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Triumph Tigress TW2 Service Sheet
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Triumph Tigress TW2 Service Sheet

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Summary of Contents for Triumph Tigress TW2

  • Page 2 SCOOTER Printed December 1959. 250 c.c. O.H.V. TWIN CYLINDER SCOOTER REMOVING THE SIDE VALANCES To remove the side valances for maintenance on the engine unit, take off the dual seat by removing the two 1/4 in. nuts and bolts coupling the "C" shaped hinges to the dual seat brackets.
  • Page 3 250 c.c. O.H.V. TWIN CYLINDER SCOOTER DISMANTLING FOR DECARBONISING The term decarbonising means the removal of all carbon deposits from the combustion chambers,piston crowns and ports. It is generally recognised as including attention to valves, guides and springs. You will need these tools below.Most of which are easy to find or modify, except for inlet valves and the steel gasket nowdays.
  • Page 4 Service Sheet No. 1002 (contd.) Scrape all carbon from the inside of the ports, (i.e., the passages in the cylinder head which allow the entry and exit of gases.) Take care to avoid damage to the seats. (These are the angular faces in the cylinder head, which, when mated with similar seats on the valves, provide a gas-tight seal.) Clean up the valves by careful...
  • Page 5 SCOOTER SERVICE SHEET 1003 Printed December 1959. 250 c.c. O.H.V. TWIN CYLINDER SCOOTER REMOVAL OF THE ENGINE, GEARBOX AND FINAL DRIVE NUT When the engine and transmission are removed for overhaul they must be taken out as a complete unit comprising the engine, gearbox and final drive.
  • Page 6 Service Sheet No. 1003 (contd.) Make sure that the petrol tap is turned off and uncouple the banjo union at the carburetter end of the petrol pipe. Be careful not to lose the two fibre washers or the small gauze filter which is fitted inside the banjo union.
  • Page 7 250 c.c. O.H.V. TWIN CYLINDER SCOOTER COMPLETE DISMANTLING OF THE ENGINE, GEARBOX AND FINAL DRIVE NUT If the oil has not already been drained from the unit it should be done at this stage. To drain the final drive take out the Phillips head screw immediately below the oil level plug and remove the oil level plug as well.
  • Page 8 Service Sheet No. 1004 (contd.) Dismantling Drive Side of Unit With the spanner provided in the toolkit remove the two sparking plugs, take off the two ~ in. nuts holding the rocker box cover, remove the steel washers and fibre washers and remove the cover. Examine the cover gasket to decide whether or not it can still be used.
  • Page 9 Service Sheet No. 1004 (contd.) When all the screws, nuts and bolts are removed, the primary drive cover can be taken off, the joint being broken by gently tapping the cover with a rawhide mallet or a hammer shaft but great care must be taken or the cover may be cracked or distorted.
  • Page 10 The plain steel clutch housing bearing sleeve can be slid off the mainshaft. Note that it is fitted with the larger diameter towards the engine. Having previously flattened the tab washer and slackened off the nut on the large primary driven gear, this gear can now be drawn off the gearbox mainshaft using service tool number 61-5025 fitted with the short extractor legs 61-1732 (Fig.
  • Page 11 Service Sheet No. 1004 (contd.) Flatten the tab washer on the rear cush drive unit and unscrew the nut, locking the assembly by applying the rear brake. The nut has a normal right-hand thread. The gearbox sprocket nut has no tab washer and is also unscrewed in a normal anti-clockwise direction. Here again it will be necessary to lock the unit by applying the rear brake, or alternatively by applying a substantial tool between the rear hub studs and locking against the bench.
  • Page 12 An oil seal is fitted in the cover from the brake shoe side, again with the lip of the oil seal facing inwards towards the bearing. If a replacement is to be fitted the old seal can be prized out with a screwdriver but care should always be taken when fitting a new oil seal to see that it is inserted squarely into the hole, and great care should be taken to avoid any damage to the feather edge of the seal.
  • Page 13 Service Sheet No. 1004 (contd.) stator unit. With the nuts and washers removed the stator can be drawn off the three studs by simply pulling it away and threading the leads through the rubber grommet in the back of the case.
  • Page 14 As the assembly is drawn out it may be that the thrust washer which is fitted to the mainshaft will drop into the case. Look for this washer and if it does drop replace it tem- porarily on the gearbox main- shaft so that its location is remembered.
