Triumph Bonneville 750 Motorcycle Engine Manuals

Manuals and User Guides for Triumph Bonneville 750 Motorcycle Engine. We have 1 Triumph Bonneville 750 Motorcycle Engine manual available for free PDF download: Workshop Manual

Triumph Bonneville 750 Workshop Manual (219 pages)

Brand: Triumph | Category: Motorcycle | Size: 6 MB

Engine and Frame Numbers
3
Guarantee
3
Factory Service Arrangements
4
Contents
5
T140E Bonneville 750 Side View
6
T140V Bonneville 750 Side View
7
TR7V Tiger 750 Side View
8
General Data
9
General Data: Lubrication System
10
General Data: Engine
10
General Data: Transmission
13
General Data: Gearbox (5 Speed)
14
General Data: Frame and Attachment Details
15
General Data: Wheels, Brakes and Tyres
15
General Data: Front Forks
16
General Data: Electrical System
16
Routine Maintenance
18
Recommended Lubricants
20
Engine Lubrication Diagram
21
Engine Lubrication System
22
Changing the Engine Oil and Cleaning the Oil Filters
22
Underside View of Engine/Gearbox Unit
23
Tappet Oil Feed Drillway
23
Tappet Oil Feed Arrangement
23
Oil Pressure
24
Stripping and Reassembling the Oil Pressure Release Valve
24
Stripping and Reassembling the Oil Pump
25
Removing and Replacing the Oil Pipe Junction Block
26
Oil Pipe Securing Clips
27
Removing and Replacing the Rocker Oil Feed Pipe
27
Contact Breaker Lubrication
27
Contact Breaker Mechanism Lubrication Points 10CA
28
Gearbox Lubrication
28
Gearbox Drain and Level Plugs
29
Primary Chaincase Lubrication
29
Section through the Primary Chaincase
29
Rear Chain Lubrication and Maintenance
30
Greasing the Steering Head Races
30
Wheel Bearing Lubrication
31
Telescopic Fork Lubrication
31
Lubrication Nipples
32
Swinging Fork Pivot
32
Lubricating the Control Cables
32
Speedometer and Tachometer Cable Lubrication
33
Brake Pedal Spindle Lubrication
33
Check Procedure for Wet Sumping
34
Engine
35
Exploded View of 750C.C. Engine Gearbox Unit
36
Engine: Description
37
Removing and Replacing the Engine Unit
38
Clutch Cable Adjustment and Gearbox Drain Plug
38
Removing and Replacing the Rocker Boxes
39
Rocker Box Securing Nuts
39
Inspecting the Pushrods
40
Stripping and Reassembling the Rocker Boxes
40
Rocker Box Assembly
40
Refitting the Rocker Spindle
41
Adjusting the Valve Rocker Clearances: Inlet Valves
41
Adjusting the Valve Rocker Clearances: Exhaust Valves
42
Removing and Replacing the Air Cleaner(S)
42
Air Cleaners (T140V Shown)
42
Exploded View of Amal MK1 Concentric Carburetor
43
Exploded View of Amal MKII Concentric Carburetor
44
Amal Concentric Carburetor: Description
45
T140V and TR7V Models: Removing and Replacing the Carburetor
45
T140E Models: Removing and Replacing the Carburetor
46
Stripping and Reassembling the Carburetor
47
Inspecting the Carburetor Components
47
T140E Needle Retaining Disc Location
47
Carburetor Adjustments
48
Twin Carburetter Arrangement: Throttle Cable
49
Twin Carburetter Arrangement: Setting Twin Carburetors
49
Removing and Replacing the Exhaust System
49
Removing the Cylinder Head Assembly
50
Cylinder Head Bolt Tightening Sequence
50
Refitting the Cylinder Head
50
Showing Assembly of Cylinder Head Studs and Nuts
51
Removing and Refitting the Valves
52
Valve Components
52
Renewing the Valve Guides
52
Decarbonising
53
Re-Seating the Valves
53
Cutting a Valve Seat
54
Valve Seating Tools
54
Removing and Replacing the Cylinder Block and Tappets
55
Refitting the Cylinder Block
55
Showing the Correct Method of Assembly of the Exhaust Tappets
56
Inspecting the Tappets and Guide Blocks
56
