Page 1 T595 DAYTONA T509 SPEED TRIPLE DAYTONA 955i SPEED TRIPLE (955cc)
Page 2 Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior notice and without incurring an obligation to make such changes to products manufactured previously.
Page 3 CONTENTS Introduction General Information Routine Maintenance Cylinder Head Clutch Balancer Crankshaft/Rods/Pistons Transmission Lubrication Fuel System Cooling System Rear Suspension/Final Drive Front Suspension/Steering Brakes Wheels/Tyres Frame/Bodywork Electrical System...
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 •...
Page 5 INTRODUCTION ASBESTOS REFERENCES This warning may apply to References following components or any References to the left-hand or right-hand side given in assembly containing one or this manual are made when viewing the motorcycle more of these components:— from the rear. WARNING Gaskets Operations covered in this manual do not always...
Page 6 Triumph parts are used. Safety features and corrosion prevention treatments embodied in the motorcycle may be impaired if other than genuine Triumph parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification.
Page 7: Table Of Contents
GENERAL INFORMATION CONTENTS Page IgnitionSystem Precautions ..........erousSubstances ..........Fluoroelastomers............. ineOils ............... HealthProtection Precautions .......... EnvironmentalProtection ........... SafetyInstructions ............Jackin lifting ............ Precautionsagainst damage ........... ineCoolant ............Cleaningcomponents ..........Lubrication............Jointsand joint faces ..........Gaskets, O-rings ............. Liquid gasket, non-permanent locking agent ......Screwthreads ............
Page 8: Table Of Contents
CONTENTS cont'd Page ueWrench 1.21 Settings ............ CylinderHead Area ........... 1.21 1.21 Clutch....................1.21 Balancer, Crankshaft and Crankcase ineCovers ............1.21 1.22 Transmission............LubricationSystem ........... 1.22 FinalDrive ............1.22 System ............1.22 Coolin 1.23 FuelSystem and Airbox ......................
Page 9: Dan G Eroussubstances
(skin cleansers and nail brushes will WARNING: Flouroelastomer material is used in the manufacture of various seals help). Preparations containing lanolin replace the in Triumph motorcycles. natural skin oils which have been removed. In fire conditions involving temperatures greater •...
Page 10: Environmentalprotection
Triumph Dealer before riding the motorcycle. Dispose of used oil and used filters through authorised Failure to take remedial action may reduce braking waste disposal contractors, to licensed waste disposal efficiency leading to an accident.
Page 11: Safetyinstructions
TIWJMPH GENERAL INFORMATION l SAFETY INSTRUCTIONS CAUTION: The coolant anti—freeze • contains a corrosion inhibitor which Jacking and lifting helps prevent damage to the metal surfaces inside the cooling system. Without this inhibitor, the Always ensure that any lifting apparatus coolant would `attack' the metals and the resulting has adequate load and safety capacity for corrosion would cause blockages in the cooling...
Page 12: Lubrication
T k J 1 GENERAL INFORMATION Liquid gasket, non- permanent locking agent Lubrication Follow manufacturer's directions for cleaning and Engine wear is generally at its maximum while the preparing surfaces where these compounds will be engine is warming up and before all the rubbing used.
Page 13: Lockin G Devices
Always use the correct replacement circlip as Seals must be pressed into place using a suitable recommended in the Triumph parts catalogue. driver. Use of improper tools will damage the seal. Self locking nuts...
Page 14: Fuelhandling Precautions
All potential - forms of ignition must be to an authorised Triumph dealer for repair or extinguished or removed (this includes any inspection. Any accident can cause damage to the appliance with a pilot light).
Page 15: Electricalprecautions
GENERAL INFORMATION I ELECTRICAL PRECAUTIONS Connectors and Harness — The engine of a motorcycle is a particularly hostile environment for electrical The following guidelines are intended to ensure the components and connectors. Always ensure these safety of the operator whilst preventing damage to the items are dry and oil free before disconnecting and electrical and electronic components fitted to the connecting test equipment.
Page 16: Disciplines
Disassembled parts should be visually inspected and replaced with new ones if there are any signs of the All genuine Triumph parts have the full backing of the following: motorcycle warranty. Triumph dealers are obliged to supply only genuine Triumph recommended parts.
Page 17: Servicetools
GENERAL INFORMATION I Service tools and garage equipment 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 I GENERAL INFORMATION T3880250 - Engine Management Diagnostics T3880300 - Wrench, Yoke Upper Nut Em® yduu T3880305 - Clutch Anti-rotation Tool T3880285 - Fork Seal/Bearing Drift gand T3880311 - Oil Filter Wrench T3880290 - Wrench, Swinging Arm Clamp gabc T3880315 - Extractor - Cylinder Liners T3880295 - Wrench, Swinging Arm Lock gabd 1.12...
Page 19 GENERAL INFORMATION 1 Full Specification T509 Speed Triple T595 Daytona Engine......3 Cylinder 12 Valve DOHC 3 Cylinder 12 Valve DOHC Arrangement......Transverse In-line Transverse In-line Displacement..... 885 cc 955 cc Borex Stroke ....... 76.0mmx65mm 79.0mmx65mm CompressionRatio ....
Page 20 GENERAL INFORMATION 1595 Daytona T509 Speed Triple Full Specification Piston/Crankshaft Cylinder Bore Dia ....76.030 mm/75.985 mm 79.030 mm/78.985 mm Piston Dia. (at 90° to gudgeon pin) ..75.980 mm/75.960 mm Cyl. Nos. 1 & 3 78.980 mm/78.960 mm Cyl. Nos 1 & 3 75.970 mm/75.960 mm Cyl.
Page 21 Tkeg" GENERAL INFORMATION l Full Specification T509 Speed Triple T595 Daytona Fuel System FuelType ......Unleaded, 95 RON Unleaded, 95 RON (U.S. 89 CLC/AKI) (U.S. 89 CLC/AKI) FuelTank Capacity ....18 Litres 18 Litres Low Level Warning Lamp ...
Page 22 Rear Tyre Tread Depth mm..... 3.0 mm — over 80 mph (130 km/h) 3.0 mm — over 80 mph (130 km/h) WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised closed course conditions. Frame Twin-spar aluminium FrameType ......
Page 23 ° TWPH GENERAL INFORMATION I Full Specification Speed Triple 955cc Daytona 955i Engine......3 Cylinder 12 Valve DOHC 3 Cylinder 12 Valve DOHC Arrangement......Transverse In-line Transverse In-line Displacement......955 cc 955 cc Borex Stroke ....... 79.0 mm x 65 mm 79.0 mm x 65 mm CompressionRatio ....
Page 24 I GENERAL INFORMATION Daytona 9551 Speed Triple 955cc Full Specification Piston/Crankshaft 79.030 mm/78.985 mm Cylinder Bore Dia ....79.030 mm/78.985 mm 78.975 mm/78.960 mm Cyl. Nos 1 & 3 to gudgeon pin) ..78.975 mm/78.960 mm Cyl. Nos. 1 & 3 Piston Dia.
Page 25 T° ^uMPH GENERAL INFORMATION l Full Specification Speed Triple 955cc Daytona 955i Fuel System Unleaded, 95 RON Unleaded, 95 RON FuelType ......(U.S. 89 CLC/AKI) (U.S. 89 CLC/AKI) FuelTank Capacity ....18 Litres 18 Litres LowLevel Warning Lamp .... . 3.5 litres remaining 3.5 litres remaining FuelPump Type ....
Page 26 Rear Tyre Tread Depth mm..... 3.0 mm — over 80 mph (130 km/h) 3.0 mm — over 80 mph (130 km/h) WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised closed course conditions. Frame Twin-spar aluminium FrameType ......
Page 27: Tor Q Uewrench Settings
GENERAL INFORMATION I Torque Wrench Settings Cylinder Head Area Application Torque(Nm) Notes Cam cover to cylinder head Short bolts Cam cover to cylinder head Long bolts Cam chain tensioner to crankcase Cam chain tensioner centre bolt Camshaft bearing caps to head Lubricate threads Camshaft sprocket to camshaft Encapsulated fixing...
Page 28: Transmission
Tkewff 1 GENERAL INFORMATION Transmission Notes Torque(Nm) Application Use new tab washer Output sprocket to output shaft Encapsulated fixing Detent wheel to selector drum Encapsulated fixing Detent arm stud Detent arm nut Selector drum bearing retaining screw Stop plate to crankcase Selector shaft retainer Spring abutment bolt Encapsulated fixing...
Page 29: Fuelsystem And Airbox
GENERAL INFORMATION 1 Fuel System and Airbox Application Torque(Nm) Notes Fuel tank to frame Fuel cap to fuel tank Fuel pump mounting plate to fuel tank Fuel pump clamp screw Fuel filter clamp screw Throttle body to cylinder head Fuel rail bracket to fuel rail Fuel rail bracket to throttle body Throttle potentiometer to throttle body Fuel feed/return pipe connections to fuel rail...
Page 30: Brakes
I GENERAL INFORMATION Front Suspension Cont'd M6 screws only Handlebar clamp to top yoke (low bars only) M8 screws only Handlebar clamp to top yoke (low bars only) Brakes Notes Torque(Nm) Application Front brake caliper to fork Front brake pad retaining pin Front brake caliper bleed screw Front brake hose to caliper Front brake master cylinder to handlebar...
Page 31: Bodywork
TJMP GENERAL INFORMATION I Bodywork Application Torque(Nm) Notes Front mudguard to fork Side panels to frame Front seat to frame Cockpit to headlamp casting Belly panel to bracket Side panel to bracket 1.25...
Page 32 MAINTENANCE CONTENTS Page Introduction.............. ServiceCheck Sheets ............. MaintenaceChart ............
Page 33 Service Check Sheets Triumph are pleased to be able to offer pads of service check sheets to aid technicians during servicing of Triumph motorcycles. Each pad has 50 single sided service sheets which have tick boxes to indicate the correct maintenance requirement at each mileage interval.
Page 34 Ti uMI MAINTENANCE 2 Scheduled Maintenance Chart Odometer Reading in Miles (Kms) or time period, whichever comes first 24000 Operation Description Every 6000 12000 18000 30000 Sec- (800) (10000) (20000) (30000) (40000) (50000) tion 1 month 1 year 2 years 3 years 4 years 5 years...
Page 35: Cylinder Head
CYLINDER HEAD CONTENTS Page ExplodedViews ............Description ..........CylinderHead CamCover ............... CamChain Tensioner ............Camshafts............... Camshaftand Bearing Cap Inspection ........3.10 ValveClearances ............3.12 CamChain ............... 3.17 Removal............3.17 Installation............3.17 CylinderHead ............3.18 Removal............3.18 Inspection............3.22 Installation............3.23 Valvesand Valve Stem Seals ..........
Page 36 TiuMI MrII 3 CYLINDER HEAD & CAMSHAFT Exploded View Cylinder Head and Valves Refer to Text 9 Nm ^--- 10 Nm...
Page 37 ThUMI CYLINDER HEAD & CAMSHAFT 3 Exploded View Cam Cover 25 Nm...
Page 38 3 CYLINDER HEAD & CAMSHAFT Exploded View Camshaft and Camshaft Drive 10 Nm 9 Nm 18 Nm...
Page 39 Tke2w CYLINDER HEAD & CAMSHAFT 3 CYLINDER HEAD DESCRIPTION CAM COVER All engines are fitted with an aluminium alloy cylinder Removal head which carries the camshaft, valves and spark Remove the seat and disconnect the battery, plugs. The -cylinder head is cast as a single entity and negative (black) lead first.
Page 40 3 CYLINDER HEAD & CAMSHAFT 3. Apply silicone sealer to the areas shown in the 7. Progressively release the cam cover bolts in the diagram below. sequence shown below. NOTE: • Two longer bolts are fitted at the right hand end adjacent to the cam chain.
Page 41 CYLINDER HEAD & CAMSHAFT 3 CAM CHAIN TENSIONER NOTE: • In addition to the crank sensor/wheel alignment, at TDC, the alignment marks on the Removal camshaft sprockets will point inwards at a point Remove the cam cover as described earlier in this level with the joint face.
Page 42 3 CYLINDER HEAD & CAMSHAFT 8. Rotate the engine through 4 full revolutions, and reset number 1 cylinder to TDC. Ensure that the 'Ti' mark on the crankshaft rotor is aligned with the crankshaft position sensor. NOTE: • The crankshaft sensor will automatically align correctly with the front, back or centre of the Ti tooth depending on the camshaft version.
Page 43 CYLINDER HEAD & CAMSHAFT 3 NOTE: CAMSHAFTS • The caps are numbered sequentially and must not be interchanged for a different position on Removal the head. The camshaft caps on the outside of the timing chain (known as outriggers) are NOTE: marked 'A' for the exhaust and 'B' for the inlet.
Page 44 Never fit a camshaft sprocket to a camshaft using Check the journal-to-head clearances, using incorrectly identified bolt holes. Severe engine `Plastigauge' (Triumph part number damage wil l result from i ncorrect attachment. 3880150-T0301) as follows: • Ensuring that the camshaft sprocket alignment...
Page 45 CYLINDER HEAD & CAMSHAFT 3 NOTE: Installation • The camshaft caps are unique to each cylinder Thoroughly clean the camshafts and journals. head and are, therefore, not available Inspect the ends of the camshafts for correct fitment individually. If a camshaft cap is worn or of the sealing plugs.
