Triumph 350 c.c. Manuals

Manuals and User Guides for Triumph 350 c.c.. We have 1 Triumph 350 c.c. manual available for free PDF download: Workshop Manual

Triumph 350 c.c. Workshop Manual (267 pages)

Brand: Triumph | Category: Motorcycle | Size: 10 MB

Introduction
7
Engine and Frame Numbers
7
General Data
7
Contents
9
Correspondence
11
Technical Advice
11
Replacement Parts
11
Repairs
11
Lubrication System
45
Guide to Lubrication Points
47
Recommended Lubricants
48
Engine Lubrication System
50
Changing the Engine Oil and Cleaning the Oil Filters
50
Oil Pressure
52
Stripping and Reassembling the Oil Pressure Release Valve
53
Stripping and Reassembling the Oil Pump
53
Removing and Replacing the Oil Pipe Junction Block
54
Oil Pump
54
Contact Breaker Lubrication
55
Gearbox Lubrication
56
Gearbox Drain and Level Plugs
56
Primary Chaincase Lubrication
57
Oil Filler Plug
57
Section through the Primary Chaincase
57
Rear Chain Lubrication and Maintenance
58
Greasing the Steering Head Ball Races
58
Wheel Bearing Lubrication
59
Telescopic Fork Lubrication
59
Lubrication Nipples
60
Lubricating the Control Cables
60
Swinging Fork Pivot
60
Speedometer Cable Lubrication
61
Brake Pedal Spindle Lubrication
61
Changing the Oil and Cleaning the Filters
66
Engine
69
Exploded View of the Engine/Gearbox Unit
70
Removing and Replacing the Engine Unit
72
Tachometer Drive Cable and Adaptor
72
Removing and Replacing the Rocker Boxes
74
Rocker Box Securing Nuts
74
Inspecting the Push Rods
75
Stripping and Reassembling the Rocker Boxes
75
Adjusting the Valve Rocker Clearances
76
Refitting the Rocker Spindle
76
Removing and Replacing the Air Cleaner
77
Inlet Valves
77
Exhaust Valves
77
Carburetor - Description
78
Exploded View of Carburetor
78
Twin Carburetor Arrangement
79
Throttle Cable
79
Setting Twin Carburettors
79
Removing and Replacing the Carburetor
80
Section Single Carburetor Models
80
Stripping and Reassembling the Concentric Carburetor
82
Inspecting the Carburetor Components
82
Stripping and Reassembling the Carburetor
83
Carburettor Adjustments
84
Removing and Refitting the Cylinder Head Assembly
85
Refitting the Cylinder Head
85
Removing and Refitting the Valves
86
Cylinder Head Bolt Tightening Sequence
86
Valve Components
86
Renewing the Valve Guides
87
Decarbonising
87
Reseating the Valves
88
Cutting the Valve Seats
88
Valve Seating Tools
88
Removing and Replacing the Cylinder Block and Tappets
89
Inspecting the Tappets and Guide Blocks
90
Renewing the Tappet Guide Blocks
90
Removing and Refitting the Pistons
91
Removing and Replacing the Piston Rings
92
Inspecting the Pistons and Cylinder Blocks
93
Table of Suitable Rebore Sizes
93
Pistons
93
Cylinder Bores
93
Renewing the Small End Bushes
94
Removing and Replacing the Contact Breaker
94
Removing and Replacing the Timing Cover
95
Ignition Contact Breaker
95
Timing Cover Oil Seal Location
95
Removing and Replacing the Oil Pump
96
Extracting and Refitting the Valve Timing Pinions
97
Extracting the Crankshaft Pinion
97
Crankshaft Pinion
98
Camshaft Pinions
98
Valve Timing
99
Ignition Timing - Initial Procedure
101
Ignition Timing Using a Stroboscopic Light
101
Static Ignition Timing
102
To Establish the Accurate Static Ignition Setting
102
Conversion Chart
102
Example of Static Setting Calculation
102
Removing and Replacing the Camshafts Only
105
Dismantling and Reassembling the Crankcase Assembly
106
Removing the Crankcase Junction Screws
106
