REPLACEMENT PARTS Tlt.ruM:PB - JRC...

I

I

REPLACEMENT PARTS

FOR THE

Tlt.ruM:PB ~·

MOTORCYCLE

150 OHV Commencing Engine No.

TIS-10 I

TRIUMPH ENGINEERING COMPANY LTD.

MERIDEN WORKS, ALLESLEY

COVENTRY Tel~pho~

Meriden 331

Issue No. I Publi>h<d October 19~:;

------------------------------

PREFACE J BEFORE ordering parts for your machine, please read very carefully the

instructions contained in the next paragraph. In many cases the information given in the order is insufficient to enable us to identify the customers' requirements with \l_,.

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

HOW TO ORDER. Every part is indicated by a number and this should be quoted together with the description. In order to assist customers. parts where possible have been ~-listed in order of assembly and exploded illustrations show the assembly order also. By each illustration, is an index quoting the part numbers of the various items and a cross reference to enable the customer to recognise the part by description (See page 55 for further details). With these aids there should be no difficulty In identifying the parts you require. Always quote the engine number and prefix letter stamped on the left hand (drive side) of the crankcase below the cylinder base flange. Always use a separate sheet of writing paper for -J your order If you are sending a letter as well.

SPECIMEN ORDER

1/7/53 ·~ To Triumph Engineering Co. Ltd.,

Meriden Works, Alles ley, Coventry.

Please supply:-

" Send C.O.D.

Engine No. T.IS-9231

GSTI5f53

E3146

Gasket Set

Valve, Inlet

Wm. Smith,

.0

Ia, Ewell Avenue, iii Ewell, Surrey. W

~ For terms of business see page 3

TELEGRAPHIC ORDERS. Orders by telegram should be addressed to •· Truscy 60221 Coventry." They are then telephoned to us, which prevents delay in delivery. It is only necessary to quote part numbers in telegraphic orders. the description can be omitted.

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

2

t

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

All communications relating to spare parts, repairs, replacements and general service, should be addressed to the Triumph Engineering Co. Ltd., Meriden Works, Allesley,Coventry, and in order to facilitate quick reference, the quoting of any order number, invoice number or reference from previous communications is of essential importance. Accessories not of our manufacture should be sent direct to the actual makers, whose names and addresses appear on page 43.

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

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

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

TERMS OF BUSINESS

THE most convenient method of paying for spare parts is by the C.O.D. system. By this method you pay the postman for the goods when he delivers them to you. As the minimum C.O.D. collection fee is IOd., only goods to the value of2/- or over can be sent

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

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

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

Postage, carriage and packing is charged at 2!0 0 on the value of the goods, minimum

charge 6d. Packing boxes, cases, crates, etc., are charged for at cost and are returnable. '

3

RIGHT HAND SIDE

LEFT HAND SIDE

4

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~

~

• ~

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CARTON PACK - GROUP I

CARTON PACK -GROUP I

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

Part No.

Big End Assembly CP.I25 ... I

I 15

CP.I26 I Export only I

I IS

Brake linings CP.I28 2

14

Clutch Inserts CP.I27 20

20

Piston Assembly CP.120 I

2

I 2

CP.I20;'20 I 2 I I 2

CP.I20!40 I 2 ... I I 2

Desr::ription and Contents

E.3163 E.3291 E.3162

E.3165 E.l762 E.3291 E.3162

W.978 W.979

T.ll27 NT.288

E.3148 E.3153

... E.3154 E.l750 ... E.l767

E.3148:20 E.3153 :20 E.3154 20 E.l750 E.l767

... E.3148!40 E.3153:40 E.3154:40

... E.l750 E.l767

5

Connecting rod assembly Crankpin Rollers

Bush, big end Bush, small end Crankpln Rollers

Linings Rivets

Cork insert, sprocket Cork insert, plate

Piston body Ring, compression Ring. scraper Pin, gudgeon Cirdip

Piston body .... 020" Ring, compression Ring, scraper Pin, gudgeon Clrclip

... Piston body + .040" Ring, compression Ring, scraper Pin, gudgeon Cirdlp

GROUP I - CARTON PACK

Part No.

Piston Rings CP.I21 2

CPI21 !20 2

CP.I21 (40 2 ...

Rear Suspension Spring Set CP.I30 2 .. .

2 .. .

Steering Races CP.I29 2

2 30

Valves CP.I24 ...

Valve Guides CP.I22 ... 2

2

Valve Springs CP.123 ... 2 ...

2

Description and Contents

E.3153 E.3154

E.3153/20 E.3154t20

E.3153/40 E.3154j40

F.3425 F.3426

H.835 H.833 S70-3

E.3146 E.3147

E.3208 E.3209

E.3214 E.3215

...

Ring, compression Ring, scraper

Ring, compression 7 .020" Ring, scraper

Ring, compression -c· .040~

Ring, scraper

Spring, main Spring, rebound

Cup, steering race Cone, steering race Ball. steering race

Valve, Inlet Valve. exhaust

Valve guide, inlet and exhaust Circllp

Spring. valve inner Spring, valve outer

For Indexes see Pages 52 to 55

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ENGINE- GROUP 2

REPLACEMENT PARTS

REF. No. PART No . DESCRIPTION QUANTITY

I 2

3 4 5 6 7 8

• 9 10 II 12 13 14

15 16 17 18 19 20 21

22 23 24 25

ENGINE- GROUP 2

Illustrated on Page 10-Fig. I

CYLINDER BARREL E314284G. 4 Barrel, cylinder ... E3216b Washer, cylinder base

PISTON CP 120 *ft.l/rc> Piston, c;w rings, gudgeon pin, etc. E3148 2.!"·: Piston, b~dy only (standard) ... E3148;20 Piston, body only -;- .020" E3148;40 Piston, body only -;- .040" E3153 Ring, compression E3153f20 Ring, compression+ .020" E3153/4Q Ring, compression + .040" E3154 Ring, scraper E3154120 Ring, scraper :- .020" Bl54f40 Ring, scraper-~ .040" E 1750 Pin, gudgeon El767 Cirdlp, gudgeon pin

• For Contents and Oversizes see page 5.

CYLINDER ,HEAD E31431S'f· :Z. Head, cylinder c/w guides and adaptor £3217 ,_:.1 Gasket, cylinder head ... £3207 r Adaptor, cylinder head exhaust £3210 II Stud, rocker inspection cover ... El987 ~ Stud, cylinder head to carburetter E3230 /1 Nut, cylinder head to barrel ... E1719A Washer, cylinder head to barrel

VALVES, GUIDES, SPRINGS, ETC. E31461.1·8 Valve, Inlet E3147.of.of' /7•'7 Valve, exhaust ... E320B !": 1'1 Guidej inlet and exhaust E3209 :;: Cirdip, inlet and exhaust guide

7

2 2 2

2

I 2 2 4 4

2 2

GROUP 2 - ENGINE

REF. No. PART No. DES CR/PT/ON

2 3 4 5

E32141; 2-

E3215 ).f E3301 ;..;s E3213 f."J..

WE259~-o

Spring, valve inner Spring, valve outer Collar, valve spring top Cup, valve spring bottom Cotter, valve split

OVERHEAD ROCKERS, COVERS, ETC. 6 E32512).// Rocker, inlet 7 8 9

10 II 12 13 14 15 16 17 18 19 20

21 22 23 24 25

26

27 28 29 30 31

E3252.Ud E3222 /· ;o E322J/-'r

~

GS6626 E3225 ,j .• -E3253 -;.; E2534) E2594J E32H'/. E3227 +7 E3228·~·7 E3226 f E3290 II E2441

Rocker, exhaust .. .

Ball pin, rocker .. . Adjuster, rocker Locknut, rocker adjuster pin Spindle, rocker inlet and exhaust

Sealing ring, rocker spindle Thrust washer, rocker spindle D.S.-f.'' Thrust washer, rocker spindle T.S.-f' Thackeray washer, rocker spindle (spring) Cover, rocker inlet inspection Cover, rocker exhaust inspection Washer, rocker cover joint Nut, rocker cover to head Washer, rocker cover to head nut

PUSH RODS AND COVER E3235 ::=r E3238N.f E3172

~

EJHJ + E2425 ·

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

TAPPETS E3285 r·; .. b Tappet

. RPcKER OIL PIPE AND FITTINGS E3244 I~'/·· Pipe, rocker oil ... ... ... .. . H400I·2. Nut, rocker oil pipe to spindle .. . El335 Washer, rocker oil pipe inner joint .. . E3249 3 Washer, rocker oil pipe outer joint ... E 1947 Connection, oil tank to oil pipe (Rubber)

8

QUANTITY

2 2 2 2 4

2 2 2 2 2 2 2 2

2 2 2

2

2

2 2 2

ENGINE - GROUP 2

REF. No. PART No. DESCRIPTION QUANTITY

FLYWHEELS AND CONNECTING ROD E31SS Flywheels and connecting rod assembly

2 E31S6 Flywheel D.S. c(w mainshaft 3 E3160 Flywheel T.S. 4 E31SS2.,+ Mainshaft D.S. 5 EISSO Key, mainshaft D.S. to flywheel 6 E31S9/i Nut, mainshaft D.S. 7 E3172 Peg, fiywheel T .S. 8 E3163 "-"'·" Rod, connecting c/w bushes

9 E316S .$'.// Bush, big end 10 El762 Bush, small end ... II E3291 I,).~ Crankpin, ciw plug 12 E3292 Plug, crankpin 13 E3162 Roller, crankpin ... IS

~ CRANKCASE 14 E31661f.·ID·• Crankcase assembly, c/w bushes IS E3170J..8 Stud, crankcase to cylinder head 4 16 E3171 Stud, crankc3.se to oil junction block ... I

~ 17 T989 Dowel, crankcase T.S., to inner cover (hollow) 2 iS E3169 Dowel, crankcase to oil junction block I 19 E3167 .;.-/ Pipe, crankcase oil return 20 E3168 Clip, crankcase oil return pipe

• 21 Tl076 Screw, crankcase oil return pipe

Pin, split, 1\1 " diameter ...

