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Table Of Contents - Triumph Trophy Service Manual
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Also See for Trophy
:
Handbook
(180 pages)
,
Handbook
(174 pages)
,
Alarm fitting and operating instructions
(4 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
Table of Contents
Contents
5
Asbestos
7
Safety Instructions
7
Tampering With Noise Control System Prohibited
7
References
7
Edges
8
Tightening Procedure
8
General Information
9
Ignition System Safety Precautions
10
Dangerous Substances
10
Engine Oils
10
Environmental Protection Precautions
11
Brakes
11
Jacking And Lifting
12
Precautions Against Damage
12
Engine Coolant Precautions
12
Cleaning Components
12
Lubrication
13
Joints And Joint Faces
13
Gaskets, O-Rings
13
Liquid Gasket, Non-Permanent Locking Agent
13
Fitting A Split Pin
14
Circlips, Retaining Rings
14
Self Locking Nuts
14
Oil And Grease Seals
14
Fuel Handling Precautions
15
Petrol - Gasoline
15
Fuel Tank Removal
15
Chassis Repairs
15
Electrical Precautions
16
Battery Disconnecting
16
Grease For Electrical Connectors
16
Disciplines
17
Electrical Wires
17
Replacement Parts
17
Service Data
17
Service Tools And Garage Equipment
18
Special Service Tools
18
Full Specification Trophy 1200
21
Full Specification Trophy 900
21
Full Specification Daytona 1000
25
Full Specification Daytona 750
25
Full Specification Daytona 1200
29
Full Specification Daytona 900
29
Full Specification Daytona Super 3
33
Full Specification Speed Triple 900
33
Full Specification Trident/Sprint 900
37
Full Specification Trident 750
37
Full Specification Thunderbird Sport 900
41
Full Specification Thunderbird/Adventurer 900
41
Full Specification Tiger 900
45
Torque Wrench Settings
49
Routine Maintenance
58
Bodywork And Fuel Tank
60
Service Check Sheets
60
Periodic Maintenance Chart
61
Battery Removal/Refit
63
Battery Electrolyte Level Check
64
Battery Installation - All Models Except Thunderbird, Thunderbird Sport & Adventurer
64
Battery Installation, Thunderbird, Thunderbird Sport & Adventurer
64
Spark Plugs Removal
65
Spark Plugs Maintenance
65
Spark Plugs Installation
65
Camshaft Cover Removal
66
Camshaft Cover Installation
67
Valve Clearance Measurement
68
Valve Clearance Adjustment
68
Cam Lobe Point Away From Valves
68
Correct Clearance Specification
68
Tool In Position On Inlet Camshaft
69
Removing/Replacing The Shim
69
Exhaust Valve Clearance Adjustment Chart
70
Inlet Valve Clearance Adjustment Chart
71
Engine Oil Specification
72
Engine Oil Inspection (Not Thunderbird, Thunderbird Sport Or Adventurer)
72
Engine Oil Level Inspection, Thunderbird, Thunderbird Sport & Adventurer
73
Engine Oil And Filter Removal
74
Engine Oil And Filter Installation
74
Cooling System
75
Coolant Level Inspection (Not Thunderbird, Thunderbird Sport Or Adventurer)
75
Coolant Level Inspection - Thunderbird, Thunderbird Sport & Adventurer
75
Coolant Replacement
76
Drainage (All Models)
76
Filling (Not Thunderbird, Thunderbird Sport Or Adventurer)
76
Radiator Hoses
77
Radiator And Cooling Fan
77
Nuts, Bolts, Fasteners - Check Security
77
Filling (Thunderbird, Thunderbird Sport & Adventurer)
77
Clutch Fluid Level Inspection
78
Clutch Fluid, Hose And Hydraulic Seals
78
Carburetor Synchronisation
79
Idle Speed Adjustment
79
Throttle Grip Inspection
81
Throttle Grip Adjustment
