REPLACEMENT PARTS - JRC Engineeringjrcengineering.com/wp-content/uploads/2015/09/T20-1957-58.pdfTriumph Replacement Parts may ... the sender must be inserted ln the space provided

REPLACEMENT PARTS

CATALOGUE No. 5

for the

tiger cub

..

200cc O.H.V. Models T20 and T20C

From Engine No. 26276

Triumph Enginee'ring Co. Ltd., Meriden Works, A/lesley, Coventry Tel. Meriden 331 Ref. 390'58 Published jan. 1958

PREFACE

BEFORE ordering parts for your machine, please read very carefully the instructions contained in the next paragraph. In many cases the information given in the order 1s insufficient to enable us to identify the customers' requirements with

certainty. Delay is frequently occasioned by our having to refer the order back for further particulars before we can supply.

HOW TO ORDER. Every part is indicated by a number and this should be quoted together with the description. In order to assist customers, parts where possible have been listed in order of assembly and exploded illustrations show the assembly order also. By each illustration, is an index quoting the part numbers of the various items and a cross reference to enable the customer to recognise the part by description (See page 59 for further details). With these aids there should be no difficulty in identifying the parts you require. Always quote the engine number and prefix letter stamped on the front engine fixing lug. Always use a separate sheet of writing paper for your order if you are sending a letter as well.

SPECIMEN ORDER

To Triumph Engineering Co. Ltd., Spares Department, Meriden Works, Allesley, Coventry.

Engine No. T.l0-28462

Please supply :-

GSTI0/56

Ell46

Gasket Set

Valve, Inlet

" Send C.O.D. Wm. Smith,

2/6/57

Ia, Ewell Avenue, Ewell, Surrey.

• For terms of business see page 3

TELEGRAPHIC ORDERS. Orders by telegram should be addressed to "Trusty 60211 Coventry." They are then telephoned to us, which prevents delay in delivery. It is only necessary to quote part numbers in telegraphfc orders~ the description can be omitted.

PATTERNS AND PARTS FOR REPAIR. It is not neces\ary to send patterns if the part number is quoted. The sending of patterns often delays the order as parcel post or rail takes longer than letter post.

2

'

Parts sent to Coventry for repair, replacement or as patterns, should bear the sender's name and address and clear instructions should accompany the parts. All parts must be forwarded carriage paid and care should be taken to ensure that all remittances are sent separately and not enclosed with the parts. Fragile units such as cylinders. etc., should always be boxed to avoid damage in transit. Complete machines should have all fitments such as horns, driving mirrors, tools, etc., removed by the sender before despatch, as it is impossible for us to accept responsfbility in the event of loss in transit. We are always pleased to give estimates for overhauls and repairs, but should an estimate not be accepted, a charge will be made covering cost of dismantling and re~assembling, if carried out.

Communications relating to parts should be addressed to the SPARES MANAGER and for repairs, guarantee claims and technical advice to the SERVICE MANAGER.

In order to facilitate quick reference, the quoting of any order number, invoice number or reference from previous communications is of essential importance. Accessories not of our manufacture should be sent direct to the actual makers, whose names and addresses appear on page 47.

WHERE TO OBTAIN. Triumph Replacement Parts may be obtained from any Triumph Dealer. and we recommend our customers to place their orders with the Triumph Dealer in their district, as we do not normally supply direct:. When parts not usually asked for are required, and for which the Dealer may have to wire or obtain specially, the postage or carriage incurred becomes payable.

We are not able to supply Transfers as originally affixed to Triumph Motor Cycles, but we are at all times willing to supply a Transfer denoting that the machine Is of genuine Triumph manufacture. providing the Frame and Engine prefix letters and numbers are quoted.

Customers are warned against the risk incurred by purchasing parts which are not of genuine Triumph manufacture. The risk is eliminated if parts are ordered as instructed. either from our recognised Dealers, or direct from the Spares Department, Meriden Works, Allesley. Coventry.

TERMS OF BUSINESS

THE most convenient method of paying for spare parts Is by the C.O.D. system. By this method you pay the postman for the goods when he delivers them to you. As the minimum C.O.D. collection fee is I i2 only goods to the value of 2/- or over can be sent

by this system. We do not despatch goods by rail C.O.D.

Where goods are not sent C.O.D., cash must accompany the order. All remittances should be made payable to the Triumph Engineering Co .• Ltd., and crossed "Barclay's Bank ltd.". if in the form of Postal Order or Cheque. letters containing currency notes must be registered.

Should a remittance be forwarded by telegraphic money order, the name and address of the sender must be inserted ln the space provided on the Post Office requisition form for a private message from remitter to payee. Unless this is complied with the Post Office omit such information from the telegram and we are not then in a position to trace the sender.

Postage, carriage and packing is charged at 5% on the value of the goods, minimum charge 1 /~. Packing boxes, cases, crates, etc., are charged for at cost and are returnable.

3

MODEL T20

MODEL T20C

4

...

CARTON PACK - GROUP I

CARTON PACK- GROUP I The following sub-assemblies are supplied in carton packs under the C.P. part number

stated. The contents of these carton packs are preserved and will not deteriorate under adverse conditlons.

Part Na. Description and Contents

Big End Assembly

CP.ISS E3624 Connecting rod c/w bushes E3600 Crankpin cjw plug

Brake linings

CP.I28 2 W978 Linings 14 W979 Rivets

Piston Assembly

CP.I41 ... E3358 Piston body E33BO Ring, chrome compression E656 Ring. compression E3387 Ring, scraper E1750 Pin, gudgeon

2 El767 Cirdip. gudgeon pin

Piston Rings

CP.150 I ... E3380 Ring, chrome compression I ... ... E656 ... Ring, compressfon

... E3387 Ring, scraper

Steering Races

CP.I29 2 H835 Cup, steering race 2 H833 Cone, steering race

30 S70-3 Ball, steering race

Valves

CP.I24 ... . .. E3146 Valve, inlet E3147 Valve, exhaust

Valve Guides

CP.I22 ... 2 E3208 Valve guide, inlet and exhaust 1 E3109 Cirdip

Valve Springs

CP.I23 ... 1 ... E3114 .. . Spring, valve Inner 2 ... E3215 ... Spring, valve outer

For Indexes see Pages 56 to 59

5

GROUP 2 -ENGINE

REPLACEMENT PARTS REF. No. PART No. DESCRIPTION QUANTITY

ENGINE- GROUP 2 1//ustroted on Poge I 0-Fig. I

CYLINDER BARREL T20TZOC

E3385 Barrel, cylinder 2 E3386 Dowel, cylinder barrel to head 2 2 3 E3368 Washer, cylinder base

PISTON

4 CP/41 Piston c,/w rings, gudgeon pin, etc.

5 E656 Ring, compression (top) 6 E3048 Ring, compression (taper) 7 E3387 Ring, oil control

8 E/750 Pin, gudgeon 9 E/767 Circlip, gudgeon pin 2 2

CYLINDER HEAD

10 E3661 Head, cylinder c/w guides and adaptor ' II E3217 Gasket, cylinder head 12 E3207 Adaptor, cylinder head exhaust 13 E3210 Stud, rocker inspection cover ... 2 2 14 E1987 Stud, cylinder head to carburetter 2 2 15 E3230 Nut, cylinder head to barrel 4 4 16 E3446 Washer, cylinder head to barrel 4 4

OVERHEAD ROCKERS, COVERS

17 E3251 Rocker, inlet assembly ... 18 E3252 Rocker, exhaust assembly 19 E3222 Ball pin, rocker 2 2 20 E3223 Adjuster, rocker 2 2 21 GS662 Locknut, rocker adjuster pin 2 2 22 E3225 Spindle, rocker inlet and exhaust 2 2 23 E32S; Sealing ring, rocker spindle 2 2 24 E2534 Thrust washer, rocker spindle L.H.-f." 4 4 25 E2594 Thrust washer, rocker spindle R.H.--r 2 2 26 E3224 Thackeray washer, washer, rocker spindle (spring) 2 2 27 E3227 Cover, rocker inlet inspection

28 E3228 Cover, rocker exhaust inspection 29 E3226 Washer, rocker cover joint 2 2 30 E3290 Nut, rocker cover to head 2 2 31 E2441 Washer, rocker cover to head nut 2 2

6

REF. No. PART No.

I

2 3 4 5 6 7 8 9

10 II 12 13 14

15

16 17 18 19 20

21 22 23 24 25 26 27 28 29

30 31

E3146 E3147 E3208 E3209 E3214 E3215 E3301 E3213 WE259A

EH72 E3537 E3172 E3540 E3391

E3285

E3244 H400 El335 E3249 E3383

E3653 E3596 E3598 E3420 E3624 E3623 El762 E3600 E3292

E3909 E3910

ENGINE -GROUP 2

DESCRIPTION

VALVES, GUIDES & SPRINGS Valve, Inlet Valve, exhaust . " Guide, inlet and exhaust Clrdip, inlet and exhaust guide Spring, valve inner Spring. valve outer Collar, valve spring top Cup, valve spring bottom Cotter. valve split

PUSH RODS AND COVER Rod, push Cover, push rod Peg, cover to crankcase locating Washer, push rod cover joint (upper) Washer, push rod cover joint (lower)

TAPPETS Tappet

ROCKER OIL PIPE Pipe, rocker oil ... Nut, rocker oil pipe to spindle Washer, rocker oil pipe inner joint ... Washer, rocker oil pipe outer joint Connection, oil tank to oil pipe (Rubber)

FLYWHEELS AND CONNECTING ROD Flywheels and connecting rod assembly Flywheels c!w mainshaft LH. Flywheels c/w plugs R.H. Plug, R.H. Flywheel Rod, connecting with bushes ... Bush, big end Bush, small end ... Crankpin cjw plugs Plug. crankpl n

SPECIAL NOTE. Subsequent to Engine No. 35847 use ·

Flywheel and connecting rod assembly Flywheel, c;w mainshaft L.H.

7

QUANTITY

TlOTlOC

I I I I 2 2 2 2 2 2 2 2 2 2 2 2 4 4

2 2 2 I I I

I

2 2

I I 2 2 2 2 2 2

I

I I I

2 2 I I I I I I

I 2 2

GROUP 2- ENGINE

REF. No. PART No.

I 2 3 4 5 6 7 8 9

10

II 12 13 t• IS 16

17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32

E3563 E3365 E3171 T989 E3169 E3560 Tl076 E2615 El335

E3930

E3655 E31n E3175 E3518 E31S2 E3379

E3178 E3421 E3185 E3184 E3183 E3186

E3393 E3409 EHIO E3194 E3195 E3412 E3413 570..4 E3191 Tl124

DESCRIPTION

CRANKCASE

Crankcase assembly c/w bushes Stud, crankcase to cylinder head Stud, crankcase to oil pipe junction block Dowel. crankcase to R.H. inner cover Dowel, crankcase to oil junction block Pipe, crankcase oil return Screw, crankcase oil return pipe Plug. crankcase oil gauge test hole Washer, crankcase plug

SPECIAL NOTE. Subsequent to Engine No. 35847 use :

Crankcase assembly cfw bushes

CRANKCASE BEARINGS (ENGINE)

Bearing, R.H. (Plain) Peg, R.H. bearing Bush, camshaft ... Bush, distributor and oil pump shaft ... Bearing, L.H. (Ball journal) Oil Seal, L.H. Bearing ...

