Replacement parts list 1972 modglS - BSA Unit Singles

,fiA+

Replacement parts list1972

5OO cmt modglS '"0'ffi.'i;i,*"'

www.bsaunitsingles.com

,SA

Replacement parts listSOOcm'models

B50T Uictor 500 Trail

B50SS

B50SS

CommencingEngine andFrame numbers

Gold Star 500 Street Scramhler

Gold Star 500 Street Scramhler(lNome and General Export)

B50MX Victor 500 Moto-Gtross

lssued byB.S.A. Motor Cycles LimitedSpares Department,Montgomery Street,Birmingham 811 1DZ.Telephone: 021 -772 0559/0537Telegrams: "Selmoto" Birmingham

JG.00101JG.00101JG.00101

B.S.A. Motor Cycles LimitedRegistered Office and Works:Armoury Road, Birmingham B11zPX.Telephone: 021 -772 2381. Telex:33315Telegrams and Cables:"Selmoto" Birmingham

BSOT

BSOSS

BSOMX

This..parts list also covers 1971 models and supersedespublication OO-5721

1972 PublicationRef.00-5732

Printed in Englandby B.S.A. Press


ffiryWW Ths ffiimnflnghnm $mnlt Arms fiurrepany Imeorponm,ted

* (301) 252*-6130BSA ttrlotorcycle e oroeiration s P. O" Box 6 79 0 ' Tovtson, \4d "

f,emffi trwwfs*#wesswffi, @tui2r244

March 24, L972

S UBJECT:

Bulletin +72-02P

ALL EASTERN tsSA DEALERS

Corrections tor L972 Parts Catalogue Ref. No. 00-5732

Listed below are the important addltions and corrections foryour I972 50Occ parts caLatr"ogue" Please make these correc-tions immedlatqly.

Corrections and,/or AdditionsPaqe No" Ref. No.

3

36

38

L-4I41935 &

37&

a

10

T2

Note:

Note:

Change:Change:

Note:

Delete:Delete:

Add:Delete:Add:Add:

Add:

Change:Change:Change:Add:Add:

Polished aluminum tanks for Trail andh4oto-Cross models (/}ru). Hi*violettanks for Street Scrambler model (/315).

00-7009 is a 10cc bottle00-7007 is a 3 cc tubeL9-2429 to R932,/IBL9-2430 to R930/62

Standard rings part number- 00-3481 set+ I/2mm rings part number- 00-3482 set+ lmm rings part number - 00-3483 set19*2430 use R930/62L9-2429 use R932/LB

1\{X after model number7I-3J,48 "H" modelMX after model numberMX after model number

MX after model number

7l*2839* to 7L*323I"l I*284I to 7I*32337G284A tu VL-3232-not avaiiabl"e separately60-3921 bolt * tach drive fixing 2 used6A-2426 spring washer for above 2 used

11

13


March 24, LE72

Paqe No. Ref. No.

-

15 5252

L7 36

23 lt1B

1B

I92431

35 34

37 3s364T

25 4I - 43 Note: A shorter k/s assembly is available,Replace as an assembly only.Item 31 - 57-4556 k/s crank cqmplete

57-4555 k/s crankItem 41 - 57-2330 rubberItem 42 - 57-L272 folding pedalItem 43 - 21-0541 pivot bolt

Add: 54952857 connector breaker lead 2 qsed

27 I Change: two per set - not one3 Delete: 70-9800 not fitted31 - 43 Change: Key numbers to 30 through 42

IllustratioR oR page 26 will then matqh

Deiete: 83-3937 not fitted to US models

33 22 Delete: 19-7458 use 6454370822 Delete: 19*7460 use 6454362623 Delete: 19-7474 use 64052453

Note: 64052455 shock absorber only23 Delete: L9-7456 use 64452487

Note: 64052488 shock absorber only25 Delete: 19-5305 use 64533645

1B29

--2- Builetin +72-0ZP

Correcti.ons and/or Additions

Deiete: 19-1262 Chanqe 47205 to 47204Delete: 19- 1259 use 47226

Note: 41-3095 16 teeth sprocket also available

Change: 6 0- 2 3 tr4 to B i I00 pae k of 50Delete: 19-1922 use 54419653De1ete: 1"9-190ti use 54419652De lete: I 9* i 84 9 use 544L9827Delete: 19- 1852 use 544 i9645Note: 57*4556 k/s crank compiete

57-4555 k/s crank

Delete: 75-2519 not fitted to US models

Delete; 7I-2725 not fitted to US modelsDe1ete: 14-1302 not fitted to US modelsDe lete : 7 1- 17 1 0 not fitted to US mode isDei.ete: 14*0101 and 14-1381 for H model


I{arch 24, 1972 *3* Bulletin *72-0?P

Paqe No. Ref . No. Corrections and,/or Additions--t+

39 Delete: 83-3475 and 83-3476 not fitted

45 1

?U

2939

46

Changei 27-6810 to 27-6813Change: 37-3584 to WMl-SBChange: 19*7707 to 40-5527Note: 37-3969 weight l/2 ounceNote: 37-3970 weight 1 opnce

Change: Following illustration numberg:37 to 36, 36 to 35, 35 to 34,34 to 33, 33 to 32, 32 to 37

Chansez 27-6810 to 27-68i3Note: 37-3969 weight I/2 ounceNote: 37-3970 weight Iounce

chansez L9-8701 to tL0054/I07Change: 19-8711 to 110054,/105Change: 19-8698 to ffl.0054,/106Change: 37-3468 to WM3-SBChange: 27-6810 to 27-68L3

47 1639

496

L718

$5 4048

51 30 Delete: 83-3523 not fitted to US models43 Chansez 42-5840 to 35-6436

53 3 Change: 97-4333 to 97'4833,/0039-13 Delete: A11 rrH' modeis. Not fitted to U$ models26 Add: Models T and SS also use this brasket27-29 Delete: All rr}Irr models. Not fitted to US mo{els

57

Delete: Not fitted to US modeisChange: 19- 1339 to 575189. Delete 57079

i Delete: 60*2242. Chanse 19-952M to L9/9529 Delete: Both numbers. Order camponent partF

on page 65.10 Delete: 60-2243, Chanse 19-i098M to 19/109911 Deiete: 19-7223. Chanse 16/364 to L6/366lI Change: 19-7240 to 532/2L2 Change: 19-7222 to CD520 (pairs)13 Chanse; 60-3499 to 60-387823 Delete: 60-2568 and 2L-2464. Not f itted.

Irlr'tII

ry

:irr I


Paqe No.l+-.|+r-+r

Merch ?4, r972

Ref. No.

253435

43-495 1-5253

54

5557585960616264

Ii?

3

7

13L7L8-2I31 & 36

I2

3

6

6

I

101I13

_1i *

Correct:c-ri:s i:nd/or Additions

Bulletin +72-0ZP

and i9*6061. Not fitted,Iror f:"tted to US models.ro 83- 3946/314ro B3- 2721/3L4ti: 83- 39451315not fitted to US models

59

6l

DeIete:Delete:Change:Change:Change:Delete:

DeIete:Change:Change:DeIete:

Delete:Delete:Delete:Delete:Delete:Delete:DeIete:De lete:

Deiete:Delete:DeIete:Delete:Delete:Delete:Delete:Delete:DeIete:

Del.ete:DeIete:Change:Delete:De lete:Add:Change:

Change:Detete:Delete:

B3-386ri83-3 i808.1*.]';4 ti

83*27i183*3945B3-.43?0

Al.l nurnbers*not fitted to US modols19-7221 tr-r ClD520 (pairs)I9*7241 to 532/A0LBoth numbers " Order component narlp

63

on pilge 65,19*2763 use19*3085 u-se19-3084 use19-3086 use19-3083 usei9-3082 use42*86 1 1 use83*3 179 not

1Bl060IB/87 T

1 r/at418,/g 6 g

12 106437 6/07 e

L8/864fitted to US models

l" 9- 1054 use 6026219*1275 and 60334 not fitted19-1088 use 5452527219-1276 and 54523659 not fitted37I not f rtted19-1095 and 31276, use 31356BSA number use Makers numberBSA number use A/akers numberllSA number use Makers number

19*9I01 use 5495962619-895"i use RSM3 003/1219*9110 tci 19*910019- 8952 ancl SSM5 A07 /03 - not fitted19-8955 use SSM5007102t\{odel number rrTrr to above19*909tJ to DIrg110l04A" Add todesc;ription: 5 ft" 6 in.19*9080 use ]r*52219*91C!1 use 54959626i9--i269 use 39784

66


fvlproh 24, L972 -5- Bulletin +72-0?P

Corrections and,/or Additions

Both numbers. Use 54335169BSA number use Maker numberBoth numbers, order component partp

tgr

67

Paqe IrIo.!+-{t-+*

65 cont.

Ref . No.

L4L7 -2019

38&3946&4751 & s3,61

61*66&70*

I5-77

I11-20232424

Delete:Delete:Delete:

Delete:

Deiete:Add:Add:Add:

BSA numbersOrder under

19-0456 useBSA numbers19- 1776 and

Delete:Delete:Delete:

Delete:Delete:Change:Change:Delete:De lete:Change:Note:Delete:Delete:Delete:DeIete:

Change:

6e

7I

on all of these itenFrMakers numbers

s44s6use makers numbers54427029, use PUZ$A

25

19-3093 use 622/}BGBSA numbers use makers numbers928/060 to 928/060-3L/2622/122 to 622/122*I06BSA numbers use Makers numbers19-3090 and 622/I0L - not fittedR930 to R930,/005R932 not available19-2430 and change R930 to R93p,/6?L9-2429 use R932/Lg19-2834 use 13/16319-3090 use 622/L01

lllustratlon numbers as follows;1 to 9, 2 to l, 3 to L2, 4 to 2,11 to 8, 10 to 3, 9 to 7, 8 to 6,5 to 10, 6 to 11, and 7 lo 4"

19-5390 not fitted to US modelg60-2084 item 1060-I907 ltem l160-3647 item 12

77

GB:ib


MODEL ABBREVIATIONSTRAILSTREET SCRAMBLERSTREET SCRAMBLER - HOME AND GENERAL EXPORTMOTO-CROSS

SUFFIX NUMBERS TO BE USED TO IDENTIFY YARYING FINISHES

When ordering components with varying finishes, please state finish required by adding the appropriate

sufrx to part. number.

EXAMPLE:-Fuel tank (B50MX) Polished aluminium, White centre stripe, Flambordeaux side stripes 83-27211314

I"UEL TANK

TSS

HMX

Polished aluminium, White centre stripe, Flambordeaux side stripes 1314

l3ts

l3ts/003

/30sl3ts

/0031007

1307

Hi-violet

MUDGUARDSRear, Hi-violetChrome

SIDECOVERS

FRONT BRAKE PLATEBlack instrument finish

OTHER PARTS

ChromeBlackSilver sheen

PRICESNo price code is given in this For prices please refer to the latest edition of the Master Price List.

Details of thread form and size are quoted after description of nuts, bolts, screws, studs and washers.

Such as: 14-7006 Socket screw (f," uN.c. x l") : t" diameter unified coarse thread, 1" long under head.

Vital components, which are manufactured from a special material, are indicated by a sign and the

British Standard symbol for the material is quoted at the foot of the page.

ABBREVIATIONS - SCREW THREADS

WhiteHi-violet

B.A.B.S.C.B.S.F.

UN.C.UN.S.

British AssociationBritish Standard CycleBritish Standard FineWhitworth FormUnified FineUnified CoarseUnified Special


BRAKES (LOCKHEED)

AUTOMOTIVE PRODUCTS CO. LIMITED, P.O. BOX 14, SOUTHAM ROAD. BANBURY,OXFORDSHIRE.

CARBURETTERS

AMAL LIMITED, HOLDFORD ROAD, WITTON, BIRMINGHAM 6.

CHAINS

RENOLDS CHAINS LIMITED, WYTHENSHAWE, MANCHESTER.

ELECTRICAL EQUIPMENT

J. LUCAS LIMITED, GREAT HAMPTON STREET, BIRMINGHAM 18.

REAR SUSPENSION UNITS

GIRLING LIMITE,D, BIRMINGHAM ROAD, WEST BROMWICH, STAFFORDSHIRE.

SPARKING PLUGS

CHAMPION SPARKING PLUG CO. LIMITED, FELTHAM, MIDDLESEX.

SPEEDOMETERS

SMITH'S INDUSTRIES LIMITED, MOTOR ACCESSORY DIVISION, 50 OXGATE LANE,LONDON N.W.2.

TYRES

DUNLOP COMPANY LIMITED, FORT DUNLOP, BIRMINGHAM 24.

T-

+


ASSEMBI,IES COMPI,ETE

IT Spares No.

,d

Description

00-7009 I-OCTITE PLASTIC GASKET 00 bottte trade pack).

00 7007 B.S.A. LOCTITE (10 tube rrade pack)

OO 31]4 GASKET SET - DECARBONISING,OO_33I6 GASKET SET - FULI- OVERHAUL.71-1863 ENGINE UNIT, LESS CARBURETTER AND EXHAUST SYSTEM (Trail).1l-2231 ENGINE UNIT, LESS CARBURETTER AND EXHAUST SYSTEM (Moto-Cross).

1l-2234 ENGINE UNIT. LESS CARBURETTER AND EXHAUST SYSTEM (Street Scrambler).7I_1810 CRANKCASE COMPLETE WITH FIXED FITTINGS.7I-3OOI OIL PUMP COMPLETE.71_1675 FLYWHEEL AND CONNECTING ROD ASSEMBLY.]1,2586 CONNECTTNG ROD AND BIG-END ASSEMBLY.57_4302 CI-UTCH ASSEMBLY COMPLETE.83-3996 FRAME COMPLETE (Trail and Street Scrambler).

83 2984 FRAME COMPLETE (Moto-Cross).

9l-4335 FRONT FORK COMPLETE (Trail and Street Scrarnbler).97 4336 FRONT FORK COMPLETE (Moto-Cross).

37-3191 FRONT WHEEL LESS tsRAKE (Trail and Moto-cross) 6" brake.31-3735 FRONT WHEEL LESS BRAKE (Street Scrambler) 8,,brake.37-3792 FRONT WHEEL WITH BRAKE (Trail and Moto-cross) 6" brake.31 3793 FRONT HUB WITH SPINDLE AND BEARINGS (Trail and Moto-Cross) 6" brake.37-3848 FRONT HUB WITH SPINDLE AND BEARINGS (Street Scrambler) 8" brake.37 3958 REAR WHEEL LESS BRAKE (Trail).

