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Bonneville 750
Workshop manual
Triumph Bonneville 750 Workshop Manual
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Engine and Frame Numbers
Guarantee
Factory Service Arrangements
Contents
T140E Bonneville 750 Side View
T140V Bonneville 750 Side View
TR7V Tiger 750 Side View
General Data
General Data: Lubrication System
General Data: Engine
General Data: Transmission
General Data: Gearbox (5 Speed)
General Data: Frame and Attachment Details
General Data: Wheels, Brakes and Tyres
General Data: Front Forks
General Data: Electrical System
Routine Maintenance
Recommended Lubricants
Engine Lubrication Diagram
Engine Lubrication System
Changing the Engine Oil and Cleaning the Oil Filters
Underside View of Engine/Gearbox Unit
Tappet Oil Feed Drillway
Tappet Oil Feed Arrangement
Oil Pressure
Stripping and Reassembling the Oil Pressure Release Valve
Stripping and Reassembling the Oil Pump
Removing and Replacing the Oil Pipe Junction Block
Oil Pipe Securing Clips
Removing and Replacing the Rocker Oil Feed Pipe
Contact Breaker Lubrication
Contact Breaker Mechanism Lubrication Points 10CA
Gearbox Lubrication
Gearbox Drain and Level Plugs
Primary Chaincase Lubrication
Section through the Primary Chaincase
Rear Chain Lubrication and Maintenance
Greasing the Steering Head Races
Wheel Bearing Lubrication
Telescopic Fork Lubrication
Lubrication Nipples
Swinging Fork Pivot
Lubricating the Control Cables
Speedometer and Tachometer Cable Lubrication
Brake Pedal Spindle Lubrication
Check Procedure for Wet Sumping
Engine
Exploded View of 750C.C. Engine Gearbox Unit
Engine: Description
Removing and Replacing the Engine Unit
Clutch Cable Adjustment and Gearbox Drain Plug
Removing and Replacing the Rocker Boxes
Rocker Box Securing Nuts
Inspecting the Pushrods
Stripping and Reassembling the Rocker Boxes
Rocker Box Assembly
Refitting the Rocker Spindle
Adjusting the Valve Rocker Clearances: Inlet Valves
Adjusting the Valve Rocker Clearances: Exhaust Valves
Removing and Replacing the Air Cleaner(S)
Air Cleaners (T140V Shown)
Exploded View of Amal MK1 Concentric Carburetor
Exploded View of Amal MKII Concentric Carburetor
Amal Concentric Carburetor: Description
T140V and TR7V Models: Removing and Replacing the Carburetor
T140E Models: Removing and Replacing the Carburetor
Stripping and Reassembling the Carburetor
Inspecting the Carburetor Components
T140E Needle Retaining Disc Location
Carburetor Adjustments
Twin Carburetter Arrangement: Throttle Cable
Twin Carburetter Arrangement: Setting Twin Carburetors
Removing and Replacing the Exhaust System
Removing the Cylinder Head Assembly
Cylinder Head Bolt Tightening Sequence
Refitting the Cylinder Head
Showing Assembly of Cylinder Head Studs and Nuts
Removing and Refitting the Valves
Valve Components
Renewing the Valve Guides
Decarbonising
Re-Seating the Valves
Cutting a Valve Seat
Valve Seating Tools
Removing and Replacing the Cylinder Block and Tappets
Refitting the Cylinder Block
Showing the Correct Method of Assembly of the Exhaust Tappets
Inspecting the Tappets and Guide Blocks
Renewing the Tappet Guide Blocks
Refitting a Tappet Guide Block
Removing and Refitting the Pistons
Removing and Replacing the Piston Rings
Refitting a Tapered Piston Ring
Inspecting the Pistons and Cylinder Bores
Cylinder Bore and Piston Grading Inspection
Table of Suitable Re-Bore Sizes
Cylinder Block and Piston Grading Details
Removing and Replacing the Contact Breaker
Ignition Timing - Initial Procedure
