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2003 Daytona 600
User Manuals: Triumph 2003 Daytona 600 Motorcycle
Manuals and User Guides for Triumph 2003 Daytona 600 Motorcycle. We have
1
Triumph 2003 Daytona 600 Motorcycle manual available for free PDF download: Service Manual
Triumph 2003 Daytona 600 Service Manual (372 pages)
Brand:
Triumph
| Category:
Motorcycle
| Size: 12 MB
Table of Contents
Contents
3
How to Use this Manual
4
General Information
6
Ignition System Safety Precautios
8
Engine Oils
8
Health Protection Precautions
8
Environmental Protection Precautions
9
Safety Instructions
10
Jacking and Lifting
10
Precautions against Damage
10
Cleaning Components
10
Lubrication
11
Joints and Joint Faces
11
Screw Heads
11
Gaskets, O-Rings
11
Fitting a Split Pin
12
Encapsulated Bolt
12
Oil and Grease Seals
12
Ball Bearing
12
Fuel Handling Precautions
13
Fuel Tank Removal
13
Chassis Repairs
13
Electrical Precautions
14
Battery Disconnecting
14
Disciplines
15
Electrical Wires
15
Special Service Tools
16
Full Specification
19
Torque Wrench Settings
23
Maintenance
28
Scheduled Maintenance Chart
30
Cylinder Head
32
Cylinder Head and Valves Exploded View
33
Cam Cover Exploded View
34
Camshaft and Camshaft Drive Exploded View
35
Cylinder Head Description
36
Cam Cover Removal
36
Cam Cover Bolts
37
Cam Cover Installation
37
Cam Chain Tensioner Removal
38
Cam Chain Tensioner Installation
39
Camshafts Removal
40
Camshaft Cap Numbering
40
Cap Bolt Release Sequence
40
Camshaft Inspection
41
Journal Diameter
41
Plastigage Check
42
Camshaft Installation
42
Cap Tightening Sequence
43
Valve Clearance Measurement
44
Valve Clearance Adjustment
45
Valve Clearance too Small
45
Valve Clearance too Large
45
Cylinder Head Removal
46
Coolant Temperature Sensor View
46
Bypass Hose
47
Camshaft Cover Bolts
47
Camshaft Timing Marks View
48
Camshaft Cap Numbering Diagram
48
Cap Release Sequence
49
Removing a Camshaft
49
Left Hand Mounting Bolt View
50
Right Hand Mounting Bolt View
50
Cylinder Head to Crankcase Bolts View
50
Bolt Release Sequence
50
Cylinder Head Inspection
51
Cylinder Head Level Check
51
Cylinder Head Installation
51
Cam Chain Rubbing Blade View
51
Bolt Tightening Sequence
52
Clip Screw-Heads View
53
Camshaft Replacement
54
Top Pad View
55
Cam Chain Tensioner Ratchet View
55
Pawl View
55
Silcone Sealatn Areas View
56
Cam Cover Bolts View
56
Air Deflector View
57
Left Switch Cube Connection View
57
Right Switch Cube Connection View
57
Fan Connection View
57
Valves and Valve Stem Seals - Removal from the Cylinder Head
58
Valves and Valve Stem Seals Installation
58
Clutch
59
Clutch Cover Exploded View
60
Clutch Assembly Exploded View
61
Clutch Controls Exploded View
62
Clutch Cable Removal
63
Clutch Cable Examination
64
Clutch Cable Assembly
64
Clutch Disassembly
65
Clutch Inspection
66
Clutch Assembly
67
Clutch Bush Grooves View
67
Inner Drum Alignment Marking View
68
Inner Plate Alignment Marking View
68
Outermost Friction Disc Location Teeth View
69
Belleville Washer View
69
Inner Plate View
69
Push Plate View
69
Clutch Lever View
70
Crankshaft, Rods and Pistons
71
Crankshaft, Connecting Rod, Piston and Liner Exploded View
72
Crankcase Exploded View
73
Engine Removal
74
Clutch Inner Cable View
76
Lock Nut View
76
Adjusting Nut View
76
Engine Installation
77
Outer Cables View
78
Throttle Twist Grip View
78
Opening Cable View
78
Locknut View
78
Closing Cable View
79
Side Stand Switch View
79
Top Hose View
80
Bottom Hose View
80
Radiator to Heat Exchanger Hose View
80
Air Deflector Shield View
80
Crankcases Disassembly
81
Upper Crankcase Bolt Release Sequence
81
Lower Crankcase Bolt Release Sequence
81
Crankcases Assembly
82
Locating Ring and Groove
82
Locating Dowel and Recess
82
Locating Dowel Positions
82
Bolt Tightening Sequence - Lower Crankcase
83
Bolt Tightening Sequence - Upper Crankcase
83
