ... ... ... ... 1
Circlip ... ... ... ... ... ... ... ... ... 1
O i l seal . . . . . . ... ... ...
Mainshaft bearing ... ... ...
Circlip . . . . . . ... ... ...
Plain washer ... ... ... ...
Pinion sleeve ... ... ... ...
Pinion spring ... ... ... ...
Kickstarter pinion ... ... ...
Kickstarter ratchet ... ... ...
Tab washer ... ... ... ...
Nut ... ... ... ... ...
Clutch operating rod . . . . . . ...

W I D E RATIO GEARS

MAINSHAFT HIGH GEAR (28T) . . .... ... ... ... 1

Mainshafr second gear (19T) . . . . . . ... ... ... ... 1
Layshaft second gear (27T) . . . . . . ... ... ... ... 1
Layshaft c/w high gear (18T) . . . . . . ... ... ... ... 1

CLOSE RATIO GEARS

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 ( 2 3 3 ... ... ... ... ... ... 1
Layshaft clw high gear (22T) . . . . . . ... ... ... ... 1

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 Fig. 9. GEARBOX O U T E R COVER

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28
 .
Ref No . Port No . DESCRIPTION QUANTITY REMARKS
I
GEARBOX OUTER COVER

GEARBOX OUTER COVER

Gearchange spindle bush ...
Kicltstarter spindle bush
Kickstarter spring anchor p i n
Guide plate stud (ii n . O.A.)
Oilseal ... ... ...
O i l seal housing . . . . . .
Gearchange quadrant . . . . . .
Rubber "0" ring ... ...
Quadrant r e t u r n spring ...
Gearchange quadrant plunger
Plunger spring . . . . . . ...
Guide plate ... ... ...
Serrated washer ... ...
Nut ... ... ... ...
Kickstarter quadrant ...
Kickstarter r e t u r n 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 ... ...
S p l i t p i n ... ... ...
Countersunk screw (s i n . O.A.)
Rubber cover . . . . . . ...
A b u t m e n t f o r clutch cable ...
Plain washer ... ... ...
Nut ... ... ... ...
Screw (23 in . U.H.) ... ...
Screw (I& in . U.H.) . . . . . .
Screw (1 in . U.H.) ... ...
Gearchange pedal ... ...
Bolt (1 i n . U.H.) ... ...
Pedal rubber ... ... ...
F O L D I N G KICKSTARTER ...
Kickstarter lever . . . . . .
Kickstarter pedal . . . . . .
Pedal locating spring ...
.
Steel bail $ i n . diam ....
Pedal b o l t . . . . . . ...
Pedal rubber ... ... ...
C o t t e r pin c/w n u t and washer
Domed n u t ... ... ...
Filler plug ... ... ...
Fibre washer ... ... ...

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 Ref. No. Port No.
I DESCRIPTION QUANTITY REMARKS

CLUTCH

Clctch securing n u t ... ... ...

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) ... ...
O u r e r place ... ... ... ...
Screwed pin (1% i n . U.H.) . . . . . .
Driving place (bonded) ... ...
Driven plate ... ... ... ...
Pressure plate . . . . . . ... ...
Adjuster pin ... ... ... ...
Nut ... ... ... ... ...
Spring cup ... ... ... ...
Spring ... ... ... ... ...
Pressure n u t ... ... ... ...
Key ... ... ... ... ...
Cupped washer ... ... ...

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 Ref . No. Part No. DESCRIPTION QUANTITY REMARKS

CHAINCASE A N D C H A I N S

Primary chain oiler tube ... ...

Clip ... ... ... . . . . . .
Spring washer ... ... ... ...
B o l t (6i 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 (5i n . U.H.) ...
Chain tensioner abutment ... ...
Chain tensioner blade . . . . . . ...
Tie rod . . . . . . ... ... ...
Trunnion ... ... ... ...
Adluster sleeve n u t ... ... ...
Primary chain. ii n . D u p l e x x 84 links
Stator stud (4% i n . O.A.) ... ...
Stator stud ... ... ... ...
Stator. R M 2 l (47205) . . . . . . ...
Sleeve n u 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 plug ... ... ... ...
Fibre washer ... ... ... ...
Screw (1 i n . U.H.) ... ... ...
Screw ( s i n . U.H.) ... ... ...
Domed n u t ... ... ... ...
Copper washer . . . . . . ... ...
Timing pointer . . . . . . ... ...
Level plug ... ... ... ...

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1! .
Ref No. Port No. DESCRIPTION QUANTITY REMARKS

FRAME

F7843 Front Frame ... ...

Hlll Steering race cup ...
570-3 .
Steel ball ( $ i n diam.)
H I 0 18 T o p cone and dust cover
F11267 Centre stand ...
R331 Pedalrubber . . . . . .
51 978 Pivot b o l t ... ...
F5679 Plain washer ... ...
F11270 Tab washer ... ...
14.0404 Nut ... ... ...
F4671 Return spring . . . . . .
F7849 Prop stand ... ...
RO2l Pivot bolt ... ...
14-0703 Self locking n u t ...
F8392 Return spring . . . . . .
F8036 Rear frame ... ...
51801 Stud (3; i n . O.A.) ...
526-1 Spring washer ... ...
14-0303 Nut ... ... ...
14-0251 Bolt (244 in . U.H.) ...
F4370 Plain washer ... ...
14-0304 Nut ... ... ...
PCW73A Spring washer . . . . . .
5588 Bolt ( I & i n. U.H.) ...
F7155 Steering srop ... ...

