british onlypartsbooks.britishonly.com/partsbooks/20-10103c.pdf · the engine number is located on...

British OnlyMOTORCYLES AND PARTS INC.

32451 PARKLANE ST.GARDEN CITY, MI 48135 USA

ENGINE REBUILDING PARTSGASKET - SEALS - BEARINGSBUSHINGS - PISTONS - RINGSCLUTCHES - TUNE UP PARTS

SPEED EQUIPMENT

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VELOCETTE ANDOVER NORTON TEC HAYNES P&P SEATING WASSELL MORGO ALPHA BEARINGS M.A.C. PRODUCTS JOE HUNT MAGNETOS J.J. CABLES BUCHANAN’S

L.A. SLEEVE MEGACYCLE CAMS T.J. WASSELL LIMITED SUDCO INTERNATIONAL ACE CLASSICS LONDON CLASSIC GASKETS BRITISH WIRING PBM ENGINEERING

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

WE ACCEPT VISA - MASTERCARD - DISCOVER - AMERICAN EXPRESS

REPLACEMENT

PARTS

CATALOGUE

FOR 1972 ·

DAYTONA (TIOOR) TROPHY 500 (TIOOC)

T R I U M P H E N G I N E E R I N G, C O M P A N Y L I M I T E D

MERIDEN WORKS • ALLESLEY • COVENTRY CVS 9AU • ENGLAND

TELEPHONE COVENTRY 20211

MERIDEN 331

1U8USHEO SEPTEMBER 1'171

TELEGRAMS "TRUSTY" COVENTRY

TELEX "TRUSTY" 31305

-ADVANCE INFORMATION

The Triumph Engineering Co. Ltd. point out that the information contained in this catalog was complete and correct at the time of printing. Distributors will be informed of any subsequent alterations.

A plastic binder, of the type used for Workshop Manuals, is available to enable this catalog and all ocher 19n season catalogs to be bound into one unit.

GUARANTEE

Please refer to your local deal�r or distributor for the latest terms of guarantee.

EASTERN U.S.A. DISTRIBUTOR:

Triumph Motorcycle Corporation, P.O. Box 6790, Towson,

. ,, _.

Bal_timore 4, Maryland 21204.

Telex-Tricor Bait. 87728 Telephone-301-252-1700

ENGINE AND FRAME NUMBERS

WESTERN U.S.A. DISTRIBUTOR:

Triumph Motorcycle Corporation, P.O. Box 2765, Eas;: Huntington Drive, Duarte, California 91010.

Telex-Tricor Duarte 675469 Telephone-213-359-3221

213-681-0255

The engine number is located on die left side of the engine, immediately below the cylinder barrel to crankcase flange.

The frame number is located on the left side of the frame head lug, beneath the fork top lug and forward of the gasoline tank.

Both the engine and frame number should be guoced in full in any correspondence relating to the machine.

2

AIR Fil TER ALTERNATOR ... AUTO-ADVANCE UNIT

BATIERY CARRIER BRAKE SWITCHES BREATHER PIPES

Page

67 9,35

25

. 67 ... 45, 73

65

CAMSHAFT, INLET AND EXHAUST CAPACITOR, IGNITION CAPACITOR PACK

9 73 73

CARBURETOR CARTON PACKS CENTRE STAND CHAINS ... CHAIN CASE CLUTCH CLUTCH LEVER ASS EMBLY COIL CONNECTING RODS CONTACT BREAKER ... CONTROL CABLES CONTROL LEYERS ... CRANKCASE ... CRANKCASE UNDER.SHIELD CRANKSHAFT ... CYLINDE�S CYLINDER HEAD

ENGINE PLATES ENGINE TORQUE STAY EXHAUST PIPES EXHAUST PIPE ADAPTOR

FENDERS FLASHERS FOOTRESTS FR.AME •.. FRONT FORKS FRONT WHEEL FUSE ASSEMBLY

GAS TANK GASKET SET GEARBOX

... 17, 19 7

43 35 35 33 31 75

9 25 71 69 11 41 9

... 21.23

... 21, 23

39 39

... 37, 41

... 21, 23

57

77 ... 41, 43

43 ... 47, 49 ... 51, 53

67

63

7 27, 29, 31

INDEX

3

HANDLEBARS ... HANDLEBAR MOUNTINGS ..• HEADLAMP HEAT SINK HORN ...

KICKSTARTER ...

MANIFOLD MUFFLERS

OIL PUMP OIL TANK OIL PIPES

PISTONS PROP STAND PUSH RODS

REAR WHEEL ... RECTIFIER REFLECTORS ROCKERS

SIDE PANEL SPARKING _PLUG S�EEDOMETER ... SPEEDOMETER GEARBOX STEERING DAMPER ... STEERING RACES SUSPENSION UNITS ... SWINGING ARM SWITCHES

Page

69 69

... 73, 77 75

75

31

15 .:. 37, 41

13 65 65

9 43

... 21, 23

55

75

. .. 57, 63

23

61 75

81 55 69 43 45 45

... 69, 77

TABLE OF STANDARD HARDWARE 81 TACHOMETER... 79 TACHOMETER GEARBOX 79 TAIL LAMP 59 TAPPETS · ... 21, 23 TIMING GEARS 9 TOOLKIT 67 TWIN SEAT 61

VALVES ... VALVE GUIDES

WIRING HARNESS

ZENER DIODE

... 21, 23

... 21, 23

77

75

HOW TO USE. THIS PARTS CATALOGUE�

First consult the index on Page 3 for the parts or group of parts which you wish to locace. When you have located che parts make sur� from the end columns that the part you have located does apply to your machine.

List the quantities required as single units; do not ask for "2 pairs" or "3 dozen".

In case of painted items always state the colour required. Painted parts are available only in the colours or alternatives specified for that model of that particular year.

Model

T100C T100R

Colour

} Cherry and Cold White

P L E A S E .N O T E

THROUGHOUT THIS LIST, ASSEMBLIES AR.E PRINTED IN CAPITALS AND THE COMPONENTS INCLUDED IN THAT ASS EMBLY ARE INDENTED IN THE .DESCRIPTION COLUMN, REYER.TING TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO OR.DER. THE COMPLETE

.,·. ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPON:NT PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.

SPECIAL WORKSHOP TOOLS

A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING YOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASES THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE, AND THEREFORE, IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN ORDER TO AID SER.VICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES IT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.

UNIFIED THREAD FORM

NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOGUE HAVE THE UNIFIED FORM OF SCREW THREADS. THIS CHANGEOVER. WILL BE CONTINUED AS AND WHEN NEW PARTS ARE INTRODUCED. EVEN WHERE PAR.TS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS WILL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS HAVING THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR. RECESS IN THEIR HEADS, STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING CIRCLES ON THE SIDE.

4

Bore and ScroKe

Capacity

Compression Ratio

Spark Plugs

Carburetor

Gearbox Sprocket

Chains

Capacities

Brakes

Tire Size

TIGER 100 (T100C) TECHNICAL DATA

Main Jee Needle Jet Needle Throccle Valve

Front Rear

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

Front and Rear, diameter

Front Rear

5

2.716 x 2.578 ins.

30 cu. ins.

9 : 1

Champion N4

Amal Concentric 170 .106 Standard No. 4

18 teeth

j in. Duplex x 78 link: i in. x j in. x 102 links

2f U.S. galls. 6 U.S. pints 2/3 pint (375 c.c.) t pint (150 c.c.) t pint (200 c.c.)

7 in. (17.18 cm.)

3.50 X 19 4.00 X 18

Bore and Stroke

Capacity

Compression Ratio

Spark Plugs

Carburetor

Gearbox Sprocket

Chains

Capacities

Brakes

Tire Size

TIGER 100 (T100R) TECHNICAL DATA

Main Jee Needle Jee Needle Throttle Valve

Front Rear

Gas Tank Oil Tank Gearbox Primary Chaincase 0nicial till) Front Forks (each leg)

Front, diameter Rear, diameter

Front Rear

6

2.716 x 2.578 ins.

30 cu. ins.

9 : 1

Champion N4

Amal Concentric 150 .106 Standard No. 3

19 teeth

f in. Duplex x 78 links fin. x tin. x 103 links

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

CA R T O N P ACK LIS T ···

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

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

E.6906

E.6884

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

T100R, T100C

Available

All pistcn 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/AM2

C.P.205

2

16

2

16

VALVE SPRINGS (all models)

C.P.177

STEERING HEAD

C.P.156

GASKET SETS

De coke Overhaul

4

4

RACES

2 1

40

99-116499-1167

NW2-0

W129

W1734

W129

. E5946

E4011

H111 H439 H1018 S70-3

7

Brake lining

Rivet

Brake lining

Rivet

Inner valve spring

Outer valve spring

Cup Cone Top cone Ball

15 14

��

�12

�13

1---7

F. 1 CRANKSHAFT AND ., . . CONNECTING RODS

8

C32

19 . 20 21

1234s

6789

101112131415161718192021222324

25262728293031323233343536 Noc illus.Noc illus.

··:. ·�':.:;."� .. ;{Pait'No.

·. . ·�

DESCRIPTION QUANTITY REMARKS

CRANKSHAFT AND CONNECTINcf RODSC . .

E9489.E9490 E3999 E9492E5870

*$1913E9915E9914$2016E3706E6884 E6893E6894E6861E6869 E12664E3734 E385154213901E3975 S1915E1580E1n1S1914E6160E400 E12717E1558 E11007E6523 E11064E9984 E9983 E9988E9502S1929E9503E8038E12660

CRANKSHAFT AND FLYWHEEL ASSEMBLYCrankshaft .:. Oil tube Screwed plugFlywheel ...Flywheel bolt (1 �� in. U.H.)

CONNECTING ROD ... Connecci:1g rod bole Self-locking nut ...