81
Choke Lever Inspection
81
Choke Lever Adjustment
82
Air Intake Assembly Removal (Not Thunderbird, Thunderbird Sport Or Adventurer)
82
Air Intake Assembly Installation (Not Thunderbird, Thunderbird Sport Or Adventurer)
83
Air Intake Assembly Removal (Thunderbird, Thunderbird Sport & Adventurer)
84
Air Intake Assembly Installation (Thunderbird, Thunderbird Sport & Adventurer)
84
Airbox Drain Pipe
85
Fuel System
85
Tyre Wear/Wheel Inspection
86
Minimum Recommended Tread Depth
86
Drive Chain Replacement
87
Drive Chain Slack Inspection
87
Drive Chain Slider (Tiger)
87
Chain Slack Adjustment (Eccentric Adjuster Method)
88
Chain Slack Adjustment (Adjustable Wheel Spindle Method)
88
Wheel Adjustment (Eccentric Adjuster Method)
89
Wheel Alignment (Adjustable Wheel Spindle Method)
89
Chain Lubrication
90
Chain Wear Inspection
90
Chain Lubrication Positions
90
Braking System Maintenance Safety Precautions
91
Disc Brake Fluid Level Inspection
92
Changing Brake Fluid, Brake Hoses And Hydraulic Seals
92
Brake Pads
93
Brake Wear Inspection
93
Brake Lights
93
Front Suspension
94
Steering Inspection
94
Steering Stem Bearing Lubrication
94
Front Fork Inspection
94
Wheel Bearings Inspection
95
Rear Suspension Inspection/Lubrication
95
Cylinder Head
97
Cylinder Head Exploded View
98
Cylinder Head Description
100
Cam Cover Removal
100
Cam Cover Installation
101
Cam Chain Tensioner Removal
102
Cam Chain Tensioner Installation
102
Camshaft Wheel Timing Marks
102
Camshafts Removal
104
Camshaft Identification
104
Camshaft Cap Numbering (4 Cylinder Illustrated)
104
Camshafts Installation
105
Camshaft Sprocket
106
Cam Chain Removal
106
Cam Chain Installation
106
Camshaft And Camshaft Cap Wear
107
Cylinder Head Remove/Refit
108
Cylinder Head Installation
110
Valves And Valve Stem Seals Removal From The Cylinder Head
112
Valves And Valve Stem Seals Installation
112
Valve To Valve Guide Clearance
113
Valve Guide
113
Valve Face Inspection
113
Valve Seat Diameter
113
Valve Seat Repair Operation
114
Checking Seat Width
114
Reducing Seat Width Using 30 Cutter
114
Reducing Seat Width Using A 60 Cutter
114
Clutch
116
Clutch Description
119
Bleeding The Clutch
119
Clutch Master Cylinder Removal
120
Clutch Master Cylinder Disassembly
120
Clutch Master Cylinder Inspection
121
Clutch Master Cylinder Assembly
121
Clutch Master Cylinder Installation
121
Clutch Slave Cylinder Removal
122
Clutch Slave Cylinder Disassembly
122
Clutch Slave Cylinder Inspection
122
Clutch Slave Cylinder Installation
122
Clutch Disassembly
123
Clutch Assembly
124
Friction Plate Inspection
126
Balancers
127
Balancers Exploded View
128
4 Cylinder Balancer Removal
129
4 Cylinder Balancer Inspection
129
4 Cylinder Balancer Installation
130
3 Cylinder Balancers Removal
131
3 Cylinder Balancers Inspection
131
3 Cylinder Balancers Installation
131
Crankshaft/Rods/Pistons
132
Crankshaft/Rods/Pistons Exploded View
133
Engine Removal/Refit
135
Disconnecting The Oil Cooler Pipes
136
Engine Installation
137
Crankcases Disassembly
139
3 Cylinder Upper Crankcase (Without Alternator Cover)
140
4 Cylinder Lower Crankcase (With Alternator Drive Cover)
140
4 Cylinder Lower Crankcase (Without Alternator Drive Cover)
140
3 Cylinder Lower Crankcase (Engines With Alternator Drive Cover)
140
Crankcases Assembly
141
3 Cylinder Lower Crankcase Screws
141
