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Table of Contents 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 '.,

Brakes WheelslTyres

Frame and Bodywork Electrical System

Service Manual - Rocket III

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ii


Introduction


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. Aiways use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of SUbstitutes may adversely affect safe operation. Where accurate measurements are required, they can only be made using calibrated, precision instruments. For the duration of the warranty period, an authorised Triumph Dealer must perform all repairs and scheduled maintenance. To maximise the life of your Motorcycle: •

Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual.

•

Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the motorcycle. Rectify all problems as soon as possible (immediately if safety related).

•

Use only genuine Triumph parts as listed in the parts catalogue/parts microfiche.

•

Follow the procedures in this manual carefully and completely. Do not take short cuts.

•

Keep complete records of all maintenance and repairs with dates and any new parts installed.

•

Use only approved lubricants, as specified in the owner's handbook, in the maintenance of the motorcycle.

iv

How to use this manual To assist in the use of this manual, the section title is given at the top. Each major section starts with a contents page, listing the information contained in the section. The individual steps comprising repair operations are to be followed in the sequence in which they appear. Adjustment and repair operations include reference to service tool numbers and the associated illustration depicts the tool. Where usage is not obvious, the tool is shown in use. Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details.

Warning, Caution and Note Particularly important information is presented in the following form:

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

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

Note: •

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


Introduction Tampering with Noise Control System Prohibited

Whenever tapping to aid removal of an item is necessary, tap lightly using a hide or plastic faced mallet.

Owners are warned that the law may prohibit: a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

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.

Repairs and Replacements

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.

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

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.

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v

Introduction


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1 General Information Table of Contents Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-3

Dangerous Susbstances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-3

Fluoroelastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-3

Oils............................................................................

1-3

Health Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-3

Environmental Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-4

Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-4

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-5

Jacking and lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Precautions against damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Cleaning components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Joints and joint faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Gaskets, O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Liquid gasket, non-permanent locking agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Screw Threads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Locking Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Filling a split pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Circlips, retaining rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Self locking nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Encapsulated bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Oil and grease seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

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

Fuel Handling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-7

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Petrol - Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Fuel tank removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Chassis repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7 1-8 1-8 1-8

Electrical Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

1-9

Battery disconnecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9 Disciplines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9 Electrical wires............................................................. 1-10 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10


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

Cylinder head area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-20 Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-20 Crankshaft and crankcases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-20 Engine Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-20 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-21 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-21 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-21 Fuel System, Exhaust System and Airbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-22 Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-22 Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-22 Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-22 Front Brakes ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-23 Rear Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-23 Footrests and Control Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-23 Bodywork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-24 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-24 Routings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Handlebar Cable Routing ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Main Wiring Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Rear Mudguard Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Front Brake Hose Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Rear Brake Pipe and Hose Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Throttle Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Fuel Hose and Fuel Tank Breather Hose Routing (non-evaporative emission control versions) Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing. . . . . . . . . . . . . . . . . . . . . . . ..

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

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.

Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles. In fire conditions involving temperatures greater than 31SoC this material will decompose and can then be potentially hazardous. Highly toxic and corrosive decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated olefins and carbon monoxide can be generated and will be present in fumes from fires. In the presence of any water or humidity hydrogen fluoride may dissolve to form extremely corrosive liquid hydrofluoric acid. If such conditions exist, do not touch the material and avoid all skin contact. Skin contact with liquid or decomposition residues can cause painful and penetrating burns leading to permanent, irreversible skin and tissue damage.

Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and or diagnostic equipment. The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death.

Dangerous Susbstances

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 adhesives. Always pay close attention to the instructions printed on labels and obey the instructions contained within. These instructions are included for your safety and well-being. NEVER DISREGARD THESE INSTRUCTIONS!

The engine and bevel box oils may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.

Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition used engine oil contains potentially harmful contaminants which can cause cancer. Wear suitable clothing and avoid skin contact.

Health Protection Precautions •

Avoid prolonged and repeated contact with oils, particularly used engine oils.

•

Wear protective clothing, including impervious gloves where practicable.

•

Do not put oily rags in pockets.

•

Overalls must be cleaned regularly. Discard heavily soiled clothing and oil impregnated footwear.

•

First aid treatment should be obtained immediately for open cuts and wounds. Always


1.3

General Information be aware of who your nearest first-aider is and where the medical facilities are kept. •

Use barrier creams, applying before each work period to protect the skin from the effects of oil and grease and to aid removal of the same after completing work.

•

Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed.

•

Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.

•

If skin disorders develop, obtain medical advice without delay.

•

Where practicable, de-grease components prior to handling.

Any risk of eye injury must be avoided. Always wear eye protection when using a hammer, air line, cleaning agent or where there is ANY risk of flying debris or chemical splashing.

Brakes

Brake fluid is hygroscopic which means it will absorb moisture from the air. Any absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction in braking efficiency. Replace brake fluid in line with the routine maintenance schedule. A dangerous riding condition could result if this important maintenance item is neglected! Do not spill brake fluid onto any area of the bodywork as this will damage any painted or plastic surface. Always use new brake fluid from a sealed container and never use fluid from an unsealed container or from one that has been previously opened. Do not mix different brands of fluid. Check for fluid leakage around brake fittings, seals and joints. Check regularly for brake hose damage. FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO AN ACCIDENT.

Environmental Protection Precautions

Do not pour oil on the ground, down sewers or drains, or into water courses. To prevent pollution of water-courses etc., dispose of used oil sensibly. If in doubt contact your local authority. Burning of used engine oil in small space heaters or boilers can be recommended only for units of approved design. If in doubt, check with the appropriate local authority and/or manufacturer of the approved appliance. Dispose of used oil and used filters through authorised waste disposal contractors, to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact your iocal authority for advice on disposal facilities.

1.4

If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir, consult your authorised Triumph Dealer for advice 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 remedial action must be taken by your authorised Triumph dealer before riding the motorcycle. Failure to take remedial action may reduce braking efficiency leading to an accident.

Use only D.O.T. 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those D.O.T. 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to an accident. Failure to change the brake fluid at the interval specified in the routine maintenance schedule may reduce braking efficiency resulting in an accident.


General Information Coolant

Never use mineral based grease in any part of the braking system or in any area where contact with the braking system is possible. Mineral based grease will damage the hydraulic seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking efficiency resulting in an accident.

Coolant mixture, which is blended with anti-freeze and corrosion inhibitors contains toxic chemicals which are harmful to the human body. Never swallow anti-freeze, corrosion inhibitors or any of the motorcycle coolant.

Safety Instructions Do not remove the radiator cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

Jacking and lifting

Always ensure that any lifting apparatus has adequate load and safety capacity for the weight to be lifted. Ensure the motorcycle is well supported to prevent any possibility of the machine falling prior during lifting or jacking or while repairs and servicing are carried out. Never rely on a single means of support when working with the motorcycle. Use additional safety supports and straps to prevent toppling. Do not leave tools, lifting equipment, spilt oil, etc. in a place where they could become a hazard to health. Always work in a clean, tidy area and put all tools away when the work is finished.

The coolant anti-freeze contains a corrosion inhibitor which helps prevent damage to the metal surfaces inside the cooling system. Without this inhibitor, the coolant would .attack' the metals and the resulting corrosion would cause blockages in the cooling system leading to engine overheating and damage. Always use the correct anti-freeze as specified in the Owner's Handbook; Never use a methanol based anti-freeze as this does not contain the required corrosion inhibition properties.

Precautions against damage Avoid spilling brake fluid or battery acid on any part of the bodywork. Wash spillages off with water immediately. Disconnect the battery earth lead before starting work, see ELECTRICAL PRECAUTIONS. Always use the recommended service tool where specified.

Distilled water must be used with the anti-freeze (see specification for anti-freeze) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Reduced cooling system efficiency may lead to the engine overheating and engine damage.

Protect exposed bearing and sealing surfaces, and screw threads from damage.

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1.5

General Information Cleaning components

Liquid gasket, non-permanent locking agent

A high flash-point solvent is recommended to reduce fire hazard.

Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly as excessive amounts of sealer may block engine 011 passages and cause serious damage.

Always follow container directions regarding the use of any solvent. Always use the recommended cleaning agent or equivalent. Do not use degreasing equipment for components containing items which could be damaged by the use of this process. Whenever possible, clean components and the area surrounding them before removal. Always observe scrupuious cleanliness when cleaning dismantled components.

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, 011 or grease (whichever is more suitable) should be applied to any rubbing surface, which has lost its lubrication film. Old grease and dirty 011 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.

Prior to reassembiy, blow through any pipes, channels or crevices with compressed air.

To prevent injury, always use eye, face and ear protection when using compressed air. Always wear protective gloves if the compressed air is to be directed in proximity to the skin.

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 011 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).

Joints and joint faces Assemble joints dry unless otherwise specified in this Manual.

If gaskets and/or jointing compound is recommended for use; remove all traces of old jointing material prior to reassembly. Do not use a tool which will damage the joint faces and smooth out any scratches or burrs on the joint faces using an 011 stone. Do not allow dirt or jointing material to enter any tapped holes.

Gaskets, a-rings

Never lubricate a thread unless instructed to do so. When a thread of a fixing is lubricated, the thread friction is reduced. When the fixing is tightened, reduced friction will cause overtightening and possible fixing failure. A fixing which falls in service could cause component detachment leading to loss of control and an accident.

Do not re-use a gasket or a-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid 011 or compression leaks.

1.6


General Information Locking Devices Always release locking tabs and fit new locking washers, do not re-use locking tabs.

the original sealing surface cannot be completely restored.

Fitting a split pin

Protect the seal from any surface which could cause damage over which it has to pass when being fitted. Use a protective sleeve or tape to cover the relevant surface and avoid touching the sealing lip.

Always fit new 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.

Lubricate the sealing lips with a recommended lubricant. This will help to prevent damage in initial use. On dual lipped seals, smear the area between the lips with appropriate grease.

Always fit new roll pins of an interference fit in the hole.

When pressing in a seal which has manufacturer's marks, press in with the marks facing out.

Circlips, retaining rings

Seals must be pressed into place using a suitable driver. Use of improper tools will damage the seal.

Replace any circlips and retaining rings that are removed. Removal weakens and deforms circlips causing looseness in the circlip groove. When installing circlips and retaining rings, take care to compress or expand them only enough to install them. Always use the correct replacement circlip as recommended in the Triumph parts catalogue.

Self locking nuts Self-locking nuts can be re-used, providing resistance can be felt when the locking portion passes over the thread of the bolt or stud. DO NOT re-use self-locking nuts in critical locations, e.g. suspension components. Always use the correct replacement self-locking nut.

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 )

An encapsulated bolt can be identified by a coloured section of thread which is treated with a locking agent.

Fuel Handling Precautions

Unless a specified repair procedure states otherwise, encapsulated bolts cannot be reused and MUST be replaced if disturbed or removed.

