You are on page 1of 388

,..

TROPHY
DAYTONA
DAYTONA SUPER 3
TRIDENT
SPRINT/SPORT/EXECUTIVE
TIGER
SPEED TRIPLE
THUNDERBIRD/SPORT
ADVENTURER

SERVICE
MANUAL
TROPHY

DAYTONA

DAYTONA SUPER 3

TRIDENT

SPRINT/SPORT/EXECUTIVE

TIGER

SPEED TRIPLE

THUNDERBIRD/SPORT

ADVENTURER

Motorcycle
Service Manual

CONTENTS

Introduction
General Information
Servicing
Cylinder Head
Clutch
Balancers
Crankshaft/Rods/Pistons
Transmission
Lubrication
Fuel System/Exhaust
Cooling System
Rear Suspension/Final Drive
Front Suspension/Steering
Brakes
Wheels/Tyres
Frame/Fairings
Electrical System/Ignition
Appendix

INTRODUCTION

INTRODUCTION

How to use this manual

This manual is designed primarily for use by trained


technicians in a properly equipped workshop.
However, it contains enough detail and basic
information to make it useful to the owner who desires
to perform his own basic maintenance and repair work.
The work can only be carried out if the owner has the
necessary hand and special service tools to complete
the job.

To assist in the use of this manual, the section title is


given at the top.
Each major section starts with a contents page, listing
the information contained in the section.
The individual steps comprising repair operations are
to be followed in the sequence in which they appear.

A basic knowledge of mechanics, including the proper


use of tools and workshop procedures is necessary in
order to carry out maintenance and repair work.
satisfactorily. Whenever the owner has insufficient
experience or doubts his ability to do the work, all
adjustments, maintenance, and repair work must be
undertaken by an authorised Triumph Dealer.

Adjustment and repair operations include reference to


Service Tool numbers and the associated illustration
depicts the tool.
Where usage is not obvious the tool is shown in use.
Adjustment and repair operations also include
reference to wear limits, relevant data, torque figures,
specialist information and useful assembly details.

In order to perform the work efficiently and to avoid


costly mistakes, read the text and thoroughly
familiarise yourself with procedures before starting
work.

Particularly important information is presented in the


following form:

All work should be performed with great care and in a


clean working area with adequate lighting.

WARNING:
This
warning
symbol
identifies
special
instructions
or
procedures which, if not correctly followed, could
result in personal injury, or loss of life.

Always use the correct special service tools or


equipment specified. Under no circumstances use
makeshift tools or equipment since the use of
substitutes may adversely affect safe operation.

1,\,
~

Where accurate measurements are required, they can


only be made using calibrated, precision instruments.

CAUTION: This caution symbol identifies


special instructions or procedures
which, if not strictly observed, could result in
damage to or destruction of equipment.

For the duration of the warranty period, all repairs and


scheduled maintenance must be performed by an
authorised Triumph Dealer.

NOTE:

To maximise the life of your Motorcycle:


Accurately follow the maintenance requirements 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 as soon as possible (immediately if
safety related).
Use only Triumph Motorcycle Parts as listed in the
parts catalogue/parts microfiche.
Follow the procedures in this manual carefully and
do not take short cuts.
Keep complete records of maintenance and repair
with dates and any new parts installed.
Use only approved lubricants, as specified in the
Owner's Handbook, in the maintenance of the
motorcycle.
ii

This note symbol indicates points of particular


interest for more efficient and convenient
operation.

INTRODUCTION

ASBESTOS

REFERENCES
This warning may apply to
any
of
the
following
components
or
any
assembly containing one or
more of these components:-

WARNING
CONTAINS
ASBESTOS
Breathing asbestos
dust is dangerous
to health

References
References to the left-hand or right-hand side given in
this manual are made when viewing the motorcycle
from the rear.

Brake Shoes or Pads

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 necessary a road test of the
motorcycle is carried out particularly where safety
related items are concerned.

Clutch Friction Material


Gaskets
Insulators

Follow safety
instructions

Dimensions

SAFETY INSTRUCTIONS

Operate if possible out of doors or in a well


ventilated place.

Preferably use hand tools or low speed tools


equipped with an appropriate dust extraction
facility.

Dampen dust and place in a properly closed


receptacle. Dispose of the closed receptacle
safely.

Never use an
components

The dimensions quoted are to design engineering


specification with service limits where applicable.
During the period of running-in from new, certain
adjustments may vary from the specification figures
given in this manual. These will be reset by the Dealer
at the After Sales Service, and thereafter should be
maintained at the figures specified in this manual.

airline to blow dust from

REPAIRS AND REPLACEMENTS


Before removal and disassembly, thoroughly clean the
motorcycle. Any dirt entering the engine or other parts
will work as an abrasive and shorten the life of the
motorcycle. Particular attention should be paid when
installing a new part, that any dust or metal filings are
cleared from the immediate area.

TAMPERING WITH NOISE CONTROL SYSTEM


PROHIBITED
Owners are warned that the law may prohibit:
(a)

(b)

The removal or rendering inoperative by any


person other than for purposes of maintenance,
repair or replacement, of any device or element
of design incorporated into any new vehicle for
the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in
use; and

Force
Common sense should dictate how much force is
necessary in assembly and disassembly. If a part
seems especially difficult to remove or install, stop and
examine what may be causing the problem. Never
lever a component as this will cause damage both to
the component itself and to the surface being levered
against.

the use of the vehicle after such device or


element of design has been removed or rendered
inoperative by any person.

Whenever tapping to aid removal of an item is


necessary, tap lightly using a hide or plastic faced
mallet.

iii

INTRODUCTION

Edges
Watch for sharp edges, especially during engine
disassembly and assembly. Protect the hands with
industrial quality gloves when lifting the engine or
turning it over.
When replacement parts are required, it is essential
that only genuine Triumph parts are used.
Safety features and corrosion prevention treatments
embodied in the motorcycle may be impaired if other
than genuine Triumph parts are fitted. In certain
territories, legislation prohibits the fitting of parts not to
the manufacturer's specification.

Tightening procedure
Generally, when installing a part with several bolts,
nuts or screws, they should all be started in their 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 sequence if
specified) by about a quarter of turn and then
removed.
Where there is a tightening sequence specified in this
Service Manual, the bolts, nuts, or screws must be
tightened in the order and by the method indicated.
Torque wrench setting figures given in this Manual
must be observed. The torque tools used must be of
accurate calibration.
Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during
removal it must be renewed. This applies particularly
to micro-encapsulated fixings which must always be
replaced if disturbed. Where necessary, the text in this
manual will indicate where such a fixing is used.

iv

General Information
CONTENTS
General precautions and fitting instructions
Ignition system safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dangerous substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health protection precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental protection precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jacking and lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions against damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine coolant caps and plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joints and joint faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gaskets, 0-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid gasket, non-permanent locking agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting a split pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circlips, retaining rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self locking nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encapsulated bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil and grease seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2
1.2
1.2
1.2
1.3
1.3
1.4
1.4
1 .4
1.4
1.5
1 .5
1.5
1.5
1 .5
1.6
1.6
1.6
1.6
1.6
1.6
1.6
1.6

Fuel handling precautions


General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Petrol- gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7
1.7
1.7
1.7

Electrical precautions
Battery disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease for electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disciplines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8
1.8
1.8
1.9
1.9
1 .9
1.9
1 .9

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 .1 0

Full Specification -Trophy 1200, Trophy 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 .13

Full Specification- Daytona 1000, Daytona 750

1.17

Full Specification - Daytona 1200, Daytona 900

1.21

Full Specification - Daytona Super 3 & Speed Triple

1.25

Full Specification- Trident I Sprint 900, Trident 750

1.29

Full Specification- Thunderbird Sport 900, Thunderbird/Adventurer 900 . . . . . . . .

1.33

Full Specification -Tiger 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.37

Torques ......................... .'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 .41

1.1

1 GENERAL INFORMATION
IGNITION SYSTEM SAFETY
PRECAUTIONS

ENGINE OILS

WARNING: The oil may be hot to the


touch. Contact with hot oil may cause the
skin to be scalded or burned.

WARNING:
The ignition system
produces extremely high voltages. Do
not touch any part of the ignition system or any
cables while the engine is running.

WARNING:
Prolonged or repeated
contact 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 contact.

An electric shock caused by contact with the


ignition system may lead to illness, injury or death.

WARNING:
Wearers of surgically
implanted heart pacemaker devices
should not be in close proximity to ignition circuits
and or diagnostic equipment.

Health Protection Precautions

The ignition system and any diagnostic equipment


may interrupt the normal operation of such
devices causing illness or death.

DANGEROUS SUBSTANCES

WARNING:
Many liquids and other
substances used in motor vehicles are
poisonous and should under no circumstances be
consumed and should, as far as possible, be kept
from contact with the skin. These substances
among others include acid, anti-freeze, asbestos,
brake fluid, fuel, lubricants, and various
adhesives. Always pay close attention to the
instructions printed on labels and obey the
instructions contained within. These instructions
are included for your safety and well being.
NEVER DISREGARD THESE INSTRUCTIONS!

Flouroelastomers

Do not put oily rags in pockets.

Overalls must be cleaned regularly. Discard


heavily soiled clothing and oil impregnated
footwear.

First aid treatment should be obtained


immediately for open cuts and wounds. Always
be aware of who your nearest first aider is and
where the medical facilities are kept.

Use barrier creams, applying before each work


period to protect the skin from the effects of oil
and grease and, to aid removal of the same after
completing work.

Wash with soap and water to ensure all oil is


removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.

Do not use petrol, kerosene, diesel fuel, gas oil,


thinners or solvents for cleaning skin.

If skin disorders develop, obtain medical advice


without delay.

Where practicable, degrease components prior to


handling.

WARNING: Flouroelastomer material is


used in the manufacture of the valve stem
oil seals in Triumph motorcycles.
In fire conditions involving temperatures greater
than 315C this material will decompose and can
then be potentially hazardous. Highly toxic and
corrosive decomposition products, including
hydrogen flouride, carbonyl flouride, flourinated
olefins and carbon monoxide can be generated
and will be present in fumes from fires.
In the presence of any water or humidity hydrogen
flouride may dissolve to form extremely corrosive
liquid hydroflouric 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
penetrating
burns
leading to permanent,
irreversible skin and tissue damage.

Avoid prolonged and repeated contact with oils,


particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.

WARNING: Any risk of eye injury must be


avoided. Always wear eye protection
when using a hammer, air line, cleaning agent or
where there is ANY risk of flying debris or
chemical splashing

1.2

GENERAL INFORMATION 1

ENVIRONMENTAL PROTECTION
PRECAUTIONS

WARNING: If there has been an


appreciable drop in the level of the fluid in
either brake fluid reservoir, consult your
authorized Triumph Dealer for advice before
riding.

'f'

CAUTION: Do not pour oil on the ground,


down sewers or drains, or into water
courses. To prevent pollution of water courses
etc., dispose of used oil sensibly. If in doubt
contact your local authority.

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 may be defective.
It is dangerous to operate the motorcycle under
such conditions and remedial action must be
taken by your authorized Triumph Dealer before
riding the motorcycle.
Failure to take remedial action may reduce braking
efficiency leading to an accident.

Burning of used engine oil in small space heaters or


boilers can be recommended only for units of
approved design. If in doubt check with the appropriate
local authority and/or manufacturer of the approved
appliance.
Dispose of used oil and used filters through authorised
waste disposal contractors, to licensed waste disposal
sites, or to the waste oil reclamation trade. If in doubt,
contact the Local Authority for advice on disposal
facilities.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.

BRAKES

WARNING: Brake fluid is hygroscopic


which means it will absorb moisture from
the air. The absorbed moisture will greatly reduce
the boiling point of the brake fluid causing a
reduction in braking efficiency.

Failure to change the brake fluid at the interval


specified in the periodic maintenance chart may
reduce braking efficiency resulting in an accident.

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.

Replace brake fluid in line with the Periodic


Maintenance chart. A dangerous riding condition
could result if this important maintenance item is
neglected!
Do not spill brake fluid onto any area of the
bodywork as this will damage any painted or
plastic surface.

Damage caused by contact with mineral based


grease may reduce braking efficiency resulting in
an accident.

Always use new brake fluid from a sealed


container and never use fluid from an unsealed
container or from one which has been previously
opened.
Do not mix different brands of fluid. 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.

1.3

1 GENERAL INFORMATION

SAFETY INSTRUCTIONS

CAUTION:
The coolant anti-freeze
contains a corrosion inhibitor which
helps prevent damage to the metal surfaces inside
the cooling system. Without this inhibitor, the
coolant would 'attack' the metals and the resulting
corrosion would cause blockages in the cooling
system leading to engine overheating and
damage. Always use the correct anti-freeze as
specified in the Owner's Handbook. Never use a
methanol based anti-freeze as this does not
contain the required corrosion inhibition
properties.

Jacking and lifting

Always ensure that any lifting apparatus


has adequate load and safety capacity for
the weight to be lifted. Ensure the motorcycle is
well supported to prevent any possibility of the
machine falling prior to lifting or jacking.
Never rely on a single means of support when
working with the motorcycle. Use additional safety
supports.

Do not leave tools, lifting equipment, spilt oil, etc.


in a place where they could become a hazard to
health. Always work in a clean, tidy area and put all
tools away when the work is finished.

CAUTION: Distilled water must be used


with the anti-freeze (see specification for
antifreeze) 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
system. Reduced cooling system efficiency may
lead to the engine overheating and suffering
severe damage.

Precautions against damage


Avoid spilling brake fluid or battery acid on any part of
the bodywork. Wash spillages off with water
immediately.

Cleaning components

Disconnect the battery earth lead before starting work,


see ELECTRICAL PRECAUTIONS.

A high flash-point solvent is recommended to reduce


fire hazard.

Always use the recommended service tool where


specified.

Always follow container directions regarding the use of


any solvent.

Protect exposed bearing and sealing surfaces, and


screw threads from damage.

Always use the recommended cleaning agent or


equivalent.

Engine Coolant

Do not use degreasing equipment for components


containing items which could be damaged by the use
of this process. Whenever possible, clean components
and the area surrounding them before removal.
Always observe scrupulous cleanliness when cleaning
dismantled components.

WARNING: Coolant mixture which


contains anti freeze and corrosion
inhibitors contains toxic chemicals which are
harmful to the human body.
Never swallow
anti-freeze or any of the motorcycle coolant.

WARNING: Do not remove the radiator


cap when the engine is hot. When the
engine is hot, the coolant inside the radiator is hot
and also under pressure.
Contact with the
pressurised coolant will cause scalds and skin
damage.

1.4

GENERAL INFORMATION 1

Lubrication

Liquid gasket, non-permanent locking


agent

Engine wear is generally at its maximum while the


engine is warming up and before all the rubbing
surfaces have an adequate lubricative film. During
assembly, oil or grease (whichever is more suitable)
should be applied to any rubbing surface which has
lost its lubricative film. Old grease and dirty oil should
be cleaned off. This is because used lubricants will
have lost some lubricative qualities and may contain
abrasive foreign particles.

Follow manufacturer's directions for cleaning and


preparing surfaces where these compounds will be
used. Apply sparingly as excessive amounts of sealer
may block engine oil passages and cause serious
damage.
Prior to reassembly, blow through any pipes, channels
or crevices with compressed air.

Use recommended lubricants. Some oils and greases


in particular should be used only in certain applications
and may be harmful if used in an application for which
they are not intended. This manual makes reference to
molybdenum disulphide grease in the assembly of
certain engine and chassis parts. Always check
manufacturer recommendations before using such
special lubricants.

WARNING: To prevent injury, always use

~ eye, face and ear protection when using

compressed air. Always wear protective gloves if


the compressed air is to be directed in proximity to
the skin.

Screw threads
Metric threads to ISO standard are used.

Joints and joint faces

Damaged nuts, bolts and screws must always be


discarded.

Assemble joints dry unless otherwise specified in this


Manual.

Castellated nuts must not be slackened back to accept


a split-pin, except in those recommended cases when
this forms part of an adjustment.

If gaskets and/or jointing compound is recommended


for use; remove all traces of old jointing material prior
to reassembly. Do not use a tool which will damage the
joint faces and smooth out any scratches or burrs on
the joint faces using an oil stone. Do not allow dirt or
jointing material to enter any tapped holes.

Do not allow oil or grease to enter blind threaded


holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can affect
the torque reading.

Gaskets, 0-rings
Do not re-use a gasket or 0-ring once it has been in
service. The mating surfaces around the gasket should
be free of foreign matter and perfectly smooth to avoid
oil or compression leaks.

1.5

1 GENERAL INFORMATION
Locking devices

Oil and grease seals

Always release locking tabs and fit new locking


washers, do not re-use locking tabs.

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.

Fitting a split pin

Ensure the surface on which the new seal is to run is


free of burrs or scratches. Renew the component if the
original sealing surface cannot be completely restored.

Always fit new split-pins of the correct size for the hole
in the bolt or stud. Do not slacken back castle nuts
when fitting split pin.

Protect the seal from any surface which could cause


damage over which it has to pass when being fitted.
Use a protective sleeve or tape to cover the relevant
surface and avoid touching the sealing lip.

Always fit new roll pins of an interference fit in the


hole.

Circlips, retaining rings

Lubricate the sealing lips with a recommended


lubricant. This will help to prevent damage in initial
use. On dual lipped seals, smear the area between the
lips with grease.

Replace any circlips and retaining rings that are


removed. Removal weakens and deforms circlips
causing looseness in the circlip groove. When
installing circlips and retaining rings, take care to
compress or expand them only enough to install them.

When pressing in a seal which has manufacturer's


marks, press in with the marks facing out.

Always use the correct replacement circlip as


recommended in the Triumph parts catalogue.

Seals must be pressed into place using a suitable


driver. Use of improper tools will damage the seal.

Self locking nuts

Press

Self-locking nuts can be re-used, providing resistance


can be felt when the locking portion passes over the
thread of the bolt or stud.

A part installed using a press or driver, such as a


wheel bearing, should first be coated with oil on its
outer or inner circumference so that it will locate
smoothly.

DO NOT re-use self-locking nuts in critical locations,


e.g. suspension components. Always use the correct
replacement self-locking nut.

Ball bearing
When installing a ball bearing, the bearing race which
is an interference fit should be pushed by a suitable
driver. This prevents severe stress or damage to the
load carrying components. Press a ball bearing until it
touches the shoulder in the bore or on the shaft.

Encapsulated bolt
An encapsulated bolt can be identified by a coloured
section of thread which is treated with a locking agent.

Press or drift seals to the depth of its housing, with the


sealing lip facing the lubricant to be retained if the
housing is shouldered, or flush with the face of the
housing where no shoulder is provided.

Unless a specified repair procedure states otherwise,


encapsulated bolts cannot be reused and MUST be
replaced if disturbed or removed.

WARNING:
Failure to replace an
encapsulated bolt could lead to a
dangerous riding condition.
Always replace
encapsulated bolts.

1.6

GENERAL INFORMATION 1

FUEL HANDLING PRECAUTIONS

WARNING: No one should be permitted


to repair components associated with
petrol/gasoline without first having specialist
training on the fire hazards which may be created
by incorrect installation and repair of items
associated with petrol/gasoline.
Repairs carried out by untrained personnel could
bring about a safety hazard leading to a risk of
personal injury.

General
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is issued
tor basic guidance only and, if in doubt, appropriate
enquiries should be made of your local Fire Officer.

A
.a.

WARNING:
Draining or extraction of
petrol/gasoline from a vehicle fuel tank
must be carried out in a well ventilated area.
The receptacle used to contain the petrol/ gasoline
must be more than adequate for the full amount of
fuel to be extracted or drained. The receptacle
should be clearly marked with its contents, and
placed in a safe storage area which meets the
requirements of local authority regulations.
When petrol/gasoline has been extracted or
drained from a fuel tank, the precautions
governing naked lights and ignition sources
should be maintained .
Failure to observe any of the above warnings could
bring about a safety hazard leading to a risk of
personal injury.

Petrol- Gasoline
When petrol (gasoline) evaporates it produces 150
times its own volume in vapour which when diluted
with air becomes a readily ignitable mixture. The
vapour is heavier than air and will always fall to the
lowest level. It can readily be distributed throughout a
workshop by air currents, consequently, even a small
spillage of petrol (gasoline) is potentially very
dangerous.

A
.a.

WARNING: Petrol (gasoline) is highly


flammable and can be explosive under
certain conditions. When opening the fuel tank
cap always observe all the following items;
Turn the motorcycle ignition switch OFF.
Do not smoke.

Fuel tank removal

Always have a fire extinguisher containing FOAM,


C02, HALON or POWDER close at hand when
handling or draining fuel or fuel systems. Fire
extinguishers must also be present in areas where
fuel is stored.

Fuel tanks should have a 'PETROL (GASOLINE)


VAPOUR' warning label attached to them as soon as
they are removed from the vehicle. In all cases, they
must be stored in a secured, marked area.

Always disconnect the vehicle battery, negative


(black) lead first, before carrying out dismantling
or draining work on a fuel system.

Chassis repairs

Whenever petrol (gasoline) is being handled,


drained or stored or when fuel systems are being
dismantled, make sure the area is well ventilated.
All potential forms of ignition must be
extinguished or removed (this includes any
appliance with a pilot light). Any leadlamps must
be flameproof and kept clear of any fuel spillage.

A
.a.

WARNING: If the motorcycle is involved


in an accident or collision it must be taken
to an authorised Triumph dealer for repair or
inspection. Any accident can cause damage to the
motorcycle which, if not correctly repaired, may
cause a second accident which may result in injury
or death.

Warning notices must be posted at a safe distance


from the site of the work to warn others that petrol
is being openly handled. The notice must instruct
the reader of the precautions which must be taken.

The frame must not be modified as any


modification to the frame such as welding or
drilling may weaken the frame resulting in an
accident.

Failure to observe any of the above warnings may


lead to a fire hazard which could result in personal
injury.

1.7

1 GENERAL INFORMATION
ELECTRICAL PRECAUTIONS

Connectors and Harness -The engine of a motorcycle


is a particularly hostile environment for electrical
components and connectors. Always ensure these
items are dry and oil free before disconnecting and
connecting test equipment. Never force connectors
apart either by using tools or by pulling on the wiring
itself. Always ensure locking mechanisms are
disengaged before removal and note the orientation to
enable correct reconnection. Ensure that any
protective covers and substances are replaced if
disturbed.

The following guidelines are intended to ensure the


safety of the operator whilst preventing damage to the
electrical and electronic components fitted to the
motorcycle. Where necessary, specific precautions are
detailed in the relevant sections of this manual which
should be referred to prior to commencing repair
operations.
Equipment - Prior to commencing any test procedure
on the motorcycle ensure that the relevant test
equipment is working correctly and any harness or
connectors are in good condition, in particular mains
leads and plugs.

Having confirmed a component to be faulty, switch off


the ignition and disconnect the battery negative (black)
lead first. Remove the component and support the
disconnected harness. When replacing the component
keep oily hands away from electrical connection areas
and push connectors home until any locking
mechanism becomes fully engaged.

WARNING:
The ignition system
produces extremely high voltages. Do
not touch any part of the ignition system or any
cables while the engine is running.

Battery disconnecting

An electric shock caused by contact with the


ignition system may lead to illness, injury or death.

Before disconnecting the battery, switch off all


electrical equipment.

WARNING:
Wearers of surgically
implanted heart pacemaker devices
should not be in close proximity to ignition circuits
and or diagnostic equipment.

WARNING: To prevent the risk of a


battery exploding and to prevent damage
to electrical components ALWAYS disconnect the
battery negative (black) lead first.
When
reconnecting the battery, always connect the
positive (red) lead first, then the negative (black)
lead. Always disconnect the battery when working
on any part of the electrical system.
Failure to observe the above warnings may lead to
electrical damage and a fire hazard which could
cause personal injury.

The ignition system and any diagnostic equipment


may interrupt the normal operation of such
devices causing illness or death.

WARNING: The battery contains harmful


materials. Always keep children away
from the battery whether or not it is fitted in the
motorcycle.
Do not jump start the battery, touch the battery
cables together or reverse the polarity of the
cables as any of these actions may cause a spark
which would ignite battery gasses causing a risk of
personal injury.

Always ensure that battery leads are routed correctly and


are not close to any potential chafing points.

Grease for electrical connectors

High Voltage Circuits- Whenever disconnecting live


H.T. circuits always use insulated pliers and never
allow the open end of the H.T. lead to come into
contact with other components. Exercise caution when
measuring the voltage on the coil terminals while the
engine is running, high voltage spikes can occur on
these terminals.

All connectors are protected against corrosion by the


application of a special spray during production.
Should connectors be disturbed in service, repaired or
replaced, use 'Action Can AC90' or similar to
re-protect the connection.

NOTE:

; .8

The use of other sprays should be avoided as


they can migrate into relays, switches etc.
contaminating the contacts and leading to
intermittent operation or failure.

GENERAL INFORMATION 1

Disciplines

WARNING:
Always have Triumph
approved
parts,
accessories
and
conversions fitted by an authorised Triumph
dealer. The fitment of parts, accessories and
conversions by a dealer who is not an authorised
Triumph dealer may affect the handling, stability or
other aspects of the motorcycle operation which
may result in an accident causing serious injury or
death.

Switch off the ignition prior to making any connection


or disconnection in the system. An electrical surge can
be caused by disconnecting 'live' connections which
can damage electronic components.
Ensure hands and work surfaces are clean and free of
grease, swart, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.

WARNING:
Always have Triumph
approved
parts,
accessories
and
conversions fitted by a trained technician. To
ensure that a trained technician is used, have an
authorised Triumph dealer fit the parts. The
fitment of parts, accessories and conversions by
personnel other than a trained technician at an
authorised Triumph dealer may affect the
handling, stability or other aspects of the
motorcycle operation which may result in an
accident causing serious injury or death.

Prior to commencing any test, and periodically during


any test, touch a good earth to discharge body static.
This is because some electronic components are
vulnerable to static electricity.

Electrical wires
All the electrical wires are either single-colour or
two-colour and, with only a few exceptions, must be
connected to wires of the same colour. On any of the
two-colour wires there is a greater amount of one
colour and a lesser amount of a second colour. A
two-colour wire is identified by first the primary colour
and then the secondary colour. For example, a yellow
wire with thin red stripes is referred to as a 'yellow/red'
wire; it would be a 'red/yellow' wire if the colours were
reversed to make red the main colour.

Service data
The service data listed in this manual gives
dimensions and specifications for brand new, original
parts. Where it is permissible to allow a part to exceed
these figures, then the service limit is given.
The terms of the motorcycle warranty will be
invalidated by the fitting of other than genuine Triumph
parts.

Inspection
Disassembled parts should be visually inspected and
replaced with new ones if there are any signs of the
following:

All genuine Triumph parts have the full backing of the


motorcycle warranty. Triumph dealers are obliged to
supply only genuine Triumph recommended parts.

Abrasions, cracks, hardening, warping, bending,


dents, scratches, colour changes, deterioration,
seizure or damage of any nature.

Specification
Triumph are constantly seeking to improve the
specification, design and production of their
motorcycles and alterations take place accordingly.

Replacement Parts
WARNING: Only Triumph approved parts
should be used to service, repair or
convert Triumph motorcycles. To ensure that
Triumph approved parts are used, always order
parts, accessories and conversions from an
authorised Triumph dealer.
The fitting of
non-approved parts, accessories or conversions
may adversely affect the handling, stability or
other aspects of the motorcycle operation which
may result in an accident causing serious injury or
death.

While every effort has been made to ensure the


accuracy of this Manual, it should not be regarded as
an infallible guide to current specifications of any
particular motorcycle.
Authorised Triumph Dealers are not agents of Triumph
and have no authority to bind the manufacturer by any
expressed or implied undertaking or representation.

1.9

1 GENERAL INFORMATION
Service tools and garage equipment
Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical
components in a practical manner without causing damage. Some operations in this Service Manual 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:3880012 -Valve Shim Removal Tool

3880040 -Alternator Shaft Locking Jig

3880015 - Carburettor Adjustment Tool

3880205- Drive Chain Service (3 tools)

3880025- Clutch Anti-rotation Tool

3880060- Spindle Aligner

1.10

GENERAL INFORMATION 1
3880065 - Head Bearing Fitment

3880085 - Fork Assembler

3880070 - Wheel Bearing Fitment

3880090 - Fork Service

3880075 - Wheel Bearing Fitment

3880095- Oil Pressure Adapter

3880105 - Angular Torque Gauge

3880080 - Fork Seal/Bearing Drift

3880120/3880125 - Float Level Gauge

1.11

1 GENERAL INFORMATION

3880130 - Allen Socket

3880155- Trim Button Fitment

3880160 - Fork Filler/Evacuator

3880139 - Tool Board

3880170 - Ignition Diagnostic Kit

3880140 - Head Race Adjusters

3880185- Six Piston CaliperPiston Retainer

3880145- Screwdriver, Thunderbird Tank


Badge

1.12

GENERAL INFORMATION 1
Full Specification

TROPHY 1200

Engine Type ................... .


Arrangement ................... .
Displacement ......................
Bore x Stroke ......................
Compression Ratio .................
Cylinder Numbering ................
Firing order ........................
Max. Power ........................
Max. Torque .......................

4 Cylinder 16 Valve DOHC


3 Cylinder 12 Valve DOHC
Transverse In-Line
Transverse In-Line
1180 cc
885 cc
76 mm x 65 mm
76 mm x 65 mm
10.6 : 1
10.6 : 1
Left to Right (No.4 adjacent to camchain) Left to Right (No.3 adjacent to camchain)
1-2-4-3
1-2-3
Refer to the owner's handbook for the model, model year and country required.
Refer to the owner's handbook for the model, model year and country required.

.
.
.
.
.
.
.

Cylinder Head
Valve Head Dia .............. ln. . . . .
Ex ....
ln .....
Valve Lift
Ex ....
Valve Stem Dia .............. ln. . . . .
Ex. . ..
Valve Guide Bore Dia. . . . . . . . . . . . . . . . .
Valve Stem to Guide Clearance ln. . . . .
Ex. . . .
Valve Seat Width (in head) ............
Valve Seat Width (valve) .............
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner ..
Outer .
Valve Clearance . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Bucket Dia.
Blue ..
Red ...
White .
Valve Bucket Bore Dia ................
Valve Timing 1 . . . . . . Inlet . . . Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Valve Timing 2 . . . . . . Inlet . . . Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Dia ................
Camshaft Journal Clearance . . . . . . . . . .
Camshaft Journal Bore Dia ............
Camshaft End Float .................
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Camchain Tensioner Spring Free Length

Clutch/Primary Drive
Primary Drive . . . . . . Type . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . . . .
Friction Plate Thickness (new) . . . . . . . .
Friction Plate Thickness (service limit) . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Clutch Shim Clearance ...............
Clutch Master Cylinder Bore Dia. . . . . . .
Clutch Slave Cylinder Bore Dia. . . . . . . .
Recommended Clutch Fluid . . . . . . . . . . .

TROPHY 900

30.0 mm
26.0 mm
7.1 mm
7.0 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.1 0 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
1o BTDC (@ 1.0 mm Lift)
30 ABDC (@ 1.0 mm Lift)
211 a
28 BBDC (@ 1.0 mm Lift)
2 ATDC (@ 1.0 mm Lift)
210
21 o BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1.0 mm Lift)
251 o
51 o BBDC (@ 1.0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0. 12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
21 o BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1.0 mm Lift)
251
51 BBDC (@ 1.0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256
1o BTDC (@ 1.0 mm Lift)
30 ABDC (@ 1.0 mm Lift)
211
28 BBDC (@ 1.0 mm Lift)
2 ATDC (@ 1.0 mm Lift)
210
22.93 mm/22.90 mm
22.936 mm/22.930 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

Gear
1. 75 (1 05/60)
Wet Multi-plate
9
3.80mm - 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT 4

Gear
1.75 (105/60)
Wet Multi-plate
9
3.80mm - 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

Valve Timing 1 - 108 PS 1200cc version and 98 PS 900cc versions.


Valve Timing 2 - 136 PS 1200cc version and 85 PS 900cc versions.

1.13

1 GENERAL INFORMATION
TROPHY 1200

TROPHY 900

Piston Ring to Groove Clearance Top . .


Second
Piston Ring Groove Width
Top . .
Second
Oil ...
Piston Ring End Gap ......... Top . .
(new ring when fitted in bore)
Second
Oil . . .
Gudgeon Pin Bore Dia. In Piston . . . . . .
Gudgeon Pin Dia ....................
Connecting Rod Small End Dia ........
Connecting Rod Big End Side Clearance
Crankshaft Big End Journal Dia ........
Crankshaft Big End Bearing Clearance .
Crankshaft Main Journal Dia. . . . . . . . . .
Crankshaft Main Bearing Clearance . . . .
Crankshaft End Float . . . . . . . . . . . . . . . .

76.05 mm/76.03 mm Cyl. Nos. 1, 3 & 4


76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1, 3 & 4
75.98 mm/75.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.03 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

76.05 mm/76.03 mm Cyl. Nos. 1 & 3


76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.98 mm/75.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.03 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 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
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Drive Ratio . . . . . . . . . . . . . . . . . . . .
Chain Type . . . . . . . . . . . . . . . . . . . . . . . . .
No. of Links . . . . . . . . . . . . . . . . . . . . . . . . .
20 Link Length . . . . . . . . . . . . . . . . . . . . . .
Drive Chain Slack . . . . . . . . . . . . . . . . . .
Chain lubrication . . . . . . . . . . . . . . . . . . . .

6 Speed Constant Mesh


6 Speed Constant Mesh
2.733(41/15)
2.733(41/15)
1.947(37/19)
1.947(37/19)
1.545 (34/22)
1.545 (34/22)
1.291 (31/24)
1.291 (31/24)
1.154 (30/26)
1.154 (30/26)
1.074 (29/27)
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 max.
0.55 max.
Chain
Chain
Variable according to model, model year and market designation
Regina 136 ORP
Regina 136 ORP
Variable according to model, model year and market designation
319 mm max.
319 mm max.
35.0- 40.0 mm
35.0- 40.0 mm
Mobil chain spray
Mobil chain spray

Full Specification
Piston/Crankshaft
Cylinder Bore Dia ............... .
Piston Dia. (at 90 to gudgeon pin)

Lubrication
Pressure Lubrication, Wet Sump
Oil Capacity (incl. filter) . . . . . . . . . . . . . . . 3. 75 litres
Recommended Oil . . . . . . . . . . . . . . . . . . . Semi synthetic 1Ow/40 oil meeting
specification AP\/SG
Oil Pressure (in main gallery) ......... 40.0 lb/in 2 min. (@ 80C Oil Temp.)
(@ 5000 rpm)
Oil Pump Rotor Tip Clearance ......... 0.15 mm (0.2 max.)
Oil Pump Body Clearance ............ 0.22 mm/0.15 mm (0.35 mm max.)
Oil Pump Rotor End Float . . . . . . . . . . . . 0.02 mm/0.007 (0.1 mm max.)

4.00 litres
Semi synthetic 1Ow/40 oil meeting
specification API/SG
40.0 \b/in2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
0.15 mm (0.2 max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)

Ignition System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Timing . . . . . Static . . . . . . . . . .
Idle . . . . . . . . . . . .
Max. Advance . . .
Electronic Rev-Limiter . . . . . . . . . . . . . . . .
Pick up Coil Air Gap . . . . . . . . . . . . . . . . .
Pick up Coil Resistance . . . . . . . . . . . . . .
Ignition Coil LT Resistance ............
Ignition Coil HT Resistance . . . . . . . . . . .
Spark Plug Type . . . . . . . . . . . . . . . . . . . .
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . .

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
26 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
29 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

1.14

GENERAL INFORMATION 1
Full Specification

TROPHY 1200

Fuel System
Fuel Type ......................... . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ..... . 25 Litres
Reserve Capacity .................. . 5 Litres
Low Level Warning Lamp ............ . 7 Litres
Fuel Tap .......................... . Vacuum Controlled, Auto Shut-off
Carburettors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIKUNI BST 36 mm Flat Slide CV

Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm

50 rpm

TROPHY 900
Unleaded, 95 RON
(U.S. 89 CLC/AKI)
25 Litres
5 Litres
7 Litres
Vacuum Controlled, Auto Shut-off
MIKUNI BST 36 mm Flat Slide CV or
KEIHIN CVK 36 mm
1000 rpm 50 rpm

Cooling System
Coolant Mixture .....................
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . .
Freezing Point . . . . . . . . . . . . . . . . . . . . . .
Cooling System Capacity . . . . . . . . . . . . .
Radiator Cap Opening Pressure . . . . . . .
Thermostat Opening Temperature . . . . .
Cooling Fan Switch On Temperature . . .

50!50 Distilled Water/Anti-Freeze


Mobil Antifreeze
-35C
3.0 Litres
1.1 Bar
83C
99C

Suspension
Front Fork Travel ................... .
Recommended Fork Oil ............. .
Oil Level (without spring) ............ .
Rear Wheel Travel .................. .
Rear Suspension Bearing Grease .... .

150 mm
150 mm
Refer to chart in front suspension section for full details
Refer to chart in front suspension section for full details
126 mm
126 mm
Mobil Grease HP 222
Mobil Grease HP 222

Brakes
Front type ......................... .
(up to vin 4901 1200cc)
(up to vin 9082 900cc)
Caliper Piston Dia ................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
Recommended Fluid ................ .

Front type ......................... .


(from vin 4902 1200cc)
(from vin 9083 900cc)
Caliper Piston Dia ................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
Recommended Fluid ................ .
Rear Type ......................... .
Caliper Piston Dia ...................
Disc Dia ...........................
Disc Thickness .....................
Disc Run-out Max...................
Master Cylinder ....................
Recommended Fluid ................

.
.
.
.
.
.

Hydraulically Actuated Two Piston


Sliding Calipers Operating on
Twin Solid Discs
2 x 27.0 mm
296.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
14.0 mm dia. Adjustable Lever
Mobil Universal Brake and Clutch Fluid
DOT4
Hydraulically Actuated Four Piston
Sliding Calipers Operating on Twin
Floating Discs
2 x 33.96 mm & 2 x 30.23 mm
310.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
15.8 mm dia. Adjustable Lever
Mobil Universal Brake and Clutch Fluid
DOT 4
Hydraulically Actuated Two Piston Sliding
Caliper Operating on Single Rigid
Rear Disc
2 x 27.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
14.0 mm dia. Remote Reservoir
Mobil Universal Brake and Clutch Fluid
DOT 4

1.15

50!50 Distilled Water/Anti-Freeze


Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99oC

Hydraulically Actuated Two Piston


Sliding Calipers Operating on
Twin Solid Discs
2 x 27.0 mm
296.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
14.0 mm dia. Adjustable Lever
Mobil Universal Brake and Clutch Fluid
DOT4
Hydraulically Actuated Four Piston
Sliding Calipers Operating on
Twin Floating Discs
2 x 33.96 mm & 2 x 30.23 mm
310.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
15.8 mm dia. Adjustable Lever
Mobil Universal Brake and Clutch Fluid
DOT 4
Hydraulically Actuated Two Piston Sliding
Caliper Operating on Single Rigid
Rear Disc
2 x 27.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
14.0 mm dia. Remote Reservoir
Mobil Universal Brake and Clutch Fluid
DOT 4

1 GENERAL INFORMATION
Full Specification

TROPHY 1200

Wheels and Tyres


Front Wheel Rim Axial Run-out .
Front Wheel Rim Radial Run-out
Front Tyres . . . . . . . . . . . . . . . . . .
Front Tyre Pressure (cold) . . . . . . . . . . .
Front Tyre Tread Depth min. . .
Rear Wheel Rim Axial Run-out . . . . . . . .
Rear Wheel Rim Radial Run-out . . . . . .
Rear Tyres . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Tyre Pressure (cold) ............
Rear Tyre Tread Depth min........

TROPHY 900

0.5 mm
0.5 mm
0.8 mm
0.8 mm
Refer to the owner's handbook for approved lyres for each model year
2.5 kg/cm2
2.5 kg/cm2
2.0 mm
2.0 mm
0.5 mm
0.5 mm
0.8 mm
0.8 mm
Refer to the owner's handbook for approved lyres for each model year
2.9 kg/cm2
2.9 kg/cm2
2.0 mm- up to 80 mph (130 km/h)
2.0 mm- up to 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)

WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised
L===-~closed cours_e_c_o_nd_it_io_n_s_.---~-----~-----~---------Frame
Frame Type
Overall Length . . . . . . . . . . . . . . .
Overall Width . . . . . . . . . . . . . . . . . . . . . . .
Overall Height . . . . . . . . . . . . . . . . . . . . . .
Ground Clearance ..................
Wheelbase . . . . . . . .
Seat Height . . . . . . . . . . . . . . . . . . . . . . .
Steering Head Angle . . . . . . . . . . . . . . . . .
Trail ...............................
Dry Weight . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Payload to VIN 29155 ...........
Max. Payload from VIN 29156
Electrical Equipment
Battery Type . . . . . . . . . . . . . . . . . . .
Battery Rating . . . . . . . . . . . . . . . . . . . . . .
Alternator Rating . . . . . . . . . . . . . . . . . . .
Regulated Voltage . . . . . . . . . . . . . . .
Stator Coil Resistance . . . .
Rotor Coil Resistance . . . . . . . . . . . . . . . .
Slip Ring Dia. . . . . . . . . . . . . . . . . . . .
Brush Length .......................
Starter Motor Commutator Dia .........
Commutator Groove Depth ...........
Starter Brush Length . . . . . . . . . . . . . . . . .
Fuses (up to VIN 29155)
Headlight .......................... .
Tail Light .......................... .
Main .............................. .
Radiator Fan ....................... .
Clock! Alarm .................. .
lnline fuse (1995 on) Brake Light .....
Fuses (from VIN 29156)
Alternator, headlights ............... .
Alarm, clock, hazard warning, indicators
Cooling fan ........................ .
Auxiliary circuits .................... .
Engine start and run systems ........ .
Brake lights, horn, instruments ....... .
Instrument illumination .............. .
All circuits from ignition switch ........ .
Lights . . . . . . . . . . . . . Head Light ..... .
Parking Light ... .
Tail Light ...... .
Indicators ..... .

Large dia. high tensile steel spine,


stressed engine
2152 mm
760 mm
1270 mm
138 mm (158mm to vin 4901)
1490 mm
780 mm
27 from vertical
105 mm
Refer to owner's Handbook
181 kg
217 kg

Large dia. high tensile steel spine,


stressed engine
2152 mm
760 mm
1270 mm
138 mm (158mm to vin 4901)
1490 mm
780mm
27 from vertical
105 mm
Refer to owner's Handbook
181 kg
217 kg

YUASA YB14L-A2
12V- 14AH
12V - 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)

YUASA YB14L-A2
12V- 14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)

10A
10A
30A
15A (10A to vin 4901)
10A
5A

10A
10A
30A
15A (10A to vin 4901)
10A
5A

30A
15A
15A
10A
15A
10A
05A
30A
60/55W H4 Halogen*
4W
21/5
10W (21W Japan)

30A
15A
15A
10A
15A
10A
05A
30A
60/55W H4 Halogen*
4W
21/5
10W (21W Japan)

* 1996 model year - 2x60/55W H4 Halogen

1.16

GENERAL INFORMATION 1
Full Specification
Engine Type .................... .
Arrangement .......................
Displacement ......................
Bore x Stroke ......................
Compression Ratio .................
Cylinder Numbering ................
Firing order ........................
Max. Power ........................

.
.
.
.
.
.
.

DAYTONA 1000

DAYTONA 750

4 Cylinder 16 Valve DOHC


Transverse In-Line
998 cc
76 mm x 55 mm
11.0:1
Left to Right (No.4 adjacent to camchain)
1-2-4-3
89.0 kW (121 PS model)@ 10500 rpm
73.5 kW (100 PS model)@ 9750 rpm

3 Cylinder 12 Valve DOHC


Transverse In-Line
748 cc
76 mm x 55 mm
11.0:1
Left to Right (No.3 adjacent to camchain)
1-2-3
71.3 kW (97.0 PS model)@ 9750 rpm
36.7 kW (50.0 PS model)@ 8000 rpm
19.8 kW (27.0 PS model) @ 6250 rpm
74.0 Nm (54.0 lbsf.ft) @ 8250 rpm
55.0 Nm (40.0 lbsf.ft) @ 5000 rpm
(50 PS model)
44.0 Nm (32.0 lbsf.ft) @ 2500 rpm
(27 PS model)

Max. Torque . . . . . . . . . . . . . . . . . . . . . . . . 88.0 Nm (64.9 lbsf.ft) @ 8500 rpm


78.0 Nm (57.0 lbsf.ft) @ 7750 rpm

Cylinder Head
Valve Head Dia. . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Lift ................... ln .....
Ex ....
Valve Stem Dia .............. ln .....
Ex. . ..
Valve Guide Bore Dia .................
Valve Stem to Guide Clearance ln .....
Ex. . ..
Valve Seat Width (in head) . . . . . . . . . . . .
Valve Seat Width (valve) .............
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner . .
Outer .
Valve Clearance ............. ln .....
Ex ....
Valve Bucket Dia. . .......... Blue ..
Red ...
White .
Valve Bucket Bore Dia ................
Valve Timing ....... Inlet ... Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Dia. . . . . . . . . . . . . . . .
Camshaft Journal Clearance . . . . . . . . . .
Camshaft Journal Bore Dia............
Camshaft End Float . . . . . . . . . . . . . . . . .
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Camchain Tensioner Spring Free Length

Clutch/Primary Drive
Primary Drive . . . . . . Type . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . . . .
Friction Plate Thickness (new) ........
Friction Plate Thickness (service limit) ..
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Clutch Shim Clearance ...............
Clutch Master Cylinder Bore Dia .......
Clutch Slave Cylinder Bore Dia. . . . . . . .
Recommended Clutch Fluid . . . . . . . . . . .

30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
21 o BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1.0 mm Lift)
251 o
51 BBDC (@ 1.0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0. 03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
21 BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1.0 mm Lift)
251
51 BBDC (@ 1.0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

Gear
1. 75 (1 05/60)
Wet Multi-plate
9
3.80mm- 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

Gear
1.75 (1 05/60)
Wet Multi-plate
9
3.80mm- 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

1.17

1 GENERAL INFORMATION
Full Specification

DAYTONA 1000

Piston/Crankshaft
Cylinder Bore Dia ..... .

DAYTONA 750

. . . . . . . . . 76.05 mm/76.03 mm Cyl. Nos. 1, 3 & 4


76.05 mm/76.04 mm Cyl. No.2
Piston Dia. (at 90 to gudgeon pin) .... 75.98 mm/75.96 mm Cyl. Nos. 1, 3 & 4
75.98 mm/75.97 mm Cyl. No. 2
Piston Ring to Groove Clearance Top .. 0.06 mm/0.02 mm
Second 0.06 mm/0.02 mm
Piston Ring Groove Width
Top . . 1.03 mm/1.01 mm
Second 1.03 mm/1.01 mm
Oil ... 2.03 mm/2.01 mm
Piston Ring Eng Gap ..... .
Top . . 0.20 mm/0.41 mm
(new ring when fitted in bore)
Second 0.35 mm/0.56 mm
Oil . . . 0.29 mm/0.85 mm
Gudgeon Pin Bore Dia. In Piston
19.008 mm/19.002 mm
Gudgeon Pin Dia. . ........... .
19.000 mm/18.995 mm
Connecting Rod Small End Dia. . ..... . 19.034 mm/19.016 mm
Connecting Rod Big End Side Clearance 0.3 mm/0.15 mm (0.5 mm max.)
Crankshaft Big End Journal Dia ....... . 40.965 mm/40.951 mm
Crankshaft Big End Bearing Clearance . 0.066 mm/0.036 mm (0.1 mm max.)
Crankshaft Main Journal Dia. . ....... . 37.981 mm/37.965 mm
Crankshaft Main Bearing Clearance ... . 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float ............... . 0.20 mm/0.05 mm (0.4 mm max.)

76.05 mm/76.03 mm Cyl. Nos. 1 & 3


76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.98 mm/75.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1 .01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

Transmission
Type ..................... .
Gear Ratios . .
. . . . . . . . . . . 1st ...
2nd ..
3rd ..
4th .. .
5th .. .
6th .. .
Gear Selector Fork Thickness ........ .
Gear Selector Groove Width ......... .
Gear Selector Fork to Groove Clearance
Final Drive ......................... .
Final Drive Ratio ................... .
Chain Type .................... .
No. of Links ........................ .
20 Link Length ......... .
Drive Chain Slack ........... .
Chain lubrication . . . . . . . . .......... .

6 Speed Constant Mesh


2.733 (41/15)
1.947 (37/19)
1.545 (34/22)
1.291 (31/24)
1.154 (30/26)
1.07 4 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 max.
Chain
2.8 (48/17)
D.I.D. 50ZV ('0' Ring)
114 Endless
319 mm max.
35.0- 40.0 mm
Mobil chain spray

6 Speed Constant Mesh


2.733 (41/15)
1.947 (37/19)
1.545 (34/22)
1.291 (31/24)
1.154 (30/26)
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 max.
Chain
2.7 (46/17)
D.I.D. 50ZV ('0' Ring)
112 Endless
319 mm max.
35.0- 40.0 mm
Mobil chain spray

Lubrication
Pressure Lubrication, Wet Sump
Oil Capacity (incl. filter) . . . . . . . . . . . . . . . 3.5 litres
Recommended Oil . . . . . . . . . . . . . .
Semi synthetic 1Ow/40 oil meeting
specification API/SG
Oil Pressure (in main gallery) ......... 40.0 lb/in 2 min. (@ 80C Oil Temp.)
(@ 5000 rpm)
Oil Pump Rotor Tip Clearance ......... 0.15 mm (0.2 max.)
Oil Pump Body Clearance ............ 0.22 mm/0.15 mm (0.35 mm max.)
Oil Pump Rotor End Float . . . . . . . . . . . . 0.02 mm/0.007 (0.1 mm max.)

3.75 litres
Semi synthetic 1Ow/40 oil meeting
specification API/SG
40.0 lb/in2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
0.15 mm (0.2 max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)

Ignition System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Timing . . . . . Static . . . . . . . . . .
Idle . . . . . . . . . . . .
Max. Advance . . .
Electronic Rev-Limiter . . . . . . . . . . . . . . . .
Pick up Coil Air Gap . . . . . . . . . . . . . . . . .
Pick up Coil Resistance . . . . . . . . . . . . . .
Ignition Coil LT Resistance ............
Ignition Coil HT Resistance . . . . . . . . . . .
Spark Plug Type . . . . . . . . . . . . . . . . . . . .
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . .

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
35 @ 6500 rpm
11000 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 9EA-9
0.8 mm- 0.9 mm

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
38 @ 6500 rpm
11000 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 9EA-9
0.8 mm- 0.9 mm

1.18

GENERAL INFORMATION 1
Full Specification

DAYTONA 1000

DAYTONA 750

Fuel System
Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Capacity (inc. reserve) ......
Reserve Capacity . . . . . . . . . . . . . . . . . . .
Low Level Warning Lamp . . . . . . . . . . . . .
Fuel Tap . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unleaded (95 RON)


25 Litres
5 Litres
7 Litres
Vacuum Controlled, Auto Shut-off

Unleaded (95 RON)


25 Litres
5 Litres
7 Litres
Vacuum Controlled, Auto Shut-off

Carburettors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIKUNI BST 36 mm Flat Slide CV
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm 50 rpm

MIKUNI BST 36 mm Flat Slide CV


1000 rpm 50 rpm

Cooling System
Coolant Mixture .....................
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . .
Freezing Point . . . . . . . . . . . . . . . . . . . . . .
Cooling System Capacity . . . . . . . . . . . . .
Radiator Cap Opening Pressure . . . . . . .
Thermostat Opening Temperature . . . . .
Cooling Fan Switch On Temperature . . .

50150 Distilled Water/Anti-Freeze


Mobil Antifreeze
-35C
3.0 Litres
1.1 Bar
83C
99C

50150 Distilled Water/Anti-Freeze


Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99oC

Suspension
Front Fork Travel . . . . . . . . . . . . . . . . . . . .
Recommended Fork Oil . . . . . . . . . . . . . .
Oil Level (without spring) .............
Rear Wheel Travel . . . . . . . . . . . . . . . . . . .
Rear Suspension Bearing Grease . . . . .

150 mm
SAE 5
132 mm (fully compressed)
126 mm
Mobil Grease HP 222

150 mm
SAE10
139 mm (fully compressed)
126 mm
Mobil Grease HP 222

Brakes
Front type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated Four Piston
Hydraulically Actuated Four Piston
Sliding Calipers Operating on Twin
Sliding Calipers Operating on
Floating Discs
Twin Floating Discs
2 x 33.96 mm & 2 x 30.23 mm
Caliper Piston Dia .................... 2 x 33.96 mm & 2 x 30.23 mm
Disc Dia ............................ 310.0 mm
310.0 mm
5.0 mm (4.5 mm min.)
Disc Thickness ...................... 5.0 mm (4.5 mm min.)
Disc Run-out Max .................... 0.15 mm (0.3 mm max.)
0.15 mm (0.3 mm max.)
Master Cylinder . . . . . . . . . . . . . . . . . . . . . 15.8 mm dia. Adjustable Lever
15.8 mm dia. Adjustable Lever
Recommended Fluid . . . . . . . . . . . . . . . . . Mobil Universal Brake and Clutch Fluid
Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
Rear Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Caliper Operating on Single Rigid
Caliper Operating on Single Rigid
Rear Disc
Rear Disc
Caliper Piston Dia .................... 2 x 27.0 mm
2 x 27.0 mm
Disc Dia ............................ 255.0 mm
255.0 mm
Disc Thickness ...................... 6.0 mm (5.0 mm min.)
6.0 mm (5.0 mm min.)
Disc Run-out Max .................... 0.1 mm (0.3 mm max.)
0.1 mm (0.3 mm max.)
14.0 mm dia. Remote Reservoir
Master Cylinder . . . . . . . . . . . . . . . . . . . . . 14.0 mm dia. Remote Reservoir
Recommended Fluid . . . . . . . . . . . . . . . . . Mobil Universal Brake and Clutch Fluid
Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
Wheels and Tyres
Front Wheel Rim Axial Run-out . . . . . . . . 0.5 mm
0.5 mm
Front Wheel Rim Radial Run-out . . . . . . 0.8 mm
0.8 mm
Front Tyres . . . . . . . . . . . . . . . . . . . . . . . . . Refer to the owners handbook for approved tyres for each model year
Front Tyre Pressure (cold) ............ 2.5 kg/cm2 (36 psi)
2.5 kg/cm 2 (36 psi)
2.0 mm
Front Tyre Tread Depth min ........... 2.0 mm
0.5 mm
Rear Wheel Rim Axial Run-out . . . . . . . . 0.5 mm
Rear Wheel Rim Radial Run-out . . . . . . 0.8 mm
0.8 mm
Rear Tyres . . . . . . . . . . . . . . . . . . . . . . . . . Refer to the owners handbook for approved tyres for each model year
2.5 kg/cm 2 (36 psi)
Rear Tyre Pressure (cold) ............ 2.5 kg/cm2 (36 psi)
2.0 mm - up to 80 mph (130 km/h)
Rear Tyre Tread Depth min. . . . . . . . . . . . 2.0 mm- up to 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)

WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised
closed course conditions.

1.19

1 GENERAL INFORMATION

Full Specification

DAYTONA 1000

DAYTONA 750

Overall Length ......................


Overall Width . . . . . . . . . . . . . . . . . . . . . . .
Overall Height . . . . . . . . . . . . . . . . .
Ground Clearance . . . . . . .
Wheelbase . . . . . . . . . . . . . . . ........
Seat Height..........
. .......
Steering Head Angle . . . . . . . . . . . . . . . . .
Trail . . . . . . . . . . . . . . . . . . . . . . . . . .
Dry Weight . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Payload ... ~.........
. ..

Large dia. high tensile steel spine,


stressed engine
2160 mm (2172 mm- German model)
690 mm (to outside of handlebars)
1270 mm (to top of screen)
158 mm
1510 mm
810 mm
27 from vertical
105 mm
Refer to owner's handbook
181 kg

Large dia. high tensile steel spine,


stressed engine
2160 mm (2172 mm- German model)
690 mm (to outside of handlebars)
1270 mm (to top of screen)
158 mm
1510 mm
810 mm
27 from vertical
105 mm
Refer to owner's handbook
181 kg

Electrical Equipment
Battery Type . . . . . . . . . . . . . .
Battery Rating . . . . . . . . . . . . . . . . . . . .
Alternator Rating . . . . . . . . . . . . . . . . . . .
Regulated Voltage ...................
Stator Coil Resistance . . . . . . . . . . . . . . .
Rotor Coil Resistance . . .
Slip Ring Dia. . . . . . . . . . . . . . . . . .
Brush Length .......................
Starter Motor Commutator Dia .........
Commutator Groove Depth . . . . . .
Starter Brush Length . .
...
Fuses . . . . . . . . . . . . . Headlight . . .
Tail Light . . . . . . .
Main ...........
Radiator Fan . .
Lights . . . . . . . . . . . . . Head Light .
Parking Light . . . .
Tail Light .
Indicators .......

YUASA YB14L-A2
12V - 14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
1OA
1OA
30A
1OA
2 x 60/55W H4 Halogen
4W
21/5 W
10W (21W Japan)

YUASA YB14L-A2
12V- 14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1 .0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
10A
2 x 60/55W H4 Halogen
4W
21/5 w
10W (21W Japan)

Frame
Frame Type

1.20

GENERAL INFORMATION 1

Full Specification

DAYTONA 1200

Engine Type . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement ........................
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio . . . . . . . . . . . . . . . . . .
Cylinder Numbering . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

4 Cylinder 16 Valve DOHC


3 Cylinder 12 Valve DOHC
Transverse In-Line
Transverse In-Line
885 cc
1180 cc
76 mm x 65 mm
76 mm x 65 mm
12.0 : 1
10.6 : 1
Left to Right (No.4 adjacent to camchain) Left to Right (No.3 adjacent to camchain)
1-2-4-3
1-2-3
Refer to the owner's handbook for the model, model year and country required.
Refer to the owner's handbook for the model, model year and country required.

Cylinder Head
Valve Head Dia .............. ln .....
Ex ....
Valve Lift . . . . . . . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Stem Dia .............. ln .....
Ex. . ..
Valve Guide Bore Dia .................
Valve Stem to Guide Clearance ln .....
Ex. . . .
Valve Seat Width (in head) . . . . . . . . . . . .
Valve Seat Width (valve) .............
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner ..
Outer .
Valve Clearance ............. ln .....
Ex. . . .
Valve Bucket Dia. . .......... Blue ..
Red ...
White .
Valve Bucket Bore Dia ................
Valve Timing 1 . . . . . . Inlet ... Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Valve Timing2 ...... Inlet ... Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Dia. . . . . . . . . . . . . . . .
Camshaft Journal Clearance . . . . . . . . . .
Camshaft Journal Bore Dia ............
Camshaft End Float .................
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Camchain Tensioner Spring Free Length

Clutch/Primary Drive
Primary Drive . . . . . . Type . . . . . . . . . . .
Reduction Ratio .
Clutch ............ Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . . . .
Friction Plate Thickness (new) . . . . . . . .
Friction Plate Thickness (service limit) . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Clutch Shim Clearance . . . . . . . . . . . . . . .
Clutch Master Cylinder Bore Dia .......
Clutch Slave Cylinder Bore Dia. . . . . . . .
Recommended Clutch Fluid . . . . . . . . . . .

DAYTONA 900

30.0 mm
26.0 mm
9.4 mm
9.3 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
27 BTDC (@ 1.0 mm Lift)
55 ABDC (@ 1 .0 mm Lift)
262
54 BBDC (@ 1.0 mm Lift)
28 ATDC (@ 1.0 mm Lift)
262
21 o BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1.0 mm Lift)
251 o
51 o BBDC (@ 1. 0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

Gear
1.75 (105/60)
Wet Multi-plate
9
3.80mm - 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

Gear
1.75 (1 05/60)
Wet Multi-plate
9
3.80mm - 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

Valve Timing 1 - 147 PS 1200cc version and 98 PS 900cc versions.


Valve Timing 2 - 136 PS 1200cc version.

1.21

30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
21 BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1 .0 mm Lift)
251
51 BBDC (@ 1.0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256

1 GENERAL INFORMATION
Full Specification

DAYTONA 1200

Piston/Crankshaft
Cylinder Bore Dia. . . . . . . . . . . . . . . . . . . . 76.0S mm/76.03 mm Cyl. Nos. 1, 3 & 4
76.0S mm/76.04 mm Cyl. No. 2
Piston Dia. (at 90 to gudgeon pin) .... 7S.98 mm/7S.96 mm Cyl. Nos. 1, 3 & 4
7S.98 mm/7S.97 mm Cyl. No. 2
0.06 mm/0.02 mm
Piston Ring to Groove Clearance Top
Second 0.06 mm/0.02 mm
Piston Ring Groove Width
Top
1.03 mm/1.01 mm
Second 1.03 mm/1.01 mm
Oil
2.03 mm/2.01 mm
Piston Ring Eng Gap ......... Top
0.20 mm/0.41 mm
(when fitted in bore)
Second 0.3S mm/O.S6 mm
Oil
0.29 mm/0.8S mm
Gudgeon Pin Bore Dia. In Piston . . . . . . 19.008 mm/19.002 mm
Gudgeon Pin Dia. . . . . . . . . . . . . . . . . . . . 19.000 mm/18.99S mm
Connecting Rod Small End Dia. . . . . . . . 19.034 mm/19.016 mm
Connecting Rod Big End Side Clearance 0.3 mm/0.1S mm (O.S mm max.)
Crankshaft Big End Journal Dia ........ 40.96S mm/40.9S1 mm
Crankshaft Big End Bearing Clearance . 0.066 mm/0.036 mm (0.1 mm max.)
Crankshaft Main Journal Dia. . . . . . . . . . 37.981 mm/37.96S mm
Crankshaft Main Bearing Clearance .... 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float . . . . . . . . . . . . . . . . 0.20 mm/O.OS mm (0.4 mm max.)
Transmission
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Ratios ................. 1st ...
2nd . .
3rd . .
4th ...
5th . . .
6th . . .
Gear Selector Fork Thickness .........
Gear Selector Groove Width ..........
Gear Selector Fork to Groove Clearance
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Drive Ratio . . . . . . . . . . . . . . . . . . . .
Chain Type . . . .
. ................
No. of Links . . . . . . . . . . . . . . . . . . . . . . . . .
20 Link Length ......................
Drive Chain Slack . . . . . . . . . . . . . . . . . . .
Chain lubrication . . . . . . . . . . . . . . . . . . . .

DAYTONA 900
76.0S mm/76.03 mm Cyl. Nos. 1 & 3
76.05 mm/76.04 mm Cyl. No. 2
7S.98 mm/7S.96 mm Cyl. Nos. 1 & 3
7S.98 mm/7S.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.3S mm/O.S6 mm
0.29 mm/0.8S mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.1S mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.96S mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

6 Speed Constant Mesh


6 Speed Constant Mesh
2.733 (41/1S)
2.733 (41/1S)
1.947 (37/19)
1.947 (37/19)
1.54S (34/22)
1.S4S (34/22)
1.291 (31/24)
1.291 (31/24)
1.1S4 (30/26)
1 .1S4 (30/26)
1.07 4 (29/27)
1.074 (29/27)
S.9 mm/5.8 mm (S.7 mm min.)
S.9 mm/S.8 mm (S.7 mm min.)
6.1 mm/6.0 mm (6.2S mm max.)
6.1 mm/6.0 mm (6.2S mm max.)
O.S5 max.
O.SS max.
Chain
Chain
Variable according to model, model year and market designation
Regina 136 ORP
Regina 136 ORP
Variable according to model, model year and market designation
319 mm max.
319 mm max.
3S.O- 40.0 mm
35.0- 40.0 mm
Mobil chain spray
Mobil chain spray

Lubrication
Pressure Lubrication, Wet Sump
Oil Capacity (incl. filter) .............. . 3.7S litres
Recommended Oil .................. . Fully synthetic Sw/40 oil meeting
specification API/SG
Oil Pressure (in main gallery) ........ . 40.0 lb/in2 min.(@ 80C Oil Temp.)
(@ SOOO rpm)
Oil Pump Rotor Tip Clearance ........ . 0.1S mm (0.2 max.)
Oil Pump Body Clearance ........... . 0.22 mm/0.1S mm (0.3S mm max.)
Oil Pump Rotor End Float ........... . 0.02 mm/0.007 (0.1 mm max.)

4.00 litres
Semi synthetic 1Ow/40 oil meeting
specification API/SG
40.0 lb/in 2 min.(@ 80C Oil Temp.)
(@ SOOO rpm)
0.1S mm (0.2 max.)
0.22 mm/0.1S mm (0.3S mm max.)
0.02 mm/0.007 (0.1 mm max.)

Ignition System
Type .............................. .
Ignition Timing . . . . . Static ......... .
Idle ........... .
Max. Advance .. .
Electronic Rev-Limiter ............... .
Pick up Coil Air Gap ................ .
Pick up Coil Resistance ............. .
Ignition Coil LT Resistance ........... .
Ignition Coil HT Resistance .......... .
Spark Plug Type ................... .
Spark Plug Gap .................... .

Inductive Transistorised
'F' Mark on Rotor
so BTDC @ 1000 rpm
26 @ 6SOO rpm
9700 rpm
0.8 mm/0.6 mm
S30 Ohms
0.6 Ohms
10.S kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

Inductive Transistorised
'F' Mark on Rotor
S0 BTDC @ 1000 rpm
26 @ 6SOO rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.S kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

1.22

GENERAL INFORMATION 1
Full Specification

DAYTONA 1200

DAYTONA 900

Fuel System
Fuel Type ......................... . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ..... . 25 Litres
Reserve Capacity .................. . 5 Litres
Low Level Warning Lamp ............ . 7 Litres
Fuel Tap .......................... . Vacuum Controlled, Auto Shut-off

Unleaded, 95 RON
(U.S. 89 CLC/AKI)
25 Litres
5 Litres
7 Litres
Vacuum Controlled, Auto Shut-off

Carburettors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIKUNI BST 36 mm Flat Slide CV
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm 50 rpm

MIKUNI BST 36 mm Flat Slide CV


1000 rpm 50 rpm

Cooling System
Coolant Mixture .....................
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . .
Freezing Point . . . . . . . . . . . . . . . . . . . . . .
Cooling System Capacity .............
Radiator Cap Opening Pressure . . . . . .
Thermostat Opening Temperature . . . . .
Cooling Fan Switch On Temperature ...

Mobil Antifreeze
-35C
3.0 Litres
1.1 Bar
83C
99C

50/50 Distilled Water/Anti-Freeze


Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99oC

Suspension
Front Fork Travel ................... .
Recommended Fork Oil ............. .
Oil Level (without spring) ............ .
Rear Wheel Travel .................. .
Rear Suspension Bearing Grease .... .

150mm
150mm
Refer to chart in front suspension section for full details
Refer to chart in front suspension section for full details
126mm
126mm
Mobil Grease HP 222
Mobil Grease HP 222

Brakes
Front type ......................... .
Caliper Piston Dia................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
.............. .
Recommended Fluid
Rear Type ......................... .
Caliper Piston Dia ................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
Recommended Fluid ................ .

Wheels and Tyres


Front Wheel Rim Axial Run-out ....... .
Front Wheel Rim Radial Run-out ..... .
Front Tyres ........................ .
Front Tyre Pressure (cold) ........... .
Front Tyre Tread Depth min. . ........ .
Rear Wheel Rim Axial Run-out ....... .
Rear Wheel Rim Radial Run-out ..... .
Rear Tyres ........................ .
Rear Tyre Pressure (cold) ........... .
Rear Tyre Tread Depth min ........... .

50150 Distilled Water/Anti-Freeze

Hydraulically Actuated Four Piston Sliding


Calipers Operating on Twin Floating Discs
2 x 33.96 mm & 2 x 30.23 mm
2 x 33.96 mm & 2 x 30.23 mm
310.0 mm
310.0 mm
5.0 mm (4.5 mm min.)
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
0.15 mm (0.3 mm max.)
15.8 mm dia. Adjustable Lever
15.8 mm dia. Adjustable Lever
Mobil Universal Brake and Clutch Fluid
Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Caliper Operating on Single Rigid
Caliper Operating on Single Rigid
Rear Disc
Rear Disc
2 x 27.0 mm
2 x 27.0 mm
255.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
0.1 mm (0.3 mm max.)
14.0 mm dia. Remote Reservoir
14.0 mm dia. Remote Reservoir
Mobil Universal Brake and Clutch Fluid
Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
0.5mm
0.5mm
0.8 mm
0.8 mm
Refer to the owners handbook for approved tyres for each model year
2.5 kg/cm 2
2.5 kg/cm 2
2.0 mm
2.0 mm
0.5mm
0.5mm
0.8mm
0.8mm
Refer to the owners handbook for approved tyres for each model year
2.9 kg/cm 2
2.9 kg/cm 2
2.0 mm- up to 80 mph (130 km/h)
2.0 mm- up to 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)

WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised
closed course conditions.

1.23

1 GENERAL INFORMATION

Full Specification

DAYTONA 1200

DAYTONA 900

Overall Length .................... .


Overall Width ..................... .
Overall Height ..................... .
Ground Clearance .................. .
Wheelbase ........................ .
Seat Height ........................ .
Steering Head Angle ................ .
Trail .............................. .
Dry Weight ........................ .
Max. Payload ...................... .

Large dia. high tensile steel spine,


stressed engine
21S2 mm
690 mm
118S mm
1S8 mm
1490 mm
790 mm
27 from vertical
10S mm
Refer to owner's handbook
181 kg

Large dia. high tensile steel spine,


stressed engine
21S2 mm
690 mm
118S mm
1S8 mm
1490 mm
790 mm
27 from vertical
10S mm
Refer to owner's handbook
181 kg

Electrical Equipment
Battery Type ....................... .
Battery Rating ..................... .
Alternator Rating ............. .
Regulated Voltage .................. .
Stator Coil Resistance .............. .
Rotor Coil Resistance ............... .
Slip Ring Dia ....................... .
Brush Length ...................... .
Starter Motor Commutator Dia. . ...... .
Commutator Groove Depth .......... .
Starter Brush Length ................ .
Fuses . . . . . . . . . . . . . Headlight ...... .
Tail Light ...... .
Main .......... .
Radiator Fan ... .
Alarm ......... .
lnline fuse (199S on) Brake Light
Lights ............. Head Light ..... .
Parking Light ... .
Tail Light ...... .
Indicators ..... .

YUASA YB14L-A2
12V -14AH
12V- 2SA
14.SV at SSOO (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.S mm (4.S mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.S mm min.)
10A
10A
30A
1SA
10A
SA
2 x 60/SSW H4 Halogen
4W
21/S w
10W (21W Japan)

YUASA YB14L-A2
12V- 14AH
12V- 2SA
14.5V at SSOO (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.S mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.S mm min.)
10A
10A
30A
1SA
10A
SA
2 x 60/SSW H4 Halogen
4W
21/S w
10W (21W Japan)

Frame
Frame Type

1.24

GENERAL INFORMATION 1

Full Specification

DAYTONA SUPER 3

Engine Type . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement . . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio . . . . . . . . . . . . . . . . . .
Cylinder Numbering . . . . . . . . . . . . . . . . .
Firing order .........................
Max. Power. . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

3 Cylinder 12 Valve DOHC


3 Cylinder 12 Valve DOHC
Transverse In-Line
Transverse In-Line
885 cc
885 cc
76 mm x 65 mm
76 mm x 65 mm
12.0 : 1
10.6 : 1
Left to Right (No.3 adjacent to camchain) Left to Right (No.3 adjacent to camchain)
1-2-3
1-2-3
Refer to the owner's handbook for the model, model year and country required.
Refer to the owner's handbook for the model, model year and country required.
For engine details of the limited edition
Speed Triple 750, refer to the Trident 750
section

Cylinder Head
Valve Head Dia. . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Lift ................... ln .....
Ex ....
Valve Stem Dia .............. ln .....
Ex. . ..
Valve Guide Bore Dia .................
Valve Stem to Guide Clearance ln .....
Ex. . ..
Valve Seat Width (in head) ............
Valve Seat Width (valve) .............
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner ..
Outer .
Valve Clearance . . . . . . . . . . . . . ln. . . . .
Ex. . . .
Valve Bucket Dia ............ Blue ..
Red ...
White .
Valve Bucket Bore Dia ................
Valve Timing . . . . . . . Inlet . . . Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Dia. . ..............
Camshaft Journal Clearance . . . . . . . . . .
Camshaft Journal Bore Dia ............
Camshaft End Float .................
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Camchain Tensioner Spring Free Length

Clutch/Primary Drive
Primary Drive ...... Type . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . . . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Friction Plate Thickness (new) . . . . . . . .
Friction Plate Thickness (service limit) . .
Clutch Shim Clearance ...............
Clutch Master Cylinder Bore Dia. . . . . . .
Clutch Slave Cylinder Bore Dia. . . . . . . .
Recommended Clutch Fluid . . . . . . . . . . .

SPEED TRIPLE 900

30.0 mm
26.0 mm
9.4 mm
9.3 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.1 0 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
27 BTDC (@ 1.0 mm Lift)
55 ABDC (@ 1.0 mm Lift)
262
54 o BBDC (@ 1.0 mm Lift)
28 ATDC (@ 1.0 mm Lift)
262
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

30.0 mm
26.0 mm
8.9mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
21 BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1.0 mm Lift)
251
51 BBDC (@ 1.0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

Gear
1.75 (105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm- 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

Gear
1.75 (105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm- 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

1.25

1 GENERAL INFORMATION
DAYTONA SUPER 3

SPEED TRIPLE 900

Piston Ring to Groove Clearance Top


Second
Piston Ring Groove Width
Top
Second
Oil
Piston Ring Eng Gap . . . . . . .
Top
(new ring when fitted in bore)
Second
Oil
Gudgeon Pin Bore Dia. In Piston
Gudgeon Pin Dia. . ................ .
Connecting Rod Small End Dia. .
Connecting Rod Big End Side Clearance
Crankshaft Big End Journal Dia ....
Crankshaft Big End Bearing Clearance
Crankshaft Main Journal Dia. . ...... .
Crankshaft Main Bearing Clearance .. .
Crankshaft End Float ....... .

76.05 mm/76.03 mm Cyl. Nos. 1 & 3


76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.98 mm/75.97 mm Cyl. No.2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

76.05 mm/76.03 mm Cyl. Nos. 1 & 3


76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.98 mm/75.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

Transmission
Type .............................. .
Gear Ratios ............ .
1st ...
2nd ..
3rd ..
4th .. .
5th .. .
6th .. .
Gear Selector Fork Thickness ........ .
Gear Selector Groove Width ... .
Gear Selector Fork to Groove Clearance
Final Drive ......................... .
Final Drive Ratio .................. .
Chain Type ........................ .
No. of Links ........................ .
20 Link Length ................. .
Drive Chain Slack .................. .
Chain lubrication .................. .

6 Speed Constant Mesh


5 Speed Constant Mesh
2.733 (41/15)
2.733 (41/15)
1.947 (37/19)
1.947 (37/19)
1.545 (34/22)
1.545 (34/22)
1.291 (31/24)
1.291 (31/24)
1.154 (30/26)
1 .154 (30/26)
1.074 (29/27) when fitted
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 max.
0.55 max.
Chain
Chain
Variable according to model, model year and market designation
Regina 136 ORP
Regina 136 ORP
Variable according to model, model year and market designation
319 mm max.
319 mm max.
35.0- 40.0 mm
35.0- 40.0 mm
Mobil chain spray
Mobil chain spray

Full Specification
Piston/Crankshaft
Cylinder Bore Dia .............. .
Piston Dia. (at 90 to gudgeon pin)

Lubrication
Pressure Lubrication, Wet Sump
4.00 litres
Oil Capacity (incl. filter) ........ .
Recommended Oil .................. . Fully synthetic Sw/40 oil meeting
specification API/SG
Oil Pressure (in main gallery) ........ . 40.0 lb/in 2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
Oil Pump Rotor Tip Clearance ....... . 0.15 mm (0.2 max.)
Oil Pump Body Clearance ........... . 0.22 mm/0.15 mm (0.35 mm max.)
Oil Pump Rotor End Float ........... . 0.02 mm/0.007 (0.1 mm max.)

4.00 litres
Semi synthetic 1Ow/40 oil meeting
specification API/SG
40.0 lb/in 2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
0.15 mm (0.2 max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)

Ignition System
Type .............................. .
Ignition Timing . . . . . Static ......... .
Idle ........... .
Max. Advance .. .
Electronic Rev-Limiter ............... .
Pick up Coil Air Gap ................ .
Pick up Coil Resistance ............. .
Ignition Coil LT Resistance ........... .
Ignition Coil HT Resistance .......... .
Spark Plug Type ................... .
Spark Plug Gap .................... .

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
26 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
26 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

1.26

GENERAL INFORMATION 1
Full Specification

DAYTONA SUPER 3

SPEED TRIPLE 900

Fuel System
Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ...... 25 Litres
Reserve Capacity . . . . . . . . . . . . . . . . . . . 5 Litres
Low Level Warning Lamp . . . . . . . . . . . . . 7 Litres
Fuel Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Controlled, Auto Shut-off

Unleaded, 95 RON
(U.S. 89 CLC/AKI)
25 Litres
5 Litres
7 Litres
Vacuum Controlled, Auto Shut-off

Carburettors
Type ............................... MIKUNI BST 36 mm Flat Slide CV
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm 50 rpm

MIKUNI BST 36 mm Flat Slide CV


1000 rpm 50 rpm

Cooling System
Coolant Mixture . . . . . . . . . . . . . . . . . . . . .
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . .
Freezing Point . . . . . . . . . . . . . . . . . . . . . .
Cooling System Capacity . . . . . . . . . . . . .
Radiator Cap Opening Pressure . . . . . .
Thermostat Opening Temperature . . . . .
Cooling Fan Switch On Temperature . . .

50/50 Distilled Water/Anti-Freeze


Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99C

50/50 Distilled Water/Anti-Freeze


Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99oC

Suspension
Front Fork Travel ...................
Recommended Fork Oil .............
Oil Level (without spring) ............
Rear Wheel Travel ..................
Rear Suspension Bearing Grease ....

150 mm
150 mm
Refer to chart in front suspension section for full details
Refer to chart in front suspension section for full details
126 mm
126 mm
Mobil Grease HP 222
Mobil Grease HP 222

.
.
.
.
.

Brakes
Hydraulically actuated 4 piston sliding
Front type ......................... . Hydraulically actuated 6 piston
calipers operating on twin floating discs calipers operating on twin floating discs
Caliper Piston Dia ................... . 2 x 30,2 mm, 2 x 25,4 mm, 2 x 22,0 mm 2 x 33.96 mm & 2 x 30.23 mm
310.0 mm
Disc Dia ........................... . 310.0 mm
5.0 mm (4.5 mm min.)
Disc Thickness ..................... . 5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
Disc Run-out Max ................... . 0.15 mm (0.3 mm max.)
15.8 mm dia. Adjustable Lever
Master Cylinder .................... . 15.8 mm dia close tolerance.
Adjustable Lever
Recommended Fluid
Mobil Universal Brake and Clutch Fluid
Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
Rear Type ......................... . Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Caliper Operating on Single Rigid
Caliper Operating on Single Rigid
Rear Disc
Rear Disc
Caliper Piston Dia ................... . 2 x 27.0 mm
2 x 27.0 mm
255.0 mm
Disc Dia ........................... . 255.0 mm
6.0 mm (5.0 mm min.)
Disc Thickness ..................... . 6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
Disc Run-out Max ................... . 0.1 mm (0.3 mm max.)
14.0 mm dia. Remote Reservoir
Master Cylinder .................... . 14.0 mm dia. Remote Reservoir
Mobil Universal Brake and Clutch Fluid
Recommended Fluid ................ . Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
Wheels and Tyres
0.5mm
Front Wheel Rim Axial Run-out ....... . 0.5mm
Front Wheel Rim Radial Run-out ..... . 0.8 mm
0.8 mm
Front Tyres ........................ . Refer to the owners handbook for approved lyres for each model year
2.5 kg/cm2
Front Tyre Pressure (cold) ........... . 2.5 kg/cm2
2.0 mm
Front Tyre Tread Depth min. . ........ . 2.0 mm
Rear Wheel Rim Axial Run-out ....... . 0.5 mm
0.5 mm
Rear Wheel Rim Radial Run-out ..... . 0.8 mm
0.8 mm
Rear Tyres ........................ . Refer to the owners handbook for approved tyres for each model year
2.9 kg/cm 2
Rear Tyre Pressure (cold) ........... . 2.9 kg/cm2
2.0 mm- up to 80 mph (130 km/h)
Rear Tyre Tread Depth min ........... . 2.0 mm- up to 80 mph (130 km/h)
3.0 mm -over 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)
WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised
closed course conditions.

