Triumph Thunderbird User manual

Triumph Thunderbird
Motorcycle Service Manual
Part Number 3850700 issue 1, 07.2009
This document is protected by copyright and may not, in whole or part be stored in aretrieval 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. 2009
SelVice Manual -Thunderbird

II
SelVice Manual -Thunderbird

TableofContents
ServiceManual–Thunderbirdiii
Introduction V
General Information 1
Scheduled Maintenance 2
Cylinder Head 3
Clutch 4
Crankshaft, Connecting Rods and Pistons 5
Balancer 6
Transmission 7
Lubrication 8
Engine Removal and Refit 9
Fuel System/Engine Management 10
Cooling 11
Brakes 12
Front Suspension 13
Rear Suspension 14
Final Drive 15
Wheels & Tyres 16
Frame and Bodywork 17
Electrical System 18


iv SelVice Manual -
Thunderbird

Introduction
Table of Contents
How to use this manual. . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . iLvi
Warnings, Cautions and Notes. ........................................................... ii.vi
Tampering with Noise Control System Prohibited ............................................. ii.vii
References . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . .
.. ii.vii
Dimensions. .........................................................................
.. iLvii
Repairs and Replacements. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iLvii
Force. ..............................................................................
.. iLvii
Edges. .............................................................................. .. ii.vii
Tightening procedure. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . .
.. iLvii
SelVice Manual -Thunderbird v

This manual is designed primarily for use by trained
technicians in aproperly 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 acontents 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:
This warning symbol identifies
special instructions or
procedures which, if not correctly followed, could result
in personal injury, or loss of life.
This caution symbol identifies special instructions or
procedures which, if not strictly observed, could result in
damage to or destruction of equipment.
Note:
• This note symbol indicates points of particular
interest for more efficient and convenient
operation.
vi Service Manual -Thunderbird

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 anew 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 apart 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.
Whenever tapping to aid removal of an item is necessary,
tap lightly using ahide 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 apart with several bolts, nuts or
screws, they should all be started in their holes and
tightened to asnug 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 aquarter of a
turn
and then removed.
Where there
is atightening 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 alocking 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 afixing is used.
SelVice Manual -Thunderbird
VII

viii
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SelVice Manual -Thunderbird

1General 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. .............................................................. 1.5
Environmental Protection Precautions. ....................................................... 1.5
Brakes. ..... .. .... .. ............... .. . .. ... .. .... .. ... .. . .. ... . .. . .. . ... . . . . . . . .. ........ 1.5
Safety Instructions. ........................................................................ 1.6
Jacking and Lifting. ................................................................. .. 1.6
Precautions against Damage.. .. ... .. . .. ... .. . . . . .. . .. . .. . . . ... . .. .... .. . .. ..... .. ... .. 1.6
Coolant. .......................................................................... .. 1.6
Cleaning components. .............................................................. .. 1.7
Lubrication. ....................................................................... .. 1.7
Joints and joint faces. ............................................................... .. 1.7
Gaskets, a-rings. ................................................................... .. 1.7
Liquid Gasket, Non-permanent Locking Agent. . . . . .. . .. .. .... .. ... .. . .. .... ..... ... ... 1.7
Screw Threads. .. .. .... .. ... .. ... .. . ... . . ... . . . .. . .. . .. . .. . . .. . .. ........ .. ... .. 1.7
Locking Devices. ................................................................... .. 1.8
Fitting aSplit Pin ................................................................... .. 1.8
Circlips, Retaining Rings. ............................................................ .. 1.8
Self Locking Nuts. .................................................................. .. 1.8
Encapsulated Bolts. ................................................................. .. 1.8
Oil and Grease Seals. ............................................................... .. 1.8
Press. .. ... ... .... .. . . .... ... ...... .. ... .. . . . . .. . .. . . .. . . ... .... .. .. . . .. . ... .. ...... 1.8
Ball Bearing. ....................................................................... .. 1.8
Chassis Bearing Lubrication. ................................................................ 1.9
Metal bushes ....................................................................... 1.10
Fuel Handling Precautions. ................................................................ 1.10
General. ......................................................................... .. 1.10
Petrol -Gasoline. .................................................................. .. 1.10
Fuel Tank Removal. .................................................................. 1.11
Chassis Repairs " . .. . . . . .. .. ... .. . .. .. . . . .. .. .. . .. 1.11
Electrical Precautions ..................................................................... 1.12
SelVice Manual -Thunderbird
1.1

Clutch and Throttle Cable Routing
Coolant Expansion Tank Hose Routing

Main Wiring Harness Routing - Thunderbird
Brake Pipe and Hose Routing - Thunderbird without ABS
Brake Pipe and Hose Routing - Thunderbird with ABS
Fuel Hose and Fuel Tank Breather Hose Routing (non-evaporative emission control versions)
Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing
. . . . . . . . . . . .

