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 See Bookmarks ClassicBike.biz ClassicBike.biz ClassicBike.biz BONNEVILLE T120lR 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 world's speed record. A true champion in every sense. the Bonneville is grea ter than ever in '67 - the smoothest tide 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 riding or in competition trim for the race minded. BONNEVILLE T120lR This is the 'top of the line' And with Triumph thatthai means somethingsomething,. A realtyreally responsive mount. Irs the one that setset. and stilistill holds, the world's speed record, A true champion iinn every sense,sense, the Bonneville is BONNEVillEBONNEVILLE 650 c.cC.c.. O.H.V .•., TWIN CARBURETOR, TWIN CYLINDER. greater than ever iinn ''6767 - Pride of ownershipownership isis buibuiltll iIntonto thisthis TriumphTr iumph., RuggedRugged good looks comcombinebine wiwithth completecomplete depedependabindability forfor suupremepreme rid eerr satisfafaction,ction. A the smoothest ride on the momodern,dern, up· to -date motorcycle with realfea l quality ffeatureea turess availaavai lableble only on Triumph, suchsuc h asas polisheishedd stainstainlessless steelsteel fen ders that wiwillll nneverever road., If you demand the lose ttheheirir lusuelusue., This is thethe greatestgreatest motorcycmotorcyclele underunder any and all road conditionsditions, and iit will ttakeake you (and(a nd a friend)iend) where youyou wantwant to go besbestt motorcycfemotorcycle on ththee road easily, quickly and comfortably, If you think that all motorcycling is the same. you owe it to yourself to test ride the new 1967 Bonneville that today, then your choichoicece has easily. qU ickly and comfortably. If you think that all motorcycling is the same. you owe to yourself to test ride the new 1967 Bonneville that to be BonnevitteBonneville. Available IS waiting fforor you at your nearest dealersdealers now. either in the road sport version for road ridingrid ing or inin FOR SPECIFI CATIONS NICAL DATA SEE P competitionition trim for the racera ce minded2 . 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 less steel fenders that will never lose their Iusue. This is the 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. 2 ClassicBike.biz ClassicBike.biz THEBONNEVILIE65O Thestandard by which all the others are judged. A streamlined 650ccholds the AMA-approved world's speed record of 245.667mph. Solid engineering, ruggedconstruction and the kindof ridethat hasto befelt to be believed. TheBonneville is in a classall by itself. Enginetype OHV Frontchain size .357x .225x.25 in. Duplex Numberof cylinders 2 Rearchain size .625x.375in. Boreand stroke 7I x 82 mm, 2.79x 3.23in. Tire,front 3.25x 19 in. (K70) Displacement 649 cc,40 cu. in. Tire,rear 4.00 x 18 in. (K70) Compressionratio 9:1 Brakediameter, front 8 in. BHPand RPM 52 @ 6,500 Brakediameter, rear 7 in. Enginesprocket teeth 29 Finish AstralRed/Silver Clutchsprocket teeth 58 Seatheight 30.5in. Gearboxsprocket teeth 19 Wheelbase 55.5in. Rearsprocket teeth 46 Length 84.5 in. RPM10 mph top gear 634 Width 27 in. Gearratios, top 4.84 Clearance 7.125in. Gearratios, third 5.76 Weight(Dry) 386lbs. Gearratios, second 8.17 Fuelcapacity 2.5 gals. Gearratios, first 11.81 Oilcapacity 6 pints Carburetor Twin/Amal930 Specificationssubject to changewithout notice. re@ TriumphWest, P.O. Box 275, Duarte, Calif . 91010 sH-70-2 ClassicBike.biz TRIUMPH 650 c.c. UNIT CONSTRUCTION TWINS 650 c.c. TRIUMPH BONNEVILLE 120 (T120) ClassicBike.biz TRIUMPH 650 C.C. UNIT CONSTRUCTION TWINS 650 CoCo (40 cu. in.) BONNEVILLE (T120R) ClassicBike.biz TRIUMPH 650 C.c. UNIT CONSTRUCTION TWINS 650 c.c. (40 cu. ;n.) TIGER 650 (TR6R) ClassicBike.biz 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 ClassicBike.biz TRIUMPH 650 c.c. UNIT CONSTRUCTION TWINS 650 c.c. (40 cu. ins.) TROPHY (TR6R) ClassicBike.biz ClassicBike.biz ClassicBike.biz ClassicBike.biz ClassicBike.biz GENERAL DATA GO T120 BONNEVILLE-(cont) CYLINDER BLOCK Material Cast Iron Bore size ... 2·7948/2·7953 in. Maximum oversize ." 