Related Manuals for Triumph T120TT
Summarization of Contents
GENERAL DATA
THREADS PER INCH
Details thread specifications for various sizes in different standards (Unified, Whitworth).
SECTION A LUBRICATION SYSTEM
ROUTINE MAINTENANCE
Outlines routine maintenance tasks for the lubrication system, specifying intervals.
TABLE OF RECOMMENDED LUBRICANTS
Lists recommended lubricants for various units, categorized by brand and application.
ENGINE LUBRICATION SYSTEM
Explains the dry sump engine lubrication system's operation and oil flow.
CHANGING THE ENGINE OIL AND CLEANING THE OIL FILTERS
Details the procedure for draining and cleaning engine oil and filters, including intervals.
OIL PRESSURE
Discusses oil pressure control by the release valve and expected readings.
STRIPPING AND REASSEMBLING THE OIL PRESSURE RELEASE VALVE
Provides instructions for dismantling and reassembling the oil pressure release valve unit.
STRIPPING AND REASSEMBLING THE OIL PUMP
Details the process of stripping and reassembling the oil pump for maintenance and inspection.
REMOVING AND REPLACING THE OIL PIPE JUNCTION BLOCK
Explains how to remove and replace the oil pipe junction block for maintenance.
REMOVING AND REPLACING THE ROCKER OIL FEED PIPE
Provides steps for removing and replacing the rocker oil feed pipe.
CONTACT BREAKER LUBRICATION
Describes the lubrication procedure for the contact breaker components.
GEARBOX LUBRICATION
Details how to lubricate the gearbox, including oil level checks and initial fill.
PRIMARY CHAINCASE LUBRICATION
Explains the lubrication of the primary chaincase, including oil level and change intervals.
REAR CHAIN LUBRICATION AND MAINTENANCE
Covers the lubrication and maintenance of the rear chain, including cleaning and elongation checks.
GREASING THE STEERING HEAD BALL RACES
Outlines the procedure for greasing the steering head ball races.
WHEEL BEARING LUBRICATION
Details the lubrication requirements for wheel bearings.
TELESCOPIC FORK LUBRICATION
Provides instructions for lubricating the telescopic fork legs with oil.
LUBRICATION NIPPLES
Explains the use and maintenance of lubrication nipples.
LUBRICATING THE CONTROL CABLES
Describes the method for lubricating control cables.
SPEEDOMETER CABLE LUBRICATION
Outlines the procedure for lubricating the speedometer cable.
REAR BRAKE PEDAL SPINDLE LUBRICATION
Details the lubrication of the rear brake pedal spindle.
CHECK PROCEDURE FOR WET SUMPING
Provides a procedure to check for wet sumping conditions in the engine lubrication system.
SECTION B ENGINE
DESCRIPTION
Provides an overview of the Triumph engine's construction and components.
SECTION B1 REMOVING AND REPLACING THE ENGINE UNIT
Details the procedure for removing and refitting the entire engine unit from the motorcycle.
SECTION B2 REMOVING AND REPLACING THE ROCKER BOXES
Explains how to remove and replace the rocker boxes, including push rod handling.
SECTION B3 INSPECTING THE PUSHRODS
Guides on inspecting pushrods for wear, damage, and straightness.
SECTION B4 STRIPPING AND REASSEMBLING THE ROCKER BOXES
Covers the process of stripping and reassembling rocker boxes, including cleaning and oil seals.
SECTION B5 ADJUSTING THE VALVE ROCKER CLEARANCES
Explains how to check and adjust valve rocker clearances for optimal engine performance.
SECTION B6 REMOVING AND REPLACING THE AIR CLEANER
Details the procedure for removing and replacing the air cleaner assembly.
SECTION B7 CARBURETTER—DESCRIPTION
Describes the components and operation of the Amal carburetter.
SECTION B8 REMOVING AND REPLACING THE CARBURETTER
Provides instructions for removing and replacing single and twin carburetter assemblies.
SECTION B9 STRIPPING AND REASSEMBLING THE CONCENTRIC CARBURETTER
Details the process for stripping and reassembling concentric carburetters.
