Another recommissioning project for me

Flatspot · Mar 17, 2023

I’ve hooked up a spare battery to check all of the electrics, but for now I don’t have a correct sized unit. Success everything works, including the starter motor. The flasher unit is flashing very slooooooowly so maybe a new one May help out there. I needed to fit a new ignition switch as the old one has succumbed like my Commando one did to too much verdigris inside. It isn’t worth battling to repair the old one. There were some lovely fat sparks when I checked the plugs

Flatspot · Mar 17, 2023

oh, one problem, the front brake light switch is f**ked, possibly from when I stripped it all down. It appears beyond repair although I’ll have another look. If it proves to be busted is there a fix, some means of a pressure switch perhaps? Suggestions please.

Flatspot · Mar 17, 2023

Finally today I collected the fuel tank, small US version of course, in sparkling paintwork along with its fuel taps. I shudder to think how long it’s been in ‘stock’ in the attic but it is immaculate. The chrome cap needed a really good session on the buffing wheel to remove all the surface rust it’s acquired over the years.

I also found a brand new pair of Campbell silencers tucked away, how old are they I wonder? I’d better take a couple of pictures tomorrow.

cliffa · Mar 17, 2023

Flatspot said:
I’ve hooked up a spare battery to check all of the electrics, but for now I don’t have a correct sized unit. Success everything works, including the starter motor. The flasher unit is flashing very slooooooowly so maybe a new one May help out there. I needed to fit a new ignition switch as the old one has succumbed like my Commando one did to too much verdigris inside. It isn’t worth battling to repair the old one. View attachment 104812

If it's a Lucas one I would definitely try to repair it. Even an old one is superior to some of the new aftermarket items. There is a little upgrade you can do as well...

Norton Owners Club of NSW - How to Rebuild a Lucas ignition Switch to Better than New

Post date: Dec 25, 2011 12:33:37 PM

sites.google.com

L.A.B. · Mar 17, 2023

Flatspot said:
If it proves to be busted is there a fix, some means of a pressure switch perhaps? Suggestions please.

It is possible to fit the '79-on T140 hydraulic switch assembly...

...or (3/8" UNF) banjo switch but involves changing the upper brake line to one with a banjo fitting.

3/8" UNF-24 Banjo Bolt with Light Switch

Switch open at rest. Switching pressure between 2.5 bar and 5.5 bar. Maximium pressure 350 bar. Nut shoulder to end of thread 19mm. Max switched voltage 24V.

www.venhill.co.uk

Flatspot · Mar 18, 2023

The T140 version looks like a neat solution, thanks.

Flatspot · Mar 18, 2023

Some cleaner carbs and a tank in waiting

Flatspot · Mar 19, 2023

I’ve dropped the sump off, and it is full of oil, showing the oil tank hadn’t been drained before shipping 33+ years ago. I’ll check the chaincase level while I’m at it.

Very clean, but it’s only 3600 miles old. I won’t reuse it

Fast Eddie · Mar 19, 2023

That could be genuine Triumph oil !!

baz · Mar 19, 2023

Flatspot said:
I’ve dropped the sump off, and it is full of oil, showing the oil tank hadn’t been drained before shipping 33+ years ago. I’ll check the chaincase level while I’m at it.

Very clean, but it’s only 3600 miles old. I won’t reuse it View attachment 104846

That's remarkably clean oil
It must have been changed just before it's sleep ?

Flatspot · Mar 19, 2023

Flatspot said:
I’ve dropped the sump off, and it is full of oil, showing the oil tank hadn’t been drained before shipping 33+ years ago. I’ll check the chaincase level while I’m at it.

Very clean, but it’s only 3600 miles old. I won’t reuse it View attachment 104846

Fast Eddie said:
That could be genuine Triumph oil !!

Any offers? I’ll save it 🤣

Flatspot · Mar 19, 2023

baz said:
That's remarkably clean oil
It must have been changed just before it's sleep ?

I don’t know what to make of it. The sump plate was smothered with blue silicone sealant, and the 2 gaskets are not obvious. So I wonder why the sump was taken off first time?

The air filter was clearly the original. The N3C Champion plugs look almost like new once they had a good dip in the ultrasonic cleaner.

