Triumph Daytona 955i Service Manual Download

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Full Specification

Speed Triple 955cc

Daytona 955i

T° ^uMPH

GENERAL INFORMATION l

Fuel System

FuelType

..........................

FuelTank Capacity ................. .
LowLevel Warning Lamp ............ .
FuelPump Type .................... .
Fuel Pressure (nominal) ............

. .

Pur

econtrol

system ............... .

Fuel Injection System

Type

...............................

Idle

Speed..........................

ectorTy

........................

Throttle

............................

ControlSensors

.....................

Cooling System
CoolantMixture

.....................

Anti-Freeze Type

....................

Freezin

Point

..................... .

Coolin

System

Capacity

.............

Radiator Cap Opening Pressure .......

Thermostat Opening Temperature .....

Cooling Fan Switch On Temperature .. .

Temperature Gauge Sensor Resistance
Suspension

Front

Fork

Travel

....................

Recommended Fork Oil Grade ........

Oil Level (fork fully compressed) .......
OilVolume

(

fill)

..................

Front Fork Pull Through

..............

RearWheel Travel

................

Rear Suspension Bearing Grease .....

Brakes

Front

type

........................

Caliper Piston Dia

. .

..................

Disc

Dia

...........................

Disc

Thickness

......................

DiscRun-out Max ................... .
Master Cylinder Diameter

............

RecommendedFluid

.................

Rear

Type

..........................

Caliper Piston Dia

. .

..................

Disc

Dia

...........................

Disc

Thickness ......................

DiscRun-out Max ................... .
Master Cylinder Diameter ............ .
Recommended Fluid

.................

Unleaded, 95 RON
(U.S. 89 CLC/AKI)
18 Litres

3.5 litres remaining
Submerged

3 .0 Bar

Electronic via fuel system ECU

Electronic, sequential
1100 RPM

Twin jet, solenoid operated plate valve

Cable/twist grip/electronic

throttle potentiometer

Barometric Pressure

Throttle Position, Coolant Temperature

Crankshaft Position,
Induction air temperature

50/50 Distilled Water/Anti-Freeze
Mobil Antifreeze

—35°C

2.8 Litres

1.1 Bar

85°C (nominal)
95°C
2.9-3.3KQ @ 15°C

120 mm

Showa SS8
76 mm

589cc

Flush with top yoke upper face
140 mm

Mobil Grease HP 222

Two Hydraulically Actuated

Four Piston Calipers acting on

twin discs
33.96 mm/30.23 mm
320 mm
4 mm (3.5 mm minimum)
0.3 mm (0.1 mm standard)

14mm

Mobil Universal Brake and Clutch
Fluid DOT4

Hydraulically Actuated 2 Piston Caliper

Single disc

27 mm
220 mm
5 mm (4.5 mm minimum)
0.3 mm (0.1 mm standard)

14mm

Mobil Universal Brake and Clutch
Fluid DOT4

Unleaded, 95 RON
(U.S. 89 CLC/AKI)
18 Litres

3.5 litres remaining
Submerged

3.0 Bar

Electronic via fuel system ECU

Electronic, sequential
1100 RPM

Twin jet, solenoid operated plate valve

Cable/twist grip/electronic

throttle potentiometer

Barometric Pressure

Throttle Position, Coolant Temperature

Cranksha

Position,

Induction air temperature

50/50 Distilled Water/Anti-Freeze

Mobil Antifreeze

-35°C

2.8 Litres

1.1 Bar

85°C (nominal)
95°C
2.9-3.3KS @ 15°C

120 mm

Showa SS8

76 mm

589cc

Flush with top yoke upper face
140 mm

Mobil Grease HP 222

Two Hydraulically Actuated

Four Piston Calipers acting on

twin discs
33.96 mm/30.23 mm
320 mm
4 mm (3.5 mm minimum)
0.3 mm (0.1 mm standard)

14 mm

Mobil Universal Brake and Clutch
Fluid DOT4

Hydraulically Actuated 2 Piston Caliper

Single disc
27 mm
220 mm

5 mm (4.5 mm minimum)
0.3 mm (0.1 mm standard)

14 mm

Mobil Universal Brake and Clutch
Fluid DOT4

1.19

Summary of Contents for Daytona 955i

Page 1: ...T595 DAYTONA T509 SPEED TRIPLE DAYTONA 955i SPEED TRIPLE 955cc...

Page 2: ...rate as possible Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior notice and without incurring an obligation to make such changes to products manuf...

Page 3: ...tion Routine Maintenance Cylinder Head Clutch Balancer Crankshaft Rods Pistons Transmission Lubrication Fuel System Cooling System Rear Suspension Final Drive Front Suspension Steering Brakes Wheels T...

Page 4: ...nts of the Periodic Maintenance Chart in the Service Manual Do not allow problems to develop Investigate unusual noises and changes in the riding characteristics of the motorcycle Rectify all problems...

Page 5: ...from the rear Operations covered in this manual do not always include reference to testing the motorcycle after repair It is essential that work is inspected and tested after completion and if necessa...

Page 6: ...holes and tightened to a snug fit evenly and in a cross pattern This is to avoid distortion of the part and or causing gas or oil leakage Conversely bolts nuts or screws should all be loosened in seq...

Page 7: ...ngs 1 6 Liquid gasket non permanent locking agent 1 6 Screwthreads 1 6 Lockin g devices 1 7 Fittin g a split pin 1 7 Circlips retaining rings 1 7 Selflocking nuts 1 7 Enca psulatedbolt 1 7 Oiland grea...

Page 8: ...shaft and Crankcase 1 21 En g ineCovers 1 21 Transmission 1 22 LubricationSystem 1 22 FinalDrive 1 22 Coolin g System 1 22 FuelSystem and Airbox 1 23 Wheels 1 23 RearSuspension 1 23 FrontSuspension 1...

Page 9: ...orm extremely corrosive liquid hydrofluoric acid If such conditions exist do not touch the material and avoid all skin contact Skin contact with liquid or decomposition residues can cause painful and...

Page 10: ...Check for fluid leakage around brake fittings seals and joints Check regularly for brake hose damage FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO AN ACCIDENT...

Page 11: ...s hot the coolant inside the radiator is hot and also under pressure Contact with the pressurised coolant will cause scalds and skin damage CAUTION The coolant anti freeze contains a corrosion inhibit...

Page 12: ...um disulphide grease in the assembly of certain engine and chassis parts Always check manufacturer recommendations before using such special lubricants Follow manufacturer s directions for cleaning an...

Page 13: ...ace encapsulated bolts Oil and grease seals Replace any oil or grease seals that are removed Removal will cause damage to an oil seal which if re used would cause an oil leak Ensure the surface on whi...

Page 14: ...others that petrol is being openly handled The notice must instruct the reader of the precautions which must be taken Failure to observe any of the above warnings may lead to a fire hazard which could...

Page 15: ...ting live H T circuits always use insulated pliers Exercise caution when measuring the voltage on the coil terminals while the engine is running high voltage spikes can occur on these terminals Connec...

Page 16: ...r aspects of the motorcycle operation which may result in an accident causing serious injury or death T MPH A WARNING Always have Triumph approved parts accessories and conversions fitted by an author...

Page 17: ...anual cannot be carried out without the aid of the relevant service tools Where this is the case the tools required will be described during the procedure Special service tools T3880012 Valve Shim Rem...

Page 18: ...nostics T3880300 Wrench Yoke Upper Nut Em I T3880285 Fork Seal Bearing Drift i gand yduu T3880305 Clutch Anti rotation Tool I T3880290 Wrench Swinging Arm Clamp T3880311 Oil Filter Wrench I T3880295 W...

Page 19: ...m Lift Duration 251 Exhaust Open 510 BBDC 1 0 mm Lift Close 25 ATDC 1 0 mm Lift Duration 256 Camshaft Journal Dia 22 93 mm 22 90 mm 22 936 mm 22 923 mm Outrigger Camshaft Journal Clearance 0 12 Max Ca...

Page 20: ...0 05 mm 0 4 mm max 0 20 mm 0 05 mm 0 4 mm max Transmission Type GearRatios 1st 2nd 3rd 4th 5th 6th Gear Selector Fork Thickness Gear Selector Groove Width Gear Selector Fork to Groove Clearance FinalD...

Page 21: ...33 96 mm 30 23 mm 320 mm 4 mm 3 5 mm minimum 0 3 mm 0 1 mm standard 14mm Mobil Universal Brake and Clutch Fluid DOT4 Hydraulically Actuated 2 Piston Caliper Single disc 27 mm 220 mm 5 mm 4 5 mm minimu...

Page 22: ...FrameType OverallLength Overall Width to mirrors OverallHeight Wheelbas SeatHeight Castor Trail DryWeight Max Payload rider passenger luggage accessories Electrical Equipment BatteryType BatteryRatin...

Page 23: ...1 0 mm Lift Duration 2410 Exhaust Open 34 BBDC 1 0 mm Lift Close 25 ATDC 1 0 mm Lift Duration 237 Camshaft Journal Dia 22 93 mm 22 90 mm 22 936 mm 22 923 mm Outrigger Camshaft Journal Clearance 0 12...

Page 24: ...05 mm 0 4 mm max 0 20 mm 0 05 mm 0 4 mm max Transmission Type GearRatios 1st 2nd 3rd 4th 5th 6th Gear Selector Fork Thickness Gear Selector Groove Width Gear Selector Fork to Groove Clearance FinalDri...

Page 25: ...emperature 50 50 Distilled Water Anti Freeze Mobil Antifreeze 35 C 2 8 Litres 1 1 Bar 85 C nominal 95 C 2 9 3 3KQ 15 C 120 mm Showa SS8 76 mm 589cc Flush with top yoke upper face 140 mm Mobil Grease H...

Page 26: ...except in authorised closed course conditions Frame FrameType OverallLength Overall Width to mirrors OverallHeight Wheelbas SeatHeight Castor Trail DryWeight Max Payload rider passenger luggage access...

Page 27: ...Clutch centre nut 105 Clutch pressure plate to centre 10 Clutch cover sound suppression plate to cover 12 Balancer Crankshaft and Crankcase Application Torque Nm Notes Crankcase upper to lower M8 fix...

