TRIUMPH 1050 Service Manual
iiu e
Motorcycle anual
1
Part Number T3856080 issue 1, 03.2005
This document is protected by copyright and may not, in whole or part be stored in a retrieval system, or
transmitted in any form or by any means, copied, photocopied, translated or reduced to any machine-readable
form without prior consent in writing from Triumph Motorcycles Limited.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care
has been taken to make it as complete and accurate as possible.
Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior notice and
without incurring an obligation to make such changes to products manufactured previously. See your authorised
Triumph Dealer for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of
publication. Illustrations in this publication are intended for reference use only and may not depict actual model
component parts.
@
Triumph Motorcycles Ltd 2005
* From VIN 21 0445 onwards.
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Service Manual - Speed Triple
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Table of Contents
Introduction
General Information
Scheduled Maintenance
Cylinder Head
Clutch
Crankshaft, Connecting Rods and Pistons
Balancer
Transmissiow
Lubrication
ngine RemovallRefit
Fuel SystemlEngine Management
Cooling
Rear Suspension
Front Suspension
Brakes
WheelsKyres
Frame and Bodywork
Electrical
Service
Manual
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Service
Manual - Speed Triple
Service Manual - Speed Triple
iii
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
perform his own basic maintenance and repair
to
work. The work can only be carried out if the owner
has the necessary hand and special service tools to
complete the job.
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, an
authorised Triumph dealer must undertake all
adjustments, maintenance, and repair work.
In order to perform the work efficiently and to avoid
costly mistakes, read the text and thoroughly
familiarise yourself with procedures before starting
work.
All work should be performed with great care and in a
clean working area with adequate lighting.
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.
Where accurate measurements are required, they
can only be made using calibrated, precision
instruments.
For the duration of the warranty period, an authorised
Triumph Dealer must perform all repairs and
scheduled maintenance.
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).
How to use this manual
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.
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.
Warning, Caution and Note
Particularly important information is presented in the
following form:
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This warning symbol identifies special instructions
or procedures which, if not correctly followed, could
result in personal injury, or loss of life.
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This caution symbol identifies special instructions or
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procedures which, if not strictly observed, could
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result in damage to or destruction of equipment.
Note:
This note symbol indicates points of
particular interest for more efficient and
convenient operation.
Caution
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Use only genuine Triumph parts as listed in the
cataloguelparts microfiche.
parts
Follow the procedures in this manual carefully
and completely. Do not take short cuts.
Keep complete records of all maintenance and
repairs with dates and any new parts installed.
Use only approved lubricants, as specified in the
owner's handbook, in the maintenance of the
motorcycle.
Service Manual - Speed Triple
Introduction
I
Tampering with Noise Control
System Prohibited
Owners are warned that the law may prohibit:
a) 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
b) 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.
Edges
Watch for sharp edges, especially during engine
disassembly and assembly. Protect the hands with
industrial quality gloves.
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.
References
1
References to the left-hand or right-hand side given in
this manual are made when viewing the motorcycle
from the rear.
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.
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
andlor causing gas or oil leakage. Conversely, bolts,
nuts, or screws, should all be loosened (in sequence if
specified) by about a quarter of a turn and then
removed.
Where there is a tightening sequence specified in this
Dimensions
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 500
be maintained at the figures specified in this manual.
J
mile1800 km service, and thereafter should
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.
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.
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.
