Triumph T595 DAYTONA Service Manual page 338

15 BODYWORK/FRAME
Assembly
1. Transfer the following items, if serviceable, from
the original frame to the new frame:
• Swinging arm spacer from inside the left hand
outrigger
/ / L 41
()
/c
2
a a
g g /
1. Spacer
2. Frame outrigger
• Starter solenoid mounting bracket
• Chain rubbing block
• Swinging arm side float adjuster and locknut
2. Position the new frame over the rear
suspension/rear mudguard assembly and engage
the rear suspension unit upper mounting bolt.
Ensure that the positive (red) ba
routed to the left hand side of the rear suspension
unit.
3. Position the drive chain as shown below and align
the swinging arm to the frame. Refit the swinging
arm spindle from the left hand side.
gaew
1. Swinging arm spindle
r'7
r z^
l
lead is
e
tt ry
Align the drag link to the frame and refit but do
4.
not tighten the drag link spindle bolt.
Lubricate the lower headstock bearing on the
5.
lower yoke spindle using Mobil Grease HP 222.
6. Align the fork/yoke assembly to the frame and fit
the lower yoke spindle into the headstock.
7. Fit the headstock adjuster nut and set the
headstock bearing adjustment as follows:
• Tighten the nut to 32 Nm.
• Loosen the nut and then retighten by hand
until any bearing free play is eliminated.
WARNING: It is essential that adjuster nut
is not over-tightened. If the adjuster is
over—tightened it will cause a pre—load on the
headstock bearings. This will introduce tight
steering which will lead to premature bearing wear
and could cause loss of control and an accident.
8. Position the headlight casting/headlight assembly
to the headstock and tighten the retaining fixings
to 6 Nm.
9. Refit the rear frame to the main frame and tighten
the four retaining bolts to 40 Nm.
10. Locate the wiring harness to the frame cross
beam.
11. Refit the starter solenoid.
12. Position the top yoke to the lower yoke spindle
and tighten the centre nut to 40 Nm using tool
T3880300. Ensure that the headstock bearing
adjuster is not disturbed during tightening.
13. Tighten the upper yoke pinch bolts to 20 Nm.
14. Position the engine below the frame.
15. Raise the engine and, during the alignment
process, fit the drive chain over the output
sprocket.
16. Locate, but do not tighten the engine mounting
bolts.
15.14
^1l ;