SECTION B9 STRIPPING AND REASSEMBLING THE MONOBLOC CARBURETTER
Outlines the procedure for stripping and reassembling monobloc carburetters.
SECTION B10 INSPECTING THE CARBURETTER COMPONENTS
Guides on inspecting carburetter components for wear and damage.
SECTION B11 CARBURETTER ADJUSTMENTS
Explains how to adjust carburettor settings like throttle stop, pilot air, and needle jet.
SECTION B12 TWIN CARBURETTER ARRANGEMENT
Describes the setup and synchronization of twin carburetters.
SECTION B13 REMOVING AND REPLACING THE EXHAUST SYSTEM
Details the process of removing and replacing the exhaust system.
SECTION B14 REMOVING AND REFITTING THE CYLINDER HEAD ASSEMBLY
Provides steps for removing and refitting the cylinder head assembly, including gasket replacement.
SECTION B15 REMOVING AND REFITTING THE VALVES
Guides on removing and refitting valves, including spring compressor use.
SECTION B16 RENEWING THE VALVE GUIDES
Explains how to renew valve guides, including pressing and reaming.
SECTION B17 DECARBONISING
Details the process of decarbonising the combustion chamber and ports.
SECTION B18 RE-SEATING THE VALVES
Guides on re-cutting valve seats and grinding in valves for a proper seal.
SECTION B19 REMOVING AND REPLACING THE CYLINDER BLOCK AND TAPPETS
Provides instructions for removing and replacing the cylinder block and tappets, emphasizing correct placement.
SECTION B20 INSPECTING THE TAPPETS AND GUIDE BLOCKS
Guides on inspecting tappets and guide blocks for wear and play.
SECTION B21 RENEWING THE TAPPET GUIDE BLOCKS
Explains how to renew tappet guide blocks, including pressing and alignment.
SECTION B22 REMOVING AND REFITTING THE PISTONS
Details the process of removing and refitting pistons, including circlip replacement and gudgeon pin handling.
SECTION B23 REMOVING AND REPLACING THE PISTON RINGS
Guides on removing and replacing piston rings, including cleaning and gap checks.
SECTION B24 INSPECTING THE PISTONS AND CYLINDER BORES
Outlines how to inspect pistons and cylinder bores for wear and damage.
SECTION B25 TABLE OF SUITABLE RE-BORE SIZES
Lists suitable bore sizes for re-boring based on piston markings.
SECTION B26 PISTON IDENTIFICATION
Provides visual identification of pistons based on markings and measurements.
SECTION B27 RENEWING THE SMALL END BUSHES
Explains how to renew small end bushes using a press or drift.
SECTION B28 REMOVING AND REPLACING THE CONTACT BREAKER
Details the removal and replacement of the contact breaker mechanism.
SECTION B29 IGNITION TIMING - INITIAL PROCEDURE
Guides on initial assembly of the contact breaker and auto advance unit for timing.
SECTION B29 IGNITION TIMING USING A STROBOSCOPIC LIGHT
Explains how to set ignition timing using a stroboscope and timing disc.
SECTION B30 IGNITION TIMING WHERE A STROBOSCOPE IS NOT AVAILABLE
Provides methods for setting ignition timing without a stroboscope, including static timing.
SECTION B31 IGNITION TIMING BY STROBOSCOPE AFTER ENGINE NUMBER DU.66245
Details ignition timing procedures for models after DU.66245 using a stroboscope.
SECTION B32 REMOVING AND REPLACING THE TIMING COVER
Explains the process of removing and replacing the timing cover.
SECTION B33 REMOVING AND REPLACING THE OIL PUMP
Guides on removing and replacing the oil pump.
SECTION B34 EXTRACTING AND REFITTING THE VALVE TIMING PINIONS
Details the extraction and refitting of valve timing gears.
SECTION B36 DISMANTLING AND REASSEMBLING THE CRANKCASE ASSEMBLY
Provides instructions for dismantling and reassembling the crankcase assembly.
SECTION B37 STRIPPING AND REASSEMBLING THE CRANKSHAFT ASSEMBLY
Guides on stripping and reassembling the crankshaft assembly, including balancing.
SECTION B38 REFITTING THE CONNECTING RODS
Details the process of refitting connecting rods to the crankshaft.
