Triumph Speed Triple User manual

iiu e
Motorcycle anual
1
Part Number T3856080 issue 1, 03.2005
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 reducedto any machine-readable
form without priorconsent inwritingfromTriumph MotorcyclesLimited.
No liability can be accepted for any inaccuraciesor omissions in this publication, although every possible care
hasbeentakento make it as complete and accurate as possible.
Triumph MotorcyclesLimitedreservesthe rightto make changes and alter specificationswithout prior notice and
without incurringan obligationto make such changes to products manufactured previously. See your authorised
Triumph Dealerfor the latest informationon product improvementsincorporatedafter this publication.
All information contained in this publication is based on the latest product information available at the time of
publication. Illustrationsin this publicationare intendedfor reference use only and may not depict actual model
componentparts.
@ Triumph Motorcycles Ltd2005
I
* FromVIN 210445 onwards.
--
Service Manual - SpeedTriple

i Table of Contents
Introduction
GeneralInformation
Scheduled Maintenance
Cylinder Head
Clutch
Crankshaft, Connecting Rods and Pistons
Balancer
Transmissiow
Lubrication
ngine RemovallRefit
Fuel SystemlEngineManagement
Cooling
Rear Suspension
Front Suspension
Brakes
WheelsKyres
Frameand Bodywork
Electrical
Service Manual - SpeedTriple

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Service Manual - SpeedTriple

Service Manual - SpeedTriple
iii

This manual is designed primarily for use by trained
technicians in a properly equipped workshop.
However, it contains enough detail and basic
informationto makeit usefulto the ownerwho 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
completethe job.
A basic knowledgeof mechanics, includingthe proper
useof toolsand workshop proceduresis necessaryin
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 careand in a
cleanworking 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 durationof the warranty period, an authorised
How to usethis manual
To assist inthe use of this manual, the section title is
c
given at the top.
Eachmajorsection starts with a contentspage, listing
the informationcontainedinthe section.
The individualsteps comprising repair operations are
to befollowed inthe sequenceinwhich they appear.
Adjustment and repairoperationsinclude referenceto
service tool numbers and the associated illustration
depictsthe tool.
Where usage is not obvious, the tool is shown in use.
Adjustment and repair operations also include
referenceto wear limits, relevant data, torque figures,
specialist informationand useful assembly details.
Warning, Cautionand Note
f'
Particularly important information is presented in the
following form:
I This warning symbol identifies special instructions /
or procedureswhich, if not correctly followed, could
result inpersonal injury, or loss of life.
To maximisethe life of your Motorcycle:
I procedures which, if not strictly observed, could /
Triumph Dealer must perform all repairs and
scheduledmaintenance.
Accurately follow the maintenance requirements
A Caution
This caution symbol identifiesspecial instructionsor
I result indamage to or destructionof equipment.
I
of the periodic maintenance chart in the service
Note:
manual.
This note symbol indicates points of (, ,
Do not allow problems to develop. Investigate
particular interest for more efficient and
unusual noises and changes in the riding
convenientoperation.
characteristics of the motorcycle. Rectify all
problems as soon as possible (immediately if
safety related).
Use only genuine Triumph parts as listed in the
partscataloguelparts microfiche.
Follow the procedures in this manual carefully
and completely. Donottake short cuts.
Keep complete records of all maintenance and
repairswith dates and any new parts installed.
Use only approved lubricants,as specified in the
owner's handbook, in the maintenance of the
motorcycle.
Service Manual - SpeedTriple