1.27

1 GENERAL INFORMATION

Full Specification
Frame
Frame Type
Overall Length .....................
Overall Width ......................
Overall Height .....................
Ground Clearance ..................
Wheelbase ................. .
Seat Height ................. .
Steering Head Angle ................
Trail ..............................
Dry Weight ........................
Max. Payload ......................

.
.
.
.

.
.
.
.

Electrical Equipment
Battery Type ....................... .
Battery Rating ..................... .
Alternator Rating ............. .
Regulated Voltage .................. .
Stator Coil Resistance ....... .
Rotor Coil Resistance ............... .
Slip Ring Dia. . ..................... .
Brush Length ...................... .
Starter Motor Commutator Dia. . ...... .
Commutator Groove Depth .......... .
Starter Brush Length ................ .
Fuses . . . . . . . . . . . . Headlight ...... .
Tail Light ...... .
Main .......... .
Radiator Fan ... .
Alarm ......... .
lnline fuse (1995 on) Brake Light
Lights . . . . . . . . . . . . . Head Light ..... .
Parking Light ... .
Tail Light ...... .
Indicators ..... .

DAYTONA SUPER 3

SPEED TRIPLE 900

Large dia. high tensile steel spine,


stressed engine
2152 mm
760 mm
1185 mm
138 mm
1490 mm
790 mm
from vertical
105 mm
Refer to owner's handbook
181 kg

Large dia. high tensile steel spine,


stressed engine
2152 mm
760mm
1185 mm
138 mm
1490 mm
790mm
27 from vertical
105 mm
Refer to owner's handbook
181 kg

YUASA YB14L-A2
12V-14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A
10A
5A
2 x 60/55W H4 Halogen
4W
21/5 w
10W (21W Japan)

YUASA YB14LA2
12V- 14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A
10A
5A
2 x 60/55W H4 Halogen
4W
21/5 w
10W (21W Japan)

2r

1.28

GENERAL INFORMATION 1

Full Specification

TRIDENT/SPRINT 900

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement. . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio . . . . . . . . . . . . . . . . . .
Cylinder Numbering . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

3 Cylinder 12 Valve DOHC


3 Cylinder 12 Valve DOHC
Transverse In-Line
Transverse In-Line
885 cc
748 cc
76 mm x 65 mm
76 mm x 55 mm
10.6 : 1
11.0: 1
Left to Right (No.3 adjacent to camchain) Left to Right (No.3 adjacent to camchain)
1-2-3
1-2-3
Refer to the owner's handbook for the model, model year and country required.
Refer to the owner's handbook for the model, model year and country required.

Cylinder Head
Valve Head Dia. . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Lift . . . . . . . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Stem Dia .............. ln. . . . .
Ex. . ..
Valve Guide Bore Dia .................
Valve Stem to Guide Clearance ln. . . . .
Ex. . ..
Valve Seat Width (in head) . . . . . . . . . . . .
Valve Seat Width (valve) .............
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Inner . .
Valve Spring 'Load at Length'
Outer .
Valve Clearance
ln .....
Ex ....
Valve Bucket Dia. . .......... Blue ..
Red ...
White .
Valve Bucket Bore Dia. . . . . . . . . . . . . . . .
Valve Timing 1 . . . . . . Inlet . . . Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Valve Timing2 . . . . . . Inlet . . . Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Dia. . . . . . . . . . . . . . . .
Camshaft Journal Clearance . . . . . . . . . .
Camshaft Journal Bore Dia. . . . . . . . . . . .
Camshaft End Float .................
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Camchain Tensioner Spring Free Length
Clutch/Primary Drive
Primary Drive . . . . . . Type . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Friction Plate Thickness (new) . . . . . . . .
Friction Plate Thickness (service limit) . .
Clutch Shim Clearance . . . . . . . . . . . . . . .
Clutch Master Cylinder Bore Dia. . . . . . .
Clutch Slave Cylinder Bore Dia. . . . . . . .
Recommended Clutch Fluid . . . . . . . . . . .

TRIDENT 750

30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
21 o BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1.0 mm Lift)
251 o
51 BBDC (@ 1.0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256
1o BTDC (@ 1.0 mm Lift)
30 ABDC (@ 1.0 mm Lift)
211 o
28 BBDC (@ 1.0 mm Lift)
2 ATDC (@ 1.0 mm Lift)
210
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

Gear
1. 75 ( 105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm - 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT 4

Gear
1.75 (105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm max)
3.80mm- 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

Valve Timing 1 - 98 PS 900cc versions and all 750cc versions.


Valve Timing 2 - 85 PS 900cc version.

1.29

30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
21 BTDC (@ 1.0 mm Lift)
50 ABDC (@ 1.0 mm Lift)
251
51 o BBDC (@ 1.0 mm Lift)
25 ATDC (@ 1.0 mm Lift)
256

1 GENERAL INFORMATION

Full Specification

TRIDENT/SPRINT 900

Piston/Crankshaft
Cylinder Bore Dia. . . . . . . . . . . . . . . . . . . . 76.05 mm/76.03 mm Cyl. Nos. 1 & 3
76.05 mm/76.04 mm Cyl. No. 2
Piston Dia. (at 90 to gudgeon pin) .... 75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
Piston Ring to Groove Clearance Top . . 0.06 mm/0.02 mm
Second 0.06 mm/0.02 mm
Piston Ring Groove Width
Top . . 1.03 mm/1.01 mm
Second 1.03 mm/1.01 mm
Oil ... 2.03 mm/2.01 mm
Piston Ring Eng Gap ......... Top . . 0.20 mm/0.41 mm
(new ring when fitted in bore)
Second 0.35 mm/0.56 mm
Oil . . . 0.29 mm/0.85 mm
Gudgeon Pin Bore Dia. In Piston . . . . . . 19.008 mm/19.002 mm
Gudgeon Pin Dia. . . . . . . . . . . . . . . . . . . . 19.000 mm/18.995 mm
Connecting Rod Small End Dia ........ 19.034 mm/19.016 mm
Connecting Rod Big End Side Clearance 0.3 mm/0.15 mm (0.5 mm max.)
Crankshaft Big End Journal Dia. . . .
40.960 mm/40.946 mm (40.932 mm min.)
Crankshaft Big End Bearing Clearance . 0.066 mm/0.036 mm (0.1 mm max.)
Crankshaft Main Journal Dia. . ........ 37.976 mm/37.960 mm (37.936 mm min.)
Crankshaft Main Bearing Clearance . . . . 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float ................ 0.20 mm/0.05 mm (0.4 mm max.)
Transmission
Type........
. ................ .
Gear Ratios . . . . . . . . . . . . . . . . . 1st .. .
2nd ..
3rd ..
4th .. .
5th .. .
6th .. .
Gear Selector Fork Thickness ..
Gear Selector Groove Width ......... .
Gear Selector Fork to Groove Clearance
Final Drive ......................... .
Final Drive Ratio ................... .
Chain Type ........................ .
No. of Links .................. .
20 Link Length ............... .
Drive Chain Slack ........... .
Chain lubrication ................ .
Lubrication
Pressure Lubrication, Wet Sump
Oil Capacity (incl. filter) ........... .
Recommended Oil ............... .

TRIDENT 750
76.05 mm/76.03 mm Cyl. Nos. 1 & 3
76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.960 mm/40.946 mm (40.932 mm min.)
0.066 mm/0.036 mm (0.1 mm max.)
37.976 mm/37.960 mm (37.936 mm min.)
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

6 Speed Constant Mesh


6 Speed Constant Mesh
2.733 (41/15)
2.733 (41/15)
1.947(37/19)
1.947(37/19)
1.545 (34/22)
1.545 (34/22)
1.291 (31/24)
1.291 (31/24)
1.154 (30/26)
1. 154 (30/26)
1.074 (29/27)
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 mm max.
0.55 mm max.
Chain
Chain
Variable according to model, model year and market designation
Variable according to model, model year and market designation
Variable according to model, model year and market designation
319 mm max.
319 mm max.
35.0- 40.0 mm
35.0- 40.0 mm
Mobil chain spray
Mobil chain spray

Oil Pump Rotor Tip Clearance ........ .


Oil Pump Body Clearance ........... .
Oil Pump Rotor End Float ........... .

4.00 litres
Semi synthetic 1Ow/40 oil meeting
specification API/SG
40.0 lb/in 2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
0.15 mm (0.2 mm max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)

4.00 litres
Semi synthetic 1Ow/40 oil meeting
specification API/SG
40.0 lb/in2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
0.15 mm (0.2 mm max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)

Ignition System
Type .............................. .
Ignition Timing . . . . . Static ......... .
Idle ........... .
Max. Advance .. .
Electronic Rev-Limiter ............... .
Pick up Coil Air Gap ................ .
Pick up Coil Resistance ............. .
Ignition Coil LT Resistance ........... .
Ignition Coil HT Resistance .......... .
Spark Plug Type ................... .
Spark Plug Gap .................... .

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
26 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
35 @ 6500 rpm
11000 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

Oil Pressure (in main gallery) ........ .

1.30

GENERAL INFORMATION 1
Full Specification

TRIDENT/SPRINT 900

TRIDENT 750

Fuel System
Unleaded, 95 RON
Fuel Type ......................... . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ..... . 25 Litres (5.5 Imp gal)
25 Litres (5.5 Imp gal)
5 Litres (1.1 Imp gal)
Reserve Capacity .................. . 5 Litres (1 .1 Imp gal)
7 Litres (1.5 Imp gal)
Low Level Warning Lamp ............ . 7 Litres (1.5 Imp gal)
Vacuum Controlled, Auto Shut-off
Fuel Tap .......................... . Vacuum Controlled, Auto Shut-off
Carburettors
MIKUNI BST 36 mm Flat Slide CV
Type .............................. . MIKUNI BST 36 mm Flat Slide CV or
KEIHIN CVK 36 mm
1000 rpm 50 rpm
Idle Speed ......................... . 1000 rpm 50 rpm
Cooling System
50150 Distilled Water/Anti-Freeze
Coolant Mixture .................... . 50/50 Distilled Water/Anti-Freeze
Mobil Antifreeze
Anti-Freeze Type ................... . Mobil Antifreeze
-35C
Freezing Point ..................... . -35C
2.8 Litres
Cooling System Capacity ............ . 2.8 Litres
1.1 Bar
Radiator Cap Opening Pressure ...... . 1.1 Bar
83C
Thermostat Opening Temperature .... . 83C
99oc
Cooling Fan Switch On Temperature .. . 99oC
255-310 Ohms @ 60C
Temperature Gauge Sensor Resistance 255-310 Ohms@ 60C
Suspension (Trident)
Front Fork Travel ................... . 150 mm
150 mm
Recommended Fork Oil ............. . Refer to chart in front suspension section for full details
Oil Level (without spring) ............ . Refer to chart in front suspension section for full details
25.0 mm (above top yoke face)
Front Wheel Pull Through ........... . 25.0 mm (above top face of yoke)
126 mm
Rear Wheel Travel .................. . 126 mm
Mobil Grease HP 222
Rear Suspension Bearing Grease .... . Mobil Grease HP 222
Brakes t
Front type ......................... . Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Calipers Operating on Twin Rigid Discs Calipers Operating on Twin Rigid Discs
Caliper Piston Dia ................... . 2 x 27.0 mm
2 x 27.0 mm
Disc Dia ........................... . 296.0 mm
296.0 mm
5.0 mm (4.5 mm min.)
Disc Thickness ..................... . 5.0 mm (4.5 mm min.)
Disc Run-out Max ................... . 0.15 mm (0.3 mm max.)
0.15 mm (0.3 mm max.)
14.0 mm dia.
Master Cylinder .................... . 14.0 mm dia.
Mobil Universal Brake and Clutch Fluid
Recommended Fluid ................ . Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
t from VIN 9083 Sprint front brakes as for Daytona 1200.
Rear Type ......................... . Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Caliper Operating on Single Rigid
Caliper Operating on Single Rigid
Rear Disc
Rear Disc
2 x 27.0 mm
Caliper Piston Dia ................... . 2 x 27.0 mm
Disc Dia ........................... . 255.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
Disc Thickness ..................... . 6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.
Disc Run-out Max ................... . 0.1 mm (0.3 mm max.)
14.0 mm dia. Remote Reservoir
Master Cylinder .................... . 14.0 mm dia. Remote Reservoir
Mobil Universal Brake and Clutch Fluid
Recommended Fluid ................ . Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
Wheels and Tyres
0.5 mm
Front Wheel Rim Axial Run-out ....... . 0.5 mm
0.8 mm
Front Wheel Rim Radial Run-out ..... . 0.8 mm
Front Tyres ........................ . Refer to the owners handbook for approved tyres for each model year
2.5 kg/cm 2
Front Tyre Pressure (cold) ........... . 2.5 kg/cm2
Front Tyre Tread Depth min. . ........ . 2.0 mm
2.0 mm
0.5mm
0.5mm
Rear Wheel Rim Axial Run-out
0.8mm
Rear Wheel Rim Radial Run-out ..... . 0.8mm
Rear Tyres ........................ . Refer to the owners handbook for approved tyres for each model year
2.9 kg/cm2
Rear Tyre Pressure (cold) ........... . 2.9 kg/cm2
2.0 mm- up to 80 mph (130 km/h)
Rear Tyre Tread Depth min ........... . 2.0 mm- up to 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)

WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised
closed course conditions.

1.31

1 GENERAL INFORMATION
Full Specification
Frame
Frame Type
Overall Length .....................
Overall Width . . . . . . . .
. ........
Overall Height .....................
Ground Clearance .............. .
Wheelbase ........................
Seat Height . . . . . . . . . . .
. ......
Steering Head Angle ................
Trail ..............................
Dry Weight ........................
Max. Payload ......................

.
.
.
.
.
.
.
.
.

Electrical Equipment
Battery Type . . . . . . . . . . ........... .
Battery Rating .......... .
Alternator Rating ........ .
Regulated Voltage ..... .
Stator Coil Resistance .............. .
Rotor Coil Resistance ............... .
Slip Ring Dia ....................... .
Brush Length ...................... .
Starter Motor Commutator Dia. . ...... .
Commutator Groove Depth ....... .
Starter Brush Length ........... .
Fuses . . . . . . . . . . . . . Headlight ...... .
Tail Light
Main .......... .
Radiator Fan ... .
Alarm ...
lnline fuse (1995 on) Brake Light
Lights . . . . . . . . . . . . . Head Light ..... .
Parking Light ... .
Tail Light ...... .
Indicators ..... .

TRIDENT/SPRINT 900

TRIDENT 750

Large dia. high tensile steel spine,


stressed engine
2152 mm
760 mm
1090 mm (1265 mm Sprint)
138 mm (158mm to vin 4901)
1510 mm (1490 mm Sprint)
775mm
27 from vertical
105 mm
Refer to owner's handbook
Refer to owner's handbook

Large dia. high tensile steel spine,


stressed engine
2152 mm
760mm
1090 mm
138 mm (158mm to vin 4901)
1490 mm
775mm
27 from vertical
105 mm
Refer to owner's handbook
181 kg

YUASA YB14L-A2
12V -14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A (10A to vin 4901)
10A
5A
*60/55W H4 Halogen
4W
21/5 w
10W (21W Japan)
*Sprint 2x60/55W H4 Halogen

YUASA YB14L-A2
12V-14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A (10A to vin 4901)
10A
5A
60/55W H4 Halogen
4W
21/5 w
10W (21W Japan)

1.32

GENERAL INFORMATION 1

Full Specification

THUNDERBIRD SPORT 900

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement ........................
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio . . . . . . . . . . . . . . . . . .
Cylinder Numbering . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

3 Cylinder 12 Valve DOHC


3 Cylinder 12 Valve DOHC
Transverse In-Line
Transverse In-Line
885 cc
885 cc
76 mm x 65 mm
76 mm x 65 mm
10.0 : 1
10.0 : 1
Left to Right (No.3 adjacent to camchain) Left to Right (No.3 adjacent to camchain)
1-2-3
1-2-3
83.0 PS @ 8500 rpm
70 PS @ 8000 rpm
76.0 Nm @ 6500 rpm
72.0 Nm @ 4800 rpm

Cylinder Head
Valve Head Dia .............. ln .....
............................ Ex ....
Valve Lift . . . . . . . . . . . . . . . . . . . ln. . . . .
............................ Ex ....
Valve Stem Dia .............. ln .....
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
Valve Guide Bore Dia .................
Valve Stem to Guide Clearance ln. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
Valve Seat Width (in head) ............
Valve Seat Width (valve) .............
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer .
Valve Clearance . . . . . . . . . . . . . ln. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
Valve Bucket Dia ............ Blue ..
............................ Red ...
............................ White .
Valve Bucket Bore Dia ................
Valve Timing . . . . . . . Inlet . . . Open .
.......................... Close .
.......................... Duration
. . . . . . . . . . . . . . . . . Exhaust Open .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Close .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Duration
Camshaft Journal Dia. . . . . . . . . . . . . . . .
............ ........................
Camshaft Journal Clearance . . . . . . . . . .
Camshaft Journal Bore Dia. . . . . . . . . . . .
Camshaft End Float .................
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Camchain Tensioner Spring Free Length

30.0 mm
26.0 mm
7.1 mm
7.0 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.1 0 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
1o BTDC (@ 1.0 mm Lift)
30 ABDC (@ 1.0 mm Lift)
211
28 BBDC (@ 1 .0 mm Lift)
2 ATDC (@ 1.0 mm Lift)
210
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

30.0 mm
26.0 mm
7.1 mm
7.0mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
1 BTDC (@ 1.0 mm Lift)
30 ABDC (@ 1.0 mm Lift)
211
28 BBDC (@ 1.0 mm Lift)
2 ATDC (@ 1.0 mm Lift)
210
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

Gear
1. 75 (1 05/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm - 0 +0.80mm
3.60mm
0.125 mm/0. 075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

Gear
1.75 (105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm- 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT4

Clutch/Primary Drive
Primary Drive . . . . . . Type . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . . . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Friction Plate Thickness (new) . . . . . . . .
Friction Plate Thickness (service limit) . .
Clutch Shim Clearance . . . . . . . . . . . . . . .
Clutch Master Cylinder Bore Dia. . . . . . .
Clutch Slave Cylinder Bore Dia. . . . . . . .
Recommended Clutch Fluid . . . . . . . . . . .

1.33

THUNDERBIRD/ADVENTURER 900

1 GENERAL INFORMATION

Full Specification

THUNDERBIRD SPORT 900

Piston/Crankshaft
Cylinder Bore Dia. . ............. .

THUNDERBIRD/ADVENTURER 900

76.05 mm/76.03 mm Cyl. Nos. 1 & 3


76.05 mm/76.04 mm Cyl. No. 2
Piston Dia. (at 90 to gudgeon pin)
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
Piston Ring to Groove Clearance Top . . 0.06 mm/0.02 mm
............................. Second 0.06 mm/0.02 mm
Top . . 1.03 mm/1.01 mm
Piston Ring Groove Width
Second 1.03 mm/1.01 mm
Oil ... 2.03 mm/2.01 mm
Piston Ring Eng Gap ......... Top .. 0.20 mm/0.41 mm
(when fitted in bore) .......... Second 0.35 mm/0.56 mm
Oil . . . 0.29 mm/0.85 mm
Gudgeon Pin Bore Dia. In Piston . . . . . . 19.008 mm/19.002 mm
Gudgeon Pin Dia .................... 19.000 mm/18.995 mm
Connecting Rod Small End Dia. . . . . . . . 19.034 mm/19.016 mm
Connecting Rod Big End Side Clearance 0.3 mm/0.15 mm (0.5 mm max.)
Crankshaft Big End Journal Dia ........ 40.960 mm/40.946 mm (40.932 mm min)
Crankshaft Big End Bearing Clearance . 0.066 mm/0.036 mm (0.1 mm max)
Crankshaft Main Journal Dia. . ........ 37.976 mm/37.960 mm (37.936 mm min)
Crankshaft Main Bearing Clearance .... 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float . . . . . . . . . . . . . . . . 0.20 mm/0.05 mm (0.4 mm max.)

Transmission
Type .............................. .
Gear Ratios ....... . . . . . . . . . 1st ...
2nd ..
3rd ..
4th .. .
5th .. .
6th .. .
Gear Selector Fork Thickness ........ .
Gear Selector Groove Width ......... .
Gear Selector Fork to Groove Clearance
Final Drive ......................... .
Final Drive Ratio ................... .
Chain Type ........................ .
No. of Links ........................ .
20 Link Length ..................... .
Drive Chain Slack .................. .
Chain lubrication ................... .

76.05 mm/76.03 mm Cyl. Nos. 1 & 3


76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.960 mm/40.946 mm (40.932 mm min.)
0.066 mm/0.036 mm (0.1 mm max.)
37.976 mm/37.960 mm (37.936 mm min)
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

6 Speed Constant Mesh


5 Speed Constant Mesh
2.733 (41/15)
2.733 (41/15)
1.947 (37/19)
1.947 (37/19)
1.545 (34/22)
1.545 (34/22)
1.291 (31/24)
1.291 (31/24)
1.154 (30/26)
1. 154 (30/26)
1.074 (29/27)
N/A
5.9 mm/5.8 mm (5.7 mm min.)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
6.1 mm/6.0 mm (6.2S mm max.)
O.S5 mm max
0.55 mm max
Chain
Chain
Variable according to model year and market designation
Variable according to model year and market designation
Variable according to model year and market designation
319 mm max.
319 mm max.
3S.O- 40.0 mm
2S.O- 30.0 mm
Mobil chain spray
Mobil chain spray

Lubrication
Pressure Lubrication, Wet Sump
Oil Capacity (incl. filter) . . . . . . . . . . . . . . . 4.00 litres
Recommended Oil . . . . . . . . . . . . . . . . . . . Semi synthetic 1Ow/40 oil meeting
specification API/SG
Oil Pressure (in main gallery) ......... 40.0 lb/in2 min. (@ 80C Oil Temp.)
(@ SOOO rpm)
Oil Pump Rotor Tip Clearance ......... 0.1S mm (0.2 mm max.)
Oil Pump Body Clearance ............ 0.22 mm/0.1S mm (0.3S mm max.)
Oil Pump Rotor End Float ............ 0.02 mm/0.007 (0.1 mm max.)

4.00 litres
Semi synthetic 1Ow/40 oil meeting
specification APIISG
40.0 lb/in2 min.(@ 80C Oil Temp.)
(@ SOOO rpm)
0.1S mm (0.2 mm max.)
0.22 mm/0.1S mm (0.3S mm max.)
0.02 mm/0.007 (0.1 mm max.)

Ignition System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Timing . . . . . Static . . . . . . . . . .
Idle . . . . . . . . . . . .
Max. Advance . . .
Electronic Rev-Limiter . . . . . . . . . . . . . . .
Pick up Coil Air Gap . . . . . . . . . . . . . . . . .
Pick up Coil Resistance . . . . . . . . . . . . . .
Ignition Coil LT Resistance ............
Ignition Coil HT Resistance . . . . . . . . . . .
Spark Plug Type . . . . . . . . . . . . . . . . . . . .
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . .

Inductive Transistorised
'F' Mark on Rotor
S0 BTDC @ 1000 rpm
30 @ 6SOO rpm
87SO rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.S kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

Inductive Transistorised
'F' Mark on Rotor
S0 BTDC @ 1000 rpm
30 @ 6500 rpm
8750 rpm
0.8 mm/0.6 mm
S30 Ohms
0.6 Ohms
1O.S kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

1.34

GENERAL INFORMATION 1
Full Specification

THUNDERBIRD SPORT 900

THUNDERBIRD/ADVENTURER 900

Fuel System
Fuel Type ......................... . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ..... . 25 Litres (5.5 Imp gal)
Reserve Capacity .................. . 5 Litres (1.1 Imp gal)
Low Level Warning Lamp ............ . 7 Litres (1.5 Imp gal)
Fuel Tap .......................... . Mechanical, gravity fed.
Carburettors
Type .............................. . KEIHIN CVK 36 mm
Idle Speed ......................... .
Cooling System
Coolant Mixture .................... .
Anti-Freeze Type ................... .
Freezing Point ..................... .
Cooling 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 ............. .
Oil Level (without spring) ............ .
Rear Wheel Travel .................. .
Rear Suspension Bearing Grease .... .
Brakes
Front type ......................... .
Caliper Piston Dia ................... .
Disc dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max................... .
Front Master Cylinder ............... .
Recommended Fluid ................ .
Rear Type ......................... .
Caliper Piston Dia................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
Recommended Fluid ................ .

1000 rpm

50 rpm

50/50 Distilled Water/Anti-Freeze


Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
100C
255-31 0 Ohms @ 60C

Unleaded, 95 RON
(U.S. 89 CLC/AKI)
15.0 Litres (3.3 Imp gal)
4.0 Litres (0.9 Imp gal)
Not fitted
Mechanical, gravity fed.
MIKUNI BST 36 mm Flat Slide CV or
KEIHIN CVK 36 mm
1000 rpm 50 rpm
50/50 Distilled Water/Anti-Freeze
Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
100C
255-31 0 Ohms @ 60C

150mm
150mm
Refer to chart in front suspension section for full details
Refer to chart in front suspension section for full details
110 mm
110mm
Mobil Grease HP 222
Mobil Grease HP 222
2 Hydraulically Actuated 2 Piston Sliding
Calipers Operating on Twin Rigid Discs
2 x 27.0 mm
310 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
12.7 mm dia.
Mobil Universal Brake and Clutch Fluid
DOT 4
Hydraulically Actuated 2 Piston Sliding
Caliper Operating on Single Rigid Disc
2 x 27.0 mm
285.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
14.0 mm dia. Remote Reservoir
Mobil Universal Brake and Clutch Fluid
DOT4

1.35

One Hydraulically Actuated 2 Piston Sliding


Caliper Operating on Single Rigid Disc
2 x 27.0 mm
320 mm
5.0mm
0.15 mm (0.3 mm max)
11.0 mm dia
Mobil Universal Brake and Clutch Fluid
DOT4
Hydraulically Actuated 2 Piston Sliding
Caliper Operating on Single Rigid Disc
2 x 27.0 mm
285.0 mm
6.0 mm
0.1 (0.3 mm max)
14.0 mm dia. Remote Reservoir
Mobil Universal Brake and Clutch Fluid
DOT4

1 GENERAL INFORMATION
Full Specification
Wheels and Tyres
Front Wheel Rim Axial Run-out
Front Wheel Rim Radial Run-out
Front Tyres ........................ .
Front Tyre Pressure (cold) ........... .
Front Tyre Tread Depth min. . ........ .
Rear Wheel Rim Axial Run-out ....... .
Rear Wheel Rim Radial Run-out ...... .
Rear Tyres ........................ .
Rear Tyre Pressure (cold) ........... .
Rear Tyre Tread Depth min ........... .

THUNDERBIRD SPORT 900

THUNDERBIRD/ADVENTURER 900

0.5 mm
0.5 mm
0.8mm
0.8mm
Refer to the owners handbook for approved lyres for each model year
2.5kg/cm 2
2.5 kg/cm 2
2.0mm
2.0mm
0.5mm
0.5mm
0.8mm
0.8mm
Refer to the owners handbook for approved lyres for each model year
2.9 kg/cm 2
2.9 kg/cm 2
2.0 mm- up to 80 mph (130 km/h)
2.0 mm- up to 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)
3.0 mm -over 80 mph (130 km/h)

WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised
closed course conditions.
- -..
-----

---~--~-----

----------------------~-

Frame
Frame Type ....................... . Large dia. high tensile steel spine,
stressed engine
Overall Length ..................... . 2250 mm
Overall Width ............... .
860mm
Overall Height ..................... . 1150 mm
Wheelbase ........................ . 1580 mm
Seat Height ........................ . 750 mm
Steering Head Angle ................ . 27 from vertical
Trail .............................. . 106 mm
Dry Weight ........................ . Refer to owner's handbook
Max. Payload ...................... . 200 kg

Large dia. high tensile steel spine,


stressed engine
2250 mm (2170 mm Adventurer)
860 mm (750 mm Adventurer)
1150 mm (1290 mm Adventurer)
1550 mm
750 mm
27 from vertical
106 mm
Refer to owner's handbook
181 kg

Electrical Equipment
Battery Type ....................... .
Battery Rating ..................... .
Alternator Rating ................... .
Regulated Voltage .................. .
Stator Coil Resistance .............. .
Rotor Coil Resistance ............... .
Slip Ring Dia. . ..................... .
Brush Length ................. .
Starter Motor Commutator Dia .... .
Commutator Groove Depth .......... .
Starter Brush Length ................ .
Fuses . . . . . . . . . . . . . Headlight ...... .
Tail Light ...... .
Main ...... .
Radiator Fan ... .
Alarm ......... .
lnline fuse ..... .
Lights . . . . . . . . . . . . . Head Light ..... .
Parking Light ... .
Tail Light
License plate light
Indicators ...... .

YUASA YB14L-A2
12V -14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1 .0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A
10A
15A (Ignition system)
60/55W H4 Halogen
4W
2 X 21/5 W
5W
10W

YUASA YB14L-A2
12V -14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A
10A
15A (Ignition system)
60/55W H4 Halogen
4W
2x21/5W
5W
10W

1.36

GENERAL INFORMATION 1

Full Specification

TIGER 900

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement. . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio ..................
Cylinder Numbering . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

3 Cylinder 12 Valve DOHC


Transverse In-Line
885 cc
76 mm x 65 mm
10.6: 1
Left to Right (No.3 adjacent to camchain)
1-2-3
62.5 kW (85 PS) @ 8000 rpm
82.0 Nm @ 6000 rpm

Cylinder Head
Valve Head Dia .............. ln .....
............................ Ex ....
Valve Lift . . . . . . . . . . . . . . . . . . . ln. . . . .
............................ Ex ....
Valve Stem Dia .............. ln .....
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
Valve Guide Bore Dia .................
Valve Stem to Guide Clearance ln .....
............................ Ex ....
Valve Seat Width (in head) . . . . . . . . . . . .
Valve Seat Width (valve) .............
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer .
Valve Clearance ............. ln .....
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
Valve Bucket Dia ............ Blue ..
............................ Red ...
............................ White .
Valve Bucket Bore Dia. . . . . . . . . . . . . . . .
Valve Timing . . . . . . . Inlet ... Open .
.......................... Close .
.......................... Duration
. . . . . . . . . . . . . . . . . Exhaust Open .
............................ Close .
............................ Duration
Camshaft Journal Dia. . . . . . . . . . . . . . . .
....................................
Camshaft Journal Clearance . . . . . . . . . .
Camshaft Journal Bore Dia ............
Camshaft End Float .................
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Camchain Tensioner Spring Free Length

30.0 mm
26.0 mm
7.1 mm
7.0 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1 .5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
41 kg min. at 26.5 mm
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
1o BTDC (@ 1.0 mm Lift)
30 ABDC (@ 1.0 mm Lift)
211 o
28 BBDC (@ 1.0 mm Lift)
2 ATDC (@ 1.0 mm Lift)
210
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm

Clutch/Primary Drive
Primary Drive . . . . . . Type . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . . . .
Plate Flatness ......................
Friction Plate Thickness (new) . . . . . . . .
Friction Plate Thickness (service limit) . .
Clutch Shim Clearance . . . . . . . . . . . . . . .
Clutch Master Cylinder Bore Dia. . . . . . .
Clutch Slave Cylinder Bore Dia. . . . . . . .
Recommended Clutch Fluid . . . . . . . . . . .

Gear
1.75 (1 05/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm - 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid, DOT 4

1.37

1 GENERAL INFORMATION

Full Specification

TIGER 900

Piston/Crankshaft
Cylinder Bore Dia. . . . . . . . . . . . . . . . . . . .
...................................
Piston Dia. (at 90 to gudgeon pin) ....
....................................
Piston Ring to Groove Clearance Top . .
............................. Second
Piston Ring Groove Width ..... Top . .
............................. Second
............................. Oil . . .
Piston Ring Eng Gap ......... Top . .
(when fitted in bore) .......... Second
............................. Oil . . .
Gudgeon Pin Bore Dia. In Piston ......
Gudgeon Pin Dia....................
Connecting Rod Small End Dia ........
Connecting Rod Big End Side Clearance
Crankshaft Big End Journal Dia ........
Crankshaft Big End Bearing Clearance .
Crankshaft Main Journal Dia. . ........
Crankshaft Main Bearing Clearance ....
Crankshaft End Float ................

76.05 mm/76.03 mm Cyl. Nos. 1 & 3


76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.960 mm/40.946 mm (40.932 mm min)
0.066 mm/0.036 mm (0.1 mm max)
37.976 mm/37.960 mm (37.936 mm min)
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

Transmission
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Ratios ................. 1st ...
2nd . .
3rd . .
4th ...
5th . . .
6th . . .
Gear Selector Fork Thickness .........
Gear Selector Groove Width ..........
Gear Selector Fork to Groove Clearance
Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . .
Final Drive Ratio . . . . . . . . . . . . . . . . . . . .
Chain Type . . . . . . . . . . . . . . . . . . .
No. of Links . . . . . . . . . . . . . . . . . . . . . . . . .
20 Link Length ......................
Drive Chain Slack . . . . . . . . . . . .
...
Chain lubrication . . . . . . . . . . . . . . . . . . . .

6 Speed Constant Mesh


2.733 (41/15)
1.947 (37/19)
1.545 (34/22)
1.291 (31/24)
1.154 (30/26)
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 mm max
Chain
Variable according to model year and market designation
Variable according to model year and market designation
Variable according to model year and market designation
319 mm max.
35.0- 40.0 mm
Mobil chain spray

Lubrication
Pressure Lubrication, Wet Sump
4.00 litres
Oil Capacity (incl. filter) ........ .
Recommended Oil .................. . Semi synthetic 1Ow/40 oil meeting
specification API/SG
Oil Pressure (in main gallery) ........ . 40.0 lb/in2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
Oil Pump Rotor Tip Clearance ........ . 0.15 mm (0.2 mm max.)
Oil Pump Body Clearance ........... . 0.22 mm/0.15 mm (0.35 mm max.)
Oil Pump Rotor End Float ........... . 0.02 mm/0.007 (0.1 mm max.)
Ignition System
Type .............................. .
Ignition Timing . . . . . Static .. .
Idle ........... .
Max. Advance .. .
Electronic Rev-Limiter .............. .
Pick up Coil Air Gap ................ .
Pick up Coil Resistance ............. .
Ignition Coil LT Resistance ........... .
Ignition Coil HT Resistance .......... .
Spark Plug Type ................... .
Spark Plug Gap .................... .

Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
29 @ 6500 rpm
8750 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm

1.38

GENERAL INFORMATION 1
Full Specification

TIGER 900

Fuel System
Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ...... 25 Litres (5.5 Imp gal)
Reserve Capacity . . . . . . . . . . . . . . . . . . . 5 Litres (1.1 Imp gal)
Low Level Warning Lamp ............. 7 Litres (1.5 Imp gal)
Fuel Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, gravity fed.
Carburettors
Type ............................... MIKUNI BST 36 mm Flat Slide CV or
KEIHIN CVK 36 mm
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm 50 rpm
Cooling System
Coolant Mixture . . . . . . . . . . . . . . . . . . . . . 50/50 Distilled Water/Anti-Freeze
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . . Mobil Antifreeze
Freezing Point . . . . . . . . . . . . . . . . . . . . . . -35C
Cooling System Capacity . . . . . . . . . . . . . 2.8 Litres
Radiator Cap Opening Pressure . . . . . . . 1.1 Bar
Thermostat Opening Temperature . . . . . 83C
Cooling Fan Switch On Temperature . . . 99C
Temperature Gauge Sensor Resistance 255-31 0 Ohms @ 60C
Suspension
Front Fork Travel . . . . . . . . . . . . . . . . . . . . 235mm
Recommended Fork Oil . . . . . . . . . . . . . . Refer to chart in front suspension section for full details
Oil Level (without spring) . . . . . . . . . . . . . Refer to chart in front suspension section for full details
Rear Wheel Travel . . . . . . . . . . . . . . . . . . . 200 mm
Rear Suspension Bearing Grease . . . . . Mobil Grease HP 222
Brakes
Front type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated 2 Piston Sliding
Calipers Operating on Twin Rigid Discs
Caliper Piston Dia. . . . . . . . . . . . . . . . . . . . 2 x 27.0 mm
Disc dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 mm
Disc Thickness ...................... 5.0 mm (4.5 mm min.)
Disc Run-out Max .................... 0.15 mm (0.3 mm max.)
Front Master Cylinder . . . . . . . . . . . . . . . . 14.0 mm dia.
Recommended Fluid . . . . . . . . . . . . . . . . . Mobil Universal Brake and Clutch Fluid
DOT4
Rear Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated 2 Piston Sliding
Caliper Operating on Single Rigid Disc
Caliper Piston Dia .................... 2 x 27.0 mm
Disc Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.0 mm
Disc Thickness . . . . . . . . . . . . . . . . . . . . . . 6.0 mm (5.0 mm min.)
Disc Run-out Max .................... 0.1 mm (0.3 mm max.)
Master Cylinder ..................... 14.0 mm dia. Remote Reservoir
Recommended Fluid . . . . . . . . . . . . . . . . . Mobil Universal Brake and Clutch Fluid
DOT4

1.39

1 GENERAL INFORMATION
Full Specification
Wheels and Tyres
Front Wheel Rim Axial Run-out
Front Wheel Rim Radial Run-out
Front Tyres ........................
Front Tyre Pressure (cold) ...........
Front Tyre Tread Depth min. . ........
Rear Wheel Rim Axial Run-out .......
Rear Wheel Rim Radial Run-out ......
Rear Tyres ........................
Rear Tyre Pressure (cold) ...........
Rear Tyre Tread Depth min ...........

TIGER 900

.
.
.
.
.
.
.
.

0.5 mm
0.8 mm
Refer to the owners handbook for approved tyres for each model year
2.1 kg/cm 2
2.0 mm
0.5 mm
0.8 mm
Refer to the owners handbook for approved tyres for each model year
2.3 kg/cm 2
2.0 mm- up to 80 mph (130 km/h)
3.0 mm -over 80 mph (130 km/h)

WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised
closed course conditions.

~---~---------~~~-'

Frame
Frame Type
Overall Length ... _...... _..........
Overall Width ...... _......... _.....
Overall Height .... ___ ..... __ .......
Wheelbase ..... _........ ___ .......
Seat Height ... __ . .
. ...........
Steering Head Angle __
Trail .. _.......... __ ....... _.
Dry Weight .... _. . . . . . . . . ........
Max. Payload ...... _. _...... _

_
.
.
.
.
_

Electrical Equipment
Battery Type . . . .
.............
Battery Rating .... ___ ........ _
Alternator Rating ___ . _... _...........
Regulated Voltage ....... _........ _..
Stator Coil Resistance _........ __ . . . .
Rotor Coil Resistance _. . . . . .
Slip Ring Dia. __ .................... _
Brush Length ... _...................
Starter Motor Commutator Dia. . . . . . ..
Commutator Groove Depth ...........
Starter Brush Length .................
Fuses .. ___ ........ Headlight ___ ....
Tail Light . . . . . . .
Main ...........
Radiator Fan . . . .
Clock*/alarm . . . .
lnline fuse
Lights .......... __ . Head Light . . . . . .
Parking Light ....
Tail Light
License plate light
Indicators . . . . . . .

Large dia. high tensile steel spine,


stressed engine
2290 mm
920 mm
1345 mm
1550 mm
850mm
27 from vertical
96mm
Refer to owner's handbook
181 kg
YUASA YB 14L-A2
12V - 14AH
12V- 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
1OA
30A
15A
1OA
*SA (Brake Light)
2 x 60/55W H4 Halogen
4W
21/5 W
N/A
1OW

* If fitted

1.40

GENERAL INFORMATION 1
Torque Wrench Settings
Cylinder Head Area
Application

Torque(Nm)

Cam cover to cylinder head - long and short screws

10

Cam chain tensioner blade to engine

18

Cam chain tensioner spring bolt to body

23

Cam chain tensioner body to cylinder head

Camshaft bearing caps to head

10

Camshaft sprocket to camshaft

15

Cam chain top pad to head

10

Cylinder head to crankcase


- M6 screws (not T'bird, Adventurer or T'bird Sport)

12

Cylinder head to crankcase


- M6 screws (T'bird, Adventurer and T'bird Sport)

14

Cylinder head to crankcase bolts

Notes
Note 1

Note 4

See section 3

Cylinder head to frame bolts

95

Cylinder head core plug

22

Note 2

Torque(Nm)

Notes

Clutch
Application
Clutch cover to crankcase

12

Inner clutch cover to outer clutch cover

10

Sound suppression plate in clutch cover

Clutch centre nut

105

Clutch spring bolts

10

Clutch slave cylinder to sprocket cover

12

Clutch slave cylinder bleed screw

Clutch hose to slave cylinder banjo bolt

25

Note 5

Clutch hose to master cylinder banjo bolt

25

Note 5

Clutch master cylinder clamp bolts

15

Clutch lever pivot bolt (not Tiger)

Clutch lever pivot bolt (Tiger)

Clutch lever pivot bolt locknut

Balancer, Crankshaft and Crankcase


Application

Torque(Nm)

Crankcase upper to lower (M8 fixings)

See section 6

Crankcase upper to lower (M6 fixings)

See section 6

Connecting rod big end nut

Oil deflector plate

10

Balancer spindle pinch bolt- 4 cylinder engines

12

1.41

Notes

Note 9

1 GENERAL INFORMATION
Balancer, Crankshaft and Crankcase (continued)
Balancer clamp to crankcase - 4 cylinder engines

12

Balancer bearing plate- 3 cylinder engines

Note 1

Sprag clutch housing to centre

16

Note 1

Idler gear retaining bolt

12

Note 1

Breather disc to crankshaft

22

Note 1

Ignition rotor to crankshaft

27

Note 1

Ignition sensor to crankcase

10

Engine Covers
Application

Torque(Nm)

Crankshaft covers to crankcase

12

Balancer cover RHS - 3 cylinder

12

Alternator gear cover to crankcase

Sprocket cover to crankcase

12

Clutch cover to crankcase

12

Oil filler cap

Notes

Hand tight

Oil sight glass (T'bird, Adventurer and T'bird Sport)

22

Oil filler plug to clutch cover (T'bird, Adventurer and T'bird Sport)

10

Note 2

Transmission
Application

Torque(Nm)

Gearbox output sprocket

Notes

132

Detent wheel to selector drum

12

Note 1

Detent arm stud

Note 1

Detent arm nut

Selector drum bearing retaining washer

12

Note 1

Selector shaft retainer

12

Note 1

Spring abutment bolt

28

Stop plate to crankcase

Neutral indicator switch

10

Note 1

Final Drive
Application

Torque(Nm)

Chain rubbing strip to swinging arm screws

Chain guard to swinging arm

Chain guard to bracket

Sprocket to rear wheel

85

Rear wheel spindle bolt

85

Eccentric housing pinch bolt

36

Chain slider to frame (Tiger)

27

1.42

Notes

Note 8

GENERAL INFORMATION 1
Lubrication System
Application

Torque(Nm)

Notes

Sump to lower crankcase

12

Sump to lower crankcase (& exhaust bracket)

12

Sump drain plug M22

48

Sump drain plug M 14

28

Sump oilway plug

45

Note 2

Pressure relief valve

15

Note 2

Oil pressure switch

20

Note 5

Oil filter bolt

18

Oil feed banjos, M6

Oil feed banjos, M8

11

Oil feed banjos, M10

25

Oil feed banjos, M14

28

Oil cooler pipe banjo bolts

25

Oil cooler adaptor

36

Oil cooler mounting bolts

Oil cooler stoneguard mounting bolts

Oil pump to lower crankcase

12

Note 1

Oil pump gear to shaft

Note 1

Oil strainer retaining screws in sump

12

Plug, main oil gallery

25

Note 5

Torque(Nm)

Notes

Note 5

Note 5

Cooling System
Application
Water pump mounting bolts

12

Water pipe outlet to upper crankcase

11

Water pipe elbow to cylinder block

11

Water temperature sensor in cylinder head

Water pipe hose clip

Hand tight

Radiator mounting bolts

18

Radiator bottom bracket bolts

9
2.5

Radiator stone guard/elec fan mounting bolts


Radiator end covers

Coolant drain screw to crankcase

13

Water pipe to pump

Water pipe to engine

10

Expansion tank to frame (T'bird, Adventurer and T'bird Sport)

Thermostat housing to frame (T'bird, Adventurer and T'bird Sport)

1.43

1 GENERAL INFORMATION
Fuel System and Airbox
Torque(Nm)

Application
Airbox halves screws

2.5

Airbox to carburettor clips

1.5

Airbox cover (T'bird, Adventurer and T'bird Sport)

Auxiliary air chamber mounting bolts


(not T'bird, Adventurer or T'bird Sport)

Auxiliary air chamber mounting bolts


(T'bird, Adventurer and T'bird Sport)

Notes

2.5
See note 7

Exhaust clamp to head


18

Exhaust stud to cylinder head

Note 1

-------

Downpipe to intermediate pipe

Balance pipe clamp

22

Exhaust silencer clamp

22

Exhaust clamp cover (T'bird, Adventurer and T'bird Sport)

Screw to exhaust downpipe

Silencer mounting bolts (not Tiger, T'bird, Adventurer or T'bird Sport)

15

Silencer mounting bolts (Tiger, T'bird, Adventurer and T'bird Sport)

27

Silencer mounting bracket to silencer

14

f----

Hand tight

Heelguard to silencer (T'bird Sport)

Low fuel sensor in tank base (not Tiger)

30

Low fuel sensor in tank base (Tiger)

r-----

Fuel gauge sensor unit to tank (Trophy 1996)

10
Hand tight

Fuel filler cap security screw


Fuel filler cap screws

Fuel tap mounting bolts (not Tiger, T'bird, Adventurer or T'bird Sport)

12

Fuel tap mounting bolts (Tiger, T'bird, Adventurer and T'bird Sport)

Fuel tank to bracket screws (not T'bird, Adventurer or T'bird Sport)

12

Fuel tank to bracket screws (T'bird, Adventurer and T'bird Sport)

Tank bracket to frame screws

12

Fuel tank badge to fuel tank (T'bird, Adventurer and T'bird Sport)

9
1.5

Carb rubber clip

Wheels
Torque(Nm)

Application
Front wheel spindle to fork bolt (except Tiger)

60

Front wheel spindle pinch bolts

20

Front wheel to forks, dome nut or spindle (Tiger)

85

Rear wheel spindle bolt

85

Rear wheel eccentric housing pinch bolt

36

Chain adjustment bolts (T'bird, Adventurer and T'bird Sport)

15

1.44

Notes

Note 8

GENERAL INFORMATION 1
Rear Suspension
Application

Torque(Nm)

Notes

Swinging arm spindle to frame bolt

85

Note 3

Drop link to swinging arm (not Tiger, T'bird, Adventurer or T'bird Sport)

55

Drop link to swinging arm (Tiger, T'bird, Adventurer and T'bird Sport)

100

Drop link to drag link (not Tiger, T'bird, Adventurer or T'bird Sport)

85

Drop link to drag link (Tiger, T'bird, Adventurer and T'bird Sport)

100

Drop link/drag link spindle pinch bolts

Drag link to linkage carriers

Note 3

100

Rear suspension grease nipples

Rear suspension unit to frame

95

Pre-load adjuster to bracket

Damping adjuster to frame

Upper crankcase and linkage carriers to frame

95

Lower crankcase and linkage carriers to frame

95

Rear suspension unit to drag link


(Tiger, T'bird, Adventurer and T'bird Sport)

55

R.S.U. reservoir bracket to head M8 (Tiger)

27

R.S.U. reservoir bracket to head M6 (Tiger)

Front Suspension
Application

Torque(Nm)

Notes

Handlebar mounting bolts (not Tiger, T'bird, Adventurer or T'bird Sport)

22

Note 2

Handlebar lower clamp to yoke


(Tiger, T'bird, Adventurer and T'bird Sport)

35

Handlebar top clamp to bottom clamp (T'bird and Adventurer)

22

Handlebar top clamp to bottom clamp (T'bird Sport)

20

Handlebar top clamp to bottom clamp (Tiger)

18

Handlebar weight

Switch assemblies to handle bars

Speedometer cable retaining screw

Hand tight

Brake hose joint to bottom yoke

18

Steering stem adjuster nut

40

Adjuster nut locking screw

Top/bottom yoke pinch bolts (not Tiger)

20

Top yoke pinch bolts (Tiger)

18

Bottom yoke pinch bolts (Tiger)

22

1.45

Note 6

1 GENERAL INFORMATION
Front Suspension (continued)
Steering stem dome nut

65

Fork cap

23

Fork cap to damping rod lock nut

15

Capscrew to damping rod (bottom of forks) (Daytona)

40

Capscrew to damping rod (bottom of forks) (T'bird and Adventurer)

20

Capscrew to damping rod (bottom of forks) (T'bird Sport)

30

Capscrew to damping rod (bottom of forks)


(not Daytona, T'bird, Adventurer or T'bird Sport)

60

Ignition switch & instrument bracket on top yoke

Shear bolt

Brake hose bracket to fork leg

Mudguard to fork leg

Cable guide to bottom yoke

Brakes
Application

Torque(Nm)

Front brake caliper bleed screw

Notes

Front brake hose banjo bolts

25

Front brake caliper mounting bolts


(not T'bird, Adventurer or T'bird Sport)

40

Front brake caliper mounting bolts (T'bird, Adventurer and T'bird Sport)

28

Front brake caliper slider pin -adjacent to bleed screw ('B' spec. only)

22

Front brake caliper slider pin- between pistons

18

Front brake caliper pad retaining pins

18

Front brake caliper pad retaining pin lockscrew


(T'bird, Adventurer and T'bird Sport)

Brake disc to front wheel

22

Rear brake caliper bleed screw

Rear brake caliper pad retaining pins

18

Rear brake caliper to carrier (not T'bird, Adventurer or T'bird Sport)

40

Rear brake caliper to carrier (T'bird, Adventurer and T'bird Sport)

28

Rear brake master cylinder/cover mounting bolts

27

Rear brake master cylinder fork end lock nut

18

Rear brake master cylinder reservoir mounting screw

Rear brake light switch

15

Rear brake hose banjo bolts

25

Rear brake hose guide screws to 'P' clips

Rear brake hose clamp screws

Note 5

Note 1

Note 5

Rear brake torque arm to swinging arm bolts

28

Note 2

Brake disc to rear wheel

22

Note 1

Brake/clutch master cylinder clamp bolts

15

1.46

GENERAL INFORMATION 1
Brakes (continued)
Brake lever pivot bolt (not Tiger)

Brake lever pivot bolt (Tiger)

Brake lever pivot bolt locknut

Brake pedal to control plate (Tiger, T'bird, Adventurer and T'bird Sport)

27

Note 2

Rear brake torque arm to caliper carrier


(T'bird, Adventurer and T'bird Sport)

28

Note 2

Brake hose clip to front mudguard (T'bird, Adventurer and T'bird Sport)

Footrests, Control Plates and Engine Mountings


Application

Torque(Nm)

Upper crankcase and linkage carriers to frame

95

Lower crankcase and linkage carriers to frame

95

Cylinder head to frame bolts

95

Front footrest assembly to control plate

45

Footrest rubber to footrest

Bank angle peg to footrest

Notes

Note 4

Control plates to frame bolts


(not Tiger, T'bird, Adventurer or T'bird Sport)

27

Control plate to frame M8x30 (Tiger)

27

Control plate to frame M10 capscrew


(T'bird, Adventurer and T'bird Sport)

45

Control plate to frame M8 capscrew (T'bird and Adventurer)

30

Outrigger finisher to frame

12

Outrigger finisher screws (upper)

12

Outrigger finisher screws (lower)

Prop rails to frame outrigger (T'bird, Adventurer and T'bird Sport)

45

Gearchange pedal to control plate (Tiger)

27

Gearchange pedal to rubber (T'bird, Adventurer and T'bird Sport)

12

Note 2

Gearchange pedal to shaft

Note 2

Gearchange linkage rod locknuts

Rear footrest assembly to footrest hanger


(not T'bird, Adventurer or T'bird Sport)

42

Rear footrest assembly to footrest hanger


(T'bird, Adventurer and T'bird Sport)

27

Seat lock assembly to footrest hanger

12

Seat lock assembly to airbox (T'bird, Adventurer and T'bird Sport)

Seat lock catch to bridge bracket

Footrest hanger to frame

27

Lifting handles to frame

27

Lifting handle bracket to frame (bolt) (1996 Trophy)

28

Lifting handle bracket to frame (nut) (1996 Trophy)

22

Centre stand to linkage carriers

40

Side stand bracket/linkage carrier to frame M 12

95

Side stand pivot bolt

20

1.47

1 GENERAL INFORMATION
Footrests, Control Plates and Engine Mountings (continued)
Side stand pivot bolt locknut

25

Side stand switch to bracket (not T'bird, Adventurer or T'bird Sport)

Side stand switch to bracket (T'bird, Adventurer and T'bird Sport)

Side stand bracket to frame (not T'bird, Adventurer or T'bird Sport)

22

Side stand bracket to engine (T'bird, Adventurer and T'bird Sport)

40

Note 2

Torque(Nm)

Notes

Electrical
Application
Spark plug

18

Alternator drive gear to shaft (nut and bolt)

40

Alternator drive gear to shaft (bolt only)

35

Alternator drive shock absorber to alternator

12

Alternator shaft bearing retaining bolt (capscrew)

12

Alternator shaft bearing retaining bolt (Torx screw)

10

Alternator mounting bolts

20

Starter motor mounting bolts

10

Starter motor cable connections

Battery terminals

Battery box bracket to frame

Battery box to bracket

Battery box and plenum chambers to frame

Electrical harness earth to frame

12

Ignition coils to frame

Rear indicator bracket to frame (not T'bird, Adventurer or T'bird Sport)

18

Indicator assemblies to bracket


(not T'bird, Adventurer or T'bird Sport)

Hand tight

Indicator to bracket, front & rear (T'bird, Adventurer and T'bird Sport)

18

Rear indicator and base to side panel (1996 Trophy)

Front indicator to fairing lower (1996 Trophy)

Tail light assembly to frame (not T'bird, Adventurer or T'bird Sport)

Hand tight

Instrument assembly to bracket/yoke

Twin headlight assembly to subframe

Trophy headlight assembly to cockpit fairing

Horn to engine (T'bird, Adventurer and T'bird Sport)

10

Horn cover to horn (T'bird, Adventurer and T'bird Sport)

Number plate lamp bracket to mudguard (T'bird and T'bird Sport)

Number plate lamp to bracket (T'bird and T'bird Sport)

Tail lamp to mudguard (T'bird and T'bird Sport)

Fuse box to battery box door (T'bird, Adventurer and T'bird Sport)

2.5

Headlamp rim

Headlamp bowl to bracket

10

Headlamp bracket to fork tube

1.48

Notes 1, 10
Note 1

Note 1

GENERAL INFORMATION 1
Bodywork
Application

Torque(Nm)

Fairing upper subframe to headstock (all +Tiger M8x12 Torx)

28

Fairing subframe to headstock (Tiger M8x30 capscrew only)

28

Fairing lower subframe brackets to crankcase

18

Fairing lower subframe to brackets

Windscreen to cockpit fairing

Notes

Hand tight

Inner trim panels to outer fairings

Cockpit and lower fairing to upper subframe

Lower fairing LHS to RHS, lower fairing to cockpit (centre)

Hand tight

Lower fairing to lower subframe

Lower fairing to cylinder head

10

Rear mudguard to frame (not T'bird, Adventurer or T'bird Sport)

15

Rear mudguard/brackets/wheel cover to frame/mudguard


(T'bird and T'bird Sport)

Rear mudguard to frame -front upper (Adventurer)

60

Rear mudguard to frame -front lower (Adventurer)

35

Rear mudguard to frame -front location (Adventurer)

Front mudguard to fork leg (not T'bird, Adventurer or T'bird Sport)

Front mudguard to fork leg (T'bird, Adventurer and T'bird Sport)

12

Mudflap to swinging arm (not Tiger)

Mudflap to swinging arm (Tiger)

Rear reflector to mudguard

Hand tight

Bayonets to side panels

Side panel to frame - under seat

Side panel to frame (T'bird, Adventurer and T'bird Sport)

Grab rail/side panel to frame (single rail bolts and twin grab rail front bolts)

27

Grab rail/side panel to frame (rear bolt- twin grab rails)

10

End cap to side panel

Rear rack to frame (Tiger)

27

Side panel and rear cover to frame M6x24 (Tiger)

Side panel and rear cover to frame M6x17 screw (Tiger)

Sump guard to control plate/crankcase (Tiger)

27

Cover plate to sump guard (Tiger)

10

Seat strap to seat (T'bird)

9.5

Seat rails to spine tube

95

NOTES: All torques quoted are in Nm only.


1.
Threads of fastener are pretreated with micro-encapsulated locking compound.
2.
Clean threads and apply Locktite 'Nutlock' Grade 242.
3.
Clean threads and apply Locktite 'Studlock' Grade 270.
4.
Lubricate threads with engine oil.
5.
Replace sealing washer every time.
6.
Refer to relevant assembly instructions.
7.
Tighten in 2 stages, first 8 Nm then 20 Nm.
8.
Apply Copper Grease to threads.
.
9.
Lubricate threads and face of nut with molybdenum disulphide grease. Tighten in 2 stages, first 14 Nm then 120 using Triumph
torque turn gauge 3880105-T0301.
10. Replace bolt/screw every time.

1.49

ROUTINE MAINTENANCE
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Periodic Maintenance Charts

2.4

Battery
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrolyte level inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6
2.7
2.7

Spark plugs
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8
2.8
2.8

Cam cover
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9
2.10

Valve clearance
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.11
2.11

Engine oil
Level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil and oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.15
2.17

Cooling system
Coolant level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling (not Thunderbird, Thunderbird Sport or Adventurer) . . . . . . . . . . . . . . . . .
Filling (Thunderbird, Thunderbird Sport & Adventurer) . . . . . . . . . . . . . . . . . . . . .
Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.18
2.19
2.19
2.19
2.20
2.20
2.20

Nuts, Bolts, Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.20

Clutch
Fluid level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch fluid replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.21
2.21
2.21

Carburettors
Carburettor synchronisation

2.22

Throttle grip & Choke lever


Inspection ............................................. , . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.24
2.25

Air intake assembly


Removal (not Thunderbird, Thunderbird Sport or Adventurer) . . . . . . . . . . . . . .
Installation (not Thunderbird, Thunderbird Sport or Adventurer) . . . . . . . . . . . . .
Removal (Thunderbird, Thunderbird Sport & Adventurer) . . . . . . . . . . . . . . . . . .
Installation (Thunderbird, Thunderbird Sport & Adventurer) . . . . . . . . . . . . . . . .
Airbox Drain Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.25
2.26
2.27
2.27
2.28

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.28

Wheelsffyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.29

2.1

2 MAINTENANCE
Drive chain
Chain slack inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive chain slider (Tiger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain slack adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.30
2.30
2.31
2.32
2.33
2.33

Brakes
Disc brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake hydraulic seals and hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake pads/wear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake light inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.34
2.35
2.35
2.35
2.36
2.36

Steering
Steering inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering head bearing lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.37
2.37

Front suspension
Front fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front fork oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.37
2.37

Wheel bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.38

Rear suspension
Rear suspension inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.38

2.2

MAINTENANCE

INTRODUCTION
This maintenance section contains information necessary to perform the recommended inspections and adjustments.

WARNING: The importance of good maintenance cannot be overestimated. The tasks described
will help to ensure the safe and reliable operation of your Triumph motorcycle. Never attempt to cut
costs by neglecting the maintenance requirements of your machine as this will result in the premature failure
of the component(s) concerned and may lead to an unsafe riding condition and an accident

All service technicians should be fully conversant with this entire chapter.

BODYWORK AND FUEL TANK

WARNING: In order to carry out most of the maintenance tasks in this section of the manual it will be
necessary to remove the fuel tank and all or part of the bodywork. For details of removal and
assembly of these items, refer to the fuel system and body sections of the manual where full details will be
found. Also, details on the safe handling and storage of fuel can be found in the general information section.
Failure to observe the information given could lead to dangerous riding and working conditions which may
cause personal injury and damage to property.

Service Check Sheets


Triumph are pleased to be able to offer pads of service check sheets to aid technicians during servicing of Triumph
motorcycles. Each pad has 50 single sided service sheets which have tick boxes to indicate the correct maintenance
requirement at each mileage interval.
The pads are available from your Triumph parts department under the following part numbers:

T3850550- Service Sheet Pad, English Language


T3850555 - Service Sheet Pad, French Language
T3850560 - Service Sheet Pad, German Language
-~

SCHEDULED MAINTENANCE CHECK SHEET- ALL MODELS

~I-- .
1:..:-.No::..ll'on
...... - -

"f)'

c-,""""'~"""""'-..

1-

Fn~~=~~Kma

J T
j

EYery600{!,_,10000Ktr4

.... _,_.....,.,_...,.

1.

U 0 :J (J

Poo"""'n-.o:>e"""""""'"poo.<""'tv<~

E"'"'"

N!l,.,.,..,.<><cy:.Lo,.Wo'y"'PP""od~a.;y
iof':<>9~~

~-~
J
~omP':el:J
T t-.rrl~m-.:~{)(X)()Kmt
E\"'Y6000rrln11000QKml

0 0 U;:)

21

~-..pte!.,,..<t>&<>!::<eon.ci:%<><1m0"' (o~t.:>

aoo

26

~..... ~.~ ......

'J

..t"U""''t-'>IJIO<""""""

o~4dt.a:ary.hf9'\.YO(b<Wt)lo..Oinl

t>o<~"+:O.Mh~~l"'>\e.s)

cr.. ..,

to...,tot.~.......-y

'i'IXI""'l

C~i9>'U """'-~-~~...._,.,.-.g

::;:,~l:.o~aod

UDCJ:l3

...... o...--.--lor ........ -

Jf"":,~=~~K-

.~,~12000mloo/2('X)(J(JK.n;.o

0 U :l 0

1'~"---~(''9"0~~~

Yn-.o:::~

--~........

~------~-...----~ .......... -

'J

28

Au~lrt<">!-..l>t<olol!t'>o~lll'>dmi'OCI

C:o ....-.gl".....,~oe>.)l>o>r"9'!<ftMp\lly

P.OI'I'>OYO~..-.:!Ivo!lv.i<M~I)'.

~~'"''"""'" ... 1<>'""9'""'1>0 ...... ,

""""'t~o~~Wtlti~P<.,.....
""""'"<>:IJ<!wt>l\1'fandobH""r-.o~_..,h.,.~
P'~O<\Ot!lV>O""""""""""""

::JC)Q:J4.
0

Q :J 5

~<\ull~a~..-yo~"*fl~<-er
1-.p~fvolO)'IIOmo.-.;ll>oo-ol<>I!Ul<><i>:r.l\)0.

cta""',O<>!"""""'.o<l~f>:lcl\a'<>g

u :J n

::J

.J

J\

:J

0:J7

.....

,1.<>;!5)".~ ... >:1~,..,"

,.,~

"'V"'

.........

!he"'?"'""""OQ..K>roidl"""""'oporo<r11
.....,.,.,.....,.,.,

I~IIVOO!o~Mc'>.out<..

~'
Q

J '.]

I()

:J "]
0

:J

::J

Cf>oc'<OMIOPWclu';Chr.ul.,.~

12 ~::~~' ~uw po.r<o '*"9 o 1'1 PfOUulo

l~tyr .. lon:~
or~

O
CJ
:J

\J

U U

~.to ~

:J

... .._.

O:J:JOJ.5

Q 18

v....... "Y.-~"'-"'"'111'"'~

r~ono

l"e ""''~ ~Qv<l u MO<ury

,._,,.,,_.,.~.0"'-"""11~,.,.,3
ROCOI\..,.,.~NI!ory.p.,.~,.,..(-J<u.d*'m

:>& CorryOUlradl"'l(h,.,..,.,m!5""'''0tro..,.'

1-.oo .... at.l>u'Qol~.<<iU

TMl<:<~o:>wflO~opofill""''"".us~becaf><l(lou!allt>l

opoct;.dt"''''''"~~O\Ie<">"ai""~"'COo'l'>HIm

Checl<.:~.'-"lrfl'l"'"..ltooo"<P"51W< ...

1!>. lnopecs!O<Ooi ... RIrom~l 01-"""""'"9<>1


"""""'ojOOOiofP!><IIOMo.."9<>eatU
16

:><

01::.