Renewing the Tappet Guide Blocks
57
Refitting a Tappet Guide Block
57
Removing and Refitting the Pistons
57
Removing and Replacing the Piston Rings
58
Refitting a Tapered Piston Ring
58
Inspecting the Pistons and Cylinder Bores
58
Cylinder Bore and Piston Grading Inspection
59
Table of Suitable Re-Bore Sizes
59
Cylinder Block and Piston Grading Details
60
Removing and Replacing the Contact Breaker
61
Ignition Timing - Initial Procedure
62
Static Timing Where no Stroboscope Is Available
62
T.D.C. Body and Plunger
63
Ignition Timing by Stroboscope
63
Rotor Marking
63
Removing and Replacing the Timing Cover
64
Timing Cover Oil Seal Location
64
Location of Three Long Screws in Timing Cover
64
Removing and Replacing the Oil Pump
64
Extracting and Refitting the Valve Timing Pinions
65
Extracting the Crankshaft Pinion
65
Camshaft Pinions
66
Extractor Tool 61-6019 Showing Protection Cap
66
Extracting the Cam Wheels
66
Valve Timing Marks from ENG No. CX06001
67
Valve Timing Marks
67
Valve Timing
68
Dismantling and Reassembling the Crankcase Assembly
68
Servicing the Crankshaft Assembly
70
Sectional View of Crankshaft-Showing Oil Tube
70
Refitting the Connecting Rods
72
Inspecting the Crankcase Components: Big-End Bearings
73
Inspecting the Crankcase Components: Main Bearings
73
Inspecting the Crankcase Components: Camshaft and Bushes
73
Inspecting the Crankcase Components: Crankcase Faces and Dowels
73
Renewing the Main Bearings
74
Roller Main Bearing
74
Renewing Camshaft Bushes
75
Removing and Replacing the Tachometer Drive
75
Exploded View of Tachometer Gearbox
75
Transmission
77
General Arrangement of Clutch and Shock Absorber Unit
78
Adjusting the Clutch Operating Mechanism
78
Exploded View of Clutch Operating Mechanism
79
Adjusting the Primary Chain Tension
79
Removing and Replacing the Primary Cover
80
Section through Primary Chaincase
80
Removing and Refitting the Clutch Plates
81
Unscrewing the Clutch Spring Nuts
81
Inspecting the Clutch Plates and Springs
81
Adjusting the Clutch Pressure Plate
82
Renewing Shock Absorber Rubbers
82
Replacing the Shock Absorber Rubbers
82
Removing and Replacing the Stator and Rotor
83
Removing and Replacing the Clutch and Engine Sprockets
84
Extracting the Clutch Centre, Using Extractor D662/3 and Locking Plate Z13
84
Inspection of the Transmission Components
85
Oil Seal Gearbox Sprocket Detachable Cover
86
Clutch and Engine Sprocket Alignment
86
Rear Chain Alternations and Repairs: Rivet Extractor
87
Five Speed Gearbox
89
Plan of Gear Components
90
Sequence of Gearchanging
91
Gear Selection Components
91
Removing and Replacing the Gearbox Outer Cover Assembly
93
Showing Gearbox Oil Level and Oil Drain Plugs
93
Gearbox Outer Cover, Showing Gearchange Mechanism, Clutch Operating Mechanism and Kickstart Quadrant
94
Dismantling and Reassembling the Kickstart Mechanism
94
Kickstart Quadrant and Spring
95
Dismantling and Reassembling the Gearchange Mechanism
95
Inspecting the Gearchange and Kickstart Components
95
Renewing Kickstart and Gearchange Bushes
96
Clutch Operating Mechanism
96
Dismantling the Gearbox
97
Gearbox Inner Cover Retaining Screws
97
Showing Removal of Engaging Dog
98
Inspection of the Gearbox Components
98
Renewing Mainshaft and Layshaft Bearings
99
Drift Dimensions
100
Section through Gearbox Mainshaft Oil Seal
100
Sketch of Needle Roller and Drift
100
Reassembling the Gearbox
100
Refitting the Gearbox Inner Cover
102
Changing the Gearbox Sprocket
102
Frame and Attachment Details
105
General Arrangement of Frame Assembly