Page 28: ...ch to crankcase 13 Use new washers Oil filter to adapter 10 Oil feed pipe to cylinder head 25 Use new washers Oil cooler connections to sump 25 Use new washers Oil cooler connections to cooler 25 Use...

Page 29: ...box to cam cover 10 1 it P Application Torque Nm Notes Front wheel spindle axle bolt 60 Front wheel spindle pinch bolts 20 Rear wheel to stub axle 146 Rear Suspension Application Torque Nm Notes Swing...

Page 30: ...Rear brake master cylinder to frame 30 Encapsulated fixing Rear brake master cylinder reservoir to battery box 5 Rear brake hose to master cylinder 25 Rear brake disc to axle shaft 22 Use new fixings...

Page 31: ...RAL INFORMATION I Bodywork Application Torque Nm Notes Front mudguard to fork 9 Side panels to frame 9 Front seat to frame 9 Cockpit to headlamp casting 5 Belly panel to bracket 8 Side panel to bracke...

Page 32: ...MAINTENANCE CONTENTS Page Introduction 2 2 ServiceCheck Sheets 2 2 MaintenaceChart 2 3 2 1...

Page 33: ...negative black lead lest Remove bodywork fuel tank and airbox as q q q q 3 31 Inspect front looks for oil leaks damage smooth necessary Always store displaced bodywork operation safely to prevent acci...

Page 34: ...renew 9 Steering check for free operation Day 12 Headstock bearing check adjust 12 Headstock bearing lubricate 12 Rear wheel bearing lubricate 11 Forks check for leaks smooth operation Day 12 Fork oil...

Page 35: ...ftand Bearing Cap Inspection 3 10 ValveClearances 3 12 CamChain 3 17 Removal 3 17 Installation 3 17 CylinderHead 3 18 Removal 3 18 Inspection 3 22 Installation 3 23 Valvesand Valve Stem Seals 3 27 Rem...

Page 36: ...12 25 131 3 2 3 CYLINDER HEAD CAMSHAFT TiuMI MrII Exploded View Cylinder Head and Valves Refer to Text 9 Nm X 0 0 10 Nm...

Page 37: ...Exploded View Cam Cover 25 Nm ThUMI CYLINDER HEAD CAMSHAFT 3 3 3...

Page 38: ...Exploded View Camshaft and Camshaft Drive 10 Nm 9 Nm 18 Nm 3 CYLINDER HEAD CAMSHAFT T MPH 3 4...

Page 39: ...to assist in the prevention of valve bounce at high engine speed and to give a smooth valve actuation When assembling the cylinder head it is important that the close wound colour coded ends of the s...

Page 40: ...leak 9 Remove the cam cover gasket 10 Remove any residual oil from the front of the head using a syringe or lint free cloth Installation 1 Check the condition of the cam cover seal Refit replace as n...

Page 41: ...ockets will point inwards at a point level with the joint face o 4f 0 gaaa Camshaft to Cylinder Head Alignment Marks 5 Place a suitable wedge between the tensioner blade and crankcase to hold the cam...

Page 42: ...oner blade when viewed from above 8 Rotate the engine through 4 full revolutions and reset number 1 cylinder to TDC Ensure that the Ti mark on the crankshaft rotor is aligned with the crankshaft posit...

Page 43: ...ggers are marked A for the exhaust and B for the inlet 4 Progressively release each of the fasteners securing the camshaft caps of the inlet camshaft to the cylinder head 5 Release the caps for the ex...

Page 44: ...o a camshaft using incorrectly identified bolt holes Severe engine damage wil l result from incorrect attachment 1 Outrigger Journal 2 Standard Journal 3 Examine all camshaft and camshaft bearing caps...

Page 45: ...camshaft at a time locate the cam chain over the cam sprocket Position the camshaft in the same position as for removal before attempting to fit the caps that is with the timing marks on the camshaft...

Page 46: ...g Away From Valve 4 Using feeler gauges measure and record the clearances for this pair of valves only 5 Repeat the process until the valve clearances for all valves have been checked NOTE If the meas...

Page 47: ...nstructions are closely followed to ensure correct tool operation 3 Loosely assemble the tool legs to the mounting plate ensuring that the legs are assembled to the correct side of the mounting plate...

Page 48: ...ing the charts shown overpage 9 Take the selected replacement shim and lubricate with engine oil Fit the shim to the top of the tappet by reversing the removal procedure 10 Turn the engine over until...

Page 49: ...UA c0 O t to I O a0 UCH 00 0 O In O 0 O LO O O T U 0 T N N N N N N N N N N N N N N N N N M M M M M O M In r 0 N U N U C 7 0 d t CF O In LIB U O CO U U O f U I O CO lf 00 O 0 In O 0 O LO O O r Lo T 0 N...

Page 50: ...U 0 c0 N N U N N N N N N N N N N N Co Co Co CO Co 0 to O U 0 U 0 M O m 0 U O U 0 0 LO 0 LO N M V cF to c0 CO N r U 00 O O O O T T N N N U N N N N N tf N O N Lo N O N to N 0 N Ln N 0 CO to Co O CO U C...

Page 51: ...crankcase after first detaching the chain from the crankshaft gear Installation 1 Refit the cam chain and locate the lower end around the crankshaft gear 2 Fit the crankshaft position sensor 3 Refit...

Page 52: ...shown above right NOTE Two longer bolts are fitted at the right hand end adjacent to the cam chain Cam Cover Bolt Release Sequence 8 Ease the water hoses to allow the cover to be removed from the lef...

Page 53: ...bed in the lubrication section 17 Disconnect the clutch cable as detailed in the clutch section 18 Remove the clutch cover to give access to the crankshaft rotor 1 Crankshaft Rotor Clamp Nut 2 Cranksh...

Page 54: ...nts 22 Remove the bolts securing the tensioner to the upper crankcase and remove the tensioner and gasket 23 Remove the cam chain top pad from the cam chain side of the cylinder head gabs 1 Cam Chain...

Page 55: ...oil feed pipe to the head Discard the copper washers 1 Oil Feed Pipe 3 Banjo Bolt 32 Remove the radiator and oil cooler as described in the cooling system section 33 Remove the exhaust downpipes and...

Page 56: ...2 4 6 Cylinder Head Bolt Release Sequence 40 Lightly tap the cylinder head with a rubber mallet to break the seal of the gasket Remove the cylinder head 41 Remove and discard the cylinder head gasket...

Page 57: ...ipe clean with a lint free cloth leaving minimal oil on the threads that is almost dry to touch Tighten the bolts using the three stage procedure given below Failure to observe these important items m...

Page 58: ...with the operation of the brakes clutch or the throttle itself Any of these conditions could result in loss of control of the motorcycle and an accident WARNING Move the handlebars to left and right...

Page 59: ...valve clearances may cause excess engine noise rough running and engine damage 22 Recheck that the crankshaft rotor Ti mark aligns with the crankshaft position sensor when the timing marks on both cam...

Page 60: ...nd adjust as described in the clutch section 37 Inspect all coolant hoses and refit the hoses and thermostat housing in their original positions 38 Reconnect the coolant temperature sensor 39 Refit th...

Page 61: ...em 2 Install the valve into the valve guide and refit the thrust washer to the valve spring recess if removed 3 Fit the valve stem seal over the valve stem and using a suitable tool press down fully u...

Page 62: ...ased CAUTION Always check for correct location of the valve collets during and after assembly If not fitted correctly the collets may become dislodged when the engine is running allowing the valves to...

Page 63: ...ge Ex plodedView Clutch Cover 4 2 ClutchCable 4 5 Removal 4 5 Examination 4 5 Assembly 4 5 Clutch 4 6 Removal 4 6 Assembly 4 8 FrictionPlate Inspection 4 11 Frictionplate thickness 4 11 Frictionplate...

Page 64: ...12 Nm 9Nm 12 Nm N 0 0 0 0 4 CLUTCH Exploded View Clutch Cover 9 Nm 5 Nm 9Nm 4 2...

Page 65: ...105 Nm 10 Nm 4 3 T MPH CLUTCH 4 Exploded View Clutch Assembly...

Page 66: ...6 Nm 4 CLUTCH Exploded View Clutch Controls 1 Nm 15 Nm V 4 4...

Page 67: ...e slots in the adjuster and locknut until the cable can be detached from the lever by pushing downwards 1 1 Nut locknut Slots 2 Cable Release Point 7 Remove the cable from the motorcycle noting the ca...

Page 68: ...Secure the setting with the knurled locknut ii 1 Clutch Lever 2 Correct Setting 0 4 0 8 mm CLUTCH Disassembly 1 Remove the seat and disconnect the battery negative black lead first 2 Remove the belly...

Page 69: ...t friction plates differ from all others and must not be fitted in any other positions They are also darker in colour NOTE It is not normally necessary to disassemble the clutch further but if the clu...

Page 70: ...eliminator is a parallel thinner gear which follows the main alternator drive gear To ensure correct engagement of the auxiliary gear with the alternator drive gear align the teeth of the alternator...

Page 71: ...the inner and outer drums together using service tool 13880305 Depress the rear brake pedal to prevent the engine from turning and tighten the clutch centre nut to 105 Nm Remove the service tool 1 1 S...

Page 72: ...ual tags in the clutch outer drum 1 Outer Clutch Friction Plate 2 Outer Drum 3 Individual Tags 15 Refit the clutch pullrod 16 Refit the clutch pressure plate together with the springs and bolts Tighte...

Page 73: ...then the negative black lead 26 Refit the seat 1 Clutch friction Plate Friction plate thickness Standard 3 80 mm 0 00 0 08 mm Service limit 3 60 mm 2 Check all plates for bend and warp as follows Pla...

Page 74: ...S Page Ex plodedView Balancer Shaft 5 2 Balancers 5 3 Ali g nmentInspection 5 3 Balancer crankcase plug replacement 5 4 BalancerShaft Removal 5 4 Disassembly 5 5 Examination 5 6 Assembly 5 6 Installat...

Page 75: ...5 2 5 BALANCERS Exploded View Balancer Shaft 40 Nm if fitted J 40 Nm...

Page 76: ...e oil into a clean container 3 Remove the clutch cover as described in the clutch section 4 Lever out the plug shown in the illustration below from the right hand side of the crankcase Take care not t...

Page 77: ...at least one hour before starting the engine Balancer Shaft Removal NOTE To remove the balancer the engine must be removed from the frame and the two halves of the crankcase separated to allow remova...