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 Fig. 13. S W I N I G N G F O R K A N D S U S P E N S I O N UNITS

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 . .
Ref No Part No. DESCRIPTION QUANTITY REMARKS

S W I N G I N G FORK A N D SUSPENSION -UNITS

F10045 SWINGING FORK . . . . . . ... ... ... 1

F6042 Pivot bush . . . . . . ... ... ... ... 2
NW100 Grease nipple . . . . . . ... ... ... ... 1
WE170 Fibre washer ... ... ... ... ... ... 1
F6821 Sleeve ... ... ... ... ... ... ... 2
F5313 Distance tube . . . . . . ... ... ... ... 1
F7848 Flanged washer ... ... ... ... ... 2
5620 .
Bolt (85 in U.H.) ... ... ... ... ... 1
F5944 Tab washer ... ... ... ... ... ... 1
5545 Nut ... ... ... ... ... ... ... 1
F7365 Brake torque stay ... ... ... ... ... 1
51802 .
Bolt (j+ In U.H.) ... ... ... ... ... 1
PCW73A Spring washer . . . . . . ... ... ... ... 2
14-0304 Nut ... ... ... ... ... ... ... 2
F8090 "0" ring ... ... ... ... ... ... 2
D2024 SUSPENSION U N I T (64052107) ... ... ... 2
Reference only Damper unit ... ... ... ... ... 2
09-0122 Bonded bush (64533645) . . . . . . ... ... 4
99-01 07 Sprinz retainer (9054,'171) ... ... ... 4
99-1 048 Spring 100 ibs . chrome (64543708) ... ... 2
99-1 047
14-0235
.
Spring 145 lbs . chrome hexdy duty (64544234)
U n i t fixing bolt (1& i t 4. U.H.) ... ... ...
Available
4
525-2 Plain washer ... ... ... ... ... ... 2
526-1 Spring washer . . . . . . ... ... ... ... 2
GS308 Plain washer ... ... ... ... ... ... 3
14-0303 Nut ... ... ... ... ... ... ... 4
F7067 Chainguard ... ... ... ... ... ... 1
F5536 Grommet ... ... ... ... ... ... 1
14-01 13 Bolt ( In. H ) ... ... ... ... ... 1
F7364 Rubber tube ... ... ... ... ... ... 1
525-1 3 Plain washer ... ... ... ... ... ... 1
14-0702 Self-locking nut ... ... ... ... ... 1
F9387 Stepped bolt ... ... ... ... ... ... 1
525-3 Plain washer ... ... ... ... ... ... 1
14-0302 Nut ... ... ... ... ... ... ... 1
F3808 Clip ... ... ... ... ... ... ... 1
F879 Nut ... ... ... ... ... ... ... 1
F1369 Bolt (;in . U.H.) ... ... ... ... ... 1
526-2 Spring washer ... ... ... ... ... 1
F7386 Brake operating rod ... ... ... ... ... 1
.
& in x $ i n . Split pin . . . . . . ... ... ... ... ... 1
F7387 Adluster nut ... ... ... ... ... ... 1
99-0725 .
Stop lamp switch type 228 (54033234) ... ... 1
TI 076 Screw (+ in U.H.) . ... ... ... ... ... 3
F4717 Self locking n u t ... ... ... ... ... 5
F5412 Switch lever ... ... ... ... ... ... 1
F5413 "D" washer ... ... ... ... ... ... 1
F3158 Spring (315738) ... ... ... ... ... 1

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 Fig. 14. E N G I N E U N I T F I T T I N G A N D FOOTRESTS

38
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 Ref. No.
- Port No . DESCRIPTION QUANTITY REMARKS

E N G I N E UNIT F I T T I N G S A N D FOOTRESTS

Stud (3& l n O.A.). ... ...

Sprlngwaher . . . . . . ...
Nut ... ... ... ...
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.) ... ... ... ... ... ... ... 2
Plaln washer ... ... ... ... ... ... ... ... 4
Spring washer . . . . . . ... ... ... ... ... ... 6
Nut ... ... ... ... ... ... ... ... ... 4 (3 on TR6C)
Extended nut . . . . . . ... ... ... ... ... ... 1 (TR6C only)
Left footrest ... ... ...
Right footrest ... ... ...
Stud (I& in. O.A.) ... ...
Plain washer ... ... ...
Nut ... ... ... ...
Peg ... ... ... ...
Footrest rubber ... ...
Stud (1: in. O.A.) ... ...
Nut ... ... ... ...
(a
Bolt in . U.H.) ... ...
Bolt (19 in. U.H.) ... ...
Spring washer . . . . . . ...
Nut ... ... ... ...
Nut ... ... ... ...
Nut ... ... ... ...
Engine torque stay ... ...
Bit1 in. U . ) ... ...
Nut ... ... ... ...
Distance piece . . . . . . ...
Brake pedal lever ... ...
Bolt (E in. U.H.) ... ...
Nut ... ... ... ...
Brake pedal ... ... ...
Crankcase undershield . . . . . .
Hook bolt ... ... ...
Plain washer ... ... ...
Nut ... ... ... ...
Nut ... ... ... ...
Plain washer ... ... ...
LEFT FOOTREST ASSEMBLY
RIGHT FOOTREST ASSEMBLY
Left footrest ... ...
Right footrest ... ...
Footrest pedal ... ...
Pivot bolt . . . . . . ...

