Street Triple - Workshop Manual

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DAYTONA 675 STREET TRIPLE STREET TRIPLE R
Triumph Daytona 675, Street Triple and Street Triple R Motorcycle Service Manual
Pa rt Number 3856750 issue 1, 06.2009
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Service Manual - Daytona 675, Street Triple and Street Triple R
Table of Contents
Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaft, Connecting Rods and Pistons Balancer Transmission Lubrication Engine Removal/Refit Fuel System/Engine Management Cooling Rear Suspension Front Suspension Brakes Wheels/Tyres Frame and Bodywork Electrical
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Introduction
Table of Contents
Howto use this manual .................................................................... Warnings, Cautions and Notes ..............................................................
Tam
.vi .vi .vii .vii .vii .vii .vii .vii .vii
p erin g
with
Noise Control System Prohibited .............................................
References.............................................................................. Dimensions......................................................................... .^, Repairs and Replacements ................................................................. Force..............................................................................

Edges .............................................................................. Tightening procedure ................................................................
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Introduction
This manual is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job. A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, an authorised Triumph dealer must undertake all adjustments, maintenance, and repair work. In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work. All work should be performed with great care and in a clean working area with adequate lighting. Always use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect safe operation. Where accurate measurements are required, they can only be made using calibrated, precision instruments. For the duration of the warranty period, an authorised Triumph dealer must perform all repairs and scheduled maintenance. To maximise the life of your Motorcycle: Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual. Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the motorcycle. Rectify all problems as soon as possible (i mmediately if safety related). Use only genuine Triumph parts as listed in the parts catalogue/parts microfiche. How to use this manual To assist in the use of this manual, the section title is given at the top of each page. Each major section starts with a contents page, listing the information contained in the section. The individual steps comprising repair operations are to be followed in the sequence in which they appear. Adjustment and repair operations include reference to service tool numbers and the associated illustration depicts the tool. Where usage is not obvious, the tool is shown in use. Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details.
Warnings, Cautions and Notes Particularly important information is presented in the following form:
Warning
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
ACaution
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.
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.
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Introduction
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. 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
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.
Generally, when installing a part with several bolts, nuts or screws, they should all be started in their holes and ti ghtened to a snug fit, evenly and in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely, bolts, nuts, or screws, should all be loosened (in sequence if specified) by about a quarter of a turn and then removed. Where there is a tightening sequence specified in this Service Manual, the bolts, nuts, or screws must be ti ghtened in the order and by the method indicated. Torque wrench setting figures given in this Manual must be observed. The torque tools used must be of accurate calibration. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. This applies particularly to microencapsulated fixings which must always be replaced if disturbed. Where necessary, the text in this manual will indicate where such a fixing is used.
Dimensions The dimensions quoted are to design engineering specification with service limits where applicable. During the period of running-in from new, certain adjustments may vary from the specification figures given in this manual. These will be reset by the dealer at the 500 mile/800 km service, and thereafter should be maintained at the figures specified in this manual.
Repairs and Replacements

Before removal and disassembly, thoroughly clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. Particular attention should be paid when installing a new part, that any dust or metal filings are cleared from the immediate area.
Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Never lever a component as this will cause damage both to the component itself and to the surface being levered against. Whenever tapping to aid removal of an item is necessary, tap lightly using a hide or plastic faced mallet.
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1 General Information
Table of Contents
IgnitionSystem Safety Precautions ...........................................................
Dan
1.4 1.4 1.4 1.4 1.4 1.4 1.5 1.5 1.6 1.6 1.6 1.6 1.7 1.7 1.7 1.7 1.7 1.7 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.10 1.10 1.10 1.10 1.11 1.11
erousSubstances
.....................................................................
ThirdParty Products ....................................................................... Fluoroelastomers ..................................................................... Oils..................................................................................... HealthProtection Precautions .......................................................... EnvironmentalProtection Precautions ........................................................ Brakes................................................................................... SafetyInstructions ......................................................................... Jackingand Lifting .................................................................... Precautionsagainst Damage ........................................................... Coolant............................................................................. CleaningComponents ................................................................. Lubrication.......................................................................... Jointsand Joint Faces ................................................................. ^., Gaskets, O-rings ...................................................................... LiquidGasket, Non-permanent Locking Agent ............................................ ScrewThreads ....................................................................... LockingDevices ...................................................................... Fittinga Split Pin .....................................................................
Circli
s,
Retaining Rings ...............................................................
SelfLocking Nuts .....................................................................

Enca
sulatedBolts
....................................................................
Oiland Grease Seals .................................................................. Press............................................................................... BallBearings ......................................................................... ChassisBearing Lubrication ............................................................ Metalbushes ....................................................................... FuelHandling Precautions ................................................................. General............................................................................ Petrol
-
Gasoline .....................................................................
FuelTank Rem oval ................................................................... ChassisRepairs ..........................................................................
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General Information
ElectricalPrecautions ..................................................................... BatteryDisconnecting ................................................................ Disciplines.......................................................................... Electrical Wires ...................................................................... ElectricalTesting ......................................................................... Ohm's Law ......................................................................... BasicElectrical Circuits ............................................................... CircuitDiagrams ......................................................................... Glossaryof Circuit Diagram Symbols ........................................................ TracingCircuits .......................................................................... ToCheck Continuity :................................................................. ToMeasure Voltage :................................................................. Splices............................................................................. CAN(Controller Area Networking) .......................................................... Alternator/Charging System ............................................................... Diagnosis- Charging Circuit .......................................................... StartingCircuit .......................................................................... GeneralFault Finding - Starter Motor and Relay .............................................. Diagnosis- Starter Circuit ................................................................. Inspection.......................................................................... ReplacementParts ................................................................... ServiceData ........................................................................ Specification........................................................................ ServiceTools and Garage Equipment ........................................................ SpecialService Tools ................................................................. Engine............................................................................. CylinderHead & Valves .............................................................. CylinderHead & Valves (continued) .................................................... Camshafts.......................................................................... Clutch/Primary Drive ................................................................ Pistons............................................................................. ConnectingRods .................................................................... Crankshaft......................................................................... Transmission........................................................................ FinalDrive .......................................................................... Lubrication......................................................................... IgnitionSystem ..................................................................... FuelSystem ........................................................................ CoolantSystem ..................................................................... Suspension......................................................................... FuelInjection System ................................................................ EmissionsControls ................................................................... Brakes............................................................................. Brakes(continued) ................................................................... Wheelsand Tyres .................................................................... Frame............................................................................. ElectricalEquipment ................................................................. 1.12 1.12 1.12 1.13 1.13 1.13 1.13 1.14 1.14 1.15 1.16 1.16 1.17 1.17 1.18 1.18 1.19 1.19 1.20 1.21 1.21 1.21 1.21 1.22 1.22 1.27 1.28 1.29 1.29 1.30 1.30 1.30 1.31 1.31 1.31 1.32 1.32 1.32 1.33 1.33 1.34 1.34 1.34 1.35 1.35 1.36 1.36
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General Information
TorqueWrench Settings ................................................................... CylinderHead Area ................................................................. Clutch............................................................................ Crankshaftand Crankcase, Sprag .....................................................
En
1.37 1.37 1.37 1.37 1.38 1.38 1.38 1.39 1.39 1.39 1.40 1.40 1.41 1.41 1.41 1.42 1.42 1.43 1.43 1.44 1.45 1.46 1.47 1.48 1.49 1.50 1.51 1.52 1.53 1.54 1.55 1.56 1.57 1.58 1.59
ineCovers
.....................................................................
Transmission....................................................................... LubricationSystem .................................................................

Final Drive .........................................................................
CoolingSystem ....................................................................
Fuel
System, Exhaust System and Airbox ...............................................
Fuel System, Exhaust System and Airbox (continued) .................................... RearSuspension .................................................................... FrontSuspension ....................................................................
Wheels .............................................................................
FrontBrakes ........................................................................
Rear Brakes................ ........................................................
Frame, Footrests, Control Plates and Engine Mountings ................................... Electrical.......................................................................... Bodywork.........................................................................
Clutch Clutch
Cable Routing - Daytona 675 ........................................................ Cable Routing - Street Triple and Street Triple R ........................................ Cable Routing - Daytona 675 ....................................................... Cable Routing - Street Triple ........................................................
Throttle Throttle
ThrottleCable Routing - Street Triple R ...................................................... Main Wiring Harness Routing - Daytona 675 up to VIN 381274 ................................. Main Wiring Harness Routing - Daytona 675 from VIN 381275 .................................. Main Wiring Harness Routing - Street Triple and Street Triple R .................................
Rear Front
Light Harness Routing - Daytona 675 ................................................... Brake Hose Routing - Daytona 675 ....................................................
FrontBrake Hose Routing - Street Triple .....................................................
::
Brake Hose Routing - Street Triple R ................................................... Rear Brake Hose Routing - All Models (Daytona 675 shown) .................................... FuelTank Breather Hose Routing - Daytona 675 .............................................. Fuel Tank Breather Hose Routing - Street Triple and Street Triple R .............................. Fuel Tank Breather Hose Routing - Models with Evaporative Emissions - Daytona 675 .............. Fuel Tank Breather Hose Routing - Models with Evaporative Emissions - Street Triple and
Street Triple R ...........................................................................
1.60 1.61
Intake
Air Flap Vacuum Hose Routing - Daytona 675 only ......................................
IN
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1.3
General Information
Ignition System Safety Precautions
Fluoroelastomers
Warning
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.
Warning
Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles. In fire conditions involving temperatures greater than 315C 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 fl uoride 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.
Warning
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 ill ness or death.
Dangerous Substances
Oils
Warning AWarning
The engine and bevel box oils may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.
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 container labels and obey the instructions contained within. These instructions are included for your safety and well-being. NEVER DISREGARD THESE INSTRUCTIONS!
Ak Warning
Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition used engine oil contains potentially harmful contaminants which can cause cancer. Wear suitable clothing and avoid skin contact. Health Protection Precautions Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including i mpervious gloves where practicable. Do not put oily rags in pockets. Overalls must be cleaned regularly. Discard heavily soiled clothing and oil impregnated footwear.
Third Party Products
Warning
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 motorcycl e co ntro l and an accident.
First aid treatment should be obtained i mmediately for open cuts and wounds. Always be aware of who your nearest first-
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General Information
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.
Brakes
Warning
Brake fluid is hygroscopic which means it will absorb moisture from the air. Any absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction in braking efficiency. Replace brake fluid in line with the routine maintenance schedule. A dangerous riding condition could result if this important maintenance item is neglected! Do not spill brake fluid onto any area of the bodywork as this will damage any painted or plastic surface. Always use new brake fluid from a sealed container and never use fluid from an unsealed container or from one that has been previously opened. Do not mix different brands of fluid. Check for fluid leakage around brake fittings, seals and joints. Check regularly for brake hose damage. FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO AN ACCIDENT
Warning
Any risk of eye injury must be avoided. Always wear eye protection when using a hammer, air line, cleaning agent or where there is ANY risk of flying debris or chemical splashing.
Ak
Warning
Environmental Protection Precautions
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 effi c i e n cy l eading to a n acc i dent.
Caution
Do not pour oil on the ground, down sewers or drains, or into water courses. To prevent pollution of watercourses etc., dispose of used oil sensibly. If in doubt contact your local aut h o rity. 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.
AWarning
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to an accident. Failure to change the brake fluid at the interval specified in the routine maintenance schedule may reduce braking efficiency resulting in an acc i de n t.
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General Information
Precautions against Damage
Warning
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 redu ce braking efficiency resulting in an accident.
Avoid spilling brake fluid or battery acid on any part of the bodywork. Wash spillages off with water immediately. Disconnect the battery earth lead before starting work, see ELECTRICAL PRECAUTIONS. Always use the recommended service tool where specified. Protect exposed bearing and sealing surfaces, and screw threads from damage. Coolant
Warning
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
Warning
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 th e m oto rcycl e coolant.
AWarning
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 scald s and skin damage.
Safety Instructions
Jacking and Lifting
Caution
Warning
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 during lifting or jacking, or while repairs and servicing are carried out. Never rely on a single means of support when working with the motorcycle. Use additional safety supports and straps to prevent toppling. Do not leave tools, lifting equipment, spilt oil, etc. in a place where they could become a hazard to health. Always work in a clean, tidy area and put all tools away when the work is finished.
The coolant anti-freeze contains a corrosion inhibitor which helps prevent damage to the metal surfaces inside the cooling system. Without this inhibitor, the coolant would 'attack the metals and the resulting corrosion would cause blockages in the cooling system leading to engine overheating and damage. Always use the correct anti-freeze as specified in the Owner's Handbook. Never use a methanol based anti-freeze as this does not contain the required corrosion inhibition properties.
Caution
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 an d engine damage.
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Cleaning Components
A high flash-point solvent is recommended to reduce fire hazard. Always follow container directions regarding the use of any solvent. Always use the recommended cleaning agent or equivalent. Do not use degreasing equipment for components containing items which could be damaged by the use of this process. Whenever possible, clean components and the area surrounding them before removal. Always observe scrupulous cleanliness when cleaning dismantled components.
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.
,A Warning
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.
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.
Screw Threads
Metric threads to ISO standard are used. Damaged nuts, bolts and screws must always be discarded. Castellated nuts must not be slackened back to accept a split-pin, except in those recommended cases when this forms part of an adjustment. Do not allow oil or grease to enter blind threaded holes. The hydraulic action on screwing in the bolt or stud could split the housing. Always tighten a nut or bolt to the recommended torque figure. Damaged or corroded threads can affect the torque reading. Unless specified, threaded fixings must always be fitted dry (no lubrication).
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 reassembly. Do not use a tool which will damage the joint faces and smooth out any scratches or burrs on the joint faces using an oil stone. Do not allow dirt or jointing material to enter any tapped holes.
Warning
Never lubricate a thread unless instructed to do so. When a thread of a fixing is lubricated, the thread friction is reduced. When the fixing is tightened, reduced friction will cause overtightening and possible fixing failure. A fixing which fails in service could cause component detachment leading to loss of con tro l a nd an accident.
Gaskets, 0-rings
Do not re-use a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.
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General Information
Locking Devices
Always release locking tabs and fit new locking washers, do not re-use locking tabs. protective sleeve or tape to cover the relevant surface and avoid touching the sealing lip. Lubricate the sealing lips with a recommended lubricant. This will help to prevent damage in initial use. On dual li pped seals, smear the area between the lips with appropriate grease. When pressing in a seal which has manufacturer's marks, press in with the marks facing out. Seals must be pressed into place using a suitable driver. Use of improper tools will damage the seal.
Fitting a Split Pin

Always fit new split-pins of the correct size for the hole in the bolt or stud. Do not slacken back castle nuts when fitting split pin, except in those recommended cases when this forms part of an adjustment. Always fit new roll pins of an interference fit in the hole.
Circlips, Retaining Rings

Replace any circlips and retaining rings that are removed. Removal weakens and deforms circlips causing looseness in the circlip groove. When installing circlips and retaining rings, take care to compress or expand them only enough to install them. Always use the correct replacement circlip as recommended in the Triumph Parts Catalogue.
Press
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil or grease on its outer or inner circumference so that it will locate smoothly.
Ball Bearings
When installing a ball bearing, the bearing race which is an interference fit should be pushed by a suitable driver. This prevents severe stress or damage to the load carrying components. Press a ball bearing until it touches the shoulder in the bore or on the shaft. Press or drift seals to the depth of its housing, with the sealing lip facing the lubricant to be retained if the housing is shouldered, or flush with the face of the housing where no shoulder is provided.
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.
Chassis Bearing Lubrication

Note: This information relates only to bearing lubrication. For the procedures necessary to replace a bearing, always refer to the relevant section of this service manual. Bearings installed in engine and transmission applications are not covered by this information. Refer to the lubrication chapter or the relevant engine chapter for additional information.
Encapsulated Bolts
An encapsulated bolt can be identified by a coloured section of thread which is treated with a locking agent. Unless a specified repair procedure states otherwise, encapsulated bolts cannot be reused and MUST be replaced if disturbed or removed.
Warning
Failure to replace an encapsulated bolt could lead to a dangerous riding condition. Always replace encapsulated bolts.
General For a bearing to be serviceable for its anticipated life span it must be checked, adjusted and lubricated at regular intervals, as specified in the service schedules given in the owner's handbook and this service manual. A correctly lubricated bearing will have a film of lubrication that separates the moving parts, disperses heat and protects the bearing surfaces from corrosion. Note: In all cases, use the lubricant recommended in the service manual. Grease the bearing, not the cavity where it is located.
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 to the seal lips when it is being fitted. Use a
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A bearing that is not regularly checked and lubricated will have a reduced life span. New Bearings New bearings are typically protected with an oil preservative to prevent corrosion etc. during storage. This is NOT the lubrication for the bearing but DOES NOT need to be washed off prior to assembly and in-service lubrication. When lubricating a new bearing with grease the following steps should be taken: 1. 2. 3. Do not clean off the oil preservative. Grease must be forced between the roller elements and the roller cage. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts. Any excess grease should be smeared on the outside of the rollers. ceon Lubrication and Checks While Servicing a Bearing 1. 2. Disassemble parts as necessary to access the bearing. Refer to the relevant service manual. Inspect the old grease covering the bearing, looking for signs of bearing damage, i.e. flakes or specks of metal. Remove the old grease. Check the bearing for smooth operation and visually check for corrosion, dents and flaking in the bearing race, rollers or cage. Replace if necessary. Refer to the relevant service manual. 3. Taper bearings (swinging arm & headstock, depending on the model) 1. 2. Grease must be forced between the inner race and the roller carrier. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts. Any excess grease should be smeared on the outside of the rollers. Sealed bearings are lubricated for life by the manufacturer. Any attempt to change the grease in a sealed bearing will damage the integrated seals. If the seals are damaged dirt and water will ingress and the life of the bearing will be greatly reduced.
4.
3. 4.
Below/overleaf several common bearing types and the lubrication procedures for each are identified:
1
Angular contact and ball bearings (headstock) 1. Grease the bearing races and the ball bearing carrier.
eon Sealed bearings (wheel bearings & swinging arm, depending on the model) Note: Sealed bearings can be identified by their integrated seals.
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General Information
2. Rotate the bearing to ensure that the grease is distributed over the entire circumference of the internal parts.
Fuel Handling Precautions

General The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled safely. It also outlines other areas of risk which must not be ignored. This information is issued for basic guidance only and, if in doubt, appropriate enquiries should be made of your local Fire Officer. Petrol - Gasoline When petrol (gasoline) evaporates it produces 150 times its own volume in vapour which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout any indoor environment by air currents, consequently, even a small spillage of petrol (gasoline) is potentially very dangerous.
Needle roller bearings (swinging arm, rear hub, rear suspension linkages, depending on the model) 1. 2. Coat the needle rollers with grease. Ensure the needle rollers turn so that the grease is distributed over the entire circumference of the internal parts. Assemble the parts, adjust and check as necessary.
Warning
Petrol (gasoline) is highly flammable and can be explosive under certain conditions. When opening the fuel tank cap always observe all the following items: Turn the motorcycle ignition switch OFF. Do not smoke. Always have a fire extinguisher containing FOAM, CO2, HALON or POWDER close at hand when handling or draining fuel or fuel systems. Fire extinguishers must also be present in areas where fuel is stored. Always disconnect the vehicle battery, negative (black) lead first, before carrying out dismantling or draining work on a fuel system. Whenever petrol (gasoline) is being handled, drained, stored or when fuel systems are being dismantled, make sure the area is well ventilated. All potential forms of ignition must be extinguished or removed (this includes any appliance with a pilot light). Any lead-lamps must be flame-proof and kept clear of any fuel spillage. Warning notices must be posted at a safe distance from the site of the work to warn others that petrol is being openly handled. The notice must instruct the reader of the precautions which must be taken. Failure to observe any of the above warnings may lead to a fire hazard which could result in personal injury.
3.
Metal bushes 1. 2. 3. Disassemble the parts as necessary to access the bush. Refer to the relevant service manual. Remove the old grease. Apply fresh grease to the metal bush.
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Chassis Repairs
Jk Warning
No one should be permitted to repair components associated with petrol/gasoline without first having specialist training on the fire hazards which may be created by incorrect installation and repair of items associated with petrol/gasoline.
AWarning
If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for repair or inspection. Any accident can cause damage to the motorcycle, which if not correctly repaired, may cause a second accident which may result in injury or death. The frame must not be modified as any modification to the frame such as welding or drilling may weaken the frame resulting in an accident.
Repairs carried out by untrained personnel could bring about a safety hazard leading to a risk of personal injury.
k. Warning
om
Draining or extraction of petrol/gasoline from a vehicle fuel tank must be carried out in a well ventilated area. The receptacle used to contain the petrol/ gasoline must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations. When petrol/gasoline has been extracted or drained from a fuel tank, the precautions governing naked lights and ignition sources should be maintained.
Failure to observe any of the above warnings could bring about a safety hazard leading to a risk of personal injury. Fuel Tank Removal Fuel tanks should have a 'PETROL (GASOLINE) VAPOUR warning label attached to them as soon as they are removed from the vehicle. In all cases, they must be stored in a secured, marked area.
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1.11
General Information
Electrical Precautions
The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the motorcycle. Where necessary, specific precautions are detailed in the relevant sections of this manual which should be referred to prior to commencing repair operations. Equipment - Prior to commencing any test procedure on the motorcycle ensure that the relevant test equipment is working correctly and any harness or connectors are in good condition, in particular mains leads and plugs. any protective covers and substances are replaced if disturbed. Having confirmed a component to be faulty, switch off the ignition and disconnect the battery negative (black) lead first. Remove the component and support the disconnected harness. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking mechanism becomes fully engaged. Battery Disconnecting Before disconnecting the battery, switch off all electrical equipment.
Ak Warning
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.
Warning
Warning
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 ill ness or death.
To prevent the risk of a battery exploding and to prevent damage to electrical components ALWAYS disconnect the battery negative (black) lead first. When reconnecting the battery, always connect the positive (red) lead first, then the negative (black) lead. Always disconnect the battery when working on any part of the electrical system. Failure to observe the above warnings may lead to electrical damage and a fire hazard which could cause personal injury. Always ensure that battery leads are routed correctly and are not close to any potential chafing points. Disciplines
Warning
The battery contains harmful materials. Always keep children away from the battery whether or not it is fitted in the motorcycle. Do not jump start the battery, touch the battery cables together or reverse the polarity of the cables as any of these actions may cause a spark which would ignite battery gasses causing a risk of personal injury. High Voltage Circuits - Whenever disconnecting live High Tension (H.T.) circuits always use insulated pliers. Exercise caution when measuring the voltage on the coil terminals while the engine is running, high voltage spikes can occur on these terminals. Connectors and Harness - The engine of a motorcycle is a particularly hostile environment for electrical components and connectors. Always ensure these items are dry and oil free before disconnecting and connecting test equipment. Never force connectors apart either by using tools or by pulling on the wiring itself. Always ensure locking mechanisms are disengaged before removal and note the orientation to enable correct reconnection. Ensure that
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, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts. Prior to commencing any test, and periodically during any test, touch a good earth to discharge body static. This is because some electronic components are vulnerable to static electricity.
1.12
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General Information
Electrical Wires All the electrical wires are either single-colour or twocolour and, with only a few exceptions, must be connected to wires of the same colour. On any of the twocolour 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 and then the secondary colour. For example, a yellow 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. the current flowing in the circuit can be calculated by using -
=1
60
12
=5
the bulb resistance can be calculated by using -
=R 15 =2.4
Electrical Testing
For any electrical system to work, electricity must be able to flow in a complete circuit from the power source (the battery) via the components and back to the battery. No circuit means no electrical flow. Once the power has left the positive side of the battery and run through the component it must then return to the battery on its negative side (this is called earth or ground). To save on wiring, connections and space, the negative side of the battery is connected directly to the frame or engine. Around the frame and engine will be various other ground points to which the wiring coming from components will be connected. In the case of the starter motor it bolts directly to the engine, which is bolted to the frame. Therefore the frame and engine also form part of the earth return path. Ohm's Law The relationship between voltage, current and resistance is defined by Ohm's Law. The potential of a battery is measured in Volts M. The flow of current in a circuit (I) is measured in Amperes. The power rating of a consumer is measured in Watts (W). The resistance (R) of a circuit is measured in Ohms (Q).
To use either of the following triangles, put your finger over the value you want to find. Multiply the remaining values if side-by-side, or divide if one is over the other.
W V I I
V R
Basic Electrical Circuits
L
Basic Circuit Diagram
In the above circuit an electrical reservoir (the battery) is connected via a cable to a terminal on the controlling device (the switch) whose contacts are either open or closed. The other terminal on the switch is connected via a cable to the consumer (the bulb), and the other side of the bulb filament is connected to ground (earth) by another cable. The ground point is usually a part of the frame or engine, to which the battery negative terminal is also connected. When the switch contacts are open (as shown in the diagram), the circuit is broken and no current flows. When the switch contacts are closed the circuit is made and current flows from the battery positive terminal through the switch contacts and bulb filament to ground. The frame completes the circuit to the battery negative terminal and the bulb illuminates. Although some circuits on the circuit diagram may at first seem more complicated, it will generally be found that they can be broken down into sections which do not differ greatly from the basic circuit above.
Ohms law, for practical work can be described as Voltage = Resistance Current Power is calculated by multiplying Volts x Amps -
Watts = Volts x Amps By transposing either of these formulae, the value of any unit can be calculated if the other two values are known. For example, if a battery of 12V is connected to a bulb of 60W:
I UMP
1.13
General Information
Circuit Diagrams
Circuit diagrams are created to provide a 'picture' of the electrical system and to identify the route taken by each individual wire through the system, in order to identify which components it feeds and which connectors the wire runs through. Circuit diagrams are an essential tool for fault finding, as it is possible to locate start and finish points for a circuit without having to manually trace the wire through the motorcycle itself. Circuits diagrams may look confusing at first but when they are studied closely they soon become logical. Due to the complex circuits and the number of individual wires, Triumph uses two types of circuit diagram in its service manuals. Within the manual conventional circuit diagrams are used to show the layout of the main circuits of the motorcycle. These are: Engine management/ignition, Lighting, Starting and Charging and Auxiliary and Accessory. In these diagrams no attempt is made to show the components of the system in any particular order or position in relation to the motorcycle. At the back of the service manual a full colour layout circuit diagram is used to show the main electrical components in a position si milar to the actual position on the motorcycle. Both of these circuit diagrams use similar symbols to ill ustrate the various system components and will be accompanied by a key to circuit diagram components and wiring colour codes. Circuit diagrams also depict the inner workings of a switch cube (I.E. which wire connects to which when a switch is turned from one position to another) so that a test of that switch can be made using the wire terminals in the connector instead of disassembling the switch itself. identify each connector. An additional number outside the box will identify the component. Diode
An electrical one-way valve. Diodes allow current to flow in one direction but will not allow it to return. The arrow, which forms part of the diode symbol, indicates the direction of current flow. Electromagnetic Winding (solenoid)
An electromagnetic winding (or solenoid) is used to convert an electrical current into a lateral movement. This can then be used to operate switches (as used in relays) or other components such as fuel injectors or secondary air injection solenoids. Fuse
2 or
A fuse is a device which protects a circuit in the event of a fault. The fuse will 'blow' should a short circuit occur, protecting that circuit from further damage. The number next to the fuse on the circuit diagram indicates the position of the fuse in the fusebox. Ground or Earth Point
on
Glossary of Circuit Diagram Symbols

The following is a description of the symbols found in the circuit diagrams used in all Triumph service manuals. Connector
This symbol is used to show ground points. This is the negative connection to either the frame or engine, and is a common cause of intermittent faults due to loose or corroded connections. Lamp or Bulb
2 3 4
21
This illustration is used to show all multi-plug type electrical connectors on Triumph circuit diagrams. The numbers in the box relate to the terminal numbers of the connector pins. On ECMs with two connectors, the number would be prefixed with the letters 'A' or 'B to
This symbol is used to show all types of light bulbs. The numbers in the box relate to the terminal numbers of the connector pins. An additional number outside the box will identify the component.
1.14
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General Information
LED (Light Emitting Diode) Switches Normally Open Triumph use LEDs for the alarm warning light, instrument ill umination and warning lights, gear change lights and rear light/brake lights on various models. Motor Normally Closed Change Over
An electric motor. This could be the starter motor or a motor within an actuator, for example within the ABS modulator. Relay
'U
'1 6 4
or
or
or
0 0
,0
A mechanical device for completing or breaking a circuit. There are three common types of switch: Normally open, normally closed and change-over.
Tracing Circuits
The following is a description of two types of common electrical failures, and some of the methods which may be used to find them.
8
Open circuit A relay is effectively an electromagnetic switch. To close the relay contacts and complete the circuit, an electromagnet in the relay is energised which causes the relay contacts to close, making the circuit complete. Relays are used when the electrical current is too great for a mechanical switch, usually when the switching must be done quickly to prevent arcing across the switch contacts. If a mechanical switch were used, the mechanical switch contacts would quickly burn away. Resistor
Break
A break in an electrical circuit - current cannot flow. Usually caused by a break in a wire or cable or by a loose connection. Open circuits can often by intermittent, making diagnosis difficult. Short circuit
A device placed in a cable to reduce a voltage or restrict the maximum current a device can draw. Splice A 'short cut' in an electrical circuit - current by-passes the intended circuit, either to earth or to another, different circuit. Often caused by failure of the cable insulation due to chafing or trapping of the wire. There are two different types of short circuit - short to ground and short to Vbatt. A short to ground means that the current is going to earth before it reaches the component it is supposed to feed. These are often caused by chafing of the harness to the frame or wires trapped between a bolted component, and will often blow the fuse on that circuit.
A hard cable joint where two or more cables are joined in the wiring harness. A potential source of both open and short circuits.
t UMP
1.15
General Information
A short to Vbatt is a short to battery voltage (12 Volts) and is caused by a live power supply wire contacting an adjacent cable. Note that it is also possible for a 5 Volt sensor reference voltage to short to an adjacent circuit, which can also cause electrical failures and DTCs (Diagnostic Trouble Code) to be stored. When tracing a wire that is suspect, carefully check the circuit diagram before starting. Remember: a wire may diverge at a splice and go off to feed other circuits. If these circuits are working, check for wiring faults from the splice onwards. the circuit diagram is not an accurate guide to the actual location of the parts when fitted on the bike. It is a schematic diagram of the circuits. particularly where engine management items are concerned, the circuit is only completed by the ECM. If the ECM is not connected, the circuit may register as open. To Check Continuity: A high resistance figure could indicate a dirty or corroded connection. If there is a break in the wire, the meter will not bleep or register a resistance.
By probing the wire in various places, the position of a high resistance or break in the wire (open circuit) can be narrowed down until it is found. To Measure Voltage: In the example below, the circuit voltage is being measured at the bulb positive (+) terminal.
ACaution
Ensure the circuit being tested is switched off before measuring continuity. Damage to the Digital Multi Meter (DMM) may result from testing a 'live circuit with the meter set to resistance (Q). In the example below, the ground circuit continuity is being tested from the battery to the frame. Voltage Check Turn the circuit to be tested ON Set the Digital Multi Meter (DMM) to Voltage check (V). Ensure the multi meter is set to dc volts for direct current circuits (most circuits) or ac volts for alternating current circuits (typically alternator output voltage tests). Set the range of the DMM to the range best suited to the voltage of the circuit being tested (typically 20 volts for most DMMs). Refer to the DMM manufacturers instructions. Connect the black (ground) lead of the DMM to a reliable ground connection (usually the battery or frame ground). Continuity (resistance) Check Locate each end of the wire. Set the Digital Multi Meter (DMM) to resistance check (Q). Probe each end of the wire. If there is continuity, the meter will usually bleep or register the resistance of the cable. Locate the positive terminal of the wire or component to be tested. connect the red (positive) lead of the DMM to the positive terminal. Read the voltage from meter.
1.16
IllMP
General Information
Splices Splices are probably the most common cause of wiring faults after connectors. Splices are made where two or more wires come together and diverge in different directions, usually to feed a different circuit. To locate a splice, it is necessary to peel back the insulation and examine the splice for its integrity. The most common fault is where one of the wires at the joint has come adrift usually causing the circuit it feeds or earths to become 'dead'. Switches To check a switch, set the multimeter to resistance/ continuity and probe the two pins that form a closed circuit when the switch is pushed. If the switch is working correctly, the resistance should register or the meter will bleep. Relays All relay cases have a circuit path engraved on them showing the circuit path across the electromagnet and the switch. Before making any checks, first note the pin designations, current paths, and whether or not there is a diode in either circuit path. ECM cabling required to allow ECMs to communicate with each other is greatly reduced. This saves cost, weight and space, and makes the system more reliable, as the physical number of wires and connections is reduced.
B28 B27
Pair of Twisted Wires
4 5
Instrument Pack
16
A34 1
KYI 3
Vehicle Speed Sensor Extract from the circuit diagram showing CAN connection between ECMs CAN works by each ECM sending out 'packets' of information (such as engine speed or fuel consumption information) on to the network bus (note that the network must be free of data before any ECM is allowed to transmit). This data is given a priority according to its i mportance (for example 'engine speed' may have a higher priority than 'low fuel level'), so that even if two ECMs send data at the same time, high priority information is always sent first. Lower priority data is then resent after the high priority data has been received by all ECMs on the network. The receiving ECM confirms the data has been received correctly and that the data is valid, and this information is then used by the ECM as necessary. Specific data not required by an ECM will still be received and acknowledged as correct but then disregarded (for example if an ECM does not require 'clutch switch position' information, this data packet would be ignored). This allows for a very high speed system of communication, which is also very reliable. Should one ECM fail or transmit corrupted or otherwise incorrect messages, none of the other ECMs on the network will be affected, and after a certain time that ECM will be prevented from transmitting further messages until the fault is rectified. This stops the ECM from clogging the network with incorrect data and preventing other messages from getting through. The fault would then be reported by a DTC (Diagnostic Trouble Code). Triumph currently use CAN for communication between the engine ECM and the instruments.
Diode 86
S
S87
Electromagnet 85 30
Make continuity checks across the electromagnet first, usually from pin 86 (positive) to pin 85 (negative). If a diode appears in the circuit use the diode check on the multimeter (volts scale) in the direction of current flow. If there is no diode, use the resistance check facility. An open circuit or unusually high resistance value indicates a faulty relay. To check the switch side, apply a 12 volt supply between pins 86 and 85. With the supply connected the relay should be heard to click and there should be continuity between pins 30 and 87. An open circuit indicates a faulty relay.
CAN (Controller Area Networking)

CAN (sometimes called CANbus) is a protocol for data communication between Electronic Control Modules (ECMs). Each ECM on the network is connected by a single pair of twisted wires (or bus) which are used for the transmission of vehicle sensor data. By using CAN, the overall number of system sensors, and the amount of
Il1MP
1.17
General Information
Alternator/Charging System
The charging system consists of an alternator and a rectifier/ regulator assembly and the battery. The alternator is made up of two parts, the stator, which is mounted to the crankcase or the engine cover, and the rotor, mounted to the end of the crankshaft. The stator is an assembly of 18 coils, arranged into 3 phases. The rotor is a series of magnets mounted in the engine flywheel, which are arranged so as to be positioned around the outside of the stator coils. As the engine rotates the alternator produces an ac (alternating current) voltage in each of the three phases of the alternator, typically of around 35 to 40 volts ac at 4000-5000 rpm, although this figure varies between models. As the battery requires dc (direct current) voltage for correct charging, this ac voltage must be first rectified to dc current, and then regulated to the correct voltage for the battery of 14.5 0.5 volts. This is done by the rectifier/regulator, which uses diodes to convert the alternator output to dc volts and limit the resulting output to the correct figure required for optimal battery charging. If the charging circuit does not operate correctly, the following basic checks must be carried out before further diagnosis is performed: Check the battery terminals are clean and tight. Check the frame and engine earth connections are clean, tight and free from corrosion. Ensure the battery is fully charged and in good condition. Check that any fuse in the circuit is not blown and is of the correct rating (See page 17-19).
Rectify any defects as necessary. Diagnosis - Charging Circuit
ENSURE THE BATTERY IS IN GOOD CONDITION AND FULLY CHARGED. CHECK ALL BATTERY AND GROUND TERMINALS ARE CLEAN AND TIGHT
Not OK
RECHARGE OR REPLACE FAULTY BATTERY AND/OR REPAIR DIRTY/ LOOSE CONNECTIONS
OK OK
WITH THE ENGINE RUNNING AT AROUND 2000 RPM, MEASURE THE BATTERY VOLTAGE AT THE BATTERY. THE BATTERY VOLTAGE SHOULD BE 14.5 0.5 VOLTS Below 14 Volts
Above 15 Volts
FAULTY RECTIFIER/ REGULATOR
STOP THE ENGINE AND DISCONNECT THE ALTERNATOR CONNECTOR. RE-START THE ENGINE AND ALLOW TO IDLE. MEASURE THE ALTERNATING CURRENT (AC) VOLTAGE FROM THE 3 ALTERNATOR OUTPUT WIRES IN TURN. THE OUTPUT VOLTAGE MUST EXCEED 10 VOLTS AC FROM EACH WIRE
Above 10 Volts AC RAISE THE ENGINE SPEED ABOVE 4000 RPM. MEASURE THE ALTERNATING CURRENT (AC) VOLTAGE FROM THE 3 ALTERNATOR OUTPUT WIRES IN TURN. THE OUTPUT VOLTAGE MUST NOW EXCEED 30 VOLTS AC FROM EACH WIRE Above 30 Volts AC
Below 30 Volts AC FAULTY ALTERNATOR
FAULTY RECTIFIER/ REGULATOR
1.18
L UMP
General Information
Starting Circuit
All Triumph models are equipped with an electric start system. This system consists of a starter relay, starter motor, starter switch, sidestand switch, engine stop switch, clutch switch and the sprag clutch. The starter motor is connected to the starter relay and the battery by heavy duty cables in order to supply the large currents required by the motor to start the engine. When the starter button is pressed the relay is energised, which then allows current to the starter motor. The starter motor will not operate unless the clutch lever is pulled in. Also, the starter will not operate if the sidestand is down, unless the transmission is in neutral. If the starter motor does not operate, the following basic checks must be carried out before further diagnosis is performed: Check the engine stop switch is in the 'RUN' position. Check the battery terminals are clean and tight. Check the frame and engine earth connections are clean, tight and free from corrosion. Ensure the battery is fully charged and in good condition. Check that any fuse in the circuit is not blown and is of the correct rating.
Using the triumph diagnostic tool, check the operation of the neutral switch or gear position sensor (if fitted), sidestand and clutch switches. Note: On all new models from Daytona 675 onwards, which use a CAN connection between the instruments and the ECM, the engine will not crank if the instruments are disconnected. Rectify any defects as necessary
General Fault Finding - Starter Motor and Relay

Symptom Starter relay does not click, starter motor does not turn Possible cause(s) Battery discharged or defective Blown main or starter relay fuse Defective starter relay wiring or starter switch Check that the sidestand, transmission and clutch lever are positioned for engine starting I.E. transmission in neutral, clutch lever pulled in and the sidestand down Defective alarm system - ensure any alarm fitted is working correctly Starter motor turns slowly Battery discharged or defective Loose, corroded or dirty battery connections Loose, corroded or dirty starter motor or starter relay connections Defective starter motor Loose, corroded or dirty battery ground connections Starter relay clicks but engine does turn over Battery discharged or defective Crankshaft does not turn due to engine defect Defective starter motor Starter cable open circuit Defective starter relay Starter motor turns but engine does not turn over Defective sprag clutch Defective idler gear, reduction gear or starter motor
1l.I MP
1.19
General Information
Diagnosis - Starter Circuit
WITH THE IGNITION SWITCH ON AND THE ENGINE STOP SWITCH AT 'RUN', CHECK FORA CLICK AT THE STARTER RELAY WHEN THE STARTER SWITCH IS PRESSED
Clicks
USING A SUITABLE HEAVY DUTY JUMPER CABLE, CONNECT THE STARTER POSITIVE TERMINAL TO THE BATTERY POSITIVE TERMINAL
Starter motor turns
Starter motor does not turn
No Click
LOOSE OR DISCONNECTED WIRE OR CABLE. FAULTY STARTER RELAY/ SOLENOID
FAULTY STARTER MOTOR
DISCONNECT THE STARTER RELAY SWITCH CONNECTOR. CHECK THE RELAY COIL EARTH (GROUND) WIRE
No Continuity
FAULTY NEUTRAL SWITCH FAULTY CLUTCH SWITCH FAULTY SIDESTAND SWITCH BAD CONTACT AT CONNECTOR OPEN CIRCUIT IN WIRING LOOM FAULTY ALARM OR ENGINE ECM (IF FITTED)
Continuity
CONNECT THE STARTER RELAY SWITCH CONNECTOR. MEASURE THE STARTER RELAY VOLTAGE AT THE STARTER RELAY SWITCH CONNECTOR
No Voltage
FAULTY IGNITION SWITCH/ENGINE STOP SWITCH BROKEN STARTER SWITCH CABLE BAD CONTACT AT CONNECTOR OPEN CIRCUIT IN WIRING LOOM FAULTY ALARM
Voltage Measured
CHECK THE STARTER RELAY OPERATION
Normal
LOOSE OR POOR CONTACT AT STARTER RELAY
Abnormal FAULTY STARTER RELAY
1.20
Il]MP
General Information
Inspection Disassembled parts 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 Service Data The service data listed in this manual gives dimensions and specifications for brand new, original parts. Where it is permissible to allow a part to exceed these figures, then the service limit is given. The terms of the motorcycle warranty will be invalidated by the fitting of other than genuine Triumph parts. All genuine Triumph parts have the full backing of the motorcycle warranty. Triumph dealers are obliged to supply only genuine Triumph recommended parts.
Warning
Only Triumph genuine parts should be used to service, repair or convert Triumph motorcycles. To ensure that Triumph genuine parts are 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 result in an accident causing serious injury or death.
Specification Triumph are constantly seeking to improve the specification, design and production of their motorcycles and alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular motorcycle. Authorised Triumph dealers are not agents of Triumph and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.
AWartill,ngAlways have Triumph genuine parts, accessories and conversions fitted by an authorised Triumph dealer. The fit ment 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.
Warning
Always have Triumph approved parts, accessories and conversions fitted by a trained technician. To ensure that a trained technician is used, have an authorised Triumph dealer fit the parts. The fitment of parts, accessories and 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.
Il,l MP
1.21
General Information
Service Tools and Garage Equipment
Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical components in a practical manner without causing damage. Some operations in this Service Manual cannot be carried out without the aid of the relevant service tools. Where this is the case, the tools required will be described during the procedure. Special Service Tools
T3880105 Angular Torque Gauge
13880315 Extractor, Cylinder Liner (use with adaptor T3880101)
Increment markings
gakh
T3880057 Engine Management Diagnostics
13880027 Chain Link Took Kit
1.22
Il1MP
General Information
3880085-T0301 Fork Piston Holder T3880102 Wrench, CamTurning
cdpr
3880160-TO301 Fork Filler / Evacuator
T3880026 Clutch Holding Tool, Universal
ccna
T3880375 Alternator Rotor Holder
T3880313 Oil Filter Wrench
111MP
1.23
General Information
T3880101 Extractor, Cylinder Liners T3880365 Puller, Alternator Rotor
gakh
T3880106 Holder, Balancer Gear
T3880028 Holder, Damping Cylinder
T3880104 Wrench, Swinging Arm Adjuster
T3880103 Wrench, Engine Mounting Adjuster
1.24
ll.l MP
General Information
T3880023 Socket 50 mm T3880003 Fork Seal and Bush Fitment
ccxb
T3880002 Support Plate
T3880067 Fork Spring Compressor
L ti
EM T3880001 Fuel Pressure Gauge 3880065 T0301 Bearing Installer
__9
so
I!lM
1.25
General Information
3880070 10301 Bearing Installer T3880123 Extension Cable
BatteryMate Battery Charger - See Latest Parts Catalogue for Part Number Information
T3880053 - Extraction Kit, Wheel Bearing
1.26
!l.l MP
General Information
Full Specification Engine
Engine Configuration ................... 3 Cylinder 12 valve DOHC ...........3 Cylinder 12 valve DOHC Arrangement......................... Transverse in-line ...................Transverse in-line Displacement......................... 674.8 cc ..........................674.8 cc Borex Stroke ......................... 74x52.3 mm....................... 74x52.3 mm CompressionRatio ..................... 12.65:1 ...........................12.65:1 CylinderNumbering ................... Left to Right ....................... Left to Right (no.3 adjacent to camchain) ...........(no.3 adjacent to camchain) CylinderSequence..................... Number 1 at left .................... Number 1 at left Firing Order ..........................1-2-3.............................1-2-3 Maximum Power ...................... 125 PS (123 bhp) at 12,500 rpm 1 ......108.2 PS (106.7 bhp) at 11,700 pm 128 PS (126 bhp) at 12,600 rpm
2
Daytona 675
Street Triple/Street Triple R
Maximum Torque ..................... 72 Nm (53.3 ft.lbf) at 11,750 rpm 1 .....68 Nm (50.1 ft.lbf) at 9,200 rpm) 73 Nm (53.3 ft.lbf) at 11,900 rpm Note:

1
For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275.
Il1Mp
1.27
General Information
Full Specification Cylinder Head & Valves
ValveHead Diameter........ In ......... 30.50 mm ......................... 30.50 mm Ex........ 25.50 mm ......................... 25.50 mm ValveLift .................. In ......... 9.25 mm.......................... 8.00 mm Ex........ 8.50 mm .......................... 7.25 mm ValveStem Diameter........ In ......... 3.975-3.990 mm .................. ServiceLimit ............... 3.975-3.990 mm
Daytona 675
.......... 3.965 mm......................... 3.965 mm 3.955-3.970 mm
ValveStem Diameter........ Ex ........ 3.955-3.970 mm .................. ServiceLimit ...............
.......... 3.945 mm......................... 3.945 mm
Valve Guide Bore Diameter .. In ......... 4.000-4.015 mm .................... 4.000-4.015 mm ServiceLimit ............... .......... 4.043 mm.........................4.043 mm
Valve Guide Bore Diameter . . Ex ........ 4.000-4.015 mm .................... 4.000-4.015 mm ServiceLimit ............... .......... 4.043 mm......................... 4.043 mm
Valve Stem to Guide Clearanceln......... 0.010-0.040 mm ....................0.01 -0.040 nom ServiceLimit ............... .......... 0.078 mm ......................... 0.078 mm 0.030-0.060 mm
Valve Stem to Guide ClearanceEx ........ 0.030-0.060 mm .................. ServiceLimit ...............
.......... 0.098 mm......................... 0.098 mm
ValveSeat Width (in head) ... In ......... 0.80-1.20 mm ...................... 0.80-1.20 mm ServiceLimit ............... .......... 1.50 mm .......................... 1.50 mm 1.00-1.40 mm
ValveSeat Width (in head) ... Ex ........ 1.00-1.40 mm ..................... ServiceLimit ...............
.......... 1.70 mm .......................... 1.70 mm

I
ValveSeat Width (valve) ..... In ......... 1.27-1.56 mm In......... 1.05-1.34 mm
..................... 1.27-1.56 mm
Ex........ 1.34-1.63 mm ..................... ValveSeat Angle ...........
1.34-1.63 mm
.......... 45 .............................. 450 508 N +/-25 N at 27.5 mm ........... 508 N +/-25N at 27.5 mm
Inlet/Exhaust Valve Spring 'Load at Length'
ValveClearance ............ In ......... 0.10-0.20 mm ...................... 0.10-0.20 mm Ex......... 0.275-0.325 mm Ex ........ 0.325-0.375 mm
I
................. 0.275-0.325 mm
Note:

1
1.28
II,I MP
General Information
Full Specification Cylinder Head & Valves (continued)
Valve Bucket Diameter....... In ......... 26.476-26.490 mm In ........
1
Daytona 675
................26.47 -26.490 mm
25.376-25.390 mm 2
I
ServiceLimit .......................... 26.468 mm
......................26.468 mm
25.368 mm 2 ValveBucket Diameter....... Ex......... 24.976-24.990 mm Ex......... 25.376-25.390 2 ServiceLimit .......................... 24.968 mm
I 1
................24.97 -24.990 mm
......................24.968 mm
25.368 mm 2 Valve Bucket Bore Diameter . . In ......... 26.515-26.535 mm In ........

