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Triumph DAYTONA 675 Service Manual

Triumph daytona 675, street triple and street triple r.
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Table of Contents
ThH
i uMP
DAYTONA 675
STREET TRIPLE
STREET TRIPLE R

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Table of Contents

   Also See for Triumph DAYTONA 675

   Summary of Contents for Triumph DAYTONA 675

  • Page 1 DAYTONA 675 STREET TRIPLE STREET TRIPLE R...
  • Page 2 Triumph Daytona 675, Street Triple and Street Triple R Motorcycle Service Manual Pa rt Number 3856750 issue 1, 06.2009 Service Manual - Daytona 675, Street Triple and Street Triple R...
  • Page 3 Cylinder Head Clutch Crankshaft, Connecting Rods and Pistons Balancer Transmission Lubrication Engine Removal/Refit Fuel System/Engine Management Cooling Rear Suspension Front Suspension Brakes Wheels/Tyres Frame and Bodywork Electrical Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 4: Table Of Contents

    Warnings, Cautions and Notes .............. with Noise Control System Prohibited ..........vii erin .vii References................Dimensions................vii Repairs and Replacements ..............vii .vii Force................vii ................Edges procedure ..............vii Tightening Service Manual - Daytona 675, Street Triple and Street Triple R Il1MP...
  • Page 5: Howto Use This Manual

    • Keep complete records of all maintenance and repairs with dates and any new parts installed. • Use only approved lubricants, as specified in the owner's handbook, in the maintenance of the motorcycle. Service Manual - Daytona 675, Street Triple and Street Triple R L UMP...
  • Page 6: Noise Control System Prohibited

    Whenever tapping to aid removal of an item is necessary, tap lightly using a hide or plastic faced mallet. Service Manual - Daytona 675, Street Triple and Street Triple R I uMP...
  • Page 7 Press................BallBearings ................. ChassisBearing Lubrication ............Metalbushes ............... 1.10 FuelHandling Precautions ..............1.10 General................1.10 Petrol Gasoline ..............1.10 FuelTank Rem oval ..............1.11 ChassisRepairs ................1.11 Service Manual - Daytona 675, Street Triple and Street Triple R II.I MP...
  • Page 8: General Information

    1.32 1.33 CoolantSystem ..............Suspension................. 1.33 1.34 FuelInjection System ..............EmissionsControls ..............1.34 Brakes................1.34 Brakes(continued) ..............1.35 1.35 Wheelsand Tyres ..............1.36 Frame................ElectricalEquipment ..............1.36 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 9 Fuel Tank Breather Hose Routing - Street Triple and Street Triple R ......1.58 Fuel Tank Breather Hose Routing - Models with Evaporative Emissions - Daytona 675 ....1.59 Fuel Tank Breather Hose Routing - Models with Evaporative Emissions - Street Triple and Triple R ................
  • Page 10: Ignitionsystem Safety Precautions

    Always be aware of who your nearest first- Service Manual - Daytona 675, Street Triple and Street Triple R L UMP...
  • Page 11: Environmentalprotection Precautions

    Failure to change the brake fluid at the interval specified in the routine maintenance schedule may reduce braking efficiency resulting in an Service Manual - Daytona 675, Street Triple and Street Triple R L UMP...
  • Page 12: Safetyinstructions

    Reduced cooling system efficiency may lead to the engine overheating an d engine damage. Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 13: Cleaningcomponents

    Do not re-use a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. Service Manual - Daytona 675, Street Triple and Street Triple R ll1Mp...
  • Page 14: Lockingdevices

    Protect the seal from any surface which could cause • Grease the bearing, not the cavity where it damage to the seal lips when it is being fitted. Use a is located. Service Manual - Daytona 675, Street Triple and Street Triple R lliMP...
  • Page 15 Grease the bearing races and the ball bearing carrier. Sealed bearings (wheel bearings & swinging arm, depending on the model) Note: • Sealed bearings can be identified by their integrated seals. Service Manual - Daytona 675, Street Triple and Street Triple R Il1MP...
  • Page 16: Metalbushes