Page 46 1AQ2" 3 CYLINDER HEAD & CAMSHAFT NOTE: VALVE CLEARANCES • The correct valve clearances are in the range Camshaft, valve, valve shim and valve seat wear affects given below. the valve clearances. The effect of this wear is to change INLET 0.10 - 0.15 mm the gap between the camshaft and valve shim, causing...
Page 47 Tk ^ ^P CYLINDER HEAD & CAMSHAFT 3 3. Loosely assemble the tool legs to the mounting VALVE CLEARANCE ADJUSTMENT plate ensuring that the legs are assembled to the Valves are adjusted, in pairs, using tool T3880012 to correct side of the mounting plate for the valve hold the valve open during shim removal and shims being changed.
Page 48 3 CYLINDER HEAD & CAMSHAFT 6. Turn the engine over until the camshaft lobes for the 10. Turn the engine over until the camshaft fully opens the valves being adjusted. Remove the tool when valves to be adjusted point directly away from the the valve is fully open.
Page 49 TIUM1 CYLINDER HEAD & CAMSHAFT 3 .^ - E a) 7 r N L_ C y= 'O +L-' N N d > C") C") "'^ 'D V i > LO N > > > > ^n O > L a) — C7 M M C>...
Page 50 MPII 3 CYLINDER HEAD & CAMSHAFT • — •C y - ^-, U RS > ^_. > ,y •N N •- ►n rV('- "^ " t.() UU O U) O c0 CO Co CO to CO U) o m m CO Co CO Co CO U"...
Page 51 1. Crankshaft Position Sensor 2. Crankshaft Rotor 3. 1.00 mm ± 0.20 mm Apply Triumph silicone grease to the grommet on the crankshaft position sensor and refit the grommet to the crankcase. Refit the camshafts etc. as described earlier in this 1.
Page 52 3 CYLINDER HEAD & CAMSHAFT NOTE: CYLINDER HEAD • Two longer bolts are fitted at the right hand end Removal adjacent to the cam chain. Remove the seat and disconnect the battery negative (black) lead first then the positive (red) lead.
Page 53 TJUMIit CYLINDER HEAD & CAMSHAFT 3 1. Crankshaft Rotor Clamp Nut 1. Coolant Drain Point 2. Crankshaft Position Sensor 12. Disconnect the top and bypass hoses at the radiator 3. Centre Bolt end. 19. Rotate the crankshaft clockwise (the normal 13.
Page 54 MpII 3 CYLINDER HEAD & CAMSHAFT 25. Progressively release each of the fasteners securing the camshaft caps of the inlet camshaft to the cylinder head. © 26. Release the caps for the exhaust camshaft. O4FQ CAUTION: Never release one camshaft •...
Page 55 CYLINDER HEAD & CAMSHAFT 3 33. Remove the exhaust downpipes and silencer as detailed in the fuel system section. Camshaft Cap Numbering NOTE: 1. Downpipe to Head Fixings • The caps are numbered sequentially and must not be interchanged for a different position on 2.
Page 56 ThU9H 3 CYLINDER HEAD & CAMSHAFT 39. Progressively release the cylinder head bolts in the 36. Release the screws securing the side of the cylinder order shown below. head to the upper crankcase. Cylinder Head Bolt Release Sequence 1. Cylinder Head to Upper Crankcase Screws Lightly tap the cylinder head with a rubber mallet to 37.
Page 57 T1WMII CYLINDER HEAD & CAMSHAFT 3 Installation CAUTION: Using the correct procedure NOTE: • to fit and tighten the cylinder head bolts • On all engines, the cylinder liners must be will ensure the long term reliability of the cylinder head gasket.
Page 58 3 CYLINDER HEAD & CAMSHAFT Fit the screws securing the side of the cylinder head WARNING: Move the handlebars to left to the crankcase and tighten to 12 Nm. and right full lock while checking that 7. Refit and tighten the frame to cylinder head bolts to cables and harnesses do not bind.
Page 59 CYLINDER HEAD & CAMSHAFT 3 O4Q1 gaaa Camshaft to Cylinder Head Alignment Marks 1. Ignition Rotor 2. Crankshaft Position Sensor CAUTION: If the camshafts and caps are fitt ed without first aligning the timing 25. Re-check that the camshaft timing marks align as marks on both the crankshaft and camshaft ill ustrated below.
Page 60 3 CYLINDER HEAD & CAMSHAFT 34. Refit the radiator and oil cooler as described in the cooling system section. 35. Refit the clutch cover incorporating a new gasket.. Tighten the clutch cover fixings to 9 Nm. 36. Refit the clutch cable and adjust as described in the clutch section.
Page 61 T° 1 U M 1' H CYLINDER HEAD & CAMSHAFT 3 VALVES AND VALVE STEM SEALS Removal from the cylinder head 1. Remove each valve from the head using a valve Close wound section -----^ spring compressor. The compressor must act on the top cup to allow removal of the valve collets.
Page 62 3 CYLINDER HEAD & CAMSHAFT T1 UMI VALVE TO VALVE GUIDE CLEARANCE CAUTION: Incorrect fitment of the valve If the valve guides are worn beyond the service limit • stem oil seals could lead to high oil given below, the cylinder head must be replaced. consumption and blue smoke emissions from the exhaust system.
Page 63 CLUTCH CONTENTS Page lodedView — Clutch Cover ..........ClutchCable ............. Removal............Examination............Assembly............Clutch..............Removal............Assembly............FrictionPlate Inspection ............ 4.11 Frictionplate thickness ..........4.11 Frictionplate bend/warp ..........4.11...
Page 64 4 CLUTCH Exploded View — Clutch Cover 12 Nm 12 Nm 5 Nm 9 Nm...
Page 65 CLUTCH 4 Exploded View — Clutch Assembly 105 Nm 10 Nm...
Page 66 4 CLUTCH Exploded View — Clutch Controls 1 Nm 15 Nm 6 Nm...
Page 67 TJMPH CLUTCH 4 CLUTCH CABLE 5. At the clutch lever end, align the adjuster and locknut slots. Removal 6. Pull in the clutch lever and turn the inner cable, 1. Remove the seat and disconnect the battery, anti-clockwise through the slots in the adjuster and negative (black) lead first.
Page 68 TWMH 4 CLUTCH Set the adjuster at the clutch end to give a CLUTCH preliminary setting of 2-3 mm of free play as measured at the lever. Disassembly Operate the clutch lever several times and recheck 1. Remove the seat and disconnect the battery, the amount of free-play present.
Page 69 T1WPH CLUTCH 4 Drain the engine oil as described in the lubrication NOTE: section. • It is not normally necessary to disassemble the clutch further, but if the clutch inner and outer 6. Remove the clutch cover. drums are to be removed, proceed as follows: 7.
Page 70 TaWM1 4 CLUTCH 15. Slide the clutch outer drum gently backwards and NOTE: forwards to dislodge the splined bearing sleeve. • The alternator drive gear is fitted with a Carefully remove the splined sleeve and needle backlash eliminator gear. The backlash while supporting clutch drum.
Page 71 T° I UM['H CLUTCH 4 1. Splined Sleeve 2. Needle Roller Bearing 7. Refit the crankshaft position sensor and adjust the air gap to 1 mm. Belleville Washer 'Out' Mark 11. Lock the inner and outer drums together using service tool 13880305. Depress the rear brake pedal to prevent the engine from turning, and tighten the clutch centre nut to 105 Nm.
Page 72 4 CLUTCH 1. Outer Clutch Friction Plate 1. Shim 2. Outer Drum NOTE: The following size shims are available: - • 3. Individual Tags 0.10mm, 0.15mm, 0.20mm, 0.25mm, 0.30mm and 0.35mm. 15. Refit the clutch pullrod. 16. Refit the clutch pressure plate together with the CAUTION: Severe engine damage will springs and bolts.
Page 73 T1IUMM CLUTCH 4 23. Set the final adjustment of the cable to give 0.4-0.8 FRICTION PLATE INSPECTION mm of free-play at the lever by turning the adjuster If any friction plate thickness is outside the service nut and locknut at the lever end. li mit, replace the friction plates as a set.
Page 74 J1JA CONTENTS Page lodedView — Balancer Shaft ..........Balancers..............nmentInspection ..........Balancer(crankcase) plug replacement ......... BalancerShaft Removal ..........Disassembly............Examination............Assembly............Installation............
Page 75 5 BALANCERS Exploded View — Balancer Shaft 40 Nm (if fitted) 40 Nm...
Page 76 TIullMoI BALANCERS 5 BALANCERS The balancer is fitted to control 'pulsing' within the engine. Without any form of balancer, the engine would 'pulse' each time the crankshaft rotated. This 'pulsing' would be felt as a vibration which would amplify as the engine speed was increased.
Page 77 3. Remove the balancer cap bolts and bearing (1236) to the front edge of each plug as shown retaining brackets (if fitted) from the crankcase. below. The adhesive is available from Triumph under part number T3450301. The adhesive must cover the complete circumference of the plug.
Page 78 TUMI MPI BALANCERS 5 Withdraw the balancer assembly from the To remove the right hand bearing, undo the crankcase. large-head capscrew from the end of the shaft and slide o the bearing and sleeve. Discard the On later models, collect the bearing from the left capscrew.
Page 79 Tke2pff 5 BALANCERS Fit the flat washer, belleville washer (dished face Examination outwards) and circlip. Before assembly, check the following items: Shaft bearings for overheating (blue coloured • WARNING: Always wear eye protection areas), loose or missing rollers etc. when fitting the circlip. The belleville washer below the circlip exerts considerable Shaft bearing areas and sleeves for overheating •...
Page 80 BALANCERS 5 TKWPMUJR Installation 1. Check that the backlash eliminator gear tooth which is marked with a line is directly in front of the balancer drive gear marked with a dot. 1. Crankshaft Drive Gear 2. Balancer Driven Gear 3. Alignment Marks 5.
Page 81 ° ZI l! 5 BALANCERS Early Models Only: Fit the bearing retaining NOTE: brackets ensuring that they are correctly located • The plug will be damaged during removal and around the balancer bearings. must be discarded. 11. Turn the engine over until the 'Ti' mark on the crankshaft rotor aligns with the centre of the crankshaft position sensor.
Page 82 RODS and PISTONS CRANKSHAFT, CONTENTS Page ExplodedViews ............EngineRemoval/Refit ............EngineInstallation ............ 6.10 Crankcases.............. 6.10 Disassembly............6.11 Assembly............6.13 ConnectingRods ............6.13 Removal............Installation............6.13 6.15 Crankshaft............... 6.17 Connecting Rod Big End Bearing Selection/Crankpin Wear Check ....6.17 Con rod big end bearing/crankpin clearance ......6.17 Crankpindiameter ............
Page 83 TIUMI MPII 6 CRANKSHAFT/RODS/PISTONS Exploded View Crankshaft, Connecting Rod, Piston and Liner See text...
Page 84 CRANKSHAFT/RODS/PISTONS 6 T^ 111 Exploded View — Crankcase 25 Nm 13 Nm dancer section 12 Nm 10 Nm...
Page 85 6 CRANKSHAFT/RODS/PISTONS ENGINE REMOVAVREFIT Removal Remove the seat and disconnect the battery, negative (black) lead first. Remove the battery. Place the motorcycle on a paddock stand. WARNING: Ensure that the motorcycle is stabilised and adequately supported to prevent the risk of injury from the motorcycle falling.
Page 86 CRANKSHAFT/RODS/PISTONS 6 11. Remove the oil cooler assembly complete with 17. Set the drive chain adjustment to allow maximum the cooler pipes. free play in the chain. Refer to the rear suspension/final drive section for chain 12. Detach the following coolant hoses; adjustment information.
Page 87 6 CRANKSHAFT/RODS/PISTONS Tke2wff 23. Release the clutch cable from the actuating arm by pushing the inner cable nipple through the arm and sliding the cable out of the slot in the arm. Detach the cable from the bracket. ; ^7 V / Il^ ^ \ 7 1.
Page 88 CRANKSHAFT/RODS/PISTONS 6 10. Tighten the lower left hand frame to engine bolt to Engine Installation 80 Nm. Position the engine beneath the frame. 11. Check the gap between the frame and engine at all right hand engine mounting locations. If any Raise the engine and loop the drive chain over gap is found to be greater than 1 mm, add spacer the output sprocket.
Page 89 TJMI 6 CRANKSHAFT/RODS/PISTONS 20. Set the final adjustment of the cable to give 0.4-0.8 mm of free-play at the lever by turning the WARNING: Move the handlebars to left adjuster nut and locknut at the lever end. Tighten and right full lock while checking that the lock ring.
Page 90 CRANKSHAFT/RODS/PISTONS 6 T1WIIMUI MPII 30. Using new seals at the cylinder head end, refit the 35. Align the oil cooler bracket to the crankcase and exhaust system as described in the fuel system tighten the fixing to 9 Nm. section. 1.
Page 91 6 CRANKSHAFT/RODS/PISTONS Release the lower crankcase bolts in the CRANKCASES sequence shown in the diagram below. The upper and lower crankcases are machined as a matched set and must never be assembled to non-matching halves. 13.10., Before the crankcase halves can be separated, the engine must be removed from the frame and the ? j ' ' ,11 1112L...
Page 92 CRANKSHAFT/RODS/PISTONS 6 TIUMI Assembly CAUTION: Do not use excessive Apply Loctite 648 to the outer races of the amounts of sealer. The extra sealer may gearbox bearings. Fit the gearbox shafts (if become dislodged and could block the oil removed), ensuring the locating ring on the input passages in the crankcases causing severe shaft is in position in the circlip groove on the engine damage.
