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Triumph Trident T160, Руководство по ремонту


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Содержание Trident T160

Страница 1: ...bic inch with Electric Starter From Engine Number 001 01 Compiled by John R Nelson M A Eng CANTAB M I Mech E CopyrightbyJ R NELSON Published by J R Technical Publications Printed by Warwick Printing L...

Страница 2: ...j J W C 0 E r z w c 0 f 1 I ClassicBike biz...

Страница 3: ...1975 Trident T160 ClassicBike biz...

Страница 4: ...feats and achievements as a single individual model to win the Isle of Man Production T T Race no less than five years in succession have earned it a place in the Annals of T T history and is truly re...

Страница 5: ...ediately available and then seek the urgent aid of his colleagues the actual Technicai Staff from the original Company making the Trident Generous contributions and material has enabled this manual to...

Страница 6: ...0 J o z W l l l en l l ir t en 0 W l l l l r ClassicBike biz...

Страница 7: ...Slippery Sam ClassicBike biz...

Страница 8: ...K September N October P November X December Yearof Manufacture J 1974 K 1975 N 1976 P 1977 X 1978 A 1979 8 1980 The third section is a numerical block of five figures which comprise the engine number...

Страница 9: ...on to proceed with and produce this Manual utilising where appropriate existing technical matter and artwork previously used on Triumph Trident publications which has proved so invaluable in the compi...

Страница 10: ...AL DATA GO LUBRICATION SYSTEM A ENGINE B PRIMARY DRIVE C TRANSMISSION GEARBOX 0 FRAME ATTACHMENTS E WHEELS BRAKES TIRES F FRONT FORK G ELECTRICAL SYSTEM H SERVICE TOOLS J CONVERSION CHARTS CT ClassicB...

Страница 11: ...ClassicBike biz...

Страница 12: ...GENERAL DATA TRIDENT MODEL TI60 750 C c 45 cu ins GDl ClassicBike biz...

Страница 13: ...rial Bore Maximum oversize see also page 00 Tappet guide block housing diameter Liner materIal CYLINDER HEAD Material Inlet port size Exhaust port size Valve seatings Type Material VALVES Stem diamete...

Страница 14: ...METER DRIVE Drive gear shaft Drive gear housIng Driven gear shaft Bush plain Bush flanged TIMING GEARS Inlet and exhaust camshaft pinions No of teeth Fit on camshaft Intermediate timing gear No of tee...

Страница 15: ...te bearing ball Operating lever bearing ball CHAINWHEEL Thrust bearing Needle roller bearing chalnca se 1 000 Ib approx 453 6 kg 035 In 889 mm 06 In 1 524 mm 17 mm X 40 mm X 12 mm X 11 X t In Torringt...

Страница 16: ...eturn springs No of werking c01ls Free length Camplate plunger spring Free length Ne of werking calls Camplate plunger housing bore Camplate plunger diameter GENERAL DATA GO 1 00 1 1019 1 1040 1 1 837...

Страница 17: ...units n 875 327 mm at mid position 382 377 In 9 7028 9 5758 mm 8 810 In m 8 mm 110Ib ln WHEELS BRAKES AND TIRES WHEELS Rim size Front Rear Spoke details Front Outer L H and R H Inner L H and R H Rear...

Страница 18: ...Lucas 989 6 watt Lucas 281 2 watt Lucas 380 21 6 watt Lucas 504 2 2 watt lucas 382 21 watt Lucas 2CP Lucas BFL Lucas SS700P Lucas 169 SA Lucas 161 5A Lucas 149 SA Lucas 118 SA 3S amperes Champion N3...

Страница 19: ...rellr Top Bottom Shock absorber assembly screws GDB GENERAL DATA 40 45 Ib ft 5 53016 221 kg m l 50 Ib ft la 913 kg m l 8 Ib ft 1 106 kg m l 25Ib ft 3 456 kg m l 23 25 IbA 3 17 3 45 kg m l 2 203 Ib ft...

Страница 20: ...REPLACING THE ROCKER OIL FEED PIPE ANTI DRAIN VALVE CONTACT BREAKER LUBRICATION TRANSMISSION GEARBOX LUBRICATION PRIMARY CHAINCASE LUBRICATION REAR CHAIN LUBRICATION AND MAINTENANCE GREASING THE STEER...

Страница 21: ...ernal oil leakage Lubricate brake pedal spindle Remove rear chain for cleaning and greasing Lubricate contact breaker and auto advance mechanism Grease speedometer drive unit Change engine oil and pri...

Страница 22: ...il Grode Engine oil tank 20 50 Primary chalncase 10 50 Transmission gearbox 90 E P all filter compartment 10 50 Wheel bearings Grease Stearing head bearings Grease Exposed cables baliloints linkage ca...

Страница 23: ...A LUBRICATION SYSTEM Fig A2 Engine lubrication diagram Ccl ur IndIO BLUE_FEED YELLOW RETURN ClassicBike biz...

Страница 24: ...Hypoy SAE 90 EP GX 90 140 90 EP lubricant EP 90 Telescopic Fork Mobil Castrol B P Es o Shell Donax Texomatlc ATF 210 T Q F Autron B Glide T 7 F Wheel Bearings SwingIng MobJlgrease MS Castrol LM B P E...