I
................26.51 -26.535 mm
25.415-25.435 mm 2
I
ServiceLimit .......................... 26.549 mm 25.449 2 Valve Bucket Bore Diameter ..
......................26.549 mm
Ex.........
25.015-25.035 mm
................25.01 -25.035 mm
Ex......... 25.415-25.435 mm 2 ServiceLimit .......................... 25.049 mm

I
......................25.049 mm
25.449 mm 2
Camshafts
Cam Timing ............... Inlet ....... Open 2749 BTDC @ 1.0 mm lift......Open 13.23 BTDC @ 1.0 mm lift Close 51.49 ABDC @ 1.0 mm lift......Close 37.23 ABDC @ 1.0 mm lift Duration... 258.98 ........................... 230.46 Exhaust .... Open 43.09 BBDC Open 43.54 BBDC Close 23.09 ATDC Close 23.54 ATDC Duration...246.1
1 I
@ 1.0 mm lift. ...Open 25.09 BBDC @ 1.0 mm lift
2 I
@ 1.0 mm lift @ 1.0 mm lift .... Close 13.09 ATDC @ 1.0 mm lift
@ 1.0 mm lift
........................... 218.18
247.08 2 Camshaft Journal Diameter .............. 23.900-23.930 mm .................23.90 -23.930 mm Camshaft Journal Clearance ............ 0.070-0.121 mm ....................0.07 -0.121 mm
ServiceLimit .......................... 0.17 mm ..........................0.17 mm Camshaft Journal Bore Diameter ......... 24.000-24.021 mm .................24.00 -24.021 mm CamshaftEnd Float ................... 0.23-0.33 mm .....................0.2 -0.33 mm
ServiceLimit .......................... 0.40 mm ..........................0.40 mm CamshaftRun-out ..................... 0.15 mm max.......................0.15 mm max
Note:
1 2
Il1MP
1.29
General Information
Full Specification Clutch/Primary Drive
PrimaryDrive Type ......... ReductionRatio ............ ClutchType ............... No. of Friction Plates ........ PlateFlatness .............. FrictionPlate Thickness ...... ServiceLimit ............... ClutchActuation Method .... CableFree Play (at lever) ..... .......... Gear ............................. Gear .......... 1.848 (46/85) ...................... 1.848 (46/85) .......... Wet multi-plate ..................... Wet multi-plate .......... 9 ............................... 9
Daytona 675
.......... Within 0.2 mm ..................... Within 0.2 mm .......... 3.00 mm.......................... 3.00 mm .......... 2.80 mm .......................... 2.80 mm .......... Cable............................. Cable .......... 2.0-3.0 mm........................ 2.0-3.0 mm
Pistons
Cylinder Bore Diameter ...... .......... 73.985-74.003 mm ................. 73.985-74.003 mm
ServiceLimit ....................... 74.100 mm ........................ 74.100 mm Piston Diameter (at 90 to gudgeon pin) ... 73.970-73.980 mm .................73.964-73.980 mm ServiceLimit ....................... 73.920 mm ....................... 73.920 mm Piston Ring to Groove Clearances Top...................... .......... 0.04-0.08 mm .................... 0.02-0.06 mm
ServiceLimit ....................... 0.095 mm.........................0.075 mm Second........... ........ .......... 0.02-0.06 mm .................... 0.02-0.06 mm
ServiceLimit ....................... 0.075 mm.........................0.075 mm Piston Ring End Gaps Top...................... .......... 0.10-0.25 mm ...................... 0.10-0.25 mm
ServiceLimit ....................... 0.55 mm..........................0.55 mm Second................... .......... 0.25-0.40 mm .................... 0.25-0.40 mm
ServiceLimit ....................... 0.70 mm..........................0.70 mm Oil....................... .......... 0.10-0.35 mm ...................... 0.10-0.35 mm
Gudgeon Pin Bore Diameter in Piston ..... 1 6.004-16.012 mm .................. 16.004-16.012 mm ServiceLimit ....................... 16.040 mm........................ 16.040 mm Gudgeon Pin Diameter ...... .......... 15.995-16.000 mm .................15.995-16.000 mm
ServiceLimit ....................... 15.985 mm........................ 15.985 mm
Connecting Rods
Connecting Rod Small End Diameter...... 16.016-16.029 mm ..................16.016-16.029 mm ServiceLimit ....................... 16.039 mm........................ 16.039 mm Connecting Rod Big End Side Clearance... 0.15-0.30 mm ...................... 0.15-0.30 mm ServiceLimit ....................... 0.50 mm..........................0.50 mm
1.30
Il1MP
General Information
Full Specification Crankshaft
Crankshaft Big End Journal Diameter...... 32.984-33.000 mm .................32.98 -33.000 mm ServiceLimit ....................... 32.960 mm........................32.960 mm Crankshaft Big End Bearing Clearance..... 0.035-0.065 mm ...................0.03 -0.065 mm ServiceLimit ....................... 0.070 mm ......................... 0.070 mm Crankshaft Main Bearing Journal Diameter . 32.984-33.000 mm ................ 32.984-33.000 mm
Daytona 675
ServiceLimit ....................... 32.960 mm........................32.960 mm Crankshaft Main Bearing Clearance ....... 0.020-0.044 mm ...................0.02 -0.044 mm ServiceLimit ....................... 0.070 mm ......................... 0.070 mm CrankshaftEnd Float .................. 0.15-0.30 mm ......................0.1 -0.30 mm
CrankshaftRun-out .................... 0.02 mm or less ....................0.02 mm or less ServiceLimit ....................... 0.05 mm .......................... 0.05 mm
Transmission
Type............................... 6 Speed, Constant Mesh .............6 Speed, Constant Mesh
1
GearRatios ................ 1st ........ 2.615 (34/13) .........................1st ........ 2.313 (37/16)
......................2.615 (34/13)
2nd....... 1.857 (39/21) ...................... 1.857 (39/21) 3rd........ 1.565 (36/23) ...................... 1.565 (36/23) 4th........ 1.350 (27/20) ......................1.350 (27/20) 5th........ 1.238 (26/21) ...................... 1.238 (26/21) 6th........ 1.136 (25/22) .......................1.136 (25/22) GearSelector Fork Thickness ........... 5.9-6.0 mm ........................ 5.9-6.0 mm
ServiceLimit ....................... 5.80 mm .......................... 5.80 mm GearSelector Groove Width ............. 5.80 mm .......................... 5.80 mm ServiceLimit ....................... 6.27 mm .......................... 6.27 mm Gear Selector Fork to Groove Clearance .. . 0.47 mm max ...................... 0.47 mm max
Final Drive
FinalDrive ........................... Chain ............................. Chain FinalDrive Ratio ....................... 2.937 (16/47) ......................2.937 (16/47) ChainType ........................... RK O-ring ......................... RK O-ring Numberof Links ...................... 116............................... 116 20 Link Length ........................ 319 mm ........................... 319 mm DriveChain Play ......................35-40 mm.........................20-25 mm ChainLubrication ...................... Mobil chain spray ................... Mobil chain spray
Note:

1
I UMP
1.31
General Information
Full Specification Lubrication
Type ..................... OilCapacity (dry fill) ........ .......... Pressure Lubrication, Wet Sump ....... Pressure Lubrication, Wet Sump .......... 3.5 litres .......................... 3.5 litres
Daytona 675
Oil Capacity (wet fill including filter) ....... 3.1 litres ........................... 3.1 litres Oil Capacity (wet fill excluding filter) ...... 2.9 litres .......................... 2.9 litres Recommended Oil Approval Rating....... API SH (or higher) and JASO MA...... API SH (or higher) and JASO MA Viscosity.................. Type..................... Oil pressure (in main gallery) . OilPump Rotor Tip Clearance .......... 10W/40 or 15W/50 ................. 10W/40 or 15W/50 .......... Semi or fully synthetic ............... Semi or fully synthetic .......... 30.0 Ib/in2 min. @ 80C ............ 30.0 Ib/in2 min. @ 80C oil temperature @ 5,000 rpm oil temperature @ 5,000 rpm .......... 0.15 mm .......................... 0.15 mm
ServiceLimit ....................... 0.20 mm..........................0.20 mm OilPump Body Clearance .... .......... 0.15-0.22 mm ...................... 0.15-0.22 mm
ServiceLimit ....................... 0.35 mm..........................0.35 mm OilPump Rotor End Float .... ServiceLimit ............... .......... 0.04-0.09 mm .....................0.0 -0.09 mm .......... 0.17 mm .......................... 0.17 mm
Ignition System
Type..................... ElectronicRev Limiter ....... .......... Digital Inductive .................... Digital Inductive .......... 14,000 (rpm)....................... 13,000 (rpm)
Pick-up Coil Resistance ...... .......... 0.21 KW +/-10% @ 20C.............0.21 KW +/-10% @ 20C IgnitionCoil Type ........... .......... Plug-top........................... Plug-top
SparkPlug Type ............ .......... NGK CR9EK....................... NGK CR9EK SparkPlug Gap ............ .......... 0.7 mm........................... 0.7 mm
Fuel System
FuelType ................. FuelTank Capacity .......... Low Level Warning Lamp .... FuelPump Type ............ FuelPressure (nominal) ...... Purge Control System ....... .......... Unleaded, 95 RON ................. Unleaded, 91 RON (U.S. 87 CLC/AKI) (U.S. 89 CLC/AKI) .......... 17.4 litres .......................... 17.4 litres .......... 4 litres remaining ................... 4 litres remaining .......... Submerged ........................ Submerged .......... 3.0 bar ........................... 3.0 bar .......... Electronic, via fuel system ECU ........ Electronic, via fuel system ECU
1.32
I UMP
General Information
Full Specification Coolant System
Note: Up to VIN 331531 use Triumph HD4X Hybrid OAT coolant when replacing the coolant. From VIN 331532 use Triumph HD4X Hybrid OAT coolant when topping up or replacing the coolant.
water/anti-freeze
Daytona 675
Coolant Mixture up to VIN 331531 ....... 50/50 Distilled .....................5 /50 Distilled water/anti-freeze
Coolant Mixture from VIN 331532 ....... 50/50 (pre-mixed as supplied .........50/50 (pre-mixed as supplied pre-mixed as supplied by Triumph) pre-mixed as supplied by Triumph)
Anti-Freeze Type up to VIN 331531 ....... Mobil anti-freeze ....................Mobil anti-freeze Anti-Freeze Type from VIN 331532 ....... Triumph HD4X Hybrid :..............Triumph HD4X Hybrid OAT coolant OAT coolant
Freezingpoint ........................- 35C............................ -35C CoolingSystem Capacity ................ 2.4 litres........................... 2.2 litres RadiatorCap Opening Pressure .......... 1.1 bar ............................1.1 bar Thermostat Opening Temperature ........ 71 C (nominal) ..................... 71 C (nominal) CoolingFan Switch On Temperature ..... 103C ............................10 C
Temperature Gauge Sensor Resistance .... 2.9 3.3 KQ@ 15C ................2.9 3.3 KQ @ 15C
Suspension
FrontFork Travel ...................... 110 mm ........................... 120 mm Recommended Fork Oil Grade........... Kayaba KHL15-10 ...................Kayaba KHL15-10 OilLevel ............................ 72 mm (up to VIN 381274)...........107 mm for Street Triple (fork fully compressed, spring removed) ... 89 mm (from VIN 381275) ...........93 mm for Street Triple R Oil Volume (dry fill) .................... 495 cc (up to VIN 381274) ...........465 cc for Street Triple 492 cc (from VIN 381275)............484 cc for Street Triple R ForkPull Through ..................... 4 mm.............................4 mm RearWheel Travel ..................... 130 mm...........................126 mm Rear Suspension Bearing Grease ......... Mobil grease HP 222 ................Mobil grease HP 222
l TMP
1.33
General Information
Full Specification Fuel Injection System
Type..................... IdleSpeed ................ Injecto
rTy
Daytona 675
.......... Electronic, sequential ................ Electronic, sequential .......... 1200 RPM ........................ 1200 RPM .......... Twin jet, solenoid ................... Twin jet, solenoid operated plate valve operated plate valve .......... Cable/twist grip/electronic ............ Cable/twist grip/electronic throttle potentiometer throttle potentiometer .......... Barometric pressure, throttle .......... position, coolant temperature, crankshaft position, vehicle speed, lambda sensor, intake air temperature, gear position, MAP Barometric pressure, throttle position, coolant temperature, crankshaft position, vehicle speed, lambda sensor, intake air temperature, gear position, MAP
...............
Throttle ................... Control Sensors ............
Emissions Controls
Catalysts.................. .......... 1, in down pipe..................... 1, in down pipe
Oxygensensor ............ .......... Heated, in down pipe................ Heated, in down pipe Secondary Air injection ..... .......... Solenoid controlled.................. Solenoid controlled, reed valve type reed valve type Evaporative Control ........ .......... Activated carbon ................... Activated carbon canister (California only) canister (California only)
Brakes
Front Type ................ .......... Two hydraulically actuated ............ Two hydraulically actuated four piston radial calipers twin piston sliding calipers acting on twin discs 1 acting on twin discs .......... 33.96 mm / 30.23 mm 4 x 32.03 mm 2 2 x 27.00 mm * 33.96 mm / 30.23 mm $
Caliper Piston Diameter ...... DiscDiameter ............. DiscThickness .............
.......... 308 mm .......................... 308 mm .......... 4 mm ............................ 4 mm
ServiceLimit ....................... 3.5 mm ........................... 3.5 mm DiscRun-out ............... Master Cylinder Diameter Recommended Fluid ........ .......... 0.3 mm Max ...................... 0.3 mm Max 19.05 mm 14.00 mm for Street Triple 19.05 mm for Street Triple R .......... Mobil universal brake................ Mobil universal brake and clutch fluid DOT4 and clutch fluid DOT4
Note:
1
* For Street Triple. # For Street Triple R
1.34
Il1MP
General Information
Full Specification Brakes (continued)
Rear Type ........................... Hydraulically actuated single .......... Hydraulically actuated single piston caliper, single disc piston caliper, single disc
Daytona 675
CaliperPiston Diameter ................. 38.18 mm .........................38.18 mm DiscDiameter ......................... 220 mm ..........................220 mm DiscThickness ........................ 5.0 mm ........................... 5.0 mm ServiceLimit ....................... 4.5 mm ........................... 4.5 mm DiscRun-out .......................... 0.3 mm Max.......................0.3 mm Max MasterCylinder Diameter ............... 14 mm............................14 mm Recommended Fluid ................... Mobil universal brake and ........... Mobil universal brake and
.................................... clutch fluid DOT4 ................... clutch fluid DOT4
Wheels and Tyres

Front Wheel Size ...................... MT 3.5 x 17 ....................... MT 3.5 x 17 FrontTyre Size ........................ 120/70 ZR 17 ...................... 120/70 ZR 17 FrontTyre Pressure ..................... 2.35 Bar (34 lb/in2)..................2.35 Bar (34 lb/in 2) Recommended Front Tyre. . . . Option 1 ... Pirelli Dragon Supercorsa Pro
2
1
. . . . . . . .
Bridgestone Battlax BT016 F
Pirelli Diablo Super Corsa SP ......... Dunlop Sportmax Qualifier $ Option 2 ... Michelin Pilot Power B Dunlop Qualifier
2 I
.............. Dunlop Sportmax Qualifier
................... Bridgestone BT015 G t

I
Option 3 ... Bridgestone BT014 G Metzeler M3 C

2
............... Pirelli Dragon Supercorsa Pro
Option4 ... N/A .............................. Bridgestone BT015 G Front Wheel Rim Axial Run-out .......... 0.5 mm ...........................0.5 mm Front Wheel Rim Radial Run-out.......... 0.5 mm ...........................0.5 mm RearWheel Size ....................... MT 5.5 x 17 ....................... MT 5.5 x 17 RearTyre Size ......................... 180/55 ZR 17 ...................... 180/55 ZR 17 RearTyre Pressure ..................... 2.5 Bar (36 1b/ft 2 ) ................... 2.9 Bar (42 lb/ft
2)
Recommended Rear Tyres.... Option 1 ... Pirelli Dragon Supercorsa Pro' ........ Bridgestone Battlax BT016 R Pirelli Diablo Super Corsa SP z ......... Dunlop Sportmax Qualifier Option 2 ... Michelin Pilot Power
z
................ B 'Dunlop Sportmax Qualifier
Dunlop Qualifier . .................. Bridgestone BT014 E $ Option 3 ... Bridgestone BT014 G Metzeler M3
2
I
............... Pirelli Dragon Supercorsa Pro
Option4 ... N/A .............................. Bridgestone BT015 E '` RearWheel Rim Axial Run-out ........... 0.5 mm ........................... 0.5 mm RearWheel Rim Radial Run-out .......... 0.5 mm ...........................0.5 mm
Note: ,.,
* For Street Triple.
# For Street Triple R.
`.
I UMP
1.35
General Information
Full Specification Frame
FrameType ............... OverallLength ............. .......... Twin-spar aluminium ................Twin-spar aluminium .......... 2010 mm (79.1 in) .................. 2000 mm (78.7 in) Street Triple 2030 mm (79.9 in) Street Triple R .......... 700 mm (27.5 in) ................... 750 mm (29.5 in) Street Triple 755 mm (29.7 in) Street Triple R .......... 1120 mm (44.1 in) .................. 1165 mm (45.8 in) Street Triple 1185 mm (46.7 in) Street Triple R .......... 1395 mm (54.9 in).................. 1390 mm (54.7 in) .......... 825 mm (32.5 in)................... 810 mm (31.8 in) Street Triple 805 mm (31.7 in) Street Triple R .......... 23.9 ............................. 24.3 Street Triple 23.9 Street Triple R .......... 89.1 mm .......................... 95.3 mm Street Triple 92.4 mm (3.64 in) Street Triple R .......... 165 kg............................ 1 67 kg .......... 195 kg............................ 195 kg
Daytona 675
Overall Width ..............
OverallHeight .............
Wheelbase................ SeatHeight ...............
Rake.....................
Trail.....................
DryWeight ................ MaximumPayload ..........
(rider, passenger, luggage and accessories)
Electrical Equipment
BatteryType ............... .......... YT 7B - BS' ........................ YTX9 - BS YTX 9 - BS2 BatteryRating .............. AlternatorRating ........... .......... 12V 6.5 Amp. Hour ............... 12V 8 Amp. Hour .......... 33.5 A at 4,000 rpm ................ 33.5 A at 4,000 rpm
Fuses*... #1 ......Dip and main beam ........... 15 Amp ..................... 20 Amp headlights, starter relay ........ #2 ......Ignition switch, starter circuit .... 1 0 Amp ..................... 1 0 Amp ........ #3 ......Auxilliary li ghting ............. 5 Amp ...................... 5 Amp ........ 1 0 Amp ..................... 1 0 Amp
........ #4 ......Indicators, Alarm, Horn
........ #5 ......Cooling fan .................. 15 Amp ..................... 15 Amp ........ #6 ......Engine management system..... 20 Amp ..................... 20 Amp *The starter solenoid has an additional 30 Amp fuse, attached directly to the solenoid, beneath the rider's seat.
Note:
1 2
1.36
I UMP
General Information
Torque Wrench Settings
Cylinder Head Area
Application Cam cover to cylinder head Torque (Nm) 10 Notes Fit new bolt seals and lubricate with clean engine oil
Secondary air injection valve covers to cam cover Cam chain tensioner to cylinder head - All models except Daytona 675 from VIN 381275 Cam chain tensioner to cylinder head - Daytona 675 from VIN 381275 Cam chain tensioner to centre bolt - All models except Daytona 675 from VIN 381275 Camshaft bearing caps and camshaft bearing ladder to head Camshaft sprocket to camshaft Cylinder head to crankcase (M6 screws) Cylinder head to crankcase bolts Sound suppression bolt in head Spark plug to cylinder head
9 9 9 7 Use new fixings
See section 3 15 10 See section 3 12 12 Use new fixings
Clutch
Application Clutch cover to crankcase Clutch centre nut Clutch pressure plate to centre Clutch lever clamp bolts to handlebar Clutch cable adjuster bracket to crankcase
Torque (Nm) 9 98 10 12 12
Notes
Crankshaft and Crankcase, Sprag

Application Crankcase upper to lower (M8 fixings) Crankcase upper to lower (M6 fixings) Connecting rod big end nut Sprag clutch to crankshaft Camshaft drive sprocket gear to crankshaft Torque (Nm) See section 6 See section 6 See section 6 See section 7 27 Use new fixing Notes
ll,1 MP
1.37
General Information
Engine Covers Application Clutch cover to crankcase Sprocket cover to crankcase Alternator cover to crankcase Crank cover to crankcase Balancer cover to crankcase Transmission Application Output sprocket to output shaft Torque (Nm) 85 12 12 12 12 20 5 9 22 6 Use a new fixing Notes Use new tab washer Use a new fixing Use a new fixing Use new fixings Use new fixings Torque (Nm) 9 9 9 9 9 Notes
Detent wheel to selector drum Detent arm bolt Input shaft bearing carrier Selector shaft retainer Spring abutment bolt Gear position sensor Gear pedal pinch bolt Gear pedal pivot bolt Gear change rod adjuster nuts Lubrication System Application Sump to crankcase Sump drain plug to sump Oil pressure relief valve to crankcase
Torque (Nm) 12 25 15
Notes
Use a new washer Apply ThreeBond 1305 to the threads Use new washers
Low oil pressure warning light switch to crankcase Oil filter to adapter Heat exchanger to crankcase
13 10 59
Use a new sealing washer Use new fixings Use new fixings Apply ThreeBond 1374 to the threads
Oil pump drive chain retainer plate Oil pump to crankcase Oil pump drive sprocket to pump shaft
9 12 14
Oil pump rotor cover to pump body bolts Transmission oil feed pipes to crankcase
12 12 Use new fixings
1.38
1lIMP
General Information
Final Drive
Application Rear sprocket to sprocket carrier Rear sprocket studs to sprocket carrier Chain guard bolts Chain rubbing strip to swinging arm Torque (Nm) 55 30 9 9 Use new fixings Notes
Cooling System
Application Water pump/oil pump assembly to crankcase Upper right hand radiator mounting to frame Upper left hand radiator mounting to frame/steering damper (if fitted) Lower radiator mounting to radiator Lower radiator mounting to engine (Daytona 675) Lower radiator mounting to engine bracket (Street Triple)) Lower radiator engine bracket to water elbow (Street Triple) Water inlet elbow to head Thermostat housing to head Fan to radiator Radiator bleed screw Top hose bleed screw (Street Triple only) Radiator cowl to radiator Torque (Nm) 12 6 12 3 9 9 12 12 9 2.5 1.5 1 5 Notes Use new fixings
Fuel System, Exhaust System and Airbox

Application Fuel tank to frame (front fixing) Fuel tank to frame (rear fixing) Fuel tank front bracket to fuel tank Fuel cap to fuel tank Fuel pump mounting plate to fuel tank Throttle body transition piece to cylinder head Throttle potentiometer to throttle body Exhaust downpipe to cylinder head Exhaust downpipe to frame Exhaust intermediate pipe to frame Silencer mounting bracket to subframe (Daytona 675) Silencer mounting bracket to subframe (Street Triple) Exhaust clamp - header to intermediate pipe Exhaust clamp - silencer to intermediate pipe (Daytona 675) Torque (Nm) 9 9 9 4 9 12 2 See section 10 19 22 27 15 15 15 Notes
ILiMP
1.39
General Information
Fuel System, Exhaust System and Airbox (continued) Application
Exhaust clamps - silencers to intermediate pipe (Street Triple) Exhaust valve actuator bracket to frame (Daytona 675) Exhaust valve actuator to bracket (Daytona 675) Exhaust valve actuator pulley wheel to Actuator shaft (Daytona 675) Airbox upper section to lower Air filter to lower airbox Airbox lower to frame Airbox trumpet to throttle body Carbon canister to bracket Carbon canister bracket to frame Carbon canister bracket to frame (upper screw - Street Triple only)
Torque (Nm)
10 9 12 5 1.5 4 3 6 3 8 4
Notes
Use new fixing
Use new fixings
Rear Suspension Application

Swinging arm spindle bolt Swinging arm rubbing strip bolts Chain adjuster locknut Rear suspension unit upper mounting bolt Rear suspension unit upper clevis to frame Rear suspension unit lower mounting bolt Drag link pivot at frame Drop links to swinging arm Swinging arm end-float adjuster sleeve
Torque (Nm)
110 9 20 48 52 48 48 48 6
Notes
1.40
I UMP
General Information
Front Suspension Application Upper yoke pinch bolt Lower yoke pinch bolt Fork top cap Upper yoke centre nut Damping cylinder bolt Handlebar clamp to fork (Daytona 675) Handlebar clamp to riser (Street Triple and Street Triple R) Handlebar riser to upper yoke (Street Triple and Street Triple R) Steering damper to lower yoke (Daytona 675 only) Steering damper to frame bracket (Daytona 675 only) Steering damper frame bracket to frame (Daytona 675 only) Steering damper rod lock nut (Daytona 675 only) Wheels Application Front wheel spindle / axle bolt Front wheel spindle pinch bolts Rear wheel spindle / axle bolt Front Brakes Application Front brake caliper to fork (Daytona 675 and Street Triple R) Front brake caliper half to caliper half (Daytona 675 and Street Triple R) Front brake caliper to fork (Street Triple) Front brake pad retaining pin Front brake pad retaining pin plug (Street Triple) Front brake caliper bleed screw Front brake hose to caliper Front brake master cylinder to handlebar Front brake master cylinder reservoir to mounting ( Daytona 675 and Street Triple R) Front brake master cylinder bleed screw Front brake hose to master cylinder Front brake disc to wheel Torque (Nm) 35 22 28 18 3 6 25 12 7 Use new fixings Notes Torque (Nm) 65 22 110 Notes Torque (Nm) 26 20 See text 90 See text 26 26 35 18 18 12 20 Use new fixings Lubricate threads with engine oil Use a new washer Notes
6 25 22 Use new fixings
1l.i MP
1.41
General Information
Rear Brakes Application Rear brake caliper to carrier (M12 fixing) Rear brake caliper to carrier (M8 fixing) Rear brake pad retaining pin Rear brake pad retaining pin plug Rear brake caliper bleed screw Rear brake hose to caliper Rear brake hose clips to swinging arm Rear brake master cylinder to control plate (includes heel guard) Rear brake lever to control plate Torque (Nm) 27 22 18 3 6 25 6 18 22 Apply ThreeBond 1360 to the threads Notes
Rear brake master cylinder reservoir to frame Rear brake hose to master cylinder Rear brake disc to wheel Frame, Footrests, Control Plates and Engine Mountings Application Upper crankcase to frame Lower crankcase to frame Cylinder head to frame Engine mounting bracket to frame Engine mounting bracket to cylinder head Control plate to frame Left hand heel guard to control plate (Daytona 675)
7 25 22 Use new fixings
Torque (Nm) See section 9 See section 9 See section 9 See section 9 See section 9 27 9
Notes
Use new fixings Apply ThreeBond 1360 to left hand fixings
Left hand heel guard to control plate (Street Triple) Rear footrest hanger to frame
12 27 Apply ThreeBond 1360 to threads on Street Triple and Street Triple R only
Side stand mounting bracket Side stand pivot
45 20 Apply ThreeBond 1360 to threads Apply ThreeBond 1360 to threads
Bank angle indicator
1.42
Il]MP
General Information
Electrical Application Alternator rotor to crankshaft Alternator stator to cover Alternator regulator to bracket Alternator regulator bracket to frame Starter motor to crankcase Spark plug to cylinder head Bodywork Application Mirror (Daytona 675) Mirror (Street Triple) Rear panels to frame Front mudguard to forks Rear mudguard to subframe Number plate bracket to silencer (Daytona 675) Number plate bracket to subframe (Street Triple) Heat shield to silencer (Daytona 675) Lower fairing fixings (Daytona 675) Cockpit fixings (Daytona 675) Windshield fixings (Daytona 675) Torque (Nm) 9 25 3 6 4 12 23 6 See section 16 See section 16 0.5 Notes Torque (Nm) 120 12 3 12 10 12 Notes
I UMP
1.43
General Information
Clutch Cable Routing - Daytona 675
1.44
IL1MP
General Information
Clutch Cable Routing - Street Triple and Street Triple R
I UMP
1.45
General Information
Throttle Cable Routing - Daytona 675
1.46
IIIMP
General Information
Throttle Cable Routing - Street Triple
I UMP
1.47
General Information
Throttle Cable Routing - Street Triple R
1.48
I UMP
General Information
Main Wiring Harness Routing - Daytona 675 up to VIN 381274
ILIMP
1.49
General Information
Main Wiring Harness Routing - Daytona 675 from VIN 381275
1.50
S UMP
General Information
Main Wiring Harness Routing - Street Triple and Street Triple R
ILIMP
1.51
General Information
Rear Light Harness Routing - Daytona 675
1.52
II.I MP
General Information
Front Brake Hose Routing - Daytona 675
I UMP
1.53
General Information
Front Brake Hose Routing - Street Triple
1.54
ll1MP
General Information
Front Brake Hose Routing - Street Triple R
lgmp
1.55
General Information
Rear Brake Hose Routing - All Models (Daytona 675 shown)
1.56
Il1MP
General Information
Fuel Tank Breather Hose Routing - Daytona 675
IIIMP
1.57
General Information
Fuel Tank Breather Hose Routing - Street Triple and Street Triple R
1.58
II,I MP
General Information
Fuel Tank Breather Hose Routing - Models with Evaporative Emissions Daytona 675
A - Purge Hose to Throttle Bodies B - Breather Hose to Carbon Canister C - Breather hose - Fuel Tank Filler Drain
iiiiiiiij
1.59
General Information
Fuel Tank Breather Hose Routing - Models with Evaporative Emissions Street Triple and Street Triple R
B - Breather Hose to Carbon Canister C - Breather hose - Fuel Tank Filler Drain
1.60
I UMP
General Information
Intake Air Flap Vacuum Hose Routing - Daytona 675 only
111MP
1.61
2 Scheduled Maintenance
Table of Contents
Introduction .............................................................................. ScheduledMaintenance Chart .............................................................. 2.2 2.3
on
I UMP
2.1
Scheduled Maintenance Introduction

To maintain the motorcycle in a safe and reliable condition, the maintenance and adjustments outlined in this section must be carried out as specified in the schedule of daily checks, and also in line with the scheduled maintenance chart. Weather, terrain and geographical location affects maintenance. The maintenance schedule should be adjusted to match the particular environment in which the vehicle is used and the demands of the individual owner. For advice on adjusting the service schedule, consult your authorised Triumph dealer. , .
Warning
All maintenance is vitally important and must not be neglected. Incorrect maintenance or adjustment may cause one or more parts of the motorcycle to malfunction. A malfunctioning motorcycle is dangerous and m ay lead to an accide nt.
Warning
Triumph Motorcycles cannot accept any responsibility for damage or injury resulting from incorrect maintenance or improper adjustment carried out by the owner. Since incorrect or neglected maintenance can lead to a dangerous riding condition, always have an authorised Triumph dealer carry out the scheduled maintenance of this motorcycle.
Ak
Warning
In order to correctly carry out the maintenance items listed in the scheduled maintenance chart, special tools and specialist knowledge will be required. As only an authorised Triumph dealer will have this knowledge and equipment, Triumph strongly recommends that your authorised Triumph dealer carries out all scheduled maintenance. A dangerous riding condition could result from incorrect maintenance leading to loss of motorcycle control and an accident.
2.2
Il1MP
Scheduled Maintenance
Scheduled Maintenance Chart
Operation Description Every Odometer Reading in Miles (Kms) or time period, whichever comes first 500 (800) 1 month Engine oil cooler - check for leaks Engine oil - renew Engine oil filter - renew Valve clearances - check Air cleaner - renew Engine ECM - check for stored DTCs Spark plugs - check Spark plugs - renew Throttle bodies - balance Throttle cables - check/adjust Cooling system - check for leaks Coolant level - check/adjust Coolant - renew Fuel system - check for leaks Lights, instruments & electrical systems - check Steering - check for free operation Headstock bearings - check/adjust Headstock bearings - lubricate Forks - check for leaks/smooth operation Fork oil - renew Brake fluid levels - check Brake fluid - renew Brake pad wear - check Brake master cylinders check for oil leaks Brake calipers - check for leaks and seized pistons Rear suspension linkage - check/lubricate Drive chain - lubricate Drive chain - wear check Drive chain slack - check/adjust Drive rubbing strip - check Fasteners - inspect visually for security Wheels - inspect for damage Wheel bearings - check for wear/smooth operation Tyre wear/tyre damage - check Tyre pressures - check/adjust Clutch cable - check/adjust Secondary air injection system - check Stand - check operation Exhaust butterfly valve cables - check/adjust (Daytona 675 only) Secondary exhaust clamp bolts - check/adjust Fuel and evaporative loss* hoses - renew Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Day Every 200 miles (300 kms) Every 500miles (800kms) 6,000 (10,000) 1 year 12,000 (20,000) 2 years 18,000 (30,000) 3 years 24,000 (40,000) 4 years
*Evaporative system fitted to California models only.
I UMP
2.3
3 Cylinder Head
Table of Contents
Ex lodedView
Cylinder Head and Valves ....................................................
3.3 3.4
ExplodedView - Camshaft Cover ............................................................ Exploded View - Camshaft and Camshaft Drive - Daytona 675 up to VIN 381274, Street Triple
and Street Triple R all VINs
.....
3.5 3.6 3.7 3.7 3.7 3.8 3.9 3.9 3.10 3.14 3.14 3.14 3.15 3.15 3.16 3.17 3.17 3.17 3.18 3.18 3.19 3.20 3.20 3.20 3.21 3.22 3.22 3.23 3.23
Exploded View - Camshaft and Camshaft Drive - Daytona 675 from VIN 381275 .................... CylinderHead Description .................................................................. CamshaftCover ........................................................................... Removal........................................................................... Installation.......................................................................... CamshaftDrive Chain Tensioner - all Models .................................................. Removal........................................................................... Installation.......................................................................... Camshaft Drive Chain Tensioner Blade - Daytona 675 - from VIN 381275 ......................... Disassembly........................................................................ Assembly........................................................................... Camshafts............................................................................... Removal........................................................................... Camshaftand Bearing Cap Inspection .................................................. Installation.......................................................................... Stage1 ............................................................................ Stage2 ............................................................................ ValveClearances .................................................................... ValveClearance Measurement ......................................................... ValveClearance Adjustment ........................................................... CamshaftDrive Chain ..................................................................... Removal.......................................................................... Inspection......................................................................... Installation......................................................................... CylinderHead ........................................................................... Removal.......................................................................... Inspection......................................................................... Installation.........................................................................
Il1MP
3.1
Cylinder Head
Valvesand Valve Stem Seals ............................................................... Removalfrom the Cylinder Head ..................................................... Installation........................................................................ Valveto Valve Guide Clearance.......... ............................................. ValveGuides ...................................................................... ValveFace Inspection ............................................................... 3.24 3.24 3.25 3.25 3.25 3.25
3.2
S UMP
Cylinder Head
Exploded View - Cylinder Head and Valves
See Text
See T vt See Text
75 10 Nm 1305 to Threads)
12 Nm
10 Nm
o
0
0
a 0 o 0
O 00
0
0
0
O p
12 Nm
C) 0 9b
ff17
L UMP
3.3
Cylinder Head
Exploded View - Camshaft Cover
10 Nm
10 Nm
Apply engine oil to seals
3.4
Il1MP
Cylinder Head
Exploded View - Camshaft and Camshaft Drive - Daytona 675 up to VIN 381274, Street Triple and Street Triple R all VINs
IN
9 Nm
I UMP
3.5
Cylinder Head
Exploded View - Camshaft and Camshaft Drive - Daytona 675 from VIN 381275
9 Nm
O
o4
3.6
Il1MP
Cylinder Head
Cylinder Head Description
The engine is fitted with an aluminium alloy cylinder head, which carries the camshafts, valves and spark plugs. The cylinder head is cast as a single entity and various components are permanently added after machining. The camshafts run directly in the head without separate bearings. Valve clearances are adjusted by changing variable thickness shims which sit between the valve tappet bucket and the valves. The camshafts are driven by a silent-type chain. The chain is guided by two blades and is tensioned by a spring loaded tensioner for Street Triple, Street Triple R and Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275 a hydraulic tensioner is fitted to tension the chain. The Hydraulic tensioner is fed oil via a gallery in the cylinder head. The combination of oil pressure and spring pressure pushes the plunger against the tensioner blade which tensions the camshaft drive chain. The hydraulic tensioner has an oil pressure relief valve located in the plunger that is set to open between 12 - 16 bar and when opens sprays oil through a drilling in the tensioner blade onto the camshaft drive chain. Oil is supplied to the head by an internal gallery. Once supplied to the head, the oil is distributed along internal drillings within the head casting and camshaft. Single valve springs are used to close both the inlet and exhaust valves. These valve springs have close wound coils at one end to assist in the prevention of valve bounce at high engine speed and to give a smooth valve actuation. When assembling the cylinder head it is i mportant that the close wound, colour coded ends of the springs are fitted downwards (towards the piston). The tip of the inlet valves are hardened to give a long service life. Due to the methods used to assemble the valve seat and valve guides to the head, these parts cannot be replaced.
1. Ignition coils
Camshaft Cover
Removal Remove the rider's seat (see page 16- 17). 2. 3. 4. 5. 6. Disconnect the battery, negative (black) lead first. Daytona 675 only: Remove the lower fairings (see page 16-20). Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Remove the ignition coils from the camshaft cover.
7.
Detach the secondary air injection hose from the reed valves on top of the camshaft cover (see page 10-135).
In any of the following operations which necessitate the removal or disconnection of the camshaft drive chain, NEVER turn the engine without the camshaft drive chain and tensioner correctly fitted and adjusted. In the disassembled condition, the pistons will contact the valves if the crankshaft is turned, causing severe engine damage.
1. Spring-close hose clip 2. Secondary air injection hose 3. Reed valve assembly
I UMP
37
Cylinder Head
8. Remove the throttle bodies, injectors and fuel rail from the cylinder head (see page 10-106). Installation 1. It is not necessary to disconnect the throttle cables. Instead, lay the assembly over the frame during the period when the engine is separated from the frame. Progressively release the camshaft cover bolts in the sequence shown below. Refit the three dowels to the camshaft ladder.
Note:
9.
Note: Two shorter bolts are fitted at the end adjacent to the camshaft drive chain. 1 5 3
1. Dowels
2. Fit a new camshaft cover seal to the cylinder head. Ensure the groove in the gasket is correctly seated to the head. Ensure the plug tower seals and the dowels are correctly located.
cdra
Camshaft Cover Bolt Release Sequence 10. Remove the camshaft cover from the motorcycle.
ACaution
Never use a lever to remove the camshaft cover from the head. Using a lever will cause damage to the head and camshaft cover which could lead to an oil leak. 11. Remove the camshaft cover gasket. If necessary, recover the three dowels from the secondary air injection holes in the camshaft ladder (these may come away in the camshaft cover or gasket). Discard the camshaft cover gasket and bolt seals. Remove any residual oil from the front of the head using a syringe or lint free cloth. 4. 3
, Q,
1. Camshaft cover seal 2. Dowels 3. Plug tower seals
3.
12. 13.
Fit the camshaft cover, ensuring that the gasket remains in the correct position. Lubricate the new camshaft cover screw seals with clean engine oil. Fit the camshaft cover screws and screw seals and tighten until finger tight. Finally, tighten the camshaft cover screws, in the same order as for removal, to 10 Nm. Refit the throttle bodies, injectors and fuel rail to the cylinder head (see page 10- 108). Check the throttle cable adjustment (see page 10103).
5. 6. 7.
3.8
1l,I MP
Cylinder Head
8. Refit the secondary air injection hose to the reed valves (see page 10-136).
Camshaft Drive Chain Tensioner - all Models

Removal 1.
2.
Remove the camshaft cover (see page 3-7).

Noting the position of the bolt fitted with the copper washer, remove the right hand crank cover. Discard the gasket.
0
cdgy
2
^^
1. Spring-close hose clip 2. Seconda ry air injection hose 3. Reed valve assembly
9.
Inspect the ignition coils seal for damage and replace if necessary.
10. Fit the ignition coils and reconnect the electrical connectors.
1. Right hand crank cover
2. Copper washer position
3.
Rotate the crankshaft clockwise (the normal direction of rotation), using the bolt fitted to the end of the crankshaft. Stop rotation when number 1 cylinder is at top dead centre (TDC), that is when the 'dot' mark on the primary gear aligns with the line on the crankcase.
1. Coils
11. Refit the airbox (see page 10-96). 12. Refit the fuel tank (see page 10-90). 13. Daytona 675 only: Refit the lower fairings (see page 16-22). 14. Reconnect the battery, positive (red) lead first. 15. Refit the rider's seat (see page 16-17).
1. ' Dot' mark 2. Marker line
I um
3.9
Cylinder Head
Note: In addition to the 'dot' mark alignment, at TDC, the alignment marks on the camshaft sprockets will point inwards at a point level with the joint face. 6. Carefully remove the centre nut from the tensioner and withdraw the tensioner spring.
gaaal Camshaft to Cylinder Head Alignment Marks 4. Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the camshaft drive chain taut during removal of the tensioner. 5. The Daytona 675 from VIN 381275 has a hydraulic tensioner. All other models have a spring loaded tensioner. For engines fitted with the spring loaded tensioner, continue from step 6 to 7. For engines fitted with the hydraulic tensioner, continue from step 8 to 9. Engines Fitted with the Spring Loaded Tensioner
1. Centre nut 2. Spring 7. Remove and discard the bolts securing the tensioner to the cylinder head. Remove the tensioner.
Engines Fitted with the Hydraulic Tensioner
Warning
The hydraulic tensioner is under spring tension. Always wear hand, eye, and face protection when withdrawing the tensioner mounting bolts and take great care to minimise the risk of injury and loss of components. Note: 8. Note the orientation of the hydraulic tensioner. Evenly release the hydraulic tensioner mounting bolts until the plunger spring tension has been released. Remove the hydraulic tensioner and discard the O-ring and gasket.
Warning
9.
The tensioner centre nut is under spring tension. Always wear hand, eye and face protection when withdrawing the centre nut and take great care in order to minimise the risk of injury and loss of c ompo n e n ts.
Installation 1. 2. Check that number 1 cylinder is still at top dead centre (TDC). Ensure that the wedge fitted earlier is still holding the camshaft drive chain tensioner blade in contact with the camshaft drive chain. Check that the camshaft ti ming marks point inwards and are level with the joint face of the head. For engines fitted with the spring loaded tensioner, continue from step 4 to step 8. Then continue from step 21. For engines fitted with the hydraulic tensioner, continue from step 9.
3.
3.10
I UMP
Cylinder Head
Engines Fitted with the Spring Loaded Tensioner 4. Check that the camshaft drive chain tensioner O-ring is not worn or damaged. If worn or damaged, replace the O-ring. Set the tensioner plunger onto the first tooth of the ratchet (i.e. minimum extension) by manually lifting the tensioner pawl. 10. Hold the resister ring ends together and pull out the plunger.
5.
sm
1. Resister ring ends 2. Plunger 11.
gabh
Remove the spring.
Tensioner Plunger Set-up 6. Fit the tensioner, complete with a new O-ring if necessary, to the cylinder head (ratchet facing upwards) and tighten the new retaining bolts to 9 Nm. Fit the sealing washer to the centre bolt. Using finger pressure only, push the ratchet section of the tensioner into firm contact with the tensioner blade. Refit the spring and centre nut to the tensioner. Tighten the centre nut to 7 Nm. Remove the camshaft drive chain tensioner blade wedge, taking care not to move or damage the tensioner blade. 20 1. Spring 12. While holding the resister ring in place, pour out the engine oil into a suitable container.
7.
8.
Engines Fitted with the Hydraulic Tensioner 9. To set the hydraulic tensioner onto the first tooth of the ratchet (i.e. minimum extension) carry out the following: Note: If installing a new hydraulic tensioner, do not release the plunger before fitting. If installing the original hydraulic tensioner, the engine oil must be drained out of the tensioner to enable the plunger to be set onto the first tooth of the ratchet.
tIIMP
3.11
Cylinder Head
13. Ensure the resister ring is correctly located as shown in the illustration below. 16. When the groove aligns with the snap ring, release the resister ring and move one end of the snap ring into the groove. Slowly release the plunger to ensure that it is held in place.
1. Resister ring
14. Refit the spring. 15. Hold the resister ends together and push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring.
1. Groove for snap ring 2. Snap ring
17. Fit a new 0-ring and gasket to the hydraulic tensioner. 18. Fit the tensioner to the cylinder head as noted for removal. Tighten the bolts to 9 Nm. 19. Remove the camshaft drive chain tensioner blade wedge, taking care not to move or damage the tensioner blade. 20. To release the hydraulic tensioner, rotate the crankshaft 1/4 of a turn anti-clockwise using the bolt fitted to the end of the crankshaft. Then rotate the crankshaft clockwise until the 'dot' mark on the primary gear aligns with the line at the bottom of the cover.
deg - 2
21.
Check that there is tension in the camshaft drive chain and the timing marks at the camshaft sprockets are correctly aligned.
1. Resister ring 2. Plunger 3. Groove for snap ring 4. Snap ring
Note: After fitting to the engine, the hydraulic tensioner will be empty of engine oil. After starting the engine, the camshaft drive chain and tensioner blade will be noisey until full pressure is felt at the tensioner plunger. This could take up to 5 seconds.
All Engines 22. Check that the tensioner plunger is correctly located in the middle of the camshaft drive chain tensioner blade when viewed from above.
3.12
Il1MP
Cylinder Head
23. Rotate the engine through 4 full revolutions, and reset number 1 cylinder to TDC. Ensure that the 'dot mark on the primary gear aligns with the line at the bottom of the cover. 25. 26. 27. 28. Re-check the tensioner plunger location against the camshaft drive chain tensioner blade. Refit the camshaft cover (see page 3-8). Fit a new gasket to the right hand crank cover. Noting the position of the bolt fitted with the copper washer, refit the crank cover, tightening the fixings to 9 Nm.
24. Check that the camshaft timing marks align as ill ustrated below.
1. Right hand crank cover 2. Copper washer position
gaaa1
Camshaft to Cylinder Head Alignment Marks
l!. MP
3.13
Cylinder Head
Camshaft Drive Chain Tensioner Blade - Daytona 675 - from VIN 381275
Disassembly Note: For the purpose of this instruction, the top of the tensioner blade is where the pad is located. Release the clips and remove the pad. 3. Release the three side locating devices.
1.
deg
1. Locating devices 2. Facing blade 4. Release the three hooks and remove the facing blade.
dee
I n lI
1. Pad 2. Clip (one side shown) 2. Detach the top hook from the tensioner blade.
deh
1. Hooks
Assembly 1. Assembly is the reverse of disassembly.
clef
1. Top hook 2. Tensioner blade
3.14
IL1MP
Cylinder Head
Camshafts
Removal 1. Remove the camshaft drive chain tensioner (see page 3-9). 6. Repeat the procedure for the inlet camshaft.
Note: It is not necessary to remove the camshaft drive chain completely.
Each camshaft and sprocket is removed as an assembly. Before commencing work, ensure the crankshaft 'dot' mark is in alignment with the line in the crankcase. 2. 3. Note the orientation of the camshaft ladder in relation to the head. Progressively release the bolts securing the camshaft ladder to the head in the sequence shown below. 1. Camshaft drive chain 2. Inlet camshaft Note: The inlet and exhaust camshafts are different. They can be identified by a raised feature in the centre of the exhaust camshaft, which is machined off on the inlet camshaft. The camshafts can be further identified a letter 'I' for inlet or 'E' for exhaust stamped on the end of the sprocket boss. 2 1
[;]
7
cogs J
I J I
LUEftIfiIUDEIc PEcID1J
J I I I
Camshaft Ladder Bolt Release Sequence 4.

