Triumph Parts Catalog 1969 Du85904

029
REPLACEMENT
PARTS
CATALOGUE No. 7
UNIT CONSTRUCTION 40 cu. ins. TWINS
TR6R TIGER 650
TR6C TROPHY 650
Tl2OR BONNEVILLE 120
From engine No. DU 85904
T R I U M P H ENGINEERING COMPANY LIMITED

MERIDEN WORKS
T E L E P H O N E M E R I D E N 331
PUBLISHED SEPTEMBER 1960
ALLESLEY
COVENfRY
ENGLAND
TELEGRAMS "TRUSTY C O V E N T R Y "

REF. SPC.7.
TRIUMPH GUARANTEE
1.
i n this Guarantee t h e w o r d "machine" refers t o t h e m o t o r cycle, scoorer, m o t o r cycle combination

o r sidecar as t h e case may be, purchased by t h e Purchaser.
2. I n o r d e r t o obtain t h e benefit o f this Guarantee, t h e Purchaser must have correctly completed t h e

registration f o r m and returned it t o us w i t h i n fourteen days o f t h e purchase.
3
1
3. W e w i l l supply, free o f charge, a n e w p a r t i n exchange for, or, i f w e consider repair sufficient, w i l l

repair free o f charge any p a r t proved w i t h i n six months o f t h e date o f purchase of any new machine,
(three months overseas) o r w i t h i n t h r e e months o f its renewal o r repair i n t h e case o f a part already
renewed o r repaired, t o be defective by reason o f o u r faulty workmanship o r materials. W e d o n o t
undertake t o bear t h e cost o f fitting such n e w o r repaired part or accessory.
4.
A n y p a r t considered t o be defective m u s t be sent t o o u r Worlcs, carriage paid, accompanied by t h e

following information:(a) N a m e o f purchaser and his address;
(b) Date o f purchase o f machine;
'
(c) Name o f dealer f r o m w h o m t h e purchase was made;
(d) Engine number and model.
5.
This Guarantee shall n o t extend t o defects o r damage appearing after misuse, neglect, abnormal stress
or strain, o r t h e incorporation o r affixing o f unsuitable attachments o r parts and i n particular:(a) H i r i n g o u t ;
(b) Racing and Competitions;
(c) Adaptation o r alteration o f any part or parts after leaving o u r W o r k s ;
(d) T h e attaching o f a sidecar i n a manner n o t approved by us o r t o an unsuitable
m o t o r cycle.
This Guarantee shall n o t extend t o machines whose trade mark, name o r manufacturing number has
been altered o r removed, o r i n 'which has been used any part n o t supplied o r approved by us, o r t o
ryres, saddles, chains, speedometers, revolution counters and electrical equipment o r t o parts supplied
t o t h e o r d e r of t h e Purchaser and different from o u r standard specification.
6. O u r liability and that o f o u r dealer w h o sells t h e machine, shall be limited t o that set o u t i n this guarantee,
and n o o t h e r claims including claims
b e admissible. A i l o t h e r conditions
implied are hereby excluded and n o
t h e machine t o which this Guarantee
7.
for consequential damage o r i n j u r y t o person o r property, shall

and warranties statutory o r otherwise and whether express o r
guarantee other than that expressly herein contained applies t o
relates o r any accessory o r p a r t thereof.
W e reserve the r i g h t t o modify o r deviate f r o m the Published Specification w i t h o u t notice,
REPAIRS G U A R A N T E E
1.
W h i l s t t h e highest standard o f workmanship and maierials is aimed at, w e cannot accept liability for
any defects appearing m o r e than t h r e e months after t h e machine, assembly o r component has left o u r
Worlcs after being repaired.
2.
W e w i l l repair o r replace a t o u r o p t i o n free o f charge any defective w o r k , materials o r parts relating

t o t h e repairs carried o u t by us appearing w i t h i n that t i m e b u t shall n o t be under any further or other
liability for any o t h e r loss o r damage w h e t h e r direct o r consequential and o u r liability shall be limited
t o t h e cost o f so making good. W e d o n o t undertake t o bear t h e cost o f fitting any replacement o r
repaired part.
3.
W e d o n o t accept liability i n respect o f parts of proprietary manufacture, e.g. tyres, saddles, chains.
speedometers, r?volution counters and electrical equipment which may be used by us i n effecting a
repair. A l i o t h e r conditions and warranties statutory or otherwise expressed o r implied are hereby
excluded.
TRIUMPH SPARES
HOW TO O R D E R . Every p a r t is indicated by number, and this should be quoted together w i t h
t h e description. In order t o assist customers, dimensions have been given i n many cases where parts are
similar. Parts w h e r e possible have been listed i n o r d e r o f assembly and a number o f t h e illustrations show
t h e assembly o r d e r also. W i t h these aids there should be no d i f i c u l t y i n identifying t h e parts you require
A l w a y s h e a d y o u r o r d e r w i t h t h e e n g i n e n u m b e r , s t a m p e d o n t h e l e f t s i d e o f t h e c r a n k case
u n d e r n e a t h t h e c y l i n d e r flange, t o g e t h e r with t h e p r e f i x letters.
W H E R E TO O B T A I N . T r i u m p h Spare Parts can only be obtained from an authorized T r i u m p h
Dealer, and w e recommend o u r customers t o place t h e i r orders w i t h the T r i u m p h Dealer i n their district.
W h e n parts n o t usually asked for are required, and f o r which the Dealer may have t o w r i t e o r obtain
specially, t h e postage o r carriage incurred becomes payable.
T r i u m p h Spares a r e n o t s u p p l i e d t o p r i v a t e o w n e r s d i r e c t f r o m t h e f a c t o r y . If d i f f i c u l t y
i s e x p e r i e n c e d in o b t a i n i n g t h e r e q u i r e d parts, t h e m a t t e r s h o u l d b e t a k e n u p d i r e c t l y with t h e
T r i u m p h Spares Department.
Customers are warned against t h e risk incurred by purchasing parts that are n o t o f genuine T r i u m p h
manufacture. This risk is eliminated i f parts are ordered as instructed f r o m recognised Dealers.
P A T T E R N S A N D P A R T S F O R R E P A I R . It is not necessary t o send patterns i f t h e part number
is quoted. T h e sending o f patterns often delays t h e order as parcel post o r rail takes longer than letter post.
Parts sent t o Coventry for repair, replacement, o r as patterns should bear t h e sender's name and address
and clear instructions should accompany t h e parts. In your o w n interest send a copy o f the advice note
under separate cover. A l l pans must be fowarded carriage paid and care should be taken t o ensure that
a l l remittances are sent separately and n o t enclosed w i t h the parts. Fragile units such as cylinders, etc.,
should always be boxed t o avoid damage i n transit. Complete machines should have all fitments such as
windscreens, driving mirrors, tools, etc., removed by t h e sender before despatch, as it is impossible for us
t o accept responsibility i n t h e event o f loss i n transit. W e are always pleased t o give estimates for overhauling and repairs, b u t should an estimate n o t be accepted, a charge w i l l be made covering cost of dismantling
and re-assembling, i f carried out.
Communications relating t o Parts should be addressed t o the SPARES DEPARTMENT and for repairs.
guarantee claims and technical advice t o t h e SERVICE DEPARTMENT. T r i u m p h Engineering Co. Ltd., Meriden
W o r k s , Allesley, Coventry. In o r d e r t o facilitate quick reference, the quoting o f any number, invoice
number o r reference from previous communications is essentizl. Accessories not o f o u r manufacture
should be sent direct t o t h e actual makers, whose names and addresses appear below.
PROPRIETARY GROUP
Ancillary equipment which i s fitted t o o u r m o t o r cycles i s o f the highest quality and is guaranteed by
t h e manufacturer and n o t by ourselves. Any repairs or claims should be made t o the actual makers o r t h e i r
local agents w h o w i l l always give owners every possible assistance. The following are t h e addresses o f t h e
various manufacturers:CARBURETTERS
Messrs. A m a l Lid.,
Holdford Rd.. W i t t o n , Birmingham 6.
SPARKING PLUGS
Champion Sparking Plug Co. Ltd..
Feltham. Middlesex.
CHAIFIS
Renold Chains Ltd.,
Wythenshawe. Manchester.
SPEEDOMETERS
Messrs. Smiths Industries Ltd.,
Cricklewood Works. London. N.W.2.
ELECTRICAL EQUIPMENT
Messrs. J. Lucas Ltd.,
Gt. H a m p t o n St., Birmingham, 18
SUSPENSION UNITS
Messrs. Girling Ltd.,
Birmingham Road, W e s t Bromwich. Staffs,
TYRES
Dunlop R u b b e r Co. Ltd..
F o r t Dunlop. Birmingham, 24
INDEX
Page
AIR FILTER
... ...
ALTERNATOR
...
AUTO-ADVANCE UNIT
...
BATTERY CARRIER
BRAKE SWITCHES
...
...
...
......
......
... 57
... 13. 33
...
23
...
...
57
65
CAMSHAFT. INLET AND EXHAUST

13
... ... 75
CAPACITOR. IGNITION
... ... ... 69 71
CARBURETTER
CARTON PACKS
... ... ...
9
CENTRE STAND
... ... ... 35
...
... ... 33
CHAINS . . . . . .
CHAINCASE . . . . . .
...
... 33
CLUTCH
... ... ... ... 31
CLUTCH LEVER ASSEMBLY
... 29
COIL
... ... ... ... . . 77
CONDENSER PACK . . . . . .
...
77
... ... 13
CONNECTING RODS
CONTACT BREAKER . . . . . .
... 23
CONTROL CABLES . . . . . .
... 65
... 63
CONTROL LEVERS . . . . . .
CRANKCASE . . . . . .
...
... 15
CRANKCASE UNDERSHIELD
... 39
CRANKSHAFT . . . . . .
...
... 13
... ... ... ... 19. 21
CYLINDERS
CYLINDER HEAD
... ... ... 19. 21
....
ENGINE PLATES
... ... ... 39
ENGINE TORQUE STAY
...
... 39
EXHAUST PIPES
... ... ... 41.43
EXHAUST PIPE ADAPTOR . . . . . . 19.21
...
FENDERS
...
FOOTRESTS
FRAME . . . . . .
FRONT BRAKE
FRONT FORKS
FRONT WHEEL
FUSE ASSEMBLY
GAS TANK
GASKET SET
GEARBOX
...
...
...
...
...
...
...
... ...
......
... ...
...
...
...
...
...
...
...
...
...
...
...
61
... 39. 67
...
35
... 49
... 45
... 49
...
57
...
53
9
25. 27. 29
...
Page
...
HANDLEBARS . . . . . .
HANDLEBAR MOUNTINGS ...
HEADLAMP
... ... ...
HEAT SINK
... ... ...
HORN . . . . . .
... ...
KICKSTARTER
......
...
MANIFOLD
MUFFLERS
...
...
...
...
...
...
OIL PUMP
OIL TANK
...
...
...
...
...
...
PISTONS
PROP STAND
PUSH RODS
...
...
...
......
...
...
REAR WHEEL
RECTIFIER
REFLECTORS
ROCKERS
......
... ...
...
......
......
... ...
...
...
...
SIDE PANEL . . . . . .
...
SPARKING PLUG
...
...
SPEEDOMETER . . . . . .
...
SPEEDOMETER GEARBOX ...
STEERING DAMPER . . . . . .
STEERING RACES
... ...
SUSPENSION UNITS . . . . . .
SWINGING FORK
... ...
SWITCHES
... ... ...
TACHOMETER . . . . . .
TACHOMETER GEARBOX
TAIL LAMP
... ...
TAPPETS
... ...
TIMING GEARS
...
TOOLKIT
... ...
TWIN SEAT . . . . . .
VALVES . . . . .
VALVE GUIDES
WIRING HARNESS
ZENER DIODE
...
...
...
...
...
...
...
...
...
...
...
T I G E R 6 5 0 (TR6R) T E C H N I C A L D A T A
B o r e a n d s t r o k e.
Capacity
.....
......
...
., .
...
...
...
...
...
...
...
71 x 82 rnrn.
2.79 x 3.23 ins.
...
...
...
...
...
...
...
...
649 C.C. (40 cu. ins.)
Compression r a t i o
S p a r k plugs
...
Carburetter
...
Champion
..
...
...
Main jet
Needle jet
Throttle valve
...
...
...
...
...
...
......
...
...
...
...
...
...
...
...
...
...
...
...
Amal Concentric 930
230
.I06
No. 3+
G e a r b o x sprocket
Chains
...
Capacities
Brakes
T i r e size
...
19 teeth
...
...
...
......
N3
Front
Rear
...
...
...
...
..
...
...
...
...
...
...
Gas Tank
...
...
Oil Tank
...
...
Gearbox
... ...
Primary Chaincase
...
Front Forks (each leg)
...
Front, diameter
Rear, diameter
Front
Rear
...
...
...
...
...
...
...
...
...
...
...
...
...
...
+" Duplex x 84 links