TIMING GEARS AND CAMSHAFT

Pinion. timing and distributor drive Bolt, timing and distributor pinion Pinion, camshaft (SOT) ... Key, camshaft pinion Camshaft, Inlet and exhaust Pinion and shaft, distributor and oil pump drive

OIL PUMP Oil pump assembly Body, oil pump ... Plunger, oil feed PI unger, oil scavenge Rod, connecting drive Pin, connecting drive rod Cirdip, connecting drive rod Ball, oil pump body Spring, oil pump body and auxiliary valves Ball, auxiliary valve

8

QUANTITY

T20 T20C

2 I I

I I

I 4 I 2

I I 2 2 4 4 2 2

..

REF. No. PART No.

2 3 4

s 6 7

8 9

10 II 12 13 14 IS 16 17 18 • 19 20 21 22

23 24

2S 26

27 28 29 30 31 32

E3192 E3197 GS299 E3188

E3177 E3176 E330l EIS64 EIS77

E3664 E3199 T989 E3460 E3603 E3204 E344S DSS7 WEI70

E391S Tl492 E3932 E3933

E3S81 W9S4

E3912 E3913

E3667• E3S79 E320S E3200 E3668 E3204

ENGINE- GROUP 2

DESCRIPTION

Plug, oil pump body Bolt, oil pump to crankcase ff in. U.H. Lockwasher, oil pump to crankcase (serrated) Washer, oil pump to crankcase joint ...

CRANKCASE FILTER Filter, crankcase ...

Spring, crankcase filter ... Washer, crankcase filter spring Cap, crankcase filter Washer, crankcase filter joint ...

INNER COVER, LEFT SIDE Cover, crankcase inner c'w dowels

Dowel, inner cover to crankcase front Dowel, inner cover to outer cover rear Sealing washer, gearbox shaft (rubber) Backing washer, sealing washer

Screw, inner cover to crankcase I in. U.H.

Screw, inner cover to crankcase -ft in. U.H .... Plug, oil level and drain ... Washer, oil level and drain plugs


Cover, crankcase L.H. inner c./w dowels

Dowel, inner cover to crankcase front Sealing washer, gearbox shaft (rubber) Retainer, sealing washer

ENGINE SPROCKET Engine sprocket, 18 teeth Distance piece, sprocket and rotor

SPECIAL NOTE. Subsequent to Engine No. 3S847 use :

Engine sprocket, 19 teeth Duplex Distance piece sprocket and rotor

OUTER COVER, LEFT SIDE Cover, L.H. outer Washer, cover joint Screw, outer cover, I~ in. U.H. Screw, outer cover, -n in. U.H. Screw, outer cover {~ in. U.H. Screw, outer cover, I in. U.H.

•See also Page 12.

9

QUANTITY

TID T20C 2 2 2 2 2 2

2 2 2

2 2 2

4 4 2 2 2 2

FIG. 1.

THE ENGINE AND

GEARBOX UNIT.

ln order to clarify th . sc e mam c rews and omponent washers et s, the

from th ' c., have be IS Illustration en omitted

the clutch and For further detail gears see F s on lgs. 2 and 3.

For index S ee Page II.

0

120

37 -

39---

38 - I 22 ~tl\ 20 ~--19- -1 18 I 21 -17 ""@ - ~

16------f

34 I

33

45

I I ! • i

9osg 1466'os I 1

5 S6 144 147

1,

I I

I

I I

35 -32 24 2J

-29 28 27 29 Jl 26 25 4 5 6 7 8

138 148

87 88

c:'l ::11:1 0 c: "'I

.... m z £! z m

!HUH. 1'10. ran NO. rage NO. ~er. Na. 11/ust, No. Yort No. rage No. Kef. No. must. No. t'art No. Page No. Ref. No. I E3385 6 ~- 53 E3ibo 7

. .. 28 101 Tlll9 15 31

2 EJ368 6 J 54 E34il 8 29 102 TI098 13 13 3 CPI41 6 4 55 See Page 8 103 TII02 13 14 4 E656 6 5 56 E3365 8 2 104 TI066 13 15 5 E3048 6 6 57 E3171 8 3 lOS TI069 13 16 6 E3387 6 7 58 T989 8 4 106 Tl248 13 18 7 E1750 6 8 59 El560 8 6 107 Tl076 13 20 8 El767 6 9 60 EJ579 9 28 108 Til SO 13 21 9 EJ66l 6 10 61 TI076 8 7 109 Tll64 I 3 22

10 E3217 6 II 62 E3655 8 II 110 Fl369 I 3 23 II El207 6 12 63 Ell75 8 ll Ill Tl159 IJ 24 12 El210 6 ll 64 El518 8 14 112 Tl184 13 25 13 E1987 6 14 65 EJI77 9 5 Ill Tl278 13 27 14 El2l0 6 15 66 EJI76 9 6 114 TII09 13 29 IS Ell46 (in) 7 I 67 E1564 9 8 115 non 13 30

E3147 (ex) 7 2 68 E1577 9 9 116 Tl070 14 I 16 E3208 7 J 69 E3178 8 17 117} See Page 14 17 El209 7 4 70 E3421 8 18 : :~~ 18 E3214 7 5 71 E3185 8 19 TI07l 14 4 19 E3215 7 6 72 EJI84 8 20 120 Tll65 15 I 20 El301 7 7 73 EJI8J 8 21 Ill 552-1 IS 8 21 E321l 7 8 74 EJ 186 8 22 122 Tl279 IS 9 22 WE2S9A 7 9 75 E3409 8 24 123 Tl281 IS II 23 EJ251 t) 6 17 76 E3194 8 26 124 Tl282 IS 12

EJ252 Ex) 6 18 77 EJ410 8 2S 125 Tl161 IS 13 24 El222 6 19 78 EJI95 8 27 126 Tll62 , 15 25 El223 6 20 79 El412 8 28 127 Tll63 15 16 26 G5662 6 21 80 570-4 8 30 128 Til 57 IS 17 27 E3225 6 22 81 E3191 8 Jl 129 Til 58 IS 18 28 E3253 6 23 82 E3192 9 I 130 See Page IS 29 E2534 6 24 83 E3191 8 ll Ill TI082 IS 23 30 E2594 6 25 84 Tlll4 8 l2 132 TIIIO IS 24 3 I E3224 6 26 85 E3581 9 23 133 E697 15 25 32 E3228 6 28 E3912 9 25 134 Tlll2 15 26 33 EJ227 6 27 86 W954 9 24 135 Tl257 15 27 34 El226 6 29 E3913 9 26 136 Tl61 IS 28 35 E3290 6 )0 87 465909 48 9 137 WE170 IS 29 36 E2441 6 31 a a E3667 9 27 138 See Pages 15 and 16 m 37 EJ372 7 10 E3917 12 5 139 Tl233 16 23 z 38 E3537 7 II 89 El664 9 10 140 Tll24 16 27 C'l 39 E3540 7 13 EJ915 9 19 141 Tll40 16 30 40 E3391 7 14 90 Ell 52 a 15 142 F879 41 14 z 41 E3285 7 15 91 D557 9 17 143 525-13 41 15 m 42 H400 7 17 92 WEI70 9 18 144 466124 48 2 43 E1335 7 18 93 El476 12 8 145 EISSO 48 8 44 E3249 7 19 94 E3293 12 9 146 El379 8 16 C'l 45 See Page 7 95 Tll47 12 II 147 46910 48 10 :Ill 46 E3S98 7 23 96 Tll49 12 12 148 E732 12 3 0 50 El624 7 25 97 Tll48 12 13 149 NE507 12 4 c 51 E3623 7 26 98 Ell 51 12 20 ISO Tl249 13 19 "a 52 E1762 7 27 99} See Fig. 2, Page 14 N

100"

GROUP 2 - ENGINE

REF. No. PART No.

I 2 3 4

5 6 7

8 9

10 II 12 13 14 15 16 17 18 19

20 21 22 23 24

E2386 E2441 E732 NE507

E3917 E3914 E3205

E3476 E3293 E3172 Tll47 Tll49 Tll48 Til SO E3204 E3220 E3221 F3775 XA69

E3151 E3345 E3221 E3231 E3220

Domed nut, middle screws Washer. copper Plug. oil filler Washer. oil filler plug

DESCRIPTION


Cover, L.H. outer Screw, outer cover l ~ in. U.H. Screw, outer cover I~ in. U.H.

INNER COVER, RIGHT SIDE

Cover, inner C.-~w bushes and dutch lever Bush. camshaft ... Peg, camshaft bush Bush, gearbox mains haft Plate, inner cover Washer, inner cover plate (Cork) Screw, inner cover plate 0.41 in. U.H. Screw, inner cover to crankcase I in. U.H. Screw, inner cover to crankcase U ln. U.H. Screw, lnner cover to crankcase 1-k fn. U.H. Vent pipe, inner cover breather (PVC) Clip, vent pipe to dutch cable

OUTER COVER, RIGHT SIDE

Cover, outer R.H. Washer. cover joint Screw. outer R.H. cover I~ in. U.H .... Screw, outer R..H. cover I~ in, U,H .... Screw, outer R.H. cover fJ in. U.H ....

GASKET SET

25 GST2056 Gasket set

12

QUANTITY

nome

2 2

4 2

I 2 2

I I I 7 I

2 2 I I

4 2

I I I I I ~.

I 2 2

I 7 I

GEARBOX- GROUP 3

REF. No. PART No. DESCRIPTION QUANTITY

GEARBOX AND CLUTCH- GROUP 3 Illustrated on Pages 10, 14 and 17-Figs. I, 2 and 3

SHAFTS AND GEARS no noc I TI083• Gear cluster, mainshaft (3rd and low) 2 TIOBS Bush, mainshaft clutch rod 3 TI078 Gear, mainshaft high ciw bush ... 4 TI080 Bush. high gear ... 5 TI089 Gear, mainshaft 2nd 6 Tl090 Thrust ring, mainshaft 2nd gear 7 TI091• Gear, cluster, layshaft (top and 2nd) 8 TI094 Gear, layshaft 3rd 9 T!095 Gear, layshaft low cfw bush

10 T!097 Bush, layshaft low gear ... • The gear clusters are sold only as an assembly and the parts cannot be

obtained separately.


II T!514 Gear, mainshaft high ccw bush ... 12 TIS IS Bush, high gear ...

SELECTOR FORKS AND SPINDLE 13 TI098 Fork, mainshaft and lays haft selector ... 2 2

"14 Tll02 Spindle, selector fork I I

CAMPLATE 15 TI066 Cam plate assembly 16 TI069 Spindle, camplate 17 .,&"x I ' Split pin, camplate to spindle 18 Tl248 Spring, camplate Index I 19 Tl249 Spring, camplate index (supplementary) I 20 TI076 Screw, camplate Index spring ... 2 2 21 Tll80 lock washer, cam plate Index spring

GEARCHANGE MECHANISM 22 Tll64 Pedal, gear change 23 F1369 Bolt, gear change pedal 24 Tl259 Spindle. quadrant and plunger assembly I 2S TIIBI Feltwasher, gear change spindle I 26 Tll84 Plunger, gear change selector 2 2 27 Tl278 Spring, gear change selector plunger 2 2 28 A:" X f" Split pin, gear change selector plunger 2 2 29 TII09 Spring, gear change return I 30 TI077 Pin, gear change return spring anchorage I 31 Ell87 Washer, gear change return spring anchorage I 32 T449 Rubber, gear change pedal

13

GROUP 3- GEARBOX

REF. No. PART No.