Selector Forks
142
Connecting Rods Removal
143
Connecting Rods Installation
143
Aligning The Connecting Rod
144
Crankshaft Removal
145
Crankshaft Installation
145
Connecting Rod Big End Bearing Selection/Crankpin Wear Check
146
Con Rod Big End Bearing/Crankpin Clearance
146
Crankpin Diameter
146
Big End Bearing Selection Chart
146
Crankshaft Main Bearing/Journal Wear
147
Crankshaft Main Bearing/Journal Wear Clearance
147
Crankshaft Main Journal Diameter
147
Crankshaft End Float
147
Pistons Disassembly
148
Piston Wear Check
148
Removing The Gudgeon Pin Circlip
148
Piston Rings/Ring Grooves
149
Piston Ring/Groove Clearance
149
Piston Ring Gap
149
Piston Ring End Gap Tolerances
149
Piston Assembly
150
Piston Ring Identification
150
Cylinder Wear
151
Cylinder Liners Removal
151
Cylinder Liners Installation
152
Left Hand Crankshaft Cover Thunderbird, Thunderbird Sport, Adventurer And All 4 Cylinder Engines
153
Cover Removal/Refit
153
Seal/Cover Renewal
153
Transmission
154
Exploded View Geartrain
155
Exploded View Auxiliary Gears
156
Exploded View Selectors
157
Exploded View Gear Pedal And Mechanism
158
Auxiliary Gears
159
Transmission Description
159
Engine Cranking
159
Oil And Water Pump Drives
159
Alternator Spindle And Sprag Clutch Removal
160
Alternator Drive Rubber Shock Absorbers
160
Alternator Spindle And Sprag Clutch Installation
161
Fitting The Alternator Shaft
161
Starter Motor Idler Gear Removal
162
Starter Motor Idler Gear Installation
163
Selector Drum Removal
164
Selector Drum And Neutral Indicator "Finger"
165
Selector Drum Inspection
166
Selector Drum Installation
166
Correct Gear Position At Maximum Extension
167
Detent Position 1St Gear
167
Detent Position Neutral
167
Input And Output Shaft Assemblies Removal
168
Input And Output Shaft Assemblies Installation
168
Input Shaft Disassembly
169
Input Shaft Assembly
170
Pressing On The Input Shaft Bearing
170
Output Shaft Disassembly
171
Output Shaft Assembly
172
3 Cylinder Oil Circuit
176
3 Cylinder Oil Circuit Description
177
4 Cylinder Oil Circuit
178
4 Cylinder Oil Circuit Description
179
Oil Cooler Removal
180
Oil Cooler Installation
180
Sump Removal
181
Sump Installation
181
Oil Pipe Removal
181
Oil Pipe Installation
182
Oil Pump And Gears Removal
182
Oil Pump Inspection
183
Oil Pump Installation
183
Oil Pressure Test
184
Low Oil Pressure Warning Light Switch Inspection
184
Fuel System/Exhaust
185
Fuel Tank - All Models Except Thunderbird, Thunderbird Sport, Adventurer & Tiger
186
Thunderbird, Thunderbird Sport & Adventurer Fuel Tank
187
Tiger Fuel Tank
188
Adventurer Exhaust System
191
Thunderbird Sport Exhaust System
192
Fuel System Description
193
Fuel Requirements
193
Oxygenated Gasoline
193
Exhaust System
194
Fuel Tank Installation
195
Positioning The Fuel Tank For Installation
195
Fuel Tank Removal: Tiger
196
Fuel Tank Installation: Tiger
196
Fuel Tank Removal: Thunderbird, Thunderbird Sport & Adventurer
197
Air Intake/Carburetor Removal - All Models Except Thunderbird, Thunderbird Sport & Adventurer
200
Air Intake/Carburetor Installation - All Models Except Thunderbird, Thunderbird Sport & Adventurer
201
Air Intake/Carburetor Removal - Thunderbird, Thunderbird Sport & Adventurer
202
Air Intake/Carburetor Installation - Thunderbird, Thunderbird Sport & Adventurer
202
Overhaul - Mikuni Carburetor Disassembly
204
