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
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
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
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