%"
x 104 links
...
...
... 3$ U.S. galls. (16 litres)
...
...
...
...
...
...
...
...
...
6 U.S. pints (2.8litres)

$ pint (500 c.c.)
...
2 pint (350c.c.)
...
f pint (200c.c.)
...
...
...
...
...
...
...
8" (20.32cm.)
7" (17.78 cm.)
T R O P H Y 650
(TR6C)
T E C H N I C A L
D A T A
B o r e and s t r o k e ...
Capacity
71 x 82 mm.
2.79 x 3.23 ins.
...
......
...
...
649
C.C.
(40cu. ins.)
S p a r k plugs
...
Carburetter
...
Champion N3
...
...
...
...
...
...
......
...
...
...
...
...
...
...
Gas Tank
...
...
O i l Tank
... ...
Gearbox
... ..,
Primary Chaincase
...
...
...
... 2$ U.S. galls. (11 litres)
Front, diameter .
Rear, diameter
...
...
Main jet
Needle jet
Throttle valve
...
...
...
...
...
...
... Amal Concentric 930

...
230
...
...
...
...
.I
06
No. 3f
Gearbox sprocket
Chains
...
Capacities
Brakes
Tiresize
...
...
Front
Rear
...
...
......
...
...
...
Front
Rear
...
...
...
...
...
...
...
.....
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
Duplex x 84 links
$"x+"xl04links
+''
...
6 U.S. pints (1.8 litres)

pint (500 c.c.)
$ pint (350 c.c.)
f pint (200 c.c.)
...
...
8" (20.32 cm.)

7" (17.78 cm.)
...
...
B O N N E V I L L E (T12OR)
T E C H N I C A L
B o r e a n d s t r o k e ...
D A T A
...
......
...
...
...
...
...
...
Capacity
Spark plugs
...
Carburetters
...
...
...
...
...
...
Main jet
...
Needle jet
...
Throttle valve . .
...
...
....
...
...
...
...
...
...
...
...
...
T i r e Size
......
(40 cu. ins.)

9 :I
...
...
...
...
...
...
...
19 teeth
...
...
...
...
+" Duplex x 84 links
...
Gas Tank
...
O i l Tank
... ...
Gearbox
...
...
...
Primary Chaincase
...
...
2; U.5, galls. (11 litres)
...
...
...
...
...
...
Front, diameter .
Rear, diameter
...
...
...
...
...
...
8" (20.32 cm.)

7" (17.78 cm.)
... Front
Capacities
...
C.C.
2 Amal Concentric 930

190
.I
06
No. 3
Rear
Brakes
649
Champion N3
...
G e a r b o x sproclcet
Chains
71 x 82 mm.
2.79 x 3.23 ins.
Front
Rear
...
...
...
...
...
...
...
...
.....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
x 104 links
5 U.5. pints (2.8 litres)

pint (500 LC.)
5 pint (350 c.c.)
...
f pint (200 c.c.)
C A R T O N P A C K L I S T
The following sub-assemblies are supplied i n carton packs under the C.P: part number stated.
contents o f these carton packs are preserved and will not deteriorate under adverse conditions.
Part No.
The
Contents
Brake Lining
C.P.38/A.M.2
......
......
...
NW243
16
......
...
W129
......
......
...
...
Brake lining
Rivet
Pistons (complete with rings, gudgeon pins and circlips). These are in effect "carton pack" assemblies.
E6868
......
...
E6867
......
...
...
...
...
...
... 9 : 1 CR.
...
...
Standard
...
...
...
Competition use only
11 :ICR.
All the above pistons are available in oversizes of 0.010 ins., 0.020 ins., 0.040 ins., (0.25 mm.,0.5 mm..lmm.)
...
...
......
...
...
...
...
...
...
De-coke Gasket Set
All models
......
O v e r h a u l Gasket S e t
Ail models
DGS7
GS/B/66/67
...
...
...
...
...
...
... CP168,64T
2 . . .
...
...
HI11
...
......
...
H439
...
...
...
...
...
......
...
HI018
......
40
......
...
570-3
...
F o r k Service pack
S t e e r i n g Race K i t
C.P.156
......
...
...
Cups
Cone
... Top cone
...
Ball
H O W TO USE THIS PARTS CATALOGUE

First check t h a t t h e engine number o f y o u r machine is subsequent t o t h a t quoted o n t h e t i t l e page.
N e x t consult t h e index o n Page 4 for t h e parts o r g r o u p o f parts which you wish t o locate. W h e n
you have located t h e parts make sure from t h e end columns t h a t t h e part you have located does apply t o
y o u r machine.
List t h e quantities required as single units; d o n o t ask for "2 pairs" o r "3 dozen".
I .
Proprietary components e.g. electrical equipment, carburetters, suspension units etc. are listed i n the
first c o l u m n ~ n d e r ~ r i u mpart
~ h numbers (prefixed either D-or99-) whereverthey are stocked a t t h e factory.
If proprietary parts are listed only under manufacturers part numbers, they are n o t available from,the factory.
In case o f painted items always state t h e colour required. Painted parts are available only in t h e colours
o r alternatives specified for that model o f that particular year.
Model
Colour
TR6 all cond~tions
Trophy Red/Silver
T12OR
Olympic Flame/Silver
N.B. T r o p h y Red and Olympic Flame are b o t h flamboyant finishes applied over Silver.
Paint is available only in Aerosol containers.
PLEASE N O T E
THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED I N CAPITALS AND THE COMPONENTS
INCLUDED I N THAT ASSEMBLY ARE INDENTED I N THE DESCRIPTION COLUMN, REVERTING
TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE
ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENT
PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.
SPECIAL
W O R K S H O P
T O O L S
A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING

YOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. I N MOST CASES
THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE. AND
THEREFORE, IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS I N
ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. I N THESE CIRCUMSTANCES
IT I S FAR MORE ECONOMICAL TO GET I N TOUCH WITH A RECOGNISED DEALER.
UNIFIED T H R E A D FORM
NEW PARTS HAVING THREADED FIXINGS INTRODUCED I N THIS CATALOGUE HAVE THE UNIFIED
FORM OF SCREW THREADS. THIS CHANGEOVER WlLL BE CONTINUED AS AND WHEN NEW PARTS
ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS
WlLL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS
HAVING THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS I N
THEIR HEADS. STUDS A CIRCULAR GROOVE O N THE END. AND NUTS HAVE INTERLOCKING
CIRCLES O N THE SIDE.
41
19
io
Fig. 1.
21
22
23
24
2s
CRANKSHAFT A N D C O N N E C T I N G RODS
Ref . N o.
Part No.
OESCRIP TlON
QUANTITY
CRANKSHAFT
"E9686
E4643
E3903
E3905
"'E9687
*E9307
E3114
E9S25
El 511
E6576
5549
E3586
E6868
E6867
E6864
E6865
E6863
E6869
El 591
E3876
E5446
E4573
E3974
99-0739
E3975
E3977
El580
E4564
E4565
E6159
E400
E4562
El558
El 463
E4563
E l 0040
El 0041
iE4700
E5316
E2256
E3300
E2879
A N D
C O N N E C T I N G
RODS
CRANKSHAFT A N D FLYWHEEL ASSEMBLY . . . . . .

...
... ...
CRANKSHAFT C/W OIL TUBE
...
... ...
O i l tube
... ... ... ...
Screwed plug
... ... ... ... ... ...
Flywheel . . . . . .
... ... ... ... ... ...
Flywheel bolt
... ... ... ... ... ... ...
Crankshaft stud ( I + in . O.A.) . . . . . .
... ... ...
CONNECTING R O D . . . . . .
... ... ... ... ...
Small end bush ...
... ... ... ... ... ...
Connecting rod bolt
... ... ... ... ... ...
Self locking nut . . . . . .
... ... ... ... ...
Big end bearing (Available in -.010 in . and -.020 in . oversizes)
PISTON COMPLETE 9 : 1 C.R.
... ... ... ... ...
... ....
PISTON COMPLETE 11 : 1 C.R. . . . . . .
...
... ... ...
Taper compression ring . . . . . .
...
... ...
...
...
O i l control ring . . . . . .
...
Gudgeon pin (long)
... ... ... ... ... ...
Circlip
... ... ... ... ... ... ... ...
Main bearing. right
...
... ... ... ... ... ...
Oil seal ...
... ... ... ... ... ... ... ...
Engine sprocket, 29 teeth Duplex ...
... ... ... ...
Distance piece . . . . . .
... ... ... ... ... ...
Rotor key
... ... ... ... ... ... ... ...
Rotor (54213901)
... ... ... ... ... ... ...
Tab washer
... ... ... ... ... ... ... ...
Nut
... ... ... ... ... ... ... ... ...
Key
... ... ... ... ... ... ... ... ...
Timing pinion . . . . . .
... ... ... ... ... ...
Nut
... ... ... ... ... ... ... ... ...
INTERMEDIATE WHEEL
...
...
... ... ... ...
Intermediate wheel bush . . . . . .
... ... ... ...
Camshaft wheel . . . . . .
... ... ... ... ... ...
Camshaft key ...
... ... ... ... ... ... ...
Inlet camshaft nut
... ... ... ... ... ... ...
... ... ...
Exhaust camshaft nut . . . . . .
... ...
Inlet camshaft. Racing type ...
... ... ... ... ...
... ...
EXHAUST CAMSHAFT. RACING TYPE . . . . . .
Tachometer drive thimble
... ... ... ... ...
Rotary breather valve . . . . . .
... ... ... ... ...
Breather valve spring . . . . . .
... ... ... ... ..
Clamping washer
... ... ... ... ... ... ...
Main bearing. left
... ... ... ... ... ... ...
...
...
' Use D524 Loctite Sealant
** For
the commencement of the season. the previous 'light' type of crankshaft

