SPARE PARTS LIST - cdnmedia.endeavorsuite.com · SPARE PARTS LIST FROM E G E AND fr.AME Nos....
62
-. • SPARE PARTS LIST FROM E G E AND fr.AME Nos. i-:!:>.OOIOI.A75R. 1970
Transcript of SPARE PARTS LIST - cdnmedia.endeavorsuite.com · SPARE PARTS LIST FROM E G E AND fr.AME Nos....
-.
•
SPARE PARTS LIST
FROM E G E AND fr.AME Nos. i-:!:>.OOIOI.A75R.
1970
SUFFIX NUl\1BERS TO BE USED TO IDENTIFY VARYING FINISHES
When ordering components with varying finishes, please state finish required by adding tthe approprial<' number to part number.
EXAMPLE:
Petrol tank. Hambo} ant red 82- 8391 170
PETROL TANKS
Blue centre. \\hi1e lining. chrome panels Flamboyant red. chrome kneegrip. white lining .. "> Flamboyant red. chrome panels. single gold lining Grey centre. chrome panels, \\bite lining Flamboyant a ircraft blue. ch rome panels. single \\bite lining
S IDECOVERS
Blue
Flamboyant red, "hite lining Flamboyant red. gold lining Grey Flambo)·ant aircraft blue
OTHER PARTS:
Chrome Black Silver
PRICES:
i268 277 173 270 228
1271 /276 279 274 227
/3 /7 1165
No price codes are quoted in this list. For prices please refer lo rhc Master Price list No. 00-5 I 25.
Where,•er possible derails of thread form a nd size are quoted afrer descripriou of nuts, bolls. screws sruds and washers. Such as: 14-7006 Socker sere" (14 U.N.C. x I") - 14 diameter unified coarse thread I• long under head.
Vital components, which a re manufactured from special material. are indicared by a sign and the British Srandard symbol for rhe marerial is quored a r rhe foot of the page.
ABBREVIATIO~S:
B.A. B.S.C . B.S.F. CSK. U.N.F. U.N.C. WHIT.
Brirish Associarion Sere\\ Threads. Brirish Standard C)cle Sere" Threads. Briri,h Standard Fine Sere" Threads. Counrcrsunk Head. Unified Fine Screw Threads. Unified Coarse Sere" Threads. \\'hit\\Orth Form Sere\\ Threads.
3
STEERING LOCK AND KEY
Lock No. Key ~ o. Lo:\... 1'0. Kc~ t--:o. Lo.k No. Ke) No.
EJR 1 lQ-5151 EJR 18 19-5168 EJ R 35 19-S ISS
EJR 2 19-5152 EJR 19 19-5169 [ JR 36 19-51S6
EJ R J 19-5153 FJR 20 19-5170 F.J R 37 19-5187
EJR 4 19-5154 I IR 21 19-5171 EJR 38 19-5188
EJ R 5 19-5155 FJR 2.2 19-5172 EJR )9 19-51•9 -
EJ R 6 19-5156 E.lk 23 19-5173 EJR 40 19-5190
EJR 7 19-5157 EJ R 24 19-5174 EJR 41 19-5191
EJ R ~ 19-515S F.JR 25 19-5175 EJR 41 19-5192
EJR 9 19-5159 [JR 26 19-5176 FJR JJ 19-5193
fJR 10 19-5160 EJR 27 19-5177 EJR 44 19-5194
-EJ R II 19· :,1(,1 EJR 28 JQ 5178 FJR 45 19-51~5
-EJR 12 19-5162 FJR 29 19-5179 FJR J6 19-5196
EJ R 13 19-516.l EJR )(l 19-5180 fJR 47 19-5197 -
EJR 14 19-516-1 EJR 31 19-5181 FJR 48 19-5198
EJR 15 19-5165 CJR 32 l'l-5182 EJR 49 19-5199
EJR 16 19-5166 EJ R JJ 19-5183 E.IR 50 19-5200
EJR 17 19- 5167 EJR 34 19-51S4
""---=,---.-...:.:__ ________ ==:..____----===---- ---'-------
PISTON CHART
PISTO 'COMPLET E I Compre~sion ---~ I Number Rntio Standard -.oos· .... . 0 10·
. -020· -.040" Per Set
9. I 70-9741 70-9761 70-9762 70-9763 70-9764 3
COMPRESSION RI NGS
70-6838 I 70-9015 I 70-9016 I I 70- 9017 I 70-9018 6
SCRAPE R RINGS
70- 9739 70-9765 70-9766 70-9767 I 70-9768 3 ' Set No . .. .. 00-3466 00-3467 00-3468 J 00- 3469 I 00-3470 Rings per set (9) I
CARBURETTERS AND SETTINGS
B.S.A. Amal Main Pilot Thronle Needle 1'eedle Air Location Number Number Jct Jet Slide Jet Position Cable Right-hand 19-2408 R.626-14 150 622-107 3 .106 2 Long Cenire 19-2415 R.626- 16 1 150 622-107 3 .106 2 Medium left-hand 19-2409 L.626-! s l 150 622-107 1 . IOI, 2 Short
5
Spares Xo.
00- 3172
00-33 I 5
00- 3466
00-3467
00-3468
00-3469
00-3470
70-7951
70-8781
70-6529
70-9740
70-S778
71-1009
70-9001
19- 7800
57-3871
1!2-9773
82- 9963
97-3911
37-3312
37- 3461
37-3317
37-3622
37- 3623
37-3608
ASSEMBLIES COMPLETE
Description
TOP OVERHAUL GASKET SET.
FULL OVERHAUL GASKET SET.
PISTON RING SET (standard).
PISTON RING SET (.005" oversize).
PISTO, RING SET (,OIO" oversize).
PISTON RI NG SET (.020" oversize).
PISTO RING SET (.040' o,ersize).
ENGINE U IT, less carburetters and exhaust system. plus oil pipes and pressure S\\it•h.
CYLINDER HEAD ASSEMBLY.
CYLINDER BLOCK ASSEMBLY.
CO NECTING ROD ASSEMBLY.
CRANKSHAFT ASS EMB LY.
CRA, KCASE COMPLETE, dri,e-sidc, centre and timing-side.
OIL PUMP COMPLETE.
CLUTCH ASSEMBLY COMPLETE.
PRIMARY DRIVE SHOCK ABSORBER ASSEMBLY.
FRAME COMPLETE.
SWI GING ARM COMPLETE.
FRONT FORK ASSEMBLY COMPLETE.
FRONT WHEEL COMPLETE, "ith spindle and bearings, less brake parts.
FRONT BRAKE ANCHOR PLATE ASSEMBLY.
FRONT HUB COMP LETE. \\ith spindle and bearings. less brake parts.
REAR WHEEL COMPLETE, "ith spindle and bearings, less brake parts.
REAR HUB COMPLETE, with spindle and bearings, less brake parts.
REAR BRAKE ANCHOR PLATE ASSEMBLY.
6
lNDEX
CYLINDER HEAD, ROCKER BOXES. EXHAUST PIPES
CYLINDER, PISTONS AND CRANKSHAFT
CRANKCASE AND TIMING GEARS
INNER PRIMARY COVER. OJL PUMP AND GEARS . .
CLUTCH
PRIMARY CASE OUTER COVER. CHAIN TENSIONER. CLu"TCH CONTROL . .
GEARBOX ..
GEARBOX COVER. GEARCHANGE A D KJCKSTART CRANK
FRAME
SWINGING ARM. CENTRE STAND. PROP STAND
STEERING HEAD
FRONT FORKS ..
FRONT WHEEL . .
REAR WHEEL
HANDRAIL. MUDGUARDS. CHAJNGUARD
PETROL TANK. HANDLEBAR AND CONTROLS
TWINSEAT. SJDECOVERS. SILENCERS . .
TOOLBOX. BATTERY CARRIER, AIR CLEANER
OIL TANK AND OIL COOLER
ELECTRICAL EQUIPMENT ..
CARBURETTERS AND THROTTLE LINKAGE
TOOL KIT
7
'
Page
8 • ll
12 - 13
14 - 17
18 - 19
20 - 21
22 • 23
24 • 25
26 • 27
28 - 29
30 - 31
32 - 33
34-35
36 - 37
38-39
40 - 43
44 - 47
48 - 49
50 - 51
52 - 53
54 • 57
58- 59
60 • 61
Plate 1
3
61 - ---60
57 56
55
54
67----- _
68 69 70 1! !
s 6 7 8 9 10
8
3
II 12 13
<IO 39 38 37 36
14 IS 16
24
25
26 27
21
17 18
28
29
30
• -
Plate I CYLINDER HEAD, ROCKER BOXES, EXHAUST PIPES
Plate Spares Ref Number
I. 70-6563 2. 54-9081 3. 70-6561 4. 70-6565 5. 14-6211 6. 71-0280* 7. 70-9240 8. 70-8820* 9. 70-6562
IO. 70-88 J 9• 11. 71 - 1290 12. 70-6565 13. 70-6564 14. 14-1401 15. 70-9239 16. 70-9237 17. 14-0202 18. 54-9081 19. 71 - 1288 20. 71- 1287 21. 70 -8773 22. 70-8782 23. 57-2166 24 . 71 1175 25. 71-1168 26. 40-0159 27. 21-0550 28. 71-1157 29. 14-0205 30. 54-9081 3 J. 70-9460 31. 70-9461 32. 70-6743 3J. 70-8860 34. 14-1201 35. 70-9626 36. 70-6744 37. 19-7638 38. 19-7606
Jnle1 rocker box cover Washer. for boll 14-6211 Inlet rocker box Rocker box cover gasket
Description
Bolt. rocker box 10 cylinder head ( ¼ • U.N.c. 3") Bolt. rocker bo., to barrel steady stay (J,j,' ¼' U.N. F. 4 '/i") Washer for bolt lines 6. 8 and JO (~s· 21 /64:'. d / 32") Bolt. rocker box to barrel (short) Exhaust rocker bo., Bolt. rocker box to barrel (Jong) Exhaust rocker, dri,e-side Rocker box cover gaske1 Exhaust rocker box cover
Stud (long). rocker box co,er ('/4' L.N.C. u.N.F. I \'g")
Washer. cover fixing nu1 (9 16' 25,'64" ,i-") Sleeve nut. cover fixing Bolt. rocker box cover(•~· U.N.F. I !,J Washer. for bolt line 17 Exhaust rocker. centre E,haust rocker. timing-side Rocker box gasket --o·· ring. inspection cap Roeker box inspection cap Connecting lube, oil feed pipes Rocker oil pipe, rocker spindle Washer. oil pipe banjo
Domed nu1. oil pipe to rocker spindles P 8 • U.N.F.)
E,haust manifold
Bolt. exhaust pipe to manifold (', • L.N.F. 11 ~·) Washer. exhaust pipe 10 manifold bolt Exhaust pipe. left-hand Exhaust pipe, right-hand Finned collar. exhaust pipe Spherical \\asher. finned collar Nut. for bolt line 29 ( 14 • u.N.F.)
Cap. for bolt line 29 .. Bolt. finned collar(¼" L.N.r. l,i ") Spark plug cover (Ripault) Spark plug (Champion N3) ..
9
'
Per Set
4
4
2 8 4
2
4 4
4 4 4
2 4
4
4
2
2 4
3 3 2 4 3 3 3
Plate I- Contd.
5 6 7 8
61 -60
59 58 /
54/
53 52
51 49 48
63
64
65
66 ~ .., 67
68 69 70 71 72
9 10
8
47 464S
10
II
40
12
I I 39 38 n
13 14 IS 16
20
24
25
26 27
28
36
Plate I- contd. CYLINDER HEAD, ROCKER BOXES, EXHAUST PIPES
Plate Ref
Spares Number
39. 70- 8781 40. 21 - 0686• 41. 70- 9510 42. 02-0861 43. 14- 0303 44. 70-6423 45. 71- 1172 46. 60-0702 47. 70-8905 48. 70--{i() 18 49. 70-9558 so. 14-7004 51. 40-0156 S2. 40-0158 53. 71- 1288 54. 71 - 1287 5S. 70- 8720 S6. 71 - 1289 57. 40-0167 58. 14-0402 59. 70- 8783 60. 71-0070 61. 75- 0124 62. 70- 8787 63. 70- 8788 64. 70-8789 65. 70-6420 66. 70- 6422 67. 70- 8981 68. 14-0301 69. 40- 2705 70. 21-0557 71. 70- 7983 72. 70- 8784 73. 19- 2199t 74 . 19- 7621t
Desrrlption
Cylinder head "ith fixed fittings Stud. head to barrel ( ·' , U.N.C. U.N.F. 43 ,) Exhaust pipe adaptor . . Washer. head to barrel stud ( J 8 • " ; , 3 32") Nut. head 10 barrel stud ( 38 * u.~.F.)
