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The Bonnie Ref: Table of Contents



Triumph Documentation

Workshop Manuals

1969 650 General Data

Triumph Service Bulletins

Parts Books & Manuals Downloads

Parts & Tools Databases

Converting Part Numbers from Alpha-Numeric to Numeric

Part Lists: Illustrated & Hyperlinked

Torque Settings

Special Tools

Other Lists & Charts

Online Parts Sources

Online Parts Suppliers

North America

United Kindom

Other Online Resources

Hermit's Classic British MC Links

Classic Triumph/British Forums

Additional Info

British Fastener Specifications

General Shop Info

Abbreviations

Alpha-Numeric Part Number Conversion

Left-Hand Threads

Fastener Threads Used on British Motorcycles

SAE threads

UNF

UNC

The British standard threads

BA

BSC/CEI/Cycle

BSF

BSW

BSPP, BSPT

Wrench Jaw Gap Sizes

Sealants and Loctite

Where to Use Loctite

The Loctite Gospel: According to John

The Loctite Gospel: According to Thomas

Sealants: Where? and What Kind?

Loctite & Sealant Product Characteristics

Loctite Blue

Loctite 518

Hylomar

Three Bond 1130

RTV

Wellseal

Applying Heat

Mini Grease Gun

Lubrication

Routine Maintenance & Lubrication

Engine Lubrication

Diagram of Triumph Unit 650 Engine Lubrication System

Selecting an Engine Oil

Changing Engine Oil

Using an External Oil Filter

Filters for use With standard Norton filter head

Colorado Norton Works Filter Adaptor

The Oil lines

Oil Line Connections for Stock Condition - No External Oil Filter

Feed Oil Line

Return Oil Line

Oil Line Connections When Using a Norton Filter Head

Removing Oil Lines at Oil Junction Block

Crankcase Breather

Oil Breather Vent Tube

Oil Pump

Oil Pressure Relief Valve

Oil Pressure Switch

The Oil Tank

Problematic Oil Tank Design - 1966

Removing Oil Tank

Replace Oil Tank

Oil Tank Mounting Adjustment

Oil Tank Mounting Measurements

Wet Sumping

Primary Chaincase Lubrication

Late-1969 and after Important Information

Oil Change

Draining the Primary Chaincase Oil

Gearbox Lubrication

Gear Oil Compatibility

Potentially Harmful Products

Oil Change Schedule

Draining and Replenishing the Gearbox Oil

Oil Leaking from Drain Bolts

Front fork

Draining Fork Oil

Contact Breaker Assembly

Speedometer Gearbox

Swinging Arm Bushing

The Engine

Pre-Ignition & Detonation

Kicking Back When Starting

Engine Removal and Installation

The Flywheel

Crankcase

Crankshaft

Sludge Trap

Crankshaft Oil Seal

Main Bearings

Connecting Rods

Tightening the Connecting Rod Big End Bolts

Timing Chest

Removing the Crankcase Pinion Gear

Valve/Cam Timing

Pistons

Removing Gudgeon Pins & Pistons

Replacing Gudgeon Pins & Pistons

Rings

Gapping Rings

Installing Rings

Cylinder Block & Tappet Blocks

Cylinder Re-Bore

Honing Cylinders

Replacing Tappet Guide Blocks

Replacing Tappets

Replacing Cylinder Block

Tightening Cylinder Base Bolts

Painting Cylinder Block

Cylinder Head

Annealing and Installing Head Gasket

Anti-Seize Compound

Installing Cylinder Head & PRTs

Head-Bolt Torque

Correct Triumph 650 Head-Bolt Torques

Torqueing the Head-Bolts

Re-Torquing Head Bolts

Rocker Boxes

Variations on a Theme: Rocker Arms, Rocker Shafts, and Thackary Washers

Rocker Spindle Washer Order Illustrated

Early Washer Order

Updated Washer Order

Removing the Rocker Boxes

Assembling & Replacing Rocker Arms & Rocker Spindles

Rocker Arm Spindle O-Rings

Pushrod Tubes (PRTs)

Pushrod Tube Styles

Pushrod Tube O-Rings

Pushrod Tube Sealing Ring & Wedding Band

Pushrod Tubes and "Crush"