assembly (Part N o. E7331) i s fitted . The flywheel only from this assembly bears
Part N o. E7332
i. Use E7050 to replace without dismantling motor
1
1
1
1
1
3
1
2
2
4
4
4
2
2
4
2
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
REMARKS
Fig. 2.
CRANKCASE
14
DESCRIPTION
CRANKCASE
C R A N K C A S E DRIVE SIDE ...
Breather disc
... ...
Locating pin-at disc
... ...
Inlet camshaft bush
...
Exhaust camshaft bush . . . . . .
Chain rensioner abutment
...
Breather pipe (metal)
... ...
C R A N K C A S E T I M I N G SIDE
...
Camshaft bush
... ... ...
Scavenge pipe
... ... ...
Locating peg (at o i l pipes)
...
H o l l o w dowel
... ... ...
Locating peg (L/S at thrust washer)
Needle roller bearing. layshaft ...
Intermediate wheel spindle
...
H o l l o w dowel . . . . . .
... ...
H o l l o w dowel . . . . . .
... ...
Screw
i n U.H.)
... ... ...
Stud (4f i n . O.A.)
... ... ...
Plain washer
... ... ... ...
Nut
... ... ... ... ...
H o l l o w dowel. tappet o i l feed
...
Oilway plug
... ... ... ...
Copper washer . . . . . .
... ...
Tachometer drive plug (L.H. thread)
Fibre washer ...
... ... ...
O i l pipe stud ( I f i n . O.A.)
......
Cylinder stud (1: in . O.A.) . . . . . .
Plug. t i m i n g hole
... ... ...
...
Bolt (2f i n . U.H.) U N . . . . . .
...
Bolt (1; i n . U.H.) U N . . . . . .
...
Bolt (1; i n . U.H.) U N . . . . . .
Stud ( 5 - h i n . O.A.)
... ... ...
Stud (3; in. O.A.)
... ... ...
Plain washer
...
...
...
...
Nut
... ... ... ... ...
Crankcase filter U N . . . . . .
...
... ...
Breather extension pipe
... ...
Drain plug ( w i t h level tube) U N
...
F ~ b r ewasher ...
...
... ...
Level plug U N . . . . . .
... ...
... ...
Drain and adiuzter plug
...
...
Fibre washer ...
... ... ...
Bianting plug ...
...
...
...
Filler plug U N . . . . . .
... ...
Fibre washer ...
... ... ...
B o l t (4 i n . U.H.) U N . . . . . .
...
Stud (4) i n . O.A.)
... ... ...
Protection blade
... ... ...
Self l o c k n u t U N
... ... ...
Rubber plug (for protection blade stud I
QUANTITY
REMARKS
...
...
...
(s .
...
...
...
...
...
...
...
....
...
...
...
...
...
...
...
...
...
2
Reference only
Reference only
2
1
1
1
1
1
2
1
2
2
2
...
2
11
...
...
1
1
...
...
...
...
...
...
...
...
...
...
...
(TR6C 3 off)
1
2
2
1
1
1
1
(Except TR6C)
TR6R. T12OR
ASSY
13
16
24
18 23
20
21
22
Fig. 3.
O I L P U M P . RELEASE VALVE, M A N I F O L D A N D TAPPETS
16
Ref . No.
Port No.
O I L
DESCRIPTION
PUMP.
E6928
Reference only
GS153
E6681
E495
570-7
E403
E2360
E3730
51 864
E3887
51 906
E6595
E7590
GS251
E6596
GS254
E7591
E l 670
51 876
E5660
E5512
525-1 3
51 877
E2962
NA43A
491 8
525-3
El310
9352
E9353
El612
HZ00
E3059R
8801
E7563
RELEASE VALVE.
O I L PUMP
... ... ...
Pump body . . . . . .
...
Feed plunger
... ...
Scavenge plunger ...
...
...
D r i v e block
Valve ball (6i n . dia.)
...
Valve spring
... ...
Screwed plug
... ...
Joint washer
... ... ...
Oil p u m p stud (I*i n. U.H.)
Serrated washer
... ...
Nut
... ... ... ...
O I L RELEASE VALVE
...
Valve body
... ...
Piston
... ... ...
Cap . . . . . .
...
...
Fibre washer
... ...
Main spring
... ...
Fibre washer ...
... ...
Stud (1Ei n . O.A.)
......
Joint washer ...
... ...
Inlet manifold . . . . . .
...
Plain washer
... ... ...
Nut
... ... ... ...
Stud ( I & i n . O.A.)
... ...
Joint washer
... ... ...
insulating bloclc
... ...
Plain washer
... ... ...
Nut
... ... ... ...
Inlet tappet guide
...
...
Exhaust tappet guide . . . . . .
Serrated washer
... ...
Set b o l t . . . . . .
... ...
Inlet tappet
...
... ...
Exhaust tappet . . . . . .
...
"O-ring
... ... ...
...
QUANTITY
MANIFOLD
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
A N D
TAPPETS
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... . . . .
...
...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
1
2
2
2
1
2
2
2
1
1
1
1
1
1
1
4
2
...
...
...
...
...
REMARKS
...
...
...
...
...
...
...
...
...
...
...
...
...
...
~6
1
1
2
2
1
1
2
2
2
2
2
& TR6C
Fig. 4.
CYLINDER BLOCK A N D H E A D , TR6
18
Ref. No.
Part No.
DESCRIPTION
QUANTITY
CYLINDER BLOCK A N D H E A D . TR6R. TR6C

Cylinder base washer . . . . . .
...
Cylinder block . . . . . .
... ...
Cylinder base n u t
... ... ...
... ...
Push r o d
...
Cover t u b e
... ... ... ...
Rubber washer . . . . . .
... ...
Cylinder head gasket . . . . . .
...
CYLINDER H E A D c / w GUIDES ...
I n l e t valve guide
... ...
Exhaust valve guide
... ...
Exhausr pipe adaptor
...
...
Inlet valve
... ... ... ...
Exhausr valve . . . . . .
...
.. .
Botrom cup
... ... ... ...
Inner valve spring (red spot) . . . . . .
O u r e r valve spring (green spot)
...
T o p collar
... ... ... ...
Split cotrer
... ... ... ...
Cylinder head b o l t ( 3 i i n U.H.)
...
...
...
Plain washer
...
B o l t (3 i n . U.H.)
... ... ...
Plain washer
...
... ...
Sealing ring
...
... ... ...
Inlet rocker b o x
... ... ...
Exhausr rocker b o x ...
... ...
Joint washer
... ... ... ...
Rocker b o x stud
i n O.A.)
...
.
.
.
.
.
.
Rocker box n u t
... ...
Plain washer
... ... ... ...
Rocker b o x bolt (2& i n . U.H.)
...
Plain washer
... ... ... ...
Cylinder head b o l t (lor t o r q u e stay)
lnspeccion cap . . . . . .
... ...
Joint washer
... ... ... ...
Locking spring . . . . . .
... ...
Fibre washer ...
...
... ...
Screw (
ii
n . U.H.)
... ... ...
ROCKER (right exhaust. l e l t inlet) ...
ROCKER (lelt exhaust. r i g h t inlet) ...
Rocker ball p i n ...
... ...
Rocker adjusting p i n . . . . . .
...
Adjuster lock n u t
... ... ...
Thrust washer. $ i n . . . .
...
...
T h r u s t washer. i n
... ...
Spring washer . . . . . .
... ...
Rocker spindle
... ... ...
...
...
...
...
(E .
....
REMARKS
Fig. 5.
C Y L I N D E R B L O C K A N D H E A D , TIIOR
20
DESCRIPTION
CYLINDER
QUANTITY
BLOCK A N D HEAD. ' ~ 1 2 0 ~
......
......
Cylinder base washer

... ... ...
Cylinder block . . . . . .
... ...
Cylinder base n u t
... . . . . . .
...
...
...
Push r o d
... ...
Cover tube
... ... . . . . . . ... ...
... ... ... ...
Cylinder head gasket . . . . . .
... ... ...
CYLINDER H E A D c / w GUIDES ...
... ...
Sleeve for head bolts passing t h r o u g h i n l e t tracts
Inlet valve guide . . . . . .
... ... ...
Exhaust valve guide
... ... ... ...
Carburetter adaptor. left
...
... ...
Carburetter adaptor. r i g h t
... ... ...
Connector . . . . . .
... ... ... ...
Balance pipe
... ... ... ... ...
Adaptor locking n u t
...
...
... ...
Exhaust pipe adaptor
... ... ... ...
Inlet valve
... ... ... ... ... ...
Exhaust valve . . . . . .
... ... ... ...
B o t t o m cup
... ... ... ... ... ...
Inner valve spring (Red spot)
...
...
...
O u t e r valve spring (green spot)
...
... ...
T o p collar
... ... ... ... ... ...
Split cotter
... ... ... ... ... ...
Cylinder head b o l t ( 3 t In. U.H.)
... ... ...
Plain washer
... ... ... ... ... ...
B o l t (3 i n . U.H.)
... ... ... ... ...
Plain washer
... ... ... ... ... ...
Sealing ring
... ... ... ... ... ...
Inlet rocker b o x
... ... ... ... ...
Exhaust rocker b o x ...
... ... ... ...
Joint washer
...
... ... ... ... ...
Rocker b o x stud
In . O.A.)
...
... ...
Nut
... ... ... ... ... ... ...
Plain washer
... ... ... ... ... ...
Rocker box bolt (2& i n . U.H.)
... ...
Plain washer
... ... ... ... ... ...
...
Cylinder head b o l t (for t o r q u e stay)
...
Inspection cap . . . . . .
... ... ... ...
... ...
Joint washer
... ... ... ...
Locking spring . . . . . .
... ... ... ...
Fibre washer ...
... ... ... ... ...
Screw (+ i n . U.H.)
... ... ... ... ...
ROCKER (right exhaust. left inlet) . . . . . .
...
ROCKER (left exhaust. r i g h t inlet) . . . . . .
...
Rocker ball p i n ...
... ... ... ...
Rocker adjusting pin . . . . . .
...
... ...
Adluster lock n u t
... ... ... ... ...
T h r u s t washer $ i n
...
... ... ...
T h r u s t washer. 4 i n . . . .
... ... ... ...
... ... ... ...
Rocker spindle . . . . . .
... ... ... ...
...
...
...
(e
...
REMARKS
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... ...
... . . . .
... ...
... ...
... ...
... ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
8
4
2
4
1
1
2
2
2
1
1
2
...
1
2
2
2
2
4
4
...
...
...
...
4
8
...
...
1
1
...
...
...
2
1
...
...
...
...
1
2
6
6
...
6
4
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
4
4
4
4
4
4
4
2
2
4
4
4
2
6
4
2
Reference only
Fig. 6.
T I M I N G C O V E R A N D C O N T A C T BREAKER
Ref . No.
Port No.
DESCRIPTION
T I M I N G
COVER A N D
...
...
QUANTITY
CONTACT BREAKER
...
...
...
...
...
...
...
...
...
...
...
...
1
1
3
2
1
Circlip ...
... ... ... ... ... ... ...
H o l l o w dowel . . . . . .
... ... ... ... ...
Screw
f f I(
In U.H.) ...
... ... ... ... ...
Screw (1 in . U.H.)
... ... ... ... ... ...
Bolt (Zin U.H.) . . . . . .
... ... ... ... ...
Plain washer
... ... ... ... ... ... ...
... ... ... ...
Rubber grommet
...
Pillar b o l t
... ... ... ... ... ... ...
Plain washer ...
... ... ... ... ... ...
Cover
. . . . . . ... ... ... ... ...
Joint washer
... ... ... ... ... ... ...
Serrated washer
... ... ... ... ... ...
Screw
in . U.H.)
... ... ... ... ... ...
... ... ...
A U T O ADVANCE U N I T (54419340)
Spring set (54415642)
... ... ... ... ...
C O N T A C T BREP.KER PLATE ASSEMBLY (54419097) . .
Contact set (54419827) . . . . . .
...
... ...
Pin. adjustment (54419220)
... ... ... ...
Dowel pin l o r auto advance . . . . . .
... ... ...
O i l pressure switch ...
... ... ... ... ...
Cover pressure switch
... ... ... ... ...
Timing label l o r C.B. cover . . . . . .
...
... ...
...
...
...
...
...
Timing cover
... ...
Patent plate
... ...
Hammer-drive screw . . . . . .
O i l seal
... ...
O i l seal (0.020 i n undersize) . .
...
...
...
...
... ...
....
...
...
...
...
(5
* E9526 Blanking plug available t o
replace oil switch i f required