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

Taper compression ring ...Oil control ring Gudgeon pin Circlip

Spacer ...Engine sprocket, 26T DuplexRotor key Rotor (99-0739) Tab washer Nut Key Timing pinionNut INTERMEDIATE WHEE:L

Bush Camshaft pinion Camshaft key ...Inlet camshaft nuc Exhaust camshaft nucInlet camsha� ... EXHAUST CAMSHAFTEXHAUST CAMSHAFT

Tachometer drive plugRetaining place ... Screw (g in. U.H.)Clamping washer Shim (0.010*) .. .Shim (0.030*) · .. . ••t

•Use DS24°

Loctice sealant·

9

1111

�-·

32224

24

224

11

11

1 I

1

1122

1

1 T100R 1 T100C1

241

As required } · A d up co s require

/-2

37----© 38----®

� 40

��

41

.3o a

31-� 34-g 33� Cl7

Fig. l. CRANKCASE

10

28

Ref. No. Part No. DESCRIPTION

CRANKCASE

1 E11268 CRANKCASE DRIVE SIDE ·2 E4147 Pivot pin ...

3 E3823 Camshaft bush 4 E3823 Camshaft bush 5 E11269 CRANKCASE TIMING SIDE 6 E9496 Oil scavenge pipe ... 7 E1509 Clip··· 8 S1920 Screw 9 14-6102 Bolt···

10 E7430 Tab washer 11 T1606 Needle roller bearing 12 E6386 Dowel at junction block ... 13 E375 Idler gear spindle ... 14 T912 Peg (at thrust washer) 15 E3716 Hollow dowel ...

16 S1926 Screw G� in. U.H.)

17 14--0225 Bolt 18 S1925 Stud (3f in. U.H.) 19 S1919 Bolt 20 S25-3 Plain washer 21 14-1302 Nut 22 S1852 Nut 23 S1864 Oil pump stud (1-t.- in. O.A.) 24 E9494 Right main bearing (ball journal) 25 S1921 Cylinder base scud (1{ in. O.A.) 26 S1922 Cylinder base stud (1ft in. O.A.) 27 E1534 Dowel 28 E9493 left main bearing (roller journal) 29 T1257 Washer .. .30 E3n4 Filter spring 31 E3n2 Filter ...

32 E3n3 Sealing washer ... 33 .E9501 Filter cap 34 E1577 Joint washer 35 S1927 Stud (3-n- in. O.A.) 36 T2167 Drain plug (with level tube) 37 E2441 Fibre washer 38 S543 level plug 39 E8896 Fibre washer 40 T2166 Filler plug 41 E8782 "O" ring 42 S1871 Blanking plug (l.H. thread) 43 E7431 "O" ring 44 r,::� Plug .J .•.• ,�

45 E11079 Cover plate 46 E9335 Outlet stub-breather 47 E11460 Joint washer 48 E11075 Screw 49 E11077 Screw Not illus. E4707 Grommet, alternator le:ids

11

'

-:-1.

QUANTITY REMARKS

1 1 .1' . .

1 1 1

1 1 1 1 Ref. only 1 1 2 2 (Not required

en lacer models) 1 2 1 3 2 1 2 1 6 2 2 1 1 1

1 1 2 2

1 2

1 (Not T100R)

/-.

1 1 1 2

7

ASSY.1

10

:··

C1

--- -

-- --

-

-----

-

-- -

---

--

- -

--

---

--

'------2-

-

-. -

-

-

-

-

- -

-

12 13

F. 3 OIL PUMP AND RELEASE VALVE 1g • •

12

9

Ref. No. Part No. DESCRIPTION QUANTITY REMARKS

0 IL PUMP AND RE LEA.SE VALVE

1 E6928 OIL PUMP 1 2 E6680 Pump body ... Reference only 3 D2363 Valve ball ... 2

4 E403 Valve spring 2

5 E2360 Screwed plug 2 6 GS153 Feed plunger 1 7 E6681 Scavenge plunger ... 1 8 E495 Drive block 1 9 E11461 Joint washer 1

10 E3887 Serrated washer 2 11 S1906 Nut 2 12 E12210 Oil release valve 1 13 E1670 Joint washer 1

13

16 15

19

Fig. 4.

14 23

MANIFOLDS INLET

14

18

----- 20

---- 21

-- 22. C6

Ref No. Port No. DESCRIPTION QUANTITY REMARKS

-

INLET MANIFOLDS

Single Carburetor Model (T100C)

1 E7578 Inlet manifold 1 -� 2 E6772 Joint washer 2 3 S25-3 Plain washer 4 4 S582 Scud (1

1

5

4 in. O.A.) 2

5 E11459 Joint washer ... 1 6 E2968 lnsubcing block 1 7 S25-3 Plain washer 2 8 14-1302 Self locking nuc 2 9 14-7024 Socket he:id scr�w (2 in. U.H.) 2

., ;·, S648 Spring washer 4 ...

·j·[ 14-6115 Bole 2

Twin Carburetor Model (T100R)

12 5582 Scud (1 ft in. U.H.) 4 13 14-1302 Self locking nuc ... 4

14 £6772 Joint washer, manifold ... 2 15 E11459 Joint washer, insul:icing block ... . 2 , . E2968 Insulating block 2 :,:•

'i7 E7136 Left manifold 1 18 E7137 Right manifold 1 19 S25-3 Plain washer 4

20 E6916 Connector 2 21 E6958 Balance pipe 1 22 E5473 Clip 2 23 14-7019 Socket head screw (fin. U.H.) 4

15

�16

27

28

19

22-----...::::-::::i•c:::!!�

33--;;;;;;;;;;;;;;;!::::{:

5

6

29

2

30

13

Fig. S. CARBURETOR TIOOC

16

i--25

' 26

4

7

es �

15

14

Ci:

Ref. No. Part No.

1 02455 2 622/101 3 Reference only 4 622/097 5 622/086 6 622/060 7 622/065 8 622/077 9 622/076

10 622/082 11 622/128 12 376/100 13 622/122 14 622/124 15 622/067 16 622/134 17 622/069 18 622/071 19 622/073 20 622/055 21 622/068 22 376/093 23 622/078 24 13 /163 25 4/035 26 5/077 27 622/062 28 622/129 29 622/089 30 14/032 31 622/147 32 622/1°51 33 F9271

DESCRIPTION

CARBURETOR, T 1.0 0 C �

CARBURETOR R626/32 "O" ring seal (99-0522)

Mixing chamber R626/C0.5 Mixing chamber top (99-1049) ... Screw (99-0521) ...

Throttle valve (4 cutaw:iy) (99-1050) Throttle return spring (copper plated) (99-0509) Throttle stop screw (99-0516) Air adjusting screw (99-0515) "O" ring (99-0520) Jee holder (99-1034) Main jet (99-1132) size 170 Needle jet (99-1035) size .106 Needle (99-1036) ... Needle clip (99-0510) Air valve guide sleeve (99-1051) Float (99-0512) Float spindle (99-0513) ...

Joint washer (99-0514) ...

Float chamber (99-1154) Float needle (99-0511) Filter (99-0438) ...

Banjo bole (99-0517) Fibre washer (99-1124) Cable adjuster Nut (99-0224) Air slide ...

Air slide sprin� (99-1038) Tickler pin Spring Drain plug (99-1152) Washer (99-1153)

Petrol pipe

17

., .

QUANTITY REMARKS

1

4 1 1 1 1 2 1 1

1 1 1

1

1 1

R.efere:ice only 1 Refere:ice only 1 Reference only Reference only 1 1 1

i,.27 5

28

6

29

2

30

'-------- 13

20--

22�--��:-::;J . ....::::,�

33--;;��

6 CARBURETOR, TIOOR Fig ••

18

' �

25

26

4

7

� 15

14

c:s

Ref. No. Part Na.

1 1 2 3 4 5 6 7 8 9

10 11

13 14 15 16 17 18 19 20 21 22 23

25 26 27 28 29 30 31 32 33

02453 02454 622/101 Reference only 622/097 622/086 622/060 622/065 622/077 622/076 622/032 622/128 376/100 622/122 622/124 622/067 622/134 622/069 622/071 622/073 622/055 622/068 376/093 622/078 13 /163 4/035 5/077 622/062 622/129 622/089 14/032 622/147 622/151 F9272

DESCRIPTION

CARBURETOR, T100R I

CARBURETOR L626/54 CARBURETOR R626/53 "O" ring seal (99-0522)

Mixing cha_mber .. . £ .. i, --:J. �/£JP..,.:;:-... Mixing chamber top (99-1049) ... Screw (99-0521) ... Throttle valve (3 cucaw:.y) (99-1125) Throttle return spring (copper plated) (99-0509) Throttle stop screw (99-0516) Air adjusting screw (99-0515) "O" ring (99-0520) Jee hclder (99-1034) Main jet (99-1131) size 150 Need le jet (99-1035) si:e .106 Need le (99-1036) ... Needle clip (99-0510) Air valve guide sleeve (99-1051) Float (99-0512) Float spindle (99-0513) ... Joint washer (99-0514) Float chamber (99-1154) Float needle (99-0511) Fi leer (99-0438) ... Banjo bolt (99-0517) Fibre washer (99-1124) Cable adjuster Nut (99-0224) Air slide ... Air slide spring (99-1038) Tickler pin Spring Drain plug (99-1152) Washer (99-1153)

Petrol pipe

19

QUANTITY REMARKS

1 1 1 4 1 1 1 1 2 1 1

1 1 1 1 1 1 1

1

Left Right

Each c:irburecor

Reference only 1 Each carburetor Reference only 1 Each carburetor Reference only Reference only 1 1

1

43 39 43 41 42 43 44 22 31 20 32 34

44

18 :--,...___

�J n-<9

16-\

r. 40 38

"-\. V

14 @

12•------·

!)

1

I

-@

Fig. 7. CYLINDER BLOCK ANO' HEAD, T100C

20

C 39

--49

t-, W.J...---3

11------8


CYLINDER BLOCK AND HEAD, T100C SIN!iiLE CARBURETOR

1 2

3 4

5 6 7 8

.9 10 11 12 13 H 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 H 35 36 37 38 39 -40 41 42 43 +44546

-48 49 so

51 52 53

E3798 E9719 E7563 S692 E9352 H200 E1612 E3753 E12644 E10229 14-0301 E6853

. E6854 E6855 E5946 E4011 E3742 99-0062E4456F2184E4675E12075E12076E951114-1401E3302E12079E1208014-6609E3857E3794E3795E3809F1880H400E4610E3751E3749E3750E7651E3223GS662E2534E3224E3748D3548E1335EH35E4008E12576E7310E11283E4671

Cylinder base gasket Cylinder block ... "O" ring Nuc (12 point) ... Tappet guide block Tappet block screw (f.- in. U.H.) Serrated washer Tappet ... CYLINDER HEAD c/w GUIDES

Valve guide (cast iron) Nut, rocker box 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 scud Wa:;he·r ... Plug, rocker box Joint washer Screw (Hin. U.H.) Plain washer Cylinder head bole (Sf.- in. U.H.) Cylinder head torque stay bole Oil feed bole Copper washer ... Domed nut lnspec�ion cap ... · Fibre washer ROCKER (right exhaust, leit inlet) .. . ROCKER (left exhaust, right inlet) .. .

