REPLACEMENT THEtrW asE - BSA Unit Singles Home Page SPC6... · REPLACEMENT PARTS CATALOGUE THEtrW asE ... TRIUMPH ENGINEERING ... We do not undertake to bear the cost of fitting any

REPLACEMENTPARTS CATALOGUE

THEtrWasE

TR25W 25 0 c.c. (15 cu. ins.)

www.bsaunitsingles.com

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REPI.ACEMENT PARTSCATALOGUE

TROPHY 250

TR.25.W.

g$otot C tle <tv *,ct,otet {t, rtcc,

Ul4ein czdgcnl 1ijt,.*Qr's,(. & n, r::..cetlc

HAWTHORNE WORKS, FAf(K STRItl , TTJAHrTrlrphonc: IHA|,IE 271 OXFORDSHIR$

COMPANY LIMTTEDCOVENTRY ENGLAND

TELEGRAMS ..TRUSTY, COVENTRY''

TRIUMPH ENGINEERINGMERIDEN WORKS ALLESLEYTELEPHONE I.IERIDEN I31

REF. No. trC6 PWI.ISHED MAECH 1968


1.

TRIUMPH GUARANTEE

ln this Guarantee the word "machine" refers to the motor cycle, scooter, motor cycle combinationor sidecar as the case may be, purchased by the Purchaser.

ln order to obtain the benefit of this Guarantee, the Purchaser must have correctly completed theregistration form and returned it to us within fourteen days of the purchase

We will supply, free of charge, a new part in exchange for, or, if we consider repair sufticient, willrepair tree of charge any part prove.d within six months of the date of purchase of any new machine,(three months overseas) or within three months of its renewal or repaii in the case of a part alreadyrenewed or repaired, to be defective by reason of our faulty workmanship or materials.

'We do not

undertake to bear the cost of fitting such new or repaired pait or accessory.

be defective must be sent to our Works, carriage paid, accompanied by the

Name of purchaser and his address;Date of purchase of machine;Name of dealer from whom the purchase was made;Engine number and model.

REPAIRS GUARANTEE

2.

3.

4. Any part considered tofollowi ng i nformatioH-

(b)(.)(d)

5. This Guarantee shall not extend to defects or damage appearing after misuse, neglect, abnormal stressor strain, or the incorporation or affixing of unsuitable attachments or parts and ii particular:-

(") Hiring out;(b) Racing and Competitions;(.) A.daptation or alteration of any part or parts after leaving our Works;(d) The attaching of a sidecar in a manner not approved by-us or to an unsuitable

This Guarantee shall ""I:i:J#:'i machines whose trade mark, name or manufacturing number hasbeen altered or removed, or in which has been used any part not supplied or approved- by us, or totyres, saddles, ch.ains, speedometers,_revolution counters and electrical'6quipmend br to parts suppliedto the order of the Purchaser and different from our standard specification.

Ou.r liability and.that of our dealer who sells the machine, shall be limited to that set out in this guarantee,and not other claims including.claims for. consequential damage or injury to person or prop-erty, shallbe admissable. All other coiditions and warranties statutor:y or othelwise'and whetfier express orimplied .are hereby excluded and no guarantee other than that expressly herein contained aiplies tothe machine to which this Guarantee relates or any accessory or part thereof.

We reserve the right to modify or deviate from the Published Specification without notice.

THE FITTING OF ANY COMPONENTS WHICH ARE NOT APPROVED BY THEMANUFACTURER INVALIDATES THE GUARANTEE

6.

7.

1' Whilst-the highest standard of workmanship. and- materials is aimed at, we cannot accept liability forany defects appearing more than three months after the machine, assembly or component has lefi ourWorks after being repaired.

We.will repair or re.place.at our option free of charge any.defective work, materials or parts relating!9.tlt. repairs carried out by us appearing within thaitime but shall nor be under any furiher or otheiliability for any other loss or damage whether direct or consequential and our liability shall be limitedto the cost of so making good. We do not undertake to bear the cost of fitting any replacement orrepaired part.

We do not accept liability in respect of parts of proprietary manufacture, e.g. tyres, saddles, chains,speedometers, revolution counters and electrical equipment which may be uied'by us in effecting arepair. All other conditions and warranties statutory or otherwise express or implied aie hereby excludEd.

2.

3.


r

Bore and stroke

Capacity

Carburettor

Compression ratio

Sparking plug

TROPHY 250 TECHNICAL DATA

Choke size

Main jetNeedle jet

Need le

Th rottle valve

F rontRear

Fuel tankOil tankGearbox ...Primary chaincase

Front forks (each leg)

Front and rear diameter

F rontRear

67 x 70 mm.

249 c.c.

10:1

Champion N3

Amal Concentric .928

28 mm.

170

.106

Stan d ard

No. 3

1 5 teeth

52 teeth

$ in.x $ in. Duplex x 70 links

j in. x 1f in. x 100 links

3.916 galls. U.S.

6 pints

{ pint

f, pintj pint

7 in. x 1j in.

