Triumph Daytona 675 User manual

Daytona 675 Motorcycle
Race Kit Manual
© Triumph Designs Ltd 2008. - A9900294 - ADC 5769 issue 2
FOR CLOSED-CIRCUIT USE ONLY

Page 2 of 33
© Triumph Designs Ltd 2008.
Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Head Gasket
0.65 mm - A9618072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
0.60 mm - A9618073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cams, Valve Spring & Sprocket Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cam - Inlet Kit - A9618055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cam - Exhaust Kit - A9618056. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Valve Spring Kit - A9618086 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Camshaft Sprocket Kit - A9618057. . . . . . . . . . . . . . . . . . . . . . . 9
Cam Chain Kit - A9618059 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cam Chain Tensioner Kit (manually adjustable) - A9618060 . . . . . . . . 12
Inlet & Exhaust Valve Kit - A9618061 . . . . . . . . . . . . . . . . . . . . . . . . 14
Conrod Bearing Shell
1.476 mm to 1.482 mm White - A110411 . . . . . . . . . . . . . . . . . 15
1.482 mm to 1.488 mm Red - A110412 . . . . . . . . . . . . . . . . . . 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
Air Funnel Kit - A9618063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust System, Stage 2 (Arrow) - A9600197. . . . . . . . . . . . . . . . . . 19
Air Filter Kit - A9618075 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Slipper Clutch Kit - A9610014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Slipper Clutch Tool - A3880037 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Transmission Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1st Gear pair & Housing Kit - A9618066. . . . . . . . . . . . . . . . . 24
Shaft, Input Kit - A9618064 (spares only) . . . . . . . . . . . . . . . 25
Gear, Output Kit - A9618065 (spares only) . . . . . . . . . . . . . . 25
Wheel Detent Kit - A9618068 (spares only) . . . . . . . . . . . . . . 25
Alternator Kit - A9618069 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Alternator Puller Tool Kit - A3880206 . . . . . . . . . . . . . . . . . . . . . . . . 27
Manual Idle Speed Adjuster Kit - A9618076 . . . . . . . . . . . . . . . . . . . 29
Race ECU Kit - A9618070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Race Harness Kit - A9618071 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Page 3 of 33
© Triumph Designs Ltd 2008.
Motorcycle Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Engine Protector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Clutch Cover, Carbon Fibre Kit - A9728028 . . . . . . . . . . . . . . . . 33
Crank Cover, Carbon Fibre Kit - A9728029 . . . . . . . . . . . . . . . . 33
Standard Alternator Cover, Carbon Fibre Kit - A9728031 . . . . . . 33
Race Alternator Cover, Carbon Fibre Kit - A9728032 . . . . . . . . . 33

Page 4 of 33
© Triumph Designs Ltd 2008.
Introduction
Daytona 675 Race Parts
Triumph's ground-breaking Daytona 675 has not only received global recognition for its
performance on the road, but also for its outstanding ability on the race track. To further
support this exceptional track ability, Triumph have launched a Racing Support Programme,
which is now further complemented by the launch of a range of Triumph Genuine Race Parts.
Factory developed in collaboration with Paul Young Racing, these parts have been designed
to give significant improvements in engine performance for race purposes. This results in
the class-leading Daytona 675 being competitive on the racetrack at the highest level.
Triumph Genuine Race Parts are sold individually and a number of the parts need to be used
in conjunction with each other to ensure the best performance gains are realised and also
to prevent premature wear on associated components. Please ensure you read the user
manual in full to understand this detail prior to fitting or using any of the Triumph Genuine
Race Parts.