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 Fig.15. E X H A U S T PIPES A N D MUFFLERS TIZOR, TR6R

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 Ref . No. Port N o . DESCRIPTION QUANTITY REMARKS
I
E X H A U S T PIPES AND MUFFLERS. T120R. T R ~ R (Seealso Page43)
I
EXHAUST PIPE D.S. . . . . . . ... ... ... ... ...
EXHAUST PIPE T.S. . . . . . . ... ... ... ... ...
Coupling pipe . . . . . . ... ... ... ... ... ...
Clip ... ... ... ... ... ... ... ... ...
Cap ... ... ... ... ... ... ... ... ...
Bolt. coupling pipe ( 1 i i n. 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 (iin . U.H.) ... ... ... ...
Hanger. frame for silencer ... ... ... ... ... ...
.
Bolt. silencer hanger t o frame (iin U.H.) . . . ... ... ...
Nut ... ... ... ... ... ... ... ... ...
Spring washer . . . . . . ... ... ... ... ... ...
Eolt. silencer to frame ($ in . U.H.) . . . . . . ... ... ...
Spring washer . . . . . . ... ... ... ... ... ...
Nut ... ... ... ... ... ... ... ... ...
Clip. silencer to exhaust pipe ... ... ... ... ...
Stay. DS and TS silencers ... ... ... ... ... ...
"DM washer ... ... ... ... ... ... ... ...
Bolt (If in . U.H.) ... ... ... ... ... ... ...
Spring washer . . . . . . ... ... ... ... ... ...
Nut ... ... ... ... ... ... ... ... ...
Coupling pipe . . . . . . ... ... ... ... ... ...
Clip ... ... ... ... ... ... ... ... ... 2 I Alternative pariz
"D" washer ... ... ... ... ... ... ... ...
Bolt ... ... ... ... ... ... ... ... ...
Nut ... ... ... ... ... ... ... ... ...

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 Fig. 16. E X H A U S T PIPES A N D M U F F L E R S (TR6C)

42
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/ Ref . No. Port No . DESCRIPTION QUANTITY REMARKS

E X H A U S T PIPES A N D MUFFLERS TR6C

Exhaust pipe D.S. lower ... ... ... ... ... ... 1
Exhaust pipe T.S. upper ... ... ... ... ... ... 1
Exhaust pipe stay ... ... ... ... ... ... ... 1
5 i n. 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
N u 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 N o t illustrated

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 ASSEMBLY REF. No.1

Fig. 17. TELESCOPIC F R O N T FORK

44
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 Ref . No. Part No . DESCRIPTION QUANTITY REMARKS
I
T E L E S C O P I C F R O N T F O R K TR6R.
FORK ASSEMBLY ... ... 1 TR6R
FORK ASSEMBLY ... ... 1 t120r
Middle lug and stem ... 1 TR6R
Middle lug and stem ... 1 t120r
B o t t o m cone ... ... 1
.
Pinch bolt (2f i n U.H.) ... 2
Plain washer ... ... 2
Cieveloc nut ... ... 2
Fork stem sleeve nut (blind) 1
Top lug ... ... ... 1
Bondedbush ... ... 2
Lock c / w 2 keys ... ... 1
Key (stare serial number) 1 .
Key Nos run
from E l k 1 t o
EJRSO
G r u b screw ... ... ... ... 1
Sealing washer ... ... ... ... 1
Locating pin ... ... ... ...
Pinch bolt (I+ i n . U.H.) ... ... ... ... I

Seated n u t . . . . . . ... ... ... ... ... 1

Left top cover ... ... ... ... ... ... 1
Right top cover . . . . . . ... ... ... ... 1
C o r k washer ... ... ... ... ... ... 2
Spring abutment . . . . . . ... ... ... ... 2
Solo main spring (Yellow/Blue) ... ... ... 2
Extra strong main spring (Yellow/Green) ... ... Available
Plain washer ... ... ... ... ... ... 2
Telescopic gaiter ... ... ... ... ... ... 2
DUST EXCLUDER SLEEVE N U T ... ... ... 2
O i l seal ... ... ... ... ... ... 2
"0" ring . . . . . . ... ... ... ... ... 2
Plain washer ... ... ... ... ... ... 2
T o p bearing ... ... ... ... ... ... 2
Damping sleeve . . . . . . ... ... ... ... 2
Stanchion . . . . . . ... ... ... ... ... 2
Lower bearing ... ... ... ... ... ... 2
Bearing n u t ... ... ... ... ... ... 2
Cap nut ... ... ... ... ...
LEFT B O T T O M MEMBER c / w CAP ...
RIGHT BOTTOM MEMBER c / w CAP
Spindlecap . . . . . . ... ...
Spring washer ... ... ...
Cap bolt (I& i n . U.H.) ... ...
Drain plug . . . . . . ... ... ...
Fibre washer ... ... ... ...
Shuttle valve ... ... ... ...
Circlip ... ... ... ... ...
Restrictor . . . . . . ... ... ...
Aluminium washer ... ... ...
Flanged bolt ... ... ... ...
Brake cable bracket ... ... ... ...
Cable retainer . . . . . . ... ... ...
Starlock washer ... ... ... ...
45
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 FORK ASSEMBLY REF. NP 1

15

@-- 21
&Zk-- 23
@?- 19
L20
Fig. 18. TRbC F O R K PARTS A N D STEERING DAMPER

46
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 Ref. No . Port No. DESCRlPTlON QUANTITY REMARKS

