User Manuals: Triumph T509 SPEED TRIPLE 885cc Engine

Manuals and User Guides for Triumph T509 SPEED TRIPLE 885cc Engine. We have 1 Triumph T509 SPEED TRIPLE 885cc Engine manual available for free PDF download: Service Manual

Triumph T509 SPEED TRIPLE 885cc Service Manual

Triumph T509 SPEED TRIPLE 885cc Service Manual (376 pages)

Brand: Triumph | Category: Motorcycle | Size: 35 MB

Table of Contents

Contents
3
Warning, Caution and Note
4
Introduction
4
How to Use this Manual
4
Safety Instructions
5
Repairs and Replacement
5
References
5
Dimensions
5
Edges
6
Tightening Procedure
6
Table of Contents
7
General Information Contents
7
Dan G Eroussubstances
9
Engine Oils
9
Ignition System Safety Precautions
9
Health Protection Precautions
9
Environmental Protection Precautions
10
Brakes
10
Jacking and Lifting
11
Precautions against Damage
11
Engine Coolant
11
Cleaning Components
11
Safetyinstructions
11
Lubrication
12
- Encapsulated Bolt
  13
- Lockin G Devices
  13
- Self Locking Nuts
  13
- Circlips, Retaining Rings
  13
- Fuel Handling Precautions
  14
- Petrol — Gasoline
  14
- Fuel Tank Removal
  14
- Chassis Repairs
  14
- Electrical Precautions
  15
- Battery Disconnecting
  15
- Electrical Wires
  16
- Inspection
  16
- Replacement Parts
  16
Disciplines
16
- Service Tools and Garage Equipment
  17
- Special Service Tools
  17
- Full Specification
  19
- Tor Q Uewrench Settings
  27
Transmission
28
Fuelsystem and Airbox
29
Brakes
30
Bodywork
31
- Maintenance Contents
  32
- Service Check Sheets
  33
- Scheduled Maintenance Chart
  34
- Cylinder Head Contents
  35
- Cylinder Head and Valves Exploded View
  36
- Cam Cover Exploded View
  37
- Camshaft and Camshaft Drive Exploded View
  38
- Cylinder Head Description
  39
- Cam Cover Removal
  39
- Coil Connections
  39
- Camshaft Position Sensor
  39
- Silicone Sealer Areas
  40
- Cam Cover Installation
  40
- Cam Cover Bolt Release Sequence
  40
- Cam Chain Tensioner Removal and Installation
  41
- Camshaft to Cylinder Head Alignment Marks
  41
- Tensioner Plunger Set—Up
  42
- Camshafts Removal
  43
- Camshaft Cap Numbering
  43
- Camshaft and Bearing Cap Inspection
  44
- Camshafts Installation
  45
- Measuring the Compressed Plastigauge
  45
- Valve Clearances
  46
- Valve Clearance Measurement
  46
- Cam Lobe Pointing Away from Valve
  46
- Typical Valve Clearance Chart
  46
- Tool in Position on Inlet Camshaft
  47
- Valve Clearance Adjustment
  47
- Tool Mounting Plate Markings
  47
- Buckets Positioned to Outside of Head
  47
- Removing/Replacing the Shim
  48
- Exhaust Valve Clearance Adjustment Chart
  49
- Inlet Valve Clearance Adjustment Chart
  50
- Cam Chain Removal and Installation
  51
- Cylinder Head Removal
  52
- Cylinder Head Inspection
  56
- Cylinder Head Bolt Release Sequence
  56
- Cylinder Head Installation
  57
- Cam Cover Bolt Tightening Sequence
  60
- Removal from the Cylinder Head
  61
- Valves and Valve Stem Seals Installation
  61
- Valve Face Inspection
  62
- Valve Guides
  62
- Valve to Valve Guide Clearance
  62
- Clutch Contents
  63
- Exploded View — Clutch Cover
  64
- Exploded View — Clutch Assembly
  65
- Exploded View — Clutch Controls
  66
- Clutch Cable Removal
  67
- Clutch Cable Examination
  67
- Clutch Cable Assembly
  67
- Clutch Disassembly
  68
- Clutch Assembly
  70
- Belleville Washer 'Out' Mark
  71
- Friction Plate Inspection
  73
- Balancer Contents
  74
- Exploded View — Balancer Shaft
  75
- Alignment Inspection
