GOLD STAR (SOOc.c.)€¦ · FOR GOLD STAR MODELS. /1 Cadmium /7 Black Enamel /2 Dull Chrome /19...
43
- GOLD STAR (SOOc.c.) "'f M ENGINE No. 080 34GS-3001. FRAME No. CBll-7001 taloaue No. 00-5076
Transcript of GOLD STAR (SOOc.c.)€¦ · FOR GOLD STAR MODELS. /1 Cadmium /7 Black Enamel /2 Dull Chrome /19...
-GOLD STAR (SOOc.c.)
"'f M ENGINE No. 080 34GS-3001. FRAME No. CBll-7001
taloaue No. 00-5076
-
CATALOGUE OF
ISSUED BY
B.S.A. Motor Cycles Ltd.
Te~one .
Tt:lt:troms
Service Department
Armoury Road
Birmingham 11 BIRMINGHAM, 021-nl- 2381
"SELMOTO BIRMINGHAM"
All Communications relatina to Spa.re P~m or Repairs to B.S.A. Motor Cycles should be addressed to the above.
B.S.A. MOTOR CYCLES LTD.
Registered Offices and Works: ARMOURY ROAD, BIRMINGHAM 11 r.,.,,,._, BIRMINGHAM, 021-7n-m,
Telerromt and Coblt:s ,.SELMOTO BIRMINGHAM'•
Co,rri1hc 1.$,A. Co. L«I.
•
Carburetters
Clutch and Front Chaincase
Colour Finishes ...
Electrical Equipment
GENERAL INDEX
Engine {Clubmans and Scrambles)
Frame and Fitting,;
Front Fork and Fittings
Front Hub and Wheel Fittings {7" brake)
Front Hub >nd Wheel Fitting,; (8" brake)
Front Hub and Wheel Fitting,; { 190 mm. brake
Gearbox ...
Handlebars, Handrail and Oil Tank {Central Fitting)
Mudguard, Chainguard, Oil Tank, Silencers and Rear Brake Control
page
49
22-24
3
47
14-19
24-,27
29-31
31-3-1
33 3s_
35
20-22
44-66
3!> 40
Petrol Tank, Handlebar, Toolbox, Dual Seat, Mudguards, Rear Brake Control 42 44
49
37
27-29
Pistons (Standard and Oversiie)
Rear Hub and Whecl Fittings ...
Rear Snspcnsion ...
Spares, Repairs and Guarantee
Stockists and Overseas Distributors
Tools and Sundries
2
Inside front cover
5-13
4;
--
SUFFIX NUMBERS TO BE USED TO IDENTIF Y VARYING FINISHES FOR GOLD STAR MODELS.
/1 Cadmium /7 Black Enamel
/2 Dull Chrome /19 Matt Silver and Chrome,
/3 Bright Chrome lined Red , /6 Rustproof Black /21 Polished. Aluminium
When ordering components with varying finishes-i.e., Petrol Tanks, Wheel Rims, Chainguards etc.,-Please state finish required by adding the appropriate suffix number to
the part number.
EXAMPLE Gold 1Star Petrol Tank
Matt Silver and Chrome, lined Red 42--8107/19
SPARKING PLUGs'
Champion Sparking Plugs l imited, Feltham, Middlesex.
ELECTRICAL EQUIPMENT
J. Lucas limited, Great King Street, Birmingham.
SPEEDOMETERS
Smith's Motor Accessories, CrickJewood Works, London.
CARBURETTERS
Messrs. Amalgamated Carburetters Ltd., Perry Barr, Birmingham.
3
•
Plate 1
Plate Rel. Number.
2 3 4 5 6 7 8 9
10 II 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 38 39 40 41 41 42 43 .. 45 46 47 48
:i 51 52 53 54 55 56 57 58 59 60 60 60 60 61 62 63 63 64 65
Model.
500 c.c. 500 c.c. soo c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. SOOc.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 e.c. 500 C,C, 500 c.e. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 5-00 c.c. 5-00 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 C,C, 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. (Clubmans)
500 c.c. 500 c.c.
500 c.c. (Clubmans) 500 c.c. {Scrambles)
500 c.e. 500 c.c. 500 c.c. 500 c.c. 500 c.c; 500 c.c. 500 c.c. 500 c.c. 500 e.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 C,C, 500 c.c.
500 c.c. {Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Scrambles)
500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.e. (Scrambles)
ENGINE Cold Star &00c.c. CJubmans and Scrambles
Pa.rt No.
65-1654 31- 8430 42-46 65--317 65-318 66-8338 65-1655
2-443 2-525
... 66-1436
... 65-403
Description.
\'alve rocker fulcrum pin Rocker oil feed pipe banjo washer (fibre) Rocker oil feed pipe com,Plcte .. . . . . Rocker oil feed pipe ban10 screw (anlet) Rocker oil feed pipe banjo terew (exhaust) Rocker oil feed pipe connection (nibbe.r) \'alve rocker fulcrum pin cord ring Exhaust lifter spindle nut Exhaust lifter spindle washer .. . Exhaust lifter lever ... .. . Exhaust lifter spi!\dle spring .. .
65-M 18 65-1117 65-1652 65-402 65- 1653 65- 1657 65- 1137 2-443 2-525
35-701
\'alve rocker fulcrum pm wa..sher ... \'a.Ive rocker fulcrum pin spn1J8 . .. Valve rocker (inlet) ...
Exhaust lifter spindle washer Valve rocker {exhaust) ...
65-1165 · 2-2894 65-387 65-401 27- 1163
2-143 65-1839 65-1590 65-1589
2-19 24-8784
... 65-2512 65-2493 65-646 65-2490 65-2459 ... 42- 2835 42-2850 15--39 65-1656 65-640 65-664 65-1591 65-1587 65-1588 65-1592 ... 66-102 65-1341 65-1776 65-647 65-2498 65-645
Valve rocker fulcrum thrust washer ... Exhaust lifter ... Exhaust lifter spindle nut Exhaust lifter washer , .. Exhaust lifter split pin Exhaust lifter spindle ... Exhaust biter bush washer (fibre ) Exhaust lifter bush Exhau.st lifter spindle washer (felt) Exhaust lifter cable holder . .• Exhaust lifter cable holder nut Rocker box Rocker box inspection cover joint washer Rocker box inspectmn cover Rocker box stud nut Rocker box stud washer (spri.ng) \'alve (exhaust) ... \' alve spnng insulating washer Valve guide (cxhau.&t) ... Valve spring collar (exhaust) . .. • . . \'alve spring split co~r (exhau.st) (h,3lves) Exhaust pipe Exhaust pipe Valve rocker fulerum pm wuher Yalve rocker fulcrum pin nut ... Cylinder head with fi.xed fitt:i.ngs Cylinder head with fixed fittings Cylinder head and rocker box stud (long) Roeker box joint washer (tower} Rocker box joint wa.shcr . .. • .. Cylinder head and rocker box stud (short) Sparking plug washer ... Sparking plug . .. .. . Sparking plug suppressor Yalve (inlet) Valve spring scat Valve guide (inlet)
... 65- 2495
... 65-2494 65-2490 65-1848 65-1456 65- 2266 65-2269
... Valve spring (inner)
... 65-2272 65-jl07 65-2544 65-2553 65-007 66-953 66 954 64-0054 15-1355 42-5(1 36-382
\'alve spring (outer) ... Valve spring collar (inlet) . .. Yalve sprmg spht cotter {inlet) (halves) Compretsion rang (bottom) ... . ..
... Compression ring {top) . .. Scraper rmg (top) .•• Scraper nng (bottom) ..• Piston complete (c.r. 8.75 to I) Piston complete (c.r. 8 to I) . . . Piston complete (c.r. 8 .5 to I) .. . Piston complete (c.r . 8.75 to I) Gudgeon pin
... Gudgeon pin retaining ring ... .. . Engine steady plate fixing bolt {bottom) Engine steady plate fixing bolt (top) ... Engine steady plate ... ... . .. Engine s-teady plate bolt washer (shakeproo() (top)
14
Numbe1 per set
2 2 I I I 2 2 I I I I 2 2 I I I 2 I I I I I I I I I I I I I 9 9 I I I I 2 I I 2 2 I I 3 I 2 6 I I I I 2 I 2 2 I 2 I I I I I I I I I 2 I 2 I 2
,,...._
• Plate 1 ENGINE
Cold Star S0Oc.c. Clubmans and Scrambles
~----~ ~--1(!
~-------111 L "
L ~ ---R
~ =~•: 11
~--:3
;g :8
'---i L--------:;;
2-------~ 'II s------$
lR C; -
15
~---:8 g •
Plate l -co11ti1111ed. ENGINE
Pl:lk Hd. :S11ml~r
Plate 2
Plate Ref. :,;'umber.
1 ~
• 5 6 7 8 9
10 II 12 13 14 15 16 17 18 19 20 21
Cole.I Star 500 c.c. Clubmans and Scramble.s
51MI .:.c. f&'nunhlci.l 50H ,,: , .. (&r;unhksJ !iOO ,:.,·. lS..:ra111l1ks) 5110 c.t:. (S..·r;unliks) $OU l' i;. (Sl'rltrlllJll•:..) S••u ,:.,:. {Scrnmblc:..J 5011 .:.c:. (Clul>n1.111S) SOU ..:.t·. (S..r.tlllhlc") ~10 c:.c. (Uulnn.111:..} 5011 cL (Str.unlik-s) 50U cc 1U11L>m,mi-J
500 \',\' 51Mt ,;.,;, 50111,'.I,'.
sou ..:.i.:. 500 l'.C. 500 ...... .sou,· I;
500..:.i.:. 5410 ,·.c. 500 c.c.:. 500 ('.4;.
500 c.c. 500 c.c 500 CC.
500ci:. 500 t. .C. 5()11 l-C, 500 c.c. sou c.:.c. 500 C.\".
500 c.c. sou c.c. I) J . 5<KI c.c. f5"fY<;. .. 500 c.c. 500 c.c. sou c.c. 5CKt c,:,.;,
:is:,~.! :.~)...~:J&'-1
2 ~2~i '.H 6040
IJCS("riptiun
Engine steady plate bolt washer (~hakcprool) (bottom) F.ngme stcadr plate dh;tance piece (top) ... lfog1ne M.e.ady pli.tte fixing bolt washer {top) {plain) Engine :neady pl.t.te focing bolt nut (bottom) Engine iteady plate fixing bolt nut (top) :?4 5160
~)-565 67 :u1 65-H17 6.i-:?542 65-1418
. . . r :irburetter stud .. .
65 2543 2-1~
:16-382 l<S-1$1$ llS lllStl 65-187.5 ~ 2~t-t7 ... 65 ~311 :."9 541 24--12:?7 29-215g 66-193fi 66-1937 65-1582 65-1650 65-1651 65-1652 65-165:1 ... 65-1~40 65 1822
l'nrburcttcr stud .. . Carburetter flange washer (paper) Curhurencr flange w0,sher (paper) Carl.mretter flange washer (Tufnol) <:arlmrctter flange washer (Tu(nol) ( arburetter stud 1wt ... ... Carburetter stud nut washer (ylinder head gasket •.. l'ush rod complete ... !' .. ·rappet guide (inlet and exhaust) Tappet {mlct and exhaust) (.'ylindcr U11rrel l!',tUd nut ( )"tinder l>a.rrel stud washer (:!-hakeproof) Cylinder barrel l!otud Pnsh rod tappet reces..,; cover screw PusJ1 rod tappet recess cover ... Push rod tappet recciss co"er jomt washer t)·linder l>al!oe \\ ,,sher l'.)•linder b.tse shim (.010'") C)'linder base shim (.020") <.:ylmder base shim (.O:t<Y) Cylmder bast- :.him (.06-I'") (yhnder holdmg down bolt ()'li1ider head bolt (:short) t)·linder head bolt w.1sher (lip.ing) ~ 290:l
6.5 IK25 fifi -'ff\'l fi5 4179 6; ·1836 65-683 65-68:!
... C)•linder barrel with liner l'.onnecting rod bush (small end) (rankpm 011 hole grub screw ... C..:cmneetmg rod with bus.hes Roller c~ge
2-1 375 Crankpin ... Crankpin roller
ENGINE Gold Star 500c.c. Clubmans and Scrambles
?.lodels. Part No. Description.
500 c.c, ... •66-1677 Crankcase with fixed fittings (drive side) 500<.<. 15-1355 Crankcase connecting bult 500 C,C, 65-1395 Bearing retaining plate .. . S(k) C,C, 65-1388 Roller beanng {dm•e side) 500 \:,C, 65-1396 Engme shaft do,tance collar (outer) 500 c.c. 65-2240 )Jain l>eanng s1mng ring 50() c.c. 65-2045 Dall bearing (dri"e :;ide) 500 c.c. 66-661 Engine shaft sh,m (dri\'e ~ide) ... 500 c.i: 65-1874 Engine shaft distance collnr 500 C-C. 65-1-138 lkaring rclllining plate lockwasht-r SOI) c.c. 31-426 licanng retammg plate bolt soo c.c. "5-lij70 Engine shaft {dri,·e iside) 500 C,C, "5 650 Flywheel \\ ith bhalt as~mliled (drive side) 500 c.c 66 6.10 C:unn~ting rod tlm1st washer ti\'Ct 500 C,C, (;&.o'.!9 Connecting rod tlm1st washer ... 500 c.c. fiS-652 F'lpvheel with s.hn(t assembled {gear side) 500 c.c. 65-1327 Crankp111 nut 500 c.c. 2 77 l'rankpin locking screw ..• 500 e.c. 24 12'l Roller bearing (gear side) 500 c.e. 65-69'l Engine ihaft driving pinion 500 c.c. 65-693 Engine shaft driving pinicm key
•Supphed only as 66--1681 crankcase drive side and gear side as-scml.lled, 16
,-Number
per set
I 2 2 I 2 2 2 I
' I I 2 2 I 2 2 2 2 2 2 4 I I I
. .. as reqd.
. .. as reqd. ••• OS ,,.qd. ,,. as reqd.
4 4 4 I I I --' ' I
24
Number per Mt.
