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Bonnie at the Castle Part 1, January 2016

1969 Triumph T120R Top End Disassembly

Bonnie was using oil during the 2015 riding season so during 2016 winter maintenance I went for a rebore and new pistons and rings. These photos show cylinder head and piston condition upon disassembly as well as a few techniques for removing the grudgeon, or wrist pins.

Cylinder Head Removed

Good news is there's no leakage between the cylinders thanks to CopperCoat, but pistons show signs of burning oil.

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Cylinder Head Combustion Chambers

Definitely been burning some oil here!

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Intake/Exhaust Pushrod Tubes

Exhaust PRT shows signs of having leaked a bit around the tappet guide block.

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Exhaust Tappets and Tappet Guide Block

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Intake Tappets and Tappet Guide Block

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Nix Nix on Connecting Rod Nicks!

Use whatever you have around to protect the connecting rods. Foam pipe insulation works well, or just cover the crankcase studs with rubber bits and secure the rods to them with rubber bands the way I've done here.

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Chill, Baby!

Ahead of heating the pistons, I used snow packed into plastic bag to chill the wrist pins for easier removal.

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Removing Wrist Pins with Homemade Tool

Threaded rod, washers and nuts, and a couple pieces of pipe are all it takes to work up a homemade wrist pin extractor. I didn't have a large enough washer to cover the indentation around the wrist pin bosses so I used a file tang as a shim.

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Pistons Removed

Keep those connecting rods well protected!

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