Académique Documents
Professionnel Documents
Culture Documents
Introduction
General Information
Scheduled Maintenance
Cylinder Head
Clutch
Crankshaft
Bevel Box and Drive Shaft
Balancer
Transmission
Lubrication
Engine Removal and Refit
Fuel System/Engine Management
Cooling
Rear Suspension
Front Suspension
>'1
Brakes
WheelslTyres
ii
Introd uction
iii
Introduction
This manual is designed primarily for use by trained
technicians in a properly equipped workshop.
However, it contains enough detail and basic
information to make it useful to the owner who desires
to perform his own basic maintenance and repair
work. The work can only be carried out if the owner
has the necessary hand and special service tools to
complete the job.
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:
iv
uCl:ICims
This warning
i
or procedures which, if not correctly followed, could
result in personal injury, or loss of life.
..
Note:
Introduction
Tampering with Noise Control
System Prohibited
References
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.
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 mile/BOO km service, and thereafter should
be maintained at the figures specified in this manual.
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.
Tightening procedure
Generally, when installing a part with several bolts,
nuts or screws, they should all be started in their
holes and tightened to a snug fit, evenly and in a
cross pattern. This is to avoid distortion of the part
and/or causing gas or oil leakage. Conversely, bolts,
nuts, or screws, should all be loosened (in sequence if
specified) by about a quarter of a turn and then
removed.
Where there is a tightening sequence specified in this
Service Manual, the bolts, nuts, or screws must be
tightened in the order and by the method indicated.
Torque wrench setting figures given in this Manual
must be observed. The torque tools used must be of
accurate calibration.
Locking devices, where specified, must be fitted. If the
efficiency of a locking device is impaired during
removal it must be renewed. This applies particularly
to micro-encapsulated fixings which must always be
replaced if disturbed. Where necessary, the text in
this manual will indicate where such a fixing is used.
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.
~-
Introduction
vi
1 General Information
Table of Contents
Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-3
Dangerous Susbstances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-3
Fluoroelastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-3
Oils............................................................................
1-3
1-3
1-4
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-4
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-5
1-5
1-5
1-5
1-6
1-6
1-6
1-6
1-6
1-6
1-7
1-7
1-7
1-7
1-7
1-7
1-7
1-7
1-7
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Petrol - Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . ..
. . . . . . . . . . . . ..
. . . . . . . . . . . . ..
..............
1-7
1-8
1-8
1-8
Electrical Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-9
1.1
General Information
Replacement Parts . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Service data ................................................................
Specification ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Service tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Special service tools:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Torque Wrench Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
1-10
1-10
1-11
1-11
1-20
1.2
1-25
1-25
1-26
1-27
1-28
1-29
1-30
1-31
1-32
1-33
General Information
Ignition System Safety Precautions
Fluoroelastomers
Dangerous Susbstances
Oils
Many liquids and other substances used in motor
vehicles are poisonous and should under no
circumstances be consumed and should, as far as
possible, be kept from contact with the skin. These
substances among others include acid, anti-freeze,
asbestos, brake fluid, fuel, lubricants, and various
Always pay close attention to the
adhesives.
instructions printed on labels and obey the
instructions contained within. These instructions
are included for your safety and well-being.
NEVER DISREGARD THESE INSTRUCTIONS!
The engine
oils may be hot to the
touch. Contact with hot oil may cause the skin to be
scalded or burned.
1.3
General Information
be aware of who your nearest first-aider is and
where the medical facilities are kept.
Brakes
Environmental Protection
Precautions
1.4
General Information
Coolant
use
grease
any part
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
not remove
cap
i
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.
a
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.
~.
1.5
General Information
Cleaning components
Always wear
air is to be
Lubrication
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
parts. Always check manufacturer recommendations
before using such special lubricants.
Screw Threads
Metric threads to ISO 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
affect the torque reading.
Unless specified, threaded fixings must always be
fitted dry (no lubrication).
Gaskets, a-rings
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.
A fixing which fails in service could cause
component detachment leading to loss of control
and an accident.
1.6
General Information
Locking Devices
Always release locking tabs and fit new locking
washers, do not re-use locking tabs.
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.
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 beari ng
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
)
1.7
General Information
Petrol - Gasoli ne
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.
Chassis repairs
m(ltolrcvclile
i
an
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.
1.8
General Information
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 - Prior to commencing any test procedure
on the motorcycle ensure that the relevant test
equipment is working correctly and any harness or
connectors are in good condition, in particular mains
leads and plugs.
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.
sur~licailly iimolantEld
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.
Disciplines
The battery contains harmful materials. Always
keep children away from the battery whether or not it
is fitted in the motorcycle.
Do not jump start the battery, touch the battery
cables together or reverse the polarity of the cables
as any of these actions may cause a spark which
would ignite battery gasses causing a risk of
personal injury.
High Voltage Circuits - Whenever disconnecting live
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.
1.9
General Information
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 'yellow!
red' wire; it would be a . red!yellow' wire if the colours
were reversed to make red the main colour.
Inspection
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.
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.
Replacement Parts
parts, accessories
and conversions fitted by an authorised Triumph
dealer. The fitment of parts, accessories and
conversions by a dealer who is not an authorised
Triumph dealer may affect the handling, stability or
other aspects of the motorcycle operation which
may result in an accident causing serious injury or
death.
1.10
Specification
Triumph are constantly seeking to improve the
specification, design and production of their
motorcycles and alterations take place accordingly.
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.
General Information
Service tools
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.
jar.
~.
gahc
1.11
General Information
T3880250 - Diagnostic tool
"',,
T3880201 - Anti-rotation jig - alternator
1.12
General Information
T3880063 - Castle wrench - 31 mm
C=::J=:::::Rllillili!rnmllP~IIIIIIIiIl[1II=:r==:J
"'9'
~'
1.13
General Information
Full Specification
Rocket III
1.14
~'
General Information
Full Specification
Rocket III
Piston/Crankshaft
Cylinder Liner Dia..................................... 101.591 -101.609 mm (std)
~.
1.15
General Information
Full Specification
Rocket III
Transmission
Final Drive Type. . . . . . . . . . . . . . . . . . . . .. . .............. Bevel geared crown wheel and pinion
Drive system .... . . . . . . . . . . . . . . . . . . .. . .............. Universal-jointed shaft with torsional damper
Final Drive Ratio. . . . . . . . . . . . . . . . . . . . .. . .............. 2.846:1
Final Drive Oil. . . . . . . . . . . . . . . . . . . . . . .. . .............. Mobilube SHC 951W 90 fully synthetic hypoid oil
(or equivalent)
Final Drive Oil Capacity. . . . . . . . . . . . . . .. . .............. 0.17 lit res
Lubrication
Oil Capacity (incl. filter, dry fill). . . . . . . . . .. . .............. 5.9 litres
Oil and filter change. . . . . . . . . . . . . . . . . .. . .............. 5.4 litres
1.16
General Information
Full Specification
Rocket III
Ignition System
Type ............................................... Digital, inductive
Electronic Rev-Limiter ................................. 6,500 rpm
Pick up Coil Air Gap .................................. Fixed, not adjustable
Pick up Coil Resistance ............................... 0.56 Kn
Ignition Coil Type ..................................... Inductive, twin output
Spark Plug Type ..................................... NGK DPR8EA9, 2 per cylinder
Spark Plug Gap ...................................... 0.9 mm
Fuel System
Fuel Type ........................................... Unleaded, 95 RON ( US - 89 RON/MaN)
Fuel Tank Capacity ................................... 25 litres
Low Level Warning Lamp .............................. 5.5 litres remaining
Fuel Pump Type ..................................... Submerged, electric
Fuel Pressure (nominal) ............................... 3.0 Bar
Purge control system ................................. Modulated, vacuum
Cooling System
Coolant Mixture ...................................... 50% anti freeze in distilled water
Anti-Freeze Type ..................................... Mobil Antifreeze
~'
1.17
General Information
Full Specification
Rocket III
............... 120 mm
Recommended Fork Oil Grade ......... . . .............. Kayaba 01 oil (SAE OW)
Oil Level (fork fully compressed) ........ . .............. . 89mm
Oil Volume (dry fill) ................... . ............... 667 cm 3 +/- 4.0 cm3
Front Fork Pull Through ............................... 0 mm (top of the outer tube flush with top yoke)
Fork spring rate . . . . . . . . . . . . . . . . . . . . .. . .............. K = 16 N/mm
Rear Wheel Travel . . . . . . . . . . . . . . . . . . .. . .............. 105 mm
Brakes
Front type. . . . . . . . . . . . . . . . . . . . . . . . . .. . .............. Two four piston callipers acting on twin discs
Caliper Piston Dia.................................... 33.96 mm/30.23 mm
Disc Dia.................... " ...................... 320 mm
Disc Thickness. . . . . . . . . . . . . . . . . . . . . .. . .............. 5.0mm standard (4.0 mm service limit)
Disc Run-out Max. . . . . . . . . . . . . . . . . . . .. . .............. 0.3 mm
Master Cylinder Diameter. . . . . . . . . . . . .. . .............. 14 mm
Recommended Fluid ......... " ...................... DOT 4
Rear Type .................. " ...................... .
Caliper Piston Dia ............ " ...................... 32 mm
Disc Dia ............................................ 316 mm
Disc Thickness. . . . . . . . . . . . . . . . . . . . . .. . .............. 7.5 mm standard (6.5 mm service limit)
Disc Run-out Max. . . . . . . . . . . . . . . . . . . .. . .............. 0.15 mm
Master Cylinder Diameter ............................. 12.7 mm
Recommended Fluid. . . . . . . . . . . . . . . . .. . .............. DOT 4
Wheels and Tyres
1.18
General Information
Full Specification
Rocket III
Frame
Frame Type ......................................... Tubular steel
Overall Length ....................................... 2480 mm
Overall Width ........................................ 880 mm
Wheelbase ......................................... 1690 mm
Seat Height ......................................... 740 mm
Castor ............................................. 32
Trail ............................................... 152 mm
Dry Weight ......................................... 320 kg
Max. Payload ........................................ 235 kg
(rider, passenger, luggage & accessories)
Electrical Equipment
Battery Rating ....................................... 12 volt, 18 amp hour
Alternator Rating ..................................... 37 amps/min at 2,000 rpm
41 amp/min at 6,000 rprn
~.
1.19
General Information
Torque Wrench Settings
Cylinder head area
Application
Torque (Nm)
10
See text
15
18
See text
See text
10
Clutch
Application
Torque (Nm)
9
105
10
Application
Connecting rod big end bolts
See text
See text
See text
See text
45
Engine Covers
Application
Torque (Nm)
28 (M8)
9 (M6)
18
1.20
General Information
Transmission
Application
Torque (Nm)
12
12
23
9
27
12
145
Lubrication System
Torque (Nm)
Application
12
25
12
Sump to crankcase
Sump plugs (front and rear)
Oil pick up strainers to sump
25
15
10
12
15
Cooling System
Application
Torque (Nm)
10
Radiator to frame
4
2
10
~.
1.21
General Information
Fuel System, Exhaust System and Airbox
Application
Torque (Nm)
9
9
5
2
12
19
22
27
27
10
3
9
Rear Suspension
Torque (Nm)
Application
Swinging arm pivot bolt - fixed (left hand)
Swinging arm pivot bolt - adjustable (right hand)
Swing arm pivot bolt lock ring (right hand)
Rear suspension unit upper mounting bolt
Rear suspension unit lower mounting bolt
100
15
100
28
28
Front Suspension
Torque (Nm)
Application
20
22
30
65
45
35
26
3
Wheels
Application
Torque (Nm)
1.22
65
22
110
General Information
Front Brakes
Torque (Nm)
Application
Disc to wheel
40
18
5
25
15
25
22
Calliper to fork
Pad retaining pin (hexagon drive)
Calliper bleed screw
Hose to calliper
Master cylinder to handlebar
Hose to master cylinder
Rear Brakes
Torque (Nm)
Application
8
25
27
7
25
15
30
22
Application
27
27
40
20
25
10
1.23
General Information
Bodywork
Application
Torque (Nm)
See text
27
See text
Electrical
Application
Torque (Nm)
28
120
12
Indicators to brackets
2
15
20
1.24
General Information
Routings
Clutch Cable Routing
ccjy
~'
1.25
General Information
Handlebar Cable Routing
1.26
General Information
Main Wiring Harness Routing
1.27
General Information
Rear Mudguard Harness Routing
1.28
General Information
Front Brake Hose Routing
1.29
General Information
Rear Brake Pipe and Hose Routing
1.30
General Information
Throttle Cable Routing
~.
1.31
General Information
Fuel Hose and Fuel Tank Breather Hose Routing (non-evaporative emission control versions)
1.32
General Information
Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing
~.
1.33
General Information
1.34
2 Scheduled Maintenance
Table of Contents
Introduction ............................................... '. . . . . . . . . . . . . . . . . . . . . ..
2-2
2-3
2.1
Scheduled Maintenance
Introduction
To maintain the motorcycle in a safe and reliable
condition, the maintenance and adjustments outlined
in this section must be carried out as specified in the
schedule of daily checks, and also in line with the
scheduled maintenance chart.
Weather, terrain and geographical location affects
maintenance. The maintenance schedule should be
adjusted to match the particular environment in which
the vehicle is used and the demands of the individual
owner. For advice on adjusting the service schedule,
consult your authorised Triumph dealer.
2.2
Motorcycles
cannot
accept
any
Triumph
responsibility for damage or injury resulting from
incorrect maintenance or improper adjustment
carried out by the owner.
Since incorrect or neglected maintenance can lead
to a dangerous riding condition, always have an
authorised Triumph dealer carry out the scheduled
maintenance of this motorcycle.
~.
Scheduled Maintenance
2.4
Scheduled Maintenance
Scheduled Maintenance Chart
Odometer Reading in Miles (Kms) or time period,
whichever comes first.
Operation Description
Every
500
(800)
1 month
Engine - check for leaks
Day
10,000
(16000)
1 year
20,000
(32000)
30,000
(48000)
40,000
(64000)
50,000
(80000)
60,000
(96000)
2 years
3 years
4 years
5 years
6 years
Day
Coolant - renew
Fuel system - check for leaks
Day
Day
Day
Day
Day
Day
Every 2 years
Day
Day
Day
Day
Day
Day
2,3
3-2
3-3
3-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-5
Cam Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation .................................................................
3-5
3-6
3-6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation .................................................. . . . . . . . . . . . . . ..
3-6
3-7
3-7
Camshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-9
Camshaft identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Cam sprocket orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation ................................................................
3-10
3-10
3-11
3-12
Valve Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14
3-14
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15
Inspection. .. .. . . .. . . . . . .. . . .. .. .. . . . . . . . .. .. . . .. .. . .. . . . .. .. . .. . . . . . . . . ...
Installation. . .. .. .. . . . . . .. . . .. .. .. .. .. .. . . . . . .. .. . . . .. ... .. .. . .. . . . . . .. . ...
3-16
3-16
3-17
3-17
3-17
Cam Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-18
3-18
~.
3.1
Cylinder Head
Exploded View - Cam Cover
r
'"
3.2
10Nm
Cylinder Head
Exploded View - Camshaft and Cam Drive
'(f(J~
18Nm
r2~
~.
(j
27 Nm
/
~
3.3
Cylinder Head
Exploded View - Cylinder Head
SEE TEXT
SEE TEXT
SEE TEXT
t~
10Nm
I)
i .r
10Nm
SNm
@~
10Nm
3.4
Cylinder Head
7.
Description
1. Cam cover
2. Cam cover bolls
3. Boll seals
8. Remove all the bolts and bolt-seals from the cam
cover.
9. Raise the cover and manoeuvre it towards the
right hand side of the engine, where it can be
removed.
Cam Cover
to remove
cam cover from the
cylinder head. Using a lever will cause damage to
the cylinder head and cam cover, which could lead
to an oil leak.
10. Collect the seal from the head.
Removal
1.
2.
3.
4.
5.
6.
3.5
Cylinder Head
Installation
1.
2.
Before
work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
Removal
1.
2.
1. 'D' sections
3.
4.
5.
6.
7.
8.
9.
",'"
1. Inspection plug
3.
1
CbpS
1. Camshafts
2. Lobes
3. Valves
4.
3.6
~.
Cylinder Head
Installation
cam
i
spring tension. Always wear hand, eye and facial
protection when releasing the centre nut as
unprotected areas of the body can be injured if the
spring tension released in an unexpected or
uncontrolled way.
5.
1.
2.
1. Tensloner
2. Tensioner plunger
3. Pawl
3. Look into the inspection hole.
Rotate the
crankshaft clockwise (as viewed from the front),
until No. 1 cylinder is at TOG. No. 1 cylinder is at
TOG when a 'dot' mark on the crank gear is in
alignment with the line in the upper crankcase.
Inspection
1.
2.
~.
3.7
Cylinder Head
In addition, timing marks on the camshaft
sprockets should point downwards at a point
level with the cylinder head. If they do not align
as shown, turn the camshafts until they do align.
7.
cbpy
1. Tensioner
8. Fit a new washer to the tensioner's centre nut.
9. Fit the spring to the tensioner body. Fit the
centre nut and tighten to 23 Nm.
cam
spring tension. Always wear hand, eye and facial
protection when releasing the centre nut as
unprotected areas of the body can be injured if the
spring tension released in an unexpected or
uncontrolled way.
10. Remove tool T3880202 and turn the crankshaft
clockwise (as viewed from the front of the
engine) through four complete revolutions. Stop
when the timing marks on the crankshaft gear
realign with the line in the upper crankcase.
rop'
1. Tool T3880202
2. Cam sprocket holes
5. Fit the tensioner to the crankcase (ratchet teeth
facing upwards) ensuring the gasket is not
damaged during the process.
6. Fit and tighten the tensioner fixings to 9 Nm.
3.8
as
Cylinder Head
12. When the timing checks have been satisfactorily
completed, refit the inspection plug tightening it
to 18 Nm.
13. Refit the cam cover (see page 3.6).
3.
Camshafts
1.
Note:
1. Top pad
always ensure
as many cam lobes as possible are facing away
from the valves. This will reduce stress on the cam
ladder during removal. Damage to the cam ladder
will result in replacement of the complete head.
4.
","
1. Camshafts
2. Lobes
3. Valves
2.
~.
1. Cam ladder
2. Cam ladder fixings (2 of 16)
3.9
Cylinder Head
Camshaft identification
6.
Note:
7.
,bqb
1. Removing a camshaft
8.
1. Sprocket
2. IN marking
3. EX marking
3.10
Cylinder Head
g) Finger-tighten the cam ladder bolts until the
under-head areas are in contact with the cam
ladder.
h) In the sequence shown below evenly and
progressively tighten the cam ladder bolts,
approximately half a turn each, until the cam
ladder is in full contact with the head.
