Page 1 Table of Contents Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaft Bevel Box and Drive Shaft Balancer Transmission Lubrication Engine Removal and Refit Fuel System/Engine Management Cooling Rear Suspension Front Suspension ' . , Brakes WheelslTyres Frame and Bodywork Electrical System Service Manual - Rocket III...
Page 2 This page intentionally left blank Service Manual - Rocket...
Page 3 Introduction Service Manual - Rocket III...
Page 4 Rectify all problems as soon as possible (immediately if safety related). • Use only genuine Triumph parts as listed in the parts catalogue/parts microfiche. • Follow the procedures in this manual carefully and completely. Do not take short cuts.
Page 5 Triumph parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification.
Page 6 Introduction This page intentionally left blank Service Manual - Rocket...
Page 7: Table Of Contents
1 General Information Table of Contents Ignition System Safety Precautions ........... Dangerous Susbstances.
Page 8: General Information
General Information Replacement Parts ............1-10 Service data 1-10...
Page 9: Ignition System Safety Precautions
Fluoroelastomer material is used in the manufacture voltages. Do not touch any part of the ignition of various seals in Triumph motorcycles. system or any cables while the engine is running. In fire conditions involving temperatures greater An electric shock caused by contact with the ignition than 31SoC this material will decompose and can system may lead to illness, injury or death.
Page 10: Environmental Protection Precautions
Burning of used engine oil in small space heaters or such conditions and remedial action must be taken boilers can be recommended only for units of by your authorised Triumph dealer before riding the approved design. If in doubt, check with the motorcycle.
Page 11: Safety Instructions
General Information Coolant Never use mineral based grease in any part of the braking system or in any area where contact with Coolant mixture, which is blended with anti-freeze the braking system is possible. Mineral based and corrosion inhibitors contains toxic chemicals grease will damage the hydraulic seals in the which are harmful to the human body.
Page 12: Cleaning Components
General Information Cleaning components Liquid gasket, non-permanent locking agent A high flash-point solvent is recommended to reduce Follow manufacturer's directions for cleaning and fire hazard. preparing surfaces where these compounds will be used. Apply sparingly as excessive amounts of sealer Always follow container directions regarding the use may block engine 011 passages and cause serious of any solvent.
Page 13: Locking Devices
Always use the correct replacement circlip as recommended in the Triumph parts catalogue. Ball beari ng When installing a ball bearing, the bearing race which Self locking nuts...
Page 14: Petrol - Gasoline
(this includes any appliance with a pilot If the motorcycle is involved in an accident or light). Any lead-lamps must be flame-proof and kept collision it must be taken to an authorised Triumph clear of any fuel spillage. dealer for repair or inspection. Any accident can...
Page 15: Electrical Precautions
General Information Electrical Precautions connectors apart either by using tools or by pulling on the wiring itself. Always ensure locking mechanisms The following guidelines are intended to ensure the are disengaged before removal and note the safety of the operator whilst preventing damage to the orientation to enable correct reconnection.
Page 16: Electrical Wires
Triumph Replacement Parts parts. All genuine Triumph parts have the full backing of the motorcycle warranty. Triumph dealers are obliged to supply only genuine Triumph recommended parts. Only Triumph genuine parts should be used to service, repair or convert Triumph motorcycles.
Page 17: Service Tools
General Information Service tools 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.
Page 18 General Information T3880250 - Diagnostic tool T3880200 - Pulier - alternator "',, T3880201 - Anti-rotation jig - alternator T3880061 - Extractor, liners 3880025-T0301 - Clutch anti-rotation jig T3880062 - Castle wrench - 38 mm 1.12 Service Manual - Rocket...
Page 19 General Information T3880064 - Drift, swinging arm bearings T3880063 - Castle wrench - 31 mm 3880090-T0301 - Fork service tool 3880085-T0301 - Fork assembly rod T3880067 - Fork spring compressor T3880202 - Cam timing jig C=:::r=:::::R !lilII@IIIIIIIIiIIIE:I!=:1:==J ""!l' ""!l' 1.13 Service Manual - Rocket III...
Page 20 General Information Full Specification Rocket III Engine · 3 Cylinder 12 Valve DOHC Arrangement · In line, longitudinal, Displacement · 2294 cc Bore x Stroke . . 101.6 x 94.3 mm Compression Ratio · 8.7:1 Cylinder Numbering · Number 1 at front Firing order ·...
Page 21 General Information Full Specification Rocket III 23.000 - 23.021 Camshaft Journal Bore Dia mm (std) Camshaft End Float 0.10 - 0.13 mm (std) Camshaft Run-out. 0.015 mm (std) Camchain Tensioner Spring Free Length 73.7 Clutch/Primary Drive Primary Drive Type Gear, with backlash eliminator 1.034:1 Reduction Ratio ..
Page 22 General Information Full Specification Rocket III Connecting Rod Big End Dia · 44.000 - 44.009 mm (std) Connecting Rod Big End Side Clearance .. · 0.15 - 0.30 mm (std) 0.50 mm (service limit) Crankshaft Big End Journal Dia · 40.946 - 40.960 mm(std) 40.922 mm (service limit) Crankshaft Big End Bearing Clearance ..
Page 23 General Information Specification Rocket III Full Oil change only 5.1 litres Recommended Oil Approval Rating API SH (or higher) and JASO MA Viscosity 10W/40 or 15W/50 Type Semi or fully synthetic Oil Pressure (in main gallery) 3.00 - 3.60 Bar at 3,500 rpm Oil Pump Rotor Tip Clearance 0.15 mm (std - both pumps) 0.20 (service limit - both pumps)
Page 24 General Information Full Specification Rocket III Cooling System Capacity · 3.2 litres Radiator Cap Opening Pressure · 1.2 bar Thermostat Opening Temperature '" 85° C Cooling Fan Switch On Temperature Temperature Gauge Sensor Resistance ....1870 at 100°C Suspension Front Fork Travel ....
Page 25 General Information Full Specification Rocket III Rear Wheel Rim Axial Run-out. 0.5 mm Rear Wheel Rim Radial Run-out. 0.5 mm Rear Tyre Size 240/50 Rear Tyre Pressure (cold) 42 Ib/in' Rear Tyre Tread Depth min Over 130 kmh - 3 mm (or minimum legal limit, whichever is greater) Under 130 kmh - 2 mm (or minimum legal limit, whichever is greater)
Page 26: Torque Wrench Settings
General Information Torque Wrench Settings Cylinder head area Application Torque (Nm) Cam cover to cylinder head Cam chain tensioner to crankcase Cam ladder to head See text Camshaft sprocket to camshaft Cam chain tensioner blade to crankcase Cam chain top pad to head See text Cylinder head to crankcase See text...
Page 27: Transmission
General Information Transmission Application Torque (Nm) Detent wheel to selector drum Selector drum bearing retaining screw Spring abutment bolt Gear change pinch bolt Gear change pedal pivot bolt Input shaft bearing retainer to crankcase Output gear to output shaft Lubrication System Application Torque (Nm) Sump to crankcase...
Page 28: Fuel System, Exhaust System And Airbox
General Information Fuel System, Exhaust System and Airbox Application Torque (Nm) Fuel tank to frame (pivot bolt) Fuel tank to frame (front fixing) Fuel pump mounting plate to fuel tank Fuel pump clamp screw Throttle body transition piece to cylinder head Exhaust headers to cylinder head Exhaust headers to cat box clamp bolt Exhaust cat box to frame...
Page 29: Front Brakes
General Information Front Brakes Torque (Nm) Application Calliper to fork Pad retaining pin (hexagon drive) Calliper bleed screw Hose to calliper Master cylinder to handlebar Hose to master cylinder Disc to wheel Fluid reservoir to bracket Rear Brakes Application Torque (Nm) Calliper bleed screw Hose to calliper Master cylinder to frame...
Page 30: Bodywork
General Information Bodywork Application Torque (Nm) Engine to frame bolts See text Front mudguard to forks Front mudguard finisher to mudguard Rear mudguard/covers to frame See text Rear seat to mudguard Side covers to frame Engine infHI panels to frame Electrical Application Torque (Nm)
Page 31: Routings
General Information Routings Clutch Cable Routing ccjy 1.25 Service Manual- Rocket III...
Page 32: Handlebar Cable Routing
General Information Handlebar Cable Routing 1.26 Service Manual - Rocket III...
Page 33: Main Wiring Harness Routing
General Information Main Wiring Harness Routing 1.27 Service Manual - Rocket...
Page 34: Rear Mudguard Harness Routing
General Information Rear Mudguard Harness Routing -------- .-:-------- ....... " ccjn 1.28 Service Manual - Rocket III...
Page 35: Front Brake Hose Routing
General Information Front Brake Hose Routing 1.29 Service Manual - Rocket III...
Page 36: Rear Brake Pipe And Hose Routing
General Information Rear Brake Pipe and Hose Routing 1.30 Service Manual - Rocket III...
Page 37: Throttle Cable Routing
General Information Throttle Cable Routing 1.31 Service Manual - Rocket III...
Page 38 General Information 9 non-evaporative emISSion control Fuel Hose and F uel Tank Breather Hose Routin ( versions) 1.32 Service Ma Rocket III nua -...
Page 39: Fuel Hose And Evaporative/Fuel Tank Breather Hose Routing
General Information Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing 1.33 Service Manual - Rocket III...
Page 40 General Information This page intentionally left blank 1.34 Service Manual - Rocket III...
Page 41 2 Scheduled Maintenance Table of Contents Introduction............... Scheduled Maintenance Chart.
Page 42 As authorised Triumph dealer carry out the scheduled only an authorised Triumph dealer will have this maintenance of this motorcycle. knowledge equipment,...
Page 43 Scheduled Maintenance This page intentionally left blank Service Manual - Rocket III...
Page 44 Scheduled Maintenance Scheduled Maintenance Chart Odometer Reading in Miles (Krns) or time period, whichever comes first. Operation Description Every 10,000 20,000 30,000 40,000 50,000 60,000 (800) (16000) (32000) (48000) (64000) (80000) (96000) 1 month 2 years 3 years 4 years 5 years 6 years 1 year...
Page 45 3 Cyl inder Head Table of Contents Exploded View· Cam Cover............Exploded View - Camshaft and Cam Drive.
Page 46: Exploded View· Cam Cover
Cylinder Head View - Cam Explode Cover 10Nm ' § " I - Rocket III Service Manua...
Page 47: Exploded View - Camshaft And Cam Drive
Cylinder Head Exploded View - Camshaft and Cam Drive '(O~ 27Nm 18Nm Service Manual - Rocket III...
Page 48: Exploded View - Cylinder Head
Cylinder Head Exploded View - Cylinder Head SEE TEXT SEE TEXT 10Nm .·r 10Nm 10Nm Service Manual - Rocket III...
Page 49: Description
Cylinder Head Release the bolts securing the cam cover to the Description head. The engine is fitted with an aluminum alloy cylinder head, which carries the camshafts, valves and spark plugs. The cylinder head is cast as a single entity, to which various components are permanently added after machining.
Page 50: Installation
Cylinder Head Installation Cam Chain Tensioner Check the condition of the cam cover seal and cam cover bolt seals. Replace as necessary. Apply silicone sealant to the cylinder head where four 'D' sections of the cam cover seal fit. Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 51: Inspection
Cylinder Head Installation Fit a new gasket to the tensioner body. Set the tensioner plunger onto the first tooth of The centre nut of the cam chain tensioner is under the ratchet by manually lifting the tensioner pawl spring tension. Always wear hand, and facial and pushing the plunger into the tensioner body.
Page 52 Cylinder Head In addition, timing marks on the camshaft Push the tensioner plunger into contact with the sprockets should point downwards at a point chain guide using finger pressure. level with the cylinder head. If they do not align as shown, turn the camshafts until they do align. cbpy 1.
Page 53: Camshafts
Cylinder Head 12. When the timing checks have been satisfactorily Remove the cam chain top pad. completed, refit the inspection plug tightening it 13. Refit the cam cover (see page 3.6). Camshafts Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 54: Camshaft Identification
Cylinder Head Camshaft identification The inlet camshaft can be identified by a groove on a machined surface in its centre. The same surface on Failure release ladder fixings the exhaust cam is plain. progressively and evenly may result in damage to the cam ladder, the camshafts or the cylinder head itself.
Page 55: Inspection
Inspect the cam chain (see page 3.7). bolt to 10 Nm. Check camshaft journal to cam ladder clearance j) Release and remove the cam ladder as using Plastigage (Triumph part number 3880150- previously described. T0301) as follows: k) Utilising the gauge provided with the Plastigage kit, measure the width of the now compressed Plastigage.
Page 56: Installation
Cylinder Head If the journal to cam ladder clearance is within the specified tolerances (see table below), remove the cam ladder and clean off all traces of Plastigage, silicone release agent and grease. Standard 0.040 - 0.091 mm Service limit 0.13 mm Check the diameter of the camshaft Journals.
Page 57 Cylinder Head 14. Ease the cam chain away from the sprockets and 10. In the sequence shown below evenly and position the cams so that the timing marks align progressively tighten the cam ladder bolts, approximately half a turn each, until the cam as shown below.
Page 58: Valve Clearances
Cylinder Head Valve Clearances Valve Clearance Adjustment Camshaft, valve, valve shim and valve seat wear Note: affect the valve clearances. The effect of this wear is • Valve clearance checking and adjustment to change the clearance between the camshaft and must be carried out with the engine cold.
