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REPLACEMENT I PARTS CATALOGUE FOR 1971

DAYTONA (TI OOR) TROPHY so~ (TI OOC)

TRIUMPH ENGINEERING COMPANY LIMITED MERIDEN WORKS • ALLESLEY • COVENTRY CVS 9AU • ENGLAND

TELEPHONE CO VENTRY 10121 MEIIIDEN Jl1

P'UIUSl-tEO JULY 1'70

FIRST AHENDHENT APkll 1971

T ELEGRAMS " TIIUSTY " COVENTIIY TELEX 0 TRUSTY" JUOS

P'UIUCATION rAkT No. ~l4

-

INDEX

AIR FILTER ALTERNATOR ... AUTO-ADVANCE UNIT

BATTERY CARRIER BRAKE SWITCHES BREATHER PIPES

Page

67 9,35

2S

67 .. . 45, 73

65

9 CAMSHAFT, INLET AND EXHAUST CAPACITOR, IGNITION CAPACITOR PACK

75 75

... 17, 19 CARBURETOR CARTON PACKS CENTRE STAND CHAINS ... CHAINCASE CLUTCH CLUTCH LEVER ASSEMBLY COIL CONNECTING RODS CONTACT BREAKER .. . CONTROL CABLES .. . CONTROL LEVERS .. . CRANKCASE ... CRANKCASE UNDERSHIELD CRANKSHAFT ... CYLINDERS CYLINDER HEAD

ENGINE PLATES ENGINE TORQUE STAY EXHAUST PIPES EXHAUST PIPE ADAPTOR

FENDERS FLASHERS FOOTRESTS FRAME ... FRONT FORKS FRONT WHEEL FUSE ASSEMBLY

GAS TANK GASKET SET GEARBOX

7 43 35 35 33 31 77 9

2S 73 69 11 -41 9

. .. 21,23

... 21, 23

39 39

... 37, 41

.. . 21,23

57 79

... 41, 43 43

... 47, 49

... S1, 53 67

63 7

27, 29, 31

3

Page

HANDLEBARS ... 69 HANDLEBAR MOUNTINGS ... 71 HEADLAMP ... 75, 79 HEAT SINK n HORN ... n

• KICKSTAATER ... 31

MANIFOLD MUFFLERS

OIL PUMP OIL TANK OIL PIPES

PISTONS PROP STAND PUSH RODS

REAR WHEEL .. . RECTIFIER REFLECTORS ROCKERS

SIDE PANEL SPARKING PLUG SPEEDOMETER ... SPEEDOMETER GEARBOX STEERING DAMPER ... STEERING RACES SUSPENSION UNITS ... SWINGING ARM SWITCHES

15 .•. 37, 41

13 65 65

9 43

... 21, 23

55 77

... 57, 63 23

61 77 81 55 71 43 45 45

... 69, 79

TABLE OF STANDARD HARDWARE TACHOMETER .. .

82 81 81 59

TACHOMETER GEARBOX TAIL LAMP TAPPETS TIMING GEARS TOOLKIT TWIN SEAT

VA1.VES ... VALVE GUIDES

WIRING HARNESS

ZENER DIODE

... 21, 23 9

67 61

. .. 21, 23

.. . 21, 23

79

77

Bore and StroKe

Capacity

Compreulon Ratio

Spark Plugs

Carburetor

Gearbox Sprocket

Chains

Capacities

Brakes

Tire Size

TIGER 100 (T100C) TECHNICAL DATA

Main Jet Needle Jet Needle Throttle Valve

Front Rear

Gas Tank 011 Tank Gearbox Primary Chalncase (lnltlal fill) Front Forks (each leg)

Front and Rear, diameter

Front Rear

5

2.716 x 2.578 ins.

30 cu. ins.

9:1

Champion N• Amal Concentric 170 .106 Standard No. • 18 teeth

i In. Duplex x 78 link, i In. x J In. X 102 links

2¼ U.S. galls. 6 U.S. pints 2/3 pint (375 c.c.) ¼ pint (150 c.c.) ½ pint (200 c.c.)

7 In. (17.18 cm.)

3.50 X 19 •.00 X 18

Bore and Stroke

Capacity

Compression Ratio

Spark Plugs

Carburetor

Gearbox Sprocket

Chains

Capacities

Brakes

Tire Size

TIGER 100 (T100R) TECHNICAL DATA

Main Jet Needle Jet Needle Throttle Valve

Front Rear

Gas Tank Oil Tank Gearbox Primary Chaincase (Initial fill) Front Forks (each leg)

Front, diameter Rear, diameter

Front Rear

6

2.716 x 2.578 ins.

30 cu. ins.

9 : 1

Champion N'4

Amal Concent ric 150 .106 Standard No. 3

19 teeth

i in. Duplex x 78 links fin.xi In. x 103 links

2i U.S. Galls. 6 U.S. pints 2/3 pint (375 c.c.) ¼ pint (150 c.c.) t pint (200 c.c.)

8 In. (20.32 cm.) 7 in. (17.18 cm.)

3.25 X 19 400 X 18

CARTON PACK LIST

The following sub-assemblies are supplied in carton packs under the part number stated. The contents of these carton packs are preserved and will not deteriorate under adverse conditions.

PISTONS (c/w rings, gudgeon pins and circlips)

E.6906

E.688-4

E.7603

7.0: 1 C.R.

9: 1 C.R.

7.5: 1 C.R.

500 c.c.

500 c.c.

500 c.c.

• ... Low grade fuel

T1 OOR, T1 OOC

AvaiLable

All piston assemblies are available In 0.010 In., 0.020 In., 0.040 In., oversizes (0.25 mm., 0.5 mm., 1.0 mm.).

BRAKE LININGS

C.P.38/AMl

C.P.205

2

16

2

16

VALVE SPRINGS (all models)

C.P.1n -4

-4

STEERING HEAD RACES

C.P.156

GASKET SETS

Decoke Overhaul

2 1 1

40

99-1164 99-1167

NWl-43

W129

W173-4

W129

E59-46

E4011

H111 H-439 H1018 570-3

7

Brake lining

Rivet

Brake lining

Rivet

Inner valve spring

Outer valve spring

Cup Cone Top cone Ball

25 30 27

u~~ 23

5-~

15 14

~~

31

~12

~13

11

7

11

19 20 21

Ref. No. Part No.

1 E9489 2 E9490 3 E3999 4 E9492 5 E5870 6 •S1913 7 E9915 8 E9914 9 S2016

10 E3706 11 E6884 12 E6893 13 E6894 14 E6861 15 E6869 16 E12517 17 E3734 18 E3851 19 54213901 20 E3975 21 S1915 22 E1580 23 E1771 24 S1914 25 E6160 26 E400 27 E4562 28 E1558 29 E11007 30 E6S23 31 E11064 32 E9984 32 E9983 33 E9988 34 E9502 35 52051 36 E9503 Not illus. E8038 Not illus. E12660

DESCRIPTION QUANTITY REMARKS

C RANKSHAFT AND CONNECTING RODS

CRANKSHAFT AND Fl YWHEEL ASSEMBLY .. Crankshaft ... Oil tube Screwed plug Flywheel ... Flywheel bolt (1# In. U.H.)

CONNECTlNG ROD .. . Connecting rod bolt Self-locking nut

• ... Big end bearing (available In - .010 and - .020 undersizes). PISTON COMPLETE C.R. 9.1

Taper compression ring . .. 011 control rl ng Gudgeon pin c1r6i1p .. .

Spacer .. . Engine sprocket. 26T Duplex Rotor key Rotor (99-0739) Tab washer Nut Key Timing pinion Nut INTERMEDIATE WHEEL

Bush Camshaft wheel Camshaft key ... Inlet camshaft nut Exhausc camshaft nut Inlet camshaft . .. EXHAUST CAMSHAFT EXHAUST CAMSHAFT

Tachometer drive plug Retaining plate ... Screw(# in. U.H.) Clamping washer Shim (0.010") Shim (0.030")

1 1 1 1 1 3 2 2 2 4 2 T100R. T100C 4 2 2 T100C, T100R 4 T100C, T100R 1

1 1 1 1 1 1 1 1 2 2 1

1 1 T100R 1 T100C 1 2 4

As required } 4 As required up to

•use D524 Loctite sealant

9

35-

., 30~

31~~ 34

J3 Cl7

CRANKCASE FiJ. 2.

10

Re(. No. Port No.

1 2 3

• 5 6 7 8 9

10 11 12 13 H 15 16

E11268 E•H7 E3823 E3823 E11269 E9496 E1509 S1920 1~102 E7430 T1606 E6386 E375 T912 E3716 S1926

17 14-0225 18 S1925 19 S1919 20 - S2S-3 21 14--1302 22 S1852 23 S1864 24 E9•9• 25 S1921 26 S1922 27 E153• 28 E9•93 29 T1257 30 E3n• 31 E3722 32 E7•31 33 E9501 3• E1577 35 S1927 36 T2167 37 E24•1 38 SS-•3 39 E8896 •O T2166 •1 E8782 •2 S1871 •3 E7•31 1• s1sn •5 E11079 •6 E9335 •7 E11•60 48 E11075 ~9 E11077 Not illus. E-4707

DESCRIPTION

C RA NKC A SE

CRANKCASE DRIVE SIDE Pivot pin ... Camshaft bush Camshaft bush

CRANKCASE TIMING SIDE 011 scavenge pipe ... Clip•·· Screw Bolt •·· Tab washer Needle roller bearing Dowel at junction block ... Idler gear spindle ... Peg (at thrust washer)

Hollow dowel ... Screw (tt In. U.H.)

Bolt Stud (3¾ In. U.H.) Bolt Plain washer Nut Nut 011 pump stud (1-h In. 0.A.) Right main bearing (ball journal) Cylinder base stud (1½ In. O.A.) Cylinder base stud (1ft in. O.A.) Dowel ... Left mal n bearing (roller journal) • ... Washer ... filter spring Filter Sealing washer ... FIiter cap Joint washer Stud (3,li In. O.A.) Drain plug (with level tube) ... fibre washer Level plug Fibre washer Filler plug "O" ring Blanking plug (L.H. thread) "O" ring ... Plug Cover plate Outlet stub-breather Joint washer Screw Screw Grommet, alternator leads

11

•· .... .. ... .. ...

