Table Of Contents - Triumph Trophy Trail TR5T 500 c.c. Workshop Manual

Table of Contents

Engine And Frame Numbers3
Correspondence4
Technical Advice4
Replacement Parts4
Repairs4
Contents5
General Data7
Lubrication System8
Frame And Fittings13
Gear Ratio Calculations16
Engine Timing Disc17
Routine Lubrication20
Recommended Lubricants21
Engine Lubrication System23
Changing The Engine Oil And Cleaning The Oil Filters23
Oil Pressure24
Stripping And Reassembling The Oil Pressure Release Valve25
Stripping And Reassembling The Oil Pump25
Removing And Replacing The Oil Pipe Junction Block26
Removing And Replacing The Rocker Oil Feed Pipe27
Contact Breaker Lubrication27
Gearbox Lubrication28
Primary Chaincase Lubrication29
Oil Filter Plug29
Rear Chain Lubrication And Maintenance30
Steering Head31
Telescopic Fork31
Wheel Bearings31
Lubricating The Control Cables32
Speedometer And Tachometer Cable32
Engine33
Exploded View Of The Engine/Gearbox Unit34
Engine Description35
Removing And Replacing The Engine Unit36
Removing And Replacing The Rocker Boxes38
Inspecting The Push Rods39
Stripping And Reassembling The Rocker Boxes39
Oil Feed Through Rocker Gear40
Refitting The Rocker Spindle40
Adjusting The Valve Rocker Clearances41
Inlet Valves41
Exhaust Valves41
Carburetor - Description42
Exploded View Of Carburettor42
Carburetor Description43
Stripping And Reassembling The Carburetor43
Inspecting Carburetor Components44
Hints And Tips45
Throttle Cable45
Petrol Feed45
Flooding45
Tracing Faults46
Carburetor Adjustments46
Indications Of Richness46
Indications Of Weakness46
Correcting Mixture47
Tuning The Carburetor47
To Cure Richness47
To Cure Weakness47
Removing And Refitting The Cylinder Head Assembly49
Removing And Refitting The Valves50
Cylinder Head Bolt Tightening Sequence50
Valve Components50
Renewing The Valve Guides51
Decarbonising51
Reseating The Valves52
Cutting The Valve Seats52
Removing And Replacing The Cylinder Block And Tappets53
Inspecting The Tappets And Guide Blocks54
Renewing The Tappet Guide Blocks54
Removing And Refitting The Pistons55
Removing And Replacing The Piston Rings55
Inspecting The Pistons And Cylinder Bores56
Table Of Suitable Rebore Sizes57
Small End57
Removing And Replacing The Contact Breaker57
Removing And Replacing The Timing Cover58
Ignition Contact Breaker58
Timing Cover Oil Seals58
Removing And Replacing The Oil Pump59
Oil Seal Protector In Position59
Extracting And Refitting The Valve Timing Pinions60
Procedure When Using D2213/D221760
Crankshaft Pinion60
Valve Timing61
Ignition Timing - Initial Procedure61
Ignition Timing Using A Stroboscopic Light62
Removing And Replacing The Camshafts Only63
Dismantling And Reassembling The Crankcase Assembly64
Parting The Crankcase Halves64
Stripping And Reassembling The Crankshaft Assembly65
Refitting The Connecting Rods67
Inspecting The Crankcase Components68
Big End Bearings68
Main Roller Bearing68
Main Ball Bearing68
Renewing The Main Bearings69
Renewing The Camshaft Bushes69
Removing And Replacing The Tachometer Drive Box70
Tachometer Drive Gearbox70
Tachometer Drive Gearbox Exploded70
Removing And Replacing The Exhaust System71
Transmission73
Adjusting The Clutch Operating Mechanism74
General Arrangement Of Clutch And Shock Absorber Unit74
Adjusting The Primary Chain Tension75
Exploded View Of Clutch Operating Mechanism75
Adjusting The Chain Tensioner75
Removing And Replacing The Primary Cover76
Section Through Primary Chaincase76
Removing And Refitting The Clutch Plates77
Inspecting The Clutch Plates And Springs77
Unscrewing The Clutch Spring Nuts77
Adjusting The Clutch Pressure Plate78
Renewing Shock Absorber Rubbers78
Replacing The Shock Absorber Rubbers78
Removing And Replacing The Stator And Rotor79
Showing Stator Location On Crankcase79
Removing And Replacing The Clutch And Engine Sprockets80
Inspection Of The Transmission Components82
Rear Chain Alterations And Repairs83