• CRANKCASE BEARINGS (ENGINE) l2 E3173/l'-6 Bearing, T.S. (Plain) 23 E317S 2·'f Bush, camshaft ... 24 E3187 .i' .. S Bush, distributor and oil pump shaft

• CRANKCASE FILTER 2S E3177 .2. 6 Filter, crankcase ... 26 E3176 ~ Spring, crankcase filter ...

t 27 E3302 .l. Washer, crankcase filter spring 28 EIS64 Cap, crankcase filter 29 EIS77 Washer, crankcase filter joint ...

9

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FIG. 17.

THE TERRIER ENGINE

AND GEARBOX UNIT.

In order to darify the main components, the

screws and washers, ett;., have been omitted

from this lltustratlon, for further details on

the dutch and gears see Figs. 2 and 3.

For index See Page J I.

120 121 139 1401161

I I I ,

I ,

93 !!2 !13 II

37

39•~~

·-35

·······=~-·==~-: .. :.. .... :.. .... :.. ... ~; --~~~~~-- 23

I 90

--~~·28

-----~29

~--~ ·---31

:.._ ·-====···-~2f> .. ............ , ·~-···~- -·-5

····--··~6 ~~~~~~ --7

~~~~~~138

I

89 85 86 144 87 88

I.

c:'l

~ c: ., ...., I m z c:'l -z m

- ,. ~ - ...... - -

' INDEX TO FIG. I- PAGE 10

Ulust. Na. Port No, Page No. Ref. No. Hiust. No. Port No. Page No. Ref, No. //lust. No. Part No, Page No. Ref- No, --··----··

I E3142 7 I 4a E1580 9 5 91 TII4S 13 6

2 E3216 7 2 49 Ell 59 9 6 98 EllS I ll 13

3 Ell48 7 4 50 Ell6l 9 a 99 (See Page 15) CP.J20 7 l 51 E3165 9 9 100 (See Page I 5)

4 Ell 53 7 7 52 E1762 9 10 101 Tlll9 14 2

5 Ell 54 7 10 53 E3291 9 I I 102 TJ098 14 12

6 E1750 7 13 54 El161 9 13 103 TII01 14 13

7 El767 7 14 ss El166 9 14 104 TJ066 14 14

8 El14l 7 IS 56 El170 9 IS 105 Tl069 14 15

9 EJ217 7 16 57 El171 9 16 IOo Tl075 14 17

10 EJ207 7 17 58 T989 9 17 107 Tl076 14 IS

II El110 7 IS 59 El167 9 19 JOB Tl180 14 19

12 E1987 7 19 60 El16B 9 20 109 Tl 164 l4 20

14 E3230 7 20 61 Tl076 9 21 110 W932 14 21

15 E3146 (Inlet) 7 22 62 El173 9 22 Ill TIIOl 14 22 E3147(Exhaus.t) 7 2l 63 ElliS 9 23 112 TIIOB 14 24

16 E320B 7 24 64 El187 9 24 Ill Tl107 14 25

17 E3209 7 25 65 El177 9 25 114 Tll09 14 27

IS El214 a I 66 El176 9 26 115 Tl077 14 28

19 ElliS 8 2 67 EISM 9 2a 116 Tl070 IS I

20 E3301 8 l •s E1577 9 29 I 17 Tl071 IS 2

21 EJ213 8 4 69 El178 12 I 118 Tl072 IS l

22 WE259A B 5 70 EliBI 12 2 119 Tl07l IS 4

2l El251 (Inlet) 8 6 71 EJ185 12 3 120 TII6S 16 I

EJ252(Exh'u") 8 7 72 Ell84 12 4 121 SS2-I 16 7

24 El222 8 8 73 Ell83 12 s 122 Tlll6 16 8

25 El22l 8 9 74 E3186 12 6 123 Til 59 16 10

26 G$662 8 10 75 E3190 12 8 124 Tl 160 16 II

27 EJ225 B II 76 EJI93 12 9 125 Tll6l 16 12

28 E3253 B 12 77 EJI94 12 10 126 Tll62 16 13

29 E2SJ4 B ll 78 EJI95 12 II 121 Tll63 16 14

30 E2594 B 14 79 Ell% 12 12 128 Til 57 16 IS

31 EJ224 8 15 80 570-4 12 ll 129 Til 58 16 16

32 El227 B 16 Bl El19l 12 14 130 Tl081 16 17

JJ EJ228 8 17 82 E3192 12 IS Ill TI082 16 18

34 El226 8 18 83 El197 12 16 132 TIIIO 16 19

3S E3290 B 19 84 GS299 12 17 Ill E697 16 20 ,

36 E2441 8 10 as EJ201'19 - 12 19 134 Tlll2 16 21 z 37 El2l5 B 21 86 W9S4 12 20 13S FISII 16 22 £! lS E323S 8 22 87 Hl93 12 21 136 T361 16 23 z 39 EJ143 B 24 613 Ell SO 12 22 137 WEI70 16 24 , 40 E1496 B 25 B9 El198 12 25 138 Tll20 16 25 I 41 E3285 B 26 90 Ell 52 12 28 139 TIISI IS ll

42 H400 a 28 91 OSS7 12 JO 140 Tll24 IS 17 C"'

43 E1335 B 29 92 WEI70 12 )I 141 Tll40 / IS 20 ::u 44 El249 a 30 9l El206 ll I 142 FS79 38 7 0

45 EJIS6 9 2 94 E3293 13 2 143 S2S-I J 38 B c 46 EJI60 9 3 9S Tll47 13 4 144 047502 44 I

.., 47 Ell 58 9 4 96 Tll49 13 5 14S EISSO 44 4 loJ

GROUP 2 - ENGINE

REF. No. PART No. DESCRIPTION

I 2 3 4 5 6

7 8 9

10 II 12 13 14 IS 16 17 18

19 20 21

22 22a 23 24

25 26 27 28 2Ba 29 30 31 32 33

TIMING GEARS AND CAMSHAFT E3178 2 2·7 Pinion, timing and distributor drive E3181 ;.:;.. Bolt, timing and distributor pinion E3185 ~7-·'u Pinion, camshaft (SOT) ... E3184 ;;:. Key, camshaft pinion E3183/6.,t.,.. Camshaft, inlet and exhaust E318611·7" Pinion and shaft, distributor and oil pump drive

OIL PUMP E318911·7 Pump, oil complete E3190 Body, oil pump E3193 ;;..o Plunger, oil feed E3194 :J..j Plunger, oil scavenge E3195 :t.-1 Rod, connecting drive E31% r; Pin, connecting rod to plunger 570-4,.. Ball. oil pump body ... E3191 '"- Spring. oil pump body ... E3192 '/ Plug, oil pump body E3197 Bolt, oil pump to crankcase GS299,.. Lockwasher, oil pump to crankcase (serrated) E318S 6 Washer. oil pump to crankcase joint ...

ENGINE SPROCKET E3201jl9/.:>~<' Sprocket engine 19T W954 ~ Distance piece, sprocket and rotor Hl93 6 Nut, engine mainshaft

OUTER COVER, DRIVE SIDE E3150 J,t;.,t. Cover, crankcase D.S. outer El344 /• '- Washer, cover joint E3205 fj Screw. outer cover, long E3200 Screw, outer cover. short

INNER COVER, DRIVE SIDE E3198 C~·(, Cover, crankcase D.S. inner E3199 Dowel, inner cover to crankcase front

.,.

T989 E3152/S:b E3379 If'· )...

Dowel, inner cover to outer cover rear ... ...

B · · " h I · h f "'"'~~N ;,1r;o ear1ng, eng1ne t1yw ee matns at o~.. ... : ..

r E3200...; DS571 WEI70 E3305 8' Fl880

Oil seal, mainshaft bearing Screw. inner cover to crankcase Plug, oil level and drain ... Washer, oil level and drain plug< Plug, oil filler Washer, oil filler plug

12

Cv-V[,'L J (-L-JAJ.f'

I

QUANTITY

I 2 2 2 2 2 I

I I 2

I 4 5

I I I I 2 2 2 I I

ENGINE - GROUP 2


2 3 4 5 6 7 8 9

10 II 12

13 lh 14 15 16

17

INNER COVER, TIMING SIDE E3206 E3293 ).. 7 E3172 Tll47 ).;1. Tll49 r

Tl148 .;7 Tll5oJ E3204 ~ E3220 6 Em(i F333911 XA69

Cover, inner T.S. c/w bushes and dutch lever Bush, camshaft ... Peg, camshaft bush Bush, gearbox mains haft Plate, inner cover Washer, inner cover plate (Cork) Screw, inner cover plate Screw, inner cover to crankcase (front and rear) Screw, inner cover to crankcase (short) Screw, inner cover to crankcase (long) Vent pipe, inner cover breather (PVC) Clip, vent pipe to clutch cable

OUTER COVER, TIMING SIDE E3151 4<>-11 Cover, outer T.S. E l345 :i. E3221

/

E3231 {, E3220

Washer, cover joint Screw, outer T.S. cover (long) ... Screw, outer T.S. cover (medium) Screw, outer T.S. cover (short)

GASKET SET GSTI5i53 'fj(, Gasket set

WHEN ORDERING :

ALL GOODS MUST BE SENT TO THE WORKS CARRIAGE PAID

ALWAYS WRITE YOUR ORDER IN BLOCK LETTERS

ALWAYS QUOTE ENGINE NUMBER AND PREFIX

DO NOT FORGET TO SIGN YOUR ORDER

SEE SPECIMEN ORDER IN PREFACE

WHEN IN DOUBT SEND SAMPLE

ALWAYS QUOTE PART NUMBERS

13

QUANTITY

I I I 2 2 I I I I

I I I 7 I

GROUP 3 - GEARBOX • ... REF. No. PART No. DESCRIPTION QUANTITY

GEARBOX AND CLUTCH- GROUP 3 • Illustrated on Pages 10, 15 and 17-Figs. I. 2 and 3

' SHAFTS AND GEARS ~ I T I 083 •fi;-tc Gear duster, mainshaft (3rd and low) ~

2 Tl119.? Key, mainshaft to dutch 3 Tl085l Bush, mainshaft clutch rod 4 T I 078 ]/.to Gear, mainshaft high ciw bush ... 5 Tl080 lt-• 0 Bush, mainshaft high 6 T/089)"'·-' Gear, mains haft 2nd 7 Tl090~ Thrust ring, mainshaft 2nd gear a T I 091•.$7>·<' Gear, duster, layshaft (top and 2nd) 9 TI094.Zl ~ Gear. lays haft 3rd

10 TI095 22-6 Gear, lays haft low c'w bush II TI097 2-3 Bush, layshaft low gear ...

• The gear dusters are sold only as an assembly and the parts cannot be obtai ned separately,

1

SELECTOR FORKS AND SPINDLE .. 12 Tl098 <l~~ Fork, mainshaft and layshaft selector ... 2 13 TII02 Spindle, selector fork I

14 Tl066 CAM PLATE 151 ~ Cam plate assembly

15 TI069 Spindle, cam plate 16 s\" x I" Split pin, cam plate to spindle 17 Tl075 Spring, camplate index 18 TI076 Screw, cam plate index spring ... 2 19 Tll80 Lockwasher, camplate index spring

FOOTCHANGE MECHANISM

~ 20 T 1164/.;t·// Pedal, footchange 21 W932 fi Bolt, footchange pedal ... 22 TII03 Spindle, quadrant and plunger assembly 23 Tl181 'i Feltwasher, footchange spindle 24 TII082·3 Plunger, footchange gear selector 2 .) r 25 Tll07 6 Spring. footchange gear selector plunger 2 26 -(r" X£" Split pin, footchange gear selector plunger 2 27 T[l09 Spring, footchange return I 28 TI077 Pin. footc:hange return spring anchorage I 29 E2287 Washer. footchange return spring anchorage I 30 T449 Rubber, footchange pedal

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GEARBOX - GROUP 3


2 3 4 5 6

lllust. No .

I 2 3 4 5 6 7 8

GEARBOX CASING BEARINGS Tl070/~~ Bearing, D.S. gearbox mainshaft (ball) TI071 i1 Oil seal, D.S. bearing (felt) TI072 Plate, D.S. bearing seal retaining T I 073 2- '1 Bearing, D.S. gearbox layshaft (plain) E3172 Peg, layshaft bearing locating ... TI074 Disc, D.S. gearbox layshaft bearing ...

6 7 4

I

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12 13 II

FIG. l. MAINSHAFT AND LAYSHAFT GEARS.

INDEX

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

Tl083 14 I 9 Tl094 Tlll9 14 2 10 TI095 TI085 14 3 II Tl097 TI078 14 4 12 T: 116 TIOBO 14 5 13 TillS TI089 14 6 14 Til 59 Tl090 14 7 15 Tll60 Tl091 14 8 16 Tll61

15

QUANTITY

Page No. Ref. No.

14 9 14 10 14 II 16 8 16 9 16 10 16 II 16 12

GROUP l - GEARBOX


2 3 4 5 6 7

__...-8 9

10 II 12 13 14 15 16

17 18

19 20 21 22 23 24

KICKSTARTER TII65J:-.·1 Kickstarter assembly, folding Tll66 ), • ., Crank, kickstarter T 1168 .;o-:11 Pedal kickstarter crank Tll69;.-f Bolt, kickstarter crank to pedal S70-3 Ball, kickstarter crank to pedal

~

Tll67 or- Spring, kickstarter crank to pedal SS2~ I Cotter. kickstarter crank C/W nut and washer Tll16_). S I(;, Spindle, kickstarter c/w bush ... TIIIBif•

1 Bush, kickstarter spindle

Til 59}. 3 Pawl, kickstarter ... "' Tll60 ~ Plunger, kickstarter pawl

