Triumph Daytona 675 Manual
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Triumph Daytona 675 Manual

2009 daytona 675 (vin 381275>) motorcycle race kit manual
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See also: Handbook , Service Manual
2009 Daytona 675
(VIN 381275>)
Motorcycle Race Kit Manual
FOR CLOSED-CIRCUIT USE ONLY
©
Triumph Designs Ltd 2009. - A9900432 - ADC 7018 issue 1

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Summary of Contents for Triumph Daytona 675

  • Page 1 2009 Daytona 675 (VIN 381275>) Motorcycle Race Kit Manual FOR CLOSED-CIRCUIT USE ONLY © Triumph Designs Ltd 2009. - A9900432 - ADC 7018 issue 1...

  • Page 2: Table Of Contents

    ......29 Detent Wheel Kit - A9618068 ......© Triumph Designs Ltd 2009. Page 2 of 47...
  • Page 3 Carbon Fibre - A9728032 ......© Triumph Designs Ltd 2009. Page 3 of 47...

  • Page 4: Introduction

    It's not just the standard parts which have been enhanced - the 2009 Daytona 675 has a full range of Race Kit products to allow riders to fully exploit the new bike for the 2009 season.

  • Page 5: General Information

    • The Race Kit parts covered in this publication are intended for racing purposes only and any Triumph motorcycle fitted with such kits MUST NOT be used on public roads. • The Race Kit parts detailed in this publication may only be used on a closed-circuit in the hands of experienced riders.
  • Page 6 Warning These accessory kits are designed for use on Triumph Daytona 675 motorcycles only and should not be fitted to any other Triumph model or to any other manufacturer’s motorcycle. Fitting these accessory kits to any other Triumph model, or to any other manufacturer’s motorcycle, will affect the performance, stability and handling of the...

  • Page 7: Engine Parts

    • The gaskets contained in the kit are a direct replacement for the standard parts, but they have been designed to be reusable. • Thoroughly clean all mating faces before fitting new gaskets. © Triumph Designs Ltd 2009. Page 7 of 47...

  • Page 8: Cylinder Head Gasket 0.65 Mm - A9618112

    The use of the following Race Kit cylinder head gaskets will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required. Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage.
  • Page 9 Remove the existing cylinder head Remove the cylinder head and head gasket in line with the procedures gasket. detailed in the Daytona 675 service manual. Measure the compressed thickness of the solder. The squish clearance must Position a piece of solder (with a be a minimum of 0.65 mm.

  • Page 10: Camshaft, Inlet - A9618055

    The use of The Race Kit camshaft, valve Spring and camshaft sprockets detailed below will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required.
  • Page 11 3 of the The slotted holes allow adjustment of Daytona 675 service manual. Ensure the valve timing. The circular holes in the springs are installed with the close the sprockets are for Triumph service...

  • Page 12: Manually Adjustable Camshaft Drive Chain Tensioner - A9618108

    Refit camshafts following procedure detailed in the Daytona 675 • Do not start the motorcycle engine service manual. with the tensioner removed. Remove the camshafts following the procedure detailed in the Daytona 675 service manual.
  • Page 13 DO NOT force the 17. Following the procedure detailed in the plunger, continue steady finger Daytona 675 service manual, check the tightening only to take up the slack in valve clearances adjust the chain as you rotate the crankshaft.

  • Page 14: Inlet & Exhaust Valve Kit - A9618061

    The use of the following Race Kit inlet & exhaust valves will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required. Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage.

  • Page 15: Conrod Bearing Shell

    • The Race Kit conrod bearing shells should be assembled in the same manner as the standard conrod bearing shells. • Follow the procedure detailed in section 5 of the Daytona 675 service manual to remove the connecting rods, select the correct bearing shells for each connecting rod and refit the connecting rods.

  • Page 16: Main Bearing Shell 1.491 Mm To 1.495 Mm (White) - A1161301

    • The Race Kit main bearing shells should be assembled in the same manner as the standard main bearing shells. • Follow the procedure detailed in section 5 of the Daytona 675 service manual to remove the standard bearing shells and select the correct bearing shells required.

  • Page 17: Oil Pump Gearing Kit - A9618096

    Apply • Refer to the appropriate sections ThreeBond 1374 thread locking in the Daytona 675 service manual compound to the fixing and tighten to carry procedures 14 Nm. outlined in steps 1 to 13. NOTE Remove the oil/water pump.
  • Page 18 Retain valve guard. motorcycle is to be returned to its original condition. Refit the clutch assembly as detailed in the Daytona 675 service manual. 10. Apply ThreeBond TB1305 thread locking compound to the new pressure Refit the oil/water pump and secure release valve bolt thread.

