Triumph Trident T160 Workshop Manual

A

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006

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WORKSHOP

For

the

Three

Cylinder

TRIUMPH

MODEL

750cc

with

Electric

(45.

Starter

T160

cubic inch)

MANUAL

TRIDENT

From Engine

CompiledbyJohnR.Nelson

©

CopyrightbyJ.R.NELSON

PublishedbyJ.R. Printed by

Theatre

Warwick.

Published Apri11982.

Warwick

Street.

Number

Technical

Printing Ltd

001

Publications

..

01

M.A.

Eng (CANTAB) M.I.Mech.E.

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ClassicBike.biz

1975 Trident T160

'SLIPPERY

ClassicBike.biz

SAM'

Ourcover design

thevery well known,

Its feats and achievementsasa single individual model to win the Isle Man Production T.T. Race no less a place in spirit and lively response T150

and

\

the

T160

shows

AnnalsofT.T. history, and is truly representativeofthe sense

model series.

the legendary Triumph Trident model which earned

but

possibly dubious

than

built

into

all

titleof"Slippery Sam".

five years in succession have earned

the

Triumph Trident models in both the

of

it

of

INTRODUCTION

ClassicBike.biz

This

Workshop TRIUMPH maintenance overhaul and repair

versions of this model.

T160

Manual

ELECTRIC

has been

START

TO

compiled

work

to provide service

'TRIOENT' MOOEL owners

on both

this

earlyT150

THIS

MANUAL

information

wishing

and

the

laterT160

for

750cc

to

(45

carry

out

Electric Start

cu.in.l

basic

The technical

original factory rewritten the Trident. the later

and Rocket 3 assistance to late collation considerable Birmingham, of

the Trident, being

The total thereby having several ways in search suddenly dispersed and writers

attempt use, The then seek the making the Trident.)

Generous although concerned undoubtedly prove invaluabletocurrent

first

in authoratative

this

much sought

content

to incorporate

butatthe

T150

and

Workshop

of

the

time

when

staff

become

Colleagues

should be

writer

therefore decidedtocollect

urgent

contributions

itisnow

it

was

class condition, even

for

has been

T150

involved in

model

not

same

Rocket3Models;

T150Trident

technical

following

co-incidentally

built

and

made

of

fresh

scattered

should

madetopreserve and present this information

aidofhis colleagues (the actual Technicai

and

some

nevertheless

those

who

after

representativeofa very successful high performance

brought

workshop

only

the

time

cover

Manualsofthat

and

Rocket3owners

information

closureofNorton Villiers

the

assembled

the

design, manufacture, production and

redundant

fields

and pastures new. The collected

overnight.Itwas

not

be

lost

material

considerable

felt

more

will

inevitably

together

manual,

features specifically exclusive to

the Disc Front and Rear Brakes

detailsofwhich

time, This version then should also beofconsiderable

.tp provide this Publication

productionofthe actual Triumph

atthe B.S.A. Factory at Small

quietly

following

has enabled

time

that

the

Trident owners wishingtokeep

importantly

be engagedonthe

and presented in a

but

were

in this category, The

folded

felt

the

demiseofthis

whatever

full

material

this

after

the end

rangeofinformation

as the inevitable

matching

has

of

course

not

includedinthe

Triumph

their

tents

that

the

that

manual tobebrought

of

overhaul and

been

the

Electric

incorporated

actual procurement

achieved

International

T160

Heath

servicingofthis

and

disappeared

T160

accumulated

famous

for

the

was

immediately

Staff

from

the

manufacture

contained

this

time

styletothatofthe

totally

Electric

cametoafinai end.

Model

name

record

the

prestigeous machine

approaches, be

ultimate

motorcycle.

updated and

Start

earlierT150

finality

at

Kitts Green in

their

knowledge

knowledgeofthe

and

available, and

original Company

to

completion

of

herein

restoration

version

on some

Model

some

Start

Model

machine

many and

that

every

for

ultimate

the model

would

totally

of of

and

was

and

of

The

first

section Reference form, detailing all dimensional dataofall

fits, limits and tolerances.

The layout of

the manual, correspondingtonormally

rebuild. The

followed which most worthwhile adaptable reader to

allowing proper intended.

It

has always been

and Reference Charts. Here

publication, and

of

T160

'ELECTRIC

by a final

were developed,

likely by

of

this

moving

this general data

START'

section

drawn,

now

provetobe no

including

willbefoundatthe

the

devise

protection

acceptedasuseful

manual

the

and

section

version

which

part

illustrations

his

own

of

the

we

have

therefore provides a GENERAL

original and recommended

wearing

deals

numbered

longer

methods

components

end

compo'nents and indicating

follows

practicetoinclude in any manual

also included those previously

the samesequence of the

established proceduresofstrip

electrical

with

avaiable.

and references

ofthis

equipment

the

originally recommended service

but

sadly never saw the

However

and solutions along the

during the operation in

Manual.

to

allow the

is fully

the

DATA

drawing

author

found

SECTION in Ready

and

the

established

main

sections

down,

described

lightofday; others

felt

well

equipped

lines

so indicated, thereby

the

manner

the

relevant

useful

manufacturing

optimum

in the body

examination and

and illustrated,

tools

some

which

thatitwould

or

keenly

originally

Conversion

from

the

earlier

JohnR.Nelson

of

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Slippery Sam

FOREWORD

ClassicBike.biz

All Triumph principles utilising a followed by a circular stamped or

amendment.

The engine

block flange.

feiture.

