Bonneville & TR6 Motorcycle Restoration Guide 1956-1983 David Gaylin OCTANE LOGO GARAMOND PREMIER PRO SEMI BOLD - TYPE AND FLAME LOCKED UP FLAME CAN BE USED WITHOUT TYPE FLAME CAN BE USED WITH OP ON BASE OCTANE LOGO COLOR OPTIONS PRINT 3 COLOR OPTIONS ARE TO BE USED AS SHOWN FLAME TEXT Gradient C 24 R 120 M 0 G 149 Y 0 B 163 COOL K 43 HEX# 7895A3 FLAME TEXT C 50 R 113 Gradient M 50 G 101 WARM Y 60 B 88 K 25 HEX# 716558 FLAME TEXT - BLACK C 0 R 239 C 0 R 35 M 95 G 65 M 0 G 31 Y 85 B 54 Y 0 B 32 BOLD K 0 K 100 HEX# EF4136 HEX# 231F20 To my daughter Charlotte who taught me how to use a keyboard, a cabernet and care when sorting life’s priorities. No father has ever been a prouder pupil. Originally published by Motorbooks, Feb. 1997 Octane Press, Edition 1.0, May 2011 Copyright © 2011 by David Gaylin All rights reserved. With the exception of quoting brief passages for the purposes of review, no part of this publication may be reproduced without prior written permission from the publisher. Library of Congress Cataloging-in-Publication Data Gaylin, David. Triumph motorcycle restoration guide: Bonneville & TR6, 1956-1983 David Gaylin. Includes index. 1. Triumph motorcycle — Conservation and restoration. ISBN 0-9821733-8-5 ISBN-13 978-0-9821733-8-1 Book design by Tom Heffron Copy edited by Joseph Holschuh On the front cover: A 1969 TR6C owned by Fred Broadway of Fredericksburg, Virginia and restored by Deer Park Cycle of Eldersburg, Maryland. Lightner Photography On the back cover: The backOCTANE LOGO cover art is a modified 1967 advertisement. Modifications by Tom Heffron. Author’s CollectionGARAMOND PREMIER PRO SEMI BOLD - TYPE AND FLAME LOCKED UP FLAME CAN BE USED WITHOUT TYPE FLAME CAN BE USED WITH OP ON BASE Printed in the United States of America www.octanepress.com OCTANE LOGO COLOR OPTIONS PRINT 3 COLOR OPTIONS ARE TO BE USED AS SHOWN FLAME TEXT Gradient C 24 R 120 M 0 G 149 Y 0 B 163 COOL K 43 HEX# 7895A3 FLAME TEXT C 50 R 113 Gradient M 50 G 101 WARM Y 60 B 88 K 25 HEX# 716558 FLAME TEXT - BLACK C 0 R 239 C 0 R 35 M 95 G 65 M 0 G 31 Y 85 B 54 Y 0 B 32 BOLD K 0 K 100 HEX# EF4136 HEX# 231F20 Contents Acknowledgments 4 Preface 5 Introduction 7 Chapter 1 Historical Perspective 10 Chapter 2 1956–1959 TR6 Trophy 21 Chapter 3 1959 Bonneville 38 Chapter 4 Duplex Twins 1960–1962 52 Chapter 5 Unit-Construction Twins 1963–1965 70 Chapter 6 Unit-Construction Twins 1966–1970 97 Chapter 7 TT Specials 1963–1967 143 Chapter 8 Umberslade Twins 1971–1975 167 Chapter 9 Meriden Co-op 750 Twins 1976–1979 196 Chapter 10 Final 750 Twins 1980–1983 218 Appendix A Specifications and Technical Data 241 Appendix B Triumph Resource Directory 264 Index 270 Introduction ver the 30-plus years I have been involved advantageous view, with control cables and Oin the Triumph restoration hobby, one of other unsightliness minimized or completely the most common mistakes made by restorers obliterated. Inevitably, the brochures represented and enthusiasts is to acquire a single piece of only what the factory had hoped to manufacture. factory literature, then use it as a sole reference Of course, mostly they got it right, but many point for a project. Often those fortunate times they didn’t. enough to locate a factory parts book take it When using a brochure, parts book, or as the gospel and are unwilling to deviate from any other document, it is a good idea to make its specifications. But even with factory revision certain it relates to the country or market in sheets, almost all of these parts manuals which your machine was originally sold. This exhibit some disparity from what Meriden is important because motorcycle specifications actually produced. These discrepancies were and finishes varied between markets during the sometimes temporary, sometimes by design, same model year. and sometimes beyond the control of Triumph. Of course, there is nothing wrong with an Factory literature is not infallible. Nowhere is American restorer rebuilding his machine to this more evident than in sales and advertising European specs, if that is the desired outcome. material. After obtaining a sales brochure, But many times a restorer will obtain a foreign many restorers make the mistake of rebuilding market brochure and unwittingly rebuild his their motorcycle to replicate the image pictured machine to match, only to find out later that the in the art. Some even go as far as to match a motorcycle is finished in a foreign market color! machine’s paint finish from a brochure — a very This is just another reason not to base a project reckless pursuit, as printed ink colors almost on a single point of reference. always