Crankshaft Removal
85
Crankshaft Inspection
85
Crankshaft Installation
86
Big End Cap View
86
Crankpin View
86
Connecting Rods
87
Connecting Rods Inspection
88
Connecting Rods Installation
88
Sealant Area View
89
Dimple (Faces Forward) View
89
Big End View
89
Connecting Rod Big End Bearing Selection/Crankshaft Journal Wear Check
90
Checking the Measured Plastigage
90
Connecting Rod Big End Bearing to Crankshaft Journal Clearance
91
Connecting Rod Big End Bearing Selection Chart (MM's)
91
Connecting Rod Bearing Selection
91
Crankshaft Main Bearing/Journal Wear Check
92
Bearing Clearance
92
Crankshaft Main Journal Diameter
92
Main Bearing Selection Chart (All Dimensions in MM's)
93
Chankshaft End Float
93
Pistons Disassembly
94
Pistons Inspection
94
Piston Wear Check
94
Piston Ring Gap
95
Piston Ring Gap Tolerances
95
Piston Rings/Ring Grooves
95
Checking Ring-Groove Clearance
95
Pistons Assembly
96
Circlip Fitment
96
Gudgeon Pin Alignment
97
Cylinder Liners Removal
98
Cylinder Liners Inspection
99
Cylinder Liners Installation
100
Refitting a Cylinder Liner
100
Transmission
101
Transmission Exploded View - Input and Output Shafts
102
Transmission Exploded View - Sprag
103
Transmission Exploded View - Gear Change Mechanism
104
Transmission Exploded View - Gear Selector Mechanism
105
Selector Shaft, Selector Forks & Drum Removal
106
Selector Shaft, Selector Forks & Drum Inspection
108
Selector Shaft, Selector Forks & Drum Installation
108
Locating the Detent Arm
109
Inserting the Gear Change Shaft
109
Input and Output Shafts Assemblies Removal
111
Input and Output Shafts Assemblies Installation
111
Input Shaft Disassembly
112
Input Shaft Assembly
112
Pressing off the Input Shaft Bearing
112
Pressing on the Bearing
113
Output Shaft Disassembly
114
Output Shaft Assembly
116
Sprag Clutch Removal
118
Sprag Clutch Inspection
118
Sprag Clutch Installation
119
Lubrication System
120
Lubrication System Exploded View - Sump
121
Lubrication System Exploded View - Oil Pump and Gears
122
Oil Circuit Diagram
123
Oil Circuit Description
124
Engine Oil Specification
125
Oil Level Inspection
126
Engine Oil and Filter Change
126
Low Oil Pressure Warning Light Switch Removal
127
Low Oil Pressure Warning Light Switch Installation
128
Heat Exchanger
129
Heat Exchanger Inspection
130
Heat Exchanger Installation
130
Sump Removal
131
Sump Installation
132
Sump Bolt Tightening Sequence
132
Oil Pump Removal
133
Oil Pump Inspection
134
Oil Pump Installation
135
Pump Insertion Illustration
135
Fuel System/Engine Management
136
Fuel Tank and Pump Exploded View
138
Fuel Rail, Throttles and Injectors Exploded View
139
Airbox Exploded View
140
Exhaust System Exploded View
141
Secondary Air Injection System Exploded View
142
Evaporative System Exploded View
143
Fuel Requirements
144
Oxygenated Gasoline
144
Ethanol, Methanol
144
MTBE (Methyl Tertiary Butyl Ether)
144
Fuel System/Engine Management: Glossary of Terms
145
Engine Management System Description
147
Engine Management System Sensors
147
Engine Management System Sensors Locations
148
Engine Management System Sensors Actuators
149
Engine Management System Sensors Actuator Locations
150
Engine Management Circuit Diagram - Daytona 600
151
ECM Connector Pin Numbering
151
Circuit Diagram - Engine Management System - Daytona 600
152
Engine Management System Diagnostics
153
On-Board Fault Detection System
153
Triumph Diagnostic Tool
153
Current Data
154
Freeze-Frame Data
154
Function Tests
155
Checks/Adjustments
155
Adaption Status
155
Build Data
155
Checks of the Status of Sensors and Actuators
156
Diagnostic Trouble Codes
157
Service Diagnostic Tool
159
Typical Screen Showing Symbols
159
Return Key
159
Validation Key
160
Help Key
160
Test Procedure
160
Connection and Power-Up
166
Select Language
166
Triumph Motorcycles
167
Switch on Bike Ignition
167
Data Link Fault Retry?
