Triumph Trophy Trail TR5T 500 c.c. Manuals

Manuals and User Guides for Triumph Trophy Trail TR5T 500 c.c.. We have 1 Triumph Trophy Trail TR5T 500 c.c. manual available for free PDF download: Workshop Manual

Triumph Trophy Trail TR5T 500 c.c. Workshop Manual (175 pages)

Twin Cylinder

Brand: Triumph | Category: Motorcycle | Size: 5.02 MB

Engine and Frame Numbers
3
Correspondence
4
Technical Advice
4
Replacement Parts
4
Repairs
4
Contents
5
General Data
7
Lubrication System
8
Frame and Fittings
13
Gear Ratio Calculations
16
Engine Timing Disc
17
Routine Lubrication
20
Recommended Lubricants
21
Engine Lubrication System
23
Changing the Engine Oil and Cleaning the Oil Filters
23
Oil Pressure
24
Stripping and Reassembling the Oil Pressure Release Valve
25
Stripping and Reassembling the Oil Pump
25
Removing and Replacing the Oil Pipe Junction Block
26
Removing and Replacing the Rocker Oil Feed Pipe
27
Contact Breaker Lubrication
27
Gearbox Lubrication
28
Primary Chaincase Lubrication
29
Oil Filter Plug
29
Rear Chain Lubrication and Maintenance
30
Steering Head
31
Telescopic Fork
31
Wheel Bearings
31
Lubricating the Control Cables
32
Speedometer and Tachometer Cable
32
Engine
33
Exploded View of the Engine/Gearbox Unit
34
Engine Description
35
Removing and Replacing the Engine Unit
36
Removing and Replacing the Rocker Boxes
38
Inspecting the Push Rods
39
Stripping and Reassembling the Rocker Boxes
39
Oil Feed through Rocker Gear
40
Refitting the Rocker Spindle
40
Adjusting the Valve Rocker Clearances
41
Inlet Valves
41
Exhaust Valves
41
Carburetor - Description
42
Exploded View of Carburettor
42
Carburetor Description
43
Stripping and Reassembling the Carburetor
43
Inspecting Carburetor Components
44
Hints and Tips
45
Throttle Cable
45
Petrol Feed
45
Flooding
45
Tracing Faults
46
Carburetor Adjustments
46
Indications of Richness
46
Indications of Weakness
46
Correcting Mixture
47
Tuning the Carburetor
47
To Cure Richness
47
To Cure Weakness
47
Removing and Refitting the Cylinder Head Assembly
49
Removing and Refitting the Valves
50
Cylinder Head Bolt Tightening Sequence
50
Valve Components
50
Renewing the Valve Guides
51
Decarbonising
51
Reseating the Valves
52
Cutting the Valve Seats
52
Removing and Replacing the Cylinder Block and Tappets
53
Inspecting the Tappets and Guide Blocks
54
Renewing the Tappet Guide Blocks
54
Removing and Refitting the Pistons
55
Removing and Replacing the Piston Rings
55
Inspecting the Pistons and Cylinder Bores
56
Table of Suitable Rebore Sizes
57
Small End
57
Removing and Replacing the Contact Breaker
57
Removing and Replacing the Timing Cover
58
Ignition Contact Breaker
58
Timing Cover Oil Seals
58
Removing and Replacing the Oil Pump
59
Oil Seal Protector in Position
59
Extracting and Refitting the Valve Timing Pinions
60
Procedure When Using D2213/D2217
60
Crankshaft Pinion
60
Valve Timing
61
Ignition Timing - Initial Procedure
61
Ignition Timing Using a Stroboscopic Light
62
Removing and Replacing the Camshafts Only
63
Dismantling and Reassembling the Crankcase Assembly
64
Parting the Crankcase Halves
64
Stripping and Reassembling the Crankshaft Assembly
65
Refitting the Connecting Rods
67
Inspecting the Crankcase Components
68
Big End Bearings
68
Main Roller Bearing
68
Main Ball Bearing
68
Renewing the Main Bearings
69
Renewing the Camshaft Bushes
69
Removing and Replacing the Tachometer Drive Box
70
Tachometer Drive Gearbox
70
Tachometer Drive Gearbox Exploded
70
Removing and Replacing the Exhaust System
71
Transmission
73
Adjusting the Clutch Operating Mechanism
74
General Arrangement of Clutch and Shock Absorber Unit
74
Adjusting the Primary Chain Tension
75
Exploded View of Clutch Operating Mechanism
75
Adjusting the Chain Tensioner
75
Removing and Replacing the Primary Cover
76
Section through Primary Chaincase
76
Removing and Refitting the Clutch Plates
77
Inspecting the Clutch Plates and Springs
77
Unscrewing the Clutch Spring Nuts
77
Adjusting the Clutch Pressure Plate
78
Renewing Shock Absorber Rubbers
78
Replacing the Shock Absorber Rubbers
78
Removing and Replacing the Stator and Rotor
79
Showing Stator Location on Crankcase
79
Removing and Replacing the Clutch and Engine Sprockets
80
Inspection of the Transmission Components
82
Rear Chain Alterations and Repairs
