REPLACEMENT

PARTS
CATALOGUE
FOR 1973

BONNEVILLE 750 T140V

TIGER 750 TR7RV

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TRIUMPH ENGINEERING COMPANY LIMITED

MERIDEN WORKS ALLESLEY COVENTRY CV5 9AU ENGLAND
TELEPHONE COVENTRY (0203) 20221
MERIDEN 331

TELEGRAMS "TRUSTY" COVENTRY

TELEX "TRUSTY" 31305
PUBLICATION PART No. 99-0980

SECOND EDITION JANUARY 1973.

ClassicBike.biz

I NTRODUCTION
The Triumph Engineering Co. Ltd. point out that the information in this catalog was complete and correct
at the time of printing. Distributors will be informed of any subsequent alterations.

GUARANTEE
Please refer to your dealer or distributor for the latest terms of guarantee.
Eastern U.S.A. Distributor:

Western U.S.A. Distributor:

Triumph Motorcycle Corporation,

P.O. Box 6790,
Towson,
Baltimore 4,
Maryland 21204.

Triumph Motorcycle Corporation,

P.O. Box 2765,
East Huntington Drive,
Duarte,
California 91010.

TelexTricor Balt. 87728

Telephon e-301-252-1700

TelexTricor Duarte 675469

Telephone-213-359-3221
213-681-0255

ENGINE AND FRAME NUMBERS

The engine number is located on the left side of the engine, immediately below the cylinder barrel to
crankcase flange.
The frame number is located on the left side of the frame headlug, beneath the fork top lug and forward
of the gasoline tank.
Both the engine and frame number should be quoted in full in any correspondence relating to the
machine.

COPYRIGHT
All rights reserved. No part of this publication may be reproduced without permission.

ClassicBike.biz

I NDEX
Page

AIR CLEANER
...
...
ALTERNATOR
...
...
AUTO-ADVANCE UNIT ...

BATTERY CARRIER ...

BRAKE SWITCH
BREATHER PIPES

...
...
...

63
31

...
...
...

79
45
43

EXHAUST PIPES

...

...

...

49

...
FENDERS
...
FLASHERS
FOOTRESTS...
FRAME
...
FRONT BRAKE
FRONT FORKS
FRONT WHEEL

...
...
...
...
...
...
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...

65
79
47
43
57
51
55

...
...

...
...

...
...

...
61
33, 35,37

HANDLEBAR...
...
...
HANDLEBAR MOUNTINGS
HEADLAMP...
...
...
HORN
...
...
...

...

...

...

37

...
...
...
...

...
...
...
...

17
47
47
49

OILPUMP
...
...
...
...
OILPIPES
...
...
...
...
OIL PRESSURE RELEASE VALVE ...

43

9,41

CAMSHAFT, INLET AND EXHAUST

9
CARBURETOR
...
...
... 27,29
CENTRE STAND
...
...
...
43
...
CHAINS
...
...
...
41
CHAINCASE...
...
...
...
41
CLUTCH
...
...
...
...
39
CLUTCH LEVER ASSEMBLY
...
37
COIL...
...
...
...
...
77
CONDENSERS
...
...
...
77
CONNECTING RODS
...
...
9
CONTACT BREAKER
...
...
31
CONTROL CABLES ...
...
...
71
CONTROL LEVERS ...
...
...
69
CRANKCASE ...
...
...
... 11,13
CRANKSHAFT
...
...
...
9
CYLINDERS ...
...
... 19,21,23,25
CYLINDER HEAD
...
... 19,21,23,25

GASTANK
GEARBOX

Page

KICKSTARTER

...
...
...
...

69
53
79
77

MANIFOLD...
...
MOTOR PLATES
...
MOTOR TORQUE STAY
MUFFLERS
...
...

15
15

PISTONS
...
PROPSTAND
PUSH RODS ...

...
...
...

...
...
9
...
...
... 19,21,23,25

REAR WHEEL
...
RECTIFIER
ROCKERS
...

...
...
...

...
...
59
77
...
...
... 19,21,23,25

...
...
SIDEPANEL ...
...
...
SPARK PLUG
...
...
SPEEDOMETER
SPEEDOMETER GEARBOX ...
...
STEERING DAMPER ...
...
SUSPENSION UNITS
...
SWINGING FORK ...
...
...
...
SWITCHES

...
...
...
...
...
...
...
...

63
77
75
59
53
45
45
45,

69

TABLE OF STANDARD HARDWARE 80, 81

75
TACHOMETER
...
75
TACHOMETER GEARBOX
67
...
...
...
...
TAILLAMP
17
...
...
...
...
TAPPETS
9
...
TIMING GEARS
73
...
...
TOOLKIT
61
...
...
...
TWINSEAT ...
...
VALVES
VALVE GUIDES

...
...

WIRING HARNESS
ZENER DIODE

ClassicBike.biz

...

... 19,21,23,2S
... 19,21,23,25
...

...

79

...

...

77

BONNEVILLE

750 (TIOV), TIGER 750 (TR7RV) TECHNICAL DATA

Compression ratio
Spark plugs
Carburetor
Main jet
...
Needle jet ...
Throttle valve

Gearbox sprocket
Chains
...
Capacities

Tire size ...

Front
Rear
Gas Tank
Oil Tank
Gearbox ...
Primary Chaincase
Front Forks (each leg)
Front
Rear

4
ClassicBike.biz

TR7RV
8 . 25 : 1
Champion N3
Amal Concentric 930
280
106
No. 34
19 teeth
Triplex x 84 li nks
i" x 4" x 107 links
3 . 6 U.S. galls.
4 . 8 U.S. pints
pint (500 c.c.)
+ pint (150 c.c.)
pint (190 c.c.)
3-25 x 19
4 . 00 x 18

T140V
8-25 : 1
Champion N3
2 Amal Concentric 930
210
106
No. 3
19 teeth
Triplex x 84 links
x i" x 107 links
3 . 6 U.S. galls.
4 . 8 U.S. pints
pint (500 c.c.)
- pint (150 c.c.)
I pint (190 c.c.)
3-25 x 19
4 . 00 x 18

HOW TO USE THIS SPARE PARTS CATALOG

First consult the index on Page 3 for the parts or group of parts which you wish to locate. When
you have located the parts make sure from the end columns that the part you have located does apply to
your machine.
List the quantities required as single units; do not ask for "2 pairs" or "3 dozen".
In case of painted items always state the color required. Painted parts are available only in the colors
or alternatives specified for that model of that particular year.
PLEASE NOTE
THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS
INCLUDED IN THAT ASSEMBLY ARE INDENTED IN THE DESCRIPTION COLUMN, REVERTING
TO THE ORIGINAL ALIGNMENT WHEN THE ASSEMBLY IS COMPLETE. TO ORDER THE COMPLETE
ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEMBLY NUMBER. ANY COMPONENT
PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.

SPECIAL WORKSHOP TOOLS

A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING
YOUR DEALER OR APPLYING DIRECT TO THE TRIUMPH SERVICE DEPARTMENT. IN MOST CASES
THESE TOOLS ARE VERY COSTLY AS THEY ARE MADE ENTIRELY FOR WORKSHOP USE, AND
THEREFORE, IT IS NOT RECOMMENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN
ORDER TO AID SERVICING THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUMSTANCES
IT IS FAR MORE ECONOMICAL TO GET IN TOUCH WITH A RECOGNISED DEALER.

UNIFIED THREAD FORM

NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOG HAVE THE UNIFIED
FORM OF SCREW THREADS. THIS CHANGEOVER WILL BE CONTINUED AS AND WHEN NEW PARTS
ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS
WILL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS
HAVING THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS IN
THEIR HEADS, STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING
CIRCLES ON THE SIDE.

COLOR
BONNEVILLE 750
Fenders Chrome.
Gas tank Hi-Fire Vermilion/Gold.
Side covers Black.
TIGER 750:
Fenders Chrome
Gas tank Astral Blue/Opal Flash.
Side covers Black.

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TRIUMPH SPARES
HOW TO ORDER. Every part is indicated by a number, and this should be quoted together with
the description. In order to assist customers, dimensions have been given in many cases where parts
are similar. Parts where possible have been listed in order of assembly and a number of the illustrations
show the assembly order also. With these aids, there should be no difficulty in identifying the parts you
require.
ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OF
THE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS.
WHERE TO OBTAIN. Triumph Spare Parts can only be obtained from an authorised Triumph
Dealer, and we recommend our customers to place their orders with the Triumph Dealer in their district.
When parts not usually asked for are required, and for which the Dealer may have to write or obtain
specially, the postage or carriage incurred becomes payable.
TRIUMPH SPARES ARE NOT SUPPLIED TO PRIVATE OWNERS DIRECT FROM THE FACTORY.
A LIST OF AUTHORISED DEALERS WHO STOCK TRIUMPH SPARES IS AVAILABLE ON REQUEST.
IF DIFFICULTY IS EXPERIENCED IN OBTAINING THE REQUIRED PARTS, THE MATTER SHOULD
BE TAKEN UP DIRECTLY WITH THE TRIUMPH SPARES DEPARTMENT.
Customers are warned against the risk incurred by purchasing parts that are not of genuine Triumph
manufacture. This risk is eliminated if parts are ordered as instructed from recognised Dealers.
PATTERNS AND PARTS FOR REPAIR. It is not necessary to send patterns if the part number
is quoted. The sending of patterns often delays the order as parcel post or rail takes longer than letter post.
Parts sent to Coventry for repair, replacement, or as patterns should bear the sender's Name and
Address and clear instructions should accompany the parts. In your own interest send a copy of the advice
note under separate cover. All parts must be forwarded carriage paid and care should be taken to ensure
that all remittances are sent separately and not enclosed with the parts. Fragile units such as cylinders,
etc., should always be boxed to avoid damage in transit. Complete machines should have all fitments such
as windscreens, driving mirrors, tools, etc., removed by the sender before despatch, as it is impossible for
us to accept responsibility in the event of loss in transit. We are always pleased to give estimates for overhauling and repairs, but should an estimate not be accepted, a charge will be made covering cost of dismantling
and re-assembling, if carried out. Work cannot be accepted at the factory direct from private owners.
Communications relating to Parts should be addressed to the SPARES DEPARTMENT and for repairs,
guarantee claims and technical advice to the SERVICE DEPARTMENT, Triumph Engineering Co. Ltd.,
Meriden Works, Allesley, Coventry. In order to facilitate quick reference, the quoting of any number,
invoice number or reference from previous communications is essential. Accessories not of our manufacture should be sent direct to the actual makers, whose Names and Addresses appear below.