Service Manual - Speed Triple
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Sewice Manual - Speed Triple
Table of Contents
Ignition System Safety Precautions
DangerousSusbstances
Fluoroelastomers
Oils
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Health Protection Precautions 1-3
Environmental Protection Precautions
Brakes
Safetylnstructions 1-5
FuelHandlingPrecautions 1-7
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Jackingandlifting 1-5
Precautionsagainstdamage 1-5
Coolant 1-5
Cleaningcomponents
Lubrication 1-6
Jointsandjointfaces 1-6
Gaskets, O-rings
Liquid gasket, non-permanent locking agent
ScrewThreads
Locking Devices 1-7
Fitting a split pin 1-7
Circlips, retaining rings
Selflockingnuts 1-7
Encapsulatedbolt 1-7
Oilandgreaseseals 1-7
Press 1-7
Ballbearing 1-7
General
Petrol-Gasoline
Fueltankremoval
Chassisrepairs
ElectricalPrecautions 1-9
Batterydisconnecting 1-9
Disciplines 1-9
Electrical wires
Inspection
Replacementparts
Servicedata
Specification 1-10
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1-4
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1-6
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1-6
1-6
1-7
1-7
1-8
1-8
1-8
1-10
1-10
1-10
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Service Manual . Speed Triple
Service Tools and Garage Equipment
Special Service Tools 1-11
Engine
CylinderHeadValves
Camshafts
Clutch / Primary Drive 1-17
Balancer
Pistons
Connecting Rods
Crankshaft
Transmission 1-19
FinalDrive 1-19
Lubrication
Ignitionsystem
Fuelsystem
FuellnjectionSystem
Emissions Controls* 1-20
Coolantsystem
Suspension 1-21
Brakes
WheelsandTyres
Frame
Electrical Equipment 1-22
TorqueWrenchSettings
CylinderHeadArea
Clutch
Balancer, Crankshaft and Crankcase 1-23
Enginecovers
Transmission
Lubrication System 1-24
CoolingSystem
Fuel System, Exhaust System and Airbox
Rearsuspension
Frontsuspension
Wheels
FrontBrakes 1-27
RearBrakes
Frame, Footrests, Control Plates and Engine Mountings
Electrical
Bodywork
Clutchcablerouting 1-29
Throttlecablerouting
Main wiring harness routing 1-31
Frontbrakehoserouting 1-32
Rearbrakehoserouting
Fueltankbreath'erhoserouting 1-34
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Service Manual . Speed Triple
General Information
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Ignition System Safety Precautions
The ignition system produces extremely high
voltages. Do not touch any part of the ignition
system or any cables while the engine is running.
An electric shock caused by contact with the ignition
system may lead to illness, injury or death.
Wearers of surgically implanted heart pacemaker
devices should not be in close proximity to ignition
circuits and or diagnostic equipment.
The ignition system and any diagnostic equipment
may interrupt the normal operation of such devices
causing illness or death.
Dangerous Susbstances
Manv liauids 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!
.
Fluoroelastomer material is used in the manufacture
of various seals in Triumph motorcycles.
In fire conditions involving temperatures greater
315OC
than
then be potentially hazardous. Highly toxic and
corrosive decomposition products, including
hydrogen fluoride, carbonyl fluoride, fluorinated
olefins and carbon monoxide can be generated and
will be present in fumes from fires.
In the presence of any water or humidity hydrogen
fluoride may dissolve to form extremely corrosive
liquid hydrofluoric 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.
this material will decompose and can
Oils
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The ennine and bevel box oils mav be hot to the
touch. Contact with hot oil may cause the skin to be
scalded or burned.
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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.
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Sewice
Manual
Health Protection Precautions
*
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
*
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
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Speed Triple
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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, de-grease components prior
to handling.
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.
rakes
Brake fluid is hygroscopic which means it will absorb
moisture from ;he air: Any absorbed moisture will
greatly reduce the boiling point of the brake fluid
causing a reduction in braking efficiency.
Replace brake fluid in line with the routine
maintenance schedule. 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.
Always use new brake fluid from a sealed container
and never use fluid from an unsealed container or
from one that 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.
recautions
drains, or into water courses. To prevent pollution of
water-courses etc., dispose of used oil sensibly. If in
doubt contact your local authority.
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
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 your local authority for
advice on disposal facilities.
andlor manufacturer of the
If there has been an appreciable drop in the level of
the fluid in either brake fluid reservoir, consult your
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applied, or if the leverlpedal 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 authorised Triumph dealer before riding the
motorcycle.