Page 5 of 33
© Triumph Designs Ltd 2008.
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 kits’ features and the
installation process.
• When removing components which incorporate a gasket ALWAYS ensure a new gasket
is fitted on re-assembly.
• 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.
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 33
© Triumph Designs Ltd 2008.
Warning
These accessory kits are for racing only. They are for use solely during closed-course
racing. A motorcycle fitted with these kits must not be used on public roads. It is illegal to
use a motorcycle fitted with these kits on public roads. A motorcycle fitted with these kits
does not comply with local laws and regulations. If you use a motorcycle fitted with these
kits on public roads, you may be prosecuted.
Warning
These accessory kits are designed for use on Triumph Daytona 675 motorcycles only and
should not be fitted to any other Triumph model or to any other manufacturer’s
motorcycle. Fitting these accessory kits to any other Triumph model, or to any other
manufacturer’s motorcycle, will affect the performance, stability and handling of the
motorcycle. This may affect the riders ability to control the motorcycle and could cause an
accident.
Warning
Always have Triumph approved parts, accessories and conversions fitted by a trained
technician of an authorised Triumph dealer. The fitment of parts, accessories and
conversions by a technician who is not of an authorised Triumph dealer may affect the
handling, stability or other aspects of the motorcycles operation which may result in loss
of motorcycle control and an accident.
Warning
Throughout this operation, ensure that the motorcycle is stabilised and adequately
supported on a paddock stand to prevent risk of injury from the motorcycle falling.
Warning
A torque wrench of known accurate calibration must be used when fitting this accessory
kit. Failure to tighten any of the fasteners to the correct torque specification may affect
motorcycle performance, handling and stability. This may result in loss of motorcycle
control and an accident.
Warning
If the engine has recently been running, the exhaust system will be hot. Before working
on or near the exhaust system, allow sufficient time for the system to cool, as touching
any part of a hot exhaust could cause burn injuries.
Caution
The use of some of these kits will require changes to the fuelling settings. To alter the
fuelling settings a third party programmable control unit will be required.

Page 7 of 33
© Triumph Designs Ltd 2008.
Head Gasket
* Thickness “t” marking location
Parts Supplied - A9618072 (0.65 mm) or A9618073 (0.60 mm)
• The thickness of the standard cylinder head gasket is 0.7 mm. The Race Kit
gaskets are available in 0.60 mm and 0.65 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
settings. To alter fuelling settings a third party programmable control unit will be
required.
Item Description Qty
1 Head gasket (t = 0.65 mm) 1
1 Head gasket (t = 0.60 mm) 1
1
*
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.

Page 8 of 33
© Triumph Designs Ltd 2008.
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, a race gasket is not always
suitable for use.
7. Fit the chosen cylinder head gasket
following the procedures detailed in the
Daytona 675 service manual.

Page 9 of 33
© Triumph Designs Ltd 2008.
Camshaft, Valve Spring & Sprocket Kits
Parts Supplied
Camshaft Inlet Kit - A9618055
Camshaft Exhaust Kit - A9618056
Valve Spring Kit - A9618086
Camshaft Sprocket Kit - A9618057
Warning
The race kit must be fitted as a complete set. If it is not fitted as a complete set a failure
may result which could cause loss of motorcycle control and an accident.
Caution
The use of the camshaft, valve spring & sprocket race kits detailed below will require
changes to the fuelling settings. To alter fuelling settings a third party programmable
control unit will be required.
5
5
4
1
32
4
3
Item Description Qty
1 Cam assy, inlet, race 1
Item Description Qty
2 Cam assy, exhaust, race 1
Item Description Qty
3 Valve spring, 14.4 id, race 12
Item Description Qty
4 Sprocket, camshaft, 34T 2
5
Socket head cap screw,
encapsulated, M6 x 10
4

Page 10 of 33
© Triumph Designs Ltd 2008.
NOTE
• The standard inlet cam is 9.25 mm max lift and 258.50oduration. The race kit
inlet cam is 9.25 mm max lift and 268.74oduration.
• The standard exhaust cam is 8.5 mm max lift and 246oduration. The race kit
exhaust cam is 8.5 mm max lift and 262.21oduration.
• The race kit valve spring must be used in conjunction with the standard
spring platforms and retainers. The fitted length of the race springs is the
same as the standard spring.
1. The race kit valve springs should be
assembled in the same manner as the
standard valve springs. Follow the
procedure detailed in section 3 of the
Daytona 675 service manual. Ensure
the springs are installed with the close
wound, colour coded end of the springs
facing downwards, towards the piston.
2. The race kit camshafts should be
assembled in the same manner as the
standard camshafts. Follow the
procedure detailed in section 3 of the
Daytona 675 service manual.
3. The race kit cam sprockets should be
mounted and secured to the camshafts
using the slotted holes in the sprocket.
The slotted holes allow adjustment of
the valve timing. The circular holes in
the sprockets are for Triumph service
tool T3880102 and should not be used
to mount the sprockets to the
camshafts.
NOTE
• No timing marks are included on
the race sprockets. Race engines
will typically have different depths
skimmed off the cylinder head and,
therefore require specific
individual timing.
4. The camshafts should be timed using
cam degreeing equipment which
typically consists of a degree wheel,
pointer, dial indicator and piston stop.
Optimum cam timing will depend on the
exact specification of the engine, but a
recommended starting point is 104o
IMOP (Inlet Maximum Opening Point)
and 104oEMOP (Exhaust Maximum
Opening Point).
5. Always check the inlet and exhaust
piston to valve clearance for the timing
selected to use, before running the
engine. You must ensure both
clearances are adequate. As a guide,
the standard nominal piston to valve
clearance is 1.3 mm inlet & 1.5 mm
exhaust.
6. When the desired timing has been set
the new socket retaining screws
provided should be tightened to
15 Nm. Note, if the screws are
released for any reason, apply
ThreeBond 1305 to the threads before
re-tightening.