  76
- Balancers
  76
- Balancer Shaft Removal
  77
- Balancers Examination
  79
- Balancers Assembly
  79
- Balancers Installation
  80
- Crankshaft, Bods and Pistons Contents
  82
- Crankshaft, Connecting Rod, Piston and Liner Exploded View
  83
- Exploded View — Crankcase
  84
- Engine Removal/Refit
  85
- Engine Installation
  88
- Crankcases Disassembly
  91
- Upper Crankcase Bolt Release Sequence
  91
- Lower Crankcase Bolt Release Sequence
  91
- Crankcases Assembly
  92
- Selector Forks
  92
- Lower Crankcase Bolt Tightening Sequence
  93
- Upper Crankcase Bolt Tightening Sequence
  93
- Connecting Rods Removal and Installation
  94
- Crankshaft Removal and Installation
  96
- Connecting Rod Bearing Selection
  98
- Checking the Measured Clearance
  98
- Big End Bearing Selection Chart
  98
- Connecting Rod Big End Bearing Selection/Crankpin Wear Check
  98
- Crankshaft Main Bearing/Journal Wear
  99
- Checking Crankpin Clearance Using Plastigauge
  99
- Pistons Disassembly
  100
- Piston Wear Check
  100
- Piston Rings/Ring Grooves
  100
- Removing the Gudgeon Pin Circlip
  100
- Piston Assembly
  101
- Piston Ring Identification
  101
- Aligning Piston Rings Using the Piston
  101
- Piston Ring to Ring Groove Clearance Check
  101
- Cylinder Wear
  102
- Test Positions for Bore Wear Check
  102
- Cylinder Liners Removal (Engine in or out of the Frame)
  103
- Paint Mark
  103
- Cylinder Liners Installation
  104
- Left Hand Crankshaft Cover
  105
- Cover Removavrefit
  105
- Seal/Cover Replacement
  105
- Transmission Contents
  106
- Exploded View, Input and Output Shafts
  107
- Exploded View, Auxiliary Gears
  108
- Exploded View, Selector Mechanism
  109
- Exploded View, Gear Pedal Etc.
  110
- Engine Cranking
  111
- Auxiliary Gears — Operation
  111
- Transmission Description
  111
- Auxiliary Gears
  111
- Alternator Spindle Removal
  112
- Alternator Spindle Installation
  113
- Sprag Clutch Removal
  114
- Sprag Clutch Inspection
  115
- Sprag Clutch Assembly
  115
- Starter Idler Gear Removal, Inspection and Assembly
  117
- Selectors, Selector Shaft and Drum Removal
  118
- Selectors, Selector Shaft and Drum Inspection and Installation
  120
- Correct Gear Position at Maximum Extension
  120
- Detent Position 1St. Gear
  121
- Detent Position Neutral
  121
- Input and Output Shaft Assemblies Removal and Installation
  122
- Input Shaft Disassembly
  123
- Input Shaft Assembly
  124
- Pressing on the Input Shaft Bearing
  124
- Output Shaft Disassembly
  125
- Output Shaft Assembly
  126
- Lubrication System Contents
  127
- Exploded View - Sump
  128
- Exploded View — Oil Pump and Gears
  129
- Exploded View - Daytona Oil Cooler
  130
- Exploded View - Speed Triple Oil Cooler
  131
- Cylinder Oil Circuit
  132
- Cylinder Oil Circuit Description
  133
- Engine Oil Specification
  134
- Triumph Engine Oil
  134
- Oil Level Inspection
  134
- Engine Oil and Filter Change
  135
- Oil Pump and Gears Removal
  136
- Oil Pump and Gears Inspection and Installation
  137
- Low Oil Pressure Warning Light Switch
  138
- Inset: Selector Shaft Keeper Plate
  138
- Sump Removal and Inspection
  139
- Sump Installation
  140
- Oil Cooler Removal, Inspection and Installation
  141
- Oil Cooler Hose Disconnection
  141
- Fuel System/Engine Management Contents
  142
- Exploded View - Fuel Tank and Pump
  144
- Fuel Rail, Throttles and Injectors
  145
- Fuel Rail, Throttles and Injectors (Later Models)