I 3 I I I I I I I 4 4 I I 6 2 I 2 2 I I I
Plate 2-continued. ENGINE Gold Star 500 c.c. Clubmans and Scrambles
Plate Ref. Number Number Model Part No. Description per set
22 500 c.c. 65-2157 Timing cover screw 9 23 500 c.e. 65-2503 Timing cover 1 24 500 c.c. 66-1920 Timing cover washer 2 25 500 c.c. 66-1923 ... Oil reed washer (rubber) 2 26 500 c.c. 66-2007 ... Cam pinion spmdle bolt 2 28 500 c.c. 66-2008 Ttmrng gear plate complete ... 1 29 soo c.c. 65-2513 Engi.ne shaft (gear side) with extension I 30 500 c.c. 27-1239 Engine shaft rivet ... ... 14 31 500 c.c. 2-49 Crankcase connecting bolt nut ... 5 32 500 c.c. 65-2425 Cam pinion spindle (inlet) 1 33 500 c.c. 65-2426 Cam pinion spandle (eJthaust) 1 34 500 c.c. (Clubmans) 65-2446 ... Exhaust cam pink>n complete . .. . .. 1
500 c.~Scrambles) 65-2446 Inlet and exhaust cam pinion complete 2 35 c.c. 65-441 Cam pioion bush . .. 4 36 500 c.c. 1-5069 Timing gear plate bolt . . . .•. ... • .. I 37 500 c.c. 36-382 Timing gear plate bolt washer (&hakeproof)" ... 3 38 500 c.c. 36-382 Timing gear plate bolt washer (shakeproof) ... 3 39 500 c.c. 21-2902 Timing gear plate bolt (Whit.) ... . . . 3 40 500 c.c. 65-695 Engine shaft ttmi.ng pinion loc.kwashcr (shakeproof) I 41 500 c.c. 29-905 Engme ibaft timing pinion nut I
500 c.c. 65-2505 Engme shaft oil seat I 43 500 c.c. 65-1884 Breather pipe ... I 44 500 c.c. 15-203 Breather pipe banjo washer I 45 500 c.c. 1--4675 Oil vake spring ball I 46 500 c.c. 66-1684 Oil valve spring .. . ..• ... . . . ... I 47 soo c.c.. ... 66-1683 Oil valve spring retaining screw washer (fibre) I 48 500 c.c. 65-2188 Oil valve Sfring retaining screw I 49 500 c.c. 65-1887 Breather pipe banjo bolt ... I 50 500 c.c. 65-1882 Engine breather valve . .. I 51 500 c.c. 65-1883 Engine breather valve spring ..• I 52 5-00 c.c. (Clubmans) 65-2442 ... Inlet eam pinion complete •.. . .. I 53 500 c.c. 65-1174 Magdyno drive idler pinio11 complete ... I 54 soo c.c. 24-195 ... Magdyno driving pimon nut ... . .. 1 55 500 c.c. 2-2903 l\ta.gdyno dnving pinion nut washer (spring) I 56 500 c.c. 65-1879 Magdyno driving pinion 1 57 500 c.c. 65-2316 Ma,gdyoo driving pinion oil seal ... I 58 500 c.e. 65-2580 Oil pump driving stndle retaining pin I 59 500 c.c. 65-2618 Oil pump and cran ease joint washer I 60 500 c.c. 29-5•1 Crankcase scavenge cover stud nut washer (shakeproof) 4 61 500 c.c. 2-51 Crankcase scavenge cover stud nut 4 62 soo c.c. 65-2611 Crankcase scavenge cover ... . .. I 63 500 c.c. 65-2612 Crankcue s,eavenge cover washer (oilproof) 2 6• 500 c.c. 65-2623 Oil pump filter ... I 65 500 c.c. 65-2604 ... Oil pump fixing bolt ... 2 66 500 c.c. 24-978 Oil pump fixing bolt washer (spnng) ... 2 67 500 c.c. 65-2589 Oil pump complete ... ... ... I 68 soo c..c .. 65-2336 Magdyno drive idler pinion bush I 69 500 c.c. 65-2335 Magdyno drive idler pimon spindle I 70 500 c.c. 36-3528 Magdyoo drive idler pmion tllru5t washer I 71 soo c.c. 66-2620 Oil pump driving spindle I 72 500 c.c. 65-2591 Oil pump feed gear (driven) I 73 500 c.c. 31-222 Crankca5e scavenge cover stud 4 74 500 c.c. 65-2606 Oil pump tap plate washer I 75 500 c.c. 65-2598 Oil pump tap plate I 76 500 c.c. 65-2592 Oil pump feed gear (driver) I 77 soo c.c. 65-2596 Oil pump body ... I 78 soo c.c. 65-2590 Oil pump scavenge gear 2 79 500 c.c. 65-2625 Oil pump bottom plate ... I 80 500 c.c. 65-2593 Oil pump valve body ball I 81 500 c.c. 65-2622 Oil pump valve body circlip I 82 500 c.c. 15-848 Oil pump bolt _ • .• .. . •. . •. • 2 83 500 c.c. 66-1707 Cush drive bearing alignment washer (.032•) ••• 4S Y,qd.
83 500 c.c. 66-1708 Cush dnvc bearing alignment wuhet (.064"') ... as Y1fd. 84 soo c.c. 65-2528 Cush drlve distance piece I 85 500 c.c. 65-2539 Cush drive bearing I 86 500 c.c. (Clubmans) 65-2511 Engine sprocket (23T) ... I 86 500 c.c. (Scrambles) 65-2537 Engine sprocket (17T) ..• .. . ... . .. I 87 500 c.c. 66-1683 Oil pipe crankcase pipe adaptor washer (6.bre) 2 88 500 c.c. 65-2252 Oil pipe crankcase pipe adat,tor 2
17
Plate 2
N
lil .. .,
., __
Q----<
cJ2:1J~fo~~~
ENGINE ~ ~ S:. ).J!}S- ,,...-co1d Star .SOOc.c:. Clubmans and Scrambles ~ /,{,2 _ t:t<,:::tt,_ z_,
I I .-ti ~ ,
.. ~
~
Ill
.. C ·oo C ...
• - Plate 2-contim,ed.
Plate ~ef. Number
89 90 91 92 93 9• 95 96 97
98 99
100 100 100 101 102 103
Model
500 c.c. 500 c.c.
500 c.c. (Clubmans) 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. {Scrambles)
500 c.c. 500 e.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
ENGINE Gold Stor 500 c.c. Clubmans and Scrambles
Part No.
•6 - 1676 ~-•-949 65-1888 ... 2-4553
28-243 67-1135 67-1136 65-2521 65-2520 66-2313 65-2353 65-2352 65-1•23 65-142.1 65-1425 2-923
29-4661 31-212 67-714 67-715 67-716 65-9163
Oescription
Crankc:ise with fixed fittings (gear !;1dc) Crankcase stud (rear) ... .•. . .• Magdyno strap {front} ... Crankcase drain plug washer Crankca.~ drain plug Cu&h dnvc sleeve Cush drive spring .. . . .. Cush drive bearing locking wa.shcr Cush drive bearing nut •.. Magneto dowtl (Lucas) ., , .. . .• Magneto and magdyno sttap C)'C plug (tapped) Magneto and magdyno strap eye plug lJ>lam} Magdyno strap (back) ... .,. .• Magneto strap (long) Magneto strap (short) ... . .. ... . . . . .. Magndo and magdyno strap clip bolt wnshcr (plain) Magneto and magdyno t1tr.ip clip bolt Crankea.&e stud (top} (rear) Timing cover sealing plate Timing cover sealing plate washer Timing cover scaling plate bolt Timing cover seahng plate bolt wire
•Supplied only u 66-1681 crankcase drive side ;ind gear side assembled.
Plate 3
Plate Ref. Number
I 2 3
4 5 5 6 7 7 7 8 9 9 9 9
10 II 12 13 13 14 15 16 17 18 19 20 21 22 23 23 24 25
Model
500 c.c. 500 c.c. 500 c.c.
500 c.c. (Clubmans) 500 c.c.
500 c.c. (Clubmans} 500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.c. (Clubmans) 500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.c. (Clubmans) 500 c.c. (Clubmans} 500 c.c. (Clubmans) 500 c.c. lScrambles) 500 c.c. Scrambles)
500 c.c. 500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. (Clubma.ns)
500 c.c. 500 c.c. 500 c.c. 500 c.c. soo c.c.. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Scrambles) SOO c.c. (Clubma.ns}
500 c.c. 500 c.c.
GEARBOX Gold Star 500 c.c. Clubmans and Scrambles
Pa.rt No.
67-3026 .. . 67-3067 .. . 24-1065 42-3135 67-3073 42-3133
... 42-3088 67-3080 67-3361 67-3302 67-3305 42-3136
... 42-3129 ... 42-3131 67-3314 67-3315 2-433
29-3800 67-3101 67-3191 42-3137 24-4217 67-3028 67-3161 67-3169 .. . 67-3162 .. .
Description
Ball bearing spring ring Cearbox sprocket oil seal Constant mesh gear ball bearing Constant mesh gear bearing (needle roller) Constant mesh gear bush ... Constant mesh gear complete (ZST) Constant mesh gear complete (2ST) Constant mesh gear bu:sh (drilled) Mainshaft sliding gear (22T) Mainshaft sliding gear ( 19T) Mainshaft sliding gear (Z2T} ~lainshaft sliding gear (24T) Geou box main.shaft with gear Mainshaft only •.• Ccarbox matnshaft with gear Maanshaft only •.. Maanshaft gear key Clutch push rod ... .. . ~fainshaft gear locating ring Mainshaft gear (1ST) ... Mainshaft gear ( t 9T) Mainshaft bearing .. . Ma.inshaft bearing spring ring ..• ... Kickstarter ratchet pinion sleeve w;tsher Kickstarter ratchet pmion bush Kick.starter ratchet SJ,>r-ing Kick.starter ratchet pmion Kick.starter ratchet ... Kickstarter ratchet and mainshaft lockwa-bhCr Kickstarter ratchet and mainshaft nut Gcarchange operating lever Gcarchange operating lever Foot operating lever rubber
67-3376 67-3167 67-3164 67-3163 65-3380 42-3017 29-3250 2-525 . . . Selector lever operating washer
19
Number ~rset
I I 1 I I 1 1 I 1 4 1 I I I I I I I I I
- z I
Number per set
Plate 3-continued. GEARBOX -Gold Star 500c,c. Clubmans and Scrambles
Plate Ref. Number Number. Models. Part No. D6Cription. per set.
26 500 c.c. 65-3361 $e1ector lever operating screw ... I 27 500 c.c. GS-3061 Outer cover fixing ecrew {long) 2
28 500 c.c. 35-702 Clutch push rod lever nut split pin I
29 500 c.c. 2-452 Clutch push rod adjustment screw nut I 30 500 c.c. 65-3403 Clutch pm;h rod adjusbnent screw complete ... I 31 500 c.c. 65-3360 Clutch push rod lever ... , .. l 32 500 c.c. 67.._'3160 Clutch operating lever complete l
33 500 c.c. 2-525 Clutch push rod lever washer ... l 34 SOOc.c. 15-1485 Clutch push rod lever nut I
35 500 c.c. 67..J353 Gearchange lever s~dle bush ... . . . 1
36 soo c.c. 67-3378 Footcbange stop p return spring . .. l 37 500 c.c. 35-709 Gear selector plate spring washer split pin I
38 500 c.c. (Scrambles) 67..J335 Selector lever spindle complete 1
38 500 c.c. 42.._'3013 Selector lever spindle complete ' t 500 c.c. 67..J2 1S Selector lever spindle circhp ... l
39 500 c.c. 67.._'3341 Gear selector p1ate l 40 500 c.c. 67..J342 Gear selector p1ate spring l 41 500 c.c. 24-868 ... Gear selector plate spring washer l 42 500 c.c. ... 67-3170 ... Footehange l(lver spindle bu.sh ... l 43 soo c.c. 65-2157 Inner cover retaining screw ... . .. I .. soo c.c . 42-3083 Gearbox inner cover with fixed fittings I 4S 500 c.c. 67..J3SO Gearchange quadrant pivot pin I 46 500 c.c. 67-3346 ... Gearbox inner cover joint washer l 47 500 c.c.. 67-3347 Gearchange quadrant complete l 48 500 c.c. (Scra.mblesl 67..J332 Gear control cam plate complete l 48 500 c.c. (CJubmans 42..J0ll Gear oontrol cam plate complete l 49 500 c.c. 67..Jll6 Gear shifter fork s.hart ... l so 500 c.c. 42-3072 Gearbox complete with fixed fittings , .. l SI 500 c.c. 67..J328 Gear cam plate pivot pin wuhcr t 52 500 c.c. 24-7000 Gear cam plate pivot pln nut ... t 53 500 c.c. 24-8504 Gearbox casing plug washer l 54 500 c.c. 42-3049 Gearbox casing plug l 55 500 c.c. 67-3117 Gear shifter fork shaft grub screw l -56 500 c.c. (Clubmans) 67..J065 =•bo• sprocket (19T) t
56 500 c.c. (SCTambl .. ) 67-3055 Gearbox sprocket (16T) 1
57 S00 c.e. 24-4263 .. . Gearbox sprocket locking washer l 58 500 e.c. 67..J053 Cc:arbox sprocket nut •.. l 59 500 c.c. 29..J449 Gearbox inspection cover washer l 60 500 c.c. 29..J448 Gearbox inspection cover I 61 500 c.c. 2-498 Gearbox inspection cover screw I 62 500 c.c. 27-4258 Gearbox mspectwn cover sc.rcw 3 63 500 c.c. 67-3023 .. . Outer cover stud 4 64 500 c.c. 2-4553 Gearbox draln p1ug washer l 65 500 c.c. 28-243 Gearbox drain plug l 66 S00 c.c. 67-3119 Gear control cam plate plunger . . . t 67 500 c.c. 67-3 121 Gear control cam plate plunger spring l 68 500 c.c. 67..J l22 Gear control cam plate plunger housing nut ••. l 69 500 c.c. 67..Jl20 Gear control cam plate p lunger housing ... l 70 500 c.c. 67..J327 Gear cam plate pivot pin l 71 500 c.c. 67..J204 Gear shifter fork . . . . . . 2 72 500 c.c. 42.._'3074 l.ayshaft needle roller bearing •.. l 73 500 c.c. 42-3078 Layshaft thrust washer {clutch end) l 74 500 c.c. 42-3079 Laysha.ft thrust washer {cover end) ... I 75 500 c.c. 42-3075 Layshaft needle rOller bearing (oove:r end) l 76 500 c.c. 42-3095 Lay,haft clr<lip ... l 78 500 c.c. 67..J l0l Layshaft gear locating ring I 79 500 c.e. (Clubmans) 42-3085 Layshaft with gear I 79 500 c.c. (Scrambles) 42-3090 Layshaft with gear l 79 500 c.c. 42-3094 Layshaft only •. . . •. l 60 500 e.c. 2-49 Kiele.starter quadrant stop nut l 81 SOOc..c. 24-8784 Kickstarter quadrant stop washer l 82 500 e.c. 67-3 151 Kicksta.rter t1pindle bush l 83 500 c.c. 67-3152 Kick9tarter quadrant stop l 84 500 c.c.rambles) 42..Jl60 Kickstarter crank spindle assembly l 84 s c.c. 42.._'3163 Kickstarter crank_ spindle complete l 85 500 c.c. (Scrambles) 67-3088 Speedometer driving gear (GT) I 85 500 c..c. {Clubmans) 42-3033 Speedometer driving gear (GT) l 86 500 c.c. 65-3377 Spe,dometer gear bush ... I 87 500 c.c. (Clubmans) 42-3032 Speedometer driven gear (JOT) l 87 500 c.c. (Scrambles) 67.._'3175 Speedometer driven gear (1 lT) , . , I 88 500 c.c. 65-3375 .. . Speedometer driven gear thrust washer l 89 500 c.c. 65-3396 Speedometer driven gear bush ... l
500 c.c. 65-3395 Speedometer driven gear scaling washer l
20
Plate 3 GEARBOX Gold Star 500c .c. Clubmans and Scrambles
21
•
Plate 3--,;ontinued.
Plate Ref ?\umber
90 93 94 95 96 97 97 97 98 99
100 100 100 101 102 104 105 100 107 108 109 110 111 112 I 13 114
115 116 117 118 119 120 120 121 122 123 124 125 126 127 128 129
Model
500 c.c. 500 c.c. 500 c.c. 500 e.e.
500 c.c. (Clubmans) 500 c.c. (Scrambles) 5-00 c.c. (Clubmans) 500 c.c. (Sc-rambles) 500 c.c. (Clubmans)
500 c.c. 500 c.c. (Sc.:ramblet) 500 c_c. (Clubmans) 500 c.c. (Clubm1ns)
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 CC, 500 c.c. 500 c.c 500 c.c. 500 e.c 500«. 500 e c.
" 500 c.c. 500 c.c. 500 c.c 500 c.e. 500 c.c. 500 c.c. SOOc.c. 500 c.c. 500 c.c. 500 c.c. 500 Ce. soo c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 5-00 c.c. 500 c.c. 500 c.c.
GEARBOX Cold Star 500 c.c. Clubman.s and Sc.rambles
Part No. Description
65-3375 .. . SJ)tt(lomcter dri"'cn gear thrust washer 67- 3153 Kickstart.cr lever spindle bush... . ..