E,haust ,alve .. Rocker oil pipe. engine 10 cooler ~, . Clip. flexible oil pipe to rockers Fle,ible oil pipe to rockers .. Bush. rocker spindle (timing-side) Rocker spindle assembly
Sere\\. rocker box 10 cyli nder head n4. U.N.C. 3 ,l Spring "asher. rocker spindle( ' , 33 64* I 32*) Washer. rocker spindle ( 1
2* )
Inlet rocker. timing-side Inlet rocker (centre) . . Top collar. valve spring Inlet rocker. drive-side Split collct, val,e spring Adjusting pin nut. rocker le,er hi-' U.N.F.)
Adjusting pin. rocker lever Rocker ball pin "O" ring. dri,c-side bush Vahe spring (inner) . . Vahe spring (outer) .. Cup. ,ahe spring (bouom) Vahe gu ide Inlet vahe
Stub insulating washer (Tufnol) Nut. stub to C) linder head ( 11, • U.N.F.)
.. '
Spring washer. stub to cy linder head (17 64" 15.'32* ,t*) Stud. stub to cylinder head ( 1, l,. , .r. l,.1'. C. 1-5/32") Stub. cylinder head Gasket. carbureller adaptor .. Spark plug Suppressor (Championf XJ87) . . Spark plug co,er (Champion WCl87)
•special material : 6.- EN16. 8.- ENl6. l0.- ENl6. 40.- ENS.
tExcept U.S.A.
II
Per Set
4 3 4
4
3
2
2 2 6 6
12
6
12 6 6 6 2 6 6 6 6 3
6
6 6 3 6 3 3
Plate 2
4 1
37
36
35-
I
2
33---32 31
30
29
28
24
3
__,
23
,
27-@ 26
~2s
12
---5
... - 7 '
8
9
22
10
- ll
21
12
13
15 - 16
17
- 18
-
•
Plate 2
Plate Spares Ref Number
I. 70-4752 2. 71 - 1238 3. 71 - 1176 4. 70-8817• 5. 70- 1532 6. 70-6529 7. 70-8914 8. 70-9465 9. 70-6496
10. 70 -9740 II. 70-9727• 12. 21-2016 13. 40-0142 14. 70-8746 14. 70-8748 15. 14-0303 16. 71- 1129 17. 70-7423 18. 70-6023 18. 70- 9027 18. 70-9028 18. 70-9029 18. 70-9030 19. 70-6577 20. 70-6026 21. 70 8780 22. 70-874S• 23. 70 8778 24. 70- 1591 25. 70-602S 26. 70-9843 27. 70-5998 27. 70--9023 27. 70--9024 27. 70 9025 27. 70- 9026 28. 70-6840 29. 70- 9741t 30. 70-6836 31. 70-9739t 32. 70-6838t 33. 70-6838t 34. 70-6509 35. 70 -8917 36. 70-6560 37. 70 6508 38. 71 1190 39. 70-4746 40. 70 4752 41. 70-6955
. CYLINDER, PISTONS Al\'D CRANKSHAFT
Descriptio11
Joint washer. push rod cover (top) Push rod. inlet and exhaust . . Cylinder head gasket . . Stud. cylinder barrel Do"el. cylinder head to barrel Cylinder barrel assembl) Cylinder barrel liner .. Do\\el. tappet block . . Cylinder base gasket •,. Connecting rod complete Connecting rod bolt (¼" u.N.F. 2-37164") Nut. connecting rod bolt (¼" u.N.F.) Screw. oil pipe to bearing cap (2 B.A. 27,64" countersunk) Tappet oil feed pipe. drive-side Tappet oil feed pipe. timing-side Locknut. bearing cap ( 3 8 • U.N.F. ) Tab washer. bearing cap nut Main bearing cap Main bearing shell (standard) Main bearing shell (.0IO" undersize) Main bearing shell (.020" undersize) Main bearing shell (.030" undersize) Main bearing shell ( .040" undersize) Crankshaft oilway plug Bearing circlip. timing-side Crankshaft bearing. timing-side (Hoffman R.125) Stud. main bearing cape ~· u.N.F. U.N.C. 4 7,8") Crankshaft assembl) .. Crankshaft bearing. drive-side (Hoffman MS. I I ) Bearing circlop. drive-side .. Rubber seal. tappet feed pipe Shell bearing. connecting rod (standard) .. Shell bearing. connecting rod (.010" undersize) Shell bearing. connecting rod (.020" undersize) Shell bearing. connecting rod (.030" undcrsize) Shell bearing. connecting rod (.040" undersizc) Gudgeon pin circlip .. Piston complete (standard) .. Gudgeon pin .. Piston scraper ring (standard) .. Piston compression ring. centre (standard) Piston compression ring. top (standard) . . Tappet block, timing-side Inlet and exhaust tappet ··o·· ring. tappet block Tappet block. drive-side Gasket, push rod cover tube Cup. pu,h rod cover (bottom) Joint washer. push rod cover (bottom ) Push rod co, er
*Special material : 4.- ENSR. ll .- 3AE.4042. condition 75 ton. 22.- EN1 6.
tSee paie 5.
13
Per Set
4 6
8 6
3 4
3 6 6 2
4-4-2 4-4-4-4-4-3 2
4-
2 4-6 6 6 6 6 6 3 3 3 3 3 2 6 4 2 4 4 4 4
Plate 3
2 34 s 6 7 8
9 II
10
84 88
98 ~
97 80 89 90
94
S3
S8 S7 56 S5 S4
14
12 13 14
15
-17 18
~i l ~~ 21
22 ' 23
~ 24
25 26
. 27
84 ~: ~8
83 ~* 82 • 29 81
~ 80
73
72
51 49
52 SO 48
~
Plate 3
Plate Ref.
Spares Number
I. 14-6220 2. 54-0055 3. 21-1931· 4. 70-8751 5. 70-8738• 6. 21-1912* 7. 21-0692 8. 70-8770 9. 70-S774
10. 70-8764 II. 70-8765 12. 70-8744 13. 90-0262 14. 14-6606 15. 70-6299 16. 70-8742 17. 40-0323 18. 70-8741 19. 70- 8740 20. 70-8739 21. 70-9706 22. 71-IOOOt 23. 70-8774 24. 14--1427 25. 14-6113 26. 70-8776 27. 70 6516 28. 19-1865 29. 70 8756 30. 19 1888 31. 19 1864 32. 70-6559 33. 70-652 1 34. 68-0331 35. 14-0208 36. 76 0291 37. 70-6572 38. 70 6519 39. 54-0170 40. 54-9012 41. 70-9266 42. 71-1130 43. 70-7879 44. 71-0006 45. 70-7880 46. 14 -66 11 47. 14-6612 48. 708763 49. 75-0223 50. 21-1852 51. 54-0055 52. 19 1260 53. 19-1259 5-1. 70 6511*
CRANKCASE AND TIMING GEARS
Description
Bolt. crankcase (¼ • u.N.c. J3 4 ) .. Washer. crankcase bolt (¼' 58' ,'.') . Stud, cylinder base <3." U.N.C./U.N.F. X JJ ,) Dowel. cvlinder base .. Stud, cylinder base do\\CJ 0 8 • U.N.F. 1-13/16') .. Stud. cylinder base () .. u.N.C. U.N.F. I 1/8 ') Nut. cilinc!cr base stud (12 point ·'• IJ.N.F.) Washer. for nut line 7 Do\\el. dri,e-sidc ..,_ .. Inlet camshaft E\haust camshaft Locating bolt ( ¼ • L.N.C. 13132") Washer. for sere\\ line 14 .. Sere\\. tachometer housing to crankcase ( ¼ • u.N.C. J ,) .. 0 .. ring. driven gear Bearing housing, tachometer dri"e .. --o-- ring. tachometer dri, e .. Dri"en gear. tachometer dri,·e Drhen gear housing. tachometer dri\'e Gasket. tachometer drive Support \\ire. tachometer cable Crankcase. centre section Do\\el. timing-side Stud. crankcase ( n, • IJ.N.C. u.N.F. 3') Oih,a) plug(¼' U.N.C. 5.') Oih,ay plug washer . . . . Scavenge cover gasket Contact set (Lucas 54419828) Grommet. contact breaker leads . . Spring. auto-advance unit (Lucas 54417992) Auto-advance unit (Lucas 54419867) Washer. contact breaker plate .. Pillar bolt. contact breaker plate (2 B.A. 1-5 32") \\ asher. auto-advance bolt line 35 , . Bolt. auto-advance unit ( '• • u.N.F. 21 4 ) Oil seal. contact breaker Co,er gasket. contact breaker Contact breaker cover Washer. cover sere" line 40 Sere", contact breaker co,er (2 8.A. 13 32") Washer. for screw lines 42 and 44 . . Sere\\, timing aperture (4 B.A. 11r·) Cover. timing aperture Pointer screw. timing aperture (4 B.A. 11 16') Gasket. timing aperture Sere". timrng cover (t,4 u.r...c. J34 ) Sere\\, timing cover(', L.N.C. 2') Nut. rotor mounting ( rr · u.N.F.) Lock washer. rotor mounting .. locknut. stator mounting (,l6 • u.N.e.) Washer. stator mounting ( 11,-• s, • ,'.') .. Alternator rotor (Lucas 54213902) Alternator stator (Lucas 47209) Stud, stator mounting (-1. • u.ts.F. 3')
15
Per Set
2 8 4 2 2 4
10 10 2
2 3
2 2 2 2 2
2
3 )
3 3 2
4
3 3
3
P late 3- Contd.
2 3 4 5 6 7 8
9 II 12 13 14
IOI
IOO
99
84 88
98 -0
83
• 97- 88 82 89 81
53 51 49
58 57 56 55 54 52 so 48
16
..,
~
~
IS
- ~6
-17 18
21
22
23
- 24
25 ~ 26
27
~
---45
46
-
• Plate 3-cootd .
Plate Spares Ref Number
55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 8~-85. 86. 87. 88. 8}. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103.
71-1270 71-1070 70-6130 70-6571 14-6226 14-6218 70-6173 54-0022 14-0401 70-6524 70-3974 21-0548• 6$ 0209 19-1863 70-7738 76-0217 14-6608 70-8760 71)-9807 70-8768 70-6088 70-7650 70-6523 70-1558 7,:)-9802 14 6104 54 0022 70-6580 70-6501 70-8779 21-1813 54-0055 14-0302 70-9856 70-8755 70- 1523 5~-0055 21-0~78 70-6727 70-6030 2 1 0547 14-6223 70 7737t 57-1920 70-6573 70-6574 71-1050t 14-6226 14 621S
CRANKCASE AND TIMit"JG GEARS
Description
Cap. main oil filler "0-' ring. fil ter cap .. Spring, filter mounting Main oil filter (Fram CA.2818) .. Bolt. crankcase clamping(¼' L.:-..c. 31;,•1 Bolt, crankcase clamping(¼' L.N.C. P,J Distance piece, timing pinion Washer, gear spindle stud nut Locknut, gear spindle stud (1/4' t:.N.F.) Timing pinion. crankshaft Ke). crankshaft pinion and rotor Stud. crankshaft ,.· U.N.F. U.N.F. P,) Grommet, for cable sea l nut Contact breaker plate (Lucas 54419327) Timing gear co,er Do\\el. timing co,cr . . . . Sere-.,. timing co,er to crankcase (' 4 U.N.c. 1 ·, Cable sleeve nut Grommet. alternator leads Circlip. intermediate gear Thrust \lasher. intermediate gear Needle b~aring (Torrington 8 .1 I 10) Nut. camshaft pinion .. Ke). camshaft pinion . . Camshaft pin ion Bolt. scavenge cover(', L.N.C. '•l Spring \\3Sher, scavenge co,er bolt Sca ... enge CO\·cr . . Sea-enge cover filter "O" ring. filter seal Stud. gearbox cover (,'~ • u.:-i.c. L.N.F. 4>4 ) Washer. crankcase stud (16 • $s• -,l6 ) Nut, c,ankcase stud (1F t;.N.F.) Sleeve. for filter "O" ring Plug. riming aperture . . . . Fi'>re \\asher. for plug line 89 .. Washer. crankcase bolt u.-· ~'s' ,'.') Socket scce". crankcase clamping (1~ • LS.C. 3",) Intermediate g.ear complete .. lnrcrmediatc gear spindle .. Stud. inrermediate gear spindle('," L.,>.C. L.,.F. '•> Bolr. crankcase clamping <,'6 • t,.'<.C. 212') Crankca ·e. ummg-side Blanking r>fug .. Oil return pipe stub .. Oil feed pipe stub Crankcase. dri,e-side Boll. crankcase clamping (-rl," u.N.C. 31,·, Bolt. crankcase clamping <,\, u.N.c. 11,')
.,
•Spc'Cial material: .3.-E 16R. 5.-EN8R. 6.-EN8R. 54.- EN8R. 66.-ENSR.
tSupplied only as crankcase complere. number 71-1009.
