Triumph T120R Bonneville 120 Replacement Parts Manual Download Page 44 | Manualshive

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Summary of Contents for T120R Bonneville 120

Page 1: ...0 TR6C TROPHY 650 Tl2OR BONNEVILLE 120 From engine No DU 85904 T R I U M P H E N G I N E E R I N G C O M P A N Y L I M I T E D M E R I D E N W O R K S ALLESLEY C O V E N f R Y E N G L A N D T E L E P...

Page 2: ......

Page 3: ...n which has been used any part not supplied o r approved by us o r t o ryres saddles chains speedometers revolution counters and electrical equipment o r t o parts supplied t o the order of the Purcha...

Page 4: ...n your own interest send a copy of the advice note under separate cover All pans must be fowarded carriage paid and care should be taken t o ensure that all remittances are sent separately and not enc...

Page 5: ...ENGINE PLATES 39 ENGINE TORQUE STAY 39 EXHAUST PIPES 41 43 EXHAUST PIPE ADAPTOR 19 21 FENDERS 61 FOOTRESTS 39 67 FRAME 35 FRONT BRAKE 49 FRONT FORKS 45 FRONT WHEEL 49 FUSE ASSEMBLY 57 GAS TANK 53 GASK...

Page 6: ...t Chains Capacities Brakes T i r e size Main jet Needle jet Throttle valve Front Rear Gas Tank Oil Tank Gearbox Primary Chaincase Front Forks each leg Front diameter Rear diameter Front Rear Champion...

Page 7: ...ain jet Needle jet Throttle valve Front Rear Gas Tank Oil Tank Gearbox Primary Chaincase Front Forks each leg Front diameter Rear diameter Front Rear 71 x 82 mm 2 79 x 3 23 ins 649 C C 40cu ins Champi...

Page 8: ...Needle jet Throttle valve Front Rear Gas Tank Oil Tank Gearbox Primary Chaincase Front Forks each leg Front diameter Rear diameter Front Rear 71 x 82 mm 2 79 x 3 23 ins 649 C C 40 cu ins 9 I Champion...

Page 9: ...Brake lining 16 W129 Rivet Pistons complete with rings gudgeon pins and circlips These are in effect carton pack assemblies E6868 9 1 CR Standard E6867 11 I CR Competition use only All the above pisto...

Page 10: ...cal equipment carburetters suspension units etc are listed in the first c o l u m n n d e r r i u m h part numbers prefixed either D or99 whereverthey are stocked atthe factory If proprietary parts ar...

Page 11: ...ERY 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 C...

Page 12: ...i I 41 19 io 21 22 23 24 2s Fig 1 CRANKSHAFT A N D CONNECTING RODS...

Page 13: ...sizes 4 PISTON COMPLETE 9 1 C R 2 PISTON COMPLETE 11 1 C R 2 Taper compression ring 4 Oil control ring 2 Gudgeon pin long 2 Circlip 4 Main bearing right 1 Oil seal 1 Engine sprocket 29 teeth Duplex 1...

Page 14: ...Fig 2 CRANKCASE 14...

Page 15: ...sher Tachometer drive plug L H thread Fibre washer Oil pipe stud If in O A Cylinder stud 1 in O A Plug timing hole Bolt 2f in U H U N Bolt 1 in U H U N Bolt 1 i n U H U N Stud 5 h in O A Stud 3 in O A...

Page 16: ...ASSY 13 16 24 18 23 20 21 22 Fig 3 O I L PUMP RELEASE VALVE M A N I F O L D A N D TAPPETS 16...

Page 17: ...3 OIL PUMP 1 Pump body 1 Feed plunger 1 Scavenge plunger 1 Drive block 1 Valve ball 6in dia 2 Valve spring 2 Screwed plug 2 Joint washer 1 Oil pump stud I i n U H 2 Serrated washer 2 N u t 2 OIL RELEA...

Page 18: ...Fig 4 CYLINDER BLOCK A N D HEAD TR6 18...

Page 19: ...rer valve spring green spot Top collar Split cotrer Cylinder head bolt 3 i in U H Plain washer Bolt 3 in U H Plain washer Sealing ring Inlet rocker box Exhausr rocker box Joint washer Rocker box stud...

Page 20: ...Fig 5 CYLINDER BLOCK A N D HEAD TIIOR 20...

Page 21: ...xhaust valve 2 Bottom cup 4 Inner valve spring Red spot 4 Outer valve spring green spot 4 Top collar 4 Split cotter 8 Cylinder head bolt 3t In U H 4 Plain washer 8 Bolt 3 in U H 1 Plain washer 1 Seali...

Page 22: ...Fig 6 T I M I N G COVER A N D C O N T A C T BREAKER...

Page 23: ...5 Bolt Zin U H 1 Plain washer 1 Rubber grommet 1 Pillar bolt 2 Plain washer 2 Cover 1 Joint washer 1 Serrated washer 2 Screw 5 in U H 2 AUTO ADVANCE UNIT 54419340 1 Spring set 54415642 1 CONTACT BREP...

