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Triumph Rocket III Classic Manuals
Manuals and User Guides for Triumph Rocket III Classic. We have
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Triumph Rocket III Classic manual available for free PDF download: Service Manual
Triumph Rocket III Classic Service Manual (627 pages)
Brand:
Triumph
| Category:
Motorcycle
| Size: 24.54 MB
Table of Contents
Table of Contents
3
Table of Contents
9
Ignition System Safety Precautions
12
Dangerous Substances
12
Third Party Products
12
Fluoroelastomers
12
Oils
12
Health Protection Precautions
12
Environmental Protection Precautions
13
Brakes
13
Safety Instructions
14
Jacking and Lifting
14
Precautions against Damage
14
Coolant
15
Cleaning Components
15
Lubrication
15
Joints and Joint Faces
15
Gaskets, O-Rings
15
Liquid Gasket, Non-Permanent Locking Agent
16
Screw Threads
16
Locking Devices
16
Fitting a Split Pin
16
Circlips, Retaining Rings
16
Self Locking Nuts
16
Encapsulated Bolts
16
Oil and Grease Seals
17
Press
17
Ball Bearing
17
Chassis Bearing Lubrication
17
Metal Bushes
18
Fuel Handling Precautions
19
General
19
Petrol - Gasoline
19
Fuel Tank Removal
19
Chassis Repairs
19
Electrical Precautions
20
Battery Disconnecting
20
Disciplines
21
Electrical Wires
21
Electrical Testing
22
Ohm's Law
22
Basic Electrical Circuits
22
Circuit Diagrams
23
Glossary of Circuit Diagram Symbols
23
Tracing Circuits
24
To Check Continuity
25
To Measure Voltage
25
Can
26
Alternator/Charging System
27
Diagnosis - Charging Circuit
28
Starting Circuit
29
General Fault Finding - Starter Motor and Relay
29
Diagnosis - Starter Circuit
30
Specification
31
Replacement Parts
31
Inspection
31
Special Selvice Tools
32
Front Wheel Size
47
Front Tyre Size
47
Front Tyre Pressure (Cold)
47
Whichever Is Greater)
47
Rear Wheel Size
47
Rear Tyre Size
47
Rear Tyre Pressure (Cold)
47
Torque Wrench Settings
48
Cylinder Head Area
48
Clutch
48
Crankshaft and Crankcases
48
Engine Covers
48
Transmission
49
Lubrication System
49
Cooling System
49
Fuel System, Exhaust System and Airbox
50
Rear Suspension
50
Front Suspension
51
Wheels
51
Front Brakes
51
Rear Brakes
52
Footrests and Control Plates
52
Bodywork
52
Electrical
53
Routings
54
Clutch Cable Routing - Rocket III and Classic
54
Clutch Cable Routing - Rocket III Touring
55
Handlebar Cable Routing - Rocket III and Classic
56
Handlebar Cable Routing - Rocket III Touring
57
Main Wiring Harness Routing - Rocket III and Classic
58
Main Wiring Harness Routing - Rocket III Touring
59
Rear Mudguard Harness Routing - Rocket III and Classic
60
Rear Mudguard Harness Routing - Rocket III Touring
61
Front Brake Hose Routing - Rocket III and Classic
62
Front Brake Hose Routing - Rocket III Touring
63
Rear Brake Pipe and Hose Routing - Rocket III and Classic
64
Rear Brake Pipe and Hose Routing - Rocket III Touring
65
Throttle Cable Routing - Rocket III and Classic
66
Throttle Cable Routing - Rocket III Touring
67
Fuel Hose and Fuel Tank Breather Hose Routing
68
Rocket III and Classic
68
Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing - Rocket III and Classic
70
Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing - Rocket III Touring
71
Exploded View - Camshaft Cover
78
Exploded View - Camshaft and Camshaft Drive
79
Exploded View - Cylinder Head
80
Description
81
Camshaft Cover
81
Removal
81
Installation
82
Camshaft Drive Chain Tensioner
82
Removal
82
Inspection
83
Installation
83
Camshaft Drive Chain
86
Removal
86
Inspection
86
Installation
87
Camshaft Drive Chain Blades
89
Removal
89
Installation
89
Camshafts
90
Removal
90
Camshaft Identification
91
Camshaft Sprocket Orientation
91
Inspection
92
Installation
93
Valve Clearances
95
Valve Clearance Adjustment
95
Cylinder Head
95
Removal
96
Inspection
97
Installation
97
Valves and Valve Stem Seals
98