17
Per Stt
4
3 3
2 5
2 2 2 6 6
2 2 2 2 2
7
' ·'
:Plate 4
42---7 41- (lit
31~
38
2 3
37--
5 6 7 8 9
<
~ -- ,s
17 16
18
Plate 4
Plate Spares Ref Number
I. 21-0585 2. 70-9634 3. 70-7248 4. 21 - 1820 5. 14-{;101 6. 70- 8786 7. 70-4705 8. 14-7006 9. 14-6606
10. 57-4018 II . 57- 2558 12. 70-8750 13. 70-6567 14. 70-6742 15. 70--{i584 16. 70- 9737 17. 70-6595 18, 70-{)503 19. 70-{)502 20. 70-6038 21. 70-6430 22. 70-6039 23. 70-6454 24. 70-6525 25. 70- 8731 26. 21 -0559 27. 71-0003 28. 70-6570 29. 70- 1532 30. 70-6455 31. 70-6889 32. 70-6459 33. 70- 8732 3t. 70- 9601 35. 21 -0536 36. 70-0402 37. 57- 3642 38. 54-0055 39. 21 - 1819 40. 70- 7249 41. 70-7250 42. 70-7246 43. 70- 6885 44. 71 - 1051 45. 70-6890 46. 70-8785
7il-9001
INNER PRIMARY COVER, OlL PUMP AND GEARS
Descrip1ion
Nut. engine sprocket ( ·', u .N.F.) .. Shim, engine sprocket (as required . maximum 4) Driving gear. oil pump Bolt, inner cover to crankcase(¼" u.N.C. 4h"J Bolt. cha in oiler clip ( ¼ • u.N.C. ½") Chain oiler pipe Clip. chain oiler pipe . . Socket screw. inner cover to crankcase( ¼" u.N.C. I") Screw (short). inner cover to crankcase ( ¼ • IJ.N.C. >< ¾ ") Inner primary cover with Rxcd fittings .. Gasket, inner cover to crankcase ' Ball. oil cont rol valve ( ~• diameter. 11. 1125 mm.) Spring. oil control valve Fibre washer. oil control valve Plug. oil control valve Fibre washer, valve body to crankcase Oil pressure release valve complete Gasket. oil pump to crankcase Oil pump base plate .. Oil pump d riven feed gear . . Oil pump body . . Oil pump driven scavenge gear Spindle. for driven gears Oil pump cover . . . . Spring washer. oil pump cover sere" line 30 (I I 64" 18 G.) Screw, oil pump cove, to body (3 B.A . 2") Screw. oil pump to crankcase (2 B.A. 21/2") Seal. oil pump to crankcase and cover Dowel. oil pump to crankcase Oil pump feed driving gear . . Oil pump sca,enge driving gear Do\\el. oil pump w,er to body Spring \\asher. o il pump sere" line 34 (13.64" 16 G.) Screw. oil pump to cran kc.ase - dowel position (2 B.A. 2{, ) Drain plug Fibre washer. drain plug Oil seal. clu tch shaft Washer. inner cover to crankcase bolt (1'." x %" ><¼") Bolt (long). inner cover to crankcase <iV u .N.c. x 4 ¼ ") Oil pump driven gear . . Sere", driven gea r to scavenge gear (2 8.A. 3 8" ) Intermed iate gear. oil pump drive Bush. intermediate oil pump gear Intermediate gear spindle Engine sprocket (28 teeth) Lockwasher. engine sprocket Oil pump complete
19
Per Set
7 2
2 2 3 2
4
2
Plate 5
I 2 .... 1,- 3 4
' . 5 ½
6
7
; 8
12 / II /
-----10
IS 16 9
17
19 20
36
21
35 3433
3
31
/ 29
28 ) 2
20
Plate 5 CLUTCH
- Plate Spares Per Ref Number Description Set
I. 57-4004 Retaining plate. shock absorber 2. 57- 3644 Oil seal. clutch pull rod 3. 57-2480 Nut. shock absorber . . 4. 57- 2478 Spacer. shock absorber nut s. 68- 3282 Shock absorber rubber 12 6. 19-8692 Primary chain (Triplex, 82 pitch) 7. 57-3643 Needle bearing. clutch shaft ( INA. SC.228) 8. 57-2581 Gasket, inner cover to outer co..,er 9. 57- 2245 Clutch sprocket (50T) ..
' 10. 57- 2214 Thrust washer. clutch sprocket II. 57- 2471 Spider, clutch shock a bsorber 12. 57- 3646 Thrust race. clutch shaft (Torrington NTA.2233) 13. 57- 3941 Tab washer for bolt line 14
3 14. 57- 3940 Bolt . shock absorber retaining plate (2 B.A. x ¾ ") 6 JS. 19- 7801 Clutch end cover assembly . . 16. 19- 7805 Clutch spring 17. 19-7804 Clutch pressure plate complete 18. 19-7803 Clutch friction plate 19. 68- 3218 Key. hub to mainshaft 20. 57- 2580 Clutch hub 21. 57- 2556 Gasket, breather duct 22. 57-2555 Breather duct cover 23. 14 6515 Screw. cover to inner chaincase (¼" u.N.C. :< 4') 24. 21--0680 Screw. cover to clutch cover (number 10 U.N.C., 'l's") 3 25. S1-31S6 Adaptor for oil tank brea ther pipe 26. S7- 3642 Oil seal. cover to mainshaft .. 27. 57- 2554 Clutch cover 28. 14-6610 Screw, cover to crankcase ( 14 • u.N.C. •~n 3 29. 57-2551 Tube. clutch co,er 30. 21-0681 Nut. hub to mainshaft (9 16' t.,.N.F.) 31. 19- 7802 Clutch housing .. 32. 57- 2S52 Clutch pull rod 33. 19- 7808 Bearing. clutch pressure plate 34. 19- 7807 Lockwasher. end cover to housing bolt 6 35. 19- 7806 Bolt. end cover to housing
12 36. 57-2479 Slee\e, mainshaft 011 seal 19-7800 Clutch assembly complete 19 7809 Facing pack for friction plate (JSC.76014) 57-3871 Shock absorber assembl)
21
Plate 6
2 3 4 5
i 7 8
41 --
40,--
39
37-~
36--e 35~
I 9@
22
10
I 2
:: ~ 15
- 16
17
10
19
-31 22 ~30 ~27
~ 28 29
34 32
Plate 6 PRIMARY CASE OUTER COVER, CHAI TENSIONER, CLUTCH CONTROL
Pla1e Spares Rtf /\'umber
I. 14--6605 2. 57-3954 3. 57-3955 4. 57-2553 5. 14 6102 6. 57- 2474 7. 57-2473 8. 57-3638 9. 14-6613
IO. 68- 3264 11. 57-3733 12. 57-1645 13. 57-2220 14. 21-0567 15. 57-3990 16. 57- 2166 17. 70-8782 18. 14-6611 19. 14-6615 20. 57- 2259 21. 57- 3733 22. 14-6504 23. 57-2244 24. 14-6612 25. 57-2215
r,--- 26. 57- 3614 27. 57-3617 28. 70-9258
"! 3 1 1 29.~ 9-i 5011' 30. 14-6509 31. 57-3643 32. 70-5977
'I f l 6'33.d<_~ · 34. 70-9258 35. 14- 1901 36. 57- 3987 37. 57-3986 38. 57-3983 39. 70-9256 40. 14-6610 41. 57-3958 42. 76--02 I 7 43. 57-0912 44. 57-2465 45. 97- 2704 46. 57- 2547 47. 57-3647 48. 14-0402
Descrip1ion
Sere,,. inspection CO\'er ( 1-~" u.N.c. o/s") .. Inspection co,er .. Inspection cover gasket Sleeve nut (f6 • U.N.F.) Bolt, clutch thrust plate spring ( 14 • U.N.C. x h ') Tab washer. for bolo line 5 .. Spring. clu1ch thrust pia1e .. Distance piece. clutch thrust plate spring .. Sere". primary outer cover ( t/4 • u.N.C. 214 ") Clutch cable grommet Sealing ring. clutch cable Adaptor. clutch cable .. Abutment for clutch cable .. Locknut for abutment (' 2 • u.N.C. l . . Washer. clutch cable locknut Oil filler plug .. "O .. ring for filler plug .. Screw. primary outer cover ( ¼ • U.N.C. 1-~• ') Sere,,. primary outer co,er ( 1f" U.N.C. 3") Plug. tensioner hole .. •·o .. ring for tensioner hole plug .. Sere". primary outer cover ( ¼ • U.N.C. ~. countersunk head) Inner gasket. primary outer cover .. Screw. outc1 to inner cover . . Thrust washer, primary outer cover Pi, ot pin. chain tcn)ioner Adjuster. chain tensioner · Saddle washer. adjuster end .. Chain tensioner blade (upper) Sere". primary outer cover ( tt, • U.N.C. I¾• countersunk head) Needle bearing (INA. SC.228) Trunnion, lower tensioner blade Chain tensior.er blade (lower) Saddle washer. chain tensioner (rear) Nut, chain tensioner support (¼" U.N.F.) Washer, thain tensioner support Support. chain tensioner Tie rod. chain tensioner Trunnion. chain tensioner Screw. primary outer cover ( 1', • U.N.C. x I Vi") Primary outer cover assembly Dowel. outer to inner chaincase Peg. clutch thrust plate Clutch thrust plate Steel ball ( \~ • diameter. 6.35 mm.) Clutch lever Bearing. clutch lever (Hoffman S5) Locknut (f.-• U.N.>.) ..
