Triumph Daytona 675 User manual

2009 Daytona 675
(VIN 381275>)
Motorcycle Race Kit Manual
© Triumph Designs Ltd 2009. - A9900432 - ADC 7018 issue 1
FOR CLOSED-CIRCUIT USE ONLY

Page 2 of 47
© Triumph Designs Ltd 2009.
Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gaskets
Side Cover Gasket Kit - A9618097 . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder Head Gasket 0.65 mm - A9618112 . . . . . . . . . . . . . . . . 8
Cylinder Head Gasket 0.60 mm - A9618113 . . . . . . . . . . . . . . . . 8
Cylinder Head Gasket 0.55 mm - A9618114 . . . . . . . . . . . . . . . . 8
Cylinder Head Gasket 0.50 mm - A9618115 . . . . . . . . . . . . . . . . 8
Cams & Valves
Camshaft, Inlet - A9618055 . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft, Exhaust - A9618056 . . . . . . . . . . . . . . . . . . . . . . . . 10
Valve Spring Kit - A9618086 . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft Sprocket Kit - A9618095. . . . . . . . . . . . . . . . . . . . . . 10
Manually Adjustable
Camshaft Drive Chain Tensioner - A9618108. . . . . . . . . . . . . . . 12
Inlet & Exhaust Valve Kit - A9618061. . . . . . . . . . . . . . . . . . . . 14
Bearings
Conrod Bearing Shell
1.476 mm to 1.482 mm (White) - A1110411. . . . . . . . . . . . . . . 15
1.482 mm to 1.488 mm (Red) - A1110412 . . . . . . . . . . . . . . . . 15
Main Bearing Shell
1.491 mm to 1.495 mm (White) - A1161301. . . . . . . . . . . . . . . 16
1.495 mm to 1.499 mm (Red) - A1161302 . . . . . . . . . . . . . . . . 16
1.499 mm to 1.503 mm (Blue) - A1161303. . . . . . . . . . . . . . . . 16
1.503 mm to 1.507 mm (Green) - A1161304 . . . . . . . . . . . . . . 16
Oil Pump
Oil Pump Gearing Kit - A9618096. . . . . . . . . . . . . . . . . . . . . . . 17
Induction & Exhaust
Air Funnel Kit - A9618090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SAI Blanking Kit - A9618094 . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Exhaust System, Race (Arrow) - A9600351. . . . . . . . . . . . . . . . 23
Air Filter Kit - A9618075 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manual Idle Speed Adjuster Kit - A9618076. . . . . . . . . . . . . . . . 28
Transmission
Slipper Clutch Tool - A3880037 . . . . . . . . . . . . . . . . . . . . . . . . 29
Slipper Clutch Kit - A9610014 . . . . . . . . . . . . . . . . . . . . . . . . . 29
Detent Wheel Kit - A9618068 . . . . . . . . . . . . . . . . . . . . . . . . . 30

Page 3 of 47
© Triumph Designs Ltd 2009.
Electrical Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Race Alternator Kit - A9618069 . . . . . . . . . . . . . . . . . . . . . . . . . 34
Alternator Puller Tool - A3880206 . . . . . . . . . . . . . . . . . . . . . . . 34
Programmable Race ECU - A9618098 . . . . . . . . . . . . . . . . . . . . . 36
Race Calibration Software (TRACS) - A9610051. . . . . . . . . . . . . . 38
TRACS Management Kit - A9618099. . . . . . . . . . . . . . . . . . . . . . 39
Race Harness Kit - A9618100 . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Quickshifter, Race, Standard Shift - A9930224 . . . . . . . . . . . . . . 44
Quickshifter, Race, Reverse Shift - A9930225 . . . . . . . . . . . . . . . 44
Chassis Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rearsets, Race, Reverse Shift - A9750536 . . . . . . . . . . . . . . . . . 45
Rearsets, Race, Standard Shift - A9750539. . . . . . . . . . . . . . . . . 46
Carbon Fibre Engine Cover Protectors . . . . . . . . . . . . . . . . . . 47
Clutch Cover Protector, Carbon Fibre - A9728028. . . . . . . . . . . . . 47
Crank Cover Protector, Carbon Fibre - A9728029. . . . . . . . . . . . . 47
Standard Alternator Cover Protector,
Carbon Fibre - A9728031 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Race Alternator Cover Protector,
Carbon Fibre - A9728032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Page 4 of 47
© Triumph Designs Ltd 2009.
Introduction
2009 Triumph Daytona 675
Triumph's award-winning Daytona 675 has been enhanced for the 2009 season with a host
of modifications & racing products to improve the bike's already class-leading handling and
performance.
Triumph's R&D department has taken an evolutionary approach with the new Daytona, using
experience gained from the 2008 Supersport World & National Championships to develop
the new machine and Race Kit parts for 2009. As a result, the standard bike now includes a
higher ratio first gear, (previously only available as a Race Kit part) revised cylinder head,
valves and a magnesium cam cover.
As could be expected from a bike with such sporting aspirations, the new Daytona chassis
comes equipped with top of the line suspension and brakes. The fully-adjustable 41mm
upside down forks and rear monoshock unit both benefit from highly sophisticated high and
low speed damping control, allowing riders to set their Daytona up with maximum accuracy.
New radial-mount Nissin monobloc calipers give even greater levels of stopping power and
rider feedback, and new lightened wheels give significant savings in unsprung mass.
It's not just the standard parts which have been enhanced - the 2009 Daytona 675 has a
full range of Race Kit products to allow riders to fully exploit the new bike for the 2009
season.
Notable additions include the new Triumph Race Calibration Software (TRACS), which allows
adjustment of many parameters within the Race Kit ECU, new adjustable camshaft
sprockets, manually adjustable cam chain tensioner & guide blade, racing oil pump gearing
kit, ‘plug and play’ quick-shifter, lightweight racing harnesses, revised air funnel kit and the
new Arrow full titanium racing exhaust system.
The Triumph Race Kit means the Daytona 675 will be competitive on the track at all levels,
from club to world championship.