L:
Remove the camshaft ladder and top pad, and collect the dowels (if loose) and spark plug tower O-rings. Lift the camshaft drive chain from the exhaust camshaft sprocket and remove the exhaust camshaft.
5.
gabol
1. Inlet camshaft 2. Machined section 3. Exhaust camshaft 4. Raised section
I UMp
3.15
Cylinder Head
Camshaft and Bearing Cap Inspection 1. Inspect the camshaft sprockets for damaged and worn teeth. Replace as necessary. 4. Check the journal-to-head clearances, using 'Plastigage' (Triumph part number 3880150-T0301) as follows: a) Ensuring that the camshaft sprocket alignment marking is located as for removal, assemble one camshaft to the head and progressively tighten the camshaft ladder in the sequence shown overleaf (see page 3-17). Remove the camshaft ladder using the bolt release sequence given earlier. Wipe the exposed areas of both the camshaft journal and a single cap area of the ladder.
Ak
Caution
b)
The same sprocket is used for both inlet and exhaust camshafts. To attach the sprocket to the different camshafts, different bolt holes are used. Never fit a camshaft sprocket to a camshaft using incorrectly identified bolt holes. Severe engine damage will result from incorrect attachment. 1
c) Apply a thin smear of grease to the journal and a small quantity of silicone release agent to the camshaft cap area of the ladder. d) Size a length of the Plastigage to fit across the camshaft journal. Fit the Plastigage to the camshaft journal using the grease to hold the strip in place. Refit the camshaft ladder then evenly and progressively tighten all the camshaft ladder bolts in the correct sequence (see camshaft installation). Release the bolts and remove the camshaft ladder. Using the gauge provided with the Plastigage kit, measure the width of the now compressed Plastigage.
e)
f)
Note: 2
1. Inlet camshaft bolt holes 2. Exhaust camshaft bolt holes
2. Measure the camshaft journals with a micrometer. If any journal is outside the specified tolerance, replace the camshaft. Standard Journal Diameters Standard: 23.900 - 23.930 mm
The camshaft ladder is unique to each cylinder head and is, therefore, not available individually. If the camshaft ladder is worn or damaged, the complete cylinder head must be replaced.
Measuring the Compressed Plastigage. 5. Calculate the journal clearance using the Plastigage chart supplied with the Plastigage kit.
1. Standard journal
3.
Examine the camshaft and camshaft ladder for excessive wear and damage.
3.16
ILIMP
Cylinder Head
Camshaft journal clearance Standard: Service limit: 0.070 - 0.121 mm 0.170 mm 4. Repeat the procedure for the other camshaft.
ACaution
If the camshafts and ladder are fitted without first aligning the timing marks on both the crankshaft and camshaft sprockets, the inlet and exhaust valves will contact each other causing damage to both the head and the valves. 5. Lubricate the camshaft bearing areas of the camshaft ladder with a 50/50 solution of engine oil and molybdenum disulphide grease. Assemble the dowels, camshaft ladder and top pad in the same location and orientation as prior to removal.
6. If the clearance measured is within the specified tolerance, remove the ladder and clean off all traces of Plastigage. Assemble the camshafts (see page 317). Note: If the measured clearance is outside the tolerance, and the camshaft journals are within tolerance, the cylinder head must be replaced.
6.
ACaution
Although Plastigage is oil soluble, all traces of the material must be removed to prevent blockage of the oil drillings and resultant engine damage. Installation 1. Thoroughly clean the camshafts and journals. Inspect the ends of the camshafts for correct fitment of the sealing plugs. Lubricate the camshafts with clean engine oil before fitting to the head. Locate each camshaft to the head ensuring the camshafts are correctly identified (inlet and exhaust) and are also correctly located over their respective valve banks. Working on one camshaft at a time, locate the camshaft drive chain over the camshaft sprocket. Position the camshaft in the same position as for removal before attempting to fit the ladder (that is, with the timing marks on the camshaft sprockets level and pointing inwards, and with the 'dot mark on the primary gear in alignment with the line on the crankcase).
Note: The bolts for the camshaft cap ladder are tightened in stages.
Stage 1 7. Lubricate the threads of the camshaft cap ladder bolts with clean engine oil, then fit and evenly tighten the bolts to 5 Nm, in the sequence shown below.
11
02
2.
.4
iC
3.
1c cjg r12 4 2 8 6 16
Camshaft Cap Ladder Bolt Tightening Sequence
Stage 2 8. In the sequence shown above, tighten the bolts to 10 Nm.
1. Camshaft drive chain 2. Inlet camshaft
I uMP
3.17
Cylinder Head
9. Before fitting the camshaft drive chain tensioner, ensure that each camshaft rotates freely using service tool T3880102. Do not rotate either camshaft by more than 5 . 12. Check that the camshaft timing marks align as ill ustrated below. Rectify any misalignment before proceeding.
gaaal
Camsha ft to Cylinder Head Alignment Marks

1. Exhaust camshaft 2. Tool T3880102
13. Check the valve clearances. Adjust as necessary (see page 3-19).
A Caution
If any components have been renewed, the valve clearances must be checked and adjusted. Running with incorrectly adjusted valve clearances may cause excess engine noise, rough running and engine d a mage. 10. Refit the camshaft drive chain tensioner (see page 310). 11. Rotate the engine through 4 full revolutions, and reset number 1 cylinder to TDC. Ensure that the 'dot' mark on the primary gear aligns with the line on the crankcase.
Valve Clearances
Camshaft, valve, valve shim and valve seat wear affects the valve clearances. The effect of this wear is to change the gap between the camshaft and tappet bucket, causing engine noise and improper running. If the valve clearances become too small, permanent damage to the valve and valve seat will take place. If the valve clearance becomes too great, the engine will become noisy and will not run correctly.
Valve Clearance Measurement

Note: Valve clearance measurement must be carried out with the engine cold. 1. 2. 3. Remove the camshaft cover (see page 3-7). Remove the spark plugs to reduce compression resistance when turning the engine. Select a high gear and, using the rear wheel, turn the engine until a pair of camshaft lobes are positioned pointing away from the valves. Using feeler gauges, measure and record the clearances for this pair of valves only. Repeat the process until the valve clearances for all valves have been checked.
4. 5.
Note: If the measurement does not fall within the specified range, adjustment must be made. The correct valve clearances are in the range given below:
3.18
^ uMP
Cylinder Head
All models except Daytona 675 from VIN 381275 Inlet: Exhaust: 0.10 - 0.20 mm 0.275 - 0.325 mm To adjust the valve clearances the camshafts must be removed. Follow the camshaft removal procedure. Remove the camshafts (see page 3-15). Remove the tappet bucket from the cylinder head. Remove the shim from the valve head. Valve Clearance Adjustment Note:
Daytona 675 from VIN 381275 only Inlet: Exhaust: 0.10 - 0.20 mm 0.325 - 0.375 mm 1. 2. 3.
ACaution
If the valve clearances are not checked and corrected, wear could cause the valves to remain partly open, which lowers performance, burns the valves and valve seats and may cause serious engine damage. 6. Record the measured valve clearances on a chart si milar to the example shown.
Typical Valve Clearance Chart
Inlet Valve No. 1 2 3 4 5 6 Exhaust Valve No. 1 2 3 4 5 6
Gap Measured as measured (mm) as measured (mm) as measured (mm) as measured (mm) as measured (mm) as measured (mm) Gap Measured as measured (mm) as measured (mm) as measured (mm) as measured (mm) as measured (mm) as measured (mm) 4. 1. Tappet bucket 2. Shim Note: The shim may withdraw with the tappet bucket. Measure the original shim, using a micrometer and select the appropriate new shim as required.
Clearance too small: Fit a thinner shim.
Clearance too large: Note: 5. 6. 7. 8. 9. 10. Shims are available ranging from 1.70 mm to 3.00 mm in increments of 0.025 mm. Fit the new shim to the valve head. Lubricate the tappet bucket(s) with a 50/50 solution of engine oil and molybdenum disulphide grease. Refit the tappet bucket. Refit the camshafts (see page 3- 17). Re-check all valve clearances. Repeat the procedure if the valves require further adjustment. Fit a thicker shim.
I uMP
3.19
Cylinder Head
Camshaft Drive Chain
Removal 1. 2. Remove the camshafts (see page 3-15). Remove the bolt from the centre of the camshaft drive chain housing in the cylinder head. 2. 3. 4. Inspection Visual in-situ checks can also be made as follows: 1. Check for significant blue discolouration of the chain plates indicating excessive heat build-up. Examine all pins for signs of rotation. Check for cracking or deep scratching of the chain plates. Check for severe wear of the inner plates as indicated in the diagram below.
00
1. Centre bolt 3. Raise the front camshaft drive chain rubbing blade and detach the camshaft drive chain from the crankshaft gear. The camshaft drive chain is removed from inside the head-space. For a more thorough check, proceed as follows: 1. 2. Remove the chain from the engine. Suspend the chain from a pin or hook with a 13kg weight attached at the lower end. 4.
3.20
Il,l MP
Cylinder Head
3. Measure across 23 links as shown in the diagram below. If the chain is within limits, the measurement should be no longer than 149.48 mm. Measurements beyond 149.48 mm indicate that the chain must be replaced. 6. Check for severe wear of the plates in the area shown below.
0
^JU o 0
0 0 0 O
OOO
ô oT T
ô oT
If any of these symptoms are evident, the camshaft drive chain must be replaced.
4. Check for severe wear of the inner surface of the outer plates at the side-contact points with the sprocket teeth.
Installation
1. 2. Fit the camshaft drive chain and locate the lower end around the crankshaft gear. Incorporating a new seal, refi t the bolt to the centre of the camshaft drive chain housing in the cylinder head, tightening to 12 Nm. Refit the camshafts (see page 3-17).
3.
cc u
5.
Check for signs of stiffness or kinking.
L UMP
3.21
Cylinder Head
Cylinder Head
Removal Note: Removal of the cylinder head is not possible with the engine in the frame. Remove the engine from the frame (see page 9-3). Remove the camshafts (see page 3-15). Remove the camshaft drive chain (see page 3-20). Remove the camshaft drive chain tensioner blades. 7. Release the screws securing the outside of the cylinder head to the upper crankcase.
1. 2. 3. 4.
5. Note the position of all tappet buckets and shims such that they can be refitted in the same positions. Remove all the tappet buckets and shims.
1. Cylinder head to upper crankcase screws
Note: Up to engine number 327506, the cylinder head bolts are coloured grey. From engine number 327507, the cylinder head bolts sliver coloured bolt and are fitted with a hardened washer. Progressively release the cylinder head bolts in the order shown below.
8.
1. Tappet bucket 2. Shim
Note: To prevent the tappet buckets and shims from becoming mixed, place the shim and tappet together in a marked container. The components must be refitted in their original positions. Disconnect the coolant bypass hose from the rear of the cylinder head. 9. 10. 3 7 5 1
6.
Cylinder Head Bolt Release Sequence Lightly tap the cylinder head with a rubber mallet to break the seal of the gasket. Remove the cylinder head. Discard the cylinder head bolts and gasket.
3.22
IIIMP
Cylinder Head
Inspection 1. 2. Thoroughly clean the surface of the head and check for damage and pitting of the combustion chambers. Using a straight edge, check the cylinder head gasket face for warp which could lead to gasket failure. Replace the head if warped.
Caution
Using the correct procedure to fit and tighten the cylinder head bolts will ensure the long term reliability of the cylinder head gasket. Clean each bolt, paying particular attention to the threads and under-bolt-head areas. If any of the threads or bolt-head areas are damaged, replace the bolt(s). Lubricate the threads with engine oil, and then wipe clean with a lint-free cloth leaving minimal oil on the threads (that is, almost dry to touch). Tighten the bolts using the three-stage procedure given below. Failure to observe these important items may lead to engine damage through a d a maged head gasket. Note: Up to engine number 327506, new cylinder head bolts and washers must be fitted. From engine number 327507, new cylinder head bolts must be fitted with the original washers. Fit new bolts and washers to the head and tighten until finger tight. The cylinder head bolts must be tightened in the following sequence: 7 3 1 5
1. Cylinder head gasket face 2. Straight edge 3. Check the camshaft drive chain tensioner blades. Renew if worn or damaged. 5. 6. Installation 1. 2. Thoroughly clean the upper faces of the crankcase, taking care not to damage the mating surfaces. Fit a new cylinder head gasket ensuring that the head to crankcase location dowels are correctly in place.
Cylinder Head Bolt Tightening Sequence 7. The head bolts are finally tightened in three stages, all using the above sequence. This is to ensure that the cylinder head gasket seals correctly to the head and crankcase. The three stages are as follows:
Note: 1. Cylinder head gasket 3. 4. Ensure that the cylinder head face is completely clean. Carefully lower the cylinder head over the camshaft drive chain and locate the head onto the dowels. For stages A and B of the head bolt tightening operation, a torque wrench of known, accurate calibration must be used.
A: Tighten the head bolts, in the sequence shown above, to 15 Nm.
L UMP
3.23
Cylinder Head
B: Tighten the head bolts in the sequence shown on the previous page, to 20 Nm. For the final torque operation, Stage C, (see below) which is carried out in the sequence shown on the previous page, a 'torque turn' method is used. The bolts must be turned through 120 to reach the final setting. To 0 accurately gauge the 120 turn, use service tool 3880105-T0301 as follows: Fit the tool between the Torx socket and the drive handle and locate the Torx drive to the head bolt. Pick an increment point on the torque turn gauge which aligns with a suitable reference point on the head. Tighten the bolts until 12 of the 10 (I.E. 120) gauge increments have rotated past the chosen point on the head.
Valves and Valve Stem Seals

Removal from the Cylinder Head 1. Remove each valve from the head using a valve spring compressor. The compressor must act on the top cup to allow removal of the valve collets.
C:
Increment markings
gadh
Valve removal 2. Once the collets are released, remove the following items: Tool T3880105-T0301 6. Fit the screws securing the side of the cylinder head to the crankcase and tighten to 10 Nm. valve spring retainer valve spring valve spring base valve stem oil seal valve (de-burr before removal)
1. Cylinder head to upper crankcase screws
7. 8.
Install the camshaft drive chain tensioner blades. Clean and lubricate the tappet buckets with a 50/50 solution of engine oil and molybdenum disulphide grease and refit the buckets and shims in the same locations from which they were removed. Refit the camshaft drive chain (see page 3-21). Refit the camshafts (see page 3-17). Install the engine to the frame (see page 9-4).
1. Valve stem seal
9. 10. 11.
3.24
Il1MP
in
Cylinder Head
Note: Ensure inlet and exhaust valve components do not become mixed.
A Caution
Incorrect fitment of the valve stem oil seals could lead to high oil consumption and blue smoke emissions from the exhaust system. Do not use excessive force in fitting the seal as this may break th e seal ring. 4. Install the valve spring over the valve stem. Ensure the close wound, colour coded ends of the springs are fitted downwards (towards the piston). Fit the valve spring retainer. Compress the valve spring ensuring that the spring is compressed squarely to prevent damage to the valve stem and cylinder head.
iZ6
1. Collets 2. Valve spring retainer 3. Valve spring 4. Valve spring base 5. Valve stem oil seal 6. Valve
^ \3 ^^ 4
5
5. 6.
7 Fit the valve collets ensuring correct collet location in the spring retainer and valve as the spring compressor is released.
A Caution
Always check for correct location of the valve collets during and after assembly. If not fitted correctly, the collets may become dislodged when the engine is running allowing the valves to contact the pistons. Any such valve to piston contact will cause severe engine damage.
Installation
Lubricate the valve stems with a 50/50 solution of engine oil and molybdenum disulphide grease. 2. 3. Install the valve into the valve guide and refit the spring base to the valve spring recess in the head. Fit the valve stem seal over the valve stem and, using a suitable tool, press down fully until the seal is correctly seated over the valve guide.
Valve to Valve Guide Clearance

If the valve guides are worn beyond the service limit given below, the cylinder head must be replaced. Valve Stem to Guide Clearance Inlet: Service limit 0.010 - 0.040 mm 0.078 mm 0.030 - 0.060 mm 0.098 mm
Note: During fitment of the valve stem seal, two distinctly different degrees of resistance will be noted when the seal is correctly fi tted. Firstly, press the seal down the valve stem until the lower side of the seal comes into contact with the valve guide. Greater resistance is felt at this contact point and further gentle pressure is then required to locate the seal over the top end of the valve guide. On application of this pressure, the seal can be felt to positively locate over the top face of the valve guide. Once correctly positioned, the seal cannot be pushed down any further.
Exhaust: Service limit
Valve Guides
If a valve guide is found to be worn beyond the service li mit, the complete cylinder head must be renewed.
Valve Face Inspection Remove any carbon build-up from the valve head area.
Examine the valve seat face, checking in particular for signs of cracking or pitting.
L UMP
3.25
4 Clutch
Table of Contents
ExplodedView - Clutch Cover ............................................................... ExplodedView - Clutch Assembly ........................................................... ExplodedView - Clutch Controls ............................................................ ClutchCable ............................................................................. Removal ........................................................................... -Inspection .......................................................................... Assembly...........................................................................
Clutch ...................................................................................
4.2 4.3 4.4 4.5 4.5 4.5 4.6 4.6 4.6 4.8 4.8 4.8 4.9
Disassembly........................................................................ FrictionPlate Inspection .................................................................... Thickness........................................................................... Bend/warp ......................................................................... Assembly...........................................................................
OR
.^
Il1MP
4.1
Clutch
Exploded View - Clutch Cover
1
9 Nm
0 0
4.2
Il1MP
Clutch
Exploded View - Clutch Assembly
98 Nm
O\ \
Ô
>
10
Nm
Il1MP
4.3
Clutch
Exploded View - Clutch Controls
12 Nm
(Le
Nm
4.4
1lIMP
Clutch
Clutch Cable
Removal 1. 2. 3. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Slacken the cable locknut and release the adjuster at the clutch cover end to give maximum play in the cable. 6. Pull in the clutch lever and turn the inner cable, anticlockwise through the slots in the adjuster and locknut, until the cable can be detached from the lever by pushing downwards.
gaau
1. Cable adjuster/lever bracket slots 2. Cable release point
7.
Remove the cable from the motorcycle noting the cable routing.
Inspection
1. Clutch cable 2. Adjuster 1.
4.
Release the clutch cable from the actuating arm by pushing the inner cable nipple through the arm and sliding the cable out of the slot. Detach the cable from the bracket.
Check the inner cable for free movement through the outer cable. Examine the inner cable for frayed strands. Examine the two inner cable nipples for signs of looseness and damage. Replace the cable if necessary.
2. 3.
OH
1. Actuating arm 2. Inner cable nipple
S.
Align the cable adjuster and lever bracket slots.
I UMP
4.5
Clutch
Assembly 1. 2. Position the cable to the motorcycle using the same routing as noted during removal. Attach the inner cable to the clutch lever and actuating arm using a reversal of the removal process. Refit the outer cable to the adjuster bracket at the clutch end.
Clutch
Disassembly 1. 2. 3. 4. Remove the rider's seat (see page 16- 17). Disconnect the battery, negative (black) lead first. Daytona 675 only: Remove the lower fairings (see page 16-20). Release the clutch cable from the actuating arm (see page 4-5). Remove the clutch cover, noting the copper washer position. Discard the clutch cover gasket.
3.
Note: 4. 5. Ensure that the two adjuster nuts are positioned one either side of the bracket. Set the lever adjuster to a point where an equal adjustment is possible in both directions. Set the adjuster at the clutch end to give a preliminary setting of 2-3 mm of free play as measured at the lever. Tighten the locknut. Operate the clutch lever several times and recheck the amount of free-play present. Set the final adjustment of the cable to give 2-3 mm of free-play at the lever by turning the adjuster nut and locknut at the lever end.
5.
6. 7.
cdpd
1. Clutch cover 2. Copper washer position
6. 7.
Undo the bolts and remove the springs and clutch pressure plate. Remove the clutch pull-rod.
1. Clutch lever 2. Correct setting, 2-3 mm
8. 9.
Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
1. Clutch pull-rod 2. Clutch pressure plate
8. Remove the clutch friction plates and steel plates together with the anti-judder spring and anti-judder seat washer.
4.6
I uMP
Clutch
Note: Record the orientation of all components as they are removed. The plates must be assembled in the same order. 9. Insert service tool 13880026 into the splines of the clutch inner drum. Using finger pressure only, tighten the adjuster screw to allow the tool to grip the splines. Do not overtighten the adjuster screw.
5 -
/1
cb
1. Steel plate 2. Inner fiction plate 3. Anti-judder spring 4. Anti-judder seat washer 5. Clutch inner drum Note: The inner and outermost friction plates are different to the remainder and are also different to each other. They must be fitted in their noted positions. The two outer steel plates are different to the other plates. They must be fitted in their noted positions. Store all plates in their correct fitted order to avoid confusion on installation. Refer to the following page of this section for details of clutch friction plate checking.
1. Service Tool T3880026 2. Adjuster screw 10. Retain the service tool to prevent the clutch inner drum from turning, then release the centre nut. Remove the tool. 11. Remove the centre nut, Belleville washer, flat washer, clutch inner drum and thrust washer.
2 /1
m1
j.:
It is not normally necessary to disassemble the clutch further, but if the clutch inner and outer drums are to be removed, proceed as follows:
1. Centre nut 2. Belleville washer 3. Flat washer 4. Inner drum S. Thrust washer
L UMP
4.7
Clutch
12. Slide the clutch outer drum assembly gently backwards and forwards to dislodge the inner bearing sleeve. Carefully remove the bearing sleeve while supporting the clutch drum. Bend/warp Check all plates for bend and warp as follows: 1. Place the plate being checked on a clean surface plate and attempt to pass a feeler gauge of the maximum specified thickness between the friction plate and surface plate at several points around the plate. If the feeler gauge can be passed beneath the friction plate at any point, renew the plates as a set.
1. Outer drum 2. Bearing sleeve
13. Remove the clutch outer drum leaving the oil pump drive sprocket, bearing and sleeve in place on the input shaft.
gaas
1. Friction plate 2. Feeler gauge 3. Surface plate
Friction Plate Inspection

Thickness 1. If any friction plate thickness is outside the service li mit, replace the friction plates as a set.
Friction plate bend/warp Standard Service limit up to 0.15 mm 0.20 mm
gaal
1. Clutch friction plate
Friction plate thickness - all plates Standard Service limit 3.00 mm 2.80 mm
4.8
Il1MP
Clutch
Assembly 1. To fully engage the outer drum, insert a suitable tool to preload and align the primary gear and backlash eli minator gear through the hole shown in the ill ustration below. 3. While holding the clutch outer drum in position and ensuring correct engagement with the oil pump drive, refit the bearing sleeve and bearing.
1. Outer drum 2. Bearing sleeve

CGao
1. Alignment hole 2. Outer drum
Note: 4. 5. 6. When the bearing sleeve is correctly fitted, it will be a flush fit with the clutch drum face. Fit the thrust washer to the shaft. Fit the clutch inner drum. Fit the flat washer, a new Belleville washer ('OUT' mark facing outwards), and refit the centre nut.
2. Position the clutch outer drum assembly to the input shaft and align the oil pump drive pegs with the corresponding holes in the rear of the clutch outer drum.
/3\
_\\/ ('
1. Clutch outer drum 2. Oil pump sprocket drive pegs 3. Oil pump drive holes
Belleville Washer 'OUT' Mark
IuMP
49
Clutch
7. Using service tool T3880026, prevent the clutch inner drum from turning, and tighten the clutch centre nut to 98 Nm. Remove the service tool. 10. Refit the clutch pressure plate together with the springs and bolts. Tighten the bolts to 10 Nm.
Note: 11. The pull-rod should be free to move in and out and also it should be free to turn. Clean and refit the clutch cover incorporating a new gasket. Install the bolt with the copper washer in the position shown below. Tighten the clutch cover bolts to 9 Nm.
1. Service tool T3880026 8. Coat all clutch friction plates in clean engine oil before fitting the friction plates, steel plates, antijudder spring and anti-judder seat washer to the clutch basket in the same order and orientation as noted during removal.
cdpd
Note: The inner and outermost friction plates are different to the remainder and are also different to each other. They must be fitted in their noted positions. The two outer steel plates are different to the other plates. They must be fitted in their noted positions. 1. Clutch cover 2. Copper washer position 12. 13. 14. 15. 16. Refit the outer cable to the adjuster bracket at the clutch end (see page 4-6). Set the clutch adjustment (see page 4-6). Refit the lower fairings (see page 16-22). Reconnect the battery positive (red) lead first. Refit the rider's seat (see page 16- 17).
,5
/1
1. Steel plate 2. Inner fiction plate 3. Anti -judder spring 4. Anti-judder seat washer 5. Clutch inner drum 9. Refit the clutch pull-rod.
4.10
Il1MP
5 Crankshaft, Connecting Rods and Pistons

Table of Contents
Exploded View - Crankshaft, Connecting Rod, Piston and Liner ................................... ExplodedView - Crankcase ................................................................. Crankcases............................................................................... Disassembly........................................................................ Assembly........................................................................... Crankshaft............................................................................... Removal........................................................................... Installation.......................................................................... ConnectingRods .......................................................................... Removal........................................................................... Installation.......................................................................... Connecting Rod Big End Bearing Selection/Crankpin Wear Check ............................... Checkingthe Measured Clearance ..................................................... ConnectingRod Bearing Selection ..................................................... Crankshaftmain bearing/journal wear .................................................. .,, Pistons .................................................................................. Disassembly........................................................................ { Piston Wear Check ................................................................... Cylinder Wear ....................................................................... CylinderLiners ........................................................................... Removal........................................................................... Installation.......................................................................... CrankcaseBreather ....................................................................... 5.2 5.3 5.4 5.4 5.4 5.6 5.6 5.6 5.8 5.8 5.8 5.10 5.10 5.11 5.12 5.13 5.13 5.13 5.16 5.16 5.16 5.17 5.18
..1
Il1MP
5.1
Crankshaft, Connecting Rods and Pistons

Exploded View - Crankshaft, Connecting Rod, Piston and Liner
sus:
LA
1!
27 Nm (Install a new bolt if removed)
5.2
IIiMP

Exploded View - Crankcase
r.
0 0
u 00
^
22 Nm
Apply ThreeBond 1305 to the threads
22 Nm
^^ 22 Nm
Apply ThreeBond 1305 to the threads
1l,i MP
5.3

Crankcases
Note:
A Caution
The upper and lower crankcases are machined as a matched set and must never be assembled to nonmatching halves. Doing so may cause seizure of the engine. 1. 2. 3. 4. 5. Remove the engine from the frame (see page 9-3). Remove the sump (see page 8-15). Remove the engine covers (see page 7-23). Remove the clutch (see page 4-6). Remove the oil pump (see page 8-9). 1.
At this point the transmission shafts, balancer, crankshaft, bearings etc. can be removed.
Note: The position of each individual bearing shell prior to removal. Collect the piston cooling jets from below the upper main bearings.
Assembly Use high flash-point solvent to clean the crankcase mating faces. Wipe the surfaces clean with a lint-free cloth. Fit the gearbox shafts (if removed), ensuring the locating ring and dowels on the output shaft bearings are positioned correctly in the crankcase. Ensure that the transmission is in neutral. Ensure that the 3 locating dowels are in position in the upper crankcase.
Disassembly
2.
ACaution
Failure to follow the correct screw release sequence may result in permanent crankcase damage. 1. Invert the engine to give access to the lower crankcase bolts.
3. 4.
2. Release the lower crankcase bolts in the sequence shown in the diagram below. Note the position of the hardened washers under bolts 19 to 26.
1
15 16 22 26 21 25 9 12 11 5 7
3 4 2
17 18 24 20 19 23 8 14
cdmx
1. Locating dowels
13
Crankcase Bolt Release Sequence 3. Separate the lower and upper crankcases ensuring that the 3 locating dowels remain in the upper crankcase.
ACaution
Do not use levers to separate the upper and lower sections of the crankcase or damage to the crankcases could result.
5.4
tl1MP

5. Apply a thin bead of silicone sealant (At the factory, ThreeBond 1215 is used) to the lower crankcase mating faces. Note: The piston cooling jet for number 3 cylinder is longer and has a larger diameter drilling than the piston cooling jets for number 1 and 2 cylinders. It can also be identified by its smaller outside diameter and a groove around its circumference. Piston cooling jets cannot be installed incorrectly. Install and lubricate the crankshaft bearing shells with clean engine oil (see bearing selection before proceeding). Lubricate the crankshaft journals with clean engine oil. Position the lower crankcase to the upper. An assistant may be required to support the crankcase during alignment. Fit the screws into the lower crankcase and hand tighten until the bolt heads are near contact with the crankcase. Note the position of the hardened washers under bolts 1 to 8.
7.
8. 9.
cdmy
10. Sealer areas
ACaution
Do not use excessive amounts of sealer. The extra sealer may become dislodged and could block the oil passages in the crankcases causing severe engine damage. 6. If removed, insert the three piston cooling jets into the main bearing housings in the upper crankcase.
Note: The crankcase screws are tightened in stages. Two different sizes of crankcase screw are used. All screws are tightened through the first stage of the tightening procedure but only the M8 size screws are tightened at the second stage.
A
CM Stage 1 - all screws 1.
Caution
Failure to follow the correct screw tightening sequence may result in permanent crankcase damage.
In the sequence shown below, tighten all crankcase screws to 12 Nm.
26 1'
1. Piston cooling jet
24 23 25 15 14 3 7 8 4 13 18 1
ACaution
Ensure the three piston cooling lets are installed. If the piston cooling jets are omitted, oil pressure will be reduced. Running the engine with low oil pressure will cause sev ere engine damage.
1; 1i
Crankcase Bolt Tightening Sequence
L UMP
5.5
Crankshaft, Connecting Rods an d Pistons

Stage 2 - M8 screws only 1. 2. In the correct sequence, tighten only the M8 size crankcase screws (numbers 1 to 8) to 32 Nm. In the correct sequence, tighten only the M8 size crankcase screws (number 9 to 14) to 32 Nm.
Crankshaft
Removal 1. 2. 3. 4. S. Remove the alternator rotor from the crankshaft (see page 17-32). Separate the two halves of the crankcase (see page 5-4). Remove the connecting rods (see page 5-8). Remove the camshaft drive chain (see page 3-20). Release and remove the crankshaft from the upper crankcase.
12 11 5 1 6 2
10 9 3 7 8 4 13
Note: Identify the location of each bearing shell. Remove all bearings and inspect for damage, wear, overheating (blueing) and any other signs of deterioration. Replace the bearings as a set if necessary. Collect the piston jets from below the upper main bearings. If the camshaft drive chain sprocket is removed from the crankshaft for any reason, always install a new fixing. Tighten to 27 Nm. Remove the balancer (see page 6-3).
14
M8 Crankcase Bolt Tightening Sequence 3. 4. S. 6. 7. 8. Rotate the crankshaft clockwise. Check for tight spots and rectify as necessary. Refit the oil pump (see page 8-13). Refit the clutch (see page 4-9). Refit the engine covers (see page 7-24). Refit the sump (see page 8-16). Install the engine in the frame (see page 9-4). 6.
Installation
Caution
Always check the bearing journal clearance (see page 512), before final assembly of the crankshaft. Failure to correctly select crankshaft bearings will result in severe engine damage. 1. If removed, insert the three piston cooling jets into the main bearing housings in the upper crankcase.
1. Piston cooling jet
5.6
IuMP

6.
Caution
Ensure the three piston cooling jets are installed. If the piston cooling jets are omitted, oil pressure will be reduced. Running the engine with low oil pressure will cause severe engine damage. Note: The piston cooling jet for number 3 cylinder is longer and has a larger diameter drilling than the piston cooling jets for number 1 and 2 cylinders. It can also be identified by its smaller outside diameter and a groove around its circumference. Piston cooling jets cannot be installed incorrectly.
Install the crankshaft ensuring that the crank pins align with the big ends and that the crankshaft and balancer gear markings align as shown in the next ill ustration.
W
1
2. Select and fit new main and big end shell bearings using the selection processes detailed later in this section.
VAJ AP!
1. Balancer backlash and drive gear markings 2. Crankshaft markings
7. 8. 9. 11.
Refit the connecting rods (see page S-8). If removed, refit the transmission shafts. Assemble the crankcases (see page 5-4).
10. Assemble the alternator rotor (see page 17-34). Refit the camshaft drive chain (see page 3-21).
cdmx
/// ` f
1. Big end shells
3. 4.
Lubricate all bearings with a 50/50 solution of engine oil and molybdenum disulphide grease. Ensure that the crankshaft is clean, and that the oilways within the crank are clean and free from blockages and debris. Refit the balancer (see page 6-4).
5.
I uMP
5.7

Connecting Rods
Removal Connecting rods may be removed from the engine after first removing it from the frame. The cylinder head must be removed and the crankcase halves separated. 1. Mark each big end cap and connecting rod to identify both items as a matched pair and to identify the correct orientation of the bearing cap to the connecting rod. Release the connecting rod bolts and remove the big end cap. Ensure that the bearing shell remains in place in the cap. Installation Note: Connecting rod bolts are treated with an anti-rust solution which must not be removed. Clean the connecting rod with high flash point solvent.
Remove all bearings and inspect for damage, wear and any signs of deterioration and replace as necessary.
2.
,A Warning.
Connecting rod bolts MUST only be used once. If the bolts are removed or undone for any reason, new bolts MUST always be used. Re-using bolts can cause connecting rods and their caps to detach from the crankshaft causing severe engine damage, loss of motorcycle control and an accident. Note: Ensure the piston is fitted correctly to the connecting rod. If a previously run engine is being rebuilt, always ensure that the piston and con-rod are assembled in the same orientation, and to the same cylinder, as prior to strip-down. Fit the piston onto the connecting rod (see page 515). Apply silicone sealer to the liner-to-crankcase mating face (At the factory, Three Bond 1215 is used).
1. Big end cap 2. Connecting rod bolt
1. 2.
Note: It may be necessary to gently tap the big end cap with a rubber mallet to release the cap. Push the connecting rod up through the crankcase and collect the piston and connecting rod from the top. Label the assembly to identify the cylinder from which it was removed.
3.
4.
A Caution
Never re-use connecting rod bolts. If the connecting rod cap is disturbed, always renew the bolts. Using the original bolts may lead to severe engine damage. 5. 6. Remove the liner using tool T3880101 (see page 516). Detach the piston from the connecting rod (see page 5-13).
coat
1. Liner 2. Sealer area
3. 4.
Fit the piston and connecting rod assembly into the li ner from the bottom. Fit the liner into the crankcase ensuring that the arrow/'dot' on the piston faces forward.
S.8
ILiMP

5. The liners must be positioned such they do not touch each other - it must be possible to pass a 0.1 mm feeler gauge between the centre liner and its adjacent liner on either side. If the liners touch at any point, rotate the liners until there is a minimum 0.1 mm clearance.
ACaution
The torque characteristics of the connecting rod bolts are sensitive to the correct lubrication being applied. If the threads and under head areas are not lubricated with molydenum disuplhide grease, the bolts may be stretched and may become loose when in service resulting in an expensive engine failure. 9. Lubricate the threads and under-head area of the new bolts with molybdenum disulphide grease. Tighten the bolts evenly and progressively in five stages as follows:
ACaution
The torque characteristics of the connecting rod bolts are sensitive to the rate at which they are tightened. If all the torque is applied in one action, the bolt may be stretched and may become loose when in service resulting in an expensive engine failure. Ensure that the piston/liner/connecting rod assembly aligns correctly with the crankpin during assembly into the crankcase. Select the big end bearing shells (see page 5-10). Fit the bearing shells to the connecting rod and big end cap and lubricate with a 50/50 solution of engine oil and molybdenum disulphide grease. Align the connecting rod to the crankshaft and fit the big end cap. r10 Increment markings a) Tighten to 22 Nm b) d) Release 1200 Tighten to 14 Nm c) Tighten to 10 Nm e) Tighten through 120 of bolt rotation as measured using the Triumph torque turn gauge 3880105T0301.
1. Liners
Note:
6. 7.
8.
Service Tool 3880105-T0301

1. Big end cap 2. Connecting rod bolt
I UMP
5.9

Connecting Rod Big End Bearing Selection/Crankpin Wear Check
1. Measure the bearing and crankpin clearance as follows. Checking the Measured Clearance Con rod big end bearing/crankpin clearance Standard: Service limit: Note: If the measured clearance exceeds the service limit, measure the crankpin diameter. 0.035 - 0.065 mm 0.070 mm
Note: The crankpin clearances are measured using 'Plastigage' (Triumph part number 3880150 T0301). Do not turn the connecting rod and crankshaft during the clearance measurement as this will damage the 'Plastigage'. Remove the big end cap from the journal to be checked. Wipe the exposed areas of the crankpin, and the bearing face inside the cap. Apply a thin smear of grease to the journal and a small quantity of silicone release agent to the bearing. Trim a length of the Plastigage to fit across the journal. Fit the strip to the journal using the grease to hold the Plastigage in place. Lubricate the threads and under-head of the bolt with molybdenum disulphide grease. Refit the bearing and cap and tighten the big end bolts (see page 5-9).
Crankpin diameter Standard: Service limit: Note: If any crankpin has worn beyond the service li mit, the crankshaft must be replaced. Due to the advanced techniques used during manufacture, the crankshaft cannot be reground and no oversize bearings are available. 32.984 - 33.000 mm 32.960 mm
a) b) c)
d)
e)
f) Release the bolts and remove the cap being measured. Using the gauge provided with the Plastigage kit, measure the width of the compressed Plastigage.
5.10
I UMP

Connecting Rod Bearing Selection Minor differences in crankshaft dimensions are compensated for by using selective bearings. For further information on bearing part number to colour crossreferences, see the latest parts information. 1. Select the correct big end bearing shell as follows: Measure each crankpin diameter. Select the correct bearings by matching the information found with the chart below. 2. Install the new bearings in the connecting rod.
Note: All dimensions in millimetres.

cdmx
Big end bearing selection chart Shell Colour Con-rod Big End Bore Dia. Crankpin Dia. Running Clearance For instance: Con-rod Big End Diameter Crankpin Diameter Required Bearing Note: Repeat the measurements for all connecting rods and their respective crankpins. It is normal for the bearings selected to differ from one connecting rod to another. 36.002 32.987 Red White 36.009 36.000 33.000 32.992 0.065 0.035 Red 36.009 36.000 32.991 32.984
1. Big end bearings
,A
Caution
Always confirm, using the Plastigage method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance.
a.
IIIMP
5.11

Crankshaft main bearing/journal wear Main Bearing Selection Chart (all dimensions in millimetres) Shell Colour Crankcase Bore Journal Dia. Running Clearance White 35.982 35.973 33.000 32.993 0.044 0.020 Red 35.981 35.973 32.992 32.984 0.044 0.020 Red 35.989 35.981 33.000 32.993 0.043 0.021 Blue 35.988 35.981 32.992 32.984 0.043 0.020 Select bearings as follows: 1. 2. Measure and record the diameter of each crankshaft main bearing journal. Measure and record each main bearing bore diameter in the crankcase (bearings removed). Blue 35.997 35.989 33.000 32.993 0.043 0.020 Green 35.997 35.989 32.992 32.984 0.044 0.020
Minor differences in crankshaft and crankcase dimensions are compensated for by using selective bearings. For further information on bearing part number to colour cross-references, see the latest parts information. Measure the bearing to crankshaft main journal clearance using Plastigage (Triumph part number 3880150-T0301) (see page 510).
Compare the data found with the chart above to select bearings individually by journal. For example Crankshaft Journal diameter Crankcase Bore Bearing Required Note: It is normal for the bearings selected to differ from one journal to another. It is also normal for there to be two options of bearing shell colour. In such cases, pick the shell size which gives the greater running clearance. 32.995 mm 35.997 mm Blue
Checking Crankpin Clearance using Plastigage Crankshaft main bearing/journal clearance Standard: Service limit: 0.020 - 0.044 mm 0.07 mm
Caution
Always confirm, using the Plastigage method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance. Crankshaft End Float Standard Note: Crankshaft end float is controlled by the tolerances in crankshaft and crankcase machining. No thrust washers are used. If the crankshaft end float is outside the specified limit, the crankshaft and/or the crankcases must be replaced. 0.15 - 0.30 mm
If the clearance exceeds the service limit, measure the diameter of the crankshaft main journal. Crankshaft main journal diameter Standard: Service limit: Note: If any journal has worn beyond the service li mit, the crankshaft must be replaced. Due to the techniques used during manufacture, the crankshaft cannot be reground and no oversize bearings are available. 32.984 - 33.000 mm 32.960 mm
5.12
lliMP
Crankshaft, Connecti ng Rods and Pistons

Pistons
Disassembly Note: It is not necessary to remove the connecting rods from the crankshaft. Remove the cylinder head (see page 3-22). Remove the liner, using the frame from tool T3880315, and tool 13880101 (see page 5-16). Remove and discard the gudgeon pin circlip from one side of the piston. Piston Wear Check 1. Measure the piston outside diameter, 8 mm up from the bottom of the piston and at 90 0 to the direction of the gudgeon pin. 3
1. 2. 3.
1. Piston outside diameter 2. Measurement point 3. Circlip removal groove
Daytona 675 All Cylinders Service limit Removing the Gudgeon Pin Circlip 4. Remove the gudgeon pin by pushing the pin through the piston and rod toward the side from which the circlip was removed. 73.970 73.980 mm 73.920 mm
Street Triple and Street Triple R All Cylinders Service limit 73.964 73.980 mm 73.920 mm
A
F'.
Caution
Replace the piston if the measured diameter falls outside the specified limit.
Never force the gudgeon pin through the piston. This may cause damage to the piston which may also damage the liner when assembled. Note: If the gudgeon pin is found to be tight in the piston, check the piston for a witness mark caused by the circlip. Carefully remove the mark to allow the pin to be removed. Piston rings must be removed from the piston using hand pressure only. Do not over-extend the piston rings during removal.
5.
Note: Om If the piston rings are to be re-used, note the orientation of the oil control rings prior to removal.
I uMP
5.13

