T300 Service Manual

,..
TROPHY
DAYTONA
DAYTONA SUPER 3
TRIDENT
SPRINT/SPORT/EXECUTIVE
TIGER
SPEED TRIPLE
THUNDERBIRD/SPORT
ADVENTURER
SERVICE
MANUAL
TROPHY
DAYTONA
DAYTONA SUPER 3
TRIDENT
SPRINT/SPORT/EXECUTIVE
TIGER
SPEED TRIPLE
THUNDERBIRD/SPORT
ADVENTURER
Motorcycle
Service Manual
CONTENTS
Introduction
General Information
Servicing
Cylinder Head
Clutch
Balancers
Crankshaft/Rods/Pistons
Transmission
Lubrication
Fuel System/Exhaust
Cooling System
Rear Suspension/Final Drive
Front Suspension/Steering
Brakes
Wheels/Tyres
Frame/Fairings
Electrical System/Ignition
Appendix
INTRODUCTION
INTRODUCTION
How to use this manual
This manual is designed primarily for use by trained

technicians in a properly equipped workshop.
However, it contains enough detail and basic
information to make it useful to the owner who desires
to perform his own basic maintenance and repair work.
The work can only be carried out if the owner has the
necessary hand and special service tools to complete
the job.
To assist in the use of this manual, the section title is

given at the top.
Each major section starts with a contents page, listing
the information contained in the section.
The individual steps comprising repair operations are
to be followed in the sequence in which they appear.
A basic knowledge of mechanics, including the proper

use of tools and workshop procedures is necessary in
order to carry out maintenance and repair work.
satisfactorily. Whenever the owner has insufficient
experience or doubts his ability to do the work, all
adjustments, maintenance, and repair work must be
undertaken by an authorised Triumph Dealer.
Adjustment and repair operations include reference to

Service Tool numbers and the associated illustration
depicts the tool.
Where usage is not obvious the tool is shown in use.
Adjustment and repair operations also include
reference to wear limits, relevant data, torque figures,
specialist information and useful assembly details.
In order to perform the work efficiently and to avoid

costly mistakes, read the text and thoroughly
familiarise yourself with procedures before starting
work.
Particularly important information is presented in the

following form:
All work should be performed with great care and in a

clean working area with adequate lighting.
WARNING:
This
warning
symbol
identifies
special
instructions
or
procedures which, if not correctly followed, could
result in personal injury, or loss of life.
Always use the correct special service tools or

equipment specified. Under no circumstances use
makeshift tools or equipment since the use of
substitutes may adversely affect safe operation.
1,\,
~
Where accurate measurements are required, they can

only be made using calibrated, precision instruments.
CAUTION: This caution symbol identifies

special instructions or procedures
which, if not strictly observed, could result in
damage to or destruction of equipment.
For the duration of the warranty period, all repairs and

scheduled maintenance must be performed by an
authorised Triumph Dealer.
NOTE:
To maximise the life of your Motorcycle:

Accurately follow the maintenance requirements of
the Periodic Maintenance Chart in the Service
Manual.
Do not allow problems to develop. Investigate
unusual noises and changes in the riding
characteristics of the motorcycle. Rectify all
problems as soon as possible (immediately if
safety related).
Use only Triumph Motorcycle Parts as listed in the
parts catalogue/parts microfiche.
Follow the procedures in this manual carefully and
do not take short cuts.
Keep complete records of maintenance and repair
with dates and any new parts installed.
Use only approved lubricants, as specified in the
Owner's Handbook, in the maintenance of the
motorcycle.
ii
This note symbol indicates points of particular

interest for more efficient and convenient
operation.
INTRODUCTION
ASBESTOS
REFERENCES
This warning may apply to
any
of
the
following
components
or
any
assembly containing one or
more of these components:-
WARNING
CONTAINS
ASBESTOS
Breathing asbestos
dust is dangerous
to health
References
References to the left-hand or right-hand side given in
this manual are made when viewing the motorcycle
from the rear.
Brake Shoes or Pads
Operations covered in this manual do not always

include reference to testing the motorcycle after repair.
It is essential that work is inspected and tested after
completion and if necessary a road test of the
motorcycle is carried out particularly where safety
related items are concerned.
Clutch Friction Material

Gaskets
Insulators
Follow safety
instructions
Dimensions
SAFETY INSTRUCTIONS
Operate if possible out of doors or in a well

ventilated place.
Preferably use hand tools or low speed tools

equipped with an appropriate dust extraction
facility.
Dampen dust and place in a properly closed

receptacle. Dispose of the closed receptacle
safely.
Never use an
components
The dimensions quoted are to design engineering

specification with service limits where applicable.
During the period of running-in from new, certain
adjustments may vary from the specification figures
given in this manual. These will be reset by the Dealer
at the After Sales Service, and thereafter should be
maintained at the figures specified in this manual.
airline to blow dust from
REPAIRS AND REPLACEMENTS

Before removal and disassembly, thoroughly clean the
motorcycle. Any dirt entering the engine or other parts
will work as an abrasive and shorten the life of the
motorcycle. Particular attention should be paid when
installing a new part, that any dust or metal filings are
cleared from the immediate area.
TAMPERING WITH NOISE CONTROL SYSTEM

PROHIBITED
Owners are warned that the law may prohibit:
(a)
(b)
The removal or rendering inoperative by any

person other than for purposes of maintenance,
repair or replacement, of any device or element
of design incorporated into any new vehicle for
the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in
use; and
Force
Common sense should dictate how much force is
necessary in assembly and disassembly. If a part
seems especially difficult to remove or install, stop and
examine what may be causing the problem. Never
lever a component as this will cause damage both to
the component itself and to the surface being levered
against.
the use of the vehicle after such device or

element of design has been removed or rendered
inoperative by any person.
Whenever tapping to aid removal of an item is

necessary, tap lightly using a hide or plastic faced
mallet.
iii
INTRODUCTION
Edges
Watch for sharp edges, especially during engine
disassembly and assembly. Protect the hands with
industrial quality gloves when lifting the engine or
turning it over.
When replacement parts are required, it is essential
that only genuine Triumph parts are used.
Safety features and corrosion prevention treatments
embodied in the motorcycle may be impaired if other
than genuine Triumph parts are fitted. In certain
territories, legislation prohibits the fitting of parts not to
the manufacturer's specification.
Tightening procedure
Generally, when installing a part with several bolts,
nuts or screws, they should all be started in their holes
and tightened to a snug fit, evenly and in a cross
pattern. This is to avoid distortion of the part and/or
causing gas or oil leakage. Conversely, bolts, nuts, or
screws, should all be loosened (in sequence if
specified) by about a quarter of turn and then
removed.
Where there is a tightening sequence specified in this
Service Manual, the bolts, nuts, or screws must be
tightened in the order and by the method indicated.
Torque wrench setting figures given in this Manual
must be observed. The torque tools used must be of
accurate calibration.
Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during
removal it must be renewed. This applies particularly
to micro-encapsulated fixings which must always be
replaced if disturbed. Where necessary, the text in this
manual will indicate where such a fixing is used.
iv
General Information
CONTENTS
General precautions and fitting instructions
Ignition system safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dangerous substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health protection precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental protection precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jacking and lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions against damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine coolant caps and plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joints and joint faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gaskets, 0-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid gasket, non-permanent locking agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting a split pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circlips, retaining rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self locking nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encapsulated bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil and grease seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
1.2
1.2
1.2
1.3
1.3
1.4
1.4
1 .4
1.4
1.5
1 .5
1.5
1.5
1 .5
1.6
1.6
1.6
1.6
1.6
1.6
1.6
1.6
Fuel handling precautions

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Petrol- gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7
1.7
1.7
1.7
Electrical precautions
Battery disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease for electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disciplines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8
1.8
1.8
1.9
1.9
1 .9
1.9
1 .9
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 .1 0
Full Specification -Trophy 1200, Trophy 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 .13
Full Specification- Daytona 1000, Daytona 750
1.17
Full Specification - Daytona 1200, Daytona 900
1.21
Full Specification - Daytona Super 3 & Speed Triple
1.25
Full Specification- Trident I Sprint 900, Trident 750
1.29
Full Specification- Thunderbird Sport 900, Thunderbird/Adventurer 900 . . . . . . . .
1.33
Full Specification -Tiger 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.37
Torques ......................... .'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 .41
1.1
1 GENERAL INFORMATION
IGNITION SYSTEM SAFETY
PRECAUTIONS
ENGINE OILS
WARNING: The oil may be hot to the

touch. Contact with hot oil may cause the
skin to be scalded or burned.
WARNING:
The ignition system
produces extremely high voltages. Do
not touch any part of the ignition system or any
cables while the engine is running.
WARNING:
Prolonged or repeated
contact with engine oil can lead to skin
dryness, irritation and dermatitis. In addition used
engine
oil
contains
potentially
harmful
contaminants which can cause cancer. Wear
suitable clothing and avoid skin contact.
An electric shock caused by contact with the

ignition system may lead to illness, injury or death.
WARNING:
Wearers of surgically
implanted heart pacemaker devices
should not be in close proximity to ignition circuits
and or diagnostic equipment.
Health Protection Precautions
The ignition system and any diagnostic equipment

may interrupt the normal operation of such
devices causing illness or death.
DANGEROUS SUBSTANCES
WARNING:
Many liquids and other
substances used in motor vehicles are
poisonous and should under no circumstances be
consumed and should, as far as possible, be kept
from contact with the skin. These substances
among others include acid, anti-freeze, asbestos,
brake fluid, fuel, lubricants, and various
adhesives. Always pay close attention to the
instructions printed on labels and obey the
instructions contained within. These instructions
are included for your safety and well being.
NEVER DISREGARD THESE INSTRUCTIONS!
Flouroelastomers
Do not put oily rags in pockets.
Overalls must be cleaned regularly. Discard

heavily soiled clothing and oil impregnated
footwear.
First aid treatment should be obtained

immediately for open cuts and wounds. Always
be aware of who your nearest first aider is and
where the medical facilities are kept.
Use barrier creams, applying before each work

period to protect the skin from the effects of oil
and grease and, to aid removal of the same after
completing work.
Wash with soap and water to ensure all oil is

removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.
Do not use petrol, kerosene, diesel fuel, gas oil,

thinners or solvents for cleaning skin.
If skin disorders develop, obtain medical advice

without delay.
Where practicable, degrease components prior to

handling.
WARNING: Flouroelastomer material is

used in the manufacture of the valve stem
oil seals in Triumph motorcycles.
In fire conditions involving temperatures greater
than 315C this material will decompose and can
then be potentially hazardous. Highly toxic and
corrosive decomposition products, including
hydrogen flouride, carbonyl flouride, flourinated
olefins and carbon monoxide can be generated
and will be present in fumes from fires.
In the presence of any water or humidity hydrogen
flouride may dissolve to form extremely corrosive
liquid hydroflouric acid.
If such conditions exist, do not touch the material
and avoid all skin contact. Skin contact with liquid
or decomposition residues can cause painful and
penetrating
burns
leading to permanent,
irreversible skin and tissue damage.
Avoid prolonged and repeated contact with oils,

particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
WARNING: Any risk of eye injury must be

avoided. Always wear eye protection
when using a hammer, air line, cleaning agent or
where there is ANY risk of flying debris or
chemical splashing
1.2
GENERAL INFORMATION 1
ENVIRONMENTAL PROTECTION
PRECAUTIONS
WARNING: If there has been an

appreciable drop in the level of the fluid in
either brake fluid reservoir, consult your
authorized Triumph Dealer for advice before
riding.
'f'
CAUTION: Do not pour oil on the ground,

down sewers or drains, or into water
courses. To prevent pollution of water courses
etc., dispose of used oil sensibly. If in doubt
contact your local authority.
If the brake lever or pedal feels soft when it is

applied, or if the lever/pedal travel becomes
excessive, there may be air in the brake lines or the
brake may be defective.
It is dangerous to operate the motorcycle under
such conditions and remedial action must be
taken by your authorized Triumph Dealer before
riding the motorcycle.
Failure to take remedial action may reduce braking
efficiency leading to an accident.
Burning of used engine oil in small space heaters or

boilers can be recommended only for units of
approved design. If in doubt check with the appropriate
local authority and/or manufacturer of the approved
appliance.
Dispose of used oil and used filters through authorised
waste disposal contractors, to licensed waste disposal
sites, or to the waste oil reclamation trade. If in doubt,
contact the Local Authority for advice on disposal
facilities.
WARNING:
Use
only
D.O.T.
4
specification brake fluid as listed in the
general information section of this manual. The
use of brake fluids other than those D.O.T. 4 fluids
listed in the general information section may
reduce the efficiency of the braking system
leading to an accident.
BRAKES
WARNING: Brake fluid is hygroscopic

which means it will absorb moisture from
the air. The absorbed moisture will greatly reduce
the boiling point of the brake fluid causing a
reduction in braking efficiency.
Failure to change the brake fluid at the interval

specified in the periodic maintenance chart may
reduce braking efficiency resulting in an accident.
WARNING: Never use mineral based

grease in any part of the braking system
or in any area where contact with the braking
system is possible. Mineral based grease will
damage the hydraulic seals in the calipers and
master cylinders.
Replace brake fluid in line with the Periodic

Maintenance chart. A dangerous riding condition
could result if this important maintenance item is
neglected!
Do not spill brake fluid onto any area of the
bodywork as this will damage any painted or
plastic surface.
Damage caused by contact with mineral based

grease may reduce braking efficiency resulting in
an accident.
Always use new brake fluid from a sealed

container and never use fluid from an unsealed
container or from one which has been previously
opened.
Do not mix different brands of fluid. Check for fluid
leakage around brake fittings, seals and joints.
Check regularly for brake hose damage.
FAILURE TO OBSERVE ANY OF THE ABOVE
WARNINGS MAY REDUCE BRAKING EFFICIENCY
LEADING TO AN ACCIDENT.
1.3
SAFETY INSTRUCTIONS
CAUTION:
The coolant anti-freeze
contains a corrosion inhibitor which
helps prevent damage to the metal surfaces inside
the cooling system. Without this inhibitor, the
coolant would 'attack' the metals and the resulting
corrosion would cause blockages in the cooling
system leading to engine overheating and
damage. Always use the correct anti-freeze as
specified in the Owner's Handbook. Never use a
methanol based anti-freeze as this does not
contain the required corrosion inhibition
properties.
Jacking and lifting
Always ensure that any lifting apparatus

has adequate load and safety capacity for
the weight to be lifted. Ensure the motorcycle is
well supported to prevent any possibility of the
machine falling prior to lifting or jacking.
Never rely on a single means of support when
working with the motorcycle. Use additional safety
supports.
Do not leave tools, lifting equipment, spilt oil, etc.

in a place where they could become a hazard to
health. Always work in a clean, tidy area and put all
tools away when the work is finished.
CAUTION: Distilled water must be used

with the anti-freeze (see specification for
antifreeze) in the cooling system.
If hard water is used in the system, it causes scale

accumulation in the water passages, and
considerably reduces the efficiency of the cooling
system. Reduced cooling system efficiency may
lead to the engine overheating and suffering
severe damage.
Precautions against damage

Avoid spilling brake fluid or battery acid on any part of
the bodywork. Wash spillages off with water
immediately.
Cleaning components
Disconnect the battery earth lead before starting work,

see ELECTRICAL PRECAUTIONS.
A high flash-point solvent is recommended to reduce

fire hazard.
Always use the recommended service tool where

specified.
Always follow container directions regarding the use of

any solvent.
Protect exposed bearing and sealing surfaces, and

screw threads from damage.
Always use the recommended cleaning agent or

equivalent.
Engine Coolant
Do not use degreasing equipment for components

containing items which could be damaged by the use
of this process. Whenever possible, clean components
and the area surrounding them before removal.
Always observe scrupulous cleanliness when cleaning
dismantled components.
WARNING: Coolant mixture which

contains anti freeze and corrosion
inhibitors contains toxic chemicals which are
harmful to the human body.
Never swallow
anti-freeze or any of the motorcycle coolant.
WARNING: Do not remove the radiator

cap when the engine is hot. When the
engine is hot, the coolant inside the radiator is hot
and also under pressure.
Contact with the
pressurised coolant will cause scalds and skin
damage.
1.4
Lubrication
Liquid gasket, non-permanent locking

agent
Engine wear is generally at its maximum while the

engine is warming up and before all the rubbing
surfaces have an adequate lubricative film. During
assembly, oil or grease (whichever is more suitable)
should be applied to any rubbing surface which has
lost its lubricative film. Old grease and dirty oil should
be cleaned off. This is because used lubricants will
have lost some lubricative qualities and may contain
abrasive foreign particles.
Follow manufacturer's directions for cleaning and

preparing surfaces where these compounds will be
used. Apply sparingly as excessive amounts of sealer
may block engine oil passages and cause serious
damage.
Prior to reassembly, blow through any pipes, channels
or crevices with compressed air.
Use recommended lubricants. Some oils and greases

in particular should be used only in certain applications
and may be harmful if used in an application for which
they are not intended. This manual makes reference to
molybdenum disulphide grease in the assembly of
certain engine and chassis parts. Always check
manufacturer recommendations before using such
special lubricants.
WARNING: To prevent injury, always use
~ eye, face and ear protection when using
compressed air. Always wear protective gloves if

the compressed air is to be directed in proximity to
the skin.
Screw threads
Metric threads to ISO standard are used.
Joints and joint faces
Damaged nuts, bolts and screws must always be

discarded.
Assemble joints dry unless otherwise specified in this

Manual.
Castellated nuts must not be slackened back to accept

a split-pin, except in those recommended cases when
this forms part of an adjustment.
If gaskets and/or jointing compound is recommended

for use; remove all traces of old jointing material prior
to reassembly. Do not use a tool which will damage the
joint faces and smooth out any scratches or burrs on
the joint faces using an oil stone. Do not allow dirt or
jointing material to enter any tapped holes.
Do not allow oil or grease to enter blind threaded

holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can affect
the torque reading.
Gaskets, 0-rings
Do not re-use a gasket or 0-ring once it has been in
service. The mating surfaces around the gasket should
be free of foreign matter and perfectly smooth to avoid
oil or compression leaks.
1.5
Locking devices
Oil and grease seals
Always release locking tabs and fit new locking

washers, do not re-use locking tabs.
Replace any oil or grease seals that are removed.

Removal will cause damage to an oil seal which, if
re-used, would cause an oil leak.
Fitting a split pin
Ensure the surface on which the new seal is to run is

free of burrs or scratches. Renew the component if the
original sealing surface cannot be completely restored.
Always fit new split-pins of the correct size for the hole
in the bolt or stud. Do not slacken back castle nuts
when fitting split pin.
Protect the seal from any surface which could cause

damage over which it has to pass when being fitted.
Use a protective sleeve or tape to cover the relevant
surface and avoid touching the sealing lip.
Always fit new roll pins of an interference fit in the

hole.
Circlips, retaining rings
Lubricate the sealing lips with a recommended

lubricant. This will help to prevent damage in initial
use. On dual lipped seals, smear the area between the
lips with grease.
Replace any circlips and retaining rings that are

removed. Removal weakens and deforms circlips
causing looseness in the circlip groove. When
installing circlips and retaining rings, take care to
compress or expand them only enough to install them.
When pressing in a seal which has manufacturer's

marks, press in with the marks facing out.
Always use the correct replacement circlip as

recommended in the Triumph parts catalogue.
Seals must be pressed into place using a suitable

driver. Use of improper tools will damage the seal.
Self locking nuts
Press
Self-locking nuts can be re-used, providing resistance

can be felt when the locking portion passes over the
thread of the bolt or stud.
A part installed using a press or driver, such as a

wheel bearing, should first be coated with oil on its
outer or inner circumference so that it will locate
smoothly.
DO NOT re-use self-locking nuts in critical locations,

e.g. suspension components. Always use the correct
replacement self-locking nut.
Ball bearing
When installing a ball bearing, the bearing race which
is an interference fit should be pushed by a suitable
driver. This prevents severe stress or damage to the
load carrying components. Press a ball bearing until it
touches the shoulder in the bore or on the shaft.
Encapsulated bolt
An encapsulated bolt can be identified by a coloured
section of thread which is treated with a locking agent.
Press or drift seals to the depth of its housing, with the

sealing lip facing the lubricant to be retained if the
housing is shouldered, or flush with the face of the
housing where no shoulder is provided.
Unless a specified repair procedure states otherwise,

encapsulated bolts cannot be reused and MUST be
replaced if disturbed or removed.
WARNING:
Failure to replace an
encapsulated bolt could lead to a
dangerous riding condition.
Always replace
encapsulated bolts.
1.6
FUEL HANDLING PRECAUTIONS
WARNING: No one should be permitted

to repair components associated with
petrol/gasoline without first having specialist
training on the fire hazards which may be created
by incorrect installation and repair of items
associated with petrol/gasoline.
Repairs carried out by untrained personnel could
bring about a safety hazard leading to a risk of
personal injury.
General
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is issued
tor basic guidance only and, if in doubt, appropriate
enquiries should be made of your local Fire Officer.
A
.a.
WARNING:
Draining or extraction of
petrol/gasoline from a vehicle fuel tank
must be carried out in a well ventilated area.
The receptacle used to contain the petrol/ gasoline
must be more than adequate for the full amount of
fuel to be extracted or drained. The receptacle
should be clearly marked with its contents, and
placed in a safe storage area which meets the
requirements of local authority regulations.
When petrol/gasoline has been extracted or
drained from a fuel tank, the precautions
governing naked lights and ignition sources
should be maintained .
Failure to observe any of the above warnings could
bring about a safety hazard leading to a risk of
personal injury.
Petrol- Gasoline
When petrol (gasoline) evaporates it produces 150
times its own volume in vapour which when diluted
with air becomes a readily ignitable mixture. The
vapour is heavier than air and will always fall to the
lowest level. It can readily be distributed throughout a
workshop by air currents, consequently, even a small
spillage of petrol (gasoline) is potentially very
dangerous.
A
.a.
WARNING: Petrol (gasoline) is highly

flammable and can be explosive under
certain conditions. When opening the fuel tank
cap always observe all the following items;
Turn the motorcycle ignition switch OFF.
Do not smoke.
Fuel tank removal
Always have a fire extinguisher containing FOAM,

C02, HALON or POWDER close at hand when
handling or draining fuel or fuel systems. Fire
extinguishers must also be present in areas where
fuel is stored.
Fuel tanks should have a 'PETROL (GASOLINE)

VAPOUR' warning label attached to them as soon as
they are removed from the vehicle. In all cases, they
must be stored in a secured, marked area.
Always disconnect the vehicle battery, negative

(black) lead first, before carrying out dismantling
or draining work on a fuel system.
Chassis repairs
Whenever petrol (gasoline) is being handled,

drained or stored or when fuel systems are being
dismantled, make sure the area is well ventilated.
All potential forms of ignition must be
extinguished or removed (this includes any
appliance with a pilot light). Any leadlamps must
be flameproof and kept clear of any fuel spillage.
A
.a.
WARNING: If the motorcycle is involved

in an accident or collision it must be taken
to an authorised Triumph dealer for repair or
inspection. Any accident can cause damage to the
motorcycle which, if not correctly repaired, may
cause a second accident which may result in injury
or death.
Warning notices must be posted at a safe distance

from the site of the work to warn others that petrol
is being openly handled. The notice must instruct
the reader of the precautions which must be taken.
The frame must not be modified as any

modification to the frame such as welding or
drilling may weaken the frame resulting in an
accident.
Failure to observe any of the above warnings may

lead to a fire hazard which could result in personal
injury.
1.7
ELECTRICAL PRECAUTIONS
Connectors and Harness -The engine of a motorcycle

is a particularly hostile environment for electrical
components and connectors. Always ensure these
items are dry and oil free before disconnecting and
connecting test equipment. Never force connectors
apart either by using tools or by pulling on the wiring
itself. Always ensure locking mechanisms are
disengaged before removal and note the orientation to
enable correct reconnection. Ensure that any
protective covers and substances are replaced if
disturbed.
The following guidelines are intended to ensure the

safety of the operator whilst preventing damage to the
electrical and electronic components fitted to the
motorcycle. Where necessary, specific precautions are
detailed in the relevant sections of this manual which
should be referred to prior to commencing repair
operations.
Equipment - Prior to commencing any test procedure
on the motorcycle ensure that the relevant test
equipment is working correctly and any harness or
connectors are in good condition, in particular mains
leads and plugs.
Having confirmed a component to be faulty, switch off

the ignition and disconnect the battery negative (black)
lead first. Remove the component and support the
disconnected harness. When replacing the component
keep oily hands away from electrical connection areas
and push connectors home until any locking
mechanism becomes fully engaged.
WARNING:
The ignition system
Battery disconnecting

Before disconnecting the battery, switch off all

electrical equipment.
WARNING:
WARNING: To prevent the risk of a

battery exploding and to prevent damage
to electrical components ALWAYS disconnect the
battery negative (black) lead first.
When
reconnecting the battery, always connect the
positive (red) lead first, then the negative (black)
lead. Always disconnect the battery when working
on any part of the electrical system.
Failure to observe the above warnings may lead to
electrical damage and a fire hazard which could
cause personal injury.

WARNING: The battery contains harmful

materials. Always keep children away
from the battery whether or not it is fitted in the
motorcycle.
Do not jump start the battery, touch the battery
cables together or reverse the polarity of the
cables as any of these actions may cause a spark
which would ignite battery gasses causing a risk of
personal injury.
Always ensure that battery leads are routed correctly and

are not close to any potential chafing points.
Grease for electrical connectors
High Voltage Circuits- Whenever disconnecting live

H.T. circuits always use insulated pliers and never
allow the open end of the H.T. lead to come into
contact with other components. Exercise caution when
measuring the voltage on the coil terminals while the
engine is running, high voltage spikes can occur on
these terminals.
All connectors are protected against corrosion by the

application of a special spray during production.
Should connectors be disturbed in service, repaired or
replaced, use 'Action Can AC90' or similar to
re-protect the connection.
NOTE:
; .8
The use of other sprays should be avoided as

they can migrate into relays, switches etc.
contaminating the contacts and leading to
intermittent operation or failure.
Disciplines
WARNING:
Always have Triumph
approved
parts,
accessories
and
conversions fitted by an authorised Triumph
dealer. The fitment of parts, accessories and
conversions by a dealer who is not an authorised
Triumph dealer may affect the handling, stability or
other aspects of the motorcycle operation which
may result in an accident causing serious injury or
death.
Switch off the ignition prior to making any connection

or disconnection in the system. An electrical surge can
be caused by disconnecting 'live' connections which
can damage electronic components.
Ensure hands and work surfaces are clean and free of
grease, swart, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
WARNING:
Always have Triumph
approved
parts,
accessories
and
conversions fitted by a trained technician. To
ensure that a trained technician is used, have an
authorised Triumph dealer fit the parts. The
fitment of parts, accessories and conversions by
personnel other than a trained technician at an
authorised Triumph dealer may affect the
handling, stability or other aspects of the
motorcycle operation which may result in an
accident causing serious injury or death.
Prior to commencing any test, and periodically during

any test, touch a good earth to discharge body static.
This is because some electronic components are
vulnerable to static electricity.
Electrical wires
All the electrical wires are either single-colour or
two-colour and, with only a few exceptions, must be
connected to wires of the same colour. On any of the
two-colour wires there is a greater amount of one
colour and a lesser amount of a second colour. A
two-colour wire is identified by first the primary colour
and then the secondary colour. For example, a yellow
wire with thin red stripes is referred to as a 'yellow/red'
wire; it would be a 'red/yellow' wire if the colours were
reversed to make red the main colour.
Service data
The service data listed in this manual gives
dimensions and specifications for brand new, original
parts. Where it is permissible to allow a part to exceed
these figures, then the service limit is given.
The terms of the motorcycle warranty will be
invalidated by the fitting of other than genuine Triumph
parts.
Inspection
Disassembled parts should be visually inspected and
replaced with new ones if there are any signs of the
following:
All genuine Triumph parts have the full backing of the

motorcycle warranty. Triumph dealers are obliged to
supply only genuine Triumph recommended parts.
Abrasions, cracks, hardening, warping, bending,

dents, scratches, colour changes, deterioration,
seizure or damage of any nature.
Specification
Triumph are constantly seeking to improve the
specification, design and production of their
motorcycles and alterations take place accordingly.
Replacement Parts
WARNING: Only Triumph approved parts
should be used to service, repair or
convert Triumph motorcycles. To ensure that
Triumph approved parts are used, always order
parts, accessories and conversions from an
authorised Triumph dealer.
The fitting of
non-approved parts, accessories or conversions
may adversely affect the handling, stability or
other aspects of the motorcycle operation which
may result in an accident causing serious injury or
death.
While every effort has been made to ensure the

accuracy of this Manual, it should not be regarded as
an infallible guide to current specifications of any
particular motorcycle.
Authorised Triumph Dealers are not agents of Triumph
and have no authority to bind the manufacturer by any
expressed or implied undertaking or representation.
1.9
Service tools and garage equipment
Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical
components in a practical manner without causing damage. Some operations in this Service Manual cannot be
carried out without the aid of the relevant service tools. Where this is the case, the tools required will be described
during the procedure.
Special service tools:3880012 -Valve Shim Removal Tool
3880040 -Alternator Shaft Locking Jig
3880015 - Carburettor Adjustment Tool
3880205- Drive Chain Service (3 tools)
3880025- Clutch Anti-rotation Tool
3880060- Spindle Aligner
1.10
3880065 - Head Bearing Fitment
3880085 - Fork Assembler
3880070 - Wheel Bearing Fitment
3880090 - Fork Service
3880075 - Wheel Bearing Fitment
3880095- Oil Pressure Adapter
3880105 - Angular Torque Gauge
3880080 - Fork Seal/Bearing Drift
3880120/3880125 - Float Level Gauge
1.11
3880130 - Allen Socket
3880155- Trim Button Fitment
3880160 - Fork Filler/Evacuator
3880139 - Tool Board
3880170 - Ignition Diagnostic Kit
3880140 - Head Race Adjusters
3880185- Six Piston CaliperPiston Retainer
3880145- Screwdriver, Thunderbird Tank

Badge
1.12
Full Specification
TROPHY 1200
Engine Type ................... .

Arrangement ................... .
Displacement ......................
Bore x Stroke ......................
Compression Ratio .................
Cylinder Numbering ................
Firing order ........................
Max. Power ........................
Max. Torque .......................
4 Cylinder 16 Valve DOHC

Transverse In-Line
Transverse In-Line
1180 cc
885 cc
76 mm x 65 mm
76 mm x 65 mm
10.6 : 1
10.6 : 1
Left to Right (No.4 adjacent to camchain) Left to Right (No.3 adjacent to camchain)
1-2-4-3
1-2-3
Refer to the owner's handbook for the model, model year and country required.
.
.
.
.
.
.
.
Cylinder Head
Valve Head Dia .............. ln. . . . .
Ex ....
ln .....
Valve Lift
Ex ....
Valve Stem Dia .............. ln. . . . .
Ex. . ..
Valve Guide Bore Dia. . . . . . . . . . . . . . . . .
Valve Stem to Guide Clearance ln. . . . .
Ex. . . .
Valve Seat Width (in head) ............
Valve Seat Width (valve) .............
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner ..
Outer .
Valve Clearance . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Bucket Dia.
Blue ..
Red ...
White .
Valve Bucket Bore Dia ................
Valve Timing 1 . . . . . . Inlet . . . Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Dia ................
Camshaft Journal Clearance . . . . . . . . . .
Camshaft Journal Bore Dia ............
Camshaft End Float .................
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Camchain Tensioner Spring Free Length
Clutch/Primary Drive
Primary Drive . . . . . . Type . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . . . .
Friction Plate Thickness (new) . . . . . . . .
Friction Plate Thickness (service limit) . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Clutch Shim Clearance ...............
Clutch Master Cylinder Bore Dia. . . . . . .
Clutch Slave Cylinder Bore Dia. . . . . . . .
Recommended Clutch Fluid . . . . . . . . . . .
TROPHY 900
30.0 mm
26.0 mm
7.1 mm
7.0 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
15 kg min. at 24.0 mm
0.15 mm/0.1 0 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
1o BTDC (@ 1.0 mm Lift)
30 ABDC (@ 1.0 mm Lift)
211 a
28 BBDC (@ 1.0 mm Lift)
2 ATDC (@ 1.0 mm Lift)
210
21 o BTDC (@ 1.0 mm Lift)
251 o
51 o BBDC (@ 1.0 mm Lift)
256
22.93 mm/22.90 mm
22.936 mm/22.923 mm (Outrigger)
0. 12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
251
256
211
210
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
Gear
1. 75 (1 05/60)
Wet Multi-plate
9
3.80mm - 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid
DOT 4
Gear
1.75 (105/60)
Wet Multi-plate
9
3.80mm - 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4
Valve Timing 1 - 108 PS 1200cc version and 98 PS 900cc versions.

1.13
TROPHY 1200
TROPHY 900
Piston Ring to Groove Clearance Top . .

Second
Piston Ring Groove Width
Top . .
Second
Oil ...
Piston Ring End Gap ......... Top . .
(new ring when fitted in bore)
Second
Oil . . .
Gudgeon Pin Bore Dia. In Piston . . . . . .
Gudgeon Pin Dia ....................
Connecting Rod Small End Dia ........
Connecting Rod Big End Side Clearance
Crankshaft Big End Journal Dia ........
Crankshaft Big End Bearing Clearance .
Crankshaft Main Journal Dia. . . . . . . . . .
Crankshaft Main Bearing Clearance . . . .
Crankshaft End Float . . . . . . . . . . . . . . . .
76.05 mm/76.03 mm Cyl. Nos. 1, 3 & 4

76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1, 3 & 4
75.98 mm/75.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.03 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)
76.05 mm/76.03 mm Cyl. Nos. 1 & 3

76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.98 mm/75.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.03 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)
Transmission
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GearRatios ................. 1st ...
2nd ..
3rd . .
4th ...
5th . . .
6th ...
Gear Selector Fork Thickness .........
Gear Selector Groove Width . . . . . . . . . .
Gear Selector Fork to Groove Clearance
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Drive Ratio . . . . . . . . . . . . . . . . . . . .
Chain Type . . . . . . . . . . . . . . . . . . . . . . . . .
No. of Links . . . . . . . . . . . . . . . . . . . . . . . . .
20 Link Length . . . . . . . . . . . . . . . . . . . . . .
Drive Chain Slack . . . . . . . . . . . . . . . . . .
Chain lubrication . . . . . . . . . . . . . . . . . . . .
6 Speed Constant Mesh

2.733(41/15)
2.733(41/15)
1.947(37/19)
1.947(37/19)
1.545 (34/22)
1.545 (34/22)
1.291 (31/24)
1.291 (31/24)
1.154 (30/26)
1.154 (30/26)
1.074 (29/27)
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 max.
0.55 max.
Chain
Chain
Variable according to model, model year and market designation
Regina 136 ORP
Regina 136 ORP
319 mm max.
319 mm max.
35.0- 40.0 mm
35.0- 40.0 mm
Mobil chain spray
Mobil chain spray
Full Specification
Piston/Crankshaft
Cylinder Bore Dia ............... .
Piston Dia. (at 90 to gudgeon pin)
Lubrication
Pressure Lubrication, Wet Sump
Oil Capacity (incl. filter) . . . . . . . . . . . . . . . 3. 75 litres
Recommended Oil . . . . . . . . . . . . . . . . . . . Semi synthetic 1Ow/40 oil meeting
specification AP\/SG
Oil Pressure (in main gallery) ......... 40.0 lb/in 2 min. (@ 80C Oil Temp.)
(@ 5000 rpm)
Oil Pump Rotor Tip Clearance ......... 0.15 mm (0.2 max.)
Oil Pump Body Clearance ............ 0.22 mm/0.15 mm (0.35 mm max.)
Oil Pump Rotor End Float . . . . . . . . . . . . 0.02 mm/0.007 (0.1 mm max.)
4.00 litres
Semi synthetic 1Ow/40 oil meeting
specification API/SG
40.0 \b/in2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
0.15 mm (0.2 max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)
Ignition System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Timing . . . . . Static . . . . . . . . . .
Idle . . . . . . . . . . . .
Max. Advance . . .
Electronic Rev-Limiter . . . . . . . . . . . . . . . .
Pick up Coil Air Gap . . . . . . . . . . . . . . . . .
Pick up Coil Resistance . . . . . . . . . . . . . .
Ignition Coil LT Resistance ............
Ignition Coil HT Resistance . . . . . . . . . . .
Spark Plug Type . . . . . . . . . . . . . . . . . . . .
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . .
Inductive Transistorised
'F' Mark on Rotor
5 BTDC @ 1000 rpm
26 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
'F' Mark on Rotor
5 BTDC @ 1000 rpm
29 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
1.14
Full Specification
TROPHY 1200
Fuel System
Fuel Type ......................... . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ..... . 25 Litres
Reserve Capacity .................. . 5 Litres
Low Level Warning Lamp ............ . 7 Litres
Fuel Tap .......................... . Vacuum Controlled, Auto Shut-off
Carburettors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIKUNI BST 36 mm Flat Slide CV
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm
50 rpm
TROPHY 900
Unleaded, 95 RON
(U.S. 89 CLC/AKI)
25 Litres
5 Litres
7 Litres
Vacuum Controlled, Auto Shut-off
MIKUNI BST 36 mm Flat Slide CV or
KEIHIN CVK 36 mm
1000 rpm 50 rpm
Cooling System
Coolant Mixture .....................
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . .
Freezing Point . . . . . . . . . . . . . . . . . . . . . .
Cooling System Capacity . . . . . . . . . . . . .
Radiator Cap Opening Pressure . . . . . . .
Thermostat Opening Temperature . . . . .
Cooling Fan Switch On Temperature . . .
50!50 Distilled Water/Anti-Freeze

Mobil Antifreeze
-35C
3.0 Litres
1.1 Bar
83C
99C
Suspension
Front Fork Travel ................... .
Recommended Fork Oil ............. .
Oil Level (without spring) ............ .
Rear Wheel Travel .................. .
Rear Suspension Bearing Grease .... .
150 mm
150 mm
Refer to chart in front suspension section for full details
126 mm
126 mm
Mobil Grease HP 222
Mobil Grease HP 222
Brakes
Front type ......................... .
(up to vin 4901 1200cc)
(up to vin 9082 900cc)
Caliper Piston Dia ................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
Recommended Fluid ................ .
Front type ......................... .

(from vin 4902 1200cc)
(from vin 9083 900cc)
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
Rear Type ......................... .
Caliper Piston Dia ...................
Disc Dia ...........................
Disc Thickness .....................
Disc Run-out Max...................
Master Cylinder ....................
Recommended Fluid ................
.
.
.
.
.
.
Hydraulically Actuated Two Piston

Sliding Calipers Operating on
Twin Solid Discs
2 x 27.0 mm
296.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
14.0 mm dia. Adjustable Lever
DOT4
Hydraulically Actuated Four Piston
Sliding Calipers Operating on Twin
Floating Discs
2 x 33.96 mm & 2 x 30.23 mm
310.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
DOT 4
Hydraulically Actuated Two Piston Sliding
Caliper Operating on Single Rigid
Rear Disc
2 x 27.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
14.0 mm dia. Remote Reservoir
DOT 4
1.15
50!50 Distilled Water/Anti-Freeze

Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99oC
Hydraulically Actuated Two Piston

Twin Solid Discs
2 x 27.0 mm
296.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
DOT4
Twin Floating Discs
2 x 33.96 mm & 2 x 30.23 mm
310.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
DOT 4
Hydraulically Actuated Two Piston Sliding
Rear Disc
2 x 27.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
DOT 4
Full Specification
TROPHY 1200
Wheels and Tyres

Front Wheel Rim Axial Run-out .
Front Wheel Rim Radial Run-out
Front Tyres . . . . . . . . . . . . . . . . . .
Front Tyre Pressure (cold) . . . . . . . . . . .
Front Tyre Tread Depth min. . .
Rear Wheel Rim Axial Run-out . . . . . . . .
Rear Wheel Rim Radial Run-out . . . . . .
Rear Tyres . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Tyre Pressure (cold) ............
Rear Tyre Tread Depth min........
TROPHY 900
0.5 mm
0.5 mm
0.8 mm
0.8 mm
Refer to the owner's handbook for approved lyres for each model year
2.5 kg/cm2
2.5 kg/cm2
2.0 mm
2.0 mm
0.5 mm
0.5 mm
0.8 mm
0.8 mm
Refer to the owner's handbook for approved lyres for each model year
2.9 kg/cm2
2.9 kg/cm2
2.0 mm- up to 80 mph (130 km/h)
2.0 mm- up to 80 mph (130 km/h)
3.0 mm- over 80 mph (130 km/h)
WARNING: Triumph motorcycles must not be operated above the legal road speed limit except in authorised
L===-~closed cours_e_c_o_nd_it_io_n_s_.---~-----~-----~---------Frame
Frame Type
Overall Length . . . . . . . . . . . . . . .
Overall Width . . . . . . . . . . . . . . . . . . . . . . .
Overall Height . . . . . . . . . . . . . . . . . . . . . .
Ground Clearance ..................
Wheelbase . . . . . . . .
Seat Height . . . . . . . . . . . . . . . . . . . . . . .
Steering Head Angle . . . . . . . . . . . . . . . . .
Trail ...............................
Dry Weight . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Payload to VIN 29155 ...........
Max. Payload from VIN 29156
Electrical Equipment
Battery Type . . . . . . . . . . . . . . . . . . .
Battery Rating . . . . . . . . . . . . . . . . . . . . . .
Alternator Rating . . . . . . . . . . . . . . . . . . .
Regulated Voltage . . . . . . . . . . . . . . .
Stator Coil Resistance . . . .
Rotor Coil Resistance . . . . . . . . . . . . . . . .
Slip Ring Dia. . . . . . . . . . . . . . . . . . . .
Brush Length .......................
Starter Motor Commutator Dia .........
Commutator Groove Depth ...........
Starter Brush Length . . . . . . . . . . . . . . . . .
Fuses (up to VIN 29155)
Headlight .......................... .
Tail Light .......................... .
Main .............................. .
Radiator Fan ....................... .
Clock! Alarm .................. .
lnline fuse (1995 on) Brake Light .....
Fuses (from VIN 29156)
Alternator, headlights ............... .
Alarm, clock, hazard warning, indicators
Cooling fan ........................ .
Auxiliary circuits .................... .
Engine start and run systems ........ .
Brake lights, horn, instruments ....... .
Instrument illumination .............. .
All circuits from ignition switch ........ .
Lights . . . . . . . . . . . . . Head Light ..... .
Parking Light ... .
Tail Light ...... .
Indicators ..... .
Large dia. high tensile steel spine,

stressed engine
2152 mm
760 mm
1270 mm
138 mm (158mm to vin 4901)
1490 mm
780 mm
27 from vertical
105 mm
Refer to owner's Handbook
181 kg
217 kg

stressed engine
2152 mm
760 mm
1270 mm
138 mm (158mm to vin 4901)
1490 mm
780mm
27 from vertical
105 mm
Refer to owner's Handbook
181 kg
217 kg
YUASA YB14L-A2
12V- 14AH
12V - 25A
14.5V at 5500 (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
YUASA YB14L-A2
12V- 14AH
12V- 25A
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A (10A to vin 4901)
10A
5A
10A
10A
30A
15A (10A to vin 4901)
10A
5A
30A
15A
15A
10A
15A
10A
05A
30A
60/55W H4 Halogen*
4W
21/5
10W (21W Japan)
30A
15A
15A
10A
15A
10A
05A
30A
60/55W H4 Halogen*
4W
21/5
10W (21W Japan)
* 1996 model year - 2x60/55W H4 Halogen
1.16
Full Specification
Engine Type .................... .
Arrangement .......................
Displacement ......................
Bore x Stroke ......................
Compression Ratio .................
Cylinder Numbering ................
Firing order ........................
Max. Power ........................
.
.
.
.
.
.
.
DAYTONA 1000
DAYTONA 750

Transverse In-Line
998 cc
76 mm x 55 mm
11.0:1
Left to Right (No.4 adjacent to camchain)
1-2-4-3
89.0 kW (121 PS model)@ 10500 rpm
73.5 kW (100 PS model)@ 9750 rpm

Transverse In-Line
748 cc
76 mm x 55 mm
11.0:1
1-2-3
71.3 kW (97.0 PS model)@ 9750 rpm
36.7 kW (50.0 PS model)@ 8000 rpm
19.8 kW (27.0 PS model) @ 6250 rpm
74.0 Nm (54.0 lbsf.ft) @ 8250 rpm
55.0 Nm (40.0 lbsf.ft) @ 5000 rpm
(50 PS model)
44.0 Nm (32.0 lbsf.ft) @ 2500 rpm
(27 PS model)
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . . 88.0 Nm (64.9 lbsf.ft) @ 8500 rpm

78.0 Nm (57.0 lbsf.ft) @ 7750 rpm
Cylinder Head
Valve Head Dia. . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Lift ................... ln .....
Ex ....
Valve Stem Dia .............. ln .....
Ex. . ..
Valve Guide Bore Dia .................
Valve Stem to Guide Clearance ln .....
Ex. . ..
Valve Seat Width (in head) . . . . . . . . . . . .
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner . .
Outer .
Valve Clearance ............. ln .....
Ex ....
Valve Bucket Dia. . .......... Blue ..
Red ...
White .
Valve Timing ....... Inlet ... Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Dia. . . . . . . . . . . . . . . .
Camshaft Journal Bore Dia............
Camshaft End Float . . . . . . . . . . . . . . . . .
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
Friction Plate Thickness (new) ........
Friction Plate Thickness (service limit) ..
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Clutch Master Cylinder Bore Dia .......
30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
251 o
256
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0. 03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
21 BTDC (@ 1.0 mm Lift)
251
256
22.93 mm/22.90 mm
0.12Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
Gear
1. 75 (1 05/60)
Wet Multi-plate
9
3.80mm- 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4
Gear
1.75 (1 05/60)
Wet Multi-plate
9
3.80mm- 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4
1.17
Full Specification
DAYTONA 1000
Piston/Crankshaft
Cylinder Bore Dia ..... .
DAYTONA 750
. . . . . . . . . 76.05 mm/76.03 mm Cyl. Nos. 1, 3 & 4

76.05 mm/76.04 mm Cyl. No.2
Piston Dia. (at 90 to gudgeon pin) .... 75.98 mm/75.96 mm Cyl. Nos. 1, 3 & 4
75.98 mm/75.97 mm Cyl. No. 2
Piston Ring to Groove Clearance Top .. 0.06 mm/0.02 mm
Second 0.06 mm/0.02 mm
Top . . 1.03 mm/1.01 mm
Oil ... 2.03 mm/2.01 mm
Piston Ring Eng Gap ..... .
Top . . 0.20 mm/0.41 mm
Oil . . . 0.29 mm/0.85 mm
Gudgeon Pin Bore Dia. In Piston
19.008 mm/19.002 mm
Gudgeon Pin Dia. . ........... .
19.000 mm/18.995 mm
Connecting Rod Small End Dia. . ..... . 19.034 mm/19.016 mm
Connecting Rod Big End Side Clearance 0.3 mm/0.15 mm (0.5 mm max.)
Crankshaft Big End Journal Dia ....... . 40.965 mm/40.951 mm
Crankshaft Big End Bearing Clearance . 0.066 mm/0.036 mm (0.1 mm max.)
Crankshaft Main Journal Dia. . ....... . 37.981 mm/37.965 mm
Crankshaft Main Bearing Clearance ... . 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float ............... . 0.20 mm/0.05 mm (0.4 mm max.)
76.05 mm/76.03 mm Cyl. Nos. 1 & 3

76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.98 mm/75.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1 .01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)
Transmission
Type ..................... .
Gear Ratios . .
. . . . . . . . . . . 1st ...
2nd ..
3rd ..
4th .. .
5th .. .
6th .. .
Gear Selector Fork Thickness ........ .
Gear Selector Groove Width ......... .
Final Drive ......................... .
Final Drive Ratio ................... .
Chain Type .................... .
No. of Links ........................ .
20 Link Length ......... .
Drive Chain Slack ........... .
Chain lubrication . . . . . . . . .......... .

2.733 (41/15)
1.947 (37/19)
1.545 (34/22)
1.291 (31/24)
1.154 (30/26)
1.07 4 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 max.
Chain
2.8 (48/17)
D.I.D. 50ZV ('0' Ring)
114 Endless
319 mm max.
35.0- 40.0 mm
Mobil chain spray

2.733 (41/15)
1.947 (37/19)
1.545 (34/22)
1.291 (31/24)
1.154 (30/26)
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 max.
Chain
2.7 (46/17)
D.I.D. 50ZV ('0' Ring)
112 Endless
319 mm max.
35.0- 40.0 mm
Mobil chain spray
Lubrication
Oil Capacity (incl. filter) . . . . . . . . . . . . . . . 3.5 litres
Recommended Oil . . . . . . . . . . . . . .
Oil Pressure (in main gallery) ......... 40.0 lb/in 2 min. (@ 80C Oil Temp.)
(@ 5000 rpm)
Oil Pump Rotor Tip Clearance ......... 0.15 mm (0.2 max.)
Oil Pump Body Clearance ............ 0.22 mm/0.15 mm (0.35 mm max.)
Oil Pump Rotor End Float . . . . . . . . . . . . 0.02 mm/0.007 (0.1 mm max.)
3.75 litres
40.0 lb/in2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
0.15 mm (0.2 max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)
Ignition System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle . . . . . . . . . . . .
Max. Advance . . .
Electronic Rev-Limiter . . . . . . . . . . . . . . . .
Spark Plug Type . . . . . . . . . . . . . . . . . . . .
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . .
'F' Mark on Rotor
5 BTDC @ 1000 rpm
35 @ 6500 rpm
11000 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 9EA-9
0.8 mm- 0.9 mm
'F' Mark on Rotor
5 BTDC @ 1000 rpm
38 @ 6500 rpm
11000 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 9EA-9
0.8 mm- 0.9 mm
1.18
Full Specification
DAYTONA 1000
DAYTONA 750
Fuel System
Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Capacity (inc. reserve) ......
Reserve Capacity . . . . . . . . . . . . . . . . . . .
Low Level Warning Lamp . . . . . . . . . . . . .
Fuel Tap . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unleaded (95 RON)

25 Litres
5 Litres
7 Litres
Unleaded (95 RON)

25 Litres
5 Litres
7 Litres
Carburettors
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 rpm 50 rpm
MIKUNI BST 36 mm Flat Slide CV

1000 rpm 50 rpm
Cooling System
Coolant Mixture .....................
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . .
Freezing Point . . . . . . . . . . . . . . . . . . . . . .
Radiator Cap Opening Pressure . . . . . . .
50150 Distilled Water/Anti-Freeze

Mobil Antifreeze
-35C
3.0 Litres
1.1 Bar
83C
99C

Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99oC
Suspension
Front Fork Travel . . . . . . . . . . . . . . . . . . . .
Recommended Fork Oil . . . . . . . . . . . . . .
Oil Level (without spring) .............
Rear Wheel Travel . . . . . . . . . . . . . . . . . . .
Rear Suspension Bearing Grease . . . . .
150 mm
SAE 5
132 mm (fully compressed)
126 mm
Mobil Grease HP 222
150 mm
SAE10
139 mm (fully compressed)
126 mm
Mobil Grease HP 222
Brakes
Front type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated Four Piston
Sliding Calipers Operating on Twin
Floating Discs
Twin Floating Discs
2 x 33.96 mm & 2 x 30.23 mm
Caliper Piston Dia .................... 2 x 33.96 mm & 2 x 30.23 mm
Disc Dia ............................ 310.0 mm
310.0 mm
5.0 mm (4.5 mm min.)
Disc Thickness ...................... 5.0 mm (4.5 mm min.)
Disc Run-out Max .................... 0.15 mm (0.3 mm max.)
0.15 mm (0.3 mm max.)
Master Cylinder . . . . . . . . . . . . . . . . . . . . . 15.8 mm dia. Adjustable Lever
Recommended Fluid . . . . . . . . . . . . . . . . . Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
Rear Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Rear Disc
Rear Disc
Caliper Piston Dia .................... 2 x 27.0 mm
2 x 27.0 mm
Disc Dia ............................ 255.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
Master Cylinder . . . . . . . . . . . . . . . . . . . . . 14.0 mm dia. Remote Reservoir
DOT4
DOT4
Wheels and Tyres
Front Wheel Rim Axial Run-out . . . . . . . . 0.5 mm
0.5 mm
Front Wheel Rim Radial Run-out . . . . . . 0.8 mm
0.8 mm
Front Tyres . . . . . . . . . . . . . . . . . . . . . . . . . Refer to the owners handbook for approved tyres for each model year
Front Tyre Pressure (cold) ............ 2.5 kg/cm2 (36 psi)
2.5 kg/cm 2 (36 psi)
2.0 mm
Front Tyre Tread Depth min ........... 2.0 mm
0.5 mm
Rear Wheel Rim Axial Run-out . . . . . . . . 0.5 mm
Rear Wheel Rim Radial Run-out . . . . . . 0.8 mm
0.8 mm
Rear Tyres . . . . . . . . . . . . . . . . . . . . . . . . . Refer to the owners handbook for approved tyres for each model year
2.5 kg/cm 2 (36 psi)
Rear Tyre Pressure (cold) ............ 2.5 kg/cm2 (36 psi)
2.0 mm - up to 80 mph (130 km/h)
Rear Tyre Tread Depth min. . . . . . . . . . . . 2.0 mm- up to 80 mph (130 km/h)
closed course conditions.
1.19
Full Specification
DAYTONA 1000
DAYTONA 750
Overall Length ......................

Overall Width . . . . . . . . . . . . . . . . . . . . . . .
Overall Height . . . . . . . . . . . . . . . . .
Ground Clearance . . . . . . .
Wheelbase . . . . . . . . . . . . . . . ........
Seat Height..........
. .......
Steering Head Angle . . . . . . . . . . . . . . . . .
Trail . . . . . . . . . . . . . . . . . . . . . . . . . .
Dry Weight . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Payload ... ~.........
. ..

stressed engine
2160 mm (2172 mm- German model)
690 mm (to outside of handlebars)
1270 mm (to top of screen)
158 mm
1510 mm
810 mm
27 from vertical
105 mm
Refer to owner's handbook
181 kg

stressed engine
2160 mm (2172 mm- German model)
690 mm (to outside of handlebars)
1270 mm (to top of screen)
158 mm
1510 mm
810 mm
27 from vertical
105 mm
181 kg
Battery Type . . . . . . . . . . . . . .
Battery Rating . . . . . . . . . . . . . . . . . . . .
Alternator Rating . . . . . . . . . . . . . . . . . . .
Regulated Voltage ...................
Stator Coil Resistance . . . . . . . . . . . . . . .
Rotor Coil Resistance . . .
Slip Ring Dia. . . . . . . . . . . . . . . . . .
Brush Length .......................
Starter Motor Commutator Dia .........
Commutator Groove Depth . . . . . .
Starter Brush Length . .
...
Fuses . . . . . . . . . . . . . Headlight . . .
Tail Light . . . . . . .
Main ...........
Radiator Fan . .
Lights . . . . . . . . . . . . . Head Light .
Parking Light . . . .
Tail Light .
Indicators .......
YUASA YB14L-A2
12V - 14AH
12V- 25A
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
1OA
1OA
30A
1OA
2 x 60/55W H4 Halogen
4W
21/5 W
10W (21W Japan)
YUASA YB14L-A2
12V- 14AH
12V- 25A
Less than 1 .0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
10A
4W
21/5 w
10W (21W Japan)
Frame
Frame Type
1.20
Full Specification
DAYTONA 1200
Engine Type . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement ........................
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio . . . . . . . . . . . . . . . . . .
Cylinder Numbering . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

Transverse In-Line
Transverse In-Line
885 cc
1180 cc
76 mm x 65 mm
76 mm x 65 mm
12.0 : 1
10.6 : 1
1-2-4-3
1-2-3
Cylinder Head
Valve Head Dia .............. ln .....
Ex ....
Valve Lift . . . . . . . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Stem Dia .............. ln .....
Ex. . ..
Ex. . . .
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Outer .
Ex. . . .
Red ...
White .
Valve Timing 1 . . . . . . Inlet ... Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Valve Timing2 ...... Inlet ... Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Reduction Ratio .
Clutch ............ Type . . . . . . . . . . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
Clutch Shim Clearance . . . . . . . . . . . . . . .
Clutch Master Cylinder Bore Dia .......
DAYTONA 900
30.0 mm
26.0 mm
9.4 mm
9.3 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
55 ABDC (@ 1 .0 mm Lift)
262
262
251 o
51 o BBDC (@ 1. 0 mm Lift)
256
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
Gear
1.75 (105/60)
Wet Multi-plate
9
3.80mm - 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4
Gear
1.75 (1 05/60)
Wet Multi-plate
9
3.80mm - 0 +0.80mm
3.60mm
0.15 mm (0.2 mm)
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4

Valve Timing 2 - 136 PS 1200cc version.
1.21
30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
50 ABDC (@ 1 .0 mm Lift)
251
256
Full Specification
DAYTONA 1200
Piston/Crankshaft
Cylinder Bore Dia. . . . . . . . . . . . . . . . . . . . 76.0S mm/76.03 mm Cyl. Nos. 1, 3 & 4
76.0S mm/76.04 mm Cyl. No. 2
Piston Dia. (at 90 to gudgeon pin) .... 7S.98 mm/7S.96 mm Cyl. Nos. 1, 3 & 4
7S.98 mm/7S.97 mm Cyl. No. 2
0.06 mm/0.02 mm
Piston Ring to Groove Clearance Top
Top
1.03 mm/1.01 mm
Oil
2.03 mm/2.01 mm
Piston Ring Eng Gap ......... Top
0.20 mm/0.41 mm
(when fitted in bore)
Second 0.3S mm/O.S6 mm
Oil
0.29 mm/0.8S mm
Gudgeon Pin Bore Dia. In Piston . . . . . . 19.008 mm/19.002 mm
Gudgeon Pin Dia. . . . . . . . . . . . . . . . . . . . 19.000 mm/18.99S mm
Connecting Rod Small End Dia. . . . . . . . 19.034 mm/19.016 mm
Connecting Rod Big End Side Clearance 0.3 mm/0.1S mm (O.S mm max.)
Crankshaft Big End Journal Dia ........ 40.96S mm/40.9S1 mm
Crankshaft Main Journal Dia. . . . . . . . . . 37.981 mm/37.96S mm
Crankshaft Main Bearing Clearance .... 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float . . . . . . . . . . . . . . . . 0.20 mm/O.OS mm (0.4 mm max.)
Transmission
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Ratios ................. 1st ...
2nd . .
3rd . .
4th ...
5th . . .
6th . . .
Gear Selector Groove Width ..........
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain Type . . . .
. ................
No. of Links . . . . . . . . . . . . . . . . . . . . . . . . .
20 Link Length ......................
Drive Chain Slack . . . . . . . . . . . . . . . . . . .
DAYTONA 900
76.0S mm/76.03 mm Cyl. Nos. 1 & 3
76.05 mm/76.04 mm Cyl. No. 2
7S.98 mm/7S.96 mm Cyl. Nos. 1 & 3
7S.98 mm/7S.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.3S mm/O.S6 mm
0.29 mm/0.8S mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.1S mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.96S mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

2.733 (41/1S)
2.733 (41/1S)
1.947 (37/19)
1.947 (37/19)
1.54S (34/22)
1.S4S (34/22)
1.291 (31/24)
1.291 (31/24)
1.1S4 (30/26)
1 .1S4 (30/26)
1.07 4 (29/27)
1.074 (29/27)
S.9 mm/5.8 mm (S.7 mm min.)
S.9 mm/S.8 mm (S.7 mm min.)
6.1 mm/6.0 mm (6.2S mm max.)
6.1 mm/6.0 mm (6.2S mm max.)
O.S5 max.
O.SS max.
Chain
Chain
Regina 136 ORP
Regina 136 ORP
319 mm max.
319 mm max.
3S.O- 40.0 mm
35.0- 40.0 mm
Mobil chain spray
Mobil chain spray
Lubrication
Oil Capacity (incl. filter) .............. . 3.7S litres
Recommended Oil .................. . Fully synthetic Sw/40 oil meeting
Oil Pressure (in main gallery) ........ . 40.0 lb/in2 min.(@ 80C Oil Temp.)
(@ SOOO rpm)
Oil Pump Rotor Tip Clearance ........ . 0.1S mm (0.2 max.)
Oil Pump Body Clearance ........... . 0.22 mm/0.1S mm (0.3S mm max.)
Oil Pump Rotor End Float ........... . 0.02 mm/0.007 (0.1 mm max.)
4.00 litres
40.0 lb/in 2 min.(@ 80C Oil Temp.)
(@ SOOO rpm)
0.1S mm (0.2 max.)
0.22 mm/0.1S mm (0.3S mm max.)
0.02 mm/0.007 (0.1 mm max.)
Ignition System
Type .............................. .
Ignition Timing . . . . . Static ......... .
Idle ........... .
Max. Advance .. .
Electronic Rev-Limiter ............... .
Pick up Coil Air Gap ................ .
Pick up Coil Resistance ............. .
Ignition Coil LT Resistance ........... .
Ignition Coil HT Resistance .......... .
Spark Plug Type ................... .
Spark Plug Gap .................... .
'F' Mark on Rotor
so BTDC @ 1000 rpm
26 @ 6SOO rpm
9700 rpm
0.8 mm/0.6 mm
S30 Ohms
0.6 Ohms
10.S kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
'F' Mark on Rotor
S0 BTDC @ 1000 rpm
26 @ 6SOO rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.S kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
1.22
Full Specification
DAYTONA 1200
DAYTONA 900
Fuel System
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ..... . 25 Litres
Reserve Capacity .................. . 5 Litres
Low Level Warning Lamp ............ . 7 Litres
Unleaded, 95 RON
(U.S. 89 CLC/AKI)
25 Litres
5 Litres
7 Litres
Carburettors

1000 rpm 50 rpm
Cooling System
Coolant Mixture .....................
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . .
Freezing Point . . . . . . . . . . . . . . . . . . . . . .
Cooling System Capacity .............
Radiator Cap Opening Pressure . . . . . .
Cooling Fan Switch On Temperature ...
Mobil Antifreeze
-35C
3.0 Litres
1.1 Bar
83C
99C
50/50 Distilled Water/Anti-Freeze

Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99oC
Suspension
150mm
150mm
126mm
126mm
Mobil Grease HP 222
Mobil Grease HP 222
Brakes
Front type ......................... .
Caliper Piston Dia................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
.............. .
Recommended Fluid
Rear Type ......................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
Wheels and Tyres

Front Wheel Rim Axial Run-out ....... .
Front Wheel Rim Radial Run-out ..... .
Front Tyres ........................ .
Front Tyre Pressure (cold) ........... .
Front Tyre Tread Depth min. . ........ .
Rear Wheel Rim Axial Run-out ....... .
Rear Wheel Rim Radial Run-out ..... .
Rear Tyres ........................ .
Rear Tyre Pressure (cold) ........... .
Rear Tyre Tread Depth min ........... .
Hydraulically Actuated Four Piston Sliding

Calipers Operating on Twin Floating Discs
2 x 33.96 mm & 2 x 30.23 mm
2 x 33.96 mm & 2 x 30.23 mm
310.0 mm
310.0 mm
5.0 mm (4.5 mm min.)
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
0.15 mm (0.3 mm max.)
DOT4
DOT4
Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Rear Disc
Rear Disc
2 x 27.0 mm
2 x 27.0 mm
255.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
0.1 mm (0.3 mm max.)
DOT4
DOT4
0.5mm
0.5mm
0.8 mm
0.8 mm
Refer to the owners handbook for approved tyres for each model year
2.5 kg/cm 2
2.5 kg/cm 2
2.0 mm
2.0 mm
0.5mm
0.5mm
0.8mm
0.8mm
2.9 kg/cm 2
2.9 kg/cm 2
2.0 mm- up to 80 mph (130 km/h)
2.0 mm- up to 80 mph (130 km/h)
1.23
Full Specification
DAYTONA 1200
DAYTONA 900
Overall Length .................... .

Overall Width ..................... .
Overall Height ..................... .
Ground Clearance .................. .
Wheelbase ........................ .
Seat Height ........................ .
Steering Head Angle ................ .
Trail .............................. .
Dry Weight ........................ .
Max. Payload ...................... .

stressed engine
21S2 mm
690 mm
118S mm
1S8 mm
1490 mm
790 mm
27 from vertical
10S mm
181 kg

stressed engine
21S2 mm
690 mm
118S mm
1S8 mm
1490 mm
790 mm
27 from vertical
10S mm
181 kg
Battery Type ....................... .
Battery Rating ..................... .
Alternator Rating ............. .
Regulated Voltage .................. .
Stator Coil Resistance .............. .
Rotor Coil Resistance ............... .
Slip Ring Dia ....................... .
Brush Length ...................... .
Starter Motor Commutator Dia. . ...... .
Commutator Groove Depth .......... .
Starter Brush Length ................ .
Fuses . . . . . . . . . . . . . Headlight ...... .
Tail Light ...... .
Main .......... .
Radiator Fan ... .
Alarm ......... .
lnline fuse (199S on) Brake Light
Lights ............. Head Light ..... .
Parking Light ... .
Tail Light ...... .
Indicators ..... .
YUASA YB14L-A2
12V -14AH
12V- 2SA
14.SV at SSOO (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.S mm (4.S mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.S mm min.)
10A
10A
30A
1SA
10A
SA
2 x 60/SSW H4 Halogen
4W
21/S w
10W (21W Japan)
YUASA YB14L-A2
12V- 14AH
12V- 2SA
14.5V at SSOO (engine) rpm
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.S mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.S mm min.)
10A
10A
30A
1SA
10A
SA
2 x 60/SSW H4 Halogen
4W
21/S w
10W (21W Japan)
Frame
Frame Type
1.24
Full Specification
DAYTONA SUPER 3
Engine Type . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement . . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Firing order .........................
Max. Power. . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

Transverse In-Line
Transverse In-Line
885 cc
885 cc
76 mm x 65 mm
76 mm x 65 mm
12.0 : 1
10.6 : 1
1-2-3
1-2-3
For engine details of the limited edition
Speed Triple 750, refer to the Trident 750
section
Cylinder Head
Valve Head Dia. . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Lift ................... ln .....
Ex ....
Valve Stem Dia .............. ln .....
Ex. . ..
Ex. . ..
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Outer .
Ex. . . .
Valve Bucket Dia ............ Blue ..
Red ...
White .
Valve Timing . . . . . . . Inlet . . . Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Dia. . ..............
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Primary Drive ...... Type . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
SPEED TRIPLE 900
30.0 mm
26.0 mm
9.4 mm
9.3 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.1 0 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
262
262
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
30.0 mm
26.0 mm
8.9mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.983 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
251
256
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
Gear
1.75 (105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm- 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4
Gear
1.75 (105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm- 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4
1.25
DAYTONA SUPER 3
SPEED TRIPLE 900
Piston Ring to Groove Clearance Top

Second
Top
Second
Oil
Piston Ring Eng Gap . . . . . . .
Top
Second
Oil
Gudgeon Pin Bore Dia. In Piston
Gudgeon Pin Dia. . ................ .
Connecting Rod Small End Dia. .
Crankshaft Big End Journal Dia ....
Crankshaft Big End Bearing Clearance
Crankshaft Main Journal Dia. . ...... .
Crankshaft Main Bearing Clearance .. .
Crankshaft End Float ....... .
76.05 mm/76.03 mm Cyl. Nos. 1 & 3

76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.98 mm/75.97 mm Cyl. No.2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)
76.05 mm/76.03 mm Cyl. Nos. 1 & 3

76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.98 mm/75.97 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.965 mm/40.951 mm
0.066 mm/0.036 mm (0.1 mm max.)
37.981 mm/37.965 mm
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)
Transmission
Type .............................. .
Gear Ratios ............ .
1st ...
2nd ..
3rd ..
4th .. .
5th .. .
6th .. .
Gear Selector Groove Width ... .
Final Drive ......................... .
Final Drive Ratio .................. .
Chain Type ........................ .
No. of Links ........................ .
20 Link Length ................. .
Drive Chain Slack .................. .
Chain lubrication .................. .

2.733 (41/15)
2.733 (41/15)
1.947 (37/19)
1.947 (37/19)
1.545 (34/22)
1.545 (34/22)
1.291 (31/24)
1.291 (31/24)
1.154 (30/26)
1 .154 (30/26)
1.074 (29/27) when fitted
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 max.
0.55 max.
Chain
Chain
Regina 136 ORP
Regina 136 ORP
319 mm max.
319 mm max.
35.0- 40.0 mm
35.0- 40.0 mm
Mobil chain spray
Mobil chain spray
Full Specification
Piston/Crankshaft
Cylinder Bore Dia .............. .
Lubrication
4.00 litres
Oil Capacity (incl. filter) ........ .
Recommended Oil .................. . Fully synthetic Sw/40 oil meeting
Oil Pressure (in main gallery) ........ . 40.0 lb/in 2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
Oil Pump Rotor Tip Clearance ....... . 0.15 mm (0.2 max.)
Oil Pump Body Clearance ........... . 0.22 mm/0.15 mm (0.35 mm max.)
4.00 litres
(@ 5000 rpm)
0.15 mm (0.2 max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)
Ignition System
Type .............................. .
Idle ........... .
Max. Advance .. .
Spark Plug Type ................... .
Spark Plug Gap .................... .
'F' Mark on Rotor
5 BTDC @ 1000 rpm
26 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
'F' Mark on Rotor
5 BTDC @ 1000 rpm
26 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
1.26
Full Specification
DAYTONA SUPER 3
SPEED TRIPLE 900
Fuel System
Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ...... 25 Litres
Reserve Capacity . . . . . . . . . . . . . . . . . . . 5 Litres
Low Level Warning Lamp . . . . . . . . . . . . . 7 Litres
Fuel Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Controlled, Auto Shut-off
Unleaded, 95 RON
(U.S. 89 CLC/AKI)
25 Litres
5 Litres
7 Litres
Carburettors
Type ............................... MIKUNI BST 36 mm Flat Slide CV

1000 rpm 50 rpm
Cooling System
Coolant Mixture . . . . . . . . . . . . . . . . . . . . .
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . .
Freezing Point . . . . . . . . . . . . . . . . . . . . . .
Radiator Cap Opening Pressure . . . . . .

Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99C

Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
99oC
Suspension
Front Fork Travel ...................
Recommended Fork Oil .............
Oil Level (without spring) ............
Rear Wheel Travel ..................
Rear Suspension Bearing Grease ....
150 mm
150 mm
126 mm
126 mm
Mobil Grease HP 222
Mobil Grease HP 222
.
.
.
.
.
Brakes
Hydraulically actuated 4 piston sliding
Front type ......................... . Hydraulically actuated 6 piston
calipers operating on twin floating discs calipers operating on twin floating discs
Caliper Piston Dia ................... . 2 x 30,2 mm, 2 x 25,4 mm, 2 x 22,0 mm 2 x 33.96 mm & 2 x 30.23 mm
310.0 mm
Disc Dia ........................... . 310.0 mm
5.0 mm (4.5 mm min.)
Disc Thickness ..................... . 5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
Disc Run-out Max ................... . 0.15 mm (0.3 mm max.)
Master Cylinder .................... . 15.8 mm dia close tolerance.
Adjustable Lever
Recommended Fluid
DOT4
DOT4
Rear Type ......................... . Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Rear Disc
Rear Disc
Caliper Piston Dia ................... . 2 x 27.0 mm
2 x 27.0 mm
255.0 mm
Disc Dia ........................... . 255.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
Master Cylinder .................... . 14.0 mm dia. Remote Reservoir
Recommended Fluid ................ . Mobil Universal Brake and Clutch Fluid
DOT4
DOT4
Wheels and Tyres
0.5mm
Front Wheel Rim Axial Run-out ....... . 0.5mm
Front Wheel Rim Radial Run-out ..... . 0.8 mm
0.8 mm
Front Tyres ........................ . Refer to the owners handbook for approved lyres for each model year
2.5 kg/cm2
Front Tyre Pressure (cold) ........... . 2.5 kg/cm2
2.0 mm
Front Tyre Tread Depth min. . ........ . 2.0 mm
Rear Wheel Rim Axial Run-out ....... . 0.5 mm
0.5 mm
Rear Wheel Rim Radial Run-out ..... . 0.8 mm
0.8 mm
Rear Tyres ........................ . Refer to the owners handbook for approved tyres for each model year
2.9 kg/cm 2
Rear Tyre Pressure (cold) ........... . 2.9 kg/cm2
2.0 mm- up to 80 mph (130 km/h)
Rear Tyre Tread Depth min ........... . 2.0 mm- up to 80 mph (130 km/h)
3.0 mm -over 80 mph (130 km/h)
1.27
Full Specification
Frame
Frame Type
Overall Length .....................
Overall Width ......................
Overall Height .....................
Ground Clearance ..................
Wheelbase ................. .
Seat Height ................. .
Steering Head Angle ................
Trail ..............................
Dry Weight ........................
Max. Payload ......................
.
.
.
.
.
.
.
.
Battery Type ....................... .
Battery Rating ..................... .
Alternator Rating ............. .
Stator Coil Resistance ....... .
Slip Ring Dia. . ..................... .
Brush Length ...................... .
Fuses . . . . . . . . . . . . Headlight ...... .
Tail Light ...... .
Main .......... .
Radiator Fan ... .
Alarm ......... .
lnline fuse (1995 on) Brake Light
Parking Light ... .
Tail Light ...... .
Indicators ..... .
DAYTONA SUPER 3
SPEED TRIPLE 900

stressed engine
2152 mm
760 mm
1185 mm
138 mm
1490 mm
790 mm
from vertical
105 mm
181 kg

stressed engine
2152 mm
760mm
1185 mm
138 mm
1490 mm
790mm
27 from vertical
105 mm
181 kg
YUASA YB14L-A2
12V-14AH
12V- 25A
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A
10A
5A
4W
21/5 w
10W (21W Japan)
YUASA YB14LA2
12V- 14AH
12V- 25A
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A
10A
5A
4W
21/5 w
10W (21W Japan)
2r
1.28
Full Specification
TRIDENT/SPRINT 900
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement. . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

Transverse In-Line
Transverse In-Line
885 cc
748 cc
76 mm x 65 mm
76 mm x 55 mm
10.6 : 1
11.0: 1
1-2-3
1-2-3
Cylinder Head
Valve Head Dia. . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Lift . . . . . . . . . . . . . . . . . . . ln. . . . .
Ex ....
Valve Stem Dia .............. ln. . . . .
Ex. . ..
Ex. . ..
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Inner . .
Valve Spring 'Load at Length'
Outer .
Valve Clearance
ln .....
Ex ....
Red ...
White .
Valve Bucket Bore Dia. . . . . . . . . . . . . . . .
Close .
Duration
Exhaust Open .
Close .
Duration
Valve Timing2 . . . . . . Inlet . . . Open .
Close .
Duration
Exhaust Open .
Close .
Duration
Camshaft Journal Bore Dia. . . . . . . . . . . .
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
No. of Friction Plates . . . . . . . . . . . . . . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
TRIDENT 750
30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
251 o
256
211 o
210
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
Gear
1. 75 ( 105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm - 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT 4
Gear
1.75 (105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm max)
3.80mm- 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4
Valve Timing 1 - 98 PS 900cc versions and all 750cc versions.

Valve Timing 2 - 85 PS 900cc version.
1.29
30.0 mm
26.0 mm
8.9 mm
8.6 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
251
256
Full Specification
TRIDENT/SPRINT 900
Piston/Crankshaft
Cylinder Bore Dia. . . . . . . . . . . . . . . . . . . . 76.05 mm/76.03 mm Cyl. Nos. 1 & 3
76.05 mm/76.04 mm Cyl. No. 2
Piston Dia. (at 90 to gudgeon pin) .... 75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
Piston Ring to Groove Clearance Top . . 0.06 mm/0.02 mm
Top . . 1.03 mm/1.01 mm
Oil ... 2.03 mm/2.01 mm
Piston Ring Eng Gap ......... Top . . 0.20 mm/0.41 mm
Oil . . . 0.29 mm/0.85 mm
Gudgeon Pin Dia. . . . . . . . . . . . . . . . . . . . 19.000 mm/18.995 mm
Connecting Rod Small End Dia ........ 19.034 mm/19.016 mm
Crankshaft Big End Journal Dia. . . .
40.960 mm/40.946 mm (40.932 mm min.)
Crankshaft Main Journal Dia. . ........ 37.976 mm/37.960 mm (37.936 mm min.)
Crankshaft Main Bearing Clearance . . . . 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float ................ 0.20 mm/0.05 mm (0.4 mm max.)
Transmission
Type........
. ................ .
Gear Ratios . . . . . . . . . . . . . . . . . 1st .. .
2nd ..
3rd ..
4th .. .
5th .. .
6th .. .
Gear Selector Fork Thickness ..
Final Drive ......................... .
Chain Type ........................ .
No. of Links .................. .
20 Link Length ............... .
Drive Chain Slack ........... .
Chain lubrication ................ .
Lubrication
Oil Capacity (incl. filter) ........... .
Recommended Oil ............... .
TRIDENT 750
76.05 mm/76.03 mm Cyl. Nos. 1 & 3
76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.960 mm/40.946 mm (40.932 mm min.)
0.066 mm/0.036 mm (0.1 mm max.)
37.976 mm/37.960 mm (37.936 mm min.)
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

2.733 (41/15)
2.733 (41/15)
1.947(37/19)
1.947(37/19)
1.545 (34/22)
1.545 (34/22)
1.291 (31/24)
1.291 (31/24)
1.154 (30/26)
1. 154 (30/26)
1.074 (29/27)
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 mm max.
0.55 mm max.
Chain
Chain
319 mm max.
319 mm max.
35.0- 40.0 mm
35.0- 40.0 mm
Mobil chain spray
Mobil chain spray
Oil Pump Rotor Tip Clearance ........ .

Oil Pump Body Clearance ........... .
Oil Pump Rotor End Float ........... .
4.00 litres
(@ 5000 rpm)
0.15 mm (0.2 mm max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)
4.00 litres
(@ 5000 rpm)
0.15 mm (0.2 mm max.)
0.22 mm/0.15 mm (0.35 mm max.)
0.02 mm/0.007 (0.1 mm max.)
Ignition System
Type .............................. .
Idle ........... .
Max. Advance .. .
Spark Plug Type ................... .
Spark Plug Gap .................... .
'F' Mark on Rotor
5 BTDC @ 1000 rpm
26 @ 6500 rpm
9700 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
'F' Mark on Rotor
5 BTDC @ 1000 rpm
35 @ 6500 rpm
11000 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
Oil Pressure (in main gallery) ........ .
1.30
Full Specification
TRIDENT/SPRINT 900
TRIDENT 750
Fuel System
Unleaded, 95 RON
(U.S. 89 CLC/AKI)
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ..... . 25 Litres (5.5 Imp gal)
25 Litres (5.5 Imp gal)
Reserve Capacity .................. . 5 Litres (1 .1 Imp gal)
Low Level Warning Lamp ............ . 7 Litres (1.5 Imp gal)
Carburettors
Type .............................. . MIKUNI BST 36 mm Flat Slide CV or
KEIHIN CVK 36 mm
1000 rpm 50 rpm
Idle Speed ......................... . 1000 rpm 50 rpm
Cooling System
Coolant Mixture .................... . 50/50 Distilled Water/Anti-Freeze
Mobil Antifreeze
Anti-Freeze Type ................... . Mobil Antifreeze
-35C
Freezing Point ..................... . -35C
2.8 Litres
Cooling System Capacity ............ . 2.8 Litres
1.1 Bar
Radiator Cap Opening Pressure ...... . 1.1 Bar
83C
Thermostat Opening Temperature .... . 83C
99oc
Cooling Fan Switch On Temperature .. . 99oC
255-310 Ohms @ 60C
Temperature Gauge Sensor Resistance 255-310 Ohms@ 60C
Suspension (Trident)
Front Fork Travel ................... . 150 mm
150 mm
Recommended Fork Oil ............. . Refer to chart in front suspension section for full details
Oil Level (without spring) ............ . Refer to chart in front suspension section for full details
25.0 mm (above top yoke face)
Front Wheel Pull Through ........... . 25.0 mm (above top face of yoke)
126 mm
Rear Wheel Travel .................. . 126 mm
Mobil Grease HP 222
Rear Suspension Bearing Grease .... . Mobil Grease HP 222
Brakes t
Front type ......................... . Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Calipers Operating on Twin Rigid Discs Calipers Operating on Twin Rigid Discs
2 x 27.0 mm
Disc Dia ........................... . 296.0 mm
296.0 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
14.0 mm dia.
Master Cylinder .................... . 14.0 mm dia.
DOT4
DOT4
t from VIN 9083 Sprint front brakes as for Daytona 1200.
Rear Type ......................... . Hydraulically Actuated Two Piston Sliding Hydraulically Actuated Two Piston Sliding
Rear Disc
Rear Disc
2 x 27.0 mm
Disc Dia ........................... . 255.0 mm
255.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.
Master Cylinder .................... . 14.0 mm dia. Remote Reservoir
DOT4
DOT4
Wheels and Tyres
0.5 mm
Front Wheel Rim Axial Run-out ....... . 0.5 mm
0.8 mm
Front Wheel Rim Radial Run-out ..... . 0.8 mm
Front Tyres ........................ . Refer to the owners handbook for approved tyres for each model year
2.5 kg/cm 2
Front Tyre Pressure (cold) ........... . 2.5 kg/cm2
Front Tyre Tread Depth min. . ........ . 2.0 mm
2.0 mm
0.5mm
0.5mm
Rear Wheel Rim Axial Run-out
0.8mm
Rear Wheel Rim Radial Run-out ..... . 0.8mm
Rear Tyres ........................ . Refer to the owners handbook for approved tyres for each model year
2.9 kg/cm2
Rear Tyre Pressure (cold) ........... . 2.9 kg/cm2
2.0 mm- up to 80 mph (130 km/h)
Rear Tyre Tread Depth min ........... . 2.0 mm- up to 80 mph (130 km/h)
1.31
Full Specification
Frame
Frame Type
Overall Length .....................
Overall Width . . . . . . . .
. ........
Overall Height .....................
Ground Clearance .............. .
Wheelbase ........................
Seat Height . . . . . . . . . . .
. ......
Steering Head Angle ................
Trail ..............................
Dry Weight ........................
Max. Payload ......................
.
.
.
.
.
.
.
.
.
Battery Type . . . . . . . . . . ........... .
Battery Rating .......... .
Alternator Rating ........ .
Regulated Voltage ..... .
Slip Ring Dia ....................... .
Brush Length ...................... .
Commutator Groove Depth ....... .
Starter Brush Length ........... .
Fuses . . . . . . . . . . . . . Headlight ...... .
Tail Light
Main .......... .
Radiator Fan ... .
Alarm ...
lnline fuse (1995 on) Brake Light
Parking Light ... .
Tail Light ...... .
Indicators ..... .
TRIDENT/SPRINT 900
TRIDENT 750

stressed engine
2152 mm
760 mm
1090 mm (1265 mm Sprint)
138 mm (158mm to vin 4901)
1510 mm (1490 mm Sprint)
775mm
27 from vertical
105 mm

stressed engine
2152 mm
760mm
1090 mm
138 mm (158mm to vin 4901)
1490 mm
775mm
27 from vertical
105 mm
181 kg
YUASA YB14L-A2
12V -14AH
12V- 25A
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A (10A to vin 4901)
10A
5A
*60/55W H4 Halogen
4W
21/5 w
10W (21W Japan)
*Sprint 2x60/55W H4 Halogen
YUASA YB14L-A2
12V-14AH
12V- 25A
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A (10A to vin 4901)
10A
5A
60/55W H4 Halogen
4W
21/5 w
10W (21W Japan)
1.32
Full Specification
THUNDERBIRD SPORT 900
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement ........................
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Firing order . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

Transverse In-Line
Transverse In-Line
885 cc
885 cc
76 mm x 65 mm
76 mm x 65 mm
10.0 : 1
10.0 : 1
1-2-3
1-2-3
83.0 PS @ 8500 rpm
70 PS @ 8000 rpm
76.0 Nm @ 6500 rpm
72.0 Nm @ 4800 rpm
Cylinder Head
Valve Head Dia .............. ln .....
............................ Ex ....
Valve Lift . . . . . . . . . . . . . . . . . . . ln. . . . .
............................ Ex ....
Valve Stem Dia .............. ln .....
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
............................ Red ...
............................ White .
Valve Timing . . . . . . . Inlet . . . Open .
.......................... Close .
.......................... Duration
. . . . . . . . . . . . . . . . . Exhaust Open .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Close .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Duration
............ ........................
Camshaft Journal Bore Dia. . . . . . . . . . . .
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
30.0 mm
26.0 mm
7.1 mm
7.0 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.1 0 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
211
28 BBDC (@ 1 .0 mm Lift)
210
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
30.0 mm
26.0 mm
7.1 mm
7.0mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1.5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
211
210
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
Gear
1. 75 (1 05/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm - 0 +0.80mm
3.60mm
0.125 mm/0. 075 mm
14.0 mm
33.6 mm
DOT4
Gear
1.75 (105/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm- 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
DOT4
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
Plate Flatness . . . . . . . . . . . . . . . . . . . . . .
1.33
THUNDERBIRD/ADVENTURER 900
Full Specification
Piston/Crankshaft
Cylinder Bore Dia. . ............. .
76.05 mm/76.03 mm Cyl. Nos. 1 & 3

76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
Piston Ring to Groove Clearance Top . . 0.06 mm/0.02 mm
............................. Second 0.06 mm/0.02 mm
Top . . 1.03 mm/1.01 mm
Oil ... 2.03 mm/2.01 mm
Piston Ring Eng Gap ......... Top .. 0.20 mm/0.41 mm
(when fitted in bore) .......... Second 0.35 mm/0.56 mm
Oil . . . 0.29 mm/0.85 mm
Gudgeon Pin Dia .................... 19.000 mm/18.995 mm
Connecting Rod Small End Dia. . . . . . . . 19.034 mm/19.016 mm
Crankshaft Big End Journal Dia ........ 40.960 mm/40.946 mm (40.932 mm min)
Crankshaft Big End Bearing Clearance . 0.066 mm/0.036 mm (0.1 mm max)
Crankshaft Main Journal Dia. . ........ 37.976 mm/37.960 mm (37.936 mm min)
Crankshaft Main Bearing Clearance .... 0.044 mm/0.020 mm (0.1 mm max.)
Crankshaft End Float . . . . . . . . . . . . . . . . 0.20 mm/0.05 mm (0.4 mm max.)
Transmission
Type .............................. .
Gear Ratios ....... . . . . . . . . . 1st ...
2nd ..
3rd ..
4th .. .
5th .. .
6th .. .
Final Drive ......................... .
Chain Type ........................ .
No. of Links ........................ .
20 Link Length ..................... .
Drive Chain Slack .................. .
Chain lubrication ................... .
76.05 mm/76.03 mm Cyl. Nos. 1 & 3

76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.960 mm/40.946 mm (40.932 mm min.)
0.066 mm/0.036 mm (0.1 mm max.)
37.976 mm/37.960 mm (37.936 mm min)
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)

2.733 (41/15)
2.733 (41/15)
1.947 (37/19)
1.947 (37/19)
1.545 (34/22)
1.545 (34/22)
1.291 (31/24)
1.291 (31/24)
1.154 (30/26)
1. 154 (30/26)
1.074 (29/27)
N/A
5.9 mm/5.8 mm (5.7 mm min.)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
6.1 mm/6.0 mm (6.2S mm max.)
O.S5 mm max
0.55 mm max
Chain
Chain
Variable according to model year and market designation
319 mm max.
319 mm max.
3S.O- 40.0 mm
2S.O- 30.0 mm
Mobil chain spray
Mobil chain spray
Lubrication
Oil Capacity (incl. filter) . . . . . . . . . . . . . . . 4.00 litres
Recommended Oil . . . . . . . . . . . . . . . . . . . Semi synthetic 1Ow/40 oil meeting
Oil Pressure (in main gallery) ......... 40.0 lb/in2 min. (@ 80C Oil Temp.)
(@ SOOO rpm)
Oil Pump Rotor Tip Clearance ......... 0.1S mm (0.2 mm max.)
Oil Pump Body Clearance ............ 0.22 mm/0.1S mm (0.3S mm max.)
Oil Pump Rotor End Float ............ 0.02 mm/0.007 (0.1 mm max.)
4.00 litres
specification APIISG
(@ SOOO rpm)
0.1S mm (0.2 mm max.)
0.22 mm/0.1S mm (0.3S mm max.)
0.02 mm/0.007 (0.1 mm max.)
Ignition System
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle . . . . . . . . . . . .
Max. Advance . . .
Electronic Rev-Limiter . . . . . . . . . . . . . . .
Spark Plug Type . . . . . . . . . . . . . . . . . . . .
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . .
'F' Mark on Rotor
S0 BTDC @ 1000 rpm
30 @ 6SOO rpm
87SO rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.S kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
'F' Mark on Rotor
S0 BTDC @ 1000 rpm
30 @ 6500 rpm
8750 rpm
0.8 mm/0.6 mm
S30 Ohms
0.6 Ohms
1O.S kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
1.34
Full Specification
Fuel System
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ..... . 25 Litres (5.5 Imp gal)
Reserve Capacity .................. . 5 Litres (1.1 Imp gal)
Low Level Warning Lamp ............ . 7 Litres (1.5 Imp gal)
Fuel Tap .......................... . Mechanical, gravity fed.
Carburettors
Type .............................. . KEIHIN CVK 36 mm
Idle Speed ......................... .
Cooling System
Coolant Mixture .................... .
Anti-Freeze Type ................... .
Freezing Point ..................... .
Cooling System Capacity ............ .
Radiator Cap Opening Pressure ...... .
Thermostat Opening Temperature .... .
Cooling Fan Switch On Temperature .. .
Temperature Gauge Sensor Resistance
Suspension
Brakes
Front type ......................... .
Disc dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max................... .
Front Master Cylinder ............... .
Rear Type ......................... .
Caliper Piston Dia................... .
Disc Dia ........................... .
Disc Thickness ..................... .
Disc Run-out Max ................... .
Master Cylinder .................... .
1000 rpm
50 rpm

Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
100C
255-31 0 Ohms @ 60C
Unleaded, 95 RON
(U.S. 89 CLC/AKI)
15.0 Litres (3.3 Imp gal)
4.0 Litres (0.9 Imp gal)
Not fitted
Mechanical, gravity fed.
MIKUNI BST 36 mm Flat Slide CV or
KEIHIN CVK 36 mm
1000 rpm 50 rpm
Mobil Antifreeze
-35C
2.8 Litres
1.1 Bar
83C
100C
255-31 0 Ohms @ 60C
150mm
150mm
110 mm
110mm
Mobil Grease HP 222
Mobil Grease HP 222
2 Hydraulically Actuated 2 Piston Sliding
Calipers Operating on Twin Rigid Discs
2 x 27.0 mm
310 mm
5.0 mm (4.5 mm min.)
0.15 mm (0.3 mm max.)
12.7 mm dia.
DOT 4
Hydraulically Actuated 2 Piston Sliding
Caliper Operating on Single Rigid Disc
2 x 27.0 mm
285.0 mm
6.0 mm (5.0 mm min.)
0.1 mm (0.3 mm max.)
DOT4
1.35
One Hydraulically Actuated 2 Piston Sliding

2 x 27.0 mm
320 mm
5.0mm
0.15 mm (0.3 mm max)
11.0 mm dia
DOT4
Hydraulically Actuated 2 Piston Sliding
2 x 27.0 mm
285.0 mm
6.0 mm
0.1 (0.3 mm max)
DOT4
Full Specification
Wheels and Tyres
Front Wheel Rim Axial Run-out
Front Tyres ........................ .
Front Tyre Pressure (cold) ........... .
Front Tyre Tread Depth min. . ........ .
Rear Wheel Rim Axial Run-out ....... .
Rear Wheel Rim Radial Run-out ...... .
Rear Tyres ........................ .
Rear Tyre Pressure (cold) ........... .
Rear Tyre Tread Depth min ........... .
0.5 mm
0.5 mm
0.8mm
0.8mm
Refer to the owners handbook for approved lyres for each model year
2.5kg/cm 2
2.5 kg/cm 2
2.0mm
2.0mm
0.5mm
0.5mm
0.8mm
0.8mm
Refer to the owners handbook for approved lyres for each model year
2.9 kg/cm 2
2.9 kg/cm 2
2.0 mm- up to 80 mph (130 km/h)
2.0 mm- up to 80 mph (130 km/h)
- -..
-----
---~--~-----
----------------------~-
Frame
Frame Type ....................... . Large dia. high tensile steel spine,
stressed engine
Overall Length ..................... . 2250 mm
Overall Width ............... .
860mm
Overall Height ..................... . 1150 mm
Wheelbase ........................ . 1580 mm
Seat Height ........................ . 750 mm
Steering Head Angle ................ . 27 from vertical
Trail .............................. . 106 mm
Dry Weight ........................ . Refer to owner's handbook
Max. Payload ...................... . 200 kg

stressed engine
2250 mm (2170 mm Adventurer)
1550 mm
750 mm
27 from vertical
106 mm
181 kg
Battery Type ....................... .
Battery Rating ..................... .
Alternator Rating ................... .
Slip Ring Dia. . ..................... .
Brush Length ................. .
Starter Motor Commutator Dia .... .
Fuses . . . . . . . . . . . . . Headlight ...... .
Tail Light ...... .
Main ...... .
Radiator Fan ... .
Alarm ......... .
lnline fuse ..... .
Parking Light ... .
Tail Light
License plate light
Indicators ...... .
YUASA YB14L-A2
12V -14AH
12V- 25A
Less than 1 .0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A
10A
15A (Ignition system)
60/55W H4 Halogen
4W
2 X 21/5 W
5W
10W
YUASA YB14L-A2
12V -14AH
12V- 25A
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
10A
30A
15A
10A
15A (Ignition system)
60/55W H4 Halogen
4W
2x21/5W
5W
10W
1.36
Full Specification
TIGER 900
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arrangement. . . . . . . . . . . . . . . . . . . . . . . .
Displacement . . . . . . . . . . . . . . . . . . . . . . .
Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio ..................
Firing order . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . .
Max. Torque . . . . . . . . . . . . . . . . . . . . . . . .

Transverse In-Line
885 cc
76 mm x 65 mm
10.6: 1
1-2-3
62.5 kW (85 PS) @ 8000 rpm
82.0 Nm @ 6000 rpm
Cylinder Head
Valve Head Dia .............. ln .....
............................ Ex ....
Valve Lift . . . . . . . . . . . . . . . . . . . ln. . . . .
............................ Ex ....
Valve Stem Dia .............. ln .....
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
............................ Ex ....
Valve Seat Angle . . . . . . . . . . . . . . . . . . . .
Valve Spring 'Load at Length' . Inner . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ex. . . .
............................ Red ...
............................ White .
Valve Bucket Bore Dia. . . . . . . . . . . . . . . .
Valve Timing . . . . . . . Inlet ... Open .
.......................... Close .
.......................... Duration
. . . . . . . . . . . . . . . . . Exhaust Open .
............................ Close .
............................ Duration
....................................
Camshaft Run-out . . . . . . . . . . . . . . . . . . .
30.0 mm
26.0 mm
7.1 mm
7.0 mm
5.490 mm/5.475 mm (5.47 mm min.)
5.470 mm/5.455 mm (5.45 mm min.)
5.515 mm/5.500 mm
0.04 mm/0.01 mm (0.07 mm max.)
0.06 mm/0.03 mm (0.09 mm max.)
1.1 mm/0.9 mm (1 .5 mm max.)
2.5 mm/1.8 mm
45
0.15 mm/0.10 mm
0.20 mm/0.15 mm
27.993 mm/27.987 mm
27.986 mm/27.980 mm
27.979 mm/27.974 mm
28.021 mm/28.000 mm
211 o
210
22.93 mm/22.90 mm
0.12 Max.
23.021 mm/23.000 mm
0.13 mm/0.03 mm (0.2 mm max.)
0.05 mm max.
73.7 mm
Reduction Ratio .
Clutch . . . . . . . . . . . . Type . . . . . . . . . . .
Plate Flatness ......................
Gear
1.75 (1 05/60)
Wet Multi-plate
9
0.15 mm (0.2 mm)
3.80mm - 0 +0.80mm
3.60mm
0.125 mm/0.075 mm
14.0 mm
33.6 mm
Mobil Universal Brake and Clutch Fluid, DOT 4
1.37
Full Specification
TIGER 900
Piston/Crankshaft
Cylinder Bore Dia. . . . . . . . . . . . . . . . . . . .
...................................
Piston Dia. (at 90 to gudgeon pin) ....
....................................
Piston Ring to Groove Clearance Top . .
............................. Second
Piston Ring Groove Width ..... Top . .
............................. Second
............................. Oil . . .
Piston Ring Eng Gap ......... Top . .
(when fitted in bore) .......... Second
............................. Oil . . .
Gudgeon Pin Bore Dia. In Piston ......
Gudgeon Pin Dia....................
Connecting Rod Small End Dia ........
Crankshaft Big End Journal Dia ........
Crankshaft Big End Bearing Clearance .
Crankshaft Main Journal Dia. . ........
Crankshaft Main Bearing Clearance ....
Crankshaft End Float ................
76.05 mm/76.03 mm Cyl. Nos. 1 & 3

76.05 mm/76.04 mm Cyl. No. 2
75.98 mm/75.96 mm Cyl. Nos. 1 & 3
75.97 mm/75.96 mm Cyl. No. 2
0.06 mm/0.02 mm
0.06 mm/0.02 mm
1.03 mm/1.01 mm
1.03 mm/1.01 mm
2.03 mm/2.01 mm
0.20 mm/0.41 mm
0.35 mm/0.56 mm
0.29 mm/0.85 mm
19.008 mm/19.002 mm
19.000 mm/18.995 mm
19.034 mm/19.016 mm
0.3 mm/0.15 mm (0.5 mm max.)
40.960 mm/40.946 mm (40.932 mm min)
0.066 mm/0.036 mm (0.1 mm max)
37.976 mm/37.960 mm (37.936 mm min)
0.044 mm/0.020 mm (0.1 mm max.)
0.20 mm/0.05 mm (0.4 mm max.)
Transmission
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Ratios ................. 1st ...
2nd . .
3rd . .
4th ...
5th . . .
6th . . .
Gear Selector Groove Width ..........
Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . .
Chain Type . . . . . . . . . . . . . . . . . . .
No. of Links . . . . . . . . . . . . . . . . . . . . . . . . .
20 Link Length ......................
Drive Chain Slack . . . . . . . . . . . .
...

2.733 (41/15)
1.947 (37/19)
1.545 (34/22)
1.291 (31/24)
1.154 (30/26)
1.074 (29/27)
5.9 mm/5.8 mm (5.7 mm min.)
6.1 mm/6.0 mm (6.25 mm max.)
0.55 mm max
Chain
319 mm max.
35.0- 40.0 mm
Mobil chain spray
Lubrication
4.00 litres
Oil Capacity (incl. filter) ........ .
Recommended Oil .................. . Semi synthetic 1Ow/40 oil meeting
Oil Pressure (in main gallery) ........ . 40.0 lb/in2 min.(@ 80C Oil Temp.)
(@ 5000 rpm)
Oil Pump Rotor Tip Clearance ........ . 0.15 mm (0.2 mm max.)
Oil Pump Body Clearance ........... . 0.22 mm/0.15 mm (0.35 mm max.)
Ignition System
Type .............................. .
Ignition Timing . . . . . Static .. .
Idle ........... .
Max. Advance .. .
Electronic Rev-Limiter .............. .
Spark Plug Type ................... .
Spark Plug Gap .................... .
'F' Mark on Rotor
5 BTDC @ 1000 rpm
29 @ 6500 rpm
8750 rpm
0.8 mm/0.6 mm
530 Ohms
0.6 Ohms
10.5 kOhms
NGK DPR 8EA-9
0.8 mm- 0.9 mm
1.38
Full Specification
TIGER 900
Fuel System
Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded, 95 RON
(U.S. 89 CLC/AKI)
Fuel Tank Capacity (inc. reserve) ...... 25 Litres (5.5 Imp gal)
Reserve Capacity . . . . . . . . . . . . . . . . . . . 5 Litres (1.1 Imp gal)
Low Level Warning Lamp ............. 7 Litres (1.5 Imp gal)
Fuel Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, gravity fed.
Carburettors
Type ............................... MIKUNI BST 36 mm Flat Slide CV or
KEIHIN CVK 36 mm
Cooling System
Coolant Mixture . . . . . . . . . . . . . . . . . . . . . 50/50 Distilled Water/Anti-Freeze
Anti-Freeze Type . . . . . . . . . . . . . . . . . . . . Mobil Antifreeze
Freezing Point . . . . . . . . . . . . . . . . . . . . . . -35C
Cooling System Capacity . . . . . . . . . . . . . 2.8 Litres
Radiator Cap Opening Pressure . . . . . . . 1.1 Bar
Thermostat Opening Temperature . . . . . 83C
Cooling Fan Switch On Temperature . . . 99C
Temperature Gauge Sensor Resistance 255-31 0 Ohms @ 60C
Suspension
Front Fork Travel . . . . . . . . . . . . . . . . . . . . 235mm
Recommended Fork Oil . . . . . . . . . . . . . . Refer to chart in front suspension section for full details
Oil Level (without spring) . . . . . . . . . . . . . Refer to chart in front suspension section for full details
Rear Wheel Travel . . . . . . . . . . . . . . . . . . . 200 mm
Rear Suspension Bearing Grease . . . . . Mobil Grease HP 222
Brakes
Front type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated 2 Piston Sliding
Calipers Operating on Twin Rigid Discs
Caliper Piston Dia. . . . . . . . . . . . . . . . . . . . 2 x 27.0 mm
Disc dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 mm
Front Master Cylinder . . . . . . . . . . . . . . . . 14.0 mm dia.
DOT4
Rear Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically Actuated 2 Piston Sliding
Caliper Piston Dia .................... 2 x 27.0 mm
Disc Dia. . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.0 mm
Disc Thickness . . . . . . . . . . . . . . . . . . . . . . 6.0 mm (5.0 mm min.)
Master Cylinder ..................... 14.0 mm dia. Remote Reservoir
DOT4
1.39
Full Specification
Wheels and Tyres
Front Wheel Rim Axial Run-out
Front Tyres ........................
Front Tyre Pressure (cold) ...........
Front Tyre Tread Depth min. . ........
Rear Wheel Rim Axial Run-out .......
Rear Wheel Rim Radial Run-out ......
Rear Tyres ........................
Rear Tyre Pressure (cold) ...........
Rear Tyre Tread Depth min ...........
TIGER 900
.
.
.
.
.
.
.
.
0.5 mm
0.8 mm
2.1 kg/cm 2
2.0 mm
0.5 mm
0.8 mm
2.3 kg/cm 2
2.0 mm- up to 80 mph (130 km/h)
~---~---------~~~-'
Frame
Frame Type
Overall Length ... _...... _..........
Overall Width ...... _......... _.....
Overall Height .... ___ ..... __ .......
Wheelbase ..... _........ ___ .......
Seat Height ... __ . .
. ...........
Steering Head Angle __
Trail .. _.......... __ ....... _.
Dry Weight .... _. . . . . . . . . ........
Max. Payload ...... _. _...... _
_
.
.
.
.
_
Battery Type . . . .
.............
Battery Rating .... ___ ........ _
Alternator Rating ___ . _... _...........
Regulated Voltage ....... _........ _..
Stator Coil Resistance _........ __ . . . .
Rotor Coil Resistance _. . . . . .
Slip Ring Dia. __ .................... _
Brush Length ... _...................
Starter Motor Commutator Dia. . . . . . ..
Commutator Groove Depth ...........
Starter Brush Length .................
Fuses .. ___ ........ Headlight ___ ....
Tail Light . . . . . . .
Main ...........
Radiator Fan . . . .
Clock*/alarm . . . .
lnline fuse
Lights .......... __ . Head Light . . . . . .
Parking Light ....
Tail Light
License plate light
Indicators . . . . . . .

stressed engine
2290 mm
920 mm
1345 mm
1550 mm
850mm
27 from vertical
96mm
181 kg
YUASA YB 14L-A2
12V - 14AH
12V- 25A
Less than 1.0 Ohm
4.0 Ohms
14.4 mm (14.0 mm min.)
10.5 mm (4.5 mm min.)
28.0 mm (27.0 mm min.)
0.7 mm (0.2 mm min.)
12.0 mm (8.5 mm min.)
10A
1OA
30A
15A
1OA
*SA (Brake Light)
4W
21/5 W
N/A
1OW
* If fitted
1.40
Torque Wrench Settings
Cylinder Head Area
Application
Torque(Nm)
Cam cover to cylinder head - long and short screws
10
Cam chain tensioner blade to engine
18
Cam chain tensioner spring bolt to body
23
Cam chain tensioner body to cylinder head
Camshaft bearing caps to head
10
Camshaft sprocket to camshaft
15
Cam chain top pad to head
10
Cylinder head to crankcase

- M6 screws (not T'bird, Adventurer or T'bird Sport)
12
Cylinder head to crankcase

- M6 screws (T'bird, Adventurer and T'bird Sport)
14
Cylinder head to crankcase bolts
Notes
Note 1
Note 4
See section 3
Cylinder head to frame bolts
95
Cylinder head core plug
22
Note 2
Torque(Nm)
Notes
Clutch
Application
Clutch cover to crankcase
12
Inner clutch cover to outer clutch cover
10
Sound suppression plate in clutch cover
Clutch centre nut
105
Clutch spring bolts
10
Clutch slave cylinder to sprocket cover
12
Clutch slave cylinder bleed screw
Clutch hose to slave cylinder banjo bolt
25
Note 5
Clutch hose to master cylinder banjo bolt
25
Note 5
Clutch master cylinder clamp bolts
15
Clutch lever pivot bolt (not Tiger)
Clutch lever pivot bolt (Tiger)
Clutch lever pivot bolt locknut
Balancer, Crankshaft and Crankcase

Application
Torque(Nm)
Crankcase upper to lower (M8 fixings)
See section 6
Crankcase upper to lower (M6 fixings)
See section 6
Connecting rod big end nut
Oil deflector plate
10
Balancer spindle pinch bolt- 4 cylinder engines
12
1.41
Notes
Note 9
Balancer, Crankshaft and Crankcase (continued)
Balancer clamp to crankcase - 4 cylinder engines
12
Balancer bearing plate- 3 cylinder engines
Note 1
Sprag clutch housing to centre
16
Note 1
Idler gear retaining bolt
12
Note 1
Breather disc to crankshaft
22
Note 1
Ignition rotor to crankshaft
27
Note 1
Ignition sensor to crankcase
10
Engine Covers
Application
Torque(Nm)
Crankshaft covers to crankcase
12
Balancer cover RHS - 3 cylinder
12
Alternator gear cover to crankcase
Sprocket cover to crankcase
12
Clutch cover to crankcase
12
Oil filler cap
Notes
Hand tight
Oil sight glass (T'bird, Adventurer and T'bird Sport)
22
Oil filler plug to clutch cover (T'bird, Adventurer and T'bird Sport)
10
Note 2
Transmission
Application
Torque(Nm)
Gearbox output sprocket
Notes
132
Detent wheel to selector drum
12
Note 1
Detent arm stud
Note 1
Detent arm nut
Selector drum bearing retaining washer
12
Note 1
Selector shaft retainer
12
Note 1
Spring abutment bolt
28
Stop plate to crankcase
Neutral indicator switch
10
Note 1
Final Drive
Application
Torque(Nm)
Chain rubbing strip to swinging arm screws
Chain guard to swinging arm
Chain guard to bracket
Sprocket to rear wheel
85
Rear wheel spindle bolt
85
Eccentric housing pinch bolt
36
Chain slider to frame (Tiger)
27
1.42
Notes
Note 8
Lubrication System
Application
Torque(Nm)
Notes
Sump to lower crankcase
12
Sump to lower crankcase (& exhaust bracket)
12
Sump drain plug M22
48
Sump drain plug M 14
28
Sump oilway plug
45
Note 2
Pressure relief valve
15
Note 2
Oil pressure switch
20
Note 5
Oil filter bolt
18
Oil feed banjos, M6
Oil feed banjos, M8
11
Oil feed banjos, M10
25
Oil feed banjos, M14
28
Oil cooler pipe banjo bolts
25
Oil cooler adaptor
36
Oil cooler mounting bolts
Oil cooler stoneguard mounting bolts
Oil pump to lower crankcase
12
Note 1
Oil pump gear to shaft
Note 1
Oil strainer retaining screws in sump
12
Plug, main oil gallery
25
Note 5
Torque(Nm)
Notes
Note 5
Note 5
Cooling System
Application
Water pump mounting bolts
12
Water pipe outlet to upper crankcase
11
Water pipe elbow to cylinder block
11
Water temperature sensor in cylinder head
Water pipe hose clip
Hand tight
Radiator mounting bolts
18
Radiator bottom bracket bolts
9
2.5
Radiator stone guard/elec fan mounting bolts

Radiator end covers
Coolant drain screw to crankcase
13
Water pipe to pump
Water pipe to engine
10
Expansion tank to frame (T'bird, Adventurer and T'bird Sport)
Thermostat housing to frame (T'bird, Adventurer and T'bird Sport)
1.43
Fuel System and Airbox
Torque(Nm)
Application
Airbox halves screws
2.5
Airbox to carburettor clips
1.5
Airbox cover (T'bird, Adventurer and T'bird Sport)
Auxiliary air chamber mounting bolts

(not T'bird, Adventurer or T'bird Sport)
Auxiliary air chamber mounting bolts

(T'bird, Adventurer and T'bird Sport)
Notes
2.5
See note 7
Exhaust clamp to head

18
Exhaust stud to cylinder head
Note 1
-------
Downpipe to intermediate pipe
Balance pipe clamp
22
Exhaust silencer clamp
22
Exhaust clamp cover (T'bird, Adventurer and T'bird Sport)
Screw to exhaust downpipe
Silencer mounting bolts (not Tiger, T'bird, Adventurer or T'bird Sport)
15
Silencer mounting bolts (Tiger, T'bird, Adventurer and T'bird Sport)
27
Silencer mounting bracket to silencer
14
f----
Hand tight
Heelguard to silencer (T'bird Sport)
Low fuel sensor in tank base (not Tiger)
30
Low fuel sensor in tank base (Tiger)
r-----
Fuel gauge sensor unit to tank (Trophy 1996)
10
Hand tight
Fuel filler cap security screw

Fuel filler cap screws
Fuel tap mounting bolts (not Tiger, T'bird, Adventurer or T'bird Sport)
12
Fuel tap mounting bolts (Tiger, T'bird, Adventurer and T'bird Sport)
Fuel tank to bracket screws (not T'bird, Adventurer or T'bird Sport)
12
Fuel tank to bracket screws (T'bird, Adventurer and T'bird Sport)
Tank bracket to frame screws
12
Fuel tank badge to fuel tank (T'bird, Adventurer and T'bird Sport)
9
1.5
Carb rubber clip
Wheels
Torque(Nm)
Application
Front wheel spindle to fork bolt (except Tiger)
60
Front wheel spindle pinch bolts
20
Front wheel to forks, dome nut or spindle (Tiger)
85
Rear wheel spindle bolt
85
Rear wheel eccentric housing pinch bolt
36
Chain adjustment bolts (T'bird, Adventurer and T'bird Sport)
15
1.44
Notes
Note 8
Rear Suspension
Application
Torque(Nm)
Notes
Swinging arm spindle to frame bolt
85
Note 3
Drop link to swinging arm (not Tiger, T'bird, Adventurer or T'bird Sport)
55
Drop link to swinging arm (Tiger, T'bird, Adventurer and T'bird Sport)
100
Drop link to drag link (not Tiger, T'bird, Adventurer or T'bird Sport)
85
Drop link to drag link (Tiger, T'bird, Adventurer and T'bird Sport)
100
Drop link/drag link spindle pinch bolts
Drag link to linkage carriers
Note 3
100
Rear suspension grease nipples
Rear suspension unit to frame
95
Pre-load adjuster to bracket
Damping adjuster to frame
Upper crankcase and linkage carriers to frame
95
Lower crankcase and linkage carriers to frame
95
Rear suspension unit to drag link

(Tiger, T'bird, Adventurer and T'bird Sport)
55
R.S.U. reservoir bracket to head M8 (Tiger)
27
R.S.U. reservoir bracket to head M6 (Tiger)
Front Suspension
Application
Torque(Nm)
Notes
Handlebar mounting bolts (not Tiger, T'bird, Adventurer or T'bird Sport)
22
Note 2
Handlebar lower clamp to yoke

(Tiger, T'bird, Adventurer and T'bird Sport)
35
Handlebar top clamp to bottom clamp (T'bird and Adventurer)
22
Handlebar top clamp to bottom clamp (T'bird Sport)
20
Handlebar top clamp to bottom clamp (Tiger)
18
Handlebar weight
Switch assemblies to handle bars
Speedometer cable retaining screw
Hand tight
Brake hose joint to bottom yoke
18
Steering stem adjuster nut
40
Adjuster nut locking screw
Top/bottom yoke pinch bolts (not Tiger)
20
Top yoke pinch bolts (Tiger)
18
Bottom yoke pinch bolts (Tiger)
22
1.45
Note 6
Front Suspension (continued)
Steering stem dome nut
65
Fork cap
23
Fork cap to damping rod lock nut
15
Capscrew to damping rod (bottom of forks) (Daytona)
40
Capscrew to damping rod (bottom of forks) (T'bird and Adventurer)
20
Capscrew to damping rod (bottom of forks) (T'bird Sport)
30
Capscrew to damping rod (bottom of forks)

(not Daytona, T'bird, Adventurer or T'bird Sport)
60
Ignition switch & instrument bracket on top yoke
Shear bolt
Brake hose bracket to fork leg
Mudguard to fork leg
Cable guide to bottom yoke
Brakes
Application
Torque(Nm)
Front brake caliper bleed screw
Notes
Front brake hose banjo bolts
25
Front brake caliper mounting bolts

40
Front brake caliper mounting bolts (T'bird, Adventurer and T'bird Sport)
28
Front brake caliper slider pin -adjacent to bleed screw ('B' spec. only)
22
Front brake caliper slider pin- between pistons
18
Front brake caliper pad retaining pins
18
Front brake caliper pad retaining pin lockscrew

Brake disc to front wheel
22
Rear brake caliper bleed screw
Rear brake caliper pad retaining pins
18
Rear brake caliper to carrier (not T'bird, Adventurer or T'bird Sport)
40
Rear brake caliper to carrier (T'bird, Adventurer and T'bird Sport)
28
Rear brake master cylinder/cover mounting bolts
27
Rear brake master cylinder fork end lock nut
18
Rear brake master cylinder reservoir mounting screw
Rear brake light switch
15
Rear brake hose banjo bolts
25
Rear brake hose guide screws to 'P' clips
Rear brake hose clamp screws
Note 5
Note 1
Note 5
Rear brake torque arm to swinging arm bolts
28
Note 2
Brake disc to rear wheel
22
Note 1
Brake/clutch master cylinder clamp bolts
15
1.46
Brakes (continued)
Brake lever pivot bolt (not Tiger)
Brake lever pivot bolt (Tiger)
Brake lever pivot bolt locknut
Brake pedal to control plate (Tiger, T'bird, Adventurer and T'bird Sport)
27
Note 2
Rear brake torque arm to caliper carrier

28
Note 2
Brake hose clip to front mudguard (T'bird, Adventurer and T'bird Sport)
Footrests, Control Plates and Engine Mountings

Application
Torque(Nm)
Upper crankcase and linkage carriers to frame
95
Lower crankcase and linkage carriers to frame
95
Cylinder head to frame bolts
95
Front footrest assembly to control plate
45
Footrest rubber to footrest
Bank angle peg to footrest
Notes
Note 4
Control plates to frame bolts

(not Tiger, T'bird, Adventurer or T'bird Sport)
27
Control plate to frame M8x30 (Tiger)
27
Control plate to frame M10 capscrew

45
Control plate to frame M8 capscrew (T'bird and Adventurer)
30
Outrigger finisher to frame
12
Outrigger finisher screws (upper)
12
Outrigger finisher screws (lower)
Prop rails to frame outrigger (T'bird, Adventurer and T'bird Sport)
45
Gearchange pedal to control plate (Tiger)
27
Gearchange pedal to rubber (T'bird, Adventurer and T'bird Sport)
12
Note 2
Gearchange pedal to shaft
Note 2
Gearchange linkage rod locknuts
Rear footrest assembly to footrest hanger

42
Rear footrest assembly to footrest hanger

27
Seat lock assembly to footrest hanger
12
Seat lock assembly to airbox (T'bird, Adventurer and T'bird Sport)
Seat lock catch to bridge bracket
Footrest hanger to frame
27
Lifting handles to frame
27
Lifting handle bracket to frame (bolt) (1996 Trophy)
28
Lifting handle bracket to frame (nut) (1996 Trophy)
22
Centre stand to linkage carriers
40
Side stand bracket/linkage carrier to frame M 12
95
Side stand pivot bolt
20
1.47
Footrests, Control Plates and Engine Mountings (continued)
Side stand pivot bolt locknut
25
Side stand switch to bracket (not T'bird, Adventurer or T'bird Sport)
Side stand switch to bracket (T'bird, Adventurer and T'bird Sport)
Side stand bracket to frame (not T'bird, Adventurer or T'bird Sport)
22
Side stand bracket to engine (T'bird, Adventurer and T'bird Sport)
40
Note 2
Torque(Nm)
Notes
Electrical
Application
Spark plug
18
Alternator drive gear to shaft (nut and bolt)
40
Alternator drive gear to shaft (bolt only)
35
Alternator drive shock absorber to alternator
12
Alternator shaft bearing retaining bolt (capscrew)
12
Alternator shaft bearing retaining bolt (Torx screw)
10
Alternator mounting bolts
20
Starter motor mounting bolts
10
Starter motor cable connections
Battery terminals
Battery box bracket to frame
Battery box to bracket
Battery box and plenum chambers to frame
Electrical harness earth to frame
12
Ignition coils to frame
Rear indicator bracket to frame (not T'bird, Adventurer or T'bird Sport)
18
Indicator assemblies to bracket

Hand tight
Indicator to bracket, front & rear (T'bird, Adventurer and T'bird Sport)
18
Rear indicator and base to side panel (1996 Trophy)
Front indicator to fairing lower (1996 Trophy)
Tail light assembly to frame (not T'bird, Adventurer or T'bird Sport)
Hand tight
Instrument assembly to bracket/yoke
Twin headlight assembly to subframe
Trophy headlight assembly to cockpit fairing
Horn to engine (T'bird, Adventurer and T'bird Sport)
10
Horn cover to horn (T'bird, Adventurer and T'bird Sport)
Number plate lamp bracket to mudguard (T'bird and T'bird Sport)
Number plate lamp to bracket (T'bird and T'bird Sport)
Tail lamp to mudguard (T'bird and T'bird Sport)
Fuse box to battery box door (T'bird, Adventurer and T'bird Sport)
2.5
Headlamp rim
Headlamp bowl to bracket
10
Headlamp bracket to fork tube
1.48
Notes 1, 10
Note 1
Note 1
Bodywork
Application
Torque(Nm)
Fairing upper subframe to headstock (all +Tiger M8x12 Torx)
28
Fairing subframe to headstock (Tiger M8x30 capscrew only)
28
Fairing lower subframe brackets to crankcase
18
Fairing lower subframe to brackets
Windscreen to cockpit fairing
Notes
Hand tight
Inner trim panels to outer fairings
Cockpit and lower fairing to upper subframe
Lower fairing LHS to RHS, lower fairing to cockpit (centre)
Hand tight
Lower fairing to lower subframe
Lower fairing to cylinder head
10
Rear mudguard to frame (not T'bird, Adventurer or T'bird Sport)
15
Rear mudguard/brackets/wheel cover to frame/mudguard

(T'bird and T'bird Sport)
Rear mudguard to frame -front upper (Adventurer)
60
Rear mudguard to frame -front lower (Adventurer)
35
Rear mudguard to frame -front location (Adventurer)
Front mudguard to fork leg (not T'bird, Adventurer or T'bird Sport)
Front mudguard to fork leg (T'bird, Adventurer and T'bird Sport)
12
Mudflap to swinging arm (not Tiger)
Mudflap to swinging arm (Tiger)
Rear reflector to mudguard
Hand tight
Bayonets to side panels
Side panel to frame - under seat
Side panel to frame (T'bird, Adventurer and T'bird Sport)
Grab rail/side panel to frame (single rail bolts and twin grab rail front bolts)
27
Grab rail/side panel to frame (rear bolt- twin grab rails)
10
End cap to side panel
Rear rack to frame (Tiger)
27
Side panel and rear cover to frame M6x24 (Tiger)
Side panel and rear cover to frame M6x17 screw (Tiger)
Sump guard to control plate/crankcase (Tiger)
27
Cover plate to sump guard (Tiger)
10
Seat strap to seat (T'bird)
9.5
Seat rails to spine tube
95
NOTES: All torques quoted are in Nm only.

1.
Threads of fastener are pretreated with micro-encapsulated locking compound.
2.
Clean threads and apply Locktite 'Nutlock' Grade 242.
3.
Clean threads and apply Locktite 'Studlock' Grade 270.
4.
Lubricate threads with engine oil.
5.
Replace sealing washer every time.
6.
Refer to relevant assembly instructions.
7.
Tighten in 2 stages, first 8 Nm then 20 Nm.
8.
Apply Copper Grease to threads.
.
9.
Lubricate threads and face of nut with molybdenum disulphide grease. Tighten in 2 stages, first 14 Nm then 120 using Triumph
torque turn gauge 3880105-T0301.
10. Replace bolt/screw every time.
1.49
ROUTINE MAINTENANCE
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Periodic Maintenance Charts
2.4
Battery
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrolyte level inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6
2.7
2.7
Spark plugs
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8
2.8
2.8
Cam cover
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9
2.10
Valve clearance
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11
2.11
Engine oil
Level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil and oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.15
2.17
Cooling system
Coolant level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling (not Thunderbird, Thunderbird Sport or Adventurer) . . . . . . . . . . . . . . . . .
Filling (Thunderbird, Thunderbird Sport & Adventurer) . . . . . . . . . . . . . . . . . . . . .
Radiator hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.18
2.19
2.19
2.19
2.20
2.20
2.20
Nuts, Bolts, Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.20
Clutch
Fluid level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch fluid replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.21
2.21
2.21
Carburettors
Carburettor synchronisation
2.22
Throttle grip & Choke lever

Inspection ............................................. , . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.24
2.25
Air intake assembly

Removal (not Thunderbird, Thunderbird Sport or Adventurer) . . . . . . . . . . . . . .
Installation (not Thunderbird, Thunderbird Sport or Adventurer) . . . . . . . . . . . . .
Removal (Thunderbird, Thunderbird Sport & Adventurer) . . . . . . . . . . . . . . . . . .
Installation (Thunderbird, Thunderbird Sport & Adventurer) . . . . . . . . . . . . . . . .
Airbox Drain Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.25
2.26
2.27
2.27
2.28
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.28
Wheelsffyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.29
2.1
2 MAINTENANCE
Drive chain
Chain slack inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive chain slider (Tiger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain slack adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.30
2.30
2.31
2.32
2.33
2.33
Brakes
Disc brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake hydraulic seals and hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake pads/wear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake light inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.34
2.35
2.35
2.35
2.36
2.36
Steering
Steering inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering head bearing lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.37
2.37
Front suspension
Front fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front fork oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.37
2.37
Wheel bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.38
Rear suspension
Rear suspension inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.38
2.2
MAINTENANCE
INTRODUCTION
This maintenance section contains information necessary to perform the recommended inspections and adjustments.
WARNING: The importance of good maintenance cannot be overestimated. The tasks described
will help to ensure the safe and reliable operation of your Triumph motorcycle. Never attempt to cut
costs by neglecting the maintenance requirements of your machine as this will result in the premature failure
of the component(s) concerned and may lead to an unsafe riding condition and an accident
All service technicians should be fully conversant with this entire chapter.
BODYWORK AND FUEL TANK
WARNING: In order to carry out most of the maintenance tasks in this section of the manual it will be
necessary to remove the fuel tank and all or part of the bodywork. For details of removal and
assembly of these items, refer to the fuel system and body sections of the manual where full details will be
found. Also, details on the safe handling and storage of fuel can be found in the general information section.
Failure to observe the information given could lead to dangerous riding and working conditions which may
cause personal injury and damage to property.
Service Check Sheets

Triumph are pleased to be able to offer pads of service check sheets to aid technicians during servicing of Triumph
motorcycles. Each pad has 50 single sided service sheets which have tick boxes to indicate the correct maintenance
requirement at each mileage interval.
The pads are available from your Triumph parts department under the following part numbers:
T3850550- Service Sheet Pad, English Language

T3850555 - Service Sheet Pad, French Language
T3850560 - Service Sheet Pad, German Language
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2.3
Service
Sheet
2 MAINTENANCE
PERIODIC MAINTENANCE CHART:AII models except Tiger
INTERVAL
:j:
Whichever
comes first
Odometer Reading Miles (Km)
OPERATION
*
500
(800)
Every
6000
(10000)
Carburettor synchronisation- check
Idle speed -check

Steering play- check
Brake fluid level -check
month
Brake light/switch - check

Clutch fluid level- check
month
Battery electrolyte level -check
month
Valve clearance - check
Airbox drain tube- drain out

Engine oil -change
f-----
year
Oil filter- replace
year
Radiator hoses, connections- check
year
Throttle and choke cables- check

Nuts, bolts, fasteners- check
Spark plug- inspect gap
Spark plug - replacement
Brake pad wear- check

Tyre wear- check/Wheels- inspect
t
t
t
Drive chain wear- check

Drive chain -lubricate
Every 200 miles (300 km)
Drive chain slack- check
t Rear suspension, swinging arm -lubricate

*
Brake fluid-- change
2 years
Clutch fluid- change
2 years
Front fork oil -change

Steering stem bearing- lubricate
2 years
Coolant - change
2 years
Master cylinder cup and dust seal - replace
2 years
Caliper piston seal and dust seal - replace
2 years
Clutch slave cylinder piston seal - replace
2 years
Brake clutch hose and pipe- replace
Clutch hose and p1pe - replace
4 years
Fuel hose - replace
4 years
4 years
Year
Evap' system fuel collection hoses- drain out
Should be serviced by an authorised Triumph Dealer.
:t:: For h1gher mileages repeat at the frequency intervals established here
t:
In severe climates (hot, dusty, etc.) repeat checks and adjustments at more frequent intervals.
2.4
Grease points- lubricate
Evap' loss system pressure regulator- renew
18000
(30000)
Fuel system -check
12000
(20000)
3 years or 24,000 miles
Air cleaner- replace
15000
(25000)
9000
(15000)
3000
(5000)
MAINTENANCE
PERIODIC MAINTENANCE CHART:- Tiger

INTERVAL
:j:
Whichever
comes first
Odometer Reading Miles (Km)
OPERATION
*
500
(800)
Every
Carburettor synchronisation -check
Idle speed - check
Steering Qlay_- check

Brake fluid level- check
month
Brake light/switch- check

Clutch fluid level- check
month
Battery electrolyte level -check
month
Valve clearance - check
Airbox drain tube- drain out

Engine oil - change
year
Oil filter- replace
year
Radiator hoses, connections- check
year
Throttle and choke cables- check
Spark plug- inspect gap
Tyre wear- check/Wheels and spokes - inspect
t Drive chain wear- check
t Drive chain- lubricate
t Rear suspension, swinging arm- lubricate
Fuel system- check
t Air cleaner- replace
Brake fluid- change
2 years
Clutch fluid- change
2 years
Front fork oil - change
Steering stem bearing- lubricate
2 years
Coolant - change
2 years
Master cylinder cup and dust seal- replace
2 years
Caliper piston seal and dust seal- replace
2 years
Clutch slave cylinder piston seal - replace
2 years
Brake clutch hose and pipe - replace
Clutch hose and pipe- replace
4 years
Fuel hose- replace
4 years
Drive chain slider renew

Year
Should be serv1ced by an authonsed Tnumph Dealer.
t: For higher mileages repeat at the frequency intervals established here.

t: In severe climates (hot, dusty, etc.) repeat checks and adjustments at more frequent
intervals.
2.5
4 years
Evap' system fuel collection hoses- drain out
Grease points- lubricate
Evap' loss system pressure regulator- renew
t Drive chain slack- check
Spark plug - replacement

Brake pad wear- check
18000
(30000)
Nuts, bolts, fasteners- check
12000
(20000)
6000
(10000)
15000
(25000)
9000
(15000)
3000
(5000)
MAINTENANCE
BATTERY REMOVAUREFIT
Removal - all models except Thunderbird,

Thunderbird Sport & Adventurer
WARNING: The battery gives off

explosive gases; keep sparks, flames
and cigarettes away. Provide adequate ventilation
when charging or using the battery in an enclosed
space.
The battery contains sulphuric acid (electrolyte).
Contact with skin or eyes may cause severe burns.
Wear protective clothing and a face shield.
If electrolyte gets on your skin, flush with
water immediately.
1.
Remove the seat and document tray (if fitted).
2.
Disconnect the battery negative (black) lead first,

then the positive (red) lead.
3.
Remove the battery strap.
4.
Take the battery, complete with breather tube, out of

the case.
5.
Wipe the battery using a clean, dry cloth. Ensure

that the battery lead connections are free from
oxidation deposits.
If electrolyte gets in your eyes, flush with

water for at least 15 minutes and SEEK MEDICAL '
ATTENTION IMMEDIATELY.
If electrolyte is swallowed, drink large
quantities of water and SEEK MEDICAL
KEEP ELECTROLYTE OUT OF THE REACH OF

CHILDREN.
----
___
___)
WARNING:
The battery contains harmful
..
motorcycle.
abies together or reverse the polarity of the
abies as any of these actions may cause a spark
which would ignite bat.tery gasses causing a risk of
ersonal injury.
1. Battery
2. Negative (-)terminal
3. Positive(+) terminal
Removal, Thunderbird, Thunderbird Sport

& Adventurer
WARNING: The battery electrolyte is

corrosive and poisonous. Never swallow
battery electrolyte or allow to come into contact
with the skin. Always wear eye and skin protectionj
when adjusting the electrolyte level
1.
Remove the seat and right hand side panel.
2.
Disconnect the battery leads, negative (-) black

lead first then the positive(+) red lead.
CAUTION: When checking the battery

electrolyte level, or adding distilled water,
ensure that the breather is not blocked. A blocked
breather may cause a build-up of gas in the battery
which would damage the battery case.
To prevent battery damage, use only distilled water

in the battery. Tap water will shorten the service life
of the battery.
Filling the battery above the UPPER LEVEL line
may cause the electrolyte to overflow, resulting in
corrosion to engine or nearby parts. Immediately
wash off any spilled electrolyte.
1. Flasher Unit Connection.
2. Battery Box Door Retaining Screw
3. Fuse Box Connection
2.6
MAINTENANCE
3.
Release the battery retaining strap.
4.
Disconnect the flasher unit and the fuse box

connection to the main harness.
5.
Gently ease the harness away from the battery

box.
6.
Release the screw securing the door to the

battery box. Release and un-clip the battery box
door.
7.
Disconnect the battery breather tube.
WARNING: Filling the battery above the

UPPER LEVEL line may cause the
electrolyte to overflow.
Electrolyte is highly
corrosive and will damage clothing and cause
burns if in contact with the skin
Never route the battery breather pipe in any way
which could cause the pipe to become blocked or
trapped. A blocked or damaged pipe will cause a
build up of pressurised, explosive gas which may
ignite.
When adding electrolyte, always wear eye and
skin protection.
NOTE:
8.
The breather tube may fall to the floor when

disconnected
Remove the battery by sliding sideways out of the
battery box.
Installation - all models except

Thunderbird, Thunderbird Sport &
Adventurer
1.
Battery Electrolyte Level Check
Check that the battery case rubber pad is

correctly located in the bottom of the battery case.
Place the battery in the battery case and connect
the battery breather pipe.
1.
Remove the battery from the motorcycle, see

Battery Removal.
2.
2.
Check that the electrolyte level in each cell is

between the upper and lower level lines.
3.
Fit the battery strap.
4.
If the electrolyte level is low in any cell, top-up the

cell with distilled water.
Reconnect the battery positive (red) lead first then

the negative (black) lead.
5.
Lightly smear a coating of petroleum jelly on

terminals to prevent corrosion.
6.
Cover the terminals with the protective caps.
7.
Refit the seat and document container (if fitted).
Installation, Thunderbird, Thunderbird

Sport & Adventurer
3.
1.
Clean the battery box.
2.
Place the battery in the battery box, and connect

the battery breather tube.
3.
Re-fit the battery retaining strap.
1. Upper Level
2. Lower Level
3. Breather Tube Connection
4.
Re-fit the door to the battery box and tighten the

door retaining screw.
4.
5.
Re-connect the flasher unit and fuse box to the

main harness.
6.
Reconnect the battery positive(+) red lead first

then the negative (-) black lead.
7.
Apply a light coat of petroleum jelly to the battery

8.
9.
Refit the right hand side panel and the seat.
On refitting, ensure that the battery breather pipe is

routed down the inside of the centre stand spring
(where a stand is fitted) or is routed between the
frame and swinging arm when no centre stand is
fitted.
The battery electrolyte level must be kept between the

upper and lower level lines. Check the electrolyte level in
each cell in accordance with periodic maintenance chart.
2.7
MAINTENANCE
NOTE:
SPARK PLUGS
The standard spark plug is shown in the specification
section. However, a winter grade spark plug has been
approved for use in climates where extremely low
ambient temperatures are experienced. Consult your
Triumph dealer or the parts information for advice
concerning winter grade spark plugs.
Spark plugs should be taken out periodically, in
accordance with the Maintenance Chart, for inspection,
resetting of the air gap, or total replacement.
Make a note of the spark plug lead positions in

the head before disconnection. This will help in
matching the correct cylinder with the correct
plug lead when refitting.
8.
Using a suitable deep socket or box spanner,

unscrew and remove the spark plugs.
NOTE:
It is advisable to cover spark plug holes if the

plugs are not being replaced immediately.
Removal
Maintenance
1.
1.
Remove the seat.
2.
Remove both side panels (not necessary on Tiger,

Adventurer, Thunderbird Sport or Thunderbird
models).
3.
Disconnect the battery negative (black) lead first.
4.
Remove the fuel tank as described in the fuel

system section.
Measure the air gap with feeler gauges and

adjust the gap, if incorrect, by gently bending the
earth electrode.
WARNING: Observe the warning advice

given in the general information section
on the safe handling of fuel and fuel containers. A
fire, causing personal injury, could result from
spilled fuel or fuel not handled and stored in the
correct manner.
5.
Remove the cam cover cowls (if fitted) from the

frame.
6.
Clean around the spark plug caps to remove all

traces of road debris and dirt.
7.
Carefully pull the spark plug caps from the spark

plugs.
Measuring the spark plug gap
NOTE:
Correct spark plug gap - 0.8-0.9mm.
2.
If the spark plug electrodes are corroded or

damaged, or if any part of the insulator is cracked,
replace the plug with a new item of the correct type
and grade.
Installation
1.
Lightly coat the threads of each plug with

'copper-slip' type grease.
~.
CAUTION: Do not overtighten the spark

plugs as damage to the threads in the
cylinder head may take place.
L.ll
1. Spark Plug Caps
2.8
2.
Fit and tighten each plug to 18 Nm.
3.
Fit the spark plug caps in the order noted in

paragraph 7 of the removal procedure.
4.
Refit the cam cover cowls (where fitted) to the

frame.
5.
Refit the fuel tank.
6.
Reconnect the battery, positive (red) lead first.
7.
Refit the side panels (if removed).
8.
Replace the seat.
MAINTENANCE
CAMSHAFT COVER
10. Remove the cam cover gasket together with the

seals from the spark plug holes.
Removal
1.
Remove the seat.
2.

models) and one lower fairing panel (fully faired
models only).
3.
Disconnect and remove the battery, negative

(black) lead first (disconnect only on Thunderbird,
Thunderbird Sport & Adventurer).
4.
11.
Remove any residual oil from the exhaust side of

the cylinder head using a syringe or lint free cloth.

system section.

correct manner.
5.
Remove the cam cover cowls from the frame (if

fitted).
6.
Remove the ignition coils and spark plug leads.
4 cylinder engines
NOTE:

the coils before disconnection. This will help in
7.
Ease the wiring harness and throttle cables to give

access to the cam cover
8.
Progressively release the cam cover bolts in the

order shown to the right. Remove the bolts and
seals.
NOTE:
The two longer bolts are fitted at the right hand

end adjacent to the cam chain.
9.
Remove the cam cover. (Lightly tap with a rubber

mallet if necessary.)
NOTE:
On Thunderbird, Thunderbird Sport &

Adventurer, the cover must be withdrawn from
the right hand side.
3 cylinder engines
CAUTION: Never use a lever to remove

the camshaft cover from the head. This
will damage the mating surfaces of the cylinder
head and cover leading to an oil leak.
Camshaft Cover Bolt Release!Tightening

Sequence
2.9
MAINTENANCE
5.
Fit the screws and seals, then tighten until finger

tight.
Check the condition of all joints and seals including

the cam cover screw seals. Replace as necessary.
6.
Finally tighten the screws, in same order as the

releasing sequence, to 1ONm.
Ensure all mating surfaces are clean and free from

oil.
7.
Apply silicone sealant, as indicated in the diagram

below, to the cylinder head, cam cover and to the
spark plug hole seals.
Fit the ignition coils and attach the spark plug leads
in the order noted in paragraph 6 of the removal
procedure.
8.
Refit the cam cover cowls to the frame (if fitted).
9.
Installation
1.
2.
3.
10. Refit the battery and reconnect, positive (red) lead

first (reconnect only on Thunderbird, Thunderbird
Sport & Adventurer).
11.
Refit both side panels and the fairing (if removed).
12. Refit the seat.
1. Silicone sealer areas

4.
Fit the cam cover, ensuring all seals are positioned

correctly.
NOTE:
On Thunderbird,
Thunderbird
Sport &
Adventurer, the cover must be installed from
2.10
MAINTENANCE
VALVE CLEARANCES
Camshaft, valve, valve shim and valve seat wear affects
the valve clearances. The effect of this wear is to change
the gap between the camshaft and valve shim causing
engine noise and improper running.
If the valve clearances become too close, permanent
damage to the valve and valve seat will take place
The valve clearance for each valve should be checked
and adjusted in accordance with the periodic
maintenance chart.
VALVE CLEARANCE MEASUREMENT

Measuring Valve Clearance
NOTE:
Valve clearance measurement must be carried
out with the engine cold.