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 oil 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.
1.4
Service Manual - Thunderbird

Health Protection Precautions
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
Do not put oily
rags in pockets.
Overalls must be cleaned regularly. Discard
heavily soiled clothing and
oil impregnated
footwear.
First aid treatment should be obtained
immediately for open
cuts and wounds. Always
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 ahammer, 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.
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 areduction
in braking efficiency.
Replace brake fluid in line with the routine maintenance
schedule. Adangerous 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.
Service Manual -Thunderbird
1.5

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 DOT 4specification brake fluid
as listed in the
General Information section of this manual. The
use of
brake fluids other than those DOT 4fluids 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.
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 4brake
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.
Adangerous 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 asingle 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 ahazard 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 ofthe
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.
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.
1.6
SelVice Manual -Thunderbird

The coolant anti-freeze contains acorrosion 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 amethanol 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.
Cleaning components
Ahigh 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 atool 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 agasket 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.
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 anut 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).
SelVice Manual -Thunderbird 1.7

Never lubricate athread unless instructed to do so.
When athread of afixing is lubricated, the thread
friction
is reduced. When the fixing is tightened,
reduced friction will
cause overtightening and possible
fixing failure.
Afixing 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 aSplit 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 asplit 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 acoloured
section
of thread which is treated with alocking agent.
Unless aspecified 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.
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 arecommended 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 asuitable driver.
Use of improper tools will damage the seal.
Press
Apart installed using a press or driver, such as awheel
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 aball bearing, the bearing race which is
an interference fit should be pushed by asuitable driver.
This prevents severe
stress or damage to the load carrying
components.
Press aball 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.
1.8 SeIVice Manual -Thunderbird

ceon
Note:
Sealed bearings
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 asealed
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
ceon
•
•
•
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:
General
For abearing 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.
Acorrectly lubricated bearing will have afilm of
lubrication that
separates the moving parts, disperses heat
and protects the bearing
surfaces from corrosion.
Note:
Chassis Bearing Lubrication
Note:
•This information relates only to bearing
lubrication.
For the procedures necessary to
replace abearing, 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.
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.
•In all cases, use the lubricant recommended.
•Grease the bearing, not the cavity where it
is
located.
•Abearing that
is not regularly checked and
lubricated will have areduced 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 washedoff prior to assembly and in-service
lubrication.
When lubricating anew bearing with
grease the following
steps should be taken:
Lubrication and Checks While Servicing aBearing
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.
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.
SelVice Manual -Thunderbird
1.9

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.
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 areadily 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 afire 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 afuel
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 apilot 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 afire hazard which could result in personal injury.
1.10
SelVice Manual -Thunderbird

No one should be permitted to repair components
assoGlted 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 asafety hazard leading
to arisk of personal injury.
Draining
or extraction of petrol/gasoline from avehicle
fuel tank must be carried out in awell 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 afuel tank, the precautions governing naked lights
and ignition
sources should be maintained.
Failure to observe any of the above warnings could
bring about asafety hazard leading
to arisk 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 asecured, 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 asecond 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- Thunderbird
1.11

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 aspark which would ignite
battery
gasses causing arisk 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 amotorcycle 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 acomponent 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 ofabattery 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 afire hazard which could cause
personal injury.
Always ensure that battery
leads are routed correctly and
are not close to any potential chafing points.
Disciplines
Switch off the ignition prior to making any connection or
disconnection
in the system. An electrical surge can be
caused by disconnecting 'live' connections which can
damage electronic components.
Ensure hands and work surfaces are clean and free of
grease, swart, etc. as grease collects dirt which can cause
tracking or high-resistance contacts.
Prior to commencing any test, and periodically during any
test, touch agood earth to discharge body static. This is
because some electronic components are vulnerable to
static electricity.
Electrical Wires
All the electrical wires are either single-colour or two-
colour and, with only afew exceptions, must
be
connected to wires of the same colour. On any of the two-
colour wires there
is agreater amount of one colour and a
lesser amount of a second colour. Atwo-colour wire is
identified by first the primary colour and then the
secondary colour.
For example, ayellow wire with thin
red stripes
is referred to as a'yellow/red' wire; it would be
a'red/yellow' wire if the colours were reversed to make
red the main colour.
1.12 Service Manual -Thunderbird