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Page 1

SUPPLEMENTARY PAGES FOR
TRIUMPH
of
WORKSHOP MANUAL FOR UNIT CONSTRUCTION
650 cc TWINS
6T THUNDERBIRD
TR6 TROPHY
T120 BONNEVILLE T120
(UPDATING 1964/5 MANUALS TO 1966 CONDITION)
© Copyright by TRIUMPH ENGINEERING CO. LTD. MERIDEN WORKS, ALLESLEY, COVENTRY, ENGLAND TEL: MERIDEN 331 TELEGRAMS 'TRUSTY COVENTRY
987166
Page 2

Page 3

INTRODUCTION
THIS manual has been compiled and prepared to provide the necessary service information for workshop, fitter, technical staff and individual owner, wishing to carry out basic maintenance and repair work on the TRIUMPH 650 C.C. series of unit construction twin cylinder models.
GENERAL DATA for all models within the above range is provided in ready reference form, and a separate section covering Service Tools is fully illustrated at the end of this manual.
The manual is divided into sections dealing with major assemblies, throughout the machine, each section sub- divided into sequence order corresponding to normal operations of strip down, examination and rebuilding procedure.
ENGINE AND FRAME NUMBERS
NOTE. The engine number is located on the left hand side of the engine immediately below the cylinder barrel to crankcase flange. The engine type is incorporated as a prefix to the engine number.
The frame number of the machine is stamped on the left side of the machine, on the frame headlug, beneath the top fork lug, and forward of the fuel tank.
Both the engine and frame numbers should be given IN FULL in any correspondence relating to the machine either with your local Triumph Dealer or the Distributor.
EASTERN U.S.A. DISTRIBUTORS
WESTERN U.S.A DISTRIBUTORS
THE TRIUMPH CORPORATION, P.O. BOX 6790, TOWSON, BALTIMORE 4, MARYLAND 21204. Cables: Triumph Baltimore.
JOHNSON MOTORS INC. P.O. BOX 457, PASADENA, CALIFORNIA 91102, 267 WEST COLORADO BLVD. Cables: "Jomo".
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::.
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Page 5

versitetit
GENERAL DATA
6T Thunderbird TR6 Trophy T120 Bonneville
Also Alternative Fitments for TR6 and T120 Sports Models
Note:Throughout this Section, read All Models as for 6T Thunderbird, unless otherwise detailed under the particular Model
Modifications for 1966 Models (Engine No. DU.24875) are listed on pages GD19 & 20
GD1
Page 6

GD
GENERAL DATA
GENERAL DATA MODEL 6T-THUNDERBIRD
LUBRICATION SYSTEM
OIL PUMP
Body material ... Bore diameter: Feed ...
Scavenge Plunger diameter: Feed
Scavenge ... Valve spring length Ball diameter Aluminium crosshead width Working clearance in plunger heads ...
:::
:::::::::
;::::
:::::::::
:::::::::
:::::::::
Brass
•3748/-3753 in.
4372/-4377 in. -3744/-3747 in. -4369/-4372 in.
in. Iz in.
-497/-498 in. ... .0015/-0045 in.
OIL PRESSURE RELEASE VALVE
Piston diameter ... Working clearance Pressure release operates Indicator spring length (Free) Release spring length (Free)
:::::
•5605/-5610 in.
·001/.002 in. 60 16./sq. in. (4.22 kg./sq. cm.)
in. in.
...
OIL PRESSURE
...
...
...
...
...
Normal running Idling ...
.. ...
... ...
... ...
... ...
... ...
... ...
65/80 lb. sq. in. 20/25 16./sq. in.
ENGINE
BASIC DETAILS
Bore and stroke ... ... Bore and stroke ... ... Cubic capacity ... Compression ratio Capacity of combustion chamber Power output (B.H.P. @ R.P.M.)
71 x 82 mm. 2.795 X 3.228 in. 649 c.c. (40 cu. in.) 7.5:1 50 C.C. (3.05 cu. in.) 37 @ 6,700
CRANKSHAFT
Type
...
...
...
Main bearing, size and type Main bearing journal dia. Main bearing housing dia. Big end journal dia.
Min. regrind dia. Crankshaft end float
... Forged two-throw crank with
bolt-on flywheel 22x1 x3 in. Ball Journal 1.72471.1250 in.
2.8095/2.8110 in. ... 1-6235/1.6240 in.
1.6035/1.6040 in. 003/.017 in.
CONNECTING RODS
Length (centres) Big end bearingstype ...
Bearing side clearance Bearing diametral clearance
::::
6.499/6.501 in. Steel backed white metal
·012/.016 in. .0005/-0020 in.
GUDGEON PIN
Material Fit in small end bush Diameter ... " Length ... ..
:::
High tensile steel
0005/-0012 in. clearance 6882/-6885 in. 2-151/2.156 in.
SMALL END BUSH
"
Material .. Outer dia. Length ... Finished bore dia.
Phosphor bronze .8140/-8145 in. 1-030/1.031 in. 6890/-6894 in.
...
GD2
Page 7

