,

REPLACEMENT PARTS LIST

Mod

Spares No.

00-3171

00-3313

00-3463

00-34o4

00-3465

00-3474

00-3475

00-3476

70-9425

70-9398

70-9548

40-3235

41-805

82- 9214

97-2565

68- 5554

68- 5535

41-6009

41-6022

ASSEMBLIES COMPLETE

Description

TOP OVERHAUL GASKET SET.

FULL OVERHAUL GASKET SET.

PISTON RING SET (standard).

PISTON RING SET (+ .010' ; .254 mm.).

PISTON RING SET (+ .020' ; .508 mm.).

PISTON RING SET (standard, alternative H. & G.).

PISTON RING SET ( + .010•, alternative H. & G.).

PISTON RING SET ( + .020•, alternative H. & G.).

ENGINE/GEARBOX UNIT COMPLETE LESS CARBURETTER AND EXHAUST SYSTEM.

CRANKCASE COMPLETE WITH FIXED FITTINGS.

FLYWHEEL AND CONNECTING ROD ASSEMBLY.

CLUTCH ASSEMBLY COMPLETE.

OIL PUMP COMPLETE.

FRAME COMPLETE WITH FIXED FITTINGS.

FRONT FORK ASSEMBLY.

FRONT WHEEL WITH SPINDLE AND BEARINGS.

FRONT HUB WITH SPINDLE AND BEARINGS.

REAR WHEEL WITH SPINDLE AND BEARINGS.

REAR HUB WITH SPINDLE AND BEARINGS.

5

PISTON CHART

PISTONS COMPLETE

Compression +.010· +.020· Ratio Standard (.254 mm.) (.508 mm.)

41-793 41-795 41-797 9.4 : I --

COMPRESSION RINGS

Taper Taper Taper Standard 41-92 (2) 41-104 (2) 41 -93(2) Fitting

Top Top Top Alternative 70-8203 70-8313 70-8293 Hepworth Taper Taper Taper & Grandage

70-8202 70-8312 70-8291 Rings

SCRAPER RINGS

Standard 41-98 41 - 102 41-99 Fitting

Alternative 70-8204 70-83 14 70-8295 Hepworth

& Grandage Rings

CARBURETTER SETTINGS

I Spares I Pilot Throttle Needle Needle Makers Main

Number I Number Jct Jct Slide Jct Position

19-2400 R.930 11 230 25 I 3 .107 2

6 ""· ·· ~. . . ~

CYLINDER HEAD, EXHAUST PIPE

CYLINDER AND CRAN KSHAFT ..

CRANKCASE

OIL PUMP, GEARBOX SPROCKET

GEAR CLUSTER ..

GEARCHANGE MECHANISM

FOOTSTART AND FOOTCHANGE .

CLUTCH AND PRIMARY COVER ..

INDEX

FRAME, BATTERY CARRIER. REAR BRAKE CONTROL .

SWINGING ARM

FOOTRESTS. Et-;GINE SHIELD

OIL TANK. SIDECOVER. TOOL TRAY ..

FRONT FORKS

FRONT WHEEL ..

REAR WHEEL

MUDGUARDS

. PETROL TANK, TWINSEAT. HANDLEBAR AND CONTROLS ..

ELECTRICAL EQUIPMENT .•

TOOLS AND SUNDRIES

CARBURETTER AND AIR CLEANER

7

Page 8- 9

10- 11

12 • 13

14 • 15

16- 17

18 • 19

20 - 23

24 . 25

26 -27

28 -29

30 • 31

32-33

34 - 37

38 . 39

-44) - 41

42. 43

44 • 47

48 • 51

52 • 53

54 . 55

'

91 LI

~ 81

61

s IZ ?? tz i zi VI

' ti-

0 LL ~~ -~~ -

a ZI- 6Z

It u

Zt

Of/J t£ •

• - ·-VE:

-St - 9t

L 0 .. L£ 9 ~

t, t

l aJl(d

Plate 1

Code Spares No.

00-3171 00-3313

I . 2-525 2. IS-5155 3. 40-417 4. 24-6040 5. 2-923 6. 40-209 7. 2-525 8. 40-56 9. 40-208

10. 41~33 11. 40-309 12. 41-789 13. 40-129* 14. 70-9467 15. 41-784 16. 42-4476 17. 70-7821 18. 6S-1417 19. 68-18• 20. 41-788 21. 68-931 22. 41~32 23. 65-2494 24. 6S-2495 25. 40-171 26. 40-167 27. 40-124 28. 66-3074 29. 40-127 30. 40-131 • 31. 70-7857 32. 40-415 33. 40-182 34. 41-31 35. 68-289 36. 41-176 37. 2-443

CYLINDER HEAD, EXHAUST PIPE

Description

Decoke gasket set Full overhaul gasket set .. Washer, for nut line 37 (¼'x ½'x.048') Washer, valve lifter (2l/64'x ½'x.048') Exhaust valve lifter .. Nut. rocker box (¼' o.s.c.) Washer, rocker box nut (¼'x¾'x¼') Nut, rocker box ( ¼ • o.s.c.) Washer, rocker box nut (¼'x ½'x.048') Gasket, rocker inspection cover Rocker inspection cover .. Exhaqst valve guide Screw. rocker inspection cover Exhaust valve

Cylinder head stud, long (¼' 8.S.C./8.S.F. X 2-15/16') ... Exhaust pipe complete Cylinder head with fixed fittings .. Carburetter stud nut (¼' o.s.c.) .. Tufnol washer, carburetter joint .. Carburettor joint gasket .. Carburetter stud(¼' 8.S.C./B.S.F.X I¾') Inlet valve Valve spring bottom cup .. Inlet valve guide Valve spring (outer) Valve spring (inner) Valve spring top collar Valve spring collet .. Cylinder head dowel stud .. Cylinder head dowel Rocker box stud (¼' 8.S.C./B.S.F. x 2-9/16') Cylinder head stud, short ( ¼ • B.S.C./8.S.F. X 2 ¼ ') Rocker box gasket ... Rocker box .. Washer, valve inspection cap Valve inspection cap "'O" ring, valve lifter Exhaust valve lifter lever Nut, valve lifter (¼ • o.s.c.)

•Special material : 13.-ENl5. 19.-ENI5. 30.-EN15.

9

~-

Per Set

2 2 7 7

3

2

2

2

2 2 2 4 2 2 2 2

2 2

......

Plate 2

~ 5

44----43--3---~ ~ 42'-----· /

41 l

40 39-

38-

~

3:3

~ - 13

~,,_~_ - _-_- _-14 15

16

~ " w-37 n------fl: ... -_-::::~_,:: 1'7t1il 20

6

35.

34'-

32 31 31

10

28 27

Plate 2

Code Spares No.

