Triumph 3T DE LUXE 1945 Workshop Instruction Manual Download

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Summary of Contents for 3T DE LUXE 1945

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Page 3: ...T I G E R I I O T R O P H Y 3 T D E L U X E MODELS 1 9 4 5 1 9 5 5 T R I U M P H E N G I N E E R I N G C O L T D MERIDEN WORKS ALLESLEY COVENTRY EHGlAHD TELEPHONE MERIDEN 331 TELEGRAMS TRUSTY COYEHTR...

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Page 5: ...y a general description It is then followed by EXAMPLE bT 93264 l a complete account of the dismantling inspection and re assembly of units and final 1 assembly This has been compiled in the most simp...

Page 6: ...s will appreciate how very difficult it is t o diagnose trouble by correspondence and this is made impossible in many cases because the information sent t o us is so scanty Every possible point which...

Page 7: ...U Carburetter Co Ltd Wood Lane Erdington Birmingham 24 Chains Renold Chains Ltd Wythenshawe Manchester Electrical Equipment J Lucas Ltd Great Hampton Street Birmingham 18 Rear Suspension Girling Ltd...

Page 8: ...xhaust Valve closes A T C I G N I T I O N Distributor Contact Point Gap Sparking Plugs Champion Dis ributor Range Sparking Plug Gap Ignition Timing Fully Retarded Crankshaft position Piston position C...

Page 9: ...Front Rear BRAKES Type Front and Rear Diameter O V E R A L L D I M E N S I O N S Seat Height Wheel Base Length Width Ground Clearance W E I G H T Unladen 4 galls 18 litres 6 pints 3 4 litres 1 pint 6...

Page 10: ...clearance for checking Inlet Valve opens B T C 26f Inlet Valve closes A B C 69f0 Exhaust Valve opens B B C 61 Exhaust Valve closes A T C 35i0 I G N I T I O N Distributor Contact Point Gap 0 014 0 016...

Page 11: ...ront and Rear Diameter O V E R A L L D I M E N S I O N S Seat Height Wheel Base Length Width Ground Clearance W E I G H T Unladen 43 teeth 43 teeth 46 teeth 46 teeth f 335 305 70 g 400 101 Solo 100 Si...

Page 12: ...e lor checking lnler Valve opens B T C 27 lnlec Valve closes A B C 48 Exhaust Valve opens B B C 48O Exhaust Valve closes A T C 27 I G N I T I O N Magneto Contact Point Gap 012 3 rnm Sparking Plugs Cha...

Page 13: ...Front and Rear Diameter O V E R A L L D I M E N S I O N S Seat Height Wheel Base Length Width Ground Clearance W E I G H T Unladen 3 galls 13 68 litres 6 pints 3 4 litres 1 pint 6 litres f pint 2 lit...

Page 14: ...T C 26f Inlet Valve closes A B C 69f0 Exhaust Valve opens B B C 61f0 Exhaust Valve closes A T C 35f0 I G N I T I O N Magneto Contact Point Gap 012 in 3 rnrn Sparking Plugs Champion NA10 Sparking Plug...

Page 15: ...E SIZES Front Rear SUSPENSION Front Rear BRAKES Type Front Diameter Rear Diameter 46 teeth 46 teeth x 335 x 305 70 Solo 69 Sidecar H x W x 100 4 galls 18 litres 6 pints 3 4 litres 1 pint 6 litres pint...

Page 16: ...lnlet Valve closes A B C Exhaust Valve opens B B C Exhaust Valve closes A T C 0 002 in 05 mm 0 004 in lo mm IGNITION Magneto Contact Point Gap 012 in 3 mrn Sparking Plugs Champion L11S Sparking Plug G...

Page 17: ...BRAKES Type Front Diameter Rear Diameter O V E R A L L D I M E N S I O N S Seat Height Wheel B x e Length Width Ground Clearance Cork in O i l Solo Sidecar 24 teeth 21 teeth 18 teeth 18 teeth 43 teeth...

Page 18: ...SPEEDOMETER I LEFT HAHD WBGHT HAND FIG 1 C O N T R O L L A Y O U T...

Page 19: ...open clockwise t o retard I i i II Carburetter Air C o n t r o l Lever TR5 O n the right hand portion of the handlebar Pull clockwise t o open air valve H o r n Button Fitted t o the left portion of...

Page 20: ...which is situated in the timing cover When the engine is running the indicator button MUST protrude to ensure that oil is being fed t o the crankshaft C A R B U R E T T E R A I R C O N T R O L A M A L...

Page 21: ...nt it may be necessary t o re adjust the rear brake see page 108 Handlebars Adjustment is made by slackening off the four U bolt nuts and turning the handlebar to the desired position The TR5 handleba...

Page 22: ...y connections secured The tyres should be checked with a pressure gauge and if necessary adjusted in accordance with the instructions on page 139 Fill the petrol tank with a premium grade of fuel and...

Page 23: ...out the hexagon headed plunger for reserve supply The main tap plunger M U S T be left in ON position I I Fitted t o Models TR5 TIM and T110 Turn on the L H tap after the supply from the RIH tap is e...

Page 24: ...N position as the engine should not be run longer than is absol teiy necessary in the EMG position For special running conditions on the EMG circuit see page 167 When the engine starts the air lever c...