General

Failure to replace an encapsulated bolt could lead to a dangerous riding condition. Always replace encapsulated bolts.

The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled safely. It also outlines other areas of risk which must not be ignored. This information is issued for basic guidance only and, if in doubt, appropriate enquiries should be made of your local Fire Officer.

Oil and grease seals Replace any oil or grease seals that are removed. Removal will cause damage to an oil seal which, if reused, would cause an oil leak. Ensure the surface on which the new seal is to run is free of burrs or scratches. Renew the component if


1.7

General Information Petrol - Gasoline When petrol (gasoline) evaporates it produces 150 times its own volume in vapour which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest ievel. It can readily be distributed throughout any indoor environment by air currents, consequently, even a small spillage of petrol (gasoline) is potentially very dangerous.

Petrol (gasoline) is highly flammable and can be explosive under certain conditions. When opening the fuel tank cap always observe all the following items; Turn the motorcycle ignition switch OFF. Do not smoke. Always have a fire extinguisher containing FOAM, C02, HALON or POWDER close at hand when handling or draining fuel or fuel systems. Fire extinguishers must also be present in areas where fuel is stored. Always disconnect the vehicle battery, negative (black) lead first, before carrying out dismantling or draining work on a fuel system. Whenever petrol (gasoline) is being handled, drained, stored or when fuei systems are being dismantled, make sure the area is well ventilated. All potential forms of ignition must be extinguished or removed (this includes any appliance with a pilot light). Any lead-lamps must be flame-proof and kept clear of any fuel spillage. Warning notices must be posted at a safe distance from the site of the work to warn others that petrol is being openly handled. The notice must instruct the reader of the precautions which must be taken. Failure to observe any of the above warnings may lead to a fire hazard which could result in personal injury.

Draining or extraction of petrol/gasoline from a vehicle fuel tank must be carried out in a well ventilated area. The receptacle used to contain the petrol/ gasoline must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regUlations. When petrol/gasoline has been extracted or drained from a fuel tank, the precautions governing naked lights and ignition sources should be maintained. Failure to observe any of the above warnings could bring about a safety hazard leading to a risk of personal injury.

Fuel tank removal Fuel tanks should have a 'PETROL (GASOLINE) VAPOUR' warning label attached to them as soon as they are removed from the vehicle. In all cases, they must be stored in a secured, marked area.

Chassis repairs

If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for repair or inspection. Any accident can cause damage to the motorcycle, which if not correctly repaired, may cause a second accident which may result in injury or death. The frame must not be modified as any modification to the frame such as welding or drilling may weaken the frame resulting in an accident.

No one should be permitted to repair components associated with petrol/gasoline without first having specialist training on the fire hazards which may be created by incorrect installation and repair of items associated with petrol/gasoline. Repairs carried out by untrained personnel could bring about a safety hazard leading to a risk of personal injury.

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.

connectors apart either by using tools or by pulling on the wiring itself. Always ensure locking mechanisms are disengaged before removal and note the orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if disturbed. Having confirmed a component to be faulty, switch off the ignition and disconnect the battery negative (black) lead first. Remove the component and support the disconnected harness. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking mechanism becomes fully engaged.

Battery disconnecting Before disconnecting the battery, switch off all electrical equipment. The ignition system produces extremely high voltages. Do not touch any part of the ignition system or any cables while the engine is running. An electric shock caused by contact with the ignition system may lead to illness, injury or death.

Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and or diagnostic equipment. The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death.

To prevent the risk of a battery exploding and to prevent damage to electrical components ALWAYS disconnect the battery negative (black) lead first. When reconnecting the battery, always connect the positive (red) lead first, then the negative (black) lead. Always disconnect the battery when working on any part of the electrical system. Failure to observe the above warnings may lead to electrical damage and a fire hazard which could cause personal injury. Always ensure that battery leads are routed correctly and are not close to any potential chafing points.

Disciplines The battery contains harmful materials. Always keep children away from the battery whether or not it is filled 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.

Switch off the ignition prior to making any connection or disconnection in the system. An electrical surge can be caused by disconnecting .live' connections which can damage electronic components. Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts. Prior to commencing any test, and periodically during any test, touch a good earth to discharge body static. This is because some electronic components are vulnerable to static electricity.

Connectors and Harness - The engine of a motorcycle is a particularly hostile environment for electrical components and connectors. Always ensure these items are dry and oil free before disconnecting and connecting test equipment. Never force


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.

Always have Triumph approved parts, accessories and conversions fitted by a trained technician. To ensure that a trained technician is used, have an authorised Triumph dealer fit the parts. The fitment of parts, accessories and conversions by personnel other than a trained technician at an authorised Triumph dealer may affect the handling, stability or other aspects of the motorcycle operation which may result in an accident causing serious injury or death.

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

All genuine Triumph parts have the full backing of the motorcycle warranty. Triumph dealers are obliged to supply only genuine Triumph recommended parts. Only Triumph genuine parts should be used to service, repair or convert Triumph motorcycles. To ensure that Triumph genuine parts are used, always order parts, accessories and conversions from an authorised Triumph dealer. The fitting of nonapproved parts, accessories or conversions may adversely affect the handling, stability or other aspects of the motorcycle operation which may result in an accident causing serious injury or death.

Always have Triumph genuine 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 resuit 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 infailible 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.

Special service tools: T3880105 - Angular torque gauge

3880160-T0301 - Fork filler evacuator

T3880048 - Fuel pressure gauge

T3880312 - Oil filter wrench

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Service Manual- Rocket III

1.11

General Information T3880250 - Diagnostic tool

T3880200 - Pulier - alternator

"',, T3880201 - Anti-rotation jig - alternator

T3880061 - Extractor, liners

3880025-T0301 - Clutch anti-rotation jig

T3880062 - Castle wrench - 38 mm

1.12


General Information T3880063 - Castle wrench - 31 mm

T3880064 - Drift, swinging arm bearings

3880085-T0301 - Fork assembly rod

3880090-T0301 - Fork service tool

T3880067 - Fork spring compressor

T3880202 - Cam timing jig

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1.13

General Information Full Specification

Rocket III

Engine

. ·

3 Cylinder 12 Valve DOHC

Arrangement

. ·

In line, longitudinal,

Displacement

. ·

2294 cc

Bore x Stroke

. ...

Compression Ratio

. ·

8.7:1

Cylinder Numbering

. ·

Number 1 at front

Firing order

. ·

1-2-3

Max. Power (DIN 70020)

. ·

142 PS at 5,750 rpm

Max. Torque

. .. . . . . . .. .. .. . .200 Nm at 2,500 rpm

. . 101.6 x 94.3 mm

Cylinder Head Vaive Head Dia

Valve Lift. Valve Stem Dia

In

37.90 mm

Ex

32.30 mm

In

8.30 mm

Ex

8.30 mm

In

5.475 - 5.490 mm (std)

Ex

5.475 - 5.490 mm (std)

Valve Guide Bore Dia. . . . . . . . . . . . . . . . .. .

5.485 - 5.500 mm (std)

Valve Seat Width (in head)

1.000 - 1.100 mm (std)

.

1.500 mm (service limit) Valve Seat Width (valve)

. . . . . . . . . .. .

1.98·2.26 mm (std)

Valve Seat Angle . . . . . . . . . . . . . . . . . . . .. .

90 0 inclusive

Valve Spring Length. . . . . . . . . . . . . . . . . .. .

.43.2 mm (std)

Valve Spring 'Load at Length'

Valve Clearance

In

180 N +/-'10 N at 36.2 mm

Ex

180 N +/. 10 N at 36.2 mm

In

0.10 - 0.15 mm

Ex

0.15·0.20 mm

Valve Bucket Bore Dia.. . . . . . . . . . . . . . . . . In

Valve Bucket Dia

28.015 - 28.035 mm

Ex

28.015 - 28.035 mm

In

27.978·27.993 mm

Ex

27.978 - 27.993 mm

open

12 BTDC

close

28 ABDC

duration

220

Valve Timing (at 1 mm lift) Inlet

Exhaust

0

0

0

open

.41 0 BBDC

close

11 0 ATDC

duration

232 0

Camshaft Journal Dia. . . . . . . . . . . . . . . . .. .

22.93 - 22.96 mm (std)

Camshaft Journal Clearance. . . . . . . . . . .. .

0.040 - 0.091 mm (std) 0.13 mm (service limit)

1.14



Rocket III

Camshaft Journal Bore Dia

23.000 - 23.021 mm (std)

Camshaft End Float

0.10 - 0.13 mm (std)

Camshaft Run-out.

0.015 mm (std)

Camchain Tensioner Spring Free Length

73.7 mm

Clutch/Primary Drive Primary Drive

Type

Gear, with backlash eliminator

Reduction Ratio .. 1.034:1 Clutch

Type

Wet, multi-plate

No. of Friction Plates

10

Plate Flatness Limit.

0.30 mm

Friction Plate Thickness (new)

3.72 - 3.88 mm

Friction Plate Thickness (service limit)

3.5 mm

Clutch Actuation Method

Cable

Cable Free Play (at lever)

2-3 mm

Piston/Crankshaft

101.591 -101.609 mm (std)

Cylinder Liner Dia

101.659 mm (service limit) 101.561 - 101.577 mm (std)

Piston Diameter

101.511 mm (service limit) Piston Ring to Groove Clearance

Top


Second


Piston Ring Groove Width

Top


Second


Piston Ring End Gap

Oil

2.51 - 2.53 mm (std & service limit)

Top


Second


Oil


GUdgeon Pin Bore Dia. In Piston


GUdgeon Pin Dia


Connecting Rod Small End Dia


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1.15


Rocket III

Connecting Rod Big End Dia

. ·

Connecting Rod Big End Side Clearance .. ·

44.000 - 44.009 mm (std) 0.15 - 0.30 mm (std) 0.50 mm (service limit)

. ·

Crankshaft Big End Journal Dia

40.946 - 40.960 mm(std) 40.922 mm (service limit)

Crankshaft Big End Bearing Clearance .... ·


. ·

Crankshaft Main Journal Dia. .

.43.092 - 43.108 mm (std) 43.068 mm (service limit)

Crankshaft Main Bearing Clearance

. ·


. ·

Crankshaft End Float


. ·

Crankshaft run-out

0.04 mm (std) 0.07 mm (service limit)

Transmission Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

5 Speed Constant Mesh

Gear Ratios

Primary

1.034:1

1sI.

2.929:1

2nd

1.947:1

3rd

1.435:1

4th

1.160:1

5th

0.964:1

Secondary

1.043:1

Gear Selector Fork Thickness. . . . . . . . . .. .


Gear Selector Groove Width . . . . . . . . . . .. .

6.05 - 6.15 mm (std) 6.30 (service limit)

Gear Selector Fork to Groove Clearance

0.05 - 0.25 mm (std) 0.50 (service limit)

Final Drive Final Drive Type. . . . . . . . . . . . . . . . . . . . .. .