Страница 25: ...situated between the scavenge side of the pump and the all cooler After lubricating the rocker spindles the ollis fed into the rocker boxes by way of grooves In the rocker arms afterwards draining dow...

Страница 26: ...raw the element THE NEW EL MENT MUST BE FinED WITH THE OPEN END INWARDS OTHERWISE THE OIL SUPPLY WILL BE CUT OFF A rubber sealing ring Is located at the Inner end of the element Ensure that this Is no...

Страница 27: ...nds and centre plain main bearings are not excessively worn If the bearings have too great a working clearance oil will escape more readily particularly when warm thus giving a reduced pressure Excess...

Страница 28: ...r should be very slight though after considerable mileage the pump may require renewal To gain access to the 011 pump remove the outer primary chalncase Section CS and the Inner primary chalncase Sect...

Страница 29: ...ckets to the frame and replace both large diameter all pipes The left side union connects to the scavenge pipe I e the pipe which connects to the metal rocker reed pipe union Tighten the union clips e...

Страница 30: ...ative that no oil from the engine lubrication system reaches the contact breaker chamber For this purpose there Is an oil seal at the back of the contact breaker unit pressed Into the timing cover How...

Страница 31: ...added to the transmission gearbox until It rises to the level shown on the dipstick when this is screwed down In addition the machine must be standing on level ground Fig AtO Transmission gear box dra...

Страница 32: ...is stretched to Its maximum free length the extension should not exceed tin 6 25 mm If It is required to remove a faulty link or shorten the chain reference should be made to Section C14 To lubricate...

Страница 33: ...to drain out then whilst standing astride the machine apply the front brake and depress the forks a few times to drain any oil remaining in the system Replace the drain plugs and pour 210 em of oil I...

Страница 34: ...lubricated by means of grease see Section A2 for correct grade It is not necessary to remove the cables completely but only to disconnect them from the Instruments and withdraw the inner cables Unscr...

Страница 35: ...pads discs tires etc Disconnect the pipe line at the caliper unit making sure that any oil draining from the pipe falls clear of the brake components and remove the complete caliper unit Drain out any...

Страница 36: ...ETS INSPECTING THE CAM FOLLOWERS INSPECTING THE TAPPET GUIDE BLOCKS REMOVING AND REFITTING THE PISTONS REMOVING AND REPLACING THE PISTON RINGS INSPECTING THE PISTONS AND CYLINDER BORES TABLE OF SUITAB...

Страница 37: ...B ENGINE Fig B1 Exploded view of the TrIdent englne transmlsslon unit 82 ClassicBike biz...

Страница 38: ...ith an automatic advance and retard mechanism and the opposite end drives the tachometer cable The three throw one piece crankshaft Is supported by two shell type be rlngs a roller be rlng t the right...

Страница 39: ...the air cleaner container on the right side This will allow the outer cover and filter element of the air cleaner to be removed The throttle cable should be removed from the B4 carbu retor linkage by...

Страница 40: ...plete engine unit It should be lifted Into the frame again utilising the two lifting bars In the same positions as for the removal transmission gearbox first from the I ft side The front of the unit c...

Страница 41: ...d as mentioned In Section B6 Remember to remake ail B6 electrical connections Take particular carc when refitting the exhaust assembly to ensure that ail the joints are correctly made If an air leak t...

Страница 42: ...h push rod which must be replaced in the same position as when removed Remove the securing bolts in the rever e order to that shown in Fig B12 I e slacken the highest number first When refitting ensur...

Страница 43: ...hipped or loose end cups also check that the push rod Is true by roiling It slowly on a truly flat surface such as piece of plate glass B8 Bent pushrods are found to be the cause of excessive mechanic...

Страница 44: ...ish can be achieved by lightly rubbing the junction surface on a sheet of emery cloth mounted on a truly flat surface such as a piece of plate glass The following method of assembly Incorporates the u...

Страница 45: ...B ENGINE I II III t LI I Z t u C 1III IIII E u u e 0 c u E u c II 0 II on ii III B10 ClassicBike biz...

Страница 46: ...in Exhaust 0 008 in Commencing with the inlet rockers turn the engine until any two rocker arms are on the rock This Is a condition whereby the two corresponding valves are open by equal amounts In t...

Страница 47: ...uts Do not tighten excessively since the body may be distorted with consequent air leakage and hence reduced filtering efficiency SECTION 87 CARBURETTER DESCRIPTION The 626 type carburetor Fig B9 has...

Страница 48: ...PILOT All SCREW 13 0 RING 1 4 JET HOLDER 15 MAIN JET 16 NEEDLE JET 17 NEEDLE 18 FLOAT Fig 89 Exploded view of carburetter 19 FLOAT SPINDLE 20 JOINT WASHER 21 FLOAT CHAMBER 22 FLOAT NEEDLE 13 FILTER 2...

Страница 49: ...e of the throttle valve remove the needle retaining spring clip and compress the throttle rod spring so that the top retaining plate can be extracted Push the bottom nipple of the throttle rod downwar...

Страница 50: ...ve Ensure that the air valve spring Is serviceable by inspecting the calls for wear 3 Inspect the throttle return spring for efficlenty signs of cracking or breakage and loss of compressive strength 4...