Rocker ball pin Rocker adjusting pin ... Adjuster lock nut Thrust washer, f.- in . ... Spring washer .. . Rocker spindle .. . Sealing rubber .. . Copper washer .. . Domed nut Push rod

., .... · .. . .• • • "f�

Cover cu be ...... �- · .. ."O" ring, push rod cover tube (boc:om) · .. ."O" ring, push rod cover cube (top)Locking spring ...

21

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

2 2 2 6 2 4 4 2 2 4 4 4 8 4 2 2 2 2 4

2 2 2

44 40 44 42 43 44 45 23

45 �

Al 39

19� 11 10

18� J

17-\

16-\

15----

13------...../

Fig. 7. CYLINDER BLOCK AND HEAD, T100R

22

� 53

�o..,z

1----51

<§}---52

Ref. No. Part No.

CYLINDER

E3798 1 2 E9719

3 E7563 4 S692

5 E9352

6 H200

7 E1612 8 E4040 9 E12643

10 . E6301

11 E3209

12 14-0301

13 E6853

14 E6854 iS1617181920212223

E6855 E5946 E4011 E3742 99-0062 E4456 F2184 E4675 E12075

24 E12076 25 E9511 2S 14-1401 27 E3302 28 E12079 29 E12080 30 14-6609 31 E3857 32 E3794 33 . E3795 34 E3809 35 F1880 36 H-40037 E461033 E375139 E374940 E375041 E765142 E322343 GS66244 E253445 E322446 E374847 03548.40

. v E133549 E143550 E4008

51 E1257652 E731053 E1128354 E4671

DESCRIPTION

BLOCK AND HEAD, T 1 00 R,

Cylinder base gasket Cylinder block ... "O" ring Nut (12 point) ... Tappet guide block Tappet block screw (-f. in. U.H.) Serrated washer Tappet, Racing type CYLINDER HEAD c/w GUIDES

Valve guide Valve guide circlip

Nut, rocker box Inlet valve Exhaust valve . . .

Boctom cup Inner. valve spring Outer valve spring Top collar Split coccer Cylinder head bolt (2g in. U.H.) . . .

Plain washer ....

Cylinder head gasket Inlet rocker box Exhaust rocker box ...

Joint washer Rocker box scud Washer ... Plug, rocker box Joint washer . . .

Screw {1± in. U.H.) Plain washer Cylinder head bole (5 1

7, in. U.H.)

Cylinder head torgue stay bolt Oil feecf bolt Copper washer ... Domed nut Inspection cap ...

Fibre washer ROCKER (right exhaust, left inlet) ... ROCKER (left exhaust, right inlet) ...

Rocker ball pin Rocker adjusting pin Adjuster lock nut Thrust washer, +. in.Spring washer .. .

Rocker spindle ... "O" ring Copper washer ... Domed nut Push rod Cover tube "O" ring, push rod cover tube (bottom) "O"_ring, push rod cover cube {top) Locking spring .•.

23

TWIN

-·.. .

QUANTITY REMARKS

CARBURETOR

1 1 2 8 2 2 2 4

4

4 4 2 2 4 4 4

4 8 4

8 1

1 2

4 4

4 4

4 4

2 2 2 6 2 4

4 2 2 4 4 4 6 2 2 2 2 2 4 2 2 2 4

'19

s'

� �

4

� - -- �·· � /le\ ,y '

I : I ��

� 24 4

lJJ---13

17

©� �16

C21

Fig. 8. TIMING COVER AND CONTACT BREAKER

24

Ref. No. Port No. DES CR/PT/ON QUANTITY RElr1ARKS

TIM I NG COYER AND CONT AC Tl BREAKER

1 E9250 Timing cover ... 1 2. E4016 Pacenc plate 1 3 D2085 Hammer-drive screw 3 4 E4568 Oil seal ... 2

5 14-6607 Screw (f in. U.H.) 4

6 $1916 Screw (1-k in. U.H.) 4

7 T989 Hollow dowel ... 1

8 54419340 AUTO-ADVANCE UNIT (99-0n1) 1 9 54415642 Spring set (99-0757) 2

10 54419097 CONTACT BREAKER. PLATE ASSEMBLY (99-0768) 1

11 54419210 Pin adjustment (99-0769) 2 12 54419827 Contact set (99-0772) 2 13 E4707 Rubber grommet 1 14 E7680 Pillar bole 2 15 E6559 Washer ... 2 16 14-0208 Bolt 1 17 S25-43 Washer ... 18 E8737 Cover 1 19 E11462 Joint washer 1 20 GS299 Serrated washer 2 21 E7354 Screw 2 22 D2133 Oil pressure switch 1 23 D2045 Cover pressure switch 1 24 E4569 Circlip ...

Noc illus. E4849 Dowel pin, auco advance co camshaft Noc illus. D2138 Timing label for C.B. cover ...

Noc illus. E9526 Blanking plug (co replace oil pressure switch) Available

25

I

11

18 19

40

35

46 C!6

Fig. 9.

26

14 43 44

12

@i - 37(s I - ·-- 38

39�

· 30


GEARBOX SHAFTS, BEARINGS AND fNNER COVER

1 T665 2 T1478 3 W680 4 14-6608s T14226 T9127 T16068 T16079 T3991

10 T400711 T403912 T139113 T399414 T141115 T404116 T399717 T399918 T139319 T142620 T366021 T366122 T145723 T148024 T148125 T421826 T141827 28 T1416 29 H688 30 T4301 31 T1417 32 D208-5 33 T1440 34 T1157 35 T1390 36 T1981 37 T1431 38 T1282 39 T1161 40 T1897 41 T1469 42 T4113 43 T732 44 S594 45 T1464 46 T1441 47 E4803

High gear be:iring (ball journal) Oil seal Circlip .. Screw Return spring place Peg Layshafc bearing Th ruse washer ... MAINSHAFT HIGH GEAR (21T)

High gear bush MAINSHAFT c/w THIRD AND LOW GEARS (16/24T)

Clu_tch rod bush ... Main shaft second gear (21 T) .. Mainsh:ift distance piece

· Layshafc c/w second and high gears (15/23T)Layshaft third gear (20T)LA YSHAFT LOW GEAR (27T)

low gear bush Pawl retaining disc. Camplace index plunger Index plunger spring .. . Selector fork spindle .. . Mainshaft selector fork Lays haft selector fork ... Gear selector camplace Camplate spindle S I. .

( I .

.l . )p IC ptn 8 In. X 4 IO.

Gear indicator pointer Screw (-?.- in. U.H.) Inner cover Gear indicator plate Indicator place rivet Hollow dowel ... Kickscarcer stop place ... Slop place anchor screw KICKSTARTER SPINDLE

Kickscarter pawl Plunger Plunger spring Needle roller bearing

Mainshaft bearing (Ball journal)Circlip ... • ..

Tab washer Mainshafc nu·c Distance· piece Ki��starcer return spring

· "O" ring

27

. -...

1

1 2 1 1 1 1 1 1 1 1 T100R 1 and � J

Wes, Coast T100C

1 1 1 1

1 1 1

Reference only 1

1 1 2 2 1 1 1 1 1 1 1 1 1

1 1 1

._-

22

23

35

46

Fig. 11.

28

40

5 Cl6

36

L..__--37

�---38

41 I

Ref; No. Part No.

9 T4029 11 T4040 13 T4031 15 T4042 16 T3997 17 T4033

9 T2532 11 T2276 13 T1832 15 T1972 16 T1842 17 T1950

DESCRIPTION

WIDE RATIO GEARS

Standard on East Coast TtOOC - '

MAINSHAFT HIGH GEAR (23T) . . .

MAINSHAFT c/w THIRD AND LOW GEAR (15/24T) ... Mainshafc second gear (20T) ... Layshafc c/w second and high gear (14/24T) Layshafc third gear (20T) LAYSHAFT LOW GEAR (29T)

CLOSE RATIO GEARS

(Available if required)

MAINSHAFT HIGH GEAR .C20TL ... MAINSHAFT c/w THIRD AND LOW GEAR (16/TIT) ... Mainshafc second gear (20T) ... Layshaic c/w second and high gear {17f23T) Layshafc third gear (21T) LA YSHAFT LOW GEAR (27T)

QUANTITY

1 1 1 1

29

REMARKS

'

35----·,I

G

34

36

.!2

12

13

16 38

11

19

18

ASSY.37

20

.,,

15

Fig. 12. GEAR BOX OU TER COVER AND LEVERS

30

Ref. No. Part No.

1 T3755 2 T1395 3 S1928 4 14-6505 5 T1942 6 T1474 7 T1436 8 T1396 9

10 D3522 11 T1871 12 T1877 13 T1878 14 T1977 15 S1877 16 T1876 17 T1874 18 T-4439 19 D2368 20 T1710 21 T1712 22 GS127 23 24 T1945 25 T1946 26 T1937 27 T3784 28 T2062 28 T2063 29 T1646 30 14-1302

· 31 S25-3 32 S1918 33 S1917 34 T1435 35 T2450 36 W932 37 T3797 38 T3742 39 T1272 40 D2364 41 T1167 42 S541 43 S644

T2330 45 T1970 46 T2239 47 T2238 48 E1612

DESCRIPTION

GEARBOX 0 UTE R COYER

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

Scud (1 � in. O.A.) Screw GEARCHANGE QUADRANT

Spring retaining pin Plunger spring Selector plunger ... s 1· • ( 5 • l • ) p It pin .:. in. X 4 in.

Sealing ring Return spring housing Return spring Thrust button Cover Nut Distance piece Distance piece Clutch lever Ball, f in. diam. Shaft Spring Plain washer Split pin (-h in. x tin.) Spoke Connector Nut Abutment Adaptor, shor.: Adaptor, long (For cable with short outer) Rubber cover Nut Plain washer Screw Screw Gearchange lever Pedal rubber Bole (1 in. U.H.) KICKSTARTER LEVER COMPLETE

Kickstarter crank Kickscarter pedal ... Steel ball (i in. diam.) Index spring Pivot bole ... Clamp bolt (1 1

5, in. U.H.)Pedal rubber Clutch operating rod OH seal .. .