R.o.,..,,.......,.,~...-.:l...,...e<ilo6ro.'I'IOVI

UQ17R..._:tleS<Irfli>V./-.I>o<..-.:!,.C.""""Jl0.9
0

O O Q :J
Q 13 1.-...,toel ..._,. lu <fli(U,

:J u

co1>uol\or

U U :J 0 33 ;':':'.,::~.,'::,."!:~~~~mo.=:
t-..w~"''Y

C~>K>.Mio!>"!'lx><'>tl>.<o,.~ ... <y<o"'d<.,

~~~"-'"'~~.ec-..,_,.,

U Q U

Cho<;V"">A!tl'>o

>&cwmo~""""

lo<<li"'"'}}

'"'~""''"'"'"o.dl.Ovo!rJfoo.opioy M."<~~

OO.JQ1t

C~aMo~~.,_""''..,.,_.~

JZA.'tld'>vocwm90"""''oucll~O<S<VI

C)

"""""oryOo<>:>tO>VII<
OJQ08

~ ~., ..... ""'"'~.o<l ~. "~ ~


t>o"<ryo.t>:~rur...,.~C"""'lhtlow<>l
P'HIV'Ow~\oV"l>:t<>Q'~O
SIOP>~o

kYd~')_, ...-x~..,..""overJ~o'""'
~.~<no:IGW>:Idooto-'0'11!<nV~

r"!>>C'"'-<>Potor-....,.

Rv~w:"eor.g.<>oo.iii'M

:J1

~all>tae......:!cU.Chm ... lt<<:yl"""''<IW"...I>$1oWI

:J2
i]3

L\.Co::aleii-'"J91'W><!di>Nr.n9'

U4

R..--~ Enotn!IO'>;~~<o,._-.

cy'.r><;lo<~~t;db<>l""co.llpt<pre,_.._...&t>ddvOiualo
fl.,._btA~..-..:I<Io(cM"'-"'l

__,_

Fnnr'YWIIl'OO!!mliM/~

:J1

.J

.J

>ll<bralul.ci'.JI<:hir<lfWih<>uf.

20

"-<~joOll.pUkp"-'J~~

:J1

~~

R.,..,.~.n~

r-Ao"m"'"Wori<C.-.M

R_.,.,...,c<ea""'

!Ad!A(mt<>l>owb,k'!IO~ch~at>::-ot-as'Occ.Gtoi$-OM:;fi;!

tt

fk,.,..,.ttmoec""'~""'m:o<><>lx>W!t!;e,........:lon<~-

2.3

Service
Sheet

2 MAINTENANCE
PERIODIC MAINTENANCE CHART:AII models except Tiger
INTERVAL

:j:

Whichever
comes first

Odometer Reading Miles (Km)

OPERATION
*

500
(800)

Every

6000
(10000)

Carburettor synchronisation- check

Idle speed -check


Steering play- check
Brake fluid level -check

month

Brake light/switch - check


Clutch fluid level- check

month

Battery electrolyte level -check

month

Valve clearance - check

Airbox drain tube- drain out


Engine oil -change

f-----

year

Oil filter- replace

year

Radiator hoses, connections- check

year

Throttle and choke cables- check


Nuts, bolts, fasteners- check

Spark plug- inspect gap

Spark plug - replacement

Brake pad wear- check


Tyre wear- check/Wheels- inspect

t
t
t

Drive chain wear- check


Drive chain -lubricate

Every 200 miles (300 km)

Drive chain slack- check

Every 500 miles (800 km)

t Rear suspension, swinging arm -lubricate


*

Brake fluid-- change

2 years

Clutch fluid- change

2 years

Front fork oil -change


Steering stem bearing- lubricate

2 years

Coolant - change

2 years

Master cylinder cup and dust seal - replace

2 years

Caliper piston seal and dust seal - replace

2 years

Clutch slave cylinder piston seal - replace

2 years

Brake clutch hose and pipe- replace

Clutch hose and p1pe - replace

4 years

Fuel hose - replace

4 years

4 years

Year

Evap' system fuel collection hoses- drain out

Should be serviced by an authorised Triumph Dealer.

:t:: For h1gher mileages repeat at the frequency intervals established here

t:

In severe climates (hot, dusty, etc.) repeat checks and adjustments at more frequent intervals.

2.4

Grease points- lubricate

Evap' loss system pressure regulator- renew

18000
(30000)

Every 24000 miles (40000 km)

Fuel system -check

12000
(20000)

3 years or 24,000 miles

Air cleaner- replace

15000
(25000)

9000
(15000)

3000
(5000)

MAINTENANCE

PERIODIC MAINTENANCE CHART:- Tiger


INTERVAL

:j:

Whichever
comes first

Odometer Reading Miles (Km)

OPERATION
*

500
(800)

Every

Carburettor synchronisation -check

Idle speed - check

Steering Qlay_- check


Brake fluid level- check

month

Brake light/switch- check


Clutch fluid level- check

month

Battery electrolyte level -check

month

Valve clearance - check

Airbox drain tube- drain out


Engine oil - change

year

Oil filter- replace

year

Radiator hoses, connections- check

year

Throttle and choke cables- check

Spark plug- inspect gap

Tyre wear- check/Wheels and spokes - inspect

t Drive chain wear- check

t Drive chain- lubricate

Every 500 miles (800 km)

t Rear suspension, swinging arm- lubricate

3 years or 24,000 miles

Fuel system- check

t Air cleaner- replace

Every 24000 miles (40000 km)

Brake fluid- change

2 years

Clutch fluid- change

2 years

Front fork oil - change

Steering stem bearing- lubricate

2 years

Coolant - change

2 years

Master cylinder cup and dust seal- replace

2 years

Caliper piston seal and dust seal- replace

2 years

Clutch slave cylinder piston seal - replace

2 years

Brake clutch hose and pipe - replace

Clutch hose and pipe- replace

4 years

Fuel hose- replace

4 years

Drive chain slider renew

2 years or 24,000 miles


Year

Should be serv1ced by an authonsed Tnumph Dealer.

t: For higher mileages repeat at the frequency intervals established here.


t: In severe climates (hot, dusty, etc.) repeat checks and adjustments at more frequent

intervals.

2.5

4 years

Evap' system fuel collection hoses- drain out

Grease points- lubricate

Evap' loss system pressure regulator- renew

Every 200 miles (300 km)

t Drive chain slack- check

Spark plug - replacement


Brake pad wear- check

18000
(30000)

Nuts, bolts, fasteners- check

12000
(20000)

6000
(10000)

15000
(25000)

9000
(15000)

3000
(5000)

MAINTENANCE

BATTERY REMOVAUREFIT

Removal - all models except Thunderbird,


Thunderbird Sport & Adventurer

WARNING: The battery gives off


explosive gases; keep sparks, flames
and cigarettes away. Provide adequate ventilation
when charging or using the battery in an enclosed
space.
The battery contains sulphuric acid (electrolyte).
Contact with skin or eyes may cause severe burns.
Wear protective clothing and a face shield.
If electrolyte gets on your skin, flush with
water immediately.

1.

Remove the seat and document tray (if fitted).

2.

Disconnect the battery negative (black) lead first,


then the positive (red) lead.

3.

Remove the battery strap.

4.

Take the battery, complete with breather tube, out of


the case.

5.

Wipe the battery using a clean, dry cloth. Ensure


that the battery lead connections are free from
oxidation deposits.

If electrolyte gets in your eyes, flush with


water for at least 15 minutes and SEEK MEDICAL '
ATTENTION IMMEDIATELY.
If electrolyte is swallowed, drink large
quantities of water and SEEK MEDICAL
ATTENTION IMMEDIATELY.

KEEP ELECTROLYTE OUT OF THE REACH OF


CHILDREN.
----

___

___)

WARNING:
The battery contains harmful
..
materials. Always keep children away
from the battery whether or not it is fitted in the
motorcycle.
Do not jump start the battery, touch the battery
abies together or reverse the polarity of the
abies as any of these actions may cause a spark
which would ignite bat.tery gasses causing a risk of
ersonal injury.

1. Battery
2. Negative (-)terminal
3. Positive(+) terminal

Removal, Thunderbird, Thunderbird Sport


& Adventurer

WARNING: The battery electrolyte is


corrosive and poisonous. Never swallow
battery electrolyte or allow to come into contact
with the skin. Always wear eye and skin protectionj
when adjusting the electrolyte level

1.

Remove the seat and right hand side panel.

2.

Disconnect the battery leads, negative (-) black


lead first then the positive(+) red lead.

CAUTION: When checking the battery


electrolyte level, or adding distilled water,
ensure that the breather is not blocked. A blocked
breather may cause a build-up of gas in the battery
which would damage the battery case.

To prevent battery damage, use only distilled water


in the battery. Tap water will shorten the service life
of the battery.
Filling the battery above the UPPER LEVEL line
may cause the electrolyte to overflow, resulting in
corrosion to engine or nearby parts. Immediately
wash off any spilled electrolyte.
1. Flasher Unit Connection.
2. Battery Box Door Retaining Screw
3. Fuse Box Connection

2.6

MAINTENANCE
3.

Release the battery retaining strap.

4.

Disconnect the flasher unit and the fuse box


connection to the main harness.

5.

Gently ease the harness away from the battery


box.

6.

Release the screw securing the door to the


battery box. Release and un-clip the battery box
door.

7.

Disconnect the battery breather tube.

WARNING: Filling the battery above the


UPPER LEVEL line may cause the
electrolyte to overflow.
Electrolyte is highly
corrosive and will damage clothing and cause
burns if in contact with the skin
Never route the battery breather pipe in any way
which could cause the pipe to become blocked or
trapped. A blocked or damaged pipe will cause a
build up of pressurised, explosive gas which may
ignite.
When adding electrolyte, always wear eye and
skin protection.

NOTE:
8.

The breather tube may fall to the floor when


disconnected
Remove the battery by sliding sideways out of the
battery box.

Installation - all models except


Thunderbird, Thunderbird Sport &
Adventurer
1.

Battery Electrolyte Level Check

Check that the battery case rubber pad is


correctly located in the bottom of the battery case.
Place the battery in the battery case and connect
the battery breather pipe.

1.

Remove the battery from the motorcycle, see


Battery Removal.

2.

2.

Check that the electrolyte level in each cell is


between the upper and lower level lines.

3.

Fit the battery strap.

4.

If the electrolyte level is low in any cell, top-up the


cell with distilled water.

Reconnect the battery positive (red) lead first then


the negative (black) lead.

5.

Lightly smear a coating of petroleum jelly on


terminals to prevent corrosion.

6.

Cover the terminals with the protective caps.

7.

Refit the seat and document container (if fitted).

Installation, Thunderbird, Thunderbird


Sport & Adventurer

3.

1.

Clean the battery box.

2.

Place the battery in the battery box, and connect


the battery breather tube.

3.

Re-fit the battery retaining strap.

1. Upper Level
2. Lower Level
3. Breather Tube Connection

4.

Re-fit the door to the battery box and tighten the


door retaining screw.

4.

5.

Re-connect the flasher unit and fuse box to the


main harness.

6.

Reconnect the battery positive(+) red lead first


then the negative (-) black lead.

7.

Apply a light coat of petroleum jelly to the battery


terminals to prevent corrosion.

8.

Cover the terminals with the protective caps.

9.

Refit the right hand side panel and the seat.

On refitting, ensure that the battery breather pipe is


routed down the inside of the centre stand spring
(where a stand is fitted) or is routed between the
frame and swinging arm when no centre stand is
fitted.

The battery electrolyte level must be kept between the


upper and lower level lines. Check the electrolyte level in
each cell in accordance with periodic maintenance chart.

2.7

MAINTENANCE

NOTE:

SPARK PLUGS
The standard spark plug is shown in the specification
section. However, a winter grade spark plug has been
approved for use in climates where extremely low
ambient temperatures are experienced. Consult your
Triumph dealer or the parts information for advice
concerning winter grade spark plugs.
Spark plugs should be taken out periodically, in
accordance with the Maintenance Chart, for inspection,
resetting of the air gap, or total replacement.

Make a note of the spark plug lead positions in


the head before disconnection. This will help in
matching the correct cylinder with the correct
plug lead when refitting.

8.

Using a suitable deep socket or box spanner,


unscrew and remove the spark plugs.

NOTE:

It is advisable to cover spark plug holes if the


plugs are not being replaced immediately.

Removal

Maintenance
1.

1.

Remove the seat.

2.

Remove both side panels (not necessary on Tiger,


Adventurer, Thunderbird Sport or Thunderbird
models).

3.

Disconnect the battery negative (black) lead first.

4.

Remove the fuel tank as described in the fuel


system section.

Measure the air gap with feeler gauges and


adjust the gap, if incorrect, by gently bending the
earth electrode.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury, could result from
spilled fuel or fuel not handled and stored in the
correct manner.

5.

Remove the cam cover cowls (if fitted) from the


frame.

6.

Clean around the spark plug caps to remove all


traces of road debris and dirt.

7.

Carefully pull the spark plug caps from the spark


plugs.

Measuring the spark plug gap

NOTE:

Correct spark plug gap - 0.8-0.9mm.

2.

If the spark plug electrodes are corroded or


damaged, or if any part of the insulator is cracked,
replace the plug with a new item of the correct type
and grade.

Installation
1.

Lightly coat the threads of each plug with


'copper-slip' type grease.

~.

CAUTION: Do not overtighten the spark


plugs as damage to the threads in the
cylinder head may take place.

L.ll

1. Spark Plug Caps

2.8

2.

Fit and tighten each plug to 18 Nm.

3.

Fit the spark plug caps in the order noted in


paragraph 7 of the removal procedure.

4.

Refit the cam cover cowls (where fitted) to the


frame.

5.

Refit the fuel tank.

6.

Reconnect the battery, positive (red) lead first.

7.

Refit the side panels (if removed).

8.

Replace the seat.

MAINTENANCE

CAMSHAFT COVER

10. Remove the cam cover gasket together with the


seals from the spark plug holes.

Removal
1.

Remove the seat.

2.

Remove both side panels (not necessary on Tiger,


Adventurer, Thunderbird Sport or Thunderbird
models) and one lower fairing panel (fully faired
models only).

3.

Disconnect and remove the battery, negative


(black) lead first (disconnect only on Thunderbird,
Thunderbird Sport & Adventurer).

4.

11.

Remove any residual oil from the exhaust side of


the cylinder head using a syringe or lint free cloth.

Remove the fuel tank as described in the fuel


system section.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury, could result from
spilled fuel or fuel not handled and stored in the
correct manner.
5.

Remove the cam cover cowls from the frame (if


fitted).

6.

Remove the ignition coils and spark plug leads.

4 cylinder engines

NOTE:

Make a note of the spark plug lead positions in


the coils before disconnection. This will help in
matching the correct cylinder with the correct
plug lead when refitting.

7.

Ease the wiring harness and throttle cables to give


access to the cam cover

8.

Progressively release the cam cover bolts in the


order shown to the right. Remove the bolts and
seals.

NOTE:

The two longer bolts are fitted at the right hand


end adjacent to the cam chain.

9.

Remove the cam cover. (Lightly tap with a rubber


mallet if necessary.)

NOTE:

On Thunderbird, Thunderbird Sport &


Adventurer, the cover must be withdrawn from
the right hand side.

3 cylinder engines

CAUTION: Never use a lever to remove


the camshaft cover from the head. This
will damage the mating surfaces of the cylinder
head and cover leading to an oil leak.

Camshaft Cover Bolt Release!Tightening


Sequence

2.9

MAINTENANCE

5.

Fit the screws and seals, then tighten until finger


tight.

Check the condition of all joints and seals including


the cam cover screw seals. Replace as necessary.

6.

Finally tighten the screws, in same order as the


releasing sequence, to 1ONm.

Ensure all mating surfaces are clean and free from


oil.

7.

Apply silicone sealant, as indicated in the diagram


below, to the cylinder head, cam cover and to the
spark plug hole seals.

Fit the ignition coils and attach the spark plug leads
in the order noted in paragraph 6 of the removal
procedure.

8.

Refit the cam cover cowls to the frame (if fitted).

9.

Refit the fuel tank.

Installation
1.

2.
3.

10. Refit the battery and reconnect, positive (red) lead


first (reconnect only on Thunderbird, Thunderbird
Sport & Adventurer).
11.

Refit both side panels and the fairing (if removed).

12. Refit the seat.

1. Silicone sealer areas


4.

Fit the cam cover, ensuring all seals are positioned


correctly.

NOTE:

On Thunderbird,
Thunderbird
Sport &
Adventurer, the cover must be installed from
the right hand side.

2.10

MAINTENANCE

VALVE CLEARANCES
Camshaft, valve, valve shim and valve seat wear affects
the valve clearances. The effect of this wear is to change
the gap between the camshaft and valve shim causing
engine noise and improper running.
If the valve clearances become too close, permanent
damage to the valve and valve seat will take place
The valve clearance for each valve should be checked
and adjusted in accordance with the periodic
maintenance chart.

VALVE CLEARANCE MEASUREMENT


Measuring Valve Clearance

NOTE:

Valve clearance measurement must be carried

out with the engine cold.


1.

2.
3.

Remove the camshaft cover as previously


described in this section.
Remove the spark plugs to reduce compression
resistance during turning of the engine.
Select a high gear and, using the rear wheel to turn
the engine over, turn the engine until a pair of
camshaft lobes are positioned pointing away from
the valves.

Correct Clearance Specification


Inlet:
0.10 - 0.15mm
Exhaust: 0.15 - 0.20mm
A_,

CAUTION: If the valve clearances are not


checked (and corrected) wear could
cause the valves to remain partly open, which
lowers performance, burns the valves and valve
seats and may cause serious engine damage.

l,U

VALVE CLEARANCE ADJUSTMENT


Valves are adjusted, in pairs, using tool 3880012 to
hold the valve open during shim removal and
replacement.
1.

Rotate each tappet bucket until the slots in the


buckets are positioned such that they are pointing
to the outside of the head.

Arrange slots to outside of head

Cam Lobe Point Away From Valves

4.

Using feeler gauges, measure and record the


clearances for this cylinder only.

5.

Repeat the process until the valve clearances for


each valve have been checked and recorded.

NOTE:

2.

If the measurement does not fall within the


specified range, adjustment must be made.
The charts which follow describe the method of
selecting as new shim.

2.11

Remove the spark plugs to reduce compression


resistance. Engage a high gear and, with the aid of
an assistant, rotate the engine by turning the rear
wheel forward until the pair of valves to be adjusted
are fully open. Take care to ensure that the tappet
buckets do not turn during opening.

MAINTENANCE

NOTE: The tool mounting plate is marked 'IN' and

3.

4.

'EX' denoting the inlet and exhaust sides of the


tool. Always ensure that the tool assembly
instructions are closely followed to ensure
correct tool operation.
Loosely assemble the tool legs to the mounting
plate ensuring that the legs are assembled to the
correct side of the mounting plate for the valve
shims being changed. For example, if changing
inlet valve shims, the legs must be fitted to the side
marked 'IN'.

6.

Turn the engine over until the camshaft lobes for the
valves to be adjusted point directly away from the
valves. The tool legs will prevent the valves from
rising, allowing the shims to be removed using a soft
faced lever and a magnet.

NOTE:

The shim is often a tight fit in the tappet. Use a


suitable soft faced lever to remove the shim
from the tappet.

Locate the mounting plate to the camshaft caps


above the valves to be adjusted. The tool legs must
face towards the spark plug tubes and be mounted
to the correct side of the tool for the valve shims
being adjusted. Tighten the mounting plate fixings
to 7 Nm.

Removing/Replacing The Shim


5.

Take the selected replacement shim and lubricate


with engine oil. Fit the shim to the top of the tappet
by reversing the removal procedure.

6.

Turn the engine over until the camshaft fully opens


the valves. Remove the tool when the valve is fully
open. Check that the shim has seated correctly and
adjust, if necessary, before proceeding.

Tool in Position on Inlet Camshaft


5.

Hold the tool legs firmly against the mounting plate


and tighten the leg to mounting plate fixings to 7 Nm.

/\.I

CAUTION: With the tool fitted, full 360


rotation of the engine/camshaft is not
possible. The engine must be turned such that the
camshaft lobes turn within the available free space
allowed by the tool. Severe tool and camshaft
damage will result from camshaft contact with the
tool.

NOTE: The tool is designed to allow adjustment of 2

7.

pairs of valves without moving the mounting


plate. This is achieved by moving the tool legs
to a new location once one pair have been
adjusted.
Repeat the procedure until all valves have been
adjusted.

NOTE:

f6
2.12

A shim selection chart can be found on the


following two pages.

Exhaust Valve Clearance Adjustment Chart


MEASURED THICKNESS OF FITTED SHIM
2.oo 1 2.o5J2.1 o 1 2.1sl 2.20 1 2.2512.30 1 2.351 2.4o 1 2.451 2.5o 1 2.5512.60 12.65 12.70 12.75 12.8o 1 2.8512.90 1 2.951 3.oo 1 3.05 1 3.1 o 1 3.15 1 3.2o
0.00-0.04
0.05-0.09
0.10-0.14

2.00

2.00

2.05

2.10 2.15

2.20 2.25

2.30

2.35

2.40 2.45

2.50

2.55

2.60

2.65

2.70 2.75

2.80 2.85

2.90

2.95

3.00

3.05

2.00

2.05

2.10

2.15 2.20

2.25 2.30

2.35

2.40

2.45 2.50

2.55

2.60

2.65

2.70

2.75 2.80

2.85 2.90

2.95

3.00

3.05

3.10

2.05

2.10

2.15

2.20 2.25

2.30 2.35

2.40

2.45

2.50 2.55

2.60

2.65

2.70

2.75

2.80 2.85

2.90 2.95

3.00

3.05

3.10

3.15

3.10

3.15

3.20

3.20

CORRECT CLEARANCE. NO CHANGE OF SHIM REQUIRED

0.15-0.20

()

z
<(

2.25

2.30 2.35

2.40 2.45

2.50

2.55

2.60 2.65

2.70

2.75

2.25

2.30

2.35 2.40

2.45 2.50

2.55

2.60

2.65 2.70

2.75

2.80

2.85

2.90

2.95

3.10

3.15

0.31-0.35

2.15

2.20

2.25

2.30

2.35

2.40 2.45

2.50 2.55

2.60

2.65

2.70 2.75

2.80

2.85

2.90

2.95

3.00 3.05

3.10 3.15

3.20

2.35

2.40

2.45 2.50

2.55 2.60

2.65

2.70

2.75 2.80

2.85

2.90

2.95

300

3.05 3.10

3.15
3.20

2.80

2.85

2.90 2.95
3.00

2.30

0.41-0.45

2.25

2.30

2.35

2.40

2.45

2.50 2.55

2.60 2.65

2.70

2.75

2.80 2.85

2.90

2.95

3.00

3.05

3.10 3.15

0.46-0.50

2.30 2.35

2.40

2.45

2.50

2.55 2.60

2.65 2.70

2.75

2.80

2.85 2.90

2.95

3.00

3.05

3.10

3.15 3.20

()

0.51-0.55

2.35 2.40

2.45

2.50

2.55

2.60 2.65

2.70 2.75

2.80

2.85

2.90 2.95

3.00

3.05

3.10

3.15

3.20

:=i

0.56-0.60

2.40 2.45

2.50

2.55

2.60

2.65 2.70

2.75 2.80

2.85

2.90

2.95 3.00

3.05

3.10

3.15

3.20

0.61-0.65

2.45 2.50

2.55

2.60

2.65

2.70 2.75

2.80 2.85

2.90

2.95

3.00 3.05

3.10

3.15

3.20

1-

0.66-0.70

2.50

2.55

2.60

2.65

2.70

2.75 2.80

2.85 2.90

2.95

3.00

3.05 3.10

3.15

3.20

:::>

0.71-0.75

2.55 2.60

2.65

2.70

2.75

2.80 2.85

2.90 2.95

3.00

3.05

3.10 3.15

3.20

0.76-0.80

2.60 2.65

2.70

2.75

2.80

2.85 2.90

2.95 3.00

3.05

3.10

3.15 3.20

0.81-0.85

2.65

2.70

2.75

2.80

2.85

2.90 2.95

3.00 3.05

3.10

3.15

3.20

0.86-0.90

2.70

2.75

2.80

2.85

2.90

2.95 3.00

3.05 3.10

3.15

3.20

0.91-0.95

2.75 2.80

2.85

2.90

2.95

3.00 3.05

3.10 3.15

3.20

0.96-1.00

2.80 2.85

2.90

2.95

3.00

3.05 3.10

3.15 3.20

1.01-1.05

2.85

2.90

2.95

3.00

3.05

3.10 3.15

3.20

1.06-1.10

2.90 2.95

3.00

3.05

3.10

3.15 3.20

1.11-1.15

2.95 3.00

3.05

3.10

3.15

3.20

1.16-1.20

3.00 3.05

3.10

3.15

3.20

1.21-1.25

3.05

3.10

3.15

3.20

1.26-1.30

3.10 3.15

3.20

1.31-1.35

3.15 3.20

1.36-1.40

3.20

(IJ

<(

J:

><
w
c
w
a:
I

2.20

2.20

2.20 2.25

2.15

2.10 2.15

0.36-0.40

...1

1\)

2.05 2.10

0.26-0.30

a:

<(

.....

0.21-0.25

:::>

(IJ

<(

w
::2:

----------~

3.00
3.05

3.05

3.20

~:::}<(--<(;

0<;;,.(J.
~<(:,.

~~
0
g

EXHAUST VALVE

1.

Measure valve clearance (with engine cold)

2.

Remove shim and measure thickness with a


micrometer

3.

Match measured valve clearance from the left hand


vertical column with measured thickness of
fitted shim.

4.

The shim size specified where the lines


intersect will give correct clearance.

NOTE: If there is no clearance fit a shim


several sizes smaller and re-measure

~
N

1\)

Inlet Valve Clearance Adjustment Chart

MEASURED THICKNESS OF FITTED SHIM


2.10

2.15

2.20

2.25 2.30

2.35 2.40

2.45

2.50

2.55 2.60

2.65

2.70

2.75

2.80

2.85 2.90

2.95

3.00

3.05

3.10

3.15

3.20

2.00

2.05

2.10

2.15 2.20

2.25 2.30

2.35

2.40

2.45 2.50

2.55

2.60

2.65

2.70

2.75 2.80

2.85 2.90

2.95

3.00

3.05

3.10

2.00

2.05

2.10

2.15

2.20 2.25

2.30 2.35

2.40

2.45

2.50

2.60

2.65

2.70

2.75

2.80

2.95

3.00

3.05

3.10

3.15

3.20

2.00 2.05

0.00-0.04
0.05-0.09
0.10-0.15

2.15

2.20

2.25

2.30 2.35

2.40 2.45

2.50

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90 2.95

3.00

3.05

3.10

3.15

0.21-0.25

2.10 2.15

2.20

2.25

2.30

2.35 2.40

2.45 2.50

2.55

2.60

2.65 2.70

2.75

2.80

2.85

2.90

2.95

3.05

3.10

3.15

3.20

0.26-0.30

2.15

2.20

2.25

2.30

2.35

2.40 2.45

2.50 2.55

2.60

2.65

2.70 2.75

2.80

2.85

2.90

2.95

3.00 3.05

3.10 3.15

3.20

0.31-0.35

2.20 2.25

2.30

2.35

2.40

2.45 2.50

2.55 2.60

2.65

2.70

2.75 2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15
3.20

(.)

w
~

2.25

2.30

2.35

2.40

2.45

2.50 2.55

2.60 2.65

2.70

2.75

2.80

2.85

2.90

2.95

3.00

3.05

3.10 3.15

0.41-0.45

2.30 2.35

2.40

2.45

2.50

2.55 2.60

2.65 2.70

2.75

2.80

2.85 2.90

2.95

3.00

3.05

3.10

3.15

0.46-0.50

2.35

2.40

2.45

2.50

2.55

2.60 2.65

2.70 2.75

2.80

2.85

2.90 2.95

3.00

3.05

3.10

3.15

3.20

0.51-0.55

2.40

2.45

2.50

2.55

2.60

2.65 2.70

2.75 2.80

2.85

2.90

2.95

3.00

3.05

3.10

3.15

3.20

2.80 2.85

2.90

2.95

3.00 3.05

3.10

3.15

3.20

3.20

0.56-0.60

2.45 2.50

2.55

2.60

2.65

0.61-0.65

2.50

2.55

2.60

2.65

2.70

2.75 2.80

2.85 2.90

2.95

3.00

3.05 3.10

3.15

1-

0.66-0.70

2.55

2.60

2.65

2.70

2.75

2.80 2.85

2.90 2.95

3.00

3.05

3.10 3.15

3.20

3.15 3.20
3.2o

0.71-0.75

2.60 2.65

2.70

2.75

2.80

2.85 2.90

2.95 3.00

3.05

3.10

0.76-0.80

2.65 2.70

2.75

2.80

2.85

2.90 2.95

3.00 3.05

3.10

3.15

a:

0.81-0.85

2.70 2.75

2.80

2.85

2.90

2.95 3.00

3.05 3.10

3.15

3.20

::::>

(J)

0.86-0.90

2.75 2.80

2.85

2.90

2.95

3.00 3.05

3.10 3.15

3.20

<t

0.91-0.95

2.80

2.85

2.90

2.95

3.00

3.05 3.10

3.15 3.20

0.96-1.00

2.85

2.90

2.95

3.00

3.05

3.10 3.15

3.20

1.01-1.05

2.90 2.95

3.00

3.05

3.10

3.15 3.20

1.06-1.10

2.95

3.00

3.05

3.10

3.15

3.20

1.11-1.15

3.00 3.05

3.10

3.15

3.20

1.16-1.20

3.05

3.10

3.15

3.20

1.21-1.25

3.10 3.15

3.20

1.26-1.30

3.15 3.20

1.31-1.35

3.20

3.00

0.36-0.40

2.70 2.75

...J

CORRECT CLEARANCE. NO CHANGE OF SHIM REQUIRED


2.10

...J

-1>-

2.90

2.05

<t
a:
<t
w
_....

2.85

0.16-0.20

(.)

1\.)

2.55

~"(-.~

~'(!...<(,

3.20

3.20

~'f'-<(;.

0<(,-a

INLET VALVE
1.

Measure valve clearance (with engine cold)

2.

Remove shim and measure thickness with a


micrometer

3.

Match measured valve clearance from the left hand


vertical column with measured thickness of
fitted shim.

4.

The shim size specified where the lines


intersect will give correct clearance.

NOTE: If there is no clearance fit a shim


several sizes smaller and re-measure

S2
~

<
Q

MAINTENANCE 2

ENGINE OIL
The engine oils which are used in all Triumph engines are
the result of careful research over a considerable period
of time. The use of an oil of the correct grade and
viscosity is most important.

The level should be checked when the motorcycle is on


level ground and in an upright position. The engine
should not have been run for at least 10 minutes. Do not
use either stand.

NOTE:

The actual level is indicated when the filler cap


has been screwed in, not when merely rested on
the top face.

1.

Stop engine, then wait for at least 10 minutes to


allow the oil to settle.

2.

Remove the dipstick, wipe clean, then fully replace


and withdraw again to measure the oil level.

Engine Oil Specification


Trident, Trophy, Daytona 1000, 900 & 750, Sprint,
Speed Triple, Tiger, Adventurer, Thunderbird Sport
and Thunderbird.
Semi Synthetic 1OW/40 or 15W/50 motorcycle oil
meeting or exceeding specification API - SG
Daytona 1200 and Daytona Super 3.
Fully Synthetic 1OW/40 or 15W/50 motorcycle oil
meeting or exceeding specification API - SG

If the oil level is too high, remove excess oil using a


syringe or other suitable device. If the oil level is too low,
add sufficient oil through the oil filler opening to bring the
oil to the correct level.

'!'

CAUTION: Triumph high performance


engines are designed to use fully
synthetic or semi-synthetic oil which must meet or
exceed API SG specification.
In particular, due to their increased performance,
the Daytona 1200 and Daytona Super 3 must only
be run on fully synthetic oil which must meet or
exceed API SG specification.
Do not add any chemical additives. The engine oil
also lubricates the clutch and additives could
cause the clutch to slip.

Do not use mineral, vegetable, non-detergent oil,


castor based oils or any oil not conforming to the
required specification as the use of these oils may
cause severe engine damage.
Ensure no foreign matter enters the crankcase
during an oil change or top-up as this will cause
engine damage.

1. Dipstick
2. Upper Oil Level Mark
3. Lower Oil Level Mark
Use only the grade listed for each model in the owner's
handbook and in the specification section of this manual.

Oil Level Inspection, (not Thunderbird,


Thunderbird Sport or Adventurer)

NOTE:

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 and dermatitis. In addition used
engine
oil
contains
potentially
harmful
contaminants which can cause cancer. Wear
suitable clothing and avoid skin contact.

The difference between upper


and lower
dipstick level is approximately 0.5 litres.

Early dipsticks are marked '3 and 4' to indicate 3


or 4 cylinder. This should not be confused with
any type of oil capacity measurement. Later
dipsticks, which are common to 3 and 4 cylinder
engines, are not marked.

WARNING: Motorcycle operation with


insufficient,
deteriorated,
or
contaminated engine oil will cause accelerated
wear and may result in engine or transmission
seizure. Seizure of the engine or transmission may
lead to loss of control and an accident.

The oil level is indicated by a dipstick incorporated in the


filler cap. The dipstick/filler cap is situated on the drive
chain sprocket cover on the left hand side of the
machine.

2.15

MAINTENANCE

NOTE:

Oil Level Inspection, Thunderbird,


Thunderbird Sport & Adventurer

WARNING:
Prolonged or repeated
contact 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 contact.

Stop engine, then wait for at least 10 minutes to


allow the oil to settle.

2.

The oil level is indicated by a sight glass situated on


the right hand side of the lower crankcase. When
the oil level is correct, the level of oil should be half
way up the sight glass.

NOTE:
The actual level is indicated when the
motorcycle is level and upright, not on the side
stand.

1. Sight Glass
2. Filler
3. Filler Plug
3.

If the oil level is too low, remove the plug situated in


the upper rear side of the clutch cover on the right
hand side of the motorcycle.

4.

Add oil, a little at a time, until the oil begins to show in


the sight glass. Then adjust to the correct level and
refit the plug.

If the oil has just been changed, fill the engine


until oil shows in the sight glass, start the
engine and allow to idle for a short time. This
ensures that all areas of the engine are filled
with oil. Stop the engine and allow the oil to
settle for a minimum of two minutes then check
and adjust the oil level.

5.

If the oil level is too high, remove the excess oil,


using a syringe or some other suitable device.

1.

2.16

WARNING: Motorcycle operation with \


insufficient,
deteriorated,
or
contaminated engine oil will cause accelerated
wear and may result in engine or transmission
seizure. Seizure of the engine or transmission may
lead to loss of control and an accident.

MAINTENANCE

.tf

ENGINE OIL AND FILTER

CAUTION: Check all '0' ring seals for


damage. If necessary, replace any
damaged '0' rings to prevent a potential oil leak.

Removal

3.

WARNING: The oil may be hot to the


touch. Contact with hot oil may cause the
skin to be scalded or burned.

Apply a smear of engine oil to the '0' ring on the filter


mounting bolt, fit the filter cover onto the bolt, and
install the spring and flat washer.

WARNING:
Prolonged or repeated
contact 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 contact.

1.

Position the motorcycle on level ground.

2.

Start the motorcycle and allow the engine to reach


normal operating temperature.

3.

Stop the engine.

4.

Place an oil pan beneath the sump.

5.

Remove the engine sump drain plug and allow the


oil to drain completely.

6.

1. Mounting Bolt
3. Spring
5. Filter Element
7. '0' Rings

2. Filter Cover
4. Flat Washer
6. Grommet

4.

Apply a smear of engine oil to the grommets on both


sides of the filter element. Rotate the filter to work
the element into place on the bolt. Ensure that the
grommets do not slip out of place.

5.

Fit the other flat washer.

6.

Install the oil filter, tightening the filter mounting bolt


to 18 Nm.

1. Sump Drain Plug

CAUTION: Replace any damaged sealing


washers before assembling the filter.
Damaged sealing washers may cause an oil leak.

2. Oil Filter Bolt

Installation
1.

After the oil has completely drained out, fit a new


sealing washer to the sump drain plug. Refit the
drain plug and tighten to 48 Nm for M22 drain
plugs and 28 Nm for M14 drain plugs.

7.

Fill the engine with oil of the correct type and grade
listed in the owner's handbook.

8.

Start the engine and allow to run for a short period at


idle speed. Ensure that the oil pressure warning
light extinguishes after starting. Stop the engine
and check for oil leaks.

1'

CAUTION: Do not pour oil on the ground,


down sewers or drains, or into water
courses. To prevent pollution of water courses
etc., dispose of used oil sensibly. If in doubt
contact your local authority.

2.

CAUTION: Stop the engine if the oil light


fails to extinguish. Investigate and rectify
the cause before re-starting the engine. Running
an engine with the oil light on will cause severe
engine damage.

Remove the oil filter and seals from the bolt noting
their relative positions. Thoroughly clean the bolt,
washers and spring and fit a new oil filter.

9.

2.17

Check the oil level and adjust to the correct level.

MAINTENANCE

COOLING SYSTEM

Coolant level inspection - Thunderbird,


Thunderbird Sport & Adventurer

Coolant level inspection {not Thunderbird,


Thunderbird Sport or Adventurer)

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.
1.

Position the motorcycle on level ground and in an


upright position.

2.

Remove the seat.

3.

Check the coolant level in the expansion tank. The


coolant level should be between the 'MAX
and 'MIN' marks.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.
1.

Position the motorcycle on level ground and in an


upright position.

2.

The coolant level should be between the 'MAX' and


'MIN' marks

1. 'MAX' mark
2. 'MIN' mark

1.
2.
3.
4.
4.

Expansion Tank
Expansion Tank Filler Cap
'Max' Mark
'Min' Mark
If the level of coolant is low remove the cap from the
expansion tank, and add coolant mixture to bring
the level up to the 'MAX' mark. Refit the cap.

"J'

CAUTION: If the coolant level is found to


be low, or if coolant has to be added
regularly, inspect the cooling system for coolant
leaks. If necessary, pressure test the system to
locate the source of the leak and rectify as
necessary.
Coolant leaks may result in engine damage
through overheating.

2.18

3.

If it is necessary to add coolant, the fuel tank must


first be removed as described in the fuel system
section.

4.

Remove the cap from the expansion tank, and add


coolant mixture through the filler opening to the
'MAX' mark. Refit the cap.

MAINTENANCE 2
Coolant

A permanent type of antifreeze is installed in the


cooling system when the motorcycle leaves the
factory. It is coloured blue, contains a 50%
solution of ethylene glycol, and has a freezing
point of -35C (-31 F).

If the coolant level is being checked because


the temperature gauge needle has gone into the
red zone, check the coolant level in the radiator.
Top-up if necessary.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

3.

Remove the crankcase coolant drain plug.

4.

Release the water pump drain plug.

WARNING: Coolant mixture which


~ contains anti freeze and corrosion
inhibitors is made from toxic chemicals which are
harmful to the human body.
Never swallow
anti-freeze or any of the motorcycle coolant.

CAUTION:
The coolant anti-freeze
contains a corrosion inhibitor which
helps prevent damage to the metal surfaces inside
the cooling system. Without this inhibitor, the
coolant would 'attack' the metal surfaces and the
resulting corrosion would cause blockages in the
cooling system leading to engine damage through
overheating. Always use the correct anti-freeze as
specified in the owner's handbook. Never use a
methanol based anti-freeze as this does not
contain the required corrosion inhibition
properties.

1. Crankcase Drain Plug


2. Water Pump Drain Plug

CAUTION: Distilled water must be used


with the anti-freeze (see specification for
antifreeze) in the cooling system.

Filling (Not Thunderbird, Thunderbird


Sport or Adventurer)

If hard water is used in the system, it causes scale


accumulation in the water passages, and
considerably reduces the efficiency of the cooling
system. Reduced cooling system efficiency may
lead to the engine overheating and suffering
severe damage.

1.

Refit the cylinder block drain plug and tighten to 13


Nm.

2.

Refit the water pump drain plug and tighten to


13 Nm.

3.

Slowly add coolant mixture to the system, through


the radiator filler, until the radiator is full.

4.

Start the motorcycle and allow the engine to idle for


a short period of time to allow any air to be expelled
from the system. Stop the engine and top up the
coolant level as necessary.

5.

Fit the coolant pressure cap.

6.

Check the expansion tank level and top up if


necessary.

7.

Refit the bodywork where necessary.

COOLANT REPLACEMENT
Drainage (all models)
1.

Remove the seat and lower fairing panels where


necessary. Place a container beneath the left hand
side of the machine to collect the displaced coolant.

2.

Remove the coolant pressure cap to help drainage.

2.19

2
8.

MAINTENANCE

Carry out a short road test to warm the engine to


normal operating temperature. Allow the engine to
cool and recheck the coolant level. Adjust as
necessary

RADIATOR HOSES

'!'

CAUTION: Some models are fitted with


crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.

Filling (Thunderbird, Thunderbird Sport &


Adventurer)

1.

Refit the cylinder block drain plug and tighten to 13


Nm.

2.

Refit the water pump drain plug and tighten to


13 Nm.

Regularly
check
all
radiator
hoses
for
cracks/deterioration and examine hose clips for security
in accordance with the periodic maintenance chart.

3.

Remove the fuel tank as described in the fuel


system section.

RADIATOR AND COOLING FAN

Check the radiator fins for obstruction by insects, mud,


leaves and general debris. Clean off any obstructions by
hand or with a stream of low pressure water.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury, could result from
spilled fuel or fuel not handled and stored in the
correct manner.
4.

Release the bleed screw on the top of the


thermostat housing.

WARNING: The cooling fan operates


automatically, even with the ignition
switch off. To prevent personal injury, keep hands
and clothing away from the fan blades at all times.
{',

CAUTION: Using high-pressure water,


such as from a car-wash facility, can
damage the radiator fins and impair the radiator's
efficiency.

Do not obstruct or deflect airflow through the


radiator by installing unauthorized accessories in
front of the radiator or behind the cooling fan.
Interference with the radiator airflow can lead to
overheating and consequent engine damage.

NUTS, BOLTS, FASTENERS- CHECK


SECURITY

1 . Thermostat housing
2. Coolant filler
3. Bleed Screw
5.

Inspect all areas of the motorcycle, at the intervals


specified in the periodic maintenance chart, for loose
fasteners etc.
Tighten any loose fasteners in
accordance with the torque chart.

Slowly add coolant mixture to the system through


the filler until the system is full. Close the bleed
screw.

6.

Temporarily refit the fuel tank. Start the motorcycle


and allow the engine to idle for a short period of time
to allow any air to be expelled from the system. Stop
the engine and top up the coolant level as
necessary.

7.

Fully refit the fuel tank as described in the fuel


system section.

WARNING: Fasteners must be inspected


at the specified interval and, if necessary,
tightened using a torque wrench of known,
accurate calibration. Failure to check and tighten
fasteners at the specified interval may result in
instability, loss of control and an accident.

2.20

MAINTENANCE 2

CLUTCH
The motorcycle is equipped with a hydraulically operated
clutch that requires no adjustment except for inspection
of the hydraulic fluid level in accordance with the periodic
maintenance chart.

A
.41&

WARNING: Ensure absolute cleanliness


when adding clutch fluid to the clutch
fluid reservoir. Do not allow moisture or debris to
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.
Always check for fluid leakage around hydraulic
fittings and for damage to hoses.

1. Fluid Reservoir (cover removed)


2. Upper Level
(except Thunderbird Sport)

A dangerous riding condition leading to an


accident could result if this warning is ignored.

CAUTION: To prevent body damage, do


not spill clutch fluid onto any area of the
bodywork.

A
.41&

WARNING: Use only DOT. 4 specification


clutch fluid as listed in the general
information section of this manual. The use of
clutch fluids other than those DOT. 4 fluids listed
in the general information section may reduce the
efficiency of the clutch system leading to an
accident.
1. Upper Fluid Level
2. Lower Fluid Level
(Thunderbird Sport)

Clutch Fluid Level Inspection


1.

The fluid level in the reservoir must be kept


between the upper and lower level lines (reservoir
held horizontal).

Clutch Fluid, Hose and Hydraulic Seals


Renew the clutch fluid, the hose and the hydraulic
seals in the master and slave cylinders in accordance
with the periodic maintenance chart.

A
.41&

WARNING: Failure to change clutch fluid,


hose and hydraulic seals at the specified
interval could result in reduced clutch efficiency
leading to loss of control and an accident.

1. Fluid Reservoir
2. Lower Fluid Level
(except Thunderbird Sport)

2.21

2 MAINTENANCE
CARBURETTORS

NOTE:

Carburettor Synchronisation

WARNING: In the following procedure,


. . . . the motorcycle engine must be run. The
exhaust fumes given off by the engine, when
running, contain carbon monoxide and other toxic
gases. Never start or leave the engine running in a
confined space unless an exhaust extraction
system is available and is connected directly to the
motorcycle exhaust system. If such a system is
not available, ensure that the building is
adequately ventilated to prevent a build up of
gases.
Remember, carbon monoxide is a
colourless, odourless gas which will cause
unconsciousness or death if inhaled in sufficient
quantity.

Any vacuum pipes to the fuel tap or evaporative


loss system may be disconnected and sealed
during the adjustment procedure.

6.

Support the vacuum gauges and position the fuel


tank adjacent to, and higher than, the carburettors.
Refit the fuel pipes to the carburettors.

ON
ALL
MODELS
EXCEPT
TIGER.
THUNDERBIRD. THUNDERBIRD SPORT &
ADVENTURER, Turn the fuel tap to the 'PRI'
position.
ON TIGER, THUNDERBIRD & ADVENTURER,
turn the fuel tap to the 'ON' position

7.

The carburettors are now ready for the adjustment


process to begin. Start the engine and allow it to idle
whilst measuring the intake vacuum for each
carburettor.

8.

On 4 cylinder engines the carburettor for number 3


cylinder is designated as a 'master' carburettor. On
3 cylinder engines, the 'master' carburettor is the
centre carburettor.
The adjustment process
matches the vacuum settings for the remaining
carburettors to the 'master' carburettor.

--------------------------

1.

Start motorcycle and allow the engine to reach


normal operating temperature.

2.

Check that the idle speed is between 950 and 1050


rpm (r/min). Adjust as necessary by turning the idle
adjusting screw on the left hand side of the
carburettors.

Vacuum at idle speed should read between 5.00


and 6.00 inches Hg (127-152 mm Hg).
9.

1. Idle Speed Adjustment


3.

4.

Open and close the throttle several times to check


that the idle speed does not fluctuate from the
original setting. Re-adjust as necessary then stop
the engine.
Remove the fuel tank as described in the fuel
system section.

10. Once the vacuum setting for the master carburettor


has been set, match the remaining carburettor
settings to the master carburettor by turning the
adjuster screws (A, B and C in the diagram right).
Once all vacuum settings are matched, reset the
idle speed and stop the engine.

NOTE:

The adjustment is very sensitive. A small


change in the adjuster position will significantly
affect the vacuum setting for the carburettor.

Each time a synchronisation adjustment is


made, idle speed should also be checked and
adjusted to between 950 and 1050 rpm (r/min).

Number one cylinder is the outer left hand


cylinder when viewed from the riding position.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire causing personal injury and damage to
property could result from spilled fuel or fuel not
handled and stored in the correct manner.

5.

Set the vacuum on the 'master' carburettor by


turning the idle speed adjuster.

Adjuster A affects cylinder No 1 on 3 & 4


cylinder engines.
Adjuster B affects cylinder No 4 on 4 cyl engines
and cylinder No 3 on 3 cylinder engines.
Adjuster C affects cylinder number 2 on 4
cylinder engines only.
11. Remove the fuel tank and disconnect the vacuum
gauges. Refit all vacuum pipes disconnected for the
adjustment process. Refit the fuel tank

Attach a set of vacuum gauges, one to each


carburettor. The vacuum take off connections are
on top of each carburettor, adjacent to the
diaphragm cover.

2.22

MAINTENANCE 2

4 Cylinder

FWD

Master Carburettor

3 Cylinder

'FWD
1. Blanking Caps
2. Fuel Tap Vacuum Pipe* (From Centre Carb On 3 Cyl)
3. Vacuum Gauge
*Not Fitted On Tiger, Thunderbird, Thunderbird Sport or Adventurer

2.23

MAINTENANCE

THROTTLE GRIP

CHOKE LEVER

If the throttle grip has excessive free-play, it will cause a


delay in throttle response, especially at low engine
speed. Also, the throttle valves may not open fully at full
throttle causing a significant reduction in the top speed of
the machine. Alternatively, if the throttle grip has no
free-play, the throttle will be hard to control, and idle
speed will be erratic. Check the throttle grip free-play
periodically in accordance with the periodic maintenance
chart.

The motorcycle is fitted with a cold start or choke device.


The cable which controls the cold start device may
occasionally require adjustment and should be checked
for correct operation and adjustment in accordance with
the Periodic Maintenance requirement.

Inspection
1.

Inspection
1.

Check that there is 2-3 mm (0.08-0.12 in.) of


free-play in the throttle grip when lightly turning
throttle grip back and forth.

2.

1. Throttle Grip
2. 2-3 Mm Free Play
1. Choke lever
2. Correct adjustment, 2-3mm of free play

Adjustment
1.

If the free play measured is incorrect, make


adjustments as detailed in the fuel system
section.

3.

To determine the amount of free-play at the choke


lever, pull the choke lever until the starter plunger
lever at the carburettor touches starter plunger. If
correct, there should be 2-3mm of free play at the
choke lever.

WARNING: Operation of the motorcycle


with an incorrectly 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 the motorcycle and an
accident.

WARNING: Move the handlebars to left


and right full lock while checking that
cables 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. Starter Plunger Lever
2. Starter Plunger

2.24

MAINTENANCE

NOTE:

Adjustment
1.

If the free play measured is incorrect, make


adjustments as detailed in the fuel system
section.

Note the relative positions of all low and high


tension cables prior to disconnection.

8.

Remove the choke cable from the carburettors by


releasing the cable locknut and fully unscrewing the
adjuster. Lift the cable to release from the location
slot and turn the nipple on the inner cable to detach
from the choke mechanism.

9.

Slacken the clips securing the carburettor rubbers


to the cylinder head.

WARNING: Operation of the motorcycle

~ with an incorrectly adjusted, incorrectly


routed or damaged' choke cable could interfere
with the operation of the brakes, clutch or the
choke itself. Any of these conditions could result
in loss of control of the motorcycle and an
accident.

10. Remove the carburettors from the cylinder head,


complete with rubbers, using a gentle rocking
motion.

WARNING: Move the handlebars to left


and right full lock while checking that
cables and harnesses do not bind. A cable or
harness which binds will restrict the steering and
may cause loss of control and an accident.

AIR INTAKE ASSEMBLY

WARNING:

Never attempt to run the

~ engine with the air intake removed. Any

debris which enters the carburettors could cause


the throttle to stick, possibly causing loss of
control and an accident.
Never obstruct the air intake pipes as engine
damage may result.

Removal (not Thunderbird, Thunderbird


Sport or Adventurer)
NOTE:

In order to gain access to the airbox assembly,


the seat, battery, side panels and fuel tank must
first be removed as described in the electrical,
body and fuel sections respectively.

1.

Remove the air intake duct(s) from the auxiliary


chambers (left hand only on Tiger models).

2.

Remove both auxiliary chambers by releasing the 2


bolts which secure each chamber to the frame.

3.

Remove the rubber gaiters from the air box.

4.

Slacken the clips securing the airbox to the


carburettors.

5.

Detach the air box and pull back from the


carburettors as far as possible.

6.

Remove the cam cover cowls and foam seal.

7.

Detach the low tension connectors from the coils.


Remove the ignition coils from the frame spine tube,
complete with spark plug leads.

1.
2.
3.
4.
5.

Air Intake Duct


Auxiliary Chamber
Rubber Gaiter
Venturi Intake Rubbers
Airbox

11. While supporting the carburettors, disconnect the


throttle cable as follows: Release the outer cable
locknut and fully unscrew the outer cable adjuster.
Lift the cable adjuster from its slot and turn the
nipple on the end of the inner cable to detach from
the throttle cam. Remove the carburettor assembly.
12. Release the clip securing the airbox breather pipe
to the clutch cover or breather cover (depending on
cylinder configuration) and detach the pipe. Note
the pipe routing in order to correctly route the pipe
on assembly.
13. Remove the air box complete with the air box drain
pipe.

2.25

MAINTENANCE

10. Position the vacuum and fuel pipes between the


main frame and the air box.

f,\

CAUTION: Tape over the inlet ports on


~ the cylinder head to prevent any debris
from entering the inlet ports. Any debris which is
allowed to enter the inlet ports could cause severe
engine damage.

11.

NOTE:

The air cleaner can only be replaced as a


complete assembly.
No separate air filter
element is available for any Triumph model
Consequently, the airbox cannot be dismantled
and the element cannot be removed or cleaned.

12. Fit the ignition coil connectors ensuring that the


electrical connections are re-made as noted during
disconnection.
13. Check the condition of all electrical connections.
14. Fit the cam cowl seal in an upright position over
choke cable and locate the ignition leads.
15. Ensure the spark plug leads are correctly fitted to
the spark plugs.

Installation (not Thunderbird, Thunderbird


Sport or Adventurer)
1.

Fit the ignition coils and secure to the frame spine


tube.

Check the condition of the venturi intake rubbers


and the positions of expansion rings in the air box.
Position the airbox.

2.

Feed the air box drain pipe between the alternator


earth strap and the alternator. Feed the drain pipe
into the left hand centre stand spring (where fitted).

3.

Position the air box in the frame to allow fitment of


the carburettors to the head and later fitment of the
airbox to the carburettors.

16. Reconnect the choke cable using a reversal of the


process used in removal.
17. Check the operation of the choke system. Also
check that the clutch hose is correctly clipped to the
water elbow and does not foul the choke operation
bar. Set the adjustment of the choke cable as
described in the fuel system section.

4.

Re-connect the throttle cable to the carburettors


using a reversal of the removal process. Ensure
both the inner and outer cables are seated correctly
by turning the throttle back and forth and checking
for smooth operation.

WARNING: Operation of the motorcycle


with an incorrectly adjusted, incorrectly
routed or damaged choke cable could interfere
with the operation of the brakes, clutch, throttle or
may cause the choke to stick. Any of these
conditions could result in loss of control of the
motorcycle and an accident.

5.

Align the carburettors to the head ensuring all fuel


and vacuum hoses are positioned upwards to
prevent accidental damage or trapping.

18. Attach the air box breather hose and secure to


either the clutch cover or breather cover (depending
on cylinder configuration).

6.

Fit the carburettors to the cylinder head. Set the


throttle cable adjustment as described in the fuel
system section.

19. Check for the correct free operation of the throttle.


Re-adjust if necessary

,-------------

----~

WARNING: Operation of the motorcycle


with an incorrectly adjusted, incorrectly
routed or damaged throttle cable could interfere
with the operation of the brakes, clutch or may
cause the throttle to stick. Any of these conditions
could result in loss of control of the motorcycle
and an accident.

~------~

WARNING: Operation of the motorcycle


with an incorrectly adjusted, incorrectly
routed or damaged throttle cable could interfere
with the operation of the brakes, clutch or may
cause the throttle to stick. Any of these conditions
could result in loss of control of the motorcycle
and an accident.

------~-----------

7.

Fit the air box to the carburettors ensuring all


rubbers are correctly seated.

8.

Securely tighten all carburettor and airbox retaining


clips.

9.

Position the carburettor vent hoses in the space


between the outer and inner carburettors.

WARNING: Move the handlebars to left


and right full lock while checking that
cables and harnesses do not bind. A cable or
harness which binds will restrict the steering and
may cause loss of control and an accident.
20. Fit the rubber gaiters to the air box.

2.26

MAINTENANCE

21. Fit the auxiliary chambers into the rubber gaiters


and align to the battery box flanged sleeves.

4.

Detach the air box and pull back from the


carburettors as far as possible.

22. Fit the screws and nut to secure the auxiliary


chambers. Tighten to 9 Nm.

5.

Detach the low tension connectors from number 3


coil. Remove the coil from the frame spine tube,
complete with spark plug lead.

23. Fit the air intake ducts.

NOTE:
NOTE:

It is advisable to check carburettor settings


once the airbox has been disturbed.
In
particular, check idle speed, choke operation
and vacuum settings.
In all cases, these
adjustments must be made before fitting the
fuel tank and bodywork.

Removal (Thunderbird, Thunderbird Sport


& Adventurer)

WARNING: Never attempt to run the


engine with the air intake removed. Any
debris which enters the carburettors could cause
the throttle to stick, possibly causing Joss of
control and an accident.
Never obstruct the air intake pipes as engine
damage may result.

Note the relative positions of the low and high


tension cables prior to disconnection.

6.

Remove the choke cable from the carburettors.

7.

Slacken the clips securing the carburettor rubbers


to the carburettors.

8.

Detach the carburettors from the rubbers using a


gentle rocking motion and slide the carburettors to
the left hand side of the motorcycle.

9.

While supporting the carburettors, disconnect the


throttle cable.

10. Taking care not to damage the coolant bypass


hose, remove the carburettors.
11.

NOTE:

In order to gain access to the airbox assembly,


the seat, side covers, airbox covers, horn, horn
bracket and fuel tank must first be removed as
described in the body and fuel sections
respectively.

1.

Release the clips securing the airbox auxiliary


chamber to the airbox.

2.

Release the screw securing the auxiliary chamber


to the seat rail and remove the auxiliary chamber.

A.

CAUTION: Tape over the inlet ports on


the cylinder head to prevent any debris
from entering the inlet ports. Any debris which is
allowed to enter the inlet ports could cause severe
engine damage.

NOTE:

The air cleaner can only be replaced as a


complete assembly.
No separate air filter
element is available for any Triumph model
Consequently, the airbox cannot be dismantled
and the element cannot be removed or cleaned.

Installation (Thunderbird, Thunderbird


Sport & Adventurer)

1. Airbox Securing Screw


3.

Release the breather hose from the airbox and


remove the airbox.

Release the clips securing the airbox to the


carburettors.

2.27

1.

Check the condition of the venturi intake rubbers


and the positions of expansion rings in the air box.
Position the airbox.

2.

Feed the air box drain pipe between the alternator


earth strap and the alternator.

3.

Position the air box in the frame to allow fitment of


the carburettors to the head and later fitment of the
airbox to the carburettors.

MAINTENANCE

4.

Position the carburettors to allow reconnection of


the throttle cable. Re-connect the throttle cable to
the carburettors using a reversal of the removal
process. Ensure both the inner and outer cables
are seated correctly by turning the throttle back and
forth and checking for smooth operation.

5.

Align the carburettors to rubbers ensuring the


coolant bypass hose, fuel and drain hoses are
positioned correctly to prevent entrapment or
damage,

6.

Connect the breather pipe to the airbox.

7.

Fit the air box to the carburettors ensuring all


rubbers are correctly seated.

8.

Tighten all carburettor and airbox retaining clips.

9.

Position the carburettor vent hoses in the space


between the outer and inner carburettors.

18. Refit the seat, side covers, airbox covers, horn


bracket, horn and fuel tank.

NOTE:

It is advisable to check carburettor settings


In
once the airbox has been disturbed.
particular, check idle speed, choke operation
and vacuum settings.
In all cases, these
adjustments must be made before fitting the
fuel tank and bodywork.

AIRBOX DRAIN PIPE

10. Reconnect the choke cable using a reversal of the


process used in removal.
11.

17. Refit the airbox auxiliary chamber using a reversal


of the removal process. Ensure that the auxiliary
chamber securing screw and the airbox to auxiliary
chamber clips are correctly tightened.

Fit the ignition coil and secure to the frame spine


tube.

The air box drainpipe must be drained in accordance


with the periodic maintenance chart.
1.

Remove the plug from the drain pipe to allow any


fluid which has accumulated in the pipe to drain out.

2.

Refit the plug

FUEL SYSTEM

12. Fit the ignition coil connectors ensuring that the


electrical connections are re-made as noted during
disconnection.

Check the fuel system for leaks, damaged, kinked or split


pipes in accordance with the periodic maintenance chart.
Renew any suspect components.

13. Check the condition of all electrical connections.

Renew the fuel hoses in accordance with the periodic


maintenance chart.

14. Ensure the spark plug leads are correctly fitted to


the spark plugs.
15. Check the operation of the choke system. Also
check that the clutch hose is correctly clipped to the
water elbow and does not foul the choke operation
bar. Set the adjustment of the choke cable as
described in the fuel system section.

A.

WARNING: Operation of the motorcycle

~ with an incorrectly adjusted, incorrectly


routed or damaged choke cable could interfere
with the operation of the brakes, clutch, throttle or
may cause the choke to stick. Any of these
conditions could result in loss of control of the
motorcycle and an accident.

16. Check for the correct free operation of the throttle.


Re-adjust if necessary

A.

WARNING: Operation of the motorcycle

~ with an incorrectly adjusted, incorrectly


routed or damaged throttle cable could interfere
with the operation of the brakes, clutch or may
cause the throttle to stick. Any of these conditions.
could result in loss of control of the motorcycle
and an accident.

2.28

WARNING: Failure to change fuel hoses


. . . at the specified intervals may result in a
fuel leak. Any fuel leak could cause a fire leading to
personal injury and damage to property.

MAINTENANCE

Minimum Recommended Tread Depth

TYRE WEAR/WHEEL INSPECTION


As the tyre tread wears down, the tyre becomes more
susceptible to puncture and failure. It is estimated that
90% of all tyre failures occur during the last 10% of tread
life (90% worn). It is false economy and unsafe to use
tyres until they are worn to their minimum.
All tyres are fitted with tread wear indicators. When the
tyre becomes worn down as far as the top of a tread wear
indicator, the tyre is worn beyond its service life and must
be replaced.

The following chart can be used as a guide to the


minimum safe tread depth.
Under 130 km/h (80mph) 2 mm (0.08 in)
Over 130 km/h
(80 mph)

Rear 3 mm (0.12 in)


Front 2 mm (0.08 in)

WARNING: Triumph motorcycles must


not be operated above the legal road
speed limit except in authorised closed course
conditions.

For further details of wheel and tyre inspection


and for tyre replacement information, refer to the
Wheei/Tyre section of this manual.

Typical
Tread
Wear --l~~M---1----tr.-r
Indicator -

In accordance with the periodic maintenance chart,


measure the depth of the tread with a depth gauge, and
replace any tyre that has worn to, or beyond the minimum
allowable tread depth.
Inspect wheels for cracks, splits and damage. Inspect
Tiger, Thunderbird, Thunderbird Sport & Adventurer
wheels for similar damage and also check spokes for
corrosion, looseness and breakage. Always replace
wheels that are suspected 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 tubeless tyres become punctured, leakage
is often very slow. Always inspect tyres very
closely for punctures.
Check the tyres for cuts, imbedded nails or other
sharp objects. On spoked wheels, check spokes
for looseness and damage.
Check the rims for dents or deformation.
Operation with damaged or defective wheels or
tyres is dangerous and loss of control or an
accident could result.
Always consult your Triumph Dealer for tyre
replacement, or for a safety inspection of the tyres.

2.29

MAINTENANCE

DRIVE CHAIN
The drive chain must be checked, adjusted, and
lubricated in accordance with the periodic maintenance
chart. For reasons of safety, and to prevent excessive
wear, never neglect any part of the drive chain
maintenance. If the chain is badly worn, or incorrectly
adjusted -either too loose or too tight -the chain could
jump off the sprockets or break. Checking of the
adjustment and lubrication should be carried out more
frequently where the machine is regularly used in dirty or
dusty conditions or where large amounts of road salt are
used.

1. Tiger Chain Slider

WARNING: A chain that breaks or jumps


off the sprockets could snag on the
engine drive sprocket or the rear wheel severely
damaging the motorcycle and causing an
accident. Never neglect chain maintenance.

4.

If correct, the vertical movement of the drive chain


midway between the sprockets should be 35-40
mm (25-30mm on Thunderbird, Thunderbird
Sport & Adventurer).

Drive Chain Replacement


Replace the drive chain when worn beyond the service
limit (refer to drive chain wear inspection). For details of
the renewal procedure, refer to the rear suspension/final
drive section.

Chain Slack Inspection


1.

Set the motorcycle up on either the side or centre


stand.

2.

Check the rear wheel alignment by reference to the


rear wheel alignment instructions later in this
section. Adjust if necessary.

3.

Rotate the rear wheel to find the position where the


chain has least slack. Measure the chain's vertical
movement, mid-way between sprockets.

1. Vertical Movement 35-40mm (25-30mm on


Thunderbird, Thunderbird Sport & Adventurer)

Drive Chain Slider (Tiger)


The drive chain slider must be replaced in accordance
with the periodic maintenance chart.

NOTE:

On Tiger models, a chain slider is fitted which, if


worn, will allow excessive chain slack. Always
check the chain slider and, if necessary, renew
before changing any other adjustments.
Always carry out the chain adjustment process
after renewing the chain slider.
The slider is bolted to the frame, immediately
behind the sprocket cover.

2.30

MAINTENANCE

Chain Slack Adjustment


(eccentric adjuster method)

7.

Re-check the rear wheel alignment and adjust if


necessary.

1.

Loosen both the left and right hand


eccentric adjuster clamp bolts.

Chain Slack Adjustment (adjustable wheel


spindle method)

2.

Insert Allen wrenches into the hexagonal holes in


the eccentric adjusters.
Turn both eccentric
adjusters equally forwards or rearwards until the
drive chain has the correct amount of slack.

1.

3.

Tighten both eccentric adjuster clamp bolts to


36 Nm.

WARNING: Operation of the motorcycle


with insecure eccentric adjuster clamp
bolts may result in impaired stability and handling
of the motorcycle. This impaired stability and
handling may lead to loss of control or an accident.
4.

Check the rear wheel alignment and adjust if


necessary

5.

Rotate the rear wheel, measure the chain slack


again at the tightest position, and re-adjust if
necessary.

Swinging Arm Markings


Adjuster Collar Notch
Wheel Spindle Nut
Adjuster

2.

If the chain is too loose, turn the left and right hand
adjuster screws evenly outwards until the correct
amount of chain slack is present.

3.

If the chain is too tight, turn the left and right hand
adjuster screws evenly inwards.

NOTE:

I
2
1. Adjuster Clamp Bolt
2. 12mm Allen Wrench
3. Eccentric Adjuster
6.

1.
2.
3.
4.

Check for correct rear brake effectiveness by


pumping the brake pedal.

Before checking the chain slack, push the rear


wheel forward.

4.

Tighten the locknuts on the adjuster screws.

5.

Tighten the wheel spindle nut to 85 Nm.

6.

Check the rear wheel alignment and adjust as


necessary.

WARNING: Operation of the motorcycle


with insecure axle or adjuster fixings may
result in motorcycle instability, loss of control and
an accident.

1. Rear Brake Pedal


2.31

7.

Rotate the rear wheel and repeat the adjustment


check. Readjust if outside the 25-30mm limit.

8.

Check for correct operation of the rear brake.

MAINTENANCE

Wheel Alignment
(eccentric adjuster method)
1.

WARNING: Operation of the motorcycle

~ with insecure eccentric adjuster clamp

bolts may result in impaired stability and handling


of the motorcycle. This impaired stability and
handling may lead to loss of control or an accident.

Remove the retaining rings from the wheel


spindle ends.

6.

Tighten the axle bolts to 85 Nm.

7.

Insert both retaining rings to secure the wheel


spindle.

8.

Check the chain slack as previously described.

Wheel Alignment (adjustable wheel


spindle method)

1. Axle Bolt
2. Eccentric Adjuster Clamp Bolt
3. Retaining Rings
2.

Loosen the axle bolts.

3.

Loosen both the left and right hand eccentric


adjuster clamp bolts.

4.

Turn the eccentric adjusters until the notches on


both sides of the swinging arm point to the same
marks on left and right adjusters. For example, if the
left hand notch aligns with an eccentric adjuster
mark 5 from the front, then the right hand eccentric
adjuster should also align with a mark 5 from the
front.

1.

Loosen the locknuts on both the left and right hand


adjuster screws.

2.

Loosen the wheel spindle nut.

3.

Turn each adjuster screw so that the notches on the


adjuster collars point to the same marks on both
sides of the swinging arm.

4.

Tighten the locknuts on the adjuster screws.

5.

Tighten the wheel spindle nut to 85 Nm.

6.

Check the chain slack setting and adjust as


necessary.

WARNING: Operation of the motorcycle


with insecure axle or adjuster fixings may
result in motorcycle instability, loss of control and
an accident.
Misalignment of the wheel will result in abnormal
tyre wear. Worn tyres may impair the stability and
handling of the motorcycle which may lead to an
accident.

1--~~__;~~

2----~~~~~~~~
1. Eccentric Adjuster Marks

2. Swinging Arm Notch

1,\

CAUTION: The settings depicted are for


reference only. The actual setting will
vary on different motorcycles.

5.

1.
2.
3.
4.

Tighten the adjuster clamp bolts to 36 Nm.

2.32

Swinging Arm Markings


Adjuster Collar Notch
Wheel Spindle Nut
Adjuster

MAINTENANCE 2

Chain Lubrication
Chain lubrication is necessary after riding through rain,
standing water, on wet roads, or any time that the chain
appears dry. Use the chain lubricant recommended in
the specification.

1\.

CAUTION: Never use a power wash


system to clean the chain as this may
cause damage to the chain components.

1.

Apply chain lubricant to the sides of the chain


rollers, and also the 0-rings. The lubricant will
penetrate the rollers and bushings and also prevent
the 0-rings from deterioration.

1. Measurement Position
2. 10-20kg Weight
4.

If the length exceeds the service limit of 319 mm, the


chain must be replaced.

WARNING: Use a genuine Triumph


supplied chain as specified in the
Triumph Parts Catalogue.
The use 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
wheel, severely damaging the motorcycle and
causing loss of motorcycle control and an
accident.
Never neglect chain maintenance and always have
chains installed by an authorised Triumph Dealer.
Chain Lubrication Positions
2.

Wipe off any excess oil.

3.

If the chain is especially dirty, clean using paraffin


before applying the lubricant.

5.

Examine the whole length of the chain. If there are


any excessively tight or loose sections, loose pins
or damaged rollers, the chain should be replaced.

6.

Inspect sprockets for unevenly or excessively worn


teeth. Also examine the sprockets for damaged
teeth.

Chain Wear Inspection

Worn Tooth
(Engine Sprocket)
1.
2.
3.

Worn Tooth
(Rear Sprocket)

Remove the chain/wheel guard from the


swinging arm.
Stretch the chain taut by hanging a 10-20 kg (20-40
lb) weight on the chain.
Measure a length of 20 links on the straight part of
the chain from pin centre of the 1st pin to pin centre
of the 21st pin. Repeat the test at various sections
of the chain to establish an average reading. This is
because the chain may wear unevenly.

(Wear exaggerated for clarity of information)

NOTE:

2.33

Sprocket wear is exaggerated for illustration.

7.

If there is any irregularity found in any of the


components, replace the drive chain and/or any
other damaged components.

8.

Refit the chain/wheel guard.

2 MAINTENANCE
BRAKES

WARNING: Use only DOT. 4 specification


brake fluid as listed in the general
information section of this manual. The use of
brake fluids other than those DOT. 4 fluids listed in
the general information section may reduce the
efficiency of the braking system leading to an
accident.

BRAKING SYSTEM MAINTENANCE SAFETY


PRECAUTIONS

WARNING: Brake fluid is hygroscopic


which means it will absorb moisture from
the air. The absorbed moisture will greatly reduce
the boiling point of the brake fluid causing a
reduction in braking efficiency.

Failure to change the brake fluid at the interval


specified in the periodic maintenance chart may
reduce braking efficiency resulting in an accident.

Replace brake fluid in line with the Periodic


Maintenance chart. A dangerous riding condition
could result if this important maintenance item is
neglected!
Do not spill brake fluid onto any area of the
bodywork as this will damage any painted or
plastic surface.

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.

Always use new brake fluid from a sealed


container and never use fluid from an unsealed
container or from one which has been previously
opened.
Do not mix different brands of fluid. 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.

Damage caused by contact with mineral based


grease may reduce braking efficiency resulting in
an accident.

ASBESTOS
This warning may apply to
the following components or
any assembly containing
any of these components:-

WARNING
CONTAINS
ASBESTOS

WARNING: If there has been an


~ appreciable drop in the level of the fluid in
either brake fluid reservoir, consult your
authorized Triumph Dealer for advice before
riding.

Brake Shoes or Pads

Breathing asbestos
dust is dangerous
to health
Follow safety
instructions

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 may be defective.

SAFETY INSTRUCTIONS

It is dangerous to operate the motorcycle under


such conditions and remedial action must be
taken by your authorized Triumph Dealer before
riding the motorcycle.

Failure to take remedial action may reduce braking


efficiency leading to an accident.

2.34

Operate if possible out of doors or in a well


ventilated place.

Preferably use hand tools or low speed tools


equipped with an appropriate dust extraction
facility.

Dampen dust and place in a properly closed


receptacle. Dispose of the closed receptacle
safely.

Never use an airline to blow dust from


components

MAINTENANCE

DISC BRAKE FLUID


In accordance with the periodic maintenance chart,
inspect the brake fluid level in the front and rear master
cylinder reservoirs. In addition, the brake fluid must be
regularly replaced, in accordance with the periodic
maintenance chart, to help prevent brake failure.

Fluid Level Inspection


1.

Ensure the brake fluid level in both the front and rear
brake fluid reservoir is between the upper and lower
level lines (reservoir held horizontal).

1. Front Reservoir Upper Level


2. Front Reservoir Lower Level
(Thunderbird Sport)

1. Front Reservoir Lower Level (all except


Thunderbird Sport)

1. Rear Reservoir Upper Level


2. Rear Reservoir Lower Level

CHANGING BRAKE FLUID, BRAKE


HOSES AND HYDRAULIC SEALS
Brake fluid, brake hoses and hydraulic seals in the
master cylinders and calipers should be changed in
accordance with the periodic maintenance chart.

WARNING: Failure to change brake fluid,


hoses and hydraulic seals at the
specified interval could result in reduced brake
efficiency leading to loss of control and an
accident.

1. Front Reservoir Upper Level (all except


Thunderbird Sport)

2.35

MAINTENANCE

BRAKE PADS

Front and rear brake pad wear is automatically


compensated for and has no effect on brake lever or
pedal action.

BRAKE WEAR INSPECTION


In accordance with the periodic maintenance chart,
inspect the brake pads for wear.
The minimum thickness of lining material for any front or
rear brake pad is 1.5 mm. If any pad has worn to the
bottom of the groove in the pad centre, replace all the
brake pads on that wheel.

1. Lining Material Thickness


2. Centre Groove

2.36

WARNING: Do not replace individual


brake pads, replace both pads in the
brake caliper. If two calipers are mounted on the
same wheel, all the pads on the wheel must be
replaced together. Replacing individual pads will
reduce braking efficiency and may cause an
accident.

BRAKE LIGHTS
Check the brake lights for correct operation, on both front
and rear brakes, in accordance with the periodic
maintenance chart.

MAINTENANCE 2
STEERING

WARNING: Move the handlebars to left


. . . . and right full lock while checking that
cables and harnesses do not bind. A cable or
harness which binds will restrict the steering and
may cause l()_l)S of _c;_ontrol_ and an accident.

Steering Inspection

WARNING: Operation with incorrectly


. . . . adjusted, worn or damaged steering head
bearings may cause impaired handling and
instability leading to an accident.
If in doubt, have the motorcycle inspected by an
authorised Triumph dealer before riding.

NOTE:

1.

Steering Stem Bearing Lubrication.

Position the motorcycle on level ground, in an


upright position.

The steering stem bearings require removal and


lubrication in accordance with the periodic maintenance
chart. Refer to the front suspension section for details of
steering bearing adjustment/lubrication.

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.
2.

For details of headstock bearing adjustment,


refer to the front suspension/steering section.

FRONT SUSPENSION

Place a block under the engine to raise the front


wheel off the ground.

Front Fork Inspection


1.

Examine each fork stanchion for any sign of


damage, scratching of the slider surface, or for oil
leaks.

2.

Position the motorcycle on level ground.

3.

While holding the handlebars and applying the front


brake, pump the forks up and down several times. If
roughness or excessive stiffness is detected, the
fork stanchions must be overhauled or replaced as
detailed in the front suspension section.

A.

CAUTION: Ensure that the support block


is positioned to avoid damaging all oil
lines which run beneath the engine.

3.

Hold the lower end of the front forks. Rock the forks
in a front to rear motion. If any free-play can be
detected, the headstock bearings require
adjustment.
After adjustment, re check for
free-play. If any free-play remains, check for correct
adjustment of the headstock bearings and also for
wear in the fork bearings. Rectify as necessary.

tI

WARNING: If roughness or excessive


stiffness is detected, investigate the
cause and take the necessary remedial 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: Ensure that the adjusters are


set to the same settings on both fork
stanchions.
Settings which vary from left to right hand
stanchions may affect handling and stability
leading to loss of control, or an accident.
Rock The Forks, Front To Rear

Fork Oil Change

4.

The oil in the forks must be changed in accordance with


the periodic maintenance chart. Refer to the front
suspension section for details of fork oil replacement.

Grasp one side of handlebars and check that a full


steering lock can be achieved in both directions.

2.37

2 MAINTENANCE
WHEEL BEARINGS

REAR SUSPENSION

If the wheel bearings in the front or rear wheel allow


play in the wheel hub, are noisy, or if the wheel does
not turn smoothly there may be wear or damage to the
wheel bearings.
The wheel bearings must be inspected at the intervals
specified in the periodic maintenance schedule.

Rear Suspension Inspection/lubrication


1.

;A

Inspection
1.

Position the motorcycle on level ground, in an


upright position.

2.

Place a block under the engine to raise the front


wheel off the ground.

3.

4.

Position the motorcycle on level ground in an


upright position.

~ARNING: To ~reven-t risk of injury from

'I

the motorcycle falling during the


spection, ensure that the motorcycle i; I
abiliz(;!d and ~ecured_ on it~ support ~lock.

_j

2.

Examine the suspension and swinging arm pivots


for wear and excess movement.

Gently rock the top of each wheel from side to


side. Repeat the process for both wheels.

3.

If excess movement is detected, investigate the


cause and take any necessary remedial action.

If any free-play can be detected, ask your


authorised Triumph dealer to inspect and rectify
any faults before riding.

4.

Apply grease to suspension bearings via the grease


nipples, in accordance with the periodic
maintenance chart.

5.

Use the specification of grease as recommended in


the specification section.

WARNING: To prevent risk of injury from


the motorcycle falling during the
inspection, ensure that the motorcycle is
stabilized and secured on its support block.

NOTE:

Do not exert extreme force against each wheel or


rock each wheel vigorously as this may cause the
motorcycle to become unstable or cause injury by
falling from its support.
Ensure that the position of the support block will
not cause damage to the oil lines beneath the
sump.

WARNING: Operation with worn or


damaged wheel bearings may cause
impaired handling and instability leading to an
accident.
If in doubt, have the motorcycle
inspected by an authorised Triumph dealer before
riding.

2.38

The swinging arm bearings also require


periodic lubrication which necessitates the
removal of the swinging arm. For details of
swinging arm removal, refer to the rear
suspension section.

MAINTENANCE

1. Tiger, Thunderbird, Thunderbird Sport &


Adventurer Rear Suspension Grease Nipples
---~~~

1. Trophy/Trident/Sprint/Daytona
Rear Suspension Grease Nipples

2.39

Cylinder Head
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Cam cover
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4
3.5

Cam chain tensioner


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6
3.6

Camshafts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8
3.9

Cam chain
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10
3.10

Camshaft and sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 0

Camshaft and camshaft cap wear


Journal diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11
3.11

Cylinder head
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12
3.14

Valve
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.16
3.16

Valve to guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.17

Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.17

Valve face inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.17

Valve seat outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.17

Valve seat width inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.17

Valve seat repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.18

3.1

3 CYLINDER HEAD
Exploded View
10 Nm

10 Nm

-------'
\~

15 Nm
9Nm

3.2

CYLINDER HEAD 3

COR DANCE
TORQUE
WITH RELIEN~~T SECTION

95Nm
25 Nm

28Nm

3.3

3 CYLINDER HEAD
CYLINDER HEAD DESCRIPTION

CAM COVER

All engines are fitted with an aluminium alloy cylinder


head which carries the camshaft, valves and spark
plugs. The cylinder head is cast as a single entity and
various components are permanently added after
machining. These components include the valve guides,
valve seats and oil gallery plugs. In order to fit these
parts, liquid nitrogen is used to contract the components
prior to fitment in the head.

Removal

The camshafts run directly in the head without additional


bearings. Valve clearances are adjusted by changing
variable thickness shims which sit between the valve
tappet and the camshaft. Various different camshaft
profiles are used depending upon engine configuration,
model type and final market destination.
The camshafts are driven by a silent type chain.
The chain is tensioned by a spring loaded device fitted in
the upper crankcase, and is guided by two rubber blades.

1.

Remove the seat.

2.

Remove both side panels (not necessary on Tiger,


Adventurer, Thunderbird Sport or Thunderbird
models).

3.

Disconnect the battery, negative (black) lead first.

4.

Remove the fuel tank as described in the fuel


section.

5.

Remove the cam cover cowls from the frame (not


Adventurer, Thunderbird Sport or Thunderbird).

6.

Clean the area around the plug leads at the joint


with the cam cover. Remove the ignition coils and
spark plug leads.

NOTE:

Oil is supplied to the head by an external feed pipe which


is situated at the right hand rear side of the head. The oil
pipe is connected to the main oil drilling in the upper
crankcase by means of banjo bolts. Once supplied to the
head, the oil is distributed along internal drillings within
the head casting and camshaft.
Dual valve springs are used to close the inlet and
exhaust valves. These valve springs have close wound
coils at one end 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
springs are fitted downwards (toward the piston). Both
the tip and flame face of the valves are hardened to give a
long service life.

Make a note of the spark plug lead positions in


the coils before disconnection. This will help in
matching the correct cylinder with the correct
plug lead when refitting.

7.

Progressively release the cam cover bolts in the


order shown, then remove the cam cover screws
and seals.
7

Due to the methods used to assemble the valve seats


and valve guides to the head, these parts cannot be
replaced.

4 cylinder engines
5

CAUTION:
In any of the following
operations
which
necessitate
the
removal or disconnection of the cam chain,
NEVER turn the engine without the cam chain and
tensioner correctly fitted and adjusted. In the
disassembled condition, the pistons will contact
the valves if the crankshaft is turned, causing
severe engine damage.

1
7

3 cylinder engines
Camshaft Cover Bolt Release/Tightening
Sequence

3.4

CYLINDER HEAD 3

NOTE:

Installation

The two longer bolts are fitted at the right hand


end adjacent to the cam chain.

8.

1.

Ease the wiring harness and throttle cable to give


access to the cam cover then remove the cam
cover. (Lightly tap with a rubber mallet if necessary.)

2.

NOTE:

3.

On Thunderbird, Thunderbird Sport and


Adventurer, the cover must be withdrawn from
the right hand side.

Check the condition of all joints and seals


including the cam cover screw seals. Replace as
necessary.
Ensure all mating surfaces are clean and free from
oil.
Apply silicone sealant, as indicated in the diagram
below, to the cylinder head, cam cover and to the
spark plug tower seals.

1\

CAUTION: Never use a lever to remove


the camshaft cover from the head. This
will damage the mating surfaces of both the
cylinder head and cam cover which could lead to
an oil leak.

9.

Remove the cam cover gasket together with the


seals from the spark plug towers.

10. Remove residual oil from exhaust side of the


cylinder head using a syringe or lint free cloth.

1. Silicone Sealer Areas


4.

Fit the cam cover, ensuring all seals are positioned


correctly.

5.

Fit the screws and screw seals, then tighten until


finger tight.

6.

Finally tighten the screws, in same order as for


removal, to 10Nm.

7.

Fit the ignition coils and spark plug leads in the order
noted in paragraph 6 of the removal procedure.

8.

Refit cam cover cowls to the frame (not


Thunderbird, Thunderbird Sport or Adventurer).

9.

Refit the fuel tank as described in the fuel system


section.

10. Refit the battery and reconnect, positive (red) lead


first.
11. Refit both side panels (if removed).
12. Refit the seat.

3.5

3 CYLINDER HEAD
4.

CAM CHAIN TENSIONER


Removal
1.

Carefully remove the centre nut from the tensioner


and withdraw the tensioner spring.

WARNING: The tensioner centre nut is


under spring tension. Always wear hand,
eye and face protection when withdrawing the
centre nut and take great care in order to minimise
the risk of injury and loss of components.

Remove the cam cover as described over. Also


remove the right-hand crankshaft cover to give
access to the ignition rotor.

5.

Remove the bolts securing the tensioner to the


upper crankcase and remove the tensioner and
gasket.

Installation
1. Check that number 1 cylinder (and number 4 if a 4
cylinder engine) is at TDC.

1.
2.
3.
4.
2.

2. Place a suitable wedge between the tensioner


blade and the inside of the upper crankcase to hold
the tensioner blade in contact with the timing chain.
Check that the camshaft timing marks point inwards
and are level with the line of the head.

Ignition Rotor Clamp Nut


Ignition Sensor
Centre Nut
Tensioner Securing Screws

Insert Wedge to secure chain

Rotate the crankshaft clockwise (the normal


direction of rotation), using the nut fitted to the end
of the crankshaft. Stop rotation when number 1
cylinder (and also number 4 cylinder for 4 cylinder
engines) is at top dead centre (TDC).

NOTE:

At TDC, the ignition rotor 'T' mark will align with


the ignition sensor, and the alignment marks on
the camshaft sprockets will point inwards at a
point level with the joint face.

1.
2.
3.
4.
5.
6.

Tensioner Blade Retaining Bolt


Tensioner Blade
Pick-up Screws
Rubber Grommet
Ignition Pick-up Sensor
Cam Chain

NOTE:

Camshaft Wheel Timing Marks


3.

Place a suitable wedge, between the tensioner


blade and crankcase, to hold the cam chain taut
during removal of the tensioner.

3.6

Early Trophy and Trident engines were fitted


with a tensioner guide over the end of the
tensioner nose. This item must be discarded if
found and the tensioner assembled to the
crankcase without the guide.

CYLINDER HEAD 3
3. Set the tensioner plunger onto the first tooth of the
ratchet (i.e. minimum extension) by manually lifting
the ratchet pawl.

9.

Re-check that the camshaft timing marks align as


illustrated over.

10. Re-check tensioner plunger location against the


tensioner blade.
11. Refit the cam and crankshaft covers.
12. Check and adjust the engine oil level.

NOTE:

1.
2.
3.
4.

Tensioner Pawl
Spring
Washer
Centre Nut

4.

Fit the tensioner, complete with a new gasket, to the


upper crankcase and tighten the retaining bolts to 9
Nm.

5.

Remove the tensioner blade wedge, taking care not


to move or damage the tensioner blade.

6.

Fit a new sealing washer to the centre nut. Using


finger pressure only, push the ratchet section of the
tensioner into firm contact with the tensioner blade.
Carefully refit the spring and centre nut to the
tensioner. Tighten the centre nut to 23 Nm.

7.

Check that the tensioner plunger is correctly


located in the middle of tensioner blade when
viewed from above.

8.

Rotate the engine through 4 full revolutions, and


reset number 1 cylinder to the TDC mark. Ensure
that the T mark on the ignition rotor is aligned with
the ignition pick-up

1. Ignition Pick up
2. Ignition Rotor

3.7

Three different types of cam chain tensioner are


fitted.
Refer to the parts information for
selection of the correct type.

3 CYLINDER HEAD
6.

CAMSHAFTS
Removal
NOTE:

The camshafts can be removed from the head


without the complete removal of the timing
chain. However, the chain must first be
detached from the camshafts. The camshafts
and sprockets are removed as an assembly.

1.

Remove the seat and disconnect the battery


negative (black) lead first.

2.

Remove the cam cover and right hand crank cover.

3.

Set number 1 piston to TDC by aligning the number


1 mark (1 and 4 on 4 cylinder) on the ignition rotor
with ignition pick-up. The alignment marks on the
camshaft sprockets will also point inwards at a point
level with the joint face.

Progressively release each of the fasteners


securing the exhaust camshaft caps to the cylinder
head. NOTE: The inlet and exhaust camshafts
can be differentiated by a plain area in the
centre of the exhaust cam and a groove in the
same place on the inlet cam.

Plain section
Exhaust cam

Inlet cam

Groove
Camshaft Identification
----------------------------,

1\.

CAUTION: Never release one camshaft


cap in isolation from the others as this
may cause the caps to crack.
Always progressively release all the camshaft
caps before final removal

7.

Camshaft wheel timing marks

Once the pressure on all camshaft caps has been


released, remove the fasteners and caps complete
with dowels.
INLET SIDE

4.

Remove the cam chain tensioner as described


earlier in this chapter.

5.

Remove cam chain top pad from the right hand side
of the head.

EXHAUST SIDE

Camshaft Cap Numbering (4 cylinder illustrated)

NOTE:

1. Cam Chain Top Pad

3.8

The caps are numbered sequentially and must


not be interchanged for a different position on
the head. The camshaft caps on the outside of
the timing chain (known as outriggers) are
marked 'A' for the exhaust and 'B' for the inlet.

CYLINDER HEAD 3
NOTE:

5.

Each cap is located by two dowels which align


the cap with the head. If the caps cannot be
removed using hand pressure, gently tap each
cap with a soft faced tool to release.

8.

Lift the cam chain from the sprocket and remove the
exhaust camshaft.

9.

Repeat procedures 6, 7 and 8 for the inlet camshaft.

Before fitting the cam chain, ensure that cam


bearing caps are not pinching the camshafts by
rotating each camshaft back and forth 5.

I:\

CAUTION: If any components have been


renewed, the valve clearances must be
checked and adjusted. Running with incorrectly
adjusted valve clearances may cause excess
engine noise, rough running and engine damage.
Refer to the maintenance section for valve
clearance adjustment details.

6.

Assemble the cam chain tensioner using the


instructions given earlier in this chapter

7.

Refit the top pad and tighten the fixings to 1ONm.

8.

Refit the cam and crankshaft covers.

9.

Refit the fuel tank, cam cowls and body panels.


Reconnect the battery, positive (red) lead first.

NOTE:

1. Exhaust Camshaft
2. Inlet Camshaft

Installation
1.

Thoroughly clean the camshafts and journals.


Inspect the ends of the camshafts for correct fitment
of the sealing plugs. Lubricate the camshafts with
clean engine oil before fitting to the head.

2.

Locate each camshaft to the head ensuring the


camshafts are correctly identified (inlet and
exhaust) and also correctly located over their
respective valve banks.

3.

Position the camshafts in the same position as for


removal before attempting to fit the caps (that is,
with the timing marks on the camshaft sprockets
level and pointing inwards, and with number 1
cylinder at TDC). Locate the cam chain over the
cam sprockets.

I:\

CAUTION: If the camshafts and caps are


fitted without first aligning the timing
marks on both the crankshaft and camshaft
sprockets, the inlet and exhaust valves will contact
each other causing damage to both the head and
the valves.

4.

Lubricate the threads of the camshaft cap screws


and evenly and progressively tighten to 10 Nm.

3.9

Various different profile camshafts are fitted.


For correct selection of camshafts, refer to the
parts information.

3 CYLINDER HEAD

CAM CHAIN

CAMSHAFT SPROCKET

Removal

It is not normally necessary to remove the sprockets


from the camshafts. However, if it becomes necessary
for the sprockets to be separated from the camshafts,
the following should be noted.

NOTE:

The camchain can be renewed with the engine


installed in the frame. The procedure to renew
the chain is basically the same as for the
replacement of the camshafts. In addition to all
the operations necessary to replace the
camshafts, the following operations are
necessary.

1.

Release the screws securing the ignition sensor to


the crankcase. Slide the sensor grommet out from
the crankcase and remove the sensor.

2.

Remove the cam chain tensioner guide from the


crankcase.

3.

Remove the oil baffle plate from below the ignition


rotor.

4.

The timing chain is removed from either the head or


crankcase after first detaching the chain from the
crankshaft gear.

The same sprocket is used for both inlet and


exhaust camshafts, however, different bolt holes
are used for inlet and exhaust camshafts as shown
in the illustration below.

2
1. Inlet Camshaft Bolt Holes
2. Exhaust Camshaft Bolt Holes

Installation
1.

1.

Refit the cam chain and locate the lower end around
the crankshaft gear.

2.

Fit the ignition sensor and adjust to give an air gap of


0.6- 0.8 mm between the timing disc projection and
the pick-up. Tighten the screws to 1 ONm.

3.

Refit the oil baffle plate and tighten to 10 Nm.

4.

Refit the tensioner guide to the crankcase.

5.

Apply Triumph silicone grease to the grommet on


the ignition sensor and refit the grommet to the
crankcase.

6.

The procedure is completed by following the


assembly instructions for replacement of the
camshafts.

NOTE:

The inlet and exhaust camshafts can be


differentiated by a plain area in the centre of the
exhaust cam and a groove in the same place on
the inlet cam.

Plain section
Exhaust cam

Inlet cam

Groove
Camshaft Identification

3.10

CYLINDER HEAD 3
CAMSHAFT AND CAMSHAFT CAP WEAR
Camshaft bearing oil clearance- 0.12mm max.

Journal Diameters
Standard:

22.93 mm

Outrigger Diameters
Standard:
1.

2.

22.936 mm
22.923 mm

Measure the camshaft journals with a micrometer. If


any journal is outside the specified tolerance,
replace the camshaft.
Examine all camshaft and camshaft bearing caps
for excessive wear and damage, paying particular
attention to the outrigger caps (A & B).

NOTE:

The outrigger caps are most important as they


control the oil feed to the camshafts.

The camshaft caps are machined to each


cylinder head and are, therefore, not available
individually. If a camshaft cap is worn or
damaged, the complete cylinder head must be
replaced.

3.

To measure the journal to head clearances, use


'Piastigauge' (Triumph part number 3880150) as
follows.
Progressively release the camshaft caps, on the
camshaft to be inspected, and fully remove the cap
from the required journal. Wipe the exposed areas
of both the journal and cap. Apply a thin smear of
grease to the journal and a small quantity of silicone
release agent to the cap.
Size a length of the plastigauge to fit across the
journal being measured. Fit the plastigauge to the
journal using the grease to hold the strip in place.
Refit the cap and evenly and progressively tighten
all the camshaft cap bolts to 10 Nm. Release all
cap bolts and remove the cap being measured.
Using the gauge provided with the plastigauge kit,
measure the width of the now compressed
plastigauge.

3.11

Measuring The Compressed Plastigauge.


4.

Calculate the journal


plastigauge chart.

5.

If the clearance measured is within the specified


tolerance, clean off all traces of plastigauge and refit
the camshaft caps. If the measured clearance is
outside the tolerance, the cylinder head must be
replaced.

I:\

clearance

using

the

CAUTION: Although plastigauge is oil


soluble, all traces of the material must be
removed to prevent blockage of the oil drillings
and resultant engine damage.

3 CYLINDER HEAD
CYLINDER HEAD REMOVE/REFIT

4.

The cylinder head can be removed with the engine in


the frame. It is necessary to remove the side panels,
lower fairing, fuel tank and exhaust system.

On
Thunderbird,
Thunderbird
Sport
and
Adventurer, remove the thermostat housing to
cylinder head hose and the bypass hose.

Removal
1.

Disconnect the battery, negative (black) lead first.


Remove the exhaust system completely.

WARNING: 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 hot
exhaust system could cause burn injuries.
2.

Drain the coolant into a clean receptacle. Retain the


coolant for re-use unless contaminated or due for
replacement.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.
3.

1. Thunderbirdffhunderbird Sport/Adventurer
Thermostat Housing
5.

Disconnect the connector from the water


temperature sensor on the left hand side of the
head.

6.

Clean the area around each spark plug lead.

7.

Remove the plug leads and spark plugs. Cap the


plug holes to prevent dirt entering the cylinders.

NOTE:

Disconnect and remove the top hose from both the


radiator and cylinder head.

Before disconnection, make a note of the spark


plug lead positions in the head. This will help in
matching the correct cylinder with the correct
plug lead when refitting.

8.

Remove the carburettors as described in the fuel


system section.

9.

Remove the banjo bolts and washers from both


ends of the oil feed pipe to the head. Remove the
pipe.

1. Top Hose.
2. Water Temperature Sensor Connection.

1\

CAUTION: Some models are fitted with


crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.

1. Oil Feed Pipe


2. Banjo Bolts
3. Crankcase To Head Bolts (Side Only Illustrated)

3.12

CYLINDER HEAD 3