Introduction
I Tamperingwith NoiseControl
System Prohibited
Owners are warned that the law may prohibit:
a) The removalor renderinginoperativeby any
personotherthanfor purposes of maintenance,
repairor replacement, of any deviceor element
of design incorporatedintoany newvehiclefor
the purposeof noisecontrol priorto its sale or
deliveryto the ultimatepurchaseror while it is in
use; and
b) the useof the vehicle after such device or
element of designhasbeen removedor rendered
inoperativeby any person.
References
Referencesto the left-handor right-handside given in
1
this manual are made when viewing the motorcycle
fromthe rear.
Operations covered in this manual do not always
include reference to testing the motorcycle after
repair. Itis essentialthat work is inspectedandtested
after completion and if necessary a road test of the
motorcycle is carried out particularly where safety
relateditemsare concerned.
Dimensions
The dimensions quoted are to design engineering
specificationwith service limitswhere applicable.
During the period of running-in from new, certain
adjustments may vary from the specification figures
giveninthis manual. These will be reset by the dealer
at the 500 mile1800km service, and thereafter should
bemaintainedat the figures specifiedinthis manual.
J
Repairs and Replacements
Before removaland disassembly, thoroughly cleanthe
motorcycle.Any dirt enteringthe engine or other parts
will work as an abrasive and shorten the life of the
motorcycle. Particularattention should be paidwhen
installinga new part, that any dust or metalfilings are
clearedfrom 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
bothto the component itself and to the surface being
leveredagainst.
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
industrialquality gloves.
When replacement parts are required, it is essential
that only genuineTriumph partsare used.
Safety features and corrosion prevention treatments
embodied inthe 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
andlor causing gas or oil leakage. Conversely, bolts,
nuts, or screws, shouldall be loosened (insequence if
specified) by about a quarter of a turn and then
removed.
Where there is a tightening sequencespecified inthis
Service Manual, the bolts, nuts, or screws must be
tightenedinthe order and bythe method indicated.
Torque wrench setting figures given in this Manual
must be observed. The torque tools used must be of
accurate calibration.
Lockingdevices,where specified, must befitted. If the
efficiency of a locking device is impaired during
removal it must be renewed. This applies particularly
to micro-encapsulatedfixings which must always be
replaced if disturbed. Where necessary, the text in
this manualwill indicatewhere such a fixing is used.
Service Manual - SpeedTriple

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Sewice Manual - SpeedTriple

Table of Contents
IgnitionSystem Safety Precautions ...................................................
1-3
DangerousSusbstances
............................................................ 1-3
Fluoroelastomers
............................................................ 1-3
. .
Oils ............................................................................ 1-3
( i
..................................................
, HealthProtectionPrecautions 1-3
EnvironmentalProtection Precautions
................................................. 1-4
Brakes
.......................................................................... 1-4
................................................................
Safetylnstructions 1-5
............................................................
Jackingandlifting 1-5
...................................................
Precautionsagainstdamage 1-5
.................................................................... Coolant 1-5
Cleaningcomponents
......................................................... 1-6
.................................................................
Lubrication 1-6
.........................................................
Jointsandjointfaces 1-6
Gaskets, O-rings
............................................................. 1-6
Liquidgasket, non-permanentlockingagent
....................................... 1-6
ScrewThreads
.............................................................. 1-6
.............................................................
Locking Devices 1-7
.............................................................
Fitting a split pin 1-7
Circlips, retaining rings
........................................................ 1-7
.............................................................
Selflockingnuts 1-7
............................................................
Encapsulatedbolt 1-7
..........................................................
Oilandgreaseseals 1-7
.....................................................................
Press 1-7
................................................................. Ballbearing 1-7
..........................................................
FuelHandlingPrecautions 1-7
General
.................................................................... 1-7
Petrol-Gasoline
............................................................. 1-8
Fueltankremoval
............................................................ 1-8
Chassisrepairs
.............................................................. 1-8
..............................................................
ElectricalPrecautions 1-9
.........................................................
Batterydisconnecting 1-9
.................................................................. Disciplines 1-9
Electricalwires
............................................................. 1-10
Inspection
................................................................. 1-10
Replacementparts
.......................................................... 1-10
Servicedata
............................................................... 1-10
...............................................................
I Specification 1-10
Service Manual . SpeedTriple