GENERAL DATA
CAPACITIES
:
Fuel tank ... .... Oil tank ... . . Gearbox ... Primary chaincase Telescopic fork legs
Frame No. DŪ.101 to DU.5824 Frame No. DU.5825 onwards
::::
4 gall. (4.8 U.S. galls., 18 litres) 5 pint (6 U.S. pints, 3 litres) 7 pint (500 c.c.)
pint (350 C.C.)
:
::
pint (175 c.c.) * pint (190 C.C.)
BASIC DIMENSIONS
::
Wheel base Overall length ... Overall width ... Overall height Ground clearance
:::::
55 in. (140 cm.) 84 in. (214 cm.) 274 in. (70 cm.) 38 in. (97 cm.) 5 in. (13 cm.)
WEIGHTS
Unladen weight. Engine unit (dry)
.
... ...
... ...
... ...
... ...
... ..
...
... ...
... ...
... ...
... 370 lb. (168 kgm.) ... 130 lb. (59 kgm.)
TORQUE WRENCH SETTINGS (DRY)
::::::::
Flywheel bolts ... Conn, rod bolts ... ... Crankcase junction bolts Crankcase junction studs Cylinder block nuts Cylinder head bolts (i in. dia.) Cylinder head bolt ( in. dia.) Rocker box nuts ... ... Rocker box bolts ... ... Rocker spindle domed nuts Oil pump nuts ... Kickstart ratchet pinion nut Clutch centre nut Rotor fixing nut .. Stator fixing nuts ... .. Primary cover domed nuts Headlamp pivot bolts ... Headrace sleeve nut pinch bolt Stanchion pinch bolts Front wheel spindle cap bolts Brake cam spindle nuts Zener diode fixing nut ... Fork cap nut
:::::::::::::::::::::::
::::::::::::::::::::::
:::::::::::::::::::::::
:::::::::::::::::::::::
33 lb. ft. (4.6 kg.m.)
Ib. ft. 3.9 kg.m.) 13 lb. ft. (1.8 kg.m.) 20 lb. ft. (2.8 kg.m.) 35 lb. ft. (4.8 kg.m.) 25 lb. ft. (3.5 kg.m.) 15 lb. ft. (2.1 kg.m.) 5 lb. ft. (-7 kg.m.) 5 lb. ft. (-7 kg.m.) 22 lb. ft. (3.0 kg.m.) 5 lb. ft. (-7 kg.m.) 45 lb. ft. (6.3 kg.m.) 50 lb. ft. 7 kg.m.) 30 lb. ft. (4.1 kg.m.) 20 lb, ft. (2.8 kg.m.)
Ib. ft. (1.4 kg.m.)
Ib. ft. (1.4 kg.m.) 15 lb. ft. (2.1 kg.m.) 25 lb. ft. (3.5 kg.m.) 25 lb. ft. (3.5 kg.m.) 20 lb. ft. (2.8 kg.m.) 1.5 lb. ft. (-21 kg.m.) 80 lb. ft. (11'1 kg.m.)
GD9
Page 8