Page 25: ...he RICH running conditions can be stated For many years motorcyclists were advised t o ride their new machines at a speed not in excess of 30 m p h for the first thousand miles W i t h a modern machin...

Page 26: ...e full throttle opening has been worked up t o at about 1 200miles Following the principle throughout that the engine must never be unduly stressed speed bursts wiil be carried out progressively W i t...

Page 27: ...be returned co the oil tank The suction oil pump plunger has twice the capacity of the pressure side in order to make certain that no surplus oil remains on the floor of the crankcase To lubricate the...

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Page 29: ...The plungers and the pump body being con stantly immersed in oil wear is negligible It is unnecessary therefore to suspect these parts if the lubrication is a t fault Should the non return valve balls...

Page 30: ...the tank in exceptional cases it may block the rocker oil feed and is prevented from entering the oil system by the tank filter C R A N K C A S E S C A V E N G E PIPE In the unlikely event o l this c...

Page 31: ...ult to separate thus causing extremely noisy gear changing For oil changing and routine maintenance see pages 31 and 32 C Y C L E PARTS Component parts such as headraces brakes and swinging fork mecha...

Page 32: ...should be removed from the machine and thoroughly cleaned After the lubrication system has been drained and re filled all the joints which have been disconnected and the oil tank drain plug should be...

Page 33: ...ill 5 000 I Check clamp bolts 1 000 I I I P R I M A R Y C H A I N C A S E 1 Drain o l and re fill f the mileage is not covered change monthly 1 000 I I Check over securlry screws 1 000 F O R K S Drain...

Page 34: ...iust above plates monthly In very hot weather check more frequently TYRE PRESSURES Check and correct weekly see page 139 CARBURETTER Dismantle and clean AIR FILTER Clean and re oil filter element 2 0...

Page 35: ...cast iron and the other die cast from aluminium alioy The l a t t e r is fitted with steel liners which can be replaced when the existing liners are worn beyond their maximum re bore limits Each cyli...

Page 36: ...7 The Engine...

Page 37: ...s a ii d d h 2 x L L p s M Z 2 i i i v 2 0 a iw c n n a L L 2 f d 3 E 2 i U Y d n u U U E C J E 22_Lm a t l Y i i c h dP A M U L u d z E GGig ijF ii a u 3 d d d r a c d d d u g o u a L L a 2 2 I u m r...

Page 38: ...o silencing ramps are incorporated in the cam form The tappet adjustment therefore differs from the other models the inlet being set at 0 002 0 05 mm and the exhaust at 0 004 0 10 mm iI A D J U S T M...

Page 39: ...e right side For the inlet clearance only slightly slacken off the adjuster so that when the rocker is held between thumb and forefinger and operated in an up and down move ment a distinct click can b...

Page 40: ...ing the throttle and air slides and take away the mixing chamber assembly Carefully tie the slide assembly t o the frame out of harm s way Carburetter S U Remove the air cleaner connection and vent pi...

Page 41: ...and tighten Care should be exercised I I I I when tightening into an alloy head TRS T100 1 Cylinder H e a d H o l d i n g Bolts Position the remaining four bolts the torque stay i bolts t o the rear...

Page 42: ...ff the branch clip bolt and remove the silencer bolt when the system can be removed T o r q u e Stays 5T 6 T Remove the nuts secuiing the stays t o the cylinder head bolts and slacken off the stays t...

Page 43: ...engine fitting Footrests Remove both footrests but leave the spindle in position F o o t b r a k e Pedal Take out the split pin securing the operating rod t o the pedal and then unscrew the pedal spin...

Page 44: ...nveniently carried out The Fig 9 shows a useful and simple method of holding the engine firmly to enable dismantling Fig 9 E N G I N E IN VICE i DISMANTLING Oil Pressure Release Valve Unscrew from the...

Page 45: ...nto the gear centre the withdrawal tool DA50 1 which is supplied with the tool kit When the tool is in position tighten the centre bolt when the gear will be withdrawn from the shaft Carnwheels If the...

Page 46: ...ose the jaws and re fit the collar t o retain them in posirion N o w turn the tommy bar clockwise when the gear will be drawn from the shaft Do not attempt to shock the p a r OH the shaft by striking...

Page 47: ...Fig 13 C R A N K S H A F T P I N I O N R E M O V A L T O O L...

Page 48: ...I N D E R H E A D Rocker Boxes Unscrew the four nuts and then the four screws when the rocker boxes can be removed from the head Wash the rocker boxes thoroughly and inspect the parts for wear Check t...

Page 49: ...placing t h e Valve Guides T o remove the old guide place a shoulder drift into the guide from the inside of the combustion chamber and drive out When fitting the new guide grease the outer diameter a...

Page 50: ...amount of wear in the upper part of the bore by comparing it with the measurements in the lower i Anything over 0 005 0 13 rnrn will denote that re boring is necessary A rough I t 1 check can be made...

Page 51: ...ge When fitting the new tappet block grease the outer surface and if possible support the cylinder flange See Fig 14 Do not forget to line up the locking screw hole In the tappet block t o that in the...

Page 52: ...groove The face with TOP etched on it must be towards the piston crown The modelsTIM TI10 and TR5 are fitted with a chrome taper ring in the top p sron ring groove This ring may be identified by its b...