    The notice must instruct the reader of the precautions which must be taken. Failure to observe any of the above warnings may lead to a fire hazard which could result in personal injury. 1.10 Service Manual - Daytona 675, Street Triple and Street Triple R Il1MP...
  • Page 17: Fueltank Rem Oval

    VAPOUR warning label attached to them as soon as they are removed from the vehicle. In all cases, they must be stored in a secured, marked area. 1.11 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 18: Electricalprecautions

    Never force connectors apart either by using tools or by pulling on the wiring itself. Always ensure locking mechanisms are disengaged before removal and note the orientation to enable correct reconnection. Ensure that 1.12 Service Manual - Daytona 675, Street Triple and Street Triple R ILiMP...
  • Page 19: Electrical Wires

    By transposing either of these formulae, the value of any unit can be calculated if the other two values are known. For example, if a battery of 12V is connected to a bulb of 60W: Service Manual - Daytona 675, Street Triple and Street Triple R 1.13 I UMP...
  • Page 20: Circuitdiagrams

    On ECMs with two connectors, the connector pins. An additional number outside the box will number would be prefixed with the letters 'A' or 'B to identify the component. 1.14 Service Manual - Daytona 675, Street Triple and Street Triple R L UMP...
  • Page 21: Tracingcircuits

    These are often caused by chafing of the harness to the short circuits. frame or wires trapped between a bolted component, and will often blow the fuse on that circuit. Service Manual - Daytona 675, Street Triple and Street Triple R 1.15 t UMP...
  • Page 22: Tocheck Continuity

    (Q). • Probe each end of the wire. • If there is continuity, the meter will usually bleep or register the resistance of the cable. 1.16 Service Manual - Daytona 675, Street Triple and Street Triple R IllMP...
  • Page 23: Splices

    (or bus) which are used for the transmission of vehicle sensor data. By using CAN, the overall number of system sensors, and the amount of 1.17 Service Manual - Daytona 675, Street Triple and Street Triple R Il1MP...
  • Page 24: Alternator/charging System

    VOLTAGE FROM THE 3 ALTERNATOR FAULTY ALTERNATOR OUTPUT WIRES IN TURN. THE OUTPUT VOLTAGE MUST NOW EXCEED 30 VOLTS AC FROM EACH WIRE Above 30 Volts AC FAULTY RECTIFIER/ REGULATOR 1.18 Service Manual - Daytona 675, Street Triple and Street Triple R L UMP...
  • Page 25: Startingcircuit

    Starter cable open circuit Defective starter relay Starter motor turns but engine does not turn over Defective sprag clutch Defective idler gear, reduction gear or starter motor 1.19 Service Manual - Daytona 675, Street Triple and Street Triple R 1l.I MP...
  • Page 26: Diagnosis- Starter Circuit

    OPEN CIRCUIT IN WIRING LOOM CONNECTOR FAULTY ALARM Voltage Measured Normal CHECK THE STARTER RELAY LOOSE OR POOR CONTACT AT STARTER RELAY OPERATION Abnormal FAULTY STARTER RELAY 1.20 Service Manual - Daytona 675, Street Triple and Street Triple R Il]MP...
  • Page 27: Inspection

    Triumph dealer may affect the handling, stability or other aspects of the motorcycle operation which may result in an accident causing serious injury or death. Service Manual - Daytona 675, Street Triple and Street Triple R 1.21 Il,l MP...
  • Page 28: Servicetools And Garage Equipment