Oil seal cover ... Serrated washer

31

QUANTITY REMARKS

ANQ LEVERS

1 1

2 1 1 2 2

2 Reference only 1

2

2 1 2

2

3

1 1 1 Reference only

As required As rec;uired 1 2 2 2 2

1 1

1 1 1 1 1

1 12

4

22 2 3

13

0 7 (j

9

10 11

12 23 5

1'1 15

Fig. 13. CLUTCH

. 19

16 '• 17 18

20 21

�

Re(. No.

1234

56789

1011121314

15 16 �

. ..

17181920212223

Port No.

T1570T3930T3931T394SS86 T4438T4436S644 T2538T1n2T1n3T4437 T423AT1362T1363T2156T2159 14-0403T1931T1560T2526

.$66-1:-:T:2179

DESCRIPTION

CLUTCH

Sprocket and housing ...Hub Thrust washerRollerNut Centre (Shock absorber body)Inner placeBole Shock absorber spider .Drive rubber (large) ...Rebound rubber (small)Oucer place Screwed pin (1-H in. U.H_.)_Driving place (bonded)Driv�n place (plain)

..... Pressure place

·Adjuster pinNut Spring cupSpringNucKey Washer

.. �

QUANTITY

12011131 331

3 6"611

133

. 3

REMARKS

�--

3

6

4

12

20---i29

28

c:o

Fig. 14. CH AINCASE AND CHAINS

34

Re(. No. Part No. DESCRIPTION QUANTITY Rf.J'rl.ARKS

CHAINCASE AND CH A I N'S

1 T1476/18 Gearbox sprocket (18 teeth) ... 1 T1476/19 Gearbox sprocket (19 teeth) ... Available 1 T1569 Gearbox sprocket (20 teeth) ... Available 2 T2536 Gearbox sprocket nut 1 3 0444 Rear chain, tin. x tin. x 102L 1 4 E7037 Cover place 1 5 E7565 Oil seal ... 6 E11419 Joint washer 1 7 E3821 Countersunk screw (i\ in. U.H.) 6 8 0358 Primary chain, tin. Duplex 78L 1 9 E6283 Chain tensioner blade ... 1

10 E4152 Tie rod ... '11 E4148 Trunnion 1 12 E9495 Scud (3-h in. O.A.) 3 13 47205 Seater, RM 21 (99..:.1006) 1 14 S25-3 Plain washer 3

15 14-0702 Nut 3 16 E4144 Rubber grommet 1 17 E9360 Sleeve nut 1 18 E1509 Clip 19 S1920 Setscrew 1 20 E11456 Joint washer 1 21 E9249 -· Chaincase ...22 T2¥0 Rotor cover 23 E11457 Joint washer 1 24 F4139 Screw 3 25 T2537 Ignition pointer ... 26 14-6101 Level plug 1 27 E2441 Copper washer ... 2 . 28 T2166 Filler plug 29 E8782 "O" ring 1 30 S1878 Screw (2,t in. U.H.) 3 31 14-6609 Screw 7 32 E9703 Adjuster sleeve nut 1 3.1 T2259 Drain plug 3.� T1738 Fibre washer 1· 35 T2056 Tab washer 1 36 E7571 Crankcase protector 1

37 14-1301 Self-locking nut 1 Not illus. E11373 Grommet 1

35

w

°'

14

-----------

16

1!l

Fig. H. EX HA UST SYSTEM

�� C46

Ref. No. Part No.

. ...... ,-. · .-�--

1 E12628 E12629

3 E12466 4 F8977 5 F8978 6 14-01027 14-13018 E98889 E7512

10 E376811 14-0217. .,·- 14-1302� ... ,.J E12017H E1201815 E271116 E376817 14-021918 S25-319 14-1202

DESCRIPTION

EXHAUST

Exhaust pipe-L.H. Exhaust pipe-R.H. Finned clip Bolt

}

Exh,m pipes to Nut cylinder head Bole Exhaust pipes Nut co brackets Coupling pipe . . .

"D" washer CouplingClip

} Bole pipe Nut Muffier-D.S. Muffler-T.S. Clip "D" washer

SYSTEM

Bole Mufflers co exhaus: pipes Washer Nut

37

QUANTITY REMARKS

(T 1 0 ctR)

1 -·1 2 2 2 2 2 1 2 4

2 2 1 1 2 4

2 2 2

..,., 00

10

26

31

C4!j

Fig. 16. MOTOn FITTINGS

Ref. No. Pare No.

1 F7333 2 F7334 3 14-02394 S25-25 14-13036 S20067 $25-38 14-13029 S2083

10 S25-311 14-030212 14-130213 E764114 E764215 14-022516 S25-317 14-130218 E477819 S26-120 S1-5221 14-022022 E711923 E3434"' .!.-:- S25-325 14-130226 F422927 F423028 14-024229 $25-2 30 14-1303 31 14-0228 32 $25-3 33 14-1302 34 $2004 �·, .. .... F5532 .;f'.J 14-1303

DESCRIPTION

MOTOR FJTilNGS '

Front motor plate-D.S. Front motor plate-T.S. Bolt Washer Front motor plates to frame ... Nut {Cleveloc) Scud (3-} In. O.A.) Washer Top-front motor plates Nut (Cleveloc) Stud (4± in. O.A.) Washer Middle-front Nut (plain) motor places Nut (Cleveloc) Exhaust bracket-0.S. Exhaust bracket-T.S ....

Washer Bottom-front motor plates Bolt

} Nut (Cleve!oc) Torque stay Washer} Torque stay coNut rocker box studs Bolt Distance piece-D.S. Distance piece-T.S. Torque stay to fr_ame Washer Nut (Cleveloc) Rear motor plate-D.S. Rear motor plate-T.S. Belt Washer Rear motor plates to crankcase ... Nut (Clevelcc) Bolt Washer Rear motor plates to frame Nut (Cleveloc) Srnd } Distance piece Bottom motor fixing Nut

39

QUANTITY REMARKS

1 1 1 1 1 1 2 2 1 (Noc T100C) 2 2 (Not T100C) 2 (Noc T100C)

1 (2 T100C) 2 1 (2 T100C) 2 2 2 1 1

1 1 1 2 2 2 1 2 2

'

i � --�====-.c-

\�

·rv

40

u 0 0

E VI t, UJ c.. >-0

0 i:.

0 z � 0 .J L:J

:r VI

-� �0 z ::, VI UJ c..

c..

IVI

::,

� J: X w


EXHAUST PIPES, UNDERSHIELD AND /OOTPEG (T1 OOC)

1 E12647 Exhaust pipe lower 1 2 E12646 Exhaust pip� upper 1 3 E12645 Tie bar 1 4 14-0101 Bolt 2 5 D2417 Washer 2 6 E9857 Washer 2 7 mos Abutment 1 8 E12019 Muffler upper ,1 9 E12020 Muffler lower 1

10 E9673 Connector 1 11 En99 Clip 1 12 14-0116 Bole 1 13 E2271 Clip 2 14 E5874 Clip 15 E3768 "D" washer 6 16 14-0219 Bolt 3 17 14-1202 Nut 3 18 E9691 Bracket (silencer to frame) 1 19 $1822 Bolt 1 20 $25-3 Washer ... 2 21 F7550 Clip, bracket to frame 22 14-0114 Bole, clip to bracket 1 23 14-1302 Nut 1 24 E9680 Leg guard 1 25 E9688 Clip 2 26 E9696 Bracket ... 27 S1954 Short screw 28 S1953 Long screw {11 in. U.H.) 1 29 F11590 LEFT FOLDING FOOTPEG 1 30 F11591 RIGHT FOLDING FOOTPEG 1 31 F6411 Pedal 2 32 S1971 Pivot bolt ... 2· 33 F11279 Undershield 34 F1700 Clip, undershield 2 35 F3078 Bracket ... 1 - , 14-0102 Bolt 4 . ., 37 $25-1 Washer ... 4 38 14-1301 Nut 4

41

r s · I,�-22

�20

49- �48 "G,;, . /; 46

47��44

7

0--45

Fig. 18., FRAME

42

@---4 . 3

�-2

13

C37


FRAME J

1 F10034 Front frame 1 2 H111 Steering race cup 2 3 D2364 Ste.el ball (t in. dia.) 40· 4 H1018 Top cone and dust cover 1 5 F5679 Washer ... 2 T100R only 6 F7155 Steering stops 2 7 F8038 Rear frame 1 8 14-0241 Bole 1 9 S25-2 \!'/asher 1

10 14-1303 Nue 1 11 S588 Bole 2 12 99-0046 Spring washer 2

. 13 F7693 Centre sc:ind 11 14 T2331 Pedal rubber . . . 1 I15 F5678 Pivot bole u T100R ooly 16 F4484 T:ib washer 17 F2725 Nut 18 F3617 Return spring 19 F11560 Prop stand 1 20 F7021 Pivot bole 1 21 14-0703 Self-locking nut . . .