I. 40-162 2. 40-159 3. 41-807 4. 62-263 5. 40-157 6. 40-1037 7. 19-762S 8. 19-7616 9. 66-102

10. 24-S63 11. 40-148 12. 40-1S8 13. 40-296 14. 40-292 15. 40-1S8 16. 68- tss• 17. 24-5160 18. 76-12 19. 41-44* 20. 41 - S49-21. 66-492 22. 41- 101 23. 41- 586 24. 41- 588 25. 41 - 183 26. 41 - 551 27. 41- S64 28. 41- S54 29. 40-43 30. 10-9S49 31. 41 - 579 32. 66-9S4 33. 41-793t 34. 26-650 35. 40-S72 36. 70- 7727 37. 41- 787 38. 41 -98t 39. 41-92t 40. 41 - 92t 41. 21 - 1964 42. 41-639 43. 14-304 44. 41-638 45. 40-294 46. 40-1S6

70-9S48 41- 548

CYLINDER AND CRANKSHAFT

Description

Nut, rocker spindle (1/s • a.s.c. domed) .. Wa.her, oil feed pipe Rocker oil feed pipe Clip, for oil pipe line 6 Thrust washer ( 1/s ") rocker spindle Flexible oil pipe, rocke, s .. Spark plug cover (Champion WC.548) .. Spark plug (Champion N4) .. Spark plug washer . . . . Nut, rocker adjusting screw (¼" a.s.c.) "O" ring, rocker spindle .. Thrust washer ( ½ ") rocker spindle Exhaust rocker complete .. Inlet rocker complete .. Thrust wa,sher ( ½ ") rocker spindle Rocker adjusting screw (¼" a.s.c.) Nut, cylinder stud (¼" a.s.c.) · .. Washer, cylinder stud (21/64" x9/ 16" x 3/ 32') .. Cylinder stud (¼" B.S.C./8.S.F. x 2-25/32") Connecting rod complete . . . . Small-end bush, connecting rod Gudgeon pin C,ankpin Crankpin nut . . . . Big-end bush, connecting rod Peg. crankpin location Engine shaft (right-hand) .. Flywheel complete (right-hand) Flywheel plug . . . . Flywheel complete (left-hand) Engine shaft (left-hand) Gudgeon pin circlip Piston complete Crankpin roller .. Crankpin roller cage Cylinder base washer Cylinder barrel .. Piston scraper ring .. Piston compression ring Piston compression ring . . Stud, cylinder holding Washer, for nut line 43 . . Nut, cylinder holding down (,t' U.N.F.) Cylinder head gasket . . . . . . Rocker spindle, inlet and exhaust Spring washer, rocker spindle . . Flywheel and connecting rod assembly .. Connecting rod and crankpin assembly ..

*Special material: 16.-EN9. 19.-EN148.

11

..

tSce page 6.

Per Set

2 4

2

2 2 2

2 2 2 2 2

2

2

24

4 .. 4

2

Plate 3

--I' 12

,47

6

"'''----~ «), ___ _

I 39 38 3

I 35 3-4

12

Plate 3

Code

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

10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 5,2. 53.

Spares No.

14-901 2-525

40-705 41-{i73 21-1896• 21-1895° 41-{il5 40-325 40-326 40-327 40-25 70-9428 70-9382 70-9381 70-9430 70-9517 24-36 70-9431 70-9383 70-9429 21-1872 70-8896 21-1892 2-923

24-732 70-9432 70-9384 40-242° 41-790 70-7739 41-958 40-118 41-560 42-5864 4G-455 41 - 569 41-567 41-565 24-724 70-9398 14-{i203 40-375 66-7518 68-383 40-241 40-246 40-9190 40-243 70-3789 21-1894• 41-143 41-146 19-8019 19-1262 29-2054 29-2053

CRANKCASE

Description

Stator self.Jock nut .. Washer, stator fixing (¼"x½"x.048") Grommet, generator lead .. Key, rotor to shaft .. Bottom stud, stator fixing(¼" u.N.F.X,lr" U.N.C.X2·9/16") Front stud, stator fixing (¼ • U.N.F. x ,Ir" U.N.C. x 2-19/32.") .. Engine sprocket (28 teeth) Engine sprocket spacer (.320-.324"; 8.128-8.229 mm.) Engine sprocket spacer (.309-.312"; 7.884-7.924 mm.) Engine sprocket spacer ( .. 294-.297"; 7.467-7.543 mm.) Oil seal, crankcase drive side Tachometer drive assembly Tachometer drive shaft gear Tachometer drive shaft "O" ring, drive shaft Drive shaft body Scaling washer, drive shaft locating pin, drive shaft .. Thrust washer, drive shaft Retaining pin, drive gear .. Plug timing aperture Washer, for plug line 18 .. Bolt, crankcase (,Ir" u.N.C. X I½") Washer, crankcase bolt (,Ir" x ¾" x n-") Bearing, right-hand (Hoffman 325) Gasket, tachometer drive . . Cover plate, tachometer drive hole Screw, tachometer drive (2 B.A. x 27/64" countersunk) Push rod, inlet and exhaust Tappet, inlet and exhaust .. Camshaft complete . . Key, camshaft p nion Key, crankshaft pinion Nut, crankshaft (¾' e.s.F.) l ockwasher, crankshaft nut Pinion, crankshaft .. Oil pump drive, crankshaft Thrust washer, oil pump drive Bearing, fcft-hand (Hoffman R.325L) Crankcase with fixed fittings Bolt, rear chain oiler ( ¼ • u.N.C. x I¼') Oil pipe, rear chain oiler . . . . Washer, chain oiler bolt (fibre ¼"x 17/32"X .078") Rear chain oiler Gasket, primary case back Screw, primary case back (2 B.A. x ,Ir") . • Clip, generator leads . . . . . . Oil seal, primary case back Cover plate, primary case back .. Rear stud, Stator fixing(¼" U.N.F.x,lr" U.N.C.X2-l9/32") Chain tensioner, primary . . . . . . . . , . Distance piece, chain tensioner .. Generator rotor (Lucas 54213901) Generator stator (Lucas 47205) .. Washer, rotor fixing Nut, rotor fixing

. . '

*Special material: 5.-EN8. .;

6.-EN14B. 25.-EN8R . 47.- EN14B. , (

Plate 4

7

27

28 ~

3S--Q 29

25

2-4 30 23

311 37 36 34 31

3 3 2 2 19 18

14

Plate 4

Code

I. 2. 3. 4. 5. 6. 7. 8. 9.

10. II. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.

Spares No.

14-302 2- 923

21- 1890 40-1033 57- 948 14-302 2-923

21- 1889 40-414 29-541 41~3 41~ 41- 712 41-606 41 - 713 41 - 714 41 -803 14-901 68- 938 21- 1893• 41-609 67-1391 41~5 41~ 41-804 41- 706 70-8315 41-{;24 67- 1288 4(-{;20

14-1401 2-525

14-901 21- 1857 68- 3168 41-3092 40-3121 40-3051* 90~74

OIL PUMP, GEARBOX SPROCKET

Deseri'ptlon

Nut, crankcase stud C,1,-" U.N.F.) .. Washer. for nut line I (¼• x ½• x ,1.-•) .. Crankcase stud. rear(¼• U.N.F./u .N.C. X2·11/l6•) Gearbox dipstick Dipstick washer

Nut, crankcase stud (¼" U.N.F.) .. Washer, for nut line 6 (,'.•x ¼· x ,1.-•) .. Crankcase stud (top) Nut, oil pump spindle(¼" e.s.c.) Lockwasher, oil pump spindle Oil pump driving gear Oil pump spindle housing Oil pump driving spindle _. Oil pump driven spindle . . Oil pump reed gear (driven) Oil pump thrust washer .. Oil pump body

Nut. oil pump mounting ( 1;. • u .N.F. ) Washer, oil pump mounting (17/64", ~8•, ,1.-· i Stud. oil pump mounting (t~ • u.N.F. 'U.N.C.x 21t") Screw, oil pump cover plate (,t-· e.s.c. x 1,t•) Oil pump cover plate Oil pump scavenge gear (driven) Oil pump scavenge gear (driver) .. Oil pump gasket Dowel. oil pump Camshaft bush Scavenge valve complete Scavenge cover gasket Scavenge cover

Stud , scavenge cover ( ¼. U.N.F./U.N.C. "· n Washer, scavenr e cover (¼" x ½"' .048.) Locknut, scavenge cover (¼• u.N.F.) Drain plug. gearbox ( ½• U.N.C.) "O" ring, drain plutt Gearbox ,procket (1 7 teeth) Lockwasher. gearbo, ,procket

Nut. gearbox sprocket (I ,t • x 20 th,eads per inch WHtr.) Fell washer. gearbo , sprocket

•Special material : Z0.- ENl4B. J8.-EN8

15

Per Set

2 2 2

2 2 2

2

2 2 2 4

2

4 4 4

Plate 5

24

21-

00---- 9 L ____ IO

16 15 14 13 12 I

16

Plate 5

Code Spares No.