Failure to take remedial action may reduce braking
efficiency leading to an accident.
in the
The use of brake fluids other than those
fluids listed in the general information section may
reduce the efficiency of the braking system leading
to an accident.
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Failure to change the brake fluid at the interval
specified in the routine maintenance schedule may
reduce braking efficiency resulting in an accident.
general information section of this manual.
0.0.7.
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Service Manual - Speed Triple
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.
Damage caused by contact with mineral based
grease may reduce braking efficiency resulting in an
accident.
Safety Instructions
Jacking and lifting
General Information
Coolant
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Coolant mixture, which is blended with anti-freeze
and corrosion inhibitors contains toxic chemicals
which are harmful to the human body. Never
swallow anti-freeze, corrosion inhibitors or any of the
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motorcycle coolant.
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.
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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
during lifting or jacking or while repairs and servicing
are carried out.
Never rely on a single means of support when
workin'g with the motorcycle. Use additional safety
supports and straps to prevent toppling.
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.
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.
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Caution
Precautions against damage
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Avoid spilling brake fluid or battery acid on any part of
the bodywork. Wash spillages off with water
immediately.
Disconnect the battery earth lead before starting
work, see
Always use the recommended service tool where
specified.
Protect exposed bearing and sealing surfaces, and
screw threads from damage.
ELECTRICAL PRECAUTIONS.
(see specification for anti-freeze) 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 engine damage.
Service
Manual
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Speed Triple
Cleaning components
A high flash-point solvent is recommended to reduce
fire hazard.
Always follow container directions regarding the use
of any solvent.
Always use the recommended cleaning agent or
equivalent.
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.
Lubrication
Liquid gasket, non-permanent locking agent
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.
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.
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The majority of engine wear occurs while the engine
is warming up and before all the rubbing surfaces
have an adequate lubrication film. During assembly,
oil or grease (whichever is more suitable) should be
applied to any rubbing surface, which has lost its
lubrication film. Old grease and dirty oil should be
cleaned off. This is because used lubricants will have
lost some lubrication qualities and may contain
abrasive foreign particles.
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
AlwaJiS
parts.
before using such special lubricants.
chFck-m~fZt~-Ec3mmeTdati~s
Joints and joint faces
Assemble joints dry unless otherwise specified in this
Manual.
If gaskets
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.
andlor jointing compound is recommended
Gaskets, O-rings
Screw Threads
Metric threads to IS0 standard are used.
Damaged nuts, bolts and screws must always be
discarded.
Castellated nuts must not be slackened back to
accept a split-pin, except in those recommended
cases when this forms part of an adjustment.
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
affectthe-&xqu
Unless specified, threaded fixings must always be
fitted dry (no lubrication).
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Never lubricate a thread unless instructed to do so.
When a thread of a fixing is lubricated, the thread
friction is reduced. When the fixing is tightened,
reduced friction will cause overtightening and
possible fixing failure.
IA fixing which fails in service could cause1
component detachment leading to loss of control
and an accident.
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Do not re-use a gasket or O-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.
Service Manual - Speed Triple
General Information
11
Locking Devices
Always release locking tabs and fit new locking
washers, do not re-use locking tabs.
Fitting a split pin
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, except in those recommended
cases when this forms part of an adjustment.
Always fit new roll pins of an interference fit in the
hole.
Circlips, retaining rings
Replace any circlips and retaining rings that are
removed. Removal weakens and deforms circlips
causing looseness in the circlip groove. When
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installing circlips and retaining rings, take care to
compress or expand them only enough to install
them.
Always use the correct replacement circlip as
recommended in the Triumph parts catalogue.
the original sealing surface cannot be completely
restored.
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.
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 appropriate grease.
When pressing in a seal which has manufacturer's
marks, press in with the marks facing out.
Seals must be pressed into place using a suitable
driver. Use of improper tools will damage the seal.
Press
A part installed using a press or driver, such as a
wheel bearing, should first be coated with oil or
grease on its outer or inner circumference so that it
will locate smoothly.
Ball bearing
Self locking nuts
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.