The prefix lettersindicate The

first

TridentT150

two

immediatelybythe

limiting

numberisto

the

numbers

prefix

letter

indicates

MonthofManufacture

A

January

B February

C

March

D

April

E

May

G

June

H

July

J

August

K

September

N

October

P

November

X

December

andT160 letter

model

ident

be

found

being

both

year

the

Models incorporated the same engine and frame numbering

prefix priortothe machines own individual number. This

type

designation. the complete sequence preceeded and ended

thereby preventing any subsequent

on the

stamped

and

month

left

sideofthe engine. immediately

onto a raised embossed pad - a

'.

monthofmanufacture.

and

yearof

manufactureasfollows:-

Yearof

formofillegal alteration

below

further

Manufacture

1974

J K

1975

N

1976

P

1977

X

1978

A

1979

8

1980

aid to counter-

the cylinder

was

The

third

section is a

commencing at The

fourth

Example

The

frame

The

frame

timeoforiginal

the ANCILLARY Carburetters

Chains

Electrical Equipment Rear Suspension Sparking Plugs

Instruments

Tyres

001

section

numberisstampedonthe

bears

the

EQUIPMENT

numerical

01.

indicated

same

manufacture.

the

serial

AND

block

model

Month

N

numberasthe engine unitfitted intoitand hence were identical at

PROPRIETARY

Amal

Renold Chains Ltd. Wythenshawe Manchester.

J Lucas Ltd. Great Hampton Street. Birmingham 18.

Girling Champion Sparking Plug Company Smiths Dunlop

of

five figures which comprise

designation.

Year

J

left

sideofthe frame. in

FITTINGS

Ltd. Holdford

Ltd. Birmingham

Industries Ltd. Cricklewood Works London

RubberCompany Ltd. Fort Dunlop Birmingham 24.

Road

Witton

Road.

Number

00101

front

of the fuel tank.

8irmingham

West

Bromwich Staffs.

Ltd.

Feltham Middx.

the

6.

engine

NW2.

number

Model

T160

ACKNOWLEDGEMENTS

ClassicBike.biz

The

compilationofthis publication results

former

Service Department, and

WoolridgeofTriumph

of

Due

greatful

Messrs Cork Gully & with previously used on Triumph and

colleagues

'Slippery

to

and produce this Manual, utilising (where appropriate) existing technical

completionofthis project.

Sam', perhaps

the

tortuous pathofownershipofthe

acknowledgement is freely giventoMr.

Jack

Harper and

Motorcycles

Co.

Arthur

with

practical

(Meriden) Ltd., andofcourse Leslie Williams the proud

the

most

famous

andtoTriumph

Trident

publications,

from

generous

Lupton,

help

Tridentofthem

Motorcycles

both

and advice from many friends, including Harry

namesofTriumph,

Dennis

which

and accurate contributions made

previously

all.

Poore, N.V.T., the Receiver N.T.I. Ltd.,

(Meriden) Ltd.

has proved so invaluable in the compilation

DISCLAIMER

for

many years

8.SA,

from

with

the

8.S.A.

owner

N.V.T.M. and 'TRIDENT',

for

permissiontoproceed

matter

and

December

artwork

J.R.N.

1981.

Whilst

maintain the development those responsibility whatsoever

errors in any

every endeavour has been madebyall

its technical accuracy,itmustbeappreciated

closureofthe

responsible

factory

facility,

for

way

whatsoever.

with

the composition and

those

where

manufacture

consequent

for

any errors,oranydamageordamages arisingorensueing

disbandmentofthe

took

publicationofthis

contributing

that

place and the loss of the associated design and

to this publication to assure and

compilation a

original drawing facilities and records,

Workshop

number

Manual, cannot accept any

of years

from

after

such

CONTENTS

ClassicBike.biz

See Bookmarks

SECTION

GENERAL

LUBRICATION

DATA

SYSTEM

ENGINE

PRIMARY DRIVE

TRANSMISSION

FRAME &

ATTACHMENTS

(GEARBOX)

WHEELS. BRAKES

..

& TIRES

GO

A

B

C

0

E

F

FRONT FORK G

ELECTRICAL SYSTEM

SERVICE

CONVERSION

TOOLS

CHARTS CT

H

J

ClassicBike.biz

·.

ClassicBike.biz

GENERAL

TRIDENT

MODEL

750

C.c.

(45 cu. ins.)

DATA

TI60

GDl

GD

ClassicBike.biz

GENERAL

DATA

OiL

PUMP

Pump

drive

Type •..

OIL

PUMP

Intermediate:

ratio

DRIVE

gear-Bore

Bush-Bore

Spindle-Diameter

OiL

PRESSURE

Release pressure

OiL

PRESSURE

Normal running

Switch operating pressure ...

BASIC

DETAILS

Bore and

CapaCity

Compression ratio

CRANKSHAFT

Crankshaft type

Main

bearing

Main

bearing

Main

bearing

Left

main Left main Centre Centre Right

Right main

Big

end

Min.

regrind

CONNECTING

Length

Big

end

Con

rod

Bearing

WRiST

CYLINDER

Clearance Diameter Length

Material

Bore...

Maximum

Tappet Liner

Material Inlet Exhaust

Valve

RELIEF VALVE

stroke

!drlVe side) size and

centre) timing

bearing housing

bearing

main

bearing

main bearing journal

main

bearing bearing

Journal

diameter

RODS

(centres)•__

bearings

side

clearance

dlametral

(GUDGEON

In

con~rod

BLOCK

..,

oversize

guide

block housing

materIal

HEAD

port

size

port

size

seatings:

Type

Material

...

VALVES

Stem

diameter~

Head

diameter:

Exhaust

valve material

-Length

funning

side) size and

diameter

Journal

diameter

housIng

housing

Journal

type

clearance

diameter

PIN)

(see also page 00)

Inlet Exhaust Inlet Exhaust

type

clearance

type

diameter

GENERAL

MODEL

LUBKICATION

T160

ENGINE

DATA

TRIDENT

SYSTEM

1-9 : 1 (engine

Geilr (duplex)

·5625/·5620

·4387/·4382 In. (11'143/11'1302 mm.)

·755/·745 In. (19·177/18·923 mm.)

·4360/·4357

85-75

85~75

3-5

p.•.!. (0,211 kg/em2..()·j522 kg/em.)

67 X70mm. (2-637 In. Y 2-756 In.) 740·4 9·5

: 1

EN16B

one

1* X

·0005/·00llln. 25

mm 2·8100/2·8095 1-1248/1·1245 2'0630/2-0625ln.!52.4002/52-3875

1·9170/1-9175In. 48·6918/48-7045

2·0447/2-0457 In. 51·9344/51·9608 0'9843/0·9840 In.!25'0012/2409936 mm.)