Bevel geared crown wheel and pinion

Drive system

Universal-jointed shaft with torsional damper

. . . . . . . . . . . . . . . . . . .. .

Final Drive Ratio. . . . . . . . . . . . . . . . . . . . .. .

2.846:1

Finai Drive Oil. . . . . . . . . . . . . . . . . . . . . . .. .

Mobilube SHC 95/W 90 fully synthetic hypoid oil (or equivalent)

Final Drive Oil Capacity. . . . . . . . . . . . . . .. .

0.17 litres

Lubrication Oil Capacity (incl. filter, dry fill). . . . . . . . . .. .

5.9 litres

Oil and filter change. . . . . . . . . . . . .. . . . .. .

5.4 litres

1.16



Rocket III

Oil change only

5.1 litres

Recommended Oil Approval Rating

API SH (or higher) and JASO MA

Viscosity

10W/40 or 15W/50

Type

Semi or fully synthetic

Oil Pressure (in main gallery)

3.00 - 3.60 Bar at 3,500 rpm

Oil Pump Rotor Tip Clearance

0.15 mm (std - both pumps) 0.20 (service limit - both pumps)

Oil Pump Body Clearance

0.15 - 0.22 mm (std - both pumps) 0.20 mm (service limit - both pumps)

Oil Pump Rotor End Float

0.02 - 0.07 mm (std - both pumps) 0.10 mm (service limit - both pumps)

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 KO

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 RaN ( US - 89 RaN/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

Fuel Injection System Type

Multi point sequential

Idle Speed

800 rpm

Injector Type

Single nozzle

Throttle

Twin butterlly

Idle speed control

Stepper motor

Control Sensors

Coolant temperature, manifold absolute pressure (all cylinders), intake air temperature, barometric pressure, gear position, road speed, primary and secondary throttle position.

Cooling System Coolant Mixture

50% anti freeze in distilled water

Anti-Freeze Type

Mobil Antifreeze

~'


1.17


Rocket III

Cooling System Capacity

. ·

3.2 litres

Radiator Cap Opening Pressure

. ·

1.2 bar

Thermostat Opening Temperature

. '"

85° C

Cooling Fan Switch On Temperature

.

Temperature Gauge Sensor Resistance

. ..... .. .. ..... . 1870 at 100°C

Suspension Front Fork Travel

. .............. . 120 mm

Recommended Fork Oil Grade

. ·

Oil Level (fork fUlly compressed)

. .............. .89 mm

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

RearVVheeITravel

. .............. . 105 mm

Kayaba 01 oil (SAE OVV)

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 Front VVheel Size . . . . . . . . . . . . . . . . . . . .. .

MT 3.5 x 17

Front VVheel Rim Axial Run-out. . . . . . . . .. .

0.5 mm

Front VVheei Rim Radial Run-out. . . . . . . .. .

0.5 mm

Front Tyre Size

150/80 R17

FrontTyre Pressure (cold) . . . . . . . . . . . . .. .

34 Ib/in'

Front Tyre Tread Depth min.. . . . . . . . . . . .. .

Over 130 kmh - 3 mm (or minimum legal limit, whichever is greater) Under 130 kmh - 2 mm (or minimum legal limit, whichever is greater)

Rear VVheel Size . . . . . . . . . . . . . . .. . .

1.18

.

MT 7.5 x 16



Rocket III

Rear Wheel Rim Axial Run-out.

0.5 mm

Rear Wheel Rim Radial Run-out.

0.5 mm

Rear Tyre Size

240/50 R16

Rear Tyre Pressure (cold)

42 Ib/in'

Rear Tyre Tread Depth min

Over 130 kmh - 3 mm (or minimum legal limit, whichever is greater) Under 130 kmh - 2 mm (or minimum legal limit, whichever is greater)

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 (rider, passenger, luggage & accessories)

235 kg

Electrical Equipment Battery Rating

12 volt, 18 amp hour

Alternator Rating

37 amps/min at 2,000 rpm 41 amp/min at 6,000 rpm

~.


1.19

General Information Torque Wrench Settings Cylinder head area Application

Torque (Nm)

Cam cover to cylinder head

10

Cam chain tensioner to crankcase

9

Cam ladder to head

See text

Camshaft sprocket to camshaft

15

Cam chain tensioner blade to crankcase

18

Cam chain top pad to head

See text

Cylinder head to crankcase

See text

Noise suppression bolt to cam chest

10

Clutch Application

Torque (Nm) 9

Clutch cover to crankcase Clutch centre nut

105

Clutch pressure plate to basket

10

Crankshaft and crankcases Torque (Nm)

Application Connecting rod big end bolts

See text

Crankcase to crankcase bolts

See text

Transmission shaft bearing cap

See text

Main bearing ladder bolts

See text

Lubrication circuit threaded inserts

45

Engine Covers Torque (Nm)

Application Clutch cover to crankcase

9

Clutch outer cover to inner cover

9

Alternator cover to crankcase

9

Torsional damper shaft cover to crankcase

28 (M8) 9 (M6)

Cam chain inspection plug to clutch cover

18

1.20

Service Manual - Rocket '"

General Information Transmission Application

Torque (Nm)

Detent wheel to selector drum Selector drum bearing retaining screw Spring abutment bolt Gear change pinch bolt

12 12 23 9

Gear change pedal pivot bolt Input shaft bearing retainer to crankcase Output gear to output shaft

27 12 145

Lubrication System Application

Torque (Nm)

12 25 12

Sump to crankcase Sump plugs (front and rear) Oil pick up strainers to sump

9

Oil pick up pipes to crankcase Oil tank drain plug to sump Oil pressure relief valve to crankcase Oil filter adapter Oil pumps to crankcase

25 15 10 12

Oil pump chain retainer plate to crankcase

9

Oil pressure relief valve

15

Cooling System Application

Torque (Nm)

Water pump to crankcase

10

Radiator to frame

9

4 2 10

Thermostat housing to head Fan shroud to radiator Cooling system bleed screw

~.


1.21

General Information Fuel System, Exhaust System and Airbox Application

Torque (Nm)

Fuel tank to frame (pivot bolt) Fuel tank to frame (front fixing) Fuel pump mounting plate to fuel tank Fuel pump clamp screw Throttle body transition piece to cylinder head Exhaust headers to cylinder head Exhaust headers to cat box clamp bolt Exhaust cat box to frame Silencer mounting bracket to frame Fuel level sensor to fuel tank Air filter cover to airbox Airbox to bracket

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

Upper yoke pinch bolt Lower yoke pinch bolt Fork top cap to inner tube Upper yoke centre nut Damping cylinder bolt Handlebar clamp to top yoke Handlebar clamp bolt Handlebar clamp cover plate bolts

Wheels Application

Torque (Nm)

Front wheel spindle/axle bolt Fork to wheel spindle pinch bolts Rear wheel spindle f1anged locknut

1.22


65 22 110

General Information Front Brakes Torque (Nm)

Application

Disc to wheel

40 18 5 25 15 25 22

Fluid reservoir to bracket

6

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

Calliper bleed screw Hose to calliper Master cylinder to frame Master cylinder reservoir to frame Hose to brake pipe joint Hose to brake light switch Brake pedal pivot bolt Brake disc to wheel

Footrests and Control Plates Torque (Nm)

Application

Side stand pivot locknut

27 27 40 20 25

Front footrest end screw to footrest

9

Heel guards to control plate bar

9

Bank angle peg to footrest

10

Foot rest mounting bar to engine (left and right) Rear footrest to hanger Side stand to engine Side stand pivot bolt


1.23

General Information Bodywork Application

Torque (Nm)

Engine to frame bolts

See text

Front mudguard to forks

27

Front mudguard finisher to mudguard

3

Rear mudguard/covers to frame

See text

Rear seat to mudguard

9

Side covers to frame

9

Engine infHI panels to frame

4

Electrical Application

Torque (Nm)

Alternator stator to crankcase

28 120 12

Alternator rectifier to bracket

9

Alternator cover to crankcase

9

Rear light to mudguard

7

Number plate light to bracket

9

Indicators to brackets

9

Starter motor to engine Alternator rotor to crank

Headlight vertical adjuster

2 15 20

Headlight bezel clamp

4

Indicator lenses to indicators Headlight horizontal adjuster

1.24


General Information Routings Clutch Cable Routing

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1.25

General Information Handlebar Cable Routing

( \

\

1.26


General Information Main Wiring Harness Routing


1.27

General Information Rear Mudguard Harness Routing

--------......................... .-:--------

......

"\\\\ \'

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1.28


0\'

General Information Front Brake Hose Routing


1.29

General Information Rear Brake Pipe and Hose Routing

1.30


General Information Throttle Cable Routing

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1.31

General Information . . control versions) . Fuel Hose and Fuel Tank Breather Hose Routin 9 ( non-evaporative emISSion

1.32

Service ManuaI - Rocket III

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

Scheduled Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

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.

In order to correctly carry out the maintenance items listed in the scheduled maintenance chart, special tools and specialist knowledge will be required. As only an authorised Triumph dealer will have this knowledge and equipment, Triumph strongly recommends that your authorised Triumph dealer carries out all scheduled maintenance. A dangerous riding condition could result from incorrect maintenance leading to loss of motorcycle control and an accident.

2.2

All maintenance is vitally important and must not be neglected. Incorrect maintenance or adjustment may cause one or more parts of the motorcycle to malfunction. A malfunctioning motorcycle is dangerous and may lead to an accident.

Triumph Motorcycles cannot accept any 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 (Krns) or time period, whichever comes first. Operation Description

Every

500 (800)

1 month Engine - check for leaks

Day

-

Engine oil - renew Engine oil filter - renew Valve clearances - check Air cleaner· renew Engine ECM ~ check for stored DTG Spark plugs - chack

Spark plugs - renew Throttle bodies - balance Throttle cables - check/adjust Cooling system - check for leaks

• • •

•

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 level - check/adjust

-

Coolant - renew Fuel system - check for leaks

Day

Lights, instruments & electrical systems - check

Day

• •

• •

-

Fuel filter - renew

• •

• • • • • •

•

• • • •

•

• • •

•

•

Steering - check for free operation

Day

•

Headstock bearings - check/adjust

-

•

Day

•

•

•

•

•

•

•

•

Headstock bearings - lubricate Forks - check for leaks/smooth operation

Brake fluid levels ~ check

Day

Day

Brake calipers - check for leaks and seizures

-

Brake master cylinders - check for leaks

-

Final drive oil - renew

•

•

• • • • • • • • •

• • • • • •

• • •

• •

•

•

•

• •

•

•

• •

• • •

•

•

•

• • •

• • • • •

• • • •

Every 2 years

Brake pad wear - check

Final drive oil - check

•

•

Brake fluid ~ renew

Final drive - check for oil leaks

•

-

Fork oil - renew

• • •

•

•

• •

• •

• •

• • • • •

Fasteners - inspect visually for security

Day

•

Wheels - inspect for damage

Day

Tyre wear/tyre damage - check

Day

• •

Tyre pressures - check/adjust

Day

•

Clutch cable - check/adjust

Day

Stand - check operation

Day

• •

• • • •

• • •

•

•

• • • • • •


• • • • • • •

• • • • •

•

• •

• •

• • •

• • • • • •

• • •

• • •

•

•

•

•

•

•

•

2,3

3 Cyl inder Head Table of Contents Exploded View· Cam Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

3-2

Exploded View - Camshaft and Cam Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

3-3

Exploded View - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

3-4

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

3-5

Cam Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

3-5

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Installation

3-5 3-6

Cam Chain Tensioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

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

Valve Clearance Adjustment. .. ,

, '" .. .. . . . ..