Page 24: ...Fig 7 GEARBOX I N N E R COVER A N D SELECTORS 24...

Page 25: ...rong index plunger spring Index plunger holder Mainshaft selector fork Layshaft selector fork Selector fork roller Selector fork rod Layshaft bearing Thrust washer GEARBOX INNER COVER Layshaft bearing...

Page 26: ......

Page 27: ...rbox sprocket 20 teeth Tab washer Gearbox sprocket nut High gear bearing Circlip Oil seal Mainshaft bearing Circlip Plain washer Pinion sleeve Pinion spring Kickstarter pinion Kickstarter ratchet Tab...

Page 28: ...Fig 9 GEARBOX O U T E R COVER 28...

Page 29: ...washer N u t Kickstarter quadrant Kickstarter return spring Kickstarter axle CLUTCH LEVER ASSEMBLY Clutch lever Lever shaft Ball i n d i m Thrust plate Return spring Plain washer Splitpin Countersunk...

Page 30: ......

Page 31: ...r Sprocket and housing 58 teeth Duplex Centre Inner plate Countersunk screw 0 417 in U H Shock absorber spider Drive rubber large Rebound rubber small Ourer place Screwed pin 1 in U H Driving place bo...

Page 32: ......

Page 33: ...t Chain tensioner blade Tie rod Trunnion Adluster sleeve nut Primary chain iin Duplex x 84 links Stator stud 4 in O A Stator stud Stator RM2l 47205 Sleeve nut Rubber grommet Plastic sleeve Plain washe...

Page 34: ......

Page 35: ...4 0303 14 0251 F4370 14 0304 PCW73A 5588 F7155 Front Frame Steering race cup Steel ball in diam Top cone and dust cover Centre stand Pedalrubber Pivot bolt Plain washer Tab washer N u t Return spring...

Page 36: ...Fig 13 S W I N I G N G FORK A N D S U S P E N S I O N UNITS...

Page 37: ...ed washer Bolt 85 in U H Tab washer Nut Brake torque stay Bolt j In U H Spring washer Nut 0 ring SUSPENSION UNIT 64052107 Damper unit Bonded bush 64533645 Sprinz retainer 9054 171 Spring 100 ibs chrom...

Page 38: ...Fig 14 E N G I N E U N I T FITTING A N D FOOTRESTS 38...

Page 39: ...ut Extended nut Left footrest Right footrest Stud I in O A Plain washer Nut Peg Footrest rubber Stud 1 in O A Nut Bolt a in U H Bolt 19 in U H Spring washer Nut Nut Nut Engine torque stay B i t 1 in U...

Page 40: ...Fig 15 E X H A U S T PIPES A N D MUFFLERS TIZOR TR6R...

Page 41: ...bolt Bolt for clip Exhaust pipe tie Spring washer Screw stay to exhaust pipe Nut stay to exhaust pipe Silencer muffler Bracket silencer bracket Spring washer Bolt bracket to silencer iin U H Hanger fr...

Page 42: ...Fig 16 E X H A U S T PIPES A N D MUFFLERS TR6C 42...

Page 43: ...bolt 3 Spring washer 3 Silencer upper 1 Silencer lower 1 Connector 1 Bolt 2 Spring washer 3 Silencer bracket 1 Clip 1 Bolt for clip 1 Nut for clip 2 Bolt hanger to frame 4 Spring washer 4 Clip 2 D wa...

Page 44: ...ASSEMBLY REF No 1 Fig 17 TELESCOPIC F R O N T FORK 44...

Page 45: ...nt Solo main spring Yellow Blue Extra strong main spring Yellow Green Plain washer Telescopic gaiter DUST EXCLUDER SLEEVE N U T Oil seal 0 ring Plain washer Top bearing Damping sleeve Stanchion Lower...

Page 46: ...FORK ASSEMBLY REF NP1 15 21 Z k 23 19 L 20 Fig 18 TRbC F O R K PARTS A N D STEERING DAMPER 46...

Page 47: ...1 Plain washer 1 Adjuster sleeve 1 Spring plate 1 Anchor plate 1 Fork stem sleeve nut 1 Rubber sleeve 1 Friction disc 1 Main spring yellowlgreen 2 All other parts are as listed on Page 45 H A N D L E...

Page 48: ......

Page 49: ...ase retainer 1 W582 Retaining ring 1 W3460 Cover plate 1 W1197 Balance weight f oz as required W1198 Balance weight 1 oz as required W3462 Brake anchor plate 1 W1996 BRAKE SHOE c w LINING 2 Reference...

Page 50: ......

Page 51: ...G x7 In 110 Spoke 8 1OG x 79 in 90 Spoke nipple Hub Sprocket 46T Bolt in U H Serrated washer Brake drum Bolt In U H Self locicing nut Wheel spindle Grease retainer brake side Grease retainer Backing r...

Page 52: ...Fig 22 GAS TANKS 52...