Страница 51: ...mes to clear the fuel Repeat the starting procedure without further priming NOTE The primer on the center carburetor is operated by means of a rocking lever B16 SLOW RUNNING Following adjustments to t...

Страница 52: ...ust pipes In front of the cylinder head and slacken the finned clips on the outer exhaust pipes adjacent to the head The pipes can now be drawn forwards off the exhaust stubs using If necessary a mall...

Страница 53: ...eating by the grinding In process described in Section B16 but It does not necessitate recuttIng the cylinder head valve seat unless new valve guides have been fitted Removal of the valves Is facilita...

Страница 54: ...TION 814 RENEWING THE VALVE GUIDES The valve gUides can be extracted using service tool 61 6063 as shown In the Illustration B16 The same method may be employed to fit the new gUide except that the re...

Страница 55: ...n kerosene paraffin Finally check the valves for pitting If necessary the valves can be ground in as shown In Section B16 SECTION 816 E SEATING THE VALVES Examine the face of the valve to see if it is...

Страница 56: ...ns B2 and B12 fOI removal and replacement of the cylinder head and rocker boxes Remove the cylinder base nuts and plain washers First release the load on each nut in turn starting from the outer nUts...

Страница 57: ...wer the cylinder block stili further until these rings also are In the block arid remove the clamp Slide the cylinder block fully home onto the crankcase studs and fit the plain washers and special nu...

Страница 58: ...ecomm ended practice and may result In a damaged piston or distorted connecting rod The need for care cannot be over stressed when using this method to remove the wrist pin When the pistons are remove...

Страница 59: ...s pattern Is achieved The recom mended grade of emery cloth for this purpose Is No 300 Thoroughly wash the bores In kerosene paraffin and check that all traces of abrasives are removed Pistons and rin...

Страница 60: ...f the bore whilst the portion below the piston ring working area remains relatively unworn Compare the diameters measured at right angles to the wrist gudgeon pin to obtain an across the thrust faces...

Страница 61: ...ction A11 The unit should be refitted into the camshaft taper and the bolt refitted without tightening The base plate should be repositioned so that the set of points with the Red Black lead Is to the...

Страница 62: ...advance unit has been removed It should only be assembled loosely Slacken and remove the auto advance central bolt and fit an oversized washer A under the bolt Fig B26 When the bolt Is tightened the n...

Страница 63: ...orrect refer to Section B2S If necessary Start the motor and direct the stroboscope beam at the pointer and rotor mark The engine should be rUn at a speed of not less than 3 500 r p m when the pointer...

Страница 64: ...rk timing Section B26 SECTION B29 EXTRACTING AND REFITTING THE VALVE TIMING PINIONS Before attempting to remove any of the valve timing pinions It Is necessary to release the load on the camshafts cau...

Страница 65: ...timing mark on the pinion and gently tap the pinion home with a piece of tubing of suitable dimensions Tlghtenin g of the securing nuts counter c1ockwlse rotation will be simplified If carried oUt aft...

Страница 66: ...nkshaft and slide the pinion over It after having greased the pinion bore Align the key and key way and drive the pinion onto the crankshaft SECTION 830 VALVE TIMING Fig B33 Valve timing marks Positio...

Страница 67: ...Remove the timing cover Section B28 13 Remove the rotar and stator To remove the right side crankcase section It is nOt necessary to remove the timing pinion and distance piece If for any reason the p...

Страница 68: ...D7 011 and the assembled tachometer drive unit Section 836 Assemble the lower main bearing shells Into the crankcase ensuring that the locking tab Is to the rear on both shells The top shell shou Id...

Страница 69: ...enable the centre and left hand big end journal and also the left hand centre main bearing to be cleared The crankshaft assembly hould be thoroughly washed In kerosene paraffin and any deposits on th...

Страница 70: ...ring Journals can be determined by Inspecting the bearing surfaces for scoring and by measuring the diameter of the journals with a micrometer Light score marks can be reduced with smooth emery cloth...

Страница 71: ...case where there is severe grooving the camshaft and tappet followers should be renewed A method of estimating the extent of wear on the cam form Is that of measuring the over all height of the cam an...

Страница 72: ...l No 60 3677 See Fig B42 and replaced with a hollow drift A small amount of Triumph Loctlte should be applied to the crankshaft before refitting the inner portion Fig 842 Extracting right side bearing...

Страница 73: ...and the tongue or slot on the gear shafts for damage The bush es In the securing sleeve should be checked for wear In accordance with the dimensions given on pageGD3 If they are to be renewed note th...

Страница 74: ...ER REFITTING THE CLUTCH COVER STRIPPING PRIMARY DRIVE REASSEMBLING PRIMARY DRIVE PRIMARY CHAIN SPROCKET ALIGNMENT REFITTING THE INNER PRIMARY CHAINCASE RENEWING SHOCK ABSORBER RUBBERS REMOVING AND REP...

Страница 75: ...rod acting on a ball bearing in the centre of the pressure plate This seperates the two friction surfaces and allows the driven plate to revolve freely between them There Is no need to IIfree the clu...