1.
2.
3.
Remove the camshaft cover as previously

described in this section.
Remove the spark plugs to reduce compression
resistance during turning of the engine.
Select a high gear and, using the rear wheel to turn
the engine over, turn the engine until a pair of
camshaft lobes are positioned pointing away from
the valves.
Correct Clearance Specification

Inlet:
0.10 - 0.15mm
Exhaust: 0.15 - 0.20mm
A_,
CAUTION: If the valve clearances are not

checked (and corrected) wear could
cause the valves to remain partly open, which
lowers performance, burns the valves and valve
seats and may cause serious engine damage.
l,U
VALVE CLEARANCE ADJUSTMENT

Valves are adjusted, in pairs, using tool 3880012 to
hold the valve open during shim removal and
replacement.
1.
Rotate each tappet bucket until the slots in the

buckets are positioned such that they are pointing
to the outside of the head.
Arrange slots to outside of head
Cam Lobe Point Away From Valves
4.
Using feeler gauges, measure and record the

clearances for this cylinder only.
5.
Repeat the process until the valve clearances for

each valve have been checked and recorded.
NOTE:
2.
If the measurement does not fall within the

specified range, adjustment must be made.
The charts which follow describe the method of
selecting as new shim.
2.11
Remove the spark plugs to reduce compression

resistance. Engage a high gear and, with the aid of
an assistant, rotate the engine by turning the rear
wheel forward until the pair of valves to be adjusted
are fully open. Take care to ensure that the tappet
buckets do not turn during opening.
MAINTENANCE
NOTE: The tool mounting plate is marked 'IN' and
3.
4.
'EX' denoting the inlet and exhaust sides of the

tool. Always ensure that the tool assembly
instructions are closely followed to ensure
correct tool operation.
Loosely assemble the tool legs to the mounting
plate ensuring that the legs are assembled to the
correct side of the mounting plate for the valve
shims being changed. For example, if changing
inlet valve shims, the legs must be fitted to the side
marked 'IN'.
6.
Turn the engine over until the camshaft lobes for the
valves to be adjusted point directly away from the
valves. The tool legs will prevent the valves from
rising, allowing the shims to be removed using a soft
faced lever and a magnet.
NOTE:
The shim is often a tight fit in the tappet. Use a

suitable soft faced lever to remove the shim
from the tappet.
Locate the mounting plate to the camshaft caps

above the valves to be adjusted. The tool legs must
face towards the spark plug tubes and be mounted
to the correct side of the tool for the valve shims
being adjusted. Tighten the mounting plate fixings
to 7 Nm.
Removing/Replacing The Shim

5.
Take the selected replacement shim and lubricate

with engine oil. Fit the shim to the top of the tappet
by reversing the removal procedure.
6.
Turn the engine over until the camshaft fully opens

the valves. Remove the tool when the valve is fully
open. Check that the shim has seated correctly and
adjust, if necessary, before proceeding.
Tool in Position on Inlet Camshaft

5.
Hold the tool legs firmly against the mounting plate

and tighten the leg to mounting plate fixings to 7 Nm.
/\.I
CAUTION: With the tool fitted, full 360

rotation of the engine/camshaft is not
possible. The engine must be turned such that the
camshaft lobes turn within the available free space
allowed by the tool. Severe tool and camshaft
damage will result from camshaft contact with the
tool.
NOTE: The tool is designed to allow adjustment of 2
7.
pairs of valves without moving the mounting

plate. This is achieved by moving the tool legs
to a new location once one pair have been
adjusted.
Repeat the procedure until all valves have been
adjusted.
NOTE:
f6
2.12
A shim selection chart can be found on the

following two pages.
Exhaust Valve Clearance Adjustment Chart

MEASURED THICKNESS OF FITTED SHIM
2.oo 1 2.o5J2.1 o 1 2.1sl 2.20 1 2.2512.30 1 2.351 2.4o 1 2.451 2.5o 1 2.5512.60 12.65 12.70 12.75 12.8o 1 2.8512.90 1 2.951 3.oo 1 3.05 1 3.1 o 1 3.15 1 3.2o
0.00-0.04
0.05-0.09
0.10-0.14
2.00
2.00
2.05
2.10 2.15
2.20 2.25
2.30
2.35
2.40 2.45
2.50
2.55
2.60
2.65
2.70 2.75
2.80 2.85
2.90
2.95
3.00
3.05
2.00
2.05
2.10
2.15 2.20
2.25 2.30
2.35
2.40
2.45 2.50
2.55
2.60
2.65
2.70
2.75 2.80
2.85 2.90
2.95
3.00
3.05
3.10
2.05
2.10
2.15
2.20 2.25
2.30 2.35
2.40
2.45
2.50 2.55
2.60
2.65
2.70
2.75
2.80 2.85
2.90 2.95
3.00
3.05
3.10
3.15
3.10
3.15
3.20
3.20
CORRECT CLEARANCE. NO CHANGE OF SHIM REQUIRED
0.15-0.20
()
z
<(
2.25
2.30 2.35
2.40 2.45
2.50
2.55
2.60 2.65
2.70
2.75
2.25
2.30
2.35 2.40
2.45 2.50
2.55
2.60
2.65 2.70
2.75
2.80
2.85
2.90
2.95
3.10
3.15
0.31-0.35
2.15
2.20
2.25
2.30
2.35
2.40 2.45
2.50 2.55
2.60
2.65
2.70 2.75
2.80
2.85
2.90
2.95
3.00 3.05
3.10 3.15
3.20
2.35
2.40
2.45 2.50
2.55 2.60
2.65
2.70
2.75 2.80
2.85
2.90
2.95
300
3.05 3.10
3.15
3.20
2.80
2.85
2.90 2.95
3.00
2.30
0.41-0.45
2.25
2.30
2.35
2.40
2.45
2.50 2.55
2.60 2.65
2.70
2.75
2.80 2.85
2.90
2.95
3.00
3.05
3.10 3.15
0.46-0.50
2.30 2.35
2.40
2.45
2.50
2.55 2.60
2.65 2.70
2.75
2.80
2.85 2.90
2.95
3.00
3.05
3.10
3.15 3.20
()
0.51-0.55
2.35 2.40
2.45
2.50
2.55
2.60 2.65
2.70 2.75
2.80
2.85
2.90 2.95
3.00
3.05
3.10
3.15
3.20
:=i
0.56-0.60
2.40 2.45
2.50
2.55
2.60
2.65 2.70
2.75 2.80
2.85
2.90
2.95 3.00
3.05
3.10
3.15
3.20
0.61-0.65
2.45 2.50
2.55
2.60
2.65
2.70 2.75
2.80 2.85
2.90
2.95
3.00 3.05
3.10
3.15
3.20
1-
0.66-0.70
2.50
2.55
2.60
2.65
2.70
2.75 2.80
2.85 2.90
2.95
3.00
3.05 3.10
3.15
3.20
:::>
0.71-0.75
2.55 2.60
2.65
2.70
2.75
2.80 2.85
2.90 2.95
3.00
3.05
3.10 3.15
3.20
0.76-0.80
2.60 2.65
2.70
2.75
2.80
2.85 2.90
2.95 3.00
3.05
3.10
3.15 3.20
0.81-0.85
2.65
2.70
2.75
2.80
2.85
2.90 2.95
3.00 3.05
3.10
3.15
3.20
0.86-0.90
2.70
2.75
2.80
2.85
2.90
2.95 3.00
3.05 3.10
3.15
3.20
0.91-0.95
2.75 2.80
2.85
2.90
2.95
3.00 3.05
3.10 3.15
3.20
0.96-1.00
2.80 2.85
2.90
2.95
3.00
3.05 3.10
3.15 3.20
1.01-1.05
2.85
2.90
2.95
3.00
3.05
3.10 3.15
3.20
1.06-1.10
2.90 2.95
3.00
3.05
3.10
3.15 3.20
1.11-1.15
2.95 3.00
3.05
3.10
3.15
3.20
1.16-1.20
3.00 3.05
3.10
3.15
3.20
1.21-1.25
3.05
3.10
3.15
3.20
1.26-1.30
3.10 3.15
3.20
1.31-1.35
3.15 3.20
1.36-1.40
3.20
(IJ
<(
J:
><
w
c
w
a:
I
2.20
2.20
2.20 2.25
2.15
2.10 2.15
0.36-0.40
...1
1\)
2.05 2.10
0.26-0.30
a:
<(
.....
0.21-0.25
:::>
(IJ
<(
w
::2:
----------~
3.00
3.05
3.05
3.20
~:::}<(--<(;
0<;;,.(J.
~<(:,.
~~
0
g
EXHAUST VALVE
1.
Measure valve clearance (with engine cold)
2.
Remove shim and measure thickness with a

micrometer
3.
Match measured valve clearance from the left hand

vertical column with measured thickness of
fitted shim.
4.
The shim size specified where the lines

intersect will give correct clearance.
NOTE: If there is no clearance fit a shim

several sizes smaller and re-measure
~
N
1\)
Inlet Valve Clearance Adjustment Chart
MEASURED THICKNESS OF FITTED SHIM

2.10
2.15
2.20
2.25 2.30
2.35 2.40
2.45
2.50
2.55 2.60
2.65
2.70
2.75
2.80
2.85 2.90
2.95
3.00
3.05
3.10
3.15
3.20
2.00
2.05
2.10
2.15 2.20
2.25 2.30
2.35
2.40
2.45 2.50
2.55
2.60
2.65
2.70
2.75 2.80
2.85 2.90
2.95
3.00
3.05
3.10
2.00
2.05
2.10
2.15
2.20 2.25
2.30 2.35
2.40
2.45
2.50
2.60
2.65
2.70
2.75
2.80
2.95
3.00
3.05
3.10
3.15
3.20
2.00 2.05
0.00-0.04
0.05-0.09
0.10-0.15
2.15
2.20
2.25
2.30 2.35
2.40 2.45
2.50
2.55
2.60
2.65
2.70
2.75
2.80
2.85
2.90 2.95
3.00
3.05
3.10
3.15
0.21-0.25
2.10 2.15
2.20
2.25
2.30
2.35 2.40
2.45 2.50
2.55
2.60
2.65 2.70
2.75
2.80
2.85
2.90
2.95
3.05
3.10
3.15
3.20
0.26-0.30
2.15
2.20
2.25
2.30
2.35
2.40 2.45
2.50 2.55
2.60
2.65
2.70 2.75
2.80
2.85
2.90
2.95
3.00 3.05
3.10 3.15
3.20
0.31-0.35
2.20 2.25
2.30
2.35
2.40
2.45 2.50
2.55 2.60
2.65
2.70
2.75 2.80
2.85
2.90
2.95
3.00
3.05
3.10
3.15
3.20
(.)
w
~
2.25
2.30
2.35
2.40
2.45
2.50 2.55
2.60 2.65
2.70
2.75
2.80
2.85
2.90
2.95
3.00
3.05
3.10 3.15
0.41-0.45
2.30 2.35
2.40
2.45
2.50
2.55 2.60
2.65 2.70
2.75
2.80
2.85 2.90
2.95
3.00
3.05
3.10
3.15
0.46-0.50
2.35
2.40
2.45
2.50
2.55
2.60 2.65
2.70 2.75
2.80
2.85
2.90 2.95
3.00
3.05
3.10
3.15
3.20
0.51-0.55
2.40
2.45
2.50
2.55
2.60
2.65 2.70
2.75 2.80
2.85
2.90
2.95
3.00
3.05
3.10
3.15
3.20
2.80 2.85
2.90
2.95
3.00 3.05
3.10
3.15
3.20
3.20
0.56-0.60
2.45 2.50
2.55
2.60
2.65
0.61-0.65
2.50
2.55
2.60
2.65
2.70
2.75 2.80
2.85 2.90
2.95
3.00
3.05 3.10
3.15
1-
0.66-0.70
2.55
2.60
2.65
2.70
2.75
2.80 2.85
2.90 2.95
3.00
3.05
3.10 3.15
3.20
3.15 3.20
3.2o
0.71-0.75
2.60 2.65
2.70
2.75
2.80
2.85 2.90
2.95 3.00
3.05
3.10
0.76-0.80
2.65 2.70
2.75
2.80
2.85
2.90 2.95
3.00 3.05
3.10
3.15
a:
0.81-0.85
2.70 2.75
2.80
2.85
2.90
2.95 3.00
3.05 3.10
3.15
3.20
::::>
(J)
0.86-0.90
2.75 2.80
2.85
2.90
2.95
3.00 3.05
3.10 3.15
3.20
<t
0.91-0.95
2.80
2.85
2.90
2.95
3.00
3.05 3.10
3.15 3.20
0.96-1.00
2.85
2.90
2.95
3.00
3.05
3.10 3.15
3.20
1.01-1.05
2.90 2.95
3.00
3.05
3.10
3.15 3.20
1.06-1.10
2.95
3.00
3.05
3.10
3.15
3.20
1.11-1.15
3.00 3.05
3.10
3.15
3.20
1.16-1.20
3.05
3.10
3.15
3.20
1.21-1.25
3.10 3.15
3.20
1.26-1.30
3.15 3.20
1.31-1.35
3.20
3.00
0.36-0.40
2.70 2.75
...J
CORRECT CLEARANCE. NO CHANGE OF SHIM REQUIRED

2.10
...J
-1>-
2.90
2.05
<t
a:
<t
w
_....
2.85
0.16-0.20
(.)
1\.)
2.55
~"(-.~
~'(!...<(,
3.20
3.20
~'f'-<(;.
0<(,-a
INLET VALVE
1.
Measure valve clearance (with engine cold)
2.
Remove shim and measure thickness with a

micrometer
3.
Match measured valve clearance from the left hand

vertical column with measured thickness of
fitted shim.
4.
The shim size specified where the lines

intersect will give correct clearance.
NOTE: If there is no clearance fit a shim

several sizes smaller and re-measure
S2
~
<
Q
MAINTENANCE 2
ENGINE OIL
The engine oils which are used in all Triumph engines are
the result of careful research over a considerable period
of time. The use of an oil of the correct grade and
viscosity is most important.
The level should be checked when the motorcycle is on

level ground and in an upright position. The engine
should not have been run for at least 10 minutes. Do not
use either stand.
NOTE:
The actual level is indicated when the filler cap

has been screwed in, not when merely rested on
the top face.
1.
Stop engine, then wait for at least 10 minutes to

allow the oil to settle.
2.
Remove the dipstick, wipe clean, then fully replace

and withdraw again to measure the oil level.
Engine Oil Specification

Trident, Trophy, Daytona 1000, 900 & 750, Sprint,
Speed Triple, Tiger, Adventurer, Thunderbird Sport
and Thunderbird.
Semi Synthetic 1OW/40 or 15W/50 motorcycle oil
meeting or exceeding specification API - SG
Daytona 1200 and Daytona Super 3.
Fully Synthetic 1OW/40 or 15W/50 motorcycle oil
meeting or exceeding specification API - SG
If the oil level is too high, remove excess oil using a

syringe or other suitable device. If the oil level is too low,
add sufficient oil through the oil filler opening to bring the
oil to the correct level.
'!'
CAUTION: Triumph high performance

engines are designed to use fully
synthetic or semi-synthetic oil which must meet or
exceed API SG specification.
In particular, due to their increased performance,
the Daytona 1200 and Daytona Super 3 must only
be run on fully synthetic oil which must meet or
exceed API SG specification.
Do not add any chemical additives. The engine oil
also lubricates the clutch and additives could
cause the clutch to slip.
Do not use mineral, vegetable, non-detergent oil,

castor based oils or any oil not conforming to the
required specification as the use of these oils may
cause severe engine damage.
Ensure no foreign matter enters the crankcase
during an oil change or top-up as this will cause
engine damage.
1. Dipstick
2. Upper Oil Level Mark
3. Lower Oil Level Mark
Use only the grade listed for each model in the owner's
handbook and in the specification section of this manual.
Oil Level Inspection, (not Thunderbird,

Thunderbird Sport or Adventurer)
NOTE:

WARNING:
engine
oil
contains
potentially
harmful
The difference between upper

and lower
dipstick level is approximately 0.5 litres.
Early dipsticks are marked '3 and 4' to indicate 3

or 4 cylinder. This should not be confused with
any type of oil capacity measurement. Later
dipsticks, which are common to 3 and 4 cylinder
engines, are not marked.
WARNING: Motorcycle operation with

insufficient,
deteriorated,
or
contaminated engine oil will cause accelerated
wear and may result in engine or transmission
seizure. Seizure of the engine or transmission may
lead to loss of control and an accident.
The oil level is indicated by a dipstick incorporated in the

filler cap. The dipstick/filler cap is situated on the drive
chain sprocket cover on the left hand side of the
machine.
2.15
MAINTENANCE
NOTE:
Oil Level Inspection, Thunderbird,

WARNING:
engine
oil
contains
potentially
harmful
Stop engine, then wait for at least 10 minutes to

allow the oil to settle.
2.
The oil level is indicated by a sight glass situated on

the right hand side of the lower crankcase. When
the oil level is correct, the level of oil should be half
way up the sight glass.
NOTE:
The actual level is indicated when the
motorcycle is level and upright, not on the side
stand.
1. Sight Glass
2. Filler
3. Filler Plug
3.
If the oil level is too low, remove the plug situated in

the upper rear side of the clutch cover on the right
hand side of the motorcycle.
4.
Add oil, a little at a time, until the oil begins to show in

the sight glass. Then adjust to the correct level and
refit the plug.
If the oil has just been changed, fill the engine

until oil shows in the sight glass, start the
engine and allow to idle for a short time. This
ensures that all areas of the engine are filled
with oil. Stop the engine and allow the oil to
settle for a minimum of two minutes then check
and adjust the oil level.
5.
If the oil level is too high, remove the excess oil,

using a syringe or some other suitable device.
1.
2.16
WARNING: Motorcycle operation with \

insufficient,
deteriorated,
or
contaminated engine oil will cause accelerated
wear and may result in engine or transmission
seizure. Seizure of the engine or transmission may
MAINTENANCE
.tf
ENGINE OIL AND FILTER
CAUTION: Check all '0' ring seals for

damage. If necessary, replace any
damaged '0' rings to prevent a potential oil leak.
Removal
3.

Apply a smear of engine oil to the '0' ring on the filter

mounting bolt, fit the filter cover onto the bolt, and
install the spring and flat washer.
WARNING:
engine
oil
contains
potentially
harmful
1.
Position the motorcycle on level ground.
2.
Start the motorcycle and allow the engine to reach

normal operating temperature.
3.
Stop the engine.
4.
Place an oil pan beneath the sump.
5.
Remove the engine sump drain plug and allow the

oil to drain completely.
6.
1. Mounting Bolt
3. Spring
5. Filter Element
7. '0' Rings
2. Filter Cover
4. Flat Washer
6. Grommet
4.
Apply a smear of engine oil to the grommets on both

sides of the filter element. Rotate the filter to work
the element into place on the bolt. Ensure that the
grommets do not slip out of place.
5.
Fit the other flat washer.
6.
Install the oil filter, tightening the filter mounting bolt

to 18 Nm.
1. Sump Drain Plug
CAUTION: Replace any damaged sealing

washers before assembling the filter.
Damaged sealing washers may cause an oil leak.
2. Oil Filter Bolt
Installation
1.
After the oil has completely drained out, fit a new

sealing washer to the sump drain plug. Refit the
drain plug and tighten to 48 Nm for M22 drain
plugs and 28 Nm for M14 drain plugs.
7.
Fill the engine with oil of the correct type and grade
listed in the owner's handbook.
8.
Start the engine and allow to run for a short period at

idle speed. Ensure that the oil pressure warning
light extinguishes after starting. Stop the engine
and check for oil leaks.
1'

2.
CAUTION: Stop the engine if the oil light

fails to extinguish. Investigate and rectify
the cause before re-starting the engine. Running
an engine with the oil light on will cause severe
engine damage.
Remove the oil filter and seals from the bolt noting
their relative positions. Thoroughly clean the bolt,
washers and spring and fit a new oil filter.
9.
2.17
Check the oil level and adjust to the correct level.
MAINTENANCE
COOLING SYSTEM
Coolant level inspection - Thunderbird,

Coolant level inspection {not Thunderbird,

Thunderbird Sport or Adventurer)
WARNING: Do not remove the coolant

pressure cap when the engine is hot.
When the engine is hot, the coolant inside the
radiator is hot and also under pressure. Contact
with the pressurised coolant will cause scalds and
skin damage.
1.
Position the motorcycle on level ground and in an

upright position.
2.
Remove the seat.
3.
Check the coolant level in the expansion tank. The

coolant level should be between the 'MAX
and 'MIN' marks.

skin damage.
1.

upright position.
2.
The coolant level should be between the 'MAX' and

'MIN' marks
1. 'MAX' mark
2. 'MIN' mark
1.
2.
3.
4.
4.
Expansion Tank
Expansion Tank Filler Cap
'Max' Mark
'Min' Mark
If the level of coolant is low remove the cap from the
expansion tank, and add coolant mixture to bring
the level up to the 'MAX' mark. Refit the cap.
"J'
CAUTION: If the coolant level is found to

be low, or if coolant has to be added
regularly, inspect the cooling system for coolant
leaks. If necessary, pressure test the system to
locate the source of the leak and rectify as
necessary.
Coolant leaks may result in engine damage
through overheating.
2.18
3.
If it is necessary to add coolant, the fuel tank must

first be removed as described in the fuel system
section.
4.
Remove the cap from the expansion tank, and add

coolant mixture through the filler opening to the
'MAX' mark. Refit the cap.
MAINTENANCE 2
Coolant
A permanent type of antifreeze is installed in the

cooling system when the motorcycle leaves the
factory. It is coloured blue, contains a 50%
solution of ethylene glycol, and has a freezing
point of -35C (-31 F).
If the coolant level is being checked because

the temperature gauge needle has gone into the
red zone, check the coolant level in the radiator.
Top-up if necessary.

skin damage.
3.
Remove the crankcase coolant drain plug.
4.
Release the water pump drain plug.

~ contains anti freeze and corrosion
inhibitors is made from toxic chemicals which are
Never swallow
CAUTION:
coolant would 'attack' the metal surfaces and the
resulting corrosion would cause blockages in the
cooling system leading to engine damage through
overheating. Always use the correct anti-freeze as
specified in the owner's handbook. Never use a
properties.
1. Crankcase Drain Plug

2. Water Pump Drain Plug

Filling (Not Thunderbird, Thunderbird

Sport or Adventurer)

severe damage.
1.
Refit the cylinder block drain plug and tighten to 13

Nm.
2.
Refit the water pump drain plug and tighten to

13 Nm.
3.
Slowly add coolant mixture to the system, through

the radiator filler, until the radiator is full.
4.
Start the motorcycle and allow the engine to idle for

a short period of time to allow any air to be expelled
from the system. Stop the engine and top up the
coolant level as necessary.
5.
Fit the coolant pressure cap.
6.
Check the expansion tank level and top up if

necessary.
7.
Refit the bodywork where necessary.
COOLANT REPLACEMENT
Drainage (all models)
1.
Remove the seat and lower fairing panels where

necessary. Place a container beneath the left hand
side of the machine to collect the displaced coolant.
2.
Remove the coolant pressure cap to help drainage.
2.19
2
8.
MAINTENANCE
Carry out a short road test to warm the engine to

normal operating temperature. Allow the engine to
cool and recheck the coolant level. Adjust as
necessary
RADIATOR HOSES
'!'
CAUTION: Some models are fitted with

crimp type hose clips which cannot be
re-used if removed. If a crimp type clip is re-used, a
coolant leak could result causing overheating and
consequently engine damage.
Filling (Thunderbird, Thunderbird Sport &

Adventurer)
1.

Nm.
2.

13 Nm.
Regularly
check
all
radiator
hoses
for
cracks/deterioration and examine hose clips for security
in accordance with the periodic maintenance chart.
3.

system section.
RADIATOR AND COOLING FAN
Check the radiator fins for obstruction by insects, mud,

leaves and general debris. Clean off any obstructions by
hand or with a stream of low pressure water.

correct manner.
4.
Release the bleed screw on the top of the

thermostat housing.
WARNING: The cooling fan operates

automatically, even with the ignition
switch off. To prevent personal injury, keep hands
and clothing away from the fan blades at all times.
{',
CAUTION: Using high-pressure water,

such as from a car-wash facility, can
damage the radiator fins and impair the radiator's
efficiency.
Do not obstruct or deflect airflow through the

radiator by installing unauthorized accessories in
front of the radiator or behind the cooling fan.
Interference with the radiator airflow can lead to
overheating and consequent engine damage.
NUTS, BOLTS, FASTENERS- CHECK

SECURITY
1 . Thermostat housing
2. Coolant filler
3. Bleed Screw
5.
Inspect all areas of the motorcycle, at the intervals

specified in the periodic maintenance chart, for loose
fasteners etc.
Tighten any loose fasteners in
accordance with the torque chart.
Slowly add coolant mixture to the system through

the filler until the system is full. Close the bleed
screw.
6.
Temporarily refit the fuel tank. Start the motorcycle

and allow the engine to idle for a short period of time
to allow any air to be expelled from the system. Stop
the engine and top up the coolant level as
necessary.
7.
Fully refit the fuel tank as described in the fuel

system section.
WARNING: Fasteners must be inspected

at the specified interval and, if necessary,
tightened using a torque wrench of known,
accurate calibration. Failure to check and tighten
fasteners at the specified interval may result in
instability, loss of control and an accident.
2.20
MAINTENANCE 2
CLUTCH
The motorcycle is equipped with a hydraulically operated
clutch that requires no adjustment except for inspection
of the hydraulic fluid level in accordance with the periodic
maintenance chart.
A
.41&
WARNING: Ensure absolute cleanliness

when adding clutch fluid to the clutch
fluid reservoir. Do not allow moisture or debris to
enter the cylinder as this will adversely affect the
fluid properties. Always use fluid from a sealed
container and do not use fluid from a container
which has been opened for any period of time.
Always check for fluid leakage around hydraulic
fittings and for damage to hoses.
1. Fluid Reservoir (cover removed)

2. Upper Level
(except Thunderbird Sport)
A dangerous riding condition leading to an

accident could result if this warning is ignored.
CAUTION: To prevent body damage, do

not spill clutch fluid onto any area of the
bodywork.
A
.41&
WARNING: Use only DOT. 4 specification

clutch fluid as listed in the general
information section of this manual. The use of
clutch fluids other than those DOT. 4 fluids listed
in the general information section may reduce the
efficiency of the clutch system leading to an
accident.
1. Upper Fluid Level
2. Lower Fluid Level
(Thunderbird Sport)
Clutch Fluid Level Inspection

1.
The fluid level in the reservoir must be kept

between the upper and lower level lines (reservoir
held horizontal).
Clutch Fluid, Hose and Hydraulic Seals

Renew the clutch fluid, the hose and the hydraulic
seals in the master and slave cylinders in accordance
with the periodic maintenance chart.
A
.41&
WARNING: Failure to change clutch fluid,

hose and hydraulic seals at the specified
interval could result in reduced clutch efficiency
leading to loss of control and an accident.
1. Fluid Reservoir
2. Lower Fluid Level
(except Thunderbird Sport)
2.21
2 MAINTENANCE
CARBURETTORS
NOTE:
Carburettor Synchronisation
WARNING: In the following procedure,

. . . . the motorcycle engine must be run. The
exhaust fumes given off by the engine, when
running, contain carbon monoxide and other toxic
gases. Never start or leave the engine running in a
confined space unless an exhaust extraction
system is available and is connected directly to the
motorcycle exhaust system. If such a system is
not available, ensure that the building is
adequately ventilated to prevent a build up of
gases.
Remember, carbon monoxide is a
colourless, odourless gas which will cause
unconsciousness or death if inhaled in sufficient
quantity.
Any vacuum pipes to the fuel tap or evaporative

loss system may be disconnected and sealed
during the adjustment procedure.
6.
Support the vacuum gauges and position the fuel

tank adjacent to, and higher than, the carburettors.
Refit the fuel pipes to the carburettors.
ON
ALL
MODELS
EXCEPT
TIGER.
THUNDERBIRD. THUNDERBIRD SPORT &
ADVENTURER, Turn the fuel tap to the 'PRI'
position.
ON TIGER, THUNDERBIRD & ADVENTURER,
turn the fuel tap to the 'ON' position
7.
The carburettors are now ready for the adjustment

process to begin. Start the engine and allow it to idle
whilst measuring the intake vacuum for each
carburettor.
8.
On 4 cylinder engines the carburettor for number 3

cylinder is designated as a 'master' carburettor. On
3 cylinder engines, the 'master' carburettor is the
centre carburettor.
The adjustment process
matches the vacuum settings for the remaining
carburettors to the 'master' carburettor.
--------------------------
1.
Start motorcycle and allow the engine to reach

2.
Check that the idle speed is between 950 and 1050

rpm (r/min). Adjust as necessary by turning the idle
adjusting screw on the left hand side of the
carburettors.
Vacuum at idle speed should read between 5.00

and 6.00 inches Hg (127-152 mm Hg).
9.
1. Idle Speed Adjustment

3.
4.
Open and close the throttle several times to check

that the idle speed does not fluctuate from the
original setting. Re-adjust as necessary then stop
the engine.
system section.
10. Once the vacuum setting for the master carburettor

has been set, match the remaining carburettor
settings to the master carburettor by turning the
adjuster screws (A, B and C in the diagram right).
Once all vacuum settings are matched, reset the
idle speed and stop the engine.
NOTE:
The adjustment is very sensitive. A small

change in the adjuster position will significantly
affect the vacuum setting for the carburettor.
Each time a synchronisation adjustment is

made, idle speed should also be checked and
adjusted to between 950 and 1050 rpm (r/min).
Number one cylinder is the outer left hand

cylinder when viewed from the riding position.

fire causing personal injury and damage to
property could result from spilled fuel or fuel not
handled and stored in the correct manner.
5.
Set the vacuum on the 'master' carburettor by

turning the idle speed adjuster.
Adjuster A affects cylinder No 1 on 3 & 4

cylinder engines.
Adjuster B affects cylinder No 4 on 4 cyl engines
and cylinder No 3 on 3 cylinder engines.
Adjuster C affects cylinder number 2 on 4
cylinder engines only.
11. Remove the fuel tank and disconnect the vacuum
gauges. Refit all vacuum pipes disconnected for the
adjustment process. Refit the fuel tank
Attach a set of vacuum gauges, one to each

carburettor. The vacuum take off connections are
on top of each carburettor, adjacent to the
diaphragm cover.
2.22
MAINTENANCE 2
4 Cylinder
FWD
Master Carburettor
3 Cylinder
'FWD
1. Blanking Caps
2. Fuel Tap Vacuum Pipe* (From Centre Carb On 3 Cyl)
3. Vacuum Gauge
*Not Fitted On Tiger, Thunderbird, Thunderbird Sport or Adventurer
2.23
MAINTENANCE
THROTTLE GRIP
CHOKE LEVER
If the throttle grip has excessive free-play, it will cause a

delay in throttle response, especially at low engine
speed. Also, the throttle valves may not open fully at full
throttle causing a significant reduction in the top speed of
the machine. Alternatively, if the throttle grip has no
free-play, the throttle will be hard to control, and idle
speed will be erratic. Check the throttle grip free-play
periodically in accordance with the periodic maintenance
chart.
The motorcycle is fitted with a cold start or choke device.

The cable which controls the cold start device may
occasionally require adjustment and should be checked
for correct operation and adjustment in accordance with
the Periodic Maintenance requirement.
Inspection
1.
Inspection
1.
Check that there is 2-3 mm (0.08-0.12 in.) of

free-play in the throttle grip when lightly turning
throttle grip back and forth.
2.
1. Throttle Grip
2. 2-3 Mm Free Play
1. Choke lever
2. Correct adjustment, 2-3mm of free play
Adjustment
1.
If the free play measured is incorrect, make

adjustments as detailed in the fuel system
section.
3.
To determine the amount of free-play at the choke

lever, pull the choke lever until the starter plunger
lever at the carburettor touches starter plunger. If
correct, there should be 2-3mm of free play at the
choke lever.
WARNING: Operation of the motorcycle

with an incorrectly adjusted, incorrectly
routed or damaged throttle cable could interfere
with the operation of the brakes, clutch or the
throttle itself. Any of these conditions could result
in loss of control of the motorcycle and an
accident.
WARNING: Move the handlebars to left

and right full lock while checking that
cables and harnesses do not bind. A cable or
harness which binds will restrict the steering and
may cause loss of control and an accident.
1. Starter Plunger Lever
2. Starter Plunger
2.24
MAINTENANCE
NOTE:
Adjustment
1.

adjustments as detailed in the fuel system
section.
Note the relative positions of all low and high

tension cables prior to disconnection.
8.
Remove the choke cable from the carburettors by

releasing the cable locknut and fully unscrewing the
adjuster. Lift the cable to release from the location
slot and turn the nipple on the inner cable to detach
from the choke mechanism.
9.
Slacken the clips securing the carburettor rubbers

to the cylinder head.
~ with an incorrectly adjusted, incorrectly

routed or damaged' choke cable could interfere
with the operation of the brakes, clutch or the
choke itself. Any of these conditions could result
in loss of control of the motorcycle and an
accident.
10. Remove the carburettors from the cylinder head,

complete with rubbers, using a gentle rocking
motion.

AIR INTAKE ASSEMBLY
WARNING:
Never attempt to run the
~ engine with the air intake removed. Any
debris which enters the carburettors could cause

the throttle to stick, possibly causing loss of
control and an accident.
Never obstruct the air intake pipes as engine
damage may result.
Removal (not Thunderbird, Thunderbird

NOTE:
In order to gain access to the airbox assembly,

the seat, battery, side panels and fuel tank must
first be removed as described in the electrical,
body and fuel sections respectively.
1.
Remove the air intake duct(s) from the auxiliary

chambers (left hand only on Tiger models).
2.
Remove both auxiliary chambers by releasing the 2

bolts which secure each chamber to the frame.
3.
Remove the rubber gaiters from the air box.
4.
Slacken the clips securing the airbox to the

carburettors.
5.
Detach the air box and pull back from the

carburettors as far as possible.
6.
Remove the cam cover cowls and foam seal.
7.
Detach the low tension connectors from the coils.

Remove the ignition coils from the frame spine tube,
complete with spark plug leads.
1.
2.
3.
4.
5.
Air Intake Duct

Auxiliary Chamber
Rubber Gaiter
Venturi Intake Rubbers
Airbox
11. While supporting the carburettors, disconnect the

throttle cable as follows: Release the outer cable
locknut and fully unscrew the outer cable adjuster.
Lift the cable adjuster from its slot and turn the
nipple on the end of the inner cable to detach from
the throttle cam. Remove the carburettor assembly.
12. Release the clip securing the airbox breather pipe
to the clutch cover or breather cover (depending on
cylinder configuration) and detach the pipe. Note
the pipe routing in order to correctly route the pipe
on assembly.
13. Remove the air box complete with the air box drain
pipe.
2.25
MAINTENANCE
10. Position the vacuum and fuel pipes between the

main frame and the air box.
f,\
CAUTION: Tape over the inlet ports on

~ the cylinder head to prevent any debris
from entering the inlet ports. Any debris which is
allowed to enter the inlet ports could cause severe
engine damage.
11.
NOTE:
The air cleaner can only be replaced as a

complete assembly.
No separate air filter
element is available for any Triumph model
Consequently, the airbox cannot be dismantled
and the element cannot be removed or cleaned.
12. Fit the ignition coil connectors ensuring that the

electrical connections are re-made as noted during
disconnection.
13. Check the condition of all electrical connections.
14. Fit the cam cowl seal in an upright position over
choke cable and locate the ignition leads.
15. Ensure the spark plug leads are correctly fitted to
the spark plugs.
Installation (not Thunderbird, Thunderbird

1.
Fit the ignition coils and secure to the frame spine

tube.
Check the condition of the venturi intake rubbers

and the positions of expansion rings in the air box.
Position the airbox.
2.
Feed the air box drain pipe between the alternator

earth strap and the alternator. Feed the drain pipe
into the left hand centre stand spring (where fitted).
3.
Position the air box in the frame to allow fitment of

the carburettors to the head and later fitment of the
airbox to the carburettors.
16. Reconnect the choke cable using a reversal of the

process used in removal.
17. Check the operation of the choke system. Also
check that the clutch hose is correctly clipped to the
water elbow and does not foul the choke operation
bar. Set the adjustment of the choke cable as
described in the fuel system section.
4.
Re-connect the throttle cable to the carburettors

using a reversal of the removal process. Ensure
both the inner and outer cables are seated correctly
by turning the throttle back and forth and checking
for smooth operation.

routed or damaged choke cable could interfere
with the operation of the brakes, clutch, throttle or
may cause the choke to stick. Any of these
conditions could result in loss of control of the
motorcycle and an accident.
5.
Align the carburettors to the head ensuring all fuel

and vacuum hoses are positioned upwards to
prevent accidental damage or trapping.
18. Attach the air box breather hose and secure to

either the clutch cover or breather cover (depending
on cylinder configuration).
6.
Fit the carburettors to the cylinder head. Set the

throttle cable adjustment as described in the fuel
system section.
19. Check for the correct free operation of the throttle.

Re-adjust if necessary
,-------------
----~

with the operation of the brakes, clutch or may
cause the throttle to stick. Any of these conditions
could result in loss of control of the motorcycle
and an accident.
~------~

and an accident.
------~-----------
7.
Fit the air box to the carburettors ensuring all

rubbers are correctly seated.
8.
Securely tighten all carburettor and airbox retaining

clips.
9.
Position the carburettor vent hoses in the space

between the outer and inner carburettors.

20. Fit the rubber gaiters to the air box.
2.26
MAINTENANCE
21. Fit the auxiliary chambers into the rubber gaiters

and align to the battery box flanged sleeves.
4.

22. Fit the screws and nut to secure the auxiliary

chambers. Tighten to 9 Nm.
5.
Detach the low tension connectors from number 3

coil. Remove the coil from the frame spine tube,
complete with spark plug lead.
23. Fit the air intake ducts.
NOTE:
NOTE:
It is advisable to check carburettor settings

once the airbox has been disturbed.
In
particular, check idle speed, choke operation
and vacuum settings.
In all cases, these
adjustments must be made before fitting the
fuel tank and bodywork.
Removal (Thunderbird, Thunderbird Sport

& Adventurer)
WARNING: Never attempt to run the

engine with the air intake removed. Any
the throttle to stick, possibly causing Joss of
damage may result.
Note the relative positions of the low and high

6.
Remove the choke cable from the carburettors.
7.

to the carburettors.
8.
Detach the carburettors from the rubbers using a

gentle rocking motion and slide the carburettors to
the left hand side of the motorcycle.
9.
While supporting the carburettors, disconnect the

throttle cable.
10. Taking care not to damage the coolant bypass

hose, remove the carburettors.
11.
NOTE:

the seat, side covers, airbox covers, horn, horn
bracket and fuel tank must first be removed as
described in the body and fuel sections
respectively.
1.
Release the clips securing the airbox auxiliary

chamber to the airbox.
2.
Release the screw securing the auxiliary chamber

to the seat rail and remove the auxiliary chamber.
A.

the cylinder head to prevent any debris
engine damage.
NOTE:

complete assembly.
Installation (Thunderbird, Thunderbird

Sport & Adventurer)
1. Airbox Securing Screw

3.
Release the breather hose from the airbox and

remove the airbox.
Release the clips securing the airbox to the

carburettors.
2.27
1.

2.

earth strap and the alternator.
3.

MAINTENANCE
4.
Position the carburettors to allow reconnection of

the throttle cable. Re-connect the throttle cable to
the carburettors using a reversal of the removal
process. Ensure both the inner and outer cables
are seated correctly by turning the throttle back and
forth and checking for smooth operation.
5.
Align the carburettors to rubbers ensuring the

coolant bypass hose, fuel and drain hoses are
positioned correctly to prevent entrapment or
damage,
6.
Connect the breather pipe to the airbox.
7.

8.
Tighten all carburettor and airbox retaining clips.
9.

18. Refit the seat, side covers, airbox covers, horn

bracket, horn and fuel tank.
NOTE:

In
In all cases, these
AIRBOX DRAIN PIPE

11.
17. Refit the airbox auxiliary chamber using a reversal

of the removal process. Ensure that the auxiliary
chamber securing screw and the airbox to auxiliary
chamber clips are correctly tightened.
Fit the ignition coil and secure to the frame spine

tube.
The air box drainpipe must be drained in accordance

1.
Remove the plug from the drain pipe to allow any

fluid which has accumulated in the pipe to drain out.
2.
Refit the plug
FUEL SYSTEM

disconnection.
Check the fuel system for leaks, damaged, kinked or split

pipes in accordance with the periodic maintenance chart.
Renew any suspect components.
Renew the fuel hoses in accordance with the periodic

maintenance chart.

the spark plugs.
A.


A.

cause the throttle to stick. Any of these conditions.
and an accident.
2.28
WARNING: Failure to change fuel hoses

. . . at the specified intervals may result in a
fuel leak. Any fuel leak could cause a fire leading to
personal injury and damage to property.
MAINTENANCE
Minimum Recommended Tread Depth
TYRE WEAR/WHEEL INSPECTION

As the tyre tread wears down, the tyre becomes more
susceptible to puncture and failure. It is estimated that
90% of all tyre failures occur during the last 10% of tread
life (90% worn). It is false economy and unsafe to use
tyres until they are worn to their minimum.
All tyres are fitted with tread wear indicators. When the
tyre becomes worn down as far as the top of a tread wear
indicator, the tyre is worn beyond its service life and must
be replaced.
The following chart can be used as a guide to the

minimum safe tread depth.
Under 130 km/h (80mph) 2 mm (0.08 in)
Over 130 km/h
(80 mph)
Rear 3 mm (0.12 in)

Front 2 mm (0.08 in)
WARNING: Triumph motorcycles must

not be operated above the legal road
speed limit except in authorised closed course
conditions.
For further details of wheel and tyre inspection

and for tyre replacement information, refer to the
Wheei/Tyre section of this manual.
Typical
Tread
Wear --l~~M---1----tr.-r
Indicator -
In accordance with the periodic maintenance chart,

measure the depth of the tread with a depth gauge, and
replace any tyre that has worn to, or beyond the minimum
allowable tread depth.
Inspect wheels for cracks, splits and damage. Inspect
Tiger, Thunderbird, Thunderbird Sport & Adventurer
wheels for similar damage and also check spokes for
corrosion, looseness and breakage. Always replace
wheels that are suspected of being damaged.
WARNING: Operation with excessively

worn tyres is hazardous and will
adversely affect traction, stability and handling
which may lead to loss of control or an accident.
When tubeless tyres become punctured, leakage
is often very slow. Always inspect tyres very
closely for punctures.
Check the tyres for cuts, imbedded nails or other
sharp objects. On spoked wheels, check spokes
for looseness and damage.
Check the rims for dents or deformation.
Operation with damaged or defective wheels or
tyres is dangerous and loss of control or an
accident could result.
Always consult your Triumph Dealer for tyre
replacement, or for a safety inspection of the tyres.
2.29
MAINTENANCE
DRIVE CHAIN
The drive chain must be checked, adjusted, and
lubricated in accordance with the periodic maintenance
chart. For reasons of safety, and to prevent excessive
wear, never neglect any part of the drive chain
maintenance. If the chain is badly worn, or incorrectly
adjusted -either too loose or too tight -the chain could
jump off the sprockets or break. Checking of the
adjustment and lubrication should be carried out more
frequently where the machine is regularly used in dirty or
dusty conditions or where large amounts of road salt are
used.
1. Tiger Chain Slider
WARNING: A chain that breaks or jumps

off the sprockets could snag on the
engine drive sprocket or the rear wheel severely
damaging the motorcycle and causing an
accident. Never neglect chain maintenance.
4.
If correct, the vertical movement of the drive chain

midway between the sprockets should be 35-40
mm (25-30mm on Thunderbird, Thunderbird
Sport & Adventurer).
Drive Chain Replacement

Replace the drive chain when worn beyond the service
limit (refer to drive chain wear inspection). For details of
the renewal procedure, refer to the rear suspension/final
drive section.
Chain Slack Inspection

1.
Set the motorcycle up on either the side or centre

stand.
2.
Check the rear wheel alignment by reference to the

rear wheel alignment instructions later in this
section. Adjust if necessary.
3.
Rotate the rear wheel to find the position where the

chain has least slack. Measure the chain's vertical
movement, mid-way between sprockets.
1. Vertical Movement 35-40mm (25-30mm on

Thunderbird, Thunderbird Sport & Adventurer)
Drive Chain Slider (Tiger)

The drive chain slider must be replaced in accordance
NOTE:
On Tiger models, a chain slider is fitted which, if

worn, will allow excessive chain slack. Always
check the chain slider and, if necessary, renew
before changing any other adjustments.
Always carry out the chain adjustment process
after renewing the chain slider.
The slider is bolted to the frame, immediately
behind the sprocket cover.
2.30
MAINTENANCE
Chain Slack Adjustment

(eccentric adjuster method)
7.
Re-check the rear wheel alignment and adjust if

necessary.
1.
Loosen both the left and right hand

eccentric adjuster clamp bolts.
Chain Slack Adjustment (adjustable wheel

spindle method)
2.
Insert Allen wrenches into the hexagonal holes in

the eccentric adjusters.
Turn both eccentric
adjusters equally forwards or rearwards until the
drive chain has the correct amount of slack.
1.
3.
Tighten both eccentric adjuster clamp bolts to

36 Nm.

with insecure eccentric adjuster clamp
bolts may result in impaired stability and handling
of the motorcycle. This impaired stability and
handling may lead to loss of control or an accident.
4.
Check the rear wheel alignment and adjust if

necessary
5.
Rotate the rear wheel, measure the chain slack

again at the tightest position, and re-adjust if
necessary.
Swinging Arm Markings

Adjuster Collar Notch
Wheel Spindle Nut
Adjuster
2.
If the chain is too loose, turn the left and right hand
adjuster screws evenly outwards until the correct
amount of chain slack is present.
3.
If the chain is too tight, turn the left and right hand
adjuster screws evenly inwards.
NOTE:
I
2
1. Adjuster Clamp Bolt
2. 12mm Allen Wrench
3. Eccentric Adjuster
6.
1.
2.
3.
4.
Check for correct rear brake effectiveness by

pumping the brake pedal.
Before checking the chain slack, push the rear

wheel forward.
4.
Tighten the locknuts on the adjuster screws.
5.
Tighten the wheel spindle nut to 85 Nm.
6.
Check the rear wheel alignment and adjust as

necessary.

with insecure axle or adjuster fixings may
result in motorcycle instability, loss of control and
an accident.
1. Rear Brake Pedal

2.31
7.
Rotate the rear wheel and repeat the adjustment

check. Readjust if outside the 25-30mm limit.
8.
Check for correct operation of the rear brake.
MAINTENANCE
Wheel Alignment
(eccentric adjuster method)
1.
~ with insecure eccentric adjuster clamp

Remove the retaining rings from the wheel

spindle ends.
6.
Tighten the axle bolts to 85 Nm.
7.
Insert both retaining rings to secure the wheel

spindle.
8.
Check the chain slack as previously described.
Wheel Alignment (adjustable wheel

spindle method)
1. Axle Bolt
2. Eccentric Adjuster Clamp Bolt
3. Retaining Rings
2.
Loosen the axle bolts.
3.
Loosen both the left and right hand eccentric

adjuster clamp bolts.
4.
Turn the eccentric adjusters until the notches on

both sides of the swinging arm point to the same
marks on left and right adjusters. For example, if the
left hand notch aligns with an eccentric adjuster
mark 5 from the front, then the right hand eccentric
adjuster should also align with a mark 5 from the
front.
1.
Loosen the locknuts on both the left and right hand

adjuster screws.
2.
Loosen the wheel spindle nut.
3.
Turn each adjuster screw so that the notches on the

adjuster collars point to the same marks on both
sides of the swinging arm.
4.
Tighten the locknuts on the adjuster screws.
5.
Tighten the wheel spindle nut to 85 Nm.
6.
Check the chain slack setting and adjust as

necessary.

with insecure axle or adjuster fixings may
result in motorcycle instability, loss of control and
an accident.
Misalignment of the wheel will result in abnormal
tyre wear. Worn tyres may impair the stability and
handling of the motorcycle which may lead to an
accident.
1--~~__;~~
2----~~~~~~~~
1. Eccentric Adjuster Marks
2. Swinging Arm Notch
1,\
CAUTION: The settings depicted are for

reference only. The actual setting will
vary on different motorcycles.
5.
1.
2.
3.
4.
Tighten the adjuster clamp bolts to 36 Nm.
2.32
Swinging Arm Markings

Adjuster Collar Notch
Wheel Spindle Nut
Adjuster
MAINTENANCE 2
Chain Lubrication
Chain lubrication is necessary after riding through rain,
standing water, on wet roads, or any time that the chain
appears dry. Use the chain lubricant recommended in
the specification.
1\.
CAUTION: Never use a power wash

system to clean the chain as this may
cause damage to the chain components.
1.
Apply chain lubricant to the sides of the chain

rollers, and also the 0-rings. The lubricant will
penetrate the rollers and bushings and also prevent
the 0-rings from deterioration.
1. Measurement Position
2. 10-20kg Weight
4.
If the length exceeds the service limit of 319 mm, the

chain must be replaced.
WARNING: Use a genuine Triumph

supplied chain as specified in the
Triumph Parts Catalogue.
The use of
non-approved chains may result in a broken chain
or may cause the chain to jump off the sprockets.
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the rear
wheel, severely damaging the motorcycle and
causing loss of motorcycle control and an
accident.
Never neglect chain maintenance and always have
chains installed by an authorised Triumph Dealer.
Chain Lubrication Positions
2.
Wipe off any excess oil.
3.
If the chain is especially dirty, clean using paraffin

before applying the lubricant.
5.
Examine the whole length of the chain. If there are

any excessively tight or loose sections, loose pins
or damaged rollers, the chain should be replaced.
6.
Inspect sprockets for unevenly or excessively worn

teeth. Also examine the sprockets for damaged
teeth.
Chain Wear Inspection
Worn Tooth
(Engine Sprocket)
1.
2.
3.
Worn Tooth
(Rear Sprocket)
Remove the chain/wheel guard from the

swinging arm.
Stretch the chain taut by hanging a 10-20 kg (20-40
lb) weight on the chain.
Measure a length of 20 links on the straight part of
the chain from pin centre of the 1st pin to pin centre
of the 21st pin. Repeat the test at various sections
of the chain to establish an average reading. This is
because the chain may wear unevenly.
(Wear exaggerated for clarity of information)
NOTE:
2.33
Sprocket wear is exaggerated for illustration.
7.
If there is any irregularity found in any of the

components, replace the drive chain and/or any
other damaged components.
8.
Refit the chain/wheel guard.
2 MAINTENANCE
BRAKES
WARNING: Use only DOT. 4 specification

brake fluid as listed in the general
information section of this manual. The use of
brake fluids other than those DOT. 4 fluids listed in
the general information section may reduce the
efficiency of the braking system leading to an
accident.
BRAKING SYSTEM MAINTENANCE SAFETY

PRECAUTIONS

Failure to change the brake fluid at the interval


neglected!
plastic surface.

master cylinders.

opened.

an accident.
ASBESTOS
the following components or
any assembly containing
any of these components:-
WARNING
CONTAINS
ASBESTOS

~ appreciable drop in the level of the fluid in
authorized Triumph Dealer for advice before
riding.
Brake Shoes or Pads
Breathing asbestos
dust is dangerous
to health
Follow safety
instructions

SAFETY INSTRUCTIONS


2.34

ventilated place.

facility.

safely.
Never use an airline to blow dust from

components
MAINTENANCE
DISC BRAKE FLUID

inspect the brake fluid level in the front and rear master
cylinder reservoirs. In addition, the brake fluid must be
regularly replaced, in accordance with the periodic
maintenance chart, to help prevent brake failure.
Fluid Level Inspection

1.
Ensure the brake fluid level in both the front and rear
brake fluid reservoir is between the upper and lower
level lines (reservoir held horizontal).
1. Front Reservoir Upper Level

2. Front Reservoir Lower Level
(Thunderbird Sport)
1. Front Reservoir Lower Level (all except

Thunderbird Sport)
1. Rear Reservoir Upper Level

2. Rear Reservoir Lower Level
CHANGING BRAKE FLUID, BRAKE

HOSES AND HYDRAULIC SEALS
Brake fluid, brake hoses and hydraulic seals in the
master cylinders and calipers should be changed in
accordance with the periodic maintenance chart.
WARNING: Failure to change brake fluid,

hoses and hydraulic seals at the
specified interval could result in reduced brake
efficiency leading to loss of control and an
accident.
1. Front Reservoir Upper Level (all except

Thunderbird Sport)
2.35
MAINTENANCE
BRAKE PADS
Front and rear brake pad wear is automatically

compensated for and has no effect on brake lever or
pedal action.
BRAKE WEAR INSPECTION

inspect the brake pads for wear.
The minimum thickness of lining material for any front or
rear brake pad is 1.5 mm. If any pad has worn to the
bottom of the groove in the pad centre, replace all the
brake pads on that wheel.
1. Lining Material Thickness

2. Centre Groove
2.36
WARNING: Do not replace individual

brake pads, replace both pads in the
brake caliper. If two calipers are mounted on the
same wheel, all the pads on the wheel must be
replaced together. Replacing individual pads will
reduce braking efficiency and may cause an
accident.
BRAKE LIGHTS
Check the brake lights for correct operation, on both front
and rear brakes, in accordance with the periodic
maintenance chart.
MAINTENANCE 2
STEERING

. . . . and right full lock while checking that
may cause l()_l)S of _c;_ontrol_ and an accident.
Steering Inspection
WARNING: Operation with incorrectly

. . . . adjusted, worn or damaged steering head
bearings may cause impaired handling and
instability leading to an accident.
If in doubt, have the motorcycle inspected by an
authorised Triumph dealer before riding.
NOTE:
1.
Steering Stem Bearing Lubrication.
Position the motorcycle on level ground, in an

upright position.
The steering stem bearings require removal and

lubrication in accordance with the periodic maintenance
chart. Refer to the front suspension section for details of
steering bearing adjustment/lubrication.
WARNING: Ensure that the motorcycle is

stabilised and adequately supported to
prevent the risk of injury from the motorcycle
falling.
2.
For details of headstock bearing adjustment,

refer to the front suspension/steering section.
FRONT SUSPENSION
Place a block under the engine to raise the front

wheel off the ground.
Front Fork Inspection

1.
Examine each fork stanchion for any sign of

damage, scratching of the slider surface, or for oil
leaks.
2.
Position the motorcycle on level ground.
3.
While holding the handlebars and applying the front

brake, pump the forks up and down several times. If
roughness or excessive stiffness is detected, the
fork stanchions must be overhauled or replaced as
detailed in the front suspension section.
A.
CAUTION: Ensure that the support block

is positioned to avoid damaging all oil
lines which run beneath the engine.
3.
Hold the lower end of the front forks. Rock the forks
in a front to rear motion. If any free-play can be
detected, the headstock bearings require
adjustment.
After adjustment, re check for
free-play. If any free-play remains, check for correct
adjustment of the headstock bearings and also for
wear in the fork bearings. Rectify as necessary.
tI
WARNING: If roughness or excessive

stiffness is detected, investigate the
cause and take the necessary remedial action
before riding the motorcycle.
Riding the motorcycle with defective or damaged
suspension can damage the motorcycle, cause
loss of control, or an accident.
WARNING: Ensure that the adjusters are

set to the same settings on both fork
stanchions.
Settings which vary from left to right hand
stanchions may affect handling and stability
leading to loss of control, or an accident.
Rock The Forks, Front To Rear
Fork Oil Change
4.
The oil in the forks must be changed in accordance with

the periodic maintenance chart. Refer to the front
suspension section for details of fork oil replacement.
Grasp one side of handlebars and check that a full

steering lock can be achieved in both directions.
2.37
2 MAINTENANCE
WHEEL BEARINGS
REAR SUSPENSION
If the wheel bearings in the front or rear wheel allow

play in the wheel hub, are noisy, or if the wheel does
not turn smoothly there may be wear or damage to the
wheel bearings.
The wheel bearings must be inspected at the intervals
specified in the periodic maintenance schedule.
Rear Suspension Inspection/lubrication

1.
;A
Inspection
1.

upright position.
2.

3.
4.
Position the motorcycle on level ground in an

upright position.
~ARNING: To ~reven-t risk of injury from
'I
the motorcycle falling during the

spection, ensure that the motorcycle i; I
abiliz(;!d and ~ecured_ on it~ support ~lock.
_j
2.
Examine the suspension and swinging arm pivots

for wear and excess movement.
Gently rock the top of each wheel from side to

side. Repeat the process for both wheels.
3.
If excess movement is detected, investigate the

cause and take any necessary remedial action.
If any free-play can be detected, ask your

authorised Triumph dealer to inspect and rectify
any faults before riding.
4.
Apply grease to suspension bearings via the grease

nipples, in accordance with the periodic
maintenance chart.
5.
Use the specification of grease as recommended in

the specification section.
WARNING: To prevent risk of injury from

the motorcycle falling during the
inspection, ensure that the motorcycle is
stabilized and secured on its support block.
NOTE:
Do not exert extreme force against each wheel or

rock each wheel vigorously as this may cause the
motorcycle to become unstable or cause injury by
falling from its support.
Ensure that the position of the support block will
not cause damage to the oil lines beneath the
sump.
WARNING: Operation with worn or

damaged wheel bearings may cause
impaired handling and instability leading to an
accident.
If in doubt, have the motorcycle
inspected by an authorised Triumph dealer before
riding.
2.38
The swinging arm bearings also require

periodic lubrication which necessitates the
removal of the swinging arm. For details of
swinging arm removal, refer to the rear
suspension section.
MAINTENANCE
1. Tiger, Thunderbird, Thunderbird Sport &

Adventurer Rear Suspension Grease Nipples
---~~~
1. Trophy/Trident/Sprint/Daytona
Rear Suspension Grease Nipples
2.39
Cylinder Head
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4
Cam cover
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4
3.5
Cam chain tensioner

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6
3.6
Camshafts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8
3.9
Cam chain
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10
3.10
Camshaft and sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 0
Camshaft and camshaft cap wear

Journal diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outrigger diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11
3.11
Cylinder head
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12
3.14
Valve
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.16
3.16
Valve to guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17
Valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17
Valve face inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17
Valve seat outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17
Valve seat width inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.17
Valve seat repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.18
3.1
3 CYLINDER HEAD
Exploded View
10 Nm
10 Nm
-------'
\~
15 Nm
9Nm
3.2
CYLINDER HEAD 3
COR DANCE
TORQUE
WITH RELIEN~~T SECTION
95Nm
25 Nm
28Nm
3.3
3 CYLINDER HEAD
CYLINDER HEAD DESCRIPTION
CAM COVER
All engines are fitted with an aluminium alloy cylinder

head which carries the camshaft, valves and spark
plugs. The cylinder head is cast as a single entity and
various components are permanently added after
machining. These components include the valve guides,
valve seats and oil gallery plugs. In order to fit these
parts, liquid nitrogen is used to contract the components
prior to fitment in the head.
Removal
The camshafts run directly in the head without additional

bearings. Valve clearances are adjusted by changing
variable thickness shims which sit between the valve
tappet and the camshaft. Various different camshaft
profiles are used depending upon engine configuration,
model type and final market destination.
The camshafts are driven by a silent type chain.
The chain is tensioned by a spring loaded device fitted in
the upper crankcase, and is guided by two rubber blades.
1.
Remove the seat.
2.

models).
3.
Disconnect the battery, negative (black) lead first.
4.

section.
5.
Remove the cam cover cowls from the frame (not

Adventurer, Thunderbird Sport or Thunderbird).
6.
Clean the area around the plug leads at the joint

with the cam cover. Remove the ignition coils and
spark plug leads.
NOTE:
Oil is supplied to the head by an external feed pipe which

is situated at the right hand rear side of the head. The oil
pipe is connected to the main oil drilling in the upper
crankcase by means of banjo bolts. Once supplied to the
head, the oil is distributed along internal drillings within
the head casting and camshaft.
Dual valve springs are used to close the inlet and
exhaust valves. These valve springs have close wound
coils at one end to assist in the prevention of valve
bounce at high engine speed and to give a smooth valve
actuation. When assembling the cylinder head it is
important that the close wound, colour coded ends of the
springs are fitted downwards (toward the piston). Both
the tip and flame face of the valves are hardened to give a
long service life.

the coils before disconnection. This will help in
7.
Progressively release the cam cover bolts in the

order shown, then remove the cam cover screws
and seals.
7
Due to the methods used to assemble the valve seats

and valve guides to the head, these parts cannot be
replaced.
4 cylinder engines
5
CAUTION:
In any of the following
operations
which
necessitate
the
removal or disconnection of the cam chain,
NEVER turn the engine without the cam chain and
tensioner correctly fitted and adjusted. In the
disassembled condition, the pistons will contact
the valves if the crankshaft is turned, causing
severe engine damage.
1
7
3 cylinder engines
Camshaft Cover Bolt Release/Tightening
Sequence
3.4
CYLINDER HEAD 3
NOTE:
Installation
The two longer bolts are fitted at the right hand

end adjacent to the cam chain.
8.
1.
Ease the wiring harness and throttle cable to give

access to the cam cover then remove the cam
cover. (Lightly tap with a rubber mallet if necessary.)
2.
NOTE:
3.
On Thunderbird, Thunderbird Sport and

Adventurer, the cover must be withdrawn from
Check the condition of all joints and seals

including the cam cover screw seals. Replace as
necessary.
Ensure all mating surfaces are clean and free from
oil.
Apply silicone sealant, as indicated in the diagram
below, to the cylinder head, cam cover and to the
spark plug tower seals.
1\
CAUTION: Never use a lever to remove

the camshaft cover from the head. This
will damage the mating surfaces of both the
cylinder head and cam cover which could lead to
an oil leak.
9.
Remove the cam cover gasket together with the

seals from the spark plug towers.
10. Remove residual oil from exhaust side of the

cylinder head using a syringe or lint free cloth.
1. Silicone Sealer Areas

4.
Fit the cam cover, ensuring all seals are positioned

correctly.
5.
Fit the screws and screw seals, then tighten until

finger tight.
6.
Finally tighten the screws, in same order as for

removal, to 10Nm.
7.
Fit the ignition coils and spark plug leads in the order
noted in paragraph 6 of the removal procedure.
8.
Refit cam cover cowls to the frame (not

Thunderbird, Thunderbird Sport or Adventurer).
9.
Refit the fuel tank as described in the fuel system

section.
10. Refit the battery and reconnect, positive (red) lead

first.
11. Refit both side panels (if removed).
12. Refit the seat.
3.5
3 CYLINDER HEAD
4.
CAM CHAIN TENSIONER

Removal
1.
Carefully remove the centre nut from the tensioner

and withdraw the tensioner spring.
WARNING: The tensioner centre nut is

under spring tension. Always wear hand,
eye and face protection when withdrawing the
centre nut and take great care in order to minimise
the risk of injury and loss of components.
Remove the cam cover as described over. Also

remove the right-hand crankshaft cover to give
access to the ignition rotor.
5.
Remove the bolts securing the tensioner to the

upper crankcase and remove the tensioner and
gasket.
Installation
1. Check that number 1 cylinder (and number 4 if a 4
cylinder engine) is at TDC.
1.
2.
3.
4.
2.
2. Place a suitable wedge between the tensioner

blade and the inside of the upper crankcase to hold
the tensioner blade in contact with the timing chain.
Check that the camshaft timing marks point inwards
and are level with the line of the head.
Ignition Rotor Clamp Nut

Ignition Sensor
Centre Nut
Tensioner Securing Screws
Insert Wedge to secure chain
Rotate the crankshaft clockwise (the normal

direction of rotation), using the nut fitted to the end
of the crankshaft. Stop rotation when number 1
cylinder (and also number 4 cylinder for 4 cylinder
engines) is at top dead centre (TDC).
NOTE:
At TDC, the ignition rotor 'T' mark will align with

the ignition sensor, and the alignment marks on
the camshaft sprockets will point inwards at a
point level with the joint face.
1.
2.
3.
4.
5.
6.
Tensioner Blade Retaining Bolt

Tensioner Blade
Pick-up Screws
Rubber Grommet
Ignition Pick-up Sensor
Cam Chain
NOTE:
Camshaft Wheel Timing Marks

3.
Place a suitable wedge, between the tensioner

blade and crankcase, to hold the cam chain taut
during removal of the tensioner.
3.6
Early Trophy and Trident engines were fitted

with a tensioner guide over the end of the
tensioner nose. This item must be discarded if
found and the tensioner assembled to the
crankcase without the guide.
CYLINDER HEAD 3
3. Set the tensioner plunger onto the first tooth of the
ratchet (i.e. minimum extension) by manually lifting
the ratchet pawl.
9.
Re-check that the camshaft timing marks align as

illustrated over.
10. Re-check tensioner plunger location against the

tensioner blade.
11. Refit the cam and crankshaft covers.
12. Check and adjust the engine oil level.
NOTE:
1.
2.
3.
4.
Tensioner Pawl
Spring
Washer
Centre Nut
4.
Fit the tensioner, complete with a new gasket, to the

upper crankcase and tighten the retaining bolts to 9
Nm.
5.
Remove the tensioner blade wedge, taking care not

to move or damage the tensioner blade.
6.
Fit a new sealing washer to the centre nut. Using

finger pressure only, push the ratchet section of the
tensioner into firm contact with the tensioner blade.
Carefully refit the spring and centre nut to the
tensioner. Tighten the centre nut to 23 Nm.
7.
Check that the tensioner plunger is correctly

located in the middle of tensioner blade when
viewed from above.
8.
Rotate the engine through 4 full revolutions, and

reset number 1 cylinder to the TDC mark. Ensure
that the T mark on the ignition rotor is aligned with
the ignition pick-up
1. Ignition Pick up
2. Ignition Rotor
3.7
Three different types of cam chain tensioner are

fitted.
Refer to the parts information for
selection of the correct type.
3 CYLINDER HEAD
6.
CAMSHAFTS
Removal
NOTE:
The camshafts can be removed from the head

without the complete removal of the timing
chain. However, the chain must first be
detached from the camshafts. The camshafts
and sprockets are removed as an assembly.
1.
Remove the seat and disconnect the battery

negative (black) lead first.
2.
Remove the cam cover and right hand crank cover.
3.
Set number 1 piston to TDC by aligning the number

1 mark (1 and 4 on 4 cylinder) on the ignition rotor
with ignition pick-up. The alignment marks on the
camshaft sprockets will also point inwards at a point
level with the joint face.
Progressively release each of the fasteners

securing the exhaust camshaft caps to the cylinder
head. NOTE: The inlet and exhaust camshafts
can be differentiated by a plain area in the
centre of the exhaust cam and a groove in the
same place on the inlet cam.
Plain section
Exhaust cam
Inlet cam
Groove
Camshaft Identification
----------------------------,
1\.
CAUTION: Never release one camshaft

cap in isolation from the others as this
may cause the caps to crack.
Always progressively release all the camshaft
caps before final removal
7.
Camshaft wheel timing marks
Once the pressure on all camshaft caps has been

released, remove the fasteners and caps complete
with dowels.
INLET SIDE
4.
Remove the cam chain tensioner as described

earlier in this chapter.
5.
Remove cam chain top pad from the right hand side
of the head.
EXHAUST SIDE
Camshaft Cap Numbering (4 cylinder illustrated)
NOTE:
1. Cam Chain Top Pad
3.8
The caps are numbered sequentially and must

not be interchanged for a different position on
the head. The camshaft caps on the outside of
the timing chain (known as outriggers) are
marked 'A' for the exhaust and 'B' for the inlet.
CYLINDER HEAD 3
NOTE:
5.
Each cap is located by two dowels which align

the cap with the head. If the caps cannot be
removed using hand pressure, gently tap each
cap with a soft faced tool to release.
8.
Lift the cam chain from the sprocket and remove the
exhaust camshaft.
9.
Repeat procedures 6, 7 and 8 for the inlet camshaft.
Before fitting the cam chain, ensure that cam

bearing caps are not pinching the camshafts by
rotating each camshaft back and forth 5.
I:\
CAUTION: If any components have been

renewed, the valve clearances must be
checked and adjusted. Running with incorrectly
adjusted valve clearances may cause excess
engine noise, rough running and engine damage.
Refer to the maintenance section for valve
clearance adjustment details.
6.
Assemble the cam chain tensioner using the

instructions given earlier in this chapter
7.
Refit the top pad and tighten the fixings to 1ONm.
8.
Refit the cam and crankshaft covers.
9.
Refit the fuel tank, cam cowls and body panels.

Reconnect the battery, positive (red) lead first.
NOTE:
1. Exhaust Camshaft
2. Inlet Camshaft
Installation
1.
Thoroughly clean the camshafts and journals.

Inspect the ends of the camshafts for correct fitment
of the sealing plugs. Lubricate the camshafts with
clean engine oil before fitting to the head.
2.
Locate each camshaft to the head ensuring the

camshafts are correctly identified (inlet and
exhaust) and also correctly located over their
respective valve banks.
3.
Position the camshafts in the same position as for

removal before attempting to fit the caps (that is,
with the timing marks on the camshaft sprockets
level and pointing inwards, and with number 1
cylinder at TDC). Locate the cam chain over the
cam sprockets.
I:\
CAUTION: If the camshafts and caps are

fitted without first aligning the timing
marks on both the crankshaft and camshaft
sprockets, the inlet and exhaust valves will contact
each other causing damage to both the head and
the valves.
4.
Lubricate the threads of the camshaft cap screws

and evenly and progressively tighten to 10 Nm.
3.9
Various different profile camshafts are fitted.

For correct selection of camshafts, refer to the
parts information.
3 CYLINDER HEAD
CAM CHAIN
CAMSHAFT SPROCKET
Removal
It is not normally necessary to remove the sprockets

from the camshafts. However, if it becomes necessary
for the sprockets to be separated from the camshafts,
the following should be noted.
NOTE:
The camchain can be renewed with the engine

installed in the frame. The procedure to renew
the chain is basically the same as for the
replacement of the camshafts. In addition to all
the operations necessary to replace the
camshafts, the following operations are
necessary.
1.
Release the screws securing the ignition sensor to

the crankcase. Slide the sensor grommet out from
the crankcase and remove the sensor.
2.
Remove the cam chain tensioner guide from the

crankcase.
3.
Remove the oil baffle plate from below the ignition

rotor.
4.
The timing chain is removed from either the head or

crankcase after first detaching the chain from the
crankshaft gear.
The same sprocket is used for both inlet and

exhaust camshafts, however, different bolt holes
are used for inlet and exhaust camshafts as shown
in the illustration below.
2
1. Inlet Camshaft Bolt Holes
2. Exhaust Camshaft Bolt Holes
Installation
1.
1.
Refit the cam chain and locate the lower end around
the crankshaft gear.
2.
Fit the ignition sensor and adjust to give an air gap of

0.6- 0.8 mm between the timing disc projection and
the pick-up. Tighten the screws to 1 ONm.
3.
Refit the oil baffle plate and tighten to 10 Nm.
4.
Refit the tensioner guide to the crankcase.
5.
Apply Triumph silicone grease to the grommet on

the ignition sensor and refit the grommet to the
crankcase.
6.
The procedure is completed by following the

assembly instructions for replacement of the
camshafts.
NOTE:
The inlet and exhaust camshafts can be

differentiated by a plain area in the centre of the
exhaust cam and a groove in the same place on
the inlet cam.
Plain section
Exhaust cam
Inlet cam
Groove
Camshaft Identification
3.10
CYLINDER HEAD 3
CAMSHAFT AND CAMSHAFT CAP WEAR
Camshaft bearing oil clearance- 0.12mm max.
Journal Diameters
Standard:
22.93 mm
Outrigger Diameters
Standard:
1.
2.
22.936 mm
22.923 mm
Measure the camshaft journals with a micrometer. If

any journal is outside the specified tolerance,
replace the camshaft.
Examine all camshaft and camshaft bearing caps
for excessive wear and damage, paying particular
attention to the outrigger caps (A & B).
NOTE:
The outrigger caps are most important as they

control the oil feed to the camshafts.
The camshaft caps are machined to each

cylinder head and are, therefore, not available
individually. If a camshaft cap is worn or
damaged, the complete cylinder head must be
replaced.
3.
To measure the journal to head clearances, use

'Piastigauge' (Triumph part number 3880150) as
follows.
Progressively release the camshaft caps, on the
camshaft to be inspected, and fully remove the cap
from the required journal. Wipe the exposed areas
of both the journal and cap. Apply a thin smear of
grease to the journal and a small quantity of silicone
release agent to the cap.
Size a length of the plastigauge to fit across the
journal being measured. Fit the plastigauge to the
journal using the grease to hold the strip in place.
Refit the cap and evenly and progressively tighten
all the camshaft cap bolts to 10 Nm. Release all
cap bolts and remove the cap being measured.
Using the gauge provided with the plastigauge kit,
measure the width of the now compressed
plastigauge.
3.11
Measuring The Compressed Plastigauge.

4.
Calculate the journal

plastigauge chart.
5.
If the clearance measured is within the specified

tolerance, clean off all traces of plastigauge and refit
the camshaft caps. If the measured clearance is
outside the tolerance, the cylinder head must be
replaced.
I:\
clearance
using
the
CAUTION: Although plastigauge is oil

soluble, all traces of the material must be
removed to prevent blockage of the oil drillings
and resultant engine damage.
3 CYLINDER HEAD
CYLINDER HEAD REMOVE/REFIT
4.
The cylinder head can be removed with the engine in

the frame. It is necessary to remove the side panels,
lower fairing, fuel tank and exhaust system.
On
Thunderbird,
Thunderbird
Sport
and
Adventurer, remove the thermostat housing to
cylinder head hose and the bypass hose.
Removal
1.

Remove the exhaust system completely.
WARNING: If the engine has recently

. . . . been running, the exhaust system will be
hot. Before working on or near the exhaust
system, allow sufficient time for the exhaust
system to cool as touching any part of a hot
exhaust system could cause burn injuries.
2.
Drain the coolant into a clean receptacle. Retain the

coolant for re-use unless contaminated or due for
replacement.

skin damage.
3.
1. Thunderbirdffhunderbird Sport/Adventurer
Thermostat Housing
5.
Disconnect the connector from the water

temperature sensor on the left hand side of the
head.
6.
Clean the area around each spark plug lead.
7.
Remove the plug leads and spark plugs. Cap the

plug holes to prevent dirt entering the cylinders.
NOTE:
Disconnect and remove the top hose from both the

radiator and cylinder head.
Before disconnection, make a note of the spark

plug lead positions in the head. This will help in
8.
Remove the carburettors as described in the fuel

system section.
9.
Remove the banjo bolts and washers from both

ends of the oil feed pipe to the head. Remove the
pipe.
1. Top Hose.
2. Water Temperature Sensor Connection.
1\

1. Oil Feed Pipe

2. Banjo Bolts
3. Crankcase To Head Bolts (Side Only Illustrated)
3.12
CYLINDER HEAD 3
10. Remove both camshafts as previously described.
Remove the tappets and shims keeping the tappet
and shim from each valve together in a marked
container.
10
NOTE:
To prevent the tappets and shims from

becoming mixed, place the shim and tappet
together in a marked container. The marked
components must be refitted in their original
positions.
11.
Release the screws securing the front and side of

the upper crankcase to the cylinder head noting the
relative position and length of each bolt.
NOTE:

Adventurer engines, the bolts securing the
cylinder head to the crankcase are accessed
from inside the head
Top.
4 Cylinder Head Bolt Release Sequence
Bottom. 3 Cylinder Head Bolt Release Sequence
1. Thunderbird!fhunderbird Sport/Adventurer
Cylinder Head to Crankcase Bolts
12. Support the engine and release the frame to
cylinder head bolts.
13. Progressively release the cylinder head bolts in the
sequence shown right.
14. Lightly tap the cylinder head with a rubber mallet to
break the seal of the gasket. Remove the cylinder
head complete with the location dowels.
15. Remove the cylinder head gasket and gasket
spacers. Discard the gasket and spacers.
3.13
3 CYLINDER HEAD
Installation
NOTE:
Ensure that the threads of the cylinder head bolt

holes in the upper crankcase are completely
clean and dry.
1.
Position the cam chain rubbing blade to the left

hand side of the upper crankcase. When correctly
fitted, the blade positively locates at the lower end
on a web. The upper section will then fit snugly into
the recess in the top of the crankcase.
2
~
1. Head Gasket
2. Gasket Spacers
3.
Ensure that the cylinder head face is completely

clean.
4.
Carefully lower the cylinder head over the rubbing

blade and locate the head onto the dowels.
CAUTION: The fitting and tightening of

the cylinder head bolts is critical to the
long term reliability of the cylinder head gasket.
Clean each bolt, paying particular attention to the
threads and under the bolt head areas. If any of the
threads or bolt head areas are damaged, replace
the bolt(s). Lubricate the threads with engine oil,
and then wipe clean with a lint-free cloth leaving
minimal oil on the threads (that is, almost dry to
touch). Failure to observe these important items
may lead to engine damage through a damaged
head gasket.
1. Cam Chain Rubbing Blade
NOTE:
2.
The cylinder liners must be lifted and re-sealed

before refitting the cylinder head. Refer to the
liner/piston section for details.
5.
Thoroughly clean the upper faces of the crankcase

and liners taking care not to damage the mating
surfaces. Position the cylinder head gasket and
gasket spacers, ensuring that the location dowels
are correctly in place.
NOTE:
3.14
Fit the bolts to the head and tighten until finger tight.
The head bolts are finally tightened in 3 stages.
This is to ensure that the cylinder head gasket seals
correctly to the head and crankcase. The 3 stages
are as follows overleaf:
For stages A and 8 of the head bolt tightening

operation, a torque wrench of known, accurate
calibration must be used.
Tighten the head bolts, in the same numerical

sequence used to release the bolts, to 20 Nm.
Crankcases WITHOUT alternator cover:

Tighten the head bolts in the same numerical
CYLINDER HEAD 3
8
Crankcases WITH alternator cover:
Tighten the head bolts in the same numerical

C
For the final torque operation, which again is

carried out in the same numerical sequence used to
release the bolts, a 'torque turn' method is used.
The bolts must be turned through goo to reach the
final setting. To accurately gauge the goo turn, use
special service tool 3880105 as follows. Fit the tool
between the torx socket and the drive handle and
locate the torx drive to the head bolt. Pick an
increment point on the torque turn gauge which
aligns with a suitable reference point on the head.
Tighten the bolts until g of the 10 gauge increments
have rotated past the chosen point on the head.
13. Continue to assemble the engine using the

camshaft renewal procedure. In addition, the
following operations must also be carried out.
14. Replace the coolant drain plug using a new sealing
washer.
15. Examine the radiator hoses for cracks, frays and
damage, renew if required. Fit the hoses.
'f

16. Connect the water temperature sensor.

17. Refit the spark plugs ensuring the plug leads are
fitted to the correct cylinders.
18. Refill the cooling system using the refill procedure
from the maintenance section.
1g. Refit the fuel tank, exhaust system and bodywork.
20. Reconnect the battery, positive (red) lead first.
1. Tool 38801 05
6.
Fit the screws securing the front and side of the

crankcase to the cylinder head and tighten to 12
Nm.
7.
Lubricate the tappet buckets with clean engine oil

and refit the tappet buckets and shims in same
locations from which they were removed.
NOTE:
Ensure that the tappets and shims are refitted in

their original positions.
8.
Refit the oil feed pipe using new sealing washers.
9.
Tighten the upper banjo bolt to 25 Nm.
10. Tighten the lower banjo bolt to 28 Nm.