SECTION B39 INSPECTING THE CRANKCASE COMPONENTS
Guides on inspecting crankcase components like bearings, camshafts, and faces.
SECTION B40 RENEWING THE MAIN BEARINGS
Explains how to renew main bearings and oil seals in the crankcase.
SECTION B41 RENEWING CAMSHAFT BUSHES
Guides on renewing camshaft bushes in the crankcase halves.
SECTION B42 REMOVING AND REPLACING THE TACHOMETER DRIVE
Details removing and replacing the tachometer drive gearbox.
SECTION C TRANSMISSION
DESCRIPTION
Describes the multiplate clutch and its components, including the shock absorber unit.
SECTION C1 ADJUSTING THE CLUTCH OPERATING MECHANISM
Explains how to adjust the clutch operating mechanism, including cable and pushrod settings.
SECTION C2 ADJUSTING THE PRIMARY CHAIN TENSION
Details how to adjust the primary chain tension using the slipper blade.
SECTION C3 REMOVING AND REPLACING THE PRIMARY COVER
Provides steps for removing and replacing the primary cover.
SECTION C4 REMOVING AND REFITTING THE CLUTCH PLATES
Guides on removing and refitting clutch plates, springs, and pressure plate.
SECTION C5 INSPECTING THE CLUTCH PLATES AND SPRINGS
Outlines how to inspect clutch plates and springs for wear and damage.
SECTION C6 ADJUSTING THE CLUTCH PRESSURE PLATE
Explains how to adjust the clutch pressure plate for true running.
SECTION C7 RENEWING SHOCK ABSORBER RUBBERS
Details the procedure for removing and replacing shock absorber rubbers.
SECTION C8 REMOVING AND REPLACING THE STATOR AND ROTOR
Provides instructions for removing and replacing the alternator stator and rotor.
SECTION C9 REMOVING AND REPLACING THE CLUTCH AND ENGINE SPROCKETS
Details the process of removing and replacing clutch and engine sprockets using special tools.
SECTION C10 INSPECTION OF THE TRANSMISSION COMPONENTS
Guides on inspecting transmission components like chains, sprockets, and shock absorber spiders.
SECTION C11 REAR CHAIN ALTERATIONS AND REPAIRS
Covers chain alterations, repairs, and the use of a rivet extractor.
SECTION D GEARBOX
DESCRIPTION
Describes the Triumph four-speed gearbox, its construction, and components.
SECTION D1 REMOVING AND REPLACING THE GEARBOX OUTER COVER ASSEMBLY
Details the procedure for removing and replacing the gearbox outer cover.
SECTION D2 DISMANTLING AND REASSEMBLING THE KICKSTART MECHANISM
Explains how to dismantle and reassemble the kickstart mechanism.
SECTION D3 DISMANTLING AND REASSEMBLING THE GEARCHANGE MECHANISM
Provides instructions for dismantling and reassembling the gearchange mechanism.
SECTION D4 INSPECTING THE GEARCHANGE AND KICKSTART COMPONENTS
Guides on inspecting gearchange and kickstart components for wear.
SECTION D5 RENEWING KICKSTART AND GEARCHANGE SPINDLE BUSHES
Explains how to renew kickstart and gearchange spindle bushes.
SECTION D6 CLUTCH OPERATING MECHANISM
Describes the clutch operating mechanism located in the gearbox outer cover.
SECTION D7 DISMANTLING THE GEARBOX
Details the step-by-step process for dismantling the gearbox, including gear and shaft removal.
SECTION D8 INSPECTION OF THE GEARBOX COMPONENTS
Guides on inspecting various gearbox components for wear and damage.
SECTION D9 RENEWING MAINSHAFT AND LAYSHAFT BEARINGS
Explains how to renew mainshaft and layshaft bearings, including heating and pressing.
SECTION D10 REASSEMBLING THE GEARBOX
Provides instructions for reassembling the gearbox, including gear and selector fork placement.
SECTION D11 CHANGING THE GEARBOX SPROCKET
Details the process of changing the gearbox sprocket, including oil seal checks.
SECTION D12 SPEEDOMETER DRIVE GEAR COMBINATIONS (BEFORE ENGINE NUMBER DU.24875)
Lists speedometer drive gear combinations required for ratio changes.