23
Per S,i
4
2
2 2 2
6
2
2
2
2
3
Plate 7
I 40 41 42
39 38 37
2 3 4
54
53
52 51 so-
48
35 34
8
57 58 60 61
33 32 31 30
24
9
fl - IO
./-- II
-:t.---18 \'!!,-------'9
20
26 24 23 22 21 29 28
27 I 25
• Plate 7
Plate Spares Ref Number
I. 14-6504 2. 57- 3633 3. 57- 2165 4 . 57-0448 s. 76-0217 6. 57-3989 7. 57-2595 8. 57-4055 9. 57- 2656
LO. 57-0397 I I. 40-9 190 12. 57 2601 13. 60-1928 14. 57- 1696 IS. 14 7101 16. 57-0412 17. 14-6121 18. 75-0176 19. 14-6614 20. 76--0217 21. 21-0594 22. 57-0732 23. 57-0731 24. 57-2170 25. 57- 1963 26. 57- 1250 27. 57 1962 28. 57-0280 29. 57 3621 30. 57 0912 3 1. 57 1607 32. 57-'l928 33. 57 3862 34. 57 3890 35. 57 1614 36. 57 386-1 37. 57 1607 38. 57-0912 39. 57 1606 40. 57-4051 41 . 572116 42. 57- 1918 43. 57-3861 44. 57- 3889 45. 57-3857 46. 57- 2176 47. 57-3785 48. 57 3982 49. 57-4054 so. 57-2172 SI. 57-3978 52. 57-4059 53. 57-3o60 54. 57-3634 55. 21 - 1872 56. 70-8896 57. 57- 2596 58. 57-0913 59. 21-1862 60. 70-9327 61. 70-9901
GEARBOX
Description
Sere" . housing to gea rbox ( ''. • u.N.F. coun1ersunk head) Oil seal housing assembly. gearbo, mainshafl Gasket. housing to gearbo, .. Bearing. gea rbox mainshaft (Hoffman N.1443) Do"el. gearbox inner co,er .. Selector fork spindle Cam plate , oiler Cam plate assembl) Gearbox d ipstick Gear selector quadrant Alternator cable clip .. Gearbox inner cover . . . . Split pin. quadrant spindle (5 64' I\') Spindle. selector quadrant . . . . Socket sere,\. inner co,e1 10 crankcase (r6" l,j.1'.C'. 31 4* ) Bu,h. footchange spindle Bolt. inner cover to crankcase(¼" L..N.c. 211• , Washer. for bolt line 17 Screw. inner cover to crankcase(', .. i...s.c. 21
2·)
Do,,el. inner cover to outer cover .. Nu t. mainshaft timing-side (9 16' L.N.F.) .. Lockwasher, ma inshaft nut Kicksta rt ratchet Kicksrart ratchet pinion Bu,h. kickstart ratchet pinion Spring. kickstart ratchet Washer. kickstart pinion slee,e Circlip. mainshafl bearing .. Bearing. main,hafl inner co,er (Hoffman LS.8 ) Peg. thrust "asher La,shaft thru,t "asher B"sh. la) shaft lo" gear La)shaft IO\\ gear complete La)shaft third gear Lai,haft needle bear111g, inner co,cr (Torrington B.1112) Lai shaft "ith high gear Layshaft thrusr \\asher Pc~. thrus1 \\asher (dri\,e-side) La)ihaft needle beanng (Torringron 1112 1 l Nut. gearbox final drive sprocket (It, L.,.e.J Lock\,asher. sprocket nut (2' • 12 G.) G~arbox final dri,e sprocker ( 19 reeth) Layshaft second gear .. Mainshaft rhird gear Mainshaft second gear Mainshaft high gear complete Bush. mainshaft high gear Mainshaft \\ith lo\\ gea r .. 0 .. ring. gearboz sprocket nut Bush. cam plate plunger Washer. cam pl:•te plunger bu,h Spring. cam plate plunger Cam plate plunger Oil seal. gearbox mainshafr final drhe Gearbox drain plug .. .. 0 .. ring. drain plug .. Mainshaft selector fork Layshaft selector fork .. Taprite .. sere", cable clip (number 6 L.r-..c.) Cable clip Gaskcr. gearbox inner cover to crankcares
25
Per Set
2
3
2
2
2
2 2
Plate 8
S 6 7 8 9 18 ii 12
13 ,4 15 16 4
3
2-
24 23 22 21 20 19 18 17
41 40 39 38 37 36 /
35 34 33 32 31 30 29
26
Plate 8 GEARBOX COVER, GEARCHANGE AND KICKSTART CRANK
Plate Spares Ref l\'11111/)er
I. 71 0037 2. 57-0404 3. 57-0407 4. 29-0541 5. 14-0301 6. 21-0547 7. 57-0406 8. 57-0405 9. 57 0409
JO. 57-3758 11. 40-0323 12. 57-3759 13. 14-6613 14. 57- 2603 15. 14-6615 16. 57- 3757 17. 89- 3208 18. 14-0201 19. 21 -0544 20. 54 0055 21. 21 1860 22. 14 0302 23. 54-0055 24. 14-6608 25. 21-0541 26. 97-2704 27. 40-3085 28. 57-1272 29. 57-2330 30. 75-0053 31. 68-0331 32. 57-2173 32. 57-3632 33. 75-3 143 34. 57-1955 35. 57-1956 36. 57-0023 37. 57-0047 38. 57- 0031 39. 57-0024 40. 57-2169 40. 57- 3732 41. -57- 3727 42. 70-9900
Key. quadrant to spindle Return spring, footchange pedal Gear control guide plate
Descriprion
Lockwasher. gear control guide plate (17 64' 15132" .024"1 ..
Nut. gear control guide plate(', lJ.1'.1.)
Stud. gear control guide plate ( t~ • L.N.C. L.N.F. 7;8 ' ) Plunger, footchange quadrant Spring. footchange quadrant Footchange plunger quadrant Footchange pedal spindle Oil seal ring. footchange Bush. footchangc shaft
Sere\,. ou1er to inner co,er (l·:a'' l...N.C. 21,'4 •) Gearbox outer cover .. Sere\\. outer to inner cover ( I 4 U.N.C. 3") Footchangc pedal
Foo1change pedal rubber Footchange pedal bolt
Domed nut, outer cover stud - top (¼ • ~-1',F.)
Washer for domed nut (,'. • 5g' ,'."J Screw. outer co,er to crankcase (I .. ~.N.C. 53 s) Nut. bottom cover stud (n, • U.N.F.)
Wa,hcr for nut line 22 C¼" 51( -h-"J Screw. outer to inner cover ( ¼ • U.N.C. I")
Bolt.. kickst.1r1 pedal pivot <¼' U.N.F. 1-532') Ball. kickstart folding pedal (11 • diameter) Spring, kicks1ar1 folding pedal
Kickstarl crank folding pedal Kick;tart pedal rubber Nut. kicksrnrt crank cotter ..
Washer. kickstar1 crank cotter (t{ · 'li" x¼") Kickstart crank only ..
Kickstart crank assembly complete .. Coner. kicks1ar1 crank
Oil seal housing. kickstart crank Oil seal. kickstart crank Bush. kickstan shaft ..
Anchor pin. kickstart return spring Return spring. kickstan Kickstart shaft ..
Kickstart quadrant
Kickstart quadrant and spindle assembly Kickstart quadrant stop
Gasket. gearbox inner to outer cover
27
P,r Set
2
4
~
4
2 2
2
Plate 9
G
~ 48
1!iJl 25
I
~ 21
28
--
Plate 9 FRAME
Pl ale Spt1res Ref Number Description
I. 2. 3. 4. 5. 6. 7. 8. 9.
10. II . 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 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. SI. 52. 53. 54. 55. 56. 57. 58. 59.
14-0237 Bolt. Steady stay 10 frame ( •,.· U.N.>. · 21/2") 02- 2138 Washer. steady sla> 10 frame (•is' ; 4 ,'.') 82- 9378 Steady stay (left-hand) 82-9773 Frame complete 97-0111 Steering head cup . . . . 14-0403 Nut. steady stay 10 cylinder head (}/ L.1'.F.J 02-2138 Washer. steady stay 10 cylinder head <3 8• J,4 ,\-") 82 9379 Steady stay (right-hand) .. 14-0304 Nut. front engine bolt hi· u.N.F.) .. 02 1967 Spring washer, front engine bolt (,1 • rs• 16 G.) 14-1903 Nut. steady stay 10 frame (3~• U.1'.F.) 82-9625 Footrest (left-hand) .. 82-8508 Spacer, front engine bolt 21...()779* Front engine stud(¾" u.N.F./U.N.F. 7") .. 15-0431 Washer, front engine bolt (,t"x¾· ,'.") 14-0145 Bolt. left-hand footrest (½" u.N.F. n .. 82-8510 Spacer. bottom engine bolt .. 82-9642 Engine plate (right-hand) . . 15--0431 Washer. bottom engine bolt(¾" }."xn-•1 21-0780* Bottom engine stud (,t" U.N.F.)L.N.F. 11 ½") 4()-4850 Footres1 rubber (right-hand) .. 82-9686 Footres1 rubber (left•hand) .. 82-9624 Footres1 (righ1-hand) .. 03-0107 Spring washer. for bolt line 24 (17/ 32" <49/64" x 11 G.) 21-2018 Footrest boll. right-hand footres1 (%" u.N.F. I') 82- 5943 Foo1res1 peg 14-0J0J Nut. pillion footrest anchor bolt (1/s • li.N.F.) 02-0522 Spring washer. anchor bolt (l(!" •'• x 17 G.) 82-9652 Silentbloc. silencer moun1ing . . 54-4302 Fibre washer, for grease nipple line JO 47-9012 Grease nipple. brake pedal .. 24-8784 Spring washer. stop peg 14-0302 Nut. SI0p peg (,\-" U.N.F.) 02-1967 Spring washe,. bottom engine boll b¼" ½" x 16 G.) 14-0304 Nu1. bottom engine bolt (it"" u.N.F.) 82-9641 Engine plate (left-hand) 82- 8918 Brake pedal bush 82-8513 Brake pedal slop peg .. 42-8034 Nu1 for ··Oddie .. clip .. 42-5099 Lockwasher for .. Oddie .. clip 68-9115 .. Oddie .. clip. sidecover 82-9653 Anchor bolt. pillion footrest 14-0402 Nu!, ,wivel bolt (¼" U.N.F.) 36-0382 Lockwasher. swivel bolt 04-2276 Washer. pillion footres1 68-4835 Pillion foo1re>1 comple1e 21-756* Swivel bolt, pillion footrest (('6 " U.N.F. I") 82-9684 Engine shield .. 29- 7583 Pillion footrest rubber 65-8317 Sere\\ for .. Oddie .. clip(½" ½") .. 14- 1302 Nu!. rear engine plale bolt (,l•• U.N.F. ) 02-0923 Washer, rear engine plale bolt (¼" 5,8" i'.") 14-0221 Bolt. engine 10 righ1-hand engine pla1e (¼" u.1>.F. 2") 02-0923 Washer. rear engine plate bolt (f,r" h" · ,\-") .. 14-0115 80l1. righ1-hand engine pla1e to frame (¼" u.N.F. }8") 14-0220 Boll, engine to left-hand engine plate (¼" u.N.F. il4) 02-0923 Washer, rear engine plate bolt (¼" ¾" 1J?) .. 82-8509 Spacer, rear engine plate (lefl-hand) 14-1302 Nut. rear engine plate bolt (¼" u.N.F.) 14-0218 Bolt, left-hand engine pla1e to frame (¼" U.N.F. x I 3/8 ")
•Special material: 14.-ENl6T. 20.-EN16T. 24.-EN 14B.
29
46.-EN14B.