  • Page 19: Air Funnel Kit - A9618090

    The use of the following Race Air Funnel Kit will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required. Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage.
  • Page 20 Apply ThreeBond 1364 locking compound to the threads only and tighten the fixings to a torque value of 6 Nm. 1. Retention tab 2. Fixing © Triumph Designs Ltd 2009. Page 20 of 47...

  • Page 21: Sai Blanking Kit - A9618094

    • Refer to the appropriate sections in the Daytona 675 service manual to carry out the procedures outlined in steps 1 to 8. Remove the SAI solenoid valve.
  • Page 22 Secure with the M6 x 16 mm bolts provided. Tighten to 9 Nm. 1. Reed valve cover, single 2. Reed valve cover, double 3. Bolt, M6 x 16 mm Refit the airbox. © Triumph Designs Ltd 2009. Page 22 of 47...

  • Page 23: Exhaust System, Race (Arrow) - A9600351

    The use of the Arrow Race Exhaust System will require changes to the fuelling and ignition settings. To alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required. Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage.
  • Page 24 2. Gasket NOTE • To obtain maximum performance exhaust port should machined, removing material from the area shown in red. The exhaust port shape should match the inside surface primary header bush. © Triumph Designs Ltd 2009. Page 24 of 47...
  • Page 25 Loosely secure the assembly to the outside original exhaust mounting point using the original bolt and M8 locknut provided, as shown. 1. Intermediate pipe 2. Original bolt 1. Exhaust mounting point 2. Original bolt © Triumph Designs Ltd 2009. Page 25 of 47...
  • Page 26 15. Refit the radiator, rear bodywork, lower 2. Intermediate pipe fairings, battery and seat as described 3. Spring in the Daytona 675 service manual. 4. Silencer mounting point NOTE • The radiator fan, rear light and 12. Check the exhaust system is correctly...

  • Page 27: Air Filter Kit - A9618075

    The three plastic retaining washers should be fitted to the three rear fixings as shown above. Tighten the fixings to a torque value of 4 Nm. © Triumph Designs Ltd 2009. Page 27 of 47...

  • Page 28: Manual Idle Speed Adjuster Kit - A9618076

    Daytona 675 service manual. Daytona 675 service manual. Remove item 3 (M5 nut) and item 4 Adjust the idle speed using the manual (throttle stop screw) from the throttle adjuster screw (item 1) as required.

  • Page 29: Slipper Clutch Tool - A3880037

    • If you have any queries with regard to the slipper clutch kit, in the first instance contact STM. For contact details see www.slipperclutch.com. Slipper Clutch Tool - A3880037 • It is recommended to use the Slipper Clutch Tool when fitting the Slipper Clutch. © Triumph Designs Ltd 2009. Page 29 of 47...

  • Page 30: Detent Wheel Kit - A9618068

    Release the two fixings and remove the Remove the clutch as described in baffle plate from crankcase section 5 of the Daytona 675 service breather. Discard the fixings. manual. cdnl 1. Crankcase breather baffle plate 2. Fixings © Triumph Designs Ltd 2009.
  • Page 31 • The detent arm is held in position under spring pressure. Prior to removal, note the orientation of the detent arm, fixing and spring, relative selector drum detent wheel. same orientation must be retained on assembly. © Triumph Designs Ltd 2009. Page 31 of 47...
  • Page 32 Tighten the fixing to 12 Nm. cdnj 1. Gear change shaft seal 2. Gear change shaft bearing 1. Detent arm 2. Fixing 3. Spring 4. Selector drum detent wheel © Triumph Designs Ltd 2009. Page 32 of 47...
  • Page 33 1. Gear change shaft 2. Abutment bolt 21. Refit the clutch and clutch cover as 3. Spring detailed in section 5 of the Daytona 675 service manual. 17. Ensure that the gear change shaft fingers locate in the detent wheel/arm and that the spring fits either side of the abutment bolt.

  • Page 34: Electrical Parts

    Screw, skt hd cap, M5 x 0.8 x 10 Plate, wire retainer Plate, wire retainer Gasket, alternator cover (standard part) Cover, alternator (unpainted sand casting) Alternator Puller Tool - A3880206 Item Description Puller tool, alternator © Triumph Designs Ltd 2009. Page 34 of 47...
  • Page 35 10. Position the new gasket provided (8) to the crankshaft dowels, then fit the race alternator cover and stator assembly to the crankcase following the procedure detailed in the service manual. © Triumph Designs Ltd 2009. Page 35 of 47...