SECTION D13 GEARBOX SPROCKET AND MAINSHAFT HIGH GEAR
Discusses alterations to gearbox sprockets and high gears, including part interchangeability.
SECTION D14 SPEEDOMETER DRIVE GEARS
Notes the deletion of speedometer drive gears on later models.
SECTION E FRAME AND ATTACHMENT DETAILS
REMOVING AND REFITTING THE FUEL TANK
Guides on removing and refitting the fuel tank, including securing bolts and unions.
SECTION E2 REMOVING AND REPLACING THE PANELS (6T) EARLIER 6T ONLY
Details removing and replacing rear enclosure panels on earlier 6T models.
SECTION E3 REMOVING AND REPLACING THE SWITCH PANEL (TR6 AND T120)
Explains how to remove and replace the switch panel on TR6 and T120 models.
SECTION E4 REMOVING AND REPLACING THE OIL TANK
Provides instructions for removing and replacing the oil tank, including draining and filter cleaning.
SECTION E5 REMOVING AND REPLACING THE BATTERY CARRIER
Details the process of removing and replacing the battery carrier and its components.
SECTION E6 REMOVING AND REPLACING THE REAR MUDGUARD
Guides on removing and replacing the rear mudguard, including electrical connections.
SECTION E7 ADJUSTING THE REAR SUSPENSION
Explains how to adjust the rear suspension spring loading and setting positions.
SECTION E8 REMOVING AND REFITTING THE REAR SUSPENSION UNITS
Details the procedure for removing and refitting the rear suspension units.
SECTION E9 STRIPPING AND REASSEMBLING THE SUSPENSION UNITS
Covers stripping and reassembling suspension units, including spring compression and bush renewal.
SECTION E10 REMOVING AND REFITTING THE SWINGING FORK
Provides steps for removing and refitting the swinging fork, including pivot spindle adjustment.
SECTION E11 RENEWING THE SWINGING FORK BUSHES
Explains how to renew swinging fork bushes, including pressing and alignment.
SECTION E12 REMOVING AND REPLACING THE REAR FRAME
Details removing and replacing the rear frame section.
SECTION E13 FRAME ALIGNMENT
Guides on checking and correcting frame alignment using specialized tools and measurements.
SECTION E14 FAIRING ATTACHMENT LUGS AND STEERING LOCK
Describes fairing attachment lugs and the steering lock mechanism.
SECTION E15 FITTING REPLACEMENT SEAT COVERS
Provides instructions for fitting replacement seat covers, emphasizing preparation.
SECTION E16 REPAIRS
Covers simple repairs for dents and minor bodywork damage using basic tools.
SECTION E17 PAINTWORK REFINISHING
Details the process of paint stripping, priming, filling, and finishing for a professional paint job.
SECTION F WHEELS, BRAKES AND TYRES
REMOVING AND REFITTING THE FRONT WHEEL
Guides on removing and refitting the front wheel, including brake adjuster and cable disconnection.
SECTION F2 REMOVING AND REFITTING THE REAR WHEEL
Details removing and refitting the rear wheel, including chain and brake adjustments.
SECTION F3 REMOVING AND REFITTING THE QUICKLY DETACHABLE REAR WHEEL
Explains how to remove and refit the Q.D. rear wheel, including spline alignment.
SECTION F4 FRONT AND REAR WHEEL ALIGNMENT
Provides a method for aligning front and rear wheels using straight edges.
SECTION F5 BRAKE ADJUSTMENTS
Details how to adjust front and rear brake mechanisms for proper operation.
SECTION F6 STRIPPING AND REASSEMBLING THE BRAKES
Covers the process of stripping and reassembling brake plates, shoes, and cams.
SECTION F7 RENEWING THE BRAKE LININGS
Explains how to renew brake linings by riveting new linings to the shoes.
SECTION F8 REMOVING AND REFITTING THE WHEEL BEARINGS
Guides on removing and refitting wheel bearings, including cleaning and inspection.
SECTION F9 WHEEL BUILDING
Notes that wheel building is a specialist task, detailing spoke tension and rim alignment.