2-3718 Kickitarter spring screw 67-3174 J<ickstartcr spring ... 42-3086 l.ayshaft gear (1ST) •2-3024 ... Layshaft sliding gear (24T) 42'-3026 La)'1halt s!id;ng gear (21T) 67-3212 Layshaft sliding gear (21T) 67-31~ l.ayshaft shdmg gear (19T) 67- 3203 ... Layshaft thrust washer... • . . 42-3082 ... Layshaft gear complete (27T) .. . •2-3138 Layshaft gear complete (24T) .. . •2-3086 tayshaft gear complete (18i) . . . 67- 3093 Layshaft gear bush -67- 3128 Layshaft spc,edo driving gear peg 66-3074 Dowel ... ... ... . .. 67-3354 Gearbox outer CO\'er jolnt washer
2-4553 Oil level plug washer 28 243 Oil level plug •. , . .. .•. . .. 67 3351 ... Gearbox outer co"er with fixed fittings 27-4401 K.ck!tarter spring locknut ... 67-1705 Outer cover fixing screw (short) ~2080 Grease nipple . . . . . . 2-923 Outer cover 6,ung washer
67- 3034 Outer cover fixing nut ... . .. 67-3176 Speedo dr1ven g~r retaining pm ... 67- 1709 Speedometer driven gear retaining pin washer (fibre) 15-4240 Gearchange operating ~pindle circ.lip 64--3106 Inspection covtt jomt washer ...
.. . 67-3024 Inspection cover . .. 2•- 7178 Inspection co"er fixing screw 2-2579 K,ckstarter crank cotter
42--3037 Kick.starter crank complete ... 42-3-038 Kick.starter crank only . ..
IS--515.S Kickstartcr crank washer 2- 2578 Kickstartcr c-rank nut ...
65-3427 .. . Kick.starter crank pedal 42-3159 K1ckstarter crank rubber 66-4707 Ki.ckstartcr pedal washer (s.hakeproof) 29-5156 ... Kickstartcr pedal bolt ... ... • . . 65-3428 Ki(kstarter crank pedal spring
2-220 K1(kstarter crank spring bolt , .• . .. ~541 Kickstarter crank s-pnng bolt washer (shakeproof) ...
Plate 4 CLUTCH and FRONT CHAINCASE
Pate Ref. Number.
I 3 4 5 6 7 8 9
10 II
Model.
SOO c_c. 500 c.c. 500 c.c. 500 c..c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 C.C-,
500 e.e. 500 c.c.
Gold Star SOOc.c. Clubmana and Scramble•
Part No.
42-3125 67-1706 65-3063 42-3249
... 66-3SOO 66-3781 42-3056 42-3120 GS-3911 65-3910 42,-3061
Description.
... Clutch completo . .. • .. Primary chainca.se front fixing acrew .. . Primary chaincase front fuung tcrew .. . Clutch spring reta.aning stud nut .. . Clutch spnng . .• Clutch spnng cup Clutch actuating cap complete Clutch plate ferodo insert Clutch ballrace inner nng .. . Clutch ballrace retaining ri.ng with balls Clutch chamwhcel fcrodo insert
22
Number per set
I I I I I I I I I I I I I I I 2 I I I I I I I 4 4 I I I I I 2 I I I I I I I I I I I I
Numbu pe.r aet.
I 5 7 6 6 6 I
120 I 2
24
-
-
Plate 4 CLUTCH and FRONT CHAINCASE Gold Star 5:>oc.c. Clubmans and Scrambles
• • ; " C: ... ] u
,0 ~
i .. ... .._
1 .. .,: " ~ :,
u .. ~
.,. .. .., ;:;
- ~
0 ..,
., ,:i ..
~
,0 .. <;;; ... ..
... .. • .. .., .. ,-.
23
Plate 4-continued CLUTCH and FRONT CHAINCASE
l'Late Ref. Numbtt
12 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 • l
Plate 5
Plate Ref. Number
l 2
3
• 6
7 8 9
10 II 12 16 17
19 20 21 22 23 24 25 26 27 28 29
\lodtl
500 c.c. {Scramb~) 500 c.e. (Clubmans}
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 CC, 500 CC, 500 c.c. soo c.c. 500 c.c 500 C.C. soo c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
Model
500cc 500 c.c. 500 c.c.
500 c.c. 500 c.c. 500 c.c.
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 5-00 c.c. 500 c.c. 500 c.c.
500 c.c. 500 c.c. (Scrambles)
500 c.c. 500 CC. 500 CC, 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
Cold Star 500 c.c. Clubmana and Scram.bite
Part No.
2~716 24-8932 6$-3873 6$-3833 •.. 66-7523 2-1•62 ... 2-•43
65-109 15-7563 35-33
Primary chain Primary chain Clutch sleeve
Desc.npbon
Clutch sleeve colb.r .. . Primary chaincase sJiding plate bolt Pnmary chamcase shd1ng plate bolt washer (spnng) Pnmary cba.mcase &l.tdmg plate bolt out Primary chainea.se back fixing bolt Primary chaincase back fixing bolt distance collar ... Primary cbaincase back 6xmg bolt washer {spnng) Pnmary chainca.se back 6,ung bolt nut Pnmary chaincue dowel Pnmary chaioease (back) Primary chainca.se washer (00(,kr'(felt) Primary chaincase sliding plate complete Clutch plate . .. . .. ... . . . Clutch chaanwhecl complete (43T) Clutch baUrace nng Primary chaancue JOlnt washer {paper) Clutch driven plate (plain)
2-•9 66-3074 •2-7502 42-7504 66-7520 65-3872 •2-3224 65-3912 42-7507 29-3832 •2-3119 42-3220 65-3822 66-3787 67-42 6$-33&4 42-7508 •2-7506 66-7575 24-8784 67-4028
. .. Clutch driving plate with inserts ... Clutch dnving plate centre with studs )Jama.ha.ft nut Jock.mg washer .. . . .. Maan&balt nut Primary cha.incase inspection cap wuher (fibre) Prir:na.ry chaincue inspection cap ••• Primary chaincas,e front fixing 1Crew ... Primary chaincase (front) .. . Pnmary chaincase and cran.kcase joint washer .. . Primary chaincaae back accuring bolt washer (spring) Prun.ary charneue back seeunn_g bolt
FRAME and FITTINGS Gold Star 500 c.c. Clubman1 a nd Scramblea
Part No.
42-4132 42-4816 65-ji95
15-5753 ... 65-4182
2-522
2-•6 2-1945 2-1967 2-1925
42-4077 27-5683
2-•6 2-522
27-5683 27-5683 42-4125 29-3319 2-1309
66-4149 42-4208 28-2(18() 66-4707 2-46
42-4010
Description
Rear engme and gearbox plate bolt (top} Rear en.glne plate stud (when footrests an rear position) Rear engine plate stud washer (s.hakeproof) (wben footrest,
in rear potition) ... ... ... ... . .. . .. Rear engine plate stud nut (when footrests in rear position) Rear engine and gearbox plate stud (top and bottom rear) Rear engine and gearbox plate stud washer (spring) (top and
bottom rear) ... Rear engine and gearbox plate stud nut (top and bottom rear) Gearbox plvot stud washer (plain) Gearbox pivot stud washer (spring) .. Gearbox pavot stud nut Gearbox pivot stud .. . .. . .. . . .• . .. Rear engine and gearbox plate stud (bottom front) ... Cra.nkca.se and rear en.gi.ne plate fixing stud nut (bottom) ... Crankcue and rea.r engane plate fixing stud wuber (spnng)
(bottom) •.. • ... •.• •• Crankcase rear engine plate fixing stud (bottom) ... . .. Crankcase fixing 5tud (front) (when crankcase shield is fitted) Front eng"ine plate cover ... . .. ... ... . .. Front engine plate cover screw washer (sh.ak.eproof) Front engine plate cover screw . .. .. . ... Bau head cup .. • .. • • .. • .. Frame complete watb central stand ... &II head grease nipple Saddle front fixing bolt was.her ($ha.keproof) Saddle front fixing bolt nut ... .. . . .. Front engine plate and frame distance tube ...
24
Number ptrstt
l l I I 2 2 2 l I l I 2 l l I l l l l 5 5 l l l I I 3 l l 3 3
Number ptrstt
2 2 l
5 5 2 2 2 l l 2
2 l l l 6 6 2 l l I I I
~====-:=-====-::--===---=:-::::==- --===-===-=========--=---=--==-====-
Plate 5--ccntinued. FRAME and FITTINGS Gold Star 500c.c, Clubmans and Scram.ble1
Plate Ref. Number. Model. Part No. Numbet
Description. per set.
30 500 c.c. 27-5690 Front engine plate frame stud (top} ... . .. I 31 500 c.c. 2-522 Front engine plate frame stud washer (spring) 4 32 500 c.c. 2-46 Front engine plate frame stud nut 4 33 500 c.c. 2-46 Crankcase front fix.log stud nut ... . .. 6 34 500 c.c. 2-522 Crankcase front fixing stud washer (spring) ••. 6 35 500 c.c. 27-5684 Crankcase and front engine plate front 6.iing stud 3 36 500 c.c. 42-4070 Front engine plate and frame distance tube . .. ... • .. I 37 500 c.c. ... 42-4099 Front engme plate stud ~ttom) and horn fixing stud ... I 37 500 u. (Scrambleo) 27-6275 Front engine plate stud ( ttom ) (when horn ts not fitted} ..• I 38 S00 c.c. 42--4072 ... Rear engine and gearbox. plate {top) .. . 2 39 500 c.c. 42-4073 Rear engine and gearbox plate (bottom) ... 2 40 500 c.c. -•82 Crankcase and rear engine plate top ~ing stud I 41 500 c.c. 42--4071 Front cngme plate dJstance collar ... . . . 2 42 500 c.c. 42-4068 Front engine plate (offside) ..• I 42 500 c.c. 42-4066 Front engane slate (nearside) •. . ... ... ... I 43 500 c.c. 2--46 Crankcase an rear engine plate top fixing stud nut ... 2 44 500 c.c. 2-522 Crankcase and rear engine plate top fixing stud washer {spnng) ... ... 2 46 500 c.c. 2-1925 Cearbox locking stud nut ...
I 47 500 c.c. 66--4708 Gearbox lockini stud washer (shakeproof) I 48 500 c.c. 42--4076 Gearbox ad1usting screw ... . .• I 49 500 c.c. 2-1616 Gearbox ad1u.sting screw locknut I 50 500 c.c. 15-5664 Gurbo.x i.djustang screw nut . . . . . . I 51 500 c.c. 27-5705 Gearbox adjustmg screw stop . . . . .. I SIA 500 c.c. 42-4075 Cearbox locking stud washer (serrated) I 52 500 c.c. 42-4074 Gearbox locking stud complete ... . .. I 53 500 c.c. 2-1482 Gearbox ad~usting screw stop washer (spring) I 54 500 e.c. 2-2395 Gearbox ad1usbng screw stop nut . . . . .. I 55 500 c.c. (Clubmans) 2~70 Battery base plate bolt •.. 4 56 500 e.e. {Clubmans) 2-923 Battery base plate bolt washer (plain) 2 57 500 e.e. (Clubma...) 1-24 Battery base plate bolt nut . . . ... 2 58 500 c.c. (Clabman,) 36-382 Batwry ba.se plate washer (wkeproof) 4 59 500 e.c. (Clubmus) 42-4515 Battery base a:.•te .. . ... ... I 60 500 c.~Clubmans) 42-4284 Rear engine p te cover complete ... I 61 c.c. 28-2080 Saddle front fixing bolt grease nipple ... I 62 500 c.c. 67-4030 Sa.ddle front fuung bolt . . . . .. I 500 c.c. (Clubmam) 42-4514 Battery ca.rtier complete I 63 500 c.c. (Clubmant) 42-4516 Battery strap !side) complete ... I 64 500 c.c. (Clubmans) 42--4502 Battery strap top) .. . .. . I 65 500 c.c. (Clubmans) U-7343 Battery strap bolt
2 66 500 c.c. 42-9032 ... Saddle ... ... I 66A 500 c.c. (Clubmans} 2-6537 Battery strap bolt washer ... 2 67 500 c.c. (Clubawa) 42-4505 Battery strap swivel pm (plain) 2 68 500 c.c. {Clubmans) 42-4506 Battery strap swivel pm (tapped) 2 69 500 c.e. (Clubm&M) 42-4503 Battery strap {side) I 70 500 c.e. 2--49 Saddle rear ftx.ing stud nut . . . • . . 4 71 500 c.c. 2-923 Saddle rear fixing stud washer (plain) • 72 500 c.c. 67--4040 Saddle rear fixing stud . .. . . . . .. 2 73 500 c.c. (Clubmana) 42--4813 .Footrest banger stud (nearside) (when footrests in """ position) ... I 74 500 e.c. (Clubnw,s) 2--46 Footrest anchor bolt out (when footrests in rear position) ... 2 75 500 c.c. (Clubm.u,s) 2-522 Footrest anchor bolt wuhe:r (spring) (when footrests in rear
position) 2 76 500 c.e. (Clubmans) 42-4812 Footrest hanger bracket (when footrests in rear position) ... 2 77 500 c.c. (Clubmans) 24-6040 Folding footrest lWivel bolt nut (when footrests in reat positaon) .. , ... ... ... ... ... . .. 2 78 500 c.e. (Clubmana) 36-382 Folding footrest swivel bolt wa&b.er (sl\a.keproof) (when foot-rests in rear position) .. . 2 79 500 c.c. (Clubmans) 29-7581 Folding footrest (when footrests in rear position) ... 2 79A 500 c.c. (Clubm.ans) 29-7583 Footrest rubbtr (when footresq in rear position) 2 80 500 c.c. flubma.ns) -917 Footrest anchor bol_t (when footrests m rear position) _ ... 2 81 SOO e.c. Clubmans) 29-756• Folding footrest swJVel bolt (when footrest:$ m rear posjbon) 2 82 S-00 c.c. (Clubmaos) 2-46 Footrest banger stud nut (when footrests in rear pOISition) ... 2 83 500 c.e. (Clubmans) ... 66--4707 Footrest hanger stud washer (sha.keproof) (when footrests in rear posation) ... •.. ... ... . .. 2 Sf 500 c.c. (Oubmans) 2-861 Footrest hanger $tud washer (pla.i.n) (when footrests io rear position) .,. •·· 2 85 500 c.c. (Clubmans) 42--4815 Footrest hanger stud diata..oce tube (nearside) (when footrest1
42-4835 m rear pos.itlon) ... 86 500 c.c. (Clubmam) Pillion footr"C$t complete UICmbly (neanide) 86A 500 c.c. {Clubmana) 42-4836 PiJJion footrest complete assembly (offside) ...
25
Plate 5 FRAME and FITTINGS Gold Star 50Qc.c. Clubmans anJ Scrambles
r
26
. ,,.,
---
Plate 5-continued
Plate Ref. Number
87 tl8 89 90 91 92 93
94 95
Plate 6
Plate Ref. Number.
I 2 3 4 5 6 7 8 9
10 II 12 13 14 15
16
17
18
19
20 21
-112 '23 23 24 24 25 26
27 28 29 30 31 32 33
Model
500 c.c. (Clubmans} 500 ~-C, (Clubmans) 500 c.c. {Clubmans) 500 c.c. (Clubmans} 500 c.c. {Clutimans) 500 c.c. {Clubman.s} 500 c.c. (Clubmans) 500 c.c. (Clubmans)
500 c.c. (Clubman.s) 500 c.c. {Clubmans) 500 c.c. {Clubman!.) 500 c.c. (Clubmans)
Model.
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 Cc. 500 c_c,
SOO c.c. (Clubmans)
SOO c.c. (Oubmans) 500 c.c. (Clubmans)
500 c.c. 500 c.c.
