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Triumph Sprint ST Manuals
Manuals and User Guides for Triumph Sprint ST. We have
1
Triumph Sprint ST manual available for free PDF download: Service Manual
Triumph Sprint ST Service Manual (430 pages)
Brand:
Triumph
| Category:
Motorcycle
| Size: 12 MB
Table of Contents
Table of Contents
1
General Information
2
Ignition System Safety Precautions
3
Dangerous Susbstances
3
Fluoroelastomers
3
Oils
3
Health Protection Precautions
3
General Information
4
Environmental Protection Precautions
4
Brakes
4
Safety Instructions
5
Jacking and Lifting
5
Precautions against Damage
5
Coolant
5
Cleaning Components
6
Lubrication
6
Joints and Joint Faces
6
Gaskets, 0-Rings
6
Liquid Gasket, Non-Permanent Locking Agent
6
Screw Threads
6
Locking Devices
7
Fitting a Split Pin
7
Circlips, Retaining Rings
7
Self Locking Nuts
7
Encapsulated Bolt
7
Oil and Grease Seals
7
Press
7
Ball Bearing
7
Fuel Handling Precautions
7
General
7
Petrol - Gasoline
8
Fuel Tank Removal
8
Chassis Repairs
8
Electrical Precautions
9
Battery Disconnecting
9
Disciplines
9
Electrical Wires
10
Inspection
10
Replacement Parts
10
Service Data
10
Specification
10
Service Tools and Garage Equipment
11
Special Service Tools
11
Full Specification
15
Torque Wrench Settings
22
Cylinder Head Area
22
Clutch
22
Balancer, Crankshaft and Crankcase
22
Engine Covers
23
Transmission
23
Lubrication System
23
Final Drive
24
Cooling System
24
Fuel System, Exhaust System and Airbox
24
Rear Suspension
25
Front Suspension
25
Wheels
25
Front Brakes
26
Rear Brakes
26
ABS System
26
Footrests, Control Plates and Engine Mountings
27
Electrical
27
Throttle Cable Routing
28
Fuel Tank Breather Hose Routing
29
Clutch Cable Routing
30
Main Wiring Harness Routing
31
Front Brake Hose Routing - Models Without ABS Brakes
32
Front Brake Hose Routing - Models with ABS Brakes
33
Rear Brake Hose Routing - Models Without ABS Brakes
34
Rear Brake Hose Routing - Models with ABS Brakes
35
Scheduled Maintenance
38
Scheduled Maintenance Chart
39
Exploded View - Cylinder Head and Valves
42
Exploded View - Cam Cover
43
Exploded View - Camshaft and Camshaft Drive
44
Cylinder Head Description
45
Cam Cover
45
Removal
45
Installation
46
Cam Chain Tensioner
48
Removal
48
Installation
49
Camshafts
50
Removal
50
Camshaft and Bearing Cap Inspection
51
Installation
52
Valve Clearances
53
Valve Clearance Measurement
54
Valve Clearance Adjustment
54
Cam Chain
55
Removal
55
Inspection
56
Cylinder Head
56
Inspection
58
Installation
58
Valves and Valve Stem Seals
60
Removal from the Cylinder Head
60
Installation
60
Valve to Valve Guide Clearance
61
Valve Face Inspection
61
Exploded View - Clutch Cover
64
Exploded View - Clutch Assembly
65
Exploded View - Clutch Controls
66
Clutch Cable
67
Removal
67
Inspection
67
Clutch
67
Disassembly
68
Friction Plate Inspection
70
Thickness
70
Bend/Warp
70
Assembly
71
Crankshaft, Connecting Rods and Pistons
74
Exploded View - Crankshaft, Connecting Rod, Piston and Liner
74
Exploded View - Crankcase
75
Crankcases
76
Disassembly
76
Assembly
76
Crankshaft
78
Removal
78
Installation
79
Connecting Rods
79
Removal
79
Installation
80
Connecting Rod Big End Bearing Selection/Crankpin Wear Check
81
Checking the Measured Clearance
82
Connecting Rod Bearing Selection
82
Pistons
84
Disassembly
84
Piston Wear Check
84
Cylinder Liners
87
Removal
87
Installation
88