10. Remove both camshafts as previously described.
Remove the tappets and shims keeping the tappet
and shim from each valve together in a marked
container.

10

NOTE:

To prevent the tappets and shims from


becoming mixed, place the shim and tappet
together in a marked container. The marked
components must be refitted in their original
positions.

11.

Release the screws securing the front and side of


the upper crankcase to the cylinder head noting the
relative position and length of each bolt.

NOTE:

On Thunderbird, Thunderbird Sport &


Adventurer engines, the bolts securing the
cylinder head to the crankcase are accessed
from inside the head

Top.
4 Cylinder Head Bolt Release Sequence
Bottom. 3 Cylinder Head Bolt Release Sequence
1. Thunderbird!fhunderbird Sport/Adventurer
Cylinder Head to Crankcase Bolts
12. Support the engine and release the frame to
cylinder head bolts.
13. Progressively release the cylinder head bolts in the
sequence shown right.
14. Lightly tap the cylinder head with a rubber mallet to
break the seal of the gasket. Remove the cylinder
head complete with the location dowels.
15. Remove the cylinder head gasket and gasket
spacers. Discard the gasket and spacers.

3.13

3 CYLINDER HEAD

Installation
NOTE:

Ensure that the threads of the cylinder head bolt


holes in the upper crankcase are completely
clean and dry.

1.

Position the cam chain rubbing blade to the left


hand side of the upper crankcase. When correctly
fitted, the blade positively locates at the lower end
on a web. The upper section will then fit snugly into
the recess in the top of the crankcase.

2
~

1. Head Gasket
2. Gasket Spacers

3.

Ensure that the cylinder head face is completely


clean.

4.

Carefully lower the cylinder head over the rubbing


blade and locate the head onto the dowels.

CAUTION: The fitting and tightening of


the cylinder head bolts is critical to the
long term reliability of the cylinder head gasket.
Clean each bolt, paying particular attention to the
threads and under the bolt head areas. If any of the
threads or bolt head areas are damaged, replace
the bolt(s). Lubricate the threads with engine oil,
and then wipe clean with a lint-free cloth leaving
minimal oil on the threads (that is, almost dry to
touch). Failure to observe these important items
may lead to engine damage through a damaged
head gasket.

1. Cam Chain Rubbing Blade

NOTE:

2.

The cylinder liners must be lifted and re-sealed


before refitting the cylinder head. Refer to the
liner/piston section for details.

5.

Thoroughly clean the upper faces of the crankcase


and liners taking care not to damage the mating
surfaces. Position the cylinder head gasket and
gasket spacers, ensuring that the location dowels
are correctly in place.

NOTE:

3.14

Fit the bolts to the head and tighten until finger tight.
The head bolts are finally tightened in 3 stages.
This is to ensure that the cylinder head gasket seals
correctly to the head and crankcase. The 3 stages
are as follows overleaf:

For stages A and 8 of the head bolt tightening


operation, a torque wrench of known, accurate
calibration must be used.

Tighten the head bolts, in the same numerical


sequence used to release the bolts, to 20 Nm.

Crankcases WITHOUT alternator cover:


Tighten the head bolts in the same numerical
sequence used to release the bolts, to 27 Nm.

CYLINDER HEAD 3
8

Crankcases WITH alternator cover:

Tighten the head bolts in the same numerical


sequence used to release the bolts, to 35 Nm.
C

For the final torque operation, which again is


carried out in the same numerical sequence used to
release the bolts, a 'torque turn' method is used.
The bolts must be turned through goo to reach the
final setting. To accurately gauge the goo turn, use
special service tool 3880105 as follows. Fit the tool
between the torx socket and the drive handle and
locate the torx drive to the head bolt. Pick an
increment point on the torque turn gauge which
aligns with a suitable reference point on the head.
Tighten the bolts until g of the 10 gauge increments
have rotated past the chosen point on the head.

13. Continue to assemble the engine using the


camshaft renewal procedure. In addition, the
following operations must also be carried out.
14. Replace the coolant drain plug using a new sealing
washer.
15. Examine the radiator hoses for cracks, frays and
damage, renew if required. Fit the hoses.

'f

CAUTION: Some models are fitted with


crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.

16. Connect the water temperature sensor.


17. Refit the spark plugs ensuring the plug leads are
fitted to the correct cylinders.
18. Refill the cooling system using the refill procedure
from the maintenance section.
1g. Refit the fuel tank, exhaust system and bodywork.
20. Reconnect the battery, positive (red) lead first.

1. Tool 38801 05

6.

Fit the screws securing the front and side of the


crankcase to the cylinder head and tighten to 12
Nm.

7.

Lubricate the tappet buckets with clean engine oil


and refit the tappet buckets and shims in same
locations from which they were removed.

NOTE:

Ensure that the tappets and shims are refitted in


their original positions.

8.

Refit the oil feed pipe using new sealing washers.

9.

Tighten the upper banjo bolt to 25 Nm.

10. Tighten the lower banjo bolt to 28 Nm.


11.

Ensure that the oil feed pipe is not distorted during


the tightening operation.

12. Refit the frame to engine bolts and tighten to


95 Nm.

3.15

3 CYLINDER HEAD
VALVES AND VALVE STEM SEALS

Installation

Removal from the cylinder head


1.

Remove each valve from the head using a valve


spring compressor. The compressor must act on
the top cup to allow removal of the valve collets.

1.

Apply a thin coat of molybdenum disulphide grease


to the valve stem.

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 until the seal
is correctly seated over the valve guide.

NOTE:

1. Valve Removal Using A Valve Spring


Compressor
2.

Once the collets are released, remove the following


collets
valve spring cap
valve springs
valve stem seal
thrust washer
valve (de-burr before removal)

~~

Close wound section

1::.

----r:

~CAUTION: Incorrect fitment of the valve


~ stem oil seals could lead to high oil
consumption and blue smoke emissions from the
exhaust system. Do not use excessive force in
fitting the seal as this may break the seal ring.
4.

Install the valve springs over the valve stem


ensuring that the close wound coil end faces
towards cylinder head.

5.

Compress the valve spring ensuring that the spring


is compressed squarely to prevent damage to the
valve stem and cylinder head.

6.

Fit the valve collets ensuring correct collet location


in the spring cap and valve as the spring
compressor is released.

~~:

5
tlJ ~
~ ~:

During fitment of the valve stem seal, two


distinctly different degrees of resistance will be
noted when the seal is correctly fitted.
Firstly, press the seal down the valve stem until
the lower side of the seal comes into contact
with the valve guide. Greater resistance is felt at
this contact point and further gentle pressure is
then required to locate the seal over the top end
of the valve guide. On application of this
pressure, the seal can be felt to positively locate
over the top face of the valve guide. Once
correctly positioned, the seal cannot be pushed
down any further.

------~--

1\

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 contact the pistons. Any
such valve to piston contact will cause severe
engine damage.

1. Collets
2. Valve Spring Cap
3. Inner Valve Spring
4. Outer Valve Spring
5. Thrust Washer
6. Stem Oil Seal
7. Valve

3.16

CYLINDER HEAD 3
VALVE TO VALVE GUIDE CLEARANCE

VALVE FACE INSPECTION

If the valve guides are worn beyond the service limit


given below, the cylinder head must be replaced.

1.

Valve/valve guide clearance


Inlet
Exhaust

Standard
0.01 - 0.04 mm
0.03 - 0.06 mm

Remove any carbon build-up from the valve head


area. Examine the valve seat face, checking in
particular for signs of cracking or pitting.

VALVE SEAT DIAMETER

Service Limit
0.07 mm max
0.09 mm max

1.

VALVE GUIDE
The valve guides are fitted using liquid nitrogen to
contract the guide prior to fitment in the cylinder head.
Considerable force would be required to remove and
replace the guide which could cause the head to warp.
As liquid nitrogen is not generally available to the public,
it is not recommended that valve guides be renewed.
If a valve guide is found to be worn beyond the service
limit, the complete cylinder head must be renewed.

Measure the outside diameter of seating area on


the valve seat. If the seat area is not within the
specified range, the valve seat must be repaired.

Valve seating surface outside diameter


Standard:
Inlet:
Exhaust:

29.3- 29.5mm
25.3 - 25.5mm

VALVE SEAT WIDTH INSPECTION


1.

Measure the width of the valve seat to valve contact


face. If the seat area is not within the specified
range, the valve seat must be repaired.

NOTE:

Measure the portion of the seat where there is


no carbon build up.

Valve seating surface width (IN and EX)


0.9-1.1 mm
1.5mm

Standard:
Service limit:

1.
2.
3.
4.

3.17

Valve
Valve Seat
Valve Seat To Valve Contact Face
Seat Outside Diameter

3 CYLINDER HEAD
VALVE SEAT REPAIR
Operation
The valve seat can be repaired if pitted. If cracks or
larger burnt areas are present then the cylinder head
must be replaced. The width of the seat is critical and the
tolerance band given must be observed. In general, if the
seat width requires adjustment then metal must be
removed from either the top face (too large) using a 30
cutter or the bottom face (too small) using a 60 cutter. In
all cases, a hand cutter is used.
1.

Clean the valve seat area thoroughly.

Reducing Seat Width Using 30 Cutter

2.

Coat the valve seat with engineers blue.

8.

3.

Fit a 45 cutter to the holder and slide the cutter


guide into the valve guide.

a.

Using light pressure, grind the seating surface.

b.

4.

Measure the valve seat width and if necessary,


adjust as follows:
if the
grind
if the
grind

CAUTION: Over grinding will cause the


valve to sink deeper into the head. This
may make the valve clearance impossible to set,
leading to complete replacement of the head.

seat width is too narrow, repeat the 45


until the seat width is within tolerance.
seat width is too wide, fit a 60 cutter and
the seat until it is within tolerance.

'.'.

5.

Check the outside diameter of the seat surface:


a.

if the diameter is too small, grind using a 45


cutter until the diameter is within range.
if the diameter is too large, grind using a 30
cutter until the diameter is within range.

b.

6.

~eat Width

Once the correct seat diameter is established check


the seat width across the contact face.

/~

Reducing Seat Width Using a 60 Cutter


Seat Width

NOTE:

Checking Seat Width


7.

To reduce the face width, fit a 30 cutter and grind


the seat one turn of the cutter at a time.

CAUTION: A 30 cutter will remove metal


very quickly. Check the seat width after
each turn to prevent irreparable head damage.

3.18

A 60 cutter is used at this stage to avoid


sinking the valve any deeper into the cylinder
head.

9.

Lap the valve into the valve seat as follows;


a.

apply fine grinding compound to each valve

b.

rotate each valve against the valve seat until


the compound produces a smooth, matched
surface on both faces.

CYLINDER HEAD 3

Seat Width

Contact Area Too High


1. Valve Lapping Tool
2. Valve Seat
3. Valve
Seat Width

NOTE:

The seating area should be marked around the


centre of the valve face.

10. Remove all traces of the grinding compound from


both the valves and valve seats.
11. To confirm the correct contact area has been
ground, apply a thin smear of engineers blue to the
valve seat and fit the valve through the valve guide
and onto the valve seat. Press on the valve with
sufficient pressure to make a clear pattern in the
blue. Examine the contact area and compare with
the diagrams over. The correct contact area is in the
centre of the valve.

Contact Area Too Low

NOTE:

The location of the valve seat in relation to the


valve face is very important for good sealing

If the contact area is too high on the valve, the


seat must be lowered using the 30 cutter.

If the contact area is too low on the valve, the


seat must be raised using a 60 cutter.

3.19

Clutch
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch master cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch slave cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Friction plate inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

4.2
4.4
4.4
4.5
4.5
4.6
4.6
4.6
4.7
4. 7
4.7
4. 7
4.7
4.8
4.9
4.11

4 CLUTCH

15Nm

'

L __ _
25 Nm

@~25Nm
\.Y~

4.2

CLUTCH 4

10 Nm

4.3

4 CLUTCH

CLUTCH DESCRIPTION

WARNING: Ensure absolute cleanliness


when adding clutch fluid to the clutch
fluid reservoir.
Do not allow moisture or debris to 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.
Always check for fluid leakage around hydraulic
fittings and for damage to hoses.
A dangerous riding condition leading to an
accident could result if this warning is ignored.

All models fitted with a hydraulically operated, wet plate


clutch. Clamping loads are varied from model to model
by fitting different rate springs to the pressure plate. The
clutch is operated by a hydraulic master cylinder which
controls a slave cylinder mounted on the engine. The
slave cylinder acts upon a pushrod which runs though
the centre of the gearbox input shaft.
The clutch has nine friction plates located between the
inner and outer drums. A geartrain, situated behind the
friction plate area distributes engine power to the
gearbox input shaft. An auxiliary geartrain also drives
the alternator, oil and water pumps, and receives input
from the starter motor via a sprag gear. On four cylinder
engines, the clutch gear also drives the balancers.

CAUTION: To prevent body damage, do


not spill clutch fluid onto any area of the
bodywork.

BLEEDING THE CLUTCH


1.

On models equipped with an adjustable lever, set


the adjuster wheel to No.1. (Note the original
setting of the wheel in order that it can be
returned to this position when the bleeding
operation is complete).

2.

Remove the dust cap from the bleed nipple on the


slave cylinder.

3.

Attach a transparent plastic tube to the bleed nipple.

4.

Place the other end of the tube in suitable


receptacle containing new clutch fluid.

5.

Turn the handlebars to bring the fluid reservoir to a


level position.

6.

Release and remove the 2 screws securing the


clutch reservoir cover.

8.

Check condition of the sealing diaphragm fitted


beneath the cover. Replace the diaphragm if
necessary.

9.

Release the bleed nipple

1/

turn.

10. Slowly pull in and release the clutch lever several


times until no more bubbles appear in the pipe.

WARNING:
Use
only
D.O.T.
4
specification clutch fluid as listed in the
general information section of this manual. The
use of clutch fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the clutch system leading
to an accident.
7.

1. Bleed Nipple Rubber Cap


2. Bleed Nipple

11.

Maintain the clutch fluid level between the upper


and lower levels whilst bleeding is being carried out.

NOTE:

Carefully remove the cover taking care not to spill


fluid.

During bleeding, do not allow the fluid level to


fall below the lower level mark in the reservoir.
If the level is allowed to fall below this mark,
air may enter the system and the sequence of
bleeding must be repeated.

12. When all the air has been expelled from the system,
hold in the clutch lever and close the bleed nipple.
Tighten to 7 Nm.

4.4

CLUTCH 4

13. Fill the reservoir to the upper level.

CLUTCH MASTER CYLINDER

WARNING:
Use
only
D.O.T.
4
specification clutch fluid as listed in the
general information section of this manual. The
use of clutch fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the clutch system leading
to an accident.

1.

Remove the reservoir cover. Drain the fluid from the


master cylinder using the bleed process described
over.

2.

14. Replace the reservoir cover and diaphragm


ensuring correct fitment of the diaphragm before
final tightening of the screws

Remove the pivot bolt securing the clutch lever to


the master cylinder. On Tiger models, also remove
the knuckle guard.

3.

Remove the clutch lever from the master cylinder.

15. Remove the transparent bleed pipe.

4.

Release the banjo bolt securing the clutch hose to


the master cylinder. Disconnect the clutch hose.

5.

Disconnect the starter lock-out switch from the


under side of the master cylinder.

6.

Release the handlebar clamp screws and remove


the clamp and master cylinder.

Removal

16. Replace the bleed nipple dust cap.


17. Reset the adjuster wheel on the clutch lever to the
original setting.

WARNING:
Always return the lever
adjuster to the original setting as noted in
paragraph 1. Operating the motorcycle with lever
settings which are unfamiliar may lead to loss of
control or an accident.

1. Handlebar Clamp

Disassembly

4.5

1.

Remove dust cover/boot (1) from the rear of the


master cylinder body.

2.

Remove the circlip (2) from the end of the master


cylinder bore.

3.

Remove the cylinder pushrod (3).

4.

Remove the washer (4) from part way down the


bore.

4 CLUTCH

5.

Remove the piston, seal and spring (5) noting the


position of the seal lip in relation to the piston.

2. Tighten the clamp bolts, upper first and then lower


to 15 Nm.
3. Re-connect the starter lock out switch to the master
cylinder.
4. Position the clutch lever ensuring that pivot boss is
correctly aligned and fitted to the push rod. On
Tigers, fit the knuckle guard and flanged sleeve.
Tighten the pivot bolt to 1 Nm on all except Tiger,
and 6Nm on Tiger.
5. Tighten the locknut to 6Nm (all models). On Tigers,
refit the plug to the pivot bolt

1 . Dust Cover/Boot
2. Circlip
3. Pushrod
4. Washer
5. Piston, Seal and Spring

Inspection
1.

Check the following for wear, damage, cracks or


signs of deterioration and replace as necessary:
cylinder bore and piston
1.
2.
3.
4.

seals
dust cover

Plug (Tiger only)


Pivot bolt
Flanged Sleeve (Tiger only)
Nut

spring
2.

6. Align and fit the banjo bolt to the clutch hose using
new sealing washers. Connect the hose to the
master cylinder.

Ensure that the fluid return and supply ports on


cylinder are not blocked.

7. Tighten the banjo bolt to 25 Nm.

Assembly
1.

Clean all disassembled parts with new clutch fluid.


Apply clutch fluid to the bore of cylinder.

2.

Fit a new seal and piston set ensuring that the seal
is fitted in the same position as noted during
removal.

3.

Assemble all components to the master cylinder in


the reverse order to removal. Ensure that the dust
cover is correctly located over both the pushrod and
cylinder body.

8. Bleed the clutch as described earlier and then


examine the system for;
a.
b.

Installation
1. Locate the master cylinder to the handlebars and
position the clamp with the 'Up' arrow pointing
upwards. Align the master cylinder/clamp split line
with the dot mark on the handlebar.

4.6

correct clutch operation.


fluid leakage.

CLUTCH 4

CLUTCH SLAVE CYLINDER

Removal
1.

Position a suitable container for the collection of


clutch fluid.

2.

Release the banjo bolt from the clutch slave


cylinder. Place the hose fitting into the container to
collect the fluid.

CAUTION: To prevent body damage, do


not spill clutch fluid onto any area of the
bodywork.

L.l..).

3.

Release the three bolts securing the clutch slave


cylinder to the sprocket cover.

4.

Detach the cylinder taking care to ensure that the


piston remains in the cylinder.

5.

If the cylinder is not to be stripped, retain the piston


to the slave cylinder using a rubber band or cable
tie.

1. Spring
2. Seal
3. Dust Cover

Assembly
1.

Apply clutch fluid to outside of both the piston and


seal.

2.

Refit the piston, ensuring that the spring is correctly


positioned. Retain the piston using a rubber band or
cable tie prior to final assembly on the sprocket
cover.

Installation
1.

Remove the cable tie or rubber band from the slave


cylinder.

2.

Apply a smear of grease to end of push rod.

3.

Align and fit the banjo bolt to the clutch hose using
new sealing washers. Connect the hose to the
slave cylinder.

4.

Fit the slave cylinder to the sprocket cover ensuring


that the push rod locates correctly in the cylinder.
Tighten the cylinder to sprocket cover bolts to
12Nm.

Disassembly

5.

Tighten the clutch hose banjo bolt to 25 Nm.

The spring inside the cylinder will push the piston out far
enough for removal by hand.

6.

Bleed the clutch as described earlier in this section


and then examine the system for;

1. Clutch Slave Cylinder


2. Retaining Tie
3. Clutch Pushrod

Inspection
1.

a.
b.

Check the following for wear, damage, cracks or


deterioration and replace as necessary:
cylinder inner wall and piston
dust cover
spring

4.7

correct clutch operation.


fluid leakage.

4 CLUTCH
CLUTCH

r
'

1.
2.
3.
4.
5.
6.
7.
8.
9.

Bolt
Clutch spring
Pressure Plate
Bearing
Pushrod end piece
Friction Plate
Clutch Plate
Anti Judder Plate
Centre Nut

10. Centre Drum


11. Pushrod
12.Bush
13. Needle Bearing
14. Splined Collar
15. Auxiliary Drive Gear
16. Outer Drum
17. Shim
18. Washer

Disassembly
1.

Detach the rubber breather pipe (where fitted) from


the clutch cover.

2.

Drain the engine oil and remove the ring of bolts


securing the clutch cover to the crankcase.
Remove the cover.

3.

Remove the bolts and springs from the clutch


pressure plate. Remove the pressure plate.

4.

Remove clutch push rod and end piece.

5.

Remove all the clutch friction plates together with


the anti judder plate.

NOTE:

4.8

It is not normally necessary to disassemble the


clutch further, but if the clutch inner and outer
drums are to be removed, proceed as follows:

6.

Rotate the engine until number1 cylinder (1 and 4


on a 4 cylinder engine) is at TDC.

CLUTCH 4

7.

Engage 1st gear, and lock the inner and outer clutch
drums together using service tool 3880025

11.

Remove the centre nut and clutch inner drum.

12. Remove the large flat washer and shim from the
input shaft.

~~

13. Slide the clutch outer drum gently backwards and


forwards to dislodge the splined bearing sleeve.
Carefully remove the sleeve and needle roller
bearing while supporting clutch drum.
14. Remove clutch drum by easing out of the
crankcase, left-hand side first.
15. Remove the auxiliary drive gear.

Assembly
1.
1. Service Tool 3880025

8.

Depress the rear brake pedal to prevent the engine


from turning, then loosen but do not remove the
clutch centre nut and belleville washer.

9.

Check that number 1 cylinder (1 and 4 for 4 cylinder


engines) is still at TDC.

Position the auxiliary gear (with the deeper dish side


towards the crankcase) between the oil pump drive
gear and alternator drive gear.
Ensure full
engagement of the auxiliary gear with the alternator
gear.

J,\

CAUTION: On 4 cylinder engines, the


clutch and balancer gears are carefully
matched to ensure correct crankshaft to balancer
alignment.
Instruction 10 must be correctly
observed to avoid a potentially serious engine
vibration resulting in severe engine damage.

10. Mark the primary balancer tooth, adjacent to the 'lip'


on crankcase, to ensure correct timing of balancer
on re-assembly.

1. Alternator Drive Gear


2. Oil Pump Drive Gear

\\ \__)

2.

Temporarily fit the sleeve, needle roller bearing and


splined sleeve to correctly locate the auxiliary gear
centrally. Carefully remove the splined sleeve and
needle roller bearing.

3.

Fit the clutch outer drum, making sure that the


marked tooth on the balancer gear is still aligned
with 'lip' on the crankcase.

1\

CAUTION: Incorrect alignment of the 4


cylinder balancer drive gear will cause a
severe engine vibration resulting in severe engine
damage.

Lip

Gear Tooth

4.

Mark the gear tooth adjacent to the crankcase lip


1. Clutch Outer Basket
2. Balancer Gear

4.9

Align the splines of clutch drum with the splines on


auxiliary gear (it may be necessary to remove clutch
outer drum and rotate by one tooth to align spline).
Re-check the balancer alignment and adjust if
necessary.

4 CLUTCH

5.

While holding clutch outer drum in position, refit the


splined sleeve and needle roller bearing. When the
sleeve is correctly fitted, it is flush with clutch drum
face.

9.

Lock the inner and outer drums together using


service tool 3880025. Depress the rear brake pedal
to prevent the engine from turning, and tighten the
clutch centre nut to 105 Nm. Remove the service
tool.

A.

CAUTION:
Re-check the drive gear
position on the 4 cylinder balancer and
repeat operations 2, 3, 4 and 5 if the balancer is not
correctly aligned.
Severe engine damage could result from incorrect
balancer alignment.

L.b

6.

Fit the shim and large washer to the outer drum.

7.

Fit the clutch inner drum.

8.

Fit the belleville washer


outwards), and centre nut.

('out'

mark facing

1. Service tool 3880025


10. Disengage first gear and check for free rotation of
the clutch inner drum.

A.

doe~

CAUTION: If the inner drum


not
rotate freely, it must be removed and
shimi'Tied to pr:vent severe engine dama_g_e_._

_J

NOTE:

Friction plates and clutch plates must be


inspected for signs of wear, damage or
distortion before re-use, and replaced if not in a
serviceable condition. (see Friction plate
wear/warp).

11.

Soak all clutch plates in oil before fitting to the clutch


basket in the same order as removal.

Belleville Washer 'Out' Mark

12. Carefully refit the clutch pushrod and end piece


ensuring that the pushrod seals in the crankcase do
not become displaced or damaged.
13. Refit the clutch pressure plate together with the
springs and bolts. Tighten the bolts to 10 Nm
14. Clean and refit the clutch cover using a new gasket.
Tighten the clutch cover bolts to 12 Nm.
15. Refit the breather hose and clip (where fitted).
16. Re-fill the engine with the correct grade and type of
engine oil.

4.10

CLUTCH 4

FRICTION PLATE INSPECTION


1.

If any friction plate thickness is outside the seNice


limit, replace the friction plates as a set.

1. Clutch friction Plate

Friction plate thickness


Standard:
Service limit:

2.

3.80 mm - 0.00 + 0.08 mm


3.60 mm

Check all plates for bend and warp as follows:


Place the plate being checked on a clean surface
plate and attempt to pass a feeler gauge of the
maximum specified thickness between the friction
plate and surface plate at several points around the
plate. If the feeler gauge can be passed beneath
the friction plate at any point, renew the plates as a
set.

1. Friction Plate
2. Feeler Gauge
3. Surface Plate
Standard:
Service limit:

0.15 mm

0.20 mm

4.11

Balancers
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2

Balancer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3

Balancers, 4 Cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3
5.3
5.4

Balancer, 3 Cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5
5.5
5.5

5.1

5 BALAN-;;C~ER=S--Exploded

---

v1ew

4 CYLINDER ENG INES

12 Nm

12 Nm

9Nm

3 CYLINDER ENGINES

5.2

BALANCERS 5
BALANCERS
Both three and four cylinder models are fitted with
balancer systems to control 'pulsing' within the engine.
Without any form of balancer, the engine would 'pulse'
each time the crankshaft rotated. This 'pulsing' would be
felt as a vibration which would amplify as the engine
speed was increased.
The balancer has the effect of a counterbalance weight
which creates an equal amount of energy in the opposite
direction and at the same time as that produced by the
crankshaft. Because the opposing pulses occur at the
same point of crankshaft rotation, and are of an equal
magnitude, a state of equilibrium or balance is reached
and no vibration occurs.

4.

Support the balancer weights and carefully


withdraw the spindles in the direction of the
balancer clamps.

5.

Remove the balancers taking care to retain the


thrust washers which are fitted at both ends of both
balancers.

On the three cylinder engine, a single balancer is used


which is driven by a gear fitted to the left hand end of the
crankshaft.
On four cylinder versions, two balancers are fitted which
are driven by the large clutch gear.

4 Cylinder Balancer

1 . Balancer Removal

Removal
1.

Remove the sump as described in the lubrication


section.

2.

Release the pinch bolts from both balancer clamps.

3.

Remove the balancer clamp from the lower


crankcase.

Inspection
1.

Remove the balancer gear from the balancer


weight by sliding the gear from the weight.

1. '0' Rings
2. Thrust Washers
3. Needle Roller Bearings
4. Balancer Gear
5. Shock Absorbers
6. Balancer Weight
7. Bearing Spacer
1. Balancer Clamp Pinch Bolts
2. Balancer Clamp To Crankcase Screws
3. Balancer Clamp
4. Balancers
5. Balancer 'Dot' Marks

5.3

2.

Visually inspect the rubber shock absorbers for


damage or deterioration. Replace as necessary.

3.

Visually check the needle bearings and bearing


tracks for abrasion, colour change (blueing), or
other damage. Always replace damaged bearings.

5 BALANCERS

4.

Fit new '0' rings whenever the balancers are


stripped.

5.

Once satisfied with the condition of all the


components, clean and re-assemble the balancers.

5.

Installation

Rotate the front spindle (nearest the crank)


clockwise until the spindle cannot be further
turned. This indicates that the gears are meshed
tightly together. Turn the spindle back fractionally
and tighten the pinch bolt to 12 Nm.

6.

1.

Set the crankshaft with number 1 and 4 cylinders at


TDC.

2.

Position each balancer in the crankcase, ensuring


that the gears mesh correctly, and the timing mark
on each balancer lines up with cast mark on
crankcase.

Clockwise Arrow- Front Spindle Direction of


Rotation
Anticlockwise Arrow- Rear Spindle Direction of
Rotation
1. Balancer Alignment Marks

3.

Fit the balancer spindles with the dots on the end of


the spindles facing downwards.

WARNING: In the following procedure,


the motorcycle engine must be run. The
exhaust fumes given off by the engine, when
running, contain carbon monoxide and other toxic
gases. Never start or leave the engine running in a
confined space unless an exhaust extraction
system is available and is connected directly to the
motorcycle exhaust system. If such a system is
not available, ensure that the building is
adequately ventilated to prevent a build up of
gases.
Remember, carbon monoxide is a
colourless, odourless gas which will cause
unconsciousness or death if inhaled in sufficient
quantity.

7.

Refit the sump and fill the engine with oil (refer to the
lubrication section). Start the engine and allow to
idle. Loosen the pinch bolt and adjust each spindle
in turn until there is no rattle (gears too far out of
mesh) and no whine (gears too far into mesh).
When correctly adjusted, tighten the pinch bolts to
12 Nm.

NOTE:
The balancer spindles must be adjusted, and
the pinch bolts tightened, individually.

1. Balancer Spindles with Dot Positions Arrowed


2. Spindle Pinch Bolts

4.

Fit the balancer clamp and tighten the retaining


screws to 12 Nm.

5.4

BALANCERS 5
3 Cylinder Balancers
Removal
1.

Remove the left-hand crankshaft cover.

NOTE:

Early models were fitted with an oil feed pipe


to the left hand crankshaft cover which must
also be removed.

On Thunderbird, Thunderbird Sport and


Adventurer, a centrifugal breather is fitted to
the left hand end of the crankshaft. Ensure
that the oil seal located in the left hand cover
is replaced before re-assembly.

2.

Rotate the crankshaft until No.1 cylinder is at TDC.

3.

Loosen the screws securing the balancer locking


plate to the crankcase. The screws are accessed
through holes in balancer gear.

1. Access Holes for Locking Plate Fixings


2. Timing Marks

NOTE:

4.

The locking plate screws are accessed


through the holes in the balancer gear.

A.

CAUTION: Use hand pressure only to


align the back-lash gear. The use of any
metal faced object will damage the gear faces.

When the locking plate drops down, the balancer


assembly can be withdrawn by sliding out from the
crankcase.

4.

Slide the locking plate upwards into position.

5.

Tighten the right-hand (rear) screw, and then the


left-hand (front) screw to 9 Nm.

6.

Refit the left-hand crankshaft cover using a new


gasket. Tighten the cover screws to 12 Nm.

Inspection
1.

Examine the backlash springs for wear, breakage


and looseness. Renew if in doubt.

2.

Check for ball bearing wear. If any bearing is worn,


the complete balancer must be replaced.

Installation
1.

Clean the threads of the locking plate screws and


holes.

2.

Apply 'Loctite 242' to the screw threads and loosely


fit the locking plate with the curved edge level with
the bearing bore.

3.

Check that No. 1 cylinder is still at TDC. Fit the


balancer assembly to the crankcase. To bring the
gear fully into mesh, compress the back-lash gear
while aligning the timing marks on the gear teeth as
shown over.

5.5

Crankshaft/Rods/Pistons
including Engine Removal/Installation
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4

Engine
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4
6.6

Crankcase
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8
6.1 0

Connecting rods
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12
6.12

Crankshaft
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14
6.14

Con rod big end bearing/crankpin wear


Con rod big end bearing/crankpin clearance . . . . . . . . . . . . . . . . . . . . . .
Crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15
6.15
6.15

Crankshaft main bearing/journal wear


Crankshaft main bearing/journal clearance . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft main journal diameter/bearing selection . . . . . . . . . . . . . . . .

6.16
6.16

Pistons
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston outside diameter/wear check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston ring/groove clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston ring end gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17
6.17
6.18
6.18
6.19

Cylinder wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.20

Cylinder liners
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.20
6.21

Left Hand Crankshaft Cover, all 4 Cylinder and


Thunderbird/Thunderbird Sport & Adventurer Engines . . . . . . . . . . . . . .

6.22

6.1

6 CRANKSHAFT/RODS/PISTONS
Exploded View

TORQUE IN ACCORDANCE
WITH RELEVANT SECTION

22Nm

27 Nm

6.2

CRANKSHAFT/RODS/PISTONS 6

95Nm

95Nm

6.3

6 CRANKSHAFT/RODS/PISTONS

DESCRIPTION

ENGINE REMOVAUREFIT

NOTE:

Removal

In order to carry out repairs to the crankshaft


and connecting rods, the engine must first be
removed from the motorcycle frame and the two
halves of the crankcase separated.

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.

The aluminium alloy crankcase houses, not only the


crankshaft, but also the geartrain and associated
components. Wet cylinder liners are fitted which are not
a press fit. The liners are sealed by means of a bead of
Hylomar at the joint face in the upper crankcase and the
cylinder head provides all necessary clamping load on
the liners. It is not necessary to check liner stand proud
from the upper crankcase as all tolerances are correctly
produced during manufacture.
Forged steel connecting rods are used which are not
bushed at the small end. The gudgeon pin runs direct in
the connecting rod and is lubricated via the splash feed
from the big end exit drilling. Connecting rods are
matched for weight and are fitted as matched sets for
optimum engine balance

1.

Remove the seat, disconnect the battery, negative


(black) lead first and remove the battery.

2.

Remove the fuel tank as described in the fuel


system section.

WARNING: Observe the warning advice

~ given in the general information section

on the safe handling of fuel and fuel containers. A


fire causing personal injury and damage to
property could result from spilled fuel or fuel not
handled and stored in the correct manner.
3.

Remove the bodywork, including the lower fairings

4.

Drain the engine oil into a suitable container.

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 and dermatitis. In addition used
engine
oil
contains
potentially
harmful
contaminants which can cause cancer. Wear
suitable clothing and avoid skin contact.
1. Connecting Rod Grade Markings
"'

CAUTION: Do not pour oil on the ground,


down sewers or drains, or into water
courses. To prevent pollution of water courses
etc., dispose of used oil sensibly. If in doubt
contact your local authority.

With the exception of number 2 cylinder, pistons and


liners are not graded. The piston and liner for number 2
cylinder are specially selected as a matched, close
tolerance set. On later models, number 2 cylinder liner is
marked 'B' on the mating face with the cylinder head
gasket. Selective fit crankshaft bearing shells are used
to produce an engine as close to the 'blueprinted'
specification as possible and to compensate for minor
variations (microns) in the crankcase and connecting
rods. On 4 cylinder engines, a centrifugal breather disc is
fitted to the left hand end of the crankshaft and is
connected to the airbox by a flexible hose. The breather
on 3 cylinder engines is integral with the clutch cover
and, as with the four cylinder, is connected to the airbox
by a flexible hose.

5.

Remove the coolant drain plugs and drain the


coolant into a suitable container. Retain the coolant
for re-use (if serviceable). Refit the drain plugs
when all coolant has drained out.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
cooling system is hot and also under pressure.
Contact with the pressurised coolant will cause
scalds and skin damage.

6.4

CRANKSHAFT/RODS/PISTONS 6

6.

1o. Remove the exhaust system completely.

Disconnect the top and bottom hoses and remove


the radiator. On Thunderbird, Thunderbird Sport
and Adventurer also disconnect the bypass and
cylinder head hoses.

7.

Tiger only: Remove the sump guard.

8.

Disconnect the oil cooler hoses (where fitted) from


the inlet and outlet points on the sump. Release the
oil cooler brackets from the side of the engine and
remove the cooler from the motorcycle frame.

11.

, - - - - - - - - - - - - -.. - - - - - - - - -

A.

CAUTION: Always hold the hexagonal


part of the oil cooler and any sump unions
with a spanner while releasing the cooler/pipe
unions. Damage to the oil cooler and/or pipes and
unions may result from failure to support the oil
cooler during release of the unions.

1.
2.
3.
4.
5.

Water Pump Hose Cover


Retaining Bolt
Washer
Lower Mounting Point
Upper Mounting Point

12. Remove the side stand assembly. Disconnect the


side stand switch cables from the switch.
13. Disconnect the following electrical connections to
the engine;
Alternator
Neutral indicator switch
Starter motor
Ignition pick-up sensor
Water temperature sensor
Oil pressure switch

1. Banjo Bolt
2. Feed Pipe
3. Return Pipe
9.

Release the gearchange rod from the pedal


(Thunderbird, Thunderbird Sport and Adventurer,
remove the gearchange pedal).

14. Remove the clutch slave cylinder from the sprocket


cover. Secure the piston with a cable tie to prevent
accidental loss of clutch fluid.

Disconnecting the oil cooler pipes


2

\ It
1. Clutch Slave Cylinder
2. Cable Tie

1. Oil Cooler Bracket


2. Oil Cooler

6.5

6 CRANKSHAFT/RODS/PISTONS

"J'

CAUTION: To prevent paint and body


damage, ensure that any displaced
clutch fluid does not come into contact with any
part of the engine or bodywork.

WARNING: If the swinging arm is allowed


to pull on the rear brake hose, however
briefly, the hose MUST be replaced. The damage
caused to the brake hose could lead to reduced
brake performance leading to loss of control and
an accident.

LU

15. Remove the clutch pushrod and remove the


sprocket cover from the engine.

19. Loosen all the engine mounting bolts then remove


the rear bolts only. Lower the rear of the engine and
disconnect the chain. Remove the front engine
mounting bolts and lower the engine from the
frame.

16. Release the chain adjusters to give maximum chain


slack.

Engine Installation
1.

Locate the engine to the support and position


beneath the frame. Inspect the chain rubbing block
and strip, renew as necessary.

2.

Align the engine to the rear mounting points


ensuring that the top edge of the chain is positioned
above the rubbing strip. Connect the chain to the
output sprocket.

1. Adjuster Clamp Bolt


2. Adjuster Wrench
3. Swinging Arm
17. Remove the lower outrigger finishers by releasing
the outer ring of capscrews (plastic plugs fitted to
early bikes). Remove the wire clips (where fitted)
and slacken the swinging arm spindle bolts.
Remove the chain guard.

-~-"-"~-"~"""--~~-"------

WARNING: The engine is heavy! Ensure


that the support method used is of
sufficient weight capacity to support the engine.
An engine which falls or becomes unstable during
removal could cause serious injury to the operator
and also cause damage to engine and fram]e
components.

NOTE: 'New' Trophy, remove both control plates to


gain access to the swinging arm spindle.

J,\_

CAUTION: Ensure the oil warning light


wiring does not become trapped during
alignment of the engine to the frame. damage to
both the switch and the wiring may take place if the
wiring becomes trapped.

L_U

18. Place a jack or other suitable support beneath the


engine and raise sufficiently to support the engine
weight during disconnection of the engine mounting
bolts. Place a block behind and in front of the rear
wheel to prevent the machine from moving.

3.

WARNING: The engine is heavy! Ensure


that the support method used is of
sufficient weight capacity to support the engine.
An engine which falls or becomes unstable during
removal could cause serious injury to the operator
and also cause damage to engine and frame
components.

Fit new engine mounting bolts and nuts, front first


then rear. Tighten the engine mounting bolts to
95Nm.

WARNING:
Never re-use engine
mounting bolts.
Reusing old engine
mounting bolts could lead to the bolt loosening in
service leading to loss of control and an accident.
4.

Tighten the swinging arm spindle bolts to 85 Nm.


Refit the wire clips (where fitted) to the bolts. Refit
the outrigger finishers (control plates on 1996
Trophy).

5.

Refit the clutch pushrod. Clean and refit the


sprocket cover using a new gasket. Tighten the
sprocket cover bolts to 12 Nm.

"J'

CAUTION: When removing the engine,


ensure that the swinging arm and rear
wheel are well supported at all times. When the
rear engine mountings bolts are removed, the
swinging arm and linkage carriers are free to move.
Any excessive movement of the swinging arm will
cause damage to the rear brake hose.

LU

6.6

CRANKSHAFT/RODS/PISTONS 6

6.

Adjust the drive chain tension and wheel alignment


as detailed in the maintenance section.

CAUTION: Always hold the hexagonal


part of the oil cooler and any sump unions
with a spanner while releasing or tightening the
cooler/pipe unions. Damage to the oil cooler
and/or pipes and unions may result from failure to
support the oil cooler during release or tightening
of the unions.

WARNING: Operation of the motorcycle

~ with insecure eccentric adjuster clamp


bolts may result in impaired stability and handling
of the motorcycle. This impaired stability and
handling may lead to loss of control or an accident.

14. Tiger only, refit the sump guard.


7.

Remove the retaining band from the clutch slave


cylinder and refit the cylinder to the sprocket cover.

8.

Refit the side stand assembly and reconnect the


side stand switch. Tighten the centre mounting bolt
to 95 Nm and the upper fixing to 22 Nm.

9.

15. Fit the radiator and stone guard to the frame and
reconnect all coolant hoses. Use new hose clips
where necessary.

'f

CAUTION: Some models are fitted with


crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.

Reconnect the following electrical connections;


Alternator
Neutral indicator switch
Starter motor
Ignition pick-up sensor
Water temperature sensor
Oil pressure switch

16. Refit the fuel tank as described in the maintenance


section.
17. Add engine oil to the correct level as described in
the lubrication section of this manual.

10. Refit the choke and throttle cables to the


carburettors. Locate the airbox into the frame and
assemble;
the carburettors to the engine
the airbox to the carburettors.
Adjust the throttle and choke cables as detailed in
the fuel system section.

~ CAUTION: Refer to the owners handbook


~ for the correct grade of engine oil. Use of
the wrong grade of oil could damage the engine.
18. Add coolant to the correct level as described in the
cooling section of this manual.

WARNING: Operation of the motorcycle

19. Refit and reconnect the battery, positive (red) lead


first.

~ with an incorrectly adjusted, incorrectly


routed or damaged throttle and/or choke cable
could interfere with the operation of the brakes,
clutch or the throttle. Any of these conditions
could result in loss of control of the motorcycle
and an accident.

20. Refit the bodywork and seat.

WARNING: Move the handlebars to left


and right full lock while checking that
cables and harnesses do not bind. A cable or
harness which binds will restrict the steering and
may cause loss of control and an accident.
11.

Refit the exhaust system using new gaskets.

12. Connect and adjust the gear-change rod


(Thunderbird, Thunderbird Sport and Adventurer,
refit the gearchange pedal).
13. Refit the oil cooler and brackets to the engine. Refit
the oil cooler pipes using new sealing washers to
the banjo bolts.

6.7

6 CRANKSHAFT/RODS/PISTONS

CRANKCASES

upper crankcase screws 1-12 for 4 cylinder


engines WITHOUT alternator cover,

Before splitting the crankcases, the following items must


be removed
1.

Sump.

2.

Engine covers

3.

Alternator drive cover (where fitted).

4.

Alternator.

5.

Starter motor.

7.

Ignition pick-up.

8.

Cylinder Head and cam chain.

Disassembly
NOTE:

Four different types of crankcase have been


used in the manufacture of Triumph engines.
All four crankcases have a different screw
release sequence. Always ensure that you have
correctly identified the crankcase type being
worked on from the series of diagrams which
follow.
Having correctly identified the
crankcase type, ensure that the screw release
sequence given in the selected diagram is
followed.

11
9
10
4 Cylinder Upper Crankcase (WITHOUT alternator
cover)

upper crankcase screws 1-8 for 3 cylinder engines


WITH alternator cover,

1\.
~

CAUTION: Failure to follow the correct


screw release sequence may result in
permanent crankcase damage.
----------------------~

1.

Progressively release the upper crankcase screws


in the sequence shown for the type of crankcase
being disassembled.
The correct screw release sequences are;

upper crankcase screws 1-8 for 4 cylinder engines


WITH alternator cover,

3 Cylinder Upper Crankcase {WITH alternator


cover)

4
5
6
8
4 Cylinder Upper Crankcase WITH alternator cover

6.8

CRANKSHAFT/RODS/PISTONS 6

upper crankcase screws 1-12 for 3 cylinder


engines WITHOUT alternator cover.

lower crankcase screws 1-4 for 4 cylinder engines


WITHOUT alternator drive cover,

8
3

1'1!>111Ttt----

I~JR-1+---

12

10 11
3 Cylinder Upper Crankcase (WITHOUT alternator
cover)
9

2.

Invert the engine.

3.

Progressively release the lower crankcase screws


in the sequence shown for the type of crankcase
being disassembled.
The correct screw release sequences are as
follows;

4 Cylinder Lower Crankcase (WITHOUT Alternator


Drive Cover).

lower crankcase screws 1-18 for early 3 cylinder


engines WITH alternator drive cover,

18

15

11

13

16

I:\

CAUTION: Failure to follow the correct


screw release sequence may result in
permanent crankcase damage.

lower crankcase screws 1-22 for 4 cylinder engines


WITH alternator drive cover,

21

19

17

13

15

--+-0-':1

--+fo>-("

IU--f---

3
7

.....,._~JN-dU~--

9
1

22

17

12

4
20

12
6

10

14

3 Cylinder Lower Crankcase (Engines WITH


Alternator Drive Cover).

14
4 Cylinder Lower Crankcase (WITH Alternator
Drive Cover).

6.9

6 CRANKSHAFT/RODS/PISTONS

lower crankcase screws 1-14 for later 3 cylinder


engines WITHOUT alternator cover.

1.

Apply Loctite 648 to the outer races of the gearbox


bearings. Fit the gearbox shafts ensuring the
locating ring on the input shaft is in position in the
circlip groove on the crankcase. Engage the clutch
primary gear with crankshaft gear.

2.

Ensure that the input and output gear shafts are in


the neutral position.

3.

Ensure that the 3 locating dowels are in position in


the upper crankcase. On 3 cylinder engines ensure
that the balancer locating dowel is also fitted.

4.

Use high flash-point solvent to clean the crankcase


mating faces. Wipe the surfaces clean with a
lint-free cloth.

5.

Apply a thin bead of silicone sealant to the lower


crankcase mating faces.

iA

3 Cylinder Lower Crankcase screws (Engines


WITHOUT Alternator Drive Cover)

4.

Assembly

Separate the lower and upper crankcases ensuring


that the 3 locating dowels remain in the upper
crankcase. Remove the clutch pushrod seal.

C~UTIO~:-------;;-~

not use excessive

amounts of sealer. The extra sealer may


ecome dislodged and could block the oil
assages in the crankcases causing severe
Lengine damage.

6.

__j

Fit a new '0' ring to the oil pump outlet.

1. Locating Dowels
------------ ------ I

CAUTION: Do not use levers to separate I


the upper and lower sections of the I
crankcase or damage to the crankcases could
result.
1

- - - - - ___j

6.10

Arrowed: Oil Pump '0' Ring Position.


7.

Lubricate the crankshaft journals and bearing shells


with clean engine oil.

CRANKSHAFT/RODS/PISTONS 6

8.

Position the lower crankcase to the upper, ensuring


that all selectors engage correctly. An assistant
may be required to support the crankcase during
alignment.

Stage 2 - all screws


14. Invert the engine.
In the correct sequence, tighten all lower crankcase
screws to 12 Nm.
15. Invert the engine.
In the correct sequence, tighten all upper crankcase
screws to 12 Nm.
Stage 3 - MB screws only
16. Invert the engine.
In the correct sequence, tighten the M8 lower
crankcase screws to 28 Nm.
17. Invert the engine.
In the correct sequence, tighten the M8 upper
crankcase screws to 28 Nm.

Selector Forks
9.

Fit the screws into the lower crankcase and hand


tighten.

18. Rotate the crankshaft in the direction of the arrow on


the ignition rotor (clockwise). Check for tight spots
and rectify as necessary.

10. Invert the engine.


11.

Fit the screws into the upper crankcase and hand


tighten.

19. Apply silicone sealant to the clutch push rod seal


and press into the crankcase.

NOTE:

The crankcase screws are tightened in stages,


in the same sequences used during strip down.
Refer to the strip down procedure earlier in this
section for the correct screw tightening
sequence for the type of crankcase being
assembled.
Two different sizes of crankcase screw are
used. All screws are tightened through the first
two stages of the tightening procedure but only
the MB size screws are tightened at the third
stage.

A.

CAUTION: Failure to follow the correct


screw tightening sequence may result in
permanent crankcase damage.

Stage 1 - all screws


12. Invert the engine.
In the correct sequence, tighten all lower crankcase
screws to 10 Nm.
13. Invert the engine.
In the correct sequence, tighten all upper crankcase
screws to 10 Nm.

6.11

6 CRANKSHAFT/RODS/PISTONS
CONNECTING RODS
Installation

Removal
1.

NOTE:

Release the connecting rod nuts and remove the


big end cap.

Connecting rod bolts and nuts are treated with


an anti-rust solution which must not be
removed.

Clean the connecting rod with high flash-point


solvent.

Remove all bearings and inspect for damage,


wear and any signs of deterioration and replace
as necessary.

1.

Fit new connecting rod bolts to the big end.

NOTE:

Ensure that con rod is fitted correctly, (oil hole


in the connecting rod on the opposite side from
the arrow on the piston crown).

NOTE:

It may be necessary to gently tap the big end


cap with a rubber mallet to release the cap from
the studs.

2.

Mark each big end cap and connecting rod to


identify both items as a matched pair.

3.

Ensure that the bearing shell stays in the big end


cap.

4.

Remove each piston and connecting rod assembly


together with the cylinder liner.

5.

Label the assembly to identify the cylinder from


which it was removed.

2 ----...

CAUTION: Never re-use connecting rod


~ bolts or nuts. If the connecting rod cap is
disturbed, always renew the bolts and nuts. Using~
the original nuts and bolts may lead to severe
engine damage.

1. Connecting Rod with Oil Hole Arrowed


2. Piston Arrow
2.

6.12

Apply molybdenum disulphide grease to the upper


inner surface of the connecting rod big end.

CRANKSHAFT/RODS/PISTONS 6

NOTE:

Avoid touching any bearing surfaces of the


bearing shells with the hand.

3.

Fit the piston and connecting rod assembly into the


liner. Fit the assembled liner into the crankcase
ensuring that the arrow on the piston faces forward,
and the oil hole in the connecting rod faces rearward
(see liner remove refit section).

4.

Lubricate both surfaces of bearing shell with engine


oil and fit to the connecting rod and big end cap.

5.

Align the connecting rod to the crankshaft and fit the


big end cap.

To accurately gauge the 120 turn, fit the tool


between the socket and the drive handle and
locate the socket to the big end nut. Pick an
increment point on the torque turn gauge which
aligns with a suitable reference point on the
engine. Tighten the bolts until 12 of the 10
gauge increments have rotated past the chosen
point.

Increment
marking

Service Tool 3880105-T0301

Aligning the Connecting Rod


6.

Tighten each cap (using new nuts and bolts) as


follows:

'!'

CAUTION: The torque characteristics of


the connecting rod nuts and bolts are
sensitive to the rate at which they are tightened. If
all the torque is applied in one action, the bolt may
be stretched and the nut may become loose when
in service resulting in an expensive engine failure.

Lubricate the threads of the bolt and the face of the


nut with molybdenum disulphide grease. Tighten
the nuts progressively in 2 stages;firstly to 14 Nm
then through 120 of nut rotation as measured
using the Triumph torque turn gauge
3880105-T0301.

6.13

6 CRANKSHAFT/RODS/PISTONS

CRANKSHAFT

Installation

NOTE:

Before the crankshaft can be removed, the two


halves of the crankcase must first be separated.

Removal

1\

--------------

1.

Remove the connecting rods as described in the


previous section.

2.

Remove the breather disc (where fitted) from the


crankshaft.

3.

Release and remove the crankshaft from the upper


crankcase.

CAUTION:

Always check the bearing I

journal clearance, as described in th:~


following pages, before final assembly of the
crankshaft. Failure to correctly s.elect crankshaft
bearings will result in severe engme damage.
--------------------

--------

1.

Select and fit new main and big end bearings using
the selection processes detailed over.

2.

Lubricate all bearings with engine oil.

3.

Ensure that the crankshaft is clean and that the


oilways within the crank are free from blockages
and debris. Position the crankshaft in the upper
crankcase.

4.

Fit the connecting rods, liners etc. as described in


the previous section.

5.

Refit the breather disc to the crankshaft and tighten


the fixings to 22 Nm.

NOTE:

NOTE:

Remove all bearings and inspect for damage,


wear, overheating (blueing) and any other signs
of deterioration. Replace the bearings as a set if
necessary.

Later 4 cylinder crankcases are fitted with


non-grooved main bearing shells to journals 1,
3 and 5. Journals 2 and 4 remain grooved as
before. Ensure that the non-grooved shells are
fitted to the correct journals. The non-grooved
shells are not interchangeable. REFER TO THE
PARTS INFORMATION IF IN DOUBT.

6.14

Refer to the early part of this chapter for details


of crankcase assembly.

CRANKSHAFT/RODS/PISTONS 6
CONNECTING ROD BIG END BEARING
SELECTION/CRANKPIN WEAR CHECK
1.

3.

Measure the bearing and crankpin clearance as


follows.

If the measured clearance exceeds the service


limit, measure the crankpin diameter.

Crankpin diameter
Standard:
Service limit:

NOTE:

Do not turn the connecting rod and crankshaft


during the clearance measurement as this will
damage the plastigauge.

2.

The crankpin clearances are measured using


'Piastigauge' (Triumph part number 3880150).
Remove the big end cap from the required journal.
Wipe the exposed areas of both the crankpin and
the bearing face inside the cap. Apply a thin smear
of grease to the journal and a small quantity of
silicone release agent to the bearing.
Trim a length of the plastigauge to fit across the
journal. Fit the strip to the journal using the grease
to hold the plastigauge in place. Lubricate the
threads of the bolt and the face of the nut with
molybdenum disulphide grease. Refit the bearing
and cap and tighten the big end nuts progressively
in two stages;
Firstly to 14Nm
Then through 120 of nut rotation as measured
using the Triumph torque turn gauge
38801 05-T0301.
Release the nuts and remove the cap being
measured. Using the gauge provided with the
plastigauge kit, measure the width of the
compressed plastigauge.

40.946 - 40.960 mm
40.932 mm

If any crankpin has worn beyond the service limit, the


crankshaft must be replaced. Due to the techniques
used during manufacture, the crankshaft cannot be
reground and no oversize bearings are available.

Connecting Rod Bearing Selection


Differences in connecting rod dimensions
compensated for by using selective bearings.
1.

are

Select the correct big end bearing shell as follows:


Measure each crankpin diameter.
Check connecting rod for either an A or B mark.
Select the correct bearings by matching the
information found with the chart below.

Big end bearing selection chart


(all dimensions in mm's)
Bearing Shell
Part Number
Shell Colour
Con-rod Mark
Crankpin
Diameter
Running
Clearance

1110051
White
A
40.960
40.954

For instance:
Con-rod Mark
Crankpin Diameter
Required Bearing

1110053
1110052
Blue
Red
B
B
A
40.953 40.960 40.953
40.946 40.954 40.946
0.036-0.066

A
40.951
Red

NOTE:
Repeat the measurements for all connecting
rods and their respective crankpins.

It is normal for the bearings selected to differ


from one connecting rod to another.

2.

Install the new bearings in the connecting rod.

A.

CAUTION: Always confirm, using the


plastigauge method, that the running
clearance is correct before final assembly. Severe
engine damage could result from incorrect
clearance. Ensure all traces of plastigauge are
removed after use to prevent blockage of the oil
drillings and resultant engine damage.

Checking the Measured Clearance

Con rod big end bearing/crankpin


clearance
Standard:
Service limit:

0.036 - 0.066 mm
0.1 mm

6.15

6 CRANKSHAFT/RODS/PISTONS
CRANKSHAFT MAIN BEARING/JOURNAL WEAR
Bearing Selection Chart (all dimensions in mm's)
Bearing Shell
Part Number

1160371

1160372

1160373

1160374

1160361

1160362

1160363

1160364

Shell Colour

White

Red

Red

Blue

Blue

Green

Crankcase Bore

41.126
41.118

41.126
41.118

41.135
41.127

41.135
41.127

41.144
41.136

41.144
41.136

Journal Dia'

37.976
37.969

37.968
37.960

37.976
37.969

37.968
37.960

37.976
37.969

37.968
37.960

Running
Clearance

All types
0.044- 0.020

NOTE:

1.

All dimensions in mm's Figures in italics are


bearing part numbers for later 1200 engines
(journals 1,3 and 5 only). All other engines use
standard bearings.
Measure the bearing to crankshaft main journal
clearance using plastigauge (Triumph part number
3880150). (Basic method described in connecting
rod clearance measurement).

If any journal has worn beyond the service limit, the


crankshaft must be replaced. Due to the techniques
used during manufacture, the crankshaft cannot be
reground and no oversize bearings are available.

Select bearings as follows:


1.

Measure and record the diameter of


crankshaft main bearing journal.

each

2.

Measure and record each main bearing bore


diameter in the crankcase (bearings removed).

Compare the data found with the chart above to select


bearings individually by journal.

For instance:
Crankshaft Journal diameter
Crankcase Bore
Bearing Required

37.972 mm
41.130 mm
RED

NOTE:

Checking crankpin clearance using plastigauge

CAUTION: Always confirm, using the


plastigauge method, that the running
clearance is correct before final assembly. Severe
engine damage could result from incorrect
clearance. Ensure all traces of plastigauge are
removed after use to prevent blockage of the oil
drillings and resultant engine damage.

Crankshaft main bearing/journal


clearance
Standard:
Service limit:
2.

0.020- 0.044 mm
0.08 mm max.

If the clearance exceeds the service limit, measure


the diameter of the crankshaft main journal.

Crankshaft End Float

Crankshaft main journal diameter


Standard:
Service limit:

It is normal for the bearings selected to differ


from one journal to another.

Standard
Service Limit

37.960 - 37.976 mm
37.936 mm

6.16

0.05 - 0.20 mm
0.4 mm maximum

CRANKSHAFT/RODS/PISTONS 6

PISTONS

Piston Wear Check


1.

Disassembly

Measure the piston outside diameter, 5 mm up from


the bottom of the piston and at goo to the direction of
the gudgeon pin.

NOTE:

The pistons and connecting rods can be


separated after removing the cylinder head and
liners. It is not necessary to remove the
connecting rods from the crankshaft.

1.

Remove the liner assembly from the crankcase.

2.

Remove the gudgeon pin circlip from one side of the


piston.

1. Piston Outside Diameter


2. Measurement Point (5mm Up The Piston Skirt)
3. Circlip Removal Groove

Piston outside diameter


Standard:

75.96 - 75.98 mm

Cylinder 2:

75.97- 75.96

Replace the piston if worn beyond the service limit.

Removing the Gudgeon Pin Circlip


3.

Remove the gudgeon pin by pushing the pin


through the piston and rod toward the side from
which the circlip was removed.

'!'

CAUTION: Never force the gudgeon pin


through the piston. This may cause
damage to the piston which may also damage the
liner when assembled.

NOTE:

If the gudgeon pin is found to be tight in the


piston, check the piston for a witness mark
caused by the circlip. Carefully remove the
mark to allow the pin to be removed.

4.

Piston rings must be removed from the piston using


hand pressure only.

6.17

6 CRANKSHAFT/RODS/PISTONS

Piston Rings/Ring Grooves

Piston Ring Gap

Check the pistons tor uneven groove wear by visually


inspecting the ring grooves.

NOTE:

If all the rings do not fit parallel to the groove upper and
lower surfaces, the piston must be replaced.
Fit the piston rings to the pistons. Check, using feeler
gauges, tor the correct clearance between the ring
grooves and the rings. Replace the piston and rings if
outside the specified limit.

Before final assembly the piston ring gap, when


fitted in the liner, must first be checked.

1.

Place the piston ring inside the liner.

2.

Push the ring into the top of the cylinder, using the
piston to hold the ring square with the inside of the
bore. Continue to push the ring into the bore until the
third groove of the piston is level with the cylinder
top, around full circumference of cylinder.

Piston Ring to Ring Groove Clearance Check


Aligning Piston Rings using the Piston

Piston ring/Groove Clearance


Top
Second

Standard
0.02 - 0.06 mm
0.02 - 0.06 mm

3.

Remove the piston and measure the gap between


the ends of the piston ring using feeler gauges.

Piston Ring End Gap Tolerances


Top
Second
Oil
4.

6.18

Service Limit
0.20-0.41 mm
0.35 - 0.56 mm
0.29 - 0.85 mm

If 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 new
rings fitted, the piston and liner should be replaced
as a pair.

CRANKSHAFT/RODS/PISTONS 6

3.

Piston Assembly
1.

The piston ring gaps must be arranged as shown in


the diagram below.

Clean the piston ring grooves and fit the piston rings
to the piston.

FRONT

NOTE:

The top ring upper surface is marked 'N' and can


be identified by a chamfer on the inside edge.
The top ring has a chromed appearance.

The second ring upper surface is also marked


'N' but is plain on the inside edge and has a dull
grey appearance.

The oil control rings can be fitted with either


face upward.

3=

1. Top Ring
2. Second Ring
3. Steel Oil Control Rings
4. Oil Control Ring Expander

Second Ring

4.

Piston Ring Identification


2.

Fit the piston onto the connecting rod with the arrow
on the piston crown facing AWAY from the oil hole in
the connecting rod. Align the small end in the
connecting rod with the gudgeon pin hole in the
piston.
Lubricate the piston, small end and
gudgeon pin with clean engine oil and fit the
gudgeon pin. Fit new circlips on both sides of the
gudgeon pin ensuring the circlips are correctly fitted
in the grooves.

WARNING: Failure to use new gudgeon


pin circlips could allow the pin to detach
from the piston. This could seize the engine and
lead to an accident.

6.19

The top ring gap should be positioned in the 7


o'clock position, the second ring gap in the 1
o'clock position and the steel oil control ring
gaps in the 9 & 3 o'clock positions (one in each
position).
Fit the piston into the liner using a gentle rocking
motion to engage the rings in the bore.

6 CRANKSHAFT/RODS/PISTONS

CYLINDER WEAR

CYLINDER LINERS

Measure the inside diameter of each cylinder using a


internal micrometer or similar accurate measuring
equipment.

Removal

Cylinder inside diameter


Standard:
76.03- 76.05 mm
Service limit:
76.1 mm
1. Check the diameter at points 1, 2 and 3.

Cylinder liners can be removed with engine in


the frame, after the cylinder head has been
removed.

Number 2 cylinder liner is a selective fit. On


early engines it is identified by a green dot. On
later engines, number 2 liner is also identified
by a '8' marking to the upper mating face with
the cylinder head gasket. Markings other than
the '8' are for manufacturers reference.

NOTE:

Test Positions For Bore Wear Check (bore shown


in section)
2.
If any reading is outside the specified limits, replace
the liner and piston as an assembly.

Number 2 cylinder liner typical markings (later


engine)

6.20

1.

Mark each liner to identify correct orientation and


the cylinder number from which it has been
removed.

2.

Remove each liner, using hand force only, taking


care to ensure that the piston/connecting rod is not
allowed to fall against the inside of the crankcase.

CRANKSHAFT/RODS/PISTONS 6

3.

Installation

Fit each liner over the piston using a gentle rocking


motion to allow compression of the piston rings.

NOTE:

All engines use Blue Hylomar to seal the base of


the liners to the crankcase.

1.

Remove all traces of old sealing compound from the


liners and crankcase. Ensure that all sealing areas
are completely clean and dry.

2.

Apply a bead of Blue Hylomar, 3-4mm wide, to the


corner radius of the liner. The bead of sealer must
be applied to the full circumference of the liner.

Liner Fitted In Direction Of Arrow

CAUTION: Fit each liner over whichever


piston is at TDC. When turning the
engine, do not allow the pistons to contact the
inside of the crankcase and also do not allow fitted
liners to lift off the crankcase base. If any liners do
lift, the whole sealing and fitting process MUST be
repeated.
A coolant leak, causing overheating and engine
damage, could occur if liner seal is damaged

Arrowed: Hylomar Bead


4.

CAUTION: Allow each liner to stand for


15 minutes before fitting the liner to the
crankcase.
A coolant leak, causing overheating and engine
damage, could occur if the sealer is not allowed 15
minutes curing time prior to fitment.

NOTE:

The liners have a large chamfer at the bottom of


the bore enabling fitting without need for a
piston ring compressor.

6.21

Continue fitting each liner in turn until all are fitted


and sealed.

6 CRANKSHAFT/RODS/PISTONS

Left Hand Crankshaft Cover


Thunderbird, Thunderbird Sport,
Adventurer and all 4 Cylinder Engines

A.
~

The left hand crankshaft cover on all four cylinder


engines and on the Thunderbird, Thunderbird Sport and
Adventurer is fitted, on the inside face, with a lip type
seal. The lip seal prevents oil from entering the outlet
port for the crankcase gases.

CAUTION:
The engine must not be
started or turned over for a minimum of 15
minutes after assembly to allow the seal to fully
expand onto the breather shaft.
Failure to allow time for seal expansion will result
in high engine oil consumption, smoke emissions
and possible engine damage.

Seal/Cover Renewal
Under normal circumstances it should not be necessary
to disturb the cover or the seal. However, should the
cover require removal, the following procedure must be
used.

1.

Remove the cover and carefully lever the seal from


the cover.

NOTE:

A new seal is supplied with a mandrel already


fitted.

2.

Without removing the mandrel supplied with the


seal, press the new seal into the seal recess in the
cover to a point where it is just below the face of the
recess.

A.

CAUTION: The seal must be kept level


during and after fitment. A non-level seal
will cause high engine oil consumption, smoke
emissions and possible engine damage.

Thunderbird!Thunderbird Sport/Adventurer Left


Hand Engine Cover

3.

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 shaft are
clean and dry.

4.

Fit the cover assembly taking great care not to


damage the seal during fitment and alignment of the
cover.

Cover Removal/Refit
1.

If the cover and seal are to be replaced without


renewing either component, a mandrel MUST be
inserted into the seal to prevent the seal from
distortion.

A.

NOTE:

The mandrel must remain in the seal from


immediately after removal to 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 shaft are
clean and dry.

3.

Fit the cover assembly taking great care not to


damage the seal during fitment and alignment of the
cover.

A.

CAUTION: If the seal is damaged or is


suspected of becoming damaged, it must
be replaced.
Failure to replace a damaged seal will result in high
engine oil consumption, smoke emissions and
possible engine damage.

CAUTION: If the seal is damaged or is

~ suspected of becoming damaged, it must


be replaced.
Failure to replace a damaged seal will result in high
engine oil consumption, smoke emissions and
possible engine damage.

6.22

A.

CAUTION:
The engine must not be
started or turned over for a minimum of 15
minutes after assembly to allow the seal to fully
expand onto the breather shaft.
Failure to allow time for seal expansion will result
in high engine oil consumption, smoke emissions
and possible engine damage.

Transmission
CONTENTS
Page
Exploded views...................................................

7.2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6

Alternator spindle & Sprag Clutch


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. 7
7.8

Starter motor idler gear


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9
7.10

Selector drum
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11
7.13
7.13

Input/output shaft assemblies


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15
7.15

Input shaft assembly


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.16
7.17

Output shaft assembly


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly.....................................................

7.18
7.19

7.1

7 TRANSMISSION _ _ __

Exploded
Geartrain

v1ew

132 Nm

7.2

------~T~'RA;ANNSMISSION 7
Exploded View
Jary
AUXII

Gears

12 Nm

7.3

7 TRANSMISSION
Exploded
Selectors

v1ew

12 Nm

9 Nm

12Nm

12 Nm

7.4

TRANSMISSION 7
Exploded View
Gear Pedal and Mechanism

12 Nm

9Nm

!1~:!
___________ _j~~ I
I
Thunderbird/Adventu~--~
I
I
1

9Nm

.~.. ~
L
____________ _j
I

7.5

7 TRANSMISSION
AUXILIARY GEARS

1.
2.
3.
4.
5.

Starter Motor
Alternator
Starter Idler Gear
Sprag Clutch
Alternator Drive Gear

6.
7.
8.
9.
10.

Clutch Auxiliary Drive Gear


Oil Pump Auxiliary Gear
Oil Pump Intermediate Gear and Shaft
Oil Pump Drive Gear
Oil Pump

shaft. When the starter is energized, the sprag clutch


action allows the alternator shaft on which it is mounted
to be driven by the starter idler gear. The alternator shaft
transmits drive to the crankshaft via the alternator drive
gear and clutch auxiliary drive gear.

TRANSMISSION DESCRIPTION
All Triumph motorcycles are fitted with either a five or six
speed, constant mesh transmission. All gears are
straight cut and no synchromesh system is used.
Selection of gears is via a grooved drum which actuates
three selector forks within the transmission. The forks
remain in constant contact with the gear hubs at all times.
The final drive ratio, that is to say the ratio between the
transmission output sprocket and the rear wheel
sprocket, is variable. The change in ratio is brought
about by selection of front and rear sprockets with
different numbers of teeth.
An integral part of the transmission is the auxiliary gears
which drive the following:
Water pump
Oil pump
Alternator
Starter Motor

Engine Started
When the engine starts, and the starter button is
released, the crankshaft drives the clutch and alternator
drive gears causing the alternator shaft to rotate.
Because the alternator shaft and alternator are now
being driven, under engine power, by the alternator drive
gear (as opposed to being driven by the starter idler
gear), the sprag clutch free-wheels and the starter idler
gear does not turn.

Oil and Water Pump Drives


Drive to both the oil and water pumps is supplied by a
gear and shaft in mesh with the clutch auxiliary gear.
The oil pump auxiliary gear is connected to the oil pump
by a shaft, to which an intermediate gear is fitted. The
intermediate gear drives the oil pump drive gear thus
driving the oil pump. At the other side of the oil pump, a
slotted shaft extends, from which the water pump is
directly driven.

Auxiliary Gears - Operation


Engine Cranking
The starter motor, which is fitted in the upper crankcase,
drives an idler gear in constant mesh with the sprag
clutch. The sprag clutch is mounted on the alternator

7.6

TRANSMISSION 7

ALTERNATOR SPINDLE and SPRAG


CLUTCH
NOTE:

The sprag clutch is always replaced as an


assembly. No individual parts are available.

Later models are NOT fitted with a cover above


the alternator drive gears. On these later
models, the engine must be removed from the
frame and the crankcase halves separated to
gain access to the sprag clutch Refer to the
previous section for details of engine removal
and crankcase separation.

~
gacq

1. Alternator Drive Rubber Shock Absorbers


7.
Remove the alternator drive cover (if fitted) from the
top of the upper crankcase (separate the crankcase
halves if no cover is fitted).

Removal
NOTE:

If the engine has been removed and the


crankcase halves separated, proceed to item 4.

1.

Remove the seat and disconnect the battery,


negative (black) lead first.

2.

Remove the lower fairings (if fitted) and, on later


models also remove the water pump hose cover
(not Thunderbird, Thunderbird, Thunderbird Sport
or Adventurer).

3.

8.

WARNING: The oil may be hot to the


touch. Contact with hot oil may cause the
skin to be scalded or burned. Prolonged or
repeated contact 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 contact.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire causing personal injury and damage to
property could result from spilled fuel or fuel not
handled and stored in the correct manner.
Remove the three bolts securing the alternator to
the crankcase noting the position of the earth lead
under one of the alternator bolts.

5.

Remove the alternator.

6.

Remove the alternator rubber shock absorbers


from the alternator drive housing.

If the crankcases have not been separated, position


a suitable container beneath the clutch cover to
collect engine oil. Remove the clutch cover and
complete clutch assembly as described in the
clutch section.

Remove the body side panels, fuel tank,


carburettors and airbox. Disconnect the alternator
multi-plug.

4.

~~

9.

Prevent the alternator shaft from turning by fitting


service tool 3880040 to the upper alternator
mounting bolts

Service Tool 3880040

7.7

7 TRANSMISSION

10. Remove the bolt securing the alternator drive gear


(in the clutch housing) to the alternator spindle. If
the spindle is to be renewed, release the bolt
securing the alternator drive housing to the spindle.

CAUTION: Extreme care must be taken to


ensure no parts are allowed to fall into the
bottom of the crankcase. Parts which fall into the
crankcase could cause severe engine damage.

NOTE:

Installation

Later models are fitted with a nut and bolt


arrangement to secure the alternator drive gear
and housing. The bolt passes through the
length of the alternator spindle.

1.

Position the alternator spindle to the crankcase and


feed onto the spindle; the sprag clutch spacer,
sprag clutch and spindle sleeve.

11 . Remove the service tool 3880040 and withdraw the


alternator drive housing complete with spindle. If
required, remove the alternator drive housing from
the shaft.
12. Remove the alternator drive gear from within the
clutch housing.
13. Collect the sprag clutch assembly, sprag clutch
spacer (at the alternator side).

Fitting the alternator shaft


2.
Assemble the alternator drive gear (and alternator
drive housing if removed) to the spindle. Refit tool
3880040 and tighten the alternator drive gear and
alternator drive housing bolts to 35Nm (40 Nm if a
nut and bolt arrangement).

NOTE:

If both the alternator drive gear and alternator


drive housing bolts have been removed, tighten
the alternator drive gear bolt first then the
alternator drive housing bolt.

Later models, fitted with the nut and bolt


arrangement for securing the alternator drive
housing and gear should be tightened to 40 Nm.

3.

Remove tool 3880040 and refit the rubber shock


absorbers to the alternator drive housing.

1. Sprag Clutch
2. Spacer
13. Collect the splined spacer from the clutch side of the
crankcase.

1. Splined Spacer

7.8

TRANSMISSION 7

STARTER MOTOR IDLER GEAR


NOTE:

Later models are NOT fitted with a cover above


the alternator drive gears. On these later
models, the engine must be removed from the
frame and the crankcase halves separated to
gain access to the starter idler gear. Refer to
the previous section for details of engine
removal and crankcase separation.

Removal

NOTE:
1. Alternator Drive Rubber Shock Absorbers
4.
5.

Fit the alternator drive cover (if fitted) using a new


gasket. Tighten the bolts to 9Nm
Refit the alternator and ensure that the earth strap is
correctly located under the alternator bolt. Tighten
the alternator retaining bolts to 20Nm.

If the engine has been removed and the


crankcase halves separated, proceed to item 6.

1.

Remove the seat, disconnect the battery, negative


(black) lead first and remove the body side panels.

2.

Remove the lower fairings from both sides (if fitted),


also remove the fuel tank, carburettors and airbox.

NOTE:

If the engine has been removed and the


crankcase halves separated, assembly of the
crankcases can now begin.

6.

Refit the clutch and clutch cover as detailed in the


clutch section. Top up the engine with the correct
grade of engine oil.

7.

Reconnect the alternator multi-plug and refit the


carburettors, airbox and fuel tank.

8.

Refit all bodywork previously removed. Reconnect


the battery, positive (red ) lead first.

9.

Refit the seat.

WARNING: Observe the warning advice

~ given in the general information section


on the safe handling of fuel and fuel containers. A
fire causing personal injury and damage to
property could result from spilled fuel or fuel not
handled and stored in the correct manner.
3.

If the crankcases have not been separated, position


a suitable container beneath the clutch cover to
collect engine oil. Remove the clutch cover and
complete clutch assembly as described in the
clutch section.

WARNING: The oil may be hot to the


touch. Contact with hot oil may cause the
skin to be scalded or burned. Prolonged or
repeated contact 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 contact.

7.9

7 TRANSMISSION

4.

Remove the alternator drive cover (if fitted) from the


top of the upper crankcase.

5.

Drain the coolant and remove the water pump hose


cover, water elbow and water pump hose from the
rear of the engine.

NOTE:

The sprag clutch assembly and shaft must also


be removed. Refer to the previous pages of this
section for details of sprag clutch removal.

6.

Remove the starter motor.

7.

Remove the capscrew and washer retaining the


idler spindle to the crankcase. The capscrew and
washer are located in the clutch housing.

1. Shaft
2. Gear

9.

Collect the starter idler gear from within the


alternator housing or from inside the crankcase (if a
late model).

Installation
1.

Install the new starter gear into the crankcase and fit
the spindle through the gear from inside the clutch
housing. Fit the spindle retaining bolt and washer
and tighten to 12Nm.

2.

Refit the sprag clutch and shaft as detailed earlier in


this section.

NOTE:

1. Starter Idler Gear


2. Sprag Clutch
8. Withdraw the idler gear spindle from inside the
clutch housing.

7.10

If the engine has been removed and the


crankcase halves separated, engine assembly
can now begin.

3.

Refit the alternator drive cover (if fitted) using a new


gasket. Tighten the cover bolts to 9Nm.

4.

Refit the clutch assembly and clutch cover as


detailed in the clutch section.

TRANSMISSION 7

5.

Refit the starter motor and tighten the fixings to


10Nm.

SELECTOR DRUM

Removal
NOTE:

In order to gain access to the selector drum, the


engine must be removed from the frame and the
crankcase halves separated. For details of
these procedures, refer to the crankcase
section.
Once the crankcase halves are
separated, lift out both transmission shafts and
proceed as follows:

1.

Remove the capscrew and take out the 'U' shaped


keeper plate from the selector shaft.

1. Starter
2. '0' ring
6.

Top up the engine with the correct grade of engine


oil.

7.

Refit the water elbow using a new gasket. Refit the


water pump hose and water pump hose cover and
refill the cooling system to the correct level.

8.

Refit the carburettors, airbox, fuel tank and all body


panels previously removed. Reconnect the battery,
positive (red) lead first.

9.

Refit the seat.

1. Selector Shaft Keeper Plate

NOTE:

To ensure that the selector fork positions are


maintained on assembly, mark each fork with
felt pen or similar to denote their relative
positions.

2.

Using finger pressure, push the selector shaft out of


crankcase in the direction of the keeper plate.
Collect each selector fork from the lower crankcase
as they become released from the selector shaft.

Selector Forks

7.11

7 TRANSMISSION

3.

Remove the oil pump auxiliary gear and oil pump.


Refer to the lubrication section for details of oil
pump removal.

4.

Remove the nuts and washers securing both the


neutral and gear detent arms to the lower
crankcase.

9.

Remove the capscrew from the bearing lock (detent


end of the selector drum).

7
1.
2.
3.
4.
5.
6.
7.

1. Gear Detent Arm


2. Neutral Detent Arm

5.

Remove the detent arms and springs noting the


colour of the detent springs and the position of each
component.

NOTE:

Detent springs MUST NOT be interchanged. The


NEUTRAL spring has a white mark and is fitted
rearmost.

6.

Lock the selector drum in position and remove the


screw securing the detent wheel to the selector
drum. Remove the detent wheel.

7.

Remove the 2 screws securing the selector drum


stop plate to the crankcase. Remove the stop plate
from the selector drum.

8.

Remove the spring abutment bolt from the gear


quadrant. The bolt is situated on the outside of the
left hand side of the crankcase. Slide the quadrant
out of mesh.

Detent Wheel Bolt


Detent Wheel
Selector Drum Bearing
Selector Drum
Dowel
Bearing Lock
Capscrew

10. Remove the selector drum bearing by pushing


through from inside the crankcase to outside using
hand pressure only.
11. Collect the
crankcase.

selector

drum

from

inside

NOTE:

Earlier models are fitted with a circular gear


position indicator plate secured to the selector
drum by a circlip. Later models are fitted with a
'finger' type indicator which can be fitted in two
positions when engaged with the locating roll
pin in the selector drum. Position 1 is used for
all models except Thunderbird Sport. Position
2 is used for Thunderbird Sport only (see
illustrations).

2
1. Quadrant
2. Abutment Bolt

Selector Drum and Neutral Indicator 'Finger'

7.12

the

TRANSMISSION 7

Installation
1.

Locate the selector drum into the crankcase.


Lubricate the selector drum bearing with clean
engine oil.

2.

Support the drum and refit the selector drum


bearing. Retain with the bearing lock and capscrew.
Tighten the capscrew to 12Nm.

3.

Align the quadrant with the selector drum.

NOTE:

Align the centre gear tooth on the selector drum


between the centre gear teeth on the gear
quadrant.

Position 1 (All models except Thunderbird Sport)

1. Stop Plate
2. Quadrant Shaft
3. Return Spring

4.
Position 2 (Thunderbird Sport only)

Inspection
Examine all components for damage or wear paying
particular attention to selector drum and selector forks.
Replace any suspect parts.

Gear selector fork thickness:


Standard:
Service Limit:

5.9mm/5.8mm
5.7mm min

Gear selector groove width:


Standard:
Service Limit:

6.1 mm/6.0mm
6.25mm max

Selector fork to groove clearance:


0.55mm max

7.13

Refit the gearchange abutment bolt to the lower


crankcase. Tighten the bolt to 28Nm.

7 TRANSMISSION

5.

Push the gearchange down until the quadrant


contacts the abutment bolt (arrowed below). Check
that the gear teeth mesh as shown below. Rectify if
incorrect by removing and re-engaging the gear
quadrant.

10. Check that the detent arms correctly align when


neutral and all gears are selected. Also check that
there is no binding of the arms during operation.

Abutment
~bolt

Detent Position 1st. Gear


Correct Gear Position at Maximum Extension
6. Apply 'Loctite 242' to the stop plate fixings. Refit the
selector drum stop plate and tighten the fixings to
9Nm.
7.

Refit the detent wheel and tighten the centre bolt to


12Nm.

8.

Refit the detent springs to the studs. Ensure that the


springs are re-fitted in the same positions as noted
during removal.

NOTE:

Detent springs MUST NOT be interchanged. The


NEUTRAL spring has a white mark and is fitted
rearmost.

9.

Fit the detent arms, washers and nuts. Align the


springs to the arms and tighten the retaining nuts to
9Nm.

Detent Position Neutral


11. Refit the oil pump and oil pump drive gears by
reference to the lubrication section.
12. Position the selector forks to the selector drum, in
the order noted during removal.

NOTE:

13. Support the selectors and feed the selector shaft


through the crankcase and selectors. Fit the shaft
keeper and tighten the retaining bolt to 12Nm.

The neutral detent arm is angled in toward the


crankcase whereas the gearchange detent arm
is angled out toward the detent wheel.

7.14

TRANSMISSION 7

INPUT AND OUTPUT SHAFT ASSEMBLIES


Removal
The input and output shafts can be lifted out of the lower
crankcase after the crankcase halves have been
separated. For details of crankcase separation, refer to
the crankcase section.

Installation
Ensure the bearing sleeve dowels, oil seal and retaining
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.

1. Input Shaft Dowel (Drive sprocket side)


2. Crankcase Location

Ensure that all gears are correctly meshed.

1. Oil seal
2. Retaining Ring (Output Shaft Illustrated)

1. Output Shaft Dowel (Clutch Side)


2. Crankcase Location

NOTE:

7.15

It is recommended that the semi-circular input


shaft retaining ring (adjacent to the clutch) is
posjtioned to engage an equal amount in the
upper and lower crankcases.

7 TRANSMISSION

INPUT SHAFT

er0--

Disassembly
Remove the clutch assembly from the shaft (if not
already removed). Working from the opposite end to
where the clutch assembly is fitted, dismantle the input
shaft as follows:
1.

Remove the pegged bearing sleeve (1) from the


end of the shaft.

2.

Detach the circlip (2) from the circlip groove.

3.

Slide off the needle bearing (3) and thrust washer


(4).

4.

Remove second gear (5).

5.

Remove sixth gear (7), complete with the splined


bush (6) which runs inside the gear.

1'-,
I
"
I

I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I........

On models fitted with a five speed gearbox, 6th


gear and the splined bush are replaced by a
sleeve.

6.

Remove the lipped thrust washer (8) from in front of


the circlip between sixth and third/fourth gear.

7.

Remove the circlip (9) from the shaft.

8.

Slide off the combined third/fourth gear (1 0).

9.

Remove the circlip (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 and the clutch end
of the shaft facing the press ram. Protect the shaft
thread with a thread protector or similar and press
the shaft through the bearing.

Never wear loose clothing which could become


trapped in the press and cause crushing injury to
the hand, arms or other parts of the anatomy.

7.16

Bearing Sleeve
Circlip
Needle Roller Bearing
Thrust Washer
Second Gear
Splined Bush
Sixth Gear
Thrust Washer
Circlip
Third/Fourth Gear
Circlip
Thrust Washer
Fifth Gear
Input Shaft
Input Shaft Bearing

4
5

@10'----Q __

8
9

10
11
12

13
I

'.....J

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

WARNING: When using a press, always


wear overalls, eye, face and hand
protection. Objects such as bearings frequently
break-up under load and the debris caused during
break-up may cause damage and injury to
unprotected parts of the body.

0-

NOTE:

TRANSMISSION 7

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 gear (1 0) with the


smaller gear facing toward fifth gear. Ensure that
the double oil hole in the mainshaft aligns with the oil
hole in the gear.

1. Pressing Off The Input Shaft Bearing

Assembly
NOTE:

1.

Lubricate each gear and bush with clean engine


oil during assembly.
Examine all gears, bearings and sleeves for
damage, chipped teeth and wear beyond the
service limits. Replace all suspect components
and always use new circlips to assemble the
shaft.
Place the input shaft bearing on press bars
ensuring the inner race of the bearing is supported
by the bars and the circlip groove is pointing
upwards. Position the mainshaft to the bearing
with the clutch end pointing downwards through
the bearing. Press the shaft through the bearing
until the bearing comes into contact with the fixed
gear on the shaft. OBSERVE THE WARNING
FOLLOWING PARAGRAPH 12 ON THE
PREVIOUS PAGE REGARDING THE DANGERS
OF USING A PRESS

1. Input Shaft Double Oil Hole


2. Third/Fourth Gear Oil Hole
6.

Fit a new circlip (9) to the input shaft ensuring that


the clip is correctly located in the circlip groove.

7.

Fit the thrust washer (8) to the input shaft and slide
up the shaft until in contact with the circlip.

8.

Fit the splined bush (6) from sixth gear ensuring that
the oil hole in the input shaft aligns with the oil hole in
the bush.

NOTE:

On models fitted with a five speed gearbox, 6th


gear and the splined bush are replaced by a
sleeve.

9.

Fit sixth gear (7) with the dog teeth facing


third/fourth gear.

10. Fit second gear (5) with the stepped side facing
away from the clutch end of the input shaft.
11. Fit the thrust washer (4) adjacent to second gear
and slide on the needle roller bearing (3). Retain all
with a new circlip (2).
12. Finally, fit the bearing sleeve (1) to the needle roller
bearing.

Pressing On the Input Shaft Bearing


2.

Fit fifth gear (13) to the input shaft with the dog teeth
pointing away from the input shaft bearing.

3.

Slide on the thrust washer (12).

7.17

7 TRANSMISSION

OUTPUT SHAFT
Working from the opposite end to the drive sprocket,
dismantle the output shaft as follows.

1---- 1
1
-m~m&
I

Disassembly
1.

Remove the output bearing sleeve (1 ), needle roller


bearing (2) and hardened thrust washer (3).

2.

Mark one side of first gear to denote its correct


orientation. Remove first gear (4) from the shaft.

3.

Slide fifth gear (5) from the shaft.

4.

Remove the circlip (6) from in front of the third gear.

5.

Remove the lipped thrust washer (7) from the shaft.

6.

Remove the third gear (8) together with the inner


splined bush (9).

7.

Slide fourth gear (10) off the shaft and also remove
the splined bush (11) and thrust washer (12).

8.

Remove the circlip (13) from in front of sixth gear.

9.

Remove sixth gear (14) from the shaft.

19---

20---B

21---~

25-----9

22------0

23--------~

24--~

I
I
I
o-----13
I
I
I
0--12
I
I
I
I
I
I
I
I
I
I
I
e~e?llg._-8
I
I
I
7
I
Q----6
I
I
I
I
I
I
I
I
I
I
I
~3
I
I
I
I

@___11

18 --------10. Remove the circlip (15) from in front of second gear.


11. Remove thrust washer (16) and slide off second
gear (17).
12. Position the output shaft (18) in a vice with soft jaws
fitted. Tighten the vice to prevent the shaft from
turning and release the lock tab (20) from the output
sprocket nut (19), then release the nut.
13. Remove the transmission sprocket nut (19), locktab
(20), sprocket (21) and sleeve (25).

16

14. Collect the oil seal (22) and retaining ring (23).

15---------~

--------10
L.

e---5
--4
---2
e-1

I
I

--_J

15. If it is found necessary to replace the large bearing


(24) at the end of the shaft, remove the outer race
and detach the inner section from the shaft by
splitting.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

WARNING: When removing the output


shaft bearing, always wear overalls, eye,
face and hand protection. The bearing races are
hardened and are liable to splinter if broken.
Debris from broken bearings could cause injury to
eyes, face and any unprotected parts of the body.

A.

CAUTION:
The bearing cannot be
removed intact. If the bearing is removed.
from the shaft, the complete bearing will be
damaged and must be renewed.

7.18

Bearing Sleeve
Needle Roller Bearing
Thrust Washer
First Gear
Fifth Gear
Circlip
Thrust Washer
Third Gear
Third Gear Bush
Fourth Gear
Fourth Gear Bush
Thrust Washer

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

Circlip
Sixth Gear
Circlip
Thrust washer
Second Gear
Output Shaft
Nut
Locktab
Output Sprocket
Oil Seal
Retaining Ring
Bearing
Sleeve

TRANSMISSION 7

6.

Assembly
NOTE:

Lubricate each gear and bush with clean engine


oil during assembly.
Examine all gears, bearings and sleeves for
damage, chipped teeth and wear beyond the
service limits. Replace all suspect components
and always use new circlips to assemble the
shaft

1.

Working from the output sprocket end of the shaft, fit


a new bearing (24) to the shaft using a press and
press bars.

Fit sixth gear (14) with the 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

1'.

CAUTION: Incorrect alignment of the oil


holes will result in severe damage to the
gears and gear selectors.

7.

Fit a new circlip (13) to retain sixth gear.

8.

Fit the thrust washer (12) to the rear of fourth gear


and fit the splined sleeve (11) for fourth gear.
Ensure correct alignment of the oil hole in the shaft
with the oil hole in the sleeve. Fit fourth gear (1 0) to
the shaft with the large step side facing away from
the output sprocket.

9.

2.

Fit the retaining ring (23) to the shaft. Lubricate and


fit a new oil seal (22) and fit the sprocket sleeve (25).

3.

Transfer the shaft to the vice and secure between


soft jaws. Fit the sprocket (21), locktab (20) and nut
(19). Tighten the nut to 132Nm.

Fit the splined bush (9) for third gear taking care to
align the oil hole in the shaft with the corresponding
hole in the bush. Fit third gear (8) with the larger
step side facing the output sprocket.

4.

Withdraw the shaft from the vice and continue to


assemble from the opposite end to the output
sprocket.

10. Fit the thrust washer (7) and retain with a new circlip
(6).

5.

Locate the second gear (17) to the shaft with the


large step side facing away from the output
sprocket end. Fit the thrust washer (16) and retain
with a new circlip (15).

11.

Fit the fifth gear (5) to the shaft with the circular dog
teeth facing away from the output sprocket.

12. Fit first gear (4) to the shaft as marked during


disassembly.
13. Finally fit the thrust washer (3), needle roller bearing
(2) and bearing cap (1) to the end of the shaft.

7.19

Lubrication
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2

Oil Circuit
3 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4
8.6

Oil cooler
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8
8.8

Sump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9
8.9

Oil feed pipe


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.9
8.10

Oil pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 0
8.11
8.11

Oil pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12

Oil pressure switch


Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.12

8.1

8 LUBRICATION

~ 9 Nm (Where fitted)

8.2

LUBRICATION 8

w--12Nm

~ ~12Nm

15Nm

20Nm\0

b9

12 Nm

r12Nm
I-

12Nm

9"'36Nm
48 Nm (M22) or
28 Nm (M14)

'

!1--18Nm

8.3

8 LUBRICATION
3 Cylinder Oil Circuit

:::111
8.4

LUBRICATION 8
3 CYLINDER OIL CIRCUIT DESCRIPTION
Oil is collected from the sump and is drawn through a mesh strainer into the oil pump rotor. Pressurised oil is then
delivered to the outside of the oil filter where the low oil pressure warning light switch and the oil pressure relief valve are
fitted. The relief valve is set to open at 70 lb/in 2 and when open, returns high pressure oil direct to the sump. The oil
pump is fitted with a single pumping rotor and can be easily identified as a 3 cylinder oil pump by the marking '3' on the
pump outlet to the upper crankcase.
Filtered oil is drawn from the centre of the oil filter along the oil filter retaining bolt. Part of this filtered oil is supplied,
through a non-pumping passage in the oil pump, to a horizontal gallery at the rear of the upper crankcase. Once
received in the upper crankcase gallery, the oil is delivered to the crankshaft main bearings and, via drillings 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 passed through an oil cooler (where fitted) and is supplied to drillings in the lower
crankcase by internal, detachable pipes. These lower crankcase drillings deliver oil directly to the end of each gearbox
shaft. Oil is circulated along the inside of the gearbox shafts to exit holes which feed directly onto the selectors, bearings
and gears. When the oil cooler is not fitted, a small external link pipe is fitted to complete the circuit.
The same upper crankcase gallery which feeds the crankshaft also feeds the cylinder head and camshafts through an
external link pipe. The pipe, located at the rear of the engine, links a drilling in the head to the oil gallery in the upper
crankcase. This head drilling supplies oil to the front camshaft bearings which, in turn, deliver oil through the hollow
camshafts to the camshaft bearings, tappet buckets and valves.
Early models were fitted with an internal oil pipe which fed the auxiliary gear train. This internal pipe was deleted as was
an external feed to the engine balancer. Both were found to be unnecessary as splash feed only is required for these
items.

8.5

8 LUBRICATION

4 Cylinder Oil Circuit

J!t

----,I

I\--

rl=

-1.
~

rl

IL

8.6

f-----;