................................................
ServiceTools and Garage Equipment 1-11
.........................................................
SpecialServiceTools 1-11
Engine
.................................................................... 1-16
CylinderHeadValves
......................................................... 1-16
Camshafts
................................................................. 1-17
........................................................
Clutch / PrimaryDrive 1-17
Balancer
................................................................... 1-17
Pistons
.................................................................... 1-18
Connecting Rods
............................................................ 1-18
Crankshaft
................................................................. 1-18
............................................................... Transmission 1-19
.................................................................. FinalDrive 1-19
Lubrication
................................................................. 1-19
Ignitionsystem
............................................................. 1-20
Fuelsystem
................................................................ 1-20
FuellnjectionSystem
........................................................ 1-20
..........................................................
Emissions Controls* 1-20
Coolantsystem
............................................................. 1-20
.................................................................
Suspension 1-21 (
Brakes ..................................................................... 1-21
WheelsandTyres
........................................................... 1-21
Frame
..................................................................... 1-22
.........................................................
ElectricalEquipment 1-22
TorqueWrenchSettings
.......................................................... 1-23
CylinderHeadArea
.......................................................... 1-23
Clutch
..................................................................... 1-23
............................................
Balancer,Crankshaftand Crankcase 1-23
Enginecovers
.............................................................. 1-24
Transmission
............................................................... 1-24
..........................................................
LubricationSystem 1-24
-- ... - - ... - . .. - ~ .... ..- -... ~~ . .- . . ...--. ...
3-25,
alDrive,.
..................................................................
CoolingSystem ............................................................. 1-25
.........................................
Fuel System, ExhaustSystem and Airbox 1-25
Rearsuspension
............................................................ 1-26
Frontsuspension
............................................................ 1-26
Wheels
.................................................................... 1-26
FrontBrakes 1-27
.
...............................................................
RearBrakes ................................................................ 1-27
Frame, Footrests,ControlPlates and Engine Mountings
............................. 1-27
Electrical
.................................................................. 1-28
Bodywork
.................................................................. 1-28
..............................................................
Clutchcablerouting 1-29
Throttlecablerouting
............................................................. 1-30
........................................................
Mainwiring harness routing 1-31
..........................................................
Frontbrakehoserouting 1-32
Rearbrakehoserouting
.......................................................... 1-33
.....................................................
Fueltankbreath'erhoserouting 1-34
Service Manual . SpeedTriple

General Information
I I IgnitionSystem Safety Precautions
The ignition system produces extremely high
voltages. Do not touch any part of the ignition
systemor any cableswhile the engine is running.
An electric shock caused by contact with the ignition
system may leadto 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 illnessor death.
Fluoroelastomermaterial is usedinthe manufacture
of various seals inTriumphmotorcycles.
In fire conditions involving temperatures greater
than
315OC 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 generatedand
will bepresent infumesfromfires.
In the presence of any water or humidity hydrogen
fluoride may dissolve to form extremely corrosive
liquidhydrofluoricacid.
If such conditions exist, do not touch the material
andavoid all skincontact. Skin contactwith liquidor
decomposition residues can cause painful and
penetrating burns leadingto permanent, irreversible
skinand tissue damage.
DangerousSusbstances Oils
Manv liauids 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 includedfor your safety and well-being.
NEVER DISREGARDTHESE INSTRUCTIONS!
I The ennine and bevel box oils mav be hot to the I
touch. Contactwith hot oil may causethe skinto be
scaldedor burned.
I Prolonged or repeated contact with engine oil can I
lead to skin dryness, irritation and dermatitis. In
addition usedengine oil contains potentially harmful
contaminants which can cause cancer. Wear
suitableclothing and avoid skin contact.
Health ProtectionPrecautions
*
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloveswhere practicable.
*
Do not put oily rags inpockets.
* Overalls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
* First aid treatment should be obtained
immediatelyfor open cuts and wounds. Always
Sewice Manual - SpeedTriple
1.3

be aware of who your nearest first-aider is and
where the medicalfacilitiesare 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
completingwork.
Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help). Preparationscontaininglanolin replacethe
naturalskin oilswhich have been removed.
Do not use petrol, kerosene, diesel fuel, gas oil,
thinners or solventsfor cleaningskin.
If skin disorders develop, obtain medical advice
without delay.
Where practicable, de-grease components prior
to handling.
Any riskof eye injurymust beavoided. Always wear
eye protection when using a hammer, air line,
cleaning agent or where there is ANY risk of flying
debris or chemical splashing.
rakes
Brakefluid is hygroscopicwhich means itwillabsorb
moisture from;he air: Any absorbed moisture will
greatly reduce the boiling point of the brake fluid
causinga reductionin brakingefficiency.
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 paintedor plastic
surface.
Always use new brake fluid from a sealed container
and never use fluid from an unsealed container or
from onethat has beenpreviouslyopened.
Do not mix different brands of fluid. Check for fluid
leakage around brakefittings, seals and joints.
Check regularlyfor brake hosedamage.
FAILURE TO OBSERVE ANY OF THE ABOVE
WARNINGS MAY REDUCE BRAKING
EFFICIENCYLEADINGTO AN ACCIDENT.
recautions
If there has been an appreciabledrop inthe level of
the fluid in either brake fluid reservoir, consult your
drains, or into water courses. To prevent pollutionof
water-coursesetc., dispose of usedoil sensibly. If in
doubt contactyour 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 localauthority andlor 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 disposalfacilities.
1 applied, or if the leverlpedal travel becomes 1
excessive, there may be air inthe 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 leadingto an accident.
in the general information section of this manual.
The use of brake fluids other than those
0.0.7. 4
fluids listed in the general information section may
reduce the efficiency of the braking system leading
to an accident.
I Failure to change the brake fluid at the interval
specified in the routine maintenanceschedule may
reduce brakingefficiency resultingin an accident.
Service Manual - SpeedTriple