DO NOT re-use self-locking nuts in critical locations,
e.g. suspension components. Always use the correct
replacement self-locking nut.
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.
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.
Encapsulated bolt
An encapsulated bolt can be identified by a coloured
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section of thread which is treated with a locking agent.
Unless a specified repair procedure states otherwise,
encapsulated bolts cannot be reused and MUST be
replaced if disturbed or removed.
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Failure to replace an encapsulated bolt could lead to
a dangerous riding condition. Always replace
encapsulated bolts.
Fuel Handling Precautions
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
for basic guidance only and, if in doubt, appropriate
enquiries should be made of your local Fire Officer.
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Oil and grease seals
Replace any oil or grease seals that are removed.
Removal will cause damage to an oil seal which, if reused, would cause an oil leak.
Ensure the surface on which the new seal is to run is
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free of burrs or scratches. Renew the component if
Service Manual - Speed Triple
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
any indoor environment by air currents, consequently,
even a small spillage of petrol (gasoline) is potentially
very dangerous.
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.
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.
Always disconnect the vehicle battery, negative
(black) lead first, before carrying out dismantling or
draining work on a fuel system.
Whenever petrol (gasoline) is being handled,
drained, stored or when fuel systems are being
dismantled, make sure the area is well ventilated. All
potential forms of ignition must be extinguished or
.(this
removed
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light). Any leadJIamis mu3 be flame-proof and kept
clear of any fuel spillage.
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.
Failure to observe any of the above warnings may
lead to a fire hazard which could result in personal
injury.
Draining or extraction of petrollgasoline from a
vehicle fuel tank must be carried out in a well
ventilated area.
The receptacle used to contain the
petrol1 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.
petrollgasoline has been extracted or drained
When
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.
Fuel tank removal
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.
Chassis repairs
If-the-motorcycle-is=involved-in-anraccident=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.
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.
No one should be permitted to repair components
associated with
petroilgasoline without first having
specialist training on the fire hazards which may be
created by incorrect installation and repair of items
associated with petrollgasoline.
Repairs carried out by untrained personnel could
bring about a safety hazard leading to a risk of
personal injury.
Service Manual - Speed Triple
General Information
I
Electrical Precautions
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
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.
Prior to commencing any test procedure
connectors apart either by using tools
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.
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.
or<by pulling on
Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment.
The ignition system produces extremely high
voltages. Do not touch any part of the ignition
system or any cables while the engine is running.
An electric shock caused by contact with the ignition
system may lead to illness, injury or death.
Wearers of surgically implanted heart pacemaker
devices should not be in close proximity to ignition
circuits and or diagnostic equipment.
The ignition system and any diagnostic equipment
may interrupt the normal operation of such devices
causing illness or death.
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.
Always ensure that battery leads are routed correctly
and are not close to any potential chafing points.
The battery contains harmful materials.
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.
-
High Voltage Circuits
H.T. circuits always use insulated pliers. Exercise
caution when measuring the voltage on the coil
terminals while the engine is running, high voltage
spikes can occur on these terminals.
Connectors and Harness
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
Whenever disconnecting live
-
The engine of a
Always
Sewice Manual - Speed Triple
Disciplines
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, swarf, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
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 twocolour 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
red' wire; it would be a 'redlyellow' wire if the colours
were reversed to make red the main colour.
'yellow1
Inspection
I
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.
Disassembled parts should be visually inspected and
replaced with new ones if there are any signs of the
following:
Abrasions, cracks, hardening, warping, bending,
dents, scratches, colour changes, deterioration,
seizure or damage of any nature.
Replacement Parts
Only Triuniph genuine parts should be used to
service, repair or convert Triumph motorcycles. To
ensure that Triumph genuine parts are used, always
order parts, accessories and conversions from an
authorised Triumph dealer. The fitting of
approved parts, accessories or-conversions-may
adversely affect the handling, stability or other
aspects of the
result in an accident causing serious injury or death:
Always have Triumph genuine parts, accessories
and conversions fitted by an &uthorised 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.
motorcycle operation which may
non-
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.