GENERAL DATA
newry
.
mmmm..
SR
GENERAL DATA
MODEL TR6_TROPHY
FOR DATA NOT GIVEN HERE REFER TO GENERAL DATA-MODEL 6T
ENGINE
BASIC DETAILS
Bore and stroke ... .. Bore and stroke ... ... Cubic capacity ... Compression ratio Capacity of combustion chamber Power output (B.H.P. @ R.P.M.)
::::
::::
::::::
::::
::::::
71 X 82 mm. 2.795 X 3.228 in. 649 C.C. (40 cu. in.) 8.5:1
43-3 C.C. (2-64 cu. in.) ... 40 @ 6,500
PISTONS
Material Clearance: Top of skirt ...
Bottom of skirt Gudgeon pin hole diameter
... ...
Aluminium Alloy--Die Casting
0088/-0098 in. 0033/.0043 in. 6882/6886 in.
VALVE SPRINGS (White Spot)
Outer | Inner ... 2zin. La in.
..
..
..
..
..
...
... ...
... 638
Free length ... Total No. of coils... Tot fitted load:
Valve open s Valve closed ...
130 lbs. 77 lbs.
...
...
VALVE TIMING
Set all tappet clearances @ .020 in. (-50 mm.) for checking
rinlet opens 34�� before top centre J Inlet closes 55�� after bottom centre 7 Exhaust opens 48�� before bottom centre (Exhaust closes 27�� after top centre
ROCKERS
Material Bore diameter Rocker spindle diameter Tappet clearance (Cold): Inlet ...
Exhaust
:::::
:::::
... ...
High tensile steel forging
•5002/-5012 in. 4990/-4995 in,
·002 in. (-05 mm.) .004 in. (-05 mm.)
...
...
CAMSHAFTS
Journal diameter: Left ...
Right Diametral clearance: Left
Right End float
ro Cam lift: Inlet ...
Exhaust Base circle diameter
::::::::
-8100/-8105 in. .8730/-8735 in.
·0010/.0025 in.
·0005/-0020 in. 013/020 in. -314 in. 296 in. .812 in.
IGNITION TIMING
Crankshaft position (B.T.D.C.)
Eng. No. DU.101 Eng. No. DU.5825
to DU.5824
onwards
110
15��
390
390
Static timing
Fully advanced Piston position (B.T.D.C.)
Static timing
Fully advanced Advance range:
Contact breaker Crankshaft .
in. (9 mm.) in. (11.5 mm.)
Torin. (1.6 mm.)
in. (11.5 mm.)
14�� 28��
12�� 24
GD10
Page 9

GENERAL DATA
WHEELS, BRAKES AND TYRES
WHEELS
Rim size: Front ... Spoke details: Front
WM2-18 ... 40 off 8/10 SWG butted 576 in.
U.H. straight WM3 - 18 (Q.D.) WM2-18 (Std.)
Rim size: Rear
..
.
REAR WHEEL DRIVE
Sep soprlock e
t
See ��GEARBOX�� 46
le
i
Gearbox sprocket teeth Rear wheel sprocket teeth Chain details:
No. of links: Solo ...
Sidecar Pitch Width
;
... ... ... ...
103 102 i in.
in.
;:
TYRES
Size: Front
Rear ... Tyre pressures: Front ...
Rear
...
..:
3.25 x 18 in. 3.50 x 18 in. 201b./sq. in. (1.4 kg. /sq. cm.) 20 lb./sq. in. (14 kg./sq. cm.)
MARE
FRONT FORKS, NB:AFTER DU.5825, AS 6T Spring details: Solo
Eng. No. DU.101 to D.U.5824 Free length ...
17*in. No. of working coils Spring rate ...
32 lb./in. Colour code ... ...
Black/green
52
185 in.
Spring details: Sidecar
Free length ... No. of working coils Spring rate .... Colour code ... ...
58
37 1b./in. Red white
9
Shine
AH
ELECTRICAL EQUIPMENT
::
: : : :
: : :
::
6V-MLZ9E or ML9E Lucas 2DS506 Lucas RM.19 8H (6v.)
No.
Type
Battery type Rectifier type Alternator type ... Horn Bulbs:
Headlight ... Parking light Stop and tail light ... Speedometer light ...
www
:
::
; ; iiii
...
:
::
::
Coil type - Contact breaker type Fuse rating Sparking plugs:
Type ... Plug gap settings Thread size ...
Lucas 312 30/24 watts pre focus Lucas 988
4 watts---MCC Lucas 384 6/18 watts offset pin Lucas 990 or
2 watts special Smiths P.52305 |
... Lucas MA6 (6v.)
Lucas 4CA 25 amp.
Champion N4 ... 020 in. (-50 mm.) ... 14 mm. Xin. Reach
...
: ;
::
:::
MAR
BASIC DIMENSIONS
Wheelbase ... Overall length Overall width Overall height Ground clearance
55 in. (140 cm.) 84 in. (214 cm.) 27 in. (68.5 cm.) 38 in. (97 cm.) 5 in. (13 cm.)
WEIGHTS
Unladen weight ... Engine unit (dry)
363 Ib. (165 kg.m.) 130 lb. (59 kg.m.)
....
...
GD15
Page 10