83
Gearbox
85
Plan of Gearbox Components
86
Gearbox Description
87
Removing and Replacing the Gearbox Outer Cover Assembly
87
Dismantling/Reassembling the Clutch and Gearchange Operating Mechanism
88
Renewing the Gearchange Spindle Bush
89
Removal and Replacement of the Gearbox Inner Cover Assembly
89
Kickstarter Operating Mechanism
91
Dismantling and Rebuilding the Gearbox Inner Cover Assembly
91
Inspection of the Gearbox Components
92
Removing and Replacing the Gearbox High Gear
93
Renewing the Mainshaft and Layshaft Bearings
93
Renewing Gearbox Sprocket Without Dismantling the Gearbox
94
Mainshaft High Gear Bush
94
Layshaft
94
Sequence of Gearchanging
95
Second Gear
96
Third Gear
97
Fourth Gear
97
Frame
99
Frame Alignment
101
Showing Frame on Setting Table
101
Chainguard Removal
102
Rear Suspension Units
102
Cam Ring Adjustment
102
Exploded View of Suspension Unit
103
Swinging Arm Assembly Details
103
Removing the Swinging Arm
104
Swinging Arm Bearings
104
Checking Swinging Arm Alignment
104
Twin Seat
106
Prop Stand
106
Rear Brake Pedal
106
Mudguards
106
Air Cleaner
107
Removing and Replacing the Electrics Platform
107
Battery Carrier and Toolbox
108
Removal of Headlamp
109
Removing and Replacing Rear Stop Switch
109
Removing and Replacing the Horn
109
Petrol Tank Removal
110
Applying Transfers (Decals)
110
Centre Stand
111
Control Cable Replacement
111
Clutch Cable
111
Front Brake Cable
111
Telescopic Forks
113
Steering Head Adjustment
114
Renewing Head Races
115
Stripping and Reassembling the Fork Legs
115
Assembly of Bleed Valve
116
Removing the Oil Seal from the Fork Leg
117
Replacing the Oil Seal
117
Fork Assembly Details
118
Sectional View of Assembled Fork Leg
119
Fork Alignment
120
Hydraulic Damping
121
Wheels, Brakes and Tyres
123
Removing and Refitting the Front Wheel
124
Removing and Refitting the Front Wheel Bearings
124
Stripping and Reassembling the Front Brake Single Leading Shoe Type
125
Stripping and Reassembling Rear Brake
126
Rear Wheel Removal and Replacement
126
Removing and Replacing Rear Wheel Bearings
127
Brake Adjustment
128
Rear Chain Adjustment
129
Renewing Brake Linings
129
Wheel Building
130
Wheel Balancing
131
Wheel Alignment
131
Braking Performance Data
132
Removing and Refitting Tyres
133
Refitting the Tyre
133
Security Bolts
134
Tyre Maintenance
135
Tyre Pressures
136
Electrical System
137
Battery Inspection and Maintenance
138
Routine Maintenance
139
Specific Gravity of Electrolyte for Filling the Battery
139
Maximum Permissible Electrolyte Temperature During Charge
139
Coil Ignition System
140
Checking the Low Tension Circuit for Continuity
140
Fault Finding in the Low Tension Circuit
140
Ignition Coils
141
Bench Testing an Ignition Coil
141
Contact Breakers
142
Checking the High Tension Circuit
142
Sparking Plugs
143
Charging System
144
Checking the D.C. Output at the Rectifier
145
Checking the Alternator Output
145
Rectifier Maintenance and Testing
145
Testing the Rectifier
146
Bench Testing the Rectifier
146
Checking the Charging Circuit for Continuity
147
Constructing a One-Ohm Load Resistor
147
Zener Diode Charge Control
148
Zener Diode Charging Regulator
149
Electric Horn
150
Tail and Stop Lamp Unit
150
Horn Adjustment
150
Direction Indicator Lamps
151
Ignition Switch
151
Other Light Units
151
Headlamp
152
Beam Adjustment
152
Capacitor Ignition
153
Identification of Capacitor Terminals
153
Storage Life of Model 2MC Capacitor
153
Fuses
154
Wiring and Installation
154
Exploded View of Fuse Holder Assembly
154
Wiring Diagram
157
Workshop Service Tools
159
Inches to Millimeters - Units
166
Decimals to Millimeters - Fractions
166
Fractions to Decimals and Millimeters
167
Millimetres to Inches - Units
168
Millimetres to Inches - Fractions
168
Drill Sizes
169
Wire Gauges
169
B.S.W. Screw Threads
170
B.S.F. Screw Threads
170
B.S.C. Screw Threads
171
B.A. Screw Threads
172
Foot Pounds to Kilogrametres
173
Miles to Kilometres
173
Pounds to Kilograms
173
Miles Per Gallon to Litres Per 100 Kilometres
173
Pints to Litres
174
Gallons to Litres
174

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Triumph Trophy Trail TR5T 500 c.c. Manuals

Triumph Trophy Trail TR5T 500 c.c. Workshop Manual (175 pages)

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