3.25 x 18

4.00 x 18

Gearbox sprocket

Final Drive Sprocket

Chains

Capacities

Brakes

Tyre size


AIR FILTER

ALTERNATOR

BATTERY CARRIER

Poge

39

41

27

13

77

29

9

25

27

35

4t

11

41

31

75

47

7

2s

43

39

39

13

29

HORN

MUFFLER

OIL PUMP

OIL TANK

PISTON

PILLION FOOTRESTS

CARBURETOR

CHAINGUARD

CARTON PACKS

CONTACT BREAKER

CONTROL CABLES

CONTROL LEVERS

CHAINS

CLI-,'TCH

cotL

FENDERS

21,35

21

41

CRANKCASE

CRANKSHAFT

EXHAUST PIPES

CYLINDER HEAD

PROP STAND

REAR PANELS

REAR WHEEL

RECTIFIER

SPARK PLUGS

SPEEDOMETER

swlTcHEs

TIMING GEARS

STEERING RACES

SUSPENSION UNITS

27 41, 13

FOOTRESTS

FRONT FORKS

FRONT WHEEL

GAS TANK

GASKET SETS

GEARBOX

37

29

31

33

TWINSEAT

TOOLKIT

VALVES

19

45

39

11

4139

7

WIRING HARNESS

INDEX

Poge

47

15,43

23

HANDLEBARS

17,19 ZENER DIODE 43


-I

I

i

ILLUSTRATION INDEX

Fig. No.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

CYLINDER AND CRANKSHAFT

Poge No

8&10

17 &14

16 & 18

CRANKCASE

GEAR CLUSTER

CLUTCH

FRAME COMPLETE

SWINGING ARM

TELESCOPIC FRO

FRONT WHEEL

OIL-TANK, PANELS AND EXHAUST SYSTEM

FOOTRESTS AND BRAKE LINKAGE

NT FORK

20

72

74

26

28

30

32

34

36

38

42

44

46

GAS TANK, TWIN SEAT AND HANDLEBARS

ELECTRICAL EQUIPMENT

REAR WHEEL

FENDERS

TOOL KIT

CARBURETTOR

,10 &


TRIUMPH SPARES

HOYY TO ORDER. Every part is indicated by a number, and this should be quoted totether withthe description.. ln order to assist customers, dimensions have been given in many cises wheie parts aresimilar. Partswherepossiblehavebeenlistedinorderofassemblyandinumberoftheillustrationsihowtheassembly order also. With these aids, there should be no difficulty in identifying the parts you require.

ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OFTHE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS.

\ffHERE TO OBTAIN. Triumph Spare Parts can only be obtained from an authorised TriumphDealer, and we recommend our customers to place their ordeis with the Triumph Dealer in their distrii:t.When parts not usually asked for are required, ind for which the Dealer may have io write or obtain specially,the postage or carriage incurred becomes payable.

Customers are warned. against th-e risk incurred by purchasing parts that are not of genuine Triumphmanufacture. This risk is eliminated if parts are ordered is instrucied from recognised Deilers.

PROPRIETARY G ROUP

. Ancill-ary equipme.nt which is fitted to our motor cycles is of the highest quality and is guaranteed bythe manufacturers and not by ourselves. Any repairs or claims should-be diiected to rhe-actual makertor their local agents-who will always give owners every possible assistance. The following are the addressesof the various manufacturers:-

CARBURETTORS.Messrs. Amal Ltd.,Holdford Road,

Witton,Birmingham, 6

CHAINS.Reynold Chains Ltd.,Wythenshawe,Manchester.

ELECTRICAL EAUIPMENT.Messrs. J. Lucas Ltd.,Gt. Hampton Street.Birmingham, 18.

TYRES.Dunlop Rubber Co. Ltd.,Fort Dunlop,Birmingham, 24

The Avon lndia Rubber Co. Ltd.,Melksham,

Wilts,

SPARKING PLUGS.Champion Sparking Plug Co. Ltd.,Fe lt ham,

Middlesex.

SPEEDOMETERS.Messrs. Smiths lndustries Ltd.,Cricklewood Works,London, N.W.2.

SUSPENSION UNITS.Messrs. Girling Ltd.,Birmingham Road,

West Bromwich,Staffordshi re.


HOW TO USE THIS PARTS CATALOGUE

First check that the engine number of your machine is subsequent to that guoted on the title page.

Next consult the index on Page 0 for the parts or group of parts which you w.ish to locate. Whenyou have located the parts make slure from the end columns that the Part you have located does apply toyour machine.

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

Items marked "reference only" are not available from the factory.

ln case of painted items always state the colour.for that model of that particular year.

Model

Painted parts are available only in the colours specified

TR25W

N.B. Hi-Fi Scarlet is a flamboyant finish applied over GoldPaint is available only in Aerosol containers.

ColourHi-Fi Scarlet

PLEASE NOTE

THROUGHOUT TH]S LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTSINCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN, REVERTING

TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE

ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENTPARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.

SPECIAL WORKSHOP TOOLS

A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTINGVoun DEALER oR APPLYING DIREcT To THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASES

THESE Tools ARE

'ERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE' AND

rHEneronr, tr ts Noi RECoMMENDED THAT THE pRlvATE owNER PURCHASES THE Tools lN

ONOTN TO AID SERVICING 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 PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS

WILI- SE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS HAVINGTHIS 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.


The following sub-assemblies are supplied in carton packs under the C.P. part number stated. Thecontents ofthese carton packs are preserved and will not deteriorate under adveise conditions.

PISTON (complete with rings, gudgeon pin and circlips). These are in effect'carton pack'assemblies.

E7998

E8772

E8273

PISTON RINGS

cP 211

(Standard size)

PISTON RINGS

cP211120 1

(0.020 in. oversize) 1

1

PISTON RINGS

cP211140

(0.040 in. oversize)

OVERHAUL GASKET SET

DECOKE GASKET SET

CARTON PACK LIST

10:1 C.R.

10:1 C.R.'10:1 C.R.

E8276

E8782E8779

99-0031

99-0040

STANDARD SIZE

0.020 in. oversize0.040 in. oversize

Top Compression Ring

Middle Compression RingScraper Ring


Middle Compression RingScraper Ring


Middle Compression Ring

Scraper Ring

1

1

1

E8277

E8283

E8280

1 E8278

1 E8284

1 E8281


r

65

€)'!3 -ooce)-

\ -42u"--@)6)

sgtl o?

