~JTRIUMPHI

SERVICE TRAINING NOTES

FRONT
SUSPENSION &
STEERING
TRIUMPH 2000
 ~TRIUMPH
-~--

.1) 8! ':> "'1T~ ','-' T~.

011 11

-,
GROUP SAkES ANO SERviCE TRA ~ING cn"Tflf
rYl"'~" ""lTO~ ~CR ("" I
~'::>fO!'Il. cO\'[tiTott t"Gv.
 l:iTROIlUCTIIl:i

Thi. boc>~ 0,," ;!I o«ompanylng fllmot";p ,ho", m.

..... in f.o'.,", 01 ,h. f,on' Su,_,i"" ond S,... in9 /;".d
'0 ,h. Triumpl. 2000.

Po" On. f,,,,,, s"'p-o,i",,

P.., T"o Rod ood Pinion S, ... ing
Po,' Th,•• f,,,,,' End Ch.cking
It i. in'end.d ,h., ,h. fll ..,,,;p .ho.ld lorm ,h. bod.
b"". 01 0 I"".,". TM ,ubl.e' ..,,,.. COn b•• Iob.... '.d or
.bbl•• i.,.d t. ,uit 'M ,'.ndo,d 01 ,h. oudieoe•.

Tho 1>ookl., by 1...11 O'ovi&... h.n~y pock., ""'0.... 1

I.....dy ,el.,ence.
 mIUMl'1 ?lMN
'e-
. . 1'.,
- ----j",

,
FRAME 10101.

PART!
FRONT
SUSPENSION

PART l.

FRONT SUSPENSIOtl

T'" T,jumph 2000 ,u,pon.i",,;, ~n_n .. ,k. , ..,,;c.1

,t<ut typo.

Tk. o... mbly i. buil, ,0..0<1 th.....,';cal liok "".

c"",j." of t'"
lollowiog:_

o. V.."icol Illu' .... mbly

FRi.ME !'lo. 2-

COH'~HSltlG
S'~ltlG eHO~E
~[HOVltlG

vEOnC.. l SHUT
.. SSEHel y
f~OH C"~

SEP/l,RATING MID REMOVING OF

SPRING /l,ND DAMPER UNIT

Thoro 0'0 ,''. woy. of 'oc'I;"Il ,hi. job.

MEHIOo 1.
I. Jod"p tho fr..., 01",0 cor 0' ",0 cono<' jocki"ll
poin' g".j ,om""" tho ....... 1.

•
2. PIGc.o ,,""... j.c~ ""..., 'no .d,hb"". O' dou'"
.n•••"ieol I;"~ a. p""ibl. 0'" •• mG•• ioc~ ItG..
vn.... ,h.
\><>dy.

3. Apply a I"". "" 'h. I,,,,,, wing which will cou •• ,h.
'~'ng '0 com"' ....

4. Fit a.",chill,~ing clip S.)2\I. a•• nOW" a...t ,.1.0"

,~.

6. Ro",,,,,o,,,," It C<J< by '.'Gching ,h,•• I<o<;a';"g n"U

0' ,h. 'Gp "". I /i.i"g b"l .. ,,' ,h. OGttam.

!'lOTE:
By c"mpto .. ing ,h•• ~'ng hoi... ,o.,,,,,i"g .n. ani,
It.... , ... co, ..... ,h. u.. G! """.n... ,,,,,dol ,..,1
which ",ill b. ,hown in .,.,.04 2. F'G'" N" 3 I..
'.""'G'ing tho dGml"" f<cm 'ho .~i"g.

,
FRAME tlo.3.

CHU.CHlll HA"'O . . . . . ' ' ' ' ' A

"OAno., '''''A, I
' •• ''''C cu. I"•

••
, COH ••",""'C ' •• '''C
A,fn
"HOV,,,,, vuncOl
,nUT A"EHIlY
'.0.. C".

~EPARATltlG AtlD REMOVING OF

SPRING AtlO DAMPER UNIT

1. Jock up rho h.", of ,h. cor 0' rho conoc, 10cld";

poin' ond r.""",. th. wh•• I.

Continued

•
2. R... O". ,h.
I"", bo"o.. I""G'i"~ bGh. wi'" ~i"G"c.
pi.c. If_ the d."'l* ....mbly Gnd .. p'''G'. it f",..
tho , ..tical lin•.

3. R• ." .... ,h. ,op ,hr•• o"""h... <tt nu" o"~ "i,hrl.o"
,h. uni' fro.. ,h. co,.

4. C.mr..... ,h. opting by ",ing Churchill Hand Pr...

$.4221,\ on4 .dop,OI' ,., $.4221,\_5. I;"in~ ,pri"ll
cI;05.320., .ho ... n. I' i ••••• ",;ol '0 u,. ,h••• '001,
I", ,h. ,ol.,y of ,h. m.chanic.