3-14

Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15

"

Inspection. .. .. . . .. . . . . . .. . . .. .. .. . . . . . . . .. .. . . .. .. . .. . . . .. Installation .... " .. . . . . . .. . . .. .. .. .. .. .. . . . . . .. .. . . . .. ... ..

.. . . . . . . . . .. . . . . . .. .

3-16 3-16

Valves and Valve Stem Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

3-17

Removal from the cylinder head................................................ Installation

3-17 3-17

Cam Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

3-18

Inspection

"


" ..

. . . . . . .. . . . .. .. ..

3-18

3.1

Cylinder Head Exploded View - Cam Cover

r '§"

3.2

Service Manua I - Rocket III

10Nm

Cylinder Head Exploded View - Camshaft and Cam Drive

'(O~ 18Nm

r2~

~'


(j

27Nm

/ ~

3.3

Cylinder Head Exploded View - Cylinder Head

SEE TEXT

SEE TEXT

10Nm

/)

i .·r

10Nm

8Nm

@~ 10Nm

3.4


Cylinder Head 7.

Description

Release the bolts securing the cam cover to the head.

The engine is fitted with an aluminum alloy cylinder head, which carries the camshafts, valves and spark plugs. The cylinder head is cast as a single entity, to which various components are permanently added after machining. A silent-running cam chain drives the twin-overhead camshafts, which run directly in the cylinder head without additional bearings. The chain is tensioned by a spring-loaded device fitted to the cylinder head, and is guided by two Teflon-coated rubber-faced blades. Valve clearances are adjusted by changing variable thickness shims that sit between the camshaft and valve tappet bucket. The valves are fitted with single, symmetrical valve springs. Both the tip and seat face of the valves are hardened to give a long service life. Due to assembly methods used, the valve seats and valve guides cannot be replaced. Oil is supplied to the cylinder head by an internal passageway inside the engine. Once it arrives at the cylinder head, it is passed through a restrictor, and is then delivered to the camshaft bearing journals along grooves in the cam ladder. The camshaft lobes are splash fed by oil coming from the camshaft journals.

-

1. Cam cover 2. Cam cover bolts 3. Bolt 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

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.

Never use a lever to remove the 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.

Remove the rider's seat (see page 17.9). Disconnect the battery, negative (black) lead first.

3.

Raise and prop the fuel tank (see page 11.98).

4.

Remove the intake duct (see page 11.105) together with its bracket.

5.

Disconnect the spark plug leads from the spark plugs then remove the coil brackets with the coils attached. Remove the bungs from the heads of the cam cover fixings.

6.


3.5

Cylinder Head Installation

Cam Chain Tensioner

1.

Check the condition of the cam cover seal and cam cover bolt seals. Replace as necessary.

2.

Apply silicone sealant to the cylinder head where four 'D' sections of the cam cover seal fit.

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.

Removal 1.

Remove the cam cover (see page 3.5).

2.

Remove the inspection plug from the clutch cover.

1. 'D' sections

3.

Fit the seal ensuring the four 'D' sections seat in the corresponding half-rounds in the cylinder head. Position the spark plug tower seals to the six plug towers.

4.

Fit the cam cover to the cylinder head. Ensure that the seal remains in position, paying particular attention to the six spark plug tower areas.

5.

Fit the cam cover bolts, complete with their seals (steel ring side facing upwards) and tighten to finger tight.

6.

Progressively and evenly tighten the cam cover bolts to 10 Nm.

7. 8. 9.

Refit the coil bracket and coils.

",q, 1. Inspection plug

3.

Turn the engine until the maximum numbers of cam lobes are facing away from the valves. This will prevent the cams from springing around when the cam chain tensioner is removed.

Reattach the plug leads to the plugs. Refit the intake duct bracket, tightening its bolts to 9 Nm.

10. Refit the intake duct (see page 11.109). 11. Seat the fuel tank on the frame and secure it (see page 11.99). 12. Reconnect the battery, positive (red) lead first. 13. Refit the rider's seat.

1 CbpS

1. Camshafts 2. Lobes 3. Valves 4. Remove the center nut and washer from the cam chain tensioner.

3.6


Cylinder Head Installation

The centre nut of the cam chain tensioner is under 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.

Fit a new gasket to the tensioner body. Set the tensioner plunger onto the first tooth of the ratchet by manually lifting the tensioner pawl and pushing the plunger into the tensioner body.

Withdraw the spring and nut from the tensioner body.

1. Cam chain tensioner 2. Centre nut 6. Remove the cam chain tensioner body from the head.

1. Tensioner 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 TOC. No. 1 cylinder is at TOC when a 'dot' mark on the crank gear is in alignment with the line in the upper crankcase.

Inspection 1.

Inspect the tensioner spring for damage and deformation. Renew as necessary.

2.

Inspect the tip of the tensioner plunger for wear and damage. Renew as necessary.

1. Crankshaft 'dot' mark 2. Upper crankcase line

~.


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.

Push the tensioner plunger into contact with the chain guide using finger pressure.

cbpy

1. Inlet cam timing marks 2. Exhaust cam timing marks 4. Fit the dowels of tool T3880202 to location holes in the cam sprockets, as shown in the diagram below. This will hold the cams in the correct timing position and prevent them from turning while the chain tensioner is fitted.

1. Tensloner 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.

The centre nut of the cam chain tensioner is under 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.

1. Tool T3BB0202 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.

1. Crankshaft 'dol' mark 2. Upper crankcase line 11. Check that the camshaft marks align described previously. Rectify as necessary.

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.

Remove the cam chain top pad.

Camshafts

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. Note: •

Either camshaft can be removed from the cylinder head without complete removal of the cam chain. However, the cam chain must first be detached from the camshafts. Remove the cam cover (see page 3.5).

1.

Note: •

Turn the engine until the maximum number of cam lobes are facing away from the valves. This will prevent the cams from springing around when the cam chain tensioner is removed.

1. Top pad

To avoid damage to the cam ladder, 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.

Progressively and evenly release the remaining cam ladder fixings, half a turn each, until the upward pressure on the bolt heads has been released. Always start from the centre of the engine.

"," 1. Camshafts 2. Lobes 3. Valves

2.

Remove the cam chain tensioner (see page 3.6).

~.

1. Cam ladder 2. Cam ladder flxings (2 of 16)

SeNice Manual - Rocket III

3.9

Cylinder Head Camshaft identification

Failure to release the cam ladder fixings progressively and evenly may result in damage to the cam ladder, the camshafts or the cylinder head itself. A damaged cam ladder cannot be replaced as an individual item. It can only be obtained as part of a new cylinder head. 5.

Once all the upward force on the cam ladder has been progressively released, collect all the bolts and remove the ladder.

6.

Secure the cam chain to prevent it from falling into the front of the engine.

The inlet camshaft can be identified by a groove on a machined surface in its centre. The same surface on the exhaust cam is plain.

Note: •

7.

The sound suppression bolt will prevent the cam chain from falling completely away from the head. Lift the cam chain from one of the camshafts to allow removal of the shaft from the cylinder head.

1. Inlet cam (grooved) 2. Exhaust cam (plain) Cam sprocket orientation The same drive sprocket is used for both inlet and exhaust cams. To attach the sprocket in the correct relationship to the cams, two pairs of offset bolt holes are used, with inlet and exhaust bolt holes being clearly marked ('IN' for inlet and 'EX' for eXhaust). The holes will also prevent the sprockets from being fitted 1800 out of alignment.

,bqb

1. Removing a camshaft 8. Repeat for the second camshaft.

1. Sprocket 2. IN marking 3. EX marking To fit a sprocket to an inlet cam, position the sprocket to the cam and align the hole marked 'IN' with one of the threaded holes in the camshaft. If both bolt-holes in the cam line up correctly with the holes in the sprocket, the sprocket is in the correct place. If the holes do not line up, then the sprocket should be rotated by a half-turn.

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.

Inspection 1.

Inspect the sprockets for damage and worn or broken teeth.

2.

Inspect the bearing surfaces in the cylinder head and cam ladder. If wear or damage is found, the cylinder head must be replaced.

3.

Inspect the cam chain (see page 3.7).

4.

Check camshaft journal to cam ladder clearance using Plastigage (Triumph part number 3880150T0301) as follows:

1. Cam ladder lightening sequence i) In the same sequence, torque each cam ladder bolt to 10 Nm.

j) Release and remove the cam ladder as previously described. k) Utilising the gauge provided with the Plastigage kit, measure the width of the now compressed Plastigage.

During the flowing procedure, the engine must not be rotated. Damage to valves, pistons and the cylinder head can result from rotating the engine. a) Position a camshaft to the cylinder head in it's correct location, (inlet cam to inlet valves, exhaust cam to exhaust valves). Ensure that the timing marks on the cam sprocket are positioned as for removal. b) Release and remove the cam ladder as previously described. Wipe the exposed areas of one of the camshaft journals and the corresponding position on the cam ladder. c) Apply a thin smear of grease to the wiped camshaft journal and a small quantity of silicone release agent to the corresponding position on the cam ladder. d) Size a piece of Plastigage to fit across the wiped camshaft journal.

1. Taking a plastigage measurement 5.

Calculate the cam journal clearance using the chart provided with the Plastigage kit.

e) Fit the Plastigage to the camshaft journal using the grease to hold it in place. f) Position the cam ladder to the cylinder head, aligning bearing areas with cam journals. At this stage, it is not necessary to fit the cam chain top pad.


3.11

Cylinder Head 6.

If the journal to cam ladder clearance is within the specified tolerances (see table below), remove the cam ladder and clean off all traces of Plastigage, silicone release agent and grease.

Standard

0.040 - 0.091 mm

Service limit

0.13 mm

7.

Check the diameter of the camshaft Journals.

I Standard

I 22,93 - 22.96 mm

I

If any of the journal to cam ladder clearances are outside the specified tolerances, but the camshaft journals are within their specified tolerances, the cylinder head must be replaced.

8.

6.

Installation 1.

Correctly identify the inlet and exhaust cams as previously described. Position the camshafts to the two banks of valves ensuring that the inlet cam is located to the inlet valves and the exhaust cam to the exhaust valves. Turn the engine over so that all three pistons are away from TDC (approximately 15°ATDC).