2 3 4 5 6

TI070 TI071 TIOn TI073 E31n Tl269

DESCRIPTION

GEARBOX CASING BEARINGS Bearing, L.H. gearbox mainshaft (ball) Oil seal, L.H. bearing (felt) Plate, L.H. bearing seal retaining Bearing, L.H. gearbox layshaft (plain) Peg, layshaft bearing locating ... Disc, L.H. gearbox layshaft bearing ...


7 H1168 Oil seal, L.H. bearing

' I I <: 13 17 ::' " g •

FIG. 2, MAINS HAFT AND LAYSHAFT GEARS.

INDEX

lllust. No. Part No. Page No. Ref. No. lllust. No. Part No. Page No.

I TI083 13 I 9 TI094 13 2 Tlll9 IS 31 10 TI095 13 3 Tl085 13 2 II Tl097 13 4 TI078 13 3 12 Tl279 15

Ti514 13 II 13 TillS 15 5 TI080 13 4 Tl515 13 12 14 TJ181 IS

6 TI089 13 5 15 Tl282 15 7 Tl090 13 6 16 Tll61 15 8 TI091 13 7 17 Tl274 IS

14

QUANTITY

TlO TlOC

Ref. No.

8 9

10 9

10 II 12 13 14

GEARBOX-GROUP 3

REF. No. PART No. DESCRIPTION

KICKSTARTER I Tll65 Kickstarter assembly, folding ... 2 Tll66 Crank, kickstarter 3 Tll68 Pedal, kickstarter crank 4 Fl814 Rubber, kickstarter pedal 5 Tll69 Bolt. kickstarter crank to pedal 6 S70-3 Ball, kickstarter crank to pedal 7 Tll67 Spring, kickstarter crank to pedal 8 552-1 Cotter, kfckstarter crank c;w nut and washer 9 Tl279 Spindle, kickstarter cfw bush

10 TillS Bush, kickstarter spindle II Tl281 Pawl, kickstarter ... 12 Tl282 Plunger, kickstarter pawl 13 Tll61 Spring, kickstarter plunger 14 T1274 Disc, pawl retaining 15 Tll62 Sprlng, kickstarter return 16 Tll63 Phte, kkkstarter return spring anchor 17 TJ 157 Plate, klckstarter stop ... 18 Til 58 Screw, kickstarter stop plate

GEARBOX SPROCKET •19 TIOSI Sprocket. gearbox, 17 teeth

20 Tl369 Sprocket, gearbox 16 teeth


21 TIS13;18 Sprocket. gearbox 18 teeth 22 TISI3/16 Sprocket, gearbox 16 teeth 23 T I 082 Nut, gearbox sprocket

24 25 26 27 28 29

30 31 32 33

TIIIO E697 Tlll2 Tl257 T361 WEI70

TIHI Tlll9 Tl347 Tl348

FILLER, LEVEL AND DRAIN PLUGS Plug. gearbox filler Washer, gearbox filler plug Plug, gearbox drain Washer, gearbox drain plug Plug, gearbox level Washer. gearbox level plug

CLUTCH Clutch. complete(! in. pitch chain) Key, clutch to mainshaft Tabwasher, dutch nut Nut, clutch to mainshaft

IS

QUANTITY

no noc

GROUP 3 - GEARBOX

REF. No. PART No

I 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 29 30

Tl343 Tll24 Tl264 T1345 T1314 T1128 T1364 T1350 T1346 T1132 T1318 T1315 T1294 T1253 T1256 G$662 T1144 T1145 T1146

Tl493 Tl509 TIS03

Tl233 T/235 T/236 Til 55 Tl/24 ftrtl X f' Tl234 Tll40

DESCRIPTION

Housing and sprocket (36 teeth) Ball, clutch sprocket bearing .. . Bearing ring, clutch sprocket .. . Shock absorber assembly comprising lines 6 to !2 Clutch centre Backplate ... Cup, centre driving Pin, driving cup Spider Rubber, drive Rubber, rebound Driven Plate Driving plate complete with linings Pressure plate Adjuster, pressure plate Nut, for adjuster Cup pressure spring Spring, dutch pressure ... Nut, dutch pin

SPECIAL NOTE. Subsequent to Engine No, 35847 use :

Clutch complete (; in. pitch duplex chain) Housing and sprocket (48 teeth duplex) Driving plate complete w1th linings ...

CLUTCH CONTROL

Lever, clutch operating assembly Lever, dutch operating Pin. operating lever fulcrum Cup, operating lever thrust Ball, cup to rod , .. Split-pin, cup to lever ... Fulcrum, dutch operating lever Rod, clutch operating

16

QUANTITY

nonoc I I

16 16 I I 1 1 1 1 1 1 3 3 3 3 1 1 3 3 3 3 3 3 3 3 1 1 1 1 1 1 3 3 3 3 3 3

I 3 3

I i I "' ' 3 4 5 Q a 10 II 13 12 13 '4 15 17 19

FIG. J. CLUTCH AND SHOCK ABSORBER UNIT.

INDEX

lllust. No. Part No. Page No. Ref. No. lllust. No. Part No. Page No. Ref. No.

I Tll28 16 6 II Tll4l 16 I 2 Tll32 16 10 Tl509 16 21 J TillS 16 II 12 TillS 16 12 4 TIJ46 16 9 ll Tl294 16 13

5 TIJ47 15 32 TI50J 16 22

6 Tlll4 16 5 14 TI25J 16 14 15 GS662 16 16

7 Tll64 16 7 16 Tl256 16 15 8 TIJSO 16 8 17 Tll44 16 17 9 Tll24 16 2 18 Tll45 16 18

10 Tl264 16 3 19 Tl146 16 19

------··--··

GROUP 4 - EXHAUST SYSTEM GROUP 5 - FRAME


EXHAUST SYSTEM- GROUP 4

EXHAUST PIPE nonoc

E3257 Pipe, exhaust 2 E3883 Pipe, exhaust 3 E3259 Clip, pipe to head 4 E3260 Bolt. pipe clip 5 $25-13 Wa.her, clip bolt

SILENCER

6 E3637 Silencer 7 E3840 Silencer


8 E3928 Silencer '''

9 E3269 Clip, silencer to pipe 10 TEI64E Bolt, silencer clip ... I II TE164D 'D' Washer, clip bolt I

~

12 TEI64C 'D' Nut, dip bolt I 13 F929 Bolt, silencer to bracket .. A 14 S26-l Washer, spring I 15 POI72A Nut. silencer bolt I

FRAME- GROUP 5

16 F4050 Frame, front 17 F4252 Frame, front


18 F4418 Frame, front 19 F4420 Frame, front 20 0402;3 Lock, steering head c;w keys ... A A 21 F4051 Frame, rear 22 F4253 Frame. rear 23 F3929 Collar, engine bolts 2 24 E3843 Collar, engine bolts 2 25 S25-2 Distance washer. rear bolt I 26 F3953 Bolt, engine mountings I <i ln. U.H. 2 2 27 F3954 Bolt, engine mounting 2}i ins. U.H .... I I 28 S25-2 Washer, rear and bottom nut ... 2 2 29 F3955 Nut. engine bolts 3 3

18


EI023 Stud, seat stays 3! ins. O.A. 2 S26-l Washer. spring 3 POI72A Nut, seal stays stud

SWINGING FORK 4 F4068 Swinging fork cjw bushes 5 F4076 Bush, fork pivot ... 6 F4079 Spindle, fork pivot 7 F4079 Washer, spacing R.H. 8 F4385 Shim, 0·003 in. ... 9 F4386 Shim, 0·005 in. ...

10 KW194 Grease nipple, pivot lug II WEI70 Washer, fibre

PILLION FOOTREST BRACKETS 12 F4080 Bracket, pillion footrest L.H. 13 F4278 Bracket, pillion footrest L.H. ... 14 F4081 Bracket, pillion footrest R.H .... IS F4087 Bolt, bracket to spindle I! ln. U.H. 16 PCW73A Washer, spring 17 Ell96 Stud, bracket to frame I,';· in. O.A. 18 S26-l Washer. spring • 19 Sl-51 Nut, bracket stud

CRANKCASE SHIELD 20 F4258 Shield, crankcase 21 F4260 Clip, shield 22 DS57 Bolt, dip Jlr in. U.H. 23 El612 Washer, shakeproof 24 F879 Nut, clip bolt

STAND- GROUP 6

CENTRE STAND 25 Fl957 Stand. centre 26 F3960 Spring. stand return 27 F3520 Bolt, stand pivot 28 H193 Nut, pivot bolt

PROP STAND 29 F3681 Prop stand, c.fw fittings 30 F4277 Prop stand, cjw fittings 31 F3097 Pin, stand pivot ... 32 F3096 Tab washer 33 F2610 Spring, stand return

19

FRAME - GROUP 5 STAND- GROUP 6

QUANTITY

no noc I

2 2 2 2

as necessary as necessary

I I I

I 2 2 2 2 2 2 2 2 2 2

I 2 2

I I 2 2 2

GROUP 5 - FRAME

32

30

3

19

18

19

18

8

7

34

12

14 13

.~"':~

24

21 22 I I I I

27 26 25 28 10 6 41 40 37 FIG. 4. FRAME AND COMPONENTS.

For l index. See Page 2 t.

20

31

5

4

2

... 9

16

17

i 38 39

FRAME - GROUP 5

INDEX TO FIG. 4

lllust. No, Part No. Page No. Ref. No,

I Sees)age 18 2 F40 I IS 21

F42S3 IS 22 3 EI023 19 I 4 S26-1 19 2 5 POI72A 19 3 6 F4068 19 4 7 F4087 19 15 8 PCW73A 19 16 9 See page 53

10 F4080 19 12 F427S 19 13

II F4081 19 14 12 E1396 19 17 13 S26-3 19 18 14 Sl-51 19 19 15 Fl760 53 22 16 S25-2 53 23 17 POI72A 53 24 18 F3953 18 26 ISA F3954 18 27 19 F3955 18 29 20 F3929 18 23

E3843 18 24 21 F3957 19 25 22 F3960 19 26 23 F3520 19 27 24 Hl93 19 2S 25 F3681 19 29

F4277 19 30 26 F3097 19 31 27 F3096 19 32 28 F2610 19 33 29 H835 27 29 30 F3498 39 II 31 Sl-51 39 13 32 E667A 53 3 33 Sl-51 53 5 34 F4090 42 2 35 S26-l 42 4 36 P0172A 42 3 37 F4311 53 25 38 F3207 53 27 39 H622 53 26 40 EI330C 53 28 41 Sl-51 53 29

21

GROUP 7 - TELESCOPIC FRONT FORK

5--------------------················------,

28

31--·

2--

4

34 .

27--

26

'1---·---15

'---- --33

'----------32

........... ----32

14

16

17

'-------------------- II

FIG. 5.

TELESCOPIC FRONT FORK.

For Index See Page 23.

21

TELESCOPIC FRONT FORK - GROUP 7

INDEX TO FIG. 5. PAGE 22.

11/ust. No. Port No. Page No. Ref. No.

