Triumph Rocket III Classic User manual

(
\
Triumph Rocket Ill, Rocket III Classic and
Rocket
III Touring
Motorcycle Service Manual
Part Number 3851160 issue 1,09.2007
This document is protected by copyright and may not, in whole or part be stored in a retrieval system, or transmitted in
any form or by any means, copied, photocopied, translated or reduced to any machine-readable form without prior
consent in writing from Triumph Motorcycles Limited.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken
to make it as complete and accurate as possible.
Triumph Motorcycles Limited reserves the right to make changes and alter specifications without prior notice and without
incurring an obligation to make such changes to products manufactured previously. See your authorised Triumph dealer
for the latest information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations in this publication are intended for reference use only and may not depict actual model component parts.
© Triumph Motorcycles Ltd 2007
SelVice Manual- Rocket Ill/ Classic / Touring
1

2
SelVice Manual -Rocket 1111 Classic 1Touring

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 Ill/ Classic / Touring

ii SelVice Manual -Rocket
Ill/ Classic / Touring

Introduction
SelVice Manual -Rocket Ill/ Classic / Touring iii

Introduction
This manual is designed primarily for use by trained
technicians in a properly equipped workshop. However, it
contains enough detail and basic information to make it
useful to the owner who desires to perform his own basic
maintenance and repair work. The work can only be
carried out
if the owner has the necessary hand and
special service tools to complete the job.
A basic knowledge of mechanics, including the proper use
of tools and workshop procedures is necessary in order to
carry out maintenance and repair work satisfactorily.
Whenever the owner has insufficient experience or doubts
his ability to do the work, an authorised Triumph dealer
must undertake all adjustments, maintenance, and repair
work.
In order to perform the work efficiently and to avoid costly
mistakes, read the text and thoroughly familiarise yourself
with procedures before starting work.
All work should be performed with great care and in a
clean working area with adequate lighting.
Always use the correct special service tools or equipment
specified. Under no circumstances use makeshift tools or
equipment
since the use of substitutes may adversely
affect safe operation.
Where accurate measurements are required, they
can
only be made using calibrated, precision instruments.
For the duration of the warranty period, an authorised
Triumph dealer must perform all repairs and scheduled
maintenance.
To maximise the life of your Motorcycle:
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.
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.
Warnings, Cautions and Notes
Particularly important information is presented in the
following form:
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.
iv
SelVice Manual - Rocket III I Classic I Touring

Tampering with Noise Control
System Prohibited
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/800 km service, and thereafter should be maintained
at the
figures specified in this manual.
Repairs and Replacements
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.
Introduction
Whenever tapping to aid removal of an item is necessary,
tap
lightly using a hide or plastic faced mallet.
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.
Service Manual - Rocket Ill/ Classic / Touring v

Introduction
This page intentionally left blank
vi
SelVice Manual -Rocket Ill/ Classic

1 General Information
Table of Contents
Ignition System Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Dangerous Substances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Third Party Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Fluoroelastomers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Oils........................ ... ........ ....................... ... ...... ......... ...... ... 1.4
Health Protection Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Environmental Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Brakes. . .. . . . . .. . . . ... . . . .. . .. . .. . .. .. . .. . . . . . . . .. . . . .. . . . . .. . .. . .. . . .. . .. . .. . . . ... ... .. . 1.5
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Jacking and Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.6
Precautions against Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.6
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.7
Cleaning components.. . . . . . . . . . . . . . . . . .. . .. . . . . .. . .. . .. . . . . . . . . . . .. . . . . . . .. . . . . . . . . .. 1.7
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.7
Joints and joint faces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.7
Gaskets, O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 1.7
Liquid Gasket, Non-permanent Locking Agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8
Screw Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8
Locking Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8
Fitting a Split Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8
Circlips, Retaining Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8
Self Locking Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8
Encapsulated Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8
Oil and Grease Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.9
Press. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . .. . . . . . . . . . . . . . . . . .. . . . . .. . .. . .. . .. .. 1.9
Ball Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.9
Chassis Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.9
Metal bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.10
Fuel Handling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.11
Petrol -Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.11
Fuel Tank Removal. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . .. . . . . .. . . . .. 1.11
Chassis Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.11
Electrical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
SelVice Manual- Rocket 1111 Classic 1Touring
1.1

General Information
1.2
Battery Disconnecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Disciplines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Electrical Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Electrical Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Ohm's law.......... ......................... .............. ... . ........... ...... ... 1.14
Basic Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Circuit Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
Glossary of Circuit Diagram Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
Tracing Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
To Check Continuity: ........... , ........................ , . . . . . . . . . .. . . . . . . . .. . . . . . . . . 1.17
To Measure Voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
CAN (Controller Area Networking> .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
Alternator/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19
Diagnosis -Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.20
Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21
General Fault Finding -Starter Motor and Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21
Diagnosis -Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.23
SelVice Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.23
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.23
SelVice tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.24
Special selVice tools: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.24
Torque Wrench Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
Cylinder Head Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.40
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.40
Crankshaft and Crankcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.40
Engine Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.40
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.41
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.41
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
Fuel System, Exhaust System and Airbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.42
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.42
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.43
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.43
Front Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.43
Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.44
Footrests and Control Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.44
Bodywork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.44
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.45
Routings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
Clutch Cable Routing -Rocket III and Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.46
Clutch Cable Routing -Rocket III Touring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.47
Handlebar Cable Routing -Rocket III and Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.48
Handlebar Cable Routing -Rocket III Touring ............................... ; . . . . . . . . . . .. 1.49
Main Wiring Harness Routing -Rocket III and Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.50
SelVice Manual- Rocket 1111 Classic 1Touring