Tl161 I; Spring, kickstarter plunger Tll621·3 Spring, klckstarter return Tll63 Plate, kickstarter return spring anchor Til 57 Plate, kickstarter stop ... Til 58 Screw, kickstarter stop plate

GEARBOX SPROCKET TIOSII;:.c Sprocket, gearbox Tl082 I·IC' Nut, gearbox sprocket

FILLER, LEVEL AND DRAIN PLUGS TIIIO I· 7 Plug, gearbox filler E697 Washer, gearbox filler plug Tl112 .J..:J' Plug, gearbox drain Fl511.,.. Washer, gearbox drain plug T361 if Plug, gearbox level WEI70 Washer, gearbox level plug

CLUTCH 25 Tll20 Clutch complete 26 Tll361·l 27 Tll82$-28f1 1'-1:- b Tll22 ...... 29 "TII24 30 4 TII25 31 "TII26 r 32 Tll27 ..3 33 Tll37 _f;tt 34 Tll38 9·J 35 NT288

Nut, clutch to mainshaft Washer, dutch to mainshaft nut Sprocket c,fw bearing and cork inserts Ball, clutch sprocket bearing ... Plate, clutch sprocket bearing retaining Rivet, dutch sprocket retaining plate Cork insert, dutch sprocket ... Plate, clutch driven (plain) Plate, clutch driving (corked) Cork insert, clutch driving plate

" See Page 57 before ordering replacements.

16

QUANTITY

I I

58 2 5

20 2 2

40

- - - -

12 I 14 10 II 13 2 3 3 8 9 FIG. 3. CLUTCH AND SHOCK ABSORBER UNIT.

INDEX

lllust. No. Part No. Page No. Ref. No. lllust. No. Part No. Page No. Ref. No. C\

I •TII22 16 28 9 Tll46 18 5 ~ ::D

2 Tl127 16 32 10 Tll29 18 6 = 3 Tll37 16 33 II Tll30 18 7 0

>< 4 Tll38 16 34 12 Tll28 18 8 I 5 NT288 16 35 13 Tll34 18 9 6 Tll41 18 I 14 Tll31 18 10 C\

::D 7 Tll45 18 3 IS Tll32 18 II 0 8 TJ 144 18 4 16 Tll33 18 12 c .,

• See Note on Page 57. ....

GROUP 4 - EXHAUST SYSTEM


I 2 3 4 5 6 7 8 9

10 II 11

13 14 15 16 17 18 19 20

21 ll 23 24

Tll41 Tll43 Tll45 i? Tll-44/·1. Tll46 ~ Tll29 ...... , Tll30 1c Tll28 If.+ Tlt341f Till! 22j Tll31/·2. Tll33 -(;

Plate, dutch pressure cfw button Button, dutch pressure plate thrust Spring. dutch pressure ... Cup, dutch spring Nut, dutch spring Centre clutch Cup, dutch centre driving Plate, dutch backing Pin, dutch backing plate Spider. dutch Rubber, dutch drive Rubber, dutch rebound

CLUTCH CONTROL TIISI Tll53 2-3 Tll54 '~ TIISSI/ Tll24 ~·X t" Til 52 Tll40 dly)

lever, dutch operating assembly Lever. dutch operating Pin, operating lever fulcrum Cup, operating lever thrust

$',~ ,I Ball, cup to rod ... }:i.l. Split-pin, cup to lever ... Fulcrum, clutch operating lever Rod, dutch operating ...

EXHAUST SYSTEM- GROUP 4

EXHAUST PIPE E3257.!7'6 Pipe, exhaust E3259 ~-/c Clip. exhaust pipe to cylinder head E3260 If Bolt, exhaust pipe to cylinder head 525-13 Washer. exhaust pipe to cylinder head dip bolt

SILENCER 25 E3261 '1-5"{- Silencer ... 26 E3269 j'.:)l Clip, silencer to exhaust pipe 27 TE 164E Bolt, silencer to exhaust pipe clip 28 TE 164D 'D' Washer, silencer to exhaust pipe dip bolt 39 TEI64C 'D' Nut, silencer to exhaust pipe dip bolt 30 F929 Bolt, silencer to frame ... .. .... 31 51-51 Nut,silencertoframebolt 32 526-2 Washer, silencer to frame bolt ...

18

QUANTITY

I I 3 3 3 I 3 I 3 I 3 3

' • •

•

' t

ft

' '

FRAME - GROUP 5 CENTRE STAND - GROUP 6


I 2 3 4 5 6

7 8 9

10 II 12 13 14 15 16 17 18 19 20 21

22 23 24 25 26 27

FRAME-GROUPS Illustrated on Pages 20 and 21-figs. 4 and 5

FRAME F3390 F3391 Fl7602-3 E2774 M/W76 G$308

Frame. cjw rear suspension Frame, only Bolt. front and rear engine mountlng ... Bolt, lower engine mounting ... Nut, engine mounting bolt Washer, engine mounting bolt

REAR SUSPENSION F3455) "J~ Fork end, R.H. c;w grease nipple F3454 ).Ji. Fork end, LH. c;w pin and grease nipple NWIOO Nipple, fork end grease ... F3424 Pin, fork end brake anchorage F3422 Backing washer, plunger lug (top) F3577 Cup, plunger lug (bottom) F3423 .;..":o Gaiter, plunger lug bottom (rubber) F3425 ;;,-:11 Spring, suspension main F3426 J.). Spring, suspension rebound F3427 Cover, suspension spring (lower) F3428 Cover, suspension spring (upper) F3429 Rod, plunger guide F3430 Bolt, plunger guide to lug clamp E470 Nut, plunger guide to lug clamp $25-3 Washer, plunger guide to lug damp ...

CENTRE STAND- GROUP 6 Illustrated on Page 20-Fig. 4

F3469 Stand, cfw fittings F3438 Stand, only

F351y· Spring, stand ... F3520 2.j.t"'lf'<:(.Bolt, stand pivot, LiH ./ F352 Bolt, stand pivot, R JH DS47 Nut, pivot bolt

19

I 2 I 3 3

2

2 2 2 2 2 2 2 2 2 2 2

I 2

GROUP 5 - FRAME

12

r---~--------~---------30

~-------------31 ~

F~~----------~----19

i 13 15 16 33

FIG. 4. FRAME AND COMPONENTS. For Index See Page 21.

20

9

. '

FRAME - GROUP 5

~ 6 INDEX TO FIG. 5.

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

~ E3455 19 7 E3454 19 8

·····--3 2 NWIOO 19 9 3 FH24 19 10 4 F3422 (Upper) 19 II

• F3577 (Lower) 19 12 _____ .. -----------7 5 F3423 19 13 6 F3425 19 14

e 7 F3426 19 15 • 8 F3427 19 16 ---5

' 9 F3428 19 17

@. ~----- 4 10 F3429 19 18

INDEX TO FIG. 4. PAGE 10.

~ 11/ust. No. Part No. Page No. Ref. No. /1/ust. No. Part No. Page No. Ref. No.

I F3390 19 I 18 F2596 37 19 2 Fl760 19 3 19 Sl-51 37 21 3 E2774 19 4 20 F3468 37 22

~ 4 W76 19 5 21 F3449 38 10 5 F3455 19 7 22 F3450 38 II 6 F3454 19 8 23 Fl695 38 12 7 F3423 19 13 24 F3448 38 13 8 F3427 19 16 25 Hl93 38 14

·~ 9 F3428 19 17 26 F3456 39 I

10 F3430 19 19 27 F3459 39 2 II E470 19 20 28 Sl-51 39 3 12 F3438 19 23 29 T224 39 5 13 F3519 19 24 30 F3498 37 7 14 F3520 19 25 31 Sl-51 37 8 IS F3521 19 26 32 F3460 39 7 16 DS47 19 27 33 F3463 39 II 17 H835 25 15

21

GROUP 7 - TELESCOPIC FRONT FORK

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

37-----------------

28--------------~'

38--------G~

39---t» 22

TELESCOPIC FRONT FORK - GROUP 7


•. 11/ust. No. Port No. Page No. Ref. No . • I H828 24 2 2 H834 24 3 3 H518 24 4 4 S25-3 24 5

~ 5 H837 24 6 6 H570 24 7 7 Sl-51 24 8 8 S25-3 24 9 9 H840 24 10

10 H843 H/- 24 II II NWIOO 24 12 12 H845 24 13 13 H846 24 14. 14 H847 24 17

• IS H850 24 18 16 H851 24 19 17 H852 24 20 18 Sl-51 24 21

• 19 H853 24 22 20 H856 24 23

- 21 W932 24 24 22 El612 24 25 23 H857 24 26 24 H860 24 27 25 H861 25 I 26 H862 25 2 27 H863 25 3 28 H823 25 4 29 H822 25 5 30 H877 25 6 31 H878 25 7 32 H833 25 16 33 H936 25 19 34 H873 30 10 35 H864 39 IS 36 H865 39 16 ,, 37 F879 39 17 39 H902 24 16 39 H903 24 15

23 •

TELESCOPIC FRONT FORK- GROUP 7


I


11/ustrnted on Page 22-Fig. 6

FRONT FORK I H827 Fork. assembly 2 HB2B *"' Lug. fork stem and middle I 3 H834 7.·3

~ Bolt, middle lug pinch ... 2

4 HSIB /:, Nut, middle lug pinch bolt 2

5 525-3 Washer. middle lug pinch bolt 4 6 H83717·'! Lug. fork top

~ 7 H570 2·1 Bolt, fork top lug clamp ... 8 Sl-51 Nut, fork top lug clamp bolt . 9 525-3 Washer, fork top lug clamp bolt

10 H840..i'·..2- Sleeve nut, fork stem II H843 61/: Stanchion fork c .·w bush 2 12 NWIOO Grease nipple, stanchion 2 13 H845 .;,~-; Bush, stanchion bottom 2 14 HB46 ..>~II Nut, stanchion to top lug 2 IS H903 if Buffer, stanchion rubber 2 16 H9J2 Washer. stanchion rubber buffer 2 17 H847 Spring, fork C/w studs, etc. 2 18 HBSQI·-f Stud, fork spring (short) top 2 19 H851 /6 Stopnut, fork spring (bottom) 2

"" 20 H852 Rod. fork spring anchor (bottom) 2 • 21 Sl-51 Nut, fork spring (short) stud ... 2 22 H853 Member. outer lower c:w cap 2 23 H856 Cap, outer lower member lug spindle 2 24 W932 Bolt, outer lower member lug spmdle 4 25 El612 Washer, outer lower member lug spindle 4 26 H857 Clip, brake anchorage ... I 27 H8604'.,; Bush, outer lower member top 2

24

• It

-~

~ ..

' • '

'


REF. No. PART Na • DESCRIPTION QUANTITY

2 3 4 5 6 7 8 9

10 ll 12 13 14

15 16 17 18

19

H861 Sleeve nut, outer lower member H862f Washer, sleeve nut (steel) ,. H863-+ Washer, sleeve nut (felt) H823.>:2-0:: Nacelle, bottom unit H822l1-~ Nacelfe, top unit,.. H877 (..;r Flash, L.H. (Motif) H878 '·/c Flash, R..H. (Motif) H688 Screw, flash and top and bottom unit H691 Nut, flash and top and bottom unit E2880 Washer, flash and top and bottom unit -H916"' Screw. flash and top and bottom unit (centre) H689 Screw, top and bottom unit (rear) H691 Nut, top and bottom unit (rear) E2880 Washer. top and bottom unit (rear)

STEERING RACES HB3S5.C Cup, steering race (top and bottom) H833 .:,t.-1' Cone, steering race (top and bottom) 570-3 Ball. steering race (top and bottom) H836 1·/o Cover, steering race dust

LICENCE HOLDER 0261 Holder, licence

2 2 2 I

2 2 2 2 2 2 2

2 2

30

DESPATCHING GOODS. Parts being returned to either the Distributor or Triumph Service Department for rectification should be well packed to avoid damage in transit, Cylinder barrels and cylinder heads are extremely vulnerable to breakage of the fins ; when casing, pack straw or old newspapers etc., round the flnning to prevent damage due to shock. Advice of despatch should be forwarded to the consignee and the sender MUST securely attach a label to the returned parts. dearly stating his name and address.

RECEIVING GOODS. Every possible precaution is taken to ensure that the sender's order has been correctly interpreted and the goods despatched are correct to the invo1ce. Parts sent in for repair are rested before despatch and are subsequently covered by our guarantee on Page 51. In the event of any shortage on damage in transit, we must be advised withlV 48 hours of arrival in order that the necessary action can be taken. No claim can be entertained after this period.

25

10 3 5

6 4 12

FIG. 7. FRONT WHEEL.

For Index See Page 27 .

•• .......

II

20

-

19

18

t.--------13