11
Inspection
1.
2.
3.
4.
"'"
5.
3.11
Cylinder Head
6.
Standard
0.040 - 0.091 mm
Service limit
0.13 mm
7.
I Standard
I 22,93 - 22.96 mm
8.
6.
Installation
1.
2.
3.
Located camshafts
Lubricate the cam bearing areas of the cam
ladder with a 50/50 solution of engine oil and
molybdenum disulphide grease.
obqh
1. Cam ladder
2. Cam bearing areas
7.
8.
9.
4.
5.
3.12
Cylinder Head
10. In the sequence shown below evenly and
progressively tighten the cam ladder bolts,
approximately half a turn each, until the cam
ladder is in full contact with the head.
11
713
14. Ease the cam chain away from the sprockets and
position the cams so that the timing marks align
as shown below. Allow the cam chain to drop
back onto each sprocket after positioning each
cam.
15
rop'
~.
1. TooIT3880202
2. Cam sprocket holes
16. Refit and assemble the cam chain tensioner
plunger, spring and centre nut (see page 3.7).
17. Remove tool T3880202.
18. Turn the engine over at least four times, then
check the cam timing again. Reset as necessary
19. Check all valve clearances (see page 3.14).
Adjust as necessary to give the correct
clearances.
20. Refit the cam cover (see page 3.6).
3.13
Cylinder Head
Valve Clearances
Note:
1.
2.
3.
4.
Inlet
0.10 to 0.15 mm
Exhaust
0.15 to 0.20 mm
5.
Note:
1.
2.
3.
4.
5.
be
Note:
3.14
Cylinder Head
9.
Cylinder Head
Before starting
ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
3.
4.
5.
6.
7.
1. Top hose
2. Bypass hose
8. Disconnect the coolant temperature sensor and
low oil pressure switch connections.
===o:=~\\
-;&f,
In-fill panel
10. Identify the position of each of the tappet buckets
and shims before removing them from the head.
11. Remove the sound suppression bolt from the
cam chain chest.
12. Progressively release the cylinder head bolts in
the order shown below.
"'"
~.
3.15
Cylinder Head
Installation
Inspection
Thoroughly clean the surface of the cylinder
head and check for damage and/or pitting of the
combustion chambers.
Using a straight edge and feeler gauges, check
the cylinder head gasket face for warp, which
could lead to gasket failure. Replace the cylinder
head if warped beyond the flatness limit.
1.
2.
1.
2.
3.
4.
of the
liner to
position
position
,"""
1. Dowels
0.030 mm
3.16
5.
6.
Cylinder Head
7.
2.
"""
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
collets
valve spring
Installation
1.
2.
3.
Note:
4.
5.
In".nm."t fitment
lead to high oil consumption and blue smoke
emissions from the exhaust system. Do not use
excessive force in fitting the seal as this may break
the seal ring.
6.
~.
3.17
Cylinder Head
7.
8.
Cam Chain
Inspection
An in-situ check can be made as follows:
1.
2.
3.
4.
""1'
3.18
1.
2.
3.
Cylinder Head
6.
234
4.
5.
~.
3.19
Cylinder Head
3.20
4 Clutch
Table of Contents
Exploded View - Clutch Controls .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4.2
4.3
4.4
Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation .................................................................
4.5
4.6
4.6
Clutch Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4.7
4.7
4.7
Clutch. . ... .. . . .. .... . . . ... .. .. ... .. .. .... . . . .. ... .. .. .. .. .. . .. ... .. .... ... .. ...
4.7
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
4.7
4.9
Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9
4.9
~.
4.1
Clutch
Exploded View - Clutch Controls
15NmZ::
e~~
3Nm
3Nm
~
~_--\O
"
4.2
3Nm
Clutch
Exploded View - Clutch
.~
10Nm
4.3
Clutch
Exploded View - Clutch Cover
00
9Nm
4.4
Clutch
4.
Clutch Cable
Removal
5.
1. Clutch Cable
2. Adjuster
1. Locknut
2. Lever adjuster
4.5
Clutch
6.
Installation
1.
2.
3.
Note:
4.
5.
6.
1. Nut/locknut Slots
2. Cable Release Point
7.
7.
Note:
Examination
1.
2.
3.
1. Clutch Lever
2. Correct Setting, 2-3 mm
8.
g.
4.6
Clutch
Clutch Cover
Clutch
Removal
Removal
1.
2.
3.
4.
5.
6.
7.
2.
Installation
Thoroughly clean the cover and crankcase
mating faces.
Position a new gasket to the crankcase.
Refit the cover ensuring that the gasket does not
become dislodged.
1.
2.
3.
3.
Note:
4.
5.
6.
7.
1
1. Lifter piece
2. Needle bearing
3. Thrust washer
4.7
Clutch
4.
4 __
6.
7.
"',,"
1. Friction Plates
2. Steel Plate
3. Anti-judder Seat Washer
4. Anti-judder Spring
Note:
5.
1. Centre Nut
2. Belleville washer
3. Plain washer
4. Inner Drum
5. Thrust Washer
8. Slide the clutch outer drum outwards from the
engine, collecting the bearing sleeve on removal
of the drum.
1. Outer drum
2. Bearing sleeve
4.8
Clutch
Friction Plate Inspection
Thickness
1.
1. Friction Plate
2. Feeler Gauge
3. Surface Plate
'""
1. Clutch friction Plate
Assembly
3.72 - 3.88 mm
Service limit
3.5mm
2.
I 0.30 mm
1.
2.
~.
4.9
Clutch
3.
(
2
7.
1. Primary gear
2. Backlash eliminator
3. Crank gear
4. Arrowed; alignment hole
Note:
4.
1.3880025-T0301
8.
Note:
1. Thrust washer
5.
6.
4.10
Clutch
11. Refit the clutch pull rod.
Note:
4.11
Clutch
4.12
5 Crankshaft
Table of Contents
Exploded View - Crankshaft, Connecting Rod and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-2
5-3
5-4
Crankcases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-5
5-5
5-7
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
5-9
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation .................................................. . . . . . . . . . . . . . ..
5-9
5-9
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10
5-10
5-10
5-11
5-12
5-13
5-13
5-13
5-14
5-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Piston Wear Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Rings/Ring Grooves. . . .. . .. . .. .. . . ... .. .. .. .... ... ... .. . . .. ... .. .. . .. ..
Piston Ring Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Cylinder Wear. ...................... ...... ................... ..............
5-15
5-15
5-16
5-16
5-16
5-18
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation ................................................................
5-18
5-19
~.
5.1
Crankshaft
Exploded View - Crankshaft, Connecting Rod and Piston
i!>
c::
c::
:>
:>
LL
~~~
""
5.2
SEE TEXT
Crankshaft
Exploded View - Crankcase Fixings
~.
5.3
Crankshaft
Exploded View - Crankcase and Liners
~"Nm
Co
fj
!X:gj
5.4
Crankshaft
Crankcases
upper
crankcases are
as a
matched set and must never be assembled to nonmatching halves. Doing so will cause seizure of the
engine.
1. all pipes
2. Remove the non-return valve from the scavenge
oil pump, by gently pulling it outwards from its
location.
Note:
Removal
1.
2.
3.
4.
5.
6.
7.
8.
1. Non-return valve
3. In the sequence shown below, release the bolts
securing the main bearing ladder to the
crankcases.
Disassembly
1.
~.
5.5
Crankshaft
4.
6.
5.
Note:
7.
1. Dowel locations
8.
5.6
Crankshaft
Assembly
1.
2.
1. Dowels
3.
Apply a thin bead of silicone sealant to the lower
crankcase mating faces (at the factory, Three
Bond 1207B is used).
Sealer areas
""P
1. Main bearing ladder
2. Baffle
3. Baffle lugs
5.
Note:
5.7
Crankshaft
Stage 3
5.8
Crankshaft
Installation
Crankshaft
Removal
1.
2.
10.2).
3.
2.
3.
4.
""
4.
5.
5.
6.
7.
8.
~.
5.9
Crankshaft
Connecting Rods
Installation
Note:
Removal
Note:
The connecting rods and cap are etchmarked on one side to identify their
correct orientation. However, the cylinder
from which they are individually removed
should also be identified, using a laundry
marker or similar.
1.
1.
2.
3.
4.
10.2).
2.
3.
4.
5.
6.
7.
cbye
5.
6.
7.
8.
9.
5.10
1. Liner
2. Sealer Area
Crankshaft
8.
9.
1. Piston
2. Arrow
,,,"
1. Crankpin
2. Big End
AI\va~'s renew
are
torqued near to their yield point when first installed
and are severely weakened if reused. Re-using the
original bolts may cause bolt breakage resulting in
engine damage, loss of motorcycle control and an
accident.
5.11
Crankshaft
Connecting Rod Big End Bearing
Selection/Crankpin Wear Check
1.
3.
4.
5.
6.
7.
Crankpin diameter
Note:
2.
Note:
Standard
40.946 - 40.960 mm
Service limit
40.922 mm
Note:
0.065 - 0.035 mm
Service Limit
0.100 mm
5.12
Crankshaft
Connecting Rod Bearing Selection
Note:
White
Red
Crankpin
diameter
40.960 to
40.954
40.953 to
40.946
For Instance:
Crankpin diameter
40.958
Required Bearing
White
0.018 - 0.041 mm
Service limit
0.100mm
2.
Note:
Repeat the
measurements
for
all
connecting rods and their respective
crankpins. It is normal for the bearings
selected to differ from one connecting rod
to another.
43.092 - 43.108 mm
Service limit
43.068 mm
Note:
2.
Note:
5.13
Crankshaft
Compare the data found with the chart above to select bearings individually by journal.
Shell
Colour
White
Red
Red
Blue
Blue
Green
Crankcase
bore
diameter
46.105 to
46.097
46.105 to
46.097
46.114 to
46.106
46.114 to
46.106
46.123 to
46.115
46.123 to
46.115
Crankshaft
journal
diameter
43.108 to
43.100
43.099 to
43.092
43.108to
43.100
43.099 to
43.092
43.108to
43.100
43.099 to
43.092
For example:
Crankcase Bore
46.099 mm
43.095 mm
Bearing Required
BLUE
Standard
0.05 - 0.20 mm
Service limit
0.40 mm
Note:
Note:
rm,
i
the running clearance is correct before final
assembly. Severe engine damage could result from
incorrect clearance resulting in loss of motorcycle
control and an accident.
5.14
Crankshaft
Note:
Pistons
Disassembly
1.
1.
Note:
2.
101.561 - 101.577 mm
101.511 mm
3.
Note:
4.
5.
5.15
Crankshaft
Piston Rings/Ring Grooves
1.
2.
3.
",,,
3.
Top - standard
0.20 - 0.35 mm
0.55 mm
Second - standard
0.30 - 0.50 mm
0.675 mm
0.20 - 0.70 mm
Top - standard
0.02 - 0.06 mm
0.16 mm
0.875 mm
0.02 - 0.06 mm
0.16 mm
4.
1.
2.
service
Piston Assembly
1.
Note:
5.16
Crankshaft
7.
...
FRONT
3=
2.
3.
1. Top Ring
2. Second Ring
3. Steel Oil Control Rings
8. Oil Control Ring Expander
Note:
9.
1. Piston
2. Direction arrow
4.
5.
6.
5.17
Crankshaft
Cylinder Wear
1.
Cylinder Liners
Service limit
101.659 mm
Removal
1.
2.
3.
///////////
---
--
---+-
3
~1L//L~
Cbxz
gaep
2.
1. Tool T3880061
2. Locking nut
3. Extraction nut
5.18
Crankshaft
4.
Installation
1.
2.
3.
1. Cylinder liner
2. Studs
3. Head-bolt holes
5. Fully engage the bolt threads in the head bolt
holes. It is not necessary to fully tighten the
bolts.
6. Turn the locking nut clockwise until the rubber
sleeve on the tool tightly grips the bore of the
liner.
7. Turn the extraction nut clockwise sufficient to
raise the liner and break the seal between the
liner and crankcase.
Note:
S.
9.
1. Liner
2. Sealer Area
4. Apply a thin bead of silicone sealer to the liner to
crankcase mating face.
1ri-----L
1. Liner
2. Sealer area
5.19
Crankshaft
5.
Note:
Note:
5.20
6.2
6.3
6.3
6.3
6.4
Bevel Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
6.4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation .................................................................
6.4
6.4
Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
6.5
6.1
6.2
Before
work, ensure
is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the
I
1.
1. Bevel box
2. Flllerlievel plug
2. Have an assistant stand the bike upright.
~.
3.
4.
6.3
Removal
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
starting
ensure
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
3.
4.
5.
)
1. Bevel box
2. Drain plug
2. Remove the drain plug and allow the oil to fully
drain out.
3.
Installation
Note:
Note:
4.
5.
6.
7.
2.
6.4
Note:
Note:
4.
5.
6.
7.
Drive shaft
Drive shaft details can be found in the rear
suspension section on page 13.5.
6.5
6.6
7 Balancer
Table of Contents
Exploded View - Balancer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
7-2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3
Removal ........................................ , .. .. . . .. . . . . . . . . . . . . . . .. ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
7-3
7-4
7-4
~.
7.1
Balancer
Exploded View - Balancer
7.2
Balancer
Introduction
In an engine with an even number of cylinders (i.e. 2,
4, 6 etc.), a piston on an upward stroke is always
counter-balanced by one on a descending stroke.
However, in an engine with an odd number of
cylinders, such as that fitted to the Rocket III, this
natural state of balance does not occur. Therefore a
balancer is fitted to the engine in order to control
irregular pulses caused by the odd number of
cylinders. Without a balancer, the engine would 'pulse'
each time the crankshaft rotated. This 'pulsing' would
be felt as a vibration which would amplify as engine
speed increases.
The balancer has the effect of a pair of
counterbalance weights, which create an equal
amount of energy in the opposite direction, and at the
same time as that produced by the crankshaft, pistons
and connecting rods. Because the opposing pulses
occur at the same point of crankshaft rotation, and are
of an equal magnitude, a state of equilibrium or
balance is reached.
1. Balancer
2. Crankshaft
4.
Removal
ensure
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
3.
1. Balancer
2. Bearing
Nole:
7.3
Balancer
Note:
Inspection
1.
2.
Assemblyllnstallation
2~ ....~=::::::~
Note:
Note:
1. Balancer shaft
2. Slot marks
1.
---'~
cbrh
7.4
.-~
Balancer
2.
3.
1......;...?t1
2
ro,
ro'
1. Bearing dowels
2. Upper crankcase slots
1. Circlips
2. Grooves
4. Check that the balancer and crank dot marks are
still in alignment.
5. Assemble the crankcase halves as described on
page 5.7.
6. Refit the engine to the frame as described on
page 10.5.
~.
7.5
Balancer
7.6
8 Transmission
Table of Contents
Exploded View Input and Output Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
82
83
84
85
86
87
87
89
89
811
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation ................................................................
811
812
812
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation ...................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
812
813
Output Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
814
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
815
815
816
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
818
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
819
820
820
8.1
Transmission
Exploded View - Input and Output Shafts
@.
000~
'~~Qb
8.2
Transmission
Exploded View - Gear Change Mechanism
12Nm
~.
8.3
Transmission
Exploded View - Gear Selector Mechanism
27Nm
9Nm
,~
\
\,'\
9Nm
cclg
8.4
Transmission
Exploded View - Torsional Damper Shaft Housing
28Nm
L~
28Nm
,,@
ti
9Nm
Ta&!!!rB'
8.5
Transmission
Exploded View - Torsional Damper Shaft
8.6
Transmission
Selector Shaft, Selector Forks and
Drum
6.
Removal
Note:
1.
2.
3.
4.
8.
1. Selector shaft
'c' clip
5. Insert an M6 bolt, hand tight only, into the thread
at the front end of the selector shaft.
2.
8.7
Transmission
9.
cbyj
1. Selector drum
2. Detent wheel
1. Actuator shaft
Note:
8.8
Transmission
5.
Inspection
Inspect all springs for over-extension (Le.
abnormal gaps between coils). Replace as
necessary.
Inspect all seals for damage and distortion.
Renew as necessary.
Check the selector forks and selector grooves for
Renew
wear beyond the service limits.
components as necessary.
1.
2.
3.
Item
Standard
Selector fork
thickness
5.90
mm
6.00
5.80 mm
Selector
groove width
6.05
mm
6.15
6.30 mm
Fork to groove
clearance
0.05
mm
0.25
0.50 mm
Service Limit
1. Detent wheel
2. Selector Drum
3. Pin
4. Recess
Installation
1.
2.
6.
7.
1. Inner bearing
2. Selector drum
3.
4.
1. Detent arm
2. Spring eye
3. Shaft
8.
9.
8.9
Transmission
10. Feed the gear change shaft through the
crankcase, engaging it in the actuator arm and
also attaching the free end of the detent arm
spring over the spring abutment bolt. Ensure that
the gear change return spring also engages over
the spring abutment bolt.
The
13. Place the transmission in neutral.
transmission is in neutral when the wheel of the
detent arm rests in a tooth on the detent wheel
that has a V-shaped cut-out.
==
1
cbyu
Note:
1. Selector forks
2. Selector drum
3. Selector shaft
16. Feed the selector shaft through the selector forks
and secure it with a new 'C' clip.
17. Assemble the crankcases as described on page
5.7.
18. Refit the engine as described on page 10.5.
8.10
~.
Transmission
Torsional Damper Shaft
5.
6.
Removal
1.
2.
3.
4.
8.11
Transmission
Input and Output Shaft Assemblies
Installation
1.
Note:
Note:
2.
3.
4.
5.
6.
Removal
Note:
1.
2.
Note:
3.
4.
Note:
8.12
Transmission
5.
4.
5.
1. Torx fixings
2. Notches
3. Stake marks
6. Refit the selectors and shaft as described on
page 8.9.
7. Refit the output shaft to the crankcase ensuring
the snap-ring on the outside of the inner bearing
locates in their corresponding groove in the
crankcase.
1. M6 bolts
2. Bearing housing
7. With the bearing housing released, withdraw the
input shaft through the aperture for the bearing
housing.
Installation
1.
2.
3.
8.
~.
9.
8.13
Transmission
Output Shaft
24
25
26
19
18
14
"",
1
1. Ball bearing
2. Thrust washer
3. First gear
4. Needle roller bearing
5. Thrust washer
6. Fifth gear
7. Circlip
8. Thrust washer
9. Fourth gear
10. Third gear
11. Splined bush
12. Thrust washer
13. Circlip
8.14
Transmission
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to the
hand, arms or other parts of the anatomy.