Page 5 of 47
© Triumph Designs Ltd 2009.
General Information
Please note:
• The Race Kit parts detailed in this publication are made in accordance with FIM
technical regulations and are NOT street legal.
• The Race Kit parts covered in this publication are intended for racing purposes only and
any Triumph motorcycle fitted with such kits MUST NOT be used on public roads.
• The Race Kit parts detailed in this publication may only be used on a closed-circuit in
the hands of experienced riders.
• Before fitting any Race Kit parts, customers should check the technical regulations of
their race class to ensure conformity.
• The information provided in this publication should always be used together with the
official Triumph Daytona 675 service manual.
• Completely read all the instructions before commencing the installation and set up of
the Race Kit in order to become thoroughly familiar with the kit’s features and the
installation process.
• When removing components which incorporate a gasket ALWAYS ensure a new gasket
is fitted on re-assembly. The standard engine side cover gaskets can be replaced with
re-usable items as supplied in the Side Cover Gasket Kit A9618097 (see page 7).
• The Race Kit parts detailed in this publication are not covered by any warranty.
• Prices and specifications are subject to change without notice.
• The information contained in this publication is accurate at the time of final approval,
however, Triumph Motorcycles reserves the right to amend the information at any time
without notice.
• Whilst every effort is made to include the latest information in the service manual, this
is not always possible. The latest information and technical changes are provided to
authorised Triumph dealers via Technical News. It is recommended you contact an
authorised Triumph dealer to request this information.
Warnings, Cautions and Notes.
Throughout this publication particularly important information is presented in the following
form:
NOTE
• This note symbol indicates points of particular interest for more efficient and
convenient operation.
Warning
This warning symbol identifies special instructions or procedures, which if not correctly
followed could result in personal injury, or loss of life.
Caution
This caution symbol identifies special instructions or procedures, which if not strictly
observed, could result in damage to, or destruction of, equipment.

Page 6 of 47
© Triumph Designs Ltd 2009.
Warning
These accessory kits are for racing only. They are for use solely during closed-course
racing. A motorcycle fitted with these kits must not be used on public roads. It is illegal to
use a motorcycle fitted with these kits on public roads. A motorcycle fitted with these kits
does not comply with local laws and regulations. If you use a motorcycle fitted with these
kits on public roads, you may be prosecuted.
Warning
These accessory kits are designed for use on Triumph Daytona 675 motorcycles only and
should not be fitted to any other Triumph model or to any other manufacturer’s
motorcycle. Fitting these accessory kits to any other Triumph model, or to any other
manufacturer’s motorcycle, will affect the performance, stability and handling of the
motorcycle. This may affect the riders ability to control the motorcycle and could cause an
accident.
Warning
Always have Triumph approved parts, accessories and conversions fitted by a trained
technician of an authorised Triumph dealer. The fitment of parts, accessories and
conversions by a technician who is not of an authorised Triumph dealer may affect the
handling, stability or other aspects of the motorcycles operation which may result in loss
of motorcycle control and an accident.
Warning
Throughout this operation, ensure that the motorcycle is stabilised and adequately
supported on a paddock stand to prevent risk of injury from the motorcycle falling.
Warning
A torque wrench of known accurate calibration must be used when fitting this accessory
kit. Failure to tighten any of the fasteners to the correct torque specification may affect
motorcycle performance, handling and stability. This may result in loss of motorcycle
control and an accident.
Warning
If the engine has recently been running, the exhaust system will be hot. Before working
on or near the exhaust system, allow sufficient time for the system to cool, as touching
any part of a hot exhaust could cause burn injuries.
Caution
The use of some of these kits will require changes to the fuelling and ignition settings. To
alter these settings, a Triumph Programmable Race ECU combined with Triumph TRACS
Race Calibration Software will be required. Failure to correct the fuelling and ignition
settings will result in poor engine performance and could result in engine damage.

