Triumph Bonneville T120 Recall

Discussion in 'Technical Help' started by RickM46, Dec 28, 2024.

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  1. alfie

    alfie Getting older but still going for it
    Subscriber

    Jan 27, 2018
    384
    213
    Bath, Zumerset
    Small cockup on my part....
     

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  2. RickM46

    RickM46 Active Member

    Oct 12, 2023
    76
    28
    US
    #22 RickM46, Mar 30, 2026
    Last edited: Mar 30, 2026
    OK, guys here it is:
    I have a subscription to the Triumph Technical Information website. The following is a link to TTIs instructions to the dealer to splice in new connections to avoid the burn problem.

    Read their instructions and it looks like 3 black wires out of the alternator out of the engine block have to be spliced with 3 black wires into the main harness going up under the seat after the old connector block is cut away.

    Don't know if you will be able to follow the link unless you have a subscription:
    https://triumphtechnicalinformation...db60c2927dfaf25e4?topics=13802360331&active=0

    What could possibly go wrong: the black wires are not marked and the tech would have to keep track of which black wire splices with the next by their position into the old connector blocks.

    Thanks Alfie; you got the repair pdf that is at the TR subscription site.

    I am not nuts about this fix.
     
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  3. TRIPLE X

    TRIPLE X Senior Member

    Sep 1, 2021
    699
    243
    Norfolk
    Agree, not a great fix. Surely there is a connector that will not melt which could have been used? So now the alternator is permanently connected to the main harness, so how do you replace it if it fails?
     
  4. RickM46

    RickM46 Active Member

    Oct 12, 2023
    76
    28
    US
    #24 RickM46, Mar 30, 2026
    Last edited: Apr 1, 2026
    Well, just some questions:
    Why the original recall clip?
    Was there a defect in the connector blocks?
    Maybe susceptible to water/moisture causing deterioration? If so, I would just wrap a baggy around them.
    Do the connector blocks perform some other electron management function?
    Is there a way to replace the connector blocks?

    When weather gets warmer, I am going to take a ride and shoot the connector block with a temperature gun at the beginning and end to see if the connectors are heating up.
     
  5. RickM46

    RickM46 Active Member

    Oct 12, 2023
    76
    28
    US
    Regit nogara mentioned in my 'Bonneville' post on this recall that 'Water ingress maybe???'; the wrapping of a plastic bag around the block might be a fix.
     
  6. Zwniana

    Zwniana Member

    Nov 11, 2024
    13
    8
    Philadelphia, PA
    Is it worth holding off?
     
  7. RickM46

    RickM46 Active Member

    Oct 12, 2023
    76
    28
    US
    When the weather gets warmer here, I will take the bike on a ride into town 7 miles and back and take a temp reading on the plug to see if heat is a factor.

    I am not nuts about this fix.

    I do not ride in the rain; Considering water egress, I am considering wrapping the plug in that contact clear plastic protector available in hardware stores anyway.
     
  8. Zwniana

    Zwniana Member

    Nov 11, 2024
    13
    8
    Philadelphia, PA
    Agree... I may do the same. I did notice that when I bought it they had put in the 3 wire clip. Good idea about wrapping the plug
     
  9. RickM46

    RickM46 Active Member

    Oct 12, 2023
    76
    28
    US
    #29 RickM46, Apr 13, 2026 at 9:15 PM
    Last edited: Apr 14, 2026 at 3:24 PM
    Used my heat measuring gun on 2 rides to get an idea of how hot the brown alternator block in question gets.
    Short 2 mile neighborhood ride round trip:
    Outside temp 70F.
    Brown alternator electrical block: 70F.
    Black connector block up to left: 78F.
    Engine block: 124F

    Ride into town 14 mile round trip:
    Outside temp 75F.
    Brown alternator electrical block: 86F.
    Black connector block up to left: 90F.
    Engine block: 174F

    Hence, brown alternator block does not get that hot; if anything it is mildly heated by the heat off the engine block. Am not going to do anything with this recall except wrap the block in some clear plastic sticky to protect it from water - especially since it is right above the chain.

    I am not an Electrical Engineer, not nuts butchering what looks like good engineering; hence, time will tell if my experiment holds.
     
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