PROPRIETARY GROUP
Ancillary equipment which is fitted to our motor cycles is of the highest quality and is guaranteed by
the manufacturers and not by ourselves. Any repairs or claims should be directed to the actual makers
or their local agents who will always give owners every possible assistance. The following are the addresses
of the various manufacturers:
CARBURETORS
Messrs. Amal Ltd.,
Holdford Road,
Witton,
Birmingham, 6.
CHAINS.
Renold Chains Ltd.,
Wythenshawe,
Manchester.

TIRES.
Dunlop Rubber Co. Ltd.,
Fort Dunlop,
Birmingham, 24.
The Avon Rubber Co. Ltd.,
Melksham,
Wilts.

SPARK PLUGS.
Champion Sparking Plug Co. Ltd.,
Feltham,
Middlesex.
I NSTRUMENTS.
Messrs. Smiths Industries Ltd.,
Cricklewood Works,
London, N.W.2.
SUSPENSION UNITS.
Messrs. Girling Ltd.,
Birmingham Road,
West Bromwich,
Staffordshire.

ELECTRICAL EQUIPMENT.
Messrs. J. Lucas Ltd.,
Gt. Hampton Street,
Birmingham, 18.

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The following part numbers have no direct conversion to the group numbering system, and have therefore been allocated
new numbers.
A3
A40
A44
A52
A56
A61
D208-5
D343-7
E1719A
GS299
GS299A
GS511
NW236
PCW73A
S25-1
S25-2
S25-3
S25-13
S26-2
S66-1
S79-2
T423A
WE259A
WF32
XA69

60-0003
60-0778
60-00 44
60-0052
60-0056
60-0061
60-4255
60-4258
71-3749
60-4256
60-4257
60-4249
37-4199
60-4251
60-4245
60-4246
60-4247
60-4248
60-4250
60-4253
37-4200
57-4754
71-3748
60-4252
60-4254

becomes

SS

OVERSIZE PISTONS AND RINGS

Piston assembly
Compression ring
Scraper ring

+ 0 . 010
+ 0 . 010
+ 0 . 010

71-3686
71-3691
71-3696

Piston assembly
Compression ring
Scraper ring

+ 0 . 020
+ 0 . 020
+ 0 . 020

71-3687
71-3692
71-3697

Piston assembly
Compression ring
Scraper ring

+ 0 . 040
+ 0 . 040
+ 0. 0

71-3689
71-3694
71-3699

GASKET SETS
Decoke
Overhaul

99-3022
99-3023

ClassicBike.biz

17

16
13

iI1 II1
,^^i1

tl)

Fig. 1. CRANKSHAFT AND CONNECTING RODS

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

CRANKSHAFT AND CONNECTING RODS

1
71-3674
2
71-3298
3
70-3903
4
71-2800
5
71-2425
6
*71-3552
7
71-1003
8
70-3114
9
71-3006
7 9914
10
11
60-3761
7 3586
12
13
71-3676
14
71-3690
15
71-3695
16
71-3354
17
71-3700
18
6 167
19
71-3542
20
71-3544
71-0082
21
22
54213901
23
7 3975
24
21-2182
70-1580
25
26
70-4564
27
71-2877
70-6159
28
29
70-00
71-3666
30
71558
31
71-1007
32
33
70-6523
71-3011
34
35
71-3010
36
7 9988
37
7 3300
70-2879
38
Not illus. 71-2663
Not illus. 7 8038
Not illus. 71-2660

CRANKSHAFT AND FLYWHEEL ASSEMBLY

1
CRANKSHAFT C/W. OIL TUBE
...
1
Oil tube
...
1
Screwed plug
1
Flywheel ...
1
Flywheel bolt
3
Washer
...
3
...

Crankshaft stud (li in. 0.A.)

1
CONNECTING ROD
2
Connecting rod bolt
4
Self locking nut ...
...
...
... 4
Big end bearing (Available in . 010 in. and . 020 in. undersizes) 4
PISTON COMPLETE ...
... 2
4
Taper compression ring ...
2
Oil control ring ...
2
Gudgeon pin
...
...
Circlip
4
1
Main bearing, right
...
...
Motor sprocket, 29 teeth Triplex
1
1
Distance piece ...
1
...
Rotor key
1
Rotor (99-0739)
1
Tab washer
...
1
Nut
...
1
Key
...
1
Timing pinion
1
Nut
...
1
...
INTERMEDIATE WHEEL
1
Intermediate wheel bush
2
Camshaft pinion
...
2
Camshaft key ...
1
Inlet camshaft nut
1
Exhaust camshaft nut
1
Inlet camshaft ...
1
EXHAUST CAMSHAFT . ...
1
Tachometer drive plug ...
1
Clamping washer
1
Main bearing, left
1
...
...
1
...
...
Spacer ...
As required (up to 4)
Engine sprocket
Shim (0 . 010 in.)
As required (up to 4)
Shim (0 . 030 in.)

*Use 60-0524 Loctite

Sealant

9
ClassicBike.biz

Fig. 2 CRANKCASE

10

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

CRANKCASE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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

71-3677
71-0287
71-0287
7 5088
71-3678
71-0286
70-4538
70-6386
57-0989
57-0912
57-1606
70-0375
70-8751
1 1 5
6
246
1 0303
7 1532
7 9330
82-1880
21-1871
70-8896
21-1863
21-1865
71-3013
21-1872
21-1870
1 6220
1 6223
1 0230
21-1823
6 2330
1 1302
70-9336
70-5315
57-2167
57-1257
21-0543
70-2441
57-2259
70-6299
57-1920
57-2166
70-8782
1 6242
21-0669
70-7573
402
1
71-1072
71-1075

CRANKCASE DRIVE SIDE ...

Camshaft bush
Camshaft bush
Chain tensioner abutment
CRANKCASE TIMING SIDE
Camshaft bush
Scavenge pipe
Locating peg (at oil pipes)
Hollow dowel
...
...
Locating peg (L/S at thrust washer)
Needle roller bearing, layshaft ...
Intermediate wheel spindle
...
Hollow dowel
Stud
...
Plain washer
Nut
...
Hollow dowel, tappet oil feed
Oilway plug
...
Copper washer
Tachometer drive plug (L.H. thread)
Fibre washer
Oil pipe stud
Cylinder stud
Cylinder stud ...
Plug, timing hole
Bolt
Bolt
Bolt
Bolt
Bolt
Plain washer
Nut
..
...
Crankcase filter
Joint washer
...
Drain plug (with level tube) ...
Fibre washer ...
Level plug
...
Copper washer
Drain and adjuster plug
"0" ring
Blanking plug
Filler plug
"0- ring
Bolt
Stud
Rubber plug
Nut, exhaust ties
...
Breather cover plate assembly
...
Screw

11

ClassicBike.biz

...

...

...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...

1
1
1
1
1
2
Reference only
Reference only
2
1
1

1
2
1
2
1
1
1
2
1
4
4
1
1
1
1
2
10
5
1
1
1
1
1
1
1
Reference only
2
2
1
1
1
2
1
1

Fig. 2 CRANKCASE

12

ClassicBike.biz

No.

Part No.

QUANTITY REMARKS

DESCRIPTION

CRANKCASE (continued)
49
50
51
52
53
54
55
56

70-9335
71-1460
71-1077
71-3174
71-3175
60-4250
14-0101
71-1345

...
...
...
...
Outlet stub
...
...
...
Joint washer ...
...
...
...
...
Screw ...
...
...
Tube, primary chain oiler
...
...
...
...
...
Clip
...
...
...
Spring washer ...
Bolt (r in. U.H.)
Grommet, alternator leadsexternal

...
...
...
...
...
...

...
...
...
...
.
...

...
...
...
...
...
...

...
...
...
...
...
...

...

...

...

...

13
ClassicBike.biz

1
1
2
1
1
1
1
1

Fig. 3. OIL PUMP AND RELEASE VALVE

14

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

OIL

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

70 -9421
Referenceonly
70-9269
70-6681
70-0495
60-2363
70-0403
70-2360
71-1461
21-1864
70-3887
21-1906
70-6595
70-7590
70-8752
70-7591
70-6596
70-8754
70-1670

QUANTITY

REMARKS

PUMP AND RELEASE VALVE

...
...
...
OIL PUMP
...
...
...
...
Pump body...
...
...
...
Feed plunger
...
...
Scavenger plunger
...
...
Drive block
...
...
Valve ball (,'
j in. dia.)
...
...
...
Valve spring
...
...
...
Screwed plug
...
Joint washer
...
...
Oil pump stud ...
..
...
...
...
Serrated washer
.
Nut
..
OIL PRESSURE RELEASE VALVE ...
Body
...
.
...
...
Piston
..
...
...
...
Spring
...
...
...
...
Cap ...
...
..
...
...
Joint washer (cap to body)
...
...
....
...
...
Joint washer
.

...
...
...
...
...

...
...
...
...
...

...
...
...
...
...

...
...
...
...
...

...
...

...
...
...
...
..

...
...
..
...
...

..
...
.
...
...

...

...

...

...
...
...
...
...
...
...

...
...

...
...
...
...
...
...
...

15

ClassicBike.biz

...
...
...
...

...
...

1
1
1
1
1
2
2
2
1
2
2
2
1
Reference only
1
1
1
1
1

Fig. 4. MANIFOLD AND TAPPETS

10

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

MANIFOLD AND TAPPETS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

71-3556
70-5660
21-1876
60-4248
21-1877
21-1996
70-9554
70-9555
14-1301
71-3339
71-3338
71-2813
71-3573
70-9554
70-9555
14-1301
71-3313
71-3577
83-4898
21-1903
70-9352
70-9352
70-7563
97-0200
70-2441
70-3059
70-8801

Inlet manifold ...

...
...
...
...
...
...
Joint washer ...
...
...
...
...
...
...
Stud
Manifold to head
Washer
...
...
...
...
Nut
J
Stud
...
Insulating ring ...
...
L
Cup
...
...
...
Carburettor to manifold
Nut
...
...
...
J
...
Inlet manifoldL.H.
...
...
...
...
...
...
...
...
...
Inlet manifoldR.H.
Stud
...
...
...
Joint washer ...
I
Carburettor to manifold
Insulating ring ...
...
and head
Cup
...
...
...
...
Nut
...
...
J
...
...
...
...
Connector
...
...
...
...
...
...
...
...
Connector pipe
...
...
...
...
...
BracketAir control lever ...
...
...
...
...
...
...
Screw ...
...
...
...
...
...
...
Inlet tappet guide block
...
...
...
...
Exhaust tappet guide block ...
...
...
...
...
...
...
'0' ring ...
...
...
...
...
...
...
...
Set bolt ...
...
...
...
...
...
...
...
Washer ...
...
...
...
...
...
...
...
Inlet tappet
...
...
...
...
...
...
Exhaust tappet

17
ClassicBike.biz

...
...
...