QUANTITY

1 1 1 1 1 1 1

1 Ref. only 1 1 2 2 (Not required

REMARKS

on later models) 1 2 1 3 2 1 2 1 6 2 2 1 1 1 1 1 1 2 2 1 1 1 1 2 1

1 1 1 1 1 2 1 1

(Not T100R)

7-------.

- :::::-- :::: -::::::::: --- :::: ASSY.1 - -- -------6

- -- 2 - 2 --- ---- ---10-----J

9

3-----Q) Q> 00- b 4----gi I) -- =-cJ9 s----1& o_ .

12 13

C1 Fis, 3. OIL PUMP ANO RELEASE VALVE

12

Ref. No. Port No. DESCRIPTION QUANTITY REMARKS

,,-OIL PUMP AND RELEASI VAL VI

1 E6928 OIL PUMP -· 1 2 E6680 Pump body ... ~· Reference only 3 D2363 Valve ball . .. ·~ l -4 E'403 Valve spring l s E2360 Screwed plug 2 6 GS153 Feed plunger 1 7 E6681 Scavenge plunger ... 1 8 E-495 Drive block 1 9 E11-461 Joint washer • 1 ""' 10 E3887 Serrated washer 2

11 S1906 Nut . 2 12 E12210 0 11 release valve 1 13 E1670 Joint washer 1

r--,,

13

16 15 14 23

13 19 12

• 4. INLET MANIFOLDS F,,.

14

18

•

20

21

22 C6

- ---==-=-:::-::::--==---_

Ref. No . Part No. DE.SCRIPT/ON QUANTITY REMARKS

.,,-0 I L P U MP AND RELEASI VAL VI

1 E6928 OIL PUMP 1 2 E6680 Pump body . .. Reference only 3 D2363 Valve ball ... 2 -4 E-403 Valvo spring , .. 2 s E2360 Screwed plug 2 6 GS153 Feed plunger 1 7 E6681 Scavenge plunger .. . 1 8 E495 Drive block 1 9 E11-461 Joint was her • 1 .....

10 E3887 Serrated washer 2 11 S1906 Nut • 2 12 E1ll10 Oil release valve 1 13 E1670 Joint washer 1

r'\

13

16 15 17

I

13 19 12

1 2

14 23

Fig. 4• INLET M ANIFOLDS

14

18

20

22 C6

Ref. No. Part No. DESCRIPTION QUANTITY REMARKS

,,_.,,_ IN LET MANIFOLDS

Single Carburetor Model (TtOOC)

1 E7578 Inlet manifold 1 2 E6772 Joint washer 2

3 S25-3 Plain washer 4

4 S582 Stud (1 n in. 0.A.) 2 5 E11459 Joint washer 1

6 E2968 Insulating block 1 7 S25-3 Plain washer . ,. 2

8 14-1302 Self locking nut ....

2 9 14-7024 Socket head screw (2 In. U.H.) 2

10 S648 Sprl ng washer 4

11 14-6115 Bolt 2

Twin Carburetor Model (TtOOR)

12 S582 Stud (1 -r, In. U.H.) 4

13 14-1302 Self locking nut ... 4

14 E6m Joint washer, manifold ... 2 15 E11459 Joint washer, insulating block 2

16 E2968 Insulating block 2 17 E7136 Left manifold .. . 1

18 E7t37 Right manifold ... 1 19 S25-3 Plain washer 4 20 E6916 Connector 2 21 E6958 Balance pipe 22 E5473 Clip 2

23 H--7019 Socket head screw (t In. U.H.) 4

15

~-'{

28

19

22-------l

33

23-- --

27 5

&

g

8

11-------13

Pis. S. CAIIIUIIITOII TIOOC

16

25

26

"

7

~ ~--15

11----14

CIS


CARBURETOR, T1 DOC

1 D2455 CARBURETOR R626/32 1 2 622/101 "O" ring seal (99-0m} 1 3 Reference only Mixing chamber R626/005 1 4 622/097 Mixing chamber top (99-1049) ... 4 5 622/086 Screw (99-0521) ... 1 6 622/060 Throttle valve (4 cutaway) (99-1050) 1 7 622/06S Throttle return spring (copper plated) (99-0509) 1 8 622/077 Throttle stop screw (99-0S16) 1 9 622/076 Air adjusting screw (99-0515) • 2 .....

10 622/082 "O" ring (99-0520) ... 1 11 622/128 Jet holder (99-1034) - . 1 12 376 /100 Main jet (99-1132) size 170 1 13 622/122 Needle Jet (99-1035) size .106 1

I""'. 14 622/124 Needle (99-1036) ... 1 15 622/067 Needle clip (99-0510) 1 16 622/134 Air valve guide sleeve (99-1051) 1 17 622/069 Float (99-0512) ... 1 18 622/071 Float spindle (99-0513) ... 1 19 622/073 Joint washer (99-0514) .. . 1 20 622/055 Float chamber (99-1154) 1 21 622/068 Float needle (99-0511) 1 22 376/093 Filter (99-0438) ... 1 23 622/078 Banjo bolt (99-0517) 1 24 13/163 fibre washer (99- 1124) 1 25 4/035 Cable adjuster Reference only 26 5/on Nut (99-0224) 1 27 622/062 Air slide ... Reference only 28 622/129 Air slide sprln~ (99-1038) 1 29 622/089 Tickler pin Reference only 30 14/032 Spring Reference only 31 622/147 Drain plug (99-1152) 1 32 622/151 ',:'lasher (99-1153) 1 33 F9269 Petrol pipe 1

17

27 5

2

19

2 2------'

33

23-- - - -l

Fig , 6. CARBURETOR, TIOOR

18

U--25 ~26 ~~4

~ - -15

lt---- - - 14

Cl5

•


CARBURETOR, T1 00R

1 D2453 CARBURETOR L626/54 1 Left 1 D2454 CARBURETOR R626/53 1 Right

2 622/101 "O" ring seal (99-0522) 1

3 Reference only Mixing chamber ... 1 4 622/097 Mixing chamber top (99-1°'49) ... 1 5 622/086 Screw (99-0521) ... 4 6 622/060 Throttle valve (3 cutaway) (99-1125) 1 7 622/065 Throttle return spring (copper plated) (99-0509) 1

8 622/077 Throttle stop screw (99-0516) • 1 9 622/076 Air adjusting screw (99-0515)

. ..... 1

10 622/082 "O" r ing (99-0520) , .. 2 11 622/128 Jet holder (99-1034) 1 12 376/100 Main jet (99-1131) size 150 1

r-- 13 622/122 Needle jet (99-1035) size .106 1 Each carburetor

14 622/124 Needle (99-1036) ... 1 15 622/067 Needle cl ip (99-0510) 1 16 622/134 Air valve guide sleeve (99-1051) 1 17 622/069 Float (99-0512) ... 1 18 ~22/071 Float spindle (99-0513) ... 1 19 622/073 Joint washer (99-0514) 1 20 622/055 Float chamber (99-1154) 1 21 622/068 Float needle (99-0511) 1 22 376/093 FIiter (99-0438) ... 1

....r--- 23 622/078 Banjo bolt (99-0517) 1 24 13/163 fibre washer (99-1124) 1 25 4/035 Cable adjuster Reference only

26 5/077 Nut (99-0224) 1 Each carburetor

27 622/062 Air slide ... Reference only

28 622/129 Air slide spring (99-1038) 1 Each carburetor

29 622/089 Tickler pin Reference only 30 14/032 Spring Reference only

31 622/147 Drain plug (99-1152) 1

~ 32 622/151 Washer (99-1153) 1 33 F9271 Petrol pipe 1

19

43 39 43 41 42 43 44 22

rl 40 38

18~

17~

"~ 15--\ 14---tg)

12-------'

19

4,--(il

31 r 32

,----------37

~ =:II-!'----23 25

w---26

54

---49

«<==>3>----52 0

0

1----!50

C39

FIJ. 7. CYLINDER BLOCK AND HEAD, T100C

20

..,


~ CYLINDER BLOCK AND HEAD , T100C SINGLE CARBURETOR

1 2 3 • 5 6 7 8 9

10 11 12 13 H 15 16 17 18 19 20 21 22 23 2• 25 26 27 28 29 30 31 32 33 3• 35 36 37 38 39 •O •1 •2 •3 .... •5 •6 '47 '48 '49 so 51 52 53 5•

E3798 E9719 E7563 5692 E93S2 H200 E1612 E3753 E102n E10229 E9510 E68S3 E68S• E68SS ES9•6 E-4011 E37'42 99-0062 E+4S6 F218• E•67S E12075 E12076 E9S11 1•-1'401 E3302 E12079 E12080 1•-6609 E3857 E379• E379S E3809 F1880 H•OO E•610 E3751 E37•9 E3750 E76S1 E3223 GS662 E2S3• E322• E37'48 035'48 E133S E1•3S E•OOS E12S76 E7310 E11283 E•671 1•-0301

Cylinder base gasket Cylinder block ... "O" ring Nut (12 point) ... Tappet guide block Tappet block screw (n In. U.H.) Serrated washer Tappet ... CYLIN DER HEAD c/w GUIDES

Valve gu ide (cast Iron) Exhaust pipe adaptor ... Inlet valve Exhaust valve .. . Bottom Cup Inner valve spring Outer valve spring Top collar Split cotter Cylinder head bolt (2 25/ 32 In. U.H.) Plain washer Cylinder head gasket Inlet rocker box Exhaust rocker box Joint washer Rocker box stud Washer ... Plug, rocker box Joint washer Screw (ft in. U.H.) Plain washer Cylinder head bolt (Sn in. U.H.) Cylinder head torque stay bolt 011 feed bolt Copper washer .. . Domed nut Inspection cap .. . fibre washer ROCKER (right exhaust, left inlet) .. . ROCKER (left exhaust, right Inlet) .. .

Rocker ball pin Rocker adjusting p in ... Adjuster lock nut Thrust washer, n In .... Spring washer .. . Rocker sp indle . . . Sealing rubber .. . Copper washer .. . Domed nut Push rod Cover tube "O" ring, push rod cover tube (bottom) "O" ring, push rod cover tube (top) Locking spring .. . Nut (line 25) .. .