TR6C FORK PARTS A N D STEERING DAMPER

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

1
All other parts are as listed on Page 45

HANDLEBAR MOUNTINGS

Handlebar eyebolt
Plain washer ...
Bolt ( I $ in . U.H.)
... ... ... ...
... ... ... ...
... ... ... ...
Hemispherical washer . . . . . .
Self-locking nut
... ...
... ... ... ...
...
...
...
...
...
...
...
...
... ...
i!
...
2
TR6R. T12OR
Steady rubber . . . . . . ... ... ... ... ... ... 2
Distance piece . . . . . . ... ... ... ... ... ... 2
Cup ... ... ... ... ... ... ... ... ... 2
Solid bush (lor handlebar-mounted windscreen) ...... ... as required

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 Ref. No. Porf No.
I DESCRIPTION QUANTITY REMARKS

FRONT WHEEL

W3458 FROEJT WHEEL COMPLETE ... ... ... ... ... 1

W1721
W1230
.
RIM SPOKES A N D HUB ASSEMBLY
Front wheel r i m (WM2-19) ...
...
...
...
...
...
...
1
1
W1328 .
Spoke (8/10G x 55 in straight) ... ... ... ... 20
W1708 Spoke (8/10G x 4 W i n. 78'j .... ... ... ... 10
W1709 .
Spoke (8/10G xG i n 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 ring ... ... ... ... ... ... 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 Nut . . . . . . ... ... ... ... ... ... ... 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

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/ Ref . No. P o n No . DESCRIPTION QUANTITY REMARKS

REAR WHEEL

W2102 REAR WHEEL COMPLETE . . . . . . ...

W1486 .
RIM SPOKES A N D H U B ASSEMBLY
Rear wheel r i m WM3-18 . . . . . .
W1007
W1107 Spoke (8/10G x7-& i n 90") . ...
W3402 Spoke (8/1OG x7-& I n. 110") ...
Wll08 Spoke (8/1OG x 79 i n . 90") . . . . . .
579-2 Spoke nipple . . . . . . ... ...
W1472 Hub . . . . . . ... ... ...
W1499 Sprocket. 46T ... ... ... ...
W 1 500 .
Bolt ( # i n U.H.) ... ... ...
El612 Serrated washer . . . . . . ... ...
W1498 Brake drum ... ... ... ...
W1690 Bolt (+In . U.H.) . . . . . . ... ...
W1691 Self locicing nut . . . . . . ... ...
W1281 Wheel spindle ... ... ... ...
W1474 Grease retainer (brake side) ... ...
W1654 Grease retainer . . . . . . ... ...
Wl022 Backing ring ... ... ... ...
W653 Bearing ... ... ... ... ...
W1021 RETAINING RING ... ... ...
W1710 Locking screw (& in. U.H.) ...
W1278 Distance tube ... ... ... ...
W1024 Distance piece ... ... ... ...
Wlll2 Bralce anchor plate ... ... ...
W3426 Nut . . . . . . ... ... ... ...
" W1406 LEADING BRAKE SHOE C / W LINING
W1407 TRAILING BRAKE SHOE C / W LINING
Reference only Brake lining . . . . . . ... ...
Reference only Brass rivet ... ... ... ...
W1415 Thrust pad ... ... ... ...
W135 Shoe return spring ... ... ...
W1083 Brake cam . . . . . . ... ... ...
W2015 Brake cam lever . . . . . . ... ...
525-6 Plain washer ... ... ... ...
51-52 Nut . . . . . . ... ... ... ...
W1090 Lever return spring ... ... ...
W163S Grease retainer . . . . . . ... ...
W1476 Speedometer adaptor ... ... ...
W1477 Distance piece ... ... ... ...
D637 Speedometer gearbox . . . . . . ...
W1280 Plain washer ... ... ... ...
W2089 Chain adjuster . . . . . . ... ... ...
W1015 Adjuster end plate ... ... ... ...
14-1 902 Self-locking nut ... ... ... ...
F1747 Spindle nut ... ... ... ... ...
WM3 Tire security bolt ... ... ... ...
W3425 N u t inner D.S. ... ... ... ...
W1467 Pivot pin ... ... ... ... ...

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 Fig. 22. GAS T A N K S

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52
I
.
Ref No. Port No . DESCRIPTION QUANTITY REMARKS

GAS TANKS

Gas tank (3f gallons) ... ... ... ...

Gas tank (24 gallons) . . . . . . ... ...
Gas tank (2f gallons) ... ... ... ...
Styling unit (left) ... ....... ...
Styling unit (right) ... ... ... ...
Styling unit screw (front) ... ... ...
Styling unit screw (rear) ... ... ...
Left knee grip ... ... ... ... ...
Right knee grip ... ... ... ...
Centre styling strip ... ... ... ...
Hook screw ... ... ... ... ...
Serrated washer ... ... ... ...
Nut ... ... ... ... ... ...
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 ... ... ... ...
Nut ... ... ... ... ... ...
Double spigot rubber . . . . . . ... ...
Rubber washer . . . . . . ... ... ...
Bolt 1 inH . ) ... ... ... ...
Reflector bracket ... ... ... ...
.
Reflector Amber (57161)
Decal-Bonneville
... ...
... ... ...
...
...
Decal-Trophy 650 ... ... ... ...
Decal-Trophy Sports ... ... ...
Decal-Made in England ... ... ...