23
REMARKS
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
....
...
...
...
...
...
...
For reground
crankshaft
1
3
5
1
1
1
2
2
1
1
2
2
1
1
1
2
2
N o t illustrated
1
1
N o t illustrated
Fig.7. G E A R B O X I N N E R C O V E R A N D SELECTORS
24
Ref . No.
Port No.
DESCRIPTION
QUANTITY
REMARKS
G E A R B O X I N N E R COVER A N D SELECTORS
Stud (3 in. O.A.)

... ... ...
Hollow dowel . . . . . .
... ...
Gear selector camplate
... ...
Camplate index plunger
... ...
Index plunger spring . . . . . .
...
Strong index plunger spring . . . . . .
Index plunger holder . . . . . .
...
...
Mainshaft selector fork
...
Layshaft selector fork . . . . . .
...
Selector fork roller ...
... ...
Selector fork rod
... ... ...
Layshaft bearing
... ... ...
Thrust washer . . . . . .
... ...
GEARBOX INNER COVER
...
Layshaft bearing . . . . . .
...
Gearchange spindle bush. . . . . .
Kickstarter stop . . . . . .
...
Camplate operating quadrant . . . . . .
Quadrant spindle
... ... ...
Split pin . . . . . .
... ... ...
Bolt (1; in. U.H.)
... ... ...
Plain washer ...
... ... ...
Screw (1 in. U.H.)
... ... ...
Socket screw (1; i n . U.H.)
... ...
Countersunk screw (# in U.H.)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
as required
Ref. No .
Port No .
DESCRIPTION
AND
GEARBOX SHAFTS
MAINSHAFT c/w L O W GEAR (16T)

Clutch rod bush . . . . . .
...
MAINSHAFT HlGH GEAR (26T) ...
High gear bush ...
... ...
Mainshaft third gear (24T) ...
...
Mainshaft second gear (20T) . . . . . .
LAYSHAFT L O W GEAR (30T) ...
Low gear bush ...
... ...
Layshaft second gear (26T) . . . . . .
Layshaft third gear (22T)
... ...
Layshaft c/w high gear (20T)
...
Gearbox sprocket (15 teeth) . . . . . .
Gearbox sprocker (19 teeth) . . . . . .
Tab washer
... ... ... ...
Gearbox sprocket nut
...
...
High gear bearing
...
... ...
...
...
...
Circlip ...
...
O i l seal . . . . . .
...
... ...
Mainshaft bearing
...
...
...
Circlip . . . . . .
...
... ...
...
...
Plain washer ...
...
Pinion sleeve ...
...
... ...
...
...
Pinion spring ...
...
...
Kickstarter pinion
...
...
...
Kickstarter ratchet
...
...
Tab washer
...
...
... ...
Nut
...
... ... ... ...
Clutch operating rod . . . . . .
...
W I D E
RATIO
REMARKS
QUANTITY
GEARS
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
;I
See pages 5 t o
...
...
1
1
1
1
1
1
GEARS
MAINSHAFT HIGH GEAR (28T) . .

Mainshafr second gear (19T) . . . . . .
Layshaft c/w high gear (18T) . . . . . .
...
...
1
1
1
1
CLOSE RATIO GEARS
MAINSHAFT c/w L O W GEAR (18T)

MAINSHAFT HIGH GEAR (24T) . . .
Mainshaft third gear (23T) ...
...
Mainshaft second gear (21T) . . . . . .
...
LAYSHAFT L O W GEAR (28T)
Layshaft third gear ( 2 3 3
... ...
Layshaft clw high gear (22T) . . . . . .
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
1
1
1
1
7 for standard
sizes
Fig. 9.
GEARBOX O U T E R COVER
28
Ref No .
Port No
DESCRIPTION
GEARBOX OUTER COVER

GEARBOX OUTER COVER
Gearchange spindle bush ...
Kicltstarter spindle bush
Kickstarter spring anchor p i n
Guide plate stud (ii n . O.A.)
Oilseal
... ... ...
O i l seal housing . . . . . .
Gearchange quadrant . . . . . .
Rubber "0" ring
... ...
Quadrant r e t u r n spring
...
Gearchange quadrant plunger
...
Plunger spring . . . . . .
Guide plate
... ... ...
Serrated washer
... ...
Nut
... ... ... ...
Kickstarter quadrant
...
Kickstarter r e t u r n spring
...
Kickstarter axle
... ...
C L U T C H LEVER ASSEMBLY
... ...
Clutch lever
Lever shaft
... ...
Ball. i n d i m . . .
...
Thrust plate
...
...
Return spring
... ...
Plain washer
... ...
S p l i t p i n ...
... ...
Countersunk screw
i n . O.A.)
Rubber cover . . . . . .
...
A b u t m e n t f o r clutch cable ...
Plain washer
... ... ...
Nut
... ... ... ...
Screw (23 in . U.H.)
... ...
Screw (I& in . U.H.) . . . . . .
Screw (1 in . U.H.)
... ...
Gearchange pedal
...
...
Bolt (1 i n . U.H.)
... ...
Pedal rubber ...
...
...
F O L D I N G KICKSTARTER ...
Kickstarter lever . . . . . .
Kickstarter pedal . . . . . .
Pedal locating spring
...
Steel bail $ i n . diam
Pedal b o l t . . . . . .
...
Pedal rubber ...
... ...
C o t t e r pin c/w n u t and washer
Domed n u t
... ... ...
Filler plug
... ... ...
Fibre washer ...
... ...
(s
....
QUANTITY
REMARKS
Ref. No.
Port No.
DESCRIPTION
CLUTCH
Clctch securing n u t ...

... ...
...
Hub
... ... ...
Thrust washer . . . . . .
... ...
Roller ...
... ... ... ...
Sprocket and housing (58 teeth Duplex)
Centre . . . . . .
... ... ...
Inner plate
... ... ... ...
Countersunk screw (0.417 in. U.H.)
Shock absorber spider
... ...
Drive rubber (large) . . . . . .
...
Rebound rubber (small)
... ...
O u r e r place
... ... ... ...
Screwed pin (1% i n . U.H.) . . . . . .
Driving place (bonded)
... ...
Driven plate ...
... ... ...
Pressure plate . . . . . .
... ...
Adjuster pin ...
... ... ...
Nut
... ... ... ... ...
Spring cup
...
... ... ...
Spring ...
... ... ... ...
Pressure n u t ...
... ... ...
Key
... ... ... ... ...
Cupped washer
... ... ...
...
QUANTITY
REMARKS
Ref . No.
Part No.
DESCRIPTION
CHAINCASE A N D C H A I N S
...
...
Primary chain oiler tube

Clip
... ... . . . . . .
...
Spring washer ...
...
...
B o l t (6i n . U.H.)
...
Rear chain, 5 i n . x i i n . x 104 links ...
Joint washer
... ... ...
Cover plate
... ... ...
...
O i l seal . . . . . .
...
Countersunlc screw (5i n . U.H.)
Chain tensioner abutment ...
...
Chain tensioner blade . . . . . .
...
Tie rod . . . . . .
... ... ...
Trunnion
... ... ... ...
Adluster sleeve n u t
... ...
Primary chain. ii n . D u p l e x x 84 links
Stator stud (4% i n . O.A.)
... ...
Stator stud
... ... ... ...
Stator. R M 2 l (47205) . . . . . .
...
Sleeve n u t
... ... ... ...
...
Rubber grommet
... ...
Plastic sleeve ...
... ... ...
Plain washer
... ... ... ...
Self-locking n u t
... ... ...
Joint washer
... ... ... ...
Chaincase
... ... ... ...
Rotor cover
...
... ... ...
Joint washer
... ... ... ...
Screw ...
... ... ... ...
C v p e r washer
... ... ...
... ...
Drain and adluster plug
Fibre washer ...
... ... ...
Filler plug
... ... ... ...
Fibre washer ...
... ... ...
Screw (1 i n . U.H.)
... ... ...
... ... ...
Screw ( s i n . U.H.)
Domed n u t
... ... ... ...
... ...
Timing pointer . . . . . .
... ...
Level plug
... ...
...
...
...
...
...
...
...
...
...
...
QUANTITY
REMARKS
1!
Ref No.
Port No.
DESCRIPTION
FRAME
F7843
Hlll
570-3
H I 0 18
F11267
R331
51 978
F5679
F11270
14.0404
F4671
F7849
RO2l
14-0703
F8392
F8036
51801
526-1
14-0303
14-0251
F4370
14-0304
PCW73A
5588
F7155
Front Frame
... ...
Steering race cup
...
Steel ball ( $ i n diam.)
T o p cone and dust cover
Centre stand
...
Pedalrubber . . . . . .
Pivot b o l t
... ...
Plain washer ...
...
Tab washer
... ...
Nut
... ... ...
Return spring . . . . . .
Prop stand
... ...
Pivot bolt
... ...
Self locking n u t
...
Return spring . . . . . .
Rear frame
... ...
Stud (3; i n . O.A.)
...
Spring washer ...
...
Nut
... ... ...
Bolt (244 in . U.H.)
...
Plain washer
... ...
Nut
... ... ...
Bolt ( I & i n. U.H.)
...
Steering srop ...
...
QUANTITY
REMARKS
Fig. 13.
S W I N I G N G F O R K A N D S U S P E N S I O N UNITS
. .
Ref No
Part No.
DESCRIPTION
QUANTITY
REMARKS
S W I N G I N G
F10045
F6042
NW100
WE170
F6821
F5313
F7848
5620
F5944
5545
F7365
51802
PCW73A
14-0304
F8090
D2024
Reference only
09-0122
99-01 07
99-1 048
99-1 047
14-0235
525-2
526-1
GS308
14-0303
F7067
F5536
14-01 13
F7364
525-1 3
14-0702
F9387
525-3
14-0302
F3808
F879
F1369
526-2
F7386
& in x $ i n
F7387
99-0725
TI 076
F4717
F5412
F5413
F3158
FORK A N D SUSPENSION -UNITS
SWINGING FORK . . . . . .
... ... ...
Pivot bush . . . . . .
... ...
...
... ...
Grease nipple . . . . . .
... ...
Fibre washer ...
... ...
Sleeve ...
... ... ... ... ... ...
Distance tube . . . . . .
... ... ... ...
Flanged washer
... ... ... ... ...
Bolt (85 in U.H.)
... ... ... ... ...
Tab washer
... ... ... ... ... ...
Nut
... ... ... ... ... ... ...
Brake torque stay
... ... ... ... ...
Bolt (j+ In U.H.)
... ... ... ... ...
... ... ... ...
Nut
... ... ... ... ... ... ...
"0" ring
... ... ... ... ... ...
SUSPENSION U N I T (64052107)
... ... ...
Damper unit
... ... ... ... ...
Bonded bush (64533645) . . . . . .
... ...
... ... ...
Sprinz retainer (9054,'171)
... ...
Spring 100 ibs . chrome (64543708)
Spring 145 lbs . chrome hexdy duty (64544234)
U n i t fixing bolt (1& i t 4. U.H.)
... ... ...
Plain washer
... ... ... ... ... ...
... ... ... ...
Plain washer
... ... ... ... ... ...
Nut
... ... ... ... ... ... ...
Chainguard
... ... ... ... ... ...
Grommet
... ... ... ... ... ...
Bolt ( In. H )
... ... ... ... ...
...
...
Rubber tube ...
...
... ...
Plain washer ...
... ... ... ... ...
Self-locking nut
... ... ... ... ...
Stepped bolt ...
... ... ... ... ...
Plain washer
... ... ... ... ... ...
Nut
...
... ... ... ... ... ...
Clip
... ... ... ... ... ... ...
Nut
... ... ... ... ... ... ...
...
...
Bolt (;in . U.H.)
...
... ...
Spring washer
...
...
... ... ...
Brake operating rod ...
... ... ... ...
Split pin . . . . . .
... ... ... ... ...
Adluster nut ...
... ... ... ... ...
Stop lamp switch type 228 (54033234)
...
...
Screw (+ in U.H.)
... ... ... ... ...
Self locking n u t
... ... ... ... ...
Switch lever
... ... ... ... ... ...
"D" washer
... ... ... ... ... ...
Spring (315738)
...
... ... ... ...
...
...
...
...
1
2
1
1
2
1
2
1
1
1
1
1
2
2
2
2
2
4
4
2
Available
4
2
2
3
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
5
1
1
1
Fig. 14.
E N G I N E U N I T F I T T I N G A N D FOOTRESTS
38
Ref. No.
-
Port No
DESCRIPTION
QUANTITY
REMARKS
E N G I N E UNIT F I T T I N G S A N D FOOTRESTS
Stud (3& l n O.A.)

