Triumph Bonneville T120 Instruction manual

WORKSHOP
MANUAL
UNIT CONSTRUCTION 650 C.c. TWINS
T120 TR6 & 6T· FROM ENGINE No. DU.IOI
1963 to 1970
© Copyright by
TRIUMPH ENGINEERING CO LTD
MERIDEN WORKS· ALLESLEY . COVENTRY . ENGLAND
TELEPHONE MERIDEN 311 TELEGRAMS "TRUSTY" COVENTRY
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This is the 't op of the line'
And with Triumph thai
means something, A really
responsive
mount. Irs the
one that set. and stili holds,
the
world's speed record,
A true champion in every
sense, the Bonneville
is
greater than ever in '67 -
the smoothest ride
on the
road , If you demand the
best motorcycle
on the road
today, then your choice has
to be Bonneville. Available
either in the road sport
version for road rid ing or in
competition trim for the
ra ce
minded.
BONNEVILLE T120 lR
BONNEVillE 650 C.c. O.H .V .• TWIN CARBURETOR , TWIN CYLINDER .
Pride of ownership is built into this Triumph, Rugged good looks combine
with comp lete dependabi lity for supreme rid er sa t is faction, A
modern,
up· to -date motorcycle with real quality features avai lable only on Triumph, such as polished stainless steel fen d ers that wil l never
lose their lusue, This
is th e greatest motorcycle under any and all road conditions, and it will take you (a nd a friend) where you want to go
easily, qu ickly and comfortab ly , If you think that all motor cycling is t he same. you owe it to yourself to test ride the new 1967 Bonneville that
IS waiting for you at your nearest dealers now .
This is the 'top of the line'
And wi t h T riumph that
means something. A really
responSl\/e mount,
It'S the
one that
set, and sllil holds,
the
worl d's speed record.
A true champion in every
sense. the Bonneville is
grea t
er than ever in '67 -
the smoothest tide on the
road. If you demand the
bes t motorcycle on the road
today, then your choice has
to be Bonneville. Available
either in the road sport
ve rsion fo r road riding or in
competition trim for the race
minded.
2
BONNEVILLE T120 lR
BONNEVILLE 650 c.c. O.H. V., TWIN CARBURETOR , TWIN CYLINDER .
Pride of ownership is bui ll Into this Tr iumph. Rugged good looks com bine wi th complete dependabi lity for supr eme rid er sa t is fa ction. A
modern, up· to -date motorcycle
with f ea l quality f ea t ures available only on Triumph, suc h as polished stain l ess steel fen d ers that wi ll never
lose their lusue. This
is the greatest motorcycle under any and all road conditions, and it will take you (and a friend) where you want to go
easily.
qU ickly and comfortably. If you think that all motorcycling is the same. you owe it to yourse lf to test ride the new 1967 Bonneville that
IS wai ting for you at your nearest dealers now .
FOR SPECIFI C ATIONS NICA L DATA SEE P
This is the 'top of the line'
And with Triumph that
means something. A realty
responsive mount.
Irs the
one that
set and still holds,
the world's speed record,
A true champion in every
sense, the Bonneville
is
greater than ever in '67 -
the smoothest ride on the
road. If you demand the
bes t motorcycfe on the road
today, then your choice
has
to be Bonnevitte. Available
either in the road sport
version for road riding or in
competition trim for the race
minded.
2
BONNEVILLE T120 lR
BONNEVillE 650 C.c. O.H.V., TWIN CARBURETOR , TWIN CY LI NDER .
Pnde of ownership IS buil! IntO this Triumph. Rugged good looks combme with complete dependability for supreme rider satisfaction. A
modern, up· to -date motorcycle
with real quality features avaitable only on Triumph, such as polished stain l ess steel fenders that wi ll never
lose their Iusue. This
is th e greatest motorcycle under any and all road conditions. and it witt take you (and a friend) whele you want to go
easily, qUickly and comfortably.
If you thtnk thai all motorcycling IS the same , you owe II to yourself to test ride the new 1967 Bonneville thai
IS waiting for you at your nearest dealers now .
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THE
BONNEVILIE65O
The
standard
bywhichalltheothers
are
judged.
A
streamlined
650cc
holdsthe
AMA-approved
world'sspeed
record
of
245.667mph.Solid
engineering,
rugged
constructionand
thekindofridethat
hasto
befelttobebelieved.
The
Bonnevilleisin
aclassall
byitself.
Specifications
subject
tochangewithout
notice.
re@
Engine
type OHV Frontchainsize .357 x .225x.25in.Duplex
Numberofcylinders 2 Rear chainsize .625x.375
in.
Bore
andstroke 7I x82mm,
2.79x3.23 in. Tire,front 3.25x 19
in.