Page 11 of 33
© Triumph Designs Ltd 2008.
Cam Chain Kit
Parts supplied - A9618059
1. Remove the existing cam chain
following the procedures detailed in
section 3 of the Daytona 675 service
manual.
2. Fit the race cam chain following the
procedures detailed in section 3 of the
Daytona 675 service manual.
1
Item Description Qty
1 Cam chain 1

Page 12 of 33
© Triumph Designs Ltd 2008.
Manually Adjustable Cam Chain Tensioner Kit
Parts supplied - A9618060
1. Remove the standard tensioner
following the procedure detailed in the
Daytona 675 service manual.
NOTE
• Do not start the motorcycle engine
with the tensioner removed.
2. Thoroughly clean the tensioner
mounting surface on the cylinder head.
3. Remove the crank cover to gain access
to the crankshaft.
4. Back off the plunger locknut on the new
tensioner assembly before installation.
1. Plunger locknut
Item Description Qty
1 Tensioner, camchain, manual, assembly 1
2 Bolt, reduced hex head flange, S/less, M6 X 16, encapsulated 2
2
2
1
1

Page 13 of 33
© Triumph Designs Ltd 2008.
5. Lightly coat the large O-ring with oil,
install the new tensioner assembly and
secure with the new fixings provided.
6. Tighten the tensioner fixings to a
torque value of 9 Nm.
7. Finger tighten the plunger on the new
tensioner while turning the crankshaft
by hand. At certain points during
engine rotation you will feel the plunger
tighten as it takes up the slack in the
cam chain. DO NOT force the plunger,
continue steady finger tightening only
to take up the slack in the chain as you
rotate the crankshaft.
1. Plunger
2. Plunger locknut
8. When the slack in the cam chain has
been completely taken up, back off the
plunger by 1/4 turn.
9. While holding the plunger in position,
tighten the plunger locknut to a torque
value of 9 Nm. Ensure the plunger is
not allowed to turn while tightening the
locknut.
2
1

Page 14 of 33
© Triumph Designs Ltd 2008.
Inlet & Exhaust Valve Kit
Parts supplied - A9618061
• The valves supplied in the race kit are used to increase compression ratio, by
having a flat face on the combustion chamber side. They are made from the
same material and have the same mass as the standard valves.
1. Remove the existing inlet and exhaust
valves following the procedure detailed
in section 3 of the Daytona 675 service
manual.
2. The valve seat widths on the race kit
valves are narrower than the standard
valves, therefore the bottom angle
(120o) of the cylinder head valve seats
must be modified to ensure the seat on
the head matches the seat on the valve.
3. Check the head seat and valve seat are
matched correctly by applying
engineers blue to the cylinder head seat
(90o) and then assembling a valve.
4. When the correct match of head seat
and valve seat have been confirmed
assemble the race inlet and exhaust
valves, following the procedure detailed
in section 3 of the Daytona 675 service
manual.
Caution
The use of the following race kit inlet & exhaust valves will require changes to the fuelling
settings. To alter fuelling settings a third party programmable control unit will be
required.
1
2
Item Description Qty
1 Inlet valve, 29.65 dia 6
2 Exhaust valve, 24.85 dia 6

Page 15 of 33
© Triumph Designs Ltd 2008.
Conrod Bearing Shell
Parts supplied - A1110411
Parts supplied - A1110412
• The race conrod bearing shells should be assembled in the same manner as
the standard conrod bearing shells.
• Follow the procedure detailed in section 5 of the Daytona 675 service manual
to remove the connecting rods, select the correct bearing shells for each
connecting rod and refit the connecting rods.