5· R.mov. ""i' f'om hood pr .... "i'hd'aw .plit pin,

••"'0". ,.".lla,.d n"'. th." "i,hd.. w 'op ...,.Io"i<
OI... "';ng ""h "a.h." .nd opting.

,
FRAN! 14•.••

Th •• ,,_ .t.-. f!w <_ _

It_ •••,.....;......... 1,•
8', !!Ho. _kG .p ....

•
FRAME ~o. S.

VERTICAL STRUT ASSEMBLy]

1. Tho d• ."r>o' i. . . . . 10<1 ..,i,.od <on'.in< ,h. ,.b....

<lOp.

2. Th.... ;ng i< !;.0<1 M''''"" •• "'po' body .n••• "'r>o'

.<'''''''ing .od.

C"",jnuo<l

,
 •. Moh ..... g.I•• , I. <••".etly po."'on.d ..., 0<"
""""Il
,0<1 bof... fi"i"ll .",Ing ....mbly.

b. A... mbl.... Ing .n'. d.m I,h .",Ing ..'.ining

pon ond 0 ,ub...... 01 ••• i,h nd of .",Ing.

c. FI, ..... I ....h.... im "l>"' .h.ped h.I••

d. A.....bl. " ••1.1•••• In' ....,.I... ic ,ub"', bu.h

.nd fit "'. , cno,.d ,ab ~·a,h." In•• "".ilion
.. I,h g..a ~I"Il .u.. ,h. P.T.F,E •• urlac .....
lacing .u' d••

•• Plac. o.u .. b1. in'a .a,IIl on, fi, .,.. 1 " •• h" .nd
figl·'.n coo,.llo'o<I nut ling•• tighl, th.n "",k•• u"
'r:<I"Il coil .nd. . . . I....,d. m.~h •• 1 I•••oid
po .. lblll,y.f .",i"ll f...,ling I>ody

f. Ti.h,"" ca".lI.tod nu' 'a 16 _ \8Ib. ft. 12.2 _ 2.S

kg/.. l.nd ..c...... i!h .pli' pin.

'"
 FITTING VERTICAL STRUT
ASSEMBLY INTO POSITION

1. Thot""lIhly <I.~n,h. in,id. of ,h. f,,,,,, ,poinll 'u".,

hou,lnll, ,.'n''''nll .11 diu .nd .Id '.oli"li <ompouno,

2. Apply 0 ,"'ip 01 ,001., "rip ,""nO ,h. too l""o"nll

f1~nll. of ,h. ,."i<~1 ,,'u,.( T~oI.ft olc"... ).

C"""n......

"
HOTE. $o.li"" I. I.,,,,,,••M ......'.e. be"'ing .ud.c.,
f,,,,,, di".
3. Po.llion .h. o bly in" tIo. I""., ond 100•• ly
o"oc~ ,~. ,~, c",i ... nu".(Top 'igh' Pi<'u,.~

4. Po.itlon ,h. bo"o," .nd 0/ ,h•••"icol "'u' '0 ,h.

"""01 link .nd ,.,u,. 1"..1, I. ""'ilion with 10...
bol .. , locking wo.~." and a dl.,on,. pioc. on .oe~
.1 ,h. ''''0 .op bol" b.'....." "'fieol lin' and or,",.
(80Ho," pi, .... )

5. Fln.ll, 'ighl.n tho 'op .. ,,,,Ing nu" ." .... ing ,h.,
,h. boo.d.d .""~ wop i' in ploeo.
FRAME No.7.

PAn"

PART 2.

RACK AND PINION STEERING

T~;.
n. ;,'""
Iro"'" .~ow. m.
,ook .n.
pinion " •• ';n~ unl••
.how. ,~....... 'ng box ;n grn'.r •••• ,1.

In Iro.... 9on. 10 ,~ .... mod o! odlu'''og ,~. p;o;on

at>d plunger ;•• hown.
FRAME I'l •. a.

MACK AND PINION

STEERING

Th;. fr.",," .how. ,h. or,.....",.n' .f 'h. ,.,~ .nd

p;n;on " ••"""
Th.....mbly I. ,,,bb.,, ",oun'•• ,. til. Iron, <""•.
mo",Oo' ,. ,odLIC. ,00<1 .hoc •••
 FR ....... E No.9.

ADJUHlNC "N'ON
'ND flO'"
..... ~ "001'(0]_.'