11.
Ensure that the oil feed pipe is not distorted during

the tightening operation.
12. Refit the frame to engine bolts and tighten to

95 Nm.
3.15
3 CYLINDER HEAD
VALVES AND VALVE STEM SEALS
Installation
Removal from the cylinder head

1.
Remove each valve from the head using a valve

spring compressor. The compressor must act on
the top cup to allow removal of the valve collets.
1.
Apply a thin coat of molybdenum disulphide grease

to the valve stem.
2.
Install the valve into the valve guide and refit the
thrust washer to the valve spring recess (if
removed).
3.
Fit the valve stem seal over the valve stem and,
using a suitable tool, press down fully until the seal
is correctly seated over the valve guide.
NOTE:
1. Valve Removal Using A Valve Spring

Compressor
2.
Once the collets are released, remove the following

collets
valve spring cap
valve springs
valve stem seal
thrust washer
valve (de-burr before removal)
~~
Close wound section
1::.
----r:
~CAUTION: Incorrect fitment of the valve

~ stem oil seals could lead to high oil
consumption and blue smoke emissions from the
exhaust system. Do not use excessive force in
fitting the seal as this may break the seal ring.
4.
Install the valve springs over the valve stem

ensuring that the close wound coil end faces
towards cylinder head.
5.
Compress the valve spring ensuring that the spring

is compressed squarely to prevent damage to the
valve stem and cylinder head.
6.
Fit the valve collets ensuring correct collet location

in the spring cap and valve as the spring
compressor is released.
~~:
5
tlJ ~
~ ~:
During fitment of the valve stem seal, two

distinctly different degrees of resistance will be
noted when the seal is correctly fitted.
Firstly, press the seal down the valve stem until
the lower side of the seal comes into contact
with the valve guide. Greater resistance is felt at
this contact point and further gentle pressure is
then required to locate the seal over the top end
of the valve guide. On application of this
pressure, the seal can be felt to positively locate
over the top face of the valve guide. Once
correctly positioned, the seal cannot be pushed
down any further.
------~--
1\
CAUTION:
Always check for correct
~ location of the valve collets during and
after assembly. If not fitted correctly, the collets
may become dislodged when the engine is running
allowing the valves to contact the pistons. Any
such valve to piston contact will cause severe
engine damage.
1. Collets
2. Valve Spring Cap
3. Inner Valve Spring
4. Outer Valve Spring
5. Thrust Washer
6. Stem Oil Seal
7. Valve
3.16
CYLINDER HEAD 3
VALVE TO VALVE GUIDE CLEARANCE
VALVE FACE INSPECTION
If the valve guides are worn beyond the service limit

given below, the cylinder head must be replaced.
1.
Valve/valve guide clearance

Inlet
Exhaust
Standard
0.01 - 0.04 mm
0.03 - 0.06 mm
Remove any carbon build-up from the valve head

area. Examine the valve seat face, checking in
particular for signs of cracking or pitting.
VALVE SEAT DIAMETER
Service Limit
0.07 mm max
0.09 mm max
1.
VALVE GUIDE
The valve guides are fitted using liquid nitrogen to
contract the guide prior to fitment in the cylinder head.
Considerable force would be required to remove and
replace the guide which could cause the head to warp.
As liquid nitrogen is not generally available to the public,
it is not recommended that valve guides be renewed.
If a valve guide is found to be worn beyond the service
limit, the complete cylinder head must be renewed.
Measure the outside diameter of seating area on

the valve seat. If the seat area is not within the
specified range, the valve seat must be repaired.
Valve seating surface outside diameter

Standard:
Inlet:
Exhaust:
29.3- 29.5mm
25.3 - 25.5mm
VALVE SEAT WIDTH INSPECTION

1.
Measure the width of the valve seat to valve contact

face. If the seat area is not within the specified
range, the valve seat must be repaired.
NOTE:
Measure the portion of the seat where there is

no carbon build up.
Valve seating surface width (IN and EX)

0.9-1.1 mm
1.5mm
Standard:
Service limit:
1.
2.
3.
4.
3.17
Valve
Valve Seat
Valve Seat To Valve Contact Face
Seat Outside Diameter
3 CYLINDER HEAD
VALVE SEAT REPAIR
Operation
The valve seat can be repaired if pitted. If cracks or
larger burnt areas are present then the cylinder head
must be replaced. The width of the seat is critical and the
tolerance band given must be observed. In general, if the
seat width requires adjustment then metal must be
removed from either the top face (too large) using a 30
cutter or the bottom face (too small) using a 60 cutter. In
all cases, a hand cutter is used.
1.
Clean the valve seat area thoroughly.
Reducing Seat Width Using 30 Cutter
2.
Coat the valve seat with engineers blue.
8.
3.
Fit a 45 cutter to the holder and slide the cutter

guide into the valve guide.
a.
Using light pressure, grind the seating surface.
b.
4.
Measure the valve seat width and if necessary,

adjust as follows:
if the
grind
if the
grind
CAUTION: Over grinding will cause the

valve to sink deeper into the head. This
may make the valve clearance impossible to set,
leading to complete replacement of the head.
seat width is too narrow, repeat the 45

until the seat width is within tolerance.
seat width is too wide, fit a 60 cutter and
the seat until it is within tolerance.
'.'.
5.
Check the outside diameter of the seat surface:

a.
if the diameter is too small, grind using a 45

cutter until the diameter is within range.
if the diameter is too large, grind using a 30
cutter until the diameter is within range.
b.
6.
~eat Width
Once the correct seat diameter is established check

the seat width across the contact face.
/~
Reducing Seat Width Using a 60 Cutter

Seat Width
NOTE:
Checking Seat Width

7.
To reduce the face width, fit a 30 cutter and grind

the seat one turn of the cutter at a time.
CAUTION: A 30 cutter will remove metal

very quickly. Check the seat width after
each turn to prevent irreparable head damage.
3.18
A 60 cutter is used at this stage to avoid

sinking the valve any deeper into the cylinder
head.
9.
Lap the valve into the valve seat as follows;

a.
apply fine grinding compound to each valve
b.
rotate each valve against the valve seat until

the compound produces a smooth, matched
surface on both faces.
CYLINDER HEAD 3
Seat Width
Contact Area Too High

1. Valve Lapping Tool
2. Valve Seat
3. Valve
Seat Width
NOTE:
The seating area should be marked around the

centre of the valve face.
10. Remove all traces of the grinding compound from

both the valves and valve seats.
11. To confirm the correct contact area has been
ground, apply a thin smear of engineers blue to the
valve seat and fit the valve through the valve guide
and onto the valve seat. Press on the valve with
sufficient pressure to make a clear pattern in the
blue. Examine the contact area and compare with
the diagrams over. The correct contact area is in the
centre of the valve.
Contact Area Too Low
NOTE:
The location of the valve seat in relation to the

valve face is very important for good sealing
If the contact area is too high on the valve, the

seat must be lowered using the 30 cutter.
If the contact area is too low on the valve, the

seat must be raised using a 60 cutter.
3.19
Clutch
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch master cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch slave cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Friction plate inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
4.2
4.4
4.4
4.5
4.5
4.6
4.6
4.6
4.7
4. 7
4.7
4. 7
4.7
4.8
4.9
4.11
4 CLUTCH
15Nm
'
L __ _
25 Nm
@~25Nm
\.Y~
4.2
CLUTCH 4
10 Nm
4.3
4 CLUTCH
CLUTCH DESCRIPTION

when adding clutch fluid to the clutch
fluid reservoir.
Do not allow moisture or debris to enter the
cylinder as this will adversely affect the fluid
properties.
Always use fluid from a sealed container and do
not use fluid from a container which has been
opened for any period of time.
All models fitted with a hydraulically operated, wet plate

clutch. Clamping loads are varied from model to model
by fitting different rate springs to the pressure plate. The
clutch is operated by a hydraulic master cylinder which
controls a slave cylinder mounted on the engine. The
slave cylinder acts upon a pushrod which runs though
the centre of the gearbox input shaft.
The clutch has nine friction plates located between the
inner and outer drums. A geartrain, situated behind the
friction plate area distributes engine power to the
gearbox input shaft. An auxiliary geartrain also drives
the alternator, oil and water pumps, and receives input
from the starter motor via a sprag gear. On four cylinder
engines, the clutch gear also drives the balancers.

bodywork.
BLEEDING THE CLUTCH

1.
On models equipped with an adjustable lever, set

the adjuster wheel to No.1. (Note the original
setting of the wheel in order that it can be
returned to this position when the bleeding
operation is complete).
2.
Remove the dust cap from the bleed nipple on the

slave cylinder.
3.
Attach a transparent plastic tube to the bleed nipple.
4.
Place the other end of the tube in suitable

receptacle containing new clutch fluid.
5.
Turn the handlebars to bring the fluid reservoir to a

level position.
6.
Release and remove the 2 screws securing the

clutch reservoir cover.
8.
Check condition of the sealing diaphragm fitted

beneath the cover. Replace the diaphragm if
necessary.
9.
Release the bleed nipple
1/
turn.
10. Slowly pull in and release the clutch lever several

times until no more bubbles appear in the pipe.
WARNING:
Use
only
D.O.T.
4
specification clutch fluid as listed in the
use of clutch fluids other than those D.O.T. 4 fluids
reduce the efficiency of the clutch system leading
to an accident.
7.
1. Bleed Nipple Rubber Cap

2. Bleed Nipple
11.
Maintain the clutch fluid level between the upper

and lower levels whilst bleeding is being carried out.
NOTE:
Carefully remove the cover taking care not to spill

fluid.
During bleeding, do not allow the fluid level to

fall below the lower level mark in the reservoir.
If the level is allowed to fall below this mark,
air may enter the system and the sequence of
bleeding must be repeated.
12. When all the air has been expelled from the system,
hold in the clutch lever and close the bleed nipple.
Tighten to 7 Nm.
4.4
CLUTCH 4
13. Fill the reservoir to the upper level.
CLUTCH MASTER CYLINDER
WARNING:
Use
only
D.O.T.
4
specification clutch fluid as listed in the
use of clutch fluids other than those D.O.T. 4 fluids
reduce the efficiency of the clutch system leading
to an accident.
1.
Remove the reservoir cover. Drain the fluid from the

master cylinder using the bleed process described
over.
2.
14. Replace the reservoir cover and diaphragm

ensuring correct fitment of the diaphragm before
final tightening of the screws
Remove the pivot bolt securing the clutch lever to

the master cylinder. On Tiger models, also remove
the knuckle guard.
3.
Remove the clutch lever from the master cylinder.
15. Remove the transparent bleed pipe.
4.
Release the banjo bolt securing the clutch hose to

the master cylinder. Disconnect the clutch hose.
5.
Disconnect the starter lock-out switch from the

under side of the master cylinder.
6.
Release the handlebar clamp screws and remove

the clamp and master cylinder.
Removal
16. Replace the bleed nipple dust cap.

17. Reset the adjuster wheel on the clutch lever to the
original setting.
WARNING:
Always return the lever
adjuster to the original setting as noted in
paragraph 1. Operating the motorcycle with lever
settings which are unfamiliar may lead to loss of
control or an accident.
1. Handlebar Clamp
Disassembly
4.5
1.
Remove dust cover/boot (1) from the rear of the

master cylinder body.
2.
Remove the circlip (2) from the end of the master

cylinder bore.
3.
Remove the cylinder pushrod (3).
4.
Remove the washer (4) from part way down the

bore.
4 CLUTCH
5.
Remove the piston, seal and spring (5) noting the

position of the seal lip in relation to the piston.
2. Tighten the clamp bolts, upper first and then lower

to 15 Nm.
3. Re-connect the starter lock out switch to the master
cylinder.
4. Position the clutch lever ensuring that pivot boss is
correctly aligned and fitted to the push rod. On
Tigers, fit the knuckle guard and flanged sleeve.
Tighten the pivot bolt to 1 Nm on all except Tiger,
and 6Nm on Tiger.
5. Tighten the locknut to 6Nm (all models). On Tigers,
refit the plug to the pivot bolt
1 . Dust Cover/Boot
2. Circlip
3. Pushrod
4. Washer
5. Piston, Seal and Spring
Inspection
1.
Check the following for wear, damage, cracks or

signs of deterioration and replace as necessary:
cylinder bore and piston
1.
2.
3.
4.
seals
dust cover
Plug (Tiger only)

Pivot bolt
Flanged Sleeve (Tiger only)
Nut
spring
2.
6. Align and fit the banjo bolt to the clutch hose using
new sealing washers. Connect the hose to the
master cylinder.
Ensure that the fluid return and supply ports on

cylinder are not blocked.
7. Tighten the banjo bolt to 25 Nm.
Assembly
1.
Clean all disassembled parts with new clutch fluid.

Apply clutch fluid to the bore of cylinder.
2.
Fit a new seal and piston set ensuring that the seal
is fitted in the same position as noted during
removal.
3.
Assemble all components to the master cylinder in

the reverse order to removal. Ensure that the dust
cover is correctly located over both the pushrod and
cylinder body.
8. Bleed the clutch as described earlier and then

examine the system for;
a.
b.
Installation
1. Locate the master cylinder to the handlebars and
position the clamp with the 'Up' arrow pointing
upwards. Align the master cylinder/clamp split line
with the dot mark on the handlebar.
4.6
correct clutch operation.

fluid leakage.
CLUTCH 4
CLUTCH SLAVE CYLINDER
Removal
1.
Position a suitable container for the collection of

clutch fluid.
2.
Release the banjo bolt from the clutch slave

cylinder. Place the hose fitting into the container to
collect the fluid.

bodywork.
L.l..).
3.
Release the three bolts securing the clutch slave

cylinder to the sprocket cover.
4.
Detach the cylinder taking care to ensure that the

piston remains in the cylinder.
5.
If the cylinder is not to be stripped, retain the piston

to the slave cylinder using a rubber band or cable
tie.
1. Spring
2. Seal
3. Dust Cover
Assembly
1.
Apply clutch fluid to outside of both the piston and

seal.
2.
Refit the piston, ensuring that the spring is correctly

positioned. Retain the piston using a rubber band or
cable tie prior to final assembly on the sprocket
cover.
Installation
1.
Remove the cable tie or rubber band from the slave

cylinder.
2.
Apply a smear of grease to end of push rod.
3.
Align and fit the banjo bolt to the clutch hose using
new sealing washers. Connect the hose to the
slave cylinder.
4.
Fit the slave cylinder to the sprocket cover ensuring

that the push rod locates correctly in the cylinder.
Tighten the cylinder to sprocket cover bolts to
12Nm.
Disassembly
5.
Tighten the clutch hose banjo bolt to 25 Nm.
The spring inside the cylinder will push the piston out far
enough for removal by hand.
6.
Bleed the clutch as described earlier in this section

and then examine the system for;
1. Clutch Slave Cylinder

2. Retaining Tie
3. Clutch Pushrod
Inspection
1.
a.
b.

deterioration and replace as necessary:
cylinder inner wall and piston
dust cover
spring
4.7
correct clutch operation.

fluid leakage.
4 CLUTCH
CLUTCH
r
'
1.
2.
3.
4.
5.
6.
7.
8.
9.
Bolt
Clutch spring
Pressure Plate
Bearing
Pushrod end piece
Friction Plate
Clutch Plate
Anti Judder Plate
Centre Nut
10. Centre Drum

11. Pushrod
12.Bush
13. Needle Bearing
14. Splined Collar
15. Auxiliary Drive Gear
16. Outer Drum
17. Shim
18. Washer
Disassembly
1.
Detach the rubber breather pipe (where fitted) from

the clutch cover.
2.
Drain the engine oil and remove the ring of bolts

securing the clutch cover to the crankcase.
Remove the cover.
3.
Remove the bolts and springs from the clutch

pressure plate. Remove the pressure plate.
4.
Remove clutch push rod and end piece.
5.
Remove all the clutch friction plates together with

the anti judder plate.
NOTE:
4.8
It is not normally necessary to disassemble the

clutch further, but if the clutch inner and outer
drums are to be removed, proceed as follows:
6.
Rotate the engine until number1 cylinder (1 and 4

on a 4 cylinder engine) is at TDC.
CLUTCH 4
7.
Engage 1st gear, and lock the inner and outer clutch
drums together using service tool 3880025
11.
Remove the centre nut and clutch inner drum.
12. Remove the large flat washer and shim from the
input shaft.
~~
13. Slide the clutch outer drum gently backwards and

forwards to dislodge the splined bearing sleeve.
Carefully remove the sleeve and needle roller
bearing while supporting clutch drum.
14. Remove clutch drum by easing out of the
crankcase, left-hand side first.
15. Remove the auxiliary drive gear.
Assembly
1.
1. Service Tool 3880025
8.
Depress the rear brake pedal to prevent the engine

from turning, then loosen but do not remove the
clutch centre nut and belleville washer.
9.
Check that number 1 cylinder (1 and 4 for 4 cylinder

engines) is still at TDC.
Position the auxiliary gear (with the deeper dish side

towards the crankcase) between the oil pump drive
gear and alternator drive gear.
Ensure full
engagement of the auxiliary gear with the alternator
gear.
J,\
CAUTION: On 4 cylinder engines, the

clutch and balancer gears are carefully
matched to ensure correct crankshaft to balancer
alignment.
Instruction 10 must be correctly
observed to avoid a potentially serious engine
vibration resulting in severe engine damage.
10. Mark the primary balancer tooth, adjacent to the 'lip'

on crankcase, to ensure correct timing of balancer
on re-assembly.
1. Alternator Drive Gear

2. Oil Pump Drive Gear
\\ \__)
2.
Temporarily fit the sleeve, needle roller bearing and

splined sleeve to correctly locate the auxiliary gear
centrally. Carefully remove the splined sleeve and
needle roller bearing.
3.
Fit the clutch outer drum, making sure that the

marked tooth on the balancer gear is still aligned
with 'lip' on the crankcase.
1\
CAUTION: Incorrect alignment of the 4

cylinder balancer drive gear will cause a
severe engine vibration resulting in severe engine
damage.
Lip
Gear Tooth
4.
Mark the gear tooth adjacent to the crankcase lip

1. Clutch Outer Basket
2. Balancer Gear
4.9
Align the splines of clutch drum with the splines on

auxiliary gear (it may be necessary to remove clutch
outer drum and rotate by one tooth to align spline).
Re-check the balancer alignment and adjust if
necessary.
4 CLUTCH
5.
While holding clutch outer drum in position, refit the

splined sleeve and needle roller bearing. When the
sleeve is correctly fitted, it is flush with clutch drum
face.
9.
Lock the inner and outer drums together using

service tool 3880025. Depress the rear brake pedal
to prevent the engine from turning, and tighten the
clutch centre nut to 105 Nm. Remove the service
tool.
A.
CAUTION:
Re-check the drive gear
position on the 4 cylinder balancer and
repeat operations 2, 3, 4 and 5 if the balancer is not
correctly aligned.
Severe engine damage could result from incorrect
balancer alignment.
L.b
6.
Fit the shim and large washer to the outer drum.
7.
Fit the clutch inner drum.
8.
Fit the belleville washer

outwards), and centre nut.
('out'
mark facing
1. Service tool 3880025

10. Disengage first gear and check for free rotation of
the clutch inner drum.
A.
doe~
CAUTION: If the inner drum

not
rotate freely, it must be removed and
shimi'Tied to pr:vent severe engine dama_g_e_._
_J
NOTE:
Friction plates and clutch plates must be

inspected for signs of wear, damage or
distortion before re-use, and replaced if not in a
serviceable condition. (see Friction plate
wear/warp).
11.
Soak all clutch plates in oil before fitting to the clutch

basket in the same order as removal.
Belleville Washer 'Out' Mark
12. Carefully refit the clutch pushrod and end piece

ensuring that the pushrod seals in the crankcase do
not become displaced or damaged.
13. Refit the clutch pressure plate together with the
springs and bolts. Tighten the bolts to 10 Nm
14. Clean and refit the clutch cover using a new gasket.
Tighten the clutch cover bolts to 12 Nm.
15. Refit the breather hose and clip (where fitted).
16. Re-fill the engine with the correct grade and type of
engine oil.
4.10
CLUTCH 4
FRICTION PLATE INSPECTION

1.
If any friction plate thickness is outside the seNice

limit, replace the friction plates as a set.
1. Clutch friction Plate
Friction plate thickness

Standard:
Service limit:
2.
3.80 mm - 0.00 + 0.08 mm

3.60 mm
Check all plates for bend and warp as follows:

Place the plate being checked on a clean surface
plate and attempt to pass a feeler gauge of the
maximum specified thickness between the friction
plate and surface plate at several points around the
plate. If the feeler gauge can be passed beneath
the friction plate at any point, renew the plates as a
set.
1. Friction Plate
2. Feeler Gauge
3. Surface Plate
Standard:
Service limit:
0.15 mm
0.20 mm
4.11
Balancers
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
Balancer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
Balancers, 4 Cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
5.3
5.4
Balancer, 3 Cylinder
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
5.5
5.5
5.1
5 BALAN-;;C~ER=S--Exploded
---
v1ew
4 CYLINDER ENG INES
12 Nm
12 Nm
9Nm
3 CYLINDER ENGINES
5.2
BALANCERS 5
BALANCERS
Both three and four cylinder models are fitted with
balancer systems to control 'pulsing' within the engine.
Without any form of balancer, the engine would 'pulse'
each time the crankshaft rotated. This 'pulsing' would be
felt as a vibration which would amplify as the engine
speed was increased.
The balancer has the effect of a counterbalance weight
which creates an equal amount of energy in the opposite
direction and at the same time as that produced by the
crankshaft. Because the opposing pulses occur at the
same point of crankshaft rotation, and are of an equal
magnitude, a state of equilibrium or balance is reached
and no vibration occurs.
4.
Support the balancer weights and carefully

withdraw the spindles in the direction of the
balancer clamps.
5.
Remove the balancers taking care to retain the

thrust washers which are fitted at both ends of both
balancers.
On the three cylinder engine, a single balancer is used

which is driven by a gear fitted to the left hand end of the
crankshaft.
On four cylinder versions, two balancers are fitted which
are driven by the large clutch gear.
4 Cylinder Balancer
1 . Balancer Removal
Removal
1.
Remove the sump as described in the lubrication

section.
2.
Release the pinch bolts from both balancer clamps.
3.
Remove the balancer clamp from the lower

crankcase.
Inspection
1.
Remove the balancer gear from the balancer

weight by sliding the gear from the weight.
1. '0' Rings
2. Thrust Washers
3. Needle Roller Bearings
4. Balancer Gear
5. Shock Absorbers
6. Balancer Weight
7. Bearing Spacer
1. Balancer Clamp Pinch Bolts
2. Balancer Clamp To Crankcase Screws
3. Balancer Clamp
4. Balancers
5. Balancer 'Dot' Marks
5.3
2.
Visually inspect the rubber shock absorbers for

damage or deterioration. Replace as necessary.
3.
Visually check the needle bearings and bearing

tracks for abrasion, colour change (blueing), or
other damage. Always replace damaged bearings.
5 BALANCERS
4.
Fit new '0' rings whenever the balancers are

stripped.
5.
Once satisfied with the condition of all the

components, clean and re-assemble the balancers.
5.
Installation
Rotate the front spindle (nearest the crank)

clockwise until the spindle cannot be further
turned. This indicates that the gears are meshed
tightly together. Turn the spindle back fractionally
and tighten the pinch bolt to 12 Nm.
6.
1.
Set the crankshaft with number 1 and 4 cylinders at

TDC.
2.
Position each balancer in the crankcase, ensuring

that the gears mesh correctly, and the timing mark
on each balancer lines up with cast mark on
crankcase.
Clockwise Arrow- Front Spindle Direction of

Rotation
Anticlockwise Arrow- Rear Spindle Direction of
Rotation
1. Balancer Alignment Marks
3.
Fit the balancer spindles with the dots on the end of

the spindles facing downwards.

the motorcycle engine must be run. The
gases.
quantity.
7.
Refit the sump and fill the engine with oil (refer to the
lubrication section). Start the engine and allow to
idle. Loosen the pinch bolt and adjust each spindle
in turn until there is no rattle (gears too far out of
mesh) and no whine (gears too far into mesh).
When correctly adjusted, tighten the pinch bolts to
12 Nm.
NOTE:
The balancer spindles must be adjusted, and
the pinch bolts tightened, individually.
1. Balancer Spindles with Dot Positions Arrowed

2. Spindle Pinch Bolts
4.
Fit the balancer clamp and tighten the retaining

screws to 12 Nm.
5.4
BALANCERS 5
3 Cylinder Balancers
Removal
1.
Remove the left-hand crankshaft cover.
NOTE:
Early models were fitted with an oil feed pipe

to the left hand crankshaft cover which must
also be removed.

Adventurer, a centrifugal breather is fitted to
the left hand end of the crankshaft. Ensure
that the oil seal located in the left hand cover
is replaced before re-assembly.
2.
Rotate the crankshaft until No.1 cylinder is at TDC.
3.
Loosen the screws securing the balancer locking

plate to the crankcase. The screws are accessed
through holes in balancer gear.
1. Access Holes for Locking Plate Fixings

2. Timing Marks
NOTE:
4.
The locking plate screws are accessed

through the holes in the balancer gear.
A.
CAUTION: Use hand pressure only to

align the back-lash gear. The use of any
metal faced object will damage the gear faces.
When the locking plate drops down, the balancer

assembly can be withdrawn by sliding out from the
crankcase.
4.
Slide the locking plate upwards into position.
5.
Tighten the right-hand (rear) screw, and then the

left-hand (front) screw to 9 Nm.
6.
Refit the left-hand crankshaft cover using a new

gasket. Tighten the cover screws to 12 Nm.
Inspection
1.
Examine the backlash springs for wear, breakage

and looseness. Renew if in doubt.
2.
Check for ball bearing wear. If any bearing is worn,

the complete balancer must be replaced.
Installation
1.
Clean the threads of the locking plate screws and

holes.
2.
Apply 'Loctite 242' to the screw threads and loosely

fit the locking plate with the curved edge level with
the bearing bore.
3.
Check that No. 1 cylinder is still at TDC. Fit the

balancer assembly to the crankcase. To bring the
gear fully into mesh, compress the back-lash gear
while aligning the timing marks on the gear teeth as
shown over.
5.5
Crankshaft/Rods/Pistons
including Engine Removal/Installation
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
Engine
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
6.6
Crankcase
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8
6.1 0
Connecting rods
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12
6.12
Crankshaft
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14
6.14
Con rod big end bearing/crankpin wear

Con rod big end bearing/crankpin clearance . . . . . . . . . . . . . . . . . . . . . .
Crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.15
6.15
6.15
Crankshaft main bearing/journal wear

Crankshaft main bearing/journal clearance . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft main journal diameter/bearing selection . . . . . . . . . . . . . . . .
6.16
6.16
Pistons
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston outside diameter/wear check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston ring/groove clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston ring end gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.17
6.17
6.18
6.18
6.19
Cylinder wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.20
Cylinder liners
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.20
6.21
Left Hand Crankshaft Cover, all 4 Cylinder and

Thunderbird/Thunderbird Sport & Adventurer Engines . . . . . . . . . . . . . .
6.22
6.1
6 CRANKSHAFT/RODS/PISTONS
Exploded View
TORQUE IN ACCORDANCE
WITH RELEVANT SECTION
22Nm
27 Nm
6.2
CRANKSHAFT/RODS/PISTONS 6
95Nm
95Nm
6.3
DESCRIPTION
ENGINE REMOVAUREFIT
NOTE:
Removal
In order to carry out repairs to the crankshaft

and connecting rods, the engine must first be
removed from the motorcycle frame and the two
halves of the crankcase separated.

falling.
The aluminium alloy crankcase houses, not only the

crankshaft, but also the geartrain and associated
components. Wet cylinder liners are fitted which are not
a press fit. The liners are sealed by means of a bead of
Hylomar at the joint face in the upper crankcase and the
cylinder head provides all necessary clamping load on
the liners. It is not necessary to check liner stand proud
from the upper crankcase as all tolerances are correctly
produced during manufacture.
Forged steel connecting rods are used which are not
bushed at the small end. The gudgeon pin runs direct in
the connecting rod and is lubricated via the splash feed
from the big end exit drilling. Connecting rods are
matched for weight and are fitted as matched sets for
optimum engine balance
1.
Remove the seat, disconnect the battery, negative

(black) lead first and remove the battery.
2.

system section.
~ given in the general information section

3.
Remove the bodywork, including the lower fairings
4.
Drain the engine oil into a suitable container.

WARNING:
engine
oil
contains
potentially
harmful
1. Connecting Rod Grade Markings
"'

With the exception of number 2 cylinder, pistons and

liners are not graded. The piston and liner for number 2
cylinder are specially selected as a matched, close
tolerance set. On later models, number 2 cylinder liner is
marked 'B' on the mating face with the cylinder head
gasket. Selective fit crankshaft bearing shells are used
to produce an engine as close to the 'blueprinted'
specification as possible and to compensate for minor
variations (microns) in the crankcase and connecting
rods. On 4 cylinder engines, a centrifugal breather disc is
fitted to the left hand end of the crankshaft and is
connected to the airbox by a flexible hose. The breather
on 3 cylinder engines is integral with the clutch cover
and, as with the four cylinder, is connected to the airbox
by a flexible hose.
5.
Remove the coolant drain plugs and drain the

coolant into a suitable container. Retain the coolant
for re-use (if serviceable). Refit the drain plugs
when all coolant has drained out.

cooling system is hot and also under pressure.
Contact with the pressurised coolant will cause
scalds and skin damage.
6.4
6.
1o. Remove the exhaust system completely.
Disconnect the top and bottom hoses and remove

the radiator. On Thunderbird, Thunderbird Sport
and Adventurer also disconnect the bypass and
cylinder head hoses.
7.
Tiger only: Remove the sump guard.
8.
Disconnect the oil cooler hoses (where fitted) from

the inlet and outlet points on the sump. Release the
oil cooler brackets from the side of the engine and
remove the cooler from the motorcycle frame.
11.
, - - - - - - - - - - - - -.. - - - - - - - - -
A.
CAUTION: Always hold the hexagonal

part of the oil cooler and any sump unions
with a spanner while releasing the cooler/pipe
unions. Damage to the oil cooler and/or pipes and
unions may result from failure to support the oil
cooler during release of the unions.
1.
2.
3.
4.
5.
Water Pump Hose Cover

Retaining Bolt
Washer
Lower Mounting Point
Upper Mounting Point
12. Remove the side stand assembly. Disconnect the

side stand switch cables from the switch.
13. Disconnect the following electrical connections to
the engine;
Alternator
Starter motor
Ignition pick-up sensor
Water temperature sensor
Oil pressure switch
1. Banjo Bolt
2. Feed Pipe
3. Return Pipe
9.
Release the gearchange rod from the pedal

(Thunderbird, Thunderbird Sport and Adventurer,
remove the gearchange pedal).
14. Remove the clutch slave cylinder from the sprocket

cover. Secure the piston with a cable tie to prevent
accidental loss of clutch fluid.
Disconnecting the oil cooler pipes

2
\ It
2. Cable Tie
1. Oil Cooler Bracket

2. Oil Cooler
6.5
"J'
CAUTION: To prevent paint and body

damage, ensure that any displaced
clutch fluid does not come into contact with any
part of the engine or bodywork.
WARNING: If the swinging arm is allowed

to pull on the rear brake hose, however
briefly, the hose MUST be replaced. The damage
caused to the brake hose could lead to reduced
brake performance leading to loss of control and
an accident.
LU
15. Remove the clutch pushrod and remove the

sprocket cover from the engine.
19. Loosen all the engine mounting bolts then remove

the rear bolts only. Lower the rear of the engine and
disconnect the chain. Remove the front engine
mounting bolts and lower the engine from the
frame.
16. Release the chain adjusters to give maximum chain

slack.
Engine Installation
1.
Locate the engine to the support and position

beneath the frame. Inspect the chain rubbing block
and strip, renew as necessary.
2.
Align the engine to the rear mounting points

ensuring that the top edge of the chain is positioned
above the rubbing strip. Connect the chain to the
output sprocket.
1. Adjuster Clamp Bolt

2. Adjuster Wrench
3. Swinging Arm
17. Remove the lower outrigger finishers by releasing
the outer ring of capscrews (plastic plugs fitted to
early bikes). Remove the wire clips (where fitted)
and slacken the swinging arm spindle bolts.
Remove the chain guard.
-~-"-"~-"~"""--~~-"------
WARNING: The engine is heavy! Ensure

that the support method used is of
sufficient weight capacity to support the engine.
An engine which falls or becomes unstable during
removal could cause serious injury to the operator
and also cause damage to engine and fram]e
components.
NOTE: 'New' Trophy, remove both control plates to

gain access to the swinging arm spindle.
J,\_
CAUTION: Ensure the oil warning light

wiring does not become trapped during
alignment of the engine to the frame. damage to
both the switch and the wiring may take place if the
wiring becomes trapped.
L_U
18. Place a jack or other suitable support beneath the

engine and raise sufficiently to support the engine
weight during disconnection of the engine mounting
bolts. Place a block behind and in front of the rear
wheel to prevent the machine from moving.
3.
WARNING: The engine is heavy! Ensure

that the support method used is of
sufficient weight capacity to support the engine.
An engine which falls or becomes unstable during
removal could cause serious injury to the operator
and also cause damage to engine and frame
components.
Fit new engine mounting bolts and nuts, front first

then rear. Tighten the engine mounting bolts to
95Nm.
WARNING:
Never re-use engine
mounting bolts.
Reusing old engine
mounting bolts could lead to the bolt loosening in
service leading to loss of control and an accident.
4.
Tighten the swinging arm spindle bolts to 85 Nm.

Refit the wire clips (where fitted) to the bolts. Refit
the outrigger finishers (control plates on 1996
Trophy).
5.
Refit the clutch pushrod. Clean and refit the

sprocket cover using a new gasket. Tighten the
sprocket cover bolts to 12 Nm.
"J'
CAUTION: When removing the engine,

ensure that the swinging arm and rear
wheel are well supported at all times. When the
rear engine mountings bolts are removed, the
swinging arm and linkage carriers are free to move.
Any excessive movement of the swinging arm will
cause damage to the rear brake hose.
LU
6.6
6.
Adjust the drive chain tension and wheel alignment

as detailed in the maintenance section.

with a spanner while releasing or tightening the
cooler/pipe unions. Damage to the oil cooler
and/or pipes and unions may result from failure to
support the oil cooler during release or tightening
of the unions.

14. Tiger only, refit the sump guard.

7.
Remove the retaining band from the clutch slave

cylinder and refit the cylinder to the sprocket cover.
8.
Refit the side stand assembly and reconnect the

side stand switch. Tighten the centre mounting bolt
to 95 Nm and the upper fixing to 22 Nm.
9.
15. Fit the radiator and stone guard to the frame and
reconnect all coolant hoses. Use new hose clips
where necessary.
'f

Reconnect the following electrical connections;

Alternator
Starter motor
Ignition pick-up sensor
Oil pressure switch
16. Refit the fuel tank as described in the maintenance

section.
17. Add engine oil to the correct level as described in
the lubrication section of this manual.
10. Refit the choke and throttle cables to the

carburettors. Locate the airbox into the frame and
assemble;
the carburettors to the engine
the airbox to the carburettors.
Adjust the throttle and choke cables as detailed in
the fuel system section.
~ CAUTION: Refer to the owners handbook

~ for the correct grade of engine oil. Use of
the wrong grade of oil could damage the engine.
18. Add coolant to the correct level as described in the
cooling section of this manual.
19. Refit and reconnect the battery, positive (red) lead

first.

routed or damaged throttle and/or choke cable
could interfere with the operation of the brakes,
clutch or the throttle. Any of these conditions
and an accident.
20. Refit the bodywork and seat.

11.
Refit the exhaust system using new gaskets.
12. Connect and adjust the gear-change rod

(Thunderbird, Thunderbird Sport and Adventurer,
refit the gearchange pedal).
13. Refit the oil cooler and brackets to the engine. Refit
the oil cooler pipes using new sealing washers to
the banjo bolts.
6.7
CRANKCASES
upper crankcase screws 1-12 for 4 cylinder

engines WITHOUT alternator cover,
Before splitting the crankcases, the following items must

be removed
1.
Sump.
2.
Engine covers
3.
Alternator drive cover (where fitted).
4.
Alternator.
5.
Starter motor.
7.
Ignition pick-up.
8.
Cylinder Head and cam chain.
Disassembly
NOTE:
Four different types of crankcase have been

used in the manufacture of Triumph engines.
All four crankcases have a different screw
release sequence. Always ensure that you have
correctly identified the crankcase type being
worked on from the series of diagrams which
follow.
Having correctly identified the
crankcase type, ensure that the screw release
sequence given in the selected diagram is
followed.
11
9
10
4 Cylinder Upper Crankcase (WITHOUT alternator
cover)
upper crankcase screws 1-8 for 3 cylinder engines

WITH alternator cover,
1\.
~
CAUTION: Failure to follow the correct

screw release sequence may result in
permanent crankcase damage.
----------------------~
1.
Progressively release the upper crankcase screws

in the sequence shown for the type of crankcase
being disassembled.
The correct screw release sequences are;
upper crankcase screws 1-8 for 4 cylinder engines

WITH alternator cover,
3 Cylinder Upper Crankcase {WITH alternator

cover)
4
5
6
8
4 Cylinder Upper Crankcase WITH alternator cover
6.8
upper crankcase screws 1-12 for 3 cylinder

engines WITHOUT alternator cover.
lower crankcase screws 1-4 for 4 cylinder engines

WITHOUT alternator drive cover,
8
3
1'1!>111Ttt----
I~JR-1+---
12
10 11
3 Cylinder Upper Crankcase (WITHOUT alternator
cover)
9
2.
Invert the engine.
3.
Progressively release the lower crankcase screws

in the sequence shown for the type of crankcase
being disassembled.
The correct screw release sequences are as
follows;
4 Cylinder Lower Crankcase (WITHOUT Alternator

Drive Cover).
lower crankcase screws 1-18 for early 3 cylinder

engines WITH alternator drive cover,
18
15
11
13
16
I:\

screw release sequence may result in
lower crankcase screws 1-22 for 4 cylinder engines

WITH alternator drive cover,
21
19
17
13
15
--+-0-':1
--+fo>-("
IU--f---
3
7
.....,._~JN-dU~--
9
1
22
17
12
4
20
12
6
10
14
3 Cylinder Lower Crankcase (Engines WITH

Alternator Drive Cover).
14
4 Cylinder Lower Crankcase (WITH Alternator
Drive Cover).
6.9
lower crankcase screws 1-14 for later 3 cylinder

engines WITHOUT alternator cover.
1.
Apply Loctite 648 to the outer races of the gearbox

bearings. Fit the gearbox shafts ensuring the
locating ring on the input shaft is in position in the
circlip groove on the crankcase. Engage the clutch
primary gear with crankshaft gear.
2.
Ensure that the input and output gear shafts are in

the neutral position.
3.
Ensure that the 3 locating dowels are in position in

the upper crankcase. On 3 cylinder engines ensure
that the balancer locating dowel is also fitted.
4.
Use high flash-point solvent to clean the crankcase

mating faces. Wipe the surfaces clean with a
lint-free cloth.
5.
Apply a thin bead of silicone sealant to the lower

crankcase mating faces.
iA
3 Cylinder Lower Crankcase screws (Engines

WITHOUT Alternator Drive Cover)
4.
Assembly
Separate the lower and upper crankcases ensuring

that the 3 locating dowels remain in the upper
crankcase. Remove the clutch pushrod seal.
C~UTIO~:-------;;-~
not use excessive
amounts of sealer. The extra sealer may

ecome dislodged and could block the oil
assages in the crankcases causing severe
Lengine damage.
6.
__j
Fit a new '0' ring to the oil pump outlet.
1. Locating Dowels
------------ ------ I
CAUTION: Do not use levers to separate I

the upper and lower sections of the I
crankcase or damage to the crankcases could
result.
1
- - - - - ___j
6.10
Arrowed: Oil Pump '0' Ring Position.

7.
Lubricate the crankshaft journals and bearing shells

with clean engine oil.
8.
Position the lower crankcase to the upper, ensuring

that all selectors engage correctly. An assistant
may be required to support the crankcase during
alignment.
Stage 2 - all screws

14. Invert the engine.
In the correct sequence, tighten all lower crankcase
screws to 12 Nm.
In the correct sequence, tighten all upper crankcase
screws to 12 Nm.
Stage 3 - MB screws only
In the correct sequence, tighten the M8 lower
crankcase screws to 28 Nm.
In the correct sequence, tighten the M8 upper
crankcase screws to 28 Nm.
Selector Forks
9.
Fit the screws into the lower crankcase and hand

tighten.
18. Rotate the crankshaft in the direction of the arrow on

the ignition rotor (clockwise). Check for tight spots
and rectify as necessary.

11.
Fit the screws into the upper crankcase and hand

tighten.
19. Apply silicone sealant to the clutch push rod seal

and press into the crankcase.
NOTE:
The crankcase screws are tightened in stages,

in the same sequences used during strip down.
Refer to the strip down procedure earlier in this
section for the correct screw tightening
sequence for the type of crankcase being
assembled.
Two different sizes of crankcase screw are
used. All screws are tightened through the first
two stages of the tightening procedure but only
the MB size screws are tightened at the third
stage.
A.

screw tightening sequence may result in
Stage 1 - all screws

In the correct sequence, tighten all lower crankcase
screws to 10 Nm.
In the correct sequence, tighten all upper crankcase
screws to 10 Nm.
6.11
CONNECTING RODS
Installation
Removal
1.
NOTE:
Release the connecting rod nuts and remove the

big end cap.
Connecting rod bolts and nuts are treated with

an anti-rust solution which must not be
removed.
Clean the connecting rod with high flash-point

solvent.
Remove all bearings and inspect for damage,

wear and any signs of deterioration and replace
as necessary.
1.
Fit new connecting rod bolts to the big end.
NOTE:
Ensure that con rod is fitted correctly, (oil hole

in the connecting rod on the opposite side from
the arrow on the piston crown).
NOTE:
It may be necessary to gently tap the big end

cap with a rubber mallet to release the cap from
the studs.
2.
Mark each big end cap and connecting rod to

identify both items as a matched pair.
3.
Ensure that the bearing shell stays in the big end

cap.
4.
Remove each piston and connecting rod assembly

together with the cylinder liner.
5.
Label the assembly to identify the cylinder from

which it was removed.
2 ----...
CAUTION: Never re-use connecting rod

~ bolts or nuts. If the connecting rod cap is
disturbed, always renew the bolts and nuts. Using~
the original nuts and bolts may lead to severe
engine damage.
1. Connecting Rod with Oil Hole Arrowed

2. Piston Arrow
2.
6.12
Apply molybdenum disulphide grease to the upper

inner surface of the connecting rod big end.
NOTE:
Avoid touching any bearing surfaces of the

bearing shells with the hand.
3.
Fit the piston and connecting rod assembly into the

liner. Fit the assembled liner into the crankcase
ensuring that the arrow on the piston faces forward,
and the oil hole in the connecting rod faces rearward
(see liner remove refit section).
4.
Lubricate both surfaces of bearing shell with engine

oil and fit to the connecting rod and big end cap.
5.
Align the connecting rod to the crankshaft and fit the

big end cap.
To accurately gauge the 120 turn, fit the tool

between the socket and the drive handle and
locate the socket to the big end nut. Pick an
increment point on the torque turn gauge which
aligns with a suitable reference point on the
engine. Tighten the bolts until 12 of the 10
gauge increments have rotated past the chosen
point.
Increment
marking
Service Tool 3880105-T0301
Aligning the Connecting Rod

6.
Tighten each cap (using new nuts and bolts) as

follows:
'!'
CAUTION: The torque characteristics of

the connecting rod nuts and bolts are
sensitive to the rate at which they are tightened. If
all the torque is applied in one action, the bolt may
be stretched and the nut may become loose when
in service resulting in an expensive engine failure.
Lubricate the threads of the bolt and the face of the

nut with molybdenum disulphide grease. Tighten
the nuts progressively in 2 stages;firstly to 14 Nm
then through 120 of nut rotation as measured
using the Triumph torque turn gauge
3880105-T0301.
6.13
CRANKSHAFT
Installation
NOTE:
Before the crankshaft can be removed, the two

halves of the crankcase must first be separated.
Removal
1\
--------------
1.
Remove the connecting rods as described in the

previous section.
2.
Remove the breather disc (where fitted) from the

crankshaft.
3.
Release and remove the crankshaft from the upper

crankcase.
CAUTION:
Always check the bearing I
journal clearance, as described in th:~

following pages, before final assembly of the
crankshaft. Failure to correctly s.elect crankshaft
bearings will result in severe engme damage.
--------------------
--------
1.
Select and fit new main and big end bearings using
the selection processes detailed over.
2.
Lubricate all bearings with engine oil.
3.
Ensure that the crankshaft is clean and that the

oilways within the crank are free from blockages
and debris. Position the crankshaft in the upper
crankcase.
4.
Fit the connecting rods, liners etc. as described in

the previous section.
5.
Refit the breather disc to the crankshaft and tighten

the fixings to 22 Nm.
NOTE:
NOTE:
Remove all bearings and inspect for damage,

wear, overheating (blueing) and any other signs
of deterioration. Replace the bearings as a set if
necessary.
Later 4 cylinder crankcases are fitted with

non-grooved main bearing shells to journals 1,
3 and 5. Journals 2 and 4 remain grooved as
before. Ensure that the non-grooved shells are
fitted to the correct journals. The non-grooved
shells are not interchangeable. REFER TO THE
PARTS INFORMATION IF IN DOUBT.
6.14
Refer to the early part of this chapter for details

of crankcase assembly.
CONNECTING ROD BIG END BEARING
SELECTION/CRANKPIN WEAR CHECK
1.
3.
Measure the bearing and crankpin clearance as

follows.
If the measured clearance exceeds the service

limit, measure the crankpin diameter.
Crankpin diameter
Standard:
Service limit:
NOTE:
Do not turn the connecting rod and crankshaft

during the clearance measurement as this will
damage the plastigauge.
2.
The crankpin clearances are measured using

'Piastigauge' (Triumph part number 3880150).
Remove the big end cap from the required journal.
Wipe the exposed areas of both the crankpin and
the bearing face inside the cap. Apply a thin smear
of grease to the journal and a small quantity of
silicone release agent to the bearing.
Trim a length of the plastigauge to fit across the
journal. Fit the strip to the journal using the grease
to hold the plastigauge in place. Lubricate the
threads of the bolt and the face of the nut with
molybdenum disulphide grease. Refit the bearing
and cap and tighten the big end nuts progressively
in two stages;
Firstly to 14Nm
Then through 120 of nut rotation as measured
using the Triumph torque turn gauge
38801 05-T0301.
Release the nuts and remove the cap being
measured. Using the gauge provided with the
plastigauge kit, measure the width of the
compressed plastigauge.
40.946 - 40.960 mm
40.932 mm
If any crankpin has worn beyond the service limit, the

crankshaft must be replaced. Due to the techniques
used during manufacture, the crankshaft cannot be
reground and no oversize bearings are available.
Connecting Rod Bearing Selection

Differences in connecting rod dimensions
compensated for by using selective bearings.
1.
are
Select the correct big end bearing shell as follows:

Measure each crankpin diameter.
Check connecting rod for either an A or B mark.
Select the correct bearings by matching the
information found with the chart below.
Big end bearing selection chart

(all dimensions in mm's)
Bearing Shell
Part Number
Shell Colour
Con-rod Mark
Crankpin
Diameter
Running
Clearance
1110051
White
A
40.960
40.954
For instance:
Con-rod Mark
Crankpin Diameter
Required Bearing
1110053
1110052
Blue
Red
B
B
A
40.953 40.960 40.953
40.946 40.954 40.946
0.036-0.066
A
40.951
Red
NOTE:
Repeat the measurements for all connecting
rods and their respective crankpins.
It is normal for the bearings selected to differ

from one connecting rod to another.
2.
Install the new bearings in the connecting rod.
A.
CAUTION: Always confirm, using the

plastigauge method, that the running
clearance is correct before final assembly. Severe
engine damage could result from incorrect
clearance. Ensure all traces of plastigauge are
removed after use to prevent blockage of the oil
drillings and resultant engine damage.
Checking the Measured Clearance
Con rod big end bearing/crankpin

clearance
Standard:
Service limit:
0.036 - 0.066 mm
0.1 mm
6.15
CRANKSHAFT MAIN BEARING/JOURNAL WEAR
Bearing Selection Chart (all dimensions in mm's)
Bearing Shell
Part Number
1160371
1160372
1160373
1160374
1160361
1160362
1160363
1160364
Shell Colour
White
Red
Red
Blue
Blue
Green
Crankcase Bore
41.126
41.118
41.126
41.118
41.135
41.127
41.135
41.127
41.144
41.136
41.144
41.136
Journal Dia'
37.976
37.969
37.968
37.960
37.976
37.969
37.968
37.960
37.976
37.969
37.968
37.960
Running
Clearance
All types
0.044- 0.020
NOTE:
1.
All dimensions in mm's Figures in italics are

bearing part numbers for later 1200 engines
(journals 1,3 and 5 only). All other engines use
standard bearings.
Measure the bearing to crankshaft main journal
clearance using plastigauge (Triumph part number
3880150). (Basic method described in connecting
rod clearance measurement).
If any journal has worn beyond the service limit, the

crankshaft must be replaced. Due to the techniques
used during manufacture, the crankshaft cannot be
reground and no oversize bearings are available.
Select bearings as follows:

1.
Measure and record the diameter of

crankshaft main bearing journal.
each
2.
Measure and record each main bearing bore

diameter in the crankcase (bearings removed).
Compare the data found with the chart above to select

bearings individually by journal.
For instance:
Crankshaft Journal diameter
Crankcase Bore
Bearing Required
37.972 mm
41.130 mm
RED
NOTE:
Checking crankpin clearance using plastigauge
CAUTION: Always confirm, using the

plastigauge method, that the running
clearance is correct before final assembly. Severe
engine damage could result from incorrect
clearance. Ensure all traces of plastigauge are
removed after use to prevent blockage of the oil
drillings and resultant engine damage.
Crankshaft main bearing/journal

clearance
Standard:
Service limit:
2.
0.020- 0.044 mm
0.08 mm max.
If the clearance exceeds the service limit, measure

the diameter of the crankshaft main journal.
Crankshaft End Float
Crankshaft main journal diameter

Standard:
Service limit:
It is normal for the bearings selected to differ

from one journal to another.
Standard
Service Limit
37.960 - 37.976 mm
37.936 mm
6.16
0.05 - 0.20 mm
0.4 mm maximum
PISTONS
Piston Wear Check

1.
Disassembly
Measure the piston outside diameter, 5 mm up from

the bottom of the piston and at goo to the direction of
the gudgeon pin.
NOTE:
The pistons and connecting rods can be

separated after removing the cylinder head and
liners. It is not necessary to remove the
connecting rods from the crankshaft.
1.
Remove the liner assembly from the crankcase.
2.
Remove the gudgeon pin circlip from one side of the

piston.
1. Piston Outside Diameter

2. Measurement Point (5mm Up The Piston Skirt)
3. Circlip Removal Groove
Piston outside diameter

Standard:
75.96 - 75.98 mm
Cylinder 2:
75.97- 75.96
Replace the piston if worn beyond the service limit.
Removing the Gudgeon Pin Circlip

3.
Remove the gudgeon pin by pushing the pin

through the piston and rod toward the side from
which the circlip was removed.
'!'
CAUTION: Never force the gudgeon pin

through the piston. This may cause
damage to the piston which may also damage the
liner when assembled.
NOTE:
If the gudgeon pin is found to be tight in the

piston, check the piston for a witness mark
caused by the circlip. Carefully remove the
mark to allow the pin to be removed.
4.
Piston rings must be removed from the piston using

hand pressure only.
6.17
Piston Rings/Ring Grooves
Piston Ring Gap
Check the pistons tor uneven groove wear by visually

inspecting the ring grooves.
NOTE:
If all the rings do not fit parallel to the groove upper and
lower surfaces, the piston must be replaced.
Fit the piston rings to the pistons. Check, using feeler
gauges, tor the correct clearance between the ring
grooves and the rings. Replace the piston and rings if
outside the specified limit.
Before final assembly the piston ring gap, when

fitted in the liner, must first be checked.
1.
Place the piston ring inside the liner.
2.
Push the ring into the top of the cylinder, using the
piston to hold the ring square with the inside of the
bore. Continue to push the ring into the bore until the
third groove of the piston is level with the cylinder
top, around full circumference of cylinder.
Piston Ring to Ring Groove Clearance Check

Aligning Piston Rings using the Piston
Piston ring/Groove Clearance

Top
Second
Standard
0.02 - 0.06 mm
0.02 - 0.06 mm
3.
Remove the piston and measure the gap between

the ends of the piston ring using feeler gauges.
Piston Ring End Gap Tolerances

Top
Second
Oil
4.
6.18
Service Limit
0.20-0.41 mm
0.35 - 0.56 mm
0.29 - 0.85 mm
If the ring gap is found to be too small, the ring end

must be carefully filed until the correct gap is
achieved. If the gap is too large, replace the rings
with a new set. If the gap remains too large with new
rings fitted, the piston and liner should be replaced
as a pair.
3.
Piston Assembly
1.
The piston ring gaps must be arranged as shown in

the diagram below.
Clean the piston ring grooves and fit the piston rings
to the piston.
FRONT
NOTE:
The top ring upper surface is marked 'N' and can

be identified by a chamfer on the inside edge.
The top ring has a chromed appearance.
The second ring upper surface is also marked

'N' but is plain on the inside edge and has a dull
grey appearance.
The oil control rings can be fitted with either

face upward.
3=
1. Top Ring
2. Second Ring
3. Steel Oil Control Rings
4. Oil Control Ring Expander
Second Ring
4.
Piston Ring Identification

2.
Fit the piston onto the connecting rod with the arrow
on the piston crown facing AWAY from the oil hole in
the connecting rod. Align the small end in the
connecting rod with the gudgeon pin hole in the
piston.
Lubricate the piston, small end and
gudgeon pin with clean engine oil and fit the
gudgeon pin. Fit new circlips on both sides of the
gudgeon pin ensuring the circlips are correctly fitted
in the grooves.
WARNING: Failure to use new gudgeon

pin circlips could allow the pin to detach
from the piston. This could seize the engine and
lead to an accident.
6.19
The top ring gap should be positioned in the 7

o'clock position, the second ring gap in the 1
o'clock position and the steel oil control ring
gaps in the 9 & 3 o'clock positions (one in each
position).
Fit the piston into the liner using a gentle rocking
motion to engage the rings in the bore.
CYLINDER WEAR
CYLINDER LINERS
Measure the inside diameter of each cylinder using a

internal micrometer or similar accurate measuring
equipment.
Removal
Cylinder inside diameter

Standard:
76.03- 76.05 mm
Service limit:
76.1 mm
1. Check the diameter at points 1, 2 and 3.
Cylinder liners can be removed with engine in

the frame, after the cylinder head has been
removed.
Number 2 cylinder liner is a selective fit. On

early engines it is identified by a green dot. On
later engines, number 2 liner is also identified
by a '8' marking to the upper mating face with
the cylinder head gasket. Markings other than
the '8' are for manufacturers reference.
NOTE:
Test Positions For Bore Wear Check (bore shown

in section)
2.
If any reading is outside the specified limits, replace
the liner and piston as an assembly.
Number 2 cylinder liner typical markings (later

engine)
6.20
1.
Mark each liner to identify correct orientation and

the cylinder number from which it has been
removed.
2.
Remove each liner, using hand force only, taking

care to ensure that the piston/connecting rod is not
allowed to fall against the inside of the crankcase.
3.
Installation
Fit each liner over the piston using a gentle rocking

motion to allow compression of the piston rings.
NOTE:
All engines use Blue Hylomar to seal the base of

the liners to the crankcase.
1.
Remove all traces of old sealing compound from the

liners and crankcase. Ensure that all sealing areas
are completely clean and dry.
2.
Apply a bead of Blue Hylomar, 3-4mm wide, to the

corner radius of the liner. The bead of sealer must
be applied to the full circumference of the liner.
Liner Fitted In Direction Of Arrow
CAUTION: Fit each liner over whichever

piston is at TDC. When turning the
engine, do not allow the pistons to contact the
inside of the crankcase and also do not allow fitted
liners to lift off the crankcase base. If any liners do
lift, the whole sealing and fitting process MUST be
repeated.
A coolant leak, causing overheating and engine
damage, could occur if liner seal is damaged
Arrowed: Hylomar Bead

4.
CAUTION: Allow each liner to stand for

15 minutes before fitting the liner to the
crankcase.
A coolant leak, causing overheating and engine
damage, could occur if the sealer is not allowed 15
minutes curing time prior to fitment.
NOTE:
The liners have a large chamfer at the bottom of

the bore enabling fitting without need for a
piston ring compressor.
6.21
Continue fitting each liner in turn until all are fitted

and sealed.
Left Hand Crankshaft Cover

Thunderbird, Thunderbird Sport,
Adventurer and all 4 Cylinder Engines
A.
~
The left hand crankshaft cover on all four cylinder

engines and on the Thunderbird, Thunderbird Sport and
Adventurer is fitted, on the inside face, with a lip type
seal. The lip seal prevents oil from entering the outlet
port for the crankcase gases.
CAUTION:
The engine must not be
started or turned over for a minimum of 15
minutes after assembly to allow the seal to fully
expand onto the breather shaft.
Failure to allow time for seal expansion will result
in high engine oil consumption, smoke emissions
and possible engine damage.
Seal/Cover Renewal
Under normal circumstances it should not be necessary
to disturb the cover or the seal. However, should the
cover require removal, the following procedure must be
used.
1.
Remove the cover and carefully lever the seal from

the cover.
NOTE:
A new seal is supplied with a mandrel already

fitted.
2.
Without removing the mandrel supplied with the

seal, press the new seal into the seal recess in the
cover to a point where it is just below the face of the
recess.
A.
CAUTION: The seal must be kept level

during and after fitment. A non-level seal
will cause high engine oil consumption, smoke
emissions and possible engine damage.
Thunderbird!Thunderbird Sport/Adventurer Left

Hand Engine Cover
3.
When refitting the cover, remove the mandrel only

at the point when the cover assembly is to be refitted
and ensure that the seal and breather shaft are
clean and dry.
4.
Fit the cover assembly taking great care not to

damage the seal during fitment and alignment of the
cover.
Cover Removal/Refit
1.
If the cover and seal are to be replaced without

renewing either component, a mandrel MUST be
inserted into the seal to prevent the seal from
distortion.
A.
NOTE:
The mandrel must remain in the seal from

immediately after removal to the point where
the cover is to be fitted.
2.
When refitting the cover, remove the mandrel only

at the point when the cover assembly is to be refitted
and ensure that the seal and breather shaft are
clean and dry.
3.
Fit the cover assembly taking great care not to

damage the seal during fitment and alignment of the
cover.
A.
CAUTION: If the seal is damaged or is

suspected of becoming damaged, it must
be replaced.
Failure to replace a damaged seal will result in high
engine oil consumption, smoke emissions and
possible engine damage.
CAUTION: If the seal is damaged or is
~ suspected of becoming damaged, it must

be replaced.
Failure to replace a damaged seal will result in high
engine oil consumption, smoke emissions and
possible engine damage.
6.22
A.
CAUTION:
The engine must not be
started or turned over for a minimum of 15
minutes after assembly to allow the seal to fully
expand onto the breather shaft.
Failure to allow time for seal expansion will result
in high engine oil consumption, smoke emissions
and possible engine damage.
Transmission
CONTENTS
Page
Exploded views...................................................
7.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6
Alternator spindle & Sprag Clutch

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. 7
7.8
Starter motor idler gear

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9
7.10
Selector drum
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.11
7.13
7.13
Input/output shaft assemblies

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.15
7.15
Input shaft assembly

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.16
7.17
Output shaft assembly

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly.....................................................
7.18
7.19
7.1
7 TRANSMISSION _ _ __
Exploded
Geartrain
v1ew
132 Nm
7.2
------~T~'RA;ANNSMISSION 7
Exploded View
Jary
AUXII
Gears
12 Nm
7.3
7 TRANSMISSION
Exploded
Selectors
v1ew
12 Nm
9 Nm
12Nm
12 Nm
7.4
TRANSMISSION 7
Exploded View
Gear Pedal and Mechanism
12 Nm
9Nm
!1~:!
___________ _j~~ I
I
Thunderbird/Adventu~--~
I
I
1
9Nm
.~.. ~
L
____________ _j
I
7.5
7 TRANSMISSION
AUXILIARY GEARS
1.
2.
3.
4.
5.
Starter Motor
Alternator
Starter Idler Gear
Sprag Clutch
Alternator Drive Gear
6.
7.
8.
9.
10.
Clutch Auxiliary Drive Gear

Oil Pump Auxiliary Gear
Oil Pump Intermediate Gear and Shaft
Oil Pump Drive Gear
Oil Pump
shaft. When the starter is energized, the sprag clutch

action allows the alternator shaft on which it is mounted
to be driven by the starter idler gear. The alternator shaft
transmits drive to the crankshaft via the alternator drive
gear and clutch auxiliary drive gear.
TRANSMISSION DESCRIPTION
All Triumph motorcycles are fitted with either a five or six
speed, constant mesh transmission. All gears are
straight cut and no synchromesh system is used.
Selection of gears is via a grooved drum which actuates
three selector forks within the transmission. The forks
remain in constant contact with the gear hubs at all times.
The final drive ratio, that is to say the ratio between the
transmission output sprocket and the rear wheel
sprocket, is variable. The change in ratio is brought
about by selection of front and rear sprockets with
different numbers of teeth.
An integral part of the transmission is the auxiliary gears
which drive the following:
Water pump
Oil pump
Alternator
Starter Motor
Engine Started
When the engine starts, and the starter button is
released, the crankshaft drives the clutch and alternator
drive gears causing the alternator shaft to rotate.
Because the alternator shaft and alternator are now
being driven, under engine power, by the alternator drive
gear (as opposed to being driven by the starter idler
gear), the sprag clutch free-wheels and the starter idler
gear does not turn.
Oil and Water Pump Drives

Drive to both the oil and water pumps is supplied by a
gear and shaft in mesh with the clutch auxiliary gear.
The oil pump auxiliary gear is connected to the oil pump
by a shaft, to which an intermediate gear is fitted. The
intermediate gear drives the oil pump drive gear thus
driving the oil pump. At the other side of the oil pump, a
slotted shaft extends, from which the water pump is
directly driven.
Auxiliary Gears - Operation

Engine Cranking
The starter motor, which is fitted in the upper crankcase,
drives an idler gear in constant mesh with the sprag
clutch. The sprag clutch is mounted on the alternator
7.6
TRANSMISSION 7
ALTERNATOR SPINDLE and SPRAG

CLUTCH
NOTE:
The sprag clutch is always replaced as an

assembly. No individual parts are available.
Later models are NOT fitted with a cover above

the alternator drive gears. On these later
models, the engine must be removed from the
frame and the crankcase halves separated to
gain access to the sprag clutch Refer to the
previous section for details of engine removal
and crankcase separation.
~
gacq
1. Alternator Drive Rubber Shock Absorbers

7.
Remove the alternator drive cover (if fitted) from the
top of the upper crankcase (separate the crankcase
halves if no cover is fitted).
Removal
NOTE:
If the engine has been removed and the

crankcase halves separated, proceed to item 4.
1.
Remove the seat and disconnect the battery,

2.
Remove the lower fairings (if fitted) and, on later

models also remove the water pump hose cover
(not Thunderbird, Thunderbird, Thunderbird Sport
or Adventurer).
3.
8.

skin to be scalded or burned. Prolonged or
repeated contact with engine oil can lead to skin
engine
oil
contains
potentially
harmful

Remove the three bolts securing the alternator to
the crankcase noting the position of the earth lead
under one of the alternator bolts.
5.
Remove the alternator.
6.
Remove the alternator rubber shock absorbers

from the alternator drive housing.
If the crankcases have not been separated, position

a suitable container beneath the clutch cover to
collect engine oil. Remove the clutch cover and
complete clutch assembly as described in the
clutch section.
Remove the body side panels, fuel tank,

carburettors and airbox. Disconnect the alternator
multi-plug.
4.
~~
9.
Prevent the alternator shaft from turning by fitting

service tool 3880040 to the upper alternator
mounting bolts
Service Tool 3880040
7.7
7 TRANSMISSION
10. Remove the bolt securing the alternator drive gear

(in the clutch housing) to the alternator spindle. If
the spindle is to be renewed, release the bolt
securing the alternator drive housing to the spindle.
CAUTION: Extreme care must be taken to

ensure no parts are allowed to fall into the
bottom of the crankcase. Parts which fall into the
crankcase could cause severe engine damage.
NOTE:
Installation
Later models are fitted with a nut and bolt

arrangement to secure the alternator drive gear
and housing. The bolt passes through the
length of the alternator spindle.
1.
Position the alternator spindle to the crankcase and

feed onto the spindle; the sprag clutch spacer,
sprag clutch and spindle sleeve.
11 . Remove the service tool 3880040 and withdraw the

alternator drive housing complete with spindle. If
required, remove the alternator drive housing from
the shaft.
12. Remove the alternator drive gear from within the
clutch housing.
13. Collect the sprag clutch assembly, sprag clutch
spacer (at the alternator side).
Fitting the alternator shaft

2.
Assemble the alternator drive gear (and alternator
drive housing if removed) to the spindle. Refit tool
3880040 and tighten the alternator drive gear and
alternator drive housing bolts to 35Nm (40 Nm if a
nut and bolt arrangement).
NOTE:
If both the alternator drive gear and alternator

drive housing bolts have been removed, tighten
the alternator drive gear bolt first then the
alternator drive housing bolt.
Later models, fitted with the nut and bolt

arrangement for securing the alternator drive
housing and gear should be tightened to 40 Nm.
3.
Remove tool 3880040 and refit the rubber shock

absorbers to the alternator drive housing.
1. Sprag Clutch
2. Spacer
13. Collect the splined spacer from the clutch side of the
crankcase.
1. Splined Spacer
7.8
TRANSMISSION 7
STARTER MOTOR IDLER GEAR

NOTE:
Later models are NOT fitted with a cover above

the alternator drive gears. On these later
models, the engine must be removed from the
frame and the crankcase halves separated to
gain access to the starter idler gear. Refer to
the previous section for details of engine
removal and crankcase separation.
Removal
NOTE:
1. Alternator Drive Rubber Shock Absorbers
4.
5.
Fit the alternator drive cover (if fitted) using a new

gasket. Tighten the bolts to 9Nm
Refit the alternator and ensure that the earth strap is
correctly located under the alternator bolt. Tighten
the alternator retaining bolts to 20Nm.

crankcase halves separated, proceed to item 6.
1.
Remove the seat, disconnect the battery, negative

(black) lead first and remove the body side panels.
2.
Remove the lower fairings from both sides (if fitted),

also remove the fuel tank, carburettors and airbox.
NOTE:

crankcase halves separated, assembly of the
crankcases can now begin.
6.
Refit the clutch and clutch cover as detailed in the

clutch section. Top up the engine with the correct
grade of engine oil.
7.
Reconnect the alternator multi-plug and refit the

carburettors, airbox and fuel tank.
8.
Refit all bodywork previously removed. Reconnect

the battery, positive (red ) lead first.
9.
Refit the seat.

3.
If the crankcases have not been separated, position

a suitable container beneath the clutch cover to
collect engine oil. Remove the clutch cover and
complete clutch assembly as described in the
clutch section.

skin to be scalded or burned. Prolonged or
repeated contact with engine oil can lead to skin
engine
oil
contains
potentially
harmful
7.9
7 TRANSMISSION
4.
Remove the alternator drive cover (if fitted) from the

top of the upper crankcase.
5.
Drain the coolant and remove the water pump hose

cover, water elbow and water pump hose from the
rear of the engine.
NOTE:
The sprag clutch assembly and shaft must also

be removed. Refer to the previous pages of this
section for details of sprag clutch removal.
6.
Remove the starter motor.
7.
Remove the capscrew and washer retaining the

idler spindle to the crankcase. The capscrew and
washer are located in the clutch housing.
1. Shaft
2. Gear
9.
Collect the starter idler gear from within the

alternator housing or from inside the crankcase (if a
late model).
Installation
1.
Install the new starter gear into the crankcase and fit
the spindle through the gear from inside the clutch
housing. Fit the spindle retaining bolt and washer
and tighten to 12Nm.
2.
Refit the sprag clutch and shaft as detailed earlier in

this section.
NOTE:
1. Starter Idler Gear

2. Sprag Clutch
8. Withdraw the idler gear spindle from inside the
clutch housing.
7.10

crankcase halves separated, engine assembly
can now begin.
3.
Refit the alternator drive cover (if fitted) using a new

gasket. Tighten the cover bolts to 9Nm.
4.
Refit the clutch assembly and clutch cover as

detailed in the clutch section.
TRANSMISSION 7
5.
Refit the starter motor and tighten the fixings to

10Nm.
SELECTOR DRUM
Removal
NOTE:
In order to gain access to the selector drum, the

engine must be removed from the frame and the
crankcase halves separated. For details of
these procedures, refer to the crankcase
section.
Once the crankcase halves are
separated, lift out both transmission shafts and
proceed as follows:
1.
Remove the capscrew and take out the 'U' shaped

keeper plate from the selector shaft.
1. Starter
2. '0' ring
6.
Top up the engine with the correct grade of engine

oil.
7.
Refit the water elbow using a new gasket. Refit the

water pump hose and water pump hose cover and
refill the cooling system to the correct level.
8.
Refit the carburettors, airbox, fuel tank and all body

panels previously removed. Reconnect the battery,
positive (red) lead first.
9.
Refit the seat.
1. Selector Shaft Keeper Plate
NOTE:
To ensure that the selector fork positions are

maintained on assembly, mark each fork with
felt pen or similar to denote their relative
positions.
2.
Using finger pressure, push the selector shaft out of

crankcase in the direction of the keeper plate.
Collect each selector fork from the lower crankcase
as they become released from the selector shaft.
Selector Forks
7.11
7 TRANSMISSION
3.
Remove the oil pump auxiliary gear and oil pump.