Disassembly
Note:
1.
2.
3.
4.
5.
6.
7.
8.
9.
2
3
1. Press
2. Output shaft
3. Centre bearing
15. Press the shaft through the bearing.
Inspection
1.
i
wear overalls, eye
and hand
Objects such as bearings
frequently break-up under load and the debris
caused during break-up may cause damage and
injury to unprotected parts of the body.
~.
8.15
Transmission
Assembly
Note:
Note:
1
The circlips used on the output shaft have
a flat side and an angled side. Illustrations
throughout the assembly text indicate
which orientation of each circlip is correct.
1. Output shaft
2. Bearing
3. Circlip groove
4. Press bars
2. Locate the output shaft (19) to the bearing, with
the threaded end pointing through the bearing
(I.e. away from the press).
3. Press the output shaft through the bearing until
the shoulder in the centre of the shaft contacts
the bearing face.
ove,raliis. eye
and hand protection. Objects such as bearings
frequently breakup under load and the debris
caused during break-up may cause damage and
injury to unprotected parts of the body.
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to the
hand, arms or other parts of the anatomy.
4.
1.
5.
6.
8.16
Transmission
7.
8.
ttbh
1. Second gear
2. Circlip
9. Fit the splined dog ring (14) to the shaft.
10. Retain the dog ring with a new circlip (13),
orientating the circlip as shown below.
13. Fit the thrust washer (8), then a new circlip (7),
orientating the circlip as shown below.
1. Third/fourth gear
2. Clrclip
14. Fit fifth gear (6) to the shaft, followed by the
thrust washer (5).
15. To complete assembly of the output shaft, fit the
needle roller bearing (4), first gear (3), thrust
washer (2) and bearing (1).
1. Dog ring
2. Clrclip
11. Fit the thrust washer (12) and splined bush (11).
12. Slide third and fourth gears (10 and 9) onto the
splined bush.
~.
8.17
Transmission
Input Shaft
15
14
1. Torx screws
2. Bearing retainer plate
3. Ball bearing
4. Retaining ring
5. Input shaft
6. Thrust washer
7. Belleville washers
8.18
8. Fifth gear
9. Fifth gear bush
10. Thrust washer
11. Circlip
12. Thirdlfourth gear
13. Circllp
14. Second gear
15. Circlip
Transmission
9.
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
Note:
1. Press bars
2. Bearing/housing
When
i the bearing out
never
support the housing on its peripheral lugs, as they
will break under the loads imparted by the press.
Always support the housing on its outer
circumference ensuring the maximum arc of that
circumference is supported.
""m
Pressing out the bearing
Ttqea.
8.19
Transmission
Inspection
1.
2.
.'.
'.
...... ..
.'
2.
Assembly
Note:
Note:
3.
oVE,rallls, eye
and hand protection. Objects such as bearings
frequently break-up under load and the debris
caused during breakup may cause damage and
injury to unprotected parts of the body.
Never wear loose clothing, which could become
trapped in the press and cause crushing injury to the
hand, arms or other parts of the anatomy.
4.
8.20
1. Shaft
2. Bearing/housing
3. Press bars
5. Working now on the opposite end to the bearing,
slide on the thrust washer (6).
Transmission
6.
7.
1. Third/fourth gear
1. Thrust washer
2. Belleville washers
3. Bush
8.
9.
Fit fifth gear (8) and the fifth gear thrust washer
(10).
Retain the assembly with a new circlip (11).
orientating the circlip as shown below.
2. Circlip
12. Slide on second gear (14).
13. Retain second gear with a new circlip (13).
orientating the circlip as shown below.
1. Second gear
2. Circllp
1. Fifth gear
2. Fifth gear thrust washer
3. Circllp
10. Fit the third/fourth gear (12) to the shaft.
~.
8.21
Transmission
8.22
9 Lubrication
Table of Contents
Exploded View - Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
9-2
9-3
9-4
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Scavenge System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
9-4
9-4
9-4
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
9-6
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Triumph Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Inspection ........................................... . . . . . . . . . . . . . . .
Oil and Oil Filter Change. .. .. . . .. . .. .. .. .. . . . . . .. .. . . . .. . . .. . .. . .. .. .. .. . .. ...
Disposal of Used Engine Oil and Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6
9-6
9-6
9-7
9-8
9-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Installation .................................................. . . . . . . . . . . . . .. 9-10
Sump. . . .. .. . . .. . . .. ... .. . ... .. .. . .. .. .. . . . .. . . .. ... .. .. .. . ... .. . . . . . .. ... .. ..
9-10
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation ............................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-10
9-10
9-11
Oil Pumps. .. . . .. .. . . .. . .. .. .. .. . . .. . .. .. .. . . . . .. . . . . . . .. .. . .. . . . . . . .. .. . .. . . .. .
9-11
~~~ ..................................................................
Inspection. . . . .. . . .. .. . . . .. .. .. . .. . . .. . . .. ... .. .. ... ... .. .. . . . ... ... .. .. ...
Installation .................................... '" . .. .. .. ... . .. .. . .. .. . . ...
Oil Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Relief Valve ......................... '" .. . . . .. ... . .. ... .. .. . . ...
9-13
9-14
9-15
9-15
9-16
Removal ................................................................. ,
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation ................................................................
Oil Transfer Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
9-16
9-16
9-16
9-16
~.
~11
9.1
Lubrication
Exploded View-Sump
..
..
i
12Nm
~
q
..
..
sb6J~~___. ..o:::::::::::~Q')
jffo@
25Nm
@f({t)
22 Nm
12Nm
}~
12 Nm
9.2
25 Nm
'\
25Nm
Lubrication
Exploded View - Oil tank, filter and pumps
28Nm
/~
13 Nm
~~\
12Nm
9Nm
~.
9.3
Lubrication
Oil Circuit
General Description
The Rocket III utilises a dry sump lubrication system
whereby a pressure pump takes oil from an oil tank
and delivers oil under pressure to the engine and
transmission. A scavenge pump collects oil from the
sump and returns it to the oil tank.
The oil tank is attached to the upper crankcase on the
left hand side of the motorcycle. Situated within the
lower crankcase, the pressure pump is gravity fed
from the oil tank via an internal drilling. An oil tank
drain plug is situated at the lowest point in the drilling,
in the sump itself.
Scavenge System
Pickups from the double-ended scavenge pump
collect oil from the front and rear of the sump and
return it to the oil tank. Further drain plugs are fitted to
the front and rear of the sump to drain residual oil
from the sump.
Pressure System
9.4
Lubrication
PRESSURE SYSTEM
SCAVENGE SYSTEM
~'
9.5
Lubrication
Oil Level Inspection
Engine Oil
Specification
Use a semi or fully synthetic 10W/40 or 15W/50
motorcycle engine oil which meets specification API
SH (or higher) and JASO MA, such as Mobil 1 Racing
4T (fully synthetic) or Mobil Extra 4T (semi synthetic).
""
1. Oil tank
2. Oil tank cap
3. Dipstick
4. Maximum mark
5. Minimum mark
2.
Note:
3.
9.6
~.
Lubrication
4.
5.
6.
2.
Prcllol1aEld or
can
lead to skin dryness, irritation and dermatitis. In
addition, used engine oil contains harmful
contamination that can lead to skin cancer. Always
wear suitable protective clothing and avoid skin
contact with used oil.
Allow the engine to idle briefly, then stop the engine
and secure the motorcycle in an upright position.
1.
3.
4.
may
with hot oil may cause the skin to be scalded or
burned.
7.
9.7
Lubrication
8.
1. Oil filter
2. Oil filter cover
9.
)
Disposal of Used Engine Oil and Oil Filters
To protect the environment, do not pour oil on the
ground, down sewers or drains, or into watercourses.
Db not place used oil filters in with general waste. If in
doubt contact your local authority.
1. Tool T3880312
9.8
Lubrication
Low Oil Pressure Warning Light
Switch
6.
Note:
7.
not pour
oil on the ground, down sewers
or drains, or into watercourses. To prevent pollution
of watercourses etc., dispose of used oil sensibly. If
in doubt contact your local authority.
Removal
1.
2.
3.
4.
5.
Note:
8.
11.104.
9.
~.
9.9
Lubrication
Installation
1.
Sump
Removal
1.
2.
engine I can
lead to skin dryness, irritation and dermatitis.
Furthermore, used engine oil contains potentially
harmfu I contaminants that can cause cancer. When
handling used engine oil, always wear protective
clothing and avoid any skin contact with the oil.
1. Low oil pressure warning light switch
2.
3.
4.
5.
6.
7.
8.
4.
Inspection
If the oil pick-ups are removed, always use new pickup bolts during reassembly. Use of the original bolts
may lead to pick-up detachment leading to severe
engine damage.
9.10
Lubrication
1.
Oil Pumps
Note:
"""
1. Oil pick-ups
Installation
1.
2.
3.
4.
5.
Do not pour
on
or drains, or into watercourses. To prevent pollution
of watercourses etc., dispose of used oil sensibly. If
in doubt contact your local authority.
Removal
Note:
Note:
1.
2.
9.11
Lubrication
3.
6.
1. Mesh filter
1. Drive sprocket shaft
2. Locknut
7.
4.
8.
5.
P',""":P)~~ab'~~
I~~~
G
)
~@~
9.12
~,1
Lubrication
9.
1.
"'"
1. Scavenge pump
2.
Inspection
Standard
Service limit
0.15 mm
0.30 mm
0.15
mm
0.22
0.35 mm
0.02 mm
0.07
0.10 mm
~.
9.13
Lubrication
Installation
4.
Fill the oil pumps with new engine oil, turning the
pump rotors as the oil is poured into the pump.
Position the scavenge pump to the crankcase
and engage it to the mounting dowels. Ensure
the drive blade is facing towards the front of the
engine.
2.
5.
1. Mounting dowels
3.
1. Mesh filter
6.
7.
9.14
Lubrication
8.
1. Pump sprocket
2. Drive sprocket
3. Chain
4. "OUT" mark
9.
~.
9.15
Lubrication
Oil Tank
Installation
1.
2.
3.
Removal
1.
2.
3.
4.
5.
6.
7.
8.
4.
5.
6.
Inspection
1.
2.
3.
9.16
"I'b_u'
~
10.2
10.5
10.1
ensure
I
stabilised and adequately supported. This will help
prevent it from falling and causing Injury to the
operator or damage to the motorcycle.
To gain access to the engine for removal:
1.
2.
3.
4.
5.
6.
7.
8.
system
1. Heel guard
2. Heel guard fixings
17. Remove the clip from the rear brake pedal cievis
pin. Remove the clevis pin.
as
Note:
9.
1. Pedal
2. Pushrod
3. Clevis
10.2
=-----=!~
~~!==~\I:=j~1:{:==
1. Brake Pipe
2. Clips
20. Remove the heat shield from the brake pipe joint.
"'"
1. Gear change crank
2. Selector shaft
~.
10.3
its
cbs;
1. Breather hose
2. Clip
Note:
Battery earth
10.4
Installation
Note:
1.
2.
Battery earth
5.
3.
1
1. Left hand footrest mounting bar
2. Fixings
10.5
cbue
"'"'
1. Selector rod
2. Gear change crank
3. Pinch bolt
1. Pedal
2. Pushrod
3. Clevis
4. Clip
10.6
~=I
,----'\-
"
Z))
~~~@
Il't$f~-----<Y':
1. Heel guard
2. Heel guard fixings
----~>
- ~~!=~,"~~~~:={
1. Brake pipe
2. Clip
~.
10.7
10.8
11.7
11.8
11.9
11.10
11.11
11.12
Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.13
11.13
11.13
Oxygenated Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.13
Ethanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.13
Methanol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.13
11.13
Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
Air temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
ATDC ...................................................................
11.14
Barometric pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
Battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
BTDC ...................................................................
11.14
Catalyst. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
Coolant temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
11.14
DTC ....................................................................
11.14
ECM ....................................................................
11.14
Engine speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
Freeze frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
Idle fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
Ignition advance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.14
11.14
~.
11.1
11.14
11.14
11.14
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.15
11.16
11.16
11.16
11.17
11.18
11.19
11.21
11.22
11.22
11.22
11.23
11.23
11.24
11.24
11.24
11.24
11.24
11.25
11.26
11.28
11.28
11.2
11.20
11.28
Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.58
Before Disconnection:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.58
11.58
11 .58
11 .58
11.58
11.59
Further Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.59
Crankshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.60
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 .60
11.62
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.62
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 .64
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.64
11.66
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.66
Purge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.68
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 .68
Ignition Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.70
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.70
11.72
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.72
11.74
PinpointTests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.74
11.76
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.76
System Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.77
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.77
11 .78
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.78
Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11. 79
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11. 79
11.80
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.80
11.81
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.81
Lambda Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.82
Pinpoint Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.82
11.83
~.
11.3
11.83
11.84
11.85
11.85
11.86
11.86
11.88
11.88
11.90
11.90
11.91
11.91
11.92
11.92
11.93
11.93
11.94
11.94
11.95
11.95
11.96
11.96
11.97
11.98
11.98
Fuel tank - lowering and securing ............................................. . 11.99
Fuel tank - removal . ...................................................... . 11.100
Fuel tank - refit. .......................................................... . 11.101
Fuel tank - raising ......................................................... .
11.4
11.101
11.101
11.103
11.103
11.104
11.105
11.105
11.106
11.109
11.111
11.111
11.112
11.112
Removal ............................................................... .
Installation ............................................................. .
11.112
11.112
11.113
Removal ............................................................... .
Installation ............................................................. .
11.113
11.113
11.113
Removal ............................................................... .
Installation ............................................................. .
11.113
11.113
11.114
Removal ............................................................... .
Installation ............................................................. .
11.114
11.114
11.115
Removal ............................................................... .
Installation ............................................................. .
11.115
11.115
11.116
Removal ............................................................... .
Installation ............................................................. .
11.116
11.116
11.117
Removal ............................................................... .
11.117
11.118
11.118
11.119
11.121
11.121
Throttle Body................................................................. .
11.122
Removal ............................................................... .
Installation ............................................................. .
11.122
11.123
11.125
Removal ............................................................... .
Assembly/installation ..................................................... .
11.125
11.126
11.126
Removal ............................................................... .
Installation ............................................................. .
11.126
11.127
11.128
Removal ............................................................... .
Installation ............................................................. .
11.128
11.128
11.130
Removal ............................................................... .
Installation ............................................................. .
11.130
11.130
11.133
11.133
Examination ............................................................ .
Installation .................................................. . .......... .
~.
11.5
11 .133
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11 .133
Typical Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11 .133
Fault Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11.134
Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6
11 .134
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11 .134
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
11.136
11.138
11 .138
Component Locations (all situated behind the left hand side cover) . . . . . . . . . . . . . . . . . ..
11.138
11 .139
11 .140
11.7
11.8
SNm
3.SNm
6Nm
~'
11.9
~~.
9Nm
1-1.5 Nm
11.10
~~ee
7Nm
11.11
00
11.12
Fuel Requirements
Fuel Requirements - all countries except USA
Outside America, the Rocket III must be run on 95
RON unleaded fuel.
Fuels containing
should not
Triumph motorcycles as damage to components in
the fuel system can be caused by contact with
methanol.
Oxygenated Gasoline
To help in meeting clean air standards, some areas of
the U.S. use oxygenated gasoline to help reduce
harmful emissions. The Rocket III will give best
performance when using unleaded gasoline.
However, 'the following should be used as a guide to
the use of oxygenated fuels.
Ethanol
Ethanol fuel is a mixture of 10% ethanol and 90%
gasoline and is often described under the names
'gasohol', 'ethanol enhanced', or 'contains ethanol'.
This fuel may be used in Triumph motorcycles.
~'
11.13
DTC
The following
this section.
what some
abbreviations
ECM
Engine Control Module.
Air temperature
The air temperature in the air box and intake hose.
Engine speed
The crankshaft revolutions per minute.
Freeze frame
A data set captured at the time a Diagnostic Trouble
Code (DTC) is set.
ATDC
Idle fuel trim
Barometric pressure
Pressure of the air in the airbox.
Idle fueling
Battery voltage
BTDC
Before Top Dead Centre (TDC).
Catalyst
Ignition advance
Coolant temperature
Ignition timing
11.14
MIL
Short circuit
Neutral switch status
The 'neutral' or 'in gear' status of the gearchange.
Open circuit
A break in an electrical circuit - current cannot flow.
Sidestand status
The 'up' or 'down' position of the side stand.
Over temp
High temperature within the Electronic Control
Module (ECM) caused by an internal or external
failure.
Throttle position
Throttle voltage
Vbatt
Battery voltage.
~.
11.15
System Sensors
11.16
CLUTCH SWITCH
PRIMARY THROTTLE
POSITION SENSOR
BAROMETRIC
PRESSURE SENSOR
SECONDARY THROTTLE
POSITION SENSOR
""i
COOLANT
TEMPERATURE
SENSOR
ROAD SPEED
SENSOR
SIDE STAND
SWITCH
MANIFOLD ABSOLUTE
PRESSURE SENSOR
INTAKE AIR
TEMPERATURE SENSOR
oolh
~'
CRANKSHAFT
POSITION SENSOR
11.17
11.18
Note:
INJECTORS
FALL DETECTION
SWITCH
MAIN POWER
RELAY
CANISTER PURGE
VALVE
""'i
FUEL PUMP
ccdg
COOLING FAN
IGNITION COILS
11.19
Key
Item Description
Code
Wiring Colour
Black
Diagnostic Connector
Blue
Brown
Sidestand Switch
Green
Instrument Assembly
Slate/Grey
Orange
7
8
Clutch Switch
Pink
Starter Relay
Red
10
Purple
11
White
12
MAP Sensor
Yellow
13
LG
Light Green
14
Lambda Sensor
LU
Light Blue
15
Cooling Fan
16
17
18
19
20
Ignition Coils
B
B9 ~
21
22
23
24
25
26
27
Fuel Injectors
28
29
30
Crankshaft Sensor
11.20
A
LBI
:~:,~~~~
~OOOOOOOO
B34
-=-(Jooogooor
I'
B26
OOOOOOGiJll1I AI4
OOOOOOGif/1f
\~!TA20
A26
~'
11.21
System Diagnostics
The engine management system has an on-board
diagnostics feature which allows service technicians
to retrieve stored data from the ECM using a Triumph
service tool. Full details of the tool's operation and
how to interpret the results are given elsewhere in
this section.
The tool is connected to the motorcycle using a
dedicated diagnostic plug situated beneath the seats.
By using a dedicated plug, no electrical connectors
associated with the system are disturbed, reducing
potential connector damage.
The tool allows the user to retrieve data associated
with the system sensors and actuators, test various
component functions, read build data and make minor
adjustments to the set-up of the system. The data
and tests available are described on the following
pages.