106
Removing and Replacing the Fuel Tank
107
Fuel Tank Mounting
107
Removing Side Panels and Filter Housing
107
Removing the Prop Stand
108
Removing the Centre Stand
108
Removing Rear Brake Pedal
108
Removing and Servicing the Rear Brake Pedal Spindle
108
Rear Brake Pedal Spindle Assembly Exploded View
109
Brake Pedal Return Spring - Frame Location
109
Refitting the Brake Pedal Return Spring
109
Removing Twinseat
110
Chainguard Removal
110
Control Cable Replacement
111
Removing and Replacing the Coil Plate
111
Coil Plate Mountings
112
Removing and Replacing Rear Light Unit
113
Removing the Horn
113
Removing Rear Stop Switch
113
Removing and Replacing the Flasher Unit
113
Removing and Replacing the Mudguards
114
Adjusting the Rear Suspension
114
Exploded View of the Rear Suspension Unit
115
Removing and Refitting the Rear Suspension Units
116
Gas Filled Suspension Unit Fitted after Frame
116
Oil Hydraulic Suspension Unit Fitted Prior to Frame
116
Stripping and Reassembling the Suspension Units
116
Removing and Refitting the Swinging Fork
117
Swinging Arm Components
117
Renewing the Swinging Fork Bushes
118
Removing and Replacing the Swinging Arm Bushes Using Service Tool 61-6117
118
Frame Alignment
119
Fracture at Rear of Head Lug
120
Fracture at Bottom Bearing Housing
120
Basic Frame Dimensions
121
Checking the Swinging Fork
122
Paintwork Refinishing: Paint Stripping
123
Paintwork Refinishing: Undercoat
123
Paintwork Refinishing: Wet and Dry Sanding/Priming
123
Paintwork Refinishing: Applying Stopper
123
Paintwork Refinishing: Polishing
124
Fitting Replacement Seat Covers
124
Brakes Wheels and Tyres
125
Front and Rear Brake Caliper Exploded View
126
Front Brake Components
127
Rear Brake Components
128
Rear Brake Adjustment
129
Brake Fluid Level
130
Showing the Front Brake Reservoir Fluid Level
130
Rear Brake Reservoir
130
Brake Pad Lining - Front and Rear
131
Showing Arrangement for Bleeding the Rear Brake
131
Showing Arrangement for Bleeding the Front Brake
131
'Bleeding' the Hydraulic System - Front and Rear
132
Folded Condition of Rubber Diaphram
132
Flushing the Hydraulic System
133
Hydraulic Brake Pipes and Hoses - Removal and Refitment
134
Front Brake Pipe Installation
134
Rear Brake Pipe Installation
135
Rear Brake Master Cylinder and Reservoir
136
Rear Brake Master Cylinder and Reservoir: Push Rod Adjustment
136
Front Brake Master Cylinder
137
Exploded View of Master Cylinder
137
Hydraulic Flow Diagram - Front Brake
139
Showing Angle of Brake Reservoir
140
Stripping and Reassembling the Front and Rear Brake Calipers
141
Brake Discs
142
Removing and Refitting the Front Wheel
143
Removing and Refitting the Front Wheel Bearings
143
Exploded View of Front Wheel Bearing Arrangement
143
Removing and Fitting the Rear Wheel
144
Removing and Replacing the Rear Wheel Bearings
145
Rear Wheel Bearing Drift
146
Stripping and Reassembling Rear Brake
146
Removing Brake Shoes
146
Position of Brake Shoes
147
Rear Wheel Removal and Replacement
147
Removing and Replacing Rear Wheel Bearings
148
Drifting the Wheel Bearings
148
Exploded View of Rear Wheel Assembly
149
Renewing Rear Brake Linings
150
Punching Lining Rivets
150
Chiselling off Brake Rivets
150
Wheel Building
151
Wheel Balancing
151
Front and Rear Wheel Alignment
152
Removing and Refitting Tyres
153
Security Bolts
154
Tyre Maintenance
155
Tyre Pressures
156
Rear Chain Adjustment
156
Braking Performance Data
157
Fault Finding-Front and Rear Hydraulic Disc Brakes
159
Telescopic Forks: Index
161