GD
GENERAL DATA
GENERAL DATA ALTERNATIVE FITMENTS FOR SPORTS MODELS TR6 AND T120
ENGINE
PISTONS (11 :1 C.R.)
Material ...
Aluminium Alloy-Die Casting Clearance: Top of skirt ...
.0093/-0103 in. Bottom of skirt
0073/-0083 in. Gudgeon pin hole diameter
.6882/-6886 in.
TAPPETS ("R" TYPE)
Material
High tensile steel-stellite tip Tip radius ... ... ...
... 1.125 in. Tappet diameter ...
... •3105/-3115 in. Clearance in guide block
... .005/.0015 in. N.B. From engine number DU.24975 T120 models have the above tappets fitted as standard equipment.
IGNITION TIMING A.C. Magneto (E.T.) Ignition equipment
Crankshaft position (B.T.D.C.)
Static timing
Fully advanced Piston position (B.T.D.C.)
Static timing
Fully advanced Advance range:
Contact breaker ... Crankshaft
in. (6.3 mm. I in. (11.5 mm.)
CONTACT BREAKER A.C. Magneto (E.T.) Ignition equipment
Gap setting Advance range ... Fully advanced at:... .
·014016 in. (-35--40 mm.) 50 2,000 R.P.M.
...
CYLINDER HEAD (T120)
Material ... Inlet port size ... Exhaust port size ... Valve seatings:
Type ... Material
D.T.D. 424 Aluminium Alloy 1. in. diameter, tapering to 1fin. 1 in, diameter
Cast-in Cast iron
389/95 330
...
25
FUEL SYSTEM
Carburetter (T120)
Amal type - Main jet size ... Pilot jet size ... Needle jet size Needle type ... Needle position Throttle valve:
Type ...
Return spring free length Carburetter nominal bore size Air cleaner type ... ...
::::::
::::::
::::::
•106
::::
::
::::
::::
389/4 24 in.
13in. diameter ... Paper element
GEARBOX
RATIOS
Internal ratios (Close): 4th (Top)
3rd
,
2nd
...
::::
::::
1.00:1 1.09 : 1 1.30 : 1 1.695:1
::::
1st (Bottom) Internal ratios (Wide): 4th (Top)
3rd 2nd ...
1st (Bottom) ...
Gearbox sprocket...
::::
::::
::::
1.00:1 1.425:1 2.21 : 1 2.915:1
:
...
...
15, 16, 17, 18, 19 or 20 teeth
:
GD16
Page 11

GENERAL DATA
FRONT FORKS
TELESCOPIC FORK
Oil restrictor assembly:
Rod diameter Cup outer diameter Body bore diameter
...
...
...
...
...
...
...
3115/.3125 in. -58457-5855 in.
590/-592 in.
...
ELECTRICAL SYSTEM ELECTRICAL EQUIPMENT A.C. Magneto (E.T.) Ignition equipment
: : :
RM19E.T. Clear hooter, A.C. 585, S.G. 3 E.T. 54441582 Lucas 4CA
������.
Alternator type ... Horn, type Coil type .. Condensers (Capacitors) Contact breaker type ... Lighting system:
Bulbs (6v.):
Headlight
Stop and tail light Sparking plugs:
Type ... Plug gap setting Thread size ...
: :
No.
Lucas 166 ......24/24 watts-Pre Focus ... Lucas 384 .......6/18 watts-Offset pin
...
: : :
... Champion N58R
·020 in. (-5 mm.) ... 14 mm.x in. reach
GENERAL
CAPACITIES
Fuel tank
...
...
...
...
...
...
...
...
...
...
... 34 gall. (4 U.S. galls., 14.75 litres)
TACHOMETER
Type of tachometer gearbox
Drive ratio Cable length . Tachometer head ...
90�� drive from L/H end of exhaust
camshaft 4:1 28 in. RSM 3003/01
GD17
Page 12