21

,··· ......

1 1 2 8 2 2 2 4 1 4 2 2 2 4

• 4

• 8 4 8 1 1 1 2

• 4 .. • .. • 2 2 2 6 2 .. • 2 2

• • .. 8

• 2 2 2 2

• 2 2 2

• •

44 40 44 42 43 44 45 23 32 21 33 36 35

l l

20 10

13-------'

22

--@

~--------38

IJ-----50

..:=>9...---53 ~-,-

r---51

~ ~,sg,>----52

CIJ[]iJl)---3 11----- 8

Cl4

Fig. 7. CYLI N DER BLOCK AND HEA D, TIOOR

22

Ref. No. Port No. DESCRIPTION QUANTITY REMARKS CYLINDER BLOCK AND HEAD, T1 0 0R , TWIN C ARBURETOR

1 E3798 Cylinder base guket 1 2 E9719 Cylinder block ... 1 3 E7563 .. O" ring 2 4 S692 Nut (12 point) .. . 8 5 E9352 Tappet guide block 2 6 H200 Tappet block screw (fr in. U.H.) 2 7 E1612 Serrated washer 2 8 E4040 Tappet, Racing type

"' 4 9 E9507 CYLINDER HEAD c/ w GUIDES 1 10 E6301 Valve guide • 11 E3209 Valve guide clrclip .. ... 4

12 E9510 Exhaust pipe adaptor ... 2 13 E6853 Inlet valve .. , .•. 2 14 E685• Exhaust valve "' 2 15 E6855 Bottom cup • 16 E5946 Inner valve spring 4 17 E4011 Outer valve spring 4 18 E3742 Top collar • 19 99-0062 Split cotter 8 20 E4456 Cylinder head bolt (2if In. U.H.) • 21 f2184 Plain washer 8 22 E4675 Cylinder head gasket 1 23 E12075 Inlet rocker box 1 24 E12076 Exhaust rocker box 1 25 E9511 Joint washer 2 26 14-1401 Rocker box stud 4 27 E3302 Wuher ... • 28 E12079 Plug, rocker box 4 29 E12080 Joint wuher 4 30 14-6609 Screw (1 ¼ in. U.H.) 4 31 E3857 Plain washer 4 32 E379• Cylinder head bolt (5fr In. U.H .) 2 33 E3795 Cylinder head torque stay bolt 2 34 E3809 Oil feed bolt 2 35 F1880 Copper wuher ... 6 36 H400 Domed nut 2 37 E4610 Inspection cap ... 4 38 E3751 Fibre wuher 4 39 E3749 ROCKER (right exhaust, left Inlet) ... 2 40 E37S0 ROCKER (left exhaust, right Inlet) ... 2 41 E7651 Rocker ball p in 4 42 E3223 Rocker adjusting pin • 43 GS662 Adjuster lock nut 4 44 E2534 Thrust wuher, fr in . 6 45 E3224 Spring washer . .. 2 46 E3748 Rocker spindle ... 2 47 D3548 "O" ring 2 48 E1335 Copper washer ... 2 49 EH35 Domed nut 2 so E4008 Push rod 4 S1 E12576 Cover tube 2

~ 52 E7310 "O" r ing, push rod cover tube (bottom) 2 53 E11283 "O" r ing, push rod cover tube (top) 2 S4 E4671 Locking spring .. . 4 ss H - 0301 Nut (line 26) ... 4

23

5

5

~ 4

19

~Cf 22 23

6 1

L]}-13

C21

Fig, 8. TIMING COVER AND CO NTACT BREAKER

24

Ref. No. Port No.

1 E9250 2 E'4-016 3 D2085 4 E-4568 5 1~7 6 51916 7 T989 8 5#193'40 9 5#15642

10 5#19097 11 54419220 12 54419827 13 E-4707 H E7680 15 E6559 16 14-0208 17 S25-43 18 E8737 19 E11462 20 GS299 21 E7354 22 02133 23 02045 24 E-4569 Not Illus. E-48-49 Not Illus. 02138 Not illus. E9526

DESCRIPTION QUANTITY

TIMING COVER AND C ONTA C T BREAKER

Timing cover ... Patent plate Hammer-drive screw Oil seal ... Screw (j In. U.H.) Screw (1¼ In. U.H.) Hollow dowel ... AUTO-ADVANCE UNIT (99-0n1)

..... _ ... Spring set (99-0757) . .. ... . .. • ...

CONTACT BREAKER PLATE ASSEMBLY (9l..o768) Pin adjustment (9941769) Contact set (99-0m)

Rubber grommet Pillar bolt Washer .. . Bolt Washer . . . Cover .. . Joint washer Serrated washer Screw Oil pressure switch Cover pressure switch Circllp ... Dowel pin, auto advance to camshaft Timing label for C.B. cover ... Blanking plug (to replace oil pressure switch)

25

·"

1 1 3 2 4 4 1 1 2 1 2 2 1 2 2 1 1 1 1 2 2 1 1 1 1 1 Available

REMARKS

-

'

22 23

FIJ. 9.

/

11 /

18

36

35

3344546

AND INNER COVER GEARBOX SHAFTS, BEARINGS

26

l

14 43 44

12

l -- 37

"--- 38

41

C

n Ref. No. Port No. DE.SCRIPT/ON QUANTITY REMARKS

GEARBOX SHAFTS , BEARING S AND INN ER COVER

1 T66S High gear bearing (ball Journal) 1 2 T1478 Oil seal 1 3 W680 Circllp ... 1 4 1~608 Screw 2 5 T1422 Return spring plate 1 6 T912 Peg 1 7 T1606 Layshaft bearing 1 8 T1607 Thrust washer . .. 1 9 T3991 MAINSHAFT HIGH GEAR (22T) 1

10 HOO? High gear bush • 1 ... ... 11 H039 MAINSHAFT c/w THIRD AND LOW GEARS (16/2-4T) 1 12 T1391 Clutch rod bush ... 1 T100R 13 T3994 Mainshaft second gear (21T) .. . 1 and • 14 T1411 Malnshaft distance piece 1 West Coast T100C ,,....._ 15 T4041 layshaft c/w second and high gears (1 SJ23T) 1 16 T3997 layshaft third gear (20T) 1 17 T3999 LAYSHAFT LOW G EAR (27T) 1 18 T1393 Low gear bush 1 19 T1426 Pawl retaining disc 1 20 T3660 Camplate index plunger 1 21 T3661 Index plunger spring ... 1 22 T1457 Selector fork spindle . .. 1 23 T1480 Mainshaft selector fork 1 2.4 T1481 lays haft selector fork . .. 1 25 T4218 Gear selector camplate 1 26 T1418 Camplaie spindle 1 27 Split pin (¼ in. x ¾ in.) Reference only 28 T1416 Gear indicator pointer 1 29 H688 Screw (-h In. U.H.) 1 30 T4301 Inner cover 1 31 T1417 Gear indicator plate 1 32 D208-5 Indicator plate r ivet 2 33 T1440 Hollow dowel ... 2 34 T1157 Kickstarter stop plate ... 1 35 T1390 Stop plate anchor screw 1 36 T1981 KICKSTARTER SPINDLE 1 37 T1431 Klckstarter pawl 1 38 T1282 Plunger 1 39 T1161 Plunger spring 1 40 T1897 Needle roller bearing 1 41 T1469 Mainshaft bearing (Ball Journal) 1 42 H113 Clrcllp ... 1 43 T732 Tab washer 1 44 SS94 Mainshaft nut 1 45 T1464 Distance piece 1 , 46 T1441 Klckstarter return spring 1 47 E4803 "O" ring 1

27

' 15

3344546 5 C l6

GEARBOX SHAFTS, BEARINGS AND INNER COVER FiJ. II.

28

14 43

44 12

1 37

38

39

35-----

34----1

~2~ 26 ~.

24 ~32

30

36-----------

5

n} ~ ~" 42 22 ,_, ,;,: • (, 12

21~0

~ 7 ~\l 13

r,.._ .. 16

38 11

19

13 12 43 r 18

ASSY.37 20

Fis, 12. GEARBOX OUTER COVER AND LEVERS

30 -

Ref. No. Port No.

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28 29 30 31 32 33 3-4 35 36 37 38 39 40 41 42 43 44 45 46 47 48

T3755 ,,T1395 S1928 14-6505 T1942 T1474 T1436 T1396

03522 T1871 T18n T1878 T1977 S1877 T1876 T1874 T4439 02368 T1710 T1712 GS127

T1945 T1946 T1937 T3784 T2062 T2063 T1646 14-1302 S25-3 S1918 S1917 T1435 T2450 W932 T3797 T3742 T12n 02364 T1167 S541 S644 T2330 T1970 T2239 T2238 E1612

DE.SCRIPT/ON QUANTITY

GEARBOX OUTER COVER AND LEVERS

GEARBOX OUTER COVER .. . Gearchange spindle bush .. .

Stud (1,'r in. O.A.) Screw GEARCHANGE QUADRANT

Spring retaining pin Plunger spring Selector plunger . .. Split pin (/. In. x ¾ In.)

Sealing ring Return spring housing Return spring Thrust button Cover Nut Distance piece Distance piece Clutch lever Ball, i in. diam. Shaft Spring ... Plain washer Split pin (/. ljl. x ½ In.) Spoke Connector Nut Abutment Adaptor, short

• ~-·

··.\

Adaptor, long (For cable with short outer) Rubber cover · Nut Plain washer Screw Screw Gearchange lever Pedal rubber Bolt (1 In. U.H.) KICKSTARTER .LEVER COMPLETE

Klckstarter crank Klckstarter pedal .. . Steel ball (¼ In. diam.) Index spring Pivot bolt ... Clamp bolt (1,'r in. U.H.)

Pedal rubber . .. Clutch operating rod Oil seal ... 011 seal cover ... Serrated washer

31

1 1 2 1 1 2 2 2 Reference only 1 1 2 2 1 2 2 1 1 3 1 1 1 Reference only 1 1

1 As required As required 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2

-

REMARKS

,;. ~ ....

lfl~ u 0 N co

" 0,. -

!!:?