Parting the Crankcase Halves
107
Stripping and Reassembling the Crankshaft Assembly
108
Sectional View of Crankshaft
108
Refitting the Connecting Rods
110
Inspecting the Crankcase Components
111
Big End Bearings
111
Main Ball Bearing
111
Main Journal Bearing
111
Renewing the Main Bearings
112
Renewing Camshaft Bushes
112
Oil Seal
112
Oil Feed through Rocker Gear
114
Connecting Rod Small End
116
Extracting and Refitting the Valve Timing Pinions
117
Crankshaft Oilways
118
Renewing the Camshaft Bushes
121
Removing and Replacing the Tachometer Drive Box
121
Removing and Replacing the Exhaust System
122
Transmission
125
Adjusting the Clutch Operating Mechanism
126
General Arrangement of Clutch and Shock Absorber Unit
126
Adjusting the Primary Chain Tension
127
Exploded View of Clutch Operating Mechanism
127
Adjusting the Chain Tensioner
127
Removing and Replacing the Primary Cover
128
Section through Primary Chaincase
128
Removing and Refitting the Clutch Plates
129
Inspecting the Clutch Plates and Springs
129
Unscrewing the Clutch Spring Nuts
129
Adjusting the Clutch Pressure Plate
130
Renewing Shock Absorber Rubbers
130
Replacing the Shock Absorber Rubbers
130
Removing and Replacing the Stator and Rotor
131
Showing Stator Location on Crankcase
131
Removing and Replacing the Clutch and Engine Sprockets
132
Inspection of the Transmission Components
134
Rear Chain Alterations and Repairs
135
Gearbox
139
Removing and Replacing the Gearbox Outer Cover Assembly
141
Showing Gearbox Oil Level and Oil Drain Plugs
141
Dismantling and Reassembling the Clutch and Gearchange
142
Renewing the Gearchange Spindle Bush
143
Removal and Replacement of the Gearbox Inner Cover Assembly
143
Kickstarter Operating Mechanism
145
Dismantling and Rebuilding the Gearbox Inner Cover Assembly
145
Inspection of the Gearbox Components
146
Removing and Replacing the Gearbox High Gear
147
Renewing the Mainshaft and Layshaft Bearings
147
Renewing Gearbox Sprocket Without Dismantling the Gearbox
148
Mainshaft High Gear Bush
148
Layshaft
148
Sequence of Gearchanging
150
First Gear
151
Second Gear
151
Third Gear
152
Fourth Gear
152
Frame and Attachment Details
153
General Arrangement of Front and Rear Frame Assembly
154
Removing and Replacing the Fuel Tank
155
Removing and Replacing the Switch Panel
155
Prior to Engine Number
155
Removing and Replacing the Tool Tray
155
Removing and Replacing the Battery Carrier Assembly
156
Removing and Replacing the Oil Tank
156
Removal and Replacement of the Zener Diode and Heat Sink
157
Removal and Replacement of the Rectifier
157
Removing and Replacing the Rear Mudguard
158
Adjusting the Rear Suspension
158
Adjusting the Rear Suspension Unit
158
Exploded View of the Rear Suspension Unit
159
Removing and Refitting the Rear Suspension Units
160
Stripping and Reassembling the Suspension Unit
160
Removing and Refitting the Swinging Fork from Engine Number
161
Removing and Refitting the Swinging Fork up to Engine Number
162
Renewing the Swinging Fork Bushes
163
Removing and Replacing the Rear Frame
164
Frame Alignment
164
Front Frame
164
Rear Frame
165
Frame Assembly
165
Sketch of Frame Checking Test Bar
165
Checking the Front Frame Alignment
166
Basic Dimensions of the Frame Assembly
167
Swinging Form
169
Checking the Swinging Fork
169
Removal of Dents
170
Tools Used for Panel Repairs
170
Removing a Dent with Dolly Block and Spoon
170
Paint Work Refinishing
171
Paint Stripping
171
Undercoat
171