?A:,VO':)1 4t(@l

,r6R6fr

n"Y'ft"$

da7(6&

.ru

€

B14

Ofr\:6--- ./

I

36

-LF

N4'l

3S

@

20

NFis. 1 CYLINDER AND CRANKSHAFT


Ref. No Port No. DESCRIPT'ON QUANIIIY

1

2

3

4

5

6

7

8

8

9

10

11

17'13

14

15

16

17'18

19

70

21

22

73

74

24

25

76

27

78

79

30

31

32

33

34

35

36

37

38

39

40

41

E8031

88032

E8033

E8034

E8035

E8037

E8028

E8038

E8039

E1 580

E8144

E8836

E3705

E7977

E,+003

E6068

E7998

E8044

E8047

E8050

wE203EwE479El 895

E7728

E8053

E8055

E7739

E8008

E81 96

E821 5

E8197

E8228

E8229

E8079

E801 0

E8080

E8777

E8225

88276

E8081

E8137

E81 36

E7820

CYLINDER AND CRANKSHAFT

Flywheel d riveside

Flywheel bolts upper (1$ in. U.H.)

Flywheel bolts lower (2 in. U.H.)

FLYWHEEL TIMING SIDE

Flywheel screwed plug

WasherCran kshaft assy.

Shi m

Shim

Cran kshaft pin ion key

Rotor key

CONNECTING ROD

Connecting rod boltSelf-locking nut

Small end bush (split)Big end bush

PISTON COMPLETE

Plain compression ring

Taper compression ring

Oil control ring

Gudgeon pin

CirclipCylinder barrel ...Cylinder base washer

Push rod (exhaust)

Push rod (inlec) ..

Cam followerCylinder barrel stud

Stud nut ...WasherCYLINDER HEAD

Stud-short (2ft in o.A.)Stud

Stud-long (3fr in. O.A.)DowelStud (2"1{ in. o.A.)Carburettor stud (1$ in. O.A.)Valve guide (inlet)Valve guide (exhaust)

Cylinder head gasket

Carburettor stud nutCarburettor flange washer

Distance piece

1

4

4

1

1

8

1

A.R.

A.R.

1

1

1

2

2

1

2 halves4

1

1

1

1

2

1

1

1

1

2

7

2

2

1

2

2

3

2

7

2

1

1

1

7

1

1


r -T

u"--@)6)sst" g?

-i'..F

N4'l

39

1\qr.

/S- ,/ ^\S'e-Nl/ zs) \(UL 5- -2t

!"

Fis. 1 CYLINDER AND CRANKSHAFT


Ref. No. Port No. DESCRIPT'ON QUANI'TY

42

43

44

45

46

47

46

48

49

50

51

52

53

54

55

55

57

58

59

60

60

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

E7911

E7858

E7787

E7790

E1483

E7791

E1 483

El 575

E1 330

E8952

E8085

E8086

E8116

E8117

D911E81 38

D1002

1 4-0403

E8084

E7958

E7959

E7960

E1564

E1577

E8087

E8088

E8089

E8072

E8082

E8083

E81 05

E81 06

E81 07

E8110

E8111

E8112

E7777

E8113

E8114

E811s

CYLINDER AND CRANKSHAFTRocker boxRocket box gasket

Rocker spindleINLET ROCKER

Ball end

EXHAUST ROCKERBall end

Thrust washerTh rust washerlnspection coverGasket

Screw (l{ in. U.H.)Top collarSplit collet

SPARK PLUG (N3)Washer

Plug coverLockn utWasher

Corrugated ring...Corrugated ring...Corrugated ringlnspection Cap

WasherNutWasherNutWasherUnionFibre washerOIL FEED PIPE

Rubber connectionNippleUnion nut

Cliplnlet valve

Exhaust valve

Bottom cup

Valve spring-outerValve spring-inner

1

1

2

1

1

1

1

2

2

1

1

2

7

4 halves

1

1

1

2

2

A.R.

A.R.A.R.2

2

2

2

7

7

1

1

1

1

1

1

1

1

1

2

2

2

11


68K71

rF> /

Y@

M"rA1f il,,,(@l\\7 -5m-*brqHNi,t1t- 2lii

, il' 1 78

.r-l t[,---: \!,--[') ^s-.,'\*;+l'-"s,,"

W>W.o.--),u;' .ou @-::'"1o6gw ffi-,"ryg/ffi_-"& 27

-//o ,/) FJ( /n)^ ED-/ 45 'YW,,-H n 33

fu'' o'o" fui}#

so

1*@>4./1,w2.7 ffi,t'_ruvw/ 8."t9(fl po oo</15 35' -.\:-i,XJ /':" =,--{*-eNqy'p--l) sz IlJn!9- 34

-35

@

"/ lt

72

' 1'"

66

60/61

57 da

13

sa--@

u.--n@\=y

Fig. 2 CRANKCASE

63

\&

rn 1l

)xiP r

.>illLi r)* L,/// ll I/1r

a9J/ln !:

*q(ea\f9\-13:-€-]. -(a) -AJ

12

65


Ref. No. Port No. DESCRIPT/ON QUANTITY

11 E8009 DowelI

1

7

3

4

5

6

7

I9

10

17

13

14

15

16

17

18

19

20

71

22

23

24

25

76

27

28

79

30

31

32

33

34

35

36

37

38

39

40

41

42

43

E8000

E8006

E8003

E8025

1 4-0303

E81 35

E8007

E8008

E81 33

E8088

E801 6

E801 0

E801 1

E8012

E8017

E8064

E8070

E8072

E8071

E801 3

E8127

E81 32

E81 33

E81 34

E8090

E8092

E8093

E8094

E8095

E8096

E8097

E8098

E8099

E81 00

E8071

F9041

E81 03

E8A71

E8104

E8004

E8059

E8060

CRANKCASE

CRANKCASE COMPLETE

Cylinder securing stud

Crankcase bearing

Crankcase oil seal

Cylinder securing nutWasherCrankcase stud-top (2{f in. O.A.)Crankcase stud-rear (2j{ in. O.A.) .