Page 53: ...aft bushes normally shbw very little signs of wear until a considerable mileage has been covered T o make a rough check fit the camshaft into the bearing and ascertain the up and down movement if it i...

Page 54: ...mpletely dismantle the pump by removing the t w o plungers and the t w o body plugs when the non return ball valves and springs will be released Wash the pump body and examine the bail seatings if the...

Page 55: ...0 6885 1 7488 cms Connecting rod end float All 0 0290 0 737 mm 0 0320 0 813 rnm Light score marks on the crank big end journals can be carefully eased down with smooth emery but after this operation...

Page 56: ...e old parts should never be re used and fully tighten Lock the nuts by centre punching the periphery of the thread Oil the journal bearings and tit the respective connecting rods Before doing this mea...

Page 57: ...g the camshaft Insert the other camshaft into the exhaust front of engine camshaft bush Crankcase Timing Side Lubricate the main bearing and camshaft bushes Lightly smear jointing compound on the inne...

Page 58: ...the left hand nut Screw down the nut until it contacts the outer tool then to prevent the camshaft turning when the nut is screwed down hold the end of the rod 8 with a suitable tool When the camwhee...

Page 59: ...Timing Gear Markings Arrows show Fig 19 Position of Timing Pinion in relation to Camwheels and crankshaft Pinion 57...

Page 60: ...s Magneto Assemble the magneto t o the crankcase and secure with the three nuts Magneto D r i v i n g Gear Fit the gear t o the magneto shaft and loosely screw on the nut Distributor See Ignition Timi...

Page 61: ...s the piston ring clips will fall clear and can be withdrawn over the connecting rods Guide the block over I the base studs and then remove the wedges from the tappets Fit the eight holding nuts and s...

Page 62: ...ne over until both inlet push rods are nearly level and then assemble the rocker box t o the cylinder head and push rod cover Check that the gaskets have not been misplaced during assembly and then en...

Page 63: ...ure that the rezr lower I stud engages with the rear engine plates j F r o n t Engine Plates Tilt the engine back and swing the plates into pcsition I P e fit all studs and nuts t o both front and rea...

Page 64: ...Tank Replace the tank and secure with the bolts and rubber pads Con nect the petrol pipes The bolts should be locked by wiring the two rear and the two front together Twinseat o r Saddle Fir in posit...

Page 65: ...Pedal Fit to the spindle and replace the spring washer plain washer and finally secure with the nut Connect the operating rod t o pedal and secure with the plain washer and split pin Ensure that the s...

Page 66: ...appet Adjustment Ensure that the tappet is on the base of the cam and then adjust the rocker pin t o give 0 020 0 50 mm clearance between the pin and the vaive tip A t a l a t e r stage t o check t h...

Page 67: ...f the remaining two keyways tried D o not forget t o mark the I i keyway already tried with an indelible pencil t o prevent it being accidentally tried again I N L E T C A M S H A F T T I M I N G Repe...

Page 68: ...the ignition for acing purposes Fit the disc t o the engine shaft and find the true T D C then clip the pointer t o indicate ZERO degrees Set the magneto with the contact points just breaking and the...

Page 69: ...LET valve closes continue gently t o rotate the rear wheel until the piston reaches the top of the rrroke this is known as TOP DEAD CENTREw T D C The correct piston position can be felt with the timin...

Page 70: ...inder Drive side IGNITION TIMING COIL R E P L A C I N G T H E D I S T R I B U T O R A N D D R I V I N G P I N I O N Replacing t h e Distributor A d a p t o r and Coil Assemble the distributor complete...

Page 71: ...i Setting t h e Contact Breaker Points Slacken the distributor clamp bolt and rotate the distributor slowly until the contact breaker heel is on the peak of the cam lobe when the point should be separ...

Page 72: ...freely turned t o the left o r right N o w lean across the saddle or twinseat and rotate the distributor housing slightly contact breaker points nearly vertical until the points just visibly open Ret...

Page 73: ...entral position for the next selection When the pedal is depresed the upper quadrant plunger moves under the guide plate whereas the lower one being released connects with the gear operating quadrant...

Page 74: ...Gearbox Fig 24 GEARBOX COMPONENT PARTS...

Page 75: ...ar operating quadrant Camplate gear control Roller gear control carn plate Plunger gear control cam plate 47 Bush plunger 48 Spring plunger 49 Fork gear selector rnain shaft 50 Fork gear selector lays...

Page 76: ...outer cover pulling the stator lead through the inner cover Engine Sprocket and Rotor Bend back the locking tab on the rotor retaining washer and loosen the retaining nut Clutch Remove as indicated on...

Page 77: ...t t o frame bolts and the silencer bolts when the assembly can be eased off the exhaust stubs Footrests Remove the left hand footrest withdraw the right hand footrest and spindle as an assembly Take c...

Page 78: ...starter crank and withdraw the cover from the gearbox Gearbox Inner Cover Bend back the tab on the kickstarter ratchet and pinion lockwasher and placing a block between the gearbox sprocket and the vi...

Page 79: ...sed 1 in sufficiently t o allow the lever t o be withdrawn past it after removal of the lever i arm peg screw The peg screw should be changed if the peg shows any sign of wear Re assemble in the rever...