3l-3959 REAR WHEEL LESS BRAKE (Moto-Cross).

37-3957 R.EAR WHEEL LESS BRAI(E (Street Scrambler).

31 3180 R.EAR WHEEL WITH BRAKE (Trail).

31-3960 REAR WHEEL WITH BRAKE (Moto-Cross).

31 3991 REAR WI{EEL WITH BRAKE (Streer Scrarrbler).

37 3908 REAR HUB WITH SPINDLE AND BEARiNG (Moro-Cross).3l-3901 REAR HUts WITH SPINDLE AND BEARINGS (Trail and Street Scrambler).OO_5220 TACHOMETER KIT.19-2429 CARBURETTER COMPLETE (Moto-Cross).

19 2430 CAR.BURETTER COMPLETE (Trail and Street Scrambler).

bT


-_=-

PISTON CF{ART

PISTON COMPLETE

+PISTON RINGS (STANDARD)

71-2155

PISTON RINGS (** mm.)

COMPRESSTON (2) SCRAPERUpper Segment

SCRAPERLower Segment

PISTON RINGS (f l mm.)

SCRAPERUpper SegmentModel

TSSHMX

COMPRESSTON (2)

Taper

71-2154

CARBURETTER


,4

INDEX

ASSEMBLIES COMPLETE

CYLINDER HEAD - EXHAUST PIPE

CYLXNDER - CRANKSHAFT

CRANKCASE

OIL PUMP - SUMF - GEARBOX SPROCKET

GEAR CLUSTER

GEARCHANGE MECHANISM

KICKSTART - GEARCHANGE

CLUTCH - PRIMARY COVER

FRAME - BATTERY CARR.IER - TOOL TRAY - ENGINE SHIELD

SWINGING ARM - REAR SUSPENSION - CHAINGUARD . .

REAR BRAKE CONTROL - FOOTREST -SILENCER

AIR FILTER - SIDECOVERS - OII, PIPES

FRONT FORKS ..

FRONT WHEEL (6" Brake)

FRONT WHEEL (8" Brake)

REAR WHEEL _ CHAIN GUIDE

MUDGUARDS - HANDRAIL

FUEL TANK - TWINSEAT - CONTROLS

ET,ECTRICAL EQUIPMENT

CARBURETTER

TOOLS - ACCESSOR.IES

Page

5

8-9

10-11

t2-15

t6-17

18-91

20-2t

)7 -7<

26-27

28-31

32-33

34-37

38-39

40-43

44-45

46-47

48-51

52-55

56-61

62-69

70-7r

72-7t

PIate

Plate

Plate 3

Plate 4

Plate 5

Plate 6

Plate 7

Plate 8

Plate 9

Plate 10

Plate 11

Plate 12

Plate 13

Plate 14

Plate 15

Plate 16

Plate 17

Plate 18

Plate 19

Plate 20

Plate 21

I

2

a

W


----T

T

iKC) ./w',,,,/e)'

/_8

19-- xrsrg cx,rffi

{6- -------- -6)Ws

Plate 1

6#r


Plate ICYLINDER F{EAD - EXFIAUST PIPE

*rModel Key No. Spares No. Description Per Set

TSSH ITSSH 2TSSH 3TSSH 4TSSHMX 5TSSHMX 5TSSHMX 5TSSHMX 7TSSHMX 8TSSHMX 9TSSHMX 10TSSHMX 11

TSSHMX 12TSSHMX 13TSS 14

H14MX 14

TSSHMX 15TSSHMX 16

MX 17TSSH I7TSSH 18

MX 18TSSH 19TSSHMX 20TSSHMX 21

TSSHMX 22TSSHMX 23TSSHMX 24TSSHMX 25TSSHMX 26TSSHMX 27TSSHMX 28TSSHMX 29TSSHMX 30TSSHMX 31TSSHMX 32TSSHMX 33TSSHMX 34TSSH 35TSSH 36

02 0443o2-0525r5-515540 04tlt4-0302r4-040260-242860 23307l-142940 02087t 1627

40-03097 t-11 36

2t-213571,2n77 r-3148tt 28997t-1132l4-13027t-259270 78217 I-142t7 1-2593t4-t6197 1-113568-093 I7r-162665-249465-24957 1-11657t u6621-21337 1-1 989

2I-213421 2492t I-16237 r-163840 096940-096868-02897 t-2938

Nut - vaive lifter (+" B.s.c.)Washer - valve lifter, inner (.255' r .500"X .048")

Washer - valve lifter, outer ('328' x . 505" 'x .048")

IIII7

2

9

9IIIIIJ

I1

IIzIIII7I2Iz2

Spindle - exhaust valve lifterNut - rocker box (t'6" uN.r.)Nut - rocker box, beneath head steadv bracketSpring washer -- rocker box nutWasher - rocker box nut (.333' :< -625'x .040")

Gasket - rocker inspection coverCover - pLrsh rod inspectionValve gLride - exhaustScrerv - push rod inspection cover (2n.a. r l$")Exhaust valveStud -- cylinder head (fi" uN.c./uN.r. x 3+")Exhaust pipe completeExhai-rst pipe complete (low level)E.rhaust pipe completeCylinder head with fixed fittingsNut - carburetter fixing (fi" uN.r.)"Tr-rfnol" washer - carburetter joint"Tufnol" washer - carburetter jointGasket - carburetter jointCasket - carburetter jointCarbr-rretter stud (-:,"" uN.c./uN.r. x 1]")Inlet valveCup - valve spring, bottomValve guide -- inlet .

Valve spring - outerValve spring - innerCollar - valve spring, top . .

Collet - valve springStrrC - cylinder head (16" uN.r../uN.c. / 2#')Dowel - cylinder headStud - cylinder head (*" uN.c./uN.r. ;:2ft')Stud - rocker box (1u-" uN.c./uN.r. x 3]")Gasl<et - rocker boxRocker boxWasher - valve inspection capCap - valve insepection"O" ring - valve lifter spindleLever - exha.ust valve lifter

a

2

4

2

2

2

2

II2

2

1

t

FT


Plate 2

,_reircvffi'ow* -'

30

'rtSE/ tt-/ /',4 --\ii \rltA/

t

I

I

t

r

I

"f;l ;l0


Flate 2CYLINDER -. CRANKSFIAFT

fi Model Key No. Spares No. Description Per Set

TSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSH

MXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXISSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMTSSHMTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMX

40-016240 0r5941-080740-01 59

19-164119-76t6t9-160624-056368 015540-01 57

40-029640 029240 015840-014814-0302l6-001221-20347 t-163566 04921 t-27 41

7 I,t6t64 r -0588lt n9941-055 I71-16817 t-16177t 1618

7 t-151 67 ) -16321I 29701 r,27 45*70-7850]t 1624I r 12t91r-2161'k1 t-2155*1r 2152*7l-25497 1-t2t82t 203341 063914-03047l-162540-029440-01 56

t !-161 51 t-2586

I,J

4

5

6

6

7

8

910

11

l213

t4l5t617

l8t9202l))23

242526^11

28

29

3031

3233

343s36373839404l424344

Nut - rocker spindle (domed fi" n.s.c.)Copper washer - oil feed r-rnion

Nr"rt - rocker adjusting screw ($" n.s.c.)Screw - rocker adjusting 1-r,r" n.s.c.)Thrust washer - rocker spindle

2

2

I2

1

II2

2

2

I

Rocker oil feed pipeCopper washer - oil feed unionSpark plug cover - Champion WC200Spark plug - Champion N4Spark plug

- Champion N3

r^

Rocker complete - exhaustRocker complete - inletThrust washer -- rocker spindle"O" ring - rocker spindleNut - cylinder barrel stud (*" uN.r.)Washer - cylinder barrel stud ('328' x .563" ><.093') . .

Stud - cylinder barrel (1|" uN.c./uN.r. r 3$")Connecting rod completeBr,rsh - connecting rod small-end .

Gudgeon pin . .

CrankpinNut - crankpinBush - connecting rod big-endPeg - crankpin locationEngine shaft - rightFlywheel complete - rightFlyrvheel plugFlywheel complete - leftEngine shaft - left . .

Circlip - gr-rdgeon pin locatingPiston complete (standard)Needle roller - big-end bearingGasket cylinder linerCylinder barrel comoietePiston ring scraper. lower segnrent (standard)Piston ring -- scraper. upper segment (standard)Piston ring -- taper (standard)Peg--cyiinderlinerLir.rer - cylinder barrelStud - cylinder head and barrel fixingWasher - cylinder barrel (.440"x '781" ><.128')Nut -- cylinder barrel ('l5" uru.p.) .

Gasket -- cylinder headRocker spindle - inlet and exhar-rst

Spring washer -- rocker spindleFlywheel and connecting rod assemblyConnecting rod and crankpin assembly

*See page 6 for piston details

I

22

2

2

71

III2

IIII

II2

zII

I

lII

7

1

I444I2

2

II

ll


Plate 3

+-,

II

I

12


Plate 3CRANKCASE

k fr Model Key No. Spares No. Description Per Set

F

I

I

I

I

I

I

I

I

II

J

J

iI

I

2

2

2

1:

TSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSH

MXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMX

14-190r

02-0525

40-0705

414613

2t-1896

2l-1895

7t-l63471-1630

7 1-1629

7t-323t*70-9382

7t-3233

10-9430

71-3232

2+0036

70-943t

70-9383

70-9429

21-1872

70-8896

t4-6219

02-0923

24-0724

71 1422

t0-9384

40 02421'

7 t-1620

71 2513

7r-1680

7 t-2561

4t-0560

2t-2039

40 0455

41 0569

4t-0567

41,0565

J

J

I

iI

I

1

as reqcl-

as reqd-

I

I)J

4

5

5

7

8

8

9

10

11

t213

t415

t6l718

19

20

2t22

tl

z4

25

26'r'7

27

28

29

30

31

32

33

Nut - stator fixing (]" uN.E.)

Washer -- stator fixing (.255" x . 500" X .048")

Grommet - alternator lead

Key - alternator rotorStud - stator fixing, bottom

Stud - stator fixing, front .

Engine sprocket -- 28 teeth

Shim (.015") - engine sprocket

Shim ('030") - engine sprocket

Tachometer drive assembly complete

Gear - tachometer drive shaft

Tachometer drive shaft

"O" ring - drive shaft

Housing - tachometer drive shaft

Sealing washer -- drive shaft

Pin -- drive shaft locating . .

Thrust washer - drive shaft

Pin - drive gear retaining . .

Plug - timing aperture

Washer - timing aperture plug

Bolt - crankcase (jr" uN.c. x l!")Washer - crankcase bolt (.377" x.'625" x.064")Bearing --roller, right (Hoffmann R325L)

Gasket - tachometer drive

Plate - tachometer drrve cover

Screw - tachometer drive (2r.a. y.21 154" countersllnk)

Push rod - inlet and exhaust

Tappet - inlet and exhaust

Canrshaft complete . .

Carnshaft complete

Key - crankshaft pinion

Nut - crankshaflt, right (3" uN.r.)

Lockwasher - crankshaft nut

Pinion - crankshaft

Oil pump drive -- crankshaft

Distance piece - oil pun,p drive . .

*See page 5 for tachometer kit complete.

f Special material: 25-EN8R.

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Plate 3-continued

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Plate 3-continuedCRANKCASE

t- Model Key No. Spares No. Description Per Set

-I SSHMX 34

TSSHMX 35

TSSHMX 36

TSSHMX 37

TSSHMX 38

T'SS H MX 39

TSSHMX 40

TSSHMX 4ITSSHMX 42

TSSHMX 43

TSSHMX 44

TSSHMX 45

TSSHMX 46

MX 47

TSSHMX 48

T SS H IvIX 49

TSSH 50

MX 50

TSSHMX 5ITSSH 52

MX 52

TSSHMX 53

TSSHMX 54

1lt87A14-6502

1 t-2649

24-0724

7F265A

7 l-1631

65-5883

t4-61o2

66-1 518

tt-t4t940-0246

70-3789

40_.0243

40-9190

2t-r8944t-0143

4t-0146

7t-2923

19-8019

19-1262

19-12s9

7 I-11 3t

21,2066

60-392r**

60-2426**

Crankcase complete with fixed fittings

Screw - bearing retaining ring ({" uN.c. x }")Retaining ring - left, crankcase bearing . .

Bearing - roller, left, inner (Hoffmann R325L)

Distance piece -- left, crankcase bearings, outer races

Distance piece -- left, crankcase bearings, innbr races

Bearing - ball, left, outer (Hoffmann LS9)

Bolt - chain oiler blanking (]" uN.c. x $")Fibre washer - chain oiler blanking

Gasket - primary chaincase backplate

Screw - primary chaincase backpiate (2n.a,. xt'6)Backplate -

primary chaincase

Oil seal - primary chaincase backplate . .

Clip - alternator lead

Stud - stator fixing, rear

Primary chain tensioner

Distance piece - chain tensioner

Distance piece - chain tensioner

Alternator rotor (Lucas 54213901)

Alternator stator (Lucas 47205)

Alternator stator (Lucas 41226)

Lockwasher - rotor fixing

Nut - rotor fixing (8" uN.r.)

Bolt - Tachometer drive fixing

Sprin-e Washer - Tachometer drive fixing bolt . .

**Not illustrated

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Plate 4

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Flate 4OIL PUMP - SUMP - GEARBOX SPROCKET

fiaModel Key No. Spares No. Description Per Set

2

2

2

II2

22IIIIIIII3

J

7I+I

III2

2

I

III44A+

I

II

IIiI

I

h*

TSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXT SS H N,IX

TSSHMXT'SS H MXTSSHMXTSSHMXT

SSHMX

TSSHMXTSSHMXTSSHMX

I 14 03022 02,09233 21-18904 40-10335 57-09486 14 03027 02-09238 2t 20429 14-1301

l0 29 054111 41 060312 71-21t913 71-212314 1t-114715 1t-212116 7l-3001t7 14 1901

18 68,093819 21-059719 14-16C)6

20 41-06092t 67-139122 1t-212423 11-212224 1t-211525 4t-070626 1t-114827 70 831528 7t-217t29 71-t42430 11-29333t 14-140132 A2-052533 14-190134 2I-211135 60-353036 41-309436 41-309236 51-430637 40 312138 40 3051

39 90-6A74

Nr.rt - crankcase stud (1|" uN.n.)Washer - crankcase stud (. 3ll" x .625" x .064')Stud - crankcase, rear (fi" uN.r./uN.c. x2#') ..Gearbox dipstickWasher - gearbox dipstickNut - crankcase stud ($"Washer - crankcase stud (Stud -- crankcase, topNut - oil pump drive gear fixing .