NutWasher

Cran kcase boltHollow dowelSolid dowelSump stud

Scavenge pipe completeSump coverGasket

Plain washer

NutOil union stud (1{ in. O.A.)Oil pipes and union block'O' ringUnion nutWasherOIL PUMP COMPLETE

Spindle housing

Spind le

Spindle gear

Feed gear-drivenScavenge gear-drivingScavenge gear-d rivenDriven gear spindleBottom plate

Screw

Spindle gear nutSpindle gear washer

Gasket

Holding nutWasher

Camshaft bush

Camshaft

Camshaft pinion

(;//'.:' ,it C;.,clc dir --,, : *if {l;;, isdfg

l,tl.taitr *ttgcnt \C,,&,,;.8. #r "i"i' ,:'r""fq

llA\,"\/TH(JRi.L tt()Rl(5. fARK 5!"i{ t'i" T}"{nfrlftolcphonc: TTIAME 2:rl -1g ()XFt)trDSHIRi.


pd68K

78

\el

,.dvi'-52

55

41 az ,,43-36

s1-,,ffi-,"'&_,,

"$#t565t da

54- v g\>u.-@ F,,}\2o

Fig. 2 CRANKCASE

14


Ref. No. Port No. DESCRIPT'ON QUANT'TY

44

;4546

47

48

49

50

51

57

5354

55

56

57

58

59

50

61

62

63

64

64

64

65

66

67

68

68

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

E8051

E8041

E8040

E8043

E8042

E81 23

E8121

E81 20

E8122

T2696T2697

E8179

E81 73

E81 80

E81 81

E81 48

E3789

E3832

E3833

E3821

E8140

E8141

E8147

E81 39

E8144

E81 43

E7779

E7778

E8026

T2695

E8071

E8077

99-0739

E8224

E8146

E8174

E81 25

E8126

E7885

E81 59

E8288

E8022

T948

DipstickNyloc nutWasherRotor

Nut

Washer

Dowel

CRANKCASE

Woodruff key

Drive gear

Crankshaft pinionLockwasher

NutPressure release valve plug

Plug washerSpring

Ball

Gearbox drain plug'O' ringChain oilerRubber pipeFibre washer

Bolt (1j in. U.H.)Generator lead grommetOil seal housing

Gasket

Oil seal

Screw

Distance plece

Distance piece

Distance piece

Engine sprocket (23T)

Chain tensionerDistance piece

1

1

1

1

1

1

1

6

A.R.

A.R.

A.R.

1

1

2

1

1

1

1

3

3

1

1

1

1

I

1

1

1

2

2

1

GeneratorGeneratorGenerator

stud-rear (2ii in.)

stud-front (2if in.)

stud-bottom

Lockwasher

Non-return valve spri ng

Valve ball

Valve screwSealing plug

Stud (21f in. O.A.)

'O' Ring for dipstick

15


T ./""K) ,53,,'s+/q'?--

2V

{'l

8469

P\62

GEAR CLUSTER

59

Fis. 3

16

<-q^l ffi/)\ru82

f o-,"

7a z6

^/t 77

oK^,1i"'/,^ I

,A'iL

lq o@


Ref. No. Port No. DESCR/PflON QUANrln/

1

2

3

4

5

6

6

6

7

8

II9

10

11

12

13

14

15

16

17

17

18

19

20

21

22

23

24

25

26

77

28

29

30

31

31

31

32

33

34

35

36

T2661

T2676T2753

E801 5

E801 4T2678T2679

T2680

T2673r2664T266512666r2662T2663

E81 51

E81 52

T2677

T2685

T2686

T2667

T2671

T2672

E8005

T2668T2669

T7674T2675

T2752T2670T2733

T1 391

T2750T2699

T2700E801 9

T2765T2701

T2766

T2702

T1434T1164

r2450T2703

GEAR CLUSTER

Mainshaft complete with bush

HIGH GEAR (22T)

High gear bush

Mainshaft oil seal

Mainshaft bearingThrust washer

Thrust washerThrust washerMainshaft second gear (21T)

Spacer

Spacer

LockwasherNutGear change pedal

Pedal rubber

1

1

2

1

1

A.R.

Spacer A. R.

Mainshaft third gear (24T) 1

Mainshaft Iow gear (16T)

Mainshaft bearing

Bearing circlipFelt washer

LockwasherMainshaft n utLayshaft and high gear (14T)

Thrust washerThrust washerLayshaft bearing ...Layshaft second gear (22T)

Layshaft circlipLayshaft third gear (19T)

LAYSHAFT LOW GEAR COMPLETE (27T)Low gear bush

Spacing shim

Clutch push rodPush rod bush

Clutch lever completeClutch operating rackClutch operating pinionThrust ball

Gearbox sprocket (15T)



A.R.A.R.

1

A.R.A.R.

AlternativeAlternative

1

1

1

1

1Pedal bolt (j{ in. U.H.)

17


_--1

34

ffi2V

{

.R82

@-zs76

t/ -rz

,(

78

-K^,1i"'{,^ i

'ro ,L

93

/ .e6/," 95wW{'*

/q ot@


Ref. No. Port No. DESCR/PTlON QUANIIIY

3738394041

42434445464748495051

5253545556575B596061

62636465666768697071

72737475767778798081

82838485868788899091

9293949596

T2692T2693T1277T7107r2435r2106T210sT1109T7689T2659T2588T2690T1 069T7691T1749T1076T'1180E81 50E3172E81 53E81 54E8157E8'155T2763T2774T2330T1169T1167E81 25r2704T27AsT2706r264.3E8005T2687T2660T2657T2658E2681E2682T2683T2684E8172E8072E7919E81 60E8161E8232E801 0T2641T2647E8167E81 58E81 60E8169E81 70E8171E8737E7882E7354E81 6s

GEAR CLUSTER

GEARCHANGE QUADRANT COM PLETEGearchange quadrantSpring rivetKeeper plateScrewSpringPl u ngerReturn spring

Selector forkAnchor boltSelector spinCleCam plateCamplate spindlelndex springSpring backing

1

1

21

1

271

21

1

1

1

1

1

21

1

1

1

1

1

1

1

1

I1

1

1

1

1

1

1

1

1

1

521

21

1

3

1

43

1

1

1

1

22

Camshaft oil sealCrankshaft T/S oil sealOil seal circlip

SpringSteel ball

Cotter pinCotter washer

Return springAnchor pin

ScrewLockplateCamshaftP.g

KickstartCirclipK ic kstartBushPin ionSpri ng

Washer

Cable grommetKICKS1ART CRAN K cov pLiir

Kickstart folding pedalPedal rubber ...