(K70)
Displacement 649cc,40cu.
in. Tire,rear 4.00x 18 in.(K70)
Compressionratio 9:1 Brakediameter, front 8 in.
BHP
and
RPM 52
@
6,500 Brakediameter,
rear 7 in.
Enginesprocketteeth 29 Finish AstralRed/Silver
Clutchsprocket
teeth 58 Seat
height 30.5in.
Gearboxsprocket
teeth 19 Wheelbase 55.5in.
Rearsprocketteeth 46 Length 84.5in.
RPM
10mph
top
gear 634 Width 27in.
Gear
ratios,top 4.84 Clearance 7.125
in.
Gear
ratios,third 5.76 Weight
(Dry) 386lbs.
Gear
ratios,second 8.17 Fuel
capacity 2.5
gals.
Gear
ratios,
first 11.81 Oil
capacity 6pints
Carburetor Twin/Amal930
TriumphWest,
P.O.Box275,Duarte,
Calif
.91010 sH-70-2
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TRIUMPH 650 c.c. UNIT CONSTRUCTION TWINS
650 c.c. TRIUMPH BONNEVILLE 120 (T120)
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TRIUMPH 650 C.C. UNIT CONSTRUCTION TWINS
650 CoCo (40 cu. in.) BONNEVILLE (T120R)
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TRIUMPH 650 C.c. UNIT CONSTRUCTION TWINS
650 c.c. (40 cu. ;n.) TIGER 650 (TR6R)
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TRIUMPH 650 C.c. UNIT CONSTRUCTION TWINS
650 c.c. (40 cu. in.) BON NEVILLE T.T. SPECIAL (T120TT)
DISCONTINUED AFTER ENGINE NUMBER DU. 66245
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TRIUMPH 650 c.c. UNIT CONSTRUCTION TWINS
650 c.c. (40 cu. ins.) TROPHY (TR6R)
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T120 BONNEVILLE-(cont)
CYLINDER BLOCK
Material
Bore size ...
Maximum oversize ."
Tappet guide bloc.k housing diameter
CYLINDER HEAD
Material
Inlet
port size
Exhaust
port size
Valve
seatings:
Type
Material
VALVES
Stem diameter: Inlet
Exhaust ...
Head diameter: Inlet
Exhaust
Exhaust valve material
VALVE GUIDES
Material ...
Bore diameter (Inlet and exhaust)
Outside diameter (Inlet and exhaust)
Length: Inlet
Exhaust
GENERAL DATA
VALVE SPRINGS (RED SPOT INNER)
(GREEN SPOT OUTER)
Free length
Total
number of coils
Total fitted load:
Valve open
Valve closed
Fitted
length (valve closed):
Inner ...
Outer ...
VALVE TIMING
Set all tappet clearances @ -020 in. (-5 mm_) for checking
ROCKERS
Material
Bore diameter
Rocker spindle diameter
Tappet clearance (cold): Inlet
Exhaust
CAMSHAFTS
Journal diameter: Left
Right
Ojametral clearance: Left
Right
End float
Cam lift: Inlet and
exhaust
Base circle diameter
TAPPETS
Material
Cast Iron
2·7948/2·7953 in.
2.8348/2-8353 in.
·999 /·9985 in.
D.T.D. 4H Aluminium
GO
1-h in. dia. tapering to 11 in.
1) in. dia.
Cast-in
Cast iron
·3095;.3100 in.
·3090/·3095 in.
1-592/1-596 in.
1-434/1,440 in.
21/4NS
Aluminium-Bronze
'3127/"3137 in.
'5005/·5010 in.
1* in.
2it in.
Outer
11 in.
St
Inlet
1431bs.
75 Ibs.
1,\ in.
1-h- in.
{
'n'et opens
Inlet closes
. Exhaust
opens
Exhaust closes
Inner
1-H in.
7!
Exhaust
155 Ibs.
87 Ibs.
1. in.
l-h in.
34° before top centre
55° after bottom centre
55° before bottom centre
34° after top centre
High tensile steel forging
'5002/-5012
in.
·4990/·4995 in.
·002 in. (·05 mm.)
·004 in. (-10 mm.)
·8100/"8105 in.
·8730{·8735 in.
·0010/·0025 in.
'0005/·0020 in.
-013/·020 in.
·314 in.
-812 in.
High
tensile steel body-Stellite
tip
Tip radius .__ 1·125 in.
Tappet diameter '3110/'3115 in.
Clearance in guide block __ . ... ... ·0005{·0015 in.
Exhaust
tappet has flat, -h in. tall. 1·884 in./1·881 in. below top of tappet, flat is -032 in. deep, and'oil hole is ·047 in. diameter.
GD3
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GO
T120 BONNEVILLE-(eant)
TAPPET GUIDE BLOCK
Diameter of bores
Outside diameter
Interference fit in cylinder block
CAMSHAFT BEARING BUSHES
Material
Bore diameter (fitted): Left
Right
Outside diameter: Left ...
Right
length: left inlet
Left exhaust
Right inlet and exhaust
Interference fit in crankcase: Left
Right
TIMING GEARS
Inlet and exhaust camshaft pinions:
No. of teeth ...
Interference fit on camshaft
Intermediate timing gear:
No. of teeth ...
Bore diameter
Intermediate timing gear bush:
Material
Outside diameter
Bore diameter
Length
Working clearance on spindle
Intermediate wheel spindle:
Diameter
Interference fit in crankcase
Crankshaft pinion:
No. of teeth ...
Fit on crankshaft
IGNITION TIMING
Crankshaft position (B.T.D.C.)
Static timing
...
Fully advanced
Piston position (B.T.D.C.)
Static timing
...
Fu"yadvanc;:ed
Advance
range:
Contact breaker
Crankshaft
CONTACT BREAKER
Gap setting
Fully advanced at
SPARKING PLUG
Type
Gap setting
Thread size
GD4
GENERAL DATA
·3120/·3125 in.
1·0000/·9995 in.
·0005/-0015 in.
High density sintered bronze
-8125/·8135 in.
·874/·875 in.
1·0010/1·0015 in.
1·126/1·127 in.
1·104/1·114 in.
·932/·942 in.
1·010/1·020 in.
·001/·002 in.
·0010/·0025 in
50
'000/-001 in.
47
'5618/-5625 in.
Phosphor bronze
·5635/·5640 in.
·4990/·4995 in.
'6775/·6825 in.
·0005/·0015 in.
.4980/.4985 in.
.0005/.0015 in.
25
+ ·0003/-·0005 In.
·060 in. (1·5 mm.)
·415 in. (10·4 mm.)
12'
24'
'014-·016 in. (·35-·40 mm.)
2,000 r.p.m.
Champion N3
·025 In. (·635 mm.)
14 mm. X I in. reach
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GENERAL DATA
GD
T120 BONNEVILLE-(cont)
FRAME AND ATTACHMENT DETAILS
HEAD RACES
No. of balls: Top ...
Bottom
Ball diameter
SWINGING FORK
Bush type '..
Bush bore diameter
Sleeve diameter... ...
Distance between fork ends
REAR SUSPENSION
Type
Spring details:
Fitted length
Free length ".
Mean coil diameter ...
Spring rate ...
Colour code ... ...
load at fitted length
20
20
tin.
Pre-sized. steel-backed-
phosphor bronze
1·+460/1·+470 in.
1·4+45/1·+450 In.
7t in.
Swinging fork controlled by com-
bined coil spring/hydraulic
damper units
8 in.
8,\ in.
11 in.
14S Ibs.Jin.
Blue/yellow
38 lb.
WHEELS, BRAKES AND TYRES
WHEELS
Rim size: Front and rear
Type: Front
Rear
Spoke details: Front: Left side
Right side
Right side
Rear: Left side
Right side
WHEEL BEARINGS
Front and rear, dimensions and type ...
Front and rear, spindle diameter (at bearing journals)
STANDARD REAR WHEEL
Bolt size for detachable sprocket
Number of bolu ...
Q.D. REAR WHEEL
Bearing type
Bearing sleeve: journal diameter
Brake
drum bearing
Bearing sleeve: journal diameter
Bearing housing: internal diameter
REAR WHEEL DRIVE
Gearbox sprocket ...
Rear wheel
sprocket teeth
Chain details:
No. of links: Solo
Sidecar
Pitch ...
Width
Speedometer drive gearbox ratio
Speedometer cable length
... WM2-19 FrontWM2-18
rear
... Spoke-single cross lacing
... ". Spoke-double cross lacing
20 off 8/10 SWG butted Si in. U.H. straight
10off 8/10 SWG butted 4H in. U. H. 780 head
10 off 8/10 SWG butted 41 in. U.H. 1000 head
20off8/10SWG butted 7..... in. U.H. 900 head
20 off 8/10 SWG butted 7. ih. U.H. 90° head
20X47x14 mm.-Ball Journal
·7862/·7867 in.
tin. dia.xti in. U.H.x26 C.E.I.
8
ix1ix-h in. Ball Journal
·7500/·7495 in.
t X2 X -h in. Ball Journal
·8745/·8740 in.
1·9890/1-9980 in.
See "Gearbox"
46
104
103
i in.
.. in.
2:1
6S ins.
G07
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