Page 7 of 47
© Triumph Designs Ltd 2009.
Side Cover Gasket Kit
Parts Supplied - A9618097
NOTE
• The gaskets contained in the kit are a direct replacement for the standard
parts, but they have been designed to be reusable.
• Thoroughly clean all mating faces before fitting new gaskets.
1
2
3
4
Item Description Qty
1 Gasket, clutch cover, race 1
2 Gasket, alternator cover, race 1
3 Gasket, crank cover, race 1
4 Gasket, balancer cover, race 1
Engine Parts

Page 8 of 47
© Triumph Designs Ltd 2009.
Cylinder Head Gasket
* Thickness “t” marking location
Parts Supplied - A9618112 (0.65 mm), A9618113 (0.60 mm),
A9618114 (0.55 mm) or A9618115 (0.50 mm)
• The thickness of the standard cylinder head gasket is 0.7 mm. The Race Kit
gaskets are available in 0.60 mm, 0.65 mm, 0.55 mm and 0.50 mm
thicknesses. The thickness (t) of the gasket is clearly marked on the gasket in
the position (*) shown above.
NOTE
• Due to variation in production tolerances, the Race Kit cylinder head gaskets
may not be suitable for all engines. Use the appropriate gasket to adjust the
squish height (the squish height is the gap between the flat portion of the
piston and the cylinder head). Always ensure that the chosen gasket provides
a minimum squish height of 0.65 mm.
Caution
The use of the following Race Kit cylinder head gaskets will require changes to the fuelling
and ignition settings. To alter these settings, a Triumph Programmable Race ECU
combined with Triumph TRACS Race Calibration Software will be required. Failure to
correct the fuelling and ignition settings will result in poor engine performance and could
result in engine damage.
Item Description Qty
1 Cylinder head gasket (t = 0.65 mm) 1
1 Cylinder head gasket (t = 0.60 mm) 1
1 Cylinder head gasket (t = 0.55 mm) 1
1 Cylinder head gasket (t = 0.50 mm) 1
1
*

Page 9 of 47
© Triumph Designs Ltd 2009.
1. Remove the existing cylinder head
gasket in line with the procedures
detailed in the Daytona 675 service
manual.
2. Position a piece of solder (with a
diameter approximately 1.3 mm) on
the four squish surfaces of each piston.
Position the solder in line with the
corresponding squish surfaces on the
cylinder head and hold in place with a
small amount of grease.
3. Refit the cylinder head with the head
gasket.
4. Slowly turn the engine over, by hand,
to compress the solder to the same
height as the squish clearance.
5. Remove the cylinder head and head
gasket.
6. Measure the compressed thickness of
the solder. The squish clearance must
be a minimum of 0.65 mm. If the
thickness of the solder is less than
0.65 mm repeat steps 2 to 6 with a
thicker head gasket until the squish
clearance is at an acceptable level.
NOTE
• In some cases, it may be necessary
to use a standard cylinder head
gasket to achieve the correct
squish clearance.
7. Fit the chosen cylinder head gasket
following the procedures detailed in the
Daytona 675 service manual.
Warning
Running the engine at less than the minimum recommended squish height can lead to the
pistons contacting the cylinder head, causing major engine damage. This could cause loss
of motorcycle control and an accident.

Page 10 of 47
© Triumph Designs Ltd 2009.
Camshaft, Valve Spring & Camshaft Sprocket Kits
Parts Supplied
Camshaft, Inlet - A9618055
Camshaft, Exhaust - A9618056
Valve Spring Kit - A9618086
Camshaft Sprocket Kit - A9618095
Warning
The Race Kit camshaft, valve Spring and camshaft sprockets must be fitted as a complete
set. If they are not fitted as a complete set a failure may result which could cause loss of
motorcycle control and an accident.
Caution
The use of The Race Kit camshaft, valve Spring and camshaft sprockets detailed below
will require changes to the fuelling and ignition settings. To alter these settings, a Triumph
Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be
required. Failure to correct the fuelling and ignition settings will result in poor engine
performance and could result in engine damage.
6
5
4
1
32
3
6
Item Description Qty
1 Camshaft, inlet, race 1
Item Description Qty
2 Camshaft, exhaust, race 1
Item Description Qty
3 Valve spring, 14.4 id, race 12
Item Description Qty
4 Sprocket, camshaft,
inlet, 34T 1
5 Sprocket, camshaft,
exhaust, 34T 1
6
Socket head cap screw,
encapsulated, M6 x 10
4