168
Service Data - Dealer
168
Service Data - Date
169
Main Menu
169
Diagnostics (if "Diagnostics" Is Selected)
170
Current Data Display
170
Stop Engine Display
171
To Select "Read Stories DTCS" (Diagnostic Trouble Codes) from the Main Menu
171
Stored DTCS
172
Three Options Are Now Available
172
Freeze Frame
173
Stored DTCS Display
173
Stored DTCS, Erase All DTC Data
174
To Select "Function Tests" from the Main Menu
174
Function Tests Display
175
Function Test Display
175
To Select "Checks/Adjustments" from the Main Menu (Operation 8)
179
Check/Adjust
179
Checks Display
180
Build Data Display
180
Sensor Data
181
Adaption Status Display
181
Adjust Display
183
Adjust Tune
183
Update Tune Displays
184
Update Tune (Confirm Selected)
187
Restarting Tune Download
187
Electrical Connector
188
When Disconnecting a Connector
188
When Inspecting a Connector
188
When Connecting a Connector
188
Disconnection of ECM Connectors
189
Reconnection of ECM Connectors
189
Further Diagnosis
189
Crankshaft Sensor
190
Pinpoint Tests
190
Idle Speed Control
191
Fuel Injectors
192
Throttle Position Sensor
193
Purge Valve
194
Ignition Coils
195
Coolant Temperature Sensor
196
Inlet Air Temperature Sensor
197
Fuel Pump Relay
198
System Voltage
199
Cooling Fan Relay
200
Tachometer
201
Coolant Temperature Gauge
202
Vehicle Speed Output
203
Lambda Sensor
204
Lambda Sensor Heater
205
EEPROM Error
206
Fall Detection Switch
207
2Nd Throttle Position Sensor
208
2Nd Throttle Actuator
209
Secondary Air Injection Valve
210
Vehicle Speed Sensor
211
Ambient Pressure Sensor
212
Manifold Absolute Pressure (MAP) Sensor
213
Fault Findings - Non Electrical
214
To Remove the Fuel Tank
215
Fuel Tank Installation
216
Fuel Pump Removal
217
Fuel Pump Assembly
218
Fuel Pressure Checking
219
Fuel Filter Removal
220
Fuel Filter Assembly
221
Low Fuel Filter Sender Removal
222
Low Fuel Filter Sender Assembly/Installation
223
Airbox Removal
223
Airbox Installation
224
Air Filter Removal
225
Air Filter Assembly
225
Raising the Filter Housing
225
Replacing the Air Filter Element
225
Intake Air Temperature Sensor Removal
226
Intake Air Temperatur Sensor Installation
226
Crankshaft Position Sensor Removal
227
Crankshaft Position Sensor Installation
227
Throttle Cables Removal
228
Throttle Cables Examination
229
Throttle Cables Installation
229
Throttle Cable Adjustment
229
Throttle Body Balancing
231
Typical Analyser Display View
231
Typical Display of Imbalanced Throttles
231
Throttle Body Removal
233
Throttle Body Installation
234
Circled-Clip Screw-Heads View
234
Injectors/Fuel Rail/Fuel Pressure Regulator Removal
235
Injectors and Connectors View
235
Injectors/Fuel Rail/Fuel Pressure Regulator Assembly/Installation
236
Correct Injector Position View
236
Primary Throttle Potentiometer Removal
237
Primary Throttle Potentiometer Installation
237
Primary Throttle Position Sensor View
237
Secondary Throttle Potentiometer Removal
239
Secondary Throttle Potentiometer Installation
239
Secondary Throttle Position Sensor View
239
Idle Speed Control Stepper Motor Removal
241
Idle Speed Control Stepper Motor Installation
242