...
...
...

...
...
...
...
...
...
...
...
...
...
...

1
2
4
4
4
2
2
2
2
1
1
4
2
4
4
4
2
1
1
1
1
1
2
2
2
2
2

TR7RV

TI40V

Fig. 5. CYLINDER BLOCK AND HEAD, TR7RV

18

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

CYLINDER BLOCK AND HEAD TR7RV

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

70-6309
71-3679
21-2177
21-0692
71-3329
71-3330
71-1707
70-4752
70-7310
71-1283
71-3681
71-3558
71-3294
71-3295
70-4603
70-2904
71-3296
70-4221
70-7400
70-1543
99-0062
21-2201
21-2200
21-2204
21-2205
71-3553
82-2184
14-0241
14-1401
70-3302
14-0301
21-2206
21-1875
60-4248
21-2197
37-2338
60-2331
14-1303
71-2599
71-2569
71-2570
71-2572
71-2574
71-3549
60-3548

Cylinder base washer ...

Cylinder block
...
Cylinder base nut
...
Cylinder base nut (12 point)
Push rod cover tube ...
Push rod
...
...
Sleeve ...
...
..
Sealing ring
...
...
'0' ringbottom
...
'0' ringtop ...
..
Cylinder head gasket ...
CYLINDER HEAD
...
Inlet valve guide
Exhaust valve guide
Inlet valve
...
...
Exhaust valve ...
...
Bottom cup
...
...
Inner valve spring
...
Outer valve spring
...
Top collar
...
...
Split cotter
...
...
Studcylinder head (e in.)
Studcylinder head (-Mn.)
i
Socket nut (Bin.)
..
Socket nut (,bin.)
...
Bridge plate
...
...
...
Washer ...
...
Boltcylinder head ...
Studrocker box
...
...
Washer ..
..
...
...
...
Nut
Boltrocker box
...
...
Boltrocker box
...
...
Washer ...
...
Stud
Distance piece ...
.
Washer ...
...
...
Nut
...
...
Rocker box gasket
...
Inlet rocker box
Exhaust rocker box ...
Tappet inspection cover
...
...
Gasket ...
...
Rocker spindle
...
...
Sealing ring

...
...
...
...
...

...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
L
r
J
...
...
...
...
...
...
...

...
...
...
...
...

...
...

...
...

Cover tubes

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
.
...
...
...
...
...
...
...
...
...
...

Torque stay
...
...
...
...
...
...
...
...

19
ClassicBike.biz

...
...
...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...

...

..

...
...
...
...
...
...
...

...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...

1
1
4
4
2
4
2
2
2
2
1
1
2
2
2
2
4
4
4
4
8
4
2
4
2
1
8
4
6
6
6
4
4
4
2
2
2
2
2
1
1
2
2
2
2

20

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

CYLINDER BLOCK AND HEAD, TR7RV (continued)

46
47
48
49
50
51
52
53
54
55

70-1457
70-1458
71-0070
70-1513
70-0470
70-1574
70-1575
70-1330
14-6103
60-2329

Rocker (right exhaust, left inlet)

Rocker (left exhaust, right inlet)
Ball pin ...
...
...
...
Adjusting pin ...
...
Lock nut
...
...
Spring washer ...
...
...
Thrust washer ('z in.) ...
...
Thrust washer (in.) ...
...
...
Set screw
...
...
...
Washer ...
...
...

...
...
...
...
...
...
...
...
...
...

21
ClassicBike.biz

...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...

..
...
...
...
...
...
...
...
...
...

2
2
4
4
4
4
6
2
8
8

REMARKS

Fig. 7. CYLINDER BLOCK AND HEAD,TI4OV

22

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

CYLINDER BLOCK AND HEAD, TI40V

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

70-6309
71-3679
21-2177
21-0692
71-3329
71-3330
71-1707
70-4752
70-7310
71-1283
71-3681
71-3023
71-3294
71-3295
70-4603
70-2904
71-3296
70-4221
70-7400
70-1543
99-0062
21-2201
21-2200
21-2204
21-2205
71-3553
82-2184
14-0241
14-1401
70-3302
14-0301
21-2206
21-1875
60-4248
21-2197
37-2338
60-2331
14-1303
71-2599
71-2569
71-2570
71-2572
71-2574
71-3549
60-3548

Cylinder base washer ...

...
...
...
Cylinder block
...
...
...
...
Cylinder base nut
...
...
Cylinder base nut (12 point)
...
...
Push rod cover tube ...
...
...
...
Push rod
...
...
...
...
...
..
Sleeve ...
..
...
...
...
Sealing ring
Cover tubes
`O' ringbottom
...
r
...
...
...
'0' ringtop ...
Cylinder head gasket ...
...
...
...
...
...
CYLINDER HEAD
...
...
Inlet valve guide
...
...
...
Exhaust valve guide
...
...
...
...
Inlet valve
...
...
...
...
...
Exhaust valve ...
...
...
...
...
Bottom cup
...
...
...
...
Inner valve spring
...
...
...
...
...
Outer valve spring
...
...
...
...
...
...
...
...
Top collar
...
...
...
Split cotter
...
...
Studcylinder head (Bin.)
...
...
...
...
...
Studcylinder head (fin.) ...
...
...
...
...
Socket nut (gin.)
...
...
...
...
Socket nut (,Sh in.)
...
...
...
...
Bridge plate
...
...
...
...
Washer ...
...
...
...
...
Boltcylinder head ...
...
...
...
...
Studrocker box
...
...
...
...
Washer ...
...
...
...
...
...
...
...
Nut
...
...
...
...
Boltrocker box
...
...
...
...
Boltrocker box
...
...
...
...
...
Washer ...
Stud
...
...
1
...
Distance piece ...
L Torque stay
Washer ...
.
...
...
...
...
Nut
...
...
...
...
Rocker box gasket
...
...
...
...
Inlet rocker box
...
...
...
Exhaust rocker box ...
...
Tappet inspection cover
...
...
...
...
...
Gasket ...
...
...
...
...
Rocker spindle
...
...
...
...
...
Sealing ring

1
J

...

...

...

23
ClassicBike.biz

...

...

...
...

...
...

...
...

...
...
...
...
...
...

...
...
...
...
...
...

...

...
...
...
...
...
...

...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
..

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...

...
...
...
...
...
...
...

...
...
...
...
...
..
...

...
...
...
...
...
...
...

...

...

...

...

1
1
4
4
2
4
2
2
2
2
1
1
2
2
2
2
4
4
4
4
8
4
2
4
2
1
8
4
6
6
6
4
4
4
2
2
2
2
2
1
1
2
2
2
2

REMARKS

Fig. 7. CYLINDER BLOCK AND HEAD, T140V

24

ClassicBike.biz

Ref. No. Part No.

CYLINDER

46

47
48
49
50
51
52
53
54
55

71457
71458
71-0070
71513
7
70
71574
71575
71330
1
103
6 2329

QUANTITY

DESCRIPTION

BLOCK

AND

HEAD,

Rocker (right exhaust, left inlet)

Rocker (left exhaust, right inlet)
Ball pin
Adjusting pin
Lock nut
...
Spring washer
Thrust washer (1 in.)
Thrust washer (f in.)
...
Set screw
Washer ...

25
ClassicBike.biz

T140V

(continued)

2
2
4
4
4
4
6
2
8
8

REMARKS

15

lH

Fig. 8. AMAL CARBURETOR, TR7RV

26

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

CARBURETOR TR7RV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

60-2183
Reference only
928/098
622/086
928/060
622/131
622/067
622/124
928/062
622/129
928/103
622/077
622/076
622/082
622/122
622/128
376/100
622/069
622/071
622/055
622/073
622/068
376/093
622/078
376/092
622/147
622151
83-4887
70-9711

CARBURETOR (R930/89) less "0" ring ...

...
Mixing chamber (930/005)
...
Mixing chamber top (99-1032) ...
...
Screw (99-0521) ...
...
...
...
Throttle valve (3i cutaway) (99-0527) ...
...
Throttle return spring (99-1033)
Needle clip (99-0510)
...
...
...
...
...
...
Needle (99-1036) ...
...
...
...
Air slide (99-0528)
...
Spring (99-1038) ...
...
...
Air valve guide sleeve (99-1037)
...
...
Throttle stop screw (99-0516) ...
...
Air adjusting screw (99-0515) ...
...
...
"0" ring (99-0520)
...
...
...
Needle jet (0 . 106) (99-1035)
...
...
...
Jet holder (99-1034)
Main jet (280) (99-0455)
...
...
...
...
...
Float (99-0512) ...
...
...
Float spindle (99-0513) ...
...
...
Float chamber (99-0506)
...
...
Joint washer (99-0514) ...
...
...
...
Needle (99-0511) ...
...
...
...
Filter (99-0438) ...
...
...
...
Banjo bolt (99-0517)
...
...
Fibre washer (99-0437) ...
...
...
...
Drain plug (99-1152)
...
...
...
Washer (99-1153)
...
...
...
...
...
Petrol pipe
...
...
...
...
...
"0" ring

27
ClassicBike.biz

...
...
...

...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
. .
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...

..
...
...
...
...
...
...
...
...
...
...

...
...
...

1
1
1
4
... 1
... 1
.. 1
... 1
... 1
... 1
... 1
... 1
... 1
... 2
... 1
... 1
1
1
1
... 1
... 1
... 1
1
... 1
... 1
... 1
... 1
... 1
... 1

REMARKS

Fig. 9. AMAL CARBURETOR, T140V

28

ClassicBike.biz

Ref No. Part No.