Crankcase Breather
89
Exploded View - Balancer Shaft
92
Balancer
92
Removal
93
Inspection
93
Assembly/Installation
94
Exploded View, Input and Output Shafts
98
Exploded View, Sprag Clutch and Starter Gears
99
Exploded View, Gear Selectors and Drum
100
Exploded View, Gear Change Mechanism
101
Selector Shaft, Selector Forks and Drum
102
Inspection
104
Installation
104
Input and Output Shafts Assemblies
107
Removal
107
Installation
107
Input Shaft
108
Disassembly
108
Assembly
110
Pressing on the Input Shaft Bearing
110
Output Shaft
112
Disassembly
112
Assembly
114
Starter Drive Gears/Sprag Clutch
116
Removal
116
Inspection
117
Installation
118
Exploded View - Sump
120
Exploded View - Oil Pump and Gears
121
Exploded View - Oil Cooler
122
Engine Oil Circuit
123
Engine Oil Circuit Description
124
Engine Oil
124
Specification
124
Triumph Engine Oil
124
Oil Level Inspection
125
Oil and Oil Filter Change
125
Disposal of Used Engine Oil
126
Oil Pump
126
Removal
127
Inspection
127
Installation
128
Low Oil Pressure Warning Light Switch
129
Installation
129
Sump
129
Removal
129
Inspection
130
Installation
130
Oil Cooler
131
Removal
131
Inspection
132
Installation
132
Engine Removal/Refit
134
Engine Installation
137
Fuel System/Engine Management
144
Fuel Requirements
149
Glossary of Terms
150
Engine Management System
152
System Diagnostics
158
Electrical Connectors
195
When Inspecting a Connector
195
When Connecting a Connector
195
Disconnection of ECM Connectors
195
Reconnection of ECM Connectors
196
Further Diagnosis
196
Crankshaft Sensor
197
Pinpoint Tests
197
Idle Speed Control
199
Fuel Injectors
201
Pinpoint Tests
201
Throttle Position Sensor
203
Pinpoint Tests
203
Purge Valve
205
Pinpoint Tests
205
Ignition Coils
207
Pinpoint Tests
207
Coolant Temperature Sensor
209
Pinpoint Tests
209
Inlet Air Temperature Sensor
211
Pinpoint Tests
211
Fuel Pump Relay
213
Pinpoint Tests
213
System Voltage
214
Pinpoint Tests
214
Cooling Fan Relay
215
Pinpoint Tests
215
Lambda Sensor
216
Pinpoint Tests
216
Lambda Sensor Heater
217
Pinpoint Tests
217
EEPROM Error
218
Fall Detection Switch
219
Pinpoint Tests
220
Vehicle Speed Sensor
220
Instrument Communication (CAN)
221
Pinpoint Tests
221
Fuel Level Sensor
222
Pinpoint Tests
223
Ambient Pressure Sensor
223
Pinpoint Tests
224
Manifold Absolute Pressure (Map) Sensor
224
Fueltank
225
Removal
225
Installation
226
Fuel Pump and Filter Assembly
226
Removal
226
Assembly
227
Fuel Level Sender Assembly/ Float Replacement
227
Removal
227
Inspection
228
Assembly
228
Fuel Pressure Checking
228
Fuel Delivery System
229
Airbox
230
Removal
230
Inspection
231
Installation
231
Air Filter Element
231
Removal
231
Installation
232
Intake Air Temperature Sensor
232
Removal
232
Assembly
232
Map Sensor
232
Barometric Pressure Sensor
233
Removal
233
Installation
233
Fall Detection Switch
233
Installation
234
Crankshaft Position Sensor
234
Removal
234
Throttle Cable
234
Adjustment
234
Removal
235
Examination
236
Installation
236
Throttle Bodies/Injectors
237
Removal
237
Inspection
237
Installation
238
Throttle Body Balancing
238
Throttle Position Sensor
239
Removal
239
Installation
239
Idle Speed Control Stepper Motor
240
Removal
240
Installation
241
Exhaust System
243
Removal
243
Assembly
245
Secondary Air Injection
246
System Purpose and Operation
246
Secondary Air Injection Solenoid Valve
247
Removal
247
Installation
247
