Part Orientations,
by Part Number

2 Dec 2018


14-
14-0234
Bolt
UNF 3/8-24TPI X 1 3/4 U.H. (Tool-9/16)
Ref# 24  Fig. 14 Page 39 #7 (Qty:2)
 Engine mount plates, bottom, both sides
 Orient: Head in, nut out


14-0235
Bolt
UNF 3/8-24TPI X 1 5/16 U.H. (Tool-9/16)
Ref# 21  Fig. 13 Page 37 #7 (Qty:4)
 Shock mounts, top/bottom
 Orient: Bolt heads in, nuts out


14-0302
Nut, plain
UNF 5/16-24TPI (Tool-1/2)
Ref# 12  Fig. 14 Page 39 #7 (Qty:4)
 Engine mount plates, bolt 39/8, top/front, middle both sides
 Orient: Nuts out


14-0303
Nut, plain
UNF 3/8-24TPI (Tool-9/16)
Ref# 25  Fig. 13 Page 37 #7 (Qty:4)
 Rear shock absorber mount, top/bottom
 Orient: Nuts out or it scrapes brake drum cover


14-0402  (1 Spares)
Nut, locking
UNF 5/16-24TPI thin locking
Ref# 24  Fig. 26 Page 61 #7 (Qty:2)
 Front fender, center and front stays to bracket (R#5)
 Orient: Nuts face out


14-0403
Nut, locking
UNF 3/8-24TPI thin locking (Tool-9/16)
Ref# 27  Fig. 14 Page 39 #7 (Qty:2)
 Engine mount plates, bolts 39/23, top/rear, both sides
 Orient: Head in, nut out


14-0703
Nut, locking
UNF 3/8-24TPI thin Philidas
Ref# 13  Fig. 12 Page 35 #7 (Qty:1)
 Side stand bolt F7021
 Orient: Nut faces out


14-6608
Screw, Posidrive
UNC 1/4-20TPI X 1" U.H. (Tool-Posidrive)
Ref# 34  Fig.  9 Page 29 #7 (Qty:1)
 Gearbox outer cover
 Orient: Rear-most screw



21-
21-0620 / S620
Bolt
BS 9/16-?20TPI/16TPI X 8 5/8 U.H. (Tool-7/8)
Ref# 8   Fig. 13 Page 37 #7 (Qty:1)
 Swinging fork
 Torque: 45 LBS
 Orient: Bolt head to T.S.


21-1873 / S1873
Screw
UNC 1/4-20TPI X 13/16 U.H.
Ref# 18  Fig.  2 Page 15 #7 (Qty:2)
 Crankcase halves
 Orient: Fastens DS/TS crankcases
Through hollow dowel 15/17


21-1878 / S1878
Screw, Posidrive
UNC 1/4-20TPI X 2 3/4 U.H. (Tool-Posidrive)
Ref# 32  Fig.  9 Page 29 #7 (Qty:2)
 Gearbox outer cover
 Orient: Top & bottom screws (match case locators)
 ¹ Fig 9 is wrong/confusing.



37-
37-1024 / W1024
Distance piece
Stepped
Ref# 22  Fig. 20 Page 51 #7 (Qty:1)
 Rear wheel
 Orient: Small end to hub


37-1237 / W1237  (1 Spares)
Dust cover
Cupped(.215"Deep); Inside lip .235"High; .79-.82"ID
Ref# 11  Fig. 19 Page 49 #7 (Qty:1)
 Bearing, front wheel
 Orient: Cup to bearing


37-1281 / W1281
Spindle
Ref# 14  Fig. 20 Page 51 #7 (Qty:1)
 Rear wheel
 Orient: Shoulder to T.S.


37-1406 / W1406
Brake shoe, leading (with lining)
Ref# 25  Fig. 20 Page 51 #7 (Qty:1)
 Rear brake
 Orient: See p50 #7
For correct lead/trail orientation


37-1407 / W1407
Brake shoe, trailing (with lining)
Ref# 26  Fig. 20 Page 51 #7 (Qty:1)
 Rear brake
 Orient: See page 50 #7 for correct leading/trailing orientation.