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 10
Fig. 23. OIL TANK

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54
 Ref. No. Port No . DESCRIPTION QUANTITY REMARKS

OIL TANK

O i l tank ... ... ... ... ... ...

FILLER CAP . . . . . . ... ... ...
Joint washer ... ... ... ...
Drain plug ... ... ... ... ...
Fibre washer ... ... ... ... ...
O i l tank filter . . . . . . ... ... ...
Fibre washer ... ... ... ... ...
Upper feed pipe ... ... ... ...
Union nut ... ... ... ... ...
Flexible connector ... ... ... ...
Clip ... ... ... ... ... ...
O i l pipes and junction block . . . . . . ...
Joint washer ... ... ... ... ...
Plain washer ... ... ... ... ...
Nut ... ... ... ... ... ...
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 refill" e t c. . . .

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 Fig.14. BATTERY CARRIER A N D A I R FILTERS

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/ Ref. No . Part N o. DESCRIPTION QUANTITY REMARKS

Battery carrier ... ... ... ...

Battery carrier rubber tray . . . . . . ...
Battery carrier strap . . . . . . ... ...
Battery strap anchorage ... ... ...
Battery carrier rubber strip . . . . . . ...
Transfer positive earth ... ... ...
Vent pipe ... ... ... ... ...
Circlip. v e n t pipe ... ... ... ...
Battery (PUZSA) 54027029 ... ... ...
AIR CLEANER ... ... ... ... ...
Air cleaner element (filter cloth &gauze)
AIR CLEANER ... ... ... ... ... T120R
A i r cleaner element (filter cloth & gauze)
Fuse assembly . . . . . . ... ... ... Reference only
Clip for air cleaner cover ... ... ... 1 Not illustrated

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1 Ref. No . Port No. DESCRIPTION QUANTITY REMARKS

PANEL A N D TWINSEAT

Side panel and toolbox

Decal-TIGER 650 ...
Decal-TROPHY 650 ...
Decal-BONNEVILLE ...
Panel knob ......
Washer . . . . . . . . .
Panel nut ......
Panel grommet . . . . . .
TWINSEAT ... ...
Twinsear cover ...
T r i m strip ......
T r i m 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 rail . . . . . . ...
Bolt ( % i n. U.H.) ...
Spring washer . . . . . .

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 Fig. 26. FENDERS

60
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 9ef. No . Part No . DESCRIPTION OUANTITY REMARKS

FENDERS

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 . . . . . . ... ... 1
Tail lamp adaptor ... ... ... 1
Tail lamp plate . . . . . . ... ... 1
Number plate bracket ... ... 1
Reflector red (57111) . . . . . . ... 2
Push fix . . . . . . ... ... ... 4
Rubbermat ... ... ... ... 2
Wiring protector ... ... ... 1
Tail lamp lead grommet ... ... Reference only
Bolt (i,in. U.H.) ... ... ... 5
Plain washer ... ... ... ... 12
Nut ... ... ... ... ... 13
Bolt ( & i n . U.H.) ... ... ... 4
Nut ... ... ... ... ... 2
Bolt (f in. U.H.) ... ... ... 3
Plain washer ... ... ... ... 2
Washer . . . . . . ... ... ... 3
Nut ... ... ... ... ... 3
Self-locking nut ... ...
Plain washer ... ... ...
Bolt (2 in. U.H.) ... ...
Bolt ( i n . U.H.) ... ...
Spring washer . . . . . . ...
Spring washer . . . . . . ...
Screw ... ... ... ...
Washer . . . . . . ... ...
Nut ... ... ... ...
Stud (+in. O.A.) ... ...
Nut ... ... ... ...

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 Fig. 27. H A N D L E B A R S A N D C O N T R O L LEVERS

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 Ref. No. Pan N o . DESCRIPTION OUANTITY REMARKS

HANDLEBARS A N D C O N T R O L LEVERS (SEE A L S O PAGE 65)

H1870 Handlebar ... ... ...... ... ... ...

H I 425 Packing piece . . . . . . ... ... ... ... ...
99-0248 M I S T G R I P (161364) . . . . . . ... ... ......
99-0245 Body top half (161328) . . . . :. ... ... ...
99-0246 Body bottom half (161329) ... ... ... ...
99-0244 Rotor (161091) ... ...... ... ... ...
99-0238 Friction spring (161008) . . . . . . ... ... ...
99-0239 Friction spring screw (161009) . . . . . . ... ...
99-0240 Locknut (161010) . . . . . . ... ... ... ...
99-022s Screw (111013) ... . . . . . . ... ... ...
Reference only Grip ... ... ... ... ... ... ...
99-0241 Cable stop (161011) ... ... ... ... ...
D2073 FRONT BRAKE A N D AIR LEVER ASSEMBLY (181978)
99-0262 Brake lever (ball end) (181754) ... ... ...
99-0266 Lever bracket (181776) . . . . . . ... ... ...
99-0234 Control body (121619) . . . . . . ... ... ...
99-0226 Screw ('11/014) . . . . . . ... ... ... ...
99-0225 Screw (111013) ... ... ... ... ... ...
99-0252 Fulcrum screw (181087) . . . . . . ... ... ...
99-0250 Self locking nut (181053) ... ... ... ...
99-1031 Cable adjuster and nut (18/1708/1709) ... ...
99-0228 Lever (121556) ... ... ... ... ... ...
121607 Bolt ... ... ... ... ... ... ...
121606 Cap . . . . . . ... ... ... ... ... ...
121033 Spring washer ... ... ... ... ... ...
D2074 CLUTCH LEVER ASSEMBLE 181952 ... ... ...
99-0261 Clutch lever (ball end) (181752) . . . . . . ... ...
99-0265 Clutch lever bracket (181773) . . . . . . ... ...
99-0230 Clamp (121595) . . . . . . ... ... ... ...
99-0226 Screw (11/014) . . . . . . ... ... ... ...
99-0252 Fulcrum screw (181087) . . . . . . ... ... ...
99-0250 Self locking nut (181053) ... ... ... ...
99-1031 Cable adjuster and nut (18/1708/1709) ... ...
Reference only Handlebar grip . . . . . . ... ... ... ... ...
99-0555 Horn push and dip switch (31563) . . . . . . ... ...
99-0630 Backing rubber (380459) ... ... ... ... ...
H1994 Self-tapping screw (o i n. U.H.) ... ... ... ...