Page 78: ...the circlip exerts considerable upward pressure and can cause the clip to jump o ff during release Eye damage could result from contact with a displaced circlip 4 Collect the belleville washer flat wa...

Page 79: ...tor gear such that the line marking on the backlash eliminator gear is in line with the dot marked balancer drive gear tooth 4 Fit the flat washer belleville washer dished face outwards and circlip WA...

Page 80: ...the teeth of the drive gear For ease of identification during assembly apply a small paint spot to the outside face of the dot marked balancer drive gear tooth 2 Apply Three Bond 1375B high strength l...

Page 81: ...se Take care not to mark or damage the case during removal NOTE The plug will be damaged during removal and must be discarded 11 Turn the engine over until the Ti mark on the crankshaft rotor aligns w...

Page 82: ...Main Bearing Journal Wear 6 18 Crankshaft main bearing journal clearance 6 18 Crankshaftmain journal diameter 6 18 CrankshaftEnd Float 6 18 Pistons 6 19 Disassembly 6 19 PistonWear Check 6 19 Pistonou...

Page 83: ...See text c 6 2 6 CRANKSHAFT RODS PISTONS TIUMI MPII Exploded View Crankshaft Connecting Rod Piston and Liner 1...

Page 84: ...Exploded View Crankcase 25 Nm 13 Nm dancer section O 12 Nm 10 Nm T 111 CRANKSHAFT RODS PISTONS 6 6 3...

Page 85: ...with engine oil can lead to skin dryness irritation and dermatitis In addition used engine oil contains potentially harmful contaminants which can cause cancer Wear suitable clothing and avoid skin c...

Page 86: ...earchange adjuster rod Slacken the locknuts securing the gearchange rod to the ball joints and turn the rod until it becomes detached at both ends gafx 1 Gearchange Rod 17 Set the drive chain adjustme...

Page 87: ...26 Place a support beneath the engine and ensure that the frame is adequately and securely supported 27 Remove the frame to head bracket from the left hand side of the motorcycle 7 V v 3 7 J Il 1 Fra...

Page 88: ...mm add spacer part number 3550220 T0301 to reduce the gap below 1 mm NOTE If a spacer is needed for the lower right hand rear engine mounting bolt an equivalent sized spacer must also be fitted to th...

Page 89: ...and harnesses do not bind A cable or harness which binds will restrict the steering and may cause loss of control and an accident 1 Adjuster Twist Grip End 2 Adjuster Throttle Body End 22 Set the cabl...

Page 90: ...pass Hose rear 33 Refit the coolant drain plug and tighten to 13 Nm 34 Refit the oil cooler to the radiator and tighten the fixings to 9 Nm 2 Oil Cooler to Crankcase Bracket 36 Using new washers on bo...

Page 91: ...shaft position sensor Disassembly A CAUTION Failure to follow the correct screw release sequence may result in permanent crankcase damage 1 Working on the upper crankcase bolts first release the bolts...

Page 92: ...new O ring to the oil pump outlet 7 Install and lubricate the crankshaft bearing shells with clean engine oil 1 1 gagr 1 Locating dowels 4 Use high flash point solvent to clean the crankcase mating f...

Page 93: ...CRANKSHAFT RODS PISTONS T1IUMI MPH NOTE The crankcase screws are tightened in stages in the same sequences used during strip down Two different sizes of crankcase screw are used All screws are tighten...

Page 94: ...lts and nuts Using the original nuts and bolts may lead to severe engine damage 5 Remove the liner using tool T3880315 as described later in this section Installation NOTE Connecting rod bolts and nut...

Page 95: ...cap using new nuts and bolts as follows Lubricate the threads of the bolt and the face of the nut with molybdenum disulphide grease Tighten the nuts progressively in 2 stages CAUTION The torque chara...

Page 96: ...ck the bearing journal clearance as described in the following pages before final assembly of the crankshaft Failure to correctly select crankshaft bearings will result in severe engine damage 1 Selec...

Page 97: ...fication during assembly apply a small paint spot to the outside face of the dot marked balancer drive gear tooth 5 Fit the crankshaft to the crankcase aligning the two dot marked teeth on the cranksh...

Page 98: ...iameter Standard 40 946 40 960 mm Service limit 40 932 mm NOTE If any crankpin has worn beyond the service limit the crankshaft must be replaced Due to the advanced techniques used during manufacture...

Page 99: ...the clearance exceeds the service limit measure the diameter of the crankshaft main journal Crankshaft main journal diameter Standard 37 960 37 976 mm Service limit 37 936 mm NOTE If any journal has w...

Page 100: ...p Carefully remove the mark to allow the pin to be removed 4 Piston rings must be removed from the piston using hand pressure only CRANKSHAFT RODS PISTONS 6 Piston Wear Check 1 Measure the piston outs...

Page 101: ...the ring gap is found to be too small the ring end must be carefully filed until the correct gap is achieved If the gap is too large replace the rings with a new set If the gap remains too large with...

Page 102: ...below 1 Top Ring 2 Second Ring 3 Steel Oil Control Rings 4 Oil Control Ring Expander NOTE The top ring gap should be positioned in the 7 o clock position the second ring gap in the 1 o clock position...

Page 103: ...re can be easily damaged Handle with care ensuring the cylinder bore is not scratched 4 Carefully fit the tool fully into the cylinder bore positioning the tool legs on the crankcase Turn the locking...

Page 104: ...2 Sealer Area 4 Fit each liner over the piston using a gentle rocking motion to allow compression of the piston rings 1 Piston 2 Liner CAUTION Fit each liner over whichever piston is at TDC When turn...

Page 105: ...moval until the point where the cover is to be fitted 2 When refitting the cover remove the mandrel only at the point when the cover assembly is to be refitted and ensure that the seal and breather sh...

Page 106: ...ler Gear 7 12 Removal 7 12 Inspection 7 12 Assembly 7 12 Selectors Selector Shaft Drum 7 13 Removal 7 13 Inspection 7 15 Gearselector fork thickness 7 15 Gearselector groove width 7 15 Selectorfork to...

Page 107: ...132 Nm 7 2 7 TRANSMISSION TkQ2WH Exploded View Input and Output Shafts...

Page 108: ...lONm 10 Nm 12Nm 16 40 Nm TIUMI MP1 TRANSMISSION 7 Exploded View Auxiliary Gears 12 Nm 7 3...

Page 109: ...12 10 Nm 7 TRANSMISSION Exploded View Selector Mechanism 12 Nm 7 4...

Page 110: ...7 5 TRANSMISSION 7 Exploded View Gear Pedal etc JJ 9Nm 9Nm 9Nm 28 Nm...

Page 111: ...rankcase drives an idler gear in constant mesh with the sprag clutch The sprag clutch is mounted on the alternator shaft When the starter is energised the sprag clutch action allows the alternator sha...

Page 112: ...tially harmful contaminants which can cause cancer Wear suitable clothing and avoid skin contact 8 Drain the coolant as described in the cooling section then remove the water elbow from the rear of th...

Page 113: ...ing inwards 3 Fit tool 3880040 T0301 to the front alternator mounting bolt holes 4 Fit a new nut to the alternator drive housing end where the bolt head extends through Hold the nut and tighten the bo...

Page 114: ...itive red lead first 17 Refit the seat SPRAG CLUTCH NOTE In order to remove the sprag clutch the engine must first be removed from the frame and the two halves of the crankcase separated Removal 1 Rem...

Page 115: ...t bearing Remove the sprag clutch and collect the spacer from inside the crankcase NOTE The bearing is not an interference fit no force is required to move the bearing within the crankcase 13 Remove t...

Page 116: ...g inwards 7 Fit a new nut to the alternator drive housing end where the bolt head extends through Hold the nut and tighten the bolt to 40 Nm 8 Remove tool 3880040 T0301 9 Check the alternator 0 ring f...

Page 117: ...l J 1 _ 1 _ gacu 1 Idler Gear Shaft 2 Retaining Screw and Washer 3 Slide the shaft from the crankcase and collect the idler gear 1 Shaft 2 Gear Inspection 1 Check the spindle for damage pitting etc R...

Page 118: ...ure push the selector shaft out of the crankcase in the direction of the keeper plate Collect each selector fork from the lower crankcase as they are released from the selector shaft 1 Selector Forks...

Page 119: ...ower crankcase 11 Remove the oil pressure relief valve 12 Remove the 2 screws securing the selector drum stop plate to the crankcase Remove the stop plate gadb r J 1 Selector Drum Stop Plate 13 Remove...

Page 120: ...te the selector drum bearing with clean engine oil 3 Support the drum and refit the selector drum bearing Retain with the bearing lock and capscrew Tighten the capscrew to 12 Nm 4 Align the quadrant w...

Page 121: ...so check that there is no binding of the arms during operation 1w ME Detent Position 1st Gear Detent Position Neutral 11 Apply Loctite 270 to the oil pressure relief valve threads and tighten the valv...

Page 122: ...taining rings are correctly located when refitting both shafts NOTE Apply a small amount of Loctite 648 to the bearing locations in the upper crankcase before fitting the assembled transmission shafts...

Page 123: ...11 from in front of fifth gear 10 Remove the lipped thrust washer 12 adjacent to fifth gear 11 Remove fifth gear 13 12 Place the shaft in a press with the input shaft bearing supported on press bars a...

Page 124: ...from the input shaft bearing 3 Slide on the thrust washer 12 4 Fit a new circlip 11 to the input shaft ensuring that the clip is correctly located in the circlip groove 5 Fit the combined third fourth...

Page 125: ...then release the nut 13 Remove the transmission sprocket nut 19 locktab 20 sprocket 21 and sleeve 25 14 Collect the oil seal 22 and retaining ring 23 15 If it is found necessary to replace the large b...

Page 126: ...he selector fork groove facing away from the output sprocket end Ensure that the oil hole in the gear aligns with the double oil hole in the output shaft 1 Double Oil Hole 2 Gear Oil Hole CAUTION Inco...

Page 127: ...m p hEn gine Oil 8 8 OilLevel Inspection 8 8 En g ineOil and Filter Change 8 9 OilPump And Gears 8 10 Removal 8 10 Inspection 8 11 Installation 8 11 LowOil Pressure Warning Light Switch 8 12 Sump 8 13...