SECTION F10 WHEEL BALANCING
Explains how to balance wheels using weights, with a note on rear wheel balancing.
SECTION F11 REMOVING AND REPAIRING TYRES
Details the procedure for removing and fitting tyres, including bead seating and valve alignment.
SECTION F12 SECURITY BOLTS
Explains the purpose and fitting of security bolts for rear wheels.
SECTION F13 TYRE MAINTENANCE
Covers tyre maintenance, including pressure, wear, and cleaning recommendations.
SECTION F14 SIDECAR ALIGNMENT
Provides guidance on aligning motorcycle and sidecar wheels for optimal tyre wear and steering.
SECTION G TELESCOPIC FORKS
REMOVING AND REFITTING THE NACELLE TOP COVER (6T)
Details removing and refitting the nacelle top cover on 6T models.
SECTION G2 REMOVING THE TELESCOPIC FORK UNIT
Explains how to remove the complete telescopic fork unit from the frame.
SECTION G3 DISMANTLING THE TELESCOPIC FORK
Guides on dismantling telescopic forks, covering different types and procedures.
SECTION G4 INSPECTION AND REPAIR OF FORK COMPONENTS
Details inspecting fork components like stanchions, lugs, and bushes for wear and damage.
SECTION G5 RENEWING THE STEERING HEAD RACES
Explains how to renew steering head races, including cup and cone replacement.
SECTION G6 RENEWING THE FRONT FORK OIL SEALS
Guides on renewing front fork oil seals, including removal and fitting procedures.
SECTION G7 REASSEMBLING AND REFITTING THE TELESCOPIC FORK UNIT
Provides instructions for reassembling and refitting the telescopic fork unit.
SECTION G8 TELESCOPIC FORK ALIGNMENT
Details the procedure for checking and correcting telescopic fork leg alignment.
SECTION G9 ADJUSTING THE STEERING HEAD RACES
Explains how to adjust steering head races to compensate for wear and ensure proper steering.
SECTION G10 CHANGING THE FRONT FORK MAIN SPRINGS
Guides on changing front fork main springs, including spring rates and colour codes.
SECTION G11 THE HYDRAULIC DAMPING UNIT
Describes the hydraulic damping unit, its operation, and servicing.
SECTION H ELECTRICAL SYSTEM
INTRODUCTION
Provides an overview of the electrical system, its power source, and components.
SECTION HI BATTERY INSPECTION AND MAINTENANCE
Covers battery inspection, maintenance, and electrolyte specific gravity.
SECTION H2 BATTERY CONNECTIONS-TWO 6 VOLT BATTERIES IN SERIES
Details the correct method for connecting two 6-volt batteries in series for a 12-volt system.
SECTION H3 COIL IGNITION SYSTEM
Explains the coil ignition system, its components, and basic troubleshooting.
SECTION H3 PART A. CHECKING THE LOW TENSION CIRCUIT FOR CONTINUITY
Guides on checking low tension circuit continuity to locate faults.
SECTION H3 PART B. FAULT FINDING IN THE LOW TENSION CIRCUIT
Details procedures for fault finding in the low tension ignition circuit using a voltmeter.
SECTION H3 PART C. IGNITION COILS
Explains how to test ignition coils for proper operation.
SECTION H3 PART D. CONTACT BREAKER
Guides on testing and troubleshooting the contact breaker.
SECTION H3 PART E CONTACT BREAKER FROM DU.66246
Details specific procedures for contact breakers used from DU.66246.
SECTION H3 PART F. CHECKING THE HIGH TENSION CIRCUIT
Outlines how to check the high tension circuit for ignition faults.
SECTION H3 PART G. CHECKING THE EMERGENCY STARTING CIRCUIT-ONLY PRIOR TO ENGINE NUMBER DU.24875
Describes checking the emergency starting circuit on specific models.
SECTION H4 SPARKING PLUGS
Guides on inspecting, cleaning, and testing sparking plugs, including diagnosis of fouling.
SECTION H5 CHARGING SYSTEM
Explains the charging system, including alternator, rectifier, and Zener diode operation.
SECTION H5 PART A. CHECKING THE D.C. INPUT TO BATTERY
Details how to check the D.C. input to the battery using an ammeter.