Static Timing Where no Stroboscope Is Available
T.D.C. Body and Plunger
Ignition Timing by Stroboscope
Rotor Marking
Removing and Replacing the Timing Cover
Timing Cover Oil Seal Location
Location of Three Long Screws in Timing Cover
Removing and Replacing the Oil Pump
Extracting and Refitting the Valve Timing Pinions
Extracting the Crankshaft Pinion
Camshaft Pinions
Extractor Tool 61-6019 Showing Protection Cap
Extracting the Cam Wheels
Valve Timing Marks from ENG No. CX06001
Valve Timing Marks
Valve Timing
Dismantling and Reassembling the Crankcase Assembly
Servicing the Crankshaft Assembly
Sectional View of Crankshaft-Showing Oil Tube
Refitting the Connecting Rods
Inspecting the Crankcase Components: Big-End Bearings
Inspecting the Crankcase Components: Main Bearings
Inspecting the Crankcase Components: Camshaft and Bushes
Inspecting the Crankcase Components: Crankcase Faces and Dowels
Renewing the Main Bearings
Roller Main Bearing
Renewing Camshaft Bushes
Removing and Replacing the Tachometer Drive
Exploded View of Tachometer Gearbox
Transmission
General Arrangement of Clutch and Shock Absorber Unit
Adjusting the Clutch Operating Mechanism
Exploded View of Clutch Operating Mechanism
Adjusting the Primary Chain Tension
Removing and Replacing the Primary Cover
Section through Primary Chaincase
Removing and Refitting the Clutch Plates
Unscrewing the Clutch Spring Nuts
Inspecting the Clutch Plates and Springs
Adjusting the Clutch Pressure Plate
Renewing Shock Absorber Rubbers
Replacing the Shock Absorber Rubbers
Removing and Replacing the Stator and Rotor
Removing and Replacing the Clutch and Engine Sprockets
Extracting the Clutch Centre, Using Extractor D662/3 and Locking Plate Z13
Inspection of the Transmission Components
Oil Seal Gearbox Sprocket Detachable Cover
Clutch and Engine Sprocket Alignment
Rear Chain Alternations and Repairs: Rivet Extractor
Five Speed Gearbox
Plan of Gear Components
Sequence of Gearchanging
Gear Selection Components
Removing and Replacing the Gearbox Outer Cover Assembly
Showing Gearbox Oil Level and Oil Drain Plugs
Gearbox Outer Cover, Showing Gearchange Mechanism, Clutch Operating Mechanism and Kickstart Quadrant
Dismantling and Reassembling the Kickstart Mechanism
Kickstart Quadrant and Spring
Dismantling and Reassembling the Gearchange Mechanism
Inspecting the Gearchange and Kickstart Components
Renewing Kickstart and Gearchange Bushes
Clutch Operating Mechanism
Dismantling the Gearbox
Gearbox Inner Cover Retaining Screws
Showing Removal of Engaging Dog
Inspection of the Gearbox Components
Renewing Mainshaft and Layshaft Bearings
Drift Dimensions
Section through Gearbox Mainshaft Oil Seal
Sketch of Needle Roller and Drift
Reassembling the Gearbox
Refitting the Gearbox Inner Cover
Changing the Gearbox Sprocket
Frame and Attachment Details
General Arrangement of Frame Assembly
Removing and Replacing the Fuel Tank
Fuel Tank Mounting
Removing Side Panels and Filter Housing
Removing the Prop Stand
Removing the Centre Stand
Removing Rear Brake Pedal
Removing and Servicing the Rear Brake Pedal Spindle
Rear Brake Pedal Spindle Assembly Exploded View
Brake Pedal Return Spring - Frame Location
Refitting the Brake Pedal Return Spring
Removing Twinseat
Chainguard Removal
Control Cable Replacement
Removing and Replacing the Coil Plate
Coil Plate Mountings
Removing and Replacing Rear Light Unit
Removing the Horn
Removing Rear Stop Switch
Removing and Replacing the Flasher Unit
Removing and Replacing the Mudguards
Adjusting the Rear Suspension
Exploded View of the Rear Suspension Unit