500 c.c. (Clubmans) 500 c.c. (Clubmans)
500 c.c. (Clubmans)
500 c.c. (Clubmans)
500 c.c. (Clubn1ans)
500 c.c (Clubmans)
500 c.c. 500 c.c.
500 c.c. {Scrambles) 500 c.c. (Clubman~) 500 c.c. (ScramblC>i) 500 c.--::. (Clubmans) 500 c.c. (Scrambles)
500 c.c. 500 c.c.
500 c.c. 500 ..;.c. (~er-ambles)
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
FRAME and FITTINGS Gold Star 500 c.c. Clubmans and Sc.rambte.s
Number Part No. J>c~nption per set
Pillion footrest ruhltcr .. 2 Pillion footrest swivel bolt 2 Pilhon footn-,;t anchor bolt {nearside) I Pilhon footre-1,t anchor lx>lt wasl1cr (spnng) 2 Pillion footrei;t anchor bolt nut. 2 !'illion foottet,t i1wi\"el bolt washer (sh.-.kcproof) 2 l_,.illion footrest 5" iw:I bolt nut 2
2\l 758:1 ~ 75&1 29-75f0
2-522 2-46
36-3b2 24-6040
2-522 ... Footrest hanger stud washer (springl {when footrests in rear po1S1hon) . 2
2 46 -12-4814 42--1845 42-4852
Foottci;t hanger §tud nut (whe,, footre~~ in rear pos1t1on> ... 2 FootrC!tl hanger 5tnd (ofl11~c) (when footl'C!stl11 in rear position) 1 Footrest assemhl)' (relr pusition) 'l Pillion footrest am:hor bolt (offside) .. . I
REAR SUSPENSION Gold St.1.r 500c.c. Clubmans and Scrambles
Pltrt No.
42-4719 28-2080 42-4730 42-4713 42-471-1 2-1945 ~-1967
24 5&lO 42-4806
42-4804 42-4808 42-4117 --12-4116 29-7551 65-481 I
42-4805
24-591-1
65 695
15-5753
I 1796 2-522
Descnption.
Central stand complete ... Central stand grease nipple Central stand sprang Cent.ral :stand dust.ancc tube Centrn1 ~t 10d pivot ~t11d ••. Central sund pivot s-tud washer (plain) Central stand pivot stud wa.sher (spring} (cntr.i.l stand p1\10t stud nut ... . .. Footrest distance tube complete {offside) (when lootre~ts rn
forwc1;rd poi-1tion) •.. ••• .,. ••• •.. , •• Footrest bracket (offside) (when footrccit.s in forward position) Footrest stud complete (when rootTC:l>t.s in forward position) Sw111gmg a.rm fork -spindle locknut washer .. Swmgmg arm fork spindle locknut .Footrcil-l rubber (when footrc:sts in forward po51tion) Footre:-.t di!\tance tul>e wmplete (ne.4ri;.ide> (when footre~ts in
forw.ird J')O:)ition) Footrei.t bracket (neamde) (when footresu in forward
~1tion) ... Footrest .,tud washer (plain) (when footfC5ls m forward
i)Os1tion) . , . Footr1.~t ~tud w.i;,,.her (.:,lukeproof) (when foot.rest~ in forward
po:,ition) Footre:..t l>tud securing nut (when footresL-. in forward
position) ... .. ... Rear mudguard bracket and dampc:r top fixing bolt nut Rca.r mudguard bracket a.nd damper top fix.mg bolt washer
(spring) 42-2001 frankca:se is.h1cld ••• 42-4291 Rear ~m~pen$iOn outer $hroud .. . 42---4141:l ... He,,r 31tliopension outer shroud .. . --12- -IW-1 ... Hear suspension damper spring 42-4:l99 . .. Rear suspens..ion damper ispnng ... 65-4185 Rear mudguard l>racket. and d;unper top fixing l>olt
2 1733 Rear mudguard l>racket and damper top fixing bolt washer
42 6763 4'l--H61 42-4115 ... 42-1112 36-382 66-2010 42~2$
(rla,o) .•• • Re.1r mud1tmlrd l,r.icket and damper !.()a<.:nl,; coll"r Hear $11:,pt:nsi<,m damper complete . ,. Swinging .1rm housing "silent bloc" . Swinging arm fork spindle complete ... .. . . .. Swinging arm fork spindle ~unng bolt wa.<;her (shakeproof) Swinging arm fork spindle securing bolt ... . .. . .. Hear ibuS.pc1h1ion split spring retainer (retaining outer shroud)
(bo halveltl) ...
Number per set.
I I I· I I I I 2
I I I I I 2
2
2
2 I 2 2 2 2 2
2 2 2 2 2
2
Plate 6 ' REAR SUSPENSION Gold Star SOOc.c. Clubman1 and Scramblee
j
l l J
• a: ii =
~ 18- !!:
28
Plate 6-wntinued
Plate Ref. Number
34 34 36 37 38 39 40 41 42 43 44
45 46 47
48
49 so SI
52
53 54
Plate 7
Plate Ref. Number.
I 2 3 4 5 6 7 8 9
10 II 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 28
Model
500 c.c. (Clubmans) SOO c.c. (Scrambles)
500 c.c. 500 c.c. (Clubmans)
500 c.e. 500 c.e. 500 c.c. 500 c.c. 500 c.c. 500 c.e. 500 c.e.
500 c.c. 500 c.c. {Scrambles) 500 c.c. (Scrambles)
500 c.c. (Sc.rambles)
500 c.c. (Scraml>I .. ) 500 c.c. (Scrambles) 500 c.c. (Scrambles)
500 c.c. (Scrambles)
500 c.c. (Scrambles) 500 c.c. (Sc.-aml>leo)
Model.
500 c.c. (Clubm;ms) 500 c.c. (Scrambles) 500 c.c. (Scrambles)
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.c. lClubmans) 500 c.c. Clubmans) 500 c.c. (Clubmans) SOO c.c. (Clubmans) 500 c.c, (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans} 500 c.c. (Clubman.s)
500 c.c. 500 c.c.
500 c.c. (Scrambleo) 500 c.c. (Clubmans) 500 c.c. (Scramb1es) 500 c.c. (Clubmans)
REAR SUSPENSION Gold Star 500 c.c. C lubmans and Scrambles
Number Part No. Oescripti.on per set
Rear su11p,cnsion inner shroud . .. 2 Re.ar suspcnA.ion inner shroud ... 2 Rear susrension metalastic bush 4 Rear suspens:ion damper complete ... 2
42-4292 42-4149 19--5305 42-4460 3 1399 2- 1733
42--6040 24--Sl,3 42-4317 67-4129 66-4707
Rear suspension damper bottom fudng bolt 2 ... Rear suspension damper bottom fixing bolt wa&her (pla.i.n) .. . 2
AdfUSting screw for r~ar wheel . .. 2
2-46 42-4830 42-4832
24-8784
2-24 13 42-4816 65-695
IS-5753
•2-4831 42-4833
AdJuSt:in.g screw lo,eknut for rear wheel 2 Swi.nglng arm complete . .. .. ... I Rear suspension damper bottom fix.mg bolt washer 2 Rear suspension damper bottom fixing bolt washer (shake--q .. 2
Rear suspen&.ion damper bottom fixing bolt nut 2 Footrest (nearside) (when footrests irfforward position} . . . I Footrest locking C3.p (nearside) (when footrests in forward
position) . .. . .. .. . .. . . .. Footrest cap bolt washer (spring) (when footrests in forward
position) . .. . .. 8 F'ootrnt cap bolt (when footrest& in forward position) 8 Rear engine plate stud (when footrests In forward position)... l Rear engme plate stud washer {$hidcepf'OO() (when footrests
in forward position} •.. 2 Rear engine plate stud nut (when footrests in forward
position} ... ... ... ... . .. .. . 2 Footrest (offside) (when footrnts in forward position) 2 Footrest locking cap (offside) (when footrests m forward
position}
FRONT FORK and FITTINGS Gold Star 500c.c. Clubmans a nd Scrambles
Part No.
42- 5022 42-5003 65-oGI? 42--5011 6$-5332 65--5331 29-5315 ... 67-5024 67--5023 65-5334 65--5426
2-370 2-370 2-0026
67-5009 ... 67-5009 ... 24--8784
42-9204 42-9203
2-46 2-923
42-9116 ... 2-1934
42--5024 42--5027
2-1309 2-292
Description.
Front fork complete assembly . . . Front fork complete assembly .. . Competition number plate bracket Front fork top yoke Frok tube nut was.her ... Fork tube nut fork top yoke chp bolt out ... Stccnng stem ad1ustang sleeve cap Steeri1ig 'Item adjusting s.leeve .. . Handlebar and yoke clip bolt .. . Steering d;imper knob securing plate ... Ha.ndlebar clip and damper knob securmg bolt distance piece Handlebar clip and damper knob securing bolt distance piece Handlebar chp and damper knob securing bolt Fork outer &.lccve (offs:1de) Fork outer sleeve (nearside) Top headlamp bracket bolt washer l..ower headlamp bracket with clips ... Top headlamp bracket ... Top headlamp bracket bolt nut Top headlamp bracket bolt washer Top headlamp bracket clip .. . Top headlamp bracket bolt Front fork spring cover .. . Front fork shaft ... Fork drain plug . .• Fork drain plug washer ... Front fork shaft . .. . .. 89- 5061
65-5420 65-5410 67-5057
... Fork slidmg tube (offsade) Fork &.liding tube (offtade) Fork sliding tube (nearside)
29
Number per set.
I I I I 2 2 I I I 2 I 1 I 2 I I 2 I I 2 2 2 2 2 2 2 2 2 I I I
Plate 7 FRONT FORK and FITTINGS Cold Star SOOc.c. Clubmans and Scrambles
I 2
23 2
33 34
Front Fork and Fittl"C'
30
Plate 7-continued.
Plate Ref. Number
28 29 30 31 32 33 34 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 so 51 52 53 54 55 56 57 58 59 60 61 62 R3 64 65
Model
500 c.c. {Scrambles) 500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. 500 c.c.
500 c.c. (Clubman.s) 500 c.c. (Scrambles)
soo c.c. 500 c.c. 500 c.c, 500 c.c. 500 c.c. 500 c.c. 500 c.c. 5-00 c.c. 500 c.c. 500 c.c.
500 c.c. {Clubmans) 500 c.c
500 c.c. (Clubmans) soo c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 e.c. 500 c.c. 500 c.c. 500 c.c. SOOt.c . 500 c.c. 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Scramble:s) 5-00 c.c. (Sc~mbles) 500 c.c. (Scrambles) 500 c.c. (Scrambles)
FRONT FORK and F ITTINGS Cold Star 500 c.c. Clubm ans and Scra m bles
Part No.
65 5408 2 -291\3
65-5295 65-6616
.. 29-5289 36-382
. . . 42-5015 42- 5012 29 -5283 29-5338 29-5347
... 65-5424 29 5320 29-5313 29-5310 89-5036 36-382
2-49 24 5160 2-2395 2 204
65-5127 1- 4675
65- 5126 66- 5204 65-5328 25-5247 42-5014 65-5380
... 24 6035 67-5021 27-5135 65-5333
2-923 28-2338 15 7161 27 8560 2 1462 22395
Description
Fork sliding tube (nearside) Fork end bolt wou,her (spring) ~--Fork end bolt . .. ... . .. CompetittOn number plait (front) &ttom yoke bolt .. . Bottom yolce bolt was.her (sha.keproo£) Fork bottom yoke Fork bottom yoke ... Front fork shaft plug . .. Front fork shaft plug wuher Front fork bot-tom bearing
. . . Front fork top bcanng ... Front fork top bearing circlip . .... Front fork die seat
. . 1-~ork oi.l ~al holder ... .. Front fork spring ... . ..
Steering da.mper plate bolt washer .. Steering dain~r plate bolt nut
Bottom yoke bolt nut . •• Steering lock stop bolt nut
. .. Steenng lock stop bolt ... Steering h~ad ballra« cone (bottom) . .• Steering head balls ... Steering head ballrace cone (top} Steering head dust cap . . . Stttring damper centre .. . Stttflng damper star was.her . .. Steermg damper anchor plate ... Steering damper fnetaon washer Steering damper knob spring wathcr ... Steering damper adJUStmg rod . •• Fork top yoke chp bolt • Handlebar clip •.. Stttnng damper anchor plate bolt washer Steenn« damper an<:hor plate bolt . . . Competibon number plate bracket screw Competition number pl.ltt: bracket washer (plain) Competition number plate bracket wa.she1' (spnng) ... Competition number plate bracket nut
Plate 8 FRONT HUB and WHEEL FITTINGS (7• Brake) Gold Star 500 c .c. Scrambles
Plate Ref. Number
I 2 3 • 5 6 7 8 9
10 11 12 13 I• 15 16 17 18
Model
500 e.c. (Scrambles) 500 c.e. (Scrambl~) SOO c.e. Scrambles) SOO c.e. Scramblf":!l) SOO e.c. Scrambles) .SOO e.c. Scrambles} 500 e.e. Scrambles) 500 e.e. (Scrambles} 500 c .c, (Scrambles) SOO c .c. (Scrambles} 500 c.c. (Scrambles) 500 c.c. (Scrambles) 5-00 c.c. (Scrambles} 500 c.c. (Scrambles) SOO c.c. (Scrambles) SOO e .c. (Scrambles) 500 e .e. (Scrambles) 500 c.c. (Scrambles) 500 c .c. (Scrambles)
Part No.
4:l,..5522 42-552•
r>escription
Front wheel complete (less brake and tyre} (W~ll- 21) Front whttl spoke (long)
27 6808 65 5929 65--5892 65-5893 65-5890
Front whee' spoke nipple ... Front hub spmdle
Front hub spindle distance piece Front brake CO\!er plate nut
.. 65-5888
.. 65-5886 .. . 65-5887 .. . 65-5883 .. . 65-5889 •.. •2-5525 28-2080
•• 65 5884 65-5883 65-5885 65-5891 31-6015
Front hub distance collar .. . Front hub felt washer retaining cup Front hub washer (felt) Front hub felt ...,-asher retaining ring Front hub ball Journal ... Front hub spindle sleeve • ... Front hub shell complete (with spindle and bearings) Front hub grease nipple Front hub bearing thrust washer Front hub ball joumal .. _. . . . Front hub ~anng retaining rmg Front hub di.Sta.nee piece Front wheel spoke (short)
3 1
Number per set
I 2 2 I 2 2 I I 2 2 2 2 2 2 2 2 I I 2 2 2 I
40 I I I I I I I I I 2 I I I 2 I I
Number per set
I 20 20
I I I I I I I I I I I I I I I
20
Plate 8 FRONT HUB and WHEEL FITTINGS (7" Brake) Gold Star 500c.c. Scrambles
• .. C .t ll:
] ~ .., a -" ::, :c ~ ' C 0 il::
. '
ii;
;;; :!
::; • ..,
" .., "' •
"
r--- Plate 3
Plate Ref. Number.
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 38 37 38 39
Plate 9
Plate Ref. Number.
I 2 3 4 5 6 7 8 9
10 10 II 12 13 14 15 16 17 18 19 20 21 22 23 24 2S 26 27 28 29 30 31 32
FRONT HUB and WHEEL FITTINGS (7" Brake) Gold Star 500c.c. Sc.rambles,
Num~r Model. Patt No. Description. per set.