~~~----------21

1-------7

c:'l :a 0 c: "1:1

OC>

I

~ = m m (;;;

WHEELS - GROUP 8

REF. No . PART No. DESCRIPTION QUANTITY

• WHEELS- GROUP 8 Illustrated on Pages 26 and 28-Figs. 7 and 8

• FRONT WHEEL I WIOOI Wheel, complete front ... 2 W960 Wheel, less bearing brake assembly, etc. 3 WI002 Rim, front wheel WMI-19 4 W964(5 T Spoke and nipple, R.H. 90'' 20 -

' 5 W963.:5 7 Spoke and nipple, LH. 90° 20 6 W965 Nipple, spoke -10 7 W961 ,J ... o Hub and brake drum assembly I 8 W%7 le>-t Spindle, front wheel

~ 9 W980 /·;;!. Nut, front wheel spindle to anchor plate ...

10 T530 /1•0 Bea . f t h I L H //.>' //-<>J""I'JwHN nng. ron w ee . . ... ... ... II W%6 /•').. Dust cap. front wheel L.H. 12 T532 'fi Circlip, front wheel L.H. dust cap 13 H826 ,;;.f Bearing, front wheel R.H. ...

- 14 W96B ).:l- Ring, front wheel R.H. locking

• FRONT WHEEL BRAKE

• 15 W969 Plate, front brake anchor 16 W973 ,-:,/ Cam assembly, front brake

' 17 W976 _,'. t> Lever, front brake I 18 T224 Nut, front brake lever ... I 19 S25-2 Washer, front brake lever I 20 W9771.i...I'C Shoe, front brake c:w lining 2

• 21 W978 /t'J·Ii:- Lining. front brake 2 22 W979 Rivet, front brake lining 12 23 W200 Spring, front brake shoe 2 24 Sl-52 Nut, front brake anchorage to dip I 25 S26·1 Washer, front brake anchorage to dip .. INDEX TO FIG. 7. PAGE 16.

11/ust. No. Part No. Page No. Ref. No. 1/fust. No. Part No. Page No. Ref. No.

I WI002 27 3 12 W968 27 14

' 2 W964S 27 4 13 W969 27 IS 3 W963.5 27 s 14 W973 27 16 4 W965 27 6 IS W976 27 17 5 W961 27 7 16 T224 27 IS 6 W967 27 8 17 W977 27 20

It 7 W980 27 9 18 W978 27 21 J B T530 27 10 19 W979 27 22

9 W966 27 II 20 W200 27 23 10 T532 27 12 21 Sl-52 27 24 II H826 27 13

' 27

C'l ;11:1 0

7 8 14 IS 10 c 21 24 21 22 I .,

I I co I

I ~

J ::c m m I"'" ...,

I

SHORT

I I 17 23 5 2 3 4 II 28 25 26 27

FIG. 8. REAR WHEEL.

For Index See Page 29,

• - ... ... ...