I Hl231 26 4 2 H834 26 6 3 H518 26 9 4 $25-3 26 7 s H837 26 10 6 H570 26 12 7 Sl-51 26 13 8 $25-3 26 14 9 H640 26 IS

10 HI035 26 17 II H519A 26 19 12 H84S 26 21 13 H846 26 22 14 HI037 26 23 15 H850 26 25 16 HI047 26 29 17 Hl048 26 30 18 Sl-51 26 27 19 Hl040 26 31 20 H856 27 5 21 W932 27 7 22 El612 27 6 23 HI043 27 I 24 Hl046 27 8 25 HI045 27 10 26 H862 27 9 27 HI044 27 12 28 H823 27 IS 29 H822 27 19 30 H878 27 21 31 H877 27 20 32 H633 27 31 33 H636 27 33 34 H873 33 13 35 H864 42 17 36 H865 42 18 37 F879 42 19 36 E2267 26 28 39 H430 26 20 40 WEI70 27 4 41 HI042 27 3

23

GROUP 7- TELESCOPIC FRONT FORK 8

7------------------------

30 15

33

28

31 32

43 42

2 3

4 4 .~

14

J4

25 16

2

26

17

'----------------II

FIG. 6. TELESCOPIC FRONT FORK TIOC

24

TELESCOPIC FRONT FORK- GROUP 7

INDEX FIG. 6

//lust. No. Port No. Page No. Ref. No.

I Hl233 26 5 2 H834 26 6 3 H518 26 9 4 525·3 26 7 5 Hll33 26 II 6 H570 26 12 7 51·51 26 13 8 525·3 26 14 9 Hll37 26 16

10 Hll90 26 18 II H519A 26 19 12 H845 26 21 13 H846 26 22 14 H1191 26 24 15 HI I 53 26 26 16 H1047 26 29 17 H1048 26 30 18 51·51 26 27 19 H1149 26 32 20 H856 27 5 21 W932 27 7 .. 22 El612 27 6 23 HI I 50 27 2 24 H1046 27 8 25 Hll51 27 II 26 H862 27 9 27 H1044 27 12 28 H824 27 16 29 H822 27 19 30 H878 27 21 31 H877 27 20 32 H833 27 31 33 H836 27 33 34 HI I 52 27 14 35 H864 42 17 36 H865 42 18 37 F879 42 19 38 E2287 26 28 39 H430 26 20 40 WEI70 27 4 41 Hl042 27 3 42 Hl222 27 17 43 D404 27 18

25

GROUP 7- TELESCOPIC FRONT FORK

REF. No. PART No.

I 2

3

4 5 6 7 8 9

10 II 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Hl230 Hll73

Hl232

Hl231 Hl233 H834 525-3 F3098 H518 H837 Hll33 H570 Sl-51 525-3 H840 Hll37 HI035 Hll90 H519A H430 H845 H846 H1037 Hll91 H850 HIIS3 Sl-51 E2287 HI047 HI048 HI040 Hll49

Fork assembly Fork assembly

DESCRIPTION

SPECIAL NOTE. Subseguent to Engine No. 35847 use :

Fork assembly

Middle lug and stem Middle lug and stem Bolt, middle lug pinch ... Washer, bolt and nut Clip, brake cable ... Nut, pinch bolt lug, fork top Lug, fork top Bolt, top lug pinch Nut, pinch bolt ... Washer, pinch bolt Sleeve nut, fork stem Sleeve nut, fork stem Stanchion, cfw bush Stanchion, cjw bush Plug, oil filler ;\ in. U.H. Washer, fibre Bush, stanchion bonom Nut, stanchion to top lug Spnng, c/w restrictor rod and stud Spring. cjw restrictor rod and stud Stud, top I fs in. O.A. Stud, top 2f. ins. O.A .. Nut, top stud Washer, shakeproof Rod, restrictor ... Stud, restrictor rod I kin. in O.A. Member, outer, c/w cap L.H. Member, outer, c/w cap L.H.

26

QUANTITY

T20T20C

I

2 2 4 4 I J' 2 2

2 2

2 2 2 2 2 2 2 2 2

2 2

2 2 2 2 2 2 2 2 2 I

REF. No. PART No.

HI043 2 HI ISO 3 H1042 4 WEI70 5 H856 6 El612 7 W932 8 H1046 9 H862

10 HI045 II HilS I 12 HI044 13 Hl221 14 HI I 52 IS H823 16 H824 17 Hl222 18 D404 19 H822 20 H877 21 H878

• 22 H688 23 H691 24 E2880 25 H916 26 H689 27 H691 28 E2880 29 H961

30 H835 31 H833 32 570-3 33 H836

TELESCOPIC FRONT FORK- GROUP 7

DESCRIPTION

Member, outer, c,/w cap R.H. Member, outer, c/w cap R.H. Stud, oil drain ~~ in. O.A. Washer, fibre Cap. wheel spindle Washer, shakeproof Bolt, spindle cap I in. U.H. Bush, fork cop Washer, sleeve nut, steel Sleeve nut, dust excluder

Sleeve nut, dust excluder Oil seal, rubber ...

QUANTITY

TlO TlOC I

2 2 2 2 2 2 4 4 4 4 2 2 2 2 2

2 2 2

Shim, oil seal (prior to Engine No. 34214) Washer, felt

when necessary

Nacelle, bottom unit Nacelle, bottom unit

Gaiter, telescopic Clip, gaiter Nacelle, top unit ... Flash, L.H. (motif) Flash R.H. (motif) Screw, flash and top and bottom unit ft in. U.H. Nut, flash and top and bottom unit ...

Washer, flash and top and bottom unit Screw, flash and top and bottom unit (centre) :l92 in. U.H. Screw, top and bottom unit (rear) l in. U.H. Nut, cop and botcom unit (rear) Washer, top and bottom unit (rear) Grommet, control cables

STEERING RACES

Cup, steering race (top and bottom) Cone, steering race (top and bottom) Ball, steering race (top and bottom)

Cover, steering race, dust

27

2

2 2

2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3

2 2 2 2

30 30 I

C'l = 10 5

() c: ~

Cl)

19 I

18 ~ = m m [;;

~r-r-----------21

-----7

SHORT

I 9 8 6 2 4

FIG. 7. FRONT WHEEL

For Index See Page 29 •

•

•

WHEELS - GROUP 8

REF. No. PART No DESCRIPTION

WHEELS- GROUP 8

FRONT WHEEL I Wll71 Wheel, front complete 2 Wl303 Wheel, front complete ... 3 Wll72 Rim, spokes and hub assembly 4 Wl285 Rim, spokes and hub assembly 5 Wl173 Rim, front wheel, W.M.2.-16 ... 6 WI002 Rim, front wheel, W.M.I-19 ... 7 Wll74 Spoke and nipple, L.H. 6~ ins. 90'' 8 Wll75 Spoke and nipple, R.H., 5" Ins. 90'' 9 Wl289 Spoke and nipple L.H., Bt ln. 90'

10 Wl205 Spoke and nipple. R.H. 6! Ins. /00° II Wl206 Spoke and nipple, R.H. 6~ ins. 80' 12 W965 Nipple, spoke 13 W961 Hub and brake drum 14 Wl286 Hub and brake drum 15 W967 Spindle, front wheel 16 WI093 Nut, front wheel spindle to anchor plate 17 T530 Bearing, front wheel L.H. 18 W966 Dust cap, front wheel L.H. 19 T532 Clrcllp, front wheel L.H. dust cap 20 H826 Bearing, front wheel R.H. 21 W968 Ring. front wheel R.H. locking

FRONT WHEEL BRAKE 22 Wl065 Plate, front brake anchor 23 Wll28 Cam assembly, front brake 24 Wll33 Lever, front brake 25 T224 Nut, front brake lever ... 26 S25-71 't'asher, front brake lever

INDEX TO FIG, 7. PAGE 28.

11/ust. No. Part No. Page No. Ref. No. 11/ust. No. Part No. Wll73 29 5 9 W966 WI002 29 6 10 T532

2 Wii75 29 8 II H826 Wl205 29 10 12 W968 Wl206 29 II 13 Wl065

3 Wll74 29 7 14 WillS Wl289 29 9 15 Wllll

4 W965 29 12 16 T224 5 W%1 29 13 17 W977

Wl286 29 14 IB W978 6 W967 29 IS 19 W979 7 Wlll9J 29 16 20 W200 8 TSJO 29 17 21 51-52

29

Page No. 29 29 29 29 29 29 29 29 31 ll 31 ll 31

QUANTITY

. ..

TlO TlOC

20 20

- 20 - 10 - 10

40 40

Ref. Na. 18 19 20 21 22 29 24 25

I 2 l 4 5

GROUP 8 - WHEELS (tS------------~

~~-----: 0

~--~~-------------~ <!"-----~

~~--------------

~----§---N

~----------1

;:;;------~

<t N

..... ;:;; "e~

N .., ~

N

"' N

30 ~ 0

WHEELS - GROUP 8


no nne W977 Shoe. front brake c:w lining 2 2

2 W978 Lining, front brake 2 2 3 W979 Rivet, front brake lining 12 12 4 W200 Spring, front brake shoe 2 2 5 s 1-52 Nut, front brake anchorage to dip 6 $26-1 Washer, front brake anchorage to clip

REAR WHEEL 7 •w1211 Wheel, rear, complete 8 •WI304 Wheel. rear. complete 9 Wl2~6 Rim, spokes and hub assembly

10 Wl290 Rim, spokes and hub assembly II Wll73 Rim, rear wheel W.M.2-16 li. Wl296 Rim, rear wheel W.M.2-19 13 Wl213 Spoke and nipple L.H. 51\i ins. 100'' 10 14 Wl214 Spoke and nipple L.H. 51\i ins. 80" 10 IS Wl259 Spoke and nipple R.H. 6·!! ins. 90'' 20 16 Wl294 Spoke and nipple L.H. 6~ ins. 100' 10 17 Wl295 Spoke and nipple LH. 6; ins. 80' 10 18 Wl293 Spoke and nipple R.H. 8 ins. 90' 20

,19 W965 Nipple, spoke 40 40 20 WI2S7 Hub and brake drum I I 21 •WI076 Sprocket, 54 teeth I

• SPECIAl NOTE. Subsequent to Engine No. 35847 use :

22 W1321 Wheel, rear, complete 23 WI33S Wheel, rear, complete 24 Wl320 Sprocket, 46 teeth


tltust. No. Part No. No. Uluse, NcL Port No. No.