Page 93 T1IUMI 6 CRANKSHAFT/RODS/PISTONS Stage 2— all screws NOTE: 15. Invert the engine. • The crankcase screws are tightened in stages, in the same sequences used during strip down. In the correct sequence, tighten all lower crankcase • Two different sizes of crankcase screw are screws to 12 Nm.
Page 94 CRANKSHAFT/RODS/PISTONS 6 CONNECTING RODS Installation Removal NOTE: • Connecting rod bolts and nuts are treated with Connecting rods may be removed from the engine after an anti-rust solution which must not be first removing it from the frame. The cylinder head must removed.
Page 95 14 Nm of nut rotation as measured then through 120 1. Liner using the Triumph torque turn gauge 3880105-T0301. 2. Sealer Area To accurately gauge the 120° turn, fit the tool 4. Fit the piston and connecting rod assembly into between the socket and the drive handle and the liner.
Page 96 CRANKSHAFT/RODS/PISTONS 6 CRANKSHAFT Installation NOTE: CAUTION: Always check the bearing • Before the crankshaft can be removed, the two journal clearance, as described in the halves of the crankcase must first be separated. following pages, before final assembly of the crankshaft.
Page 97 6 CRANKSHAFT/RODS/PISTONS NOTE: • If the markings on the balancer gears do not align at the same point, the backlash eliminator gear can be rotated independently of the drive gear by gently moving it against the drive gear teeth. • For ease of identification during assembly, apply a small paint spot to the outside face of the dot marked balancer drive gear tooth.
Page 98 The crankpin clearances are measured using 'Plastigauge' • If any crankpin has worn beyond the service (Triumph part number 3880150-T0301). li mit, the crankshaft must be replaced. Due to Remove the big end cap from the journal to be the advanced techniques used during checked.
Page 99 Measure and record the diameter of each Measure the bearing to crankshaft main journal crankshaft main bearing journal. clearance using plastigauge (Triumph part number 3880150-T0301). Use the method Measure and record each main bearing bore described in connecting rod clearance diameter in the crankcase (bearings removed).
Page 100 I JMPH CRANKSHAFT/RODS/PISTONS 6 PISTONS Piston Wear Check 1. Measure the piston outside diameter, 5 mm up from Disassembly the bottom of the piston and at 90 to the direction of NOTE: the gudgeon pin. • The pistons and connecting rods can be separated after removing the cylinder head and liners.
Page 101 6 CRANKSHAFT/RODS/PISTONS Piston Ring End Gap Tolerances — 885cc engine 0.15 — 0.30 mm Second 0.26 — 0.41 mm Oil Control 0.20 — 0.70 mm Piston Ring End Gap Tolerances — 955cc engine 0.15 — 0.30 mm Second 0.30 — 0.45 mm Oil Control 0.20 —...
Page 102 TiIuMoI CRANKSHAFT/RODS/PISTONS 6 Fit the piston onto the connecting rod with the Cylinder Wear arrow on the piston crown facing AWAY from the oil hole in the connecting rod. Measure the inside diameter of each cylinder using an internal micrometer or similar accurate measuring 3.
Page 103 6 CRANKSHAFT/RODS/PISTONS CYLINDER LINERS CAUTION: The cylinder liners are made of • aluminium alloy and therefore can be Removal (Engine In Or Out Of The Frame) easily damaged. Handle with care, ensuring the cylinder bore is not scratched. NOTE: • Cylinder liners can be removed with engine in Carefully fit the tool fully into the cylinder bore, the frame, after the cylinder head has been...
Page 104 CRANKSHAFT/RODS/PISTONS 6 NOTE: Installation • The liners have a large chamfer at the bottom of Thoroughly clean the liner removing all traces of the bore enabling fitting of the piston without old silicone sealer. need for a piston ring compressor. Remove all traces of sealer from the crankcase bores.
Page 105 6 CRANKSHAFT/RODS/PISTONS LEFT HAND CRANKSHAFT COVER i\ CAUTION: The engine must not be • started or turned over for a minimum of 15 The left hand crankshaft cover is fitted, on the inside minutes after assembly to allow the seal to fully face, with a lip type seal.
Page 106 TRANSMISSION CONTENTS Page ExplodedViews ............TransmissionDescription ..........— Operation ..........AuxiliaryGears AlternatorSpindle ............Removal......................Installation..... SpragClutch ............. 7.10 Inspection............7.10 Assembly............7.12 ..........StarterIdler Gear ..7.12 Removal............7.12 ......Inspection......7.12 Assembly............7.13 Selectors, Selector Shaft & Drum ..........7.13 Removal............
Page 107 7 TRANSMISSION TkQ2WH Exploded View, Input and Output Shafts 132 Nm...
Page 108 TIUMI TRANSMISSION 7 Exploded View, Auxiliary Gears 12Nm lONm 10 Nm 40 Nm 12 Nm...
Page 109 7 TRANSMISSION Exploded View, Selector Mechanism 10 Nm 12 Nm...
Page 110 TRANSMISSION 7 Exploded View, Gear Pedal etc. '\JJ^ 28 Nm...
Page 111 7 TRANSMISSION Tke2pn AUXILIARY GEARS 1. Starter Motor 2. Alternator 3. Starter Idler Gear Sprag Clutch 5. Alternator Drive Gear 6. Clutch Auxiliary Gear 7. Oil Pump Auxiliary Gear 8. Oil Pump Intermediate Gear 9. Oil Pump Drive Gear 10. Oil Pump Engine Started TRANSMISSION DESCRIPTION When the engine starts, and the starter button is...
Page 112 TRANSMISSION 7 10. Prevent the alternator shaft from turning by fitting ALTERNATOR SPINDLE service tool 3880040-T0301 to the front alternator Removal mounting-bolt holes. Remove the seat and disconnect the battery, negative (black) lead first. Remove the lower fairings (if fitted). Remove the body side panels.
Page 113 Tiu9ii 7 TRANSMISSION Check the alternator `0' ring for damage and 14. Remove the alternator drive housing from the old distortion. Replace as necessary. spindle. Installation 1. Assemble the alternator drive housing to the alternator end of the new spindle. 1.
Page 114 TIZ 1 l! M 1' H TRANSMISSION 7 10. Refit the water elbow to the upper crankcase using SPRAG CLUTCH a new gasket. Tighten the water elbow bolts to 12 NOTE: • In order to remove the sprag clutch, the engine must first be removed from the frame and the two halves of the crankcase separated.
Page 115 7 TRANSMISSION Tkewff NOTE: Hold the nut at the drive housing end and remove • The bearing is not an interference fit, no force is the bolt securing the alternator drive gear (in the required to move the bearing within the clutch housing) to the alternator spindle.
Page 116 TRANSMISSION 7 Refit the bearing to the alternator side of the crankcase and tighten the two retaining screws to 12 Nm. Refit the alternator spindle and drive taking care to align all components during installation. Fit service tool 3880040-T0301 to the front alternator mounting bolt holes.
Page 117 TJM?H 7 TRANSMISSION Assembly STARTER IDLER GEAR 1. Position the gear into the crankcase with the smaller Removal gear (which meshes with the sprag clutch) facing Remove the sprag clutch as described earlier in this inwards. section. Remove the screw and washer securing the starter idler gear shaft to the crankcase.
Page 118 TRANSMISSION 7 4. Remove the screw securing the oil pump auxiliary SELECTORS, SELECTOR SHAFT & DRUM gear. Remove the gear from the shaft. Removal NOTE: • In order to remove the selector mechanism, the engine must first be removed from the frame and the two halves of the crankcase separated.
Page 119 7 TRANSMISSION 14. Remove the spring abutment bolt from the gear 8. Release the screws securing the oil pump to the quadrant and slide the quadrant out of mesh. lower crankcase. /;^1 o \ 1 0j gagz 1. Quadrant 1. Oil Pump Retaining Screws 2.
Page 120 T° 1 l,! M I' H TRANSMISSION 7 17. Lift out the selector drum. Fit a new sealing washer to the gearchange abutment bolt and refit it to the lower crankcase. Inspection Tighten the bolt to 28 Nm. Examine all components for damage or wear paying Push the mechanism down until the quadrant particular attention to selector drum and selector forks.
Page 121 7 TRANSMISSION 14. Support the selectors and feed the selector shaft NOTE: through the crankcase and selectors. Fit the shaft • Detent springs MUST NOT be interchanged. The keeper plate and tighten the retaining bolt to 6 Nm. NEUTRAL spring has a white mark and is fi tted rearmost in the crankcase.
Page 122 TRANSMISSION 7 INPUT AND OUTPUT SHAFT ASSEMBLIES _ ntl "In Removal The input and output shafts can be lifted out of the lower crankcase after the crankcase halves have been separated. For details of crankcase separation, refer to the crankcase section. Installation Ensure the bearing sleeve dowels, oil seal and retaining rings are correctly located when refitting both shafts.
Page 123 7 TRANSMISSION INPUT SHAFT Disassembly Remove the clutch assembly from the shaft (if not already removed). Working from the opposite end to where the clutch assembly is fitted, dismantle the input shaft as follows: 1I1111DIi Remove the pegged bearing sleeve (1) from the 01111l:I end of the shaft.
Page 124 TRANSMISSION 7 Fit a new circlip (11) to the input shaft ensuring that the clip is correctly located in the circlip groove. 5. Fit the combined third/fourth gear (10) with the smaller gear facing toward fifth gear. Ensure that the double oil hole in the mainshaft aligns with the oil hole in the gear.
Page 125 7 TRANSMISSION OUTPUT SHAFT , ^I11^^ jt1^11 ►I Working from the opposite end to the drive sprocket, dismantle the output shaft as follows. Disassembly Remove the output bearing sleeve (1), needle roller bearing (2) and hardened thrust washer (3). Mark one side of first gear to denote its correct l^I^llllll ^ll^lll,ltll^^.
Page 126 TRANSMISSION 7 6. Fit sixth gear (14) with the selector fork groove Assembly facing away from the output sprocket end. Ensure that the oil hole in the gear aligns with the double oil NOTE: hole in the output shaft. • Lubricate each gear and bush with clean engine oil during assembly.
Page 127: Lubrication System
LUBRICATION SYSTEM CONTENTS Page ExplodedViews ............3 Cylinder Oil Circuit ............EngineOil ..............Specification............Oil ........... Trium OilLevel Inspection ........... ineOil and Filter Change .......... 8.10 OilPump And Gears ............8.10 Removal............8.11 Inspection............8.11 Installation............8.12 LowOil Pressure Warning Light Switch ........8.13 Sump..............
Page 128 TJMPH 8 LUBRICATION Exploded View - Sump 8 Nm 10 Nm 28 Nm 12 Nm 10 Nm...
Page 129 TwMaIi LUBRICATION 8 Exploded View — Oil Pump and Gears 15 Nm 12 Nm 9Nm ^...
Page 130 8 LUBRICATION Exploded View - Daytona Oil Cooler 25 Nm 25 Nm 25 Nm...
Page 131 LUBRICATION 8 Exploded View - Speed Triple Oil Cooler 9 Nm 25 Nm `'•0i^^vi^^ 25 Nm 9 Nm 25 Nm...
Page 132 8 LUBRICATION 3 Cylinder Oil Circuit Li 6= 9 11 gact...
Page 133 LUBRICATION 8 3 CYLINDER OIL CIRCUIT DESCRIPTION Oil is collected from the sump and is drawn through a mesh strainer into the oil pump rotor. Pressurised oil is then delivered to the outside of the oil filter where the oil pressure relief valve is fitted. The relief valve is set to open at 75 lb/in2 and when open, returns high pressure oil direct to the sump.
Page 134 API-SG or API-SH specification, side of the motorcycle. When correct, the level of oil Mobil 1 Racing 4T specially filled for Triumph is an oil should be half way up the sight glass. which meets the above requirements.
Page 135 LUBRICATION 8 Engine Oil and Filter Change WARNING: Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. Furthermore, used engine oil contains potentially harmful contaminants which can cause cancer. When handling used engine oil, always wear protective clothing and avoid any skin contact with the oil.
Page 136 8 LUBRICATION NOTE: OIL PUMP AND GEARS • To ensure that the selector fork positions are Removal maintained on assembly, mark each fork with felt pen or similar to denote their relative positions. NOTE: • The oil pump is located in the lower crankcase. 3.
Page 137 TJUllMII LUBRICATION 8 ^ 9a9= 1. Oil Pump Retaining Screws Remove the oil pump from inside the lower 1. Rotor Tip Clearance crankcase. 2. Pump Body Clearance Withdraw the oil pump intermediate gear by sliding through the crankcase from outside to in. CAUTION: If any part of the oil pump is 10.
Page 138 8 LUBRICATION 3. Locate the oil pump into the lower crankcase. Low Oil Pressure Warning Light Switch The low oil pressure warning light switch is located at the lower end of the camshaft oil feed pipe. 9a'. 1. Oil Pump Intermediate Gear 2.
Page 139 LUBRICATION 8 Remove the oil filter. SUMP Release the bolts securing the sump to the lower Removal crankcase. Remove the seat and disconnect the batte negative (black) lead first. Remove the belly panel and both lower fairings (where fitted). Note the position of the oil cooler pipes prior to disconnecting the pipes from the sump.