... ...
Sprlngwaher . . . . . .
...
Nut
... ... ...
Stud (8& in O.A.)
... ...
Distance plece ...
... ...
Left rear engine plate
...
Rlght rear engine plate
...
Bolt (I# in. U.H.)
... ...
Bolt (2 in. U.H.)
... ...
Plaln washer ...
... ...
...
Nut
... ... ... ...
Extended nut . . . . . .
...
Left footrest ...
... ...
Right footrest ...
... ...
Stud (I& in. O.A.)
... ...
Plain washer ...
... ...
Nut
... ... ... ...
Peg
... ... ... ...
Footrest rubber
... ...
Stud (1: in. O.A.)
... ...
Nut
... ... ... ...
Bolt in . U.H.)
... ...
Bolt (19 in. U.H.)
...
...
...
Nut
...
... ... ...
Nut
... ... ... ...
Nut
... ... ... ...
Engine torque stay
... ...
Bit1
in. U . )
... ...
Nut
... ... ... ...
...
Brake pedal lever
... ...
Bolt
in. U.H.)
... ...
Nut
... ... ... ...
Brake pedal
... ... ...
Crankcase undershield . . . . . .
Hook bolt
... ... ...
Plain washer
...
... ...
Nut
... ... ... ...
Nut
...
... ... ...
Plain washer
... ... ...
LEFT FOOTREST ASSEMBLY
RIGHT FOOTREST ASSEMBLY
... ...
Left footrest
... ...
Right footrest
Footrest pedal
... ...
Pivot bolt . . . . . .
...
...
(a
(E
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
2
4
6
4
1
(3 on TR6C)
(TR6C only)
Fig.15.
E X H A U S T PIPES A N D MUFFLERS TIZOR, TR6R
I
I
Ref . No.
Port N o .
E X H A U S T
DESCRIPTION
PIPES AND
MUFFLERS.
QUANTITY
T120R.
...
EXHAUST PIPE D.S. . . . . . .

...
EXHAUST PIPE T.S. . . . . . .
...
Coupling pipe . . . . . .
... ...
Clip
... ... ... ... ... ...
Cap
... ... ... ... ...
... ...
Bolt. coupling pipe ( 1 i i n. U.H.)
Nut. coupling pipe
... ... ...
Clip. exhaust pipe to head ...
... ...
Spherical washer clip bolt ...
... ...
Bolt (for clip) . . . . . .
... ... ...
Exhaust pipe tie
... ... ... ...
... ... ...
Screw. stay to exhaust pipe . . . . . .
...
Nut. stay t o exhaust pipe
... ... ...
Silencer (muffler)
... ... ... ...
Bracket. silencer bracket
... ... ...
... ... ...
...
Bolt. bracket to silencer (iin . U.H.)
Hanger. frame for silencer ...
... ...
Bolt. silencer hanger t o frame (iin U.H.) . . .
Nut
... ... ... ... ... ...
... ... ...
Eolt. silencer to frame ($ in . U.H.) . . . . . .
... ... ...
Nut
...
... ... ... ... ...
Clip. silencer to exhaust pipe
... ...
Stay. DS and TS silencers
... ... ...
"DM washer
... ... ... ... ...
Bolt (If
in . U.H.)
... ... ... ...
...
... ...
Nut
... ... ... ... ... ...
Coupling pipe . . . . . .
...
...
Clip
... ... ... ... ... ...
"D" washer
... ... ... ... ...
Bolt
... ... ... ... ... ...
Nut
...
... ... ... ... ...
...
...
...
...
...
REMARKS
T R ~ R (Seealso Page43)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.......
... ...
... ...
... ...
... ...
... ...
...
...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
...
...
... ...
... ...
... ...
... ...
...
...
...
...
...
...
I Alternative pariz
Fig. 16.
E X H A U S T PIPES A N D M U F F L E R S (TR6C)
42
Ref . No.
Port No
QUANTITY
DESCRIPTION
E X H A U S T
PIPES
A N D
MUFFLERS
... ...
... ...
Exhaust pipe D.S. lower

Exhaust pipe T.S. upper
Exhaust pipe stay
...
5 i n. bolt
...
...
Spring washer
...
Silencer. upper . . . . . .
...
Silencer. lower . . . . . .
...
Connector
...
Bolt
... ... ...
...
Silencer bracket
...
Clip
... ... ... ...
Bolt (for clip) . . . . . .
...
N u t (for clip) ...
Bolt hanger t o frame . . . . . .
...
Clip
... ... ... ...
"D" washer
... ... ...
Bolt washer
...
...
...
Nut
... ... ... ...
Clip
... ... ... ...
Bolt
... ... ... ...
Clip
... ... ... ...
Leg guard
... ... ...
Clip
... ... ... ...
Bracket . . . . . .
... ...
Screw (short) . . . . . .
...
Screw (long) I $ in. U.H.
...
Washer (for lines 28 and 29) . .
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
REMARKS
TR6C
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
3
3
1
1
1
2
3
1
1
1
2
4
4
2
6
3
3
3
1
1
1
1
2
1
1
1
2 N o t illustrated
ASSEMBLY
REF. No.1
Fig. 17.
TELESCOPIC F R O N T FORK
44
Ref . No.
Part No .
QUANTITY
DESCRIPTION
REMARKS
T E L E S C O P I C F R O N T F O R K TR6R.
...
...
FORK ASSEMBLY
...
FORK ASSEMBLY
... ...
Middle lug and stem
Middle lug and stem
B o t t o m cone
... ...
Pinch bolt (2f i n U.H.) ...
... ...
Plain washer
Cieveloc nut
... ...
Fork stem sleeve nut (blind)
Top lug
... ... ...
Bondedbush
... ...
Lock c / w 2 keys ...
...
Key (stare serial number)
1
1
1
1
1
2
...
2
1
1
2
1
1
G r u b screw
... ... ... ...
Sealing washer
... ... ... ...
Locating pin
... ... ... ...
... ...
Pinch bolt (I+ i n . U.H.)
Seated n u t . . . . . .
... ... ...
Left top cover
... ... ... ...
Right top cover . . . . . .
... ...
C o r k washer
... ... ... ...
Spring abutment . . . . . .
... ...
Solo main spring (Yellow/Blue)
...
Extra strong main spring (Yellow/Green)
... ...
Plain washer
...
Telescopic gaiter ...
... ... ...
...
DUST EXCLUDER SLEEVE N U T
O i l seal
... ... ... ...
"0" ring . . . . . .
... ... ...
Plain washer
... ... ... ...
T o p bearing
... ... ...
Damping sleeve . . . . . .
... ...
Stanchion . . . . . .
... ... ...
Lower bearing
... ... ... ...
... ... ...
Bearing n u t
...
Cap nut ...
... ... ... ...
LEFT B O T T O M MEMBER c / w CAP ...
RIGHT BOTTOM MEMBER c / w CAP
Spindlecap . . . . . .
... ...
... ... ...
Spring washer
... ...
Cap bolt (I&
i n . U.H.)
...
...
Drain plug . . . . . .
...
Fibre washer
... ... ...
Shuttle valve
... ... ... ...
Circlip
... ... ... ... ...
Restrictor . . . . . .
... ... ...
Aluminium washer
... ... ...
...
Flanged bolt
... ...
Brake cable bracket ...
... ... ...
Cable retainer . . . . . .
... ... ...
Starlock washer
... ... ... ...
...
...
...
...
45
TR6R
t120r
TR6R
t120r
Key Nos run

from E l k 1 t o
EJRSO
1
1
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
2
2
2
Available
2
2
2
2
2
2
2
2
2
2
2
FORK ASSEMBLY REF. NP 1
15
@--
21
23
&Zk--
@?-
19
L20
Fig. 18.
TRbC F O R K PARTS A N D STEERING DAMPER
46
Ref. No
Port No.
DESCRlPTlON
QUANTITY
TR6C FORK PARTS A N D STEERING