Страница 76: ...the cable which must then have all slackness removed by means of adjuster A Fine adjustment only Is provided at the handlebar Now screw ln the rod P just sufficiently to give a P Fig Cl Showing clutch...

Страница 77: ...0 1 F 3 2 countersunk C _ 5Ji 3 C 0 r _ t THE OUTER CHAINCASE To take off this Item It wlll be necessary to remove the clutch operating mechanism as described earlier In this Section Remove nine cros...

Страница 78: ...s no tab washer under the chainwheel nut but before attempting removal cover the threads of the clutch pull rod with a strip of sellotape to prvenec damage to the oil seal on removal Both sprockets ar...

Страница 79: ...oss outwards over the spindle meshing with the crankshaft and oil pump gears Replace the chainwheel assembly on the clutch shaft and the engine sprocket on the crankshaft without the chain if necessar...

Страница 80: ...d without the chain In position Replace the engine sprocket together with any shims formerly fitted between the sprocket and the oil pump drive gear behind It Drive the sprocket home with a tubular dr...

Страница 81: ...cUts or other damage The old seal can be prlsed out with a screwdriver this of course destroys the seal A new seal should then be fitted with the spring side Inserted first Tap In evenly as far as po...

Страница 82: ...ice This Is shown in Fig C9 together with the special leverage bar which will be essential for this task The Jig and bar can be made up to the dimensions shown in Fig C10 The chainwheel shock absorber...

Страница 83: ...Section CS The gear shift quadrant must be taken off the cross shaft on which It Is lotated by two flats and retained by a self locking nut and washer Straighten the engine sprocket nut tab washer and...

Страница 84: ...ft splines The spider should be a push fit onto the splines and there should not be any rotary movement Similarly check the fit of the engine sprocket splines on the crankshaft Again there should not...

Страница 85: ...Jaws should rest on a chain roller free of chain link plates see below Fig en Chain link dvet extractor Open the jaws by pressing down the iever see below 4 Turn the screw clockwise until the punch co...

Страница 86: ...ANTLING AND REASSEMBLING THE GEAR SHIFT CROSS SHAFT INSPECTING THE GEAR SHIFT AND KICKSTART COMPONENTS RENEWING KICKSTART AND GEAR SHIFT SPINDLE BUSHES DISMANTLING THE TRANSMISSION G ARBOX INSPECTION...

Страница 87: ...1 FOURTH GEAR S FIFTH GEAR 6 loW GEAR 7 SECOND GEAR a THIRD GEAR 9 FOURTH GEAR 10 FIFTH GEAR 11 HAINSHIFT 12 LAYSHIFT 13 FIRST GEAR LAYSHAFT SELECTOR FORK H THIRD GEAR LA l SHAFT SELECTOR FORK 15 HAIN...

Страница 88: ...ks The neutral positions of the cam plate and gears are shown In Fig D3 1I 1 2 1 TIMING SiDE GEARSHIFT FORK 1 QUADRANT J CAHPLATE PLUNGER GEAR CONTR OL QUADRANT S SELECTOR FORK 6 SELeCTOR SPINDLE When...

Страница 89: ...rth gear while the malnshaft fourth gear Is moved Into a neutral position Finally fifth gear Is obtained by a final movement of the lever In the same direction The malnshaft 04 selector fork will brin...

Страница 90: ...crewed more easily by subsequently applying the rear brake when required Unscrew the three screws two long and one short which secure the round Inspection cover Take off the cover Remove the self lock...

Страница 91: ...Instructions Finally refill the transmission gearbox to the correct level with the recommended grade of oil See Section A2 SECTION 03 DISMANTLING AND REASSEMBLING THE KICKSTART MECHANISM Slacken the...

Страница 92: ...are that they are not suddenly ejected from their seats during assembly It Is unlikely that the gearshift fork will need to be removed but If for any reason It does It should be remembered that it Is...

Страница 93: ...y drive case with the appro priate amount and grade of lubricant Section A2 SECTION 06 INSPECTING THE GEARSHIFT AND KICKSTART MECHANISM GEARSHIFT 1 Inspect the gearshift plungers for wear and ensure t...

Страница 94: ...bush which shoul be done whilst the tover Is still hot SECTION D8 DISMANTLING THE TRANSMISSION GEARBOX Remove the outer cover as snQwn In Section D2 leaving the transmission with 5th top gear selecte...

Страница 95: ...e crankcase To remove the gearbox sprocket disconnect the rear chain and remove It from around the sprocket which can now be easily withdrawn through the aperture The oil Is preveneed from leaving the...

Страница 96: ...hes Make sure that the splines are free on their respective shafts wlth DUt any tendency to bind and that the bushes In the malnshaft third gear layshaft second gear and layshaft first gear are not lo...

Страница 97: ...3 078 In of the bearing protrudes above the cover face see Fig D 12 The left needle roller bearing Is of the closed end type and Is accessible from the left through the sprocket cover plate perture Th...

Страница 98: ...and engage with the malnshaft fifth and fourth gears note that with the gearbox in the neutral position none of the sliding dogs will be engaged Replace the layshaft third gear with Its respective sel...

Страница 99: ...temporarily assemble the outer cover and gearchange lever and check that the gearchanglng sequence Is correct by simultaneously operating the D14 gearchange pedal and turning the rear wheel In the eve...