Piston Rings/Ring Grooves Check the pistons for uneven groove wear by visually inspecting the ring grooves. If all the rings do not fit parallel to the groove upper and lower surfaces, the piston must be replaced. Clean the piston ring grooves. 1. Fit the piston rings to the pistons. Check, using feeler gauges, for the correct clearance between the ring grooves and the rings. Replace the piston and rings if outside the specified limit. 2. Place the piston ring inside the liner. Push the ring into the top of the cylinder, using the piston to hold the ring square with the inside of the bore. Continue to push the ring into the bore until the third groove of the piston is level with the cylinder top, around the full circumference of cylinder. Piston Ring Gap Note: The piston ring gap, with the piston ring fitted in the liner, must be checked before final assembly.
EM Piston Ring to Ring Groove Clearance Check Aligning Piston Rings using the Piston 1. Remove the piston and measure the gap between the ends of the piston ring using feeler gauges.
Piston ring/Groove Clearance Top ring Service limit Second Service limit 0.040 - 0.080 mm 0.095 mm 0.020 - 0.060 mm 0.075 mm Top
Piston Ring End Gap Tolerances 0.10 - 0.25 mm 0.37 mm 0.25 - 0.40 mm 0.52 mm 0.10 - 0.35 mm 0.49 mm
Service limit Second Service limit Oil Control Service limit Note:
If the end gap is too large, replace the piston rings with a new set If the gap remains too large with the new piston rings, both the pistons and barrels must be replaced If the gap is too small, check the cylinder bore for distortion, replacing as necessary. Do not file piston rings!
5.14
It,I MP

Piston Assembly 1. Clean the piston ring grooves and fit the piston rings to the piston.
A Warning
Failure to use new gudgeon pin circlips could allow the pin to detach from the piston. This could seize the engine and lead to an accident. 5. The piston ring gaps must be arranged as shown in the diagram below.
Note: The top ring upper surface is marked 'T1' and can be identified by a chamfer on the inside edge. When new, the top ring also has a blue paint marking on its outer edge. The second ring upper surface is marked 'T2', is plain on the inside edge and has a bronze appearance. When new, the second ring also has a yellow paint marking on its outer edge. When new, the oil control rings can be fi tted with either face upward. Used oil control rings must be refitted in the same orientation as noted prior to removal. When new, the oil control rings have white paint markings on their outside edge.
1
2
FRONT
+
3
4 5
1
^^
2
1. Top ring 2. Second ring
3. Fi rst steel oil control ring

4. Oil control ring expander 5. Second steel oil control ring
Note:
Second Ring
cbxyt
Piston Ring Identification 1. Fit the piston onto the connecting rod. 6.
The top ring gap should be positioned in the 12 o'clock position, and the second ring gap in the 6 o'clock position. The first steel oil control ring gap should be in the 12 o'clock position and the second steel oil control ring should be in the 6 o'clock position. The oil control ring expander should be in the 7 o'clock position. Fit the piston into the liner from below using a gentle rocking motion to engage the rings in the bore.
Note: Connecting rods may be fitted either way around. However, ensure all three are fitted the same way. 2. Lubricate the piston, small end and gudgeon pin with a 50/50 solution of engine oil and molybdenum disulphide grease. Align the small end in the connecting rod with the gudgeon pin hole in the piston and fit the gudgeon
pin.
3.
4.
Fit new circlips on both sides of the gudgeon pin ensuring the circlips are correctly fitted in the grooves.
ll1MP
5.15

Cylinder Wear Measure the inside diameter of each cylinder using an internal micrometer or similar accurate measuring equipment. Cylinder bore diameter Standard: Service limit: 73.985 74.003 mm 74.100 mm
Cylinder Liners
Removal 1. Assemble the frame from tool T3880315 to Tool T3880315 as shown below.
ME
1. Frame from tool T3880315
gaep
2. Tool T3880101
Test Position For Bore Wear Check (bore shown in section) 1. 2. Measure the inside diameter 10 mm from the top of the bore as shown above. If the reading is outside the specified limits, replace the liner and piston as an assembly.
1. Paint mark
2.
Mark each liner to identify correct orientation and the cylinder number from which it has been removed.
5.16
S UMP
Crankshaft, Connectin g Rods and Pistons

3. Turn the crankshaft until the piston in the liner to be removed is at the bottom of its stroke. 3 Apply silicone sealer to the liner to crankcase mating face (at the factory, ThreeBond 1215 is used). Fit each liner over the piston using a gentle rocking motion to allow compression of the piston rings.
gajw 1.Tool T3880315 and T3880101 2. Extraction nut 3. Locking nut 4. 5. Check that the locking nut on tool T3880101 is loose, then fully unscrew the extraction nut. Carefully fit the tool fully into the cylinder bore, positioning the tool legs on the crankcase. Turn the locking nut clockwise until the rubber sleeve on the tool tightly grips the bore of the liner. Check that the tool legs are positioned to allow withdrawal of the liner, then turn the extraction nut clockwise to extract the liner. Take care to ensure that the piston/connecting rod is not allowed to fall against the inside of the crankcase. Turn the locking nut counter-clockwise to release the li ner.
1. Liner 2. Sealer area 3. Chamfer
Note: The liners have a large chamfer at the bottom of the bore enabling fitting of the piston without need for a piston ring compressor.
6.
7.
Note: The tool must be used to release the seal between the liner and the crankcase. It is not intended that the tool is used to fully extract the liner. Once the seal is released, the tool must be removed and the liner extracted by hand.
Installation 1. 2. Thoroughly clean the liner removing all traces of old silicone sealer. Remove all traces of sealer from the crankcase bores.
1l.I MP
5.17

Crankcase Breather
Caution
Fit each liner over whichever piston is at TDC. When turning the engine, do not allow the pistons to contact the inside of the crankcase and also do not allow fitted li ners to lift off the crankcase base. 5. Continue fitting each liner in turn until all are fitted and sealed.
The upper crankcase is fitted with a labyrinth type breather system, which requires no maintenance. During engine disassembly and overhaul, check the oil drain tube for blockage and contamination.
Note: When the liners have been fitted, they should not be disturbed. If it is necessary to remove the liner after fitting, the sealer must be re-applied.
5.18
Il1MP
6 Balancer
Table of Contents
ExplodedView - Balancer Shaft .............................................................. Balancer................................................................................. Removal........................................................................... Inspection.......................................................................... Assembly/Installation ................................................................. 6.2 6.3 6.3 6.3 6.4
I UMP
6.1
Balancer
Exploded View - Balancer Shaft
LI
6.2
(LIMP
Balancer
Balancer
The balancer is fitted to control 'pulsing within the engine. Without any form of balancer, the engine would 'pulse' each time the crankshaft rotated. This 'pulsing' would be felt as a vibration which would amplify as the engine speed was increased. The balancer has the effect of a pair of counterbalance weights which create an equal amount of energy in the opposite direction, and at the same time as that produced by the crankshaft, pistons and connecting rods. Because the opposing pulses occur at the same point of crankshaft rotation, and are of an equal magnitude, a state of equilibrium or balance is reached. 5. To strip the backlash eliminator from the drive gear, release the circlip and remove the wave-washer, backlash gear and spring.
Removal 1. 2. Separate the crankcase halves (see page 5-4). With the crankcase halves separated, lift out the balancer shaft complete with the shaft bearings/ circlips.
r .r. 1. Balancer shaft 2. Wave washer 3. Circlip
Note: As the shaft is released from the crankcase, the backlash eliminator gear will spring out of alignment with the crankshaft. 3. To remove the left hand bearing, slide the bearing, circlip and bearing sleeve from the balancer shaft. Note the orientation of the bearing prior to removal. To remove the right hand bearing, remove the circlip and washer, and, using a press and press bars remove the bearing race from the shaft, ensuring the inner bearing race is supported. Note the orientation of the bearing prior to removal. DO NOT remove the drive gear from the shaft. Inspection 1. 2. Inspect all gears for chipped or missing teeth. Inspect all bearings for signs of overheating (blue discolouration), seized or damaged rollers, and any other damage. Inspect the backlash spring for deformities, damage etc. Inspect the gear teeth for overheating (blue discolouration).
4.
3. 4.
Warning
When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body. Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.
Caution
Do not remove the drive gear from the balancer shaft. The drive gear is aligned to the shaft. If the balancer and drive gear are not correctly aligned, severe engine vibration will occur leading to damage to components.
IIiMP
6.3
Balancer
Assembly/ Installation
Note: Before assembling the backlash gear to the balancer shaft, lubricate all contact surfaces of the balancer drive gear, backlash spring and backlash gear with a 50/50 solution of engine oil and molybdenum disulphide grease. 1. If the backlash gear was disassembled, fit the backlash spring over the shaft and position to the balancer drive gear, positioning the spring ends on either side of the peg. Fit the backlash gear, ensuring its peg is located anticlockwise (viewed from the left hand bearing end of the shaft) of the balancer gear peg and also between the spring ends. 4. Using a press and press bars, fit the right hand bearing to the shaft, with the circlip positioned nearest to the drive gear. Ensure the inner race of the bearing is supported when installing the bearing.
Warning
When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body. Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy. 5. 6. Refit the washer and a new circlip to the shaft. Lubricate and fit the left hand bearing and install a new circlip in the same orientation as noted prior to removal.
2.
Note: 3
Prior to installation in the crankcase, it is essential that the markings on the backlash eliminator and drive gears are brought into alignment against the tension of the spring. This will facilitate correct positioning of the balancer in relation to the crankshaft when both are installed in the crankcase.
1 O
1. Balancer shaft 2. Backlash gear 3. Backlash spring
3.
Fit the wave washer and secure all components in position with the circlip.
kaA l
1. Drive gear 'dot' 2. Backlash gear line
2 7. Using tool T3880106, bring the backlash and drive gear marks into alignment against the backlash spring as follows: Engage the peg of tool T3880106 into a tooth of the backlash gear. Rotate the backlash gear against the spring until the marks align.
cdon
1. Balancer shaft 2. Wave washer 3. Circlip
6.4
^ uMP
Balancer
Note: When in alignment, the line on the backlash gear must be located directly above the drive gear tooth marked with a 'dot'. Since the drive gear 'dot cannot be seen when the backlash gear is in alignment, always mark the 'dot'-marked gear tooth with a paint mark in order that it can always be identified. 8. Secure the backlash gear in position with the fixture supplied with the tool by placing the fixture pegs across two gear teeth (ensure that the fixture will not be in the way when assembling the balancer to the crank). 9. With the drive and backlash eliminator gears still correctly aligned, locate the balancer to the crankcase. Align the balancer gears and crankshaft as shown in the illustration below.
IIU!
cdmz ) / // ^J
1. Balancer gear marking 2. Crankshaft markings
10. Ensure that the right hand bearing circlip and dowel locate correctly in the corresponding groove in the crankcase.
cdon
1. Tool T3880106 2. Securing fixture 3. Balancer backlash gear marking
Caution
If the balancer and cranksha ft are not correctly aligned, severe engine vibration will occur leading to damage to components.
1. Balancer shaft (right hand bearing)
2. Circlip
3. Dowel
I UMP
6.5
Balancer
11. Ensure that the left hand bearing circlip and dowel locate correctly in the corresponding groove in the crankcase 12. Remove the securing fixture. 13. Check that the balancer and crankshaft are correctly aligned before continuing to assemble the crankcase halves. 14. Assemble the crankcase halves (see page 5-4).
2
1. Balancer shaft (left hand bearing) 2. Circlip 3. Dowel
6.6
111MP
7 Transmission
Table of Contents
Exploded View, Input and Output Shafts - up to Engine Number 330118 .......................... Exploded View, Input and Output Shafts - from Engine Number 330119 ........................... ExplodedView, Sprag Clutch and Starter Gears ................................................ ExplodedView, Gear Selectors and Drum .....................................................
Ex
7.2 7.3 7.4 7.5 7.6 7.7 7.7 7.9 7.9 7.12 7.12 7.13 7.14 7.14 7.15 7.16 7.19 7.19 7.20 7.21 7.23 7.23 7.24 7.24
lodedView ,
Gear Change Mechanism .....................................................
SelectorShaft, Selector Forks and Drum ...................................................... Removal............................................................................ Inspection........................................................................... Installation...........................................................................

In utand
Output Shafts Assemblies ........................................................
Removal........................................................................... Installation..........................................................................
In
utShaft
..............................................................................
Disassembly........................................................................ Inspection.......................................................................... ExplodedView - Input Shaft ............................................................... OutputShaft ............................................................................ Disassembly........................................................................

Ex
lodedView
- Output Shaft ..............................................................
Assembly........................................................................... StarterDrive Gears/Sprag Clutch ........................................................... Removal.......................................................................... Inspection......................................................................... Installation.........................................................................
Il.l MP
7.1
Transmission
Exploded View, Input and Output Shafts - up to Engine Number 330118
See text
12 Nm
7.2
IIJMP
Transmission
Exploded View, Input and Output Shafts - from Engine Number 330119
See text
_^
12 Nm
ILIMP
73
Transmission
Exploded View, Sprag Clutch and Starter Gears
11111
See xt
7.4
Il1 MP
Transmission
Exploded View, Gear Selectors and Drum
12 Nm
V
12 Nm
12 Nm
I UMP
7.5
Transmission
Exploded View, Gear Change Mechanism
9 Nm
6 Nm _- 22 Nm , CO
6Nm
7.6
IIIMP
Transmission
Selector Shaft, Selector Forks and Drum
Removal 1. 2. 3. 4. Remove the engine from the frame (see page 9-3). Separate the two halves of the crankcase (see page 5-4). Remove the output shaft from the crankcase (see page 7-12). Release the two fixings and remove the baffle plate from the crankcase breather. Discard the fixings. 7. Withdraw the gear change shaft from the clutch end of the crankcase.
1. Gear change shaft Note: The detent arm is held in position under spring pressure. Prior to removal, note the orientation of the detent arm, fixing and spring, relative to the selector drum detent wheel. The same orientation must be retained on assembly. Remove and discard the fixing securing the detent arm. Withdraw the detent arm complete with its flanged sleeve, spring and washer.
8. 9. 1. Crankcase breather baffle plate 2. Fixings 5. If not already removed, note the position and orientation of the gear pedal crank in relation to the shaft, then remove the crank. 6. Remove the E-clip and washer from the gear pedal end of the gear change shaft.
1 1
a
kalj,t
1. Detent arm 2. Fixing 3. Spring 4. Detent wheel
1. Gear change shaft 2. E-clip 3. Washer
I UMP
77
Transmission
10. Remove and discard the two selector shaft retaining fixings, noting the position of the washer and the selector drum keeper plate. 11. Slide the output selector shaft from the crankcase in the direction of the clutch. Collect the two selector forks as they are released by the selector shaft.
1. Selector drum keeper plate 2. Input selector shaft fixing 3. Output selector shaft fixing and washer
1. Output selector shaft 2. Sixth gear selector fork 3. Fifth gear selector fork 12. Noting the position of the selector fork, remove the input selector shaft, leaving the selector fork in the gearbox.
Caution
The two output shaft selector forks can be fitted incorrectly. Ensure the position and orientation of the selector forks are marked prior to removal. Incorrect fitting of the selector forks will cause gearbox damage. Note: All models except the Daytona 675 from VIN 381275: The fifth gear selector fork, located nearest to the clutch, has a special molybdenum coating on the selector forks. This special coating is identified by its dull grey colour, when compared to the sixth gear selector fork which is chromed. Daytona 675 from VIN381275: The fifth and sixth gear selector forks have a special molybdenum coating on the selector forks.
1. Input selector shaft 2. Selector fork
7.8
Il1MP
Transmission
13. Withdraw the selector drum from within the crankcase. Installation 1. Position the input shaft selector fork into the crankcase, locating the forks into the selector groove on the input shaft. Ensure the fork is fitted in the position noted during removal.
1. Selector drum removal
14. Collect the input shaft selector fork from the crankcase. Inspection 1. Examine all components for damage and/or wear, paying particular attention to the selector forks and selector drum. Replace any parts that are damaged and/or worn.
1. Input shaft selector fork 2. Input shaft
2. Using clean engine oil, lubricate the selector drum bearings. Lubricate the selector drum tracks with a 50/50 solution of engine oil and molybdenum disulphide grease. 3. Position the selector drum into the crankcase.
Gear selector fork thickness Standard Service limit Gear selector groove width Standard Service limit 6.10 - 6.17 mm 6.27 mm 5.90 - 6.00 mm 5.80 mm
Selector fork to groove clearance Service limit 2. 0.47 mm max
Examine the gear change shaft seal for damage and/ or wear. Replace the seal if damaged and/or worn.
1. Selector drum
4.
Rotate the selector drum and ensure a smooth movement. Rectify as necessary.
Caution
The selector forks can be fitted incorrectly. Ensure the position and orientation of the selector forks are the same as noted during removal. Incorrect fitting of the selector forks will cause ge a r box da mage.
L UMP
7.9
Transmission
5. Push the input selector shaft into the crankcase from the clutch end. As the shaft is inserted locate the selector fork onto the shaft. Ensure the fork is fitted in the position noted during removal. 7. Fit two new selector shaft retaining fixings, ensuring the washer and the selector drum keeper plate are fitted in the positions noted during removal. Tighten the fixings to 12 Nm.
cdmd
'
/j
--^^^^^^^^^ A
///fit
2. Fixing
^`^
^2
1. Input selector shaft 2. Selector fork
1. Selector drum/shaft keeper plate 3. Output selector shaft fixing and washer
Note: For Daytona 675 up to VIN 381274, Street Triple and Street Triple R all VINs: The fifth gear selector fork, located nearest to the clutch, has a special molybdenum coating on the selector forks. This special coating is identified by its dull grey colour, when compared to the sixth gear selector fork which is chromed. For Daytona 675 from VIN381275 only: The fifth and sixth gear selector forks have a special molybdenum coating on the selector forks. 6. Push the output selector shaft into the crankcase from the clutch end. As the shaft is inserted, locate the selector forks. Ensure the selector forks are fitted in the positions noted during removal.
8. Assemble the detent arm as noted on removal with a new fixing and place up to the crankcase.
o (î
LU
1. Spring 2. Washer 3. Detent arm 4. Flanged sleeve 5. Fixing
1. Output selector shaft 2. Sixth gear selector fork 3. Fifth gear selector fork
7.10
L UMP
Transmission
9. Hold the detent arm assembly in position and insert a new fixing. Start the thread and push the detent arm, using finger pressure only, to locate on the selector drum detent wheel. Ensure the detent arm remains correctly located on the detent wheel and the spring is correctly seated in the recess in the crankcase. Ensure the shoulder of the flanged sleeve is located in the bore of the detent arm and tighten the fixing to 12 Nm. 11. Using clean engine oil, lubricate the lip of the seal on the gear change shaft. o
G ^ G
b
cdnj ^
O0
0
_2
1. Gear change shaft seal 2. Gear change shaft bearing

I
P)c) 2
/2)
12. Lubricate, with a 50/50 solution of engine oil and molybdenum disulphide grease, both sides of the forks and the slider plates of the selector mechanism on the gear change shaft.
1. Detent arm 2. Fixing 3. Spring 4. Selector drum detent wheel
A Caution
Take care to avoid damaging the lip of the seal when inserting the gear change shaft into the crankcase. A damaged seal will lead to oil loss and could result in engine damage. 13. Insert the gear change shaft into the crankcase. Gently push the gear pedal end of the shaft through the bearing and lip seal at the clutch side of the crankcase, and the sealed bearing, located at the gear pedal side of the crankcase.
10. Rotate the selector drum to the neutral position. Ensure that the detent arm locates in the raised profile in the detent wheel (neutral position).
1. Detent arm 2. Neutral position
1.Gearchange shaft 2.Abutment bolt 3.Spring

14. Ensure that the gear change shaft fingers locate in the detent wheel/arm and that the spring fits either side of the abutment bolt.
I uMP
7.11
Transmission
15. Fit the washer and E-clip to the gear pedal end of the gear change shaft.
Input and Output Shafts Assemblies

Removal Note:
The input and output shafts may be removed from the upper crankcase after first separating the lower crankcase from the upper.
Note: The rear needle roller bearing on the input shaft remains in the crankcase on removal of the shaft. Remove the engine from the frame (see page 9-3). Separate the two halves of the crankcase (see page 5-4). Lift the output shaft from the upper crankcase, noting the orientation of each bearing, their circlips and dowels. Remove the selector shafts and forks (see page 7-7).
1.
kakhl
1. Gear change shaft 2. E-clip 3. Washer
2. 3.
16. Fit the gear pedal crank to the shaft in the same orientation as noted prior to removal. Ensure the 'dot' mark on the shaft aligns with the split line on the gear pedal crank. Tighten the fixing to 9 Nm. 17. Incorporating new fixings, refit the baffle plate to the crankcase breather. Tighten the fixings to 9 Nm. 18. Refit the output shaft (see page 7-13). 19. Assemble the two halves of the crankcase (see page 5-4). 20. Refit the engine to the frame (see page 9-4).
4.
Note: The input shaft bearing housing fixings may not be re-used but should be retained for use during installation of the input shaft. Up to engine number 330118: Release the three fixings securing the input shaft bearing housing to the upper crankcase.
5.
cdmb
1. Fixings 2. Bearing housing
7.12
tl1MP
Transmission
6. From engine number 330119 only: Release the three fixings securing and remove the retaining plate. 2. Locate the input shaft to the upper crankcase, installing it through the aperture for the bearing housing. Fit the bearing housing into the aperture, by hand, as deeply as possible. Using the old fixings, evenly and progressively tighten them to draw the bearing housing into the upper crankcase until fully home. Remove and discard the fixings.
3. 4.
1. Fixings 2. Retaining plate 3. Bearing housing
7.
All engines: Insert two M6 bolts into the two threaded holes at the periphery of the bearing housing. Evenly and progressively tighten both bolts to draw the bearing housing and input shaft from the crankcase.
I!
5. 6.
1. Bearing housing
2. Fixings 3. M6 threaded holes 4. Transmission oil tube
Up to engine number 330118: Install new fixings to the bearing housing and tighten to 12 Nm. From engine number 330119: Fit the retaining plate. Install new fixings and tighten to 12 Nm.
0
cdmt
1. Bearing housing 2. M6 threaded holes 3. Transmission oil tube
8. If required, the transmission oil tube can now be removed. Remove and discard the three oil tube O-rings.
1. Fixings 2. Retaining plate 3. Bearing housing
Installation 1. If removed, check the transmission oil tube for blockages and contamination. Carefully fit new O-rings to the transmission oil tube and insert the tube into the crankcase, ensuring the tag on the tube locates in the slot in the crankcase.
7.
Refit the selectors and shafts (see page 7-9).
IIiMP
7.13
Transmission
8. Refit the output shaft to the crankcase ensuring the snap-ring locates in the corresponding groove in the crankcase, and the dowel locates in the slot in the upper crankcase. 9. Ensure the output shaft seal aligns with its recess in the crankcase.
Input Shaft
Disassembly Note: The numbers in brackets in the following text refer to the exploded view on page 716.
Working from the opposite end to where the clutch assembly is fitted, dismantle the input shaft as follows: 1. 2. 3. 4. Slide off the plain thrust washer (1). Mark one side of second gear to denote its correct orientation. Remove second gear (2). Remove the splined lock washers (3 and 4). Mark one side of sixth gear to denote its correct orientation. Remove sixth gear (6), complete with the splined bush (5) which runs inside the gear. Remove the splined thrust washer (7) from in front of the circlip between sixth and third/fourth gear. Remove the circlip (8) from the shaft. Mark one side of the combined third/fourth gear to denote its correct orientation. Remove the combined third/fourth gear (9). Remove the circlip (10) from in front of fifth gear. Remove the splined thrust washer (11) adjacent to fifth gear. Mark one side of fifth gear to denote its correct orientation. Remove fifth gear (12), complete with the plain bush (13) which runs inside the gear.
5.
1. Groove in crankcase 2. Snap ring 3. Dowel 4. Seal
6. 7.
10. Ensure the hole in the output shaft needle roller bearing outer race is positioned to locate onto the dowel provided in the upper crankcase.
8. 9. 10.
Note: Unless the bearing at the clutch end of the input shaft is damaged or worn, it is not normally necessary to remove it from the shaft. The bearing is pressed onto the shaft and is also pressed into its housing. The bearing and housing are removed from the shaft together and are then separated. Up to engine number 330118, the bearing is retained in the bearing housing with a circlip. Up to engine 330118 only: Remove the circlip (15) from the bearing housing.
1. Roller bearing 2. Dowel
11.
11. 12.
Assemble the two halves of the crankcase (see page 5-4). Refit the engine to the frame (see page 9-4).
7.14
L UMP
Transmission
13. All engines: Support the outer circumference of the bearing housing on press bars, then press the bearing through the housing. Up to engine number 330118 From engine number 330119
Warning
When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body. Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, arms or other parts of the anatomy. 12. Support the bearing and housing (16 and 17) on press bars, then press the shaft (14) through the bearing and housing as shown below.
Pressing out the Bearing
Inspection 1. Examine all gears, bearings and bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all defective components and always use new circlips to assemble the shaft. Thoroughly clean the bearing housing and inspect for damage, scoring and cracks. Replace the housing if necessary.
2.
1. Press bars 2. Bearing/housing
I UMP
7.15
Transmission
Exploded View - Input Shaft
From engine number 330119 a e
18
16 Up to engine number 330118

15
7 ^J 6
14
4 -
1. Thrust washer 2. Second gear 3. Lock washer 4. Splined washer 5. Splined bush 6. Sixth gear 7. Splined thrust washer 8. Circlip 9. Third/fourth gear
10. Circlip 11. Splined thrust washer 12. Fifth gear 13. Plain bush 14. Input shaft 15. Circlip 16. Bearing 17. Bearing housing 18. Bearing retainer
7.16
111MP
Transmission
Assembly Note: The numbers in brackets in the following text refer to the exploded view on page 716. Lubricate each gear, thrust washer and bush with clean engine oil during assembly. 2. Support the housing on press bars as shown below and press the bearing fully into the housing in the direction of the arrow. Up to engine number 330118 From engine number 330119
A. Warning
When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body. Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, a rms or other parts of the anatomy. SM 1. Bearing housing 2. Bearing 3.
Caution
Bushes and gears with oil holes must always be MISALIGNED with the corresponding oil holes in the input shaft. Reduced oil pressure and gear lubrication may result from alignment of the oil holes, which would cause premature wear of engine and transmission components.
Up to engine number 330118 only: Retain the bearing with a new circlip.
Caution
Press only on the bearing inner race to prevent bearing damage. 4 Locate the bearing and housing to the input shaft. Carefully support the shaft on the press bed, and using a suitable sleeve over the input shaft to ensure the bearing is pressed only on the inner race, press the bearing onto the shaft.
Caution
Removing the input shaft bearing from the shaft and its housing will damage the bearing and snap ring. Neve removed bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage. Also, check for damage to the housing itself. om 1. Up to engine number 330118 only: Apply approximately 1 gram of ThreeBond 1375B to the circumference of a new bearing and position the bearing to the housing, ensuring the bearing dowel aligns with the slot in the housing. Ensure no ThreeBond enters the bearing.
Caution
M 1. Sleeve 2. Bearing/housing 3. Press bars 4. Input shaft 5. 6. Fit the plain bush (13) to the shaft. Fit fifth gear (12) to the input shaft as noted during disassembly, with the dog teeth pointing away from the input shaft bearing.
Press only on the bearing outer race to prevent bearing damage.
ll p
7.17
Transmission
7. Slide on the splined thrust washer (11). 11. Fit the splined thrust washer (7) to the input shaft and slide up the shaft until in contact with the circlip. 12. Fit the splined bush (5) from sixth gear. Ensure that the oil hole in the input shaft DOES NOT align with the oil hole in the gear. 13. Fit sixth gear (6) as noted during disassembly, with the dog teeth facing third/fourth gear. 14. Fit the splined and lock washers (4 and 3), ensuring the tabs in the smaller washer (3) locate in the slots in the larger (4) washer.
8. Fit a new circlip (10) to the input shaft ensuring that the clip is located in the circlip groove as shown below.
1. Fifth gear 2. Thrust washer 3. Circlip
9. Fit the combined third/fourth gear (9) as noted during disassembly, with the larger gear facing toward fifth gear. Ensure that the oil hole in the input shaft DOES NOT align with the oil hole in the gear.
EM
1. Second gear 2. Large splined lock washer 3. Small splined lock washer
Warning
If the oil hole in the third/fourth gear is aligned with the corresponding hole in the input shaft, engine oil pressure and gear lubrication will be reduced. Reduced oil pressure and gear lubrication will cause engine damage and could also lead to engine seizure resulting in loss of motorcycle control and an accident 10. Fit a new circlip (8) to the input shaft ensuring that the circlip is located in the circlip groove as shown below.
15. Fit second gear (2) to the shaft as noted during disassembly. 16. Fit the plain thrust washer (1) adjacent to second gear.
camp
1. Sixth gear 2. Thrust washer 3. Circlip
7.18
ILiM^
Transmission
Output Shaft
Note: The numbers in brackets in the following text refer to the exploded view on page 720. 13. Remove the splined thrust washer (19). 14. Mark one side of second gear to denote its correct orientation. Remove second gear (21) from the shaft, complete with the plain bush (20) which runs inside the gear. 15. Position the output shaft (22) in a vice with soft jaws fitted. Tighten the vice to prevent the shaft from turning and release the tab washer (28) from the output sprocket nut (29), then release the nut. 16. Remove the output sprocket nut (29), tab washer (28) and sprocket (27). 17. Collect the output shaft seal (26). 18. If it is found necessary to replace the large bearing (24) at the end of the shaft, use a press to remove both the bearing and output shaft sprocket spacer (25) together.
Working from the opposite end to the drive sprocket, dismantle the output shaft as follows.
Disassembly 1. 2. Remove the output shaft bearing (1) and plain thrust washer (2). Mark one side of first gear to denote its correct orientation. Remove first gear (3) from the shaft, complete with the plain bush (4) which runs inside the gear. Remove the plain thrust washer (5). Mark one side of fifth gear to denote its correct orientation. Remove fifth gear (6) from the shaft. Remove the circlip (7) and splined thrust washer (8) from in front of fourth gear. Mark one side of fourth gear to denote its correct orientation. Remove fourth gear (9) complete with the splined bush which runs inside the gear (10). Remove the splined lock washers (11 and 12). Mark one side of third gear to denote its correct orientation. Remove third gear (14) off the shaft complete with the splined bush (13) which runs inside the gear. Remove the splined thrust washer (15).
3. 4. 5. 6.
,A
Warning
When removing the output shaft bearing, always wear overalls, eye, face and hand protection. The bearing races are hardened and are liable to splinter if broken. Debris from broken bearings could cause injury to eyes, face and any unprotected parts of the body.
7. 8.
9.
10. Remove the circlip (16) from in front of sixth gear. 11. Mark one side of sixth gear to denote its correct orientation. Remove sixth gear (17) from the shaft. 12. Remove the circlip (18) from in front of second gear.
lllMP
7.19
Transmission
Exploded View - Output Shaft
17 18 19 20
22
^^- 23
24
CJ ^ 25 26
27
28
29
1. Bearing 2. Thrust washer 3. First gear 4. Plain bush 5. Thrust washer 6. Fifth gear 7. Circlip 8. Splined thrust washer 9. Fourth gear 10. Splined bush 11. Lock washer 12. Splined washer 13. Splined bush 14. Third gear 15. Splined washer 16. Circlip 17.Sixth gear
18. Circlip
19. Splined thrust washer 20. Plain bush 21. Second gear 22. Output shaft 23. Snap ring 24. Bearing 25. Sprocket spacer 26. Output shaft seal 27. Output sprocket 28. Tab washer 29. Output sprocket nut
7.20
ll1Mp
Transmission
Assembly Note: The numbers in brackets in the following text refer to the exploded view on page 720. Lubricate each gear and bush with clean engine oil during assembly. Examine all gears, bearings and sleeves for damage, chipped teeth and wear beyond the service limits. Replace all suspect components and always use new circlips, a new output shaft seal and a new sprocket tab washer to assemble the shaft. 1. Working from the output sprocket end of the shaft, fit a new bearing (24) and a new sprocket spacer (25) to the shaft using a press and press bars. Fit the sleeve with the large chamfer facing outwards.
Warning When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body. Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, arms or other parts of the anatomy.
1. Output shaft 2. Bearing 3. Press bars
2. 3.
Lubricate and fit a new output shaft seal (26). Transfer the shaft to the vice and secure between soft jaws. Fit the output sprocket (27), new tab washer (28) and nut (29). Tighten the nut to 85 Nm. Close the tab washer. Withdraw the shaft from the vice and continue to assemble from the opposite end to the output sprocket. Fit the plain bush (20) to the shaft. Locate second gear (21) to the shaft as noted during disassembly, with the large step side facing towards the output sprocket end. Fit the splined thrust washer (19) and retain with a new circlip (18) as shown below.
A Caution
Bushes and gears with oil holes must always be MISALIGNED with the corresponding oil holes in the output shaft. Reduced oil pressure and gear lubrication may result from alignment of the oil holes, which would cause premature wear of engine and transmission components.
4.
5. 6.
ACaution
Removing the output shaft bearing from the shaft will damage the bearing and snap ring. Never re-use removed bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage.
A Caution
Press only on the bearing inner race to prevent bearing damage.
1. Second gear 2. Thrust washer 3. Circlip
Il1MP
7.21
Transmission
7. Fit sixth gear (17) as noted during disassembly, with the selector fork groove facing away from the output sprocket end. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft. Fit a new circlip (16) to retain sixth gear. Fit the splined thrust washer (15) to the rear of third gear as shown below. 12. Fit fou rth gear (9) as noted during disassembly, with the larger step side facing towards the output sprocket. 13. Fit the splined thrust washer (8) and retain with a new circlip (7) as shown below.
8.
1. Fou rth gear 2. Splined thrust washer

r.^
3. Circlip
1. Third gear 2. Splined thrust washer 3. Circlip
9. Fit the splined bush (13) for third gear. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft. Fit third gear (14) to the shaft with the large step side facing away from the output sprocket. 10. Fit the splined lock washers (12 and 11), ensuring the tabs in the smaller washer (11) locate in the slots in the larger washer (12) as shown below.
14. Fit the fifth gear (6) to the shaft with the groove facing towards the output sprocket. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft. 15. Fit the first gear thrust washer (5) and plain bush (4). 16. Fit first gear (3) to the shaft as marked during disassembly as shown below.
1. First gear 2. Thrust washer 3. Thrust washer 1. Third gear 2. Large splined lock washer 3. Small splined lock washer 4. Needle roller bearing
17.
Finally fit the thrust washer (2) and needle roller bearing (1) to the end of the shaft.
11. Fit the splined bush (10) from fourth gear. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft.
7.22
I UMP
Transmission
Starter Drive Gears/Sprag Clutch
Removal Note: The sprag clutch may be detached after first removing the rider's seat and the battery (disconnect the negative (black) lead first). The left hand lower fairing (Daytona 675 only) and the alternator must also be removed. Refer to the relevant sections for removal procedures. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Daytona 675 only: Remove the left hand lower fairing (see page 16-20). Release the bolts securing the left hand engine cover noting the position of the copper washer under the head of one of the upper bolts. Collect the solenoid/ fairing bracket from under the front two bolts. Remove the left hand engine cover and position aside. 6. Withdraw the starter idler gear and shaft, noting the fitted position of the components.
1. 2. 3. 4.
1. Idler gear 2. Idler shaft
Remove the alternator rotor (see page 17-33). 8. Withdraw the starter drive gear from the sprag clutch.
5.
cdnb
1. Starter drive gear 1. Left hand engine cover 2. Copper washer position 3. Solenoid/fairing bracket 2. Sprag clutch/housing 3. Alternator rotor
9. Remove and discard the fixings securing the sprag clutch housing to the alternator rotor. Withdraw the sprag clutch housing.
puuu1LlrH
7.23
Transmission
10. Remove the sprag clutch from the housing 3. 4. Ensure that the housing is squarely seated and is not ja mmed on the rotor. Install new fixings. Working in the sequence shown, tighten the bolts to 16 Nm. Once all six bolts have been tightened, go around again in sequence and recheck each bolt is correctly torqued, if any bolt moves, go around again. Repeatedly check the bolts in sequence until all are correctly torqued and do not move when checked, this will ensure the sprag clutch housing is correctly seated on the rotor.
1. Sprag clutch housing 2. Sprag clutch assembly
^^ O^ ^' 11 s
Inspection
1. Check the sprag clutch bearings for overheating, wear and/or non-smooth operation. Replace the sprag clutch if overheating, wear and/or non-smooth operation is found. Examine all gears for chipped teeth, overheating (going blue) and for any other damage. With the sprag clutch mounted in the housing, check the sprag clutch for smooth, free movement in one direction only (as indicated by the arrow marked on the sprag clutch body). 5.
Bolt Tightening Sequence Fit the starter drive gear to the sprag clutch.
2. 3.
Installation
1. Locate the sprag clutch to the housing as shown below. Push firmly until the lip seats in the recess provided in the housing.
IW
cdnb _%%L .7r
S
1. Sta rt er drive gear 2. Sprag clutch housing 3. Alternator rotor
II)
1. Sprag clutch housing 2. Sprag clutch assembly
2.
Fit the housing to the alternator rotor.
7.24
IUMP
Transmission
6. 7. 8. Refit the alternator rotor (see page 17-34). Lubricate the idler gear shaft with a 50/50 solution of engine oil and molybdenum disulphide grease. Fit the starter idler gear and shaft to the crankcase. 11. Ensure the bolt with the copper washer is correctly located. Refit the solenoid/fairing bracket to the front two bolts. Tighten the cover bolts to 9 Nm.
1. Left hand engine cover 1. Idler gear 2. Idler shaft 2. Copper washer position 3. Solenoid/fairing bracket
9.
Thoroughly clean the left hand engine cover.
12.
10. Position a new gasket to the crankcase dowels then refit the left hand engine cover.
Daytona 675 only: Refit the left hand lower fairing (see page 16-22).
13. Reconnect the battery, positive (red) lead first. 14. Refit the rider's seat (see page 16-17)
L UMP
7.25
8 Lubrication
Table of Contents
ExplodedView - Sump ..................................................................... Exploded View - Oil Pump/Water Pump, Gears and Heat Exchanger ..............................
En
8.2 8.3 8.4 8.5 8.5 8.6 8.6 8.6 8.6 8.7 8.8 0.", 8.9 8.12 8.13 8.13 8.15 8.15 8.15 8.15 8.16 8.18 8.18 8.18 8.19
ineOil
Circuit .........................................................................
EngineOil Circuit Description ............................................................... HeatExchanger ........................................................................... EngineOil.............. ................................................................. Specification........................................................................ TriumphEngine Oil .................................................................. OilLevel Inspection ........................................................................ Oiland Oil Filter Change ................................................................... Disposalof Used Engine Oil........................................................... oilrump ................................................................................ Removal........................................................................... Inspection.......................................................................... Assembly...........................................................................
.-M
Installation.......................................................................... LowOil Pressure Warning Light Switch ...................................................... Installation.......................................................................... Sump.................................................................................. Removal...........................................................................
Installation.......................................................................... HeatExchanger......... ................................................................. Removal........................................................................... Inspection.......................................................................... Installation..........................................................................
1 uMP
8.1
Lubrication
Exploded View - Sump
O '
25 Nm
12
Nm
8.2
S UMP
Lubrication
Exploded View - Oil Pump/Water Pump, Gears and Heat Exchanger
13 Nm
hm
9Nm 9 Nm 99
.7
9 Nm 12 IN 10Nm
- -----^ -J 59 Nm
Î yThreeBond 1305 ie threads 15 Nm
Il1MP
8.3
Lubrication
Engine Oil Circuit
^0 0 D D D D
A - COOLED OIL
A - I INrnnI Fn nil
8.4
IIIMP
Lubrication
Engine Oil Circuit Description
Oil is collected from the sump and is drawn through a mesh strainer into the oil pump rotor. The oil pump is fitted with a single pumping rotor which supplies pressurised oil to the lubrication circuit via the oil pressure relief valve. The relief valve is set to open at 5.1 bar (75 Ib/in 2 ) and when open, returns high pressure oil direct to the sump. Pressurised oil is delivered to the oil to water heat exchanger (mounted on the front of the engine), where it is cooled. The cooled oil is then delivered to the outside rim of the oil filter, where it is filtered by passing through the filter membrane. Filtered oil is then fed into the lower crankcase gallery. From here it is distributed around the engine: Oil is delivered to the crankshaft main bearings and, via drillings in the crankshaft, to the big end bearings.
Spray lets located in the upper crankcase, behind the main bearing shells, lubricate the pistons and connecting rod small ends. These jets are fed oil from the crankshaft oil feed. A low oil pressure warning light switch is also located in the upper crankcase gallery. Some oil is sent directly to the cylinder head via an internal gallery. Oil that arrives at the cylinder head is fed to both cams via a gallery in the cylinder head casting that delivers oil directly to the sprocket end of the camshafts. Oil is then fed through the hollow camshafts to the other camshaft bearings, the tappet buckets and the valves. Oil is fed to the gearbox via internal oil pipes and drillings that supply oil directly to the end of each shaft. Oil is circulated along the gearbox shafts to exit holes that feed directly to the bearings, gears and selectors.
On the Daytona 675, Street Triple and Street Triple R, oil is also fed to the alternator to aid cooling of the alternator components. The oil is taken from the crankshaft oil feed and directed to the alternator via a jet, located above the alternator rotor, in the upper crankcase.
Heat Exchanger
The heat exchanger is used to transfer heat from the engine oil into the coolant. Oil is delivered to the heat exchanger via a hollow centre bolt, after which it flows around the end tank and into the heat exchanger core, where it is circulated. Coolant is pumped around the outside of the heat exchanger core to cool the oil. The cooled oil then exits the heat exchanger and flows to the oil filter. An additional benefit of the heat exchanger is that, as the engine coolant reaches its operating temperature more quickly than the engine oil, the oil is heated by the engine coolant at lower engine temperatures; this allows the engine oil to reach its optimum operating temperature more quickly, thereby helping to i mprove engine oil life, reduce exhaust emissions and reduce engine wear.
cdwe
A - COOLED OIL 0 - UNCOOLED OIL - COOLANT Heat Exchanger Circuit
il1MP
8.5
Lubrication
Engine Oil
Specification Use semi or fully synthetic 1OW/40 or 15W/50 motorcycle engine oil which meets specification API SH (or higher) and JASO MA, such as Mobil 1 Racing 4T.
Oil Level Inspection