FORK ASSEMBLY
... ... ...
Middle lug and stem
... ...
Top lug ...
... ...
Cap . . . . . .
... ... ...
Plain washer
... . . . . . . .
Bolt (1$ in U.H.) ...
... ...
Steering damper rod c/w knob ...
Plain washer
... ...
Adjuster sleeve ...
... ...
...
Spring plate
...
Anchor plate
...
...
... ...
Fork stem sleeve nut
Rubber sleeve
... ...
Friction disc
...
...
...
Main spring (yellowlgreen)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
DAMPER
...
...
...
...
...
...
...
...
... ... ...
... ... ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
....
...
All other parts are as listed on Page 45
HANDLEBAR
MOUNTINGS
Handlebar eyebolt
... ... ... ...
Plain washer ...
... ... ... ...
Bolt ( I $ in . U.H.)
... ... ... ...
Hemispherical washer . . . . . .
... ...
Self-locking nut
... ... ... ...
Steady rubber . . . . . .
... ... ...
... ... ...
Cup
... ... ... ... ... ...
Solid bush (lor handlebar-mounted windscreen)
...
...
...
...
...
...
...
...
... ...
...
...
REMARKS
...
...
... ...
......
i!
...
...
...
...
...
1
1
1
2
4
4
1
1
1
1
1
1
1
1
2
1
2
2
2
2
as
TR6R. T12OR
required
Ref. No.
Porf No.
DESCRIPTION
QUANTITY
REMARKS
FRONT WHEEL
W3458
W1721
W1230
W1328
W1708
W1709
579-2
W1693
W2057
W653
W1237
T280
W3337
W1481
W582
W3460
W1197
W1198
W3462
W1996
Reference only
Reference only
W2026
W135
W200l
W3453
140302
W3454
W2003
W2005
140401
W3522
W2058
WF32
W2027
W1991
5650
F2351
...
...
FROEJT WHEEL COMPLETE
RIM SPOKES A N D HUB ASSEMBLY
...
Front wheel r i m (WM2-19)
Spoke (8/10G x 55 in . straight)
....
Spoke (8/10G x 4 W i n. 78'j
...
Spoke (8/10G xG i n 100")
... ...
Spoke nipple . . . . . .
... ...
Hub and brake drum
... ... ... ...
Wheel spindle
Bearing
.... ... ... ... ...
Dust cover
... ... ... ...
Circlip
... ... ... ... ...
... ...
Bearing support ring
... ... ...
Grease retainer ...
Retaining ring
... ... ... ...
Cover plate
... ... ... ...
... ...
Balance weight. f oz. . . .
... ...
Balance weight. 1 oz. . . .
... ... ...
Brake anchor plate
...
BRAKE SHOE c/w LINING ...
... ...
Brake lining . . . . . .
Brass rivet ...
... ...
... ...
Abutment pad
Shoe return spring
... ...
Brake cam
... ... ... ...
Brake cam lever (front) . . . . . .
... ... ... ...
Nut . . . . . .
...
Brake cam lever (rear) . . . . . .
... ... ...
Rod . . . . . .
... ... ...
Fork end. threaded
...
... ... ...
...
Locknut
... ... ...
Lever return spring
...
Anchor plate nut . . . . . .
...
...
Pivot pin . . . . . .
Splic pin ...
... ... ... ...
Plain washer
... ... ... ...
...
Anchor plate gauze (for a i r scoop)
...
...
...
Taptite screw
...
...
...
...
Plain washer
...
...
...
...
...
...
...
... ...
...
...
...
...
...
...
...
...
...
...
... ...
... ... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ...
... ... ...
... ... ...
... ... ...
... ...
... ... ...
... ...
... ...
... ... ...
... ...
... ...
... ...
...
... ...
... ...
...
... ...
... ...
... ...
... ...
... ...
...
...
...
...
...
...
...
...
...
...
1
20
10
10
... 40
... 1
... 1
... 2
... 1
... 1
... 1
. 1
... 1
... 1
... as required
... as required
... 1
... 2
... 2
... 16
... 2
... 2
... 2
... 1
2
... 1
... 1
... 1
... 1
... 1
... 1
... 2
... 2
... 2
... 1
... 3
... 3
...
...
Ref . No.
P o n No .
DESCRIPTION
REAR WHEEL
W2102
REAR WHEEL COMPLETE . . . . . .
...
RIM SPOKES A N D H U B ASSEMBLY
W1486
Rear wheel r i m WM3-18 . . . . . .
W1007
...
Spoke (8/10G x7-& i n 90")
W1107
...
Spoke (8/1OG x7-& I n. 110")
W3402
Spoke (8/1OG x 79 i n . 90") . . . . . .
Wll08
Spoke nipple . . . . . .
... ...
579-2
Hub . . . . . .
... ... ...
W1472
Sprocket. 46T
... ... ... ...
W1499
Bolt ( # i n U.H.)
... ... ...
W 1 500
Serrated washer . . . . . .
... ...
El612
Brake drum
... ... ... ...
W1498
Bolt (+In . U.H.) . . . . . .
... ...
W1690
Self locicing nut . . . . . .
... ...
W1691
Wheel spindle
... ... ... ...
W1281
Grease retainer (brake side)
... ...
W1474
Grease retainer . . . . . .
... ...
W1654
Backing ring
... ... ... ...
Wl022
Bearing
... ... ... ... ...
W653
RETAINING RING
... ... ...
W1021
...
Locking screw (& in. U.H.)
W1710
Distance tube
... ... ... ...
W1278
Distance piece
... ... ... ...
W1024
Bralce
anchor
plate
... ... ...
Wlll2
Nut . . . . . .
... ... ... ...
W3426
LEADING BRAKE SHOE C / W LINING
" W1406
TRAILING BRAKE SHOE C / W LINING
W1407
Brake lining . . . . . .
... ...
Reference only
Brass rivet ...
... ... ...
Reference only
Thrust pad ...
... ... ...
W1415
Shoe
return
spring
... ... ...
W135
Brake
cam
.
.
.
.
.
.
... ... ...
W1083
Brake
cam
lever
.
.
.
.
.
. ... ...
W2015
... ...
Plain
washer
...
...
525-6
...
... ...
N
u
t
.
.
.
.
.
.
...
51-52
Lever
return
spring
...
... ...
W1090
Grease
retainer
.
.
.
.
.
.
... ...
W163S
Speedometer
adaptor
...
... ...
W1476
...
... ...
Distance
piece
...
W1477
Speedometer
gearbox
.
.
.
.
.
. ...
D637
...
...
Plain
washer
...
...
W1280
...
...
Chain
adjuster
.
.
.
.
.
.
...
W2089
...
...
Adjuster
end
plate
...
...
W1015
...
...
Self-locking
nut
...
...
14-1 902
... ... ... ... ...
Spindle nut
F1747
...
...
...
Tire security bolt
WM3
...
...
...
N u t inner D.S.
...
W3425
...
...
...
...
Pivot pin
...
W1467
...
QUANTITY
REMARKS
Fig. 22.
GAS T A N K S
52
Ref No.
DESCRIPTION
Port No
QUANTITY
GAS TANKS
...
Gas tank (3f gallons)

... ...
Gas tank (24 gallons) . . . . . .
...
Gas tank (2f gallons) ...
... ...
Styling unit (left)
... .......
Styling unit (right)
... ...
Styling unit screw (front)
... ...
Styling unit screw (rear)
... ...
Left knee grip
... ... ...
Right knee grip
... ... ...
Centre styling strip ...
... ...
Hook screw
... ... ... ...
Serrated washer
... ... ...
Nut
... ... ... ... ...
FILLER CAP . . . . . .
... ...
FILLER CAP c/w CHAIN ...
...
Joint washer
'... ... ...
Petrol tap (left)
... ... ...
Petrol tap with reserve tube . . . . . .
Petrol tap nut . . . . . .
... ...
Petrol tap seal . . . . . .
... ...
Steel washer ...
... ... ...
... ...
Spigot rubber . . . . . .
... ...
Cup
... ... ... ... ...
Shouldered stud
... ... ...
Nut
... ... ... ... ...
Double spigot rubber . . . . . .
...
... ...
Bolt 1
inH . )
... ... ...
Reflector bracket
... ... ...
Reflector Amber (57161)
... ...
Decal-Bonneville
... ... ...
Decal-Trophy 650 ...
...
...
Decal-Trophy Sports
...
Decal-Made in England
... ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
REMARKS
10
Fig. 23.
OIL TANK
54
Ref. No.
Port No
DESCRIPTION
OIL TANK
...
...
O i l tank
... ... ...
...
FILLER CAP . . . . . .
... ... ...
Joint washer
...
... ...
Drain plug
... ... ... ...
Fibre washer ...
... ... ... ...
O i l tank filter . . . . . .
... ...
Fibre washer ...
... ... ... ...
Upper feed pipe
... ... ... ...
Union nut
... ... ... ... ...
Flexible connector
... ... ... ...
Clip
... ... ... ... ... ...
O i l pipes and junction block . . . . . .
...
Joint washer ...
... ... ... ...
Plain washer ...
... ... ... ...
Nut
... ... ... ... ... ...
Vent pipe
... ... ... ... ...
"T" piece
... ... ... ... ...
Extension pipe . . . . . .
... ... ...
Clip
... ... ... ... ... ...
Front strap
... ... ... ... ...
Rear Strap
... ... ... ... ...
Spigot rubber . . . . . .
... ... ...
... ... ...
Bolt ($ in. U.H.)
... ... ... ...
Self locking nut
...
...
... ...
Metering screw
... ... ... ...
Coil spring
... ... ... ... ...
Screwed peg ...
... ... ... ...
Plain washer ...
... ... ... ...
Nut
... ... ... ... ... ...
Rubber connector
... ... ... ...
Rocker oil feed pipe . . . . . .
...
...
Copper washer
... ... ... ...
Domed nut
... ... ... ... ...
Bracket . . . . . .
... ... . . . . . .
Grommet
... ... ... ... ...
Bolt (f in. U.H.)
...
... ... ...
Flexible pipe ...
... ... ... ...
Clip
... ... ... ... ... ...
Sleeve nut
... ... ... ... ...
Grouped transfer "Drain and refill" e t c. . . .
...
...
...
QUANTITY
REMARKS
Fig.14. BATTERY CARRIER A N D A I R FILTERS
Ref. No
Part N o
DESCRIPTION
QUANTITY
REMARKS
...
Battery carrier
... ... ...
Battery carrier rubber tray . . . . . .
...
...
Battery carrier strap . . . . . .
Battery strap anchorage
... ... ...
Battery carrier rubber strip . . . . . .
...
Transfer positive earth
... ... ...
Vent pipe
... ... ... ...
Circlip. v e n t pipe
... ... ...
Battery (PUZSA) 54027029
... ...
AIR CLEANER ...
... ... ... ...
Air cleaner element (filter cloth &gauze)
AIR CLEANER ...
... ... ... ...
A i r cleaner element (filter cloth & gauze)
Fuse assembly . . . . . .
... ... ...
Clip for air cleaner cover
... ... ...
...
...
...
...
T120R
Reference only
1 Not illustrated
Ref. No
Port No.
DESCRIPTION
PANEL A N D TWINSEAT
Side panel and toolbox