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 mastercylinders.
Damage caused by contact with mineral based
grease may reduce brakingefficiency resulting inan
accident.
Safety Instructions
Jacking and lifting
Always ensure that any lifting apparatus has
adequate load and safety capacity for the weight to
be lifted. Ensurethe motorcycleis well supported to
prevent any possibility of the machine falling prior
during liftingorjacking orwhile repairsand servicing
arecarriedout.
Never rely on a single means of support when
workin'g with the motorcycle. Use additional safety
supports and straps to preventtoppling.
Do not leavetools, lifting equipment, spilt oil, etc. in
a place where they could become a hazard to
health. Always work ina clean, tidy area and putall
tools away when the work isfinished.
Precautionsagainst damage
1 I
Avoid spilling brakefluidor battery acid on any partof
the bodywork. Wash spillages off with water
immediately.
Disconnect the battery earth lead before starting
work, see
ELECTRICALPRECAUTIONS.
Always use the recommended service tool where
specified.
Protect exposed bearing and sealing surfaces, and
screw threadsfrom damage.
Coolant
' -- ,. A-warning ?-
" c
" 3
- '
I)
, I
-. ' s- ,
Coolant mixture, which is blended with anti-freeze
and corrosion inhibitors contains toxic chemicals
which are harmful to the human body. Never
swallowanti-freeze, corrosion inhibitorsor any of the
I motorcyclecoolant.
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
skindamage.
A Caution
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 resultingcorrosionwould causeblockages inthe
cooling system leading to engine overheating and
damage. Always use the correct anti-freeze as
specified in the Owner's Handbook. Never use a
methanolbasedanti-freezeas this does not contain
the requiredcorrosion inhibition properties.
(see specification for anti-freeze) in the cooling
system.
If hard water is used inthe system, it causes scale
accumulation in the water passages, and
considerably reduces the efficiency of the cooling
system. Reduced cooling system efficiency may
leadto the engine overheatingand engine damage.
Service Manual - SpeedTriple

Cleaningcomponents
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 cleaningdismantledcomponents.
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
cleanedoff. This is becauseused lubricantswill have
lost some lubrication qualities and may contain
abrasiveforeign 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 inthe assembly of certain engine and chassis
parts. AlwaJiS
chFck-m~fZt~-Ec3mmeTdati~s
beforeusing such special lubricants.
Joints andjoint faces
Assemblejoints dry unless otherwise specified inthis
Manual.
If gaskets andlorjointing compound is recommended
for use; remove all traces of oldjointing 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 usingan oil stone. Do not allow dirt
orjointing materialto enter any tapped holes.
Gaskets, O-rings
Liquidgasket, non-permanent lockingagent
(
\
Follow manufacturer's directions for cleaning and
preparing surfaces where these compounds will be
used. Apply sparingly as excessive amountsof sealer
may block'engine oil passages and cause serious
damage.
Priorto reassembly, blowthroughany pipes, channels
or creviceswith compressedair.
To prevent injury, always use eye, face and ear
protectionwhen usingcompressedair. Always wear
protective gloves if the compressed air is to be
directed inproximity.tothe skin.
Screw Threads
f
Metricthreadsto IS0standardare 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 thisforms partof 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
affectthe-&xqu
Unless specified, threaded fixings must always be
fitted dry (no lubrication).
I Never lubricateathread unless instructedto do so. I
When a thread of a fixing is lubricated, the thread
friction is reduced. When the fixing is tightened,
reduced friction will cause overtightening and
possiblefixing failure.
IA fixing which fails in service could cause1
component detachment leading to loss of control
and an accident.
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 perfectlysmooth
to avoid oil or compressionleaks.
Service Manual - SpeedTriple