In order for the engine, transmission, and clutch to function correctly, maintain the engine oil at the correct level, and change the oil and oil filter in accordance with scheduled maintenance requirements.
Caution
Warning Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated engine wear and may result in engine or transmission seizure. Seizure of the engine or transmission may lead to loss of motorcycle control and an accident. 1. 2. 3. Start the engine and run at idle for approximately five minutes. Stop the engine, then wait for at least three minutes to allow the oil to settle. Remove the dipstick, wipe clean and screw fully home in the crankcase.
Triumph high performance fuel injected engines are designed to use semi or fully synthetic motorcycle engine oil which meets specification API SH (or higher) AND JASO MA. Do not add any chemical additives to the engine oil. The engine oil also lubricates the clutch and any additives could cause the clutch to slip. Do not use mineral, vegetable, non-detergent oil, castor based oils or any oil not conforming to the required specification. The use of these oils may cause instant, severe engine damage. Ensure no foreign matter enters the crankcase during an oil change or top-up. Triumph Engine Oil Your Triumph Motorcycle is a quality engineered product which has been carefully built and tested to exacting standards. Triumph Motorcycles are keen to ensure that you enjoy optimum performance from your machine and with this objective in mind have tested many of the engine lubricants currently available to the limits of their performance. Mobil 1 Racing 4T consistently performed well during our tests and has become our primary recommendation for the lubrication of all current Triumph motorcycle engines. Mobil 1 Racing 4T, specially filled for Triumph, is available from your authorised Triumph dealer.
1. Filler 2. Dipstick location in crankcase 3. Dipstick 4. Upper marking 5. Lower marking
8.6
ILiMP
%.i
Lubrication
Note: The actual level is indicated when the motorcycle is level and upright, not on the side stand, and when the filler has been screwed fully home. Do not add oil through the dipstick hole in the crankcase. Remove the dipstick. The oil level is indicated by lines on the dipstick. When full, the indicated oil level must be level with the upper marking on the dipstick. If the oil level is too low, remove the filler plug and add oil a little at a time through the filler plug hole in the clutch cover, until the correct level is reached. Once the correct level is reached, fit the dipstick and the filler plug.
Oil and Oil Filter Change
Warning
4. 5.
Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contamination which can cause cancer. Wear suitable clothing and avoid skin contact. The engine oil and filter must be replaced in accordance with scheduled maintenance requirements. 1. 2. 3. Warm up the engine thoroughly, and then stop the engine. Daytona 675 only: Remove the lower fairings (see page 16-20). Place an oil pan beneath the engine.
6.
7.
on
A
4.
,Warning
The oil may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned. Remove the oil drain plug
cdga 1. Oil drain plug 2. Oil filter 5. With the motorcycle on level ground, and on the sidestand, allow the oil to completely drain.
I UMP
8.7
Lubrication
6. Unscrew and remove the oil filter using Triumph service tool 13880313. 12. Start the engine and allow to idle.
ACaution
Racing the engine before the oil reaches every part can cause engine damage or seizure. 13. Ensure that the oil pressure warning light extinguishes shortly after starting.
ACaution
If the engine oil pressure is too low, the low oil pressure warning light will illuminate. If this light stays on when the engine is running, stop the engine immediately and investigate the cause. Running the engine with low oil pressure will cause engine damage.
1. Oil filter 2. Tool T3880313
14. Stop the engine and check the oil level. Adjust if necessary. 15. Daytona 675 only: Refit the lower fairings (see page 16-22).
7. 8. 9.
Discard the oil filter. Apply a smear of clean engine oil to the sealing ring of the new oil filter. Fit the oil filter and tighten to 10 Nm using Triumph service tool T3880313.
Disposal of Used Engine Oil To protect the environment, do not pour oil on the ground, down sewers or drains, or into water courses. Dispose of used oil sensibly. If in doubt contact your local authority.
10. After the oil has completely drained out, fit a new sealing washer to the drain plug. Fit and tighten the plug to 25 Nm. 11. Fill the engine with new oil of the type and grade listed previously and in the specification section.
8.8
IL1MP
Lubrication
Oil Pump
A
Warning
Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. Furthermore, used engine oil contains potentially harmful contaminants which can cause cancer. When handling used engine oil, always wear protective clothing and avoid any skin contact with the oil.
Warning
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. 5. 6. Remove the sump (see page 8-15). Remove the clutch (see page 4-6).
A,
Caution
7. Release and discard the two fixings and remove the oil transfer pipe. Remove and discard the two 0-ring seals.
Do not pour engine 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. Removal Note: The oil pump and water pump are supplied as an assembly and cannot be separated. This procedure covers the removal of the oil and water pump assembly. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Drain the coolant (see page 11-6 for Daytona 675, or page 11-8 for Street Triple and Street Triple R). Drain the engine oil (see page 8-7). 1. Oil transfer pipe 2. Fixings 8. Release and discard the two fixings and remove the oil pick-up. Remove and discard the 0-ring seal.
1. 2. 3. 4.
Warning
The oil may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.
1. Oil pick-up 2. Fixings
I UMP
8.9
Lubrication
9. Remove and discard the bolt securing the coolant inlet elbow to the crankcase and withdraw the elbow. Remove and discard the 0-ring from the elbow. 11. Release the fixings securing the drive chain guide to the crankcase and remove the guide.
-d pk
1. Coolant inlet elbow 2. Fixing 10. Remove and discard the bolt securing the coolant outlet pipe to the crankcase and withdraw the pipe. Remove and discard the three 0-rings from the pipe.
I // I
II
v l nl
1. Oil pump drive chain guide 2. Fixings 12. Slide the oil pump drive sprocket gently backwards and forwards to dislodge the inner needle roller bearing.
1. Oil pump drive sprocket 2. Needle roller bearing 1. Coolant outlet pipe 2. Fixing
8.10
I UMP
Lubrication
13. Carefully remove the bearing while supporting the oil pump drive sprocket.
X
I ^^\11 ^
^^
15. Using a suitable tool, slide the dowel upwards to release the oil pump from the crankcase. It is not necessary to remove the dowel completely from the oil pump.
b-1 //
II
cdwg
\`1
\\
1. Needle roller bearing 2. Oil pump drive sprocket
14. Release the fixings securing the drive chain cover to the oil pump. Remove the drive chain cover. `..
1. Oil pump 2. Dowel 16. Detach the drive chain from the oil pump.
1. Oil pump 2. Fixings 3. Drive chain cover 1. Oil punip 2. Drive chain
17. Carefully withdraw the oil pump from the crankcase. 18. Remove and discard the 0-ring from the inlet sleeve on the water pump body.
il.1 MP
8.11
Lubrication
Inspection 1. Release the fixing and remove the drive sprocket and spacer washer. 3. Measure the rotor tip clearance using feeler gauges.
Rotor Tip Clearance Standard: Service limit: 0.15 mm 0.20 mm
3 ,4
1. Oil pump 2. Spacer washer 3. Drive sprocket 4. Fixing
2.
Release the three fixings and withdraw the oil pump body.
Rotor Tip Clearance 4. Measure the pump body clearance using feeler gauges.
z
0
o /+
En
1. Oil pump body 2. Fixings
Pump Body Clearance
Caution
Pump Body Clearance Standard: LService limit: 5. 0.15 - 0.22 mm 0.35 mm
If any part of the oil pump is found to be outside the service limit, the complete pump must be replaced. Severe engine damage may result from the continued use of a faulty oil pump.
Measure the pump end clearance.
Pump End Clearance Standard: Service limit: 0.04 - 0.09 mm 0.17 mm
8.12
II,I MP
Lubrication
Assembly 1. If all clearances are within service limits, liberally apply clean engine oil to all internal components and refit the oil pump body to the oil pump rotor. Refit the fixings and tighten to 12 Nm. If any clearance measured is outside the service li mits, renew the complete pump. Inspect the sprockets and chain for wear and/or damage. Replace the sprockets and chain if wear and/or damage is found. Check the water pump shaft and shaft bearings for side and end float. Renew if necessary. Check for corrosion and scale build-up around the i mpeller and in the pump body. Renew if necessary. Check the oil pump location dowel for damage. Renew if necessary. Refit the spacer washer and drive sprocket. Apply ThreeBond 1374 to the fixing and tighten to 14 Nm. 3. Position the oil pump to the crankcase and insert the water pump inlet sleeve into the opening in the crankcase. Fit the oil pump to the crankcase, ensuring the oil pump dowel correctly locates into the bolt hole in the crankcase.
4.
2. 3.
ACaution
Do not use excessive force to insert the dowel into the crankcase. Severe dowel or crankcase damage may result from the use of excessive force. 5. 6. 7. 8. Using a suitable pin punch, gently tap the dowel downwards into the crankcase until it seats. Feed the drive chain over the transmission input shaft and fit to the sprocket. Fit the drive chain to the sprocket on the oil pump. Support the oil pump drive sprocket and carefully refit the needle roller bearing.
4. 5. 6. 7.
3 ,4
1. Oil pump 2. Spacer washer 3. Drive sprocket 4. Fixing 1. Needle roller bearing 2. Oil pump drive sprocket
Installation
ACaution
M
Before fitting the oil pump to the crankcase ensure the pump internal surfaces have been 'wetted' with clean engine oil. The pump may fail to pick-up oil from the sump if the surfaces have not been 'wetted'. This will cause the engine to run without engine oil pressure and will lead to severe engine damage. 1. Install a new 0-ring to the inlet sleeve on the water pump body. Fill the oil pump with new engine oil, turning the pump rotor as the oil is poured in to ensure all surfaces are coated with oil.
M
2.
on
I UMP
8.13
Lubrication
9. Refit the oil pump drive chain cover to the oil pump and fit new bolts. Tighten the bolts to 12 Nm. 12. Install three new O-rings to the coolant outlet pipe and position the pipe through the crankcase, locating it to the water pump outlet. Install a new fixing and ti ghten to 9 Nm.
1. Oil pump 2. Fixings 3. Drive chain cover 1. Coolant outlet pipe 2. Fixing
10. Refit the oil pump drive chain guide. Install new fixings and tighten to 9 Nm. 11. Install a new O-ring to the coolant inlet elbow and position the elbow to the water pump inlet. Fit a new bolt and tighten to 9 Nm.
13. Install a new 0-ring to the oil pick-up and refit the oil pick-up. Fit new bolts and tighten to 12 Nm. 14. Install two new O-rings to the oil transfer pipe and refit the oil transfer pipe. Fit new bolts and tighten to 12 Nm. 15. Refit the clutch (see page 4-9). 16. Refit the sump, ensuring the water pump drain tube is correctly installed (see page 8-16). 17. Reconnect the battery, positive (red lead) first. 18. Refit the rider's seat (see page 16-17). 19. Refill the engine with oil (see page 8-7). 20. Refill the cooling system (see page 11-7 for Daytona 675, or page 11-9 for Street Triple and Street Triple R).
1. Coolant inlet elbow 2. Fixing
8.14
t uMP
Lubrication
Low Oil Pressure Warning Light Switch
The low oil pressure warning light switch is located in the upper crankcase, behind the cylinder head.
Sump
Removal
1. 2. 3.
Remove the rider's seat (see page 16- 17). Disconnect the battery, negative (black) lead first. Drain the engine oil (see page 8-7).
. Warning
The oil may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.
Warning 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. 4. Remove the exhaust system (see page 10-116 for Daytona 675 or page 10-122 for Street Triple and Street Triple R).
1. Low oil pressure warning light switch 2. Electrical connection
1. 2. 3. 4.
Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Disconnect the electrical connection to the switch. Remove the switch and collect the copper washer.
I nstallation
Warning
1. 2. 3. 4.
Incorporating a new copper washer, fit the switch and tighten to 13 Nm. Refit the electrical connection. Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
The exhaust system will be hot if the engine has recently been running. Always allow sufficient time for the exhaust to cool before working on or near the exhaust system. Contact with a hot exhaust could result in burn injuries. 5. Release the bolts securing the sump to the lower crankcase.
1. Sump 2. Fixings
I UMP
8.15
Lubrication
6. Detach the sump and collect the water pump drain tube. Remove and discard the four drain tube 0-rings. Note: The water pump drain tube may remain attached to the water pump or become detached with the sump. 8. If necessary, release and discard the oil transfer pipe fixings and remove the oil transfer pipe. Remove and discard the two 0-rings from the crankcase.
1. Oil transfer pipe 2. Fixings
Installation 1. Water pump drain tube 2. 0-rings Note: From engine number 395930 a new sump gasket/baffle was introduced and is retrofitable.
CG
2
1. Oil transfer pipe 2. Fixings 1.
AASZ z
If removed, fit the oil transfer pipe incorporating new 0-rings. Fit new fixings and tighten to 12 Nm.
1. Gasket 2. Gasket/baffle 7. Up to engine number 395929 only: Remove and discard the sump gasket. From engine number 395930 only: Remove the sump gasket/baffle.
8.16
I UMP
Lubri cation
2. Incorporating new 0-rings, position the water pump drain tube to the oil pump. Note: 6. 7. 8. 9. 10. 11. CM Use new exhaust askets at the dowpp e n i 9 connections with the cylinder head. Fill the engine with the correct grade of engine oil (see page 8-6). Reconnect the battery, positive (red) lead first. Start the engine and ensure that the low oil pressure warning light goes out shortly after starting. Stop the engine and check the engine oil level. Adjust if necessary (see page 8-6). Daytona 675 only: Refit the lower fairings (see page 16-20). Refit the rider's seat (see page 16-17).
1. Water pump drain tube 2. O-rings
3.
Up to engine number 395929 only: Incorporating a new sump gasket/baffle, position the sump to the lower crankcase. From engine number 395929 only: Check the sump gasket/baffle for wear or damage, replace if necessary. Position the sump to the lower crankcase. Tighten the sump fixings to 12 Nm.
4.
5-
1. Sump 2. Fixings 5. Refit the exhaust system (see page 10-119 for Daytona 675 or page 10-124 for Street Triple and Street Triple 10.
ll1MP
8.17
Lubrication
Heat Exchanger
Removal
Note: Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly. 1. 2. 3. 4. 5. 6. Position the motorcycle on level ground on the sidestand. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Daytona 675 only: Remove the lower fairings (see page 16-20). Drain the coolant (see page 11-6 for Daytona 675, or page 11-8 for Street Triple and Street Triple R). Drain the engine oil (see page 8-7).
1. Heat exchanger 2. Centre bolt 3. Coolant hose clips
8.
Remove the centre bolt from the heat exchanger and withdraw it from the crankcase. Remove and discard the heat exchanger O-ring and the centre bolt sealing washer.
AW,
Ming
Inspection
1. Check the heat exchanger body for corrosion and/or damage.
The oil may be hot to the touch. Contact with hot engine oil may cause skin to be scalded or burnt.
I. Warning
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. 7. Disconnect the coolant hoses from the heat exchanger.
8.18
^ UMp
Lubrication
Installation 1. Fit a new O-ring to the heat exchanger, and a new sealing washer to the centre bolt. 3. Fit the coolant hoses to the heat exchanger and tighten the coolant hose clips.
1. Heat exchanger 2. Centre bolt 1. Centre bolt 2. Sealing washer 3. Heat exchanger 4. 0-ring Note: To ensure correct positioning, ensure that the tab on the heat exchanger locates in the boss provided in the crankcase. 3. Coolant hoses
4.
Refill the cooling system (see page 11-7 for Daytona 675 and page 11-9 for Street Triple and Street Triple R). Refill the engine with oil (see page 8-7).
Daytona 675 only: Refit the lower fairings (see
5.
6.
page 16-22). 7.
U.
Reconnect the battery, positive (red) lead first. t e engine an c ec or of I I eak s. O n ce a eak d h kf 1 check has been made, stoptthe engine and allow to stand for 3 minutes. Adjust the engine oil level (see page 8-6). Refit the rider's seat (see page 16-17).
h S tart
ACaution
Do not rely on the tab to hold the heat exchanger in position while tightening the centre bolt. The tab will bend and will not prevent the heat exchanger from turning. Instead, firmly hold the heat exchanger in position by hand.
1
9. 10.
1. Heat exchanger tab 2. Crankcase boss
2.
Fit the heat exchanger to the crankcase and tighten the centre bolt to 59 Nm.
I UMP
8.19
Im
Table of Contents
9 Engine Removal/Refit
ExplodedView - Frame Fixings ..............................................................
En
9.2 9.3 9.3 9.4
ineRemoval/Refit
......................................................................
Removal........................................................................... Installation..........................................................................
Il1MP
9.1
Engine Removal/Refit
Exploded View - Frame Fixings
See
text 48 Nm
\
6 Nm 48 Nm
<
o 48 Nm
See Nm
^ D 48 Nm
-^
text
text
9.2
ll1MP
Engin e Removal/Refit
Removal 1. 2. 3. Remove the seat(s) (see page 16-17). Disconnect the battery, negative (black) lead first and remove the battery (see page 17-14). Place the motorcycle on a paddock stand. 19. 20. Note the position of the two spacers installed to the lower gearbox bolt, one on either side of the engine. Release the nuts securing the rear gearbox mounting bolts and remove the two bolts. Collect the two spacers from the lower bolt.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 4. Remove the rear panel(s) (see page 16-18 for Daytona 675 or page 16-19 for Street Triple and Street Triple R). Daytona 675 only: Remove the lower fairings (see page 16-20). Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Remove the throttle bodies (see page 10- 106). Drain the engine oil (see page 8-7).
1. Rear gearbox bolt 2. Right hand spacer
5. 6. 7 8. 9.
10. Drain the coolant (see page 11-6 for Daytona 675 or page 11-8 for Street Triple and Street Triple R). 11. Remove the radiator (see page 11-13 for Daytona 675, or page 11-1S for Street Triple and Street Triple R). Note: Secure the coolant hoses to prevent damage as the engine is removed.
1. Left hand spacer
12. Remove the exhaust system completely (see page 10-116 for Daytona 675 or page 10-122 for Street Triple and Street Triple R).
ti.
13. Set the drive chain adjustment to allow maximum free play in the chain (see page 12-7). 14. Disconnect the gearchange linkage at the gearbox shaft. 15. Remove the sprocket cover.
Caution
To prevent chain damage, do not allow the chain to come into contact with dirt, road grit etc. 16. Disconnect all electrical connections from the main harness to the engine. 17. Disconnect the clutch cable (see page 4- 5). 18. Place a support beneath the engine and ensure that the frame is still adequately and securely supported.
I UMP
9.3
Note: The frame is fitted with four frame adjuster sleeves, located on the left hand side of the frame, as shown below. 23. Using tool T3880103, slacken the centre and front frame adjuster sleeves.
C]
2 4
COLIC
1. Front frame adjuster position 2. Centre frame adjuster position 3. Rear upper frame adjuster position 4. Rear lower frame adjuster position 21. Using tool 13880103, slacken the two rear frame adjuster sleeves.
1.Tool T3880103 2. Front frame adjuster 3. Centre frame adjuster 24. Remove the two remaining (right hand) engine mounting bolts and lower the engine sufficiently to allow the drive chain to be detached from the output sprocket. Remove the engine from the frame.
25.
A
Installation 1. 2.
Caution
To prevent damage to components, lower the engine very carefully.
Position the engine beneath the frame. Raise the engine, looping the drive chain over the output sprocket as it is raised.
, 1.Tool T3880103 2. Rear upper frame adjuster 3. Rear lower frame adjuster 22. Release the nuts securing the left hand centre and front engine mounting bolts and remove the bolts.
Caution
Unless the following engine mounting bolt installation/ tightening sequence is precisely followed, severe frame damage can occur. 3. Align the engine to the frame and carefully fit the right hand centre engine mounting bolt (located at the rear of the cylinder head) ensuring the engine is still adequately and securely supported. Align the left hand centre engine mounting and using tool T3880103, tighten the frame adjuster to 3 Nm. Carefully fit the bolt but do not fully tighten at this stage.
4.
9.4
t uMP
5. Temporarily insert the lower rear (gearbox) bolt from the left hand side, ensuring the two spacers are installed as noted during removal, The bolt should only be inserted far enough to support the two spacers, as fully inserting the bolt will restrict access to the frame adjuster sleeve. Do not fit the nut. Note: The frame is fitted with four frame adjuster sleeves, located on the left hand side of the frame, as shown below.
1. Rear gearbox bolt 2. Right hand spacer
1. Front frame adjuster position 2. Centre frame adjuster position 3. Rear upper frame adjuster position 4. Rear lower frame adjuster position 6. Using tool T3880103, tighten the two rear frame adjuster sleeves to 10 Nm.
1. Left hand spacer 1. Tool T3880103 2. Rear upper frame adjuster 3. Rear lower frame adjuster 7. Fit the right hand front bolt (located at the front of the cylinder head), fit a new nut and tighten to 48 Nm.
1L1MP
Service Manual -Daytona 675, Street Triple and Street Triple R
9.5
8. Remove the left hand centre engine mounting bolt fitted earlier and recheck the torque on the frame adjuster, using tool T3880103. Re-tighten the adjuster to 3 Nm. Refit the bolt, and tighten to 48 Nm. 19. Refit the sprocket cover and tighten the bolts to 9 Nm. 20. Fit new seals to the cylinder head. Ensure that the face of the seal with the tab is facing the cylinder head.
MM 1. Tool T3880103 2. Centre frame adjuster 9. Tighten the right hand centre bolt to 48 Nm. 10. Remove the lower rear (gearbox) bolt from the right hand side and insert it from the left hand side. Fit a new nut and tighten to 48 Nm. 11. Using tool T3880103, tighten the front frame adjuster to 3 Nm. 1. Cylinder head 2. Seal 3. Seal tab 21. Refit the exhaust system (see page 10-119 for Daytona 675 or page 10-124 for Street Triple and Street Triple R). Refit the radiator (see page 11-14 for Daytona 675 or page 11-16 for Street Triple and Street Triple R). Fill the engine with oil of the correct grade and viscosity (see page 8-7). Refit the throttle bodies (see page 10- 108). Check the throttle cable adjustment (see page 10103). Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90). Daytona 675 only: Refit the lower fairings (see page 16-22). Refit the rear panel(s) (see page 16-18 for Daytona 675 or page 16-19 for Street Triple and Street Triple R). Refit the battery to the battery box and reconnect, positive (red) lead first (see page 17-15). Refill the cooling system (see page 11-7 for Daytona 675, or page 11-9 for Street Triple and Street Triple R). Remove the motorcycle from the paddock stand and place on the side stand. Refit the seats (see page 16-17).
22. 23. 24. 25. 26. 27. 28. 29.
ri
30. 1.Tool T3880103 2. Front upper frame adjuster 12. Fit the upper rear (gearbox) bolt from the left hand side. Fit a new nut and tighten to 48 Nm. 13. Fit the left hand front bolt and fit a new nut. Tighten to 48 Nm. 14. Remove the support from beneath the engine. Reconnect all electrical connections to the engine. 31.
32. 33.
15. Refit the clutch cable (see page 4-6). 16. 17. Set the drive chain adjustment (see page 12-7). 18. Refit the gearchange linkage.
9.6
Il1MP
Fuel System/Engine Management
10 Fuel System/Engine Management

ExplodedView - Fuel Tank and Fuel Pump ................................................... ExplodedView - Fuel Rail, Throttles and Injectors .............................................
Ex
10.7 10.8 10.9 10.10 10.11 10.12 10.13 10.14 10.15 10.15 10.15 10.15 10.15 10.15 10.15 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.16 10.17 10.17 10.17 10.17 10.17
lodedView
- Airbox - Daytona 675 ......................................................
Exploded View - Airbox - Street Triple and Street Triple R ............. ........................ ExplodedView - Exhaust System - Daytona 675 ............................................. Exploded View - Exhaust System - Street Triple and Street Triple R ..............................
Ex
p lodedView - Evaporative System .......................................................
ExplodedView - Secondary Air Injection .................................................... FuelRequirements ...................................................................... FuelRequirements - all countries except USA......... .................................. FuelRequirements - USA ............................................................ OxygenatedGasoline ............................................................... Ethanol........................................................................... Methanol.......................................................................... MTBE(Methyl Tertiary Butyl Ether) .................................................... Glossaryof Terms ....................................................................... Airtemperature .................................................................... Airtemperature sensor .............................................................. ATDC ............................................................................. Barometricpressure ................................................................. Batteryvoltage ..................................................................... BTDC ............................................................................. Catalyst........................................................................... Closedthrottle position .............................................................. Coolanttemperature ................................................................ Coolanttemperature sensor .......................................................... Coolingfan status .................................................................. DTC.............................................................................. ECM.............................................................................. Enginespeed ...................................................................... EXBV............................................................................. Falldetection ...................................................................... Freezeframe ....................................................................... Gearposition sensor ................................................................ Idlefuel trim ....................................................................... Idlefueling ........................................................................ Idlereference speed ................................................................ Ignitionadvance .................................................................... Ignitionswitch position ..............................................................
I nitiontiming
.....................................................................
In ector
j Lambda02 Sensor ................................................................. Longterm fuel trim ................................................................. MAPsensor .......................................................................
p ulse ti me ..................................................................
ll.i MP
1 0.1

MIL.............................................................................. Opencircuit ....................................................................... Overtemp ........................................................................ Primarythrottle position sensor ....................................................... Primarythrottle stepper motor .......................................................
evalve duty cycle .............................................................. g Roadspeed sensor ................................................................. Pur
10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.17 10.18 10.18 10.18 10.19 10.20 10.21
Secondaryair injection .............................................................. Sensorsupply voltage ............................................................... Shortcircuit ....................................................................... Shortterm fuel trim ................................................................ Sidestandstatus .................................................................... Targetdwell time ................................................................... Throttleposition .................................................................... Throttlevoltage .................................................................... TDC .............................................................................. Vbatt............................................................................. EngineManagement System .............................................................. SystemDescription ................................................................. SystemSensors .................................................................... SensorLocations ................................................................... SystemActuators .................................................................. ActuatorLocations .................................................................. Engine Management Circuit Diagram - Daytona 675 - up to VIN 300525 withoutthe Fuel Pump Relay ............................................................. Engine Management Circuit Diagram - Daytona 675 - up to VIN 300525 withoutthe Fuel Pump Relay ............................................................. Fuel Purnp Circuit Diagram - Daytona 675 - from VIN 300526 to VIN 323544 withthe Fuel Pump Relay ................................................................ Fuel Pump Circuit Diagram - Daytona 675 - from VIN 300526 to VIN 323544 withthe Fuel Pump Relay ................................................................ Circuit Diagram - Engine Management System - Daytona 675 - from VIN 323545 to VIN 381274... Circuit Diagram - Engine Management System - Daytona 675 - from VIN 323545 to VIN 381274... Circuit Diagram - Engine Management System - Daytona 675 - from VIN 381275 ................ Circuit Diagram - Engine Management System - Daytona 675 - from VIN 381275 ................ Engine Management Circuit Diagram - Street Triple and Street Triple R ......................... Engine Management Circuit Diagram - Street Triple and Street Triple R ......................... SystemDiagnostics ...................................................................... On-board Fault Detection System .................................................... DiagnosticTool Connection ......................................................... TriumphDiagnostic Software .............................................................. BuildData ........................................................................ CurrentData ..................................................................... SensorData ......................................................................
Ada tionStatus
10.22
10.23
10.24
10.25 10.26 10.27 10.28 10.29 10.30 10.31 10.32 10.32 10.32 10.33 10.33 10.34 10.35 10.37
....................................................................
1 0.2
I UMP

FunctionTests ..................................................................... Adj st
u Tune
10.38 10.39 10.39 10.40 10.43 10.43 10.43 10.43 10.43 10.43 1 0.44 10.44 10.45 10.45 10.46 10.46 10.48 10.48 10.50 10.50 1 0.52 1 0.52 10.54 10.54 10.56 10.56 10.58 10.58 10.60 1 0.60 10.61 10.61 10.62 10.62 10.63 10.63 10.64 10.65 10.65 10.66 10.66 10.67 10.67
. ......................................................................
Freeze-frame Data ................................................................. DiagnosticTrouble Codes ........................................................... ElectricalConnectors ..................................................................... BeforeDisconnection :.............................................................. WhenDisconnecting a Connector :................................................... WhenInspecting a Connector :....................................................... WhenConnecting a Connector :...................................................... Disconnectionof ECM connectors .................................................... Reconnectionof ECM connectors .................................................... Fu rt herDiagnosis ....................................................................... CrankshaftSensor ....................................................................... PinpointTests ..................................................................... IdleSpeed Control ...................................................................... PinpointTests ..................................................................... FuelInjectors ........................................................................... PinpointTests ..................................................................... ThrottlePosition Sensor .................................................................. PinpointTests ..................................................................... PurgeValve ............................................................................ PinpointTests ..................................................................... IgnitionCoils ...........................................................................
Pin ointTests
.....................................................................
CoolantTemperature Sensor .............................................................. PinpointTests ..................................................................... IntakeAir Temperature Sensor ............................................................ PinpointTests ..................................................................... SystemVoltage ......................................................................... PinpointTests ..................................................................... CoolingFan Relay ....................................................................... ^-Pinpoint Tests............... ....................................................... LambdaSensor ......................................................................... PinpointTests ..................................................................... LambdaSensor Heater ...................................................................
Pin ointTests
.....................................................................
EEPROMError ..........................................................................
Fall Detection Switch .....................................................................

PinpointTests ..................................................................... VehicleSpeed Sensor .................................................................... PinpointTests ..................................................................... InstrumentCommunication (CAN) .........................................................
Pin
ointTests
.....................................................................
L UMP
1 0.3

FuelLevel Sensor .......................................................................
Pin
10.68 10.68 10.69 10.69 10.70 10.70 10.71 10.71 10.72 10.72 10.74 10.74 10.76 10.76 10.78 10.78 10.80 10.80 10.81 10.81 10.82 10.82 10.84 10.84 10.85 10.85 10.86 10.87 10.87 10.88 10.89 10.89 10.90 10.91 10.91 10.92 10.92 10.92 10.93 10.95 10.95
ointTests
.....................................................................
Ambient(Barometric) Pressure Sensor ...................................................... PinpointTests ..................................................................... ManifoldAbsolute Pressure (Map) Sensor ................................................... PinpointTests ..................................................................... GearPosition Sensor .....................................................................
Pin
ointTests
......................................................................
SecondaryAir Injection Valve .............................................................

Pin
ointTests
.....................................................................
Fuel Pump - up to VIN 300525 - without Fuel Pump Relay .................................... PinpointTests ..................................................................... FuelPump - from VIN 300526 - with Fuel Pump Relay ....................................... PinpointTests ..................................................................... IntakeAir Flap Solenoid - Daytona 675 only ................................................. PinpointTests ..................................................................... Exhaust Butterfly Valve (EXBV) Position Sensor - Daytona 675 only ............................. PinpointTests ..................................................................... Exhaust Butterfly Valve (EXBV) Motor - Daytona 675 only ..................................... PinpointTests ...................................................................... EMSMain Relay Circuit .................................................................. PinpointTests ..................................................................... EMSIgnition Voltage Input Circuit ......................................................... PinpointTests ..................................................................... 5 Volt Sensor Supply Circuit ..............................................................
Pin
ointTests
.....................................................................
TuneLock .............................................................................. ECMor Tune ID Incorrect ................................................................ PinpointTests ..................................................................... Fault Finding - Non Electrical .............................................................. FuelTank .............................................................................. Removal......................................................................... Installation....................................................................... Fuel Tank - Raising and Supporting - Street Triple and Street Triple R only ..... .................. Fuel Tank - Lowering and Securing - Street Triple and Street Triple R only .......... ............. FuelPump, Fuel Filter and Low Fuel Level Sensor ............................................ Removal......................................................................... Installation....................................................................... FuelPressure Checking .................................................................. FuelDelivery System .................................................................... Airbox................................................................................
1 0.4
IL1MP

Removal......................................................................... Inspection........................................................................ Installation........................................................................ AirFilter Element ........................................................................ Removal......................................................................... Installation........................................................................ IntakeAir Temperature Sensor ............................................................ 10.95 10.96 10.96 10.97 10.97 10.97 10.98 10.98 10.98 10.98 10.98 10.98 10.99 10.99 10.99 10.99 10.99 10.99 10.100 10.100 10.100 10.100 10.100 10.100 10.101 10.101 10.101 10.101 10.101 10.101 10.102 10.103 10.103 10.103 10.104 10.105 10.105 10.106 10.106 10.107 10.108 10.109 10.110 10.110
Removal......................................................................... Installation........................................................................ MapSensor ............................................................................ Removal......................................................................... Installation........................................................................ BarometricPressure Sensor - Daytona 675 only .............................................. Removal......................................................................... Installation........................................................................ Barometric Pressure Sensor - Street Triple and Street Triple R only .............................. Removal......................................................................... Installation........................................................................ Fall Detection Switch - Daytona 675 only ................................................... Removal......................................................................... Installation........................................................................ Fall Detection Switch - Street Triple and Street Triple R only ................................... Removal......................................................................... Installation........................................................................ IntakeAir Duct - Daytona 675 only ....................................................... Removal......................................................................... Installation........................................................................ IntakeAir Flap Actuator - Daytona 675 only ................................................ Operation........................................................................ Removal......................................................................... Installation........................................................................ Crankshaftposition sensor ............................................................... ThrottleCable ......................................................................... Adjustment....................................................................... Removal......................................................................... Inspection........................................................................ Installation........................................................................ ThrottleBodies/Injectors ................................................................. Removal......................................................................... Inspection........................................................................ Installation........................................................................ ThrottleBody Balancing .................................................................
ThrottlePosition Sensor ................................................................. Removal.........................................................................
L UMP
1 0.5

Installation....................................................................... IdleSpeed Control Stepper Motor ........................................................ Removal......................................................................... Installation....................................................................... EngineManagement Adaption ........................................................... GeneralInformation ............................................................... AdaptionStatus ................................................................... Terminology...................................................................... TypicalValues .....................................................................
Forcin ada
10.110 10.112 10.112 10.112 10.115 10.115 10.115 10.115 10.115 10.115 10.116 10.116 10.119 10.119 10.122 10.122 10.124 10.126 10.126 10.127 10.128 10.128 10.129 10.129 10.131 10.134 10.134 10.135 10.135 10.135 10.135 10.135 10.136 10.136 10.137 10.137 10.137 10.138 10.139
p tion to take place .......................................................
ExhaustSystem - Daytona 675 ........................................................... Removal......................................................................... Inspection........................................................................ Assembly........................................................................ ExhaustSystem - Street Triple and Street Triple R ........................................... Removal......................................................................... Assembly........................................................................ ExhaustButterfly Valve Actuator - Daytona 675 only ........................................ Removal......................................................................... Installation....................................................................... ExhaustButterfly Valve Cables - Daytona 675 only .......................................... Removal......................................................................... Inspection........................................................................ Installation....................................................................... Exhaust Butterfly Valve Cable Adjustment - Daytona 675 only ................................ SecondaryAir Injection ................................................................. SystemPurpose and Operation ...................................................... SecondaryAir Injection Solenoid Valve .................................................... Removal......................................................................... Installation....................................................................... SecondaryAir Injection Reed Valves ...................................................... Removal......................................................................... Inspection........................................................................ Installation....................................................................... EvaporativeEmissions Control System ..................................................... California Models Only ............................................................. ComponentLocations .............................................................. EvaporativeControl System - Engine Off .............................................. EvaporativeControl System - Engine Running .........................................
1 0.6
I UMP

Exploded View - Fuel Tank and Fuel Pump
9 Nm
H-. `
c
I
i
9 Nm
9 Nm
E^^J
See text
1LIMP
1 0.7

Exploded View - Fuel Rail, Throttles and Injectors
3.5 Nm
3.5 N m
1 0.8
L UMP

Exploded View - Airbox - Daytona 675
1.5 Nm
6N
3 Nm
3 Nm
7
7 Nm
7 Nm
I UMP
1 0.9

Exploded View - Airbox - Street Triple and Street Triple R
4 Nm 9
1.5 Nm
6 Nm
4 Nm
3 Nm
7 Nm
11*
7 Nm
4 ii
1 0.10
IllMP

Exploded View - Exhaust System - Daytona 675
e e
10 Nm ^
o
^ I o
0
27 Nm
\_
15 Nm
4
4
9Nm 5 Nm
^ Ô
12 Nm
2 Nm 19 Nm
/ 12
Nm
lllMP
10.11

Exploded View - Exhaust System - Street Triple and Street Triple R
7-// /
8 Nm
\ From VIN 330766
/N
/, /
8 Nm / 15 Nm ^/' Nm \
Up to VIN 330765
j/ 77
%/
15 Nm 8 Nm
/.
'/ 10 \ 15 Nm \'/ 22 Nrr
m
a
See text
19 Nm
5 Nm
1 0.12
S UMP

Exploded View - Evaporative System
M
m 8 Nm m 3 Nm a \
NI
\\
8 Nm
I UMp
10.13

Exploded View - Secondary Air Injection
9 Nm
1 0.14
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Fuel Requirements
Fuel Requirements - all countries except USA
Outside of America, Daytona 675 must be run on 95 RON (or higher) unleaded fuel, and Street Triple and Street Triple R must be run on 91 RON (or higher) unleaded fuel.
Methanol
ACaution
Fuels containing methanol should not be used in Triumph motorcycles as damage to components in the fuel system can be caused by contact with methanol.
MTBE (Methyl Tertiary Butyl Ether) Fuel Requirements - USA

In the United States of America where the octane rating of fuel is measured in a different way, the following information may be applied: Daytona 675 is designed to run on unleaded gasoline with a CLC or AKI octane rating (R+M)/2 of 89 or higher. Street Triple and Street Triple R are designed to run on unleaded gasoline with a CLC or AKI octane rating (R+M)/2 of 87 or higher. Note: If 'knocking' or 'pinking' occurs at a steady engine speed under normal load, use a different brand of gasoline or a higher octane rating. The use of gasolines containing up to 15% MTBE (Methyl Tertiary Butyl Ether) is permitted in Triumph motorcycles.
Caution
The use of leaded gasoline is illegal in some countries, states or territories and will invalidate the vehicle and emissions control warranties. Additionally, leaded gasoline will cause damage to emissions control components.
Oxygenated Gasoline
To help in meeting clean air standards, some areas of the U.S. use oxygenated gasoline to help reduce harmful emissions. This model will give best performance when using unleaded gasoline. However, the following should be used as a guide to the use of oxygenated fuels.
Caution
Because of the generally higher volatility of oxygenated fuels, starting, engine response and fuel consumption may be adversely affected by their use. Should any of these difficulties be experienced, run the motorcycle on normal unleaded gasoline.
Ethanol
Ethanol fuel is a mixture of 10% ethanol and 90% gasoline and is often described under the names 'gasohol', 'ethanol enhanced', or 'contains ethanol'. This fuel may be used in Triumph motorcycles.
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Glossary of Terms
The following terms and abbreviations will be found in this section. Below is given a brief explanation of what some of the more common terms and abbreviations mean.
DTC
Diagnostic Trouble Code.
ECM
Engine Control Module.
Air temperature
The air temperature in the air box and intake system.
Engine speed
The crankshaft revolutions per minute.
Air temperature sensor EXBV

Sensor located in the airbox to detect the temperature of the incoming air. Exhaust Butterfly Valve.
ATDC
After Top Dead Centre (TDC).
Fall detection
The fall detection switch will detect if the motorcycle is on its side and will cut power to the ECM immediately.
Barometric pressure
Pressure of the ambient air.
Freeze frame
A data set captured at the time a Diagnostic Trouble Code (DTC) is set.
Battery voltage
The voltage at the input to the Electronic Control Module (ECM).
Gear position sensor

Gearbox mounted sensor which delivers information to the ECM. This is converted to the gear position value that is displayed on the instrument's gear position indicator and/or neutral lamp.
BTDC
Before Top Dead Centre (TDC).
Catalyst
Device placed in the exhaust system which reduces exhaust emissions by stimulating secondary combustion of the exhaust gases.
Idle fuel trim

The percentage above or below the nominal fuel requirement for the volume of air entering at idle.
Idle fueling Closed throttle position

Throttle position at idle (i.e. against end stop), measured as a voltage and expressed as percentage. Adjustment of fueling at idle to suit the actual air inducted.
Idle reference speed

The target idle speed as determined by the Electronic Control Module (ECM). (It should be the same as the actual idle speed if the motorcycle is operating correctly.)
Coolant temperature
The coolant temperature in the cylinder head.
Coolant temperature sensor

Sensor which detects coolant temperature.
Ignition advance
The timing of the ignition at the spark plug relative to top dead centre (TDC).
Cooling fan status Ignition switch position

The 'on' or 'off condition of the cooling fan. The 'ON' or 'OFF' position of either or both the ignition switch and the engine stop switch.
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Ignition timing
Same as 'ignition advance'.
Road speed sensor

Gearbox mounted sensor which delivers information to the ECM. This is converted to the road speed value that is then displayed on the speedometer.
Injector pulse time

The time during which an injector remains open (i.e. delivering fuel).
Secondary air injection

The secondary air injection system helps reduce levels of pollutants in the exhaust gases. It does this by introducing a small amount of air into each exhaust port which promotes further combustion of the fuel mixture in the exhaust system after it has left the combustion chamber.
Lambda 0 2 Sensor
The Lambda sensor measures the Oxygen levels in the exhaust gases and feeds this information to the ECM. Based on this information, adjustments to air/fuel ratio are made.
Sensor supply voltage

Supply voltage to the system sensors (nominally 5 Volts).
Long term fuel trim

Fueling after adapting to the engine's long term fueling requirements (closed loop only). See also short term fuel tri m.
Short circuit
A 'short cut' in an electrical circuit - current by-passes the intended circuit (usually to earth).
MAP sensor
Manifold Absolute Pressure (the air pressure in the intake system). Measured after the throttle valves. This reading is compared to the ambient pressure reading to allow the ECM to calculate engine load.
Short term fuel trim

A correction applied to the fuel mixture during closed loop catalyst operation. This, in turn has an effect on the long term fuel trim in that, if an engine constantly requires mixture correction, the long term fuel trim will adapt to this requirement thus reducing the need for constant short term adjustment.
MIL
Malfunction Indicator Lamp. Ill uminates when most Diagnostic Trouble Codes (DTCs) are set.
Sidestand status
The 'up' or 'down' position of the side stand.
Open circuit
A break in an electrical circuit - current cannot flow.
Target dwell time

The actual time from coil 'on' to coil 'off'.
Over temp
High temperature within the Electronic Control Module (ECM) caused by an internal or external failure.
Throttle position
The position of the throttle butterfly given as a percentage of the movement range. When the data is displayed on the diagnostic software, fully open need not be 100% nor fully closed 0%.
Primary throttle position sensor

Sensor for the primary (lower) throttle position.
Throttle voltage Primary throttle stepper motor

Stepper motor used to vary throttle opening at idle and when the engine is cold. Voltage at the throttle potentiometer.
TDC
Top Dead Centre.
Purge valve duty cycle

The time the purge valve is open in an open/close cycle, expressed as a percentage of the cycle time.
Vbatt
Battery voltage.
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Engine Management System
System Description The Daytona 675, Street Triple and Street Triple R models are fitted with an electronic engine management system which encompasses control of both ignition and fuel delivery. The electronic control module (ECM) draws information from sensors positioned around the engine, cooling and air intake systems and precisely calculates ignition advance and fueling requirements for all engine speeds and loads. In addition, the system has an on-board diagnostic function. For additional information, see page 10-32. from which the actual crankshaft position is calculated. The crankshaft position sensor information is used by the ECM to determine engine speed and crankshaft position in relation to the point where fuel is injected and ignition of the fuel occurs. Engine coolant temperature sensor situated at the rear of the cylinder head. Coolant temperature information, received by the ECM, is used to optimise fueling at all engine temperatures and to calculate hot and cold start fueling requirements. Throttle position sensor - situated at the right end of the throttle body. Used to relay throttle position information to the ECM. Throttle opening angle is used by the ECM to determine fueling and ignition requirements for all throttle positions. Road speed sensor - situated in the upper crankcase, in front of the engine breather. The road speed sensor provides the ECM with data from which road speed is calculated and displayed on the speedometer. Lambda sensor - situated in the exhaust header system upstream of the catalyst. The la mbda sensor constantly feeds information to the ECM on the content of the exhaust gases. Based on this information, adjustments to the air/fuel ratio are made. Side stand switch - situated at the top of the sidestand leg. If the sidestand is in the down position, the engine will not run unless the transmission is in neutral. Gear position sensor - situated in the upper crankcase, behind the gearbox output sprocket cover, on the left hand side of the engine. The gear position sensor provides the ECM with selected gear information. This is used to prevent the engine from starting if the transmission is in gear. The sensor also provides information to the gear position indicator and the neutral lamp in the instruments. Fall detection switch - Daytona 675 situated below the instrument pack. Street Triple and Street Triple R - situated on the relay and fuse box bracket below the fuel tank. The fall detection switch will detect if the motorcycle is on its side and will cut power to the ECM immediately. This prevents the engine from running and the fuel pump from delivering fuel. In the event of a fall, the switch is reset by returning the bike to an upright position and switching the ignition off then back on again.
System Sensors Intake air temperature sensor - situated in the top of the airbox. As the density of the air (and therefore the amount of oxygen available to ignite the fuel) changes with temperature, an intake air temperature sensor is fitted. Changes in air temperature (and therefore air density) are compensated for by adjusting the amount of fuel injected to a level consistent with clean combustion and low emissions. Barometric pressure sensor - Daytona 675 - situated behind the cockpit and below the instrument pack. Street Triple and Street Triple R - situated on the rear subframe, forward of the rear light unit. The barometric pressure sensor measures atmospheric air pressure. With this information, the amount of fuel injected is adjusted to suit the prevailing conditions. Manifold Absolute Pressure (MAP) sensor - situated to the left side of the airbox, connected to each of the three throttle bodies by equal length tubes. The MAP sensor provides information to the ECM which is used at shallow throttle angles (very small throttle openings) to provide accurate engine load indications to the ECM. This degree of engine load accuracy allows the ECM to make very small adjustments to fuel and ignition which would otherwise not be possible from throttle angle data alone. Clutch switch - situated on the clutch lever. The clutch must be pulled in for the starter motor to operate. Crankshaft position sensor - situated in the alternator cover. The crankshaft position sensor detects movement of teeth attached to the alternator rotor. The toothed rotor gives a reference point
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Sensor Locations
\Il
FALL
INTAKE AIR TEMPERATURE SENSOR COOLANT TEMPERATURE SENSOR
//d o ^'
/ O
DETECTION SWITCH w o
00:. _.
%cs;o^y.
LAMBDA SENSOR
^{J INTAKE AIR TEMPERATURE SENSOR COOLANT TEMPERATURE SENSOR a o

O
DETECTION SWITCH
^'
o
f
v
LAMBDA SENSOR
pYd '
BAROMETRIC PRESSURE SENSOR CLUTCH SWITCH THROTTLE POSITION SENSOR
/^ I_ ^_^^ woe o '^^ ^1
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR ROAD SPEED SENSOR
CRANK POSITION SENSOR \^. oòab^ :;Ord: ^ 0
\p
Q
GEAR POSITION SENSOR SIDE STAND SWITCH
CLUTCH SWITCH THROTTLE POSITION SENSOR ROAD SPEED SENSOR CRA TION S K OR o. 77^ I1 :0 o ^ ^
G
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR BAROMETRIC PRESSURE SENSOR GEAR POSITION SENSOR SIDE STAND SWITCH
o `'
=o
/... ^'
-^
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1 0.19

System Actuators In response to signals received from the sensors, the ECM controls and directs messages to a series of electronic and electro-mechanical actuators. The function and location of the actuators is given below. Throttle stepper motor - situated between cylinders two and three of the throttle bodies. The throttle stepper actuates a cam/lever which causes variations in the closed throttle position. Although used primarily to ensure target idle speed is maintained, it also increases throttle opening when the engine is cold. Canister purge valve (California models only) - situated in the vapour return line between the carbon canister and the throttle bodies. The purge valve controls the return of vapour which has been stored in the carbon canister during the period when the engine is switched off. The valve is 'pulsed' by the ECM to give control over the rate at which the canister is purged. Injectors - located on the throttle body. The engine is fitted with three injectors. The spray pattern of the injectors is fixed but the length of time each injector can remain open is variable according to operating conditions. The duration of each injection is calculated by the ECM using data received from the various sensors in the system. Ignition coils - plug-top coils are located in the cam cover. There are three coils fitted, one for each spark plug. The ECM controls the point at which the coils are switched on and off. In calculating the switch-on time, the ECM allows sufficient time for the coils to charge to a level where a spark can be produced. The coils are switched off at the point of ignition, the timing of which is optimised for good engine performance. EMS main relay - Daytona 675 - situated forward of the fuse box. Street Triple and Street Triple R - situated on the relay and fuse box bracket below the fuel tank. When the ignition is switched on, the EMS main relay is powered up to provide a stable voltage supply for the ECM. When the ignition is turned off, the ECM carries out a power down sequence during which the EMS main relay remains powered by the ECM for 1 minute. The ECM power down sequence includes: writing the adaption data to ECM memory and referencing the position of the throttle stepper motor. Fuel pump - located inside the fuel tank. The electric pump delivers fuel into the fuel system, via a pressure regulator, at a constant 3 bar pressure. The pump is run continuously when the engine is operating and is also run briefly when the ignition is first switched on to ensure that 3 bar is available to the system as soon as the engine is cranked. Fuel pressure is controlled by a regulator also situated inside the fuel tank. Cooling fan - located behind the radiator. The ECM controls switching on and off of the cooling fan in response to a signal received from the coolant temperature sensor. When the coolant temperature rises to a level where the cooling effect of natural airflow is insufficient, the cooling fan is turned on by the ECM. When the coolant temperature falls sufficiently, the ECM turns the cooling fan off. The fan only becomes operational when the engine is running. It will not operate at any other time. Secondary air injection solenoid - located forward of the airbox, on the left hand side of the air intake. The secondary air injection solenoid controls airflow through the secondary air injection system. Intake air flap - Daytona 675 only - located in the air intake, between the headlamps. The purpose of the intake air flap is to improve low down power delivery. The intake air flap is closed up to 4500 rpm and 12 degrees of throttle, above which it opens. Exhaust butterfly valve - Daytona 675 only - located in the exhaust headers downstream of the Lambda sensor. The purpose of the exhaust valve is to improve low down power delivery. At idle, the exhaust valve is 30% open, rising to approximately 50% open at 4500 rpm, and fully open at 7000 rpm and above. The profile that the exhaust valve follows has been designed to give no reduction of torque at full throttle. Note: In this system, the starter lockout system (clutch switch, gear position sensor, sidestand switch) all operate through the engine management ECM.
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Actuator Locations
THROTTLE STEPPER MOTOR EXHAUST BUTTERFLY
MoD ., o
^
^`_ 0 c o o
COOLING FAN
VALV
oo_
a^.
I\
IGNITION COILS
E\\\
THROTTLE
STEPPER ^^ ^
IGNITION COILS
G
o
MOTOR
// a
n
c
o O
i 1
COOLING FAN
SECONDARY AIR INJECTION SOLENOID
`_l^
^
/
oe
FUEL PUMP
INTAKE AIR FLAP
FUEL INJECTORS CANISTER PURGE VALVE
MAIN POWER
RELAY
.O`: '
FUEL PUMP SECONDARY AIR INJECTION SOLENOID n