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 23 25

TROPHY

24 25
24

Fig. 28. C O N T R O L CABLES

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 ?ef. No. Part No . DESCRIPTION QUANnTY REMARKS

C O N T R O L C A B L E S A N D T120R TWISTCRIP
CLUTCH CABLE ... ... ... ... ... ... ... 1
Ferrule ... ... . . . . . . ... ... ... ... 2
Nipple (Handlebar end) ... ... ... ... ... i
Nipple ... ... ...... ... ... ... ... 1
Adjuster . . . . . . ... ...... ... ... ... 1
N u t ...... ... . . . . . . ... ... ... ... 1
FRONT BRAKE CABLE . . . . . . ... ... ... ... 1
Front stop switch . . . . . . ... ... ... ... ... 1
Cover for switch . . . . . . . . . ... ... ... ... 1
Ferrule ... ... ... ... ... ... ... ... 2
Nipple (Handlebar end) ... ... ... ... ... 1
Fork end . . . . . . ... ... ... ... ... ... 1
Pivot pin (spring-fix) . . . . . . ... ... ... ... ... 1
T H R O T L E CABLE . . . . . . ... ... ... ... ... 1 TR6R. TR6C
THROTTLE CABLE . . . . . . ... ... ... ... ... 1 t120r
Ferrule ... ... ... ... ... ... ... ... 8
Nipple ... ... ... ... ... ... ... ... 1
Nipple ... ... ... ... ... ... ... ... 1
Adjuster ... ... ... ... ... ... ... ... 1
AIR CONTROL CABLE ... ... ... ... ... ... 1 TR6. TR6C
AIR CABLE ASSEMBLY ... ... ... ... ... ... 1 t120
Lever cable ... ... ... ... ... ... ... 1
Carburetter cable ... ... ... ... ... ... 2
Junction box (2441104) . . . . . . ... ... ... ... 1
Nipple (Handlebar end) ... ... ... ... ... 1
Ferrule ... ... ... ... ... ... ... ... 6
Nipple ... ... ... ... ... ... ... ... 3
Clip. rubber ... ... ... ... ... ... ... ... as required
T W I N ROTOR TWISTGRIP (313113) ... ... ... ... 1 t120r
Body top half (313/008) . . . . . . ... ... ... ... 1
Body bocrom half (3131009) ... ... ... ... ... 1
Rotor (3131013) . . . . . . ... ... ... ... ... 1
Bolt (41048) ... ... ... ... ... ... ... 2
Friction spring (161008) ... ... ... ... ... ... 1
Adjuster screw (2101007) ... ... ... ... ... 1
Rotor stop (2101008) ... ... ... ... ... ... 1
N u t (210/009) ... ... ... ... ... ... ... 2
Grip ... ... ... ... ... ... ... ... 1
Cable stop (16/011) ... ... ... ... ... ... 2
Cable clip (metal) ... ... ... ... ... ... ... as required

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 Fig.29. TOOLKIT A N D PILLION FOOTRESTS

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 Ref. No. Port N o. DESCRIPTION QUANTITY REMARKS

TOOLKIT AND PILLION FOOTRESTS

TOOLKIT COMPLETE ... ...

Tool roll ...... ... ...
+
Open spanner x 6 in. W h i r ....
+
Open spanner xiri; in. W h i t .:..
.
Ring spanner 5 x 9in W h 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 . . . . ... ... ... ... I
Clutch hub extractor . . . . . . ... ... ... ... ... As required
PILLION FOOTREST ... ... ...
Pedal ... ... ... ...
Hanger ... ... ... ...
Bolt (E .
in U.H.) ... ... ...
Pivot bolt . . . . . . ... ...
Thrackeray (spring) washer ...
Nut . . . . . . ... ... ...
Pedal rubber ... ... ...

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 Fig. 30. A M A L CARBURETTER, TR6R TR6C

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 . .
I Ref. No Part No DESCRIPTION

A M A L CARBURETTER TR6R. TR6C

D770 CARBURElTER (R930123) . . . . . .