Engine Management Adaption
245
Forcing Adaption to Take Place
245
Fault Indicators
245
Exhaust System Removal
246
Exhaust System Installation
247
Secondary Air Injection System Operation
248
Header Tightening Sequence
248
Reed Valve Assembly Removal
249
Reed Valve Assembly Disassembly
249
Reed Valve Assembly Inspection
250
Reed Valve Assembly Assembly
250
Reed Valve Assembly Installation
250
Evaporative Loss Control System - California Models Only
250
Evaporative Control System - Engine off
251
Evaporative Control System - Engine Running
252
Cooling System
253
Cooling System Exploded View
254
Coolant
255
Oil Cooler/Heat Exchanger
255
Coolant Level Inspection
255
Coolant Replacement
256
Coolant Drainage
256
Coolant Refill
257
Radiator Hoses Inspection
258
Radiator and Cooling Fan Inspection
258
Coolant Pressure Cap Inspection
258
Water Pump Removal
259
Water Pump Installation
260
Radiator Removal
261
Radiator Inspection
262
Radiator Installation
262
Thermostat Removal
263
Thermostat Inspection
263
Thermostat Installation
264
O-Ring/Groove View
264
Rear Suspension
265
Swinging Arm Exploded View
266
Rear Hub Exploded View
267
Rear Suspension Unit Exploded View
268
Drop/Drag Link Exploded View
269
Rear Suspension Unit Removal
270
Rear Suspension Unit Inspection
271
Rear Suspension Unit Installation
271
Drag Link Removal
272
Drag Link Inspection
273
Drag Link Installation
273
Drive Chain
274
Chain Slack Inspection
274
Drive Chain Adjustment
274
Chain Lubrication
275
Chain Wear Inspection
275
Swinging Arm/Drive Chain Renewal Removal
276
Swinging Arm/Drive Chain Renewal Inspection
278
Swinging Arm/Drive Chain Renewal Installation
279
Final Drive Removal
281
Final Drive Installation
281
Front Suspension
282
Front Fork Exploded View
283
Handlebards Exploded View
284
Fork Inspection
285
Front Fork Removal
285
Front Fork Installation
286
Fork Oil Change
287
Peload Adjuster Marks View
287
Fork Oil Level Chart
289
Front Fork Dismantling
290
Damper Assembly
291
Dust Seal
291
Circlip
291
Front Fork Inspection
292
Front Fork Assembly
292
Headstock Bearing Check
294
Checking Headstock Bearings
294
Headstock Bearing Adjustment
295
Braking System
296
Fronk Brake Master Cylinder Exploded View
297
Front Brake Caliper Exploded View
298
Rear Brake Master Cylinder Exploded View
299
Rear Brake Caliper Exploded View
300
Braking System Maintenance Safety Precautions
301
Fluid Level Inspection
302
Changing Brake Fluid
302
Brake Pads
302
Brake Wear Inspection
302
Bleeding the Front Brakes, Renewing Brake Fluid
303
Front Brake Pads Removal
304
Front Brake Pads Installation
305
Front Brake Caliper Removal
305
Front Brake Caliper Disassembly
306
Front Brake Caliper Inspection
306
Front Brake Caliper Assembly
306
Front Brake Caliper Installation
307
Front Discs Wear
307
Front Discs Removal
308
Front Discs Installation
308
Front Brake Master Cylinder Removal
308
Front Brake Master Cylinder Disassembly
309
Front Brake Master Cylinder Inspection
309
Front Brake Master Cylinder Assembly
309
Front Brake Master Cylinder Installation
309
Bleeding the Rear Brakes, Renewing Brake Fluid
311
Rear Brake Pads Removal