SECTION H5 PART B. CHECKING THE ALTERNATOR OUTPUT
Explains how to check the alternator output using an A.C. voltmeter and load resistor.
SECTION H5 PART C. RECTIFIER MAINTENANCE AND TESTING
Covers rectifier maintenance and bench testing procedures.
SECTION H5 PART D. CHECKING THE CHARGING CIRCUIT FOR CONTINUITY
Guides on checking the charging circuit for continuity using a voltmeter.
SECTION H5 PART E. CONSTRUCTING A ONE-OHM LOAD RESISTOR
Provides instructions for constructing a 1-ohm load resistor for testing.
SECTION H6 ZENNER DIODE CHARGE CONTROL (12 VOLT MACHINES ONLY)
Explains the Zener diode charge control system for 12-volt machines.
SECTION H7 ZENNER DIODE LOCATION
Details the location and mounting of the Zener diode and its heat sink.
SECTION H8 A.C. IGNITION (E.T.) AND A.C. LIGHTING SYSTEMS
Describes the A.C. magneto ignition and lighting systems.
SECTION H8 PART A. A.C. IGNITION
Explains the working of the A.C. ignition system and rotor/stator positioning.
SECTION H8 PART D DIRECT LIGHTING SYSTEM
Discusses the electrical power supply for the direct lighting system.
SECTION H9 ALTERNATOR AND STATOR DETAILS SPECIFICATIONS AND OUTPUT FIGURES
Lists specifications and output figures for alternators and stators.
SECTION H10 ELECTRIC HORN
Describes the operation and adjustment of the electric horn.
SECTION H11 HEADLAMP
Covers headlamp description, beam adjustments, and removal/refitting.
SECTION H12 REMOVING AND REFITTING THE HEADLAMP
Details the procedure for removing and refitting the headlamp unit.
SECTION H13 TAIL AND STOP LAMP UNIT
Explains how to access and replace bulbs in the tail and stop lamp unit.
SECTION H14 FUSES
Locates and describes the fuse, its rating, and holder.
SECTION H15 IGNITION SWITCH
Details the ignition switch, its lock mechanism, and removal.
SECTION H16 IGNITION CUT-OUT ("KILL") BUTTON
Describes the function and types of the ignition cut-out button.
SECTION H17 WARNING LAMPS
Explains the function and location of warning lamps in the headlamp shell.
SECTION H18 CAPACITOR IGNITION (MODEL 2MC)
Details the capacitor ignition system, its advantages, and heat sink requirements.
SECTION J WORKSHOP SERVICE TOOLS
INTRODUCTION
Introduces the section on workshop service tools for major operations.
SECTION J1 ENGINE
Illustrates service tools specifically for engine dismantling and reassembly.
SECTION J2 TRANSMISSION
Illustrates service tools required for transmission operations.
SECTION J3 GEARBOX
Illustrates service tools applicable to gearbox maintenance.
SECTION J4 WHEELS
Illustrates service tools related to wheels.
SECTION J5 FRONT FORKS
Illustrates service tools for front fork maintenance.
SECTION J6 MOTORCYCLE TOOLKIT
Mentions the motorcycle toolkit, although not detailed here.
SECTION CT CONVERSION TABLES
CONVERSION TABLES
Provides conversion tables from inches to millimeters and vice versa.
INCHES TO MILLIMETRES-UNITS
Table for converting inches to millimeters for units.
DECIMALS TO MILLIMETRES-FRACTIONS
Table for converting decimal inches and fractions to millimeters.
FRACTIONS TO DECIMALS AND MILLIMETRES
Table for converting fractions to decimals and millimeters for screw threads.
WIRE GAUGES
Lists wire gauges with corresponding sizes in inches and millimeters.
FOOT POUNDS TO KILOGRAMETRES
Conversion table for force measurements.
MILES PER GALLON (IMPERIAL) TO LITRES PER 100 KILOMETRES
Table for converting fuel efficiency units.
POUNDS PER SQUARE INCH TO KILOGRAMS PER SQUARE CENTIMETRE
Conversion table for pressure measurements.
Need help?
Do you have a question about the T120TT and is the answer not in the manual?
Questions and answers