~~~-of

6)tt=

LUBRICATION 8
4 CYLINDER OIL CIRCUIT DESCRIPTION.
A twin rotor pump is fitted to 4 cylinder engines. The pump can be identified by the marking '4' on the outlet to the upper
crankcase. The right hand rotor (in the drawing) collects hot oil from the sump area beneath the balancers.
The collected oil is then pumped through the oil cooler and returned to the sump at a lower temperature. The right hand
rotor does not contribute to the main gallery oil pressure and is used solely to circulate oil through the cooler.
The main oil supply is collected from the deepest part of the sump and is drawn through a mesh strainer into the left hand
oil pump rotor. Pressurised oil is then delivered to the outside of the oil filter where the low oil pressure warning light
switch and the oil pressure relief valve are fitted. The relief valve is set to open at 70 lb/in 2 and when open, returns high
pressure oil direct to the sump.
Filtered oil is drawn from the centre of the oil filter along the oil filter retaining bolt. This filtered oil is supplied, through a
non-pumping passage in the oil pump, to a horizontal gallery at the rear of the upper crankcase.
Once received in the upper crankcase, the oil is delivered to the crankshaft main bearings and, via drillings 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 non-pumping gallery also directs oil into a detachable internal oil pipe which feeds the transmission and engine
balancers through drillings in the lower crankcase. Oil is circulated along the inside of the gearbox shafts to exit holes
which feed directly onto the selectors, bearings and gears. Drillings within the balancer shafts direct oil to the balancer
bearings.
The same upper crankcase gallery which feeds the crankshaft also feeds the cylinder head and camshafts through an
external link pipe. The pipe, located at the rear of the engine, links a drilling in the head to the oil gallery in the upper
crankcase. This head drilling supplies oil to the front camshaft bearings which, in turn, deliver oil through the hollow
camshafts to the camshaft bearings, tappet buckets and valves.
Early models were fitted with an internal oil pipe which fed the auxiliary gear train. This internal pipe was deleted as
splash feed only is required.

8.7

8 LUBRICATION

5.

OIL COOLER

Release the three bolts securing the oil cooler to the


cooler sub-frame.

Removal
1.

Remove both lower fairings from the frame.

2.

Place a suitable container beneath the engine and


drain the engine oil.

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 and dermatitis. In addition used
engine
oil
contains
potentially
harmful
contaminants which can cause cancer. Wear
suitable clothing and avoid skin contact.

'!'
~

1. Oil Cooler Bolts


3. Oil Cooler Subframe

2. Oil Cooler

6.

Remove the oil cooler complete with oil pipes.

7.

Detach the oil pipes from the cooler having first


marked the relative position of the pipes to the
cooler to aid correct assembly.

1,\

CAUTION: Always hold the hexagonal


part of the oil cooler and any sump unions
with a spanner while releasing or tightening the
cooler/pipe unions. Damage to the oil cooler
and/or pipes and unions may result from failure to
support the oil cooler during release or tightening
of the unions.

CAUTION: Do not pour oil on the ground,


down sewers or drains, or into water
courses. To prevent pollution of water courses
etc., dispose of used oil sensibly. If in doubt
contact your local authority.

Installation

1. Banjo Bolt
2. Oil Cooler Feed Pipe
3. Return Pipe Union
4.

On 4 cylinder engines, hold the oil cooler union to


prevent turning and release the oil cooler return
pipe from the adaptor on the sump. On 3 cylinder
engines, release the second banjo bolt.

1.

Assemble the oil pipes to the oil cooler as marked


during removal. Tighten the cooler to cooler pipe
unions to 25 Nm. Position the oil cooler and secure
to the subframe. Tighten the retaining bolts to 9 Nm.

2.

On 4 cylinder engines, connect the oil cooler return


pipe to the sump union. Hold the union and tighten
the connection to 25 Nm.
On 3 cylinder engines, fit the banjo bolt using new
washers. Tighten to 25 Nm.

3.

Fit new washers to the banjo bolt and connect the


feed pipe to the sump. Tighten to 25 Nm.

4.

Refit the lower fairings.

1,\

CAUTION: Always hold the hexagonal


part of the oil cooler and any sump unions
with a spanner while releasing or tightening the
cooler/pipe unions. Damage to the oil cooler
and/or pipes and unions may result from failure to
support the oil cooler during release/tightening of
the unions.

'!'

CAUTION: Always support the oil cooler


union to prevent damage to the sump
and/or union during release of the cooler pipe. If
the union is not supported, an oil leak could be
created which could damage the engine.

5.

8.8

Fill the engine with the correct grade of engine oil,


start the engine and check for oil leaks. Stop the
engine and adjust the oil level as necessary.

LUBRICATION 8

SUMP
Installation

Removal
On all models, the sump can be removed from the engine
whilst still fitted in the frame. On all models, the exhaust
system must be removed and on Tigers, the sump guard
must also be removed.

WARNING: The oil may be hot to the


touch. Contact with hot oil may cause the
skin to be scalded or burned.

1.

Fit new '0' rings to all joints which have been


disturbed during removal.

2.

Fit a new sump gasket.

3.

Position the sump.

4.

On 3 cylinder engines, apply a smear of grease to all


oil pipe '0' rings and locate the pipes to the sump.

5.

Secure the sump with the perimeter and central


fasteners, tightening to 12 Nm.

6.

Replace the oil filter element and refit the filter using
a new '0' ring. Tighten the filter bolt to 18 Nm. Refill
the engine with correct specification oil.

--------~~~-

WARNING:
Prolonged or repeated
contact 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 contact.
1.

NOTE:

Drain the engine oil and remove the oil filter.


Disconnect the oil switch connection. Progressively
release the central fasteners securing the sump to
the lower crankcase then release the perimeter
fasteners.

The two screws securing the exhaust bracket


(where fitted) should be cleaned and Loctite 242
applied to the threads.

7.

Start the engine and allow to run for a short period at


idle speed. Ensure that the oil pressure warning
light extinguishes after starting. Stop the engine
and check for oil leaks. Check the oil level and
adjust to the correct level.

OIL PIPE
Removal
1.

Release the banjo bolts and washers securing the


oil feed pipe to the lower crankcase.

2.

Carefully withdraw the oil pipe fitting from


crankcase taking care not to damage the joint face
or distort the oil pipe.

3
2

1. Central Sump Fasteners


2. Perimeter Fasteners
3. Sump
2.

On 4 cylinder engines the sump can now be


removed. On 3 cylinder engines, oil pipes are
internally fitted between the sump and lower
crankcase. These pipes are secured by '0' rings.
To detach the oil pipes, support the sump and insert
a lever to separate the pipes from the sump.

3.

Remove and discard the sump gasket.

4.

Remove and discard the '0' ring seal between


sump and lower crankcase and all internal oil pipe
'0' rings.

1.
2.
3.
4.

8.9

'0' Ring
Banjo Bolts
Oil Feed Pipe (4 Cyl Illustrated)
'0' Ring Location.

8 LUBRICATION

Installation

OIL PUMP AND GEARS

1.

Replace all '0' rings

2.

Apply a smear of grease to the '0' rings and


carefully position the oil pipe.

Removal

3.

Replace all banjo bolt washers and fit the banjo


bolts.

4.

Tighten the banjo bolts to 8 Nm.

NOTE: On 4 cylinder engines the banjo bolts


have different size holes.

NOTE:

The oil pump is located in the lower crankcase.


Access can only be gained by removing the
engine from the frame and separating the
crankcase halves.
For details of engine
removal and crankcase separation, refer to the
crankcase section.

5
1.
2.
3.
4.
5.
6.
7.

Auxiliary Gear Screw


Washer
Auxiliary Gear
Intermediate Gear And Shaft
Circlip
Thrust Washer
Oil Pump Gear

1.

Remove the gearbox shafts from the crankcase.

2.

Remove the gear selector shaft and forks as


described in the transmission section.

3.

Remove the screw from the centre of the oil pump


auxiliary gear.

1. Oil Pump Auxiliary Gear


2. Oil Pump Gear Circlip

8.10

LUBRICATION 8

4.

Release the screws securing the water pump to the


crankcase and remove the pump.

5.

Release the screws securing the oil pump to the


lower crankcase. Align the drive slot to a vertical
position and remove the pump.
1

-=:=:,

-c..
u

lI

M\ I~

1. Rotor Tip Clearance


2. Pump Body Clearance

1. Oil Pump Retaining Screws

6.

Remove the circlip and thrust washer securing the


oil pump gear and shaft, then remove the gear and
shaft from the inside of the crankcase.

7.

Remove oil pump auxiliary gear, intermediate gear


and shaft by sliding the gear shaft inwards and
collecting the outer gear from inside the clutch
housing.

Oil Pump Inspection


Remove the oil pump end covers.

2.

Measure the rotor tip clearance using feeler


gauges.

3.

Installation
1.

Fill the pump with new engine oil.

0.15mm
0.20mm max.

Clean the screw threads of the oil pump and


auxiliary gear fixings and apply Loctite
'Nutlock' Grade 242 to the threads prior to
fitment.

2.

Assemble the oil pump auxiliary gear, intermediate


gear and shaft to the crankcase and tighten the
retaining screw to 9Nm.

3.

Fit the oil pump drive gear to the crankcase. Fit the
thrust washer (clutch housing side) and retain the
gear and thrust washer with a new circlip.

4.

Refit the oil pump ensuring that the dowels are


correctly positioned and that the drive slot is
correctly aligned with the gear. Tighten the retaining
screws to 12Nm.

5.

Refit the water pump using a new '0' ring and


tighten the fixings to 12 Nm.

6.

Apply 'Loctite' 648 to the gearbox bearing outer


tracks and refit to the crankcase. Fit the selector
shaft and forks.

Measure the pump body clearance using feeler


gauges.
Standard:
Service Limit:

0.22- 0.15mm
0.35mm max.

NOTE:

CAUTION: If any part of the oil pump is


found to be outside the service limit, the
complete pump must be renewed. Severe engine
damage may result from the continued use of a
faulty oil pump.

NOTE:

1.

Standard:
Service Limit:

1,\

4 cylinder engines have 2 sets of rotors,


3 cylinder engines have 1 set of rotors.

8.11

8 LUBRICATION

OIL PRESSURE TEST

LOW OIL PRESSURE WARNING LIGHT


SWITCH

NOTE:

Measure the oil pressure when the engine has


reached normal operating temperature.

1.

Attach an oil pressure gauge and adapter 3880095


to the main oil gallery. If correct, the oil pressure
should be 40 lb/in 2 at 5000 r.p.m with the oil
temperature at 80C.

Oil pressure:
40 lb/in2 (2.8 Kg/cm2)
temperature).

The oil pressure switch is located in the back of the sump


on the right hand side of the motorcycle.

NOTE

Inspection
@

5000 r.p.m,

80C (oil

1.

NOTE

Later models have the low oil pressure warning


light switch fitted at the lower end of the
camshaft oil feed pipe.

If the oil pressure falls outside the specified


range, check the oil pump, oil pressure relief
valve and crankshaft bearings for damage or
wear.

If the oil pressure warning light illuminates at idle,


renew the oil warning light switch. If the light
continues to illuminate, carry out an oil pressure
check.

1. Oil Warning Light Switch Connection


2.

8.12

Apply Loctite 242 to seal the pressure switch


threads.

Fuel System/Exhaust
CONTENTS
Page
Exploded view....................................................

9.2

System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Requirement- Not USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Requirement- USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.9
9.9
9.9

Exhaust
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.10
9.10

Fuel Tank
Trophy, Trident, Sprint, Daytona Super 3, Speed Triple and Daytona .
Tiger.........................................................
Thunderbird, Thunderbird Sport & Adventurer . . . . . . . . . . . . . . . . . . . . .

9.11
9.12
9.13

Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.14

Choke............................................................

9.15

Air lntake/Carburettor- All Except Thunderbird, Thunderbird Sport &


Adventurer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.16
9.17

Air lntake/Carburettor- Thunderbird, Thunderbird Sport & Adventurer


Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.18
9.18

Carburettor Overhaul - Mikuni Carburettors


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.20
9.20
9.21

Carburettor Overhaul - Keihin Carburettors


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly.....................................................

9.22
9.22
9.23

Fuel System Cleanliness Inspection................................

9.24

Fuel level measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.25

Fuel level adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.26

Carburettor Setting
Mixture Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Synchronisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .

9.27
9.28

Evaporative Loss System- US California Models


System Layout/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.30

9.1

9 FUEL SYSTEM/EXHAUST

Fuel Tank- All models except Thunderbird, Thunderbird Sport, Adventurer & Tiger
3 Nm

Hand Tight

30 Nm

C>
@

L-12Nm

10Nm~

9.2

FUEL SYSTEM/EXHAUST 9

Thunderbird, Thunderbird Sport & Adventurer Fuel Tank

12 Nm

'~

I
I

9Nm~

~
I
I

9 Nm
9Nm

9.3

'

9 FUEL SYSTEM/EXHAUST

Tiger Fuel tank

3Nm---g
e:2\

Hand

Tight~~

~
y9Nm
'8
~

Q
Q

7Nm

9.4

FUEL SYSTEM/EXHAUST 9

Late 3 Cylinder Headers


(not Thunderbird or Adventurer)

Refer To Text

22Nm

Tiger

7Nm

~22Nm

14Nm

3 Cylinder Chrome Silencers

Js;

~Q)

~14Nm
~~-14Nm

4 Cylinder
Chrome Silencers

,.&~ ~22Nm

22Nm~

14Nm
15Nm

@Q)CD

,~vi~

(~~

I~

14Nm

22Nm

Early 3 Cylinder Headers

/14Nm
15Nm

4 Cylinder Headers

22Nm

7Nm

9.5

9 FUEL SYSTEM/EXHAUST

Daytona & Speed Triple Silencers


15Nm

\E)>

Thunderbird Headers & Silencers

'22 Nm

1f

22 Nm

~
/

>

/
/

/
/

<

<

Q\

'

7 Nm

9.6

FUEL SYSTEM/EXHAUST 9

Adventurer Exhaust System

27 Nm

27 Nm

J__~

14Nm

l}~~

r
"0

.. l

22Nm

I
I

I
_)

~o

\._\~
\

9.7

9 FUEL SYSTEM/EXHAUST

Thunderbird Sport Exhaust System

27 Nm

Refer to text

,I
~

22 Nm

C(a'--......7Nm

,//,//
22 Nm----'

9.8

7 Nm

FUEL SYSTEM/EXHAUST 9

FUEL SYSTEM DESCRIPTION

Oxygenated Gasoline
To help in meeting 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 motorcycles will give best performance when
using unleaded gasoline. However, the following should
be used as a guide to the use of oxygenated fuels.

All models are fitted with variable choke carburettors


each of which supply fuel to an individual engine cylinder.
Changes in the fuel requirements of each model are
achieved by fitting jets of different sizes to the
carburettors. These changes in jet sizes increase or
decrease the amount of air/fuel mixture delivered. A
manual cold start device is fitted, controlled by a
handlebar mounted lever connected to the carburettors
by a cable.

lf

CAUTION:
Because of the generally
higher volatility of oxygenated fuels,
starting, engine response and fuel consumption
may be adversely affected by their use. Should
any of these difficulties be experienced, run the
motorcycle on normal unleaded gasoline.

A fuel tap is fitted in the base of the fuel tank which, on


Tiger, Adventurer Thunderbird and Thunderbird Sport
models only, is a gravity fed tap. All other models are
fitted with a vacuum operated tap which is connected by
means of a vacuum hose, to one of the carburettors.

Ethanol

WARNING:
On Tiger, Adventurer,
~ Thunderbird Sport and Thunderbird
models, which are fitted with a manual fuel tap,
always turn the fuel tap to the OFF position when
the engine is switched off. Failure to turn the fuel
tap to the OFF position may lead to a fuel spillage
which could start a fire causing personal injury
and damage to property.

Ethanol fuel is a mixture of 10% ethanol and 90%


gasoline and is often described under the names
'gasohol', ethanol enhanced', or 'contains ethanol'. This
fuel may be used in Triumph motorcycles.

MTBE (Methyl Tertiary Butyl Ether)


The use of gasolines containing up to 15% MTBE
(Methyl Tertiary Butyl Ether) is permitted in Triumph
motorcycles.

Fuel Requirements (outside USA)


Outside America, all motorcycles are designed to be run
on 95 RON unleaded fuel. Some models are fitted with
catalytic converters, where these are fitted, unleaded
fuel only may be used.

Methanol

lf

CAUTION: Fuels containing methanol


should not be used in Triumph
motorcycles as damage to components in the fuel
system can be caused by contact with methanol.

Fuel Requirements (USA)


In America where the octane rating of fuel is measured in
a different way, the following information may be applied:

Exhaust System

Triumph motorcycles are designed to run on unleaded


gasoline with a CLC or AKI octane rating (R+M)/2 of 89 or
higher.
Federal regulations require that pumps
delivering unleaded gasoline are marked 'UNLEADED'
and that the Cost of Living Council (CLC) or Anti-Knock
Index (AKI) octane rating is also displayed. These
ratings are an average of the Research Octane Number
(RON) and the Motor Octane Number (MON).

Various configurations of exhaust system are used


depending on model and model year.

U.S. California, Swiss and German Models Exhaust System


Some models made for the German, Swiss and
California markets have catalytic convertors fitted to the
header system. For information on which models are
fitted with catalytic convertors, always refer to the latest
edition of the parts catalogue.

lf

CAUTION: The use of leaded gasoline is


illegal in some countries, states or
territories. Check local regulations before using
leaded gasoline.

9.9

9 FUEL SYSTEM/EXHAUST

EXHAUST SYSTEM

Installation
1. Reverse the removal procedure ensuring new
gaskets are fitted to cylinder head.

WARNING: 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 hot
exhaust system could cause burn injuries.

NOTE:

Tighten the exhaust clamps to the cylinder head


in 2 stages:
Stage 1. Tighten to 8 Nm.
Stage 2. Tighten to 20 Nm.

Refit complete system loosely before final


tightening of the clamps and joints.

Align all components before final tightening of


the fixings.

Evenly tighten all fasteners to avoid placing


undue stress on the system.

Examine the centre stand stop (where fitted) for


damage and deterioration.
Replace if
necessary.

'-----------------------------'

NOTE:

Early Trophy, Daytona and Trident models were


fitted with a mounting bracket which was
welded to the silencer. Later models are fitted
with a 'bolt-on' bracket which can be replaced
independently of the silencer.

Removal
1.

Remove the lower fairing from both sides of the


machine. On Tiger only, remove the body side
panels.

2.

Release the silencer clamps at the joints with the


downpipes.

3.

Remove the bolt, flanged sleeve and rubber bush


securing each silencer to the frame/rear footrest
bracket. On Thunderbird, Thunderbird Sport &
Adventurer, release the rear footrest mounting
which secures the silencer to the footrest hanger.

4.

Remove the exhaust silencers.

5.

Remove the oil cooler and oil cooler sub-frame


(where fitted) as described in the lubrication
section.

6.

Release and remove the support clamp bolt (where


fitted) at the rear of the engine.

7.

On 4 cylinder engines, release the balance pipe


clamp. Release the nuts securing the exhaust
downpipes to the cylinder head. Remove the
downpipes as an assembly on 3 cylinder and
separate at the balance pipe and remove as pairs
on 4 cylinder.

8.

Remove the downpipes.

9.

Collect the downpipe gaskets from the cylinder


head.

9.10

FUEL SYSTEM/EXHAUST 9
FUEL TANK

6.

Removal: Trophy, Trident, Sprint, Daytona


Super 3, Speed Triple & Daytona.

Installation:

WARNING:
To prevent fuel spillage,
ensure that the fuel tap is in the 'ON'
position when disconnecting the fuel lines. A
serious fire causing personal injury could result
from spilled fuel.

1.
2.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury and damage to
property, could result from spilled fuel or fuel not
handled and stored in the correct manner.

NOTE: Before removing any fuel or vacuum


pipes, make a note of their relative positions on
the fuel tap and tank in order to prevent
incorrect assembly.

1.

Remove the seat. Disconnect the battery, negative


(black) lead first. Remove the battery.

2.

Remove the body side panels.

3.

Remove the two outer tank bracket bolts from each


side.

4.

Carefully raise and support the rear of the tank and


disconnect the low fuel level sensor wires.

5.

While supporting the tank, release the hose clips


(where fitted) and disconnect the following:
fuel tank drain pipe,
fuel pipes from the fuel tap,
vacuum pipe from the fuel tap.
connection to roll-over valve (California models
only)

Support the front and rear of tank, slide the tank


rearwards taking care not to damage the painted
surfaces, and lift clear.

Ensure that the front fuel tank mounting bushes


are correctly positioned.
Support the front and rear of the fuel tank and slide
forward into position taking care not to damage any
painted surfaces.

Positioning The Fuel Tank For Installation

3.

Carefully raise the rear of the tank and support the


tank beneath the fuel tank bracket.

4.

Connect the following pipes and tighten the clips


(where fitted)
vacuum pipe to the fuel tap,
fuel pipes to the fuel tap,
fuel tank drain pipe,
connection to roll-over valve (California models
only.

5.

Connect the fuel pipes to the fuel tap. Tighten the


hose clips.

6.

Connect the drain pipe and hose clip and position


the pipe in the right-hand centre stand spring.

NOTE:

1.
2.
3.
4.
5.

Fuel Tank Bracket


Fuel Level Sensor Connector
Drain Pipe
Fuel Pipes
Vacuum Pipe

Some models are not fitted with a centre stand,


the drain pipe is routed along side the rear
suspension unit.

7.

Connect the low fuel level sensor wires.

8.

Remove the support from beneath the fuel tank


bridge and align the tank to the mounting brackets.
Secure the tank in position using the 4 mounting
bolts.

9.

Tighten the mounting bolts to 12 Nm.

10. Refit and reconnect the battery, positive (red) lead


first. Refit the seat.

9.11

9 FUEL SYSTEM/EXHAUST
FUEL TANK

5.

Carefully raise the tank and disconnect the low fuel


level sensor wires.

6.

Release the hose clip from both the fuel pipe and
the tank breather pipe. Disconnect both pipes.

Removal:
Tiger

WARNING:
To prevent fuel spillage,
ensure that the fuel tap is in the 'OFF'
position when disconnecting the fuel lines. A fire,
causing personal injury and damage to property
could result from spilled fuel.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire causing personal injury and damage to
property, could result from spilled fuel or fuel not
handled and stored in the correct manner.

WARNING: Tiger motorcycles are fitted

~ with a fuel tank made from an impact

1. Tiger Fuel Tap

resistant plastic material. Never allow any hot


objects or hot surfaces to contact the fuel tank. In
the event of the tank incurring damage from hot
objects or surfaces, the tank must be replaced.
Any such contact damage may prejudice the fuel
integrity of the tank both in normal operation or in
an accident. If in doubt, have the fuel tank
inspected by an authorised Triumph dealer.

7.

Gently raise the fuel tank and slide rearwards to


remove, taking care not to damage any painted
surface.

Installation
1.

Slide the fuel tank into position, taking care not to


damage any painted surface.

2.

Remove the seat and disconnect the battery,


negative (black) lead first.

Support the tank and reconnect the low fuel warning


light sensor, fuel tank breather pipe and fuel pipe.
Tighten the hose clips.

3.

Refit and tighten the fuel tank fixings to 9Nm.

2.

Remove the cockpit to fuel tank fixings.

4.

Refit the airbox covers.

3.

Remove the airbox covers by releasing the self


tapping screws from the front edge of the cover.

5.

Refit and tighten the cockpit to fuel tank fixings to


7Nm.

4.

Remove the front and rear fuel tank bracket fixings.

6.

Refit and reconnect the battery, positive (red) lead


first. Refit the seat.

1.

NOTE: Before removing any fuel pipes, make a


note of their relative positions on the fuel tap
and tank in order to prevent incorrect assembly.

t:.l

1. Rear Fuel Tank Fixings


2. Front Fuel Tank Fixing

9.12

FUEL SYSTEM/EXHAUST 9
FUEL TANK

4.

Removal:

Remove the tank bracket fixings from the rear of the


tank.

Thunderbird, Thunderbird Sport &


Adventurer

WARNING:
To prevent fuel spillage,
. . . ensure that the fuel tap is in the 'OFF'
position when disconnecting the fuel lines. A fire,
causing personal injury and damage to property
could result from spilled fuel.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire causing personal injury and damage to
property, could result from spilled fuel or fuel not
handled and stored in the correct manner.
1. Fuel Tank Fixings

NOTE: Before removing any fuel pipes, make a


note of their relative positions on the fuel tap
and tank in order to prevent incorrect assembly.

1.

Remove the seat.

2.

Disconnect the battery, negative (-) lead first.

3.

Ensure fuel tap is in the 'OFF' position.

5.

Disconnect the fuel pipe from the fuel tap.

6.

Disconnect the fuel tank breather pipe.

7.

Ensure that the tank cap is securely fitted. Gently


raise the rear of the fuel tank and slide rearwards in
an upwards arc to remove.

Installation

1. Fuel Tap

9.13

1.

Slide the fuel tank into position, taking care not to


damage any painted surface.

2.

Support the tank and reconnect the fuel tank


breather pipe and fuel pipe. Tighten the hose clips.

3.

Refit and tighten the fuel tank fixings to 9Nm.

4.

Refit and tighten the fuel tank bracket fixings to


9Nm.

5.

Reconnect the battery, positive (red) lead first. Refit


the seat.

9 FUEL SYSTEM/EXHAUST
THROTTLE GRIP

2.

Turn the knurled adjuster (2) until the correct


amount of free-play at the throttle grip is achieved.

If the throttle grip has excessive free-play, it will cause a


delay in throttle response, especially at low engine
speed. Also, the throttle valves may not open fully at full
throttle causing a significant reduction in the top speed of
the machine. Alternatively, if the throttle grip has no
free-play, the throttle will be hard to control, and idle
speed will be erratic. Check the throttle grip free-play
periodically in accordance with the Periodic
Maintenance Chart, and adjust if necessary.

3.

Tighten the locknut against the knurled adjuster to


secure the adjustment.

4.

If the throttle cable cannot be correctly adjusted by


using the cable adjuster at upper end of throttle
cable, additional adjustments must be made at the
carburettor end of the cable.

Inspection

It is necessary to remove the carburettors


before adjustments can be made to the lower
end of the throttle cable.

5.

At the throttle grip end of the cable, loosen the


locknut on the throttle grip and back-off the knurled
adjuster. Tighten the adjuster locknut.

6.

Remove the retaining clip for the adjuster nut


(where fitted). Loosen the locknut at the carburettor
end and adjust the outer cable until 2-3mm of free
play is found at the throttle grip.

1.

Check that there is 2-3 mm (0.08-0.12 in.) of


free-play in the throttle grip when lightly turning the
throttle grip back and forth.

NOTE:

/;
1. Throttle Grip
2. 2-3 Mm Free Play
2.

!f#4

If the free play measured is incorrect, make


adjustments as follows.

Adjustment
1.

Loosen the locknut (1) at the front of the throttle grip.

1. Adjusting Nut
2. Locknut
7.

3. Throttle Cable
4. Clip (where fitted)

Tighten the locknut and refit the adjuster clip (where


fitted) and the carburettors.

WARNING: Move the handlebars to left


and right full lock while checking that
cables and harnesses do not bind. A cable or
harness which binds will restrict the steering and
may cause loss of control and an accident.

WARNING: Operation of the motorcycle


with an incorrectly adjusted, incorrectly
routed or damaged throttle cable could interfere
with the operation of the brakes, clutch or may
cause the throttle to stick. Any of these conditions
could result in loss of control of the motorcycle
and an accident.

1. Locknut
2. Knurled Adjuster
3. Throttle Cable

9.14

FUEL SYSTEM/EXHAUST 9

CHOKE LEVER
The motorcycle is fitted with a cold start or choke device.
The cable, which controls the cold start device, may
occasionally require adjustment and should be checked
for correct operation and adjustment in accordance with
the Periodic Maintenance chart.

Inspection
1.

Check that the choke lever returns fully and that the
inner cable slides smoothly through the outer cable.
If the choke cable does not slide smoothly or sticks,
the inner cable may have become frayed and
should be removed and inspected. Replace the
cable as necessary.

1. Starter plunger lever


2. Starter plunger

Adjustment

,-~~~~~~-~---~~~----------,

NOTE:

WARNING: Operation of the motorcycle


with an incorrectly adjusted, incorrectly
routed or damaged choke cable could interfere
with the operation of the brakes, clutch, throttle or
may cause the choke to stick. Any of these
conditions could result in loss of control of the
motorcycle and an accident.
2.

To gain access to the choke cable adjuster, the


fuel tank must first be removed.

1.

Loosen the locknut at the middle of choke cable.

2.

Turn the cable adjusting nut until the cable has


correct amount of free-play using the measurement
method previously described.

3.

Tighten the locknut after correct adjustment has


been made.

Push the choke lever all the way to its fully released
position (away from the riding position).

1. Choke Lever
2. Correct Adjustment, 2-3mm of Free Play
3.

1. Locknut
2. Adjuster Nut

To determine the amount of free-play in the cable,


operate the choke lever until the starter plunger
lever at the carburettor touches the starter plunger.
If correct, there should be 2-3mm of free play at the
choke lever.

4.

WARNING: Move the handlebars to left


and right full lock while checking that
cables and harnesses do not bind. A cable or
harness which binds will restrict the steering and
may cause loss of control and an accident.

NOTE:

Re-check the adjustment after final assembly and


repeat if necessary.

The starter plunger slides in a lateral direction


rather than in a rotational way.

9.15

9 FUEL SYSTEM/EXHAUST
AIR INTAKE/CARBURETTOR
Removal - All models except
Thunderbird, Thunderbird Sport &
Adventurer

WARNING: Never attempt to run the


engine with the air intake removed. Any
debris which enters the carburettors could cause
the throttle to stick, possibly causing loss of
control and an accident.
Never obstruct the air intake pipes as engine
damage may result.

NOTE:

In order to gain access to the airbox assembly,


the seat, battery, side panels and fuel tank must
first be removed.
For information on the
removal of these items, refer to information
given in this and other sections of this manual.

1.

Remove the air intake duct(s) from the auxiliary


chambers (left hand only on Tiger models).

2.

Remove both auxiliary chambers by releasing the


bolts which secure each chamber to the frame.

3.

Remove the rubber gaiters from the airbox.

4.

Slacken the clips securing the airbox to the


carburettors.

5.

Detach the airbox and pull back from


carburettors as far as possible.

6.

Remove the cam cover cowls and foam seal.

7.

Detach the low tension connectors from the coils.


Remove the ignition coils from the frame spine tube,
complete with the spark plug leads.

the

2. Auxiliary Chamber
4. Venturi Intake Rubbers

11. While supporting the carburettors, disconnect the


throttle cable as follows: Release the outer cable
locknut and fully unscrew the outer cable adjuster.
Lift the cable adjuster from its slot and turn the
nipple on the end of the inner cable to detach from
the throttle cam. Remove the carburettor assembly.
12. Release the clip securing the airbox breather pipe
to the clutch cover or breather cover (depending on
cylinder configuration) and detach the pipe. Note
the pipe routing in order to correctly route the pipe
on assembly.
13. Remove the airbox complete with the airbox drain
pipe.

NOTE:

1. Air Intake Duct


3. Rubber Gaiter
5. Airbox

Note the relative positions of all low and high


tension cables prior to disconnection.

8.

Remove the choke cable from the carburettors by


releasing the cable locknut and fully unscrewing the
adjuster. Lift the cable to release from the location
slot and turn the nipple on the inner cable to detach
from the choke mechanism.

9.

Slacken the clips securing the carburettor rubbers


to the cylinder head.

10. Remove the carburettors from the head, complete


with rubbers, using a gentle rocking motion.

9.16

CAUTION: Tape over the inlet ports on


the cylinder head to prevent any debris
from entering the inlet ports and damaging the
engine.

NOTE:

The air cleaner can only be replaced as a


complete assembly.
No separate air filter
element is available for any Triumph model
Consequently, the airbox cannot be dismantled
and the element cannot be removed or cleaned.

FUEL SYSTEM/EXHAUST 9

Installation
1.

2.

3.

4.

Check the condition of the venturi intake rubbers


and the positions of expansion rings in the airbox.
Position the airbox in the frame.
Feed the airbox drain pipe between the alternator
earth strap and the alternator. Locate into the left
hand centre stand spring (where fitted).
Position the airbox in the frame to allow fitment of
the carburettors to the head and later fitment of the
airbox to the carburettors.
Re-connect the throttle cable to the carburettors
using a reversal of the removal process. Ensure
both the inner and outer cable are seated correctly
by turning the throttle back and forth and checking
for smooth operation.

5.

Align the carburettors to the head ensuring all fuel


and vacuum hoses are positioned upwards to
prevent accidental damage or trapping.

6.

Fit the carburettors to the cylinder head. Set the


throttle cable adjustment as described earlier in this
chapter.

7.

Fit the airbox to the carburettors ensuring all


rubbers are correctly seated.

8.

Securely tighten all carburettor and airbox retaining


clips.

9.

Position the carburettor vent hoses in the space


between the outer and inner carburettors.

10. Position the vacuum and fuel pipes between the


main frame and the airbox.
11.

Fit the ignition coils and secure to the frame spine


tube.

12. Fit the ignition coil connectors ensuring that the


electrical connections are re-made as noted during
disconnection.
13. Check the condition of all electrical connections.
14. Fit the cam cowl seal in an upright position over the
choke cable and locate the ignition leads.
15. Ensure the spark plug leads are correctly fitted to
the spark plugs.
16. Reconnect the choke cable using a reversal of the
process used in removal.
17. Check the operation of the choke system and also
check that the clutch hose is correctly clipped to the
water elbow and does not foul the choke operation
bar. Set the adjustment of the choke cable as
described earlier in this chapter.

9.17

18. Attach the airbox breather hose and secure to either


the clutch cover or breather cover (depending on
cylinder configuration).
19. Check tor the correct free operation of the throttle.
Re-adjust if necessary.
20. Fit the rubber gaiters to the airbox.
21. Fit the auxiliary chambers into the rubber gaiters
and align to the battery box flanged sleeves.
22. Fit the screws and nut to secure the auxiliary
chambers. Tighten to 9 Nm.
23. Fit the air intake ducts.

NOTE:

It is advisable to check carburettor settings


once the airbox has been disturbed.
In
particular, check idle speed, choke operation
and vacuum settings.
In all cases, these
adjustments must be made before fitting the
fuel tank and bodywork.

9 FUEL SYSTEM/EXHAUST

Removal- Thunderbird, Thunderbird


Sport & Adventurer

WARNING:

4.

Detach the air box and pull back from the


carburettors as far as possible.

5.

Detach the low tension connectors from number 3


coil. Remove the coil from the frame spine tube,
complete with spark plug lead.

Never attempt to run the

~ engine with the air intake removed. Any

debris which enters the carburettors could cause


the throttle to stick, possibly causing loss of
control and an accident.
Never obstruct the air intake pipes as engine
damage may result.

Note the relative positions of the low and high


tension cables prior to disconnection.

6.

Remove the choke cable from the carburettors.

NOTE:

7.

Slacken the clips securing the carburettor rubbers


to the carburettors.

8.

Detach the carburettors from the rubbers using a


gentle rocking motion and slide the carburettors to
the left hand side of the motorcycle.

9.

While supporting the carburettors, disconnect the


throttle cable.

NOTE:

In order to gain access to the airbox assembly,


the seat, side covers, airbox covers, horn, horn
bracket and fuel tank must first be removed as
described in the body and fuel sections
respectively.

1.

Release the clips securing the airbox auxiliary


chamber to the airbox.

2.

Release the screw securing the auxiliary chamber


to the seat rail and remove the auxiliary chamber.

10. Taking care not to damage the coolant bypass


hose, remove the carburettors.
11.

Release the breather hose from the airbox and


remove the airbox.

A.

CAUTION: Tape over the inlet ports on


the cylinder head to prevent any debris
from entering the inlet ports. Any debris which is
allowed to enter the inlet ports could cause severe
engine damage.

NOTE:

1. Securing Screw
3.

Release the clips securing the airbox to the


carburettors.

9.18

The air cleaner can only be replaced as a


complete assembly.
No separate air filter
element is available for any Triumph model
Consequently, the airbox cannot be dismantled
and the element cannot be removed or cleaned.

Installation -Thunderbird, Thunderbird


Sport & Adventurer
1.

Check the condition of the venturi intake rubbers


and the positions of expansion rings in the air box.
Position the airbox.

2.

Feed the air box drain pipe between the alternator


earth strap and the alternator.

3.

Position the air box in the frame to allow fitment of


the carburettors to the head and later fitment of the
airbox to the carburettors.

FUEL SYSTEM/EXHAUST 9

4.

5.

Position the carburettors to allow reconnection of


the throttle cable. Re-connect the throttle cable to
the carburettors using a reversal of the removal
process. Ensure both the inner and outer cables
are seated correctly by turning the throttle back and
forth and checking for smooth operation.
Align the carburettors to rubbers ensuring the
coolant bypass hose, fuel and drain hoses are
positioned correctly to prevent entrapment or
damage,

6.

Connect the breather pipe to the airbox.

7.

Fit the air box to the carburettors ensuring all


rubbers are correctly seated.

8.

Securely tighten all carburettor and airbox retaining


clips.

9.

Position the carburettor vent hoses in the space


between the outer and inner carburettors.

10. Reconnect the choke cable using a reversal of the


process used in removal.
11.

Fit the ignition coil and secure to the frame spine


tube.

12. Fit the ignition coil connectors ensuring that the


electrical connections are re-made as noted during
disconnection.
13. Check the condition of all electrical connections.
14. Ensure the spark plug leads are correctly fitted to
the spark plugs.
15. Check the operation of the choke system. Also
check that the clutch hose is correctly clipped to the
water elbow and does not foul the choke operation
bar. Set the adjustment of the choke cable as
described in the fuel system section.
16. Check for the correct free operation of the throttle.
Re-adjust if necessary

WARNING: Operation of the motorcycle


with an incorrectly adjusted, incorrectly
routed or damaged throttle or choke cable could
interfere with the operation of the brakes, clutch,
throttle or may cause the choke or throttle to stick.
Any of these conditions could result in loss of
control of the motorcycle and an accident.

9.19

17. Refit the airbox auxiliary chamber using a reversal


of the removal process. Ensure that the auxiliary
chamber securing screw and the airbox to auxiliary
chamber clips are correctly tightened.
18. Refit the seat, side covers, airbox covers, horn
bracket, horn and fuel tank.

NOTE:

It is advisable to check carburettor settings


once the airbox has been disturbed.
In
particular, check idle speed, choke operation
and vacuum settings.
In all cases, these
adjustments must be made before fitting the
fuel tank and bodywork.

9 FUEL SYSTEM/EXHAUST

OVERHAUL- MIKUNI CARBURETTORS

Inspection
1.

Carburettor Disassembly
1.

Remove the carburettor vent pipes and detach the


fuel feed pipes from their connections.

2.

Remove the choke lever from the carburettor


assembly.

3.

Remove the screws securing the upper and lower


mounting brackets.

4.

Carefully separate the carburettor bodies.

As the carburettors separate from each other,


the throttle butterfly adjuster springs will
become detached. Take care to collect the
springs before finally releasing the carburettors
from each other.

5.

Remove the choke needle assembly (1) from the


carburettor body.

6.

Remove the screws (2) securing the carburettor


cover.

7.

Remove the cover and collect the '0' ring (3).

8.

Lift out the carburettor piston/diaphragm and spring


(4,5&6).

9.

Remove needle and spacers (7, 8 & 9) from the


inside of the piston/diaphragm.

10. Remove the float chamber cover ( 10) by detaching


the cover screws. Collect the float chamber gasket
(11).
11.

Detach the float assembly (12) by gently pulling the


float downwards until the '0' ring mounting points
become detached from the carburettor body.

12. Remove the pilot jet (13) from inside the float
chamber.
13. Remove the main jet (14) from the centre of the
carbu rettor.
14. Remove pilot air screw, '0' ring and spring (15)
noting the number of turns necessary to release the
thread.
15. Remove needle jet (16) by sliding upwards.

9.20

Inspect the parts listed below for wear, cracks and


any sign of damage and replace as necessary.
Carburettor body
Float chamber
Floats
Needle
Main jet
Pilot jet
Pilot air screw
Needle jet
Diaphragm
Jets should always be replaced if any signs of
polishing are evident. Polishing indicates that wear
has taken place which may make the carburettor
difficult to tune.

2.

Inspect all jets for blockage. Clear any blockage


using compressed air. In particular, clear all jet
passages.

FUEL SYSTEM/EXHAUST 9

Assembly

WARNING: To prevent injury, always use


. . eye, face and ear protection when using
compressed air to clear blockages. Always wear
protective gloves if the compressed air is to be
directed in proximity to the skin.

NOTE:

Clean all parts in a petroleum based solvent


before assembly.

1.

Refit the needle jet (16) into the carburettor body


taking care to align the flat on the bottom of the jet
with the tag in the carburettor body.

2.

Refit the pilot air spring and screw (15). Fit the
screw to the same depth as was noted during
removal.

3.

Refit the main jet (14) and pilot jet (13).

4.

Fit new '0' rings to the float assembly (12) and refit
to the carburettor body. Fit a new gasket (11) to the
float chamber cover (10). Fit and tighten the
retaining screws.

5.

Fit the needle and spacers (7, 8, and 9) to the inside


of the piston/diaphragm (5 and 4) and locate the
piston/diaphragm to the carburettor body.

6.

Fit a new '0' ring (3) to the top of the carburettor


body.

7.

Position the piston spring (6) and fit the cover.


Tighten the cover screws (2).

8.

Refit the choke needle (1) , fuel pipes and vent pipe.

9.

Assemble the individual


mounting brackets.

Ensure that the throttle butterfly adjuster


springs are correctly positioned during
assembly and that the throttles open and close
correctly and without sticking.

13--#
14

5
4

to

the

'

~-

Choke Needle Assembly


Cover Screw
Cover And 'o' Ring
Piston
Diaphragm
Spring
Needle
Needle Spacer

WARNING:

Always ensure that the


have
been
correctly
assembled and that the throttle opens smoothly
and closes without sticking. Use of the motorcycle
with an incorrectly assembled, sticking or
damaged carburettor throttle mechanism could
interfere with the safe operation of the motorcycle.
Any of these conditions could result in loss of
control of the motorcycle and an accident.

~ carburettors

10

1.
2.
3.
4.
5.
6.
7.
8.

carburettors

9.
10.
11.
12.
13.
14.
15.
16.

Spring Spacer
Float Chamber
Gasket
Float Assembly
Pilot Jet
Main Jet
Pilot Air Screw
Needle Jet

9.21

9 FUEL SYSTEM/EXHAUST

OVERHAUL- KEIHIN CARBURETTORS

Inspection

Carburettor Disassembly

1.

1.

Remove the carburettor vent pipes and detach the


fuel feed pipes from their connections.

2.

Remove the screws securing the upper and lower


mounting brackets.

3.

Release the carburettor through-bolt

4.

Carefully separate the carburettor bodies.

As the carburettors separate from each other,


the butterfly adjuster spring will become
detached. Take care to collect the spring before
finally releasing the carburettors from each
other.

Inspect the parts listed below for wear, cracks and


any sign of damage and replace as necessary.
Carburettor body
Float chamber
Floats
Needle
Main jet
Jet needle
Diaphragm
Jets should always be replaced if any signs of
polishing are evident. Polishing indicates that wear
has taken place which may make the carburettor
difficult to tune.

2.

Inspect all jets for blockage. Clear any blockage


using compressed air. In particular, clear all jet
passages.

5.

Remove the screws (1) securing the carburettor


cover.

6.

Lift out the carburettor piston/diaphragm and spring


(2, 3 & 4).

~ eye, face and ear protection when using

7.

Remove needle (5) and needle holder (6) from the


inside of the piston/diaphragm.

compressed air to clear blockages. Always wear


protective gloves if the compressed air is to be
directed in proximity to the skin.

8.

Remove the float chamber cover (7) by detaching


the cover screws (8). Collect the float chamber
gasket (9).

9.

Gently push the float pivot pin through the


carburettor body and collect the float (1 0) and float
needle (11).

10. Remove the main jet (12).

9.22

WARNING: To prevent injury, always use

FUEL SYSTEM/EXHAUST 9

Assembly

NOTE:

___.___.
(
I
I
I

___.___.----

I
I
I

I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I

5-i
2/3

v_.-- _.--

1.
2.
3.
4.
5.
6.

Cover Screw
Diaphragm
Piston
Spring
Needle
Needle Holder

1.

Refit the main jet (12).

2.

Assemble the float needle (11), float (10) and float


pivot and fit to the carburettor body.

3.

Check and adjust the float height if necessary.

4.

Fit the float gasket (9) to the float chamber cover (7)
and secure using the float cover screws (8).

5.

Assemble the needle (5) to the piston (2/3) and fit


the needle holder (6).

6.

Fit the piston and diaphragm assembly to the


carburettor.

NOTE:

The piston will only fit into the carburettor body


when it is facing the correct way round.
7.
Ensure that the diaphragm is correctly seated in the
rim of the carburettor body and refit the cover.

)
/

Clean all parts in a petroleum based solvent


before assembly.

_.---1

8.

Refit the spring (4).

9.

Secure the cover using the cover screws (1 ).

10. Assemble each carburettor to the upper and lower


mounting brackets. Tighten the fixings.
7. Float Cover
8. Cover Screw
9. Gasket
10. Float
11 . Float Needle
12. Main Jet

11. Fit and tighten the through bolt and screws

Ensure that the butterfly adjuster springs are


correctly positioned during assembly and that
the throttles open and close correctly and
without sticking.

WARNING:
Always ensure that the
. . . . carburettors
have
been
correctly
assembled and that the throttle opens smoothly
and closes without sticking. Use of the motorcycle,,
with an incorrectly assembled, sticking or >
damaged carburettor throttle mechanism could'
interfere with the safe operation of the motorcycle.
Any of these conditions could result in loss of
control of the motorcycle and an accident.

9.23

9 FUEL SYSTEM/EXHAUST

FUEL SYSTEM CLEANLINESS


INSPECTION
1.

Place a suitable container below the carburettors.

2.

On all models except Tiger, Adventurer,


Thunderbird Sport and Thunderbird turn the fuel
tap to the 'PRI' position. On Tiger, Adventurer,
Thunderbird Sport and Thunderbird, turn the tap
to the 'ON' position.

Fuel Tap (all models except Tiger, Adventurer,


Thunderbird Sport & Thunderbird)
3.

Loosen the float chamber drain screw.

NOTE:

4.
5.
1. Tiger Fuel Tap

If any water or dirt appears, clean the fuel


system.
Tighten the float chamber drain screw.
On all models except Tiger, Adventurer,
Thunderbird Sport and Thunderbird turn fuel tap
back to ON. (The tap should already be in the 'ON'
position on Thunderbird, Thunderbird Sport, Tiger
and Adventurer).

NOTE:

----

Later models are fitted with in-line fuel filters to


assist in trapping any dirt which enters the fuel
system. No maintenance is required for the
in-line filters which are situated in the fuel
delivery pipes between the carburettors.

1. Thunderbird, Thunderbird Sport & Adventurer


Fuel Tap

1. In-line Fuel Filter

9.24

FUEL SYSTEM/EXHAUST 9

5.

FUEL FLOAT LEVEL MEASUREMENT


1.

Place the motorcycle on level ground and on the


centre stand (support adequately for those
machines not fitted with a centre stand). On all
except Tiger, Adventurer, Thunderbird Sport
and Thunderbird turn the fuel tap to the 'ON'
position. On Tiger, Adventurer, Thunderbird
Sport and Thunderbird, turn the fuel tap to the
'OFF' position.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire causing personal injury and damage to
property could result from spilled fuel or fuel not
handled and stored in the correct manner.

1. Fuel Hose Connected To 3880125


2. Fuel Level

2.

Remove the float chamber drain screw and drain


the fuel in the chamber into a suitable container.

3.

On Mikuni carburettors, fit service tool adaptor


3880120 in place of the float chamber drain screw.
On Keihin carburettors, attach a length of fuel
hose to the drain point in the base of the float bowl,
then open the drain screw.

NOTE:

WARNING: A small amount of fuel will be


lost as the float chamber drain screw is
removed. Place a suitable fuel storage container
beneath the carburettor before removing the drain
screw. A fire causing personal injury and damage
to property could result from spilled fuel or fuel not
handled and stored in the correct manner.
3.

Connect the fuel level gauge 3880125 to the drain


point adapter using a short length of fuel hose.

4.

ON ALL MODELS EXCEPT THUNDERBIRD,


THUNDERBIRD SPORT. ADVENTURER and
TIGER turn fuel tap to the 'PRJ' (prime) position.
ON THUNDERBIRD, THUNDERBIRD SPORT,
ADVENTURER and TIGER, turn the fuel tap to the
'ON' position.

6.

Ensure that the hose leading from the float bowl


does not become kinked as this will give a false
fuel level indication.
Measure the fuel level in the carburettor by
comparing the fuel level in the tool with the scale.
Repeat the test for the remainder of the
carburettors.

Correct Fuel Height Above Joint Face:


1.5mm 1mm (tool marked in 1mm divisions)

NOTE:

9.25

When checking the fuel level, it is important that


the tool is held in exactly the same position on
each carburettor.
Similarly, it is equally
important that the centre of the scale marks on
the tool are held level with the joint face on the
carburettor.

Fuel level readings on each carburettor should


be equal.

9 FUEL SYSTEM/EXHAUST

FUEL FLOAT LEVEL ADJUSTMENT

AIRBOX DRAIN PIPE

1.

If the fuel level is found to be incorrect, the fuel level


can be adjusted in the following manner.

a.

Remove the carburettors from the motorcycle.

The airbox drain pipe must be drained in line with the


Periodic Maintenance Chart.
1. Remove the plug from the drain pipe to allow any
fluid which has accumulated in the pipe to drain out.

b.

Inspect the float valve seat and needle valve.


Replace if worn or suspect.

1. Worn Needle Valve


2. Serviceable Needle Valve
c.

If both valve seat and needle valve are in good


condition, adjust the float level by carefully bending
the float tab.

1. Float Tab (Mikuni Carburettor Illustrated)

NOTE:

Bend the float tab by very small amounts at a


time. A very small change in tab angle will bring
about a large change in fuel level.

2.

Assemble and refit the carburettors and recheck the


fuel level as previously described. Repeat the
adjustments as necessary.

9.26

2.

Refit the plug.

FUEL SYSTEM/EXHAUST 9

CARBURETTOR SETTING

Carburettor Mixture Adjustment

Using Tool 3880015 To Adjust Mixtures

NOTE:

The fuel mixture is set during manufacture and should


not be disturbed unless the carburettor is dismantled and
the adjustment setting changed.
A special screwdriver, part number 3880015, is available
should it become necessary to reset the mixtures.
Adjustment is carried out, after balancing the
carburettors, by varying the height of the pilot screw.

CORRECT MIXTURE SETTING (OUTSIDE USA)


2.5-4.5% CO at idle (950-1050 R.P.M.)

CORRECT MIXTURE SETTING (USA)


1.0% CO at idle (950-1050 R.P.M.)

WARNING: In the USA carburettors are


sealed to prevent alteration of the idle
mixture setting. The mixture setting given for the
USA has been set to comply with State and Federal
emission laws. Any tampering with, or deviation
from the factory setting may cause the motorcycle
to be in breach of State and Federal law. This
would make the motorcycle illegal for road use and
may also invalidate emission warranties

'!'

CAUTION: It is not possible to accurately


gauge the setting of each individual
carburettor using a CO meter which takes a
measurement solely from the silencer outlet.
A meter which is adapted to take a measurement
from the exhaust downpipe for each individual
cylinder must be used.
Using the silencer outlet to measure CO will result
in incorrect mixture adjustment, high fuel
consumption, high CO emissions and rough
running.

9.27

9 FUEL SYSTEM/EXHAUST
CARBURETTORS

Carburettor Synchronisation

WARNING: In the following procedure,


. . . . the motorcycle engine must be run. The
exhaust fumes given off by the engine, when
running, contain carbon monoxide and other toxic
gases. Never start or leave the engine running in a
confined space unless an exhaust extraction
system is available and is connected directly to the
motorcycle exhaust system. If such a system is
not available, ensure that the building is
adequately ventilated to prevent a build up of
gases.
Remember, carbon monoxide is a
colourless, odourless gas which will cause
unconsciousness or death if inhaled in sufficient
quantity.

ON
ALL
MODELS
EXCEPT
TIGER,
ADVENTURER, THUNDERBIRD SPORT &
THUNDERBIRD, Turn the fuel tap to the 'PRI'
position.
ON TIGER, ADVENTURER, THUNDERBIRD
SPORT & THUNDERBIRD, turn the fuel tap to the
'ON' position

7.

The carburettors are now ready for the adjustment


process to begin. Start the engine and allow it to idle
whilst measuring the intake vacuum for each
carburettor.

8.

On 4 cylinder engines the carburettor for number 3


cylinder is designated as a 'master' carburettor. On
3 cylinder engines, the 'master' carburettor is the
centre carburettor.
The adjustment process
matches the vacuum settings for the remaining
carburettors to the 'master' carburettor.

1.

Start motorcycle and allow the engine to reach


normal operating temperature.

Vacuum at idle speed should read between 5.00


and 6.00 inches Hg (127-152 mm Hg).

2.

Check that the idle speed is between 950 and 1050


rpm (r/min). Adjust as necessary by turning the idle
adjusting screw on the left hand side of the
carburettors.

9.

3.

Open and close the throttle several times to check


that the idle speed does not fluctuate from the
original setting. Re-adjust as necessary then stop
the engine.

4.

Remove the fuel tank as described earlier in this


section.

WARNING: Observe the warning advice


..... given in the general information section
on the safe handling of fuel and fuel containers. A
fire causing personal injury and damage to
property could result from spilled fuel or fuel not
handled and stored in the correct manner.
5.

Attach a set of vacuum gauges, one to each


carburettor. The vacuum take off connections are
on top of each carburettor, adjacent to the
diaphragm cover.

NOTE:

Any vacuum pipes to the fuel tap or evaporative


loss system may be disconnected and sealed
during the adjustment procedure.

6.

Support the vacuum gauges and position the fuel


tank adjacent to, and higher than, the carburettors.
Refit the fuel pipes to the carburettors.

Set the vacuum on the 'master' carburettor by


turning the idle speed adjuster.

10. Once the vacuum setting for the master carburettor


has been set, match the remaining carburettor
settings to the master carburettor by turning the
adjuster screws (A, B and C in the diagram right).
Once all vacuum settings are matched, reset the
idle speed and stop the engine.

NOTE:

The adjustment is very sensitive. A small


change in the adjuster position will significantly
affect the vacuum setting for the carburettor.

Each time a synchronisation adjustment is


made, idle speed should also be checked and
adjusted to between 950 and 1050 rpm (r/min).

Number one cylinder is the outer left hand


cylinder when viewed from the riding position.

Adjuster A affects cylinder No 1 on 3 & 4


cylinder engines.
Adjuster B affects cylinder No 4 on 4 cyl engines
and cylinder No 3 on 3 cylinder engines.
Adjuster C affects cylinder number 2 on 4
cylinder engines only.
11. Remove the fuel tank and disconnect the vacuum
gauges. Refit all vacuum pipes disconnected for the
adjustment process.
12. Refit the fuel tank as described earlier in this
section.

NOTE:

9.28

As an alternative to analogue vacuum gauges,


the Souriau Indiana digital vacuum tool will
enable more accurate balancing (see inset)

FUEL SYSTEM/EXHAUST 9

4 Cylinder

FWD
Master Carburettor

3 Cylinder

~FWD

Souriau Indiana
Digital Vacuum
Gauge

1. Blanking Caps
2. Fuel Tap Vacuum Pipe* (From Centre Carb On 3 Cyl)
3. Vacuum Gauge
.
*Not Fitted On Tiger, Adventurer, Thunderbird Sport or Thunderbird

9.29

9 FUEL SYSTEM/EXHAUST

Evaporative Loss System - US California Specification Models


All models are fitted with an evaporative loss control system. The system is fitted to ensure that fuel vapour in the fuel
tank or carburettor float chambers cannot escape to atmosphere at any time. Instead, when the engine is not running,
the vapour is 'stored' in two charcoal canisters. When the engine is started, fuel vapour is drawn by vacuum from the
canisters into the engine combustion chambers.

Other changes include;

When fitted with Mikuni carburettors, Sprint,


Trophy 900, Trident 900, Tiger, Adventurer and
Thunderbird are fitted with catalytic converters
to the exhaust system headers. When Keihin
carburettors are fitted, the catalyst is
unnecessary and is not used.
Changes to wiring harnesses to incorporate
float chamber vent solenoids.
Special fuel tank with vapour collection
chamber.
Changes to carburettor jets from the standard
version.

Sprint, Trophy 900 and Trident 900 fitted with an


airbox similar to the Tiger.
Sprint, Trophy 900 and Trident 900 fitted with a
high torque engine.
Special lock set which includes a fuel filler cap
which allows air to enter as the fuel is used but
prevents fuel vapour from escaping.
Daytona 1200 fitted with 136 PS engine.

Evaporative Loss System Layout


Roll Over Valve
(In breather line from fuel tank)
Prevents fuel escape from the vapour chamber if the motorcycle falls over

Float Chamber Vent Solenoids


(Attached to main spine tube of frame)

(situated below
rear mudguard)

Pressure Control Valve


(Regulates vapour pressure in fuel tank)

Secondary Canister
(situated near the battery)

9.30

FUEL SYSTEM/EXHAUST 9
Evaporative Loss System Operation- Engine Switched Off

L-----------~

,- Float Chamber Vent 1


Solenoids \
1

I
I

Pipe 'A'

Roll Over Valve

Liquid Fuel Collection Point

~ Pipe 'A' Continued


Pressure Control Valve
Liquid Fuel Collection Point

Because the float chamber vent solenoids


are closed (to prevent vapour escaping to
the atmosphere), fuel vapour will pass
through pipe 'C' to the secondary canister.

When the engine is switched off, any


pressure increase in the fuel tank due to a
rise in ambient temperature will cause fuel
vapour to collect in the vapour collection
chamber and pass down pipe 'A', through
the roll over valve, to the pressure control
valve.

Any liquid fuel which condenses in the


system is collected in the liquid fuel
collection points and is drained out at each
service.

If the pressure rises above 0.75 lb/in2 the


pressure control valve will open, allowing
the vapour to pass through pipe 'B.' to the
primary charcoal canister.

The canisters store fuel vapour until the


engine is started.

9.31

9 FUEL SYSTEM/EXHAUST
Evaporative Loss System Operation - Engine Running

L-----------~

I
I
I
I
I
I
I

El
When the engine is started, vacuum is applied via
pipe 'D' to the vacuum switch on the primary
charcoal canister. This applied vacuum causes the
vacuum switch to open.
Vacuum, via pipe 'F', draws fuel vapour from the
primary canister into the engine to be burnt.
Vacuum applied to pipe 'E' directly purges any
vapour stored in the secondary canister.
Restrictors in pipes 'E' and 'F' limit the effective size
of the pipes and help to maintain the balance of air
being drawn into the carburettors.

9.32

To allow air to enter the float chambers, an electrical


charge is applied to the float chamber vent
solenoids causing them to open to the atmosphere.
Because air is constantly being drawn into the
chambers while the engine is running, no fuel
vapour escapes.
As the volume of fuel in the fuel tank reduces, air
enters the tank through a one way valve in the filler
cap. Because the valve opens in one direction only,
it allows air to enter the tank but does not allow
vapour to escape.

Cooling System
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.4

Coolant
Level Inspection- all models except Thunderbird, Thunderbird Sport &
Adventurer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Level Inspection- Thunderbird, Thunderbird Sport & Adventurer . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoses........................................................
Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5
10.5.
10.6
10.7
10. 7

Water pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8
10.8
10.9

Radiator
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.10
10.11
10.11

Thermostat - all models except Thunderbird, Thunderbird Sport & Adventurer


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.12
Thermostat - Thunderbird, Thunderbird Sport & Adventurer
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.13
10.13
10.13

Coolant Pressure Cap


Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.14

10.1

10 COOLING SYSTEM

Cooling System- All Models Except Thunderbird, Thunderbird Sport & Adventurer

11 N m -

-~2.5Nm

~~-10Nm

t~

10.2

COOLING SYSTEM 10

Cooling System - Thunderbird, Thunderbird Sport & Adventurer

\'

11 Nm

7 Nm

'"1
\ ~~
\

,)

1.

'\

..

'

<.>

i '

~ 7 Nm

'

'

11 Nm

18 Nm

-~

2.5 Nm

'-~~

'

/
I

12 Nm

(J
/

10 Nm

10.3

@
I
I

2.5 Nm

10 COOLING SYSTEM

COOLING SYSTEM DESCRIPTION

COOLANT

All motorcycles are fitted with a radiator mounted in front


of the engine. On faired models, ducts direct air through
the radiator to ensure adequate cooling. The ducts are
not necessary on unfaired models.

A permanent type of antifreeze is installed in the cooling


system when the motorcycle leaves the factory. It is
coloured blue, contains a 50% solution of ethylene
glycol, and has a freezing point of -35C (-31F).

Attached to the radiator is an electric fan controlled by a


temperature sensitive switch which cuts in when the
coolant temperature reaches 94-1 05C. The system is
fitted with a pressure cap which has a blow off valve limit
of 1.1 Bar. The coolant displaced, if the cap valve is
released, is re-circulated to the expansion tank beneath
the seat (beneath the fuel tank on Thunderbird,
Thunderbird Sport & Adventurer).
A thermostat is used to aid rapid warming of the engine to
normal operating temperature. The thermostat opens at
88C. It is located, on Thunderbird, Thunderbird Sport &
Adventurer, in a housing beneath the fuel tank and in the
top hose on all other models.
An engine driven water pump is used to circulate coolant
through the system. Drive for the pump is taken from an
extension of the oil pump which is, in turn, driven by the
auxiliary drive gears. Rubber hoses carry coolant
between the radiator, water pump and crankcase. On
most later models, the hose clips must be renewed if the
hoses are disturbed.
A 50% anti-freeze mixture must be maintained at all
times. This is necessary to prevent corrosion of the
cooling system which could create blockages and lead to
overheating and coolant leaks.

10.4

WARNING: Coolant mixture which


. . . . contains anti freeze and corrosion
inhibitors contains toxic chemicals which are
harmful to the human body.
Never swallow
anti-freeze or any of the motorcycle coolant.

1:\.

CAUTION:
The coolant anti-freeze
contains a corrosion inhibitor which
helps prevent damage to the metal surfaces inside
the cooling system. Without this inhibitor, the
coolant would 'attack' the metals and the resulting
corrosion would cause blockages in the cooling
system leading to engine overheating and
damage. Always use the correct anti-freeze as
specified in the Owner's Handbook. Never use a
methanol based anti-freeze as this does not
contain the required corrosion inhibition
properties.

1:\.

CAUTION: Distilled water must be used


with the anti-freeze (see specification for
antifreeze) 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
system. Reduced cooling system efficiency may
lead to the engine overheating and suffering
severe damage.

COOLING SYSTEM 10

Coolant level inspection (not Thunderbird,


Thunderbird Sport & Adventurer)

Coolant level inspection - Thunderbird,


Thunderbird Sport & Adventurer

WARNING: Do not remove the coolant


~ pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

WARNING: Do not remove the coolant


~ pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

1.

Position the motorcycle on level ground and in an


upright position.

1.

Position the motorcycle on level ground and in an


upright position.

2.

Remove the seat.

2.

3.

Check the coolant level in the expansion tank. The


coolant level should be between the 'MAX
and 'MIN' marks.

The coolant level should be between the 'MAX' and


'MIN' marks

1. Expansion Tank
3. 'Max' Mark
4.

1. 'Max' mark
2. 'Min' mark

2. Expansion Tank Filler Cap


4. 'Min' Mark

If the level of coolant is low remove the cap from the


expansion tank, and add coolant mixture to bring
the level up to the 'MAX' mark. Refit the cap.