Refer to the lubrication section for details of oil
pump removal.
4.
Remove the nuts and washers securing both the

neutral and gear detent arms to the lower
crankcase.
9.
Remove the capscrew from the bearing lock (detent

end of the selector drum).
7
1.
2.
3.
4.
5.
6.
7.
1. Gear Detent Arm

2. Neutral Detent Arm
5.
Remove the detent arms and springs noting the

colour of the detent springs and the position of each
component.
NOTE:
Detent springs MUST NOT be interchanged. The

NEUTRAL spring has a white mark and is fitted
rearmost.
6.
Lock the selector drum in position and remove the

screw securing the detent wheel to the selector
drum. Remove the detent wheel.
7.
Remove the 2 screws securing the selector drum

stop plate to the crankcase. Remove the stop plate
from the selector drum.
8.
Remove the spring abutment bolt from the gear

quadrant. The bolt is situated on the outside of the
left hand side of the crankcase. Slide the quadrant
out of mesh.
Detent Wheel Bolt

Detent Wheel
Selector Drum Bearing
Selector Drum
Dowel
Bearing Lock
Capscrew
10. Remove the selector drum bearing by pushing

through from inside the crankcase to outside using
hand pressure only.
11. Collect the
crankcase.
selector
drum
from
inside
NOTE:
Earlier models are fitted with a circular gear

position indicator plate secured to the selector
drum by a circlip. Later models are fitted with a
'finger' type indicator which can be fitted in two
positions when engaged with the locating roll
pin in the selector drum. Position 1 is used for
all models except Thunderbird Sport. Position
2 is used for Thunderbird Sport only (see
illustrations).
2
1. Quadrant
2. Abutment Bolt
Selector Drum and Neutral Indicator 'Finger'
7.12
the
TRANSMISSION 7
Installation
1.
Locate the selector drum into the crankcase.

Lubricate the selector drum bearing with clean
engine oil.
2.
Support the drum and refit the selector drum

bearing. Retain with the bearing lock and capscrew.
Tighten the capscrew to 12Nm.
3.
Align the quadrant with the selector drum.
NOTE:
Align the centre gear tooth on the selector drum

between the centre gear teeth on the gear
quadrant.
Position 1 (All models except Thunderbird Sport)
1. Stop Plate
2. Quadrant Shaft
3. Return Spring
4.
Position 2 (Thunderbird Sport only)
Inspection
Examine all components for damage or wear paying
particular attention to selector drum and selector forks.
Replace any suspect parts.
Gear selector fork thickness:

Standard:
Service Limit:
5.9mm/5.8mm
5.7mm min
Gear selector groove width:

Standard:
Service Limit:
6.1 mm/6.0mm
6.25mm max
Selector fork to groove clearance:

0.55mm max
7.13
Refit the gearchange abutment bolt to the lower

crankcase. Tighten the bolt to 28Nm.
7 TRANSMISSION
5.
Push the gearchange down until the quadrant

contacts the abutment bolt (arrowed below). Check
that the gear teeth mesh as shown below. Rectify if
incorrect by removing and re-engaging the gear
quadrant.
10. Check that the detent arms correctly align when

neutral and all gears are selected. Also check that
there is no binding of the arms during operation.
Abutment
~bolt
Detent Position 1st. Gear

Correct Gear Position at Maximum Extension
6. Apply 'Loctite 242' to the stop plate fixings. Refit the
selector drum stop plate and tighten the fixings to
9Nm.
7.
Refit the detent wheel and tighten the centre bolt to

12Nm.
8.
Refit the detent springs to the studs. Ensure that the

springs are re-fitted in the same positions as noted
during removal.
NOTE:
Detent springs MUST NOT be interchanged. The

NEUTRAL spring has a white mark and is fitted
rearmost.
9.
Fit the detent arms, washers and nuts. Align the

springs to the arms and tighten the retaining nuts to
9Nm.
Detent Position Neutral

11. Refit the oil pump and oil pump drive gears by
reference to the lubrication section.
12. Position the selector forks to the selector drum, in
the order noted during removal.
NOTE:
13. Support the selectors and feed the selector shaft

through the crankcase and selectors. Fit the shaft
keeper and tighten the retaining bolt to 12Nm.
The neutral detent arm is angled in toward the

crankcase whereas the gearchange detent arm
is angled out toward the detent wheel.
7.14
TRANSMISSION 7
INPUT AND OUTPUT SHAFT ASSEMBLIES

Removal
The input and output shafts can be lifted out of the lower
crankcase after the crankcase halves have been
separated. For details of crankcase separation, refer to
the crankcase section.
Installation
Ensure the bearing sleeve dowels, oil seal and retaining
rings are correctly located when refitting both shafts.
NOTE:
Apply a small amount of 'Loctite 648' to the

bearing locations in the upper crankcase before
fitting the assembled transmission shafts.
1. Input Shaft Dowel (Drive sprocket side)

2. Crankcase Location
Ensure that all gears are correctly meshed.
1. Oil seal
2. Retaining Ring (Output Shaft Illustrated)
1. Output Shaft Dowel (Clutch Side)

2. Crankcase Location
NOTE:
7.15
It is recommended that the semi-circular input

shaft retaining ring (adjacent to the clutch) is
posjtioned to engage an equal amount in the
upper and lower crankcases.
7 TRANSMISSION
INPUT SHAFT
er0--
Disassembly
Remove the clutch assembly from the shaft (if not
already removed). Working from the opposite end to
where the clutch assembly is fitted, dismantle the input
shaft as follows:
1.
Remove the pegged bearing sleeve (1) from the

end of the shaft.
2.
Detach the circlip (2) from the circlip groove.
3.
Slide off the needle bearing (3) and thrust washer

(4).
4.
Remove second gear (5).
5.
Remove sixth gear (7), complete with the splined

bush (6) which runs inside the gear.
1'-,
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I........
On models fitted with a five speed gearbox, 6th

gear and the splined bush are replaced by a
sleeve.
6.
Remove the lipped thrust washer (8) from in front of

the circlip between sixth and third/fourth gear.
7.
Remove the circlip (9) from the shaft.
8.
Slide off the combined third/fourth gear (1 0).
9.
Remove the circlip (11) from in front of fifth gear.
10. Remove the lipped thrust washer (12) adjacent to

fifth gear.
11. Remove fifth gear (13).
-............._
12. Place the shaft in a press with the input shaft

bearing supported on press bars and the clutch end
of the shaft facing the press ram. Protect the shaft
thread with a thread protector or similar and press
the shaft through the bearing.
Never wear loose clothing which could become

trapped in the press and cause crushing injury to
the hand, arms or other parts of the anatomy.
7.16
Bearing Sleeve
Circlip
Needle Roller Bearing
Thrust Washer
Second Gear
Splined Bush
Sixth Gear
Thrust Washer
Circlip
Third/Fourth Gear
Circlip
Thrust Washer
Fifth Gear
Input Shaft
Input Shaft Bearing
4
5
@10'----Q __
8
9
10
11
12
13
I
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
WARNING: When using a press, always

wear overalls, eye, face and hand
protection. Objects such as bearings frequently
break-up under load and the debris caused during
break-up may cause damage and injury to
unprotected parts of the body.
0-
NOTE:
TRANSMISSION 7
4.
Fit a new circlip (11) to the input shaft ensuring that

the clip is correctly located in the circlip groove.
5.
Fit the combined third/fourth gear (1 0) with the

smaller gear facing toward fifth gear. Ensure that
the double oil hole in the mainshaft aligns with the oil
hole in the gear.
1. Pressing Off The Input Shaft Bearing
Assembly
NOTE:
1.
Lubricate each gear and bush with clean engine

oil during assembly.
Examine all gears, bearings and sleeves for
damage, chipped teeth and wear beyond the
service limits. Replace all suspect components
and always use new circlips to assemble the
shaft.
Place the input shaft bearing on press bars
ensuring the inner race of the bearing is supported
by the bars and the circlip groove is pointing
upwards. Position the mainshaft to the bearing
with the clutch end pointing downwards through
the bearing. Press the shaft through the bearing
until the bearing comes into contact with the fixed
gear on the shaft. OBSERVE THE WARNING
FOLLOWING PARAGRAPH 12 ON THE
PREVIOUS PAGE REGARDING THE DANGERS
OF USING A PRESS
1. Input Shaft Double Oil Hole

2. Third/Fourth Gear Oil Hole
6.
Fit a new circlip (9) to the input shaft ensuring that

the clip is correctly located in the circlip groove.
7.
Fit the thrust washer (8) to the input shaft and slide
up the shaft until in contact with the circlip.
8.
Fit the splined bush (6) from sixth gear ensuring that
the oil hole in the input shaft aligns with the oil hole in
the bush.
NOTE:
On models fitted with a five speed gearbox, 6th

gear and the splined bush are replaced by a
sleeve.
9.
Fit sixth gear (7) with the dog teeth facing

third/fourth gear.
10. Fit second gear (5) with the stepped side facing
away from the clutch end of the input shaft.
11. Fit the thrust washer (4) adjacent to second gear
and slide on the needle roller bearing (3). Retain all
with a new circlip (2).
12. Finally, fit the bearing sleeve (1) to the needle roller
bearing.
Pressing On the Input Shaft Bearing

2.
Fit fifth gear (13) to the input shaft with the dog teeth
pointing away from the input shaft bearing.
3.
Slide on the thrust washer (12).
7.17
7 TRANSMISSION
OUTPUT SHAFT
Working from the opposite end to the drive sprocket,
dismantle the output shaft as follows.
1---- 1
1
-m~m&
I
Disassembly
1.
Remove the output bearing sleeve (1 ), needle roller

bearing (2) and hardened thrust washer (3).
2.
Mark one side of first gear to denote its correct

orientation. Remove first gear (4) from the shaft.
3.
Slide fifth gear (5) from the shaft.
4.
Remove the circlip (6) from in front of the third gear.
5.
Remove the lipped thrust washer (7) from the shaft.
6.
Remove the third gear (8) together with the inner

splined bush (9).
7.
Slide fourth gear (10) off the shaft and also remove
the splined bush (11) and thrust washer (12).
8.
Remove the circlip (13) from in front of sixth gear.
9.
Remove sixth gear (14) from the shaft.
19---
20---B
21---~
25-----9
22------0
23--------~
24--~
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e~e?llg._-8
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@___11
18 --------10. Remove the circlip (15) from in front of second gear.

11. Remove thrust washer (16) and slide off second
gear (17).
12. Position the output shaft (18) in a vice with soft jaws
fitted. Tighten the vice to prevent the shaft from
turning and release the lock tab (20) from the output
sprocket nut (19), then release the nut.
13. Remove the transmission sprocket nut (19), locktab
(20), sprocket (21) and sleeve (25).
16
14. Collect the oil seal (22) and retaining ring (23).
15---------~
--------10
L.
e---5
--4
---2
e-1
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15. If it is found necessary to replace the large bearing

(24) at the end of the shaft, remove the outer race
and detach the inner section from the shaft by
splitting.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
WARNING: When removing the output

shaft bearing, always wear overalls, eye,
face and hand protection. The bearing races are
hardened and are liable to splinter if broken.
Debris from broken bearings could cause injury to
eyes, face and any unprotected parts of the body.
A.
CAUTION:
The bearing cannot be
removed intact. If the bearing is removed.
from the shaft, the complete bearing will be
damaged and must be renewed.
7.18
Bearing Sleeve
Needle Roller Bearing
Thrust Washer
First Gear
Fifth Gear
Circlip
Thrust Washer
Third Gear
Third Gear Bush
Fourth Gear
Fourth Gear Bush
Thrust Washer
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Circlip
Sixth Gear
Circlip
Thrust washer
Second Gear
Output Shaft
Nut
Locktab
Output Sprocket
Oil Seal
Retaining Ring
Bearing
Sleeve
TRANSMISSION 7
6.
Assembly
NOTE:
Lubricate each gear and bush with clean engine

oil during assembly.
Examine all gears, bearings and sleeves for
damage, chipped teeth and wear beyond the
service limits. Replace all suspect components
and always use new circlips to assemble the
shaft
1.
Working from the output sprocket end of the shaft, fit

a new bearing (24) to the shaft using a press and
press bars.
Fit sixth gear (14) with the selector fork groove

facing away from the output sprocket end. Ensure
that the oil hole in the gear aligns with the double oil
hole in the output shaft.
1. Double Oil Hole

2. Gear Oil Hole
1'.
CAUTION: Incorrect alignment of the oil

holes will result in severe damage to the
gears and gear selectors.
7.
Fit a new circlip (13) to retain sixth gear.
8.
Fit the thrust washer (12) to the rear of fourth gear

and fit the splined sleeve (11) for fourth gear.
Ensure correct alignment of the oil hole in the shaft
with the oil hole in the sleeve. Fit fourth gear (1 0) to
the shaft with the large step side facing away from
the output sprocket.
9.
2.
Fit the retaining ring (23) to the shaft. Lubricate and

fit a new oil seal (22) and fit the sprocket sleeve (25).
3.
Transfer the shaft to the vice and secure between

soft jaws. Fit the sprocket (21), locktab (20) and nut
(19). Tighten the nut to 132Nm.
Fit the splined bush (9) for third gear taking care to
align the oil hole in the shaft with the corresponding
hole in the bush. Fit third gear (8) with the larger
step side facing the output sprocket.
4.
Withdraw the shaft from the vice and continue to

assemble from the opposite end to the output
sprocket.
10. Fit the thrust washer (7) and retain with a new circlip
(6).
5.
Locate the second gear (17) to the shaft with the

large step side facing away from the output
sprocket end. Fit the thrust washer (16) and retain
with a new circlip (15).
11.
Fit the fifth gear (5) to the shaft with the circular dog
teeth facing away from the output sprocket.
12. Fit first gear (4) to the shaft as marked during

disassembly.
13. Finally fit the thrust washer (3), needle roller bearing
(2) and bearing cap (1) to the end of the shaft.
7.19
Lubrication
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2
Oil Circuit
3 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4
8.6
Oil cooler
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8
8.8
Sump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9
8.9
Oil feed pipe

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9
8.10
Oil pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 0
8.11
8.11
Oil pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12
Oil pressure switch