  146
- Purge and Idle Air Control System (Early Models)
  147
- Purge and Idle Air Control System (Late Models)
  148
- Typical Exhaust System (T595 Daytona Illustrated)
  149
- Methanol
  150
- Oxygenated Gasoline
  150
- Ethanol
  150
- Fuel Rerquirements
  150
- Glossary of Terms
  151
- Engine Management System
  153
- System Description
  153
- System Sensors
  153
- Sensor Locations
  154
- System Actuators
  155
- Actuator Locations
  156
- Key to Wiring Circuit Diagram
  157
- Key to Wiring Colour Codes
  157
- Circuit Diagram — Engine Management System up to VIN 71698
  158
- Engine Management System from VIN 71699
  160
- Triumph Diagnostic Tool
  161
- On-Board Fault Detection System
  161
- System Diagnostics
  161
- Current Data
  162
- Freeze—Frame Data
  162
- Function Tests
  162
- Checks/Adjustments
  162
- Diagnostic Trouble Codes
  163
- Checks
  166
- Service Diagnostic Tool
  166
- Test Procedure
  167
- Typical Screen Showing Symbol Examples
  167
- Tool Keys
  167
- Return Key
  167
- Connection and Power-Up
  173
- Select Language
  173
- Switch on Bike Ignition
  174
- Triumph Motorcycles
  174
- Data Link Fault Retry?
  175
- Service Data - Dealer
  175
- Service Data - Date
  176
- Main Menu
  176
- Diagnostics
  177
- Stop Engine
  178
- To Select `READ STORED DTCS' from the Main Menu
  178
- Stored DTCS
  179
- Three Options Are Now Available
  179
- Freeze Frame
  180
- Stored DTCS, Erase All DTC Data
  181
- To Select `FUNCTION TESTS' from the Main Menu
  181
- To Select `CHECKS/ADJUSTMENTS' from the Main Menu
  186
- Check/Adjust
  186
- Build Data
  187
- Sensor Data
  188
- To Access the `ADJUSTMENTS' Menu
  188
- Adjust
  189
- Adjust Tune
  189
- Adjust Tune (Idle Fuel Adjustment)
  190
- Adjust Tune (Closed Throttle Position)
  191
- Adjust Tune (Set Adaptive Stepper Position)
  191
- Adjust Tune (Set Long Term Fuel Trim)
  192
- Update Tune
  192
- Update Tune (Confirm Selected)
  195
- Restarting Tune Download
  195
- Electrical Connectors
  196
- Before Disconnecting
  196
- When Disconnecting, Inspecting and Connecting a Connector
  196
- ECM Connector
  196
- Further Diagnosis
  197
- ECM Connector Pin Numbering
  197
- Crankshaft Sensor
  198
- Pinpoint Tests
  198
- Circuit Diagram
  198
- Camshaft Sensor
  199
- Idle Air Control
  200
- Fuel Injectors
  201
- Barometric Pressure Sensor
  202
- Throttle Position Sensor
  203
- Purge Valve
  204
- Ignition Coils
  205
- Coolant Temperature Sensor
  206
- Inlet Air Temperature Sensor
  207
- Fuel Pump Relay
  208
- Road Speed Sensor
  209
- Sensor Supply Voltage
  210
- System Voltage
  211
- Malfunction Indication Lamp
  212
- Cooling Fan Relay
  213
- Coolant Temperature Gauge
  214
- Tachometer
  215
- Fault Finding - Non Electrical
  216
- Fuel Tank
  217
- Fuel Tank Installation
  218
- Fuel Pump Removal and Assembly
  219
- Fuel Filter Removal and Assembly
  220
- Fuel Filter Inspection/Test
  220
- Fuel Pressure Regulator
  221
- Fuel Pressure Regulator Assembly
  221
- Fuel Hose Connectors Removal and Inspection
  221
- Fuel Hose Connectors Assembly
  222
- Fuel Pressure Checking
  222
- Fuel Delivery System
  223
- Airbox Removal
  224
- Airbox Assembly
  225
- Air Filter Element Removal and Assembly
  225
- Raising the Housing
  225
- Replacing the Air Filter Element
  225
- Barometric Pressure Sensor Removal and Assembly
  226
- Intake Air Temperature Sensor Removal and Assembly
  227
- Crankshaft Position Sensor Removal