1. 40-394 2. 29-3857 3. 57-3872 4. 40-3020 4. 40-3126 4. 40-3127 5. 57-3876 6. 40-3019 6. 40-3119 6. 40-3120 7. 41-3063 8. 41-3089 9. 40-3007

10. 40-3254 11. 40-3258 12. 40-3262 13. 57-3874 14. 57-3877 15. 41-3078 16. 41 -3070 17. 41-3068 18. 41-3074 18. 41-3072 19. 40-3292 20. 40-3265 21. 41-3045 22. 41-3054 23. 70-6026

GEAR CLUSTER

Dtsrriptio11

Dowel. inner cover to crankcase .. Mainshaft bearing (Hoffman 130) Pinion, mainshaft top gear (22 teeth) Spacer (.093-.094"; 2.3622-2.3876 mm.) Spacer (.098-.099"; 2.4892-3.1146 mm.) Spacer (.103-.104"; 2.6162-2.6416 mm.) Pinion, layshaft second gear (21 teeth) .. Spacer (.075-.076"; 1.905-1.9304 mm.) Spacer (.070-.071"; 1.778-1.8034 mm.) Spacer (.080-.081•; 2.032-2.0574 mm.) Pinion, mainshaft third gear (24 teeth) . . Pinion, mainshaft first gear (16 teeth) . . Mainshaft bush, push rod Mainshaft with bush Layshaft shim Bush, layshafl fi(Sl gear .. Pinion. layshaft ftrst gear (27 teeth) Pinion, layshaft third gear (19 teeth) Layshaft circlip

Pinion. layshaft second gear (22 teeth) .. Layshaft with top gear (14 teeth) Thrust washer (.083- .085·; 2.1082- 2.159 mm.) Thrust washer (.078-.080"; 1.9812- 2.032 mm.) layshaft bearing (Torrington B.108) Clutch push rod Bush, mainshafl top gear .. Mainshaft oil seal .. Circlip. mainshaft oil seal ..

17

•

Per Set

2

. . as reqd.

.. as reqd. as reqd.

.. as reqd.

.. as reqd.

.. as reqd.

as reqd. as reqd.

2

Plate 6

2 @--- - ! ~ 5 '

18

\

Plate 6 GEARCHANGE MECHANISM

Code Spores No. Description Per Set

1. 67- 1236 Crankcase dowel 2. 21 - 1972 Pressure release valve plug 3. 67- 1498 Washer, pressure release valve 4. 40-387 Spring, pressure release valve 5. 90-241 Ball, pressure release valve (¼" diameter) 6. 40-3043 Spring plate . . 7. 40-3042 Cam plate spring 8. 40-3045 Lock plate, for screw line 9 9. 40-3044 Screw. cam plate spring (2 8.A. x ¾") 2

10. 57- 3850 Camplate, gearchange 11. 40-3193 Plunger, gearchange quadraot 2 12. 40-3323 Screw, plunger keeper plate (5 B. A. x ¼") 13. 40-3194 Keeper plate, gearchange quadrant 14. 40-3321 Geatchange quadrant complete IS. 40-3059 Rivet, plunger spring 2 16. 40- 3155 Plunger spring 2 17. 40-3061 Gearchange return spring 18. 57- 3763 Anchor bolt. return spring 19. 60-2724 Split pin, cam plate spindle (3/ 32" x I' ) 20. 40-3291 Camplate spindle 21. 40-3032 Selector fork spindle 22. 40-3033 Layshaft selector fork 23. 57- 3854 Mainshaft selector fork 24. 14-302 Nut, oil pipe union stud (¼' u .N.F.) 25. 36-382 Lockwasher, union stud 26. 21- 1891 Stud, oil pipe union (¼' U.N.F./ U.N.C. X I ¼') .. 27. 40-1035 Crankcase oil pipe union .. 28. 70-8259 "O" ring. oil union pipe .. 2

,

-

Plate 7

7't-l -- -

7,0-- - ~2:-7

68 - -+~~a~~ ~~~~~~~ 65,---

6,,--.

58

-49

~ r I I

8 9 -::::::--- 10

- -- 11 -·- --12

~~ 6

----- . 13 '--- 14

====-~, ......... 20

,, 20

-

Plate 7 FOOTSTART AND FOOTCHANGE

Code Spares No. Description ' PerSd

I. 40-977 Oil seal, crankshaft .. 2. 68- 289 ..0 .. ring, inner cover 3. 41 - 715 Grommet, contact breaker cable ..

4. 40- 222 Camshaft bush 5. 40-28 Camshaft bush peg . . 6. 14-o

Plate 1-continued

I 2

70r--

65.

:•:e, -=---- ..::: 50-

3 f ~ . ' '

58

6 7 I

491---- 'ft -

46-- --==--=--=7, 45---44

43

42t---

22

~ --20

'/

26 'lo/'(? '~- --27

·' "4iio 28

Plate 1-continued FOOTSTART AND FOOTCHANGE

Code Spares No. Description Per Set

37. 40-236 Screw, outer cover (2 B.A. x ¾ •) .. 3 38. 14-6611 'fr. Screw, outer cover(¼• U.N.c.x J¾•)

39. 57- ~ ~ Oil seal, kickstart spindle . . . . 40. 14-6612 Screw, outer cover ( ¼ • u.N.C. x 2').

3 41 . 14-6614 Screw, outer cover(¼• u.N.C.X2½•) 42. 57- 2759 Pedal rubber, kickstart lever 43. 57- 2646 Folding pedal, kickstart lever 44. 40-3084 Bolt, kickstart folding pedal c,1;· e.s.c.x In-·) 45. 40-3085 Spring, kickstart folding pedal 46. 97-2704 Ball, kickstart folding pedal (¼ • diameter) 47. 14-6609 Screw, outer cover ( ¼ • U.N.C. x I¼") 48. 14-6606 Screw, puter cover (¼• U.N.C. X ¾•) 49. 57-2642 Bush, kickstart spindle so. 40-3275 Return spring, kickstart lever SI. 40-3277 Circlip, kickstart quadrant stop 52. 40-3276 Kickstart quadrant stop 53. 57- 2643 • Kickstart spindle complete 54. 40-32~2 - Bearing, kickstart spindle (Torrington B.108) ss. 40-3283 Pinion, clutch operating lever 56. 57-2750 Clutch lever complete 57. 70-9433 Outer timing cover .. 58. 40-3282 Rack, clutch operating 59. 65-2593 Ball, clutch push rod thrust (7/32" diameter) 60. 40-3272 Bush, kickstart ratchet pinion 61. 40-3271 Kickstart ratchet pinion 62. 40-3279 Kickstart ratchet 63. 76-528 Circlip, mainshaft bearing .. 64. 90-11 Bearing, gearbox mainshaft (Hoffman L.27) 65. 57-3764 Anchor bolt, kickstart return spring 66. 66-3074 Dowel, outer to inner cover

2 67. 21-1899 Screwed plug, inner cover .. 68. 14-6608 Screw, inner cover ( ¼ • U.N.c. x 1 •) 69. 70-9408 Inner cover complete 70. 75-257 Breather pipe, inner cover 71. 53-3049 Plug, mainshaft oil feed

• 23

Plate 8

2

I

34 3~

8

24

---~ 9 G,-· --

I -·-_ - 12

J 14 __; •

-Plate 8

Code Spares No.