500 (;,C. {Scrambles) 27-6808 Front wb e nipple 500 c.c. (Serambl .. ) 42-5523 eel rim (WMl-21) I 500 c.c. (Serambl .. ) 65-5899 Front brake shoe fulcn.im pin I 500 c.c. (Scrambles) 35-6436 Front brake shoe lining rivet 14 500 c.c. (Scrambles) 6$-5903 Front brake shoe lining . .. 2 500 c.c. (Scrambles) 65-5901 Front brake shoe with lining 2 500 c.c. (Scrambles) 6$-5895 Front brake cover plate complete I 500 c.c. (Scrambles) 6$-5893 Front brake cover plate nut •.. ... I 500 c.c. (Scrambles) 2~45 Front brake fulcrum p in serrated washer I 500 c.c. (Scrambles) 2- Front brake fulcrum pin nut ... I 500 c.c. (Scrambles) 15-431 Front brake shoe cam wa§:bcr (plain) . .. I 500 c.c. !Scrambles) 66-4708 Front brake shoe cam was.her (sh.ikeproof) I 500 c.c. Scrambles) 2-440 ... Front brake shoe cam nut ~- I 500 c.c. (Scrambles) 29-5871 Front br.tke lever toggle I 500 c.c, 1Scramblcs) 2-510 Front brake lever toggle &erew I 500 c.c. Scrambles) 65-5907 Front brake shoe cam lever I 500 c.c. (Scrambles 2-1462 Front brake lever toggle washer (spring} I 500 c.c. (Scrambles 2-443 Front brake lever toggle nut . .. . .. I 500 c.c. (Scrambles ... 6h5674 . .. Front brake shoe cam bearing oil hole clip I 500 c.c. (Scrambles 65-5904 Front brake shoe spring 2 500 c.c. (Scrambles 65-5005 Front brake 5hoe cam complete I
FRONT HUB and WHEEL FITTINGS (8" Brake)
Model.
500 c.c. (Clubmans)
500 c.c. (Clubman.s)
500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans 500 c.c. (Clubmans 500 c.c. (Clubmaos 500 c.c. {Clubma.os 500 c.c. {Clubmans 500 c.c. (Clubmans 500 c.c. (Clubmaos) 500 c.c. (Clubmaos) S-00 c.c. Clubma.1u) 500 c.c. Clubmans) 500 c.c. Clubmans) 500 c.c. Clubmans) 500 c.c. CJubmans) 500 c.c. Clubmans) 500 c.e. Clubmans) 500 e.c. Clubmana) 500 e.c. Clubma.os) 500 c.c. Clubmall$) 500 c.c. Clubmans) 500 c.c. Clubmans) 500 e.e. Clubmans! 500 c.c. Clubma.os 500 c.c. Clubmans) 500 c.e. Clubmaos) 500 e.c. Clubmarui) 500 c.c. Clubmans} 500 c.c. Clubmans) 500 e.c. Clubm.ans) 500 c.c.1Clubmam) 500 c.c. Clubmaos) 500 c.c. Clubmans)
Cold Star 500<:.c. Clubmans
Patt No.
42-5543
4W544
67-5544 27-ilS I0 67-5566 67-5561 35-701 67-5563 65-5883
Description. Number per oet.
Front wheel comptet.e (steel rim) (less brake and tyre) (WMl-19)
Front wheel complete (alloy rim) (less brake and (WMl-19) ... ...
Front wheel spoke (short) (19' wheel) Front wheel spols:e ojpple Front hub spindle ..• . .. Front hub bearing locking ring (nearside) •.. Front hub bearing lockin.g ring retaining pin Front hub bearing od retaining washer (nearside) Front hub ball journal ...
ty"') . .. as reqd.
20 40
I I I I
... 28-2080 ...
... 42-5538 42-5509 42-5510 67-5545 67-5565 65-5883 ... 67-5564 ... 35-701 67-5562 67-5575 67-5602 65-5904
Front hub grease nipple •.. •.. ... . .. . .. Front hub shell complete (with spindle sleeve and bearings)
..• Front wheel rim {\VMJ-19) (steel) Front wheel rim (\VMl-19) (alloy) .. .
I I I I
.. . 67-5576 67-5555 42-5520 32-194 15-716 15-541 25-0014 3$-37
2-2527 29-5871 2-443 2-1462 2-510
Front wheel spoke (lon_g} ( t9· wheel) . . . Front hub spindle sleeve Front hub ball journal ••.
.. ,
Front hub bearing oil retaining washer (offside) Front hub bearing locking ring retaining pin • Front hub bearing locking ring (off.side) Front brake shoe lining rivet . . . . . . Front brake shoe lining ... Front brake shoe spring Front brake fulcrum and adjusting pin Front brake cover plate with fixed fittings Fron t brake anchor e:trap ... . .. Front brake anchor strap bolt . .. •.. • .. Front brake cam plate and anchor strap washer (spring) Front brake cover plate and anchor strap nut Front brake fulcrum and adjusting pin was.her (plain) Front brake fu.k:ru.m and ad1usti.ng pin washer {spnng) Front brake fulcrum and ad1usting pin nut Front brake lever toggle Front brake lever toggle nut Front brake lever toggle washer Front brake lever toggle screw
•.. o.s rl.fd. 20
I I I 1 I
14 2 2 I I I 2 I I I I 1 I 1 I I
Plate 9 FRONT HUB and WHEEL FITTINGS (8" Brake) Gold Star 500c.c. Clubmo.ns
... 1 .. .0 :, •. :c
•
Plate 9-amtd. FRONT HUB and WHEEL FITTINGS (8" Brake)
Plate Ref. Number
33 34 35 36 37 38 39 40
Plate 10
Plate 8ef. Number
I 2 2 2 2 3 4 5 6 7
8 9
10 II 12 12A 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Model
500 c.c. (Clubmans) 500 c.c. (C1ubmans) 500 c.c. {Clubmans) 500 c.c. (Clubmatu1) 500 c.c. (C"lubmans) 500 c.c. (Cluhmans} 500 c.c. (Clubmans) 5-00 c.c. (Uubmans}
Cold Star 500 c.c. Clubmans
Part No.
2-440 66-4708 JS-431 65-5907 28 2080 67 5567 67~572 67 5601
l>e!t.(nphon
Front bnke shoe cam nut .. . Front brake shoe cam washer (shakeproof) f'ront brake iJh°' um was.her (plam) ... Front brake oper.1.ting lever ... . .. Front brake fnlcn1m pin gre.uc nipple Front brake cam beanng ... . Front brake shoe cam complete Front brake shoe with lining ...
..
FRONT HUB and WHEEL FITTINGS (190 mm. Brake)
Model
500 c.c. (Clubmans)
500 c.c. (Clubmans)
500 c.c. (Clubma,u)
500 c.c. (Clubman1}
! 00 c.c. (Clubmans) 500 c.c. (Clubmana) 500 c.c. (Clubmant) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. {Clubmans} 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmaru,)
500 c.c. (Clubmans) 500 c.c. (CJubmans) 500 c.c. {Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmam) 500 c.c. (Clubmans} 500 c.c. (Clubmans} 500 c.c. (Clubmans} 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans} 500 c.c. (CJubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmant) 500 c.c. (Clubmans} 500 c.c. (Clubmans) 500 c.c. (Clubmans) S-00 c.c. (Clubma.na) 500 c.c. (Clubmans} 500 c.c. (Clubmans) 500 c.c. Clubmans) 500 c.c. Clubmans) 500 c.c. Clubmans) 500 c.c. Clubmans} 500 c.c. Clubmans) 500 c.c. Clubmans) 500 c.c. Clubmans)
Gold Star 500 c.c. Clubmans
Part No.
42-5548
42-5549
42-5586
42 -5587
Description
Front wheel tomplete (la, brake and tyre) (\\''.\11 -19 steel ri1n) ... ... . ... ... . ..
front wheel complete (less brake and tyre) (\\"~II 19 light alloy rim) ... .. . . ..
Front wheel complete (less brake ~nd ty~l {\\'M2 19 steel nm) ... ... ... ... .
Front whttl complete (l~s brake and lyre) (\\''.\t2 19 alloy rim)
67-5566 42-5550 42-5551 42-5588 42-5589 67-5561
... Front hub 1tpindle Front wheel rim (\\'~t I 19 steel) Front wheel rim (\\'~tl- 19 light all•>)'I Front wheel rim (W~l2- 19 steel) Front whttl nm (W~l2-19 alloy Front hub be.i.ring lock ring. (nearside) .. " Front hub bearing oil ret.1.1nmg w,usher (near,1de) Front hub bearing . . _. .. . _ .. .. .
67 5563 65-5883 ... 35-701 42-5569
Front hub bcanng lock rmf:t retaining pm , •. l-"'ront hub complete with bearings, lock ring:,, ~pi1ldle sltt\/e
and oil retammg washers Front hub spindle slee\·e Front brake shoe complete .front brake s.hoe lining •..
67 5565 42-5564 42-5566 67 5564 42-5567 32. 194
.. Front hub bearing oil ret.1.ining WJ.~her (off&ide)
67 5578 67 5577
... 24 5860 ...
... JS-716 JS-541 28-2080 65-5907 15-431 2-440
66-4708 2-2527
t-'ront bra.kc cam ... Front brake anchor strap bolt Frunt. brake anchor strap Front brake anchor atrap stud Front brake anchor strap stud locknut Front brake anchor strap washer (spnng) Front brake anchor ,trap nut ... Front brake cam grease nipple Front bra.kc operating lever ... Front brake cam washer (plain) Front brake cam nut ... Front brake cam was.her (shakeproof) ... Front brake fulcrum and adJuStcr atrap nut ...
... 35-37 25 6014 42~560 67-5562 42-5562 35-6440 67-5575 42-5558 42-5557 27-6810 42-5552
... Front brake fulcrum and adJUlter stop washer (spnng) Front brake and adjuster itop washer (plam) Front brake anchor plate ... .. . Front hub bearmg lock ring _(offside) .. . Front bnke fulcrum and adJuster stop Front brake shoe spnng Brake shoe lining nvct •.. Front hub and br.ike drum dowel Front hub and brake drunl ecrcw Front whttl spoke nipple Front wheel spoke ...
35
Number per tet
I I I I I I I 2
Xumber per -set
I I I I I I I I 2 I
I I
~- 8B.J'jl~1 I I •
20 5 5
40 40
Plate 10 FRONT HUB and WHEEL FITTINGS (190mm. Brake) Gold Star 500c.c. C.tubmans -
• ..
36
•
Plate 11
Plate Rel. Number
l 2 3 4 5 6 7 8 9
10 II 12 13 13 14 15 16 17 18 19 20 21 21 21 21 21 22
23 24 25 26 27 28 29 so 31 31
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
REAR HUB and WHEEL FITTINGS
Model
500 c.c. {Ctubmant) 500 c.c. (Clubman1) 500 c.c. (Clubman.!1) 500 c.c. (Clubmans) 500 c.c. (Scrambles)
.S00 CC, 500 c.c. 500 c.c. 500.c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
500 c.c. {Clubmans) 500 c.c. (Suamblc,)
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
500 c .c. (Clubmruu) 500 c.e. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Scrambles)
500 c.c. 500 e.c. {Clubmans)
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Clubmans) 500 c.c. (Clubma.ns)
500 c.c. 500 c.e. 500 c.c. 500 c.e. 500 c.c. 500 c.c. 500 c.c. 500 c.c. soo c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c
Cold Star 500 c.c. Clubmans and Scrambles
Part No. 1)('51..:ription Num~r per set
Hear wheel cumpl~tc (l(.".';i. hrakc :rnd tyre) (\\'M:? 19) (~tccl) I Kear whe-ct co1111•lclc {II!""-'< br,tkc and l)'rl.:) (\\\I'.! l~J (alloy) ,u trfd. Rear wheel complete (b-. brake and t)'tt) (W~t2 18) (~Leri) as mpl. Rt.•ar whee-I wmplctc fie~ hr~,kc ;md tyre) (W)l2 18) (,,lloy) as rrqd.
42 60CH 67 ~ 177 42 6007 42 -6009 42 6001 2-440
66-4708
Hear wh<'el ,:omplcte (le,.'4 hmk1: and t)·re) (\\')13 19) (sLeelJ I ... H...-ar hrake op1:r;.1t111g lc.•\·cr nul •. I
1$-431 65 5674 21 431
Z-833 42 6036 35-698 42~37 42 6034 35 6436 65-5941
... 42-9034 42-9033 65-5883 67-6033 67-6034 67-6030 42-6019 65-5885 27-6810 42-63-06 65-6308
l{e.tr hr.,ke uperatmg len;r ,, ,,sher {!!,ht1ke1>roof) 1 Rear brake operating lc,·er wa..ffler (plain) ... J C.',un l>canng 011 hole chp I .\1lc,;hor ,tr.tJ> OOJt nut .. , •• I .\nchor ~trap bolt was.ht-r '(,plam) 1 Hear br;ike t1"4,;hnr :.tr-1)) I .\nchor .,tr.ip IK1lt :.pht pin '"-' I Rear brake anchor -.tr.tp bull I Rear brnke cam ... ... t Brake shoe lining n\·et .. . 14 Brake !'.hoc lining . .• 2 Ttanj1nts.Mon \:ham (re.lr) I Tran!3m111:,ion cham (ttar) 1 He.u hub b,111 lte;u•inK •. . 1 Hub ball jm1rn,ll shim I Retaming sprin,K rin~ 1 Rear brake drum hearing slce\·c 1 l)n\·mg flange .. .. I Hut, 00.llracc rcl.;unmg rmg I He.ar wheel llJ)Ok<' mpplc -IU Hear wheel nm (\\')12 H:I) I Hear wheel nm(\\ \I:! -IH) (all1,yl ... as rtqd
.. 42 6008 42~10 42-6002 67-6017 42-601 I 28-2080 67 6136 65 5883 GS -51!87 65 5886 67~133 65-5890 67-6028 67-6016 42-6012
Rear wheel rim (\\'~11 18) (,tl'l·l) ... ,u m1d •• Rear wheel rim (\\'~12 IK) (alto)·) ... as uqd
Rear wheel run (\\"~l:J 19j (,tc-clj I Rear whttl spoke {ne,lr.ulc) :!O Rear whc,cl ,pc,kc (nc.ir,,;1dc) (fur \\ \I:! 18 ,tccl rim) :!O Rear hub gre.,se nipple • , I
.,. Rear hub shell \,:ompk·tl' "1th ltc•.irini,:, l N.ear hub ball bc:iring . . . I 1:elt wn-;her ret.uning rmg I Rear huh wa.sher f(dt.J .. I
... End cover I
... 42-SSIS
67~161 ... 67 6051
67-60'27
Hub spmdle dl-<iL1n,e .,·oll.1t I Hub spindle di!o.t,1n1,:e ... 1<'\~\'c I R<'ilr wheel spoke (ufhtd(') :!0 Rear wheel ,poke (ufh1dc) {fur W\I:! IK ,tt.'f"I nmt . . :!O Rear whttl nipple ww,hcr (for \\'~It IK .Uld W)J:! 1H .tlloy
rim) . Hear huh ;,.pm<lle Huh ~hell w.;1.!!>her (ruhherJ Huh ,pindle -.;Jee\ c Huh lx·:uing thru ... t w,1,hcr 65 588-1
65 5883 67-6038 67 6031
... Rear hub hall bcarin,g Brake drum securing bolt
40 l I I I I 6 I l 3 6 2
42 6018 67 6039
2-452 65 5904 65 5940 42 6033 67 6032 ... 42 6030 65 5111 ... 24 7000 67-6().J6 42-6046
... 42--6045 30-729
Rc.ar hub :.pmdle nnt ... .. . . .. Rear brake drum .md chainwhecl (46T) Brake drum OOlt 101.:kmg t-.tnp ..• Hear wh('('I M!C;:unn,t holt Rear hr;,41ke !ipru\g •• Hear br.lke ,hoe complete Hear brake fulcrum pin Rear huh collar ... . .. Kear brake ~·o\'Cr plate complete with fixed fittings Rear brake fulcrum pm w,u,her (spring) Rear brake luk:rum pm nut Rear hrnke outrigger 5trap Brake pedal return 'lpnng l(ear l>rake t.peral1nl( le,·er lh ... .i.r bra,r;.e fulcrum pin wd:,her (plain)
2
Plate 11 REAR HUB and WHEEL FITTINGS Gold Star 500c.c. Clubm.an8 and Scrambles
= ~ 1
!:! .,, .. .. .. .., ..