Pivot bolt (1 in U.H.)

Cotter nutKICKSTART SPINDLE

Needle roller

stoP

ratc h et

Contact breaker clip

lnner timing coverln ner cover screw-shortlnner cover screw-bottomOUTER TIMING COVER

front

DowelKickstart oilBush

seal

Outer cover screwOuter cover screwlnner cover screwOuter cover screw ($ in. U.H.)lnner cover screw (jf in. U.H.)Outer cover screw (2$ in. U.H.)CoverGas ketScrew ({S e r rated

in. U.H.)washer

19


10

\ ,,-.-@19 ,,"

\16

Fis. 4 CLUTCH


Ref. No. Port No. DESCRIPTION QUANrtry

CLUTCHFiller plugFibre washerPrimary chaincase coverChaincase gasket

5 E8168 Cover screw6 E8160 Cover screw

E8174 Drain plugI9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

Washer

Screw ({ in. U.H.)

Centre

Spring nut

1 E8231

2 NE507

3 E8953

4 E7856

2

2

1

1

, 7 F9174 lrrain nrrr-

E8175

E801 0

D951

E8176

E895s

E8178

E8177

T2713T2714

T2715

T2716T2719r2720Reference on lyr2721T2722T2723

T2724T272s

T2726

T2727

r1144T2748T2728T2729

F879

T2730T2731

T2732

Chaincase dowelPrimary chain (701.)

lgnition pointer screw ...lnspection coverGasket

Clutch hub

Clutch hub key ...Clutch spiderSprocket and housing

RollerINNER RETAINING PLATE

Spring studOuter retaining plafe

Shock absorber-drive and rebound

Driven plateDriving plateSpring

cuP

Pressure plateAdjuster...Lockn utRetaining nutPlain washerLockwasher

1

1

1

25

1

4

1

4I1

5

4

4

4

4

1

1

1

1

1

1

21


,41

fu+z F-o,[email protected] U

e\l_38

cl,s

@Jr>a3g,-@-44@-ou

.27

q.'33 dg

-51g'

Fig. 5 FRAME COMPLETE

35

'o-p

,/----'\/--l. a 0 \r.(

i

N

19 "(O.I^

\K?rs--1Gn I -\rzYre 1s

itr'

11LL

L

-


Ref. No. Port No. DESCR/PTlON QUANr/Ty

1

23

456789

1011

17131415161718192021

2273242526277829303'1

3733343535373839404142434445464748495051

52535455

F8451F8994Reference onlyF8995F8996F881 9F9029E81 34F8984E8084E8194F8985F8987F8986E81 89F5535s25-2881 34E81 33F9745F5535E8084E8194E81 91F8988F9094F9093F9090Reference onlyReference on lyF9091F9097E8071F9060E8072E8071F8989F8285F9003F9004F9005F9006F9007F9008E8137F9086F9007F901 0E8194F9087F9227F9084F9023w1691E8088

NutBolt (3 in. U.H.)Mounting rubber

FRAME COMPLETE

FrameSWINGING ARM SPINDLE

Spindle locking plateSpindle nutShakeproof washerEngine shieldBolt (l in. U.Shakeproof was

(j in. u.H.) ..,eproof washer

Front engine fixing bolt (3fr in. U.H.)S pacerNutRear stud (21| in. O.A.)Rear nutWasherSteady bracketBoltWasherShakeproof washerNutEngine steady stayBoltPlain washerNutShakeproof washerSteering race cupBracketRubber bufferTool trayFastener clipPop rivetBolt (.641 in.SpacerNutBolt ($ in.WasherNutBottom boltBattery carrierBattery tray rubberHookBattery strapBoltMou nting ru bberWasher

221

271

221

1

1

221

3

3

3

3

21

1

1

612

1U.H.)

U.H.)

WasherNut

Nut

S pace rTank anti-roll rubber'P'clipBolt (j{ in. U.H.)

Washer

23


Fis. 6 SWINGING ARM

24

*---** ',c


Ref. No. Port No. DESCR'PflON QUANTITY

SW I N G I N G A R M

1

7

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

F8992

F8993

F8876

F8997

F8998

F8999

F9085

F9766

F3097

F3096

F2610

F9059

F9060

E8071

w2336E8084

F908s

Swinging armSilentblocSuspension unitUnit fixing boltPlain washer

1

2

2

2

2

2

2

1

1

1

1

1

1

1

1

1

1

Swivel pin

Lockwasher

NutNutPropstand

Spring

BoltNutBolt

Nut

Chai nguard

I

'11

,l

il

I

Plain washer

.]:,'.l

ULlotot C; cie & j)eoe*r {x*inccla/lein e,tgcnt 9.'S,cxt'' & 'Aeloccttc

HAWTHORhIE vt'()RKS, PAR.K sTR'Nl' -fl-:Al{}

Trlcphoncr YHAi'4.E 277 C)XFORDSHIRf

25


p11

.2\/12w

w814

\

13 ""

btrg '\>1-q,

32

s ..-:-1---\J + U --..\'@>,$.

i

I

l

Nri

I

I

\-

OIL-TANK, PANELS AND EXHAUST SYSTEM


Ref No. Port No. DESCR'PT'ON QUANT'N'

1

2

3

4

5

67

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

78

29

30

31

33

34

35

F9241F8975

F9128

F9179

s5102

14-011414-0707

F8981

E9514

F8976

F8977

F8978

F9743

F9067

F9068

F6039

F9075

F9076

F8874

F9070

F9071

F9146

F9073

F9124

E5473

t't927D1922F9477

D1923

F9478

D1006

olL TANK, pANELS AND EXHAUST SYSTEM

MufflerFIXING CLIP

Pin

Swivel

NutBoltNutPlain washerExhaust pipeFinned clipScrew (ff in. U.H.)NutOil tankBolt (1f in. U.H.)NutRubber sleeve

Filler cap c/w dipstickFiller cap washerBanjo

Fibre washer

FilterRubber connection

Oddie stud-long, 32 D982 Oddie stud-standard

33 D893

ClipRubber connection

ClipSleeve

Panel motif D/S . .