Страница 100: ...ed and the transmIssion sprocket withdrawn The sprocket will need to be removed using the extractor 61 6046 Before fitting the new sprocket check that the transmission case oil seal Is in good conditi...

Страница 101: ...ClassicBike biz...

Страница 102: ...ANDLE ETC ADJUSTING THE REAR SUSPENSION REMOVING AND REFITTING THE REAR SUSPENSiON UNITS DISMANTLING AND REASSEMBLING THE SUSPENSION UNITS REMOVING AND REFITTING THE SWINGING FORK RENEWING THE SWINGIN...

Страница 103: ...E E2 FRAME iii il ClassicBike biz...

Страница 104: ...at and unscrew the plastic securing knob at the tOP front of the panel Slide It forwards off the two mounting pegs at the rear to remove from the frame Refitting the panels Is a direct reversal of the...

Страница 105: ...rown blue lead to the battery together with the starter cable and then the red positive cable Unhook the rubber retaining strap at the front of the carrier and take the battery out from the left side...

Страница 106: ...removed this portion of the guard can be lifted out together with all Its fittln s such as tail lite assem blYi number plates Indicator lites and wiring harness The fender may now be dismantled on a b...

Страница 107: ...ullc damping mechanism Is completely sealed but the static loading of the spring Is adjustable SECTION E7 REMOVING AND REFITTING THE REAR SUSPENSION UNITS Removal of the suspension units Is achieved b...

Страница 108: ...iently to allow the two retainers to be extracted The same tool Is used for replacing or renewing the spring The damper unit should be checked for leakage bending of the plunger rod and damping action...

Страница 109: ...e wheelis removed during chain adjustment and the washers must be replaced In their original position The securing nUt Is of the self locking type and It Is advisable to fit a new one when re assembll...

Страница 110: ...should be greased packed see Fig E12 Recommended grades of grease are given In the table on page AS The 0 rings should be Inserted Into their housings and fitted over the ends of the fork cross tube...

Страница 111: ...bore of the housing see Fig E10 Fig E10 RemovIng a swinging fork bush New bushes are of the steel backed pre sized type and when carefully pressed In using a smear of grease to assist assembly they w...

Страница 112: ...ent at the same time labelling Each connector so that It can be replaced on Its proper terminal on re assembly Remove the all tank Section E3 Remove the rear wheel Section F17 Remove the rear suspensi...

Страница 113: ...ed to support the spindle and head lug on a plane parallel to and approx 6 Ins 15 em from the checking table surface For this purpose two V blocks packing pieces and two suitable G ciamps will be requ...

Страница 114: ...FRAME E Fig E14 Checking the fron frame alignment Fig E1S Checking the ront frame alignment E13 ClassicBike biz...

Страница 115: ...The best means of checking rear frame alignment Is that of fitting It to the front frame and taking readings as Indicated In the following paragraph E14 FRAME ASSEMBLY Securely bolt the rear frame to...

Страница 116: ...k that the distance between the fork ends Is as given in General Data It Is now necessary to lever the fork ends In the correcting direction until the wheel spindle can be Inserted and found to be par...

Страница 117: ...d should be renewed after re fittlng the lock Fig E18 Fairing attachment lug Fig E19 Steering lock SECTION EI4 FITTING REPLACEMENT SEAT COVERS winseats have a cover retained by sprags hlch are part of...

Страница 118: ...show any high Spots there may be and use the dolly and spoon to remove them Note Do not file more than is necessary to show up the high spots Care should be taken to keep filing to a minimum otherwis...

Страница 119: ...layers or Insufficient drying time will result In risk of surface cracking EiB UNDERCOAT SURFACER Most cellulose undercoats also called surfacers will suffice for a base for TRIUMPH finishes About tw...

Страница 120: ...r most purposes the 2nd coat of finish Ing Is more than adeGuate Between each coati the surface may be flatted by hand with 320 or 400 abrasive paper as reGulred 1st Coat 2nd Coat 3rd Coat 4th Coat 50...

Страница 121: ...I I ClassicBike biz...

Страница 122: ...EAR BRAKE CYLINDER STRIPPING AND REASSEMBLING BRAKE CALIPER REPLACEMENT PARTS REMOVING AND REPLACING FRONT WHEEL REMOVING AND REPLACING FRONT WHEEL BEARINGS REMOVING AND REPLACING REAR WHEEL REMOVING...

Страница 123: ...ribed on page F4 wili restore the fluid to Its orlglnallevel Other essential maintenance Is to the pipeline union nuts ali of which must be checked at regular Intervals for signs of fluid leakage The...

Страница 124: ...BRAKES WHEELS AND TIRES F Fig Fl Disc b _ecompo ncnts Front F3 ClassicBike biz...

Страница 125: ...N ate If during the life of the previous pads It had been found necessary to replenish the hydraulic fluid In the reservoir the level will rise as the plungers are seperated and under extreme condi ti...

Страница 126: ...lly bleed the brake as described in Section F7 IMPORTANT NOTE If the system has been contaminated by a minerai oil all rubber parts including flexible hoses must be replaced SECTION F7 BLEEDING THE SY...

