Triumph 675 User Manual

Daytona 675 Motorcycle

Race Kit Manual

Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Head Gasket

0.65mm - A9618072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

0.60mm - A9618073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cams, Valve Spring & Sprocket Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cam - Inlet Kit - A9618055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cam - Exhaust Kit - A9618056. . . . . . . . . . . . . . . . . . . . . . . . . . 7

Valve Spring Kit - A9618058 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Camshaft Sprocket Kit - A9618057. . . . . . . . . . . . . . . . . . . . . . . 7

Cam Chain Kit - A9618059 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cam Chain Tensioner Kit (manually adjustable) - A9618060 . . . . . . . . 10

Inlet & Exhaust Valve Kit - A9618061. . . . . . . . . . . . . . . . . . . . . . . . 12

Air Funnel Kit - A9618063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Exhaust System, Stage 2 (Arrow) - A9600197. . . . . . . . . . . . . . . . . . 15

Air Filter Kit - A9618075 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Slipper Clutch Kit - A9618039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Transmission Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1st Gear pair & Housing Kit - A9618066. . . . . . . . . . . . . . . . . 20

Shaft, Input Kit - A9618064 (spares only) . . . . . . . . . . . . . . . 22

Gear, Output Kit - A9618065 (spares only) . . . . . . . . . . . . . . 22

Wheel Detent Kit - A9618068 (spares only) . . . . . . . . . . . . . . 22

Alternator Kit - A9618069 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Alternator Puller Tool Kit - A3880206 . . . . . . . . . . . . . . . . . . . . . . . . 23

Manual Idle Speed Adjuster Kit - A9618076 . . . . . . . . . . . . . . . . . . . 25

Race ECU Kit - A9618070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Race Harness Kit - A9618071 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Motorcycle Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Engine Protector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Clutch Cover, Carbon Fibre Kit - A9728028 . . . . . . . . . . . . . . . . 29

Crank Cover, Carbon Fibre Kit - A9728029 . . . . . . . . . . . . . . . . 29

Standard Alternator Cover, Carbon Fibre Kit - A9728031 . . . . . . 29

Race Alternator Cover, Carbon Fibre Kit - A9728032 . . . . . . . . . 29

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Introduction

Daytona 675 Race Parts

Triumph's ground-breaking Daytona 675 has not only received global recognition for its performance on the road, but also for its outstanding ability on the race track. To further support this exceptional track ability, Triumph have launched a Racing Support Programme, which is now further complemented by the launch of a range of Triumph Genuine Race Parts.

Factory developed in collaboration with Paul Young Racing, these parts have been designed to give significant improvements in engine performance for race purposes. This results in the class-leading Daytona 675 being competitive on the racetrack at the highest level.

Triumph Genuine Race Parts are sold individually and a number of the parts need to be used in conjunction with each other to ensure the best performance gains are realised and also to prevent premature wear on associated components. Please ensure you read the user manual in full to understand this detail prior to fitting or using any of the Triumph Genuine Race Parts.

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General Information

Please note:

• The race kits detailed in this publication are not covered by any warranty.

• The Race Kit parts covered in this publication are intended for racing purposes only and any Triumph motorcycle fitted with such kits MUST NOT be used on public roads.

• The information contained in this publication is accurate at the time of final approval, however, Triumph Motorcycles reserves the right to amend the information at any time without notice.

• The information provided in this publication should always be used together with the official Triumph Daytona 675 service manual.

• A standard Triumph Daytona 675 motorcycle fitted with the Race Kits detailed in this publication will fully comply with the current FIM Supersport regulations.

• Completely read all the instructions before commencing the installation and set up of the race kit in order to become thoroughly familiar with the kits features and the installation process.

• When removing components which incorporate a gasket ALWAYS ensure a new gasket is fitted on re-assembly.

Warnings, Cautions and Notes.

Throughout this publication particularly important information is presented in the following form:

Warning

This warning symbol identifies special instructions or procedures, which if not correctly followed could result in personal injury, or loss of life.

Caution

This caution symbol identifies special instructions or procedures, which if not strictly observed, could result in damage to, or destruction of, equipment.

NOTE

• This note symbol indicates points of particular interest for more efficient and convenient operation.

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Warning

These accessory kits are for racing only. They are for use solely during closed course racing. A motorcycle fitted with these kits must not be used on public roads. It is illegal to use a motorcycle fitted with these kits on public roads. A motorcycle fitted with these kits does not comply with local laws and regulations. If you use a motorcycle fitted with these kits on public roads, you may be prosecuted.

Warning

These accessory kits are designed for use on Triumph Daytona 675 motorcycles only and should not be fitted to any other Triumph model or to any other manufacturer’s motorcycle. Fitting these accessory kits to any other Triumph model, or to any other manufacturer’s motorcycle, will affect the performance, stability and handling of the motorcycle. This may affect the riders ability to control the motorcycle and could cause an accident.