GD
GENERAL DATA
MODIFICATIONS FOR 1965 MODELS (ENGINE NO. DU.13375
ONWARDS) LUBRICATION SYSTEM
OIL PRESSURE RELEASE VALVE
Spring length Load at 1 in. Rate
...
. ...
*** ...
..
...
...
...
...
... 147 ins. ... 12/12 lbs. ... 37'16.7ins.
...
FRONT FORKS Engine Numbers and Model
DU101-DU5824
DU13375
6T TR6 & T120
6T
TR6
6T
DU5825-DU13374
6T TR6 & T120
H1695 H1649
m
STANCHIONS Part Number ...
...
1 H1123
H1299
H1595
H1890
H1889
Length
202 in.
22 in.
22 in.
22 in.
202 in.
Yes
22 in. No
22 in. No
No
Yes
No
Yes
One jo in. Filler Hole Damping Holes Level from Bottom-5 in.
2 No. 42 holes
2 No. 42
holes
2 No. 42
holes
2-7 in.
4in.
41in.
4
in.
2-
in.
-44 in. ---376 in. _-24 in. - 11 in.
2- in. 2- in. 2- in. 2 No. 42
2- in. 2 No. 42
2-pin. 2- in. 2 No. 42
2- in. 2-76 in. 2 No. 42
2 No. 42
2 No. 42
2 No. 42
To use 6T type stanchion where appropriate for TR6 or T120, solder up the filler hole. Note:-No. 42 hole is 0-0935 in.
DAMPER SLEEVE
Length
...
...
.. | 46 in. | 34 in. | 4* in. |
34 in.
|
34 in.
|
24in.
|
24 in.
Internal Diameter
...
...
...
...
...
...
...
...
...
...
...
1•387/1.393 ins.
SPRINGS
...
...
...
-
Free length No, working coils Spring rate Gauge ... Colour code
124
Solo 9 in. 265 lb. in. 6 SWG Yellow/blue
Sidecar 92 in. 154 32. lb. in. 5 SWG Yellow/green
WHEELS, BRAKES AND TYRES Q.D. REAR WHEEL (All Models)
Bearing Type
... Bearing sleeve: journal dia.
... Brake drum bearing ... Bearing sleeve: journal dia. ... Bearing housing: internal dia. ...
x11xit in. Ball journal 7500/-7495 in. 2x2* in. Ball journal
8745/-8740 in. 1.9990/1.9980 in.
GD18
Page 13

GENERAL DATA
GD
MODIFICATIONS FOR 1966 MODELS (ENGINE NO. DU.24875
ONWARDS)
ENGINE
Main bearing (drive side) size and type
Crankshaft
2+2 x 1ģxi in. Single lipped roller bearing Located by the timing side main bearing
...
...
...
PISTONS (T120)
Material
Clearance: Top of skirt ...
Bottom of skirt Gudgeon pin hole diameter Compression ratio
: : : : :
Aluminium Alloy--Die Casting
0098/-0108 in. .0043/-0053 in. .6882/-6886 in. 9.0:1
EXHAUST TAPPETS (PRESSURE LUBRICATED)
Material ...
:
High tensile steel body-Stellite
;
tip .750 in.
Tip radius: (6T, TR6)
(T120) Tappet diameter .. Clearance in guide block
::::
: : :
1.125 in.
•3105/3115 in. ... .0005/-0015 in.
INLET TAPPETS
Material
Tip radius: (6T, TR6)
(1120) Tappet diameter ... Clearance in guide block...
... ... ...
High tensile steel body-Stellite
tip .750 in. 1.125 in. -3105/-3115 in. .0005/-0015 in.
TAPPET GUIDE BLOCK
...
sre
Diameter of bores Outside diameter Interference fit in cylinder block
-3120/-3125 in.
9995/1.000 in. -0005/-0015 in.
EXHAUST CAMSHAFT (T120) Journal diameter: Left ...
Right ... Diametral clearance: Left
Right End float ... ... " Cam lift .. Base circle diameter
:::::::
:::::::
.8110/-8105 in. .8730/-8735 in.
·0010/.0025 in. -0005/-0020 in. .013/.020 in. .314 in. -812 in.
VALVE SPRINGS (RED SPOT)
inner
Free length
- -- -- -- -- -- 13 in.
Outer
1 in. ... 54
11 in. 77
14 in.
****
***
"
...
...
Total number of coils Total fitted load:
Valve open ... Valve closed ...
...
...
142 lbs. 74 lbs.
VALVES
Seat angle (included) ... ... Stem diameter: Inlet ... ...
Exhaust ... Head diameter (T120): Inlet ...
Exhaust Exhaust valve material ...
::;;::
90�� .3095/-3100 in.
•3090/-3095 in. 1.434/1-440 in. 1.592/1.596 in. 21/4NS
...
...
GD19
Page 14

