Triumph Trident T160 Instruction manual
A
WORKSHOP
MANUAL
For
the
Three
Cylinder
TRIUMPH
TRIDENT
MODEL
T160
750cc
(45.
cubic inch)
with
Electric
Starter
From Engine
Number
001
01
Compiled
by
John
R.
Nelson
M.A.
Eng (CANTAB) M.I.Mech.E.
©
CopyrightbyJ.R.NELSON
Published
by
J.R.
Technical
Publications
Printed by
Warwick
Printing Ltd
..
Theatre
Street.
Warwick.
Published Apri11982.
ClassicBike.biz
006
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'SLIPPERY
SAM'
Ourcover design
shows
the legendaryTriumph Tridentmodel which earned
thevery well known,
but
possibly dubious
title
of
"Slippery Sam".
Its feats and achievements
as
asingle individual model to win the Isle
of
Man Production T.T. Race no less
than
five years in succession have earned
it
aplace in
the
Annals
of
T.T. history, and is truly representative
of
the sense
of
spirit and lively response
built
into
all
the
Triumph Trident models in both the
T150
and
T160
model series.
\
ClassicBike.biz
INTRODUCTION
TO
THIS
MANUAL
This
Workshop
Manual
has been
compiled
to provide service
information
for
750cc
(45
cu.in.l
TRIUMPH
T160
ELECTRIC
START
'TRIOENT' MOOEL owners
wishing
to
carry
out
basic
maintenance overhaul and repair
work
on both
this
early
T1
50
and
the
later
T1
60
Electric Start
versions of this model.
The technical
content
has been
brought
together
and presented in a
matching
style
to
that
of
the
original factory
T150
model
workshop
manual,
but
has
of
course
been
totally
updated and
rewritten
to incorporate
not
only
the
features specifically exclusive to
the
Electric
Start
version
of
the Trident.
but
at
the
same
time
cover
the Disc Front and Rear Brakes
incorporated
on some
of
the later
T150
and
Rocket
3
Models;
details
of
which
were
not
included
in
the
earlier
T1
50
Model
and Rocket 3
Workshop
Manuals
of
that
time, This version then should also be
of
considerable
assistance to late
T1
50
Trident
and
Rocket
3
owners
in this category, The
actual procurement
and
collation
of
the
technical
information
.tp provide this Publication
achieved
finality
some
considerable
time
following
closure
of
Norton Villiers
Triumph
International
at
Kitts Green in
Birmingham,
when
co-incidentally
the
production
of
the actual Triumph
T160
Electric
Start
Model
of
the Trident, being
built
and
assembled
atthe B.S.A. Factory at Small
Heath
came
to
afinai end.
The total
staff
involved in
the
design, manufacture, production and
servicing
of
this
machine
thereby having
become
made
redundant
quietly
folded
their
tents
and
disappeared
their
many and
several ways in search
of
fresh
fields
and pastures new.The collected
T160
Model
knowledge
was
suddenly dispersed and
scattered
overnight.
It
was
felt
that
the
accumulated
knowledge
of
the
writers
Colleagues
should
not
be
lost
following
the
demise
of
this
famous
name
and
that
every
attempt
should be
made
to
preserve and present this information
for
the
record
and
for
ultimate
use, The
writer
therefore decided
to
collect
whatever
material
that
was
immediately
available, and
then seek the
urgent
aid
of
his colleagues (the actual Technicai
Staff
from
the
original Company
making the Trident.)
Generous
contributions
and
material
has enabled
this
manual to
be
brought
to
completion
and
although
it
is
now
some
considerable
time
after
the end
of
the
manufacture
of
the model
concerned
it
was
nevertheless
felt
that
the
full
range
of
information
contained
herein
would
undoubtedly prove invaluable
to
current
Trident owners wishing
to
keep
this
prestigeous machine
in
first
class condition, even
more
importantly
as the inevitable
time
approaches, be
totally
authoratative
for
those
who
will
inevitably
be engaged
on
the
overhaul and
ultimate
restoration
of
this
much sought
after
representative
of
avery successful high performance
motorcycle.
The
first
section
of
this
manual
therefore provides aGENERAL
DATA
SECTION in Ready
Reference form, detailing all
the
original and recommended
drawing
and
manufacturing
dimensional data
of
all
moving
and
wearing
compo'nents and indicating
the
established
optimum
fits, limits and tolerances.
The layout
of
this general data
section
follows
the same sequence of the
main
sections
in the body
of
the manual, corresponding
to
normally
established procedures
of
strip
down,
examination and
rebuild.
The
T160
'ELECTRIC
START'
version
electrical
equipment
is fully
described
and illustrated,
followed
by afinal
section
which
deals
with
the
originally recommended service
tools
some
of
which
were developed,
drawn,
part
numbered
but
sadly never saw the
light
of
day; others
which
most
likely by
now
prove
to
be no
longer
avaiable.