  • Page 15 Service Sheet No. 1004 (contd.) Dismantling the Gear Cluster Take out the selector fork spindle, which is a push fit into the cover, and remove the two selector forks. The mainshaft and layshaft can then be removed from the bearings in the outer cover, and this will only leave the cam plate and its pivot pin in the outer cover.
  • Page 16 Service Sheet No. 1004 (contd.) Removal of the camshaft pinion will expose the oil pump link which is driven by an eccentric on the camshaft and is retained in position by a phosphor bronze plate held by two large countersunk screws. These screws can be removed with a normal type screwdriver, after which the phosphor bronze plate can be taken off and the distance piece removed showing the eccentric and linkage assembly.
  • Page 17 Service Sheet No. 1004 (contd.) Removal of the Connecting Rods and Pistons With the crankcase and cylinder block upside down on the bench flatten the tab washers underneath the connecting rod cap bolt nuts and unscrew the nuts. Take off the tab washers and lift off the big end caps.
  • Page 18 The only parts now left are the fixed items such as studs and the crankshaft bush. This is a press fit into the timing side and again the block should be heated in hot water or a suitable degreasing vat, if the old bush is worn or scored and therefore to be replaced. Note that the replacement is fitted from inside the crankcase and that there is a locating peg through the steel face of the bush into the case.
  • Page 19 250 c.c. O.H.V. TWIN CYLINDER SCOOTER RE-ASSEMBLY OF THE ENGINE, GEARBOX AND FINAL DRIVE UNIT Before commencing re-assembly make sure that all the necessary gaskets, tab washers and woodruff keys are available to replace any that have been damaged during dismantling. Another essential is to ensure absolute cleanliness of all parts.
  • Page 20 SERVICE SHEET No. 1005 (contd.) We now come to one of the bearings which requires special mention ; this is the gearbox mainshaft and pinion sleeve bearing which is a special sealed bearing, the seal being outwards, and the rear swinging arm bearing plate must be refitted before this bearing can be inserted through the gearbox.
  • Page 21 two tabs which are opposite each other on to the cap of the connecting rod. Tighten the nuts down with a torque wrench which has been set to 15 lb./ft., finally turning up the single tab on to one of the flats on the nut and repeat this operation for the other cylinder.
  • Page 22 (contd.) SERVICE SHEET No. 1005 Apply jointing compound to the face of the gearbox and the mating face of the cover (place thrust washer between the splined end of the mainshaft and the pinion sleeve), and slide the mainshaft through the pinion sleeve, at the same time engaging the selector fork shaft and the lay shaft at the back of the box.
  • Page 23 SERVICE SHEET No. 1005 (contd.) A" To complete the assembly on the fan side it is only necessary to fit the cowl, using 3 small Phillips head screws and one slotted screw at the top front. This screw with its nut also secures the throttle cable clip.
  • Page 24 • S E R V I C E S H E E T N o . 1 0 0 5 (contd.) Place the gearbox sprocket in the other end of the chain and slide the rear half of the chaincase together with the sprocket and chain over the gearbox mainshaft, screw on the nut securing the gearbox sprocket and secure by centre punching between the inside diameter of the, nut and the outside diameter of the shaft.
  • Page 25 SERVICE SHEET No. 1005 (contd. ) The simplest way to assemble the remaining parts of the clutch is to assemble all the plates on to the clutch centre, which is the splined component with the three holes for the spring studs. First slide on a plain steel plate up to the outer flange, then a lined plate, next a steel...
  • Page 26 Apply jointing compound to both the inner and outer cover faces, place the paper washer and outer cover in position, replace the Phillips screws and the one 4" nut over the stud at the top of the cover together with one shakeproof washer and replace the -&" nut and bolt at the front end of the cover. This bolt also carries the starter motor support bracket when a starter motor is fitted.
  • Page 27 250 c.c. O.H.V. TWIN CYLINDER SCOOTER ATTENTION TO VALVES To remove a valve, compress the springs with Service Tool No. 61-5001. Take out the split collets and remove the valve spring cup and springs, the valve will then drop down through its guide. Each valve is removed in the same way.
  • Page 28 The exhaust rockers are situated at left and right hand of the cylinder head with the inlet rockers in the middle. To take out an exhaust rocker shaft remove the small hexagon headed bolt from the sparking plug side rocker post and tap the shaft through towards the plug side. A small piece of tube must be fitted over the end of the shaft so that the steel ball which is pressed into the shaft to close the drilled °...