    T3880105 — Angular Torque Gauge 13880315 — Extractor, Cylinder Liner (use with adaptor T3880101) Increment markings gakh T3880057 — Engine Management Diagnostics 13880027 — Chain Link Took Kit 1.22 Service Manual - Daytona 675, Street Triple and Street Triple R Il1MP...
  • Page 29 T3880102 — Wrench, CamTurning cdpr 3880160-TO301 — Fork Filler / Evacuator T3880026 — Clutch Holding Tool, Universal ccna T3880375 — Alternator Rotor Holder T3880313 — Oil Filter Wrench 1.23 Service Manual - Daytona 675, Street Triple and Street Triple R 111MP...
  • Page 30 T3880365 — Puller, Alternator Rotor gakh T3880106 — Holder, Balancer Gear T3880028 — Holder, Damping Cylinder T3880103 — Wrench, Engine Mounting Adjuster T3880104 — Wrench, Swinging Arm Adjuster 1.24 Service Manual - Daytona 675, Street Triple and Street Triple R ll.l MP...
  • Page 31 T3880003 — Fork Seal and Bush Fitment ccxb T3880002 — Support Plate T3880067 — Fork Spring Compressor L ti T3880001 — Fuel Pressure Gauge 3880065 — T0301 — Bearing Installer _ _ 9 1.25 Service Manual - Daytona 675, Street Triple and Street Triple R I!lM...
  • Page 32 T3880123 — Extension Cable 3880070 — 10301 — Bearing Installer T3880053 - Extraction Kit, Wheel Bearing BatteryMate Battery Charger - See Latest Parts Catalogue for Part Number Information 1.26 Service Manual - Daytona 675, Street Triple and Street Triple R !l.l MP...
  • Page 33: Engine

    ..68 Nm (50.1 ft.lbf) at 9,200 rpm) 73 Nm (53.3 ft.lbf) at 11,900 rpm Note: For Daytona 675 up to VIN 381274. • For Daytona 675 from VIN 381275. • 1.27 Service Manual - Daytona 675, Street Triple and Street Triple R Il1Mp...
  • Page 34: Cylinderhead & Valves

    ....0.275-0.325 mm Ex..0.275-0.325 mm Ex ..0.325-0.375 mm Note: For Daytona 675 up to VIN 381274. • For Daytona 675 from VIN 381275. • Service Manual - Daytona 675, Street Triple and Street Triple R 1.28 II,I MP...
  • Page 35: Camshafts

    ServiceLimit ......0.40 mm ......0.40 mm CamshaftRun-out ..... 0.15 mm max.......0.15 mm max Note: For Daytona 675 up to VIN 381274. • For Daytona 675 from VIN 381275. • 1.29 Service Manual - Daytona 675, Street Triple and Street Triple R Il1MP...
  • Page 36: Clutch/primary Drive

    Connecting Rod Small End Diameter..16.016-16.029 mm ....16.016-16.029 mm ServiceLimit ....... 16.039 mm......16.039 mm Connecting Rod Big End Side Clearance... 0.15-0.30 mm ...... 0.15-0.30 mm ServiceLimit ....... 0.50 mm......0.50 mm 1.30 Service Manual - Daytona 675, Street Triple and Street Triple R Il1MP...
  • Page 37: Crankshaft

    DriveChain Play ......35-40 mm......20-25 mm ChainLubrication ...... Mobil chain spray ....Mobil chain spray Note: For Daytona 675 up to VIN 381274. • For Daytona 675 from VIN 381275. • Service Manual - Daytona 675, Street Triple and Street Triple R 1.31 I UMP...
  • Page 38: Lubrication

    FuelPump Type .... FuelPressure (nominal) ....3.0 bar ......3.0 bar Purge Control System ....Electronic, via fuel system ECU ..Electronic, via fuel system ECU 1.32 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 39: Coolantsystem

    Up to VIN 331531 use Triumph HD4X Hybrid OAT coolant when replacing the coolant. • From VIN 331532 use Triumph HD4X Hybrid OAT coolant when topping up or replacing the coolant. Coolant Mixture up to VIN 331531 ..50/50 Distilled .....5 /50 Distilled...
  • Page 40: Fuelinjection System

    Note: • For Daytona 675 up to VIN 381274. • For Daytona 675 from VIN 381275. • * For Street Triple. • # For Street Triple R 1.34 Service Manual - Daytona 675, Street Triple and Street Triple R Il1MP...
  • Page 41: Brakes(continued)

    Note: • For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275. • • For Street Triple. • # For Street Triple R. 1.35 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 42: Frame