However
the
author
felt
that
it
would
be
worthwhile
including
the
illustrations
and references
to
allow the
well
equipped
or
keenly
adaptable reader to
devise
his
own
methods
and solutions along the
lines
so indicated, thereby
allowing proper
protection
of
the
components
during the operation in
the
manner
originally
intended.
It
has always been
accepted
as
useful
practice
to
include in any manual
the
relevant
Conversion
and Reference Charts. Here
we
have
also included those previously
found
useful
from
the
earlier
publication, and
will
be
found
at
the
end
ofthis
Manual.
John
R.
Nelson
ClassicBike.biz
FOREWORD
All Triumph
Trident
T1
50
and
T1
60
Models incorporated the same engine and frame numbering
principles utilising a
two
letter
prefix prior
to
the machines own individual number. This
was
followed
immediately
by
the
model
type
designation. the complete sequence preceeded and ended
by acircular stamped
limiting
ident
thereby preventing any subsequent
form
of
illegal alteration
or
amendment.
The engine
number
is
to
be
found
on the
left
side
of
the engine. immediately
below
the cylinder
block flange.
the
numbers
being
stamped
onto araised embossed pad - a
further
aid to counter-
feiture.
'.
The prefix letters indicate
both
year
and
month
of
manufacture.
The
first
prefix
letter
indicates
the
month
and
yearof
manufacture
as
follows:-
Month
of
Manufacture
A
January
BFebruary
C
March
D
April
E
May
G
June
H
July
J
August
K
September
N
October
P
November
X
December
Yearof
Manufacture
J
1974
K
1975
N
1976
P
1977
X
1978
A
1979
8
1980
The
third
section is a
numerical
block
of
five figures which comprise
the
engine
number
commencing at
001
01.
The
fourth
section
indicated
the
model
designation.
Example
Month
NYear
JNumber
00101
Model
T160
The
frame
number
is
stamped
on
the
left
side
of
the frame. in
front
of the fuel tank.
The
frame
bears
the
same
serial
number
as
the engine unitfitted into
it
and hence were identical at
the
time
of
original
manufacture.
ANCILLARY
EQUIPMENT
AND
PROPRIETARY
FITTINGS
Carburetters
Chains
Electrical Equipment
Rear Suspension
Sparking Plugs
Instruments
Tyres
Amal
Ltd. Holdford
Road
Witton
8irmingham
6.
Renold Chains Ltd. Wythenshawe Manchester.
JLucas Ltd. Great Hampton Street. Birmingham 18.
Girling
Ltd. Birmingham
Road.
West
Bromwich Staffs.
Champion Sparking Plug Company
Ltd.
Feltham Middx.
Smiths
Industries Ltd. Cricklewood Works London
NW2.
Dunlop
RubberCompany Ltd. Fort Dunlop Birmingham 24.
ClassicBike.biz
ACKNOWLEDGEMENTS
The
compilation
of
this publication results
from
generous
and accurate contributions made
from
former
colleagues
Jack
Harper and
Arthur
Lupton,
both
previously
for
many years
with
the
8.S.A.
Service Department, and
with
practical
help
and advice from many friends, including Harry
Woolridge
of
Triumph
Motorcycles
(Meriden) Ltd., and
of
course Leslie Williams the proud
owner
of
'Slippery
Sam', perhaps
the
most
famous
Trident
of
them
all.
Due
to
the
tortuous path
of
ownership
of
the
names
of
Triumph,
8.SA,
N.V.T.M. and 'TRIDENT',
greatful
acknowledgement is freely given
to
Mr.
Dennis
Poore, N.V.T., the Receiver N.T.I. Ltd.,
Messrs Cork Gully &
Co.
and
to
Triumph
Motorcycles
(Meriden) Ltd.
for
permission
to
proceed
with
and produce this Manual, utilising (where appropriate) existing technical
matter
and
artwork
previously used on Triumph
Trident
publications,
which
has proved so invaluable in the compilation
and
completion
of
this project.
J.R.N.
December
1981.
DISCLAIMER
Whilst
every endeavour has been made
by
all
those
contributing
to this publication to assure and
maintain
its technical accuracy,
it
must
be
appreciated
that
compilation a
number
of years
after
the
closure
of
the
factory
where
manufacture
took
place and the loss of the associated design and
development
facility,
with
consequent
disbandment
of
the
original drawing facilities and records,
those
responsible
for
the composition and
publication
of
this
Workshop
Manual, cannot accept any
responsibility whatsoever
for
any errors,
or
any
da
mage
or
damages arising
or
ensueing
from
such
errors in any
way
whatsoever.
ClassicBike.biz
ClassicBike.biz
·.
GENERAL
DATA
TRIDENT
MODEL
TI60
750
C.c.
(45 cu. ins.)