Page 80: ...up with the screw hole Kickstarter Ratchet and Pinion This assembly has already been removed to take off the inner cover The pinion and ratchet should be checked for chipped or broken teeth and the s...

Page 81: ...inner race When replacing first warm the casing and then press the bearing into the hous ng securing it with a circlip Lubricate with oil when in posit on Press a new 011seal into the ball race housin...

Page 82: ...ce the layshaft low gear over the layshaft end with the inrernal teeth facing inwards Piace a strzight edge over the gearbox end and test the clearance between the running face of the layshaft low gea...

Page 83: ...inner cover and fit the cable nipple into the clutch lever Footrest Rod If the removal process was carried out as described the rod and right hand footrest and footrest nut should have remained as one...

Page 84: ...sher Speedometer Cable Insert the cable end into the gearbox ensuring that it mates with the driving spindle and then tighten up the attachment nut Clutch Cable Connect cable nipple to clutch operatin...

Page 85: ...equipment to reduce the new inserts t o the correct thickness at each side of the plate and t o ensure an even overall sudace The better method is t o exchange the old plates for service replacement...

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Page 87: ...thus making an effective locking device which prevencs the nut unscrewirg when in service To facilitate removal insert a knife blade A under the head of the nut in order t o hold the spring away from...

Page 88: ...with the clutch i n situ Ifthe shock absorber shows no sign of wwr the uni should not be disturbed the operator proceeding with dismantling from Clutch Push Rod poge 87 Shock Absorber Outer Retaining...

Page 89: ...relea e the pressure on I 1 the spanner when the drive rubbers can be removed Although this chapter deals with the dismantling of the clutch and shock absorber it is desirable at this point to explain...

Page 90: ...tool illustrated in Fig 33 Bend back the locking washer tab and then place a good box spanner on the nut and shock it loose by striking the spanner tommy bar a few sharp blows with a hammer Unscrew th...

Page 91: ...3 C L U T C H L O C K I N G TOOL 89 I 1I Removing Clutch C l u t c h Housing T o remove this unit screw the tool Part No DA50 1 seen in Fig 31 into the clutch centre and by turning the centre bolt the...

Page 92: ...or pitting o r indentation Failure at this point can be rectified by pressing out the old spool and replacing it with a new one which must be ground after fitting Lastly check the housing slots in whi...

Page 93: ...he cable T r u e i n g t h e Clutch The clutch outer pressure plate must spin true otherwise the plates will not separate when the clutch is disengaged thus causing faulty gear changing and the engine...

Page 94: ...s by cable When close ratio gears are employed a plug is supplied t o blank OH the speedometer drive in the gearbox inner cover CHAINS Slack or badly adjusted chains are a prolific cause of harsh runn...

Page 95: ...sters These are located in the rear frame fork ends To TIGHTEN the c h i n slacken off the locknuts and tighten clockwise the adlusrers Pal iicuiar care must be taken nor t o disturb the alignmen of t...

Page 96: ...he adjuster Adjuster If the primary chain is t o be TIGHTENED slacken off the front locknut a few turns and then tighten up the REAR LOCKNUT until the chain tension is correct To SLACKEN the chain rev...

Page 97: ...afin bath moving it about until the joints are washed clean Finally rinse in clean paraffin and leave t o drain and dry The chain after drying will then be ready for lubricating Immerse the chain in a...

Page 98: ...taining an EVEN NUMBER O F PITCHES remove the dark parts shown in No 1 and replace by cranked double I nk and s ngle cranded N o 2 link No 2 N o 3 To SHORTEN a chain contain ng an ODD NUMBER O F PlTCn...

Page 99: ...ver chain and release the lever Jaws should rest on a chain roller free of chain link plates See Fig 38 4 Turn screw clockwise until punch contacts and pushes out rivet and through chain outer link pl...

Page 100: ...t the springs It is estimated that under normal conditions the time between fork overhauls should be about 20 000 miles 30 M O kms This work should be carried out by a dealer or by the Trlurnph Servic...

Page 101: ...d steering damper knob and proceed from Stanchion Cap Nuts First remove the front wheel mudguard headlamp assembly and nacelle top unit as described on pages 109 174 and 177 and proceed as follows Han...

Page 102: ...Telescopic Fork Fig 40 TELESCOPIC FORK...

Page 103: ...ust excluder 23 Washer felt 24 Washer 25 Washer 26 Bearing upper 27 Stanchion 28 Plug oil filler Index h o Description 29 Washer 30 Nut cap 31 Bearing stanchion lower 32 Nut hydraulic stop 33 Spring f...

Page 104: ...t the bottom tube covers and let the oil drain out Pressure T u b e Body Bolt Remove these bolts from the base of the bottom cover tube Pressure T u b e Assembly and Spring Withdraw from the forks by...

Page 105: ...y compressed the springs are fit for further service The free length of the spring should be within j 12 7 mrn of the original length which i s 19 L 49 cms solo and 20 51 cms s c Ball Races Cups cones...

Page 106: ...Ai gnlnxTC LICO IC Fork Fig 41 ALIGNING THE FRONT FORK 104...

Page 107: ...satisfactory tighren che pinch bolts and make anotlirr 1 lleci2 I ASSEIIIILINC AND I N S T A L L I N G THE F O R K NACELLE TYPE I Befort lrrnrr cdrg to assemble the fork lubricate ill pars I Stanc dr...

Page 108: ...nchlon will not be drawn into the top lug and excessive strain will be put on the crown and stem F o r k Crown Pinch Bolts Tighten up the pinch bolts See Fig 41 and text describing fork alignment Hand...

Page 109: ...sidecar purposes the I I operator should remove the headlamp and nacelle top cover as described on page 177 and the handlebars as described on page 99 dnd proceed as follows I I Cap Nuts Unscrew the t...

Page 110: ...mum amount of grip on the lever After making an adjustment spin the wheel t o ensure that the brake shoes are not binding on the brake drum Rear Brake The adjustment is made by turning the knurled thu...

Page 111: ...he cable Withdraw the pivot pin A n c h o r Plate Bolt Unscrew the nut and remove the bolt connecting the anchor plate t o the fork leg Spindle N u t Remove from the spindle F r o n t Stand Lower the...

Page 112: ...Ffont Wheel Fig 43 F R O N T W H E E L ST 6 T TRS...

Page 113: ...the brake shoe fulcrum pin I N S P E C T I O N AND R E P L A C E M E N T O F W O R N PARTS I Washing All parts with the exception of the brake shoes should be thoroughly washed with petrol o r paraffi...

Page 114: ...Front wheel...

Page 115: ...extra cost If the old brake shoes are to be used for further service inspect the rivet heads as these must be below the surface of the lining Rivets which show signs of contact with the brake drum can...

Page 116: ...too tight clean out the lug and remove any burrs o r enamel If this is not effective open up the split lug gap This procedure must be carried out t o ensure that the left hand fork leg aligns itself...

Page 117: ...Aligning Front Wheel...

Page 118: ...derneath the saddle unscrew the nuts connecting the mudguard to the frame and take OHthe mudguard TR5 The mudguard of the TR5 is designed to allow removal of the rear wheel and it is therefore unneces...

Page 119: ...Rigid Rear Wheel d w u ul 2 N a...

Page 120: ...arts with the exception of the brake shoes should be thoroughly washed in petrol o r paraffin A n c h o r Plate Examine the anchor plate for distortion and wear particularly in the brake cam housing C...

Page 121: ...ngs to the retaining hooks then taking a shoe in each hand and at the same time holding the springs in tension posltion the shoes to the anchor plate By turning the top of the shoes inwards the assemb...

Page 122: ...n be placed into the brake drum Screw the remaining shouldered locknut small shoulder towards the brake drum onto the spindlo and tighten fully t o that already in position Ease the brake lever toward...

Page 123: ...uires no adjustment Slackness in the bearings can be checked by f i r s t placing the machine on the central stand and then testing the lateral movement which should be hardly perceptible if the beari...

Page 124: ...Fig 48 REAR WI IEEL SWINGING ARM FRAME...

Page 125: ...ng tabs and remove the eight bolts and nuts when the drum can be released D I S M A N T L I N G T H E REAR BRAKE A N C H O R PLATE Brake Shoes Take off both brake shoe return springs and remove the br...

Page 126: ...s the procedure is the same as that listed for the rigid frame rear wheel on page 118 Bearings Clean and dry the bearings thoroughly Test the end float and inspect the balls for any signs of indentati...

Page 127: ...cking tabs up the sides of the bolts t o lock them Bearing Brake Drum Side Place the locking ring into the hub from the brake drum side until it contacts the small shoulder inside the hub Press the be...

Page 128: ...d of splining the hub into the brake drum thus eliminating the necessity of removing the rear chain and disconnecting the rear brake All other details are as the rigid frame rear wheel R E M O V I N G...

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Page 130: ...o r q u e Stay Remove the rear nut Spindle Sleeve Nut Unscrew this nut and remove the brake drum assembly from the frame D I S M A N T L I N G T H E B R A K E A N D D R U M SPROCKET ASSEMBLY A n c h o...

Page 131: ...d at the same time holding the springs in tension position the shoes t o the anchor plate By turning the top of the shoe inwards the assembly can be placed over the cam and the fulcrum pin and snapped...

Page 132: ...ween the dust cover and the spindle sleeve Screw one of the locknuts onto the sleeve until a nip is felt and then slacken back a t of a turn so that the sleeve will rotate freely Tighten the other nut...

Page 133: ...uctions a e given however for owners who wish t o carry out their own maintenance and repairs N o attempt should be made td dlsmantlethe plunger guide box without the aid of the special jig illustrate...

Page 134: ...Spring Wheel Fig 52 REAR SPRING W H E E L C O M P O N E N T PARTS...

Page 135: ...nd guide 23 Roller slipper 24 Sleeve L H distance 25 Spring inner main 26 Spring outer main 27 Spring rebound Anchor Plate Pivot Unscrew the two locknuts a t the top of the anchor plate pivot and remo...

Page 136: ...more than 0 002 0 05 mm EACH SIDE it will be in order to proceed with the dismantling Should the clearance be above the l mit make a note of the dimensions to assist rectification on assembly After c...

Page 137: ...hard wood drift out the brake drum side bearing End Plate Bearing Tap out this bearing using a suitable soft drift Removal can be facilitated by heating the back plate to approximately 100 C D I S M A...

Page 138: ...nerally noticed on the thrust side only Front pad on the chain side and rear pad on the opposite To remove unscrew the t w o screws holding the pad in position Manufactured by Messrs A E Baines Ltd Ha...

Page 139: ...L A T E A S S E M B L Y Brake C a m Spindle Grease the spindle and fit t o the anchor plate Fit the return spring and lever arm making certain that the lever arm i s in the correct position Fit the re...

Page 140: ...c l u d e r Assembly L H Replace the dust excluder asembly with the concave side t o the front and secure with the t w o screws Ensure that the wheel spindle is in i t s topmost position and the brake...

Page 141: ...e Dunlop Booklet which advises the necessary increased inflation pressure E X A M I N A T I O N Espectally during the period when the roads are being tarred and gritted the tyres should be examined pe...

Page 142: ...d in steps of 2 3 nches 5 t o 8 cms until the i bead is away from the rim I n n e r Tube Push the valve out of the rim and remove the inner tube Removing t h e Second Bead Stand the wheel upright and...

Page 143: ...of the rim diametrically opposite the valve Insert a lever a s close a s possible to the point where the bead passes over the flange and lever the bead into the flange at the same time pressing the fi...

Page 144: ...is fitted in order t o obtain the clearance which should be between OOOSa 0 0065 0 013 0 16 mrn A grease nipple is fitted t o the frame t o provide access for grease t o the bearing by means of a gre...

Page 145: ...N D E X TO FIG 57 GiRLlNG HYDP AULIC SUSPENSION UNIT Index No Description 1 Damper unit 2 Spring suspension 3 Dirt shield upper 4 Dirt shield lower Index No Description 5 etainer spring 6 Bush rubber...

Page 146: ...sufficiently to enable the removal of the split spring retainer collars Spring Remove the dust cover and spring ASSEMBLY The assembly is carried out in exactly the revetse order t o the dismantling se...

Page 147: ...head t o the handlebar and withdraw the head ASSEMBLY Rotor Sleeve t o Head These can be replaced before assembling to the handlebar Lightly grease rotor end ring and fit the rotor sleeve into the hea...

Page 148: ...r sleeve Index No Description 1 Head assembly 2 Plate retaining 3 Circlip 4 Sleeve assembly 5 Thimble cable Head Assemble top and bottom halves to the handlebar and rotor sleeve Enter the clamp screws...

Page 149: ...e a d assembly plain half 2 H e a d assembly threaded half 3 Screw friction adjuster 4 Sleeve assembly Rotor Sleeve Stop Adjacent to the knurled damper screw Is a small screw and nut and by slackening...

Page 150: ...TTING A SIDECAR RIGID FRAME MODELS also see Supplement First the motorcycle must be prepared for sidecar use Fork springs of the heavier type must be fitted t o counteract the additional load placed o...

Page 151: ...th the rear wheel of the machine Should the sidecar have a tendency t o lift easily on left hand bends lean the machine more t o the vertical If these few precautions are taken during fitting the ride...

Page 152: ...keep the engine running at a low tick over when the twistgrip is shut off Pilot Air Screw To set the idling mixture this screw should be set in or our t o enrich or weaken normal number of turns is ab...

Page 153: ...K SPRING SPRING BARREL THROTTLE SPRING AIR SLIDE SPRING THROTTLE SLIDE STOP SCREW LOCK SCREW AIR SCREW NEEDLE JET MAIN JET 7 UNION N U T FLOAT NEEDLE j es a HOLDING BOLT Fig 60 AMAL C A R B U R E E R...

Page 154: ...frequent intervals When dry re oil the element with Vokes Trifiltrene filter oil If this is unobtainable SAE 20 grade oil may be used The filter element should be changed every 10 000 miles 15 000 km...

Page 155: ...When detaching the suction chamber and piston assembly from the main carburetter body necessary when checking o r changing the needle it will be necessary t o remove the OIL CAP After the t w o side s...

Page 156: ...S U Corburetter Fig 63 S U CARBURETTER C O M P O N E N T PARTS...

Page 157: ...rottle barrel 3 Screw adaptor t o body 4 Gasket adaptor t o body 5 Abutment throttle cable 6 Screw 7 Screw plug 2 B A 8 Washer 9 Chamber suction complete 10 Spring piston 11 Washer thrust 12 Screw nee...

Page 158: ...OIL THREE DROPS MONTHLY I THROTTLE DISC v FIBRE FRICTION WASHERS...

Page 159: ...fuel consumption This defect is easily detectable When the engine is not running the piston should rest upon the bridge 28 When raised by the hand through the air intake the p i s t n should drop free...

Page 160: ...jet have become laterally displaced in service due t o inadequate tightening of the locking screw IS o r any other cause This operation will of course also be necessary if the let and its associated p...

Page 161: ...st be detached from the jet head the locking screw 15 removed and the entire jet and jet bush ass mblywithdrawn O n re assembly great care should be taken t o replace all parts in their correct situat...

Page 162: ...ignition control is working properly that the timing i s correct and in particular that it is not over advanced especially at idling AIR FILTER THE AIR FILTER SHOULD NOT BE DISCONNECTED I N A N ATTEM...

Page 163: ...ulator should be re set by a Lucas Service Depot o r Agent Accurate measuring equipment is required t o set the regulator correctly A m m e t e r Readings Normally during day timcrunning when the batt...

Page 164: ...Tp TAIL Fig 66 WIRING DIAGRAM TI00 T11Q...

Page 165: ...plete contact breaker must be removed for this purpose Take out the hexagon headed screw from the centr e of the contact breaker and carefully lever the contact breaker off the tapered shaft on which...

Page 166: ...screw Carefully lever the contact breaker off the tapered shaft on which it fits Push aside the locating spring and lift the rocker arm OHi t s pivot when it will be possible t o clean the contacts W...

Page 167: ...series connected coils one pair being permanently connected across the rectifier bridge network The purpose of this latter pair is t o provide some degree of charging current for the battery whenever...

Page 168: ...A r Generator Fig 67 P R I M A R Y C H A I N C A S E C O V E R R E M O V E D T O S H O W R O T O R A N D S T A T O R...

Page 169: ...D pGRWS SHOW NG 5w l r c PO51TIONS LOOX fl6 aY TOP OF SWITCH Fig 68 WIRING DIAGRAM 5T 6T...

Page 170: ...or carried on and driven by an extension to the crankshaft The rotor has an hexagonal steel core each face of which carries a high energy permanent magnet keyed to a laminated pole tip The pole tips a...

Page 171: ...the cam with one of the greases recommended for the grease gun use in the Recommended Lubricants chart in the Instruction Book If this is not available clean C engine oil may be used 1 I W A R N I N G...

Page 172: ...p width is correct the gauge will be a sliding fir If the gap width varies appreciably from the gauge thickness the setting must be adjusted To do this keep the engine in the position giving the maxim...

Page 173: ...lead t o the coil Nexc connect the volt meter between the coil terminal marked C B and earth N o reading here with the ignition I switched on indicates a fault in the coil primary winding If these te...

Page 174: ...O R T TO F R A N C E O N L Y These lamps have a double filament pre focus 6 volt 36 36 watt bulb yellow with a three point connection t o the lamp Basically the above lamps are identical the differenc...

Page 175: ...rit fit the reflector t o the shell and locate with the rubber head assemble the rim and glass engaging the tongue into the top of the shell and the fastener catch into the rim S E T T I N G T H E H E...

Page 176: ...urn the plastic lens H E A D L A M P A N D T O P N A C E L L E UNIT R E M O V A L Dynamo Equipped Models Battery Disconnect the battery positive lead Steering Damper Unscrew and remove Headlamp Unscre...

Page 177: ...to remove the top unit only it is unnecessary t o proceed any further If the forks are to be removed however it will be necessary t o disconnect the blue lead from the dipper switch t o switch positi...

Page 178: ...he sample has been taken DO NOT M U W I N XX MKH ELECTROLYTE Fig 72 TAKING HYDROMETER READINGS Measurements should not be taken immediately after the cells have been topped up as the electrolyte will...

Page 179: ...t one inch and thread one bared end through the knurled nut and coilet Bend back the cable strands over the narrow end of the collet and insert the coliet and cable into the terminal block Secure the...

Page 180: ...nt is necessary turn the screw one notch at a time If the original performance cannot be restored by adjustment do not attempt t o dismantle the horn but return it t o a Lucas Service Depot for examin...

Page 181: ...tening only Always use a tubular box spanner t o avoid possib e fracture t o the insulator but do not under any circumstances use a movable wrench i Paint splashes accumulation of grime and dust etc o...

Page 182: ...Toolkit ft 5 Fig 74 TOOLKIT L a r...

Page 183: ...to points I I i i DA 72 Spanner open x Whit Wheel bearing nuts I r ii PA 56 i Spanner combination General 1 t NA 55 Spanner open 1 x v Whit i i j DA 16 1 Spahner open X Whir 3 KA 50 Spanner open 0 375...

Page 184: ...return of the oil from the overhead rocker gear on the elrlier models is by internal oil ways in the cylinder head and block but i n 1949 external oil drain pipes were fitted from the cylinder head to...

Page 185: ...lier A C equipped models in that the alternator stator is mounted on the inner half of the chaincase i Therefore it is unnecessary t o disconnect the aiternasor lead when removing the i outer half of...

Page 186: ......

Page 187: ...aight edge and if necessary very carefully trued up with a fine file o r emery cloth used on a flat surface such as plate glass When refitting the carburetter always use a new p aper joint washer and...

Page 188: ...f the push rod tubes TAPPET ADJUSTMENT 3T Tappet adjustment is made on the rocker arms after removing the t w o tappet inspection covers on the rocker boxes Method of adjustment is described in the Wo...

Page 189: ...nd lightly oil the bearing portion of the crank journal Care should be taken t o allow no oil to reach the portion which mates with the flywheel hole Fit the connecting rod to the drive side crank wit...

Page 190: ...Little end bush 27 lnterrnediate pinion 8 D S crank 28 Bush intermediate pinion 9 Flywheel 29 Automatic timing device 10 T S crank 30 Nut exhaust camshaft 11 O i l seal tube 31 Nut inlet camshaft 12...

Page 191: ...spindles can be tapped out from the threaded end using a soft tool and the rocker arms extended from the rocker box 6 To remove the cylinder block on early models it is only necessary t o raise it cle...