Note:
11.22
Freeze-frame Data
Function Examined
Engine speed
Result Reported
(Scale)
RPM
Calculated load
Coolant temperature
Throttle Position
Vehicle speed
Ignition Advance
km/h
degrees
volts
mm/hg
RPM
Calculated load
Coolant temperature
Throttle Position
Vehicle speed
Ignition Advance
Result Reported
(Scale)
km/h
degrees
volts
mm/hg
11.23
Adaption status
Function Examined
Report Method
Instrument panel
Visual
inspection
instruments
Function Examined
adaptedlnot adapted
control
Idle
speed
stepper motor
control
Cooling fan
Stored fault
operation
2nd
throttle
stepper motor
, If a fault
IS
control
of
code'lfan
Idle
speed
adaption status
Report Method
Build data
The following items of build data can also be read.
detected.
Function Examined
Vehicle identification Number (VIN)
Checks/Adjustments
11.24
Result Unit
numeric
numeric
milliseconds
milliseconds
milliseconds
milliseconds
degrees BTDC
degrees BTDC
degrees BTDC
degrees BTDC
Item Checked
Result Unit
% open
pressure
Volts
pressure
sensor
Atmospheric pressure
Volts
mmHg
Volts
mmHg
Battery voltage
Volts
Volts
Coolant
voltage
temperature
sensor
Volts
milliseconds
milliseconds
milliseconds
milliseconds
'othe~
is:
Volts
Item Checked
Volts
MIL off/on
Volts
Fan olllon
Volts
Starter on/off
Normal/over
% open
Heater on/off
Volts
SAlon/off
Volts
Engine rpm
RPM
Volts
Vehicle speed
kmlh
Volts
2nd throttle
voltage
position
sensor
Calculated load
Idle reference speed
Idle speed control target steps
Purge valve duty cycle
Result Unit
+1-100%
%
RPM
numeric
Gear position
numeric value
Neutral switch
Gear/neutral
On/off
11.25
Number of
no-fault
cycles
before
turning off
MIL
Number of
no-fault
cycles
before
DTCis
erased
MIL
illuminated
40
Yes
P0202
40
Yes
P0203
40
Yes
P1201
40
Yes
P1202
40
Yes
P1203
40
Yes
P0335
40
Yes
P0032
40
Yes
P0031
40
Yes
P0030
40
Yes
P0136
40
Yes
P0122
40
Yes
P0123
40
Yes
P0107
40
Yes
P0108
40
Yes
P1105
40
Yes
P1107
40
Yes
P1108
40
Yes
P0112
40
Yes
P0113
40
Yes
P0117
40
Yes
P0118
40
Yes
P0500
40
Yes
Diagnostic
Trouble
Code
(DTC)
Fault Description
P0201
11.26
when fault
is logged
Number of
no-fault
cycles
before
DTCis
erased
MIL
illuminated
when fault
is logged
40
Yes
P1553
40
Yes
P1231
40
Yes
P1232
40
Yes
P0444
40
Yes
P0445
40
Yes
P0617
40
Yes
P0616
40
Yes
P0414
40
Yes
P0413
40
Yes
P0222
40
Yes
P0223
40
Yes
P0638
40
Yes
P0505
40
Yes
P1631
40
Yes
P1632
40
Yes
P0560
40
Yes
P1500
40
No
P0654
40
No
P1115
40
No
P0460
40
No
P0705
40
No
P0656
40
No
P1610
40
No
P0630
EEPROM fault
40
No
Diagnostic
Trouble
Code
(DTC)
Fault Description
P1552
11.27
Tool Keys
In most cases, the Return key (.J) enables the user to
return to the screen last displayed.
go,
1. Memory card
2. Screen
3. Return key
4. Up key
5. Down key
6. Validate key
7. Help key
The memory card (1) contains all the information
necessary to allow the technician to follow a number
of different paths to:
I
Diagnose faults
Obtain data
Return key
a
[
I R G N
U R R E N T
R E R D
...
F U N [
5 T I
D T [
D R T R
5 T D R E
T I
T E 5 T 5
11.28
gaeg
gaee
Help key
gael
Validation key
11.29
CONNECT BIKE
SELF TEST
SYSTEM ERROR
False
CHECK CARD
Absent
Present
SELECT LANGUAGE
ENGLISH
FRANCAIS
DEUTSCH
ESPANOL
NEDERLANDS
TRIUMPH MOTORCYCLES
DIAGNOSTIC TOOL
SOFTWARE VERSION
2004_01
VALIDATE
False
Main Menu
SERVICE DATA
DEALER 555555
11.30
SERVICE DATA
DATE 15/06/04
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Quit
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Error Count
STORED ERRORS
FAULT COUNT 02
IGNITION COIL 1 OPEN CIRCUIT
INJECTOR 3 OPEN CIRCUIT
Diagnostics
Starred DTC
DIAGNOSTICS
CURRENT DATA
FAULT CODES
FUNCTION TESTS
QUIT
Fault codes
STORED ERRORS
FREEZE FRAME DATA
CLEAR DTCS
Current data
CURRENT DATA
ENGINE SPEED
CALCULATED LOAD
COOLANT TEMPERATURE
SHORT TERM FUEL TRIM
THROTTLE POSITION
INTAKE AIR TEMPERATURE
VEHICLE SPEED
IGNITION ADVANCE
OXYGEN SENSOR OUTPUT VOLTAGE
INTAKE MANIFOLD ABSOLUTE PRESSURE
FUEL SYSTEM STATUS
STORED ERRORS
Return
RETURN TO DTCS
CLEAR DTCS
STOP ENGINE
Clear
STORED ERRORS
ERASE ALL DTC DATA
YES
NO
No
RESETDTCS
Yes
11.31
~ Diagnostics
DIAGNOSTICS
CURRENT DATA
FAULT CODES
FUNCTION TEST
QUIT
Function test
FUNCTION TEST
DTCs present
./
~+ No DTCs present
FUNCTION TEST
INSTRUMENT PANEL
IDLE SPEED CONTROL STEPPER MOTOR
PURGE CONTROL VALVE
FUEL PUMP RELAY
FUEL PUMP OPERATION
COOLING FAN
2ND THROTTLE CONTROL STEPPER MOTOR
Cancel
Error Count
Screen
FUNCTION TEST
"TEST NAME"
PROCEED
CANCEL
Proceed
FUNCTION TEST
TEST NAME
TESTING ......
OBSERVE
or
TESTDTCS
DTe present
Zero DTCs
FUNCTION TEST
TEST NAME
TEST FAILED Pllll
SIC TQ VBATT
+
FUNCTION TEST
TEST NAME
TEST COMPLETE
CLEAR DTC
Yes
FUNCTION TEST
PERFORM ANOTHER TEST
YES
NO
No
11.32
Main Menu
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Check/Change
Check/Adjust menu
CHECK/ADJUST
Quit
CHECK
Adjust menu
ADJUST
QUIT
Check
CHECK/ADJUST
ADJUST TUNE
Adjust
Check menu
UPDATE TUNE
QUIT
CHECK
READ BUILD DATA
READ SENSORS
READ ADAPTION 8TATUS
QUIT
Quit
Adjust menu
Read sensors
ADJUST
THROTILE BALANCE
AOAPTrON RESET
REPLACETPS
REPLACE Ise STEPPER
TUNE UPDATE
QUIT
VOLTAGES
THROTTLES/COILS/INJECTORS
OTHER
Build data
f--
THROTILE BALANCE
THROTILE 1 1234 MMfHG
THROTTLE 2 1234 MM/HG
THROTTLE 3 1234 MMfHG
No
Yes
f-----
ADAPTtON RESET
CONFIRM YIN
I----
BUILD DATA
VIN
XXXXXXXXXXXxx
TRIUMPH ECU PART NUMBER
XXXXXX
KEfHIN EGU PART NUMBER
XXXXXXXXXXXXX
ECU SERIAL NO
XXXXXXXXXXXX
SOFTWARE VERSION NUMBER
XXXXXXXXXXX
DATE OF MANUFACTURE
XXXXXXXXXXX
CALIBRATION 10
XXXXXXXXXXX
Adaption status
ADAPTION STATUS
ECU RESET CLOSED THROTILE POSITION REF STATUS
IDLE SPEED CONTROL ADAPTJON STATUS
02 SENSOR ADAPTION STATUS - OFF IDLE
02 SENSOR ADAPTION RANGE - OFF IDLE
02 SENSOR ADAPTION STATUS -IDLE
02 SENSOR ADAPTION RANGE - IDLE
11.33
Main menu
MAIN MENU
DIAGNOSTICS
CHECK/ADJUST
QUIT
Check/Adjust
CheckiAdjusl menu
CHECK/ADJUST
ADJUST TUNE
UPDATE TUNE
QUIT
Quit
.
UPDATE TUNE
SELECT MODEL
ROCKET III
Update tune
ROCKET III
TUNE XXXXX
TUNE XXXXX
TUNE XXXXX
UPDATE TUNE
???????
UPDATE TUNE
TUNEXXXX
CONFIRM
CANCEL
QUIT
Confirm
Cancel
Pass
TEST PASSWORD
UPDATE TUNE
DOWNLOADING . ...
10% COMPLETE
Fail
SECURITY
ACCESS DENIED
DOWNLOAD OK?
Yes
11.34
No
UPDATE TUNE
UPDATE TUNE
DOWNLOAD COMPLETE
DOWNLOAD FAILED
5 E L E
~
.' "
.'.'
"
E N G L I
5 H
F R R N [
R I 5
0 E U T 5
E 5 P R N
oL
L R N G U R G E
T R L I
R N 0
N E 0 E R L R N 0 5
1. Tool
2. Connection to Main Harness
Connect the tool to the dedicated rnultiplug under the
seat.
(~l
,_.
/3)
I~!
11.35
T R j' lu /'lIP HI
Nla
,
,i a"I ' RIG
I
EI,,
a FiTIIJ-RTR
i
;
I
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iii
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i
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5,1.1"
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10
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1r1
11.36
ID!
'*'.
R T R
L I
N K
E R L E R
(GUl
R T R
5 5 5 5 5 5
llSJJl
.~
I~f
g.,
If the above is displayed, check that the ignition is
switched on.
~
I~
F R U L T
R E T R !I ;>
c'1
'*' to
'*'
g.,
/~
I~!
'*'.
'*'.
~.
11.37
,,
i
i5 E
R 1/ I
!e
/ oi~
8. MAIN MENU
E
aiR
I
~I-
1'1
@I
[iH E [
K /
Diu
I @I
ailI R G
5 T
Ra
N(
11'1 E N U
5!
10
tTi
!
($1
,
1
IT
10
I~(
12>(
Enter the date using the 'Up' and 'Down' keys in the
same way that the Dealer number was entered.
Note:
'DIAGNOSTICS'
'CHECK/ADJUST
11.38
selected)
U R R E N T
0 I
R G N
5 T I
5 T R R T
?
R E R 0
U R R E N T
0 R T R
5 T 0 R E 0
R L [
gall!
1'2>
N E
L 0 R 0
T E 1'1 P
2 9 96
1 5
0 T [ 5
lGDl
llSDl
@I
U L R T E 0
T E N G I N E
~
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E N G I
0 R T R
/~
<$1
galll
Iz:, (
'*'.
I t1
IZ>
.~
Iz:, ~
'*'
~.
11.39
iSTOPI
H-t-+-+-+-+-+--,'
ENGliNE
1'1 R I iN
il7 EiN U
io il
---
tRIG N 0 S T I
![lHiEiC
,
I
'
I i'i
~:-i+-'
,i
I 1
I R 0 J
U I
,is
UiS T
!
f-+-+-+-+-+---t--
I<DZ:>(
Switch off the engine.
@I
ID
I @I Iz:, {
Use the 'Up' and 'Down' keys to position the cursor
opposite DIAGNOSTICS.
Press the
Validation
'DIAGNOSTICS' menu.
key
'*'
to
display
11.40
a
i' P
"p
a1 1
a2 a
au
R E
N T
0 T
5 T
"
F R E E Z E
[
L E R R
R E
F R R fI E
T [
T [
0 R T R
lGVl
(GDl
9"
.~
.~
I~~
I~(
9"
Align 'FREEZE FRAME DATA' with the cursor, and
to display 'FREEZE
press the validation key
FRAME' (see 15.).
'*'
'*'
P01l7
Help text
MAP SENSOR
LOW VOLTAGE
'*'
to continue (operation
IMPORTANT:
If a DTC has an asterisk (*) to its right, this indicates
that a snap shot of engine data at the time the DTC
was stored is available to aid your fault diagnosis. To
access this information, press the Validation key
to
go to operation 14. and open 'FREEZE FRAME
DATA'.
'*'
~.
11.41
:
?
iF !? E E
I
i
F Ii! R 1'1
5 T 0 Ii! E 0
Ei
i i
'f'11J R I! TIE
'
R!T E 0
!R I
10
R 0
9 %
1 5
TiE 1'1 P
I
'f'!? E T
'
T 0
,0 T
0 T
'
6"\
I~(
1'0
I~(
'*'
'*' to go on to operation
Note:
'*'
11.42
UIRH
L EiRI!?1
0 TI[ 5
R L L
0 T
0 T
0 I R G N 0 5 T I [ 5
0 R T R
N 0
[
~
R E R 0
galu
I~
0 R T R
5 T 0 R E 0
L E R R
0 T
0 T [ 5
(~l.~
llSUl
@I
U R R E N T
.~
I j IE>!,
QIlIU
I~!
Note:
~.
11.43
ric
p RJE 5 E
8 ElF 0 R E
I
,IT
E 5
INI
N T
JeL
-1--+-+
'R Ie' T
T
i
;> 1 N 5 T R U 1'1 E N T
TI
6"1
I @I
I~Q
T E 5 T
islr
i
i
I @I
lz:,(
13.).
'*'
Note:
The fault(s) which caused the DTC's to be
set must be rectified and cleared before
continuing the Function Tests.
A full list of all the possible DTCs can be
found earlier in this section.
'*'
P RIN E L
E'P p E R
@I
F U N C T 1 OiN
T 5
10
lz:,!
Instrument panel.
Idle speed control stepper.
Purge valve.
Fuel pump prime.
Cooling fan operation.
Fuel pump operation.
Second throttle control stepper motor.
11.44
I
~
N 5 T Ii! U 1'1 E N T
T E 5 T
P R N E L
P Ii! 0 C E E 0
C R N C E L
Note:
lGJl
<$1
gO"
I~
.,;j)
I <$] IE> (
11.45
F U 1'1 [
I
1'1
@I
T E S T
E L
1'1
S T IR
IF U 1'1
!
T E S T
UII'I E 1'1 T
T Eis TI
Riu
1'1 P L E T E
G E S
:~
@I
10
II t~!
II lz:.(
11.46
'*'
F U N [
P E R F
~
R 1'1
R N
T E 5 T
T H E R
T E 5 T
T I
!J E 5
F U N [
T I
N 5 T R U 1'1 E N T
T E 5 T
F R I
L E
aN
T E 5 T
P R N E L
p 1 1 1 1
(GDl
~
(GDl
.~
I~(
<$"1
I~
.~
I~!
g""
This display allows you to decide whether you wish to
test another component
g""
If the test selected at operation 22. is unsatisfactory, a
DTC will be displayed on line 3 of this display.
'*'
'*'
'*'
'*'
~.
11.47
27. CHECK/ADJUST
l'IiE N U
I
1'1
GNOST/lciS
--+--~I
I
c
c
H E C K /
H E C K
R 0 J U 5 T
U I
@I
<$1
-t-
1:0
I~I
10
I @ IE:>!
Use the 'Up' and 'Down' keys to position the cursor
opposite 'CHECK/ADJUST'.
Press the Validation key '*'; the 'CHECK/ADJUST'
menu will be displayed.
11.48
IT
R OiJ U liS T
to
return
to 'MAIN
MENU'
28. CHECKS
[
~
R E R
R E R
R
a
a
5 E N 5
B U I L
R p T I
a
a
H E [ K 5
B U I L
5 T R T U 5
TT
R I U 1'1 P H
~.
llSJJl
/~
I <$] 12>(
gall!
You now have the option to access the motorcycle
'BUILD DATA' or the 'SYSTEM DATA', or to quit.
llSDl
I~
R T R
X X X X X X X X X X X X X X X X X X
R T R
~
CI
tJ I N
R 5
@I
12>
12> r
gaiu
Providing the information was recorded at the time of
build, the display will show the following information
relating to the motorcycle under test by scrolling up
and down.
Before displaying the recorded
information, the tool will briefly display the message,
'PLEASE WAIT, CHECKING BUILD DATA'.
I <$1
Tune Number
11.49
ENS ,faiR
'
aiR T R
p T
E
i
? R
iR
51E NI5
T R
!R
!
TIE
5 [
@I
Note:
The help information shows the likely
range of readings for a correctly
functioning system at normal operating
temperature.
11.50
'*'
R R N G E
iE RI5 E
IJ R
I~(
,iL
OIUiT
1:--2>
I~I
5 T !R T U 5
T E 1'1 P
5 tJ
nip
to return to 'CHECK!
5 E
a
a
R p T I
T H R
R p T I
5 E N 5
a
a
R T R
T T L E
R p
/;
96
5 1 96
lGDl
~
/3)
I~~
Function Examined
Report Method
adapted/not adapted
Idle
speed
control
adaption status
Oxygen
adaption
idle)
sensor
status (off
Oxygen
adaption
idle)
sensor
range (off
sensor
Oxygen
adaption status (idle)
Oxygen
sensor
adaption range (idle)
Note:
11.51
R 0 JUS T
T
R E
TUN E
5E
, ,;
,
i
ri; iI R
0 R P T I
T H R 0 T TIL E
I
sf
T H R 0 TTT LTE
OiN
8 R L R N [IE
~
IT UiN E
i
R 0 J U 51 T
5i
EI/J
iR EiN
i
!
P 0 T
51TlE P P E R
! ;
N]E
R!E
;
lJl
l~l
I~(
'*'
'*'
gall!
/~
I~(
11.52
T H R D T T L E 5
N[
E D
1 2 3
I? I? I H G
!:/ E 5
T H R D T T L E
1 2 3
I? I? I H G
N D
T H R D T T L E
1 2 3
I? I? I H G
D N F I
R I?
(~l
llBJl
<$!
gaiu
I)
($'1
I~(
galu
B R L R
T H R D T T L E
R E 5 E T
~.
I ~I
I~
/~
IE> (
11.53
P 0 R T E
IT
U N E
I
5 5 5 515
,
[ E 5 5
OiN N E
@I
I<I
I <I ID!