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.

""h 1. Cam ladder 2. Cam bearing areas

7. 8. 9. 4. 5.

Working on one cam at a time, locate the cam chain over the camshaft sprockets. Ease the cam chain away from the sprockets then turn each camshaft until as many lobes as possible are facing away from the valves. Allow the chain to drop back onto the cams.

Lubricate the threads of the cam ladder bolts with clean engine oil. Position the cam ladder to the cylinder head, aligning bearing areas with cam journals. Finger-tighten the cam ladder bolts until the bolt's under-head areas are in contact with the cam ladder.

To avoid damage to the cam ladder, always ensure as many cam lobes as possible are facing away from the valves. This will reduce stress on the cam ladder during assembly. Damage to the cam ladder will result in replacement of the complete head.

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.

1. Cam ladder lightening sequence 11. In the same sequence, torque each cam ladder bolt to 10 Nm. 12. Fit the cam chain top pad. Tighten the top pad fixings to 10 Nm. 13. Ease the cam chain away from the cams. Rotate the crankshaft clockwise (as viewed from the front), until No. 1 cylinder is at TDC. No. 1 cylinder is at TDC when a 'dot' mark on the crank gear is in alignment with the line in the upper crankcase.

1. Crankshaft 'dot' mark 2. Upper crankcase line Note: •

•

After placing each cam in the timing position, it will be necessary to have an assistant hold the cams in position until tool T3880202 is fitted. Set the exhaust cam first, then the inlet.

~.

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.

1. Inlet timing mark 2. EXhaustliming mark 15. Fit tool T3880202 to location holes in the cam sprockets as shown in the diagram below. This will hold the cams in the correct timing position and prevent them from turning while the chain tensioner is filled.

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

Valve Clearance Adjustment

Camshaft, valve, valve shim and valve seat wear affect the valve clearances. The effect of this wear is to change the clearance between the camshaft and the adjustment shim, causing engine noise and/or improper running. If the valve clearances are incorrect, permanent damage to components in the valve-train will take place and engine performance will be affected.

Note:

Correct valve clearances are in the range given in the table below.

•

Measure and record all valve clearances as described previously. Remove the camshafts (see page 3.9). Remove a shim from one of the valves whose clearance required adjustment. Measure the original shim, using a micrometer. Calculate the shim thickness required to give the correct clearance. Clearance too small; fit a thinner shim. Clearance too large; fit a thicker shim.

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.

Valve clearance adjustment must carried out with the engine cold.

be

Remove the cam cover (see page 3.5). Remove a spark plug from each cylinder to reduce compression resistance when turning the engine. Select a high gear and, using the rear wheel, turn the engine over until a pair of camshaft lobes are positioned pointing directly away from the valves. Using feeler gauges, measure and record the clearances for this pair of valves only. Repeat the process until the clearances for all valves have been checked.

Valve clearance checking and adjustment must be carried out with the engine cold.

Note:

•

Shims are available ranging from 2.00 mm to 3.20 mm in increments of 0.025 mm. 6. Fit the selected shim to the tappet bucket. 7. Repeat the procedure until all valves requiring adjustment have been correctly set. B. Refit the camshafts (see page 3.12). 9. Rotate the engine several times to fully seat the shims. 10. Repeat the clearance checks on all valves, adjust as necessary. 11. Refit the cam cover (see page 3.6).

If any of the recorded clearances fall outside the specified range, adjustments must be made. If all measured clearances are within tolerance, refit the cam cover (see page 3.6).

3.14


Cylinder Head 9.

Cylinder Head

Remove both engine in-fill panels.

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. 4. 5. 6. 7.

Remove the fuel tank (see page 11.100). Drain the cooling system (see page 12.6). Remove the exhaust header system (see page 11.134). Remove the throttle bodies (see page 11.122). Remove the oil tank (see page 9.16). Remove the camshafts (see page 3.9). Disconnect the top and bypass hoses from the cylinder head.

1. Top hose 2. Bypass hose 8. Disconnect the coolant temperature sensor and low oil pressure switch connections.

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.

"'"

Head bolt release sequence 13. Remove the head bolts including two smaller bolts situated at the front of the engine. 14. Remove the head from the crankcase. Note: •

If necessary, lightly tap the head with a soft-faced mallet to break the gasket seal. 15. Remove and discard the head gasket. 16. Remove the cylinder liners (see page 5.18). Note: •

Cylinder liners must be resealed if the head is removed.

1. Low oil pressure warning light switch

~.


3.15

Cylinder Head Inspection

Installation

1.

1.

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.

2.

2. 3. 4.

Thoroughly clean the upper faces crankcase and liners. Also clean the crankcase mating faces. Fit the cylinder liners (see page 5.19). Move the cam chain rubbing blades to a that allows the head to fit over them. Ensure that both head dowels remain in in the crankcase.

of the liner to

position position

1

Checking head flatness

Cylinder head flatness tolerance 3.

0.030 mm

Check the cam chain rubbing blades. Renew if worn or damaged.

Ensure all traces of fluid (coolant, oil etc.) are removed from the threaded holes in the crankcase. Should any fluid remain in any of the threaded holes, severe crankcase damage could result from hydraulic locking of head bolts on assembly of the engine.

3.16

.",,"

1. Dowels 5. Position a new cylinder head gasket to the crankcase. 6. Lower the cylinder head over the cam chain rubbing blades and locate it onto the dowels.

Cylinder head bolts must never be reused and must always be replaced if removed or loosened. Use the correct procedure to tighten the cylinder head bolts carefully following the three-stage procedure below. This will ensure the long-term reliability of the cylinder head gasket. Failure to follow the correct tightening procedure or reuse of old head bolts may lead to engine damage and premature failure of the cylinder head gasket.


Cylinder Head 7.

In the order shown below, tighten the cylinder head bolts in three stages as follows:

Valves and Valve Stem Seals Removal from the cylinder head 1.

Remove each valve from the head using a valve spring compressor. The compressor must act on the top cup to allow removal of the valve collets. Once the collets are released, remove the following items:

2.

""" 8. 9. 10.

11. 12.

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

24. 25.

Cylinder head bolt tightening sequence In the sequence shown above, tighten bolts through 8 to 20 Nm. In the sequence shown above, tighten bolts 1 through 8 to 50 Nm. In the sequence shown above, tighten bolts 1 through 8 through a further 90° using tool T3880105 or similar to measure the torqueangle. Tighten bolts 9 and 10 to 12 Nm. Lubricate the tappet buckets with a 50/50 solution of molybdenum disulphide grease and engine oil, then refit them and the valve shims to their original locations in the head. Refit the camshafts (see page 3.12). Check and adjust the valve clearances (see page 3.14). Reconnect the coolant temperature sensor. Refit the bypass and top hoses. Refit the oil tank (see page 9.16). Refit the throttle bodies (see page 11.123). Refit the exhaust system (see page 11.136). Refill the cooling system (see page 12.7). Refit the fuel tank (see page 11.101). Refit both engine in-fill panels, tightening the fixings to 4 Nm. Start the engine and allow it to idle while checking for air, oil, coolant and exhaust leaks. Rectify as necessary. Check and top up the cooling system (see page 12.5). Check and top up the oil level (see page 9.7).

•

collets

•

valve spring cap

•

valve spring

•

valve stem seal

•

valve spring thrust washer

Installation 1. 2.

3.

Note: •

4.

5.

During fitment of the valve stem seal, two distinctly different degrees of resistance will be noted when the seal is correctly fitted. Firstly, press the seal down the valve stem until the lower side of the seal comes into contact with the valve guide. Greater resistance is felt at this contact point and further gentle pressure is then required to locate the seal over the top end of the valve guide. On application of this pressure, the seal can be felt to positively locate over the top face of the valve guide. Once correctly positioned, the seal cannot be pushed down any further.

Incorrect fitment of the valve stem oil seals could lead to high oil consumption and blue smoke emissions from the exhaust system. Do not use excessive force in fitting the seal as this may break the seal ring. 6.

~.

Apply a thin coat of molybdenum disulphide grease to the valve stem. Install the valve into the valve guide and refit the thrust washer to the valve spring recess (if removed). Fit the valve stem seal over the valve stem and, using a suitable tool, press down fully until the seal is correctly seated over the valve guide.

Install the valve spring.


3.17

Cylinder Head 7.

8.

Compress the valve spring ensuring that the spring is compressed squarely to prevent damage to components. Fit the valve collets ensuring their correct location in the spring cap and valve as the spring compressor is released.

Always check for correct location of the valve collets during and after assembly. If not fitted correctly, the collets may become dislodged when the engine is running allowing the valves to contact the pistons. Any such valve to piston contact will cause severe engine damage.

Cam Chain Inspection An in-situ check can be made as follows: 1.

Check for significant blue discolouration of the chain plates indicating excessive heat build-up.

2. 3.

Examine all pins for signs of rotation. Check for cracking or deep scratching of the chain piates.

4.

Check for severe wear of the inner piates as indicated in the diagram below.

""1'

For a more thorough check, proceed as follows:

3.18

1. 2.

Remove the chain from the engine. Suspend the chain from a pin or hook with a 13kg weight attached at the lower end.

3.

Measure across 23 links as shown in the diagram. If the chain is within limits, the measurement should be no longer than 147.63 mm. Measurements beyond 147.63 mm indicate that the chain must be replaced.


Cylinder Head 6.

4.

5.

Check for severe wear of the inner surface of the outer plates at the side-contact points with the sprocket teeth.

Check for severe wear of the plates in the area shown below.

-

If any of these symptoms are evident, the cam chain must be replaced.

Check for signs of stiffness or kinking.

~.


3.19

Cylinder Head


3.20


4 Clutch Table of Contents Exploded View - Clutch Controls .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

4.2

Exploded View - Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

4.3

Exploded View - Clutch Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

4.4

Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Installation

4.5 4.6 4.6

Clutch Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

4.7

Removal. . .. Installation

...

.. .. . .. .. .. .. . . . . . . .

. . . . .. .. .. . .. .. . . . .

. . . ..

4.7 4.7

Clutch. . ... .. . . ..

...

.. ..

.. .. .. .. .. . ..

..

4.7

.. ..

. . . ..

..

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

4.7

Friction Plate Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

4.9

Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 4.9

~.


4.1

Clutch Exploded View - Clutch Controls

15NmZ::

e~~

r

"

4.2


3Nm 3Nm

~ ~-----'O 3Nm

Clutch Exploded View - Clutch

@


4.3

Clutch Exploded View - Clutch Cover

•

o

00

0

0

•

•

•

•

•

4.4


Clutch 4.

Clutch Cable Removal

Release the clutch cable from the actuating arm by pushing the inner cable nipple through the arm and sliding the cable out. Detach the cable from the bracket.

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.

Remove the rider's seat as described on page 17.9. Disconnect the battery, negative (black) lead first. Slacken the cable locknut and release the adjuster at the engine end to give maximum play in the cable. 1. Actuating Arm 2. Inner Cable

5.

