Featured 1976 One For 2022

So I ordered some nice new shiny standard cams (I nearly got some half race cams but decided against it as the engine nor I are as young as we once were)



Then there was the tappets, the existing ones are in pretty good condition. One was stamped with an 'R'. Bollox maybe the PO really did know what he was doing. So had to check what tappets I had and what they are supposed to be.

Quote from Vintage Bike Magazine:
"All early T140 engines had 'R' radius (1 1/8") exhaust cam followers while all intake cam followers were standard (3/4") radius"
There we have it, other than what years were 'early' engines. I've always thought that means before the parallel ported engines on the D and E models (someone could put me right on that). I've always thought I was safe as I've only ever had V engines.
So check the tappets (followers):



As can be seen, this is the exhaust tappet as it has the oil feed hole. I've drawn a couple of circles in me note book of 1 1/8" radius and 3/4" radius and this is clearly 1 1/8". So that's good then, we're ok.

 

Feked Classic Bike Parts down in Dorset. They've always given me a great service.

 

And then check the inlet tappets:



Note the 'R' stamp on this one. Again correct as it is a 3/4" radius. Good to continue with rebuild.

Temporary installation of the new camshafts (with the crankcases bolted together and the barrels bolted on) had no movement at all in the bushes! I thought I'd check but wasn't expecting anything other than having to install and ream new bushes. So that was a nice surprise

 

Cor, worth a fortune these days. I met an ex Para a few years ago who collects Arnhem stuff. I did some commemorative stuff for him. He has one of those little two stroke Villiers monkey bikes. He also found a mobile canteen in Holland that he repatriated and restored! Deep pockets required for that stuff. And, no, sorry, it's not one of those in the crate.

 

Build continues with insertion of all new bearings. Lots of heat and lots of whacking with various size whacking things. New shells on journals, polishing of rods etc. Then timing side. (I've loaded the picture up a bit larger so the timing marks are visible to those that may want to see them).



Stick in the cam plate, indent thingy and filler into the gearbox



Slide in top gear and hold with the front sprocket



And build the 5 speed gearbox. I enjoy building the gearbox up so much that I took it out again for fun That is honestly exactly what I did as it is a very satisfying thing to do.

 

Rebuild inner gearbox cover. Hold that in place and index the gearbox while in 1st gear



New rings on pistons, hone barrels as they were pretty good



Insert new tappet blocks and hold tappets with a zip tie.



Bung the head on, rebuild the rockers (with the plain washer next to the aluminium cover and the thackery washer inside that) *Edit - see note below*

 

Phew, nearly there



New rubbers in clutch centre, new primary chain, tensioner from stash. Torque all up.



And after a little problem having to replace a worn kickstart quadrant (that was jamming everything up). It's all done innit. Just about up to speed now.



Nice having an engine on a stand. Pretty. I may just buy engines in the future to keep as ornaments.

 

Yep, that's what we want. I defo gonna do some of those. Don't know if the Admin Staff would want them in the house but brilliant.

 

Edit and note to post #55 above:

I thought I'd best add a note as @darkman pulled me up on the positioning of the washers. Quite right too, he's forgotten more than I know about this stuff

There's been discussions over many years concerning the placement of plain washers and spring (Thackery) washers in the rocker covers. Here's the extract from service bulletin (I think number 25):



More simply:





The BSA designers and ultimate owners of Triumph advised the engine builders at Triumph to change the washers around. But the guys at Triumph basically carried on with what they always had and ignored the boffins at BSA.

Triumph owners and those that work on the engines have been discussing the correct way round for the washers since 1969. It's almost become a greeting amongst the people that own the best motorcycle that the world has ever seen - and will ever see.

 

Onto the frame. So I spent some time (bloody hours it was) cleaning the grime, grease, stone chippings, oil and dead badgers off the frame and wondered about what I wanted to do with this build.



Cleaned the swingarm and discovered that the grease nipples were newish but that hadn't been done soon enough for the bushes not to be worn. In fact, once cleaned, it was pretty sloppy. So new bushes and spindle ordered (I think most of the wear is in the spindle from the looks of the rust pitting).



I wasn't going to mount the silly electrical rear brake light switch (I'll use a hydraulic switch on the banjo) and there was a ding in the frame. So I welded those up.

 

I made up my mind and while the grinder was out I de-lugged the bits I'm not intending to use.
The pillion footrest/zorsts brackets gone, the seat hinge brackets gone, the seat clip gone, the headstock lock ring gone and the chain guard bolt and runner gone. I considered removing the rear loop to the shocks but I think I'll keep that for now.



I checked the frame (under the paint) for known crack areas and all is well. Stuck the wheels back in, the Indian remake of a tank back on and some western bars. This is how it sits while I consider what to do next.



Then this shows up with a rake of boxes full of engine etc. Ha the Admin Staff loves me.



Over....for a while as I de-clutter myself

 

Right, decluttered. Bits put away so I don't mix them up with this build. It'll be another exciting re-build if I can figure out this one.
Today's enthralling episode is mainly cleaning, sorry.
This is a standard T140's spaghetti junction of a brake brake set up. Works pretty well but is a bit confusing if you mix things up. They can be difficult to dismantle and put together as the footrest and engine mounts are in the mix too.



Take off the grease and paint etc. And then grind off the casting joint marks.



I do the footrests and kick stand too. They will all be assembled for the first build to check everything fits and works as they should before dismantle, polish and paint (or I have it in mind to try our recommended local powder coating outfit - recommended by a local Harley Custom builder who turns out some very nice custom work)



I want to eliminate the braking master cylinders (both back and front) and replace with something a bit well..... less bulky. So build the fiddly components back into the frame.

 

Nope, brake assembly goes in before the footrest and make sure the spring is the right way round. So take out and reassemble at least 3 times before it's all working as it should be.



Clean and service brakes



And the front



I had to apply some compressed air to get the pistons out. Blimey, nearly killed myself as one came out with a loud pop and shot across the garage like a bloody bullet!!! I pushed the others out a bit and pulled them out with pliers after that rush of excitement. Pistons are ok once cleaned so will only need new seals, o rings and bleed valves.



These had had new-ish pads with copper grease on the back. The grease had just taken the paint off and allowed them to rust. I'm always amazed at the state of the gunk behind the pistons when so much care is taken to keep the fluid clean. But they were still working!
My advice is, if you are installing new pads, take the calipers off, have a look at the exposed pistons and if they are looking a bit shitty, get them out and have a rebuild. It's not too difficult and it could be well worth the time. Laters , said with a Bristol (like a Pirate) accent.

 

I've always been a bit, erm, not entirely happy with the looks of the skinny back wheels on these. Probably due to my fondness of hardtails and the like. So thought I'd use this build to see what can be done about that. Here it is with the antique tyre in place:



So, out with the wheel and give it a bit of a wipe down



The new tyres are here so take off the old one. Was cold in the garage so this warmed me up no end. Phew.