GDl
ClassicBike.biz
GD
OiL
PUMP
Pump
drive
ratio
Type •..
OIL
PUMP
DRIVE
Intermediate:
gear-Bore
Bush-Bore
-Length
Spindle-Diameter
OiL
PRESSURE
RELIEF VALVE
Release pressure
OiL
PRESSURE
Normal running
Switch operating pressure ...
GENERAL
DATA
GENERAL
DATA
MODEL
T160
TRIDENT
LUBKICATION
SYSTEM
1-9 : 1 (engine
to
pump)
Geilr (duplex)
·5625/·5620
In.
(14·287/4·2748 mm.)
·4387/·4382 In. (11'143/11'1302 mm.)
·755/·745 In. (19·177/18·923 mm.)
·4360/·4357
In.
(11·0744/11-0668 mm.)
85-75
p.•.
I.
(5·976-5'273 kg/em2
.)
85~75
p.'.!' (5-976-5·273 kg/em2.)
3-5
p.•.!. (0,211 kg/em2..()·j522 kg/em.)
ENGINE
BASIC
DETAILS
Bore and
stroke
CapaCity
Compression ratio
CRANKSHAFT
Crankshaft type
Main
bearing
!drlVe side) size and
type
Main
bearing
centre)
funning
clearance
Main
bearing
timing
side) size and
type
Left
main
bearing housing
diameter
Left main
bearing
Journal
diameter
Centre
main
bearing
housIng
diameter
Centre
main bearing journal
diameter
Right
main
bearing
housing
diameter
Right main
bearing
Journal
diameter
Big
end
Journal
diameter
Min.
regrind
diameter
CONNECTING
RODS
Length
(centres)
•
__
Big
end
bearings
type
Con
rod
side
clearance
Bearing
dlametral
clearance
WRiST
PIN
(GUDGEON
PIN)
Clearance
In
con~rod
Diameter
Length
CYLINDER
BLOCK
Material
Bore...
..,
Maximum
oversize
(see also page 00)
Tappet
guide
block housing
diameter
Liner
materIal
CYLINDER
HEAD
Material
Inlet
port
size
Exhaust
port
size
Valve
seatings:
Type
Material
...
VALVES
Stem
diameter~
Inlet
Exhaust
Head
diameter:
Inlet
Exhaust
Exhaust
valve material
GD2
67 X
70
mm. (2-637 In. Y2-756 In.)
740·4
em'
(45-2
cu.
In.) .
9·5
:1
EN16B
hardened
and
tempered
stamplng~
one
piece
1* X
2+t
x+t
In.
(caged ball)
·0005/·00llln.
(·0127/·05588 mm.)
25
mm
X52 mm X15 mm (roller)
2·8100/2·8095
In.
(71·3740/71·3613
mm.)
1-1248/1·1245
In.
(28·5699/28·5623
mm'l
2'0630/2-0625ln.!52.4002/52-3875
mm.
1·9170/1-9175In. 48·6918/48-7045
mm.
2·0447/2-0457 In. 51·9344/51·9608
mm.)
0'9843/0·9840 In.!25'0012/2409936 mm.)
1·6240/1·6235In. 41/2496/41·2369 mm.)
1-6200/1-6195In. 41-148/41'1353 mm.)
5·751/5-749
In.
(14-6075/14-6024 mm.)
BI~metal.
5teel backed
·008/·014
In.
0·2032/0·3556 mm.)
·0005/·0020 in. minimum
(·0127/·0508 mm.)
'005/·0011
In.
(0127/·0279 mm.)
·6883/·6885 In.(17·4828/17·4880 mm.)
2·250/2·235
In.
(57·150/56·769 mm.)
Aluminum
Alloy
2-6366/2-6363 In. (66'9696/66-962 mm.)
+·040 In. (1-016 mm.)
1-1562/1-1557
In.
(29·3675/29·3548
mm.)
Austenitic
steel
Alum alloy dIe casting
1-p;" dia. (2S·575mm)
(c'
bore
1t·)
(31·75mm)
1.ln.
dla. (31'75 mm.)
Cast-In
Cast
iron
·3100/·3095
In.
(7·8740/7·8613 mm.)
·3095/·3090 In. (7·8613/7·8495 mm.)
1·534/1-528
In.
(38·9636/38·812 mm.)
1315/1·309
in.
(lJ·401/33·2486
mm.)
Chromlum-Manganese-Nlckel-Nitrogen
valve
steel
(heat
treated)
ClassicBike.biz
VALVE
GUIDES
Material
_.....
Inside
diameter
(Inlet and
exhaust)
Outside
diameter
(Inlet and exhaust)
~
Length:
Inlet
'"
...
_..
.
..
•
"IA
Exhaust
I""
.",11.
s".~
VALVE
SPRINGS
(RED
AND
WHITE)
~_
Free
length:
Inner
..
,
'.
I
~.\.