Wfi7J 31 II 12 W987 32 5 Wl296 31 12 13 W988 32 6

2 Wl213 31 13 14 W9S4 32 7 Wl214 31 14 IS Wl223 32 8 Wl294 31 16 16 Wl219 32 9 Wl295 31 17 17 Wll28 32 10

3 Wl259 31 15 18 Wl221 32 II WJ293 31 18 19 T224 J2 l2

4 W965 31 19 20 $25-71 32 13 5 Wl257 31 20 21 W977 32 14 6 Wl076 31 24 22 W978 l2 15

W1320 J I 24 23 W979 32 16 7 Wl322 32 I 24 W200 l2 17 a Wll22 32 2 25 Wl224 32 21 9 W989 32 8 26 Wl227 32 22

10 WIOOO 32 24 27 F879 32 23 II HB26 32 4 28 0175 32 28

31

GROUP 8 - WHEELS


TlO TlOC I Wl322 Bolt, sprocket to drum, ! in. U.H. 8 a 2 Wll22 Washer, spring 8 8 3 W989 Spindle, rear wheel I 4 H826 Bearing, rear wheel, L.H. and R.H. 2 2 5 W987 Backing ring, L.H. bearing I 6 W988 Locking ring, L.H. bearing I 7 W954 Distance piece, R.H. Inner I 8 Wl223 Distance piece. R.H. outer I

REAR WHEEL BRAKE •

9 Wl219 Plate, brake anchor 10 Wl128 Cam, brake II Wl221 Lever, rear brake 12 T224 Nut, brake lever 13 525-71 Washer. plain I 14 W977 Shoe. brake c/w lining 2 2 15 W97S Lining, brake 2 2 16 W979 Rivet, brake lining 12 12 ~

17 W200 Spring, shoe return 2 2 18 H211 Bolt, brake anchor, 1! in. U.H. I 19 F2184 Washer, plain I 20 F3955 Nut, anchor bolt

REAR CHAIN ADJUSTER

21 Wl224 Adjuster, rear chain 2 2

22 Wl227 End plate, adjuster 2 2 23 F879 Nut, adjuster 2 2 24 WIOOO Nut, wheel spindle 2 2

32

MUDGUARDS - GROUP 9


MUDGUARDS -GROUP 9

FRONT MUDGUARD nonoc I H929 Mudguard, front I 2 HI I 56 Mudguard, front 3 H871 Stay, mudguard, L.H. 4 H872 Stay, mudguard, R.H. 5 HI I 57 Stay assembly 6 Hll61 Bridge, mudguard support 7 DS57 Bolt, mudguard stay, * in. U.H. 4 6 8 El612 VVasher, shakeproof 4 9 525-1 VVasher, plain 6

10 F879 Nut, mudguard ... 4 6 II FB79 Nut, stay to fork lug 2 2 12 El612 VVasher, shakeproof 2 2 13 H873 Clip, bridge to fork leg 2 14 GS218 Bolt, dip and bridge !. in. U.H. 2 4 15 El612 VVasher, shakeproof 2 4 16 F879 Nut 2 4

• LICENCE HOLDER

17 D261 licence holder ...

REAR MUDGUARD

18 F4094 Mudguard, rear ...

SPECIAL NOTE. Subsequent to Engine No. 35847 use ;

19 f4391 Mudguard, rear ... 20 F4270 Mudguard, rear ... 21 F4097 Stay, guard to frame front 2 22 F4262 Stay, guard to frame front 2 23 DS57 Bolt, guard to stay and frame, * in. U.H. 4 4 24 525-1 VVasher, plain 4 4 25 F879 Nut, guard bolts 4 4 26 D$55 Bolt, stay to bracket ~~ ln. U.H. I 27 $26-3 VVasher, spring 28 Sl-51 Nut, bracket bolt 29 PF204 Clip, centre I 30 F-444 Backing plate I I 31 525-1 VVasher, plain 2 2 32 523-42 Bolt, centre dip 2 2 33 E3203 Grommet, wiring harness 2 2