Page 53: ...ip Right knee grip Centre styling strip Hook screw Serrated washer Nut FILLER CAP FILLER CAP c w CHAIN Joint washer Petrol tap left Petrol tap with reserve tube Petrol tap nut Petrol tap seal Steel wa...

Page 54: ...10 Fig 23 OIL TANK 54...

Page 55: ...Oil pipes and junction block Joint washer Plain washer Nut Vent pipe T piece Extension pipe Clip Front strap Rear Strap Spigot rubber Rubber washer Bolt in U H Self locking nut Metering screw Coil sp...

Page 56: ...Fig 14 BATTERY CARRIER A N D AIR FILTERS...

Page 57: ...Battery strap anchorage Battery carrier rubber strip Transfer positive earth Vent pipe Circlip vent pipe Battery PUZSA 54027029 AIR CLEANER Air cleaner element filter cloth gauze AIR CLEANER A i r cle...

Page 58: ......

Page 59: ...TIGER 650 Decal TROPHY 650 Decal BONNEVILLE Panel knob Washer Panel nut Panel grommet TWINSEAT Twinsear cover Trim strip Trim strip sprag Rubber buffer Hinge front Hinge rear Spring washer Bolt In U H...

Page 60: ...Fig 26 FENDERS 60...

Page 61: ...g handle Bracket Clip Backing plate Tail lamp adaptor Tail lamp plate Number plate bracket Reflector red 57111 Push fix Rubbermat Wiring protector Tail lamp lead grommet Bolt i in U H Plain washer Nut...

Page 62: ...Fig 27 HANDLEBARS A N D C O N T R O L LEVERS...

Page 63: ...dy bottom half 161329 Rotor 161091 Friction spring 161008 Friction spring screw 161009 Locknut 161010 Screw 111013 Grip Cable stop 161011 FRONT BRAKE AND AIR LEVER ASSEMBLY 181978 Brake lever ball end...

Page 64: ...23 25 TROPHY 24 25 24 Fig 28 C O N T R O L CABLES...

Page 65: ...Nipple Nipple Adjuster AIR CONTROL CABLE AIR CABLE ASSEMBLY Lever cable Carburetter cable Junction box 2441104 Nipple Handlebar end Ferrule Nipple Clip rubber TWIN ROTOR TWISTGRIP 313113 Body top hal...

Page 66: ...Fig 29 TOOLKIT A N D PILLION FOOTRESTS...

Page 67: ...anner x 6 in Whir Open spanner xiri in Whit Ring spanner 5 x 9in Whit C spanner and tappet key Screwdriver for chain tensioner Tyre lever Tyre lever and tomrny bar Screwdriver Ring spanner x in Whit C...

Page 68: ...Fig 30 A M A L CARBURETTER TR6R TR6C 68...

Page 69: ...ber 0 ring seal 622 101 Mixing chamber top 9281098 Screw 622 086 Thrortle valve 4 cutaway 9281060 Throttle return spring 622 131 Throttle stop screw 6221077 Air adjusting screw 6221076 0 ring 6221082...

Page 70: ......

Page 71: ...amber top 9281098 Screw 6221086 Throttle valve 3 cutaway 9281060 Throttle return spring 6221131 Throttle stop screw 6221077 Air adjusting screw 6221076 0 ring 6221082 Jet holder 6221128 Main jet 220 3...

Page 72: ...Fig 33 SPEEDOMETER A N D TACHOMETER...

Page 73: ...talastik bush Washer N u t Bolt l in U H Trip control Distance piece Sleeve nut Bracket Bolt fin U H Spring washer Speedometer cable 65 ins long D609W inner only TACHOMETER GEARBOX E5758 Body Securing...

Page 74: ...Fig 34 I G N I T I O N CAPACITOR A N D HEADLAMP TR6C...

Page 75: ...n U H Nut HEADLAMP ASSEMBLY MCH 66 60087 Shell Rim 534343 Light unit 54524526 Fixing wire 504665 Bulb 40127 W Vertical Dip Pre focus 464 Bulbholder pilot 554710 Bulb 3W M C C 989 Adaptor c w leads Bol...

Page 76: ...Fig 35 I G N I T I O N COILS H O R N RECTIFIER A N D ZENER D I O D E...

Page 77: ...Sparking plug Cha Plug cover Left coil bracket Right coil bracket Bolt 5 in U H Serrated washer Bolt mpion N3 N u t Ignition coil ib 32 000 Clip Sib3 32 000 1 CONDENSER PACK CP Condenser 47638 Cover...

Page 78: ...Fig 36 HEADLAMP WIRING HARNESS SWITCHES A N D TAIL LAMP 78...

Page 79: ...type 2AR 36403 1 Grommet 1 Bolt 2 Plain washer 2 Lighting switch 35710 1 Warning light body red 38189 1 Bulb 1W BA7S 281 1 Warning light body green 38191 1 Warning bulbholder 54945043 1 Distance piece...

Page 80: ...Printed In Englond by WARWICK PRINTING COMPANY LIMITED WARWICK...

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