DESCRIPTION

QUANTITY REMARKS

CARBURETOR T140V
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

60-3777
60-3778
Reference only
928/098
622/086
928/060
622/131
622/067
622/124
928/062
622/129
928/103
622/077
622/076
622/082
622/122
622/128
376/100
622/069
622/071
622/055
622/073
622/068
376/093
622/078
376/092
622/147
622/151
83-3927
70-9711

CARBURETORL.H. (R930/88
Less " O " ring
CARBURETORR.H. (R930/87)
...
Mixing chamber (L930/005 and R930/005)
...
...
Mixing chamber top (99-1032) ...
...
...
...
Screw (99-0521) ...
...
...
Throttle valve (3 cutaway) (99-0527) ...
...
...
Throttle return spring (99-1033)
...
...
...
Needle clip (99-0510)
...
...
...
...
...
Needle (99-1036) ...
...
...
...
...
Air slide (99-0528)
...
...
...
...
Spring (99-1038) ...
...
...
Air valve guide sleeve (99-1037)
...
...
Throttle stop screw (99-0516) ...
...
...
Air adjusting screw (99-0515) ...
...
...
...
...
"0" ring (99-0520)
...
...
...
Needle jet (0 . 106) (99-1035)
...
...
...
...
Jet holder (99-1034)
...
...
...
Main jet (210) (99-0448)...
...
...
...
...
Float (99-0512) ...
...
...
...
Float spindle (99-0513) ...
...
...
...
Float chamber (99-0506) ...
...
...
...
Joint washer (99-0514) ...
...
...
...
...
Needle (99-0511) ...
...
...
...
Filter (99-0438) ...
...
...
...
Banjo bolt (99-0517)
Fibre washer (99-0437) ...
...
...
...
...
Drain plug (99-1152)
...
...
...
...
Washer (99-1153)
...
...
...
...
...
...
Petrol pipe
...
...
...
...
...
..:
"O" ring

29
ClassicBike.biz

...

.. .

1
1

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...

...
...
...
...

1
1
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1

Each
carburetor

1
2

Fig. 10. TIMING COVER AND CONTACT BREAKER

30

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY REMARKS

TIMING COVER AND CONTACT BREAKER

1
2
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Not illus.

70-9246
70-4016
60-2085
70-4568
70-6387

...
...
Timingcover ...
...
...
Patentplate
...
...
Hammer-drive screw ...
...
Oilseal ...
...
...
Oil seal (0 . 020 in. undersize) ...

70-4569
57-0989
14-6609
14-6608
14-0208
70-8163
70-4707
70-7680
70-6559
70-8737
71-1462
60-4256
70-7354
54425657
54412229
54425160
60600271
54419220
60-2133
60-2045
60-2138

...
...
...
...
...
...
Circlip ...
...
...
...
...
Hollowdowel ...
...
...
...
...
...
...
...
Screw...
...
...
...
...
...
Screw ...
...
...
...
...
...
...
...
...
Bolt
...
...
...
Plain washer ...
...
...
...
...
...
...
Rubbergrommet
...
...
...
...
...
...
...
Pillarbolt
...
...
...
...
Plainwasher
...
...
...
...
...
...
...
...
Cover...
...
...
...
...
...
Jointwasher ...
...
...
...
...
...
Serratedwasher
...
...
...
Screw(z in. U.H.)
...
...
...
...
AUTO ADVANCE UNIT (99-1263)
...
...
...
...
Springset (99-1264)
CONTACT BREAKER PLATE ASSEMBLY (99-1265)
...
...
...
...
Contactset (99-1266)
...
...
...
Pin, adjustment (99-0769
...
...
...
...
Oilpressure switch ...
...
...
...
...
Coverpressure switch
...
...
...
Timinglabel for C.B. cover ...

...
...
...
..

31
ClassicBike.biz

...
...
..
..
...

...
...
...

...

...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

... 1
... 1
... 3
... 5
... 1
... 1
... 1
... 2
... 2
... 1
... 1
... 2
... 2
... 1
... 1
... 1
... 2
... 2
... 1
... 1
... 1

...
...

1
1
3
2
For reground
crankshaft

Fig. II GEARBOX INNER COVER AND SELECTORS

32

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

REMARKS

GEARBOX INNER COVER AND SELECTORS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

57-4795
57-1614
57-0412
57-0045
57-1607
57-0989
21-2149
21-1907
70-3446
14-6608
14-7023
57-4624
57-4363
57-1896
57-3989
57-3660
57-4459
57-4400
57-3978
71-3096
57-4364
57-4366
57-4660

GEARBOX INNER COVER ...

...
...
...
Layshaft bearing ...
Gearchange spindle bush...
...
...
...
...
Kickstart stop
...
...
...
Thrust washer ...
...
...
...
Hollow dowel ...
...
...
...
Stud
...
...
...
...
...
Bolt
...
...
...
Washer ...
...
...
...
...
...
...
Screw ...
...
...
...
...
...
Screw ...
...
...
...
...
Cam plate
...
...
Operating quadrant ...
...
...
Quadrant spindle
...
...
...
Split pin (5 in. x 1.8 in.)
...
...
...
Selector fork rod
...
...
Index plunger ...
...
...
...
...
Plunger spring ...
...
...
Housing, index plunger
...
...
...
...
Washer ...
Joint washer, inner cover to crankcase
Selector fork - mainshaft 4th gear ...
...
Selector fork - layshaft 3rd gear
...
Selector fork-layshaft 1st gear

33

ClassicBike.biz

...
...
...
...
...
...
...
...
...
...
...
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...

...
...
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...
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...
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...
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...
...
...
...
...
...
...
...

1
1
1
1
2
4
2
1
1
1
1
1
1
1
Reference only
1
1
1
1
1
1
1
1
1

34

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

REMARKS

GEARBOX SHAFTS AND GEARS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Not illus.
25
26
27
28
29
30
31
32
33
34
35

60-3500
70-3789
57-4628
60-3511
60-3500
57-4432
57-3988
57-4376
57-4377
57-4575
57-4653
57-4548
57-4550
57-4384
57-4647
57-4657
57-4662
57-4654
57-4663
60-3494
57-4661
57-4533
57-4396
57-4395
60-3512
70-0489
60-3552
57-4113
57-1962
57-1963
57-1250
57-0730
57-0731
57-2240
21-0594
57-1736

Oil seal, cover plate ...

...
...
Cover plate
MAINSHAFT HIGH GEAR
...
BEARING) ...
Needle roller bearing
Oil seal, high gear
...
MAINSHAFT ...
...
...
Bush
...
Mainshaft 4th gear
MAINSHAFT 3rd GEAR
...
Bush
...
Mainshaft 1st and 2nd gear
...
...
LAYSHAFT
Layshaft high gear
Layshaft 4th gear
...
Layshaft 3rd gear
LAYSHAFT 2nd GEAR
...
...
Bush
LAYSHAFT 1st GEAR
...
...
Bush
...
...
Circlip ...
...
...
Driving dog
Gearbox sprocket-20T
...
...
Locknut
...
...
Lock washer
...
Oil seal, gearbox
...
...
Circlip ...
...
Mainshaft bearing
...
...
Circlip ...
...
..
Washer ..
...
...
Pinion sleeve
...
...
Pinion spring
...
Kickstart pinion
Kickstart ratchet
...
...
...
Tab washer
...
..
...
Nut
Clutch operating rod ...

...
...
...
...
...
...
...
...
...
...
...
...
ASSEMBLY (C/W HIGH GEAR
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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...
...
...
...
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...

35
ClassicBike.biz

1
1
1
2
1
1
1
1
1
Reference only
1
1
Reference only
Refererrice only
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
I

Fig. 13. GEARBOX OUTER COVER

36

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

REMARKS

GEARBOX OUTER COVER

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

57-3760
57-0023
57-0057
57-0047
21-0547
57-1956
57-1955
57-0437
60-3530
57-0404
57-0406
57-0405
57-0407
70-1612
14-0301
57-4117
57-0031
57-0024
57-4587
57-4588
5-1710
60-2368
57-4589
57-1712
57-3673
21 1 879
57-1646
57-3762
60-4247
14-0302
21-2162
14-6609
14-6608
57-3757
14-0201
57-2450
57-3632
57-2173
57-1272
57-1167
60-2364
21-0541
57-2330
57-4356
21-0544
57-2166
70-8782

GEARBOX OUTER COVER

Kickstarter spindle bush ...
Gearchange spindle bush
Kickstarter spring anchor pin
...
Guideplate stud ...
...
...
...
Oilseal
...
Oilseal housing ...
...
Gearchange quadrant ...
...
...
Rubber"0" ring
...
Quadrant return spring
Gearchange quadrant plunger
...
...
Plungerspring ...
...
...
...
Guideplate
...
...
Serratedwasher
...
...
...
...
Nut
...
Kickstarter quadrant ...
...
Kickstarter return spring
...
...
Kickstarteraxle
CLUTCH LEVER ASSEMBLY
...
...
Clutchlever
...
...
Levershaft
...
Ball, a in. diam. ...
...
...
Thrustplate
...
...
Returnspring
...
...
Plainwasher
Split pin ( 64 in. x .' in.) ...
...
...
Countersunk screw
...
...
Rubbercover ...
...
Abutment for clutch cable
...
...
...
Plainwasher
...
...
...
...
Nut
...
...
...
...
Screw
...
...
...
...
Screw
...
...
...
...
Screw
...
...
Gearchange pedal
...
...
...
...
Bolt
...
...
Pedalrubber ...
FOLDING KICKSTARTER ...
...
Kickstarter lever ...
...
Kickstarter pedal ...
...
Pedal locating spring
...
Steel ball, 4 in. diam.
...
...
Pedalbolt
...
...
Pedalrubber ...
Cotter pin caw nut and washer
...
...
...
Domednut
...
...
...
Fillerplug
...
...
...
"0" ring

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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...
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..
...
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...

37

ClassicBike.biz

...

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...

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...
.. .
...
...
...
...
...
...
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...

2
2
2
4
4

...
...
...
...
...

3
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.. .
...
...
.. .
...
...
...
...
...

...

.
...

1
1
Reference only
2
1
2
2
2

38

ClassicBike.biz

Ref. No. Part No.

DESCRIPTION

QUANTITY

CLUTCH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

21-0586
57-3929
57-3931
57-394
57-4640
57-4438
57-4436
21 21 57
57-4636
57-1722
57-1723
57-4437
57-0423
57-1362
57-1363
57-4590
57-2159
14-0403
57-1931
57-4644
57-2526
60-4253
57-2279

Clutchsecuring nut ...

...
...
Hub
...
...
Thrustwasher ...
...
...
Roller ...
Sprocketand housing ...
...
...
Centre...
...
...
Innerplate
...
...
...
Bolt
Shock absorber spider
Driverubber (large) ...
Reboundrubber (small)
...
...
Outerplate
...
...
Screwedpin
Driving plate (bonded)
...
Drivenplate ...
...
Pressureplate
...
...
Adjusterpin
Nut

...

Springcup
Spring ...
Pressurenut
...
Key
Washer...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
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...
...
...
...

...
...
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...

...
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...
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...

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...
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...
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...
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...
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...
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...
...
...
...
...