. 1 22 F8382 Return spring 1 23 F4214 Left foocresc 1 24 F4215 Righe footrest 1 25 NF704 Pedal rubbe, 2 26 14-0251 Bole 2 27 F4370 Plain washer 2 28 14-1304 Nuc 2 29 F5087 Lefe pillion fcocrest supporc ... 30 F5088 Right pillion fooeresc support 31 14-0115 Bole (# in. U.H.) 4 32 S25-3 Washer ... 4 33 F7705 Pedal stop screw 1 34 14-0302 Nut 2 35 F9369 PILLION FOOTREST ... 2 :-:: F9370 Footrest hanger 2 37 S1910 Bole ... 2 38 S26-1 Washer 2 39 F1694 Pedal 2 40 F9371 Pivot bole 2 41 F2277 Washer 2 42 14-1302 Nut ... 6 43 F1695 Pedal rubber 2 44 F7706 Brake pedal spindle 45 14-1305 Nue 46 F7703 Brake pedal

D3541 Spring washer 48 S25-2 Plain washer 1 49 14-0403 Nue so 14-0216 Bole 51 14-0402 Nuc Noc illus. D2452 Transfer, 'Safety Standards' 1

43

'�J -· •) 3,1-. -{,�<l=====------

QW) 9 c;:;:s "- --..,

4'.Jjfl . _1rn-" - 46 � (r)-44 7f$.} 1 21 ft---Ja

12 ·�--

7. .• )

•I

·II ,,

,. � r " � ,,_, �� -J,� I ff§ � \ is�@- . �:: �====�,,�

· - ��- � ,t(�,, M�(uf;:��,-�--�� 1

.!) 48 �5 10

/1

16·---A/JI

2 Fig. 19. SWINGING ARM. SUSPENSION UNITS AND CHAINGUARO

3

�11�

I] �-,<- -12

.��

21

8 �/2

; � . ./ -r�

47 4 CJ/

Ref. No. Part No. DESCRIPTION QUANTITY REf.1ARKS

SWINGING ARM, SUSPENSION UN ITS AIN D CHAINGUARD

1 F7375 SWINGING ARM 1 2 F4076 Pivot bush ... 2 3 F7342 Spindle . . . 1 4 F7270 Gaiter . . . 2 5 F4385 Shim 0.003 in. As required 5 F4386 Shim 0.005 in. As required 6 F10037 Left distance piece 1 7 S580 Pivec bolc-lefc 1 8 S579 Pivec bolc-righc 1 9 64052107 SUSPENSION UNIT (D2024) 2

10 64533645 Bonded bush (99-0122) ... 4 11 9054/171 Spring recainer (99-0107) 4

12 64543708 Spring, 100 lbs. chrcme (59-1048) 2 n 14-0235 Unic fixing bole 4

14 S25-2 Plain washer 8 15 14-1303 Nut 4

16 F7707 Chainguard 1 17 14-0101 Bolt 1 18 526-2 Washer ... 19 F4134 Front bracket 20 14-0113 Bole 1 21 F7343 Tab washer 2 22 NW100 Lubricator 23 14-0702 Self-locking nut 24 F9387 Scepped bole 25 S25-3 Plain washer ...

26 14-1302 Nuc. ...

27 14-0128 Bole 1 28 14-1303 Nuc 1

29 DS47 Nut . . . 1 30 99-0046 Spring washer ... 1 31 F7386 Brake operating rod 1 32 Split pin (-h in. x tin.) Reference only

• 33 F7387 Adjuster nuc 1 34 F11780 Brake torque stay 1 35 99-0046 Torque stay washe.r 36 14-1304 Torque stay nut 37 F6046 Front chainguard. 38 14-0101 Bole 39 S25-1 Washer ... 40 14-1301 Nuc 41 54033234 Stop lamp switch (99--0725) 42 F3158 Spring (315738) 1 43 T1076 Bole (t in. U.H.) 3 44 F4717 Self-locking nut s

45 F5687 Lever •.·, FS413 "D" washer '":I F7774 Right distance piece 1

48 14-0702 Nut 49 F4078 Th ruse washer ... Noc illus. WE170 Washer, lubricator

45

53

35�

37-(/ 36�

38---@

10

12� 11-9

11--e-·

�20 (1-�2:i

23 I.

�2

5 26

27

28

22

Fig. 20. TELESCOPIC FRONT FORK

46

7�

29

Ref No. Part No.

1 1 2 3 4 5 6 7A 7 8 9

10

11 12 13 14 15

16 17 18 19 20 20 21

22 23 24 25 26 27 28 29 30 31

33 34 35

36 37 38 39 40 41

42

+,; 45 46 47 48

H4120 H4119 H2288 H439 H2290 S25-2 14-1303 H2108 H2263 H3662 F6738 0623

S578 H2266 H2107 S684 S685 H2198 H2199 F4047 H1657 H1892 H189i 03273 H3635 H4167 D3274 H2119 H431

H441 H1896 H3904 H443 H2091 H2245 H3921 H3922 H1844 E3446 S2024 14-1202 H3894 H3893 H2154

H2127 H2090 H1062 H2126 H3682 H2270 F8245

DESCRIPTION

I TELESCOPIC FRONT FORK

FORK ASSEMBLY FORK ASSEMBLY

Middle lug and stem Bottom cone Pinch bole (2t in. U.H.) Plain washer Cleveloc nut Fork seem sleeve nuc Fork stem sleeve nut Top lug lock c/w 2 keys ... Key (state serial number)

Grub screw Sealing washer Locating pin Pinch bole (1t in. U.H.) Seated nuc ... Left top cover Right top cover Cork washer Spring abutment Main spring (Yellow/Green) Main spring (Yellow/clue) Plain washer Telescopic gaiter ... DUST EXCLUDER SLE=VE NUT

Oil seal "O" ring ... Plain washer Top bearing Damping sleeve STANCHION lower bearing Bearing nut Cap nut LEFT BOTTOM MEMBER c/w CAP RIGHT BOTTOM MEMBER. c/w CAP

Spindle cap .. . Plain washer .. . Stud ...

Nut, self locking Drain plug ... Sealing washer Shuttle valve Circlip Restrictor ... Aluminium washer Flanged bolt Bracket Cable retainer Scarlock washer

47

QUANTITY REMARKS

1 T100R 1 TiOOC 1 1 2

3 2 1 T100C 1 T100R 2 1 1 Key no's run from

EJ R 1 co EJ R SO

1 1 2 2 2 TiOOC 2 T1COR 2 2 2

2 2 2 2 2 2 2 2 2

1 2 4 4 4 2 2 2 2 2 2 2 1

1

35�

37--IJ 36� 38--@

.U

jO

12-----0 �

-· tl-9,,_

�20

IJ=-

2!

1

{Jr--23

�

25

26

27

28

33

Fig. 20. TELESCOPIC FRONT FORK

48

7�

29


TELESCOPIC FRONT F O_R K (cJncinued)

49 H3926 Square nut 2 5,') H722 Cap ... 2 51 S25-3 Plain washer -4 52 S589 Bole {1-k in. U.H.) ... -4 53 H1696 Top cover ... Available for use where

headlamp removed 54 H2208 Rubber mounting, headlamp bracket 2 55 H4121 Headlamp brackec-D.S. 1

55 H4203 Headlamp brackec-T.S .... 56 H2209 Rubber buffer 4 57 H2210 Washer, headlamp bracket 4 58 S2095 Accachmenc bole ... 4 l'ic� illus. F6784 Cable grommet (righc cop cover)

-49

V1 0

12

16 10 14

9

4 8

13 10 15

Fig. 21. FRONT WHEEL T100R

Front wheel complete NO 1

19

38 CII . 29 35 31 30

� Ref. No. Part No. DESCRIPTION QUANTITY REMARKS

I

FRONT WHEEL (T100R)

1 W3458 FR.ONT WHEEL COMPLETE 12 w1n1 RIM, SPOKES AND HUB ASSEMBLY 13 W1230 Front wheel rim (WM2-19) 4 W1328 Spoke (8/10G x St in. straight) c/w nipple 205 W1708 Spoke (8/10G x +Hin. 78°) c/w nipple 106 W1709 Spoke (8/10G x � in. 100°) c/w nipple 107 S79-2 Spoke nipple ... 408 W1722 Hub and brake drum 19 W3582 Wheel spindle 1

10 W653 Bearing 211 W1237 Dust cover12 D80 Circlip . . .

13 W3337 Bearing support ring14 W1481 Grease retainer 1

15 W582 Retaining ring 116 W3460 Cover place 17 W1197 Balance weight, t oz. As required18 W1198 Balance weight, 1 oz. As required19 W3461 BRAKE ANCHOR PLATE ASSEMBLY 1 20 W1996 BRAKE SHOE c/w LINING 2 21 Reference only Brake lining ! }Each shoe22 Reference only Brass rivet .... 23 W2026 Thrust pad 224 W135 Shoe return spring 2

.!.5 W2001 Brake cam 26 W3453 Brake cam lever (front) 127 14-1303 Nut 2 28 W3454 Brake cam lever (rear) ... 129 W2003 Rod assembly 30 W2005 Fork end, threaded31 14-0401 Locknut 132 W3522 Lever return spring 1

33 S1995 Anchor plate nut 134 WF32 Pivot pin ... 2.:: ... Split pin (+.- in. x tin. long) Reference only-·· S25-6 Plain washer 2 37 W1991 Anchor plate gauze (for air scoop) 138 S1998 Tapcite screw 339 E2351 Washer for taptite screws 3

51

V, N

12

16 10 14

9

4 8

13 10 15

25 24

Fig. 22. FF\ONT WHEEL TIOOC

Front wheel complete NO 1

25

23

38 CII 29 35 31 30

Ref No. Part No.

1 W34302 W21323 W12304 W21375 W21386 W21397 W21368 W33259 W3582

10 W653 11 W123712 T280 13 W333714 WHa1·15 WS82 16 W344317 W119718 W119819 W345520 W344621 Reference only22 Reference only23 W2026 24 W135 15 W200126 W3453 27 14-130328 W3-t54 29 W345030 W200531 14-040132 W3522 33 S1995 34 WF3235

:;o S25-637 W199138 S1998 39 E2351

DESCRIPTION

FRO NT WHEEL (T-100 C >'

FRONT WHEEL COMPLETE RIM SPOKES AND HUB ASSEMBLY

Fronc wheel rim (WM2-19) Spo�e D.S. . ..

Spoke T.S. Spoke T.S.Spoke nipple ... Hub and brake drum

Wheel spindle Wheel bearingDust cover Circlip Bearing support ringGrease retainer Retaining ring Cover place Balance weight t oz.Balance weight 1 oz.

-

BRAKE ANCHOR PLATE ASS EMBLYBRAKE SHOE c/w LINING

Brake lining Brass rivet

Thrust pad ... Shoe return springBrake cam ... Brake cam lever (front)Nut Brah cam lever (rear)Rod assembly Fork end, threadedLocknut Lever return springAnchor place nut ...Pivot pin . . .

Split pin (n- in. x fin. long)Pl.lin washer Anchor place gauze (for air scoop)Tapcice screw Washer for taptice screws

53

QUANTITY

111

201010 40112111

As requiredAs required1

2� }each shoe

221121

1

1

1

112 Reference only2 133

REMARKS

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

u, -"'"

43 44 34 33 35 26 30 31 13

12 3 15 21 7

11 20 19 10 17 46

Fig. 23. REAR WHEEL

5 5

4 6 4n 14

16 18

36 37 38

39 24 45 43

40 42 44

259

Re(. No. Part No.