    *The starter solenoid has an additional 30 Amp fuse, attached directly to the solenoid, beneath the rider's seat. Note: For Daytona 675 up to VIN 381274. • For Daytona 675 from VIN 381275. • 1.36 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 43: Torquewrench Settings

    Secondary air injection valve covers to cam cover Use new fixings Cam chain tensioner to cylinder head - All models except Daytona 675 from VIN 381275 Cam chain tensioner to cylinder head - Daytona 675 from VIN 381275...
  • Page 44: Engine Covers

    Oil pump drive sprocket to pump shaft Apply ThreeBond 1374 to the threads Oil pump rotor cover to pump body bolts Transmission oil feed pipes to crankcase Use new fixings 1.38 Service Manual - Daytona 675, Street Triple and Street Triple R 1lIMP...
  • Page 45: Final Drive

    Silencer mounting bracket to subframe (Daytona 675) Silencer mounting bracket to subframe (Street Triple) Exhaust clamp - header to intermediate pipe Exhaust clamp - silencer to intermediate pipe (Daytona 675) 1.39 Service Manual - Daytona 675, Street Triple and Street Triple R ILiMP...
  • Page 46: Rearsuspension

    Rear suspension unit upper clevis to frame Rear suspension unit lower mounting bolt Drag link pivot at frame Drop links to swinging arm Swinging arm end-float adjuster sleeve 1.40 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 47: Frontsuspension

    Torque (Nm) Notes Front brake caliper to fork (Daytona 675 and Street Triple R) Front brake caliper half to caliper half (Daytona 675 and Street Triple R) Use new fixings Front brake caliper to fork (Street Triple) Front brake pad retaining pin...
  • Page 48: Rear Brakes

    Street Triple and Street Triple R only Side stand mounting bracket Side stand pivot Apply ThreeBond 1360 to threads Bank angle indicator Apply ThreeBond 1360 to threads 1.42 Service Manual - Daytona 675, Street Triple and Street Triple R Il]MP...
  • Page 49: Electrical

    Number plate bracket to subframe (Street Triple) Heat shield to silencer (Daytona 675) Lower fairing fixings (Daytona 675) See section 16 Cockpit fixings (Daytona 675) See section 16 Windshield fixings (Daytona 675) 1.43 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 50: Clutch Cable Routing - Daytona 675

    General Information Clutch Cable Routing - Daytona 675 1.44 Service Manual - Daytona 675, Street Triple and Street Triple R IL1MP...
  • Page 51: Clutch Cable Routing - Street Triple And Street Triple R

    General Information Clutch Cable Routing - Street Triple and Street Triple R 1.45 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 52: Throttle Cable Routing - Daytona 675

    General Information Throttle Cable Routing - Daytona 675 1.46 Service Manual - Daytona 675, Street Triple and Street Triple R IIIMP...
  • Page 53: Throttle Cable Routing - Street Triple

    General Information Throttle Cable Routing - Street Triple 1.47 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 54: Throttlecable Routing - Street Triple R

    General Information Throttle Cable Routing - Street Triple R 1.48 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP...
  • Page 55: Main Wiring Harness Routing - Daytona 675 Up To Vin 381274

    General Information Main Wiring Harness Routing - Daytona 675 up to VIN 381274 1.49 Service Manual - Daytona 675, Street Triple and Street Triple R ILIMP...
  • Page 56: Main Wiring Harness Routing - Daytona 675 From Vin 381275

    General Information Main Wiring Harness Routing - Daytona 675 from VIN 381275 1.50 Service Manual - Daytona 675, Street Triple and Street Triple R S UMP...
  • Page 57: Main Wiring Harness Routing - Street Triple And Street Triple R

    General Information Main Wiring Harness Routing - Street Triple and Street Triple R 1.51 Service Manual - Daytona 675, Street Triple and Street Triple R ILIMP...
  • Page 58: Rear Light Harness Routing - Daytona 675

    General Information Rear Light Harness Routing - Daytona 675 1.52 Service Manual - Daytona 675, Street Triple and Street Triple R II.I MP...