1. 57-2166 1. 70-9800 2. 14-6610 3. 76-4116 4. 68-$39 5. 68-$40 6. 40-1005 7. 14-6611 8. 70-9427 9. 21-1951

10. 66-3074 11. 21-1855 12. 40-740 13. 40-3222 14. 40-3220 15. 40-3233 16. 40-3234 17. 40-3221 18. 40-3227 19. 2-2395 20. 40-3230 21. 40-3218 22. 21-1943 23. 41-3091 24. 41-3215 25. 70-8782 26. 41-3212 27. 19-8683 28. 40-3206 29. 70-7856 30. 40-3201 31. 40-3150 32. 40-3203 33. 40-3207 34. 41-3210 35. 41-3209 36. 40-3210 37. 40-3330

CLUTCH AND PRIMARY COVER

Dtscriptiou

Screwed plug, primary cover Screwed breather plug. primary cover Primary cover screw. short ( ¼ • u.N.C. '· I½'), . Inspection cover screw (2 B.A. , \~ ") Timing inspection cover Gasket, inspection cover .. Ignition timing pointer Primary cover screw. long (I.~• u.N,C, x P.") Primary cover assembly Primary eover screw. dowel hole ( ¼ • U.N.C. > I}~") Dowel, primary cover to crankcase Primary case oil level screv. ( 14 • u.N.C., I-'.") Washer, for screw line 10 (alloy 17 64', -' s • ,\ ") Clutch pressure plate Clutch driven plate .. Clutch driving plate Spacing wa;her Lockwasher. for nut line 18 Clutch retaining nut Nut. clutch adjusting screw ( 1, • s.s.c.) .. Clutch adjusting sere" ( % • s.s.c. $ ,> Clutch spring dip Primary case drain plug Clutch spring Clutch spring nut Washer. for screwed plugs lines I I Rubber pad, drive and rebound Primary chain (72 pitch) Clutch roller .. Gasket, primary cover Clutch hub .. Clutch hub key Clutch chainwheel Retaining plate (inner) Clutch centre Clutch spider Retaining plate (outer) Screw, inner and outer retaining plates (I " a.A. 15 '16")

25

... - • 2 -~

Per Ser

5 4

3

2

5 4

4

4

4

2 8

25

Plate 9

• -14----@

· - ~~ 12 ~"

I

20 ~ 16 21 --.,... ~17 23

24-~G

i1~p 55 54 l 53 52

51

,,,,,,___ I

40

41 42

26

-

-

Plate 9

Code

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

10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. so. 51. 52. 53. 54. 55. 56. 57.

FRAME, BATTERY CARRIER, REAR BRAKE CONTROL

Spares No.

~30• 3-111

30-196 82- 9958 47- 7013 41 - 7007 47-7003 28-2080 2-1096

29- 541 2- 1027 2-1967 2-1925

6o-4149 82- 9214 40-948 42-4475 2-2138

75-4813 2-49

36-382 83- 1460 41-175 42-4475 40-4077• 2- 522 2-46

19- 1035 42-4475 2-2138

66-4705 75-4813 40-4031• 2- 2138

14- 803 21 - 1934• 42-4343 42-4364 65-8326 90-4294 40-4524 42-4475 3~733 82-8285 40-4530 40-4524 82-9008 42-4476 4-2608

68-4577 68-4597" 47-4214 41-7037 65-6274 ~7029 2- 525

~2683

Description

Bolt, brake pedal fulcrum (1/s' a.s.c. x ¾') Spring wastier, for bolt line I Washer, brake pedal pivot Stop peg, brake pedal 81 ake pedal . . .. Brake fulcrum pin . . . . Bolt, brake pedal ( ¼ • a.s.c.) Grease nipple, brake pedal Washer, brake pedal (,i-' x¾•x .044•) . . Lockwasher, brake pedal .. Nut, brake pedal (¼ • o.s.c .) .. Spring washer, fulcrum pin (,t-•x ¼'xn-•) Nut, fulcrum pin (,t-· o.s.c .) Steering head cup . . Frame complete . . Engine steady stay . . . . . . Nut, steady stay to frame and bracket (1/s. e.s.c.) . . . . Washer, steady stay to frame and "bracket ( 1/s • x ¾ • x ,\-') . . Bolt, steady stay to frame and bracket ( 1/s • o.s.c.) . . Nut, bracket to head (¼. e.s.c.) . . . .. Lockwasher, bracket to head (¼' ) Pivot pin, rear brake rod . . Steady bracket . . . . . . Nut, front engine bolt (1/s• o.s.c.) .. Rear engine stud (1/s • o.s.c./o.s.c. x 2-9/ 16. ) Spring washer, engine stud (1/s• X ¾ • x .056•) Nut, rear engine stud (1/s' o.s.c .) Side reflector (Lucas 57162A) Nut, reflector mounting ( 1/s • o.s.c.) . . Washer, reflector mounting (½ • x ¾ • x n-•l Lockwasher, reflector mounting .. Bolt, reflector mounting (1/s• e.s.c .) Front engine bolt (1/s• B.S.C. X 3-13/ 16•) Spacer, front and bottom engine bolts . . Nut, bottom engine bolt (1/s' u .N.F.) . . Bottom engine bolt(½• V.N.F. x 7-15/ 16· ) Nut, swinging arm spindle (13/ 16' e.s.c.) Lockwasher, spindle nut . . . . Bolt, battery carrier (1/s • o.s.c. x 3') Spacer, battery carrier Rubber, battery carrier Nut, battery carrier (1/s• B.S.C.) . • Washer, battery carrier (.390" x ¼ •" ,\-•i Battery carrier Bolt, battery carrier (¼. o.s.c .) .. Rubber, battery carrier Washer, battery carrier . . Nut, battery carrier (¼• B.S.C.) .. Strap hook .. Battery strap Battery tray . . . . Swinging arm spindle assembly . . Brake rod .. Swivel pin, brake rod Brake rod adjuster . . . . Washer, brake rod pivot pin Split pin, brake rod pivot

• Special material: 1.- EN14B. 25.-EN15. 33.- ENI4B. J6 • ..:..ENl5R.

Note:- Code 9. No. 2-1096 Washer is now cancelled.

27

Per Set

2

2 2 2

2

2 2 2 2 2

2 2 2

2

2

3

2 4 2 2

Plate 10

23--

22!---

21---

ff~--18 e--17

·----16

l}---14

~ .--1s

28

-

C

--

Plate 10

Code Spores No.

I. 40-6910* 2. 2-1733 3. 2-449 4. 19-7441 5. 82-8933 6. 19-7452 7. 19-5305 7. 19-5307 8. 67-1171* 9. 2-861

JO. 82-9953 11 . 14-113 12. 2-2138 13. 14-902 14. 29-3319 15. 40-246 16. 82-9952 17. 40-414 18. 2-220 19. 41~105 20. 40-4752 21. 40-4735 22. 40-4734 23. 40-4733• 24. 14-903 25. 82-9210 26. 40-4241

SWINGING ARM

Descriplion

Bolt, damper to;, (1/s' a.s.c. x I ¼') Washer, damper top (1/s"x 13/16'xn-·) Nut, damper lop (1/s' e.s.c.) Spring only, rear damper (Girling 64543708) .. Dust cover, damper bottom Rear damper complete (Girling 4644) .. Damper bush, top (G irling 64533645) .. Dampe, bush, bouom (Girling 64533654) Bolt, chain guide and anchor slrap (1/s' e.s.c. x I¼') Washor, chain guide and anchor strap ( 1/s' x ¾ • x 3/32')

' Chain guide .. Bolt, chain gua,d to swinging arm (¼' U.N.F. x ¼') .. Washer, chain guard to swinging arm (1/s'X ¾"x,\-') Nut, chain guard to swinging arm (¼" U.N.F.) Lockwasher, chain guard extension

Plate 11

25

I I

22

7

e- 9 ®-- - 18

~7

28 9

\ 10 9 31

30

2 3 -

6

"~

-

~-------iJ ~14

'.,__ _ ___ ,s

Plate 11

Code Spares No.