  • Page 36: Programmable Race Ecu - A9618098

    24. However, due to variation between race prepared engines fuelling adjustments will be required. • The tune is for motorcycles fitted with a rubber fuel hose only, Triumph Part No. 1240177, it is NOT suitable for motorcycles fitted with a plastic fuel hose.
  • Page 37 Roll over sensor Gear position sensor Ignition switch circuit problem Battery voltage supply problem Cooling fan relay Airflap solenoid Instrument communication error Vehicle speed sensor Main relay Continuous Harness or instruments Short Flash © Triumph Designs Ltd 2009. Page 37 of 47...

  • Page 38: Race Calibration Software (Tracs) - A9610051

    Diagnostic plug connector USB lead NOTE • TRACS is a computer program which allows all Triumph Daytona 675 Programmable Race ECUs to be tuned using a laptop computer. • The TRACS software is supplied with a diagnostic plug connector and a USB lead to allow connection to the ECU using the dedicated diagnostic plug on the motorcycle.

  • Page 39: Tracs Management Kit - A9618099

    (Programmable Race ECU and Race Calibration Software Bundle) Parts supplied - A9618099 Item Description TRACS software CD Diagnostic plug connector USB lead Programmable Race ECU NOTE • Refer to the user instruction files on the software CD supplied. © Triumph Designs Ltd 2009. Page 39 of 47...

  • Page 40: Race Harness Kit - A9618100

    This is to allow fitment of race bodywork. The original fixing bolts (item 8) should be retained for reuse. © Triumph Designs Ltd 2009. Page 40 of 47...
  • Page 41 • The Race Harness is suitable for use with both the standard and Race Kit alternator. It is recommended to always run an alternator, without it the battery will discharge in a very short period of time. © Triumph Designs Ltd 2009. Page 41 of 47...
  • Page 42 A9930224 - Quickshifter, Race, Standard Shift , or A9930225 - Quickshifter, Race, Reverse Shift. The default cut time is 40ms. By using the Triumph TRACS Race Calibration Software, the cut time for low, medium and high engine speeds can be individually adjusted.
  • Page 43 • To avoid false triggering in wet conditions, all switches used should be of a sealed type. • Do not connect the black wire to the pink/brown wire on the race harness in any circumstances as this will result in a short circuit. © Triumph Designs Ltd 2009. Page 43 of 47...

  • Page 44: Quickshifter, Race, Standard Shift - A9930224

    Gear selector rod Cable tie NOTE • This part is suitable for fitment to Arrow Rearsets A9750536 only. • For fitment, refer to the comprehensive fitting instructions supplied with the quickshifter. © Triumph Designs Ltd 2009. Page 44 of 47...

  • Page 45: Rearsets, Race, Reverse Shift - A9750536

    Heel guard, right hand side Footrest mounting assembly, right hand side Screw, M6 Washer, M6 Support, rear brake fluid reservoir • For fitment, refer to the comprehensive fitting instructions supplied with the rearset kit. © Triumph Designs Ltd 2009. Page 45 of 47...

  • Page 46: Rearsets, Race, Standard Shift - A9750539

    Footrest mounting assembly, right hand side Screw, M6 Washer, M6 Support, rear brake fluid reservoir Screw, M5 NOTE • For fitment, refer to the comprehensive fitting instructions supplied with the rearset kit. © Triumph Designs Ltd 2009. Page 46 of 47...

  • Page 47: Carbon Fibre Engine Cover Protectors

    COMPANIES AND ITS REPRESENTATIVES IN THE UNITED STATES, SPECIFICALLY DISCLAIM ALL LIABILITY ARISING OUT OF THE USE OF THIS RACING KIT. IN NO EVENT SHALL TRIUMPH MOTORCYCLES LTD, ITS RELATED COMPANIES OR ITS UNITED STATES REPRESENTATIVES BE LIABLE FOR ANY DAMAGES ARISING OUT OF THE USE OF THIS RACING KIT. THIS MEANS THAT, IN NO EVENT, SHALL TRIUMPH MOTORCYCLES LTD, ITS RELATED COMPANIES OR ITS UNITED STATES REPRESENTATIVES BE LIABLE FOR ANY GENERAL, INDIRECT OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OF THIS RACING KIT.

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