General Information
Main Wiring Harness Routing -Rocket III Touring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.51
Rear Mudguard Harness Routing -Rocket III and Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
Rear Mudguard Harness Routing -Rocket III Touring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.53
Front Brake Hose Routing -Rocket III and Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54
Front Brake Hose Routing -Rocket III Touring .......................................... 1.55
Rear Brake Pipe and Hose Routing -Rocket III and Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
Rear Brake Pipe and Hose Routing -Rocket III Touring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57
Throttle Cable Routing -Rocket III and Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.58
Throttle Cable Routing -Rocket III Touring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.59
Fuel Hose and Fuel Tank Breather Hose Routing (non-evaporative emission control versions> -
Rocket III and Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.60
Fuel Hose and Fuel Tank Breather Hose Routing (non-evaporative emission control version> -
Rocket III Touring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.61
Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing -Rocket III and Classic. . . . . . . . . . 1.62
Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing -Rocket III Touring. . . . . . . . . . . . . 1.63
SelVice Manual- Rocket Ill/ Classic / Touring 1.3

General Information
Ignition System Safety Precautions
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.
Dangerous Substances
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!
Third Party Products
Many propriety products, such as chemicals, solvents
and cleaning agents, will cause damage to components
if used incorrectly or inappropriately. Always follow the
manufacturer's
instructions printed on the product
container's
labels and obey the instructions given. These
instructions are included for your safety and well-being.
Damage to the motorcycle components caused by the
incorrect or inappropriate
use of chemicals, solvents and
cleaning agents may reduce the components efficiency,
resulting in loss of motorcycle control and an accident.
Fluoroelastomers
Fluoroelastomer material is used in the manufacture of
various seals in Triumph motorcycles.
In fire conditions involving temperatures greater than
315°C 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.
Oils
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.
1.4 Service Manual -Rocket
Ill/ Classic / Touring

First aid treatment should be obtained
immediately for open cuts and wounds.
Always 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.
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
local authority for advice on disposal facilities.
General Information
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.
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.
SelVice Manual- Rocket 1111 Classic 1Touring 1.5

General Information
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.
Before installation, all internal brake components should
be cleaned and lubricated with clean new DOT 4 brake
fluid.
Never use solvents, petrol (gasoline), engine oil or any
other petroleum distillate on internal brake components
as this will cause deterioration of the hydraulic seals in
the calipers and master cylinders.
A dangerous riding condition leading to loss of
motorcycle control and an accident could result if this
warning is ignored.
Safety Instructions
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 to 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.
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.
Protect exposed bearing and sealing surfaces, and screw
threads from damage.
1.6 SelVice
Manual- Rocket Ill/ Classic / Touring

Coolant
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.
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.
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.
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.
General Information
Cleaning components
A high flash-point solvent is recommended to reduce fire
hazard.
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 scrupulous 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, oil or grease
(whichever is more suitable> should be applied to any
rubbing surface, which has lost its lubrication film. Old
grease and dirty oil should be cleaned off. This is because
used
lubricants will have lost some lubrication qualities
and may contain abrasive foreign particles.
Use recommended lubricants. Some oils and greases in
particular should be used only in certain applications and
may be harmful if used in an application for which they
are not intended. This manual makes reference to
molybdenum disulphide grease in the assembly of certain
engine and chassis parts. Always check manufacturer
recommendations before
using such special lubricants.
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 re-
assembly. Do not use a tool which will damage the joint
faces and smooth out any scratches or burrs on the joint
faces using an oil stone. Do not allow dirt or jointing
material to enter any tapped holes.
Gaskets, O-rings
Do not re-use a gasket or O-ring once it has been in
service. The mating surfaces around the gasket should be
free of foreign matter and perfectly smooth to avoid oil or
compression
leaks.
SelVice Manual - Rocket III I Classic I Touring
1.7

General Information
Liquid Gasket, Non-permanent Locking Agent
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 oil passages and cause serious damage.
Prior to re-assembly, 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 oil or grease to enter blind threaded holes.
The hydraulic action on screwing in the bolt or stud could
split the housing.
Always tighten a nut or bolt to the recommended torque
figure. Damaged or corroded threads can affect the
torque
reading.
Unless specified, threaded fixings must always be fitted
dry (no lubrication>.
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 fails in service could cause component
detachment
leading to loss of control and an accident.
Locking Devices
Always release locking tabs and fit new locking washers,
do not re-use locking tabs.
Fitting a Split Pin
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 a split pin, except in those recommended cases
when this forms part of an adjustment.
Always fit new roll pins of an interference fit in the hole.
Circlips, Retaining Rings
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.
Encapsulated Bolts
An encapsulated bolt can be identified by a coloured
section of thread which is treated with a locking agent.
Unless a specified repair procedure states otherwise,
encapsulated
bolts cannot be reused and MUST be
replaced
if disturbed or removed.
Failure to replace an encapsulated bolt could lead to a
dangerous
riding condition. Always replace
encapsulated bolts.
1.8
SelVice Manual - Rocket Ill/ Classic / Touring