39
ClassicBike.biz

... 1
... 1
... 1
... 20
... 1
... 1
... 1
... 3
... 1
... 3
... 3
... 1
... 3
... 6
... 6
... 1
... 1
... I
... 3
... 3
... 3
... 1
... 1

REMARKS

40

ClassicBike.biz

IU
z

Do
LL

Ref. No. Part No.

QUANTITY

DESCRIPTION

REMARKS

CHAINCASE AND CHAINS

1
2
3
4
5
6

60-2118
71 - 1 419
57-4643
14-6101
70-3821
70-5976

Rear chain, 8 in.xe in.x107links

...
...
Joint washer ...
...
...
Timing pointer ...
...
...
...
Level plug
...
Countersunk screw ...
Chain tensioner abutment ...

7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

70-5085
70-4152
70-5087
70-9703
60-4125
21-2199
21-2198
47205
70-9360
70-4144
70-5449
60-4247
14-0702
71-1463
71-3555
57-4645
71-1457
57-4646
70-2441
57-2166
70-8782
14-6608
14-6620
21-0544
82-1880

Chain tensioner blade ...

...
...
Tie rod
...
...
Trunnion
Adjuster sleeve nut ...
Primary chain, e in. Triplex
...
...
Stator stud
...
...
Stator stud
Stator, RM21 (99-1006)
...
...
Sleeve nut
...
Rubber grommet
...
Plastic sleeve ...
...
Plain washer ...
...
Self-locking nut
...
Joint washer ...
...
...
Chaincase
...
Rotor cover
...
...
Joint washer ...
...
Screw ...
...
...
Copper washer
...
...
Filler plug
...
"0" ring
...
...
Screw ...
...
..
Screw ...
...
...
...
Domed nut
...
Copper washer

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...

... 1
... 1
... 1
... 1
... 6
... 1

...
...
...
...
...
...
...
...
x 84 links
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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.
.
...
...
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...
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...
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...
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...
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..
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...

41
ClassicBike.biz

1
1
1
I
1
2
1
1
1
1
1
3
3
1
1
1
1
3
1
1
1
6
2
2
2

(also listed with

crankcase group)

42

ClassicBike.biz

LL

LL

Ref. No. Part No.

DESCRIPTION

QUANTITY

FRAME
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Not illus.
Not illus.
Not illus.

83-4753
71-3463
60-3616
83-4783
71-3316
83-2829
60-2330
21-2025
14-1302
82-5343
70-1335
71-3478
71-3754
21-1908
70-3446
71-3550
70-1335
21-0550
71-3551
70-6848
71-2345
70-6848
82-9073
71-3450
71-2349
71-1149
83-4813
83-1610
60-2253
60-2252
83-1615
97-3894
82-4717
83-4615
83-3793
21-2077
14-1304
83-1560
82-7021
14-1303
82-8382
60-3361
14-0114
14-0402

...
...
...
...
Frame ...
...
...
...
Oil filler cap ...
...
...
...
...
"0" ring
...
...
...
Oil filter
...
...
...
Sump plate
...
...
...
Gasket ...
...
...
...
...
Washer
Sump plate to frame ...
Stud
...
Nut
J
...
Drain plug
...
...
...
...
...
...
Joint washer ...
...
...
Oil junction block
...
...
...
...
Joint washer ...
Nut
Washer Junction block to crankcase
Rocker oil pipe
...
...
...
...
...
...
Washer ...
...
Nut
...
...
...
...
...
...
Rocker feed pipe
...
...
Cliprocker feed pipe
...
...
Oil return pipe
...
...
...
...
...
...
Clipreturn pipe
...
...
Clipfeed pipe
...
...
...
Oil feed pipe ...
...
...
...
...
Oil vent pipe ...
...
Crankcase breather pipefront
...
Crankcase breather piperear
...
...
...
...
"T" piece
Clipbreather pipefront ...
...
Clipbreather piperear ...
...
...
Clipbreather pipe to fender
...
...
...
...
Screw ...
...
...
...
...
Nut
...
...
...
...
Centre stand ...
...
...
...
...
Spring ...
...
...
...
...
Pivot bolt
...
...
...
...
...
Nut
...
...
...
...
Prop stand
...
...
...
...
...
Bolt
...
...
Nut
...
...
...
...
...
...
Spring ...
...
Transfer "Made in England" ...
...
Bolt }Prop stand stop
Nut

If

43
ClassicBike.biz

...
...
...
...
...
...
...
...

...

...
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....
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...
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...

...
...
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...
...
...
...
...

...
...
...
...

...
...
...
...

...
...
...
...

...

...

...

. . "" "' "'

...
...
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...
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...
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...
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...
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...
...
...
...
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...
...
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...
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...
...

1
1
1
1
1
2
4
4
4
1
1
1
1
1
1
4
2
1
2
1
2
2
1
1
1
1
1
2
1
4
4
4
1
1
2
2
1
1
1
1
1
1

REMARKS

44

ClassicBike.biz

4
z
D
z
0
G
Z
W
&
N
3
M
0
Z
4
w

2
0
z
6
z

4
E

Ref. No. Part No.

QUANTITY

DESCRIPTION

REMARKS

SWINGING ARM AND SUSPENSION UNITS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

83-2513
60-1841
60-1841
83-2521
83-2691
83-2690
83-2689
83-2692
21-2087
83-2266
1 1307
83-2656
1 0305
60-2431
1 0133
37-2330
14-1304
64052564
6405263
64533645
9054/171
64543708
1 0235
6 2331
1 1303
1 0234
60-2331
1 1303
83-2641
1 0206
6 2347
34815
6 3550
97-1388

SWINGING ARM
Grease nipple
...
Washer, grease nipple
Bush, pivot arm ...
Sleeve, swinging arm pivot
Distance piece R.N.
Distance piece L.H.
Dirt excluder ...
Stud, swinging arm pivot
Washer, swinging arm pivot
Nut, swinging arm pivot
...
Brake torque stay
Nut, torque stay to brake plate
Washer, torque stay to brake plate
Bolt, torque stay to swinging arm
Washer, torque stay to swinging arm
Nut, torque stay to swinging arm ...
SUSPENSION UNIT (63957)
...
Damper unit
Bonded bush (99-0122) ...
...
Spring retainer (99-0107)
Spring, 110 lbs. chrome (99-1048)
...
Bolt, dampertop
Washer, dampertop
...
Nut, dampertop
Bolt, damper, lower ...
Washer damper lower
Nut damper lower
Chainguard
Bolt, chainguard fixingfront
Washer, chainguard fixingfront ...
Stop lamp switch-118SA (99-1028)
...
Screw
Washer ...

45

ClassicBike.biz

1
2
2
.4
2
... 1
... 1
.. 4

...

...

1
... 1
Also listed
with rear wheel
1
... 1
... 1
... 2
... Reference only
4
... 4

... 1
2

46

ClassicBike.biz

0D

LL

DESCRIPTION

Ref. No. Part No.

MOTOR UNIT FITTINGS AND

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Not illus.
Not illus.

83-2854
83-2855
14-0259
60-2333
82-9279
83-2841
82-9053
83-3207
14-0217
82-9089
14-1302
14-1303
82-2184
82-9054
83-2666
14-0103
14-0301
21-2045
14-1303
70-8084
83-2860

83-4277
82-7387
83-3024
83-3023
14-0115
14-0116
14-1302
60-2330
14-0220
14-0221
1 4-1 302
60-2321
83-2846
83-2847
21-2112
14-1304
60-2332
83-2848
83-2849
14-0254
14-1304
60-2332
83-3537
14-0129
83-3329
60-2331
83-4086
14-1305
83-3602

...
...
...
...
FootrestL.H. ...
...
...
...
FootrestR.H....
...
...
...
...
...
...
...
Bolt
...
...
...
...
...
Washer ...
...
...
...
...
Footrest rubber
...
...
...
PILLION FOOTREST ...
...
...
...
...
...
Pedal
...
...
...
Hanger bolt
...
Bolt
...
...
Footrest swivel
Washer
...
Nut
J
...
...
Nut
Footrest to frame
Washer
...
...
..
Footrest rubber ...
...
...
...
...
Rear brake pedal
...
...
Screw
Stop light adjustment
Nut
...
...
...
...
...
Pivot pin
...
...
...
...
...
...
Nut
...
...
...
...
...
...
Washer
...
...
...
Rear brake operating rod
!
...
...
...
in.
x
e
in.)
Split pin ( i 6
...
...
...
...
Distance piece
...
...
...
Adjuster nutbrake rod
...
...
...
Rear motor plate R.H.
...
...
...
Rear motor plateL.H.
...
Bolt
...
Bolt
I Rear motor plates to fram
Nut
...
Washer
...
Bolt
Bol
..
"'
Motor to motor plates ...
Nut
ut

Washer
Distance pieceL.H.
Distance pieceR.H.
Motor to frame centre
Bolt
Nut
Washer
Distance pieceL.H.
.
Distance pieceR.H
Motor fixing front
Bolt
Nut
Washer
...
...
Steady bracket motor to frame
Bolt
Bracket to frame
Distance piece
Washer
J
Attachment plate
..
...
..
Nut
"
Footrestbolt
Collar }
...
...
...

LPA
ClassicBike.biz

QUANTITY

REMARKS

FOOTRESTS
...
...
...
...
...
...
...
...

...
...
...
...
...
..
...
...

...
...
...
...
...
...
...
...

...

...

...

...

...

...

1
1
2
2
2
2
I
1
1
1
1
1

...
...
...

...
...
...

...
...
...

1
1
1

...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...

...
...

...
...

... 1
... 1
... 1
... 1
... Reference only
... 1
... 2
... 1
... 1
... 5
... 1
... 6
. 12
... 2

"'

..
...
bottom ...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
..
...
...

...
...
...
...
...
...
...
...
...
...
...

...

...

...
...

...

...
..

...

...
...

2
4
8
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2

48

ClassicBike.biz

A
LL

Ref. No.

Part No.

DESCRIPTION

EXHAUST PIPES AND MUFFLERS,

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

71-3755
71-3758
71-2465
21-0778
21-2186
70-6857
14-2205
7 7471
70-7512
70-3768
1 0217
14-1202
70-9888
70-2271
70-3768
1 0219
6 247
1 1202
71-3723
71-3761
14-0101
14-1301

QUANTITY
TR7RV, T140V

Exhaust pipeL.H.
Exhaust pipeR.H.
Finned clip
}
Nut
Exhaust pipes to cylinder head

Screw
Exhaust pipe stay
Screw

Nut
Clip
1
"B D"
It washer

Exhaust pipes to coupling pipe

Nut

Coupling pipe
Cli
p
"D" washer

Bolt
Washer
Nut
Muffler ...