All genuine Triumph parts have the full backing of the
motorcycle warranty. Triumph dealers are obliged to
supply only genuine Triumph recommended parts.
1
Specification
Triumph are constantly seeking to improve the
specification, design and production of their
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.
.
ly .---_
-
-
,-
f
(
Sewice Manual - Speed Triple
General Information
Service
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
T3880105 - Angular Torque Gauge
Tools
Service
and Garage Equipment
Tools
T3880371
-
Holder, Oil Pump Drive Gear
cbxt
T3880250 - Engine Management Diagnostics
A993801 7
-
Chain Link Took Kit
Service
Manual - Speed Triple
1.1
1
3880085-TO301 - Fork Piston Holder T3880017 - Holder, Sprag Clutch
38801 60-TO301
ccha
T3880375 - Alternator Rotor Holder
-
Fork Filler / Evacuator 13880305 - Clutch Anti-rotation Tool
1.12
Service
Manual
-
Speed Triple
General Information
T3880315 - Extractor, Cylinder Liners T3880365 - Puller, Alternator Rotor
-
7-388001 6
Holder, Balancer Gear
-
Holder,
Damping Cylinder
T3880290 - Wrench, Swinging Arm Adjuster
cdet
T3880295
Ring
-
Wrench, Swinging Arm Adjuster Lock
Sewice
Manual
-
Speed Triple
1.13
T3880024 - Socket 45 mm
13880003 -.Fork Seal and Bush Fitment
cdbp
'
T3880002 - Support Plate
ffixa
T3880001 - Fuel Pressure Gauge
ffixb
13880067 - Fork Spring Compressor
CqlW
-
3880065-TO301
Bearing Installer
Sewice
Manual
-
Speed Triple
General Information
3880075-TO301 - Bearing Installer
3880070-TO301 - Bearing Installer
Service
Manual
-
Speed Triple
1.15
Full Specification Speed Triple
Engine
Engine Configuration
Arrangement
Displacement
Bore x Stroke.
Compression Ratio.
Cylinder Numbering ................................. .Left to Right (110.3 adjacent to camchain)
Cylinder Sequence.
Firing Order
Maximum Power.
Maximum Torque
Cylinder Head Valves
Valve Head Diameter.
Valve Lift.
Valve Stem Diameter
Service Limit
Valve Stem Diameter
......................................
......................................
.......................................
...........................
................................
.....................................
.................................
.3 Cylinder 12 valve DOHC
.Transverse in-line
.I050 cc
.79x71.4 mm
.12.0:1
................................. .Number 1 at left
.I-2-3
....................................
...................................
.................
In.
............
...........
Ex.
In.
............
...........
Ex.
130PS (1 28bhp) at 9,100rpm
.I05 Nm (78ft.lbf)at 5,100 rpm
.33.5 mm
.27.0 mm
.8.75 mm
.7.45 mm
.................. In. ............ .4.975-4.990 mm
....................................
.................. Ex
............
.4.965 mm
.4.955-4.990 mm
Service Limit.
Valve Guide Bore Diameter
Valve Guide Bore Diameter
Service Limit.
Valve Stem to Guide Clearance.
Valve Seat Width (in head).
Service Limit.
Valve Seat Width (in head).
Service Limit.
Valve Seat Width (valve)
Valve Seat Angle
/
Exhaust Valve Spring 'Load at Length'
Inlet
Valve Clearance. ..................... In. ............ .0.10-0.20 mm
Valve Bucket Diameter.
Service Limit.
................................... .4.945 mm
.............
.............
...................................
In.
............
Ex
............
.5.000-5.015 mm
.5.000-5.035 mm
,5063 mm
......... In. ............ .0.010-0.040 mm
............. In. ............ .0.9-1.1 mm
...................................
.............
Ex
............
...................................
.............................
.I
.5 mm
.I .I
-1.3 mm
.I
.7 mm
.I
51.9 mm
................................... .45"
..............
........... .0.20-0.30 mm
EX..