;:!: :i: u I-

II) :::, ., M

u N

CX) ,.;

!::! .. ii: --

S2 ,,......,_

<>

M " - co

32

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

CLUTCH

1 T1570 Sprocket and housing ... 1 2 T3930 Hub 1 3 T3931 Thrust washer 1 4 T39-4 Roller 20

5 S586 Nut 1 6 T1719 Centre (Shock absorber body) 1 7 T1TI0 Inner plate 1 8 T10-40 Countersunk screw (0.417 In. U.H.) 6 9 T2538 Shock absorber spider • 1 ...

10 T1nl Drive rubber (large) .. . 3 11 T1n3 Rebound rubber (small) 3 12 T1TI4 Outer plate 1 13 H23A Screwed pin (1½½ In. U.H.) 3

r, 14 T1362 Driving plate (bonded) 6 15 T1363 Driven plate (plain) 6 16 TI156 Pressure plate 1 17 TI159 Adjuster pin 1 18 14--0403 Nut 1 19 T1931 Spring cup 3 20 T1560 Spring 3 21 T2526 Nut 3 22 S66-1 Key 1 23 m79 Washer ... 1

LATER MODELS USE THE FOLLOWING:-

6 T-4438 Centre (shock absorber body) 1 7 T-4436 Inner plate 1 8 S644 Bolt 3

12 T-4437 Outer ... 1

L\,, ----------~-=---33_.-s__;...-....,.....:;;...-~-.,~-:::::;;~J,~

12 ,_,

23 -

21 -

- 27~

2s--4i

Fis. t•.

fr 38

fl', 37

,,_ \ (Ol ~ - ~~ I 33 CIO

24. ~ 22

ND CHAINS CHAINCASE A

34

5

29

28

Re(. No. Port No. DESCRIPTION QUANTITY REMARKS

CHAIN CASE AND CHAINS

1 T1•76/ 18 Gearbox sprocket (18 teeth) ... 1 1 T1476/19 Gearbox sprocket (19" teeth) ... Available 1 T1569 Gearbox sprocket (20 teeth) ... Available 2 T2536 Gearbox sprocket nut 1 3 0-444 Rear chain, i In.xi In. x 102L 1 4 E7037 Cover plate 1 5 E7565 Oil seal .. . 1 6 E11419 Joint washer 1 7 E3821 Countersunk screw (,'r in. U.H.) 6 8 0358 Primary chain, i In. Duplex 78L ..... 1 9 E6283 Chain tensioner blade ... ...

1 10 E-4152 Tie rod .. . . 1 ... 11 E-41•8 Trunnion 1 12 E9-495 Stud (3,'r in. 0.A.) 3 13 -4n05 Stator, RM 21 (99-1006) 1 14 S25-3 Plain washer 3 15 14-0702 Nut 3 16 E-4144 Rubber grommet 1 17 E9360 Sleeve nut 1 18 E1509 Clip 1 19 S1920 Setscrew 1 20 E11456 Joint washer 1 21 E92-49 Chalncase 1 22 T2440 Rotor cover 1

~ 23 E11457 Joint washer 1 24 ~ j,2-'f/.t.9Screw 3 25 T2537 Ignition pointer ... 1 26 14-6101 Level plug 1 27 E2441 Copper washer .. . 2 28 T2166 Filler plug 1 29 E8782 .. 0,. ring 1 30 S1878 Screw (2¾ in. U.H.) 3 31 14-6609 Screw 7 32 E9703 Adjuster sleeve nut 1 33 T2259 Drain plug 1 34 T1738 Fibre washer 1 35 T20S6 Tab washer 1 36 E7571 Crankcase protector 1 37 14-1301 Self-locking nut 1 38 E7573 G rommet 1

35

... 0,

r1

!:5- s

1

""'

2

!:5-

)

~ 1,

Cl

~-' ··-- -

:.._~'-:::o.-,;,:,o. _,..,;;:,,_ -\ - .~ __,;•;''

\ ,<?' ,.0 15 S 1 W ' ,,.

K" /~ ' 17

-» - )

~ ~=====~ ""

Pis, IS. EXHAUST snnM

I 13

)

. -·

)


EXHAUST SYSTEM ( T1 0 0R) ~ a

1 E9662 Exhaust plpe- O.S. 1 2 E9663 Exhaust pipe-T.S. 1 3 E-49-47 finned clip 2 -4 E-409 Bolt } Exhaust pipes to 2 s E410A Washer cylinder head 2 6 H -O102 Bolt} Exhaust pipes 2 7 H-1301 Nut to brackets 2 8 E9888 Coupling pipe ... 1 9 E7512

C"p } 2

10 E3768 "D" washer Coupling ... 4 11 14-0217 Bolt pipe ... 2 12 14-1302 Nut ..... 2 13 E12017 Mufller-O.S. ... 1 H E12018 Mufller-T.S. ... 1 15 E2711

C"p } 2

16 E3768 11 0" washer 4 17 14-0219 Bolt Mufflers to exhaust pipes 2 18 525-3 Washer 2 19 14-1202 Nut 2

37

w 00

)

15

16

2 4

5

)

9 30

29

\

16 17

Fis, 16. MOTOR FITTINGS

t)

20

19

33 • ~2

)

20

19

25 24

26

18

23

c,s

) )

Re(. No. Part No. DESCRIPTION QUANTITY REMARKS

MOTOR FITTINGS

1 F7333 Front motor plate-O.S. 1 2 F733• Front motor plate-T.S. 1 3 H--0239 Bolt 1 4 S25-2 Washer Front motor plates to frame ... 1 5 H-1303 Nut (Cleveloc) 1 6 52006 Stud (3i In. O.A.) 1 7 S25-3 Washer Top-front motor plates 2 8 14-1302 Nut (Cleveloc) 2 9 S2083 Stud (-4¼ in. O.A.) 1 (Not T100C) • 10 525-3 Washer Middle-front ... 2

11 14-0302 Nut (plain) motor plates 2 (Not T100C) 12 14-1302 Nut (Cleveloc) 2 (Not T100C) 13 E7641 Exhaust bracket-O.5. 1 14 E7642 Exhaust bracket-T.S .... 1 15 14-0225 Bolt } 1 (2 T100C) 16 S2S-3 Washer Bottom-front motor plates 2 17 14-1302 Nut (Cleveloc) 1 (2 T100C) 18 E•n8 Torque stay 2 19 525-1 Washer }Torque stay to 2 20 14-1302 :::: ca,~,oc) ~r ....... 2 21 14-0220 1 22 E7119 Distance plece-O.5. 1 23 E3434 Distance piece- T.S. Torque stay to frame 24 525-3 Washer 1 25 14-1302 Nut (Cleveloc) 1 26 F4229 Rear motor plate-D.S. 1 27 F4230 Rear motor platc-T.S. 1 28 14-0242 Bolt 1 29 525-2 Washer Rear motor plates to crankcase ... 1 30 14-1303 Nut (Cleveloc) 1 31 14-0228 Bolt 2 32 525-3 Washer Rear motor plates to frame 2 33 14-1302 Nut (Cleveloc) 2

39

, 7 2

¥ ~~-;~~~~~......._ ~------------

34~

• ... v1f;l

,1,-----..,,,....,,..._ e-15 ~-I::'\\~ 0-15

~ 17

, 26

f---30

C29

Fig. 17. EXHAUST PIPES. UNDEI\SHIELD AND FOOTPEGS (TIOOC)

-


EXHAU S T PIPES, UNDERSHIELD AND FO OTPEG ( T1 OO C)

1 E10019 Exhaust pipe D.S. lower 1 2 E10017 Exhaust pipe T.S. upper 1 3 E6981 Stay 1 .. 14-011-4 Bolt 2 s SlS-3 Washer ... 3 6 14-0302 Nut 1 7 mos Abutment 1 8 E9669 Silencer upper .. . 1 9 E9670 Silencer lower ... ~- 1

10 E9673 Connector 1 11 E7299 Clip ... ... 1 12 1+-0116 Bolt 1 13 E2271 Clip 2 1-4 ESSH Clip 1 15 E3768 "D" washer 6 16 1+-0219 Bolt 3 17 1+-1202 Nut 3 18 E9691 Bracket (silencer to frame) 1 19 S1822 Bolt 1 20 S2.S-3 Washer ... 2 21 F7550 Clip, bracket to frame 1 22 14-0114 Bolt, clip to bracket 1 23 1+-1302 Nut 1 2-4 E9680 Leg guard 1 25 E9688 Clip 2 26 E9696 Bracket ... 1 27 S195-4 Short screw 1 28 S1953 Long screw (1¾ In. U.H.) 1 29 F11S90 LEFT FOLDING FOOTPEG ... 1 30 F11S91 RIGHT FOLDING FOOTPEG 1 31 F6'411 Pedal 2 32 S1971 Pivot bolt .. . 2 33 F11279 Undershleld 1 34 F1700 Clip, undershleld 2 35 F3078 Bracket ... 1 36 14-0102 Bolt .. 37 SlS-1 Washer .. . .. 38 1+-1301 Nut 4 Not Illus. E98S7 Washer (for lines 27 and 28) ... 2

-41

III 1~ 22

&--20

A ~",,·. 29 34

3738 '~ ~ 30

36,- ~- ~ /I-/i-40

42~ ~ 41

"" 39

35 ~ 43

Fis. 18. FRAME

42

• ...