Reference only Mixing chamber . . . . . . ...
99-0552 "0" ring seal (622/101) ... ...
99-1 032 Mixing chamber top (9281098) ....
99-0521 Screw (622/086) . . . . . . ...
99-0527 Thrortle valve (4 cutaway) (9281060)
99-1 033 Throttle return spring (622/131)
99-051 6 Throttle stop screw (6221077)
99-0515 A i r adjusting screw (6221076) ...
99-0520 "0" ring (6221082) ... ....
99-1 034 J e t holder (67.21128) ... ...
99-0441 Main jet (230) (3761100) ...
99-1035 Needle jet (0.107) (6221122) ...
99-1036 Needle (6221124) ... ...
99-051 0 Needle clip (6221067) ... ...
99-1037 Air valve guide sleeve (9281103)
99-051 2 Float (6221069) . . . . . . ...
99-051 3 Float spindle (6221071) . . . . . .
99-051 4 Joint washer (6221073) . . . . . .
99-0506 Float chamber (6221050) . . . . . .
99-051 1 Needle (6221068) ... ...
99-0438 Filter (3761093) . . . . . . ...
99-0517 Banjo bolt (622/078) ... ...
99-0437 Fibre washer (3761092) . . . . . .
61132A Cable ferrule ... ... ...
99-0528 Air slide (9281062) ... ...
99-1038 Spring (6221129) . . . . . . ...
F9271 Petrol pipe ... ... ... ...

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 Ref . No. Part No. DESCRIPTION QUANTITY REMARKS

A M A L C A R B U R E T T E R T12OR

D771 CARBURETTER-L.H. (L930110) ...

D772 CARBURETTER-R.H. (R930/9) ...
Reference only Mixing chamber . . . . . . ...
99-0552 "0" ring seal (622/101) . . . . . . .
99-1 032 Mixing chamber top (9281098) ...
99-0521 Screw (6221086) . . . . . . ...
99-0527 Throttle valve (3 cutaway) (9281060)
99-1 033 Throttle return spring (6221131)
99-051 6 Throttle stop screw (6221077)
99-051 5 A i r adjusting screw (6221076) ...
99-0520 "0" ring (6221082) ... ...
99-1 034 Jet holder (6221128) ... ...
99-0441 Main jet (220) (3761100) . . . . . .
99-1 035 Needle jet (0.107) (6221122) ...
99-1036 Needle (6221124) . . . . . . ...
99-051 0 Needle clip (6221067) ... ...
99-1037 Air valve guide sleeve (9281103)
99-0512 Float (6221069) . . . . . . ...
99-051 3 Float spindle (6221071) . . . . ..
99-051 4 Joint washer (6221073) ... ...
99-0506 Float chamber (6221050) . . . . . .
99-051 1 Needle (6221068) . . . . . . ...
99-0438 Filter (3761093) . . . . . . ...
99-0517 Banjo bolt (6221078) ... ...
99-0437 Fibre washer (3761092) . . . . ..
611 32A Cable ferrule ... ... ...
99-0528 A i r slide (9281062) ... ...
99-1 038 Spring (6221129) . . . . . . ... ... L

F8133 Petrol pipe ... ... ... ... ... 1

99-0530 Air intake tube (9281066) ... ... ... Available
NA43A Joint washer ... ... ... ... ... 1
E2968 Insulating block ... ... ... ... 1
Reference only Stude 1 in. . . . ... ... ... ... 4
S1932 Self-lock nut ... ... ... ... ... 4
E9555 Cup ... ... ... ... ... ... 4
E9554 Insulating ring . . . . . . ... ... ... 4

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 Fig. 33. SPEEDOMETER A N D T A C H O M E T E R

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 Part No. DESCRIPTION QUANTITY REMARKS
Ref. No.

Speedometer head MPH (SSM5001/06) ... ... ... ... 1

Brass fitting a t cable connection ... ... ... ... ... 1 Not illustrated
Bulb3W.MES . . . . . . ... ... ... ... ...
Bulb holder (554710) . . . . . . ... ... ... ...
M O U N T I N G BRACKET ... ... ... ... ...
Metalastik bush . . . . . . ... ... ... ...
Washer . . . . . . ... ... ... ... ... ...
Nut ... ... ... ... ... ... ... ...
Bolt (l+in. U.H.) ... ... ... ... ... ...
T r i p control ... ... ... ... ... ... ...
Distance piece . . . . . . ... ... ... ... ...
Sleeve n u t ... ... ... ... ... ... ...
Bracket . . . . . . ... ... ... ... ... ...
Bolt ( f i n . U.H.) ... ... ... ... ... ...
Spring washer . . . . . . ... ... ... ... ...
Speedometer cable (65 ins. long) (D609W inner only) ...
E9331 TACHOMETER GEARBOX (E5758 Body) ... ...
E9332 Securing screw ... ... ... ... ... ...
Reierence only Bush . . . . . . ... ... ... ... ...
E5155 Flanged bush . . . . . . ... ... ... ...
E5157 Driving gear ... ... ... ... ... ...
E5759 End cap ... ... ... ... ... ... ...
E6300 "0" ring . . . . . . ... ... ... ... ...
E5578 Driven gear ... ... ... ... ... ...
E6122 Driven gear housing ... ... ... ... ...
E6299 "0"ring ... ... ... ... ... ...
Reference only Bush . . . . . . ... ... ... ... ...
E3309 "0" ring . . . . . . .
... , . ... ... ...
E5881 Set screw . . . . . . ... ... ... ... ...
D578 Tachometer cable (28 in. long) (D578W inner only) ...
99-01 66 Tachometer (RSM3003/01) ... ... ... ... ...
... ,.. ... ... ... ...
:J
31-371-398 Spade ... ...
D494 Circlip . . . . . . ... ... ... .,. ... ... ...
E6961 Sealing washer . . . . . . ... ... ... ... ... ...
"'
1
D546 Blanking plug (replaces tacho bulb holder) ... ... . 1 Not illustrated