WHEELS - GROUP 8

REF. No . PART No. DESCRIPTION QUANTITY

• REAR WHEEL WI004 Wheel complete, rear

2 W981 Wheel, less bearings, brake assembly, etc. 3 WI002 Rim, rear wheel, WMI-19 I

' ,

Spoke, and nipple, L.H. 90 20 4 W964.5 l s W963 ·s 7 Spoke, and nipple, R.H. 90' 20 6 W96S Nipple, spoke 40 7 W982 ~ Hub and brake drum assembly

' 8 W98414 -t Sprocket, rear wheel 48T 9 W98S Bolt, rear wheel sprocket 8

10 El612 Washer, rear wheel sprocket 8 II W989JH Spindle, rear wheel I 12 WIOOO I· 'I- Nut, rear wheel spindle 2 13 H826 /2·o Bearing, rear wheel R.H. and L.H. ,.:fo.r,;-""M/i'/.V' //7. 2 14 W987/i Backing ring, rear wheel bearing R.H.

15 W988l·1. Locking ring, rear wheel bearing L.H.

16 W9S4 Distance piece, rear wheel spindle, inner R.H. ~ 17 W99S Distance piece, rear wheel spindle, outer R.H. • REAR WHEEL BRAKE

18 W990 Plate, rear brake anchor

.. 19 W973 Cam, assembly, rear brake 20 W993 .x.~- Lever, rear brake

~ 21 T224 Nut, rear brake lever "'

22 S2S-2 Washer, rear brake lever

23 W977 Shoe, rear brake c./w lining 2 24 W978 Lining, rear brake 2

' 2S W979 Rivet, rear brake 12 26 W200 Spring, rear brake shoe 2


/1/ust. No . Part No. Page No. Ref. No. /1/ust. No. Part No. Page No. Ref. No. .. I WI002 29 3 IS W99S 29 17 2 W964.5 29 4 16 W990 29 18 3 W963 S 29 s 17 W973 29 19 4 W96S 29 6 18 W993 29 20 s W982 29 7 19 T224 29 21 6 W98448 29 8 20 S2S-2 29 22 7 W98S . 29 9 21 W977 29 23 8 El612 29 10 22 W978 29 24 9 W989 29 II 23 W979 29 25

10 WIOOO 29_ 12 24 W200 29 26 II H826 29 13 2S W996 30 I 12 W987 29 14 26 W999 30 2 13 W988 29 IS 27 F879 30 3 14 W9S4 29 16 28 DI7S 48 23

29

GROUP 9 - MUDGUARDS AND REAR CARRIER ~


REAR WHEEL CHAIN ADJUSTER ~ W996/•1° Adjuster, rear chain .. .'- 2

"' 2 W999B End plate, rear chain adjuster 2 3 F879 Nut, rear chain adjuster 2 ..

MUDGUARDS AND REAR CARRIER- GROUP 9 Illustrated on opposite page

FRONT MUDGUARD 4 H868$'J· '- Mudguard, front ... 5 H871 Stay. front mudguard, L.H. I 6 H872 Stay, front mudguard, R.H. I 7 DS57 Bolt, front mudguard stay 4

~ 8 F879 Nut, front mudguard stay 4 9 El612 Washer, front mudguard stay 4

10 H873 Clip, nacelle to centre bridge 2 II GS218 Bolt, nacelle to centre bridge clip 2 -12 F879 Nut, nacelle to centre bridge cllp 2

~ 13 El612 Washer, nacelle to centre bridge clip 2 14 F3023 Distance piece. stay bolt 2 15 GS218 Bolt, stay to fork lug bottom ... 2 16 E1612 Washer, stay to fork lug bottom 2


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

I H868 30 4 19 F879 32 14 2 H871 30 5 20 F3523 32 16 3 H872 30 6 21 DS57 32 17 4 DS57 30 7 22 F879 32 18 5 F879 30 8 23 H874 32 20 6 G$218 30 II 24 H741 32 21

"!" 7 F879 30 12 25 H687 32 22 tl 8 G$218 30 15 26 H745 32 23 9 F3479 32 I 27 •F3508 32 24

10 F3484 32 2 28 F929 32 25 II F3488 32 3 29 Sl-51 32 26 12 DS57 32 4 30 D274 32 28 • 13 F879 32 5 31 F3431 33 I 14 E470 32 7 32 D557 33 2 15 Fl369 32 8 33 F3436 33 4 16 F879 32 10 34 F3437 33 5 17 F3483 32 II 35 H745 33 6 18 DS57 32 12 36 DSS7 33 7

" See Note on Page 32.

30

t

' •

-

'

'

MUDGUARDS AND REAR CARRIER - GROUP 9

~;;::::::::::::::::::::=:::~~~--31 8-------------------------35 u------------------------34

1------------------------33

FIG. 9. MUDGUARDS, NUMBER PLATES, CARRIER AND REAR CHAINGUARD. For Index See Page 30.

31

........

GROUP 10- NUMBER PLATES


I 2 3 4 5 6 7 8 9

10 II 12 13 14 15

16 17 18 19

10 21 22 23

24 25 26 27 28 19

, REAR MUDGUARD F3479 ".>.o Mudguard, rear ... FH84 Stay, rear mudguard L.H. FH88 Stay, rear mudguard R.H. "'· DS57 Bolt, rear mudguard stays F879 Nut, rear mudguard stays El612 Washer, rear mudguard stays E470 Nut, rear mudguard stays to plunger clamp bolt F 1369 Bolt, rear mudguard to bridge ... El612 Washer, rear mudguard to bridge F879 Nut, rear mudguard to bridge F3483 Backing strip, mudguard to frame bridge DS57 Bolt, backing strip El612 Washer, backing strip bolt F879 Nut, backing strip bolt ... F3327 Grommet for mudguard unused holes

REAR CARRIER F3523 Carrier, rear DSS7 Bolt, carrier to mudguard front F879 Nut, carrier to mudguard front 526-2 Washer, carrier to mudguard front ...

Use rear number plate top bolt to secure carrier rear bracket.

H874 H741 H687 H745

NUMBER PLATES-GROUP 10 Illustrated on Page 31-Fig. 9

FRONT NUMBER PLATE Plat.e, front number Clip, assembly front number plate Screw, assembly front number plate to clip ... Nut, front number plate to clip screw

REAR NUMBER PLATE F3508* Plate, rear number F929 Bolt, rear number and carrier top Sl-51 Nut, rear number, top bolt S26-3 Washer, rear number, top bolt 0274 Refiector, c:w Nut 068 Transfer, rear number plate motif

* Use Part No. F3508 Exp. when Stop Tall Lamp (525) Is fitted.

QUANTITY

4 4 4 2

I 2 2 2 2

I 2 2 2

I I I 2 I

~

~

.,

t

•

•

• ' '

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


I 2 3 4 5 6 7

a 9

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

REAR CHAINGUARD- GROUP II

F343i2t'·>

DS57 526-2 F3436 F3437 H745 DS57

Illustrated on Page 3!-Fig. 9

Chai nguard, rear Bolt, chainguard to crankcase Washer, chainguard to toolbox, front Screw, chainguard to mudguard. lower Distance piece, chainguard to mudguard. lower Nut, chainguatd to mudguard, lower Bolt, chainguard to mudguard stay

TOOLBOX, BATTERY CARRIER AND AIR CLEANER

GROUP 12

F3491 F3470 F3418 H251 F3492 F3471 $25-13 F3473 FHn F879 F3493 l"'-iF3474 F3475 F3478J.o$ F3208

Illustrated on Page 34--Fig. 10

Toolbox:, battery and air cleaner assembly casing Pad, battery, rubber moulded ... Container. air cleaner ... Beading, air cleaner container, rubber ... Element, air cleaner Screw, air cleaner to case Washer, air cleaner to case Strap, battery case Hook-bolt, battery case strap and lid Nut, battery case hook bolt Lid, casil)g CiW knob Knob. casing lid

I Circlip, casing lid knob... ... ...

Lf "'Connector. air cleaner to carburetter / Grommet, wiring harness and oil tank vent

33

GROUP 13 - TOOLS 2 II

TOOLS - GROUP 13

TF~JUJVJPH

D299

• '

' '

FIG. II. TOOLS.

35

GROUP 14 - PETROL AND OIL TANKS

2----~~

15--"-_:y~

14--__;

;::----7

r----;~----5

FIG. ll. PETROL AND OIL TANKS. for Index See Page 37.

36

. 4

•

•

• PETROL AND OIL TANKS -GROUP 14


' PETROL AND OIL TANKS- GROUP 14 Illustrated on opposite page

• PETROL TANK F3505 Tank, petrol, less fittings

2 F3220 Cap, petrol tank (IS£ A:P *'f.. I 3 F3494/..l"-c Styling band, petrol tank L.H. I 4 F3495/~~o Styling band, petrol tank R.H. I 5 F3496

r Name plate, petrol tank 2

6 Fl497t. Screw, name plate and band to tank 4 7 F3498/•-f Bolt, petrol tank to frame 2 8 Sl-51 Nut. petrol tank to frame bolt 2

• 9 525-3 Washer, petrol tank to frame bolt 3 9a F3098 Clip. L.H. front bolt I

10 F3506/.,·f Tap, petrol tank ... I I I E697 Washer, petrol tank tap joint ... I 12 .~ F3499;f • .,t- Pipe, petrol feed

" 13 Fl605 Knee grip. petrol tank R.H. 14 Fl606 Knee grip. petrol tank l.H.

OIL TANK 15 F3464 Tank, oil, less fittings

- 16 F3216 IH Cap, oil tank '"' ,,,

17 Fl465 Filter, oil tank ... 18 FIS II Washer, oil tank filter joint 19 F2596 Bolt, oil tank to frame bottom

' 20 F3477 Distance piece, oil tank bottom I 21 Sl-51 Nut, oil tank bolt 2 22 F3468 Bolt, oil tank to frame top I 23 F3476 Distance piece, oil tank top 2

' INDEX TO FIG. 11. PAGE 36.