Washer - oil pump drive gear fixingDriving gear - oil pumpSpindle housing -- oil pumpDriving spindle - oil pumpSpindle - oil pump driven gearsGear - oil pump feed, drivenOil pr"rmp completeNut - oil pump fixing ({" uN.r.)Washer - oil pump fixing (. 266" x . 625" x. .O56,,)

Stud -- oil pump fixing (f" uN.r./uN.c. x 29,,)Stud - oil pump fixing (f " uN.E./uN.c. x if")Screw - oil pr,rnrp cover plate (t'6 " r.s.c. x l#")Cover plate - oil pumpScavenge gear

- oil pump, drivenScavenge gear

- oil pump, drivingGasket - oil pump . .

Dowel --- oil pump locatingDowel - oil pump body locating . .

Bush - camshaft, at crankcase

uN.r.) .

'317"x.625"x.064")

Scavenge valve completeGasket - scavenge coverSump filterStud - scavenge cover fixing (]" un.r./uN.c. x 1,,)Washer - scavenge cover fixing (.255' x .500',x .048")Nut - scavenge cover fixing (|" uN.r.)f)rain plug - gearbox"O" ring - drain plugGearbox sprocket - 15 teethGearbox sprocket - l7 teethGearbox sprocket - 14 teethLockrvasher - gearbox sprocketNut - gearbox sprocket (l*" r 20 t.p.i.. w.r.)Felt washer - gearbox sprocket

*.'?L1


Plate 5

n

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Plate 5GEAR. CLUSTER

4rModel Key No. Spares No. Description Per Set

TSSHMX 1

TSSHMX 2

TSSHMX 2

TSSHMX 3

TSSHMX 4

TSSHMX 4

TSSHMX 4

TSSHMX 5

TSSHMX 6

TSSHMX 6

TSSHMX 6

TSSHMX 7

TSSH 8

MX8TSSHMX 9

TSSHMX 10

TSSHMX 11

TSSHMX 12

TSSH 13

MX 13

TSSHMX 14

TSSHMX 15

l SSHMX 16

TSSHMX 17

TSSHMX 18

TSSHMX 18

TSSHMX 19

TSSHMX 20

TSSHMX 2ITSSHMX 22

TSSHMX 23

TSSHMX 24

TSSHMX 25

Thrnst washer (. 07 5-. 07 6')

Thrust washer (' 070-'071")Thrust washer (' 080-. 081")

Gear - mainshaft third (24 teeth)

Gear - mainshaft first (16 teeth)

Gear - mainshaft first (18 teeth)

4V0394

29,3851

29-3857

57-3812

40-3020

40-3126

40-3t27

57-3876

40-3019

40-31 t9

40-3120

41-3063

4l-3089

41-3065

40-3007

57-4344

40-3258

40-3262

57-3874

41-3073

51-3817

4t-3018

4t-3070

4i-3068

41 3074

41 3At2

40-3292

40-3265

4l-3045

7 l-127 |

4t-3054

10 6026

1 t-2547

Dowel - inner cover locating, front 2

I

1

I

Bearing - Hoffmann 130

Bearing - gearbox mainshaft, left (Hoffmann 130)

Gear - mainshaft top (22 teeth)

Thrust washer (.093-.094") .. as reqd.

Thrust washer (.098-.099") .. as reqd-

Thrust washer (.103-'104") . . as reqd.

Gear - mainshaft second (21 teeth) I

Y*

Bush - mainshaft, c

Mainshaft complete

lutch pushrod

Shim -- layshaft first gear ..Bush - layshaft first gear . .

Gear - layshaft first (27 teeth)

Gear - layshaft first (25 teeth)

Gear -- la1'shaft third (19 teeth)

Circlip -- layshaft second gear

Gear - la1'shaft second (22 teeth)

Layshaft with top gear (14 teeth) .

Thlust washer (' 083-' 085")

Tl.rrust washer (' 078-' 080')

Bearing - needle roller. layshaft (Torrington B108)

Clutch push rod

Bush - mainshalt top gear

Shield -- left gearbox bearing

Oil seal - gearbox

Circlip -- gearbox oil seal . .

Dotel iuner cover locating. rear

as reqd.

as reqd.

as reqd.

I

I

I

1

I

II

t

I

I

I

ii

as reqd"

as reqd.

I

I

2

I

I

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Plate 6

f\, t

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GEARCHANGE MECF{ANISM

Model Key No. Spares No. Description Per Set

TSSHMX 1

TSSHMX 2

TSSHMX 3

TSSHMX 4

TSSHMX 5

TSSHMX 6

TSSHMX 7

TSSHMX 8

TSSHMX 9

TSSHMX 10

TSSHMX 11

TSSHMX 12

TSSHMX 13

TSSHMX 14

TSSHMX 15

TSSHMX 16

TSSHMX I7TSSHMX 18

TSSHMX 19

TSSHMX 20

TSSHMX 2ITSSHMX 22

TSSHMX 23

TSSHMX 24

TSSHMX 25

TSSHMX 26

TSSHMX 27

TSSHMX 28

67-1236

10-1670

7t-2370

40-3043

40-3042

40-3045

40-3044

57-3850

40-3 193

40-3323

40-3t94

40-3321

40-3059

40-3 I 55

40-3061

57-4454

r4-1302

60-2330

60-2724

40-3291

40-3032

40-3033

57-3854

21-21t7

7t-26s6

62-0263

40-t037

71-26s8

Dowel - crankcase locating

Fibre washer - pressure relea

Pressure release valve complete

Spring plate

Spring - camplate locating

Lockplate - camplate spring

Screw - caniplate spring (2n

Camplate - gearchange

Plunger - gearchange quadrant

Screw - plunger retaining plate (5n.e'. x $")Retaining plate - quadrant

Gearchange quadrant comp

plungers

Rivet - plunger spring

Plunger spring

Gearchange return spring

Anchor bolt - return spring

Locknut __ footchange return spring anchor (t'6" uN.r.)

Washer - 1s{u1n spring anchor

Split pin - camplate spindle locating (3fu" x 1') . .

Spindle-cantplate..Spindle - selector forks

Selector fork - layshaft

Selector fork - mainshaft

Nut -- oil feeC and return pipes

Oil return pipe

Clamp - rocker feed pipe

Rocker oil feed pipe

Oil feed pipe . .

se valve

,A.X 3")

lete

K{t*2t

I

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Plate 7

2343

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70

69=-68

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Plate 7KICKSTART - GEARCHANGE

F".trt

Model Key No. Spares No. Description

, T SS H MX 1 53_3049 plug _ mainshaft oil feed . .

T SS H MX 2 40_0962 Circlip _ crankshaft oil sealT SS H MX 3 40_0971 Oil seal _ crankshaftt - -^ "-*-

' T SS H MX 4 6g_02g9 ..O.' ring _ inner coverT SS H MX 5 75_A257 Breather pipe _ - inner coverT SS H MX 6 404222 Bush _ camshaft, at inner cover .

T SS H MX 7 40-002g peg _ camshaft bush locaring . .

T SS H MX 8 14-6610 Screw - inner cover to crankcase ({" uN.c. x l}")T SS H MX 9 404679 Oil seal _ camshaftT SS H MX t0 70_9526 Sealing plug .

T SS H MX 11 60_2364 Ball _ non_return valve ({,,)T SS H MX 12 40_03g5 Spring _ non_return valve . .

T SS H MX 13 2t_2044 plug _ non_return ..,alve

T ss H MX 14 14-6606 Screw - inner cover, bottom (f " uN.c. x f,,)T SS H MX t5 57_4339 Kickstart ratchetT ss H MX 16 57-4343 Lockwasher

- kickstart ratchet nutT SS H MX 17 76_0211 Nr-rt _ kickstart ratcher

F ,4h ""*" iJ il_i?,i iJ',:Tffi;#J_j:."T_j":::::,::i;:,:;T ss H MX 19 r9-1g49 contact set (Lucas 54419g27)T SS H MX 2A 40-0682 Washer - contact breaker plate fixing (.182'x .375" x .064,,).

-

T SS H MX 21 40-0683 Pillar bolt -- contact breaker plate fixingT SS H MX 22 6g-0331 washer - auto-advance unit fixingT ss H MX 23 r 4-0209 Bolt - auto-advance unit fixing (f', uN.r. r 2],,)T SS H MX 24 19*1852 Contact breaker plate complete (Lucas 54419645)T ss H MX 25 i0_'737 cover - contact breaker compreteT SS H MX 26 54-0042 Fibre r,vasher - contact breaker coverT SS H MX 27 7U7354 Screw - contact breaker cover fixing (2a.a. x l$")T SS H MX 28 40_30j3 Gearchange pedalT SS H MX 29 89_3209 Rubber _ gearchange pedal

' T ss H MX 30 2r-5403 Bolt - gearchange pedal (],, B.s.c. x t,) . .

T SS H MX 31 57_2164 Kickstart lever completeT ss H MX 31 57*2652 crank onry - kickstart lever' T SS H MX 32 57-4357 Cotter - kickstart leverT SS H MX 33 602320 Washer - kickstart lever cotter (.270" x .562" x .055")T ss H MX 34 14-1301 Nut - kickstart lever cotter ({', uw.E.)T SS H MX 35 7l-1423 Gasket .-- contact breaker cover

Per Set

I

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I

I

1

I

I

4

I

I

I

1

I

2

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tI

I

I

2

2

I

I

I

I

2

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I

III

F-'"t

23


Plate 7-continued

2345

$_ro

45.

--* --

-€ 40

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Flate 7-continuedKICKSTART - GEARCI{ANGE

.il|lvf odel Key No. Spares No. Description Per Set

TSSHMX 36

TSSHMX 37

TSSHMX 38

TSSHMX 39

TSSHN{X 4O

TSSHMX 4ITSSHMX 42

TSSHMX 43

TSSHMX 44

TSSHMX 45

TSSHMX 46

TSSHMX 47

TSSHMX 48

TSSHMX 49

TSSHMX 50

TSSHMX 5ITSSHMX 52

TSSHMX 53

TSSI{MX 54

TSSHMX 55

TSSHMX 56

TSSHMX 57

TSSHMX 58

TSSHMX 59

TSSHMX 60

TSSHMX 6ITSSHMX 62

TSSHMX 63

TSSHMX 64

TSSHMX 65

TSSHMX 66

TSSHMX 67

TSSHMX 68

TSSHMX 69

TSSHMX 70

TSSHMX 71

4A-0236

14-6611

57-264t

t4-6612

t4-6614

57-21 59

51-2646

40-3084

40-3085

60,2:,61

l4-5610

14,6605

57 2642

57 -433840,3277

51-4342

57-4341

40-3292

57-21 50

40-3283

71-2946

14-6612

60-3755

40-3282

60-2363

57-4336

40 3272

40 3273

57 4452

16-0528

90-001 I

57-3764

66-3074

2t-1899

14-6608

I t-2652

Screrv - outer cover (2n.e. x 3")

Screw - outer cover (]" uN.c. x 1f")Oil seal - kickstart spindle

Screw - oLlter cover (]" uN.c. x 2")

Screw - outer cover (:1" uN.c. r 2]")Rubber - kickstart lever pedal

Folding pedal - kickstart iever

Bolt - kickstart folding pedal

Spring - kickstart folding pedal

Ball - kickstart folding pedal (f")Screw - ollter cover (]" uN.c. r 1]")Screw - ollter cover (]" t-iN.c. I f")Bush - kickstart spindle

Spring - kickstart lever return

Circlip - kickstart quadrant stop locat;ng

Stop - kickstart quadrant

Kickstart spindie and quadrant assembly. .

Bearing -- layshaft, kickstart spindle (Torrington Bl08)Clutch lever

Pinion - clutch operating lever

Outer timing cover complete

Screw - oLlter cover (]" uN.c. x 2"y

Gromm:t - contact breaker lead

Reck - clLrtcir operating

Ball - clr,rtch push rod (3!")Kickstart ratchet pinion

Bush - kickstart ratchet pinion

Spring - kiclcstart ratchet

Washer - kickstart ratchet

Circlip - gearbox m;rinsha

spring

ft bearing

I

I

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I

I

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I

I

t

t

tt

II

z

I

I

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I

I

I

I

I

I

2

I

I

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Bearing - gearbox mainshaft, at inner cover (Hoffmann LS7)

Anchor - kickstart retllrn spring . .

Dowel - ollter to inner cover

Screwed plLrg - inner cover

Screw -- inner cover (]" uu.c. x l")Inner cover complete

Iio;

25


Plate I

L

L,

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2

26

fr:c


Piate ICLUTCH -- PRIMARY COVER


TSSHMXTSSHMX 1

TSSHMX 2

TSSHMX 3TSSHMX 4TSSHMX 5

TSSHMX 6TSSHMX 7TSSHMX 8TSSHMX 9

TSSHMX 10

TSSHMX 1ITSSHMX 12TSSHMX 13TSSHMX 14

TSSHMX 15

TSSHMX T5.TSSHMX 17

TSSHMX 18

TSSHMX 19

TSSHMX 20TSSHMX 21

TSSHMX 22

TSSHMX 23

TSSHMX 24.TSSHMX 25

TSSHMX 26TSSHMX 27TSSHMX 28

TSSHMX 29

TSSHMX 3ITSSHMX 32T'SS H MX 33

TSSHMX 31TSSHMX 35TSSHMX 36TSSHMX 37TSSHMX 38TSSHMX 39TSSHMX 40TSSHMX 4ITSSHMX 42TSSHMX 43

5t-430257 215610 818270-980076-411668-0839]t 1420

71 1619

83-412260-22527t,2927t4-661060-314571-29322t 215366-307457-40t940-322040 323340-323440-322140-3227l4-040151-418951-41212l-19434t-30914t 32157r-r06514 180441-3212r 9-868340-3206I I-14185l-420040 315057-393157-430357 4508

5745n41,320957-451057-4507

Clirtch assembly conipleteInspection plLrg - primary coverWasher - inspectior.r plugsInspection plug primary cover, ventedScrew - inspectiou cover (2n.1. r *")Cover - timing inspection . .

