The Bonnie Ref
Table of Contents
1. Triumph Documentation
Workshop Manuals
1969 650 General Data
Triumph Service Bulletins
Parts Books & Manuals Downloads
2. Parts
Alpha-Numeric Part Number Conversion
The British Motorcycle Fasteners Database
Hermit's 1969 650 Parts Lists: Hyperlinked & Illustrated
Torque Settings
3. Parts Suppliers
Parts Suppliers
North America
United Kindom
4. Special Tools
Special Tool Lists & Illustrations
5. Other Online Resources
Triumph Models
Classic Triumph/British Forums
Classic British MC Links
6. General Shop Info
Abbreviations
Left-Hand Threads
British Motorcycle Fasteners: Threads
SAE threads
UNF
UNC
The British standard threads
BA
BSC/CEI/Cycle
BSF
BSW
BSPP, BSPT
Wrench Jaw Gap Sizes
Loctite Thread Lockers
Where to Use Loctite
The Loctite Gospel: According to John
The Loctite Gospel: According to Thomas
Loctite Thread Locker Characteristics
Loctite Red
Loctite Blue
Loctite Purple
Sealants
Sealants: Where? and What Kind?
Loctite 518 Sealant
Hylomar Sealant
Three Bond 1130 Sealant
RTV Sealant
Wellseal Sealant
Gaskets
Bearing Retainer
Assembly Lube
Applying Heat
7. 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
8. The Engine
Pre-Ignition & Detonation
Kicking Back When Starting
Engine Removal and Installation
Crankcase
Crankcase Junction Studs
Crankcase Cylinder Base Studs
Crankcase Howel Dowels
Parting the Crankcases
Reassemble the Crankcases
Crankshaft
Exploded view of Crankshaft and Camshafts
Sludge Trap
The Flywheel
Triumph Crankshaft Balancing
DS Crankshaft Oil Seal
Main Bearings
Connecting Rods
Assembling Connecting Rods and Shell Bearings to Crankshaft Journals
Updated Torque Spec for Connecting Rod Bolts
Distinguishing Between Older and Newer Connecting Rod Types
Achieving Correct Connecting Rod Bolt Torque
Timing Chest
Removing Timing Chest Cover
Disassemble Timing Chest
Removing the Crankshaft Pinion Gear
Removing the Camshaft Pinion Gears
Valve/Camshaft Timing
Replacing the Patent Plate
Pistons
Removing Stuck Pistons
Gudgeon Pin Removal & Small End Bushes
Piston Skirt Clearance
Replacing Gudgeon Pins
Rings
Gapping Rings
Installing Rings
Cylinder Block & Tappet Blocks
Cylinder Rebore
Cylinders, displacement
Honing Cylinders
Tappet Guide Blocks
Tappets
Reinstalling Cylinder Block with a Piston Board
Cylinder Block Repros
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
Removing the Rocker Boxes
Valve Train
Rocker Arms, Rocker Shafts, and Thackary Washers
Variations
Unpacking the Triumph Rocker Box "Mystery"
Rocker Spindle Washer Order Illustrated
Early Washer Order
Updated Washer Order
Assembling Rocker Arms, Spindles, & Washers
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
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
9. Exhaust System
Removing Exhaust System
Sealing Exhaust Leaks
Loose Baffles
10. The Transmission
Primary Chaincase
Primary Chaincase Lubrication
Primary Chaincase Cover and Gasket
Primary Chaincase Inner Cover Plate, AKA "Trap Door"
The Primary Chain
Check Primary Chain Wear
Check Primary Chain Tension
Adjust Primary Chain Tension
Dismantle the Transmission
Step-by-Step Procedure
Inspecting Transmission Components
Clutch Pack Thickness
Clutch
Shock Absorber Rubbers
Clutch Hub & Thrust Washer Compatibility
Assemble the Transmission
Assemble Clutch Hub, Rollers, and Clutch Center
Install Duplex & Engine Sprockets & Primary Chain
Adjust the Pressure Plate
Adjust 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
11. 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
Dismantle & Assemble the Gearchange Mechanism
Kickstart Mechanism
Replace Outer Gearbox Cover
Inner Gearbox Cover
Remove the Inner Cover & Dismantle the Gearbox
Inspect the Gearbox Components
Layshaft End Play
Gearbox Sprocket
Illustration: Gear Cluster (1969 T120R)
Illustration: Gears, Shafts, Bearings & Bushes (1969 T120R)
Gearbox Bearings
Bearing Identification
Remove Mainshaft Bearings
Remove DS Mainshaft Bearing (57-0448)
Remove TS Mainshaft Bearing (60-3552)
Replace Mainshaft Bearings
Replace DS Mainshaft Bearing (57-0448)
Replace TS Mainshaft Bearing (60-3552)
Remove Layshaft Bearings
Remove DS Layshaft Bearing (57-1606)
Remove TS Layshaft Bearing (57-1614)
Replace Layshaft Bearings
Replace DS Layshaft bearing (57-1606)
Replace TS Layshaft Bearing (57-1614)
Replace High Gear & Gearbox Sprocket
Gear Ratios & Tooth Count: 4/5-Speeds
Install 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
Positioning the Camplate for Indexing
Positioning the Quadrant for Indexing
Note on Replacing Gearbox Inner Cover
Bonnie Notes
12. The Fuel System
Gas tank
Gas Line
Gas Taps
Installing/Removing
Sealing leaks
Rebuilding and Lubricating Originals
Carburettors
Random Notes
Carburettor to Adaptor O-Rings
Amal Concentric 930 Cross-Section
Amal Concentric Carburettor Parts
Amal Concentric Carburettor Setup Summary
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
13. Control Cables
Lubricating Cables
Throttle Cables
Throttle Twist Grip
Clutch Cable
Routing
14. 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
15. Handlebars
Handlebar Styles
Handlebar Shock-Absorber Mounting
Removing Handlebar Mounting Bonded Bushes
Handlebar Grips
16. Rear Suspension
Shock Absorbers
Disassembling Shocks
Installing Shocks
17. Front Fork
Front Fork
Front Fork Gaiters
Replacing Front Fork Seals
Stanchion Tubes
Refitting Stanchion Tubes
Removing Front Fork As a Unit
Removing Front Fork Legs Separately
Dismantling Front Fork Legs
Reassemble Front Fork Legs
Refitting Complete Fork Assembly to Frame
Aligning Front Fork
Steering Head
Removing & Replacing Steering Head Races
Refitting Upper & Lower Yokes
Steering Damper
Steering lock
18. Axles, Wheels & Brakes
Axles
Front Axles
Wheels, Building & Balancing
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
Assembling the Brake Rod
Replacing the Brake Spring
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
19. Tires
Tire Pressure
Front Tire and Tube
Rear Tire
Tubes for Dunlops
20. 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
Replace Oil Tank and Battery Carrier Straps
Seat
21. 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
Electronic Ignitions (EI)
EI versus Points
Pazon Ignition
Pazon Schematic Diagram
Pazon - Trouble-Shooting
Boyer Ignition Trouble-Shooting
Podtronics Rectifier/Voltage Regulator