I’m now waiting for an exhaust system before I can set about prodding some life into it. Plenty of time yet.

I am struggling to get the fuel tank to fit over the 2 rubber buffers, lightly oiled or washing up liquid neither helps. So I’m going to see if I can slim them down on the sanding machine in case they’ve swollen.

baz · Mar 19, 2023

Flatspot said:
I don’t know what to make of it. The sump plate was smothered with blue silicone sealant, and the 2 gaskets are not obvious. So I wonder why the sump was taken off first time?

The air filter was clearly the original. The N3C Champion plugs look almost like new once they had a good dip in the ultrasonic cleaner.

I’m now waiting for an exhaust system before I can set about prodding some life into it. Plenty of time yet.

I am struggling to get the fuel tank to fit over the 2 rubber buffers, lightly oiled or washing up liquid neither helps. So I’m going to see if I can slim them down on the sanding machine in case they’ve swollen.

That's weird about the tank mount rubbers
Did the tank come off the rubbers ok?

Flatspot · Mar 19, 2023

No, the rubbers have been on the frame for as long as I’ve known it 20+ years. The tank is the original, it was scratched and has been repainted.

L.A.B. · Mar 19, 2023

Flatspot said:
I am struggling to get the fuel tank to fit over the 2 rubber buffers, lightly oiled or washing up liquid neither helps. So I’m going to see if I can slim them down on the sanding machine in case they’ve swollen.

My T160's tank mounting rubbers have been thinned and I can't remember doing that.
They're still tight so I've used rubber (or other?) grease.

Reggie · Mar 19, 2023

I have two tanks for my T160, a UK and a US version.
I also had to slim down one set of rubber mounts because the US tank wouldn't go onto the frame without me doing this. As LAB said, some rubber grease will help the tank push onto the rubbers.

Flatspot · Monday at 9:11 AM

This T160 is really pissing me off. Everything is conspiring against us, I think it’s cursed.
While cleaning up under the sump in readiness of replacing it along with new gaskets I cleaned off some stray floor paint that had been applied to the centrestand. Look what I found next - a lovely crack waiting to cause a problem. That‘ll have to wait until I can get it off the ramp and on the sidestand. Then clean, weld, repaint, refit.

Back to the fuel tank saga. I’ve now sanded down and lubed up the rubbers and the tank won’t slide forwards onto them.

So I’ve taken my tank off and test fitted it and it fits a treat. Tried his tank on my frame - not a chance. It is the tank that was removed from the bike, albeit 33 years ago, and then it was painted and stashed away in the dry. Wtf! Has the tunnel mysteriously closed up somehow?

Those rubbers are going to get a serious trim 🤬

I then phoned him and was told he’s sorted a front exhaust system, good news. Oh and he’s ordered new rubbers. I asked who from knowing what the answer would be, and when I asked if he’d added the half dozen parts I’d got waiting in the basket, he said no, I thought you‘d ordered them already. So now I still need to place an order and he’ll have to pay the carriage. Grrr!

Reggie · Monday at 10:05 AM

Are you trimming the circumference or the width of the rubber mounts. I had to trim the width / flat ends.

Fast Eddie · Monday at 10:18 AM

The tank doesn’t fit because the bike is rejecting it…

It wants a tank painted in the ‘proper’ colours FFS !!

L.A.B. · Monday at 10:25 AM

Flatspot said:
Wtf! Has the tunnel mysteriously closed up somehow?

Those rubbers are going to get a serious trim 🤬

I measure 3.595" across the rubbers if that's of any help.

My T160 also has the small* "2.5 gallon" (according to the books but holds approx. 3.7 Imp. gal.) tank.

*(The large T160 tank also holds considerably more than the stated "4.5 gallons" even if Imperial gallons).

Another recommissioning project for me

Flatspot

Flatspot

Flatspot

cliffa

Norton Owners Club of NSW - How to Rebuild a Lucas ignition Switch to Better than New

L.A.B.

Moderator

3/8" UNF-24 Banjo Bolt with Light Switch

Flatspot

Flatspot

Flatspot

Fast Eddie

baz

Flatspot

Flatspot

baz

Flatspot

L.A.B.

Moderator

Reggie

Flatspot

Reggie

Fast Eddie

L.A.B.

Moderator