Per Set
2 2 2
2 2
2
2
2
4 2 2 2
I. 2
6 6 3 2 2 2 2 2 2
2 6 5 5 2 5 3 2
10 3 5 3
Plate 10
7 8 9
2 3 4 5 6
19
22 23
43
38
30
10 11 12
;;; / ~ I
15 14 13
16
-------29 - ~ .----
--
Plate IO •
Plate Spares Ref Number
I. 19-7447 2. 14-0235 3. 19-7446 4 . 19- 5305 5. 70-8770 6. 14-1303 7. 14-0401 8. 14-0106 9. 83- 1641
10. 82- 9665 11. 60-2683 12. 40-2705 13. 83- 1752 14. 37- 1467 15. 82- 7387 16. 82- 9963 17. 15- 5155 18. 14-0217 19. 82-8468 20. 36-0382 21. 14-0113 22. 14-0235 23. 54-4307 24. 19- 5305 25. 02-2138 26. 14-J 303 27. 54-4302 28. 47-9012 29. 82- 8475 30. 82- 8478 31. 82- 8477 32. 42-4364 33. 21 - 0755 34. 60-2683 35. 15-0039 36. 03- 1346 37. 82-8413 38. 57- 2331 39. 82-$382 40. 82-$660 41. 21--0769 42. 14-0404 43. 68-4708 44. 54-4302 45. 47- 9012 46. 82-8582 47. 82- 8476 48. 14-0405 -49. 83- 1535
SWINGI G ARM, CE TRE STAND, PROP STAND
Description
Damper spring (solo) - Girling 64544120 Top bolt. damper mounting p; U.N.F. x i') Rear damper complete (solo) - Girling 64052105 Top bush. rear damper - Girling 64533645 Washer, top damper mounting bolt Nut. Top damper mounting bolt (%' U.N.F.) locknut. brake pedal stop (¼. U.N.F.) .. Screw, brake pedal Slop (14 • U.N.F. 1 ¼") Rear brake pedal Brake operating shaft .. Split pin, brake rod to pedal Washer, brake rod to pedal Rear brake rod Pivot pin. brake rod Adjuster nut. brake rod ( ¼ • U.N.F.) Swinging arm with bushes Washer, for bolt line 18
... .,
Pinch bolt. brake pedal (¼' U.N.F. I¼' ) Spindle. swinging arm . . lockwasher, swinging arm spindle lock plate bolt (i.r' J Bolt, swinging arm spindle lock plate (¼' U.N.F. ¾") Bolt, rear damper bottom mounting (%" u.N.F. X2") Washer, rear damper bouom mounting Bottom bush. rear damper - Girling 64533645 .. Washer, rear damper bottom mounting Nut, rear damper bottom mounting(%" U.N.F.) Washer. for grease nipple line 28 Grease nippJe, S\\inging arm Bush, swinging arm Thrust bearing. swinging arm Dust cap, swinging arm spindle lockwasher. swinging arm spindle nut Nut. swinging arm spindle (13/ 16• u.N.F. ) Split pin. centre stand pivot (-h-'xJs') Washer, centre stand pivot ( ½• x 27/32" -h-") Spring washer, centre stand pivot (17/ 32' x }g" 19 G.) Centre stand Pedal rubber, centre stand Return spring. prop stand Prop stand leg . . Bolt. prop stand pivot (¼' u.N.F. I¼") Locknut, prop stand pivot bolt (iV U.N.F.) Return spring. centre stand . . Washer. for grease nipple line 45 .. Grease nipple. centre stand .. Coupling. centre stand pivot Spacer tube. swinging arm spindle .. locknut. centre stand pivot ba, 0,2• U.N.F.) Pivot bar. centre stand
31
Per Set
2 2 2 2 2 2 2 2
2 2 2 2 2
2 2 2
2 2 2
2 2
2 2
Plate 11
'=-------35 ~-----34
=------33
=------ 32 31
6,-----7- - - - -' 81-------..::::J:/!i
c . • _,,(}-- 30
9-®
~~10
~ II
~12
13-@t __ 14
is-&~ 16 11•--""
~28
32
23
o.----- 39 t\---40 a-41 w-42
$---43 ~ 44
Plate lJ
Plate Spares Ref Number
I. 97- 2108 2. 21--0589 3. 82- 1335 4. 21 -0684* 5. 68-5050 6. 97- 2266 7. 21--0578 8. 21--0685 9. 97- 1018
10. 97- 2275 II. 97- 2237 12. 97- 2236 13. 54-8003 14. 54-0022 15. 14-0113 16. 14-6102 17. 97- 2107 18. 14-1303 19. 54-4307 20. 82- 8245 21. 97- 3682 22. 97- 2270 23. 97-2290 24. 97- 2622 25. 97 2621 26. 97-0439 27. 97-2704 28. 14- 1903 29. 97 2293 30. 97-2245 31. 97- 1529 32. 97-1527 33. 97- 2221 34. 97- 1580 35. 97- 1581 36. 97- 2291* 37. 68 -8166 38. 97- 3602 39. 97 0565 40. 97 1618 41. 97 0435 42. 97- 1797 43. 97-0095 44 . 97- 3601
STEERING HEAD
Description
Sleeve nut, steering column ( I " u .N.F.)
Bolt. handlebar clamp hk" U. N.F. x 1 \ g") Washer. handlebar clamp (21164" 17132" ¼ ")
Bolt. top yoke pinch (3 .. U.N.F. I ~'g") . . Lock a nd key. steering (Wilmot Breeden 7- 9398) Sealing washer . . Grub screw. steering lock Nut. pinch bolt (Jg" L.N.F.) ..
Top cone \\ith dust cap Heat sink plug . . Diode heat sink Hea t sink bracket Washer. brac~et to fork leg bolt Washer, bracket bolt .. Bolt. bracket 10 fork leg (-r6 • L.1'.F. 58' )
Bolt. bracket 10 heat sink ( 11, • u.1-.. c . ~/ )
Pi n, damper adjusting stee,e
Nut. bo11om yoke pinch bolt (·', u .1-. .F.)
Washer. pinch bolt Lockwasher. cable guide bracket Cable guide bracket . . Cable retainer . . Pinch bolt. bo11om )Oke P R' u.1-. .F. 2%') Dust co,er. bo11om cone 8O11Om yoke assembly Bou om cone Steering head ball ( ' 4 diameter) Nut. handlebar clamp (N) toe )s' LN.F.) . .
Top )oke Top cap nut. main stanchion Washer. handlebar clamp (25 64' ' 8 • 3 32') Bush. handlebar clamp Cup. handlebar mounting Rubber. handlebar mounting Distance piece. handlebar mounting Handlebar clamp Badge. damper knob .. Damper rod complete Abutment \\asher Rubber bush Damper friction disc Damper anchor plate Damper spring plate . . Damper adjusting sleeve
• ,.
*Special material : 4.- EN8R. 36.- EN16.
33
Per Stt
2 2
2
2
2
-10 2
2 4
2 2 2 2 2
Plate 12 •
@-,
6
8
\ ,\
@---13 L/ r----14
~ '
1-0 ~ II • 0----,0 Q----9
34
1----27
Plate 12 FRONT FORKS
C Plate Spare$ Per Ref. Number Description Set
I . 97- 1971 Cable grommet. headlamp bracket .. 4 2. 97- 2300 Outer cover (left-hand) 2. 97- 2301 Outer cover (right-hand) 3. 82-4047 Cork "asher 2 4. 97- 1657 Spring abutment (top) 2 5. 97-3635 Fork rubber gaiter 2 6. 97-1892 Main spri ng ... 2 1. 97-2127 Circlip. shuttle ..
·< 2 8. 97- 1656 Spring support (lower) 2 9. 97-2091 Nut. hydraulio stop lln-" u.N.F.) 2
10. 75- 5104 Lower bush 2 11. 97-2154 Shullle. damping 2 J2. 97-3904 Stanchion 2 13. 75- 5099 Oil seal .. 2 14. 97-3633 Lower cover tube 2 15. 75-5199 •·o·· ring. sleeve 2 16. 75- 5088 Outer retaining washer 2 17. 75- 5105 Upper bush 2 18. 75- 5091 l nner sleeve 2 -- 19. 97- 3921 Outer member (left-hand) 20. 40-5069 Sealing \\asher .. 2 21. 97- 2126 Bolt. res1ric1or ( ''4 • t..N.F. 1-3/32" J 2 22. 75- 5095 Cap. outer member 2 23. 54-8003 Washer. cap bolt 4 2-1. 14-0218 Bolt. outer member cap (¼" U.N.• . 1%") 4 25. 97 0519 Drain plug 2. 26. 54-0042 Drain plug joint washer 2 27. 97-3922 Outer member (right-hand) 28. 97 2090 Res1ric1or. damping 2
97- 3911 Fork complete ..
35
Plate 13
I 2 3
41 40 39 ~
37
32
36
35
ID- 34
33 /
, e
36
5
@
• 10
ti
30
' 6
12
13
27 26 28 25 24
• Plate 13
Plate Spares Re( ,\ 'umber
I. 2. 3. 4 . 5. 6. 7. 8. 9.
10. I I. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 35. 36. 37. 38. 39. 40. 41.
42- 5819 37- 1481 37- 2240 37- 3317 37- 3582 37- 3337 42- 5819 42- 6335 37-2001 37- 1996 42- 5841 37- 2026 37- 2129 82- 2351 21-1998 37- 1991 37-3522 37- 3453 37- 2027 14-0303 21 - 1995 14-0-1-0I 37-2005 14-0303 37- 2027 37- 2003 42-5836 60-2683 37-3454 37-2026 19-7734 37-2059 42-5812 37-1197 37-1198 37- 1709 37- 1708 37-1230 37- 1328 37-2092 42-5820 57-0280 37- 3312 37- 3461
FRONT WHEEL
Description
Bearing (Hoffman 120) Grease retaining cap (left-hand) Nave plate . . . . From hub \\ith spindle and bearings Wheel spindle .. Backing ring . . Bearing (Hoffman 120) Bearing reta.iner Brake cam Brake shoe complete . . Brake shoe spring
" .. Brake shoe abutment pad Brake anchor plate with gauze. less brake details Washer. for sere" line 15 Sere". gauze fixing (Taptite 4-40 ,'
0-"J
Gauze shield. air scoop Brake lever return spring Brake lever (front) .. Washer. lever fixing nut (1-1 32" 17132" 13 G.) Nut. lever fixing {3g" u.N.F.) Brake anchor plate nut Brake rod fork end locknut (¼ ' U.N.F.) Brake rod fork end Nut, rear lever fixing (3 8 • U.N.F.) .. Washer. rear lever fixing nut (1-J/32" 17,32" 13 G.l Brake rod Brake rod pivot pin Split pin, pivot pin fixing(,'.' x-18') Brake lever (rear) Brake shoe abutment pad Brake lining Brake lining rivet Spoke nipple Balance weight ( ·' ,J Balance \\eight (I") Spoke (right-hand inner) Spoke (right-hand outer) Rim (WM2-19, steel) .. Spoke (left-hand) Screw. nave plate fixing (4 e.A. x ¼ ') Dust cap Circlip. dust cap fixing Wheel complete with spindle and bearings Brake anchor plate complete with brake details ..
37
Per Set
2 2 2
3 3
3 3
2 14 40
as reqd. as reqd.
10 10
20 3
Plate 14
33
c? 3• 3S
IC> 38
II
12 32
13 31
1• 30
29
28
t©Y@ 27 26 2S 16
17 0~ N '/ 22 I)
~ /!,'OJ@ 18
~ 6SJ ~ ' 19
20 21
38
• Plate 14
Plate Spares Ref Number
1. 14-0304 2. 40-4071 3. 83- 1687 4. 14-0403 5. 37- 2027 6. 37 2015 7. 37- 1710 8. 37- 3587 9. 42- 5819
10. 37- 1022 11. 37- 1474 12. 37- 1278 13. 37-3623 14. 37-3575 15. 37-1104 16. 37-1106 17. 37 0270 18. 42-5812 19. 37-3468 20. 14-1902 21. 40-6040 22. 2 1-0585 23. 37 2089 24. 21-2013 25. 37-1280 26. 19-9221 27. 37-1477 28. 37-3588 29. 37-1654 30, 42-5819 31. 37-1635 32. 37-3589 33. 37-3592 34. 41-6078 35. 41 - 6076 36. 14-1202 37. 21-2011 • 38. 37-3585 39. 37- 1024 40. 37- 3412 41. 35-6436 42. 19-7711 43. 29-0541 44. 21-2010• 45. 41 -6073 46. 42-5841 47. 37-3590 48. 21-2014 49. 37-1090 50. 82-9997 51. 82-8919 52. 2 1-1802 53. 40-407 I 54. 14-0304 55. 19-8693
37-3622 37-3608
REAR \VHEEL
Description
Nul. lorque slay l0 brake plale (*' U.N.F.) Spring washer. for nut line I Torque slay. brake plale . Nut, brake lever 10 cam spindle (J, U.N.F.) Washer. for nut line 4 Le,er. brake plate .. Locking sere\\, bearing reiaincr (drive-side) Bearing rc1ainer (drive-side) .. Bearing. drive-side (Hoffman 120) Backing ring. drive-side bearing Grease rerniner (drh·e-side) .. Spacer tube Hub \\ilh spindle and bearings Spoke (drive-side inner) Spoke (drive-side ou1er) Spoke (liming-side) Wheel rim (WM3- 19) Spoke nipple Securily boll . . Nu1. "heel adjusler (¼" v.N.F.) End plate, wheel adjuster Nul, ouler spindle (-', U.N.E.F.J Wheel adjusler .. Reiaining nul (liming-side -', U.N.E.F.) Washer. for nut li ne 24 Speedometer gearbox. m.p.h. and k.p.h. (Sm ilhs BG.5330, 168) Dis1ancc piece Speedome1cr drive ring Inner dusl cap (liming-side) .. Bearing (Hoffman 120) Grease relainer (liming-side) . . Wheel spindle .. Brake cam spindle Pivol pad for brake shoe Trailing brake shoe Nul. b1ake drum 10 hub (¼" U.N.F.) Bolt, brake drum 10 hub (¼' U.N.F. ¾ ') Brake drum Dislance piece. drive-side bearing Sprockel (53 l<elh) Rivel. brake lining Brake li ning Lockwasher. for boll line 44 Boll. sprockel 10 brake drum ('~• U.N.F. x JJ/16") Leading brake shoe Spring. brake shoe Brake anchor plate less brake delails Nut, inner drive-side spindle Relurn spring. brake lever .. Chain oiler pipe (shorl) Chain oiler pipe (long) . . Boll. anchor slrap 10 swinging arm(¾' u.N.F. x 27/32') Spring \\asher. for nul line 54 . . . . . . . . Nu(, for boll line 51 (¼' U.N.F.) . . Rear chain Os' x-\'s' 108 pitch) .. Rear wheel wilh spindle and bearings Rear brake anchor plate with brake de1ails
•Special ma1erial: 37.-ENSR. 4-4.-ENSR.