Overhaul - Mikuni Carburetors Inspection
204
Overhaul - Mikuni Carburetor Assembly
205
Overhaul - Keihin Carburetor Disassembly
206
Overhaul - Keihin Carburetor Inspection
206
Overhaul - Keihin Carburetor Assembly
207
Fuel System Cleanliness Inspection
208
Fuel Tap (All Models Except Tiger, Adventurer, Thunderbird Sport & Thunderbird)
208
Fuel Float Level Measurement
209
Correct Fuel Height Above Joint Face
209
Fuel Float Level Adjustment
210
Carburetor Setting
211
Carburetor Mixture Adjustment
211
Evaporative Loss System - Us California Specification Models
214
Evaporative Loss System Layout
214
Evaporative Loss System Operation - Engine Switched Off
215
Evaporative Loss System Operation - Engine Running
216
Cooling System Exploded View - All Models Except Thunderbird, Thunderbird Sport & Adventurer
218
Cooling System Exploded View - Thunderbird, Thunderbird Sport & Adventurer
219
Cooling System Description
220
Coolant
220
Coolant Level Inspection (Not Thunderbird, Thunderbird Sport & Adventurer)
221
Rear Suspension/Final Drive
231
Rear Suspension: All Except Tiger, Thunderbird, Thunderbird Sport & Adventurer
232
Rear Suspension: Tiger
233
Rear Suspension: Thunderbird, Thunderbird Sport & Adventurer
234
Final Drive
235
Remote Damping Force Adjuster Removal
237
Remote Damping Force Adjuster Installation
237
Rear Suspension Unit Removal
238
Rear Suspension Unit Installation
239
Thunderbird Sport Remote Rsu Reservoir
239
Swinging Arm Removal
240
Swinging Arm Inspection
241
Swinging Arm Installation
241
Final Drive, Engine Sprocket Removal
243
Final Drive, Engine Sprocket Inspection
244
Final Drive, Engine Sprocket Installation
244
Tape Splines To Prevent Damage
245
Ensure Gear Linkage Arrowed Is Fitted Vertically
245
Final Drive, Rear Sprocket Removal
246
Final Drive, Rear Sprocket Inspection
246
Final Drive, Rear Sprocket Installation
246
Rear Wheel Cush Drive Removal
246
Front Suspension/Steering
250
Torque Figures - Trophy, Trident & Sprint
251
Torque Figures - Daytona, Daytona Super 3 And Speed Triple
252
Torque Figures - Tiger
253
Torque Figures - Thunderbird, Thunderbird Sport & Adventurer
254
Fork Oil Change
256
Fork Oil Level Chart
257
Fork 'Pull Through' Chart
258
Front Fork Removal
259
Fork Installation
260
Fork Disassembly/Assembly
261
Kayaba Non-Adjustable Forks Inspection
261
Kayaba Non-Adjustable Forks Assembly
261
Showa Non-Adjustable Forks Inspection
263
Showa Non-Adjustable Forks Assembly
263
Kayaba Adjustable Forks
265
Kayaba Adjustable Forks Inspection
266
Kayaba Adjustable Forks Assembly
266
Headstock Bearing Adjustment
268
Early (1991) Trophy, Trident And Daytona Models
268
Headstock Bearing Replacement - Removal
270
Headstock Bearing Replacement - Assembly
271
Tiger Handlebar Alignment Mark
272
Front Brake Layouts
274
Rear Brakes Layouts
275
Brake Master Cylinders
276
Braking System Specifications And Identification
277
Front Brake Pads, Type A Removal
281
Front Brake Pads, Type A Installation
281
Front Brake Pads, Type B And Tiger Removal
282
Front Brake Pads, Type B And Tiger Installation
282
Front Brake Pads, Type C Removal
283
Front Brake Pads, Type C Installation
283
Front Brake Pads, Types D & F Removal
284
Front Brake Pads, Types D & F Installation
284
Rear Brake Pads, A & B Types Removal
285
Rear Brake Pads, C Type
286
Rear Brake Pads, A & B Types Installation
286