Decal-TIGER 650
Decal-TROPHY 650
Decal-BONNEVILLE ...
Panel knob
......
Washer . . . . . . . . .
Panel nut
......
Panel grommet . . . . . .
TWINSEAT
... ...
Twinsear cover ...
......
T r i m strip
T r i m strip sprag
...
Rubber buffer . . . . . .
Hinge-front
......
Hinge-rear
... ...
Bolt (+ In. U.H.)
...
Check wire
......
Self tapping screw
...
Washer . . . . . . . . .
Spring ...
... ...
Split pin . . . . . .
...
Seat catch plunger
...
Seat rail . . . . . .
...
Bolt ( % i n. U.H.)
...
...
...
QUANTITY
REMARKS
Fig. 26.
FENDERS
60
9ef. No
Part No
DESCRIPTION
OUANTITY
REMARKS
FENDERS
Front fender (painted)
...
Front fender (stainless steel) ...
Front stay
... ...
Front stay
... ... ...
Centre stay
... ... ...
Centre stay
... ... ...
Bottom stay
... ... ...
Bottom stay
... ... ...
Bracket
... ... ...
Rear fender
... ... ...
Rear fender
... ... ...
Bridge . . . . . .
... ...
Lifting handle . . . . . .
...
Bracket . . . . . .
... ...
Clip
... ... ... ...
Backing plate . . . . . .
...
Tail lamp adaptor
... ...
Tail lamp plate . . . . . .
...
Number plate bracket
...
Reflector red (57111) . . . . . .
Push fix . . . . . .
... ...
Rubbermat
... ... ...
Wiring protector
... ...
...
Tail lamp lead grommet
... ...
Bolt (i,in. U.H.)
Plain washer ...
... ...
Nut
... ... ... ...
Bolt ( & i n . U.H.)
... ...
Nut
... ... ... ...
Bolt (f in. U.H.)
... ...
Plain washer ...
... ...
Washer . . . . . .
... ...
... ...
Nut
...
Self-locking nut
... ...
Plain washer ...
... ...
Bolt (2 in. U.H.)
... ...
Bolt ( i n . U.H.)
... ...
...
...
Screw ...
... ... ...
Washer . . . . . .
... ...
Nut
... ... ... ...
Stud (+in. O.A.)
...
...
Nut
... ... ... ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
2
4
2
1
Reference only
5
12
13
4
2
3
2
3
3
Fig. 27.
H A N D L E B A R S A N D C O N T R O L LEVERS
Ref. No.
DESCRIPTION
Pan N o
HANDLEBARS
H1870
H I 425
99-0248
99-0245
99-0246
99-0244
99-0238
99-0239
99-0240
99-022s
Reference only
99-0241
D2073
99-0262
99-0266
99-0234
99-0226
99-0225
99-0252
99-0250
99-1031
99-0228
121607
121606
121033
D2074
99-0261
99-0265
99-0230
99-0226
99-0252
99-0250
99-1031
Reference only
99-0555
99-0630
H1994
A N D C O N T R O L LEVERS
...
OUANTITY
(SEE A L S O PAGE 65)
......
Handlebar
...
... ... ...
Packing piece . . . . . .
... ... ...
...
M I S T G R I P (161364) . . . . . .
...
Body top half (161328) . . . .
...
...
Body bottom half (161329)
... ... ...
Rotor (161091)
...
...
...
Friction spring (161008) . . . . . .
... ...
Friction spring screw (161009) . . . . . .
... ...
... ...
Locknut (161010) . . . . . .
...
Screw (111013) ...
. . . . . . ... ... ...
Grip
... ... ... ... ...
...
Cable stop (161011)
... ... ... ...
FRONT BRAKE A N D AIR LEVER ASSEMBLY (181978)
Brake lever (ball end) (181754)
... ... ...
Lever bracket (181776) . . . . . .
... ... ...
Control body (121619) . . . . . .
... ... ...
Screw ('11/014) . . . . . .
... ... ... ...
Screw (111013)
... ... ... ... ... ...
Fulcrum screw (181087) . . . . . .
... ... ...
Self locking nut (181053)
... ... ... ...
Cable adjuster and nut (18/1708/1709)
... ...
Lever (121556)
... ... ... ... ... ...
Bolt
... ... ... ... ... ... ...
Cap . . . . . .
... ... ... ... ... ...
Spring washer
... ...
... ...
CLUTCH LEVER ASSEMBLE 181952
... ... ...
Clutch lever (ball end) (181752) . . . . . .
... ...
Clutch lever bracket (181773) . . . . . .
... ...
Clamp (121595) . . . . . .
... ... ... ...
Screw (11/014) . . . . . .
... ... ... ...
Fulcrum screw (181087) . . . . . .
... ... ...
Self locking nut (181053)
... ... ...
Cable adjuster and nut (18/1708/1709)
... ...
Handlebar grip . . . . . .
... ...
... ...
Horn push and dip switch (31563) . . . . . .
... ...
Backing rubber (380459)
... ... ... ... ...
Self-tapping screw (o i n. U.H.)
... ... ... ...
...
:.
...
......
...
...
...
...
...
...
...
...
...
...
REMARKS
...
...
...
23
TROPHY
24
25
24
Fig. 28.
C O N T R O L CABLES
25
?ef. No
Part No
DESCRIPTION
QUANnTY
C O N T R O L C A B L E S A N D T120R
...
CLUTCH CABLE
... ...
Ferrule
... . . . . . .
Nipple (Handlebar end)
...
Nipple
... ...
Adjuster . . . . . .
...
N u t ......
...
FRONT BRAKE CABLE
Front stop switch . . . . . .
...
Cover for switch . . . . . . . . .
Ferrule
... ... ... ...
...
Fork end . . . . . .
... ...
Pivot pin (spring-fix) . . . . . .
...
T H R O T L E CABLE . . . . . .
...
THROTTLE CABLE . . . . . .
...
Ferrule
... ... ...
Nipple
... ... ...
Nipple
... ... ... ...
Adjuster
... ...
AIR CONTROL CABLE
... ...
AIR CABLE ASSEMBLY
... ...
Lever cable
... ... ...
Carburetter cable
... ...
Junction box (2441104) . . . . . .
...
Ferrule
... ...
...
Nipple
... ... ... ...
Clip. rubber ...
... ...
T W I N ROTOR TWISTGRIP (313113)
Body top half (313/008) . . . . . .
Body bocrom half (3131009)
...
Rotor (3131013) . . . . . .
...
Bolt (41048)
... ... ...
Friction spring (161008) ...
...
Adjuster screw (2101007)
...
Rotor stop (2101008)
... ...
... ... ...
N u t (210/009)
Grip
... ... ... ...
Cable stop (16/011)
... ...
... ... ...
Cable clip (metal)
...
......
...
...
...
...
......
. . . . . . ...
. . . . . . ...
...
...
...
...
...
...
...
...
...
...
TWISTCRIP
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
... ... ...

... ... ...
... ... ...
... ... ...
... ...
... ... ...
...
REMARKS
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
i
1
1
1
1
1
1
2
1
1
1
1
1
8
1
1
1
1
1
1
2
1
1
6
3
as
1
1
1
1
2
1
1
1
2
1
2
as
TR6R. TR6C
t120r
TR6. TR6C
t120
required
t120r
required
Fig.29.
TOOLKIT A N D PILLION FOOTRESTS
Ref. No.
Port N o.
DESCRIPTION
TOOLKIT
AND
PILLION
TOOLKIT COMPLETE
... ...
Tool roll
... ...
Open spanner x 6 in. W h i r ....
Open spanner xiri; in. W h i t .:..
Ring spanner 5 x 9in W h i t . . . .
"C" spanner and tappet key ...
Screwdriver for chain tensioner
Tyre lever . . . . . .
... ...
Tyre lever and tomrny bar
...
Screwdriver
... ... ...
Ring spanner & x in. W h i t . . . .
Clutch hub extractor . . . . . .
...
PILLION FOOTREST
... ...
Pedal
... ... ... ...
Hanger
... ... ... ...
Bolt
in U.H.)
... ...
Pivot bolt . . . . . .
... ...
Thrackeray (spring) washer
...
Nut . . . . . .
... ... ...
... ... ...
Pedal rubber
QUANTITY
REMARKS
FOOTRESTS
......
+
+
...
(E .
...
...
...
...
...
...
...
...
...
As required
Fig. 30. A M A L CARBURETTER, TR6R TR6C
68
Ref. No
Part No
DESCRIPTION
A M A L CARBURETTER TR6R. TR6C

D770
Reference only
99-0552
99-1 032
99-0521
99-0527
99-1 033
99-051 6
99-0515
99-0520
99-1 034
99-0441
99-1035
99-1036
99-051 0
99-1037
99-051 2
99-051 3
99-051 4
99-0506
99-051 1
99-0438
99-0517
99-0437
61132A
99-0528
99-1038
F9271
CARBURElTER (R930123) . . . . . .
Mixing chamber . . . . . .
...
"0" ring seal (622/101)
...
Mixing chamber top (9281098) ....
Screw (622/086) . . . . . .
Thrortle valve (4 cutaway) (9281060)
Throttle return spring (622/131)
Throttle stop screw (6221077)
A i r adjusting screw (6221076) ...
"0" ring (6221082)
... ....
J e t holder (67.21128)
... ...
Main jet (230) (3761100)
...
Needle jet (0.107) (6221122)
...
Needle (6221124)
... ...
Needle clip (6221067)
... ...
Air valve guide sleeve (9281103)
Float (6221069) . . . . . .
...
Float spindle (6221071) . . . . . .
Joint washer (6221073) . . . . . .
Float chamber (6221050) . . . . . .
Needle (6221068)
... ...
Filter (3761093) . . . . . .
...
Banjo bolt (622/078)
... ...
Fibre washer (3761092) . . . . . .
Cable ferrule
... ... ...
Air slide (9281062)
... ...
Spring (6221129) . . . . . .
...
Petrol pipe
... ... ... ...
...
...
Ref . No.
Part No.
DESCRIPTION
QUANTITY
REMARKS
A M A L C A R B U R E T T E R T12OR
...
CARBURETTER-L.H. (L930110)
D771
CARBURETTER-R.H.
(R930/9) ...
D772
Mixing chamber . . . . . .
...
Reference only
"0" ring seal (622/101) . . . . . . .
99-0552
Mixing chamber top (9281098)
99-1 032
Screw (6221086) . . . . . .
...
99-0521
Throttle valve (3 cutaway) (9281060)
99-0527
Throttle return spring (6221131)
99-1 033
Throttle stop screw (6221077)
99-051 6
A i r adjusting screw (6221076) ...
99-051 5
"0" ring (6221082)
... ...
99-0520
Jet holder (6221128)
... ...
99-1 034
Main jet (220) (3761100) . . . . . .
99-0441
Needle jet (0.107) (6221122) ...
99-1 035
Needle (6221124) . . . . . .
...
99-1036
Needle clip (6221067) ...
...
99-051 0
Air valve guide sleeve (9281103)
99-1037
Float (6221069) . . . . . .
...
99-0512
Float spindle (6221071) . . . . . .
99-051 3
Joint washer (6221073) ...
...
99-051 4
Float chamber (6221050) . . . . . .
99-0506
Needle (6221068) . . . . . .
...
99-051 1
Filter (3761093) . . . . . .
...
99-0438
Banjo bolt (6221078)
... ...
99-0517
Fibre washer (3761092) . . . . . .
99-0437
Cable ferrule
... ... ...
611 32A
... ...
A i r slide (9281062)
99-0528
Spring (6221129) . . . . . .
...
99-1 038
Petrol pipe
... ... ... ...
F8133
Air intake tube (9281066)
... ...
99-0530
Joint
washer
...
...
... ...
NA43A
... ...
Insulating
block
...
E2968
... ... ...
Reference only Stude 1 in. . . .
Self-lock nut ...
... ... ...
S1932
Cup
... ... ... ... ...
E9555
Insulating ring . . . . . .
... ...
E9554
...
...
...
...
...
...
...
...
...
...
1
Available
1
1
4
4
4
4
Fig. 33.
SPEEDOMETER A N D T A C H O M E T E R
Ref. No.
Part No.
Speedometer head MPH (SSM5001/06)