312
Anti-Rattle Spring Installation
313
Rear Brake Caliper Removal
315
Rear Brake Caliper Disassembly
315
Rear Brake Caliper Inspection
315
Rear Brake Caliper Assembly
315
Rear Brake Caliper Installation
316
Rear Brake Disc Wear
316
Rear Master Cylinder Removal
317
Rear Master Cylinder Disassembly
317
Rear Master Cylinder Inspection
317
Rear Master Cylinder Assembly
318
Rear Master Cylinder Installation
318
Wheels
319
Front Wheel Exploded View
320
Rear Wheel and Final Drive Exploded View
321
Tyres
322
Wheel Marking
322
Tyre Marking
322
Tyre Pressure
322
Tyre Wear/Wheel Inspection
323
Tread Wear Indicator
323
Minimum Recommended Tread Depth
323
Important Tyre Information
324
Front Wheel Removal
325
Fork Pinch Bolts View
325
Right Hand Spacer View
325
Left Hand Spacer View
325
Front Wheel Installation
326
Rear Wheel Removal
327
Rear Wheel Spindle Nut View
327
Rear Wheel Installation
327
Fitting the Chain Illustration
328
Carrier Locating Slot View
328
Flanged Spacer (Right Side) View
328
Bodywork & Frame
329
Frame Exploded View
330
Seat Rails Exploded View
331
Cockpit and Mountings Exploded View
332
Lower Fairings and Belly Panels Exploded View
333
Rear Bodywork Exploded View
334
Rear Mudguard Exploded View
335
Footrests and Mountings Exploded View
336
Frame, Footrests and Fairings Inspection
337
Bank Angle Peg View
337
Seats Removal
338
Seats Installation
338
Side Panels Removal
339
Side Panels Installation
339
Belly Panels Removal
340
Panel to Panel Fixings View
340
Hook and Eye Attachments View
340
Belly Panels Installation
341
Lower Fairing Removal
341
Lower Fairing Installation
342
Cockpit Removal
343
Air Intake Finisher View
343
Cockpit Subframe Fixings View
343
Cockpit Installation
344
Electrical System
345
Instruments Exploded View
346
Alternator Exploded View
347
Starter Motor Exploded View
348
Headlight Exploded View
349
Rear Light and Indicators Exploded View
350
Battery Removal
351
Battery Installation
352
New Battery Commissioning
352
Charging - Battery Already in Service
353
Battery Maintenance
353
Fuses
354
Front Fuse Box Access
354
Fuse Identification
354
Front Fuse Box and Rear Fuse Box
354
Headlight
355
Headlight Adjustment
355
Headlight Bulb Replacement
356
Headlight Bulb Installation
356
Front Position Lights
357
Bulb Replacement
357
Position Light Bulb Location
357
Front Position Lights Installation
357
Rear Light - Bulb Replacement
358
Indicator Lights - Bulb Replacement
359
Licence Plate Light - Bulb Replacement
359
Alternator Removal
360
Left Hand Cranskshaft Cover View
360
Alternator Assembly
361
Alternator Rectifier
361
Starter Motor Removal
362
Starter Motor Installation
362
Relays Identification and Location
363
Starting and Charging
364
Key to Circuit Diagram
364
Key to Wiring Colours
364
Circuit Diagram - Starting and Charging
365
Lighting - Key to Circuit Diagram and Wiring Colours
366
Circuit Diagram - Lighting
367
Auxiliary Circuits - Key to Circuit Diagram and Wiring Colours
368
Circuit Diagram - Auxiliary Circuits
369
Complete System - Key to Circuit Diagram and Wiring Colours
370
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