@- -4

<0--- ;

~ 6

@-2

15

'}---- 5

r,:---16

'---17

C37


FRAME

1 F10034 Front frame 1 2 H111 Steering race cup 2 3 02364 Steel ball (! In. dia.) 40 4 H1018 Top cone and dust cover 1 s FS679 Washer ... 2 T100R only 6 F71SS Steering stops 2 7 F8038 Rear frame 1 8 14-02-41 Bolt 1 9 S2S-2 Washer ... ..... 1

10 1+-1303 Nut ~ .. 1 11 1 +-011 S Bolt 2 12 99-00-46 Spring washer 2 13 F7693 Centre stand 1 1-4 TI331 Pedal rubber 1 15 FS678 Pivot bolt 2

T100R only 16 F-4-48-4 Tab washer 2 17 F2ns Nut 2 18 F3617 Return spring 1 19 F11560 Prop stand 1 20 F7021 Pivot bolt 1 21 1+-0703 Self-lockl ng nut 1 22 F8382 Return spring 1 23 F-421-4 Left footrest 1 2-4 F-4215 Right footrest 1 25 NF70-4 Pedal rubber 2 26 1+-0251 Bolt 2 27 1'4370 Plain washer 2 28 1+-130-4 Nut 2 29 FS087 Left pillion footrest support . .. 1 30 FS088 Right pillion footrest support 1 31 1+-0115 Bolt (ff In. U.H.) -4 32 S2S-3 Washer ... 4 33 mos Pedal stop screw 1 3-4 1+-0302 Nut 2 JS F9369 PILLION FOOTREST .. . 2 36 F9370 Footrest hanger 2 37 S1910 Bolt ... 2 38 S2~1 Washer 2 39 F169-4 Pedal 2 40 F9371 Pivot bolt . .. 2 41 S2S-3 Washer 2 -42 1+-1302 Nut ... 6 -43 F169S Pedal rubber 2 -4-4 m06 Brake pedal spindle 1 -45 1+-130S Nut 1 '46 moJ Brake pedal 1 -47 S2~16 Sprl ng washer

. 1

-48 S2S-2 Plain washer 1 49 14-0-403 Nut 1

............ so 14-0216 Bolt 1 51 1+-0-402 Nut 1 Not illus. D2452 Transfer, 'Safety Standards' 1

-43

:t

36 35

~-----~. - fr;: f . 45

0

46~ • @-44 \j' 38

12~

J f

16----~

) L]