Page 59 Cylinder Head Remove both engine in-fill panels. Cylinder Head Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the fuel tank (see page 11.100).
Page 60: Inspection
Cylinder Head Inspection Installation Thoroughly clean the surface of the cylinder Thoroughly clean the upper faces of the crankcase and liners. Also clean the liner to head and check for damage and/or pitting of the crankcase mating faces. combustion chambers. Using a straight edge and feeler gauges, check Fit the cylinder liners (see page 5.19).
Page 61: Valves And Valve Stem Seals
Cylinder Head In the order shown below, tighten the cylinder Valves and Valve Stem Seals head bolts in three stages as follows: Removal from the cylinder head 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.
Page 62: Cam Chain
Cylinder Head Compress the valve spring ensuring that the Cam Chain spring is compressed squarely to prevent damage to components. Inspection Fit the valve collets ensuring their correct location in the spring cap and valve as the spring An in-situ check can be made as follows: compressor is released.
Page 63 Cylinder Head Check for severe wear of the plates in the area shown below. Check for severe wear of the inner surface of the outer plates at the side-contact points with the sprocket teeth. If any of these symptoms are evident, the cam chain must be replaced.
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Page 65 4 Clutch Table of Contents Exploded View - Clutch Controls ........... .. Exploded View - Clutch.
Page 66: Exploded View - Clutch Controls
Clutch Exploded View - Clutch Controls 15NmZ:: ~-----'O " Service Manual - Rocket III...
Page 67: Exploded View - Clutch
Clutch Exploded View - Clutch Service Manual - Rocket...
Page 68: Exploded View - Clutch Cover
Clutch Exploded View - Clutch Cover • • • • • • Service Manual - Rocket III...
Page 69: Clutch Cable
Clutch Release the clutch cable from the actuating arm Clutch Cable by pushing the inner cable nipple through the arm and sliding the cable out. Detach the cable Removal from the bracket. Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 70: Examination
Clutch Pull in the clutch lever and turn the inner cable, Installation anti-clockwise through the slots in the adjuster and locknut, until the cable can be detached from Position the cable to the motorcycle following the the lever. same routing as noted during removal. Attach the inner cable to the clutch lever and actuating arm using a reversal of the removal process.
Page 71: Installation
Clutch Clutch Clutch Cover Removal Removal Before starting work, ensure the motorcycle is Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help stabilised and adequately supported. This will help prevent it from falling and causing injury to the prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 72 Clutch Remove all the clutch friction plates and steel Depress the rear brake pedal to prevent the plates together with the anti-judder seat washer engine from turning, and then release the clutch spring. Note the orientation of all centre nut. components as they are removed.
Page 73: Friction Plate Inspection
Clutch Friction Plate Inspection Thickness If any friction plate thickness is outside the service limit, replace the friction plates as a set. 1. Friction Plate 2. Feeler Gauge 3. Surface Plate Friction plate bend/warp Service limit 0.30 mm 1. Clutch friction Plate Assembly Friction plate thickness - all plates Position the bearing sleeve then the clutch outer...
Page 74 Clutch Pre-Ioad and align the primary gear and backlash eliminator with the crank gear. Align the gears through the hole arrowed below. 1. Belleville Washer 'Out' Mark Lock the Inner and outer drums together using service tool 3880025-T0301. Depress the rear 1.
Page 75 Clutch 11. Refit the clutch pull rod. Note: 12. Refit the clutch pressure plate together with the • The pull rod should be free to move in and springs and bolts. Tighten the bolts to 10 Nm. out and also it should be free to turn. 13.
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Page 77 5 eran kshaft Table of Contents Exploded View - Crankshaft, Connecting Rod and Piston ........Exploded View - Crankcase Fixings.
Page 78: Exploded View - Crankshaft, Connecting Rod And Piston
Crankshaft Exploded View - Crankshaft, Connecting Rod and Piston ::» <: "> <: :> SEE TEXT "" Service Manual - Rocket III...
Page 79: Exploded View - Crankcase Fixings
Crankshaft Exploded View - Crankcase Fixings ALL FIXINGS - SEE TEXT :==== ====: It§l Service Manual - Rocket...
Page 80: Exploded View - Crankcase And Liners
Crankshaft Exploded View - Crankcase and Liners ~45Nm lX:gi Service Manual - Rocket III...
Page 81: Crankcases
Crankshaft Crankcases The following procedures often require lifting of heavy components. To avoid injury, always lift heavy components with a hoist or block and tackle and never attempt to manually lift items that are too heavy. Injury may result from failure to use the correct lifting equipment.
Page 82 Crankshaft Collect the bolts, then detach the ladder and From inside the rear of the crankcases, collect the bearing cap securing the output shaft to the baffle plate from the crankcase noting the lower crankcase. position of both location dowels, which should be removed for safe-keeping.
Page 83 Crankshaft Assembly Use high flash-point solvent to clean the crankcase mating faces. Wipe the surfaces clean with a lint-free cloth. Ensure that the three locating dowels are in position in the upper crankcase. Installing the crankshaft Install and lubricate the balancer ensuring it is 'timed' to the crankshaft correctly (see page 7.4).
Page 84 Crankshaft Stage 3 In the correct sequence, tighten lixings 9 through 35 Failure to lollow the correct screw tightening sequence may result in permanent crankcase damage. Stage 1 - all screws " In the correct sequence, tighten all crankcase lixings to 10 Nm.
Page 85: Removal
Crankshaft Installation Crankshaft Removal Always check the main bearing journal clearance Remove the engine from the frame (see page (see page 5.13), before final assembly of the 10.2). crankshaft. Failure to correctly select crankshaft Separate the lower and upper crankcases (see bearings will result in severe engine damage.
Page 86: Connecting Rods
Crankshaft Connecting Rods Installation Note: Removal • Connecting rod bolts and nuts are treated with an anti-rust solution, which must not Note: be removed. • The connecting rods and cap are etch- marked on one side to identify their Clean the connecting rod with high flash-point correct orientation.
Page 87: Right Hand (Exhaust) Side
Tighten the bolts, in two stages as follows;- a) Tighten to 14 Nm. b) Tighten through of bolt rotation as measured using the Triumph torque turn gauge 1. Piston 3880105-T0301. Arrow Right hand (exhaust) side Note: •...
Page 88: Connecting Rod Big End Bearing Selection/Crankpin Wear Check
Measure the bearing and crankpin clearance as follows. Crankpin diameter Note: Standard 40.946 - 40.960 mm • The crankpin clearances are measured using 'Plastigage' (Triumph part number Service limit 40.922 mm 3880150·T0301). turn Note: connecting rod and crankshaft during the •...
Page 89: Connecting Rod Bearing Selection
Select the correct big end bearing shell as follows: Measure the bearing to crankshaft main journal clearance using Plastigage (Triumph part Measure each crankpin diameter. number 3880150-T0301). Use the same method Select the correct bearings by matching the as described in connecting rod clearance information found with the chart below.
Page 90: Crankshaft End Float
Crankshaft Compare the data found with the chart above to select bearings individually by journal. Shell White Blue Blue Green Colour Crankcase 46.105 to 46.105 to 46.114 to 46.114 to 46.123 to 46.123 to bore 46.097 46.097 46.106 46.106 46.115 46.115 diameter Crankshaft...
Page 91: Pistons
Crankshaft Note: Pistons • The rings may be removed using a proprietary piston ring expander tool or, if Disassembly a tool is not available, carefully spread the ring opening using thumb pressure then Remove the cylinder head and liners (see page push up on the opposite side of the ring to 3.5).
Page 92: Piston Rings/Ring Grooves
Crankshaft Piston Rings/Ring Grooves Check the pistons for uneven groove wear by visually inspecting the ring grooves. Clean the piston ring grooves. Fit the piston rings to the pistons. Check, using feeler gauges, for the correct clearance between the ring grooves and the rings. Replace the piston and rings if outside the specified limit.
Page 93 Crankshaft The piston ring gaps must be arranged as shown in the diagram below. FRONT Piston ring identification marks Install a new circlip to one side of the piston. 1. Top Ring Locate the piston to the connecting rod ensuring 2.
Page 94: Cylinder Wear
Crankshaft Cylinder Wear Cylinder Liners Measure the internal diameter of each cylinder Removal liner using an internal micrometer or Mercer gauge. Always check in two places, at 90° to Mark each liner to identify correct orientation and each other, as well as at three heights in the liner. the cylinder number from which it has been removed.
Page 95: Installation
Crankshaft Carefully fit the rubber section of the tool fUlly Installation into the cylinder liner, positioning studss supplied with the tool diagonally across a pair of head Thoroughly clean the liner removing all traces of bolt-holes. old silicone sealer. Remove all traces of sealer from the crankcase bores.
Page 96 Crankshaft Note: Carefully fit each liner over the piston using a gentle rocking motion to allow compression of • The liners have a large chamfer at the the piston rings. bottom of the bore, enabling fitting of the piston without need for a piston ring compressor.
Page 97 6 Bevel Box and Drive Shaft Table of Contents Sectioned view - bevel box and drive shaft..........Bevel box and drive shaft specification.
Page 98: Bevel Box And Drive Shaft
Bevel Box and Drive Shaft Sectioned view - bevel box and drive shaft Service Manual - Rocket III...
Page 99: Bevel Box And Drive Shaft Specification
Bevel Box and Drive Shaft Bevel box and drive shaft Bevel box oil specification specification The bevel box must be filled and topped up with Mobil Mobilube 1 SHC 75W/90 fUlly synthetic hypoid oil or The Rocket III is fitted with a shaft drive coupling the equivalent.
Page 100: Bevel Box Oil Change
Bevel Box and Drive Shaft Bevel Box Bevel box oil change Removal Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 101: Drive Shaft
Bevel Box and Drive Shaft Align the bevel box by fUlly inserting the wheel Note: spindle through the bevel box and swinging arm • Before tightening the bevel box nuts, fUlly then, in the order shown below, tighten all the insert the wheel spindle through the bevel box nuts to 20 Nm, then to 64 Nm.
Page 102 Bevel Box and Drive Shaft This page intentionally left blank Service Manual - Rockellll...
Page 103 7 Balancer Table of Contents Exploded View - Balancer............Introduction.
Page 104: Balancer
Balancer Exploded View - Balancer Service Manual - Rocket III...
Page 105: Introduction
Balancer Introduction In an engine with an even number of cylinders (i.e. 2, 4, 6 etc.), a piston on an upward stroke is always counter-balanced by one on a descending stroke. However, in an engine with an odd number of cylinders, such as that fitted to the Rocket Ill, this natural state of balance does not occur.
Page 106: Inspection
Balancer Note: Inspection • A further alignment check can be made if Inspect all gears for chipped or missing teeth and required. When number one cylinder in for overheating (blue discolouration). the engine is on top-dead-centre (TOe), Inspect all bearings for signs of overheating (blue slots on the end of the balancer will align discolouration), seizure and any other damage.
Page 107 Balancer Position the balancer bearings such that the Ensure the circlips fitled to the balancer bearings dowel pegs locate in slots in the upper locate and seat correctly in corresponding crankcase. grooves, also in the upper crankcase. 1. Bearing dowels 1.
Page 108 Balancer This page intentionally left blank Service Manual - Rocket...
Page 109 8 Transmission Table of Contents Exploded View - Input and Output Shafts..........Exploded View - Gear Change Mechanism .
Page 110: Exploded View - Input And Output Shafts
Transmission Exploded View - Input and Output Shafts °a 000~ '~~Qb Service Manual - Rocket III...
Page 111: Exploded View - Gear Change Mechanism
Transmission Exploded View - Gear Change Mechanism 12Nm Service Manual - Rocket III...
Page 112: Exploded View - Gear Selector Mechanism
Transmission Exploded View - Gear Selector Mechanism 27Nm cclg SelVice Manual - Rocket III...
Page 113: Exploded View - Torsional Damper Shaft Housing
Transmission Exploded View - Torsional Damper Shaft Housing 28Nm 28Nm 28Nm 28Nm TI@9H' Service Manual - Rocket III...
Page 114: Exploded View - Torsional Damper Shaft
Transmission Exploded View - Torsional Damper Shaft 185Nm Service Manual - Rocket III...
Page 115: Selector Shaft, Selector Forks And Drum
Transmission Selector Shaft, Selector Forks and Pulling on the inserted bolt, ease the selector shaft out from the crankcase, collecting each Drum selector fork as the exiting shaft releases them. Removal Note: • Prior to removal, mark, or make a note of the relative positions of each selector fork in the selector drum.
Page 116 Transmission Slide the gear change shaft out of the crankcase, 11. Release the small screw securing the selector drum, bearing and keeper plate to the crankcase. collecting the gear change actuator arm and detent spring at the same time. cbyj 1.
Page 117 Transmission Inspection Position the detent wheel to the selector drum, engaging the pin on the drum with the corresponding recess in the rear of the wheel. Inspect all springs for over-extension (Le. abnormal gaps between coils). Replace as necessary. Inspect all seals for damage and distortion. Renew as necessary.