Exhaust pipes to mufflers ...

Hangermuffler and pillion footrest

Bolt }

Nut

1
1
2
2
2
2
2
2
2
4
2
2
1
2
4
2
2
2
2
2
4
4

Muffler to hanger

49
ClassicBike.biz

REMARKS

46

47
3

38
9

a^

6
36

50 49 48

24

Fig. 20. TELESCOPIC FRONT FORK

50

ClassicBike.biz

IIII7

Ref. No. Part No.

DESCRIPTION

QUANTITY

TELESCOPIC FRONT FORK

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Not illus.
51

97-4396
97-4397
14-0234
14-1303
60-2331
14-1034
82-6738
60-0623
21-0578
97-2266
83-2007
97-4031
97-4028
97-4385
14-0237
97-4476
82-2184
14-1303
97-4380
97-4076
97-4011
97-4514
97-4515
97-4456
97-4457
21-2102
14-0302
60-2428
97-4001
97-3894
97-3893
97-4003
97-4009
14-1019
97-4004
97-4325
97-4395
97-4166
97-4317
21-2189
97-4387
97-4461
97-4002
97-4480
97-4481
97-4121
97-4203
97-2208
97-2209
97-2210
21-2095
82-6784
97-4012

FORK ASSEMBLY
...
...
...
Top Yoke ...
...
...
...
Pinch Bolt
...
...
...
...
...
Nut
...
...
Washer
...
...
...
...
Cap Screw ...
...
...
...
Lock c/w 2 keys
...
...
Key (state serial no.)
...
...
Grub Screw
...
...
...
Sealing Washer ...
...
...
Abutment Ring ...
...
...
Taper roller bearing
...
...
...
...
...
Dust cover
...
Bottom yoke and stem ...
...
...
Pinch bolt ...
...
...
...
...
Pinch bolt ...
Washer
...
...
...
...
..
...
...
...
Nut
Stanchion
...
...
...
...
...
...
End Plug ...
...
...
Main Spring
...
...
OUTER MEMBERL.H.
OUTER MEMBERR.H.
...
Cap, wheel spindleL.H.
Cap, wheel spindleR.H. ...
...
...
...
Stud ...
...
...
...
Nut ...
...
...
...
Washer
...
...
Oil Seal
...
...
...
Drain Plug ...
...
...
...
...
Washer
...
...
...
...
`O' ring
...
...
...
Recoil Spring
...
...
...
Cap Screw ...
...
...
Cap Screw Seal ...
Damper Tube and Valve Assembly
...
...
...
Top Cap Nut
...
...
...
...
Washer
...
...
Steering Stem Nut
Stud, Caliper to Outer Member
...
Cap Screw, Top Cap Nut
...
Rubber Ring, Outer Cover
...

Scraper Sleeve
...
...
Outer CoverL.H.
...
...
Outer CoverR.H.
...
Headlamp BracketL.H.
...
Headlamp BracketR.H.
...
...
Rubber Mounting
...
...
...
Rubber Buffer
...
...
...
Backing washer
Attachment Bolt ...
...
Grommet, throttle cable
...
...
Nut, damper valve
51
ClassicBike.biz

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

1
1
1
1
1
2
1
1
1
1
2
2
2
1
1
1
4
2
2
2
2
1
1
1
1
8
8
8
2
2
2
2
2
2
2
2
2
2
1
2
2
2
2
1
1
1
1
2
4
4
4
1
1

REMARKS

10

Fig. 21.

HANDLEBAR MOUNTINGS AND STEERING DAMPER

52

ClassicBike.biz

QUANTITY

DESCRIPTION

Ref. No. Part No.

REMARKS

HANDLEBAR MOUNTINGS AND STEERING DAMPER

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

97-2291
82-1335
21-0589
97-1527
97-1529
97-1581
97-1580
97-2221
14-1303
97-3875
60-2438
97-0435
97-1797
97-0095
60-2329
97-4102

...
Handlebar eyebolt
...
...
Washer ...
...
...
...
Bolt
...
Metalastic bush
Hemispherical washer ...
...
Distance piece ...
...
Rubber washer ...

...
...
...
...
...
...
...

...
..
...
...
...
...
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...

...
...
...
...
...
...
...

...

...

...

...

...

...

...

...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...

..
...
...
...
...
...
...
...
...

Cup

...

...

...
...
...
...
Nut
Steering damper rod c/w knob
...
...
Spring washer ...
...
...
...
Friction disc
...
...
Anchor plate ...
...
...
...
Spring plate
...
...
...
...
Washer
...
...
...
Bottom nut
...
Split pin ( in. x Z in.)

...
...
...
...
...
...
...
...
...

53

ClassicBike.biz

...
...
...
...
...
...
...
...
...

2
2
2
2
4
2
2
2
2
1
1
1

Available

1
1
I

Reference only

54

ClassicBike.biz

LLN

LL

Ref. No. Part No.

DESCRIPTION

QUANTITY

FRONT WHEEL

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

37-4141
37-4143
37-4129
37-4126
37-4127
37-4131
37-4130
37-2294
37-4133
37-4134
57-1070
37-4135
37-1257
37-0653
57-0280
37-4132
37-4136
21-2207
60-2322
14-1303
37-3969
37-3970

...
...
FRONT WHEEL COMPLETE
RIM, SPOKES AND HUB ASSEMBLY
...
...
...
Rim
...
...
...
...
HubL.H. half
...
...
...
HubR.H. half
...
...
...
SpokeOuter
...
...
...
SpokeInner
...
...
...
Spoke Nipple
...
...
...
LocknutL.H.
...
...
...
...
Lock RingL.H. ...
...
...
BearingL.H.
...
...
...
...
Grease retainerL.H.
...
...
Dust CoverR.H.
...
...
...
...
BearingR.H.
...
...
...
...
CirclipR.H.
...
...
...
...
Spindle
...
...
...
...
...
...
Disc
Bolt
...
...
Disc to hub
Washer
Nut
...
...
...
...
Balance weight
...
...
...
...
Balance weight

...

...

55

ClassicBike.biz

...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...

...
...

...

...

... 1
... 1
... 1
... 1
... 1
... 20
... 20
... 40
... 1
... 1
... 1
... 1
... 2
... 1
... 1
... 1
... 1
... 4
... 4
4
... As reqd.
... As reqd.

...

REMARKS

Fig. 23. FRONT BRAKE

56

ClassicBike.biz

DESCRIPTION

Ref. No. Part No.

QUANTITY

REMARKS

FRONT BRAKE

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Not illus.
26
27
28
29
30
31

60-4102
60-4206
3761/270
3528/441
21-2191
14-1201
21-2192
21-2194
70-7573
60-4183
60-4182
60-4184
60-4176
60-4179
60-4180
60-4181
60-4175
97-4477
14-0103
60-2427
60-4178
60-4101
4741/537
K19866TP2
3486/229
363400
60-2331
14-1303
37-4170
21 -21 96
60-4156
60-4186

...
...
MASTER CYLINDER (4222/979)
...
...
...
BRAKE LEVER ASSY
...
...
...
...
Piston ...
...
...
...
...
Spirol pin

Pivot screw
Lever pivot
Nut
...
...
...
...
...
Screw
...
...
...
...
...
Screw
...
...
...
...
...
...
Plug
...
...
...
...
Banjo bolt (30420)
...
...
...
Sealing washer (KL 44516)
...
...
...
Sealing washer (KL 44518)
Hose, master cylinder to top yoke (KL 58505)
Pipe, top yoke to bottom yoke (ZT 2071 N)
...
...
Locknut
...
...
...
...
Washer ...
Hose, bottom yoke to fork leg (KL 56612) ...
...
Bracket, pipe support ...
Bolt
Bracket to fork leg
Washer
...
Pipe, fork leg to caliper (ZTA 2070N)
...
CALIPER (4823/432) ...
...
...
...
...
Brake pad
...
...
...
...
Retaining pin
...
...
...
...
Bleed nipple
...
...
...
Cover, bleed nipple
Washer l
...
Caliper to outer member
..
Nut
..
...
...
...
Cover, caliper
Screw, cover attachment
...
...
...
Decal, caliper cover ...
...
...
Rubber boot, master cylinder

57
ClassicBike.biz

1
1
Reference only
Reference only
1
1

...
...
...
...

...
...
...
...
...

...
...
...
...
...

...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
..

... 2
... 2
... 1
... 1
... 1
... 1
... 1
... 1
... 3
... 3
... 1
... 1
22

...

...

...
...
...
...
...
...
...
...
...
...

...
...
...
...

1
1
Reference only
... Reference only
... Reference only
... Reference only

...
...

...
...
...
...

...

2L

...
...
...
...

1
2
1

58

ClassicBike.biz

Ref. No.

DESCRIPTION

Part No.

QUANTITY

REAR WHEEL

1
2
3
4
5
6
7
8
9
10
11
12
13
14

15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

37-3968
37-4182
37-3784
37-3724
37-3725
37-3726
37-2294
37-4179
37-3468
37-3749
37-0653
37-4181
37-4180
37-3753
37-1654
37-3747
1 0207
6 2320
1 1301
37-3856
37-3872
37-4034
1 1303
60-2331
37-3870
1 305
6 2431
37-3925
37-3926
37-2328
37 049
83-2656
1 0133
37-2330
1 1304
37-3965
37-3750
60-3213
37-3746
1 1307
83-2266
37-3751
83-3082
37-3742
1 10
1 0301
60-1841
71-2501

1
1

...
REAR WHEEL COMPLETE ...
RIM SPOKES AND HUB ASSEMBLY
Rim

Spoke (innerL.H.)
Spoke (outerL.H.)
SpokeR.H. ...
...
...
Nipple...
Hub and brake drum
Tyre security bolt...
Support ringL.H.
...
...
Bearing
Locking ring--L.H.
...
Spacer
...
Spacer
Grease retainerR.H.
Sprocket 47 teeth
Bolt
Washer Sprocket to hub
..
Nut
Brake anchor plate
Brake cam
Brake lever
Nut
Washer
Brake pivot
1
Nut
Brake pivot to torque arm
Washer f

Brake shoe complete (leading) ...