~
Total
numberOou/~~il';;
Inn~;'
~'z.,.
.1
Queer
Ij
pair
Total
fitted
load
t!1
Valve
open:
Inner
...-11.;;:1
Outer
~,P
Valve closed: Inner
~-
Outer
GENERAL
DATA
GD
Hldural 5
·313"/,312'
(7,950/7,924
mm,)
,5005/,5010
In,
(12,7127/12,7254
mm,)
1·875 In. 147'625 mm.)
1·875
In.
47·625
mm.\
10468 In. (37·2872 mm.)
1,600 In, (40,64 mm,)
6
5,
88 Ibs, (39'952 kg,)
121
Ibs, (54-934 kg,)
37-40 Ibs,
(16'798-18,144
kg,)
48-53 Ibs,
(21·792-24,062
kg.)
,,
VALVE
TIMING
(Mechod
1)
Set
all
tappet
c1ear_{50:
[nletcpens,
beforeT.D.C.
:loees @0-020
In
(0'
64
0Inlet closes.
after
B.D.C.
50
mmf
for checkln
67
Exhaust
opens,
before
B.D.C.
g
47"
Exhaust closes,
after
T.O.C.
ROCKERS
Bore
...
Rocker
spindle
diameter
...
Tappet
clearance (cold): Inlet
Exhaust •..
CAMSHAFTS
Journal
diameters
Dlametral clearances
End
float
Cam
11ft:
Inlet
and
exhaust
Base
circle
radius
TAPPETS
Tip
radius
..•
Tappet
diameter
...
Clearance
In
guide
block
TAPPET
GUIDE
BLOCK
Diameter
of
bores
...
Outside
diameter
•.. .
..
Interference
fit
In
cylinder
block
IGNITION
TIMING
Crankshaft
position
(B.T.D.C.) Fully
advanced
...
Piston
position
(B.T.D.C.) Fully
advanced
TACHOMETER
DRIVE
Drive
gear
shaft
Drive
gear
housIng
Driven
gear
shaft
Bush (plain)
Bush (flanged)
TIMING
GEARS
Inlet
and
exhaust
camshaft
pinions:
No.
of
teeth
.
Fit
on
camshaft
.
Intermediate
timing
gear
No.
of
teeth
Bore
Bush
bore
...
IntermedIate
wheel
spindle
Diameter
Crankshaft
pinion:
No.
of
teeth
...
Fit
on
crankshaft
CONTACT
BREAKER
(7CA)
Gap
setting
...
Advance
range
Fully
advanced
at
(Mechod 2)
5tall
til
ts Z
{At
piston
T.O.C.
(Exhaust
Stroke)
cfearancepr~r
chee:k~
Jnlct valve
open
0·125/0·135
In
(3·18/3'4
mm
Ing only Exhaust valve
open
0·125/0·135
In
(3·18/3·4
mml
(measured
on
valve
top
collar)
·5002/,5012 In,
(12,7050/12,7304
mm.)
,4990/,4995 In. (12·6746/12-6873
mm,)
·006 In. (0,1524 mm.)
·008
In.
(0·2032 mm.)
1'061/10060 In, (26,9494/26,9240
mm,)
,0025/,001 In, (0·063S/0,0254 mm.)
,007/,021 In. (,178/0,305
mm,)
,329 In, (8,3566
mm.)
,406
In,
dla, (10·3124
mm.)
1-125 In. (28'575 mm,)
·3115/3105
In,
(7,9121/7,8994
mm,)
,0025/,001 In, (0,0635/0·02S4 mm,)
·3130/,3125 In, (7,9502/7,9375
mm.)
1-1517/1-1572 In. (29,4055/29,3929 mm,)
,002/,001 In, (0,0508/0,0254 mm,)
38'
,357 In, (9'0678 mm,)
'280/'2791n,
dla.
(7,112/7,087
mm.)
,2822/,2807 In, dla,
~'168/7'130
mm,)
·2410/·2405 In, dla,
6,121/6·109
mm,)
,2435/·2425 In, dla.
6·185/6·160
mm,)
,2435/,2425, In. dla,
(6,185/6,160
mm,)
50
,000/·001 In, (,000/,0254
mm.)
47
,8745/·8740·
(22,2123/22'1996
mm.)
,6892/,6885 In.
(17'5056/17'4879
mm.)
,6880/·6877 In, (17,475/17,467
mm,)
25
+,0005 In.
(+
,0127
mm,)
-·0005 In,
(-
·0117
mm.)
,01'1-,016 In. (0,355..
1H06
mm,)
12'
(24" crankshaf<)
2,000
r.p,m,
GD3
ClassicBike.biz
.
GO
PISTONS
Clearance
at
skirt
(thrust
faces)
measured
·500"
from
bottom
of
skirt
Gudgeon
pin hole dla.
Compression ratio ...