Wet and Dry Sanding
171
Polishing
172
Flamboyant Finishes
172
Metallic Finishes
172
Frame
173
Removing and Replacing the Tool Carrier
174
Stripping and Reassembling the Rear Suspension Unit
174
Exploded Rear Suspension Unit
175
Removing and Refitting the Swinging Fork
176
Fairing Attachment Lugs and Steering Lock
176
Fitting Replacement Seat Covers
177
Wheels, Brakes and Tyres
179
Removing and Refitting the Front Wheel
180
Removing and Refitting the Standard Rear Wheel
180
Removing and Refitting the Quickly Detachable Wheel
180
Front and Rear Wheel Alignment
181
Aligning the Front and Rear Wheels
181
Brake Adjustment
182
Stripping and Re-Assembling the Brake
182
Inspection Procedure
183
Refitting Brake Shoes
183
Renewing the Brake Linings
184
Removing and Refitting the Wheel Bearings
184
Front Wheel
184
Rear Wheel
185
Quickly Detachable
186
Exploded View of Q.D. Rear Wheel
186
Wheel Building
187
Wheel Balancing
187
Removing and Repairing the Tyres
188
Refitting the Tyre
188
Security Bolts
189
Tyre Maintenance
190
Stripping and Reassembling the Brakes
192
Front Brake
192
Telescopic Forks
195
Removing and Refitting the Headlamp
196
Removing and Refitting the Nacelle Top Cover
197
Removing the Telescopic Fork Uit
197
Dismantling the Telescopic Fork
198
Inspection and Repair of Fork Components
199
Checking the Top Lug for Alignment
199
Renewing the Steering Head Races
202
Renewing the Front Fork Oil Seals
202
Reassembling and Refitting the Telescopic Fork Unit
203
Telescopic Fork Alignment
205
Adjusting the Steering Head Race
207
Changing the Front Fork Main Springs
207
Handlebar Mountings
207
After Engine Number
207
The Hydraulic Damping Unit
208
Fork Stanchion Modification
214
Electrical System
215
Battery Inspection and Maintenance
216
Dry Charged Batteries
216
Exploded View of Battery
216
Routine Maintenance
217
Coil Ignition System
217
Checking the Low Tension Circuit for Continuity
218
Fault Finding in the Low Tension Circuit
218
Ignition Coils
219
Bench Testing an Ignition Coil
219
Contact Breaker
219
Checking the High Tension Circuit
220
Checking the Emergency Start Circuit
220
Sparking Plugs
221
Sparking Plug Diagnosis
221
Charging System
222
Schematic Illustration of 6 Volt Charging Circuit
222
6 Volt and 12 Volt Circuits
223
Schematic Illustration of 12 Volt Charging Circuit
223
Checking the D.C. Input to Battery
224
Checking the Alternator Output
224
Rectifier Maintenance and Testing
224
Testing the Rectifier
225
Bench Testing the Rectifier
225
Checking the Charging Circuit for Continuity
226
6 Volt Machines
226
12 Volt Machines
227
Constructing a One-Ohm Load Resistor
227
Zener Diode Charge Control
228
Testing the Zener Diode
228
Procedure for Testing on the Machine
228
Location and Maintenance
229
A.C. Ignition and A.C. Lighting Systems
229
A.C. Ignition
230
Testing the A.C. Ignition System
230
Direct Lighting System
231
Electric Horn
232
Horn Adjustment
232
Headlamp
232
Beam Adjustments
232
Tail and Stop Lamp Unit
233
Fuses
233
Ignition Cut-Out Button
234
Ignition Warning Lamp
234
Main Beam Warning Lamp
234
Wiring Diagram
235
Warning Lamps
244
Ignition Switch
244
Stop Lamp Switches
245
Oil Pressure Switch
245
Location of Oil Pressure Switch
245
Wiring Diagrams
246
Workshop Service Tools
253
Motorcycle Toolkit Complete
260

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Triumph 350 c.c. Workshop Manual (267 pages)

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