1·6240/1·6235In. 41/2496/41·2369 mm.) 1-6200/1-6195In. 41-148/41'1353 mm.)

5·751/5-749

BI~metal.

·008/·014

·0005/·0020 in. minimum (·0127/·0508 mm.)

'005/·0011

·6883/·6885 In.(17·4828/17·4880 mm.)

2·250/2·235

Aluminum

2-6366/2-6363 In. (66'9696/66-962 mm.)

+·040 In. (1-016 mm.)

1-1562/1-1557 Austenitic

Alum alloy dIe casting 1-p;" dia. (2S·575mm)

1.ln. Cast-In

Cast

·3100/·3095

·3095/·3090 In. (7·8613/7·8495 mm.)

1·534/1-528

1315/1·309 Chromlum-Manganese-Nlckel-Nitrogen

valve

to

pump)

In.

(14·287/4·2748 mm.)

In.

(11·0744/11-0668 mm.)

p.•.I.(5·976-5'273 kg/em2.)

p.'.!' (5-976-5·273 kg/em2.)

em'

(45-2

cu.

In.) .

hardened

piece

2+t

x+t

X 52 mm X 15 mm (roller)

5teel backed

In.

dla. (31'75 mm.)

iron

steel

and

tempered

In.

(caged ball)

(·0127/·05588 mm.)

In.

(71·3740/71·3613

In.

(28·5699/28·5623

In.

(14-6075/14-6024 mm.)

0·2032/0·3556 mm.)

In.

(0127/·0279 mm.)

In.

(57·150/56·769 mm.)

Alloy

In.

(29·3675/29·3548

steel

(c'

bore

In.

(7·8740/7·8613 mm.)

In.

(38·9636/38·812 mm.)

in.

(lJ·401/33·2486

(heat

treated)

stamplng~

mm.) mm'l mm.

mm.

mm.)

1t·)

(31·75mm)

mm.)

GD2

GENERAL

ClassicBike.biz

.

DATA

GD

.",11.

~_

'.

I

~'z.,.

I j

...-11.;;:1

~,P

~-

VALVE

•

"IA

~

s".~

I""

~.\.

pair

t!1

.1

~

VALVE

Set

:loees @ 0-020In(0'

50

GUIDES Material Inside

diameter

Outside

Length:

Free

Total

all

mmf

ROCKERS

CAMSHAFTS

diameter

Inlet

Exhaust

SPRINGS

length:

numberOou/~~il';;

fitted

Valve

Valve closed: Inner

TIMING

tappet

for checkln

Bore

...

Rocker

spindle

Tappet

clearance (cold): Inlet

Journal

diameters

Dlametral clearances

End

float

Cam

11ft:

Base

circle

(Inlet and

(Inlet and exhaust)

'"

(RED

Inner..,

load

open:

Inner

Outer

c1ear_{50:

g

diameter

Inlet

and

radius

_.....

exhaust)

...

_..

.

..

AND

WHITE)

Inn~;'

Queer

(Mechod

[nletcpens,

640Inlet closes. 67

Exhaust

47"

Exhaust closes,

Exhaust •..

exhaust

...

1)

beforeT.D.C.

after

opens,

B.D.C.

before after

B.D.C.

T.O.C.

Hldural 5

·313"/,312' ,5005/,5010 1·875 In. 147'625 mm.) 1·875

10468 In. (37·2872 mm.) 1,600 In, (40,64 mm,)

6

5,

88 Ibs, (39'952 kg,)

121 37-40 Ibs, 48-53 Ibs,

, ,

5t all

til

ts Z

cfearancepr~r

Ing only Exhaust valve

{At

chee:k~

Jnlct valve (measuredonvalve

·5002/,5012 In, ,4990/,4995 In. (12·6746/12-6873

·006 In. (0,1524 mm.)

·008

1'061/10060 In, (26,9494/26,9240

,0025/,001 In, (0·063S/0,0254 mm.) ,007/,021 In. (,178/0,305 ,329 In, (8,3566 ,406

In.

47·625

Ibs, (54-934 kg,)

(16'798-18,144 (21·792-24,062

(Mechod 2)

piston

T.O.C.

open

In.

(0·2032 mm.)

In,

dla, (10·3124

(7,950/7,924 In,

(12,7127/12,7254

(Exhaust

0·125/0·135In(3·18/3'4

open

(12,7050/12,7304

mm,)

mm.\

Stroke)

0·125/0·135

top

collar)

mm.)

mm,)

mm.)

kg,) kg.)

In

mm,)

(3·18/3·4

mm.) mm,)

mm,)

mm

mml

TAPPETS

Tip

radius

Tappet

diameter

ClearanceInguide

TAPPET

IGNITION

TACHOMETER

TIMING

GUIDE Diameterofbores Outside Interference

Crankshaft

Piston

Drive Drive Driven

diameter

TIMING

position

gear gear

gear Bush (plain) Bush (flanged)

GEARS

Inlet

and

exhaust

No.ofteeth

Fitoncamshaft

Intermediate

No.ofteeth

Bore

Bush

IntermedIate

Diameter

Crankshaft

No.ofteeth Fitoncrankshaft

position

shaft housIng

bore

..• ...

block

BLOCK

...

•.. .

fitIncylinder

(B.T.D.C.) Fully

DRIVE

shaft

camshaft

.

timing

wheel

pinion:

.

gear

spindle

...

..

block

pinions:

...

advanced

...

1-125 In. (28'575 mm,)

·3115/3105 ,0025/,001 In, (0,0635/0·02S4 mm,)

·3130/,3125 In, (7,9502/7,9375

1-1517/1-1572 In. (29,4055/29,3929 mm,)

,002/,001 In, (0,0508/0,0254 mm,)

38'

,357 In, (9'0678 mm,)

'280/'2791n, ,2822/,2807 In, dla,

·2410/·2405 In, dla, ,2435/·2425 In, dla. ,2435/,2425, In. dla,

50

,000/·001 In, (,000/,0254

47

,8745/·8740· ,6892/,6885 In.