PISTON
RINGS
Compression
rings
(tapered)
Width
Thickness
Fltt~d
gilp
••
,
Clearance
in
groove
011
control
ring: (Apex 3piece)
Thickness
Fit
In
groove
·0021/·0015 in. (0·05J3/0·0381
mm.)
·6887/·6885 In. (17'493/17'4879 mm.)
9-5
a·s
(Identified
by
'L' stamped
on
front
engine
lug)
2-729/2-577
mm.
·0625/·0615 In. (1·5875/1·5621 mm.)
·012/·017 In. (0.305/0·432
mm.)
·0035/·0015 In. (0'089/0·038
mm.)
·115
In.
(3-175
mm)
Nominal.
Central spring expander
FUEL
SYSTEM
Triple
carburetters
.•.
Amal
type
•.. •..
Main
let
size
Need eJet size
Needle
type
•..
Needle position
Throttle
valve ..•
Carburetter
nominal bore size
Air cleaner
element
...
~,
ConcentrIc
626
150
·106
STD
2
4
27
rnm
.
Paper
(special).
PRIMARY DRIVE
AND
GEARSHIFT
CLUTCH
DETAILS
Single diaphragm
spring-release
load
Minimum
travel
to
disengage •..
Allowable
wear
of
friction plate
Pressure
plate bearing (ball)
Operating
lever bearing (ball)
CHAINWHEEL
Thrust
bearing ... '"
;,.;:
..
Needle
roller
bearing (chalnca.se) ...
1,000 Ib,
(approx.)
(453.6 kg.)
'035 In. (·889 mm.)
·06 In. (1,524
mm.)
17 mm. X40
mm.
X12 mm.
!"
X
11-"
X
t"
In.
Torrington NTA
2233
1t (shaft) X
It''
X
t"
TRANSMISSiON
(GEARBOX)
To
find
the
gear ratios of amachine, calculate
the
top
gear
as
follows:-
Divide
the
number
of teeth on
the
primary chainwheel by
the
number of teeth on
the
engine
sprocket
and multiply
the
result
by
the
number
of
teeth
on
the
rear
wheel sprocket, divided
by
the
number
of
teeth
on
the
gearbox sprocket,
as
example:-
.,
clutch
sprocket
(43)
engine sprocket
(23)
x
rear
wheel
sprocket
(50)
gearbox
sprocket
(19)
2150
437
4·92
To
find
the
Intermediate gear ratio, multiply
the
overall
top
gear
ratio
by
the
Internal gear ratio concerned,
as
example:-
top
gear
ratio 4·92 X
bottom
gear
Internal
ratio
2·58=12·7
bottom geor
overoll
ratio
loyshoft gear
mOlnshoft
top
geor
Gearbox
Internal ratio
as
example:-
Third
gear Internal ratio
GD4
=malnshaft gear
(Iayshoft
3rd)
18T
(malnshaft 3rd) 18T x
xloyshaft
top
geor
(malnshaft
tOp)
21T
(/oyshoft
top)
15T
1·4
ClassicBike.biz
RATIOS
Internal ratios: 5th (Top)
".
4th
.,.
3rd
2nd
1st
(Bottom)
Overall ratios: 5th (Top)
".
4th...
...
3rd
2nd
...
...
1st (Bottom)
.._
Engln.
R.P.M.
@10
M.P.H.
In
5th
(Top)
goa'
Transmission
sprocket
teeth
GEAR
DETAILS
Malnshaft high
gear:
Bearing type
Bearing length
...
Spigot diameter
GEARBOX
SHAFTS
Malnshaft:
Left end diameter
Right end
diameter
length
,.,
Layshaft:
Left end diameter
Right end diameter
Length
~
..
BEARINGS
Malnshaft bearing (left) (Supplied
with
gear)
Malnshaft bearing
(right)
.•,.•.
Laysnaft
hearing (Iert) .
Layshaft bearing (right)
..,
layshaft
1st
gear (bush fitted)
Bore ...
Shaft diameter
,..
.,.
Layshaft 2nd gear (bush fitted)
Bore
Shaft diameter
...
Layshaft
4th
gear (bush
fitted)
Bore ..•
Shaft diameter
...
KICKSTART
RATCHET
MECHANISM
Bush
bore
Spindle working clearance
In
bush
Ratchet spring free
length
KICKSTAIjTER
Crank
spindle dla.
Crank bush
bore
GEARSHIFT
MECHANISM
Plungers:
Outer
diameters
Working
clearance
in
bore
Plutlger springs: .
No. of working calls
...
Free length
Inner bush
bore
(Gearchange fork)
Clearance
en
shaft
...
...
Outer
bush
bere
Clearance
en
shaft
Quadrant
return
springs:
No. of werking
c01ls
Free length
Camplate plunger
spring:
Free length
Ne.
of werking calls
Camplate plunger housing
bore
Camplate
plunger'diameter
...
