Bonneville America Forums Forums Technical Forums Performance Mods Before starting my big bore install.....

I just ordered my 904cc kit today, and thought I'd ask for advice from some of you that have installed it yourself: What else should I have ready when installing this kit. I'm thinking of things like gaskets, RTV, misc bolts/small parts and such. This won't be my first engine rebuild, but it is my first motorcycle(and Triumph) motor. I've read Dinqua's excellent writeup(and will read it several times more before my parts arrive), but I thought I'd try and take advantage of as much experience as I can. Any advice/tips much appreciated.

after reading Dinqua's site it seems to me that you'll need about 2 cases of beer to properly install the big bore kit.

Don't forget oil and filters (non-synthetic for run in and fully-synthetic for after 800kn), cam chain tensioner+clutch cover+rotor cover gaskets, clutch springs, copper washers if your engine well used, Valve stem seals if you intend to port your head (highly recommended). This is all cheap stuff that is worth replacing when rebuilding.

Good luck, you will be happy with results....

Thanks, time for another run to the dealer I suppose.

Use the Barnett clutch springs or you will fry your stock clutch quickly. They are about $20 for a set and are available from any dealer. have them get the ones for the BA/SM or even the regular Bonnie/T100 will do.
You do not have to replace your clutch plates either, just the springs. Oh yeh, you may need the special clutch tool too if you have to remove your clutch basket. You probably willnjot have to as most of the bikes since late 02 had the newer clutch with the larger center hole and they are self aligning. You'll know when you get in there.

With a two hour drive to the dealer I'm trying to get a list of everything I'll need so I can make only one trip, so This information is great. List is growing a lot, clutch springs to valve guides, so thanks.

bike bandit also sells triumph oem parts that you can order and have shipped to you. they are in the tech vault

Frank

maybe this could be a good thing to add in the tech vault, all tools and parts needed for big bore?

Frank

Thanks for the tip on BikeBandit. So far my order is 4 valve seals, RH side cover gasket, clutch cover gasket, and some carb needles. I couldn't find the Barnett clutch springs on their site, so I'll try the dealer for them. Anything else you all can think of before I order?

Also anyone have a source for oversize valves? I'll be tearing the motor down next week, and I'd like to get everything together to send to the machine shop at the same time.

From Barnet site Clutch parts for Triumph - ALL The Bonnevilles and America are right near the top of the page, about 3-4 down.

MT-5-4 is correct part number. I have always just ordered the MT-5-5 from my dealer since they cannot seem to locate the MT5-4, the difference is that you get 5 springs and only need 4 of them. After several big bores I now have a spare set of 4.