.470 N +/-30 at 26.30 mm (inner)
.............................. .28.476-28.490 mm
...................................
.28.549 mm
Service
Manual
-
Speed Triple
Full
1'
Specification Speed Triple
Valve Bucket Bore Diameter.
Service Limit 28.549 mm
Camshafts
...........................
28.51 5-28.535 mm
.....................................
General Information
Cam Timing.
Camshaft Journal Diameter 22.930-22.960 mm
Camshaft Journal Clearance 0.040-0.091 mm
i
Service Limit 0.1 3 mm
Service Limit 0.1 3 mm
Camshaft Journal Bore Diameter
Camshaft End Float
Service Limit 0.20 mm
Camshaft Run-out. 0.05 mm max.
Clutch / Primary Drive
.........................
............................
...........................
.....................................
.....................................
........................
..................................
.....................................
...................................
...........
Inlet
Duration
Exhaust
Duration
Outrigger
Open 11 .25" BTDC (8 1.0 mm lift)
Close 41.25" ABDC (81 .0 mm lift)
........
........
232.50"
Open 34" BBDC
Close 4" ATDC
........
.......
(@
1.0 mm lift)
(@
1.0 mm lift)
228"
22.953-22.956 mm (outrigger)
0.044-0.068 mm
23.000-23.021 mm
0.03-0.1 2 mm
Primary Drive
Reduction Ratio. 1.750 (6011 05)
Clutch
No, of Friction Plates.
Plate Flatness. Within 0.2 mm
Friction Plate Thickness (inner and outer).
Friction Plate Thickness (all others)
Clutch Actuation Method. Cable
Cable Free Play (at lever)
Balancer
End Float. 0.06-0.41 rnm
..............................
Service Limit 3.60 mm
Service Limit 3.1 0 mm
........................
Type..
.........
.....................................
Type.
..........
.................................
.......................................
.................
.....................................
......................
.....................................
..............................
..............................
..........................................
Gear
Wet multi-phase
10
3.80 mm
3.30 mm
2.0-3.0 mm
Service
Manual
-
Speed Triple
Full Specification Speed Triple
Pistons
Cylinder Bore Diameter .79.040-79.060 mm
Service Limit. .79.110'mm
Piston Diameter (at 90" to gudgeon pin)
Service Limit
Piston Ring to Groove Clearances
...............................................
Top 0.02-0.06mm
Service Limit. .0.075
Second 0.02-0.06mm
Piston Ring End Gaps
Top 0.28-0.49mm
Second 0.43-0.64mm
Oil 0.33-0.89mm
Gudgeon Pin Bore Diameter in Piston.
............................................
Service Limit .0.075
...............................................
Service Limit .0.61
............................................
Service Limit .0.76
................................................
Service Limit.
Service Limit .17.029 mm
....................................
.....................................
....................................
....................................
....................................
..............................
...................................
.................
.78.970-78.980 mm
.78.930 mm
...................................
...................................
..................
.I
.16.993-17.001 mm
.03 mm
Gudgeon Pin Diameter. .16.984-16.989 mm
Service Limit .16.974 mm
C0s;lneetimg
Connecting Rod Small End Diameter
Service Limit. .17.028 mm
Connecting Rod Big End Side Clearance
Service Limit .0.50 mm
Crankshaft
Crankshaft Big End Journal Diameter
Service Limit .34.960 mm
Crankshaft Big End Bearing Clearance.
Service Limit. .0.10 mm
Crankshaft Main Bearing Journal Diameter.
Service Limit .37.936 mm
Crankshaft End Float. .0.05-0.20 mm
Service Limit. .0.40 mm
Crankshaft Run-out
Service Limit. .0.05 mm
....................................
....................................
....................................
.....................................
..............................
...................
.17.005-17.018 mm
...................................
................
...................
.................
.0.15-0.30 mm
.34.948-35.000 mm
.0.036 mm-0.066
...................................
..............
.37.960-37.967 mm
...............................
...................................
.................................
.0.02 mm or less
...................................