Installing Pushrod Tubes & Cylinder Head

PRT O-Ring & Seal Dimensions

Rocker Box Gaskets

Replacing Push Rods and Rocker Boxes

Lightweight Pushrods & Rocker Box Gasket Modification

Replacing Rocker Oil Feed Pipe

Replacing Engine Torque Stays

Valves

Replacing Valves in Head

Adjusting Valve/Rocker Clearance

Valve adjustment tools

Coarse adjustment by position

Adjustment by sound and feel

Positioning Valves for Clearance Adjustment

Adjustment after Re-torqueing

Engine Compression

Compression Test

Sudden Loss of Compression

Ignition Timing

Setting Ignition Timing with Points

Determining When the Points Open

Setting Ignition Timing with Pazon

Static Timing

Dynamic Timing

Primary Cover Timing Pointer

Replacing rotor cover after timing

Removing magnetic rotor center

Spark Plugs

The Exhaust System

Removing Exhaust System

Sealing Exhaust Leaks

Loose Baffles

The Transmission

Primary Chaincase

Primary Chaincase Lubrication

Primary Chaincase Cover and Gasket

Checking Primary Chain Wear & Adjusting Chain Tension

Checking Primary Chain for Wear

Checking Primary Chain Tension

Adjusting Primary Chain Tension

Dismantling the Transmission

Step-by-Step Procedure

Inspecting Transmission Components

Clutch Pack Thickness

Clutch Center

Shock Absorber Rubbers

Clutch Center & Thrust Washer Compatibility

Reassembling the Transmission

Reassemble the Clutch Center

Reinstalling Engine Sprocket & Clutch Assembly

Adjusting the Pressure Plate

Adjusting the Clutch Operating Mechanism & Clutch Cable

Adjustment Tips & Techniques

Clutch Operating Mechanism (Ball & Ramp)

Clutch Problems

Clutch Operating Mechanism Pops or Clicks

Clutch Drags & Neutral Hard to Get

Clutch Pull Very Stiff

Kickstart Lever Won't Turn Engine/Gearbox Won't Engage with Engine

Gears Crunch When Selecting First from Neutral

Causes

The Gearbox

Hermit's Gearbox Articles, Illustrations, Photos & Animations

Gearbox Lubrication

Gearbox Problems

Jumping out of Gear

Outer Gearbox Cover

Kickstart Lever Tapered Pin

Removing Outer Gearbox Cover

Dismantling and Reassembling the Gearchange Mechanism

Kickstart Mechanism

Replacing Outer Gearbox Cover

Removing Inner Gearbox Cover

Removing the Inner Cover & Dismantling the Gearbox

Inspecting the Gearbox Components

Layshaft End Play

Gearbox Sprocket

1969 T120R Gear Cluster Illustrations

Gears, Shafts, Bearings, & Bushes('69 T120R)