Страница 127: ...be separated The stop light switch is retained in the control lever body by a small screw which must be removed when the switch and Its two leads can be withdrawn but still attached to the triple swi...

Страница 128: ...TIRES F A FEED POR T B BREATHER 4 1 PUSH ROO 2 piSTON 3 CHECKVAL Ve l SPRING S PRIMARY SEAL 6 CIRCLIP 7 piSTON WASHER B SECONDAI YSEAL 9 SPRING RETAINER 10 DUST COVER Fig FS Hydraulic flow diagram F7...

Страница 129: ...oles to prOVide an unblocked passage to the wheel cylinders On releasing the front brake lever the retUrn spring 4 thrusts the piston 2 back faster than the fluid is able to return from the wheel cyli...

Страница 130: ...fluid before assembly Do not use petrol trichlorethylene or any other cleaning agents to wash the parts Fit the secondary seal 8 onto the piston 2 so that the lip of the seal faces towards the head d...

Страница 131: ...essary to split the brake caliper check that the fluid channel seal Is undamaged before reassem bling The caliper and bridge bolts should be thoroughly clean and dried prior to reassembly and naturall...

Страница 132: ...s the dust seal Into the mouth of the piston bore using a G clamp and support plate untillts outer edges are flush with the bore Repeat with the second dust seal and retainer Fit new brake pads See Se...

Страница 133: ...e several times to restore brake pressure and check that It functions normally SECTION FI6 REMOVING AND REPLACING FRONT WHEEL BEARINGS Remove the front wheel See Section F15 Un screw the wheel spindle...

Страница 134: ...Its spindle and other components on the left side can then be extracted and lowered to the ground It is most Important that the brake should not be applied whilst the wheel Is oUt of the fork otherwi...

Страница 135: ...e commencing reassembly check the condition of the dust covers grease retainer and distance pieces etc It Is advisable to replace any damaged parts Ciean the bearing housings First fit the grease reta...

Страница 136: ...ignment SECTION F20 WHEEL BALANCING When awheel is unbalanced It Is often due to varia tions In weight distribution In the tires which are usually marked on the wall with a white spotts to Indicate th...

Страница 137: ...F12 The attachment of the balance weights SECTION F21 WHEEL BUILDING Wheel building or adjustment to the spokes to realign the wheel rim should only be undertaken by a specialist and the following In...

Страница 138: ...spindle which must first be released by slack enlng the nut on the right side The adjuster bolts C must be tightened by the same amount after releasing locknut D in order to preserve chain alignment...

Страница 139: ...ond lever close to the first and prise the bead over the rim flange Remove the first lever and reinsert a little furcher round the rim from the second lever Continue round the bead In steps of two to...

Страница 140: ...y water Squeeze the beads together at the valve position to prevent the tube from slipping back Inside the tire and offer the cover to the rim as shownin Flg F19at the same time threading the valve th...

Страница 141: ...Handbook and check fitting lines again Inflation should not be tOO rapid particularly ac the com mencement to allow the beads to seat correctly on the rim Tighten down any security bolts Wheels with...

Страница 142: ...120 each side of the valve To fit the bolts remove the tire and tube mark the bolt positions and drill the rim between two spoke nipples to the required size of the bolt After removing any burr from t...

Страница 143: ...e irregular wear on the tires It is essential that the recommendations governing pressures and general malntenante are followed The folloWing points should be carefully observed 2 Note Under Inflation...

Страница 144: ...G TELESCOPIC FORKS DESCRIPTION STEERING HEAD ADJUSTMENT DISMANTLING AND REASSEMBLING THE FORK LEGS RENEWING STEERING HEAD BEARINGS FORK ALIGNMENT HYDRAULIC DAMPING Section G1 G2 G3 G4 GS G1 ClassicBi...

Страница 145: ...G G2 TELESCOPIC FORKS Fig Gl F ark assembly details ClassicBike biz...

Страница 146: ...forwards when any play will be felt immediately by the left hand To adjust the bearings support the crankcase on a box 50 that the front wheel is clear of the ground and slacken the pinch bolt A Fig G...

Страница 147: ...the base of the fork leg Is being unscrewed The tip of Service Tool 61 6113 Is rounded For more recent forks it will be advantageous to grind a flat on the tip making it screwdriver shaped At this sta...

Страница 148: ...h or damage the precision edge of the seal Even a scratch which may not be readily visible to the eye will cause leakage at the seal A drift will be required to Insert the oil seal into the hocslng Th...

Страница 149: ...Is adequate 1 1 order to obtain access to these bearings proceed as In Section G2 to the point where the fork stanchions have been removed from the top and bottom yokes Next slacken the pinch bolt B F...

Страница 150: ...tion a hand press Is required Place the stanction on two V blocks one at either end and apply pressure to the raised portion of the stanctlon By means of al ornately pressing In this way and checking...

Страница 151: ...SPRING 3 RUBBER COLLAR 1 OILSEAL 5 SCRAPER SLEEVE 6 DAMPER VAlVE C RING 7 RECOILSPR ING a STANCHION END pLUG 9 CAMPER TUBE 10 BLEED HOLES DAMPER TUBE 11 DAHPERTUBESOCKETSCREW G8 I I Fig GB Section 1 v...