,6880/·6877 In, (17,475/17,467

25

+,0005 In.

- ·0005 In,(-·0117

In,

(7,9121/7,8994

dla.

(7,112/7,087

~'168/7'130

6,121/6·109 6·185/6·160

(6,185/6,160

(22,2123/22'1996

(17'5056/17'4879

(+

,0127

mm,)

mm.)

mm,)

mm.)

mm,)

mm,) mm,) mm,)

mm,)

mm.)

CONTACT

Gap Advance Fully

BREAKER

setting

range

advanced

(7CA)

...

at

,01'1-,016 In. (0,355.. 12'

(24" crankshaf<)

2,000

r.p,m,

1H06

mm,)

GD3

GO

ClassicBike.biz

PISTONS

Clearanceatskirt

Gudgeon

Compression ratio ...

PISTON

Compression

011

FUEL

Triple Amal

Main

Need e Jet size Needle Needle position Throttle Carburetter Air cleaner

CLUTCH

Single diaphragm

Minimum

Allowable

Pressure Operating

CHAINWHEEL

Thrust

Needle

pin hole dla.

RINGS

Width Thickness

Fltt~d

Clearanceingroove

control

Thickness

In

Fit

SYSTEM

carburetters

type

let

size

type

valve ..•

DETAILS

bearing ... '"

roller

(thrust

faces)

measured

rings

(tapered)

gilp

groove

••

,

ring: (Apex 3 piece)

.•.

•.. •..

•..

nominal bore size

element

PRIMARY DRIVE

spring-release

traveltodisengage •..

wearoffriction plate

plate bearing (ball)

lever bearing (ball)

bearing (chalnca.se) ...

load

;,.;:

·500"

from

bottomofskirt

...

AND

..

·0021/·0015 in. (0·05J3/0·0381

·6887/·6885 In. (17'493/17'4879 mm.)

9-5

a·s

(Identified

engine

lug)

2-729/2-577

·0625/·0615 In. (1·5875/1·5621 mm.)

·012/·017 In. (0.305/0·432

·0035/·0015 In. (0'089/0·038

·115

In.

(3-175

Central spring expander

ConcentrIc

626

150

·106

STD

2

~,

4

27

Paper

rnm

.

(special).

GEARSHIFT

1,000 Ib,

'035

In. (·889 mm.)

·06 In. (1,524

17 mm. X 40

!"

X

11-"

Torrington NTA

1t (shaft) X

by

mm.

mm)

(approx.)

mm.)

mm.

Xt"In.

It''

'L' stamped

Nominal.

(453.6 kg.)

X 12 mm.

2233

X

t"

mm.)

on

front

To

find

the

Divide

the

and multiply

on

the

gearbox sprocket,asexample:-

clutch

engine sprocket

To

find

the

as

example:-

Gearbox

as

example:-

Third

gear Internal ratio

TRANSMISSiON

gear ratios of a machine, calculate

number

the

of teeth on

resultbythe

sprocket

(43)

the

primary chainwheel by

numberofteethonthe

x

(23)

Intermediate gear ratio, multiply

top

gear

ratio 4·92X

Internal ratio

bottom

gear

=

(Iayshoft

(malnshaft 3rd) 18T

the

top

rear

wheel

gearbox

the

sprocket

overall

Internal

loyshoft gear

malnshaft gear

3rd)

18T

(GEARBOX)

gearasfollows:-

the

number of teeth on

rear

wheel sprocket, dividedbythe

sprocket

ratio

(19)

top

gear

2·58=12·7

(50)

ratiobythe

bottom geor

x

(malnshaft

x

(/oyshoft

the

engine

sprocket

numberofteeth

2150

4·92

437

Internal gear ratio concerned,

overoll

ratio

mOlnshoft

loyshaft

tOp)

21T

top

geor

1·4

top)

15T

.,

GD4

GENERAL

ClassicBike.biz

DATA

GO

RATIOS

Internal ratios: 5th (Top)

Overall ratios: 5th (Top)

Engln.

R.P.M.

Transmission

GEAR

DETAILS

Malnshaft high

Bearing type

Bearing length

Spigot diameter

GEARBOX

Malnshaft:

Left end diameter Right end

length

Layshaft:

Left end diameter

Right end diameter

Length~..

BEARINGS

Malnshaft bearing (left) (Supplied

Malnshaft bearing

Laysnaft

Layshaft bearing (right) layshaft

Bore ...

Shaft diameter

Layshaft 2nd gear (bush fitted)

Bore

Shaft diameter

Layshaft

Bore ..• Shaft diameter

4th

.,.

3rd

2nd

1st

(Bottom)

4th...

3rd

2nd

1st (Bottom)

@10

M.P.H.

sprocket

gear:

...

SHAFTS

diameter

,.,

hearing (Iert) .

1st

gear (bush fitted)

,..

4th

...

gear (bush

...

teeth

(right)

fitted)

".

... ...

In

5th

.,.

...

.._

(Top)

with

gear)

.•, .•.

..,

goa'

1·00 : 1 1019:

1

1040:

1

1·837 : 1

B85

: 1

4·92

5-85

6·89 9·04 12-71 663 19

ft"

X

1ft"

;<

i"

Needle

Ball

roller

mm'j

Journal

roller

·875/·8651n. (22·23/21·97 mm.)

1·50n/l·5072

·8103/·8098 In. 120.58/20'57 mm.) -

·7494/·7498 In. 19·044/19·054 mm.} 10·37 In. (263 mm.)

·6875/·6870 In. 117'46/17'404 '6875/·6870 In. 17·46/17·404 mm. 6·47 In. (164-33 mm.)

1!

X

t x

11

*x

*X

·810/·809 In. (20·574/20·548 mm.)

·8075/·8070 In. (20'511/20'498 mm.) .810/·809 In. (20·574/20·548 mm)

'8075/'8070 In. (20·511/20'498 mm.)

-8103/'8093 In. (20·582/20·556 mm.)