7 21 ~ 37

~~~39 32-f g___40

'-- ~ 6 17

~ - if418 ~'ra · ~ 20 1""

10 19 48 rtl!}j>5

~ 1·

1 I 2 3

Fls. 19. SWINGING ARM, SUSPENSION UNITS AND CHAINGUARD

) J

9

~ 11 ~

• ~ ----12

8 22

_J 47 4 C31

) )


SWINGING ARM , SUSPENSION UN ITS AND CHAINGUARD

1 F7375 SWINGING ARM 1

2 F-4076 Pivot bush ... 2

3 F7342 Spindle ... 1

4 m10 Gaiter ... 2

5 F-4385 Shim 0.003 In. As required

5 F4386 Shim 0.005 In. As required

6 F10037 Left distance piece 1

7 S580 Left bolt ... 1

8 S579 Right bolt 1

9 6-4052107 SUSPENSION UNIT (D2024) • 2 ...... 10 64533645 Bonded bush (99--0122) 4

11 9054/171 Spring retainer (99--0107) ... , 4 12 6'1543708 Spring, 100 lbs. chrome (99-1048) 2

13 14--0235 Unit fixing bolt 4

H S2S-2 Pia! n washer 8

15 14-1303 Nut 4

16 F7707 Chalnguard 1

17 DS57 Bolt (ft In. U.H.) 1

18 525-1 Washer ... 1

19 F4134 Front bracket 1

20 14--0113 Bolt 1

21 F7343 Tab washer 2

22 NW100 Lubricator 1

23 14--0702 Self-locking nut 1

24 F9387 Stepped bolt 1

25 S25-3 Plain washer 1

26 14-1302 Nut 1

27 14--0128 Bolt 1

28 14-1303 Nut 1

29 DS47 Nut 1

30 99--0046 Sprl ng washer 1

31 F7386 Brake operating rod 1

32 Split pin (n- In. x f In.) Reference only

33 F7387 Adjuster nut 1

34 F11780 Brake torque stay 1

35 99--0046 Torque stay washer 1

36 14-1304 Torque stay nut 1

37 F6046 Front chalnguard 1

38 14--0101 Bolt 1

39 S25-1 Washer ... 1

-40 14-1301 Nut 1

41 5-4033234 Stop lamp switch (99--0725) 1

42 F3158 Spring (315738) .... 1

43 T1076 Bolt (i In. U.H.) 3

44 F4717 Self-lock! ng nut 5

45 F5687 Lever 1

46 F5413 "D" washer 1

47 F7774 Right distance piece 1

48 14--0702 Nut 1

r, 49 F-4078 Thrust washer ... 1

45

ASUHILY IUF. No. 1

8---

53

35~

37 I 36 ~

38 --@

12

12- 25

26

27

28

33

22

J-43 rt. - 44

- 45 C 38

Fl1. 20. TELESCOPIC FRONT FORK

7~

--32

- 29


TELESCOPIC FRONT FORK

1 H4120 FORK ASSEMBLY 1 T100R 1 H4119 FORK ASSEMBLY 1 T100C 2 H2288 Middle lug and stem 1 3 H439 Bottom cone 1 4 H2290 Pinch bolt (2¼ In. U.H.) .. . 2 s S25-2 Plain washer 3 6 14-1303 Cleveloc nut 2 7A H2108 Fork stem sleeve nut , T100C 7 H2263 Fork stem sleeve nut 1 T100R 8 H3662 Top lug • 2 .... 9 F6738 Lock c/w 2 keys ... 1

10 D623 Key (state serial number) 1 Key no's run from

11 SS78 Grub screw EJR 1 to EJR SO

1 12 H2266 Sealing washer , 13 H2107 locating pin 1 1-4 S684 Pinch bolt (1J In. U.H.) 1 15 S685 Seated nut ... 1 16 H2198 Len top cover 1 17 H2199 Right top cover 1 18 F4047 Cork washer 2 19 H1657 Spring abutment 2 20 H1892 Main spring (Yellow/Green) 2 T100C \

20 H1891 Main spring (Yellow/ Blue) 2 T100R 21 D3273 Plain washer 2 22 H3635 Telescopic gaiter . .. 2 23 H4167 DUST EXCLUDER SLEEVE NUT 2 24 D3274 Oil seal 2 2S H2119 "O" ring ... 2 26 H431 Plain washer 2 27 H441 Top bearing 2

,28 H1896 Damping sleeve 2 29 H3904 STANCHION 2

I'""'\. 30 H443 lower bearing 2 31 H2091 Bearing nut 2 32 H224S Cap nut 2 33 H3921 LEFT BOTTOM MEMBER c/w CAP 1 34 H3922 RIGHT BOTTOM MEMBER c/w CAP 1 35 H1844 Spindle cap ... 2 36 E3446 Plain washer ... 4 37 S2024 Stud ... 4 38 14-1202 Nut, self locking 4 39 H3894 Drain plug .. . ' 2 40 H3893 Sealing washer 2 41 H2154 Shuttle valve 2 42 H2127 Circlip 2 43 H2090 Restrlctor . .. 2 44 H1062 Aluminium washer 2 45 H2126 Flanged bolt 2 46 H3682 Bracket 1 47 H2270 Cable retainer 1 48 F8245 Starlock washer 1

47

,2--

7~

22

J-43 ' ;,4 C 3S

Fie. JI. TELESCOPIC FRONT PORK

::::::::::::::~==-=--___;;~....,..--------- - - ---,--- -


TELESCOPIC FRO NT FORK (continued)

49 H3926 Square nut 2 so Hm Cap .. . 2 51 S25-3 Piaf n washer -4 52 S589 Bolt (11 In. U.H.) ... -4 53 H1696 Top cover ... Available for use where

headlamp removed S-4 Hnoa Rubber mountln&, headlamp bracket 2 55 H-4203 Headlamp bracket- O.S. 1 55 H-4203 Headlamp bracket- T.S .. .. 1 56 HU09 Rubber buffer • -4 ..... 57 HU10 Washer, headlamp bracket -4 -58 S2095 Attachment bolt . .. . -4 ... Not illus. F678-4 Cable grommet (right top cover) 1

16 10 14 4 8

Front wheel complete NO 1

?

19

37 ~

32

11 9

23 ,

7 5 6 17 18 13 10

38 CII 29 35 31 30

Fig. 21. FRONT WHEEL Tto0R

) L) ) ) C) )

Ref No. Part No. DESCRIPTION QUANTITY REMARKS

- FR O N T W H EEL (T t 0 0 R )

1 W3458 FRONT WHEEL COMPLETE 1 2 W1721 RIM, SPOKES AND HUB ASSEMBLY 1 3 W1230 Front wheel rim (WM2-19) 1 4 W1328 Spoke (8/10G x SJ in. straight) c/w nipple 20 5 W1708 Spoke (8/ 10G x 4ff In. 78°) c/w nipple 10 6 W1709 Spoke (8/10G x 'ft in. 100°) c/w nipple 10 7 S79-2 Spoke nipple ... 40 8 W1722 Hub and brake drum 1 9 W3582 Wheel spindle • 1 .... 10 W653 Bearing 2 11 W1237 Oust cover 1 12 nao Circllp 1 13 W3337 Bearing support ring

H W1481 Grease retainer 1 15 W582 Retaining ring 1 16 W3460 Cover plate 1 17 W1197 Balance weight, ½ oz. As required 18 W1198 Balance weight, 1 oz. As required 19 W3461 BRAKE ANCHOR PLATE ASSEMBLY 1 20 W1996 BRAKE SHOE c/w LINING 2 21 Reference only Brake lining ... ! }Each shoe 22 Reference only Brass rivet 23 W2026 Thrust pad 2 2-4 W135 Shoe return spring 2 25 W2001 Brake cam 1 26 WJ-453 Brake cam lever (front) 1 27 H-1303 Nut 2 28 WHS-4 Brake cam lever (rear) 1 29 W2003 Rod assembly 1 30 W2005 Fork end, threaded 1 31 14-0401 Locknut 1 32 W3522 Lever return spring 1 33 S1995 Anchor plate nut 1 H WF32 Pivot pin ... 2 35 Split pin (-h In. x tin. long) Reference only 36 S25~ Plain washer 2 37 W1991 Anchor plate gauze (for air scoop) 1 38 S1998 Taptlte screw 3 39 E2351 Washer for taptlte screws 3

51

16 10 14 4 8

Front wheel «:omplete NO 1

2

~

7 5 6 17

38 CII 29 35 31 30

Fir. 22. FRONT WHEEL TIOOC

l ) )

Re(. No. Part No. DESCRIPTION QUANTITY REMARKS

FRONT WHEEL (T t OOC) ..,, - 1 W3430 FRONT WHEEL COMPLETE 1

2 W2132 RIM SPOKES AND HUB ASSEMBLY 1

3 W1230 Front wheel rim (WM2-19) 1

4 W2137 Spoke D.S. 20

5 W2138 Spoke T.S. 10

6 W2139 Spoke T.S. 10

7 W2136 Spoke nipple .. . '40 8 W3325 Hub and brake drum 1

9 W3582 Wheel spindle 1

10 W653 Wheel bearing • 2 -~ 11 W1237 Dust cover 1

12 TISO Clrcllp 1

13 W3337 Bearing support ring 1 ,......_ H WH81 Grease retainer 1

15 W582 Retaining ring 1

16 W3443 Cover plate 1

17 W1197 Balance weight ½ oz. As required

18 W1198 Balance weight 1 oz. As required

19 W3455 BRAKE ANCHOR PLATE ASSEMBLY 1

20 W3#6 BRAKE SHOE c/w LINING 2

21 Reference only Brake lining . .. ! }each shoe 22 Reference only Bras.s rivet 23 W2026 Thrust pad ... 2

~ 24 W135 Shoe return spring 2

25 W2001 Brake cam ... 1

26 WH53 Brake cam lever (front) 1

27 14-1303 Nut 2

28 WH54 Brake cam lever (rear) 1

29 W3450 Rod assembly 1

30 W2005 Fork end, threaded .. , 1

31 14-0401 Locknut 1

32 W3522 Lever return spring 1

,......_ 33 S1995 Anchor plate nut .. . 1

34 WF32 Pivot pin ... 2

35 - '\ Split pin (n In. x f In. long) Reference only

36 s~ Plain washer 2

37 W1991 Anchor plate gauze (for air scoop) 1

38 S1998 Taptlte screw 3

39 E2351 Washer for taptlte screws 3

'

. - .. . ·~A -~~

,___ __________ ...... __ ---=---" ------------- -....... P 53

45 42 41 47 23 29 25 27 28 22 8 9 10 12315217

~

~3 44 34 33 35 26 30 31 13 11 20 1918 17 46

Fig. 32. REAR WHEEL

)\ ) \

5 5 16 18

.,

4 6 4 • 14 36 37 38

)

39 24 45 43

40 42 44

159

:) )


REAR WHEEL

1 W3607 REAR WHEEL COMPLETE ... 1 2 W3610 RIM, SPOKES AND HUB ASSEMBLY 1 3 W1007 Rear wheel rim WM3-18 ... 1 4 W1107 Spoke (8/10G x 7n in. 90°) 10 4A W3402 Spoke (8/10G x 7n In. 110°) 10 5 W1108 Spoke {8/10G x 7t in. 90°) ... 20 6 S79-2 Spoke nipple ... 40 7 W3586 Hub ... 1 8 W1499 Sprocket, 46T .. 1 9 S2010 Bolt ... 8

10 E1612 Serrated washer . ... 8 .. ... 11 W3S8S Brake drum 1 12 S2011 Bolt (ft in. U.H.) 8

/"°'\ 13 14-1202 Self-locking nut ... 8 14 W3589 Wheel spindle 1 15 W1474 Grease retainer (brake side) 1 16 W1654 Grease retainer 1 17 W1022 Backing ring 1 18 W653 Bearing 2 19 W3587 RETAINING RING 1 20 W1710 Locking screw (,\ in. U.H.) 1 21 W1278 Distance tube 1 22 W1024 Distance piece 1 23 W3590 Brake anchor plate 1 24 S2013 Nut 1 2S W1406 LEADING BRAKE SHOE C/W LINING 1 26 W1407 TRAILING BRAKE SHOE C/W LINING 1 27 Reference only Brake lining ... 2 28 Reference only Brass rivet ... 16 29 W1415 Thrust pad 2 30 W13S Shoe return spring 2 31 W3592 Brake cam 1

~ 32 W2014 Brake cam lever 1 33 ~ Plain washer 1 34 W2027 Nut 1 35 W1488 Lever return spring 1 36 W1635 Grease retainer ... 1 37 W3588 Spe~ometer adaptor 1 38 W1477 Distance piece 1 39 D373 Speedometer gearbox 1 40 W1280 Plain washer 1 -41 S2014 Nut D.S. Inner 1 -42 W2089 Chain adjuster ... 2 -43 W1015 Adjuster end plate 2 -44 14-1902 Self-locking nut 2 -45 S585 Spindle nut 2 -•6 WM3 Tyre security bolt WM3 2 •7 W11 Pivot pin 1

----SS

~

)

j4 ~o

32 - o/ O

~

() 0

0

40

39 -

0

23·

17

::::3t / ~1 35\$ V--® 36 2425

33

)

26

~-

1

~

6 7

✓ ~

5

Fis. :IA. FEN D ERS

3

4

)

2

9.

·~ '

1)J6l. 14

-n~

8 12 13

) )

Ref. No. Port No. DESCRIPTION QUANTITY REMARK5

FENDER S

1 H388-4 Front fender (stainless) 1 T100C

1 H3882 Front fender 1 T100R

2 H3663 Front stay (chrome) ... 1 T100C

2 H1681 Front stay 1 T100R

3 H366'4 Centre stay (chrome) ... 1 T100C

3 H1683 Centre stay 1 T100R

4 H4046 Bottom stay (chrome) ... 1 T100C

4 H<IO+I Bottom stay 1 T100R

5 H-0101 Bolt } 6

6 Sl.5-1 Washer Stays to fender • 6 ...... 7 14--1201 Nut (Cleveloc) 6

8 H1685 Bracket D.S. and T.S. fork leg to stays 2 T100R

8 H1688 Bracket D.S. and T.S. fork leg to stays 2 T100C

9 14--0113 Bolt } 2

9A H4071 Tab washer Brackets to fork leg 2

10 D302S Washer 2

11 14--0115 Bolt } Top and centre stays 2

12 F-4299 Washer to bracket 2

13 14--1302 N" (C'='oc)} 2

1-4 14--0115 Bolt Bottom stay to 2

15 Sl.5-3 Washer fork leg 2

16 14--0702 Nut 2

17 F12995 Rear fender (stainless) 1 T100C

17 F12876 Rear fender 1 T100R

18 F6916 Bracket ... 1

19 14--0101 ~" } 1

20 F6310 Washer Bracket to 1

21 S16-2 Washer fender 1

22 14--1201 Nut (Cleveloc) 1

23 F6915 Bridge ... 1

24 14--0102 ~,. } 2

25 F6310 Washer Bridge to 2

26 Sl.5-1 Washer fender 2

27 14--1201 Nut (Cleveloc) 2

28 F12879 Lifting handle ... 1

29 14--0102 Bolt } 2

30 515-1 Washer Lifting handle to fender 2

31 14--1201 Nut (Cleveloc) 2

32 f5994 Clip 1

33 F6031 Backing plate 1

34 14--0113 Bolt } 2

35 Sl.5-3 Washer Clip to fender 2

36 14--1302 Nut (Cleveloc) 2

37 F7826 WI ring protector 1

38 14--0102 Bolt } ... 2

39 S25-1 Washer Wiring protector to fender 2

40 14--1201 Nut (Cleveloc) 2

41 57079 Reflector-red (99-1162) 2

42 D2391 Washer ... 2

43 F4717 Nut 2

-~ .. ....

.,, ' I

;:

\ 58

N

..,

..__

...

-- -

~ 0 ... ... ::> ., 0 z < ... X j ... ~ ~ .!.O ...


TAIL LAMP AND S UPP O R T

1 F12877 Tail lamp support 1

2 14-0101 Bolt } . 2

3 D2-426 Washer Tall lamp support-rear fixing 2

4 F12n7 Rear number plate bracket-L.H. ... 1

5 F12n8 Rear number plate bracket-R.H. ... 1

6 14-0101 Bolt } ... 4

7 D2338 Washer Number plate bracket to fender . .. 4

8 14-1301 N~ ... 4

9 H961 Grommet-tail lamp lead 1

10 53973 STOP AND TAIL LAMP~79 (99-0597) ,. 1

11 54577109 Lens (99-1046) 1

12 144921 Screw (99-1189) ... 2

13 54525286 Lamp base assembly Reference only

14 380 Bulb (99-0542) 1

59

0

1 ~ I

9

Fis- l6.

16

~12.

@

Ii 14 15 13

TWINSEAT PANELS AND

60

r~« 18 19 20


PANELS AND TWINS EAT

1 F8042 Left panel and toolbox 1 2 F11357 Toolbox screw ... 1 3 F11377 Washer .. . 1 4 F12874 Nut, tool box knob 1 5 14-1303 Nut, tool box knob 1 6 F6673 Grommet 2 7 F11573 TWINSEAT 1 8 F9715 Twlnse.at cover 1

Not Illus. A52 Transfer, positive earth • 1 ..... 9 D696 Trim strip (bright) 1

10 D697 Sprag ..... 4 11 F4898 Buffer front 2 12 F7835 Buffer rear 2 13 F8026 Hinge front 1 14 F7862 Hinge rear 1 15 S26-2 Spring washer 4 16 14--0101 Bolt (n In. U.H .) 4 17 D374 Check wire 1 18 D2381 Self tapping screw 2 19 E1719A Washer ... 1 20 F-4228 Spring ... 1 21 Split pin (if In. x ½ in.) Reference only ll F7560 Seat knob and plunger 1 Not }D2105 Transfer Trophy 500 T100C Illus. D2106 Tran sf er Daytona 1 T100R

61

1---J

~ 16

~ 17

~ 18

Q- 19 @- 20

21

' •

29

~ 30_.

8

27 @1260@ ..

25

~-28

Cl9

Fis. 27. GAS TANK

62

~

?-9

14

<=>-10 e.._,1

13

6


GAS TAN KS

1 f11804 Petrol tank 1 T100R 1 F11803 Petrol tank 1 T100C 2 F9701 Styling unit (left) 1 3 F11339 Styling unit screw (27/ 6-4 In. O.A.) front 2 4 F7888 Styling unit screw (35/ 6-4 In. O.A.) rear 2 5 F9700 Styling unit (right) 1 6 F8192 Left knee grip .. . 1 } Not used on 7 F8193 Right knee grip 1 later models

8 F10007 Centre styling strip • 1 ,.. 9 F10008 Hook, screw 1

10 F'4019 Serrated washer 1 11 H919 Nut 1 12 F7388 Rear bolt 1 13 F5336 Double spigot rubber ... 1 H F967 Rubber washer ... 1 15 F38H Cup 1 16 F5228 Rubber washer ... 2 17 F5229 Spigot rubber 2 18 F38H Cup 2 19 S1883 Stud 2 20 1,4....1302 Nut 2 21 F13875 FILLER CAP 1 22 F'40'48 Joint washer 1 23 F3217 Jack chain 1 24 F12801 Petrol tap-O.S. 1 25 F12800 Petrol tap-T.S. 1 26 E73516 Petrol up seal 2 27 F1000 Steel washer 2 28 F1000 Tap nut 2 29 F12903 Reflector bracket 2 30 57183 Reflector, amber (99-1161) 2 31 02391 Washer (front reflectors) 2 32 F4717 Nut (front reflectors) .. . 2 Not {A56 Transfer, World Speed Record 1 illus. A61 Transfer, Made In England 1

02105 Transfer, Trophy 500 1 02106 Transfer. Daytona 1

\

63

5,- "' 4, -

7

6.

1 ..

C4 1

10

OIL TANK Fis, 21.

31


0 IL TANK

1 F13290 Oil tank ... 1 2 F9659 FILLER CAP AND DIPSTICK 1 3 F-40-47 Joint washer 1

" F5H3 Drain plug 1 5 99--0048 Fibre washer 1 6 F3179 Oil tank filter 1 7 F1713 Fibre washer 1 8 F6103 Upper feed pipe 1 9 F3182 Union nut • 1 ,.,

10 E-l59-l Flexible connector, long ... ... 2 11 E6&18 Clip " 12 eno3 Oil pipes and Junction block .. . 1 13 E11458 Joint washer 1

.r'\ H E3~ Plain washer 1 15 S1908 Nut 1 16 F6039 Grommet 1 17 E68"9 Clip (rocker pipe) 1 18 F9255 Front strap 1 19 F8028 Rear strap 1 20 F6673 Spigot rubber " 21 F6968 Rubber washer .. . 2 n 1+-0103 Bolt 2 23 1+-0701 Self-locking nut 2

r-"! 2-l H3894 2 BA Screw 4 25 F-4717 2 BA Nut " 26 F7510 Screwed peg 2 27 SlS-13 Plain washer 4 28 H-1301 Nut 3 29 E6353 Rubber connector 1 30 E7576 Rocker oil feed pipe 1 31 F6898 Bracket ... 1 32 FSOH Spigot nut 1 Not illus. 01816 Grouped transfer "Drain and Refill" etc. 1 33 E11H9 Breather vent pipe 1 34 02253 Clip breather vent pl pe 2 35 f11610 •r• piece connector 1 36 F11613 Froth tower vent pipe 1 37 F11614 Breather pipe, rear guard 1 38 02252 Clip, pipe to 'T' piece 1 39 F1161S Clip, pipe to rear guard 1

65

22