Telescopic Forks: Description
162
Telescopic Forks: Steering Head Adjustment
162
Renewing Head Races
163
Stripping and Reassembling the Fork Legs
163
Damper Valve Assembly
164
Removing Oil Seal
165
Fork Assembly Details
166
Fork Alignment
167
Hydraulic Damping
168
Electrical System
169
Battery Inspection and Maintenance
170
Exploded View of Battery
170
Electrical System: Routine Maintenance
171
Specific Gravity of Electrolyte for Filling the Battery
171
Maximum Permissible Electrolyte Temperature During Charge
171
Coil Ignition System
172
Fault Finding in the Low Tension Circuit
172
Checking the Low Tension Circuit for Continuity
172
Bench Testing an Ignition Coil
173
Ignition Coil Test Rig
174
Contact Breaker
174
Checking the High Tension Circuit
174
Sparking Plugs
175
Sparking Plug Diagnosis
175
Charging System
176
Schematic Diagram of 12 Volt Charging Circuit
176
Checking the D.C. Output at the Rectifier
177
Checking the Alternator Output
177
Rectifier Maintenance and Testing
177
Testing the Rectifier
178
Bench Testing the Rectifier
178
Rectifier Test Sequence for Checking Forward Resistance and Back Leakage
179
Checking the Charging Circuit for Continuity
179
Constructing a Oneohm Load Resistor
179
Zener Diode Charge Control
180
Zener Diode Charge Control: Maintenance
180
Zener Diode Charging Regulator: Test Procedure
181
Zener Diode Location
182
Alternator and Stator Details
182
Electric Horn: Adjustment
183
Headlamp: Beam Adjustments
183
Removing and Refitting the Headlamp
184
Fuses
184
Exploded View of Fuseholder Assembly
184
Tail and Stop Lamp Unit
184
Ignition Switch
185
Removing and Refitting Front Flasher Lamps
185
Removing and Refitting Rear Flasher Lamps
185
Warning Lamps
186
Stop Lamp Switches
186
Oil Pressure Switch
186
Capacitor Ignition (Model 2MC)
187
Identification of Capacitor Terminals
187
Storage Life of Model 2MC Capacitor
187
Capacitor Ignition: Testing
188
Capacitor Ignition: Wiring and Installation
188
Capacitor Ignition: Service Notes
188
Electrical System: Wiring Diagram
189
Triumph Motorcycles 1979 Electrical Specification
193
Charging System Components
193
Charging Circuit
194
Ignition Circuit
194
Ignition System Components
195
Ignition System Technical Data
196
Charging System Fault Diagnosis and Testing
196
Alternator AC Output Test
197
Alternator AC Continuity Test
198
Rectifier DC Output Test
198
Ignition System Fault Diagnosis and Testing
199
Zender Diode Voltage Regulator
199
Ignition Coil Primary Circuit Test
200
Amplifier Main Harness Connector
201
Lights on with Ignition
202
Workshop Service Tools
203
Workshop Service Tools: Engine
204
Workshop Service Tools: Transmission
206
Workshop Service Tools: Gearbox
206
Workshop Service Tools: Wheels
207
Workshop Service Tools: Front Forks
208
Inches to Millimetres - Units
210
Decimals to Millimetres - Fractions
210
Fractions to Decimals and Millimetres
211
Millimetres to Inches - Units
212
Millimetres to Inches - Frections
212
Drill Sizes
213
Wire Gauges
213
Foot Pounds to Kilogrametres
214
Miles to Kilometres
214
Pounds to Kilograms
214
Miles Per Gallon to Litres Per 100 Kilometres
214
Pints to Litres
215
Gallons to Litres
215
Pounds Per Square Inch to
215
Kilograms Per Square Centimetre
215
U.N.E.F. Screw Threads
216
B.A. Screw Threads
216
B.S.W. Screw Threads
217
B.S.F. Screw Threads
217
U.N.C. Screw Threads
217
U.N.F. Screw Threads
217

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Triumph Bonneville 750 Workshop Manual (219 pages)

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