·8078/·8073 In. (20'518/20'505 mm.)

In.

(38·36/38·28 mm.)

2!

x i in. Roller bearing

x

-r..

In.

txt

In. in.

Needle Needle

txt

KICKSTART

KICKSTAIjTER

GEARSHIFT

Bush

bore

Spindle working clearanceInbush

Ratchet spring free

Crank Crank bush

Plungers:

Outer Working

Plutlger springs: .

No. ofworking calls

Free length

Inner bush

Clearanceenshaft

Outer

Clearanceenshaft

Quadrant

No. of werking

Free length

Camplate plunger

Free length Ne.

of werking calls

Camplate plunger housing Camplate

RATCHET

spindle dla.

bore

MECHANISM

diameters

clearanceinbore

bore

(Gearchange fork)

bush

bere

return

springs:

c01ls

spring:

plunger'diameter

MECHANISM

length

...

bore

...

'751/·752 In. (19·0754/19·1008 mm.)

-0012/'0026 in. (·0304/-0660 mm.)

fin.

(12-7 mm.)

·748/·747 In. (18·999/18-974

·753/·752 In. (19·126/19·101 mm.

'4315/-4320 In. (10·9601/10·9728 mm.) '0005/'0015 In. (0-0127/·0381 mm.)

12

1*

In.

(31,75 mm.)

'5632/·5622 In. (14·3053/14·2799 mm.)

·0025/-001 In. (0·0635/0-0254 mm.)

·753/·751 In. (19·1262/19-0754 mm.) '0045/·002 In. (0'1143/0'0508 mm.)

11

It

In.

(44·45 mm.)

2·14 In. (58 mm.)

19

·4385/·4375 In. 1110138/1101125

·4365/·4355 In. 11-087/11·0617 mm.

mm'j

GD5

GO

ClassicBike.biz

GENERAL

DATi,

GEARSHIFT

Cross-shaft

Needle Link

Link Din diam.

STARTER

Solenoid Intermediate

Adapter

Intermediate

HEAD

SWINGING

RACES

Taper

roller (top and bottom)

Bush

type

Bush

bore

Bobbin Distance

REAR

SUSPENSION

Type

.. ,

Centres Bush

bore

Length of free spring

Spring

CROSS·SHAFT

diamC!tcr

railer

bC<lring

bOie

rlOTOR

and

plate bush

diameter

between

(extended unit)

rate

bearing shaft

shaft bush

shaft

FORK

.•••

...

MECHANISI"'!

diameter

housing bush

bore

diameter

fork ends

bore

...

bore

FRAME

AND

ATTACHMENT

6250/·6245 in. (15'875/15-862] mm.)

'!"

;.:

+ttl

;.:

·378/·376 In. (=}-601/9·550 mm.)

·3751/·3749 (9·527519·5225 mm.)

1·0018/1·0013

1'0003/·9998In(25'407/25·395 mm.)

·7530/·7518 '4387/'4382 '4372/·4367

til'·

In.

(25'446/25'433 mm.)

In.

(19'126/19'096 mm.)

In.

(11'143/11-130 mm.)

In.

(11·105/11·092 mm.)

DETAILS

Tlmken LM11949L/LMl1910fLM11900E.

Pre-sized

1-4460/1-4470 1-4445/1-4450 7·81 In. (198,4 mm.)

Swinging fork controlled

coil sprlng/hydraullc

n·875

·382/·377 8·810 110Ib,./ln.

steel-backed-phosphor

In.

(36.7284/36·7538 mm.)

In.

(36·6903/36·703 mm.)

(327 mm.)atmid position

In.

(m·8

damper

(9-7028/9-5758 mm.)

mm.)

bronze

by

units

combined

WHEELS

Rim size:

Spoke details:

WHEEL

Front Front Rear sleeve

REAR

WHEEL

Gearbox

Rear wheel

Chain details:

Width Speedometer Speedometer

BRAKES

Operation

Type

Diameter:

jl'

Brake pad (front) Brake pad (rear)

WHEELS,

Front Rear

BEARINGS

and

rear,

spindle diameter (at bearing Jour,nats).

sprocket

No.

of

links: Solo

Pitch

...

Front Rear

... ..,

Front

Outer

Inner (L.H. and R.H.)

Rear: tnner (L.H. and R.H.)

Ouw Outer (R.H.)

dImensions and type

diameter

DRIVE

sprocket

(at bearing Journals)

...

-teeth

...

... ...

drive gearbox ratio

cable length _." ..,

.. , ..,

(L.H. and R.H.)

(L.H.)

.., ...

BRAKES

'.::+

AND

TIRES

WM2·19 WM3·19 20

off 10 SWG 7·87

head .

20

off 10 SWG 7·84 in. (mean length)

20

off 10

10 off 10 SWG 8·16 10 off 10 SWG

25

·9841/·9836 (24-9961/24-98:! mm.)

See 'Transmission'. 50

110

tin.

i

1·25 : 1 . 70·5

SWG

head

X 52 X 15

·7873/·7868 (19·9974 (19-9847 mm.)

In.

(1791

HydraulIc Disc 101n.

254

in.

254

mm.

10 A.P.4741-537 A.P.4741-570

In.

(overall length)

7·84 in. (mean length) 96"'head

tn.

(overall

8in.

(overall length)

mm.-Ball

mm.)

Journals

96;

length)

80;

80'

head

75;l

head

TIRES

Size:

Front Rear

Tire

pressure:

GD6

Front

Rear

4·10 X 19 in. 4·10

;.:19In. 26Ib./'q. 28

In.

lb./,q. In. (1,97 kg./sq. em.)

(1-828 kg./'q. em.)

GENERAL

ClassicBike.biz

DATA

GD

TELESCOPIC

Typo ...

Spring

Stanchion

Outer

Tachometer cable length

FORK

details:

Free

length

No. working colis

Rate

Gauge

Colour

code

diameter:

member

Battery

Coil

Contact

breaker

Generator

Horn

...

Rectifier

Zener

Diode ...