Removal from the Cylinder Head
98
Installation
98
Exploded View - Clutch Controls - Rocket'" and Classic
102
Exploded View - Clutch Controls - Rocket'" Touring
103
Exploded View - Clutch
104
Exploded View - Clutch Cover
105
Clutch Cable
106
Removal
106
Examination
107
Installation
107
Clutch Cover
107
Removal
107
Clutch
107
Removal
108
Friction Plate Inspection
109
Thickness
109
Installation
110
Exploded View - Crankshaft, Connecting Rod and Piston
114
Exploded View - Crankcase Fixings
115
Exploded View - Crankcase and Liners
116
Crankcases
117
Removal
117
Disassembly
117
Assembly
120
Crankshaft
120
Removal
123
Installation
124
Connecting Rods
124
Removal
124
Installation
125
Connecting Rod Big End Bearing Selection/Crankpin Wear Check
126
Connecting Rod Bearing Selection
127
Crankshaft Main Bearing/Joumal Wear
127
Checking Crankshaft Clearance Using Plastigage
127
Crankshaft End Float
128
Pistons
129
Disassembly
129
Piston Wear Check
129
Piston Rings/Ring Grooves
130
Piston Ring Gap
130
Piston Assembly
130
Cylinder Wear
132
Cylinder Liners
132
Removal
132
Installation
133
Bevel Box and Drive Shaft
136
Sectioned View - Bevel Box and Drive Shaft
136
Bevel Box and Drive Shaft Specification
137
Bevel Box Oil Specification
137
Bevel Box Oil Level Check
137
Bevel Box Oil Change
138
Bevel Box
138
Removal
138
Installation
138
Drive Shaft
139
Balancer
142
Exploded View - Balancer
142
Introduction
143
Removal
143
Inspection
144
Exploded View - Input and Output Shafts - up to Engine Number 300895
148
Exploded View - Input and Output Shafts - from Engine Number 300896
149
Exploded View - Gear Change Mechanism
150
Exploded View - Gear Selector Mechanism - Rocket III and Classic
151
Exploded View - Gear Selector Mechanism - Rocket III Touring
151
Exploded View - Torsional Damper Shaft Housing
152
Exploded View - Torsional Damper Shaft
153
Selector Shaft, Selector Forks and Drum
154
Removal
154
Inspection
156
Installation
156
Torsional Damper Shaft
158
Removal
158
Disassembly
159
Assembly
161
Installation
163
Input and Output Shaft Assemblies
164
Removal
164
Installation
164
Output Shaft - up to Engine Number 300895
166
Disassembly
167
Inspection
167
Assembly
168
Output Shaft - from Engine Number 300896
170
Disassembly
171
Inspection
171
Bearing
173
Circlip
173
Input Shaft
174
Disassembly
175
Press Bars
175
Inspection
176
Assembly
176
Second Gear
177
Orientating the Circlip as Shown below
177
Exploded View - Sump - up to Engine Number 217501
180
Exploded View - Sump - from Engine Number 217502
181
Exploded View - Oil Tank, Filter and Pumps
182
Oil Circuit
183
Scavenge System
184
Pressure System
184
Engine Oil
185
Specification
185
Triumph Engine Oil
185
Oil Level Inspection
185
Oil and Oil Filter Change
186
Disposal of Used Engine Oil and Oil Filters
187
Low Oil Pressure Warning Light Switch
188
Removal
188
Installation
189
Sump
189
Removal
189
Inspection
189
Installation
190
Oil Pumps
190
Removal
190
Inspection
192
Installation
192
Oil Non-Return Valve
194
Oil Pressure Relief Valve
194
Oil Tank
195
Removal
195
Inspection
195
Installation
195
Oil Transfer Pipes
195
Fuel System/Engine Management
206
Exploded View - Fuel Tank - Rocket III and Classic
211
Exploded View - Fuel Tank - Rocket'" Touring
212
Exploded View - Fuel Pump - Rocket'" and Classic
213
Exploded View - Fuel Pump - Rocket'" Touring
214
Exploded View - Fuel Rail, Throttles and Injectors
215
Exploded View - Airbox - Rocket'" and Classic
216
Exploded View - Airbox - Rocket'" Touring
217
Exploded View - Exhaust System - Rocket III and Classic
218
Exploded View - Exhaust System - Rocket'" Touring
219
Exploded View - Evaporative System
220
Fuel Requirements
221
Glossary of Terms
222
Engine Management System
224
System Description
224
System Sensors
224
Sensor Locations
225
System Actuators
226
Actuator Locations
227