33

GROUP 9 - MUDGUARDS

~-------------------25

----···-5

'---···-~~-4

'-~-·····-~-~~-::J

~~~---~------------2 8-·~~~~-~~-·····~-~ 29

17~----~

10--~--

12 II

31

t 32

I 16 15

,----28

FIG. 9. MUDGUAI!DS, NUMBER PLATES AND REAR CHAINGUARD. For Index See Poge 35.

34

..

NUMBER PLATES- GROUP 10


I 2 3 4 5

6 7 8 9

10 II 12 13 14

H874 F2996 H741 H687 H745

F3508 F929 Sl-51 S26-3 Fl369 FB79 $26-2 D68 57080

NUMBER PLATES- GROUP 10

FRONT NUMBER PLATE

Plate, front number Plate, front number Clip, assembly, front number plate ·-Screw. front number plate to clip Nut, clip screw

, REAR NUMBER PLATE

Plate, rear number Bolt, number plate top~ in. U.H. Nut, top bolt Washer, top bolt Bolt, number plate bottom ~ in. U.H. Nut. bottom bolt Washer, bottom bolt Transfer, number plate motif ... Reflector, c:'w nut and washer


//lust. No. Part No. No. Ref. No. /1/ust. No. Part No.

I H929 33 I 17 523-42 2 H871 33 3 20 Fl369 3 H872 33 4 21 F879 4 DS57 33 7 22 57080 5 F879 33 10 23 H874 6 GS218 33 14 F2996 7 F879 33 16 24 H741 8 HI042 27 3 25 H687 9 F4094 33 18 26 H745

F4391 33 19 27 F3508 F4270 33 20 28 F929

10 PF204 33 29 29 Sl-51 II DS57 33 23 30 E3203 12 DSSS 33 26 31 DS57 13 Sl-51 33 28 32 F4152 14 F4097 33 21 33 DS57

F4262 33 22 34 F4089 15 F879 33 25 F4269 16 F444 33 30

35

Page No.

33 35 35 35 35 35 35 35 35 35 35 35 33 36 36 36 36 36

QUANTITY

T20TlOC

I 2 2 2 2 2 2

I 2 2 2 2 2 2

Ref. No.

32 10 II 14 I 2 3 4 5 6 7 8

33 12 II 3 I 2

GROUP II - REAR CHAINGUARD GROUP 12- TOOLBOX, BATTERY CARRIER AND AIR CLEANER

REF. No. PART N>. DESCRIPTION QUANTITY

REAR CHAINGUARD- GROUP II

TIOTIOC

F4089 Chainguard, rear ... 2 F4269 Chainguard, rear ... 3 DS57 Bolt, front and rear 2 2 4 S26-2 Washer, spring (front) I 5 525-1 Washer, plain (rear) 6 F4265 Clip, to swinging fork 7 E2818 Bolt, clip I f.. in. U.H. B F4263 Distance piece ... 9 El612 Washer, shakeproof

10 F879 Nut, dip bolt II F4152 Chainguard, front portion 12 DS57 Bolt, to crankcase -k in. U.H .... 13 525-13 Washer, plain 14 526-2 Washer. spring

TOOLBOX, BATTERY CARRIER AND AIR CLEANER

GROUP 12

IS F3491 Toolbox, battery and air cleaner assembly casing 16 F3470 Pad, battery, rubber moulded ... 2 2 17 F3418 Container, air cleaner ... IB H251 Beading, air cleaner container, robber ... 19 F3492 Element, air cleaner 20 F3656 Stud, air cleaner to case 21 H745 Nut, air cleaner to case "" . 22 F3473 Strapf battery case 23 F3472 Hook-bolt, battery case strap and lid 24 F879 Nut, battery case hook bolt 25 F3493 Lid, casing cfw knob 26 F3474 Knob, casing lid 27 F3475 Circlip, casing lid knob ... 28 F3478 Connector, air cleaner to carburetter 29 E3203 Grommet, oil tank vent 30 199002 Grommet, wiring harness

36

TOOLS- GROUP 13 II

FIG. 10. TOOLBOX, BATTERY CARRIER AND AIR CLEANER.

INDEX TO FIG. 10

11/ust. No . Part No. Page No. Ref. No. 11/ust. No. Part No. Page No. Ref. No. • I F3470 36 16 7 F879 36 24

2 F3418 36 17 8 F3493 36 25 3 F3492 36 19 9 FH74 36 26 4 F3656 36 20 10 F3475 36 27 5 F3473 36 22 II F3478 36 28 6 F3472 36 23 12 H745 36 21

TOOLS- GROUP 13 Illustrated on page 38


nonoc 0290 Tool kit, complete I I

2 0291 Tool bag ... 3 0299 Spanner, open ended, r x ft-* Whit. 4 0292 Spanner. open ended, t H :< -l~r >.: r X * "Whit. 5 0293 Spanner, combination square X ftr" X -fir" ~ V Whit. 6 0294 Spanner, screwdriver and box, t • Whit. 7 OA70 Key, clutch adjusting ... 8 NAI4A Lever, tyre 9 0335 Screwdriver, Phillips No. 2

10 0196 Inflator, tyre (not included in 0290)

37

GROUP 13 - TOOLS

~,' C£22~· .. ~~==lJJ

D294

FIG. II. TOOLS.

38

PETROL AND OIL TANKS- GROUP 14


2 3 4

5 6 7 8 9

10 II 12 13 14 15 16 17

•is

19 20 21 22 23 24

//lust. No.

2 3

4

5 6 7 8 9

10 II

PETROL AND OIL TANKS- GROUP 14 See also page 64 Illustrated on page 40

PETROL TANK nonoc F3963 F3505 F3220 F4048 F4032 F4033 F3494 F3495 F3496 F3497 F3498 S25-3 s 1-51 F3506 E697 F3499 Fl605 Fl606

Petrol tank, less fittings Petrol tank, less fittings Cap, filler c,/w washer Washer, filler cap Styling band, L.H. Styling band, R.H. Styling band, L.H. Styling band, R.H. Name plate Screw, name plate f& in. U.H. Bolt, tank to frame, 2~ in. U.H. Washer, plain Nut, tank bolt Tap, petrol Washer, fibre Pipe, petrol feed Knee grip, R.H .... Knee grip, L.H.

OIL TANK F3464 F4318 F3216 F4047 Fl792 PT104B

Part Na.

F3963 F3505 F3220 F4032 F3494 F4033 F3495 F3496 F3497 F3506 E697 F3499 Fl605 Fl606

Oil tank. less fittings Oil tank, less fittings Cap, filler c./w washer Washer, filler cap Drain plug, oil tank Washer, fibre


Page No. Ref. Na. //lust. No. Part No.

39 I 12 F3464 39 2 F4318 39 3 13 F3216 39 5 14 F3876 39 7 15 Fl511 39 6 16 E3270 39 8 17 F3503 39 9 18 F3504 39 10 19 F3077 39 14 20 E3244 39 15 21 E3383 39 16 22 Fl792 39 17 23 PTI04B 39 18

39

Page No.

39 39 39 41 41 41 41 41 41 7 7

39 39

2 2 4 4 2 2 3 3 2 2

Ref. No.

19 20 21

I 2 9

II 12 10 16 2P 23 24

GROUP 14- PETROL AND OIL TANKS

>--------8

6----------------------

r

~~-~;:---12 (fir----- 2 233

IS _______ _/ '1'"4

14---_/ 19----11 18 -------~,?Y

~---22

19 17 FIG. 12. PETROL AND OIL TANKS.


40

PETROL AND OIL TANKS - GROUP 14

FOOTRESTS- GROUP 15

RE.F. No. PART No. DESCRIPTION QUANTITY

nonoc I F3876 Filter, oil tank ". I I 2 FISII Washer, fibre I 3 F2596 Bolt. tank to frame bottom, 11 ln. U.H. 4 F3477 Distance piece, bottom I 5 F3468 Bolt, tank to frame top 21;, ins. U.H. I I 6 F3476 Distance piece, top 2 2 7 Sl-51 Nut, tank bolts 2 2 a S25-3 Was her, top bolt I I 9 E3270 Pipe assembly; tank to engine ... I I

10 F3077 Connection, rubber 2 2 II F3503 Pipe, feed top half I 12 F3504 Union nut, feed pipe 13 F3274 Joint washer, pipe to engine 14 F879 Nut, pipe to engine IS 525-13 Washer, plain 16 A3 Transfer (Minimum Oil level)

FOOTRESTS- GROUP 15 •

17 F3449 Footrest L.H. I 18 F3450 Footrest R.H. I I 19 Fl695 Rubber 2 2 20 F3448 Rod, footrest hanger 6! in. O.A. I I 21 Hl93 Nut, footrest rod 2 2


22 F4383 Footrest, L.H.

PILLION FOOTREST

23 F4327 Footrest, pillion complete 2 2 24 Fl694 Pedal, footrest ... 2 2 25 Fl695 Rubber, footrest pedal 2 2 26 F2271 Bolt, footrest pedal pivot 2 2 27 SI-SI Nut, footrest pedal pivot bolt 2 2 28 F2277 Washer, footrest pedal pivot bolt 2 2 29 F2268 Hanger, footrest pedal ... 2 2 30 F4309 Stud, footrest pedal I i ln. O.A. 2 2 31 PO InA Nut, footrest pedal stud 2 2 32 $26-1 Washer, footrest pedal stud 2 2

41

GROUP 16- REAR BRAKE PEDAL GROUP 17 - HANDLEBAR


I 2 3 4 5 6 7 8 9

10 II

12 13 14 IS 16 17 18 19 20 21

22 23 24 25 26 27

REAR BRAKE PEDAL-GROUP 16

F4091 F4090 P0172A S26-l T224 S25-3 F4093 F3461 F3594 (u- in X ~in,

F3463

701510 Hl192 91 f322 H934 H881 H864 HB65 F879 S25-13 l6f069

Pedal, rear brake Spindle, brake pedal Nut, to frame Washer. spring Nut, pedal to spindle Washer plain Rod, brake operating Washer, pedal to rod Washer. rod to pedal (for stop lamp) Split pin, rod to pedal Adjuster. brake rod

HANDLEBARS-GROUP 17

Illustrated on Page 43-Fig. 13

Handlebar, c/w levers and twlstgrip ... Handlebar, cjw levers and twistgrip , .. Handlebar, cjw lever brackets Handlebar bend only Grommet, handlebar to nacelle Support, handlebar to top lug "U" bolt, handlebar Nut, "U .. bolt ... Washer, plain Grip, handlebar ...

CONTROL LEVERS

70;316 Lever, dutch control 70317 lever, front brake control 100'006 Screw, lever to bracket 70,'016 Washer, Spring ... 18/717 Nut, lever screw 70005 Stop. brake and clutch cable

42

QUANTITY

T20T20C

I I A A I I I I

I 2 2 2 2 2 2 4 4 4 4

I

I I 2 2 2 2

6-·

7------

11/ust. No. Part No. I 91'322 2 16069 3 70!316 4 100·006 5 18.717 6 70;016 7 H886

HANDLEBAR - GROUP 17

' 6 3

FIG. ll. HANDLEBAR AND COMPONENTS.

INDEX TO FIG. 13.

Page No. Ref. No. lllust. No. Part No. Page No. Ref. No. ··--

42 14 8 306.·004 44 13 42 21 9 306.010 44 16 42 22 10 16010 44 IS 42 24 II 306!001 44 II 42 26 12 306003 44 12 42 25 13 306 007 44 17 49 33

43

GROUP 17- HANDLEBAR GROUP 18- CONTROL CABLES

REf. No. PART No DESCRIPTION QUANTITY

TlO TlOC 18/763 Lever Assembly, dutch I

2 18/762 Lever Assembly, front brake 3 18/752 Lever, clutch (Ball end) 4 18/754 Lever, front brake (Ball end) I 5 18/234 Bracket, lever fulcrum ... 2 6 12/040 Clamp, lever bracket ... 2 7 11/014 Screw. bracket, to damp 4 8 181087 Screw. lever pivot 2 9 18;053 Nut, pivot screw 2

TWISTGRIP (See also page 64)

10 306/1 Twistgrip, complete II 306/001 Body, twistgdp I 12 306j003 Grub screw, body fixing 3 3 13 306(004 Spring, friction ... I 14 306;005 Screw, friction spring ... IS 16/010 locknut, friction screw I 16 306f010 Rotor, twlstgrip ... I .. 17 306/007 Cable stop I 18 16/070 Grip, rubber

CONTROL CABLES GROUP 18

FRONT BRAKE CABLE

19 D323 Cable assembly, front brake 20 D323C Casing, front brake cable 21 D323W WIre. front brake cable 22 D321 Cable assembly, clutch ... 23 D321C Casing, front, brake cable 24 D321W Wire, front brake, cable 25 DI03 Ferrule. casing ... 2 2 26 18}107 Nipple (Handlebar end) I 27 DBI Nipple (Handlebar end) 28 DS73 Nipple (Wheel end) 29 D279 Adjuster, cable ... 30 F879 Nut, adjuster lock 31 D280 Clevis, brake wire 32 D281 Pin, clevis

33 1~ in x! ln. Split pin, clevis pin

44

REF. No. PART No.

CONTROL CABLES- GROUP 18 HANDLEBAR (U.S.A.) -GROUP 19

DE.SCRIPTION QUANTITY

THROTTLE CABLE no noc I 2 3 4 5 6 7 8 9

10 II 12 13 14 15 16

• 17 18 19 20 21 22 23

24 25 26

27 28 29 30

D316 D316C D316W D317 D317C D317W 12/083 D285 1482/050

D331 D331C D331W D332 D332C D332W DI03 18!706 D81 D334 D319 D268 D288 D333

H933 H934 16/069

18;557 18/556 18/528 18/234

Throttle cable Casing, throttle cable Wire, throttle cable Throttle cable ... Casing, throttle cable Wire, throttle cable Ferrule, casing ... Nipple (Twistgrip) Nipple (Carburetter)

CLUTCH CABLE

Clutch cable Casing, dutch cable Wire, dutch cable Clutch cable Casing, dutch cable Wire, clutch cable Ferrule. casing ... Nipple (Handlebar) Nipple (Handlebar) Nipple (Clutch) Adjuster cable Locknut, adjuster Abutment (Handlebar) Abutment (Clutch)

HANDLEBAR (U.S.A.) -GROUP 19

HANDLEBAR

Handlebar c;w control lever and Twistgrip .. Handlebar bend only ... Grip, handlebar rubber

CONTROL LEVERS

Lever assembly, dutch control Lever assembly, front brake control Lever only, dutch and brake ... Bracket, lever fukrum

45

I 2 2

I I I I 2 2 2 2

GROUP 19 - HANDLEBAR (U.S.A.) GROUP 20- NACELLE GEAR INDICATOR


I 2 3 4

5 6 7 8 9

10

II 12 13 14 15 16 17 18 19 20

12i040 11;014 18!087 18;053

Clamp, lever bracket Screw, lever bracket to damp Screw, lever fulcrum pin Nut, lever fulcrum pin "'"

TWISTGRIP and CONTROL CABLES for U.S.A. Handlebars are exactly as specified for standard TIOC.

NACELLE GEAR INDICATOR-GROUP 20

NACELLE GEAR INDICATOR

HI020 Rack and pinion assembly H689 Screw, rack and pinion to nacelle tin. U.H .... H937 Spindle assembly H939 Finger, indicator H688 Screw, finger to spindle f.r in. U.H. H921 Plate, gear indicator

GEAR INDICATOR CABLE

D282 Cable assembly, gear indicator D282C Casing. gear indicator cable D282W Wire, gear indicator cable 12/083 Ferrule, gear indicator casing D285 Nipple, gear indicator cable (Engine end) 18/115 Nipple, gear indicator casing (Indicator end) E3280 Abutment gear indicator cable C/case ... H1019 Spring, gear indicator cable D284 Adjuster, gear indicator cable ... H745 Locknut, gear indicator cable adjuster

no noc 2 2 4 4 2 2 2 2

I I 2 2 I I I

I I I 2 2 I I 2 2 I I I I I I I

~

PROPRIETARY FITTINGS

Ancillary equipment which is fitted to our motor cycles is of the highest quality and is guaranteed by the manufacturers and not by ourselves. Any repairs or claims should be sent to the actual maker, or one of their accredited agents who will always give owners every possible assistance. The following are the addresses of the various manufacturers.

CARBURETTERS

CHAINS

ELECTRICAL EQUIPMENT

HORN ...

SPARKING PLUGS

SPEEDOMETERS

SUSPENSION UNITS (Service)

(Guarantee claims only)

Messrs. Amal Ltd., Holdford Road, Witton, Birmingham; 6.

Renold Chain, Ltd., Wythenshawe Manchester.

Messrs. J. Lucas, Ltd., Great Hampton Street, Birmingham, 18.

Messrs. Clear Hooters Ltd., Hampton Street, Birmingham, 19.

Champion Sparking Plugs Ltd., Feith am, Middlesex.

K.L.G. Sparking Plugs Ltd., Cricklewood Works, London, N.W.2.

Lodge Plugs Ltd .. Rugby, Warwickshl re.

... Messrs. Smiths Motor Accessories Ltd., Cricklewood Works, London, N.W.2.

... Girling Ltd ..

47

Kings Road. Tyseley, Birmingham. II.

Tciumph Engineering Co. Ltd., Meriden Works, Alles ley. Coventry.

GROUP 21 - LUCAS ELEaRICAL EQUIPMENT


LUCAS ELECTRICAL EQUIPMENT- GROUP 21 ALTERNATOR (RMI3) nonoc

I 047518 Alternator assembly 2 466124 Rotor I 3 468678 Stator complete I I 4 862898 Cable, stator output I I 5 E3475 Grommet, alternator cable I I 6 E3204 Screw, stator to chaincase. ! in. U.H. 5 5 7 El612 Washer, shakeproof 5 5 8 E1580 Key, rotor to shaft I 9 465909 Nut, rotor to shaft I

10 465910 Washer, rotor nut

RECTIFIER

II 47111A Rectifier 12 F3600 Nut, to frame

IGNITION COIL (MA6)

13 45077A Coil I 14 OS 57 Bolt, to bracket 2 2 ·-15 El612 Washer, shakeproof 2 2 16 F879 Nut, coil bolt 2 2 17 422567 Grommet, H.T. Cable I I 18 421863 Clip, H.T. cable ... I 19 236741 Sleeve, LT. cable 2 2

DISTRIBUTOR (ISDI)

20 40529A Distributor 21 406105 Clamping plate assembly 22 421106 Contact set 23 421327 Condenser 24 423759 Cam 25 421407 Spring set, auto advance 26 4210565 Weight set, auto advance 27 421054 Shaft and action plate 28 419645 Sundry parts set 29 DS57 Bolt, plate to crankcase i'. in. U.H. 30 525-13 Washer, plain 31 E3309 Sealing ring, distributor

BATTERY (PUZSE/11)

32 408200 Battery ...

48

LUCAS ELECTRICAL EQUIPMENT - GROUP 21


HEADLAMP (MCF S7S) TIOT20C

1 51519A Headlamp assembly I 2 516723 Rim, headlamp ". I 3 500291 Wire, light unit fixing ... 4 4 4 516728 Light unit I I 5 554946 Adaptor assembly 6 554710 Bulbholder, pilot 7 553780 Interior, pilot a 312 Bulb, main 30,"24W 9 988 Bulb, pilot 3W ...

10 H876 Adjuster screw, headlamp II H745 Locknut, adjuster screw 12 H875 Spring, adjuster screw '"·

LIGHTING AND IGNITION SWITCH (P.R.S. 8) 13 31443E LIGHTING AND IGNITION SWITCH 14 318323 Grommet, lor key 15 318241 Key ... 16 319333 Screw, for knob 17 318346 Knob 18 318343 Plate, index

• DIPPER SWITCH 19 380521 Switch, dipper

TAIL LAMP (529) 20 S3256A Lamp, tail 21 526404 Lens I 22 526406 Window, number plate I 23 133551 Screw, fixing lens 2 2 24 161385 Grommet, screw ... 2 2 25 554719 Bulb holder I I 26 526408 Base, rubber I I 27 988 Bulb, 3W ... I 28 526410 Screw, lamp to number plate 3 3 29 166103 Nut, lamp to number plate 3 3 30 188366 Washer, lamp to number plate 3 3

WIRING HARNESS 31 838121 Harness wiring ...

HORN (CLEAR HOOTER) 32 D300 Horn 33 H886 Button, horn (No. IS). 34 D314 Bracket, horn

49

GROUP 22-AMAL CARBURETTER

FIG. 14.

AMAL CARBURETTER


'---------------6

---------4

~-------5

~~=====~3~4 ~----------------~

-----------------------14

~------------------------17

>--------------------22

50

AMAL CARBURETTER - GROUP 22

R£F. No. PART No. DESCRIPTION QUANTITY

AMAL CARBURETTER- GROUP 22 (See also page 61 for Zenith Carburetter)

CARBURETTER T20T20C

332/J Carburetter. complete

MIXING CHAMBER 2 332/001 Body, mixing chamber ... 3 332{012 Cap, mixing chamber 4 332{013 Spring, mixing chamber cap 5 332/014 Screw, mixing chamber cap spring and throttle locating 6 332.'011 Top, mixing chamber ... 7 52}068 Adjuster, throttle cable ... 8 332/005 Valve, throttle (Cutaway '4) 9 332J021 Spring, throttle valve ...

10 332/018 Screw, throttle adjusting II 3321020 Nut, throttle adjusting screw 12 332/017 Screw, air adjusting 13 4/148 Spnng, air adjusting screw 14 332(002 Jet for needle (0·086 in.) 15 332/003 Needle for jet 16 332/004 Clip, jet needle ...

.. 17 4'042 Jet, main (size 100) 18 376'076 Jet, pilot (size 20) 19 332'026 Nut, pilot jet cover 20 1WI62 Washer, cover nut


/flust. No. Part No. Page No. Ref. No. 11/ust. No. Part No. Page No. Ref. No. , __ , _____ ~

I 0316 45 I 18 376;076 51 18 2 332 001 51 2 19 333 016 52 I 3 332.'012 51 3 20 14.189 52 2 4 332013 51 4 21 4 043 52 3 5 332 014 51 5 22 4053 52 4 6 332 011 51 6 23 62214 52 6 7 52.068 51 7 24 62212 52 7 8 332.005 51 8 25 62204 52 8 9 JJ2021 51 9 26 22 016 52 9

10 332 018 51 10 27 22 013 52 10 II ll2 020 51 II 28 62207 52 II 12 323.017 51 12 29 352208 52 12 13 4•148 51 13 30 352.207 52 13 14 332:'002 51 14 31 14;178 52 14 IS 332 .. 003 51 IS 32 14 175 52 IS 16 332 004 51 16 33 332 026 51 19 17 4 042 51 17 34 116;162 51 20

51

GROUP 22- AMAL CARBURETTER GROUP 23 - SPEEDOMETER GROUP 24- SPARKING PLUG

REF. No. PART No.. DESCRIPTION

I 2 3 4

~

6 7 8 9

10 II 12 13 14 IS

16 17 18 19

20 21 22 23 24 25 26 27 28 29

30 31 32 33

333:016 14,:189 4.043 41053

Screw, mixing chamber plug Washer, plug screw Bolt, holding Washer, holding bolt