37-1481 / W1481
Grease retainer
Cupped, tapered to center; .205"Deep; .885"ID
Ref# 14  Fig. 19 Page 49 #7 (Qty:1)
 Front wheel bearing, D.S.
 Orient: Cup to bearing


37-1654 / W1654  (1 Spares)
Grease retainer
Cupped(.283"Deep); Inside lip.08"High; 1.025ID
Ref# 16  Fig. 20 Page 51 #7 (Qty:1)
 Rear wheel T.S.
 Orient: Cup to bearing



57-
57-0397 / T397
Quadrant
Ref# 17  Fig.  7 Page 25 #7 (Qty:1)
 Gear selectors
 Orient: Wider pivot boss goes towards gear side


57-0406 / T406  (2 Spares)
Plunger, gearchange quadrant
OD 0.4315-.4320" Bore clearance 0.0005-.0015"
Ref# 11  Fig.  9 Page 29 #7 (Qty:2)
 Gearchange quadrant
 Orient: Single bevel to guide plate
 ¹ Height: Orig.936-.937"; MAPCycle.901-.902"; New unused.860"


57-0407 / T407  (1 Spares)
Guide plate
Ref# 13  Fig.  9 Page 29 #7 (Qty:1)
 Gearchange plunger assembly
 Orient: Beveled edges face away from center
 ¹ Original part


57-0946 / T946
Oil seal
Ref# 17  Fig.  8 Page 27 #7 (Qty:1)
 High gear bearing
 Orient: Open lip/springs face gearbox


57-1222 / T1222
Pin; nut; washer
Comes with nut, washer
Ref# 45  Fig.  9 Page 29 #7 (Qty:1)
 Kickstarter lever
 Orient: Nut must face forward for clearance with footrest
 ¹ One Ref# for all


57-1607 / T1607
Washer, thrust
New: .0905-.0910; Used 2018: .0938(outer)/.0916(inner spun)
Ref# 12  Fig.  7 Page 25 #7 (Qty:2)
 Gearbox inner cover, layshaft
 Orient: Grooved sides face AWAY from bearings


57-1735 / T1735
Washer, thrust
Thickness .052/.054 in. Bronze or Copper & Steel
Ref# 3   Fig. 10 Page 31 #7 (Qty:1)
 Clutch center
 Orient: 57-3931 bronze side to clutch basket / 57-1735 bevel to hub
 ¹ Use washer 57-1735 w hub 57-1734; Use 57-3931 w hub 57-3929


57-2538 / T2538
Shock absorber spider
Ref# 9   Fig. 10 Page 31 #7 (Qty:1)
 Clutch center
 Orient: Wider shoulder engages inner clutch center plate



60-
60-0477 / D477
Chain, primary
(3/8 in. duplex) (Tool-D496)
Ref# 15  Fig. 11 Page 33 #7 (Qty:1)
 Primary chaincase
 Orient: Shop manual: 3/8" (1/2" elsewhere) free tightest point


60-0530 / D530 TSUBAKI 530QR
Chain, rear
(5/8 x 3/8 in. x 104 links)*
Ref# 5   Fig. 11 Page 33 #7 (Qty:1)
 Rear wheel
 Orient: Slack: 3/4" on tires, tightest; or 1 3/4" on stand, slackest
 ¹ '15@65K(TSU)'14@60K(TSU)'13@53K(REN)


60-0771 / D771 AMAL L930/10 (1 Spares)
Carburetter, L.H.
Ref# 1   Fig. 31 Page 71 #7 (Qty:1)
 Carburetter
 Orient: Gasline fitting on Banjo bolt: [rear][<][front]
 (Model: T120R)


60-0772 / D772 AMAL L930/9 (1 Spares)
Carburetter, R.H.
Ref# 1   Fig. 31 Page 71 #7 (Qty:1)
 Carburetter
 Orient: Gasline fitting on Banjo bolt: [rear][<][front]
 (Model: T120R)



70-
70-3300 / E3300
Washer, clamping (thrust)
Ref# 40  Fig.  1 Page 13 #7 (Qty:1)
 Crankshaft, T.S.
 Orient: Chamfer faces main bearing (H Hancox)


70-3876 / E3876
Oil seal
2 1/8 x 1 27/64
Ref# 19  Fig.  1 Page 13 #7 (Qty:1)
 Crankshaft, D.S.
 Orient: Open lip/springs face sprocket (Fig. B39 WSManual)


70-4144 / E4144
Grommet, rubber
Ref# 20  Fig. 11 Page 33 #7 (Qty:1)
 Primary chaincase, alternator leads
 Orient: Inside primary chaincase


70-4573 / E4573
Distance piece, sprocket to rotor
Ref# 21  Fig.  1 Page 13 #7 (Qty:1)
 Crankshaft, D.S.
 Orient: Chamfer towards sprocket


70-5446 / E5446
Sprocket, engine
29T Duplex (Tool-Z151 WassellTL107)
Ref# 20  Fig.  1 Page 13 #7 (Qty:1)
 Crankshaft, D.S.
 Orient: Side with number (W-08 70-4572) goes in