Страница 152: ...ively sealed off by a plastic sleeve and the damping Increases until the stanchion Is trapped on a cushion of oil which acts as the final bump stop During this operatJO 1 a vacuum Is created in the sp...

Страница 153: ...ClassicBike biz...

Страница 154: ...C OUTPUT ATTHE RECTIFIER bl CHECKING THE ALTERNATOR OUTPUT e RECTIFIER MAINTENANCEANDTESTING dl CHECKING THE CHARGING CIRCUIT FOR CONTINUiTY e MAKING A 1 OHM LOAD RESiSTOR ZENER DIODE CHARGE CONTROLA...

Страница 155: ...start facility is provided On these models there is however sufficient voltage to start the machine when a dis charged battery is in circuit SECTION H1 BATTERY INSPECTION AND MAINTENANCE The battery...

Страница 156: ...rged Filling Fully charged 1 250 1 280 1 300 1 210 1 220 1 240 Every 1 000 miles 1 500 km 1 or monthly or more regularly in hot climates the battery should be cleaned as follows Remove the battery cov...

Страница 157: ...Section H3 part D The ignition coils can be removed for testing as in Section H3 part C merely by disconnecting the terminals grasping each coil in turn and lifting it firmly away from rubber mounting...

Страница 158: ...Vel terminal and earth on all three coils No voltage reading indicates a breakdown between the battery and the coil Vel terminal ot th t the switch connections are faulty 3 Connect the voltmeter betwe...

Страница 159: ...cked that the ignition points are actually making good electrical contact when closed and that the moving contact is insulated from earth ground when open See Test H3 Part B It is advisable to remove...

Страница 160: ...connection tab and through the spring location eye Apply a smear of grease to the C B cam and moving contact pivot post Every 3 000 miles and or contact replacement apply two drops of clean engine oil...

Страница 161: ...y caused by w eak carburation although plugs which have been operating whilst not being screwed down sufficiently can easily become over heated due to heat that is normally dissipated through to the c...

Страница 162: ...available to solve these problems from the plug manufacturer who should be consulted Note if the air filter has been removed it will affect the carburation of the machine and hence may adversely affec...

Страница 163: ...s tight It should always be kept clean and dry to ensure good cooling and spilt oil washed off immediately with hot water Note The nuts clamping the rectifier plates together must not be disturbed or...

Страница 164: ...is faulty and the rectifier should be disconnected and bench tested so that the fault can be located Note AII of the above conclusions assume that the alternator A C output figures were satisfactory A...

Страница 165: ...the rectifier centre terminal by connecting a D C voltmeter with a 1 ohm load resistor parallel between the rectifier centre terminal not the end terminal and earth remember ve positive earth ground...

Страница 166: ...ent is by passed by the Diode because of it being non conducting due to the low battery terminal volts However as the battery is quickly restored to a full state of charge the system voitage rises unt...

Страница 167: ...ed to the frame of the machine by it fixing bolts and a separate earth lead The black lead connects to the Zener Diode Lucar terminal C Start the engine ensure that all the lights are off and graduall...

Страница 168: ...CTRIC HORNS DESCRIPTION The horn is of a high frequency single note type and is operated by a direct current from the battery The method of operation is that of a magnetically operated armature which...

Страница 169: ...ght assembly H16 bulb voltage and wattage specification and type before fitting Focusing with this type of light unit is unnecessary and there is no provision for such A parking or pilot bulb E is als...

Страница 170: ...reference should be made to the wiring diagram in Section H20 Finally set the headlamp main beam as detailed in Section H9 SECTION H11 TAIL AND STOP LAMP UNIT Fig H16 Access to tail stop light and dir...

Страница 171: ...a spring loaded plunger This can be depressed with a pointed instrument through a small hole in the side of the switch body and the lock assembly withdrawn after the lock and switch together have been...

Страница 172: ...the unit could arise if there is any shortage of lubrication Neutral gear between first and second ratios is indicated by a green light D This comes on only when neutral is engaged Access to the bulb...

Страница 173: ...iming is less critical Provided the centre of the rotor and stator poles are roughly in line in the fully retarded position I e as normal battery emergency start condition which is 30 past magnetic ne...

Страница 174: ...t be connected to the rectifier centre D C terminal brown white and the positive terminal must be connected to the centre bolt earthing terminal The mounting spring should be attached to any convenien...

Страница 175: ...or the 6 volt ignition coils in the machines own 12 volt circuit However when the starter motor is operated the current drain reduces the circuit H22 voltage It is then that the ballast resistor is by...

Страница 176: ...hten Move probe from engine earth stud to battery positive terminal and from starter body to engine earth stud Depress starter button Volt drop should not exceed volt If more replace cable The total v...

Страница 177: ...ATESHAFTBUSH 17 HOUSING TO CLUTCH CQVERSCAClN 18 HOUSINGTOCLUTCH COVER SCREW 19 HOUSING TO END DRIVE BAACKETSCREW 20 HOUSING TO END DRIVE BRACKET STUD 21 NUT FOR HOUSING STUD 22 WASHER 23 SQLENOID 24...