  227
- Crankshaft Position Sensor Assembly
  228
- Camshaft Position Sensor Removal
  229
- Camshaft Position Sensor Assembly
  230
- Road Speed Sensor Removal and Assembly
  230
- Throttle Cable Removal
  230
- Throttle Cable Examination, Installation and Adjustment
  231
- Throttle Bodies Removal
  232
- Throttle Bodies Inspection
  233
- Later Model Air Bypass System
  233
- Throttle Bodies Assembly
  234
- Throttle Body Balancing
  235
- Typical Analyser Display
  235
- Typical Display Ofi Imbalanced Throttles
  235
- Injectors Removal
  236
- Injectors Inspection, Testing and Assembly
  237
- Removing the Injectors/Fuel Rail
  237
- Throttle Position Sensor Removal, Inspection and Assembly
  238
- Idle Air Control Valve Removal
  238
- Idle Air Control Valve Inspection and Assembly
  239
- Early Air Bypass System
  239
- Exhaust System Removal
  240
- Exhaust System Assembly
  241
- Evaporative Loss Control System
  242
- Component Locations
  242
- Evaporative Control System — Engine off
  243
- Evaporative Control System — Engine Running
  244
- Cooling System Contents
  245
- Exploded View - Cooling System
  246
- Coolant
  247
- Coolant Level Inspection
  247
- Coolant Replacement
  248
- Drainage
  248
- Filling
  248
- Radiator Hoses
  249
- Radiator and Cooling Fan
  249
- Arrowed — Potential Air-Lock Area
  249
- Water Pump Removal and Inspection
  250
- Coolant Pressure Cap Inspection
  250
- Water Pump Installation
  251
- Radiator Removal
  252
- Radiator Inspection and Installation
  253
- Thermostat Removal
  253
- Thermostat Inspection and Assembly
  254
- Thermostat Mounting Point
  254
- Thermostat `Nose' Mounting Point
  254
- Rear Suspension Contents
  255
- Exploded View - Swinging Arm
  256
- Rear Hub
  257
- Rear Suspension Unit
  258
- Drop/Drag Link
  259
- Rear Suspension Unit Removal, Inspection and Installation
  260
- Drop Link Removal
  261
- Drop Link Inspection and Installation
  262
- Removing Drop Link Spindle
  262
- Drag Link Removal
  263
- Drag Link Inspection and Installation
  264
- Drive Chain
  265
- Chain Slack Inspection
  265
- Drive Chain Adjustment
  265
- Chain Lubrication
  265
- Chain Wear Inspection
  266
- Swinging Arm/Drive Chain Removal
  267
- Typical Drive Chain Support
  268
- Removing the Swinging Arm
  269
- Swinging Arm/Drive Chain Inspection
  270
- Swinging Arm/Drive Chain Assembly
  271
- Staking the Nut
  272
- Final Drive Removal
  273
- Final Drive Inspection, Assembly and Installation
  275
- Drive Chain Removal
  276
- Drive Chain Replacement
  277
- Fitting Side Plate
  277
- Front Suspension Contents
  279
- Exploded View - Front Fork
  280
- Low Handlebars
  281
- Tall Handlebars
  282
- Front Suspension
  283
- Fork Inspection
  283
- Fork Oil
  283
- Oil Change
  283
- Fork Oil Level Chart
  285
- Fork Pull through
  285
- Front Fork Removal and Installation
  286
- Fork Dismantling/Assembly
  287
- Preload Adjuster Marks
  287
- Fork Inspection
  289
- Headstock Bearing Check/Adjustment
  290
- Checking Headstock Bearing Adjustment
  290
- Braking System Contents
  291
- Exploded View — Front Brake Master Cylinder
  292
- Front Brake Caliper
  293
- Rear Brake Master Cylinders
  294
- Rear Brake Caliper
  295
- Braking System Maintenance Safety Precautions
  296
- Fluid Level Inspection
  297
- Changing Brake Fluid
  297
- Brake Pads
  297
- Brake Wear Inspection
  297
- Safety Clip
  298
- Bleeding the Front Brakes Renewing Brake Fluid