Page 118 Transmission 10. Feed the gear change shaft through the 13. Place transmission neutral. crankcase, engaging it in the actuator arm and transmission is in neutral when the wheel of the also attaching the free end of the detent arm detent arm rests in a tooth on the detent wheel spring over the spring abutment bolt.
Page 119: Removal
Transmission Torsional Damper Shaft Withdraw the damper shaft assembly. Removal Remove the engine from the frame (see page 10.2). Remove the fixings securing the gear position sensor to the torsional damper shaft housing. Withdraw the sensor and collect its O-ring. Collect the gear position indicator shaft from inside the crankcase, taking care to not drop the spring and plunger from its outer end.
Page 120: Removal
Transmission Installation Input and Output Shaft Assemblies Place a new torsional damper shaft housing Removal gasket over the crankcase. Note: Note: • The input and output shafts may be • The gear position indicator shaft can also removed from the upper crankcase after be filled after installing the torsional first separating the lower crankcase from damper shaft housing.
Page 121: Installation
Transmission Release the three Torx fixings securing the input Fit new Torx fixings to the bearing housing. shaft bearing housing to the upper crankcase. Tighten them to 12 Nm. Using a small punch, stake the Torx heads to the corresponding notches in the upper crankcase. 1.
Page 122: Output Shaft
Transmission Output Shaft 1. Ball bearing 14. Dog ring 2. Thrust washer 15. Circllp 3. First gear 16. Thrust washer 17. Second gear 4. Needle roller bearing 5. Thrust washer 18. Second gear bush 6. Fifth gear 19. Output shaft 7.
Page 123: Disassembly
Transmission Never wear loose clothing, which could become Disassembly trapped in the press and cause crushing injury to the Note: hand, arms or other parts of the anatomy. • All numbers given within brackets in the 14. Place the shaft (19) in a press with the threaded procedure below, refer directly to the end of the shaft facing the press ram.
Page 124: Assembly
Transmission Assembly Note: • Lubricate each gear, thrust washer and bush with clean engine during assembly. Note: • The circlips used on the output shaft have a flat side and an angled side. Illustrations throughout the assembly text indicate which orientation of each circlip is correct. Bushes with oil holes must always be MISALIGNED 1.
Page 125 Transmission Fit second gear (17) and thrust washer (16). 13. Fit the thrust washer (8), then a new circlip (7), orientating the circlip as shown below. Fit a new circlip (15), orientating the circlip as shown below. ttbh 1. Third/fourth gear 2.
Page 126: Input Shaft
Transmisslo Input Shaft /)0 9 . ccbk .scre~:iner 8 Fifth gear 1. Torx plate g . Fifth gear bush 2. Bearmg r.e sher 10. Thrust wa bearm~ 3. Ball 4 Retaining rlng Circlip . Thirdlfourth gea 5' Input shaft 6 · Thrust washer 13.
Page 127: Disassembly
Transmission Support the bearing and housing on press bars, Disassembly then press the shaft through the bearing and housing as shown below. Remove the circlip (15) from in front of second gear (14). Remove second gear (14). Remove the circlip (13) from in front of third/ fourth gear (12).
Page 128: Inspection
Transmission Inspection Caution Examine all gears, bearings and bushes and thrust washers for damage, distortion, chipped Press only on the bearing outer race to prevent teeth and wear beyond the service limits. bearing damage. Replace all defective components and always Support the housing on press bars as shown use new circlips to assemble the shaft.
Page 129 Transmission Fit the bush (9). 11. Retain third/fourth gear with a new circlip (13), orientating the circlip as shown below. Fit the Belleville washers (7) over the bush, arranging them as shown below. 1. Thircllfourth gear 2. Circlip 1. Thrust washer 2.
Page 130 Transmission This page intentionally left blank 8.22 Service Manual· Rocket...
Page 131 Triumph Engine Oil........
Page 132: Explode D View-Sump
Lubrication Explode d View-Sump sb6J~~ . . o : : : : : : : : : ~ < ; " ' ) 12Nm jffo@ 25Nm @f((t) 22 Nm 12Nm 25Nm 12 Nm 25 Nm al - Rocket III SelVice Manu...
Page 133: Exploded View - Oil Tank, Filter And Pumps
Lubrication Exploded View - Oil tank, filter and pumps 28Nm ~~~\ 13 Nm 12Nm Service Manual - Rocket III...
Page 134: Oil Circuit
Lubrication Oil is also fed from the main oil gallery, through Oil Circuit internal drillings and pipes, to the transmission. The transmission input shaft is both drilled through its General Description entire length and cross-drilled. The cross drillings provide oil directly to the gears, selector forks and The Rocket III utilises a dry sump iubrication system bearings.
Page 135: Scavenge System
Lubrication PRESSURE SYSTEM SCAVENGE SYSTEM Service Manual - Rocket III...
Page 136: Engine Oil
5. Minimum mark recommendation for the lubrication of all current Triumph motorcycle engines. Mobil 1 Racing 4T, specially filled for Triumph, is available from your authorised Triumph dealer. Ensure no foreign matter or contamination enters the oil tank during an oil change or top-up.
Page 137: Oil And Oil Filter Change
Lubrication The maximum oil level is indicated by marks on Remove the oil tank drain plug from the bottom of the filler cap/dipstick. When the oil level is the sump and allow the oil tank to drain. correct, the indicated oil level must be between the maximum and minimum lines on the dipstick.
Page 138: Disposal Of Used Engine Oil And Oil Filters
Position the oil drain pan beneath the oil filter. extinguishes shortly after starting. 15. Turn off the ignition, check the oil level using the 10. Unscrew and remove the oil filter using Triumph service tool T3880312. Dispose of the old filter method previously described, and top-up to in an environmentally friendly way.
Page 139: Low Oil Pressure Warning Light Switch
Lubrication Low Oil Pressure Warning Light Withdraw the rubber boot from the low oil pressure warning light switch. Switch Note: • The low pressure warning light may be removed after first removing the rider's seat and disconnecting the battery leads, negative (black) lead first.
Page 140: Removal
Lubrication Installation Sump Incorporating a new sealing washer, fit the low oil Removal pressure light switch, tightening it to 28 Nm. Remove the rider's seat as described on page 17.9. Disconnect the battery, negative (black) lead first. Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis.
Page 141: Oil Pumps
Lubrication Check the pick-ups for blockages Oil Pumps restrictions. Remove and clean if found to be Note: blocked or restricted. • Two oil pumps are fitted to this model. A pressure pump supply oil under pressure to various parts of the engine, and a twin-rotor scavenge pump to return oil to the oil tank from the sump.
Page 142 Lubrication Prevent the oil pump drive sprocket from turning Recover the mesh filter situated between the pressure pump and crankcase. using a hand-hold only. Remove the locknut from the drive sprocket shaft. 1. Mesh filter 1. Drive sprocket shaft Separate the crankcase halves as described on 2.
Page 143: Inspection
Lubrication Ease the pump from its dowels and withdraw it Measure the rotor tip clearance using feeler from the crankcase. gauges. Scavenge pump Rotor tip clearance Measure the pump body clearance using feeler gauges. Inspection If any part of either of the oil pumps is found to be outside the service limit, the complete pump must be replaced.
Page 144: Installation
Lubrication Installation Position the pressure pump and spray bar to the crankcase, aligning the drive blade on the scavenge pump with the slot on the drive pressure pump. As a precaution, before fitting the oil pumps to the crankcase ensure the pump internal surfaces have been 'wetted' with clean engine oil.
Page 145: Oil Non-Return Valve
Lubrication Assemble the pump sprocket and drive socket to Oil Pressure Relief Valve the chain ensuring the "OUT" mark on the pump The oil pressure relief valve is located in the lower socket is facing outwards. crankcase, adjacent to the scavenge pump. is a threaded fit in the crankcase.
Page 146: Oil Tank
Lubrication Oil Tank Installation Fit a new O-rings to the oil tank outlet and both Removal ends of the link tUbe. Lubricate the O-rings with engine oil or petroleum jelly. Remove the throttle bodies as described on page Refit the link tube to the upper crankcase. 11.121.
Page 147 10 Engine Removal and Refit Table of Contents Removal..............10.2 Installation .
Page 148 Engine Removal and Refit Removal 16. Remove the rear brake master cylinder heel guard. Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. To gain access to the engine for removai: Raise and securely support the motorcycle and engine.
Page 149 Engine Removal and Refit 18. Temporarily support the rear brake master 21. Release the fixing securing the brake pipe joint to cylinder then remove the bolts securing it to the the frame outrigger. footrest mounting bar. =-----=!~ 1. Brake pipe joint 1.
Page 150 Engine Removal and Refit 26. Release the bolts securing the left hand footrest mounting bar to the frame and engine. Detach the bar. 27. Noting their respective positions, disconnect the spark plug leads from the spark piugs. 28. Disconnect the side stand sWitch. 29.
Page 151 Engine Removal and Refit Reconnect the remaining electrical connections Installation to the engine. These include: Note: • Low oil pressure warning light switch • As the frame is being lowered onto the • Crankshaft position sensor engine, reconnect the low oil pressure warning light switch and attach the •...
Page 152 Engine Removal and Refit 12. Position the gear change crank to the selector 16. Fit and tighten the bar's mounting bolts to 27 Nm. shaft engaging the splines as noted during removal. cbue 1. Right hand footrest mounting bar "'"' 2.
Page 153 Engine Removal and Refit 21. Refit the front mudguard as described on page 17.11. 22. Refit the front wheel as described on page 16.7. 23. Refit the swinging arm, bevel box and rear lr---\-~ suspension units as described in section 6. 24.
Page 154 Engine Removal and Refit This page intentionally left blank 10.8 Service Manual - Rocket III...
Page 155 11 Fuel System/Engine Management Exploded View - Fuel Tank............11.7 Exploded View - Fuel Pump.
Page 156 11.20 Engine Management Circuit Diagram - Rocket III Circuit Diagram - Engine Management System - Rocket III 11.21 11.22 System Diagnostics 11.22 On-board Fault Detection System Triumph Diagnostic Tool. 11.22 11.23 Current Data 11.23 Freeze-frame Data 11.24 Function Tests 11.24 Checks/Adjustments 11.24...
Page 157 Fuel System/Engine Management Tool Keys 11.28 Electrical Connectors 11.58 Before Disconnection: 11.58 When Disconnecting a Connector: 11.58 When Inspecting a Connector: 11.58 When Connecting a Connector 11.58 Disconnection of ECM connectors 11.58 Reconnection of ECM connectors 11.59 Further Diagnosis 11.59 Crankshaft Sensor 11.60 Pinpoint Tests...
Page 158 Fuel System/Engine Management Pinpoint Tests 11.83 EEPROM Error 11.84 Fall Detection Switch 11.85 Pinpoint Tests 11.85 11.86 2nd Throttle Position Sensor Pinpoint Tests 11.86 2nd Throttle Actuator 11.88 Pinpoint Tests 11.88 Vehicie Speed Sensor 11.90 Pinpoint Tests 11.90 Ambient Pressure Sensor 11.91 Pinpoint Tests 11.91...
Page 159 Fuel System/Engine Management Intake Air Temperature Sensor 11.112 Removal 11.112 11.112 Installation Manifold Absolute Pressure (Map) Sensor 11.113 Removal 11.113 Installation 11.113 Barometric Pressure Sensor 11.113 Removal 11.113 11.113 Installation Gear Position Sensor 11.114 Removal 11.114 Installation 11.114 Road Speed Sensor 11.115 11.115 Removal...
Page 160 Fuel System/Engine Management Adaption Status 11.133 Terminology 11.133 Typical Values 11.133 Fault Indications 11.134 Exhaust System 11.134 Removal. 11.134 Installation 11.136 Evaporative Loss Control System - California Models Only 11.138 California Models Only 11.138 Component Locations (all situated behind the left hand side cover) 11.138 Evaporative Control System - Engine Off 11.139...
Page 161 Fuel System/Engine Management Exploded View - Fuel Tank 11.7 Service Manual - Rocket III...
Page 162 Fuel System/Engine Management Exploded View - Fuel Pump tftc ~r--, 1--' Nrr.-! L... ---J "- 11.8 Service Manual - Rocket III...
Page 163 Fuel System/Engine Management Exploded lew - V· Fuel Rail Throttles and Injectors 3.5Nm Service Manual - Rocket III 11.9...
Page 164 I System/Engine Man agement Explo e d d View - Airbox • 1-1.5 Nm 11.10 Service Manual - Rocket III...
Page 165 Fuel System/Engine Management Exploded View - Exhaust System ~~ee 11.11 Service Manual - Rocket III...
Page 166 Fuel System/Engine Management Exploded View - Evaporative System 11.12 Service Manual - Rocket III...
Page 167 Ethanol 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. 11.13 Service Manual - Rocket III...
Page 168 Fuel System/Engine Management Glossary of Terms Diagnostic Trouble Code. The following terms and abbreviations will be found in this section. Below is given a brief explanation of what some of the more common terms and abbreviations mean. Engine Control Module. Air temperature Engine speed The air temperature in the air box and intake hose.
Page 169 This function is not currently requires mixture correction, the long term fuel trim will used in the Triumph system. adapt to this requirement thus reducing the need for constant short term adjustment.
Page 170: Engine Management System
ECM memory. and cold start fueling requirements. This stored data can then be recovered using a special service tool which is mandatory for all Triumph • Primary throttle position sensor - situated at dealers. In this way, precise diagnosis of a fault can the rear of the lower throttle spindle.