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12
8.1
8 LUBRICATION
~ 9 Nm (Where fitted)
8.2
LUBRICATION 8
w--12Nm
~ ~12Nm
15Nm
20Nm\0
b9
12 Nm
r12Nm
I-
12Nm
9"'36Nm
48 Nm (M22) or
28 Nm (M14)
'
!1--18Nm
8.3
8 LUBRICATION
3 Cylinder Oil Circuit
:::111
8.4
LUBRICATION 8
3 CYLINDER OIL CIRCUIT DESCRIPTION
Oil is collected from the sump and is drawn through a mesh strainer into the oil pump rotor. Pressurised oil is then
delivered to the outside of the oil filter where the low oil pressure warning light switch and the oil pressure relief valve are
fitted. The relief valve is set to open at 70 lb/in 2 and when open, returns high pressure oil direct to the sump. The oil
pump is fitted with a single pumping rotor and can be easily identified as a 3 cylinder oil pump by the marking '3' on the
pump outlet to the upper crankcase.
Filtered oil is drawn from the centre of the oil filter along the oil filter retaining bolt. Part of this filtered oil is supplied,
through a non-pumping passage in the oil pump, to a horizontal gallery at the rear of the upper crankcase. Once
received in the upper crankcase gallery, the oil is delivered to the crankshaft main bearings and, via drillings in the
crankshaft, to the big end bearings. Oil exits from the big ends through holes in the connecting rods and then splash
lubricates the bores and pistons.
The remainder of the filtered oil is passed through an oil cooler (where fitted) and is supplied to drillings in the lower
crankcase by internal, detachable pipes. These lower crankcase drillings deliver oil directly to the end of each gearbox
shaft. Oil is circulated along the inside of the gearbox shafts to exit holes which feed directly onto the selectors, bearings
and gears. When the oil cooler is not fitted, a small external link pipe is fitted to complete the circuit.
The same upper crankcase gallery which feeds the crankshaft also feeds the cylinder head and camshafts through an
external link pipe. The pipe, located at the rear of the engine, links a drilling in the head to the oil gallery in the upper
crankcase. This head drilling supplies oil to the front camshaft bearings which, in turn, deliver oil through the hollow
camshafts to the camshaft bearings, tappet buckets and valves.
Early models were fitted with an internal oil pipe which fed the auxiliary gear train. This internal pipe was deleted as was
an external feed to the engine balancer. Both were found to be unnecessary as splash feed only is required for these
items.
8.5
8 LUBRICATION
4 Cylinder Oil Circuit
J!t
----,I
I\--
rl=
-1.
~
rl
IL
8.6
f-----;
~~~-of
6)tt=
LUBRICATION 8
4 CYLINDER OIL CIRCUIT DESCRIPTION.
A twin rotor pump is fitted to 4 cylinder engines. The pump can be identified by the marking '4' on the outlet to the upper
crankcase. The right hand rotor (in the drawing) collects hot oil from the sump area beneath the balancers.
The collected oil is then pumped through the oil cooler and returned to the sump at a lower temperature. The right hand
rotor does not contribute to the main gallery oil pressure and is used solely to circulate oil through the cooler.
The main oil supply is collected from the deepest part of the sump and is drawn through a mesh strainer into the left hand
oil pump rotor. Pressurised oil is then delivered to the outside of the oil filter where the low oil pressure warning light
switch and the oil pressure relief valve are fitted. The relief valve is set to open at 70 lb/in 2 and when open, returns high
pressure oil direct to the sump.
Filtered oil is drawn from the centre of the oil filter along the oil filter retaining bolt. This filtered oil is supplied, through a
non-pumping passage in the oil pump, to a horizontal gallery at the rear of the upper crankcase.
Once received in the upper crankcase, the oil is delivered to the crankshaft main bearings and, via drillings in the
crankshaft, to the big end bearings. Oil exits from the big ends through holes in the connecting rods and then splash
lubricates the bores and pistons.
The non-pumping gallery also directs oil into a detachable internal oil pipe which feeds the transmission and engine
balancers through drillings in the lower crankcase. Oil is circulated along the inside of the gearbox shafts to exit holes
which feed directly onto the selectors, bearings and gears. Drillings within the balancer shafts direct oil to the balancer
bearings.
The same upper crankcase gallery which feeds the crankshaft also feeds the cylinder head and camshafts through an
external link pipe. The pipe, located at the rear of the engine, links a drilling in the head to the oil gallery in the upper
crankcase. This head drilling supplies oil to the front camshaft bearings which, in turn, deliver oil through the hollow
camshafts to the camshaft bearings, tappet buckets and valves.
Early models were fitted with an internal oil pipe which fed the auxiliary gear train. This internal pipe was deleted as
splash feed only is required.
8.7
8 LUBRICATION
5.
OIL COOLER
Release the three bolts securing the oil cooler to the

cooler sub-frame.
Removal
1.
Remove both lower fairings from the frame.
2.
Place a suitable container beneath the engine and

drain the engine oil.

WARNING:
engine
oil
contains
potentially
harmful
'!'
~
1. Oil Cooler Bolts

3. Oil Cooler Subframe
2. Oil Cooler
6.
Remove the oil cooler complete with oil pipes.
7.
Detach the oil pipes from the cooler having first

marked the relative position of the pipes to the
cooler to aid correct assembly.
1,\

support the oil cooler during release or tightening
of the unions.

Installation
1. Banjo Bolt
2. Oil Cooler Feed Pipe
3. Return Pipe Union
4.
On 4 cylinder engines, hold the oil cooler union to

prevent turning and release the oil cooler return
pipe from the adaptor on the sump. On 3 cylinder
engines, release the second banjo bolt.
1.
Assemble the oil pipes to the oil cooler as marked

during removal. Tighten the cooler to cooler pipe
unions to 25 Nm. Position the oil cooler and secure
to the subframe. Tighten the retaining bolts to 9 Nm.
2.
On 4 cylinder engines, connect the oil cooler return

pipe to the sump union. Hold the union and tighten
the connection to 25 Nm.
On 3 cylinder engines, fit the banjo bolt using new
washers. Tighten to 25 Nm.
3.
Fit new washers to the banjo bolt and connect the

feed pipe to the sump. Tighten to 25 Nm.
4.
Refit the lower fairings.
1,\

support the oil cooler during release/tightening of
the unions.
'!'
CAUTION: Always support the oil cooler

union to prevent damage to the sump
and/or union during release of the cooler pipe. If
the union is not supported, an oil leak could be
created which could damage the engine.
5.
8.8
Fill the engine with the correct grade of engine oil,

start the engine and check for oil leaks. Stop the
engine and adjust the oil level as necessary.
LUBRICATION 8
SUMP
Installation
Removal
On all models, the sump can be removed from the engine
whilst still fitted in the frame. On all models, the exhaust
system must be removed and on Tigers, the sump guard
must also be removed.

1.
Fit new '0' rings to all joints which have been

disturbed during removal.
2.
Fit a new sump gasket.
3.
Position the sump.
4.
On 3 cylinder engines, apply a smear of grease to all

oil pipe '0' rings and locate the pipes to the sump.
5.
Secure the sump with the perimeter and central

fasteners, tightening to 12 Nm.
6.
Replace the oil filter element and refit the filter using
a new '0' ring. Tighten the filter bolt to 18 Nm. Refill
the engine with correct specification oil.
--------~~~-
WARNING:
engine
oil
contains
potentially
harmful
1.
NOTE:
Drain the engine oil and remove the oil filter.

Disconnect the oil switch connection. Progressively
release the central fasteners securing the sump to
the lower crankcase then release the perimeter
fasteners.
The two screws securing the exhaust bracket

(where fitted) should be cleaned and Loctite 242
applied to the threads.
7.
Start the engine and allow to run for a short period at

idle speed. Ensure that the oil pressure warning
light extinguishes after starting. Stop the engine
and check for oil leaks. Check the oil level and
adjust to the correct level.
OIL PIPE
Removal
1.
Release the banjo bolts and washers securing the

oil feed pipe to the lower crankcase.
2.
Carefully withdraw the oil pipe fitting from

crankcase taking care not to damage the joint face
or distort the oil pipe.
3
2
1. Central Sump Fasteners

2. Perimeter Fasteners
3. Sump
2.
On 4 cylinder engines the sump can now be

removed. On 3 cylinder engines, oil pipes are
internally fitted between the sump and lower
crankcase. These pipes are secured by '0' rings.
To detach the oil pipes, support the sump and insert
a lever to separate the pipes from the sump.
3.
Remove and discard the sump gasket.
4.
Remove and discard the '0' ring seal between

sump and lower crankcase and all internal oil pipe
'0' rings.
1.
2.
3.
4.
8.9
'0' Ring
Banjo Bolts
Oil Feed Pipe (4 Cyl Illustrated)
'0' Ring Location.
8 LUBRICATION
Installation
OIL PUMP AND GEARS
1.
Replace all '0' rings
2.
Apply a smear of grease to the '0' rings and

carefully position the oil pipe.
Removal
3.
Replace all banjo bolt washers and fit the banjo

bolts.
4.
Tighten the banjo bolts to 8 Nm.
NOTE: On 4 cylinder engines the banjo bolts

have different size holes.
NOTE:
The oil pump is located in the lower crankcase.

Access can only be gained by removing the
engine from the frame and separating the
crankcase halves.
For details of engine
removal and crankcase separation, refer to the
crankcase section.
5
1.
2.
3.
4.
5.
6.
7.
Auxiliary Gear Screw

Washer
Auxiliary Gear
Intermediate Gear And Shaft
Circlip
Thrust Washer
Oil Pump Gear
1.
Remove the gearbox shafts from the crankcase.
2.
Remove the gear selector shaft and forks as

described in the transmission section.
3.
Remove the screw from the centre of the oil pump

auxiliary gear.
1. Oil Pump Auxiliary Gear

2. Oil Pump Gear Circlip
8.10
LUBRICATION 8
4.
Release the screws securing the water pump to the

crankcase and remove the pump.
5.
Release the screws securing the oil pump to the

lower crankcase. Align the drive slot to a vertical
position and remove the pump.
1
-=:=:,
-c..
u
lI
M\ I~
1. Rotor Tip Clearance

2. Pump Body Clearance
1. Oil Pump Retaining Screws
6.
Remove the circlip and thrust washer securing the

oil pump gear and shaft, then remove the gear and
shaft from the inside of the crankcase.
7.
Remove oil pump auxiliary gear, intermediate gear

and shaft by sliding the gear shaft inwards and
collecting the outer gear from inside the clutch
housing.
Oil Pump Inspection

Remove the oil pump end covers.
2.
Measure the rotor tip clearance using feeler

gauges.
3.
Installation
1.
Fill the pump with new engine oil.
0.15mm
0.20mm max.
Clean the screw threads of the oil pump and

auxiliary gear fixings and apply Loctite
'Nutlock' Grade 242 to the threads prior to
fitment.
2.
Assemble the oil pump auxiliary gear, intermediate

gear and shaft to the crankcase and tighten the
retaining screw to 9Nm.
3.
Fit the oil pump drive gear to the crankcase. Fit the
thrust washer (clutch housing side) and retain the
gear and thrust washer with a new circlip.
4.
Refit the oil pump ensuring that the dowels are

correctly positioned and that the drive slot is
correctly aligned with the gear. Tighten the retaining
screws to 12Nm.
5.
Refit the water pump using a new '0' ring and

tighten the fixings to 12 Nm.
6.
Apply 'Loctite' 648 to the gearbox bearing outer

tracks and refit to the crankcase. Fit the selector
shaft and forks.
Measure the pump body clearance using feeler

gauges.
Standard:
Service Limit:
0.22- 0.15mm
0.35mm max.
NOTE:
CAUTION: If any part of the oil pump is

found to be outside the service limit, the
complete pump must be renewed. Severe engine
damage may result from the continued use of a
faulty oil pump.
NOTE:
1.
Standard:
Service Limit:
1,\
4 cylinder engines have 2 sets of rotors,

3 cylinder engines have 1 set of rotors.
8.11
8 LUBRICATION
OIL PRESSURE TEST
LOW OIL PRESSURE WARNING LIGHT

SWITCH
NOTE:
Measure the oil pressure when the engine has

reached normal operating temperature.
1.
Attach an oil pressure gauge and adapter 3880095

to the main oil gallery. If correct, the oil pressure
should be 40 lb/in 2 at 5000 r.p.m with the oil
temperature at 80C.
Oil pressure:
40 lb/in2 (2.8 Kg/cm2)
temperature).
The oil pressure switch is located in the back of the sump

on the right hand side of the motorcycle.
NOTE
Inspection
@
5000 r.p.m,
80C (oil
1.
NOTE
Later models have the low oil pressure warning

light switch fitted at the lower end of the
camshaft oil feed pipe.
If the oil pressure falls outside the specified

range, check the oil pump, oil pressure relief
valve and crankshaft bearings for damage or
wear.
If the oil pressure warning light illuminates at idle,

renew the oil warning light switch. If the light
continues to illuminate, carry out an oil pressure
check.
1. Oil Warning Light Switch Connection

2.
8.12
Apply Loctite 242 to seal the pressure switch

threads.
Fuel System/Exhaust
CONTENTS
Page
Exploded view....................................................
9.2
System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Requirement- Not USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Requirement- USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.9
9.9
9.9
Exhaust
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10
9.10
Fuel Tank
Trophy, Trident, Sprint, Daytona Super 3, Speed Triple and Daytona .
Tiger.........................................................
Thunderbird, Thunderbird Sport & Adventurer . . . . . . . . . . . . . . . . . . . . .
9.11
9.12
9.13
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14
Choke............................................................
9.15
Air lntake/Carburettor- All Except Thunderbird, Thunderbird Sport &

Adventurer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.16
9.17
Air lntake/Carburettor- Thunderbird, Thunderbird Sport & Adventurer

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.18
9.18
Carburettor Overhaul - Mikuni Carburettors

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.20
9.20
9.21
Carburettor Overhaul - Keihin Carburettors

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly.....................................................
9.22
9.22
9.23
Fuel System Cleanliness Inspection................................
9.24
Fuel level measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.25
Fuel level adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.26
Carburettor Setting
Mixture Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Synchronisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .
9.27
9.28
Evaporative Loss System- US California Models

System Layout/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.30
9.1
9 FUEL SYSTEM/EXHAUST
Fuel Tank- All models except Thunderbird, Thunderbird Sport, Adventurer & Tiger
3 Nm
Hand Tight
30 Nm
C>
@
L-12Nm
10Nm~
9.2
FUEL SYSTEM/EXHAUST 9
Thunderbird, Thunderbird Sport & Adventurer Fuel Tank
12 Nm
'~
I
I
9Nm~
~
I
I
9 Nm
9Nm
9.3
'
Tiger Fuel tank
3Nm---g
e:2\
Hand
Tight~~
~
y9Nm
'8
~
Q
Q
7Nm
9.4
Late 3 Cylinder Headers

(not Thunderbird or Adventurer)
Refer To Text
22Nm
Tiger
7Nm
~22Nm
14Nm
3 Cylinder Chrome Silencers
Js;
~Q)
~14Nm
~~-14Nm
4 Cylinder
Chrome Silencers
,.&~ ~22Nm
22Nm~
14Nm
15Nm
@Q)CD
,~vi~
(~~
I~
14Nm
22Nm
Early 3 Cylinder Headers
/14Nm
15Nm
4 Cylinder Headers
22Nm
7Nm
9.5
Daytona & Speed Triple Silencers

15Nm
\E)>
Thunderbird Headers & Silencers
'22 Nm
1f
22 Nm
~
/
>
/
/
/
/
<
<
Q\
'
7 Nm
9.6
Adventurer Exhaust System
27 Nm
27 Nm
J__~
14Nm
l}~~
r
"0
.. l
22Nm
I
I
I
_)
~o
\._\~
\
9.7
Thunderbird Sport Exhaust System
27 Nm
Refer to text
,I
~
22 Nm
C(a'--......7Nm
,//,//
22 Nm----'
9.8
7 Nm
FUEL SYSTEM DESCRIPTION
Oxygenated Gasoline
To help in meeting clean air standards, some areas of the
U.S. use oxygenated gasoline to help reduce harmful
emissions. These gasolines are a blend of conventional
gasoline and another compound such as alcohol.
Triumph motorcycles will give best performance when
using unleaded gasoline. However, the following should
be used as a guide to the use of oxygenated fuels.
All models are fitted with variable choke carburettors

each of which supply fuel to an individual engine cylinder.
Changes in the fuel requirements of each model are
achieved by fitting jets of different sizes to the
carburettors. These changes in jet sizes increase or
decrease the amount of air/fuel mixture delivered. A
manual cold start device is fitted, controlled by a
handlebar mounted lever connected to the carburettors
by a cable.
lf
CAUTION:
Because of the generally
higher volatility of oxygenated fuels,
starting, engine response and fuel consumption
may be adversely affected by their use. Should
any of these difficulties be experienced, run the
motorcycle on normal unleaded gasoline.
A fuel tap is fitted in the base of the fuel tank which, on

Tiger, Adventurer Thunderbird and Thunderbird Sport
models only, is a gravity fed tap. All other models are
fitted with a vacuum operated tap which is connected by
means of a vacuum hose, to one of the carburettors.
Ethanol
WARNING:
On Tiger, Adventurer,
~ Thunderbird Sport and Thunderbird
models, which are fitted with a manual fuel tap,
always turn the fuel tap to the OFF position when
the engine is switched off. Failure to turn the fuel
tap to the OFF position may lead to a fuel spillage
which could start a fire causing personal injury
and damage to property.
Ethanol fuel is a mixture of 10% ethanol and 90%

gasoline and is often described under the names
'gasohol', ethanol enhanced', or 'contains ethanol'. This
fuel may be used in Triumph motorcycles.
MTBE (Methyl Tertiary Butyl Ether)

The use of gasolines containing up to 15% MTBE
(Methyl Tertiary Butyl Ether) is permitted in Triumph
motorcycles.
Fuel Requirements (outside USA)

Outside America, all motorcycles are designed to be run
on 95 RON unleaded fuel. Some models are fitted with
catalytic converters, where these are fitted, unleaded
fuel only may be used.
Methanol
lf
CAUTION: Fuels containing methanol

should not be used in Triumph
motorcycles as damage to components in the fuel
system can be caused by contact with methanol.
Fuel Requirements (USA)

In America where the octane rating of fuel is measured in
a different way, the following information may be applied:
Exhaust System
Triumph motorcycles are designed to run on unleaded

gasoline with a CLC or AKI octane rating (R+M)/2 of 89 or
higher.
Federal regulations require that pumps
delivering unleaded gasoline are marked 'UNLEADED'
and that the Cost of Living Council (CLC) or Anti-Knock
Index (AKI) octane rating is also displayed. These
ratings are an average of the Research Octane Number
(RON) and the Motor Octane Number (MON).
Various configurations of exhaust system are used

depending on model and model year.
U.S. California, Swiss and German Models Exhaust System

Some models made for the German, Swiss and
California markets have catalytic convertors fitted to the
header system. For information on which models are
fitted with catalytic convertors, always refer to the latest
edition of the parts catalogue.
lf
CAUTION: The use of leaded gasoline is

illegal in some countries, states or
territories. Check local regulations before using
leaded gasoline.
9.9
EXHAUST SYSTEM
Installation
1. Reverse the removal procedure ensuring new
gaskets are fitted to cylinder head.

been running, the exhaust system will be
NOTE:
Tighten the exhaust clamps to the cylinder head

in 2 stages:
Stage 1. Tighten to 8 Nm.
Stage 2. Tighten to 20 Nm.
Refit complete system loosely before final

tightening of the clamps and joints.
Align all components before final tightening of

the fixings.
Evenly tighten all fasteners to avoid placing

undue stress on the system.
Examine the centre stand stop (where fitted) for

damage and deterioration.
Replace if
necessary.
'-----------------------------'
NOTE:
Early Trophy, Daytona and Trident models were

fitted with a mounting bracket which was
welded to the silencer. Later models are fitted
with a 'bolt-on' bracket which can be replaced
independently of the silencer.
Removal
1.
Remove the lower fairing from both sides of the

machine. On Tiger only, remove the body side
panels.
2.
Release the silencer clamps at the joints with the

downpipes.
3.
Remove the bolt, flanged sleeve and rubber bush

securing each silencer to the frame/rear footrest
bracket. On Thunderbird, Thunderbird Sport &
Adventurer, release the rear footrest mounting
which secures the silencer to the footrest hanger.
4.
Remove the exhaust silencers.
5.
Remove the oil cooler and oil cooler sub-frame

(where fitted) as described in the lubrication
section.
6.
Release and remove the support clamp bolt (where

fitted) at the rear of the engine.
7.
On 4 cylinder engines, release the balance pipe

clamp. Release the nuts securing the exhaust
downpipes to the cylinder head. Remove the
downpipes as an assembly on 3 cylinder and
separate at the balance pipe and remove as pairs
on 4 cylinder.
8.
Remove the downpipes.
9.
Collect the downpipe gaskets from the cylinder

head.
9.10
FUEL TANK
6.
Removal: Trophy, Trident, Sprint, Daytona

Super 3, Speed Triple & Daytona.
Installation:
WARNING:
To prevent fuel spillage,
ensure that the fuel tap is in the 'ON'
position when disconnecting the fuel lines. A
serious fire causing personal injury could result
from spilled fuel.
1.
2.

fire, causing personal injury and damage to
property, could result from spilled fuel or fuel not
NOTE: Before removing any fuel or vacuum

pipes, make a note of their relative positions on
the fuel tap and tank in order to prevent
incorrect assembly.
1.
Remove the seat. Disconnect the battery, negative

(black) lead first. Remove the battery.
2.
Remove the body side panels.
3.
Remove the two outer tank bracket bolts from each

side.
4.
Carefully raise and support the rear of the tank and

disconnect the low fuel level sensor wires.
5.
While supporting the tank, release the hose clips

(where fitted) and disconnect the following:
fuel tank drain pipe,
fuel pipes from the fuel tap,
vacuum pipe from the fuel tap.
connection to roll-over valve (California models
only)
Support the front and rear of tank, slide the tank

rearwards taking care not to damage the painted
surfaces, and lift clear.
Ensure that the front fuel tank mounting bushes

are correctly positioned.
Support the front and rear of the fuel tank and slide
forward into position taking care not to damage any
painted surfaces.
Positioning The Fuel Tank For Installation
3.
Carefully raise the rear of the tank and support the

tank beneath the fuel tank bracket.
4.
Connect the following pipes and tighten the clips

(where fitted)
vacuum pipe to the fuel tap,
fuel pipes to the fuel tap,
fuel tank drain pipe,
connection to roll-over valve (California models
only.
5.
Connect the fuel pipes to the fuel tap. Tighten the

hose clips.
6.
Connect the drain pipe and hose clip and position

the pipe in the right-hand centre stand spring.
NOTE:
1.
2.
3.
4.
5.
Fuel Tank Bracket

Fuel Level Sensor Connector
Drain Pipe
Fuel Pipes
Vacuum Pipe
Some models are not fitted with a centre stand,

the drain pipe is routed along side the rear
suspension unit.
7.
Connect the low fuel level sensor wires.
8.
Remove the support from beneath the fuel tank

bridge and align the tank to the mounting brackets.
Secure the tank in position using the 4 mounting
bolts.
9.
Tighten the mounting bolts to 12 Nm.
10. Refit and reconnect the battery, positive (red) lead

first. Refit the seat.
9.11
FUEL TANK
5.
Carefully raise the tank and disconnect the low fuel

level sensor wires.
6.
Release the hose clip from both the fuel pipe and
the tank breather pipe. Disconnect both pipes.
Removal:
Tiger
WARNING:
ensure that the fuel tap is in the 'OFF'
position when disconnecting the fuel lines. A fire,
causing personal injury and damage to property
could result from spilled fuel.

WARNING: Tiger motorcycles are fitted
~ with a fuel tank made from an impact
1. Tiger Fuel Tap
resistant plastic material. Never allow any hot

objects or hot surfaces to contact the fuel tank. In
the event of the tank incurring damage from hot
objects or surfaces, the tank must be replaced.
Any such contact damage may prejudice the fuel
integrity of the tank both in normal operation or in
an accident. If in doubt, have the fuel tank
inspected by an authorised Triumph dealer.
7.
Gently raise the fuel tank and slide rearwards to

remove, taking care not to damage any painted
surface.
Installation
1.
Slide the fuel tank into position, taking care not to

damage any painted surface.
2.

Support the tank and reconnect the low fuel warning

light sensor, fuel tank breather pipe and fuel pipe.
Tighten the hose clips.
3.
Refit and tighten the fuel tank fixings to 9Nm.
2.
Remove the cockpit to fuel tank fixings.
4.
Refit the airbox covers.
3.
Remove the airbox covers by releasing the self

tapping screws from the front edge of the cover.
5.
Refit and tighten the cockpit to fuel tank fixings to

7Nm.
4.
Remove the front and rear fuel tank bracket fixings.
6.
Refit and reconnect the battery, positive (red) lead

first. Refit the seat.
1.
NOTE: Before removing any fuel pipes, make a

note of their relative positions on the fuel tap
and tank in order to prevent incorrect assembly.
t:.l
1. Rear Fuel Tank Fixings

2. Front Fuel Tank Fixing
9.12
FUEL TANK
4.
Removal:
Remove the tank bracket fixings from the rear of the

tank.

Adventurer
WARNING:
. . . ensure that the fuel tap is in the 'OFF'
position when disconnecting the fuel lines. A fire,
causing personal injury and damage to property
could result from spilled fuel.

1. Fuel Tank Fixings
NOTE: Before removing any fuel pipes, make a

note of their relative positions on the fuel tap
and tank in order to prevent incorrect assembly.
1.
Remove the seat.
2.
Disconnect the battery, negative (-) lead first.
3.
Ensure fuel tap is in the 'OFF' position.
5.
Disconnect the fuel pipe from the fuel tap.
6.
Disconnect the fuel tank breather pipe.
7.
Ensure that the tank cap is securely fitted. Gently

raise the rear of the fuel tank and slide rearwards in
an upwards arc to remove.
Installation
1. Fuel Tap
9.13
1.
Slide the fuel tank into position, taking care not to

damage any painted surface.
2.
Support the tank and reconnect the fuel tank

breather pipe and fuel pipe. Tighten the hose clips.
3.
Refit and tighten the fuel tank fixings to 9Nm.
4.
Refit and tighten the fuel tank bracket fixings to

9Nm.
5.
Reconnect the battery, positive (red) lead first. Refit

the seat.
THROTTLE GRIP
2.
Turn the knurled adjuster (2) until the correct

amount of free-play at the throttle grip is achieved.
If the throttle grip has excessive free-play, it will cause a

delay in throttle response, especially at low engine
speed. Also, the throttle valves may not open fully at full
throttle causing a significant reduction in the top speed of
the machine. Alternatively, if the throttle grip has no
free-play, the throttle will be hard to control, and idle
speed will be erratic. Check the throttle grip free-play
periodically in accordance with the Periodic
Maintenance Chart, and adjust if necessary.
3.
Tighten the locknut against the knurled adjuster to

secure the adjustment.
4.
If the throttle cable cannot be correctly adjusted by

using the cable adjuster at upper end of throttle
cable, additional adjustments must be made at the
carburettor end of the cable.
Inspection
It is necessary to remove the carburettors

before adjustments can be made to the lower
end of the throttle cable.
5.
At the throttle grip end of the cable, loosen the

locknut on the throttle grip and back-off the knurled
adjuster. Tighten the adjuster locknut.
6.
Remove the retaining clip for the adjuster nut

(where fitted). Loosen the locknut at the carburettor
end and adjust the outer cable until 2-3mm of free
play is found at the throttle grip.
1.
Check that there is 2-3 mm (0.08-0.12 in.) of

free-play in the throttle grip when lightly turning the
throttle grip back and forth.
NOTE:
/;
1. Throttle Grip
2. 2-3 Mm Free Play
2.
!f#4

adjustments as follows.
Adjustment
1.
Loosen the locknut (1) at the front of the throttle grip.
1. Adjusting Nut
2. Locknut
7.
3. Throttle Cable
4. Clip (where fitted)
Tighten the locknut and refit the adjuster clip (where

fitted) and the carburettors.


and an accident.
1. Locknut
2. Knurled Adjuster
3. Throttle Cable
9.14
CHOKE LEVER
The motorcycle is fitted with a cold start or choke device.
The cable, which controls the cold start device, may
occasionally require adjustment and should be checked
for correct operation and adjustment in accordance with
the Periodic Maintenance chart.
Inspection
1.
Check that the choke lever returns fully and that the
inner cable slides smoothly through the outer cable.
If the choke cable does not slide smoothly or sticks,
the inner cable may have become frayed and
should be removed and inspected. Replace the
cable as necessary.
1. Starter plunger lever

2. Starter plunger
Adjustment
,-~~~~~~-~---~~~----------,
NOTE:

2.
To gain access to the choke cable adjuster, the

fuel tank must first be removed.
1.
Loosen the locknut at the middle of choke cable.
2.
Turn the cable adjusting nut until the cable has

correct amount of free-play using the measurement
method previously described.
3.
Tighten the locknut after correct adjustment has

been made.
Push the choke lever all the way to its fully released
position (away from the riding position).
1. Choke Lever
2. Correct Adjustment, 2-3mm of Free Play
3.
1. Locknut
2. Adjuster Nut
To determine the amount of free-play in the cable,

operate the choke lever until the starter plunger
lever at the carburettor touches the starter plunger.
If correct, there should be 2-3mm of free play at the
choke lever.
4.

NOTE:
Re-check the adjustment after final assembly and

repeat if necessary.
The starter plunger slides in a lateral direction

rather than in a rotational way.
9.15
AIR INTAKE/CARBURETTOR
Removal - All models except
Adventurer
WARNING: Never attempt to run the

engine with the air intake removed. Any
damage may result.
NOTE:

the seat, battery, side panels and fuel tank must
first be removed.
For information on the
removal of these items, refer to information
given in this and other sections of this manual.
1.
Remove the air intake duct(s) from the auxiliary

chambers (left hand only on Tiger models).
2.
Remove both auxiliary chambers by releasing the

bolts which secure each chamber to the frame.
3.
Remove the rubber gaiters from the airbox.
4.
Slacken the clips securing the airbox to the

carburettors.
5.
Detach the airbox and pull back from

6.
Remove the cam cover cowls and foam seal.
7.
Detach the low tension connectors from the coils.

Remove the ignition coils from the frame spine tube,
complete with the spark plug leads.
the
2. Auxiliary Chamber
4. Venturi Intake Rubbers
11. While supporting the carburettors, disconnect the

throttle cable as follows: Release the outer cable
locknut and fully unscrew the outer cable adjuster.
Lift the cable adjuster from its slot and turn the
nipple on the end of the inner cable to detach from
the throttle cam. Remove the carburettor assembly.
12. Release the clip securing the airbox breather pipe
to the clutch cover or breather cover (depending on
cylinder configuration) and detach the pipe. Note
the pipe routing in order to correctly route the pipe
on assembly.
13. Remove the airbox complete with the airbox drain
pipe.
NOTE:
1. Air Intake Duct

3. Rubber Gaiter
5. Airbox
Note the relative positions of all low and high

8.
Remove the choke cable from the carburettors by

releasing the cable locknut and fully unscrewing the
adjuster. Lift the cable to release from the location
slot and turn the nipple on the inner cable to detach
from the choke mechanism.
9.

to the cylinder head.
10. Remove the carburettors from the head, complete

with rubbers, using a gentle rocking motion.
9.16

from entering the inlet ports and damaging the
engine.
NOTE:

complete assembly.
Installation
1.
2.
3.
4.

and the positions of expansion rings in the airbox.
Position the airbox in the frame.
Feed the airbox drain pipe between the alternator
earth strap and the alternator. Locate into the left
hand centre stand spring (where fitted).
Position the airbox in the frame to allow fitment of
Re-connect the throttle cable to the carburettors
using a reversal of the removal process. Ensure
both the inner and outer cable are seated correctly
by turning the throttle back and forth and checking
for smooth operation.
5.
Align the carburettors to the head ensuring all fuel

and vacuum hoses are positioned upwards to
prevent accidental damage or trapping.
6.
Fit the carburettors to the cylinder head. Set the

throttle cable adjustment as described earlier in this
chapter.
7.
Fit the airbox to the carburettors ensuring all

8.

clips.
9.

10. Position the vacuum and fuel pipes between the

main frame and the airbox.
11.
Fit the ignition coils and secure to the frame spine

tube.

disconnection.
14. Fit the cam cowl seal in an upright position over the
choke cable and locate the ignition leads.
the spark plugs.
17. Check the operation of the choke system and also
described earlier in this chapter.
9.17
18. Attach the airbox breather hose and secure to either

the clutch cover or breather cover (depending on
cylinder configuration).
19. Check tor the correct free operation of the throttle.
Re-adjust if necessary.
20. Fit the rubber gaiters to the airbox.
21. Fit the auxiliary chambers into the rubber gaiters
and align to the battery box flanged sleeves.
22. Fit the screws and nut to secure the auxiliary
chambers. Tighten to 9 Nm.
23. Fit the air intake ducts.
NOTE:

In
In all cases, these
Removal- Thunderbird, Thunderbird

Sport & Adventurer
WARNING:
4.

5.
Detach the low tension connectors from number 3

coil. Remove the coil from the frame spine tube,
complete with spark plug lead.
Never attempt to run the
~ engine with the air intake removed. Any

damage may result.
Note the relative positions of the low and high

6.
Remove the choke cable from the carburettors.
NOTE:
7.

to the carburettors.
8.
Detach the carburettors from the rubbers using a

gentle rocking motion and slide the carburettors to
the left hand side of the motorcycle.
9.
While supporting the carburettors, disconnect the

throttle cable.
NOTE:

the seat, side covers, airbox covers, horn, horn
bracket and fuel tank must first be removed as
described in the body and fuel sections
respectively.
1.
Release the clips securing the airbox auxiliary

chamber to the airbox.
2.
Release the screw securing the auxiliary chamber

to the seat rail and remove the auxiliary chamber.
10. Taking care not to damage the coolant bypass

hose, remove the carburettors.
11.
Release the breather hose from the airbox and

remove the airbox.
A.

engine damage.
NOTE:
1. Securing Screw
3.
Release the clips securing the airbox to the

carburettors.
9.18

complete assembly.
Installation -Thunderbird, Thunderbird

Sport & Adventurer
1.

2.

earth strap and the alternator.
3.

4.
5.
Position the carburettors to allow reconnection of

the throttle cable. Re-connect the throttle cable to
the carburettors using a reversal of the removal
process. Ensure both the inner and outer cables
are seated correctly by turning the throttle back and
forth and checking for smooth operation.
Align the carburettors to rubbers ensuring the
coolant bypass hose, fuel and drain hoses are
positioned correctly to prevent entrapment or
damage,
6.
Connect the breather pipe to the airbox.
7.

8.

clips.
9.


11.
Fit the ignition coil and secure to the frame spine

tube.

disconnection.
the spark plugs.

routed or damaged throttle or choke cable could
interfere with the operation of the brakes, clutch,
throttle or may cause the choke or throttle to stick.
Any of these conditions could result in loss of
control of the motorcycle and an accident.
9.19
17. Refit the airbox auxiliary chamber using a reversal

of the removal process. Ensure that the auxiliary
chamber securing screw and the airbox to auxiliary
chamber clips are correctly tightened.
18. Refit the seat, side covers, airbox covers, horn
bracket, horn and fuel tank.
NOTE:

In
In all cases, these
OVERHAUL- MIKUNI CARBURETTORS
Inspection
1.
Carburettor Disassembly
1.
Remove the carburettor vent pipes and detach the

fuel feed pipes from their connections.
2.
Remove the choke lever from the carburettor

assembly.
3.
Remove the screws securing the upper and lower

mounting brackets.
4.
Carefully separate the carburettor bodies.
As the carburettors separate from each other,

the throttle butterfly adjuster springs will
become detached. Take care to collect the
springs before finally releasing the carburettors
from each other.
5.
Remove the choke needle assembly (1) from the

carburettor body.
6.
Remove the screws (2) securing the carburettor

cover.
7.
Remove the cover and collect the '0' ring (3).
8.
Lift out the carburettor piston/diaphragm and spring

(4,5&6).
9.
Remove needle and spacers (7, 8 & 9) from the

inside of the piston/diaphragm.
10. Remove the float chamber cover ( 10) by detaching

the cover screws. Collect the float chamber gasket
(11).
11.
Detach the float assembly (12) by gently pulling the

float downwards until the '0' ring mounting points
become detached from the carburettor body.
12. Remove the pilot jet (13) from inside the float
chamber.
13. Remove the main jet (14) from the centre of the
carbu rettor.
14. Remove pilot air screw, '0' ring and spring (15)
noting the number of turns necessary to release the
thread.
15. Remove needle jet (16) by sliding upwards.
9.20
Inspect the parts listed below for wear, cracks and

any sign of damage and replace as necessary.
Carburettor body
Float chamber
Floats
Needle
Main jet
Pilot jet
Pilot air screw
Needle jet
Diaphragm
Jets should always be replaced if any signs of
polishing are evident. Polishing indicates that wear
has taken place which may make the carburettor
difficult to tune.
2.
Inspect all jets for blockage. Clear any blockage

using compressed air. In particular, clear all jet
passages.
Assembly

. . eye, face and ear protection when using
compressed air to clear blockages. Always wear
protective gloves if the compressed air is to be
directed in proximity to the skin.
NOTE:
Clean all parts in a petroleum based solvent

before assembly.
1.
Refit the needle jet (16) into the carburettor body

taking care to align the flat on the bottom of the jet
with the tag in the carburettor body.
2.
Refit the pilot air spring and screw (15). Fit the
screw to the same depth as was noted during
removal.
3.
Refit the main jet (14) and pilot jet (13).
4.
Fit new '0' rings to the float assembly (12) and refit
to the carburettor body. Fit a new gasket (11) to the
float chamber cover (10). Fit and tighten the
retaining screws.
5.
Fit the needle and spacers (7, 8, and 9) to the inside

of the piston/diaphragm (5 and 4) and locate the
piston/diaphragm to the carburettor body.
6.
Fit a new '0' ring (3) to the top of the carburettor

body.
7.
Position the piston spring (6) and fit the cover.

Tighten the cover screws (2).
8.
Refit the choke needle (1) , fuel pipes and vent pipe.
9.
Assemble the individual

mounting brackets.
Ensure that the throttle butterfly adjuster

springs are correctly positioned during
assembly and that the throttles open and close
correctly and without sticking.
13--#
14
5
4
to
the
'
~-
Choke Needle Assembly

Cover Screw
Cover And 'o' Ring
Piston
Diaphragm
Spring
Needle
Needle Spacer
WARNING:
Always ensure that the

have
been
correctly
assembled and that the throttle opens smoothly
and closes without sticking. Use of the motorcycle
with an incorrectly assembled, sticking or
damaged carburettor throttle mechanism could
interfere with the safe operation of the motorcycle.
~ carburettors
10
1.
2.
3.
4.
5.
6.
7.
8.
carburettors
9.
10.
11.
12.
13.
14.
15.
16.
Spring Spacer
Float Chamber
Gasket
Float Assembly
Pilot Jet
Main Jet
Pilot Air Screw
Needle Jet
9.21
OVERHAUL- KEIHIN CARBURETTORS
Inspection
Carburettor Disassembly
1.
1.
Remove the carburettor vent pipes and detach the

fuel feed pipes from their connections.
2.
Remove the screws securing the upper and lower

mounting brackets.
3.
Release the carburettor through-bolt
4.
Carefully separate the carburettor bodies.
As the carburettors separate from each other,

the butterfly adjuster spring will become
detached. Take care to collect the spring before
finally releasing the carburettors from each
other.
Inspect the parts listed below for wear, cracks and

any sign of damage and replace as necessary.
Carburettor body
Float chamber
Floats
Needle
Main jet
Jet needle
Diaphragm
Jets should always be replaced if any signs of
polishing are evident. Polishing indicates that wear
has taken place which may make the carburettor
difficult to tune.
2.
Inspect all jets for blockage. Clear any blockage

using compressed air. In particular, clear all jet
passages.
5.
Remove the screws (1) securing the carburettor

cover.
6.
Lift out the carburettor piston/diaphragm and spring

(2, 3 & 4).
~ eye, face and ear protection when using
7.
Remove needle (5) and needle holder (6) from the

inside of the piston/diaphragm.
compressed air to clear blockages. Always wear

protective gloves if the compressed air is to be
directed in proximity to the skin.
8.
Remove the float chamber cover (7) by detaching

the cover screws (8). Collect the float chamber
gasket (9).
9.
Gently push the float pivot pin through the

carburettor body and collect the float (1 0) and float
needle (11).
10. Remove the main jet (12).
9.22
Assembly
NOTE:
___.___.
(
I
I
I
___.___.----
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
5-i
2/3
v_.-- _.--
1.
2.
3.
4.
5.
6.
Cover Screw
Diaphragm
Piston
Spring
Needle
Needle Holder
1.
Refit the main jet (12).
2.
Assemble the float needle (11), float (10) and float

pivot and fit to the carburettor body.
3.
Check and adjust the float height if necessary.
4.
Fit the float gasket (9) to the float chamber cover (7)
and secure using the float cover screws (8).
5.
Assemble the needle (5) to the piston (2/3) and fit

the needle holder (6).
6.
Fit the piston and diaphragm assembly to the

carburettor.
NOTE:
The piston will only fit into the carburettor body

when it is facing the correct way round.
7.
Ensure that the diaphragm is correctly seated in the
rim of the carburettor body and refit the cover.
)
/
Clean all parts in a petroleum based solvent

before assembly.
_.---1
8.
Refit the spring (4).
9.
Secure the cover using the cover screws (1 ).
10. Assemble each carburettor to the upper and lower

mounting brackets. Tighten the fixings.
7. Float Cover
8. Cover Screw
9. Gasket
10. Float
11 . Float Needle
12. Main Jet
11. Fit and tighten the through bolt and screws
Ensure that the butterfly adjuster springs are

correctly positioned during assembly and that
the throttles open and close correctly and
without sticking.
WARNING:
Always ensure that the
. . . . carburettors
have
been
correctly
assembled and that the throttle opens smoothly
and closes without sticking. Use of the motorcycle,,
with an incorrectly assembled, sticking or >
damaged carburettor throttle mechanism could'
interfere with the safe operation of the motorcycle.
9.23
FUEL SYSTEM CLEANLINESS

INSPECTION
1.
Place a suitable container below the carburettors.
2.
On all models except Tiger, Adventurer,

Thunderbird Sport and Thunderbird turn the fuel
tap to the 'PRI' position. On Tiger, Adventurer,
Thunderbird Sport and Thunderbird, turn the tap
to the 'ON' position.
Fuel Tap (all models except Tiger, Adventurer,

Thunderbird Sport & Thunderbird)
3.
Loosen the float chamber drain screw.
NOTE:
4.
5.
1. Tiger Fuel Tap
If any water or dirt appears, clean the fuel

system.
Tighten the float chamber drain screw.
On all models except Tiger, Adventurer,
Thunderbird Sport and Thunderbird turn fuel tap
back to ON. (The tap should already be in the 'ON'
position on Thunderbird, Thunderbird Sport, Tiger
and Adventurer).
NOTE:
----
Later models are fitted with in-line fuel filters to

assist in trapping any dirt which enters the fuel
system. No maintenance is required for the
in-line filters which are situated in the fuel
delivery pipes between the carburettors.
1. Thunderbird, Thunderbird Sport & Adventurer

Fuel Tap
1. In-line Fuel Filter
9.24
5.
FUEL FLOAT LEVEL MEASUREMENT

1.
Place the motorcycle on level ground and on the

centre stand (support adequately for those
machines not fitted with a centre stand). On all
except Tiger, Adventurer, Thunderbird Sport
and Thunderbird turn the fuel tap to the 'ON'
position. On Tiger, Adventurer, Thunderbird
Sport and Thunderbird, turn the fuel tap to the
'OFF' position.

1. Fuel Hose Connected To 3880125

2. Fuel Level
2.
Remove the float chamber drain screw and drain

the fuel in the chamber into a suitable container.
3.
On Mikuni carburettors, fit service tool adaptor

3880120 in place of the float chamber drain screw.
On Keihin carburettors, attach a length of fuel
hose to the drain point in the base of the float bowl,
then open the drain screw.
NOTE:
WARNING: A small amount of fuel will be

lost as the float chamber drain screw is
removed. Place a suitable fuel storage container
beneath the carburettor before removing the drain
screw. A fire causing personal injury and damage
to property could result from spilled fuel or fuel not
3.
Connect the fuel level gauge 3880125 to the drain

point adapter using a short length of fuel hose.
4.
ON ALL MODELS EXCEPT THUNDERBIRD,

THUNDERBIRD SPORT. ADVENTURER and
TIGER turn fuel tap to the 'PRJ' (prime) position.
ON THUNDERBIRD, THUNDERBIRD SPORT,
ADVENTURER and TIGER, turn the fuel tap to the
'ON' position.
6.
Ensure that the hose leading from the float bowl

does not become kinked as this will give a false
fuel level indication.
Measure the fuel level in the carburettor by
comparing the fuel level in the tool with the scale.
Repeat the test for the remainder of the
carburettors.
Correct Fuel Height Above Joint Face:

1.5mm 1mm (tool marked in 1mm divisions)
NOTE:
9.25
When checking the fuel level, it is important that

the tool is held in exactly the same position on
each carburettor.
Similarly, it is equally
important that the centre of the scale marks on
the tool are held level with the joint face on the
carburettor.
Fuel level readings on each carburettor should

be equal.
FUEL FLOAT LEVEL ADJUSTMENT
AIRBOX DRAIN PIPE
1.
If the fuel level is found to be incorrect, the fuel level

can be adjusted in the following manner.
a.
Remove the carburettors from the motorcycle.
The airbox drain pipe must be drained in line with the

Periodic Maintenance Chart.
1. Remove the plug from the drain pipe to allow any
fluid which has accumulated in the pipe to drain out.
b.
Inspect the float valve seat and needle valve.

Replace if worn or suspect.
1. Worn Needle Valve

2. Serviceable Needle Valve
c.
If both valve seat and needle valve are in good

condition, adjust the float level by carefully bending
the float tab.
1. Float Tab (Mikuni Carburettor Illustrated)
NOTE:
Bend the float tab by very small amounts at a

time. A very small change in tab angle will bring
about a large change in fuel level.
2.
Assemble and refit the carburettors and recheck the

fuel level as previously described. Repeat the
adjustments as necessary.
9.26
2.
Refit the plug.
CARBURETTOR SETTING
Carburettor Mixture Adjustment
Using Tool 3880015 To Adjust Mixtures
NOTE:
The fuel mixture is set during manufacture and should

not be disturbed unless the carburettor is dismantled and
the adjustment setting changed.
A special screwdriver, part number 3880015, is available
should it become necessary to reset the mixtures.
Adjustment is carried out, after balancing the
carburettors, by varying the height of the pilot screw.
CORRECT MIXTURE SETTING (OUTSIDE USA)

2.5-4.5% CO at idle (950-1050 R.P.M.)
CORRECT MIXTURE SETTING (USA)

1.0% CO at idle (950-1050 R.P.M.)
WARNING: In the USA carburettors are

sealed to prevent alteration of the idle
mixture setting. The mixture setting given for the
USA has been set to comply with State and Federal
emission laws. Any tampering with, or deviation
from the factory setting may cause the motorcycle
to be in breach of State and Federal law. This
would make the motorcycle illegal for road use and
may also invalidate emission warranties
'!'
CAUTION: It is not possible to accurately

gauge the setting of each individual
carburettor using a CO meter which takes a
measurement solely from the silencer outlet.
A meter which is adapted to take a measurement
from the exhaust downpipe for each individual
cylinder must be used.
Using the silencer outlet to measure CO will result
in incorrect mixture adjustment, high fuel
consumption, high CO emissions and rough
running.
9.27
CARBURETTORS
Carburettor Synchronisation

. . . . the motorcycle engine must be run. The
gases.
quantity.
ON
ALL
MODELS
EXCEPT
TIGER,
ADVENTURER, THUNDERBIRD SPORT &
THUNDERBIRD, Turn the fuel tap to the 'PRI'
position.
ON TIGER, ADVENTURER, THUNDERBIRD
SPORT & THUNDERBIRD, turn the fuel tap to the
'ON' position
7.
The carburettors are now ready for the adjustment

process to begin. Start the engine and allow it to idle
whilst measuring the intake vacuum for each
carburettor.
8.
On 4 cylinder engines the carburettor for number 3

cylinder is designated as a 'master' carburettor. On
3 cylinder engines, the 'master' carburettor is the
centre carburettor.
The adjustment process
matches the vacuum settings for the remaining
carburettors to the 'master' carburettor.
1.
Start motorcycle and allow the engine to reach

Vacuum at idle speed should read between 5.00

and 6.00 inches Hg (127-152 mm Hg).
2.
Check that the idle speed is between 950 and 1050

rpm (r/min). Adjust as necessary by turning the idle
adjusting screw on the left hand side of the
carburettors.
9.
3.
Open and close the throttle several times to check

that the idle speed does not fluctuate from the
original setting. Re-adjust as necessary then stop
the engine.
4.
Remove the fuel tank as described earlier in this

section.

..... given in the general information section
5.
Attach a set of vacuum gauges, one to each

carburettor. The vacuum take off connections are
on top of each carburettor, adjacent to the
diaphragm cover.
NOTE:
Any vacuum pipes to the fuel tap or evaporative

loss system may be disconnected and sealed
during the adjustment procedure.
6.
Support the vacuum gauges and position the fuel

tank adjacent to, and higher than, the carburettors.
Refit the fuel pipes to the carburettors.
Set the vacuum on the 'master' carburettor by

turning the idle speed adjuster.
10. Once the vacuum setting for the master carburettor

has been set, match the remaining carburettor
settings to the master carburettor by turning the
adjuster screws (A, B and C in the diagram right).
Once all vacuum settings are matched, reset the
idle speed and stop the engine.
NOTE:
The adjustment is very sensitive. A small

change in the adjuster position will significantly
affect the vacuum setting for the carburettor.
Each time a synchronisation adjustment is

made, idle speed should also be checked and
adjusted to between 950 and 1050 rpm (r/min).
Number one cylinder is the outer left hand

Adjuster A affects cylinder No 1 on 3 & 4

cylinder engines.
Adjuster B affects cylinder No 4 on 4 cyl engines
and cylinder No 3 on 3 cylinder engines.
Adjuster C affects cylinder number 2 on 4
cylinder engines only.
11. Remove the fuel tank and disconnect the vacuum
gauges. Refit all vacuum pipes disconnected for the
adjustment process.
12. Refit the fuel tank as described earlier in this
section.
NOTE:
9.28
As an alternative to analogue vacuum gauges,

the Souriau Indiana digital vacuum tool will
enable more accurate balancing (see inset)
4 Cylinder
FWD
Master Carburettor
3 Cylinder
~FWD
Souriau Indiana
Digital Vacuum
Gauge
1. Blanking Caps
2. Fuel Tap Vacuum Pipe* (From Centre Carb On 3 Cyl)
3. Vacuum Gauge
.
*Not Fitted On Tiger, Adventurer, Thunderbird Sport or Thunderbird
9.29
Evaporative Loss System - US California Specification Models

All models are fitted with an evaporative loss control system. The system is fitted to ensure that fuel vapour in the fuel
tank or carburettor float chambers cannot escape to atmosphere at any time. Instead, when the engine is not running,
the vapour is 'stored' in two charcoal canisters. When the engine is started, fuel vapour is drawn by vacuum from the
canisters into the engine combustion chambers.
Other changes include;
When fitted with Mikuni carburettors, Sprint,

Trophy 900, Trident 900, Tiger, Adventurer and
Thunderbird are fitted with catalytic converters
to the exhaust system headers. When Keihin
carburettors are fitted, the catalyst is
unnecessary and is not used.
Changes to wiring harnesses to incorporate
float chamber vent solenoids.
Special fuel tank with vapour collection
chamber.
Changes to carburettor jets from the standard
version.
Sprint, Trophy 900 and Trident 900 fitted with an

airbox similar to the Tiger.
Sprint, Trophy 900 and Trident 900 fitted with a
high torque engine.
Special lock set which includes a fuel filler cap
which allows air to enter as the fuel is used but
prevents fuel vapour from escaping.
Daytona 1200 fitted with 136 PS engine.
Evaporative Loss System Layout

Roll Over Valve
(In breather line from fuel tank)
Prevents fuel escape from the vapour chamber if the motorcycle falls over
Float Chamber Vent Solenoids

(Attached to main spine tube of frame)
(situated below
rear mudguard)
Pressure Control Valve

(Regulates vapour pressure in fuel tank)
Secondary Canister
(situated near the battery)
9.30
Evaporative Loss System Operation- Engine Switched Off
L-----------~
,- Float Chamber Vent 1

Solenoids \
1
I
I
Pipe 'A'
Roll Over Valve
Liquid Fuel Collection Point
~ Pipe 'A' Continued

Pressure Control Valve
Liquid Fuel Collection Point
Because the float chamber vent solenoids

are closed (to prevent vapour escaping to
the atmosphere), fuel vapour will pass
through pipe 'C' to the secondary canister.
When the engine is switched off, any

pressure increase in the fuel tank due to a
rise in ambient temperature will cause fuel
vapour to collect in the vapour collection
chamber and pass down pipe 'A', through
the roll over valve, to the pressure control
valve.
Any liquid fuel which condenses in the

system is collected in the liquid fuel
collection points and is drained out at each
service.
If the pressure rises above 0.75 lb/in2 the

pressure control valve will open, allowing
the vapour to pass through pipe 'B.' to the
primary charcoal canister.
The canisters store fuel vapour until the

engine is started.
9.31
Evaporative Loss System Operation - Engine Running
L-----------~
I
I
I
I
I
I
I
El
When the engine is started, vacuum is applied via
pipe 'D' to the vacuum switch on the primary
charcoal canister. This applied vacuum causes the
vacuum switch to open.
Vacuum, via pipe 'F', draws fuel vapour from the
primary canister into the engine to be burnt.
Vacuum applied to pipe 'E' directly purges any
vapour stored in the secondary canister.
Restrictors in pipes 'E' and 'F' limit the effective size
of the pipes and help to maintain the balance of air
being drawn into the carburettors.
9.32
To allow air to enter the float chambers, an electrical

charge is applied to the float chamber vent
solenoids causing them to open to the atmosphere.
Because air is constantly being drawn into the
chambers while the engine is running, no fuel
vapour escapes.
As the volume of fuel in the fuel tank reduces, air
enters the tank through a one way valve in the filler
cap. Because the valve opens in one direction only,
it allows air to enter the tank but does not allow
vapour to escape.
Cooling System
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4
Coolant
Level Inspection- all models except Thunderbird, Thunderbird Sport &
Adventurer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Level Inspection- Thunderbird, Thunderbird Sport & Adventurer . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoses........................................................
Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5
10.5.
10.6
10.7
10. 7
Water pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8
10.8
10.9
Radiator
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.10
10.11
10.11
Thermostat - all models except Thunderbird, Thunderbird Sport & Adventurer

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.12
Thermostat - Thunderbird, Thunderbird Sport & Adventurer
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.13
10.13
10.13
Coolant Pressure Cap

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.14
10.1
10 COOLING SYSTEM
Cooling System- All Models Except Thunderbird, Thunderbird Sport & Adventurer
11 N m -
-~2.5Nm
~~-10Nm
t~
10.2
COOLING SYSTEM 10
Cooling System - Thunderbird, Thunderbird Sport & Adventurer
\'
11 Nm
7 Nm
'"1
\ ~~
\
,)
1.
'\
..
'
<.>
i '
~ 7 Nm
'
'
11 Nm
18 Nm
-~
2.5 Nm
'-~~
'
/
I
12 Nm
(J
/
10 Nm
10.3
@
I
I
2.5 Nm
10 COOLING SYSTEM
COOLING SYSTEM DESCRIPTION
COOLANT
All motorcycles are fitted with a radiator mounted in front

of the engine. On faired models, ducts direct air through
the radiator to ensure adequate cooling. The ducts are
not necessary on unfaired models.
A permanent type of antifreeze is installed in the cooling

system when the motorcycle leaves the factory. It is
coloured blue, contains a 50% solution of ethylene
glycol, and has a freezing point of -35C (-31F).
Attached to the radiator is an electric fan controlled by a

temperature sensitive switch which cuts in when the
coolant temperature reaches 94-1 05C. The system is
fitted with a pressure cap which has a blow off valve limit
of 1.1 Bar. The coolant displaced, if the cap valve is
released, is re-circulated to the expansion tank beneath
the seat (beneath the fuel tank on Thunderbird,
Thunderbird Sport & Adventurer).
A thermostat is used to aid rapid warming of the engine to
normal operating temperature. The thermostat opens at
88C. It is located, on Thunderbird, Thunderbird Sport &
Adventurer, in a housing beneath the fuel tank and in the
top hose on all other models.
An engine driven water pump is used to circulate coolant
through the system. Drive for the pump is taken from an
extension of the oil pump which is, in turn, driven by the
auxiliary drive gears. Rubber hoses carry coolant
between the radiator, water pump and crankcase. On
most later models, the hose clips must be renewed if the
hoses are disturbed.
A 50% anti-freeze mixture must be maintained at all
times. This is necessary to prevent corrosion of the
cooling system which could create blockages and lead to
overheating and coolant leaks.
10.4

. . . . contains anti freeze and corrosion
inhibitors contains toxic chemicals which are
Never swallow
1:\.
CAUTION:
coolant would 'attack' the metals and the resulting
corrosion would cause blockages in the cooling
system leading to engine overheating and
damage. Always use the correct anti-freeze as
specified in the Owner's Handbook. Never use a
properties.
1:\.


severe damage.
COOLING SYSTEM 10
Coolant level inspection (not Thunderbird,

Thunderbird Sport & Adventurer)
Coolant level inspection - Thunderbird,


~ pressure cap when the engine is hot.
skin damage.

~ pressure cap when the engine is hot.
skin damage.
1.

upright position.
1.

upright position.
2.
Remove the seat.
2.
3.
Check the coolant level in the expansion tank. The

coolant level should be between the 'MAX
and 'MIN' marks.
The coolant level should be between the 'MAX' and

'MIN' marks
1. Expansion Tank
3. 'Max' Mark
4.
1. 'Max' mark
2. 'Min' mark
2. Expansion Tank Filler Cap

4. 'Min' Mark
If the level of coolant is low remove the cap from the

expansion tank, and add coolant mixture to bring
the level up to the 'MAX' mark. Refit the cap.
A.

necessary. Loss of coolant may cause the engine
to overheat and suffer severe damage.
3.
If it is necessary to add coolant, the fuel tank must

first be removed as described in the fuel system
section.
4.
Remove the cap from the expansion tank, and add

coolant mixture through the filler opening to the
'MAX' mark. Refit the cap.
I!'

necessary. Loss of coolant may cause the engine
to overheat and suffer severe damage.
10.5
10 COOLING SYSTEM
COOLANT REPLACEMENT
Filling (Not Thunderbird, Thunderbird

Sport & Adventurer)
Drainage (all models)

1.
2.
Remove the seat and lower fairing panels where

necessary. Place a container beneath the left hand
side of the machine to collect the displaced coolant.
1.

Nm.
2.

13 Nm.
3.
Slowly add coolant mixture to the system, through

the radiator filler, until the radiator is full.
4.
Start the motorcycle and allow the engine to idle for

a short period of time to allow any air to be expelled
from the system. Stop the engine and top up the
coolant level as necessary.
5.
Fit the coolant pressure cap.
6.
Check the expansion tank level and top up if

necessary.
7.
Refit the bodywork where necessary.
8.
Carry out a short test to warm the engine to normal

operating temperature. Allow the engine to cool
and recheck the coolant level. Adjust as necessary
Remove the coolant pressure cap to help drainage.

skin damage.
1. Crankcase Drain Plug

2. Water Pump Drain Plug
10.6
COOLING SYSTEM 10
Filling (Thunderbird, Thunderbird Sport &

Adventurer)
Radiator and Cooling Fan
1.

Nm.
2.

13 Nm.
3.

system section.

correct manner.
4.
1. Thermostat housing 2. Coolant filler

3. Bleed Screw
6.
Temporarily refit the fuel tank. Start the motorcycle

and allow the engine to idle for a short period of time
to allow any air to be expelled from the system. Stop
the engine and top up the coolant level as
necessary.
7.
Fully refit the fuel tank as described in the fuel

system section.

CAUTION: Using high-pressure water, as
from a car-wash facility, can damage the
radiator fins and impair the radiator's efficiency.
Slowly add coolant mixture to the system through

the filler until the system is full. Close the bleed
screw.
1,\,
~
screw on the top of the
5.
Check the radiator fins for obstruction by insects, mud,

leaves and general debris. Clean off any obstructions
by hand or with a stream of low pressure water.
Radiator Hoses
Regularly check radiator hoses and hose clips for
cracks, leaks or deterioration in accordance with the
Periodic Maintenance Chart.
10.7
Do not obstruct or deflect airflow through the

radiator by installing unauthorized accessories in
front of the radiator or behind the cooling fan.
Interference with the radiator airflow can lead to
overheating and consequent engine damage.
10 COOLING SYSTEM
WATER PUMP
Removal
1.
Remove the lower fairing, where fitted, to give

access to the radiator hoses.
2.
Drain the engine coolant as described earlier.

. . . pressure cap when the engine is hot.
skin damage.
3.
On faired motorcycles, remove the oil cooler, left

hand oil cooler bracket and sub-frame to give
access to the water pipe.
On Tiger, remove the sump guard and on
Thunderbird, Thunderbird Sport & Adventurer,
remove the horn assembly.
1. Hose Clip
2. Water Pump Outlet Hose
3. Water Pipe Mounting Bolt
4. Water Pipe Retaining Bolt
5. Water Pump Bolts
6. Water Pump
7. Bypass Hose (Thunderbird, Thunderbird Sport &
Adventurer only)
8.
Release and remove the bolts securing the water

pump to the lower crankcase.
9.
Remove the water pump.
Inspection
1.
2.
3.
4.
5.

Retaining Bolt
Washer
5.
Release the hose clip and remove the water pump

outlet hose from the water pump. On Thunderbird,
Thunderbird Sport & Adventurer, also remove the
bypass hose from the water pump.
6.
Remove the water pipe mounting bolt and fibre

washer from the front edge of the crankcase joint.
7.
Remove the bolt securing the water pipe to the

water pump and detach the pipe.
10.8
1.
Check the shaft and shaft bearings for side and end
float. Renew if necessary
2.
Check for corrosion and scale build-up around the

impellor and in the pump body. Renew if necessary
COOLING SYSTEM 10
11. Carry out a short test to warm the engine to normal

operating temperature and re-adjust the coolant
level once the engine has been allowed to cool.
Installation
1.
Replace the water pump '0' ring seal.
2.
Align the drive slot in the pump with the drive slot on
the oil pump ( the water pump will not fully locate
unless the drive slots are aligned).
1. '0' Ring
2. Drive Slot
3.
Locate the pump and tighten the pump bolts to

12Nm.
4.
Fit a new '0' ring to the water pipe and fit to the water
pump. Tighten the retaining bolt to 8Nm.
5.
Refit the bolt securing the water pipe to the

crankcase and tighten to 1ONm.
6.
Refit the oil cooler sub-frame and cooler as

described in the lubrication section. On Tiger, refit
the sump guard.
7.
Refit the water pump outlet hose to the water pump.

On Thunderbird, Thunderbird Sport & Adventurer,
also reconnect the bypass hose.
8.
Refit the water pump hose cover (where fitted).
'f

9.
Refit the bodywork removed earlier.
10. Refill the cooling system as described earlier using

50% anti freeze mixture.
10.9

skin damage.
10 COOLING SYSTEM
6.
RADIATOR
Removal
1.
2.

negative (black) lead first. Remove the lower
fairings, where fitted, to give access to the radiator.
Drain the engine coolant as described earlier.

skin damage.
3.
Release the top and bottom hoses at the

connections to the radiator. On all models except
disconnect the expansion tank hose.
!f\

7.
Disconnect the cooling fan switch from the lower left

hand side of the radiator (not necessary on
Thunderbird, Thunderbird Sport & Adventurer).
On later Tridents and all Speed Triples, remove the

self adhesive reflectors from the radiator end
covers to expose the end cover retaining screws.
NOTE:
The reflectors are retained with an adhesive

pad. If the reflectors are removed, they must be
replaced. The original items will not have
sufficient adhesive to adhere to the end covers.
4.
Where fitted, release the end cover screws and

remove the end covers.
5.
On later Tridents and all Speed Triples, remove the

bolt and release the clip securing the top hose cover
to the radiator and top hose. Remove the cover.
1. Cooling Fan Switch

8.
Disconnect the cooling fan at the wiring harness

connector.
NOTE:
The clip securing the top hose cover to the hose

is located at the lower inside face of the cover
(as arrowed below).
1. Cooling Fan Connection
1. Reflector
2. End Cover Bolt
3. End Cover
4. Top Hose Cover Screw
5. Top Hose Cover
Arrowed. Cover Clip Position
10.10
COOLING SYSTEM 10
9.
Release the four bolts (two per side) securing the

radiator lower mountings to the brackets. Support
the radiator and remove the upper mounting bolts.
Slide the radiator out to one side taking care not to
damage any painted surfaces.
4.
On later Tridents and all Speed Triples, position the

top hose cover to the top hose and locate the
retaining clip to the tag inside the cover. Align the
cover to the radiator and tighten the retaining bolt
and clip.
5.
Fit the radiator end covers (if necessary).
NOTE:
1. Radiator Lower Mounting Bolts
On Trident and Speed Triple, new reflectors

must be used on the radiator end tanks.
6.
Reconnect the
connections.
7.
Refit the coolant drain plugs using new sealing

washers.
8.
Refill the cooling system as described earlier using

50% anti freeze mixture.
9.
Refit any bodywork removed for access and

reconnect the battery positive (red) lead first.
cooling
fan
and
fan
switch
Inspection
10. Refit the seat.
1.
Check the radiator guard for stone damage.
2.
Check the radiator core, for damage to fins or

obstructions to air flow.
11. Carry out a short test to warm the engine to normal

3.
Repair any damage and clear all obstructions.

with the pressurised c'oolant will cause scalds and
skin damage.
CAUTION: To avoid overheating and

consequent engine damage, replace the
radiator if the cores are blocked or if the fins are
badly deformed or broken.
Installation
1.
Position the radiator assembly to the upper

mounting points and loosely fit the capscrews.
2.
Align the lower mounting brackets to the radiator.

Align the brackets and fit the retaining bolts.
Tighten the upper mounting bolts to 18 Nm and the
lower bolts to 9 Nm.
3.
Refit the top and bottom and hoses replacing the

hose clips if necessary. On all models except
connect the expansion tank hose.

10.11
10 COOLING SYSTEM
THERMOSTAT
2.
Removal -all models except Thunderbird,

To check the valve opening temperature, suspend

the thermostat in a container of water and raise the
temperature of the water until the thermostat opens.
3.
If the temperature at which thermostat opening

takes place is incorrect, replace the thermostat.
NOTE:
The thermostat is located inside the top hose, at

the larger diameter end.
1.
Remove the lower fairings, where fitted, to give

access to the radiator hoses.
2.
Drain engine coolant as described earlier.
Thermostat valve opening temperature:
Installation -all models except

Adventurer
1.
aaoc
Insert the thermostat into the hose.

skin damage.
CAUTION: Always install the thermostat

with the 'bulb' end pointing away from the
radiator and the bleed hole uppermost. Incorrect
installation of the thermostat will cause
overheating and consequently engine damage.
3.
Remove the clip securing the top hose to the

radiator.
2.
4.
Using a pair of pliers, carefully extract the

thermostat from the hose.
~
1
J!'

3.
Refill the cooling system as described earlier using

50% coolant mixture.
4.
Refit any bodywork previously removed.
5.

t
II
........
:;tn (CS)D

skin damage.
ll ~11
/
/
Thermostat Location
1. Thermostat
2. Top Hose
Inspection
1.
Fit a new hose clip and locate the hose to the

radiator. Tighten the hose clip.
Inspect the thermostat at room temperature. If the

valve is open, the thermostat must be replaced.
10.12
COOLING SYSTEM 10
THERMOSTAT
Inspection
Removal - Thunderbird, Thunderbird

Sport & Adventurer
1.

system section.

2.
1.
Inspect the thermostat at room temperature. If the

valve is open, the thermostat must be replaced.
2.
To check the valve opening temperature, suspend

the thermostat in a container of water and raise the
temperature of the water until the thermostat opens.
3.
If the temperature at which thermostat opening

takes place is incorrect, replace the thermostat.
Assembly -Thunderbird, Thunderbird

Sport & Adventurer
1.
Drain the cooling system as described earlier in this

section.
Locate the thermostat into the rear half of the

housing such that the feet of the thermostat align
with the thermostat mounting points in the housing.

skin damage.
3.
Detach all hoses connected to the thermostat

housing and disconnect the fan switch wiring.
4.
Release the 2 screws securing the thermostat

housing to the frame.
Arrowed: Thermostat Mounting Point

2.
Fit a new '0' ring to the front half of the thermostat

housing.
3.
Align the two haves of the thermostat housing so

that the 'nose' of the thermostat aligns with the
central lug in the front half of the housing.
Arrowed: Thermostat Housing to Frame Screws

5.
Separate the 2 halves of the thermostat housing by

releasing the 2 securing screws.
WARNING: The thermostat is spring

loaded. Always wear eye hand and face
protection when disassembling the thermostat
housing as the spring loaded components could
cause injury to unprotected skin and eyes.
6.
Arrowed: Thermostat 'Nose' Mounting Point
Remove the thermostat from the housing.
10.13
10 COOLING SYSTEM
4.
Evenly close the two halves of the thermostat

housing and tighten the retaining screws to 7 Nm.
COOLANT PRESSURE CAP
Inspection
'.'.
CAUTION: Ensure that the thermostat is

correctly seated in both sides of the
housing before tightening the thermostat housing
screws. Damage to the housing and thermostat
will result from an incorrectly seated thermostat.

skin damage.
Ensure that the 0 ring does not become damaged

during assembly. A damaged 0 ring may cause a
coolant leak causing overheating and engine
damage.
1.
5.
Refit the thermostat housing to the frame and

reconnect the fan switch wiring and all coolant
hoses.
6.
Refit the coolant drain plugs.
7.
Refill the cooling system as described earlier in this

section using 50% coolant mixture.
8.
9.


skin damage.
Check condition of the top and bottom seals of the

coolant pressure cap.
1. Lower Seal
2. Upper Seal
3. Spring
NOTE:
If there is any sign of damage or deterioration

replace the cap.
2.
Pressure test the cap to the blow off pressure of 1.1 ,

bar. If the cap opens at a lower pressure or fails to
open at 1.1 bar, replace the cap.
Cap opening pressure: 1.1 bar
10.14
Rear Suspension/Final Drive

CONTENTS
Page
Exploded views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 .2
Rear suspension
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Damping force adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6
11.6
11.7
Rear suspension unit (RSU)

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.8
11.8
Swinging arm
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 .1 0
11.11
11.11
Final drive, engine sprocket

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 .13
11.14
11.14
Final drive, rear sprocket

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.16
11.16
11.16
Rear wheel cush drive

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 .16
11.16
Drive Chain
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.17
11 .17
11.1
11 REAR SUSPENSION/FINAL DRIVE

Rear Suspension: All except Tiger, Thunderbird, Thunderbird Sport and Adventurer
95 Nm
~~.
36 Nm
9Nm
p
95 Nm
~\
\
\
11.2
REAR SUSPENSION/FINAL DRIVE 11

Rear Suspension: Tiger
95Nm
lP
\
j
11.3
I
'

Rear Suspension: Thunderbird, Thunderbird Sport and Adventurer
11.4

Final Drive
7Nm
7Nm
~~ 7Nm
85 Nm
11.5

REAR SUSPENSION
The rear suspension consists of a single spring/damper
unit, actuated by a variable rate linkage system. On Tiger
and Thunderbird Sport models, a remote reservoir is
included in the system to assist suspension damping
characteristics. All parts of the suspension system
contain pressurised gas.
Some models have suspension systems which can be
adjusted for both spring pre-load and rebound damping
characteristics.
WARNING: On Tiger models, the remote

reservoir, hose and rear suspension unit
must never be separated from each other. All parts
of the assembly contain gas under pressure which
could lead to serious injury if any part of the
system is disturbed.
Inspection/Lubrication
1.
Position the motorcycle on level ground in an

upright position.
2.
Examine all suspension pivots for wear and excess

movement.
3.
If excess movement is detected in the swinging arm

bearings, the drag or drop links or in the rear
suspension unit bushes, investigate the cause and
take the necessary remedial action.
4.
Apply correct specification grease to

suspension bearings via the grease nipples.
Suspension Lubrication Point (NOT Tiger)
the
Tiger, Thunderbird, Thunderbird Sport and

Adventurer Suspension Lubrication Points
11.6
REMOTE DAMPING FORCE ADJUSTER (if

fitted)
Installation
1.
Raise the cover on the suspension unit and set the

red mark on the nylon gear in line with detent ball.
2.
Set the adjuster knob between positions 4 and 1.
3.
Fit the adjuster gearwheel ensuring the gears mesh

correctly. Fit the adjuster and cable.
4.
Rotate the adjuster knob through one full revolution

and reset to No.1 position.
5.
Check the that the red mark and detent ball align
with each other. If there is any mismatch, repeat the
adjustment process.
Removal
1.
Set the adjuster to No.1 position.
2.
Release and remove the screws securing the

damping adjuster to the frame.
3.
Release the cable locknut adjacent to the rear

suspension unit.
4.
Remove the damping adjuster from the rear

suspension unit by rotating the adjuster and cable
anti-clockwise. Collect the gearwheel from inside
the cable location.
1
2
3
1. Cover
2. Red Mark
3. Detent Ball
"'
CAUTION:
If there is any mismatch
between the detent ball and red mark,
remove the adjuster, reposition and repeat the
check/adjust procedure.
Damage to the
suspension unit will result from incorrect adjuster
assembly
6.
11.7
Tighten the damping adjuster to the frame mounting

bolts to 7 Nm.
REAR SUSPENSION UNIT (RSU)

Removal
1.
Raise and support the rear of the motorcycle.

Remove the rear bodywork.

falling.
2.
3.
Remove the battery and battery box.
4.
Remove the left hand auxiliary airbox (complete

auxiliary airbox on Thunderbird, Thunderbird Sport
and Adventurer).
1.
2.
3.
4.
5.
Tiger only, remove the fuel tank and fuel tank

mounting bridge (SEE FUEL HANDLING
PRECAUTIONS
IN
THE
GENERAL
INFORMATION SECTION).
On Tiger and Thunderbird Sport, release the
suspension unit reservoir.
12. All except Tiger, Thunderbird, Thunderbird

Sport and Adventurer, lower the rear wheel and
swinging arm to allow the linkage spindle to clear
the exhaust system. Withdraw the spindle and
collect the rear suspension unit.
6.

Adventurer, remove the lower suspension unit
bolt. Lift the swinging arm and carefully remove the
rear suspension unit.
WARNING: On Tiger and Thunderbird

Sport models, the remote reservoir, hose
and rear suspension unit must never be separated
from each other. All parts of the assembly contain
gas under pressure which could lead to serious
injury if any part of the system is disturbed.
7.
Release the remote pre-load adjuster from the

frame (where fitted).
8.
Remove the rebound damping adjuster knob from

the frame (where fitted).
9.
All except Tiger, Thunderbird, Thunderbird

Sport and Adventurer: Loosen the drag link
clamp bolts and release the linkage spindle bolt. Do
not remove the spindle.
Tiger, Thunderbird and Adventurer:
do not remove the lower RSU bolt.
Drag Link Clamp Bolts (where used)

Linkage Spindle Bolt
Splash Guard Bolts
Splash Guard
Release but
10. Remove the bolts securing the splash guard (where

fitted) to the swinging arm.
11. Support the rear wheel and remove the top
suspension unit bolt.
11.8
7.
Installation
1.
On Tiger and Thunderbird Sport, refit the RSU

remote reservoir.
Raise the swinging arm to allow fitment of the rear

suspension unit. Take care to guide the suspension
adjusters and/or RSU reservoir into position during
fitment.
Thunderbird Sport Remote RSU Reservoir
8.
Refit the left hand auxiliary airbox (complete

auxiliary chamber on Thunderbird, Thunderbird
Sport and Adventurer).
Refit the linkage spindle (on Tiger, Thunderbird,

Thunderbird Sport and Adventurer refit the lower
RSU mounting bolt).
9.
Refit the rear bodywork.
3.
Lift the swinging arm and fit a new top mounting bolt
and nut to the rear suspension unit.
11. Reconnect the battery, positive (red) lead first.
4.
Tighten the suspension bolts as follows
Installing the Rear Suspension Unit
2.
Top suspension unit bolt (all)- 95 Nm.
Tiger lower suspension unit bolt- 55 Nm.
T'bird/T'bird Sport & Adv' lower suspension

unit bolt- 55 Nm.
Linkage spindle
bolt
(not
T'bird/Sport/Adv')- 85 Nm.
Spindle clamps (not Tiger or T'bird/Sport/Adv')

-8Nm.
Tiger
or
5.
Where fitted, refit and tighten the splash guard to

swinging arm bolts to 7 Nm.
6.
Refit the pre-load and damping adjusters (where

fitted). Tighten the damping force adjuster screws
to 7 Nm.
11.9
10. Refit the battery box and battery.

SWINGING ARM
9.
Removal
1.
Remove the drop link finishers from the underside

of the swinging arm.
Remove the rear bodywork and chain/wheel guard.

Raise and support the motorcycle to allow removal
of the rear wheel and swinging arm.

. . stabilised and adequately supported to
falling.
2.
On all except Tiger, remove the exhaust silencers.
3.
Disconnect the battery negative (black) lead first.

Remove the battery.
4.
Remove the chain/wheel guard.
5.
Remove the rear wheel as described in the wheel

section.
6.
7.
1. Drop Link Finisher Location

10. On models with a rear brake caliper fitted below the
brake disc, disconnect the brake hose clamp on the
right hand side of the swinging arm.
Release the locknut (early models only) and

capscrew securing the rear brake strut to the
swinging arm. Collect the sleeve from inside the
swinging arm lug and discard the brake strut
capscrew.
11 . Release the locknuts and remove the bolts securing

the splash guard (where fitted) to the swinging arm.
Secure the strut to prevent damage to the brake

hose during the remainder of the procedure.
1. Splash Guard
2. Splash Guard Bolts
3. Drop Link Fixing Location
1. Capscrew
2. Brake Strut
8.
12. Remove the upper drop link bolts and locknuts.
Lightly support the swinging arm.
13. Slacken but do not remove the frame to engine bolts

(not cylinder head to frame bolts).
14. Remove the swinging arm spindle finishers by
releasing the outer ring of capscrews (plastic
blanking plugs on early models).
NOTE:
11.10
'New' Trophy and Sprint Executive, remove

both control plates.
15. Remove the swinging arm spindle retaining rings

(where fitted) from the swinging arm spindle bolts.
Installation
1.
Apply general purpose grease to the swinging arm

bearings.
2.
Apply general purpose grease to the drop link

bearings.
3.
Align the swinging arm to the frame ensuring that

the spacer is correctly positioned at the front edge of
the arm between the linkage carriers, and that the
brake pipe, breather pipes and drive chain are
correctly positioned.
16. Release the swinging arm spindle bolt and washer

(right-hand side) and remove the spindle.
17. Remove the swinging arm from the frame, ensuring
that the swinging arm sleeve remains in position
and the brake pipe and drive chain are protected
from damage.
CAUTION: Always support the drive

chain when the swinging arm is removed.
This will protect the chain from direct contact with
a dusty or dirty surface.
While removing the swinging arm, ensure that the
breather pipes which are situated at the front edge
do not become damaged or trapped.
Inspection
1.
Visually check both drop link and swinging arm

needle bearings for damage. Replace as
necessary.
2.
Inspect the chain rubbing strip, chain slider (Tiger

only) and chain sleeve. Renew parts as necessary.
1. Spacer
4.
Fit the swinging arm spindle using service tool

3880060 to align the bearings, arm and spacer.
When the spindle is fitted, remove the tool and
position a support beneath the swinging arm.
1. Tool 3880060
2. Swinging Arm Spindle
11.11
12. Fit the brake strut sleeve to the swinging arm and
align the strut to the swinging arm. Fit and tighten a
new brake strut bolt to 28 Nm.
WARNING: If the swinging arm is allowed

. . . . to pull on the rear brake hose, however
briefly, the hose MUST be replaced. The damage
caused to the brake hose could lead to reduced
brake performance leading to loss of control and
an accident.
5.
Fit the swinging arm spindle bolt and tighten to 85

Nm. Refit the retaining rings (where fitted) and
finishers/caps.
NOTE:
6.
7.
8.
WARNING: The brake strut bolt has an
~ area of micro-encapsulation which is
'New' Trophy and Sprint Executive, refit both

control plates.
Check for correct positioning of the various breather
and drain pipes and adjust if necessary.
Lubricate the needle roller bearings in the drop links
(bearings fitted in the swinging arm on Tiger,
Thunderbird, Thunderbi.rd Sport and Adventurer).
Align the drop links to the swinging arm and fit the
drop link bolts.
Tighten the drop link bolts to 55 Nm on all except
Adventurer, and 100 Nm on Tiger, Thunderbird,
Thunderbird Sport and Adventurer.
destroyed if the bolt is disturbed. Failure to

replace the bolt could result in an unsafe riding
condition leading to loss of control and an
accident.
13. On models with a rear brake caliper fitted below the
brake disc, align and fit the brake hose clamp on the
right hand side of the swinging arm.
14. Refit the rear wheel and adjust the drive chain
tension and wheel alignment.
bolts or adjuster locknuts may result in impaired

stability and handling of the motorcycle. This
impaired stability and handling may lead to loss of
15. Refit and connect the battery, positive (red) lead
first.
16. Refit the exhaust silencers (if removed).
9.
Refit the drop link finishers (where fitted).
17. Refit the seat, chain/wheel guard and body side

panels.
10. Tighten the frame to engine bolts to 95 Nm.

11. Refit and tighten the splash guard to swinging arm
bolts to 7 Nm (where fitted).
1. Splash Guard
2. Splash Guard Bolts
3. Drop Link Fixing Location
11.12
REAR SUSPENSION/FINAL DRIVE II

Adventurer: Remove the gearchange pedal and
the left hand footrest and control plate.
FINAL DRIVE, ENGINE SPROCKET

Removal
1.
4.
Remove the rear bodywork and chain/wheel

guard. Support the motorcycle on the centre
stand or on a paddock stand.
NOTE:

falling.
2.
Drain the engine oil into a suitable container.
On Thunderbird and Adventurer, proceed to

item 9. Thunderbird Sport proceed to item 8.
5.
Release and remove the capscrew from the

sidestand pivot bracket. On Tiger, remove the
sump guard fixing.
6.
Release and remove the frame to engine bolt, nut

and boss (boss fitted to early models only) which
secures the pivot bracket to the frame.
7.
Remove the side stand assembly taking care not to

place undue stress on side stand switch cable.
8.
Release the clamp bolt securing the gearchange

linkage to the gear change shaft. Remove the
linkage.
9.
Remove the water pump hose cover (if fitted).
WARNING: The engine oil may be hot and
~ will cause a scald if in contact with the

skin. Avoid skin contact with used engine oil and
always follow the advice given in the general
information section on skin care and contact with
used engine oil.
3.
Lower the side stand.
On all except Thunderbird and Adventurer:

Release the two locknuts (if fitted) on the gear
change actuating rod. If a clevis pin and clip are
fitted at the gear-pedal end of the actuating rod,
release the clip and withdraw the clevis pin. Detach
the rod by either unscrewing in a clockwise direction
(locknut type) or by lowering the rod once the clevis
pin has been removed.
10. Release the three bolts securing the clutch slave

cylinder to the sprocket cover. Detach the slave
cylinder.
NOTE: To ensure that the piston does not

accidentally become detached from the slave
cylinder, retain the piston with a strong elastic
band.
'!'
CAUTION: To prevent paint and body

damage, ensure that any displaced
clutch fluid does not come into contact with any
part of the engine or bodywork.
1.
2.
3.
4.
5.
6.
7.
8.
Gear Rod Locknuts

Gearchange Rod
Sidestand Bracket Capscrew
Sidestand Bracket
Frame To Engine Bolt
Side Stand
Gearchange Clamp
Clutch Slave Cylinder

2. Retaining Band
3. Clutch Pushrod
11.13
II REAR SUSPENSION/FINAL DRIVE
11. Withdraw the clutch push rod from the sprocket

cover.
12. Place a suitable container beneath the sprocket
cover.
Installation
1.
13. Progressively release the bolts securing the

sprocket cover to the crankcase.
Clean the gearbox output shaft and support the

drive chain while fitting the sprocket. Also fit a new
lock washer to the shaft. Fit the chain to the
sprocket.
14. Remove the sprocket cover and discard the gasket.

15. Check the condition of all displaced component
parts especially the push rod seal and the slave
cylinder seal. Replace as necessary.
16. Release the lock tabs from the output sprocket nut.
17. Depress the rear brake pedal to lock rear wheel.
18. Remove the nut and lock washer from the output
sprocket.
19. Release the drive chain adjusters to allow
maximum free movement in the chain. Support the
chain to allow release of the drive sprocket and
remove the sprocket.
Inspection
1. Unbent Tab
2. Tab (locked)
3. Lock Washer
1.
Examine all sprocket teeth for wear.
NOTE:
2.
Examine the side rubbers for signs of deterioration.
The sprocket can be fitted either way round
3.
Check the sleeve and seal for corrosion or damage.

Replace as necessary.
2.
Depress the rear brake pedal to lock rear wheel.

Tighten the output sprocket nut to 132 Nm. Bend
over the locktab in two places to secure the sprocket
nut.
3.
Remove all dirt from the sprocket cover using a

suitable cleaning agent. Fit a new oil seal to the
gearchange shaft hole in the sprocket cover.
4.
Apply a small amount of grease to the top right-hand

corner of a new sprocket cover gasket. This will help
retain the gasket during assembly.
5.
Fit the gasket to the crankcase.
NOTE:
When cleaning the sprocket cover area, seal the

two oil holes and the clutch pushrod hole with
plugs to avoid cleaning fluid entering
crankcase. Remove the seals after cleaning.
1. Drive Sprocket
2. Oil Holes
11.14
6.
Ensure the sprocket cover locating dowels are in

place, then fit sprocket cover.
10. Fit the gear change clamp in a vertical position and

tighten the pinch bolt to 9 Nm.
NOTE:
Tape over the gear change rod splines to

prevent damage to the seal lip when fitting the
sprocket cover.
Ensure Gear Linkage Arrowed is Fitted Vertically
Tape splines to prevent damage
7.
8.
Remove the tape from the shaft when the cover is

correctly located and tighten the sprocket cover
bolts to 12 Nm.
Remove the rubber band from the clutch slave
cylinder and fit the clutch pushrod through the
crankcase. Fit the clutch slave cylinder and tighten
the bolts to 12 Nm.
NOTE:
On Thunderbird and Adventurer, proceed to

item 12.
9.
Refit the water pump hose cover (if fitted).
11. Refit the side stand and bracket. Tighten the

sidestand upper fixing to 22 Nm (27 Nm on Tiger)
and the centre bolt to 95 Nm.
On Tiger, tighten the sump guard to side stand
bracket fixing to 27 Nm.
12. On all except Thunderbird and Adventurer: Fit
the gear change actuating rod/clevis pin to the
pedal/linkage. Adjust the pedal height to suit the
individual rider by turning the turn buckle or rod.
Tighten the linkage locknut(s) to 9 Nm.
On Thunderbird and Adventurer:
Refit the
gearchange pedal tightening the clamp bolt to 9
Nm. Refit the left hand control plate tightening the
fixings to 45 Nm (M1 0 capscrew) and 30 Nm (M8
capscrew).
13. Refill the engine with the correct grade of engine oil.
14. Check and adjust the chain slack and rear wheel
alignment as described in the maintenance section.

with insecure eccentric adjuster clamp
bolts or adjuster locknuts may result in impaired
stability and handling of the motorcycle. This
impaired stability and handling may lead to loss of
15. Refit the wheel/chain guard and rear bodywork.
1.
2.
3.
4.
5.

Retaining Bolt
Washer
11.15
FINAL DRIVE, REAR SPROCKET
REAR WHEEL CUSH DRIVE
Removal
Removal
1.
1.

section.
2.
Lay the wheel on one side with the drive sprocket

facing upwards.

section.

falling.
2.
Lay the wheel on one side with the drive sprocket

facing upwards.
CAUTION: Do not allow the wheel to rest

on the brake disc as this may damage the
disc. Support the wheel on wooden blocks,
equally spaced around the rim, such that the brake
disc is raised above the ground.
3.

on the brake disc as this may damage the
3.
Lift out the sprocket complete with carrier.
4.
Remove the cush rubbers from the cush drive

housing in the wheel.
Remove the sprocket from the wheel by releasing

the ring of sprocket securing nuts.
Inspection
1.
Inspect the gear teeth for signs of excessive wear

and any cracking. Renew as necessary.
Worn Tooth
(Engine Sprocket)
Worn Tooth
(Rear Sprocket)
Cush Drive Assembly
Inspection
Installation
1.
Clean the rear wheel to sprocket location and fit the

sprocket with the recess facing outwards.
WARNING: The sprocket MUST be fitted

with the recess (and number of teeth
stamp) facing outwards. Chain disengagement
could result from incorrect fitment of the chain
sprocket leading to loss of control or an accident.
1.
Examine cush
deterioration.
rubbers
2.
Renew the rubbers as a set.
for
cracking
and
Assembly
1.
2.
Locate and tighten the sprocket retaining nuts to 85

Nm.
3.
Refit the rear wheel.
11.16
Assembly is a reversal of the removal procedure.
DRIVE CHAIN
Replacement
Removal
NOTE:
NOTE:
The following procedure describes the fitment

of a replacement chain using a split link. If the
replacement chain to be fitted is a 'continuous'
type, removal of the swinging arm and sprocket
cover is necessary (as described earlier in this
section).
The replacement chain is supplied in a 'split'

condition, complete with a link kit to join the
two ends.
WARNING: Throughout this operation,

ensure that the motorcycle is stabilised
and adequately supported on a paddock stand to
prevent risk of injury from the motorcycle falling.
1.
Raise the rear of the motorcycle and securely

support with the rear wheel clear of the ground.
2.
Remove any convenient chain link pin using the

chain splitter tool as follows:
Unscrew the knurled knob to withdraw the arbor as

far as possible, and unscrew the pin punch until the
link pin extractor is fully withdrawn.
Position the tool over the chain link pin to be

extracted, and turn the knurled knob clockwise to
move the arbor inwards until the chain link is
supported. Check that the chain lies squarely in the
tool and the extractor aligns with the pin to be
removed.
CAUTION: The component parts of the

new link kit are coated with a special
grease which must not be removed. Removal of
this special grease will severely reduce the service
life of the chain.
1.
Use the old drive chain to pull the new chain into
position as follows:
NOTE:
2.
3.
Do not use the new connector link as the special

grease on it may be removed.
Temporarily attach the end of the new chain to a free
end of the old chain using an old connector link.
Carefully pull the other end of the old chain to pull
the new chain around the sprockets.
Disconnect the two chains. Turn the chain and the
rear wheel until the ends of the chain are in a
convenient working position.
1. Pin punch
2. Arbor
5
Turn the pin punch clockwise, and continue to turn

with the aid of a suitably sized spanner until the link
pin has been pushed out of its link.
Remove the tool and separate the two ends of the
chain.
Link kit
1. '0' rings (4)
2. Connector link
3. Side plate
11.17
CAUTION: Always hold the connector

link by its plate, NOT by the pins. The
special grease on the pins must not be disturbed.
Removal of the special grease will severely reduce
the service life of the chain.
4
Fit two of the '0' rings onto the inboard (nearest the
wheel) side of the links to be joined, and fit the
connector link from the same side without
disturbing the '0' rings.
5.
Fit the other two '0' rings on the outboard side of the
links (side nearest the exhaust).
8.
Remove the tool.
9.
Use the riveting tool to secure the side plate as

follows:
1. Slide
2.Punch
WARNING: To prevent risk of injury, do

not place fingers or hands inside the
slide. The slide is spring loaded and will cause
injury to fingers or hands which become trapped
inside the slide.
10. Pull back the slide on the riveting tool and position
the tool over one of the two pins to be secured.
Release the slide.
11. Use a hammer to apply a sharp blow to the tool
punch 4 times. Rotate the punch by 45 between
each blow.
Ensure arbor plate is fitted
Fitting side plate

6.
Retract the threaded arbor of the side plate installer

tool as far as it will go and place the arbor plate over
the chain location pin. Fit the side plate into the
arbor and position the tool over the chain link to be
connected.
CAUTION: Fitting the side plate without

the arbor plate present will cause damage
to the chain link resulting in premature failure of
the chain.
7.
Turn the threaded arbor clockwise to press the side

plate onto the connector link pins. The tool will not
allow the plate to be fitted too deeply as a stop
mechanism is incorporated in the tool to prevent
incorrect fitment. Turn the threaded arbor as far as
it will go without excessive force.
11.18
12. Remove the tool and examine the end of the link
pin to check that is has been securely riveted over.
13. Repeat the riveting operation with the second link
pin.
20. Check that the links can rotate freely around the
pins. If not, the link just fitted must be removed and
discarded and a new link fitted.
Correctly rivetted link

21. Adjust the drive chain tension and rear wheel
alignment.
22. Lower the motorcycle to the ground.
11.19
Front Suspension/Steering
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2
Front suspension
Front fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.6
Front fork
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil level chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fork Pull Through Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fork Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fork Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7
12.8
12.9
12.10
12.11
Fork Overhaul - Kayaba non adjustable forks

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.12
12.12
Fork Overhaul- Showa non adjustable forks

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly.....................................................
12.14
12.14
Fork Overhaul - Kayaba adjustable forks

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.16
12.17
Headstock bearings
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation ............... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.19
12.21
12.22
12.1
12 FRONT SUSPENSION/STEERING
Torque Figures - Trophy, Trident & Sprint

~
65Nm~~
4 Nm
/20Nm
~~4~
~\
\
22 Nm
~20Nm
65 Nm
"~
12.2
60 Nm
FRONT SUSPENSION/STEERING 12
Torque Figures - Daytona, Daytona Super

3 and Speed Triple
65N~
<>
../20Nm
':
0
~~40Nm
~\
22 Nm
~20Nm
(\)
~8Nm
65 Nm
\
'
\
'
t \\~: ~
\
15 Nm
G
~
ev- /
'
/20Nm
~
L>
20 Nm
,,
~
. t----40Nm
12.3
Torque Figures - Tiger
65 Nm
23 Nm
I
I
I
8Nm
I
I
'\
40Nm
~
I
I
<11
60Nm ~
12.4
tJ lliQ:v
22 Nm
Torque Figures -Thunderbird,

65Nm--Q
@!
20 Nm
'
~8 Nm
-~ 20 Nm
';
/'\
\_/
23Nm--e
aL--
u\
I
I
---\Gl
25 Nm----1
\
\
20Nm
\
~
~
$
35 Nm
'
\
\
~ ,~20Nm
'
_\
0
[')
~"
/20 Nm
-,~~
20Nm~
(43 Nm Sport)
12.5
FRONT SUSPENSION
All models are equipped with hydraulic, telescopic front
forks some of which are adjustable depending on the
type fitted. A gaiter is fitted to Tiger forks. Periodic
inspection for damage and fluid leaks is essential for safe
riding. Always follow the inspection instructions at the
intervals stated in the Periodic Maintenance chart.
FORK INSPECTION- ALL MODELS

1.
Lift each fork gaiter (Tiger only) from the lower end.
2.
Visually inspect the fork inner tube assembly for rust

and damage. Repair or replace as necessary.
3.
Visually inspect the dust/oil seal areas for signs of

damage and fluid leaks. If oil leaks are found, the
fork must be stripped and overhauled or replaced
completely.
4.
Refit the gaiter (Tiger only) when the visual

inspection is complete.
5.
Check for smooth operation of the forks as follows:
Place the motorcycle on level ground
While holding the handlebars and applying the

front brake, pump the forks up and down
several times.
12.6
WARNING: If roughness or excessive

stiffness is detected, investigate the
cause and take the necessary remedial action
before riding the motorcycle.
Riding the motorcycle with defective or damaged
suspension can damage the motorcycle, cause
loss of control, or an accident.
WARNING: All suspension units contain

pressurised gas. Always wear eye, face
and skin protection during fork disassembly.
NOTE:
The suspension movement will be affected by

any changes to the suspension adjustments.
NOTE:
FORK OIL
Oil change
1.
Remove the fork assembly as described later in this

section.
Zero level on the tool is set at the small exit hole

in the side of the scale tube, NOT AT THE END
TIP. Do not attempt to block this side hole as
this will cause the final fluid level to be
incorrect.
NOTE:
2.
To aid removal, slacken but do not remove the

top cap before releasing the fork from the yoke.
Remove the fork top cap, washer, spacer and fork
spring.
Zero level measured from oil hole

Set dimension 'A' to the required oil level
WARNING: The fork cap will spring clear

due to spring tension. To prevent injury,
always wear eye, face and hand protection when
removing spring loaded items.
3.
Invert the fork assembly and allow the oil to drain

into a suitable container.
4.
Fill the fork with the grade of oil specified in the table
to a level above that which will finally be required.
5.
Set the scale on tool 3880160 to the level specified

for the model being worked on (see table to the
right/below for the correct level setting).
Plate arrowed must

be level with fork slider
1.
2.
3.
4.
6.
1. Fork Oil Level Setting (fork fully compressed}
Tool 3880160
Adjustment Plate
Scale Area
Hole (zero position}
WARNING:
Incorrect tool adjustment
and/or failure to keep the tool level with
the fork slider will affect the final fluid level setting.
Incorrect fork oil levels could result in an unsafe
riding condition leading to Joss of control and an
accident.
Operate the fork several times to expel any trapped

air from the valves, then fully compress the fork.
Insert the scale end of the tool into the fork slider.
Hold the tool adjuster plate level with the upper
surface of the fork slider and draw fluid into the
syringe until fluid flow ceases (empty the syringe if
the body becomes full before fluid flow stops). The
fluid level in the fork is now set to the height set on
the tool scale. Check the tool scale setting and
repeat the process if incorrectly set. When the
correct level has been set, fit and assemble the
spring, spacer-washer and cap to the fork. Refit the
fork.
12.7
FORK OIL LEVEL CHART
Model
Oil Grade
Oil Level (std)
Oil Level (max)
Trophy 1200 to VIN 4901
SAE10
103 mm
103 mm
Trophy 900 to VIN 4901
SAE10
84mm
84mm
Trophy 900 & 1200 from VIN 4902 to 9082
SAE10
117 mm
102 mm
SAE15
117mm
102 mm
SAE10
105 mm
105 mm
SAE 10w-20
133 mm
133 mm
Daytona 750 (All)
SAE10
139 mm
139 mm
Daytona 1200, 1000, 900 to VIN 9082
SAE 5
132 mm
132 mm
Daytona 1200, 900, Super 3 from VIN 9083 to 29155
SAE 5
139 mm
132 mm
SAE 5
128 mm
128 mm
SAE 5
139 mm
132 mm
Daytona 1200, 900, Super 3 from VIN 36446
SAE 5
128 mm
128 mm
Sprint 900 to VIN 7491
SAE10
109 mm
97 mm
Sprint 900 from VI N 7492 to 11541
SAE10
117 mm
102 mm
Sprint 900 from VIN 11542
SAE15
117 mm
102 mm
Trident 900 & 750 to VIN 4901
SAE10
94mm
94mm
Trident 900 & 750 from VIN 4902 to VIN 44301
SAE10
109 mm
97 mm
SAE 10w-20
141 mm
141 mm
SAE10
130 mm
130 mm
SAE 10w-20
144 mm
144 mm
900 Speed Triple to VIN 29155
SAE10
141 mm
141 mm
900 Speed Triple from VIN 29156
SAE10
130 mm
130 mm
750 Speed Triple
SAE10
141 mm
141 mm
Thunderbird & Adventurer to VIN 43509
SAE 15
109 mm
109 mm
SAE 10w-20
126 mm
126 mm
SAE 5
145 mm
145 mm
Sprint Executive
SAE10
117 mm
117 mm
Sprint Sport
SAE 5
139 mm
139 mm
Trophy 900 and 1200 from VIN 42275
Trident 900 & 750 from VIN 44302

Tiger 900 to VIN 43523
Tiger 900 from VIN 43524
Thunderbird & Adventurer from VIN 43510

Thunderbird Sport
NOTE: All figures with fork fully compressed and fork spring removed.
A
t
WARNING: Any variation in fork oil level from the figures quoted above could result in an unsafe
riding condition leading to loss of control and an accident.
= Column identifies supplier of fork.
K = Kayaba supplied fork

S = Showa supplied fork
12.8
FORK'PULLTHROUGH'CHART
Model
Fork 'Pull Through' Dimension (Dimension 3 below)
Trophy to VIN 29155
25mm above top yoke face
Trophy from VIN 29156
Daytona, Daytona Super 3 &

Speed Triple to VIN 29155
Daytona, Daytona Super 3 &

Speed Triple from VIN 29156
Flush with top yoke face
Sprint to VIN 29155
Sprint from VIN 29156
Trident to VIN 29155
Trident from VIN 29156
Tiger
Thunderbird
Thunderbird Sport
Adventurer
r 1 Tl
1. Fork
2. Top Yoke
3. Pull Through
Measurement
2~
{ 1
J
J.
I
~
1y
12.9
I@
FRONT FORK
Tiger Mudguard
Removal
1. Remove all facia panels (where fitted).
2. Raise the motorcycle sufficient to remove the front
wheel.

falling.
1. Internal Mudguard Screws

2. External Mudguard And Fork Cover Screws
3. Fork Cover Screws
3. Detach the brake caliper(s) without disturbing the

brake hydraulics.
WARNING: Do not allow the calipers to

hang on the brake hoses as this may
damage the hoses and could lead to an accident.
4. Remove front wheel as described in the wheel

section.
5. Remove front mudguard taking care not to damage
the painted surfaces.
2
Later
Trophy
Mudguard
1. Mudguard to Fork Screws
2. Front to Rear Section Screws
6. Slacken all bottom yoke clamp bolts (either side).

7. Slacken but do not remove both master cylinder
clamps (not Tiger, Thunderbird, Thunderbird Sport
or Adventurer).
8. Rotate each master cylinder assembly to allow
access to the top yoke clamp bolts (not Tiger,
Thunderbird, Thunderbird Sport or Adventurer).
1. Calipers
2. Mudguard retaining screws
~------------------------,
WARNING: Do not invert either master
~ cylinder as this will introduce air into the
brake and clutch systems and may also cause

brake fluid to damage the bodywork.
A dangerous riding condition leading to loss of
control or an accident could result if this warning
is ignored.
9. Remove the top yoke cover (where fitted) and

slacken the top yoke clamp bolts.
Thunderbird, Thunderbird Sport & Adventurer
Mudguard mountings
12.10
NOTE:
Fork Installation
If the fork is to be stripped, slacken the top cap

before releasing the top yoke clamp bolts
10. On models with 'clip-on' handlebars, slacken the
handlebar mounting bolts.
1.
Position the forks in the yokes and adjust the fork

'pull through' height in line with the chart.
2.
When the correct 'pull through' dimension is

reached, tighten the top and bottom yoke bolts to
the following torque figures.
11. Using a downward twisting motion withdraw each

fork in turn.
Top yoke bolts . . . . . . 20

18
Bottom yoke bolts . . 20
22
12.11
Nm
Nm
Nm
Nm
(all except Tiger)

(Tiger)
(all except Tiger)
(Tiger)
3.
On models with 'clip-on handlebars', tighten the

handlebar mounting bolts to 22 Nm .
4.
Refit the top yoke cover (where originally fitted).
5.
Align the master cylinder/clamp split line with the

dot mark on the handlebar and tighten the master
cylinder fixings, upper first and then the lower to 15
Nm.
6.
Refit the front mudguard and on Tiger, the fork

covers.
7.
Refit the front wheel as described in the wheel

section.
8.
Align the brake caliper(s) to the forks and tighten the

caliper mounting bolts to:
40 Nm (all except Thunderbird, Thunderbird
Sport and Adventurer)
28 Nm (Thunderbird, Thunderbird Sport and
Adventurer).
9.
Where necessary, refit the facia panels and check

the brakes for correct operation.
Rectify as
necessary.
10. Hold the inner cylinder with the engaged tool and
remove the capscrew (6) situated in the outside
base of the outer tube.
FORK DISASSEMBLY/ASSEMBLY
Kayaba Non-adjustable Forks
1.
11 . Remove and discard the copper sealing washer (7)

from the capscrew (6).
Clamp the fork outer tube in a soft jawed vice, taking

care not to mark or damage the caliper mounting
bosses. On Tiger models, remove the fork gaiter.
12. Remove the tube from the vice. Remove the

service tool, invert the assembly and collect the
damping cylinder (8), rebound spring (17) and any
excess oil. Remove and discard the piston ring (16).
1,\
CAUTION: Use the caliper mounting

points to secure the outer tube in the vice.
Never clamp directly onto the tube itself as this will
cause the tube to distort beyond repair.
13. Remove the wire circlip (9) from the inside lip of the
outer tube.
-----~----------
2.
Unscrew the fork cap cap (1 ).
14. Pull sharply upwards on the inner tube until the seal
(13) washer (10) and bushes (14) become
dislodged from the outer tube.

_.a
15. Separate the inner and outer fork tubes (11 and 12).
Invert the outer tube and collect the oil lock (15).
Inspection
3.
Remove the spacer tube (2).
4.
Remove the assembly from the vice and while

keeping the assembly vertical, slide the inner tube
down into the outer tube.
1.
Examine all components for damage through

scoring, scratching etc.
2.
Examine the bushes for excessive wear.
5.
Remove the spring (3) and spring guide (4).
3.
Always renew the oil seal, piston ring and dust seal.
6.
Pour the fork oil into a suitable container.
7.
Using a small lever, gently prise the dust seal (5)

from the outer tube.
8.
Clamp the assembly horizontally in a vice, taking

bosses.
9.
Slide the hexagonal end of service tool 3880090

down the inner tube and turn until a positive
engagement is felt in the cylinder.
Assembly
WARNING: The front fork consists of

. . . many
precision
machined
parts.
Rebuilding must take place in a dirt/dust free
environment.
Dirt ingress may cause damage to the fork parts
leading to instability, loss of control or an accident.
1.
Slide the bushes (14) and washer (10) onto the

inner tube.
1,\
CAUTION:
Do not over expand the
bushes while fitting over the inner tube.
Permanent bush damage will result from ANY over
expansion of the bushes.
2.
Clamp the outer tube (12) horizontally in a vice

taking care not to mark or damage the caliper
mounting bosses.
3.
Insert the oil lock (15) into the lower end of the outer
fork tube (11) with the thinner wall of the oil lock
uppermost.
NOTE:
1. Spanner
2. Allen Key
3.Tool3880090
Use a clean rod to guide the oil lock into place.

Do not use force as this will damage the oil lock.
4.
Locate the inner tube (11) into the outer tube (12).
12.12
1_ _.~
2-0
4
5.
Fit a new plastic piston ring (16) into the groove on

the damping cylinder (8).
6.
Slide the rebound spring (17) onto the damping

cylinder (8) and carefully locate the cylinder
assembly into the outer tube.
7.
Fit a new sealing washer (7) to the capscrew (6) and

refit special tool 3880090 to the cylinder. Prevent
the cylinder from turning using the inserted tool and
tighten the capscrew at the base of the outer tube to
60 Nm (all except Thunderbird, Thunderbird
Sport and Adventurer)
20 Nm (Thunderbird, and Adventurer)
43 Nm (Thunderbird Sport)
8.
Slide the bush (14) into position in the inner tube

and fit the washer (1 0) above the bush. Using the
square faced end of tool 3880080, drift the bush and
washer fully home in the outer tube.
~5
c:r----9
@)--13
16--~
---_10
a.___14
17
'-----12
11---a
~I
1.Tool3880080
2. Outer Tube
3. Inner Tube
9.
Lubricate a new oil seal (13) and locate over the
inner tube. Using the recessed end of tool 3880080,
drift home the seal. Fit a new wire circlip (9).
~6
10. Lubricate a new dust seal (5) and press into position
over the oil seal and circlip.
11. Add oil to the assembly and operate the inner tube
several times to expel air. Check for smooth
operation and rectify as necessary.
1. Fork Cap
2. Spacer Tube
3. Spring
4. Spring Guide
5. Dust Seal
6. Capscrew
7. Sealing Washer
8. Damping Cylinder
9. Wire Circlip
10. Washer
11. Inner Tube
12. Outer Tube
13. Oil Seal
14. Bushes
15. Oil Lock
16. Piston Ring
17. Rebound Spring
12. Add oil to the correct level as described in the fork

level checking procedure.
13. Fit a new '0' ring to the cap (1). Fit the spring (3),
spring guide (4), spacer tube (2) and cap ( 1) to the
inner tube. Tighten the cap to 23 Nm.
12.13
9.
Showa Non-adjustable Forks
1.
10. Remove the damping cylinder capscrew (6) and

discard the copper sealing washer (7).
Clamp the fork outer tube in a soft jawed vice, taking

bosses. On Tiger models, remove the fork gaiter.
12. Remove the fork from the vice, invert the assembly
and collect the damping cylinder (8), rebound
spring (17) and any excess oil. Remove and discard
the piston ring (16).

2.

bosses.
outer tube.
Release the damping cylinder bolt (6) from the base

of the fork, then lightly re-tighten to prevent oil from
escaping.
(13) washer (1 0) and bushes (14) become
15. Separate the inner and outer fork tubes (11 and 12).
Invert the outer tube and collect the oil lock (15).
Inspection

2.
3.
Always renew the oil seal, piston ring and dust seal.
Assembly
galb

many
precision
machined
parts.
environment.
1. Damping cylinder bolt

2. Damping cylinder
3.
1.

Unscrew the fork cap cap (1 ).
1.

~ due to spring tension. To prevent injury,
Slide the bushes (14) and washer (1 0) onto the

inner tube.
CAUTION:
expansion of the bushes.
4.
Remove the spacer tube (2).
5.
Remove the assembly from the vice and while

keeping the assembly vertical, slide the inner tube
down into the outer tube.
6.
Remove the spring (3) and spring guide (4).
7.
Pour the fork oil into a suitable container.
8.
Using a small lever, gently prise the dust seal (5)

from the outer tube.
2.
Clamp the outer tube (12) horizontally in a vice

taking care not to mark or damage the caliper
mounting bosses.
3.
Insert the oil lock (15) into the lower end of the outer
fork tube (11) with the thinner wall of the oil lock
uppermost.
NOTE:
12.14
Use a clean rod to guide the oil lock into place.

Do not use force as this will damage the oil lock.
4--~e::.J
~5
o---9
(}--13
16-----C>
4.
Locate the inner tube (11) into the outer tube (12).
5.
Fit a new plastic piston ring (16) into the groove on

the damping cylinder (8).
6.
Slide the rebound spring (17) onto the damping

cylinder (8) and carefully locate the cylinder
assembly into the outer tube.
7.
Fit a new sealing washer (7) to the capscrew (6) and

refit, hand tight, back into the base of the fork.
8.
Slide the bush (14) into position in the inner tube

and locate the washer (1 0) above the bush. Using
the square faced end of tool 3880080, drift the bush
and washer fully home in the outer tube.
---_10
8-__14
17
~-----12
11---o
I'\ I
C>
8--_6
1. Tool 3880080
2. Outer Tube
3. Inner Tube
9.
Lubricate a new oil seal (13) and locate over the
inner tube. Using the recessed end of tool 3880080,
drift home the seal.
10. Fit a new wire circlip (9).
11. Lubricate a new dust seal (5) and press into position
over the oil seal and circlip.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
12. Add oil to the assembly and operate the inner tube
several times to expel air. Check for smooth
operation and rectify as necessary.
Fork Cap
Spacer Tube
Spring
Spring Guide
Dust Seal
Capscrew
Sealing Washer
Damping Cylinder
Wire Circlip
Washer
Inner Tube
Outer Tube
Oil Seal
Bushes
Oil Lock
Piston Ring
Rebound Spring
13. Add oil to the correct level as described in the fork

level checking procedure.
14. Fit a new '0' ring to the cap (1 ). Fit the spring (3),
spring guide (4), spacer tube (2) and cap (1) to the
inner- tube. Tighten the cap to 23 Nm.
15. Tighten the damping cylinder screw in the base of
the fork to 40 Nm.
12.15
7.
Drain the oil from the assembly into a suitable

container.
Kayaba Adjustable Forks
8.

bosses.
9.
Slide the square end of service tool 3880090 down

the inner tube and turn until a positive engagement
is felt in the inner cylinder.
1.
Clamp the outer tube in a soft jawed vice, taking

bosses.

2.
Unscrew the top cap (1 ).
3.
While holding the assembly vertical, slide the inner

tube (3) fully into the outer.
4.
Slide a spanner above the guide washer (5) onto the

locknut (6). Release the locknut and unscrew the
pre-load adjuster to release the top cap assembly.
1. Spanner
2. Allen Key
3. Tool 3880090 (use square end inset)
10. Hold the inner cylinder with the engaged tool and
remove the capscrew (9) situated in the outside
base of the outer tube.
11.
Remove and discard the copper sealing washer

(1 0) from the capscrew (9).
12. Remove the tool and collect the damping cylinder

(8). Drain excess oil by inverting fork.
1. Spanner
2. Guide Washer
3. Adjuster Assembly
outer tube.
5.
(13), washer (14) and upper bush (15) become
Remove the spanner from the locknut and unscrew

the locknut from the threaded rod. Collect the guide
washer (5) and spring (4).
15. Separate inner and outer fork tubes and remove the
lower bush (15). Invert the outer tube and collect
the oil lock (16).

6.
NOTE:
Remove the centre adjusting rod (7) from the

damping rod (8) by sliding the rod upwards. Also
remove the dust seal (11 ).
12.16
The rebound spring cannot be separated from

the inner tube as it is crimped into place.
Inspection
1.

2.
3.
Always renew the oil and dust seals.
Assembly

many
precision
machined
parts.
environment.
6
7

1. Locate the oil lock (16) into the outer tube with the
larger diameter to the bottom.
-D
~13
15~
16---e
'
t...-'
2.
o--11
CJ--12
~14
15
Refit the bushes (15) onto the inner tube.
1:\.
CAUTION:
Iexpansion of the bushes.
,, ~
3.
Slide the inner tube (3) into the outer tube. Locate
the cylinder (8) into the inner tube.
4.
Fit the washer (14) into the recess above the top
bush. Using the square faced end of tool 3880080,
drift the top bush into place in the outer tube.
_ /'
~I
~10
i-- 9
8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Top Cap
'0' ring
Inner tube
Spring
Spring Guide
Locknut
Adjuster Rod
Damping Cylinder
Capscrew
Sealing Washer
Dust Seal
Wire Circlip
Oil Seal
Oil Seal Washer
Bush
Oil Lock
1. Tool3880080
2. Outer Tube
3. Inner Tube
5.
Lubricate and fit a new oil seal (13) to the inner tube
and using the recessed end of tool 3880080, drift
home the seal. Fit a new wire circlip (12).
6.
Lubricate and fit a new dust seal (11 ).
12.17
7.
Refit tool3880090 and fit a new copper washer (10)

to the capscrew (9). Engage the tool into the
damping rod and tighten the capscrew in the base of
the outer cylinder to 43 Nm. Withdraw the tool.
13. Renew the top cap '0' ring (2) and refit the top
cap/adjuster assembly (1 ). While holding the
locknut, tighten the adjuster assembly to the locknut
to 15Nm.
8.
Add oil to the fork and work several times to expel

air. Check for smooth operation and rectify as
necessary. Adjust the oil level to the specified
setting. Refer to the oil level chart earlier in this
section for details of the correct oil level setting.
NOTE:
9.
Lift the damping cylinder using tool 3880085 by

engaging the tool thread in the top of the cylinder.
Ensure that the locknut and cylinder do not

rotate during tightening of the adjuster. Repeat
the adjustment procedure in paragraph 11 if
rotation occurs.
14. Locate the top cap to the inner tube and tighten to
23Nm.
15. Reset the rebound, compression and spring
pre-load adjustments to the desired settings.
WARNING: Ensure that the adjusters are

. . . . set to the same settings on both fork
stanchions.
Settings which vary from left to right hand
stanchions may affect handling and stability
leading to loss of control, or an accident.
1. Tool 3880085
2. Damping Cylinder
3. Inner Tube
10. Refit the spring (4), guide washer (5) and locknut
(6).
11. Compress the spring and adjust the position of the
locknut to give 11.0 mm of damping cylinder thread
showing above the locknut.
1. Spring
2. Locknut
12. Assemble the adjuster rod (7) to the inside of the
damping cylinder.
12.18
6.
HEADSTOCK BEARING ADJUSTMENT
Adjust the headstock bearing by moving the

adjusting nut, clockwise to take out play/increase
pre-load, or anticlockwise to add play/decrease
pre-load. Correct adjustment is reached when the
bearing play is eliminated without pre-loading the
bearings.
Early (1991) Trophy, Trident and Daytona

Models
NOTE: Early models were fitted with an adjuster

which was retained with a pinch bolt. This
adjuster has been superseded by a nut and
locknut method. It is possible to fit the later
adjusters (as a pair) to earlier models. For
details of the adjustment method for models
fitted with the later adjusters, refer to the
following page.
1.
2.

upright position.
3
1. Domed Nut
2. Pinch Bolt
3. Adjuster Nut

falling.
1,\

3.
Slacken but do not remove both master cylinder

clamps. Rotate each master cylinder to allow
access to the top yoke pinch bolts.

cylinder as this will introduce air into the
is ignored.
4.
If necessary for access reasons, remove the

instruments. Reduce the load on the top yoke by
slackening the clamp bolts at the top of the forks.
7.
Tighten the adjuster pinch bolt to 7 Nm.
8.
Tighten the yoke clamp bolts to 20 Nm. Refit the

instruments if previously removed.
9.
Tighten the domed nut in the centre of the top yoke

to 65 Nm.
10. Align the master cylinder/clamp split lines with the

dot marks on the handlebars and tighten the master
cylinder fixings, upper first and then the lower to 15
Nm.
11. Check that the steering will fall to either lock from
the centre position without undue effort.
If
excessive effort is required or the steering feels tight
or notchy, it is likely that the bearings have been
pre-loaded and the adjustment procedure should
be repeated until correct. Similarly, if free-play (end
float) is still present in the bearings, then the
adjustment should be repeated until the correct
setting is reached. If all the free-play (end float)
cannot be eliminated, the bearings have been worn
beyond their service limit and must be replaced.
NOTE:
A true check can only be made when all fixings

are correctly torqued.

adjusted, worn or damaged steering head
1. Clamp Bolt
5. . Release the pinch bolt on the adjusting nut using
service tool 3880130. Slacken the domed nut in the
centre of the top yoke.
12.19
12. Remove all supports and lower the motorcycle to

the ground. Support the motorcycle on either the
side or centre stand.
HEADSTOCK BEARING ADJUSTMENT

All Models built from 1992 onwards
1.

upright position.
2.


falling.
.-----------
1. Service tools 3880140
--------------------.
A.
~

7.
Tighten the yoke clamp bolts to the following torque

figures:
Top yoke bolts
20 Nm (all except Tiger)
18 Nm (Tiger)
Bottom yoke bolts
20 Nm (all except Tiger)
22 Nm (Tiger) 20 Nm (18 Nm on Tiger).
Refit the instruments if previously removed.
8.
Tighten the domed nut in the centre of the top yoke

to 65 Nm.
9.
If previously slackened, align the master

cylinder/clamp split lines with the dot marks on the
handlebars and tighten the master cylinder fixings,
upper first and then the lower to 15 Nm.
-------
3.
If necessary, slacken but do not remove both

Rotate each master
master cylinder clamps.
cylinder to allow access to the top yoke pinch bolts.

cylinder as this will introduce air into the
is ignored.
4.
If necessary for access reasons, remove the

instruments.
5.
Reduce the load on the top yoke by slackening the

top yoke clamp bolts. Slacken the domed nut in the
centre of the top yoke.
6.
Release the adjuster locknut using service tool

3880140. Hold the adjuster nut (the lower nut) to
prevent accidental movement.
Adjust the
headstock bearing by moving the adjuster nut,
clockwise to take out play/increase pre-load, or
anticlockwise to add play/decrease pre-load.
Correct adjustment is reached when the bearing
play is eliminated without pre-loading the bearings.
When the adjustments have been made, lock the
locknut to the adjuster nut to a torque of 40 Nm.
10. Check that the steering will fall to either lock from
the centre position without undue effort.
If
excessive effort is required or the steering feels tight
or notchy, it is likely that the bearings have been
pre-loaded and the adjustment procedure should
be repeated until correct. Similarly, if free-play (end
float) is still present in the bearings, then the
adjustment should be repeated until the correct
setting is reached. If all the free-play (end float)
cannot be eliminated, the bearings have been worn
beyond their service limit and must be replaced.
CAUTION: A true check can only be made
when all fixings are correctly torqued.

adjusted, worn or damaged steering head
11.
12.20
Remove all supports and lower the motorcycle to

the ground. Support the motorcycle on either the
side or centre stand.
9.
HEADSTOCK BEARING REPLACEMENT

Removal
1.

2.

system section. Also remove the lower and cockpit
fairings (where fitted).
10. Remove the speedometer cable from the rear of the

speedometer.
11 . Note the position of any cable ties and cut the ties as
necessary. Disconnect the ignition switch from the
main harness and reposition instruments and wiring
to gain access to the yokes.
12. Remove the domed nut and washer from the top of
the stem. Release the locknut and nut from the
head bearing adjuster using tool 3880140. Remove
the bottom yoke, bearing and steering stem.

correct manner.
3.
Slacken the upper and lower yoke clamp bolts and,

using a downward twisting motion, withdraw each
fork stanchion in turn.
Remove the brake caliper(s). Support the caliper(s)

during the remainder of the operation.
WARNING: Do not allow the caliper(s) to

. . . . hang on the brake hoses. This may
4.


. . . . stabilised and adequately supported to
falling.
1. Tool 3880140, Headstock Bearing Adjusters
NOTE:
1::\.

5.
Remove the front wheel.
6.
Remove the fork covers (where fitted), cable guides

and the front mudguard.
7.
Detach the handlebars from the top yoke and allow

to rest over the front of the motorcycle. On Tiger,
also remove the cable guides from beneath the
yoke.
14. Collect the steering head bearing.

15. Remove the top and bottom bearing outer races by
drifting the races out of the headstock.
1::\.
CAUTION: Ensure that the headstock

cup remains in the headstock during
removal of the bearing outer race.
Always replace the outer cup if any displacement
takes place during removal of the bearing race

. . . . cylinder as this will introduce air into the

is ignored.
8.
Early models were fitted with a stem adjuster

which was locked by means of a pinch bolt.
Where this type of adjuster is found, release the
pinch bolt using tool 3880130 to allow the
removal of the bottom yoke
13. Remove the top yoke.
WARNING: To prevent injury, always

. . . wear eye, hand and face protection when
using a drift.
Detach the front brake hose splitter from the bottom

yoke (not fitted on Thunderbird and Adventurer).
12.21
16. Remove the lower bearing from the steering stem.

To remove the bearing, it may be necessary to split
the bearing inner section to release the grip on the
lower yoke. Alternatively, a suitable puller may be
used.
Assembly
1.

wear eye, hand and face protection when
splitting a bearing. Debris from a bearing which
breaks up may cause severe injury to unprotected
parts of the body.
Fit a new inner bearing to the steering stem using a

suitable drift tube. Do not drift against the outer
cage or rollers as this will damage the bearings.
Ensure that the bearing is fully home on the steering
stem.

using a drift. Prevent damage to the bearing by
using the solid inner part of the bearing to drift
against.
1~
2.
2~
Ensure that cup (8) is still correctly fitted in the

headstock. Position the outer bearing cup of the
upper bearing in the headstock. Position tool
3880065 to the bearing cup with the smaller
diameter end facing the bearing. Position tool
3880075 against the lower end of the headstock
and pull the upper bearing cup into the headstock
using a suitable draw bolt.
$.i
~7
Use this tool face for the lower bearing
~8
Use this tool face for the upper bearing
1. 3880065, Bearing Outer Race Tool

2. 3880075, Bearing Support
CAUTION: Ensure that the correct end of

the bearing tool is selected. Permanent,
irreparable damage to the frame will result from
incorrectly selected tools
3.
1. Domed Nut
2. Washer
3. Top Yoke
4. Pinch Bolt (Early Models Only)
5. Bottom Yoke and Steering Stem
6. Bottom Bearing
7. Upper Bearing
8. Steering Head Cup
Fit the outer race of the lower bearing using the

larger diameter end of tool 3880065 to face the
bearing. Pull the bearing race into the headstock
using the same method as for the upper bearing.
NOTE:
12.22
The lower bearing is a larger diameter than the

upper bearing. The larger end of tool 3880065 is
used to fit the lower bearing.
---------
WARNING: The headstock bearings will

require adjustment following assembly.
The procedure described earlier in this section
must be followed in order to correctly adjust the
headstock bearings. Incorrect adjustment will
result in an unsafe riding condition which may
cause loss of control and an accident.
1. Using Tool 3880065 To Draw In The Outer Race

Of The Upper Bearing
2.Tool3880075
Tiger Handlebar Alignment Marks
NOTE:
Re-align Tiger, Thunderbird, Thunderbird Sport

and Adventurer handlebars such that the dot(s)
align with the centre of the retaining caps.
Later Tiger models are fitted with handlebars
with only one dot mark to align the handlebars.
4.
WARNING:
The steering must be
checked daily before riding. The steering
action, from lock to lock, should be smooth but not
loose and operate without binding of the control
cables.
1. Tool 3880075
2. Using Tool 3880065 To Draw In The Outer Race
Of The Lower Bearing
Continue to assemble the motorcycle using a
reverse of the strip down procedure.
NOTE:

Adventurer, align the split line of the master
cylinder clamp with the dot mark on the
handlebar.
On other models, the master
cylinder reservoirs must be level when the front
wheel is pointing straight ahead.
5.
Bleed the brakes and clutch as described in the

brake/clutch sections.
6.
Adjust the headstock bearings as described earlier

in this section.
12.23
Faulty steering may result in instability leading to

loss of control and an accident.
Brakes
CONTENTS
Page
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification/Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake wear inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front brake pads - A Type
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front brake pads - B Type & Tiger
Front brake pads - C Type
Front brake pads - D & F Type
Rear brake pads - A & B Types
Rear brake pads - C Type
Bleeding the front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front caliper - A Type
Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection/Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front caliper- B Type & Tiger
Removal/Disassembly/Inspection/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front caliper - C Type
Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
/1 nspection/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front caliper - D & F Type
Removal/Disassembly/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Caliper - A & B Types
Removal/Disassembly/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Caliper - C Type
Removal/Disassembly/Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.2
13.5
13.6
13.7
13.7
13.8
13.9
13.10
13.11
13.12
13.13
13.14
13.15
13.16
13.17
13.18
13.19
13.20
13.21
13.22
13.22
13.23
13.24
13.24
13.25
13.25
Front master cylinder

Removal/Disassembly/Inspection/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear master cylinder
Removal/Disassembly/Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.27
13.28
Brake Pedal Height

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.29
Brake disc
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.29
13.29
13.1
13.26
13.27
13 BRAKES
Front Bra ke Layouts
D & F SPECIFICATION
__a;:CD-
28 Nm
28Nm
13.2
BRAKES 13
Rear Brakes Layouts
A SPECIFICATION
22 Nm
22 Nm
40Nm
~7Nm
2BNm~
22Nm
13.3
13 BRAKES
Brake Master Cylinders
;--
25 Nm
9Nm-l_
~V ~
~'L 5) ~\@rf'\1
~@e
'"'
25Nm
25Nm
15 Nm
i
!---~
28 Nm
Rear
I
7Nm-------... ~
~o~:
I)'
27Nm
g
0
8
I
25 Nm
----\j
~
I
13.4
I p
.
~\
\~
BRAKES 13
BRAKING SYSTEM SPECIFICATIONS and
IDENTIFICATION
ASBESTOS
the following components or
any assembly containing
any of these components:-
Various different specification braking systems are fitted

to Triumph motorcycles which can be identified by
certain visible characteristics.
The braking system types are identified using the charts
below.
WARNING
CONTAINS
ASBESTOS
FRONT
DESIGNATION
IDENTIFICATION
TYPE A
4 Piston Caliper
Twin Floating Discs
TYPES 8 & F
2 Piston Caliper*
Twin Fixed Discs
TYPEC
TYPED
Breathing asbestos
dust is dangerous
to health
Follow safety
instructions
SAFETY INSTRUCTIONS
6 Piston Caliper
Twin Floating Discs
2 Piston Caliper*
Single Fixed Disc
* Both pistons on one side of the caliper only

ventilated place.

facility.

safely.
Never use an airline to blow dust from

components
REAR
DESIGNATION
IDENTIFICATION
TYPE A
Caliper fitted below the

brake disc
TYPES
Caliper fitted above the

brake disc. Torque arm
mounted to caliper
TYPEC
Caliper fitted above the

brake disc. Torque arm
mounted to caliper
carrier
Brake Shoes or Pads
WARNING: Because the braking system

specification varies from model to model,
always refer to the latest parts information to
ensure that the correct specification parts are
obtained. Failure to fit the correct replacement
parts may lead to an unsafe riding condition which
may cause an accident.
WARNING: Front and rear brake systems

are fitted to a motorcycle as independent
systems. Because of this, always check the type of
system being worked on with the chart above
before starting work. For example, a motorcycle
fitted with type 'A' front brakes will often be fitted
with a different system designation on the rear.
Following the instructions for a braking system
different to that being worked on may lead to a
dangerous riding condition causing loss of control
and an accident.
13.5
13 BRAKES
BRAKING SYSTEM MAINTENANCE SAFETY

PRECAUTIONS


master cylinders.
an accident.

neglected.
plastic surface.
opened.

appreciable drop in the level of the fluid in
authorised Triumph Dealer for advice before
riding.
WARNING:
Use
only
D.O.T.
4
Failure to change the brake fluid at the interval.
13.6
BRAKES 13
FLUID LEVEL INSPECTION

inspect the brake fluid level in the front and rear master
cylinder reservoirs. In addition, the brake fluid must be
regularly replaced, again in accordance with the periodic
maintenance chart, to help prevent brake failure.
1.
Ensure that the brake fluid level in the front and rear
brake fluid reservoirs is between the upper and
lower level lines (reservoir held horizontal).

(Thunderbird Sport)

(all except Thunderbird Sport)
---_/----::;;;;;;;;:,
~--

CHANGING BRAKE FLUID, BRAKE

HOSES AND HYDRAULIC SEALS
Brake fluid, brake hoses and hydraulic seals in the
master cylinders and calipers should be changed in
accordance with the periodic maintenance chart.
(all except Thunderbird Sport)
WARNING: Failure to change brake fluid,

. . . hoses and hydraulic seals at the
specified interval could result in reduced brake
efficiency leading to loss of control and an
accident.
13.7
13 BRAKES
BRAKE PADS
WARNING: Do not replace individual

brake pads, replace both pads in the
brake caliper. If two calipers are mounted on the
same wheel, all the pads on the wheel must be
replaced together. Replacing individual pads will
reduce braking efficiency and may cause an
accident.
Front and Rear Brake pad wear is automatically

compensated for and has no effect on brake lever or
pedal action.
BRAKE WEAR INSPECTION
BRAKE LIGHTS
In accordance with the Periodic Maintenance Chart,

inspect the brake pads for wear.
The minimum thickness of lining material for any front
or rear brake pad is 1.5mm. If any pad has worn to
the bottom of the groove in the pad centre, replace all
the brake pads on that wheel.
Check the brake lights for correct operation, on both front

and rear brakes, in accordance with the periodic
maintenance chart.
1. Lining material thickness

2. Centre groove
13.8
BRAKES 13
FRONT BRAKE PADS, TYPE A
Installation
Removal
1.

. . . grease in any part of the braking system
master cylinders.
an accident.
Release and remove the brake pad retaining pin

and inspect the pin for damage.
1.
2.
1. Retaining Pin
2. Anti-rattle Spring
3. Brake Pads
2.
3.
Remove the anti-rattle spring and inspect the spring

for damage.
WARNING: Do not apply more than a

. . . minimum coating of grease to the pad
retaining pins. Excess grease may contaminate
the brake pads, hydraulic seals and discs causing
reduced braking efficiency and an accident.
Gently prise the brake pads apart to force the

caliper pistons back and allow withdrawal of the
pads.
A.
CAUTION: Never lever directly against

~ the disc, caliper or the pad lining material
as this will damage these components. Always
use a levering tool made from a soft material which
will not cause damage to the load bearing
surfaces.
Brake fluid will be displaced as the caliper pistons
are compressed. To prevent body damage, ensure
that the displaced fluid does not come into contact
with any part of the bodywork.
4.
Remove both brake pads and inspect for damage

and wear beyond the seNice limit.
5.
Repeat steps 1 to 4 for the other caliper.
Replace the brake pads as an axle set or, if all the

pads are in a seNiceable condition, clean the pad
grooves before replacing all pads in their original
positions.
Lubricate the pad retaining pins using a minimum
amount
of
proprietary
high
temperature
'Copperslip' type grease. Fit the anti-rattle spring
over the pads and push down in the centre to allow
the pad retaining pin to slide across the top of the
spring.
3.
Tighten the pad retaining pins to 18 Nm.
4.
When both sides are correctly fitted, pump the

brake lever to correctly position the caliper pistons.
5.
Check the front brake fluid level and adjust as

required with new DOT 4 fluid.
WARNING:
Use
only
D.O.T.
4
. . . specification brake fluid as listed in the
Observe the brake fluid handling warnings given
earlier in this section of the manual.
13.9
13 BRAKES
FRONT BRAKE PADS, TYPE 8 AND TIGER
Installation
Removal
1.

master cylinders.
an accident.
Slacken both brake pad retaining pins.
1.
Fit the anti-rattle spring into the caliper. Press the

caliper pistons back into the caliper using hand
pressure only.
"!'
CAUTION: Brake fluid will be displaced

as the caliper pistons are compressed.
To prevent body damage, ensure that the
displaced fluid does not come into contact with
any part of the bodywork.
1. Caliper Bolts
2. Pad Retaining Pins
2.
---------
3.
4.
2.

pads are in a serviceable condition, clean the pad
positions.
3.

amount
of
proprietary
high
temperature
'Copperslip' type grease. Press down on both pads
and fit the retaining pins.
Remove the caliper mounting bolts and spacers

(where fitted).
A WARNING: Do not allow the caliper to

. . . hang on the brake hoses as this may
Position the caliper to allow withdrawal of the pad
retaining pins. Support the caliper to prevent the full
weight of the caliper from hanging on the brake
hoses.

minimum coating of grease to the pad
Press downwards on both pads and remove the

pad retaining pins.
4.
Position the caliper over the disc ensuring the pads

are correctly aligned on both sides of the disc.
5.
Align the caliper, spacers (where fitted) and bolts.

Tighten the caliper bolts to 40 Nm and tighten the
pad retaining pins as follows: pin between pistons
18 Nm; pin adjacent to bleed screw 22Nm.
6.
When both sides are correctly fitted, pump the

Check the brake fluid level and adjust as required
with new DOT 4 fluid.
1. Anti-Rattle Spring
2. Brake Pads
5.
Remove the pads and inspect for damage and wear

beyond the service limit.
6.
Remove the anti-rattle spring and inspect for

damage.
----~
13.10
WARNING:
Use
only
D.O.T.
4
BRAKES 13
FRONT BRAKE PADS, TYPE C
Installation
1.
Removal
1.
Remove the caliper mounting bolts.
Press the caliper pistons back into the caliper using

hand pressure only.
'!'

2.
Position the caliper to allow withdrawal of retaining

pins. Support the caliper to prevent the full weight of
the caliper from hanging on the brake hoses.

positions.
3.
Locate the anti-rattle spring to the pads and position

the pad retaining pins into the caliper.
4.
Press down in the centre of the anti-rattle spring

while drifting the pad retaining pins fully into place.
WARNING: Pad retaining pins that are not

correctly fitted could come loose
resulting in an unsafe riding condition and an
accident. Always ensure that the pad retaining
pins are correctly located.
WARNING: Do not allow the caliper to

hang on the brake hoses as this may
3.
2.
Drift the brake pad retaining pins through the caliper

using a suitable soft drift. The pins are removed by
drifting from the inside (wheel side) to the outside.
Press down in the centre of the anti-rattle spring to
finally release the pins
5.
Locate the caliper to the disc ensuring that the brake

pads are correctly aligned on either side of the disc.
6.
Refit the brake caliper bolts and tighten to 40 Nm.
7.
When both calipers are correctly fitted, pump the

8.

WARNING:
Use
only
D.O.T.
4
1. Pad Retaining Pin
WARNING: To prevent personal injury,

wear eye, face and hand protection when
using a drift.
4.
Collect the anti-rattle spring and examine for

damage and deterioration.
5.
Remove the pads and inspect for damage and wear

beyond the service limit.
13.11
13 BRAKES
4.
FRONT BRAKE PADS, TYPES D & F
Remove the brake pads from the lower end of the

caliper.
Removal
1.
Remove the grub screw from the outer end of the

brake pad pin.
!.
Withdrawing Brake Pads

5.
Collect the anti rattle springs from inside the caliper.
Releasing the Grub Screw
Installation
2.
Release the brake pad pin using an Allen key and

withdraw the pin from the caliper.
1.
Fit the anti-rattle springs into the caliper.
2.
Lubricate the pad retaining pin using a minimum

amount
of
proprietary
high
temperature
'Copperslip' type grease.
WARNING:
Do not apply more than a
~ minimum coating of grease to the pad
retaining pin. Excess grease may contaminate the

brake pads, hydraulic seals and disc causing
reduced braking efficiency which may lead to loss
of control and an accident.
3.
Install the brake pads into the caliper ensuring that

the upper end is correctly engaged in the anti-rattle
spring.
Releasing the Brake Pad Pin

3.
Using hand pressure only, retract the caliper pistons

by gently pushing the caliper toward the wheel.
'f'

Correct Pad Engagement in the Anti-rattle Spring

4.
13.12
Align the pads and fit the pad retaining pin. Tighten
the pin to 18 Nm.
BRAKES 13
5.
Refit the grub screw to the caliper and tighten to 3

Nm.
REAR BRAKE PADS, A & 8 TYPES
6.

Removal
1.
Remove the right hand silencer (not Tiger).
WARNING:
Use
only
D.O.T.
4

. . . . been running, the exhaust system will be

earlier in this section of the m_~an:_:_u~a~l_.~~~----'
2.
Slacken both brake pad retaining pins.
3.

2. Caliper Mounting Bolts
4.
Position the caliper to allow withdrawal of retaining

pins.

. . . . hang on the brake hoses as this may
5.

pad retaining pins.
If\

6.
13.13
Remove the brake pads and inspect for damage

and wear beyond the service limit.
13 BRAKES
7.
When the caliper is correctly fitted, pump the brake

pedal to correctly position the caliper pistons.
8.

WARNING:
Use
only
D.O.T.
4
1. Brake Pads
2. Anti Rattle Spring
7.
Remove the anti-rattle spring and inspect for
damage.
9.
Installation
REAR BRAKE PADS, C TYPE
,-------
Refit the right hand silencer (not Tiger).
_________,
------,,,,
The procedure for replacement of type C rear brake pads

is the same as for type D & F front brake pads.

system is possible. Mineral based grease witt
master cylinders.
Please refer to the instructions for type D & F front brake

pads when replacing type C rear brake pads.
Damage caused by mineral based grease may

1.
Fit the anti-rattle spring into the caliper.
2.
Replace the brake pads as an axle set or, if all pads

are in serviceable condition, clean the pad grooves
before replacing all pads in their original positions.
3.

amount
of
proprietary
high
temperature
'Copperslip' type grease. Press down on both pads
and fit the retaining pins.

4.

5.
Align the caliper, carrier and torque arm and fit the
caliper retaining bolts. Tighten the caliper bolts to 40
Nm.
6.
Tighten the brake pad retaining pins to 18 Nm.
13.14
BRAKES 13
BLEEDING
THE
FRONT
BRAKES,
REPLACING BRAKE FLUID, ALL TYPES
1.
On models equipped with adjustable levers, set

adjuster wheel to No.1. Note the original setting
of the adjuster wheel in order that it can be
returned to the same position when the
bleeding operation is complete.
8.
Check the condition of the sealing diaphragm for

the reservoir. Replace if necessary.
9.
Release the bleed nipple.
10. Slowly pull in and release the brake lever several

times until no more air bubbles appear in the bleed
tube.
11. Maintain the brake fluid level between the upper
and lower reservoir levels whilst bleeding is being
carried out.
WARNING:
Use
only
D.O.T.
4
NOTE:
1. Adjuster
2.
Remove the rubber cap from the bleed nipple on the

right hand caliper.
3.
Attach a transparent tube to the bleed nipple.
4.
Place the other end of the tube in a suitable

receptacle containing new brake fluid.
5.
Turn the handlebars to bring the fluid reservoir to a

level position.
6.
Release and remove both screws securing the

brake reservoir cover.

fall below the lower level mark in the reservoir. If
the level is allowed to fall below this mark, air
may enter the system and the sequence of
12. When all air has been expelled from the system,
hold the lever in and close the bleed nipple. Tighten
the nipple to 5 Nm.

when adding brake fluid to the brake fluid
reservoir. Do not allow moisture or debris to enter
the cylinder as this will adversely affect the fluid
properties.
Always use fluid from a sealed
1.
2.
3.
4.


not spill brake fluid onto any area of the
bodywork.
7.
Carefully remove the reservoir cover taking care not

to spill any fluid.
13.15
Bleed Nipple
Spanner
Bleed Pipe
Container
13 BRAKES
13. Fill the reservoir to the upper level with new DOT 4
fluid.
WARNING:
Use
only
D.O.T.
4
BLEEDING REAR BRAKES, REPLACING

BRAKE FLUID, ALL TYPES
1.
Remove the body side panels together with the

right-hand engine air intake duct.
2.
Remove the cap from the rear bleed nipple.
3.

14. Remove the transparent bleed tube.
15. Replace the bleed nipple cap.
16. Repeat the procedure for the left-hand caliper.
17. Replace the reservoir cover and diaphragm
ensuring correct fitment of the diaphragm before
final tightening of the screws.
18. Reset the brake lever adjuster to the original
setting.
1. Bleed Nipple
2. Spanner
3. Bleed Tube
4.
WARNING:
Place the other end of the tube in a suitable

receptacle containing new brake fluid.
19. Check that the brake operates correctly.


when adding brake fluid to the brake fluid
reservoir. Do not allow moisture or debris to enter
the cylinder as this will adversely affect the fluid
properties.
Always use fluid from a sealed
13.16
BRAKES 13
FRONT BRAKE CALIPER,
A SPECIFICATION

~ not spill brake fluid onto any area of the
bodywork.
6.
7.
Release the bleed nipple.
8.
Slowly depress and release the footbrake pedal

several times until no more air bubbles appear in the
bleed tube.
9.
Removal
Check the condition of the sealing diaphragm.

Replace the diaphragm as necessary.
1.
Disconnect the brake hose at the caliper and place

the free end of hose in a suitable container to collect
brake fluid.
2.
Slacken the pad retaining pin.
3.
Gently prise the brake pads apart to force the

pistons back. Remove the brake pads.
Maintain the brake fluid level between the upper

and lower reservoir levels whilst bleeding is being
carried out. SEE WARNING FOLLOWING ITEM
11 BELOW.
/;
NOTE:

fall below the lower level mark in the reservoir. If
the level is allowed to fall below this mark, air
may enter the system and the sequence of
10. When all air has been expelled from the system,
hold down the brake pedal and close the bleed
nipple. Tighten the nipple to 5 Nm.
11.
Caliper Pin Removal
Fill the reservoir to the maximum level with new

DOT 4 fluid.
CAUTION: Never lever directly against

the disc, caliper or the pad lining material.
Always use a levering tool made from a soft
material which will not cause damage to the load
bearing surfaces.
WARNING:
Use
only
D.O.T.
4
Brake fluid will be displaced as the caliper pistons

are compressed. To prevent body damage, ensure
that the displaced fluid does not come into contact
with any part of the bodywork

4.
Remove the caliper securing bolts.
5.
Repeat steps 1 to 4 for the remaining caliper.
Disassembly
12. Fit the reservoir cover and diaphragm. Check for

correct diaphragm fitment before final tightening of
the cover.
13. Remove the bleed tube from the nipple.
1.
Separate the two halves of the caliper by removing

the connecting bolts.
2.
Cover the caliper opening with a clean, heavy cloth

and, using either compressed air or by
reconnecting the master cylinder and pumping the
brake lever, remove the pistons one at a time.
14. Replace the bleed nipple dust cap.

15. Fit the right-hand air intake duct and replace the
body side panels.
16. Check that the brake operates, then carry out a road
test to verify correct brake operation.
13.17
WARNING: To prevent injury, never place

fingers or hands inside the caliper
opening when removing the pistons. Always wear
eye, hand and face protection when using
compressed air. Eye, face and skin damage will
result from direct contact with compressed air.
13 BRAKES
Inspection
Installation
1.
1.
Position the caliper over the disc and tighten the

caliper bolts to 40 Nm.
2.

amount
of
proprietary
high
temperature
'Copperslip' type grease. Fit the brake pads to the
caliper and locate the anti-rattle spring over the
pads. Push down in the centre of the anti rattle
spring to allow the pad retaining pin to slide across.
Check the piston and caliper bore for corrosion,

scoring and damage. Renew as necessary.
WARNING: Always renew caliper seals,

pistons and bolts after removal from the
caliper. An effective hydraulic seal can only be
made if new components are used.
2.
Inspect the brake pads for damage and wear

beyond the service limit. Renew as necessary.
Assembly

master cylinders.
1.
Renew the fluid seals. Apply brake fluid to the

outside of the caliper pistons and fluid seal.
2.
Push the pistons into the cylinder by hand.
WARNING: Ensure that the caliper bores

do not become scratched during removal
and assembly.
Ensure that the pistons do not tip during assembly
as this could damage the caliper.
Always renew the '0' rings between the caliper
halves.
accident could result if these warnings are
ignored.
3.

3.
Tighten the brake pad retaining pin to 18 Nm.
4.
Connect the brake hose to the caliper using new

sealing washers on each side of the banjo bolt.
5.
Tighten the banjo bolt to 25 Nm.
6.
Fill the master cylinder with new, DOT 4 brake fluid

from a sealed container.
WARNING:
Use
only
D.O.T.
4
7.
Assemble the two halves of the caliper ensuring that

new joint '0' rings are correctly fitted in their locating
grooves. Tighten new caliper joint bolts to 25 Nm.
13.18
Bleed the brake line as described earlier.
BRAKES 13
FRONT BRAKE CALIPER
8 SPECIFICATION AND TIGER
Inspection
1.

Removal
1.
WARNING: Always renew caliper seals

and pistons after removal from the
Disconnect the brake hose and place the free end of

the hose in a suitable container to collect the brake
fluid.
2.

2.

Assembly

master cylinders.
1. Caliper Bolts

3.
1.
Fit new fluid seals to the caliper. Apply new, clean

brake fluid to the outside of the pistons and fluid
seals.
2.
Push the pistons into the cylinder using hand

pressure only.
Remove the caliper securing bolts and spacers

(where fitted), then remove the caliper from the
disc/fork leg.
Disassembly
1.
2.
Remove the brake pad retaining pins, brake pads

and anti-rattle spring.

and assembly. Ensure that the pistons do not tip
during assembly as this could damage the caliper.



3.

amount
of
proprietary
high
temperature
'Copperslip' type grease.

13.19
13 BRAKES
4.
Install the anti-rattle spring in the calipers. Refit the

brake pads and pad retaining pins.
Installation
1.
Position the caliper over the brake disc ensuring

that the pads are correctly positioned within caliper.
2.
Tighten the caliper securing bolts to 40 Nm.
3.
Tighten the pad retaining pins as follows:

pin between pistons 18 Nm;
pin adjacent to bleed screw 22 Nm.
4.

washers on each side of the banjo bolt.
5.
6.

WARNING:
Use
only
D.O.T.
4
7.
13.20
BRAKES 13
FRONT BRAKE CALIPER,
C SPECIFICATION.
NOTE:
The caliper is overhauled one side at a time. It is

not possible to withdraw all six pistons
together. Complete the overhaul of the first set
of three pistons before commencing overhaul
of the second set.
WARNING:
When pushing back the
caliper pistons, cover the brake hose
connection to prevent brake fluid from coming into
contact with the bodywork. Severe body damage
will result from contact with brake fluid.
2.
Removal
1.

brake fluid.
2.
Remove the brake caliper from the fork.
3.
Drift the brake pad retaining pins through the caliper

using a suitable soft drift. The pins are removed by
drifting from the inside (wheel side) to the outside.
Press down in the centre of the anti-rattle spring to
finally release the pins.
Insert tool 3880185 into the caliper with the rubber

face towards one set of pistons.
NOTE:
The tool must be fitted from the outside face of

the caliper (arrowed below).
1. Tool 3880185
2. Air Line Connection
3.
WARNING:
The use of air pressure
greater than 3 bar will damage the caliper.
Never re-use a caliper which has been serviced
using air pressure greater than 3 bar as this may
lead to reduced braking efficiency and an accident.
1. Pad Pin
Disassembly
WARNING: The caliper is manufactured

in two halves but must not be split during
caliper overhaul. If the seals between the caliper
halves are disturbed or start to leak, the caliper
must be replaced before riding the motorcycle.
WARNING: Always wear hand, face and

eye protection when using compressed
air. Eye, face and skin damage will result from
direct contact with compressed air.
I:\

1.
Connect an air line to the brake hose connection

point on the top of the caliper. Apply air pressure
until all 3 pistons have moved outwards to contact
the rubber face of the tool.
CAUTION: When using compressed air
~ to eject the caliper pistons, there is a
Withdraw the brake pads and anti-rattle spring from

the caliper and ensure all 6 pistons are pushed fully
back into their bores.
possibility of brake fluid becoming dispersed in

the air stream. To prevent body damage, always
carry out this operation at a safe distance from
bodywork and other painted components.
4.
13.21
Withdraw the tool and collect the pistons from their

bores. Remove the seals from the caliper (2 per
piston bore) taking care not to mark the caliper bore
or seal grooves. Discard the seals.
13 BRAKES
A.
CAUTION: Use a tool made from a soft

material, such as brass, to remove caliper
seals. Tools made from steel etc. will damage the
caliper bores and seal grooves.
WARNING:
Incorrectly fitted caliper
~ seals will result in an unsafe riding
condition leading to an accident. Always ensure

that the seals are not twisted and are the correct
diameter for the bore in which they are fitted.
Inspection
1.
Check for scoring of the caliper bores, scoring or

corrosion of the pistons and leakage between the
caliper halves. Renew components as necessary.
4.
Lightly smear one of each size wiper seal with

silicone grease but do not soak in brake fluid.
Taking care to match the seal diameter with the
same diameter caliper bore, insert the wiper seals
into the upper seal grooves in the caliper. Ensure
that the seal sits squarely in the bore and is not
twisted.
5.
Lightly smear each piston with the silicone grease

described in paragraph 2 and insert into its
appropriate bore. Ensuring that the piston is square
with the bore, gently press the piston fully into the
bore using hand pressure only.
Assembly

master cylinders.
A.
1.
Carefully clean the pistons, caliper bores and seal

grooves using a clean, lint-free cloth.
2.
Lightly smear one of each size pressure seal with

silicone grease such as Molykote PG 54 or allow to
soak for a minimum of 10 minutes in new, clean
brake fluid.
CAUTION: Do not force the piston into

the caliper bore as this will damage both
the piston and caliper. Use hand pressure only to
fit the piston.
NOTE:
Once the first set of three pistons have been

fully assembled, repeat the process for the
remaining three pistons on the other side of the
caliper.
Installation
1.

positions.
2.
Locate the anti rattle spring to the pads and position

the pad retaining pins into the caliper.
3.
Press down in the centre of the anti rattle spring

while drifting the pad retaining pins fully into place.
Ensure that the pad retaining pins are drifted
correctly into place.
1. Wiper Seal Section
2. Pressure Seal Section

NOTE:
The pressure seal has a much thicker section

than the wiper seal.
3.
Taking care to match the seal with the same

diameter caliper bore, insert the pressure seals into
the lower seal grooves in the caliper. Ensure that
the seal sits squarely in the bore and is not twisted.
WARNING: Pad retaining pins that are not

correctly fitted could come loose
resulting in an unsafe riding condition leading to
an accident. Always ensure that the pad retaining
pins are correctly located.
4.
Locate the caliper to the disc ensuring that the brake

pads are correctly aligned either side of the disc.
5.
Refit the brake caliper bolts and tighten the fixings to

40Nm
13.22
BRAKES 13
6.
Align the brake hose to the caliper and fit new

sealing washers to both sides of the banjo bolt.
FRONT
BRAKE
SPECIFICATION
7.

Removal
WARNING:
Use
only
D.O.T.
4
&
1.

brake fluid.
2.
Remove the brake caliper from the fork.
3.
Remove the brake pads as described earlier in this

section.
Disassembly

8.
CALIPER,
1.

WARNING: To preve~t i~jury, never p~ace

fingers or hands ms1de the caliper
Inspection
1.


2.
13.23

13 BRAKES
Assembly
REAR BRAKE CALIPER, A & B TYPES

Removal

master cylinders.
1.
Fit new fluid seals to the caliper. Apply new, clean

brake fluid to the outside of the pistons and fluid
seals.
2.
Push the pistons into the cylinder using hand

pressure only.
1.
Remove the right hand silencer (not Tiger).
2.
Disconnect the rear brake hose at the caliper and

place the free end of hose in a suitable container to
collect brake fluid.
3.
Slacken the two pad retaining pins.
4.
5.
Remove the brake caliper assembly.

and assembly. Ensure that the pistons do not tip
during assembly as this could damage the caliper.
3.
Refit the brake pads as described earlier in this

section.
4.
Tighten the pad retaining pin to 18 Nm and the grub

screw to 3 Nm.
Installation
1.
Position the caliper over the brake disc ensuring

that the pads are correctly positioned within caliper.
2.
Tighten the caliper securing bolts to 28 Nm.
3.

4.
5.

Rear Caliper Removal
Disassembly
1.

retaining pins. Remove the brake pads.
2.

WARNING:
Use
only
D.O.T.
4


6.

13.24
BRAKES 13
4.
Inspection
1.


Position the brake pads in the calipers. Lubricate

the pad retaining pins using a minimum amount of
proprietary high temperature 'Copperslip' type
grease. Press down on both pads and fit the pad
retaining pins.
WARNING:
Do not apply more than a
~ minimum coating of grease to the pad


Installation
2.

beyond the seNice limit. Renew as necessary.
1.

2.
Align the caliper, carrier and torque arm and fit the
caliper retaining bolts. Tighten the bolts to 40 Nm.

master cylinders.
3.
Tighten the brake pad retaining pins to 18 Nm.
4.

5.

6.

Assembly
1.
2.
Fit new fluid seals to the caliper. Apply brake fluid to

the outside of the caliper piston and fluid seal.
Push the piston into the cylinder by hand.
A.
WARNING:
Use
only
D.O.T.
4
CAUTION: Ensure that the caliper bores
~ and pistons do not become scratched
during removal and assembly. Ensure that the

pistons do not tip over during assembly as this
could damage the caliper.

3.
7.
8.
Refit the right hand silencer (not Tiger).
REAR BRAKE CALIPER, C TYPE

The procedure for the overhaul of type C rear brake
calipers is the same as for type D & F front brake calipers.
Please refer to the instructions for types D & F front brake
calipers when overhauling type C rear brake calipers.

2. Brake Pads
13.25
13 BRAKES
FRONT MASTER CYLINDER
Disassembly
Removal
1.
On models equipped with adjustable levers note the

original setting of the adjuster wheel in order that it
can be returned to the same position when the
overhaul operation is complete.
1.
Detach the boot from the lever end of the cylinder.
2.
Remove the circlip from beneath the boot.
3.
Remove the piston set from the master cylinder

bore noting the relative position of the seals and
piston components.
2
2.
3.
Drain the fluid from the master cylinder by bleeding

the system until all fluid has been expelled.
Remove the pivot bolt securing the brake lever to
the master cylinder. On Tiger, also collect the
knuckle guard and flanged sleeve.
1. Boot
2. Circlip
3. Piston Set
Inspection
1.

deterioration:
Cylinder bore
Dust cover
Spring
Piston
Pivot Bolt
2.
Always renew the piston and seal set if the cylinder

is dismantled.
3.
Check that the relief and supply ports on the

cylinder are not blocked.
Assembly
1.
2.
3.
4.
Plug (Tiger only)

Pivot bolt
Flanged Sleeve (Tiger only)
Nut
4.
Remove the brake lever.
5.
Disconnect the brake hose from the master

cylinder.
6.
Disconnect the brake light switch connections from

the master cylinder.
7.
Release the clamp screws from the handlebars.
8.
Remove the master cylinder.

master cylinders.
1.
13.26
Lubricate the piston and cylinder with new, clean

brake fluid.
BRAKES 13
2.
Fit the new piston set into the master cylinder and
retain with a new circlip.
8.
WARNING: Ensure that the piston and

piston seal are fitted facing the same way
as noted during removal. A dangerous riding
condition leading to an accident could result from
incorrect assembly of the master cylinder.
WARNING:
3.
Refit the master cylinder boot.
9.
Installation
1.
2.
Tighten the clamp bolts, upper first and then the

lower to 15 Nm.
3.
Re-connect the brake light switch to the master

cylinder.
4.
Position the brake lever ensuring that pivot boss is

correctly aligned and fitted to the push rod. On
Tigers, fit the knuckle guard and flanged sleeve.
Tighten the pivot bolt to 1 Nm on all except Tiger,
and 6Nm on Tiger.
5.
Tighten the locknut to 6Nm (all models). On Tiger,

refit the plug to the pivot bolt.
6.
Using new sealing washers on both sides of the

banjo bolt, align and connect the brake hose to the
master cylinder. Tighten the banjo bolt to 25 Nm.
Removal
1.

negative (black) lead first. Remove the body side
panels. On Tiger, remove the master cylinder
cover.
2.
Drain the fluid from the master cylinder by bleeding

the system until all fluid has been expelled.
3.
Remove the split pin or clip (whichever is fitted)

from the clevis pin at the lower end of the brake
pushrod . Remove the clevis pin.
4.
Remove the reservoir hose from the master

cylinder.
5.
Disconnect the brake light switch connections and

detach the rear brake hose.
6.
Remove the capscrews and washers retaining the

cylinder and cover (where fitted) to the frame.
7.
Remove the master cylinder from the frame.
Disassembly
1.
Remove the boot from the cylinder and push rod.
2.
Remove the circlip retaining the pushrod to the

cylinder.
3.
Remove the piston set from the master cylinder

bore noting the relative position of the seals and
piston components.
Fill and bleed the front brakes as described earlier.
WARNING:
Use
only
D.O.T.
4
. . . specification brake fluid as listed in the
Examine the system for correct operation and fluid

leaks. Rectify as necessary.
REAR MASTER CYLINDER
Locate the master cylinder to the handlebars and

position the clamp with the 'Up' arrow pointing
upwards. Align the master cylinder/clamp split line
with the dot mark on the handlebar.
1. Arrow Mark
7.
Reset the brake lever adjuster (if fitted) to the

original setting.
Inspection
1.
Visually inspect the master cylinder bore for wear,

scratches or corrosion. Replace as necessary.
2.
Check the piston and cylinder bore for damage,

wear or deterioration. Replace as necessary.
Always renew the piston seals if the cylinder has
been dismantled.
3.
Examine the pushrod for bends and damage.

13.27
13 BRAKES
Assembly
WARNING:
Use
only
D.O.T.
4

master cylinders.


7.
1.
Clean the master cylinder bore, piston and seals,

with new brake fluid.
2.
Ensure all ports are clear of obstruction.
3.
Install the spring and piston set together.
Reconnect the battery positive, (red) lead first and

refit the body side panels.
WARNING: Ensure that the piston and

piston seal are fitted facing the same way
as noted during removal. A dangerous riding
condition leading to an accident could result from
incorrect assembly of the master cylinder.
4.
Apply a small amount of brake grease to the

push rod.
5.
Install the pushrod in the master cylinder and retain

with a new circlip. Refit the boot.
Installation
4
1.
Fit the reservoir hose to the master cylinder.
2.
Secure the master cylinder and cover (where fitted)

to the frame.
Tighten the master cylinder
capscrews to 27 Nm.
NOTE:
'
On Tiger, the master cylinder cover is held by

separate fixings.
3.
Connect the push rod to the brake pedal with a new

clevis pin. Retain to the pedal with a new split pin or
clip (whichever is fitted).
4.
Fit new washers to the brake hose connection and

fit to the master cylinder. Tighten to 28 Nm.
5.
Reconnect the brake light switch.
6.
Fill and bleed the rear brake system as described

earlier.
~-
~
I
1.
2.
3.
4.
5.
6.
7.
13.28
Split pin
Clevis pin
Reservoir hose
Capscrew and washer
Dust boot
Circlip
Piston set
1...__,
BRAKES 13
BRAKE PEDAL HEIGHT ADJUSTMENT
1.
2.
BRAKE DISCS
Check that the height of the foot-plate on the rear

brake pedal is sufficiently below the height of the
footrest to prevent accidental application during
normal riding.
Wear
1.
If incorrect, the pedal height can be varied by

adjusting the length of the actuating rod to the rear
master cylinder.
Replace any brake disc if worn beyond the service

limit or exceeds the disc run-out limit.
Front Disc Thickness (Except Tiger)

Standard: ........ 5.0 mm
Service Limit: . . . . 4.5 mm
Front Disc Thickness (Tiger)
Standard: . . . . . . . . 4.0 mm
Rear Disc Thickness (Except Tiger)

Standard: . . . . . . . . 6.0 mm
Rear Disc Thickness (Tiger)

Standard: . . . . . . . . 5.0 mm
Disc Run-out (All Models)

Standard: ........ 0.1 mm
NOTE:
It is not necessary to remove the rod from the

pedal to make the adjustments.
3.
WARNING: Do not replace front brake

discs individually. Discs must always be
replaced in pairs even if one of a pair is
serviceable.
To adjust the pedal height, slacken the locknut (2)

and turn the master cylinder rod (1) until the
required pedal height is reached. Screw the master
cylinder rod into the clevis pin fork to lower the pedal
height, and outwards to raise the pedal height.
Re-tighten the locknut when the pedal is set to the
required height.
Measure disc run out using an accurate dial gauge

mounted on a surface plate.
WARNING: Ensure that the master

cylinder rod has adequate thread
engagement in the clevis pin fork (minimum 1Omm
of thread engagement).
WARNING: After adjusting the pedal,

operate the motorcycle in a safe area
away from traffic to gain familiarity with the new
pedal setting.
Operation of the motorcycle without first
becoming familiar with the new pedal setting could
1. Disc
2. Dial Gauge
13.29
Wheels/Tyres
CONTENTS
Page
Tyres/Wheels
Tyre Inflation Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tyre and Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.5
14.6
14.6
Tyre Safety Information

Safety Informationall models EXCEPT Tiger, Thunderbird, Thunderbird Sport
and Adventurer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tiger, Thunderbird, Thunderbird Sport and Adventurer . . . . . . . . . . . . .
14.7
14.8
Wheel Removal/Installation
Front.........................................................
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.9
14.10
Wheel bearings
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation....................................................
14.11
14.12
14.1
14 WHEELSII'YRES
Wheels: All except Tiger, Thunderbird, Thunderbird Sport and Adventurer
85 Nm
14.2
WHEELSITYRES 14
Wheels: Tiger
14.3
14 WHEELS/lYRES
Wheels: Thunderbird, Thunderbird Sport
and Adventurer
'
I
I'
I
'
I
I
'
14.4
WHEELS!TYRES 14
TV RES
Tiger, Thunderbird, Thunderbird Sport

and Adventurer
Trophy, Trident, Sprint, Speed Triple,

Daytona Super 3 and Daytona
Tiger, Thunderbird, Thunderbird Sport and Adventurer

motorcycles are fitted with spoked wheels which require
a tyre suitable for use with an inner tube.
All the above range of motorcycles are equipped with

tubeless tyres, valves, and wheel rims. Only tyres
marked 'TUBELESS' and tubeless type tyre valves
mounted on rims marked 'TUBELESS TYRE
APPLICABLE' can be used.
---------======-~-~
WARNING: Tyres that have been used on

. . . a rolling road dynamometer may become
damaged. In some cases, the damage may not be
visible on the external surface of the tyre.
Tyres must be replaced after such use as
continued use of a damaged tyre may lead to
____
WARNING: Failure to use an inner tube in

. . . a spoked wheel will cause deflation of the
tyre resulting in loss of control and an accident.
Tyre Pressures, All Models

Correct inflation pressure will provide maximum stability,
rider comfort and tyre life.
Rim Marking
Tyre pressures should be checked frequently and

adjusted as necessary. See the Owner's Handbook or
the specification section for the correct inflation
pressures for your model.
WARNING: Incorrect tyre inflation will

. . . cause abnormal tread wear and
instability problems which may lead to loss of
Underinflation may result in the tyre slipping on, or
coming off the rim. Over-inflation will cause
instability and accelerated tread wear.
Both conditions are dangerous as they may cause
loss of control leading to an accident.
Tyre Marking
WARNING: Tyres that have been used on

. . . a rolling road dynamometer may become
damaged. In some cases, the damage may not be
visible on the external surface of the tyre.
Tyres must be replaced after such use as
continued use of a damaged tyre may lead to
14.5
14 WHEELS/TYRES
Minimum Recommended Tread Depth
Tyre Wear/Wheel Inspection, All Models

As the tyre tread wears down, the tyre becomes more
susceptible to puncture and failure. It is estimated that
90% of all tyre failures occur during the last 10% of tread
life (90% worn). It is false economy and unsafe to use
tyres until they are worn to their minimum.
All tyres are fitted with tread wear indicators. When the
tyre becomes worn down as far as the top of a tread wear
indicator, the tyre is worn beyond its service life and must
be replaced.
Typical
Tread
Wear
Indicator -
In accordance with the Periodic Maintenance Chart,

measure the depth of the tread with a depth gauge, and
replace any tyre that has worn to, or beyond the minimum
allowable tread depth.
Inspect wheels for cracks, splits and kerbing damage.
Inspect Tiger wheels for similar damage and also check
spokes for corrosion, looseness and breakage. Always
replace wheels that are suspected of being damaged.

worn tyres is hazardous and will
adversely affect traction, stability and handling
which may lead to loss of control or an accident.
When tubeless tyres become punctured, leakage
is often very slow. Always inspect tyres very
closely for punctures.
Check the tyres for cuts, imbedded nails or other
sharp objects. On spoked wheels, check spokes
for looseness and damage.
Check the rims for dents or deformation.
Operation with damaged or defective wheels or
tyres is dangerous and loss of control or an
accident could result.
Always consult your Triumph Dealer for tyre
replacement, or for a safety inspection of the tyres.
14.6
The following chart can be used as a guide to the

minimum safe tread depth.
Under 130 km/h (80mph) 2 mm (0.08 in)
Over 130 km/h
(80 mph)
Rear 3 mm (0.12 in)

Front 2 mm (0.08 in)
WARNING: Triumph motorcycles must

not be operated above the legal road
speed limit except in authorised closed course
conditions.
WHEELS!TYRES 14
IMPORTANT TYRE INFORMATION

worn or damaged tyres will adversely
affect handling and control leading to loss of
All Models except Tiger, Thunderbird,

Thunderbird Sport and Adventurer
All Triumph motorcycles are carefully and extensively
tested in a range of riding conditions to ensure that the
most effective tyre combinations are approved for use on
each model.
It is essential that approved tyre
combinations are used when purchasing replacement
tyres as the use of non approved tyres or approved tyres
in non approved combinations may lead to motorcycle
instability. Always refer to the Owner's Handbook data
section for details of approved tyres and tyre
combinations.
WARNING: If a tyre sustains a puncture,

the tyre must be replaced. Failure to
replace a punctured tyre, or operation with a
repaired tyre can lead to instability, loss of control
or an accident.
Never use an inner tube to repair a punctured tyre.
The rough surface inside the tyre can chafe the
tube leading to instability, rapid deflation, loss of
WARNING: Do not install tube-type tyres

on tubeless rims. The bead will not seat
and the tyres could slip on the rims, causing tyre
deflation that may result in a loss of vehicle control
and an accident.
Do not install an inner tube inside a tubeless tyre.
This may cause instability and excessive heat
build-up may cause the tube to burst resulting in
rapid tyre deflation, loss of vehicle control and an
accident.
WARNING: Accurate wheel balance is

necessary for safe, stable handling of the
motorcycle. Do not remove or change any wheel
balance weights. Incorrect wheel balance may
cause instability leading to loss of control and an
accident.
When wheel balancing is required, such as after
tyre replacement, see your authorised Triumph
Dealer.
Only use self-adhesive weights. Clip on weights
will damage the wheel and tyre resulting in tyre
deflation, loss of control and and an accident.
WARNING: The use of tyres other than

those listed in the specification section of
the owner's handbook may adversely affect
handling leading to loss of control or an accident.
Use the recommended tyre options only in the
combinations given in the owner's handbook.
Do not mix tyres from different manufacturers or
tyres from the same manufacturer but from
another option.
For example, do not use Daytona option 2 front
tyres with Daytona option 3 rear tyres.
WARNING: When replacement tyres are

required,
consult your authorised
Triumph dealer who will arrange for the tyres to be
fitted according to the tyre manufacturers
instructions.
When tyres are replaced, allow time for the tyre to
seat itself to the rim (approximately 24 hours).
During this seating period, ride cautiously as an
incorrectly seated tyre could cause loss of control
or an accident. Initially, the new tyre will not
produce the same handling characteristics as the
worn tyre and the rider must allow adequate riding
distance (approximately 100 miles) to become
accustomed to the new handling characteristics.
After both 24 hours and 100 miles, the tyre
pressures should be checked and adjusted and
the tyre examined for correct seating and rectified
as necessary.
Use of a motorcycle when not accustomed to its
handling characteristics may lead to loss of
WARNING: Always check tyre pressures

before riding when the tyres are cold.
Operation with incorrectly inflated tyres may affect
handling leading to loss of control and an
accident.
14.7
14 WHEELSITYRES
IMPORTANT TYRE INFORMATION
WARNING: Always check tyre pressures

before riding when the tyres are cold.
Operation with incorrectly inflated tyres may affect
handling leading to loss of control and an
accident.
Tiger, Thunderbird, Thunderbird Sport

and Adventurer
All Triumph motorcycles are carefully and extensively
tested in a range of riding conditions to ensure that the
most effective tyre combinations are approved for use on
each model.
It is essential that approved tyre
combinations are used when purchasing replacement
tyres as the use of non approved tyres or approved tyres
in non approved combinations may lead to motorcycle
instability. Always refer to the Owner's Handbook data
section for details of approved tyres and tyre
combinations.
WARNING: If a tyre or inner tube sustains

a puncture, the tyre and inner tube must
be replaced together.
Failure to replace a
punctured tyre and inner tube together, or
operation with a repaired tyre or inner tube can
lead to instability, loss of control or an accident.
When replacing a tyre, always inspect the rim tape
(rim protection band) to ensure that it is correctly
protecting the tube from the spoke threads. A
damaged rim tape may lead to rapid tyre deflation
causing loss of control and an accident.

worn or damaged tyres will impair
stability and handling and control leading to loss
of control or an accident.
WARNING: Accurate wheel balance is

necessary for safe, stable handling of the
motorcycle. Do not remove or change any wheel
balance weights. Incorrect wheel balance may
cause instability leading to loss of control and an
accident.
When wheel balancing is required, such as after
tyre replacement, see your authorised Triumph
Dealer.
Only use self-adhesive weights. Clip on weights
will damage the wheel and tyre resulting in tyre
deflation, loss of control and and an accident.
WARNING: When replacement tyres are

required,
consult your authorised
Triumph dealer who will arrange for the tyres to be
fitted according to the tyre manufacturers
instructions.
When tyres are replaced, allow time for the tyre to
seat itself to the rim (approximately 24 hours).
During this seating period, ride cautiously as an
incorrectly seated tyre could cause loss of control
or an accident. Initially, the new tyre will not
produce the same handling characteristics as the
worn tyre and the rider must allow adequate riding
distance (approximately 100 miles) to become
accustomed to the new handling characteristics.
After both 24 hours and 100 miles, the tyre
pressures should be checked and adjusted and
the tyre examined for correct seating and rectified
as necessary.
Use of a motorcycle when not accustomed to its
handling characteristics may lead to loss of
WARNING: The use of tyres other than

those listed in the specification section of
the owner's handbook may adversely affect
handling leading to loss of control or an accident.
Use the recommended tyre options only in the
combinations given in the owner's handbook.
Do not mix tyres from different manufacturers or
tyres from the same manufacturer but from
another option ..
For example, do not use Tiger option 2 front tyres
with Tiger option 3 rear tyres.
14.8
WHEELSITYRES 14
WHEEL REMOVAL
CAUTION: To prevent wheel and bearing

damage, ensure there is no dirt ingress to
the wheel bearings while the wheel is removed.
Front
1.
Remove the speedometer cable retaining screw.
2.
Disconnect the speedometer cable.
3.
Release the upper and lower brake caliper

mounting bolts and spacers.
4.
Remove the calipers (do not discoonect the brake

hoses).

~ hang on the brake hoses as this may
5.
Do not allow the wheel to rest on the brake disc as

this may damage the disc. Always place wooden
blocks beneath the wheel to raise the disc above
ground level.
Installation
The wheels are installed using a reversal of the
removal procedure. However, the following points
should be noted:
NOTE:
Raise the front of the motorcycle to allow removal of

the front wheel.
Ensure the speedometer drive tongues mate

with speedometer drive cutouts in the wheel.
0
2~

falling.
,,
, @\
6.
Release the wheel spindle bolt (domed nut on

Tigers).
7.
Release the spindle pinch bolts from both sides (not

Tiger).
8.
Support the wheel and remove the spindle.
9.
Remove the wheel from between the forks.
10. Remove the speedometer drive assembly.
1. Speedometer Drive
2. Drive Tongues
3. Drive Cutouts
11. Remove spindle sleeve.
NOTE:
5
Ensure the bearing sleeve is clean and smooth

before refitting. Lightly smear the sleeve
surface with grease to prevent damage to the
seal (Not Tiger).
1. Speedometer Screw 4. Pinch Bolts

2. Speedometer Cable 5. Caliper Mounting Bolts
3. Spindle Bolt
4. Wheel Bearing Sleeve (Not Tiger)
14.9
14 WHEELS/TYRES
Front wheel installation cont'd
REAR WHEEL
All except Tiger
NOTE:
1.
Tighten the front wheel spindle bolt to 60 Nm.
The wheel can be removed without removal of

silencers.
2.
Tighten the front wheel spindle pinch bolts to

20Nm.
On continental models, the rear mudguard

extension must be removed.
3.
Tighten the brake caliper mounting bolts to

40 Nm (all except Thunderbird, thunderbrid
Sport & Adventurer)
28 Nm (Thunderbird, Thunderbird Sport &
Adventurer).
4.
Refit the speedometer cable.
5.
Check the operation of front brake after fitting by

pumping the brake lever several times to establish
correct operation. Confirm correct operation by a
road/roller test.
Removal
1.
Remove the chain guard or wheel guard.
2.
Raise the rear of the motorcycle to allow removal of

the rear wheel.

falling.
Tiger
1.
Tighten the front wheel spindle dome nuts to 85 Nm
2.
Tighten the brake caliper mounting bolts to 40 Nm.
3.
Refit the speedometer cable.
4.
Check the operation of front brake after fitting by

pumping the brake lever several times to establish
correct operation. Confirm correct operation by a
road/roller test.
3.
Remove the rear wheel bolt retaining rings from

both sides (eccentric adjuster type swinging arms
only).
-
4.
Remove the wheel bolt/nut and spindle.
1. Retaining Rings
2. Spindle Bolt
5.
Lower the wheel and lift the chain from the rear
sprocket.
6.
Inspect the sprocket for worn or damaged teeth.
7.
Remove the spacer from the left hand side sprocket

carrier.
8.
Lift/lower the brake caliper carrier (lower models

fitted with an underslung rear caliper) and remove
the right hand spacer.
14.10
WHEELSITYRES 14
NOTE:
WHEEL BEARINGS
Make a note of the orientation of the spacers to

ensure correct fitment on assembly.
WARNING: Operation with worn or

damaged steering head or wheel
instability leading to an accident. If in doubt, have
the motorcycle inspected by an authorised
Triumph dealer before riding.
Removal
1.
Remove the wheel as described earlier.
2.
Lay the wheel on its side while supporting the wheel

on wooden blocks to prevent damage to the brake
disc.
1. Left Hand Side Spacer

2. Right Hand Side Spacer
2.
A.
Lift/lower the brake caliper carrier (lower models

fitted with an underslung rear caliper) and remove
the wheel.
~ on the brake disc as this may damage the

3.
Remove the oil seals and bearing circlip. Collect the

speedometer drive ring.
4.
Using a suitable drift, through the centre of the

wheel, drift out each bearing. Collect the centre
sleeve.
{L
~
1. Caliper Carrier
Installation
1.
To refit the wheel, reverse the removal procedure,

taking note of the following:
a.
b.
c.
the wheel spindle should be cleaned and

lightly oiled.
the drive chain and wheel alignment should
be adjusted with reference to relevant
section.
tighten the wheel spindle bolt/nut to 85 Nm
and fit new retaining rings (where originally
fitted).
WARNING: To prevent injury. always

using a drift.
WARNING: Ensure the caliper carrier

sleeve is correctly fitted. If the sleeve is
fitted incorrectly, the rear brake could lock up
when in use, causing loss of control and an
accident.
h>. '
14.11
14 WHEELS/TYRES
Installation
NOTE:
1.
Install bearings with the marked or shielded sides

face out.
Refer to the chart below for the correct tool and tool
face to use when inserting bearings.
Bearings are installed by means of a draw bolt
acting on the insertion tool. A support tool is located
on the opposite side of the hub to the insertion tool
and as the draw bolt is tightened, the bearing is
drawn into the hub.
Insert bearings with the marked or shielded side
facing outwards and always fit a new bearing circlip.
WARNING: When using bearing service

tools always ensure that the selected tool
matches the diameter of the bearing being
installed. Damage to the wheel and bearing will
result from incorrect tool selection which may
cause loss of control and an accident.
Ensure that the bearing remains square to the hub
during the drawing in procedure. Damage to the
bearing and hub will result from forcing a bearing
which is not square to the hub which could cause
loss of control and an accident. .
Always install bearings with the marked or
shielded sides facing outwards.
1. Tool 3880075 in position
Bearing Tool Selection Chart

FRONT
Bearing
Insertion Tool
Support Tool
Left Bearing
3880070
Small face to
bearing
3880075
Large face to
hub
Right Bearing
3880070
Small face to
bearing
3880075
Large face to
hub
REAR
Bearing
Insertion Tool
Support Tool
Left Bearing
3880070
Small face to
bearing
3880075
Small face to
hub
Right Bearing
3880070
Large face to
bearing
3880075
Small face to
hub
Cush Drive
3880075
Small face to
bearing
N/A
14.12
2.
Refit the speedometer drive ring with the drive tags

facing outwards.
3.
Lubricate and fit new seals to the wheel hubs.
4.
Refit the wheel as described earlier.
Frame/Fairings
CONTENTS
Page
Exploded view....................................................
15.2
Seat
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daytona/Speed Triple Seat Hump

Removal/Refit to Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hump not in Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side panels
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thunderbird, Thunderbird Sport & Adventurer side panel removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.9
15.9
15.1 0
15.10
15.11
15.12
15.12
Cockpit fairing- not 'new' Trophy

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.13
15.14
Cockpit fairing - 'new' Trophy

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.14
15.14
Lower Fairings - not 'new' Trophy

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.15
15.15
Lower Fairings- 'new' Trophy

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.16
15.17
Cam cover cowl

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.17
15.17
Frame
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bank Angle Peg Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15.18
15.18
15.1
15 FRAME/FAIRINGS
Body Panels - Trident, Daytona/Trophy
10 Nm
15.2
_ _ _ _ _ _ FRAME/FAIRINGS 15
Footrests and Body, Tiger
Push Fit
Push Fit
27;;: '
~~
~
~~ ~~27Nm
42Nrl
27N~
'-
95
~~
27 Nm
7 Nm
J ~
15.3
7Nm
15 FRAME/FAIRINGS
Thunderbird T
~~~enturer
_: srd~s~:rbird
Sport &and
y
nd, Footrest
Hand Tight
7 Nm
12\
~'';
7Nm
_,'1~~~
6J%~
25Nm
12 Nm
-i,.:::-
7Nm
f! ~~
15.4
'"'
Hand Tight
?Nm
5 Nm
---~
20Nm
FRAME/FAIRINGS 15
Thunderbird & Thunderbird Sport Frame
~
I
@
I
~
I
15.5
15 FRAME/FAIRINGS
Adventurer Frame
95 Nm
u?f~
28 Nm
15.6
FRAME/FAIRINGS 15
Frame and Fittings -All models except Tiger, Thunderbird, Thunderbird Sport &
Adventurer
27Nm
95Nm
9Nm
42Nm
27 Nm
27 Nm
15.7
IS FRAME/FAIRINGS
Bodywork - 1996 Trophy
10 Nm
r27Nm
fi:>
:
3Nm
r
,J
9N~~
I
/ ~~"1>
I
I
I
-.I
I
3 Nm
___.
5 Nm
7 Nm
.-~
10 Nm
' .~
3Nm
10Nm9
3 Nm
'
3 Nm 3 Nm
..1
3 Nm
3Nm~
,.
3 Nm
15.8
5Nm
FRAME/FAIRINGS IS
SEAT
Removal -All except Adventurer with