General Information
11
Locking Devices
Always release locking tabs and fit new locking
washers, do not re-uselockingtabs.
Fittinga split pin
Alwaysfit newsplit-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
caseswhen this forms partof 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
( i installing circlips and retaining rings, take care to
compress or expand them only enough to install
them.
Always use the correct replacement circlip as
recommendedintheTriumph parts catalogue.
Self lockingnuts
Self-lockingnutscan be re-used, providing resistance
can be felt when the locking portion passes over the
thread of the boltor stud.
DO NOT re-use self-locking nuts in critical locations,
e.g. suspension components. Always use the correct
replacementself-lockingnut.
Encapsulatedbolt
An encapsulatedbolt can be identified by a coloured
I
sectionof thread which istreatedwith a lockingagent.
Unless a specified repair procedure states otherwise,
encapsulated bolts cannot be reused and MUST be
replacedif disturbedor removed.
I Failureto replacean encapsulatedbolt could leadto I
a dangerous riding condition. Always replace
encapsulatedbolts.
Oil and grease seals
Replace any oil or grease seals that are removed.
Removalwill causedamage to an oil seal which, if re-
used, would cause an oil leak.
Ensure the surfaceon which the new seal is to run is
I J
free of burrs or scratches. Renew the component if
the original sealing surface cannot be completely
restored.
Protectthe 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
surfaceand avoid touchingthe 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 inwiththe marks facing out.
Seals must be pressed into place using a suitable
driver. Use of impropertools 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 circumferenceso that it
will locatesmoothly.
Ball bearing
When installing a ballbearing, the bearing racewhich
is an interferencefit should be pushed by a suitable
driver. This prevents severe stress or damage to the
load carryingcomponents. Press a ball bearing untilit
touchesthe shoulder inthe bore or onthe shaft.
Pressor driftseals to the depthof its housing, with the
sealing lip facing the lubricant to be retained if the
housing is shouldered, or flush with the face of the
housingwhere no shoulder is provided.
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 informationis issued
for basic guidance only and, if in doubt, appropriate
enquiries should be madeof your local Fire Officer.
ServiceManual - SpeedTriple

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 motorcycleignitionswitchOFF.
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
drainingwork on a fuel system.
Whenever petrol (gasoline) is being handled,
drained, stored or when fuel systems are being
dismantled,makesurethe area iswell ventilated. All
potential forms of ignition must be extinguished or
removed
.(this includes any ap_plLancewitha-pilot
-- --
-- -
- -- -- - -- -- - -
light). Any leadJIamismu3beflame-proofand kept
clear of any fuel spillage.
Warning notices must be posted at a safe distance
fromthe site of the work to warn othersthat petrolis
beingopenly handled. The notice must instruct the
readerof the precautionswhich must betaken.
Failure to observe any of the above warnings may
lead to a fire hazard which could result in personal
injury.
No one should be permittedto repair components
associated with petroilgasoline without first having
specialist training on the fire hazards which may be
created by incorrect installation and repair of items
associatedwith petrollgasoline.
Repairs carried out by untrained personnel could
bring about a safety hazard leading to a risk of
personalinjury.
Draining or extraction of petrollgasoline from a
vehicle fuel tank must be carried out in a well
ventilatedarea.
The receptacle used to contain the petrol1gasoline
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
requirementsof localauthority regulations.
When petrollgasoline has beenextractedor drained
from a fuel tank, the precautions governing naked
lightsand ignitionsources should be maintained.
Failureto observe any of the above warnings could
bring about a safety hazard leading to a risk of
personalinjury.
Fuel tank removal
Fuel tanks should have a 'PETROL (GASOLINE)
VAPOUR' warning label attached to them as soon as
they are removedfrom the vehicle. In all cases, they
must bestored ina secured, marked area.
Chassis repairs
If-the-motorcycle-is=involved-in-anraccident=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 resultininjuryor death.
The frame must not be modifiedas any modification
to the frame such as welding or drilling may weaken
the frame resulting inan accident.
Service Manual - SpeedTriple