1. 82- 8448 2. 414105 3. 654917 4. 29-5293 5. 424926 6. 42-4476 7. 684081* 8. 27- 5676 9. 2-522

10. 246 11. 82- 9608 12. 82- 9603 13. 36-382 14. 14-113 15. 82-8819 16. 28-2338 17. 47- 9010 18. 2- 923 19. 75-6594 20. 684835 21. 29- 5293 22. 404820 22. 654917 23. 414105 24. 2- 2138 25. 414835 26. 14-702 27. 14-116 28. 404810 29. 2- 1967 30. 2- 1945 31. 404818 32. 40-4355• 33. 42-4476 34. 4-2276

FOOTRESTS, ENGINE SHIELD

Description

Footrest bracket Nut, anchor bolt to bracket \ ¼ • e.s.c.) Footrest anchor bolt ( 1/s • e.s.c.) .. Footrest pivot bolt (¼ • e.s.c . x I ¼") Folding footrest Nut, pivot bolt (¼" B.S.C.) Bolt, right-hand footrest bracket (1/s" e.s.c. x 2-15/ 16") Washer, right-hand bracket Spring washer, right-hand bracket (.390" x ¾' x .056") Nut, for bolt line 7 ( 1/s • e.s.c.) .. Rubber: folding footrest .. Rubber, pillion footrest Lockwasher, for bolt line 14 (¼") Bolt, engine shield front (¼" U.N.F. x %") Engine shield Bolt, engine shield clip (¼" e.s.c. x 23/32") Clip, engine shield rear Washer, for nut line 19 (¼"x1/g'x¼') Nut, engine shield clip bolt (¼' e.s.c.) Pillion footrest Pivot bolt, pillion footrest(¼" e.s.c. x I¼') Anchor bolt, left-hand (1/s" e.s.c.) Anchor bolt, right-hand (¼' e.s.c.) Nut, anchor bolt (¼" e.s.c.) Washer, anchor bolt (1/g" x ¾'x¼") Bracket, right-hand pillion footrest Nut, footrest bracket (¼' u.N.F.) Bolt, footrest bracket (¼" u.N.F. x n .. Nut, footrest stud, left-hand (rr" e .s.c. left-hand) Spring washer, footrest stud (rr" X ¼" X ¼') Washer, footrest stud (rr' x ¾(X¼') . . Lock plate, footrest stud ..

, '

Footrest stud, left-hand

Plate 12

9,-

10 -

II

16

5

'-'ii 6--- _J _,._- 7

20

32

Plate 12 OIL TANK, SIDECOVER, TOOL TRAY

Code Spares No. Descriptlon Per Ser

1. 68-9223 "Oddie" stud (short)

2. 68-9287 "Oddie" stud (long) 3. 82-8614 Sidecover, left-hand

4. 68-9227 Rubber washer, "Oddie" stud 5. 40-9188 Rubber pad , sidecover to frame ..

6. 68-8368 Filler cap/dipstick . . 7. 68-9226 Rubber washer, "Oddie" stud 3

8. 67-42 Washer, filler cap . . 9. 42-3249 Nut, oil tank bolt line II (¼. e.s.c.) 2

10. 82--f!,18fj (.t>J~ubber bush, tank mounting 2

11. 40-8435 Bolt, tank mounting(¼. e.s.c. x I¾") 2

12. 82-8625 Oil tank with fixed fittings 13. 65-9270 Tank transfer 14. 2-525 Washer, tool tray bolt (¼•x ½·x.048.)

15. 2-220 Bolt, tool tray (¼• B.S.C. X 1/g•) . . 16. 40-9187 Bracket, sidccover pad 17. 40-8046 Rubber pad, sidecover 2

18. 68-9337 Rivel, "Oddie" clip 2

19. 68- 9115 "Oddie" clip, sidecover 20. 40-414 Nut, tool 11ay to frame(¼' e.s.c.)

21. 15-7563 Spacer, tool tray

22. 2- 1354 Bolt, tool tray to frame(¼ • e.s.c. x 41/64') 23. 40-9172 Tool tray 24. 40-414 Nut, for bolt line 15 (¼' e.s.c.) 25. 21-771 Bolt, oil tank lower mounting (¼' U.N.F. x I¾') 26. 40-8401 Rubber sleeve, oil tank 27. 29-7962 Oil tank filter 28. 29- 7971 Fibre washer, banjo union 2

29. 82-8874 Banjo union, oil feed 3-0. 68-8382 Clip, oil fee~ pipe . . 2 31. 68-8383 Oi_l feed pipe 32. 40-8382 Oil return pipe

33. 68-8343 Clip, oil return pipe 2

60-2041 Sidecover transfer (not illustrated)

33

Plate 13

19

@ ---2" ® >----21

~18 0 22

16-

15 14 13-12-

,--e 7 0 a------..lil~•·'

so-@

Plate 13

Code

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

10. 11.

12. 13. 14. 15. 16. 17. 17. 18. 19. 19. 20. 21.

Spares No.

41 - 5146 65- 5332 97-2513 89- 5036 68-5144 29-5347 29- 5338 'J7-2700 65-5295 2-2903

68-5134 40-414 41-5134 41-5139 41-5140 41-5144 97-3693 97-3694 68-5104 97-1932 68-5108 2-49

68-5170 22. 68-5i7 I 23. 41 -5135 24. 68-5143 25. 41-5124 26. 97-2514 27. 6~-5451 28. 97-2682 29. 41-5145 30. 97-2688 31. 65-5424 32. 97-2564 33. 68-5146

FRONT FORKS

Top cap nut .. Washer. top cap nut Fork bellows Fork spring Fork shaft Fork lower bush Washer for shaft plug Fork shaft plug

Description

Pinch bolt, lo,.er member (!8' 9.S.c. ~ I )s' ) . . Spring washer. for bolt line 9 ( 13132', 9/ 16" x ,~ ") . . Spacer, top bearing Nut,

Plate l 3-continued

19

I ~

2--©

6

7

8

0- ,0 @-'

~18 0 2

54 7

53

23 Jg) 52

24 51

so -@ 49

16 ~ IS ~ 14 0 I)- • 2 12- -e

~ - 26

44 -

43 - - -

42 ~ @ ' r:::::',-2e

11-- --'e 29 _ __.:.::;i; 8 ~. ll : ____ \::::_~ :~ -~--'9•"-~~o

e 32-0 ~

Kl

9--

36

33

39 ~. 31&---- ~ , ' 3 3~ &--64

®-65

36,--- _e,

--

Plate 13--continued

Code

34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59.

'°· 61.

Spores No.

41- 5141 68-5197 75-3144 68-9429 36-382 29-9388 2-923

40-9134 14-303 2-2138

97-2526 40-5144 97-2704 40-5143 40-5145 97-2525 64-6016 41-5143 65-5333 15-5155 68- 5056 40-5018 76-9325 68- 5137 27-5135 21- 785• 40-5090 47- 5065

62. 47-5064 63. 68-9428 64. 2-49 65. 2-923

97-2565

FRONT FORKS

Description

Fork drain plug Washer, drain plug .. Nut, heat sink bolt (¼' e.s.c.) Diode retaining clip Lockwasher, heat sink Spacer, heat sink Washer, heat sink .. Bolt, heat sink(¼' e.s.c. x 3') Nut, for bolt line 59 (¾' U.N.F.) Washer, pinch bolt nut Fork bottom yoke .. Steering bottom cone Steel ball, steering head Steering top cone .. Top cone dust cover Fork top yoke

Nut, for bolt line 58 (¾ • B.S.C.) Inner circlip, damper tube Handlebar clip

Washer, for bolt line 54 (21/64" x ½'x .048') .. Bolt, handlebar clip (¼' B.S.C. X 11/g') .. Steering head cap nut Grommet, guide bracket .. Cable guide bracket Pinch bolt, top yoke (¾' B.S.c.)J .. Pinch bolt, bottom yoke (¾ • U.N.F. X 2¥) Cable guide clip Oil seal Oil seal retainer Heat sink

Nut, heat sink bolt (¼' e.s.c.) Washer, heat sink (¼' x 1/s'x,\-') Front fork complete

•Special material :

37

..