&
01
!0
IDr
'*'
11.54
0 E N
uP
5 E L E
~R
K E T
D R T E
R D
T U N E
fI D D E L
T U N E
2 X X X X
T U N E
2 X X X X
T U N E
2 X X X X
galu
1'2)
<$1
I~(
galu
lGUl
.~
K E T
(GUl
<$1
1'0
.~
I~(
11.55
Ei
u p a RiriE
. ,
21 x x x x
[i O N F
[IA N [
@!
I cl
,
T U N E
R 1'/
ulN
!
i
L :OIR
N G
r-144---+-+_t-1
1
%1'-+-[+0-+-I'/+p-I L
a!, :
Ii
E L
I~
! T U ,N E
U paR TIE
@I
I,',
I~,i-+++-i
E' T ! E I
!
i3.
i~(
lz:, (
'*'.
'*'
'*' to
Note:
11.56
~.
U 1'1 P H
R G N
F T
'"
R R E
aa
1'1
5 T I
R [
tJ E R 5 I
'I
':I
aa
L E 5
L
11.57
Note:
Note:
11.58
Further Diagnosis
The tables that follow will, if used correctly, help to
pinpoint a fault in the system once a diagnostic
trouble code has been stored.
1.ECM
2. Large connector
3. Small connector
2.
~.
11.59
Possible cause
Action
P0335
Pinpoint Tests
Test
1 Check terminal and cable integrity:
- ECM pin A13
- ECM pin A14
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
Proceed to test 6
Faulty
11.60
Crankshaft
Sensor
Engine
Control Module
,f--U'=i;]14
1
2 r--U8
'--------'--'
~'
A13
11.61
Possible cause
Action
P0505
Pinpoint Tests
Result
Action
OK
Proceed to test 2
Faulty
40 to 120
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
40 to 120
Proceed to test 7
Faulty
Test
1 Check cable and terminal integrity:
2
ECM
ECM
ECM
ECM
pin
pin
pin
pin
B23
B07
B11
B03
ECM
ECM
ECM
ECM
pin
pin
pin
pin
B23 to earth
B07 to earth
B 11 to earth
B03 to earth
pin
pin
pin
pin
A
A1
B
B1
11.62
Control odule
Sub arness
t"
~'
En~ne
E~ine
ON
A'
10
ow
807
OU
11
8'
OK
12
OU
OK
803
Bll
11,63
Possible cause
Action
Injection system fault - Injector 1/21 View & note diagnostic tool 'freeze
frame' data if available.
- Misfire indicates open circuit
Ensure relevant injector connector
is secure. Disconnect ECM and
- Flooding indicates short circuit
proceed to pinpoint test 1
P0201/02/03
Pinpoint Tests
Test
2
Check
- ECM
- ECM
- ECM
resistance
pin A20 to
pin A20 to
pin A20 to
pin
pin
pin
pin
A20 to
B05 to
B06 to
B17 to
Action
OK
Proceed to test 2
Faulty
12.50 to 14.00
Proceed to test 3
Open circuit
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
12.50 to 14.00
Proceed to test 7
Faulty
value:
ECM pin B05 (injector 1)
ECM pin B06 (injector 2)
ECM pin B17 (injector 3)
- ECM
- ECM
- ECM
- ECM
Result
11.64
ECM
AlO
En~ine
Sub- arness
Fuse Box
Fuse6
NK
2 1
2 2
, 3
NK
YK
YP
VB
YK
BOS
yp
B06
VB
817
Fuel Injectors
~.
11.65
Possible cause
P0122
P0123
Throttle
voltage
circuit)
Throttle
voltage
supply)
Action
position sensor low input View & note diagnostic tool 'freeze
(short to ground or open frame' data if available.
View & note diagnostic tool 'sensor'
position sensor high input data.
(short circuit to sensor Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1
Pinpoint Tests
Test
1 Check
- ECM
- ECM
- ECM
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short ci rcu it
11.66
Engine
Sub-Harness
Connector
ECM
Throttle
Position Sensor
O=:=GY
2
~'
KB _____ KB
E
17
GY
18
KB
A07
19
A01
A10
11.67
Possible cause
P0444
Open circuit or short circuit to earth View & note diagnostic tool 'sensor'
data.
Ensure purge valve connector is
secure.
Disconnect ECM and
proceed to pinpoint test 1
P0445
Action
Disconnect
purge
valve
proceed to pinpoint test 5
and
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin 831
2 Check resistance value:
- ECM pin A20 to ECM pin 831
Result
Action
OK
Proceed to test 2
Faulty
24Qt028Q
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
24Q to 28Q
Proceed to test 7
Faulty
11.68
~.
EMS Relay
=EJ
[eM
Purge Valve
NK~/~YR
"--------NI'
831
AlO
Fuse Box
fuse6
~.
11.69
Possible cause
Action
P0351 152/53
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
l.4n to 1.Sn
Proceed to test 3
Open circuit
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
1.4n to I.Sn
Proceed to test 7
Faulty
11.70
Service
Manual -
Rocket III
EMS Relay
ECM
Fuse Box
Fuse6
'----<;----------INK
A20
~--NK -----'jZ,"""~GK
829
K-----'j/,""~GP
NK -----'j/l""~G8
826
801
Ignition Coils
11.71
Possible cause
P0118
Open circuit, or short circuit to View & note diagnostic tool 'freeze
battery+
frame' data if available.
View & note diagnostic tool 'sensor'
data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1:-
P0117
Action
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Short circuit
OK
Proceed to test 5
Open circuit
OK
Proceed to test 5
Short circuit
OK
Proceed to test?
Faulty
OK
Proceed to test?
Short circuit
11.72
200 to 4000
Cold engine:
20C ambient
2.35 to 2.65KO
-10C ambient
8.50 to 10.25KO
Coolant
Tem~erature
Engine
Sub-Harness
Connector
I:
ECM
Q=~:----1i ~:il
~.
11.73
Possible cause
Action
P0113
Open circuit, or short circuit to View & note diagnostic tool 'freeze
battery+
frame' data if available.
View & note diagnostic tool 'sensor'
data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpointtest 1:-
P0112
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Open circuit
Short circuit
OK
Proceed to test 5
Open circuit
OK
Proceed to test 5
Short circuit
OK
Proceed to test?
Faulty
OK
Proceed to test?
Short circuit
11.74
Resistance value
200 to 4000
2.35 to 2.65KO
B.50 to 10.25KQ
Inlet Air
EeM
Temperature
Sensor
~KB~
~KO~
~.
11.75
Fault Code
Possible cause
P1231
Fuel pump relay open circuit, or Check if pump runs briefly when
ignition is switched on.
short circuit to ground
Ensure fuel pump relay connector
is secure.
Disconnect ECM and proceed to
pinpoint test 1:-
P1232
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
OK
Proceed to test 5
Short circuit
Circuit Diagram
Fuel Pump Relay
EMS Relay
ECM
:==~_'K==~~----,~:=EJ
Fuse Box
Fuse 6
11.76
Possible cause
Action
P0560
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
Circuit Diagram
EMS Relay
ECM
NK
Fuse Box
Fuse 6
~'
f:
AlO
A06
608
609
11.77
Possible cause
Action
P1552
Fan relay open circuit, or short View & note diagnostic tool 'sensor'
data.
circuit to ground
Ensure fan relay connector is
secure.
Disconnect ECM and proceed to
pinpoint test1:-
P1553
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin B10
2 Check cable for short circuit:
- ECM pin B10 to ground
3 Check cable continuity:
- Fan relay pin 4 to ECM pin B10
- Fan relay pin 6 to EMS relay pin 8
4 Check cable for short circuit:
- ECM pin B10 to ECM pin A20
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Proceed to test 5
Short circuit
Circuit Diagram
EMS Relay
ECM
Fuse Box
Fuse6
11.78
Possible cause
Action
P0654
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin B14
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
Circuit Diagram
Instruments
~
J
Fuse Box
FuseS
G
LGN
GR
R
10
~.
c=::::J
ECM
'It:
814
A06
B<l'
,og
11.79
Possible cause
P1115
Temperature Indication system fault View & note 'freeze frame' data if
available.
View & note 'sensor' data.
Ensure instrument connector is
secure.
Disconnect ECM and proceed to
pinpoint test 1:-
Action
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
Circuit Diagram
Instruments
~
~
LGN
GRJ
15
10
11.80
EeM
YW
'1 F:
63'
A06
B08
809
Fuse Box
Fuse 5
==:J
Possible cause
Action
P1500
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin 832
- ECM pin 808
- ECM pin 809
- ECM pin A06
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
Circuit Diagram
Instruments
~
J
Fuse Box
Fuse 5
G
LGN
G.
13
10
~.
E==:J
ECM
.0
'1 f:
'32
A06
'08
'09
11.81
Possible cause
Action
P0130
Pinpoint Tests
Test
1 Check cable and terminal integrity:
ECM pin A11
ECM pin AO?
2 Check cable for short circuit:
ECM pin A 11 to ECM pin AO?
ECM pin A 11 to ECM pin A20
3 Check cable continuity:
ECM pin A 11 to sensor pin 1
ECM pin A 11 to sensor pin 2
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
Circuit Diagram
EMS Relay
Lambda Sensor
ECM
'---w
83,
~----K6
07
L..---------NK
A2a
11
Fuse Box
Fuse6
11.82
Possible cause
Action
POO31
Lambda sensor heater circuit short View & note '1reeze frame" data if
available.
circuit to ground or open circuit.
View & note "sensor" data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test 1:
POO32
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- Ecm pin 833
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 5
Open circuit
OK
Circuit Diagram
EMS Relay
lambda Sensor
ECM
83'
11
Fuse Box
KB
A07
NK
AlO
Fuse6
~.
11.83
Possible cause
Action
P0603
EEPROM error
11.84
Possible cause
P1631
Fall detection
voltage
Action
P1632
switch
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A04
2 Check cable for short circuit:
- ECM pin A04 to ground
- ECM pin A04 to ECM pin A20
3 Check cable continuity:
- ECM pin A01 to sensor pin 4
- ECM pin A04 to sensor pin 5
- ECM pin AO? to sensor pin 6
4 Check cable for short circuit:
- Sensor pin 4 to sensor pin 5
- Sensor pin 4 to sensor pin 6
5 Check voltage (with ignition on):
- Sensor pin 4
6 Reconnect harness, clear fault code.
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Proceed to test 5
Short circuit
12V
voltage)
OK
Circuit Diagram
fall
Detection
Switch
ECM
r;J="'=D
A04
07
AOl
KU
11.85
Possible cause
PD222
2nd throttle position sensor low View & note "freeze frame" data if
voltage. (short circuit to ground or available.
open circuit)
View & note "sensor" data
Ensure sensor connector is secure.
2nd throttle position sensor high Disconnect ECM and proceed to
voltage. (short circuit to sensor pinpoint testt :
supply)
PD223
Action
Pinpoint Tests
Test
11.86
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
ECM
Sub- arness
Connector
2nd Throttle
Position Sensor
Ll:=~
2
~.
K8 --e----KB
8
16
A02
18
KB
A07
19
AOI
11.87
Possible cause
Action
P0638
2nd throttle actuator motor / wiring View & note "freeze frame" data if
fault
available.
View & note "sensor" data
Ensure actuator connector is
secure.
Disconnect ECM and proceed to
pinpoint test1:
Pinpoint Tests
Result
Action
OK
Proceed to test 2
Faulty
4n to Ion
Open circuit
Proceed to test 4
Short circuit
OK
Proceed to test 7
Short circuit
OK
Proceed to test 6
Open circuit
OK
Proceed to test 6
Short circuit
4n to Ion
Proceed to test 7
Test
1 Check cable and terminal integrity:
-
ECM
ECM
ECM
ECM
pin
pin
pin
pin
821 to ground
822 to ground
812 to ground
804 to ground
11.88
OK
2nd Throttle
A' G N
GW
[g
8
GU
8'
~.
En~ne
Sub Harness
Connector
Actuator
GK
Control odule
GN
821
GW
822
GU
812
GK
804
11.89
Possible cause
Action
P0500
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A21
- Instrument pin 18
2 Check cable for short circuit:
- ECM pin A21 to ground
- ECM pin A21 to ECM pin A01
- ECM pin A21 to battery
3 Check cable for continuity:
- ECM pin A21 to sensor pin 3
- Sensor pin 2 to ground
- Instruments pin 18 to sensor pin 1
Result
Action
OK
Faulty
OK
Proceed to test 3
Faulty
OK
Open circuit
Circuit Diagram
Alarm
Control Unit
Instruments
il-GR
Kill
Switch
J~LGN
Fuse Box
Fuse 5
G--EE=::J==:C3--
lj-'Y
ECM
KY -
_ _ _--jA11
Road
Speed Sensor
11.90
Possible cause
Action
P110?
Ambient pressure sensor circuit View & note '~reeze frame" data if
short circuit to ground
available.
View & note "sensor" data.
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test1:
P1108
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A23
- ECM pin AO?
- ECM pin A01
2 Check cable for short circuit:
- ECM pin A23 to ECM AO?
3 Check cable for continuity:
- ECM pin A23 to sensor pin 3
- ECM pin AO? to sensor pin 2
- ECM pin A01 to sensor pin 1
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Open circuit
OK
Short circuit
sensor and
Circuit Diagram
Ambient
Pressure
Sensor
EeM
AD7
All
A01
K6=tJ
K1
KP
11.91
Possible cause
Action
P01O?
MAP sensor circuit short circuit to View & note "freeze frame" data if
available.
ground
View & note "sensor" data
Ensure sensor connector is secure.
Disconnect ECM and proceed to
pinpoint test1:
P0108
P1105
sensor
and
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin A03
- ECM pin AD?
- ECM pin AD1
2 Check cable for short circuit:
- ECM pin AD3 to ECM AD?
3 Check cable for continuity:
- ECM pin AD3 to sensor pin 3
- ECM pin AD? to sensor pin 2
- ECM pin AD1 to sensor pin 1
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Open circuit
OK
Short circuit
Circuit Diagram
MAP
Sensor
EeM
'07
AOl
A01
11.92
"=tJ
K5
Possible cause
Action
P0705
Pinpoint Tests
Test
1 Check cable and terminal integrity:
"ECM pin A26
2 Check cable for short circuit:
" ECM pin A26 to ground
3 Check cable continuity:
" ECM pin A26 to sensor pin 1
" ECM pin A 19 to sensor pin 2
4 Check cable for short circuit:
" Sensor pin 1 to sensor pin 2
5 Reconnect harness, clear fault code.
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
Circuit Diagram
Gear
PosH"lon
Sensor
ECM
2 r--BW
A19
Id--BK==t]"
'-------'--'
~.
11.93
Possible cause
Action
P0460
Pinpoint Tests
Test
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Proceed to test 4
Open circuit
OK
Short circuit
OK
Circuit Diagram
Fuel
level
Sensor
11.94
[CM
Possible cause
Action
P1610
Pinpoint Tests
Test
Result
Action
OK
Proceed to test 2
Faulty
OK
Disconnect instrument
proceed to test 3
Short circuit
OK
Open circuit
assembly
and
Circuit Diagram
Alarm
Control Unit
Instruments
Kill
Switch
~
J
Fuse Box
Fuse 5
LGN
GR
4
10
ECM
:
1f
BG
c::==J
830
AM
BOB
B09
11.95
Possible cause
P0656
Accessory fuel level gauge circuit Ensure fuel level gauge connector
fault
is secure.
Disconnect ECM and proceed to
pinpoint test1:
Action
Pinpoint Tests
Test
1 Check cable and terminal integrity:
- ECM pin AOS
- Gauge pin 1
2 Check cable for short circuit:
- ECM pin AOS to ground
- ECM pin AOa to ECM pin A20
3 Check cable continuity:
- ECM pin Aoa to gauge pin 1
- Gauge pin 2 to earth
- Gauge pin 3 to alarm control unit pin 1
4 Reconnect harness, clear fault code_
Result
Action
OK
Faulty
OK
Proceed to test 3
Short circuit
OK
Open circuit
OK
Circuit Diagram
Alarm
Control Unit
Access0J'
Fuel Leve
Gauge
Kill
Switch
~
~
LGN
ECM
GRJ
BG
'1 f:
11_96
A08
A06
BOB
B09
Fuse Box
Fuse 5
c==J
Possible cause(s)
11.97
Fuel Tank
Note:
i
I
information section on the safe handling of fuel and
fuel containers.
A fire, causing personal injury and damage to
property could result from spilled fuel or fuel not
handled or stored correctly.
,""
5.
iI@
Remove the intake cover from the left hand side
of the tank as follows, release the two screws
from its front and rear edges and then slide it
downwards to release it from two support studs
in its centre.
""'"
1. Intake cover
2. Intake cover screws
6.
1. Instrument pack
2. Handlebar clamp cover
3. Fixings
1. Fixing
11.98
1. Coil bracket
2. Fuel tank prop
8.
1. Coil bracket
2. Fuel tank prop
3.
4.
5.
6.
7.
~-
11.99
2.
cbrp
1. Fuel hose
2. Electrical connection
4. Disconnect the electrical connection from the
fuel pump plate.
5. Support the fuel tank while removing the rear
mounting bolt.
1. Fuel tank
2. Breather hoses
pressure.
releasing the fuel pipe union, wear eye protection
and protective clothing and ensure that the
pressurised fuel is not exposed to naked flames,
light bulbs, etc. A fire, causing personal injury and
damage to property, may result from fuel exposure
to naked flames, light bulbs and any other source of
ignition.
Note:
Cbrq(\
7.
11.100
3.
4.
"'"
~.
11.101
7.
6.
S.
"'"Screw
1.
2. Pressure regulator
Note:
1. Filter
2. Clip
3. Inlet hose
4. Filter arrow
11.102
"""
1. Fuel pump
2. Fuel pump clamp
3. Mounting bar
Inspection
1.
2.
Assembly
1.
1. Fuel pump
2. Electrical connection
1. Fork
2. Isolator feet
00pI
1. Fuel pipe
2. Pump
11.103
,b",
1. Fuel pump
2. Fuel pump clamp
3. Mounting bar
3. Locate the fuel pipe and hose to the pump outlet.
4.
5.
6.
,.,.
1. Fuel pump
2. Electrical connection
12. Check that the fuel level sender arm moves
freely along its full range of travel, and comes to
rest on the pump plate. Rectify as necessary.
Installation
2.
3.
1.
1. Filter
2. Clip
3. Inlet hose
4. Filter arrow
7.
8.
9.
11.104
Removal
1.
2.
3.
11.100.
4.
5.
6.
7.
1. Evaporative canister
2. Hoses
3. Cable ties
11. Remove the canister.
12. Disconnect the electrical connections to the fall
detection switch and alternator rectifier.