Page 128: ...O p 0 0 O o 8 Nm M WE 8 LUBRICATION TJMPH Exploded View Sump 28 Nm 0 10 Nm 12 Nm 10 Nm 8 2...

Page 129: ...9Nm l 12 Nm TwMaIi LUBRICATION 8 Exploded View Oil Pump and Gears 15 Nm 9Nm 8 3...

Page 130: ...2 8 4 8 LUBRICATION Exploded View Daytona Oil Cooler 25 Nm 25 Nm 25 Nm...

Page 131: ...I A 9 Nm 4i O 0i vi ii 9Nm 25 Nm 0 0 0 O T LUBRICATION 8 Exploded View Speed Triple Oil Cooler 9 Nm 25 Nm C O 25 Nm 8 5...

Page 132: ...8 LUBRICATION 3 Cylinder Oil Circuit Q D 0 D D D LI Li 6 9 11 gact 8 6...

Page 133: ...ings in the crankshaft to the big end bearings Oil exits from the big ends through holes in the connecting rods and then splash lubricates the bores and pistons The remainder of the filtered oil is pa...

Page 134: ...et the required specification or does not fall into the correct viscosity band Triumph Engine Oil 100 Synthetic MobilH racing 4T Your Triumph Motorcycle is a quality engineered product which has been...

Page 135: ...ng washer to the sump plug and refit the plug tightening it to 28 Nm 6 Move the container to a point below the oil filter 7 Using tool T3880311 to release the filter cartridge unscrew and remove the o...

Page 136: ...on of the keeper plate Collect each selector fork from the lower crankcase as they are released from the selector shaft 1 Gear Screws 2 Washers 3 Auxiliary Gear 4 Intermediate Gear And Shaft 5 Oil Pum...

Page 137: ...the retaining screw to 9 Nm 2 Fit the oil pump intermediate gear and shaft to the crankcase TJUllMII LUBRICATION 8 0 1 1 foJ 9a9 1 1 1 Oil Pump Retaining Screws 8 Remove the oil pump from inside the l...

Page 138: ...er plate and tighten the retaining bolt to 6 Nm Inset Selector Shaft Keeper Plate 9 Refit the input and output shafts Low Oil Pressure Warning Light Switch The low oil pressure warning light switch is...

Page 139: ...sump WARNING The oil may be hot to the touch Contact with hot oil may cause the skin to be scalded or burned WARNING Prolonged or repeated contact with engine oil can lead to skin dryness irritation a...

Page 140: ...the oil cooler pipes Tighten the cooler pipe banjo bolts to 25 Nm 5 Apply a smear of clean engine oil to the seal of a new oil filter 6 Fit the oil filter and tighten to 10 Nm 7 Refit the exhaust syst...

Page 141: ...damaged during release of the hose connections Always follow the above method to avoid oil cooler damage 6 Using the same method disconnect the return hose Oil Cooler Hose Disconnection LUBRICATION 8...

Page 142: ...ELECTRICALCONNECTORS 9 55 ECMConnector 9 55 ECMConnector Pin Numbering 9 56 FURTHERDIAGNOSIS 9 57 FUELTANK 9 76 FuelTank Removal 9 76 Installation 9 77 FUELPUMP 9 78 Removal 9 78 Assembly 9 78 FUELFIL...

Page 143: ...tion 9 90 Adjustment 9 90 THROTTLEBODIES 9 91 Removal 9 91 Inspection 9 92 Assembly 9 93 THROTTLEBODY BALANCING 9 94 INJECTORS 9 95 Removal 9 95 Inspection 9 96 Testing 9 96 Assembly 9 96 THROTTLEPOSI...

Page 144: ...FUEL SYSTEM ENGINE MANAGEMENT 9 Exploded View Fuel Tank and Pump 12 Nm b I s JIII 6Nm 9 3...

Page 145: ...20 5Nm 5 Nm 5Nm 9 Nm 0 2Nm o Nm 9 FUEL SYSTEM ENGINE MANAGEMENT TI MPI Exploded View Fuel Rail Throttles and Injectors early models 20 Nm 20 Nm o o 20 Nm o o 9 4...

Page 146: ...9N I FUEL SYSTEM ENGINE MANAGEMENT 9 Exploded View Fuel Rail Throttles and Injectors later models G 9 5...

Page 147: ...9 FUEL SYSTEM ENGINE MANAGEMENT T1UMI MPH Exploded View Purge and Idle Air Control System early models moo 9 6...

Page 148: ...TUMI MPI FUEL SYSTEM ENGINE MANAGEMENT 9 Exploded View Purge and Idle Air Control System late models 9 7...

Page 149: ...See Text oo m 9 8 9 FUEL SYSTEM ENGINE MANAGEMENT Tkewff Exploded View Typical Exhaust System T595 Daytona Illustrated...

Page 150: ...clean air standards some areas of the U S use oxygenated gasoline to help reduce harmful emissions These gasolines are a blend of conventional gasoline and another compound such as alcohol Triumph mot...

Page 151: ...op measured as a voltage and expressed as percentage 0 0 volts 100 5 volts Coolant temperature The coolant temperature in the thermostat housing Coolant temperature sensor Measurement in volts at the...

Page 152: ...system Open circuit A break in an electrical circuit current cannot flow Over temp High temperature within the Electronic Control Module ECM caused by an internal or external failure Purge valve duty...

Page 153: ...sition in relation to the point where fuel is injected and ignition of the fuel occurs Because each cylinder fires once per two revolutions of the crankshaft it is not possible to determine by cranksh...

Page 154: ...ne Control Module Barometric Pressure Sensor Engine Coolant Temperature Sensor behind battery in airbox right hand side in thermostat housing beneath fuel tank Neutral Switch Throttle Position Sensor...

Page 155: ...coils mounted directly onto the top of each spark plug The ECM controls the point at which the coils are switched on and off In calculating the switch on time the ECM allows sufficient time for the c...

Page 156: ...r The ECM controls switching on and off of the cooling fan in response to a signal received from the coolant temperature sensor When the coolant temperature rises to a level where the cooling effect o...

Page 157: ...d switch 18 Starter motor 19 Diagnostic connector 20 Road speed sensor early models only 21 Crankshaft sensor 22 Camshaft sensor early models only 23 Idle air control valve stepper motor 24 Neutral sw...

Page 158: ...All 9 17 T 1 U M 1 H FUEL SYSTEM ENGINE MANAGEMENT 9 Circuit Diagram Engine Management System up to VIN 71698 29 30 31 32...

Page 159: ...utch lever switch 17 Sidestand switch 18 Starter motor 19 Diagnostic connector 20 Not used 21 Crankshaft sensor 22 Not used 23 Idle air control valve stepper motor 24 Neutral switch 25 Coolant tempera...

Page 160: ...FUEL SYSTEM ENGINE MANAGEMENT 9 Circuit Diagram Engine Management System from VIN 71699 29 30 31 32 9 19...

Page 161: ...ill be logged in the ECM s memory and the MIL Malfunction Indicator Lamp on the motorcycle instrument panel is illuminated Once a fault is confirmed the number of warm up cycles made by the engine is...

Page 162: ...sident in the ECM Function Tests The system allows the diagnostic tool to perform a series of function tests on various actuators in the engine management system In some cases it is necessa ry to make...

Page 163: ...d P0335 Crankshaft sensor circuit malfunction 3 40 Yes P1335 Crankshaft sensor incorrect sequence pattern 3 40 Yes P0340 Camshaft sensor malfunction 3 40 Yes P0341 Camshaft sensor circuit fault 3 40 Y...

Page 164: ...circuit malfunction 3 40 Yes P0112 Intake air temperature too high 3 40 Yes P0113 Intake air temperature too low 3 40 Yes P0230 Fuel pump relay fault 3 40 Yes P1 231 Fuel pump relay open circuit 3 40...

Page 165: ...t open circuit N A 40 No P1117 Coolant temperature gauge short to battery voltage over temperature N A 40 No P1 386 Tachometer short circuit open circuit N A 40 No P1387 Tachometer short to battery vo...

Page 166: ...BTDC ATDC Throttle voltage Volts Corrected Throttle position Percentage Purge valve duty cycle Percentage Idle air control valve stepper position Incremental steps ranging from 0 to 255 Ignition swit...

Page 167: ...get more information about that line of text To return to the diagnostic screen from the help area press the help button again N gaei Return key The Up and Down keys press to move the lines of text up...

Page 168: ...FUEL SYSTEM ENGINE MANAGEMENT 9 9 27...

Page 169: ...frame data CURRENT DATA CALCULATED LORD FREEZE FRRI1E WATER TER CALCULATED LORD IDLE FUEL TRIP WATER TE17P OFF IDLE TRIP1 IDLE FUEL TRII7 REP COUNT OFF FUEL TRIP RIR TERP REP COUNT 1G1Y RDVRIYCE RIR T...

Page 170: ...NT PRIYEL IRC URLPE PURGE LRLPE FUEL PU17P COOLING FRIY FUEL PU17P PRIME FUNCTION TEST DTCS PRESENT CLEAR BEFORE TEST RCTIOIY Error Count Screen Cancel FUPICTION TEST TEST fIAP1E PROCEED CRIYCEL Proce...

Page 171: ...I Read sensors RERD SENSORS RIR SENSOR RIR TEP1P URTER TEI7P SENSOR IJRTER TEP7P REV COUNT IDLE REF BRTTER9 SENSOR REF INJECTOR RIR PRESSURE CALCULATED LORD TGT QUELL IGNITIDtI TMING THROTTLE THROTTLE...

Page 172: ...STICS CHECK ADJUST QUIT Check Adjust Check Adjust menu CHECK ADJUST CHECK CHANGE QUIT Change ADJUST ADJUST TUNE UPDRTE TUNE QUIT Update tune UPDRTE TUNE r r r r r PP2 TEST PASSWORD Fail SECURITY ACCES...

Page 173: ...D 5 9 FUEL SYSTEM ENGINE MANAGEMENT TUUMaI MPII 1 CONNECTION AND POWER UP 2 SELECT LANGUAGE SELECT LANGUAGE will then be displayed Use the Up and Down keys to move the cursor in column 1 and select t...

Page 174: ...give the diagnostic software version and the software release year Press the validation key to move on If the Return key J is pressed the tool will return to the SELECT LANGUAGE display Switch on the...