\\ o
j
p
FUEL
I NJECTORS
MAIN POWER RELAY
c
}
'Q
^ 4D
'
CANISTER
PURGE
VALVE
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1 0.21

Engine Management Circuit Diagram - Daytona 675 - up to VIN 300525 without the Fuel Pump Relay
Key To Wiring Circuit Diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Item Description Engine Control Module Diagnostic Connector Instrument Assembly Vehicle Speed Sensor Clutch Switch Starter Relay Sidestand Switch Gear Position Sensor Lambda Sensor Barometric Pressure Sensor Intake Air Temperature Sensor MAP Sensor Coolant Temperature Sensor Fall Detection Switch Throttle Position Sensor Exhaust Butterfly Valve Actuator Low Fuel Sensor Idle Speed Control Stepper Motor Cooling Fan Cooling Fan Relay Fuse Box (fuse 5)
0
Key To Wiring Colour Codes Code B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate/Grey Orange Pink Red Purple White Yellow Light Green Light Blue
ECM Connector Pin Numbering
Connector B (Grey)
B18 B01
Connector A (B(ack)
n0r^Ôn
A 18
q n rr
tn^
A01
'a 00000a00000000000
6b'3666ZS
O
aoo 000â , A36
b ^ E'6eSi^- ei 6`6^Ti3o 6o cÊc ^ .. )
Intake Air Flap Solenoid Ignition Coils Secondary Air Injection Solenoid Engine Stop Switch Fuel Pump Heated Lambda Sensor Purge Valve Fuel Injectors Crankshaft Position Sensor Engine Management System (EMS) Main Relay The above illustration shows the pin numbering system used in the engine management circuit diagram. The black connector's pins are prefixed A and the grey connector's pins B. As viewed from the mating face with the ECM (as per the illustration), pins are numbered from right to left with number one in the top right corner.
B36 B19
A19
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Engine Management Circuit Diagram - Daytona 675 - up to VIN 300525 without the Fuel Pump Relay
31
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Fuel Pump Circuit Diagram - Daytona 675 - from VIN 300526 to VIN 323544 - with the Fuel Pump Relay
Key To Wiring Circuit Diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 Item Description Fuel Pump Relay Secondary Air Injection (SAI) Solenoid Secondary Air Injection (SAI) Connector (Sub harness) Secondary Air Injection (SAI) Connector (Main harness) Secondary Air Injection (SAD In-line Connector (Sub harness) Fuel Pump Fuel Pump Connector (Main harness) Fuel Pump In-line Connector (Sub harness) Engine Earth Engine Control Module Engine Management System (EMS) Main Relay Engine Stop Switch Key To Wiring Colour Codes Code B U N G S 0 K
R
Wiring Colour Black Blue Brown Green Slate/Grey Orange Pink

Red
P W Y LG LU
Purple White Yellow Light Green Light Blue
Connector B (Grey)
B18
a 000 oo 00000 0000000
Connector A (Black)
801 A18 A01
q nrr---ten q G O D O O D O O O D O v O O O D O O
\ t314 -G-6^ti Z! - "Ea`fi -c o 0 6"o tTF

P
A
JJJMMMIII
B36
819
A36
A19
The above illustration shows the pin numbering system used in the engine management circuit diagram. The black connector's pins are prefixed A and the grey connector's pins B. As viewed from the mating face with the ECM (as per the illustration), pins are numbered from right to left with number one in the top right corner.
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Fuel Pump Circuit Diagram - Daytona 675 - from VIN 300526 to VIN 323544 - with the Fuel Pump Relay
FUEL PUMP SUBHARNESS r---------------------------------I
NK -13 NK 1
BP J2
I
213
2 2 -NK
PW
5 I
1 1-YO
Y0
YO
NK
NK
1
4 I5
I
PW
6
B 2
I
I
718
BP 2 1 BP
PW
1 2
NK
B B8 B36 I
9
I
10
I- ------------------------J
11
4 3 1 2 5 -
z
5
12
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1 0.25

Circuit Diagram - Engine Management System - Daytona 675 - from VIN 323545 to VIN 381274
Key To Wiring Circuit Diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Item Description Engine Control Module Diagnostic Connector Instrument Assembly Vehicle Speed Sensor Clutch Switch Starter Relay Sidestand Switch Gear Position Sensor Lambda Sensor Barometric Pressure Sensor Intake Air Temperature Sensor MAP Sensor Coolant Temperature Sensor Fall Detection Switch Throttle Position Sensor Exhaust Butterfly Valve Actuator Low Fuel Sensor Idle Speed Control Stepper Motor Cooling Fan Cooling Fan Relay Fuse Box (fuse 5) Intake Air Flap Solenoid Ignition Coils Secondary Air Injection Solenoid Fuel Pump Heated Lambda Sensor Purge Valve Fuel Injectors Crankshaft Position Sensor Engine Management System (EMS) Main Relay Fuel Pump Relay The above illustration shows the pin numbering system used in the engine management circuit diagram. The black connector's pins are prefixed A and the grey connector's pins B. As viewed from the mating face with the ECM (as per the illustration), pins are numbered from right to left with number one in the top right corner.
B36 B19 A36
B18
Connector B (Grey)
Connector A (B(ack)
n 0 .^-mo o n
Bo1
A18 â o oa00000000oa oac ob ^ J o^000de Io'o` ooc
A01
([- a00000000000000000
ii-ti nâ
o000000r\
A19
1 0.26
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Circuit Diagram - Engine Management System - Daytona 675 - from VIN 323545 to VIN 381274
30
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1 0.27

Circuit Diagram - Engine Management System - Daytona 675 - from VIN 381275
Key To Wiring Circuit Diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Item Description Engine Control Module Diagnostic Connector Instrument Assembly Vehicle Speed Sensor Clutch Switch Starter Relay Sidestand Switch Gear Position Sensor Lambda Sensor Barometric Pressure Sensor Intake Air Temperature Sensor MAP Sensor Coolant Temperature Sensor Fall Detection Switch Throttle Position Sensor Accessory quickshifter Exhaust Butterfly Valve Actuator Low Fuel Sensor Idle Speed Control Stepper Motor Cooling Fan Cooling Fan Relay
a .'l a a F6 O O O O a a O a O
Connector B (Grey)
B18 B01
Connector A (B ( ack)
\ ^
nO ^r-^0 n ^ /
a a oa
A18
u__o aaoo ao o a ao a a a a a d
A01
Fuse Box (fuse 5) Intake Air Flap Solenoid Ignition Coils Secondary Air Injection Solenoid Fuel Pump Heated Lambda Sensor Purge Valve Fuel Injectors Crankshaft Position Sensor Engine Management System (EMS) Main Relay Fuel Pump Relay
B36 B19
aaa00000Sâo6a"3E, , A36 A19
The above illustration shows the pin numbering system used in the engine management circuit diagram. The black connector's pins are prefixed A and the grey connector's pins B. As viewed from the mating face with the ECM (as per the illustration), pins are numbered from right to left with number one in the top right corner.
1 0.28
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Fuel System/Engine Management Circuit Diagram - Engine Management System - Daytona 675 - from VIN 381275
31
lgmp
1 0.29

Engine Management Circuit Diagram - Street Triple and Street Triple R
Key To Wiring Circuit Diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Item Description Engine Management System (EMS) Main Relay Crankshaft Position Sensor Fuel Injector - cylinder 1 Fuel Injector - cylinder 2 Fuel Injector - cylinder 3 Purge Valve Fuse Box (fuse 5) Cooling Fan Relay Idle Speed Control Stepper Motor Cooling Fan Heated Lambda Sensor Secondary Air Injection Solenoid Ignition Coil - cylinder 1 Ignition Coil - cylinder 2 Ignition Coil - cylinder 3 Low Fuel Sensor Fuel Pump Relay Fuel Pump Lambda Sensor Coolant Temperature Sensor Engine Subharness Connector MAP Sensor Gear Position Sensor Quickshifter (Street Triple R only) Intake Air Temperature Sensor Barometric Pressure Sensor Throttle Position Sensor Fall Detection Switch Sidestand Switch Starter Relay Clutch Switch Vehicle Speed Sensor Instrument Assembly Alarm Diagnostic Connector Engine Control Module The above illustration shows the pin numbering system used in the engine management circuit diagram. The black connector's pins are prefixed A and the grey connector's pins B. As viewed from the mating face with the ECM (as per the illustration), pins are numbered from right to left with number one in the top right corner.
B36 B18 Connector B (Grey) Connector A (B(ack)
BO1
A 18
Qnrt^^n0 \ ^
ooc000000000000aoo
,a o a o e o
y
Ao1
(^
^01
0 0 0 0 0 0 0_0_0_0_0_0 o a o 0 ppp 0 00000 o616'b ^ ,
o b o c,
819
A36
A19
1 0.30
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Engine Management Circuit Diagram - Street Triple and Street Triple R
1
IVJI II
3 1
^^ I ^^ ^ r P B UP Al UB A9
36
E23
B5
3Y ^f-BY
N^^34
9
B 35
A24
YS B15
BG
B
7
4
GR
GR
3
1
3 ^
Y
A15
7K -AK4
All B2B
KY
GA
6
5
R
U
R
U BY
33
YP - YP
14
B27
4 9
7
I
1 YB -YB A13 BY 6
J
I 3 3 2
A34 YR -YA B9
KY
1.A
0 ' J 3 1 5
A 4 ON
NK A6
0 A22 A33 60
31
BO
n A"
7
B2 8' 3
1
O W 0 A23 A20 OU U A21 OK K
B 8 B6 N
_JS H
YN
B
'
30
1132 BR
29 ^
10
L n n _ B B21 U 5 KU---{ ^
I K _ ( J 4 B
II
I V'
28
lJ
1
A10 BY- B30
K W 014 KB
3 2
27
61
K P 1 2 26
NK
11
627
620 KB
12
NK ^YO 1 3 YO 38
0
All
A30
0
B '
25
^Y
NK
r---
+ 1^^ 4
24
GK GK B17 821
3
B 2 B 3
K
-B1
NK ^GP
GP AIB
24
15
4K ---23
KB GB
BIB 22e
^ -^
1 ]
ss
K
KB
22
F-
l l-f-BU -BG
14
E[II]
21
K5 2 KB
16
2 5 1 8
M a^
BP
B B B
B
329
B35 B16 1135
^9
1
3
KG
20 0
KB
B19
1
19
A26
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1 0.31

System Diagnostics
The engine management system has an on-board diagnostics feature which allows service technicians to retrieve stored data from the ECM using the Triumph diagnostic software. Full details of the Triumph diagnostic software operation and how to interpret the results are given in the Triumph Diagnostic Tool User Guide. The software is connected, via an interface cable, to the motorcycle using a dedicated diagnostic plug situated beneath the seats. By using a dedicated plug, no electrical connectors associated with the system are disturbed, reducing potential connector damage. The software allows the user to retrieve data associated with the system sensors and actuators, test various component functions, read build data and make minor adjustments to the set-up of the system. The data and tests available are described on the following pages. Note: When a fault has been rectified, the MIL will remain illuminated until sufficient non-fault warm-up cycles have taken place to turn it off. The MIL will be immediately extinguished if, after first rectifying the fault, the DTC (diagnostic trouble code) that caused the MIL illumination is erased from the ECM memory using the Triumph diagnostic software. Note: In most cases, when a fault is detected, the engine management system will revert to a 'li mp-home' mode. In this mode, the engine will still function though the performance and fuel economy may be marginally affected. In some cases, the rider may not notice any appreciable difference from normal operation.
On-board Fault Detection System Diagnostic Tool Connection The on-board diagnostic system has two stages to fault detection. When a fault is detected, the DSM (Diagnostic Status Manager) raises a flag to indicate that a fault is present and increments a counter. The counter checks the number of instances that the fault is noted. For example, if there is a fault in the crankshaft position sensor, the counter will increment its count each time the crankshaft 0 turns through 360 , provided the fault is still present. When the count begins, the fault is detected but not confirmed. If the fault continues to be detected and the count reaches a pre-determined threshold, the fault becomes confirmed. If the fault is an emissions related fault or a serious malfunction affecting engine performance, a DTC (Diagnostic Trouble Code) and freeze-frame data will be logged in the ECM's memory and the MIL (Malfunction Indicator Lamp) on the motorcycle instrument panel is illuminated. Once a fault is confirmed, the number of warm-up cycles made by the engine is counted. If the fault clears, the warm-up cycle counter will extinguish the MIL (Malfunction Indicator Lamp) at a pre determined count, and erase the DTC and freeze frame data from the ECM memory at another (higher) count. A single warm-up cycle is deemed to have taken place when the following criteria have been met: The coolant temperature must be raised to 72 C or more. The coolant temperature must have risen by 23 C or more from its start temperature, when 72 C is reached. A controlled power-down sequence must take place. 1. To connect the Triumph diagnostic interface to the motorcycle, Remove the rider's seat (see page 16-17) and release the diagnostic connector from its locating tang. Plug the diagnostic interface directly in to the diagnostic connector.
2.
1. Diagnostic connector (Daytona 675 shown) 2. Diagnostic interface
3. 4.
When the diagnostic session is completed, disconnect the Triumph diagnostic interface. Refit the diagnostic connector to its locating tang and refit the rider's seat (see page 16-17).
1 0.32
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Triumph Diagnostic Software
Described on the following pages is the range of information which can be retrieved from the ECM's memory and the adjustments which can be performed using the Triumph diagnostic software. The tables indicate which tests are performed by the on-board system and what information can be retrieved by the Triumph diagnostic software. Note: Full details of how to operate the software and how to interpret the data can be found in the Triumph Diagnostic Tool User Guide, which can be downloaded by authorised Triumph dealers from www.triumphonline.net .
Build Data The Build Data screen will display the following information: Motorcycle model; Vehicle Identification Number (VIN); ECM type; ECM I D; ECM serial number; Tune number; Date of last tune download; Total tune downloads since manufacture; The lock status of the ECM (ECM Locked, Unlocked or Not Applicable).
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Current Data The data available under Current Data is: Function Examined Fuel system status 1 Calculated load value Engine coolant temperature Short term fuel trim - Bank 1 Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance - cylinder 1 Intake air temperature Absolute throttle position Bank 1 - oxygen sensor 1 Bank 1 - oxygen sensor 1 - short term fuel trim Volts mm/hg RPM km/h degrees C C Result Reported (Scale) open or closed loop operation
1 0.34
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Sensor Data When using this function it is possible to check the status of various sensors and actuators. The data sets are divided into seven groups - Sensor Voltages; Sensor Readings; Injector Data; Ignition Data; Idle Speed, Throttle Data and Inputs and Adaption Status. Each of these screens is described on the following pages. Sensor Voltages The data available under sensor voltages is: Item Checked Battery voltage Voltage from ignition switch to ECU Air temperature sensor voltage Coolant temperature sensor voltage Atmospheric pressure sensor voltage Manifold absolute pressure sensor 1 voltage Manifold absolute pressure sensor 2 voltage Throttle position sensor voltage Fuel level sensor voltage Oxygen sensor output 1 voltage Exhaust butterfly valve sensor voltage$ Result Unit Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts
4 Applies to models fitted with an exhaust butterfly valve only. All other models will show Not Applicable in this field. Sensor Readings The data available under sensor readings is: Item Checked Air temperature Coolant temperature Atmospheric (barometric) pressure Short term fuel trimt Manifold absolute pressure (one reading per cylinder) Low fuel light Oxygen sensor 1 short term fuel trim Oxygen sensor 1 heater status Exhaust butterfly valve sensor voltaget Result Unit C C mmHg % mmHg on/off % on/off %
t Applies to models fitted with an exhaust butterfly valve only. All other models will show Not Applicable in this field.
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Injector Data The data available under injector data is: Item Checked Injector 1 pulse time Injector 2 pulse time Injector 3 pulse time Ignition Data The data available under ignition data is: Item Checked Ignition timing cyl 1 Ignition timing cyl 2 Ignition timing cyl 3 Coil dwell time Idle Speed and Throttle Data The data available under idle speed and throttle data is: Item Checked Engine speed Idle reference speed Idle speed control current steps Idle speed control target steps Throttle position Secondary air injection statust Result Unit RPM RPM numeric numeric % open SAI on/off Result Unit degrees BTDC degrees BTDC degrees BTDC milliseconds Result Unit milliseconds milliseconds milliseconds
t Applies to models fitted with a Secondary air injection only. All other models will show Not Applicable in this field.
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Sensor Data When using this function it is possible to check the status of various sensors and actuators. The data sets are divided into seven groups - Sensor Voltages; Sensor Readings; Injector Data; Ignition Data; Idle Speed, Throttle Data and Inputs and Adaption Status. Each of these screens is described on the following pages. Sensor Voltages The data available under sensor voltages is: Item Checked Battery voltage Voltage from ignition switch to ECU Air temperature sensor voltage Coolant temperature sensor voltage Atmospheric pressure sensor voltage Manifold absolute pressure sensor 1 voltage Manifold absolute pressure sensor 2 voltage Throttle position sensor voltage Fuel level sensor voltage Oxygen sensor output 1 voltage Exhaust butterfly valve sensor voltage* Result Unit Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts
t Applies to models fitted with an exhaust butterfly valve only. All other models will show Not Applicable in this field. Sensor Readings The data available under sensor readings is: Item Checked Air temperature Coolant temperature Atmospheric (barometric) pressure Short term fuel trim$ Manifold absolute pressure (one reading per cylinder) Low fuel light Oxygen sensor 1 short term fuel trim Oxygen sensor 1 heater status Exhaust butterfly valve sensor voltaget t Applies to models fitted with an exhaust butterfly valve only. All other models will show Not Applicable in this field. on/off mmHg on/off Result Unit C C mmHg
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Injector Data The data available under injector data is: Item Checked Injector 1 pulse time Injector 2 pulse time Injector 3 pulse time Ignition Data The data available under ignition data is: Item Checked Ignition timing cyl 1 Ignition timing cyl 2 Ignition timing cyl 3 Coil dwell time Idle Speed and Throttle Data The data available under idle speed and throttle data is: Item Checked Engine speed Idle reference speed Idle speed control current steps Idle speed control target steps Throttle position Secondary air injection statust Result Unit RPM RPM numeric numeric % open SAI on/off Result Unit degrees BTDC degrees BTDC degrees BTDC milliseconds Result Unit milliseconds milliseconds milliseconds
t Applies to models fitted with a Secondary air injection only. All other models will show Not Applicable in this field.
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Inputs The data available under inputs is: Item Checked EMS Main relay status Fuel pump relay status Starter relay status Starter switch status Side stand status Fall detection switch status Clutch switch status Neutral switch status Gear position status Vehicle speed Malfunction indicator light status Cooling fan status Air flap solenoid statust Calculated load Purge valve duty cyclet % Result Unit relay on/off on/off starter on/off switch on/off up/down normal/over release/grip gear/neutral numeric value or neutral km/h MIL on/off fan on/off off/on
t Applies to models fitted with an intake air flap only. All other models will show Not Applicable in this field. t Applies to models fitted with a purge valve only. All other models will show Not Applicable in this field. Adaption Status Because the fuel system is adaptive, the engine management system is able to automatically adjust to new working conditions, such as changes in altitude, component wear, air leaks etc. This screen displays information on the adaption status of the vehicle which will show if it has adapted or not. Function Examined Closed Throttle Position Adapted Idle speed control adaption status Oxygen sensor 1 adaption range (off idle) Oxygen sensor 1 adaption range (idle) Oxygen sensor 1 adaption status (off idle) Oxygen sensor 1 adaption status (idle) Report Method adapted/not adapted % % % % %
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Function Tests The system allows the diagnostic software to perform a series of function tests on various actuators in the engine management system. In some cases it is necessary to make a visual observation of a component and in others, if faults are present, DTCs will be logged. The function tests available are: Function Examined Instrument Panel Idle Air Control Stepper Motort Purge Valvet Fuel Pump - Priming Fuel Pump - Continuous Operation Report Method Observe instrument panel, refer to service manual Observe throttle position/Stored fault code* Listen for valve operation/Stored fault code* Listen for fuel pump operation/Stored fault code* Fuel pressure test/Listen for fuel pump operation/Stored fault code* Observe the cooling fan/Stored fault code* Observe second throttle position/Stored fault code* Listen for valve operation/Stored fault code* Listen for intake air flap solenoid operation Listen or observe for exhaust butterfly valve actuator operation/Stored fault code*
Cooling Fan Controlt Second Throttle Stepper Motort Secondary Air Injectiont Intake Air Flap Solenoidt Exhaust Butterfly Valve Actuatort * If a fault is detected. t Test will only be displayed if the component is fitted. Instrument Panel Function Test
On the diagnostic software navigate to and select the 'FUNCTION TESTS' option. Click the start button and observe the instruments for the following: tachometer needle move to 7,500 rpm; the neutral indicator and fuel warning with the malfunction indicator light (MIL) lights alternate on and off; coolant temperature increments up to maximum temperature; coolant warning light illuminates when coolant temperature gauge is at maximum; end of test. Instruments return to normal operation.
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Adjust Tune Using the Triumph diagnostic software, it is possible to: reset the adaptions; balance the throttle bodies.
Further functions are provided to allow correct replacement and adjustment of the: throttle position sensor; idle speed control stepper motor.
These functions are needed as, after replacement of the parts concerned, adjustments have to be made to specific Voltage settings, with the throttles set in a specific position. To reset adaptions, see page 10-115. To replace and adjust the throttle position sensor, see page 10-110. To replace and adjust the ISC stepper motor, see page 10-112. To balance the throttles, see page 10-109. Freeze-frame Data Freeze frame data is stored at the time a DTC is recorded (confirmed) by the ECM. If multiple DTCs are recorded, the freeze-frame data which is stored will relate to the first recorded DTC only. By calling up freeze frame data associated with the first recorded DTC, the technician can check the engine condition at the time the fault occurred. The data available is: Function Examined DTC Fuel system status 1 Calculated load Coolant temperature Short term fuel trim - bank 1 Intake manifold absolute pressure Engine speed Vehicle speed Ignition advance Intake air temperature Throttle position Oxygen sensor 1 output Voltage Oxygen sensor 1 short term fuel trim On Volts mm/hg RPM km/h degrees C C Result Reported (Scale) Diagnostic Trouble Code (DTC) number open or closed loop operation
on
,,.,
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Diagnostic Trouble Codes Diagnostic trouble codes (DTCs) are logged in the ECM memory when there is a confirmed fault in the system The codes are reported to the Triumph diagnostic software as a four digit code. As mentioned earlier, when the system detects a fault, it begins to count the number of times the fault occurs before ill uminating the MIL and storing a fault code. Similarly, if a fault clears, the ECM also records this fact and will turn off the MIL when sufficient no-fault warm-up cycles have taken place. Any fault codes will remain in the ECM memory until the required number of no-fault warm-up cycles have taken place. The number of warm-up cycles required to extinguish the MIL will always be less than the number required to remove a DTC from the ECM memory. DTCs can be removed at any time using the Triumph diagnostic software. The system will log the diagnostic trouble codes listed below/over: Diagnostic Trouble Code (DTC) Fault Description Number of no-fault cycles before turning off MIL 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Number of no-fault cycles before DTC is erased 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 MIL illuminated when fault is logged
P0201 P0202 P0203 P1201 P1202 P1203 P0351 P0352 P0353 P0335 P0032 P0031 P0030 P0136 P0122 P0123 P0107 P0108 P1105 P1107 P1108 P0112 P01 13 P0117 P01 18
Injector 1 circuit malfunction Injector 2 circuit malfunction Injector 3 circuit malfunction Injector 1 open circuit/short to ground Injector 2 open circuit/short to ground Injector 3 open circuit/short to ground Ignition coil 1 circuit malfunction Ignition coil 2 circuit malfunction Ignition coil 3 circuit malfunction Crankshaft sensor circuit malfunction Oxygen sensor heater short circuit to battery Oxygen sensor heater open circuit/short to ground Oxygen sensor heater circuit malfunction Oxygen sensor circuit malfunction Throttle position sensor low input Throttle position sensor high input Manifold absolute pressure sensor low voltage Manifold absolute pressure sensor high voltage Manifold absolute pressure sensor pipe malfunction Ambient air pressure sensor circuit low voltage Ambient air pressure sensor circuit high voltage Intake air temperature too high Intake air temperature too low Engine coolant temperature too high Engine coolant temperature too low
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
1 0.40
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Diagnostic Trouble Code (DTC) Fault Description Number of no-fault cycles before turning off MIL 3 3 3 3 3 3 3 3 3 3 3 3 3 Number of no-fault cycles before DTC is erased 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 MIL illu minated when fault is logged
P0500 P1552 P1553 P1628 P1231 P1232 P1629 PO444 PO445 P0617 P0616 PO414 PO413 P0505 P1631 P1632 P0560 P1500 P0654 P1115 PO460 P0705 P1610 P0630 P1690 P1078
Vehicle speed sensor malfunction Cooling fan short circuit/open circuit Cooling fan short to battery voltage/over temperature Fuel pump short circuit to ground or open circuit Fuel pump relay short circuit to ground or open circuit fuel pump relay short circuit to battery Fuel pump short circuit to battery Purge valve system short circuit to ground or open circuit Purge valve system short circuit to battery Starter relay short circuit to battery Starter relay short circuit to ground or open circuit Secondary air injection system short circuit to battery Secondary air injection system short circuit to ground or open circuit Idle speed control system malfunction Fall detection sensor circuit low voltage Fall detection sensor circuit high voltage System voltage - battery circuit malfunction Vehicle speed output circuit malfunction* Tachometer circuit malfunction* Coolant temperature gauge circuit malfunction* Fuel level sensor circuit malfunction* Gear position sensor circuit
malfunction*
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No No Yes Yes
3 3 3 3 0 0 0 0 0 0 0 N/A 3 3 3
Low fuel output circuit malfunction* EEPROM fault* CAN communication fault Exhaust control valve actuator position sensor circuit low voltage (short to ground) (Daytona 675 only) Exhaust control valve actuator position sensor circuit high voltage (short to Vcc) (Daytona 675 only) Exhaust control valve ( Daytona 675 only) actuator circuit malfunction
P1079 P0078
40
Yes
P1080
Exhaust control valve actuator mechanism malfunction ( Daytona 675 only)
40
Yes
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Diagnostic Trouble Code (DTC) Fault Description Number of no-fault cycles before turning off MIL 3 3 3 Numberof no-fault cycles before DTC is erased 40 40 MIL illuminated when fault is logged
P1670
Intake flap solenoid circuit short to ground or open circuit ( Daytona 675 only) Intake flap solenoid circuit short to Vbatt (Daytona 675 only) EMS main relay circuit malfunction
Yes
P1671 P1685
Yes Yes
40
*-Supported by DTC P1690 P1659 P1698 P1602 EMS ignition voltage input malfunction Sensor supply (Vcc) circuit malfunction Tunelock 3 3 Only if Tunelock is unlocked Only if Instrument ID Matching 40 40 Yes Yes Flashing
P 1614
ECM or tune ID Incorrect
Flashing
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Electrical Connectors
Before beginning any diagnosis, the following connector related information should be noted: Note: A major cause of hidden electrical faults can be traced to faulty electrical connectors. For example: Dirty/corroded terminals. Damp terminals. Broken or bent cable pins within multiplugs.
Disconnection of ECM connectors

Note: Two different coloured and shaped connectors are used in the ECM, which ensures correct connection is always made. The connectors on the ECM are coloured black and grey, and correspond with identical coloured connectors on the main harness.
A Caution
When disconnecting a connector, never pull directly on the wires as this may result in cable and connector damage.
For example, the electronic control module (ECM) relies on the supply of accurate information to enable it to plan the correct fueling and ignition timing. One dirty terminal will cause an excessive voltage drop resulting in an incorrect signal to the ECM.' ;.. If, when carrying out fault diagnosis, a fault appears to clear by simply disconnecting and reconnecting an electrical plug, examine each disconnected plug for the following.
ACaution
Never disconnect the ECM when the ignition switch is in the 'ON' position as this may cause multiple fault codes to be logged in the ECM memory. Always disconnect an ECM after disconnecting the battery negative (black) lead first. 1. Turn the ignition to the 'OFF' position and wait at least 1 minute for the ECM to complete its power down sequence. Press down on the locking device and gently pull back on the connector to release it from the ECM.
Before Disconnection:
If testing with a voltmeter, the voltage across a connector should be virtually battery volts (unless a resistor is fitted in the circuit). If there is a noticeable change, suspect faulty/dirty connections.
2.
When Disconnecting a Connector:

Check for a security device that must be released before the connector can be separated. E.G. barb, hook and eye etc.
When Inspecting a Connector:

Check that the individual pins have not been bent. Check for dampness/dirt/corrosion. Check cables for security. Check cable pin joints for damage.
When Connecting a Connector:

M Ensure there is no dirt around the connector/seal. Push together squarely to ensure terminals are not bent or incorrectly located. Push the two halves together positively.
1. Locking device Note: The ECM is located beneath the fuel tank, on the upper section of the airbox.
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Reconnection of ECM connectors Note: Two different coloured and shaped connectors are used in the ECM, which ensures correct connection is always made. The connectors on the ECM are coloured black and grey, and correspond with identical coloured connectors on the main harness. 2. 1. Fit the first connector into its socket and, whilst holding the connector in place, insert it fully into the ECM until the locking device retains it. Repeat the above for the second connector.
Further Diagnosis
The tables that follow will, if used correctly, help to pinpoint a fault in the system once a diagnostic trouble code has been stored.
ACaution
Damage to the connector pins may result if an attempt to fit the connectors incorrectly is made.
1. ECM (Daytona 675 shown, Street Triple and Street Triple R similar)
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Crankshaft Sensor
Fault Code P0335 Possible cause Crankshaft sensor system fault Action View & note diagnostic software 'freeze frame data if available. Ensure sensor is fitted correctly and connector is secure. Disconnect ECM pinpoint test 1: and proceed to
Pinpoint Tests
Test 1 Check terminal and cable integrity: - ECM pin A01 - ECM pin A09
Result OK
Action Disconnect sensor and proceed to test 2
Faulty 2 Check cable for short circuit: - ECM pin A01 to earth - ECM pin A09 to earth 3 Check cable continuity: - ECM pin A09 to sensor pin 1 - ECM pin A01 to sensor pin 2 4 Check cable for short circuit: - ECM pin A01 to ECM pin A09 OK Short circuit OK OK Open circuit OK Short circuit
Rectify fault, proceed to test 6 Proceed to test 3 Locate and rectify wiring fault, proceed to test 6 Proceed to test 4 Locate and rectify wiring fault, proceed to test 6 Renew crankshaft sensor, proceed to test 6 Locate and rectify wiring fault, proceed to test 6 Proceed to test 6
Check crank toothed wheel: - Damage to teeth - magnetic debris contamination
t. 6 Reconnect harness, clear fault code and run engine to verify fault cleared
Faulty
Clean / renew toothed wheel, proceed to test 6 Action complete - quit test Contact Triumph service
OK Fault still present
Circuit Diagram
Crankshaft Sensor ECM _UB A09 UP A01
ET-
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Idle Speed Control
Fault Code P0505 Possible cause ISC stepper motor / wiring fault Action View & note diagnostic software 'freeze frame' data if available. View & note 'sensor' data. diagnostic software
Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: and proceed to
Pinpoint Tests Action Proceed to test 2 Rectify fault, proceed to test 7
Test 1 Check cable and terminal integrity: - ECM pin A20 - ECM pin A21 - ECM pin A22 - ECM pin A23 2 Check resistance value: - ECM pin A20 to ECM pin A21 - ECM pin A22 to ECM pin A23
Result OK Faulty
4Q to 12Q Open circuit
Disconnect stepper motor and proceed to test 3 Disconnect stepper motor and proceed to test 4
Short circuit OK Short circuit
Disconnect stepper motor and proceed to test 5 Proceed to test 7 Locate and rectify wiring fault, proceed to test 7
Check cable for short circuit: - ECM pin A20 to earth - ECM pin A21 to earth - ECM pin A22 to earth - ECM pin A23 to earth
Check cable continuity: - ECM pin A22 to stepper motor pin A - ECM pin A23 to stepper motor pin Al - ECM pin A20 to stepper motor pin B - ECM pin A21 to stepper motor pin B1
OK Open circuit
Proceed to test 6 Locate and rectify wiring fault, proceed to test 7
Check cable for short circuit: - ECM pin A22 to ECM pin A23 - ECM pin A20 to ECM pin A21
OK Short circuit
Check stepper motor resistance: - Motor pin A to motor pin Al - Motor pin B to motor pin B1
452 to 1252 Faulty
Proceed to test 7 Renew stepper motor, proceed to test 7 Action complete - quit test
Reconnect harness, clear fault code and run OK diagnostic software function test to visually verify operation of stepper motor Fault still present
Contact Triumph service
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Circuit Diagram
ECM Idle Speed Control Stepper Motor A4 Al B2 B3 ON OW OU OK A22 A23 A20 A21
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Fuel Injectors
Fault Code P0201/02/03 Possible cause Injection system fault - injector 1/2/3 - Misfire indicates open circuit - Flooding indicates short circuit Action View & note diagnostic software 'freeze frame' data if available. Ensure relevant injector connector is secure. Disconnect ECM and proceed to pinpoint test 1:
Pinpoint Tests
Test 1 Check cable and terminal integrity: - ECM pin A15 - ECM pin A14 - ECM pin A13 2 Check resistance value: - ECM pin A06 to ECM pin A15 (injector 1) - ECM pin A06 to ECM pin A14 (injector 2) - ECM pin A06 to ECM pin A13 (injector 3)
Result OK Faulty
Action Proceed to test 2 Rectify fault, proceed to test 7
11.02to 12.552
Proceed to test 3
Open circuit Short circuit 3 Check cable for short circuit to ground: - ECM pin A15 to earth - ECM pin A14 to earth - ECM pin A13 to earth 4 Check cable continuity: - ECM pin A06 to relevant injector pin 2 - ECM pin A15 to injector 1 pin 1 - ECM pin A14 to injector 2 pin 1 - ECM pin A13 to injector 3 pin 1 5 Check cable for short circuit to supply box: - ECM pin A06 to ECM pin A15 (1nj 1) - ECM pin A06 to ECM pin A14 (inj 2) - ECM pin A06 to ECM pin A13 (inj 3) 6 Check relevant injector resistance: - Injector pin 1 to injector pin 2 7 Reconnect harness, clear fault code and run engine to verify fault cleared 1 1.OQ to 12.5Q Faulty OK OK Short circuit OK Open circuit OK Short circuit
Disconnect relevant injector and proceed to test 4 Disconnect relevant injector and proceed to test 5 Proceed to test 7 Locate and rectify wiring fault, proceed to test 7
Proceed to test 7 Renew relevant injector, proceed to test 7 Action complete - quit test
Fault still present
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Circuit Diagram
EMS Main Relay
ECM 3 1 2 5
NK NK Z
2 1
t t t
Fuel Injectors
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Fuel System/Engine Management Throttle Position Sensor

Fault Code P0122 P0123 Possible cause Action Throttle position sensor low input View & note diagnostic software voltage (short to ground or open 'freeze frame data if available. circuit) View & note diagnostic software Throttle position sensor high input 'sensor' data. voltage (short circuit to sensor supply) Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: and proceed to
Pinpoint Tests Result OK Action Disconnect sensor and proceed to test 2
Test 1 Check cable and terminal integrity: - ECM pin B01 - ECM pin B20 - ECM pin A10
Faulty 2 Check cable for short circuit: - ECM pin A10 to ground Short circuit OK
Rectify fault, proceed to test 5 Proceed to test 3
Locate and rectify wiring fault, proceed to test 5 Proceed to test 4
Check cable continuity: - ECM pin A10 to sensor pin 1 - ECM pin B20 to sensor pin 2 - ECM pin B01 to sensor pin 3
OK
Open circuit
Locate and rectify wiring fault, proceed to test 5 Renew throttle position sensor, proceed to test 5
Check cable for short circuit: - ECM pin A10 to ECM pin B01 - ECM pin A10 to ECM pin B20
OK
Short circuit
Locate and rectify wiring fault, proceed to test 5 Action complete - quit test
Reconnect harness, clear fault code and run engine to verify fault cleared
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Circuit Diagram
Throttle Position Sensor
ECM
1 2 3
GY KB K
A10 B20 81
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Purge Valve
Fault Code PO444 Possible cause Open circuit or short circuit to earth Action View & note 'sensor' data. Ensure secure. purge diagnostic valve and software is to
connector proceed
Disconnect ECM pinpoint test 1: PO445 Short circuit to battery+
Disconnect purge valve and proceed to pinpoint test 5:
Pinpoint Tests Result OK Faulty 24Q to 282 Open circuit Short circuit 3 Check cable for short circuit: - ECM pin B09 to earth Check cable continuity: - ECM pin B09 to valve pin 2 - ECM pin A06 to valve pin 1 5 Check cable for short circuit: - ECM pin A06 to ECM pin B09 Check purge valve resistance: - Valve pin 1 to valve pin 2 7 Reconnect harness, clear fault code and run diagnostic software function test to visually verify operation of purge valve OK Short circuit OK Short circuit OK Open circuit Action Proceed to test 2 Rectify fault, proceed to test 7 Disconnect purge valve and proceed to test 3 Proceed to test 4 Disconnect purge valve and proceed to test 5 Disconnect purge valve and proceed to test 7 Locate and rectify wiring fault, proceed to test 7 Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Proceed to test 7 Renew purge valve, proceed to test 7 Action complete - quit test
Test 1 Check cable and terminal integrity: - ECM pin B09 2 Check resistance value: - ECM pin A06 to ECM pin B09
24Q to 28Q Faulty OK
Fault still present
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Circuit Diagram
EMS Main Relay
ECM 3 1 2 ^ Purge Valve

7 2
NK
YR
809
A06
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Ignition Coils
Fault Code P0351/52/53 Possible cause Ignition system fault - ignition coil 1/2/ 3 Action View & note diagnostic software 'freeze frame' data if available. Ensure relevant ignition coil connector is secure. Disconnect ECM and proceed to pinpoint test 1:
Pinpoint Tests
Test 1 Check cable and terminal integri ty : - ECM pin B17 - ECM pin A18 - ECM pin B18 2 Check resistance value: ECM pin A06 to - ECM pin (ignition coil 1) B17 - ECM pin (ignition coil 2) A18 - ECM pin (ignition coil 3) B18 Result OK Faulty Action Proceed to test 2 Rectify fault, proceed to test 7
0.8Q to 1.2Q
Proceed to test 3
Open circuit
Disconnect relevant ignition coil and proceed

to test 4
Sho rt circuit 3 Check cable for short circuit: - ECM pin B17 to ea rt h - ECM pin A18 to ea rth - ECM pin B18 to ea rth 4 Check cable continuity: EMS main relay pin 5 to any ignition coil
pin 2
Disconnect relevant ignition coil and proceed

to test 5
OK Short circuit
OK Open circuit
Proceed to test 6 Locate and rectify wiring fault, proceed to test

7
ECM pin B17 to ignition coil 1 pin 1 - ECM pin A18 to ignition coil 2 pin 1 - ECM pin B18 to ignition coil 3 pin 1
-
Check cable for short circuit: ECM pin A06 to - ECM pin (ignition coil 1) B19 - ECM pin (ignition coil 2) A18 - ECM pin (ignition coil 3) B18
OK Short circuit
Check relevant ignition coil resistance: - Ignition coil pin 1 to ignition coil pin 2
0.8Q to 1.2Q Faulty OK Fault still present
Proceed to test 7 Renew relevant ignition coil, proceed to test 7 Action complete - quit test Contact Triumph service
Reconnect harness, clear fault code and run engine to verify fault cleared
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Circuit Diagram
EMS Main Relay
ECM
NK GK GP GB
A06 B17 A18 B18
Ignition Coils
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1 0.55
Fuel System/Engine Management Coolant Temperature Sensor

Fault Code P01 18 Possible cause Open circuit, battery+ or short circuit Action to View & note diagnostic software 'freeze frame' data if available. View & note 'sensor' data. diagnostic software
Ensure sensor connector is secure. Disconnect ECM and proceed to pinpoint test 1: P0117 Short circuit to ground Disconnect sensor and proceed to test 6:
Pinpoint Tests Result OK Faulty Action Proceed to test 2 Rectify fault, proceed to test 7
Test 1 Check cable and terminal integrity: - ECM pin A29 - ECM pin B20 2 Check resistance value: - ECM pin A29 to ECM pin B20 (Temperature dependent - see below)
OK Open circuit
Disconnect temp sensor and proceed to test 6 Disconnect sensor and proceed to test 3 Disconnect temp sensor and proceed to test 4 Proceed to test 5 Locate and rectify wiring fault, proceed to test 7 Proceed to test 5 Locate and rectify wiring fault, proceed to test 7 Proceed to test 7 Renew temp sensor, proceed to test 7 Proceed to test 7 Locate and rectify wiring fault, proceed to test 7 Action complete - quit test Contact Triumph service
Short circuit 3 Check cable continuity: - ECM pin A29 to sensor pin 1 - ECM pin B20 to sensor pin 2 4 Check cable for short circuit: - ECM pin A29 to ECM pin B20 OK Open circuit OK Short circuit
Check sensor resistance: - Sensor pin 1 to sensor pin 2 (Temperature dependent - see below)
OK Faulty OK Short circuit
Check cable for short circuit: - ECM pin A29 to ground Reconnect harness, clear fault code and run engine to verify fault cleared
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Circuit Diagram Resistance data under typical conditions: Warm engine: Cold engine: 20C ambient -10C ambient 2.35 to 2.65K-Q 8.50 to 10.25KQ 200 to 400Q
Coolant Temperature Sensor 2 1 KB KG
ECM
B20 A29
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Intake Air Temperature Sensor
Fault Code P01 13 Possible cause Open circuit, battery+ or short circuit Action to View & note diagnostic software 'freeze frame' data if available. View & note 'sensor' data. diagnostic software
Ensure sensor connector is secure. Disconnect ECM and proceed to pinpoint test 1: P01 12 Short circuit to ground Disconnect sensor and proceed to pinpoint test 6:
Pinpoint Tests Result OK Faulty Action Proceed to test 2 Rectify fault, proceed to test 7
Test 1 Check cable and terminal integrity: - ECM pin All - ECM pin B20 2 Check resistance value: - ECM pin All to ECM pin B20 (Temperature dependent - see below)
OK Open circuit Short circuit
Disconnect temp sensor and proceed to test 6 Disconnect temp sensor and proceed to test 3 Disconnect temp sensor and proceed to test 4 Proceed to test 5 Locate and rectify wiring fault, proceed to test 7 Proceed to test 5 Locate and rectify wiring fault, proceed to test 7 Proceed to test 7 Renew temp sensor, proceed to test 7 Proceed to test 7 Locate and rectify wiring fault, proceed to test 7 Action complete - quit test Contact Triumph service
Check cable continuity: - ECM pin All to sensor pin 1 - ECM pin B20 to sensor pin 2
OK Open circuit
Check cable for short circuit: - ECM pin All to ECM pin B20
OK Short circuit
Check sensor resistance: - Sensor pin 1 to sensor pin 2 (Temperature dependent - see below)
OK Faulty OK Short circuit
Check cable for short circuit: - ECM pin All to ground Reconnect harness, clear fault code and run engine to verify fault cleared
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Circuit Diagram If engine is warm, remove sensor and allow time to cool to ambient prior to test. Resistance data: Ambient temp 80C 20C -10C Resistance value 200 to 400Q 2.35 to 2.65KQ 8.50 to 10.25KQ
Inlet Air ECM Temperature Sensor 620 A11 KB KO 2 1
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System Voltage
Fault Code P0560 Possible cause Bike voltage system fault Action View & note 'sensor data. diagnostic software battery is
Ensure voltage across acceptable, note voltage. Disconnect ECM pinpoint test 1: and
proceed
to
Pinpoint Tests Result OK Faulty Same as 'across battery' voltage Less than 'across battery' voltage OK Action Proceed to test 2 Rectify fault, proceed to test 3 Proceed to test 3 Locate and rectify wiring fault, proceed to test 3 Action complete - quit test Contact Triumph service
Test 1 Check cable and terminal integrity: - ECM pin A06 2 With Ignition 'ON', check voltage at:
- ECM pin A06 3 Reconnect harness, clear fault code and run engine to verify fault cleared
Fault still present Circuit Diagram