Page 171 Fuel System/Engine Management Sensor Locations CLUTCH SWITCH PRIMARY THROTTLE POSITION SENSOR SECONDARY THROTTLE POSITION SENSOR COOLANT SIDE STAND TEMPERATURE SWITCH SENSOR ooJi MANIFOLD ABSOLUTE OXYGEN (LAMBDA) SENSOR PRESSURE SENSOR INTAKE AIR TEMPERATURE SENSOR CRANKSHAFT POSITION SENSOR oolh Service Manual- Rocket III 11.17...
Page 172 Fuel System/Engine Management System Actuators • Main power relay - situated behind the left hand side cover. When the ignition is switched on, the In response to signals received from the sensors, the main power relay is powered up to provide a ECM controls and directs messages to a series of stable voltage supply for the ECM.
Page 173 Fuel System/Engine Management Actuator Locations PRIMARY & SECONDARY INJECTORS THROTTLE STEPPER MOTORS FALL DETECTION ~~~~~~ SWITCH "'~ MAIN POWER RELAY CANISTER PURGE VALVE ""' i FUEL PUMP COOLING FAN IGNITION COILS ccdg 11.19 Service Manual - Rocket III...
Page 174 Fuel System/Engine Management Engine Management Circuit Diagram - Rocket III Key To Wiring Circuit Diagram Key To Wiring Colour Codes Code Wiring Colour Item Description Black Engine Control Module Blue Diagnostic Connector Vehicle Speed Sensor Brown Sidestand Switch Green Instrument Assembly Slate/Grey Accessory Fuel Gauge Orange...
Page 175 Fuel System/Engine Management Circuit Diagram - Engine Management System - Rocket III ,-----17 r8-~ [J}=up- A17 - K G - -A14 A21 --KY N K - 1 - N K - ------' ..!..-YK- - Y I ( - L . - - B Y - ------' 2 / ..!..-yp- 1 - y p -...
Page 176 ECM using a Triumph turn it off. The MIL will be immediately service tooi. Full details of the tool's operation and...
Page 177 Fuel System/Engine Management Current Data Freeze-frame Data By using the Triumph diagnostic tool, live engine data Freeze frame data is stored at the time a DTC is (engine running) recovered from recorded (confirmed) by the ECM. If multiple DTCs are recorded, the freeze-frame data which is stored motorcycle.
Page 178 Checks/Adjustments Triumph ECM part number Adjustments ECM manufacturer's part number Using the Triumph diagnostic tool, it is possible to ECM serial number reset the ECU to the factory default settings and to Software version number (tune number) balance the throttle bodies.
Page 179 Fuel System/Engine Management Checks When using this function it is possible to check the The data available under throttles/coils/injectors is: status of various sensors and actuators and also check certain items of factory data logged during Item Checked Result Unit vehicle assembly.
Page 180 Diagnostic trouble codes (DTCs) are logged in the ECM memory when there is a confirmed fault in the system. The codes are reported to the Triumph diagnostic tool as a four digit code. As mentioned earlier, when the system detects a fault, it begins to count the number of times the fault occurs before illuminating the MIL and storing a fault code.
Page 181 Fuel System/Engine Management Number of Number of Diagnostic Fault Description no-fault illuminated Trouble no-fault cycles cycles when fault Code before before is logged (DTC) turning off DTCis erased Cooling fan short circuiVopen circuit P1552 Cooling fan short to battery voltage/over temperature P1553 P1231 Fuel pump short circuit to ground or open circuit...
Page 182 Fuel System/Engine Management Service Diagnostic Tool "'... Cursors to indicate that further lines of text are available to be seen above and/or below those already in view, by scrolling the text up or down using the 'Up' or 'Down' keys. 4~\\~~ Cursor to show which line of text is 'active'.
Page 183 Fuel System/Engine Management The Help key can be used when the '?' symbol The Up and Down keys - press to move the lines of text up or down. They are also used to enter the shows, to get more information about that line of text. Dealer number and the date.
Page 184 SYSTEM ERROR False CHECK CARD Absent Present SELECT LANGUAGE ENGLISH FRANCAIS INSERT MEMORY CARD DEUTSCH ESPANOL NEDERLANDS TRIUMPH MOTORCYCLES DIAGNOSTIC TOOL SOFTWARE VERSION 2004_01 SWITCH ON BIKE IGNITION False DATA LINK FAULT VALIDATE RETRY Main Menu MAIN MENU Quit SERVICE DATA...
Page 185 Fuel System/Engine Management MAIN MENU DIAGNOSTICS Error Count CHECK/ADJUST QUIT STORED ERRORS FAULT COUNT 02 IGNITION COIL 1 OPEN CIRCUIT Diagnostics INJECTOR 3 OPEN CIRCUIT Starred DTC DIAGNOSTICS CURRENT DATA FAULT CODES Fault codes FUNCTION TESTS QUIT STORED ERRORS FREEZE FRAME DATA Current data CLEAR DTCS Freeze frame data...
Page 186 Fuel System/Engine Management Main Menu MAIN MENU DIAGNOSTICS CHECK/ADJUST QUIT Diagnostics DIAGNOSTICS CURRENT DATA FAULT CODES FUNCTION TEST QUIT Function test FUNCTION TEST DTes present TEST DTC COUNT DTCS PRESENT CLEAR BEFORE TEST ACTION ;"',1,. No DTes present FUNCTION TEST INSTRUMENT PANEL IDLE SPEED CONTROL STEPPER MOTOR Error Count...
Page 187 Build data • I---- THROTILE CLOSED CURRENT VOLTS 0.54 V BUILD DATA XXXXXXXXXXXxx REPLACE ISC STEPPER TRIUMPH ECU PART NUMBER XXXXXX THROTTLE CLOSED CURRENT VOLTS 0.54 V KEfHIN EGU PART NUMBER THROTILE OPEN XXXXXXXXXXXXX CURRENT VOLTS 0.51 V ECU SERIAL NO...
Page 188 Fuel System/Engine Management Main menu MAIN MENU DIAGNOSTICS CHECK/ADJUST QUIT Check/Adjust ChecklA djusl menu CHECK/ADJUST Quit ADJUST TUNE UPDATE TUNE QUIT UPDATE TUNE SELECT MODEL ROCKET III Update tune ROCKET III XXXXX TUNE XXXXX TUNE XXXXX TUNE UPDATE TUNE ??????? UPDATE TUNE TUNEXXXX Confirm...
Page 189 System/Engine Management Fuel 1. Connection and Power-Up 2. SELECT LANGUAGE E L E U R G E N G L I 0 E U T 5 • • • N E 0 E " " " " " .." ..
Page 190 "'!a "r§1 r§! galu Switch on the ignition. Do NOT start the engine. The screen will display the message 'Triumph Motorcycles Diagnostic Tool' and will also give the '*'. Press the validation key During a short delay diagnostic software version and the software reiease period the tool will carry out certain validation checks.
Page 191 When all 5 digits have been entered correctly, press '*'. the Validation key You must enter a valid Dealer Number to continue. If you do not know your dealer number, contact Triumph or your importer for advice. 11.37 Service Manual- Rocket III...
Page 192 Either 'DIAGNOSTICS' (operation 9.) or 'CHECK/ ADJUST (operation 27.) will be displayed, dependent on the selection. Note: • If 'QUIT' is selected and the validation key '*' pressed, the display will return to 'TRIUMPH MOTORCYCLES'. 11.38 Service Manual - Rocket III...
Page 193 'FUNCTION TESTS' (see operation 18.) displayed. • If 'QUIT' is selected, the display will return to Press any key to return to the 'CURRENT DATA' text. 'TRIUMPH MOTORCYCLES'. When all information has been noted, press either the Validation or Return (.J) keys. 11.39...
Page 194 Fuel System/Engine Management 12. To select 'READ STORED DTCS' 11. STOP ENGINE (Diagnostic Trouble Codes) from the MAIN MENU: 1 IN --,' 1' 1 EiN U IRIG N ![lHiE:C I'i J UiS T +-+-+-!-+-+.. _;-- - ~:~i+-' I<§DZ:>( Switch off the engine. lz:, { As the tool is powered from the motorcycle, this will Use the 'Up' and 'Down' keys to position the cursor...
Page 195 Fuel System/Engine Management 14. Three options are now available: 13. STORED DTCS 0 T [ 5 T 0 0 U N T • i' P 0 F R E E Z E R fI 0 R T R 1 1 1 "...
Page 196 Fuel System/Engine Management FREEZE FRAME STORED DTCS F I< R f'I El I< TI[ 5 I< UIRH "I< RIl<l <$"1 When a fault occurs which causes a DTC to be stored 2 options are now available: in the memory, the engine condition data at that Scroll to 'RETURN TO DTCS' and press the Validate instant is logged in the ECM.
Page 197 Fuel System/Engine Management 17. STORED DTCS, ERASE ALL DTC 18. To select 'FUNCTION TESTS' from the DATA MAIN MENU: 5 T 0 R 0 I R G N 0 5 T 1 [ 5 R R 5 R L L 0 R T R 0 R T R 0 T [ 5...
Page 198 Fuel System/Engine Management FUNCTION TEST 19. FUNCTION TESTS F U N C T 1 OiN F UiN C T P RIN E L T R U E N T R C T 1' 1 is!r TI 5 6"1 lE> ( @I 1E>! '*'.
Page 199 Fuel System/Engine Management Fuel pump operation: This test provides you with the FUNCTION TEST means to physically check the pump operation. DTCs are set if a malfunction is found. The pump is F U N C T I 0 N energised when the test is confirmed and ended when the Validation key '*' is pressed for a second 5 T R U...
Page 200 ..el System/Engine Management 22. FUNCTION TEST 23. FUNCTION TEST F U N IF U N rES r sirlR E N r N E L I IN G L E r E Rill j§1 Iz:.( /§I The screen now displayed will be specific to the If the test is satisfactory the display will read 'TEST component being tested: COMPLETE'.
Page 201 Fuel System/Engine Management FUNCTION TEST FUNCTION TEST F U N T I 0 N F U N T E 5 T P R N E L R 1' 1 N 0 T U 1' 1 E N T !J E I L E P 1 1 1 1 (gJ]...
Page 202 Fuel System/Engine Management 26. To select 'CHECKS/ADJUSTMENTS' 27. CHECK/ADJUST from the MAIN MENU (operation 8.): 01J U liS T I7R!/jN 171ENU --+--~I G NOS T 0 J U <$1 IE:>! Use the 'Up' and 'Down' keys to position the cursor as '*': follows, and then press the Validation key Use the 'Up' and 'Down' keys to position the cursor...
Page 203 • Vehicle Identification Number (VIN) Opposite 'READ BUILD DATA' - 'BUILD DATA' • Triumph ECM part number (operation 29.) will be displayed. • Manufacturer's ECM part number Opposite 'ADAPTION STATUS' - 'ADAPTION DATA' (operation 31.) will be displayed if the coolant •...
Page 204 Fuel System/Engine Management SENSOR DATA ADAPTION STATUS ia iR aiR T R !R 0 R alUiT 1' 1 NI5 0 5 tJ R N 6 E 51 E IJ R iE RI5 1:--2> gaiu The display can be scrolled to show: Because adaption only takes place at normal operating temperature, the above screen will be...
Page 205 Fuel System/Engine Management R 0 R P 0 R T R Function Examined Report Method L 0 5 E 0 0 T T L E Closed throttle position adapted/not adapted R 0 R P reference status R 0 R P 5 1 96 Idle speed...
Page 206 ADJUST TUNE (see operation 33.). Position the cursor opposite the setting you wish to In special circumstances, Triumph will request you to '*'. adjust and press the Validation key introduce a completely new engine tune. Given this RESET ADAPTIONS.·...
Page 207 Fuel System/Engine Management 34. ADJUST TUNE (adaption reset) BALANCE THROTTLES E 5 E D N F I R I? I? I? I? I? 1 2 3 I? I? (lgJJ 19JJ <$1 I§) 6$'1 gaiu galu Using the BALANCE THROTTLES command, the After selecting the adaption reset option, confirm or throttles may be balanced without the need to connect reject the option by positioning the cursor 'pposite the...
Page 208 <§I (Accessed from operation 32.). On receipt of special If the Password number has been incorrectly entered, instructions from Triumph you may be asked to input a the screen will display 'ACCESS DENIED'. Press the completely new engine tune. Validation...
Page 209 Fuel System/Engine Management 38. UPDATE TUNE 39. UPDATE TUNE R T E K E T fI D D X X X X X X X X X X X X (gJl 19J1 <$1 1'2) <$1 galu galu Align the cursor with the model to which a tune is to Scroll to the tune required and press the Validation be downloaded and, when satisfied that the selection key '*' to move on to operation 39.
Page 210 Fuel System/Engine Management UPDATE TUNE (confirm selected) UPDATE TUNE RirlE U paR TIE T U N U ,N E I . ' x x x x 0 IJ!N T UIN I~+!.+++-i L i 0 r-144-+-+ a +/'I+p-I +[+0- LE' TIE /' I f - ' [lA N...
Page 211 Fuel System/Engine Management 42. RESTARTING TUNE DOWNLOAD T R I U 1' 1 P T 0 R 1' 1 R G N 0 T 0 0 L tJ E R 5 I 0 N 5 0 F T R R E If, for any reason down loading is interrupted, the ECM will not function and tune download cannot be 2 0 0...