2 3 4 4A 5 6 7 8 9

10 11 . '

13 14 15 16 17 18 19 20 21 22

24 25 26 27 28 29 30 31 32 33

35 36 37 38 39 40 41 42 43 4-i 45 46 417

W3607 W3610 W1007 W1107 W3402 W1108 S79-2 W3586 W1499 S2010 E1612 W3585 S2011 14-1202W3589W1474W1654W1022W653W3587W1710W1278W1024W3590S2013W1406W1407Reference onlyReference onlyW1415W135W3592W2014S25-6

W2027 W1488 W1635 W3588 W1477 0373 W1280 S2014 ·W2089W1015�'�-'!902S585

WM3w11

DESCRIPTION

REAR WHEEL

REAR WHEEL COMPLETE RIM, SPOKES AND HUB ASSEMBLY

Rear wheel rim WM3-18 ... Spoke (8/10G x 7-?. in. 90°) Spoke (8/1 OG x 7 ,'. in. 110°) Spoke (8/10G x 77 in. 90j ... Spoke nipple ... Hub ...

Sprocket, 46T Bolt Serrated washer Brake drum Bole (ti- in. U.H.) Self-locking nut ... Wheel spindle Grease retainer (brake side) Grease retainer Backing ring Bearing RETAINING RING

Locking screw (fr in. U.H.) Distance cube Distance piece Brake anchor plate Nut LEADING BRAKE SHOE CJW LINING TR.AILING BRAKE SHOE CfW LINING

Brake lining Brass rivet Thrust pad

Shoe return spring Brake cam Brake cam lever Plain washer Nut lever return spring Grease retainer ... Speedometer adaptor Distance piece Speedometer gearbox Plain washer Nut D.S. inner

Chain adjuster ... Adjuster end place Self-locking nut Spindle nut Tyre security bolt WM3 Pivot pin

55

QUANTITY

1 1 1

10 10 20 40

1 8 8 1 8 8 1 1 1 1 2 1 1

1 1

1 1 1 1

2 16 2 2 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2

REMARKS

Vl

°'

0 0

0

::·,,·· . /. · . ......

.i'.:?[i .

,, ..... ,,, .. ,.

0

I

I

33

1

6,.

Fig. 'H. FENDERS

I 4

T'i ,. Cl%�

. 9a

. I 10

��.-�

er .! : I 8 12 13

-

Ref. No. Port No.

1 H3884 1 H3882 2 H3663 2 H1681 3 H3664 3 H1683 4 H4046 4 H3885 s 14-0101 6 S25-1 7 14-1201 8 H1685 8 H1688 9 14-0113 9A H4071

10 D302S 11 14-011512 F4299 13 14-1302 14 14-011 S15 S25-3 16 14-0702 17 F12995 �7 F12876 13 F6916 19 14-0101 20 F6310 21 S26-2 22 14-1201 23 F6915 24 14-010225 F6310 26 S25-1 27 14-1201 •,."'I,

.. .: F12879 29 14-010230 S25-1 31 14-120132 F599433 F6031 34 14-0113 35 S25-336 14-1302 37 F7826 3c ·j ·:J-010239 S25-1 40 14-1201

57079 02391

43

4142

F4717 Not illus. 0343/3

DESCRIPTION

FENDERS

Front fender (stainless) Front fender Front stay Front stay Centre stay Centre stay Bottom stay Bottom stay Bolt } Washer Stays co fender Nut (Cleveloc) Bracket D.S. and T.S. fork leg to stays Bracket D.S. and T.S. fork leg to stays Bolt } ... Tab washer Brackets to fork leg ... Washer ... Bolt I T d ... W h

J op an centre stays -as er b k ...

N to rac et UC •••

Bole I Washer

J Bottom stay co

N fork leg UC

Rear fender (stainless) Rear fender Bracket ... Bolt } Washer Bracket to Washer fender Nut (Cleveloc) Bridge ...

Bolt } Washer Bridge co Washer fender Nut (Cleveloc) Lifting handle . . .

Bolt } Washer Lifting handle to fender Nut (Cleveloc) Clip Backing plate Bolt } Washer Clip to fender Nut (Cleveloc) Wiring protector

. . .

Bolt -1 Wiring protector to fond·��Washer Nut (Cleveloc) jReflector-red (99-1162) Washer ...Nut Cable clip

57

QUANTITY REMARKS

i

. 1 T100C 1 T100R 1 T100R

T1COC 1 T100R 1 r.1ooc 1 T100R 1 T100C 6

6

6

2 T100R 2 T100C 2· 2 2 2 2 2 2 2 21. T100C1 T100R 1 1 1 1 1 1 2 2 2 2 1 2 2 2 1 1 2 2 2 1

2 2 2

2

( \ \

---

- \

... .. -�-

I

\ I

\_

/ I

-e

I

\

58

C) "' u

IC::

0 0.. 0.. :, "' 0

z <

0.. :r < ..J ..J

�

Ref. No. Pare No.

1 F12877 2 14-0101 3 D2426 4 F12n7 5 F12728 6 14-0101 7 D2338 8 14-1301 9 H961

10 F13275 11 53973 ';2 54577109 13 144921 14 54525286 15 380

DESCRIPTION

TAIL LAMP AND SUPPORT

Tail lamp support Bole } . W h Tail lamp support-rear fixingas er

Rear number place brackec-L.H. ...

Rear number place brackec-R.H. . . .

Bok }

... Washer Number place bracket co fender ... Nut ... Grommet-tail lamp lead Rubber bleeding scrip ... STOP AND TAIL LAMP-679 (99-0597)

Lens (99-1046) Screw· (99-1189) . . .

Lamp base assembly Bulb (99-0542)

59

QUANTITY REMARKS

1

2 2 1

1 4 4 4

1 2 1 1 2 Reference only 1

Fig. 26. PA

12 13 14

NELS AND TWINSEAT

60

\ �

5

Ref. No. Pore No. DESCRIPTION

PANELS AND TWINS.EAT

1 F11358 Left panel and coolooxF11357 Toolbox screw ...

3 F11377 Washer ... 4 F10222 Captive nut5 F6673 Grommet 6 F11573 TWINSEAT7 F9715 Twinseat cover

Not illus. A52 Transfer, positive ear ch8 0697 Sp rag 9 0696 Trim scrip (bright)

10 F4898 Buffer front Noc illus. F7835 Buffer rear 11 FS026 Hinge front12 F7862 Hinge rear 13 S26-2 Spring washerH 14-0101 Bole 15 0374 Check wire16 02381- Self capping screw17 E1719A Washer ... 18 F4228 Spring 19 Splic pin (}

2 in. x � in.)

20 F7560 Seat knob and plunger Noc

{ D2105 Transfer Trophy 500 i!lus. 02106 Transfer Daytona

61

QUANTITY

'

1

12

1114 122

4 4 121 1 Reference only1 1 T100C

T100R

REMARKS

5

1---

3

®----16.

@----1,

§--1s

o----,9 @}--20

21

22·�

32� 31

--;:::-©

29

30 ---

•

27 �26�

C!9

. 27 GAS TANKFig. •

62

-·� y

13

e--10 0-_,1

Ref. No. Pare No. DESCRIPTION QUANTITY REMARKS

I

GAS TAN KS -

}.fj-b3 �--� FHSEH Pefrol tank .. r 1 T100R. : .E.11 SOJ. Pcc1 o! eafik 1 T100C 2 F9701 Styling unit (left) 1 3 F11339 Styling unit screw (27/64 in. O.A.) front 2 4 F7888 Styling unit screw (35/64 in. O.A.) rear 2 5 F9700 Styling unit (right) 1 6 F8192 Left knee grip ... � }Av�ilable 7 F8193 Right knee grip 8 F10007 Centre styling strip 1 9 F10008 Hook, screw 1

10 F4019 Serrated washer 1 ...

1 I H919 Nut 1 : :� F7388 Rear bole 13 F5336 Double spigot rubber ... 14 F967 R.ubbt,r washer ... 1 15 F3814 Cup 1

16 F5228 Rubber washer ... 2 17 F5229 Spigot rubber 2 18 F3814 Cup 2 19 S1883 Scud 2 20 14-1302 Nuc 2 21 F13875 FILLER. CAP 1 21 F4048 Joint washer 1 ' F3217 Jack chain 1 24 F12801 Petrol tap-D.S. 1 25 F12800 Petrol tap-T.S. 1 26 E7351 Petrol tap seal 2 27 F10002 Steel washer 2 28 F1000 Tap nuc 2 29 F12903 Reflector bracket 2 30 57183 Reflector, amber (99-1161) 2 31 D2391 Washer (front reflectors) 2 32 F4717 Nut (front reflectors) ... 2 Not {A56 Transfer, World Speed Record 1 iP:.:::. ,A61 Transfer, Made in England

D2105 Transfer, Trophy 500 1 D2106 Transfer, Daytona 1

:63

5

4

19·

�----�

10

. 28 OIL TANK Fig. •

64

-20

ifi

. 22


j

0 IL TANK

· 1 F13290 Oil tank ... 1

2 F9659 FILLER CAP AND DIPSTICK 1

3 F-4047 Joint washer 1

4 F5343 Drain plug 1

5 99-0048 Fibre washer 1 6 F3179 Oil tank filter 1

7 F1713 Fibre washer 1

8 F3655 Upper feed pipe 1

9 F3182 Union nut 1

10 E-4594 Flexible connector, long 2

11 E6848 Clip 4

12 E7203 Oil pipes and junc:ion block ... 1

13 E11458 Joint washer H E3446 Plain washer 1

15 S1908 Nut 1

16 F6039 Grommet 1

17 E6849 Clip (rocker pipe) 1

18 F9255 Front s·trap 1

19 F8028 Rear strap 20 F6673 Spigot rubber 4

21 F6968 Rubber washer ... . ... 2

22 H-0103 Bole 2

23 14-0701 Self-locking nuc . . . 2

24 H3894 2 BA Screw .. . 4

25 F4717 2 BA Nut 4

26 F7510 Screwed peg 2

27 S25-13 Plain washer 4

28 14-1301 Nut 3

29 E6353 Rubber connector 1 30 E7576 Rocker oil feed pipe 1

31 F6898 Bracket •.. 1

32 F8034 Spigot nut 1

Not illus. 01816 Grouped transfer "Drain and Refill" etc. 1 33 E11149 Breacher·venc pipe 1 34 D2253 Clip breacher vent pipe ·233 F11610 'T' piece connector 136 F11613 Froth cower vent pipe 137 F11614 Breacher pipe, rear guard 138 02252 Clip, pipe co 'T' piece 1

39 F11615 Clip, pipe to rear guard 1

65

--:�22....?,.-

4

J-- -- 7

----6

17

21

re�-- �� 22 j e:z-s;§§)i"·�e, ·?