Bleeding The Front Brakes, Replacing Brake Fluid, All Types
287
Bleeding Rear Brakes, Replacing Brake Fluid, All Types
288
Front Brake Caliper, A Specification Removal
289
Front Brake Caliper, A Specification Disassembly
289
Caliper Pin Removal
289
Front Brake Caliper, A Specification Inspection
290
Front Brake Caliper, A Specification Assembly
290
Front Brake Caliper, A Specification Installation
290
Front Brake Caliper B Specification And Tiger Removal
291
Front Brake Caliper B Specification And Tiger Disassembly
291
Front Brake Caliper B Specification And Tiger Inspection
291
Front Brake Caliper B Specification And Tiger Assembly
291
Front Brake Caliper B Specification And Tiger Installation
292
Front Brake Caliper, C Specification Removal
293
Front Brake Caliper, C Specification Disassembly
293
Front Brake Caliper, C Specification Inspection
294
Front Brake Caliper, C Specification Assembly
294
Front Brake Caliper, C Specification Installation
294
Front Brake Caliper, D & F Specification Removal
295
Front Brake Caliper, D & F Specification Disassembly
295
Front Brake Caliper, D & F Specification Inspection
295
Front Brake Caliper, D & F Specification Assembly
296
Front Brake Caliper, D & F Specification Installation
296
Rear Brake Caliper, A & B Types Removal
296
Rear Brake Caliper, A & B Types Disassembly
296
Rear Brake Caliper, C Type
297
Rear Brake Caliper, A & B Types Inspection
297
Rear Brake Caliper, A & B Types Assembly
297
Rear Brake Caliper, A & B Types Installation
297
Front Master Cylinder Removal
298
Front Master Cylinder Disassembly
298
Front Master Cylinder Inspection
298
Front Master Cylinder Assembly
298
Front Master Cylinder Installation
299
Rear Master Cylinder Removal
299
Rear Master Cylinder Disassembly
299
Rear Master Cylinder Inspection
299
Rear Master Cylinder Assembly
300
Rear Master Cylinder Installation
300
Rear Brake Master Cylinder
300
Brake Pedal Height Adjustment
301
Brake Discs
301
Wheels/Tyres
302
Wheels: All Except Tiger, Thunderbird, Thunderbird Sport And Adventurer
303
Wheels: Tiger
304
Wheels: Thunderbird, Thunderbird Sport And Adventurer
305
Tyres
306
Tyre Pressures, All Models
306
Tyre Wear/Wheel Inspection, All Models
307
Important Tyre Information
308
Front Wheel Removal
310
Front Wheel Installation
310
Rear Wheel Removal
311
Rear Wheel Installation
312
Wheel Bearings Removal
312
Wheel Bearings Installation
313
Bearing Tool Selection Chart
313
Frame/Fairings
314
Body Panels - Trident, Daytona/Trophy
315
Footrests And Body, Tiger
316
Thunderbird, Thunderbird Sport & Adventurer - Sidestand, Footrest And Body
317
Thunderbird & Thunderbird Sport Frame
318
Adventurer Frame
319
Frame And Fittings - All Models Except Tiger, Thunderbird, Thunderbird Sport & Adventurer
320
Bodywork - 1996 Trophy
321
Seat Removal
322
Seat Installation
322
Seat Hump
323
Removal From The Seat
323
Refit
323
Hump Not In Use
323
Side Panels Removal
324
Side Panels Installation
325
Side Cover Removal - Thunderbird, Thunderbird Sport & Adventurer
325
Side Cover Assembly
325
Airbox Covers Removal
325
Cockpit Fairing Removal
326
Cockpit Fairing Installation
327
Cockpit Fairing - "New" Trophy Removal
327
Cockpit Fairing - "New" Trophy Assembly
327
Lower Fairings Removal
328
Lower Fairings Installation
328
Lower Fairings - "New" Trophy
329
Lower Fairings - "New" Trophy Installation