A.

CAUTION: If the coolant level is found to


be low, or if coolant has to be added
regularly, inspect the cooling system for coolant
leaks. If necessary, pressure test the system to
locate the source of the leak and rectify as
necessary. Loss of coolant may cause the engine
to overheat and suffer severe damage.

3.

If it is necessary to add coolant, the fuel tank must


first be removed as described in the fuel system
section.

4.

Remove the cap from the expansion tank, and add


coolant mixture through the filler opening to the
'MAX' mark. Refit the cap.

I!'

CAUTION: If the coolant level is found to


be low, or if coolant has to be added
regularly, inspect the cooling system for coolant
leaks. If necessary, pressure test the system to
locate the source of the leak and rectify as
necessary. Loss of coolant may cause the engine
to overheat and suffer severe damage.

10.5

10 COOLING SYSTEM

COOLANT REPLACEMENT

Filling (Not Thunderbird, Thunderbird


Sport & Adventurer)

Drainage (all models)


1.

2.

Remove the seat and lower fairing panels where


necessary. Place a container beneath the left hand
side of the machine to collect the displaced coolant.

1.

Refit the cylinder block drain plug and tighten to 13


Nm.

2.

Refit the water pump drain plug and tighten to


13 Nm.

3.

Slowly add coolant mixture to the system, through


the radiator filler, until the radiator is full.

4.

Start the motorcycle and allow the engine to idle for


a short period of time to allow any air to be expelled
from the system. Stop the engine and top up the
coolant level as necessary.

5.

Fit the coolant pressure cap.

6.

Check the expansion tank level and top up if


necessary.

7.

Refit the bodywork where necessary.

8.

Carry out a short test to warm the engine to normal


operating temperature. Allow the engine to cool
and recheck the coolant level. Adjust as necessary

Remove the coolant pressure cap to help drainage.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

1. Crankcase Drain Plug


2. Water Pump Drain Plug

10.6

COOLING SYSTEM 10

Filling (Thunderbird, Thunderbird Sport &


Adventurer)

Radiator and Cooling Fan

1.

Refit the cylinder block drain plug and tighten to 13


Nm.

2.

Refit the water pump drain plug and tighten to


13 Nm.

3.

Remove the fuel tank as described in the fuel


system section.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury, could result from
spilled fuel or fuel not handled and stored in the
correct manner.

4.

1. Thermostat housing 2. Coolant filler


3. Bleed Screw

6.

Temporarily refit the fuel tank. Start the motorcycle


and allow the engine to idle for a short period of time
to allow any air to be expelled from the system. Stop
the engine and top up the coolant level as
necessary.

7.

Fully refit the fuel tank as described in the fuel


system section.

WARNING: The cooling fan operates


automatically, even with the ignition
switch off. To prevent personal injury, keep hands
and clothing away from the fan blades at all times.
CAUTION: Using high-pressure water, as
from a car-wash facility, can damage the
radiator fins and impair the radiator's efficiency.

Slowly add coolant mixture to the system through


the filler until the system is full. Close the bleed
screw.

1,\,
~

screw on the top of the

5.

Check the radiator fins for obstruction by insects, mud,


leaves and general debris. Clean off any obstructions
by hand or with a stream of low pressure water.

Radiator Hoses
Regularly check radiator hoses and hose clips for
cracks, leaks or deterioration in accordance with the
Periodic Maintenance Chart.

10.7

Do not obstruct or deflect airflow through the


radiator by installing unauthorized accessories in
front of the radiator or behind the cooling fan.
Interference with the radiator airflow can lead to
overheating and consequent engine damage.

10 COOLING SYSTEM

WATER PUMP

Removal
1.

Remove the lower fairing, where fitted, to give


access to the radiator hoses.

2.

Drain the engine coolant as described earlier.

WARNING: Do not remove the coolant


. . . pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.
3.

On faired motorcycles, remove the oil cooler, left


hand oil cooler bracket and sub-frame to give
access to the water pipe.
On Tiger, remove the sump guard and on
Thunderbird, Thunderbird Sport & Adventurer,
remove the horn assembly.

1. Hose Clip
2. Water Pump Outlet Hose
3. Water Pipe Mounting Bolt
4. Water Pipe Retaining Bolt
5. Water Pump Bolts
6. Water Pump
7. Bypass Hose (Thunderbird, Thunderbird Sport &
Adventurer only)
8.

Release and remove the bolts securing the water


pump to the lower crankcase.

9.

Remove the water pump.

Inspection

1.
2.
3.
4.
5.

Water Pump Hose Cover


Retaining Bolt
Washer
Lower Mounting Point
Upper Mounting Point

5.

Release the hose clip and remove the water pump


outlet hose from the water pump. On Thunderbird,
Thunderbird Sport & Adventurer, also remove the
bypass hose from the water pump.

6.

Remove the water pipe mounting bolt and fibre


washer from the front edge of the crankcase joint.

7.

Remove the bolt securing the water pipe to the


water pump and detach the pipe.

10.8

1.

Check the shaft and shaft bearings for side and end
float. Renew if necessary

2.

Check for corrosion and scale build-up around the


impellor and in the pump body. Renew if necessary

COOLING SYSTEM 10

11. Carry out a short test to warm the engine to normal


operating temperature and re-adjust the coolant
level once the engine has been allowed to cool.

Installation
1.

Replace the water pump '0' ring seal.

2.

Align the drive slot in the pump with the drive slot on
the oil pump ( the water pump will not fully locate
unless the drive slots are aligned).

1. '0' Ring
2. Drive Slot
3.

Locate the pump and tighten the pump bolts to


12Nm.

4.

Fit a new '0' ring to the water pipe and fit to the water
pump. Tighten the retaining bolt to 8Nm.

5.

Refit the bolt securing the water pipe to the


crankcase and tighten to 1ONm.

6.

Refit the oil cooler sub-frame and cooler as


described in the lubrication section. On Tiger, refit
the sump guard.

7.

Refit the water pump outlet hose to the water pump.


On Thunderbird, Thunderbird Sport & Adventurer,
also reconnect the bypass hose.

8.

Refit the water pump hose cover (where fitted).

'f

CAUTION: Some models are fitted with


crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.

9.

Refit the bodywork removed earlier.

10. Refill the cooling system as described earlier using


50% anti freeze mixture.

10.9

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

10 COOLING SYSTEM

6.

RADIATOR
Removal
1.

2.

Remove the seat and disconnect the battery,


negative (black) lead first. Remove the lower
fairings, where fitted, to give access to the radiator.
Drain the engine coolant as described earlier.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.
3.

Release the top and bottom hoses at the


connections to the radiator. On all models except
Thunderbird, Thunderbird Sport & Adventurer,
disconnect the expansion tank hose.

!f\

CAUTION: Some models are fitted with


crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.

7.

Disconnect the cooling fan switch from the lower left


hand side of the radiator (not necessary on
Thunderbird, Thunderbird Sport & Adventurer).

On later Tridents and all Speed Triples, remove the


self adhesive reflectors from the radiator end
covers to expose the end cover retaining screws.

NOTE:

The reflectors are retained with an adhesive


pad. If the reflectors are removed, they must be
replaced. The original items will not have
sufficient adhesive to adhere to the end covers.

4.

Where fitted, release the end cover screws and


remove the end covers.

5.

On later Tridents and all Speed Triples, remove the


bolt and release the clip securing the top hose cover
to the radiator and top hose. Remove the cover.

1. Cooling Fan Switch


8.

Disconnect the cooling fan at the wiring harness


connector.

NOTE:

The clip securing the top hose cover to the hose


is located at the lower inside face of the cover
(as arrowed below).

1. Cooling Fan Connection

1. Reflector
2. End Cover Bolt
3. End Cover
4. Top Hose Cover Screw
5. Top Hose Cover
Arrowed. Cover Clip Position

10.10

COOLING SYSTEM 10

9.

Release the four bolts (two per side) securing the


radiator lower mountings to the brackets. Support
the radiator and remove the upper mounting bolts.
Slide the radiator out to one side taking care not to
damage any painted surfaces.

4.

On later Tridents and all Speed Triples, position the


top hose cover to the top hose and locate the
retaining clip to the tag inside the cover. Align the
cover to the radiator and tighten the retaining bolt
and clip.

5.

Fit the radiator end covers (if necessary).

NOTE:

1. Radiator Lower Mounting Bolts

On Trident and Speed Triple, new reflectors


must be used on the radiator end tanks.

6.

Reconnect the
connections.

7.

Refit the coolant drain plugs using new sealing


washers.

8.

Refill the cooling system as described earlier using


50% anti freeze mixture.

9.

Refit any bodywork removed for access and


reconnect the battery positive (red) lead first.

cooling

fan

and

fan

switch

Inspection

10. Refit the seat.

1.

Check the radiator guard for stone damage.

2.

Check the radiator core, for damage to fins or


obstructions to air flow.

11. Carry out a short test to warm the engine to normal


operating temperature and re-adjust the coolant
level once the engine has been allowed to cool.

3.

Repair any damage and clear all obstructions.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised c'oolant will cause scalds and
skin damage.

CAUTION: To avoid overheating and


consequent engine damage, replace the
radiator if the cores are blocked or if the fins are
badly deformed or broken.

Installation
1.

Position the radiator assembly to the upper


mounting points and loosely fit the capscrews.

2.

Align the lower mounting brackets to the radiator.


Align the brackets and fit the retaining bolts.
Tighten the upper mounting bolts to 18 Nm and the
lower bolts to 9 Nm.

3.

Refit the top and bottom and hoses replacing the


hose clips if necessary. On all models except
Thunderbird, Thunderbird Sport & Adventurer,
connect the expansion tank hose.

CAUTION: Some models are fitted with


crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.

10.11

10 COOLING SYSTEM

THERMOSTAT

2.

Removal -all models except Thunderbird,


Thunderbird Sport & Adventurer

To check the valve opening temperature, suspend


the thermostat in a container of water and raise the
temperature of the water until the thermostat opens.

3.

If the temperature at which thermostat opening


takes place is incorrect, replace the thermostat.

NOTE:

The thermostat is located inside the top hose, at


the larger diameter end.

1.

Remove the lower fairings, where fitted, to give


access to the radiator hoses.

2.

Drain engine coolant as described earlier.

Thermostat valve opening temperature:

Installation -all models except


Thunderbird, Thunderbird Sport &
Adventurer
1.

aaoc

Insert the thermostat into the hose.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

CAUTION: Always install the thermostat


with the 'bulb' end pointing away from the
radiator and the bleed hole uppermost. Incorrect
installation of the thermostat will cause
overheating and consequently engine damage.

3.

Remove the clip securing the top hose to the


radiator.

2.

4.

Using a pair of pliers, carefully extract the


thermostat from the hose.

~
1

J!'

CAUTION: Some models are fitted with


crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.

3.

Refill the cooling system as described earlier using


50% coolant mixture.

4.

Refit any bodywork previously removed.

5.

Carry out a short test to warm the engine to normal


operating temperature and re-adjust the coolant
level once the engine has been allowed to cool.

t
II

........

:;tn (CS)D

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

ll ~11

/
/

Thermostat Location
1. Thermostat
2. Top Hose

Inspection
1.

Fit a new hose clip and locate the hose to the


radiator. Tighten the hose clip.

Inspect the thermostat at room temperature. If the


valve is open, the thermostat must be replaced.

10.12

COOLING SYSTEM 10

THERMOSTAT

Inspection

Removal - Thunderbird, Thunderbird


Sport & Adventurer
1.

Remove the fuel tank as described in the fuel


system section.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire causing personal injury and damage to
property could result from spilled fuel or fuel not
handled and stored in the correct manner.
2.

1.

Inspect the thermostat at room temperature. If the


valve is open, the thermostat must be replaced.

2.

To check the valve opening temperature, suspend


the thermostat in a container of water and raise the
temperature of the water until the thermostat opens.

3.

If the temperature at which thermostat opening


takes place is incorrect, replace the thermostat.

Assembly -Thunderbird, Thunderbird


Sport & Adventurer
1.

Drain the cooling system as described earlier in this


section.

Locate the thermostat into the rear half of the


housing such that the feet of the thermostat align
with the thermostat mounting points in the housing.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.
3.

Detach all hoses connected to the thermostat


housing and disconnect the fan switch wiring.

4.

Release the 2 screws securing the thermostat


housing to the frame.

Arrowed: Thermostat Mounting Point


2.

Fit a new '0' ring to the front half of the thermostat


housing.

3.

Align the two haves of the thermostat housing so


that the 'nose' of the thermostat aligns with the
central lug in the front half of the housing.

Arrowed: Thermostat Housing to Frame Screws


5.

Separate the 2 halves of the thermostat housing by


releasing the 2 securing screws.

WARNING: The thermostat is spring


loaded. Always wear eye hand and face
protection when disassembling the thermostat
housing as the spring loaded components could
cause injury to unprotected skin and eyes.
6.

Arrowed: Thermostat 'Nose' Mounting Point

Remove the thermostat from the housing.

10.13

10 COOLING SYSTEM

4.

Evenly close the two halves of the thermostat


housing and tighten the retaining screws to 7 Nm.

COOLANT PRESSURE CAP

Inspection
'.'.

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 thermostat
will result from an incorrectly seated thermostat.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

Ensure that the 0 ring does not become damaged


during assembly. A damaged 0 ring may cause a
coolant leak causing overheating and engine
damage.

1.

5.

Refit the thermostat housing to the frame and


reconnect the fan switch wiring and all coolant
hoses.

6.

Refit the coolant drain plugs.

7.

Refill the cooling system as described earlier in this


section using 50% coolant mixture.

8.

Refit the fuel tank.

9.

Carry out a short test to warm the engine to normal


operating temperature and re-adjust the coolant
level once the engine has been allowed to cool.

WARNING: Do not remove the coolant


pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.

Check condition of the top and bottom seals of the


coolant pressure cap.

1. Lower Seal
2. Upper Seal
3. Spring

NOTE:

If there is any sign of damage or deterioration


replace the cap.

2.

Pressure test the cap to the blow off pressure of 1.1 ,


bar. If the cap opens at a lower pressure or fails to
open at 1.1 bar, replace the cap.

Cap opening pressure: 1.1 bar

10.14

Rear Suspension/Final Drive


CONTENTS
Page
Exploded views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 .2

Rear suspension
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Damping force adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.6
11.6
11.7

Rear suspension unit (RSU)


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.8
11.8

Swinging arm
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 .1 0
11.11
11.11

Final drive, engine sprocket


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 .13
11.14
11.14

Final drive, rear sprocket


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.16
11.16
11.16

Rear wheel cush drive


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 .16
11.16

Drive Chain
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.17
11 .17

11.1

11 REAR SUSPENSION/FINAL DRIVE


Rear Suspension: All except Tiger, Thunderbird, Thunderbird Sport and Adventurer

95 Nm

~~.

36 Nm

9Nm

p
95 Nm

~\

\
\

11.2

REAR SUSPENSION/FINAL DRIVE 11


Rear Suspension: Tiger
95Nm

lP
\
j

11.3

I
'

11 REAR SUSPENSION/FINAL DRIVE


Rear Suspension: Thunderbird, Thunderbird Sport and Adventurer

11.4

REAR SUSPENSION/FINAL DRIVE 11


Final Drive

7Nm

7Nm

~~ 7Nm

85 Nm

11.5

11 REAR SUSPENSION/FINAL DRIVE


REAR SUSPENSION
The rear suspension consists of a single spring/damper
unit, actuated by a variable rate linkage system. On Tiger
and Thunderbird Sport models, a remote reservoir is
included in the system to assist suspension damping
characteristics. All parts of the suspension system
contain pressurised gas.
Some models have suspension systems which can be
adjusted for both spring pre-load and rebound damping
characteristics.

WARNING: On Tiger models, the remote


reservoir, hose and rear suspension unit
must never be separated from each other. All parts
of the assembly contain gas under pressure which
could lead to serious injury if any part of the
system is disturbed.

Inspection/Lubrication
1.

Position the motorcycle on level ground in an


upright position.

2.

Examine all suspension pivots for wear and excess


movement.

3.

If excess movement is detected in the swinging arm


bearings, the drag or drop links or in the rear
suspension unit bushes, investigate the cause and
take the necessary remedial action.

4.

Apply correct specification grease to


suspension bearings via the grease nipples.

Suspension Lubrication Point (NOT Tiger)

the

Tiger, Thunderbird, Thunderbird Sport and


Adventurer Suspension Lubrication Points

11.6

REAR SUSPENSION/FINAL DRIVE 11

REMOTE DAMPING FORCE ADJUSTER (if


fitted)

Installation
1.

Raise the cover on the suspension unit and set the


red mark on the nylon gear in line with detent ball.

2.

Set the adjuster knob between positions 4 and 1.

3.

Fit the adjuster gearwheel ensuring the gears mesh


correctly. Fit the adjuster and cable.

4.

Rotate the adjuster knob through one full revolution


and reset to No.1 position.

5.

Check the that the red mark and detent ball align
with each other. If there is any mismatch, repeat the
adjustment process.

Removal
1.

Set the adjuster to No.1 position.

2.

Release and remove the screws securing the


damping adjuster to the frame.

3.

Release the cable locknut adjacent to the rear


suspension unit.

4.

Remove the damping adjuster from the rear


suspension unit by rotating the adjuster and cable
anti-clockwise. Collect the gearwheel from inside
the cable location.

1
2

3
1. Cover
2. Red Mark
3. Detent Ball

"'

CAUTION:
If there is any mismatch
between the detent ball and red mark,
remove the adjuster, reposition and repeat the
check/adjust procedure.
Damage to the
suspension unit will result from incorrect adjuster
assembly

6.

11.7

Tighten the damping adjuster to the frame mounting


bolts to 7 Nm.

11 REAR SUSPENSION/FINAL DRIVE

REAR SUSPENSION UNIT (RSU)


Removal
1.

Raise and support the rear of the motorcycle.


Remove the rear bodywork.

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.

2.

Disconnect the battery, negative (black) lead first.

3.

Remove the battery and battery box.

4.

Remove the left hand auxiliary airbox (complete


auxiliary airbox on Thunderbird, Thunderbird Sport
and Adventurer).

1.
2.
3.
4.

5.

Tiger only, remove the fuel tank and fuel tank


mounting bridge (SEE FUEL HANDLING
PRECAUTIONS
IN
THE
GENERAL
INFORMATION SECTION).
On Tiger and Thunderbird Sport, release the
suspension unit reservoir.

12. All except Tiger, Thunderbird, Thunderbird


Sport and Adventurer, lower the rear wheel and
swinging arm to allow the linkage spindle to clear
the exhaust system. Withdraw the spindle and
collect the rear suspension unit.

6.

Tiger, Thunderbird, Thunderbird Sport and


Adventurer, remove the lower suspension unit
bolt. Lift the swinging arm and carefully remove the
rear suspension unit.

WARNING: On Tiger and Thunderbird


Sport models, the remote reservoir, hose
and rear suspension unit must never be separated
from each other. All parts of the assembly contain
gas under pressure which could lead to serious
injury if any part of the system is disturbed.
7.

Release the remote pre-load adjuster from the


frame (where fitted).

8.

Remove the rebound damping adjuster knob from


the frame (where fitted).

9.

All except Tiger, Thunderbird, Thunderbird


Sport and Adventurer: Loosen the drag link
clamp bolts and release the linkage spindle bolt. Do
not remove the spindle.
Tiger, Thunderbird and Adventurer:
do not remove the lower RSU bolt.

Drag Link Clamp Bolts (where used)


Linkage Spindle Bolt
Splash Guard Bolts
Splash Guard

Release but

10. Remove the bolts securing the splash guard (where


fitted) to the swinging arm.
11. Support the rear wheel and remove the top
suspension unit bolt.

11.8

REAR SUSPENSION/FINAL DRIVE 11

7.

Installation
1.

On Tiger and Thunderbird Sport, refit the RSU


remote reservoir.

Raise the swinging arm to allow fitment of the rear


suspension unit. Take care to guide the suspension
adjusters and/or RSU reservoir into position during
fitment.

Thunderbird Sport Remote RSU Reservoir

8.

Refit the left hand auxiliary airbox (complete


auxiliary chamber on Thunderbird, Thunderbird
Sport and Adventurer).

Refit the linkage spindle (on Tiger, Thunderbird,


Thunderbird Sport and Adventurer refit the lower
RSU mounting bolt).

9.

Refit the rear bodywork.

3.

Lift the swinging arm and fit a new top mounting bolt
and nut to the rear suspension unit.

11. Reconnect the battery, positive (red) lead first.

4.

Tighten the suspension bolts as follows

Installing the Rear Suspension Unit

2.

Top suspension unit bolt (all)- 95 Nm.

Tiger lower suspension unit bolt- 55 Nm.

T'bird/T'bird Sport & Adv' lower suspension


unit bolt- 55 Nm.

Linkage spindle
bolt
(not
T'bird/Sport/Adv')- 85 Nm.

Spindle clamps (not Tiger or T'bird/Sport/Adv')


-8Nm.

Tiger

or

5.

Where fitted, refit and tighten the splash guard to


swinging arm bolts to 7 Nm.

6.

Refit the pre-load and damping adjusters (where


fitted). Tighten the damping force adjuster screws
to 7 Nm.

11.9

10. Refit the battery box and battery.

11 REAR SUSPENSION/FINAL DRIVE


SWINGING ARM

9.

Removal
1.

Remove the drop link finishers from the underside


of the swinging arm.

Remove the rear bodywork and chain/wheel guard.


Raise and support the motorcycle to allow removal
of the rear wheel and swinging arm.

WARNING: Ensure that the motorcycle is


. . stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.
2.

On all except Tiger, remove the exhaust silencers.

3.

Disconnect the battery negative (black) lead first.


Remove the battery.

4.

Remove the chain/wheel guard.

5.

Remove the rear wheel as described in the wheel


section.

6.

7.

1. Drop Link Finisher Location


10. On models with a rear brake caliper fitted below the
brake disc, disconnect the brake hose clamp on the
right hand side of the swinging arm.

Release the locknut (early models only) and


capscrew securing the rear brake strut to the
swinging arm. Collect the sleeve from inside the
swinging arm lug and discard the brake strut
capscrew.

11 . Release the locknuts and remove the bolts securing


the splash guard (where fitted) to the swinging arm.

Secure the strut to prevent damage to the brake


hose during the remainder of the procedure.

1. Splash Guard
2. Splash Guard Bolts
3. Drop Link Fixing Location

1. Capscrew
2. Brake Strut
8.

12. Remove the upper drop link bolts and locknuts.

Lightly support the swinging arm.

13. Slacken but do not remove the frame to engine bolts


(not cylinder head to frame bolts).
14. Remove the swinging arm spindle finishers by
releasing the outer ring of capscrews (plastic
blanking plugs on early models).

NOTE:

11.10

'New' Trophy and Sprint Executive, remove


both control plates.

REAR SUSPENSION/FINAL DRIVE 11

15. Remove the swinging arm spindle retaining rings


(where fitted) from the swinging arm spindle bolts.

Installation
1.

Apply general purpose grease to the swinging arm


bearings.

2.

Apply general purpose grease to the drop link


bearings.

3.

Align the swinging arm to the frame ensuring that


the spacer is correctly positioned at the front edge of
the arm between the linkage carriers, and that the
brake pipe, breather pipes and drive chain are
correctly positioned.

16. Release the swinging arm spindle bolt and washer


(right-hand side) and remove the spindle.
17. Remove the swinging arm from the frame, ensuring
that the swinging arm sleeve remains in position
and the brake pipe and drive chain are protected
from damage.

CAUTION: Always support the drive


chain when the swinging arm is removed.
This will protect the chain from direct contact with
a dusty or dirty surface.
While removing the swinging arm, ensure that the
breather pipes which are situated at the front edge
do not become damaged or trapped.

Inspection
1.

Visually check both drop link and swinging arm


needle bearings for damage. Replace as
necessary.

2.

Inspect the chain rubbing strip, chain slider (Tiger


only) and chain sleeve. Renew parts as necessary.

1. Spacer

4.

Fit the swinging arm spindle using service tool


3880060 to align the bearings, arm and spacer.
When the spindle is fitted, remove the tool and
position a support beneath the swinging arm.

1. Tool 3880060
2. Swinging Arm Spindle

11.11

11 REAR SUSPENSION/FINAL DRIVE

12. Fit the brake strut sleeve to the swinging arm and
align the strut to the swinging arm. Fit and tighten a
new brake strut bolt to 28 Nm.

WARNING: If the swinging arm is allowed


. . . . to pull on the rear brake hose, however
briefly, the hose MUST be replaced. The damage
caused to the brake hose could lead to reduced
brake performance leading to loss of control and
an accident.
5.

Fit the swinging arm spindle bolt and tighten to 85


Nm. Refit the retaining rings (where fitted) and
finishers/caps.

NOTE:

6.
7.

8.

WARNING: The brake strut bolt has an

~ area of micro-encapsulation which is

'New' Trophy and Sprint Executive, refit both


control plates.
Check for correct positioning of the various breather
and drain pipes and adjust if necessary.
Lubricate the needle roller bearings in the drop links
(bearings fitted in the swinging arm on Tiger,
Thunderbird, Thunderbi.rd Sport and Adventurer).
Align the drop links to the swinging arm and fit the
drop link bolts.
Tighten the drop link bolts to 55 Nm on all except
Tiger, Thunderbird, Thunderbird Sport and
Adventurer, and 100 Nm on Tiger, Thunderbird,
Thunderbird Sport and Adventurer.

destroyed if the bolt is disturbed. Failure to


replace the bolt could result in an unsafe riding
condition leading to loss of control and an
accident.
13. On models with a rear brake caliper fitted below the
brake disc, align and fit the brake hose clamp on the
right hand side of the swinging arm.
14. Refit the rear wheel and adjust the drive chain
tension and wheel alignment.

WARNING: Operation of the motorcycle

~ with insecure eccentric adjuster clamp

bolts or adjuster locknuts may result in impaired


stability and handling of the motorcycle. This
impaired stability and handling may lead to loss of
control or an accident.
15. Refit and connect the battery, positive (red) lead
first.
16. Refit the exhaust silencers (if removed).

9.

Refit the drop link finishers (where fitted).

17. Refit the seat, chain/wheel guard and body side


panels.

10. Tighten the frame to engine bolts to 95 Nm.


11. Refit and tighten the splash guard to swinging arm
bolts to 7 Nm (where fitted).

1. Splash Guard
2. Splash Guard Bolts
3. Drop Link Fixing Location

11.12

REAR SUSPENSION/FINAL DRIVE II

On Thunderbird, Thunderbird Sport and


Adventurer: Remove the gearchange pedal and
the left hand footrest and control plate.

FINAL DRIVE, ENGINE SPROCKET


Removal
1.

4.

Remove the rear bodywork and chain/wheel


guard. Support the motorcycle on the centre
stand or on a paddock stand.

NOTE:

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.
2.

Drain the engine oil into a suitable container.

On Thunderbird and Adventurer, proceed to


item 9. Thunderbird Sport proceed to item 8.

5.

Release and remove the capscrew from the


sidestand pivot bracket. On Tiger, remove the
sump guard fixing.

6.

Release and remove the frame to engine bolt, nut


and boss (boss fitted to early models only) which
secures the pivot bracket to the frame.

7.

Remove the side stand assembly taking care not to


place undue stress on side stand switch cable.

8.

Release the clamp bolt securing the gearchange


linkage to the gear change shaft. Remove the
linkage.

9.

Remove the water pump hose cover (if fitted).

WARNING: The engine oil may be hot and

~ will cause a scald if in contact with the


skin. Avoid skin contact with used engine oil and
always follow the advice given in the general
information section on skin care and contact with
used engine oil.
3.

Lower the side stand.

On all except Thunderbird and Adventurer:


Release the two locknuts (if fitted) on the gear
change actuating rod. If a clevis pin and clip are
fitted at the gear-pedal end of the actuating rod,
release the clip and withdraw the clevis pin. Detach
the rod by either unscrewing in a clockwise direction
(locknut type) or by lowering the rod once the clevis
pin has been removed.

10. Release the three bolts securing the clutch slave


cylinder to the sprocket cover. Detach the slave
cylinder.

NOTE: To ensure that the piston does not


accidentally become detached from the slave
cylinder, retain the piston with a strong elastic
band.

'!'

CAUTION: To prevent paint and body


damage, ensure that any displaced
clutch fluid does not come into contact with any
part of the engine or bodywork.

1.
2.
3.
4.
5.
6.
7.
8.

Gear Rod Locknuts


Gearchange Rod
Sidestand Bracket Capscrew
Sidestand Bracket
Frame To Engine Bolt
Side Stand
Gearchange Clamp
Clutch Slave Cylinder

1. Clutch Slave Cylinder


2. Retaining Band
3. Clutch Pushrod

11.13

II REAR SUSPENSION/FINAL DRIVE

11. Withdraw the clutch push rod from the sprocket


cover.
12. Place a suitable container beneath the sprocket
cover.

Installation
1.

13. Progressively release the bolts securing the


sprocket cover to the crankcase.

Clean the gearbox output shaft and support the


drive chain while fitting the sprocket. Also fit a new
lock washer to the shaft. Fit the chain to the
sprocket.

14. Remove the sprocket cover and discard the gasket.


15. Check the condition of all displaced component
parts especially the push rod seal and the slave
cylinder seal. Replace as necessary.
16. Release the lock tabs from the output sprocket nut.
17. Depress the rear brake pedal to lock rear wheel.
18. Remove the nut and lock washer from the output
sprocket.
19. Release the drive chain adjusters to allow
maximum free movement in the chain. Support the
chain to allow release of the drive sprocket and
remove the sprocket.

Inspection

1. Unbent Tab
2. Tab (locked)
3. Lock Washer

1.

Examine all sprocket teeth for wear.

NOTE:

2.

Examine the side rubbers for signs of deterioration.

The sprocket can be fitted either way round

3.

Check the sleeve and seal for corrosion or damage.


Replace as necessary.

2.

Depress the rear brake pedal to lock rear wheel.


Tighten the output sprocket nut to 132 Nm. Bend
over the locktab in two places to secure the sprocket
nut.

3.

Remove all dirt from the sprocket cover using a


suitable cleaning agent. Fit a new oil seal to the
gearchange shaft hole in the sprocket cover.

4.

Apply a small amount of grease to the top right-hand


corner of a new sprocket cover gasket. This will help
retain the gasket during assembly.

5.

Fit the gasket to the crankcase.

NOTE:

When cleaning the sprocket cover area, seal the


two oil holes and the clutch pushrod hole with
plugs to avoid cleaning fluid entering
crankcase. Remove the seals after cleaning.

1. Drive Sprocket
2. Oil Holes

11.14

REAR SUSPENSION/FINAL DRIVE 11

6.

Ensure the sprocket cover locating dowels are in


place, then fit sprocket cover.

10. Fit the gear change clamp in a vertical position and


tighten the pinch bolt to 9 Nm.

NOTE:

Tape over the gear change rod splines to


prevent damage to the seal lip when fitting the
sprocket cover.

Ensure Gear Linkage Arrowed is Fitted Vertically

Tape splines to prevent damage

7.

8.

Remove the tape from the shaft when the cover is


correctly located and tighten the sprocket cover
bolts to 12 Nm.
Remove the rubber band from the clutch slave
cylinder and fit the clutch pushrod through the
crankcase. Fit the clutch slave cylinder and tighten
the bolts to 12 Nm.

NOTE:

On Thunderbird and Adventurer, proceed to


item 12.

9.

Refit the water pump hose cover (if fitted).

11. Refit the side stand and bracket. Tighten the


sidestand upper fixing to 22 Nm (27 Nm on Tiger)
and the centre bolt to 95 Nm.
On Tiger, tighten the sump guard to side stand
bracket fixing to 27 Nm.
12. On all except Thunderbird and Adventurer: Fit
the gear change actuating rod/clevis pin to the
pedal/linkage. Adjust the pedal height to suit the
individual rider by turning the turn buckle or rod.
Tighten the linkage locknut(s) to 9 Nm.
On Thunderbird and Adventurer:
Refit the
gearchange pedal tightening the clamp bolt to 9
Nm. Refit the left hand control plate tightening the
fixings to 45 Nm (M1 0 capscrew) and 30 Nm (M8
capscrew).

13. Refill the engine with the correct grade of engine oil.
14. Check and adjust the chain slack and rear wheel
alignment as described in the maintenance section.

WARNING: Operation of the motorcycle


with insecure eccentric adjuster clamp
bolts or adjuster locknuts may result in impaired
stability and handling of the motorcycle. This
impaired stability and handling may lead to loss of
control or an accident.

15. Refit the wheel/chain guard and rear bodywork.

1.
2.
3.
4.
5.

Water Pump Hose Cover


Retaining Bolt
Washer
Lower Mounting Point
Upper Mounting Point

11.15

11 REAR SUSPENSION/FINAL DRIVE

FINAL DRIVE, REAR SPROCKET

REAR WHEEL CUSH DRIVE

Removal

Removal

1.

1.

Remove the rear wheel as described in the wheel


section.

2.

Lay the wheel on one side with the drive sprocket


facing upwards.

Remove the rear wheel as described in the wheel


section.

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.
2.

Lay the wheel on one side with the drive sprocket


facing upwards.

CAUTION: Do not allow the wheel to rest


on the brake 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.

CAUTION: Do not allow the wheel to rest


on the brake 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.

Lift out the sprocket complete with carrier.

4.

Remove the cush rubbers from the cush drive


housing in the wheel.

Remove the sprocket from the wheel by releasing


the ring of sprocket securing nuts.

Inspection
1.

Inspect the gear teeth for signs of excessive wear


and any cracking. Renew as necessary.
Worn Tooth
(Engine Sprocket)

Worn Tooth
(Rear Sprocket)

Cush Drive Assembly

Inspection
Installation
1.

Clean the rear wheel to sprocket location and fit the


sprocket with the recess facing outwards.

WARNING: The sprocket MUST be fitted


with the recess (and number of teeth
stamp) facing outwards. Chain disengagement
could result from incorrect fitment of the chain
sprocket leading to loss of control or an accident.

1.

Examine cush
deterioration.

rubbers

2.

Renew the rubbers as a set.

for

cracking

and

Assembly
1.

2.

Locate and tighten the sprocket retaining nuts to 85


Nm.

3.

Refit the rear wheel.

11.16

Assembly is a reversal of the removal procedure.

REAR SUSPENSION/FINAL DRIVE 11

DRIVE CHAIN

Replacement

Removal

NOTE:

NOTE:

The following procedure describes the fitment


of a replacement 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).

The replacement chain is supplied in a 'split'


condition, complete with a link kit to join the
two ends.

WARNING: Throughout this operation,


ensure that the motorcycle is stabilised
and adequately supported on a paddock stand to
prevent risk of injury from the motorcycle falling.
1.

Raise the rear of the motorcycle and securely


support with the rear wheel clear of the ground.

2.

Remove any convenient chain link pin using the


chain splitter tool as follows:

Unscrew the knurled knob to withdraw the arbor as


far as possible, and unscrew the pin punch until the
link pin extractor is fully withdrawn.

Position the tool over the chain link pin to be


extracted, and turn the knurled knob clockwise to
move the arbor inwards until the chain link is
supported. Check that the chain lies squarely in the
tool and the extractor aligns with the pin to be
removed.

CAUTION: The component parts of the


new link kit are coated with a special
grease which must not be removed. Removal of
this special grease will severely reduce the service
life of the chain.
1.

Use the old drive chain to pull the new chain into
position as follows:

NOTE:

2.

3.

Do not use the new connector link as the special


grease on it may be removed.
Temporarily attach the end of the new chain to a free
end of the old chain using an old connector link.
Carefully pull the other end of the old chain to pull
the new chain around the sprockets.
Disconnect the two chains. Turn the chain and the
rear wheel until the ends of the chain are in a
convenient working position.

1. Pin punch
2. Arbor
5

Turn the pin punch clockwise, and continue to turn


with the aid of a suitably sized spanner until the link
pin has been pushed out of its link.
Remove the tool and separate the two ends of the
chain.

Link kit
1. '0' rings (4)
2. Connector link
3. Side plate

11.17

11 REAR SUSPENSION/FINAL DRIVE

CAUTION: Always hold the connector


link by its plate, NOT by the pins. The
special grease on the pins must not be disturbed.
Removal of the special grease will severely reduce
the service life of the chain.
4

Fit two of the '0' rings onto the inboard (nearest the
wheel) side of the links to be joined, and fit the
connector link from the same side without
disturbing the '0' rings.

5.

Fit the other two '0' rings on the outboard side of the
links (side nearest the exhaust).

8.

Remove the tool.

9.

Use the riveting tool to secure the side plate as


follows:

1. Slide
2.Punch

WARNING: To prevent risk of injury, do


not place fingers or hands inside the
slide. The slide is spring loaded and will cause
injury to fingers or hands which become trapped
inside the slide.

10. Pull back the slide on the riveting tool and position
the tool over one of the two pins to be secured.
Release the slide.
11. Use a hammer to apply a sharp blow to the tool
punch 4 times. Rotate the punch by 45 between
each blow.

Ensure arbor plate is fitted

Fitting side plate


6.

Retract the threaded arbor of the side plate installer


tool as far as it will go and place the arbor plate over
the chain location pin. Fit the side plate into the
arbor and position the tool over the chain link to be
connected.

CAUTION: Fitting the side plate without


the arbor plate present will cause damage
to the chain link resulting in premature failure of
the chain.
7.

Turn the threaded arbor clockwise to press the side


plate onto the connector link pins. The tool will not
allow the plate to be fitted too deeply as a stop
mechanism is incorporated in the tool to prevent
incorrect fitment. Turn the threaded arbor as far as
it will go without excessive force.

11.18

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 operation with the second link
pin.

REAR SUSPENSION/FINAL DRIVE 11

20. Check that the links can rotate freely around the
pins. If not, the link just fitted must be removed and
discarded and a new link fitted.

Correctly rivetted link


21. Adjust the drive chain tension and rear wheel
alignment.
22. Lower the motorcycle to the ground.

11.19

Front Suspension/Steering
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.2

Front suspension
Front fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.6

Front fork
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil level chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fork Pull Through Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fork Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fork Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.7
12.8
12.9
12.10
12.11

Fork Overhaul - Kayaba non adjustable forks


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.12
12.12

Fork Overhaul- Showa non adjustable forks


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly.....................................................

12.14
12.14

Fork Overhaul - Kayaba adjustable forks


Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.16
12.17

Headstock bearings
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation ............... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.19
12.21
12.22

12.1

12 FRONT SUSPENSION/STEERING

Torque Figures - Trophy, Trident & Sprint


~

65Nm~~

4 Nm

/20Nm

~~4~
~\

\
22 Nm
~20Nm

65 Nm

"~

12.2

60 Nm

FRONT SUSPENSION/STEERING 12

Torque Figures - Daytona, Daytona Super


3 and Speed Triple

65N~

<>
../20Nm

':
0

~~40Nm
~\

22 Nm

~20Nm

(\)
~8Nm
65 Nm

\
'

\
'

t \\~: ~
\

15 Nm

G
~
ev- /

'

/20Nm

~
L>

20 Nm

,,
~

. t----40Nm

12.3

12 FRONT SUSPENSION/STEERING

Torque Figures - Tiger

65 Nm

23 Nm

I
I
I

8Nm

I
I

'\

40Nm

~
I
I

<11

60Nm ~

12.4

tJ lliQ:v

22 Nm

FRONT SUSPENSION/STEERING 12

Torque Figures -Thunderbird,


Thunderbird Sport & Adventurer

65Nm--Q
@!
20 Nm
'

~8 Nm

-~ 20 Nm

';

/'\

\_/

23Nm--e

aL--

u\

I
I

---\Gl

25 Nm----1

\
\

20Nm

\
~

~
$

35 Nm

'

\
\

~ ,~20Nm

'
_\

0
[')

~"

/20 Nm

-,~~

20Nm~

(43 Nm Sport)

12.5

12 FRONT SUSPENSION/STEERING

FRONT SUSPENSION
All models are equipped with hydraulic, telescopic front
forks some of which are adjustable depending on the
type fitted. A gaiter is fitted to Tiger forks. Periodic
inspection for damage and fluid leaks is essential for safe
riding. Always follow the inspection instructions at the
intervals stated in the Periodic Maintenance chart.

FORK INSPECTION- ALL MODELS


1.

Lift each fork gaiter (Tiger only) from the lower end.

2.

Visually inspect the fork inner tube assembly for rust


and damage. Repair or replace as necessary.

3.

Visually inspect the dust/oil seal areas for signs of


damage and fluid leaks. If oil leaks are found, the
fork must be stripped and overhauled or replaced
completely.

4.

Refit the gaiter (Tiger only) when the visual


inspection is complete.

5.

Check for smooth operation of the forks as follows:

Place the motorcycle on level ground

While holding the handlebars and applying the


front brake, pump the forks up and down
several times.

12.6

WARNING: If roughness or excessive


stiffness is detected, investigate the
cause and take the necessary remedial 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


pressurised gas. Always wear eye, face
and skin protection during fork disassembly.

NOTE:

The suspension movement will be affected by


any changes to the suspension adjustments.

FRONT SUSPENSION/STEERING 12
NOTE:

FORK OIL

Oil change
1.

Remove the fork assembly as described later in this


section.

Zero level on the tool is set at the small exit 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.

NOTE:

2.

To aid removal, slacken but do not remove the


top cap before releasing the fork from the yoke.
Remove the fork top cap, washer, spacer and fork
spring.

Zero level measured from oil hole


Set dimension 'A' to the required oil level

WARNING: The fork cap will spring clear


due to spring tension. To prevent injury,
always wear eye, face and hand protection when
removing spring loaded items.

3.

Invert the fork assembly and allow the oil to drain


into a suitable container.

4.

Fill the fork with the grade of oil specified in the table
to a level above that which will finally be required.

5.

Set the scale on tool 3880160 to the level specified


for the model being worked on (see table to the
right/below for the correct level setting).

Plate arrowed must


be level with fork slider

1.
2.
3.
4.

6.

1. Fork Oil Level Setting (fork fully compressed}

Tool 3880160
Adjustment Plate
Scale Area
Hole (zero position}

WARNING:
Incorrect tool adjustment
and/or failure to keep the tool level with
the fork slider will affect the final fluid level setting.
Incorrect fork oil levels could result in an unsafe
riding condition leading to Joss of control and an
accident.

Operate the fork several times to expel any trapped


air from the valves, then fully compress the fork.
Insert the scale end of the tool into the fork slider.
Hold the tool adjuster plate level with the upper
surface of the fork slider and draw fluid into the
syringe until fluid flow ceases (empty the syringe if
the body becomes full before fluid flow stops). The
fluid level in the fork is now set to the height set on
the tool scale. Check the tool scale setting and
repeat the process if incorrectly set. When the
correct level has been set, fit and assemble the
spring, spacer-washer and cap to the fork. Refit the
fork.

12.7

12 FRONT SUSPENSION/STEERING
FORK OIL LEVEL CHART
Model

Oil Grade

Oil Level (std)

Oil Level (max)

Trophy 1200 to VIN 4901

SAE10

103 mm

103 mm

Trophy 900 to VIN 4901

SAE10

84mm

84mm

Trophy 900 & 1200 from VIN 4902 to 9082

SAE10

117 mm

102 mm

Trophy 900 & 1200 from VIN 9083 to 29155

SAE15

117mm

102 mm

Trophy 900 & 1200 from VIN 29156 to 42274

SAE10

105 mm

105 mm

SAE 10w-20

133 mm

133 mm

Daytona 750 (All)

SAE10

139 mm

139 mm

Daytona 1200, 1000, 900 to VIN 9082

SAE 5

132 mm

132 mm

Daytona 1200, 900, Super 3 from VIN 9083 to 29155

SAE 5

139 mm

132 mm

Daytona 1200, 900, Super 3 from VIN 29156 to 33785

SAE 5

128 mm

128 mm

Daytona 1200, 900, Super 3 from VIN 33786 to 36445

SAE 5

139 mm

132 mm

Daytona 1200, 900, Super 3 from VIN 36446

SAE 5

128 mm

128 mm

Sprint 900 to VIN 7491

SAE10

109 mm

97 mm

Sprint 900 from VI N 7492 to 11541

SAE10

117 mm

102 mm

Sprint 900 from VIN 11542

SAE15

117 mm

102 mm

Trident 900 & 750 to VIN 4901

SAE10

94mm

94mm

Trident 900 & 750 from VIN 4902 to VIN 44301

SAE10

109 mm

97 mm

SAE 10w-20

141 mm

141 mm

SAE10

130 mm

130 mm

SAE 10w-20

144 mm

144 mm

900 Speed Triple to VIN 29155

SAE10

141 mm

141 mm

900 Speed Triple from VIN 29156

SAE10

130 mm

130 mm

750 Speed Triple

SAE10

141 mm

141 mm

Thunderbird & Adventurer to VIN 43509

SAE 15

109 mm

109 mm

SAE 10w-20

126 mm

126 mm

SAE 5

145 mm

145 mm

Sprint Executive

SAE10

117 mm

117 mm

Sprint Sport

SAE 5

139 mm

139 mm

Trophy 900 and 1200 from VIN 42275

Trident 900 & 750 from VIN 44302


Tiger 900 to VIN 43523
Tiger 900 from VIN 43524

Thunderbird & Adventurer from VIN 43510


Thunderbird Sport

NOTE: All figures with fork fully compressed and fork spring removed.

A
t

WARNING: Any variation in fork oil level from the figures quoted above could result in an unsafe
riding condition leading to loss of control and an accident.

= Column identifies supplier of fork.

K = Kayaba supplied fork


S = Showa supplied fork

12.8

FRONT SUSPENSION/STEERING 12

FORK'PULLTHROUGH'CHART
Model

Fork 'Pull Through' Dimension (Dimension 3 below)

Trophy to VIN 29155

25mm above top yoke face

Trophy from VIN 29156

20mm above top yoke face

Daytona, Daytona Super 3 &


Speed Triple to VIN 29155

28mm above top yoke face

Daytona, Daytona Super 3 &


Speed Triple from VIN 29156

Flush with top yoke face

Sprint to VIN 29155

25mm above top yoke face

Sprint from VIN 29156

20mm above top yoke face

Trident to VIN 29155

25mm above top yoke face

Trident from VIN 29156

20mm above top yoke face

Tiger

Flush with top yoke face

Thunderbird

Flush with top yoke face

Thunderbird Sport

Flush with top yoke face

Adventurer

Flush with top yoke face

r 1 Tl
1. Fork
2. Top Yoke
3. Pull Through
Measurement

2~

{ 1

J
J.
I

~
1y

12.9

I@

12 FRONT SUSPENSION/STEERING

FRONT FORK
Tiger Mudguard

Removal
1. Remove all facia panels (where fitted).
2. Raise the motorcycle sufficient to remove the front
wheel.

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.

1. Internal Mudguard Screws


2. External Mudguard And Fork Cover Screws
3. Fork Cover Screws

3. Detach the brake caliper(s) without disturbing the


brake hydraulics.

WARNING: Do not allow the calipers to


hang on the brake hoses as this may
damage the hoses and could lead to an accident.

4. Remove front wheel as described in the wheel


section.
5. Remove front mudguard taking care not to damage
the painted surfaces.
2

Later
Trophy
Mudguard
1. Mudguard to Fork Screws
2. Front to Rear Section Screws

6. Slacken all bottom yoke clamp bolts (either side).


7. Slacken but do not remove both master cylinder
clamps (not Tiger, Thunderbird, Thunderbird Sport
or Adventurer).
8. Rotate each master cylinder assembly to allow
access to the top yoke clamp bolts (not Tiger,
Thunderbird, Thunderbird Sport or Adventurer).

1. Calipers
2. Mudguard retaining screws

~------------------------,

WARNING: Do not invert either master

~ cylinder as this will introduce air into the

brake and clutch systems and may also cause


brake fluid to damage the bodywork.
A dangerous riding condition leading to loss of
control or an accident could result if this warning
is ignored.

9. Remove the top yoke cover (where fitted) and


slacken the top yoke clamp bolts.
Thunderbird, Thunderbird Sport & Adventurer
Mudguard mountings

12.10

FRONT SUSPENSION/STEERING 12

NOTE:

Fork Installation

If the fork is to be stripped, slacken the top cap


before releasing the top yoke clamp bolts
10. On models with 'clip-on' handlebars, slacken the
handlebar mounting bolts.

1.

Position the forks in the yokes and adjust the fork


'pull through' height in line with the chart.

2.

When the correct 'pull through' dimension is


reached, tighten the top and bottom yoke bolts to
the following torque figures.

11. Using a downward twisting motion withdraw each


fork in turn.

Top yoke bolts . . . . . . 20


18
Bottom yoke bolts . . 20
22

12.11

Nm
Nm
Nm
Nm

(all except Tiger)


(Tiger)
(all except Tiger)
(Tiger)

3.

On models with 'clip-on handlebars', tighten the


handlebar mounting bolts to 22 Nm .

4.

Refit the top yoke cover (where originally fitted).

5.

Align the master cylinder/clamp split line with the


dot mark on the handlebar and tighten the master
cylinder fixings, upper first and then the lower to 15
Nm.

6.

Refit the front mudguard and on Tiger, the fork


covers.

7.

Refit the front wheel as described in the wheel


section.

8.

Align the brake caliper(s) to the forks and tighten the


caliper mounting bolts to:
40 Nm (all except Thunderbird, Thunderbird
Sport and Adventurer)
28 Nm (Thunderbird, Thunderbird Sport and
Adventurer).

9.

Where necessary, refit the facia panels and check


the brakes for correct operation.
Rectify as
necessary.

12 FRONT SUSPENSION/STEERING

10. Hold the inner cylinder with the engaged tool and
remove the capscrew (6) situated in the outside
base of the outer tube.

FORK DISASSEMBLY/ASSEMBLY
Kayaba Non-adjustable Forks
1.

11 . Remove and discard the copper sealing washer (7)


from the capscrew (6).

Clamp the fork outer tube in a soft jawed vice, taking


care not to mark or damage the caliper mounting
bosses. On Tiger models, remove the fork gaiter.

12. Remove the tube from the vice. Remove the


service tool, invert the assembly and collect the
damping cylinder (8), rebound spring (17) and any
excess oil. Remove and discard the piston ring (16).

1,\

CAUTION: Use the caliper mounting


points to secure the outer tube in the vice.
Never clamp directly onto the tube itself as this will
cause the tube to distort beyond repair.

13. Remove the wire circlip (9) from the inside lip of the
outer tube.

-----~----------

2.

Unscrew the fork cap cap (1 ).

14. Pull sharply upwards on the inner tube until the seal
(13) washer (10) and bushes (14) become
dislodged from the outer tube.

WARNING: The fork cap will spring clear


due to spring tension. To prevent injury,
always wear eye, face and hand protection when
removing spring loaded items.

_.a

15. Separate the inner and outer fork tubes (11 and 12).
Invert the outer tube and collect the oil lock (15).

Inspection

3.

Remove the spacer tube (2).

4.

Remove the assembly from the vice and while


keeping the assembly vertical, slide the inner tube
down into the outer tube.

1.

Examine all components for damage through


scoring, scratching etc.

2.

Examine the bushes for excessive wear.

5.

Remove the spring (3) and spring guide (4).

3.

Always renew the oil seal, piston ring and dust seal.

6.

Pour the fork oil into a suitable container.

7.

Using a small lever, gently prise the dust seal (5)


from the outer tube.

8.

Clamp the assembly horizontally in a vice, taking


care not to mark or damage the caliper mounting
bosses.

9.

Slide the hexagonal end of service tool 3880090


down the inner tube and turn until a positive
engagement is felt in the cylinder.

Assembly

WARNING: The front fork consists of


. . . many
precision
machined
parts.
Rebuilding must take place in a dirt/dust free
environment.
Dirt ingress may cause damage to the fork parts
leading to instability, loss of control or an accident.

1.

Slide the bushes (14) and washer (10) onto the


inner tube.

1,\

CAUTION:
Do not over expand the
bushes while fitting over the inner tube.
Permanent bush damage will result from ANY over
expansion of the bushes.

2.

Clamp the outer tube (12) horizontally in a vice


taking care not to mark or damage the caliper
mounting bosses.

3.

Insert the oil lock (15) into the lower end of the outer
fork tube (11) with the thinner wall of the oil lock
uppermost.

NOTE:
1. Spanner
2. Allen Key
3.Tool3880090

Use a clean rod to guide the oil lock into place.


Do not use force as this will damage the oil lock.

4.

Locate the inner tube (11) into the outer tube (12).

12.12

FRONT SUSPENSION/STEERING 12

1_ _.~

2-0
4

5.

Fit a new plastic piston ring (16) into the groove on


the damping cylinder (8).

6.

Slide the rebound spring (17) onto the damping


cylinder (8) and carefully locate the cylinder
assembly into the outer tube.

7.

Fit a new sealing washer (7) to the capscrew (6) and


refit special tool 3880090 to the cylinder. Prevent
the cylinder from turning using the inserted tool and
tighten the capscrew at the base of the outer tube to
60 Nm (all except Thunderbird, Thunderbird
Sport and Adventurer)
20 Nm (Thunderbird, and Adventurer)
43 Nm (Thunderbird Sport)

8.

Slide the bush (14) into position in the inner tube


and fit the washer (1 0) above the bush. Using the
square faced end of tool 3880080, drift the bush and
washer fully home in the outer tube.

~5

c:r----9

@)--13
16--~

---_10
a.___14

17

'-----12

11---a
~I

1.Tool3880080
2. Outer Tube
3. Inner Tube
9.
Lubricate a new oil seal (13) and locate over the
inner tube. Using the recessed end of tool 3880080,
drift home the seal. Fit a new wire circlip (9).

~6

10. Lubricate a new dust seal (5) and press into position
over the oil seal and circlip.
11. Add oil to the assembly and operate the inner tube
several times to expel air. Check for smooth
operation and rectify as necessary.

1. Fork Cap
2. Spacer Tube
3. Spring
4. Spring Guide
5. Dust Seal
6. Capscrew
7. Sealing Washer
8. Damping Cylinder
9. Wire Circlip
10. Washer
11. Inner Tube
12. Outer Tube
13. Oil Seal
14. Bushes
15. Oil Lock
16. Piston Ring
17. Rebound Spring

12. Add oil to the correct level as described in the fork


level checking procedure.
13. Fit a new '0' ring to the cap (1). Fit the spring (3),
spring guide (4), spacer tube (2) and cap ( 1) to the
inner tube. Tighten the cap to 23 Nm.

12.13

12 FRONT SUSPENSION/STEERING

9.

FORK DISASSEMBLY/ASSEMBLY
Showa Non-adjustable Forks
1.

10. Remove the damping cylinder capscrew (6) and


discard the copper sealing washer (7).

Clamp the fork outer tube in a soft jawed vice, taking


care not to mark or damage the caliper mounting
bosses. On Tiger models, remove the fork gaiter.

12. Remove the fork from the vice, invert the assembly
and collect the damping cylinder (8), rebound
spring (17) and any excess oil. Remove and discard
the piston ring (16).

CAUTION: Use the caliper mounting


points to secure the outer tube in the vice.
Never clamp directly onto the tube itself as this will
cause the tube to distort beyond repair.

2.

Clamp the assembly horizontally in a vice, taking


care not to mark or damage the caliper mounting
bosses.

13. Remove the wire circlip (9) from the inside lip of the
outer tube.

Release the damping cylinder bolt (6) from the base


of the fork, then lightly re-tighten to prevent oil from
escaping.

14. Pull sharply upwards on the inner tube until the seal
(13) washer (1 0) and bushes (14) become
dislodged from the outer tube.
15. Separate the inner and outer fork tubes (11 and 12).
Invert the outer tube and collect the oil lock (15).

Inspection

Examine all components for damage through


scoring, scratching etc.

2.

Examine the bushes for excessive wear.

3.

Always renew the oil seal, piston ring and dust seal.

Assembly

galb

WARNING: The front fork consists of


many
precision
machined
parts.
Rebuilding must take place in a dirt/dust free
environment.

1. Damping cylinder bolt


2. Damping cylinder
3.

1.

Dirt ingress may cause damage to the fork parts


leading to instability, loss of control or an accident.

Unscrew the fork cap cap (1 ).

1.

WARNING: The fork cap will spring clear


~ due to spring tension. To prevent injury,
always wear eye, face and hand protection when
removing spring loaded items.

Slide the bushes (14) and washer (1 0) onto the


inner tube.

CAUTION:
Do not over expand the
bushes while fitting over the inner tube.
Permanent bush damage will result from ANY over
expansion of the bushes.

4.

Remove the spacer tube (2).

5.

Remove the assembly from the vice and while


keeping the assembly vertical, slide the inner tube
down into the outer tube.

6.

Remove the spring (3) and spring guide (4).

7.

Pour the fork oil into a suitable container.

8.

Using a small lever, gently prise the dust seal (5)


from the outer tube.

2.

Clamp the outer tube (12) horizontally in a vice


taking care not to mark or damage the caliper
mounting bosses.

3.

Insert the oil lock (15) into the lower end of the outer
fork tube (11) with the thinner wall of the oil lock
uppermost.

NOTE:

12.14

Use a clean rod to guide the oil lock into place.


Do not use force as this will damage the oil lock.

FRONT SUSPENSION/STEERING 12

4--~e::.J

~5

o---9

(}--13
16-----C>

4.

Locate the inner tube (11) into the outer tube (12).

5.

Fit a new plastic piston ring (16) into the groove on


the damping cylinder (8).

6.

Slide the rebound spring (17) onto the damping


cylinder (8) and carefully locate the cylinder
assembly into the outer tube.

7.

Fit a new sealing washer (7) to the capscrew (6) and


refit, hand tight, back into the base of the fork.

8.

Slide the bush (14) into position in the inner tube


and locate the washer (1 0) above the bush. Using
the square faced end of tool 3880080, drift the bush
and washer fully home in the outer tube.

---_10

8-__14

17

~-----12

11---o
I'\ I

C>

8--_6

1. Tool 3880080
2. Outer Tube
3. Inner Tube
9.
Lubricate a new oil seal (13) and locate over the
inner tube. Using the recessed end of tool 3880080,
drift home the seal.
10. Fit a new wire circlip (9).
11. Lubricate a new dust seal (5) and press into position
over the oil seal and circlip.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

12.
13.

14.
15.
16.
17.

12. Add oil to the assembly and operate the inner tube
several times to expel air. Check for smooth
operation and rectify as necessary.

Fork Cap
Spacer Tube
Spring
Spring Guide
Dust Seal
Capscrew
Sealing Washer
Damping Cylinder
Wire Circlip
Washer
Inner Tube
Outer Tube
Oil Seal
Bushes
Oil Lock
Piston Ring
Rebound Spring

13. Add oil to the correct level as described in the fork


level checking procedure.
14. Fit a new '0' ring to the cap (1 ). Fit the spring (3),
spring guide (4), spacer tube (2) and cap (1) to the
inner- tube. Tighten the cap to 23 Nm.
15. Tighten the damping cylinder screw in the base of
the fork to 40 Nm.

12.15

12 FRONT SUSPENSION/STEERING

FORK DISASSEMBLY/ASSEMBLY

7.

Drain the oil from the assembly into a suitable


container.

Kayaba Adjustable Forks

8.

Clamp the assembly horizontally in a vice, taking


care not to mark or damage the caliper mounting
bosses.

9.

Slide the square end of service tool 3880090 down


the inner tube and turn until a positive engagement
is felt in the inner cylinder.

1.

Clamp the outer tube in a soft jawed vice, taking


care not to mark or damage the caliper mounting
bosses.

CAUTION: Use the caliper mounting


points to secure the outer tube in the vice.
Never clamp directly onto the tube itself as this will
cause the tube to distort beyond repair.

2.

Unscrew the top cap (1 ).

3.

While holding the assembly vertical, slide the inner


tube (3) fully into the outer.

4.

Slide a spanner above the guide washer (5) onto the


locknut (6). Release the locknut and unscrew the
pre-load adjuster to release the top cap assembly.

1. Spanner
2. Allen Key
3. Tool 3880090 (use square end inset)
10. Hold the inner cylinder with the engaged tool and
remove the capscrew (9) situated in the outside
base of the outer tube.
11.

Remove and discard the copper sealing washer


(1 0) from the capscrew (9).

12. Remove the tool and collect the damping cylinder


(8). Drain excess oil by inverting fork.
1. Spanner
2. Guide Washer
3. Adjuster Assembly

13. Remove the wire circlip (12) from the inside lip of the
outer tube.

5.

14. Pull sharply upwards on the inner tube until the seal
(13), washer (14) and upper bush (15) become
dislodged from the outer tube.

Remove the spanner from the locknut and unscrew


the locknut from the threaded rod. Collect the guide
washer (5) and spring (4).

15. Separate inner and outer fork tubes and remove the
lower bush (15). Invert the outer tube and collect
the oil lock (16).

WARNING: The fork cap will spring clear


due to spring tension. To prevent injury,
always wear eye, face and hand protection when
removing spring loaded items.
6.

NOTE:

Remove the centre adjusting rod (7) from the


damping rod (8) by sliding the rod upwards. Also
remove the dust seal (11 ).

12.16

The rebound spring cannot be separated from


the inner tube as it is crimped into place.

FRONT SUSPENSION/STEERING 12

Inspection
1.

Examine all components for damage through


scoring, scratching etc.

2.

Examine the bushes for excessive wear.

3.

Always renew the oil and dust seals.

Assembly

WARNING: The front fork consists of


many
precision
machined
parts.
Rebuilding must take place in a dirt/dust free
environment.

6
7

Dirt ingress may cause damage to the fork parts


leading to instability, loss of control or an accident.
1. Locate the oil lock (16) into the outer tube with the
larger diameter to the bottom.

-D

~13

15~

16---e
'

t...-'

2.

o--11
CJ--12

~14

15

Refit the bushes (15) onto the inner tube.

1:\.

CAUTION:
Do not over expand the
bushes while fitting over the inner tube.
Permanent bush damage will result from ANY over
Iexpansion of the bushes.

,, ~

3.

Slide the inner tube (3) into the outer tube. Locate
the cylinder (8) into the inner tube.

4.

Fit the washer (14) into the recess above the top
bush. Using the square faced end of tool 3880080,
drift the top bush into place in the outer tube.

_ /'
~I

~10

i-- 9

8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Top Cap
'0' ring
Inner tube
Spring
Spring Guide
Locknut
Adjuster Rod
Damping Cylinder
Capscrew
Sealing Washer
Dust Seal
Wire Circlip
Oil Seal
Oil Seal Washer
Bush
Oil Lock

1. Tool3880080
2. Outer Tube
3. Inner Tube
5.

Lubricate and fit a new oil seal (13) to the inner tube
and using the recessed end of tool 3880080, drift
home the seal. Fit a new wire circlip (12).

6.

Lubricate and fit a new dust seal (11 ).

12.17

12 FRONT SUSPENSION/STEERING

7.

Refit tool3880090 and fit a new copper washer (10)


to the capscrew (9). Engage the tool into the
damping rod and tighten the capscrew in the base of
the outer cylinder to 43 Nm. Withdraw the tool.

13. Renew the top cap '0' ring (2) and refit the top
cap/adjuster assembly (1 ). While holding the
locknut, tighten the adjuster assembly to the locknut
to 15Nm.

8.

Add oil to the fork and work several times to expel


air. Check for smooth operation and rectify as
necessary. Adjust the oil level to the specified
setting. Refer to the oil level chart earlier in this
section for details of the correct oil level setting.

NOTE:

9.

Lift the damping cylinder using tool 3880085 by


engaging the tool thread in the top of the cylinder.

Ensure that the locknut and cylinder do not


rotate during tightening of the adjuster. Repeat
the adjustment procedure in paragraph 11 if
rotation occurs.
14. Locate the top cap to the inner tube and tighten to
23Nm.
15. Reset the rebound, compression and spring
pre-load adjustments to the desired settings.

WARNING: Ensure that the adjusters are


. . . . set to the same settings on both fork
stanchions.
Settings which vary from left to right hand
stanchions may affect handling and stability
leading to loss of control, or an accident.

1. Tool 3880085
2. Damping Cylinder
3. Inner Tube
10. Refit the spring (4), guide washer (5) and locknut
(6).
11. Compress the spring and adjust the position of the
locknut to give 11.0 mm of damping cylinder thread
showing above the locknut.

1. Spring
2. Locknut
12. Assemble the adjuster rod (7) to the inside of the
damping cylinder.

12.18

FRONT SUSPENSION/STEERING 12

6.

HEADSTOCK BEARING ADJUSTMENT

Adjust the headstock bearing by moving the


adjusting nut, clockwise to take out play/increase
pre-load, or anticlockwise to add play/decrease
pre-load. Correct adjustment is reached when the
bearing play is eliminated without pre-loading the
bearings.

Early (1991) Trophy, Trident and Daytona


Models

NOTE: Early models were fitted with an adjuster


which was retained with a pinch bolt. This
adjuster has been superseded by a nut and
locknut method. It is possible to fit the later
adjusters (as a pair) to earlier models. For
details of the adjustment method for models
fitted with the later adjusters, refer to the
following page.

1.
2.

Position the motorcycle on level ground, in an


upright position.
Place a block under the engine to raise the front
wheel off the ground.

3
1. Domed Nut

2. Pinch Bolt
3. Adjuster Nut

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.

1,\

CAUTION: Ensure that the support block


is positioned to avoid damaging all oil
lines which run beneath the engine.

3.

Slacken but do not remove both master cylinder


clamps. Rotate each master cylinder to allow
access to the top yoke pinch bolts.

WARNING: Do not invert either master


cylinder as this will introduce air into the
brake and clutch systems and may also cause
brake fluid to damage the bodywork.
A dangerous riding condition leading to loss of
control or an accident could result if this warning
is ignored.

4.

If necessary for access reasons, remove the


instruments. Reduce the load on the top yoke by
slackening the clamp bolts at the top of the forks.

7.

Tighten the adjuster pinch bolt to 7 Nm.

8.

Tighten the yoke clamp bolts to 20 Nm. Refit the


instruments if previously removed.

9.

Tighten the domed nut in the centre of the top yoke


to 65 Nm.

10. Align the master cylinder/clamp split lines with the


dot marks on the handlebars and tighten the master
cylinder fixings, upper first and then the lower to 15
Nm.
11. Check that the steering will fall to either lock from
the centre position without undue effort.
If
excessive effort is required or the steering feels tight
or notchy, it is likely that the bearings have been
pre-loaded and the adjustment procedure should
be repeated until correct. Similarly, if free-play (end
float) is still present in the bearings, then the
adjustment should be repeated until the correct
setting is reached. If all the free-play (end float)
cannot be eliminated, the bearings have been worn
beyond their service limit and must be replaced.

NOTE:

A true check can only be made when all fixings


are correctly torqued.

WARNING: Operation with incorrectly


adjusted, worn or damaged steering head
bearings may cause impaired handling and
instability leading to an accident.
If in doubt, have the motorcycle inspected by an
authorised Triumph dealer before riding.

1. Clamp Bolt
5. . Release the pinch bolt on the adjusting nut using
service tool 3880130. Slacken the domed nut in the
centre of the top yoke.

12.19

12. Remove all supports and lower the motorcycle to


the ground. Support the motorcycle on either the
side or centre stand.

12 FRONT SUSPENSION/STEERING

HEADSTOCK BEARING ADJUSTMENT


All Models built from 1992 onwards
1.

Position the motorcycle on level ground, in an


upright position.

2.

Place a block under the engine to raise the front


wheel off the ground.

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.
.-----------

1. Service tools 3880140

--------------------.

A.
~

CAUTION: Ensure that the support block


is positioned to avoid damaging all oil
lines which run beneath the engine.

7.

Tighten the yoke clamp bolts to the following torque


figures:
Top yoke bolts
20 Nm (all except Tiger)
18 Nm (Tiger)
Bottom yoke bolts
20 Nm (all except Tiger)
22 Nm (Tiger) 20 Nm (18 Nm on Tiger).
Refit the instruments if previously removed.

8.

Tighten the domed nut in the centre of the top yoke


to 65 Nm.

9.

If previously slackened, align the master


cylinder/clamp split lines with the dot marks on the
handlebars and tighten the master cylinder fixings,
upper first and then the lower to 15 Nm.

-------

3.

If necessary, slacken but do not remove both


Rotate each master
master cylinder clamps.
cylinder to allow access to the top yoke pinch bolts.

WARNING: Do not invert either master


cylinder as this will introduce air into the
brake and clutch systems and may also cause
brake fluid to damage the bodywork.
A dangerous riding condition leading to loss of
control or an accident could result if this warning
is ignored.
4.

If necessary for access reasons, remove the


instruments.

5.

Reduce the load on the top yoke by slackening the


top yoke clamp bolts. Slacken the domed nut in the
centre of the top yoke.

6.

Release the adjuster locknut using service tool


3880140. Hold the adjuster nut (the lower nut) to
prevent accidental movement.
Adjust the
headstock bearing by moving the adjuster nut,
clockwise to take out play/increase pre-load, or
anticlockwise to add play/decrease pre-load.
Correct adjustment is reached when the bearing
play is eliminated without pre-loading the bearings.
When the adjustments have been made, lock the
locknut to the adjuster nut to a torque of 40 Nm.

10. Check that the steering will fall to either lock from
the centre position without undue effort.
If
excessive effort is required or the steering feels tight
or notchy, it is likely that the bearings have been
pre-loaded and the adjustment procedure should
be repeated until correct. Similarly, if free-play (end
float) is still present in the bearings, then the
adjustment should be repeated until the correct
setting is reached. If all the free-play (end float)
cannot be eliminated, the bearings have been worn
beyond their service limit and must be replaced.
CAUTION: A true check can only be made
when all fixings are correctly torqued.

WARNING: Operation with incorrectly


adjusted, worn or damaged steering head
bearings may cause impaired handling and
instability leading to an accident.
If in doubt, have the motorcycle inspected by an
authorised Triumph dealer before riding.
11.

12.20

Remove all supports and lower the motorcycle to


the ground. Support the motorcycle on either the
side or centre stand.

FRONT SUSPENSION/STEERING 12

9.

HEADSTOCK BEARING REPLACEMENT


Removal
1.

Remove the seat and disconnect the battery,


negative (black) lead first.

2.

Remove the fuel tank as described in the fuel


system section. Also remove the lower and cockpit
fairings (where fitted).

10. Remove the speedometer cable from the rear of the


speedometer.
11 . Note the position of any cable ties and cut the ties as
necessary. Disconnect the ignition switch from the
main harness and reposition instruments and wiring
to gain access to the yokes.
12. Remove the domed nut and washer from the top of
the stem. Release the locknut and nut from the
head bearing adjuster using tool 3880140. Remove
the bottom yoke, bearing and steering stem.

WARNING: Observe the warning advice


~ given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury, could result from
spilled fuel or fuel not handled and stored in the
correct manner.
3.

Slacken the upper and lower yoke clamp bolts and,


using a downward twisting motion, withdraw each
fork stanchion in turn.

Remove the brake caliper(s). Support the caliper(s)


during the remainder of the operation.

WARNING: Do not allow the caliper(s) to


. . . . hang on the brake hoses. This may
damage the hoses and could lead to an accident.
4.

Place a block under the engine to raise the front


wheel off the ground.

WARNING: Ensure that the motorcycle is


. . . . stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.

1. Tool 3880140, Headstock Bearing Adjusters

NOTE:

1::\.

CAUTION: Ensure that the support block


is positioned to avoid damaging all oil
lines which run beneath the engine.

5.

Remove the front wheel.

6.

Remove the fork covers (where fitted), cable guides


and the front mudguard.

7.

Detach the handlebars from the top yoke and allow


to rest over the front of the motorcycle. On Tiger,
also remove the cable guides from beneath the
yoke.

14. Collect the steering head bearing.


15. Remove the top and bottom bearing outer races by
drifting the races out of the headstock.

1::\.

CAUTION: Ensure that the headstock


cup remains in the headstock during
removal of the bearing outer race.
Always replace the outer cup if any displacement
takes place during removal of the bearing race

WARNING: Do not invert either master


. . . . cylinder as this will introduce air into the
brake and clutch systems and may also cause
brake fluid to damage the bodywork.

A dangerous riding condition leading to loss of


control or an accident could result if this warning
is ignored.
8.

Early models were fitted with a stem adjuster


which was locked by means of a pinch bolt.
Where this type of adjuster is found, release the
pinch bolt using tool 3880130 to allow the
removal of the bottom yoke
13. Remove the top yoke.

WARNING: To prevent injury, always


. . . wear eye, hand and face protection when
using a drift.

Detach the front brake hose splitter from the bottom


yoke (not fitted on Thunderbird and Adventurer).

12.21

12 FRONT SUSPENSION/STEERING

16. Remove the lower bearing from the steering stem.


To remove the bearing, it may be necessary to split
the bearing inner section to release the grip on the
lower yoke. Alternatively, a suitable puller may be
used.

Assembly
1.

WARNING: To prevent injury, always


wear eye, hand and face protection when
splitting a bearing. Debris from a bearing which
breaks up may cause severe injury to unprotected
parts of the body.

Fit a new inner bearing to the steering stem using a


suitable drift tube. Do not drift against the outer
cage or rollers as this will damage the bearings.
Ensure that the bearing is fully home on the steering
stem.

WARNING: To prevent injury, always


wear eye, hand and face protection when
using a drift. Prevent damage to the bearing by
using the solid inner part of the bearing to drift
against.

1~

2.

2~

Ensure that cup (8) is still correctly fitted in the


headstock. Position the outer bearing cup of the
upper bearing in the headstock. Position tool
3880065 to the bearing cup with the smaller
diameter end facing the bearing. Position tool
3880075 against the lower end of the headstock
and pull the upper bearing cup into the headstock
using a suitable draw bolt.

$.i
~7

Use this tool face for the lower bearing

~8

Use this tool face for the upper bearing

1. 3880065, Bearing Outer Race Tool


2. 3880075, Bearing Support

CAUTION: Ensure that the correct end of


the bearing tool is selected. Permanent,
irreparable damage to the frame will result from
incorrectly selected tools

3.

1. Domed Nut
2. Washer
3. Top Yoke
4. Pinch Bolt (Early Models Only)
5. Bottom Yoke and Steering Stem
6. Bottom Bearing
7. Upper Bearing
8. Steering Head Cup

Fit the outer race of the lower bearing using the


larger diameter end of tool 3880065 to face the
bearing. Pull the bearing race into the headstock
using the same method as for the upper bearing.

NOTE:

12.22

The lower bearing is a larger diameter than the


upper bearing. The larger end of tool 3880065 is
used to fit the lower bearing.

FRONT SUSPENSION/STEERING 12

---------

WARNING: The headstock bearings will


require adjustment following assembly.
The procedure described earlier in this section
must be followed in order to correctly adjust the
headstock bearings. Incorrect adjustment will
result in an unsafe riding condition which may
cause loss of control and an accident.

1. Using Tool 3880065 To Draw In The Outer Race


Of The Upper Bearing
2.Tool3880075

Tiger Handlebar Alignment Marks

NOTE:

Re-align Tiger, Thunderbird, Thunderbird Sport


and Adventurer handlebars such that the dot(s)
align with the centre of the retaining caps.
Later Tiger models are fitted with handlebars
with only one dot mark to align the handlebars.

4.

WARNING:
The steering must be
checked daily before riding. The steering
action, from lock to lock, should be smooth but not
loose and operate without binding of the control
cables.

1. Tool 3880075
2. Using Tool 3880065 To Draw In The Outer Race
Of The Lower Bearing
Continue to assemble the motorcycle using a
reverse of the strip down procedure.

NOTE:

On Thunderbird, Thunderbird Sport and


Adventurer, align the split line of the master
cylinder clamp with the dot mark on the
handlebar.
On other models, the master
cylinder reservoirs must be level when the front
wheel is pointing straight ahead.

5.

Bleed the brakes and clutch as described in the


brake/clutch sections.

6.

Adjust the headstock bearings as described earlier


in this section.

12.23

Faulty steering may result in instability leading to


loss of control and an accident.

Brakes
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake wear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front brake pads - A Type
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front brake pads - B Type & Tiger
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front brake pads - C Type
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front brake pads - D & F Type
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear brake pads - A & B Types
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear brake pads - C Type
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front caliper - A Type
Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection/Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front caliper- B Type & Tiger
Removal/Disassembly/Inspection/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front caliper - C Type
Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
/1 nspection/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front caliper - D & F Type
Removal/Disassembly/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Caliper - A & B Types
Removal/Disassembly/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Caliper - C Type
Removal/Disassembly/Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.2
13.5
13.6
13.7
13.7
13.8
13.9
13.10
13.11
13.12
13.13
13.14
13.15
13.16
13.17
13.18
13.19
13.20
13.21
13.22
13.22
13.23
13.24
13.24
13.25
13.25

Front master cylinder


Removal/Disassembly/Inspection/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear master cylinder
Removal/Disassembly/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.27
13.28

Brake Pedal Height


Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.29

Brake disc
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.29
13.29

13.1

13.26
13.27

13 BRAKES
Front Bra ke Layouts

D & F SPECIFICATION
__a;:CD-

28 Nm

28Nm

13.2

BRAKES 13
Rear Brakes Layouts
A SPECIFICATION

22 Nm

22 Nm

40Nm

~7Nm

2BNm~

22Nm

13.3

13 BRAKES
Brake Master Cylinders

;--

25 Nm

9Nm-l_

~V ~
~'L 5) ~\@rf'\1
~@e
'"'

25Nm

25Nm

15 Nm

i
!---~

28 Nm

Rear

I
7Nm-------... ~

~o~:

I)'

27Nm

g
0

8
I

25 Nm

----\j

~
I

13.4

I p
.

~\
\~

BRAKES 13
BRAKING SYSTEM SPECIFICATIONS and
IDENTIFICATION

ASBESTOS
This warning may apply to
the following components or
any assembly containing
any of these components:-

Various different specification braking systems are fitted


to Triumph motorcycles which can be identified by
certain visible characteristics.
The braking system types are identified using the charts
below.

WARNING
CONTAINS
ASBESTOS

FRONT
DESIGNATION

IDENTIFICATION

TYPE A

4 Piston Caliper
Twin Floating Discs

TYPES 8 & F

2 Piston Caliper*
Twin Fixed Discs

TYPEC
TYPED

Breathing asbestos
dust is dangerous
to health
Follow safety
instructions

SAFETY INSTRUCTIONS

6 Piston Caliper
Twin Floating Discs
2 Piston Caliper*
Single Fixed Disc

* Both pistons on one side of the caliper only

Operate if possible out of doors or in a well


ventilated place.

Preferably use hand tools or low speed tools


equipped with an appropriate dust extraction
facility.

Dampen dust and place in a properly closed


receptacle. Dispose of the closed receptacle
safely.

Never use an airline to blow dust from


components

REAR
DESIGNATION

IDENTIFICATION

TYPE A

Caliper fitted below the


brake disc

TYPES

Caliper fitted above the


brake disc. Torque arm
mounted to caliper

TYPEC

Caliper fitted above the


brake disc. Torque arm
mounted to caliper
carrier

Brake Shoes or Pads

WARNING: Because the braking system


specification varies from model to model,
always refer to the latest parts information to
ensure that the correct specification parts are
obtained. Failure to fit the correct replacement
parts may lead to an unsafe riding condition which
may cause an accident.

WARNING: Front and rear brake systems


are fitted to a motorcycle as independent
systems. Because of this, always check the type of
system being worked on with the chart above
before starting work. For example, a motorcycle
fitted with type 'A' front brakes will often be fitted
with a different system designation on the rear.
Following the instructions for a braking system
different to that being worked on may lead to a
dangerous riding condition causing loss of control
and an accident.

13.5

13 BRAKES

BRAKING SYSTEM MAINTENANCE SAFETY


PRECAUTIONS

WARNING: Brake fluid is hygroscopic


which means it will absorb moisture from
the air. The absorbed moisture will greatly reduce
the boiling point of the brake fluid causing a
reduction in braking efficiency.

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.
Damage caused by contact with mineral based
grease may reduce braking efficiency resulting in
an accident.