T~o lollow'n; proc" ...o ,h""ld bo <o<t;od ""' whon

odiu",;n; pi";"" ond 1100'.

I. F,! ,ho p;n,"" ;n,o "".ili"" w;,h '.'o;n;n; <in; .. inu,

·,,"0" dog OM no ,h, .. ""d. Thon Ii! <"clip.

"
2, So, 0 d""k ~ou~ "" ,h •• ad of ,h. pia,,,,, • .",h nod
ch.,k ,atol.oo'f1"",.

J. Mo~ •• p 0 .hi""",,~ 100 .. 'ho ,... 0 ';'0. ovo,loblo

0,004"(0.10 .... ) ood 0.010" (0.2S .."') '0
~;v •.
",in;","", <10",00<0 ",dh h .. '0'0';"".

~. Fi' .k;",,,,,,,k, .. ,oin;og dog lit'od ... ;,h""", "0"

'ing, '),.0 n ... ",bl. ond ..c"•• in h."".;"ll ... i,h 0
c;,d,p .

..
FR..I.ME tlo. 10.

Til. foll_i~ ptoc.d",• • h.... kl .. co"i.o out ... h."

aojo"ing '00' plong.' .",moot.

1. Fi, ,h. pt.".,. pod and 000 no', rh.n oc,.'" d"","
by hond a. fa, a. p"' . . ibl•.

C.."in<>O<l

"
2. W;,~ f•• I•• ~0"li.' "'0"". ,h. <I.or.n<o 0.,,,,••"
,~. ~i"i"" ho."in~ oM ,h.loc. of ,~. cop nu'.

3. R... ov. cop 0",. ,h.n "",k. up ••hi.. ~o<k .~""I '0
,h. d.or""c. "''''''UfO<! ~Iu. 0.1Xl.l" (0.10 .... 1.

4. R.pl.c.<o~n'" wi,h .h'mpod • ..d 'p"ng th.n 'i~h'.n

ou'lully.

HOTE. Tn. ,.ok no'" ho •• "'...... n' 01 0.004 "(O.l~",).

 FRAME Il •. '1.

C~E(KING R~(K PLUNGU

LOAOING TO PINION

..... ,-

' .......i.
•' =-'

Wi,~ ,~. '"'~ .~d pi~i"'"...."'bl.d m.k•• 1i~.1 eh.d ,na,

'ho ',,"ning I" •• ,.~ui,.d ,. ,a','. ,h. pini"", d... ~ ..
•" ..d 2 lb •. (0.9.kg.) p~II.,. ,.di~•• f 8"(20.3 .•. ",.)

If ,h. f,,«. '0 ,.,.,. pini"", . "••d. 2Ib •. (0.9.~g)

odd .~i",. ,. pl"ng.. eo. n,,'.
If ,h. f"oo ,. '.'0'. pini"n i. I... 'h.n 2 lb •. (0.9
~~. ).ub',,,,,, .~;",. f,.m plunge< eop ~""

IlOTE. Do ~., u.<.d 2 fb •. (0.9.'g.).

~RMlE N. 12.

1. A... mOI. tho 1>011 i.lo" wi'h ••hlmF>O<k io oxeo ..

cf ,h.
'.qu;,ed ....uo,.

C... tln... d

'"
2, \lI;,~I .. I., g~ug .. "'"~."'•• h. gop bo'",•• n ,h•• 1....
nu' Ilong., .. w lock '00 ond COp nu' f~<o.

3. Mo~. up ~ .himpock of 'hidn ... O.lX)2" (O.OS ... )

Ie.. I~~",h. gop .... o."..d 10 gl •• C""''' boll jo;n'
odju .....n'.
4. C~.d foo I,..do," of mo.....n' "~.n ligh' Mnd p...
.. "'. i •• pplied.

"
FR"""E No. 13.

"'hon fi";n~ tho ro,k.ndp,nio;' .... mbly '0 'ho Cf...

mOm.. , i' ;, imp"".n! ,h., ,h. f.II.~i"V d.,.d, .ro
.".ndod ,.:_

I. Fi' ,h. rub.., bu,h., t. tho rock 'u" ..,k;nv .....

'h.y or. c'"".";ng ,h. fI.og ...

Conhn..-d
2, Fi' "u" bolt ""i' ift po.i,ion ""d 1 ly •..:...
wilh plo,.. ""d nyloc "0", En."" ,hg' lip d. ,Iott.d
plo'" .. ok. <""'0<' wi'h 'M", .dg•• 01«0 be, .