Page 175: ...ns for which the operator has to input information without which the testing cannot proceed further Enter your Dealer number as follows The number 555555 is displayed with the cursor pointing down at...

Page 176: ...DIAGNOSTICS menu provides access to Current data e g actual engine temperature engine speed etc Diagnostic Trouble Codes DTC s i e access to codes stored in the motor cycle ECM which indicate a confi...

Page 177: ...can be accessed by scrolling using the Up and Down keys At the end of each line of text the actual reading at that instant is provided to assist diagnosis e g ENGINE TEMP 95C CURRENT DATA AVAILABLE Fu...

Page 178: ...TICS Press the Validation key to display DIAGNOSTICS menu T MPH FUEL SYSTEM ENGINE MANAGEMENT 9 11 STOP ENGINE STOP EnGr TIE Switch off the engine As the tool is powered from the motorcycle this will...

Page 179: ...L DTC DATA YES NO Information about each DTC can be obtained by scrolling the text until the appropriate code is opposite the in line 3 then press the Help key DTC example P0035 Help text CRRNKSHRFT S...

Page 180: ...be gained by scrolling the text line in question to line 3 then press the Help key as before Press the Validation key to display STORED DTCS operation 16 FREEZE FRAME DATA AVAILABLE Function Memorised...

Page 181: ...be inhibited unless the DTC s have been erased If NO is selected press the Validation key to return to operation 13 That completes the DTC cycle Use Up and Down keys to select DIAGNOSTICS menu The fo...

Page 182: ...key each time Because the DTC s have now been erased FUNCTION TEST operation 20 will now be displayed The following Function Tests can be made Instrument Panel 2 Idle air control valve IACV test 3 Pu...

Page 183: ...ion opposite the By pressing the Validation key your selection will be noted and FUNCTION TEST operation 21 will be displayed Press the Help key for more information NOTE If the Return key J is presse...

Page 184: ...being tested In the example selected INSTRUMENT PANEL the instruction is to observe the gauges After a period of time the screen will automatically change to either TEST COMPLETE see operation 23 whic...

Page 185: ...the Validation key to return to DIAGNOSTICS menu operation 9 If the test at operation 22 is unsatisfactory a DTC will be displayed on line 3 of this display except fuel pump tests Press the Help key...

Page 186: ...UST Press the Validation key the CHECK ADJUST menu will be displayed 27 CHECK ADJUST EWE C K R 0 J U 5T I CHECK RO JUST 0 U 1 1 T This is the Checks and Adjustments menu Use the Up and Down keys to po...

Page 187: ...tion 30 will be displayed Opposite READ BUILD DATA BUILD DATA operation 29 will be displayed Opposite QUIT to return to MAIN MENU operation 8 Providing the information was recorded at the time of buil...

Page 188: ...tain further data information scroll the appropriate line to the help key mark and press the Help key NOTE The help information shows the likely range of readings for a correctly functioning system at...

Page 189: ...key see operation 36 33 ADJUST TUNE The following sequence shows status data and allows adjustments to be made to items which affect the engine operation IDLE FUEL ADJ Idle fuelling See operation 34...

Page 190: ...entage reading as measured by an exhaust gas analyser The tool reports idle fuelling as a percentage of the maximum fuelling range NOT AS A PERCENTAGE CO READING Start the engine and allow it to warm...

Page 191: ...tion ADJUST r unE T I f ER P 0 5 f TI Oil S B F f IY T The electronic value of the closed throttle position is automatically reset by the tool Press either the validate or return J to return to the ma...

Page 192: ...nu Accessed from operation 32 On receipt of special instructions from Triumph you may be asked to input a completely new engine tune To do this they will give you a Password Number which must be enter...

Page 193: ...still invalid the screen will display ACCESS DENIED DISCONNECT AND RETRY The diagnostic tool must be disconnected and the complete procedure re started Align the cursor with the model to which a tune...

Page 194: ...Validation key to move on to operation 43 Press the help key for information on the applicability of each tune number Scroll to either CONFIRM CANCEL or QUIT quit option will not be visible until the...

Page 195: ...and has not yet been fully replaced Download interruption can occur for a variety of reasons such as accidental disconnection of the tool a flat battery turning the ignition switch to OFF during downl...

Page 196: ...tery volts unless a resistor is fitted in the circuit If there is a noticeable change suspect faulty dirty connections WHEN DISCONNECTING A CONNECTOR Check for a security device which must be released...

Page 197: ...and schematic wiring diagrams used throughout this manual 28 iiiiiii FFfFFfFFFFFFFFFiiiiii 1 55 iiiiiii iiiiii 29 88 56 gall ECM Connector Pin Numbers FURTHER DIAGNOSIS The tables which follow will if...

Page 198: ...ctify wiring fault proceed to test 7 3 Check cable continuity ECM pin 14 to sensor pin 1 ECM pin 41 to sensor pin 2 OK Proceed to test 4 Open circuit Locate and rectify wiring fault proceed to test 7...

Page 199: ...OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 6 3 Check cable continuity ECM pin 1 to sensor pin 3 ECM pin 18 to sensor pin 2 ECM pin 34 to sensor pin 1 OK Procee...

Page 200: ...rectify wiring fault proceed to ECM pin 32 to earth test 7 ECM pin 60 to earth ECM pin 61 to earth 4 Check cable continuity OK Proceed to test 6 ECM pin 4 to stepper motor pin A Open circuit Locate an...

Page 201: ...nect relevant injector and proceed to test 5 3 Check cable for short circuit OK Proceed to test 7 ECM pin 2 to earth Short circuit Locate and rectify wiring fault proceed to ECM pin 31 to earth test 7...

Page 202: ...OK Proceed to test 3 ECM pin 13 to earth Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity OK Proceed to test 4 ECM pin 34 to sensor pin 1 Open circuit Locate a...

Page 203: ...34 2 Check cable for short circuit OK Proceed to test 3 ECM pin 15 to earth Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity OK Proceed to test 4 ECM pin 34 to...

Page 204: ...e and proceed to test 5 3 Check cable for short circuit ECM pin 26 to earth OK Proceed to test 7 Short circuit Locate and rectify wiring fault proceed to test 7 4 Check cable continuity ECM pin 26 to...

Page 205: ...eed to test 7 ECM pin 27 to earth Short circuit Locate and rectify wiring fault proceed to ECM pin 28 to earth test 7 ECM pin 54 to earth 4 Check cable continuity OK Proceed to test 6 Fuel pump relay...

Page 206: ...able continuity ECM pin 46 to sensor pin 1 ECM pin 34 to sensor pin 2 OK Proceed to test 5 Open circuit Locate and rectify wiring fault proceed to test 7 4 Check cable for short circuit ECM pin 46 to...

Page 207: ...pin 11 to sensor pin 1 ECM pin 34 to sensor pin 2 OK Proceed to test 5 Open circuit S Locate and rectify wiring fault proceed to test 7 4 Check cable for short circuit ECM pin 11 to ECM pin 34 OK Proc...

Page 208: ...or short circuit ECM pin 80 to earth OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity ECM pin 80 to relay pin4 Relay pin 6 to alarm control...

Page 209: ...cate and rectify wiring fault proceed to test 5 3 Check cable continuity ECM pin 1 to sensor pin 3 ECM pin 19 to sensor pin 2 ECM pin 34 to sensor pin 1 OK Proceed to test 4 Open circuit Locate and re...

Page 210: ...proceed to test 4 2 Check for short circuit ECM pin 12 to ECM pin 34 OK Reconnect ECM proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 4 3 With ignition on check voltag...

Page 211: ...ge is acceptable note voltage Pinpoint Tests Test Result Action 1 Check cable and terminal integrity ECM pin 69 OK Proceed to test 2 Faulty Rectify fault proceed to test 3 2 With Ignition on check vol...

Page 212: ...st 5 2 Check cable for short circuit ECM pin 22 to earth OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity Warning light pin 3 to ECM pin 22...

Page 213: ...ck cable for short circuit ECM pin 25 to earth OK Proceed to test 3 Short circuit Locate and rectify wiring fault proceed to test 5 3 Check cable continuity Relay pin 4 to ECM pin 25 Relay pin 6 to EC...

Page 214: ...proceed to test 6 3 Check cable resistance ECM pin 81 to temp gauge pin 1 9 5 to 10 5Q Proceed to test 4 Faulty Renew 1OQ in line resistor proceed to test 6 4 Check cable continuity Temp gauge pin 2...

Page 215: ...6 2 Check cable for short circuit OK Proceed to test 3 ECM pin 62 to earth Short circuit Locate and rectify wiring fault proceed to test 6 3 Check cable resistance 1 1 to 1 3KQ Proceed to test 4 ECM...

Page 216: ...aused by loose fuel pipes to the fuel pump and filter One way valve inside pipe from throttle bodies to IACV Idle Air Control Valve sticking Rev limitation cutting in too early Crankshaft sensor air g...

Page 217: ...over 4 Disconnect the fuel hoses by pressing the metal tag between the hose and socket inwards Once released the hoses will spring out from the socket 1 Socket 2 Hose 3 Metal Tag NOTE I When disconnec...

Page 218: ...nd tighten the fuel tank mounting bolts to 12 Nm 4 Reconnect the fuel feed and return hoses by inserting each hose into the corresponding socket and gently pushing inwards until the hoses engage gala...

Page 219: ...the fuel hose to the pump Disconnect the fuel pump electrical connection at the pump 7 Loosen the fuel pump clamp screw and ease the pump from the bracket ensuring the gauze pick up filter is not dama...

Page 220: ...the filter from the bracket gaih 1 Fuel Filter 2 Fuel Pump 3 Fuel Exit Connection Outlet Inspection Test Renew the fuel filter in accordance with the scheduled maintenance chart Assembly 1 Locate the...

Page 221: ...ct the battery negative black lead first 2 Remove the fuel tank as described elsewhere in this section 3 Drain the fuel tank into a suitable container 1 1 Fuel Pressure Regulator 2 Circlip 5 Ease the...

Page 222: ...ction 3 Refill the fuel tank with the fuel drained earlier 4 Reconnect the battery positive red lead first 5 Refit the seat FUEL PRESSURE CHECKING Tool T3880048 Test Procedure 1 In order to connect th...

Page 223: ...should the fuel pump be activated by switching on the ignition with either or both of the fuel hoses disconnected Although there is little risk of a fuel leak due to the use of dry fit connectors if...