Replace brake fluid in line with the Periodic


Maintenance chart. A dangerous riding condition
could result if this important maintenance item is
neglected.
Do not spill brake fluid onto any area of the
bodywork as this will damage any painted or
plastic surface.
Always use new brake fluid from a sealed
container and never use fluid from an unsealed
container or from one which has been previously
opened.
Do not mix different brands of fluid. 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.

WARNING: If there has been an


appreciable drop in the level of the fluid in
either brake fluid reservoir, consult your
authorised 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 may be defective.
It is dangerous to operate the motorcycle under
such conditions and remedial action must be
taken by your authorized Triumph Dealer before
riding the motorcycle.
Failure to take remedial action may reduce braking
efficiency leading to an accident.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Failure to change the brake fluid at the interval.
specified in the periodic maintenance chart may
reduce braking efficiency resulting in an accident.
13.6

BRAKES 13

FLUID LEVEL INSPECTION


In accordance with the periodic maintenance chart,
inspect the brake fluid level in the front and rear master
cylinder reservoirs. In addition, the brake fluid must be
regularly replaced, again in accordance with the periodic
maintenance chart, to help prevent brake failure.
1.

Ensure that the brake fluid level in the front and rear
brake fluid reservoirs is between the upper and
lower level lines (reservoir held horizontal).

1. Front Reservoir Upper Level


2. Front Reservoir Lower Level
(Thunderbird Sport)

1. Front Reservoir Lower Level


(all except Thunderbird Sport)

---_/----::;;;;;;;;:,

~--

1. Rear Reservoir Upper Level


2. Rear Reservoir Lower Level

CHANGING BRAKE FLUID, BRAKE


HOSES AND HYDRAULIC SEALS
Brake fluid, brake hoses and hydraulic seals in the
master cylinders and calipers should be changed in
accordance with the periodic maintenance chart.
1. Front Reservoir Upper Level
(all except Thunderbird Sport)

WARNING: Failure to change brake fluid,


. . . hoses and hydraulic seals at the
specified interval could result in reduced brake
efficiency leading to loss of control and an
accident.

13.7

13 BRAKES
BRAKE PADS

WARNING: Do not replace individual


brake pads, replace both pads in the
brake caliper. If two calipers are mounted on the
same wheel, all the pads on the wheel must be
replaced together. Replacing individual pads will
reduce braking efficiency and may cause an
accident.

Front and Rear Brake pad wear is automatically


compensated for and has no effect on brake lever or
pedal action.

BRAKE WEAR INSPECTION

BRAKE LIGHTS

In accordance with the Periodic Maintenance Chart,


inspect the brake pads for wear.
The minimum thickness of lining material for any front
or rear brake pad is 1.5mm. If any pad has worn to
the bottom of the groove in the pad centre, replace all
the brake pads on that wheel.

Check the brake lights for correct operation, on both front


and rear brakes, in accordance with the periodic
maintenance chart.

1. Lining material thickness


2. Centre groove

13.8

BRAKES 13
FRONT BRAKE PADS, TYPE A

Installation

Removal
1.

WARNING: Never use mineral based


. . . grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.
Damage caused by contact with mineral based
grease may reduce braking efficiency resulting in
an accident.

Release and remove the brake pad retaining pin


and inspect the pin for damage.

1.

2.

1. Retaining Pin

2. Anti-rattle Spring
3. Brake Pads
2.
3.

Remove the anti-rattle spring and inspect the spring


for damage.

WARNING: Do not 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.

Gently prise the brake pads apart to force the


caliper pistons back and allow withdrawal of the
pads.

A.

CAUTION: Never lever directly against


~ the disc, caliper or the pad lining material
as this will damage these components. Always
use a levering tool made from a soft material which
will not cause damage to the load bearing
surfaces.
Brake fluid will be displaced as the caliper pistons
are compressed. To prevent body damage, ensure
that the displaced fluid does not come into contact
with any part of the bodywork.
4.

Remove both brake pads and inspect for damage


and wear beyond the seNice limit.

5.

Repeat steps 1 to 4 for the other caliper.

Replace the brake pads as an axle set or, if all the


pads are in a seNiceable condition, clean the pad
grooves before replacing all pads in their original
positions.
Lubricate the pad retaining pins using a minimum
amount
of
proprietary
high
temperature
'Copperslip' type grease. Fit the anti-rattle spring
over the pads and push down in the centre to allow
the pad retaining pin to slide across the top of the
spring.

3.

Tighten the pad retaining pins to 18 Nm.

4.

When both sides are correctly fitted, pump the


brake lever to correctly position the caliper pistons.

5.

Check the front brake fluid level and adjust as


required with new DOT 4 fluid.

WARNING:
Use
only
D.O.T.
4
. . . specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.

13.9

13 BRAKES
FRONT BRAKE PADS, TYPE 8 AND TIGER

Installation

Removal
1.

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.
Damage caused by contact with mineral based
grease may reduce braking efficiency resulting in
an accident.

Slacken both brake pad retaining pins.

1.

Fit the anti-rattle spring into the caliper. Press the


caliper pistons back into the caliper using hand
pressure only.

"!'

CAUTION: Brake fluid will be displaced


as the caliper pistons are compressed.
To prevent body damage, ensure that the
displaced fluid does not come into contact with
any part of the bodywork.

1. Caliper Bolts
2. Pad Retaining Pins
2.

---------

3.

4.

2.

Replace the brake pads as an axle set or, if all the


pads are in a serviceable condition, clean the pad
grooves before replacing all pads in their original
positions.

3.

Lubricate the pad retaining pins using a minimum


amount
of
proprietary
high
temperature
'Copperslip' type grease. Press down on both pads
and fit the retaining pins.

Remove the caliper mounting bolts and spacers


(where fitted).

A WARNING: Do not allow the caliper to


. . . hang on the brake hoses as this may
damage the hoses and could lead to an accident.
Position the caliper to allow withdrawal of the pad
retaining pins. Support the caliper to prevent the full
weight of the caliper from hanging on the brake
hoses.

WARNING: Do not 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.

Press downwards on both pads and remove the


pad retaining pins.

4.

Position the caliper over the disc ensuring the pads


are correctly aligned on both sides of the disc.

5.

Align the caliper, spacers (where fitted) and bolts.


Tighten the caliper bolts to 40 Nm and tighten the
pad retaining pins as follows: pin between pistons
18 Nm; pin adjacent to bleed screw 22Nm.

6.

When both sides are correctly fitted, pump the


brake lever to correctly position the caliper pistons.
Check the brake fluid level and adjust as required
with new DOT 4 fluid.

1. Anti-Rattle Spring
2. Brake Pads
5.

Remove the pads and inspect for damage and wear


beyond the service limit.

6.

Remove the anti-rattle spring and inspect for


damage.

----~

13.10

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.

BRAKES 13
FRONT BRAKE PADS, TYPE C

Installation
1.

Removal
1.

Remove the caliper mounting bolts.

Press the caliper pistons back into the caliper using


hand pressure only.

'!'

CAUTION: Brake fluid will be displaced


as the caliper pistons are compressed.
To prevent body damage, ensure that the
displaced fluid does not come into contact with
any part of the bodywork.

2.

Position the caliper to allow withdrawal of retaining


pins. Support the caliper to prevent the full weight of
the caliper from hanging on the brake hoses.

Replace the brake pads as an axle set or, if all the


pads are in a serviceable condition, clean the pad
grooves before replacing all pads in their original
positions.

3.

Locate the anti-rattle spring to the pads and position


the pad retaining pins into the caliper.

4.

Press down in the centre of the anti-rattle spring


while drifting the pad retaining pins fully into place.

WARNING: Pad retaining pins that are not


correctly fitted could come loose
resulting in an unsafe riding condition and an
accident. Always ensure that the pad retaining
pins are correctly located.

WARNING: Do not allow the caliper to


hang on the brake hoses as this may
damage the hoses and could lead to an accident.
3.

2.

Drift the brake pad retaining pins through the caliper


using a suitable soft drift. The pins are removed by
drifting from the inside (wheel side) to the outside.
Press down in the centre of the anti-rattle spring to
finally release the pins

5.

Locate the caliper to the disc ensuring that the brake


pads are correctly aligned on either side of the disc.

6.

Refit the brake caliper bolts and tighten to 40 Nm.

7.

When both calipers are correctly fitted, pump the


brake lever to correctly position the caliper pistons.

8.

Check the brake fluid level and adjust as required


with new DOT 4 fluid.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.

1. Pad Retaining Pin

WARNING: To prevent personal injury,


wear eye, face and hand protection when
using a drift.
4.

Collect the anti-rattle spring and examine for


damage and deterioration.

5.

Remove the pads and inspect for damage and wear


beyond the service limit.
13.11

13 BRAKES
4.

FRONT BRAKE PADS, TYPES D & F

Remove the brake pads from the lower end of the


caliper.

Removal
1.

Remove the grub screw from the outer end of the


brake pad pin.

!.

Withdrawing Brake Pads


5.

Collect the anti rattle springs from inside the caliper.

Releasing the Grub Screw

Installation
2.

Release the brake pad pin using an Allen key and


withdraw the pin from the caliper.

1.

Fit the anti-rattle springs into the caliper.

2.

Lubricate the pad retaining pin using a minimum


amount
of
proprietary
high
temperature
'Copperslip' type grease.

WARNING:

Do not apply more than a

~ minimum coating of grease to the pad

retaining pin. Excess grease may contaminate the


brake pads, hydraulic seals and disc causing
reduced braking efficiency which may lead to loss
of control and an accident.
3.

Install the brake pads into the caliper ensuring that


the upper end is correctly engaged in the anti-rattle
spring.

Releasing the Brake Pad Pin


3.

Using hand pressure only, retract the caliper pistons


by gently pushing the caliper toward the wheel.

'f'

CAUTION: Brake fluid will be displaced


as the caliper pistons are compressed.
To prevent body damage, ensure that the
displaced fluid does not come into contact with
any part of the bodywork.

Correct Pad Engagement in the Anti-rattle Spring


4.

13.12

Align the pads and fit the pad retaining pin. Tighten
the pin to 18 Nm.

BRAKES 13
5.

Refit the grub screw to the caliper and tighten to 3


Nm.

REAR BRAKE PADS, A & 8 TYPES

6.

Check the brake fluid level and adjust as required


with new DOT 4 fluid.

Removal
1.

Remove the right hand silencer (not Tiger).

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.

WARNING: 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 hot
exhaust system could cause burn injuries.

Observe the brake fluid handling warnings given


earlier in this section of the m_~an:_:_u~a~l_.~~~----'

2.

Slacken both brake pad retaining pins.

3.

Remove the caliper mounting bolts.

1. Pad Retaining Pins


2. Caliper Mounting Bolts
4.

Position the caliper to allow withdrawal of retaining


pins.

WARNING: Do not allow the caliper to


. . . . hang on the brake hoses as this may
damage the hoses and could lead to an accident.
5.

Press downwards on both pads and remove the


pad retaining pins.

If\

CAUTION: Brake fluid will be displaced


as the caliper pistons are compressed.
To prevent body damage, ensure that the
displaced fluid does not come into contact with
any part of the bodywork.

6.

13.13

Remove the brake pads and inspect for damage


and wear beyond the service limit.

13 BRAKES
7.

When the caliper is correctly fitted, pump the brake


pedal to correctly position the caliper pistons.

8.

Check the brake fluid level and adjust as required


with new DOT 4 fluid.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.

1. Brake Pads
2. Anti Rattle Spring
7.
Remove the anti-rattle spring and inspect for
damage.

9.

Installation

REAR BRAKE PADS, C TYPE

,-------

Refit the right hand silencer (not Tiger).

_________,

------,,,,

The procedure for replacement of type C rear brake pads


is the same as for type D & F front brake pads.

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease witt
damage the hydraulic seals in the calipers and
master cylinders.

Please refer to the instructions for type D & F front brake


pads when replacing type C rear brake pads.

Damage caused by mineral based grease may


reduce braking efficiency resulting in an accident.

1.

Fit the anti-rattle spring into the caliper.

2.

Replace the brake pads as an axle set or, if all pads


are in serviceable condition, clean the pad grooves
before replacing all pads in their original positions.

3.

Lubricate the pad retaining pins using a minimum


amount
of
proprietary
high
temperature
'Copperslip' type grease. Press down on both pads
and fit the retaining pins.

WARNING: Do not 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.

Position the caliper over the disc ensuring the pads


are correctly aligned on both sides of the disc.

5.

Align the caliper, carrier and torque arm and fit the
caliper retaining bolts. Tighten the caliper bolts to 40
Nm.

6.

Tighten the brake pad retaining pins to 18 Nm.

13.14

BRAKES 13
BLEEDING
THE
FRONT
BRAKES,
REPLACING BRAKE FLUID, ALL TYPES
1.

On models equipped with adjustable levers, set


adjuster wheel to No.1. Note the original setting
of the adjuster wheel in order that it can be
returned to the same position when the
bleeding operation is complete.

8.

Check the condition of the sealing diaphragm for


the reservoir. Replace if necessary.

9.

Release the bleed nipple.

10. Slowly pull in and release the brake lever several


times until no more air bubbles appear in the bleed
tube.
11. Maintain the brake fluid level between the upper
and lower reservoir levels whilst bleeding is being
carried out.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.

NOTE:

1. Adjuster

2.

Remove the rubber cap from the bleed nipple on the


right hand caliper.

3.

Attach a transparent tube to the bleed nipple.

4.

Place the other end of the tube in a suitable


receptacle containing new brake fluid.

5.

Turn the handlebars to bring the fluid reservoir to a


level position.

6.

Release and remove both screws securing the


brake reservoir cover.

During bleeding, do not allow the fluid level to


fall below the lower level mark in the reservoir. If
the level is allowed to fall below this mark, air
may enter the system and the sequence of
bleeding must be repeated.

12. When all air has been expelled from the system,
hold the lever in and close the bleed nipple. Tighten
the nipple to 5 Nm.

WARNING: Ensure absolute cleanliness


when adding brake fluid to the brake fluid
reservoir. Do not allow moisture or debris to 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.
Always check for fluid leakage around hydraulic
fittings and for damage to hoses.
1.
2.
3.
4.

A dangerous riding condition leading to an


accident could result if this warning is ignored.

CAUTION: To prevent body damage, do


not spill brake fluid onto any area of the
bodywork.

7.

Carefully remove the reservoir cover taking care not


to spill any fluid.

13.15

Bleed Nipple
Spanner
Bleed Pipe
Container

13 BRAKES
13. Fill the reservoir to the upper level with new DOT 4
fluid.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.

BLEEDING REAR BRAKES, REPLACING


BRAKE FLUID, ALL TYPES
1.

Remove the body side panels together with the


right-hand engine air intake duct.

2.

Remove the cap from the rear bleed nipple.

3.

Observe the brake fluid handling warnings given


earlier in this section of the manual.
14. Remove the transparent bleed tube.
15. Replace the bleed nipple cap.
16. Repeat the procedure for the left-hand caliper.
17. Replace the reservoir cover and diaphragm
ensuring correct fitment of the diaphragm before
final tightening of the screws.
18. Reset the brake lever adjuster to the original
setting.

1. Bleed Nipple
2. Spanner
3. Bleed Tube
4.

WARNING:
Always return the lever
adjuster to the original setting as noted in
paragraph 1. Operating the motorcycle with lever
settings which are unfamiliar may lead to loss of
control or an accident.

Place the other end of the tube in a suitable


receptacle containing new brake fluid.

19. Check that the brake operates correctly.

1. Rear Reservoir Upper Level


2. Rear Reservoir Lower Level

WARNING: Ensure absolute cleanliness


when adding brake fluid to the brake fluid
reservoir. Do not allow moisture or debris to 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.
Always check for fluid leakage around hydraulic
fittings and for damage to hoses.
A dangerous riding condition leading to an
accident could result if this warning is ignored.

13.16

BRAKES 13
FRONT BRAKE CALIPER,
A SPECIFICATION

CAUTION: To prevent body damage, do


~ not spill brake fluid onto any area of the
bodywork.
6.
7.

Release the bleed nipple.

8.

Slowly depress and release the footbrake pedal


several times until no more air bubbles appear in the
bleed tube.

9.

Removal

Check the condition of the sealing diaphragm.


Replace the diaphragm as necessary.

1.

Disconnect the brake hose at the caliper and place


the free end of hose in a suitable container to collect
brake fluid.

2.

Slacken the pad retaining pin.

3.

Gently prise the brake pads apart to force the


pistons back. Remove the brake pads.

Maintain the brake fluid level between the upper


and lower reservoir levels whilst bleeding is being
carried out. SEE WARNING FOLLOWING ITEM
11 BELOW.

/;

NOTE:

During bleeding, do not allow the fluid level to


fall below the lower level mark in the reservoir. If
the level is allowed to fall below this mark, air
may enter the system and the sequence of
bleeding must be repeated.

10. When all air has been expelled from the system,
hold down the brake pedal and close the bleed
nipple. Tighten the nipple to 5 Nm.
11.

Caliper Pin Removal

Fill the reservoir to the maximum level with new


DOT 4 fluid.

CAUTION: Never lever directly against


the disc, caliper or the pad lining material.
Always use a levering tool made from a soft
material which will not cause damage to the load
bearing surfaces.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.

Brake fluid will be displaced as the caliper pistons


are compressed. To prevent body damage, ensure
that the displaced fluid does not come into contact
with any part of the bodywork

Observe the brake fluid handling warnings given


earlier in this section of the manual.

4.

Remove the caliper securing bolts.

5.

Repeat steps 1 to 4 for the remaining caliper.

Disassembly

12. Fit the reservoir cover and diaphragm. Check for


correct diaphragm fitment before final tightening of
the cover.
13. Remove the bleed tube from the nipple.

1.

Separate the two halves of the caliper by removing


the connecting bolts.

2.

Cover the caliper opening with a clean, heavy cloth


and, using either compressed air or by
reconnecting the master cylinder and pumping the
brake lever, remove the pistons one at a time.

14. Replace the bleed nipple dust cap.


15. Fit the right-hand air intake duct and replace the
body side panels.
16. Check that the brake operates, then carry out a road
test to verify correct brake operation.

13.17

WARNING: To prevent injury, never place


fingers or hands inside the caliper
opening when removing the pistons. Always wear
eye, hand and face protection when using
compressed air. Eye, face and skin damage will
result from direct contact with compressed air.

13 BRAKES
Inspection

Installation

1.

1.

Position the caliper over the disc and tighten the


caliper bolts to 40 Nm.

2.

Lubricate the pad retaining pins using a minimum


amount
of
proprietary
high
temperature
'Copperslip' type grease. Fit the brake pads to the
caliper and locate the anti-rattle spring over the
pads. Push down in the centre of the anti rattle
spring to allow the pad retaining pin to slide across.

Check the piston and caliper bore for corrosion,


scoring and damage. Renew as necessary.

WARNING: Always renew caliper seals,


pistons and bolts after removal from the
caliper. An effective hydraulic seal can only be
made if new components are used.
A dangerous riding condition leading to an
accident could result if this warning is ignored.
2.

Inspect the brake pads for damage and wear


beyond the service limit. Renew as necessary.

Assembly

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. 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.

Renew the fluid seals. Apply brake fluid to the


outside of the caliper pistons and fluid seal.

2.

Push the pistons into the cylinder by hand.

WARNING: Ensure that the caliper bores


do not become scratched during removal
and assembly.
Ensure that the pistons do not tip during assembly
as this could damage the caliper.
Always renew the '0' rings between the caliper
halves.
A dangerous riding condition leading to an
accident could result if these warnings are
ignored.
3.

WARNING: Do not 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.
3.

Tighten the brake pad retaining pin to 18 Nm.

4.

Connect the brake hose to the caliper using new


sealing washers on each side of the banjo bolt.

5.

Tighten the banjo bolt to 25 Nm.

6.

Fill the master cylinder with new, DOT 4 brake fluid


from a sealed container.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.
7.

Assemble the two halves of the caliper ensuring that


new joint '0' rings are correctly fitted in their locating
grooves. Tighten new caliper joint bolts to 25 Nm.

13.18

Bleed the brake line as described earlier.

BRAKES 13
FRONT BRAKE CALIPER
8 SPECIFICATION AND TIGER

Inspection
1.

Check the piston and caliper bore for corrosion,


scoring and damage. Renew as necessary.

Removal
1.

WARNING: Always renew caliper seals


and pistons after removal from the
caliper. An effective hydraulic seal can only be
made if new components are used.

Disconnect the brake hose and place the free end of


the hose in a suitable container to collect the brake
fluid.

2.

A dangerous riding condition leading to an


accident could result if this warning is ignored.
2.

Inspect the brake pads for damage and wear


beyond the service limit. Renew as necessary.

Assembly

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.
1. Caliper Bolts
2. Pad Retaining Pins

A dangerous riding condition leading to an


accident could result if this warning is ignored.

3.

1.

Fit new fluid seals to the caliper. Apply new, clean


brake fluid to the outside of the pistons and fluid
seals.

2.

Push the pistons into the cylinder using hand


pressure only.

Remove the caliper securing bolts and spacers


(where fitted), then remove the caliper from the
disc/fork leg.

Disassembly
1.
2.

Remove the brake pad retaining pins, brake pads


and anti-rattle spring.

WARNING: Ensure that the caliper bores


do not become scratched during removal
and assembly. Ensure that the pistons do not tip
during assembly as this could damage the caliper.

Cover the caliper opening with a clean, heavy cloth


and, using either compressed air or by
reconnecting the master cylinder and pumping the
brake lever, remove the pistons one at a time.

WARNING: To prevent injury, never place


fingers or hands inside the caliper
opening when removing the pistons. Always wear
eye, hand and face protection when using
compressed air. Eye, face and skin damage will
result from direct contact with compressed air.

A dangerous riding condition leading to an


accident could result if this warning is ignored.
3.

Lubricate the pad retaining pins using a minimum


amount
of
proprietary
high
temperature
'Copperslip' type grease.

WARNING: Do not 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.

13.19

13 BRAKES

4.

Install the anti-rattle spring in the calipers. Refit the


brake pads and pad retaining pins.

1. Anti Rattle Spring

Installation
1.

Position the caliper over the brake disc ensuring


that the pads are correctly positioned within caliper.

2.

Tighten the caliper securing bolts to 40 Nm.

3.

Tighten the pad retaining pins as follows:


pin between pistons 18 Nm;
pin adjacent to bleed screw 22 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.

6.

Fill the master cylinder with new, DOT 4 brake fluid


from a sealed container.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.
7.

Bleed the brake line as described earlier.

13.20

BRAKES 13
FRONT BRAKE CALIPER,
C SPECIFICATION.

NOTE:

The caliper is overhauled one side at a time. It is


not possible to withdraw all six pistons
together. Complete the overhaul of the first set
of three pistons before commencing overhaul
of the second set.

WARNING:
When pushing back the
caliper pistons, cover the brake hose
connection to prevent brake fluid from coming into
contact with the bodywork. Severe body damage
will result from contact with brake fluid.
A dangerous riding condition leading to an
accident could result if this warning is ignored.
2.

Removal
1.

Disconnect the brake hose at the caliper and place


the free end of hose in a suitable container to collect
brake fluid.

2.

Remove the brake caliper from the fork.

3.

Drift the brake pad retaining pins through the caliper


using a suitable soft drift. The pins are removed by
drifting from the inside (wheel side) to the outside.
Press down in the centre of the anti-rattle spring to
finally release the pins.

Insert tool 3880185 into the caliper with the rubber


face towards one set of pistons.

NOTE:

The tool must be fitted from the outside face of


the caliper (arrowed below).

1. Tool 3880185
2. Air Line Connection
3.

WARNING:
The use of air pressure
greater than 3 bar will damage the caliper.
Never re-use a caliper which has been serviced
using air pressure greater than 3 bar as this may
lead to reduced braking efficiency and an accident.

1. Pad Pin

Disassembly

WARNING: The caliper is manufactured


in two halves but must not be split during
caliper overhaul. If the seals between the caliper
halves are disturbed or start to leak, the caliper
must be replaced before riding the motorcycle.

WARNING: Always wear hand, face and


eye protection when using compressed
air. Eye, face and skin damage will result from
direct contact with compressed air.

I:\

A dangerous riding condition leading to an


accident could result if this warning is ignored.
1.

Connect an air line to the brake hose connection


point on the top of the caliper. Apply air pressure
until all 3 pistons have moved outwards to contact
the rubber face of the tool.

CAUTION: When using compressed air

~ to eject the caliper pistons, there is a

Withdraw the brake pads and anti-rattle spring from


the caliper and ensure all 6 pistons are pushed fully
back into their bores.

possibility of brake fluid becoming dispersed in


the air stream. To prevent body damage, always
carry out this operation at a safe distance from
bodywork and other painted components.
4.

13.21

Withdraw the tool and collect the pistons from their


bores. Remove the seals from the caliper (2 per
piston bore) taking care not to mark the caliper bore
or seal grooves. Discard the seals.

13 BRAKES

A.

CAUTION: Use a tool made from a soft


material, such as brass, to remove caliper
seals. Tools made from steel etc. will damage the
caliper bores and seal grooves.

WARNING:

Incorrectly fitted caliper

~ seals will result in an unsafe riding

condition leading to an accident. Always ensure


that the seals are not twisted and are the correct
diameter for the bore in which they are fitted.

Inspection
1.

Check for scoring of the caliper bores, scoring or


corrosion of the pistons and leakage between the
caliper halves. Renew components as necessary.

4.

Lightly smear one of each size wiper seal with


silicone grease but do not soak in brake fluid.
Taking care to match the seal diameter with the
same diameter caliper bore, insert the wiper seals
into the upper seal grooves in the caliper. Ensure
that the seal sits squarely in the bore and is not
twisted.

5.

Lightly smear each piston with the silicone grease


described in paragraph 2 and insert into its
appropriate bore. Ensuring that the piston is square
with the bore, gently press the piston fully into the
bore using hand pressure only.

Assembly

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. 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.

A.

1.

Carefully clean the pistons, caliper bores and seal


grooves using a clean, lint-free cloth.

2.

Lightly smear one of each size pressure seal with


silicone grease such as Molykote PG 54 or allow to
soak for a minimum of 10 minutes in new, clean
brake fluid.

CAUTION: Do not force the piston into


the caliper bore as this will damage both
the piston and caliper. Use hand pressure only to
fit the piston.

NOTE:

Once the first set of three pistons have been


fully assembled, repeat the process for the
remaining three pistons on the other side of the
caliper.

Installation
1.

Replace the brake pads as an axle set or, if all the


pads are in a serviceable condition, clean the pad
grooves before replacing all pads in their original
positions.

2.

Locate the anti rattle spring to the pads and position


the pad retaining pins into the caliper.

3.

Press down in the centre of the anti rattle spring


while drifting the pad retaining pins fully into place.
Ensure that the pad retaining pins are drifted
correctly into place.

1. Wiper Seal Section

2. Pressure Seal Section


NOTE:

The pressure seal has a much thicker section


than the wiper seal.
3.

Taking care to match the seal with the same


diameter caliper bore, insert the pressure seals into
the lower seal grooves in the caliper. Ensure that
the seal sits squarely in the bore and is not twisted.

WARNING: Pad retaining pins that are not


correctly fitted could come loose
resulting in an unsafe riding condition leading to
an accident. Always ensure that the pad retaining
pins are correctly located.

4.

Locate the caliper to the disc ensuring that the brake


pads are correctly aligned either side of the disc.

5.

Refit the brake caliper bolts and tighten the fixings to


40Nm

13.22

BRAKES 13
6.

Align the brake hose to the caliper and fit new


sealing washers to both sides of the banjo bolt.
Tighten the banjo bolt to 25 Nm.

FRONT
BRAKE
SPECIFICATION

7.

Fill the master cylinder with new, DOT 4 brake fluid


from a sealed container.

Removal

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.

&

1.

Disconnect the brake hose at the caliper and place


the free end of hose in a suitable container to collect
brake fluid.

2.

Remove the brake caliper from the fork.

3.

Remove the brake pads as described earlier in this


section.

Disassembly

Observe the brake fluid handling warnings given


earlier in this section of the manual.
8.

CALIPER,

1.

Bleed the brake line as described earlier.

Cover the caliper opening with a clean, heavy cloth


and, using either compressed air or by
reconnecting the master cylinder and pumping the
brake lever, remove the pistons one at a time.

WARNING: To preve~t i~jury, never p~ace


fingers or hands ms1de the caliper
opening when removing the pistons. Always wear
eye, hand and face protection when using
compressed air. Eye, face and skin damage will
result from direct contact with compressed air.

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 the
caliper. An effective hydraulic seal can only be
made if new components are used.
A dangerous riding condition leading to an
accident could result if this warning is ignored.
2.

13.23

Inspect the brake pads for damage and wear


beyond the service limit. Renew as necessary.

13 BRAKES
Assembly

REAR BRAKE CALIPER, A & B TYPES


Removal

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. 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 seals to the caliper. Apply new, clean


brake fluid to the outside of the pistons and fluid
seals.

2.

Push the pistons into the cylinder using hand


pressure only.

1.

Remove the right hand silencer (not Tiger).

2.

Disconnect the rear brake hose at the caliper and


place the free end of hose in a suitable container to
collect brake fluid.

3.

Slacken the two pad retaining pins.

4.

Remove the caliper mounting bolts.

5.

Remove the brake caliper assembly.

WARNING: Ensure that the caliper bores


do not become scratched during removal
and assembly. Ensure that the pistons do not tip
during assembly as this could damage the caliper.
A dangerous riding condition leading to an
accident could result if this warning is ignored.
3.

Refit the brake pads as described earlier in this


section.

4.

Tighten the pad retaining pin to 18 Nm and the grub


screw to 3 Nm.

Installation
1.

Position the caliper over the brake disc ensuring


that the pads are correctly positioned within caliper.

2.

Tighten the caliper securing bolts to 28 Nm.

3.

Connect the brake hose to the caliper using new


washers on each side of the banjo bolt.

4.

Tighten the banjo bolt to 25 Nm.

5.

Fill the master cylinder with new, DOT 4 brake fluid


from a sealed container.

Rear Caliper Removal

Disassembly
1.

Press downwards on both pads and remove the


retaining pins. Remove the brake pads.

2.

Cover the caliper opening with a clean, heavy cloth


and, using either compressed air or by
reconnecting the master cylinder and pumping the
brake lever, remove the pistons one at a time.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.

WARNING: To prevent injury, never place


fingers or hands inside the caliper
opening when removing the pistons. Always wear
eye, hand and face protection when using
compressed air. Eye, face and skin damage will
result from direct contact with compressed air.

Observe the brake fluid handling warnings given


earlier in this section of the manual.
6.

Bleed the brake line as described earlier.


13.24

BRAKES 13
4.

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 the
caliper. An effective hydraulic seal can only be
made if new components are used.

Position the brake pads in the calipers. Lubricate


the pad retaining pins using a minimum amount of
proprietary high temperature 'Copperslip' type
grease. Press down on both pads and fit the pad
retaining pins.

WARNING:

Do not 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.

A dangerous riding condition leading to an


accident could result if this warning is ignored.

Installation
2.

Inspect the brake pads for damage and wear


beyond the seNice limit. Renew as necessary.

1.

Position the caliper over the disc ensuring the pads


are correctly aligned on both sides of the disc.

2.

Align the caliper, carrier and torque arm and fit the
caliper retaining bolts. Tighten the bolts to 40 Nm.

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.

3.

Tighten the brake pad retaining pins to 18 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.

A dangerous riding condition leading to an


accident could result if this warning is ignored.

6.

Fill the master cylinder with new, DOT 4 brake fluid


from a sealed container.

Assembly

1.
2.

Fit new fluid seals to the caliper. Apply brake fluid to


the outside of the caliper piston and fluid seal.
Push the piston into the cylinder by hand.

A.

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.

CAUTION: Ensure that the caliper bores

~ and pistons do not become scratched

during removal and assembly. Ensure that the


pistons do not tip over during assembly as this
could damage the caliper.

Observe the brake fluid handling warnings given


earlier in this section of the manual.

3.

7.

Bleed the brake line as described earlier.

8.

Refit the right hand silencer (not Tiger).

REAR BRAKE CALIPER, C TYPE


The procedure for the overhaul of type C rear brake
calipers is the same as for type D & F front brake calipers.
Please refer to the instructions for types D & F front brake
calipers when overhauling type C rear brake calipers.

1. Anti Rattle Spring


2. Brake Pads

13.25

13 BRAKES
FRONT MASTER CYLINDER

Disassembly

Removal
1.

On models equipped with adjustable levers note the


original setting of the adjuster wheel in order that it
can be returned to the same position when the
overhaul operation is complete.

1.

Detach the boot from the lever end of the cylinder.

2.

Remove the circlip from beneath the boot.

3.

Remove the piston set from the master cylinder


bore noting the relative position of the seals and
piston components.

2
2.
3.

Drain the fluid from the master cylinder by bleeding


the system until all fluid has been expelled.
Remove the pivot bolt securing the brake lever to
the master cylinder. On Tiger, also collect the
knuckle guard and flanged sleeve.

1. Boot
2. Circlip
3. Piston Set

Inspection

1.

Check the following for wear, damage, cracks or


deterioration:
Cylinder bore
Dust cover
Spring
Piston
Pivot Bolt

2.

Always renew the piston and seal set if the cylinder


is dismantled.

3.

Check that the relief and supply ports on the


cylinder are not blocked.

Assembly

1.
2.
3.
4.

Plug (Tiger only)


Pivot bolt
Flanged Sleeve (Tiger only)
Nut

4.

Remove the brake lever.

5.

Disconnect the brake hose from the master


cylinder.

6.

Disconnect the brake light switch connections from


the master cylinder.

7.

Release the clamp screws from the handlebars.

8.

Remove the master cylinder.

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. 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.

13.26

Lubricate the piston and cylinder with new, clean


brake fluid.

BRAKES 13
2.

Fit the new piston set into the master cylinder and
retain with a new circlip.

8.

WARNING: Ensure that the piston and


piston seal are fitted facing the same way
as noted during removal. A dangerous riding
condition leading to an accident could result from
incorrect assembly of the master cylinder.

WARNING:
Always return the lever
adjuster to the original setting as noted in
paragraph 1. Operating the motorcycle with lever
settings which are unfamiliar may lead to loss of
control or an accident.

3.

Refit the master cylinder boot.

9.

Installation
1.

2.

Tighten the clamp bolts, upper first and then the


lower to 15 Nm.

3.

Re-connect the brake light switch to the master


cylinder.

4.

Position the brake lever ensuring that pivot boss is


correctly aligned and fitted to the push rod. On
Tigers, fit the knuckle guard and flanged sleeve.
Tighten the pivot bolt to 1 Nm on all except Tiger,
and 6Nm on Tiger.

5.

Tighten the locknut to 6Nm (all models). On Tiger,


refit the plug to the pivot bolt.

6.

Using new sealing washers on both sides of the


banjo bolt, align and connect the brake hose to the
master cylinder. Tighten the banjo bolt to 25 Nm.

Removal
1.

Remove the seat and disconnect the battery


negative (black) lead first. Remove the body side
panels. On Tiger, remove the master cylinder
cover.

2.

Drain the fluid from the master cylinder by bleeding


the system until all fluid has been expelled.

3.

Remove the split pin or clip (whichever is fitted)


from the clevis pin at the lower end of the brake
pushrod . Remove the clevis pin.

4.

Remove the reservoir hose from the master


cylinder.

5.

Disconnect the brake light switch connections and


detach the rear brake hose.

6.

Remove the capscrews and washers retaining the


cylinder and cover (where fitted) to the frame.

7.

Remove the master cylinder from the frame.

Disassembly
1.

Remove the boot from the cylinder and push rod.

2.

Remove the circlip retaining the pushrod to the


cylinder.

3.

Remove the piston set from the master cylinder


bore noting the relative position of the seals and
piston components.

Fill and bleed the front brakes as described earlier.

WARNING:
Use
only
D.O.T.
4
. . . specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.

Examine the system for correct operation and fluid


leaks. Rectify as necessary.

REAR MASTER CYLINDER

Locate the master cylinder to the handlebars and


position the clamp with the 'Up' arrow pointing
upwards. Align the master cylinder/clamp split line
with the dot mark on the handlebar.

1. Arrow Mark

7.

Reset the brake lever adjuster (if fitted) to the


original setting.

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. Replace as necessary.
Always renew the piston seals if the cylinder has
been dismantled.

3.

Examine the pushrod for bends and damage.


Replace as necessary.

13.27

13 BRAKES
Assembly

WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.

WARNING: Never use mineral based


grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.

Observe the brake fluid handling warnings given


earlier in this section of the manual.

A dangerous riding condition leading to an


accident could result if this warning is ignored.

7.
1.

Clean the master cylinder bore, piston and seals,


with new brake fluid.

2.

Ensure all ports are clear of obstruction.

3.

Install the spring and piston set together.

Reconnect the battery positive, (red) lead first and


refit the body side panels.

WARNING: Ensure that the piston and


piston seal are fitted facing the same way
as noted during removal. A dangerous riding
condition leading to an accident could result from
incorrect assembly of the master cylinder.
4.

Apply a small amount of brake grease to the


push rod.

5.

Install the pushrod in the master cylinder and retain


with a new circlip. Refit the boot.

Installation
4

1.

Fit the reservoir hose to the master cylinder.

2.

Secure the master cylinder and cover (where fitted)


to the frame.
Tighten the master cylinder
capscrews to 27 Nm.

NOTE:

'

On Tiger, the master cylinder cover is held by


separate fixings.

3.

Connect the push rod to the brake pedal with a new


clevis pin. Retain to the pedal with a new split pin or
clip (whichever is fitted).

4.

Fit new washers to the brake hose connection and


fit to the master cylinder. Tighten to 28 Nm.

5.

Reconnect the brake light switch.

6.

Fill and bleed the rear brake system as described


earlier.

~-

~
I

1.
2.
3.
4.
5.
6.
7.

13.28

Split pin
Clevis pin
Reservoir hose
Capscrew and washer
Dust boot
Circlip
Piston set

1...__,

BRAKES 13
BRAKE PEDAL HEIGHT ADJUSTMENT
1.

2.

BRAKE DISCS

Check that the height of the foot-plate on the rear


brake pedal is sufficiently below the height of the
footrest to prevent accidental application during
normal riding.

Wear
1.

If incorrect, the pedal height can be varied by


adjusting the length of the actuating rod to the rear
master cylinder.

Replace any brake disc if worn beyond the service


limit or exceeds the disc run-out limit.

Front Disc Thickness (Except Tiger)


Standard: ........ 5.0 mm
Service Limit: . . . . 4.5 mm

Front Disc Thickness (Tiger)

Standard: . . . . . . . . 4.0 mm
Service Limit: . . . . 3.5 mm

Rear Disc Thickness (Except Tiger)


Standard: . . . . . . . . 6.0 mm
Service Limit: . . . . 5.0 mm

Rear Disc Thickness (Tiger)


Standard: . . . . . . . . 5.0 mm
Service Limit: . . . . 4.0 mm

Disc Run-out (All Models)


Standard: ........ 0.1 mm
Service Limit: . . . . 0.3 mm

NOTE:

It is not necessary to remove the rod from the


pedal to make the adjustments.

3.

WARNING: Do not replace front brake


discs individually. Discs must always be
replaced in pairs even if one of a pair is
serviceable.
A dangerous riding condition leading to an
accident could result if this warning is ignored.

To adjust the pedal height, slacken the locknut (2)


and turn the master cylinder rod (1) until the
required pedal height is reached. Screw the master
cylinder rod into the clevis pin fork to lower the pedal
height, and outwards to raise the pedal height.
Re-tighten the locknut when the pedal is set to the
required height.

Measure disc run out using an accurate dial gauge


mounted on a surface plate.

WARNING: Ensure that the master


cylinder rod has adequate thread
engagement in the clevis pin fork (minimum 1Omm
of thread engagement).
A dangerous riding condition leading to an
accident could result if this warning is ignored.

WARNING: After adjusting the pedal,


operate the motorcycle in a safe area
away from traffic to gain familiarity with the new
pedal setting.
Operation of the motorcycle without first
becoming familiar with the new pedal setting could
lead to loss of control and an accident.
1. Disc
2. Dial Gauge

13.29

Wheels/Tyres
CONTENTS
Page
Tyres/Wheels
Tyre Inflation Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tyre and Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.5
14.6
14.6

Tyre Safety Information


Safety Informationall models EXCEPT Tiger, Thunderbird, Thunderbird Sport
and Adventurer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tiger, Thunderbird, Thunderbird Sport and Adventurer . . . . . . . . . . . . .

14.7
14.8

Wheel Removal/Installation
Front.........................................................
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.9
14.10

Wheel bearings
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation....................................................

14.11
14.12

14.1

14 WHEELSII'YRES
Wheels: All except Tiger, Thunderbird, Thunderbird Sport and Adventurer

85 Nm

14.2

WHEELSITYRES 14
Wheels: Tiger

14.3

14 WHEELS/lYRES
Wheels: Thunderbird, Thunderbird Sport
and Adventurer

'

I
I'
I
'

I
I
'

14.4

WHEELS!TYRES 14
TV RES

Tiger, Thunderbird, Thunderbird Sport


and Adventurer

Trophy, Trident, Sprint, Speed Triple,


Daytona Super 3 and Daytona

Tiger, Thunderbird, Thunderbird Sport and Adventurer


motorcycles are fitted with spoked wheels which require
a tyre suitable for use with an inner tube.

All the above range of motorcycles are equipped with


tubeless tyres, valves, and wheel rims. Only tyres
marked 'TUBELESS' and tubeless type tyre valves
mounted on rims marked 'TUBELESS TYRE
APPLICABLE' can be used.
---------======-~-~

WARNING: Tyres that have been used on


. . . a rolling road dynamometer may become
damaged. In some cases, the damage may not be
visible on the external surface of the tyre.
Tyres must be replaced after such use as
continued use of a damaged tyre may lead to
instability, loss of control and an accident.

____

WARNING: Failure to use an inner tube in


. . . a spoked wheel will cause deflation of the
tyre resulting in loss of control and an accident.

Tyre Pressures, All Models


Correct inflation pressure will provide maximum stability,
rider comfort and tyre life.

Rim Marking

Tyre pressures should be checked frequently and


adjusted as necessary. See the Owner's Handbook or
the specification section for the correct inflation
pressures for your model.

WARNING: Incorrect tyre inflation will


. . . cause abnormal tread wear and
instability problems which may lead to loss of
control and an accident.
Underinflation may result in the tyre slipping on, or
coming off the rim. Over-inflation will cause
instability and accelerated tread wear.
Both conditions are dangerous as they may cause
loss of control leading to an accident.

Tyre Marking

WARNING: Tyres that have been used on


. . . a rolling road dynamometer may become
damaged. In some cases, the damage may not be
visible on the external surface of the tyre.
Tyres must be replaced after such use as
continued use of a damaged tyre may lead to
instability, loss of control and an accident.

14.5

14 WHEELS/TYRES
Minimum Recommended Tread Depth

Tyre Wear/Wheel Inspection, All Models


As the tyre tread wears down, the tyre becomes more
susceptible to puncture and failure. It is estimated that
90% of all tyre failures occur during the last 10% of tread
life (90% worn). It is false economy and unsafe to use
tyres until they are worn to their minimum.
All tyres are fitted with tread wear indicators. When the
tyre becomes worn down as far as the top of a tread wear
indicator, the tyre is worn beyond its service life and must
be replaced.

Typical
Tread
Wear
Indicator -

In accordance with the Periodic Maintenance Chart,


measure the depth of the tread with a depth gauge, and
replace any tyre that has worn to, or beyond the minimum
allowable tread depth.
Inspect wheels for cracks, splits and kerbing damage.
Inspect Tiger wheels for similar damage and also check
spokes for corrosion, looseness and breakage. Always
replace wheels that are suspected 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 tubeless tyres become punctured, leakage
is often very slow. Always inspect tyres very
closely for punctures.
Check the tyres for cuts, imbedded nails or other
sharp objects. On spoked wheels, check spokes
for looseness and damage.
Check the rims for dents or deformation.
Operation with damaged or defective wheels or
tyres is dangerous and loss of control or an
accident could result.
Always consult your Triumph Dealer for tyre
replacement, or for a safety inspection of the tyres.

14.6

The following chart can be used as a guide to the


minimum safe tread depth.
Under 130 km/h (80mph) 2 mm (0.08 in)
Over 130 km/h
(80 mph)

Rear 3 mm (0.12 in)


Front 2 mm (0.08 in)

WARNING: Triumph motorcycles must


not be operated above the legal road
speed limit except in authorised closed course
conditions.

WHEELS!TYRES 14
IMPORTANT TYRE INFORMATION

WARNING: Operation with excessively


worn or damaged tyres will adversely
affect handling and control leading to loss of
control or an accident.

All Models except Tiger, Thunderbird,


Thunderbird Sport and Adventurer
All Triumph motorcycles are carefully and extensively
tested in a range of riding conditions to ensure that the
most effective tyre combinations are approved for use on
each model.
It is essential that approved tyre
combinations are used when purchasing replacement
tyres as the use of non approved tyres or approved tyres
in non approved combinations may lead to motorcycle
instability. Always refer to the Owner's Handbook data
section for details of approved tyres and tyre
combinations.

WARNING: If a tyre sustains a puncture,


the tyre must be replaced. Failure to
replace a punctured tyre, or operation with a
repaired tyre can lead to instability, loss of control
or an accident.
Never use an inner tube to repair a punctured tyre.
The rough surface inside the tyre can chafe the
tube leading to instability, rapid deflation, loss of
control and an accident.

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 an accident.
Do not install an inner tube inside a tubeless tyre.
This may cause instability and excessive heat
build-up may cause the tube to burst resulting in
rapid tyre deflation, loss of vehicle control and an
accident.

WARNING: Accurate wheel balance is


necessary for safe, stable handling of the
motorcycle. Do not remove or change any wheel
balance weights. Incorrect wheel balance may
cause instability leading to loss of control and an
accident.
When wheel balancing is required, such as after
tyre replacement, see your authorised Triumph
Dealer.
Only use self-adhesive weights. Clip on weights
will damage the wheel and tyre resulting in tyre
deflation, loss of control and and an accident.

WARNING: The use of tyres other than


those listed in the specification section of
the owner's handbook may adversely affect
handling leading to loss of control or an accident.
Use the recommended tyre options only in the
combinations given in the owner's handbook.
Do not mix tyres from different manufacturers or
tyres from the same manufacturer but from
another option.
For example, do not use Daytona option 2 front
tyres with Daytona option 3 rear tyres.

WARNING: When replacement tyres are


required,
consult your authorised
Triumph dealer who will arrange for the tyres to be
fitted according to the tyre manufacturers
instructions.
When tyres are replaced, allow time for the tyre to
seat itself to the rim (approximately 24 hours).
During this seating period, ride cautiously as an
incorrectly seated tyre could cause loss of control
or an accident. Initially, the new tyre will not
produce the same handling characteristics as the
worn tyre and the rider must allow adequate riding
distance (approximately 100 miles) to become
accustomed to the new handling characteristics.
After both 24 hours and 100 miles, the tyre
pressures should be checked and adjusted and
the tyre examined for correct seating and rectified
as necessary.
Use of a motorcycle when not accustomed to its
handling characteristics may lead to loss of
control and an accident.

WARNING: Always check tyre pressures


before riding when the tyres are cold.
Operation with incorrectly inflated tyres may affect
handling leading to loss of control and an
accident.

14.7

14 WHEELSITYRES
IMPORTANT TYRE INFORMATION

WARNING: Always check tyre pressures


before riding when the tyres are cold.
Operation with incorrectly inflated tyres may affect
handling leading to loss of control and an
accident.

Tiger, Thunderbird, Thunderbird Sport


and Adventurer
All Triumph motorcycles are carefully and extensively
tested in a range of riding conditions to ensure that the
most effective tyre combinations are approved for use on
each model.
It is essential that approved tyre
combinations are used when purchasing replacement
tyres as the use of non approved tyres or approved tyres
in non approved combinations may lead to motorcycle
instability. Always refer to the Owner's Handbook data
section for details of approved tyres and tyre
combinations.

WARNING: If a tyre or inner tube sustains


a puncture, the tyre and inner tube must
be replaced together.
Failure to replace a
punctured tyre and inner tube together, or
operation with a repaired tyre or inner tube can
lead to instability, loss of control or an accident.
When replacing a tyre, always inspect the rim tape
(rim protection band) to ensure that it is correctly
protecting the tube from the spoke threads. A
damaged rim tape may lead to rapid tyre deflation
causing loss of control and an accident.

WARNING: Operation with excessively


worn or damaged tyres will impair
stability and handling and control leading to loss
of control or an accident.

WARNING: Accurate wheel balance is


necessary for safe, stable handling of the
motorcycle. Do not remove or change any wheel
balance weights. Incorrect wheel balance may
cause instability leading to loss of control and an
accident.
When wheel balancing is required, such as after
tyre replacement, see your authorised Triumph
Dealer.
Only use self-adhesive weights. Clip on weights
will damage the wheel and tyre resulting in tyre
deflation, loss of control and and an accident.

WARNING: When replacement tyres are


required,
consult your authorised
Triumph dealer who will arrange for the tyres to be
fitted according to the tyre manufacturers
instructions.
When tyres are replaced, allow time for the tyre to
seat itself to the rim (approximately 24 hours).
During this seating period, ride cautiously as an
incorrectly seated tyre could cause loss of control
or an accident. Initially, the new tyre will not
produce the same handling characteristics as the
worn tyre and the rider must allow adequate riding
distance (approximately 100 miles) to become
accustomed to the new handling characteristics.
After both 24 hours and 100 miles, the tyre
pressures should be checked and adjusted and
the tyre examined for correct seating and rectified
as necessary.
Use of a motorcycle when not accustomed to its
handling characteristics may lead to loss of
control and an accident.

WARNING: The use of tyres other than


those listed in the specification section of
the owner's handbook may adversely affect
handling leading to loss of control or an accident.
Use the recommended tyre options only in the
combinations given in the owner's handbook.
Do not mix tyres from different manufacturers or
tyres from the same manufacturer but from
another option ..
For example, do not use Tiger option 2 front tyres
with Tiger option 3 rear tyres.

14.8

WHEELSITYRES 14
WHEEL REMOVAL

CAUTION: To prevent wheel and bearing


damage, ensure there is no dirt ingress to
the wheel bearings while the wheel is removed.

Front
1.

Remove the speedometer cable retaining screw.

2.

Disconnect the speedometer cable.

3.

Release the upper and lower brake caliper


mounting bolts and spacers.

4.

Remove the calipers (do not discoonect the brake


hoses).

WARNING: Do not allow the caliper to


~ hang on the brake hoses as this may
damage the hoses and could lead to an accident.

5.

Do not allow the wheel to rest on the brake disc as


this may damage the disc. Always place wooden
blocks beneath the wheel to raise the disc above
ground level.

Installation
The wheels are installed using a reversal of the
removal procedure. However, the following points
should be noted:

NOTE:

Raise the front of the motorcycle to allow removal of


the front wheel.

Ensure the speedometer drive tongues mate


with speedometer drive cutouts in the wheel.
0

2~

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.

,,

, @\

6.

Release the wheel spindle bolt (domed nut on


Tigers).

7.

Release the spindle pinch bolts from both sides (not


Tiger).

8.

Support the wheel and remove the spindle.

9.

Remove the wheel from between the forks.

10. Remove the speedometer drive assembly.

1. Speedometer Drive
2. Drive Tongues
3. Drive Cutouts

11. Remove spindle sleeve.

NOTE:
5

Ensure the bearing sleeve is clean and smooth


before refitting. Lightly smear the sleeve
surface with grease to prevent damage to the
seal (Not Tiger).

1. Speedometer Screw 4. Pinch Bolts


2. Speedometer Cable 5. Caliper Mounting Bolts
3. Spindle Bolt
4. Wheel Bearing Sleeve (Not Tiger)

14.9

14 WHEELS/TYRES
Front wheel installation cont'd

REAR WHEEL

All except Tiger

NOTE:

1.

Tighten the front wheel spindle bolt to 60 Nm.

The wheel can be removed without removal of


silencers.

2.

Tighten the front wheel spindle pinch bolts to


20Nm.

On continental models, the rear mudguard


extension must be removed.

3.

Tighten the brake caliper mounting bolts to


40 Nm (all except Thunderbird, thunderbrid
Sport & Adventurer)
28 Nm (Thunderbird, Thunderbird Sport &
Adventurer).

4.

Refit the speedometer cable.

5.

Check the operation of front brake after fitting by


pumping the brake lever several times to establish
correct operation. Confirm correct operation by a
road/roller test.

Removal
1.

Remove the chain guard or wheel guard.

2.

Raise the rear of the motorcycle to allow removal of


the rear wheel.

WARNING: Ensure that the motorcycle is


stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.

Tiger
1.

Tighten the front wheel spindle dome nuts to 85 Nm

2.

Tighten the brake caliper mounting bolts to 40 Nm.

3.

Refit the speedometer cable.

4.

Check the operation of front brake after fitting by


pumping the brake lever several times to establish
correct operation. Confirm correct operation by a
road/roller test.

3.

Remove the rear wheel bolt retaining rings from


both sides (eccentric adjuster type swinging arms
only).
-

4.

Remove the wheel bolt/nut and spindle.

1. Retaining Rings
2. Spindle Bolt
5.

Lower the wheel and lift the chain from the rear
sprocket.

6.

Inspect the sprocket for worn or damaged teeth.

7.

Remove the spacer from the left hand side sprocket


carrier.

8.

Lift/lower the brake caliper carrier (lower models


fitted with an underslung rear caliper) and remove
the right hand spacer.

14.10

WHEELSITYRES 14
NOTE:

WHEEL BEARINGS

Make a note of the orientation of the spacers to


ensure correct fitment on assembly.

WARNING: Operation with worn or


damaged steering head or wheel
bearings may cause impaired handling and
instability leading to an accident. If in doubt, have
the motorcycle inspected by an authorised
Triumph dealer before riding.

Removal
1.

Remove the wheel as described earlier.

2.

Lay the wheel on its side while supporting the wheel


on wooden blocks to prevent damage to the brake
disc.

1. Left Hand Side Spacer


2. Right Hand Side Spacer
2.

A.

Lift/lower the brake caliper carrier (lower models


fitted with an underslung rear caliper) and remove
the wheel.

CAUTION: Do not allow the wheel to rest

~ on the brake 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 oil seals and bearing circlip. Collect the


speedometer drive ring.

4.

Using a suitable drift, through the centre of the


wheel, drift out each bearing. Collect the centre
sleeve.

{L

~
1. Caliper Carrier

Installation
1.

To refit the wheel, reverse the removal procedure,


taking note of the following:
a.
b.

c.

the wheel spindle should be cleaned and


lightly oiled.
the drive chain and wheel alignment should
be adjusted with reference to relevant
section.
tighten the wheel spindle bolt/nut to 85 Nm
and fit new retaining rings (where originally
fitted).

WARNING: To prevent injury. always


wear eye, hand and face protection when
using a drift.

WARNING: Ensure the caliper carrier


sleeve is correctly fitted. If the sleeve is
fitted incorrectly, the rear brake could lock up
when in use, causing loss of control and an
accident.
h>. '

14.11

14 WHEELS/TYRES
Installation

NOTE:

1.

Install bearings with the marked or shielded sides


face out.

Refer to the chart below for the correct tool and tool
face to use when inserting bearings.
Bearings are installed by means of a draw bolt
acting on the insertion tool. A support tool is located
on the opposite side of the hub to the insertion tool
and as the draw bolt is tightened, the bearing is
drawn into the hub.
Insert bearings with the marked or shielded side
facing outwards and always fit a new bearing circlip.

WARNING: When using bearing service


tools always ensure that the selected tool
matches the diameter of the bearing being
installed. Damage to the wheel and bearing will
result from incorrect tool selection which may
cause loss of control and an accident.
Ensure that the bearing remains square to the hub
during the drawing in procedure. Damage to the
bearing and hub will result from forcing a bearing
which is not square to the hub which could cause
loss of control and an accident. .
Always install bearings with the marked or
shielded sides facing outwards.

1. Tool 3880075 in position

Bearing Tool Selection Chart


FRONT
Bearing
Insertion Tool

Support Tool

Left Bearing

3880070
Small face to
bearing

3880075
Large face to
hub

Right Bearing

3880070
Small face to
bearing

3880075
Large face to
hub

REAR
Bearing
Insertion Tool

Support Tool

Left Bearing

3880070
Small face to
bearing

3880075
Small face to
hub

Right Bearing

3880070
Large face to
bearing

3880075
Small face to
hub

Cush Drive

3880075
Small face to
bearing

N/A

14.12

2.

Refit the speedometer drive ring with the drive tags


facing outwards.

3.

Lubricate and fit new seals to the wheel hubs.

4.

Refit the wheel as described earlier.

Frame/Fairings
CONTENTS
Page
Exploded view....................................................

15.2

Seat
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daytona/Speed Triple Seat Hump


Removal/Refit to Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hump not in Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side panels
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thunderbird, Thunderbird Sport & Adventurer side panel removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.9
15.9
15.1 0
15.10
15.11
15.12
15.12

Cockpit fairing- not 'new' Trophy


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.13
15.14

Cockpit fairing - 'new' Trophy


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.14
15.14

Lower Fairings - not 'new' Trophy


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.15
15.15

Lower Fairings- 'new' Trophy


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.16
15.17

Cam cover cowl


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.17
15.17

Frame
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bank Angle Peg Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.18
15.18

15.1

15 FRAME/FAIRINGS
Body Panels - Trident, Daytona/Trophy

10 Nm

15.2

_ _ _ _ _ _ FRAME/FAIRINGS 15
Footrests and Body, Tiger

Push Fit

Push Fit

27;;: '
~~
~
~~ ~~27Nm
42Nrl

27N~

'-

95

~~

27 Nm

7 Nm

J ~

15.3

7Nm

15 FRAME/FAIRINGS
Thunderbird T
~~~enturer
_: srd~s~:rbird
Sport &and
y
nd, Footrest

Hand Tight
7 Nm
12\

~'';

7Nm

_,'1~~~

6J%~

25Nm

12 Nm

-i,.:::-

7Nm

f! ~~

15.4

'"'

Hand Tight

?Nm

5 Nm

---~

20Nm

FRAME/FAIRINGS 15
Thunderbird & Thunderbird Sport Frame

~
I

@
I

~
I

15.5

15 FRAME/FAIRINGS
Adventurer Frame

95 Nm

u?f~

28 Nm

15.6

FRAME/FAIRINGS 15
Frame and Fittings -All models except Tiger, Thunderbird, Thunderbird Sport &
Adventurer

27Nm

95Nm

9Nm

42Nm

27 Nm

27 Nm

15.7

IS FRAME/FAIRINGS
Bodywork - 1996 Trophy

10 Nm

r27Nm

fi:>
:

3Nm

r
,J

9N~~
I

/ ~~"1>

I
I
I

-.I

I
3 Nm

___.
5 Nm
7 Nm

.-~

10 Nm

' .~
3Nm

10Nm9

3 Nm

'

3 Nm 3 Nm

..1

3 Nm

3Nm~

,.

3 Nm

15.8

5Nm

FRAME/FAIRINGS IS

SEAT

Removal -All except Adventurer with


Dual Seat

NOTE:

Throughout the model range, there are differing


locations for the seat lock.
Refer to the
diagrams below for an explanation of the
various seat lock locations.
~

1';<r,~
I

f \

\~

1.

Insert the ignition switch key into the seat lock.

2.

Turn the key while pressing down on the rear of the


seat.

3.

Lift the rear of the seat and remove from the frame.

NOTE:

If the seat does not release readily from the lock,


gently tap the rear of the seat with the palm of
the hand.

Removal - Adventurer with Dual Seat


1.

1.

Pull the ring situated to the left side of the seat to


release the rear of the seat. The rear of the seat will
spring upwards slightly.

2.

Insert the ignition key into the seat lock, situated in


the left hand side panel, and turn to the left while
pressing down on the centre part of the seat.

3.

To fully detach, lift the rear of the seat and slide


rearwards.

Seat Lock - all except Trophy 1996, Tiger,


Thunderbird, Thunderbird Sport & Adventurer

NOTE:

1.

1.

Tiger Seat Lock

If the seat does not release readily from the lock,


gently tap the rear of the seat with the palm of
the hand.

Installation - All variants

Thunderbird, Thunderbird Sport &


Adventurer Seat Lock

1.

To refit the seat, remove the key from the seat lock
and return it to the ignition switch.

2.

Locate the front section to the back of the fuel tank


and press down on the rear (and centre on
Adventurer with dual seat) of the seat to engage in
the seat lock.

3.

Grasp the seat and check that it is securely retained


by the lock(s).

NOTE:

When the seat is correctly engaged in the lock,


an audible click will be heard.

WARNING: Failure to correctly secure


the seat in the seat lock will result in an
unsafe riding condition which may cause
instability, loss of control and an accident.

1. 1996 Trophy Seat Lock

15.9

15 FRAME/FAIRINGS

SEAT HUMP (WHERE FITTED)

Hump Not in Use

Removal from the Seat

1.

Remove the hump from the seat as described over.

1.

Unlock and remove the seat.

2.

Position the seat end trim to the end cap as shown


below.

2.

Release the two fixings from either side of the seat


and slide the hump rearwards and upwards.

Refit
1.

Align the hump to the seat in the direction of the


lower arrow. Engage the rear edge of the hump
beneath the rear edge of the seat.

2.

Rotate the hump forward without disengaging the


rear edge, until the holes in the side of the seat align
with the corresponding holes in the hump. Fit and
tighten the bolts.
End Trim

3.

Retain the end trim by fitting the grab rail. Tighten


the grab rail bolts to 27 Nm.

1. Locate Lower Edge


2. Rotate Forward
3. Retain With Allen Bolts

NOTE:

The lumbar support can be removed from the


seat hump by detaching the screws from inside
the hump.

1. Grab Rail
2. End Trim
3. Grab Rail Bolt

NOTE:

4.

Seat Hump Lumbar Pad Fixings

15.10

Where twin grab rails are fitted, the front bolts


should be tightened to 27 Nm and the rear bolts
to 10 Nm.
Refit the seat.

FRAME/FAIRINGS 15

4.

SIDE PANELS

Removal
All models except Thunderbird,
Thunderbird Sport & Adventurer
NOTE:

On all except Tiger and early Daytona models,


the side panels are removed as an assembled
set. On early Daytona models, the seat end cap
must first be removed and the side panels are
then removed separately. Tiger side panels can
be removed independently of each other.

1.

Remove the seat and release the grab rail(s) (seat


only on Tiger).

The side panels are retained by a series of bayonets


which locate in grommets on the frame. To detach
the panels, gently pull the panel in an outward
direction until the bayonets detach from the
grommets.
Once all bayonets have become
detached, the panels can be removed from the
frame.

1. Bayonets
5.

To separate the panels, release the screws


securing the end cap to the side panels and remove
the end cap.

1. Grab Rail
2. Grab Rail Bolt
2.

Release the screws and plastic washers securing


the side panels to the rear frame.
NOTE: On Tiger models the side panels can
now be removed.

3.

Early Daytona only: Release the screws and


plastic washers securing the seat end cap and lift
the cap from its locating bayonets.
1. Self Tapping screw
2. Washer
3. Torx Screw
4. Washer
(Trident panels illustrated)

NOTE:

1. Side Panel Screws


2. End Cap Screws
15.11

Later Sprint and Trophy side panels have a


different end cap to side panel fixing
arrangement though the side panels must still
be removed as an assembled pair.

15 FRAME/FAIRINGS

Installation

Side Cover Removal -Thunderbird,


Thunderbird Sport & Adventurer

All models except Thunderbird,


Thunderbird Sport & Adventurer
1.

Position the side panels adjacent to the frame.

2.

Carefully push the bayonets into their grommets


using hand pressure only (Tiger refit using the
screws and washers removed in paragraph 2 of
removal).
1

1.

Remove the seat as described earlier.

2.

Remove the screw securing each side panel to the


frame and collect the flanged sleeve.

3.

To detach the side panel, lift the panel (in the


direction of the arrow) until it is clear of the two
locating pegs on the frame.

1. Tiger Side Panel Fixings

3.

Early Daytona only: Repeat for the second side if


removed.

4.

Early Daytona only: Refit the seat end cap.

5.

Position the grab rail and fit the bolts (not Tiger).

6.

Fit the screws and washers securing the side panel


assembly to rear frame.

7.
8.

Assembly
1.

Check that the grommets are in place on the side


cover and fit the cover to the locating pegs on the
frame.

Ensure that the complete assembly is correctly


seated.

2.

Locate the flanged sleeve to the cover

Tighten the grab rail bolts to 27 Nm.

3.

Fit and tighten the side cover screw to 3 Nm.

NOTE:

9.

1. Screw
2. Flanged Sleeve

Where twin grab rails are fitted, the front bolts


should be tightened to 27 Nm and the rear bolts
to 10 Nm.
Tighten the side panel to rear frame screws to
3 Nm.

Airbox Covers -Thunderbird,


Thunderbird Sport & Adventurer
Removal
1.

Release the screws securing the cover and badge


to the airbox

2.

Remove the cover.

10. Refit the seat.

NOTE:

The badge has an adhesive back and will remain


attached to the airbox cover.

Refit
1.

Align the cover to the airbox.

2.

Fit and tighten the airbox cover screws to 3 Nm.

15.12

FRAME/FAIRINGS 15
COCKPIT FAIRING (NOT 'NEW' TROPHY)

4.

Removal

Remove the locknuts securing the mirrors to the


cockpit (not Tiger). Remove the mirrors together
with the mounting bolts.

1. Remove the seat and disconnect the battery,

negative (black) lead first. Release the screws


securing the left-hand and right-hand facia panels.
Raise the right hand panel and disconnect the clock
(if fitted). Remove the facia panels.

/?> v'
~

1. Cockpit To Side Fairing Fasteners


5.

Remove the windscreen.

6.

Ease the cockpit fairing forward (not Tiger) to give


temporary access to the wiring harness.

7.

Disconnect the two connections from the right and


left-hand direction indicators, together with the
headlight connection.

8.

Release the grommets, nuts, washers and spring


washers securing the direction indicators to the
upper sub-frame.

9.

Remove the direction indicators.

1. Right Hand Facia Panel (early Trophy Illustrated)

NOTE:

Additional covers, which must also be


removed, are fitted to later Daytona and
Daytona Super 3 models.
2. Release the bolts securing the lower side fairing (if
fitted) to the cockpit fairing.
Tiger models only, remove the bolts securing the
cockpit and side fairings to the fuel tank. Remove
the cockpit and side fairings.

10. Release any remaining bolts securing the cockpit to


the subframe. Remove the cockpit.

Tiger Bodywork
1. Lower Fairing To Tank Fixings
2. Cockpit Fixings
3. Windscreen To Cockpit Screw
3.

Sprint Cockpit
1. Cockpit Fixings
2. Indicators

Support the cockpit fairing.

15.13

15 FRAME/FAIRINGS

1\

CAUTION:
Always store the cockpit
fairing in a safe place where damage to
the painted surfaces is unlikely. Do not allow the
rear part of the Sprint cockpit to drag across the
fuel tank during removal.

Installation
Installation is a reversal of the removal procedure.
However, the following points should be noted.

NOTE:

When assembled, test the indicators for correct


operation.

Reconnect the battery positive (red) lead first.

COCKPIT FAIRING - 'NEW' TROPHY


Removal

Arrowed - Headlamp Adjuster Cable

1.

Remove the seat and disconnect the battery,


negative (black) lead first.

2.

Release the screws securing the upper facia panels


to the inside of the cockpit.

7.

Release the screws securing the cockpit to the


lower fairings.

1. Upper Facia to Cockpit Screw


3.

Remove both mirrors.

4.

Remove the chin panel from the underside of the


cockpit.

5.

---------

1. Cockpit to Lower Fairing Screws


8.

Remove the screws securing the base of the


headlamp assembly to the cockpit subframe.

Ease the cockpit away from the cockpit subframe


and separate the headlamp wiring connectors. The
cockpit can then be detached from the motorcycle

Assembly
Installation is a reversal of the removal procedure.
However, the following points should be noted.

NOTE:

Reconnect the battery positive (red) lead first.

Reconnect the headlamps during assembly of


the cockpit to the cockpit subframe.

Test
all
electrical
reconnection.

Refit and test the headlamp adjuster cable.

1. Headlamp to subframe screws

15.14

circuits

following

FRAME/FAIRINGS 15

LOWER FAIRINGS- (NOT 'NEW' TROPHY)


Removal

5.

Release and remove the 3 screws securing the left


and right-hand fairings together.

6.

Early Models Only: Release and remove the self


tapping screws securing the left and right
hand radiator ducts to each other.

NOTE:

On Sprint models, the cockpit and fairing is a


one piece assembly.
On early Trophy models, the two sections of the
radiator ducts are secured together with
screws. These screws are also used to retain
the oil cooler grille (where fitted) to the oil
cooler.

1.

Release and remove the screws securing the


facia panels (where fitted) to the lower fairing.

6.
7.
8.
9.
7.

Oil Cooler To Radiator Duct Fasteners


Right Hand To Left Hand Fairing Fasteners
Self Tapping Screws
Radiator Ducts
Release the screws securing the lower fairing to the
cockpit. The fairing can now be carefully removed.

/':\.

CAUTION: Always store the displaced


fairing in a safe place where damage to
the painted surfaces is unlikely.

1. Facia
2. Facia Screws
3. Lower Fairing To Cockpit Fasteners

Installation

2.

Release the bolts securing the fairing bracket,


visible through the aperture in the fairing side, to the
cylinder head.

3.

Release and remove the screws securing the


fairing to the lower sub-frame.

4. Fairing Bracket
5. Fairing To Lower Subframe Fasteners
4.

Early Models only: Release the screws and


washers securing the radiator ducts to the oil cooler.

15.15

Installation is the reverse of the removal procedure.

15 FRAME/FAIRINGS

5.

LOWER FAIRINGS - 'NEW' TROPHY

Release the screw securing the upper facia panel to


the inside of the cockpit.

NOTE:

The lower fairing is removed as an assembly


complete with infill panels and facia.

1.

Remove the seat and disconnect the battery,


negative (black) lead first.

2.

Release the screws securing the fairing belly panel


to the fairings.
(

babi

()

1. Upper Facia to Cockpit Screw


6.

Release the screws securing the fairing to the frame


and engine.

-----------

1. Belly Panel
3.

Open the facia storage container and release the


screw securing the storage box to the fairing
bracket.

NOTE:

If removing the right hand fairing, also


disconnect the headlamp adjuster cable.
~

J
5052
1. Storage box to bracket screw
1. Fairing to Frame/Engine Screws
Arrowed - Headlamp Adjuster Cable
4.

Release the screws securing the cockpit to the


lower fairing.

NOTE:

15.16

On 3 cylinder models, an additional screw


secures the lower infill panel to the head
bracket.

FRAME/FAIRINGS 15

2.

With the fuel tank removed, detach the fuel tank


mounting bushes from the ends of the frame
outriggers.

1. 3 Cylinder lnfill Panel to Head Screw


7.

Ease the fairing away from the engine and


disconnect the indicator. On right hand fairings,
also disconnect the fuse box at its connection to the
main harness.

1. Fuel Tank Mounting Bushes


2. Cam Cover Cowls
3. Foam Seal

NOTE:

3.

Remove the spark plug leads from the plugs and


also detach the leads from the foam seal in the cam
cowls.

4.

Release the fixings from the cowls and detach from


the frame.

Once all electrical disconnections have been


made, the fairing may be completely removed.

Installation
Installation is a reversal of the removal procedure.
However, the following points should be noted.

Installation

NOTE:

When assembled, test the indicators and other


electrical circuits for correct operation.

Reconnect the battery positive (red) lead first.

Check for correct operation of the headlamp


adjuster.

1.

Position the foam seal over the choke cable and


locate the spark plug leads in the seal slots. Fit the
leads to the spark plugs.

2.

Check the operation of the choke and, at the same


time, ensure that the clutch hose does not foul the
choke operating bar on the carburettors.

CAM COVER COWL


/)...

CAUTION:
Ensure that the radiator
overflow pipe does not become trapped
during replacement of the cowls.

Removal
1.

To gain access to the cam cover cowls the following


items must be removed:
Cockpit fairing
Lower fairing (where fitted)
Fuel tank
In all cases, refer to the relevant section for
instructions on the safe removal and refitting
procedures for these items.

3.

Refit the cowls to the frame and secure using the


original fixings.

4.

Fit the cowls ensuring the correct fitment of the foam


seals in the cowl cut-outs.

5.

Refit the fuel tank mounting bushes.

15.17

IS FRAME/FAIRINGS

FRAME, FOOTRESTS AND FIXINGS

Inspection
1.

Inspect the frame, footrests and fairings for


damage, cracks, chafing and other dangerous
conditions.
Check fairing and frame fixings for security.

2.

Inspect the bank angle pegs for wear. If more than


50% of the radiused end is worn away, the bank
angle peg must be replaced.

Bank Angle Peg Wear Limit


(Trophy type illustrated)

WARNING: Use of a motorcycle with


bank angle pegs worn beyond the
maximum limit will allow the motorcycle to be
banked to an unsafe angle.
Banking to an unsafe angle may cause instability,
loss of control and an accident causing injury or
death.
WARNING: If the motorcycle is involved
in an accident or collision it must be taken
to an authorised Triumph dealer for repair or
inspection. Any accident can cause damage to the
motorcycle which, if not correctly repaired, may
cause another accident which may result in injury
or death.

WARNING:
The frame must not be
modified as any modification to the frame
such as welding or drilling may weaken the frame
resulting in an accident.

15.18

Electrical System/Ignition
CONTENTS
Page
Battery
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery electrolyte level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.7
16.8
16.9

Instruments
Instrument packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel gauge sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.9
16.9

Alternator
Removal/1 nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.11

Ignition system
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition pickup sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.12
16.14
16.14
16.14

Starter motor
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation/component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.27
16.28
16.29

Starter solenoid
Removal/1 nstallation

16.31

Cooling system
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.32
16.34

Fuse box
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.35

Lights
Tail Light Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight adjustment/bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.37
16.38

Wiring diagrams
Trophy, Trident and Daytona to VIN 4902 . . . . . . . . . . . . . . . . . . . . . . . . .
Trophy from VIN 4902 to VIN 29155Trident,
Sprint, Speed Triple and Daytona from VIN 4902 onwards . . . . . . . . . .
Trophy from VIN 29156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tiger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thunderbird , Thunderbird Sport & Adventurer . . . . . . . . . . . . . . . . . . . .

16.1

16.45
16.47
16.49
16.51
16.53

16 ELECTRICAL SYSTEM/IGNITION

I
~--18Nm

16.2

ELECTRICAL SYSTEM/IGNITION 16

~~@__~

Hand tight

/
{it__

ii(

Hand tight

Hand tight -

18 Nm

f\~

Hand tight

<_\
~f(-~ ':>

18Nm

~~

~ ~ /li>i!IJ

~\ Hand tight

Handtig\

~~

Hand tight

/iJP~J/)1

'~
~~~~ 0::\
4
.

~/ /

16.3

'>
Hand tight

16 ELECTRICAL SYSTEM/IGNITION

Hand tight

--=::'

16.4

'--.._ 12 Nm

ELECTRICAL SYSTEM/IGNITION 16

9 Nm

----J
e

16.5

16 ELECTR /CAL SYSTEM/IGNITION - - - - - - - -

7Nm

e.,@~

~~
I
I
I
I

16.6

ELECTRICAL SYSTEM/IGNITION 16

BATTERY

Battery Charging
New (Dry) Battery

WARNING: The battery gives off


explosive gases; keep sparks, flames
and cigarettes away. Provide adequate ventilation
when charging or using the battery in an enclosed
space.

To ensure that a new battery is correctly commissioned


and will deliver maximum capacity for starting, the
following procedure must be followed.
1.

Remove the sealing tape and vent cap.

The battery contains sulphuric acid (electrolyte).


Contact with skin or eyes may cause severe burns.
Wear protective clothing and a face shield.

2.

Remove the filler plugs and fill the battery with


electrolyte to the upper level. The electrolyte
must be specific gravity 1.28.

3.

Allow the battery to stand for 30 minutes and then


adjust the electrolyte level back to the upper level
mark.

4.

Charge the battery continuously at 1.4 A


maximum for 15-20 hours

5.

After charging, top up the battery using distilled


water only.

6.

Replace the filler plugs and vent cap, and


thoroughly clean the battery.

If electrolyte gets on your skin, flush with


water immediately.
If electrolyte gets in your eyes, flush with
water for at least 15 minutes and SEEK MEDICAL
ATTENTION IMMEDIATELY.
If electrolyte is swallowed, drink large
quantities of water and SEEK MEDICAL
ATTENTION IMMEDIATELY.
KEEP ELECTROLYTE OUT OF THE REACH OF
CHILDREN.

WARNING: The battery contains harmful


materials. Always keep children away
from the battery whether or not it is fitted in the
motorcycle.
Do not jump start the battery, touch the battery
cables together or reverse the polarity of the
cables as any of these actions may cause a spark
which would ignite battery gasses causing a risk of
personal injury.

Battery Already in Service


When re-charging a battery in service, the following
precautions must be taken to avoid damage to the
battery.
1. The charging rate must not exceed 10% of the
battery capacity. The standard Triumph battery
capacity is a 14 Amp. hour unit and therefore the
charging rate must not exceed 1.4 A.

WARNING: The battery electrolyte is


corrosive and poisonous. Never swallow
battery electrolyte or allow to come into contact
with the skin. Always wear eye and skin protection
when adjusting the electrolyte level

CAUTION: When checking the battery


electrolyte level, or adding distilled water,
ensure that the breather is not blocked. A blocked
breather may cause a build-up of gas in the battery
which would damage the battery case.

2.

Before the battery reaches the gassing stage, this


rate may be briefly exceeded but the temperature
of the electrolyte must not be allowed to rise
above 55C.

3.

After charging, allow the battery to cool and then


top up the electrolyte level with distilled water.

4.

Never allow the battery to stand in a discharged


state or with the electrolyte level below the
minimum level.

/,'.
CAUTION: Using a battery charger set to
~ a charge rate greater than 10% of the
battery capacity will cause permanent damage to
the battery. Therefore, the maximum rate of charge
is 1.4 Amps.

To prevent battery damage, use only distilled water


in the battery. Tap water will shorten the service life
of the battery.
Filling the battery above the UPPER LEVEL line
may cause the electrolyte to overflow, resulting in
corrosion to engine or nearby parts. Immediately
wash off any spilled electrolyte.

16.7

16 ELECTRICAL SYSTEM/IGNITION

Removal - all models except Thunderbird,


Thunderbird Sport & Adventurer

3.

Release the battery retaining strap.

4.

Disconnect the flasher unit and the fuse box


connection to the main harness.

1.

Remove the seat and document tray (if fitted).

2.

Disconnect the battery negative (black) lead first,


then the positive (red) lead.

5.

Gently ease the harness away from the battery


box.

3.

Remove the battery strap.

6.

4.

Take the battery, complete with breather tube, out of


the case.

Release the screw securing the door to the


battery box. Release and un-clip the battery box
door.

7.

Disconnect the battery breather tube.

5.

Wipe the battery using a clean, dry cloth. Ensure


that the battery lead connections are free from
oxidation deposits.

NOTE:
8.

The breather tube may fall to the floor when


disconnected
Remove the battery by sliding sideways out of the
battery box.

Battery Electrolyte Level Check


1.

Remove the battery from the motorcycle, see


Battery Removal.

2.

Check that the electrolyte level in each cell is


between the upper and lower level lines.

3.

If the electrolyte level is low in any cell, top-up the


cell with distilled water.

1. Battery
2. Negative(-) terminal
3. Positive(+) terminal
3

Removal, Thunderbird, Thunderbird Sport


& Adventurer
1.

Remove the seat and right hand side panel.

2.

Disconnect the battery leads, negative (-) black


lead first then the positive(+) red lead.