  • Page 29 c.c. O.H.V. TWIN CYLINDER SCOOTER REPLACING, THE ENGINE; GEARBOX AND FINAL DRIVE UNIT IN THE FRAME With the front engine studs in position, pick up the unit and holding it tilted slightly to the left pass the rear. drive, unit through the two vertical frame members. Bring the engine upright and slide it into position so that the two crankcase lugs slide into the mounting brackets on the two vertical frame pillars.
  • Page 30 SERVICE SHEET No. 1007 (contd. Replace the petrol pipe on the float chamber, making sure that the gauze filter is inside the banjo union, and that the large fibre washer is between the union and the float chamber, with the small fibre washer between the head of the bolt and the outside face of the banjo union.
  • Page 31 1008 SCOOTER SERVICE SHEET Printed January 1960 250 c.c. O.H.V. TWIN CYLINDER SCOOTER ADJUSTMENTS WHICH CAN BE CARRIED OUT WITHOUT EXTENSIVE DISMANTLING It is essential for the efficient running of the machine that certain checks are carried out periodically, in accordance with the summary of routine maintenance laid down in the instruction manual.
  • Page 32 SERVICE SHEET No. 1008 (contd.) Note that turning the plate clockwise advances and anti-clockwise retards the timing. Also rem emb e r th e im p ort an c e o f t he c ontac t bre ake r g ap, f o r ev e n a sl igh t v ar ia tion ten d s to alt er t h e timi ng . ( O p e n i n g t h e p o i n t s a d v a nc e s t he ti m i ng ;...
  • Page 33 SERVICE SHEET No. 1008 (contd.) Adjusting Clutch and Throttle Control Cables. A djustment of both these cables may b e necessary after a short initial mileage on the machin e as outer casings are liable to contract. Adjusters are situated behind the headlamp and in front of the ste er in g c o lu mn , bu t d o n ot a ttem pt t o c ar ry o ut ad jus tme nt t o e ith e r ca ble un le ss th er e is a def in i te nee d .

  • Page 34: Throttle Control

    SERVICE SHEET No. 1008 (contd.) Throttle Control. To adjust the throttle for tick-over, lift the dual seat to gain access to the screw on the right hand side of the carburetter. (14 Fig. 28). By screwing this in clockwise the throttle slide is raised to provide a faster tick-over or lowered to slow down the tick-over speed.
  • Page 35 SERVICE SHEET No. 1008 (contd.) Release the lightning fastener round the spare wheel cover, take off the two nuts securing the rear carrier and spare wheel and slacken the two bolts securing the rear carrier at each side of the dual seat. Lift up the carrier and take off the spare wheel, then remove the cover and place the spare on the ground next to the wheel to be changed.
  • Page 36 SERVICE SHEET 1008 (contd.) ''i--,~' , . Sparking "...
  • Page 37 (con/d.l t" It, .. "\1 ..Jii•.•••..
  • Page 38 float chamber and remove the float chamber complete with the nylon float. Be very careful not to damage the paper gasket which will be found between the float chamber and the body of the carburetter. The float can now be lifted out and the chamber cleaned thoroughly of any accumulation of water or foreign matter.
  • Page 39 250 c.c. O.H.V. TWIN CYLINDER SCOOTER REMOVING AND REFITTING FRONT MUDGUARD AND LEGSHIELD ASSEMBLY AND STEERING HEAD TUBE If the steering head tube is to be replaced, for example after accident damage, it is first of all necessary to remove the front mudguard and legshield assembly.
  • Page 40 1010 SCOOTER SERVICE SHEET Printed Jan. 1960 250 c.c. O.H.V. TWIN CYLINDER SCOOTER DISMANTLING AND RE-ASSEMBLY OF THE FRONT FORK AND WHEEL To withdraw the front fork from the steering column, sufficient clearance must be obtained at the front of the machine to allow the fork to be drawn out and downwards.
  • Page 41 washer 'B ' which will be seen under the spindle nut ` C' and unscrew the nut in a normal anti-clockwise direction. Take off the tab washer and draw the brake drum complete with bearings off the spindle. Examination of the drum will show that there is a large bearing ` D' on the inner end of the shell adjacent to an oil seal ` E' which has the lip facing towards the bearing.
  • Page 42 S service Sheet No. 1010 (contd.) can be from the head tube by tapping it with a suitable punch round the outside edge. The top cup removed by driving it from inside the tube, again using a suitable punch or drift. Replacements should be pressed on and into the tube;...