Brake shoe complete (trailing) ...
Return spring (brake shoe)
Return spring (brake lever)
Brake torque arm
Bolt
Washer Torque arm to frame
Nut
...
Wheel spindle
...
Distance piece inner
Speedometer drive gearbox
...
Distance piece outer
1
Nut
Wheel spindle
Washer

...
Speedometer drive ring
Cover plate-swinging arm fork end
Chain adjuster ...
Screw}

Nut

Chain adjuster

Grease nipple
Fibre washer

59

ClassicBike.biz

10
10
20
40
1
2
1
. 2
1
1
1
1
1
5
5
5
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
2
.1. 2
2
2
1
1

.
.

REMARKS

26

6-13
--14
-9

, ---28

Fes,

15

16-

B22
4

17 -V

42
f

ii;-

--11

Fig. 25 GAS TANKS AND TWINSEAT

60

ClassicBike.biz

33

Ref No. Part No.

DESCRIPTION

QUANTITY

REMARKS

GAS TANK AND TWINSEAT

2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

83-4861
83-4862
83-4931
83-4932
83-4930
60-2330
82-9063
83-4934
83-3814
14-1202
83-4395
14-0113
60-2428
83-4776
83-4763
82-9700
82-9701
83-1339
82-7888
83-3875
82--4048
83-2800
83-2801
70-7351
83-0002
83-4786
83-4789
83-4782
83-4802
14-0101
60-2417
82-9093
60-2087
60-2381
82-7560
82-4228

70-1719

...
...
Gas tank
...
...
...
...
Gas tank
...
...
Steady rubber
...
Mounting rubber
...
...
...
Centre fixing bolt
...
...
...
Washer ...
...
...
Distance tube ...
...
Mounting rubber
...
...
...
Washer ...
...
...
...
...
Nut
...
...
...
...
Tie strap
...
...
...
...
Bolt
...
...
...
Washer ...
...
Badgetank grommet
...
...
Grommet
.
...
...
Tank motifL.H.
...
...
Tank motifR.H.
...
Screwfronttank motif
...
Screwreartank motif
...
...
...
Filler cap
...
...
...
Joint washer
...
...
...
Gas tap ...
...
...
Gas tapreserve
...
...
...
Tap seal
...
...
...
Washer ...
...
...
...
Twinseat
...
Twinseat cover ...
...
...
...
Hinge--rear
...
...
Hingefront ...
Bolt
Hinge attachment
Washer
...
...
Rubber buffer ...
...
...
...
Check wire
...
...
Screwself-tapping
...
...
...
Seat plunger
...
...
...
Spring ..
...
Split pin (32 in. x z' in.)
Washer ...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
..
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...

...
...
...
...
...
...
.
...
...
...

...
...
...
...
..
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...

...
...
...
...
...
...
...
...
...
...

...

...
...
...
...
...
...
...

...
...
...

...
...
...
...
...
...
...

61

ClassicBike.biz

...
...
...
...
...

...
...
...
...
...
...
...

1 T140V
1 TR7RV
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
4
4

.. 4
... 1
... 1
... 1
... 1
... Reference only
... 1

62

ClassicBike.biz

4
LL

Ref. No.

Part No.

AIR

83-5010
83-5011
83-4606
1
83-4607
1
83- 4809
2
4 810
832
83-5012
83-5013
1
83- 4845
1
83-4609
2
83- 4807
83- 4808
2
3
60-3618
83-3417
4
1 0221
5
82-8245
6
7
6 2438
302
1
8
9
60-3539
21-0501
10
1 0218
11
60-2418
12
13
83-2626
83- 4614
14
71-1860
15
6 3975
16
17
83-4854
83- 4803
18
82-6673
19
1
102
20
60-4150
21
60-4169
22
6 148
22
60-4153
23
60-4152
24
601 54
25
82-4717
26
82-4129
27
Not illus. 83-5236

QUANTITY

DESCRIPTION

CLEANER

AND

SIDE

PANELS

AIR CLEANER ASSEMBLYL.H. ...

AIR CLEANER ASSEMBLYR.H. ...
...
BodyL.H.
BodyR.H.
CoverL.H.
CoverR.H.
...
AIR CLEANER ASSEMBLYL.H. ...
AIR CLEANER ASSEMBLYR.H. ...
BodyL.H.
BodyR.H.
CoverL.H.
CoverR.H.
Element ...
Clip, element
Bolt
...
...
Cover to body ...
Retainer
Washer
Nut
Screw }
L.H. assy to R.H. assy
Nut
Bolt
...
Air cleaner to frame
Spring washer ...
f
Connector pipe
Connector pipe
Carburetor adaptor
...
...
Clip
Side panelL.H.
Side panelR.H.
Panel grommet ...
...
Bolt
Name plate
...
Motif
...
Motif
Rubber bush
...
Rubber plug
n
' Spire ' nut
- Name plate attachment
...
Nut
...
J
Screw ...
Rubber stripside panel

63
ClassicBike.biz

REMARKS

1
1

Twin Carb
T140V

1
1
Single Carb
1
... 1 r TR7RV
1
1 i
21
4
2
. 2
All models
. 2
2
2

2
2
2

2
1 or 2
1 or 2
1
1
2
4
2
2
2
2
2
2
2
2
2

T140V
TR7RV

TR7RV
T140V

64

ClassicBike.biz

W
W

G
z

DESCRIPTION

Ref. No. Part No.

QUANTITY

FENDERS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

97-4439
97- 4 533
97- 4 534
97- 4 535
1 0101
60-4 245
1 1201
97-444 6
1 0103
6 2427
1 0116
60-2330
1 1302
1 6114
60-2428
83-4 805
1 0101
60-2329
1 1301
1 0114
60-2330
1 1302
834 600
1 0102
60-2329
1 1301
83-5145
1 0102
60-2329
1 1301

Front fender
Front stay
Centre stay
Bottom stay
Bolt
Washer
Nut
Bracket
Bolt
Washer
Bolt
Washer
Nut
Bolt
Washer ...
Rear fender
Bolt
Washer
Nut
Bolt
Washer ...
...
...
Nut
Bridgerear fender
...
Bolt
Washer ...
...
Nut
Lifting handle
...
Bolt
Washer ...
...
Nut

1
1
6

6
Stays to fender
6
1
2
Bracket to fork leg
2
2
2
Front and centre stays to bracket
2
2
Bottom stay to fork leg
2
1
2
2
Fender top fixing
2
2
2
Fender front fixing
2
1
2
2
Bridge to fender
2

Lifting handle to fender

65

ClassicBike.biz

2
2
2

REMARKS

66

ClassicBike.biz

0
uM

I-

d
0.

oG
U-

Ref. No.

Pan No.

DESCRIPTION

QUANTITY

REMARKS

TAIL LAMP AND SUPPORT

1
2
3
4
5
6
7
8
9
10
Not illus.
11
12
13
14
15
Not illus.
Not illus.

83-4774
21-2225
60-4250
1 0301
83-5001
83-4784
82-6850
1 0102
60-2329
1 1301
83-4806
56513
54584930
54534931
54583924
380
6 103
6 3748

Tail lamp support

'
Stud
Washer Tail lamp support to fender
Nut
Support plate ...
Rear no. plate brackettop ...
Rear bo. plate bracketbottom
Bolt

Washer No. plate brackets and support plate to fender

Nut
...
...
...
Wiring protector
...
STOPTAIL LAMPL917 (99-1252)
Lens (complete with screws) (99-1257)
...
Base assembly
...
Gasket
Bulb (99-0542)
Cable grommet
Decal '5 SPEED'

67
ClassicBike.biz

1
1
1
1
1
1
1
4
4
4
1
1
1
Reference only
Reference only
1
5
1

68

ClassicBike.biz

W
W
J
J

H
Z

DO
U.

Ref. No. Part No.

HANDLEBARS AND

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

97-4411
97-1425
16/364
16/328
16/329
16/008
16/009
16/010
99-0244
11/013
97-0958
16/011
97-2124
60-3567
12/556
12/607
12/606
12/033
60-4256
60-3896
*60 391
6 3981
21-2048
1 1201
6 3585
60-3586
39595
54033666
54340882
54115246
54033751

QUANTITY

DESCRIPTION

CONTROL

LEVERS

Handlebar
...
...
Sleeve, handlebar mounting
TWISTGRIP (99-0248)
Body, top half (99-0245) ...
...
BODY, BOTTOM HALF (99-0246)
Friction spring
Screw
Locknut
Rotor
...
Screw (99-0225) ...
...
...
Grip
Cable stop (99-0241) ...
Grip
...
...
...
AIR CONTROL LEVER
Lever
...
Bolt
Cap ...
...
Spring washer
Shakeproof washer
Screw ...
...
Front brake lever
Clutch lever
Pivot pin
Nut
...
Adjuster
Lockring
...
...
...
HANDLEBAR SWITCHL.H.
...
Switch half (99-1235)
Lever half (99-1187)
Screw (99-1188) ...
...
Handlebar switchR.H. (99-1268)
*Front brake and master cylinder details are shown on page 57

69

ClassicBike.biz

REMARKS

1
4
1
1
1
Reference only
Reference only
Reference only
1
2
1
1
1
1
Reference only
Reference only
Reference only
Reference only
2
2
Reference only
1
1
1
2
2
Reference only
1
1
4
1

CLUTCH
CABLE
IN2 6

19
21

20

B26

Fig. 30. CONTROL CABLES

70

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

CONTROL
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

60-1819
618Q6
6 3925
60 -4194
6 126
6 127
244 /104
60- 4128
313/13
18/084
313/020
313/021
16/008
210/007
5/077
313/004
210/008
5/077
97-2125
6 0777
60-4258
97-4112

QUANTITY

REMARKS

CABLES

Throttle cable ...

Throttle cable ...
Clutch cable
...
Air control cable
AIR CONTROL CABLE
...
Cable, lever to junction box
...
Junction box (99-0341) ...
Cable, junction box to carburetor
TWIN ROTOR TWISTGRIP (99-0347)
Screw
...
Body, top half
...
BODY, BOTTOM HALF
Friction spring
Screw ...
Nut ...
Rotor

Rotor stop screw ...

Nutrotor stop screw
Grip
Cable clip
...
Cable clip
Handlebar clip ...

71

ClassicBike.biz

2
1
1

T140V
TR7RV

TR7RV
T140V

1
1
1
2
1

T140V

Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
Reference only
1
2
15
4

Fig. 31. TOOLKIT

72

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

TOOLKIT

1
2
3
4
5
6
7
8
9
10

60-2112
6 0291
60-2184
60-1911
60-2084
60-0971
60-1907
60-0974
60-0767
6 1050
6 3711

TOOLKIT COMPLETE
Tool roll ...
Damper unit spanner
...
Tommy bar
Spanneropen ended
Box spanner
Ring spanner
Tyre valve key
Screw driver
Plug spanner
...
...
...
Tommy bar, rear wheel spindle

73

ClassicBike.biz

1
1
1
1
1
1
1
1
1
1
1

REMARKS

74

ClassicBike.biz

ao
LL

Ref. No. Part No.