Страница 178: ...ATOR FLASHER UNIT 19 HEAOLITEWARNING UNIT INonh America only 20 Oil PRESSURE SWITCH 21 NEUTRAllNDICATOR SWITCH 22 SPEEDOMETER 23 TACHOMETER 24 WARNING liTE directIon lndieatorJ 25 WARNING UTE main hea...

Страница 179: ...ClassicBike biz...

Страница 180: ...strations would in many cases facilitate local fabrication or adaption from existing equipment The section is divided into sub sections relating to the main section heading in this manual iIIustrating...

Страница 181: ...seat cutter Inlet 61 7026 60 01832 Valve seat cutter lexhaust 61 7025 60 01836 Blending cutter Inlet 161 7028 60 01835 Blending cutter 161 7027 60 01863 Arbor pilot and tommy bars 161 7029 60 01810 Ca...

Страница 182: ...UED J 61 6019 Crankshaft pinion extractor 60 1858 Ignition timing plug and body 61 6063 Valve guide removal and replacement tool 61 6052 Piston ring clamp 61 6024 Crankshaft pinion replacement drift a...

Страница 183: ...ENGINE CONTINUED 61 6046 Engine and gearbox sprocket extractor 60 2135 Oil pressure release valve spanner 61 6020 Timing side main bearing outer spool drift 61 6021 Drive side main bearing drift J4 C...

Страница 184: ...TOOLS ENGINE CONTINUED J 60 3677 Crankshaft beaming removal tool inner race SECTION J2 TRANSMISSION 61 3808 Universal extractor 60 862 Shock absorber extractor 60 860 Clutch hub extractor J5 ClassicB...

Страница 185: ...ottomgearflxture for 5 speed left footshift gearboxes 61 6061 Gearbox sprocket nut box spanner J6 SECTION J3 WHEELS 61 3694 Wheel bearing retainer peg spanner 61 7024 SECTION J4 FRONT FORKS Fork dampe...

Страница 186: ...SERVICE TOO LS Headrace bearing drift 61 612 1 SECTION J 5 FRAME 61 6050 Swinging arm bush assembly tool J J7 ClassicBike biz...

Страница 187: ...ClassicBike biz...

Страница 188: ...CONVERSION TABLES en ClassicBike biz...

Страница 189: ...939 8 119308 8 203 2 457 2 711 2 965 2 1219 2 9 228 6 482 6 736 6 990 6 124406 One Inch 2S 39997B mlllimetres One t etre 39 370113 Inches One Mile 1 6093 kilos One Kllo 6213B miles DECIMALS TO MILLIM...

Страница 190: ...10 7156 7 16 4375 11 1125 29 64 453125 11 5094 15 32 46875 11 9062 31 64 484375 12 3031 1 2 5 12 7000 Fractions Decimals mm 33 64 515625 13 0969 17 32 53125 13 4937 35 64 546675 1J B906 9 16 5625 14...

Страница 191: ...725 2 44095 2 83465 3 22835 3 62205 3 2 08662 2 48032 2 87402 3 26772 3 66H2 4 2 12599 2 51969 2 91339 3 30709 3 70079 5 2 16536 2 55906 2 95276 3 34646 3 7 4016 6 2 20473 2 59843 2 99213 3 38583 3 77...

Страница 192: ...AUGES No of Im rlal Standard Brown and Sharpe s Gauge Ire Gauge American Wire Gauge Inches Mlilimetres Inches Mllletres oo 400 10 160 460 11 684 000 372 9 448 410 10 404 00 348 8 639 365 9 265 0 324 8...

Страница 193: ...6 107 1570716 159 325 90 POUNDS TO KILOGRAMS 4 0 1 1 3 5 6 7 8 9 00454 0 907 1 361 1 814 2 268 20711 3 175 30619 4 081 10 4 536 990 5 443 50987 6 350 6 804 7 257 7 711 8 165 8 618 10 10 9 072 9 515 9...

Страница 194: ...7 300 0ll 30 579 309 115 313 671 60 70 316 117 312 761 317 308 331 854 336 400 340 946 145 491 350 038 354 584 359 130 70 60 363 676 368 111 371 768 3n 314 3d1 860 366 406 390 951 395 498 400 044 404...

Страница 195: ...In 1 7 16 In 18 103n41n 10385 In 3 4 In 20 6959 In 45 64 In 1 1 2 In 18 104399 In 10447 In 13 161n 20 7584 In 49 64 In 1 9 16 In 18 104948 In 1 1 f2 In 7jB In 20 8209 In 53 64 In 1 5 8 In 18 1 S649 I...

Страница 196: ...n 5 1 5335 In 1 35 In 21n 1f2 1 7594 In 1 25f32In 8 S F SCREW THREADS 01 3 of Thr ads Dja up Core bole per drill dl a Inch Inch Inch 7132 26 1770 1731 114 26 2055 2007 9132 26 238 2320 5116 22 261 25...

Страница 197: ...ClassicBike biz...

Страница 198: ...G c Ft j b cfirf c i but T ey j to i _1 Sole J Primed In E n land by WAR WICK PRINTING COMPANY L1HITED WARWICK ClassicBike biz Relay Connection Info for Electric Starter C 1 Lg Black C 2 Black C 4 Wh...

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