\
2
1. Relay pack
2. Airbox
3. Screws
4. Roll-over valve
8. Ease the relay pack from the airbox.
Note:
9.
11.105
1. Fuse box
2. Fir-tree pi ugs
Electrical connections
17. Place the ECM to one side.
18. Remove the three screws from the ECM bracket,
then detach the bracket.
,~.
1. ECM bracket
Note:
Before proceeding. make a note of the
cable routings around the ECM and ECM
bracket.
15. Working on the right hand side, remove the
screws securing the engine management ECM
to its bracket.
1. Relays
2. Battery box
1. ECM
2. Screws
11.106
..
""
1. Seat Lock
2. Screws
23. Release the two screws securing the battery box
assembly to the frame.
1. Battery box
2. Screw (left hand shown)
24. Maneouvre the battery box assembly from the
motorcycle and place aside.
~.
1. Throttle bodies
2. Clips
26. Noting their orientation, release the two clips
securing the intake plenum to the intake duct.
1. Intake plenum
2. Intake duct
3. Clips
27. Carefully detach the intake plenum from the
throttle bodies and intake duct. Place the intake
plenum aside.
11.107
1. Intake hose
2. Intake duct
3. Clip
1. Intake duct
2. Fixing
pressure
1. MAP sensor
Cbsi
1. Breather hose
Note:
2. Clip
11.108
1. Airbox
2. Fixings
1.
Installation
Reconnect the
sensors.
MAP
and
air temperature
1. MAP sensor
2. Air temperature sensor
3. Connectors
6.
1. Airbox
2. Semi-circular feature
3. Frame cross tube
2.
3.
~.
11.109
1. Relays
2. Battery box
2. Airbox
3. Screws
4. Roll-over valve
1. ECM bracket
2. Cables
11.110
detection
switch
and
~.
Air Filter
Removal
1.
2.
3.
4.
1. Evaporative canister
2. Hoses
3. Cable ties
21. Refit the rear mudguard as described on page
17.13.
22. Refit the rear wheel as described on page 16.9.
23. Refit and reconnect the battery as described on
page 18.10.
24. Refit both side covers as described on page
17.9.
25. Refit the fuel tank as described on page 11.101.
26. Refit the rider's seat as described on page 17.9.
I..
1. Filter element
6. Inspect the cover seal for damage.
~.
11.111
Assembly
1.
2.
3.
4.
5.
6.
Removal
1.
2.
3.
4.
5.
Installation
1.
2.
11.112
3.
4.
5.
Removal
1.
2.
3.
4.
1.
2.
3.
4.
"'"
1. MAP sensor
2. Multi-plug
5.
6.
6.
Instal.lation
Installation
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
11.113
1.
Removal
1.
2.
3.
Note:
4.
2.
3.
4.
5.
6.
7.
Fit a new a-ring to the sensor. Lubricate the 0ring with a smear of petroleum jelly.
Position the sensor to the engine and route the
wiring as noted prior to removal.
Retain the sensor with the two screws, tightening
them to 9 Nm.
Connect the sensor to the main wiring harness.
Reattach the connector to the bracket.
Position the left hand engine infill panel to the
frame. Align the screw holes in the panel with
those in the connector bracket and frame. Fit
and tighten the screws to 3 Nm.
Reconnect the battery, positive (red) lead first.
Refit the rider's seat as described on page 17.9.
6.
11.114
Installation
1.
Removal
Remove the rider's seat as described on page
17.9.
Disconnect the battery negative (black) lead first.
Remove the engine intill panel from the left hand
side of the engine (see page 17.10).
1.
2.
3.
Note:
4.
2.
3.
4.
5.
6.
7.
Fit a new O-ring to the sensor. Lubricate the 0ring with a smear of petroleum jelly.
Position the sensor to the engine and route the
wiring as noted prior to removal.
Retain the sensor with the screw then tighten the
screw to 9 Nm.
Connect the sensor to the main wiring harness.
Reattach the connector to the bracket.
Position the left hand engine infill panel to the
frame. Align the screw holes in the panel with
those in the connector bracket and frame. Fit the
screws and tighten to 3 Nm.
Reconnect the battery, positive (red) lead first.
Refit the rider's seat as described on page 17.9.
5.
Note:
6.
11.115
Installation
Fit a new O-ring to the sensor. Lubricate the 0ring with a smear of petroleum jelly.
Position the sensor to the engine and route the
wiring as noted prior to removal.
1.
Removal
1.
2.
3.
2.
3.
Note:
Note:
4.
4.
5.
6.
7.
5.
Note:
6.
11.116
Throttle Cables
i
throttle bodies. If the throttle cables are incorrectly
adjusted, either too tight or too loose, the throttle
may be difficult to control and performance will be
adversely affected.
Check the throttle grip free-play in accordance with
scheduled maintenance requirements and make
adjustments as necessary.
Always be alert for changes in the 'feel' of the
throttle and have the throttle system checked by an
authorised Triumph dealer if any changes are
detected. Changes can be due to wear in the
mechanism, which could lead to a sticking throttle.
An incorrectly adjusted, sticking or stuck throttle will
lead to loss of motorcycle control and an accident.
9.
Removal
Note:
1.
2.
3.
4.
5.
6.
1. Throllie cables
2. Screw
3. Union
11.117
Installation
Note:
1.
2.
3.
4.
5.
1. Master cylinder
2. Screws
o
cbsz
1. Split line
2. Dot mark
1. Twist grip
2. Throttle cables
13. Note the routing of the throttle cables, then
remove them from the frame.
6.
7.
8.
Examination
1.
1. Throttle cables
2. Retainer screw
3. Union
11.118
2
~-H'---1
~'
11.119
an
of the motorcycle
adjusted, incorrectly routed or damaged throttle
cable could interfere with the operation of the
brakes, clutch or the throttle itself. Any of these
conditions could result in loss of control of the
motorcycle and an accident.
2.
3.
4.
5.
6.
7.
11.120
1.
2.
3.
T H R
T H R
T H R
T H R
a
a
a
a
T T L E 5
B R L R N
T T L E
1 i! 3
1'1 1'1 / H G
T T L E
i!
1 i! 3
1'1 1'1 / H G
T T L E
1 i! 3
1'1 1'1 / H G
,I'"~
1. Adjuster 1
2. Adjuster 2
5.
4.
11.121
Throttle Body
Removal
1.
2.
3.
4.
1. Intake hose
2. Intake duct
3. Clip
8.
1. Throttle bodies
2. Clips
5.
1. MAP sensor
2. Air temperature sensor
3. Connectors
1. Intake plenum
2. Intake duct
3. Clips
6.
11.122
Installation
1. Intake duct
2. Fixing
the injectors.
1.
2.
1. Transition piece
2. O-ring
3.
4.
5.
"",
Note:
1. Throllle body
2. Clips
6.
~.
11.123
each injector.
9.
~1
1. Intake duct
2. Fixing
11.124
1. Intake plenum
2. Intake duct
3. Clips
13. Reconnect the MAP and air temperature sensor
connections.
Removal
1.
2.
3.
4.
""
1. Fuel rail
2. Screws
Note:
5.
1. Fuel rail
2. Injectors
11.125
Removal
1.
2.
3.
"'"
1. Clips
2. Injectors
7.
8.
4.
Assembly/installation
1.
2.
3.
4.
5.
6.
7.
8.
11.126
cbti
5.
8.
2.
P R I
fI R R !J
T H R D T T L E
[ UR R E N T
9.
/I D L T 5
T P 5
L D 5 E D
5 6 /I
Note:
10.
1. Sensor Insertion position (dotted line)
2. Sensor Initial fitted position (solid line)
3.
4.
5.
6.
7.
R 0 J U 5 T
R E 5 E T
~
P 0 T
5 T E P P E R
12.
13.
14.
T U N E
R 0 R P T I 0 N 5
T H R 0 T T L E
11.
R E N E /J
R E N E /J
~.
11.127
Move
and
checking that cables and harnesses do not bind. A
cable or harness that binds will restrict the steering
and may cause loss of control and an accident.
15. Support the tank, remove and stow the tank
prop, then lower the tank to the frame and secure
it as described on page 11.99.
16. Refit the intake cover as described on page
11.99.
17. Reconnectthe battery, positive (red) lead first.
18. Refit the rider's seat.
Removal
1.
2.
3.
4.
Gblj
5.
Installation
1.
2.
11.128
7.
Removal
1.
2.
3.
4.
=0-
Installation
1.
1. Collar
2. Spring
11.130
2.
3.
1. Collar
2. Spring
4. Fit the plastic washer through the lever then fit
the metal washer and nut.
5. Refit the throttle bodies as described earlier in
this section, but do not fit the intake cover.
6. Temporarily reconnect the battery, positive (red)
lead first.
7. Turn the ignition to the ON position.
8. Connect the service diagnostic tool and scroll
through to, and select the 'ADJUST TUNE'
option.
~.
7.
Removal
1.
2.
3.
4.
=-
Installation
1.
2.
3.
1. Collar
2. Spring
4. Fit the plastiC washer through the lever then fit
the metal washer and nut.
1. Collar
2. Spring
5.
6.
7.
8.
11.130
R 0 R P T I 0 N 5
T H R 0 T T L E
~I
5 [
T U N E
P 0 T
5 T E P P E R
R E N E IJ
R E N E IJ
T H R 0 T T L E
[ UR R E N T
I'
L T 5
5 T E P P E R
[
5 E
5 8 I'
"'"
T H R
[ UR R E N T
T T L E
I'
L T 5
5 T E P P E R
P E N
1 2 I'
~~
O.Smm
1. Idle speed conlrol cam
2. Throttle roller
11.131
the handleilars
checking that cables and harnesses do not bind, A
cable or harness which binds will restrict the
steering and may cause loss of control and an
accident.
23. Support the tank, remove and stow the tank
prop, then lower the tank to the frame and secure
it as described on page 11.99.
24. Refit the intake cover as described on page
11.99.
25. Reconnect the battery, positive (red) lead first.
26. Refit the rider's seat.
o
1. Adjustment nut.
Operation
adjusted throttle position sensor, or a throttle
position sensor that causes the throttle to stick could
result in loss of throttle control. Loss of throttle
control could result in loss of control of the
motorcycle and an accident.
11,132
Typical Values
General Information
Report Method
control
adaption
adapted/not
adapted
Between + 100
and -100%
Between +100
and -100%
0% +/- 10%
Between + 100
and -100%
1.
2.
Note:
Terminology
adaption
0% +/-10%
3.
%
control
Adapted
Read Out
Function Examined
~.
11.133
Exhaust System
Removal
Note:
Note:
1.
1. Heat Shie Id
2. Heat shield fixings
2. Disconnect the battery, negative (black) lead first.
11.134
9.
"'''
4.
II
1\
1. Silencer bracket
2. Fixings
5.
6.
7.
8.
""'=
1. Header downpipe
2. Fixings
12. Detach and remove the header assembly.
~.
11.135
1. Catalyst box
2. Fixing
2.
1. Catalyst box
2. Right hand mounting
3. BolVwasher
Note:
3.
--\
\\_~:::
II
4.
5.
6.
11.136
15.
01
~4
W
~1. Lower heal shield
2. Brackel
3.lsolalor
4. Upper heal shields
11.137
1. Carbon canister
2. Purge valve
3. Canister ties
11.138
~.
~PIPEA
~ ROLL OVER VALVE
CANISTER
THROTTLE BODIES
PIPE C
\,-f
~PIPEB
PURGE CONTROL VALVE
11.139
~PIPEA
~ ROLL OVER VALVE
CANISTER
THROTTLE BODIES
PIPE C
\-f
~PIPEB
PURGE CONTROL VALVE
11.140
12 Cooling
Table of Contents
Exploded View - Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2
12-3
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4
Radiator Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4
12-4
12-5
12-5
Coolant Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-6
Drainage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling ........ " .. . . . . . .. .. .. . . . . . . . .. .. .. .. .. . . .. .. .. .. . .. . . . . .. . . . . . ....
12-6
12-7
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-7
Removal ...... " .. .. . . ... . . .. .. . . .. .. . . .. ... . ... . . . ... . ... .. . . ..... ... .. ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation ................................................................
12-7
12-8
12-8
12-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-9
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
Installation ............................................................... 12-10
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
12-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation ...............................................................
12-11
12-13
12-13
12.1
Cooling
Exploded View - Radiator
3Nm
_---3Nm
/'i?
3Nm
~
9Nm
"\
7Nm
/
9Nm
/~
7Nm
~gm
12.2
Cooling
Exploded View - Water Pump, Expansion Tank and Hoses
4Nm
~/
__ .vNm
"II"
~.
12.3
Cooling
Coolant
i
chemicals that are harmful to the human body.
Never swallow neat anti-freeze or any of the coolant
mixture.
Using high-pressure water, as from a pressurewasher, can damage the radiator fins and impair the
radiator's efficiency.
Do not obstruct or deflect airflow through the
radiator by installing unauthorized accessories in
front of the radiator or behind the cooling fan.
Interference with the radiator airflow can lead to
overheating and consequent engine damage.
Radiator Hoses
Regularly check all radiator hoses and hose clips for
cracks, leaks or deterioration.
12.4
Cooling
Coolant Level Inspection
i
work, ensure
motorcycle
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
Position the motorcycle on level ground and in an
upright position.
1.
not remove
expansion
or radiator
pressure cap when the engine is hot. When the
engine is hot, the coolant inside the expansion tank
will be hot and also under pressure. Contact with
hot coolant will cause scalds and skin damage.
1.
2.
Note:
2.
""iIN'_~--3
1. Intake cover
2. Intake cover screws
3.
Note:
1. Expansion tank
2. MAX mark
3. MIN mark
4. Fluid level
3.
12.5
Cooling
2.
Coolant Replacement
Drainage
not remove
coolant pressure cap when the
engine is hot. When the engine is hot, the coolant
inside the radiator is hot and also under pressure.
Contact with hot coolant will cause scalds and skin
damage.
is
Before starting work, ensure the
stabilised and adequately supported. This will help
prevent it from falling and causing Injury to the
operator or damage to the motorcycle.
1.
1. Radiator cap
2. Security screw
3. Position a container beneath the water pump to
collect the displaced coolant.
4. Detach the bottom hose from the water pump
and allow the coolant to drain out.
Note:
1. Radiator cover
12.6
~.
Cooling
Water Pump
Filling
1.
2.
3.
Removal
!'lo!mo ~t~,t;in,n
ensure
motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
3.
1. Bleed screw
4.
5.
6.
7.
Do not remove
pressure cap when the
engine is hot. When the engine is hot, the coolant
inside the cooling system is hot and also under
pressure. Contact with hot coolant will cause scalds
and skin damage.
B.
cbxi
6.
Note:
7.
~.
12.7
Cooling
Inspection
1.
2.
3.
Installation
1.
cbxk
3.
4.
5.
6.
7.
cbxj
2.
coxk
Note:
12.8
Cooling
Coolant Pressure Cap
Thermostat
Inspection
Removal
not remove
pressure cap
engine is hot. When the engine is hot, the coolant
inside the radiator is hot and also under pressure.
Contact with hot coolant will cause scalds and skin
damage.
ensure
motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
3.
2.
1. Lower Seal
2. Upper Seal
3. Spring
Note:
3.
4.
1. Top hose
2. Bypass hose
5. Release the fixings securing the thermostat
housing to the cylinder head.
6. Withdraw the housing and collect the thermostat.
12.9
Cooling
4.
Inspection
1.
2.
3.
Installation
ccei
1.
2.
1. O-ring/groove
5. Locate the thermostat housing to the head,
ensuring that the O-ring does not become
detached. Tighten the fixings to 4 Nm.
6. Reconnect the top hose and secure with the
hose clip
7. Reconnect the battery, positive (red) lead first.
8. Refit the rider's seat.
9. Refill the cooling system as described on page
12.7.
1. Thermostat
2. Jiggle pin
3. Rotate the thermostat until the jiggle pin is in the
fully upright position.
Note:
12.10
Cooling
Radiator
Removal
not remove
pressure cap when the
engine is hot. When the engine is hot, the coolant
inside the radiator is hot and also under pressure.
Contact with hot coolant will cause scalds and skin
damage.
3.
4.
6.
~I
7.
1. Top hose
2. Bypass hose
5.
12.11
Cooling
8.
12.12
Cooling
Inspection
Installation
1.
2.
1.
3.
2.
3.
4.
5.
Ta&!!!JB'
12.13
Cooling
12.14
13 Rear Suspension
Table of Contents
Exploded View - Swinging Arm .......... " . . ... .. .. ... .. .. ... .. . . . .. ... . .. . . . .. . . . . .
13.2
13.3
13.4
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suggested Suspension Settings. . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
..
..
..
..
13.4
13.4
13.4
13.5
13.5
13.5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation .................................................. . . . . . . . . . . . . . .
13.5
13.6
13.6
13.8
Removal ................................................................ , .
Installation .................................................. . . . . . . . . . . . . . .
13.8
13.8
..............
..............
..............
..............
..............
.
.
.
.
.
..
..
..
..
..
.........
.........
.........
.........
.........
13.1
Rear Suspension
Exploded View - Swinging Arm
69Nm
-~-
l\~Nm
100Nm
13.2
Rear Suspension
Exploded View - Rear Suspension Units
28Nm
~'
13.3
Rear Suspension
Rear Suspension Units
Note:
Adjustment
The rear suspension is adjustable for pre-load only.
To change the rear suspension spring pre-load
setting, insert the adjustment tool supplied in the tool
kit into the hole provided in the adjuster ring.
Removal
Note:
2.
Ensure
are set to
same setting
on both rear suspension units. Settings that vary
from left to right may affect handling and stability
resulting in loss of motorcycle control, and an
accident.
Suspension Preload
Setting
Rider only
Position 1
Position 2
Position 5
13.4
Rear Suspension
Inspection
1.
2.
3.
Removal
i
This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
Note:
as a
even if only one appears to be faulty. If only one
suspension unit is replaced, the handling of the
motorcycle could be adversely affected. This could
result in an unsafe riding condition leading to a loss
of motorcycle control and an accident.
Installation
1.
2.
1.
2.
3.
4.
5.
Note:
3.
4.
1. Brake pipe
2. Clips (rear of two shown)
3. Rearward clip location on swinging arm
13.5
Rear Suspension
6.
1. Locking ring
2. Swinging arm pivot
1. Drive shaft
2. Gearbox output shaft
3. Tool T3880062
7.
Inspection
Note:
8.
9.
1.
2.
3.
Installation
Note:
1. Swinging arm
1.
2.
2. Drive shaft
13.6
Rear Suspension
3.