Panel D/S

Panel motif T/S

Panel T/S

Stud rubberStud rubberFastener clipRivet

1

3

1

2

4

D984

Reference onlyReference only

27


N30

24

2sdr^1e31

b,z4 $**[*gfu, ,a

N,,,;%6,Y*w k"

ei#\^" ^y2'sw

Pkb,( \/re*ge--*

35YRN^

Fis. 8 FOOTRESTS AND BRAKE LINKAGE


Ref. No. Port No. DESCRIPTION QUANT'T)'

1

2

3

4

5

6

7

I9

10

11

12

13

14

15

16

17

18

''920

21

22

23

24

25

26

27

28

29

3o

31

32

33

34

35

35

36

37

38

39.{0

41

42

F9031

F9032

F9033

F9034

E81 93

s26-1

F9035

F9036

w2006F9037

F9038

F9039

F9040

F8979

F9041

F9042

F9043

F8448

F9044

F9045

F9046

F8986

F8987

F9085

19047

F9048

F9049

F9050

F9034

F9051

F9057

E8137

F9053

F9054

t9044F9055

E8084

F9085

t9057E8137

F91 33

F8991

E81 37

FOOTRESTS AN D BRAKE LI N KAGE

Rear brake pedal

Fulcrum pin

NutWasherBolt (f in. U.H.) ...Spring WasherPlain washer

Rear brake rod

Toggle spring pin

Bnake pedal stop

Swivel pin

Adjuster nutAdjuster boltWasherShakeproof washer

NutFolding footrestFootrest bracket

Anchor bolt

1

1

1

1

1

1

1

1

1

1

1

1

2

2

,t

2

2

7

2

Bolt (2jf in. U.H.) 1

Plain washer 1

Spring washer 1

1

2

1

1

1

1

1

2

2

2

2

7

1

1

2

2

2

2

1

3

4

NutNutStud (2 in. O.,A.)

Locking plate

Washer

NutSpring washerFootrest rubberBolt

Pillion footrestRu bber

Anchor bolt O/SAnchor bolt N/S

Plain washerNutBolt (1{ in. U.H.)NutPillion footrest support bracket O/S

Bolt

Nut

Nut

29


R"EI

;" mr,'

52&

Ag4 6"'I 'eh4 \\k\n \\ \

w;\\ \

*&46--€.Or-@ae'=€l4e__g??tg

-g*sq-@ 4s

36---\d<:g 22L_ry /

Fig. e TELESCOPIC FRONT FORK


Ref. No. Port No. DESCR'PT/ON QUANflT)',

1

23

44567I9

10111213141516171819202122232475262728293031

323334353637383940414743444546474849505152535455565758596061

H3610H2679F8980H3652H3653H2513H2630l-12631H2632H2633H2634H263sH2636H2637H2638H2639H2640H7514H2641H2643H3678H2536H2s7sH2645H2646H2647H2648E8125H2650H2651H2652H2653l-12526s78514-0303H2654H2655H2656F8981H26s8H2659H2660H7661H2662H2688H2664H2665H2666t12667E8071H2668H766eE81 33H7670112671H7237H362514421714{7021+6102s2l12E8088

FRONT FORKS

FORK ASSEMBLY COMPLETEBolt (1ft in. U.H.)Spring washerSleeve complete N/SSleeve complete O/SGaiterWasherSpacerSealing washerSealing washerDrain plugFibre washerStanchionTop bearing

Oil seal holder and bearing spacerMain springGaiter ringTop LugBoltSpecial nutTop coneBottom coneSteering headDust cap ...Sleeve nutNutPlain washer

Bottom bearing ...Shaft plugPlug washerOil seal holderOil seal

ball

1

441

1

227422222222222221

1

1

1

1

401

1

221

221

24422222222227222221

1

1

1

1

21

Middle lug and stemPinch boltNutCable guideHandlebar clamp

Damper Tube

Cable guide bracketGronnmet

BushCirclipBoltCirclipValve collarValve

Washer

Valve seatingNut

Damper rodNutSealing.washerRetainerHeat slnkBracketBoltNutBoltWasherSpacer

31


22

\dd

Fis.10 FRONT WHEEL

32


Ref. No. Port No. DESCRIPI/ON QUANTTTv

1

2

3

3

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

71

22

22

23

w3424w3323w1230w3325w1236w3329w330s79-7w653w1237w1238w1641w1481w2710w3337w582w1301w1639E8084

E8999

w7069w492w2000w202714-0403w1197w1198w1246w1406w1407Reference onlyReference onlyReference onlyw141sw13sw'I640

FRONT WHEEL

FRONT WHEEL COMPLETE (LESS BRAKE AND TYRE)FRONT WHEEL RIM, HUB AND SPOKES ASSEMBLY

Rim

Hub

Spoke D/S

Spoke T/S

Spoke T/S

N ippleBeari ng

Dust coverCirclipSpind le

Grease cap D/S

Cover plate

Bearing support ringBearing retainerAnchor plate

Fulcrum pin

Fulcrum pin washerFulcrum pin nutBrake cam

Lever returnBrake cam

sPnnS

Brake cam washerBrake cam nutBalance weightBalance weightSpindle nutLEADING BRAKE SHOE

TRAILING BRAKE SHOE

Brake shoeBrake liningBrass rivetPivot pad

Brake shoe springCable abutment

shortlong

1

1

1

1

20

10

10

40

7

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

A.R.