Bulbs-headlamp

-head

lamp (pilot)

-'Narnlng

-stop-tall

-speedometer/tachometer

-direction

Condenser Pack

Flasher

unit

Headlamp ,., ..•

Handlebar

Handlebar switch (leit)

Ignition switch

Rear

Fuse

Sparking

Starter

Ballast Neutral Starter

Solenoid

switch

stop

switch

ratlng...

Plugs

-Typo

-Gap

-Thread Motor

resistor

Indicator

relay

setting

bore

unit

(main)

lamps

lamp

indicators.••

••.

(right)

...

size

...

(top)

(bottom)

ELECTRICAL

ill

urn

1nation

FRONT

"

...

FORKS

EQUIPMENT

....

Telescopic-oil

19·50

In. 56·5 35 Ib./in. 6·25 kg/em. kg./m.)

7 s.w.g.

Orange 1·35501·3537 1-3616,1-3605 In.(34·5B46/34·5567 mm.)

1-365j1-363 In. (33·15/33·1 mm.)

In

(762 mm.)

30

Lucas MCZ 9-8 Lucas 17 M 6

7CA

Lucas LucasRM21 Lucas 6H lucas

2D5.506

Lucas

ZD.715 Lucas 370. Lucas 989. 6 Lucas 281. 2 Lucas 380. Lucas 504 2.2 lucas

382.21watt

Lucas 2CP

BFL

Lucas Lucas SS700P. Lucas 169 SA Lucas 161.5A Lucas 149 SA Lucas 118 SA 3S

amperes

Champion N3

·020 In. (,50

14 mm. X i In.

Lucas

M3 Lucas 41790 Lucas 147SA Lucas 22RA Lucas 175 76849

damping

(495·3 mm.)

and

red

In.(34·417/34·3B46 mm.)

45/40

watt watt watt

21/6

watt

mm.)

reach

CAPACITIES

Fuel

tank

Oil

tank

Transmission

Primary Front

(orks

BASiC

DIMENSIONS

Wheel

base

Overall

Overall Grou ndcIearance Seat

height

Unladen

Conn.

rod Crankcase Crankcase Cylinder Cylinder Rocker Rocker

(Gearbox)

chalncase

(each leg)

... length width height

...

weight

bolts Junction bolts Junction

block

base

head

bolts/nuts

box

nuts

box

bolts

studs

nuts

TORQUE

M

ISCELLAN

EOUS

:s:.,.

WRENCI-:(SETTINGS

Alternatives-5!

U.S.

pints (5 Imp. pints) (3·0 lIeers)

6

1:

U.S. pints

•

U.S.

pints(tImp. pines) (350 em

210

C.c.

5B

In.

(147·5 em.)

BB

In.

(223·5 em.)

29

In.

(73·5

46·5

In.

(11

7 In.

(17-8

31'25 in. (79,4 em.)

503 Ib,.

(22B

-3

(1!-

em.)

B em.)

em.)

k8.)

U.S. galls.

liters)

U.S. galls.

liters)

Imp.

(DRY)

21-5/22·5 12 Ib.ft. (1-659 kg.m.) 15

20/22 Ib.fe.

18 Ib.fe. (2·4B9 kg.m.)

Ib.n.

(2-967/3·105

Ib.ft. (2·074 kg.m.)

(:·765/3-042

(·B3

kg.m.)

6Ib.ft. 6 Ib.fe.

pints)

kg.m.)

(4t

Irop.

(2t

.Imp.

850 em.')

kg.m.l

galls.

20

galls.

11

J

)

GD7

GD

ClassicBike.biz

GENERAL

DATA

Kickstart

Rotor Stator Stanchion

Front wheel spindle

Zener

Fork cap

Clutch

Transmission (Gearbox)

Chainwheel sheck absorber nut

Crankshaft centre bearing nuts

Engine

Camshaft pinion

Stanchion end plug..,

Engine mounting bolts

Rear engine plates to frame

Rear

Sump

Timing cover screws lbrlght zinc)

Timing cover screws yellow)

Rocker box socket screws

Front

Shock

ratchet

fixing

fixing nuts

diode fixing nut

nut

centre

sprocket

Bottom

Front

R.ear

damper bolts ..,

cover

frametorellr

Top

Bottom

absorber

pinion

nut

pinch bolts

...

nut

...

plate nuts

...

assembly

nut

cap

bolts

...

".

sprocket-Lock

....

..

......

.,_

.., ...

screws

...

nut

40/45 Ib.ft. 50

8 Ib.ft. 1·106 kg.m.l 25Ib.ft. 3·456 kg.m.l 23/25 2/203 25/30 Ib.ft. (3·45/4·14 kg.m.l 60

5B 75/BO 17·5/1B·5

5B/63

75

(5-53016,221

Ib.ft'la'913 kg.m.l

IbA

(3·17/3-45 kg.m.l

Ib.ft. ('277/·3174 kg.m.)

Ib.ft. (8,295 kg.m.l

'b.ft'IB'019 kg.m·l

10.

t. (10·369/11·06 kg.m.l

Ib.f~

Ib.ft.(B·00/B·69 kg.m.l

Ib.ft. (10·369 kg.m.)

(2·41/2-55 kg.m.)

kg.m.l

45/50 Ib.lt. (6·21/6·90.kg.m.l

30/35 Ib.ft. (4·14/4.B3 kg.m.l 30/35

23/25Ib.ft. 3·17/3-45 kg.m.

.,. 23/25 Ib.ft. 3·17/3-45 kg.m.

1B

Ib.ft. (2·48 kg.m.)

6 Ib.ft.

...

3·5/405 Ib.ft. (·4B/·62 kg.m.l 6·5/7-5 Ib.ft. (·B97/1-035 kg.m.l 6 Ib.ft.

23/25 Ib.ft. (3·17/3·45 kg.m'l 30/35 Ib.ft. (4·14/4-83 kg.m.

'b.ft·1

(·83

('B3

4'14

kg.m.)

/4-B3

kg.m'l

2/3 Ib.ft. ('277/·414 kg.m.'