Gasket - inspection cover . .

Ignition timing pointerBreather pipeClip --- breather pipeStub - breather or-rtletScrew - prirrrary cor-er (a!" uN.c. x l+")Fiiter - breather pipePrimary cover completeScrew - primary cover, at dowel holes (f' uN.c. ><l-39164')Dowel - primary cover locating . .

Pressure plateDriven plate .

Driving plate .

Distance piece - clr-rtch retaining nutLockwasher - clutch retaining nutNut -- clutcl.r centre retaining (|" n.s.c.) . .

Nut - clutch pr.rsh rod adjusting screw ({" uN.E.)Screw - clutch pLrsh rod adjr-rster . .

Cup - pressure plate springDrain plug - primary case

Spring - pressure plateNr-rt - pressllre plate spring adjusterWasher - oil level screwScrew - oiI levelRubber - shock absorber . .

Primary chain - endless (72 pitches)Roller (fr";:fr")Gasket - primary coverClutch hr-rb

Key - clutch hubThrr-rst washerClutch chainwheelRetaining plate - innerClutch centreClutch spiderRetaining plate -- outerRivet - inner and outer retaining plates . .

II2

I4II

I

I

I

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II2z1

5

5

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8

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Plate 9

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Plate 9FRAME - BATTERY CARRIER - TOOL TRAY - ENGINE SHIELD

F, 'ilModel Key No. Spares No. Description Per Set

TSSH 1

TSSH 2

l SSH 3

TSSHMX 4

TSSHMX 5

TSSHMX 6

MX7TSSH 7

TSSHMX 8

TSSHMX 9

TSSHMX 10

TSSHMX 11

TSSHMX 12

TSSHMX 13

TSSHMX 14

TSSHMX 15

TSSHMX 16

TSSHMX 17

TSS MX 18

H18TSSHMX 19

TSSHMX 20

TSSHMX 2ITSSHMX 22

TSSHMX 23

TSSHMX 24

TSSH 25

TSSHMX 26

TSSHMX 27

TSSHMX 28

TSSHMX 29

TSSHMX 30

TSSHMX 31

TSSHMX 32

TSSHMX 33

TSSHMX 34

TSSHMX 35

76-0101

83-22M

83-201 8

t4-0t2610-3751

83-3046

83-2984

83-3996

68492s

60-2332

t4-0252

21,2r60

2t*07 55

37-2085

83-3556

21)16010-8110

83,2005

83-201 5

83-3937

70-8110

2t-0671

r+otl414-1303

10*8170

83-2014

83-2006

2t-2015

r4-1302

75-0t76

t4-1304

60-2332

83-3998

14-1303

60-233r

83*3840

83-3838

Washer -- battery carrier mounting ('266'x '150'x '080')

Bush -- battery carrier mounting . .

Battery carrier

Bolt - engine steady stay fixing ($" uN.r. x *') . .

Washer - oil filler cap

Oil filler cap and dipstick

Fraure complete

Frame complete

Distance piece - exhaust pipe mounting

Washer - engine mounting, front ('458"x'875"x'048')Bolt - engine mounting, front ({6" uN.F. x 3') . .

Bolt -- engine mounting, bottom ($" uN.r. x 8$")

Nut - srvinging arrWasher - swinging a

pivot ({f " uN.c.)

rm pivot

Adjuster - swinging arm pivot, right

Bolt - engine mounting, bottom (3" x 8')

Washer - engine mounting, bottom

Distance piece - engine mounting, bottonl

Engine mounting plate -- rear, right

Engine plate and silencer bracket ..

Washer - engine mottnting, reat . .

Bolt - engine mounting, rear ($" uN.F. x 39")

Bolt -- engine plate mounting, rear ($" uN.r. x f ")

Locknut - engine mounting, rear ($" ux.n.)

Washer - engine mounting, rear . .

Engine mounting plate - rear, left

Grommet - battery carrier mounting

Oil drain plug

Nut - engine mounting plate bolt, rear (1|" uN.n.)

Washer -- engine mounting plate bolt, rear ('328" x '531"x '048")

Nut - engine mounting, front (f6" uN.n.)

Washer - engine mounting, front ('458" x '875" x '048")

Distance piece - engine mounting, front. .

Nut - engine steady ($" uN.r.)

Washer -'engine

steady (*" xt" x5164'l . .

Engine steady stay

Engine steady bracket

4

4

1

2

I

I

1

I

I

I

I

I

1

F

I

I

2

2

I

I

I

2

I

4

I1

I

I

I

4

8

I

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2

I

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Plate 9-continued

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Plate 9-continuedFRAME - BATTERY CARRIER - TOOL TRAY _ ENGINE SHIELD


TSSHMX 36

TSSHMX 37

TSSH 38

TSSH 39

TSSH 40

TSSH 4ITSSH 42

TSSH 43

TSSH 44

TSSHMX 45

TSSHMX 46

TSSH 47

TSSH 48

TSSH 49

TSSH 50

TSSH 51

60-2330

t4-1302

l4-1301

68-4s97

82-9004

68-4577

60_2341

2t-2060

83-2611

s4*8006

83-3554

2t-2137

6V2329

6A2427

14-1301

832228

Washer - engine steady fixing (' 333" x '625' x ' 040") ' .

Nut - engine steady fixing (t'6" uN.r')

Nut - battery carrier mounting (!" uN.n')

Battery tray

Hook - battery straP

Battery strap .

Washer - tool tray mountin g ('270" x '625" x ' 040") . .

Bolt - tool tray and battery carrier mounting ({" uN.r'. x4t'). .

Tool tray

Washer - drain plug

Spindle assembly - swinging arm

Stud - engine shield fixing (|" uN'n. x57164')

Washer - engine shield fixing ('270' x ' 562' x '036) . .

Spring washer - engine shield fixing ('281" x'465'x'092")

Nut - engine shield fixing 1f" ux.n.)

Engine shield

For colour finish codes refer to page 3

2

2

2

1

I

1

4

2

1

f,i

\$im-

3l


Plate L0

;_\@,

1il12

@-209-',

t7 t6 15 14 13

I

ff,, ;

t,

f

,

I

32


Plate L0SWINGING ARM - REAR SUSPENSION - CIdAIN GUARD

r.41il Per SetModel Key No. Spares No. Description

TSSHTSSHTSSHTSSHTSSHTSSH

HHHH

TSSHTSSHTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSH

MXTSSH

MXTSSHMXTSSHMXTSSHMX

TSSHMXTSSHTSSHTSSHTSSHTSSH

L 68-4708

21-2105

3 83-4218

4 83-3165

s 14-1303

6 83-2614

7 83-3793

I 2V2477

9 t4-1304

10 83-3170

11 60-"2339

l2 t4-1302

13 832233

t4 83-3014

15 83*2012

16 83-2244

t7 83-2245

18 83-1959

t9 60-1841

20 24-1088

21 832212

22 19-7458

22 19*1460

23 t9-7474

23 19-7456

24 ru-An425 19-5305

26 60-232'2

Spring - prop stand

Screw *-- prop stand

Prop stand

1

I

t

1

1

I

I

2

2

1

I

1

,2

,}

2

2

2

I

2

2

I

2

2

2

2

4

4

Distance piece - prop stand mounting

Locknut - prop stand screw ($" uN.n')

F .h.'

Chainguard extension

Spring -- centre stand

Bolt - centre stand fixing .

Locknut - centre stand fixing (ft" uN.r.)

Centre stand .

Washer - chainguard to swinging arm ('333'x'750'x'072')Nut - chainguard to swinging arm (i5" uN.r.) .

Thrust washer - swinging arm

Seal - thrust washer

Sleeve - inner

Oil seal -- swinging arm

Needle roller bearing - swinging arm (Torrington B1616) ..

Distance tube - swinging arm bearing

Grease nipple - swinging arm

Fibre wash"r - grease niPPle

Swinging arm complete

Suspension unit spring (Girling 64543708)

Suspension unit spring (Girling 64543626)

Suspension unit complete (Girling 64052453)

Suspension unit complete (Girling 64A52487)

Bolt - suspension unit fixing, top and bottom ($" uw'r'x lf;")

Bush -- suspension unit (Girling 64533645)

Washer - suspension unit fixing, top and bottom(.395'x'750" x'072')

Nut - suspension unit fixing, top and bottom ($" uN.n.)

Bolt - chainguard to swinging arm (fr" uN'F. x 2")

Chainguard

Screw - chainguard extension fixing (|" uN.c' x +")

Spring washer - chainguard extension fixing

Washer - chainguard extension fixing ('270' x ' 562' x ' 036') " '

For colour finish code refer to page 3

27

28

29

30

31

32

t4-1 303

r4-022r

83-2224

14-6101

6A-2417

60-2329

F*a'JJ


Plate 11

h. 1

TF,, ;

f'itrt

i

\

r8

t9

20

TT34 33

37136I r34

t6J,t ifh

YI

35

l3 t4

il-__--\h--{g

I'r1,, q

\

Pe /{n,t\d7

eI

&

34


Plate 11REAR BRAKE CONTROL - FOOTREST - SILENCER

Description Per SetModel Key No. Spares No.

r

TMXTMXTMXTMXTMXTMXTMXTMXTMXTMXTSSHMXTSSHMX

SSHTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMX

SSHSSH

TSSHMXTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHMXTSS MX

H

I 42-4925

2 83-3092

3 t4-0216

4 83-3095

5 14-1302

6 83-3094

7 83-2218

7 83-2220

8 83-2781

8 83-3013

9 14-1303

10 02J138

11" 83-3015

t2 2t-2A45

13 60-2683

t4 83-4277

ls 14-1301

16 14-0103

17 02-2138

18 83-2040

19 83-2616

20 14-1303

2t 83-3017

22 40-4850

23 212094

24 14-1303

2s 40-0157

26 83-3638

27 83-4133

28 144216

29 14-1302

30 68-4835

31 29-1583

32 83-3032

33 14-0218

34 7l-2894

34 75-2519

Rubber -- folding footrest . .

Folding footrest

Bolt - folding footrest pivot ({-" uN.F. x 1-}")

Spring - folcling footrest return

Nut - folding footrest pivot (S" uN.n.) .

Peg -- return spring anchor

Bracket - folding footrest, left

Bracket - folding footrest, right

Folding footrest complete -- left . '

Folding footrest complete - right

Nut - footrest bolt ($" uN.r.)

Washer - footrest bolt ('380" x '750" x '064') . .

Footrest - left

Pivot -- rear brake pedal

Split pin -* brake rod (1f" x $")

Washer - brake rod ('256" x ' 500" x '040")

Locknut - brake pedal adjuster (]" uN.r.)

Screw * brake pedal adjuster (f" uN.r. x f")Washer - brake pedal pivot ('380" x. '750' x'064')Brake pedal

Brake rod

Locknut - brake pedal pivot ($" uN.n.)

Footrest - right

Footrest rubber

Footrest bolt . .

Nut - rear footrest anchor bolt (*" uN.r.)

Washer - rear footrest anchor bolt ('391" x '781'x '031")

Lockwasher - reat footrest, right

Anchor bolt - rear footrest

Bolt - rear footrest pivot ffi" uN.F. x 1+")

Locknut - rear footrest pivot ffi" uN.n.)

Rear footrest . .

Rubber - rear footrest

Rear footrest complete - left and right ..Bolt - silencer clamp

'oD" washer - clamp bolt

"D" washer - clamp bolt

2

2

2

2

2

2

I

I

I

1

1

I

I

I

I

I

1

I

1

I

I

II

2

1

2

2

I

2,2

2

2

2

2

1

)2

F*Vl''

35


Plate 12

q6-

llYq,nll N '',,z'\ I \ll22 * @6

,

F.. '- |

i

)

f*,

38

'f,Si


Plate 12 AIR FILTER - SIDECOVERS - OIL PIPES


TSSHTSSHMXlSSH

MXMXMXMXMXMXMXMXMXMXMX

TSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHT

SSHTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMX

MXMXMXMX

I23

3

4

45

6

78

9

10

11

12

13

l415

16

t718

19202l'r)23

2424252626

27

28?q

3031

3233

83 293760-264r83-354183 329983 3305r'40-2105*14-0101 *

14-0102"60-2421*t4 0102,'14-t 301 'r'

76-0101'o60 3483*83 3035

83 3121

83-363214-010283 218558-91r560-3 l 59

60-353683-293860 316083-2501r 4-010340 2t0560-3 r6 1

14-l 301

21-8560I 4-l 901 *

60)421d',29-A541*83-360514 0401'k

83 200583 200683-341160-373260 373440 8331

B2-943040-832240-832368-834383,307883-307683-3413*83 3474"83-341 5*183-3416*1

Sidecover - leftF,lement - air cleanerAir filter box . .

Air filter box . .

Air filter fixing plateWasher - air filter element fixing (' 266" x ' 469" x ' 064')Bolt _- air filter elernent fixing ({" uN.F. x +")Bolt - air filter box top fixing ({" uN.F. x *")Spring washer - top fixing bolt ('281'x'465" x'064")Bolt - bottom fixing (1" uN.E. r $")Nut -- bottom fixing bolt (|" uN.n.)

Washer - bottom fixing bolt ('266' x'150'x '080")Connecting hose - air filter to carburetter .

Bracket - - sidecover fixing .

Bracket - sidecover fixing

I1

1

III1

2

2

I1

1

III

2

I242

2

2I

I2

I1

I4I1

Tab washer - front fixing bracketBolt -- front fixing bracket (]" uN.r. x f")Rivet -- "Oddie" clip fixing"Oddie" clip - sidecover fixing"Oddie" fastenerClamp -- carbr-rretter hoseSidecover -- rightRubber washer - "Oddie" fastenerConnecting hose -- air filter to carburetterBolt -- air filter box mounting (]" ux.l. x f")Washer air filter box mounting ('266" x '469'x '064')Crommet - air filter box mounting, topNut -- front fixing bracket (]" uN.r.)Washer - front fixing bracket ('255' x ' 625' x '048') . .

Nut -- air filter element fixing (]" uN.r.) .

Spring washer - air filter element fixing ('281" x."465" x'092"1Serrated washer '. stud and element fixingStud assembly *- air filter element fixing . .