General Information
I ElectricalPrecautions
The following guidelines are intended to ensure the
safetyof the operator whilst preventing damageto 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
repairoperations.
Equipment
- Priorto 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
leadsand plugs.
The ignition system produces extremely high
voltages. Do not touch any part of the ignition
systemor any cableswhile the engine is running.
An electric shock causedby contact with the ignition
system may leadto illness, injuryor 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
keepchildrenaway from the batterywhether or not it
isfitted inthe motorcycle.
Do not jump start the battery, touch the battery
cablestogether 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
personalinjury.
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 theseterminals.
Connectors and Harness
- The engine of a
motorcycle is a particularly hostile environment for
electrical componentsand connectors.Always ensure
these items are dry and oil free before disconnecting
and connecting test equipment. Never force
connectorsapart either by usingtools or<bypullingon
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
replacedif disturbed.
Havingconfirmed a component to befaulty, switchoff
the ignition and disconnect the battery negative
(black) leadfirst. Removethe componentand support
the disconnected harness. When replacing the
component keep oily hands away from electrical
connectionareasand pushconnectorshome untilany
locking mechanism becomesfully engaged.
Batterydisconnecting
Before disconnecting the battery, switch off all
electricalequipment.
To prevent the risk of a battery exploding and to
prevent damage to electrical components ALWAYS
disconnect the battery negative (black) lead first.
When reconnectingthe battery, always connect the
positive (red) lead first, then the negative (black)
lead. Always disconnect the battery when working
on any part of the electricalsystem.
Failureto observe the above warnings may lead to
electrical damage and a fire hazard which could
cause personalinjury.
Always ensure that battery leads are routed correctly
and are not closeto any potential chafing points.
Disciplines
Switch off the ignition priorto making any connection
or disconnection in the system. An electrical surge
can be caused by disconnecting 'live' connections
which can damage electronic components.
Ensurehandsandwork surfaces are clean andfree of
grease, swarf, etc. as grease collects dirt which can
causetrackingor high-resistancecontacts.
Priorto commencing any test, and periodically during
any test, touch a good earthto discharge body static.
This is because some electronic components are
vulnerableto static electricity.
Sewice Manual - SpeedTriple

Electricalwires
All the electricalwires are either single-colouror two-
colour and, with only a few exceptions, must be
connectedto 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
andthenthe secondarycolour. For example,a yellow
wire with thin red stripes is referred to as a 'yellow1
red' wire; it would be a 'redlyellow' wire if the colours
were reversedto make redthe maincolour.
Inspection
Disassembledparts 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.
Replacement Parts
Only Triuniph genuine parts should be used to 1
service, repair or convert Triumph motorcycles. To
ensurethat Triumphgenuine partsare used, always
order parts, accessories and conversions from an
authorised Triumph dealer. The fitting of non-
approved parts, accessories or-conversions-may
adversely affect the handling, stability or other
aspects of the motorcycle operation which may
resultinan accidentcausing serious injury or death:
Always have Triumph genuine parts, accessories
and conversions fitted by an &uthorised Triumph
dealer. The fitment of parts, accessories and
conversions by a dealer who is not an authorised
Triumph dealer may affect the handling, stability or
other aspects of the motorcycle operation which
may result in an accident causing serious injury or
death.
I Always have Triumph approved parts, accessories
and conversions fitted by a trained technician. To
ensure that a trained technician is used, have an
authorisedTriumph dealer fit the parts. The fitment
of parts, accessoriesand 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.
Servicedata
The service data listed in this manual gives
dimensions and specifications for brand new, original
parts. Where it is permissibleto allow a partto exceed
these figures,then the service limit is given.
The terms of the motorcycle warranty will be
invalidatedby the fitting of otherthan genuineTriumph
parts.
All genuine Triumph parts have the full backingof the
motorcycle warranty. Triumph dealers are obliged to
supply only genuineTriumph recommended parts.
Specification
Triumph are constantly seeking to improve the
specification, design and production of their
. ly.---_ ,-
- -
While every effort has been made to ensure the
accuracy of this Manual, it should not be regardedas
an infallible guide to current specifications of any
particular motorcycle.
f
Authorised Triumph Dealers are not agents of (
Triumph and have no authority to bind the
manufacturer by any expressed or implied
undertakingor representation.
Sewice Manual - SpeedTriple

General Information
Service Tools and Garage Equipment
Special servicetools have beendeveloped to facilitate removal, dismantlingand assembly of certain mechanical
components in a practical manner without causing damage. Some operations inthis Service Manual cannot be
carried out without the aid of the relevant service tools. Where this is the case, the tools required will be
describedduringthe procedure.
Special Service Tools
T3880105 - Angular Torque Gauge T3880371
- Holder, Oil Pump DriveGear
cbxt
T3880250 - EngineManagement Diagnostics A9938017
- Chain LinkTook Kit
Service Manual - SpeedTriple
1.1 1

3880085-TO301 - Fork Piston Holder T3880017 - Holder, Sprag Clutch
3880160-TO301
- Fork Filler / Evacuator 13880305 - ClutchAnti-rotationTool
ccha
T3880375 - Alternator Rotor Holder
1.12
Service Manual - SpeedTriple