GENERAL
DATA
GO
1·00 : 1
1019:
1
1040:
1
1·837 :1
B85
:1
4·92
5-85
6·89
9·04
12-71
663
19
ft"
X
1ft"
;<
i"
Needle
roller
·875/·8651n. (22·23/21·97 mm.)
1·50n/l·5072
In.
(38·36/38·28 mm.)
·8103/·8098 In. 120.58/20'57 mm.) -
·7494/·7498 In. 19·044/19·054 mm.}
10·37 In. (263 mm.)
·6875/·6870 In. 117'46/17'404
mm'j
'6875/·6870 In. 17·46/17·404 mm.
6·47 In. (164-33 mm.)
1!
X
2!
xiin. Roller bearing
tx
11
x
-r..
In.
Ball
Journal
*x
txt
In.
Needle
roller
*X
txt
in.
Needle
roller
·810/·809 In. (20·574/20·548 mm.)
·8075/·8070 In. (20'511/20'498 mm.)
.810/·809 In. (20·574/20·548 mm)
'8075/'8070 In. (20·511/20'498 mm.)
-8103/'8093 In. (20·582/20·556 mm.)
·8078/·8073 In. (20'518/20'505 mm.)
'751/·752 In. (19·0754/19·1008 mm.)
-0012/'0026 in. (·0304/-0660 mm.)
fin.
(12-7 mm.)
·748/·747 In. (18·999/18-974
mm'j
·753/·752 In. (19·126/19·101 mm.
'4315/-4320 In. (10·9601/10·9728 mm.)
'0005/'0015 In. (0-0127/·0381 mm.)
12
1*
In.
(31,75 mm.)
'5632/·5622 In. (14·3053/14·2799 mm.)
·0025/-001 In. (0·0635/0-0254 mm.)
·753/·751 In. (19·1262/19-0754 mm.)
'0045/·002 In. (0'1143/0'0508 mm.)
11
It
In.
(44·45 mm.)
2·14 In. (58 mm.)
19
·4385/·4375 In. 1110138/1101125
mm'j
·4365/·4355 In. 11-087/11·0617 mm.
GD5
ClassicBike.biz
GO
GEARSHIFT
CROSS·SHAFT
Cross-shaft
diamC!tcr
Needle
railer
bC<lring
Link
pin
bOie
Link Din diam.
STARTER
rlOTOR
MECHANISI"'!
Solenoid
and
bearing
housing bush
bore
Intermediate
shaft
diameter
Adapter
plate bush
bore
...
Intermediate
shaft bush
bore
Intermediate
shaft
diameter
GENERAL
DATi,
6250/·6245 in. (15'875/15-862] mm.)
'!"
;.:
+ttl
;.:
til'·
·378/·376 In. (=}-601/9·550 mm.)
·3751/·3749 (9·527519·5225 mm.)
1·0018/1·0013
In.
(25'446/25'433 mm.)
1'0003/·9998
In
(25'407/25·395 mm.)
·7530/·7518
In.
(19'126/19'096 mm.)
'4387/'4382
In.
(11'143/11-130 mm.)
'4372/·4367
In.
(11·105/11·092 mm.)
FRAME
AND
ATTACHMENT
DETAILS
HEAD
RACES
Taper
roller (top and bottom)
SWINGING
FORK
Bush
type
Bush
bore
.•••
Bobbin
diameter
Distance
between
fork ends
REAR
SUSPENSION
Type
..,
Centres
(extended unit)
Bush
bore
Length of free spring
Spring
rate
...
Tlmken LM11949L/LMl1910fLM11900E.
Pre-sized
steel-backed-phosphor
bronze
1-4460/1-4470
In.
(36.7284/36·7538 mm.)
1-4445/1-4450
In.
(36·6903/36·703 mm.)
7·81 In. (198,4 mm.)
Swinging fork controlled
by
combined
coil sprlng/hydraullc
damper
units
n·875
(327 mm.)
at
mid position
·382/·377
In.
(9-7028/9-5758 mm.)
8·810
In.
(m·8
mm.)
110Ib,./ln.
WHEELS,
BRAKES
AND
TIRES
WHEELS
Rim size:
Front
Rear
... ..,
..,..,
Spoke details:
Front
Outer
(L.H. and R.H.)
Inner (L.H. and R.H.)
Rear: tnner (L.H. and R.H.)
Ouw
(L.H.)
Outer (R.H.)
WHEEL
BEARINGS
Front
and
rear,
dImensions and type
Front
spindle diameter (at bearing Jour,nats).
Rear sleeve
diameter
(at bearing Journals)
REAR
WHEEL
DRIVE
Gearbox
sprocket
...
Rear wheel
sprocket
-teeth
Chain details:
No.
of
links: Solo
Pitch
Width
...
... ...
