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Triumph Manuals
Motorcycle
2003 Daytona 600
Service manual
Triumph 2003 Daytona 600 Service Manual
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Contents
How to Use this Manual
General Information
Ignition System Safety Precautios
Engine Oils
Health Protection Precautions
Environmental Protection Precautions
Safety Instructions
Jacking and Lifting
Precautions against Damage
Cleaning Components
Lubrication
Joints and Joint Faces
Screw Heads
Gaskets, O-Rings
Fitting a Split Pin
Encapsulated Bolt
Oil and Grease Seals
Ball Bearing
Fuel Handling Precautions
Fuel Tank Removal
Chassis Repairs
Electrical Precautions
Battery Disconnecting
Disciplines
Electrical Wires
Special Service Tools
Full Specification
Torque Wrench Settings
Maintenance
Scheduled Maintenance Chart
Cylinder Head
Cylinder Head and Valves Exploded View
Cam Cover Exploded View
Camshaft and Camshaft Drive Exploded View
Cylinder Head Description
Cam Cover Removal
Cam Cover Bolts
Cam Cover Installation
Cam Chain Tensioner Removal
Cam Chain Tensioner Installation
Camshafts Removal
Camshaft Cap Numbering
Cap Bolt Release Sequence
Camshaft Inspection
Journal Diameter
Plastigage Check
Camshaft Installation
Cap Tightening Sequence
Valve Clearance Measurement
Valve Clearance Adjustment
Valve Clearance too Small
Valve Clearance too Large
Cylinder Head Removal
Coolant Temperature Sensor View
Bypass Hose
Camshaft Cover Bolts
Camshaft Timing Marks View
Camshaft Cap Numbering Diagram
Cap Release Sequence
Removing a Camshaft
Left Hand Mounting Bolt View
Right Hand Mounting Bolt View
Cylinder Head to Crankcase Bolts View
Bolt Release Sequence
Cylinder Head Inspection
Cylinder Head Level Check
Cylinder Head Installation
Cam Chain Rubbing Blade View
Bolt Tightening Sequence
Clip Screw-Heads View
Camshaft Replacement
Top Pad View
Cam Chain Tensioner Ratchet View
Pawl View
Silcone Sealatn Areas View
Cam Cover Bolts View
Air Deflector View
Left Switch Cube Connection View
Right Switch Cube Connection View
Fan Connection View
Valves and Valve Stem Seals - Removal from the Cylinder Head
Valves and Valve Stem Seals Installation
Clutch
Clutch Cover Exploded View
Clutch Assembly Exploded View
Clutch Controls Exploded View
Clutch Cable Removal
Clutch Cable Examination
Clutch Cable Assembly
Clutch Disassembly
Clutch Inspection
Clutch Assembly
Clutch Bush Grooves View
Inner Drum Alignment Marking View
Inner Plate Alignment Marking View
Outermost Friction Disc Location Teeth View
Belleville Washer View
Inner Plate View
Push Plate View
Clutch Lever View
Crankshaft, Rods and Pistons
Crankshaft, Connecting Rod, Piston and Liner Exploded View
Crankcase Exploded View
Engine Removal
Clutch Inner Cable View
Lock Nut View
Adjusting Nut View
Engine Installation
Outer Cables View
Throttle Twist Grip View
Opening Cable View
Locknut View
Closing Cable View
Side Stand Switch View
Top Hose View
Bottom Hose View
Radiator to Heat Exchanger Hose View
Air Deflector Shield View
Crankcases Disassembly
Upper Crankcase Bolt Release Sequence
Lower Crankcase Bolt Release Sequence
Crankcases Assembly
Locating Ring and Groove
Locating Dowel and Recess
Locating Dowel Positions
Bolt Tightening Sequence - Lower Crankcase
Bolt Tightening Sequence - Upper Crankcase
Crankshaft Removal
Crankshaft Inspection
Crankshaft Installation
Big End Cap View
Crankpin View
Connecting Rods
Connecting Rods Inspection
Connecting Rods Installation
Sealant Area View
Dimple (Faces Forward) View
Big End View
Connecting Rod Big End Bearing Selection/Crankshaft Journal Wear Check
Checking the Measured Plastigage
Connecting Rod Big End Bearing to Crankshaft Journal Clearance
Connecting Rod Big End Bearing Selection Chart (MM's)
Connecting Rod Bearing Selection
Crankshaft Main Bearing/Journal Wear Check
Bearing Clearance
Crankshaft Main Journal Diameter
Main Bearing Selection Chart (All Dimensions in MM's)
Chankshaft End Float
Pistons Disassembly
Pistons Inspection
Piston Wear Check
Piston Ring Gap