11/ust. No. Port No. Pogef"o. Ref. No. 11/ust. No. Port No. Poge No. Ref. No. -I F3505 37 I 12 F3464 37 IS 2 F3220

, 37 2 13 F3216- 37 16

3 F3494 37 3 14 F3465 37 17 , 4 F3495 37 4 IS FISII 37 18 5 F3496 37 5 16 F3270 38 2 6 F3497 37 6 17 F3503 38 3 7 F3506 37 10 18 F3504 38 4 8 E697 37 II 19 F3077 38 5 - 9 E3499 37 12 20 E3244 8 27

10 F1605 37 13 21 El947 8 31 II Fl606 37 14

37

GROUP 15 - FOOTRESTS


I 2 3 4 5 6 7 B 9

10 II 12 13 14

15 16 17 18 19 20 21 22 23 24

525-3 E327011·) F35032.J F3504 ii F3077 E3274 F879 525-13 A3

Washer, oil tank top bolt Pipes. oH tank to engine Pipe, oil tank feed, top half Nut, oil tank feed, top half union Connection. oil tank feed and return pipes ... Washer, oil tank pipe junction block joint Nut, junction block to crankcase Washer, junction block to crankcas-t!'nut Transfer (minimum oil level)

FOOTRESTS- GROUP IS

Illustrated on Poge 20-Fig. 4

RIDER'S FOOTREST F3449/<H. Footrest L.H. F3450 /<>•f. Footrest R.H. F1695 Rubber F3448 :J..{, Rod, footrest hanger Hl93 Nut, footrest hanger rod

PILLION FOOTREST F3514 Footrest, pillion complete Fl694 Pedal, footrest ... Fl695 Rubber, footresr pedal F2271 Bolt, footrest pedal pivot Sl-51 Nut, footrest pedal pivot bolt F2277 Washer, footrest pedal pivot bolt F2268 Hanger, footrest pedal ... F3515 Stud, footrest pedal PO InA Nut, footrest pedal stud 526-1 Washer, footrest pedal stud

3B

QUANTITY

I 2

I 2 I 2

2 2 2 2 2 2 2 2 2 2

•

. 4

~

I

f\

• ' ' ~ •

REAR BRAKE PEDAL- GROUP 16 HANDLEBAR- GROUP 17


2 3 4 5 6 7 8 9

10 II

12 13 14 15 16 17 18 19

20 20a 21 22 23

REAR BRAKE PEDAL-GROUP 16

F3456 IS"-11

F3459 2·3 s 1-51 S26-3 T224 S25-3

F3460 '-" F3461 F3594 -ft" X l" F3462 F3463

Illustrated on Page 20-Fig. 4

Pedal, rear brake

Spindle. rear brake pedal Nut, brake pedal spindle to frame Washer, brake pedal spindle to frame Nut, brake pedal to spindle Washer, brake pedal to spindle Rod, rear brake operating Washer, rear brake rod to pedal Washer, rear brake rod to pedal (for stop lamp) ... Split-pin, rear brake rod to pedal Pivot-pin, rear brake rod to lever Adjuster, rear brake rod

HANDLEBAR- GROUP 17

Illustrated on Page 40-Fig. 13

HANDLEBAR H866 Handlebar c/w control levers and twistgrip ... H867 Handlebar bend only H881 1• if. Grommet, handlebar to nacelle H864 Support, handlebar to top lug H865 'U' bolt, handlebar to top lug F879 Nut, handlebar to top lug S25-13 Washer, handlebar to top lug ... H885 J . ., Grip, handlebar, rubber

CONTROL LEVERS H879 LH. !;-!, Lever, clutch control H879 RH. Lever, front brake control H880 'i Screw, lever to bracket F879 Nut, lever to bracket screw S26-2 Washer, lever to bracket nut

39

2 2 2 4 4

I I 2 2 2

... 0

3

4

//lust. No.

I 2 3 4 5 6 7 8 9

10 II 12 13 14 IS

7

INDEX.

Part No. Page No. Ref. No .

H867 H885 H879• H880 F879 526-2 H905 H906 H909 H906 H910 H911 H912 H913 H884

39 39 39 39 39 39 41 41 41 41 41 41 41 41 41

*State L.H. or R.H.

13 19 20 21 22 23

2 3 6 7 8 9

10 II 12

IS 10

FIG. 13. HANDLEBAR AND COMPONENTS.

- -

a ~

4 0 c ., ""' I

::r > z 0 r-m = > ~

5 6

-

• ' •

• ' ' ' ' ' '

CONTROL CABLES - GROUP 18

REF. No. PART No. DES CR/PTION

I 2 3 4 5 5 7 a 9

10 II 12

13 14 IS 16 17 IS 19 20 21 22 23

24 25 26 27 28 29

TWISTGRIP HSS3 22·'] Twistgrip complete H905 Body, twistgrip ... H906 Grub screw, body fixing H907 Spring, body to rotor tension ... H903 Rivet, body to rotor tension spring H909 Rotor sleeve, twistgrip ... HSOS'J Grub screw, cable to rotor fixing H910 Clip, twistgrip body H911 Screw, twistgrip body clip H912 Adjuster, throttle cable ... H913 Locknut, throttle cable adjusting HSS4]-c Grip, twistgrip rubber

CONTROL CABLES- GROUP 18

FRONT BRAKE CABLE 0278 '?· 7 Cable assembly. front brake 027SC Casing, front brake cable 0278W Wire, front brake cable 0102 Ferrule, front brake cable casing 18;107 Nipple, front brake cable wire (Handlebar end) OS.73 Nipple, front brake cable wire (Clutch end) 0279 2·~ Ad;uster. front brake cable F879 Nut, front brake cable adjuster

r 0280 /~ Clevis, front brake cable wire ...

0281 5 Pin. front brake cable clevis -1~ ~'. }" Split-pin, clevis pin

THROTTLE CABLE 0289 k-·1 Cable assembly. throttle D289C Casing, throttle cable 0289W Wire, throttle cable 12'083 Ferrule, throttle casing

083 Nipple. throttle wire (Twistgrip) NSI91 Nipple, throttle wire (Carburetter)

41

QUANTITY

I I 3

I 2

I 2

I 2 I I

GROUP 19- NACELLE GEAR INDICATOR


I 2 3 4 5 6 7 8 9

10

II 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26

GEAR INDICATOR CABLE 0282 "/·7 Cable assembly, gear indicator ... D282C Casing, gear indicator cable 0282W Wire, gear indicator cable 12/083 Ferrule, gear indicator casing mas Nipple, gear indicator cable (Engine end) 181115 Nipple, gear indicator casing (Indicator end) E3280 Abutment, gear indicator cable c/cas:e 0283 Spring, gear indicator cable D284 Adjuster, gear indicator cable .. , H745 Locknut, gear indicator cable adjuster

CLUTCH CABLE 0287"1'7 Cable assembly, clutch D287C Casing, clutch cable 0287W Wire, clutch cable 0101 Ferrule, clutch cable casing 18/107 Nipple, clutch wire (Handlebar end) ... 18/147 Nipple, clutch cable (Clutch end) 0267 2·1 Adjuster, clutch cable ... D268'#- locknut, clutch cable ... 0288 Abutment. clutch cable (Handlebar end) 16j011 Abutment, clutch cable (Clutch end)

NACELLE GEAR INDICATOR- GROUP 19

H887 H890 H689 H894 H904 H689

Rack and pinion assembly, indicator Spindle assembly, indicator Screw, rack and pinion to nacelle

Finger assembly, indicator Plate, indicator position Screw, indicator position plate

42

QUANTITY

I 2 I 2 I

2 I

I 2 I I 2

. 4

•

' ' ' • ' '

' '

•

PROPRIETARY FITTINGS

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

CARBURETTERS

CHAINS

ELECTRICAL EQUIPMENT

HORN ...

SADDLES

SPARKING PLUGS

SPEEDOMETERS

43

Messrs. Amal Ltd., Holford Works, Perry Barr. Birmingham, 20.

The Renold and Coventry Chain Co. Ltd., Didsbury. Manchester.

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

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

Messrs. T errys Ltd., 210, Corporation Street, Birmingham, 4.

Messrs. Wright Saddle Co. Ltd., Dale Road, Selly Oak, Birmingham, 29.

K.L.G. Sparking Plugs, Putney Vale, London, S.W.IS.

Messrs. Lodge Plugs Ltd., Rugby.

Champion Sparking Plugs Ltd., Feith am, Middlesex.

Messrs. Smiths Motor Accessories Ltd., Cricklewood Works, London, S.W.I.

GROUP 20- LUCAS ELECTRICAL EQUIPMENT

REF. No. PART No DESCRIPTION

LUCAS ELECTRICAL EQUIPMENT- GROUP 20 ALTERNATOR (RM13)

2 3 4

5 6 7 8 9

10 II 12

13 14 IS 16

17 18 19 20 21 22 23 24 25 26 27 28

29

047502 E3203 E3104 El580

47103A F3527 F919 525-3 DS57 F879 El612 E2922

45036A D$57 E1612 F3528

40399A 406105 421106 421327 421043 416199,5 4210565 421053 419645 DS57 $25-13 E3309

4062000

30 51519A 31 <- 516723 32 l-<isi/:i 516710 !/¥ 76 33 500291

Alternator assembly Grommet, alternator cable Screw, alternator stator to cover Key. rotor to mainshaft. ..

RECTIFIER (FSW ISOOA) Rectifier ... Bracket, rectifier mounting Bolt, bracket to seat lug (front) Washer, bracket to seat lug (front) ... Bolt, bracket to top bridge seat stays Nut, bracket to top bridge seat stays ... Washer, bracket to top bridge seat stays Nut, rectifier to bracket

IGNITION COIL (CQ6) Coil Bolt, coil to mudguard ... W>Sher, coil to mudguard bolt Backing strip, coil to mudguard

DISTRIBUTOR (ISDI-R019) Distributor Clamping plate assembly Contact set Condenser Cam Spring. auto advance Weights assembly Shaft and action plate Sundry parts set Bolt, lever to crankcase ... Washer, lever to crankcase bolt Sealing ring, distributor

BATTERY (PU3SE) Battery

HEADLAMP (MCF S7S) Headlamp assembly Rim, headlamp Screw, rim fixing Wire, light unit fixing

QUANTITY

I I 5

I 2 2 I

4

• •

• .t

' LUCAS ELECTRICAL EQUIPMENT - GROUP 20


' 12 516728 Light unit 13 554946 Adaptor a»embly 14 554710 Bulbholder, pilot

• 15 553780 Interior. pilot 16 312 Bulb, main 17 988 Bulb, pilot

~-ii.1tec:: 18 H876~ Adjuster screw, head lamp 19 H745 ~ locknut. adjuster screw 20 H.S756 Spring. adjuster screw , ..