:l. COllI""" hOlh" U" bolt. O<!tword. 0> for g. po"'bl.

ood 'igh'.n "~". Th. '""", .. "..""",,'ed _"m.n'
g'.i,h... flo..... i.lIS"13.2mm)
 (fIITULJSIIIG tACIt JOt COllllrolll'
TO SUUIII<; CMU""

_.........
- .... -- .
~"''''CATION

1."',,,_ _-..', _,.,

,. ,... -

..... the ~;,,_. Xy '"

_~I
.i_.11'. . ..,.......
..."... ....'"'B.ing the 'ed "'.

do., •• _1 Ie Ieoottlo
of the
<_I
1••• _
,.d ....

"""
..,.1
.,' I.- _i'"
the .,_
,.....,-.
_ I Ie ....

"
!'lOTE. Tile do"... Ii",," X .. i, '0 tho inn,", fo<o.

To I"b<ic.'. ,h. 'o,k .n" pin'on ,~. foll.",i1\9 pta-

,.d",. ,h."ld" ca"i •• 0"':-
1. R.m"". pl~ ond fit gr.... nippl••

2. Po.ition Iron' wh.. I, a, foll... o:_

Fat R.H. ".,""n~ tho 'on•• I, ,"uor .. ""n.d .n<l

h.ld on fulll.h loc~.

Fat L.H. "_in~ ,ho .. ~ •• I, ","or 00 , ... ""d .nd ~.Id

on 1"11 ri~h, l<>ck

!'lOTE. Thl' pt<>c.d..... n'",., ,h., 51'. . . . ;, f.«.o al""g

,h. ,.d ,"00 ,. lul><;ca'. ,h. rock ,"b. bu,h., and
appg,". balll.;n'.
 PART 3

fRONT ENO CHECKING

B.l",. <... ,~;ng ou' on~ f,,,,,, .nd ch.c~ing ,,,.

folio.. ;..... d.'ail. m"",'" .".nd.d ,.:_

2. Hub b••" ....... nd oil hod ,od I;n~.g. f, .. It_

<ACO • . , •• play,
3. V.h ic I. i" 0 "g';C 1.0." c""d ;';"" 15011. •. (68 kg ) 1'0'
••ot.

5. Ty'. po.""''' corroe'.

TYRE SIZES AND PRE5SURES

Dunlop C.41 6.50_ 13

F'''''' <>nd ••'" 14 Ib •.• ~.ln. (1.7~g•• q.c .. )

Dunlop SP41 175 _ 13

F< ... , ond ,.'" 26 lb •• ~.in. ( 1.8 ~g .• q.cm.)

"
FR.lIME He. 16.

w,'~ 'ho <0' <""o<.ly p".poo.d I.. <~0<~;"11 wn•• ,

.I,,,,",.n.,t~. lollow,nli ..,,'nod .~ .... Id bo .,o"p'..I:_

1. C..".I ••• 'ho ...... "11 wh..11>y <"""'.'nli .... n.... boo
01 ...... 1<... lock ." lock, ..... ' ........ wh.. 1 Ioack
""If 'ho .",.1 .-.•.

c.... ,.....,j
2. 0-:\ !he VO"ll. lot K<W""Y •••- . . I. I......
3. P••I,,_ . 1 , - , VO""' k. ,Md"'iI"
•. II ..1 ,. , _ , ;. """' _ 1..k_
1M ,.1..- <I,,,, "'- .Iec:\ tIM Iec:\ ~ .... _
"'""" ...... ,..I •.
So J.li."""" ....d •..1 ••_ , . _ c.."", ....-
lot, 1101 •• 1/16"( 1.6_1_ .

6. T lec:k """, ... <heck ""'" " ..,... ,w"""

..',.. <11 .
HOTE, R...dl ol.""l~ boo ••k... in Of I , tN•• dll·
I...., "".;.1 ,he ,",,001., '0111 tho Y.Io.
1<14 I..",... f <~ .",,< 1•• ,.odl"i!' The
.... ~g. <>! ,he ,• ..11... " boi"ll d.
FRI.ME 1l0.1].

Whon '100 <a, ;, «,,,o<.l y ",.pa,•• 10«ho<~;"iI ......

1<Ill link"". ,h. 1011owl"ll ... ,hod ,10",,1. b. ""o,,,.d.