Removing and Refitting the Rear Suspension Units
Gas Filled Suspension Unit Fitted after Frame
Oil Hydraulic Suspension Unit Fitted Prior to Frame
Stripping and Reassembling the Suspension Units
Removing and Refitting the Swinging Fork
Swinging Arm Components
Renewing the Swinging Fork Bushes
Removing and Replacing the Swinging Arm Bushes Using Service Tool 61-6117
Frame Alignment
Fracture at Rear of Head Lug
Fracture at Bottom Bearing Housing
Basic Frame Dimensions
Checking the Swinging Fork
Paintwork Refinishing: Paint Stripping
Paintwork Refinishing: Undercoat
Paintwork Refinishing: Wet and Dry Sanding/Priming
Paintwork Refinishing: Applying Stopper
Paintwork Refinishing: Polishing
Fitting Replacement Seat Covers
Brakes Wheels and Tyres
Front and Rear Brake Caliper Exploded View
Front Brake Components
Rear Brake Components
Rear Brake Adjustment
Brake Fluid Level
Showing the Front Brake Reservoir Fluid Level
Rear Brake Reservoir
Brake Pad Lining - Front and Rear
Showing Arrangement for Bleeding the Rear Brake
Showing Arrangement for Bleeding the Front Brake
'Bleeding' the Hydraulic System - Front and Rear
Folded Condition of Rubber Diaphram
Flushing the Hydraulic System
Hydraulic Brake Pipes and Hoses - Removal and Refitment
Front Brake Pipe Installation
Rear Brake Pipe Installation
Rear Brake Master Cylinder and Reservoir
Rear Brake Master Cylinder and Reservoir: Push Rod Adjustment
Front Brake Master Cylinder
Exploded View of Master Cylinder
Hydraulic Flow Diagram - Front Brake
Showing Angle of Brake Reservoir
Stripping and Reassembling the Front and Rear Brake Calipers
Brake Discs
Removing and Refitting the Front Wheel
Removing and Refitting the Front Wheel Bearings
Exploded View of Front Wheel Bearing Arrangement
Removing and Fitting the Rear Wheel
Removing and Replacing the Rear Wheel Bearings
Rear Wheel Bearing Drift
Stripping and Reassembling Rear Brake
Removing Brake Shoes
Position of Brake Shoes
Rear Wheel Removal and Replacement
Removing and Replacing Rear Wheel Bearings
Drifting the Wheel Bearings
Exploded View of Rear Wheel Assembly
Renewing Rear Brake Linings
Punching Lining Rivets
Chiselling off Brake Rivets
Wheel Building
Wheel Balancing
Front and Rear Wheel Alignment
Removing and Refitting Tyres
Security Bolts
Tyre Maintenance
Tyre Pressures
Rear Chain Adjustment
Braking Performance Data
Fault Finding-Front and Rear Hydraulic Disc Brakes
Telescopic Forks: Index
Telescopic Forks: Description
Telescopic Forks: Steering Head Adjustment
Renewing Head Races
Stripping and Reassembling the Fork Legs
Damper Valve Assembly
Removing Oil Seal
Fork Assembly Details
Fork Alignment
Hydraulic Damping
Electrical System
Battery Inspection and Maintenance
Exploded View of Battery
Electrical System: Routine Maintenance
Specific Gravity of Electrolyte for Filling the Battery
Maximum Permissible Electrolyte Temperature During Charge
Coil Ignition System
Fault Finding in the Low Tension Circuit
Checking the Low Tension Circuit for Continuity
Bench Testing an Ignition Coil
Ignition Coil Test Rig
Contact Breaker
Checking the High Tension Circuit
Sparking Plugs
Sparking Plug Diagnosis
Charging System
Schematic Diagram of 12 Volt Charging Circuit
Checking the D.C. Output at the Rectifier
Checking the Alternator Output
Rectifier Maintenance and Testing
Testing the Rectifier
Bench Testing the Rectifier
Rectifier Test Sequence for Checking Forward Resistance and Back Leakage
Checking the Charging Circuit for Continuity
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