' LIGHTING AND IGNITION SWITCH (P.R. 58) 21 31443 Switch

Key, ignition

• DIPPER SWITCH 22 380521 Switch, dipper

23 53256A TAIL LAMP {529)

Lamp, tail I 24 526404 Lens ... ". I

' 25 526406 Window, number plate ... I 26 133551 s,rew, fixing lens 2 17 573825 Grommet, screw.,. 2 29 554719 Bulb holder I 30 526408 Base, rubber I

1 31 988 Bulb I 32 526410 Screw, lamp to number plate 3 33 166103 Nut, lamp to number plate 3 34 188366 Washer. lamp to number plate 3

• STOP TAIL LAMP (525) 35 53269A Lamp, stop tail I 36 573819 Lens I 37 572072 Screw. lens fixing 2 38 573825 Grommet. lens fixing screw 2 39 860428 Bulb holder I

' 40 573814 Gasket, rubber " . I 41 352 Bulb I 42 166014 Nut, lamp to number plate 2 43 188330 Washer, lamp to number plate 2 44 31437A Switch lamp I

' 45 F3158 Spring, lamp switch I

WIRING HARNESS 46 835951 Harness wiring ".

~ HORN (CLEAR HOOTER) 47 HFISO Horn 48 HB86 Button, horn (No. 15) ...

45

GROUP 21 - AMAL CARBURETTER • REF. No. PART No. DESCRIPTION QUANTITY

AMAL CARBURETTER- GROUP 21 4 Illustrated on opposite page

CARBURETTER 332;1 Carburetter, complete • MIXING CHAMBER

2 3321001 Body, mixing chamber ... 3 332/012 Cap, mixing chamber ... 4 332(013 Spring, mixing chamber cap 5 332;014 Screw, mixing chamber cap spring and throttle locating 6 332j022 Air valve assembly 7 52/068 Adjuster, throttle cable ... a 332/005 Valve, throttle ... 9 332j021 Spring, throttle valve ...

10 332/018 Screw~ throttle adjusting II 332;020 Nut, throttle adjusting screw 12 332;017 Screw, air adjusting

/l 13 4/148 Spring, air adjusting screw

t 14 332/002 Jet for needle . IS 332:003 Needle for jet 16 331:004 Clip. jet needle ...

.~F 4/042 Jet, main (size I CO) 18 332/016 Jet, pilot ... 19 333;016. Screw, pilot jet and mixing chamber ..• 2 20 14/189 Washer, pilot jet and mixing plug chamber ... 2

_P:~~-,. 21 4(043 Bolt, holding I 22 4J053 Washer, holding bolt 2


lllust. No. Port No. Page No. Ref. No. 11/ust. No, Part No. Page No. Ref. No .

I D289 41 24 17 4042 (100) 46 17 • 2 332!001 46 1 18 331 016 46 18 3 332.011 46 3 19 333.016 46 19 4 331.013 46 4 10 14.189 46 10 5 331;014 46 5 11 41043 46 11 6 331021 46 6 21 4'053 46 22 • 7 52068 46 7 23 62.214 48 2 8 332'005 46 8 24 621212 48 3 9 332,'021 46 9 25 61(104 48 4

10 332018 46 10 26 12.016 48 5 • II 332020 46 II 27 22i013 48 6 12 332.•017 46 12 28 621207 48 7 13 4!148 46 13 29 352:208 48 8 14 332•002 46 14 30 352!207 48 9 15 332;003 46 15 31 14!178 48 10 16 332:004 46 16 32 14175 48 II

46

•

• ' I

• t

• t

FIG. 14.

AMAL CARBURETTER

For Index See Page 46.

-L 28

25-··

·~ 24

29-~

30 I

26

• 3l-------0.i

27-------L&

AMAL CARBURffiER- GROUP 21

1---------3

'--------6

8

4

5

ll'lf------------14

1--------------17

>----·-------22

GROUP 22 - SPEEDOMETER GROUP 23- SPARKING PLUG


2 3 4 s 6 7 8 9

10 II

12 13 14 IS

16 17 18 19 20 21 22 23

24 2S 26 27

FLOAT CHAMBER

3EB 62/214 62/212 62/204 22;016 22/013 62/207 3S2/208 3S21207 14.:178 14.ci7S

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

Washer, seating locknut

E32S4 E32SO F879 S2S-13

CARBURETTER FIXINGS (TRIUMPH)

Block, insulating carb to head

80421/9 2 80421 I '2 31 4!2!1 31 I !7 0286 D286C D286W DI7S

H/4 LJOS F70 D297

Joint washer, carb to head Nut, carburetter flange Washer, carburetter flange nuts

SPEEDOMETER -GROUP 22

Speedometer 70 m.p.h.-NON TRIP ... Speedometer 120 k.p.h.-NON TRIP Fixing strap, speedometer to nacelle ...

Nut, fixing strap ... Cable assembly speedometer drive, 49" long (S339S) Casing, speedometer drive outer (S3398) Wire, speedometer drive inner (S21 08/ I) Gearbox, speedometer drive (S2283.64 3)

SPARKING PLUG- GROUP 23

Plug, sparking (Lodge) ... Plug, sparking (Champion) Plug, sparking (K.L.G.) ... Cover, sparking plug

48

QUANTITY

2 I

2 2 2

•

. 4

• •

' ' •

• • • 1

' ' • -•

REF. No. PART No.

SADDLE, TWINSEAT AND PILLION SEAT- GROUP 24 CHAINS - GROUP 25

DESCRIPTION QUANTITY

SADDLE, TWINSEAT AND PILLION SEAT-GROUP 24

SADDLE I F3501 *Saddle 2 F3SOIC *Cover, saddle I 3 F3501D *Springs, saddle main 2 4 W76 Nut, saddle bracket to frame 4 5 F3502 Stud, saddle bracket to frame 2 6 525-2 Washer, saddle bracket to frame 4

" State Manufacturer (Terry or Wright) when ordering .

TWINSEAT 7 F3529 Twinseat cjw Attachments I 8 F3535 Bracket, Twlnseat Centre I 9 F879 Nut. centre bracket to pan 2

10 E1611 Washer. centre bratket to pan 2 II F3536 Stud, centre bracket to frame ... 2 12 P0172A Nut, centre bracket to frame .. , 2 13 526-1 Washer, centre bracket to frame 2 14 E667 Bolt, front bracket to frame ... I IS Sl-51 Nut, front bracket to frame ... I 16 526-3 Washer, front bracket to frame I 17 DS57 Bolt, rear bracket to mudguard 2 18 F879 Nut, rear bracket to mudguard 2 19 E1612 Washer, rear bracket to mudguard 2

PILLION SEAT 20 F3522 Seat, pillion I 21 523-42 Bolt, pillion seat fixing 4 22 54-9 Nut, pll!;on seat fixing ... 4 23 525-1 Washer, pillion seat fixing 4

CHAINS- GROUP 25 ~· I;.,;.'/.

' ' .J ~

24 D276 Chain, primary endless, 110038-l" x ~ x 62 Links 25 0277 Chain, rear, 110044-!" x .335" x 112 Links

49

GUARANTEE W E give the following guarantee with our motor cycles, motor cycle combinations

and sidecars including all accessories and component parts other than tyres, saddles, chains and lighting and electrical equipment, and other than accessories and component

parts supplied to the order of the Purchaser and different from those comprised in the standard specifications supplied with our motor cycles, motor cycle combinations and sidecars, but including accessories and parts supplied by way of exchange as hereinafter provided. This guarantee is given in place of any implied conditions or warranties or any liabiHties whatsoever statutory or otherwise ; no guarantee except that hereinafter con., rained and no conditions or warranty whatsoever statutory or otherwise is given or is to be implied, nor are we to be under any liability whatsoever except under the guarantee hereinafter contained. Any statement, description, condition or representation contained in any catalogue, advertisement, leaflet or other publication shall be construed as enlarging, varying or overriding anything herein contained. In the case of machines (a) which have been used for .. hiring out" purposes or (b) any motor cycle and/or sidecar used for any dirt tracks, cinder track or grass track racing or competitlons (or any competition of any kind within an enclosure for which a charge is made for admisslon to take part in or view the competition) or (c) machines from which the trade mark, name or manufacturing number has been altered or removed or (d) any machines in which parts have been used not supplied by or approved by the motor cycle manufacturer, or (e) any machine from which the silencing system as fitted by the manufacturer has been partially or wholly re· moved or interfered with, no guarantee, condition or warranty of any kind statutory or otherwise ls given or is to be implied nor are we to be under any liability whatsoever in respect of any such machine.

We guarantee. subject to the conditions mentioned below, that all precautions which are usual and reasonable have been taken by us to secure excellence of materials and workmanship, but this guarantee is to extend and be in force for six months only in the U.K. and ninety days overseas from date of purchase, or date of exchange in case of any accessory or part supplied by way of exchange as hereinafter provided, and damages for which we make ourselves responsible under this guarantee are limited to the free repair of or supply of a new part or accessory In exchange for the part of the motor cycle, motor cycle combination or side car or accessory which may have proved defective. We undertake, subject to the condltwns mentioned below. to make good in manner aforesaid any part or accessory covered by this guarantee which has proved defective within the said period of six months. We do not undertake to replace or refix. or bear the cost of replacing or refixing any such new part or accessory in the motor cycle, motor cycle combination or sidecar. As motor cycles, motor cycle combinations and sidecars are easily liable to derangement by neglect or misuse. this guarantee does not apply to defects caused by wear and tear, misuse or neglect.