70-6857 / E6857  (2 Spares)
Bracket
Ref# 11  Fig. 15 Page 41 #7 (Qty:2)
 Exhaust pipe
 Orient: Goes in front of tab on exhaust pipe


70-7565 / E7565
Oil seal
1.500"x 1.060"x 0.250"
Ref# 8   Fig. 11 Page 33 #7 (Qty:1)
 Inner cover plate
 Orient: Open lip/springs to primary case and flush on that side


70-8751 / E8751
Hollow dowel
Counter-bored with metering pin
Ref# 22  Fig.  2 Page 15 #7 (Qty:2)
 Tappet oil feed, crankcase T.S. forward
 Orient: Larger bore faces out
 ¹ #7 "... on the timing cover face", it's on the crankcase


70-8801 / E8801  (1 Spares)
Tappet, exhaust
Ref# 35  Fig.  3 Page 17 #7 (Qty:2)
 Tappet guide block
 Orient: Machined cutaways must face OUT.



71-
71-1345 / E1-1345
Grommet, rubber
Ref# 20  Fig. 11 Page 33 #7 (Qty:1)
 Primary chaincase, alternator leads
 Orient: Outside primary chaincase
 ¹ Not shown/listed in #7



82-
82-3808 / F3808
C-clamp
Ref# 35  Fig. 13 Page 37 #7 (Qty:1)
 Chainguard to torque stay
 Orient: C-clamp goes on top of chain guard bracket


82-6915 / F6915
Bridge
Ref# 7   Fig. 26 Page 61 #7 (Qty:1)
 Rear fender beneath seat
 Orient: Bridge fits inside rear frame loop.


82-8133 / F8133
Gas pipe
Ref# 28  Fig. 31 Page 71 #7 (Qty:1)
 Carburetter
 Orient: Accute angle of pipes goes forward
 (Model: T120R)



97-
97-1500 / H1500
Oil seal
Ref# 25  Fig. 17 Page 45 #7 (Qty:2)
 Stanchion tube
 Orient: Open lip/springs go down (to threaded end of seal holder)


97-1685 / H1685
Bracket
Ref# 5   Fig. 26 Page 61 #7 (Qty:2)
 Front fender stay to fork leg
 Orient: Brackets face forward, angle projects up. Stay go outside.


97-1896 / H1896  (2 Spares)
Sleeve, damping
Ref# 29  Fig. 17 Page 45 #7 (Qty:2)
 Stanchion tube
 Orient: Built-up ends of PVC damping sleeves go DOWN.


97-3635 / H3635
Gaiter, front forks
Ref# 23  Fig. 17 Page 45 #7 (Qty:2)
 Stanchion tube
 Orient: End with pin hole goes DOWN.


97-3663 / H3663
Stay, front
Ref# 2   Fig. 26 Page 61 #7 (Qty:1)
 Front fender
 Orient: Inside/Out: bolt, top stay, front stay, bracket, flat, nut
 (Model: T120R-TR6R)


97-3664 / H3664
Stay, center
Ref# 3   Fig. 26 Page 61 #7 (Qty:1)
 Front fender
 Orient: Inside/Out: bolt, top stay, front stay, bracket, flat, nut
 (Model: T120R-TR6R)



99-
99-0338 AMAL 210/008
Screw, twistgrip rotor stop
Ref# 35  Fig. 28 Page 65 #7 (Qty:1)
 Twistgrip
 Orient: Rotor stop screw on top, friction screw on the bottom
 (Model: T120R)


99-0515 AMAL 622/076
Screw, air adjustment
Ref# 9   Fig. 31 Page 71 #7 (Qty:2)
 Carburetter
 Orient: Out 2 1/4 - 2 1/2 turns. In is richer.
 (Model: T120R)
 ¹ Approx 2 1/2 turns out


99-0517 AMAL 622/078
Bolt, banjo
Ref# 23  Fig. 31 Page 71 #7 (Qty:2)
 Carburetter
 Orient: Acute angle > front of bike
 (Model: T120R)


99-0542
Bulb (380)
Ref# 27  Fig. 36 Page 79 #7 (Qty:1)
 Stoplight bulbholder
 Orient: 6 1/2W. offset pin
 (Model: T120R-TR6R)


99-0772 LUCAS 54419827
Contact set
Gap .014-.016 IN. Check at 1000 MI.
Ref# 21  Fig.  6 Page 23 #7 (Qty:2)
 Contact breaker plate
 Orient:
 ¹ Blk/Yel (Rear) T.S.
Blk/Wht (forward) D.S.


99-1036 AMAL 622/124
Needle
Ref# 14  Fig. 31 Page 71 #7 (Qty:2)
 Carburetter
 Orient: Middle notch (up=richer)
 (Model: T120R)



EOF