59.-EN15.

Per Set

.2 2

2

2

40

2 2 4 4

2 2

2

2 4

Plate 14

f 3 4 r --6

5- ·()- --CJ

- 8

6) 9

IO

-

38

Plate 14 FRONT WHEEL

Code Spares No. Dt1l'ription Per Set

1. 67-5566 Wheel spindle 2. 68-5551 Bearing retainer (left-hand) 3. 41-6016 Bearing (Hoffman LS9RS) 4. 68-5556 Wheel rim (WM2-19) 5. 67-5545 Spoke (long) .. 20 6. 27~810 Spoke nipple 40 7. 42-5873 Balance weight C'. ") as reqd. 7. 42-5875 Balance weight (I") .. as reqd. 8. 67-5544 Spoke (short) 20 9. 28-2080 Hub grease nipple '.

10. 68-5535 Hub with spindle and bearings . . ' 11. 67-5565 Spindle sleeve 12. 41-6016 Bearing (Hoffman LS.9RS) 13. 60-2683 Split pin, bearing retainer (n-' x ¾") 2 14. 68-5541 Leading brake shoe 15. 19-7732 Brake lining .. 2 16. 67-5576 Fulcrum pin .. 17. 24-5860 Nut, anchor strap stud (rr' e.s.c.) 18. 42-5520 Anchor strap 19. 15-716 Spring washer, anchor strap (29/64" x 15/16" X n-") 20. 15-541 Nut, anchor strap (rr' e.s.c.) 21. 67-5577 Stud, anchor strap (,¼-" e.s.c.) n . 25-6014 Washer, fulcrum pin 23. 35-37 Spring washer, fulcrum pin 24. 42-5883 Nut, fulcrum pin (1/s" e.s.c.) 25. 28-2080 Grease nipple, cam spindle 26. 67-5555 Brake anchor plate . . 27. 2--440 Nut, brake lever (,¼-" e.s.c.) 28. 66-4708 Lockwasher, brake lever (,¼-") 29. 15-431 Washer, brake lever (,¼-"x¾•x,'r") 30. 65-5907 Brake lever . ' 31. 37-2243 Cam spindle .. 32. 67-5575 Rivet, brake lining , . 14 33. 68-5543 Trailing brake shoe 34. 68-5552 Bearing retainer (right-hand} 35. 65-5904 Spring, brake shoe .. 2

68-5554 Wheel with spindle and bearings

39

Plate 15

33 34 35

43

9 10 II 8

'i '1

I 46 4 48 49

40

14

I s~ sl

Plate 15

Code Spares No.

1. 68-6066 2. 2-440 3. 66-4708 4. 15-431 5. 42-«)45 ,. 28- 2080 7. 41-6093 8. 65-5940 9. 19-7717

10. 37- 2226 11. 65-5883 12. 41~ 13. 41-6091 14. 19-8687 15. 67~38* 16. 2-452 17. 42~19 18. 68-6095* 19. 24-8784 20. 68~133 21. 68~135 22. 65-5904 23. 41~22 24. 35436 25. 65-5111 26. 24-7000 27. 41-6094 28. 68~134 29. 40-6033 30. 40-6040 31. 2-923 32. 42-4476 33. 67~33 34. 67- 6034 35. 41~32 36. 68~81 37. 41~16 38. 65-5884 39. 67~51 40. 27~10 41. 42~11 42. 42~12 43. 68- 9575 44. 42~371 45. 67~27 46. 41~16 47. 65-5887 48. . 65-5886 49. 41~21 50. 41~19 51. 6~142 52. 19-9217 53. 41-6098 54. 41-6082

41-6009

REAR WHEEL

Spindle nut (left-hand) .. Nut. brake lever (,t' a .s.c.)

Dtsrrlption

Lockwasher, brake lever . . . . Washer, brake lever (,t'x•¼"xn-') Brake lever . . . . . . Grease nipple, cam spindle Brake anchor plate .. Brake sboe complete Brake lining Cam spindle .. Bearing (Hoffman LS.9) .. Brake drum .. Rear chainwheel (49 teeth) Rear chain (¼'x ¼'xlOO pitch) Bolt, llan3e to drum (1/s' a.s.c.) .. Nut, flange to drum (¾' e.s.c.) .. Drivini flange . . . . . . . . . . Bolt, chainwbeel to drum(¼' u.N.F. X 13/32') Spring washer, for bolt line· IS (¼' X½'x.040') Fulcrum pin . . . . Lockplate, for bolt line 15 Return spring, brake shoe Hub with spindle and bearings .. Rivet for brake linings . . Spring washer, fulcrum pin (½') Nut, fulcrum pin ( ½' e.s.c.) Anchor strap Return spring, brake lever Wheel adjuster .. Wheel adjuster cap . . . . . . . . Washer, wheel adjuste, (¼'x ½ ' X i',-' ) .. Nut, wheel adjuster (¼ • B.S.C.) . . . . Bearing shim Bearing circlip Fixed spindle Bearing retainer . . . . Bearing (Hoffman LS.9RS) Thrust ring, bearing Rubber seal . . Spoke nipple Spoke (left-hand) Spoke (right-band) Security boll . . . . Wheel rim (WM3- J8) Spindle sleeve .. Bearing (Hoffman LS.9RS) Retainer (inner) Felt washer .. Retainer (outer) Inner spacer (right-hand) . . End cover . . . . Speedometer gearbox ( 1.25 to I) Wheel spindle Outer spacer (right-hand) .. Rear wheel with spindle and bearings

*Special material: 15.-ENI4B.

41

18.-ENl4B.

Per Set

2 2

6 6

10 10

3 2

14

2 2 2 2

40 20 20

2

Plate 16

32 33 3I

' e

42

9

~16

19

-

----

Plate 16 MUDGUARDS

Codt Spores No. Description

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

10. 11. J2. J3. J4. 15. 16. 17. J8. 19. .20. 20. 21. 22. 23. 23. 24. 24. 25. 26. 27. 28. 29. .30. 31. . 32. 33. 34. .35. 36. 37. .38. 39. 39. 40. 41. 42. 42. 43. 43. 44. 45. 46. 47. .48. 49. se.

28- 2338 2- 923

7~594 41-9152 2-204

27-8560 40-414 41-6533 82- 8394 3-1156

15-7354 2-923

36-382 2-1616

75-3144 64-6054* 2-370

40-6022 40-6570 82-8367 82-9989 42-4476 67-6839 76-101 76-100 83-254 83- 270 41-6782 68-6802 27-6742 2- 923

24-8784 2-49

68-6835 27-8560 2-204

54-170 21-5161 82-8195 82- 8140 19-943 54-9003 54-9012 47-6806 40-414 31-222 70-2980 68-6832 54-9081 42-3249 2- 204