EMS Main Relay
ECM NK B B B A06 B35 B16 A35
B19
1 0.60
ll,l MP

Cooling Fan Relay
Fault Code P1552 Possible cause Fan relay open circuit, or short circuit to ground Action View & note 'sensor data. diagnostic software
Ensure fan relay connector is secure. Disconnect ECM pinpoint test 1: P1553 Short circuit to battery+ and proceed to
Disconnect fan relay and proceed to pinpoint test 4:
Pinpoint Tests
Test 1 Check cable and terminal integrity: - ECM pin B30 2 Check cable for short circuit: - ECM pin B30 to ground 3 Check cable continuity: - Fan relay pin 2 to ECM pin B30 - Fan relay pin 1 to EMS main relay pin 5 4 Check cable for short circuit: - ECM pin B30 to ECM pin A06
Result OK Faulty OK Short circuit
Action Disconnect fan relay and proceed to test 2 Rectify fault, proceed to test 5 Proceed to test 3 Locate and rectify wiring fault, proceed to test 5 Proceed to test 4 Locate and rectify wiring fault, proceed to test 5
OK Open circuit
OK Short circuit
Proceed to test 5 Locate and rectify wiring fault, proceed to test 5 Action complete - quit test
Reconnect harness, clear fault code and run OK diagnostic software function test to visually verify operation of cooling fan Fault still present
Circuit Diagram
EMS Main Relay
Cooling Fan Relay
2 5
ECM
Y K
B30 A06
I UMP
1 0.61

Lambda Sensor
Fault Code P0130 Possible cause Lambda sensor circuit fault Action View & note 'freeze frame' data if available. View & note 'sensor' data. Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: and proceed to
Pinpoint Tests
Test 1 Check cable and terminal integrity:
Result OK
Action Disconnect Lambda sensor and proceed to test 2 Rectify fault, proceed to test 4
- ECM pin A26 - ECM pin B20 2 Check cable for short circuit: - ECM pin A26 to ECM pin B20 - ECM pin A26 to ECM pin A06 3 Check cable continuity: - ECM pin A26 to sensor pin 2 - ECM pin B20 to sensor pin 1 4 Reconnect harness, clear fault code and run engine. Check adaptation status
Faulty
OK Short circuit
OK Open circuit
Action complete - quit test Contact Triumph service
Circuit Diagram
EMS Main Relay
Lambda Sensor
3 1
2 5
yy
ECM
B14
B HA26 KB NK B20 A06
1 0.62
Il1MP

Lambda Sensor Heater
Fault Code P0031 Possible cause Action Lambda sensor heater circuit short View & note 'freeze frame' data if circuit to ground or open circuit available. View & note 'sensor' data. Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: P0032 Lambda sensor heater circuit, short circuit to battery and proceed to and
Disconnect la mbda sensor proceed to pinpoint test 4:
Pinpoint Tests Action Disconnect Lambda sensor and proceed to test 2 Rectify fault, proceed to test 5 Proceed to test 3 Locate and rectify wiring fault, proceed to test 5 Proceed to test 5 Locate and rectify wiring fault, proceed to test 5 OK Renew Lambda sensor and proceed to test 5
Test 1 Check cable and terminal integrity: - ECM pin B14
Result OK
Faulty 2 Check cable for short circuit: - ECM pin B14 to ground Check cable continuity: - ECM pin B14 to sensor pin 4 - ECM pin A06 to sensor pin 3 4 Check cable for short circuit: - ECM pin B14 to ECM pin A06 Short circuit OK Short circuit OK Open circuit
Locate and rectify wiring fault, proceed to test 5 Action complete, quit test Contact Triumph service
Reconnect harness, clear fault code and run engine. Check adaption status
Circuit Diagram
EMS Main Relay
Lambda Sensor
ECM
w
B KB
B14 A26 B20
NK A06
I UMP
1 0.63

EEPROM Error
Fault Code P0603 Possible cause EEPROM error Action View & note 'freeze frame' data if available. No tests available - contact Triumph service.
1 0.64
Il1MP

Fall Detection Switch
Fault Code P1631 P1632 Possible cause Fall detection switch low input voltage Fall detection switch voltage or open circuit high input Action View & note 'freeze frame' data if available. View & note 'sensor' data Ensure switch connector is secure. Disconnect ECM pinpoint test 1: and proceed to
Pinpoint Tests Result OK Faulty OK Short circuit Action Disconnect sensor and proceed to test 2 Rectify fault, proceed to test 6 Proceed to test 3 Locate and rectify wiring fault, proceed to test 6 Proceed to test 4 Locate and rectify wiring fault, proceed to test 6
Test 1 Check cable and terminal integrity: - ECM pin B21 2 Check cable for short circuit: - ECM pin B21 to ground
Check cable continuity: - ECM pin B01 to sensor pin 4 - ECM pin B21 to sensor pin 5 - ECM pin B20 to sensor pin 6
OK Open circuit
Check cable for short circuit: - ECM pin B21 to ECM pin B1 - ECM pin B21 to ECM pin B20
OK Short circuit
Connect ECM and proceed to test S Locate and rectify wiring fault, proceed to test 6
Check voltage (with ignition 'ON') between: - Sensor pin 4 and sensor pin 6 Reconnect harness, clear fault code
5V Less than 4.8V OK Fault still present
Renew fall detection switch and proceed to test 6 Locate and rectify wiring fault, proceed to test 6 Action complete, quit test Contact Triumph service
Circuit Diagram
Fall ECM Detection Switch KB KU K 6 S 4
B20 B2t B1
111MP
1 0.65

Vehicle Speed Sensor
Fault Code P0500 Possible cause Vehicle speed sensor circuit fault Action View & note 'freeze frame' data if available. View & note 'sensor data. Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: and proceed to
Pinpoint Tests
Test 1 Check cable and terminal integri ty : - ECM pin A34 - Instrument pin 9 2 Check cable for short circuit: - ECM pin A34 to ground - ECM pin A34 to Instruments pin 9 3 Check cable for continuity: OK Open circuit OK Faulty Proceed to test 3 Locate and rectify wiring fault, proceed to test 4 Renew vehicle speed sensor and proceed to test 4 Locate and rectify wiring fault, proceed to test 4 Result OK Faulty Action Disconnect sensor and proceed to test 2 Rectify fault, proceed to test 4
- ECM pin A34 to sensor pin 3 - Sensor pin 2 to ground - Instruments pin 9 to sensor pin 1 4 Reconnect harness, clear fault code and run engine
Action complete, quit test Contact Triumph service
Circuit Diagram
Alarm Control Unit Engine Stop Switch
Fuse Box I G 2 I 10A
Instruments
I'
b-- GN
6 GR
---^
JBY ECM
1 3
2
KY
B
A34
Road
Speed Sensor
1 0.66
1L1MP

Instrument Communication (CAN)
Fault Code P1690 Possible cause Fault in CAN communication between ECM and instrument pack. Action View & note 'freeze frame available. View & note 'sensor' data. Ensure instrument connector is secure. Disconnect ECM pinpoint test 1: and proceed to data if
Pinpoint Tests Result OK Faulty Action Disconnect instruments and proceed to test 2 Rectify fault, proceed to test 4
Test 1 Check cable and terminal integrity: - ECM pin B27 - ECM pin B28 - Instrument pin 4 - Instrument pin 5 2 Check cable for short circuit: - ECM pin B27 to B28 - ECM pin B27 to ground - ECM pin B28 to ground 3 Check cable continuity: - ECM pin B28 to Instrument pin 4 - ECM pin B27 to Instrument pin 5 4 Reconnect harness, clear fault code and run engine
OK Faulty
OK Open circuit
Contact Triumph service Locate and rectify wiring fault, proceed to test 4
Action complete, quit test Contact Triumph service
Circuit Diagram
Instruments 4 5 R U
ECM B28 B27
Il1MP
1 0.67

Fuel Level Sensor
Fault Code PO460 Possible cause Fuel level sensor circuit fault Action View & note 'freeze frame available. View & note 'sensor' data. Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: and proceed to data if
Pinpoint Tests
Test 1 Check cable and terminal integrity: - ECM pin B04 2 Check cable for short circuit: - ECM pin B04 to ground 3 Check cable continuity: - ECM pin B04 to sensor pin 1 - Sensor pin 2 to ground 4 Check cable for short circuit: - Sensor pin 1 to sensor pin 2 5 Reconnect harness, clear fault code
Result OK Faulty OK Short circuit OK Open circuit
Action Disconnect sensor and proceed to test 2 Rectify fault, proceed to test 5 Proceed to test 3 Locate and rectify wiring fault, proceed to test 5 Proceed to test 4 Locate and rectify wiring fault, proceed to test 5
OK Short circuit OK Fault still present
Renew fuel level sensor and proceed to test 5 Locate and rectify wiring fault, proceed to test 5 Action complete, quit test Contact Triumph service
Circuit Diagram
ECM B4 BG
Fuel Level Sensor 2
1 0.68
I uMP

Ambient (Barometric) Pressure Sensor
Fault Code P1107 Possible cause Action data if
Ambient pressure sensor circuit short View & note 'freeze frame circuit to ground available. View & note 'sensor' data.
Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: P1108 Ambient pressure sensor circuit, short circuit to supply or open circuit and proceed to
Disconnect ambient pressure sensor and proceed to pinpoint test 4:
Pinpoint Tests
Test 1 Check cable and terminal integrity: - ECM pin A27 - ECM pin B20 - ECM pin B01 2 Check cable for short circuit: - ECM pin A27 to ECM B20 - ECM pin A27 to ground 3 Check cable for continuity:
Result OK Faulty
Action Disconnect ambient proceed to test 2 pressure sensor and
Rectify fault, proceed to test 5
OK Short circuit
OK Open circuit
Renew ambient pressure sensor and proceed to test 5 Locate and rectify wiring fault, proceed to test 5
- ECM pin A27 to sensor pin 1 - ECM pin B20 to sensor pin 2 - ECM pin B01 to sensor pin 3 4 Check cable for short circuit: - ECM pin A27 to ECM pin B01
OK
Renew ambient pressure sensor and proceed to test 5 Locate and rectify wiring fault, proceed to test 5 Action complete, quit test Contact Triumph service
Short circuit Reconnect harness, clear fault code and run engine
Circuit Diagram
Ambient Pressure Sensor KB KP K 2 1 3
ECM B20 A27 601
L UMP
1 0.69

Manifold Absolute Pressure (Map) Sensor
Fault Code P0107 Possible cause Action
MAP sensor circuit short circuit to View & note 'freeze frame' data if ground available. View & note 'sensor data. Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: and proceed to
P0108
MAP sensor circuit, short circuit to supply or open circuit MAP sensor pipe fault
Disconnect MAP sensor and proceed to test 4: Check connection/condition of pipe from MAP sensor to throttle body.
P1105
Pinpoint Tests Result OK Faulty Action Disconnect MAP sensor and proceed to test 2 Rectify fault, proceed to test 5
Test 1 Check cable and terminal integrity: - ECM pin A28 - ECM pin B20 - ECM pin B01 2 Check cable for short circuit: - ECM pin A28 to ECM B20 - ECM pin A28 to ground 3 Check cable for continuity: - ECM pin A28 to sensor pin 1 - ECM pin B20 to sensor pin 2 - ECM pin BOl to sensor pin 3 4 Check cable for short circuit: - ECM pin A28 to ECM pin B01
OK Short circuit
OK Open circuit
Renew MAP sensor and proceed to test 5 Locate and rectify wiring fault, proceed to test 5
OK
Renew MAP sensor and proceed to test 5
Short circuit OK Fault still present Circuit Diagram
Reconnect harness, clear fault code and run engine
ECM
MAP Sensor
B20 A28 B01
KB KS K
2 1 3
1 0.70
IIIMP

Gear Position Sensor
Fault Code P0705 Possible cause Gear position sensor circuit fault Action View & note 'freeze frame' data if available. View & note 'sensor' data. Ensure sensor connector is secure. Disconnect ECM pinpoint test 1: and proceed to
Pinpoint Tests Action Disconnect sensor and proceed to test 2 Rectify fault, proceed to test 5 Proceed to test 3 Locate and rectify wiring fault, proceed to test 5 Proceed to test 4 Locate and rectify wiring fault, proceed to test 5
Test 1 Check cable and terminal integrity: - ECM pin B24 2 Check cable for short circuit: - ECM pin B24 to ground Check cable for continuity: - ECM pin B24 to sensor pin 1 - ECM pin B20 to sensor pin 2 - ECM pin A31 to sensor pin 3 4 Check cable for short circuit: - Sensor pin 1 to sensor pin 2 - Sensor pin 1 to sensor pin 3
Result OK Faulty OK Short circuit OK Open circuit
OK
Renew gear position sensor and contact pin and proceed to test 5
Short circuit
Reconnect harness, clear fault code
Circuit Diagram
Gear ECM Position Sensor A31 B24 B20 BW BK KB 3 1 2
I uMP
1 0.71

Secondary Air Injection Valve
Fault Code PO413 Possible cause Open circuit or short circuit to earth Action View & note diagnostic software sensor data. Ensure SAI valve connector is secure. Disconnect ECM and proceed to pinpoint test 1: Disconnect SAI valve and proceed to pinpoint test 5:
PO414
Short circuit to battery positive
Pinpoint Tests Result OK Faulty 2052 to 25Q Open circuit Short circuit 3 Check cable for short circuit: - ECM pin B08 to ground Check cable continuity: - ECM pin B08 to valve pin 1 - ECM pin A06 to valve pin 2 5 Check cable for short circuit: - ECM pin B08 to ECM pin A06 Check SAI valve resistance: - Valve pin 1 to Valve pin 2 7 Reconnect harness, clear fault code and run diagnostic software function test to visually verify operation of SAI valve OK Short circuit Action Proceed to test 2 Rectify fault, proceed to test 7 Disconnect SAI valve and proceed to test 3 Proceed to test 4 Disconnect SAI valve and proceed to test S Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Proceed to test 7 Renew SAI valve, proceed to test 7 Action complete - quit test
Test 1 Check cable and terminal integrity: - ECM pin B08 2 Check resistance value: - ECM pin B08 to ECM pin A06
OK Open circuit
OK Short circuit 20Q to 25Q Faulty OK
Fault still present
1 0.72
ILIMP

Circuit Diagram
EMS Main Relay
`' 3 1 2 5 Secondary Air Valve NK Z YO NK
ECM
BO8 A06
I uMP
1 0.73

Fuel Pump - up to VIN 300525 - without Fuel Pump Relay
Fault Code P1628 Possible cause Open circuit or short circuit to earth Action View & note diagnostic software 'sensor' data. Ensure fuel pump connector is secure. Disconnect ECM and proceed to pinpoint test 1: Disconnect fuel pump and proceed to pinpoint test 5:
P1629
Pinpoint Tests
Test 1 Check cable and terminal integrity: - ECM pin B36 2 Check resistance value: - ECM pin B36 to fuse box Fuse 2, note that the engine stop switch must be in the 'RUN' position and any alarm fitted must be disarmed
Result OK Faulty 2Q to 6Q
Action Proceed to test 2 Rectify fault, proceed to test 7 Disconnect fuel pump and proceed to test 3
Open circuit Short circuit 3 Check cable for short circuit: - ECM pin B36 to earth 4 Check cable continuity: - ECM pin B36 to Pump pin 2 - Fuse box fuse 2 to fuel pump pin 1, note that the engine stop switch must be in the 'RUN' position and any alarm fitted must be disarmed 5 Check cable for short circuit: - ECM pin B36 to fuse box Fuse 2, note that the engine stop switch must be in the 'RUN' position and any alarm fitted must be disarmed 6 Check fuel pump resistance: - Pump pin 1 to pump pin 2 7 Reconnect harness, clear fault code and run diagnostic software function test to verify operation of fuel pump OK Short circuit OK Open circuit
Proceed to test 4 Disconnect fuel pump and proceed to test 5 Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Proceed to test 6 Locate and rectify wiring fault, proceed to test 7
OK Faulty
2Q to 6Q Faulty OK
Proceed to test 7 Renew fuel pump module, proceed to test 7 Action complete - quit test
Fault still present
1 0.74
tl1MP

Circuit Diagram
Engine
Stop Switch
2
ECM
PW
BP
636
^ V Service Manual - Daytona 675, Street Triple and Street Triple R
1 0.75

Fuel Pump - from VIN 300526 - with Fuel Pump Relay
Fault Code P1231 Possible cause Fuel pump relay short ground or open circuit circuit to Action Check if pump runs briefly when ignition is switched on. Ensure fuel pump relay connector is secure. Disconnect ECM pinpoint test 1: P1232 Fuel pump relay short circuit to battery positive and proceed to
Disconnect fuel pump relay proceed to pinpoint test 4:
and
Pinpoint Tests
Test 1 Check cable and terminal integrity: - ECM pin B29 2 Check cable for short circuit to ground: - ECM pin B29 to earth
Result OK Faulty OK Short circuit
Action Disconnect fuel pump relay and proceed to test 2 Rectify fault, proceed to test 5 Proceed to test 3
Locate and rectify wiring fault, proceed to test 5 Proceed to test 4 Locate and rectify wiring fault, proceed to test 5
Check cable continuity: - ECM pin B29 to fuel pump relay pin 2 - Fuel pump relay pin 1 to ECM pin A19
OK Open circuit
Check cable for short circuit: - ECM pin B29 to Alarm pin 1 or 3
OK Short circuit
Proceed to test 5 Locate and rectify wiring fault, proceed to test 5 Action complete - quit test
Reconnect harness, clear fault code and run diagnostic software function test to verify operation of fuel pump
OK
Fault still present
1 0.76
Il1MP

Circuit Diagram
Fuel Pump Main Relay
PW
ECM Alarm 1 3 g B l B29 A19
BP GR
I uMP
1 0.77

Intake Air Flap Solenoid - Daytona 675 only
Fault Code P1670 Possible cause Open circuit or short circuit to earth Action View & note diagnostic software 'sensor' data. Ensure intake air flap solenoid connector is secure. Disconnect ECM and proceed to pinpoint test 1: Disconnect intake air flap actuator and proceed to pinpoint test 5:
P1671
Pinpoint Tests Result OK Faulty 40Q to 50Q Open circuit Short circuit Action Proceed to test 2 Rectify fault, proceed to test 7 Disconnect intake flap solenoid and proceed to test 3 Proceed to test 4 Disconnect intake flap solenoid and proceed to test 5 Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 OK Faulty 40Q to 5052 Faulty OK Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Proceed to test 7 Renew intake flap solenoid, proceed to test 7 Action complete - quit test
Test 1 Check cable and terminal integrity: - ECM pin B 10 2 Check resistance value: - ECM pin B 10 to ECM pin A06
Check cable for short circuit: - ECM pin B 10 to earth
OK Short circuit
Check cable continuity: - ECM pin B10 to Actuator pin 2 - ECM pin A06 to Actuator pin 1
OK Open circuit
Check cable for short circuit: - ECM pin B 10 to ECM pin A06 Check Intake Air Flap Solenoid resistance: - Solenoid pin 1 to Actuator pin 2
Reconnect harness, clear fault code and run engine to visually verify operation of Intake Flap Actuator (see below)
Fault still present Note:
To verify the correct operation of the air intake flap, start the engine and briefly raise the engine speed above 4500 rpm. The flap should be seen to open as the engine speed rises and close again as the engine speed falls.
1 0.78
Ii1MP

Circuit Diagram
Intake Air Flap Solenoid
EMS Main Relay
3 1
ECM
OR yK
B10 A06
1liMP
1 0.79

Exhaust Butterfly Valve (EXBV) Position Sensor - Daytona 675 only
Fault Code P1078 Possible cause Exhaust butterfly valve position sensor low input voltage (short to ground or open circuit) Action
P 1079
View & note diagnostic software 'freeze frame data if available. View & note diagnostic software 'sensor' data. Ensure actuator connector is secure. Exhaust butterfly valve position sensor Disconnect ECM and proceed to high input voltage (short circuit to pinpoint test 1: sensor supply)
Pinpoint Tests Result OK Faulty Action Disconnect Actuator and proceed to test 2 Rectify fault, proceed to test 5
Test 1 Check cable and terminal integrity: - ECM pin B02 - ECM pin B01 - ECM pin B20 2 Check cable for short circuit: - ECM pin B02 to ground
OK
Proceed to test 3
Short circuit
Locate and rectify wiring fault, proceed to test 5 Proceed to test 4 Locate and rectify wiring fault, proceed to test 5
Check cable continuity: - ECM pin B02 to Actuator pin 2 - ECM pin B01 to Actuator pin 3 - ECM pin B20 to Actuator pin 1
OK Open circuit
Check cable for short circuit:
OK Short circuit
Renew exhaust proceed to test 5
control
valve
actuator,
- ECM pin B02 to ECM pin B01 - ECM pin B02 to ECM pin B20 5 Reconnect harness, clear fault code and run diagnostic software function test to visually verify operation of the exhaust control valve actuator
Locate and rectify wiring fault, proceed to test 5
OK
Action complete - quit test
Fault still present Circuit Diagram
ECM B20 B01 B02 KB K GW
Exhaust Valve Position Sensor 1 3 2 6 S
1 0.80
ILIMP

Exhaust Butterfly Valve (EXBV) Motor - Daytona 675 only
Fault Code P0078 Possible cause Exhaust butterfly valve motor circuit fault Action View & note diagnostic software 'freeze frame' data if available. View & note diagnostic software 'sensor' data. Ensure actuator connector is secure. Disconnect ECM and proceed to pinpoint test 1: Proceed to pinpoint test 5:
P1080
Cable or Mechanism fault
Pinpoint Tests
Test 1 Check cable and terminal integrity: - ECM pin A07 - ECM pin A08 2 Check cable for short circuit: - ECM pin A07 to ground - ECM pin A08 to ground
Result OK Faulty
Action Disconnect actuator and proceed to test 2 Rectify fault, proceed to test 6
OK
Proceed to test 3
Short circuit 3 Check cable continuity: - ECM pin A07 to Actuator pin 6 - ECM pin A08 to Actuator pin 5 4 Check cable for short circuit: - ECM pin A07 to ECM pin A08 Check adjustment of cables is within specification. Disconnect cables and check that the cables are free to slide through the cable outers (see page 10- 131) Using a suitable tool check that the exhaust control valve can be rotated manually 6 OK Open circuit OK Short circuit
Locate and rectify wiring fault, proceed to test 6 Proceed to test 4 Locate and rectify wiring fault, proceed to test 6 Renew exhaust proceed to test 6 control valve actuator,
Locate and rectify wiring fault, proceed to test 6 Renew Exhaust proceed to test 6 control valve actuator,
OK
Faulty
Renew relevant part and proceed to test 6 Action complete - quit test
Reconnect harness, clear fault code and run OK diagnostic software function test to visually verify operation of the exhaust control valve actuator Fault still present
Circuit Diagram
ECM Exhaust Valve Actuator 3 1 2 A7 A8 GY GU 6 S
!!.
1 0.81

EMS Main Relay Circuit
Fault Code P1685 Possible cause EMS main relay circuit fault Action Note that the starter motor cannot be powered if a main relay fault exists. Ensure the EMS main relay connector is secure. Proceed to pinpoint test 1:
Pinpoint Tests
Test 1 Ensure ignition has been switched off for greater than one minute. Identify EMS Main Relay on the harness. Check that relay operates when the ignition is switched ON. 2 Check fuse box Fuse 6 integrity
Result OK
Action Proceed to test 2
Faulty
Disconnect ECM and proceed to test 4 Disconnect ECM and proceed to test 4 Disconnect ECM and proceed to test 3 Replace Fuse 6 and proceed to test 4 Locate and rectify wiring fault, replace Fuse 6 and proceed to test 7 Disconnect Main Relay and proceed to test 5 Rectify fault, proceed to test 7
OK Faulty
Check cable for short circuit: - ECM pin A06 to ground - EMS Main relay pin 3 to ground
OK Short circuit OK Faulty
Check cable and terminal integrity: - ECM pin A06 - ECM pin B15 - EMS Main Relay pin 1 - EMS Main Relay pin 2 - EMS Main Relay pin 3 - EMS Main Relay pin 5
Check cable for short circuit: - ECM pin B15 to ground
OK Short circuit OK
Proceed to test 6 Locate and rectify wiring fault, proceed to test 7 Replace EMS Main Relay and proceed to test 7 Locate and rectify wiring fault, proceed to test 7
Check cable continuity:
- ECM pin A06 to EMS Relay pin 5 - ECM pin B15 to Relay pin 1 - EMS Main Relay pin 2 to ground - EMS Main Relay pin 3 to Fuse box Fuse 6 7 Reconnect harness, clear fault code. Switch ignition off for longer than one minute. Switch ignition on and check that the EMS main relay operates. Start engine as final check
Open circuit
OK
Fault still present
1 0.82
Il1MP

Circuit Diagram
Fuse box F EMS Main Relay
ECM NK YS A06 B15
.1
L UMP
1 0.83

EMS Ignition Voltage Input Circuit
Fault Code P1659 Possible cause EMS ignition voltage input circuit fault Action Disconnect ECM pinpoint test 1: and proceed to
Pinpoint Tests
Test 1 Check Fuse box Fuse 2 integrity
Result OK Faulty
Action Proceed to test 3 Proceed to test 2 Replace Fuse 2 and proceed to test 3
Check cable for short circuit: - ECM pin A19 to ground
OK
Short circuit 3 Check cable and terminal integrity: - ECM pin A19 - Alarm Connector pin 1 - Alarm Connector pin 2 - Right hand switchcube pin 2 - Right hand switchcube pin 5 4 Check cable continuity: OK OK Faulty
Locate and rectify wiring fault, replace Fuse 2 and proceed to test 5 Proceed to test 4 Rectify fault, proceed to test 5
Proceed to test 5 Locate and rectify wiring, i mmobiliser or engine stop switch fault, proceed to test 5
- ECM pin A19 to fuse box Fuse 2, note that Open circuit the engine stop switch must be in the 'RUN position and any Alarm fitted must be disarmed 5 Reconnect harness, clear fault code and run engine to verify fault cleared OK Fault still present Circuit Diagram
Action complete - quit test Contact Triumph service
Engine Stop Switch
Alarm Control Unit
Fuse Box
1 ECM
r z
10A
co co
G GN GR A19
1 0.84
111MP
Fuel System/Engine Management 5 Volt Sensor Supply Circuit

Fault Code P1698 Possible cause Sensor supply circuit shorted Sensor supply circuit shorted to ground Sensor supply circuit shorted to battery positive Action View & note 'sensor data. Note ECM sensors requiring a power supply will not be active. Disconnect ECM and proceed to pinpoint test 1:
Pinpoint Tests Test 1 Check cable and terminal integrity: - ECM pin B01 - ECM pin B20 2 Check cable for short circuit - ECM pin B01 to ECM pin B20 Result OK Faulty OK Faulty 3 Disconnect the following sensors in turn: - MAP sensor - Ambient pressure sensor - Throttle position switch - Exhaust control valve actuator - Fall detection sensor and retest for short circuit - ECM pin B01 to ECM pin B20 4 Check cable for short circuit: - ECM pin B01 to ground - ECM pin B20 to ground - ECM pin B01 to A06 - ECM pin B20 to A06 - ECM pin B01 to battery positive - ECM pin B20 to battery positive 5 OK Faulty Action Proceed to test 2 Rectify fault, proceed to test S Proceed to test 4 Proceed to test 3 Replace sensor last removed and proceed to test 5 Proceed to test 4
OK Short circuit
Reconnect harness, clear fault code and use OK service software to check for correct sensor outputs and 5V sensor supply voltage level Fault still present
Circuit Diagram
Ambient Pressure Sensor 2 ECM
620 BOt KB K
MAP Sensor
Fall Detection Switch 6 4
Throttle Position 2 3
Exhaust Valve Position Sensor
II.I MP
1 0.85

Tune Lock
Fault Code P1602 Possible cause ECM is locked to prevent motorcycle from being operated Action the This is also identified by a fast flashing MIL indication, and a disabled engine management system. Unlock the ECM using the diagnostic software and supplied unlock code from Triumph service.
1 0.86
I UMP

ECM or Tune ID Incorrect
Fault Code P 1614 Possible cause ECM or tune is incorrect, causing the ECM to be disabled to prevent the motorcycle from being operated Action This is also identified by a fast flashing MIL indication, and a disabled engine management system.
Pinpoint Tests
Test 1 Check ECM part number is correct for the motorcycle
Result OK Incorrect
Action Proceed to test 2
Replace ECM with correct part and proceed to test 3 Proceed to test 3
Check that the tune is correct for the OK motorcycle, using the diagnostic software Incorrect
Update tune using the diagnostic software, proceed to test 3 Action complete - quit test Contact Triumph service
Clear fault code, check for normal operation
I UMP
1 0.87

Fault Finding - Non Electrical
Symptom Poor throttle response at low RPM Possible cause(s) Low fuel pressure caused by filter blockage/leaks
Cutting out at idle
Throttle bodies out of balance ISC (Idle Speed Control) actuator inoperative Low fuel pressure Weak mixture caused by air leak at the throttle body/ transition piece to cylinder head face
Idle speed too low/high
ISC (Idle Speed Control) actuator sticking Incorrect closed throttle position setting Mechanical fault with the throttle linkage
Diagnostic software malfunctions during tune download procedure Throttle hang-up Bike will start but cuts out immediately
Low battery voltage Incorrect closed throttle position setting ISC motor stuck Low fuel pressure caused by filter blockage/leaks
Abnormally high fuel pressure Temperature gauge reads cooler than normal Intake air flap inoperative - (Daytona 675 only)
Fuel pressure regulator inoperative Cooling system airlocked resulting in coolant temperature sensor operating in air instead of coolant Vacuum leak to actuator, vacuum reservoir or hoses
1 0.88
ILIMP

Fuel Tank
Removal 4. Withdraw the spacer sleeve from the frame.
A Warning
Observe the warning advice given in the general information section on the safe handling of fuel and fuel containers. A fire, causing personal injury and damage to property, could result from spilled fuel or fuel not handled or stored correctly. 1. 2. 3. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Release the bolts securing the fuel tank to the frame
1. Spacer sleeve
5. Raise the fuel tank and disconnect the electrical connections to the fuel pump and the low fuel level sensor.
Warning
When disconnected, the fuel tank is self-sealing but a small amount of fuel may escape causing clothing and components to be coated with fuel. This would represent a serious fire hazard which could lead to burn injuries and damage to property. 6. On models fitted with a double check clip (from early 2007), ease the latch away from the connector until the release buttons are exposed.
Zvc
1. Rear fuel tank to frame bolt

1
.l.
I
ii' 1. Front fuel tank to frame bolts 1.Locked Position 2.Unlocked Position
7. Disconnect the fuel hose by squeezing the sides of the connector and pulling the hose free from its spigot on the fuel pump plate.
Il1MP
1 0.89
Fuel System/Engine M anagement

Note: On Street Triple and Street Triple R models, access to the fuel hoses connector is restricted. An assistant may be required to support the fuel tank whilst disconnecting the fuel hose on these models. Before disconnection, note the position of the two breather hoses so that they can be returned to the same locations when refitting the tank. Disconnect the two breather hoses. 3 4 Installation 1. 2. Position the fuel tank to the frame. Connect the two breather hoses as previously noted.
Note: The fuel hose has different coloured connectors on each end, to aid orientation. The orange end must be fitted to the fuel tank, the grey end must be fitted to the fuel rail. Reconnect the fuel feed hose by gently pushing inwards until the hose ehgages with a click. Slide the double check latch down (i.e. towards the spigot) until the release buttons are covered. If the latch will not slide into position, then the fuel hose is not fully home on its spigot and must therefore be refitted correctly. Reconnect the fuel pump electrical connection. Reconnect the low fuel level sensor.
8.
5. 4 6.
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1. Fuel hose 2. Fuel pump electrical connection 3. Low fuel level sensor connection 4. Breather hoses
9.
Remove the fuel tank from the frame.
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1. Fuel hose 2. Fuel pump electrical connection 3. Low fuel level sensor connection 4. Breather hoses
7.
Align the fuel tank to the mounting points. Refit the rear spacer sleeve. Fit and tighten the three bolts to 9 Nm. Reconnect the battery, positive (red) lead first. Start the engine and check carefully for fuel leaks. Rectify as necessary. Refit the rider's seat (see page 16-17).
8. 9. 10.
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Fuel System/Eng ine Management

Fuel Tank - Raising and Supporting Street Triple and Street Triple R only
Note: The fuel tank may be raised without being removed completely, for access to fuse box and relays. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank support from its location under the seat base.
Fuel Tank - Lowering and Securing Street Triple and Street Triple R only
1. 2. 3. Support the fuel tank and remove the tank support. Lower the fuel tank into position and secure with the two fixings. Tighten to 9 Nm. Refit the fuel tank support to its location under the seat base.
1. 2. 3.
1. Fuel tank support 2. Seat base
4.
1. Fuel tank support 2. Seat base
Reconnect the battery, positive (red) lead first. Refit the seat (see page 16- 17).
5.
4.
Remove the front fuel tank fixings and pivot the fuel tank upwards at the front.
Note: It is permissible to use either the left hand or right hand fixing holes to support the fuel tank. While supporting the fuel tank in the raised position, locate the fuel tank support into the fixing hole in the frame and into the fixing hole in the fuel tank bracket.
5.
1. Fuel tank support 2. Fuel tank
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Fuel Pump, Fuel Filter and Low Fuel Level Sensor
Removal Note: The fuel pump, fuel filter and low fuel level sensor assembly is a sealed for life unit and must be replaced as a complete assembly. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Drain the fuel tank into a suitable container.
1. Fuel pump assembly
8.
Noting its orientation, remove and discard the sealing ring from the fuel pump assembly.
1. 2. 3. 4.
A Warning
2. Sealing ring location
Observe the warning advice given in the general information section on the safe handling of fuel and fuel containers. A fire, causing personal injury and damage to property, could result from spilled fuel or fuel not handled or stored correctly. 5. 6. Invert the fuel tank and place on a protective surface to prevent paint damage. Remove the fixings securing the fuel pump mounting plate to the fuel tank.
Installation 1. Install a new sealing ring in the fuel pump assembly, with the seal lip facing uppermost, and ensure that it is correctly seated.
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1. Sealing ring 2. Seal lip
2. Taking care to ensure the sealing ring is not damaged or dislodged, manoeuvre the fuel pump assembly into the fuel tank aperture.
1. Mounting plate 2. Mounting plate fixings
7.
Lift the fuel pump assembly and manoeuvre it from the fuel tank aperture.
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3. Ensure the locating peg on the fuel pump assembly is located in the cut out on the mounting plate and the offset hole is positioned as shown below.
Fuel Pressure Checking
A Warning
Observe the fuel handling precautions given in the general information section. Fuel pressure is checked using service tool 13880001.
__ 9
R l^^
1. Offset hole position 2. Locating peg 4. In the sequence shown below, tighten the mounting plate fixings to 9 Nm.
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Tool T3880001 Remove the rider's seat (see page 16-17). Remove the fuel tank (see page 10-89) and place on a suitable support, close to the motorcycle. Using the extension cable 13880123, carefully connect the fuel pump connection on the main harness to the fuel tank. Connect the other end of the extension cable to the motorcycle main harness. Select the fuel pressure gauge adapter marked 'B' from service tool T3880001.
1. 2.
o/
3.
4.
Fuel pump mounting plate torque sequence S. 6. 7. L.. Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16- 17).
A Warning
Always us the correct fuel pressure gauge adapter (adapter 'B' for Daytona 675, Street Triple and Street Triple R). Use of an incorrect adapter will result in a fuel leak. A fuel leak can result in a fire causing damage to property and injury to pe rsons.
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5. Connect the adapter hose to the fuel pump plate outlet as shown in the illustration below. 7. Connect the fuel pressure gauge to the adaptor hose as shown below by pushing the gauge spigot in to adapter until a click can be heard.
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1. Adaptor hose 'B' 2. Fuel pump plate outlet 3. Extension cable T3880123 6. Connect the fuel hose to the adaptor hose as shown in the illustration below.
1.Adaptor hose 2. Fuel pressure gauge Note: To release the fuel pressure gauge from the adapter, slide the outer ferrule downwards. This will allow the gauge to spring upwards from the adapter. Ensure the gauge is visible to the side of the motorcycle. Start the engine and observe the fuel pressure reading on the gauge.
8. 9.
Note: The fuel pressure should be 3.0 bar nominally.
1. Motorcycle fuel hose (Daytona 675 shown) 2. Adaptor hose 'B' 3. Fuel pump connection 4. Wiring extension T3880123 5. Fuel pump connection 6. Fuel pump plate outlet
10. When fuel pressure checking is complete, disconnect the fuel pressure gauge adapter and wiring extension. 11. Refit the fuel tank (see page 10-90). 12. Refit the rider's seat (see page 16-17).
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Fuel Delivery System
Fuel is delivered to the injectors by a pump located inside the fuel tank. Fuel flows in the direction of the arrows shown in the diagram below. Incorporated in the fuel pump assembly is a filter, a pressure regulator and a pick-up strainer. The fuel pump assembly also contains the low fuel level sensor.
Airbox
Removal 1. 2. 3. 4. 5. Remove the rider's seat (see page 16- 17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Disconnect the ECM connectors (see page 10-43). Street Triple and Street Triple R only: Remove the three fixings and detach the relay and fuse box bracket. Without disconnecting any connectors, position the bracket assembly aside.
1. Relay and fuse box bracket 2. Fixings
6. Direction of Fuel Flow
All models: Disconnect the intake air temperature sensor multi-plug.
1. Intake air temperature sensor 2. Multi-plug
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7. Disconnect the map sensor multi-plug. 11. Release the spring hose clip and disconnect the secondary air injection hose at the airbox.
1. Map sensor 2. Multi-plug
1. Secondary air injection hose 2. Spring hose clip
8.
Release the eight fixings and remove the airbox upper section.
12. Release the spring hose clip and disconnect the engine breather hose at the airbox.
1. Airbox upper section 2. Fixings 1. Engine breather hose 2. Spring hose clip
9.
Release the six fixings and remove the airbox intake trumpets.
13. Remove the airbox from the motorcycle.
10. Release the fixing securing the airbox to the frame. Inspection 1. 2. 3. Thoroughly clean the inside and outside of the airbox. Check the airbox and intake trumpets for damage. Check the air intake seal at the front of the airbox for damage.
Installation 1. 2.
1. Airbox front fixing location 2. Airbox intake trumpet fixings
Position the airbox to the frame. Connect the engine breather hose and refit the spring hose clip. Connect the secondary air injection hose and refit the spring hose clip.
3.
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4. Align the front of the air box to the frame and loosely install the fixing. Do not tighten the fixing at this stage. Align the rear of the airbox to the throttle bodies and fit the airbox intake trumpets. Tighten the fixings to 6 Nm. Tighten the airbox front fixing to 3 Nm. Refit the airbox upper section and tighten the fixings to 1.5 Nm. Reconnect the air temperature and map sensor multi-plugs. Street Triple and Street Triple R only: Reposition the relay and fusebox bracket to the airbox and install the three fixings. Tighten the fixings to 3 Nm. 1. 2. 3. 4. 5.
Air Filter Element

Removal Note: The air filter element can be accessed after first removing the airbox upper section. It is not necessary to remove the lower section. Remove the rider's seat (see page 16-17). Disconnect the battery negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox upper section (see page 10-95). Remove and discard the six fixings then remove the air filter element from the airbox lower section.
5.
6. 7. 8. 9.
1. Relay and fuse box bracket 2. Fixings 10. All models: Reconnect the ECM connectors (see page 10-44). 11. Refit the fuel tank (see page 10-90). 12. Reconnect the battery, positive (red) lead first. 13. Refit the rider's seat (see page 16-17).
1.Air filter element 2. Fixings Installation 1. 2. 3. 4. 5. 6. 7 Thoroughly clean the inside and outside of the airbox. Seat the air filter element in the lower section. Secure the air filter element with new fixings. Tighten to 4 Nm. Refit the airbox upper section (see page 10-96). Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first Refit the rider's seat (see page 16- 17).
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Intake Air Temperature Sensor
Removal 1. 2. 3. 4. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Disconnect the intake air temperature sensor multiplug.
Map Sensor
Removal 1. 2. 3. 4. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Disconnect the map sensor multi-plug.
1. Intake air temperature sensor (Daytona 675 shown) 2. Multi-plug
1. Map sensor 2. Multi-plug 3. Fixing 4. Vacuum hose
Note: 5. The intake air temperature sensor has a threaded base. Unscrew the sensor to remove it from the airbox.
5. 6.
Disconnect the vacuum hose from the sensor. Release the fixing screw securing the sensor to the airbox and remove the sensor.
Installation 1. 2. 3. 4. 5. Fit the air temperature sensor to the airbox. Tighten the sensor to 4 Nm. Reconnect the intake air temperature sensor multiplug. Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
Installation 1. 2. 3. 4. 5. 6. Fit the sensor to the airbox, tightening the fixing to 3 Nm. Refit the vacuum hose. Reconnect the map sensor multi-plug. Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
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Barometric Pressure Sensor Daytona 675 only
Removal Note: The barometric pressure sensor is located on the intake air duct behind the fairing cockpit. It is not necessary to remove the cockpit to access the sensor. 1. 1. 2. 3. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the windscreen (see page 16-22 for Daytona 675 up to VIN 381274, see page 16-23 for Daytona 675 from VIN 381275). Disconnect the multi-plug. Release the fixing securing the sensor to the intake air duct and remove the sensor. 2. 3. 4. 5. 6.
Barometric Pressure Sensor - Street Triple and Street Triple R only

Removal Note: The barometric pressure sensor is located on the rear subframe, forward of the rear light unit. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the rear bodywork (see page 16-19). Remove the rear light unit (see page 17-26). Disconnect the multi-plug. Release the fixing securing the sensor to the rear subframe and remove the sensor.
4. 5.
1. Barometric pressure sensor 1. Barometric pressure sensor (cockpit shown removed for clarity) 2. Multi-plug 3. Fixing M 2. Fixing 3. Multi-plug
Installation 1. 2. 3. 4. 5. 6. Fit the sensor to the rear subframe, tightening the fixing to 3 Nm. Reconnect the multi-plug. Refit the rear light unit (see page 17-26). Refit the rear bodywork (see page 16-25). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
Installation 1. 2. 3. Fit the sensor to the intake air duct, tightening the fixing to 3 Nm. Reconnect the multi-plug. Refit the windscreen (see page 16-22 for Daytona 675 up to VIN 381274, see page 16-25 for Daytona 675 from VIN 381275). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16- 17).
4. 5. CM
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Fall Detection Switch - Daytona 675 only
Removal Note: The fall detection switch is located on the instrument bracket behind the fairing cockpit. It is not necessary to remove the cockpit to access the switch. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the windscreen (see page 16-22 for Daytona 675 up to VIN 381274, see page 16-23 for Daytona 675 from VIN 381275). Disconnect the multi-plug. Release the fixings securing the switch to the instrument bracket and remove the switch.
Fall Detection Switch - Street Triple and Street Triple R only

Removal Note: The fall detection switch is located on the relay bracket fitted to the airbox. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Disconnect the multi-plug. Release the fixings securing the switch to the relay bracket and remove the switch.
1. 2.
1. 2. 3.
3. 4. 5.
4. 5.
1. Fall detection switch 2. Multi-plug 3. Fixings mvs

1. Fall detection switch (cockpit shown removed for clarity) 2. Multi-plug 3. Fixings
Installation 1. 2. 3. 4. 5. Fit the switch to the relay bracket, tightening the two fixings to 3 Nm. Reconnect the multi-plug. Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
Installation 1. 2. 3. Fit the switch to the instrument bracket, tightening the two fixings to 3 Nm. Reconnect the multi-plug. Refit the windscreen (see page 16-22 for Daytona 675 up to VIN 381274, see page 16-25 for Daytona 675 from VIN 381275). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16- 17).
4. 5.
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Intake Air Duct - Daytona 675 only
Removal 1. 2. 3. 4. 5. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the cockpit (see page 16-23). Remove the barometric pressure sensor (see page 10-99). Detach the instrument pack bracket, together with the fall sensor and its bracket (see page 17-20) and tie aside. Disconnect the vacuum hose from the intake air flap actuator. Release the four fixings securing the intake air duct to the frame headstock and remove the duct. Operation The intake air flap actuator is located on the intake air duct, forward of the instruments. It is vacuum operated, being controlled by a solenoid valve which is in turn operated by the ECM.
Intake Air Flap Actuator - Daytona 675 only
Removal 1. 2. 3. 4. 5. 6. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the cockpit (see page 16-23). Remove the grille from the intake air duct. Disconnect the vacuum hose from the intake air flap actuator. Rotate the actuator one quarter turn clockwise to release it from the intake air duct.
6. 7
1. Intake air duct 2. Fixings (left hand shown)
Installation
1. Actuator
1. 2. 3. 4. 5. 6. 7
Position the duct to the frame headstock and refit the four fixings. Tighten the fixings to 7 Nm. Reconnect the intake air flap actuator vacuum hose. Refit the instrument bracket and fall detection switch bracket (see page 17-21). Refit the barometric pressure sensor (see page 1099). Refit the cockpit (see page 16-24). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
2. Actuator release direction
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7. Disconnect the actuator rod from the intake air flap and remove the actuator. Installation 1. Position the actuator to the intake air duct and connect the actuator rod to the intake air flap.
1 1
1. Actuator 2. Actuator rod removal direction 1. Actuator 2. Actuator rod installation direction
2.
Rotate the actuator one quarter turn anti-clockwise to refit the actuator to the intake air duct.
1. Actuator 2. Actuator installation direction
3. 4. 5. 6. 7.
Reconnect the intake air flap actuator vacuum hose. Refit the intake air duct grille. Refit the cockpit (see page 76-24). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
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Fuel System/Engine Management Crankshaft position sensor

Note: The alternator stator and crankshaft position sensor are supplied as an assembly and cannot be separated. For additional information, refer to alternator (see page 17-33 for removal and page 17-34 for installation). Adjustment Note: Minor adjustments to the opening cable can be made using the adjuster near the throttle grip end of the throttle. Where a correct setting cannot be achieved this way, the adjusters at the throttle end of both cables must be used. The opening cable must be set first followed by the closing cable.
Throttle Cable
cc
1. Throttle grip 2. Correct setting, 2-3 mm
1. 2. 3.
Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Set the 'opening' cable adjuster at the throttle grip end such that it has an equal amount of adjustment in each direction. Tighten the locknut. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95).
4. 5.
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6. Set the 'opening' cable adjuster at the throttle body end to give 2-3 mm of play at the throttle grip. Tighten the locknut. Removal Note: Before beginning to remove the throttle cables, note the exact routing and location of both cables to help ensure that they are returned to the same locations and routing on assembly. Remove the rider's seat (see page 16- 17). Disconnect the battery, negative (black) lead first. (see page 17-14). Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Detach the throttle bodies (see page 10- 106). Slacken the adjuster locknuts at the throttle body end of the cables such that they will allow the outer cables to be detached from the cable bracket. Detach the inner cable nipples from the throttle cam.
1. 2. 3. 4. 5. 6. 1. 'Opening Cable Adjuster (Throttle End) 2. 'Closing' Cable Adjuster (Throttle End) 3. Closing cable free play measurement point 7. With the throttle fully closed, ensure that there is 2-3 mm of free play in the 'closing' cable. Adjust if necessary ensuring that the locknut is secure afterwards.
7.
Warning
Operation of the motorcycle with incorrectly adjusted, incorrectly routed or damaged throttle cables could interfere with the operation of the brakes, clutch or the throttle itself. Any of these conditions could result in loss of motorcycle control and an accident.
II
Warning
Move the handlebars to left and right full lock while checking that cables and harnesses do not bind. Cables or harness that bind will restrict the steering and may ca u se loss of motorcycle control and an accident.
1.Throttle cam 2. Opening cable 3. Closing cable 4. Opening cable nipple 5. Closing cable nipple
8. 9.
Warning
Ensure that the adjuster locknuts are tightened. A loose throttle cable adjuster could cause the throttle to stick leading to loss of motorcycle control and an accident. Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90).
10. Reconnect the battery, positive (red) lead first. 11. Refit the rider's seat (see page 16-17).
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Fuel System/ Engine Management

8. At the throttle grip end, slide off the rubber boot and release the screws which secure the two halves of the throttle grip guide to each other. I 2. Engage the inner cable nipples to the throttle grip, ensuring the 'opening' cable is located in the upper slot in the throttle grip, and the 'closing' cable is located to the lower slot.
1. Throttle grip guide 2. Screws 3. Rubber boot 1. Opening cable 2. Closing cable
9.
Separate the two halves of the guide then release the inner cables from the throttle grip.
3.
Assemble the two halves of the cable guide ensuring that the outer cables are correctly located in the guide and the guide is positioned on the handlebars as noted prior to removal. Fit and tighten the two screws to 4 Nm. 14
1. Opening cable 2. Closing cable
10. Detach the cables from the motorcycle.