Align the slots in the lever adjuster and locknut.

1. Clutch Cable 2. Adjuster 1. Locknut 2. Lever adjuster


4.5

Clutch 6.

Pull in the clutch lever and turn the inner cable, anti-clockwise through the slots in the adjuster and locknut, until the cable can be detached from the lever.

Installation 1.

Position the cable to the motorcycle following the same routing as noted during removal. Attach the inner cable to the clutch lever and actuating arm using a reversal of the removal process. Refit the outer cable to the adjuster bracket at the engine end.

2.

3.

Note: • 4. 5.

1. Nut/locknut Slots 2. Cable Release Point 7. Remove the cable from the motorcycle noting the cable routing, particularly where it passes through steering area.

6. 7.

Ensure that the two adjuster nuts are positioned, one either side of the bracket. Set the lever adjuster to a point where an equal adjustment is possible in both directions. Set the adjuster at the clutch end to give a preliminary setting of 2-3 mm of free play as measured at the lever. Operate the clutch lever several times and recheck the amount of free-play present. Set the final adjustment of the cable to give 23 mm of free-play at the lever by turning the adjuster nut and locknut at the lever end. Secure the setting with the knurled locknut.

Note: •

To ensure the same route can be followed on installation, tie a length of string to one end while pulling the cable through from the other. When installing the new cable, tie the string to one end of the cable and use it to guide the new cable into position.

Examination 1. 2. 3.

4.6

Check the inner cable for free movement through the outer cable. Examine the inner cable for frayed strands. Examine the two inner cable nipples for signs of looseness and damage. Replace the cable if necessary.

1. Clutch Lever 2. Correct Setting, 2-3 mm 8. Reconnect the battery positive (red) lead first. g. Refit the rider's seat.


Clutch Clutch Cover

Clutch

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. Remove the radiator as described on page 12.11. Remove the water pump as described on page 12.7. Remove the coolant pipe running between the crankcase and water pump. Disconnect the clutch cable as described on page 4.5. Release the ring of bolts securing the clutch cover to the crankcases. Place an oil catch tray beneath the clutch cover to collect any oil that may spill out on removal. Carefully withdraw the cover disengaging the litter arm as it is eased forward.

1.

2. 3.

4.

5. 6. 7.

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.

Remove the clutch cover as described on page 4.5. Undo the bolts, withdraw the springs and remove the clutch pressure plate.

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.

1. Pressure plate bolts 2. Springs 3. Pressure plate 3. Remove the litter piece, needle bearing and thrust washer.

Note: •

4. 5. 6. 7.

Ensure that the litter piece engages correctly with the litter arm during assembly. It way be necessary to pull the litter arm forward to allow assembly to take place. Fit and tighten the bolts to 9 Nm. Tighten the bolts in a diagonal sequence. Refit the coolant pipe, tightening its fixing to 9Nm. Refit the water pump as described on page 12.8. Refit the radiator as described on page 12.13.

1. Llfler piece 2. Needle bearing 3. Thrust washer


4.7

Clutch 4.

Remove all the clutch friction plates and steel plates together with the anti-judder seat washer and spring. Note the orientation of all components as they are removed.

6.

7.

Depress the rear brake pedal to prevent the engine from turning, and then release the clutch centre nut. Remove the centre nut, Belleville washer, plain washer, clutch inner drum and thrust washer.

cl""

1. Friction Plates 2. Steel Plate 3. Anti-judder Seat Washer 4. Anti-judder Spring Note: •

•

•

5.

The inner and outermost friction plates are different to the remainder and are also different to each other. They must not be fitted in any other positions. Refer to the following page of this section for details of clutch friction plate inspection. It is not normally necessary to disassemble the clutch further, but if the clutch inner and outer drums are to be removed, proceed as follows:

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.

Engage any gear and lock the inner and outer clutch drums together using service tool 3880025-T0301 .

1. Outer drum 2. Bearing sleeve

1. Service tool 3880025-T0301

4.8


Clutch Friction Plate Inspection Thickness 1.

If any friction plate thickness is outside the service limit, replace the friction plates as a set.

1. Friction Plate 2. Feeler Gauge 3. Surface Plate

-

Friction plate bend/warp Service limit

1. Clutch friction Plate

Assembly

Friction plate thickness - all plates Standard

3.72 - 3.88 mm

Service limit

3.5 mm

2.

I 0.30 mm

Check all plates for bend and warp as follows: Place the plate being checked on a clean surface plate and attempt to pass a feeler gauge of the maximum service limit thickness between the friction plate and surface plate. If the feeler gauge can be passed beneath the friction plate at any point, renew the plates as a set.

1. 2.

Position the bearing sleeve then the clutch outer drum to the input shaft. Align the oil pump drive pegs with the corresponding holes in the rear of the clutch outer drum.

1. Clutch outer drum 2. Oil pump sprocket drive pegs 3. Oil pump drive holes

~.


4.9

Clutch 3.

Pre-Ioad and align the primary gear and backlash eliminator with the crank gear. Align the gears through the hole arrowed below.

1. Belleville Washer 'Out' Mark 7. Lock the Inner and outer drums together using service tool 3880025-T0301. Depress the rear brake pedal to prevent the engine from turning, and tighten the clutch centre nut to 105 Nm. Remove the service tool,

1. Primary gear 2. Backlash eliminator 3. Crank gear 4. Arrowed; alignment hole Note: When the outer drum is correctly fitted and the gears are pre-Ioaded correctly, the bearing sleeve will be a flush fit with the clutch drum face. In addition, a groove around the input shaft will be visible.

•

4.

Fit the thrust washer to the shaft.

1.3880025-T0301 8. Disengage second gear and check for free rotation of the clutch inner drum. 9. Coat all clutch friction plates in clean engine oil 10. Fit the friction plates, steel plates, anti-judder seat and spring to the clutch basket, in the same order as noted during removal. Note: 1. Thrust washer 5. Fit the clutch inner drum. 6. Refit the plain washer, fit a new Belleville washer ('out' mark facing outwards), and refit the centre nut.

4.10

•

The inner and outermost friction plates are different to the remainder and are also different to each other. They must not be fitted in any other positions.


Clutch 11. Refit the clutch pull rod.

Note:

12. Refit the clutch pressure plate together with the springs and bolts. Tighten the bolts to 10 Nm.

•

The pull rod should be free to move in and out and also it should be free to turn. 13. Fit the clutch cover as described on page 4.7.


4.11

Clutch


4.12


5 eran kshaft Table of Contents Exploded View - Crankshaft, Connecting Rod and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

5-2

Exploded View - Crankcase Fixings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

5-3

Exploded View - Crankcase and Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

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

Removal.. .. . . .. ... .. .. ... . . . . .. . ... .. .. .. .. . . . . ... .. .. .. . . .. ... ... . . .. Installation .......................................................... Right hand (exhaust) side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10 5-10 5-11

Connecting Rod Big End Bearing Selection/Crankpin Wear Check. . . . . . . . . . . . . . . . . . . . . . . . . .

5-12

Connecting Rod Bearing Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13

Crankshaft Main Bearing/Journal Wear.. .. . . .. .. .. .. .. .. .. . .. . . .. .. .. ... .. .. .. . .. .. ..

5-13

Checking crankshaft clearance using Plastigage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

5-13 5-14

Pistons.. .. ... . ... . .. .. .. ... . .... .. .. . ... .. .. .. . . .. .. .. ... ... . . . . .. .. ... .. . . . ..

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

cC

::»

< 1. Press bars 2. Bearing/housing 10. Remove the snap-ring from the bearing housing.

When pressing the bearing out of the housing, 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. 11. Support the outer circumference of the bearing housing on press bars, then press the bearing through the housing.

""m Pressing out the bearing


8.19

Transmission Inspection 1.

Examine all gears, bearings and bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all defective components and always use new circlips to assemble the shaft. Thoroughly clean the bearing housing and inspect for damage, scoring and cracks. Replace the housing if necessary

2.

A

Caution

Press only on the bearing outer race to prevent bearing damage. 2.

Support the housing on press bars as shown below and press the bearing fUlly into the housing in the direction of the arrow.

Assembly Note:

•

Lubricate each gear, thrust washer and bush with clean engine oil during assembly.

Note: The circlips used on the input shaft have a flat side and an angled side. Illustrations throughout the assembly text indicate which orientation of each circlip is correct.

•

1. Bearing housing 2. Bearing

3. When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under ioad 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.

Retain the bearing with a new snap ring.

Press only on the bearing inner race to prevent bearing damage. 4.

Locate the bearing and housing to the input shaft. Support the shaft on the press bed and press the bearing onto the shaft.

Bushes with oil holes must always be MISALIGNED with the corresponding oil holes in the output shaft. Reduced oil pressure and gear lubrication may result from alignment of the oil holes, which would cause premature wear of engine and transmission components.

Removing the input shaft bearing from the shaft and its housing will damage the bearing and snap ring. Never re-use removed bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage. Also, check for damage to the housing itself. 1.

Position a new bearing to the housing.

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.

Fit the bush (9).

7.

Fit the Belleville washers (7) over the bush, arranging them as shown below.

1. Thrust washer 2. Belleville washers 3. Bush 8. Fit fifth gear (8) and the fifth gear thrust washer (10). 9.

11. Retain third/fourth gear with a new circlip (13), orientating the circlip as shown below.

1. Thircllfourth gear 2. Circlip 12. Slide on second gear (14). 13. Retain second gear with a new circlip (13), orientating the circlip as shown below.

Retain the assembly with a new circlip (11), 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

Service Manual· Rocket III

9 Lubrication Table of Contents Exploded View - Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

9-2

Exploded View - Oil tank, filter and pumps

9-3

Oil Circuit ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

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

Low Oil Pressure Warning Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-9

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Installation 9-10 Sump. . . .. .. . . .. . . ..

.. .

.. .. . .. .. .. . . . .. . . ..

.. .. .. .

.. . . . . . ..

.. ..

9-10

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation .................................