Page 212 Fuel System/Engine Management Electrical Connectors Disconnection of ECM connectors Note: Before beginning any diagnosis, following connector related information should be noted: • Two different sized connectors are used in ECM, which ensures correct Note: connection is always made. • A major cause of hidden electrical faults traced faulty electrical...
Page 213 Fuel System/Engine Management Reconnection of ECM connectors Further Diagnosis The tables that follow will, if used correctly, help to pinpoint a fault in the system once a diagnostic trouble code has been stored. 1.ECM 2. Large connector 3. Small connector Fit the connector into its socket and, whilst holding the connector in place, insert it fUlly into the ECM until the locking device retains it.
Page 214 Clean / renew toothed wheel, proceed to test 6 6 Reconnect harness, clear fault code and OK Action complete - quit test run engine to verify fault cleared Fau It still present Contact Triumph service 11.60 Service Manual - Rocket III...
Page 215 Fuel System/Engine Management Circuit Diagram Crankshaft Engine Sensor Control Module lI1l--u,------jAi4l U.1--U8~ 11.61 Service Manual - Rocket III...
Page 216 - Motor pin B to motor pin B1 test 7 Action complete - quit test 7 Reconnect harness, clear fault code and OK diagnostic tool function test to visually verify operation of stepper motor Contact Triumph service Fault 11.62 Service Manual - Rocket III...
Page 217 Fuel System/Engine Management Circuit Diagram Engjne Engine Idle Speed Control ~arness Control Module Stepper Motor ~w----IN 11.63 Service Manual - Rocket III...
Page 218 - Injector pin 1 to injector pin 2 Faulty Renew relevant injector, proceed to test 7 7 Reconnect harness, clear fault code and OK Action complete - quit test run engine to verify fault cleared Fault still present Contact Triumph service 11.64 Service Manual - Rocket...
Page 219 Fuel System/Engine Management Circuit Diagram EMS Relay En~ine Sub- arness Fuse Box Fuse6 Fuel Injectors 11.65 Service Manual- Rocket III...
Page 220 Short ci rcu it Locate and rectify wiring fault, proceed to test 5 5 Reconnect harness, clear fault code and OK Action complete - quit test run engine to verify fault cleared Fault still present Contact Triumph service 11.66 Service Manual - Rocket...
Page 221 Fuel System/Engine Management Circuit Diagram Engine Sub-Harness Connector Throttle Position Sensor D=:=GY KB _____KB 11.67 Service Manual - Rocket...
Page 222 Renew purge valve, proceed to test 7 7 Reconnect harness, clear fault code and OK Action complete - quit test run diagnostic tool function test to visually verify operation of purge valve Fault Contact Triumph service 11.68 Service Manual - Rocket...
Page 223 Fuel System/Engine Management Circuit Diagram EMS Relay Purge Valve NK~/~VR " - - - - - - - - N I K Fuse Box fuse6 11.69 Service Manual- Rocket...
Page 224 - 19n coil pin 1 to ign coil pin 2 Faulty Reconnect harness, clear fault code and run OK Action complete - quit test engine to verify fault cleared Fault still present Contact Triumph service 11.70 Service Manual - Rocket III...
Page 225 Fuel System/Engine Management Circuit Diagram EMS Relay ' - - - - , , - - - - - - - - - - I N ' Fuse Box Fuse6 Ignition Coils 11.71 Service Manual- Rocket...
Page 226 - ECM pin A09 to ground Locate and rectify wiring fault, proceed to test? Reconnect harness, clear fauit code and run OK Action complete - quit test engine to verify fault cleared Fault Contact Triumph service 11.72 Service Manual - Rocket...
Page 227 Fuel System/Engine Management Circuit Diagram Resistance data under typical conditions: Warm engine: 200 to 4000 Cold engine: 20·C ambient 2.35 to 2.65KO -10·C ambient 8.50 to 10.25KO Engine Sub-Harness Coolant Connector Temperature Sensor f2l-KB L0-KG ---~ 11.73 Service Manual - Rocket...
Page 228 - ECM pin A22 to ground Short circuit Locate and rectify wiring fault, proceed to test? Reconnect harness, clear fault code and run OK Action complete - quit test engine to verify fault cleared Contact Triumph service Fault 11.74 Service Manual - Rocket...
Page 229 Fuel System/Engine Management Circuit Diagram If engine is warm, remove sensor and allow time to cool to ambient prior to test. Resistance data: Resistance value Ambient temp 4000 2.35 2.65KO 8.50 10.25Kn Inlet Air Temperature Sensor ~KB~ ~KO~ 11.75 Service Manual - Rocket III...
Page 230 5 Action complete - quit test 5 Reconnect harness, clear fault code and OK run diagnostic tool function test to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fuel Pump Relay EMS Relay :==~_'K==~~----,~:=EJ Fuse Box Fuse 6 11.76...
Page 231 3 3 Reconnect harness, clear fault code and OK Action complete - quit test run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram EMS Relay Fuse Box Fu,e6 11.77 Service Manual - Rocket III...
Page 232 5 Reconnect harness, clear fault code and OK Action complete - quit test run diagnostic tool function test to visually verify operation of cooling fan Fault still present Contact Triumph service Circuit Diagram Cooling Fan Relay EMS Relay P.-+"'='-':-,-+I, LBY-J:l...
Page 233 5 5 Reconnect harness, clear fault code and OK Action complete - quit test run diagnostic tool function test to visually verify operation of tachometer Fault still present Contact Triumph service Circuit Diagram Fuse Box FuseS Instruments c=::::J 'It: 11.79...
Page 234 5 5 Reconnect harness, clear fault code and OK Action complete - quit test run diagnostic tool function test to visually verify operation of instruments Fault still present Contact Triumph service Circuit Diagram Fuse Box Fuse 5 Instruments ==:J '1 F: 11.80...
Page 235 5 5 Reconnect harness, clear fault code and OK Action complete· quit test run diagnostic tool function test to visually verify operation of speedometer. Fault still present Contact Triumph service Circuit Diagram Fuse Box Fuse 5 Instruments E==:J 11.81...
Page 236 - ECM pin A11 to sensor pin 2 4 Reconnect harness, clear fault code and OK Action complete· quit test run engine. Check adaptation status. Fault still present Contact Triumph service Circuit Diagram EMS Relay Lambda Sen'or ' - - - w...
Page 237 Locate and rectify wiring fault, proceed to test Reconnect harness, clear fault code and OK Action complete, quit test run engine. Check adaption status. Fault still present Contact Triumph service Circuit Diagram EMS Relay Lambda Sensor Fuse Box Fuse6 11.83...
Page 238 Fuel System/Engine Management EEPROM Error Fault Code Possible cause Action '~reeze P0603 EEPROM error View note frame" data if & available. No tests available - contact Triumph service. 11.84 Service Manual - Rocket...
Page 239 Less than 12V Locate and rectify wiring fault, proceed to - Sensor pin 4 test 6 6 Reconnect harness, clear fault code. Action complete, quit test Fault still present Contact Triumph service Circuit Diagram fall Detection Switch r:l=:=fl L;}-K----U 11.85...
Page 240 Short circuit Locate and rectify wiring fault, proceed to test 5 - ECM pin A02 to ECM pin AD? 5 Reconnect harness, clear fault code. Action complete, quit test Fault still present Contact Triumph service 11.86 Service Manual - Rocket...
Page 241 Fuel System/Engine Management Circuit Diagram En~ine Sub- arness Connector 2nd Throttle Position Sensor rn=:=~ K8 ------KB 11.87 Service Manual - Rocket III...
Page 242 - Sensor pin B to sensor pin B renew actuator and proceed to test 7 Action complete, quit test Reconnect harness, clear fault code. Run diagnostic tool function test to visually verify operation of actuator Contact Triumph service Fault still present 11.88 Service Manual - Rocket...
Page 243 Fuel System/Engine Management Circuit Diagram Engine 2nd Throttle Engine Sub Harness Actuator Control Module Connector ' 2 1 • 11.89 Service Manual - Rocket...
Page 244 - Sensor pin 2 to ground - Instruments pin 18 to sensor pin 1 4 Reconnect harness, clear fault code and OK Action complete, quittest run engine. Fault still present Contact Triumph service Circuit Diagram Alarm Kill Control Unit Switch...
Page 245 Short circuit Locate and rectify wiring fault, proceed to test 5 5 Reconnect harness, clear fault code and OK Action complete, quit test run engine Fault still present Contact Triumph service Circuit Diagram Ambient Pressure Sensor KO={] 11.91 Service Manual - Rocket III...
Page 246 Short circuit Locate and rectify wiring fauit, proceed to test 5 5 Reconnect harness, clear fault code and OK Action complete, quit test run engine Fault still present Contact Triumph service Circuit Diagram Sensor "=tJ 11.92 Service Manual - Rocket III...
Page 247 • Sensor pin 1 to sensor pin 2 Short circuit Locate and rectify wiring fault, proceed to test 5 5 Reconnect harness, clear fault code. Action complete, quit test Fault still present Contact Triumph service Circuit Diagram Gear PosH",on Sensor II1l--BK -------JA26l ~BW~ 11.93...
Page 248 - Sensor pin 3 to sensor pin 4 Short circuit Locate and rectify wiring fault, proceed to test 5 5 Reconnect harness, clear fault code. Action complete, quit test Fault still present Contact Triumph service Circuit Diagram Fuel level Sensor -fAMl 11.94...
Page 249 1 4 Reconnect harness, clear fault code and OK Action complete, quit test run diagnostic tool function test to visually verify operation of instruments Fault still present Contact Triumph service Circuit Diagram Alarm Kill Control Unit Switch Fuse Box...
Page 250 4 - Gauge pin 2 to earth - Gauge pin 3 to alarm controi unit pin 1 4 Reconnect harness, clear fault code. Action complete, quit test Fault still present Contact Triumph service Circuit Diagram Kill Alarm Switch Control Unit...
Page 251 Fuel System/Engine Management Fault Finding - Non Electrical Symptom Possible cause(s) Poor throttle response at low RPM Low fuel pressure caused by filter blockage/leaks Low fuel pressure caused by loose fuel pipes to the fuel pump and filter Cutting out at idle Throttle bodies out of balance ISC (Idle Speed Control) actuator inoperative Low fuel pressure caused by loose fuel pipes to the...
Page 252 Fuel System/Engine Management Fuel Tank Tilt the instruments forward. Note: • The fuel tank may be raised without being removed completely, for access to the top of the engine. ignition coils, spark plugs etc. Observe the warning advice given in the general information section on the safe handling of fuel and fuel containers.
Page 253 Fuel System/Engine Management Pivot the fuel tank upwards at the front, support Fuel tank - lowering and securing the tank while detaching the tank prop from two clips on the outside of the coil bracket. Support the tank and remove the tank prop. Continue to support the tank while refitting the prop to the two clips on the outside side of the coil bracket.
Page 254 Fuel System/Engine Management Disconnect the fuel pipe from the fuel pump plate Fuel tank - removal in the base of the tank and discard the sealing washers. Drain the pipe contents into a suitable Raise and prop the tank as described on page fuel container.
Page 255 Fuel System/Engine Management Fuel Pump, Filter and Pressure Fuel tank - refit Regulator Position the fuel tank to the frame and install the rear mounting bolt. Pivot the front of the tank upwards at the front Removal and refit the tank prop to the frame and tank Remove the fuel tank as described on page Tighten the rear fuel tank mounting bolt to 9 Nm.
Page 256 Fuel System/Engine Management Separate the pump/filter/regulator assembly from To release the pressure regulator, release the the fuel tank. Discard the pump plate seal. hose clips from the pump plate and filter then gently ease the regulator, link pipe and hoses upwards.
Page 257 Fuel System/Engine Management Release the screw securing the fuel pipe bracket 12. Release the screw securing the fuel pump clamp and fuel level sensor to the mounting bar. to its mounting bar. Discard the screw after removal. ""' " 1. Fuel pipe bracket 2.
Page 258 Fuel System/Engine Management Refit the pump clamp and tighten a new screw to 11. Reconnect the two electrical connections to the 2Nm. pump plate, in the positions noted/marked prior to removal. 'b", Fuel pump ,bp< 2. Fuel pump clamp 1. Fuel pump 3.
Page 259 Fuel System/Engine Management 10. Make a note of (or mark) the hose locations Airbox, Intake Duct and Hoses before disconnecting them from the evaporative canister. Removal Remove the rider's seat as described on page 17.9. Disconnect and remove the battery as described on page 18.9.
Page 260 Fuel System/Engine Management 13. Release the fir-tree plugs securing the fuse box Electrical connections to the battery box. 17. Place the ECM to one side...., 18. Remove the three screws from the ECM bracket, then detach the bracket. -===== ctnv 1.
Page 261 Fuel System/Engine Management 21. Lay the relays, ECM connectors and other wiring 25. Noting their orietation, release the three clips securing the intake plenum to the throttle bodies. aside. 22. Release the two screws securing the seat lock to the frame, then lay the seat lock (still attached to its cable) to one side.