  • Page 43 Service Sheet No.-1010 (contd.) Make sure that all cables and controls pass down the front of the steering head and do not allow an acute bend above the instrument pane), as a cable in this condition may foul the stop-.plate. Connect the front brake by screwing the cable adjuster into the lower member and refit' the clevis pin in the brake lever.
  • Page 44 CHANGING BRAKE SHOES After a very considerable mileage it will be necessary to replace the brake shoes, this-can be done without dismantling the hubs. Rear Brake To change the rear brake shoes first lift the machine off the stand so that the rear wheel is clear of the ground ground and place a small trestle or block of wood under the rear cross member of the frame Remove the rear wheel by taking off the three, hub huts and take out the single countersunk screw which...
  • Page 45 Service Sheet No. 1011 (contd.) Front Brake The presence of the stub axle makes the procedure for the front brake somewhat different from that for the rear. Raise the front of the machine so that the front wheel is clear of the ground by placing a block of wood approximately 2"...
  • Page 46 1012 SCOOTER SERVICE SHEET Printed Jan. 1960 250 c.c. O.H.V. TWIN CYLINDER SCOOTER REMOVING AND REPLACING THE PETROL TANK Removal It is sometimes necessary to remove and clean a petrol tank where foreign matter such as dirt or water has got into the fuel.
  • Page 47 250 c.c. O.H.V. TWIN CYLINDER SCOOTER CHANGING SPEEDOMETER OR SPEEDOMETER CABLE If it is necessary at any time to change the speedometer head or the cable, the following procedure., should be adopted. When the cable is to be-replaced, disconnect the cable at the rear-brake drum under neath the swinging arm by unscrewing the outer casing union nut and pull the inner cable out of mesh .with the drive.
  • Page 48 Service Sheet No. 1013 (contd.) and into position, making sure that the two brackets on the underside of the panel lie between the rear portion of the leg shields and the front panel and that the panel fits over the top edge of the leg shields and is also clipping over the plastic beads round the outer edges of the leg shields.
  • Page 49 250 c.c. O.H.V. Twin Cylinder Scooter fitted with Lucas 5AF Alternator General Description Designed specially for enclosed engines where fan cooling is necessary, the 5AF alternator consists of a conventional, RM13 type, wound stator for bolting to the engine crankcase but its RM15 type rotor is cast integral with the engine flywheel.

  • Page 50: Output Control

    SERVICE SHEET No. 1050 (contd.) Output Control The standard circuit has the output wires from the generator connected by their snap connectors to similarly coloured wires on the wiring harness and provides the following output control. Lighting Switch in "OFF" Position The output is taken from one pair of coils by means of the Green/White and Green/Black wires, and the remaining coils (Green/White and Green/Yellow wires) are open-circuited.
  • Page 51 SERVICE SHEET No. 1050 (contd.) Checking D. C. Input to Battery Test 1. Ammeter connected in series with main Test 2. Disconnect main lead from battery. lead and battery. Connect 1 ohm resistor in place of battery. Feed ignition coil separately from battery. Turn ignition switch to IGN position.
  • Page 52 SERVICE SHEET No. 1050 (contd.) Testing the Alternator on the Machine, using an A. C. Voltmeter and I Ohm Load Resistor Conclusions from these Tests Low reading on any group of coils indicates shorted turns. Zero reading will indicate open-circuit coil. If all coils read low, partial de-magnetization of rotor may have occurred as a result of faulty rectifier.
  • Page 53 SERVICE SHEET No. 1050 (contd.) Rectifier-Bench Testing VI-will measure the volt drop across the rectifier plate. V2-must be checked when testing the rectifier plate, to make certain the voltage is the recommended 12 volts on load. supply It is essential that the supply is kept at 12 volts for these Tests. Forward Resistance Test Test 1.
  • Page 54 SERVICE SHEET No. 1050 (contd.) Testing the External Wiring Circuit Using D.C. Voltmeter only 1. All cables, including battery, to be connected as normal. 2. Connect voltmeter Red test lead to earth. Testing Charging Circuit through Ignition Switch 3. Connect Black test lead to No. 2 terminal on rectifier. 4.
  • Page 55 SERVICE SHEET No. 1050 (contd.) Wiring Diagram 6 Volt Model...