Page 224: ...nd rear of the airbox 7 On early models only release the bolt securing the front of the airbox to the bracket at the front edge of the cam cover NOTE On later models no bolt is fitted the airbox is re...

Page 225: ...Barometric pressure sensor 7 Position the thermostat housing to the airbox Tighten the thermostat housing to airbox fixings to 5 Nm 8 Reconnect the coolant temperature sensor 9 Reconnect the air intak...

Page 226: ...e battery negative black lead first 2 Remove the fuel tank and airbox as described elsewhere in this section NOTE The barometric pressure sensor is a push fit in the airbox and is retained by a barbed...

Page 227: ...rtighten 2 Refit the airbox and fuel tank as described elsewhere in this section 3 Reconnect the battery positive red lead first 4 Refit the seat CRANKSHAFT POSITION SENSOR Removal 1 Remove the seat a...

Page 228: ...een the sensor probe and the rotor to 1 mm 0 20 mm NOTE Always recheck the gap after tightening the screws Rest the gap if the setting has moved 1 1 Crankshaft Position Sensor 2 Crankshaft Rotor 3 1 0...

Page 229: ...the seat CAMSHAFT POSITION SENSOR early models only NOTE This item has been deleted from later models Removal 1 Remove the seat and disconnect the battery negative black lead first 2 Remove the side...

Page 230: ...t bolt heads aligns with the sensor 3 Slacken the sensor bracket bolts and adjust the sensor bracket to give a 1mm gap between the sensor and the bolt head THROTTLE CABLE Removal 1 Remove the seat and...

Page 231: ...orrectly adjusted incorrectly routed or damaged throttle cable could interfere with the operation of the brakes clutch or the throttle itself Any of these conditions could result in loss of control of...

Page 232: ...e at 3 bar pressure it is essential that the fuel pressure is reduced before any dismantling of the throttle bodies takes place If the throttle bodies are dismantled without first reducing fuel pressu...

Page 233: ...il 7 Disconnect the multi plugs to each injector 8 Disconnect the multiplug to the idle air control valve gahz 1 Injector Multi plugs 9 Release the screws securing the throttle body assembly to the cy...

Page 234: ...gine Only 4 Locate the throttle body assembly to the cylinder head 5 Ensuring that the idle air control valve early models only is refitted in its original location tighten the throttle body to cylind...

Page 235: ...xposed skin To avoid skin damage always allow the hot parts to cool before hose disconnection connection Typical Analyser Display NOTE The hose connections on the tool are marked 1 2 3 etc denoting wh...

Page 236: ...ve range adjust the closed throttle position using the Triumph service diagnostic tool Refer to the tool s operating instructions for details INJECTORS Removal 1 Remove the seat and disconnect the bat...

Page 237: ...The injectors cannot be pressure tested Assembly 1 Fit new injector O rings if necessary 2 Locate the injectors to the fuel rail and rotate the injectors such that the electrical connections will fac...

Page 238: ...ensuring that the D shaped extension of the throttle spindle engages in the mating recess in the sensor yam 1 D Shaped Spindle Extension 2 D Shaped Switch Recess 2 Tighten the sensor fixings to 2 Nm...

Page 239: ...body for cracks damage and deterioration Replace as necessary Assembly 1 Assemble the stepper motor to the valve body and secure using the original fixings 2 Position the valve bracket to the throttl...

Page 240: ...ounting Bracket 2 Rear Footrest Support 6 Remove the silencer 7 Drain the cooling system and remove the radiator as described in the cooling system section to gain access to the downpipe fixings WARNI...

Page 241: ...as described in the cooling section 5 Position and engage the silencer to the downpipe 6 Align the silencer mounting bracket to the rear footrest support 7 Ensuring that the flanged sleeves bushes an...

Page 242: ...nt There are two distinct phases to the system s operation engine off and engine running These two conditions are explained overleaf Component Locations Carbon Cannister behind the throttle bodies Pre...

Page 243: ...tank due to a rise in ambient temperature will cause the fuel vapour to pass down the breather pipe A through the roll over valve to the pressure control valve When the pressure is greater than 0 75 l...

Page 244: ...to the vacuum switch on the canister causing the canister valve to open Direct return of vapour to the idle control housing is prevented by the purge control valve which is governed by the engine man...

Page 245: ...cement 10 4 Drainage 10 4 Filling 10 4 RadiatorHoses 10 5 RadiatorAnd Cooling Fan 10 5 CoolantPressure Cap 10 6 Inspection 10 6 WaterPump 10 6 Removal 10 6 Inspection 10 6 Installation 10 7 Radiator 1...

Page 246: ...Exploded View Cooling System 12 Nm 0 0 5Nm 10 Nm 0 9Nm M 10 COOLING SYSTEM TiUiMII 10 2...

Page 247: ...specification for anti freeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling syste...

Page 248: ...e 1 Thermostat Housing 2 Bleed Screw 5 Remove the left hand lower fairing if fitted 6 Position a container to collect the displaced coolant 7 Remove the coolant drain plug 1 1 Coolant Drain Plug Filli...

Page 249: ...engine to idle for a short period of time to allow any air to be expelled from the system In particular check for air locks in the area of the radiator top hose Arrowed Potential Air lock Area 12 Sto...

Page 250: ...MP Removal 1 Remove the seat 2 Disconnect the battery negative black lead first 3 Remove the fuel tank cover belly panel and left hand lower fairing where fitted 4 Drain the coolant as described earli...

Page 251: ...efit the coolant drain plug and tighten to 13 Nm 1 1 Coolant Drain Plug 6 Refill the cooling system as described earlier in this section 7 Reconnect the battery positive red lead first 8 Start the mot...

Page 252: ...at the radiator gaku 4 F 1 Top hose 2 Thermostat Housing to Cylinder Head Hose 3 Bypass Hose 4 Bottom Hose 6 Release the fixings which secure the oil cooler to the radiator 7 Detach and support the oi...

Page 253: ...elled from the system 10 Stop the engine and top up the coolant level as necessary 11 Fit the coolant pressure cap 12 Check the expansion tank level and top up if necessary 13 Refit the fuel tank cove...

Page 254: ...n the retaining screws to 7 Nm A CAUTION Ensure that the thermostat is correctly seated in both sides of the housing before tightening the thermostat housing screws Damage to the housing and thermosta...

Page 255: ...k 11 9 Removal 11 9 Inspection 11 10 Installation 11 10 DriveChain 11 11 ChainSlack Inspection 11 11 Drivechain adjustment 11 11 ChainLubrication 11 11 ChainWear Inspection 11 12 Swin gin g Arm Drive...

Page 256: ...9 Nm 9 Nm 55 Nm rH 9 Nm 9 Nm 60 Nm 11 2 2 11 REAR SUSPENSION TkQ2WH Exploded View Swinging Arm 7 T21...

Page 257: ...Exploded View Rear Hub A K1 J I TIUMI MPII REAR SUSPENSION 11 11 3...

Page 258: ...11 REAR SUSPENSION Exploded View Rear Suspension Unit 48 Nm 11 4...

Page 259: ...48 Nm iiii REAR SUSPENSION 11 Exploded View Drop Drag Link C e 11 5...

Page 260: ...lower mountings lower mounting spacers and 0 rings drop link bearings sleeves and seals Renew as necessary 2 Check the drop link upper bearings and drag link bearings for wear Overhaul as necessary s...

Page 261: ...NG If the engine has recently been running the exhaust system will be hot Before working on or near the exhaust system allow sufficient time for the exhaust system to cool as touching any part of a ho...

Page 262: ...link must be fi tted the correct way round and its spindle MUST be fitted with its internally threaded end towards the right hand side 1 gafd 1 Cut away area 2 Position the drop link to the swinging a...

Page 263: ...WARNING Ensure the motorcycle is stabilised and adequately supported to 1 Raise and support the rear of the motorcycle beneath the frame or engine Position a block to support the rear wheel 1 Rear sus...

Page 264: ...tallation 1 Pack the drag link bearings with grease position the drag link and spacers to the frame and fit the spindle Fit the securing bolt hardened washer under the bolt head and nut and tighten to...

Page 265: ...s 3 If correct the vertical movement of the drive chain midway between the sprockets should be 35 40 mm gags 1 Vertical Movement 35 40mm Drive chain adjustment 1 Slacken the swinging arm hub pinch bol...

Page 266: ...of non approved chains may result in a broken chain or may cause the chain to jump off the sprockets A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear...

Page 267: ...and causing damage or injury 5 Remove the rear wheel as described in the wheel section 6 Remove the rear brake hose cover from the upper chain guard then remove the upper chain guard 1 Swinging arm 2...

Page 268: ...e axle shaft brake disc assembly to one side Typical Drive Chain Support 17 Release the brake fluid reservoir from the battery box and move it to one side A CAUTION The brake fluid reservoir has an ai...

Page 269: ...f the swinging arm spindle I i4 i 1 o I e N2 1 1 Tool T3880290 2 Clamping ring 25 Support the swinging arm and remove the swinging arm spindle yacw 1 Swinging arm spindle 26 Carefully detach the arm f...

Page 270: ...eft 34 Collect the spacer tube 9 7 6 2 gagn 1 1 Seal 6 Seal 2 Circlip 7 Needle roller bearing 3 Bearing sleeve 8 Seal 4 Ball bearing 9 Bearing Sleeve 5 Sleeve NOTE The needle roller bearing in the lef...

Page 271: ...to 18 Nm 1 Tool T3880290 2 Clamping ring A CAUTION Incorrect adjustment of the swinging arm clamping ring will damage the bearings seals and swinging arm Never overtighten the clamping ring or set the...

Page 272: ...brake pads in the caliper Rectify as necessary if correct brake operation is not restored 3 2 3 1 Swinging arm hub pinch bolt 2 Rear brake caliper 3 Rear brake caliper fixings 29 Align the rear brake...

Page 273: ...jury 5 Remove the rear wheel as described in the wheel section 6 Remove the rear brake hose cover from the upper chain guard then remove the chain guard n ___ 1 Swinging arm 2 Brake pipe clip 9 Withou...

Page 274: ...the chain sprocket 11 REAR SUSPENSION gafm 1 C Spanner 2 Swinging arm hub pinch bolt 13 To release the final drive unit remove the staked nut discard the nut belleville washer and stepped washer ga g...