Engine Management Circuit Diagram - Rocket'" & Rocket'" Classic
228
Engine Management Circuit Diagram - Rocket'" Touring
230
System Diagnostics
232
On-Board Fault Detection System
232
Triumph Diagnostic Tool
232
Current Data
233
Freeze-Frame Data
233
Function Tests
234
Checks/Adjustments
234
Adjustments
234
Adaption Status
234
Build Data
234
Checks
235
Diagnostic Trouble Codes
236
Exploded View - Radiator
418
Exploded View - Water Pump, Expansion Tank and Hoses
419
Coolant
420
Radiator Hoses
420
Radiator and Cooling Fan
420
Coolant Level Inspection
421
Coolant Replacement
422
Drainage
422
Filling
423
Water Pump
424
Removal
424
Inspection
424
Installation
424
Coolant Pressure Cap
425
Inspection
425
Thermostat
426
Removal
426
Inspection
426
Installation
426
Radiator
427
Removal
427
Inspection
429
Installation
430
Exploded View - Swinging Arm
432
Exploded View - Rear Suspension Units
433
Rear Suspension Units
434
Suggested Suspension Settings
434
Removal
434
Inspection
436
Swinging Arm and Drive Shaft
437
Removal
437
Output Shaft
438
Inspection
438
Installation
438
Swinging Arm Bearings
440
Removal
440
Installation
441
Fork Inspection
450
Removal
450
Installation
451
Oil Refilling
453
Disassembly
455
Inspection
458
Assembly
458
Check
461
Adjustment
461
Yoke Removal
464
Bearing Removal
466
Installation
470
Oil Draining
471
Oil Refilling
472
Disassembly
474
Inspection
476
Assembly
476
Steering Head Bearing Check and Adjustment - Rocket III Touring
478
Check
478
Adjustment
478
Bottom Yoke and Headstock Bearings - Rocket III Touring
480
Yoke Removal
480
Bearing Removal
482
Installation
482
Exploded View - Front Brake Master Cylinder Rocket III and Classic
487
Exploded View - Front Brake Master Cylinder Rocket III Touring
488
Exploded View - Front Brake Caliper and Disc
489
Exploded View - Rear Brake Master Cylinder - Rocket III and Classic
490
Exploded View - Rear Brake Master Cylinder - Rocket III Touring
491
Exploded View - Rear Brake Caliper and Disc - Rocket III and Classic
492
Exploded View - Rear Brake Caliper and Disc - Rocket III Touring
493
Braking System Maintenance Safety Precautions
494
Brake Fluid Level Inspection
495
Changing Brake Fluid
495
Brake Pads
495
Brake Wear Inspection
495
Bleeding the Front Brakes, Renewing Brake Fluid
496
Front Brake Pads
498
Removal
498
Installation
499
Front Brake Caliper
500
Removal
500
Disassembly
501
Inspection
501
Assembly
501
Installation
502
Front Discs
503
Wear
503
Removal
503
Installation
504
Front Brake Master Cylinder - Rocket III and Classic
504
Removal
504
Disassembly
505
Inspection
505
Assembly
506
Installation
506
Front Brake Master Cylinder - Rocket III Touring
508
Removal
508
Inspection
509
Assembly
510
Installation
510
Bleeding the Rear Brakes, Renewing Brake Fluid
511
Rear Brake Pads, Rear Brake Caliper
513
Removal
513
Installation
514
Rear Brake Caliper
516
Rear Brake Disc
516
Wear
516
Removal
516
Installation
516
Rear Master Cylinder
517
Removal
517
Disassembly
518
Inspection
518
Assembly
519
Installation
519
Exploded View - Front Wheel- Rocket III and Classic
522
Exploded View - Rear Wheel and Cush Drive - Rocket III and Classic
523
Exploded View - Front Wheel- Rocket III Touring
524
Exploded View - Rear Wheel and Cush Drive - Rocket III Touring
525
Tyres
526
Tyre Pressures
526
Tyre Wearlwheel Inspection
526
Minimum Recommended Tread Depth
527
Important Tyre Information
527
Front Wheel- Rocket III and Classic
528
Removal
528
Installation
529
Front Wheel- Rocket III Touring
530
Removal
530
Installation
531
Front Wheel Bearing
531
Removal
531
Inspection
532
Installation
532
Rear Wheel- Rocket III and Classic
533
Removal
533
Installation
534
Rear Wheel - Rocket III Touring
535
Removal
535
Installation
537
Cush Drive
538
Removal
538
Installation
539
Rear Wheel Bearing
540
Removal
540
Inspection
540
Installation
540