Gearbox85
Plan Of Gearbox Components86
Gearbox Description87
Removing And Replacing The Gearbox Outer Cover Assembly87
Dismantling/Reassembling The Clutch And Gearchange Operating Mechanism88
Renewing The Gearchange Spindle Bush89
Removal And Replacement Of The Gearbox Inner Cover Assembly89
Kickstarter Operating Mechanism91
Dismantling And Rebuilding The Gearbox Inner Cover Assembly91
Inspection Of The Gearbox Components92
Removing And Replacing The Gearbox High Gear93
Renewing The Mainshaft And Layshaft Bearings93
Renewing Gearbox Sprocket Without Dismantling The Gearbox94
Mainshaft High Gear Bush94
Layshaft94
Sequence Of Gearchanging95
Second Gear96
Third Gear97
Fourth Gear97
Frame99
Frame Alignment101
Showing Frame On Setting Table101
Chainguard Removal102
Rear Suspension Units102
Cam Ring Adjustment102
Exploded View Of Suspension Unit103
Swinging Arm Assembly Details103
Removing The Swinging Arm104
Swinging Arm Bearings104
Checking Swinging Arm Alignment104
Twin Seat106
Prop Stand106
Rear Brake Pedal106
Mudguards106
Air Cleaner107
Removing And Replacing The Electrics Platform107
Battery Carrier And Toolbox108
Removal Of Headlamp109
Removing And Replacing Rear Stop Switch109
Removing And Replacing The Horn109
Petrol Tank Removal110
Applying Transfers (Decals)110
Centre Stand111
Control Cable Replacement111
Clutch Cable111
Front Brake Cable111
Telescopic Forks113
Steering Head Adjustment114
Renewing Head Races115
Stripping And Reassembling The Fork Legs115
Assembly Of Bleed Valve116
Removing The Oil Seal From The Fork Leg117
Replacing The Oil Seal117
Fork Assembly Details118
Sectional View Of Assembled Fork Leg119
Fork Alignment120
Hydraulic Damping121
Wheels, Brakes And Tyres123
Removing And Refitting The Front Wheel124
Removing And Refitting The Front Wheel Bearings124
Stripping And Reassembling The Front Brake Single Leading Shoe Type125
Stripping And Reassembling Rear Brake126
Rear Wheel Removal And Replacement126
Removing And Replacing Rear Wheel Bearings127
Brake Adjustment128
Rear Chain Adjustment129
Renewing Brake Linings129
Wheel Building130
Wheel Balancing131
Wheel Alignment131
Braking Performance Data132
Removing And Refitting Tyres133
Refitting The Tyre133
Security Bolts134
Tyre Maintenance135
Tyre Pressures136
Electrical System137
Battery Inspection And Maintenance138
Routine Maintenance139
Specific Gravity Of Electrolyte For Filling The Battery139
Maximum Permissible Electrolyte Temperature During Charge139
Coil Ignition System140
Checking The Low Tension Circuit For Continuity140
Fault Finding In The Low Tension Circuit140
Ignition Coils141
Bench Testing An Ignition Coil141
Contact Breakers142
Checking The High Tension Circuit142
Sparking Plugs143
Charging System144
Checking The D.c. Output At The Rectifier145
Checking The Alternator Output145
Rectifier Maintenance And Testing145
Testing The Rectifier146
Bench Testing The Rectifier146
Checking The Charging Circuit For Continuity147
Constructing A One-Ohm Load Resistor147
Zener Diode Charge Control148
Zener Diode Charging Regulator149
Electric Horn150
Tail And Stop Lamp Unit150
Horn Adjustment150
Direction Indicator Lamps151
Ignition Switch151
Other Light Units151
Headlamp152
Beam Adjustment152
Capacitor Ignition153
Identification Of Capacitor Terminals153
Storage Life Of Model 2Mc Capacitor153
Fuses154
Wiring And Installation154
Exploded View Of Fuse Holder Assembly154
Wiring Diagram157
Workshop Service Tools159
Inches To Millimeters - Units166
Decimals To Millimeters - Fractions166
Fractions To Decimals And Millimeters167
Millimetres To Inches - Units168
Millimetres To Inches - Fractions168
Drill Sizes169
Wire Gauges169
B.s.w. Screw Threads170
B.s.f. Screw Threads170
B.s.c. Screw Threads171
B.a. Screw Threads172
Foot Pounds To Kilogrametres173
Miles To Kilometres173
Pounds To Kilograms173
Miles Per Gallon To Litres Per 100 Kilometres173
Pints To Litres174
Gallons To Litres174