Page 275: ...e cush drive housing and secure with nuts tightened to 33 Nm 2 Fit the 0 ring to the cush drive hub 3 Fit the cush rubbers 4 Locate the spacer in the cush drive housing and fit the hub Installation 1...

Page 276: ...eplacement chain using a split link If the replacement chain to be fitted is a continuous type removal of the swinging arm and sprocket cover is necessary as described earlier in this section 1 Raise...

Page 277: ...placement NOTE The replacement chain is supplied in a split condition complete with a link kit to join the two ends A CAUTION The component parts of the new link kit are coated with a special grease w...

Page 278: ...to the tool punch 4 times Rotate the punch by 45 between each blow 12 Remove the tool and examine the end of the link pin to check that is has been securely riveted over 13 Repeat the riveting operati...

Page 279: ...orkInspection All Models 12 5 ForkOil 12 5 Oilchange 12 5 ForkOil Level Chart 12 7 FrontFork 12 8 Removal 12 8 Installation 12 8 Dismantling 12 9 Inspection 12 11 Assembly 12 11 HeadstockBearing Check...

Page 280: ...12 FRONT SUSPENSION STEERING Exploded View Front Fork 40Nm 20 Nm 1 22 Nm p 1 0 1 9 Nm 9Nm o 20 Nm 00 35 Nm 12 2...

Page 281: ...I U N FRONT SUSPENSION STEERING 12 Exploded View Low Handlebars 1 4 F m 1 6Nm 6 Nm O 35 Nm M8 screws 20 Nm M6 screws 6 Nm 12 3...

Page 282: ...um 1 12 FRONT SUSPENSION STEERING Y jHn Exploded View Tall Handlebars 35 Nm I 12 4...

Page 283: ...action before riding the motorcycle Riding the motorcycle with defective or damaged suspension can damage the motorcycle cause loss of control or an accident WARNING All suspension units contain press...

Page 284: ...it hole in the side of the scale tube NOT AT THE END TIP Do not attempt to block this side hole as this will cause the final fluid level to be incorrect 7 Operate the fork several times to expel any t...

Page 285: ...Inner tube flush with upper face of top yoke Daytona 955i 76 mm 589 cc Showa SS8 Inner tube flush with upper face of top yoke 955cc Speed Triple 76 mm 589 cc Showa SS8 Inner tube flush with upper fac...

Page 286: ...ding to loss of control or an accident could result if this warning is ignored NOTE If the fork is to be dismantled slacken the fork cap at the top of the fork and the damping cylinder securing bolt a...

Page 287: ...or damage the mountings 2 If not already done release the torque on the damping cylinder securing bolt then lightly re tighten to prevent oil from escaping 3 Note the position of the preload adjuster...

Page 288: ...e out the dust seal from the outer tube and remove the circlip from beneath the seal 1 gafi 1 Circlip 9 Remove the damping cylinder securing bolt from the lower end of of the assembly Discard the copp...

Page 289: ...ameter end of tool T3380285 6 Secure the assembly with the circlip 7 Fit a new dust seal spring band upwards over the inner tube tapping it into position in the outer tube using the larger diameter en...

Page 290: ...adstock top nut 3 Headstock adjustment nut 5 Adjust the bearing free play as follows Tighten the nut to 32 Nm Loosen the nut and then retighten by hand until any bearing free play is eliminated WARNIN...

Page 291: ...scs 13 12 Wear 13 12 FrontDisc Thickness 13 12 DiscRun out 13 12 Removal 13 12 Installation 13 13 FrontBrake Master Cylinder 13 13 Removal 13 13 Disassembly 13 13 Inspection 13 14 Assembly 13 14 Insta...

Page 292: ...Exploded View Front Brake Master Cylinder 12 Nm 15 Nm 1 Nm 0 12 Nm 25 Nm I 6 Nm 0 P 13 BRAKING SYSTEM 25 Nm 13 2...

Page 293: ...BRAKING SYSTEM 13 Exploded View Front Brake Caliper 25 Nm 7Nm r o 0 0 0 0 0 0 0 0 0 O 000 o o 0 0 0 e 0 22Nm oo o 0 0 o o 0 0 0 0 0 0 0 0 0 o o 13 3...

Page 294: ...Exploded View Rear Brake Master Cylinders 25 Nm N1 25 Nm 7 Nm 13 4 7N 13 BRAKING SYSTEM ThJPII...

Page 295: ...Exploded View Rear Brake Caliper 22 Nm w v OvvO 40 Nm 20 Nm NNN 7 Nm CM l it TI CuM1 BRAKING SYSTEM 13 13 5...

Page 296: ...rised Triumph Dealer for advice before riding If the brake lever or pedal feels soft when it is applied or if the lever pedal travel becomes excessive there may be air in the brake lines or the brake...

Page 297: ...ntenance chart BRAKE PADS Front and Rear pad wear is automatically compensated for and has no effect on brake lever or pedal action BRAKE WEAR INSPECTION In accordance with the scheduled maintenance c...

Page 298: ...enter the cylinder as this will adversely affect the fluid properties Always use fluid from a sealed container and do not use fluid from a container which has been opened for any period of time Alway...

Page 299: ...bleed tube 15 Replace the bleed nipple cap 16 Repeat the procedure for the left hand caliper 17 Refit the reservoir cover and diaphragm Refit the safety clip and screw WARNING Always return the lever...

Page 300: ...g pins to 25 Nm and secure with new split pins 5 Pump the brake lever to correctly position the caliper pistons Observe the brake fluid handling warnings given earlier in this section of the manual 6...

Page 301: ...Mineral based grease will damage the hydraulic seals in the calipers and master cylinders A dangerous riding condition leading to an accident could result if this warning is ignored 1 Fit new fluid se...

Page 302: ...limit or exceeds the disc run out limit Front Disc Thickness Standard Service Limit Disc Run out Standard Service Limit Measure disc run out using an a mounted on a surface plate 4 0 mm 3 5 mm 0 1 mm...

Page 303: ...st CAUTION To prevent body damage do not spill brake fluid onto any area of the bodywork 2 To drain the fluid from the master cylinder attach a tube to the right hand caliper bleed nipple slacken the...

Page 304: ...ding to an accident could result if this warning is ignored 1 Lubricate the piston and cylinder with new clean brake fluid A WARNING Ensure that the piston and piston seal are fitted facing the same w...

Page 305: ...ating the motorcycle with lever settings which are unfamiliar may lead to loss of control or an accident BLEEDING THE REAR BRAKES RENEWING BRAKE FLUID 1 Remove the body side panel assembly 2 Remove th...

Page 306: ...all air has been expelled from the system hold down the brake pedal and close the bleed nipple Tighten the nipple to 7 Nm 11 Fill the reservoir to the maximum level with new DOT 4 fluid WARNING Use on...

Page 307: ...apply more than a minimum coating of grease to the pad retaining pins Excess grease may contaminate the brake pads hydraulic seals and discs causing reduced braking efficiency and an accident 4 Lubric...

Page 308: ...remove the pistons one at a time Inspection 1 Check the piston and caliper bore for corrosion scoring and damage Renew as necessary WARNING Always renew caliper seals and pistons after removal from t...

Page 309: ...ighten to 40 Nm 3 Tighten the brake pad retaining pins to 20 Nm 4 Connect the brake hose to the caliper using new washers on each side of the banjo bolt 5 Tighten the banjo bolt to 25 Nm WARNING Use o...

Page 310: ...d piston components Inspection 1 Visually inspect the master cylinder bore for wear scratches or corrosion Replace as necessary 2 Check the piston and cylinder bore for damage wear or deterioration Re...

Page 311: ...ect orientation of the brake hose tighten the banjo bolt to 25 Nm 5 Fit the brake light switch WARNING Use only D O T 4 specification brake fluid as listed in the general information section of this m...

Page 312: ...mRecommended Tread Depth 14 5 I m portantTyre Information 14 6 FrontWheel 14 7 Removal 14 7 Installation 14 7 RearWheel 14 8 Removal 14 8 Installation 14 8 FrontWheel Bearings 14 9 Removal 14 9 Instal...

Page 313: ...1 14 WHEELS TYRES _ Exploded view Front Wheel 60 Nm 14 2...

Page 314: ...i 1 UNI WHEELS TYRES 14 Exploded View Rear Hub 146 Nm ON 14 3...

Page 315: ...lead to instability loss of control and an accident Tyre Pressures All Models Correct inflation pressure will provide maximum stability rider comfort and tyre life Tyre pressures should be checked fr...

Page 316: ...pected of being damaged WARNING Operation with excessively worn tyres is hazardous and will adversely affect traction stability and handling which may lead to loss of control or an accident When tubel...

Page 317: ...n accident A WARNING Do not install tube type tyres on tubeless rims The bead will not seat and the tyres could slip on the rims causing tyre deflation that may result in a loss of vehicle control and...

Page 318: ...e is no dirt ingress to the wheel bearings while the wheel is removed WARNING Do not allow the wheel to rest on either brake disc as this may damage the disc and could lead to an accident 8 Thoroughly...

Page 319: ...2 Remove the silencer as described in the fuel system engine management section Installation 1 Fit the wheel aligning with the 4 location dowels 2 Hold the wheel squarely in position while fitting co...

Page 320: ...ke disc as this may damage the disc Support the wheel on wooden blocks equally spaced around the rim such that the brake disc is raised above the ground 3 Remove the circlips from the hub 4 Using a su...

Page 321: ...r l REAR WHEEL BEARINGS Removal 1 Remove the seat 2 Disconnect the battery negative black lead first 3 Remove the silencer as described in the fuel system section WARNING If the engine has recently b...

Page 322: ...De stake then slacken the nut securing the final drive unit to the axle shaft 13 Remove the staked nut discard the nut belleville and stepped washers from the axle shaft 14 Pull the axle shaft through...

Page 323: ...that the final drive spacer is fitted to the left hand side of the axle shaft 4 Align the final drive assembly to the axle shaft fitting the chain during assembly 5 Fit the stepped washer belleville w...

Page 324: ...lt 2 Rear brake caliper 3 Rear brake caliper fixings 10 Align the rear brake pipe and clip to the right hand side of the swinging arm and tighten the clip fixing 11 Refit the upper and lower chain gua...