-

~~~~~-7

! re= 44 =

Fis. lt.

~-6

--- 5

15

21

•

ND Alll FILTER BATTERY, TOOLKIT A

66

20

C28


BATTERY , TOOLKIT AND AIR FILTER

1 5'4027029 Battery PUZSA (99-0719) 1 2 F7-431 Vent pipe 1 3 F8033 Battery retaining strap 1 -4 F8032 Battery strap anchorage 1 s F802• Battery carrier .. . 1 6 F8031 Battery carrier rubber 1 7 F8091 Battery carrier tray 1 8 5•938986 Fuse assembly ... 1 9 F11609 AIR FILTER • 1 or 2 ......

10 F6866 Filter element (Filter cloth and gauze) 1 or 2 11 F-4810 Clip for cover .

1 or 2 12 E-4576 Adaptor 1 or 2 13 D177/8 Clip 1

D2110 TOOL KIT 1 14 D291 Tool roll 1 1S D2251 Ring spanner 1! In. x 1,'. In. AF. 1 16 D370 Ring spanner,'. In. x ¼ In. WHIT ... 1 17 D208-4 Open end spanner t In. x-h in. AF. 1 18 DA16 Open end spanner f in. x -h In. WHIT 1 19 D218-4 C spanner 1 20 02185 Tappet spanner 1 21 0 87 Box spanner for sparking plug 1 22 0767 Screwdriver c/w blade 1 23 01911 Tommy bar ... 1

·67

~-:

Q: - .:3 . .

g,

13

J '~)i

28. ' 't7

16- i 17-----e 15_J.___6J

14-'( ~ 18·

~

Fis. 30. HANDLEBAR AND CONTROL LEVERS

) )

.9

C5>

) )

Ref. No. Port No.

1 1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21 21 22 22 23 24 25 26 27 28 29 30 31 32 33 3-4

H4251 H4252 HH25 16/36-4 16/328 16/329 16/008 16/009 16/010 99-02-4-4 11 /013 H2125 16/011 H21H 12/608 12/556 12/607 12/606 12/033 12/0-40 11 /014 D3583 D31-43 D3657 D31-4-4 S20-48 1-4-1301 D3585 D3586 39595 5-4033666 543-40883 54115246 39596 5-4033667 54340882 54115246

DESCRIPTION QUANTITY

HANDLEBAR AND CONTROL LEVERS

Handlebar Handlebar (Western) . .. Sleeve, handlebar mounting TWISTGRIP (99-0248)

Body, top half (99-0245) ... BODY, BOTTOM HALF (99-0246)

Friction spring Screw .. . Locknut

Rotor Screw (99~225) Grip

Cable stop (99-02-41) Grip AIR CONTROL LEVER (03246)

Lever Bolt .. . Cap .. . Spring washer Clamp Screw

Front brake lever (alloy) Front brake lever (steel) Clutch lever (alloy) Clutch lever (steel) Pivot pin Nut Adjuster ... Lockrlng HANDLEBAR SWITCH-l.H.

Switch half .. . Lever half (99-121S) Screw (99-1188) ...

HANDLEBAR SWITCH- R.H. Switch half . .. Lever half (99- 1187) Screw (99-1188) ...

69

.•. -~

1 Available .. 1 T100C 1 1 Reference only Reference only Reference only

2 1 1 1 1 . Reference only Reference only Reference only Reference only Reference only Reference only 1 1 T100C 1 1 T100C 2 2 2 2 Reference only Reference only 1 .. Reference only Reference only 1 ..

REMARKS

• ...

15

~ 5 10

8

7 (5J 16 14

~17 11

® 4 ~ 13

@)_5 9

~ 6 12

C42

Fis, JO. STEERING DAMPER

70

4

2s, -----...__ 24

23

3

J--12 "E9 13

10

=-

C20

Fla. 33. TtOOC IGNITION C APACITOR AND H EADLAMP

7-4

14

,......._ Ref. No. Port No. DE.SCRIPT/ON QUANTITY RE.MARKS

T 1 0 0 C IGNITION CAPACITOR AND HEADLAMP

1 S4170009 Ignition capacitor (99-0737) ... Available 2 544831S6 Mounting spri ng (99-0n8) ... Available 3 60261 HEADLAMP COMPLETE- MCH66 (99- 1219) 1 4 534343 Rim (99~91) 1 s S4S2S272 light unit (99- 1212) 1 6 S0466S fixing wi re (99- 0683) 6 7 370 Main bulb (4S/3S W) (99- 1214) ... 1 8 S4S73S90 Bulbholder, pilot (99-069S) • 1 ...... 9 989 Pilot bulb (99-0S48) ... 1

10 S54602 Bulbholder, main .. . . . Reference only

11 3S710 Lighting switch (99- 0S63) 1 12 144921 Screw Reference only 13 S34296 Plate Reference on ly

" H S43634S4 Warning light, red (99- 1208) 1 1S 281 Bulb (99-0S37) 3 16 S43634S5 Warning light, green (99- 1209) ... 1 17 S4363453 Warning light, amber (99- 1207) 1 18 S4140331 Sealing washer (99- 1210) ... 3 19 S4S2S212 Warning light shield Reference only 20 47638 CAPACITOR PACK-2CP Refere nce only 21 54420128 Capacitor (99- 1043) 2 22 S4418S28 Cover (99-0767) ... 1 23 S4418S26 Base plate (99- 1160) 1 24 F8082 Capacitor pack bracket 1 2S E4638 Screw, bracket to frame 2 26 f10033 Bolt 2 27 GS299 Shakeproof washer 2 28 f3799 Nut 2 29 862217 qrommet Reference only

7S

9 8 7

6 - 3

5 -~

18

17~ ©

~ 19 "I)'

16

23

~ ~© ~

24 -,if' 22

-El 0- 26 28 8 <!Ji- 25

27

29

30

I I

2

• ...

34 15

32

13

I ~rB:>

14

Fig. 3-4. IGNI TION COIL• S HORN, RECTIFIER A ND ZENER DIODE

76

20

t27

~

-,......

r- Ref. No. Port No. DESCRIPTION QUANTITY RE.MARK

,- • IGNITION COILS, HORN , RECTIFIER AND ZENER DIODE

1 •5223 Ignition coil (Dll06) Lucas type 17 M12 2 2 D2207 H.T, cable c/w clip and grommet non-resistive 2 3 F11533 Coil bracket 2 • 14--0103 Bolt (Coil to bracket) ... • 5 S25-1 Washer ... • 6 1•- 1301 Nut • 7 14--011• Bolt (Coil bracket to frame) ... 2 8 S25-3 Washer ... -~ 2 9 1•-1302 Nut 2

10 131023 Plain washer E2351 ..... . • 11 188330 Serrated washer (GS299) • 12 166043 Nut (F3799) • 13 5•9•2078 Lucar connector As required 1-4 5•1900•2 Insulating cover ... As requ ired 15 N• Champion sparking plug Reference on If 16 F7552 Horn (Clearhooter 27899) 1 17 F•n1 Screw (t in. U.H.) 2 18 F3799 Nut 3 19 GS299 Serrated washer 3 20 •90n Rectifier, type 2DS 506 (99-0589) 1 21 F5338 Nut 1 22 Hll37 Heat sink 23 •93•5 Zener Diode (99-0590) 1 - 2• H•262 Hut sink bracket 1 25 1•-6102 Bolt 1 26 S26-2 Washer ... 1 27 14--0113 Bolt, bracket to fork lug 1 28 S26-3 Washer ... 1 29 Hll75 Plug, heatsink ... 1 30 5•190000 Earth blade, rectifier (99- 1159) 1 31 350•8 Flasher unit (99- 1201) ... 1 32 5•385091 Clip, flasher unit (99- 120•) 1 33 F13600 Bracket, flasher unit ... 1 H F12569 Grommet, flasher unit 1

LATER MODELS USE THE FOLLOWIN G:-

D365• Spring

1 } fluS,c '"" mo'"""•

F10033 Bolt E2351 Washer F•717 Nut S25-13 Washer

n

31

---

2

Fis. 35.