Frame and Bodywork
545
Exploded View - Frame and Fixings - Rocket III and Classic
545
Exploded View - Frame and Fixings - Rocket III Touring
546
Exploded View - Front and Rear Mudguards - Rocket III and Classic
547
Exploded View - Front and Rear Mudguards - Rocket III Touring
548
Exploded View - Front and Rear Footrests - Rocket III
549
Exploded View - Front Footboards - Rocket III Classic
550
Exploded View - Front and Rear Footboards - Rocket III Touring
551
Exploded View - Pannier Rail- Rocket III Touring
552
Exploded View - Seat and Tool Kit - Rocket III
553
Exploded View - Seat and Tool Kit - Rocket III Classic
553
Exploded View - Seat - Rocket III Touring
554
Exploded View - Side Panels - Rocket III Classic
555
Exploded View - Side Panels - Rocket III Touring
555
Exploded View - Windscreen - Rocket III Touring
556
Exploded View - Side Stand - Rocket III and Classic
557
Exploded View - Side Stand - Rocket III Touring
557
General Frame Inspection
558
Bank Angle Indicators - Rocket III and Classic
558
Bank Angle Indicators - Rocket III Touring
559
Seats
559
Rear Seat - Rocket III Only
559
Rocket III Classic Only
560
Seat - Rocket III Touring
560
Side Covers
561
Removal
561
Installation
561
Engine Infill Panels
562
Removal
562
Installation
562
Pannier Rail- Rocket III Touring
563
Removal
563
Installation
564
Front Mudguard - Rocket III and Classic
564
Removal
564
Mudguard Embellisher Removal
565
Embellisher Assembly
565
Installation
565
Front Mudguard - Rocket III Touring
566
Removal
566
Installation
566
Rear Mudguard - Rocket III and Classic
566
Installation
568
Rear Mudguard - Rocket III Touring
569
Removal
569
Installation
571
Windscreen - Rocket III Touring
572
Removal
572
Installation
572
Handlebars - Rocket III and Classic
573
Removal
573
Installation
575
Handlebar - Rocket III Touring
576
Removal
576
Installation
577
Mirrors
579
Removal
579
Installation
579
Side Stand
580
Removal
580
Installation
580
Exploded View - Alternator
585
Exploded View - Starter Motor
586
Exploded View - Battery, Horn and Wiring - Rocket III Touring
592
Battery
593
Battery Disposal
593
Battery Removal
593
Battery Installation
593
Battery Commissioning and Charging
594
New Battery
594
Battery Maintenance
594
Battery Already in Service
594
Table of Battery Charging Times
595
Fuses
595
Fuse Box - Rocket III and Classic
595
Fuse Box - Rocket III Touring
596
Fuse Identification - Rocket III Touring
596
Headlights
597
Headlight Bulb Replacement
599
Rear Light
600
Bulb Replacement
600
Indicator Lights
601
Bulb Replacement - Rocket III and Classic
601
Bulb Replacement - Rocket III Touring
601
Alternator
602
Removal
602
Inspection
603
Assembly
603
Alternator Rectifier
604
Removal
604
Installation
604
Starter Motor
605
Removal
605
Installation
605
Relays
606
Identification and Location
606
Relay Identification - Left Hand Side
606
Alternator Stator
608
Pinpoint Tests
608
Rectifier/Regulator
610
Pinpoint Tests
610
Lighting Circuit - Rocket III and Classic
612
Circuit Diagram - Lighting - Rocket III and Classic
613
Lighting Circuit - Rocket III Touring
614
Circuit Diagram - Lighting - Rocket III Touring
615
Starting and Charging Circuit - Rocket III and Classic
616
Circuit Diagram - Starting and Charging - Rocket III and Classic
617
Starting and Charging Circuit - Rocket III Touring
618
Circuit Diagram - Starting and Charging - Rocket III Touring
619
Auxiliary and Accessory Circuit - Rocket III and Classic
620
Circuit Diagram - Auxiliary and Accessory - Rocket III and Classic
621
Auxiliary and Accessory Circuit - Rocket III Touring
622
Circuit Diagram - Auxiliary and Accessory - Rocket III Touring
623
Complete System - Rocket III and Classic
624
Key to Circuit Diagram
624
Complete System - Rocket III Touring
626
Key to Circuit Diagram
626
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