Page 140 TIUllMH 8 LUBRICATION Refit the exhaust system as described in the fuel system section. NOTE: Use new exhaust gaskets at the downpipe • connections with the cylinder head. Fill the engine with the correct grade of engine oil Refit the belly panel and lower fairings (if removed). 10.
Page 141 LUBRICATION 8 I UMI' H Release the oil cooler to bracket fixings noting the OIL COOLER position of the rubber grommets and flanged sleeves. Removal Remove the seat and disconnect the battery Inspection negative (black) lead first. Inspect the cooler connection points for fractures Remove the belly panel and right hand lower fairing and signs of oil leakage.
Page 142 FUEL SYSTEM/ENGINE MANAGEMENT CONTENTS Page EXPLODEDVIEWS ............FUELREQUIREMENTS ........... ENGINEMANAGEMENT SYSTEM .......... 9.12 SystemDescription ........... 9.12 SystemSensors ............9.12 SensorLocations ............. 9.13 SystemActuators ............ 9.14 ActuatorLocations ............ 9.15 SystemDiagnostics ........... 9.20 SERVICEDIAGNOSTIC TOOL ..........9.25 ToolKeys ............9.25 DIAGNOSTICTEST PROCEDURE ......... 9.26 Tune Restartin...
Page 143 CONTENTS cont'd Page 9.86 INTAKEAIR TEMPERATURE SENSOR ........9.86 Removal............9.86 Assembly............9.86 CRANKSHAFTPOSITION SENSOR ........9.87 Removal............9.87 Assembly............9.88 CAMSHAFT POSITION SENSOR (early models only) ......9.88 Removal............9.89 Assembly............9.89 ROADSPEED SENSOR (early models only) ......... 9.89 Removal............
Page 144 FUEL SYSTEM/ENGINE MANAGEMENT 9 Exploded View — Fuel Tank and Pump 12 Nm s'JIII...
Page 145 9 FUEL SYSTEM/ENGINE MANAGEMENT Exploded View — Fuel Rail, Throttles and Injectors (early models) 20 Nm 20 Nm 20 Nm ° 5 Nm 9 Nm...
Page 146 FUEL SYSTEM/ENGINE MANAGEMENT 9 Exploded View — Fuel Rail, Throttles and Injectors (later models)
Page 147 9 FUEL SYSTEM/ENGINE MANAGEMENT T1UMI Exploded View - Purge and Idle Air Control System (early models) `moo...
Page 148 FUEL SYSTEM/ENGINE MANAGEMENT 9 TUMI Exploded View - Purge and Idle Air Control System (late models)
Page 149 9 FUEL SYSTEM/ENGINE MANAGEMENT Tkewff Exploded View — Typical Exhaust System (T595 Daytona Illustrated) See Text...
Page 150 In the United States of America where the octane rating The use of gasolines containing up to 15% MTBE of fuel is measured in a different way, the following (Methyl Tertiary Butyl Ether) is permitted in Triumph information may be applied: motorcycles.
Page 151 9 FUEL SYSTEM/ENGINE MANAGEMENT GLOSSARY OF TERMS Coolant temperature sensor The following terms and abbreviations will be found in Measurement in volts at the Electronic Control Module this section. Below is given a brief explanation of what (ECM) of the coolant temperature in the thermostat housing as signalled by the coolant temperature sensor.
Page 152 The percentage above or below the nominal fuel requirement for the volume of air entering at engine speeds other than idle. This function is not currently used in the Triumph system. Open circuit A break in an electrical circuit — current cannot flow.
Page 153 ECM memory. Engine coolant temperature sensor - situated in the • This stored data can then be recovered by a Triumph thermostat housing above the airbox. Coolant dealer using a special service tool which is mandatory for temperature information, received by the ECM, is used all Triumph dealers.
Page 154 1 U9E1 FUEL SYSTEM/ENGINE MANAGEMENT 9 Engine Management System Sensor Locations Intake Air Temperature Sensor Engine Control Module Barometric Pressure Sensor Engine Coolant Temperature Sensor (behind battery) (in airbox, right hand side) (in thermostat housing, beneath fuel tank) Neutral Switch Throttle Position Sensor (in transmission case, left hand side) (right hand end of throttle bodies)
Page 155 FUEL SYSTEM/ENGINE MANAGEMENT ThUMH System Actuators • Canister purge valve (California models only) - situated in the vapour return line between the In response to signals received from the sensors, the carbon canister and the throttle. The purge valve ECM directs messages to a series of electronic and controls the return of vapour which has been stored electro-mechanical actuators.
Page 156 Tjurii FUEL SYSTEM/ENGINE MANAGEMENT 9 • Fuel pump — located inside the fuel tank. The • Cooling fan — located in front of the radiator. The electric pump delivers fuel into the fuel system, via a ECM controls switching on and off of the cooling fan pressure regulator, at a constant 3 bar pressure.
Page 157 FUEL SYSTEM/ENGINE MANAGEMENT UMOIPH Key To Wiring Colour Codes Key To Wiring Circuit Diagram Wiring Colour Code Key Item Black Battery Blue Fusebox Brown Cooling fan Green Ignition switch Grey Alarm control unit (where fitted) Orange Fuel pump relay Pink ECM Main power relay Light Green Cooling fan relay...
Page 158 T° 1 U M FUEL SYSTEM/ENGINE MANAGEMENT 9 1' H Circuit Diagram — Engine Management System up to VIN 71698 29 30 31 32 9.17...
Page 159 T° 1 U M 1' 9 FUEL SYSTEM/ENGINE MANAGEMENT Key To Wiring Colour Codes Key To Wiring Circuit Diagram Wiring Colour Code Key Item Black Battery Blue Fusebox Brown Cooling fan Green Ignition switch Grey Alarm control unit (where fitted) Orange Fuel pump relay Pink...
Page 160 FUEL SYSTEM/ENGINE MANAGEMENT 9 Circuit Diagram — Engine Management System from VIN 71699 29 30 31 32 9.19...
Page 161 ECM The MIL will be immediately extinguished if, using a Triumph service tool. Full details of the tool's after first rectifying the fault, the DTC operation and how to interpret the results are given (diagnostic trouble code) that caused the MIL elsewhere in this section.
Page 162 0— 1.25 Volts. Adjustments Freeze—frame Data Using the Triumph diagnostic tool, it is possible to adjust the value of two items which affect the idle speed and idle Freeze frame data is stored at the time a DTC is recorded (confirmed) by the ECM.
Page 163 ECM memory until the required number of no-fault warm-up cycles have taken place. The number of The codes are reported to the Triumph diagnostic tool as warm-up cycles required to extinguish the MIL will a four digit code, as required by California legislation.
Page 164 T1IUPI FUEL SYSTEM/ENGINE MANAGEMENT 9 UQ2" Diagnostic Fault Description Number of Number of Trouble no-fault no—fault illuminated Code cycles cycles when fault (DTC) before before DTC is logged turning off is erased P1351 Ignition coil 1 open circuit/short circuit to ground P1352 Ignition coil 2 open circuit/short circuit to ground P1353...
Page 165 9 FUEL SYSTEM/ENGINE MANAGEMENT Number of Number of Fault Description Diagnostic no—fault illuminated no-fault Trouble cycles when fault cycles Code before DTC is logged before (DTC) is erased turning off P1 552 Cooling fan relay short circuit/open circuit Cooling fan relay short to battery voltage/over temperature P1553 Coolant temperature gauge short circuit/open circuit P1116...
Page 166 FUEL SYSTEM/ENGINE MANAGEMENT 9 Checks Service Diagnostic Tool When using this function It is possible to check the status of various sensors and actuators and also check certain items of factory data logged during vehicle assembly. It is also possible to check when the ECM was last interrogated for stored information and who the dealer was that did it.
Page 167 TWMaI 9 FUEL SYSTEM/ENGINE MANAGEMENT Press the Validation key (*) to move on to the next R G n o s r z message. C U R R E M T I ► 5 T 0 R R f R D D T C I ♦...
Page 168 FUEL SYSTEM/ENGINE MANAGEMENT 9 9.27...
Page 169 9 FUEL SYSTEM/ENGINE MANAGEMENT TJMPH Main Menu Error Count fR!!Y l9ENU DIRGIYOSTICS STORED ERRORS CHFCn/RDJUST FAULT COUNT 02 QUIT CRnSHRFT SENSOR 1G1Y COIL DC/SC Diagnostics Starred DTC D1RGHOST1CS CURRENT DRTR FAULT CODES STORED ERRORS Fault codes CTIO TESTS FREEZE FRRl9E DRTR QUIT CLERK DTCS Current...
Page 170 FUEL SYSTEM/ENGINE MANAGEMENT 9 Main Menu 17Alr! r1EfU DIRGIYOSTICS CHECK/ADJUST QUIT Diagnostics DIRGIYOSTICS DATA CURREIIT FAULT CODES FUNCTION TEST QUIT Function test FUNCTION TEST DTCs present TEST DTC COUNT CLEAR DTCS PRESENT BEFORE TEST RCTIOIY No DTCs present FUNCTION TEST INSTRU17ENT PRIYEL IRC URLPE PURGE LRLPE...
Page 171 9 FUEL SYSTEM/ENGINE MANAGEMENT Main menu fiRln 17E!U DIRGIYOSTICS CHECK/RDJUST QUIT Check/Change Check/Adjust Menut CHECK/RDJUST Quit CHECK CHRIYGE QUIT Change Check Check menu Change menu CHECK CHAt/GE Quit Quit BUILD DATA RDJUST TUNE RERD SENSORS TUNE UPDATE QUIT QUIT Adjustments Read sensors RERD SENSORS RDJUST TUNE...
Page 172 TaJMH FUEL SYSTEM/ENGINE MANAGEMENT 9 Main menu l7Alti J?ENU DIAGNOSTICS CHECK/ADJUST QUIT Check/Adjust Check/Adjust menu CHECK/ADJUST Quit CHECK CHANGE QUIT Change TUNE ADJUST ADJUST TUNE UPDRTE TUNE QUIT Update tune SPRINT ST UPDRTE TUNE r'r^r'r'r'PP2 E TUNE 98'16 Confirm Cancel Pass CANCEL QUIT...
Page 173 9 FUEL SYSTEM/ENGINE MANAGEMENT TUUMaI MPII 1. CONNECTION AND POWER-UP 2. SELECT LANGUAGE SFL ECT L AtYG URGE FMG1! ► F R R h C ft! DEUTSCH ES P R IY O L RL R h D 5 TI EBE 1.
Page 174 G IY 7 T W R 4 4 8 The screen will display the message `Triumph Switch on the ignition. Do NOT start the engine. Motorcycles Diagnostic Tool' and will also give the diagnostic software version and the software release Press the validation key `*'.
Page 175 `Return' key (.J) to start again. 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. 9.34...
Page 176 Validation key ' *' 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'. 9.35...
Page 177 — `FUNCTION TESTS' (see operation 18) Coolant temperature —40— +215°C — If `QUIT' is selected, the display will return to Idle fuel trim —100 — + 99.2% `TRIUMPH MOTORCYCLES'. Off idle fuel trim Not used Engine speed 16,383 RPM 0— Air temperature —40 —...
Page 178 FUEL SYSTEM/ENGINE MANAGEMENT 9 11. STOP ENGINE 12. To select `READ STORED DTCS' (Diagnostic Trouble Codes) from the MAIN MENU:— rI'Fnu fiRr n STOP EnGr TIE I ► d! RGIY05T I CS CHECK/ADJUST QUIT Switch off the engine. Use the `Up' and 'Down' keys to position the cursor As the tool is powered from the motorcycle, this will end opposite DIAGNOSTICS.
Page 179 TUMH FUEL SYSTEM/ENGINE MANAGEMENT 13. STORED DTCS 14. Three options are now available:— STORED DTCS1 DTC C COUNT DATA F'Rf f Z f FkR17f VP0035 I 1P1 335 The second line — `DTC COUNT', shows the number of Align `FREEZE FRAME DATA' with the cursor, and DTC's stored in the ECM memory.
Page 180 N2" FUEL SYSTEM/ENGINE MANAGEMENT 9 15. FREEZE FRAME 16. STORED DTCS RIf Q !O TC 5 FREEZE F R R !7 E D TC 5 PCRLCULR I VRETURN TEDD L EAR D T I TUR T E R Tfl7P 51:1 2 options are now available: When a fault occurs which causes a DTC to be stored in the memory, the engine condition data at that instant is...
Page 181 9 FUEL SYSTEM/ENGINE MANAGEMENT 18. To select `FUNCTION TESTS' from the MAIN 17. STORED DTCS, ERASE ALL DTC DATA MENU: DTCS STORED Dl A hOS T C 5 I ► EP T I ► ST OR,f D DTCSI READ FUlYCTt ON TESTS Scroll to position either `YES' or `NO' opposite the Use `Up' and `Down' keys to select `DIAGNOSTICS'...
Page 182 FUEL SYSTEM/ENGINE MANA GEMENT 9 19. FUNCTION TESTS 20. FUNCTION TEST Funcrr!Qn r FS rs Funrri;on: rEsr P k f S f IY 7 C L!E R R BEFORE ACT! ON TEST Pt nsraurIEnr PANEL PAL LI E To clear the DTC's, press the Validation key '*'. The following Function Tests can be made: `STORED DTCS' will be displayed (see operation 13).
Page 183 9 FUEL SYSTEM/ENGINE MANAGEMENT Fuel pump priming test: The fuel pump is run for a 21. FUNCTION TEST specific time to check for satisfactory priming. A message will then be displayed to that effect. FuncrI on TEST S T RUl7f MT PR'Mf Fuel pump test: This test provides you with the means to I ►...