... ...
Brass fitting a t cable connection
... ... ...
Bulb3W.MES . . . . . .
... ... ... ...
... ... ...
Bulb holder (554710) . . . . . .
M O U N T I N G BRACKET
... ... ... ...
... ... ...
Metalastik bush . . . . . .
... ... ... ...
Washer . . . . . .
...
Nut
...
... ... ... ... ... ...
... ... ... ...
Bolt (l+in. U.H.)
...
T r i p control
...
... ... ... ... ...
... ... ... ...
Sleeve n u t
... ... ... ... ... ...
... ... ...
Bracket . . . . . .
...
...
... ...
...
Bolt ( f i n . U.H.)
...
...
... ...
...
...
Speedometer cable (65 ins. long) (D609W inner only)
E9331
E9332
Reierence only
E5155
E5157
E5759
E6300
E5578
E6122
E6299
Reference only
E3309
E5881
D578
99-01 66
31-371-398
D494
E6961
D546
QUANTITY
DESCRIPTION
...
TACHOMETER GEARBOX (E5758 Body)
...
...
...
Securing screw ...
...
... ... ...
Bush . . . . . .
...
Flanged bush . . . . . .
...
... ...
...
...
...
Driving gear
...
...
...
...
...
End cap
... ... ...
...
...
...
"0" ring . . . . . .
...
Driven gear
... ... ... ... ...
...
...
Driven gear housing
... ...
...
...
"0"ring
... ... ...
Bush . . . . . .
... ... ... ...
... ...
"0" ring . . . . . .
... , .
Set screw . . . . . .
... ... ... ...
Tachometer cable (28 in. long) (D578W inner only)
... ...
...
Tachometer (RSM3003/01) ...
Spade ...
... ,.. ... ... ... ...
... ... .,. ...
Circlip . . . . . .
...
...
...
...
Sealing washer . . . . . .
...
...
Blanking plug (replaces tacho bulb holder)
...
...
...
...
...
1
1
REMARKS
Not illustrated
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
"'
:J
1
1
Not illustrated
Fig.34.
I G N I T I O N C A P A C I T O R A N D H E A D L A M P TR6C
3ef. No .
Port No
DESCRIPTION
QUANTITY
REMARKS
I G N I T I O N CAPACITOR A N D HEADLAMP. TR6C
...
...
Ignition capacitor (type 2MC) (54170009)
Capacitor mounting spring (54483156)
... ...
Cap. wiring harness terminal
... ... ...
Wiring harness (54955719) . . . . . .
... ...
Kill button type 151SA (35835)
... ... ...
... ... ... ... ...
Cup
...
...
Clip
... ... ... ... ... ... ...
Bolt ( + i n U.H.)
... ... ... ... ...
Nut
... ... ... ... ... ... ...
...
HEADLAMP ASSEMBLY. MCH 66 (60087)
Shell
... ... ... ... ... ...
Rim (534343)
... ... ... ... ...
Light unit (54524526) . . . . . . .
... ...
Fixing wire (504665)
...
... ...
Bulb (40127 W . Vertical Dip. Pre-focus) (464)
Bulbholder pilot (554710)
... ... ...
Bulb (3W . M.C.C.) (989)
... ... ...
... ... ... ...
Adaptor c/w leads
Bolt
... ... ... ... ... ...
Washer
... ... ... ... ... ...
Lighting swirch (35710) . . . . . .
... ...
Dip switch (31620)
... ... ... ...
Screw
... ... ... ... ... ...
...
Plate (534296)
... ... ... ...
Warning light. red (38189)
... ... ...
Warning bubholder (54945043)
...
...
... ...
Bulb (2W . BA75) (181) . . . . . .
...
Warning light. green (38191) . . . . . .
... ...
Horn push. Clear Hooters N o. 10
...
Nut for lighting switch . . . . . .
...
...
...
Serrated washer (for H745) . . . . . .
Available
Available
Available
TR6C
...
Fig.35.
I G N I T I O N COILS, H O R N , RECTIFIER A N D Z E N E R D I O D E
Ref. No.
Port No.
I G N I T I O N
DESCRIPTION
COILS,
H O R N ,
RECTIFIER A N D
I G N I T I O N COIL, Type M A 1 2 (45110)

... ... ...
Bracket
Lucar terminal
...
Plain washer ( ~ 2 3 5 i j
...
Serrated washer ( ~ 5 2 9 9 ) " '
N u t (F3799)
...
Rubber g r o m m e t . . . . . .
Cable clip . . . . . .
... ...
Screw
Square n u t
...
"D" washer (422369)
...
Lucar connector
...
Insulating cover
... ...
B o l t ( I & in. U.H.)
... ...
Rubber g r o m m e t
... ...
Distance piece
... ...
Self locking n u t
...
Sparking plug (Cha mpion N3)
... ... ...
Plug cover
Left coil bracket
... ...
Right coil bracket
... ...
B o l t (5 in. U.H.)
... ...
Serrated washer
... ...
... ... ... ...
Bolt
Nut
...
...
...
...
Ignition coil, ~ib;'32,000
... ...
Clip. Sib3 32,000/1
... ...
CONDENSER P A C K
......
Condenser (47638)
... ...
Cover (54420128)
... ...
Condenser pack bracket (51418528) ...
Bolt, bracket t o frame
... ...
Bolt, oack to bracltet
... ...
~ h a k & r o o f washcr
Nut
...
...
H o r n , type 6 H i?0197j"
...
Scrcw [a
...
...
," in. U.H.)
Nut
... ... ... ...
Serratcd washer
Rcctificr, t y p c 2DS 506'(49072)'
...
Nut
Heat sink
... ... ...
Zcner diode (49345) . . . . . .
Brsclcet . . . . . .
... ...
Washer . . . . . .
...
B o l t (bracket t o heat sink)
B o l t (bracket to fork)
Plug heat sink . . . . . .
Washer . . . . . .
...
H i g h tension lead
...
H o r n R.H.
... ...
H o r n L.H.
...
H o r n relay (33188)
...
Bolt
... ... ...
Washer . . . . . .
...
OUANTITY
ZENER
REMARKS
D I O D E
...
...
...
...
...
...
...
...
...
...
CP
...
Nut
... ...
.....
...
Bracltet .
Relay stay
...
...
...
...
...
...
...
...
as required
as reouired
Fig. 36.
HEADLAMP, W I R I N G HARNESS, SWITCHES A N D TAIL LAMP
78
Ref. No.
Port No.
DESCRIPTION
HEADLAMP. WIRING
QUANTITY
REMARKS
HARNESS. SWITCHES A N D T A I L LAMP

TR6R. T12OR
HEADLAMP COMPLETE TYPE SS700P (59883) . . . . . . .

Shell only
...
...
Rim (553248)
... ... ...
...
Light u n i t (516798)
... ... ... ...
Fixing w i r e (504665)
... ...
... ...
Screw
...
... ... ... ... ...
Plate (534296)
... ... ... ... ... ...
Bulb (50/40W vert dip pre focus) (446)
.......
Main bulbholder (54520540)
... ...
E u l b ( 6 W M C C ) (989)
... ... ... ...
... ... ... ...
Pilot bulbholder (554710)
Ammeter. type 2AR (36403) ...
... ... ...
Grommet ...
... ... ... ... ... ...
Bolt
... ... ... ... ... ... ...
Plain washer
... ... ... ... ... ...
... ... ...
Lighting switch (35710) . . . . . .
Warning light body (red) (38189)
... ... ...
Bulb (1W BA7S) (281) . . . . . .
... ... ...
Warning light body (green) (38191) . . . . . .
...
Warning bulbholder (54945043)
... ... ...
... ... ... ... ...
W i r i n g harness (54955257) . . . . . .
... ... ...
Stop and t a i l lamp. type L679 (53973)
... ... ...
Lcns (54577109) . . . . . .
... ... ... ...
Screw
... ... ... ... ... ... ...
Bulb holder w i t h reflector (54574348) . . . . . .
...
... ... ... ...
Contact assembly (573818)
Bulb (6/12W offset pin) (380) . . . . . .
... ...
Gasket (51571677)
... ... ... ... ...
Screw
... ... ... ... ... ... ...
Ignition zvditch type 545 (31899)
... ... ... ...
N u t ...
... ... ... ... ... ... ...
Ignition loci< c / w keys . . . . . .
... ... ... ...
... ...
Ignition key (state serial No.) . . . . . .
Ignition switch cover . . . . . .
... ... ... ...
... ... ...
Ignition rubber cable clip (rear lamp)
...
...
...
...
...
...
...
... ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
1
1
1
6
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
I
1
1
...
...
2
1
1
1
1
...
1
1
1
1
As required
1
1
...
...
...
...
...
...
Printed In Englond by
WARWICK PRINTING COMPANY LIMITED

WARWICK

Triumph Parts Catalog 1969 Du85904

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029

T R I U M P H ENGINEERING COMPANY LIMITED

TELEGRAMS "TRUSTY C O V E N T R Y "

i n this Guarantee t h e w o r d "machine" refers t o t h e m o t o r cycle, scoorer, m o t o r cycle combination

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

3. W e w i l l supply, free o f charge, a n e w p a r t i n exchange for, or, i f w e consider repair sufficient, w i l l

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

for consequential damage o r i n j u r y t o person o r property, shall

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

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

CAMSHAFT. INLET AND EXHAUST

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

Amal Concentric 930

+" Duplex x 84 links

... 3$ U.S. galls. (16 litres)

6 U.S. pints (2.8litres)

... 2$ U.S. galls. (11 litres)

... Amal Concentric 930

6 U.S. pints (1.8 litres)

8" (20.32 cm.)

(40 cu. ins.)

+" Duplex x 84 links

2; U.5, galls. (11 litres)

8" (20.32 cm.)

2 Amal Concentric 930

5 U.5. pints (2.8 litres)

Competition use only

De-coke Gasket Set

... Top cone

H O W TO USE THIS PARTS CATALOGUE

TR6 all cond~tions

Paint is available only in Aerosol containers.

A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING

CRANKSHAFT A N D FLYWHEEL ASSEMBLY . . . . . .

' Use D524 Loctite Sealant

the commencement of the season. the previous 'light' type of crankshaft

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

CYLINDER BLOCK A N D H E A D , TR6

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

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

Cylinder base washer

* E9526 Blanking plug available t o

replace oil switch i f required

Stud (3 in. O.A.)

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

MAINSHAFT HIGH GEAR (28T) . .

CLOSE RATIO GEARS

MAINSHAFT c/w L O W GEAR (18T)

GEARBOX OUTER COVER

Clctch securing n u t ...

Primary chain oiler tube

FORK A N D SUSPENSION -UNITS

Stud (3& l n O.A.)

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

EXHAUST PIPE D.S. . . . . . .

Exhaust pipe D.S. lower

Key Nos run

FORK ASSEMBLY REF. NP 1

TRbC F O R K PARTS A N D STEERING DAMPER

TR6C FORK PARTS A N D STEERING

All other parts are as listed on Page 45

Gas tank (3f gallons)

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