1. Po.I.I"" .h. Ir""• ..nul. «n!tolly On ° PO" af '",n·

'''II ,odi~. ~o~~ ...
1l0TE,
(0) Pac. ,h. ,ota, "hul. '0 ..... 0... h.igh, a .....
,od;~. ~O"~ .. '0 ~ •• p ,h. <or potoll.1 '0 'ho
;rwnd, "'1. I. . . . ."'101 fOf .h. 10'.' .'o~••
"Io.n <Ioo<~;"g eo",b., ond co .....
 (b) Apply foe' bto'. and fl~ ;, f", all ,h.d •. ,hi.
po....... ,h. fton' ...h. . l. f,o", ,ototinll ~h.n
,,,,"ing tho ,odiu, goug...

Ie) Wh.n ''''ning ,h. ~h•• I, hOI loc~ '0 loco. u'. ,h•
..... 'ng ...... 1 ono hold ;, ot xf~hil. ehook i,
w;ng mod.

2. ....I'h 'l>o ~heol. in ,h•• "illh, oh.ad p,,,ition '.'0 ,h.

goug.'.

J. T...n 'ho "~t-hond ",h•• I 20·"el< I.ek and choek

'hot ,h. ,,,,,d;ng 01 'ho 1.It...o,," ~h.el I. 19·fto n'
lad. Th.n ,ov.".
,h. pooc.d .... o...l .b..... ,h.
,.od;ng ..... ,h. ,igh'.hond ...h•• I.
1oI0TE,
0
If 'he d;II.'.n<. ;..."'. 'han 1 ,h. lollowing 1"""
.hould bo ch.,'od.

o. Ou,.. "ocl< ,od, "".quol in I.ng'h.

c. S'ub .,1. b.n'.

FRAAlE N~. lB.

CUTOR, CAMBER AND

~.P.l. {HE(~IHG GAUGE

Thi. I,~ ..how. tho 'II.av•• Ca,'''', Co",;", ~O~

K.P.1. 1l~"II hi<h <"".i." of tho loll.... ioll PO'" ,-

o. Di"on<. Wa.h.,.

b. ".apr...
 Th.~i"~""."~,,,,, i. v,od 0., ....... ,h. hub bo"""li
h"",i"l! ~n~ "dGpOor '0 hold ,h. odop'or in ,h. '0"" plo ..
0' ,h. "vb 0.1 •.

Th. odop'or i, h.ld in oo.i,i"" by,... c1".., gripping

,ho,hr.o~ 01 ,h•• 'ub oAI. b.,...." ,h. c~ .. il",i"",
of ,h.
hub "u,.
It i, i",p""o", '0 , •• ,ho' ,h. ,plit pin d... ne'
ob ..,u<' ,h. !,tling of ,ho odoptor. if i' d... ,h.
,plit pin
,"v.l bo ,.",,,,,ed ~nd ,oplo<od wi,h 0 now pin oft.. ,h.
<hod, f",v. bo.n "",d•.
 .~ .
B.I... 0"1 chock. <0" . . . . . . . . th. ;0"11" ... " "-
c .... ,'I, "",,11....~.

~. ...~I~" II;.P.1. , . ." Je..el I. 1lIol It ,. 110'" • ,Ih 100M .

CAMBER CHECK

b. Tok • .Ii,... , ,oodlng of combe, off 1.11 han<! .col•.

Th. c"".c' cam"-, ongl. i. lo 0 ... g.

CASTOR CHECK

a. T,,"n "h... l. 20'bod lock and "'0 ,h. bubbl. "" ,h.
,igh' han<! .cal •.

b. T,,"n "h•• I. 20' f,on' lock gn<! '.0.1 ,h. ca.'''' gngl.
fro.. ,h. ligh' h""d .col.

Th. c"".c' co"" angl. i. 2'1,' po.i'i,•.

STEERING AXLE INCLINATION IK.P.I.

Th ....,hod i. tho
.hauld 1>0 ,""d.d "0' 0'
'ho
.0_.0...
a. f.. ,h. co"'" ch.ck and
,I""" ,ooo,"li ,h. K.P.I.
ongl. on tho 'op 0<01••

C""tlnuod
 .... ,h •• <01. only r..,d, '0 8' .Ithe< "'o~ oM ,h •
..... I"lI IncloM,ion i. \1~'0 .l;gh,l~ dlff.ren' f"oc.dvr.
h•• '0 b. odop,.,j.

1. T"'" ",h••12O\ock I.ck

2. In ...od 01 •• "lfIlI ,h. bubbl .... 0·, •• , bubble ,,, 5'
('o"'.rd. ,h. Iron' 1th.r. i. ,h." "" .~'."ded "01 •
•oocIlng 5"0 0 ,,, 8"" 13'
3. Turn ~h •• I. 20'''..., lock.
4. R.od ,c.l. ~hlch .h"uld "od 6~'if ....ring 10cl'".I1...
1.<"... "(II~·).
~TRIUMPH

'"