~
~------f -::!------~------<i
.., N
~ N .., .,,
N
.e ~ N
"
38
• - Plate 12 Mudguards, Chainguard, Oil T ank, Silencer, Rear Brake Control
Gold Star S00 c.c. Clubmans and Scrambles
Plate Ref. Number
I 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 zo 21 21? 23
24 25 26 27 27 28 29 30
31 32 33 34 34 35 35 36 36 37 38 39 40 40 41 42 42 43 44 45 46 47 48 •9 50 SI 52 53 54 55 56 57 58 59 60 61 62 63
Model
500 c.c. 500 c.c. SOOc.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c 500 c.c. 500 c.c. 500 c.c. 500 c.c, 500 c:.c. 500 c.c.
500 c.e. (Clubmans} 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
SOO c..c. (Scramble,) 500 c.c. (Scrambles) 500 c.c. (Clubmans) 500 c.c. ~Clubman.s) 500 c.c. (Clubman.s) 500 c.c. {Clubmans) 500 c.c. (Clubmans) 500 c.c. {Clubmans) 500 c.c. (Scrambles) 500 c.c. (S<rambl,.) 500 c.c. (s«ambles) 500 c.c. (Scrambles} 500 c.c. (Clubmans)
500 c.c. 500 c.c. SOOc.c.
500 c.c.(Clubmant) 500 c.c. (Scrambles) 500 c.c. (Clubmana} 500 c.c. (Sa-ambles) 500 c.c. {Clubmans) 500 c.c. (Scrambles)
500 c.c. 500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. {Clubmans)
500 c.c. SOO c.c. (Clubmans) 500 c.c. (Seramble:s)
500 c.c. 500 c.c.
500 e.e. (Clubman1} 500 e.c. 500 c.c. 500 c.c. soo e.c. 500 C,C, 500 c.e. 500 c.c. 500 c.e. 500 c.c. 500 c.c. 500 c.c. soo c.c. 500 c.c. 500 c.c. SOOc.e. 500 c.e. 500 c.c. 500 c.c.
Part No.
42-7705 2 353 2-923
42-7703 2-•9
24--8784 2-•9
24-8784 3-353
. .. 24--8784 2-46
36-382 42-7012 42-7005 2-143 2-510
42 7011 2-2395
29-541 2-1096
H~7354 2-923 2 1934 2-370 2-923
36-382 2-1616
42-oSI0 . .. 65..()612
24 8784 2-1616 2-1462
29-541 2-2395 2-49
36-J8',? 42-oSII 42-6505
... 64--605• 3-1156
42~10 65-6612 2-2395 2-1462
. .. 27--8560
... 656576 65--6576 67-6546 42-o.509 42-o503 27-8560
2 204 3-1156
42-8426 42-8343 42-8367 67-•2
... 65 8500
Description Number per set
Hear chainguard .. .•. ... I (hainguard fh:1ng bolt (short) ..• 2 Chamguard fixing bolt wa.sher (plam) 2 Chamguard d•~tanec tube {s.hort) I Cha.mguard fixing bolt nut ... I
... Chainguard fixing bolt washer (spring) l Chainguard long fix ing bolt nut ... l Chainguard fixing bolt was.her (sprang) t Chamguard fixing bolt (short) ... •.. 2 Cha.inguard short fixing bolt washer (spring) 2 Brake ptdal fulcrum pin dut . .. I Brake pedal fulcrnm pin tab washer ... I Brake ped:al fulcrum pin ... .... ... ... ... I Brake pedal with adjuster screw complete. (rear pcmtton footrest~} I Brake rod toggle end screw nut •··· I
. .. Brake rod toggle end &crew I Brake ptdal ad1uster screw I Brake ptdal adJuster screw nut I Brake pedal adJuster screw washer I Brake pedal .ad1uster screw washer {plain} 1 Front and rear stay bolt 3 Front and rear stay bolt washer -I Mudguard front stay bolt (offside) ... ... I Mudguard front stay distance piece (ofts1de) 1 Front $Uly washer (plain} . . . •. . . .• -I Front stay wall.her (shakeproof) 4 Front stay locknut .. . 4 Mudguard bottom stay ... I Mudguard bottom stay ... I Stay bolt washer (spring) 4 Front and rear stay locknut •.. 4
... Mud,cu.1rd fi.iung screw wuher (spring) 6 Mudguard fixing s«ew washer (shakeproof) ..• 6 Mudguard fixing screw nut 6 Centre stay bolt nut ... ... ... 4 Centre stay bolt washer ($hakeproof) . .. 4 Mudguard centre stay I Mudguard centre stay I Centre stay bolt 2 Centre stay bolt 4 Mudguard top stay ... I Mudguard top stay . .. ... I Front number plate fixmg stud nut 2 F,ont number plate fixong stud washer 2 Front numbe.r plate fixing stud washer 2 Front num~r plate ... ot .-q,J 1-·.ront num~r plate t \ludguard bridge and stay insulator 6 Front mudguard with fixed fittings I Front mudguard with fixed fittmgs . .. l Mudguard fixing screw washer {plain) · 6 Mudguard fixing screw •.. 6 Centre stay bolt (nearside) 2 Oil tank filter ... I Oil tank filter washer ... I Oil tank ... ... •.. I 01J tank filler cap washer I
... 42-8341 ... 29-5239
011 tank filler cap .•. 1 Oil tank top and front mounhng p.td ... 3 Oil tank top fixing bolt... I
2 537 .. 42--8339
42--8331 15-203 42--8340 42-&185
.. 42-8341 2 537 2-49
42--8329 42-3331
Oil tink top fixing bolt washer (plain) 1 Otl tank top fixi.ng bolt distance tube I OJI tank top fixing bolt spacmg tube ... ... I Rocker €~ pipe b,1.njo wuher (bottom} (fibre) I Roeker feed pipe banJO locknut 1 Oil tank 6xmg bolt •.. ... ... I Oil tank top fix ing bolt mounting pad (rubbtr) 2 Oil ta.nk top fix.mg bolt washer {plai.n) 1 Od tank top fixing bolt nut I Oil tank front fixing bolt saddle washer I Oil tank front fixing bolt spacing tube I
39
Plate 12-contd. Mudguards, Chainguard, Oil Tank, Silencer, Rear Brake Control Gold Star 500 c.c. Clubmaoe and Scrambles
Plate Ref. Number
64 65 66 67 68 69 70 71 72 73 74 75 76 77
78
79
80 81 82 83 84 85 66 87 88 89 90 91 91
~ ¥ rs 1.f.).-6f') /94 _..-....,_ 94
~ l-- e,y,? ;~
p,: e/-.,~ J!,t;;rr
PJ.f'e-
97 98 99
100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126
, ..
Model
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
SOO c.c. (Scrambles) 500 c.c. {Scrambles)
500 c.c. 500 c.c. (Clubmans) 500 c.c. (Clubmans} 500 c.c. (Clubmans) 500 c.c. {Scrambles)
Part No.
42-8330 42-8341
2-537 2-49
42-8422 1~7161 27-8560
... 42-8351 67-6887 67-6851 67-6839 .. . 42-6845 .. .
500 e,c, {Clubma.m) .. . .. 500 c.c. (Clubmans)
42,,2896 2-522
500 c.c. (Clubmans}
500 c.c. (Clubmans}
500 c:.c. (Clubmans) 500 c.c. (Clubmans} 500 c.c. (Clubmans)
500 e.c. 500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.c. (Serambtes) 500 c.c. (Scrambles) 500 c.c. (Scrambles)
500 c.c. 500 c.c.
500 c.c. (Scrambles) 500 c.c. {Scrambles)
500 c.c. 500 e.e. (Seramblcs)
500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Clubmans} 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.e. (Clubmans) 500 c.c. (Scrambles} 500 c.c. (Sc.rambles} 500 c.c. (Sc-rambles} 500 e.c. (Scrambles) 500 e.c. !Scrambles) .500 c.e. Scrambles)
500 c.c. 500 c.e. .500 c.c. 500 c.c.
500 e.e~Ctubmans) 500 e.e. Clubman5) 500 e.c. Clubmans} 500 e.e. Clubmans) 500 c.e. Clubmans} 500 e.c. Clubman.s)
e.e. 500 c.e. 500 c.e. 500 c.c. 500 c.c. 500 c.e. 500 e.e. 500 e.e.
2-449
2-803
27-8560 2-220 Z-1462
24-6770 2-49
2Hl784 2-1462 Z-2395
42-6832 2-49
36-382 42-6846 42-6848 42-8422 42-6785 ... 42-6761 42-6762 Z-923
67-8313 24-8784 28-2338 2-449 Z-522
42-2935 2-803 Z-204
27-8560 42-6782 42-6759 2-1462 2-2395 2-46 Z-522
30-196 67-4032 ... 24-7343 29-541 2-2395
24-7343 29-541 Z-2395
29-7368 ~4 1~1312 Z-2395
42-7007 33-4089
2-923 42-7703
Descripti.on
Oil tank front fixing bolt bracket cup ... Oil tank front 6.xmg bolt mountmg pad (rubber} Oil tank front foung bolt washer (plain) Oil tank front fixing bolt nut ... ... Oil return ptpe ... Mudguard securing screw ... Mudguard securing nut was.her Otl tank fixing bracket ... Rear number plate Rear number plate rubber extrusion Rear mudguard wii-ing grommet Rear mudguard with fixed fittings Silencer ... ... -· .•. ... ... Silencer 6.xmg bracket washer (Sl>nng) (when pillion ...
footrest is not fitted) ... ... ~lenccr fixing bracket bolt nut (when pillion footrests are not
fitted) ... ... ... ... ... ... Silencer fixing brncket bolt (when pillion footrests are not
fitted) ... ... ... Rear number plate fixing bolt washer Rear number plate fixing bolt ... ... ... Re.a.r number plate fixing bolt washer (spring) Mudguard stay bolt ... Mudguard stay bolt nut... Mudguard stay bolt washer Mudguard securing nut washer Mudguard securing nut ... .. . Mudguard bridge ... ... • .. Mudgua.rd bracket and stay bolt nut •.. Mudguard stay brieket bolt washer ... Re.tr mudguard stay !offside) •.. Rear mudguard stay ncanide} Oil Iced pipe .. . ... .. . Rear mudguard 6xing clip ... Rear mudguard suy bracket (offside} Rear mudguard stay bracket (nearside) Mudguard bracket bolt was.her Mudguard bracket to frame bolt Mudguard braeket to frame bolt washer Mudguard braclcet and stay bolt ... Exhaust pipe extension braeket bolt nut .. . Exhaust pipe extension bracket bolt was.her .. . Exhaust pipe extension ... ... . .. . .. Exhaust pipe extension bracket bolt ... ... Mudguard stiffening plate and fixing clip bolt Mudguard stiffening plate and fixing bolt washer Mudguard clip stiffening plate ... ... . .. Rear mudguard fixing clip .. . Rear mudguard fudng clip wuber Rear mudguard fixing clip nut R~ brake pedal fulcrum pin nut Rear brake pedal washer (spring) Rear brake pedal &tud washer ... Rea.r brJ.ke pedal stud . . . . .. Exhaust pipe and extension bolt Exhaust pipe and extension bolt washer Exhau.st pipe and extension bolt nut .. . Silencer and extension pipe bolt .. . Silencer and extension pipe bolt washer Silencer and txtension pipe bolt nut Rear brake. adjuster nut Rear brake lever swivel pi.n Rear brake rod spring •.. Rear brake rod spring nut Rear brake rod . .. • .. Cbainguard fixing bolt {long) ... Chainguard fixing bolt washer •.. Cbaingua1d distance tube (short)
40
Number per .. t
I I I 1 I 5 9 I 1 I z 1 I
I
• 4 4 • 8
10 9 9 1 4 4 I I 1 I I I 4 2 2 4 I 1 I I 4 4 2 1 4 4 I 1 I 1 I I 1 1 I I 1 1 I I I I I 1
• Plate 12 Mud~uards, Chain~uard, Oil Tank, Silencer, Rear Brake Control
Gold Star 500c.c, Clubmans and Scrambtu
41
•
Petrol Tank, Handlebar, Tool Box, Dual Seat, Mud~uards, Rear Brake Control Plate 13 C old Star 500 c.c. Clubmans and Scrambles
r Plate Rel. Number Numbor. Models. Part No. Dacnption. per set.