Page 262 Fuel System/Engine Management 28. Release the clip securing the intake hose to the 30. Release the fixing securing the intake duct to its intake duct. bracket. Remove the duct. Intake hose 1. Intake duct 2. Intake duct Fixing Clip 31. Release the clip securing the intake hose to the 29.
Page 263 Fuel System/Engine Management 34. Release the two fixings securing the airbox to the frame. Ensure the hose is positively located to the airbox and is retained by the clip through its full circumference. Rectify if necessary as poor engine performance and engine damage may resuit from poor hose sealing.
Page 264 Fuel System/Engine Management 10. On the right hand side, fit the two relays and 14. Reconnect the barometric pressure sensor. sockets to their mounting points on the battery box. Ensure that both relays are fully engage on their mountings. Barometric pressure sensor 15.
Page 265 Fuel System/Engine Management 20. If fitted, position and secure the evaporative Air Filter canister to the airbox using new cable-ties. Reattach the hoses to the canister ensuring they Removal are fitted in the positions noted during strip. down. Remove the rider's seat as described on page 17.9.
Page 266 Fuel System/Engine Management Assembly Intake Air Temperature Sensor Clean the air filter cover and interior of the airbox. Removal Locate the new filter element to the airbox. Refit (or replace if necessary) the cover seal, fit Remove the rider's seat as described on page the filter cover and tighten the screws to 3 Nm.
Page 267 Fuel System/Engine Management Manifold Absolute Pressure (Map) Barometric Pressure Sensor Sensor Removal Removal Remove the rider's seat as described on page 17.9. Remove the rider's seat as described on page Disconnect the battery negative (black) lead first. 17.9. Remove the right hand side cover as described Disconnect the battery negative (black) lead first.
Page 268 Fuel System/Engine Management Installation Gear Position Sensor Fit a new O-ring to the sensor. Lubricate the 0- Removal ring with a smear of petroleum jelly. Position the sensor to the engine and route the Remove the rider's seat as described on page wiring as noted prior to removal.
Page 269 Fuel System/Engine Management Road Speed Sensor Installation Fit a new O-ring to the sensor. Lubricate the 0- Removal ring with a smear of petroleum jelly. Position the sensor to the engine and route the Remove the rider's seat as described on page wiring as noted prior to removal.
Page 270 Fuel System/Engine Management Crankshaft Position Sensor Installation Fit a new O-ring to the sensor. Lubricate the 0- Removal ring with a smear of petroleum jelly. Position the sensor to the engine and route the Remove the rider's seat as described on page wiring as noted prior to removal.
Page 271 Always be alert for changes in the 'feel' of the throttle and have the throttle system checked by an authorised Triumph dealer if any changes are detected. Changes can be due to wear in the mechanism, which could lead to a sticking throttle.
Page 272 Fuel System/Engine Management 11. Release, but do not remove completely, the two Installation screws securing the master cylinder to the Note: handlebar. • The opening and closing cables must be correctly identified and fitted to the correct positions as noted prior to removal. Locate the cables to the frame following the routing noted du ring removal.
Page 273 Move the handlebars to left and right full lock while your authorised Triumph dealer. checking that cables and harnesses do not bind. A cable or harness that binds will restrict the steering and may cause loss of control and an accident.
Page 274 Fuel System/Engine Management 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.
Page 275 • Rocket III throttles cannot be balanced using equipment to measure vacuum in each throttle. Instead, the Triumph diagnostic tool must be used. Remove the intake cover as described on page 11.98 to allow access to the adjuster screws. Connect the diagnostic tool, start the engine and navigate to 'ADJUSTMENTS' as described in section 11.24.
Page 276 Fuel System/Engine Management Throttle Body Noting its orientation, release the clip securing the intake hose to the intake duct. Removal Remove the rider's seat Disconnect the battery negative (black) lead first. Raise and prop the fuel tank as described on page 11.98.
Page 277 Fuel System/Engine Management Release the fixing securing the intake duct to its 16. Raise the throttle bodies from the transition bracket. Remove the duct. pieces and, feeding the fuel hose and wiring past the frame etc. remove the throttle bodies from the engine.
Page 278 Fuel System/Engine Management On California models, reconnect the evaporative return hoses to each throttle body. Connect the multi-plugs to; • both of the throttle position sensors, • the idle speed control stepper motor, • the second throttle stepper motor, • each injector.
Page 279 Fuel System/Engine Management Injectors and Fuel Rail Removal Ensure the plenum is positively located to the throttle bodies and intake duct and is retained by the Remove rider's seat. clips through their full circumference. Rectify if necessary as poor engine performance and Disconnect the battery, negative (black) lead first.
Page 280 Fuel System/Engine Management Ease the clips from the top of each injector. Primary Throttle Potentiometer Note: • primary secondary throttle position sensors are different and must never transposed. ease identification, the primary throttle position sensor has a shorter connector cable than the secondary.
Page 281 Fuel System/Engine Management Installation On pressing the validation key, the diagnostic tool will send a command, which drives the primary throttle to the fUlly closed position. The Lubricate the sensor 'O'-ring with a smear of tool will also display the voltage reading coming petroleum jelly.
Page 282 Fuel System/Engine Management Secondary Throttle Potentiometer Note: • primary secondary throttle Move the handlebars to left and right full lock while position sensors are different and must checking that cables and harnesses do not bind. A never transposed. ease cable or harness that binds will restrict the steering identification, the primary throttle position and may cause loss of control and an accident.
Page 283 _ _ _ _ _ _ _ _ _ _ _ _:..:Fuel System/Engine Management second tlatte!Y. negative ttvonle stJll held in rhe luny open 1.. 0I&c0MeC1 the (blitdc) lead liO$l. posoI'on. inseIlltle sensor to the Ihroltle body at 15. Check that tne throtlle opens and closes without th.
Page 284 Fuel System/Engine Management Idle Speed Control Stepper Motor Remove the two screws securing the idle speed control stepper motor to its bracket, then remove the stepper motor. Removal Remove the rider's seat. Disconnect the battery, negative (black) lead first. Remove the throttle bodies as described on page 11.122.
Page 285 Fuel System/Engine Management At the next screen, align the cursor with ISC· STEPPER RENEW (see below) then press the validation key which is marked '.'. • ISC = Idle Speed Control U 5 T R 0 R P T I 0 H R 0 P 0 T R E N E IJ...
Page 286 Fuel System/Engine Management 18. With the stepper fUlly opened, check the voltage shown on the tool and adjust the nut on the top of the stepper arm until the tool shows a voilage equivalent to X+0.12 (+/- 0.05V) where X= the Move the handlebars to left and right full lock while voilage measured in step 12 (or 15 if re-...
Page 287 Fuel System/Engine Management Engine Management Adaption Typical Values In a correctly adapted motorcycle, the following will be typical: General Information The engine management system fitted to this model is Function Examined Read Out adaptive. This means that the system is able to learn about new or changing operating conditions and Closed throttle position reference Adapted...
Page 288 Fuel System/Engine Management Exhaust System Fault Indications If 'range' figures at 100% are seen, then the adjusted has reached maximum indicating a mechanical fault Removal exists on the motorcycle. This can be due to a number of faults but the most likely causes will be low! high fuel pressure, faulty injectors or air leaks at the throttle bodies or airbox.
Page 289 Fuel System/Engine Management Release the clamps securing the silencers to the Remove the lower heat shield from the headers. catalyst box. After removal, collect the small rubber isolators from the brackets on the inner heat shield (or on a tag on the end of the upper shields, depending on where they are retained).
Page 290 Fuel System/Engine Management Installation Check and if necessary renew the catalyst mounting box grommets. Fit the mounting The catalyst box is located very close to the starter grommets to the mounting points on the catalyst cables. Ensure you have disconnected the battery. box.
Page 291 Fuel System/Engine Management 16. Fit the upper heat shield screws; spring washers Tighten all the header nuts to 19 Nm. and flat washers, then tighten the screws to Tighten the catalyst box mounting bolt to 27 Nm. 7Nm. Tighten the header to catalyst box clamp bolt to 17.
Page 292 Fuel System/Engine Management Evaporative Loss Control System - Component Locations (all situated behind the left hand side cover) California Models Only California Models Only All California models are fitled with an evaporative emissions control system to prevent the eXhausting of fuel vapour into the atmosphere.
Page 293 Fuel System/Engine Management Evaporative Control System - Engine Off When the engine is switched off, hydrocarbon fuel vapour passes down the breather pipe A, through the roll-over valve to the canister. Vapour is then stored in charcoal layers within the canister. ~PIPEA ROLL OVER VALVE CANISTER...
Page 294 Fuel System/Engine Management Evaporative Control System - Engine Running When the engine is started, vacuum from the engine is applied through pipe C to the vacuum sWitch on the canister, causing the canister return valve to open. Direct return of vapour, along pipe B, to the throttle bodies is prevented by the purge control vaive which is governed by the engine management system.
Page 295 12 Cooling Table of Contents Exploded View - Radiator............12-2 Exploded View - Water Pump, Expansion Tank and Hoses.
Page 296 Cooling d " tor V"ew - Ra la Exploded ~3Nm -3Nm "\ 2 5Nm ..J'A{l'iUlIIIl ~"I " -------~~~~~al - Rocket III 12.2 Service Manu...
Page 297: Exploded View - Water Pump, Expansion Tank And Hoses
Cooling Exploded View - Water Pump, Expansion Tank and Hoses 12Nm 12.3 Service Manual- Rocket III...
Page 298: Coolant
Cooling Coolant Radiator and Cooling Fan A all-seasons type of anti-freeze is installed in the The motorcycle is fitted with a thermostatically cooling system when the motorcycle leaves the controlled electric fan situated behind the radiator. factory. It is coloured blue, contains a 50% solution of The fan cowl is fitted with six flap valves to add control ethylene glycol, and has a freezing point of -35°C to the air flow through the radiator.
Page 299: Coolant Level Inspection
Cooling Coolant Level Inspection Do not remove the expansion tank or radiator pressure cap when the engine is hot. When the Before starting work, ensure the motorcycle is engine is hot, the coolant inside the expansion tank stabilised and adequately supported. This will help will be hot and also under pressure.
Page 300: Coolant Replacement
Cooling Release the security screw and remove the Coolant Replacement coolant pressure cap on the radiator. Drainage 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 hot coolant will cause scalds and skin damage.
Page 301: Filling
Cooling Water Pump Filling If removed, refit the water pump drain plug. Removal Tighten the plug to 10 Nm. Reconnect the bottom hose and tighten the clip. Open the cooling system bleed screw. Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 302: Inspection
Cooling Inspection Remove the pump outer cover to check for corrosion and scale build-up around the impellor and in the pump body. Renew if necessary. Check the water pump shaft and shaft bearings for side and end float. Clean or renew if necessary.
Page 303: Coolant Pressure Cap
Cooling Coolant Pressure Cap Thermostat Removal Inspection Do not remove the coolant pressure cap when the Before starling work, ensure the motorcycle is engine is hot. When the engine is hot, the coolant stabilised and adequately supported. This will help inside the radiator is hot and also under pressure.
Page 304: Inspection
Cooling Position a new O-ring to the thermostat housing Inspection and seat into the groove. Inspect the thermostat at room temperature. If the valve is open, the thermostat must be replaced. check the valve opening temperature, suspend the thermostat in a container of water together with a thermometer.
Page 305: Radiator
Cooling Radiator Removal Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the rider's seat. Disconnect the battery, negative (black) lead first. 1.
Page 306 Cooling Remove the radiator side grilles. 11. Release the radiator upper mounting bolts. 1. Side grille fixings 1. Radiator upper mounting bolts 12. Release the lower mounting bolt from the right Remove the upper radiator cover. hand side. 13. Disconnect the cooling fan. 14.
Page 307: Inspection
Cooling Inspection Installation Check the radiator for stone damage. Align the radiator to the lower mounting stud, reconnect the cooling fan before fitting the upper Check the radiator core, for damage to fins or and lower mounting bolts. obstructions to air flow. Tighten the mounting bolts to 9 Nm.
Page 308 Cooling This page intentionally left blank 12.14 Service Manual - Rocket...
Page 309 13 Rear Suspension Table of Contents Exploded View - Swinging Arm " ......13.2 Exploded View - Rear Suspension Units..........13.3 Rear Suspension Units.
Page 310: Exploded View - Swinging Arm
Rear Suspension Exploded View - Swinging Arm 69Nm -~ ffu/~ 15 Nm 100Nm 13.2 Service Manual - Rocket III...
Page 311: Exploded View - Rear Suspension Units
Rear Suspension Exploded View - Rear Suspension Units 28Nm 13.3 Service Manual - Rocket III...
Page 312: Rear Suspension Units
Rear Suspension Rear Suspension Units Note: • The details given in the table are to be used as a guide only where the rider and Adjustment passenger each weigh 90 kg or less. The rear suspension is adjustable for pre-Ioad only. Selting requirements should be increased for heavier riders and passengers and To change the rear suspension spring pre-Ioad...
Page 313: Removal
Rear Suspension Inspection Swinging Arm and Drive Shaft Remove all traces of dirt and inspect for damage/ Removal wear to the mountings and springs. Inspect the unit closely for fluid leaks from all parts of the unit and for cracks and damage to the springs.
Page 314: Inspection
Rear Suspension Using tool T3880062, release the locking ring on 10. If necessary, detach the shaft from the drive the right hand swinging arm gearbox output shaft by pulling it gently towards pivot. the rear of the motorcycle. 1. Locking ring 2.