1. Upper Level
2. Lower Level
3. Breather Tube Connection
4.

On refitting, ensure that the battery breather pipe is


routed down the inside of the centre stand spring
(where a stand is fitted) or is routed between the
frame and swinging arm when no centre stand is
fitted.

The battery electrolyte level must be kept between the


upper and lower level lines. Check the electrolyte level in
each cell in accordance with periodic maintenance chart.

1. Flasher Unit Connection.


2. Battery Box Door Retaining Screw
3. Fuse Box Connection

16.8

ELECTRICAL SYSTEM/IGNITION 16

INSTRUMENTS

WARNING: Filling the battery above the


. . . UPPER LEVEL line may cause the
electrolyte to overflow.
Electrolyte is highly
corrosive and will damage clothing and cause
burns if in contact with the skin

All models are fitted with an instrument pack containing


an electronic tachometer and a mechanical
speedometer. In some cases, a coolant temperature
gauge is also fitted.

Never route the battery breather pipe in any way


which could cause the pipe to become blocked or
trapped. A blocked or damaged pipe will cause a
build up of pressurised, explosive gas which may
ignite.

In addition, the 1996 Trophy is fitted with a fuel gauge


All main part of the instrument packs may be serviced.

FUEL GAUGE LEVEL SENSOR


1996 TROPHY

When adding electrolyte, always wear eye and


skin protection.

A rheostat type sensor is located in the base of the fuel


tank of the 1996 Trophy model.

Installation - all models except


Thunderbird, Thunderbird Sport &
Adventurer

The sensor operates via a buoyant arm which floats on


the fuel within the tank.

1.

Removal

2.

Check that the battery case rubber pad is


correctly located in the bottom of the battery case.
Place the battery in the battery case and connect
the battery breather pipe.

1.

Remove the fuel tank as described in the fuel


system section.

3.

Fit the battery strap.

4.

Reconnect the battery positive (red) lead first then


the negative (black) lead.

5.

Lightly smear a coating of petroleum jelly on


terminals to prevent corrosion.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury and damage to
property, could result from spilled fuel or fuel not
handled and stored in the correct manner.

6.

Cover the terminals with the protective caps.

2.

Remove the screws securing the sensor to the


base of the tank.

7.

Refit the seat and document container (if fitted).

3.

Remove the sensor unit from the tank.

Installation, Thunderbird, Thunderbird


Sport & Adventurer
1.

Clean the battery box.

2.

Place the battery in the battery box, and connect


the battery breather tube.

3.

Re-fit the battery retaining strap.

4.

Re-fit the door to the battery box and tighten the


door retaining screw.

5.

Re-connect the flasher unit and fuse box to the


main harness.

6.

Reconnect the battery positive(+) red lead first


then the negative H black lead.

7.

Apply a light coat of petroleum jelly to the battery


terminals to prevent corrosion.

8.

Cover the terminals with the protective caps.

9.

Refit the right hand side panel and the seat.

Fuel Gauge Sensor Unit

A_
L_U

CAUTION: The sensor unit is fitted with


an arm to which a float is attached.
During removal of the unit from the fuel tank, do
not use excessive force as this will damage the
arm.

16.9

16 ELECTRICAL SYSTEM/IGNITION

NOTE:

2.

Locate the sensor unit into the tank and tighten


the sensor fixings to 10 Nm.

3.

Refit the fuel tank as described in the fuel system


section.

To prevent damage to the float arm, it will be


necessary to turn the sensor as it is withdrawn
from the tank.

Inspection
Check for broken/damaged connections, a punctured
float and damaged rheostat windings. Replace the
sensor if suspect.

Assembly
1.

Fit a new gasket to the base of the fuel tank.

Fuel Gauge Sensor Circuit


The wiring circuit for the fuel gauge sensor unit is
shown below/right.
FUSE 9

For details of other circuits on the 1996 Trophy,


refer to the circuit diagrams later in this section.

N
.------ NR

cEJ N~
-eEl-I
NR

.---1
4

..__________,

w
N
0

L.-

L.-

FUEL GAUGE

~1------GY
L---------GB

GB

FUEL LEVEL
SENSOR

16.10

I
LL
LL

IGNITION
SWITCH

ELECTRICAL SYSTEM/IGNITION 16

ALTERNATOR

Installation

Removal

1.

Fit the alternator cush drive rubbers to the alternator


drive.

2.

Clean the alternator lugs and crankcase where the


alternator is grounded.

3.

Fit a new '0' ring to the alternator housing.

WARNING: To prevent personal injury


and damage to components, disconnect
the battery, negative (black) lead first, then the
positive (red) lead.

NOTE:
1.

Unplug the alternator connection to the main


harness.

2.

Detach the rubber boot from the earth lead and


remove the securing bolt.

Apply a small amount of engine oil to rubber


dampers and the '0' ring on the alternator
housing.

1. '0' Ring
1. Earth Connection

NOTE:

3.

On Thunderbird, Thunderbird Sport &


Adventurer, remove the horn and bracket from
the engine.
Release the remaining bolts securing the alternator
to the crankcase.

4.

Remove the alternator.

5.

Remove the four rubbers from the alternator cush


drive housing.

4.

Reconnect the alternator to the main harness.

5.

Fit the alternator and secure with two bolts.

6.

Attach and secure the earth strap. Refit the rubber


boot.

7.

Tighten all alternator mounting bolts to 20 Nm.

NOTE:
On Thunderbird, Thunderbird Sport &
Adventurer, refit the horn and bracket to the
engine.

WARNING: To prevent personal injury


and damage to components, connect the
battery, positive (red) lead first, then the negative
(black) lead.

1. Cush Drive Rubbers

16.11

16 ELECTRICAL SYSTEM/IGNITION

IGNITION SYSTEM

The peg passing the sensor causes a signal of low


voltage electricity to be sent to the igniter. This signal is
the reference point which causes the primary voltage to
be switched off and on by the igniter (the dwell period).
This switching, the timing of which is variable with engine
speed (advance), induces a high voltage in the
secondary circuit of the coils which is delivered to the
spark plugs via the plug leads.

Description
The ignition system fitted to all Triumph motorcycles is a
digital electronic type and must not be confused with the
capacitor discharge system (CDI) which is common to
other machines.
The Triumph system has three
transistor output stages which are controlled by advance
curves which vary from engine type to engine type.
Within the overall system there are four major
components as follows.
Ignition Coils
Igniter unit
Signal Generator or Pick-Up Sensor
Igniter Sub-Harness

WARNING:
The ignition system
produces extremely high voltages. Do
not touch any part of the ignition system or any
cables while the engine is running.
An electric shock caused by contact with the
ignition system may lead to illness, injury or death.

There are two separate sections to the ignition system,


the low voltage primary circuit which contains the logic
controls and crankshaft sensor, and the secondary
circuit which which provides the higher voltage supply to
the spark plugs

WARNING:
Wearers of surgically
implanted heart pacemaker devices
should not be in close proximity to ignition circuits
and or diagnostic equipment.
The ignition system and any diagnostic equipment
may interrupt the normal operation of such
devices causing illness or death.

Ignition Coils
Coils with low resistance primary windings are fitted to
allow a more rapid coil action than found in conventional
coils. This rapid action allows the coil to function
correctly at both low and high engine speeds.
Igniter
The igniter evaluates information from the crankshaft
sensor which is received in the form of electronic pulses.
From the received pulses, the igniter calculates the
output required from the coils. The basis for the
calculations come from pre-programmed ignition
parameters within the igniter unit. The calculations made
include;
dwell angle
ignition timing (which is variable with engine speed)
the firing order of the cylinders
Because the igniter uses electronic components to carry
out these functions, it is able to operate without electronic
arcing and, therefore, has a much longer service life than
conventional switching systems.

Ignition Circuit
On the following page, a schematic diagram of the
ignition circuit can be found.

Signal Generator (Pick-up Sensor)


As there is no distributor in the Triumph ignition system, a
sensor is mounted to the crankcase which interprets
signals from a disc which turns with the crankshaft.
The function of the disc and sensor is to register the
position of each piston in relation to top dead centre, and
also to record engine speed. This data is transmitted to
the igniter unit for evaluation. The sensor and disc
operate in the following way.
A peg on the disc passes the sensor at the precise
moment (of engine rotation) at which the spark is to
occur.

16.12

The circuit depicted is for 1996 Trophy though other


models are similar in layout.

NOTE:

On models other than 1996 Trophy, fuse


numbers and wiring colours may differ from
those shown in the diagram opposite. For full
details of other models, refer to the full wiring
circuit diagrams at the end of this section.

ELECTRICAL SYSTEM/IGNITION 16
Ignition circuit (Trophy 1996 model illustrated)
Code

Colour

Black

Blue

Brown

Green

Grey

Orange

Pink

LG

Light
Green

NR

Red

Purple

White

Yellow

FUSE 9

----L8------L8---

N
NR

FUSE 7

~w--@:J-w

L_

W
N

1JJ
~

IGNITION
SWITCH

GY--0=J- GY
FUSES

G------!:&--

TACHOMETER

'---+-- 0 K

or-----,_---w

,r

:+-?J
,.-IGNITER

GN--~.---G N

s
1-----t--- s N
r - - - t - - - su

IGNITION
COILS

FLOAT CHAMBER
VENT SOLENOIDS
(US California ONLY)

GN---.

IGNITER
PICK-UP

o=

R
B

----!

ALARM
SOUNDER

5
'-_

r rial--- SU
SU ---141
ALARM
L~ BR-T--4r~-----11r~ BR ~CONTROL UNIT
al

a:

a:

al

al

d-1
m
(!)UlZ

SIDESTAND
SWITCH

16.13

SIDESTAND
RELAY

16 ELECTRICAL SYSTEM/IGNITION

PICK-UP SENSOR

IGNITION COILS

Removal

Removal

1.

Remove the seat and disconnect the battery


negative (black) lead first.

2.

Remove the fuel tank as described in the fuel


system section. Remove the cam cover cowls.

Remove the seat and disconnect the battery


negative (black) lead first, then the positive (red)
lead.

WARNING: To prevent personal injury


and damage to components, disconnect
the battery, negative (black) lead first, then the
positive (red) lead.

2.

Remove the lower fairing (if fitted).

3.

Remove the right-hand crankshaft cover.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury, could result from
spilled fuel or fuel not handled and stored in the
correct manner.

Installation

NOTE:

1.

Install the ignition pickup sensor using a reversal of


the removal procedure. The following points must
be noted

Make a note of the spark plug lead positions in


the head before disconnection. This will help in
matching the ignition coils with the correct plug
lead when refitting.

Install the ignition pickup and adjust to give a


clearance (air gap) between the timing rotor
projection and ignition pickup of 0.6 - 0.8mm.

3.

Disconnect the high and low tension leads and


remove the ignition coils from the frame.

Installation
1.

Install the ignition coils ensuring the high tension


connections are made as noted during removal.

IGNITION SYSTEM DIAGNOSIS


An ignition diagnosis kit is available to trace ignition
primary faults. It is recommended that ignition diagnosis
be carried out by an authorised Triumph dealer who will
have the necessary training to accurately diagnose faults
and carry out the work.

1. Timing Rotor
2. Ignition Pick-Up Sensor
3. Air Gap (0.6-0.8 mm)

2.

Examine the grommet recess in the crankcase for


casting flash and sharp edges. Clean out the
recess with a file if necessary.
Apply silicone sealant to the ignition sensor
grommet and refit to the crankcase.

3.

Fit and tighten the pick-up screws to 10 Nm.

16.14

ELECTRICAL SYSTEM/IGNITION 16

Tester General Information

Connect the tester unit to the tester harness and


tighten the harness retaining screws.

All Other Models:


Remove the seat to gain access to the igniter and
sub-harness (Thunderbird, Thunderbird Sport &
Adventurer - also remove the right hand side
cover).

Disconnect the igniter sub-harness from the main


harness. Attach the tester male connector to the
main harness and female connector to the igniter
sub-harness.

Connect the tester unit to the tester harness and


tighten the harness retaining screws.

This tester is designed to carry out a series of tests on the


ignition system primary circuit and also is able to check
ignition coil secondary resistance. The tester will reveal
a fault if the component or circuit being tested falls
outside pre-programmed parameters for
voltage,
resistance, etc.
Faults in the ignition secondary circuit, such as spark
plug or H.T. lead breakdown, must be determined by
other means.
The tester uses the following conventions to indicate test
results.

GREEN LIGHT ON: ......... Circuit/component


operating correctly
GREEN LIGHT OFF: ........ Fault on the circuit
or component
RED LIGHT ON:
.......... Fault on the circuit
or component
GREEN & RED LIGHTS OFF: Fault on the circuit
or component

NOTE:

Intermittent faults are often caused by poor


connections due to corrosion and cable fatigue.
Always check ignition connections if the tester
shows all circuits are working correctly but an
intermittent fault persists.

WARNING:

In the following procedure,

~ the motorcycle engine must be run. The


exhaust fumes given off by the engine, when
running, contain carbon monoxide and other toxic
gases. Never start or leave the engine running in a
confined space unless an exhaust extraction
system is available and is connected directly to the
motorcycle exhaust system. If such a system is
not available, ensure that the building is
adequately ventilated to prevent a build up of
gases.
Remember, carbon monoxide is a
colourless, odourless gas which will cause
unconsciousness or death if inhaled in sufficient
quantity.

NOTE:

To Attach The Tester To The Motorcycle

Tiger and 1996 Trophy:


Remove the cockpit fairing to gain access to the
igniter and sub-harness.

Disconnect the igniter sub-harness from the main


harness. Attach the tester male connector to the
main harness and female connector to the igniter
sub-harness.

16.15

References to coil numbers on the tester


correspond directly with the cylinder numbers
on a 3 cylinder engine and correspond as
follows on a four cylinder engine:
Coil 1 - cylinders 1 and 4
Coil 2- cylinders 2 and 3
In all cases, number 1 cylinder is the left hand
cylinder when viewed from the riding position.

16 ELECTRICAL SYSTEM/IGNITION

Main Switch

Static/Dynamic
Switch
DYNAMIC
STATI: ~
r-=_ 4-CYL

\ I

Set Up for Static Tests

/J.CYL

IGNITION SYSTEM TESTER

SUPPL*

Turn the tester main switch to


'ON'.

Turn the static/dynamic switch to


'STATIC'.

Turn the ignition switch to 'ON'.

Ensure that the engine 'kill'


switch, on the right hand
handlebar, is in the 'RUN'
position.

All LEDs will illuminate briefly to


indicate that the tester is
functioning correctly.

All LEOs ON then OFF indicates


correct tester operation, proceed to the next test leaving
the ignition 'ON', the rnain switch
'ON' and static/dynamic switch in
the 'STATIC' position.

All LEOS fail to illuminate,


proceed as follows:

Check for a supply to igniter pin 9


using a voltmeter. If correct, the
supply voltage should equal
battery voltage. If no feed is
present, check for a faulty ignition
switch or engine kill switch, a
faulty side stand switch or
damaged/broken wiring.

Check for correct earth path from


igniter pin 4 to the earth point at
the black/yellow wire beneath the
seat. Rectify as necessary.

CKUPCOI~
MPLITUD
L

16.16

ELECTRICAL SYSTEM/IGNITION 16

Main Switch

Static/Dynamic
Switch

Ignition switch

To Test The Battery


Voltage

The 'Supply' LED should be ON.

LED ON indicates correct


battery voltage, proceed to next
test.
Supply LED not ON
indicates a battery fault, proceed
as follows:

Check
battery
and
connections,
rectify
necessary.

Re-charge
discharged.

Replace the battery if faulty.

If all battery checks indicate a


satisfactory battery condition,
repeat the tests from page 16 for
supply to pin 9 and earth from pin
4. Rectify as necessary

IGNITION SYSTEM TESTER

~CK..UPCOIL
/ T'~ESISTANCE

SUPPLY

PICK-UP COIL
AMPLITUDE

LOW

OK

~0

O EARTH FAULT
PICIWPCOI.

IGN.~o

the

earth
as

battery

if

IGN.~o

IGN.~o
TAC~o

,..--"=" I

1r

""" :::J

Pin 9
Pin 4

~~I.F---tJ....,:~,,~,.....,:;;..---

16.17

16 ELECTRICAL SYSTEM/IGNITION

Main Switch

Static/Dynamic
Switch

To Test Pick-up Coil


Resistance

Ignition switch

STATIC

IGNITION SYSTEM TESTER

SUPPLY

PICK.lJP COIL
AMPLITUDE

LOW

Green LED ON indicates a


correct pick up coil resistance,
proceed to next test. Red
pick-up LED ON or neither
pick-up LED ON indicates a
fault, proceed as follows:

Red LED ON check for short


circuit to earth between the igniter
pin 7 and the pick-up red lead by
examining the harness for
damaged cable insulation and
trapped wires.
Rectify as
necessary.

Neither LED ON indicates a


pick-up resistance outside the
permitted
range
or
wiring/pick-up open circuit.
Connect an ohm-meter across
the connections to igniter pins 1 &
7. Check for a resistance value of
530 ohms1 0%. If the reading
found indicates that the pick-up is
open circuit (meter indicates a nil
value), repeat the test at the
pick-up connection to the main
harness (located below the
airbox).
Replace the pick-up if the
resistance check at the pick-up
connection to the main harness
continues to indicate an open
circuit (nil value). If the check at
the connection to the main
harness indicates a resistance
within the specified limit, check
w1nng
for
damaged/broken
between the main harness to
pick-up connector and the igniter
(including
the
igniter
sub-harness). Rectify the wiring
as necessary and repeat the tests
to confirm correct operation.
Replace the pick-up if the
resistance value is outside the
specified
limit
and
cable
continuity is confirmed by the
preceding checks.

OK

SPEED

~.COIL1

IGN.~

~.COIL2

IGN-~o

~-awnNUrTY

Check that the green pick-up


coil resistance LED is ON and
the red pick-up coil earth fault
LED is OFF.

CRAM<IIIG

PAWl. COIIITlNUITY

IGN.~o

TACHOM~o

,.--..~ I
I r'Cf'~

Pin7
Pin1

-::;"'IIIPt-#-----

16.18

ELECTRICAL SYSTEM/IGNITION 16

Main Switch

Static/Dynamic
Switch

Ignition switch

IGNITION SYSTEM TESTER

SUPPLY

*PPLY

~CK.UPCOIL
/ T'~ESISTANCE

O PICIWPCOIL
EARTH FAULT

PICK-UP COIL

AMPLITUDE

LOW

To Test Ignition Coil


Primary Continuity.

3 cylinder engines: Check that


ignition coil primary continuity
LEOs 1, 2 and 3 are ON.

4 cylinder engines: Check that


ignition coil primary continuity
LEOs 1 and 2 are ON.

Correct number of LEOs ON


indicates correct coil continuity,
proceed to next test. One or
more LEOs OFF indicates a
fault, proceed as follows:

Check for supply to each coil


primary (+) connection using a
voltmeter.
Correct reading
should be equal to battery
voltage. If a supply fault is found,
check the cable continuity to each
coil using a multi-meter as
follows;
Igniter pin 6 to coil 1,
Igniter pin 11 to coil 2,
Igniter pin 12 to coil 3 (3 cyl only).
Rectify as necessary.

To confirm a coil fault, attach an


Ohm meter (0-1 Ohm scale)
across
the
coil
primary
connectors. Replace coils with a
resistance outside 0.63.0hms
10%.

OK

~0
IGN.~o
IGN.~o

IGN.CQL3
DII'IIE

r~o

l,..r--7!rd

0----~l~s~
Coil Ohm meter Test

16.19

NOTE:
Complete the dynamic tests if
any primary coil circuits
indicate a defect and all the
above manual checks do not
indicate a fault. A dynamic
fault indicated on the same
cylinder/coil in both the static
and dynamic tests indicates a
faulty igniter.

16 ELECTRICAL SYSTEM/IGNITION

Main Switch

Static/Dynamic
Switch DYNAMIC
STATK: ~

Ignition switch

To Test the Starter


Lockout System

,..---=. 4-CYL

\ I

/3.CYL

Engage neutral and place the


sidestand in the down position.

Check that the enabled LED is


ON and the disabled LED is
OFF.

Engage 1st or 2nd gear leaving


the sidestand down.

Check that the enabled LED is


OFF and the disabled LED is
ON.

0 AMPLITUDE 0OK
LOW

This indicates correct function of


the starter lockout system,
proceed to next test.
Any different combination of
LEOs from those listed above
indicates a fault.

Check for an open circuit side


stand switch, faulty side stand
relay, wiring fault to side stand
switch or wiring fault to relay.

Check for faulty neutral indicator


switch or wiring fault in the neutral
indicator circuit.

IGNITION SYSTEM TESTER

SUPPLY

*PPLY

~ICKUP COIL

/ T'

RESISTANCE

PICIWPCOI.
O EAR1ll
FAULT

~.COI.1

PAM. COIIITlNUfTY

~.COIL2

~PRIM. CONTINOOY

~~
o~-*I~

PICK-UP COIL

CRAIII<IIIG

SPEED

IGN.~o

IGN-~o
IGN.~o

TACHOM~o

I
LSTAre~ 1,.----~
r3Cf,:::l

IGMTlON

DISABLED

ENABLED

IGN. COIL
SECONDARY

RESISTANCE

~6g
NOTE: THUNDERBIRD, THUNDERBIRD SPORT & ADVENTURER MODEL
On Thunderbird, Thunderbird Sport & Adventurer, the side stand switch is connected to the igniter in a different way
to all other models as no side stand relay is fitted. In place of the relay, there are two 'enable' lines to the igniter. One
goes directly to the side-stand switch and one directly to the neutral switch. The engine will run if either are switched
to earth, I.E. if the side-stand is up or the gearbox is in neutral.
This means that, on Thunderbird , Thunderbird Sport & Adventurer, the enabled light on the diagnostic unit effectively
becomes a side-stand up light and the disabled light, a side-stand down light. The neutral light is a new line and is
not connected to the diagnostic unit. Therefore, to test the starter lockout system on the Thunderbird , Thunderbird
Sport & Adventurer, proceed as follows
Static Mode
1. Side-stand up ............... Ignition enabled light should be on
2. Side-stand down ............ Ignition disabled light should be on

16.20

ELECTRICAL SYSTEM/IGNITION 16

To Test The Battery


Supply During Cranking

IGNITION SYSTEM TESTER

SUPPLY

Engage neutral and place the


sidestand in the down position.

Turn the tester main switch to


'OFF'.

Turn the static/dynamic switch to


'DYNAMIC' selecting the correct
number of cylinders depending
on the model under test.

Turn the ignition switch to 'ON'.

Crank the engine and check that


the supply LED on the right hand
side of the unit is ON during
correct
cranking
indicating
battery voltage. Proceed to the
next test.

PICK-UP C O l *
AMPLITUD

PICK-UP COIL
RESISTANCE

PICIWPCOIL
EARTH FAUlT

JGN.COIL1

IGN-~o

PRIM. CONllNUITY

Supply LED OFF indicates a


fault in battery voltage during
cranking.

JGN.COIL2

PRIM. CONrNJITY

JGN.~o

Check
battery
and
connections,
rectify
necessary.

Re-charge or replace the battery


if discharged or faulty.

Check starter motor current draw,


should be 22 A at 11.5 V under no
load conditions. Replace the
starter if outside these limits.

LOW

JGN.~o

JGN.COIL3

PRIM. COIIITIIJOOY

TACHOMETER

,'~~J
1/-mt
,'

.diNAMJC

earth
as

NOTE: MODELS WITH 'GILL'


IGNITER
Any readings from the starter
lockout test on the static side
are to be ignored even though
the unit will indicate a disabled
condition if the side stand is
down.

16.21

16 ELECTRICAL SYSTEM/IGNITION

Main Switch

Ignition switch

To Test the Pick-up Coil


Amplitude

Crank the engine and check that


the green LED 'Pick-Up Coil
Amplitude O.K.' is ON indicating
correct pick-up coil amplitude.
Proceed to next test

Red 'LOW' indication or


neither LED ON indicates a
fault, proceed as follows:

Check that the air gap between


the pick-up and rotor is
0.6-0.Bmm. Adjust as required
then repeat test. If a fault is still
indicated, replace the pick-up.

IGNITION SYSTEM TESTER

SUPPLY

PICK-UP COIL
RESISTANCE

SUPPL*

O JIICK.UPCOI.
EARTH FAULT
0

IGN.COI.1

PRIM. CONT1IIIUITY

IGN.~

IGN.COI.2

PRIM. COIIITIIIUITY

IGN.~o

IGN.COI.3

IGN.~

PRIM. CONT1IIIUITY

TACHOMETER

.~~d

,'
diNAMJC
r-::r:::.
I /3-CYL
4-CYL

16.22

1. Rotor
2. Pick-up
3. Air gap, 0.6-0.Smm

ELECTRICAL SYSTEM/IGNITION 16

To Test For Correct


Cranking Speed

Crank the engine and check that


the cranking speed LED is ON
indicating that the cranking
speed is correct (above the
minimum limit). Proceed to next
test.

Cranking speed LED OFF


indicates a fault (low cranking
speed), proceed as follows:

Check for satisfactory starter


motor earth at the alternator
boss.

Investigate the starter motor for


wear or faults and also check the
auxiliary gearing for damage.
Rectify as necessary.

IGNITION SYSTEM TESTER

SUPPLY

PICK-UP COIL
RESISTANCE

SUPPL*

PICK-UP

COl~

0 AMPLITUD
LOW

O PICIC.UPCOI.
EARTH FAULT
0

IGN.COI.1

PAWl. CONTlNUITV

IGN.~o

IGN.COI.2
PAWl. CONT1MJTV

IGN.~o

IGN.COI.3

IGN.~o

PAWl. CONTWOOY

TACHOMETER

.~~J

;
,'

~IC

r~~t

16.23

16 ELECTRICAL SYSTEM/IGNITION

Main Switch

Static/Dynamic
Switch,~
,'

STATIC~

Ignition switch

lfnwl,r;;

r-::t:: 4-CYL

\ I

/3.CVL

IGNITION SYSTEM TESTER

SUPPLY

PICK-UP COIL
RESISTANCE

SUPPL*

Turn the tester main switch to


'ON'.

Start the engine.

3 cyl engines, check that all 3


coil drive LEOs are ON
indicating correct coil switching
by the igniter. Proceed to next
test.

4 cyl engines, check that coil


drive LEOs 1 and 2 are ON
indicating correct coil switching
by the igniter. Proceed to next
test.

One or more LEOs OFF


indicates a fault, proceed as
follows:

Replace the igniter.

PICK-UP C O l *

AMPLITUD
0
LOW

EARTH FAULT
O PICK-UPCOIL

To Test for Correct


Igniter Coil Switching

IGN.COIL1

PRIM. COIIIT1IIIUfTY

IGN.COIL2

IGN.COI.3

PRIM. CONTIIIOOY

PRIM. CONTIIIOOY

,'~,
,'

dfNAMtc

r--r:::_ ~YL

/3.CVL

16.24

ELECTRICAL SYSTEM/IGNITION 16

Main Switch

Static/Dynamic

Ignition switch

To Check for Correct


Tachometer Output

Switch:~

,'

m-IC

~4-CYL

/3-CYL

Start the engine and check that


the tachometer output LED is
ON indicating correct supply to
the tachometer. Proceed to next
test.

Tachometer supply LED OFF


indicates a fault.

Check for continuity between


igniter pins 11 t (later 3 cyl) and
12t (later 4 cyl) and the
tachometer using a multi-meter,
rectify as necessary.
t Pin 6 (3 and 4 cyl) on early
models

Check tachometer supply at the


brown/white lead, should be
battery voltage. Rectify as
necessary.

IGNITION SYSTEM TESTER

SUPPLY

PICK-UP COIL
RESISTANCE

SUPPL*

PICK-UP C O *

0 AMPLITUD
LOW

O PICK-UPcaL

~FAULT

IGN.COIL1
PRIII/I. COIIIT1NUfTY

IGN.~

IGN.COIL2
PRIII/I. COIIITI\IUITY

IGN.~*

Tachometer
continues
to
malfunction, replace tachometer.

IGN.~*

IGN.COI.3
PRIII/I. COIIITI\IUITY

Tachometer
continues
to
malfunction, replace the igniter
and refit the original tachometer.

. ~,
.dfNAMIC

,'

'r3.CVL
~4-CYL

Pin11
Pin6
Pin12

16.25

16 ELECTRICAL SYSTEM/IGNITION

Static/Dynamic
Switch

Main Switch

Ignition switch

IGNITION SYSTEM TESTER

SUPPLY

PICK-UP COIL
RESISTANCE

SUPPLY

PICK-UP COIL
AMPLITUDE

LOW

EARTH FAULT
O PICIWPCOI.

CRAN<IIIG

SPEED

PRI't'l. CONT1NUITY

IGIII.~

IGI\I. COIL 3
PRI't'l. COIIITIIIWTY

IGN.~o

IGIII. COIL 2

PRI't'l. CONTINUITY

~~~

TACHOM~o

I
Lsr.re~ 1~-___;;~
"'Yl :::::~

DISABLED

IGIII. COIL
SECQI\IlARY

Remove the fuel tank as


described in the fuel system
section of this manual.

Fit the additional test leads to the


socket on the front panel and
proceed as follows.

Select the 'static' position on the


tester switch.

3 Cylinder engines, disconnect


the coil primary leads and
connect the tester leads between
any primary coil connection and
the secondary (H.T.) pole.

4 Cylinder engines, disconnect


the coil primary leads and
connect the tester leads across
both secondary (H.T.) poles.

Repeat for each coil in turn and


check that the 'PASS' indication
is illuminated for each coil tested.

Replace any coil(s) giving a 'FAIL'


indication.

Disconnect the tester, reconnect


the coil primary connections and
refit the fuel tank. Reconnect the
igniter to the sub-harness and
refit the seat.

0
0

IGIII. lXII. 1

0OK

IGIII.~

To Test the Secondary


Resistance of the
Ignition Coils

ENABlED

3 Cyl
4Cyl

16.26

ELECTRICAL SYSTEM/IGNITION 16

Other checks

STARTER MOTOR

If the tester reveals that no fault is present in any


part of the system but an ignition problem is still
present, proceed as follows.

Check for a fault in the high tension leads (plug


leads).

Check for correct function, air gap etc of the spark


plugs.

Check for reverse polarity of the ignition pick-up


by ensuring that the black (light green on early
models) sub harness wire from pin 1 is connected
through to the black pick-up wire. Connection to
any other colour must be rectified.

Removal
1.

Remove the seat and disconnect the battery,


negative (black) lead first. Remove the fuel tank
and carburettors as described in the fuel system
section.

WARNING: Observe the warning advice


given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury, could result from
spilled fuel or fuel not handled and stored in the
correct manner.
2.

Remove the lower fairing (if fitted) and drain the


cooling system as described in the cooling system
section. Remove the water pump hose cover
(where fitted) and water outlet elbow from the
crankcase.

Pin1

Check for any loose connections which would


begin to break down when the machine is in
motion.

Check for part-fractured cables by 'joggling' the


cables during testing.

NOTE:
In certain cases, although the tests made by
the tester will reveal correct functioning of the
system and further tests confirm wiring
continuity, a fault may still be present in the
internal circuits of the igniter itself. This is
possible with the tests for the tachometer
output, pick-up coil amplitude and coil
primary continuity. In such cases, fitting a
substitute igniter will confirm a fault in the
original.

NOTE:
Always complete the dynamic tests if any
primary coil circuits indicate a defect and all
the manual checks do not indicate a fault. A
dynamic fault indicated on the same
cylinder/coil in both the static and dynamic
tests indicates a faulty igniter.

1. Water Pump Hose Cover


2. Retaining Bolt
3. Washer
4. Lower Mounting Point
5. Upper Mounting Point/Outlet Elbow
3.

16.27

On 4 cylinder engines, disconnect the breather


hose from the left hand crankshaft cover.

NOTE:
On Thunderbird, Thunderbird Sport &
Adventurer, remove the horn and bracket from
the engine.

16 ELECTRICAL SYSTEM/IGNITION

4.

Release the terminal nut from the starter cable and


remove the cable.

3.

1. Armature
2. Yoke assembly

1. Starter Motor
2. Terminal Nut
5.

Release the two bolts securing the starter motor to


the crankcase.

6.

Remove the starter motor.

CAUTION:
To prevent component
damage, do not allow grease from the
rear bearing to come into contact with the brushes.

4.

Disassembly
1.

Remove the brush holder from the end frame.

Remove the brushes from the brush holder by


carefully lifting the spring from the brush holder.

Unscrew the two through bolts and remove the


starter housing.

1.Brush
2. Retaining Spring

5.
1. Through Bolts

Loosen the terminal nut attached to the end frame


and remove the upper and lower insulators, '0' ring
and brush.

NOTE:

Before removing or installing pinion end, cover


the teeth of the pinion with thin tape to prevent
damage to the oil seal.

2.

Hold the pinion of the armature in one hand and


remove the yoke.

1. Insulation

16.28

ELECTRICAL SYSTEM/IGNITION 16

Assembly
1.

Assemble the starter motor by reversing, the


disassembly procedure.

Align the yoke projections with the brush plate


and end cover location holes.

6.

Connect the water pump hose and refill the cooling


system as described in the cooling system section.

7.

Refit the carburettors and fuel tank. Refit the


bodywork previously removed and reconnect the
battery, positive (red) lead first.

STARTER MOTOR COMPONENT TEST


Armature
1.

Set the multi meter to the 1Q range.

2.

Measure the resistance


commutator segments.

If there is a high resistance or no reading


between any two segments, a winding is open
circuit and the armature/starter must be
replaced.

between

any

two

1. Projection
2. Location Holes

3.

Set the multimeter to the highest range.

4.

Measure the resistance between the commutator


and the shaft.

NOTE:

If any reading is detected, there is a short circuit


and the armature/starter must be replaced.

If all checks prove to be negative but the starter


continues to malfunction, replace starter motor
with a new one.

When rebuilding the housing and yoke


assembly, align
the marks on the yoke
assembly with the clearance hole in the
housing.

1. Alignment Mark

Starter Installation
1.

Clean the mating faces of the crankcase and starter


motor to ensure efficient grounding.

2.

Apply a small amount of engine oil to a new starter


'0' ring. Fit the '0' ring to the starter.

1. Segment
2. Shaft

Commutator
Cleaning and Inspection

3.

Fit the starter motor and tighten the starter bolts to


10Nm.

1.

Smooth the commutator surface with fine emery


cloth, clean out all grooves.

4.

Connect the starter motor feed cable. Tighten the


cable nut to 7Nm.

2.

Measure the diameter of the commutator.

5.

Refit the water outlet elbow using a new gasket.


Tighten the elbow bolts to 11 Nm.

Commutator diameter

16.29

Standard:
Service limit:

28mm
27mm

16 ELECTRICAL SYSTEM/IGNITION

NOTE:

Brush Plate

Replace the starter motor, if the commutator


diameter is below the service limit.

1.

Set the multi meter to the1 kQ range.

2.

Measure the resistance between the brush and the


plate.

The multimeter should indicate continuity


between the brush and the plate i.e. no
resistance. If there is no reading, replace the
plate.

3.

Measure the resistance between metal the plate


and the brush holders.

The multimeter should indicate NO continuity


between the brush and plate, i.e. no reading. If
there is a reading, replace the plate.

Smoothing the Commutator

Yoke
1.

Check the yoke magnets for cracks and peeling.


Replace as necessary.

1. Resistance Between Brush and Plate


2. Resistance Between Holder and Plate

Brush and Lead Assembly


1.

Measure the resistance between the brush and the


terminal bolt.

The multimeter should indicate continuity


between the brush and terminal bolt, i.e. no
resistance. If there is no reading, replace the
brush and lead assembly.

1
1. Magnets

1. Brush
2. Terminal Bolt
16.30

ELECTRICAL SYSTEM/IGNITION 16

Brush and Brush Spring

Commutator End Housing

1.

1.

Measure the length of each brush and replace as


necessary.

Length
Standard:
Service limit:

Check the end housing for wear.


Lubricate the bearing housing with grease to
prevent seizure.

STARTER SOLENOID
12mm
8.5mm

The starter solenoid is located beneath the seat,


adjacent to the battery box.

Removal
1.

Disconnect the battery, negative (black) lead first.

2.

The solenoid is mounted in a rubber holder with the


wiring connector retained by an '0' ring. Release
the '0' ring, starter and battery feed wires and the
wiring connector from the solenoid.
Remove the solenoid and rubber holder from the
two mounting barbs.

NOTE:

1. Brush Length
2. Brush Spring

Later models are fitted with a solenoid which is


retained solely by the rubber mounting and
barbs.

Installation
2.

Check each brush spring for cracks, bending etc.


Replace as necessary.

Bearing
1.

Check all bearings for smooth running and lubricate


with grease as necessary.

1.

Locate the solenoid to the rubber holder and fit to


the two barbs. Reconnect the wiring connector,
battery and starter feed wires. Retain the connector
with the '0' ring.

STARTER MOTOR CIRCUIT DIAGRAM


Refer to the following page for a diagram of the wiring
circuit for the starter motor on a 1996 Trophy.

Drive End Housing


1.

Check for grooving and signs of excessive wear.


Lubricate with grease if serviceable.

2.

Check the condition of the oil seal and replace as


necessary.

1. Oil Seal

16.31

For details of the starting circuit on other models, refer to


the main circuit diagrams at the end of this section.

16 ELECTRICAL SYSTEM/IGNITION

Starter Circuit (1996 Trophy)

BATTERY
(14Ah)
FUSE 9

N
NR

cG
cG
,...--.--

1
WB

N
NR

w
y

IS?+J
0
,....

u.
u.

'---

IGNITION
SWITCH

FUSE5

OFF

,...-

,...-

YR ---1--<Y

ENGINE
START/STOP
o4--, SWITCH

ON

IGN

~2

BR

11
'--

WR

BR

----11~0 'E'

b :~~
-

STARTER
SOLENOID

STARTER
MOTOR

nr-

BK

B
BS

.--

BY

11

BR

- -

STARTER
CUT-OUT
SWITCH

NEUTRAL
SWITCH

16.32

ELECTRICAL SYSTEM/IGNITION 16
Fan check

COOLING SYSTEM
Cooling Fan

1.

Disconnect the 2-pin connector to the fan leads.

2.

Connect a 12V supply to the fan.


Blue fan wire to positive (+Ve)
Black fan wire to negative (-ve)

3.

If the fan does not operate, the motor is defective


and must be replaced.

FAN
SWITCH

FAN

Bl

-nr---

COOLING FAN SWITCH


Removal

BI/W

Bk~

1.

Drain the cooling system as described in the cooling


section.

All models except Thunderbird, Thunderbird


Sport & Adventurer: The fan switch, is fitted to the
left side of the radiator and is retained by a 'bayonet'
type locking ring.
The ring must be rotated
anti-clockwise to remove.

Thunderbird, Thunderbird Sport & Adventurer:


The fan switch is located in the thermostat housing
beneath the fuel tank and is retained by means of a
'U' shaped clip.
Detach the clip by pulling
rearwards.

2.

The switch is then removed from the


radiator/housing by gently pulling the switch from
the rubber seal, in an outwards direction.

Bk/Y

BI/Bk

"M
+
BATTERY
(14 Ah)
FUSE BOX

Installation
1.

Inspect the switch seal and renew if necessary.

All models except Thunderbird, Thunderbird


Sport & Adventurer: Refit the switch, fit and turn
the locking bayonet to secure to the radiator.
Connect the electrical terminals.

Thunderbird, Thunderbird Sport & Adventurer:


Refit the switch and secure with the U clip. Connect
the electrical terminals.

2.

Refill the cooling system as described in the cooling


section.

Cooling Fan Circuit

WARNING: The cooling fan operates


automatically, even with the ignition
switch off. To prevent personal injury, keep hands
and clothing away from the fan blades at all times.

Circuit check
1.

Disconnect the wires from the cooling fan switch.

2.

Using a length of spare wire, connect the switch


wires together (this simulates the operation of
cooling fan switch).

The fan should turn when the two wires are


bridged. If the fan fails to turn, inspect the wires,
connections, main fuse and fan.
On Thunderbird, Thunderbird Sport &
Adventurer, the fan switch is located in the
thermostat housing beneath the fuel tank.

16.33

16 ELECTRICAL SYSTEM/IGNITION

Inspection

WATER TEMPERATURE
GAUGE/WARNING LIGHT

1.

Connect a multimeter across the terminals to check


for correct operation of the switch.

2.

Suspend the switch in a container of water.

3.

Suspend a thermometer in the coolant.

Check for correct operation of the


temperature gauge or warning light after
turning the ignition to the 'On' position.

4.

Raise the temperature of the coolant.

Gauge

5.

The switch contacts should close at 99C at which


point the resistance between the switch terminals
should change. Check that both open and closed
switch resistances are as specified below. Replace
the switch if the readings obtained deviate from
those specified.

1.

Disconnect the wire from the temperature sensor


on the cylinder head. The gauge should read 'C'.

2.

Earth the sensor wire against the cylinder head.


The gauge should read 'H'.

If these readings cannot be obtained, check for


damaged wiring and/or a faulty gauge.

Resistance between switch terminals


On :

Less than 0.5Q

Off:

More than 1MQ

Warning Light
1.

Disconnect the wire from the temperature sensor


on the cylinder head. The warning light should stay
off.

2.

Earth the sensor wire against the cylinder head.


The warning light should illuminate.

If the warning light fails to operate, check for a


blown bulb and/or damaged wiring

1. Fan Switch

WATER TEMPERATURE GAUGE


I

I
I
I
I
I
L _ _ _ ...J
INSTRUMENT
PANEL

~~ :I111----~

Br

Br

i
w

Bk!Y

Y/W

COOLANT
TEMPERATURE
SENSOR

Bk!Y

Temperature Gauge
Circuit

+
R

BATTERY
. (14 Ah)

~-w,

MAIN FUSE

L-----...l

FUSE BOX

16.34

ELECTRICAL SYSTEM/IGNITION 16

Temperature/warning light sensor


inspection

Fuse Box

1.

Drain the cooling system as described in the cooling


section.

2.

Remove the temperature sensor.

3.

Connect one lead of a multimeter to the spade


terminal on temperature sensor.

4.

Suspend the temperature sensor in a container of


water.

5.

Set the multimeter to the resistance range.

6.

Connect the other lead of the multimeter to the body


of temperature sensor.

Fuses are arranged in the fuse box located beneath the


seat (behind the right hand side panel on Thunderbird,
Thunderbird Sport & Adventurer). If a fuse fails during
operation, inspect the electrical system to determine the
cause. Always replace a blown fuse with a new fuse of
the same (correct) current rating.

Temperature sensor resistance:

255 - 310 .Q

@ 60C,

2
1. Fuse Box
2. Spare Fuses

1. Temperature Sensor

5048
1. 1996 Trophy Fuse Box

1. Thunderbird/Thunderbird Sport/Adventurer Fuse


Box

16.35

16 ELECTRICAL SYSTEM/IGNITION

A blown fuse can be readily identified by the link bar in the


clear centre being divided.

WARNING: Always replace a blown fuse


with a new item of the correct current
rating, as specified on the fuse box cover. Never
replace a blown fuse with a replacement of a higher
rating than specified for the original as this may
cause damage to the wiring circuits leading to a
risk of injury from a wiring fire.

Fuse Diagnosis
A blown fuse is indicated when all of the systems
protected by the fuse become inoperative. When
checking for a blown fuse, the following guide will
indicate which fuse circuit is blown.

Normal

Failed

All models except Thunderbird, Thunderbird


Sport, Adventurer and 1996 Trophy

WARNING: Early motorcycles are fitted


with a 10 Amp. fuse for the cooling fan.
Later models are fitted with a different cooling fan
requiring a 15 Amp. fuse. Use of a fuse of the
correct rating is essential in either case. Always
refer to the fuse box cover for information before
replacing the cooling fan fuse.
Never replace a blown fuse with a replacement of a
higher rating than specified for the original as this
may cause damage to the wiring circuits leading to
a risk of injury from a wiring fire.

Fuse 1 ....... Headlamps


Fuse 2 ....... Tail Lamp
Fuse 3 ....... All Systems
Fuse 4 ....... Cooling Fan
Fuse 5 ....... Alarm (when fitted)
In-line fuse

Rear Light

Thunderbird, Thunderbird Sport & Adventurer


Fuse 1 ....... Headlamps, pass switch
Fuse 2 ....... Tail Lamp, stop lamp, panel lights, horn.
Fuse 3 ....... Ignition switch, main power.
Fuse 4 ....... Cooling Fan, flasher unit.
Fuse 5 ....... Alarm (when fitted)
In-line fuse

Starter solenoid, ignition system.

1996 Trophy
Fuse 1 ....... Headlamps, alternator
Fuse 2 ....... Alarm, clock, hazard lights, indicators
Fuse 3 ....... Cooling fan.
Fuse 4 ....... Auxiliary circuits
Fuse 5 ....... Engine start and run systems
Fuse 6 ....... Alarm signal, headlamp relays
Fuse 7 ....... Brake lights, horn, instruments
Fuse 8 ....... Instrument illumination, side lights
Fuse 9 ....... All circuits from ignition switch

16.36

ELECTRICAL SYSTEM/IGNITION 16

LIGHTS

Direction Indicator

Tail/Brake Light Bulb Replacement

Removal

Removal

1.

Remove the screw securing the lens to the direction


indicator body.

1.

Remove the screws securing the lamp lens to the


tail light body and the remove lens.

2.

Remove the lens.

2.

Push the bulb whilst turning it anti-clockwise and


remove from the reflector.

1. Direction Indicator Lens

3.

Push the bulb whilst turning it anti-clockwise and


remove from the reflector.

1. Lamp Lens

Installation
1.

Locate a new bulb to the tail lamp and secure by


twisting to the locked position.

2.

Refit the lens.


CAUTION: Never overtighten the lamp
lens screws as this will damage the lens.

1. Bulb
2. Reflector

4.

Check the bulb and replace as necessary.

Installation
1.

Turn the bulb clockwise whilst pushing, until it locks


in position.

2.

Fit the lens and tighten the screw.


CAUTION: Never overtighten the lamp
lens screws as this will damage the lens.

16.37

16 ELECTRICAL SYSTEM/IGNITION

HEADLIGHTS

Trophy Headlight Bulb replacement (pre


1996 model)

All models with twin headlights have different adjustment


arrangements to those models with a single headlight. In
addition, the pre 1996 Trophy single headlight is different
to that fitted to the Trident/Speed Triple.

Removal

Trophy Headlight (pre 1996 model)


Horizontal and vertical adjustment of the headlight beam
is made by the two screws on the back of the headlight.
The screws can be reached from underneath the front of
the fairing.
Rotate both screws equally for VERTICAL adjustment.
Clockwise to lower the beam. Anti-clockwise to raise the
beam.
Rotate each screw equally in opposite directions for
HORIZONTAL adjustment.
Rotate the left hand side screw clockwise and the right
hand side screw anti-clockwise to move the beam to the
right.
/"'

1.

Disconnect the battery, negative (-) black lead first.

2.

Release the screws and lift up the facia panels.


Disconnect the clock and remove both facia panels.

3.

Remove the locknuts securing the mirrors to the


cockpit.

4.

Remove the mirrors and mirror mounting pads.

5.

Remove cockpit fairing to lower fairing screws.

6.

Repeat steps 2 and 3 for the other side.

7.

Support the cockpit fairing.

8.

Remove the rubber dust cover.

9.

Disconnect the multi-pin electrical connector at the


rear of the headlight.

10. Rotate the bulb retaining ring anti-clockwise.


11.

Remove the halogen bulb.

Arrowed: retaining ring direction of release

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 the
glass is touched or gets dirty, clean with alcohol
before re-use.

1. Trophy Headlight Adjustment Screws

WARNING: Adjust road speed to suit the


visibility conditions in which the
motorcycle is being operated.
Ensure that the beam is adjusted to illuminate the
road surface sufficiently far ahead without
dazzling oncoming traffic. An incorrectly adjusted
headlight may impair visibility causing an accident

~
CAUTION:
Changes made to the
~ horizontal adjusters will marginally
change the vertical setting of the headlamp beam.
Similarly, changes made to the vertical adjusters
will marginally change the horizontal setting.
Always allow for additional adjustment to
compensate for this factor.

Installation
1.

Fit the new bulb to the bulb holder.

2.

Fit the retaining ring and rotate clockwise to lock in


position.

3.

Fit the multi-pin connector to the rear of the


headlight.

4.

Fit the dust cover.

5.

Position the cockpit and fit the mirrors complete with


mounting pads.

6.

Fit the locknuts to secure the mirrors and hand


tighten.

16.38

ELECTRICAL SYSTEM/IGNITION 16

7.

Refit the cockpit to lower fairing screws.

HEADLIGHT- 1996 TROPHY

8.

Position the facia panels and reconnect the clock.


Locate the panels to the cockpit and tighten the
facia panel screws.

Headlight Adjustment
Both right and left hand headlamps are adjusted, as a pair,
by single horizontal and vertical adjusters.

Vertical Adjustment:
Open the right hand storage compartment, remove the
ignition key from the storage compartment lock and turn
the ignition switch to the 'ON' position. Turn the headlamp
dip beam on.
Turn the adjuster wheel clockwise to raise the beam and
anticlockwise to lower the beam. Turn the headlamp off on
completion.

1.
2.
3.
4.

Headlamp Bulb
Retaining Ring
Parking Lamp Bulb Holder
Parking Lamp Bulb

WARNING: Do not reconnect the battery


until the assembly process has been
completed. Reconnect the battery positive (red)
lead first then the negative (black) lead second.

Parking Light Bulb Replacement


The parking light bulb can be accessed in exactly the
same manner as the headlight bulb (steps 1-7).

Removal

1. Vertical Adjustment Control

1.

Disconnect the battery, negative (-) black lead first.

Horizontal Adjustment:

Remove the parking light bulb holder from the


headlight housing.

3.

Push the bulb whilst turning anti-clockwise and


remove from the housing.

Remove the cockpit 'chin panel' from beneath the cockpit


fairing and switch the headlamp dip beam on.

Installation
1.

Position and turn the bulb clockwise whilst pushing,


until the bulb locks in position.

2.

Fit the bulb holder into the housing.

3.

Re-assemble as for headlight bulb replacement.

WARNING: Do not reconnect the battery


until the assembly process has been
completed. Reconnect the battery positive (red)
lead first then the negative (black) lead second.

1. Cockpit Chin Panel

16.39

16 ELECTRICAL SYSTEM/IGNITION

Using a screwdriver, adjust the horizontal beam by turning


the adjuster clockwise to move the beam to the right and
anticlockwise to move the beam to the left. Turn the
headlamp off and refit the 'chin' panel when adjustments
are completed.

Headlight Bulb Replacement


1996 Trophy
Each halogen bulb can be replaced as follows:
Disconnect the battery, negative (black) lead first.
Remove the cockpit 'chin panel'.

Pull back the rubber cover from the headlamp bulb.

Disconnect the multi-pin electrical connector from the


bulb.

Rotate the bulb retainer anticlockwise to release.

The bulb can now be removed.

Installation is the reversal of removal.

2. Horizontal Adjustment Control

WARNING: Adjust road speed to suit the


visibility conditions in which the
motorcycle is being operated.
Ensure that the beam is adjusted to illuminate the
road surface sufficiently far ahead without
dazzling oncoming traffic. An incorrectly adjusted
headlight may impair visibility causing an accident
1. Bulb Retainer

CAUTION:
Changes made to the
horizontal adjusters will marginally
change the vertical setting of the headlamp beam.
Similarly, changes made to the vertical adjusters
will marginally change the horizontal setting.
Always allow for additional adjustment to
compensate for this factor.

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 the
glass is touched or gets dirty, clean with alcohol
before re-use.

WARNING: Do not reconnect the battery


until the assembly process has been
completed. Reconnect the battery positive (red)
lead first, then the negative (black) lead second.

16.40

ELECTRICAL SYSTEM/IGNITION 16

Headlight Adjustment
Twin Circular Headlamps

Headlight Bulb Replacement

Each headlight is adjustable individually and has two


adjustment screws, one for horizontal adjustment and
one for vertical adjustment.

Right Hand Lamp: Turn the horizontal adjuster screw


clockwise to move the beam to the left and
counterclockwise to move the beam to the right.
Left Hand Lamp: Turn the horizontal adjuster screw
clockwise to move the beam to the right and
counterclockwise to move the beam to the left.
Both Lamps: Turn the vertical adjuster clockwise to
lower the beam and anti-clockwise to raise the beam.

Removal
1. . Disconnect the battery, negative (-) black lead first.
2.

Remove the screws securing the facia panels.


Remove the panels.

3.

Disconnect the multi-pin electrical connector from


the rear of the headlight.

4.

Remove the rubber dust cover.

5.

Un-hook the wire retainer.

6.

Remove the bulb from the bulb holder.

1. Wire Retainer

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 the
glass is touched or gets dirty, clean with alcohol
before re-use.

1. Horizontal Adjustment Screws


2. Vertical Adjustment Screws

WARNING: Adjust road speed to suit the


visibility conditions in which the
motorcycle is being operated.
Ensure that the beam is adjusted to illuminate the
road surface sufficiently far ahead without
dazzling oncoming traffic. An incorrectly adjusted
headlight may impair visibility causing an accident

Installation
1.

Installation is the reversal of the removal procedure.

WARNING: Do not reconnect the battery


until the assembly process has been
completed. Reconnect the battery positive (red)
lead first then the negative (black) lead second.

CAUTION:
Changes made to the
horizontal adjusters will marginally
change the vertical setting of the headlamp beam.
Similarly, changes made to the vertical adjusters
will marginally change the horizontal setting.
Always allow for additional adjustment to
compensate for this factor.

16.41

16 ELECTRICAL SYSTEM/IGNITION

Trident, Thunderbird, Thunderbird Sport,


Adventurer and Speed Triple Headlight
Adjustment

Headlight Bulb Replacement


Removal

Horizontal adjustment of the headlight beam is controlled


by the screw in the rim of the headlight.
Vertical adjustment of the headlight beam is controlled by
slackening the headlight assembly mounting bolts.
Always re-tighten the bolts after adjustment.

1.

Disconnect the battery, negative (-) black lead first.

Remove the two retaining screws and whilst


supporting light unit, disconnect the multi-pin
electrical connector.

3.

Remove the rubber dust cover.

4.

Un-hook the wire retainer.

5.

The bulb can now be removed.

1. Horizontal Adjustment
2. Vertical Adjustment
3. Light Unit Retaining Screws (one each side)
1. Wire Retainer

WARNING: Adjust road speed to suit the


visibility conditions in which the
motorcycle is being operated.
Ensure that the beam is adjusted to illuminate the
road surface sufficiently far ahead without
dazzling oncoming traffic. An incorrectly adjusted
headlight may impair visibility causing an accident

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 the
glass is touched or gets dirty, clean with alcohol
before re-use.

A.

Installation

CAUTION:
Changes made to the
horizontal adjusters will marginally
change the vertical setting of the headlamp beam.
Similarly, changes made to the vertical adjusters
will marginally change the horizontal setting.
Always allow for additional adjustment to
compensate for this factor.

1.

Installation is reversal of removal.

WARNING: Do not reconnect the battery


until the assembly process has been
completed. Reconnect the battery positive (red)
lead first then the negative (black) lead second.

16.42

ELECTRICAL SYSTEM/IGNITION 16

WIRING CIRCUIT DIAGRAMS


Engine Stop Switch Operation

Horn Switch Operation

Engine Stop Switch

Y/R

Horn Switch

OFF
RUN

8k!W

ON

Dip Switch Operation

Headlight Switch Operation

Headlight Dip Switch

RNJ
OFF
0
RUN

R/81

81/Y

81

HIGH
LOW

Direction Indicator Switch Operation


Direction Indicator Switch

Starter Button Operation

GY
8k!R

PUSH

RIGHT
LEFT

Starter Button

8k/R

R/Y

81/y

R/8k

Headlight Switch

Hazard Warning Light Switch Operation

Front Brake Light Switch Operation

Hazard Warning Light Switch

Front Brake Light Switch

RELEASED
ON

8k

8k

ON
OFF

.-- r-e

W/8 0/G
k

-----

On

Starter Lockout Switch Operation


Starter Lockout Switch

8k!Y
RELEASED
DEPRESSED

Pass Button

Ignition Switch Operation


w 8r y
81
R

- - -

GY

Pass Button Operation

Ignition Switch Operation

ON
OFF/
LOCK

8k!Y

Y/G

LG

16.43

R/8k

8r

16 ELECTRICAL SYSTEM/IGNITION

Key To Wiring Circuit Diagrams


The following codes are used to denote all wiring colours
used on the following circuit diagrams.
Where two colours are used, the first colour named is the
principal wire colour and the second colour named is a
trace colour. For example, Bk/Y indicates a black wire
with a yellow trace.

Number

Description

12

Low Fuel Warning Light

13

Front Indicator Lamp, Right

14

Headlight

15

Side Light

16

Front Indicator Light, Left

17

Fuel Level Sensor

Code

Colour

18

Headlight Relay

Bk

Black

19

Ignition Switch

20

Headlight switch

21
22

Front Brake Light Switch


Engine Start/Stop Switch

Bl

Blue

Br

Brown

Green

GY

Grey

LB

Light Blue

23

Horns

LG

Light Green

24

Alternator

Or

Orange

25

Cooling Fan

Pi

Pink

Pu

Purple

26

Cooling Fan Switch

Red

27

Ignition Coils

Slate

28
29

Coolant Temperature Sensor

30
31

Igniter Pick-Up
Rear Brake Light switch

32

Stop!Tail Lamp

33

Fuse Box

34
35

Battery
Starter Solenoid

36

Starter Motor

37

Oil Pressure switch

38

Neutral Switch

39

Starter Cut-Out switch

40

Passing Button

41

Horn Button

42

Headlamp Beam Dip Switch

43

Direction Indicator Switch

44

Hazard Warning Light Switch

45

Rear Indicator Lamp, Right

46

Rear Indicator Lamp, Left

47

Clock

48

Alarm Connection, Sounder

49

Alarm Connection, Control Unit

50

Side Stand Switch

51

Side Stand Relay

52

Indicator Relay

Violet

White

Yellow

Key To Component Numbers


All major components on the diagram are given a key
number. The following is table must be used to identify
the components.
Number

Description

Right Turn Warning Light

High Beam Warning Light

Instrument Illumination

Tachometer

Neutral Warning Light

Instrument Illumination

Oil Pressure Warning Light

Water Temperature Gauge

Instrument Illumination

10

Side Stand Down Warning Light

11

Left Turn Warning Light

16.44

Igniter

ELECTRICAL SYSTEM/IGNITION 16

20
19

1 I
2 I

I II

I
I
I
I
I
I
I

25

I f

I I ~ II

~~~ >-3: sg

'-

- -~

24

T-

/ _!,Q ,C:s

I
I

\
I

--- - - -- ~

27

27

27

i ij

22

21

~ 45

8
.

i
I

9 !
10 !
11 I
12 I

!..

-,II

"o'>

52

I
.I
"'a:

I
~

~'>
i

---{]::J- A

l l

-n H

>~

33

38

~
Wiring Circuit

o1agram

Trophy - 0 aytona - Tn'd ent


1991/2 Models

16.45

16 ELECTRICAL SYSTEM/IGNITION

Key To Wiring Circuit Diagrams


The following codes are used to denote all wiring colours
used on the following circuit diagrams.
Where two colours are used, the first colour named is the
principal wire colour and the second colour named is a
trace colour. For example, Bk/Y indicates a black wire
with a yellow trace.

Number

Description

14

Headlight

15

Side Light

16

Front Indicator Light, Left

17

Fuel Level Sensor

18

Headlight Relay

19

Ignition Switch

Code

Colour

20

Headlight switch

Bk

Black

21

Front Brake Light Switch

Bl

Blue

22

Engine Start/Stop Switch

Br

Brown

23

Horns

Green

24

Alternator

GY

Grey

25

Cooling Fan

LB

Light Blue

LG

Light Green

Cooling Fan Switch

Or

Orange

26
27

Pi

Pink

28

Coolant Temperature Sensor

Pu

Purple

29

Igniter

Red

Igniter Pick-Up

s
v
w

Slate

30
31

White

Yellow

Violet

Key To Component Numbers


All major components on the diagram are given a key
number. The following is table must be used to identify
the components.

Ignition Coils

Rear Brake Light switch

32
33

Stop!Tail Lamp

34
35

Battery
Starter Solenoid

36

Starter Motor

37

Oil Pressure switch

38
39

Neutral Switch
Starter Cut-Out switch

Fuse Box

Number

Description

40

Passing Button

Right Turn Warning Light

41

Horn Button

High Beam Warning Light

42

Headlamp Beam Dip Switch

Instrument Illumination

43

Direction Indicator Switch

Tachometer

44

Hazard Warning Light Switch

Neutral Warning Light

45

Rear Indicator Lamp, Right

Instrument Illumination

46

Rear Indicator Lamp, Left

Oil Pressure Warning Light

47

Clock

Water Temperature Gauge

48

Alarm Connection, Sounder

Instrument Illumination

49

Alarm Connection, Control Unit

10

Side Stand Down Warning Light

50

Side Stand Switch

11

Left Turn Warning Light

51

Side Stand Relay

12

Low Fuel Warning Light

52

Indicator Relay

13

Front Indicator Lamp, Right

53
54

In-line fuse, Brake Light**


Float Chamber Vent Solenoids*

55

In-Line fuse - Vent Solenoids*

US California Models Only


** VIN 16922 onwards

16.46

ELECTRICAL SYSTEM/IGNITION 16
20

21

25

2
3

, ;;;;; ;:r,,
~~~mwm

a:~~~

a:

0:

55

a:~>-

"'

-:..:-:~:.:~-==~ I

6
7

10

I
I
I

11

12

L __ __ __ __ I

32

13

"""

~il:

~-- '

50

37

34

~
B
I]J

=Trophy
= Daytona/Sprint/Super 3

!i

= Trident/Speed Triple

Wiring Circuit Diagram


Daytona- Daytona Super 3
Trident- Sprint- Speed Triple

16

1993 Models Onwards


Trophy (VIN 4902 to 29155}

16.47

16 ELECTRICAL SYSTEM/IGNITION

Key To Wiring Circuit Diagrams


The following codes are used to denote all wiring colours
used on the following circuit diagrams.
Where two colours are used, the first colour named is the
principal wire colour and the second colour named is a
trace colour. For example, Bk!Y indicates a black wire
with a yellow trace.

19

High-beam warning light

20

Instrument illumination

21

Left turn warning light

22

Neutral switch

23

Neutral warning light

24

Oil pressure switch

Code

Colour

25

Oil pressure warning light

Black

26

Right turn warning light

Blue

27

Side stand down warning light

Brown

28

Side stand switch

Green

29

Tachometer

Grey

30

Water temperature sensor

Orange

31

Water temperature warning light

Pink

32

Direction indicator switch

LG

Light Green

33

Front brake light switch

Red

34

Front indicator light, left

Purple

White

35

Front indicator light, right

Yellow

36

Hazard warning light switch

37

Relay, headlight cut-out

Key To Component Numbers

38

Headlight dip beam relay

All major components on the diagram are given a key


number. The following is table must be used to identify
the components.

39
40

Headlight dip beam switch

41

Headlight

Headlight high beam relay

Alternator

42

Indicator relay

Auxiliary fuse connection

43

Lighting switch

Battery

44

Passing switch

Fuse box

45

Rear brake light switch

Engine start/stop switch

46

Rear indicator light, left

Carburettor vent solenoid (California model


only)

47

Rear indicator light, right

48

Side light

Igniter

49

Stop/tail light

Igniter pick-up

50

Alarm connection -control unit

Ignition coils

51

Alarm connection - sounder

10

Ignition switch

52

Cooling fan

11

Side stand relay

53

Cooling fan switch

12

Starter cut out switch

54

Horn

13

Starter motor

55

Horn button

14

Starter solenoid

Headlamp cut-out during starting (if fitted)

15

Alarm LED

16

Clock

17

Fuel gauge

18

Fuel level sensor

16.48

ELECTRICAL SYSTEM/IGNITION 16
10

43

33 45

1
7

47

r-r ""'

j=

16

. -

14 .. 0

BIW

GIW .q-f'1'l. 8

--t..EJ=w

7~P/G

: ::

0/K

10

GiW

G/U

8 ~

,_

~=

w- ~

I<=

1~

' -

L......1

d;A

YIB

GIB - - ,

~"'

'--

=- =

49

lr1n
~E

f--

--

A3o

46

GiW

s-----U.....L-

.,=:::r:::-

,----'-, 40

41

m0~

48
41
48

42

"'

+1v \ _

= =I
Gf,A==;~;::::::=::::I----...J
_...,
' ' .......... __ _
--~-:~ I
A '., .: :' .
D' - -'
'.:
i ,_ "
~.
I
I

I
~R ..
: : ... .. - -- .......... ~ ,

~ ~
wz

37

6i

14 _I
------

CIRCUIT HEAD LAMP


CUT-OUT DURING STARTING

Wiring Circuit Diagram


Trophy from VIN 29156

16.49

16 ELECTRICAL SYSTEM/IGNITION
Number

Description

14

Headlight

15

Side Light

where two colours are used, the first colour named is the

16

Front Indicator Light, Left

principal wire colour and the second colour named is a


trace colour. For example, Bk!Y indicates a black wire
with a yellow trace.

17

Fuel Level Sensor

18

Headlight Relay

19

Ignition Switch

Key To Wiring Circuit Diagrams


The following codes are used to denote all wiring colours
used on the following circuit diagrams.

Code

Colour

20

Headlight switch

Bk

Black

21

Front Brake Light Switch

Bl

Blue

22

Engine Start/Stop Switch

Br

Brown

23

Horns

Green

24

Alternator

GY

Grey

25

Cooling Fan

LB

Light Blue

26

Cooling Fan Switch

LG

Light Green

Or

Orange

Ignition Coils

Pi

Pink

27
28

Coolant Temperature Sensor

Pu

Purple

29

Igniter

Red

30

Igniter Pick-Up

Slate

Rear Brake Light switch

Violet

31
32

White

Fuse Box

Yellow

33
34
35

Starter Solenoid

36
37

Starter Motor
Oil Pressure switch

38

Neutral Switch

Key To Component Numbers


A11 major components on the diagram are given a key
1umber. The following is table must be used to identify
he components.

Stopffail Lamp
Battery

Description

39
40

Starter Cut-Out switch

Number

Right Turn Warning Light

41

Horn Button

High Beam Warning Light

42

Headlamp Beam Dip Switch

3
4

Instrument Illumination

43

Direction Indicator Switch

Tachometer

44

Hazard Warning Light Switch

Neutral Warning Light

45

Rear Indicator Lamp, Right

Instrument Illumination

46

Rear Indicator Lamp, Left

Oil Pressure Warning Light

47

Clock

Water Temperature Gauge

48

Alarm Connection, Sounder

Instrument Illumination

49

Alarm Connection, Control Unit

10

Side Stand Down Warning Light

50

Side Stand Switch

11

Left Turn Warning Light

51

Side Stand Relay

12

Low Fuel Warning Light

52

Indicator Relay

13

Front Indicator Lamp, Right

53
54

In-line fuse, Brake Light**


Float Chamber Vent Solenoid*

55

In-Line Fuse, Vent Solenoids*

* US California Models Only


** VIN 16922 onwards

16.50

Passing Button

ELECTRICAL SYSTEM/IGNITION 16

20

21

22

..------

24

2
3
4
5
6
7
8

....

11
12

Gy
Bk/Y

::[1]:

Bk
W =

=q)

BVR

""'

32

' tlK/1 -

RVS

Bk/Y : : t [ f W
G
Bk

-- -----==~

I
I
I
I
I
I
I

14
15

14
15

16

@J=: =QJ..=":"- _]

_43

~====row

'----

38

44

Wiring Circuit Diagram


Tiger

16.51

16 ELECTRICAL SYSTEM/IGNITION

Key To Wiring Circuit Diagrams


The following codes are used to denote all wiring colours
used on the following circuit diagrams.
Where two colours are used, the first colour named is the
principal wire colour and the second colour named is a
trace colour. For example, Bk/Y indicates a black wire
with a yellow trace.

Number

Description

16

Ignition Switch

17

Headlight switch

18

Front Brake Light Switch

19

Engine Start/Stop Switch


Horns

Cooling Fan Switch

Code

Colour

Black

20
21
22
23

Blue

24

Ignition Coils

Brown

Coolant Temperature Sensor

Green

25
26

Grey

Igniter Pick-Up

Orange

Pink

LG

Light Green

Red

Purple

White

Yellow

27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

Key To Component Numbers


All major components on the diagram are given a key
number. The following is table must be used to identify
the components.
Number

Description

1
2
3
4

Right Turn Warning Light

5
6
7

*
**

High Beam Warning Light


Instrument Illumination
Tachometer

44
45
46
47

Neutral Warning Light


Instrument Illumination
Oil Pressure Warning Light

8
9

Water Temperature Warning Light

10
11

Left Turn Warning Light

12

Front Indicator Lamp, Right

13
14

Headlight
Side Light

15

Front Indicator Light, Left

Instrument Illumination
Instrument Illumination

US California Models Only


Not fitted to Adventurer

16.52

Alternator
Cooling Fan

Igniter
Rear Brake Light switch
Stop!Tail Lamp
Fuse Box
Battery
Starter Solenoid
Starter Motor
Oil Pressure switch
Neutral Switch
Starter Cut-Out switch
Passing Button
Horn Button
Headlamp Beam Dip Switch
Direction Indicator Switch
Hazard Warning Light Switch
Rear Indicator Lamp, Right
Rear Indicator Lamp, Left
Alarm Connection, Sounder
Alarm Connection, Control Unit
Side Stand Switch
Indicator Relay

48

In-line fuse*

49
50

Float Chamber Vent Solenoid*


Number Plate Lamp**

ELECTRICAL SYSTEM/IGNITION 16

16

17

18

19
28

21

48

~ e
z

42

YNI ~
25
~

29

B!Y ....q}- B
G

-c[]= w

43

13
14

I
15~~~-;- J

34

31

F
35

Wiring Circuit Diagram


Thunderbird, Thunderbird Sport & Ad ven t urer

16.53

Appendix
CONTENTS
Page
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.1

17.1

17 APPENDIX

TROUBLESHOOTING
NOTE:

This is not a complete list of all possible


problems that may occur. It should only
be used as a guide to more common types
of fault.
Engine Does Not Start, Starting Difficulty:
Starter motor does not rotate
Side stand or neutral switch trouble
Starter motor faulty
Battery voltage low
Starter relay (solenoid) not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch faulty
Fuse blown

Compression low:
Spark plug loose
Cylinder head not correctly tightened down
No valve clearance
Cylinder/piston worn
Piston ring faulty (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
Cylinder head gasket leaking or damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or
carbon build up on seat face)

Poor Running at Low Speed:


Spark weak:
Battery voltage low
Spark plug dirty, damaged, or incorrectly adjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not correctly fitted
Spark plug incorrect
IC igniter faulty
Pickup coil faulty
Ignition coil faulty
Moisture around spark plug

Starter motor rotates but engine does not turn


over:
Starter motor sprag clutch faulty

Fuel/air mixture incorrect:


Pilot screw incorrectly adjusted
Pilot jet, or air jet blocked
Air bleed pipe bleed holes blocked
Air cleaner clogged, poorly sealed, or missing
Choke starter plunger stuck open
Fuel level in carburettor float bowl too high or too low
Fuel tank air vent obstructed
Carburettor mounting loose
Air cleaner duct loose or missing

Engine won't turn over:


Valve seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Alternator shaft bearing seizure
Balancer bearing seizure

Compression low:
Spark plug loose
Cylinder head not correctly tightened down
No valve clearance
Cylinder/piston worn
Piston ring faulty (worn, weak, broken or sticking)
Piston ring/land clearance excessive
Cylinder head warped
Cylinder head gasket leaking or damaged
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or
carbon build up on seat face)

No fuel flow:
Fuel tank air vent obstructed
Fuel filter clogged
Fuel tap clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Fuel level in carburettor bowl too high
Float valve worn or stuck open
No spark; spark weak:
Battery voltage low
Spark plug dirty, or incorrectly adjusted
Spark plug cap or high tension wiring faulty
Spark plug cap incorrectly fitted
Spark plug incorrect
IC igniter faulty
Neutral, or side stand switch faulty
Pickup coil faulty
Ignition coil faulty
Ignition or engine stop switch shorted
Wiring shorted or open
Fuse blown

Other:
IC igniter faulty
Carburettors synchronized
Carburettor piston sticking
Engine oil viscosity too high
Drive train trouble
Brake dragging

17.2

APPENDIX 17

Poor Running or No Power at High Speed:

Overheating:

Firing incorrect:
Spark plug dirty broken or incorrectly adjusted
Spark plug cap shorted or not fitted correctly
Spark plug of wrong grade
IC igniter faulty
Pickup coil faulty
Ignition coil faulty

Firing incorrect:
Spark plug dirty, broken or incorrectly adjusted
Spark plug incorrect
IC igniter faulty

Fuel/air mixture incorrect:


Starter plunger stuck open
Main jet blocked or wrong size
Jet needle or needle jet worn
Air jet clogged
Fuel level in carburettor float bowl too high or too low
Bleed holes of air bleed pipe or needle jet blocked
Air cleaner clogged, poorly sealed, or missing
Air intake duct poorly sealed
Water or dirt in fuel
Carburettor mounting loose
Fuel tank air vent obstructed
Fuel tap blocked
Fuel line blocked
Compression low:
Spark plug loose
Cylinder head not correctly tightened down
No valve clearance
Cylinder/piston worn
Piston ring bad (worn, weak, broken or sticking)
Piston ring/land clearance excessive
Cylinder head gasket leaking or damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn or
carbon build up on seat face)

Fuel/air mixture incorrect:


Main jet blocked or wrong size
Fuel level in carburettor float bowl too low
Carburettor mounting loose
Air cleaner poorly sealed, or missing
Air cleaner duct poorly sealed
Air cleaner clogged
Fuel tank air vent obstructed
Fuel tap blocked
Fuel line blocked
Fuel filter blocked
Compression high:
Carbon built up in combustion chamber
Engine faults:
Clutch slipping
Engine oil level too high
Engine oil viscosity too high
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Gauge incorrect:
Water temperature gauge broken/faulty
Water temperature sensor broken/faulty
Coolant incorrect:
Coolant level too low
Coolant deteriorated

Knocking or Pinking:
Carbon build up in combustion chamber
Fuel poor quality or incorrect grade
Spark plug incorrect grade
IC igniter faulty

Cooling system:
Radiator waterways
Thermostat sticking/faulty
Radiator cap faulty
Thermostatic fan switch faulty
Fan motor faulty
Fan blade damaged
Water pump seized
Water pump impeller damaged

Miscellaneous:
Throttle valve won't open fully
Carburettor piston stuck
Brake dragging
Clutch slipping
Overheating
Engine oil level too high or too low
Engine oil viscosity too high
Drive train trouble

Over Cooling:
Gauge incorrect:
Water temperature gauge faulty
Water temperature sensor faulty
Cooling system component incorrect:
Thermostatic fan switch faulty
Thermostat sticking/faulty

17.3

17 APPENDIX

Clutch Problems:

Connecting rod bent


Gudgeon pin/piston holes worn

Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Spring plate worn or warped
Clutch spring broken or weak
Clutch release mechanism jamming/faulty
Clutch hub or housing unevenly worn

Valve noise:
Valve clearance incorrect
Valve spring broken or weak
Camshaft bearing worn

Clutch not disengaging properly:


Clutch plate warped
Clutch spring tension uneven
Engine oil deteriorated
Engine oil viscosity too high
Engine oil level too high
Clutch housing frozen on drive shaft
Clutch release mechanism faulty
Clutch hub locknut loose
Air in clutch fluid line
Clutch fluid leak
Clutch fluid deteriorated
Master cylinder primary or secondary seal damaged
Master cylinder bore damaged

Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken or stuck
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner faulty
Camshaft chain, sprocket, guide worn
Balancer gear worn or chipped
Balancer shaft position incorrectly adjusted
Balancer bearing worn
Balancer or alternator shaft cush rubber damaged

Abnormal Drive Train Noise:

Gear Change Faults:

Clutch noise:
Weak or damaged damper springs
Clutch housing/friction plate clearance excessive
Clutch housing gear worn

Does not select gear; pedal does not return:


Clutch not disengaging
Selector fork bent or seized on shaft
Gear stuck on shaft
Gear detent arm binding
Neutral detent arm binding
Gear change return spring weak or broken
Gear shaft seized
Ball joint seized
Gear change shaft broken
Selector drums pawl broken

Transmission noise:
Bearings worn
Transmission gears worn or chipped
Engine oil insufficient
Drive chain noise:
Drive chain adjusted incorrectly
Chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned
Chain rubbing strip damaged

Jumps out of gear:


Selector fork worn
Gear groove worn
Gear dogs and/or dog holes worn
Selector drum groove worn
Gear detent arm spring weak or broken
Selector fork pin worn
Input shaft, output shaft, and/or gear splines worn

Abnormal Frame Noise:


Front fork noise:
Oil insufficient or too thin
Spring weak or broken

Overshifts:
Gear detent arm spring weak or broken
Gear change spring abutment bolt broken

Rear shock absorber noise:


Shock absorber damaged
Bearing seized

Abnormal Engine Noise:


Knocking:
IC igniter faulty
Carbon built up in combustion chamber
Fuel poor quality or incorrect grade
Spark plug incorrect
Overheating

Disc brake noise:


Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper faulty
Other noise:
Brackets, nuts, bolts, etc. incorrectly mounted or
tightened

Piston slap:
Cylinder/piston clearance excessive
Cylinder/piston worn

17.4

APPENDIX 17

Oil Pressure Warning Light Comes On/Stays


On:

Shock absorption unsatisfactory:


(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Tyre air pressure too high
Front fork bent
Suspension settings incorrect
(Too soft)
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
Suspension settings incorrect

Engine oil pump damaged


Engine oil screen clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearings worn
Crankshaft bearings worn
Oil pressure switch faulty
Relief valve stuck open
0-ring at oil pipe in crankcase damaged

Exhaust Smokes Excessively:


Brakes Poor, Not Working:

White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Engine oil level too high

Air in brake line


Pad or disc worn
Brake fluid leak
Caliper seized on pins
Caliper piston seized
Pad jammed in caliper
Disc warped
Contaminated pad
Brake fluid deteriorated
Master cylinder primary or secondary seal damaged
Master cylinder bore scratched

Black smoke:
Air cleaner clogged
Main jet too large or fallen off
Choke starter plunger stuck open
Fuel level in carburettor float bowl too high
Brown smoke:
Main jet too small
Fuel level in carburettor float bowl too low
Air cleaner duct loose
Air cleaner poorly sealed or missing

Brakes Judder or Snatch:


Disc warped
Disc loose
Caliper mountings loose
Caliper pins loose/bent
Pads incorrectly fitted
Disc or pad contaminated
Floating disc bushes seized/worn

Handling and/or Stability Unsatisfactory:


Handlebar hard to turn:
Steering stem adjuster nut too tight
Bearing damaged
Steering bearing lubrication inadequate
Steering stem bent
Tyre air pressure too low
Cables/wiring/hoses trapped/binding

Battery Discharged:
Battery faulty (e.g., plates sulphated, shorted
through
sedimentation, electrolyte level too low)
Electrolyte contaminated
Battery leads making poor contact
Load excessive (e.g., bulb of excessive wattage)
Ignition switch faulty
Alternator faulty
Wiring faulty

Handlebars shake or excessively vibrate:


Tyre worn
Swing arm pivot bearing worn
Rim buckled or not balanced
Wheel bearing worn
Handlebar clamp loose
Steering stem adjuster nut loose

Battery Overcharged:

Handlebars pull to one side:


Frame twisted
Wheel misalignment
Swing arm bent or twisted
Front fork bent
Right/left fork legs unbalanced (oil level, adjustment
settings)

Alternator faulty

17.5