  298
- Front Brake Pads Removal
  299
- Front Brake Pads Installation
  300
- Front Brake Caliper Removal
  300
- Front Brake Caliper Disassembly, Inspection, Assembly and Installation
  301
- Front Discs Wear
  302
- Front Discs Removal
  302
- Front Discs Installation
  303
- Front Brake Master Cylinder Removal and Disassembly
  303
- Front Brake Master Cylinder Inspection, Assembly and Installation
  304
- Bleeding the Rear Brakes Renewing Brake Fluid
  305
- Rear Brake Pads Removal
  306
- Rear Brake Pads Installation
  307
- Rear Brake Caliper Removal, Disassembly, Inspection and Assembly
  308
- Rear Brake Disc Wear
  309
- Rear Brake Caliper Installation
  309
- Rear Master Cylinder Removal, Disassembly, Inspection and Assembly
  310
- Rear Master Cylinder Installation
  311
- Wheels Contents
  312
- Exploded View - Front Wheel
  313
- Tyres
  315
- Tyre Pressures
  315
- Rim Marking
  315
- Tyre Marking
  315
- Tyre Wear/Wheel Inspection
  316
- Minimum Recommended Tread Depth
  316
- Important Tyre Information
  317
- Front Wheel Removal and Installation
  318
- Rear Wheel Removal and Installation
  319
- Front Wheel Bearings Removal and Installation
  320
- Bearing Tool Selection Chart
  320
- Rear Wheel Bearings Removal
  321
- Rear Wheel Bearings Inspection and Installation
  323
- Bodywork and Frame Contents
  325
- Exploded View - Frame
  326
- Seat Rails
  327
- Cockpit and Mountings
  328
- Rear Panels
  329
- Footrests and Mountings
  330
- Seat Removal and Refit
  331
- Side Panel Removal and Installation
  332
- Belly Panel Removal and Installation
  332
- Side Panel Fixings
  332
- Lower Fairings Removal and Installation
  333
- Cockpit Removal and Installation
  334
- Footrest Wear Limit
  335
- Frame Renewal
  335
- Strip down
  335
- Frame, Footrests and Fixing Inspection
  335
- Rotate the Handlebars Inboard
  337
- Lifting the Frame from the Forks
  337
- Lifting the Frame from the Rear Suspension
  337
- Electrical System Contents
  342
- Exploded View — Instruments
  344
- Alternator and Starter Motor
  345
- Daytona Headlight
  346
- Speed Triple Headlight
  347
- Rear Lights and Indicators
  348
- Battery
  349
- Battery Types
  349
- Direction of Battery Removal
  350
- Battery Refit
  350
- Battery Removal
  350
- Battery Charging - Yuasa Wet Battery
  351
- Battery Charging - GS Sealed Battery
  351
- New Battery
  351
- Battery Already in Service
  351
- Battery Maintenance
  352
- Battery Lead Conversion - Wet to Sealed Battery
  353
- Headlights - Daytona
  355
- Headlight Adjustment
  355
- Headlight Bulb Replacement
  356
- Headlight Removal and Assembly
  356
- Position Lamp Bulb Replacement
  356
- Headlights - Speed Triple
  357
- Headlight Bulb Replacement and Installation
  358
- Bulb Replacement
  359
- Tail Light Removal and Installation
  359
- License Plate Light
  359
- Bulb Installation
  360
- Indicator Removal and Replacement
  360
- Lighting Circuit Diagram
  361
- Starting/Charging Circuit Diagram up to VIN 71698
  363
- Starting/Charging Circuit Diagram from VIN 71699
  365
- Alternator Removal, Inspection and Installation
  367
- Starter Motor Removal and Installation
  368
- Instruments Removal and Installation
  369
- Fuses
  369
- Fuse Identification
  369
- Instrument Waring Lights Removal and Installation
  370
- Relay Pack
  370
- Identification of Relays
  370
- Wiring Circuit Diagram
  372

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