,ca: ---- . ..;;--- -

ND AIR FILTER Fig. 29. BATTERY, TOOLKIT A

66

8

18 20

23

19

c:a

Re(. No. Port No. DESCRIPTION QUANTITY REMARKS

BATTERY, TOOLKIT AND A I R -· F I L T E R

1 54027029 Battery PUZ5A (99-0719) 1 2 F7431 Vent pipe 1 3 F8033 Battery retaining strap 1 4 F8032 Battery scrap anchorage 5 F8024 Battery carrier ... 6 F8031 Battery carrier rubber 1 7 F8091 Battery carrier tray 1 8 54938986 Fuse assembly .. . 1 9 F11609 AIR FILTER 1 or 2

10 F6866 Filter element (Filter cloch and gauze) 1 or 2 11 F4810 Clip for cover 1 or 2 n E12086 Adaptor 1 er 2 13 0708 Clip 1

02110 TOOL KIT 1 14 0291 Tool roll 1 15 D2251 Ring spanner 1f in. x 1 f. in. AF. 1 16 D370 Ring spanner

13. in. x tin. WHIT: .. 1

17 D2084 Open end spanner t in. x 1

1• in. AF. 1

18 DA16 Open end spanner f in. x /. in. WHIT 19 D2184 C spanner 20 D2185 Tappet spanner 21 D87 Box spanner for sparking plug 22 0767 Screwdriver c/w blade 13 D1911 Tommy bar

67

I

··1

63

VI C: w > w ..J

..J

0 C: 1-z

0 u

0

z

<

C: < c:l w ..J 0 z

� J:

0 M

04 ii:

Re(. No. Part No. DESCRIPTION QUANTITY REMARKS

I

HANDLEBAR AND CONTROL LEVERS

1 H4251 Handlebar Available 1 H4252 Handlebar (Western) 1 2 H1425 Sleeve, handlebar mounting 4

3 16/364 TWISTGRIP (99-0248) 1 T100C 4 16/328 Body, top half (99-0245) ... 1 5 16/329 BODY, BOTTOM HALF (99-0246) 1 6 16/008 Friction spring Reference only 7 16/009 Screw ... Reference only 8 16/010 Locknut Reference only_9 99-0244 Rotor

10 11 /013 Screw (99-0225) 2 11 H2125 Grip ·;·2 16/011 Cable stop (99-0241) 13 H2124 Grip 14 12/608 AIR CONTROL LEVER (D3246) 15 12/556 Lever Reference only 16 12/607 Bole ... Reference only 17 12/606 Cap ... Reference only 18 12/033 Spring washer Reference only 19 12/040 Clamp Reference only 20 11 /014 Screw Reference only 21 D3583 Front brake lever (alloy) 1 2! D3143 Front brake lever (steel) 1 T100C . . D3657 Clutch lever (alloy) 1 ..,_ D3144 Clutch lever (steel) 1 T100C .1.i..

23 S2048 Pivot pin 2 24 14-1301 Nut 2 25 D3585 Adjuster ... 2 26 D3586 Lockring 2 27 39596 HANDLEBAR SWITCH-L.H. Reference only 28 54033666 Switch half ... Reference only 29 54340882 Lever half (99-1187) 1

30 54115246 Screw (99-1188) . .. 4

31 39595 HANDLEBAR SWITCH-R.H. Reference only . , . 54033667 Swiech half ... Reference only 33 54340883 Lever half (99-1215) 1 34 54115246 Screw (99-1188) ... 4

35 H3602 Steering damper rod c/w knob 1 36 H565 Washer ... 1 37 H1618 Rubber sleeve 1 38 H2108 Sleeve nut 1

39 H435 Friction disc 1 T100C

40 H1797 Anchor plate 1 41 H95 Spring place 1 �2 H3601 Adjuster sleeve ... 1

69

14

16

22 21 C24

Fig. 31. c ONTROL CABLES

70

Ref. No.

.. I

l

3 4

5 6 7 8 9

10 11 ·-·iJ14

15 . 16

17 18 19 20 21 22 "'!?

..... �:

25 26 27

Part No.

01823 01822 D1994 02076 D2086 WF32

D3270 D3271 D3272 244/104 D745 ....__ XA69 D343/7 F9918 H4112 313 /13 18/084 313/020 313/021 16/008 210/007 5/077 313/004 210/008 5/077 H2125 16/011

DESCRIPTION

CONTROL CABLE.S

Throttle cable Throttle cable Clutch cable Front brake cable Cover, scop switch Pivot pin Split pin .... Air control cable AIR CONTROL CABLE

Cable, lever co junction box Junction box (0685) Cable, junction box co carburetor

Clip, metal Clip, rubber Clip, metal Cable clip TWIN ROTOR TWISTGR!P (99-0347)

Screw (99-0251) ...

Body, top half (99-0348) ... Body, bottom half (99-0349)

Friction spring Screw ... Nut

Rotor (99-0344) Rotor stop (99-0338) Nut (99-0224) Grip Cable stop (99-0241)

71

QUANTITY

j j

... 1 T100C 2 T100R 1 1 1 1 Reference only 1 T100C 1 T100R 1 1

2

} As required

4

1 T100R 2

1

}R,fmna ooly

1

1

1

2

REMAH.KS

25�

3

t)--9

20

ss

1

2---®=@

Fig. 32. TIOOC IGNITION CAPACITOR AND HEADLAMP

72

Ref. No.

�

I

.·•

3 4

s

6 7 8 9

10 11 12 ... �.,,

., -

1-:-

15 16 17 18 19 20 21 22 23 °' , - .

15

26 27 28 29

Part No.

T 100 C

54170009 54483156 60261 534343 54525272 504665 370 54573590 989 554602 35710 144921 534296 54363454 281 54363455 54363453 54140331 54525212 47638 54420128 54418528 54418526 F8082 E4638 F10033 G5299 F3799 862217


IGNITION CAPACITOR AND HEADLAMP

Ignition capacitor (99-0737) . . . Available Mounting spring (99-0778) . .. Available HEADLAMP COMPLETE-MCH66 (99-1219)- 1

Rim (99-0691) 1 Light unit (99-1212) 1 Fixing wire (99-0683) 6 Main bulb (45/35 W) (99-1214) ... 1 Bulbholder, pilot (99-0695) 1 Pilot bulb (99-0548) 1 Bulbholder, main ... Reference only Lighting swicch (99-0563) 1 Screw Reference only Place Reference only Warning light, red (99-1208) 1 Bulb (99-0537) 3 Warning light, green (99-1209) ... Warning light, amber (99-1207) 1 Sealing washer (99-1210) ...

• ·,! 3 Warning light shield Reierence only

CAPACITOR PACK-2CP Reference only Capadcor (99-1043) 2 Cover (99-0767) ... 1

Base place (99-1160) Capacitor pack bracket 1 Screw, bracket co frame 2 Bole 2 Shake proof washer 2 Nut 2 Grommet Reference only

73

22

27

Fig. JJ. IGNITION COILS, HORN,

74

\

32

15

ZENER DIODE RECTIFIER ANO

20

I

I

Ref No.

1

2

3 4 5 6 7 8 9

10 11 12 . · .,

.i }

15 16 17 18 19 20 21

22 23 ::�

26 27 28 29 30 31 32 33 34 �';

- .37

Part No.

IGNITION

45223 D262 F11533 14-0103S25-114-130114-0114S25-314-13021310231883301e.604354942078

· 54190042N4

F7552F4771F3799GS29949072F5338H223749345H426214-6102S26-214-0113S26-3H2275541900003504854385091D3654F10033E2351F4717S25-13


' '

CO I LS, HORN, RECTIFIER·AND ZENER DIODE

Ignition coil (D2206) Lucas type 17 M12 2 Plug cover 2 Coil bracket 2 Bole (Coil to bracket) ... 4 Washer ... 4 Nut 4 Bolt (Coil bracket co frame) ... 2 'vVasher ... 2 Nut 2 Pl:1in washer E2351 4 Serrated washer (GS299) 4

Nut (F3799) 4

Lucar connector As required Insulating cover ... As required Champion sp:1rking plug Reference only Hern (Clearhoocer 27899) 1 Screw (i in. U.H.) 2 Nut 3 Serrated washer 3 Rectifier, type 2DS 506 (99-0589) Nut 1 Heat sink 1 Zener Diode (99-0590) 1 Heat sink bracket 1

Bole Washer ... 1 Bole, bracket to fork lug 1 Washer ... Plug, heatsink ... 1 Earth blade, rectifier (99-1159) 1

Flasher unit (99-1201) ... 1 Clip, flasher unit (99-1204) 1

Spring Bolt Washer Nut 1

Washer

75

Fig. 34.

1

22

23

G HARNESS, S WIRIN HEADLAMP,

. 76

I

27

15

1� "

��@� I 20 21 19

C34

28

24

. NO TAIL LAHP WITCHES A

Re(. No. Part No. DESCRIPTION QUANTITY REMARKS

1 HEADLAMP AND FLASH E·R 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 14492 Screw Reference only

6 534296 Plate Reference only

7 370 Main bulb (45/35W) (99-1214) ... 1

8 554602 Bulbholder Reference only

9 989 Pilot bulb (99-0548) 1

10 54573590 Pilot bulbholder (99-1213) 1

11 54363454 Warning light (Red) (99-1208) ... 12 54363455 Warning light (Green) (99-1209)

13 54363453 Warning light (Amber) (99-1207) 1

14 54140331 Sealing washer (99-1210) ... 3

15 35710 Light switch (57SA) (99-0563) 1

16 54525212 Shield, warning light Reference only

17 281 Bulb, warning light (99-0537) 3

Not illus. 54959628 Wiring harness (99-1158) 1

18 31899 IGNITION SWITCH (TYPE S45) (99-0558) 1

19 54130041 Nut ... Reference only

2C F6981 IGNITION LOCK C/W KEY 1

21 D622 Key (state serial number) As required

22 H2262 Cover, ignition switch 1 --, 56147 FLASHER. LAMP (99-1109) 4 1 . .J

::� 54581638 Lens (99-1191) 25 54580300 Gasket Reference only

26 554548 Bulbholder Reference only

27 573832 Interior assembly ... Reference only

28 382 Bulb (99-1192) 1 29 54123401 Screw (99-1193) ...