  • Page 56 SERVICE SHEET No. 1050 (contd.) Checking Rectifier in Position on Machine Reading with Leads Voltmeter and Resistor Connected as Shown Connected Across 7.0 (min.) 6 volt Terminal No. 2 (or centre terminal on latest type) and 6.5 (min.) 12 volt frame of machine Procedure Connect the alternator leads as detailed direct to the rectifier terminals No.
  • Page 58 SERVICE SHEET No. 1050 (contd.)

  • Page 59: Maintenance

    1051 SCOOTER SERVICE SHEET Printed March 1960 250 c.c. O.H.V. TWIN CYLINDER SCOOTER THE LUCAS MODEL M3 PRE-ENGAGED STARTING MOTOR WITH ROLLER-CLUTCH DRIVE Introduction and Servicing GENERAL Model M3 manually pre-engaged starting motor is a four-pole two-brush earth return machine with series-connected field coils.
  • Page 60 Service Sheet No. 1051 (cont.) Bench Testing (i) Measuring the Light Running Current. With the starting motor clamped in a vice and using two fully charged, series-connected, 6-volt 12 amp.hr. batteries, check the light running current and compare with the value given in paragraph on Performance Data. Look for excessive arcing at the commutator and, if necessary, remedy.
  • Page 62 1052 SCOOTER SERVICE SHEET Printed March 1960 250 c.c. O.H.V. TWIN CYLINDER SCOOTER TWIN COIL IGNITION SYSTEMS AND EMERGENCY STARTING A description of the working principles of twin-coil ignition systems. GENERAL The 250 c.c. scooters have engines of the vertical twin-cylinder, four-stroke pattern. They are fitted with a Lucas alternator and coil ignition system incorporating two ignition coils and double contact-breaker units.
  • Page 63 cylinder, it gradually effects a reduction in the amount of energy available for transfer to the ignition coil. This reduction in spark energy will cause misfiring to occur, which in the event of the rider omitting to return the ignition key from position "...
  • Page 64 Service Sheet No. 1052 (cont.) In other words the maximum " magneto " performance of the alternator can only be obtained when the piston is accurately set to the timing position recommended, i.e., 5 ° before top dead centre. Faulty Circuit Connections Faulty or dirty connections anywhere in the alternator electrical circuit will obviously have a bad effect on performance.
  • Page 65 EMERGENCY STARTING CIRCUIT GREEN WHITE CIRCUIT WITH No.1 CONTACTS CLOSED f--E-CIRCUIT WITH CONTACTS No l OPEN ~ FRAME ~ OF / MACHINE % (EARTH EMG. CONTACTS...
  • Page 67 Taking out an Inlet Valve using Spring Compressor 5001 (250 c.c.). Pulling off the Flywheel with Extractor 5040 (175 c.c.). 61-5002 is similar but for 250 c.c. only. Replacing a Piston is made easier using Slipper (250 c.c.) 5051 (17 5 c.c.).
  • Page 68 Scooter Service Sheet No. 1054 (contd.) Removing the Auto Advance and with Extractor 61-5005 (250c.c.). Pulling off the Crankshaft Pinion (250c.c.) with Ex- tractor 61-5025. Similar to 5050 Primary Gear Extractor (175 c.c.). Removing the Clutch Centre with Extractor 5007 (175 and 250 c.c.).
  • Page 69 Scooter Service Sheet No. 1054 (contd.) Feeding Front Fork Damper Rod through the Sliding Member using tool number 6Z-5o18 (175 25o c.c.}. Drawing out the Speedo- meter Drive Bush with tool number 6i-5019 (175 25o c.c.). Holding the Crankshaft with tool number 61 -5022 (175 25o c.c.).
  • Page 70 Scooter Service Sheet No. 1054 (contd.) with tool number 61 5035 (250 c.c.). U n s c r e w i n g t h e R e a r Spindle Bearing Lock Ring with tool number 61 5026 (175 and c.c.).
  • Page 71 Scooter Service Sheet No. 1054 (contd.) Driving in an Inlet Valve Guide using Punch 61-3382 (250 c.c.). Re-cutting a Valve Seat with Cutter number 61-5036 (250 c.c.). Engine Assembly jig number 61-5046 (175 and 250 . c.c.).
  • Page 72 Scooter Service Sheet No. 1054 (contd). Parting the Flywheels (175 Assembling the Flywheels c.c.) using Bolster 61 3207, (I75 c.c.) using Bolster Stripping Bars 61-3208(2), 61-3207, Adapter 6I-5047, Dismantling Punch 61 3209 Bridge 61 3210...