9-10 9-10 9-11

Oil Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-11

~~~

~11

Inspection. . . . .. . . .. .. . . . .. .. .. . .. . . .. . . .. .. .. .. .. . .. .. .. '" . .. .. .. .. . .. .. . . Installation Oil Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . '" .. . . . .. .. .. . . Oil Pressure Relief Valve

9-13 9-14 9-15 9-15

Oil Tank

'" .. .. .. . . . . . .. .. . . . .. .. .. .. . .. .. . . . . . . ..

. . .. . .. ..

Removal , Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Installation Oil Transfer Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..


9-16 9-16 9-16 9-16 9-16

9.1

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1 11.21

Fuel System/Engine Management Note:

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 tooi. Full details of the tool's operation and how to interpret the results are given elsewhere in this section. The tooi is connected to the motorcycle using a dedicated diagnostic plug situated beneath the seats. By using a dedicated plug, no electricai 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.

•

When a fault has been rectified, the MIL will remain illuminated until sufficient nonfault warm-up cycles have taken place to turn it off. The MIL will be immediately extinguished if, after first rectifying the fault, the DTC (diagnostic trouble code) that caused the MIL illumination is erased from the ECM memory using the Triumph diagnostic tool.

Note: •

In most cases, when a fault is detected, the engine management system will revert to a 'limp-home' mode. In this mode, the engine will still function though the performance and fuel economy may be marginally affected. In some cases, the rider may not notice any appreciable difference from normal operation.

On-board Fault Detection System The on-board diagnostic system has two stages to fault detection. When a fault is detected, the DSM (Diagnostic Status Manager) raises a flag to indicate that a fault is present and increments a counter. The counter checks the number of instances that the fault is noted. For example, if there is a fault in the crankshaft position sensor, the counter will increment its count each time the crankshaft turns through 360°, provided the fault is stili present. When the count begins, the fault is detected but not confirmed. If the fault continues to be detected and the count reaches a pre-determined threshold, the fault becomes confirmed. If the fault is an emissions related fault or a serious malfunction affecting engine performance, a DTC (Diagnostic Trouble Code) and freeze-frame data will be logged in the ECM's memory and the MIL (Malfunction Indicator Lamp) on the motorcycle instrument panel is illuminated. Once a fault is confirmed, the number of warm-up cycles made by the engine is counted. If the fault clears, the warm-up cycle counter will extinguish the MIL (Maifunction Indicator Lamp) at a pre determined count. and erase the DTC and freeze frame data from the ECM memory at another (higher) count.

Triumph Diagnostic Tool Described on the following pages is the range of information which can be retrieved from the ECM's memory and the adjustments which can be performed using the Triumph service diagnostic tooi. The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic tooi. Full details of how to operate the tool and how to interpret the data follow later in this section.

A single warm-up cycle is deemed to have taken place when the following criteria have been met: •

The coolant temperature must be raised to 72°C or more.

•

The coolant temperature must have risen by 23°C or more from its start temperature. when nOc is reached.

•

A controlled power-down sequence must take place.

11.22


Fuel System/Engine Management Current Data

Freeze-frame Data

By using the Triumph diagnostic tool, live engine data (engine running) can be recovered from the motorcycle. The data available is:

Freeze frame data is stored at the time a DTC is recorded (confirmed) by the ECM. If multiple DTCs are recorded, the freeze-frame data which is stored will relate to the first recorded DTC only.

Function Examined Engine speed

Result Reported (Scale) RPM

Calculated load

%

Coolant temperature

QC

Short term fuel trim

%

Throttle Position

%

Intake air temperature

QC

Vehicle speed Ignition Advance

km/h degrees

Heated oxygen sensor output voltage

volts

Intake manifold absolute pressure

mm/hg

Fuel system status

By calling up freeze frame data associated with the first recorded DTC, the technician can check the engine condition at the time the fault occurred. The data available is: Function Examined Engine speed

RPM

Calculated load

%

Coolant temperature

QC


%

Throttle Position

%

Intake air temperature

QC

Vehicle speed Ignition Advance

open or closed loop operation

Result Reported (Scale)

km/h degrees

Heated oxygen sensor output voltage

volts

Intake manifold absolute pressure

mm/hg

Fuel system status


open or closed loop operation

11.23

Fuel System/Engine Management Function Tests

Adaption status

The system allows the diagnostic tool to perform a series of function tests on various actuators in the engine management system. In some cases it is necessary to make a visual observation of a component and in other, if faults are present, DTCs will be logged.

Because the fuel system is adaptive, the tool is able to automatically adjust to new working conditions. This screen displays information as to the adaption status of the vehicle which will show if it has adapted or not.

The function tests available are:

Closed throttle position reference status

Function Examined

Report Method

Instrument panel

Visual inspection instruments

Function Examined

adaptedlnot adapted

control

%

Oxygen sensor adaption status (off idle)

%

Stored fault code' Stored fault code'

Oxygen sensor adaption range (off idle)

%

Purge control valve Fuel pump relay

Stored fault code'

%

Fuel pump operation

Stored fault code'/Fuel pressure test

Oxygen sensor adaption status (idle) Oxygen sensor adaption range (idle)

%

Idle speed stepper motor

control

Cooling fan

Stored fault operation

2nd throttle stepper motor

• If a fault

IS

controi

of

code'/fan

Stored fault code'

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

Triumph ECM part number Adjustments

ECM manufacturer's part number

Using the Triumph diagnostic tool, it is possible to reset the ECU to the factory default settings and to balance the throttle bodies.

ECM serial number Software version number (tune number)

Further facilities are provided to allow correct replacemenVadjustment of the primary throttle position sensor and the primary throttle stepper motor. These facilities are needed as, after replacement of the parts concerned, adjustments have to be made to specific voltage settings, all with the throttles in a specific position. Full details of these procedures are prOVided later in this section.

11.24


Fuel System/Engine Management Checks When using this function it is possible to check the status of various sensors and actuators and also check certain items of factory data logged during vehicle assembly.

The data available under throttles/coils/injectors is: Item Checked

Result Unit

The data sets are dived into three groups, voltagesl pressures, throttles/coils/injectors and other data

2nd throttle current steps

numeric

2nd throttle target steps

numeric

The data available under voltages is:

Injector 1 pulse time

milliseconds


milliseconds


milliseconds


milliseconds

Ignition timing cyl 1

degrees BTDC


degrees BTDC


degrees BTDC


degrees BTDC

Item Checked

Result Unit

Throttle position sensor voltage Throttle position absolute Manifold sensor voltage

% open pressure

Manifold absolute pressure (one reading per cylinder) Atmospheric voltage

Volts

pressure

sensor

Atmospheric pressure

Volts mmHg Volts mmHg

Battery voltage

Volts

Battery voltage scaling

Volts

Coolant voltage

temperature

sensor

Volts

Coil t dwell time

milliseconds

Coil 2 dwell time

milliseconds

Coil 3 dwell time

milliseconds

Coil 4 dwell time

milliseconds

The data available under

'othe~

is:

Air temperature sensor voltage

Volts

Item Checked

Oxygen sensor voltage

Volts

Malfunction indicator light status

MIL off/on

Oxygen sensor reading

Volts

Fan relay status

Fan offlon

Volts

Starter relay status

Starter on/off

Fall detection status

Normal/over

% open

Oxygen sensor heater status

Heater on/off

Gear position sensor voltage

Volts

Secondary air injection status

SAlon/off

Fuel level sensor voltage

Volts

Engine rpm

RPM

Fall detection switch voltage

Volts

Vehicle speed

kmlh

Fuel sensor voltage

Volts


2nd throttle voltage

position

sensor

2nd throttle position

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

Low fuel alarm status


On/off

11.25

Fuel System/Engine Management Diagnostic Trouble Codes Diagnostic trouble codes (DTCs) are logged in the ECM memory when there is a confirmed fault in the system. The codes are reported to the Triumph diagnostic tool as a four digit code. As mentioned earlier, when the system detects a fault, it begins to count the number of times the fault occurs before illuminating the MIL and storing a fault code. Similarly, if a fault clears, the ECM also records this fact and will turn off the MIL when sufficient no-fault warm-up cycles have taken place. Any fault codes will remain in the ECM memory until the required number of no-fault warm-up cycles have taken place. The number of warm-up cycles required to extinguish the MIL will always be less than the number required to remove a DTC from the ECM memory. DTCs can be removed at any time using the Triumph diagnostic tool The system will log the diagnostic trouble codes listed below/over: Diagnostic Trouble Code (DTC)

Fault Description

MIL

Number of no-fault cycles before DTCis erased

Number of no-fault cycles before turning off

MIL illuminated when fault is logged

P0201

Injector 1 circuit malfunction

3

40

Yes

P0202


3

40

Yes

P0203


3

40

Yes

P1201

Injector 1 open circuit/short to ground

3

40

Yes

P1202


3

40

Yes

P1203


3

40

Yes

P0335

Crankshaft sensor circuit malfunction

3

40

Yes

P0032

Oxygen sensor heater short circuit to battery

3

40

Yes

P0031

Oxygen sensor heater open circuit/short to ground

3

40

Yes

P0030

Oxygen sensor heater circuit malfunction

3

40

Yes

P0136

Oxygen sensor circuit malfunction

3

40

Yes

P0122

Throttle position sensor low input

3

40

Yes

P0123

Throttle Position sensor high input

3

40

Yes

P0107

Manifold absolute pressure sensor low voltage

3

40

Yes

P0108

Manifold absolute pressure sensor high voltage

3

40

Yes

P1105

Manifold absolute pressure sensor pipe malfunction

3

40

Yes

P1107

Ambient air pressure sensor circuit low voltage

3

40

Yes

P1108

Ambient air pressure sensor circuit high voltage

3

40

Yes

P0112

Intake air temperature too high

3

40

Yes

P0113

Intake air temperature too low

3

40

Yes

P0117

Engine coolant temperature too high

3

40

Yes

P0118

Engine coolant temperature too low

3

40

Yes

P0500

Vehicle speed sensor malfunction

3

40

Yes

11.26


Fuel System/Engine Management Diagnostic Trouble Code (DTC)

Number of no-fault cycles before turning off

Fault Description

MIL

Number of no-fault cycles before DTCis erased

MIL illuminated when fault is logged

P1552

Cooling fan short circuiVopen circuit

3

40

Yes

P1553

Cooling fan short to battery voltage/over temperature

3

40

Yes

P1231

Fuel pump short circuit to ground or open circuit

3

40

Yes

P1232

Fuel pump relay short circuit to battery

3

40

Yes

P0444

Purge valve system short circuit to ground or open circuit

3

40

Yes

P0445

Purge valve system short circuit to battery

3

40

Yes

P0617

Starter relay short circuit to battery

3

40

Yes

P0616

Starter relay short circuit to ground or open circuit

3

40

Yes

P0414

Secondary air injection system short circuit to battery