39
Per Set
10 lO 20
40 2 2 2 2 2
2
8 8
16 2 8 8
2
Plate 15
10
\
14---
16 -----=---l5 - ~'[I
61
---60
~~;0-~1l--57 54~~
!:~:2 /l ' ~ -56 ~ 51 50 49
~
35 36
26
.r--
Plate 15 • HANDRAIL, MVDGVARDS, CHAlN GUARD
Plaie Spares Per Ref. Number Description Set
I. 82-8490 Rear chainguard 2. 29-0541 Spring washer. chainguard bolt 3. 14-0206 Chainguard bolt. fron1 fixing (' • • L.N.F. I ',I 4. 14-0101 Boil. siay to mudguard (14 L.,.,. I ~ • ) 2 s. 97-3897 Fron1 mudgaurd siay . . 6. 68-6524• Fron1 number plate . . 7. 42-6558• Number pla1e beading . ... 8. 82-9020• Spring "asher. number pla1c 2 9. 02-2395* Nut. front number plate ( ', e.s.c.) 2
10. 82-8485 Handrail 11. 21-1990 Bolt. handrail IO frame (¼" U. N.F. ~s") .. 2 12. 15-5155 Washer, handrail to frame li6 • I •
l .048") 2 13. 14-1202 Nut, handrail to frame <io • u.N.F.) 2 14. 14-1301 ut. mudguard to frame n, L.l',.f.) 2 15. 27-8560 Washer. mudguard 10 frame 2 16. 82-9327 Rear lamp support 17. 68--0829 Rear lamp support plate 18. 54-9012 Screw, plate to support (2 B.A. 13 32") 3 19. 14-0101 Bolt. number pla1e bracket ( •·• • l...N. F. I ! ") 2 20. 54-9081 Washer. number plate bracket 4 21. 68-6830 1'umber plate bracket 2 2. 14-1201 Nut. number plate bracket bolt ( ' • u.N.~.) 2 23. 54-0170 Locb,asher (bottom scre" only) 24. 21-5161 Nut for bottom sere\\ (2 B.A.)
25. 82-8195 Push-fix. rear ,ide reflector 4 26. 82-8528 Rear mudguard (U.S.A.) 26. 83-1632 Rear mudguard (standard) 17. 19-0943 Rear side reflec1or ( Lucas 5711 1) 2 18. 82-8140 Rubber pad. side rcflec1or . . 2 29. 21-0547 Stud. rear lamp support ( 11, • u.N.C.1 u.N.F. 7,g ") 30. 42-5575 Washer. suppo, t s1ud .. 3 1. 14-1201 Nut. suppoll stud (I .. U.N.F.) 32. 27-8560 Washer. mudguard 10 frame ( •~ • ;s" .048") 2
41
Plate 15- Contd.
, ' ~•-~~,, -s,
°' S4 55 5352 - L;-56
I /.. SI SO
7._,s. - 49
_:(j; "!\ ,
10
16----~-
17---· - , 3S 36
293031
"-, .....,
• Plate 15- co111i1111ed
Pia re Spare, Rd. \'umber
33. 14-0101 34. 14-0113 35. 14-0101 :¼. 27-85(,0 37. 27 8560 38. 14-1301 39. 82-8518 40. 02-0923 -II. 14- 1302 42. 68-6837* -13. 14- 060-I* ..... 27- 8560* -15. 29-054 I• -16. 21 - 5102 -17. 82-9020 48. 14-0301 49. 14-0114 50. 54-0055 51. 14-0702 52. 14-1301 53. 02-0525 5,1. 21-1822 ss. 54-5504 56. 97-3926 57. 82-8520 58. 14-1301 59. 02-0525 60. 97- 3919 60. 97- 3896 61. 14-0101
HANDRAIL. :\IUDGl'ARDS. CHAINGl:ARD
D/scription
Bolt. mudguard to frame ( 14 L.'-.F.
Bolt. bndge to mudgua,d ( r';, l.'- .F.
Bolt. mudguard to frame (I, L.N.F.
Washer. mudguard to frame Washer. mudguard to frame Nut. mudguard to frame ( 1, " L., .F. )
Rear mudguard bndge Washer. bridge 10 mudguard Nut. bridge 10 mudguard (r~-· L.,o.)
Rear number plate Top mounting bolt \Vasher. rear number plate Lock\,a;her. rear number plate Nut. rear number plate ( I 4 • BS. F. ) ..
Spring \\ll'>hcr. rear number plate .. Nut. rear number plate (I, L.N.F.)
Bolt. ;tay to fork (T~ . l,.'\.I·. ) ,)
Wa,her. Sta> to fork(¼" ~~- ,\") Nut. ,tay to fork (n;-" L . ...,.F,)
Nut. stay to mudguard (' 4 • 1,.,.r.)
I 1 ")
5 ~/")
I 2 •)
.. ...
\Vasher. ,tay to mudguard(', ' 1• .048"> 80•1. bracket 10 fork <,l6 l .'I.F. 1
1 ·1 Washer. bracket to fork Square nut. bracket 10 fork (f.-" t.. .1'.F.) Front mudguard bracket Nut. mudguard 10 bracket (' 4 u.rs.F.) Washer. mudguard 10 bracket Front mudguard (standard) .. Front mudguard (U.S.A.) Bolt. mudguard to bracket ( 14 U.N.F. I 2 ")
*Except U.S.A. models
43
Per Ser
2 2 2 2 2 2
2 2
2
2
2 2 2 2 2 2 2 2 2 2
4
4
4
Plate 16
4 s
~ .._,
51 \ so 2
49
41 40 39 36 37
44
6
14 •IS 16
~- ;? ~,
J ¼'~ _, , ~ S ~01112~
7
32
33
34
JS
36
-17
• Plate 16 PETROL TANK, HANDLEBAR AND CONTROLS
r--Plate Spares Per Ref Vumber Descriprion Set
8.S.A. :SO. \IAKERS ~O.
I. 60- 2445 Clutch control cable 2. 40~960 Handlebar 3. 75-4909 Handlebar slee,e 4 4. 60-2060 Air control cable. right-hand (carbure11er to junction box) 4. 60- 2061 Air control cable. centre (carbure11er 10 junction box) .. 4. 60- 2062 Air cont rol cable. left-hand (carburetter to junction box) 5. 60-1978 Junction box, air control cable 6. 11, 014 Brake Je,er clamp sere" (short)
' 6. 11 013 Brake lever clamp sere" (long) 6. 11 01~ Clutch lever clamp screw 2 7. 60-1968 Air control cable, j unction box to lever 8. 12 556 Air control le,er assembly 9. 60-2076 Front brake cable complete
10. 19, 001 Brake control lever body 10. 19 002 Clutch control Je,er body 11 . 18,053 Clutch and brake lever fulcrum pin nut 2 12. 18,087 Clutch and brake lever fulcrum pin 2 13. 18 754 Brake lever only 13. 18 752 Clutch le,er only
Po-- l4. 60-2071 18 1708 Brake and clutch cable adjuster (-\ 3" l),1'.F,) 2
"'" 15. 60-2072 18 1709 Brake and clutch cable adjuster locknut (-' $" ~.:s.>.l 2 16. 12 595 Clutch le,er clamp 17. 60-2241 19 978M F ront brake and air control complete 18. 60-2202 Throttle control cable 19. 19- 7237 364 11 Throttle control complete 20. 11 013 Body sere", throttle control .. 2 21. 364, 013 Body top half, throttle control 22. 5,077 Locknut, rotor stop screw 23. 364 020 Adjusting screw. rotor stop .. 24. 16 008 Friction spring, throttle control 25. 16 010 Locknut, friction spring screw
45
Plate 16- Contd.
-
49
47
18
21 ~~-20
22 ~- 24
2~ ~ 28 "~t ~ -26 - 30 7
~ - 31
_ 32
33 @
A 34
35 38 37 , ~v 39 <10 41
36
46
Plate 16-Contd. • PETROL TANK, HANDLEBAR AND CONTROLS
Plat, Spares Per Ref. ,Vumber Description Ser
8.S.A. ,o. \IAKCRS NO.
26. 16 009 Sere\,. friction spring .. 27. 82-9919 Tank mounting rubber (front) 28. 364 014 Body bollom hair. thro11le control .. 29. 364 017 Rotor. throule control 30. 19-7222 Handlebar grip (right-hand) . . 31. 21-6206 Screw, badge and panel mounting (2 B.A. ~-:t) .. 6 32. 82-8610 Tank badge (left-hand) 32. 82- 8611 Tank badge (righ t-hand) 33. 83-0002 Seal \\asher, petrol tap ., 2 34. 70-7351 Petrol tap seal . . 2 35. 82-4972 Main petrol tap 35. 82-497 1 Reserve petrol tap 36. 82-9436 Petrol pipe assembly 37. 82-8591 Knee grip (right-hand) 37. 82- 8590 Knee grip (left-hand) .. 38. 82- 8589 Tank panel (right-hand) 38. 82- 8588 Tank panel (left-hand) 39. 21- 1993 Tank mounting bolt (y0 ' u.i,. .F. 3-r.-' ) -'O. 82-8391 Petrol tank with fixed fillings 41. 82- 9920 Tank mounting rubber (rear) 42. 82- 8327 Spacer tube, tank mounting . . 43. 03- 0101 Washer, tank mounting 2 44. 76-4120 Space, tube, tank mounting 45. 40-8085 Tank mounting rubber 46. 14-0302 Nut, for bolt line 39 (¼' U.N.F.)
47. 82- 8947 Washer, for screw line 48 4 48. 82- 8946 Screw, petrol lank styling strip (2 B.A. x ~6•) 4 49. 82-8609 Petrol tank styling st rip .so. 60-2242 19.952M Clutch control complete .SI. 68- 8717 Handlebar grip (left-hand)
Note:- Where no B.S.A. part number is quoted. the part is only available from the makers.
47
Plate 17
2 3
J2~
l' ,;J
s
, ,
6 7
4 IJ
---1
48
• Plate 17
Plme Ref
Sp.ires Number
I. 97- 2273 2. 68- 9223 2. 3. -1.
5. 6. 7. 8. 8. 9.
83- 1430 68- 9226 82- 8850 82- 8744 82- 8942 40-8046 60-0853 60-0354 21- 0767
9. 21 - 1979 10. 82- 9964 11. 82-8849 12. 83-1456 13. 14-0219 14. 54-2537 IS. 70- 9037 15. 70- 9036 16. 82- 8519 17. 14-0101 18. 75-27 19 19. 14-1302 20. 14-0302 2 I. 02--0923 22. 14-1902 23. 82-8667 24. 14- 1303 25. 82-8584 25. 8~8583 26. 02-1733 27. 14-0129 28. 76--0:l 12 28. 54-8003 29. 14--0113 29. 21 - 1822 30. 14-1301 3 1. 14-1202 32. 15- 5155
TWINSEAT, SIDECOVERS, SILENCERS
D1!$<·riptio11
Clutch cable clip "Oddie" stud. left-hand sideco-,r .. Sidecover fastener "Oddie" stud rubber .. Sidecover complete (left-hand) Styling strip. sidecovers Twinseat complete Front mounting rubb<,r, t\\ inseat Sidecover name plate (right-hand ) Sidecover name plate (left-hand) Screw, sidecover to oil tank ( •;, • U.N.F.
Screw. sidecover to oil tank . . Rubber washer. sideco,er to oil tank screw Sidecover complete (right-hand) Protective strip. sidecover (right-hand) Bolt, silencer to exhaust pipe clip (¼" u .N.F. 11'2' ) Clip, silencer to exhaust pipe Silencer (right-hand) Silencer (left-hand) Silencer support stay Bolt, support stay to silencer ( '• • U.N.F. 1 i · 1 Saddle "asher, silencer clip .. Nut. silencer clip bolt (¼* u .N.F.)