330
Cam Cover Cowl Removal
330
Cam Cover Cowl Installation
330
Frame, Footrests And Fixings Inspection
331
Electrical System/Ignition
332
Battery Charging
338
New (Dry) Battery
338
Battery Already In Service
338
Battery Removal - All Models Except Thunderbird, Thunderbird Sport & Adventurer
339
Battery Removal, Thunderbird, Thunderbird Sport & Adventurer
339
Battery Installation
340
Instruments
340
Fuel Gauge Level Sensor 1996 Trophy Removal
340
Fuel Gauge Level Sensor 1996 Trophy Inspection
341
Fuel Gauge Level Sensor 1996 Trophy Assembly
341
Fuel Gauge Sensor Circuit
341
Alternator Removal
342
Alternator Installation
342
Ignition System Description
343
Ignition Circuit
343
Ignition Circuit (Trophy 1996 Model Illustrated)
344
Pick-Up Sensor Removal
345
Pick-Up Sensor Installation
345
Ignition Coils Removal
345
Ignition Coil Installation
345
Tester General Information
346
To Attach The Tester To The Motorcycle
346
Set Up For Static Tests
347
To Test The Battery Voltage
348
To Test Pick-Up Coil Resistance
349
To Test Ignition Coil Primary Continuity
350
To Test The Starter Lockout System
351
To Test The Battery Supply During Cranking
352
To Test The Pick-Up Coil Amplitude
353
To Test For Correct Cranking Speed
354
To Test For Correct Igniter Coil Switching
355
To Check For Correct Tachometer Output
356
To Test The Secondary Resistance Of The Ignition Coils
357
Starter Motor Removal
358
Starter Motor Disassembly
359
Starter Motor Assembly
360
Starter Installation
360
Starter Motor Component Test
360
Yoke
361
Brush Plate
361
Brush And Lead Assembly
361
Starter Motor Circuit Diagram
362
Brush And Brush Spring
362
Drive End Housing
362
Starter Solenoid Removal/Installation
362
Starter Circuit (1996 Trophy)
363
Cooling Fan
364
Cooling Fan Switch Removal
364
Cooling Fan Switch Installation
364
Cooling Fan Switch Inspection
365
Resistance Between Switch Terminals
365
Water Temperature Gauge/Warning Light
365
Temperature/Warning Light Sensor Inspection
366
Temperature Sensor Resistance
366
Fuse Box
366
Fuse Diagnosis
367
Lights
368
Tail/Brake Light Bulb Replacement
368
Direction Indicator Removal
368
Direction Indicator Installation
368
Headlights
369
Trophy Headlight (Pre 1996 Model)
369
Trophy Headlight Bulb Replacement
369
Parking Light Bulb Replacement
370
Headlight - 1996 Trophy Adjustment
370
Vertical Headlight Adjustment
370
Horizontal Headlight Adjustment
370
Headlight Bulb Replacement 1996 Trophy
371
Headlight Adjustment Twin Circular Headlamps
372
Headlight Bulb Replacement Removal
372
Headlight Bulb Replacement Installation
372
Trident, Thunderbird, Thunderbird Sport, Adventurer And Speed Triple Headlight Adjustment
373
Wiring Circuit Diagrams
374
Key To Wiring Circuit Diagrams
375
Key To Component Numbers
375
Appendix
385
Troubleshooting
386
Engine Does Not Start, Starting Difficulty
386
Poor Running At Low Speed
386
Poor Running Or No Power At High Speed
387
Clutch Problems
388
Gear Change Faults
388
Abnormal Engine Noise
388
Abnormal Drive Train Noise
388
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This manual is also suitable for:
Daytona
Daytona super 3
Sprint sport
Sprint executive
Tiger
Speed triple
...
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Thunderbird
Thunderbird sport
Adventurer
Trident
Sprint
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