Nut - air filter stud fixing (]" uN.r.)Grommet -- air filter box niounting, lowerGromnret - sidecover mountingBreather pipe - oil reservoirTransfer - sidecoverTransfer -- sidecoverFibre wasl.rer -'frame oil filterOil filter -- frameOil feed pipe . .

Nut --oil pipe r"rnion

Clamp -. oil pipeOil feed pipe - franre to engineOil return pipe - engine to frameNumber plate - leftNumber plate - rightNumber plate - leftNumber plate - right

I

2

42

2II

2

III1

4

I1

1

III

*Not illustrated

39

tHome arrd General Export


Plate ll-continued

Itk'-,]

I

I

1#rr, 'i{

I

r8

t9

@t--b

2l

22

r36

Dil*d^s 9Ts)lll

35 34 33

l3 14

il_'____\

A)---{g

/,&

'.f>

45

l*@b

ql

46

36


Plate LL-continuedREAR BRAKE CONTROL - FOOTREST - SILENCER

Description Per SetModel Key No. Spares No.F-'.Cf'II

it'I

t

TSS

TSSH

TSS

TSS

TSS

TSSHTSS

HTSS

TSS

TSS

TSS

TSS

MX

MX

MXMXMXMX

HHHMXHH

71-2895

1t-272s

21-1908

l4*1302

54*8003*

t+220368-0331

14-01 13

7t-2114

7l-17t07t-2401

1t-2901*

14-01 I 5*

02-0370*

l4-r302r'

14-01 16

15-s155

83-4322

r4-t30214-0101 *

14-1381*

82-1387

1l-2402

40-4080

35

35

36

36

37

38

39

40

4l4l

Clamp - silencer to exhaust PiPe

Clamp - silencer to exhaust PiPe

Nut - silencer clamp bolt ' .

Nut - silencer clamP bolt . .

Washer - silencer clamp bolt

Screw - heat shield fixing (]" ux.n. x t'")

Washer - heat shield fixing ('265'x '500" x '064")

Bolt - silencer fixing, lorver (t'6" uN.n. x $")

Heat shield

Silencer

Silencer

Megaphone

Bolt - megaphorre bracket to frame (ff" uN.n. x !'")

Distance piece - megaphone bracket to frame . .

Nut - megaphone fixing (fr" uN.E.)

Bolt - -silencer fixing, top (fi" uN.r. x 1")

Washer - silencer fixing (' 328" x ' 505" x '048")

Distance piece - silencer top fixing

Nut - silencer fixing (fi" uN.r.)

Bolt - silencer to bracket ' .

Locknut -- silencer bracket bolt

Adiuster nut - brake rod ' .

Heat shield - taii PiPe

Distance piece - rear footrest, right

*Not illustrated

1

1

I

I

I

5

5

I

I

I

1

I

1

1

1

I

4

1

2

2

2

I

1

1

I

p.fr

42

43

44

45

46

47

48

TSS

TSS

TSS

37


Plate 12

9

I

I

tuY@ *,

IITK'n,! I l\-. ',' ,,ztl\-\l, %^,22 _@

/ MWv"' lu

>-o, ',ll

ffi,>

38


Plate 12 AIR FILTER - SIDECOVERS - OIL PIPES

Model Key No. Spares No Description Per Set

F:6n TSSHTSSHMXTSSH

MXMXMXMXMXMXMXMXMXMXMX

TSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHT

SSHTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMX

MXMXMXMX

445

6789

10

11

12

13

t415

l6l718

19

202rt123

2424252626)1

2829

3031

3233

83 293160-264183-354183 329983-33051'40-2705*14-0 101 "14-0102*60 2427*14 0102"14-1301d'

76 0101'''

60 3483*83-303583,312183-363214 0t0283-218568-911560-3 I 59

60-353683 293860-3 I 60

83-2501r4 010340-214560-316114-l 301

27-8560I 4-l 901 *

60-2427*29-A541*83 3605

14 0401'k

83-200683-200683-307160-313260 313440-833 1

82-943040-832240-832368 8343

83-307883-307683-3413',8

83,3474*83-3475*t83-3416*l

I7

3

3

Sidecover - leftElement - air cleanerAir filter box . .

Air filter box . .

Air filter fixing plateWasher - air filter element fixing ('266" x '469" x '064")Bolt - air filter elernent fixing ({" uN.n. x }")Bolt air fiiter box top fixing (n!" uN.E. x .")Spring rvasher - top fixing bolt ('281'x '465" ><'064")Bolt - bottom fixing (]" uN.r. x i")Nut - bottom fixing bolt (f" uN.r.)Washer - bottom fixing bolt ('266' 'r. '750" x '080')Connecting hose - ziir filter to carburetter .

Bracket -- sidecover fixrng .

Bracket - sidecover fixingTab washer - front fixing bracketBoit - front fixing bracket (]" uN.n. r f ')Rivet -- "Oddie" clip fixing"Oddie" clip -- sidecover fixing"Oddie" fastenerClamp -- carburetterSidecover - right

hose

I2

42

2II2

1

242

2

2II2

1

II41

2

2

IIII4

1

I

III1

r. .d;

Rubber washer - "Oddie" fastenerConnecting hose -- air filter to carburetter . .

Bolt -- air filter box mounting (f" ux.r. x f')Washer - air filter box mountjng ('266" 'x '469" x'064")Grommet - air filter box mounting, topNut -- front fixing bracket (f" uN.r.)Washer - front fixing bracket ('255' x '625" x '048') . .

Nut - air filter element fixing (|" uN.r.) .

Spring washer - air filter element fixing ( '281" x '465" r '092"'1

Serrated washer - -stud and element fixingStuci assembly - air filter element fixing .

Nut - air filter stud fixing (f" uN.r.)Grommet - air filter box niouttting, Jower

Gromnret - sidecover mounting . .

Breather pipe - oil reservotrTransfer - sidecoverTransfer - sidecoverFibre washer --frame oil filterOil filter -- frameOil feed pipe . .

Nut -' oil pipe unionClamp - oil pipeOil feed pipe - frante to engine

Oil return pipe - engine to frameNumber plate - leftNumber plate - rightNumber plate - leftNumber plate - right

6f*ffi *Not illustraled

39

fHome and General Export


Plate 13

h,* -'t

l

G;,.'l

@-zao@;.r_ro

@-,

tfr*fl40


Plate 13FRONT FORKS

E'ai,Model Key No. Spares No. Description Per Set

TSSHMX

TSSH 1

TSSHMX 2

TSSHMX 3

TSSHMX 4

TSSHMX 5

TSSHMX 6

TSSH 7

TSSH 8

TSSH 9

TSSH 10

TSSH 11

TSSH 12

TSSH 13

MX 13

TSSH 14

TSSHMX 15

TSSHMX 16

TSSH 17

TSSH I7TSSH 18

TSSH 19

TSSH 20

T SS H 2'1,

TSSHMX 22

TSSHMX 23

TSSHMX 24

TSSHMX 25

TSSHMX 26

TSSHMX 27

TSSHMX 28

TSSHMX 29

SSH 30

TSSHMX 31

97-4335

97-4336

97-4426

t4-0236

97-43t',7

t4-6219

42-0157

91-0722

68-5050*

2l-1 809

60-2338

97-2266

21-0518

83-2211

91-4115

91,398s

83-2209

r4-r 303

02-2138

97-4048

97-4050

21-2062

60-2333

60-2630

82-9046

83 2001

97-4031

91-4319

t4,1203

a2-2138

91-3981

97-2270

97-3682

60-2336

14-7308

Front fork complete

Front fork complete

Bracket -- speedometer mounting

Pinch bolt - top yoke ($" uN.r. x 2{")

Nut - steering stem adjuster

Bolt - handlebar clamp (fr" uN.c. x l+")

Washer - handlebar clamp ('330'x '580" t'047")Handlebar clamp

Steering lock and key

Nut - headlamp mounting, top (domed *" uN'r'.;

Washer - headlamp mounting, top ('278" x '625" x '056")

Sealing washer *- steering lock grub-screw

Grub screw - steering lock locating

Distance piece - headlamp mounting bushes

Top yoke complete with lock and keY

Top yoke

Rubber bush - headlamp mounting

Nut -- top yoke pinch bolt ($" uN.r.)

Washer - top yoke pinch bolt ('280" x'150" /:.'064') . .

Bracket - headlamp mounting, left

Bracket - headlamp mounting, right

Sleeve nut - headlamp mounting bracket

Washer - sleeve nut ('520" x I '00" x '056')

Grommet - sleeve nut, headlamp mounting bracket

Washer - sleeve nut (' 375" 'x I '0A" x '064')

Abutment ring - steering head bearing . .

Taper roller bearing - steering head (Timken LMll949L)Steering stem

Nut - bottom yoke pinch bolt ($" uN.r.)

Washer - bottom yoke pinch bolt ('280"x^750"x'064')

Bottom yoke .

Retainer - brake cable

Bracket - brake cable retainer

Washer - steering stem ('781" x.l'50" x '012') . .

Locknut - steering stem (f" uw.c.)

*See page 2 for details of replacement keys

I

II

I

I

4

4

2

1

2

2

I

I

2

1

1

F, {n}-

4

I

I

I

1

2

2

2

2

2

2

I

2

4

I

I or2I or2

1

I

_ll


Plate l3-continued

J=

,?,@-"

.fr=-,r

lGF";-"4

42

if*tl


Plate l3-continuedFRONT FORKS

16- Model Key No. Spares No. Description Per Set

TSSHMX 32

TSSHMX 33

TSSHMX 34

TSSHMX 35

TSSH 36

MX 36

TSSH 37

TSSHMX 38

TSSHMX 39

TSSHMX 40

TSSHMX 4ITSSHMX 42

TSSHMX 43

TSSHMX 44

TSSHMX 45

TSSHMX 46

TSSHMX 47

TSSHMX 48

TSSHMX 49

TSSHMX 49

TSSHMX 50

TSSHMX 51

TSSHMX 52

TSSHMX 53

TSSHMX 54

TSSHMX 55

TSSHMX 56

97-4004

97-4076

97-4A09

97-3996

t4-0240

t4-0239

82-824s

91-40rc

97-4003

97-4020

97-4012

91-3894

97-3893

I4-0302

60-2428

97-3947

r4-1019

2r-2102

97-4032

97-4033

97400t97-4402

97-4007

97401r97-4166

97-4258

97-4028

Washer - damper tube (Dowty)

Stanchion end plug complete

Recoil spring .. 2

Damper tube complete 2

Bolt - bottom yoke pinch bolt ($" uN.F. x 3i\ . . 2

(fr" uN.r.)

k end cap ('344' x'600"x'064') ..

2

2

Bolt - bottom yoke pinch bolt ($" uN.F. x 3")

Star lockwasher - brake cable retainer

Washer - damper

"O" ring - damper valve .

Valve - damper

Nut - damper valve

Drain screw - outer member

Fibre washer - drain screw

2

I or22

2

2,)

)2

8

8

2

2

8

II

2

2

2

2

2

2

1

Nut - fork end cap

Spring washer -- for

Fork end cap

Allen screw - damper tube (1|" uN.F. x 3)Stud - fork end cap (fe" uN.n./uN.c. x 1$")

Outer member complete - right

Outer member complete - left

Oil seal - outer merrrber

Scraper sleeve - outer member

Fork stanchion

Main spring

Washer - top cap nut

Nut - top caP

Dust cover - steering head

.J,

,li

ri1

illi

J,,

'

i

i

I

I

t

43


Plate 14

3l

30

29 -____a

28-- _/

^rP

w

F: _,a

ff;-.-l

;f**-l


Plate 14FRONT WHEEL (6" Brake)

f'.''tfi} Key No. Spares No. Description Per Set

TTTTTTTTTTTTTTTT

TTTTTTTTTTTTTTTTTTTTTTTTTT

MXMXMXMXMXMXMXMXMXMXMXMXMXMXMXMX

MX 15

MX 16

MX I7MX 18

MX 19

MX 20MX 2IMX 22

MX 23

MX 24

MX 25MX 26

MX 27

MX 28MX 29

MX 30MX 31

MX 32

MX 33

MX 34MX 35MX 36

MX 37

MX 38

MX 39MX 39

31-379r37-319227*68t031,379s37-358437-379660-263231-379137-06533',1-3159

14-130460-2332r4-013483-2660t4-130460-2332

21,2063l4-130360-233t31-3694l4-l 303

6A 268342,583660-23313'7-20s837,310431-379931-379837 38446s-s90419-710129-585331-319337-148131 06533t-123157 028037-369731-369631-369537-396937-3974

10

as reqd.as reqd.

Front wheel, less brakeFront wheel, with brakeSpoke nipple ..Wheel rim (WMl x20)

1

1

40II

l

1)34567

8

9

L0

11

12

13't4

Security boltWheel spindleCirclip - grease retainer, rightGrease retainer - rightBearing (Hoffmann 120)

Lock ring - bearing, rightLocknr"rt - anchor strap, at fork leg (1|" uN.r.) . .

Washer - anchor strap, at fork leg ('458' x '875" x '048')

Bolt - anchor strap, at fork leg (1|" uN.r. x 1]")Anchor strap .

Locknut - anchor strap, at brake plate (fr" uN.E.)

Washer - nut, anchor strap, at brake plate(.458'x'815' x '048")

Stud - anchor strap, at brake Plate

[.=f",l!|llf

Locknut - brake lever (*" uN.r.) .

Washer - nut, brake lever ('395'x'75A" x '048")

Brake leverLocknut - fulcrum pin ($" uN.r.)Split pin - brake cable PivotPivot pin - front brake cable

Washer - nut, fulcrum pin (' 395" x '7 50" x ' 048')Locknut - brake anchor Pla.te

Brake anchor plate

Brake camFulcrum pin . .

Brake shoe completeSpring - brake shoe returnLining - brake shoe

Rivet - brake shoe lining .

Hub complete with spindle and bearings . .

Grease retainer - left, innerBearing (Hoffmann 120)

Grease retainer - left, outer

Circlip - grease retainer, leftSpoke-left..