differ from reality. Any source of information whether from Moreover, catalog images were often print or person, should be part of a library of creatures of company propaganda. They were reference material gathered. These should subject to embellishments and retouching by include as many factory publications as can be the ad department, always depicting the most found, such as a parts catalogs, sales literature, 7 magazine ads, and of course, workshop and their correctness cannot be questioned. It is owners manuals. these machines that reveal the truths of factory Clearly, the best source for the visual decal placement, cable routing, original fastener points of a restoration are magazine road tests. plating, etc. These motorcycles also offer the Most were accompanied by photographs of advantage of continued use without fouling the machine, and although often in black and a fresh paint job, and allow a fuller enjoyment white, the images are from the period and free than do those that are “too good to ride!” of factory or designer interpretation. But once again, just because a machine’s details are clearly Concours Advice pictured does not mean this was the only way a It is natural that after a comprehensive and model was offered, and that all other versions exhaustive restoration, a proud owner can’t wait should be discounted. To help the restorer find a to show his work to others. So after transporting period road test covering his or her Bonneville, his pride and joy to the event and waiting all TR6 or TR7, a listing of British and American day in anticipation, how does it happen that magazines appears in the Appendix. the owner finds his motorcycle taking second Another commonly made error is the place to one that is inferior, inaccurate, or over- misjudgment of what is and is not original. For restored? example, a 1956 Trophy 650 that was restored Yes, it happens to everyone, and there are in 1967 will be wearing a 40-year-old paint job as many reasons for it as there are motorcycle today. Add to this an uncertain (undocumented) shows. history and possibly a high price paid for Perhaps the most common explanation is the machine, and a new owner will become that those making the evaluations may not be convinced he has found an untouched example! qualified to do so. An old saying goes that those Even after confronted with a mountain of most competent to assess restored machinery documentation to show otherwise, they will are also the most unwilling to do so! Show not be swayed. This is unfortunate, and if organizers are often more concerned with a friendship is to be maintained, it’s sometimes person’s availability and willingness to judge, best not to be too insistent — after all, they just rather than their qualifications. Those who are might be right! unlucky enough to be conscripted for judging But if you are satisfied that you’ve indeed duty, usually forfeit their time and enjoyment of found an original unrenewed machine, the a show without any recompense. next question should be whether or not a And when these volunteers are finally restoration ought to be undertaken at all. This rewarded for their service — with arguments really is a matter of the owner’s priorities and and verbal abuse from restorers — it’s no wonder how much the machine has suffered. But many that they bolt whenever the word ‘judge” is owners place a high value on shiny finishes heard again! A concours entrant should always and showroom appearances. They’ll rush into try to keep these things in mind when waiting a motorcycle restoration, giving no thought to for the awards ceremony. the historical artifact they’re about to destroy. Assuming that in some cases your motorcycle There are no shortages of restored Triumphs, may be evaluated by individuals completely even accurate ones, at bike rallies and concours. unfamiliar with Triumphs, it’s always sound But even the examples properly completed are policy to make as accurate as possible general nothing more than someone’s interpretation of features that the judge will probably spot, such how they originally appeared. as paint finishes, plating, and so on. Untouched machines, sometimes with tired For instance, many restorers opt for stainless paint and partially rubbed-off pinstriping, have steel wheel spokes and fasteners. An owner may a special place in the Triumph hobby because also want the superiority of powder coating, or 8 perhaps Imron paint for the sheet metal, both so on, as well as performance goodies. But it is materials being clearly superior to the finishes always wise to bring documentation and ads to used by the Triumph factory.