GDB

SECTION

ClassicBike.biz

A

ROUTINE

TABLE OF

ENGINE

CHANGING

OIL

THE

REMOVING

ANTI-DRAIN

LUBRICATION

PRESSURE

OIL

PRESSURE

LUBRICATION

RECOMMENDED

SYSTEM

THE

ENGINE

...

RELEASE

AND

REPLACING

AND

REPLACING

AND

REPLACING

VALVE

LUBRICATION

LUBRICANTS

OIL

AND

CLEANING

VALVE

THE

OIL

THE

OIL

THE

ROCKER OIL

...

.'

PUMP

COOLER

THE OIL

FEED

SYSTEM

FILTERS

PIPE

Section

...

A1

... A2

...

A3

...

A4

...AS

'"

A6

...

A7

...

A8

...

A9

...

A10

CONTACT

TRANSMISSION

PRIMARY

REAR

GREASING

WHEEL

TELESCOPIC FORK

LUBRICATION

LUBRICATING

SPEEDOMETER CABLE

REAR BRAKE SPINDLE

CHANGING

BREAKER

CHAINCASE

CHAIN

THE

BEARING

THE

(GEARBOX)

LUBRICATION

STEERING

LUBRICATION

NIPPLES

THE

OILINTHE

LUBRICATION

AND

HEAD

LUBRICATION

CONTROL

LUBRICATION

CABLES

BRAKING

MAINTENANCE

RACES

SYSTEMS

...

A11

An

A13

A14

A1S

A16

A17

A18

A19

A20

A21

A22

A1

A

ClassicBike.biz

LUBRICATION

SYSTEM

Every 250 miles

Check

Every 1,0'00 miles (1,600 Kms.)

Lubricate control cables

Grease

Check

Every 3,000 miles (3,800 Kms.)

Check

Check Lubricate brake pedal spindle

Remove Lubricate contact Grease Change Renew Ciean

Every 6,000 miles (9,600 Kms.)

Change Change

(400

Kms.)

levelinoil

swinging fork pivot ...

brake pipes and brake connections

transmission oil level (Gearbox) front

rear

speedometer

engine oil and primary chalncase oil.

full

all

filters.

oilIntransmission (Gearbox) oilinfront forks

tank

forks for external

chain for cleaning and greasing.

breaker

drive unit.

flow filter.

SECTION

ROUTINE

oil

leakage

and auto-advance mechanism.

...

LUBRICATION

AI

Sec

...

A4

...

A19 A18

... A14

...

An

..•

A17

'"

A21

..,An

.., A17

lion

Every

12,000 miles (19,200 Kms.)

Grease

Grease Change

wheel bearings steering head bearings

oilinbraking systems

.., A16

A15

..,

All

A2

LUBRICATION

ClassicBike.biz

SYSTEM A

Ref.

10

Fig.

AI.

LUBRICATION

NumbersIncircles refertoright NumbersInsquares refer to left Other

numbers

No.

1

3

4

5

6

7

B

9

Engine oil

tank Primary chalncase 10/50 Transmission (gearbox)

all

filter

compartment

Wheel

bearings Stearing head bearings Exposed cables, baliloints, linkage,

carbo

Telescopic

SWinging

Speedometer

Hydraulic

etc.

fork

brake

refertocenterofmachine

Description

..

pivot

drive unit Grease

reservoirs Spec

CHART

sideofmachine

S.A.E.

Auto

329

Oil

Grode

20/50

90

E.P.

10/50

Grease

10/30

trans.

fluid

Grease

(D.O.T. 3.U.S.A.)

11 11

Rear chain 20/50 Contact

breaker

and auto-advance Thin Grease / 20/50

A3

A

ClassicBike.biz

LUBRICATION

SYSTEM

Fig. A2.

Engine

lubrication

diagram

Ccl<~ur

IndIO>:

BLUE_FEED

YELLOW-RETURN

LUBRICATION

ClassicBike.biz

SYSTEM

A

FACTORY

UNIT

Engine and Primary Chaincase

Transmission (Gearbox)... Mobllube

Telescopic

Wheel

Fork and

Speedometer

Easing Rusted Parts

The

above lubricants

".

..,

Fork

...

Bearings, SwingIng

Steerl

ng Races

DrIve

Unit.

were

RECOMMENDED

MOBIL

Mobil

...

.

..

MobJlgrease

...

recommended

011

Super

90

GX

Mobil

ATF

210

or

Mobllgrease

Super

Mobil

Handy Castrol

011

for all operating temperatures

SECTION

CASTROL

I

Castrol GTX

or

Castrol 20W/50

XL

20/50

Castrol

Hypoy

A2

LUBRICANTS

B.P.

Super

Vlsco.Static

B.P.

Gear

011

SAE90EP

Esso Gear Oil Shell

GX

Esse

Unlflo

90/140

(All

Markets)

SHELL

Shell Super Havollne

Motor

011

Spira><

90

EP

I

Castrol

T.Q.F.

MS

Castrol

Grease

Penetrating Oil

LM

B.P.

Autron

B.P.

L2

-

above--18QC

'B'

Es,o

Glide

Es,o

Multipurpose Retlnax A

Grease

Es,o

Penetrating

(O:F).

Shell Donax Texomatlc

T.7

Shell

H

all

Shell Graphlted

Easing

Oil Penetrating

TEXACO

Motor

Hultlgrear

lubricant

EP

90

'F'

Marrak

All

Purpose

all

011

AS

A

ClassicBike.biz

LUBRICATION

SYSTEM

ENGINE

The

engine lubrication systemIsof

type

utilising a duplex gear pump and

the

tank

to

by gravity from pressure

cartridge shaft whenceitescapes and lubricates

outer

parts.

crankcase

an anti-drain valve situated behind

The

shaft is controlled

After mission,

from

the

feed pump, allIsforced via a

type

filter

to

the

Inner main bearings and big ends,

main bearings, and

all

Is

prevented from draining

when

the

all

pressure

lubricating

the

between

by

the

all drains

through

engineIsstationarybymeans

a release valve.

engine and primary

through

the

drillingsInthe

other

the

pump and

a filtertothe

SECTION

the

pump.