FLOAT CHAMBER 3EB 62/214 62/212 62!204 22j016 22j013 62;207 352/208 352!207 14 Jl78 14f175

Float chamber complete Body, float chamber Cover, float chamber complete Screws, float chamber cover Float Needle, float Tickler Spring, tickler Screw, tickler spring fixing Locknut, seating Washer, seating locknut

E3254 E3250 F879 S2S-13

CARBURETTER FIXINGS (TRIUMPH) Block, Insulating carb. to head Joint waasher, carb. to head ...

Nut. carburetter flange Washer, carburener flange nuts

SPEEDOMETER-GROUP 23 80421 '36.2 Speedometer, 80 m.p.h.-Non-Trip ". 80421:55/2 Speedometer, 80 m.p.h.-Non-Trip ". 80421.·37'2 Speedometer, 140 k.p.h.-Non-Trip ... 31 :4:211 Fixing strap. speedometer 3 I! I 7 Nut, fixing strap 0356 Cable, speedometer drive 58 ins. (53395) D356C Casing. speedometer drive (53398) 0356W Wire, speedometer drive (52108;1) 0175 Gearbox, speedometer drive (52283/64;3) F3098 Clip, speedometer cable

SPARKING PLUG- GROUP 24 HN Plug. sparking (Lodge) ... F80 Plug (single point) sparking (K.L.G.) ... LIOS Plug, sparking (Champion) 0297 Cover, sparking plug

52

QUANTITY

no noc I I I I

I 2 2

I 2

I 2 2 2

A

2

I 2 2 2

·-

TWINSEAT- GROUP 25 CHAINS - GROUP 26

GIRLING SUSPENSION UNIT - GROUP 27


I 2

3 4 5 6 7 8 9

10 II 12 13

14 IS

16 17

18 19 20 21 22 23 24 25 26 27 28 29

F4098 F4272

E667A S25-3 s 1-51 F4105 F4261 El612 F879 F4361 F4129 GS299 H745

0338 D341

0382 0277

TWINSEAT- GROUP 25

Twinseat, c/w attachments Twinseat, c/w attachments

SPECIAL NOTE. Seat less rear bracket interchangeable :

Bolt, front bracket to frame. I! ins. U.H. Washer, plain Nut, front bolt Bracket, rear Bracket, rear Washer, shakeproof Nut. bracket, to pan Safety strap twinseat Screw, strap to seat, ~ in. U.H. Washer, shake proof Nut. strap screw ...

CHAINS- GROUP 26

Chain, primary 110044. ~ in, >: fu in. x 48 !inks Chain, rear I 1044,! in. x ~~ in :< I 16 links


Chain, primary I 14038, ; in. •.· ;, in. Duplex '' 62 links ... Chain, rear 110044, ! in. x ih in .• < I 12 links

GIRLING SUSPENSION UNIT- GROUP 27

SC2.6l209 Suspension unit, complete SC3.204 Suspension unit. complete 9054!316A Bonded bush, top 9054i316J Bonded bush, bottom ... Fl760 Bolt, unit top, I i~ in. U.H. $25-2 Washer, unlt top and bottom ... P0172A Nut. unit top and bottom F-4311 Bracket, unit bottom ... H622 Bolt, bracket, I g in, U.H. F3207 Spacer, bracket bolt EIDOC Washer, plain Sl-51 Nut, bracket bolt

53

T20T20C

I

2 2 2 2 A A 4 4 4 4 4 4

2 2

2 2 2 2 2 2 4 4 4 4

2 2 2 2 2

GUARANTEE

W E give the following guarantee with our motorcycles, motorcycle combinations and sidecars, including all accessories and component parts other than tyres, saddles, chains and lighting and electrical equipment, and other than accessories and

component parts supplied to the order of the Purchaser and differing from those comprised in the standard specifications supplied with our motorcycles. motorcycle combinations and sidecars, but including accessories and parts supplied by way of exchange as hereinafter provided. This guarantee is given in pface of any implied cond1tions or warranties or any liabilities whatsoever statutory or otherwise ; no guarantee except that hereinafter contained and no conditions or warranty whatsoever statutory or otherwise is given or Is to be Implied, nor are we to be under any liability whatsoever except under the guarantee hereinafter contained. Any statement, description, condition or representation contained in any catalogue. advertisement. leaflet or other publication shall not be construed as enlarging, varying or overriding anything herein contained. In the case of machines (a) which have been used for "hiring out" purposes or (b) any motorcycle and 'or sidecar used for any dirt track, cinder crack or grass track racing or competitions (or any competition of any kind within an enclosure for which a charge is made for admission to take part in or view the competition) or (c) machines from which the trade mark, name or manufacturing number has been altered or removed or (d) any machines in which parts have been used not supplied by or approved by the motorcycle manufacturer or (e) any machine from which the silencing system as fitted by the manufacturer has been partially or wholly removed or interfered with. no guarantee, condition or warranty of any kind statutory or otherwise, is given or is to be implied. nor are we to be under any liability whatsoever in respect of any such machine. We guarantee, subject to the conditions mentioned below, that all precautions which are usual and reasonable have been taken by us to secure excellence of materials and workmanship but this guarantee is to extend and be in force for six months only in U.K. and ninety days overseas from date of purchase, or date of exchange in case of any accessory or part supplied by way of exchange as hereinafter provided, and damages for which we make ourselves responsible under this guarantee are limited to the free repair of or supply of a new part or accessory in exchange for the part of the motorcycle, motorcycle combination or sidecar or accessory which may have proved defective. We undertake, subject to the conditions mentioned below, to make good in manner aforesaid any part or accessory covered by this guarantee which has proved defective within the said period. We do not undertake to replace or refix or bear the cost of replacing or refixing any such new part or accessory in the motorcycle, motorcycle combination or sidecar. As motorcycles, motorcycle combinations and sidecars are easily liabfe to derangement by neglect or misuse, this guarantee does not apply to defects caused by wear and tear, misuse or neglect. The term "misuse" shall include, amongst others, the following acts : 1, The attaching of a sidecar to a motorcycle in such a manner as to cause damage or calculated to render the latter unsafe when ridden. 2. The use of a motorcycle or of a motorcycle and sidecar combined. when carrying more persons or a greater weight than that for which the machine was designed by the manufacturers. 3. The attaching of a sidecar to a motorcycle by any form of attachment not provided, supplied or approved by the manufacturers, or to a motorcycle which is not designed for such use. We do not guarantee tyres, saddles, chains or fighting and electrical equipment, or any accessories or component parts supplied to the order of the Purchaser differlng from those comprised in the standard specifications supplied with our motorcycle combinations or sidecars. As regards all such tyres, saddles, chains, lighting and electrical equipment. accessories and component parts, no guarantee, condition or warranty of any kind statutory or otherwise is given or is to be implied, and we are to be under no liability whatsoever in respect thereof.

54

CONDITIONS OF GUARANTEE

If a defective part or accessory should be found in our motorcycles. motorcycle combinations or sidecars, or in any part or accessory supplied by way of exchange as before provided, it must be sent to us CARRIAGE PAID and accompanied by an intimation from the owner that he desires to have it repaired or exchanged free of charge under our guarantee, and he must also furnish us at the same time with the frame number of the machine, the date of purchase or the date when the alleged defective pare or accessory was exchanged as the case may be. Failing compliance with the above, such articles will lie here at THE RISK OF THE OWNER. and this guarantee and any implied guarantee, warranty or condition shall not be enforceable.

REPAIRS

Any motorcycle. motorcycle combination or sidecar sent to us to be plated, enamefled or repaired will be repaired upon the following conditions, Le., we guarantee that all precautions which are usual and reasonable have been taken by us to secure excellence of materials and workmanship, such guarantee to extend and be in force for three months only from the time such work shall have been executed. and this guarantee is in lieu and in exclusion of all conditions and warranties statutory or otherwise, and all liabilities whatsoever and the damages recoverable are limited to the cost of any further work which may be necessary to amend and make good the work found to be defective.

NOTE

We do not appoint agents for the sale on our behalf of our motorcycles or other goods, but we assign to motorcycle Dealers areas in which we supply to such Dealers exclusively for re-sale in such areas. No such Dealer is aurhorised to transact any business, give any warranty, make any representation or incur any liability on our behalf. Published retail pnces are for delivery free of charge at Dealers' premises. All goods are offered for sale subject to the price ruling at time of delivery. We reserve the right to modify or deviate from the published specification.

TRIUMPH SERVICE

There are Triumph distributors and dealers in all parts of the world who carry adequate stocks ofTriumph parts and who are ready at all times to help and advise owners ofTriumph motorcycles.

55

INDEX

Group I-CARTON PACKS

Group 2-ENGINE Crankcase ... Crankcase bearings (engine) Crankcase filter Cylinder barrel ... Cylinder head Engine sprocket Flywheels and connecting rod ... Gasket set Inner cover, left side Inner cover. right side ... Oil pumps Overhead rocker and covers Outer cover. left side .. . Outer cover, rtght side .. . Piston

Push rods and cover Rocker oil pipe ... Tappets ... Timing gears and camshaft Valves, guides and springs

Group 3-GEARBOX AND CLUTCH Complate ... Clutch Clutch control Filler, level and drain plugs Gearbox casing bearings Gearbox sprocket Gearbox change mechanism Kkkstarter Selector forks and spindle Shafcs and gears

Group 4--EXHAUST SYSTEM

Group 5-FRAME

56

Page No.

5

6 8 8 9 6 6 9 7

12 9

12 8 6 9

12 6 7 7 7 8 7

13 13 15 16 15 14 15 13 15 13 13

18

18

Crankcase shield ... Pillion footrest brackets Swinging fork

Group 6-STAND ...

Group 7-TELESCOPIC FRONT FORK Steering races

Group 8-WHEELS Front wheel Front wheel brake Rear wheel Rear wheel brake Rear wheel chain adjuster

Group 9-MUDGUARDS Front mudguard ... Licence holder Rear mudguard ...

Group 10-NUMBER PLATES

Page No.

19 19 19

19

26 27

29 29 29 31 32 32

33 33 33 33

35

Group II-REAR CHAINGUARD 36

Group 12-TOOLBOX, BATTERY, CARRIER AND AIR CLEANER 36

Group ll-TOOLS 37

Group 14-PETROL AND OIL TANKS 39

Group 16-REAR BRAKE PEDAL ... 42

Group 17-HANDLEBAR 42 Control levers 42 Twistgrlp ... 44

57

Group 18-CONTROL CABLES Clutch cable Front brake cable Throttle cable ...

Group 19-HANDLEBAR (U.S.A.) ...

Group 20-NACELLE GEAR INDICATOR

PROPRIETARY FITTINGS

Group 21-LUCAS ELECTRICAL EQUIPMENT Alternator Battery ... Dipper switch ... Distributor Head lamp Horn Ignition Coil Lighting and ignition switch Rectifier ... Tail lamp Wiring harness

Group 22-AMAL CARBURETTER

Group ll-SPEEDOMETER

Group 24--SPARKING PLUG

Group 25-TWINSEAT

Group 26-CHAINS

GROUP 27-GIRLING SUSPENSION UNITS

58

44 45 44 45

45

46

48 48 48 49 48 49 49 48 49 48 49 49

51

52

52

53

53

53

•

INDEX TO ILLUSTRATIONS Page No.

Fig I. Engine and gearbox unit 10

.. 2. Malnshaft and layshaft gears 14

.. 3 . Clutch and shock absorber unit ... 17

" 4. Frame and components 20

" 5. Telescopic front fork 22

.. 6. Telescopic front fork T20C 24

.. 7 . Front wheel 28

" 8. Rear wheel ... 30

" 9. Mudguard, number plates and rear chainguard 34

.. 10. Toolbox, battery carrier and air deaner 37

.. II . Tools 38

.. 12. Petrol and oil tanks 40

.. 13. Handlebar and components 43

.. 14 . Amat carburetter .. , so

" 15. Zenith Carburetter 63

To assist the owner and dealer in identifying requirements. this book contains numerous exploded views of the major assemblies. Each component part on the illustration Is numbered, and by cross reference to the appropriate index, the part number of the component will be found. Against each part number a page and reference number is shown and by referring to the appropriate page. the full description of the part will be found against the reference number.

EXAMPLE.

To find the part number of the cylinder head gasket :

I. Refer to the illustration Index above, where It will be found that the engine Is illustrated on page 10.

2. Note that the number of the gasket in the Illustration is 9.

3. Refer to the Index on page II.

4. Note that illustration number 9 Is part number E3217 listed on page 6, line II.

59

Tournez ~·u voos plait. vease al dorsa. 6itte wenden.

MANIERE D'IDENTIFIER LA PIECE DE RECHANGE REQUISE Afin d'assister MM. !es marchands et MM. les possesseurs a !'identification des pieces de rechange.

ce livre contient de nombreuses illustrations des montages principaux en fa~on de "perspectives CclatCes", Chaque piece composante a !'illustration est numerotSe : en se rCferant a !'index approp;h~: on peut

trouver le numero relatif, A cOte de chaque pl(:ce illustrCe se trouve le numCro de Ia page et re numero de reference ; en se

referant a Ia page appropriC Ia description complete de Ia piC.ce sera fadlement constatC.

Exemple. Pour identifier le numCro de reference du joint de <:ulasse :

I. Se referer a Ia page intitulee "Index to Illustrations" oU on trouvera que le moteur est illustrE!e sur Ia page 10.

2. Noter qu'a cOte du joint de eulas.se se trouve le numero 9. 3. Se rCfc!:rer a l'index donne sur Ia page numero II. 4. On y constatera que sulvant le numero 9 se trouve :

(c) le numero relatif-E.32!7 (b) le numero de Ia page d'index-6 (c) Ia ligne de reference-! L

MAN ERA DE ENCONTRAR LA PIEZA DESEADA Para ayudar a! propietario y a! r-epresentante en Ia identificaci6n de las piezas deseadas este llbro

contiene numerosas ilustraclones de los prindpales montages. Cada pieza componente en la ilustrad6n esd: numerada y al referlrse al indke aproplada, se encontrari

el nUmero de Ia piez.a, Contra el nUmero de cada pieza se muestra el nUmero de referenda, y al referirse a Ia pi!gina apropiada

a descripdon completa de cada pieza se encontraroi contra el nUmero de referenda,

Ejemplo. "t Para encontrar el nUmero de piez:a de Ia empaquetadura de Ia culata de <:ilindro : I. Referirse a Ia piglna "Index to Illustrations" donde se vera que Ia ilustrad6n del motor est! en

Ia p!gina 10. 2. N6tesc que el nUmero de Ia empaquetadura en Ia ilustrad6n es 9. 3. Referirse al indice de Ia ilustraci6n en questi6n en Ia p<lgioa ! !. 4. Notese que no, 9 es pieza nUmero E.32J7 en Ia lista de Ia pligina 6, linea de referenda no. ll

ANWEISUNG ZUR IDENTIFIZIERUNG BENOETIGTER ERSATZTEILE Dieses Buch enthlilt uhlreiche Zerlege·AbbHdungen der Haupnusammenstellungen, un dem Besiter

t.<nd dem Verteifer beim lndentifizieren seiner fOrderungen zu helfen. Jedes Teil auf der Abbildvng ist mit einer Nummer versehen, und die Bestandtednummer wird durch Nachschlagen des bezUglichen Ver:reichnlsses gefunden. Mit jeder Teilnummer ist die seite und die Referenznummer gegeben. und durch Nachschlagen der bezUglkhen Selte wird die vollstandtge Beschre!bung des Teiles unter de Referenznummer gefunden.

Zum Beispiel. Um die Nummer der Zylinderkopfdichtung zu flnden ; 1. Sdtlagen Sie das Abbildungverz:eichnis, oben, nach, wo es gefunden wird. dass die Ma.schine auf

Seite 10 abgebildet ist. 2. Merken Sie, dass Nr. 9 ist die Nummer der Dichtung auf der Abbl!dung. 3. Schlagen Sie das Verzeichnis auf Seite t I, nach. 4, Merken Sle, da.ss die Abbildungnummer 9 ist die TeilntJmmer E..3217, eingetragen auf Seite 6

Zeile I r.

60

ZENITH 17 MX CARBURETTER T20 AND T20C

from Engine No. 39167

NEW TRIUMPH PARTS nonoc

I E3957 Cylinder head assembly 2 E3954 Adaptor, carb. to head I I 3 E3956 Stud, adaptor to head 2 2 4 F4470 Petrol pipe assembly I 5 D406 Cable, throttle I 6 D407 Nipple, carburetter 7 D411 Nipple, twistgrip 8 F4469 Rubber, air cleaner

ZENITH PARTS

9 17MXZ-CS5 Carburetter c/w throttle cable 10 017620 Body, carburetter II 017129 Fibre washer, large 12 017130 Gauze, filter 13 017131 Bolt, union 14 017132 Fibre washer. small 15 017133 Jet, slow running (SO)

• 16 017134 Jet main (78) 17 017621 Tube, emulsion ... 18 017624 Slide, throttle 19 017625 Spring. throttle slide 20 017628 Slide, starter (65) 21 017629 Top. mixing chamber 22 07087 Screw, top to body 23 017143 Adjuster, cable ... 24 07323 Locknut, adjuster 25 017144 Screw, throttle stop 26 017156 Spring, throttle stop screw 27 017145 Bolt, clamp 28 15321 Nut, clamp bolt ... 29 220630 Float 30 216472 Pin, float hinge 31 017630 Washer, joint 32 017583 Bowl, float I 33 07087 Screw, float bowl 2 2 34 017570 Adaptor, intake ... I I 35 07967 Screw, adaptor 2 2 36 04692 Washer, adaptor screw 2 2 37 017729 "0" ring. carburetter to adaptor I I

61

26

'~----·····----·~~······28