Page 315 Rear Suspension Engage the threads of the swinging arm pivots to Thoroughly lubricate the swinging arm bearings with general purpose grease before positioning the frame. them to the sWinging arm. Pivots Swinging arm Frame Bearing Position the swinging arm bearings to the pivots. Position the swinging arm to the drive shaft and Engage the pivots to the swinging arm bearings.
Page 316: Swinging Arm Bearings
Rear Suspension Swinging Arm Bearings 13. Refit the drive shaft sleeve. Removal Before starting work, ensure the motorcycle is ~~~~~~:~ stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the SWinging arm as described on page 13.5.
Page 317 Rear Suspension Apply general purpose grease to both bearings Press the new bearing outer cups and plugs into each side of the swinging arm using tool before refitting the swinging arm as described on T3BB0064, until both are pressed fUlly up to their page 13.7.
Page 318 Rear Suspension This page intentionally left blank 13.10 SelVice Manual - Rocket...
Page 319 14 Front Suspension Table of Contents Exploded View - Front Fork ............14-2 Exploded View - Top and Bottom Yokes/Steering Head Bearings.
Page 320: Front Suspension
Front Suspension Exploded View - Front Fork SEE TEXT 20Nm 22Nm--. ~2Nm ~ 5Nm ccgi 14.2 Service Manual - Rocket III...
Page 321: Exploded View - Top And Bottom Yokes/Steering Head Bearings
Front Suspension Exploded View - Top and Bottom Yokes/Steering Head Bearings 26Nm 26Nm ~l1d 11 'fi ~-~~5Nm 14.3 Service Manual - Rocket III...
Page 322: Fork Inspection
17.10. If roughness or excessive stiffness is detected, Slacken the top yoke clamp bolts. consult your authorised Triumph dealer. Riding the motorcycle with defective or damaged suspension is dangerous and may lead to loss of motorcycle control and an accident.
Page 323: Installation
Front Suspension Slacken the bottom yoke clamp bolts and slide Fork Oil Change the forks out of the yokes. Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 324 Front Suspension Fit tool T3880067 over the top cap. Position the two adjustable arms to the holes in the spring spacer. Screw in the arms until they positively engage in the spring spacer holes. While compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down onto the fork.
Page 325: Oil Refilling
Front Suspension Note: Oil refilling • Zero level on the tool is set at the small exit The oil level specified for Rocket III forks is 89 mm hole in the side of the scale tube, NOT AT from the upper surface of the fork outer tube, with the THE END TIP.
Page 326 Front Suspension 13. Refit the top cap to the damper rod. 14. Hold the top cap while tightening the damper rod locknut to 16 Nm. While recompressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down onto the fork.
Page 327: Front Fork
Front Suspension Front Fork Before starting work, ensure the motorcycle is stabilised and adequately supported. from falling and causing injury to the operator or damage to the motorcycle. Disassembly "'ob Fork components 1. Top cap 9. Circlip 2.0-ring 10. Oil seal 3.
Page 328 Front Suspension Remove the forks as described on page 14.9. Secure the fork in a soft jawed vice, gently clamping it on the caliper mounting. While compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down onto the fork.
Page 329 Front Suspension Remove the spacer, spring cap and spring. 1. Tool 3880090·T0301 2. Damping cylinder 1. Spacer 2. Spring cap 13. Remove the tool, then the damping cylinder from 3. Spring the inner tube. Holding both the outer and inner tubes together, invert the fork and pour out the fork oil into a suitable container.
Page 330: Inspection
Front Suspension 15. Remove the circlip from above the seal. Assembly The front forks comprise many precision machined parts. Total cleanliness must be observed at all times and, assembly must take place in a dirtldust- free environment. All parts must be washed in non- flammable solvent before assembly.
Page 331 Front Suspension Carefully fit the outer tube to the inner ensuring Position the seal as noted prior to removal, then position it to the outer tube and drift into place that the oil and dust seal lips do not become using tool 3880080-T0301.
Page 332 Front Suspension 14. Refit tool T3860067 to the spring spacer, Refit the damping rod locknut leaving 15.5mm of thread and rod exposed above the nut. compress the fork spring and refit the spring holder. ~15.5mm --~--'-------' ",,!::-. Fill the fork with oil as described on page 14.7. 1.
Page 333: Steering Head Bearing Check And Adjustment
Front Suspension Steering Head Bearing Check and Adjustment Adjustment Slacken the top yoke clamp bolts. Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Check Raise and support the motorcycle so that the front wheel is clear of the ground.
Page 334 Front Suspension Pivot the instruments forward to reveal the Note: steering stem top nut. • Ensure the adjuster nut does not move the locknut is tightened. Seat the top yoke assembly in position then refit the washer and top nut, tightening it to 65 Nm. 1.
Page 335: Bottom Yoke And Headstock Bearings
Front Suspension Bottom Yoke and Headstock Bearings Slacken and remove the top nut and washer from the steering stem. Lift and support the handlebar and top yoke assembly to gain access to the Yoke Removal bearing adjuster nut and locknut. Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 336: Installation
Front Suspension Evenly and progressively drive new bearing outer Installation races into the frame headstock. Fit a new dust shield to the steering stem on the bottom yoke. --;---1 obwm 1. Headstock 2. Bearing outer race 3. Bottom yoke Installation 1.
Page 337 Front Suspension Install the forks as described on page 14.5. Check that the free play has been eliminated and that the steering can be turned freely from lock to 10. Recheck that the free play has been eliminated lock without any sign of tightness. Re-adjust if and that the steering can be turned freely from necessary.
Page 338 Front Suspension This page intentionally left blank 14.20 Service Manual - Rocket III...
Page 339 15 Brakes Table of Contents Exploded View - Front Brake Master Cylinder......... . 15-3 Exploded View - Front Brake Caliper and Disc.
Page 340 Brakes Installation 15-23 Rear Brake Caliper 15-24 Rear Brake Disc 15-24 Wear 15-24 Removal. 15-25 Installation 15-25 Rear Master Cylinder 15-25 Removal. 15-25 Disassembly 15-26 Inspection 15-27 Assembly 15-27 Installation 15-28 15.2 Service Manual - Rocket III...
Page 341: Exploded View - Front Brake Master Cylinder
Brakes Exploded View - Front Brake Master Cylinder 2Nm_ 15Nm~ " 15.3 Service Manual - Rocket III...
Page 342: Exploded View - Front Brake Caliper And Disc
Brakes Exploded View - Front Brake Caliper and Disc 40Nm~ ~ONm SEE TEXT 22 Nm 15.4 Service Manual - Rocket III...
Page 343: Exploded View - Rear Brake Master Cylinders
Brakes Exploded View - Rear Brake Master Cylinders "' " 15.5 Service Manual - Rocket...
Page 344: Exploded View - Rear Brake Caliper And Disc
Brakes Exploded View - Rear Brake Caliper and Disc ~ ~8Nm SEETE~ 22Nm """ 15.6 " I ' b _ ' Service Manual - Rocket III...
Page 345: Braking System Maintenance Safety Precautions
It is dangerous to operate the motorcycle under such conditions and you must have your authorised Triumph dealer take remedial action before you allemptto ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 346: Brake Fluid Level Inspection
Brakes Brake Fluid Level Inspection Changing Brake Fluid Brake fluid must be changed every two calendar years, irrespective of the mileage the motorcycle has covered in that time. Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help Brake Pads prevent it from falling and causing injury to the Front and rear brake pad wear is automatically...
Page 347: Bleeding The Front Brakes, Renewing Brake Fluid
Brakes Place the other end of the tube in a suitable Bleeding the Front Brakes, receptacle containing new brake fluid. Renewing Brake Fluid Turn the handlebars to bring the fluid reservoir to a level position. Remove the screws from the reservoir cover. Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 348 11. When all air has been expelled from the system, Triumph Dealer take remedial action before you hold the lever in and close the bleed nipple. attempt to ride the motorcycle again. Failure to take Tighten the nipple to 7 Nm.
Page 349: Front Brake Pads
Brakes Front Brake Pads Remove both brake pads and inspect for damage and wear beyond the service limit. Removal Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 350 It is dangerous to operate the motorcycle with defective brakes and you must have your authorised Triumph Deaier take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency...
Page 351: Front Brake Caliper
Brakes Front Brake Caliper Disassembly Removal Do not attempt to split the two halves of the caliper. A dangerous riding condition leading to loss of motorcycle control and an accident could occur if Before starting work, ensure the motorcycle is this warning is ignored.
Page 352: Inspection
Brakes Inspection Check the pistons and caliper bores for corrosion, scoring and damage. Renew as Ensure that the bores do not become scratched necessary. during piston removal and assembly. Ensure that the pistons remain square to their bores during fitment, as incorrect fitment can lead to seal and bore damage.
Page 353: Front Discs
Do not renew front brake discs individually. Discs Triumph Dealer take remedial action before you must always be renewed in pairs even if one of a attempt to ride the motorcycle again. Failure to take pair is serviceable.
Page 354: Installation
It is dangerous to operate the motorcycle with defective brakes and you must have your authorised Triumph Dealer take remedial action before you attempt to ride the motorcycle again. Failure to take To prevent paint damage, do not spill brake fluid remedial action may reduce braking efficiency onto any area of the bodywork.
Page 355: Disassembly
Brakes Disassembly Remove the piston set from the master cylinder bore noting the relative position of the seals and piston components. Remove the pivot locknut and bolt securing the brake lever to the master cylinder. Remove the lever. Detach the dust cover from the lever end of the cylinder.
Page 356: Assembly
Brakes Fit the new piston set into the master cylinder Check that the relief and supply ports on the and retain with a new circlip. cylinder are not blocked. cb~m 1. Piston 1. Ports 2. Seal (in correct orientation) Refit the master cylinder dust cover. Assembly Installation Locate the master cylinder to the handlebars.
Page 357 Fit and tighten the pivot bolt to 6 Nm, and the locknut to 1 Nm. Triumph Dealer take remedial action before you attempt to ride the motorcycle again. Failure to take Connect the brake hose to the master cylinder...
Page 358: Bleeding The Rear Brakes, Renewing Brake Fluid
Brakes Bleeding the Rear Brakes, Renewing Brake Fluid Before starting work, ensure the motorcycle is stabiiised and adequately supported. This wili help prevent it from faliing and causing injury to the operator or damage to the motorcycle. Remove the cap from the rear bleed nipple. Attach a transparent tube to the bleed nipple.
Page 359 Triumph Dealer take remedial action before you Slowly depress the brake pedal and, holding the attempt to ride the motorcycle again. Failure to take pedal fUlly down, close the bleed nipple.
Page 360: Rear Brake Pads, Rear Brake Caliper
Brakes If removing the calliper completely, disconnect Rear Brake Pads, Rear Brake the brake hose. Otherwise, leave the hose Caliper attached. Removal Raise and support the rear of the motorcycle. Do not allow the caliper to hang on the brake hoses as this may damage the hoses and could lead to reduced brake efficiency causing loss of motorcycle control and an accident.
Page 361 Brakes Installation Lubricate the pad retaining pin using a minimum amount proprietary high temperature 'Copperslip' type grease. Refit the pin and retain with both 'R' clips. Position the spacer between the wheel hub and caliper carrier. Never use mineral based grease in any part of the braking system or in any area where contact with the braking system is possible.
Page 362 It is dangerous to operate the motorcycle with defective brakes and you must have your authorised 7.5 mm Standard Triumph Dealer take remedial action before you Service limit 6.5 mm attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency...
Page 363 Remove the master cylinder heel guard. It is dangerous to operate the motorcycle with defective brakes and you must have your authorised Triumph Dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 364 Brakes Remove the clip from the brake pedal c1evis pin. Release the bolts securing the master cylinder to the footrest mounting bar. Detach the master Remove the clevis pin. cylinder. ~3~~~'~j==='T\I~1==~,~,rl ==;;; 1. Pedal 1. Footrest mounting bar 2. Pushrod 2.
Page 365 Brakes Assembly Remove the pushrod and piston set from the master cylinder bore noting the relative position of the seals and piston components. Never use mineral based grease in any part of the braking system or in any area where contact with i .
Page 366 Brakes Align the brake pedal with the pushrod, engage the clevis and retain it with the clip. Ensure the clip is filted as shown below. 1. Pushrod 2. Circlip Refit the master cylinder boot. 1. Pedal 2. Pushrod Installation 3. Clevis Position the master cylinder to the footrest mounting bar.
Page 367 10. Check the operation of the rear brake. Rectify as defective brakes and you must have your authorised necessary. Triumph Dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 368 Brakes This page intentionally left blank 15.30 Service Manual - Rocket...
Page 369 16 WheelslTyres Table of Contents Exploded view - Front Wheel ............16.2 Exploded View - Rear Wheel and Cush Drive .
Page 370: Exploded View - Front Wheel
WheelslTyres Exploded view - Front Wheel 16.2 Service Manual - Rocket III...
Page 371: Exploded View - Rear Wheel And Cush Drive
WheelslTyres Exploded View - Rear Wheel and Cush Drive 110 Nm "'ll' 16.3 Service Manual- Rocket III...