40-6790 2-1462 2-2395

28-2338 2-923

Bolt, handrail to support rail (¼ • a.s.c. x 23/32") Washer, handrail to support rail (¼"x ¾' x -r.•) Nut, handrail to support rail (¼' a.s.c.) . . Handrail . . . . . . . . . . Bolt, stay to mudguard ( ¼ • a.s.c. x ½ ') Washer, stay to mudguard ( ¼ • x ¾ • x .048") .. Nut, stay to mudguard ( ¼ • e.s.c.) Front mudguard . . . . Ceofre stay, front mudguard . . . . . . Bolt, stay to fork leg, left-hand (¼. B.S.C. X Ya') Bolt, stay to fork end, left-hand (¼ • a.s.c. x ¾ ') Washer, stay to fork end (¼"x ¾'x -r.·) Lockwasher, stay to fork end ( ¼ ") . . Nut, stay to fork end (¼' e.s.c.) . . . . Nut, ~tay to fork leg (¼" a.s.c.) . . . . . . Bolt, stay to fork leg, right-hand(¼" B.S.C.X 1-7/64") Spacer, stay to fork end : . . . . . . . Bolt, stay to fork end, right-hand (¼" a.s.c. X 1/gj .. Bottom stay, front mudguard . . . . . . Rear mudguard - first sets only Rear mudguard ~ after first sets Nut, guard to support rail (¼" a.s.c.) . . Wiring grommet . . . . . . . . Spacer, tail lamp support - first sets only Spacer, tail lamp support - after first sets Tail lamp support complete - first sets only . . Tail lamp support complete - after first sets . . Support rail . . . . Bracket, support rail to guard .. Bolt, bracket to support rail (¼" B.s.c. X 37/64") Washer, bracket to support rail (n;-•x¾' X¼j . . Spring washer, bracket to support rail (¼"X ¾"x.040') Nut, bracket to support rail (¼" e.s.c.) Tail lamp support plate . . . . . . Washer, for bolt line 33 (¼'x¾' x .048j . . . . Bolt, number plate bracket (¼" a.s.c. x ½") . . . . Lockwasher, support plate bottom screw - after first sets .. Nut, support plate bottom screw (2 B.A.) - after first sets .. Push-fix, rear reflector Rubber pad, rear reflector

· Rear reflector (Lucas 571 I I) . . . . . . Screw, support plate to support (2 B.A. x ¼ ") - first sets only Screw, support plate to support (2 e.A. x 13/32") - after first sets Number pla te bracket Nut, for bolt line 3.3 (¼ • a.s.c.) . . . . Stud, tail lamp support (¼" a.s.c./ WHIT.) - first sets only . . Stud, tail lamp support - after first sets . . . . . . Washer, tail lamp support - first sets only Washer, tail lamp support - after first sets Nut, tail lamp support stud (¼" a.s.c.) Bolt, mudgua,d to frame(¼ " a.s.c.x ½1 Washer, mudguard to frame . . . . Spring washer, mudguard to frame (¼"x 19/32" x .040j Nut, mudgua,d to frame (¼' a.s.c.) .. Bolt, mudguard to top frame (¼' a.s.c. x 23/32") Washer, mudguard to top frame (¼"x ¾"x n •)

•special material: 16.- ENl5.

43

Per Set

2 2 2

4 4 4

2

2 2 2 4 2

2 2

2 2 2 2 2

2 2

4 2 2 3 3 2 2

2 2 2 2 2 2

Plate 17

" 50

••

,, ?I

70

"' ••

47

••

( ---= 2425

@

44

-23

2, 27 28

~"

15 __.. 07 ,. __,. 20

293031 32 31 11 I I o I I I •

:2'(1~ ' ,. t ~

"b

-

Plate 17 PETROL TANK, TWINSEAT, HANDLEBAR AND CONTROLS

Code Sports No. Description

8.S.A. NO.

I . 19-7221 2. 60-2074 3. 60-2083 4. 37-2006 5. 60-2119 5. 60-883 6. 7. 8. 60-2090 9.

10.

11. 11. 12.

13. 13. 14. 15. 16.

17. 18. 19. 20. 19-7222 21. 40-8121 22. 42-8052 23. 41-8107 24. 2-2395 25. 2-1462 26. 82-9945 27. 14-302 28. 24-8784 29. 21- 1908 30. 54-8003 31. 75-2719 32. 70-5874 33. 14-219 34. 14-115 35. 2- 204 36. 54-9003 37. 70-8960

MAKERS NO.

Rubber grip (left-hand) I 8/952 Clutch control complete

Clutch control cable .. Spring pin for brake cable . .

,

Froni brake cable complete with stop switch - after first sets Front brake cable - first sets only

11 /014

12/595 18/951 M 18/ 1708 18/ 1709 18/ 773 18/ 777 18/087 18/752 18/754

18/053 16/011 16/009 16/010 16/008 16/091

Clamp screw. brake and clutch controls Clamp, brake and clutch controls Brake control complete Cable adjuster. brake and clutch .. Adjuster nut. brake and clutch Bracket, clutch corurol Bracket, brake control

Fulcrum screw, brake and clutch controls Clutch lever only Brake lever only Nut for fulcrum pin Throttle cable stop Screw, friction spring .. Nut, friction spring screw Friction spring, twist grip Twist grip rotor Rubber grip (right-hand) Tank mounting rubber (front) Anti-roll rubber Petrol tank side transfer

Nut, silencer to bracket (¼' e.s.c.) Spring washer, silencer to bracket ( ¼ • x 19/32' x .040') Silencer bracket Nut, bracket to frame (¼" u.N.F.) .•

Spring washer, bracket to frame (¼'x ¼'X .040') Nut, silencer clip(¼' u.N.F.) Spring washer, silencer clip "D" washer, silencer clip Silencer clip complete Bolt, silencer clip (¼' U.N.F. XI½') Bolt, bracket to frame (¼' u.N.F.X ¼1 Bolt, silencer to bracket ( ¼ • e.s.c. x ½ ') .. Screw, heat shield Heat shield

45

Per Set

4 2

2 2

2

2

2 2 2

2

2 2

2

2 2 2

Plate 11-continued

2 /

72 !! ..... 71 ~~c'l ,0 ., .. .. ~

S2 • .. ~ L\ 50 •• ... '~

... -

>

" 62

" ., .. ss

54

2)

2& 27 2•

46

n -,. - -

-

Plate 17-continued

a ,

72 I! -71 ~~c'l ,0 ., "' .. ~

.. • .. ~1, 50 •• ... '~

.. -

]

"

., .. .. ..

n

"

a,

2& 27 2•

] 7-

,.--

-

Plate 11-continued PETROL TANK, TWINSEAT, HANDLEBAR AND CONTROLS

-.... Code Spares No. Drscription Per Set

8.S.A. NO. MAKERS NO.

38. 70-9654 Silencer 39. 27-8560 Spacer, twinseat 2

40. 41 - 9131 Rear bracket, twinseat 41. 2- 51 Nut, twinseat (¼' a.s.c.) 2

42. 2- 1462 Spring washer, twinseat (¼ • x 19/32' x .040") 2 43. 82- 9732 Twinseat complete

44. 68-8024 Petrol tap

45. 82- 8718 Petrol- pipe assembly complete

46. 82- 9204 Seal wa,her, for petrol tap . . as reqd. 46. 65-8218 Seal washer, for petrol tap . . . . as reqd. 46. 65-8219 Seal washer, for petrol tap . . as reqd. 47. 40-8140 , Tank mounting rubber (rear)

48. 68-8046 Spacer tube, tank mounting .. . . 49. 42- 8017 Rubber sleeve. tank mounting

50. 68-8016 Washer, tank mounting 51. 68- 8014 Nut, tank mounting (¼' s .s.c.)

I 52. 42- 8010 Grommet, tank mounting

53. 60-2042 Petrol tank top transfer 54. 68-8045 Bolt, tank mounting (¼' s .s.c . x 2¼')

55. 4Q-8101 Petrol tank with fixed fillings

56. 29- 5655 Washer, tank mounting (¼' x 25/32'x .104' ) ;----, 57. 2- 923 Washer, tank mounting (¼' x ¼' x ,\-') .. 58. 11/013 Body screw, twist grip 2

59. 16/ 328 Body (top-half), twist grip . . 60. 16/329 Body (bottom half) , twist grip 61 . 19-7223 16/ 364 Twist grip control complete . . . 62. 4Q-8657 Throttle cable complete

63. 4Q-4960 Handlebar

64. 41 - 8548 Exhaust lifter control cable ..

65. 42-861 I 18/864 Exhaust lifter control complete 66. 19- 3082 376/079 Clamp screw, exhaust lifter .. 2 67. 19- 3083 12/064 Handlebar clamp, exhaust lifter

68. 19- 3084 11 /014 Lever fulcrum pin, exhaust lifter 69. 19-3086 18/869 Bracket, exhaust lifter

70. 19- 3085 18/871 Lever, exhaust lifter .. 71. 19-3087 Lockwasher, for nut line 72 . .