A.R.1

1

1

2l Not2 lServiced

1 6J Separately

2

7

1

242576

77

28

29


31M

44 at^tff€4-{J

Fig.11 REAR WHEEL

'14W19

34


Ref. No. Port No. DESCRIPTION QUANfln',

REAR \^/HEEL

REAR WHEEL COMPLETE (LESS BRAKERIM, HUB AND SPOKES ASSEMBLY

1

73

456789

1011

17131415161718192021

22232475767728793031

3233343536373839404142434445464748495051

5253545555

w2789w2290w2297w2297w2293w2294w2291w2309w2339w101sE8137E8088w2335w2335w2337F9085w2325w2324w2323w2327w2327Reference onlyReference on lyw2328w7329w2276w2326w2334w2330w2331w2332w2317D1 02stw2314w2317w2311w231sw2316w2308w2305w2298w2299w2313w2310w2300w229sw2318w2354*w2319w2320w2302w2301w2303w2304D1026w2306w2307w2333

AND TYRE)

Hub completeSpoke N/SSpoke O/SN ippleRim

Fixed spindle nutChain adjusterChain adjuster end cap ...Adjuster nutAd juster washerTorque stayBolt (1..| in. U.H.)WasherNut

1

1

1

202040

1

1

22221

1

1

1

1

1

1

1

2

1

1

1

1

1

1

3

1

1

1

1

661

1

71

1

1

1

21

1

1010

1

1

1

1

1

1

1

1

Nut

Fulcrum pinFulcrum pinFulcrum pinBrake anchor plateBRAKE SHOE COMPLETE WITH LINING

Brake liningBrass rivet

Brake shoe springBrake cam lever ..BRAKE CAM

Grease nippleBrake lever return springPlain washerShakeproof washerNutLocking plateRear Chain (fDriving FlangeBearing circlipBearing Shim

x j x rozlj

Bolt

nut...washer

2l NotServiced1 4-,;l Separately

2

Fixed spind leBearing retainerBeari ngThrust washerWasherBeari ngSpind le sleeveSecu rity boltBrake drumChainwheel (52T)Chainwheel boltSpring washerlnner retainerFelt washerOuter retainerHub end coverSpeedometer gearboxDistance collar inner O/SDistance collar outer O/SHub spindle

tEarly editions have 99 Link chain D1023

35

*Early editions have 49T chainwheel 41-6091


l''t''\

@,.aY55--st 1e

flw"' eb

,P12 11

6't3

@^:

qq., .t3

%

Fis.12 FENDERS

36


Ref. No. Port No. DESCR'PTION QUANTITY

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

't6

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

F9016

H3619

H3621

H3523

F9019

F9068

F9029

E8088

w1691F9017

F9088

r W1691

t8991

E8088

E81 34

F9026

F9506

F901 9

F9027

F9020

F879

F9023

E8088

E81 37

F9028

F9481

F9023

E8088

w'l691F81 39

E2980

F9132

s25-1

F9030

F9068

F9198

F9019

s25-1

E8071

FENDERS

Front fenderFront stay

Bridge stay

Bottom Stay

Bolt (j in. U.H.) ...NutBoltWasherNutBolt ($ in. U.H.)Bolt (1$ in. U.H.)Nut

Plain washer

Spring washer

NutRear fenderBolt ({ in. U.H.)Special washer

Spring washerNutBolt (ff in. U.H.)WasherNutWiring grommetRear fender support railBolt (ff in. U.H.)Washer

Tail lamp supportStud (jf in. o.A.)Support plateWasher

Spacer

NutRear number plate bracketBolt (| in. U.H.)WasherNut

Nut

$q'. b'' Fevgaourrtllolot Cyclc & 'scoottt

{nginccs '

";;;;;'"rcnt B'e''&' & 'ndocette

iilH:l*li^N:lf ''T*'lTilhJ5"i$37


7

)

-5

-4

26

)fu" F.tt-,,uoV #\WT

zo@

,, Jl

&312930

Fis.13 GAS TANK, TWIN SEAT AND HANDLEBARS


Ref. No. Port No. DESCRIPI/ON QUANI'TY

1

2

3

4

5

6

7

8

9

10

11

1Z

13

't3

14

15

16

17

18

19

19

20

2t

72

23

24

25

26

27

28

29

30

31

37

33

34

35

36

37

38

39

40

41

42

43

F9479

F9061

F9134

s1 824

F9063

E8088

F9064

F9065

1 4-0302

F9480

F4715

H430

F6888

F6887

F8192

F81 93

F4179

F7888

F9769

F4971

F4972

E7351

F9226

F9744

F9196

s5662

E8088

w2320F9472

F9476

F9020

E81 01

s602

H2628

D957

D959

D960

D961

D962

D862

D963

D964

F9020

D965

D966

GAS TANK, TvvtN SEAT AND HANDLEBARS

Gas tankMounting rubber-rearMounting rubber-front

Distance tubePlain washer

Mounting rubberPlain washer

Trim stripScrew

WasherStyling unit TiS

Styling unit D/S

Knee grip D/S

Knee grip T/S

Styling unit screw-frontStyling unit screw-rearGas pipe ...Gas tap-ShortGas tap-longGas tap washerFiller cap

Tie barSpacer

BoltPlain washer

Spring washer

Twin seat

Rear fixing bracketSpring washerNutPlain washer

Hand lebar-Western typeThrottle twist gripDummy gripFront brake controlClutch controlThrottle cable

Front brake cable

Cable toggleScrew

Spring washerNut

Bolt

Nut

7'l

1

1

1

2

2

1

1

1

2

I

I

2

2

2

7

1

1

2

2

2

1

1

1

1

1

1

1

'l

1

1

1

1Clutch cable

39


3

/'\

'--....----7\ c,,t

'/'

2

- --1.5a-'

\-,L6J-G\

6

O)A4 -1aIt't-)

*, t9

(rei)l'3L_17)'\

-d"a /\

&N-

I

20

ir -]'(,..