1. Swinging arm
2. Bearing
4. Position the swinging arm to the drive shaft and
manoeuvre the arm along the drive shaft.
5.
1. Pivots
2. Frame
6. Position the swinging arm bearings to the pivots.
7. Engage the pivots to the swinging arm bearings.
8.
9.
1. Tool T3880062
~.
13.7
Rear Suspension
Swinging Arm Bearings
Removal
1.
Note:
1. Drive shaft
2. Swinging arm
3. Sleeve
14. Align the two brake pipe clips to the right hand
side of the swinging arm. Tighten the clip fixings
t07 Nm.
2.
Note:
3.
4.
1. Brake pipe
2. Clips
3. Forward clip location on swinging arm
Installation
Note:
1.
13.8
Rear Suspension
2.
3.
13.9
Rear Suspension
13.10
14 Front Suspension
Table of Contents
Exploded View - Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-2
14-3
Fork Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14-4
Front Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation ................................................................
14-4
14-5
14-5
Oil refilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14-7
Front Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
14-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
Inspection.. . . .. .. . . .. . .. .. . . . .. . . .. .. . . .. . . .. ... .. . . . . . .. . . . . . . . . . . . .. ... 14-12
Assembly.. .. . . .. ... . . .. ... . .. . .. .. . . . ... . . .. . . . .. ... . . . . . . . . .. . . . . . .. ... 14-12
Steering Head Bearing Check and Adjustment.. . . . .. . . . .. . . . .. .. . .. . . .. . .. .. . . . . . .. ..
14-15
14-15
14-15
14-17
14-17
14-17
14-18
~.
14.1
Front Suspension
Exploded View - Front Fork
SEE TEXT
~r
20Nm
--
22Nm--.
o ~2Nm
~5Nm
ccgi
14.2
Front Suspension
Exploded View - Top and Bottom Yokes/Steering Head Bearings
3Nm
26Nm
/\
26Nm
~l1d
11 'fi
~-~~5Nm
9Nm
~.
14.3
Front Suspension
Fork Inspection
Front Fork
Removal
is
This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
3.
4.
5.
def,scti've or rl",n""p.rl
suspension is dangerous and may lead to loss of
motorcycle control and an accident.
,
1. Top yoke clamp bolt
14.4
'1'D_u"
:.~
Front Suspension
6.
1.
2.
Installation
1.
2-___
1. Fork
2. Caliper mounting
1~
1. Outer tube
2. Outer tube lip
3. Top yoke
2.
3.
4.
5.
6.
7.
~.
3.
Note:
4.
5.
14.5
Front Suspension
6.
"""
1. Spacer
2. Spring cap
3. Spring
Note:
">ok
1. Damper locknut
2. TooIT3880067
3. Spring holder
8. Slacken the locknut, unscrew and remove the top
cap. Recompress the fork spring to remove the
holder.
14.6
Front Suspension
Note:
Oil refilling
4.
5.
89mm
6.
2.
3.
""yg
1. Tool 3880160-T0301
2. Adjuster plate
3. Scale area
4. Hole (zero position)
1. Tool 3880085-T0301
10. Refit the spring spacer.
14.7
Front Suspension
13. Refit the top cap to the damper rod.
14. Hold the top cap while tightening the damper rod
locknut to 16 Nm.
i
spring holder is in place always wear protective
equipment for the face and eyes and never stand
directly above or look directly down onto the fork. If
the spring compressor or holder should dislodge or
detach, the resulting release of spring tension could
cause parts to fly off resulting in injury to the user.
11. Refit tool T3880067 as previously described,
compress the fork spring and refit the spring
holder.
recompressing
spring holder is in place always wear protective
equipment for the face and eyes and never stand
directly above or look directly down onto the fork. If
the spring compressor or holder should dislodge or
detach, the resulting release of spring tension could
cause parts to fly off resulting in injury to the user.
15. Recompress the spring to remove the spring
holder.
16. Lubricate the O-ring on the top cap with a smear
of fork oil then screw the top cap fully into the
inner tube.
17. Tighten the top cap to 30 Nm.
Note:
1. Tool T3880067
2. Spring holder
5.5mm
14.8
Front Suspension
Front Fork
Disassembly
12
~11
,.....-10
~ ...-----9
~8
1. Top cap
2. O-ring
3. Spacer
4. Spring seat
5. Spring
6. Damper rod/cylinder
7. Inner tube
8. Dust seal
~.
14
;;r---
~15
Fork components
9. Circlip
10. Oil seal
11. Washer
12. Bush
13. Outer tube
14. Sealing washer
15. Damper rod bolt
14.9
Front Suspension
1.
2.
0001
1. Fork
2. Caliper mounting
",,'
1. Damper locknut
2. TooIT3880067
3. Spring holder
7. Slacken the locknut, unscrew and remove the top
cap. Recompress the fork spring to remove the
holder.
Note:
3.
Note:
4.
5.
14.10
spring
spring holder is in place always wear protective
equipment for the face and eyes and never stand
directly above or look directly down onto the fork. If
the spring compressor or holder should dislodge or
detach, the resulting release of spring tension could
cause parts to fly off resulting in injury to the user.
Front Suspension
8.
1. Tool 3880090-T0301
1. Spacer
2. Spring cap
3. Spring
9. Holding both the outer and inner tubes together,
invert the fork and pour out the fork oil into a
suitable container. Pump the damper rod to
remove all oil.
2. Damping cylinder
13. Remove the tool, then the damping cylinder from
the inner tube.
1. Damping cylinder
2. Inner tube
14. Using finger pressure, remove the dust seal from
the outer tube.
""'m
1. Inner tube
2. Outer tube
12. Remove the damper rod locknut then insert the
square end of tool 3990090-T0301 over the
damper rod and engage the square in the
damping cylinder cup inside the fork. Hold the
hexagonal end of the tool to prevent the cylinder
from turning while removing the damper bolt from
the bottom of the fork.
1. Dust seal
2. Outer tube
~.
14.11
Front Suspension
15. Remove the circlip from above the seal.
Assembly
Note:
1. Circlip
1.
2.
1. Seal removal
1. Outer lube
2. Washer
Inspection
1.
2.
3.
14.12
Front Suspension
3.
1. Seal
2. Tool 3880080-T0301
4.
5.
1. Inner tube
2. Outer tube
6. Fit the damper to the inner tube and engage tool
3880090-T0301 to the damper cup (as for
removal).
7. Clean the threads of the damping cylinder bolt
and fit a new sealing washer. Apply a drop of
three-bond 1342 to the threads then install the
bolt. Prevent the cylinder from turning by holding
the hexagonal end of tool 3880090-T0301 while
tightening the damping cylinder bolt to 45 Nm.
"","
1. Dust seal
2. Outer tube
1. Tool 3880090-T0301
2. Cylinder
~.
14.13
Front Suspension
6.
5.5mm
1. TooIT3880067
2. Spring holder
15. Refit the top cap to the damper rod
16. Hold the top cap while tightening the damper rod
locknut to 16 Nm.
,"'"
1. Tool 3880085-T0301
13. Refit the spring spacer.
Note:
14.14
Front Suspension
Steering Head Bearing Check and
Adjustment
Adiustment
1.
1.
2.
3.
2.
1. Upper cover
2. Screws
14.15
Front Suspension
Pivot the instruments forward to reveal the
steering stem top nut.
3.
Note:
7.
1. Top nut
Note:
4.
1. Top nut
8.
1. Locknut
2. Adjuster nut
5.
6.
14.16
Front Suspension
Bottom Yoke and Headstock Bearings
5.
Yoke Removal
i
This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
1. Locknut
2. Adiuster nut
6. Remove the locknut and adjuster nut.
7.
Bearing removal
1.
1. Upper cover
2.
2. Screws
3.
4.
1. Top nut
14.17
Front Suspension
3.
Installation
1.
""'-";---1
obwm
1. Headstock
2. Bearing outer race
3. Bottom yoke Installation
1. Steering stem
2. Dust shield
2.
4.
5.
6.
7.
1. Bearing
2. Press
3. Press bed
1. Top nut
14.18
Front Suspension
8.
14.19
Front Suspension
14.20
15 Brakes
Table of Contents
Exploded View - Front Brake Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-3
15-4
15-5
15-6
15-7
15-8
15-8
Brake Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-8
15-8
15-9
15-11
Removal.................................................................
Installation ..................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-11
15-11
15-13
Removal. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . .
Inspection. . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Installation .................... . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
... . ... .. .. . .... .. .. .. ... .. . ... .. ... . ..
.... ... . .. . .. ... .. .. ... ... . . ... .. ... ...
.......................................
.......................................
15-13
15-13
15-14
15-14
15-14
Front Discs. . ... . .. ... . . . .... .. . . ... . ... . ... ... ... . ... .. .. .. .... ... .... .. .... ..
15-15
Wear....................................................................
Removal.... . . .. . . . . . .. .. . . .. . . ... . . . . . . . .... . .. ... .. . .. .. ... ... ... . . .. ..
Installation ..................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
15-15
15-15
15-16
Front Brake Master Cylinder. . .. . . . . . ... . ... ... . ... . . . . . . . .. .. .. .. . ... . . . .. . .. .. ...
15-16
Removal . . . . . . . . . . . . . . . . . . . . . .
Disassembly.. . . . . .. .... . . . . ...
Inspection. . . . . . . . . . . . . . . . . . . . .
Assembly.. .. ... . .. . ... ... . ...
Installation ....................
15-16
15-17
15-17
15-18
15-18
15-20
15-22
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-22
~.
15.1
Brakes
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-24
15-24
Wear. .. . . . . . . . . . . . . . . . .. . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rear Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
15.2
15-23
15-24
15-25
15-25
15-25
15-25
15-26
15-27
15-27
15-28
Brakes
i
15Nm~
"
~.
6Nm
15.3
Brakes
Exploded View - Front Brake Caliper and Disc
5Nm
;r
\
~@
40Nm~
SEE TEXT
~22 Nm
15.4
~ONm
Brakes
Exploded View - Rear Brake Master Cylinders
2Nm
it
"'"
30Nm
~.
15.5
Brakes
Exploded View - Rear Brake Caliper and Disc
~ ~8Nm
~@J)
fV
SEETE~
22Nm
15.6
"I'b_'
~
Brakes
Braking System Maintenance
Safety Precautions
means
moisture from the air. The 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 scheduled
maintenance chart. A dangerous riding condition
could result if this important maintenance item is
neglected.
Do not spill brake fluid onto any area of the
bodywork as this will damage any painted or plastic
surface.
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
TO
LOSS
OF
EFFICIENCY
LEADING
MOTORCYCLE CONTROL AND AN ACCIDENT.
use
grease i any part
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 loss of motorcycle
control and an accident.
If there has
an
drop in
the fluid in either brake fluid reservoir, consult your
authorised Triumph Dealer before riding.
If the brake lever or pedal feels soft when it is
applied, or if the lever/pedal travel becomes
excessive, there may be air in the brake lines or the
brake may be defective.
It is dangerous to operate the motorcycle under
such conditions and you must have your authorised
Triumph dealer take remedial action before you
attempt to ride the motorcycle again. Failure to take
remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.
~.
15.7
Brakes
Brake Fluid Level Inspection
Brake Pads
Front and rear brake pad wear is automatically
compensated for and has no effect on brake lever or
pedal action.
15.8
Brakes
Bleeding the Front Brakes,
Renewing Brake Fluid
4.
5.
6.
1. Diaphragm
9. Release the bleed nipple.
1. Bleed Nipple
2. Spanner
3. Bleed Tube
4. Container
~.
15.9
Brakes
Note:
to operate
i
defective brakes and you must have your authorised
Triumph Dealer take remedial action before you
attempt to ride the motorcycle again. Failure to take
remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.
only.
spedlficaition
in the general information section of this manual.
The use of brake fluids other than those D. O. T. 4
fluids listed in the general information section may
reduce the efficiency of the braking system leading
to loss of motorcycle control and an accident.
Observe the brake fluid handling warnings given
earlier in this section of the manual.
15.10
Brakes
Front Brake Pads
4.
Removal
Before starting
ensure
moto
i
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
Installation
"'"
1. Retaining Pin
2. Anti-rattle Spring
3. Brake Pads
1.
2.
use
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
loss of motorcycle control and an accident.
~-
15.11
Brakes
1.
It I
to operate
with
defective brakes and you must have your authorised
Triumph Dealer take remedial action before you
attempt to ride the motorcycle again. Failure to take
remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.
3.
4.
5.
15.12
Brakes
Disassembly
2.
3.
4.
~-
1. Caliper
2. Fluid supply
1. Caliper
2. Wheel
15.13
Brakes
Inspection
1.
Installation
Assembly
1.
use
grease
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. A dangerous riding
condition leading to loss of motorcycle control and
an accident could result from use of mineral grease.
1.
2.
3.
4.
5.
1. Caliper bore
2. Fluid seal
6.
7.
B.
15.14
Brakes
Removal
Front Discs
1.
2.
Wear
S.Omm
Service limit
4.0mm
Disc Run-out
Standard
0.1 mm
Service limit
0.3mm
cbzh
1. Wheel
2. Support block
3.
4.
5.
dug
1. Disc
2. Dial Gauge
15.15
Brakes
Installation
1.
2.
3.
4.
5.
Removal
1.
is
to operate
motorcycle
defective brakes and you must have your authorised
Triumph Dealer take remedial action before you
attempt to ride the motorcycle again. Failure to take
remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.
3.
4.
5.
1. Lever
2. Adjuster wheel
3. Triangular mark
15.16
6.
7.
Brakes
Disassembly
1.
2.
4.
1. Piston Set
Inspection
"'''
1. Dust cover
3. Remove the circlip from beneath the dust cover.
cbzj
1. Circlip
1.
"',,'
1. Cylinder bore (1)
2. Dust cover (2)
3. Spring (3)
4. Piston (4)
5. Pivot Bolt (5)
Note:
~.
15.17
Brakes
2.
2.
cb~m
1. Ports
1. Piston
2. Seal (in correct orientation)
Assembly
3.
Installation
1.
2.
3.
\I\,:"::---;~
1. Split line
2. Dot mark
4. Tighten the clamp bolts, upper first and then the
lower to 15 Nm.
15.18
Brakes
5.
6.
7.
8.
9.
15.19
Brakes
Bleeding the Rear Brakes,
Renewing Brake Fluid
starting
ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
1. Bleed Nipple
2. Spanner
3. Bleed Tube
3.
15.20
Brakes
5.
1. Diaphragm
6.
Note:
7.
8.
9.
~.
15.21
Brakes
Rear Brake Pads, Rear Brake
Caliper
4.
Removal
1.
1. Caliper
2. Caliper carrier
6.
1. Wheel spindle
2. Caliper carrier
3.
",.
1. 'R' Clips
2. Pad retaining pin
7.
1. Torque reaction bolt
2. Spacer
15.22
8.
Brakes
4.
Installation
5.
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
mineral based grease may reduce braking efficiency
resulting in loss of motorcycle control and an
accident.
2.
1. Wheel hub
2. Spacer
6.
7.
8.
9.
3.
~.
15.23
Brakes
11. If the brake hose has been disconnected, bleed
the rear brake as described on page 15.20.
12. Pump the brake pedal to correctly position the
caliper pistons.
7.5mm
Service limit
6.5mm
Disc Run-out
Service limit
0.15 mm
\
cbzy
1. Disc
2. Dial Gauge
15.24
Brakes
Rear Master Cylinder
Removal
Removal
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
3.
Installation
1.
2.
3.
4.
"
'1
prevent
not spill brake
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.
2.
3.
1. Heel guard
2. Heel guard fixings
~.
15.25
Brakes
4.
1. Pedal
2. Pushrod
3. Clevis
5.
7.
Disassembly
1.
2.
6.
1. Circllp
1. Brake pipe
15.26
Brakes
3.
Assembly
1.
1. Piston
Inspection
1.
~5
Fit the new piston and seal set into the master
cylinder.
",,'
1. Cylinder bore
2. Dust cover
3. Spring
4. Piston
5. Pivot bolt
2.
1. Piston
2. Seals (in correct orientation)
3.
~.
4.
15.27
Brakes
5.
1. Pushrod
2. Circlip
5.
Installation
1.
2.
3.
4.
6.
1. Reservoir hose
2. Clips
1. Heel guard
2. Fixings
15.28
Brakes
7.
~.
15.29
Brakes
15.30
16 WheelslTyres
Table of Contents
Exploded view - Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.2
16.3
Tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.4
Tyre Pressures. . . . . . . . . . . . . . . . . . .
Tyre WearlWheel Inspection. . . . . . . . .
Minimum Recommended Tread Depth.
Important Tyre Information. . . . . . . . . .
......
......
......
......
..
..
..
..
....
....
....
....
....
....
....
....
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
.
.
.
.
.............
.............
.............
.............
16.4
16.4
16.5
16.5
16.6
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation .................................................. . . . . . . . . . . . . . .
16.6
16.7
Rear Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.8
16.8
16.9
Cush Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.10
16.10
16.11
~.
16.1
WheelsITyres
Exploded view - Front Wheel
16.2
WheelslTyres
Exploded View - Rear Wheel and Cush Drive
"'"
~'
110 Nm
16.3
WheelslTyres
Tyres
This model is equipped with tubeless lyres, valves,
and wheel rims. Only tyres marked TUBELESS' and
tubeless type tyre valves mounted on rims marked
'SUITABLE FOR TUBELESS TYRES' can be used.
tyre
pressures
maximum stabilily, rider comfort and tyre life. Tyre
pressures must be checked according to the
scheduled maintenance chart, when the tyres are
cold, and adjusted as necessary.
Incorrect tyre inflation pressures will cause
abnormal tread wear and instability problerns that
may lead to loss of motorcycle control and an
accident. Under-inflation may result in the tyre
slipping on, or coming off the rim. Over-inflation will
cause instability and accelerated tread wear. Both
conditions are dangerous as they may cause loss of
motorcycle control and an accident.
1. Wheel Marking
2. Tyre Marking
have
dynamometer may become damaged. In some
cases, the damage may not be visible on the
external surface of the lyre. Tyres must be replaced
after such use as continued use of a damaged tyre
may lead to instability, loss of motorcycle control and
an accident.
Tyre Pressures
The correct tyre pressures for Rocket III are shown in
the table below. The lyre pressures must always be
checked and adjusted when the tyres are cold.
Loading
condition
Front
Rear
Rider only
2.34 Bar
(34 Ib/in 2)
2.90 Bar
(42Ib/in 2)
Rider,
passenger and
luggage
2.34 Bar
(34 Ib/in 2)
2.90 Bar
(42Ib/in 2)
16.4
WheelsITyres
Important Tyre Information
2 mm (0.08 in)
Never use an I
to repair a punctured tyre.