Piston Ring Gap Tolerances
Piston Rings/Ring Grooves
Checking Ring-Groove Clearance
Pistons Assembly
Circlip Fitment
Gudgeon Pin Alignment
Cylinder Liners Removal
Cylinder Liners Inspection
Cylinder Liners Installation
Refitting a Cylinder Liner
Transmission
Transmission Exploded View - Input and Output Shafts
Transmission Exploded View - Sprag
Transmission Exploded View - Gear Change Mechanism
Transmission Exploded View - Gear Selector Mechanism
Selector Shaft, Selector Forks & Drum Removal
Selector Shaft, Selector Forks & Drum Inspection
Selector Shaft, Selector Forks & Drum Installation
Locating the Detent Arm
Inserting the Gear Change Shaft
Input and Output Shafts Assemblies Removal
Input and Output Shafts Assemblies Installation
Input Shaft Disassembly
Input Shaft Assembly
Pressing off the Input Shaft Bearing
Pressing on the Bearing
Output Shaft Disassembly
Output Shaft Assembly
Sprag Clutch Removal
Sprag Clutch Inspection
Sprag Clutch Installation
Lubrication System
Lubrication System Exploded View - Sump
Lubrication System Exploded View - Oil Pump and Gears
Oil Circuit Diagram
Oil Circuit Description
Engine Oil Specification
Oil Level Inspection
Engine Oil and Filter Change
Low Oil Pressure Warning Light Switch Removal
Low Oil Pressure Warning Light Switch Installation
Heat Exchanger
Heat Exchanger Inspection
Heat Exchanger Installation
Sump Removal
Sump Installation
Sump Bolt Tightening Sequence
Oil Pump Removal
Oil Pump Inspection
Oil Pump Installation
Pump Insertion Illustration
Fuel System/Engine Management
Fuel Tank and Pump Exploded View
Fuel Rail, Throttles and Injectors Exploded View
Airbox Exploded View
Exhaust System Exploded View
Secondary Air Injection System Exploded View
Evaporative System Exploded View
Fuel Requirements
Oxygenated Gasoline
Ethanol, Methanol
MTBE (Methyl Tertiary Butyl Ether)
Fuel System/Engine Management: Glossary of Terms
Engine Management System Description
Engine Management System Sensors
Engine Management System Sensors Locations
Engine Management System Sensors Actuators
Engine Management System Sensors Actuator Locations
Engine Management Circuit Diagram - Daytona 600
ECM Connector Pin Numbering
Circuit Diagram - Engine Management System - Daytona 600
Engine Management System Diagnostics
On-Board Fault Detection System
Triumph Diagnostic Tool
Current Data
Freeze-Frame Data
Function Tests
Checks/Adjustments
Adaption Status
Build Data
Checks of the Status of Sensors and Actuators
Diagnostic Trouble Codes
Service Diagnostic Tool
Typical Screen Showing Symbols
Return Key
Validation Key
Help Key
Test Procedure
Connection and Power-Up
Select Language
Triumph Motorcycles
Switch on Bike Ignition
Data Link Fault Retry?
Service Data - Dealer
Service Data - Date
Main Menu
Diagnostics (if "Diagnostics" Is Selected)
Current Data Display
Stop Engine Display
To Select "Read Stories DTCS" (Diagnostic Trouble Codes) from the Main Menu
Stored DTCS
Three Options Are Now Available
Freeze Frame
Stored DTCS Display
Stored DTCS, Erase All DTC Data
To Select "Function Tests" from the Main Menu
Function Tests Display
Function Test Display
To Select "Checks/Adjustments" from the Main Menu (Operation 8)
Check/Adjust
Checks Display
Build Data Display
Sensor Data
Adaption Status Display
Adjust Display
Adjust Tune
Update Tune Displays
Update Tune (Confirm Selected)
Restarting Tune Download
Electrical Connector
When Disconnecting a Connector
When Inspecting a Connector
When Connecting a Connector
Disconnection of ECM Connectors
Reconnection of ECM Connectors
Further Diagnosis
Crankshaft Sensor
Pinpoint Tests
Idle Speed Control
Fuel Injectors
Throttle Position Sensor
Purge Valve
Ignition Coils
Coolant Temperature Sensor
Inlet Air Temperature Sensor
Fuel Pump Relay
System Voltage
Cooling Fan Relay
Tachometer
Coolant Temperature Gauge
Vehicle Speed Output
Lambda Sensor
Lambda Sensor Heater
EEPROM Error
Fall Detection Switch
2Nd Throttle Position Sensor
2Nd Throttle Actuator
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