Service Manual - Speed Triple
General Information
i
1)
Full Specification
Transmission
...............................................
Type 6Speed,ConstantMesh
Gear Ratios.
Gear Selector Fork Thickness.
Service Limit
Gear Selector Groove Width.
Service Limit
Gear Selector Fork to Groove Clearance
Final Drive
Final Drive.
........................
.....................................
.....................................
.........................................
Speed Triple
............
.I
st 2.733 (1 5/41
2nd. 1.947 (1 9/37)
...........
3rd 1.545 (22134)
............
4th
............
5th
............
6th
............
..........................
...........................
..................
1.292 (24131)
1
1 074 (27129)
5.8-5.9 mm
5.7 mrn
6.0-6.1 mm
6.25 mm
0.55 mm max.
Chain
.I
54 (26130)
)
Final Drive Ratio
Chain Type
Number of Links
20LinkLength
Drive Chain Play.
Chain Lubrication
Lubrication
Type.
..............................................
Oil Capacity (dry fill)
Oil Capacity (wet fill including filter)
Oil Capacity (wet fill excluding filter)
Oil pressure (in main gallery)
Oil Pump Rotor Tip Clearance
Service Limit
Oil Pump Body Clearance.
service Limit
......................................
.........................................
.....................................
......................................
....................................
....................................
..................................
......................
......................
........................... 40.0 Iblin2 min.
...........................
..................................... 0.2 mm
.............................
.....................................
2.333 (1 8/42)
DID X-ring
106
321mm
35-40 mm
Mobil chain spray
Pressure Lubrication, Wet Sump
3.50 litres
3.20 litres
3.00 litres
Q
80°C oil temperature 8 5000
RPM
0.1 5 mm
0.1 5-0.22 mm
0.35 mm
Oil Pump Rotor End Float.
Service Limit
.....................................
.............................
Service Manual - Speed Triple
0.02-0.07 mm
0.1 0 mm
Full Specification Speed Triple
Ignition System
..............................................
Type .Digital Inductive
Electronic Rev Limiter 10,900 (rlmin)
Pick-up Coil Resistance. .0.56
Ignition Coil Type Plug-top
Spark Plug Type. .NGK CR9EK
Spark Plug Gap
Fuel System
Fuel Type
Fuel Tank Capacity.
Low Level Warning Lamp.
Fuel Pump Type. .Submerged
Fuel Pressure (nominal).
Purge Control System
Fuel Injection System
Type .Electronic, sequential
Idle Speed .I200 RPM
Injector Type.
Throttle. .Cable
Gontrol Sensors
.........................................
.............................................
........................................
......................................
..........................................
................................
.............................
......................................
...................................
....................................
.................................
............................
.0.7 mm
.unleaded, 95 RON (U.S. 89 CLCIAKI
.I8 litres
.4
...................................
.............................
...............................
--
.......................
-
..
r.
..
.3.0 bar
.Electronic, via fuel system ECU
.Twin jet, solenoid operated plate valve
-;-.
.,
.
KC2
+/-I 0% Q 20°C
litres remaining
/
twist grip
potentiometer
.Barometric -pressure, throttle position, cool
temperature, crankshaft position sensor, lambda
sensor, induction air temperature.
I
electronic throttle
Emissions Controls*
Catalysts .2, in silencer
Oxygen sensor
Secondary Air injection
Evaporative Control
*
Catalysts and oxygen sensor fitted in all markets except Australia, New Zealand and South Africa.
Coolant System
Coolant Mixture
Anti-Freeze Type .Mobil anti-freeze
Freezing point.
Cooling System Capacity.
Radiator Cap Opening Pressure
Thermostat Opening Temperature.
.........................................
1, in down pipe
....................................
..............................
.................................
.....................................
.Heated, in down pipe
.Solenoid controlled, reed valve type
.Activated carbon canister (California only)
.50/50 Distilled water
...................................
.....................................
............................
.......................
.....................