1

I1

II

II1

II1

I1

2

22

l6I1

I1

1

20

10Spoke - outer, rightSpoke - inner, rightBalance weight - shortBalance weight - Iong

lsro45


Plate 15

'FF,,*.'

lffi-'rr

rli'lt ?@ ",,1 I.%Ib# ffi*Je*#**32 3l

,n -6

38jEJ

g

lfl*qi

46


Plate 15FRONT WHEEL (8" Brake)

F4 Model Key No. Spares No. Description Per Set

FM

37-31351 57-02802 37-1231

3 37-06534 3l-1481s 37-38486 31-37967 60-2632I 37-31979 37-3932

10 31,06s311 31-3159t2 37-38t713 60 3669

t4 37-381615 31-31261.6 21-6810'17 37-3'78518 19-174319 19-774420 19-71422l 19-174122 31,376223 37-316124 37-205825 60 2639

26 31,398127 37,399628 14-130329 60-234030 61 064s31 31-401432 31-398633 14 1635

34 37,36s535 19-746636 19-1467

37 37-399738 19,774539 37-396939 37-3974

SSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSHSSH

Front wheel, Iess braket rvve vt*r\r

Circlip - grease retainer, leftGrease retainer - left, outerBearing (Hoffmann 120)

Grease retainer - left, innerHub complete with spindle and bearings . .

Wheel spindleCirclip - grease retainer,Grease retainer - right

right

Distance piece - wheel spindle, right bearing, inner

Bearing (Hoffmann 120)

Lockring - bearingSpoke - right, outerGrommet - brake drumSpoke - right, innerSpoke-1eft..Spoke nipple . .

Wheel rim (WM2x 18)

Abutment - Micram adjuster (Lockheed 25241)

Brake shoe complete (Lockheed 4523'166)

Micram adjuster (Lockheed 3 135-514)

Cage - brake adjuster (Lockheed 25253)

Tappet - brake cam

III

1

IIIII1

II

10

1

10

20

40I2222

2

"O" ring - brake tappetLocknut - wheel sPindle

"O" ring - brake cam

Brake lever - front . .DIdtrE lgvgl -

llvllt ..

Bush - cable to levers, frontNut - anchor plate to fork (3" uN.r.)Washer - anchor plate to fork ('395" x'875" x'048")Washer - cable to lever bush (' 578" x '87 5" x '064")

Return spring - bra.ke levers

Brake lever - rearStud - anchor plate to fork leg ($" uN.c./uN.r' x 1f") . .

Brake anchor plate

Lining .-. brake shoe

Rivet - brake shoe

Bush - cable to lever, rear

Spring - brake shoe returnBalance weight - shortBalance weight - long

2

I2

I1

I1

2

II1

1

210

1

2as reqd.as reqd.

d*S,tr41


Plate 16

fi.'l

(f-

440#

4t

ffi1;;; i |l

frffi\ur-

42

Ort6-s+

L23

T

I

I

@

tl

I

@ 32

s,l48


Plate 16REAR WHEEL - CHAIN GUIDE

F4l' Model Key No. Spares No. Description Per Set

SSH

MX

SSH

MXTSSHMX 1

TSSH 2

MX2TSSHMX 3

TSSHMX 4

SSH 5

TMX5T6

SSH 6

MX6TSSH 7

MX7TSSHMX 8

TSSHMX 9

TSSHMX 10

TSSH 11

MX 11

TSSH 12

MX 12

TSSHMX 13

TSSH 14

T15SSH 15

TSSHMX 16

TMXITTSSHMX 1.8

TMX19SSH 19

TSSHMX 20

TSSHMX 2I

Rear wheel, less brake



Rear wheel, with brake



Lockring - lelt bearing

Bearing - left (Hoffmann

Bearing - left (Hoffmann

Speedorneter drive gearbox

Speedometer drive gearbox

Spindle - rear wheel

x.056")

37-3958

3t-3957

37-3959

37-3180

37-3991

37-3964

37-3152

31-0653

31-t340

37-3749

14-0201

31-3992

31-3741

I 9-870 I

t9-87tt19-8698

37-3947

37-3908

60-n2al4-1301

37-3153

37 0653

37-134A

31-1654

31-3949

3l-3',151

31-37 50

19-9224

19-9223

31-3971

31-3468

27-6810

37-3784

31-3185

37-3'726

37-3125

t2a)120RS)

I

I

I

1

I

I

I

1

I

I

5

I

I

I

I

I

I

I

5

5

I

4i)

I

I

20

10

F :,'til[h

Support ring - left . .

Bolt - sprocket fixing (]" uSprocket - 47 Ieeth

Sprocket - 52 leeth

Chain - rear (t"x ]"x 107 pitches)

Chain - rear ($" x {" x 105 pitches)

Chain - rear ($" x f" x 105 pitches)

Hub complete with spindle and bearings

Hub complete with spindle and bearings

Washer - sprocket fixing (.'270" x'562"Nut - sprocket fixing (]" uN.E.)

Spacer - bearing

Bearing - right (Hoffmann

Bearing - right (Hoffmann

Grease retainer - right

Grease retainer assembly - right . .

Ring - speedometer drive .

Distance piece - speedometer drive

r20)

120RS)

21l10 (BG5330/i04)

2lr @Gs330124)

Security bolt . .

Spoke nipple ..Rim (WM3x 18)

Rim (WM2x 18)

Spoke -_ right

Spoke - left, outer

49


Plate 16-continued

.6tr-l40

lM4t

2a

i

@

rNa

50


Plate 16-continuedREAR WHEEL - CHAIN GUIDE

F". lr Model Key No. Spares No, Description Per Set

TSSHMXTSSHMXTSSHMXTSSHMXTSSHMX

MXSSH

TSSHMXTSSHMX

H30TSSHMX 31

TMX32SSH 32

TSSHMX 33

TSSHMX 34

TSSHMX 35

TSSHMX 36

TSSHMX 37

TSSHMX 38

TSSHMX 39

TSSHMX 4O

TSSHMX 41

TSSHMX 42

TSSHMX 43

MX 44

MX 45

MX 46

TSS MX 47

.r.)

11

23

24

t{

26

1,7

27

28

29

31-3124

l4-1307

83-2266

14-l 303

60-2331

37-3871

31-4034

14-0305

60-2431

83-3523

31-1461

37-3880

37-4049

60-1841

24,rc88

31-3857

37-3812

3'7-3870

37 3925

37-3926

31-2328

37-4071

r9-7140

42-s840

l4-t30340-01s7

A At26

83-42t8

Spoke - left, inner . .

Nut - wheel spindle (*" uN

Washer - wheel spindle

Nut - brake lever ($" uN.r.)

Washer - brake lever ('395" ' '750" x'048") '.Brake lever

Brake lever

Nut - torque arm to brake

Spring washer - torque arm(.531' x'851"><'092")

Torque arm

Pivot pin - brake rod

Spring - brake lever return

Spring - brake lever return

Grease nipple - brake anchor plate

Fibre washer - grease nipple

Brake anchor plate

Brake cam

Brake pivot

Brake shoe complete -- leading

Brake shoe complete - trailing

Spring - brake shoe

Brake pivot pad

Brake shoe lining

Rivet - brake shoe ..Nut - torque arm fixing ($" uN.r.)

Washer - torque arm fixing ('391' x '781" x ' 031 ')

pivot (j" uN.E.)

to brake pivot

10

I

I

1

I

I

I

I

I

1

1

I

I

I

I

I

I

I

I

I

2

2

2

t6

I

1

I

1

F.m

Bolt - torque arm fixing ($" uN.E. x f")Torque arm and chain guide assembly

5t


Plate L7

*-@20

$i$--2r22

29

%l

46

6S_-z+

3432 31 30

39

rI

I

f, {

s'rl

52


Plate 17MUDGUARDS - HANDRAIL

Ffi. Model Key No. Spares No. Description Per Set

TT

T

MXMX

MXMX

TMX5TMX6TMXTTMXS

H9H10H11Ht2H13

SS 13

SSH 14

SSH 15

SSH 16

SSH 17

SSH 18

SSH 19

TSSH 20

TSSHMX 2ITSSHMX 22

T23SSH 23

MX 23

TSSHMX 24

TSSH 25

H26H27H28H29

TSSHMX 30

TSSHMX 31

TSSH 32

1, 97-4015

2 r4-Oll43 97-4333

3 97-4072

4 60-2348

Bracket - front mudguard

Bolt - front mudgua rd fixing (t'6" uN.r. X f;")

Front mudguard

Front mudguard

Washer - front mudguard bracket mounting(.333'x.750" x'048")

Bolt - front mudguard bracket mounting (j6" ul.c. x f;")

Grommet - front mudguard fixing

Washer - front mudguard fixing (' 333" x ' 750' x '048")

Locknut - front mudguard fixing (t'6" uN.r.)

Front number plate . .

Washer - front number plate fixing

"O" ring - front number plate fixing

Screw -- front number plate fixing

Front mudguard

Front mudguard

Rubber bush - front mudguard mounting

Bracket - front mudguard mounting

Washer - front mudguard mounting

Bolt - front mudguard mounting (|" uN.r'. x f,")Star lockwasher

Retainer '_ front brake cable

Bolt - rear mudguard to frame (]" uN.n. x ]")Screw - breather pipe clip (2 n.l. x2ll64')"P" clip - breather pipe

Rear mudguard

Rear mudguard

Rear mudguard

Bolt - rear mudguard fixing (f" uN.r. x |")Nut - bracket to rear mudguard, lower (|" uN.r.)

Bracket - rear number plate mounting ,rightNut - rear number plate mounting (f" uN.r.)

Washer - rear number plate mounting ('270" x '562'x '036")

Rear number plate

Washer - rear mudguard flxing ('255" x '625'x '048')

Nut - rear mudguard fixing (f" uN.r.)

Washer -- rear number plate bracket fixing, lower(.270'x"562' x'036')

I

2

I

I

2

2

2

)2

1

2

2

2

I1

4

4

4

4

1

1

4

I

I

1

I

I

I

2

1

4

4

I

I

1

FfiD

l4-61t460-3242

60234814-1342

83-2834

90-62t9

68-0s97

4A-3044

91-4121

97-4A52

97-4021

974022

602421

l4-0103

82-824s

97-2270

14-0101

97-3894

83-4r23

83-43 I 8

83-4092

83-2934

14--0101

14-1301

832728

l,t-1301

60-2329

83-2726

27-8560

14-1301

602329

53


Plate l7-continued

a8---f\K9

20

ds_2r22

23

%I

466s_-za

35 3432 31 30

LlF,-t

nffiI

54

ffid


Plate L7 -continued MUDGUARDS - HANDRAIL

), -ffir, Key No. Spares No. Description Per Set

MXMXMXMX

TSSHMXTSSHTSSHTSSHTSSHTSSHTSSH

H

TSSHTSSHTSSH

TSSHTSSHTSSH

TSSHTSSHTSSHTSSHTSSH

83-3212

83-2693

t+0102

83-3174

19-1339

6V2391

s4-9017

60-3313

60-3370*

14-0103*

60-2347*

l4-1 301 *

33 82-4717

34 27-8560

35 14-0101

36 83-2727

37 14-1301

38 14-6101

39 83-3254

40 14*0101

4t 14-0101

42 14-1301

43 27-8s60

Grommet - rear mudguard

Bolt - mudguard fixing (f"Washer - mudguard fixing

uN.F. x 81(.210'x'625' x'040')

Nut - mudguard fixing (]" uN.r')

Nut - breather pipe clip (2 n..r..) . .

Washer - rear mudguard mounting ('255'x'625" x'048")

Bolt - rear number plate fixing, lower (f" uN.F. x *') . .

Bracket .- rear number plate mounting, left

Nut - mudguard mounting ({" uN.n.)

Bott - rear lamp mounting, front fixing (f" uN.c. x f")Triple "C" washer - rear lamp mounting

Bolt - rear number plate fixing (f" uN.r. xt') .

Bolt - rear lamp mounting, rear fixing ({" uN.r. x+") .

Nut - support rail and number plate bracket fixing (f" uN'n')

Washer - support rail and rear number plate bracket fixing

('255'x. '625" x '048")

Rubber beading - rear lamp mounting . .

Rear lamp mounting

Bolt - support rail and rea(]" uN.n. x $")

r number plate bracket flxing

\4

Support rail - rear mudguard

Reflector - rear, side (Lucas 57019)

Washer - reflector fixing ('202'x '391'x'032')

Nut - reflector fixing (2 n.r')

Spire nut - rear lamP mounting

*Not illustrated

For colour finish codes refer to page 5

5

5

5

5

1

4

2

I

4

1

I

4

2

2

2

2

I

F "i*rif

44

45

46

47

48

49

50

51

2

I1

)2

I

Frf.fi55


Plate I.8-continued

42-

4l

40-

39

38

37

36

cl--gE_E1-)

_26

r4

rf,f a

56

ifts-irl


Plate 18FUEL TANK - TWINSEAT - CONTROLS

Model I',cy No. Spares Number Description Per Seti ''ffi'

lM

TSSHMX

TSSHTSSHTSSHMXTSSHTMX

SSH

SSH

TMXTSSHTSSHTSSH

MXTSSH

TSSH

TSSH

TSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSS

H

H

TSSH

MX

MX

MX

B.S.A. No.

60-3657

602242

60-3586

60-3585

60-2083

97-4112

97-4062

97-4113

60-38 1 7

60-3s35

2t-2048

19-1332*

60-3583

60-2243

19-7223

19-1240

19-7222

19-9526

40-86s7

60-3499

Makers No.

19-952M

35956

19-1098M

161364

1

1

2

3

4

5

6

6

7

7

8

9

10

10

11

11

12

l213

13

\415

16

17

18

19

20

2l,,1

23

23

23

24

Lever - clutch control . .

Lever - clutch control complete

Adjuster nut - control cables

Adiuster sleeve - control cables

1

I

2

2

I

4

I

I

I

I

2

I

I

I

I

1I

Clutch cable

Clutch clip - handlebar . .

Handlebar ..Handlebar . .

Cable - front brake

Cable - front brake

Pivot screw - control levers

Switch assembly - direction indicator.

Lever -- front brake

Front brake control lever complete

Throttle control

Throttle control

Rubber grip - right handlebar . .

Rubber grip - right handlebar . .