The rough surface inside the tyre can chafe the tube
leading to instability, rapid deflation, loss of
motorcycle control and an accident.
operate
at
in closed-course on-road competition or on closed
course race tracks. High speed operation should
only then be attempted by riders who have been
instructed in the techniques necessary for high
speed riding and are familiar with the motorcycle's
characteristics in all conditions.
High speed
operation in any other circumstances is dangerous
and may lead to loss of motorcycle control and an
accident.
16.5
WheelsITyres
Front Wheel
Removal
handling of the motorcycle. Do not remove or
change any wheel balance weights. Incorrect wheel
balance may cause instability leading to loss of
motorcycle control and an accident.
When wheel balancing is required, such as after tyre
replacement, see your authorised Triumph dealer.
Only use self-adhesive weights. Clipon weights will
damage the wheel and tyre potentially resulting in
tyre deflation, loss of motorcycle control and an
accident.
ensure
motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
1.
2.
Note:
v
1. Fork pinch bolts
16.6
WheelslTyres
4.
Installation
1.
""'
1. Wheel spindle
5. Remove the wheel, recovering the spacer from
the right hand side.
o
o
o
o
"'wq
1. Spacer
6. Place the wheel on wooden blocks to prevent
damage to the brake discs.
prevent
ensure dirt and debris are not allowed to enter the
wheel bearings.
7.
1. Spacer
2. Hub
2. Position the wheel between the forks.
3. Raise the wheel until it is in alignment with the
spindle holes in both forks. Take care to not
dislodge the spacer.
4. Refit the wheel spindle from the left hand side
and tighten to 65 Nm.
5. Check that the brake disc is centrally located to
the caliper on the left hand side. If not, apply
gentle pressure to the fork to ensure the disc is
centred with the caliper.
6. Maintaining the above position, tighten the fork
pinch bolts to 22 Nm.
7. Thoroughly clean and degrease the brake discs.
8. Fit the brake calipers, tightening the mounting
bolts to 40 Nm.
9. Check the operation of the front brake. Rectify
as necessary.
to operate
motorcycle
defective brakes and you must have your authorised
Triumph Dealer take remedial action before you
attempt to ride the motorcycle again. Failure to take
remedial action may reduce braking efficiency
leading to loss of motorcycle control and an
accident.
16.7
WheelsITyres
Rear Wheel
4.
Removal
1. Wheel
2. Caliper carrier
3. Spacer
Note:
5.
6.
1. Wheel spindle
2. Bevel box
3.
16.8
7.
8.
WheelsITyres
Installation
6.
1.
2.
7.
3.
4.
1. Spacer
8.
1. Wheel
2. Bevel box
5.
1. Wheel spindle
2. Bevel box
~.
16.9
WheelsITyres
11. Pump the brake pedal to correctly position the
caliper pistons.
12. Check the operation of the rear brake. Rectify as
necessary.
Cush Drive
Removal
1.
2.
1. Wheel centre
2. Driven Flange
3. Circlip
3.
Note:
16.10
WheelslTyres
4.
3.
------,
1. Wheel
2. Cush Drive Rubbers
1. Driven flange
4. Retain the assembly with a new bold circlip.
Installation
1.
2.
1. Wheel centre
2. Driven Flange
3. Clrclip
5. Refit the rear wheel as described on page 16.8.
1. Driven flange
2. Spacer
16.11
Wheels/Tyres
16.12
17-2
17-3
Exploded View - Front and Rear Footrests ........ " ......... , ............... , . . .. . . . ..
17-4
17-5
17-6
17-7
17-8
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Rider's seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat lock ....................... , .. . . .. . .. . .. . .. . .. .. .. .. .. . . . .. .. . . .. . . . ..
Rear Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17-9
17-9
17-9
17-9
Side Covers .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation ..................... , ............................. " ., . . ... . . ..
17-9
17-9
17-9
17-10
17-10
17-10
17-10
17-10
17-11
17-11
17-11
17-12
17-12
17-12
17-13
17-15
17-15
17-16
17-17
17-17
17-17
17.1
.cO
SEE TEXT
SEETEXT---
17.2
~/
~
I~
27Nm
5Nm
64Nm
~"
~'
17.3
27Nm
/'/~
/
27Nm
,~ ~----- 3Nm
~...v---
3Nm ___'Y
~~'~-
17.4
9Nm
10Nm
~.
:I
17.5
9Nm
17.6
17.7
the motorcycle
involved i an accident or
collision it must be taken to an authorised Triumph
dealer for inspection and repair before it is ridden
again.
Smm
17.8
Seats
Removal
Before starting work, ensure the motorcycle is
stabilised and adequately supported. This will help
prevent it from falling and causing injury to the
operator or damage to the motorcycle.
Rider's seat
The seat lock is located at the rear of the right hand
side cover. To remove the rider's seat, insert the
ignition key into the seat lock and turn it anti-clockwise
while pressing down on the rear of the seat. This will
release the seat from its lock and allow it to be slid
upwards for complete removal from the motorcycle.
1
1. Screws
2. Side covers
Seat lock
Note:
4.
Installation
1.
2.
Rear Seat
Remove the rider's seat and release the fixings
securing the rear seat to the mudguard.
To refit the rear seat, position it to the rear mudguard
and tighten the three fixings to 9 Nm. Refit the rider's
seat.
3.
4.
5.
17.9
Front Mudguard
Removal
Removal
1. Mudguard shroud
2. Mudguard shroud fixings
3. Fork leg
1. Infill panel
2. Withdraw the infill panel.
2.
3.
Note:
Installation
1.
2.
3.
Note:
17.10
1. Mudguard Fixings
2. Mudguard
2.
1. Sticker
2. Screw head
3.
1.
Embellisher assembly
Installation
1.
1. Embellisher
2. Star washers
~.
2.
3.
4.
5.
17.11
Rear Mudguard
Removal
4.
Note:
6.
Wiring connections
1. Mudguard cover
2. Grommet
Note:
17.12
g.
--=
1. Mudguard fixings
8.
-~
1. Mudguard
2. Mudguard brace
10. Detach the brace from within the mudguard.
11. The rear light, number plate light and indicators
may all be removed by releasing the mounting
plate, behind the rear lamp, inside the mudguard.
Installation
1.
2.
3.
1. Locating arms
2. Frame cross tube
4.
~.
17.13
1. M8 fixing
2. MID fixing
1. Fixings
6.
7.
S.
9.
1. Cover
2. Grommet
17.14
Handlebars
Removal
1.
1. Upper cover
2. Screws
8. Pivot the instruments forward to reveal the
handlebar clamp bolts.
1. Handlebar
2. Spacer
3. End weight
4. Fixing
2. Release the wiring and brake hose from its clips
on either side of the handlebar.
3. Undo the screws and free the left switchgear
assembly from the handlebar.
4. Unscrew the bolts and remove the clamp from
the clutch lever assembly.
5. Undo the screws and free the right switchgear
assembly from the front brake master cylinder.
Free the switch wiring from the handlebars.
6. Unscrew the bolts and remove the clamp from
the master cylinder.
17.15
Installation
1.
2.
l/ I J
o
Cbsz
9.
~1<~Sf~
3
<:::::::>
1\ \ \ \ \ \ \\\
/e
1. Handlebar
2. Spacer
3. End weight
4. Fixing
10. Renew any damaged clips before refitting ali
wiring and the front brake hose to the clips.
11. Check that the throttle opens and closes
smoothly without sticking. Rectify as necessary.
17.16
~.
'IEJI'
'IEJI'
ood,
Installation
1.
2.
3.
4.
17.17
17.18
18 Electrical System
Table of Contents
Exploded View - Instruments ...................................................... .
18-3
18-4
18-5
18-6
18-7
18-8
Battery ....................................................................... .
18-9
18-10
18-11
18-11
Fuses ....................................................................... .
18-11
18-12
Headlights .................................................................... .
18-12
18-12
18-13
18-13
18-14
18-14
18-14
18-14
Alternator .................................................................... .
18-15
Removal ................................................................ .
Inspection ............................................................... .
Assembly ............................................................... .
18-15
18-16
18-16
18-17
Removal ................................................................ .
Installation .............................................................. .
18-17
18-17
18-18
Removal ................................................................ .
Instaliation
18-18
18-18
~.
18.1
Electrical System
Relays. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification and location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Relay identification - left hand side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Relay identification - right hand side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
ECM Connector Pin Numbering........ .... .. .......... ..... ........ . .... ... ..
Lighting Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram - Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Starting and Charging Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram - Starting and Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Auxiliary and Accessory Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram - Auxiliary and Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Complete System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key to Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
18.2
18-19
18-19
18-19
18-19
18-19
18-20
18-21
18-22
18-23
18-24
18-25
18-26
18-26
Electrical System
Exploded View - Instruments
2Nm
~'
18.3
Electrical System
Exploded View - Alternator
9Nm
9Nm
~,
r
.. rD """'ro
120Nm
18.4
Electrical System
Exploded View - Starter Motor
""
27 Nm
18.5
Electrical System
Exploded View - Headlight
4Nm
(
4Nm
18.6
Electrical System
Exploded View - Rear Light and Indicators
9Nm
~'
18.7
Electrical System
Exploded View - Battery, Horn and Wiring
7Nm
I~
PUSH FIT
/\
27N
!"'~
9Nm
L~
4Nm
J\
.-
9Nm
~/
~'"
18.8
~ I
27Nm
Electrical System
Battery Removal
Battery
materials. Always
keep children away from the battery whether or not it
is fitted in the motorcycle.
Do not attach jump leads to 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 gases causing a risk of
personal injury.
Battery Disposal
1.
2.
3.
4.
Battery
Battery strap
Positive (red) terminal
Negative terminal
1.
2.
3.
4.
5.
~.
18.9
Electrical System
Battery Installation
1.
2.
3.
4.
5.
6.
7.
18.10
Electrical System
Fuses
Terminal
Voltage
Measured
ChargeTime
(hours)
Charge Cutoff
Voltage
12.8
14.5
12.7
14.5
12.6
14.5
12.5
14.5
8-10
14.5
2
6
10
11
1. Fuse box
2. Spare fuses
Note:
Numbers
shown
in
the
diagram
correspond to the fuse position numbers
in the table below.
Battery Maintenance
Clean the battery using a clean, dry, cloth. Be sure
that the cable connections are clean.
~.
18.11
Electrical System
Fuse Identification
A blown fuse is indicated when all of the systems
protected by that fuse become inoperative. When
checking for a blown fuse, use the table below to
establish which fuse has blown.
Circuit Protected
Rating
(Amps)
Position
Accessory lights
15
30
socket,
Accessory
instrument memory,
heated grips, clock
10
Alarm,
diagnostic
connector, indicators,
brake lights
15
Instruments,
fuel
pump relay, starter
relay, main power
relay, fall detection
switch
10
Engine management
system
20
Cooling fan
15
Upper
and
lower
headlight
beams,
starter solenoid
20
Position lights
10
Main fuse
30
11
Instrument
illumination,
lights
position
Headlights
1.
2.
3.
4.
18.12
5.
6.
7.
8.
Electrical System
Headlight Horizontal Adjustment
"'"I
1.
2.
3.
4.
5.
1.
6.
2.
7.
8.
g.
3.
4.
5.
6.
7.
8.
i
process has been completed. Premature battery
reconnection could result in ignition of the battery
gases causing risk of injury.
",,'
1. Headlight bulb
2. Bulb clip
3. Position light bulb
~.
18.13
Electrical System
Rear Light
Indicator Lights
Bulb Replacement
Bulb Replacement
1. Lens
2. Lens screw
3. Bulb
Note:
2.
3.
4.
5.
6.
1.
18.14
Electrical System
7.
Alternator
Removal
1.
2.
3.
4.
1. Rotor
2. Rotor bolt
3. Tool T3880201
8. Screw tool T3880200 into the rotor centre.
9.
1. Starter motor
2. Starter motor fixings
3. Alternator cover
5. Release the bolts securing the alternator cover to
the rear of the engine.
6. Withdraw the alternator cover from the
crankcase.
Note:
1. Rotor
2. TooIT3880200
3. Tool T3880201
10. Withdraw the rotor and tool as an assembly and
then separate the tool from the rotor.
Note:
18.15
Electrical System
11. To remove the stator, release the two bolts
securing the cable retainer to the crankcase.
Assembly
1.
2.
3.
1. Cable retainer
2. Bolts
1. Stator
2. Cable retainer bracket
3. Fixings
4.
5.
6.
7.
8.
1. Stator
2. Stator bolts
Inspection
1.
2.
3.
18.16
Electrical System
9. Remove tool T3880201 .
10. Incorporating a new gasket, refit the alternator
cover to the rear of the engine.
11. Tighten the alternator cover bolts to 9 Nm.
12. Incorporating a new D-ring seal, fit the starter
motor and tighten the starter fixings to 27 Nm.
13. Refilthe engine as described on page 10.5.
14. Reconnect the battery positive (red) lead first.
15. Refit the rider's seat.
Alternator Rectifier
Note:
Removal
1.
2.
3.
4.
1. Rectifier
2. Multi-plugs
5.
Installation
1.
2.
3.
4.
5.
18.17
Electrical System
Starter Motor
Installation
1.
2.
Arrowed - O-ring
Position the starter to the alternator cover and
retain with the two bolts. Tighten the bolts to
27Nm.
Removal
1.
2.
3.
4.
5.
17.9.
Disconnect the battery, negative (black) lead first.
Remove the exhaust silencers and catalyst box
as described on page 10.2.
Disconnect the solenoid connection from the
main wiring harness.
Ease the rubber boot from the starter cable,
release the nut and disconnect the cable.
3.
4.
5.
6.
1. Boot
2. Cable
3. Starter motor
6. Release the two bolts securing the starter motor
to the alternator cover.
7.
8.
1. Starter motor
2. Bolts
7. Withdraw and remove the motor.
18.18
Electrical System
Relays
Note:
'lUll!
101 00000000
B25 IlilifoOOOOOOOD
~OOOOOOOD
B34 ~JOOOp,ooor
/'
B26
DOOOOOO~IIII
A14
DOOOOOODi1lf
~~?lA20
A26
1. Starter Relay
2. Flasher Unit
~.
18.19
Electrical System
Lighting Circuit
Key to circuit diagram
Wiring Colour
Black
Ignition Switch
Blue
Instrument Assembly
Brown
Instrument Illumination
Green
Warning Lights
Slate/Grey
Orange
Tail Lamp
Pink
Red
10
Headlamp 2
Purple
11
Headlamp 1
White
12
Starter Relay
Yellow
13
LG
Light Green
14
LU
Light Blue
Key
Item Description
18.20
Electrical System
Circuit Diagram - Lighting
~----UY
'0
,-
-------,
10
1
1
_ _ _ _ _ --1
14
L--L--'H-u ------,
\\
13
1Of--
c:E
~
~'
7 f-6 f--
18.21
Electrical System
Starting and Charging Circuit
Key to circuit diagram
Key
Item Description
Code
Wiring Colour
Battery
Black
Starter Motor
Blue
Fuse 11
Brown
Starter Relay
Green
Slate/Grey
Clutch Switch
Orange
Sidestand Switch
Pink
Red
10
Purple
11
Instrument Assembly
White
12
Yellow
13
Alarm Control
Connector
LG
Light Green
14
Starter Switch
LU
Light Blue
15
16
Ignition Switch
17
18
19
Regulator / Rectifier
20
Alternator
18.22
Unit
Or
Harness
Link
Electrical System
Circuit Diagram - Starting and Charging
'1
+
z
~ -I~I ~,
3,
,
_ J
----jB24
YN
20
6
~8K
A26
~BW
A19
A25
J:l":: ~
8R
AlB
8
9
19
,- .-
,
I
I
I
I
6\
,18
,
,
,
L
-.
~l
'--GR
-'
-NK
,.
~~~~==3-~-G---------------'
L _____ I
r.--;-:c---,
""
17
<t>
""
""
CD
13
'~.J
--lXl
p
16
15
14
2
~.
18.23
Electrical System
Auxiliary and Accessory Circuit
Key to circuit diagram
Key
Item Description
Code
Wiring Colour
Black
Ignition Switch
Blue
Brown
Green
Slate/Grey
Diagnostic Connector
Orange
Pink
Red
10
Purple
11
White
12
Yellow
13
Instrument Assembly
LG
Light Green
LU
Light Blue
14
15
Horn Switch
16
Horn
17
Indicator Relay
18
Accessory Lights
19
20
Accessory Clock
21
Accessory Socket
18.24
Electrical System
Circuit Diagram - Auxiliary and Accessory
r - - - - - - - - - - - - - -
21
I
I
I
I
I
I
I
[Th-p
20
--- - - -
Cillt=P
:
, :1
I
I
--
,\~J
00p
1
RU
[J}fP
I I:~R:
,~
RU
,~
I:lli
'u
i!;
61--'~
4 r-P8
Si-'~
I--<>
'I--<>
5!
~GP-
6
-4
-GR- 3
l
r'
I r-GR
3 r----GW-
13
r-Kr-
r--
r'-'
7
-,---I
4<l-- '-GW
'"
"
~
""
~
I
9
I" 1
GR
GW
7 -GR
12
1~
3~
2 1 - - GR
17
II
-OG
16
,
14
ffi
(Ho
10
02
I0
0
6~
OG
1~1t:~
15
~UY
5!
~/
18
5~
19
17
,
I
--I
10
~'
18.25
Electrical System
Complete System
Key to Circuit Diagram
Key
Item Description
39
Rear Light
40
41
LH Rear Indicator
42
43
44
Battery
45
Starter Relay
46
Rectifier / Regulator
47
Alternator
48
Fuse Box
49
Ignition Switch
50
51
Accessory Socket
52
Handlebar
Heated
(Accessory)
53
16
54
17
2 nd Throttle Potentiometer
55
Horn Button
18
Throttle Potentiometer
56
19
57
20
58
21
59
LH Front Indicator
22
60
Position Light 1
23
MAP Sensor
61
Headlamp 1
24
Purge Valve
62
Position Light 2
25
Ignition Coil 1
63
Headlamp2
26
Ignition Coil 2
64
Horn
27
Ignition Coil 3
65
RH Front Indicator
28
29
30
31
32
Cooling Fan
33
Diagnostic Connector
34
Sidestand Switch
35
Engine Earth
36
Crankshaft Sensor
37
38
RH Rear Indicator
Key
Item Description
Instrument Assembly
Starter Button
Lambda Sensor
10
Fuel Injector 1
11
Fuel Injector 2
12
Fuel Injector 3
13
2 nd Throttle Actuator
14
15
18.26
Grips
Connector
~.
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QW
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