Page 325: ...SidePanel 15 8 Removal 15 8 Installation 15 8 BellyPanel 15 8 Removal 15 8 Installation 15 8 LowerFairings 15 9 Removal 15 9 Installation 15 9 Cockpit 15 10 Removal 15 10 Installation 15 10 Frame Foo...

Page 326: ...15 BODYWORK FRAME Exploded View Frame See Text See Text See Text See Text e See Text A See Text U 15 2...

Page 327: ...Exploded View Seat Rails 40 Nm 15 3 Nm 1 U 1 B OD YWORK FRAME 15...

Page 328: ...15 BODYWORK FRAME 5 Nm Exploded View Cockpit and Mountings I 5 Nm I T 6 Nm I D I 5Nm _ 6 Nm 6 Nm 6 N m P 6 Nm 1 I I 6 Nm o 6 Nm 5 Nm 15 4...

Page 329: ...Nm 9 Nm 9 Nm 9Nm 9 Nm 15 5 9Nm i 9 Nm h I 1 1 U hI BODYWORK FRAME 15 Exploded View Rear Panels...

Page 330: ...r 30 Nm 16 Nm 15 6 r 15 BODYWORK FRAME Exploded View Footrests and Mountings 27 Nm 27 Nm 9 16 Nm 30 Nm...

Page 331: ...ly engaged in the lock i hUM 1 BODYWORK FRAME 15 SEAT Removal NOTE The seat lock is situated on the left hand side of the battery box in line with the footrest mounting rail on the left hand side of t...

Page 332: ...l Fixings Installation 1 Installation is the reverse of removal noting the following NOTE Reconnect the battery positive red lead first Check the rear light for correct operation after reconnection BE...

Page 333: ...the fairing brackets gakr 1 1 Lower Fairing 2 Fairing Retaining Screws 6 Support the fairing while releasing Quarter turn fastener which secures it to the duct cover Quarter turn fasteners which secur...

Page 334: ...Intake Duct Screw Location 7 Release the quarter turn fasteners on each side of the cockpit 8 Disconnect the two air ducts behind the fairings and ease the cockpit forward to disengage it from its mou...

Page 335: ...dification to the frame such as welding or drilling may weaken the frame resulting in an accident FRAME RENEWAL Strip Down 1 Mount the rear of the motorcycle on a paddock stand 2 Remove both seats 3 D...

Page 336: ...t in the chain yam 1 C spanner 2 Hub pinch bolt 14 Remove the swinging arm spindle bolts 15 Using tools T3880290 and T3880295 release the pre load adjustment on the swinging arm 1 1 Tool T3880295 2 Lo...

Page 337: ...Inboard 25 Remove the top yoke nut using tool T3880300 26 Slacken the top yoke to fork pinch bolts and remove the top yoke 27 Remove the headstock bearing adjuster nut 28 Place a support beneath the...

Page 338: ...adstock 7 Fit the headstock adjuster nut and set the headstock bearing adjustment as follows Tighten the nut to 32 Nm Loosen the nut and then retighten by hand until any bearing free play is eliminate...

Page 339: ...frame bolt on the right hand side If a gap larger than 1 mm exists between the frame and drag link but no shim was found to be necessary for the lower right hand engine mounting bolt the drag link sp...

Page 340: ...nual 36 Reconnect the inlet air temperature and barometric pressure sensors during fitment of the airbox 1 Inlet Air Temperature Connection 2 Barometric Pressure Sensor 37 Refit the thermostat housing...

Page 341: ...ip end of the cable Tighten the locknut WARNING Ensure that the adjuster locknuts are tightened A loose thro ttle cable adjuster could cause the throttle to stick leading to loss of control and an acc...

Page 342: ...16 16 Headli g htBulb Replacement 16 17 Installation 16 17 PositionLamp Bulb Replacement 16 17 LicencePlate Light 16 18 BulbReplacement 16 18 TailLight 16 18 Removal 16 18 Installation 16 18 BulbRepla...

Page 343: ...rumentWarning Lights 16 29 Removal 16 29 Installation 16 29 RelayPack 16 29 Identificationof Relays 16 29 Wiring Circuit Diagram T595 Daytona 1509 Speed Triple 885cc 16 30 Wiring Circuit Diagram Dayto...

Page 344: ...Exploded View Instruments o ELECTRICAL SYSTEM 16 a _ 5 Nm 6Nm 6 Nm 16 3...

Page 345: ...16 ELECTRICAL SYSTEM Exploded View Alternator and Starter Motor Nlllllllllll 00 16 4...

Page 346: ...Nm tUnNt slut ELECTRICAL SYSTEM 16 Exploded View Daytona Headlight 6 Nm 9 Nm o 6Nm o 9 Nm 16 5...

Page 347: ...I 7r 4 Nm 16 ELECTRICAL SYSTEM 1t tll 1 Exploded View Speed Triple Headlight 10 Nm 15 Nm 10 Nm 16 6...

Page 348: ...ELECTRICAL SYSTEM 16 Exploded View Rear Lights and Indicators U I I U I 18 Nm 16 7...

Page 349: ...n Always wear eye and skin protection when adjusting the electrolyte level A CAUTION When checking the battery electrolyte level or adding distilled water ensure that the breather is not blocked A blo...

Page 350: ...cuit or spark which would ignite battery gases causing a risk of personal injury Battery Refit WARNING Ensure that the battery terminals do not touch the motorcycle frame as this may cause a short cir...

Page 351: ...efly exceeded but the temperature of the electrolyte must not be allowed to rise above 55 C 3 After charging allow the battery to cool and then top up the electrolyte level with distilled water 4 Neve...

Page 352: ...led type and does not require any maintenance other than routine recharging such as during storage It is not possible to adjust the electrolyte level in the battery 1 Upper Electrolyte Level 2 Lower E...

Page 353: ...2 Terminal Cover 4 Take the supplementary positive cable coloured red and attach one end to the existing positive lead Secure both terminals together using the bolt and nut supplied I 1 Original Posit...

Page 354: ...runk to fit over the negative cable joint 1 Insulation Material 2 Hot Air Gun 10 Remove the original battery carrier base from the battery recess in the rear mudguard and fit the replacement item supp...

Page 355: ...ght or anti clockwise to move the beam to the left 5 On the LH headlight turn the horizontal adjustment screw anti clockwise to move the beam to the right or clockwise to move the beam to the left 1 V...

Page 356: ...screw 7 Remove the bulb from the headlight unit WARNING The bulb becomes hot during use Always allow sufficient time for the bulb to cool before handling Avoid touching the glass part of the bulb If t...

Page 357: ...the headlamp beam when the motorcycle is in motion Any attempt to adjust the headlamp beam when the motorcycle is in motion may result in loss of control and an accident Headlight Adjustment 1 Switch...

Page 358: ...elease the headlight bezel clamp screw 3 Support the headlight unit and remove the bezel Ease the headlight from the headlight bowl 4 Disconnect the multi pin electrical connector from the headlight b...

Page 359: ...the battery negative black lead first 3 Release the fixings securing the light to the rear body panels 4 Rotate the bulb holders anti clockwise and detach from the light unit 5 Withdraw the light from...

Page 360: ...ve red lead first 4 Refit the seat s INDICATOR The lens on each indicator light is held in place by a securing screw located in the body of the light rrr rr 1 Lens 2 Lens Retaining Screw Removal 1 Rel...

Page 361: ...ght Hand Headlight 4 Battery 5 Headlight Dip Beam Relay 6 Fuses 6 9 7 Headlight Main Beam Relay 8 Ignition Switch 9 Headlight Cut out Relay 10 Fuse 2 11 Lighting Switch 12 Fuse 3 13 Passing Button 14...

Page 362: ...5 7 9 11 14 ELECTRICAL SYSTEM 16 Circuit Diagram Lighting 1 2 3 U cr Cn I T B gm Co II I 32 1 3 1 0 I t 1 0 19 20 16 21...

Page 363: ...ation of components Key No Item Description 1 Battery 2 Fuses 1 9 and 7 3 Ignition Switch 4 Alternator 5 Engine Stop kill Switch 6 Engine Start Button 7 Alarm Control Unit or shorting plug 8 Starter S...

Page 364: ...Circuit Diagram Starting Charging up to VIN 71698 I N z z ri ELECTRICAL SYSTEM 16 N B III N 7 1 14 13 16 23...

Page 365: ...of components Key No Item Description 1 Battery 2 Fuses 1 9 and 7 3 Ignition Switch 4 Alternator 5 Engine Stop kill Switch 6 Engine Start Button 7 Alarm Control Unit or shorting plug 8 Starter Soleno...

Page 366: ...Circuit Diagram Starting Charging from VIN 71699 TN z z 0 p8HIi N j 1 14 13 16 25...

Page 367: ...ator capturing the 4 cush drive rubbers from the cush drive Inspection 1 Inspect the alternator O ring and renew if damaged stretched Installation 1 Fit the cush drive rubbers into the alternator cush...

Page 368: ...tor Installation 1 Clean the mating faces of the crankcase and starter motor to ensure efficient grounding 2 Inspect the sealing 0 ring and renew if damaged stretched 3 Fit the 0 ring to the starter m...

Page 369: ...TE If removing the speedometer first unscrew and remove the tripmeter knob 9 Pull out the panel illumination bulb holders Installation 1 Installation is the reverse of the removal procedure ensuring t...

Page 370: ...he bulb 1 Bulb Holders 2 Warning Light Housing Installation 1 Installation is the reverse of the above RELAY PACK A relay pack is situated beneath the front seat which also contains the indicator unit...

Page 371: ...e Control Module 32 Cooling Fan Relay 33 Fuel Pump Relay 34 Wire Link 35 Injector 3 36 Injector 2 37 Injector 1 38 Main Power Relay 39 Camshaft Position Sensor 40 Barometric Pressure Sensor 41 Throttl...

Page 372: ......

Page 373: ...nly 31 Engine Control Module 32 Cooling Fan Relay 33 Fuel Pump Relay 34 Wire Link 35 Injector 3 36 Injector 2 37 Injector 1 38 Main Power Relay 39 Not Used 40 Barometric Pressure Sensor 41 Throttle Po...

Page 374: ......

Page 375: ...Triumph Motorcycles Limited Jacknell Road Hinckley Leicestershire LE10 3BS England...

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