Cable - throttle control

Cable - throttle control

Friction spring

Rotor - throttle control

Nut - pivot screw

Clamp screw

Body - top hallBody - bottom halfNut - friction screw

Screw - friction spring ..Cable stop - throttle control

Transfer - fuel tank

Transfer - fuel tank

Tank badge

Screw - tank badge to tank

Cable clip - rubber, short

MXMX

r4-1301

60-3158

6A-3736

60-2568

2t-2064

90-9024

l61008

161091

r l/013

161328

161329

l61010

16/00e

l61011

I

I

2

2

2

4

6

F"'rfr57


Plate l8-continued

;f \\\;VIl*Ail,,\59 60

62

I

2

e==_-lal5

'420 --@zr---€zz__$

@r-----28

fi'/

{FA

58

S*il


Plate l8--continuedFUEL TANK - TWINSEAT - CONTROLS

Model Key No. Spares No. Description Per Setl *ffi,

+

24

24

TSSHTSSH

MXTSS

TSS

H

HMXMX

TSSHTSSH

MXMXMXMXMX

TSSH 29

TSSH 30

MX 30

TSSH 31

MX 31

TSSH 31

TSSHMX 32

TSSHMX 33

H34T3s

MX 35

SS 35

H35TSS MX 36

TSS MX 37

TMX38TSS MX 39

TSS MX 40

TMX4l

97-4297

66-9049

t4-1302

83-2621

19-6060

83-3866

19-6061

83-2746

19-6062

60-2428

2t-2109

t4-0302

83-27 42*

2t-2166*

14-01 I 3 *

83-2745*

60-2428*

76-9t10

83-3040

83-3208

83-2800

83-2800

83-2801

83-0002

70-73st

83-3180

83-3946

83-2721

83-3945

83-4320

83-2776

82-707 I

03-0101

40-8085

76-4120

03-0101

Cableclip-frame.. 6

Cable clip - rubber, long . 12

Nut - front bracket to seat (S" uN.n.) 2

T'winseat complete I

Twinseat cover

Twinseat complete

Twinseat cover

Seat complete

Seat cover

Spring washer - seat bolt ('344" x '600" x '064")

Stud - seat fixing

Nut - seat fixing

Front bracket - seat fixing (S" uN.r.)

Stud - rear bracket to seat

Bolt - front fixing (t'6" uN.r. x !")Distance piece ._ rear fixing

Spring washer (' 344' x' 600" x'064')Buffer - twinseat mounting

Fuel pipe

Fuel pipe

Fuel tap

Fuel tap

Fuel tap - reserve

Washer - fuel tap

Sealing washer - fuel tap . .

Trim strip - fuel tank, rear

Fuel tank - aluminium (2 gallon)

Fuel tank - aluminium (l gallon)

Fuel tank - steel (2 gallon)

Fuel tank - steel (3 gallon)

Bolt - fuel tank, centre fixing

Distance collar - fuel tank, centre bolt '

Washer - fuel tank, centre bolt (' 328' x I' I25' x '092')

Mounting rubber - fuel tank, centre bolt

Distance tube - fuel tank, centre bolt

Washer - fuel tank, centre bolt (' 328" x 1 ' 125' x '092')

26

27

28

l

F.'fr59


Plate l8-continued

^(l)\El-2eaH-27F]

@__28

(ffi1

60

.,R-*il


---I

Plate l8-continuedF'UEL TANK - TWINSEAT - CONT'ROI,S

Ftft Model Key No. Spares Number Description Per Set

B.S.A. No.

t4 0302

6B-801 6

83-3042

41-801 1

68,801 3

6B-80 1 9

82,9182

42-80r1

03-0101

2t-1999

83-3068

83-3069

19-7221

19-1241

19-1333

19-2763

l9-3087

l9-3085

t9-3084

19-3086

I 9-3083

19-3082

42-8611

83-3875

83-1541

83-3179

82-9222

83-2980

83-3563

60-3152

Makers No.

)

TSS MX 42

H43H44H45H46H47H48H49

SS 50

H51H52

TSS MX 52

TSSH 53

MX 53

TSSH 54

ri:ss H MX ss

TSSHMX 56

TSSHMX 57

TSSHMX 58

TSSHMX 59

TSSHMX 60

TSSHMX 6I

TSSHMX 62

SSH 63

TMX63H64

TSSHMX 65

TSSHMX 66

TSSHMX 66

TSSHMX 67

39595

1 8/060

I 8/87 lrtlaL41 8/869

t21064

3161079

l8/864

Nut - fr,iei tank, centre boit (fr" uN.E.)

Washer - fuel tank, centre bolt

Bolt - fuel tank, centre fixing

Distance tube - fuel tank, centre boit

Rubber ring - fuel tank mounting

Mounting ring - fuel tank

Trim strip holder . .

Mounting rubber - fr-iel tank, centre bolt

Washer -- fuel tank, centre bolt

Nut - fuel tank, centre bclt

Grommet - fuel tank, centre

Gronrmet - fuel tank, centre

Rubber grip - left handlebar . .

Rubber grip - left handlebar . .

Switch assembly - dip switch

Nut -- exhaust lifter fulcrum screw

Washer - exhaust lifter fulcrum pin

Lever -- exhaust lifter

Fulcrum screw - exhaust lifter lever

Bracket - exhaust lifter .

Clamp -- exhaust lifter

Screw - exhaust lifter clamp

Exhaust lifter control complete . .

Filler cap - fuel tank

Filler cap - fuel tank

Trim strip - front

Rubber - fuel tank steadY

Rubber - fuel tank mounting, front

Rubber - fuel tank mounting, rear

Cable - exhaust lifter control

*See page 65 for handlebar switch details

6l


Plate 19

ffit

62


Plate 19ELECTR.ICAL EQUIPMENT (PAR.T 1)

e\Per SetModel Key No. Spares Number Description

TSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSH

TSSHTSSHTSSHTSSHTSSHTSSHTSSH

MXTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSH

BSA No. Makers No19-1054 6026219-1215 60334

553343

l9-1088 s452s27219-1276 54523659

504665

989

545135903103ll534296144921

91 4241554602

l4-0404tsr-rlb holder - maNut - headlamp i

(fr" uN.r.)

1

1

2

-t

345

6

7

7

8

910

11

t2

Headlamp completeHeadlamp complete - FranceHeadlamp rimLight unit . .

Light unit - FranceClip - light unit fixingBulb - pilotEulb holder - pilottsulb - maintsulb - main, for FrancePlate - headlamp rim fixingScrew - headlamp rim fixingBracket - headlamnp lnteflor support

1

I1

1

I6

II1

II1

I1

l3t4t415

t6t718

18

t9202ltt

232425

262728293031

3233

3435363737

l9 1095 3t2165436345354363455545252t228t

lnnterior support fixing

\16Switch - hrheadlightDirection indicator warning light - amberMain beam warning light - green

Rubber cllp - warning lightsBulb - warning lightsHarness - headlamp to electrical box . .

Main harness .

Ignition harnessFuse - main harness, 35 amp. . .

Harness - electrical boxRear lamp completeScrew - rear lamp lens fixingLens - rear lampBulb - rear latnpBase plate - rear lampInterior bulb holder - rear lampGasket - rear lamp lens backingWasher - rear lamp fixing screw

Screw- rear Iamp fixingEarth lead (included in main harness) . .

Lens assembly - direction indicatorBr"rlb - direction indicatorlnterior assembly - direction indicatorBulb holder - direction indicatorGasket - direction indicatorDirection indicator lamp completeStanchion - direction indicators, frontStanchion - direction indicators, rear ".

2

III2J

I1

I1

II2

I1

1

I1

2

2

I

44

44

4422

)19 1096 5496011319-1270 5496012119-1340 5495964919-1249 188218

19-1211 5496012019 1245 53913

144921

54511109380

54s252865138285451 1 611

1 88330

1107 1 4

19-1068 5458163838257383255454854580300

19-1067 s6r4197-424883-3525

Note:-Where no B.S.A. part number is quoted, that part is available only from the manufacturer'

;i*'"ne.

63


Plate 20

Its' ..:

rF' 4

d'\l-66

36

&tn,,&

ft:e

fr_.,ti

\

62

63 I

i'L#(

fi;l64


Flate 20ELECTRICAL EQUIPMENT (PART 2)

"m,r}Model Key No. Spares Number Description Per Set

TSSH 1

TSSH 2

TSSH 3

TSSH 1

TSSH 5

TSSH 6

SSH 6

T6TSSH 7

TSSH 8

TSSH 9

TSSH 10

TSSH 11

TSSH 12

TSSH 13

TSSH 14

TSSH 15

TSSH 16

TSSH 17

TSSH 17

TSSH 18

TSSH 18

TSSH 19

TSSH 19

TSSH 20

TSSH 2ITSSH 22

TSSH 23

TSSH 24

TSSH 25

TSSH 26

TSSH 27

TSSH 28

TSSH 29

TSSH 30

TSSH 3I

BSA No

19-9101

l 9-89s3

l9-91 10

60 2600

9l-4026

19-8952

1 9-8955

1 9-8958

60-2600

97-4026

19-9098

l9-9080

l9-9101

19-1269

82-698 r

N{akers No.

54959626

RSM3003/r3

s49s9626

643

39184

1-6280

54115246

185022

54340883

54340882

54033661

54033666

39596

39595

49345

Light lead - tachometer

Tachometer

Cable -- tachometer drive

Rubber cup - tachometer

Mounting bracket - tachometer

optional

lm

SSM5007/03 Speedometer - k.p.h.

SSM5007/02 Speedometer - m.p.h.

Speedometer - m.p.h., with reversible trip

Rubber cup - speedometer

Mounting bracket - speedometer

Cable - speedometer drive

Trip shaft - speedometer

Light lead - speedometer

Bulb - speedometer and tachometer

Switch - ignition and lights

Lock and key - ignition and lights switch

Screw - handlebar switch clamping

Washer - handlebar switch clamping . .

Lever half - switch assembly, left

Lever hall - switch assembly, right

Switch half - switch assembly, direction indicator

Switch half - switch assembly, dip

Switch assembly - direction indicator . .

Switch assembly - dip

Zener diode (2D715)

Nut - bracket to frame, front (]" uN.r.)

Washer - bracket to frame, front (' 210" x ' 562" x '036")

Clip - speedometer and clutch cables .

Shakeprool washer - earth lead fixing

Bracket - electrical box mounting, front

tsolt - bracket to frame, front (]" uN.E. >< $"). .

Shouldered bolt - electrical box mounting . .

Washer - electrical box mountin g (' 317 " )< ' 625" x ' 064')

Grommet - electrical box mounting . .

Nut - bracket to frame, rear (f" uru.r.)

Washer - bracket to frame, rear ('27A" x '562" x '036')

I

I

I

I

I

I

I

8

8

I

I

I

I

I

1

1

2

2

2

I

I

2

J

J

J

2

2

1 9-r 363

t9-1364

19-1331

19-1334

19-1332

19-1333

t9-1135

l4-1 301

60-2329

83-3543

29-0541

83-38 14

u-a1022t-2128

02-0923

60-3621

1 4-1 301

60-2329

65


Plate 20-continued

(%^'Xw-'s

fi "'1

4+F 4\=:: _E-;;,re F" &--'u3i - --i9 e_28

&',-e

66


=--

Plate 2O-continuedELECTRICAL EQUIPMENT (PART 2)

Model Key No. Spares Number Description Per Set

,ffi,

TSSHTSSHTSSHTSSHTSSH

MXMX

TSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSH

BSA No

83-381 3

14-0101

14-6101

29-0541

83-38 I I

19-11 47

t9-1841

19 1345

60-2391

82-4117

83-4103

83-26'.70

76-0293

2t-1930

I 9-l 858

19-nt575-0208

4l*9030

9A-6219

19-0916

82-1044

19-1011

83-2669

76-0293

29-3319

21-2061

2t-2067

29*3319

32

-lJ

34

35

36

37

38

38

39

40

4t42

43

44

45

46

47

48

49

50

5l52

53

54

55

5tt

5/s8

59

60

6t

Makers No.

54190108

54441582

54420128

57183

Screw - clamp strip

54170009 Capacitor(2MC)49412 Rectifier (2DS506)

34815

54422864

54419914 Coil clamp

Bracket - electrical box mounting, rear . .

Bolt - rear bracket to frame (f" uN.n. r ]")Bolt - cover to electrical box (f " uN.c. x +")

Shakeproof washer - electrical box cover fixing

Cover - electrical box

Double "Lucar" connector blade .

Condenser

Condenser

Reflector - electrical box (RERl4)

Washer - reflector fixing (. 202" x . 39 I " x. . 032')

Nut - reflector fixing (2]" n.l.)Electrical box

Clamp strip - headlamp harness terminal

Washer - clamp strip (.203" x.375' X .036')

Screw - stop switch fixing

Clip - stop switch cable

Washer - stop switch fixing

Stop switch - rear . .

Distance piece - stop switch

Moulding - capacitor condenser and flasher unitPlate - capacitor rnoulding support

Washer - capacitor moulding (.203'><..375' )< '036')

Shakeproof washer - capacitor moulding

Screw - capacitor moulding

Screw - coil clamping

Shakeproof washer - coil clamping

I

2

4

4

I

1

I

I

2

2

2

1

1

2

2

I

1

2

1

2

1

2

1

I

2

2

2

2

2

I

It9-1881 45223 Coil - ignition (11M12)

67


Plate 20-continued

4

,@

a€:t *-€

<%,

Rl,"6t[-.,

@n-*

\.A*u'62M

'u&

(6.52.,

6C'Tr^

w'q"s&.=Avi * ''\

68


-=-F

1

I

Plate 20-continuedELECTRICAL EQUIFMENT (PART 2)

,@ Model Key No. Spares Number Description Per Set

MXMXMXMXMXMXMX

MX

BSA No. Ma,kers No.

61* 19-0456

61* 83-3306

61* t4-0214

61* 14-0104

61* 14-02t3

61* 14-0102

61* 60-2427

61* 14-1301

Coil - energy transfer ignition . .

Bracket - coil mounting

Bolt - coil and bracket (f" uN.n. x 4")

Bolt - coil to bracket ({" uN.n.}$")Bolt - bracket to frame ({" uN.n. x 3}")

Bolt - condenser fixing (f" uN.F. X 3")Washer - condenser fixing

(.281'x .465'x .064')

Nut - coil bracket, frame, condenser fixing(f" uN.r.)\4 --..--/

Rubber cap - high-tension lead

Clip - high-tension lead contact

High-tension lead ..High-tension lead (suppressed) .

Battery vent pipe

Flasher unit (8FL)

Nut - horn fixing ({" uN.n.)

Washer - horn fixing (.270" x .625' x .040') . .

Grommet - horn fixing .

Horn - 6H, high note

Distance piece - horn fixing

Bolt - horn fixing (]" uN.r. x f")Battery (PUZ5A) . .

*Not illustrated.

