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Manuals
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Triumph Manuals
Motorcycle
Trophy Trail TR5T 500 c.c.
Workshop manual
Triumph Trophy Trail TR5T 500 c.c. Workshop Manual
Twin cylinder
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Engine and Frame Numbers
Correspondence
Technical Advice
Replacement Parts
Repairs
Contents
General Data
Lubrication System
Frame and Fittings
Gear Ratio Calculations
Engine Timing Disc
Routine Lubrication
Recommended Lubricants
Engine Lubrication System
Changing the Engine Oil and Cleaning the Oil Filters
Oil Pressure
Stripping and Reassembling the Oil Pressure Release Valve
Stripping and Reassembling the Oil Pump
Removing and Replacing the Oil Pipe Junction Block
Removing and Replacing the Rocker Oil Feed Pipe
Contact Breaker Lubrication
Gearbox Lubrication
Primary Chaincase Lubrication
Oil Filter Plug
Rear Chain Lubrication and Maintenance
Steering Head
Telescopic Fork
Wheel Bearings
Lubricating the Control Cables
Speedometer and Tachometer Cable
Engine
Exploded View of the Engine/Gearbox Unit
Engine Description
Removing and Replacing the Engine Unit
Removing and Replacing the Rocker Boxes
Inspecting the Push Rods
Stripping and Reassembling the Rocker Boxes
Oil Feed through Rocker Gear
Refitting the Rocker Spindle
Adjusting the Valve Rocker Clearances
Inlet Valves
Exhaust Valves
Carburetor - Description
Exploded View of Carburettor
Carburetor Description
Stripping and Reassembling the Carburetor
Inspecting Carburetor Components
Hints and Tips
Throttle Cable
Petrol Feed
Flooding
Tracing Faults
Carburetor Adjustments
Indications of Richness
Indications of Weakness
Correcting Mixture
Tuning the Carburetor
To Cure Richness
To Cure Weakness
Removing and Refitting the Cylinder Head Assembly
Removing and Refitting the Valves
Cylinder Head Bolt Tightening Sequence
Valve Components
Renewing the Valve Guides
Decarbonising
Reseating the Valves
Cutting the Valve Seats
Removing and Replacing the Cylinder Block and Tappets
Inspecting the Tappets and Guide Blocks
Renewing the Tappet Guide Blocks
Removing and Refitting the Pistons
Removing and Replacing the Piston Rings
Inspecting the Pistons and Cylinder Bores
Table of Suitable Rebore Sizes
Small End
Removing and Replacing the Contact Breaker
Removing and Replacing the Timing Cover
Ignition Contact Breaker
Timing Cover Oil Seals
Removing and Replacing the Oil Pump
Oil Seal Protector in Position
Extracting and Refitting the Valve Timing Pinions
Procedure When Using D2213/D2217
Crankshaft Pinion
Valve Timing
Ignition Timing - Initial Procedure
Ignition Timing Using a Stroboscopic Light
Removing and Replacing the Camshafts Only
Dismantling and Reassembling the Crankcase Assembly
Parting the Crankcase Halves
Stripping and Reassembling the Crankshaft Assembly
Refitting the Connecting Rods
Inspecting the Crankcase Components
Big End Bearings
Main Roller Bearing
Main Ball Bearing
Renewing the Main Bearings
Renewing the Camshaft Bushes
Removing and Replacing the Tachometer Drive Box
Tachometer Drive Gearbox
Tachometer Drive Gearbox Exploded
Removing and Replacing the Exhaust System
Transmission
Adjusting the Clutch Operating Mechanism
General Arrangement of Clutch and Shock Absorber Unit
Adjusting the Primary Chain Tension
Exploded View of Clutch Operating Mechanism
Adjusting the Chain Tensioner
Removing and Replacing the Primary Cover
Section through Primary Chaincase
Removing and Refitting the Clutch Plates
Inspecting the Clutch Plates and Springs
Unscrewing the Clutch Spring Nuts
Adjusting the Clutch Pressure Plate
Renewing Shock Absorber Rubbers
Replacing the Shock Absorber Rubbers
Removing and Replacing the Stator and Rotor
Showing Stator Location on Crankcase