, ,/ tr"\,tu/ l-l

#),

Fig.14 ELECTRICALEQUIPMENT


Ref. No. Port No. DESCRIPT/ON QUANTITY

I

iI P.H.1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

t9

70

21

2i23

24

25

76

27

28

29

30

31

32

33

34

35

35

37

38

39

40

4t42

43

D1926

D962H3626D195'1

F9091

E8077

E81 02

D986

F9123

F91 31

s602

F4374

E8071

D980

D981

D997

D989

D1000

99- r 000

D994

D992E-q1e1

F5535

E8084

E8194

D996

F8273

F81 40

F81 95

F8286

F8349

D1950

D990

F9t9tF8979

99-r00r99-100299-069 I

99-068899-0683

99-054599- I 003

99- I 004

99- r 005


Speedometer head-M.Speedometer cable

Mounting cup

Speedometer lead

Bolt

Washer

Spring washer

Coil (451 l0)Coil support clipBolt ($ in. U.H.) ...WasherDistance piece

NutBattery vent pipe

Vent pipe clipH.T. lead

lgnition switchlgnition lock

lgnition switch

Horn push

nut (54130041)

HornWasherBoltWasherNutDouble Lucar blade

Rear reflectorRubber washerPush-on fixFront reflectorReflector bracketRectifierStop switch

Screw

Washer

Harness (54953550)

HEADLAMP ASSEMBLY (5988r)

Rim (534343)

Lig ht u n it (5 I 6828)

Fixing wire (504665)

Bulb (446)

Adaptor c/w leads (54520540)

Bolt (ll220l)Washer (137498)

2

7

1

1

2

7

I

I

I

I

6

I

7

2

7

41


-d':r n

&N-T

20

6)N4 -ratrtJ

.19

[e{= ''/ttE-_2

.K,RIU

32

t- ll-/ 31 e rc/'Y'b^ (z \\ \ (,,, r3o\u_(,.L/

/* _\V

2a

f-o o^ ,n-r6)\ ',' -91 L/fu t\Y"/ril

/-\e-{V3433- ..-tr/

w @&"/u

35

37

t79

o*d,"/

36

--\\-N---\\'-. -\\-\-.N

42


Ref. No. Port No.

-.l

DESCRIPT'ON QUANflrv

44

45

46

47

48

49

50

51

57

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

58

69

70

71

72

73

74

75

76

77

78

79

99-0563

99-0556144921

s5408

99-0568

5494s043

99-053799-0569

99-0695

99-0548F831 4

D988

99-1 005

D987

99-1 008

99-007799-076999-1007

99-1011

E7831

E81 63

E4747

E81 64

E81 66

D995

D991

99-0781

99-069854s74348

573828

99-054299-0780F4715

G5299

F8307

F4715

G5299


Lighting switch (35710)

Dip switch (31620)

Screw

Plate

Warning light (Red)

Warning bulbholderBulb (2W BAT5) (281)

Warning light (Green) (38191)

Pilot bulbholder (554710) ...Pilot bulb (989)

Stop-tail lead

BatteryStator (47205)

Zener diodeCoNTACT B REAKER (54419645)

Points set (54419827)

Adlusting pin (54419220)

AUTO ADVANCE UN|T (5441

Spring set (54417992)

Contact breaker boltWasherPillar boltWasherContact breaker lead sleeve

Con den se rsToP AND TAtL LAMP ASSEMBLY (53973)

Lens (54572932)

Screw (572289)

Bulbholder with reflectorcontact assy.

Bulb (6/21W offser pin) (380)

Gasket (54571677)

Screw

WasherStop and tail lamp lead tubeScrew

Washer

e6s3) ... ... .. ...

1

1

Reference onlyReference only1

Reference only2

1

1

1

Reference only1

1

1

1

2

2

1

1

1

1

2

2

I1

1

1

2

Reference onlyReference only1

1

2

2

1

2

2

43


=P10

H

\

TOOL KIT


Ref. No. Port No. DESCR'PT'ON QUANflT)',

TOOL KIT

TOOLROLL COMPLETE WITH TOOLS1

2

3

45.6

7

I9

10

'11

17

13

D967

D969

D968

D801

D970D767

D975D97',\

D972D973

D974D977

D978

XA69

Toolroll1

"l

1

1

1

1

1

1

1

1

1

9

43

Damper unit and rear chain ajuster spannerCombined tyre lever and tommy barPlug spanner

Screwdriver set

Screwd riverBox spanner

Ring spanner

Tyre leverTyre valve key

Rubber cable clipAlum. cable clipAlum. cable clip

45


ry"

Q5

'WW{w"E-- '' ?

,a& 1s t'o

ff-'

.t"t:i

Fig.16 CARBURETTOR


Ref, No. Port No. DESCR'PflON QUANTITY

1

2

3

4.5

6

7

8

9'10

11

12

13

14

15.16

17

18

19

20

21

22

23

2425

99-001 9

99452199-0221

99-0531

99-050799-051 0

99452999-0527

99-1 01 0

376-1 00

99-051 6

99-05't599-0520994572622-07399-051 8

99-051 9

99-051299-051 3

99-0511

99-0506376-093994517F9000

F9194

F9001

Gasket

Filter

CARBURETTOR

cARBU RETTOR COMPLETE (R92814)Screw and washer (622-086)

Plug screw (4-137A)Top cap (928497)Throttle spring (622-061)

Circlip (622-067)Needle (928-063)

Throttle valve (3) (928-060)

Body (Re28/00s)

Main jet (170)

Throttle stop screw (622-077)Pilot air screw (622-076)'O'-ring (622482)'O' ring (622-101)

1

41

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

Needle jet (.106) (99-0518)

Jet holder (622-080)

Float (622-069)Float spind lb (622-071)Float needle (622-068)

Float chamber (622-050)

Banjo bolt (622478)AIR CLEANER COMPLETE

Air cleaner element'O'ring

47


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REPLACEMENT THEtrW asE - BSA Unit Singles Home Page SPC6... · REPLACEMENT PARTS CATALOGUE THEtrW asE ... TRIUMPH ENGINEERING ... We do not undertake to bear the cost of fitting any