Secondary Air Injection Reed Valves
247
Inspection
248
Installation
248
Evaporative Emissions Control System
249
California Models Only
249
Component Locations
249
Evaporative Control System - Engine off
250
Evaporative Control System - Engine Running
251
Exploded View - Cooling System
254
Coolant
255
Coolant Level Inspection
255
Coolant Replacement
256
Drainage
256
Filling
256
Radiator Hoses
257
Radiator and Cooling Fan
257
Coolant Pressure Cap
258
Inspection
258
Water Pump
258
Removal
258
Installation
259
Thermostat
259
Removal
259
Inspection
259
Installation
260
Radiator
260
Removal
260
Rear Suspension
262
Exploded View - Swinging Arm
262
Exploded View - Rear Hub and Wheel
263
Exploded View - Rear Suspension Unit
264
Exploded View - Drop/Drag Link
265
Rear Suspension Unit
266
Removal
266
Inspection
266
Installation
267
Drag Link
267
Removal
267
Inspection
268
Installation
268
Drop Link
268
Removal
268
Inspection
269
Installation
269
Drive Chain
270
Chain Slack Inspection
270
Drive Chain Adjustment
270
Chain Lubrication
270
Chain Wear Inspection
271
Swinging Arm/Drive Chain
272
Removal
272
Inspection
274
Installation
275
Final Drive/Rear Hub and Bearings
277
Removal
277
Inspection
279
Assembly
279
Installation
279
Drive Chain Replacement
280
Rivet Link Type
280
Front Suspension
286
Exploded View - Front Fork
286
Exploded View - Handlebars
287
Front Suspension
287
Fork Inspection
288
Fork Oil
288
Oil Change
288
Fork Oil Level Chart
290
Front Fork
290
Removal
290
Installation
291
Fork Dismantling/Assembly
291
Dismantling
291
Inspection
293
Assembly
293
Handlebars
294
Right Hand
294
Removal
294
Installation
295
Left Hand
295
Removal
295
Installation
296
Headstock Bearing Check/Adjustment
296
Adjustment
296
Headstock Bearings
297
Removal
297
Inspection
298
Installation
298
Exploded View - Front Brake Master Cylinder
307
Exploded View - Front Brake Caliper
308
Exploded View - Front Brake Cali Per
308
Exploded View - Rear Brake Master Cylinders
309
Exploded View - Rear Brake Caliper
310
Exploded View - ABS System
311
Braking System Maintenance Safety Precautions
312
Fluid Level Inspection
313
Changing Brake Fluid
313
Brake Pads
313
Brake Wear Inspection
313
Bleeding the Front Brakes, Renewing Brake Fluid
314
Front Brake Pads
315
Removal
315
Installation
316
Front Brake Caliper
316
Removal
316
Disassembly
317
Inspection
317
Assembly
317
Installation
318
Front Discs
318
Wear
318
Removal
319
Installation
319
Front Brake Master Cylinder
319
Disassembly
320
Inspection
320
Assembly
321
Installation
321
Bleeding the Rear Brakes, Renewing Brake Fluid
321
Rear Brake Pads
323
Removal
323
Installation
323
Rear Brake Caliper
324
Removal
324
Disassembly
324
Inspection
325
Assembly
325
Installation
326
Rear Brake Disc
326
Wear
326
Removal
326
Rear Master Cylinder
327
Removal
327
Disassembly
327
Inspection
327
Assembly
328
Installation
328
Bleeding the Front Brakes, Renewing Brake Fluid, Motorcycles with ABS
329
Front ABS Wheel Speed Sensor
329
Removal
329
Installation
329
Front ABS Pulser Ring
329
Inspection
330
Installation
330
Bleeding the Rear Brakes, Renewing Brake Fluid, Motorcycles with ABS
330
Rear ABS Wheel Speed Sensor
330
Removal
330
Installation
331
Rear ABS Pulser Ring
331
Removal
331
Inspection
332
Installation
332
.ABS Hydraulic Modulator / ECM
333
Removal
333
Installation
334
Abs
334
System Description
335
Abs
335
Component Locations
336