DESCRIPTION

SPEEDOMETER

1
2
3
4
5
6
7
8
9
10
11
12
13
14

15
16
17
18

19
20
21
22

SSM5007/00A
41-148-203-10
54959626
643
60-3376
RSM3003/13
6 3933
97-4026
60-2600
71-2475
70-9332
70-5156
7 5155
7 5157
71-2480
6 3355
71-2653
71-2481
71-2482
7 7351
6 0494
31-371-398

AND

QUANTITY REMARKS

TACHOMETER

Speedometer head (60-2394)

Trip control (99-0176)
Bulb holder
...
Bulb (3W.MES)
Speedometer cable
...

...

Tachometer head (60-2396) ...

...
Tachometer cable
Mounting bracket
Rubber cup
...
TACHOMETER GEARBOX ...
SECURING SCREW
...
Bush ...
Flanged bush
Driving gear
End cap
' 0' ring
Driven gear
Welch washer
...
Spacer
Sealing washer ...
Circlip
Spade (99-0173)

75

ClassicBike.biz

1
1
Reference only
Reference only
1

1
1
2
2
1
1
Reference only
Reference only
1
1
1
1
1
1
1
1
1

3Q

iiiii l^1^

^Vi i\\\1\

Fig. 33. COIL, CAPACITOR PACK, FLASHER UNIT, ZENER DIODE AND HORN

76

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Ref. No.

Part No.

DESCRIPTION

ELECTRICAL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

83-4601
14-0102
6 2329
1 1201
1 1301
6 2329
45223
82-9561
49072
82-5338
54441582
21-2079
6 2391
21-0778
49345
N3
60-0262
35048
54385091
6 3614
21-2079
6 2391
21-0778
70228
14-0103
6 2347
6 3161
1 1301
57183
6 2391
82-4717
83-3522
83-3764
21-2120
6 2391
21-0778

QUANTITY

REMARKS

COMPONENTS

Mounting platformelectrical components

...
...
Bolt

...
Washer ...
Mounting platform attachmentrear
Nut
...
Nut
Front attachment
Washer ...
Ignition coil (17M-12) (6 2203)
Coil grommet ...
...
Rectifier (99-0589)
Nut
Condenser (99-0776)
,
Screw ...
...
...
Washer ...
Condenser attachment
Nut

,
Zener diode (99-0590)
...
...
Sparking plug ...
Plug cover (Champion WC 200)
Flasher unit (99-1201) ...
...
Clip, flasher unit (99-1204) ...

Spring ...
Flasher unit attachment
Screw ...
Washer ...
Nut

Horn-6H (99-1245) ...

...
...
...
Bolt
Horn attachment
Washer ...
Grommet
...
Nut
...
ReflectorAmber (99-1161)
...

Washer ...

Reflector mounting
Nut
...
...

Mounting rubber
.
Reflector bracket
...
...
Bolt
...
Bracket to frame
Washer ...
Nut
...
..

77
ClassicBike.biz

1
2
2
2
2
2
2
2
1
1
2
2
4
2
1
Reference only
2
1
1
1
2
3
2
1
2
4
2
2
2
2
2
2
2
4
4
4

38

ob
U.

78

ClassicBike.biz

Ref. No.

Part No.

DESCRIPTION

QUANTITY

REMARKS

HEADLAMP AND FLASHER LAMPS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Not illus.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

41

60512
553248
504665
144921
534296
370
554602
989
54573590
54363454
54363455
54363453
54140331
3 44 19
54525212
281
54115106
143086
54961593
31899
54130041
82-6981
60-0622
97-2262
56147
54581638
54580300
554548
573832
382
54123401
60600092
83-3325
82-8091
82-9353
83-3849
82-7380
83-2508
82-6039
1 1301
54027029

HEADLAMP COMPLETE (99-1267)

...
...
Rim (99-0692)
Light unit (99-1156)
...
Fixing wire (99-0683)
...
Screw
Plate
Main bulb (45/35W) (99-1214) ...
...
...
Bulbholder
...
Pilot bulb (99-0548)
...
Pilot bulbholder (99-1213)
...
Warning light (Red) (99-1208)
Warning light (Green) (99-1209)
Warning light (Amber) (99-1207)
Sealing washer (99-1210)
Light switch (99-1251) ...
...
...
Shield, warning light
Bulb, warning light (99-0537) ...
Screw, headlamp fixing (99-1223)
Washer, headlamp fixing (99-1224)
...
Wiring harness (99-1259)
IGNITION SWITCH (99-0558)
.
Nut ...
...
IGNITION LOCK CAW KEY
Key (state serial number)
...
Cover, ignition switch
FLASHER LAMP (99-1190) ...
...
Lens (99-1191)
...
Gasket
...
Bulbholder
Interior assembly ...
...
Bulb (99-1192)
...
Screw (99-1193) ...
Stanchion, flasher lamp (99-1246)
Battery carrier
...
Carrier tray
Retaining strap ...
Buckle ...
Protective strip
Shoulder screw
Battery carrier mounting
Rubber bush
Nut
BatteryPUZ5A (99-0719) ...

79
ClassicBike.biz

1
1
1
6
Reference only
Reference only
1
Reference only
1
1
1
1
1
3
1
Reference only
3
2
2
1
1
Reference only
1
As required
1
4
1
Reference only
Reference only
Reference only
1
2
4
1
1
1
1
4
3
3
1
1

STANDARD HARDWARE SPECIFICATION

BOLTS
Length under

head

Hexagon A.F.
0.500"
0.565"
0.500"
0.375"
0.438"
0.438"
0.438"
0.500"
0.500"
0.500"
0.563"
0.438"
0.500"
0.500"
0.500"
0.500"
0.500"
0.500"
0.563"
0.563"
0.563"
0.563"
0.563"
0.625"
0.438"
0.500"

Material
Steel

Part No.

Material

Thd. dia.

Hexagon A.F.

Thickness

Remarks

21-0778
21-1852
21-1906
21 -1 908
21 -1 914
21-2012
21-2013
21-2014
14-0301
14-0302
14-0401
14-0402
14-0403
14-0701
14-0702
14-0703
14-1201
14-1202
14-1301
14-1302
14-1303
14-1304
14-1305
14-1902
14-1903

Steel

No. 10 UNF
-&-" UNF
;" UNF
-" UNF
4" UNEF
UNEF
4" UNEF
4" UNEF
4" UNF
- " UNF
;" UNF
- "UNF
4" UNF
4" UNF
A-" UNF
4" UNF
4-" UNF
16" UNF
'-" UNF
,6" UNF
8" UNF
h-" UNF
4" UNF
-&" UNF
4" UNF

0.375"
0.437"
0.438"
0.438"
1.125"
1.313"
1.313"
1.313"
0.438'
0.500"
0.438"
0.500"
0.563"
0.438"
0.500"
0.563"
0.438"
0.500"
0.438"
0.500"
0.563"
0.688"
0.750"
0.500"
0.563'

0.225"
0.330"
0.188"
0.313"
0.250"
0.438"
0.313"
0.438"
0.224"
0.271"
0.161"
0.192"
0.224"
0.203"
0.246"
0.296"
0.285"
0.335"
0.245"
0.290"
0.320"
0.375"
0.435"
0.361"
0.375"

Cleveloc
Philidas
Plain
Plain
Plain
Plain
Plain
Plain
Plain
Plain
Lock
Lock
Lock
Philidas
Philidas
Philidas
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Stiffnut
Nyloc
Nyloc

,,

Thd. dia.
.f" UNF
IN UNF
6" UNC
4" UNF
1" UNF
4" UNF
4" UNF
6" UNF
" UNF
-h" UNF
4" UNF
4" UNF
" UNF
6" UNF
6" UNF
6" UNF
- " UNF
- " UNF
4" UNF
4" UNF
4" UNF
4" UNF
44" UNF
-^" UNF
4" UNC
, " UNC

Min. length
of thread

Part No.
21-1822
21 -1 910
21 -1 919
21-2010
14-0101
14-0102
14-0103
14-0113
14-0114
14-0115
14-0128
14-0208
14-0216
14-0217
14-0219
14-0220
14-0225
14-0228
14-0234
14-0236
14-0239
14-0240
14-0242
14-0251
14-6102
14-6115

4
"
18"
-6"

64"
f "
4"
e"

4"

e"
4"
e"
4"
e"
1"
24"
14"
14"
14"
14"
3"
4"
14"
24"
3"
34"
4"
24"
4"
a"

3"
g"
$"
S"
-,'"
a"
$"
1
1"
1"
1"
1"
14"

NUTS

80

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SCREWS
Part No.

21-1916
21-1917
21-1918
21-1920
21-1929
21-2079
1 0604
505
1
607
1
1
608
1
609
1 7019
1 7024

Type of head
Cheese head
Cheese head
Cheese head
Hex. head
Countersunk (82)
Cheese head
Cheese head
Countersunk (82)
Cheese head
Cheese head
Cheese head
Socket hea
Socket head

Material

Thd. dia.

Steel

r UNC
I"
4 UNC
r UNC
r UNC
14 " UNC
No. 10 UNF
+" UNF
r UNC
r UNC
+" UNC
1"
4 UNC
16 UNC
UNC

It

,,
11

91
11
1/

,,
19
99
/9

19

Length under head

18"
21"
21"
v ,,
64
iv
1"
T
4-"
7
i"
7"
8

1"
14"

2"

Type of drive
Cross recess
Cross recess
Cross recess
Slot

Pozidrive
Cross recess
Cross recess
Cross recess
Cross recess
Cross recess
Hex. socket
Hex. socket

WASHERSPLAIN
Part No.

Material

i/dia.

o/dia.

Thickness

6 245
6 246
6 247
37-2027
60-4248

Steel
Steel
Steel
Steel
Steel

0.273"
0.398"
0.336"
0.531"
0.266"

0.563"
0.750"
0.625"
1.031"
0.469"

0.048"
0.063"
0.063"
0.092"
0.064"

WASHERSSPRING
o/dia.

Part No.

Material

i/dia.

60-4259
60-4250
6 3541
21-0648

Spring Steel

1"
a clearance
I"
4 clearance

99

91

ft

ft

,,

91

W
-h"

clearance

o/a height

Thickness

0.104"
0.064"
0.040**
0.080"

13
2
7"

-1k"
7"

i"

A"

** Double coil.

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