the

cylinder walls,

Internal

the

pump.

the

LUBRICATION

dry

ollis

Under

crank-

engine

into

crank-

sump

fed

the

of

trans-

sump,

whereitIs all designed so pumping capacity than the feed gears, thus ensuring that

The

taken from a connection situated

scavenge sideofthe lubricating

rocker afterwards and Into scavenged. The timing idler pinion bearing

lubricatedbyoil draining through a drillingInthe

right

A3

SYSTEM

returnedbythe

coolertothe

the

sump remains dryatall

all feedtothe

boxesbywayofgroovesInthe

side crankcase.

all tank. The all pump has been

that

the

scavenge gears have a

valve operating mechanism

pump and

the

rocker

spindles,

draining down

the

sump, whence itIssubsequently

the

scavenge pump via

greater

times.

between

the

all cooler.

the

ollisfed

push rod

into

rocker

cover

the

Is

the

After

the arms, tubes

is

SECTION

CHANGING

The

allInneW

changed

1,500 kms) Intervals during

and

thereafterasstatedInSection A1.

It

Is

advisabletodrain

warmasIt will fiow more readily.

When

the

wire

(kerosene) and

THE

SUMP

Remove six nuts and locking washers which the

sump plate, and remove

and

wire

to

drain for approximately filter, and replace either

ensuring that the pocketed endistowards

of

the

engine.

and reconditioned engines should be

at

250, 500 and 1,000 miles (400, 800 and

oil

has

been drained ItIsessential

gauze filters

that

FILTER

gauze filter (see

sideofthe

THE

the

are

the

cartridge

Fig.

the

gaskets. A gasketIsfitted

filter. Refit

ENGINE

the

running-In 'perlod,

all when

the

A3). Allow

ten

the

washed

filterIsreplaced.

plate,

minutes. Clean

the

sump

In

two

engine

paraffin

secure

gaskets

the

sump

plate,

the

OIL

that

the

rear

A4

AND

Is

CLEANING

Fig. A3. Crankcase sump filter

THE

FILTERS

A6

THE

ClassicBike.biz

OIL

TANK

Open

the

twin

seat

and

Piace a

tray below allow approximately drain. Disconnect

unscrew

the

thoroughlyinclean

the

drain plug.

ten

the

large hexagonal headed filter. Wash

kerosene

Itisadvisable to wash oUt oil (obtainable from

most

remove

feed line union

the

remove

minutes for

(paraffin).

the

oil

tank

garages)

or,IfthisIsnot

tank

available kerosene (paraffin) will serveasa

However, if thisIsused,

removed from

the

re-filiing with oil. (For

ensure

Interior

the

of the

correct

that all

tank

gradeofoil see

Section A2).

NOTE: the of

breather

THE

This filterIsof

renewed every

is

changed.

To remove

headed cap from below

The

top

lineonthe

oil

will

FULL·FLOW

levelinthe

dipstick.

cause

excessive

pipe

duetolackofair

the

disposable

3,000

miles

the

filter,

unscrew

tank

venting

FILTER

(S,OOO

the

should

Further

space.

type

and should be

Km)

the

large hexagonally

forward

LUBRICATION

filler cap.

this and

the

oil

to

nut

and

it

with flushing

substitute

trac~s.

prior

are

to

beupto addition

through

when

the

oil

endofthe

SYSTEM

transmission the spring, and

THE

NEW

outer

cover (Item 2,

withdraw

EL~MENT

Fig.

the

element.

MUSTBEFinED

A4). Remove

WITH THE OPEN END INWARDS, OTHERWISE THE SUPPLY

A the element. Ensure

Add a small quantityofengine compartmenc before re-assembllng

Replace ring sealIsIn

to

cooler

top-up

Special Internal

add half a operate (With Issuing from

can apertureonthe side and It will be necessary spaceInthe

procedure should also be followed

cycle has

WILLBECUT OFF.

rubber

sealing ringIslocatedatthe

the

spring and cap, ensuring

good

dip-stick level, and

has

been

removed,

the

tank

afcer

Note:

parts,

the

be Inserted

To

following

pint

of engine oiltothe

starter

Ignition switched off) until allIsseen

the

return

through

frontofthe

tanktoaccommodate

not

been used for an appreciable time.

that

thisIsnot

order.

Replenish

If,

for any reason,

re~check

approximately

ensure

Immediate lubrication of

replacement

pedal

twenty

pipeInthe

the

crankcaseatthe

Inner end of

omitted.

oil

to

the

that

the

oil tank

andIfnecessary

five miles.

·of

the

crankcase and

or

thirty

tank.

spark

timing plug

to

allow sufficient

this all.

when

the

filter

filter.

the

filters,

times

The

right

motor

A

OIL

'0'

all

oil

This

)8~~'

~~.'i,

.•

@ I

f~

l~~

.

_.~,

•:J'-!tl:,,~...

':;:"i~.:11i;);.~

O\O\l!ii4:=iI1Il\

..

,

..

,."

.

,

. Fig. A4. Transmfsslon drain and filler plugs

1. Primary chaincase drain

plug

2.

Cartridge

e~

..

cap

3.

Gearbox

4.

5.

plugs

all

Neutral

all

drain and

pressure

Indicator switch

filter

switch

housing

level

A7

A

ClassicBike.biz

LUBRICATION

SYSTEM

SECTION

OIL

The

011

pressureIscontrolled

relief valve situated at

crankcase, engineiistationary

On

starting 90 Ibs., p.s.l. temporarily, reducing, when hot, to

thenormal

three

on

from cold,

thousand

the

running figureof75/90 Ibs. p.s.l.

r.p.m.

the

left side (Fig.

there

pressure

by

means

rear

of

AS).

will be no oil

maybeas high

of

the

centre

When

pressure.

the

PRESSURE

If

satisfactory readings are not obtained, check

followlng:-

(1)

That

as

at

(2)

That

mark on returnedtothe

(3)

That filter are clean and not blocked.

(4)

That that

Refer

(S)

That

the

(6)

That are too

Triumph Trident T160 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual