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#657509 - 06/19/16 2:52 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Mar 2007
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Swan Offline
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Swan  Offline

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Winona, MN
Slow and steady indeed, life tends to get in the way of motorcycle projects sometimes, but I have made some more progress. Skip finished my cylinder head with new valve seats, guides, springs, valves and Time Serts for spark plug holes and rocker covers. It is beautiful with perfect machining and the valve lift was dead on.


After buying, stripping, prepping, painting and polishing a used oil tank, I realized it was not the correct one for a 66 so I sold it on the forum and put in way too much time restoring the original chrome covered oil tank and side cover. After running it through the parts jet at the local auto parts store, I sanding off the the chrome and began the long process of filling pits, sanding, prepping, priming, painting and polishing another tank for this bike. I am please with results and am glad I bought the expensive two part catalyzed primer.


The tank took forever to clean, prep, paint and polish and though I am pleased with it, there are two minor issues with my paint job, but it will get me down the road. The badges are the high quality, made in the UK versions, but the holes are just a bit off, so I may try to fix them or re-chrome and repaint the original badges. New petcocks, grid rack, cap, knee pads and style strip.


Getting down to the wire and I still need to polish the primary cover, finish wiring the bike, install the chain and chain guard, exhaust system, cables, and the carbs. I am going to try to burn a vacation day this week to install the last bits, set the tappets and electronic ignition timing, add fluids, and hope to have her running by the weekend. Onwards...


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
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#657626 - 06/20/16 10:38 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Jan 2006
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GrandPaul Online content
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GrandPaul  Online Content
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Laredo (South) Texas, USA
Sure is looking nice. Absolutely top notch stuff.


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, some BSA & European
"The Iron in your blood should be Vintage"
#657629 - 06/20/16 10:56 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Jul 2001
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Lannis Online content
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Lannis  Online Content

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Central Virginia
That is really beautiful work. Maybe you've said it before, but what's the plan for this bike when it's done?

Lannis


OK, I admit it, I'm addicted to brake fluid.

But I can stop any time I want.
#657656 - 06/20/16 2:09 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Nov 2005
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JubeePrince Online content
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JubeePrince  Online Content

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Back on the mainland!
Looking good, Swan!

I'm curious as I've never rebuilt one, how did you torque the nuts in the timing chest and the final drive sprocket with no chain or brake?

Steve


'77 T140J
"Vintage Bike". What's in your garage?

"The paying customer is always right."

Fitting round pegs into square holes since 1961...
#657666 - 06/20/16 2:57 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Mar 2007
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Swan Offline
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Swan  Offline

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Posts: 1,152
Winona, MN
Thanks all. There is rain in the forecast for Wednesday, so I am going to burn a vacation day and spend it in the shop trying to finish this bike.

Lannis, I plan to ride this as much as possible and keep it for life. This was the first motorcycle I had as an adult and sold it like a fool, so I am not letting this one go. It will be a better bike than my Gold Star to ride with my girl on back.

JubeePrince, I torqued the nuts on the camshafts when the cylinder was on but no pistons and held the con rods in place with a steel rod through them held by pieces of oak. Chain and rear brake go on this week.


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#657675 - 06/20/16 3:38 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Jul 2001
Posts: 12,073
Lannis Online content
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Lannis  Online Content

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Central Virginia
Really glad you're going to keep it, ride it, and enjoy it. And it'll never "fool you" on a breakdown, since you know ALL of its secrets now!

Lannis


OK, I admit it, I'm addicted to brake fluid.

But I can stop any time I want.
#657706 - 06/20/16 8:13 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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BikeVice Offline
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San Rafael, Ca.
Beautiful work as usual. I'm sorry to read about your Gold Star getting hit. I read that restoration thread regularly, as I have this one. You are one of the most productive restorers on this forum, and thank you for taking the time to document and share your projects with the rest of us, not to mention the Honda CB400F you restored, posted on a Japanese bike forum, and monetized in the middle of your GS restoration. That's 3 first class restorations in what? 5 years. Thank you.

Eric

Last edited by BikeVice; 06/20/16 8:14 pm.

1971 T120RV (R.I.P.)
1973 T140V/TR7
1993 Ducati 900 SS
#657745 - 06/21/16 5:51 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Nov 2005
Posts: 7,222
JubeePrince Online content
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Back on the mainland!
Originally Posted By Swan

JubeePrince, I torqued the nuts on the camshafts when the cylinder was on but no pistons and held the con rods in place with a steel rod through them held by pieces of oak. Chain and rear brake go on this week.


Of course, S.O.P. The photo sequence threw me off!

Didn't know your GS got hit, always easy to repair and replace metal; flesh and bone, not so much...

Cheers,

Steve


'77 T140J
"Vintage Bike". What's in your garage?

"The paying customer is always right."

Fitting round pegs into square holes since 1961...
#657766 - 06/21/16 10:11 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Mar 2007
Posts: 1,152
Swan Offline
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Winona, MN
Thanks all for the kind words. I also am restoring Andrew E.'s BSA Spitfire and have a 1973 Moto Guzzi GT850 sitting on my lift too. My day job gets in the way of my wrenching time. The damage and time repairing my Gold Star set me back on this project, but the Goldie is back to normal and running really well, so I can turn my attention back to this project.


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#658323 - 06/26/16 10:24 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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Swan Offline
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Winona, MN

So close…. I spent a quiet day in the shop last week and most of yesterday working on my Bonnie. Cleaned and installed the oil tank, polished and install the gearbox cover, cables, chain, chain guard (what a PITA), battery, exhaust system, foot pegs, inspected and synchronized the carbs, and started on the electrical. There was a massive annual car show yesterday in downtown Winona and I entered my Gold Star just so I could park it in front of the shop while I worked. Dozens of people stopped in Skip’s shop while I tried to work, so I lost a lot of time chatting, but had a great time. I’ve got a busy week but will try to finish as soon as possible so I can start her up.

Here’s what’s left to do: finish wiring, install Boyer ignition, set timing, install air cleaners, swap the temporary carb cables for correct ones, polish and install primary cover, add fluids, clean the tank one last time, add gas, and then fire her up. I cannot wait to ride this bike.


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#658348 - 06/26/16 7:12 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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old mule Offline
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Chihuahuan Desert
That's a really superior looking T120- thanks for putting it up here for us.
Aren't you going to use a later front brake? It won't be correct but they are really good brakes.
Very nice job on the first oil tank- sets a standard for my work, thank you.

#658760 - 06/30/16 9:47 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Mar 2007
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Swan Offline
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Swan  Offline

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Winona, MN
Thanks Old Mule, I am glad the oil tank worked out for you.
I am getting closer! I set the tappets, installed and timed the Boyer ignition and installed new bulbs for the idiot lights. She has spark. Tomorrow I should be able to finish wiring, clean the tank, add fluids and fire her up.



1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#659393 - 07/05/16 9:58 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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Swan Offline
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Swan  Offline

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Winona, MN
She’s alive!!!!



Fired her up for the first time two nights ago and rode her for the first time yesterday. Wow, all that time, hard work, and money was worth it. She now starts on first or second kick, idles well and really pulls hard. What a joy to ride and I rode her to work this beautiful morning.


She fought me hard on the final details. After much frustration with the battery carrier and side cover, Skip and I realized it was too low and had been modified. I folded the tops of the carrier back to how it was originally, and everything fit the way it was designed. Skip loves wiring and went over my loom a few times, soldering, crimping and testing all the connections and all the electrical works as it should. Thanks man. The 2 into one cable system is frustrating to say the least and so is the cable bend in to the top of the carbs. The throttle cable routing took quite awhile to get right, so as not to raise the idle. There is not a lot of room under the tank. At times like this, I am glad I bought new AMAL carbs, fuel line, and petcocks. They all work well. The motor, primary and gearbox are drip free (so far) but the left fork is weeping oil at the bottom. The clutch cable (new) is sticking and needs to be lubed.

First ride.

Skip (right) and I setting the air mixture on the carbs.


I am going to put on more break-in miles, fettle, go over all the nuts and bolts, recheck the tappet clearances, timing the ignition again, retorque the cylinder head, change the oil, etc. I have been riding clip-on handlebars for 15 years straight and it is a very strange sensation to be sitting upright on a motorcycle. I am still getting used to the upright European bars and have not quite found where I want the bars and control levers. The blade levers may not last too long on my bike and I may switch to the solid cast AMAL type.

Anyways, thanks all for the encouragement and support during this build, it really helps. This motorcycle has special and personal meaning to me so I am keeping it for life. Time to put on some more miles….


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#659398 - 07/05/16 11:12 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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GrandPaul Online content
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Laredo (South) Texas, USA
Very good work, and what a joy.

You need to scope out some pleasant location and do some beauty shots; both sides, front, back, and close-ups as well.


GrandPaul (does not use emoticons)
Author of the book "Old Bikes"
Too many bikes to list, mostly Triumph & Norton, some BSA & European
"The Iron in your blood should be Vintage"
#659408 - 07/05/16 12:18 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: May 2010
Posts: 2,547
TR6Ray Online content
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TR6Ray  Online Content

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Illinois, USA
Swan,

That is eye-poppingly beautiful! Nice work, as always.

You may be giving that side-stand more confidence than it deserves. Just sayin'

Ray


'64 TR6R Plus some Twins from other countries (U.S., Germany, Japan)
#659674 - 07/07/16 9:49 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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Swan Offline
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Swan  Offline

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Winona, MN
Thanks guys, both your bikes were inspirations on my build. Yes Ray, I started on the side stand but now she fires up easily in one kick.

I hit my first 50 miles last night with no issues other than a blown fuse. I had a 15 amp fuse when the books say 30 amp fuse. I plan to change the oil, rinse the oil tank, check the tappet clearances, retorque bolts, etc tomorrow. She is running really well, the gearbox 'snicks' cleanly up and down through all the gears, and is an absolute pleasure to ride. I have a couple days off with great weather this weekend so I will be out as much as possible. Here are a couple of before and after shots:







1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#659705 - 07/07/16 1:28 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Dec 2004
Posts: 8,893
kommando Online content
kommando  Online Content


Joined: Dec 2004
Posts: 8,893
Scotland
Quote:
I had a 15 amp fuse when the books say 30 amp fuse.


Just watch the rating of the fuses, Lucas identified them using a different method to modern fuses so a 30 amp Lucas should be replaced with a 15 amp modern, use a 30 amp modern and your wiring is the fuse mad .

Brilliant restoration, just as good as your Goldie.

#659707 - 07/07/16 1:39 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: May 2010
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TR6Ray Online content
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TR6Ray  Online Content

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Illinois, USA
Yep, I agree with kommando.

Look here and here.

I've gone over 5000 miles running a 15A fuse, Swan. There must be a reason. Maybe try John Healy's troubleshooting method.

Your bike is gorgeous! I hope to see a lot more pictures like this in your Minnesota surroundings.

Ray


'64 TR6R Plus some Twins from other countries (U.S., Germany, Japan)
#659717 - 07/07/16 2:41 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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Swan Offline
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Swan  Offline

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Winona, MN
Lucas, sigh....Ok, thanks guys, I thought 30 amp was too heavy given the lighter gauge wire in the loom. I'll pick up a box of the correct 17 or 20 amp fuses. Always listen to John Healey.


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#659742 - 07/07/16 6:03 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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Posts: 7,222
JubeePrince Online content
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Back on the mainland!
Swann -

I use the modern 'blade' type fuse, 20A. I've blown a couple over the years with the stock loom with no detriment to the wiring, so I think you'd be safe with 20A. (Donning flame-proof suit now) Bit easier to find than 17A...

Well done...we should all be so fortunate as to have the time and resources you have! beerchug

Cheers,

Steve


'77 T140J
"Vintage Bike". What's in your garage?

"The paying customer is always right."

Fitting round pegs into square holes since 1961...
#659746 - 07/07/16 6:25 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Mar 2005
Posts: 9,970
John Healy Online content
John Healy  Online Content


Joined: Mar 2005
Posts: 9,970
Boston, Massachusetts
The Triumph Corporation in Baltimore would send out a pack of Buss SFE20 fuses anytime someone ordered Lucas 188218 fuses. For most British bike owners anything between 15 and 20 American fuse will not blow with normal use, but will blow instantly if something shorts to ground. With a 35 amp (surge rating used by Lucas et al) as kommando mention the wiring harness WILL melt before the fuse blows!!!!


#659766 - 07/07/16 10:00 pm Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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Swan Offline
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Swan  Offline

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Winona, MN
Thanks all for chiming in. I now have a box of 20A blade fuses in my tool kit under the seat. Looking forward to maintenance tomorrow and then more riding.


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#659780 - 07/08/16 3:24 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Nov 2009
Posts: 2,049
Peter R Online content
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Peter R  Online Content

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Netherlands
Swan, you did a great job, congrats bigt
I just finished the resto job on the Benelli, old bike restoration is very addictive, and the projects shown on this forum always work as an inspiration for me.


Peter.
1974 Commando 850
1972 Trident T150T
1961 Goldie DBD34
1969 Benelli 250 sport special
#661118 - 07/18/16 9:54 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
Joined: Mar 2007
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Swan Offline
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Swan  Offline

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Winona, MN
225 miles and all is good, almost. My bike starts, runs, and rides beautifully. Had a group ride this weekend with old friends, we bombed the back roads, and my bike ran perfectly. The only issue so far is that the odometer stopped working but the trip odometer is still recording mileage. The UK made speedo cable is tight and properly lubricated so it must be the internal parts of the speedo. I emailed the person who restored my gauges about the problem and I'll wait for his response.

Initially, I had intermittent noise around the top end and I finally discovered the source. One of the exhaust pipes was rubbing on the exhaust stub after it warmed up. It only happened at certain rpms so it was not the tappets, rocker spindles, etc. Of course I broke another cooling fin by tightening it too much. I used lock wire from the head to a new cooling fin and the noise is gone but I would like to find a better solution than lock wire.

I plan to change the primary oil tonight and tighten up the clutch springs because it slips a little when I really hit the throttle. The weather is perfect and I want to ride her as much as possible.





1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#661121 - 07/18/16 10:04 am Re: 1966 Triumph Bonneville T120R restoration [Re: Swan]  
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Les P Online content
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Les P  Online Content

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Kiwi in Australia.
Fantastic job but have to ask, how is the riding position with the bars so far forward ?

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