Page 184 FUEL SYSTEM/ENGINE MANAGEMENT 9 22. FUNCTION TEST 23. FUNCTION TEST TEST TEST Fu'ncrr on FuncrI on i nsrRUrrFnr I nsrRUPIFnr PRnFC PANEL TEST! n6. T EST 019PL f T F G R U G F'S The screen now displayed will be specific to the If the test is satisfactory the display will read `TEST component being tested: COMPLETE'.
Page 185 FUEL SYSTEM/ENGINE MANAGEMENT Tkewff 25. FUNCTION TEST 24. FUNCTION TEST rI o'n Funs TEST IY S 7 R U !1 f M 7 P R ff E L If the test at operation 22 is unsatisfactory, a DTC will be This display allows you to decide whether you wish to displayed on line 3 of this display (except fuel pump test another component.
Page 186 FUEL SYSTEM/ENGINE MANAGEMENT 9 IXQ29W 26. To select `CHECKS/ADJUSTMENTS' from the 27. CHECK/ADJUST MAIN MENU (operation 8):— EWE C K/ R 0'J U 5T J7 R I ff 17, F JY U CHECK DI R G M O S T! CS RO'JUST, ►...
Page 187 Position the cursor as follows and then press the down: Validation key `*': Vehicle Identification Number (VIN) Triumph ECM part number Opposite `READ SENSORS' — `SENSOR DATA' (operation 30) will be displayed. Supplier's ECM part number ECM Serial number Opposite `READ BUILD DATA' —...
Page 188 TUpH FUEL SYSTEM/ENGINE MANAGEMENT 9 30. SENSOR DATA 31. To access the `ADJUSTMENTS' menu. CHECK/R SENSOR DATA DJUST CH,FCK I ► PR!1'R S F N,5 0 R ADJUST VA! R T E J7'P 7 SCI Q U! T, The display can be scrolled to show: Use the `Up' and `Down' keys to position the cursor opposite `ADJUST'.
Page 189 TUNE (see operation 33). operation In special circumstances, Triumph will request you to IDLE FUEL ADJ. (Idle fuelling) ** introduce a completely new engine tune. Given this — See operation 34 situation, select `UPDATE TUNE' and press the Validation key `*' (see operation 36).
Page 190 FUEL SYSTEM/ENGINE MANAGEMENT 9 34. ADJUST TUNE (Idle fuel adjustment) 35. ADJUST TUNE (Idle fuel adjustment) T'UIYE ADJUST ADJUST ' T Uhf f lY G f !Y F T f J7 P DL f F UE l R A h G f COUIY'T KRPM^ PL f R Sf...
Page 191 9 FUEL SYSTEM/ENGINE MANAGEMENT 36. ADJUST TUNE (closed throttle position) 37. ADJUST TUNE (set adaptive stepper position) T UIYf ADJUST r unE ADJUST T! I) f TI Oil 8 f E M P 0 5 f TI Oil B F f IY P Q 5 I 5 f 7 The electronic value of the closed throttle position is...
Page 192 (Accessed from operation 32). On receipt of special automatically reset to nominal by the tool. instructions from Triumph you may be asked to input a completely new engine tune. Press either the validate '*' or return (.J) to return to the main menu.
Page 193 The models available at the time of writing are: If after a second attempt the entry is still invalid, the • T595 Daytona (all markets except France) screen will display `ACCESS DENIED DISCONNECT AND RETRY'. The diagnostic tool must be disconnected •...
Page 194 FUEL SYSTEM/ENGINE MANAGEMENT 9 42. UPDATE TUNE 43. UPDATE TUNE spRr (I T D RT f T U`IY'E 39Y6 T'UhF TUNE 4846 9 8 Y 7 ► , C 0' IY F t 9848. T UlYf C R IY C f L Scroll to the tune required and press the Validation key Scroll to either `CONFIRM', `CANCEL' or `QUIT' (quit ` *' to move on to operation 43.
Page 195 -_________________ 9 FUEL SYSTEM/ENGINE MANAGEMENT RESTARTING TUNE DOWNLOAD 44. UPDATE TUNE (confirm selected) r ung UPDATE If, for any reason CAUTION: • downloading is interrupted, the ECM will O R Q I not function and tune download cannot be restarted in the normal way. This is because the tool's operating system has been erased from the ECM's memory and has not yet been fully replaced.
Page 196 FUEL SYSTEM/ENGINE MANAGEMENT 9 T 1 U M 1? ELECTRICAL CONNECTORS ECM Connector Before beginning any diagnosis, the following connector Many of the diagnostic routines described in the related information should be noted: following tables call for checking of ECM connections by cable number.
Page 197 9 FUEL SYSTEM/ENGINE MANAGEMENT 1 VM H ECM Connector Pin Numbering The diagram below shows the pin sequence of the ECM main connector. These pin numbers correspond directly with the pin numbers given in the diagnostic routines and schematic wiring diagrams used throughout this manual. 28 iiiiiii FFfFFfFFFFFFFFFiiiiii 1 iiiiii 29 55 iiiiiii...
Page 198 — Damage to teeth Faulty — Magnetic debris contamination test 7 7 Reconnect harness, clear fault code and Action complete — quit test run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Battery Engine Control Module Crankshaft Sensor L__1_I ,.•,...
Page 199 6 — Magnetic debris contamination 6 Reconnect harness, clear fault code and Action complete — quit test run engine to verify fault cleared Fault still present Contact Triumph service ECM Main Circuit Diagram Power Relay Fusebox 1 648NK Engine...
Page 200 7 7 Reconnect harness, clear fault code and Action complete — quit test run diagnostic tool function test to visually verify operation of stepper motor Fault Contact Triumph service Circuit Diagram Engine Control m CD Module Changed to `OW' from...
Page 201 — Injector pin 1 to injector pin 2 Faulty Action complete — quit test 7 Reconnect harness, clear fault code and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fusebox Main Power Fuel Injectors Relay N>...
Page 202 Locate and rectify wiring fault, proceed to test 5 5 Reconnect harness, clear fault code and Action complete - quit test run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Engine Control Module Barometric Pressure Sensor...
Page 203 — ECM pin 15 to ECM pin 34 test 5 Action complete — quit test 5 Reconnect harness, clear fault code and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Engine Control Module Throttle Position Sensor...
Page 204 Renew purge valve, proceed to test 7 7 Reconnect harness, clear fault code and Action complete — quit test run diagnostic tool function test to visually verify operation of purge valve Fault Contact Triumph service Circuit Diagram ECM Main Power Relay [oro1[j Fusebox...
Page 205 Renew relevant ign coil, proceed to test 7 7 Reconnect harness, clear fault code and Action complete — quit test run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fusebox Fuel Pump Relay Ignition Coils r, 1 - PG...
Page 206 7 7 Reconnect harness, clear fault code and Action complete — quit test run engine to verify fault cleared Fault Contact Triumph service Resistance data under typical conditions: Engine Control Circuit Diagram Module Warm engine - 200 to 400Q.
Page 207 Action complete — quit test 7 Reconnect harness, clear fault code and run engine to verify fault cleared Contact Triumph service Fault If engine is warm, remove sensor and allow time to cool to ambient prior to test. Hesistance aata:...
Page 208 Locate and rectify wiring fault, proceed to test 5 5 Reconnect harness, clear fault code and Action complete — quit test run diagnostic tool function test to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Fusebox °C Alarm Fuel Control...
Page 209 — ECM pin 19 to ECM pin 34 test 5 Action complete — quit test 5 Reconnect harness, clear fault code and run bike to verify fault cleared Contact Triumph service Fault still present Circuit Diagram ECM Main Power Relay...
Page 210 Renew ECM, proceed to test 4 4 Reconnect harness, clear fault code and Action complete — quit test run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Engine Control Module Fusebox N C7 Alarm Control >-...
Page 211 Less than `across battery' voltage test 3 Action complete — quit test 3 Reconnect harness, clear fault code and run engine to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Engine Control Module Fusebox Alarm Control Unit...
Page 212 Locate and rectify wiring fault, proceed to test 5 5 Reconnect harness, clear fault code and Action complete — quit test switch ignition `on' to verify fault cleared Fault still present Contact Triumph service Circuit Diagram Engine Fusebox " Control...
Page 213 5 Action complete — quit test 5 Reconnect harness, clear fault code and run diagnostic tool function test to visually verify operation of cooling fan Fault still present Contact Triumph service Circuit Diagram Cooling Fan ECM Main ''F— Power Relay...
Page 214 6 Reconnect harness, clear fault code and Action complete — quit test run diagnostic tool function test to visually verify operation of temp gauge Fault still present Contact Triumph service Circuit Diagram Engine Control Module Fusebox cD v rn .-...
Page 215 6 Action complete - quit test 6 Reconnect harness, clear fault code and run diagnostic tool function test to visually verify operation of tachometer Contact Triumph service Fault still present ECM Main Power Relay Circuit Diagram Fusebox Alarm Control...
Page 216 TIIUPIE FUEL SYSTEM/ENGINE MANAGEMENT 9 Fault Finding - Non Electrical Symptom Possible cause(s) Poor throttle response at low Rpm Excessively low/high C.O. setting One way valve inside pipe from throttle bodies to IACV (Idle Air Control Valve) sticking or damaged Low fuel pressure caused by filter blockage/leaks Low fuel pressure caused by loose fuel pipes to the fuel pump and filter...
Page 217 UQ298 9 FUEL SYSTEM/ENGINE MANAGEMENT NOTE: FUEL TANK When disconnected, the fuel hoses are Fuel Tank Removal self-sealing. 5. Disconnect the hose leading to the fuel pressure regulator. WARNING: Observe the warning advice given in the general information section 6. Release the bolts securing the fuel tank to the on the safe handling of fuel and fuel containers.
Page 218 FUEL SYSTEM/ENGINE MANAGEMENT 9 Reconnect the hose leading to the fuel pressure Installation regulator. 1. Position the fuel tank to the motorcycle frame and reconnect the electrical connections to the fuel Refit the body side panels as described in the pump and low fuel level sensor.
Page 219 FUEL SYSTEM/ENGINE MANAGEMENT FUEL PUMP Removal Remove the seat and disconnect the battery negative (black) lead first. Remove the fuel tank as described elsewhere in this section. Drain the fuel tank into a suitable container. WARNING: Observe the warning advice gait given in the general information section 1.
Page 220 TJMPR FUEL SYSTEM/ENGINE MANAGEMENT 9 FUEL FILTER Inspection/Test Renew the fuel filter in accordance with the scheduled Removal maintenance chart. Remove the seat and disconnect the battery negative (black) lead first. Assembly Remove the fuel tank as described elsewhere in 1.
Page 221 9 FUEL SYSTEM/ENGINE MANAGEMENT Refill the fuel tank with the fuel drained earlier. FUEL PRESSURE REGULATOR Reconnect the battery, positive (red) lead first. Remove the seat and disconnect the battery negative (black) lead first. Refit the seat. Remove the fuel tank as described elsewhere in this section.
Page 222 Reconnect the battery, positive (red) lead first. Refit the seat. FUEL PRESSURE CHECKING Using Triumph service tool T3880048, allows diagnosis of fuel pump, fuel pressure relief valve and hose related Turn the ignition to the ON position and check the problems without first removing the component gauge reading.
Page 223 9 FUEL SYSTEM/ENGINE MANAGEMENT Fuel Delivery System CAUTION: Under no circumstances • should the fuel pump be activated (by Fuel is delivered to the injectors by a fully submerged switching on the ignition) with either, or both, of pump located inside the fuel tank. Fuel flows in the the fuel hoses disconnected.
Page 224 TiIuMII FUEL SYSTEM/ENGINE MANAGEMENT 9 Disconnect the multi-plug connections to the inlet AIRBOX air temperature and barometric pressure sensors. Removal Remove the seat and disconnect the battery negative (black) lead first. Remove the fuel tank as described elsewhere in this section. Disconnect the air intake hoses at the joints with the cockpit.
Page 225 9 FUEL SYSTEM/ENGINE MANAGEMENT Air Filter Element Assembly Check that the clips which secure the airbox to Removal the throttles are in place and positioned to allow tightening once fitted. Remove the seat and disconnect the battery negative (black) lead first. NOTE: Remove the fuel tank as described elsewhere in Later models are fitted with self -gripping clips...
Page 226 ThUMII FUEL SYSTEM/ENGINE MANAGEMENT 9 Locate the housing to the airbox ensuring the BAROMETRIC PRESSURE SENSOR gasket is correctly positioned. Tighten the screws. Removal Refit the fuel tank as described elsewhere in this Remove the seat and disconnect the battery section.
Page 227 9 FUEL SYSTEM/ENGINE MANAGEMENT CRANKSHAFT POSITION SENSOR INTAKE AIR TEMPERATURE SENSOR Removal Removal Remove the seat and disconnect the battery 1. Remove the seat and disconnect the battery, negative (black) lead first. negative (black) lead first. Remove the fuel tank and airbox as described 2.
Page 228 FUEL SYSTEM/ENGINE MANAGEMENT 9 Drain the engine oil as described in the lubrication section. Remove the clutch cover. Release the sensor multiplug and detach the sensor grommet from the crankcase. Release the sensor screws and detach the sensor. 1. Crankshaft Position Sensor 2.