Dual Seat
NOTE:
Throughout the model range, there are differing

locations for the seat lock.
Refer to the
diagrams below for an explanation of the
various seat lock locations.
~
1';<r,~
I
f \
\~
1.
Insert the ignition switch key into the seat lock.
2.
Turn the key while pressing down on the rear of the

seat.
3.
Lift the rear of the seat and remove from the frame.
NOTE:
If the seat does not release readily from the lock,

gently tap the rear of the seat with the palm of
the hand.
Removal - Adventurer with Dual Seat

1.
1.
Pull the ring situated to the left side of the seat to

release the rear of the seat. The rear of the seat will
spring upwards slightly.
2.
Insert the ignition key into the seat lock, situated in

the left hand side panel, and turn to the left while
pressing down on the centre part of the seat.
3.
To fully detach, lift the rear of the seat and slide

rearwards.
Seat Lock - all except Trophy 1996, Tiger,

NOTE:
1.
1.
Tiger Seat Lock
If the seat does not release readily from the lock,

gently tap the rear of the seat with the palm of
the hand.
Installation - All variants

Adventurer Seat Lock
1.
To refit the seat, remove the key from the seat lock
and return it to the ignition switch.
2.
Locate the front section to the back of the fuel tank

and press down on the rear (and centre on
Adventurer with dual seat) of the seat to engage in
the seat lock.
3.
Grasp the seat and check that it is securely retained

by the lock(s).
NOTE:
When the seat is correctly engaged in the lock,

an audible click will be heard.
WARNING: Failure to correctly secure

the seat in the seat lock will result in an
unsafe riding condition which may cause
1. 1996 Trophy Seat Lock
15.9
15 FRAME/FAIRINGS
SEAT HUMP (WHERE FITTED)
Hump Not in Use
Removal from the Seat
1.
Remove the hump from the seat as described over.
1.
Unlock and remove the seat.
2.
Position the seat end trim to the end cap as shown

below.
2.
Release the two fixings from either side of the seat

and slide the hump rearwards and upwards.
Refit
1.
Align the hump to the seat in the direction of the

lower arrow. Engage the rear edge of the hump
beneath the rear edge of the seat.
2.
Rotate the hump forward without disengaging the

rear edge, until the holes in the side of the seat align
with the corresponding holes in the hump. Fit and
tighten the bolts.
End Trim
3.
Retain the end trim by fitting the grab rail. Tighten

the grab rail bolts to 27 Nm.
1. Locate Lower Edge

2. Rotate Forward
3. Retain With Allen Bolts
NOTE:
The lumbar support can be removed from the

seat hump by detaching the screws from inside
the hump.
1. Grab Rail
2. End Trim
3. Grab Rail Bolt
NOTE:
4.
Seat Hump Lumbar Pad Fixings
15.10
Where twin grab rails are fitted, the front bolts

should be tightened to 27 Nm and the rear bolts
to 10 Nm.
Refit the seat.
FRAME/FAIRINGS 15
4.
SIDE PANELS
Removal
All models except Thunderbird,
NOTE:
On all except Tiger and early Daytona models,

the side panels are removed as an assembled
set. On early Daytona models, the seat end cap
must first be removed and the side panels are
then removed separately. Tiger side panels can
be removed independently of each other.
1.
Remove the seat and release the grab rail(s) (seat

only on Tiger).
The side panels are retained by a series of bayonets

which locate in grommets on the frame. To detach
the panels, gently pull the panel in an outward
direction until the bayonets detach from the
grommets.
Once all bayonets have become
detached, the panels can be removed from the
frame.
1. Bayonets
5.
To separate the panels, release the screws

securing the end cap to the side panels and remove
the end cap.
1. Grab Rail
2. Grab Rail Bolt
2.
Release the screws and plastic washers securing

the side panels to the rear frame.
NOTE: On Tiger models the side panels can
now be removed.
3.
Early Daytona only: Release the screws and

plastic washers securing the seat end cap and lift
the cap from its locating bayonets.
1. Self Tapping screw
2. Washer
3. Torx Screw
4. Washer
(Trident panels illustrated)
NOTE:
1. Side Panel Screws

2. End Cap Screws
15.11
Later Sprint and Trophy side panels have a

different end cap to side panel fixing
arrangement though the side panels must still
be removed as an assembled pair.
15 FRAME/FAIRINGS
Installation
Side Cover Removal -Thunderbird,

All models except Thunderbird,

1.
Position the side panels adjacent to the frame.
2.
Carefully push the bayonets into their grommets

using hand pressure only (Tiger refit using the
screws and washers removed in paragraph 2 of
removal).
1
1.
Remove the seat as described earlier.
2.
Remove the screw securing each side panel to the

frame and collect the flanged sleeve.
3.
To detach the side panel, lift the panel (in the

direction of the arrow) until it is clear of the two
locating pegs on the frame.
1. Tiger Side Panel Fixings
3.
Early Daytona only: Repeat for the second side if

removed.
4.
Early Daytona only: Refit the seat end cap.
5.
Position the grab rail and fit the bolts (not Tiger).
6.
Fit the screws and washers securing the side panel

assembly to rear frame.
7.
8.
Assembly
1.
Check that the grommets are in place on the side

cover and fit the cover to the locating pegs on the
frame.
Ensure that the complete assembly is correctly

seated.
2.
Locate the flanged sleeve to the cover
Tighten the grab rail bolts to 27 Nm.
3.
Fit and tighten the side cover screw to 3 Nm.
NOTE:
9.
1. Screw
2. Flanged Sleeve
Where twin grab rails are fitted, the front bolts

should be tightened to 27 Nm and the rear bolts
to 10 Nm.
Tighten the side panel to rear frame screws to
3 Nm.
Airbox Covers -Thunderbird,

Removal
1.
Release the screws securing the cover and badge

to the airbox
2.
Remove the cover.
10. Refit the seat.
NOTE:
The badge has an adhesive back and will remain

attached to the airbox cover.
Refit
1.
Align the cover to the airbox.
2.
Fit and tighten the airbox cover screws to 3 Nm.
15.12
FRAME/FAIRINGS 15
COCKPIT FAIRING (NOT 'NEW' TROPHY)
4.
Removal
Remove the locknuts securing the mirrors to the

cockpit (not Tiger). Remove the mirrors together
with the mounting bolts.
1. Remove the seat and disconnect the battery,
negative (black) lead first. Release the screws

securing the left-hand and right-hand facia panels.
Raise the right hand panel and disconnect the clock
(if fitted). Remove the facia panels.
/?> v'
~
1. Cockpit To Side Fairing Fasteners

5.
Remove the windscreen.
6.
Ease the cockpit fairing forward (not Tiger) to give

temporary access to the wiring harness.
7.
Disconnect the two connections from the right and

left-hand direction indicators, together with the
headlight connection.
8.
Release the grommets, nuts, washers and spring

washers securing the direction indicators to the
upper sub-frame.
9.
Remove the direction indicators.
1. Right Hand Facia Panel (early Trophy Illustrated)
NOTE:
Additional covers, which must also be

removed, are fitted to later Daytona and
Daytona Super 3 models.
2. Release the bolts securing the lower side fairing (if
fitted) to the cockpit fairing.
Tiger models only, remove the bolts securing the
cockpit and side fairings to the fuel tank. Remove
the cockpit and side fairings.
10. Release any remaining bolts securing the cockpit to

the subframe. Remove the cockpit.
Tiger Bodywork
1. Lower Fairing To Tank Fixings
2. Cockpit Fixings
3. Windscreen To Cockpit Screw
3.
Sprint Cockpit
1. Cockpit Fixings
2. Indicators
Support the cockpit fairing.
15.13
15 FRAME/FAIRINGS
1\
CAUTION:
Always store the cockpit
fairing in a safe place where damage to
the painted surfaces is unlikely. Do not allow the
rear part of the Sprint cockpit to drag across the
fuel tank during removal.
Installation
Installation is a reversal of the removal procedure.
However, the following points should be noted.
NOTE:
When assembled, test the indicators for correct

operation.
Reconnect the battery positive (red) lead first.
COCKPIT FAIRING - 'NEW' TROPHY

Removal
Arrowed - Headlamp Adjuster Cable
1.

2.
Release the screws securing the upper facia panels

to the inside of the cockpit.
7.
Release the screws securing the cockpit to the

lower fairings.
1. Upper Facia to Cockpit Screw

3.
Remove both mirrors.
4.
Remove the chin panel from the underside of the

cockpit.
5.
---------
1. Cockpit to Lower Fairing Screws

8.
Remove the screws securing the base of the

headlamp assembly to the cockpit subframe.
Ease the cockpit away from the cockpit subframe

and separate the headlamp wiring connectors. The
cockpit can then be detached from the motorcycle
Assembly
NOTE:
Reconnect the headlamps during assembly of

the cockpit to the cockpit subframe.
Test
all
electrical
reconnection.
Refit and test the headlamp adjuster cable.
1. Headlamp to subframe screws
15.14
circuits
following
FRAME/FAIRINGS 15
LOWER FAIRINGS- (NOT 'NEW' TROPHY)

Removal
5.
Release and remove the 3 screws securing the left

and right-hand fairings together.
6.
Early Models Only: Release and remove the self

tapping screws securing the left and right
hand radiator ducts to each other.
NOTE:
On Sprint models, the cockpit and fairing is a

one piece assembly.
On early Trophy models, the two sections of the
radiator ducts are secured together with
screws. These screws are also used to retain
the oil cooler grille (where fitted) to the oil
cooler.
1.

facia panels (where fitted) to the lower fairing.
6.
7.
8.
9.
7.
Oil Cooler To Radiator Duct Fasteners

Right Hand To Left Hand Fairing Fasteners
Self Tapping Screws
Radiator Ducts
Release the screws securing the lower fairing to the
cockpit. The fairing can now be carefully removed.
/':\.
CAUTION: Always store the displaced

fairing in a safe place where damage to
the painted surfaces is unlikely.
1. Facia
2. Facia Screws
3. Lower Fairing To Cockpit Fasteners
Installation
2.
Release the bolts securing the fairing bracket,

visible through the aperture in the fairing side, to the
cylinder head.
3.

fairing to the lower sub-frame.
4. Fairing Bracket
5. Fairing To Lower Subframe Fasteners
4.
Early Models only: Release the screws and

washers securing the radiator ducts to the oil cooler.
15.15
Installation is the reverse of the removal procedure.
15 FRAME/FAIRINGS
5.
LOWER FAIRINGS - 'NEW' TROPHY
Release the screw securing the upper facia panel to

the inside of the cockpit.
NOTE:
The lower fairing is removed as an assembly

complete with infill panels and facia.
1.