ABS System Circuit Diagram - Sprint ST
337
ABS System Circuit Diagram - Sprint ST
338
System Diagnostics
339
Triumph Diagnostic Tool
339
Current Data
345
14 Bleed System
353
Build Data
355
Electrical Connectors
356
Before Disconnection
356
When Disconnecting a Connector
356
ABS Warning Light on (no Dtcs Stored)
358
ABS Warning Light Does Not Illuminate (no Dtcs Stored)
360
Pinpoint Tests
362
Front Wheel Sensor Open Circuit/ Short Circuit
362
Front Wheel Sensor Abnormal Input/ Loosing Contact
364
Pinpoint Tests
364
Rear Wheel Sensor Open Circuit/ Short Circuit
365
Rear Wheel Sensor Abnormal Input/ Loosing Contact
367
Pinpoint Tests
367
Front Wheel Pulser Gear Missing Teeth
368
Pinpoint Tests
368
Rear Wheel Pulser Gear Missing Teeth
369
Pinpoint Tests
369
Front or Rear Input/Output Solenoid Open/ Short Circuit
370
Front or Rear Wheel Actuator (Hydraulic Control) Wheel Lock
371
Pinpoint Tests
371
Motor - Lock; Motor Stuck OFF; Motor Stuck on
372
Pinpoint Tests
372
Different Tyre Diameter
375
Pinpoint Tests
375
Abnormal ECU
376
Exploded View - Front Wheel
378
Exploded View - Rear Wheel & Final Drive
379
Tyres
380
Tyre Pressures
380
Tyre Wear/Wheel Inspection
380
Important Tyre Information
381
Front Wheel
382
Removal
382
Installation
383
Front Wheel Bearing
384
Removal
384
Inspection
384
Installation
385
Rear Wheel
386
Removal
386
Installation
386
Rear Wheel Bearing
387
Removal
387
Inspection
388
Installation
389
Frame and B Odywork
392
Exploded View - Frame
392
Exploded View - Seat Rails
393
Exploded View - Cockpit and Mountings
394
Exploded View - Lower Fairings
395
Exploded View - Rear Panels
396
Exploded View - Footrests and Mountings
397
Seat
398
Removal
398
Refit
398
Frame, Footrests and Fixings
398
Inspection
398
Rear Panel
399
Removal
399
Installation
399
Left and Right Facia / Cockpit Infill Panels
399
Installation
400
Fuse Box/ Stowage Box
400
Removal
400
Installation
401
Lower Fairing
401
Removal
401
Installation
402
Windscreen and Under-Screen Trim
402
Removal
402
Cockpit
403
Exploded View - Instruments
407
Exploded View - Starter Motor
408
Exploded View - Alternator
409
Exploded View - Headlight
410
Exploded View - Rear Light and Indicators
411
Battery
412
Battery Removal
412
Battery Refit
412
New Battery Commissioning
413
Charging - Battery Already in Service
413
Battery Charging - Battery Already in Service
413
Battery Maintenance
413
Headlight Adjustment
414
Main Beam Horizontal Adjustment
414
Main Beam Vertical Adjustment
414
Dipped Beam Vertical Adjustment
414
Dipped Beam Horizontal Adjustment
415
Dipped Headlight Bulb Access
415
Main Beam Headlight Bulb Replacement
415
Front Position Light
416
Bulb Replacement
416
Rear Light
417
Rear Light Replacement
417
Rear Indicator Bulb Replacement
417
Front Indicator Bulb Replacement
418
Number Plate Light Bulb
418
Alternator
418
Removal
418
Alternator Rectifier
420
Starter Motor
420
Installation
420
Fuses
420
Fuse Identification
420
Relay Pack
421
Identification of Relays
421
Instrument Pack
421
Removal
421
Installation
421
Lighting Circuit Diagram
422
Key to Circuit Diagram
422
Key to Wiring Colours
422
Starting/Charging Circuit Diagram
424
Key to Circuit Diagram
424
Key to Wiring Colours
424
Auxiliary and Accessory Circuit
426
Key to Circuit Diagram
426
Key to Wiring Colours
426
Main Wiring Circuit Diagram
428
Key to Circuit Diagram
428
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