~~~.....:;:;;;;:;.£_ .. __ -~ ...... ~------ 24

~~~-----·----·------····"'·····---·-25

~~~~~~~============~~:

I 18 20 19 21

FIG. 15. ZENITH CARBURETTER

Maker's address: ZENITH CARBURETTER CO., Honeypot Lane,

Stanmore, Middlesex

62

INDEX TO FIG. 15. ZENITH CARBURETTER

ll!ust. No. Part No. Page No. Ref. No.

I 017620 61 10 2 017629 61 21 3 017143 61 23 4 07323 61 24 5 017624 61 18 6 017625 61 19 7 07087 61 22 8 017628 61 20 9 017144 61 25

10 017156 61 26 II 017145 61 27 12 15321 61 28 13 017621 61 17 14 017134 61 16 15 017133 61 15 16 220630 61 29 17 216472 61 30 18 017630 61 31 19 017583 61 32 20 07087 61 33 21 F4470 61 4 22 017131 61 13 23 017132 61 14 24 017129 61 II 25 017130 61 12 26 017570 61 34 27 07967 61 35 28 04692 61 36 29 F4469 61 8 30 0406 61 5 31 E3954 61 2 32 017729 61 37

63

2 3 4

5 6 7 8 9

10 II 12 13 14

F4465 F4466 F4467 F4468

366/2 366/001 366;002 366!004 3661007 366!008 376!079 16,070 366!006 D407

PETROL TANK

From Engine No. 38130 use

Petrol tank, less fittings Styling unit, L.H. Styling unit, R.H. Screw, styling unit

TWISTGRIP

From Engine No, 38130 use

Twistgrip, complete Body, top half "'

Body, bottom half Rotor Spring, friction '" Screw. friction spring Screw, fixing Grip, plastic Cable stop Nipple, cable

T20T20C

4

I I I

2 2 I I I

'

Documents

REPLACEMENT PARTS - JRC Engineeringjrcengineering.com/wp-content/uploads/2015/09/T20-1957-58.pdfTriumph Replacement Parts may ... the sender must be inserted ln the space provided