GD
GENERAL DATA
Wwwwww
ELECTRICAL EQUIPMENT
Battery type (12v.) Rectifier type Alternator type in .. Horn type (12v.) ... .
PUZ SA 2DS 506 RM.19
8H
380
Bulbs:
Headlight (L/H dip) Parking light ... Stop and tail light ... Speedometer light ... Ignition warning light
High beam indicator light Zener diode type Coil type (2 off) ... Contact breakertype .. Fuse rating
No.
Type 414 50/40 watts----pre-focus 989 6 watts-MCC
6/21 watts-offset pin 987 3 watts..MES 281 2 watts (BA 75)
281 | 2 watts (BA 7S) ZD 715 MA12 (12v.) 2off Lucas 4CA (12) 35 amp.
:
:
FUEL SYSTEM (T120R and T120 TT)
Carburetter:
Amal type Main jet size Pilot jet size Needle jet size Needle type
Throttle valve: Type Return spring length Carburetter nominal bore size ...
:::::
389/95 330 25
106
:::::
: : :
:
38974
: : :
:
:::
24 in.
M
CAPACITIES
Fuel tank (6T, TR6, T120) Fuel tank (TR6, Balt 6T) ... Fuel tank (TR6C, T120Ć, T120R. T120TT) Oil tank Gearbox Primary chaincase Telescopic fork legs
::::::
:::::: :
:::::::
:::::::
4 gall. (4.8 U.S. galls; 18 litres) 3 gall. (4 U.S. galls; 16 litres) 24 gall. (2.8 U.S. galls; 11 litres) 6 pints (7.2 U.S. pints; 3.35 litres) 7 pint (500 c.c.)
pint (350 c.c.) į pint (190 c.c.)
WHEELS, BRAKES AND TYRES
REAR WHEEL (Q.D.)
Speedometer drive gearbox ratio Speedometer cable length
2:1 65 ins.
...
REAR WHEEL (STANDARD)
Speedometer drive gearbox ratio Speedometer cable length ... Bolt size for detachable sprocket Number of bolts ...
2:1
38 s
65 ins.
in. dia. x 12 in. U.H.X26 C.E.I.
m
Axa ca
FRONT BRAKE
Brake drum diameter Brake lining area ...
... ...
...
..*
... ...
... ...
... ...
... .do
... ...
8 in. 4.002 in. 28 sq. ins.
...
...
GD20
Page 15

SECTION AA
LUBRICATION SYSTEM
Modifications to the lubrication system incorporated on machines subsequent to ENGINE No. DU.24875
Section
ENGINE LUBRICATION SYSTEM ...
...
...
... AA1
AA2
EXHAUST TAPPET OIL FEED
AA1
Page 16

AA2
SCAVENGE FEED TO ROCKER GEAR
SS
**
NOSSSSS
Conto h
REAR CHAIN FEED ADJUSTER
OIL PUMP
OIL DRAIN THROUGH CYLINDER BLOCK AND PUSH ROD COVERS TO SUMP
00
FEED TO REAR CHAIN
o
.
PRESSURE FEED TO EXHAUST TAPPETS
LU
RC
RO
SCAVENGE PLUNGER
PISTON FED BY SPLASH
FEED
PLUNGER
OIL RETURN TO TANK
.
-OIL TANK
www.SOL
OIL TANK BREATHER
CRANKCASE BREATHER PIPE FROM INLET CAMSHAFT (ROTARY VALVE).
1.
OIL TANK
FILTER
Goooo
LUBRICATION SYSTEM
coco
od
332
M
PRESSURE RELEASE
VALVE
BOLT IN TIMING CASE COVER. REMOVE TO FIT OIL GAUGE WHEN TESTING OIL PRESSURE
SUMP FILTER
Fig. AA1. Engine lubrication diagram
Page 17