3

P WIRI HEADLAM•

1L_ _ _

NG HARNESS,

78

24

TAIL LAMP SWITCHES AND

-...

I'""' Ref. No. Port No. DESCRIPTION QUANTITY RF.MARKS

HEADLAMP AND FLASHER LAMPS

1 60263 HEADLAMP COMPLETE SS700P (99- 1155) 1 T100R 2 553248 Rim (99-0692) 1 3 516801 Light unit (99-1156) 1 -4 504665 Fixing wire (99-0683) 6 5 1-4492 Screw Reference only 6 53-4296 Plate Reference only 7 370 Main bulb (•5/35W) (99-1214) ... 1 8 55-4602 Bulbholder .... Reference only 9 989 Pilot bulb (99--0548) . :-:. 1

10 54573590 Pilot bulbholder (99-1213) 1 11 5'43634S-4 Warning light (Red) (99-1208) ... 1 12 5'4363•S5 Warning light (Green) (99-1209) 1 13 5'4363453 Warning light (Amber) (99-1207) 1 - ~, H 5'41'40331 Sealing washer (99-1210) ... 3 15 35710 Light switch (57SA} (99--0563) 1 ✓

16 5-4525212 Shield, warning light Reference only 17 281 Bulb, warning light (99--0537) 3 Not illus. 5-4959628 Wiring harness (99-1 158) 1 18 31899 IGNITION SWITCH (TYPE S45) (99--0558) 1 19 5-41300'41 Nut ... Reference only 20 f6981 IGNITION LOCK C/W KEY 1 21 0622 Key (state serial number) As required 22 H2262 Cover, ignition switch 1 23 56147 FLASHER LAMP (99- 1109) 4 24 5-4581638 Lens (99-1191) 1 2S 5-4580300 Guket Reference only 26 55-4548 Bulbholder Reference only 27 573832 Interior assembly ... Reference only 28 382 Bulb (99-1192) 1 29 5-4123-401 Screw (99-1193) ... 2 30 5-4582-41'4 Stanchion, flasher lamp-rear (99-119'4) " 31 E2S3-4 Washer ... -4 n 1981n1 Locknut (99/1195) -4 33 862217 Grommet Reference only Not illus. W2321 Shakeproof washer 4

79

3~ ,,.,

2

13:--11 14

34~

~

12

33 16 18

Fis. 36.

/ 9

-- --~,

" ~ ~~~ .. Q. ' • '

®-_10

4

11

,------15

27

23,- - '

17 19

80

30

8

6 7

29

\-31

© - - - 32

22 I

r-.,

_.,...

Ref. No. Port No.

1 2 3 4 5 6 7 8 9

10 11 12 13 1'4 15 16 17 18 19 20 21 22 23 H 25 26 27 28 29 30 31 32 33 34

SSM5007/02 SSMS007/03 5'49S3387 987 H1946 H1929 30-282-014-11 30-276-037-11 S590 41-148-203 H1702 H1701 H1668 14--0103 S26-2 0692 E9438 E9332 Reference only Reference only ES1S7 ES759 E6300 ESS78 E12875 E6299 Reference only T2697 ES881 0648 RSM3003/ 13 31-371-398 0494 E7351 F4366

DESCRIPTION QUANTITY REMARKS

S P E EDOMETER AND TACHOME T ER

Speedometer head MPH (02402) Speedometer head KPH (02403) Bulb holder Bulb, 2.2W. M. E.S. MOUNTING BRACKET

Metalastlk bush w .. her ... Nut Bolt (1,'r In. U.H.) Trop control D sunce piece Sleeve nut Bncket ... Bot Spr,ng washer

.. , ':>

S;,ttdometer cable (63 Ins. long) (O692W inner only) TACHOMETER GEARBOX (Body E5757)

Securing screw (Left hand thread) UNF Bush ... Flanged bush ...

Driving gear End cap ··o .. ring ... Driven gear Driven gear housing

""O" ring Bush

··o" ring .. . Set screw .. .

Tachometer cable (26½ in. long) Tochometer (D2396) Spade (99-0173) Corcl,p ... Seol,ng washer ... Spocer ...

81

1 Alternative Reference only Reference only

~} T1 OOR {Con be fitted

2 to T100C)

2 1

1}"~ 1 Smiths DF9110/00 1 1 1

1 1 1 1 T1 OOR {Con be fitted 1 to T100C) 1 1 1 1 1 1 1 1 2

STANDARD HARDWARE SPECIFICATION BOLTS

length under Min. length - 7'

Port No. Material Thd. dio. head of thread Hexagon A.F. S1822 Steel n• UNF t· ff• o.5oo· S1910 .. i' UNF tt· tt· 0.565· S1919 n•UNC 11· •• 0.500• 52010 .. t• UNF tt· t· 0.375· 1'4-0101 ¼• UNF t· 0.439• 1'4-0102 ¼' UNF 1· 0.-438' 1'4-0103 .. t• UNF 1· 0.-438· 1'4-0113 n• UNF 1· 0.500• H--011-4 n• UNF 1· o.5oo· 1+-0115 n• UNF ,.

• 0.500• 1+-0128 .. i ' UNF 1· 0.563' 1+-0208 r• UNF 2¼. ¾' 0.-438· 1+-0216 .. n• UNF 1,· •• 0,500•

1+-0217 n' UNF 1¼' r· o.soo· 1+-0219 .. n' UNF 1f' •• o.5oo· 1+-0220 .. n ' UNF 1¾' •• 0.500• 1+-0225 n' UNF 3• •• o.500' 1+-0228 .. n' UNF ... •• o.5oo· 1+-023-4

" f UNF 1r 1· 0.563'

1+-0236 t• UNF 2¼. 1 · 0.563· 1+-0239 .. t• UNF 3• 1· 0.563 · 1+-02-40 .. i' UNF 3t· 1· 0.563' 1+-02-42 i' UNF ... 1· 0.563· 1+-0251 .. -tr• UNF 2!' 1¼' 0.625' 1~102 .. ¼' UNC i ' 0.-438' 1~115 .. n•UNC r o.500'

NUTS Part No. Material Thd. dia. Hexagon AF. Thickness Remarks sn8 Steel No. 10 UNF 0.375· 0.225' Cleveloc S1852 .. n ' UNF 0.-437" 0,330• Phllidas S1906 ¼' UNF 0.-438. 0.188· Plain S1908 .. n' UNF 0.-438. 0.313" Plain S191-4 .. t • UNEF 1,125• 0.250' Plain S2012 .. t• UNEF 1.313· 0.-438· Plain S2013 ¾' UNEF 1.313' 0.313" Plain S20H .. I ' UNEF 1.313' 0.-438' Plain 1+-0301 .. r• UNF 0.-438. 0.22-4" Plain 1+-0302 n' UNF o.soo· 0.271' Plain 1+-0-401 ¼' UNF 0.-438' 0.161' Lock 1+-0-402 .. n •uNF 0.500• 0.192· Lock 1+-0-403 .. t• UNF 0.563' 0.22-4' Lock 1+-0701 ¼' UNF 0.-438' 0.203• Phllldas 1+-0702 .. n' UNF o.soo· O.H6• Philidas 1+-0703 .. t• UNF 0.563· 0.296' Philidas 1+-1201 ¼' UNF 0.-438' 0.285' Stiff nut 1+-1202 .. n• UNF 0.500' 0.335' Stiff nut 1+-1301 .. ¼' UNF 0.-438' 0.2-45' Stiff nut 1+-1302 n • UNF 0.500• 0.290' Stiffnut 1+-1303 .. f' UNF 0.563' 0.320· Stiff nut 1+-130-4 .. -tr' UNF 0.688· 0.375' Stiffnut r 1-4--1305 t• UNF 0.750' 0.-435' Stiff nut -1+-1902

" n• UNF o.soo· 0.361 • Nyloc

1-4--1903 .. t • UNF 0.563' 0.375' Nyloc r-82

SC REW S

Port No. Type of head Mater/of Thd. dlo. ~ngth under head Type of drive S1916 Cheae head Steel ¼' UNC 1,· Cross recess S1917 Cheae bad t'UNC 21· Cross recess S1918 Cheae l>ead " t" UNC 2f' Cross recess S1920 Hex. head ¼'UNC lJ. .. S1929 Countenunk (82') ¼" UNC -H" Slot S2079 Cheae had No. 10 UNF t· Pozidrive 1~ Cheaebad ¼" UNF t· Cross recess 1~505 Countersunk {82') t· UNC •• Cross recess 1~7 Cheae bead

" ¼"UNC •• Cross recess 1~608 Cheaebad " ¼" UNC 1· Cross recess 1~609 Cheael>ad ¼' UNC 1¼" Cros.s recess 1-4--7019 Soc:l<et bead ..l." UNC ... Hex. socket 1-4--702-4 Soatet bead /r'UNC 2· Hex. sotket

WASHER S- P L A I N

Port No. Mounol I /dlo. o dia. Thickness S25-1 Stttl 0.273" 0.563' 0.0-48' 525-2 Steel 0.398" 0.1so· 0.063" S2S-3 Stffl 0.336" 0.625" 0.063" S2S-6 Stttl 0.531 • 1.031 • 0.092" 525-13 Sttt_ 0.266' 0.-469' 0.06-4·

WASHER S-SPRI NG

Port No. Mounal 1/dlo. oidia. o/o height Thickness S26-1 Sprini Steel t' clearance -a· n· 0.10-4" S26-2 ¼' clearance tr 1r· 0.06-4· S26-16 -H' •• n· 0.0-40•• S6-48 /r • clearance ½' Ir' o.oao·

•• Double coll.

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