2.
Release the screws securing the fairing belly panel

to the fairings.
(
babi
()
1. Upper Facia to Cockpit Screw

6.
Release the screws securing the fairing to the frame

and engine.
-----------
1. Belly Panel
3.
Open the facia storage container and release the

screw securing the storage box to the fairing
bracket.
NOTE:
If removing the right hand fairing, also

disconnect the headlamp adjuster cable.
~
J
5052
1. Storage box to bracket screw
1. Fairing to Frame/Engine Screws
Arrowed - Headlamp Adjuster Cable
4.
Release the screws securing the cockpit to the

lower fairing.
NOTE:
15.16
On 3 cylinder models, an additional screw

secures the lower infill panel to the head
bracket.
FRAME/FAIRINGS 15
2.
With the fuel tank removed, detach the fuel tank

mounting bushes from the ends of the frame
outriggers.
1. 3 Cylinder lnfill Panel to Head Screw

7.
Ease the fairing away from the engine and

disconnect the indicator. On right hand fairings,
also disconnect the fuse box at its connection to the
main harness.
1. Fuel Tank Mounting Bushes

2. Cam Cover Cowls
3. Foam Seal
NOTE:
3.
Remove the spark plug leads from the plugs and

also detach the leads from the foam seal in the cam
cowls.
4.
Release the fixings from the cowls and detach from

the frame.
Once all electrical disconnections have been

made, the fairing may be completely removed.
Installation
Installation
NOTE:
When assembled, test the indicators and other

electrical circuits for correct operation.
Check for correct operation of the headlamp

adjuster.
1.
Position the foam seal over the choke cable and

locate the spark plug leads in the seal slots. Fit the
leads to the spark plugs.
2.
Check the operation of the choke and, at the same

time, ensure that the clutch hose does not foul the
choke operating bar on the carburettors.
CAM COVER COWL

/)...
CAUTION:
Ensure that the radiator
overflow pipe does not become trapped
during replacement of the cowls.
Removal
1.
To gain access to the cam cover cowls the following

items must be removed:
Cockpit fairing
Lower fairing (where fitted)
Fuel tank
In all cases, refer to the relevant section for
instructions on the safe removal and refitting
procedures for these items.
3.
Refit the cowls to the frame and secure using the

original fixings.
4.
Fit the cowls ensuring the correct fitment of the foam

seals in the cowl cut-outs.
5.
Refit the fuel tank mounting bushes.
15.17
IS FRAME/FAIRINGS
FRAME, FOOTRESTS AND FIXINGS
Inspection
1.
Inspect the frame, footrests and fairings for

damage, cracks, chafing and other dangerous
conditions.
Check fairing and frame fixings for security.
2.
Inspect the bank angle pegs for wear. If more than

50% of the radiused end is worn away, the bank
angle peg must be replaced.
Bank Angle Peg Wear Limit

(Trophy type illustrated)
WARNING: Use of a motorcycle with

bank angle pegs worn beyond the
maximum limit will allow the motorcycle to be
banked to an unsafe angle.
Banking to an unsafe angle may cause instability,
loss of control and an accident causing injury or
death.
WARNING: If the motorcycle is involved
in an accident or collision it must be taken
to an authorised Triumph dealer for repair or
inspection. Any accident can cause damage to the
motorcycle which, if not correctly repaired, may
cause another accident which may result in injury
or death.
WARNING:
The frame must not be
modified as any modification to the frame
such as welding or drilling may weaken the frame
resulting in an accident.
15.18
Electrical System/Ignition
CONTENTS
Page
Battery
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery electrolyte level inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.7
16.8
16.9
Instruments
Instrument packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel gauge sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.9
16.9
Alternator
Removal/1 nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.11
Ignition system
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition pickup sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.12
16.14
16.14
16.14
Starter motor
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation/component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.27
16.28
16.29
Starter solenoid
Removal/1 nstallation
16.31
Cooling system
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.32
16.34
Fuse box
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.35
Lights
Tail Light Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight adjustment/bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.37
16.38
Wiring diagrams
Trophy, Trident and Daytona to VIN 4902 . . . . . . . . . . . . . . . . . . . . . . . . .
Trophy from VIN 4902 to VIN 29155Trident,
Sprint, Speed Triple and Daytona from VIN 4902 onwards . . . . . . . . . .
Trophy from VIN 29156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tiger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thunderbird , Thunderbird Sport & Adventurer . . . . . . . . . . . . . . . . . . . .
16.1
16.45
16.47
16.49
16.51
16.53
16 ELECTRICAL SYSTEM/IGNITION
I
~--18Nm
16.2
ELECTRICAL SYSTEM/IGNITION 16
~~@__~
Hand tight
/
{it__
ii(
Hand tight
Hand tight -
18 Nm
f\~
Hand tight
<_\
~f(-~ ':>
18Nm
~~
~ ~ /li>i!IJ
~\ Hand tight
Handtig\
~~
Hand tight
/iJP~J/)1
'~
~~~~ 0::\
4
.
~/ /
16.3
'>
Hand tight
Hand tight
--=::'
16.4
'--.._ 12 Nm
9 Nm
----J
e
16.5
16 ELECTR /CAL SYSTEM/IGNITION - - - - - - - -
7Nm
e.,@~
~~
I
I
I
I
16.6
BATTERY
Battery Charging
New (Dry) Battery
WARNING: The battery gives off

explosive gases; keep sparks, flames
and cigarettes away. Provide adequate ventilation
when charging or using the battery in an enclosed
space.
To ensure that a new battery is correctly commissioned

and will deliver maximum capacity for starting, the
following procedure must be followed.
1.
Remove the sealing tape and vent cap.
The battery contains sulphuric acid (electrolyte).

Contact with skin or eyes may cause severe burns.
Wear protective clothing and a face shield.
2.
Remove the filler plugs and fill the battery with

electrolyte to the upper level. The electrolyte
must be specific gravity 1.28.
3.
Allow the battery to stand for 30 minutes and then

adjust the electrolyte level back to the upper level
mark.
4.
Charge the battery continuously at 1.4 A

maximum for 15-20 hours
5.
After charging, top up the battery using distilled

water only.
6.
Replace the filler plugs and vent cap, and

thoroughly clean the battery.
If electrolyte gets on your skin, flush with

water immediately.
If electrolyte gets in your eyes, flush with
water for at least 15 minutes and SEEK MEDICAL
If electrolyte is swallowed, drink large
quantities of water and SEEK MEDICAL
KEEP ELECTROLYTE OUT OF THE REACH OF
CHILDREN.
WARNING: The battery contains harmful

motorcycle.
cables together or reverse the polarity of the
cables as any of these actions may cause a spark
which would ignite battery gasses causing a risk of
personal injury.
Battery Already in Service

When re-charging a battery in service, the following
precautions must be taken to avoid damage to the
battery.
1. The charging rate must not exceed 10% of the
battery capacity. The standard Triumph battery
capacity is a 14 Amp. hour unit and therefore the
charging rate must not exceed 1.4 A.
WARNING: The battery electrolyte is

corrosive and poisonous. Never swallow
battery electrolyte or allow to come into contact
with the skin. Always wear eye and skin protection
when adjusting the electrolyte level
CAUTION: When checking the battery

electrolyte level, or adding distilled water,
ensure that the breather is not blocked. A blocked
breather may cause a build-up of gas in the battery
which would damage the battery case.
2.
Before the battery reaches the gassing stage, this

rate may be briefly exceeded but the temperature
of the electrolyte must not be allowed to rise
above 55C.
3.
After charging, allow the battery to cool and then

top up the electrolyte level with distilled water.
4.
Never allow the battery to stand in a discharged

state or with the electrolyte level below the
minimum level.
/,'.
CAUTION: Using a battery charger set to
~ a charge rate greater than 10% of the
battery capacity will cause permanent damage to
the battery. Therefore, the maximum rate of charge
is 1.4 Amps.
To prevent battery damage, use only distilled water

in the battery. Tap water will shorten the service life
of the battery.
Filling the battery above the UPPER LEVEL line
may cause the electrolyte to overflow, resulting in
corrosion to engine or nearby parts. Immediately
wash off any spilled electrolyte.
16.7
Removal - all models except Thunderbird,

3.
Release the battery retaining strap.
4.
Disconnect the flasher unit and the fuse box

connection to the main harness.
1.
Remove the seat and document tray (if fitted).
2.
Disconnect the battery negative (black) lead first,

then the positive (red) lead.
5.
Gently ease the harness away from the battery

box.
3.
Remove the battery strap.
6.
4.
Take the battery, complete with breather tube, out of

the case.
Release the screw securing the door to the

battery box. Release and un-clip the battery box
door.
7.
Disconnect the battery breather tube.
5.
Wipe the battery using a clean, dry cloth. Ensure

that the battery lead connections are free from
oxidation deposits.
NOTE:
8.
The breather tube may fall to the floor when

disconnected
Remove the battery by sliding sideways out of the
battery box.
Battery Electrolyte Level Check

1.
Remove the battery from the motorcycle, see

Battery Removal.
2.
Check that the electrolyte level in each cell is

between the upper and lower level lines.
3.
If the electrolyte level is low in any cell, top-up the

cell with distilled water.
1. Battery
2. Negative(-) terminal
3. Positive(+) terminal
3
Removal, Thunderbird, Thunderbird Sport

& Adventurer
1.
Remove the seat and right hand side panel.
2.
Disconnect the battery leads, negative (-) black

lead first then the positive(+) red lead.
1. Upper Level
2. Lower Level
3. Breather Tube Connection
4.
On refitting, ensure that the battery breather pipe is

routed down the inside of the centre stand spring
(where a stand is fitted) or is routed between the
frame and swinging arm when no centre stand is
fitted.
The battery electrolyte level must be kept between the

upper and lower level lines. Check the electrolyte level in
each cell in accordance with periodic maintenance chart.
1. Flasher Unit Connection.

2. Battery Box Door Retaining Screw
3. Fuse Box Connection
16.8
INSTRUMENTS
WARNING: Filling the battery above the

. . . UPPER LEVEL line may cause the
electrolyte to overflow.
Electrolyte is highly
corrosive and will damage clothing and cause
burns if in contact with the skin
All models are fitted with an instrument pack containing

an electronic tachometer and a mechanical
speedometer. In some cases, a coolant temperature
gauge is also fitted.
Never route the battery breather pipe in any way

which could cause the pipe to become blocked or
trapped. A blocked or damaged pipe will cause a
build up of pressurised, explosive gas which may
ignite.
In addition, the 1996 Trophy is fitted with a fuel gauge

All main part of the instrument packs may be serviced.
FUEL GAUGE LEVEL SENSOR

1996 TROPHY
When adding electrolyte, always wear eye and

skin protection.
A rheostat type sensor is located in the base of the fuel

tank of the 1996 Trophy model.
Installation - all models except

Adventurer
The sensor operates via a buoyant arm which floats on

the fuel within the tank.
1.
Removal
2.
Check that the battery case rubber pad is

correctly located in the bottom of the battery case.
Place the battery in the battery case and connect
the battery breather pipe.
1.

system section.
3.
Fit the battery strap.
4.
Reconnect the battery positive (red) lead first then

the negative (black) lead.
5.
Lightly smear a coating of petroleum jelly on


fire, causing personal injury and damage to
6.
2.
Remove the screws securing the sensor to the

base of the tank.
7.
Refit the seat and document container (if fitted).
3.
Remove the sensor unit from the tank.
Installation, Thunderbird, Thunderbird

Sport & Adventurer
1.
Clean the battery box.
2.
Place the battery in the battery box, and connect

the battery breather tube.
3.
Re-fit the battery retaining strap.
4.
Re-fit the door to the battery box and tighten the

door retaining screw.
5.
Re-connect the flasher unit and fuse box to the

main harness.
6.
Reconnect the battery positive(+) red lead first

then the negative H black lead.
7.
Apply a light coat of petroleum jelly to the battery

8.
9.
Refit the right hand side panel and the seat.
Fuel Gauge Sensor Unit
A_
L_U
CAUTION: The sensor unit is fitted with

an arm to which a float is attached.
During removal of the unit from the fuel tank, do
not use excessive force as this will damage the
arm.
16.9
NOTE:
2.
Locate the sensor unit into the tank and tighten

the sensor fixings to 10 Nm.
3.
Refit the fuel tank as described in the fuel system

section.
To prevent damage to the float arm, it will be

necessary to turn the sensor as it is withdrawn
from the tank.
Inspection
Check for broken/damaged connections, a punctured
float and damaged rheostat windings. Replace the
sensor if suspect.
Assembly
1.
Fit a new gasket to the base of the fuel tank.
Fuel Gauge Sensor Circuit

The wiring circuit for the fuel gauge sensor unit is
shown below/right.
FUSE 9
For details of other circuits on the 1996 Trophy,

refer to the circuit diagrams later in this section.
N
.------ NR
cEJ N~
-eEl-I
NR
.---1
4
..__________,
w
N
0
L.-
L.-
FUEL GAUGE
~1------GY
L---------GB
GB
FUEL LEVEL
SENSOR
16.10
I
LL
LL
IGNITION
SWITCH
ALTERNATOR
Installation
Removal
1.
Fit the alternator cush drive rubbers to the alternator

drive.
2.
Clean the alternator lugs and crankcase where the

alternator is grounded.
3.
Fit a new '0' ring to the alternator housing.
WARNING: To prevent personal injury

and damage to components, disconnect
the battery, negative (black) lead first, then the
positive (red) lead.
NOTE:
1.
Unplug the alternator connection to the main

harness.
2.
Detach the rubber boot from the earth lead and

remove the securing bolt.
Apply a small amount of engine oil to rubber

dampers and the '0' ring on the alternator
housing.
1. '0' Ring
1. Earth Connection
NOTE:
3.

Adventurer, remove the horn and bracket from
the engine.
Release the remaining bolts securing the alternator
to the crankcase.
4.
Remove the alternator.
5.
Remove the four rubbers from the alternator cush

drive housing.
4.
Reconnect the alternator to the main harness.
5.
Fit the alternator and secure with two bolts.
6.
Attach and secure the earth strap. Refit the rubber

boot.
7.
Tighten all alternator mounting bolts to 20 Nm.
NOTE:
Adventurer, refit the horn and bracket to the
engine.

and damage to components, connect the
battery, positive (red) lead first, then the negative
(black) lead.
1. Cush Drive Rubbers
16.11
IGNITION SYSTEM
The peg passing the sensor causes a signal of low

voltage electricity to be sent to the igniter. This signal is
the reference point which causes the primary voltage to
be switched off and on by the igniter (the dwell period).
This switching, the timing of which is variable with engine
speed (advance), induces a high voltage in the
secondary circuit of the coils which is delivered to the
spark plugs via the plug leads.
Description
The ignition system fitted to all Triumph motorcycles is a
digital electronic type and must not be confused with the
capacitor discharge system (CDI) which is common to
other machines.
The Triumph system has three
transistor output stages which are controlled by advance
curves which vary from engine type to engine type.
Within the overall system there are four major
components as follows.
Ignition Coils
Igniter unit
Signal Generator or Pick-Up Sensor
Igniter Sub-Harness
WARNING:
The ignition system
There are two separate sections to the ignition system,

the low voltage primary circuit which contains the logic
controls and crankshaft sensor, and the secondary
circuit which which provides the higher voltage supply to
the spark plugs
WARNING:
Ignition Coils
Coils with low resistance primary windings are fitted to
allow a more rapid coil action than found in conventional
coils. This rapid action allows the coil to function
correctly at both low and high engine speeds.
Igniter
The igniter evaluates information from the crankshaft
sensor which is received in the form of electronic pulses.
From the received pulses, the igniter calculates the
output required from the coils. The basis for the
calculations come from pre-programmed ignition
parameters within the igniter unit. The calculations made
include;
dwell angle
ignition timing (which is variable with engine speed)
the firing order of the cylinders
Because the igniter uses electronic components to carry
out these functions, it is able to operate without electronic
arcing and, therefore, has a much longer service life than
conventional switching systems.
Ignition Circuit
On the following page, a schematic diagram of the
ignition circuit can be found.
Signal Generator (Pick-up Sensor)

As there is no distributor in the Triumph ignition system, a
sensor is mounted to the crankcase which interprets
signals from a disc which turns with the crankshaft.
The function of the disc and sensor is to register the
position of each piston in relation to top dead centre, and
also to record engine speed. This data is transmitted to
the igniter unit for evaluation. The sensor and disc
operate in the following way.
A peg on the disc passes the sensor at the precise
moment (of engine rotation) at which the spark is to
occur.
16.12
The circuit depicted is for 1996 Trophy though other

models are similar in layout.
NOTE:
On models other than 1996 Trophy, fuse

numbers and wiring colours may differ from
those shown in the diagram opposite. For full
details of other models, refer to the full wiring
circuit diagrams at the end of this section.
Ignition circuit (Trophy 1996 model illustrated)
Code
Colour
Black
Blue
Brown
Green
Grey
Orange
Pink
LG
Light
Green
NR
Red
Purple
White
Yellow
FUSE 9
----L8------L8---
N
NR
FUSE 7
~w--@:J-w
L_
W
N
1JJ
~
IGNITION
SWITCH
GY--0=J- GY
FUSES
G------!:&--
TACHOMETER
'---+-- 0 K
or-----,_---w
,r
:+-?J
,.-IGNITER
GN--~.---G N
s
1-----t--- s N
r - - - t - - - su
IGNITION
COILS
FLOAT CHAMBER
VENT SOLENOIDS
(US California ONLY)
GN---.
IGNITER
PICK-UP
o=
R
B
----!
ALARM
SOUNDER
5
'-_
r rial--- SU
SU ---141
ALARM
L~ BR-T--4r~-----11r~ BR ~CONTROL UNIT
al
a:
a:
al
al
d-1
m
(!)UlZ
SIDESTAND
SWITCH
16.13
SIDESTAND
RELAY
PICK-UP SENSOR
IGNITION COILS
Removal
Removal
1.

2.

system section. Remove the cam cover cowls.

negative (black) lead first, then the positive (red)
lead.

and damage to components, disconnect
the battery, negative (black) lead first, then the
positive (red) lead.
2.
Remove the lower fairing (if fitted).
3.
Remove the right-hand crankshaft cover.

correct manner.
Installation
NOTE:
1.
Install the ignition pickup sensor using a reversal of

the removal procedure. The following points must
be noted

the head before disconnection. This will help in
matching the ignition coils with the correct plug
lead when refitting.
Install the ignition pickup and adjust to give a

clearance (air gap) between the timing rotor
projection and ignition pickup of 0.6 - 0.8mm.
3.
Disconnect the high and low tension leads and

remove the ignition coils from the frame.
Installation
1.
Install the ignition coils ensuring the high tension

connections are made as noted during removal.
IGNITION SYSTEM DIAGNOSIS

An ignition diagnosis kit is available to trace ignition
primary faults. It is recommended that ignition diagnosis
be carried out by an authorised Triumph dealer who will
have the necessary training to accurately diagnose faults
and carry out the work.
1. Timing Rotor
2. Ignition Pick-Up Sensor
3. Air Gap (0.6-0.8 mm)
2.
Examine the grommet recess in the crankcase for

casting flash and sharp edges. Clean out the
recess with a file if necessary.
Apply silicone sealant to the ignition sensor
grommet and refit to the crankcase.
3.
Fit and tighten the pick-up screws to 10 Nm.
16.14
Tester General Information
Connect the tester unit to the tester harness and

tighten the harness retaining screws.
All Other Models:

Remove the seat to gain access to the igniter and
sub-harness (Thunderbird, Thunderbird Sport &
Adventurer - also remove the right hand side
cover).
Disconnect the igniter sub-harness from the main

harness. Attach the tester male connector to the
main harness and female connector to the igniter
sub-harness.
Connect the tester unit to the tester harness and

tighten the harness retaining screws.
This tester is designed to carry out a series of tests on the

ignition system primary circuit and also is able to check
ignition coil secondary resistance. The tester will reveal
a fault if the component or circuit being tested falls
outside pre-programmed parameters for
voltage,
resistance, etc.
Faults in the ignition secondary circuit, such as spark
plug or H.T. lead breakdown, must be determined by
other means.
The tester uses the following conventions to indicate test
results.
GREEN LIGHT ON: ......... Circuit/component

operating correctly
GREEN LIGHT OFF: ........ Fault on the circuit
or component
RED LIGHT ON:
.......... Fault on the circuit
or component
GREEN & RED LIGHTS OFF: Fault on the circuit
or component
NOTE:
Intermittent faults are often caused by poor

connections due to corrosion and cable fatigue.
Always check ignition connections if the tester
shows all circuits are working correctly but an
intermittent fault persists.
WARNING:
In the following procedure,
~ the motorcycle engine must be run. The

gases.
quantity.
NOTE:
To Attach The Tester To The Motorcycle
Tiger and 1996 Trophy:

Remove the cockpit fairing to gain access to the
igniter and sub-harness.
Disconnect the igniter sub-harness from the main

harness. Attach the tester male connector to the
main harness and female connector to the igniter
sub-harness.
16.15
References to coil numbers on the tester

correspond directly with the cylinder numbers
on a 3 cylinder engine and correspond as
follows on a four cylinder engine:
Coil 1 - cylinders 1 and 4
Coil 2- cylinders 2 and 3
In all cases, number 1 cylinder is the left hand
Main Switch
Static/Dynamic
Switch
DYNAMIC
STATI: ~
r-=_ 4-CYL
\ I
Set Up for Static Tests
/J.CYL
IGNITION SYSTEM TESTER
SUPPL*
Turn the tester main switch to

'ON'.
Turn the static/dynamic switch to

'STATIC'.
Turn the ignition switch to 'ON'.
Ensure that the engine 'kill'

switch, on the right hand
handlebar, is in the 'RUN'
position.
All LEDs will illuminate briefly to

indicate that the tester is
functioning correctly.
All LEOs ON then OFF indicates

correct tester operation, proceed to the next test leaving
the ignition 'ON', the rnain switch
'ON' and static/dynamic switch in
the 'STATIC' position.
All LEOS fail to illuminate,

proceed as follows:
Check for a supply to igniter pin 9

using a voltmeter. If correct, the
supply voltage should equal
battery voltage. If no feed is
present, check for a faulty ignition
switch or engine kill switch, a
faulty side stand switch or
damaged/broken wiring.
Check for correct earth path from

igniter pin 4 to the earth point at
the black/yellow wire beneath the
seat. Rectify as necessary.
CKUPCOI~
MPLITUD
L
16.16
Main Switch
Static/Dynamic
Switch
Ignition switch
To Test The Battery

Voltage
The 'Supply' LED should be ON.
LED ON indicates correct

battery voltage, proceed to next
test.
Supply LED not ON
indicates a battery fault, proceed
as follows:
Check
battery
and
connections,
rectify
necessary.
Re-charge
discharged.
Replace the battery if faulty.
If all battery checks indicate a

satisfactory battery condition,
repeat the tests from page 16 for
supply to pin 9 and earth from pin
4. Rectify as necessary
~CK..UPCOIL
/ T'~ESISTANCE
SUPPLY
PICK-UP COIL
AMPLITUDE
LOW
OK
~0
O EARTH FAULT
PICIWPCOI.
IGN.~o
the
earth
as
battery
if
IGN.~o
IGN.~o
TAC~o
,..--"=" I
1r
""" :::J
Pin 9
Pin 4
~~I.F---tJ....,:~,,~,.....,:;;..---
16.17
Main Switch
Static/Dynamic
Switch
To Test Pick-up Coil

Resistance
Ignition switch
STATIC
SUPPLY
PICK.lJP COIL
AMPLITUDE
LOW
Green LED ON indicates a

correct pick up coil resistance,
proceed to next test. Red
pick-up LED ON or neither
pick-up LED ON indicates a
fault, proceed as follows:
Red LED ON check for short

circuit to earth between the igniter
pin 7 and the pick-up red lead by
examining the harness for
damaged cable insulation and
trapped wires.
Rectify as
necessary.
Neither LED ON indicates a

pick-up resistance outside the
permitted
range
or
wiring/pick-up open circuit.
Connect an ohm-meter across
the connections to igniter pins 1 &
7. Check for a resistance value of
530 ohms1 0%. If the reading
found indicates that the pick-up is
open circuit (meter indicates a nil
value), repeat the test at the
pick-up connection to the main
harness (located below the
airbox).
Replace the pick-up if the
resistance check at the pick-up
connection to the main harness
continues to indicate an open
circuit (nil value). If the check at
the connection to the main
harness indicates a resistance
within the specified limit, check
w1nng
for
damaged/broken
between the main harness to
pick-up connector and the igniter
(including
the
igniter
sub-harness). Rectify the wiring
as necessary and repeat the tests
to confirm correct operation.
Replace the pick-up if the
resistance value is outside the
specified
limit
and
cable
continuity is confirmed by the
preceding checks.
OK
SPEED
~.COIL1
IGN.~
~.COIL2
IGN-~o
~-awnNUrTY
Check that the green pick-up

coil resistance LED is ON and
the red pick-up coil earth fault
LED is OFF.
CRAM<IIIG
PAWl. COIIITlNUITY
IGN.~o
TACHOM~o
,.--..~ I
I r'Cf'~
Pin7
Pin1
-::;"'IIIPt-#-----
16.18
Main Switch
Static/Dynamic
Switch
Ignition switch
SUPPLY
*PPLY
~CK.UPCOIL
/ T'~ESISTANCE
O PICIWPCOIL
EARTH FAULT
PICK-UP COIL
AMPLITUDE
LOW
To Test Ignition Coil

Primary Continuity.
3 cylinder engines: Check that

ignition coil primary continuity
LEOs 1, 2 and 3 are ON.
4 cylinder engines: Check that

ignition coil primary continuity
LEOs 1 and 2 are ON.
Correct number of LEOs ON

indicates correct coil continuity,
proceed to next test. One or
more LEOs OFF indicates a
Check for supply to each coil

primary (+) connection using a
voltmeter.
Correct reading
should be equal to battery
voltage. If a supply fault is found,
check the cable continuity to each
coil using a multi-meter as
follows;
Igniter pin 6 to coil 1,
Igniter pin 11 to coil 2,
Igniter pin 12 to coil 3 (3 cyl only).
Rectify as necessary.
To confirm a coil fault, attach an

Ohm meter (0-1 Ohm scale)
across
the
coil
primary
connectors. Replace coils with a
resistance outside 0.63.0hms
10%.
OK
~0
IGN.~o
IGN.~o
IGN.CQL3
DII'IIE
r~o
l,..r--7!rd
0----~l~s~
Coil Ohm meter Test
16.19
NOTE:
Complete the dynamic tests if
any primary coil circuits
indicate a defect and all the
above manual checks do not
indicate a fault. A dynamic
fault indicated on the same
cylinder/coil in both the static
and dynamic tests indicates a
faulty igniter.
Main Switch
Static/Dynamic
Switch DYNAMIC
STATK: ~
Ignition switch
To Test the Starter

Lockout System
,..---=. 4-CYL
\ I
/3.CYL
Engage neutral and place the

sidestand in the down position.
Check that the enabled LED is

ON and the disabled LED is
OFF.
Engage 1st or 2nd gear leaving

the sidestand down.
Check that the enabled LED is

OFF and the disabled LED is
ON.
0 AMPLITUDE 0OK
LOW
This indicates correct function of

the starter lockout system,
proceed to next test.
Any different combination of
LEOs from those listed above
indicates a fault.
Check for an open circuit side

stand switch, faulty side stand
relay, wiring fault to side stand
switch or wiring fault to relay.
Check for faulty neutral indicator

switch or wiring fault in the neutral
indicator circuit.
SUPPLY
*PPLY
~ICKUP COIL
/ T'
RESISTANCE
PICIWPCOI.
O EAR1ll
FAULT
~.COI.1
PAM. COIIITlNUfTY
~.COIL2
~PRIM. CONTINOOY
~~
o~-*I~
PICK-UP COIL
CRAIII<IIIG
SPEED
IGN.~o
IGN-~o
IGN.~o
TACHOM~o
I
LSTAre~ 1,.----~
r3Cf,:::l
IGMTlON
DISABLED
ENABLED
IGN. COIL
SECONDARY
RESISTANCE
~6g
NOTE: THUNDERBIRD, THUNDERBIRD SPORT & ADVENTURER MODEL
On Thunderbird, Thunderbird Sport & Adventurer, the side stand switch is connected to the igniter in a different way
to all other models as no side stand relay is fitted. In place of the relay, there are two 'enable' lines to the igniter. One
goes directly to the side-stand switch and one directly to the neutral switch. The engine will run if either are switched
to earth, I.E. if the side-stand is up or the gearbox is in neutral.
This means that, on Thunderbird , Thunderbird Sport & Adventurer, the enabled light on the diagnostic unit effectively
becomes a side-stand up light and the disabled light, a side-stand down light. The neutral light is a new line and is
not connected to the diagnostic unit. Therefore, to test the starter lockout system on the Thunderbird , Thunderbird
Sport & Adventurer, proceed as follows
Static Mode
1. Side-stand up ............... Ignition enabled light should be on
2. Side-stand down ............ Ignition disabled light should be on
16.20
To Test The Battery

Supply During Cranking
SUPPLY
Engage neutral and place the

sidestand in the down position.

'OFF'.
Turn the static/dynamic switch to

'DYNAMIC' selecting the correct
number of cylinders depending
on the model under test.
Turn the ignition switch to 'ON'.
Crank the engine and check that

the supply LED on the right hand
side of the unit is ON during
correct
cranking
indicating
battery voltage. Proceed to the
next test.
PICK-UP C O l *
AMPLITUD
PICK-UP COIL
RESISTANCE
PICIWPCOIL
EARTH FAUlT
JGN.COIL1
IGN-~o
PRIM. CONllNUITY
Supply LED OFF indicates a

fault in battery voltage during
cranking.
JGN.COIL2
PRIM. CONrNJITY
JGN.~o
Check
battery
and
connections,
rectify
necessary.
Re-charge or replace the battery

if discharged or faulty.
Check starter motor current draw,

should be 22 A at 11.5 V under no
load conditions. Replace the
starter if outside these limits.
LOW
JGN.~o
JGN.COIL3
PRIM. COIIITIIJOOY
TACHOMETER
,'~~J
1/-mt
,'
.diNAMJC
earth
as
NOTE: MODELS WITH 'GILL'

IGNITER
Any readings from the starter
lockout test on the static side
are to be ignored even though
the unit will indicate a disabled
condition if the side stand is
down.
16.21
Main Switch
Ignition switch
To Test the Pick-up Coil

Amplitude

the green LED 'Pick-Up Coil
Amplitude O.K.' is ON indicating
correct pick-up coil amplitude.
Proceed to next test
Red 'LOW' indication or

neither LED ON indicates a
Check that the air gap between

the pick-up and rotor is
0.6-0.Bmm. Adjust as required
then repeat test. If a fault is still
indicated, replace the pick-up.
SUPPLY
PICK-UP COIL
RESISTANCE
SUPPL*
O JIICK.UPCOI.
EARTH FAULT
0
IGN.COI.1
PRIM. CONT1IIIUITY
IGN.~
IGN.COI.2
PRIM. COIIITIIIUITY
IGN.~o
IGN.COI.3
IGN.~
PRIM. CONT1IIIUITY
TACHOMETER
.~~d
,'
diNAMJC
r-::r:::.
I /3-CYL
4-CYL
16.22
1. Rotor
2. Pick-up
3. Air gap, 0.6-0.Smm
To Test For Correct

Cranking Speed

the cranking speed LED is ON
indicating that the cranking
speed is correct (above the
minimum limit). Proceed to next
test.
Cranking speed LED OFF

indicates a fault (low cranking
speed), proceed as follows:
Check for satisfactory starter

motor earth at the alternator
boss.
Investigate the starter motor for

wear or faults and also check the
auxiliary gearing for damage.
Rectify as necessary.
SUPPLY
PICK-UP COIL
RESISTANCE
SUPPL*
PICK-UP
COl~
0 AMPLITUD
LOW
O PICIC.UPCOI.
EARTH FAULT
0
IGN.COI.1
PAWl. CONTlNUITV
IGN.~o
IGN.COI.2
PAWl. CONT1MJTV
IGN.~o
IGN.COI.3
IGN.~o
PAWl. CONTWOOY
TACHOMETER
.~~J
;
,'
~IC
r~~t
16.23
Main Switch
Static/Dynamic
Switch,~
,'
STATIC~
Ignition switch
lfnwl,r;;
r-::t:: 4-CYL
\ I
/3.CVL
SUPPLY
PICK-UP COIL
RESISTANCE
SUPPL*

'ON'.
Start the engine.
3 cyl engines, check that all 3

coil drive LEOs are ON
indicating correct coil switching
by the igniter. Proceed to next
test.
4 cyl engines, check that coil

drive LEOs 1 and 2 are ON
indicating correct coil switching
by the igniter. Proceed to next
test.
One or more LEOs OFF

indicates a fault, proceed as
follows:
Replace the igniter.
PICK-UP C O l *
AMPLITUD
0
LOW
EARTH FAULT
O PICK-UPCOIL
To Test for Correct

Igniter Coil Switching
IGN.COIL1
PRIM. COIIIT1IIIUfTY
IGN.COIL2
IGN.COI.3
PRIM. CONTIIIOOY
PRIM. CONTIIIOOY
,'~,
,'
dfNAMtc
r--r:::_ ~YL
/3.CVL
16.24
Main Switch
Static/Dynamic
Ignition switch
To Check for Correct

Tachometer Output
Switch:~
,'
m-IC
~4-CYL
/3-CYL
Start the engine and check that

the tachometer output LED is
ON indicating correct supply to
the tachometer. Proceed to next
test.
Tachometer supply LED OFF

indicates a fault.
Check for continuity between

igniter pins 11 t (later 3 cyl) and
12t (later 4 cyl) and the
tachometer using a multi-meter,
rectify as necessary.
t Pin 6 (3 and 4 cyl) on early
models
Check tachometer supply at the

brown/white lead, should be
battery voltage. Rectify as
necessary.
SUPPLY
PICK-UP COIL
RESISTANCE
SUPPL*
PICK-UP C O *
0 AMPLITUD
LOW
O PICK-UPcaL
~FAULT
IGN.COIL1
PRIII/I. COIIIT1NUfTY
IGN.~
IGN.COIL2
PRIII/I. COIIITI\IUITY
IGN.~*
Tachometer
continues
to
malfunction, replace tachometer.
IGN.~*
IGN.COI.3
PRIII/I. COIIITI\IUITY
Tachometer
continues
to
malfunction, replace the igniter
and refit the original tachometer.
. ~,
.dfNAMIC
,'
'r3.CVL
~4-CYL
Pin11
Pin6
Pin12
16.25
Static/Dynamic
Switch
Main Switch
Ignition switch
SUPPLY
PICK-UP COIL
RESISTANCE
SUPPLY
PICK-UP COIL
AMPLITUDE
LOW
EARTH FAULT
O PICIWPCOI.
CRAN<IIIG
SPEED
PRI't'l. CONT1NUITY
IGIII.~
IGI\I. COIL 3
PRI't'l. COIIITIIIWTY
IGN.~o
IGIII. COIL 2
PRI't'l. CONTINUITY
~~~
TACHOM~o
I
Lsr.re~ 1~-___;;~
"'Yl :::::~
DISABLED
IGIII. COIL
SECQI\IlARY
Remove the fuel tank as

described in the fuel system
section of this manual.
Fit the additional test leads to the

socket on the front panel and
proceed as follows.
Select the 'static' position on the

tester switch.
3 Cylinder engines, disconnect

the coil primary leads and
connect the tester leads between
any primary coil connection and
the secondary (H.T.) pole.
4 Cylinder engines, disconnect

the coil primary leads and
connect the tester leads across
both secondary (H.T.) poles.
Repeat for each coil in turn and

check that the 'PASS' indication
is illuminated for each coil tested.
Replace any coil(s) giving a 'FAIL'

indication.
Disconnect the tester, reconnect

the coil primary connections and
refit the fuel tank. Reconnect the
igniter to the sub-harness and
refit the seat.
0
0
IGIII. lXII. 1
0OK
IGIII.~
To Test the Secondary

Resistance of the
Ignition Coils
ENABlED
3 Cyl
4Cyl
16.26
Other checks
STARTER MOTOR
If the tester reveals that no fault is present in any

part of the system but an ignition problem is still
present, proceed as follows.
Check for a fault in the high tension leads (plug

leads).
Check for correct function, air gap etc of the spark

plugs.
Check for reverse polarity of the ignition pick-up

by ensuring that the black (light green on early
models) sub harness wire from pin 1 is connected
through to the black pick-up wire. Connection to
any other colour must be rectified.
Removal
1.

negative (black) lead first. Remove the fuel tank
and carburettors as described in the fuel system
section.

correct manner.
2.
Remove the lower fairing (if fitted) and drain the

cooling system as described in the cooling system
section. Remove the water pump hose cover
(where fitted) and water outlet elbow from the
crankcase.
Pin1
Check for any loose connections which would

begin to break down when the machine is in
motion.
Check for part-fractured cables by 'joggling' the

cables during testing.
NOTE:
In certain cases, although the tests made by
the tester will reveal correct functioning of the
system and further tests confirm wiring
continuity, a fault may still be present in the
internal circuits of the igniter itself. This is
possible with the tests for the tachometer
output, pick-up coil amplitude and coil
primary continuity. In such cases, fitting a
substitute igniter will confirm a fault in the
original.
NOTE:
Always complete the dynamic tests if any
primary coil circuits indicate a defect and all
the manual checks do not indicate a fault. A
dynamic fault indicated on the same
cylinder/coil in both the static and dynamic
tests indicates a faulty igniter.
1. Water Pump Hose Cover

2. Retaining Bolt
3. Washer
4. Lower Mounting Point
5. Upper Mounting Point/Outlet Elbow
3.
16.27
On 4 cylinder engines, disconnect the breather

hose from the left hand crankshaft cover.
NOTE:
Adventurer, remove the horn and bracket from
the engine.
4.
Release the terminal nut from the starter cable and

remove the cable.
3.
1. Armature
2. Yoke assembly
1. Starter Motor
2. Terminal Nut
5.
Release the two bolts securing the starter motor to

the crankcase.
6.
Remove the starter motor.
CAUTION:
To prevent component
damage, do not allow grease from the
rear bearing to come into contact with the brushes.
4.
Disassembly
1.
Remove the brush holder from the end frame.
Remove the brushes from the brush holder by

carefully lifting the spring from the brush holder.
Unscrew the two through bolts and remove the

starter housing.
1.Brush
2. Retaining Spring
5.
1. Through Bolts
Loosen the terminal nut attached to the end frame

and remove the upper and lower insulators, '0' ring
and brush.
NOTE:
Before removing or installing pinion end, cover

the teeth of the pinion with thin tape to prevent
damage to the oil seal.
2.
Hold the pinion of the armature in one hand and

remove the yoke.
1. Insulation
16.28
Assembly
1.
Assemble the starter motor by reversing, the

disassembly procedure.
Align the yoke projections with the brush plate

and end cover location holes.
6.
Connect the water pump hose and refill the cooling

system as described in the cooling system section.
7.
Refit the carburettors and fuel tank. Refit the

bodywork previously removed and reconnect the
battery, positive (red) lead first.
STARTER MOTOR COMPONENT TEST

Armature
1.
Set the multi meter to the 1Q range.
2.
Measure the resistance

commutator segments.
If there is a high resistance or no reading

between any two segments, a winding is open
circuit and the armature/starter must be
replaced.
between
any
two
1. Projection
2. Location Holes
3.
Set the multimeter to the highest range.
4.
Measure the resistance between the commutator

and the shaft.
NOTE:
If any reading is detected, there is a short circuit

and the armature/starter must be replaced.
If all checks prove to be negative but the starter

continues to malfunction, replace starter motor
with a new one.
When rebuilding the housing and yoke

assembly, align
the marks on the yoke
assembly with the clearance hole in the
housing.
1. Alignment Mark
Starter Installation
1.
Clean the mating faces of the crankcase and starter

motor to ensure efficient grounding.
2.
Apply a small amount of engine oil to a new starter

'0' ring. Fit the '0' ring to the starter.
1. Segment
2. Shaft
Commutator
Cleaning and Inspection
3.
Fit the starter motor and tighten the starter bolts to

10Nm.
1.
Smooth the commutator surface with fine emery

cloth, clean out all grooves.
4.
Connect the starter motor feed cable. Tighten the

cable nut to 7Nm.
2.
Measure the diameter of the commutator.
5.
Refit the water outlet elbow using a new gasket.

Tighten the elbow bolts to 11 Nm.
Commutator diameter
16.29
Standard:
Service limit:
28mm
27mm
NOTE:
Brush Plate
Replace the starter motor, if the commutator

diameter is below the service limit.
1.
Set the multi meter to the1 kQ range.
2.
Measure the resistance between the brush and the

plate.
The multimeter should indicate continuity

between the brush and the plate i.e. no
resistance. If there is no reading, replace the
plate.
3.
Measure the resistance between metal the plate

and the brush holders.
The multimeter should indicate NO continuity

between the brush and plate, i.e. no reading. If
there is a reading, replace the plate.
Smoothing the Commutator
Yoke
1.
Check the yoke magnets for cracks and peeling.

1. Resistance Between Brush and Plate

2. Resistance Between Holder and Plate
Brush and Lead Assembly

1.
Measure the resistance between the brush and the

terminal bolt.
The multimeter should indicate continuity

between the brush and terminal bolt, i.e. no
resistance. If there is no reading, replace the
brush and lead assembly.
1
1. Magnets
1. Brush
2. Terminal Bolt
16.30
Brush and Brush Spring
Commutator End Housing
1.
1.
Measure the length of each brush and replace as

necessary.
Length
Standard:
Service limit:
Check the end housing for wear.

Lubricate the bearing housing with grease to
prevent seizure.
STARTER SOLENOID
12mm
8.5mm
The starter solenoid is located beneath the seat,

adjacent to the battery box.
Removal
1.
2.
The solenoid is mounted in a rubber holder with the

wiring connector retained by an '0' ring. Release
the '0' ring, starter and battery feed wires and the
wiring connector from the solenoid.
Remove the solenoid and rubber holder from the
two mounting barbs.
NOTE:
1. Brush Length
2. Brush Spring
Later models are fitted with a solenoid which is

retained solely by the rubber mounting and
barbs.
Installation
2.
Check each brush spring for cracks, bending etc.

Bearing
1.
Check all bearings for smooth running and lubricate

with grease as necessary.
1.
Locate the solenoid to the rubber holder and fit to

the two barbs. Reconnect the wiring connector,
battery and starter feed wires. Retain the connector
with the '0' ring.
STARTER MOTOR CIRCUIT DIAGRAM

Refer to the following page for a diagram of the wiring
circuit for the starter motor on a 1996 Trophy.
Drive End Housing

1.
Check for grooving and signs of excessive wear.

Lubricate with grease if serviceable.
2.
Check the condition of the oil seal and replace as

necessary.
1. Oil Seal
16.31
For details of the starting circuit on other models, refer to

the main circuit diagrams at the end of this section.
Starter Circuit (1996 Trophy)
BATTERY
(14Ah)
FUSE 9
N
NR
cG
cG
,...--.--
1
WB
N
NR
w
y
IS?+J
0
,....
u.
u.
'---
IGNITION
SWITCH
FUSE5
OFF
,...-
,...-
YR ---1--<Y
ENGINE
START/STOP
o4--, SWITCH
ON
IGN
~2
BR
11
'--
WR
BR
----11~0 'E'
b :~~
-
STARTER
SOLENOID
STARTER
MOTOR
nr-
BK
B
BS
.--
BY
11
BR
- -
STARTER
CUT-OUT
SWITCH
NEUTRAL
SWITCH
16.32
Fan check
COOLING SYSTEM
Cooling Fan
1.
Disconnect the 2-pin connector to the fan leads.
2.
Connect a 12V supply to the fan.

Blue fan wire to positive (+Ve)
Black fan wire to negative (-ve)
3.
If the fan does not operate, the motor is defective

and must be replaced.
FAN
SWITCH
FAN
Bl
-nr---
COOLING FAN SWITCH

Removal
BI/W
Bk~
1.
Drain the cooling system as described in the cooling

section.
All models except Thunderbird, Thunderbird

Sport & Adventurer: The fan switch, is fitted to the
left side of the radiator and is retained by a 'bayonet'
type locking ring.
The ring must be rotated
anti-clockwise to remove.
Thunderbird, Thunderbird Sport & Adventurer:

The fan switch is located in the thermostat housing
beneath the fuel tank and is retained by means of a
'U' shaped clip.
Detach the clip by pulling
rearwards.
2.
The switch is then removed from the

radiator/housing by gently pulling the switch from
the rubber seal, in an outwards direction.
Bk/Y
BI/Bk
"M
+
BATTERY
(14 Ah)
FUSE BOX
Installation
1.
Inspect the switch seal and renew if necessary.

Sport & Adventurer: Refit the switch, fit and turn
the locking bayonet to secure to the radiator.
Connect the electrical terminals.
Thunderbird, Thunderbird Sport & Adventurer:

Refit the switch and secure with the U clip. Connect
the electrical terminals.
2.
Refill the cooling system as described in the cooling

section.
Cooling Fan Circuit

Circuit check
1.
Disconnect the wires from the cooling fan switch.
2.
Using a length of spare wire, connect the switch

wires together (this simulates the operation of
cooling fan switch).
The fan should turn when the two wires are

bridged. If the fan fails to turn, inspect the wires,
connections, main fuse and fan.
Adventurer, the fan switch is located in the
thermostat housing beneath the fuel tank.
16.33
Inspection
WATER TEMPERATURE
GAUGE/WARNING LIGHT
1.
Connect a multimeter across the terminals to check

for correct operation of the switch.
2.
Suspend the switch in a container of water.
3.
Suspend a thermometer in the coolant.
Check for correct operation of the

temperature gauge or warning light after
turning the ignition to the 'On' position.
4.
Raise the temperature of the coolant.
Gauge
5.
The switch contacts should close at 99C at which

point the resistance between the switch terminals
should change. Check that both open and closed
switch resistances are as specified below. Replace
the switch if the readings obtained deviate from
those specified.
1.
Disconnect the wire from the temperature sensor

on the cylinder head. The gauge should read 'C'.
2.
Earth the sensor wire against the cylinder head.

The gauge should read 'H'.
If these readings cannot be obtained, check for

damaged wiring and/or a faulty gauge.
Resistance between switch terminals

On :
Less than 0.5Q
Off:
More than 1MQ
Warning Light
1.
Disconnect the wire from the temperature sensor

on the cylinder head. The warning light should stay
off.
2.
Earth the sensor wire against the cylinder head.

The warning light should illuminate.
If the warning light fails to operate, check for a

blown bulb and/or damaged wiring
1. Fan Switch
WATER TEMPERATURE GAUGE

I
I
I
I
I
I
L _ _ _ ...J
INSTRUMENT
PANEL
~~ :I111----~
Br
Br
i
w
Bk!Y
Y/W
COOLANT
TEMPERATURE
SENSOR
Bk!Y
Temperature Gauge
Circuit
+
R
BATTERY
. (14 Ah)
~-w,
MAIN FUSE
L-----...l
FUSE BOX
16.34
Temperature/warning light sensor

inspection
Fuse Box
1.
Drain the cooling system as described in the cooling

section.
2.
Remove the temperature sensor.
3.
Connect one lead of a multimeter to the spade

terminal on temperature sensor.
4.
Suspend the temperature sensor in a container of

water.
5.
Set the multimeter to the resistance range.
6.
Connect the other lead of the multimeter to the body

of temperature sensor.
Fuses are arranged in the fuse box located beneath the

seat (behind the right hand side panel on Thunderbird,
Thunderbird Sport & Adventurer). If a fuse fails during
operation, inspect the electrical system to determine the
cause. Always replace a blown fuse with a new fuse of
the same (correct) current rating.
Temperature sensor resistance:
255 - 310 .Q
@ 60C,
2
1. Fuse Box
2. Spare Fuses
1. Temperature Sensor
5048
1. 1996 Trophy Fuse Box
1. Thunderbird/Thunderbird Sport/Adventurer Fuse

Box
16.35
A blown fuse can be readily identified by the link bar in the

clear centre being divided.
WARNING: Always replace a blown fuse

with a new item of the correct current
rating, as specified on the fuse box cover. Never
replace a blown fuse with a replacement of a higher
rating than specified for the original as this may
cause damage to the wiring circuits leading to a
risk of injury from a wiring fire.
Fuse Diagnosis
A blown fuse is indicated when all of the systems
protected by the fuse become inoperative. When
checking for a blown fuse, the following guide will
indicate which fuse circuit is blown.
Normal
Failed

Sport, Adventurer and 1996 Trophy
WARNING: Early motorcycles are fitted

with a 10 Amp. fuse for the cooling fan.
Later models are fitted with a different cooling fan
requiring a 15 Amp. fuse. Use of a fuse of the
correct rating is essential in either case. Always
refer to the fuse box cover for information before
replacing the cooling fan fuse.
Never replace a blown fuse with a replacement of a
higher rating than specified for the original as this
may cause damage to the wiring circuits leading to
a risk of injury from a wiring fire.
Fuse 1 ....... Headlamps

Fuse 2 ....... Tail Lamp
Fuse 3 ....... All Systems
Fuse 4 ....... Cooling Fan
Fuse 5 ....... Alarm (when fitted)
In-line fuse
Rear Light

Fuse 1 ....... Headlamps, pass switch
Fuse 2 ....... Tail Lamp, stop lamp, panel lights, horn.
Fuse 3 ....... Ignition switch, main power.
Fuse 4 ....... Cooling Fan, flasher unit.
Fuse 5 ....... Alarm (when fitted)
In-line fuse
Starter solenoid, ignition system.
1996 Trophy
Fuse 1 ....... Headlamps, alternator
Fuse 2 ....... Alarm, clock, hazard lights, indicators
Fuse 3 ....... Cooling fan.
Fuse 4 ....... Auxiliary circuits
Fuse 5 ....... Engine start and run systems
Fuse 6 ....... Alarm signal, headlamp relays
Fuse 7 ....... Brake lights, horn, instruments
Fuse 8 ....... Instrument illumination, side lights
Fuse 9 ....... All circuits from ignition switch
16.36
LIGHTS
Direction Indicator
Tail/Brake Light Bulb Replacement
Removal
Removal
1.
Remove the screw securing the lens to the direction

indicator body.
1.
Remove the screws securing the lamp lens to the

tail light body and the remove lens.
2.
Remove the lens.
2.
Push the bulb whilst turning it anti-clockwise and

remove from the reflector.
1. Direction Indicator Lens
3.
Push the bulb whilst turning it anti-clockwise and

remove from the reflector.
1. Lamp Lens
Installation
1.
Locate a new bulb to the tail lamp and secure by

twisting to the locked position.
2.
Refit the lens.

CAUTION: Never overtighten the lamp
lens screws as this will damage the lens.
1. Bulb
2. Reflector
4.
Check the bulb and replace as necessary.
Installation
1.
Turn the bulb clockwise whilst pushing, until it locks

in position.
2.
Fit the lens and tighten the screw.

CAUTION: Never overtighten the lamp
lens screws as this will damage the lens.
16.37
HEADLIGHTS
Trophy Headlight Bulb replacement (pre

1996 model)
All models with twin headlights have different adjustment

arrangements to those models with a single headlight. In
addition, the pre 1996 Trophy single headlight is different
to that fitted to the Trident/Speed Triple.
Removal
Trophy Headlight (pre 1996 model)

Horizontal and vertical adjustment of the headlight beam
is made by the two screws on the back of the headlight.
The screws can be reached from underneath the front of
the fairing.
Rotate both screws equally for VERTICAL adjustment.
Clockwise to lower the beam. Anti-clockwise to raise the
beam.
Rotate each screw equally in opposite directions for
HORIZONTAL adjustment.
Rotate the left hand side screw clockwise and the right
hand side screw anti-clockwise to move the beam to the
right.
/"'
1.
Disconnect the battery, negative (-) black lead first.
2.
Release the screws and lift up the facia panels.

Disconnect the clock and remove both facia panels.
3.
Remove the locknuts securing the mirrors to the

cockpit.
4.
Remove the mirrors and mirror mounting pads.
5.
Remove cockpit fairing to lower fairing screws.
6.
Repeat steps 2 and 3 for the other side.
7.
Support the cockpit fairing.
8.
Remove the rubber dust cover.
9.
Disconnect the multi-pin electrical connector at the

rear of the headlight.
10. Rotate the bulb retaining ring anti-clockwise.

11.
Remove the halogen bulb.
Arrowed: retaining ring direction of release
WARNING: The bulb becomes hot during

use. Always allow sufficient time for the
bulb to cool before handling.
Avoid touching the glass part of the bulb. If the
glass is touched or gets dirty, clean with alcohol
before re-use.
1. Trophy Headlight Adjustment Screws
WARNING: Adjust road speed to suit the

visibility conditions in which the
motorcycle is being operated.
Ensure that the beam is adjusted to illuminate the
road surface sufficiently far ahead without
dazzling oncoming traffic. An incorrectly adjusted
headlight may impair visibility causing an accident
~
CAUTION:
Changes made to the
~ horizontal adjusters will marginally
change the vertical setting of the headlamp beam.
Similarly, changes made to the vertical adjusters
will marginally change the horizontal setting.
Always allow for additional adjustment to
compensate for this factor.
Installation
1.
Fit the new bulb to the bulb holder.
2.
Fit the retaining ring and rotate clockwise to lock in

position.
3.
Fit the multi-pin connector to the rear of the

headlight.
4.
Fit the dust cover.
5.
Position the cockpit and fit the mirrors complete with

mounting pads.
6.
Fit the locknuts to secure the mirrors and hand

tighten.
16.38
7.
Refit the cockpit to lower fairing screws.
HEADLIGHT- 1996 TROPHY
8.
Position the facia panels and reconnect the clock.

Locate the panels to the cockpit and tighten the
facia panel screws.
Headlight Adjustment
Both right and left hand headlamps are adjusted, as a pair,
by single horizontal and vertical adjusters.
Vertical Adjustment:
Open the right hand storage compartment, remove the
ignition key from the storage compartment lock and turn
the ignition switch to the 'ON' position. Turn the headlamp
dip beam on.
Turn the adjuster wheel clockwise to raise the beam and
anticlockwise to lower the beam. Turn the headlamp off on
completion.
1.
2.
3.
4.
Headlamp Bulb
Retaining Ring
Parking Lamp Bulb Holder
Parking Lamp Bulb
WARNING: Do not reconnect the battery

until the assembly process has been
completed. Reconnect the battery positive (red)
lead first then the negative (black) lead second.
Parking Light Bulb Replacement

The parking light bulb can be accessed in exactly the
same manner as the headlight bulb (steps 1-7).
Removal
1. Vertical Adjustment Control
1.
Horizontal Adjustment:
Remove the parking light bulb holder from the

headlight housing.
3.
Push the bulb whilst turning anti-clockwise and

remove from the housing.
Remove the cockpit 'chin panel' from beneath the cockpit

fairing and switch the headlamp dip beam on.
Installation
1.
Position and turn the bulb clockwise whilst pushing,

until the bulb locks in position.
2.
Fit the bulb holder into the housing.
3.
Re-assemble as for headlight bulb replacement.

1. Cockpit Chin Panel
16.39
Using a screwdriver, adjust the horizontal beam by turning

the adjuster clockwise to move the beam to the right and
anticlockwise to move the beam to the left. Turn the
headlamp off and refit the 'chin' panel when adjustments
are completed.
Headlight Bulb Replacement

1996 Trophy
Each halogen bulb can be replaced as follows:
Remove the cockpit 'chin panel'.
Pull back the rubber cover from the headlamp bulb.
Disconnect the multi-pin electrical connector from the

bulb.
Rotate the bulb retainer anticlockwise to release.
The bulb can now be removed.
Installation is the reversal of removal.
2. Horizontal Adjustment Control

1. Bulb Retainer
CAUTION:
Changes made to the
horizontal adjusters will marginally

before re-use.

lead first, then the negative (black) lead second.
16.40
Headlight Adjustment
Twin Circular Headlamps
Each headlight is adjustable individually and has two

adjustment screws, one for horizontal adjustment and
one for vertical adjustment.
Right Hand Lamp: Turn the horizontal adjuster screw

clockwise to move the beam to the left and
counterclockwise to move the beam to the right.
Left Hand Lamp: Turn the horizontal adjuster screw
clockwise to move the beam to the right and
counterclockwise to move the beam to the left.
Both Lamps: Turn the vertical adjuster clockwise to
lower the beam and anti-clockwise to raise the beam.
Removal
1. . Disconnect the battery, negative (-) black lead first.
2.
Remove the screws securing the facia panels.

Remove the panels.
3.
Disconnect the multi-pin electrical connector from

the rear of the headlight.
4.
5.
Un-hook the wire retainer.
6.
Remove the bulb from the bulb holder.
1. Wire Retainer

before re-use.
1. Horizontal Adjustment Screws

2. Vertical Adjustment Screws

Installation
1.
Installation is the reversal of the removal procedure.

CAUTION:
Changes made to the
16.41
Trident, Thunderbird, Thunderbird Sport,

Adventurer and Speed Triple Headlight
Adjustment

Removal
Horizontal adjustment of the headlight beam is controlled

by the screw in the rim of the headlight.
Vertical adjustment of the headlight beam is controlled by
slackening the headlight assembly mounting bolts.
Always re-tighten the bolts after adjustment.
1.
Remove the two retaining screws and whilst

supporting light unit, disconnect the multi-pin
electrical connector.
3.
4.
Un-hook the wire retainer.
5.
The bulb can now be removed.
1. Horizontal Adjustment
2. Vertical Adjustment
3. Light Unit Retaining Screws (one each side)
1. Wire Retainer


before re-use.
A.
Installation
CAUTION:
Changes made to the
1.
Installation is reversal of removal.

16.42
WIRING CIRCUIT DIAGRAMS

Engine Stop Switch Operation
Horn Switch Operation
Engine Stop Switch
Y/R
Horn Switch
OFF
RUN
8k!W
ON
Dip Switch Operation
Headlight Switch Operation
Headlight Dip Switch
RNJ
OFF
0
RUN
R/81
81/Y
81
HIGH
LOW
Direction Indicator Switch Operation

Direction Indicator Switch
Starter Button Operation
GY
8k!R
PUSH
RIGHT
LEFT
Starter Button
8k/R
R/Y
81/y
R/8k
Headlight Switch
Hazard Warning Light Switch Operation
Front Brake Light Switch Operation
Hazard Warning Light Switch
Front Brake Light Switch
RELEASED
ON
8k
8k
ON
OFF
.-- r-e
W/8 0/G
k
-----
On
Starter Lockout Switch Operation

Starter Lockout Switch
8k!Y
RELEASED
DEPRESSED
Pass Button
Ignition Switch Operation

w 8r y
81
R
- - -
GY
Pass Button Operation
Ignition Switch Operation
ON
OFF/
LOCK
8k!Y
Y/G
LG
16.43
R/8k
8r
Key To Wiring Circuit Diagrams

The following codes are used to denote all wiring colours
used on the following circuit diagrams.
Where two colours are used, the first colour named is the
principal wire colour and the second colour named is a
trace colour. For example, Bk/Y indicates a black wire
with a yellow trace.
Number
Description
12
Low Fuel Warning Light
13
Front Indicator Lamp, Right
14
Headlight
15
Side Light
16
Front Indicator Light, Left
17
Fuel Level Sensor
Code
Colour
18
Headlight Relay
Bk
Black
19
Ignition Switch
20
Headlight switch
21
22

Engine Start/Stop Switch
Bl
Blue
Br
Brown
Green
GY
Grey
LB
Light Blue
23
Horns
LG
Light Green
24
Alternator
Or
Orange
25
Cooling Fan
Pi
Pink
Pu
Purple
26
Cooling Fan Switch
Red
27
Ignition Coils
Slate
28
29
Coolant Temperature Sensor
30
31
Igniter Pick-Up
Rear Brake Light switch
32
Stop!Tail Lamp
33
Fuse Box
34
35
Battery
Starter Solenoid
36
Starter Motor
37
Oil Pressure switch
38
Neutral Switch
39
Starter Cut-Out switch
40
Passing Button
41
Horn Button
42
Headlamp Beam Dip Switch
43
44
45
Rear Indicator Lamp, Right
46
Rear Indicator Lamp, Left
47
Clock
48
Alarm Connection, Sounder
49
Alarm Connection, Control Unit
50
Side Stand Switch
51
Side Stand Relay
52
Indicator Relay
Violet
White
Yellow
Key To Component Numbers

All major components on the diagram are given a key
number. The following is table must be used to identify
the components.
Number
Description
Right Turn Warning Light
High Beam Warning Light
Instrument Illumination
Tachometer
Neutral Warning Light
Oil Pressure Warning Light
Water Temperature Gauge
10
Side Stand Down Warning Light
11
Left Turn Warning Light
16.44
Igniter
20
19
1 I
2 I
I II
I
I
I
I
I
I
I
25
I f
I I ~ II
~~~ >-3: sg
'-
- -~
24
T-
/ _!,Q ,C:s
I
I
\
I
--- - - -- ~
27
27
27
i ij
22
21
~ 45
8
.
i
I
9 !
10 !
11 I
12 I
!..
-,II
"o'>
52
I
.I
"'a:
I
~
~'>
i
---{]::J- A
l l
-n H
>~
33
38
~
Wiring Circuit
o1agram
Trophy - 0 aytona - Tn'd ent

1991/2 Models
16.45

Number
Description
14
Headlight
15
Side Light
16
17
Fuel Level Sensor
18
Headlight Relay
19
Ignition Switch
Code
Colour
20
Headlight switch
Bk
Black
21
Bl
Blue
22
Br
Brown
23
Horns
Green
24
Alternator
GY
Grey
25
Cooling Fan
LB
Light Blue
LG
Light Green
Cooling Fan Switch
Or
Orange
26
27
Pi
Pink
28
Pu
Purple
29
Igniter
Red
Igniter Pick-Up
s
v
w
Slate
30
31
White
Yellow
Violet

the components.
Ignition Coils
32
33
Stop!Tail Lamp
34
35
Battery
Starter Solenoid
36
Starter Motor
37
Oil Pressure switch
38
39
Neutral Switch
Fuse Box
Number
Description
40
Passing Button
41
Horn Button
42
43
Tachometer
44
45
46
47
Clock
48
49
10
50
Side Stand Switch
11
51
Side Stand Relay
12
52
Indicator Relay
13
53
54
In-line fuse, Brake Light**

Float Chamber Vent Solenoids*
55
In-Line fuse - Vent Solenoids*
US California Models Only

** VIN 16922 onwards
16.46
20
21
25
2
3
, ;;;;; ;:r,,
~~~mwm
a:~~~
a:
0:
55
a:~>-
"'
-:..:-:~:.:~-==~ I
6
7
10
I
I
I
11
12
L __ __ __ __ I
32
13
"""
~il:
~-- '
50
37
34
~
B
I]J
=Trophy
= Daytona/Sprint/Super 3
!i
= Trident/Speed Triple
Wiring Circuit Diagram

Daytona- Daytona Super 3
Trident- Sprint- Speed Triple
16
1993 Models Onwards

Trophy (VIN 4902 to 29155}
16.47

trace colour. For example, Bk!Y indicates a black wire
19
High-beam warning light
20
Instrument illumination
21
Left turn warning light
22
Neutral switch
23
Neutral warning light
24
Oil pressure switch
Code
Colour
25
Oil pressure warning light
Black
26
Right turn warning light
Blue
27
Side stand down warning light
Brown
28
Side stand switch
Green
29
Tachometer
Grey
30
Orange
31
Water temperature warning light
Pink
32
Direction indicator switch
LG
Light Green
33
Front brake light switch
Red
34
Front indicator light, left
Purple
White
35
Front indicator light, right
Yellow
36
Hazard warning light switch
37
Relay, headlight cut-out
38
Headlight dip beam relay

the components.
39
40
Headlight dip beam switch
41
Headlight
Headlight high beam relay
Alternator
42
Indicator relay
Auxiliary fuse connection
43
Lighting switch
Battery
44
Passing switch
Fuse box
45
Rear brake light switch
Engine start/stop switch
46
Rear indicator light, left
Carburettor vent solenoid (California model

only)
47
Rear indicator light, right
48
Side light
Igniter
49
Stop/tail light
Igniter pick-up
50
Alarm connection -control unit
Ignition coils
51
Alarm connection - sounder
10
Ignition switch
52
Cooling fan
11
Side stand relay
53
Cooling fan switch
12
Starter cut out switch
54
Horn
13
Starter motor
55
Horn button
14
Starter solenoid
Headlamp cut-out during starting (if fitted)
15
Alarm LED
16
Clock
17
Fuel gauge
18
Fuel level sensor
16.48
10
43
33 45
1
7
47
r-r ""'
j=
16
. -
14 .. 0
BIW
GIW .q-f'1'l. 8
--t..EJ=w
7~P/G
: ::
0/K
10
GiW
G/U
8 ~
,_
~=
w- ~
I<=
1~
' -
L......1
d;A
YIB
GIB - - ,
~"'
'--
=- =
49
lr1n
~E
f--
--
A3o
46
GiW
s-----U.....L-
.,=:::r:::-
,----'-, 40
41
m0~
48
41
48
42
"'
+1v \ _
= =I
Gf,A==;~;::::::=::::I----...J
_...,
' ' .......... __ _
--~-:~ I
A '., .: :' .
D' - -'
'.:
i ,_ "
~.
I
I
I
~R ..
: : ... .. - -- .......... ~ ,
~ ~
wz
37
6i
14 _I
------
CIRCUIT HEAD LAMP

CUT-OUT DURING STARTING

Trophy from VIN 29156
16.49
Number
Description
14
Headlight
15
Side Light
where two colours are used, the first colour named is the
16

trace colour. For example, Bk!Y indicates a black wire
17
Fuel Level Sensor
18
Headlight Relay
19
Ignition Switch

Code
Colour
20
Headlight switch
Bk
Black
21
Bl
Blue
22
Br
Brown
23
Horns
Green
24
Alternator
GY
Grey
25
Cooling Fan
LB
Light Blue
26
Cooling Fan Switch
LG
Light Green
Or
Orange
Ignition Coils
Pi
Pink
27
28
Pu
Purple
29
Igniter
Red
30
Igniter Pick-Up
Slate
Violet
31
32
White
Fuse Box
Yellow
33
34
35
Starter Solenoid
36
37
Starter Motor
Oil Pressure switch
38
Neutral Switch

A11 major components on the diagram are given a key
1umber. The following is table must be used to identify
he components.
Stopffail Lamp
Battery
Description
39
40
Number
41
Horn Button
42
3
4
43
Tachometer
44
45
46
47
Clock
48
49
10
50
Side Stand Switch
11
51
Side Stand Relay
12
52
Indicator Relay
13
53
54
In-line fuse, Brake Light**

Float Chamber Vent Solenoid*
55
In-Line Fuse, Vent Solenoids*
* US California Models Only

** VIN 16922 onwards
16.50
Passing Button
20
21
22
..------
24
2
3
4
5
6
7
8
....
11
12
Gy
Bk/Y
::[1]:
Bk
W =
=q)
BVR
""'
32
' tlK/1 -
RVS
Bk/Y : : t [ f W
G
Bk
-- -----==~
I
I
I
I
I
I
I
14
15
14
15
16
@J=: =QJ..=":"- _]
_43
~====row
'----
38
44

Tiger
16.51

Number
Description
16
Ignition Switch
17
Headlight switch
18
19

Horns
Cooling Fan Switch
Code
Colour
Black
20
21
22
23
Blue
24
Ignition Coils
Brown
Green
25
26
Grey
Igniter Pick-Up
Orange
Pink
LG
Light Green
Red
Purple
White
Yellow
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

the components.
Number
Description
1
2
3
4
5
6
7
*
**

Tachometer
44
45
46
47

8
9
Water Temperature Warning Light
10
11
12
13
14
Headlight
Side Light
15
US California Models Only

Not fitted to Adventurer
16.52
Alternator
Cooling Fan
Igniter
Stop!Tail Lamp
Fuse Box
Battery
Starter Solenoid
Starter Motor
Oil Pressure switch
Neutral Switch
Passing Button
Horn Button
Side Stand Switch
Indicator Relay
48
In-line fuse*
49
50
Float Chamber Vent Solenoid*

Number Plate Lamp**
16
17
18
19
28
21
48
~ e
z
42
YNI ~
25
~
29
B!Y ....q}- B
G
-c[]= w
43
13
14
I
15~~~-;- J
34
31
F
35

Thunderbird, Thunderbird Sport & Ad ven t urer
16.53
Appendix
CONTENTS
Page
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17.1
17.1
17 APPENDIX
TROUBLESHOOTING
NOTE:
This is not a complete list of all possible

problems that may occur. It should only
be used as a guide to more common types
of fault.
Engine Does Not Start, Starting Difficulty:
Starter motor does not rotate
Side stand or neutral switch trouble
Starter motor faulty
Battery voltage low
Starter relay (solenoid) not contacting or operating
Starter button not contacting
Wiring open or shorted
Ignition switch trouble
Engine stop switch faulty
Fuse blown
Compression low:
Spark plug loose
Cylinder head not correctly tightened down
No valve clearance
Cylinder/piston worn
Piston ring faulty (worn, weak, broken, or sticking)
Piston ring/land clearance excessive
Cylinder head gasket leaking or damaged
Cylinder head warped
Valve spring broken or weak
Valve not seating properly (valve bent, worn, or
carbon build up on seat face)
Poor Running at Low Speed:

Spark weak:
Battery voltage low
Spark plug dirty, damaged, or incorrectly adjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not correctly fitted
Spark plug incorrect
IC igniter faulty
Pickup coil faulty
Ignition coil faulty
Moisture around spark plug
Starter motor rotates but engine does not turn

over:
Starter motor sprag clutch faulty
Fuel/air mixture incorrect:

Pilot screw incorrectly adjusted
Pilot jet, or air jet blocked
Air bleed pipe bleed holes blocked
Air cleaner clogged, poorly sealed, or missing
Choke starter plunger stuck open
Fuel level in carburettor float bowl too high or too low
Fuel tank air vent obstructed
Carburettor mounting loose
Air cleaner duct loose or missing
Engine won't turn over:

Valve seizure
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Camshaft seizure
Alternator shaft bearing seizure
Balancer bearing seizure
Compression low:
Spark plug loose
No valve clearance
Piston ring faulty (worn, weak, broken or sticking)
Valve not seating properly (valve bent, worn, or
No fuel flow:
Fuel filter clogged
Fuel tap clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Fuel level in carburettor bowl too high
Float valve worn or stuck open
No spark; spark weak:
Battery voltage low
Spark plug dirty, or incorrectly adjusted
Spark plug cap or high tension wiring faulty
Spark plug cap incorrectly fitted
IC igniter faulty
Neutral, or side stand switch faulty
Pickup coil faulty
Ignition or engine stop switch shorted
Wiring shorted or open
Fuse blown
Other:
IC igniter faulty
Carburettors synchronized
Carburettor piston sticking
Engine oil viscosity too high
Drive train trouble
Brake dragging
17.2
APPENDIX 17
Poor Running or No Power at High Speed:
Overheating:
Firing incorrect:
Spark plug dirty broken or incorrectly adjusted
Spark plug cap shorted or not fitted correctly
Spark plug of wrong grade
IC igniter faulty
Pickup coil faulty
Firing incorrect:
Spark plug dirty, broken or incorrectly adjusted
IC igniter faulty

Starter plunger stuck open
Main jet blocked or wrong size
Jet needle or needle jet worn
Air jet clogged
Fuel level in carburettor float bowl too high or too low
Bleed holes of air bleed pipe or needle jet blocked
Air cleaner clogged, poorly sealed, or missing
Air intake duct poorly sealed
Water or dirt in fuel
Fuel tap blocked
Fuel line blocked
Compression low:
Spark plug loose
No valve clearance
Piston ring bad (worn, weak, broken or sticking)
Valve not seating properly (valve bent, worn or

Main jet blocked or wrong size
Fuel level in carburettor float bowl too low
Air cleaner poorly sealed, or missing
Air cleaner duct poorly sealed
Air cleaner clogged
Fuel tap blocked
Fuel line blocked
Fuel filter blocked
Compression high:
Carbon built up in combustion chamber
Engine faults:
Clutch slipping
Engine oil level too high
Drive train trouble
Brake dragging
Lubrication inadequate:
Engine oil level too low
Engine oil poor quality or incorrect
Gauge incorrect:
Water temperature gauge broken/faulty
Water temperature sensor broken/faulty
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Knocking or Pinking:
Carbon build up in combustion chamber
Fuel poor quality or incorrect grade
Spark plug incorrect grade
IC igniter faulty
Cooling system:
Radiator waterways
Thermostat sticking/faulty
Radiator cap faulty
Thermostatic fan switch faulty
Fan motor faulty
Fan blade damaged
Water pump seized
Water pump impeller damaged
Miscellaneous:
Throttle valve won't open fully
Carburettor piston stuck
Brake dragging
Clutch slipping
Overheating
Engine oil level too high or too low
Drive train trouble
Over Cooling:
Gauge incorrect:
Water temperature gauge faulty
Water temperature sensor faulty
Cooling system component incorrect:
Thermostatic fan switch faulty
Thermostat sticking/faulty
17.3
17 APPENDIX
Clutch Problems:
Connecting rod bent

Gudgeon pin/piston holes worn
Clutch slipping:
Friction plate worn or warped
Steel plate worn or warped
Spring plate worn or warped
Clutch spring broken or weak
Clutch release mechanism jamming/faulty
Clutch hub or housing unevenly worn
Valve noise:
Valve clearance incorrect
Camshaft bearing worn
Clutch not disengaging properly:

Clutch plate warped
Clutch spring tension uneven
Engine oil deteriorated
Clutch housing frozen on drive shaft
Clutch release mechanism faulty
Clutch hub locknut loose
Air in clutch fluid line
Clutch fluid leak
Clutch fluid deteriorated
Master cylinder primary or secondary seal damaged
Master cylinder bore damaged
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken or stuck
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Camshaft chain tensioner faulty
Camshaft chain, sprocket, guide worn
Balancer gear worn or chipped
Balancer shaft position incorrectly adjusted
Balancer bearing worn
Balancer or alternator shaft cush rubber damaged
Abnormal Drive Train Noise:
Gear Change Faults:
Clutch noise:
Weak or damaged damper springs
Clutch housing/friction plate clearance excessive
Clutch housing gear worn
Does not select gear; pedal does not return:

Clutch not disengaging
Selector fork bent or seized on shaft
Gear stuck on shaft
Gear detent arm binding
Neutral detent arm binding
Gear change return spring weak or broken
Gear shaft seized
Ball joint seized
Gear change shaft broken
Selector drums pawl broken
Transmission noise:
Bearings worn
Transmission gears worn or chipped
Engine oil insufficient
Drive chain noise:
Drive chain adjusted incorrectly
Chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned
Chain rubbing strip damaged
Jumps out of gear:

Selector fork worn
Gear groove worn
Gear dogs and/or dog holes worn
Selector drum groove worn
Gear detent arm spring weak or broken
Selector fork pin worn
Input shaft, output shaft, and/or gear splines worn
Abnormal Frame Noise:

Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Overshifts:
Gear detent arm spring weak or broken
Gear change spring abutment bolt broken
Rear shock absorber noise:

Shock absorber damaged
Bearing seized
Abnormal Engine Noise:

Knocking:
IC igniter faulty
Carbon built up in combustion chamber
Fuel poor quality or incorrect grade
Overheating
Disc brake noise:

Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper faulty
Other noise:
Brackets, nuts, bolts, etc. incorrectly mounted or
tightened
Piston slap:
Cylinder/piston clearance excessive
17.4
APPENDIX 17
Oil Pressure Warning Light Comes On/Stays

On:
Shock absorption unsatisfactory:

(Too hard)
Front fork oil excessive
Front fork oil viscosity too high
Tyre air pressure too high
Front fork bent
Suspension settings incorrect
(Too soft)
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Front fork, rear shock absorber spring weak
Rear shock absorber oil leaking
Suspension settings incorrect
Engine oil pump damaged

Engine oil screen clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearings worn
Crankshaft bearings worn
Oil pressure switch faulty
Relief valve stuck open
0-ring at oil pipe in crankcase damaged
Exhaust Smokes Excessively:

Brakes Poor, Not Working:
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Air in brake line

Pad or disc worn
Brake fluid leak
Caliper seized on pins
Caliper piston seized
Pad jammed in caliper
Disc warped
Contaminated pad
Brake fluid deteriorated
Master cylinder primary or secondary seal damaged
Master cylinder bore scratched
Black smoke:
Air cleaner clogged
Main jet too large or fallen off
Choke starter plunger stuck open
Fuel level in carburettor float bowl too high
Brown smoke:
Main jet too small
Fuel level in carburettor float bowl too low
Air cleaner duct loose
Air cleaner poorly sealed or missing
Brakes Judder or Snatch:

Disc warped
Disc loose
Caliper mountings loose
Caliper pins loose/bent
Pads incorrectly fitted
Disc or pad contaminated
Floating disc bushes seized/worn
Handling and/or Stability Unsatisfactory:

Handlebar hard to turn:
Steering stem adjuster nut too tight
Bearing damaged
Steering bearing lubrication inadequate
Steering stem bent
Tyre air pressure too low
Cables/wiring/hoses trapped/binding
Battery Discharged:
Battery faulty (e.g., plates sulphated, shorted
through
sedimentation, electrolyte level too low)
Electrolyte contaminated
Battery leads making poor contact
Load excessive (e.g., bulb of excessive wattage)
Ignition switch faulty
Alternator faulty
Wiring faulty
Handlebars shake or excessively vibrate:

Tyre worn
Swing arm pivot bearing worn
Rim buckled or not balanced
Wheel bearing worn
Handlebar clamp loose
Steering stem adjuster nut loose
Battery Overcharged:
Handlebars pull to one side:

Frame twisted
Wheel misalignment
Swing arm bent or twisted
Front fork bent
Right/left fork legs unbalanced (oil level, adjustment
settings)
Alternator faulty
17.5

T300 Service Manual

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How to use this manual

This manual is designed primarily for use by trained

To assist in the use of this manual, the section title is

A basic knowledge of mechanics, including the proper

Adjustment and repair operations include reference to

In order to perform the work efficiently and to avoid

Particularly important information is presented in the

All work should be performed with great care and in a

Always use the correct special service tools or

Where accurate measurements are required, they can

CAUTION: This caution symbol identifies

For the duration of the warranty period, all repairs and

To maximise the life of your Motorcycle:

This note symbol indicates points of particular

Brake Shoes or Pads

Operations covered in this manual do not always

Clutch Friction Material

Operate if possible out of doors or in a well

Preferably use hand tools or low speed tools

Dampen dust and place in a properly closed

The dimensions quoted are to design engineering

airline to blow dust from

REPAIRS AND REPLACEMENTS

TAMPERING WITH NOISE CONTROL SYSTEM

The removal or rendering inoperative by any

the use of the vehicle after such device or

Whenever tapping to aid removal of an item is

Fuel handling precautions

Full Specification -Trophy 1200, Trophy 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Full Specification- Daytona 1000, Daytona 750

Full Specification - Daytona 1200, Daytona 900

Full Specification - Daytona Super 3 & Speed Triple

Full Specification- Trident I Sprint 900, Trident 750

Full Specification- Thunderbird Sport 900, Thunderbird/Adventurer 900 . . . . . . . .

Full Specification -Tiger 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torques ......................... .'. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARNING: The oil may be hot to the

An electric shock caused by contact with the

Health Protection Precautions

The ignition system and any diagnostic equipment

Do not put oily rags in pockets.

Overalls must be cleaned regularly. Discard

First aid treatment should be obtained

Use barrier creams, applying before each work

Wash with soap and water to ensure all oil is

Do not use petrol, kerosene, diesel fuel, gas oil,

If skin disorders develop, obtain medical advice

Where practicable, degrease components prior to

WARNING: Flouroelastomer material is

Avoid prolonged and repeated contact with oils,

WARNING: Any risk of eye injury must be

WARNING: If there has been an

CAUTION: Do not pour oil on the ground,

If the brake lever or pedal feels soft when it is

Burning of used engine oil in small space heaters or

WARNING: Brake fluid is hygroscopic

Failure to change the brake fluid at the interval

WARNING: Never use mineral based

Replace brake fluid in line with the Periodic

Damage caused by contact with mineral based

Always use new brake fluid from a sealed

Jacking and lifting

Always ensure that any lifting apparatus