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 Fig.34. 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 TR6C

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 3ef. No . Port No . DESCRIPTION QUANTITY REMARKS

I G N I T I O N CAPACITOR A N D HEADLAMP. TR6C

Ignition capacitor (type 2MC) (54170009) ... ... Available

Capacitor mounting spring (54483156) ... ... Available
Cap. wiring harness terminal ... ... ... Available
Wiring harness (54955719) . . . . . . ... ...
Cup ...
.
Kill button type 151SA (35835)
...
... ... ...
... ... ... ... ... TR6C
Clip ... ... ... ... ... ... ...
.
Bolt ( + i n U.H.) ... ... ... ... ...
Nut ... ... ... ... ... ... ...
HEADLAMP ASSEMBLY. MCH 66 (60087) ... 1
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 N o. 10 ... ...
Nut for lighting switch . . . . . . ... ...
Serrated washer (for H745) . . . . . . ... ...

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 Fig.35. I G N I T I O N COILS, H O R N , RECTIFIER A N D Z E N E R D I O D E

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 Ref. No. Port No. DESCRIPTION OUANTITY REMARKS

I G N I T I O N COILS, H O R N , RECTIFIER A N D ZENER D I O D E

I G N I T I O N COIL, Type M A 1 2 (45110)

Bracket ... ... ... ...
Lucar terminal ... ...
Plain washer ( ~ 2 3 5 i j ...
Serrated washer ( ~ 5 2 9 9 ) " '...
N u t (F3799) ... ... ...
Rubber g r o m m e t . . . . . . ...
Cable clip . . . . . . ... ...
Screw ... ... ...
Square n u t ...
"D" washer (422369) ...
Lucar connector ... ... as required
Insulating cover ... ... as reouired
B o l t ( I & in. U.H.) ... ...
Rubber g r o m m e t ... ...
Distance piece ... ... ...
Self locking n u t ... ...
Sparking plug (Cha mpion N3)
Plug cover ... ... ...
Left coil bracket ... ...
Right coil bracket ... ...
B o l t (5 in. U.H.) ... ...
Serrated washer ... ...
Bolt ... ... ... ...
Nut ... ... ... ...
Ignition coil, ~ib;'32,000 ... ...
Clip. Sib3 32,000/1 ... ...
CONDENSER P A C K CP ......
Condenser (47638) ... ...
Cover (54420128) ... ...
Condenser pack bracket (51418528) ...
Bolt, bracket t o frame ... ...
Bolt, oack to bracltet
~ h a k & r o o f washcr ... ...
Nut ... ...
H o r n , type 6 H i?0197j" ...
Scrcw [a ," in. U.H.) ... ...
Nut ... ... ... ...
Serratcd washer
Rcctificr, t y p c 2DS 506'(49072)'
Nut ...
Heat sink ... ... ...
Zcner diode (49345) . . . . . .
Brsclcet . . . . . . ... ...
Washer . . . . . . ...
B o l t (bracket t o heat sink)
B o l t (bracket to fork) ...
Plug heat sink . . . . . .
Washer . . . . . . ...
H i g h tension lead ...
H o r n R.H. ... ...
H o r n L.H. ...
H o r n relay (33188) ...
Bolt ... ... ...
Washer . . . . . . ...
Nut ... ... ... ...
Bracltet . ..... ... ...
Relay stay ... ... ...

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 Fig. 36. HEADLAMP, W I R I N G HARNESS, SWITCHES A N D TAIL LAMP

78
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 Ref. No. Port No. DESCRIPTION QUANTITY REMARKS

HEADLAMP. WIRING HARNESS. SWITCHES A N D T A I L LAMP

TR6R. T12OR

HEADLAMP COMPLETE TYPE SS700P (59883) . . . . . . . ... 1

Shell only ... ... ... ... ... ... ... ... 1
Rim (553248) ... ... ... ... ... ... ... 1
Light u n i t (516798) ... ... ... ... ... ... 1
Fixing w i r e (504665) ... ... ... ... ... ... 6
Screw ... ... ... ... ... ... ... ... 1
Plate (534296) ... ... ... ... ... ... ... 1
Bulb (50/40W vert dip pre focus) (446) ....... ... 1
Main bulbholder (54520540) ... ... ... ... ... 1
E u l b ( 6 W M C C ) (989) ... ... ... ... ... ... 1
Pilot bulbholder (554710) ... ... ... ... ... 1
Ammeter. type 2AR (36403) ... ... ... ... ... 1
Grommet ... ... ... ... ... ... ... ... 1
Bolt ... ... ... ... ... ... ... ... 2
Plain washer ... ... ... ... ... ... ... 2
Lighting switch (35710) . . . . . . ... ... ... ... 1
Warning light body (red) (38189) ... ... ... ... 1
Bulb (1W BA7S) (281) . . . . . . ... ... ... ... 1
Warning light body (green) (38191) . . . . . . ... ... 1
Warning bulbholder (54945043) ... ... ... ... 1
Distance piece . . . . . . ... ... ... ... ... ... 1
W i r i n g harness (54955257) . . . . . . ... ... ... ... I
Stop and t a i l lamp. type L679 (53973) ... ... ... ... 1
Lcns (54577109) . . . . . . ... ... ... ... ... 1
Screw ... ... ... ... ... ... ... ... 2
Bulb holder w i t h 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

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 Printed In Englond by
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WARWICK

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