LUBRICATION SYSTEM
����
SECTION AAI ENGINE LUBRICATION SYSTEM
From engine number DU24875 the engine lubrication was modified to incorporate a positive feed to the exhaust tappets and rear chain.
SONGS
REAR CHAIN OIL FEED ADJUSTMENT SCREW
REAR CHAIN OIL FEED
All
The rear chain feed is taken from an oil junction block situated in the neck of the oil tank (see Fig. AA2). The rate of flow of oil to the chain can be controlled by a threaded tapered screw provided in the oil junction block. The screw should be turned clockwise to reduce the flow and anti- clockwise to increase it. As a separate oil feed is taken to the valve gear from the opposite side of the oil junction block the adjustment of the flow of oil to the rear chain in no way effects the valve gear oil supply.
WANA
DRAIN OIL AND REFILL. EVERY 1,500 MILES
321
Fig. AA2. Rear chain oil feed adjustment
EXHAUST TAPPET OIL FEED
A positive oil feed is provided for the exhaust tappets. The lubricant is ported through drillways from the timing cover, where a fine mesh oil filter is incorporated in conjuction with the timing cover plug, through a hollow dowel acting as a metering
jet (which has a captive metering pin), and on through the crankcase and cylinder block base flange to an annular groove machined in the tappet guide block. Two oil holes are provided in the groove to mate with the oil holes in the tappets which pro- vide a channel for the lubricant to the tappet and camshaft working faces.
SSAGE
Now
ER
SU
EXHAUST
TAPPET OIL FEED DRILLWAY
-
SO
SSENAAR
SALAM
.
www
namas
SSS
SA SOM SSAN
SAW
more
ill
WWW
Serge
We www
OUR
EXHAUST TAPPET OIL FEED DRILLWAY
G
NA
W
WW
KSESORES
AEROSTARE Sand er SOS
PRISES
w
ww
www
.
S
.
326
Fig. AA3. Tappet oil feed
Fig. AA4. Tappet oil feed arrangement
AA3
Page 18

Page 19

SECTION A
LUBRICATION SYSTEM
*
Section
ROUTINE MAINTENANCE
A1
:
TABLE OF RECOMMENDED LUBRICANTS
:
ENGINE LUBRICATION SYSTEM ...
:
CHANGING THE ENGINE OIL AND CLEANING THE OIL FILTERS
:
OIL PRESSURE
a.
...
...
...
...
.
..
...
..
A5
STRIPPING AND REASSEMBLING THE OIL PRESSURE RELEASE VALVE
STRIPPING AND REASSEMBLING THE OIL PUMP
REMOVING AND REPLACING THE OIL PIPE JUNCTION BLOCK
:
REMOVING AND REPLACING THE ROCKER OIL FEED PIPE
A9
CONTACT BREAKER LUBRICATION
...
...
:
A10
:
GEARBOX LUBRICATION ...
...
...
...
:
A11
:
PRIMARY CHAINCASE LUBRICATION ...
...
:
A12
:
REAR CHAIN LUBRICATION AND MAINTENANCE ...
:
A13
:
GREASING THE STEERING HEAD BALL RACES
:
A14
:
WHEEL BEARING LUBRICATION
A15
TELESCOPIC FORK LUBRICATION
...
:
A16
LUBRICATION NIPPLES
...
...
...
:
A17
:
LUBRICATING THE CONTROL CABLES...
A18
SPEEDOMETER CABLE LUBRICATION ...
A19
:
REAR BRAKE PEDAL SPINDLE LUBRICATION...
A20
:
FOR ADDITIONAL INFORMATION SEE SECTION AA
A1
Page 20

LUBRICATION SYSTEM
SECTION AT ROUTINE MAINTENANCE
Section
nl
...
A4
Every 250 miles (400 Kms.)
Check level in oil tank Check level in primary chaincase ... Lubricate rear chain
A12
A13
Every 1,000 miles (1,600 Kms.)
Change oil in primary chaincase Lubricate control cables ... .. Grease swinging fork pivot... in Remove rear chain for cleaning and greasing
A12 A18
A17
A13
Every 1,500 miles (2,400 Kms.)
Change engine oil ... ...
...
A4
A11
Every 3,000 miles (4,800 Kms.)
Check gearbox oil level Check front forks for external oil leakage Grease brake pedal spindle... ... ...
A16
... A20
Every 6,000 miles (9,600 Kms.)
Change oil in gearbox Change oil in front forks
A11
A16
Every 12,000 miles (19,200 Kms.)
Grease wheel bearings Grease steering head bearings
A15
A14
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