2.8348/2-8353 in. Tappet guide bloc.k housing diameter ·999 /·9985 in. CYLINDER HEAD Material D.T.D. 4H Aluminium Inlet port size 1-h in. dia. tapering to 11 in. Exhaust port size 1) in. dia. Valve seatings: Type Cast-in Material Cast iron VALVES Stem diameter: Inlet ·3095;.3100 in. Exhaust ... ·3090/·3095 in. Head diameter: Inlet 1-592/1-596 in. Exhaust 1-434/1,440 in. Exhaust valve material 21/4NS VALVE GUIDES Material ... Aluminium-Bronze Bore diameter (Inlet and exhaust) '3127/"3137 in. Outside diameter (Inlet and exhaust) '5005/·5010 in. Length: Inlet 1* in. Exhaust 2it in. VALVE SPRINGS (RED SPOT INNER) (GREEN SPOT OUTER) Outer Inner Free length 11 in. 1-H in. Total number of coils St 7! Inlet Exhaust Total fitted load: Valve open 1431bs. 155 Ibs. Valve closed 75 Ibs. 87 Ibs. Fitted length (valve closed): Inner .. 1,\ in. 1. in. Outer .. 1-h- in. l-h in. VALVE TIMING 'n'et opens 34° before top centre Inlet closes 55° after bottom centre Set all tappet clearances @ -020 in. (-5 mm_) for checking . { Exhaust opens 55° before bottom centre Exhaust closes 34° after top centre ROCKERS Material High tensile steel forging Bore diameter '5002/-5012 in. Rocker spindle diameter ·4990/·4995 in. Tappet clearance (cold): Inlet ·002 in. (·05 mm.) Exhaust ·004 in. (-10 mm.) CAMSHAFTS Journal diameter: Left ·8100/"8105 in. Right ·8730 {·8735 in. Ojametral clearance: Left ·0010/·0025 in. Right '0005/·0020 in. End float -013/·020 in. Cam lift: Inlet and exhaust ·314 in. Base circle diameter -812 in. TAPPETS Material 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 ClassicBike.biz GO GENERAL DATA T120 BONNEVILLE-(eant) TAPPET GUIDE BLOCK Diameter of bores ·3120/·3125 in. Outside diameter 1·0000/·9995 in. Interference fit in cylinder block ·0005/-0015 in. CAMSHAFT BEARING BUSHES Material High density sintered bronze Bore diameter (fitted): Left -8125/·8135 in. Right ·874/·875 in. Outside diameter: Left ... 1·0010/1·0015 in. Right 1·126/1·127 in. length: left inlet 1·104/1·114 in. Left exhaust ·932/·942 in. Right inlet and exhaust 1·010/1·020 in. Interference fit in crankcase: Left ·001/·002 in. Right ·0010/·0025 in TIMING GEARS Inlet and exhaust camshaft pinions: No. of teeth ... 50 Interference fit on camshaft '000/-001 in. Intermediate timing gear: No. of teeth ... 47 Bore diameter '5618/-5625 in. Intermediate timing gear bush: Material Phosphor bronze Outside diameter ·5635/·5640 in. Bore diameter ·4990/·4995 in. Length '6775/·6825 in. Working clearance on spindle ·0005/·0015 in. Intermediate wheel spindle: Diameter .4980/.4985 in. Interference fit in crankcase .0005/.0015 in. Crankshaft pinion: No. of teeth ... 25 Fit on crankshaft + ·0003/-·0005 In. IGNITION TIMING Crankshaft position (B.T.D.C.) Static timing ... Fully advanced Piston position (B.T.D.C.) Static timing ... ·060 in. (1·5 mm.) Fu"yadvanc;:ed ·415 in. (10·4 mm.) Advance range: Contact breaker 12' Crankshaft 24' CONTACT BREAKER Gap setting '014-·016 in. (·35-·40 mm.) Fully advanced at 2,000 r.p.m. SPARKING PLUG Type Champion N3 Gap setting ·025 In. (·635 mm.) Thread size 14 mm. X I in. reach GD4 ClassicBike.biz ClassicBike.biz ClassicBike.biz GENERAL DATA GD T120 BONNEVILLE-(cont) FRAME AND ATTACHMENT DETAILS HEAD RACES No. of balls: Top ... 20 Bottom 20 Ball diameter tin. SWINGING FORK Bush type ' .. Pre-sized. steel-backed- phosphor bronze Bush bore diameter 1·+460/1·+470 in. Sleeve diameter... ... 1·4+45/1·+450 In. Distance between fork ends 7t in. REAR SUSPENSION Type Swinging fork controlled by com­ bined coil spring/hydraulic damper units Spring details: Fitted length 8 in. Free length ". 8,\ in. Mean coil diameter ... 11 in. Spring rate .. 14S Ibs.Jin. Colour code ... ... Blue/yellow load at fitted length 38 lb. WHEELS, BRAKES AND TYRES WHEELS Rim size: Front and rear ... WM2-19 FrontWM2-18 rear Type: Front ... Spoke-single cross lacing Rear ... ". Spoke-double cross lacing Spoke details: Front: Left side 20 off 8/10 SWG butted Si in. U.H. straight Right side 10 off 8/10 SWG butted 4H in. U. H. 780 head Right side 10 off 8/10 SWG butted 41 in. U.H. 1000 head Rear: Left side 20off8/10SWG butted 7 ..... in. U.H. 90 0 head Right side 20 off 8/10 SWG butted 7. ih. U.H.