Nut, support stay to handrail (¼" u .N.F.)
Washer, support ,tay to handrail (¼* ~ 58" Tl;')
Nut, support stay to handrail l¼ • u.N.F.)
Support rubber, minseat Nut, bracket to silentbloc Ps' u.N.F.)
Silencer bracket (left-hand) . . Silencer bracket (right-hand) Washer, bracket to silentbloc Bolt, bracket to silentbloc ( ~8• U.N.F. 114 ")
'
Washer, bracket to silencer- left-hand (21 /64' 9116" 3/ 32") Washer, bracket to silencer- righ t-hand Bolt. bracket to silencer- left•hand (¼" u .N.F. %") Bolt, bracket to silencer- right-hand (,'0 * u .N.F. x ½*) Nut, support stay to silencer bolt(¼" U.N.F.) Nut, twinseat mounting(¼' u.N.F.)
Washer, twinseat mounting (¼ • x % • .040' )
49
Per Ser
2
3
2
2
2 3
2 2
2 2 4
2
2 2 2 2 2
2 2 2 2 2
2 2 2 2
Plate 18
5 t 6 6 ij 2 7 G
©--3 ® 4
8
©
22 21 20
25 24 -- -
I 2829 30
50
--
19
12
~n ® 13
17 18
37 ~ 36
35
31- ~
34
33 32
\ .._J
14
16 15
..
• Plate 18 TOOLBOX, BATTERY CARRIER, AIR CLEANER
Plore Spares Per Ref. Number Description Set
I. 82- 8495 Toolbox 2. 14-0101 Bolt. toolbox to frame ( ¼ • u.N.F. ~2 ") 2 3. 02--0525 Washer. toolbox to frame 2 4. 82-9020 Spring washer, toolbox to frame bolt (¼" ·19/32" .040") 2 5. 21 -0768 Bolt, battery carrier 10 frame (¼" u.N.F. I¾") .. 3 6. 02-2138 Washer (top), battery carrier 10 frame bolt (h" xJ4 x +.") 3 7. 40-4524 Rubber, battery carrier to frame 3 8. 82-8463 Battery carrier . . ; . ·, 9. 40-4524 Rubber, battery carrier to frame 3
10. 82-9008 Washer (bottom), battery can ier to frame bolt 3 11. 14-1202 Nut, battery ca rrier to frame (¼" U.N.F.) 3 12. 68-4577 Banery strap 13. 82-9004 Battery strap hook 14. 68-4597 Banery tray 15. 14-0213 Bolt , air cleaner box ( ¼ • u.N.F. x 3 h") 2 16. 40-2705 Washer, for bolt line 15 (17,64" 15/32" ,\-") 2 17. 82- 9562 Grommet. air cleaner box 3 18. 82-9675 Air cleaner box 19. 82-9845 Air cleaner element 20. 82-8969 Air cleaner cover 21. 29--0541 Lockwasher. a ir cleaner cover (17164" I 5132" x .024"1 2 22. 14-0101 Bolt. air cleaner co,er (¼ • u.N.F. 1,2 ") 2 23. 82- 7431 Banery ,em pipe
24. 60--0706 Clip, breather pipe to air cleaner 2 25. 82-8743 Engine breather pipe ..
26. 82- 7835 Rubber buffer, support br~cket 2 27. 82-9682 Support bracket 28. 14-1202 Nut, bracket 10 frame bolt ( ¼ • u.N.F.) 2 29. 02-0525 Washer, bracket 10 frame bolt (¼ • ½" X .048") 2 30. 14-0101 Bolt, bracket fixing ( ¼. U.N.F. X ½ ") 2 31. 82- 9654 Sleeve for coils 3 32. 14-0101 Bolt, coil support 10 frame (¼" u.N.F. ½") 33. 82-9020 Spring washer, coil support to frame bolt (¼" x 19/32' .,, .040")
34. 83-1384 Coil support complete
35. 82- 8549 Coil clamp
36. 24-7068 Spriog washer, coil clamp bolt 2 37. 21-1981 Bolt, coil cla mp (number JO u.N.F. x 2") 2
51
Plate 19
2 :; 4
5 6 7
14 1:: !2
15,---,
17'--- 8
21 20 19 13
33 32
31 30
2
ef,~
23
24 29
25
52
--Plate 19
Pia re Spares Ref Number
I . 82-9687 2. 82-8657 3. 21-0752 4. 82-8667 s. 82-8628 s. 6. 7. 8. 9.
10. II. 12. 13. 14. IS.
82-8629 02-0S2S 21-0761 19-0987 02-1096 21-0762 82- 9322 82- 8657 02-0525 14-1301 82- 9315
16. 70-8906 17. 60-0702 18. 14-1301 19. 27-8560 20. ~8436 21. 21 -0754 22. 82-9664 23. 82- 8459 2~. 02-0923 25. 14-0217 26. 83-1387 27. 68-0610 28. 83-1766 29. 82- 9530 29. 82- 9531 .30. 70-6848 31. 70-8904 32. 70-8907 33. 60-0702 34. 82-6874 35. 82- 9435 36. 82- 8627 37. 83-1386· 38. 82-9918
OIL TANK AND OIL COOLER
Description
Oil cooler cradle Rubber, oil cooler moun1ing Bolt, oil cooler moun1 ing !¼' U.N.F. 1-15164') .. Rubber pad, pelrol tank to cooler cradle Oil cooler cover (left-hand) .. Oil cooler cover (right-hand) Washer, cover fixing- front (¼ • %' x .048') Screw, co,cr fixing- fron1 (¼ • U.N.F. x 9/16') Side reflector (Lucas 57 161) .. Washer, cover fixing- rear (,t· x 38• x .044') Screw, cover fixing- rear (Posidrive number 10 9/ 16') Packing rubber, oil cooler 10 strap Rubber. cooler cradle mouniing Washer. cooler cradle mounting ( '• • ' 2 • .048") Nu1, cooler cradle mounting<'• 1-.N.F.) ..
Oil cooler Flexible pipe, oil cooler 10 rocker box Clip, flexible oil pipe , .
u1. oil tank top mounling <'• L,N,F.)
Washer. oil tank top mounting (1, ' ;R• .048") Rubber. oil tank top mounting Boll. oil rnnk 1op mouniing fl, L ..... F. P , ) Breaihe, pipe. oil tank Rubber. bonom c il innk moun1ing Washer. bonom oil tank mounting <-f. • ;, ,\-"I Bolt. bouom oil 1ank mounting (,~ • u .'I.F. I ' 4 J
Oil lank filler plug comple1e "O" ring. filter plug .. Oil 1ank "ith fixed fillings Oil feed pipe spring . . Oil return pipe spring Clip, flexible oil feed pipe Flexible pipe, oil tank 10 engine Flexible pipe, cooler lo tank Clip, flexible oil pipe .. Mete;ing screw spring Melering screw, chain oiler ( ¼ • u.N.F. x 29/64') . , Filler cap, dipstick Slud. oil lank front fixing(¼ " U.N.F./ U.N.F. x 1-9/ 16') Clip. oil pipes to frame
•Special material : 37.- ENl4B,
53
'
Per Set
2 2 2
4
4 2 2 2
8 2
l 2
2
3 4
2
2
2
4
Plate 20 ·
7 9 !O
2 3 " 5 6 8 II
•
~ v 353637 /
38 39
75
0 21--'· ,·.4 ,._,
23_)\~ 24 - ~
~ 70 69
,~ ; 'P
72 - "" " 73~ l-71 A ';::;"-65 ~
.~-74 -u' ~ ,
~ ::: -1Y 78 7980
©~ I 45 54 55 56
62 ,,6., 61~- 60
~59
~, 43 44
41 42
~~
L40J
SI
54
• Plate 20
Plate Spares Ref Number
I. 19 0~bl I. 19-1149 2. 3. 4. 4. 4. l9-i043 5. 97 1932 6. 6. 6. 19 1044 7. 8. 9.
10. 11. 12. 97-3631 13. 70-8770 14. 19-8953 15. 19-89-18 15. 19-8949 16. 19 1164 17. 82-6981 18. 19-9080 19. 19--0982 20. 19--0965 21. 19-1775 22. 97-2297 23. 19-1303 24. 19-9090 25. 19-9091 26. 75 9046 27. 40-2705 28. 14-1201 29. 30. 31.
32.
33. 19-1304 34. 34. 35. 19-1874 J(;. 19-1875 37. 19-1876 38. 19-1882 39. 19-1881 40. 19-1715
••
ELECTRICAL EQUIPMENT
Descrip1io11
Heldlamp complete. ,tandard (Lucas 59892) Headlamp complete. Europe (Lucas 59894) Headlamp rim ( Lucas 553248) Wire fixing light unit (Lucas 504665) Light unit. standard (Lucas 5 16798) Light unit. Europe (Luca, 54522680) Light u11it. Wc,t G ·rmany ,1nd Ital) (Lucas 516801) H~aulamp spacer . . . Main bulb, standard (Lucas 4461 .. Main bulb. Europe (Lucas 410) . . Main bulb. West Germany and Ital> (Lucas 370) , Sleeve, terminal (Lucas 555910) Lamp body (Lucas 54524099) .. Sere\\ fixing. headlamp rim (Lucas 144921 I Plate for rim sere" ( Lucas 534296) E.x ten,ion cover ( Lucas 54524048) .. Sleeve nut. speedometer tachometer mounting ( 10 l.".r.J Washer, for nut line 12 . Tachometer head (Smiths RSM.3003 I 3) .. Speedometer head, m.p.h (Smiths SSM.5007 001 Speedometer head, k.p.h. (Smiths SSM.5007 OJ l . A mmete1 ( Lucas 3642 I) . Ignition lock and key (Wilmot Breedon 1-6280) Speedometer trip shaft (Smiths 41-148 203-10) High beam \\Urning light. green (Lucas 38 191) Oil pressure warning light. red (Lucas 38189) Ignition switch (Lucas 31899) Binnacle complete . . . . Light lead for speedometer tachometer ( Lucas 549534461 Speedometer cable (Smiths ) Tachometer cable (Smiths DF.9111 00) Cable cli p Washer, binnacle mounting .. Nut, binnacle mounting (¼' u.N.f.) .. Washer. headlamp mounting (Lucas I 37498) Bolt, headlamp mounting (Lucas 112201) . . Pilot bulb holder (Lucas 54573590) .. Interior, pilot bulb holder (Lucas 553780)-110, illustrared Pilot bulb (Lucas 989) ..
0 Adap1or, headlamp-Europe (Lucas 553738}-1101 il!t,strmed . •Spring, retaining main bulb-Europe (Lucas 556442)-1101 illustraud
Main wiring harness (Lucas 54955800) Fuse holder complete (Lucas 54190387) .. Fuse only, 35 amp. (Lucas 188218) Identification sleeve for high-tension lead number I Identification sleeve for high-tension lead number 2 Identification ~leeve for high-tension lead number 3 . . High-tension lead (Lucas 54956435) for use with Lucas coil High-tension coil (Lucas 45221) Rectifier \\0ith nut (Lucas 49072)
55
Per Set
a 4 2 2
3 3
I
Plate 20- Contd.
7 910
2 3 4 5 6 8 II
~ y 353637 ✓
38 39
25
17•--·~ .J @ G ?
2•-••--...1, .;_;
23_:_'0 24 \--=-'" 70 69 .
•
¢---65
,'&-74
75 V
t76. 77
1 ~ -64
~ ' ~~ :.: ~
78 ,9 so G--63
"' " ",, ::~~~ ~ ,~
0~ ~ 57 I~
~ I 54 5556 //
~~ 43 4445 ~~~ 41 42 ,;,
~~ er 52 53
~40
47 --------.-.,,,------' 51
•
,. •
Plate 20-cootd.
Plate Spares Ref Number
41. 14 0 104 42. 02-0525 43. 19 2076 -13. 19- 2077 4-1 . 57 3638 45. 1-1 1901 -16. 47. -18.