2 30 54582414 Stanchion, flasher lamp (99-1194) 4

31 E2534 Washer ... 4 32 1981721 Locknut (99/1195) 4 33 862217 Grommet Reference only r:ot illus. W2321 Shakeproof washer 4

77

3---,.

,,

' y.'·

9

:::-, 34�

;

4

rll

15 27

25--0

28

26-il

23

33 16 18 17 19 20

Fig. 35. SPEEDOMETER AN D TACHOMETER

78

' '

8

I I

29

�

31

@

22 21

32

Re(. No. Port·No.

·123456789

1011

� .:.•

H 15 16 17 18

.19 20 21 22 23

._;.

15 26 27 28 29 30 31 32 33 34

SSMS007/02 54953387 987 H1946 H1929 30-282-014-1130-276-037-11S59041-148-203H1702H1701H166814--0103S26-20692E9438E9332Reference onlyReference onlyE5157E5759E6300E5578E12875E6299Reference only03522E58810648RSM3003/1331-371-3980494E7351F4366

DES CR/PT/ON QUANTITY REMARKS

I

S P E E D O M E T E R A N D T A C H ·o M E T E R

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

Metalastik bush Washer ... Nut Bolt (1-fi" in. U.H.) Trip control Distance piece ... Sleeve nut Bracket ... Bolt Spring washer Speedometer cable (63 in!. long) (D692W inner only) TACHOMETER GEARBOX (Sody E5757)

Securing screw (Left hand thre2d) UNF Bush ... Flanged bush ...

Driving gear End cap "O" ring ... Driven gear Driven gear housing

"O" ring Bush

"O" ring .. . Sec screw .. .

Tachometer cable (26t in. long) Tachometer (02396)

. Spade (99-0173) Circlip .. ." Sealing washer ... Spacer

1 .

Reference only Reference only 1

2 T100R (Can be fitted2 2 co TtOOC)

2 1

2 2 1

2 2 1

1

1 1

1

1 1

1 1 1 1

1

1

1 1

1 1

.1

1

2

T100C

T1COR (Can be fic:eci to T100C)

STANDARD HARD WA RtE SPECIFICATION BOLTS

Lengch under Min. /engch Part No. Material Thd. dia. head of thread He�ogc,, A.F. $1822 Steel •5•. UNr I • - .l.!.. o.5oo· 2 ...

$1910 t· UNF I J • I J • 0.565. ,, .. ..

$1919 ·-r.· UNC 11 • ., . o.5oo· 'i$2010 ±" UNF I J • ,. 0.375· ,, .. 4 14--0101 ±· UNF I• 0.438" l 1+-0102 1· UNF '. 0.438" ,, .. . i 14--0103 ±" UNF '. 0.438" •

14--0105 ±" UNF 1 • 0.438. 1+-0113

15,.

• UNr s. o.soo· •

1 +-011-4 -f." UNF J. o.5oo· 4 1+-0115 -h" UNF 7• o.5oo· 'i 1+-0116 -f." UNF 1 • o.5oo· �4-0126 f. UNF ' . 0.563' 4 1+-0128 t· UNF 1. · 0.563.14--0132 f; UNF ., . 0.625 • •

1+-0201 ±· UNF 1. ,. 0.438" 4 14--0202 ±" UNF 1l. ,. 0.438" 4 14-0205 ±· UNF 11 •

,. 0.438. 2_ 4 14-0208 ±· UNF 2.!." ' . 0.438" •

H-0216 -f.. UNF 1l. 7• o.5oo· •

14-0217 -f." UNF 1l" ., . o.soo· 'i' 14-0219 -r.· UNF 1-r

7• o.5oo· 'i 14---0220 "to. UNr • l. 7• o.soo· I Z° 'i' :·!-0221 -t;" UNF 2' ., . o.sco· 'i i+-0222 -f." UNF 1.!." .,. o.soo· -. 'i' 1+-0225 -f." UNf 3· �- o.soo· i' H-0228 -r.· UNf 4·· .,. o.soo· • 14-0234 f" UNF 12 • 1· 0.563.

14-0235 t• UNF r 1 • 0.563" 14-0236 t' UNF 21· 1" 0.563" 14-0237 t" UNF 2t' 1· 0.563" 1-4-0239 r UNF 3• 1" 0.563. 14-0241 t• UNF .., I, 1· 0.563" .l1 14-02-42 f" UNF -4• 1 • 0.563. H-0251 ,' •• UNF 22' 1l' o.62s·

..

·: �-6101 {-" UNC I • 0.438" l H-6102 ±" UNC s. 0.438. •

1-4-6115 "to. UNC 7• o.soo· i 1-4-6121 -?.' UNC 2t· o.soo·

01

NUTS

Part No. Material Thd. dia. Hexagon A.F. Thickness Remcrks

S778 Steel No. 10 UNF 0.375' f 0.225' Clevelcc S1852 rt• UNf 0.437' 0.330' Philichs S1906 ±" UNF 0.438" 0.188' Plain S1908 .. -t.. UNF 0.438" 0.313. Plain S1914 i" UNEr 1.125· 0.250' Plain S2012 -f' UNEF 1.313 • 0.438" Plain S2013 .. t' UNEF 1.313• 0.313" Plain S2014 .. f ° UNEF 1.313' 0.438" Plain H-0301 .. {-' UNF 0.438' 0.224" Plain 14-0302

" 1;' UNF 0.500' 0.271' Plain 1+-0303 .. l° UNF 0.563' 0.300" Plain 1+-0304 7 • 0.688" 0.375' Plain 14-0401 ±' UNF 0.438' 0.161' Lock 1+-0402 .. f.' UNf o.soo· 0.192' Lock 14-0403 t' UNF 0.563" 0.224" Leck 14-0404 -?.' UNF 0.688" 0.250· Lock 14--0701 ±' UNF 0.·138' 0.203' Phi lie as 14-0-702 -r-;' UNF o.500" 0.246' Philidas 14-0703 t· UNF 0.563". 0.296' Philicas 14-1201 ±· UNF 0.438" 0.285' Seiffnuc H-1202 -!.' UNr - o.5oo· 0.335• Stiffnuc 14-1301 ±' UNF 0.438' 0.245' Seif.nut 14-1302 f.' UNf o.soo· 0.290" Seif.nut 14-1303 t• UNF 0.563" 0.320' Seiffnut 14--1304 -?.' UNf 0.688" 0.375' Stlffn ul. 14-1305 -}' UNf 0.750' 0 .!1 �. Sciffnt.:: . . �.)

14-1901 ±' UNF 0.438" 0.233' Ny lee 14-1902

" f.' UNF o.soo· 0.361' Nyloc 14-1903 .. t• UNF 0.563" 0.375" Nylcc

SCREWS

Part No. Type of head Material Thd. dia. Length under head Type of drive S1916 Cheese head Steel ±' UNC 11.· Cross recess • S1917 Cheese head

" :t-' LiNC 21· Cross recess • S1918 Cheese head ±" UNC 22" Cross recess

I

$1920 Hex. head ±' UNC ", Cross recess ..... S1929 Countersunk 82°

±' UNC I 11 Slot TI

$2079 Cheese head No. 10 UNF '. Pozidrive l

14-0604 Cheese head ±' UNF I• Cross recess l

14-6504 Countersunk (82°) ±' UNC l' Cress recess 4

14-6505 Countersunk (82°) ±' UNC 7• Cress recess i'

14-6606 Cheese head ±' UNC l' Cross recess• 14-6607 Cheese head ±' UNC 7• Cross recessi'

14-6608 Cheese head {-' UNC 1· Cross recess14-6609 Cheese head ±' UNC 1.!. •.

Cross recess.. 14-6610 Cheese head ±' UNC �,- Cross re-::e!s1!

14-6611 Cheese head ±' UNC 1t' C:-::s� re�e!s

14-6612 Cheese head ±' UNC r Cress rece!s 14-6613 Cheese head ±' UNC 2.1.· Cross recess .. 14-6614 Cheese head ±' UNC 2f' Cress re-::es:. 14-6615 Cheese head ±' UNC r C:-css r�-:e!:�

14-7004 Socket head ±' UNC I• f-iex. seeker: ..

14-7019 Socket head s • 7• Hex. socket

... 'i

14-7024 Socket head I • 2· Hex. seeker: I>

22

WASHERS-PLAIN -

Pare No. Material ifdia. o/dia. ' Thickness S25-1 Scee I 0.273• 0.563" 0.048.

S25-2 Scee! 0.358" 0.750· 0.063'

S25-3 Sc eel 0.336. 0.625" 0.063"

S25-6 Scee! 0.531 • 1.031' 0.092'

S25-13 Steel 0.266" OA6r 0.064"

S25-71 Scee! 0.453. 0.750· 0.06-V

WASHERS-SPRING

Port No. Material if dia. o/dia. of a heighc Thickness S26-1 Spring Scee! •r clearance 11 • .i..• 0.104· TI �2

S26-2 Spring Scee! ± • cl ear:.nce I J • 1 • 0.064. TI

S26-16 Spring Scee! 11 • ,. 7 • o.o�o-sTI i . TI

S648 Spring Scee! ff

' clearance I • 5 • o.oso·l

,::._ Double coil.

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British OnlyMOTORCYCLES AND PARTS INC.

32451 PARKLANE ST GARDEN CITY, Ml 48135 USA

PHONE: 800-278-6659FAX: 734-422-9253

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TotalMichigan ResidentsAdd 6% Sales TaxAmountEnclosed

Year: Make: Model:

Signature

Email

Phone Fax

City/State/Zip

Address

Name

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Date Customer # Salesperson



PHONE: 800-278-6659FAX: 734-422-9253

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Frame #

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