1

I

I

1

I

1

I

4

I

I

I

I

I

1

2

4

2

2

I

2

I

,.ffi

TSSHTSSHTSS

H

TSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSHTSSH

62 549490tt

63 421863

64 549s6424

64 54956466

65 68-9163

66 l9-105s 35048

67 14-130r

68 60-2341

69 60-3161

70 t9-2086 10228

7r 83-3604

72 14-0103* t9-1176 54021029

Note:-Where no B.S.A. part number is quoted, that part is available only from the manufacturer.

iI

69


Plate 21

,,,,

24

2

&8+(6)

'-----€

il---\

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4f

70

s*{


- _!fF

Plate 21CARBURETTER

)Model Key No. Description Per SetSpares Nuniber

r,!r1

TSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSH

MXTSSHMX'TSSHMX

TSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSHMXTSSH

MXTSSH

MXTSSHMXTSSHMXTSSH]UX

B.S.A. No.

1 9- 3093

1 9-3095

19-3131

19-3121

Makers No.

6221086

4lt3t A9281091

622lt3r

6221061

6221124

9281060

6221122

6221128

3761100

376/100

622101t

6221068

622l0ss

31610e3

6221078

6221r47

622lrst

6221086

6221069

6221073

6221017

6221076

6221082

622110t

R930

R932

R930i2

R932/18

131163

6221rc|

1.,

3

4

5

6

7

8

9

tr0

IO

11

t213

t415

16

t718

19

20

2t))tt

23

24

24

19-3i16

1 9*3 105

t9-3143

19-3048

19 3103

19-3144

1 9*3093

19-3r02

l9-3 106

19 3098

l 9-3090

Screw and washer - top cap

Screw plug - top cap

Cap - mixing charuber . .

Spring-throttle..Clip - throttle needle

Needle - throttle

Throttle slide (No. 3] cutaway) ..Needle jet (' 106) . .

Jet holder . .

Main jet (200 c.c.)

Main jet (250 c.c.)

Float spindle

Float needle

Float chamber

Fuel filter

Banjo bolt . .

Drain plug . .

Washer - drain plug

Screw and washer - float chamber to bodv

Float

Gasket - float chamber ..Screw - throttle stop

AdjLrsting screw - pilot air

"O" ring - pilot air and throttle stop screws. .

"O" ring - carburetter flange

Carburetter body .

Carburetter body .

Carburetter complete

Carburetter complete

Washer - carburetter banjo

Adaptor - carburetter to air intake

"O" ring - carburetter to head

2

I

I

I

1

I

I

I

I

I

I

I

I

I

I

I

I

I

2

I

t9-2430

19,2429

t9-2834

71-1 860

I 9-3090

I

7T

b,,ft


Flate 22 -

iI1

,4

G {

#

{

72

ewww.bsaunitsingles.com

i

b

TOOI,S - ACCESSORIES

@ Model Key No. Spares No. Description Per Set

TSSH

TSSH

H

TSSH

TSSHMX

TSSH

TSSH

H

TSSH

TSSH

TSSH

TSSH

TSSH

65-9132

6W767

68-9464

60-2184

60*371 I

60-191 1

68-9461

l9-5390

75*9089

6A-2114

60-2084

60-1907

60-3647

1

.,

3

4

5

6

7

8

9

Spanner

Screwdriver set

Plug spanner ..

Suspension unit "C" spanner

Tommy bar

Tommy bar

Tyre valve key

Licence holder complete

Tool roll

Tool roll complete with tools

Open-ended spanner

Ring spanner - small

Ring spanner - large

I

I

I

iltT

A COMPLETE RANGE OF B.S,A. SERVICETOOL CATALOGUE, PUBLICATION No.

TOOLS IS CONTAINED IN THE SERYICE00-5126, AVATLABLE UPON REQUEST

,ffi

73


Sparesnumber

NUMERICAL INDEX

Page Key Pernumber number set

Sparesnumber

Page Keynumber number

Perset

Sparesnumber FPage Key

numb:r numberPerset

II

00-3 1 7400-31'7400-33 I 6

00-33 I 6

00-522000-700700-7009

02-037002-044302-052502-052502-052502-092302-092302492302 092302-2r 3802-21 3802 213802-21 38

03 010103-010103-0101

14-0101l 4-010114-010114 0101l4-0101I 4-010114 010114 010114-010214 0102l 4-0 10214 0102l4 0102I 4-01 02l 4-010314 01031 4-0103l4-0103l4 0103l4-0i0414 01 13

t4-01 I 314-01 14

l4-01 14

14 011514-01 1614 0t2614 0126_14-013414420714-020814 0213t4 021414-021614-0216144218144221t4-023414 023614-023914 024014-0252

202435404I11

6 ..46266ll6t417

T1

6l39

2l2 ..

L)4 ..

4611

4 ..?1

61

61

]R

28)4)

36Jbl0

14 030214-030214,030214 0302I 4-030214-0302l4-030214-030414 030514-040i14-040i14,010214 040414-t0t914,t20314 130ii4-130114 130114-1 3011,1-i 301l4-1 30 I14 130114-1 3011'l-l30I1+130114-130114 1301l4-1 301I 4-l 30114-l 301l4-130114-1 301I 4,1 30114-130114,1 30114 130214-t30214-1 30211,130214-130214-130214,130214-130214,130214 1302l4,l 30214 130214-1 303i 4-1 30314 13031 4-1 30314-l 303l 4-1 303l4-130314-1 303t4-l 30314-l 30314,1 30314-l 30314-1 30314-1 304I 4-1 30414-l 30414-1304l4-r30714 140114-1606

5

I4I6

4428L)4t?a

2223

5

t24725

9

J+385015

14 1619t4-16351,1 190114 190114-190114-1901t4-220314 6101l4 610114-610114 610214 61t1l4-6219t4-621914 6502t4-6606t4-66061 4-660814-661014 661014-661014-66tt14-66121+661214-661414 730814-7801

t5 5155I 5-51 55

r 9-045619-0916l9 10541 9-1 05519 10671 9-106819-107719 1088I 9-109519-109619 124519-121919-125919 t2-62t9-126919 127019 l27t19-127 519-121619 t33219-133219-1 33319-1 33319-133419-133719-1 339I 9-1 340I 9-1 34519 136319-136419-171519-1 735l9-t74719 177619-1847I 9-l 849

937

9 .. 19+ I JJ13 It7 1Tt7 3339 i937 3733 3055 3867 3115 4153 s13 1941 4t5 3523 11?i L1

25 1023825 4621 l125 3725 1rl

25 5725 4041 31)1 ?q

5J

5

5

5

5

5

3799

l317

i3l71'7

6535354l4t

,s9 38_s9 416i 50

it395353555555673939395565693539535569693759295337372951

454923696935353533334l434329

1

I

1

J

4J

223

1

I

1

4

I1

I

21

41

24222I2

221

I2

5

2I1

242II21

I5

I1

I22t1

41

22I

9l117

17

43596l11

51

2739

9bJ434l172331

31

35

373939495353535555555765656969

93721

293l3335353TJI

53

592929J-l

JJ

35353541

4545

51

51293345455il717

74

179

252731

2

2

2

28

2I4II1

2222I1

22I2I2

5

24i5

42222422I1

421

2

2I2

2

2I2

1

4

2

I3

3

41

5It4I2

3

44z1

I+

i22

J1,

2027

L6

10t7i6LN

3 ..43

2II

1

l+

37 :.42t62t30olb7l6351.7

273T

125 ..

2936458 ..

))325 ..

)1a

20

15

16l92875

++299 ..9 ..

13?1

31

19

{F696763696363676363636363l515

6563636363

7

6561

6565655563676565676561696723

6l5l

1

663631

53

3

13

1721

19

525213

18

20IJ

9t954

.19

. l8

. 13

.48

. 18

.39

.11

.17

.47

.20

.38

+4

2I1

1

4I

:: 38 .:19

4erf*


NUMERICAL lNDEX--continued

tu Sparesnumher


Perset

19-18521 9,1 858l9-l881I 9-1 90619-192219 208619-242919 242919-2430t9-243019 21631 9-283419-304819 30821 9-308319-30841 9-308 5

19-30861 9,30871 9-3090I 9-30901 9-309319 30931 9-309sI 9-3098l9-310219-3103l9-310519-3r0619-311619 312719-313719-3 143

19-3t441 9,530519 539019-606019 6061t9 606219-122119,722219 722319-724tt9 724119-745619-7 458t9 7460t9-146619,7 46719-7 47 419-160619,761619-764119-710719-774019-T74119,714219 174319-T'74419,174519-801 9I 9-868319 8698I 9-870119 871119-8952l9 89s3

/)6167232369

5

7t5

1t61T1'71

61

61

6t61

6I61

TI7l71

71

TI'71

7l1t7l1l'7r't1

11

TI71

JJ

135959596t57575761

3333

3347

1

4T

11

11

11

4551

47

4i47L1

15

274949496565

aA

4661

i3t8TO

55

146l60585759562325l..

185 ..

23t9l5122011

7 ..

531211

11

53

2322223536236 ..6 ..5 ..

29

21

20td19385l326 ..6 ..6 ..6 ..2 ..

2

2

I2

,ffi 6l31625

8

2222

102I1

1

2222222

F

Sparesnumber

Page Keynumber n'.unber

Perset

19 895519-895819,908019 909819-910119,910119-911019,922319 9224t9-9526

21-05782t 059721-06Tt2 1-075521-1 80921 -1 8722l-18902r-r8942 l-1 8952r-1 8962r-189921-190821-19302l-19432t,199921-20i 5

21,-203321 20342t-201921-24422t-20412t,204521 20482r-206021,20622l-20632t-206421-206621 20672r-24572r-207721 10922t-209421,21022t-21052t,zlag21,21092t-2t112r-2ttT21-212821-21332t-21342t-2t3521-2t372t-21532l-21602t-2t6021-21662t-5403

24-003624-0s6324 072424-0724

65 6 .. I65 6 .. 1

65 10 I65 9 .. 1

65 I .. I

65 11 I65 3 .. 1

49 15 1

19 15 1

51121

I41

222)-

I8

1

221

2J

22J

221

22

1

4t1'7

29294I13

1T

15

13

l32531672T

612911

11

i31T

233557

31

41

455115

616T

339

354333

5959t721

659

99

31

2729)95923

13

II13

l5

11

19

2012

I ..17

3 ..486 ..5 ..

69

45a5

51)63916)q3 ..

l3l28 ..

4318

15

5457588 ..

3023482 ..

2"1

2134)4)1272913.L1

1411

15

30

13

1 ..2t37

I2II

75

Spares Page Keynunrber nnnrber number

Perset

24-1 08 3

24 1088

27-68 10

27 681027-68 l 027-856027-8560z7-8564z7-8560

29 054129,054129 054t29-054129-33 19

29-331929-385729,38s729-585329-7583

37-065337-065337-065337 065337-065337-06s337,123737-123737-134037,134031-146137-148 I37-148137-165437-205837 205837-208537,23283T 346837-358437 365537-369437,369537-36963-t-3697]-r-31043T-372431-3',72537-312637-372631-3135ji,37353'7-374131-3'74937,375031 -31 51

3't-3'15237,3'.7533'7-1'.75937-3'7593-t-3"7613'7-3'16237-3784

lt396567676719

19

4535

'1545174149191541494951

454749454T2951

494547454545454551

494'l49

5

474949494949494547474'l

5

l223f{

13

401T

3

1418

38)t361A

222ll<

20

335l

45-t1

493953

5555

.20

.34

.1

. t6

- Id

.30

.34

.43

.2

.l

.40

.40

.40)

.tI)

2

1

1

I101020

I10102020

10:l243556592 ..2 ..

303l

I21

4221

I16

2

7 ..33

3 ..102 ..

11

342 ..2 ..

11

31

1 ..

22

5J

1413

1

108

1l2322


NUMERICAL INDEX-continued

Sparesnumber


Perset

Sparesnr"rmber'


Perset

Spares Page Ke,vnumber numberTnuntber

Perset {:r

37-3780i t-) t6+3'.1 3'78s37-3T8537-3'79t37-f1913't-3',r9237-3'79231-3-19337-379337 319s37-319637-3'79631,3'79731-379137-379831,379937-380437-38 r 637-381737-384837-384837-385737-387037-38'72.3',7-387'l37-3880i7-39013'7-390737-390837 390837-390937-392537,392637-393237,39573',7-39s737-395837-395831 395931-395931 396037-396031-39693'7-39693T-397037,397031-397'737-398637,398737 -399137-399137 399237 399637 399137-401437-403137 404937-4071

40-002840 0143.40-015640-0 l 5740-015740-0157.40-0158

4949 t947 1749 19

5 ..455-

455 ..

45 3l

45 4 ..47 6 ..4\64',7 8 ..45 26

^a a<AJ LJ

A: a1

47 144T t25-

47 5 ..5l 1i51 3751 3651 2751 325 ..

49 1 ..5-

49 7 ..49 t251 3851 394T 9 ..

{495 ..

495 ..

49

4945 3947 394s 3947 3949 1647 3247 265-

4949 5 ..47 2147 3747 3l51 2751 3251 1t

40 015940 0i5940-016240-020840 022240-023640-024240-024340424640 029240-029440-029640,030940 038s40-039440-041740-{45540-067940 068240-068340-070540486240 {96840-096940 097740 103340-103740-270540-2'70540-300740 301940 302040-303240 303340-304240,30.+340 304440-304440 3045.+0 305140-305940-306140 307340-308440-3085.+0 3t l940-l 1 2040 312140 312640-312740 315040 315540-3 I 9340 3t9440-320640,322040 322140-322140-323340 323140-3258la 325r"40 326540-327240 327340-327740,3282

40 328340-329140-329240 329240-332r40-332340 406040-485040-808540-832240-832340 833140 865740-9 l 90

41 0143414t464t 055141-05604l -05654l-056141-O5694l-058841,06034l-{6094t -06394t 067341-07064l-080741 30454t-305441-306341 30654 I -306841*30704t 30724t-307341 30744l 307841 -308941 30914t-309241-309441 320941-321241 32154r-80t 1

12 015742 192542-583642-584042 801742-861 I

47-9$A

53 3049

54 00.+2

54 800354 800654-9011

57 028057-028057 0948

t5 49li 5011 2313 2813 3313 3213 3l11 2l17 11

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Replacement parts list 1972 modglS - BSA Unit Singles

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