-19. so. 51. 19- 1245 52. SJ. 54. 19- 1848 55. 19- 1847 56. 19 1861 57. 58. 19-1873 59. 21 - 0770 60. 24-0978 61. 02- 1096 62. 19-0916 63. 82- 9692 64. 19- 1030 65. 19-6508 66. 68- 9351 67. 97-2259 68. 19-1152 69. 5.µ;510 70. 21 - 5 160 71. 97- 1994 72. 19- 1150 73. 19-1153 74. 19-1735 75. 21--0778 76. 02- 1096 77. 21--0762 78. 21--0762 79. 02-1096 80. 21--0778 81. 19--0953 82. 19- 1869
19-1776
ELECTRICAL EQUIPMENT
Desrrlption
Bolt, horn m.>unting ( •~ • U.N.F. J's") Washer. horn mounting(•~· '/ .048") Windtone horn , right-hand (Clearhooter SF725H) Windtonc horn. left-hand (Clearhooter SF725L) Sp'.1cer. horn to frame Nut. horn mountin~ I 4 u .N.F.) • Sere" for stop lamp lens (Lucas 144921). . ~ .. Lens for stop lamp (Lucas 54577109) Bulb for stop lamp (:..ucas 380) Interior, bulb holder (Lucas 573828)- 1101 illustrawl Bulb holder assembly (Lucas 54578213) Base assembly (Lucas 5-1578212) Stop tail lamp (Lucas 53973) Washer. for fi,ing screw (Lucas 188330) .. Screw for fixing lamp (Lucas 110714) . Rubber cover. condenser pack (Lucas 544185281 Condenser (Lucas 54420128) Condenser base plate (Lucas 54418526) Gas°ket. stop tail lamp (Lucas 54571677) Grommet. for tail lamp leads (Lucas 199001) Sere". stop S\,itch mounting (number 10 u.N.F. ' 2 "J Spring wa,her. stop S\\itch mounting ( '·• -i6 19 G I Washer. , top S\\itch mounting ,-a· '• .044") .. Stop lamp S\\ itch (Lucas 34815) . . Rubber co,er for light S\\ itch. line 64 Light "'itch (Lucas 31788) . . . . Oil pressure S\\ itch (Smiths 5300 I 07) Clip, cut-out switch mounting Cup. ignition cut-out s" itch . . Ignition cut-out S\\itch (Lucas 35835). Sere", cut-out S\\ itch mounting cLip Nut, for sere\\ line 69 (2 B.A.) Screw. dipper switch to handlebar (number 6 32 Taptite) Horn and dipper S\\itch less cable (Lucas .3 I 563) Mounting pad for dipper switch (Lucas 380459) Zener diode (Lucas 49345) .. Nut, horn relay mounting (number 10 u.N.F.) Washer, horn relay mounting (,t" -\8 " .044") .. Screw. horn relay mounting (number 10 u.N.F. ~3) Bolt. condenser pack mounting (number 10 u.N.F. ~8•) Washer. condenser pack mounting (,t" x 38" x .044") Nut, condenser pack mounting (number 10 u.N.F.) Horn relay ( Lucas 33188) Tail lamp lead (Lucas 54953444) . . Battery. 12 volt (Lucas 54027029) ..
*Other details are same as 19-981, headlamp.
NOTE:- Where no B.S.A. part number is quoted the part is only available from the makers.
51
Per Set
4 8
4 4
2 2
3
2 2 2 2
2
2
2 2 2 2 2 2
Plate 21
36
~ ff : ~ _ . 33
37
4-c=.-i ">
C> :~r :: I <g)--00 Qi
,7---: \! ' " I
~ ' ,,' ~44
·-. i(\\IC'i .. " 0 ,___26 0 ') "'------ - ~ I I ~ ' _ _,, ' o- -'S 'l 'l ~:~ @@
I e '-~'- :: '"J~ S2
.. "~J:5 . ©11 .._ 0 - S6 55 54 53 - -18
12!-- 6
--17
13- ®
- 16
58
• Plate 21 CARBURETTERS AND THROTTLE LINKAGE
P/J,e Ref
Spares Number Descrlp1io11
I. 2. 3.
"· s. 6. 7. 8. 9.
10.
11. 12. 13. 14. IS. 16. 17. 18. 19. 20. 21. 22. 23. u. 25. 25. 25. 26. 27. 28. 29. JO. JI. 32. 33. 3-'. 35. 36. 37. 38. 39. 40. 41. .. u. 43. 44. 4 5. -46. 47. 48. 49. .5-0. 5 1. 52. 53. 54. 55. 56.
B,S.A. NO. Jg-21 11
19- 3093
19- 3091 19- 3138 70-9Jd6
19- 3116 19- 3105 19- 3048 19-2834 19- 3103 19- 3093 19- 3132 19 3102 19- 3106 19-3099
19- 3136
MAKERS NO. 4 035 5.011 622 125 622 086 622 097 622 129 622 134 622 062 622 060
Air cable adjuster Air cable adjuster locknut Seal locating clip Screw and washer for top cap Carburetter top cap . . Air valve spring . . Air valve spring guide Air valve .. Throttle valve (3) Adaptor, carburetter intake
622 107 Pilot jet iube (nor removable) • . . 622 071 Float spindle 622 068 eedle for float 376. 093 Petrol filter .. 13 163 Fibre "asher for banjo bolt .. 622 078 Banjo bolt. petrol pipe to float chamber 622 086 Sere\\ and washer for Ooat chamber 622 050 Carburetter ftoat chamber 622 069 Carburetter float 622 073 Float chamber gasket .. 376 100 Main jet (15-0 c.c.) 622 128 Main jet holder 622 122 Needle jet (.106") 622 133 Plug sere" . . 622 076 Pilot air adjusting sere"
'
19- 3113 19- 3098 19- 2409 19- 2415 19- 2408 19 3090 19- 3137 19- 3095 60- 1937 60- 1960 60-1959
622 082 "O" ring for pilot air sere" . . L.626 15 Carburetter complete. left-hand (short air cable) R.626 16 Carburetter c.:,mplete. centre (medium air cable) R.626 14 Carburetter complete. right-hand (long air cable) 622 IOI ·•o .. ring. c:irburetter flange . 621 124 Tnrottlc needle . . 622 067 Clip for throttle needle 622 I 16 Retaining plate_. throttle rod spring 622 I 13 Retaining spring, throttle rod 622 115 Retaining cap. throttle rod 622 126 Seal washer. top cap ..
70-9243 Trunnion. throttle linkage 70- 9253 locknut. throttle rod .. 60- 1984 622 I 19 Throttle assembly 70- 9278 Arm assembly. throttle linkage 70-9073 Bush. throttle arm 70-9254 Spring. adjuster screw, throttle stop 70-982 1 Ret:tiner. throttle return spring 70-9252 Adjuster screw, throttle stop 70- 9880 Throttle return spring 70-9820 Spacer. throttle return spring 70-9243 Trunnion, throttle linkage 21--0774 Screw, support arm to adaptor 70-9242 Support arm. throttle linkage 70-9073 Bush, adaptor spindle 70-9060 Connection tube 60-0707 ··Jubilee., clip. connection tube 71--0245 Backing washer. spindle 70-9255 Circlip. spindle . . 70-9251 Spindle. throttle linkage 70-7633 Carburetter adaptor . . . . 14- 1619 Stud, carburetter mounting(¼" U.N.c./u.N.F. I¼•) 54-0055 Washer. carburetter mounting . .
· 14--0302 Nut, carburetter mounting (¼" U.N.F.) NOTE:- Where no B.S.A. part number is quoted, the part is on ly available from the makers.
- ---- ------- ---------------- -----59
Per Set
3 3 3 6 3 3 3 3 3 3 3 3 3 3 3 3 6 3 3 3 3 3
·' 3 3 3
3 3 3 3 3 3 3 3 3 3
2
2
2 3 6
2
6 6 6
Plate 22
~'...----3
~1-4
~5
10
9 ?
60
C
Plate 21 CARBURETTERS AND THROTTLE LINKAGE
Pl.lie Ref
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. 25. 25. 26. 27. 28. 29. JO. J I. -32. 33. -34. 35. -36. -37.
Spares jVumbtr Descl'iprio11
8.S,A. N:>. l~-2711
19-3093
19- 3091 19- 3138 70-9S86
MAKERS NO. 4,035 5077 622 125 622 086 622 097 622 129 622 134 622 062. 622 060
Air cable adjuster Air cable adjuster locknut Seal locating clip . . Sere" and washer for top cap Carburettc, top cap . . Air valve spring Air valve spring guide Air valve Throttle valve (3) Adaptor, carbure1ter intake . .
622 !07 Pilot jet tube (not removable) 622 071 Float spindle . . 622 068 Needle for float 376 093 Petrol filter . .
~- . 19-3 116 19- 3 105 19 3048 19- 2834 19-3103 19- 3093 19- 3132 19- 3102 19- 3 106 19- 3099
13 163 Fibre washer for banjo bolt . . . 622 078 Banjo bolt, petrol pipe to float chamber
19 3136
19- 3 11 3 19- 3098 19- 2409 19- 2415 19- 2408 19- 3090 19- 3 137 19- 3095 60- 1937 60- 1960 60-1959
622 086 Sere\\ and washer for float chamber 622 050 Carburelter float chamber 622 069 Carburetter float . . 622 073 Float cha mber gasket .. 376 100 Main jet (150 c.c.) 622 128 Main jet holder 622 122 Needle jet (.106') 622 133 Plug SQrC\\ . . 622 076 Pilot air adjusting sere" 622 082 "O" ring for pilot air sere" L.626 15 Carburetter complete, left-hand (Short a ir cable) R.626. 16 Carburetter C.'.>mplete, centre (medium air cable) R.626. 14 Carbure1ter complete. right-hand (long air cable) 622 IOI "O" ring, Clrburetter flange . . 622 124 Tnro1tlc needle . . 622 067 Clip for throttle need le 622 116 Retaining plate, th rottle rod spring 622 113 Retaining spring. throttle rod 622 115 Retaining cap. throttle rod 622 126 Seal washer, top cap . .
70-9243 Trunnion, throttle linkage 70- 9253 Locknut, throttle rod .. 60- 1984 622 119 Throttle assembly 70- 9278 Arm assembly. throttle lin kage 70-9073 Bush. throttle arm 70-9254 Spring. adjuster sere\\, throttle stop 70-9821 Ret·,iner. thro1tle return spring 70-n52 Adjuster sere", throttle stop 70-9880 Throttle return spring 70-9820 Spacer, throttle return spring 70-9243 Trunnion, throttle linkage .. 21-0774 Screw. support arm to adaptor 70- 9242 Support arm, throttle linkage 70- 9073 Bush, adaptor spindle 70-9060 Connection tube 60-0707 "Jubilee" clip, connection tube 71-0245 Backing washer, spind le 70-9255 Circlip. spind le . . . . 70-9251 Spindle, throttle linkage 70-7633 Carburetter adaptor .. 14- 1619 Stud. carbu ret1er mounting (1\r' u.N.C./U.N.F. I¼•)
38. 39. 40. 4 1. 42. 43. ..u. 4 5. 46. 47. 48. 49. 50. 5 1. 52. 53. 54. 55. 56.
54-0055 Washer. carburetter mounting · 14-0302 Nut, carburetter mounting (¼• u.N.F.)
NOTE:- Where no B.S.A. part number is quoted, the part is only available from the makers.
Per Set
3 3 3 6 3 3 3 3 3 3 3 3 3 3 3 3 6 3 3 3 3 3 _1
3 3 3
3 3 3 3 3 3 3 3 3 3
2
2
2 3 6
2
6 6 6
- ---- ------------ - --------·-----------59
Plate 22
10
9
7
60
• Plate 22
TOOL KIT
Plme Spares Per Re{. Number Desrription Set
I. 60-2251 Double-c;;c!cJ ring spanner (5 s • II 16" WHIT. )
2. 60-:084 Double o pen-ended spanner ( 11 • ¾" A.F.)
3. 60-190S Double-ended box spanner ( I 18 . 1-,i • he,agon)
-'· 60- 1910 Spark plug spanner
s. 60-1909 Double-ended box spanner (~s· 15 16" hexagon)
6. 60-2020 Tappet spanner '
7. 75-9076 .. c-• spanner "ith square socket
8. 75-9089 Tool roll
9. 60-191 1 Tommybar
10. 60-1907 Double-ended ring spanner (w' %" hexagon)
11. 60-0767 Scre\\dri,er complete
60- 1912 Tool~it complete
61