Replacing Gearbox Inner Cover Bearings

Replacing Mainshaft Bearing in Inner Gearbox Cover

Removing/Replacing Mainshaft and Layshaft Bearings in Gearbox

Removing Mainshaft & Layshaft Bearings from Casing

Replacing Mainshaft & Layshaft Bearings in Gearbox Casing

Replacing High Gear Ball Journal Bearing

Replacing Layshaft closed-end needle roller bearing

Replacing High gear and drive sprocket

Gear Ratios & Tooth Count for 4/5-Speed Gearboxes

Installing Gear Cluster

Four Variations on Gear Cluster Installation

Method 1: Juggling

Method 2: Juggling

Method 3: Workshop Manual Variation

Method 4: Hughie Hancox

Thrust Washer Locating Pegs

Thrust Washer Locating Pegs

Indexing the Camplate & Quadrant

Camplate Positioning

Quadrant Positioning

Note on Replacing Gearbox Inner Cover

Bonnie Notes

The Fuel System

Gas tank

Gas Line

Gas Taps

Installing/Removing

Sealing Gas Taps

Carburettors

Random Notes

Carburettor to Adaptor O-Rings

Amal Concentric 930 Cross-Section

Amal Concentric Carburettor Parts

Summary of Carb Specs & Settings

Choke Assembly

Float Bowl Flooding

Float Bowl Leaking

Assembling Cable, Spring, Air Slide, &

Cleaning the Pilot Jet

Tuning the Mk1 Concentric Carburettor

Adjusting Low Speed Mixture & Idle

Initial Synchronization of carburettors

Mid-Range Tuning

High Speed Tuning

Trouble-Shooting Carburation -

Air Cleaners

Installing Air Cleaners

Air Filters

Control Cables

Lubricating Cables

Throttle Cables

Throttle Twist Grip

Clutch Cable

Routing

Speedometer and Tachometer

Tachometer

Disassembly & Removal of Tachometer Drive

Lubricating Tachometer Drive Gear

Tachometer Cable Lubrication

Speedometer

Speedometer Cable

Tach & Speedometer Cable

Speedo Gearbox

Speedometer Problems

Handlebars

Handlebar Styles

Handlebar Shock-Absorber Mounting

Removing Handlebar Mounting Bonded Bushes

Handlebar Grips

Rear Suspension

Shock Absorbers

Disassembling Shocks

Installing Shocks

Front Fork

Front Fork

Front Fork Gaiters

Removing Front Fork As a Unit

Removing Front Fork Legs Separately

Dismantling Front Fork

Replacing Front Fork Seals

Stanchion Tubes

Refitting Stanchion Tubes

Refitting Fork Assembly to

Aligning Front Fork

Steering Head

Refitting Upper & Lower Yokes

Steering Damper

Steering lock

Axles, Wheels & Brakes

Axles

Front Axles

Front Wheel

The Nave Plate

Front Wheel Bearings

Front Wheel Brakes

Removing Front Brake

Reassembly

Replacing Front Brake

Adjusting Front Brake

Front Wheel Fender Brackets/Stays

Rear Wheel

Rear Wheel and Chain Guard

Removing Rear Wheel (& Chain guard)

Replacing Chainguard

Replacing Rear Wheel

Centering Rear Wheel Brake Shoes

Brake Torque Stay

Rear Wheel Bearings

Rear Wheel Brakes

Disassembly

Reassembly

Rear Wheel Brake Pedal, Brake Rod

Brake Pedal Wear

Reassembly

Brake rod cotter pin

Rear Wheel Fender Bracket

Replace

Rear Wheel Fender

Remove Rear Wheel Fender

Reassembly

Rear Chain

Removing Rear Chain

Replacing Rear Chain

Checking Rear Chain for Wear

Cleaning the Rear Chain

Lubricating the Rear Chain

Checking & Adjusting Rear Chain Slack

Tires

Tire Pressure

Front Tire and Tube

Rear Tire

Tubes for Dunlops

Frame - Stands - Tin - Pegs

Swinging Arm

Swinging Arm Incompatibility

Removing Bushes

Replacing Bushes

Reassembling & Replacing Swinging Arm Frame

Sidestand

Remove

Replace

Center Stand

Center Stand Compatibility

Replacing Center Stand Spring

Left/Right passenger footrest brackets

Remove

Rear Frame

Powder Coating

Battery Carrier

Reinstalling Battery Carrier and Oil Tank

Seat

The Electrical System

Trouble-Shooting Electrical Problems

Short Circuit

Lucas Wiring Color Codes

Wiring Diagrams

Bonnie Electrical System 2015 (no dip switch, no horn)

Bonnie Electrical System 2015 (with dip switch and horn)

Bonnie Electrical System Schematic 2006

Orignal Electrical System Schematic

Battery

Battery Specs

Fuse

Battery Carrier

Alternator

Stator Studs

Rotor Integrity

Rotor and Stator Clearance

Checking Alternator for Charging

Wiring Harness

Removing Main Wiring Harness

Routing of Wiring Harnesses

Main harness

Horn/Dimmer harness (gray plastic)

Rear brake switch harness

Bullet Connectors

Soldering Recommendations

Horns

Headlight and Headlight Shell

Headlight Reflector/Lense Fixing Clips

LED/Halogen Headlight Bulb Replacement

Tailight & Stoplight

Warning Lights

Lucas 35710 Light Switch

Ignition switch

Zenner Diode & Selenium Rectifier

Condensers

Ignition coils

Ignition Coil Heating Up

Installing Ignition Coils

Testing Ignition Coils

Ignition Coil Wiring Connections

With Pazon

With Repro Harness (2006)

With Original Harness

Capacitor Ignition

Pazon Ignition

Pazon Schematic Diagram

Pazon - Trouble-Shooting

Boyer Ignition Trouble-Shooting

Podtronics Rectifier/Voltage Regulator

Index