Page 372: Tyres
WheelslTyres Tyres This model is equipped with tubeless tyres, valves, and wheel rims. Only tyres marked 'TUBELESS' and tubeless type tyre valves mounted on rims marked Correct tyre inflation pressures will provide 'SUITABLE FOR TUBELESS TYRES' can be used. maxirnum stability, rider comfort and tyre life. Tyre pressures must be checked according to the scheduled maintenance chart, when the tyres are cold, and adjusted as necessary.
Page 373: Minimum Recommended Tread Depth
Always consult your Triumph dealer for tyre replacement, or for a If a tyre sustains a puncture, the tyre must be safety inspection of the tyres.
Page 374: Front Wheel
It is not necessary to disconnect the brake hoses. 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. Do not allow the calipers to hang on the brake hoses When tyres are replaced, allow time for the tyre to as this may damage the hoses.
Page 375: Installation
Triumph Dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
Page 376: Rear Wheel
WheelsITyres Rear Wheel As an assembly, the caliper and manoeuvre carrier until it is clear of the brake disc and wheel, collecting the spacer once it is freed from the Removal calliper carrier. Before starting work, ensure the motorcycle is stabilised and adequately supported.
Page 377: Installation
WheelslTyres Position the caliper and carrier over the disc Installation ensuring both brake pads are correctly aligned either side of the disc. Thoroughly clean and degrease the brake disc. Position the spacer between the wheel and Apply Mobil HP222 grease (or equivalent) to the calliper carrier.
Page 378: Cush Drive
This will help Triumph Dealer take remedial action before you prevent it from falling and causing injury to the attempt to ride the motorcycle again. Failure to take operator or damage to the motorcycle.
Page 379: Installation
WheelslTyres Recover the cush drive rubbers from within the Locate the driven flange assembly to the wheel wheel. centre, engaging the paddles with the cush rubbers. Ensure the spacer is not displaced ~~~ ~ j';~ ,,,,mbO -----, 1. Wheel 2. Cush Drive Rubbers 1.
Page 380 WheelslTyres This page intentionally left blank 16.12 Service Manual - Rocket III...
Page 381 17 Frame and Bodywork Table of Contents Exploded View - Frame and Fixings , ..17-2 Exploded View - Front and Rear Mudguards ,..17-3 Exploded View - Front and Rear Footrests "...
Page 382: Frame And Bodywork
Frame and Bodywork Exploded View - Frame and Fixings SEETEXT--- 17.2 Service Manual - Rocket...
Page 383: Exploded View - Front And Rear Mudguards
Frame and Bodywork Exploded View - Front and Rear Mudguards 27Nm 27Nm 64Nm 14Nm 26Nm ~" 17.3 Service Manual - Rocket III...
Page 384: Exploded View - Front And Rear Footrests
Frame and Bodywork Exploded View - Front and Rear Footrests ~~----- ~~-~- 17.4 Service Manual - Rocket III...
Page 385: Exploded View - Seat And Tool Kit
Frame and Bodywork Exploded View - Seat and Tool Kit 10Nm 17.5 Service Manual - Rocket III...
Page 386: Exploded View - Side Panels
Frame and Bodywork Exploded View - Side Panels 17.6 Service Manual - Rocket III...
Page 387: Exploded View - Side Stand
Frame and Bodywork Exploded View - Side Stand 17.7 Service Manual - Rocket III...
Page 388: General Frame Inspection
If the motorcycle is involved in an accident or Banking to an unsafe angle may cause instability, collision it must be taken to an authorised Triumph loss of motorcycle control and an accident. dealer for inspection and repair before it is ridden again.
Page 389: Seats
Frame and Bodywork Side Covers Seats Removal Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Before starting work, ensure the motorcycle Is stabilised and adequately supported.
Page 390: Engine Infill Panels
Frame and Bodywork Engine Infill Panels Front Mudguard Engine infill panels are fitted to the frame, towards the rear of the engine, on both sides of the motorcycle. Removal Removal Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the Before starting work, ensure the motorcycle is operator or damage to the motorcycle.
Page 391: Mudguard Embellisher Removal
Frame and Bodywork Release the mudguard fixings and detach the Peel back the triangular Triumph sticker to reveal mudguard. the screw head beneath it. 1. Mudguard Flxlngs 1. Sticker 2. Mudguard 2. Screw head Release the screw to allow detachment of the embellisher.
Page 392: Rear Mudguard
Frame and Bodywork Rear Mudguard Release the two fixings from each side of the rear mudguard cover. Removal Before starting work. ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 393: Installation
Frame and Bodywork Support the rear mudguard then release the Release the fixings securing the mudguard brace remaining fixings (two per side) that secure the to the mudguard. rear mudguard to the frame. Mudguard 1. Mudguard flxlngs 2. MUdguard brace Pivot the mudguard downwards at the rear.
Page 394 Frame and Bodywork Fit the mudguard cover fixings. Tighten the M8 Pivot the mudguard upwards at the rear and engage the two M6 x 16 mm fixings through the fixings to 26 Nm and the M1 0 fixings to 64 Nm. frame and into the mudguard.
Page 395: Handlebars
Frame and Bodywork Handlebars Release the two screws securing the upper cover of the handlebar clamp to the lower section. Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
Page 396: Installation
Frame and Bodywork Installation Align the clamp lower split line with the punch mark on the handlebar then evenly tighten the clamp bolts to 15 Nm. Fit the throttle twist-grip assembly then locate the handlebars in the lower halves of the clamp. Fit clamp bolts together...
Page 397: Side Stand
Frame and Bodywork Side Stand Removal Operation of the motorcycle with incorrectly adjusted, incorrectly routed or damaged throttle cables 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 Before starting work, ensure the motorcycle is motorcycle and an accident.
Page 398 Frame and Bodywork Wear hand, eye and face protection when fitting the stand spring. Take great care to minimise the risk of personal injury and loss of components. Check the operation of the side stand before riding the motorcycle. Ensure the spring holds the stand securely in the retracted position.
Page 399 18 Electrical System Table of Contents Exploded View - Instruments ............18-3 Exploded View - Alternator.
Page 400 Electrical System Relays 18-19 Identification and location 18-19 Relay identification - left hand side 18-19 Relay identification - right hand side 18-19 ECM Connector Pin Numbering 18-19 Lighting Circuit 18-20 Circuit Diagram - Lighting 18-21 Starting and Charging Circuit. 18-22 Circuit Diagram - Starting and Charging 18-23 18-24...
Page 401: Exploded View - Instruments
Electrical System Exploded View - Instruments 18.3 Service Manual - Rocket III...
Page 402: Exploded View - Alternator
Electrical System Exploded View - Alternator • """'nJ 120Nm 18.4 Service Manual· Rocket III...
Page 403: Exploded View - Starter Motor
Electrical System Exploded View - Starter Motor "" 27 Nm 18.5 Service Manual- Rocket...
Page 404: Exploded View - Headlight
Electrical System Exploded View - Headlight c;:::::::' ~------- ~15Nm CB \g) 18.6 Service Manual - Rocket III...
Page 405: Exploded View - Rear Light And Indicators
Electrical System Exploded View - Rear Light and Indicators " --..""~"'" Jill .,~ ~ ~O" PUSH FIT 2 Nm " '-"';j 18.7 Service Manual - Rocket III...
Page 406: Exploded View - Battery, Horn And Wiring
Electrical System Exploded View - Battery, Horn and Wiring PUSH FIT 27Nm /"'~ ~'" 18.8 Service Manual - Rocket III...
Page 407: Battery
Electrical System Battery Battery Removal Under some circumstances, the battery can give 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.
Page 408: Battery Installation
Electrical System Battery Installation New Battery Commissioning The battery electrolyte is corrosive and poisonous. Ensure that the battery terminals do not touch the swallow battery eiectrolyte or allow it to come Never motorcycle frame as this may cause a short circuit into contact with the skin.
Page 409: Charging - Battery Already In Service
Electrical System Fuses Terminal ChargeTime Charge Cutoff (hours) Voltage Voltage Measured 12.8 14.5 000000 fii1r 12.7 14.5 000000 12.6 14.5 WW,;.,.."..~'2345 12.5 14.5 ITIJ Less than 12.5 8-10 14.5 12. Charging current should be controlled to 10% of the nominal capacity (i.e. for a 10AH battery charging current I = 0.1 x 10= 1A).
Page 410: Fuse Identification
Electrical System Fuse Identification A blown fuse is indicated when all of the systems protected by that fuse become inoperative. When checking for a blown fuse, use the table below to Never attempt to adjust a headlamp beam when the establish which fuse has blown.
Page 411: Headlight Horizontal Adjustment
Electrical System Headlight Horizontal Adjustment The bulbs become hot during use. Always allow sufficient time for the bulbs 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.
Page 412: Rear Light
Electrical System Rear Light Indicator Lights Bulb Replacement Bulb Replacement 1. Lens Rear light bulb 2. Lens screw holder 2. Bulb Bulb Note: • The lens on each indicator light is held in place by two screws. The bulb becomes hot during use. Always allow sufficient time for the bUlb to cool before handling.
Page 413: Alternator
Electrical System To remove the rotor, prevent the crankshaft from Alternator rotating using tool T3880201, and remove the centre bolt and washer from the end of the Removal crankshaft. Remove the rider's seat. Disconnect the battery, negative (black) lead first. Remove the engine as described on page 10.2.
Page 414: Inspection
Electrical System 11. To remove the stator, release the two bolts Assembly securing the cable retainer to the crankcase. Locate the stator to the crankcase. Apply silicone sealer to the cable grommet and align the cable to the crankcase exit slot. Fit the cabie retainer bracket, routing the cables as noted on strip down.
Page 415: Alternator Rectifier
Electrical System Remove tool T3880201 . Alternator Rectifier 10. Incorporating a new gasket, refit the alternator Note: cover to the rear of the engine. • The alternator rectifier is attached to the 11. Tighten the alternator cover bolts to 9 Nm. battery box.
Page 416: Removal
Electrical System Installation Starter Motor Fit a new O-ring to the starter motor. Removal Remove the rider's seat as described on page 17.9. Disconnect the battery, negative (black) lead first. Remove the exhaust silencers and catalyst box as described on page 10.2.
Page 417 Electrical System Relays ECM Connector Pin Numbering Identification and location Note: • Relays can be found in two locations on /k;B1 :~:,==~~ ~~~~A8 the motorcycle, beneath the left and right hand side covers. Doooooclflll ~oOOOOOOD DoooooGDi1lf Relay identification - left hand side ~JOOOp,ooor ~~?tA20 The above illustration shows the pin numbering...
Page 418 Electrical System Lighting Circuit Key to circuit diagram Key To Wiring Colour Codes Wiring Colour Code Item Description Black Fuse Box (Fuses 2, 9 and 10) Blue Ignition Switch Instrument Assembly Brown Instrument Illumination Green Warning Lights Slate/Grey Engine Harness Connector Orange Oil Pressure Switch Pink...
Page 419 Electrical System Circuit Diagram - Lighting ~---~UY -------, _ _ _ _ _ -J __I}-u-------, 1Oe- 7 e- 6 e- 18.21 Service Manual - Rockellll...
Page 420 Electrical System Starting and Charging Circuit Key to circuit diagram Key To Wiring Colour Codes Code Wiring Colour Item Description Black Battery Starter Motor Blue Fuse 11 Brown Starter Relay Green Engine Control Module Slate/Grey Gear Position Sensor Orange Clutch Switch Pink Sidestand Switch Engine Management System Relay...
Page 421 Electrical System Circuit Diagram - Starting and Charging ~ -I~I~ ----jB24 '--GR L>'- '--NK R-EJ <t> <:0 "" --l5'l 18.23 Service Manual - Rocket III...
Page 422 Electrical System Auxiliary and Accessory Circuit Key to circuit diagram Key To Wiring Colour Codes Wiring Colour Code Item Description Black Fuse Box (1, 2, 3, 4 and 8) Ignition Switch Blue Front Brake Light Switch Brown Rear Brake Light Switch Green Brake / Tail Light Assembly Slate/Grey...
Page 423 Electrical System Circuit Diagram - Auxiliary and Accessory r - - - - - - - - - - - - - - - [Th-p 8 :1 ,\~J D D t = P 4f-<> 6f-<> [ J } f P 8f-<>...
Page 424 Electrical System Complete System Key to Circuit Diagram Item Description Item Description Rear Light Instrument Assembly Number Plate Light Vehicle Speed Sensor LH Rear Indicator Front Brake Lever Switch Alarm Connector (Accessory) Engine Kill Switch Starter Motor / Solenoid Assembly Starter Button Battery Fuel Gauge (Accessory)
Page 425 Circuit Diagram - Complete System ~ ii~~2 na • 7 . . • § ~ ~ i ~ a ~ ~ -...l-.-f...-th I ! . ::: 0 "" -l-A • Jg~r:~11:~i 11 12 17 18 1- }O ~=t[]37 =-~~4:00"" I-=-ow= ~Booc::J:::IoIoB -~ID:j=oo39 :::::::t®...

Triumph Rocket III Service Manual

1 General Information

3 Cyl Inder Head

4 Clutch

5 Eran Kshaft

6 Bevel Box and Drive Shaft

7 Balancer

8 Transmission

9 Lubrication

12 Cooling

13 Rear Suspension

14 Front Suspension

15 Brakes

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Summary of Contents for Triumph Rocket III