The term "misuse" shall include amongst others the following acts :-1. The attaching of a sldecar to a motor cycle in such a manner as to cause damage or

calculated to render the tatter unsafe when ridden. 2. The use of a motor cyde or of a motor cycle and sidecar combined, when carrying

more persons or a greater weight than that for which the machine was designed by the manufacturers.

3. The attaching of a sidecar to a motor cycle by any form of attachment not provided, supplied, or approved by the manufacturers; or to a motor-cycle which is not designed for such use.

We do not guarantee tyres, saddles, chains or lighting and electrical equipment, or any accessories or component parts supplied to the order of the Purchaser differing from those comprised in the standard specifications supplied with our motor cycles, motor cyde combinations or sidecars. As regards all such tyres, saddlesj chains, lighting and electrical equipment, accessories and component parts. no guarantee, condition or warranty of any kind statutory or otherwise is given or is to be implied, and we are to be under no liability whatsoever in respect thereof.

50

•

. 4

•

' ' • ' • •

• '

•

CONDITIONS OF GUARANTEE

If a defective part or accessory should be found rn our motor cycles, motor cycle combinations or sidecars, or in any part or accessory supplied by way of exchange as before provided, it must be sent to us CARRIAGE PAID, and accompanied by an intimation from the owner that he desires to have it repaired or exchanged free of charge under our guarantee and he must also furnish us at the same time with the frame number of the machine, the date of purchase or the date when the alleged defective part or accessory was exchanged as the case may be.

Failing compliance wit~ the above, such articles will lie here at THE RISK OF THE OWNER, and this guarantee and any implied guarantee, warranty or condition, shall not be enforceable.

REPAIRS

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

NOTICE

We do not appoint agents for the sale on our behalf of our motor cycles or other goods, but we assign to motor cycle Dea!ers areas in which we supply to such Dealers exclusively for re-sale in such areas. No such Dealer Is authorised to transact any business, give any warranty, make any representation or incur any liability on our behalf. All goods are offered for sa!e subject to the price ruling at time of dell very, We reserve the right to modify or deviate from the published specification,

51

INDEX

Group I-CARTON PACKS

Group 2-ENGINE Crankcase ... Crankcase bearings (engine) Crankcase filter Cylinder barrel ... Cylinder head Engine sprocket Flywheels and connecting rod ... Gasket set Inner cover drive side Inner cover timing side Oil pump ... Overhead rocker, covers. etc. Outer cover drive side ... Outer cover timing side Piston Push rods and cover Rocker oil pipe and fittings Tappets ... Timing gears and camshaft Valves, guides, springs, etc.

Group 3-GEARBOX AND CLUTCH Camplate .•. Clutch Clutch control Footchange mechanism ... Filler, level and drain plugs Gearbox casing bearings Gearbox sprocket Klckstaner Selector forks and spindle Shafts and gears

Group 4-EXHAUST SYSTEM Exhaust pipe Silencer ...

Group 5-FRAME Frame Rear suspension

Group 6-CENTRE STAND

52

Page No.

5

7 9 9 9 7 7

12 9

13 12 13 12 8

12 13 7 8 8 8

12 7

14 14 16 18 14 16 15 16 16 14 14

18 18 18

19 19 19

19

4

•

•

.

• • ' t

• •

Group 7-TELESCOPIC FRONT FORK Front fork Steering races Licence holder

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

Group 9-MUDGUARDS AND REAR CARRIER Front mudguard ... Rear mudguard Rear carrier

Group 10-NUMBER PLATES Front number plate Rear number plate

Group II-REAR CHAINGUARD

Group 12-TOOLBOX, BATTERY AND AIR CLEANER ASSEMBLY

Group 13-TOOLS

Group 14--PETROL AND OIL TANKS Oil tank ... Petrol tank

Group IS-FOOTRESTS Rider's footrest ... Pillion footrest

Group 16-REAR BRAKE PEDAL

Group 17-HANDLEBAR AND FITTINGS Control levers Handlebar Twistgrip ...

53

Page No.

24 24 25 25

27 27 27 29 29 30

30 30 32 32

32 32 32

33

33

34

37 37 37

38 38 38

39

39 39 39 41

Group IS-CONTROL CABLES Clutch cable Front brake cable Gear indicator cable Throttle cable

Group 19-NACELLE GEAR INDICATOR

PROPRIETARY FITTINGS

Group 20-LUCAS ELECTRICAL EQUIPMENT

Group 21-AMAL CARBURETTER Carburetter Carburetter fixings (Triumph) ... Mixing chamber ... Float chamber

Group 22-SPEEDOMETER

Group 23-SPARKING PLUG

Group 24-SADDLE TWINSEAT AND PILLION SEAT Saddle Twin seat Pillion seat

Group 25-CHAIN GROUP

54

Page No.

41 42 41 42 41

42

44

46 46 48 46 48

48

48

49 49 49 49

49

. 4

I

• • • ' • • • ' •

INDEX TO ILLUSTRATIONS Page No.

Fig. I. Engine and gearbox unit 10

" 2. Mainshaft and layshaft gears IS

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

.. 4 . Frame and components 20

.. 5. Rear suspension ... 21

.. 6. Telescopic front fork 22

.. 7. Front wheel 26

.. 8. Rear wheel. .. 28

.. 9. Mudguard, number plates, carrier and rear chainguard 31

.. 10. Toolbox, battery carrier and air cleaner 34

.. II. Tools 35

" 12. Petrol and oil tanks 36

" 13. Handlebar and components 40

" 14. Amal carburetter ... 47

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

EXAMPLE.

To find the part number of the cylinder head gasket:

I. Refer to the illustration index above, where it will be found that the engine is illustrated on page 10 .

2. Note that the number of the gasket fn the illustration is 9.

3. Refer to the index on page II.

4. Note that illustration number 9 is part number E3217 listed on page 7, line 16.

55

Tournez s'if vous plait. vease al dorso. 8irte wenden.

MANI~RE D'IDENTIFIER LA PI~CE DE RECHANGE REQUISE

Afin d'assister MM. les marchands et MM. les possesseurs a !'identification des pieces de rechange, ce livre contient de nombreuses illustrations des montages principaux en fat;on de "perspectives E!clatees".

Chaque piece composante a !'illustration est numeratee; en se referant a !'index approprie on peut trouver le numE!ro relatif.

A cOte de chaque piece illustree se trouve le numero de Ia page et le numero de reference ; en se refE~rant a Ia page approprie Ia description complete de Ia piece sera facilement constate.

Exemple. Pour identifier le numE!ro de reference du joint de culasse :

I. Se rE!ferer a Ia page intituiE!e "Index to lllustrat:ons" oU on trouvera que le moteur est illustrE!e sur Ia page 10.

2. Noter qu'a cOte du joint de culasse se trouve le numero 9.

3. Se referer a l'index donne sur Ia page numero II.

4. On y constatera que suivant le numero 9 se trouve : (a) le numero relatif-E.3217 (b) le numero de Ia page d'index-7 (c) Ia ligne de reference-16.

MAN ERA DE ENCONTRAR LA PIEZA DESEADA

• •

Para ayudar al propietario y al representante en Ia identiflcad6n de las piezas deseadas este libra Ill contiene numerosas ilustraciones de los prindpales montages. ..

Cada pieza componente en Ia ilustrad6n est<i numerada y al referirse al indice apropiada, se encontrar<i el nUmero de Ia pieza.

Contra el nUmero de cada pieza se muestra el nUmero de referenda, y al referirse a Ia p<igina apropiada, Ia descripdon completa de cada pieza se encontrar<i contra el nUmero de referenda.

Ejemplo. ' Para encontrar el nUmero de pieza de Ia empaquetadura de Ia culata de cilindro;

I. Referirse a Ia p<igina "Index to Illustrations" donde se vera que Ia ilustraci6n del motor est<i en Ia p<igina 10.

2. N6tese que el nUmero de Ia empaquetadura en Ia ilustrad6n es 9.

3. Referirse al indice de Ia ilustraci6n en questiOn en Ia p<igina II.

4. Notese que no. 9 es pieza nUmero E.3217 en Ia lista de Ia p<igina 7, linea de referenda no. 16.

ANWEISUNG ZUR IDENTIFIZIERUNG BENOETIGTER ERSATZTEILE

Dieses Buch enthalt zahlreiche Zerlege-Abbildungen der Hauptzusammenstellungen, un dem Besiter und dem Verteiler beim lndentiflzieren seiner FOrderungen zu helfen. Jedes Teil auf der Abbildung ist mit einer Nummer versehen, und die Bestandteilnummer wird durch Nachschlagen des bezUglichen

41

Ve rzeichnisses gefunden. Mit jeder Teilnummer ist die seite und die Referenznummer gegeben. und durch I Nachschlagen der bezi.iglichen Seite wird die vollstandige Beschreibung des Teiles unter de Referenznummer gefunden.

Zum Beispiel. Urn die Nummer der Zylinderkopfdichtung zu flnden :

I. Schlagen Sie das Abbildungverzeichnis, oben, nach, wo es gefunden wird, dass die Maschine auf • Seite 10 abgebildet ist.

2. Merken Sie, dass Nr. 9 ist die Nummer der Dichtung auf der Abbildung.

3. Schlagen Sie das Verzeichnis auf Seite II, nach.

4. Merken Sie, dass die Abbildungnummer 9 ist die Teilnummer E3217, eingetragen auf Seite 7, Zeile 19.

56

t

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I

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•

GROUP 3 - GEARBOX

APPENDIX


GEARBOX AND CLUTCH GROUP

The clutch bearing listed on page 16 under reference number 29, 30 and 31 Is now superseded by a plain cast iron bearing ring. To modify the clutch sprocket to the latter condition, remove the rivets securing the bearing retaining plates when the old bearing assembly can be removed and the new bearing ring sprung into position .

9 Tl202 i·'J Ring, dutch sprocket bearing

57

REPLACEMENT PARTS Tlt.ruM:PB - JRC...

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