..,
Speedometer
drive gearbox ratio
...
Speedometer
cable length _." ..,
BRAKES
Operation
Type
...
Diameter:
Front
jl'
Rear
Brake pad (front)
Brake pad (rear)
TIRES
Size:
Front
Rear
Tire
pressure:
Front
Rear
GD6
'.::+
WM2·19
WM3·19
20
off 10 SWG 7·87
In.
(overall length)
80'
head .
20
off 10 SWG 7·84 in. (mean length)
96;
head
20
off 10
SWG
7·84 in. (mean length) 96"'head
10 off 10 SWG 8·16
tn.
(overall
length)
75;l
head
10 off 10 SWG
8in.
(overall length)
80;
head
25
X52 X15
mm.-Ball
Journals
·9841/·9836 (24-9961/24-98:! mm.)
·7873/·7868 (19·9974 (19-9847 mm.)
See 'Transmission'.
50
110
tin.
i
In.
1·25 : 1 .
70·5
In.
(1791
mm.)
HydraulIc
Disc
101n.
254
mm.
10
in.
254
mm.
A.P.4741-537
A.P.4741-570
4·10 X19 in.
4·10
;.:
19
In.
26Ib./'q.
In.
(1-828 kg./'q. em.)
28
lb./,q. In. (1,97 kg./sq. em.)
ClassicBike.biz
TELESCOPIC
FORK
Typo ...
Spring
details:
Free
length
No. working colis
Rate
Gauge
Colour
code
Stanchion
diameter:
(top)
(bottom)
Outer
member
bore
Tachometer cable length
GENERAL
DATA
FRONT
FORKS
GD
Telescopic-oil
damping
19·50
In.
(495·3 mm.)
56·5
35 Ib./in. 6·25 kg/em. kg./m.)
7s.w.g.
Orange
and
red
1·35501·3537
In.(34·417/34·3B46 mm.)
1-3616,1-3605 In.(34·5B46/34·5567 mm.)
1-365j1-363 In. (33·15/33·1 mm.)
30
In
(762 mm.)
ELECTRICAL
EQUIPMENT
Battery
Coil
Contact
breaker
unit
Generator
Horn
...
Rectifier
Zener
Diode ...
Bulbs-headlamp
(main)
-head
lamp (pilot)
-'Narnlng
lamps
-stop-tall
lamp
-speedometer/tachometer
ill
urn
1nation
-direction
indicators.••
Condenser Pack
Flasher
unit
••.
Headlamp ,., ..•
Handlebar
switch
(right)
Handlebar switch (leit)
Ignition switch
Rear
stop
switch
Fuse
ratl
ng
...
Sparking
Plugs
-Typo
...
-Gap
setting
-Thread
size
Starter
Motor
Ballast
resistor
Neutral
Indicator
Starter
relay
...
Solenoid
"
...
Lucas MCZ 9-8
Lucas 17 M6
Lucas
7CA
Lucas
RM
21
Lucas 6H
lucas
2D5.506
Lucas
ZD.715
Lucas 370.
45/40
watt
....
Lucas 989. 6
watt
Lucas 281. 2
watt
Lucas 380.
21/6
watt
Lucas 504 2.2
watt
lucas
382.
21
watt
Lucas 2CP
Lucas
BFL
Lucas SS700P.
Lucas 169 SA
Lucas 161.5A
Lucas 149 SA
Lucas 118 SA
3S
amperes
Champion N3
·020 In. (,50
mm.)
14 mm. XiIn.
reach
Lucas
M3
Lucas 41790
Lucas 147SA
Lucas 22RA
Lucas 175 76849
CAPACITIES
Fuel
tank
Oil
tank
Transmission
(Gearbox)
Primary
chalncase
Front
(orks
(each leg)
BASiC
DIMENSIONS
Wheel
base
...
Overall
length
Overall
width
Overall
height
Ground
cI
earance
Seat
height
...
Unladen
weight
Conn.
rod
bolts
Crankcase
Junction bolts
Crankcase
Junction
studs
Cylinder
block
base
nuts
Cylinder
head
bolts/nuts
Rocker
box
nuts
Rocker
box
bolts
M
ISCELLAN
EOUS
Alternatives-5!
U.S. galls.
(4t
Irop.
galls.
20
liters)
-3
U.S. galls.
(2t
.Imp.
galls.
11
liters)
6
U.S.
pints (5 Imp. pints) (3·0 lIeers)
1:
U.S. pints
(1!-
Imp.
pints)
850 em.')
•
U.S.
pints
(t
Imp. pines) (350 emJ)
210
C.c.
5B
In.
(147·5 em.)
BB
In.
(223·5 em.)
29
In.
(73·5
em.)
46·5
In.
(11
Bem.)
7In.
(17-8
em.)
31'25 in. (79,4 em.)
503 Ib,.
(22B
k8.)
:s:.,.