Page 229 TJMPH FUEL SYSTEM/ENGINE MANAGEMENT CAMSHAFT POSITION SENSOR (early models only) NOTE: • This item has been deleted from later models. Removal Remove the seat and disconnect the battery, negative (black) lead first. Remove the side panel assembly as detailed in the body section.
Page 230 FUEL SYSTEM/ENGINE MANAGEMENT 9 Assembly THROTTLE CABLE Fit the camshaft position sensor and tighten the Removal fixing to 10 Nm. Remove the seat and disconnect the battery negative (black) lead first. Fit the ignition coils and tighten the coil fixings to 10 Remove the fuel tank and airbox as described in this section.
Page 231 9 FUEL SYSTEM/ENGINE MANAGEMENT TjMPH 1. Cable Guide 1. Inner Cable 2. Outer Cable 2. Twist Grip 4. Attach the other end of the inner cable to the 7. Note the routing of the throttle cable and remove throttle cam and locate the outer cable to the from the frame.
Page 232 1W9EI FUEL SYSTEM/ENGINE MANAGEMENT 9 THROTTLE BODIES Removal NOTE: • If the fuel rail is to be removed, select neutral, disconnect the wiring connection to the fuel pump and crank the engine briefly to reduce fuel pressure in the fuel rail. WARNING: Because fuel stored in the fuel rail will be at 3 bar pressure, it is gait...
Page 233 T1 UM1I 9 FUEL SYSTEM/ENGINE MANAGEMENT NOTE: • On models with the idle air control valve as shown in the diagram below, it is not necessary to disconnect the air bypass hoses when removing the throttle bodies. gahz 1. Injector Multi-plugs Release the screws securing the throttle body assembly to the cylinder head.
Page 234 FUEL SYSTEM/ENGINE MANAGEMENT 9 7. Reconnect the injector multi-plugs and secure the Assembly cables to the fuel rail using new cable ties. 1. Thoroughly clean the throttle body to cylinder 8. Reconnect the throttle position sensor. head mating surfaces. 9. Reconnect the multiplug to the idle air control valve.
Page 235 9 FUEL SYSTEM/ENGINE MANAGEMENT Tke2vff THROTTLE BODY BALANCING NOTE: • In order to. accurately balance the throttle bodies, Triumph recommend the use of the C^ ^^ ^.^ cam. digital inlet vacuum analyser or Souriau Indiana another similar device. Although mercury...
Page 236 16. Re—apply sealer to the adjustment screws. NOTE: 1. Fuel Rail • If the idle speed now falls outside the above range, adjust the closed throttle position using 2. Fuel Rail Screws the Triumph service diagnostic tool. Refer to the tool's operating instructions for details. 9.95...
Page 237 Check the injector `O' rings for damage, splits etc. Renew as necessary. Testing 1. Check the ECM for stored diagnostic trouble codes (DTCs) using the Triumph service diagnostic tool. Rectify as necessary. NOTE: • The injectors cannot be pressure tested.
Page 238 Reconnect the battery, positive (red) lead first. Release the screws securing the sensor to the right hand throttle body. Remove the sensor. Adjust the closed throttle position electronic value using the Triumph service diagnostic tool. NOTE: • For details of how to reset the closed throttle position value, refer to the diagnostic tool instructions elsewhere in this section.
Page 239 Inspection/test 2. Retaining Screws The valve is checked for correct operation using Reconnect the hoses as noted during the removal the Triumph service diagnostic tool. No other process. tests are possible. Refit the fuel tank as described elsewhere in this Check the valve body for cracks, damage and section.
Page 240 TKJUMiIi FUEL SYSTEM/ENGINE MANAGEMENT 9 5. Support the silencer and release the bolt securing EXHAUST SYSTEM the silencer mounting bracket to the right hand rear footrest support. Removal WARNING: If the engine has recently been running, the exhaust components may be hot to the touch. Contact with the hot components may cause damage to exposed skin.
Page 241 9 FUEL SYSTEM/ENGINE MANAGEMENT 7. Ensuring that the flanged sleeves, bushes and Assembly washers are positioned as shown in the diagram, fit the silencer mounting bolt and tighten to 18 1. Fit new seals to the cylinder head. ^^ P ^^ gaky 1.
Page 242 FUEL SYSTEM/ENGINE MANAGEMENT 9 NOTE: EVAPORATIVE LOSS CONTROL SYSTEM • On the following two pages, the earlier California Models Only evaporative system is depicted. The . later system, shown below, operates in the same way. All California models are fitted with a system to control the evaporation of fuel vapour into the atmosphere.
Page 243 MQ MPH FUEL SYSTEM/ENGINE MANAGEMENT Evaporative Control System — Engine Off. To Fuel Tank Pipe A When the engine is stationary any pressure increase in the fuel tank due to a rise in ambient temperature will cause the fuel vapour to pass down the breather pipe A, through the roll over Roll Over Valve valve to the pressure control valve.
Page 244 Thupiit FUEL SYSTEM/ENGINE MANAGEMENT 9 Evaporative Control System — Engine Running When the engine is started, vacuum is applied via pipe C to the vacuum switch on the canister, causing the canister valve to open. Direct return of vapour to the idle control housing is prevented by the purge control valve which is governed by the engine management system ECM.
Page 245 COOLING SYSTEM CONTENTS Page View — Cooling System ........... 10.2 Exploded Coolant..............10.3 CoolantLevel Inspection ..........10.3 CoolantReplacement ..........10.4 Drainage............10.4 Filling............... 10.4 RadiatorHoses ............10.5 RadiatorAnd Cooling Fan ..........10.5 CoolantPressure Cap ............. 10.6 Inspection............10.6 ..........WaterPump ....
Page 246 10 COOLING SYSTEM TiUiMII Exploded View - Cooling System 12 Nm 10 Nm 10.2...
Page 247 COOLING SYSTEM 10 COOLANT COOLANT LEVEL INSPECTION A permanent type of anti—freeze is installed in the cooling system when the motorcycle leaves the factory. It is WARNING: Do not remove the coolant coloured blue, contains a 50% solution of ethylene pressure cap when the engine is hot.
Page 248 10 COOLING SYSTEM COOLANT REPLACEMENT Drainage (all models) Remove the seat. Disconnect the battery negative (black) lead first. Remove the fuel tank cover. WARNING: 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.
Page 249 COOLING SYSTEM 10 Slowl add coolant mixture to the system, RADIATOR HOSES through the filler opening, until the system is full. If the system has filled correctly and fully there Regularly check all radiator hoses and hose clips for should be coolant visible through the bleed screw cracks, leaks or deterioration in accordance with the opening as well as in the filler opening.
Page 250 T1JUPH 10 COOLING SYSTEM WATER PUMP COOLANT PRESSURE CAP Removal Inspection 1. Remove the seat. WARNING: Do not remove the coolant Disconnect the battery, negative (black) lead first. pressure cap when the engine is hot. When the engine is hot, the coolant inside the 3.
Page 251 COOLING SYSTEM 10 Start the motorcycle and allow the engine to idle Installation for a short period of time to allow any air to be expelled from the system. Replace the water pump '0' ring seal. Stop the engine and top up the coolant level as Align the drive slot in the water pump with the necessary.
Page 252 10 COOLING SYSTEM Disconnect the cooling fan. RADIATOR Removal Remove the seats. Disconnect the battery negative (black) lead first. Remove the fuel tank cover, belly panel and lower fairings (where fitted) to give access to the radiator. Drain the engine coolant as described earlier. WARNING: Do not remove the coolant pressure cap when the engine is hot.
Page 253 COOLING SYSTEM 10 Inspection THERMOSTAT Check the radiator for stone damage. Removal Check the radiator core, for damage to fins or Remove the fuel tank cover. obstructions to air flow. Remove the seats. Repair any damage and clear all obstructions. Disconnect the battery, negative (black) lead first.
Page 254 UQ2" 10 COOLING SYSTEM Evenly close the two halves of the thermostat Inspection housing and tighten the retaining screws to 7 Nm. Inspect the thermostat at room temperature. If the valve is open, the thermostat must be replaced. CAUTION: Ensure that the thermostat is To check the valve opening temperature, correctly seated in both sides of the suspend the thermostat in a container of water...
Page 255 REAR SUSPENSION CONTENTS Page lodedViews ............11.2 RearSuspension Unit ............. 11.6 Removal............11.6 Inspection............11.6 Installation............11.6 Link ..............11.7 Removal............11.7 Inspection............11.8 Installation............11.8 Link ..............11.9 Removal............11.9 Inspection............11.10 Installation............11.10 DriveChain .............. 11.11 ChainSlack Inspection ..........11.11 Drivechain adjustment ..........
Page 256 11 REAR SUSPENSION TkQ2WH Exploded View - Swinging Arm ^7^T21 9 Nm 9 Nm 9 Nm 55 Nm 9 Nm 60 Nm 11.2...
Page 257 TIUMI MPII REAR SUSPENSION 11 Exploded View - Rear Hub A K1- I> 11.3...
Page 258 11 REAR SUSPENSION Exploded View - Rear Suspension Unit 48 Nm 11.4...
Page 259 REAR SUSPENSION 11 Exploded View - Drop/Drag Link 48 Nm iiii 11.5...
Page 260 TJUMa1 11 REAR SUSPENSION Detach the rear suspension unit reservoir from the REAR SUSPENSION UNIT battery box by releasing it from the re—usable clip. Removal Remove the rear suspension unit upper mounting nut and bolt, and lower the unit clear of the WARNING: If the engine has recently motorcycle.
Page 261 REAR SUSPENSION 11 5. Position the spacers on either side of the rear DROP LINK suspension unit lower mounting with their smaller outside diameters towards the mounting. Removal WARNING: If the engine has recently been running, the exhaust system will be hot.
Page 262 TWMaI 11 REAR SUSPENSION Detach the drop link by pulling out its mounting Installation spindle from the swinging arm. Pack all the drop link bearings with grease. NOTE: NOTE: • If tight, an M14 (1.5mm thread pitch) bolt can be •...
Page 263 TIUP1I REAR SUSPENSION Il DRAG LINK Removal WARNING: If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries.
Page 264 TRIuMo1 11 REAR SUSPENSION Inspection Clean all components and inspect for damage / wear: • drag link and bearings, • drag link spindle, rear suspension unit lower mounting bush, • spacers and '0' rings, drop link bearings, seals and sleeves. •...
Page 265 UQ2" REAR SUSPENSION 11 DRIVE CHAIN 4 1 ^^;^ The drive chain must be checked, adjusted, and lubricated in accordance with the scheduled maintenance chart. For reasons of safety, and to prevent excessive wear, never neglect any pa of the drive chain maintenance.
Page 266 Never neglect chain maintenance and always have chains installed by an authorised Triumph Dealer. 5. Examine the whole length of the chain. If there are any excessively tight or loose sections, loose pins or damaged rollers, the chain should be replaced.
Page 267 REAR SUSPENSION 11 T ° ^' U M'(' H SWINGING ARM/DRIVE CHAIN Removal Remove the seat. Disconnect the batte , negative (black) lead first. Remove the silencer as described in the fuel system section. WARNING: If the engine has recently been running, the exhaust system will be hot.
Page 268 TjMPH 11 REAR SUSPENSION Typical Drive Chain Support 1. `C' spanner 17. Release the brake fluid reservoir from the battery 2. Swinging arm/hub pinch bolt box and move it to one side. 13. De-stake then slacken the nut securing the final drive unit to the axle shaft.
Page 269 REAR SUSPENSION NOTE: • If tight, an M14 (1.5 mm thread pitch) bolt can be threaded into the spindle to assist extraction. 1. Tool T3880290 2. Clamping ring 25. Support the swinging arm and remove the swinging Removing drop link spindle arm spindle.
Page 270 11 REAR SUSPENSION 33. Remove the right hand bearing by drifting through 27. Collect the spacer from the recess inside the left from the left. hand frame outrigger. 34. Collect the spacer tube. 1. Spacer gagn 2. Frame outrigger 1. Seal 6.
Page 271 REAR SUSPENSION ll Assembly CAUTION: Incorrect adjustment of the Fit the drive chain to the output sprocket. swinging arm clamping ring will damage the bearings, seals and swinging arm. Refit the sprocket cover. Tighten the sprocket cover bolts to 9 Nm. Never overtighten the clamping ring or set the adjustment to allow excessive sideways Install the bearings (marked faces outwards),...
Page 272 11 REAR SUSPENSION 23. Fit the stepped washer, belleville washer (dished side out) and a new staked nut to the shaft. 1. Swinging arm / hub pinch bolt gagp 2. Rear brake caliper 1. Final drive unit 3. Rear brake caliper fixings 2.
Page 273 TIUMI REAR SUSPENSION 11 FINAL DRIVE Removal Remove the seat. Disconnect the battery, negative (black) lead first. Remove the silencer as described in the fuel system section. WARNING: If the engine has recently been running, the exhaust system will be hot.
Page 274 REAR SUSPENSION gafm 1. Axle shaft 1. `C' Spanner 2. Final drive 2. Swinging arm/hub pinch bolt 13. To release the final drive unit, remove the staked nut 3. Chain (discard the nut), belleville washer and stepped NOTE: washer. • Support the chain while the hub is removed to prevent it dragging through the dirt.
Page 275 REAR SUSPENSION 11 Installation Refit the axle shaft and align the spacer to the final drive side. Locate the final drive on the shaft and refit the chain to the sprocket. Fit: • collar, stepped side inwards, • belleville washer, dished side out, •...