Oil and Grease Seals
Replace any oil or grease seals that are removed.
Removal will cause damage to an oil seal which, if re-used,
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 the original
sealing surface cannot be completely restored.
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.
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.
When pressing in a seal which has manufacturer's marks,
press in with the marks facing out.
Seals must be pressed into place using a suitable driver.
Use of improper tools will damage the seal.
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 Bearing
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.
With the sealing lip facing the lubricant, press or drift a
seal to the depth of its housing, if the housing is
shouldered, or flush with the face of the housing where
no shoulder is provided.
General Information
Chassis Bearing Lubrication
Note:
• This information relates only to bearing
lubrication. For the procedures necessary to
replace a bearing, always refer to the
relevant section of this service manual.
• Bearings installed
in engine and
transmission applications are not covered by
this information. Refer to the lubrication
chapter or the relevant engine chapter for
additional information.
General
For a bearing to be serviceable for its anticipated life span
it must be checked, adjusted and lubricated at regular
intervals, as specified in the service schedules given in the
owner's handbook
and this service manual.
A correctly lubricated bearing will have a film of
lubrication that separates the moving parts, disperses heat
and protects the bearing
surfaces from corrosion.
Note:
• In all cases, use the lubricant recommended.
• Grease the bearing, not the cavity where it
is located.
• A bearing that is not regularly checked and
lubricated will have a reduced life span.
New Bearings
New bearings are typically protected with an oil
preservative to prevent corrosion etc. during storage. This
is NOT the lubrication for the bearing but DOES NOT
need to be washed off prior to assembly and in-service
lubrication.
When lubricating a new bearing with grease the following
steps should be taken:
1. Do not clean off the oil preservative.
2. Grease must be forced between the roller elements
and the roller cage.
3. Rotate the bearing to ensure that the grease is
distributed over the entire circumference of the
internal parts.
4. Any excess grease should be smeared on the outside
of the rollers.
SelVice Manual -Rocket Ill/ Classic / Touring 1.9

General Information
Lubrication and Checks While Servicing a Bearing
1. Disassemble parts as necessary to access the
bearing.
2. Inspect the old grease covering the bearing, looking
for signs of bearing damage, i.e. flakes or specks of
metal.
3. Remove the old grease.
4. Check the bearing for smooth operation and visually
check for corrosion, dents and flaking in the bearing
race, rollers or cage. Replace if necessary.
Below/overleaf several common bearing types and the
lubrication procedures for each are identified:
ceon
Sealed bearings
Note:
ceon
• Sealed bearings can be identified by their
integrated
seals.
• Sealed bearings are lubricated for life by the
manufacturer.
• Any attempt to change the grease in a
sealed bearing will damage the integrated
seals. If the seals are damaged dirt and
water will
ingress and the life of the bearing
will be greatly reduced.
Taper bearings
1. Grease must be forced between the inner race and
the
roller carrier.
2. Rotate the bearing to ensure that the grease is
distributed over the entire circumference of the
internal parts.
3. Any excess grease should be smeared on the outside
of the rollers.
ceon
Angular contact and ball bearing
1. Grease the bearing races and the ball bearing carrier.
2. Rotate the bearing to ensure that the grease is
distributed over the entire circumference of the
internal parts.
ceop
Needle roller bearings
1. Coat the needle rollers with grease.
2. Ensure the needle rollers turn so that the grease is
distributed over the entire circumference of the
internal parts.
3. Assemble the parts, adjust and check as necessary.
Metal bushes
1. Disassemble the parts as necessary to access the
bush.
2. Remove the old grease.
Apply fresh grease to the metal bush.
1.10
SelVice Manual - Rocket Ill/ Classic / Touring

Fuel Handling Precautions
General
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.
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 level. It can
readily be distributed throughout any indoor environment
by air currents, consequently, even a small spillage of
petrol (gasoline) is potentially very dangerous.
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 fuel 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.
General Information
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.
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.
SelVice Manual - Rocket III I Classic I Touring
1.11

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.
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.
The battery contains harmful materials. Always keep
children away from the battery whether or not it is fitted
in the motorcycle.
Do not jump start the battery, touch the battery cables
together or reverse the polarity of the cables as any of
these actions may cause a spark which would ignite
battery gasses causing a risk of personal injury.
High Voltage Circuits -Whenever disconnecting live H.T.
circuits always use insulated pliers. Exercise caution when
measuring the voltage on the coil terminals while the
engine
is running, high voltage spikes can occur on these
terminals.
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 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.
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.
1.12
SelVice Manual- Rocket 1111 Classic 1 Touring