TORQUE
WRENCI-:(SETTINGS
(DRY)
21-5/22·5
Ib.n.
(2-967/3·105
kg.m.l
12 Ib.ft. (1-659 kg.m.)
15
Ib.ft. (2·074 kg.m.)
20/22 Ib.fe.
(:·765/3-042
kg.m.)
18 Ib.fe. (2·4B9 kg.m.)
6Ib.ft.
(·B3
kg.m.)
6Ib.fe.
(·B3
kg.m.)
GD7
ClassicBike.biz
GD
Kickstart
ratchet
pinion
nut
Rotor
fixing
nut
Stator
fixing nuts
Stanchion
pinch bolts
Front wheel spindle
cap
bolts
Zener
diode fixing nut
Fork cap
nut
...
Clutch
centre
nut
...
".
...
Transmission (Gearbox)
sprocket-Lock
nut
Chainwheel sheck absorber nut
Crankshaft centre bearing nuts
Engine
sprocket
nut
Camshaft pinion
nut
Stanchion end plug
..
,
Engine mounting bolts
Bottom
...
Front
R.ear
....
..
Rear engine plates to frame
Rear
damper bolts ..,
Sump
cover
plate nuts
...
.
..
Timing cover screws lbrlght zinc)
Timing cover screws yellow)
...
Rocker box socket screws
.,_
Front
frame
to
rellr
Top
Bottom
...
.., ...
Shock
absorber
assembly
screws
GDB
GENERAL
DATA
40/45 Ib.ft.
(5-53016,221
kg.m.l
50
Ib.ft'la'913 kg.m.l
8Ib.ft. 1·106 kg.m.l
25Ib.ft. 3·456 kg.m.l
23/25
IbA
(3·17/3-45 kg.m.l
2/203
Ib.ft. ('277/·3174 kg.m.)
25/30 Ib.ft. (3·45/4·14 kg.m.l
60
Ib.ft. (8,295 kg.m.l
5B
'b.ft'IB'019 kg.m·l
75/BO
10.
t. (10·369/11·06 kg.m.l
17·5/1B·5
Ib.f~
(2·41/2-55 kg.m.)
5B/63
Ib.ft.(B·00/B·69 kg.m.l
75
Ib.ft. (10·369 kg.m.)
45/50 Ib.lt. (6·21/6·90.kg.m.l
30/35 Ib.ft. (4·14/4.B3 kg.m.l
30/35
'b.ft·1
4'
14
/4-B3
kg.m'l
23/25Ib.ft. 3·17/3-45 kg.m.
.,. 23/25 Ib.ft. 3·17/3-45 kg.m.
1B
Ib.ft. (2·48 kg.m.)
6Ib.ft.
(·83
kg.m.)
3·5/405 Ib.ft. (·4B/·62 kg.m.l
6·5/7-5 Ib.ft. (·B97/1-035 kg.m.l
6Ib.ft.
('B3
kg.m.)
23/25 Ib.ft. (3·17/3·45 kg.m'l
30/35 Ib.ft. (4·14/4-83 kg.m.
2/3 Ib.ft. ('277/·414 kg.m.'
ClassicBike.biz
SECTION
A
LUBRICATION
SYSTEM
ROUTINE
LUBRICATION
TABLE OF
RECOMMENDED
LUBRICANTS
...
Section
...
A1
... A2
ENGINE
LUBRICATION
SYSTEM
...
.'
...
A3
CHANGING
THE
ENGINE
OIL
AND
CLEANING
THE OIL
FILTERS
OIL
PRESSURE
...
THE
OIL
PRESSURE
RELEASE
VALVE
...
REMOVING
AND
REPLACING
THE
OIL
PUMP
REMOVING
AND
REPLACING
THE
OIL
COOLER
REMOVING
AND
REPLACING
THE
ROCKER OIL
FEED
PIPE
ANTI-DRAIN
VALVE
CONTACT
BREAKER
LUBRICATION
TRANSMISSION
(GEARBOX)
LUBRICATION
PRIMARY
CHAINCASE
LUBRICATION
REAR
CHAIN
LUBRICATION
AND
MAINTENANCE
GREASING
THE
STEERING
HEAD
RACES
WHEEL
BEARING
LUBRICATION
TELESCOPIC FORK
LUBRICATION
LUBRICATION
NIPPLES
LUBRICATING
THE
CONTROL
CABLES
SPEEDOMETER CABLE
LUBRICATION
REAR BRAKE SPINDLE
LUBRICATION
CHANGING
THE
OIL
IN
THE
BRAKING
SYSTEMS
...
A4
.
..
AS
'"
A6
...
A7
...
A8
...
A9
...
A10
...
A11
...
An
...
A13
...
A14
...
A1S
...
A16
...
A17
...
A18
...
A19
...
A20
...
A21
...
A22
A1
ClassicBike.biz
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