Page 276 MPII 11 REAR SUSPENSION T1IUMI Align the rear brake pipe and clip to the right hand DRIVE CHAIN (Split link type) side of the swinging arm and tighten the clip fixing. Removal Refit the upper and lower chain guards. Tighten the NOTE: fixings to 9 Nm.
Page 277 TiWPMI REAR SUSPENSION 11 Fit the other two '0' rings on the outboard side of the Replacement li nks (side nearest the exhaust). NOTE: • The replacement chain is supplied in a 'split' condition, complete with a link kit to join the two ends.
Page 278 TUPH 11 REAR SUSPENSION - 1. Slide 2. Punch WARNING: To prevent risk of injury, do not place fingers or hands inside the slide. The slide is spring loaded and will cause injury to fingers or hands which become trapped inside the slide.
Page 279: Front Suspension
FRONT SUSPENSION CONTENTS Page lodedViews ............12.2 ForkInspection — All Models ..........12.5 ForkOil ..............12.5 Oilchange ............12.5 ForkOil Level Chart ............12.7 FrontFork ..............12.8 Removal............12.8 Installation............12.8 Dismantling............12.9 Inspection............12.11 Assembly............12.11 HeadstockBearing Check / Adjustment ........12.12 Check..............
Page 280 FRONT SUSPENSION/STEERING Exploded View - Front Fork 40Nm 20 Nm ^• 9 Nm 22 Nm 20 Nm 35 Nm 12.2...
Page 281 I U^N FRONT SUSPENSION/STEERING 12 Exploded View — Low Handlebars 6 Nm 35 Nm (M8 screws) 20 Nm (M6 screws) 6 Nm 12.3...
Page 282 12 FRONT SUSPENSION/STEERING ^ jHn Exploded View - Tall Handlebars 35 Nm 12.4...
Page 283 ° FRONT SUSPENSION/STEERING 12 FRONT SUSPENSION FORK OIL Oil change All models are equipped with hydraulic, telescopic front 1. Remove the fork assembly as described later in forks which -are adjustable for spring pre-load, rebound this section. and compression damping. Periodic inspection for damage and fluid leaks is essential for safe riding.
Page 284 flMIJ lM / FRONT SUSPENSION/STEERING 12. Refit the fork and tighten the top cap to 22 Nm. 6. Set the scale on tool 3880160-T0301 to the level specified for the model being worked on (see the fork oil table for the correct level setting). WARNING: Incorrect tool adjustment and/or failure to keep the tool level with the fork slider will affect the final fluid level setting.
Page 285 FRONT SUSPENSION/STEERING 12 FORK OIL LEVEL CHART Model Oil Level* Oil Volume Oil Grade Fork Pull Through T595 Daytona 76 mm 589 cc Showa SS8 Inner tube flush with upper face of top yoke T509 Speed Triple 76 mm 589 cc...
Page 286 12 FRONT SUSPENSION/STEERING FRONT FORK WARNING: If working on the right hand fork, do not invert the brake master Removal cylinder as this will introduce air into the brake Raise and support the front of the motorcycle system and may also cause brake fluid to escape and damage the bodywork.
Page 287 FRONT SUSPENSION/STEERING 12 Tighten the handlebar clamp bolt to 35 Nm (M8 FORK DISMANTLING / ASSEMBLY screws) 20 Nm (M6 screws). Dismantling CAUTION: If securing the fork in a vice use the caliper mounting points. Never clamp directly onto the tube itself as this will cause the tube to distort beyond repair.
Page 288 12 FRONT SUSPENSION/STEERING U 11^I j I 8. Prise out the dust seal from the outer tube and remove the circlip from beneath the seal. 1. Fork cap gafi 2. Preload adjuster / damper 1. Circlip 5. Raise the damping cylinder rod slightly and remove: 9.
Page 289 FRONT SUSPENSION/STEERING 12 7. Fit a new dust seal (spring band upwards) over Inspection the inner tube, tapping it into position in the outer tube using the larger diameter end of tool Thoroughly clean and examine all components for T3880285. damage, wear, scoring, corrosion etc.
Page 290 1i 9uJ 12 FRONT SUSPENSION/STEERING HEADSTOCK BEARING CHECK / ADJUSTMENT Check Raise and support the front of the motorcycle. WARNING: Ensure the motorcycle is stabilised and adequately supported, to prevent it falling and causing damage or injury. gage 1. Tool T3880300 2.
Page 291 BRAKING SYSTEM CONTENTS Page 13.2 ExplodedViews ............13.6 Braking System Maintenance Safety Precautions ......13.7 FluidLevel Inspection ..........Brake Fluid ..........13.7 Chan 13.7 BrakePads ............... 13.7 BrakeWear Inspection ..........13.8 Bleeding The Front Brakes, Renewing Brake Fluid ......13.9 FrontBrake Pads ............
Page 292 13 BRAKING SYSTEM Exploded View — Front Brake Master Cylinder 12 Nm 1 Nm 15 Nm 12 Nm 25 Nm 6 Nm 25 N 13.2...
Page 293 BRAKING SYSTEM 13 Exploded View - Front Brake Caliper 25 Nm °0 ^^^ 000 ° ° ° 22Nm °o o ^ ^ 0 0 0 0 0 ° 13.3...
Page 294 13 BRAKING SYSTEM ThJPII Exploded View - Rear Brake Master Cylinders 25 Nm 25 Nm 7 Nm 13.4...
Page 295 TI CuM1' BRAKING SYSTEM 13 Exploded View - Rear Brake Caliper 40 Nm CM l it 7 Nm 20 Nm 22 Nm 13.5...
Page 296 It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph Dealer before riding the motorcycle. Failure to take remedial action may reduce braking efficiency leading to an accident.
Page 297 T11 U Mi 1' H BRAKING SYSTEM 13 FLUID LEVEL INSPECTION CHANGING BRAKE FLUID In accordance with the scheduled maintenance chart, Brake fluid should be changed at the interval specified inspect the brake fluid level in the front and rear in the scheduled maintenance chart.
Page 298 TKIUMflI 13 BRAKING SYSTEM BLEEDING THE FRONT BRAKES, RENEWING BRAKE FLUID Note the original setting of the brake lever adjuster in order that it can be returned to the same position when the bleeding operation is complete. Set the brake lever adjuster to position No.1.
Page 299 BRAKING SYSTEM 13 FRONT BRAKE PADS NOTE: • During bleeding, do not allow the fluid level to Removal fall below the lower level mark in the reservoir. If the level is allowed to fall below this mark, air may enter the system and the sequence of bleeding must be repeated.
Page 300 13 BRAKING SYSTEM TRnJMH Installation FRONT BRAKE CALIPER Removal WARNING: Never use mineral based grease in any part of the braking system CAUTION: To prevent body damage, do or in any area where contact with the braking system is possible. Mineral based grease will •...
Page 301 TjJUMH BRAKING SYSTEM Fit new fluid seals. Disassembly WARNING: Do not attempt to split the two halves of the caliper. A dangerous riding condition leading to an accident could occur if this warning is ignored. Remove the pad retaining pin and extract the pads.
Page 302 13 BRAKING SYSTEM FRONT DISCS WARNING: Use only D.O.T. 4 specification brake fluid as listed in the Wear general information section of this manual. The 1. Replace any brake disc if worn beyond the use of brake fluids other than those D.O.T. 4 fluids service limit or exceeds the disc run—out limit.
Page 303 BRAKING SYSTEM 13 FRONT BRAKE MASTER CYLINDER Removal 1. Remove the seat and disconnect the battery negative (black) lead first. CAUTION: To prevent body damage, do • not spill brake fluid onto any area of the bodywork. 2. To drain the fluid from the master cylinder, attach a tube to the right hand caliper bleed nipple, gads slacken the nipple and allow the fluid to drain into...
Page 304 ThIUMH 13 BRAKING SYSTEM 4. Remove the piston set from the master cylinder Assembly bore noting the relative position of the seals and piston components. WARNING: 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 305 T1IMPII BRAKING SYSTEM 13 5. Connect the brake hose to the master cylinder BLEEDING THE REAR BRAKES, RENEWING using new sealing washers. Tighten the banjo bolt BRAKE FLUID to 25 Nm. Remove the body side panel assembly. WARNING: Use only D.O.T. 4 Remove the cap from the rear bleed nipple.
Page 306 13 BRAKING SYSTEM Tkewn REAR BRAKE PADS WARNING: Ensure absolute cleanliness when adding brake fluid to the brake fluid Removal reservoir. Do not allow moisture or debris to enter the cylinder as this will adversely affect the fluid properties. Always use fluid from a sealed container and do not use fluid from a container which has been opened for any period of time.
Page 307 BRAKING SYSTEM 13 T1 UMOI MPII Installation WARNING: Use only D.O.T. 4 specification brake fluid as listed in the WARNING: Never use mineral based general information section of this manual. The grease in any part of the braking system use of brake fluids other than those D.O.T. 4 fluids or in any area where contact with the braking listed in the general information section may system is possible.
Page 308 TkeV^^ 13 BRAKING SYSTEM Inspection REAR BRAKE CALIPER Check the piston and caliper bore for corrosion, Removal scoring and damage. Renew as necessary. CAUTION: To prevent body damage, do WARNING: Always renew caliper seals not allow brake fluid to contact any area •...
Page 309 BRAKING SYSTEM 13 WARNING: Ensure that the pistons do not WARNING: Use only D.O.T. 4 tip during assembly as this could damage specification brake fluid as listed in the the caliper. general information section of this manual. The use of brake fluids other than those D.O.T. 4 fluids A dangerous riding condition leading to an listed in the general information section may accident could result if this warning is ignored.
Page 310 13 BRAKING SYSTEM Assembly REAR MASTER CYLINDER Removal WARNING: Never use mineral based grease in any part of the braking system Remove the seat and rear panels, and disconnect the batte negative (black) lead first. or in any area where contact with the braking system is possible.
Page 311 BRAKING SYSTEM 13 Installation Fit the reservoir hose to the master cylinder. Secure the master cylinder and cover to the frame. Tighten the securing screws to 30 Nm. NOTE: The brake light switch and spacer washer fits • between the master cylinder and frame. Connect the push rod to the brake pedal using a new clevis pin and split pin.
Page 312 WHEELS CONTENTS Page Views ............14.2 oded Tyres..............14.4 14.4 TyrePressures, All Models ..........14.5 TyreWear/Wheel Inspection, All Models ......... 14.5 MinimumRecommended Tread Depth ........14.6 ortantTyre Information ..........FrontWheel .............. 14.7 14.7 Removal............14.7 Installation............RearWheel .............. 14.8 14.8 Removal............
Page 313 ' ^1 14 WHEELS/TYRES Exploded view - Front Wheel 60 Nm 14.2...
Page 314 WHEELS/TYRES 14 i ° ^1 UNI!! ! Exploded View - Rear Hub 146 Nm 14.3...
Page 315 14 WHEELS/TYRES TYRES Tyre Pressures, All Models Correct inflation pressure will provide maximum stability, Both models are equipped with tubeless tyres, valves, rider comfort and tyre life. and wheel rims. Only tyres marked `TUBELESS' and tubeless type tyre valves mounted on rims marked Tyre pressures should be checked frequently and `SUITABLE FOR TUBELESS TYRES' can be used.
Page 316 Check the rims for dents or deformation. Operation with damaged or defective wheels or tyres is dangerous and loss of control or an accident could result. Always consult your Triumph Dealer for tyre replacement, or for a safety inspection of the tyres. 14.5...
Page 317 WARNING: When replacement tyres are required, consult your authorised Triumph Dealer who will arrange for the tyres to be WARNING: Always check tyre pressures tyre manufacturers fitted according to the before riding when the tyres are cold.
Page 318 WHEELS/TYRES 14 FRONT WHEEL CAUTION: To prevent wheel and bearing • damage, observe absolute cleanliness Removal and ensure there is no dirt ingress to the wheel bearings while the wheel is removed. WARNING: Do not allow the wheel to rest on either brake disc as this may damage the disc and could lead to an accident.
Page 319 14 WHEELS/TYRES M!1 H REAR WHEEL Installation Fit the wheel, aligning with the location dowels. Removal Hold the wheel squarely in position while fitting: • conical spacer WARNING: Ensure the motorcycle is stabilised and adequately supported, to • plain washer •...
Page 320 Triumph dealer before riding. drawn into the hub. Removal Insert bearings with the marked or shielded side facing outwards and always fit a new bearing circlip.
Page 321 j i I ^ r^l[ `} , 14 WHEELS/TYRES REAR WHEEL BEARINGS WARNING: When using bearing service tools always ensure that the selected tool Removal matches the diameter of the bearing being Remove the seat. installed. Damage to the wheel and bearing will result from incorrect tool selection which may Disconnect the batte , negative (black) lead first.
Page 322 WHEELS/TYRES 14 J` '^ ,! gatm gaen ,i C 1. Swinging arm 1. `C' spanner 2. Brake pipe clip 2. Pinch bolt 9. Without disconnecting the brake hose, detach then 12. De-stake then slacken the nut securing the final support the rear brake caliper. drive unit to the axle shaft.
Page 323 6. Prevent the hub from turning and tighten the nut to will require the use of a press and press tools. 146 Nm. Stake to secure. A more economical and timely alternative is to replace the hub assembly complete as detailed in the Triumph parts information. 14.12...