Page 192: ...r fibre 9 Rocker R H 10 Rocker L H 11 Pin ball 12 Pin adjusting 13 Nut lock 14 Spindle rocker 15 Washer 16 Washer plain 17 Washer spring 18 Nut spindle Collar split Collar spring Spring outer Spring i...

Page 193: ...able rocker oil feed pipe and exhaust pipes I 9 Run engine and carry out statlonary tests After stopping re tighten all nuts and bolts SPRING WHEEL Pik 1 The following instructions are given for the b...

Page 194: ...s the back plate 5 Fit the shims t o the hub and assemble the back plate Screw up the nuts securing the back plate and test the rotation of the spring box for freedom during the tightening Failure t o...

Page 195: ...Spring Wheel Mk 1...

Page 196: ......

Page 197: ...GEAR R A T I O S Bottom 2 D U R Arm Rigid Sw Arm Swinging Arm 0 170 lor 1950 machines S W Spring Wheel t 8 with Spring Wheel Up to Engine No 37560...

Page 198: ...Compression Ratio Power Output at r p m Tappet Clearance ins Valve Timing in Deg I G N I T I O N Type Contact Gap ins Timing fully advanced Plug Gap ins CARBU RETTER Type Main Jet Needle Jet Needle Ty...

Page 199: ...Bottom 12 70 12 20 12 20 E N G SPROCKET Solo 22 22 S dccar 19 19 C H A I N L E N G T H rrmary I x 3 0 5 78 78 Rear 3 x 4 93 93 CAPACITY Petrol plls 4 4 011 pints R Arm Rigid Sw Arm Swinging Arm 170 f...

Page 200: ...Grease Grease Part Engine Oil Tank Gearbox Primary Chaincase Spring Wheel Wheel Hubs Steering Head S A E Grease Grease 20 20 No 7 B 9 10 OIL CAN LUBRlCATiON Ail Brake Rod Joints and P ns 20 Part Brak...

Page 201: ...gine Oil Tank Gearbox Primary Chaincase Wheel Hubs Steering Head Bmke Cam Spindle S A E 20 or 30 50 20 Grease Grease Grease Pins 8 9 10 Part Footbrake Pedal Spindle Grease Exposed Cables Fork Hydrauli...

Page 202: ...RECOMMENDED LUBRICANTS UNITED KINGDOM UNIT WAKEFIELD Enginesummer Winter Gearbox Primary Chalnuse Telescopic Fork Summer Wheel Bearings Easing Rusted Parts...

Page 203: ...rol X L Castrol tc Encrgol SAE 50 Encrgol SAE 30 Encrgol SAE 20 Mobil Spring Oil Castrol Grand Prix Castrolitc Encrgrcasc L2 EssOlubc 40 Essolubc 30 Essolubc 20 Castrol Grand P r x Castrol XL Castroll...

Page 204: ...Magncto Cut out shorting N o Spark at Plugs Coil ignition Contact Points dirty Incorrect Contact Point Gap Contact Breaker A r m Sticking H T Collector shorting to body Condensation on Sparking Plugs...

Page 205: ...tion FAULT FINDING E N G I N E STOPS Check Fuel In Tank Supply at Carburettcr if no supply Rcmovc Pipes and Tank Filters if necessary See Page 150 D r y I g n t o n System Remove Carburetter and clean...

Page 206: ...nd cator Button is working Scc Page 28 Chcck Supply in Oil Tank Rcmovc Cylindcr Hcad Scc Pagc 38 Rcrnovc Cylinder Hcad Scc Pagc 38 Scc Pagc 38 Scc Pagc 16 Placc Marlt t coti tlic Stands and rc adjust...

Page 207: ...ryrc cquiprncnt 780 R P Mllc 2nd will dcvilrc slightly lrom above figurer for models nor so equipped 4 02 r 18 Rear Tyre 785 R P Milc 3 25 19 Rear Tyrc 793 R P Mile 4 W x 19 Rerr Tyrc 756 R P Mile GEA...

Page 208: ...n to camwheels and crankshaft pinion 57 20 Timing diagrams 58 21 Fitting the cylinder barrel 59 22 Magneto in timing position 67 23 Distributor in timing position 69 24 Gearbox Component arts 72 25 Ki...

Page 209: ...ring wheel Sectioned 135 Jig for compressing plunger guide box springs 136 lliustraticn showing the position of the valve if the tyre has crept round therim 140 Girling hydrauiic dampe unit 143 Twistg...

Page 210: ...ar wheel ST 6T TR5 119 Assembling the rear wheel T100 T110 125 Assembling the spring wheel 137 B Battery 177 C Carburetter Amal 150 Carburetter S U 155 Chain alterations and repairs 96 Chain maintenan...

Page 211: ...uspension damper units 142 H Headlamp and top nacelle unit 176 Horns 179 I Ignition timing Coil 68 Ignition timing Magneto 67 Inlet camshaft timing 65 Inspection and replacement of worn parts Front wh...

Page 212: ...e rear wheel from the frame ST 6T 116 Removing the rear wheel from the frame TI00 T110 121 Removing the spring wheel from the frame 131 Replacing the brake drum and sprocket in the frame Q D rear whee...

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Triumph 3T DE LUXE 1945, Workshop Instruction Manual

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