• Home
• Bonnie
• Album
• Library
• Pipeline Blues
• Divertissements

Maintenance Log Summaries

Bonnie Anomolies

• 2023 - TS conrod nuts have medium strength Loctite (Blue) because I had to back those bolts off and restart
• Lower fork leg on drive side is a used item from Don Hutchinson. A little different from original - tab for fender brace is threaded.
• One of Bonnie's gears is one tooth off from standard - i think it's layshaft 3rd with 23 teeth instead of 22
• Threaded hole for screw at 12 o'clock securing the inner cover plate (Ref.7, Fig.11) is stripped. Never been a problem. After cleaning all surfaces, put a small dab of Ultra Black RTV on the screw, put the screw in the hole and turn it in until there's just a little resistance, then put a little smear of Ultra Black over the screw head and cover. Threads for the screw at 6 o'clock may be weak also. Obviously these screws shouldn't be over-tightened. There's no reason to do so.
• Bonnie's tapered needles currently have five rings instead of three. Using middle clip. (June 2023)

Index to Major Gearbox Work

• 2018: (76,600 mi) Transmission & gearbox work documented
  
  
• 2016: (72,200 mi) Bonnie's gearshift components documented
  
  
• 2015: (65,100 mi) Transmission & gearbox work documented

Speedometer Rebuilds

• Rebuilt by Andy Henderson 2018 @ 76,606 miles
• Rebuilt by Andy Henderson 2014 @ 59,500 miles
• Rebuilt by Nissonger (exchange from Frank Holmes) 2006 @ 31,500 miles
• Rebuilt by Nissonger 2003 @ 18,700 miles

Oil Leak, 2014/15/16

During 2014/2015 oil was leaking from somewhere on the top end and flowing down the rear of the cylinders, especially the drive side, until it wound up pooling on top of the gearbox.

When I re-assembled after Jan-Mar 2016 top end refresh that leak was gone, but it was replaced by an oil leak from the cylinder base. My last gasket had a bit of a tear on one side, and rather than wait for a new one, I'd used it anyway.

In June (69,575 mi.) I removed the head and cylinders a second time and used Coventry Spares gaskets (from Baxter) for the cylinder head and the rocker boxes (with wire).

Should also note that during first 2016 assembly I used Hypolar on base and rocker box gaskets. I wouldn't do that again. On the second assembly I used grease as I always had. Another option would be a sealant like Loctite 515.

Note: 3,000 miles later and no leaks to date - May 2017 (72,500).

Reinstalling the barrels

• Dave helped me install the barrels over new rings the first time. Even with four hands it was not easy!
• The second time (after replacing the tappet guide blocks) I used ring compressors and it was much easier.
• In 2014 Paul helped me and we just fiddled around until the barrels dropped on.
• In 2016, again with Paul's help, I went back to using the ring compressors and they worked very well. I tightened the compressors right down until the rings were closed. Then, with the pistons blocked up with wooden rails, we slipped the cylinder block on. The weight of the block easily overcomes the resistance offered by the tightness of the compressors on the rings.

Ignition Coils Replacements

2017: Replaced 6v TriCor coils with 6v Taiwanese units (76,000mi).

2014: Replaced 12v German ignition coils with 6v TriCor 'High Spark' coils during changeover to Pazon CDI.

20??: Replaced 12v Lucas coils with 12v German units during changeover to Pazon CDI.

(12v originals & German coils are in inventory, along with one good 6v TriCor.

Rim Info for Bonnie

Rear Rim

Dunlop MB10 / W1007 / WM 3-18

Bonnie's Compression Check History