Removing and Replacing the Clutch and Engine Sprockets
Inspection of the Transmission Components
Rear Chain Alterations and Repairs
Gearbox
Plan of Gearbox Components
Gearbox Description
Removing and Replacing the Gearbox Outer Cover Assembly
Dismantling/Reassembling the Clutch and Gearchange Operating Mechanism
Renewing the Gearchange Spindle Bush
Removal and Replacement of the Gearbox Inner Cover Assembly
Kickstarter Operating Mechanism
Dismantling and Rebuilding the Gearbox Inner Cover Assembly
Inspection of the Gearbox Components
Removing and Replacing the Gearbox High Gear
Renewing the Mainshaft and Layshaft Bearings
Renewing Gearbox Sprocket Without Dismantling the Gearbox
Mainshaft High Gear Bush
Layshaft
Sequence of Gearchanging
Second Gear
Third Gear
Fourth Gear
Frame
Frame Alignment
Showing Frame on Setting Table
Chainguard Removal
Rear Suspension Units
Cam Ring Adjustment
Exploded View of Suspension Unit
Swinging Arm Assembly Details
Removing the Swinging Arm
Swinging Arm Bearings
Checking Swinging Arm Alignment
Twin Seat
Prop Stand
Rear Brake Pedal
Mudguards
Air Cleaner
Removing and Replacing the Electrics Platform
Battery Carrier and Toolbox
Removal of Headlamp
Removing and Replacing Rear Stop Switch
Removing and Replacing the Horn
Petrol Tank Removal
Applying Transfers (Decals)
Centre Stand
Control Cable Replacement
Clutch Cable
Front Brake Cable
Telescopic Forks
Steering Head Adjustment
Renewing Head Races
Stripping and Reassembling the Fork Legs
Assembly of Bleed Valve
Removing the Oil Seal from the Fork Leg
Replacing the Oil Seal
Fork Assembly Details
Sectional View of Assembled Fork Leg
Fork Alignment
Hydraulic Damping
Wheels, Brakes and Tyres
Removing and Refitting the Front Wheel
Removing and Refitting the Front Wheel Bearings
Stripping and Reassembling the Front Brake Single Leading Shoe Type
Stripping and Reassembling Rear Brake
Rear Wheel Removal and Replacement
Removing and Replacing Rear Wheel Bearings
Brake Adjustment
Rear Chain Adjustment
Renewing Brake Linings
Wheel Building
Wheel Balancing
Wheel Alignment
Braking Performance Data
Removing and Refitting Tyres
Refitting the Tyre
Security Bolts
Tyre Maintenance
Tyre Pressures
Electrical System
Battery Inspection and Maintenance
Routine Maintenance
Specific Gravity of Electrolyte for Filling the Battery
Maximum Permissible Electrolyte Temperature During Charge
Coil Ignition System
Checking the Low Tension Circuit for Continuity
Fault Finding in the Low Tension Circuit
Ignition Coils
Bench Testing an Ignition Coil
Contact Breakers
Checking the High Tension Circuit
Sparking Plugs
Charging System
Checking the D.C. Output at the Rectifier
Checking the Alternator Output
Rectifier Maintenance and Testing
Testing the Rectifier
Bench Testing the Rectifier
Checking the Charging Circuit for Continuity
Constructing a One-Ohm Load Resistor
Zener Diode Charge Control
Zener Diode Charging Regulator
Electric Horn
Tail and Stop Lamp Unit
Horn Adjustment
Direction Indicator Lamps
Ignition Switch
Other Light Units
Headlamp
Beam Adjustment
Capacitor Ignition
Identification of Capacitor Terminals
Storage Life of Model 2MC Capacitor
Fuses
Wiring and Installation
Exploded View of Fuse Holder Assembly
Wiring Diagram
Workshop Service Tools
Inches to Millimeters - Units
Decimals to Millimeters - Fractions
Fractions to Decimals and Millimeters
Millimetres to Inches - Units
Millimetres to Inches - Fractions
Drill Sizes
Wire Gauges
B.S.W. Screw Threads
B.S.F. Screw Threads
B.S.C. Screw Threads
B.A. Screw Threads
Foot Pounds to Kilogrametres
Miles to Kilometres
Pounds to Kilograms
Miles Per Gallon to Litres Per 100 Kilometres
Pints to Litres
Gallons to Litres
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