500 c.c. (Scrtlmbles) 42-7024 Rear brake pedal complete 2 500 c.c. {Clubmans) 24-7 148 Rear mudguard bottom bracket fixing bolt . .. 2 3 500 c.c. (Clubman.s) 42-6783 Rear mudguard bottom bracket stiffening p late I 4 500 c.c. (Clubmans) 42-6831 Rear mudguard complete with fixed fittings .. . I 5 500 c.c. (Clubmaru.) 42-6782 Rear mudguard fixing chp staffening plate , .. I 6 500 e.c. (Clubmans} 2- 1462 Rear mudguard fixing clip bolt washer {spring) 2 7 500 c.c. (Clubm,1:ns) 2- 2395 Rear mudguard fixing clip bolt nut . . . 2 8 SOO c.c. (Clubmans) 42-6834 Rear mudguard stay complete (nearside) I 8 S-00 c.c. (Clubmans) -12-6836 Rear mudguard stay complete (offside) I 9 500 c.c. (Clubmans) 42 6832 Re.-r mudguard bridge (bottom) .. , I
10 500 c.c. (Clubmans} 42-68.19 Rear mudguird tail lamp wiring grommet 2 II 500 c.c. (Ch.1bmans} 42-6832 .Rear mudguard tfridge (top) I 12 500 (:.(:. 24- ~ Duaheat rear SUJ,>J>Ort bridge bolt nut 2 13 500 c.c. 42- 9061 Dual scat rtar fix mg bolt ' ... .. . 2 14 500 c.c. 2- 923 Dut1l l\eat rear fixing bolt washer {plain) 2 15 500 c.c. 3&-33 Dunl seat rear fixi1,g bolt washer (spring) 2 16 500 c.c. U-8784 ... Dual seat rear support bridge bolt w.-sher (spring} . .. 2 17 500 c.c. 42- 9062 Dual seat rear support bracket I 18 500 e.e . 2-923 Dual 5t'at rear support bridge bolt washer (plain) . .. 2 19 500 c.c. 28-2338 Dual &tat rear impport bridge bolt 2 20 500 c.c. 42-9069 Dual 5eat oomp1ctc with br.t-ckcbl I
500 c.c. 42-9068 Dual seat loose fittings only {set} I 500 c.c. 42-9095 Racing seat (Ferida.x) ... ... a.s 'Uld. 500 e.c. 42-9178 Front fixing clip . .. . .. • •• OJ rtqd. 500 c.c. 21- 5668 Front fix mg clip bolt .. . .. . as reqd. 500 c.c. 66-8348 Front fixing chp distance piece ... as uqd
21 500 c.c. (Scrambles) 6&-850 1 Throttle control twist gnp complete (less cable and cover) ... I 22 500 c.c. (Scrambles) 42-$64 Front brake control complete (less cable and oover) I 23 500 c.c. 42-80!0 Petro. tank rubber grommet ... I 24 500 c.c. 42-8011 Petrol tank fixing bolt ... l 25 500 c.c. 2- 1945 Petrol tank fix ing bolt washer I 26 500 c.c. 42-80 12 Petrol tank mounting rubber (top) I 27 500 c.c. (Clubman!i) 42-8107 Petrol tank (4 gallons) ... I -27 500 c.c. (Clubmans) 42-8090 Petrol tank (5 gallons) ... . •• os ,eqd 27 500 c .c. (Scrambles) 42-8056 Petrol tank (2 gallons) ... ... . .. I 27 SOO c.c. (Scrambles) 42-8055 Petrol tank with filler cap (alloy) (2 gallons) ... '" reqd. 28 500 c.c. 3&-707 Petrol filler cap spht pin I 29 500 c.c. 66-8351 .. . Petrol filler cap .. . . .. I 30 500 c.c . (5<:rombl<S) 65-8675 Front brake cable and cove.r I 3 1 500 c e . (5<:rambles) 65-4960 Handlebar I 32 500 c.c. (Scrambles) 42-8638 Air control cable and cover I 33 500 c.c. (Scrambles) ... 42-8628 Throttle cable and cover I 34 500 c.c. (Scrambles) 66-8896 Air control complete {less cable and cover} I 35 500 c.c. (Scrambles) 65-8714 Ignition control cable and oover I 36 500 c.e . (Scrambl<S) 66-8810 Igmbon control (less cable and cover} I 37 500 c.c. (Scrambles) 65- 8502 Dumm)' gnp (left.hand bar) ... ..• . .. I 38 500 c.c. lSc.rambles) 42-8684 Clutch control complete (less cable and cover} I 39 500 c.c. Scrambles) 42-861 1 Exhaust control complete (less cable and cover} I 40 500 c.c. (Scrambles} 42-8620 Exhaust control cable and co,•er I 4 1 500 c.c. (Scrambles) 65-8680 Clutch control cable and cover I 42 500 c.c. 27-8346 Petrol tank breather pipe union screw I 43 500 c.c. 65-8362 Petrol tank breather p ipe complete I 44 500 c.c. 42-8034 Petrol tank badge clip screw nut 4 45 500 c.c. 42-8020 Petrol tank badge clip . .. 2 46 500 c.c. 65-8193 Petrol tank badge ... 2 41 500 c.c. 65-83 17 Petrol tank badge clip $C1'ew . .. • 48 SOO c.c. {Clubmans) 42-9038 Toolbox com~lete with lid • 49 500 c.c. (Clubmans} 29-4329 Toolbox top xmg bolt . .. I so 500 c.c. (Clubmans) 24-8784 Toolbox top fixing bolt washer I 5 1 5-00 c,c. (Clubmans} 42-8339 Toolbox top fixing bolt distance tube 2 52 5-00 c.c. 42-8052 Petrol tank mounting rubber (anti-roll) 2 53 500 e.c. 42-8051 Petrol tank ffl llUnting rubber (top tube) I 54 soo c.c. 67-8085 Petrol tank stiffening plate 2 54 500 c.c. (Clubmans) 42-8091 Petrol tank stdlenmg plate (5 gallon tank) I
500 c.c. (Clubmans) 64- 74 Petrol tank stiffening plate stud (5 gallon tank) 2 55 500 c.c. 2-923 Petrol tank stiffening plate w'-Sher 2 56 500 c.c. 36-382 Petrol tank stiffening plate washer 2 57 500 c.e . 2-49 Petrol tank stiffening plate stud nut 2 58 500 c.c. (Clubma.ns) 27-5676 Toolbox top fixing bolt washer I 59 500 c.c. (Clubmans) 2-•9 Tool box t.op fixing bolt nut I
42
Plate 13 Petrol Tank, Handlebar, Toolbox, Dual Seat, Mudguards, Rear Brake Control Cold Star S00c.c. Clubmans and Se:rambles
•3
Petrol Tank, Handlebar, Tool Box, Dual Seat, Mudguards, Rear Brake Control Plate 13-eonliNlltd Cold S tar S00 c.c. C lubmans a nd Scr .lmb lete
Plate Her. Number
~umber )lodel Part Xo. Descnpbon per set
AA 500 c.c. 27-8443 Petrol tank 6itcr 1 f,( 500 c.c. (Scrambles) 24-8504 Petrol tank filter washer (fibre) 1 61 500 c.c. (<.."lubmans) 2-1-8504 Petrol tank tilter washer (fibre) 2 62 500 c.c. (Oubmans) 25-7151 Float chaml>er flexible mountmg bolt nut 2 63 500 c.c, (tlubmans) 24-7068 Float chamber flexible mounting bolt w3.$her 2 64 500 c.c. (<.:lubmnns) 1-1621 Float chamber flexible mountfog bolt washer 2 65 500 c.c. (Clubmnns} 2 370 Float chamber mountmg bracket washer 2 (l(; 500 c.c. (Clubman&) 2-49 Float chamber mounting brncket nut 2
67 500 c.c. 42-9060 DuaJ &cat front support pin 1 fi~ 500 c.c. ... 15-&15 ... Dual seat front support Cin securing bolt 1 6'l 5-00 c.c. 4:1-9058 Dual :seat front support racket ... 1 70 500 c.c. <2-9057 Dual seat front support rubber 2 71 500 c.c. 35-33 Dual seat front fixing bolt washer 2 1'! 500 C.C, 2-9'13 ... Dual seat front tiupport bolt 'b'asher 2 n 500<.e. ... 28-2338 Dual scat front fixing bolt 2 74 500 c.c. {Clubmans) ... 29-8814 Float chamber flexible mounting bolt nut 1 75 500 c.c, {Clubmans) 1-1606 Float chamber flexible mounhng bolt 2 76 500 c.c. (Clubmans} :1-204 Rear mudguard fix ing clip bolt 2 77 500 c.c. (Clubmans) :1-525 Rear mudguard fixing clip washer 2 7K 500 t:.c. (Clubma.n111) 42-6759 Rear mudguard fixing clip 1 7S 500 c.c. (Clubmans) 42-8068 Float chamber :support bracket adaptor 1 I<() 500 c.c. (Clubmans) 42-6833 Rear mud,gl1ard bottom b racket 1 ij I 500 c.c. (Uubmans) 24-8784 Mud.guard bottom bracket washer 2 ll'1 500 c.c. (Clubmans) 2-49 Mudguard bottom bracket bolt nut . .. 2 8.1 500 c.c. (Clubmans) 15 7354 Mudguard bottom bracket fra.me fixing bolt ... 2 K4 500 c.c. (Clubman!!I) 2-I--.S784 Mudguard bottom bracket frame fixing washer 2 g,, 500 c.c. (Clubinan.s) 2-49 ... Mudguard bottom bracket frame fixing nut ... 2 ij6 500 c.c. (Oubman<i) 42-8069 Float chamber flex ible mounting bolt .•. 1 87 500 c.c. (Clubmans) ~7518 ... Float chamber mounting bolt washer (fibre) 1 &I 500 c.c. (Oubm:ms) ... 21 5202 Float chamber mounting bolt nut 3 ~9 500 c.c. (<.:lubmans) 42..S033 Float chamber flexible mounting l
90 500 c.c. ((lubmans) 29-881• Float chamber flexible mounting bolt nut 1 SI 500 c.c. (flubmans) -12 8066 Float chamber mounting bracket (left•hand) l 91 500 c.c. (Oul,mans) 42--8067 I:'Joat chamber mounting bricket (nght•h and) 1 9'! 500 c.c. {Scrambles) 65-8171 J>etrol tap 1 W! 500 c.c. (<.:lubmans) 65-8 171 Petrol tap (twin feed) .. . 2 ~:l 500 c.c. 2-930 Petrol tap washer (6bre) ... 2 S4 500 c.c. (OuUmans) 2 370 Flo:lt chamber molmtmg bracket fixing bolt washer 1 S5 500 c.c. (C.:h1hmans) 32-194 Float chamber mounting bracket fixing bolt 2 9~ 500 c.c. (C..:lubmnns) 2-49 Toolbox fixing stud nut 2 97 500 c.c. ((lubmans) 24-878-1 Toolbox fixing stud washer 2 9~ 500 C,c. (Clubmans) 65-5368 Toolbox fixing stud 2 119 500 c.c. (Clubnums) 42-8025 Copper petrol pipe complete 1
IOU SOO c_c. (Clubmans) 66-8332 ... Copper petrol pipe nut , .. 1 IUl 500 c.c. (Uubman8) 42 8024 Petrol pipe hose clip 2 102 500 c:.e. (Clubmans) ... 42-8023 Ftex,ble petrol pipe (plastic) (float chamber to carburetter) 1 10~ 500 c.c. (~rambles) ... 4'.!-8076 Flexible petrol pipe . . . • •• 1 1(),1 500 c.c. {Oubmans) ... 42-8022 Flexible petrol pipe (tank to float chamber} .. . 2 I0-1 500 c.c. (Clubmans} 42-809.t Flexible petrol pipe (5 gallon tank) 1
Plate 14 HANDLEBARS, HANDRAIL & OIL TANK (Central Fitting)
Plnte Hef Xumbcr
1 2 3 4 5 6 7 8 9
10
)(odel
500 c.c. (t'lubmans} 500 c.c. (Clubmanst 500 c.c. (Uubmans) 500 c.c. (Clubman.:,;) 500 c.c. (Uubmanis) 500 c.c. (Clubman.s) 500 c.c. ((lulJman,) 500 c.c. (Clubman9) 500 c.c. (Ch1l,imaru.) 500 c.c. (Clubmans)
Gold Star 500 c.c. C lubmans and Scntmble.s
Part Xo.
42-8685 42-8680
11esc:ription
Clutch control le\"cr (two piece handletxi.r)
65 8714 ... th1tch control cable and cover (two piece handlebar ) Ignition control cable and cover (two piece hand lebar) Handlebar {nearside} .• 42-'970
65--8502 -12--861 I 42--86211 42.8615 42-8635 4'1 -1972
llummy grip .•. ... £xhau~t contTOI (less cable and cover)(two piece ha ndlebar}
Exhat1:st control cable and cover (two piece handlebar) Ignition control (less cable and cover (two piece handlebar) Air control cable and cover (two p iece h;;rndlebar ) Handlebar (ofb1de) .. . ... . .. . ..
Number per set
1 l 1 I 1 I 1 I 1 1
-
Plate 14 HANDLEBARS, HANDRAIL and OIL TANK (Central Fitting)
1bll >. 1~
1•1
1
i' •" . ',,-:.u ,-.. • ·. \ \ . ,, ,\ \ ••
.. "' ..
Gold Star 500c.c. Clubman1 and Se:ra.mblH
-~ ~
,0 ;i\
.,
•
Plate 14-continued HANDLEBARS, HANDRAIL & OIL TANK (Central Fitting)
Plate Ref. Number.
I I 12 13 14 15
16
17 18
19 20
2 1 22
23 24 25 2G 27 28 29 30
31
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 S I 52 53 54
Model.
500 c.c. (Clubmans) 500 c.c. (Clubman.s) 500 c.c. (Clubma.ns) 500 c.c. (Clubmans) 500 c.c. (Clubmans)
500 c.c. {Clubmans)
500 c..c. (Clubmans} 500 c.c., {Clubmans)
500 c.c. (Clubmans) 500 c.c. {Clubmans)
500 c.c. (Clubmans) 500 c.c. {Clubmans) 500 c.c. (Clubmans) 500 c.c. {Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans} 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.e. {Clubmans) 500 c.c. (Clubmans) 500 c.c. (ClubmanA) 500 c.c. {Clubman.s)
500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubinan.s) SOO c.c. (Clubmans)
500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubinans) 500 c.c. (Clubmans) 500 c.e. (Clubmaru,) 500 c.c. {Clubmans) 500 c.c. (Clubmans) 500 c.c. (Scntmblcs) 500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.c. (Scnmbles) 500 c.c. (Sc,amblcs) 500 c.c. (Scrambles} 500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 C.c. (Scrambles} 500 e.c. (Sc,amble•) 500 c.c. (Scrambles) 500 c.c. (Scrambles) 500 c.c. (Scrambl .. ) 500 c.c. (Sc,ambles)
Cold Star SOO c.c. Clubmans and Sc.rambles
Part No.
66-a896 42-8622 42-8625 42-8600 -29
29-8613
. .• 42-8665 42-8678
29-138 14 65-8501
42-• . .. 42-8650
29-8811 42-8665 2!)..8813 29-8814 2-1500
66-8896 42-8720 42-8717 42-4968 GS-8717 66-8810 65-8502 42-8684
42-8685 42-8714 29-8813 2!)..8814 2-1500
42-8610
42-86 19 65-8684
. .. 24-6770 2-9"..J
36-382 2-49
42-9 173 28-2338 42-8408 2~1 2-100
42-8409 2-2395
27-&560 29-1664 42-8431 42-8391 42-8433 42-8436 65-&500 29-7971
. .. 29-7962 67-42
Description.
Air control lever (less cable and cover) (two pte<:e handlebar) Throttle twist gnp (less cable and cover (two piece handlcba.r) Throttle cable and cover (two p1oce handlebar) Front brake cable and cover (two piece handlebar) Front brake and clutch cable adjusting spring (two piece
handlebar) Front brake and clutch control lever screw (two piece bandle-
ba•) Front brake control lever (two p1ece handlebar} Front brake and •clutch cable nipple adaptor (two piece
handlebar) .. ~ ... .•. .. . ... .•. . . . Front brake and clutch lever screw nut (two piece handlebar) Throttle twist grip (less cable- and cover) (Western type
handlebar) Front brake lever complete (Western type handlebar}
.. , Front brake cable and cover (Western type handlebar)
... Front brake control body (Western type handlebar} Front brake lever only (Western type handlebar} .. . front brake control screw (Western type handlebar) rtont brake control nut (\\'C5tccn type handlebar) , , . Front brake control body screw (Western type handleb.1.r) Air control {less cable and cover) (Western type handlebar) Throttle cable and cover {Western type handlebar) Air control cable and cover {Western type handlebar) Handlebar (Western type handlebar) Ignition control cable and cove.r (Western type handlebar) lgnit10n control lever (Western type handlebar) Dummy grip (We.stem type handlebar) Clutch control lever coinplete (less cable and cover) (Western
type handlebar-) Clutch control lever only (WC$tern type handlebar) Clutch control body Clutch control lever screw (Western type handlebar) Clutch control lever- nut {We:.tern type h.l.ndlebar ) .. . Clutch control lever bOdy screw (Western type ltt1ndlebar) Exhaust control complete (less cable and cover) (Western
type handlet,a,) Exhaust lifter cable and cover (WC$tern type handlebar) Clutch cable and cover {Western type handlebar) Handrail mudguard bolt Handrail mudguard bolt washer Handrail mudguard bolt washer • ... Handrail mudguard bolt nut Dual seat bandrad Handrail mudguard stay bolt Oil return pipe Oll tank drain plug Oil tank drain plug washer OH tank base sponge rubber Oil tank strap pin nut . .. Oil tank strap pin nut washer (plain) Oil tank strap hinge pin Od tank •trap complete
. .. Oil tank with fixed fitting& Oil tank strap isponge rubber Oil tank feed pipe complete Oil tank filler cap Oil fee,d pipe banjo washer
. .. Oil ~nk filter complete ... OU ta.nk filler cap washer
46
Number per set.
I 2 2 2 2 I 2 1 I
I I I 2 I I
-
~
----
Plate 15
Plate Ref. Number
1 2 3 • 5 6 1 8 9
10 II 12 13 14 15 16 17 18 19 20 21 22 22
Plate 16
Plate Re(. Number
I 2 3 • 5 6 6 1 8 9
10 II 12 13 I• I• 16 16 16 16 17 18 18 19 20 21 :!2 22
Model
500 c.c {Clubmant) 500 c.c. (Sc-rambles)
500 c.c.. 500 c.c. 500 c.c. 500 c.c.