Item Description Thickness Colour Qty
1 Conrod bearing shell, race 1.476 mm to <1.482 mm White 1
Item Description Thickness Colour Qty
1 Conrod bearing shell, race 1.482 mm to <1.488 mm Red 1

Page 16 of 33
© Triumph Designs Ltd 2008.
Main Bearing Shell
Parts supplied - A1161301
Parts supplied - A1161302
Parts supplied - A1161303
Parts supplied - A1161304
• The race main bearing shells should be assembled in the same manner as the
standard main bearing shells.
• Follow the procedure detailed in section 5 of the Daytona 675 service manual
to remove the standard bearing shells and select the correct bearing shells
required.

Item Description Thickness Colour Qty
1 Main bearing shell, race 1.491 mm to <1.495 mm White 1
Item Description Thickness Colour Qty
1 Main bearing shell, race 1.495 mm to <1.499 mm Red 1
Item Description Thickness Colour Qty
1 Main bearing shell, race 1.499 mm to <1.503 mm Blue 1
Item Description Thickness Colour Qty
1 Main bearing shell, race 1.503 mm to <1.507 mm Green 1

Page 17 of 33
© Triumph Designs Ltd 2008.
Air Funnel Kit
Parts supplied - A9618063
NOTE
• It is essential that the race ECU kit - A9618070 is used with the air funnel race
kit to allow correct offset for fuelling cylinder 3 (short air funnel).
• The parts supplied in the race kit are designed to replace the standard intake
air funnels located in the airbox.
• Item 4 (6 off) is the standard fixing supplied with the standard air funnel. It is
not supplied in the race kit.
Caution
The use of the following race air funnel kit will require changes to the fuelling settings. To
alter fuelling settings a third party programmable control unit will be required.
Item Description Qty
1 Air funnel short, race 1
2 Air funnel long, race 2
3 Fixing retainer 3
1
2
3
4

Page 18 of 33
© Triumph Designs Ltd 2008.
1. Remove the airbox lid.
2. Remove the standard intake air
funnels. Retain the fixings (2 per air
funnel) for reuse.
3. Fit the 2 long race kit air funnels to
cylinders 1 & 2 and the short air funnel
to cylinder 3.
NOTE
• The cylinders are numbered 1 to 3
from left to right of the engine.
4. Fit one of the fixing retainers provided
to each air funnel and retain with the
original fixings. Apply ThreeBond 1364
locking compound to the threads only
and tighten the fixings to a torque value
of 6 Nm.
5. Fold the retention tabs, on the fixing
retainers, over the 6 fixings as shown
below.
1. Retention tab
2. Fixing
1
2

Page 19 of 33
© Triumph Designs Ltd 2008.
Exhaust System, Stage 2 (Arrow)
Parts supplied - A9600197
Caution
The use of the Arrow stage 2 exhaust system will require changes to the fuelling settings.
To alter fuelling settings a third party programmable control unit will be required.
Item Description Qty
1 Downpipe collector assy 1
2 Intermediate pipe 1
3 Silencer 1
4Spring 5
5 Primary header bushing 3
6 Primary header flange 3
7 Silencer bracket assembly 1
8 Capscrew, M8 6










Page 20 of 33
© Triumph Designs Ltd 2008.
1. Remove the seat, battery, rear
bodywork, lower fairings, radiator,
radiator fan, rear light, pillion foot rest
hangers and exhaust system following
the procedures detailed in the Daytona
675 service manual.
2. Remove the exhaust valve actuator
from its actuator cables.
3. Remove and discard the exhaust
gaskets and M8 studs from the cylinder
head.
1. M8 Stud
2. Gasket
NOTE
• To obtain maximum performance
the exhaust port should be
machined, removing material from
the area shown in red. The exhaust
port shape should match the inside
surface of the primary header
bush.
4. Apply silicone sealant to the mating
surface of the primary header bush
which contacts the cylinder head, the
recommended sealant is Dow Corning
Firestop 700 white silicone.
5. Fit the three primary header bushes to
the cylinder head and secure in the
orientation shown below using the
primary header flanges and M8 cap
screws provided.
NOTE
• The flat on the primary header
bush should be aligned with the
flat in the exhaust port such that
none of the exhaust port is
obscured by the primary header
bush.
1. Flat - primary header bush
1
2
-
1