3

40

Yes

P0413

Secondary air injection system short circuit to ground or open circuit

3

40

Yes

P0222

2nd throttle position sensor system low voltage

3

40

Yes

P0223

2nd throttle position sensor high voltage

3

40

Yes

P0638

2nd throttle circuit malfunction

3

40

Yes

P0505

Idle speed control system malfunction

3

40

Yes

P1631

Fall detection sensor circuit low voltage

3

40

Yes

P1632

Fall detection sensor circuit high voltage

3

40

Yes

P0560

System voltage - battery circuit malfunction

3

40

Yes

P1500

Vehicle speed output circuit malfunction

0

40

No

P0654

Tachometer circuit malfunction

0

40

No

P1115

Coolant temperature gauge circuit malfunction

0

40

No

P0460

Fuel level sensor circuit malfunction

0

40

No

P0705

Gear position sensor circuit malfunction

0

40

No

P0656

Fuel gauge circuit malfunction

0

40

No

P1610

Low fuel output circuit malfunction

0

40

No

P0630

EEPROM fault

0

40

No


11.27

Fuel System/Engine Management "'... Cursors to indicate that further lines of text are available to be seen above and/or below those already in view, by scrolling the text up or down using the 'Up' or 'Down' keys.

Service Diagnostic Tool

6 7

34~\\~~ 2>s:~ ,,)A~,,/'

~

? Indicates further help/guidance information available on that line by pressing the help key.

-=-~~A· ~

~"~~

,

N E

oR

0

2 9 96 1 5

T E fI P

[

~

19JJ

19JJ @I

L

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0 T [ 5

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E N G I

U L R T E 0

T E N G I N E

o

U R R E N T

[

~

.~

Iz::, ~

Start the engine. 'CURRENT DATA' includes the information shown in the table below which can be accessed by scrolling, using the 'Up' and 'Down' keys. At the end of each line of text, the actual reading at that instant is provided to assist diagnosis e.g. ENGINE TEMp· 75C. For a complete list of the items reported, see the table titled 'CURRENT DATA' earlier in this section. If further clarification of any line of displayed text is required, scroll that line opposite the '?' symbol in the left hand coiumn and press the Help key (?). Limited information on the selected topic will then be displayed. Press any key to return to the 'CURRENT DATA' text. When all information has been noted, press either the or Return (.J) keys. Validation

'*'

~.


11.39

Fuel System/Engine Management 12. To select 'READ STORED DTCS' (Diagnostic Trouble Codes) from the MAIN MENU:

11. STOP ENGINE

is T

,i !

a PI

--,'

E N G 1 IN E

I,

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il7 EiN U

I

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io il

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---

,i

!

i

I 1

a

U I

[

,is

T

~

I( Switch off the engine.

@I

As the tool is powered from the motorcycle, this will end the diagnostic session. To continue, return to the power-up section and select tests as required.

ID

I @I lz:, { Use the 'Up' and 'Down' keys to position the cursor opposite DIAGNOSTICS. Press the Validation 'DIAGNOSTICS' menu.

key

'*'

to

dispiay

Select 'READ STORED DTCS', and press the Validation key '*'. 'STORED DTCS' will be displayed.

11.40


Fuel System/Engine Management 14. Three options are now available:

13. STORED DTCS 5 T 0 R E 0 0 T

[

[

i' P 0 1 1 1

"p

0 U N T

0 T

[

5 T 0 R E 0

5

5

0 2

•

"

0 2 0 1

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0 R T R

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~

~

9·"

0 T [

/~

~

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I~~

I~(

The second line - 'DTC COUNT', shows the number of DTC's stored in the ECM memory.

9·" Align 'FREEZE FRAME DATA' with the cursor, and to display 'FREEZE press the validation key FRAME' (see 15.).

'*'

Lines 3 and 4 display up to two of the DTC'S stored (if any). If additional DTC'S are stored, this will be indicated by a downward pointing arrowhead, and iV they can be accessed using the 'Up' and 'Down' keys.

Align 'CLEAR DTCS' with the cursor, and press the to display 'ERASE ALL DTC DATA' validation key (see 17.).

If there are no DTC's shown, press the Return key (..1) to return to MAIN MENU.

Press the Return key (..1) to go back to 'STORED DTCS' (operation 13.).

'*'

(If DTC's are present when the Return key is pressed, display will read 'STORED DTCS, ERASE ALL DTC DATA YES/NO'.) Information about each DTC can be obtained by scrolling the text until the appropriate code is opposite the '?' in line 3; then press the Help key (?). DTC example:

P01l7

Help text

MAP SENSOR LOW VOLTAGE

Press the Validation key 14.).

'*'

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

Fuel System/Engine Management 15. FREEZE FRAME i

II

16. STORED DTCS

I< E E

Z iE

F I< R f'I El

i i I

R T E

a

L

la

R

a

T E f'I P

9 %

1 5

[

"I< E T [

L E

~

a

I< E

a

a

T

5

UIRH

T

a

RIl (

To clear the DTC's, press the Validation key '*'. 'STORED DTCS' will be displayed (see operation

T E 5 T

10 1E>!

The following can be tested: a) b) c) d) e) f) g)

Instrument panel. Idle speed control stepper. Purge valve. Fuel pump prime. Cooling fan operation. Fuel pump operation. Second throttle controi stepper motor.

If the fault is electrical, this will then be reported as a DTC. Instrument Panel test: A signal is sent which should cause the tachometer to read approximately 7,500 RPM, the water temperature gauge to show 100oC* and the speedometer 100 km/h*, all for 10 seconds. Idle speed control stepper: A signal is sent which should cause the stepper to be driven to the fUlly closed position, then to the fully open position, pausing briefly in each position. DTCs are set if a malfunction is found. * Or the imperial equivalents. Purge valve (California models only): This test allows you to cheCk operation of the valve. To detect valve operation, use a stethoscope to listen for valve operation. DTCs are set if a malfunction is found. Fuel pump prime: This test provides you with the means to physically check the pump and relay operation. DTCs are set if a malfunction is found. Cooling fan test: A signal is sent which should cause the fan to operate for a 10 second period. OTCs are set if a malfunction is found.

11.44


Fuel System/Engine Management Fuel pump operation: This test provides you with the means to physically check the pump operation. DTCs are set if a malfunction is found. The pump is energised when the test is confirmed and ended when the Validation key '*' is pressed for a second time. Second throttle stepper motor: A signal is sent which should cause the 2nd throttle stepper to be driven to the fully closed position, then to fully open. DTCs are set if a malfunction is found.

21. FUNCTION TEST F U N C T I 0 N I ~

N 5 T R U 1'1 E N T

T E 5 T

P R N E L

P R 0 C E E 0 C R N C E L

By pressing the Validation key '*', your selection will be noted and 'FUNCTION TEST' (operation 21.) will be displayed. Press the Help key (?) for more information.

~

Note: •

lGDJ

If the Return key (.J) is pressed, the tool will return to 'DIAGNOSTICS' menu (operation 9.).

.~

/(

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'. •

Vehicle Identification Number (VIN)

•

Triumph ECM part number

•

Manufacturer's ECM part number

•

ECM Serial number

•

Tune Number

Press the Validation '*' keys to return to 'CHECK! ADJUST' menu (operation 27.).


11.49

Fuel System/Engine Management 30. SENSOR DATA

31. ADAPTION STATUS

ia iR

5 E N 5 ,

'

E N !6

i ? R

T

R

I

aiR T R

i

iR

51 E NI5 0 R

5 tJ

!R I

TIE

nip

5 [

!

5 T

T E 1'1 P

I

F

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T U 5

alUiT I

I

R R N 6 E

P!L iE RI5 E

IJ R

T

I

@I

~

1:--2>

gaiu

The display can be scrolled to show: The status of the various sensors and actuators To obtain further data information, scroll the appropriate line to the help key mark (?) and press the Help key,

Note: The help information shows the likely range of readings for a correctly functioning system at normal operating temperature.

That completes examination of the Checks. Press the Validation key ADJUST' (operation 27,).

11.50

iI N!E

a

I~I

•

!R 0 R P T

'*'

J~(

Because adaption only takes place at normal operating temperature, the above screen will be displayed until the engine reaches normal operating temperature. Until the engine warms or cools to the correct temperature range, the tool will not allow access to any other functions. If you wish to escape from this area (and not carry out the adjustment) switch off the ignition and disconnect the tool. Once the correct temperature range has been reached, the ADAPTlON STATUS screen (operation 32.) will automatically be displayed.

to return to 'CHECK!


Fuel System/Engine Management

[

L 0 5 E 0

I

5

0 2

[

R 0 R P T I 0 N

0 R T R

T H R 0 T T L E

N 0

R 0 R P T I 0 N 5 E N 5 0 R

1

R 0 R P

/;

96

5 1 96

~

19J1 ~

g••

~

I~~

The display can be scrolled to show: The adaption status of the various sensors and actuators involved in the adaption process will give an indication as to whether or not the vehicle is correctly adapted. If the readings show an incorrect adaption status, refer to the table of contents for the location of further information and the actions necessary to force correct adaption.

Function Examined

Report Method

Closed throttle position reference status

adapted/not adapted

Idle speed control adaption status

%

Oxygen adaption idle)

sensor status (off

%

Oxygen adaption idle)

sensor range (off

%

Oxygen sensor adaption status (idle)

%

Oxygen sensor adaption range (idle)

%

Note: •

Several forced adaptions may be needed to fully adapt an individual motorcycle.

See page 8-110 for additional information on forcing adaption. The data displayed under this option are:


11.51

Fuel System/Engine Management 32. ADJUST

33. ADJUST TUNE i

R 0 JUS T T

R E 5 E

TUN E

i

E

T

U

T

, ,; , i

I

I ri; IR

0 R P T I

T H R 0 T T L E I

5

[

i

sf

T H R 0 TIT LTE

I

II

0 N

-

8 R L R N [lE ~

IT ui N E i

R 0 J U 5 T

,

! '

si

ElfJ iR EiN I !

P 0 T

51TiE P P E R

i

i

,

N]E R!E ;

lJl

~

l~l

~

I~(

~

Position the cursor on line 2 'ADJUST TUNE' if you wish to check and/or adjust the values of certain tune items. Then press the Validation key to display ADJUST TUNE (see operation 33.).

'*'

In special circumstances, Triumph will request you to introduce a completely new engine tune. Given this situation, select 'UPDATE TUNE' and press the Vaiidation key (see operation 36.).

'*'

gall!

~

I~(

The following allow adjustments to be made to items which affect the engine operation Position the cursor opposite the setting you wish to adjust and press the Validation key '*'. RESET ADAPTIONS.· See operation 34. BALANCE THROTTLES. - See operation 35. THROTTLE POT RENEW., See page 8·102 for details on when and how to use this function. IDLE SPEED CONTROL STEPPER RENEW· See page 8·106 for details on when and how to use this function.

11.52

Service Manual· Rocket III

Fuel System/Engine Management 34. ADJUST TUNE (adaption reset) R D R P T I D N

~

[

D N F I

!:J

E 5

R E 5 E T

R I?

N D

35. BALANCE THROTTLES

I 2 3

~

I? I? I H G

T H R D T T L E

2

I 2 3

~

I? I? I H G

T H R D T T L E

3

1 2 3

~

I? I? I H G

~

(lgJJ 6$'1

I§)

I~(

galu

After selecting the adaption reset option, confirm or reject the option by positioning the cursor 'pposite the option chosen and press the Validation key '*'. If YES is chosen, a screen will confirm that adaptions have been resel. If NO is chosen, you will be returned to the adjust tune menu. Note: •

Resetting the adaption values does not adapt the motorcycle. This can only be done by the method explained later in this section. Adaption reset only returns adaption values to their 'start' point.

~.

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1

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T H R D T T L E

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