Warning

Always have Triumph approved parts, accessories and conversions fitted by a trained technician of an authorised Triumph dealer. The fitment of parts, accessories and conversions by a technician who is not of an authorised Triumph dealer may affect the handling, stability or other aspects of the motorcycles operation which may result in loss of motorcycle control and an accident.

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.

Warning

A torque wrench of known accurate calibration must be used when fitting this accessory kit. Failure to tighten any of the fasteners to the correct torque specification may affect motorcycle performance, handling and stability. This may result in loss of motorcycle control and an accident.

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 system to cool, as touching any part of a hot exhaust could cause burn injuries.

Caution

The use of some of these kits will require changes to the fuelling settings. To alter the fuelling settings a third party programmable control unit will be required.

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Head Gasket

Caution

The use of the following race kit cylinder head gaskets will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required.

* Thickness “t” marking location

Parts Supplied - A9618072 (0.65mm) or A9618073 (0.60mm)

Item Description Qty

1 Head gasket (t = 0.65mm) 1

1 Head gasket (t = 0.60mm) 1

• The thickness of the standard cylinder head gasket is 0.7mm. The Race Kit gaskets are available in 0.60mm and 0.65mm thicknesses. The thickness (t) of the gasket is clearly marked on the gasket in the position (*) shown above.

NOTE

• Use the appropriate gasket to adjust the squish height (squish height is the gap between the flat portion of the piston and the cylinder head). Always ensure the gasket chosen provides a minimum squish height of 0.6mm.

1. Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual.

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2. Fit the chosen race kit cylinder head gasket following the procedures detailed in the Daytona 675 service manual.

Cams, Valve Spring & Sprocket Kits

Warning

The race kit must be fitted as a complete set. If it is not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident.

Caution

The use of the Camshaft, Valve spring & Sprocket race kits detailed below will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required.

Parts Supplied

Camshaft Inlet Kit - A9618055

Item Description Qty

3 Valve spring, 14.4id, race 12

Camshaft Sprocket Kit - A9618057

1 Cam assy, inlet, race 1

Camshaft Exhaust Kit - A9618056

Item Description Qty

2 Cam assy, exhaust, race 1

Valve Spring Kit - A9618058

Item Description Qty

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Item Description Qty

4 Sprocket, camshaft, 34T 2

Socket head cap screw, Encapsulated, M6x10

NOTE

• The standard inlet cam is 9.25mm max lift and 258.50 inlet cam is 9.25mm max lift and 268.74

duration.

• The standard exhaust cam is 8.5mm max lift and 246 exhaust cam is 8.5mm max lift and 262.21

duration.

duration. The race kit

• The race kit valve spring must be used in conjunction with the standard spring platforms and retainers. The fitted length of the race springs is the same as the standard spring.

1. The race kit valve springs should be assembled in the same manner as the standard valve springs. Follow the procedure detailed in section 3 of the Daytona 675 service manual. Ensure the springs are installed with the close wound, colour coded end of the springs facing downwards, towards the piston.

2. The race kit camshafts should be assembled in the same manner as the standard camshafts. Follow the procedure detailed in section 3 of the Daytona 675 service manual.

3. The race kit cam sprockets should be mounted and secured to the camshafts using the slotted holes in the sprocket. The slotted holes allow adjustment of the valve timing. The circular holes in the sprockets are for Triumph service tool T3880102 and should not be used to mount the sprockets to the camshafts.

5. Always check the inlet and exhaust piston to valve clearance for the timing selected to use, before running the engine. You must ensure both clearances are adequate. As a guide, the standard nominal piston to valve clearance is 1.3mm inlet & 1.5mm exhaust.

6. When the desired timing has been set the new socket retaining screws provided should be tightened to 15Nm. Note, if the screws are released for any reason, apply ThreeBond 1305 to the threads before re-tightening.

NOTE

• No timing marks are included on the race sprockets. Race engines will typically have different depths skimmed off the cylinder head and, therefore require specific individual timing.

4. The camshafts should be timed using cam degreeing equipment which typically consists of a degree wheel, pointer, dial indicator and piston stop. Optimum cam timing will depend on the exact specification of the engine, but a recommended starting point is 104 IMOP (Inlet Maximum Opening Point) and 104

EMOP (Exhaust Maximum

Opening Point).

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Cam Chain Kit

Parts supplied - A9618059

Item Description Qty

1 Cam chain 1

1. Remove the existing cam chain following the procedures detailed in section 3 of the Daytona 675 service manual.

2. Fit the race cam chain following the procedures detailed in section 3 of the Daytona 675 service manual.

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