.-35°C
.2.8 litres
.I .I
.88"C (nominal)
bar
/
anti-freeze
Service Manual - Speed Triple
General Information
I
Full
Specification Speed Triple
Cooling Fan Switch On Temperature
Temperature Gauge Sensor Resistance.
Suspension
Front Fork Travel 120 mm
Recommended Fork Oil Grade.
Oil Level (fork fully compressed).
Oil Volume (dry fill)
Fork Pull Through
Rear Wheel Travel. 140 mm
Rear Suspension Bearing Grease
Brakes
i
Front Type.
Caliper Piston Diameter
Disc Diameter. 320 mm
Disc Thickness
Disc Run-out Max..
Master Cylinder Diameter. 14 mm
Recommended Fluid.
Rear Type Hydraulically actuated 2 piston calliper, single
Caliper Piston Diameter 27 mm
Disc Diameter. 220 mm
~isc Thickness 6.0 mm
Service Limit 5.0 mm
.....................................
...................................
....................................
...................................
.........................................
...............................
......................................
......................................
...................................
.................................
..........................................
...............................
......................................
.......................................
.....................................
.....................
..................
2.9 - 3.3
.........................
........................
469 cc
.......................
Two hydraulically actuated four piston radial
.............................
103°C
KC? Q 15°C
Showa SS8
120 mm
Flush with top of yoke upper face
Mobil grease HP 222
callipers acting on twin discs
/
33.96 mm
4 mm (3.5 mm minimum)
0.3 mm (0.1 mm standard)
Mobil universal brake and clutch fluid DOT4
disc
30.23 mm
Master Cylinder Diameter. 14 mm
Recommended Fluid.
Wheels and Tyres
Front Wheel Size.
Front Tyre Size
Front Tyre Pressure.
Recommended Front Tyre.
Front Wheel Rim Axial Run-out.
Front Wheel Rim Radial Run-out
Rear Wheel Size.
Rear Tyre Size.
....................................
......................................
....................................
......................................
.............................
.................................
..................................
..............
Option 1
Option 2.
Option 3.
........
.......
.......
.........................
........................
Mobil universal brake and clutch fluid DOT4
MT 3.5 x 17
120/70 ZR 17
2.35 Bar
Michelin Pilot Power
Bridgestone BT014
Pirelii Diablo
0.5 mm
0.5 mm
MT 5.5 x 17
180155 ZR 17
Service Manual - Speed Triple
Full Specification Speed Triple
Rear Tyre Pressure .2.9 Bar
.................................
Recommended Rear Tyres
Rear Wheel Rim Axial Run-out
Rear Wheel Rim Radial Run-out
Frame
Frame Type
Overall Length
Overall Width
Overall Height.
Wheelbase
Seat Height
Castor
Trail
...............................
Dry Weight.
Maximum Payload
(rider, passenger, luggage and accessories)
.........................
.......................
........................
.......................
..........................
.........................
..............................
.........................
....................
.............
........................
.......................
Option 1
Option 2
Option 3
........
........
........
..............
..............
..............
...............
...............
..............
..............
...............
...............
..............
Michelin Pilot Power
Bridgestone BT 01 4
Pirelli Diablo
.0.5 mm
.0.5 mm
.Twin-spar aluminium
.2115mm (83.3in)
.780mm (30.7in)
1250mm (49.2 in)
1429mm (56.2in)
.815mm (56.2in)
.23.5
84mm
189kg
.A85 kg
Electrical Equipment
Alternator Rating .35A
Fuses.
.............................
...................................
............
#I
............
#2 .Ignition switch
............
#3 .Indicators, brake light, horn
............
#4
#5
.............
............
#6 .Engine management system
#7
............
............
#8
#9
............
............
#I0 Blank
...........
#I 1 .Main fuse
.Instruments, fuel pump relay, EMS relay, starter
.Alarm, diagnostic connector, instruments, fuel
.Blank
.Cooling fan
.Dip and main beam headlights, horn
relay
Pump
.Tail light, number plate light, side lights
Service Manual - Speed Triple
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