72. 19-2763 18/060 Fulcrum pin nut, exhaust lifter

NoTE:-Where no B.S.A. Part Number is quoted, the part is only available from the make,s.

-47

Plate 18

~i=:: 33 32 28

---

--48

... "

Plate 18 ELECTRICAL EQUIPMENT

Code Spares No. Deuriptio11

I. 2. 3. 4. s. 6. 7. 8. 9.

10. 11. 12. 13. 14. IS. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 26. 27. 28. 29. 30. 3 1. 32. 33. 34. 35. .36. 37. 38. 39. 40. 41.

42.

8.S.A. NO.

19-8944 19- 9094 83- 281 97- 3689 24-7068

2-47 19- 1166 19- 9089 68-9418 76-543 82-8283

2-525 24-978

2- 1354 83- 281 19- 9080 19- 8936

19-964

19- 982 19- 965

19- 1715 19- 986 7$-9607 19-1472

68-9304 19-1247 19-1775 2-14

75-9102

. ..

MAKERS NO.

RSM.3003/01 Tachometer head (10 order only) Tachometer cable (10 order only) Mounting cup. tachometer head (w order only) Mounting bracket. speedometer and 1achome1er (10 order only) Spring washer. speedometer or tachometer mounting Nut. speedometer or tachometer mounting

54953389 Speedometer light lead . . DF.9110}00, 63 Speedometer cable

Spacer, speedometer or tachometer mounting Screw, speedometer or tachometer mounting Mounting bracket, speedometer head only . . Washer, speedometer or tachometer bracket mounting Spring washer: speedometer or tachometer bracket mounting Boll, speedometer or tachometer bracket mounting Mounting cup. speedometer head

4 1-148-203-108-0 Speedometer trip shaft . . SSM.5001/05 Speedometer head 504665 Wire clip, headlamp light unit

144921 534296

554602 35710

54524000 112201 54140331

38191 38189 281 54945043 54573590 464

989 54524526 534343

49072 54955718 421554

76204

54130041 3 1899 '

Screw. headlamp rim Plate. headlamp rim fixing screw Main bulb holder Light switch Headlamp body .. Bolt, headlamp mounting

,· .

Seal washer. warning light body Warning light body (green) Warning light body (red) Bulb, warning light Bulb holder, warning light Pilot bulb holder, headlamp Main bulb, headlamp Pilot bulb, headlamp Light unit, headlamp

Headlamp rim Rectifier Wiring harness Grommet, high-tension lead

Horn push Ignition lock and key Nut, ignition switch

Ignition switch Bolt, coil clip mounting Spacer, coil clip mounting

Per Se,

4 4

4

4

2 2 2

5

2 2

2 2

Plate 18-continued

wt-·

~ 6. fj-•o ~ 36J,,,;;;~

so

Plate IS-continued ELECTRICAL EQUIPMENT

Code SpousNo. Description Per Set

B.S.A. NO. MAKE.It$ NO.

43. 6S-4093 Coil clip 44. 27-8560 Washer, coil clip mountiog 45. 40-414 Nut, coil clip mounting .. -46. 19-866 421863 Clip, high-tension lead 47. 19-1879 842185 High-tension lead 48. 19-1854 45110 Ignition coil 49. 66-8340 Clip, battery vent pipe 50. 68-9163 Battery vent pipe 51. 19-1735 49345 Zener-diode . . 52. 19-916 34815 Rear stop light switch 53. 2-1096 Washer, stop switch mounting .. 2 54. 42-4574 Screw, stop switch mounting 2 55. 42-4475 Nut, horn mounting 56. 66-4707 Lockwasher, horn mounting 57. 19-2064 Horn 58. 2-2138 Washer, horn mounting .. 59. 75-48 13 Bolt, horn mounting ~- 19-1747 54441582 Condenser, ignition ,1. 47-9170 54190096 Single "Lucar" blade for condenser ,2. 144921 Screw, tail lamp lens 2 63. 54577109 Tail lamp lens 64. 54578213 Bulb holder assembly, tail lamp '5. 573828 Bulb holder interior, tail lamp 66. 19-1245 53973 Stop/tail lamp complete ..

"· 110714 Screw, lamp fixing 2 68. 188330 Lockwasher, lamp fixing 2 '9. 54571677 Gasket, lamp seating 70. 54578212 Base assembly, tail lamp 71. 380 Bulb, stop/tail lamp 72. 82-8314 54953386 Tail lamp lead 73. 19-1249 Fuse (12 volt, 35 amp.) , 74. 2-2395 lll\it, capacitor mounting (ro order only) 75. 2-1462 Spring washer, capacitor mounting (to order only) 76. 82-8320 54483156 ..ing, capacitor mounting (to order only) 77. 2-525 Washer, capacitor mounting (10 order only) 78. 2-1354 Bolt, capacitor mounting (ro order only) 79. 82-8319 54170009 Capacitor (to order only)

19- 1776 54027029 Battery (not illustrated) .. 19-985 60034 Headlamp complete 00--5195 Tachometer • kr complete (to order only) 00-4403 Capacitor kit complete (ro order only)

•NoTE:-Where no B.S.A. part number is quoted, the part is only available from the makers.

51

Plate 19

2 3

G

'I 7

tJ " ' ' / '1 9 I 8

10

, 13

L_ ___ _ _____. -52

L._____ ___ --=--:-------

-Plate 19

TOOI.S AND SUNDRIFS

Code Spares No. Description Per Set

1. 60-767 Screwdriver set

2. 68-9462 ··c" spanner, rear damper 3. 60-801 Tyre lever/tommy bar

•• 65-9132 Tapper spanner s. 67-9026 Ring spanner ,. 68-9464 Plug spanner 7. 29-9252 Tyre lever

8. 40-9017 Double box spanner

9. 68-9461 Tool roll

10. 76-9136 Cable clip 5

11. 90-9024 Rubber cable clip . ' 2 12. 75-9045 Cable clip

3 13. 68-9467 Tyre valve key

60-2114 Toolkit complete

53

Plate 20

3

2

22

211----

54

G

w---- --8

- - -'12 ~.,...---113

>--- ---117

--

Plate 20 CARBUREI IER AND AIR CLEANER

Code Spores No.

B.S.A. NO.

1. 60-1053 2. 19- 7115 3. 4. 19-3093 s. 6. 19- 3095 7. 19- 3094 8. 19- 3107 9. 19-3108

10. 19- 3090 11 . 12. 19-3098 13. 14. 15. 19- 3106 16. 19- 3102 17. 19-3093 18. 19-3103 19. 19-3048 20. 2 1. 19-3105 22. 23. 19-2883 24. 25. 19-3101 26. 19-3100

19-2400

AMAL NO.

4/ 137A 622/086 928/097 622/067 622/061 928/063 928/060 622/ 101 R.930 622/082 622/076 622/077 622/073 622/069 622/086 622/078 376/093 622/050 622/068 622/071 376/100 622/080 622/079 124/026 R.930/1 I

Air cleaner complete Air cleaner element Screw plug for lop cap

Description

Screw and washer for top cap . , Mixing chamber top cap .. Throttle needle clip Throttle slide spring Throttle needle Throttle slide (number 3 cur-away) "O" ring, carbureller flange Carburcl!er body "O" ring, pilot air and lhrolllc slop screws Pilot air adjusting screw . . Throllle slop screw .. Float chamber gasket Float ..

Screw and washer, float chamber 10 body Banjo bolt Petrol filter .. Float chamber Float needle .. Float spindle Main jet (230 c.c.) . , Jet holder Needle jct (.107') Pilot jct (25 c.c.) .. Car burctter complete

NoTE:-Wherc no B.S.A. part number is quoted, the part is only available from the makers.

55

Per Set

2

2

2