Page 324 11;M `li WHEELS/TYRES 14 13. Refit the rear wheel as described in the wheel section. 14. Refit the silencer as described in the fuel system section. 15. Lower the motorcycle to the ground and place on the side stand. 16. Reconnect the battery positive (red) lead first. 17.
Page 325 BODYWORK & FRAME CONTENTS Page lodedViews ............15.2 Seat..............15.7 Removal............15.7 Refit.............. 15.7 SidePanel ............... 15.8 Removal............15.8 Installation............15.8 BellyPanel ............... 15.8 Removal............15.8 Installation............15.8 LowerFairings ............15.9 Removal............15.9 Installation............15.9 Cockpit..............15.10 Removal........
Page 326 15 BODYWORK/FRAME Exploded View - Frame See Text See Text See Text See Text See Text See Text 15.2...
Page 327 B OD YWORK/FRAME 15 ^' ►^^1^ U'?^'^! ° 1 Exploded View - Seat Rails 40 Nm 15.3...
Page 328 BODYWORK/FRAME Exploded View - Cockpit and Mountings 5 Nm I 6 N m 6 Nm 1 6 Nm ^ - - - — - ^ 6 Nm 6 Nm 6 Nm " 6 Nm 5 Nm 5 Nm 15.4...
Page 329 BODYWORK/FRAME 1`1?`U Exploded View - Rear Panels 9 Nm 9 Nm 9 Nm 9 Nm 15.5...
Page 330 15 BODYWORK/FRAME Exploded View - Footrests and Mountings 27 Nm 27 Nm 16 Nm 30 Nm 16 Nm 30 Nm 15.6...
Page 331 i hUM'1 BODYWORK/FRAME 15 4. Lift the rear of the seat and disengage the front lip SEAT from below the fuel tank. Removal Refit NOTE: 1. Position the front seat to the fuel tank and engage • The seat lock is situated on the left hand side of the front lip.
Page 332 15 BODYWORK/FRAME SIDE PANEL BELLY PANEL Removal Removal Unlock the rear seat/cowl, and lift clear. Remove the screws on each side which attach the belly panel to the engine bracket. Remove the front seat. Support the belly panel while releasing the quarter-turn fasteners.
Page 333 BODYWORK/FRAME 1 i° I^141 AMME 1 Disconnect the direction indicator at its multiplug. LOWER FAIRINGS Removal Installation Installation is the reverse of removal noting the Unlock the rear seat/cowl, and lift clear. following points. 2. Remove the front seat. NOTE: Disconnect the ba negative (black) lead first.
Page 334 BODYWORK/FRAME Disconnect the position light bulb holder from the COCKPIT light before final removal. Removal Installation Unlock the rear seat/cowl, and lift clear. 1. Refitting is the reverse of removal. Remove the front seat. NOTE: Disconnect the ba negative (black) lead first. •...
Page 335 WARNING: If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for repair or inspection. Any accident can cause damage to the motorcycle which, if not correctly repaired, may cause another accident which may result in injury or death.
Page 336 15 BODYWORK/FRAME ^' i ° 1 U^ I N1 15. Using tools T3880290 and T3880295, release the Remove the airbox assembly as described in pre load adjustment on the swinging arm. section 9 of this manual. Disconnect all electrical connections to the engine.
Page 337 ^uM ►^ BODYWORK/FRAME 15 21. Disconnect the speedometer cable at the instrument end of the cable. 22. Disconnect the electrical connection to both handlebar switches, and the ignition switch. Support the headlight casting and remove the casting retaining bolts. Without further electrical disconnections, feed the headlight casting assembly through the frame and rest the complete assembly on the rear subframe.
Page 338 15 BODYWORK/FRAME Align the drag link to the frame and refit but do Assembly not tighten the drag link spindle bolt. 1. Transfer the following items, if serviceable, from Lubricate the lower headstock bearing on the the original frame to the new frame: lower yoke spindle using Mobil Grease HP 222.
Page 339 ► ^ ^Ilt Mi11 ^ ^^ I ^ , r- p nr^ BODYWORK/FRAME 15 17. Fit the frame to head bracket to the left hand side 23. Once all the necessa shims have been added, of the motorcycle. Tighten the bracket to cylinder tighten the right hand frame to engine bolts to 80 head bolts to 30 Nm.
Page 340 ThL J 9H 15 BODYWORK/FRAME • Slacken the swinging arm/hub pinch bolt. • Using the `C' spanner from the motorcycle tool kit, turn the eccentric adjuster clockwise to increase vertical movement, anti—clockwise to take out vertical movement. • Once the correct chain setting has been achieved, tighten the swinging arm/eccentric adjuster pinch bolt to 55 Nm.
Page 341 BODYWORK/FRAME 15 ► ° ^1 ^ uM l' 1 • Make any minor adjustments as necessa give 2-3 mm of play using the adjuster at the twist grip end of the cable. Tighten the locknut. WARNING: Ensure that the adjuster locknuts are tightened.
Page 342 ELECTRICAL SYSTEM CONTENTS Page Views ............16.3 Exploded Battery..............16.8 BatteryTy ............16.8 BatteryRemoval ........... 16.9 BatteryRefit ............16.9 BatteryChar g ........... 16.10 BatteryMaintenance ..........16.11 BatteryLead Conversion ..........16.12 - Daytona ............Headli 16.14 ustment Headli htAd ..........
Page 343 Fuses..............16.29 InstrumentWarning Lights ..........16.29 Removal............16.29 Installation............16.29 RelayPack ............... 16.29 Identificationof Relays ..........16.30 Wiring Circuit Diagram T595 Daytona & 1509 Speed Triple (885cc) ....16.32 Wiring Circuit Diagram Daytona 955i & Speed Triple (955cc) ....16-2...
Page 344 ELECTRICAL SYSTEM 16 Exploded View — Instruments ® 5 Nm 6Nm ^ 6 Nm 16.3...
Page 345 16 ELECTRICAL SYSTEM Exploded View - Alternator and Starter Motor Nlllllllllll^^ ^ 16.4...
Page 346 `' ► t UnNt slut' ELECTRICAL SYSTEM 16 Exploded View — Daytona Headlight 6 Nm 9 Nm ® %^'' 9 Nm 16.5...
Page 347 1t tll 16 ELECTRICAL SYSTEM Exploded View - Speed Triple Headlight 10 Nm 15 Nm 10 Nm 4 Nm 16.6...
Page 348 ELECTRICAL SYSTEM 16 Exploded View - Rear Lights and Indicators U I'I U I 18 Nm 16.7...
Page 349 16 ELECTRICAL SYSTEM tjtrt- ! `^ BATTERY Battery Types There have been two types of battery used on the models WARNING: The ba ery gives off covered by this manual. A wet filled battery explosive gases; keep sparks, flames manufactured by Yuasa and a sealed battery and cigarettes away.
Page 350 I ^M !wl' ELECTRICAL SYSTEM 16 Battery Refit Battery Removal Unlock and remove the seat. WARNING: Ensure that the ba negative (black) lead first. Disconnect the ba terminals do not touch the motorcycle frame as this may cause a short circuit or spark Remove the battery strap and disconnect the which would ignite battery gases causing a risk of breather tube.
Page 351 The charging rate must not exceed 10% of the battery capacity. The standard Triumph battery capacity is a 14 Amp. hour unit and therefore the charging rate must not exceed 1.4 A.
Page 352 ELECTRICAL SYSTEM 16 h i ° ^ 1 U ^^LM^ I 1^1' Battery Maintenance (Yuasa wet battery) Battery Maintenance (GS sealed battery) The battery electrolyte level must be kept between the The battery is a sealed type and does not require any upper and lower level lines.
Page 353 An accessory kit is available from your authorised Triumph dealer to convert the Yuasa manufactured wet battery installation to one suitable for use with the GS Place a length of insulation material over the manufactured dry battery.
Page 354 i^l, NI!1 1 ELECTRICAL SYSTEM 16 8. Turning to the negative lead, attach the 12. Position the new battery leads and connect to the supplementa negative cable (coloured black) battery positive lead (brown lead with the red cap) and attach one end to the existing negative lead. first, then the negative (black) lead second.
Page 355 16 ELECTRICAL SYSTEM ^^ l HEADLIGHTS — DAYTONA Headlight Adjustment Each headlight can be adjusted by means of vertical and horizontal adjustment screws located on the rear of the headlight unit. Switch the headlight dipped beam on. Turn the vertical adjustment screw on each headlight clockwise to lower the beam or anti—clockwise to raise the beam.
Page 356 ELECTRICAL SYSTEM 16 i 'ZIP t^1 10"'' Headlight Bulb Replacement 1. Wire Clip Assembly 1. Headlight Unit Install the bulb and secure with the wire clip. 2. Side Fixing (RH) 3. Centre Fixing Refit the light unit as described elsewhere in this section.
Page 357 16 ELECTRICAL SYSTEM Headlight Adjustment HEADLIGHTS — SPEED TRIPLE Switch the headlight dipped beam on. The horizontal beam of each headlight can be adjusted individually. The vertical beams are adjusted as a pair. Partially release the central clamp fixing on the headlight mounting bracket and pivot both headlights upward or downward as necessary.
Page 358 ELECTRICAL SYSTEM 16 Disconnect the multi—pin electrical connector from Headlight Bulb Replacement the headlight bulb and remove the rubber cover. Unhook the wire retaining clip from behind the bulb. Remove the bulb from the headlight unit. Installation Installation is the reverse of the removal procedure. Position Lamp Bulb Replacement Position lamps are fitted to both headlight units.
Page 359 16 ELECTRICAL SYSTEM ► ` 1 !! H TAIL LIGHT LICENCE PLATE LIGHT Removal Bulb Replacement Remove the seat(s) Remove the rear bodywork, as described in the body section, to gain access to the licence plate light unit. Disconnect the battery, negative (black) lead first. Carefully remove the rubber bulb holder from the Release the fixings securing the light to the rear back of the light unit.
Page 360 ELECTRICAL SYSTEM 16 U, ' NI^!I `_ INDICATOR Installation Refit the bulb to the bulb holder. The lens on each indicator light is held in place by a securing screw located in the body of the light. Refit the bulb holders to the light and turn clockwise to lock into place.
Page 361 Wiring Colour The wiring circuit found on the following page depicts the Black lighting circuit for the T595 Daytona/Daytona 955i model. The circuit for the Speed Triple range is similar. Blue The key found below must be used for identification of Brown components.
Page 362 ELECTRICAL SYSTEM 16 Circuit Diagram — Lighting 16.21...
Page 363 Wiring Colour VIN 71698 Black The wiring circuit found on the following page depicts the starting and charging circuit for the T595 Daytona and Blue T509 Speed Triple models. Brown The key found below must be used for identification of Green components.
Page 364 ELECTRICAL SYSTEM 16 Circuit Diagram — Starting/Charging — up to VIN 71698 16.23...
Page 365 16 ELECTRICAL SYSTEM STARTING/CHARGING CIRCUIT DIAGRAM FROM VIN 71699 Wiring Colour Code The wiring circuit found on the following page depicts the Black starting and charging circuit for the Daytona 955i and Speed Triple models. Blue The key found below must be used for identification of Brown components.
Page 366 Circuit Diagram — Starting/Charging — from VIN 71699 p8HIi N \\j 14 ,( 16.25...
Page 367 TujH 16 ELECTRICAL SYSTEM ALTERNATOR Removal Remove the seat and disconnect the batte negative (black) lead first. Remove the belly panel and left hand fairing (if fitted). Drain the coolant from the crankcase as described in the Cooling System section. Detach the water pump hose at its connection to gacq ^ ^.
Page 368 ELECTRICAL SYSTEM 16 fl?Q^H Installation STARTER MOTOR 1. Clean the mating faces of the crankcase and Removal sta rter motor to ensure efficient grounding. Remove the seat and disconnect the battery, 2. Inspect the sealing ring and renew if damaged negative (black) lead first.
Page 369 Remove the cockpit fairing (where fitted) as described in the 'Body' section. Pull out the panel illumination bulb holders. On T595 Daytona models only, support the Installation headlight assembly and remove 3 fixings to detach it from the headlight casting.
Page 370 ELECTRICAL SYSTEM 16 INSTRUMENT WARNING LIGHTS RELAY PACK A relay pack is situated beneath the front seat which also Removal contains the indicator unit. 1. Remove the instrument pack and all 3 The relay are attached to the bracket by means of barbed instruments as described in 'Instruments extensions.
Page 371 Pass Switch Engine Control Module Dip Switch Cooling Fan Relay Alarm Connection (Alarm Optional) Fuel Pump Relay Low Fuel Level Sender Wire Link Rear Brake Light Switch Injector 3 T595 Daytona Headlights Injector 2 T509 Speed Triple Headlights Injector 1 16.30...
Page 373 Pass Switch Engine Control Module Dip Switch Cooling Fan Relay Alarm Connection (Alarm Optional) Fuel Pump Relay Low Fuel Level Sender Wire Link Rear Brake Light Switch Injector 3 T595 Daytona Headlights Injector 2 T509 Speed Triple Headlights Injector 1 16.32...
Page 375 Triumph Motorcycles Limited. Jacknell Road, Hinckley, Leicestershire, LE10 3BS England...

This manual is also suitable for:

Speed triple 955cc T509 speed triple 885cc Daytona 955i

Triumph T595 DAYTONA Service Manual

Quick Links

Related Manuals for Triumph T595 DAYTONA

Summary of Contents for Triumph T595 DAYTONA

This manual is also suitable for:

Table of Contents