500 c.c. (Sc:rambl~) 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.e. 500 c.c 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c. 500 c.c.
Model
500 c.c. (Scramble.) 500 c.c. (Clubmans) 5-00 c.c. {Clubmans) 500 c.c. (Clubmans> 500 c.c. (Clubmans} 500 c.c. (Clubmans} 54'0 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmam) 500 c.c. (Clubmans) 500 c.c. (Clubman.s) 500 c.c. (Clubman.s) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans) 500 c.c. {Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmani) 500 c.c. (Clubman.,) 500 c.c. (Clubmans) 500 c.c. (Clubman1) 500 c.c. (Clubmans) 500 c.c. (ClubmansJ 500 c.c. (Clubmans) 500 c.c. (Oubman~) 500 c.c. (Clubmans) 500 c.c. (Clubman11) 500 c.c. (Clubmans) 500 c.c. (('luhmans)
TOOLS and SUNDRIES Gold S ta r 500 c.c. Clubmans and Scrambles
PMt No l>CSt:ription
65 9279 Toolba~ ('11111plt·t(' with tool, 65 !1'.ll!O Toulha.l( lOlllph . .-tl' with t1K1l!io
42 9080 l>,1mper .idJu..,tmK "lliu1ncr 65-92"7 Cylinder hoh !<ip;1nncr 65 !rl<6 ... Carburetter and lallJX'l adJusllllt( spanner 29 9251 )lagd)'no ~JMnncr 6;-9200 ... J\(\x &1'l.1nncr 29-9252 Tyre lever
I 3051 Double ended ~1>onncr 29 9257 Box spanner 66-9<•16 Rox s1>anner ..... 42 90'l6 lnflator 65 9130 Tappt,t f«-lc~ (~t.) • 29 9253 Tomnw b.-.r 29 925~ ... Combil'lation ipanncr 29-9256 ... Swmglng arm p1\'0t spindle nut '>ll.tnn1.·r 65-9133 Tapper spanner ... 65-9243 C:ombmtd spanner 42-9031 .. . Petrol u1nk fixing boll spannC'r 65 9248 SparkinR plug ,.-panner 65-9282 ... Tooll>ag onlr ... 65 9115 J'klx tipanncr (small) &S-9132 Tappet 3panner 24-8957 Petrol t.1nk bolt ),,panner tommy l.,ar ... 66--9049 Cable c lip {rubber)
ELECTRICAL EQUIPMENT C old Star 500 c.c. Clubmens and Scrambles
Part No.
19-1219 ... 19-704
•2-9027 ... 65-9235 19-1 114 19-1472
... 19 2012
)lagncto D1p~r swatch Stop lamp switch opei-11-t1og hnk Stop L,mp switch operating spring Stop I.amp switch Horn pusll ... Horn push ( Weatc-rn H,mdlcOOr) . . . . .. \'oltage control toolbox buffer r,-,g (rubber) .. . \"oltage CMtrol ...
42 -9012 19-1665
.. 42 9009 2-1354
.. 25 7180 2-2395 2-1309
29-3319 2-47
19 548 19 550
... Voltage control cable grommet \'oltage control secur1ng bolt ...
19 551 19 549 65 9167 19-2138 19-2139 65-9166 65 9172 19 1011
\·oltage control securing bolt a nd toolbox "ishe-r \'oltage control securing nut Stop l3mp switch screw Stop lamp s .... itch ,icrew washer (shakeprool> Stop lamp switch -.crew "nut . .. .•• • .. Headlamp (nght4 hand dip) (t.omc) Headlam)) (Con tinent.ii) ... Headl,m1p (French)
. •• Headl.am11 (\"ert1c.1I dip) Ht,· counter fr1i:illJC hr,u,;.ktt. c1,mplctc Speedometer (m J).h.) Spccdom~..c, (k.p.h.) He,· counter head He\' lnnnter rnble Stop tntl lamp ...
~ ..
65 9160 67-9057 19 1552
Spccdo cable (when re,• t..ountcr and ~JJCt.-do 1:$ fitted) Speedometer ,.:able UolUcry
47
:-.um11C'r per ""C(
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I 1 1 1 I I 1 I 1
15
Plate 15 TOOLS and SUNDRIES Cold Star SOOc.c. Ctubma.ns and Scrambles
...
; \' 1-m ~ ·.: 1 ~ .. .., 5 -! -
48
I I
-
Plate 16-continued ELECTRICAL EQUIPMENT Gold Star S00c.c. Clubmana and Scrambles
P1ate Ref. Number.
Z3 24 25 26 27 28 29 30 31 32 33 33 34 34 34 35 35 35 36 36 36 37
Model
Model
500 c.c. (Clubmans) 500 c.c. (Clubmans! 500 c.c. (Clubni.a.as 500 c.c (Clubmans 500 c.c. Clubmans! 500 c.c. Clubmans 500 c.c. Clubm.a.ns 500 c.c. Clubmarui) 500 e.c. Clubm.1.ns) 500 Cc:: (Clubmans} 500 c.c. (Clubmans 500 c.c. (Clubman1 500 c.c. (Clubmans 500 c.e. {Clubmans 500 c.c. {Clubmans 500 c.c. (Clubmans 500 c.c. (Clubmans 500 cc (Clubmans 500 c.c. (Clubmans 500 c.e. (Clubmans) 500 c.c. (Clubmans) 500 c.c. (Clubmans)
r Type
Clubman·a 500 c.e.
I T3G.P. _. -
Scrambles 500 ·c.c:- TI0G.P.
Part No. Descri;>tion.
29-92'.?1 65 9164 67-716 19-1214 65-9171 29--541
. . . Licence holder
2 ~"95 2-443 2-1462 .. 2-204
6&-9111 65-91 II 15-7383 15-7383 ... 15--7383 27-8560 27-8560 27-8560 65-9179 ... 65-9179 65--9179 42--9046
Rev counter ge.irbox ... Rev counter gearbox lixfog bolt Magdyno ... . .. Spocdo and rev counter mounting plate .. . Speedo and rev counter fixing bolt washer (shakeproof) Speedo and rev COl1ntcr fixing bolt nut Specdo and rev counter 6xio.g OOlt locknut ... Speedo and rev counter bracket washer Speedll and rev counter bracket screw Spc,e,dometer brac.ket .. . . .. Spe,edo and rev counter mounting bracket Speedo mounting rubber ... . .. Rev counter support bracket rubber ... ' Speedo and rev counter fixing bolt rubber-Speedometer mounting washer Rev counter support bracket washer ... Specdo and rev counter fixing bolt washer Speedometer bracket bolt Speedometer at1d rev counter fi, ing bolt Rev counter bracket 6xmg bolt Hom
CARBURETTER SETTINGS
Choke Size
I I nuottle
I (inch~) Main Jet Valve No. Needle Jct
I
I - ··~~ 4 . 109
I 11, 240 5 .109
PISTON CHART
Number per set.
I I 2 I I 4 4 4 2 2 I 2 4 4 9 2 2 4 2 4 /l I
Needle Position
3
3
Model I Comp. PISTONS COMPLETE COMPRESSION RING (2) SCRAPER RING
Rabo
8.0
500 c.e.
i Standard imm.O.S. I mm.O.S. Standard l mm. o.s.rlmm. o.s. Standard I mm.O.S. lmm.O.S.
I 65-2544 65-2546 65-2548 65-2266 65-2267 I 65-2268 65-2269 I 65-2270 65-2271 65-1456 65-1457 65-1458 65-2272 65-2273 65-2274
G.S. 8.5 Clubman's
8.15
65-2553 65-2555 65-2557 65-2266 65-2267 I 65-2268 65-2269 65-2270 65--2271 65-1456 65-1457 65-1458 65--2272 65-2273 65-2273
' I 6&-907 65-909 65-911 65-2266 65-2267 65-2268 65-2269 65-2270 I 65-2271 I 65-2272 65-2273 65-2274
500 c.c. 8.75 G.S. Scrambles
65-907 65-009 65-911 65-2266 65-2267 65-2268 65-2269 65-2270
I 65--2271
I 65-2272 65-2273 65-2274
Plate 16 ELECTRICAL EQUIPMENT Gold Star St>Qc.c. Clubm.ana: and Scrambles
.. l l -; ,-o ... "' I j "'
-' - - -
-~ ,n
-•
... ~ ~ 0, !:::
" " "
-
•
STANDARD BOLTS. All Bolta are C.E.I. unless otherwlae 1tatad.
1.eogth Thocknao. Ungth nder Head. of Head. of Thread. Across Flats. Diameter.
2H I · 1132• 3 16' 13/16' ,440· Hex. 1/4' 2 ~ Ir.?' 3 16' 112· ,440 Hex. .,,. .. 2-220 3 s· 3 16' 3/8' .4•0• Hex. 114• 2-135-1 641' 187' ,641• .440"' Hex. 11•· 2-1<02 .1-s· I 8' 3,,'8* .440,.. Hex. 1/4' 2-nn 1JI 5f3Z .. 3/8"' .440' Hex. 1/4' ~125 ; 187' 3/8"' .440' Hex. 1/4' 1- :!5• 187' .615"' .s2s· Hex. 5/16' 2 I 150" !25()· .625' .4•0"' Hex. 5/16' 2-1934 ;so- 156' .625' ,440" Hex. 5/16· 2-&r.?6 1187' 156' .625' .440" Hex. 5/16' 15-4AO I 109' 250" .781' .525"' Hex. 5/16' 15-1355 1 soo· .21s· .625' .525"' Hex. 5/16' 15--7354 625• 156' .625' .440"' Hex. 5/16' 27-6311 750' .125"' 625' .(40"' Wex. 5/16' !lll-2338 718' .218 .. .687' .525" Hex. 5/16' u.,uo .sr.· 187' .811' ,594• Hex. 3/8· es'=! 2.687' '.!50" .,so- ,504• Hu. 3/8'
All Bolts a.re C.£.1. (Screwdriver slotted) unleu otherwise stated.
Length Thicknes& Length Part ~o. under Head. of Head. of Thread. Across Head. Diameter.
l-lll06 _5-00• .125• .soo· .312' 3/16' 3-360 .406' .019• .406' .312' 3/16' 2-,9R . 312· .062· .312' .312' 3/)6"' Whit . 2 1309 _343• .062· .343' .312· 3/16' 2-25S"2 .343' .125• .343' .2so· 3/16' \\'ht 2.J--7065 :250• .062' .250• .312"' 3/16' 2-77 .312"' 062' .312'" .375' 1/4' 2-79 .soo· 109' .soo· .375' 1/4' JO .&56' .093' .375"' .375'" 1/4' t:'iuO bS1 .. .109' .375· .375" IW :? ~tu 11~ .. .oo:?· .56",!· ,.-li62-" 1/4" 2-,37J"- =· 109' .656· .375' 1/4" 15-7161 S,)O' 125• .3J2' .5oo· 1/4' 2-~ 1 :?.5· 93• 625 ... 56".?" 5/16'
STA.,D.'I.RD :-;t;TS. All Nuts ar': C.F:.I. unle.ss otherwise stated.
AC.TOI$$ I'bts. T1'1.kkness. Sl:tC. Part Ko. Across Flats. Thickness. Size. ~
1~nu, 341Y Hex. .162' 3/16' '.?-1Sl3 .59-4'" Hex. .218' 3/S' 5-17 12· Mex. 140- 3/16""' 3-720 .594 Hex. .187" 3/8' S-JS..~ .?.-~-.• Hex 110- 3/16' 2ai-5161 .5~"' Hex. _343• 3/8' 1-8147 = · •• 125 .. 3/16 ... 24-5764 .782• Hex. .312" 3/8' 2-7151 340• Hex 187' 3/16" 2--t40 .594"' Hf"X .312· 7/16' 2-0032 .340'" Hex 3 JR'" 1:--1'" 2-933 .525'" Hex. .375' 7/16' 2-51 . .f-10-- Hex ::s,,- 1/4 .. 2-1925 .782• Hex. . 375' 7/16 • 2-53 440'" Hex. .109· t• Whit. 15-152 .592• Hex. .406' 7/16' 2-H3 .uo· Hu. 109' 1,4'" 15--541 .782• Hu. .281' 7/16' 2-1027 340' Hex. 1,s· 1/4' 24-5860 ... .594" Hex. .187' 7/16· 12-2-'ljj5 .440'" Hu. ,187' 1/4' 25-4325 919-" Hex. .5•o· 7/16' 12-49 .525• Ha 218'" 5/16' 2-52 ·919" Hex. .406· I 2' 25-833 .440" Hu. _343• 5/16' 2-12..f ·732• Hex .203'" 112· 25-1616 .440"' Hex I2S-"' 5/16' 24-7000 '782_,, Hex. .250'" 112· (..5196 .525"' Hex .281' 5/16' 27-67 16 ·7RZ"' Hex .187' 1/2' 4-o524 .525'" Hex. 175"' 5/16' 2-835 ,919'" Hex 375• 9J/16' 1-Sf,3 •• 40'"' Hex. .187· 5/16" 15--1455 ,782"' Hex .218' / 16' 2-6040 .szs• Hex 156' 5/16' 24-4255 -919"' Hex. ,187' 9/16' 1-1706 .594'" Hex. .250• 3/~· 28-53 .782"' Hex. ,344• 9/16' 2-46 .594" Hex. .312" 3/8'
51
t
Pan Xo.
I • lt!OI 2-130 2-:no '.!-525 2-AAI '! -9"!:t ~ 109t; '.!-1:.>91 '.!-1;17.,1 '.?-1!-J-15 '.! 213.~
Part No.
2-522 2-99S 2-146'! 2-1967 2- 2903 3- 110 3-111
Part No.
29-541 29 3319 36-3•1 36-382
STANDARD WASHERS (Plaht).
Outside 1J1a. Inside Dia Thickness. Part No.
-· 385• .012· 2 2580 6117· 380' .()80· 3-3525 625"' .317"' 156' 15-39 .sou- 255"' .Q.18· 15-431 .750' 3!!0' .n,w 15-5155 .625" .311· .062' 2•-59• ;175• 19:!" 044• 2•-7911 i50"' 5,,., .. 080' 25 -7180 tl5'," .255"' 08()· 26-9•6I .~75" H2' .064' 27-5676 _750• .380' .06,r 27-856<\
STANDARD WASHERS (Sprln&).
Outer 1)1~ lnaide 0... ThKk-. Part So.
. 750' .390" =· 15-716
.656' .380' ••. . <MO .. doub!e 24-97A
.593' zss· .l\40' 2•-35 ~75• .«o· .064' 27-•3 56:r .•06' 06:! .. 23-8784 ·HI .. .2$1" .08()· 35- ~3
.614' .406' .104"
Outside Dia.
.500' .562' .843' .750' 525•
.937'
.875' 1.00' .562'
I 00' .625'
Outtt Di..,.
937• 437• 593•
.750'
.625· soo-
Inside Dia.
.275"
.218'
.sos·
.4•2'
.328'
.sos·
.31'0"
.281'
.203· :lSO' 255"
Inside Dia
.453• 255"'
.317'
.437"
.315' _343•
Th1ckncn
.064'
.Q.18· ()64' .064' .048' .092' 156' 04A•
.048'
.092'
.048"
---,,~ . -~
.. . .040' double
..•. (M6" double .O•<Y .080'
STANDARD WASHERS (Sbakeprool).
Outer rnameter. J ns.ide Diameter
112· 3/8'
9/ 16' 9/ 16'
1/4' 3/ 16' . 5/ 16' 5/ 16'
Part No.
36-399 65 -595 66-4707 66-4708
52
Outer Diameter.
11/16' 7/8'
11/16' 3/4'
Inside Diameter.
3/S• 112· 3/8'
7/ 16'