1. Throttle grip guide 2. Screws 3. Rubber boot
Inspection 1. Check that both the throttle cables operate smoothly, without sticking or binding. Replace the cables if there is any doubt as to their correct operation.
4. 5.
Refit the boot. Attach the other end of the inner cables to the throttle cam ensuring the 'opening' cable is fitted to the top of the cam and the 'closing' cable to the bottom.
Installation 1. Locate the cables to the frame following the routing noted during removal.
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6. Locate the outer cables to the bracket and adjust until the start of the thread is 14 mm away from the back of the throttle cable bracket. Secure the adjuster and locknuts.
Throttle Bodies/Injectors
Removal Note: Because fuel stored in the fuel rail will be at 3 bar pressure, it is essential that the fuel pressure is reduced before any dismantling of the fuel rail takes place. To reduce pressure, briefly crank the engine with the fuel pump disconnected.
Warning
If the fuel rail is dismantled without first reducing pressure fuel may escape causing clothing and components to be coated with fuel. This would represent a serious fire hazard which could lead to burn injuries and damage to property. 1. 2. 3. 4. 5. 6. 7. 8. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Disconnect the throttle position sensor multi-plug. Disconnect the fuel injector multi-plugs. Disconnect the idle speed control stepper motor multi-plug. Release the clips securing the throttle bodies to the transition pieces.
1. Opening cable 2. Closing cable 7. 8. 9. Refit the throttle bodies (see page 10-108). Set the throttle cable adjustment (see page 10- 103). Refit the airbox (see page 10-96).
10. Refit the fuel tank (see page 10-90). 11. Reconnect the battery, positive (red) lead first 12. Refit the rider's seat (see page 16-17).
1.Transition piece (one per cylinder) 2. Clip location (throttle bodies removed for clarity) 9. Ease the throttle bodies from the transition pieces and lay the assembly carefully on the cam cover.
10. Release both throttle cables from the throttle cam (see page 10-104).
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Fuel System/Engine Man agement

11. Remove the throttle bodies. 12. If required, release the screws securing the fuel rail to the throttle bodies. 15. To detach the transition pieces from the head, release the screws, raise the transition pieces and collect the O-rings.
1. Fuel rail 2. Fuel rail screws
1. Transition piece 2. O-ring 3. Fi xings
13. Ease the fuel rail and injectors from the throttle bodies. 14. To detach the injectors from the fuel rail, gently ease the injector from the rail.
Inspection
1. 2. 3. Check all joints and seals for splits, cuts and damage. Check the throttles for sticking, loose or damaged throttle plates. Check the transition piece O-rings for damage.
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1. Injector 2. Fuel rail
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Installation 1. Thoroughly clean the transition piece to cylinder head mating faces. 5. Refit the injectors and fuel rail to the throttle bodies. Tighten the fuel rail screws to 3.5 Nm.
2. Refit the transition pieces to the head incorporating new O-rings to the joint face. Tighten the transition piece fixings to 12 Nm.
1. Fuel rail 2. Fuel rail screws
6.
Re-attach the throttle cables (see page 10-105).
1. Transition piece 2. 0-ring 3. Fixings
Warning
3. If the injectors have been removed from the fuel rail, refit them to the rail, ensuring the injector locating peg is fully engaged in the slot in the rail.
The throttle body clips must be positioned as shown below. If the clips are not positioned as shown this could cause the throttle to stick, leading to loss of motorcycle control and an accident. 7. Refit the throttle bodies to the transition pieces and secure with the clips.
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1. Injector 2. Fuel rail 3. Locating peg 1. Transition piece (one per cylinder) 2. Clip location (throttle bodies removed for clarity)
4.
Check the injector O-rings for splits and other damage. Replace as necessary.
8. 9.
Adjust the throttle cables (see page 10- 103). Reconnect the idle speed control stepper motor multi-plug.
10. Reconnect the fuel injector multi-plugs. 11. Reconnect the throttle position sensor multi-plug. 12. Refit the airbox (see page 10-96). 13. Refit the fuel tank (see page 10-90). 14. Reconnect the battery, positive (red) lead first. 15. Refit the rider's seat (see page 16-17).
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Throttle Body Balancing
Note: The throttles cannot be balanced using equipment to measure vacuum in each throttle. Instead, the Triumph diagnostic software must be used. Remove the rider's seat (see page 16- 17). Remove the fuel tank (see page 10-89) and place on a suitable support, close to the motorcycle. Remove the airbox (see page 10-95). 7. Connect the adapter hose to the fuel pump plate outlet as shown in the illustration below.
1. 2. 3.
4.
Warning
1. Adaptor hose 'B' 2. Fuel pump plate outlet 3. Tool T3880123 8. Connect the fuel hose to the adaptor hose as shown in the illustration below.
If the engine has recently been running, the components beneath the fuel tank may be hot to the touch. Turn the ignition to the 'OFF' position.
5. Using the extension cable T3880123, carefully connect the fuel pump connection on the main harness to the fuel tank. Connect the other end of the harness extension to the motorcycle main harness. 6. Select the fuel pressure gauge adapter marked 'B' from service tool T3880001.
A Warning
Always us the correct fuel pressure gauge adapter (adapter 'B' for Daytona 675, Street Triple and Street Triple R). Use of an incorrect adapter will result in a fuel leak. A fuel leak can result in a fire causing damage to property and injury to persons. 1. Motorcycle fuel hose 2. Adaptor hose 'B' 3. Fuel pump connection 4. Wiring extension T3880123 5. Fuel pump connection 6. Fuel pump plate outlet 9. Attach exhaust extraction hoses to the silencer. 10. Attach the Triumph diagnostic tool to the dedicated plug, refer to the Triumph Diagnostic Tool User Guide. Start the engine, and allow to idle. 11. On the diagnostic software navigate to 'ADJUST TUNE'. 12. Select 'BALANCE THROTTLES'. 13. Click the Adjust button.
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Note: The balance throttle screen will show the vacuum value of each throttle in mm/hg. In addition, when the throttles are balanced to an acceptable range of each other the word 'THROTTLES BALANCED in green text will appear on the right of the screen. At this point, no further adjustment is necessary or productive. If the throttles are not balanced to each other the word 'THROTTLES UNBALENCED' in red text will appear on the right of the screen. At this point adjustment will be necessary. The adjusters operate on the outer cylinders only (cylinders 1 and 3). The centre throttle (cylinder 2) adjustment is fixed, this being controlled by the idle speed control stepper motor. Note that the centre reading will alter slightly as the two outer cylinders are adjusted. DO NOT attempt to adjust the centre throttle stop screw, located below the idle stepper motor. The stop screw is set at the factory during manufacture, and must not be adjusted.
Throttle Position Sensor

Removal 1. 2. 3. 4. 5. 6. Remove the rider's seat (see page 16- 17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Remove the throttle body assembly (see page 10106). Release the two screws and rotate the throttle 0 position sensor clockwise through 45 to remove it from the left hand end of the throttle body. Collect the O-ring on disassembly.
14. Using the throttle adjusters, make adjustments to the two outer cylinders until the word 'THROTTLES BALANCED' in green text appears.
1. Throttle position sensor 2. Screws 3. 0-ring
Installation 1. Fit the replacement throttle position sensor ensuring the O-ring is positioned correctly between the sensor and throttle body. Rotate the sensor through 45 anti-clockwise until the screw holes align. Engage the new screws and washers supplied and part tighten such that the sensor can still be rotated. Position the throttle body assembly near to its fitted position and reconnect the sensor and all other throttle body electrical connectors. Reconnect the battery, positive (red) lead first. Attach the Triumph diagnostic tool to the dedicated plug, refer to the Triumph Diagnostic Tool User Guide. Turn the ignition to the 'ON' position. On the diagnostic software navigate to and select the 'ADJUST TUNE' option.
2. 3.
1. Adjusters
15. 16. 17. 18. 19. 20.
When balanced, stop the engine and disconnect the diagnostic tool. Disconnect the fuel pressure gauge adapter and wiring extension. Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90). Remove the exhaust extraction hoses from the silencer. Refit the rider's seat (see page 16-17).
4. 5.
6. 7.
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8. At the next screen, select Throttle Position Sensor Adjust then click the 'Adjust button.
9. On pressing the adjust button, the diagnostic tool will send a command, which drives the primary throttle to the fully closed position. The tool will also display the voltage reading coming from the throttle position sensor. Gently rotate the new throttle position sensor until the voltage reading on the software shows 0.6 Volts +/- 0.02 Volts. The reading on the screen will turn green, indicating that the reading is correct. Note: This is a setting voltage only. Because of the adaptive nature of the engine management system, the in-service voltage may vary from this setting figure. Tighten the sensor retaining screws to 2 Nm and recheck the voltage reading shown on the tool. Repeat the adjustment if the reading is outside the specified range. Click on the OK button to return the throttle to normal control and return the diagnostic tool to the 'ADJ UST TUNE' menu. 12 Disconnect the diagnostic tool.
Warning
Operation of the motorcycle with an incorrectly adjusted throttle position sensor, or a throttle position sensor that causes the throttle to stick could result in loss of throttle control. Loss of throttle control could result in loss of control of the motorcycle and an accident.
Ak Warning
Operation of the motorcycle with an incorrectly adjusted, incorrectly routed or damaged throttle cable could interfere with the operation of the brakes, clutch or the throttle itself. Any of these conditions could result in loss of control of the motorcycle a n d a n acci de nt. 14. 15. 16. 17. 18. 19. Disconnect the battery, negative (black) lead first. Refit the throttle body assembly (see page 10- 108). Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first. Check and clear any stored faults using the diagnostic tool, refer to the Triumph Diagnostic Tool User Guide. Refit the rider's seat (see page 16- 17).
i[s7
13 Check that the throttle opens and closes without obstruction/sticking and has a smooth action throughout the full range of its movement. Rectify as necessary.
20.
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1 0.111

Idle Speed Control Stepper Motor
Removal
1. 2. 3. 4. 5. 6. Remove the rider's seat (see page 16-17). Disconnect the batte ry, negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Remove the throttle bodies (see page 10-106). Remove the nut, metal washer and plastic washer attaching the idle control stepper arm to the idle speed control lever.
cdax
8.
Leave the plastic collar and spring on the stepper motor arm.
1. Collar 2. Spring
Installation
1. Ensure the Idle speed control lever is correctly positioned in relation to the throttle cam as shown below.
I'
Cd
1. Idle speed control lever 2. Nut etc. 7. Remove the two screws securing the idle speed control stepper motor to its bracket, then remove the stepper motor in the direction shown.
rs
J^
ME
(U
^. J
11
3
cda
w
I
I
1. Idle speed control stepper motor 2. Bracket 3. Fi xings 4. Direction of removal
0 '
1 0.112
Il1MP

2. If removed, loosely fit the spring and collar on the stepper motor arm. 5. 6. 7. Mount the throttle body onto the engine. Temporarily reconnect the battery, positive (red) lead first. Attach the Triumph diagnostic tool to the dedicated plug, refer to the Triumph Diagnostic Tool User Guide. Turn the ignition to the 'ON' position. On the diagnostic software navigate to and select the 'ADJUST TUNE' option.
1
8. 9.
10. Select Idle Speed Control Stepper Motor Adjust then click the Adjust button. 11. On pressing the adjust key, the diagnostic tool will send a command that drives the throttle to the fully closed position. The tool will also display the voltage reading coming from the throttle position sensor which should be between the target voltage range of 0.58V and 0.62V 12. Tighten the stepper arm nut on the idle speed stepper motor until a clearance of 0.5 mm can be measured between the idle speed control cam and the throttle roller.
1. Collar 2. Spring
3.
Locate the stepper motor to its bracket and tighten the fixings to 3.5 Nm.
3
1. Idle speed control stepper motor 2. Bracket 3. Fixings 4. Direction of fitting 1. Idle speed control lever 2. Throttle roller
4.
Fit the plastic washer to the lever then fit the metal washer and nut.
13. Check the voltage reading shown on the software. If the reading is between the target voltage range, then proceed to step 17. If the reading is not within this range, adjustment must be made as described in steps 14 to 16. 14. Slacken the screws on the throttle position sensor.
15. Gently turn the throttle position sensor until the voltage reading shown on the software is between the target voltage range. 16. Tighten the sensor retaining screws to 2 Nm and recheck the voltage reading shown on the software. Repeat the adjustment if the reading is outside the specified range. 17. Click the OK button to progress to the next adjustment. cc
1. Idle speed control lever 2. Nut etc.
1llMP
Service Manual - Daytona
675, Street Triple and Street Triple R
10.1 13

Note: The diagnostic software will calculate the target voltage range for when the throttle is in the fully open position. 21. Turn the ignition to the 'OFF' position. 22. 23. 24. Disconnect the diagnostic tool. Disconnect the battery, negative (black) lead first. Check and adjust the throttle cable settings (see page 10- 103).
18. On pressing the OK button, the diagnostic tool will send a command that drives the throttle to the fully open position. The tool will also display the voltage reading coming from the throttle position sensor which should be between the target voltage range calculated by the software and shown on the screen. 19. With the stepper fully opened, check the voltage shown on the software and, if necessary, adjust the nut on the top of the stepper arm until the software shows a voltage within the target voltage range shown on the screen. The reading on the screen will change from red to green, indicating that the reading is correct.
A Warning
Move the handlebars to left and right full lock while checking that the cables and harnesses do not bind. A cable or harness which binds will restrict the steering and may cause loss of control and an accident. 25. 26. 27. 28. Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16- 17).
1. Adjustment nut 20. Click the OK button to fully close the idle speed control stepper motor. After a minimum of 15 seconds (the tool will show 'Adapting and not allow further actions to take place during this period), click the OK button again to return the ECM to normal control.
ACaution
Do not operate the throttle while the stepper motor is being adjusted, otherwise the incorrect value will be adapted and the engine will not start.
1 0.114
ILiMP

Engine Management Adaption
General Information
The engine management system fitted to the Daytona 675, Street Triple and Street Triple R is adaptive. This means that the system is able to learn about new or changing operating conditions and continuously adapt itself without needing to constantly make major adjustments from a fixed baseline setting. Adaptive changes can become necessary because of changing rider behaviour, changes in the region in which the bike is operated (i.e. operation at high altitude where it was previously used at sea level) or because a new part may have been fitted which has slightly different characteristics to the old part. All adaptive changes are automatic and require no intervention by rider or dealer.
Typical Values
In a correctly adapted motorcycle, the following will be typical: Function Examined Closed throttle position reference status Idle speed control adaption status Read Out Yes (Adapted)
Between +100 and -100% 0% +/- 10%
Oxygen sensor adaption status (off idle) Oxygen sensor adaption range (off idle) Oxygen (i dle) Oxygen (i dle) sensor adaption status range
Between +100 and -100% 0% +/- 10%
Adaption Status
To see if a motorcycle has fully adapted, a facility named 'ADAPTION STATUS' is provided on the diagnostic software. The following adaption details can be examined: Function Examined position reference Report Method adapted/not adapted % %
sensor
adaption
Between +100 and -100%
Forcing adaption to take place

If the read out indicates that the motorcycle is not adapted, the following will force the system to make adaptions: 1. 2. Ensure the engine is cold. WITHOUT TOUCHING THE THROTTLE, start the engine and allow it to warm up until the cooling fan comes on. Leave the engine to idle for a further 12 minutes.
Closed status
throttle
Idle speed control adaption status Oxygen sensor adaption status (off idle) Oxygen sensor adaption range (off idle) Oxygen sensor adaption status (idle) Oxygen sensor adaption range (idle)
3.
Note: As an alternative to the above process, connect the diagnostic tool, select ADJUST TUNE (see the Triumph Diagnostic Tool User Guide) and select RESET ADAPTIONS. This will force a fast adaption routine to take place in around 5 seconds. For this to happen, the engine MUST be running, it must be at normal operating temperature and in closed loop control mode. Under any other conditions fast adaption will not take place and may cause default values to be loaded, which may then require a normal 12 minute adaption routine to be run. Fault Indications If 'range' figures at 100% are seen, then the adjustment has reached maximum indicating a mechanical fault exists on the motorcycle. This can be due to a number of faults but the most likely causes will be low/high fuel pressure, faulty injectors or air leaks at the throttle bodies or airbox. In these circumstances, locate and rectify the fault, and reset the adaptions as described above.
% %
Terminology
Where the term 'status' is used, this indicates how far the present operating parameter is from the stored (baseline) value. The nearer these figures are to zero the better as it indicates the motorcycle has adapted to its current operating conditions. The term 'range' indicates how much (in percentage terms) of the adjustment range has been used to reach the current operating status.
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1 0.115

Exhaust System - Daytona 675
Removal 6. Support the silencer and release the bolt and nut securing the silencer mounting bracket to the rear frame.
A
1. 2. 3. 4. 5.
Warning
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries. Remove the seats (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the rear bodywork (see page 16-18). Disconnect the direction indicator and licence plate la mp electrical connector. Release the clamp securing the silencer to the intermediate pipe.
1. Silencer mounting bracket fixing
7. 8.
Move the silencer rearwards to disengage it from the intermediate pipe and remove. If the rear light bracket is to be removed, release the four silencer heatshield fixings and remove the two heatshields.
1. Silencer 2. Intermediate pipe 3. Clamp 1. Silencer 2. Heatshields 3. Fixings

cdov j
1 0.116
ILIMP
Fue l System/Engine Management

9. Release the four fixings and remove the rear light bracket from the silencer. 12. Disconnect the oxygen sensor from the main harness.
1. Oxygen sensor 1. Silencer i.. .. 2. Rear light bracket 3. Fixings (left hand shown)
13. Remove the cover from the butterfly valve cables on the actuator.
10. 11.
Remove the lower fairings (see page 16-20). Release the clamp securing the intermediate pipe to the header pipe.
1. Cover 2. Fixings
14. Slacken both cable adjusters at the actuator to give the maximum amount of slack in the cables.
1. Intermediate pipe
2. Clamp 3. Header pipe
cd*z
1. Actuator 2. Adjusters
MP
1 0.117

15. Remove and discard the actuator pulley wheel fixing. 20. Release the fixings securing the header pipe joints to the cylinder head. Discard the fixings.
1. Actuator pulley wheel 2. Fixing 16. Slide the actuator pulley off the actuator shaft. 17. Slide the outer portion of the cables out of the actuator. 18. Detach the inner portion of the cables from the actuator pulley wheel.
1. Header pipes 2. Fixings 21. Remove the bolt from the header pipe rear mounting point.
1. Header pipe 2. Header pipe rear mounting point
3
cdps
22. Detach the header pipe assembly and collect the seals from the cylinder head ports.
1. Actuator pulley wheel 2. Opening cable 3. Closing cable 19. Remove the radiator (see page 11-13).
1 0.118
IuMP
Fuel System/Engi ne Management

23. Remove the intermediate pipe fixing and remove the intermediate pipe downwards through the swinging arm. Assembly 1. Refit the intermediate pipe upwards through the swinging arm and tighten the fixing to 22 Nm.
2. Fit new seals to the cylinder head. Ensure that the face of the seal with the tab is facing the cylinder head. Note: A smear of grease may be used to retain the seals in the cylinder head during assembly.
1. Intermediate pipe 2. Fixing
Inspection Using an open ended spanner on the flats of the spindle, check that the exhaust valve in the header pipes is free to rotate and operates smoothly. If the exhaust valve is seized or does not operate smoothly, proceed as follows: Spray penetrating fluid into the spindle bushes of the butterfly valve, and again using an open-ended spanner on the flats of the spindle, turn the spindle end until it rotates freely. Once free, check the spindle end-float. The standard end-float is 0.5 to 1.5 mm but, if end float is less then 0.5 mm, the header pipes must be renewed. Once satisfied that the valve is in a serviceable condition, refit the header pipes to the motorcycle and adjust the butterfly valve cables (see page 10-131).
1. Cylinder head 2. Seals 3. Seal tab
3. Locate the header pipes and align the header pipe flanges to the fixing points. Fit new nuts and hand tighten. 4. Assemble the rear mounting point fixing but do not tighten at this stage.
ILiMp
1 0.119

5. Tighten the header pipe to cylinder head nuts in the sequence shown below: 11 Align the clamp to the intermediate to header pipe joint and tighten to 15 Nm. Ensure the clamp is aligned as shown below.
Up to VIN 381274 Stage 1: Tighten the header pipe nuts in sequence to 2 Nm. Stage 2: Tighten the header pipe nuts in sequence to 19 Nm.
From VIN 381275 Stage 1: Tighten the header pipe nuts in sequence to 2 Nm. Stage 2: Tighten the header pipe nuts in sequence to 15 Nm.
1. Exhaust clamp position 2. Exhaust cut-out 3. Exhaust clamp alignment feature
12. 13. 14.
If removed, refit the rear light bracket to the silencer. Tighten the fixings to 12 Nm. Refit the silencer heatshields. Tighten the fixings to 6 Nm. Position and engage the silencer to the intermediate pipe. Ensure the front of the outer (cosmetic) heatshield is located over the two rubber mounting grommets on the rear subframe. Align the silencer mounting bracket to the frame. Tighten the fixing to 27 Nm.
15. Header Pipe Tightening Sequence 6. 7. 8. Tighten the rear mounting point fixing to 19 Nm. Refit the radiator and refill the cooling system (see page 11-14). Connect the butterfly valve control cables and pulley wheel to the actuator (see page 10-129, from paragraph 3 to paragraph 6). Adjust the butterfly valve control cables (see page 10-131, from paragraph 6 to paragraph 24). Refit the oxygen sensor and tighten to 25 Nm.
9. 10.
A Warning
Incorrect alignment of the exhaust clamp may cause interference with the rear suspension which may lead to loss of motorcycle control and an accident.
1. Silencer mounting bracket fixing
A'warninglIncorrect alignment of the exhaust clamp may cause interference with the rear suspension which may lead to loss of motorcycle control and an accident.
1 0.120
Il1MP

16. Align the clamp to the silencer to exhaust pipe joint and tighten to 15 Nm. Ensure the clamp is aligned as shown below. 17. Reconnect the battery, positive (red) lead first.
Caution
Do not install the exhaust system or run the engine without the exhaust heatshields fitted. Components protected by the exhaust heatshields may suffer severe damage or a fire if the motorcycle is operated without the heatshields being fitted. 18. 19. 20. 21. 22.
1. Exhaust clamp position 2. Exhaust cut-out 3. Exhaust clamp alignment feature
Start the engine and check for exhaust gas leaks. Rectify if necessary. Refit the lower fairings (see page 16-20). Reconnect the direction indicator and licence plate la mp electrical connector. Refit the rear bodywork (see page 16-18). Refit the seats (see page 16-17).
on
L UMP
1 0.121

Exhaust System - Street Triple and Street Triple R
Removal 5. Support the right hand silencer and release the bolt and nut securing the silencer mounting bracket to the rear frame.
Warning
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries. 1. 2. 3. 4. Remove the seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the rear bodywork (see page 16-19). Release the clamps securing the silencers to the intermediate pipe. cere
1. Silencer mounting bracket fixing 2. Nut
6.
Move the silencer rearwards to disengage it from the intermediate pipe and remove. If fitted, collect the spacer from the rear subframe. Repeat steps 5 and 6 above for the left hand silencer. Release the clamp securing the intermediate pipe to the header pipes.
7. 8.
1. Clamp bolts 2. Intermediate pipe 3. Left hand silencer 4. Right hand silencer
1. Intermediate pipe 2. Clamp 3. Header pipes
1 0.122
111MP
Fuel System/E ngine Management

9. Remove the intermediate pipe to rear subframe fixing. 16. Disconnect the oxygen sensor from the main harness. Release the oxygen sensor harness from its retaining points as shown below.
1. Intermediate pipe fixing
10. Loosen the rear subframe lower fixings to the main frame. 11. With the aid of an assistant support the rear subframe. 12. Remove the rear subframe upper fixings to the main frame. 13. Carefully raise the rear subframe until the intermediate pipe can be released from the header pipe. 14. With the rear subframe still supported, manoeuvre the intermediate pipe until it can be removed upwards through the swinging arm, taking care not to damage the swinging arm or intermediate pipe as you do so. 15. Align the rear subframe to the frame and refit the fixings. Do not fully tighten at this stage.
ce m
1. Oxygen sensor connector 2. Retaining points
17. 18.
Remove the radiator (see page 11-15). Release the fixings securing the header pipe joints to the cylinder head. Discard the fixings.
1. Header pipes 2. Fixings
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1 0.123

19. Remove the bolt from the header pipe rear mounting point. 4. 5. Assemble the rear mounting point fixing but do not tighten at this stage. Tighten the header pipe to cylinder head nuts in the sequence shown below: Stage 1: Tighten the header pipe nuts to 2 Nm. Stage 2: Tighten the header pipe nuts to 19 Nm.
1. Header pipe 2. Header pipe rear mounting point 20. 21. Detach the header pipe assembly and collect the seals from the cylinder head ports. If necessary, remove the oxygen sensor cover from the header pipe and then remove the oxygen sensor.
Assembly Header Pipe Tightening Sequence 1. If removed, install the oxygen sensor and tighten to 25 Nm. Install the oxygen sensor cover and secure with the fixing, tightening to 12 Nm. 2. Fit new seals to the cylinder head. Ensure that the face of the seal with the tab is facing the cylinder head. Note: A smear of grease may be used to retain the seals in the cylinder head during assembly. 6. 7. 8. Tighten the rear mounting point fixing to 19 Nm. Refit the radiator and refill the cooling system (see page 11-16). Reconnect the oxygen sensor and secure the harness behind its retaining points as noted on disassembly. With the aid of an assistant support the rear subframe. Remove the rear subframe upper fixings to the main frame. Carefully raise the rear subframe until the intermediate pipe can be installed. With the rear subframe still supported, manoeuvre the intermediate pipe until in can be installed downwards through the swinging arm, taking care not the damage the swinging arm or intermediate pipe as you do so. Position and engage the intermediate pipe to the header pipe. Align the rear subframe to the frame and refit the fixings. Tighten all four subframe fixings to 48 Nm. Refit the intermediate pipe to rear subframe fixing. Tighten to 22 Nm.
9. 10. 11. 12.
13. 14. 15. 1. Cylinder head 2. Seal 3. Seal tab 3. Locate the header pipes and align the header pipe flanges to the fixing points. Fit new nuts and hand tighten.
1 0.124
Il]MP

20. Align the intermediate pipe joint clamps such that the bolts are vertical as shown below, and tighten to 10 Nm.
Warning
Incorrect alignment of the exhaust clamp may cause interference with the rear suspension which may lead to loss of motorcycle control and an accident. 16. Align the intermediate pipe clamp to the header pipe as shown below and tighten to 15 Nm.
1. Intermediate pipe joint clamps showing bolt alignment 2. Header pipes 3. Left hand silencer 4. Right hand silencer
21.
Reconnect the battery, positive (red) lead first.
1. Intermediate pipe 2. Clamp 3. Header pipe 4. Alignment marks
Ak Caution
Do not install the exhaust system or run the engine without the exhaust heatshields fitted. Components protected by the exhaust heatshields may suffer severe damage or a fire if the motorcycle is operated without the heatshields being fitted. 22. 23. 24. Start the engine and check for exhaust gas leaks. Rectify if necessary. Refit the rear bodywork (see page 16-18). Refit the seat (see page 16- 17).
17. Position and engage the right hand silencer to the intermediate pipe. 18. Refit the spacer (if removed) to silencer bolt in the rear subframe, and align the silencer mounting bracket to the spacer. Refit the nut. Tighten the fixings to 15 Nm.
cere
1. Silencer mounting bracket fixing 2. Nut
19. Repeat steps 17 and 18 above for the left hand silencer.
IuMP
10.125

Exhaust Butterfly Valve Actuator Daytona 675 only
Removal 5. Slacken both cable adjusters at the actuator to give the maximum amount of slack in the cables.
Q
1. 2. 3. 4.
Warning
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the right hand lower fairing (see page 1620). Remove the cover from the butterfly valve cables on the actuator.
6.
Remove and discard the actuator pulley wheel fixing.
1. Actuator pulley wheel 2. Fixing 1. Cover 2. Fixings
7. 8.
Slide the actuator pulley off the actuator shaft. Slide the outer portion of the cables out of the actuator.
1 0.126
ILIMP

9. Detach the inner portion of the cables from the actuator pulley wheel. 11. Disconnect the electrical connector and remove the actuator.
3
cdps
1. Actuator pulley wheel 2. Opening cable 3. Closing cable
1. Actuator 2. Connector
10. Release the two fixings and detach the actuator.
Installation 1. Check that the exhaust valve in the header pipes is free to rotate and operates smoothly (see page 10119). Position the actuator to the motorcycle and connect the electrical connector. Refit the actuator to the frame and tighten the two fixings to 12 Nm. Connect the butterfly valve control cables and pulley wheel to the actuator (see page 10-129, from paragraph 3 to paragraph 6). Adjust the butterfly valve control cables (see page 10-131, from paragraph 6 to paragraph 24). Refit the right hand lower fairing (see page 16-20). Reconnect the battery, red (positive) lead first. Refit the rider's seat (see page 16-17).
2. 3. 4.
5. 6.
1. Actuator 2. Fixings
7. 8.
I UMP
1 0.127

Exhaust Butterfly Valve Cables Daytona 675 only
Removal 5 Slacken both cable adjusters at the actuator to give the maximum amount of slack in the cables.
Warning
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn inj u ries. 1. 2. 3. 4. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the right hand lower fairing (see page 1620). Remove the cover from the butterfly valve cables on the actuator.
CON2
11
6.
Remove the cover from the butterfly valve cables on the exhaust header.
1. Cover 1. Cover 2. Fixings 2. Fixings
7.
Remove and discard the actuator pulley wheel fixing.
1. Actuator pulley wheel 2. Fixing
1 0.128
II,I MP

8. 9. Slide the actuator pulley off the actuator shaft. Slide the outer portion of the cables out of the actuator.
Inspection
1. Check that both the exhaust valve cables operate smoothly, without sticking or binding. Replace the cables if there is any doubt as to their correct operation. Using an open ended spanner on the flats of the spindle, check that the exhaust valve in the header pipes is free to rotate and operates smoothly. If the exhaust valve is seized or does not operate smoothly, proceed as follows: Remove the header pipes (see page 10-116). Spray penetrating fluid into the spindle bushes of the butterfly valve, and again using an open-ended spanner on the flats of the spindle, turn the spindle end until it rotates freely. Once free, check the spindle end-float. The standard end-float is 0.5 to 1.5 mm but, if end float is less then 0.5 mm, the header pipes must be renewed. Once satisfied that the valve is in a serviceable condition, refit the header pipes to the motorcycle and adjust the butterfly valve cables (see page 10131).
10. Detach the inner portion of the cables from the actuator pulley wheel. 2.
9 3. 4.
5. K^
cdps
6.
1. Actuator pulley wheel 2. Opening cable 3. Closing cable 11. Slacken the adjuster locknuts at the exhaust valve end of the cables such that they will allow the outer cables to be detached from the exhaust headers. Note: The adjuster/locknuts are coloured black on the upper, opening cable and silver on the lower, closing cable. 12. Noting the orientation of the cables, detach the inner cable nipples from the exhaust valve pulley wheel and remove the cables.
Installation
1. Insert the cable threaded ends into the exhaust headers as noted on removal, ensuring the adjuster/ locknuts are positioned one on either side of the cable retainer casting on the exhaust header. Do not tighten the adjuster/locknuts at this stage. Note: For identification, the adjuster/locknuts are coloured black on the upper, opening cable and silver on the lower, closing cable.
1. Opening cable adjuster/locknuts 2. Closing cable adjuster/locknuts 3. Opening cable nipple 4. Closing cable nipple 5. Exhaust valve pulley wheel
I uMP
1 0.129
Fuel System/E ngine Management

2. Fit the cable nipples into the exhaust valve pulley wheel. 4. 5. 6. Insert the outer portion of the cables into the actuator. Slide the actuator pulley onto the actuator shaft. Install a new actuator pulley wheel fixing and tighten to 5 Nm.
1. Opening cable adjuster/locknuts 2. Closing cable adjuster/locknuts 3. Opening cable nipple 4. Closing cable nipple 5. Exhaust valve pulley wheel Note: Where the outer cables locate into the actuator, the cable outer sleeve is coloured black on the upper, opening cable and silver on the lower, closing cable.
1. Actuator pulley wheel 2. Fixing 7. 8. 9. 10. Adjust the exhaust valve cables (see page 10-131). Refit the right hand lower fairing (see page 16-20). Reconnect the battery, red (positive) lead first. Refit the rider's seat (see page 16-17).
3. Fit the inner portion of the cables to the actuator pulley wheel, ensuring the pulley wheel is installed with the fixing boss facing outwards, and the opening (black) cable uppermost.
3
cdps
1.Actuator pulley wheel (fixing boss facing outwards) 2. Opening cable 3. Closing cable 4. Fixing boss 5. Black coating on cable outer
1 0.130
ILlMP

Exhaust Butterfly Valve Cable Adjustment - Daytona 675 only
6. Remove the cover from the butterfly valve cables on the exhaust header.
/^-
A. Warning
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries.
1. 2. 3. 4.
Remove the rider's seat (see page 16-17). Disconnect the batte ry, negative (black) lead first. Remove the right hand lower fairing (see page 1620). Remove the cover from the butterfly valve cables on the actuator.
1. Cover 2. Fixings
7. Slacken the butterfly valve cable locknuts and, using the adjuster nuts, set the distance between the end of the cables and the cable retainer casting on the exhaust header to 5 mm. Tighten the locknuts to 5 Nm.
5 mm
1. Cover 2. Fixings 5. Slacken both cable adjusters at the actuator to give the maximum amount of slack in the cables.
11 L
cdo, 5 mm --04
1. Locknuts 2. Adjuster nuts
*II
dc
1 0.131
8. 9.
Reconnect the batte ry, red (positive) lead first. Attach the Triumph diagnostic tool to the dedicated plug, refer to the Triumph Diagnostic Tool User Guide.
10. Turn the ignition to the 'ON' position. 11. On the diagnostic software navigate to and select the 'ADJUST TUNE' option.
L UMP

Using light finger pressure, squeeze the cables together at the position shown below.
Ak Warning
Clicking the adjust button will cause the exhaust valve actuator to move to the adjustment position. To prevent injury, never place loose clothing, fingers or hands near the exhaust valve actuator, cables or the valve on the header pipe, until the actuator has moved to the adjustment position. Loose clothing, fingers or the hands could become trapped during valve/actuator movement and cause crushing injury to the fingers, hands or other parts of the anatomy. 12. Select Exhaust Butterfly Valve Cable Adjust then click the adjust button. 13. On clicking the adjust button, the diagnostic software will send a command, which drives the exhaust valve actuator to the middle position. The diagnostic software will then show adjust cable on the screen. Click the OK button. 14. The exhaust butterfly cables can now be adjusted as follows: 15. Turn the adjuster shown in the illustration below until the butterfly valve pulley wheel arrow is level with the lower edge of the butterfly valve 'stop casting.
cdxa
1. Cable slack measurement position
Whilst maintaining light finger pressure, measure the distance between the two cables. When the cable slack is correct, the distance between the two cables should be 12 - 14 mm.
cdxa
1. Adjuster 1. Butterfly valve pulley wheel arrow 2. Butterfly valve 'stop' casting 3. Adjuster 2. Correct setting, 12 - 14 mm
16. Turn the adjuster shown in the illustration below to remove the slack from the cables. Measure the cable slack as follows:
1 0.132
IL1MP

17. Tighten the cable adjuster locknuts. Note: If the cable adjustment procedure has been correctly carried out, the exhaust valve will now be in the closed position. If the adjustment is not correct, the exhaust valve will be set in the open position and the Malfunction Indicator Light (MIL) will be illuminated, indicating the presence of DTCs ( Diagnostic Trouble Codes). The following screen will be displayed: Rectify the DTCs as necessary by repeating the adjustment procedure. On the diagnostic software, scroll to the 'DIAGNOSTICS' menu and select 'READ STORED DTCS', refer to the Triumph Diagnostic Tool User Guide. Re-check for any stored DTCs and rectify as necessary. Turn the ignition to the 'OFF' position Disconnect the Triumph diagnostic tool Refit the cover to the butterfly valve cables on the actuator. Tighten the fixings to 2 Nm. Refit the cover to the butterfly valve cables on the exhaust header. Tighten the fixings to 12 Nm. Refit the right hand lower fairing (see page 16-20). Refit the rider's seat (see page 16-17).
19. 20.
1. Actuator 2. Adjusters 3. Locknuts
21. 22.
Ak Warning
Clicking the OK button will cause the exhaust valve actuator to move to the closed position and then the fully open position. To prevent injury, never place loose clothing, fingers or hands near the exhaust valve actuator, cables or the valve on the header pipe, until the actuator has stopped. Loose clothing, fingers or the hands could become trapped during valve/actuator movement and cause crushing injury to the fingers, hands or other parts of the anatomy. 18. On the diagnostic software, click the OK button to return the actuator to normal control and return the diagnostic software to the 'ADJUST TUNE' menu.
23. 24. 25. 26.
1l _MP
1 0.133

Secondary Air Injection
System Purpose and Operation
The secondary air injection system is an aid to reducing levels of pollutants in the exhaust gases. It does this by introducing a small amount of air into each exhaust port as the exhaust valve opens. The introduced air helps promote further combustion of the fuel mixture in the exhaust system after it has left the combustion chamber. At certain specific engine speeds (determined by the factory programming of engine management system), the secondary air injection control valve is opened by the ECM and allows an air feed into the secondary air system where, each time a pair of exhaust valves open, the exhaust gases in the exhaust port create a depression which causes reed valves in the secondary air injection system to open. When open, the depression in the exhaust port draws air from the control valve, through the open reed valves, into the exhaust port. This air promotes secondary combustion of the exhaust gases in the ports and the header system. At other engine speeds, the system is disabled by closing the control valve in the system. This allows an oxygen sensor to control air to fuel ratios. If air was fed to the exhaust system when the oxygen sensor was operational, the incoming air would cause inaccuracies in the readings sensed by the oxygen sensor (which requires access to 'raw' combustion gases) which would lead to rough running.
1 0.134
ILIMP

Secondary Air Injection Solenoid Valve
Removal 1. 2. 3. 4. 5. 6. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Release the hoses attached to the valve. Disconnect the multi-plug.
Secondary Air Injection Reed Valves

Removal 1. 2. 3. 4. 5. Remove the rider's seat (see page 16- 17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Detach the secondary air injection feed hoses from the reed valves on the camshaft cover.
1. Secondary air injection hose 2. Spring-close clip 1. Solenoid valve 2. Retainer 3. Spring hose clips 4. Multiplug
6. 7
Release the bolts securing the valve covers to the camshaft cover. Ease the valve covers from the valves.
7.
Gently pull the valve to detach from the retainer.
Installation 1. 2. 3. 4. 5. 6. 7. Refit the hoses to the valve. Locate the valve to the retainer. Reconnect the multi-plug. Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
1. Valves
8.
Detach the valves from the camshaft cover.
I uMP
1 0.135
Fuel System/Engin e Management

Installation 1. 2. 3. Fit the reed valves to the camshaft cover. Refit the valve covers and tighten the fixings to 9 Nm. Refit the secondary air injection feed hoses to the reed valves.
1
cdra
1. Reed valves
Inspection 1. 2. 3. Check for cracks, bending or other damage to the valve flaps. Replace as necessary. Check for damage to the seal areas. Replace as necessary. Check the valve body to cylinder head seal for damage.
1. Secondary air injection hose 2. Spring-close hose clip
4. 5. 6. 7.
Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first Refit the rider's seat (see page 16- 17).
1 0.136
I uMP

Evaporative Emissions Control System
California Models Only All California models are fitted with a system to control the evaporation of fuel vapour to the atmosphere. A carbon filled canister absorbs vapour while the engine is not running. When the engine is started, the vapour is returned to the engine and burnt. There are two distinct phases to the system's operation, engine off and engine running. These two conditions are explained overleaf.
Component Locations Carbon Filled Canister (2) - below the swinging arm. Purge Control Valve (3)- adjacent to frame, left hand side (electronically controlled by the ECM)
1. Breather hoses 2. Carbon filled canister 3. Purge valve 4. Purge hose to throttle bodies
I UMP
1 0.137

Evaporative Control System - Engine Off When the engine is stationary any pressure increase in the fuel tank due to a rise in ambient temperature will cause the fuel vapour to pass down the breather hose (1) to a carbon filled canister (2) which stores the vapour. Once in the canister, vapour cannot enter the engine because the purge valve is closed.
1. Breather hoses 2. Carbon filled canister 3. Purge valve (closed) 4. Purge hose to throttle bodies
1 0.138
111MP

Evaporative Control System - Engine Off When the engine is stationary any pressure increase in the fuel tank due to a rise in ambient temperature will cause the fuel vapour to pass down the breather hose (1) to a carbon filled canister (2) which stores the vapour. Once in the canister, vapour cannot enter the engine because the purge valve is closed.
1. Breather hoses 2. Carbon filled canister 3. Purge valve (closed) 4. Purge hose to throttle bodies
1 0.138
I UMP

Evaporative Control System - Engine Running When the engine is running, engine vacuum is applied to the purge hose (4) from the throttle bodies. At certain times, the ECM opens the purge valve. The vacuum applied to the purge hose (4) now begins to draw stored vapour from the carbon filled area of the canister and returns it to the throttle bodies for burning in the engine. In order to control the speed at which vapour is purged from the canister, the engine management system shuttles the purge control valve between open and closed positions.
1. Breather hoses 2. Carbon filled canister 3. Purge valve (open under ECM control) 4. Purge hose to throttle bodies
1LlMP
1 0.139
11 Cooling
Table of Contents
ExplodedView - Cooling System - Daytona 675 .............................................. Exploded View - Cooling System - Street Triple and Street Triple R ...............................
Coolant................................................................................. RadiatorHoses ........................................................................... Radiatorand Cooling Fan ..................................................................
11.2 11.3
11.4 11.5 11.5
Coolant
Level Inspection - Daytona 675 ......................................................
11.5 11.6 11.6

11.6 11.7
Coolant Level Inspection - Street Triple and Street T ri ple R ......................................
Coolant
Replacement - Daytona 675 ........................................................
Drainage........................................................................... Filling..............................................................................
Coolant Replacement - Street Triple and Street Triple R ........................................

Drainage........................................................................... Filling............................................................................. WaterPump ............................................................................ CoolantPressure Cap .................................................................... I nspection......................................................................... Thermostat.............................................................................
11.8
11.8 11.9 11.10 11.11 11.11 11.11 11.11 11.12 11.12 11.13 11.13 11.14 11.14
Removal ..........................................................................
I nspection......................................................................... I nstallation.........................................................................
Radiator
Daytona 675 ..................................................................
Removal.......................................................................... I nspection......................................................................... I nstallation.........................................................................
Radiator- Street
Triple and Street Triple R ...................................................
11.15
11.15 11.16 11.16
Removal ..........................................................................
I nspection......................................................................... I nstallation.........................................................................
on
,^
I UMP
11.1
Cooling
Exploded View - Cooling System - Daytona 675
2.5 Nm
2 Nm
r,.
12 Nm 3Nm 9Nm 2 Nm 12 Nm 2 Nm
^^ Q 9 Nm
2 Nm /
Im
3 Nm 2 Nm
12 Nm
11.2
IL] MP
Cooling
Exploded View - Cooling System - Street Triple and Street Triple R
M
1 Nm
v
2 Nm
9 Nm
I
2 Nm
2 Nm
12 Nm
o 2.5 Nm
"-
YO
9Nm
^ 3Nm
10 Nm 12 Nm 51
2 Nm
1/
5 Nm
Il1MP
Service Manual Daytona 675, Street Triple and Street Triple R
11.3
Cooling
Coolant
A permanent type of anti-freeze is installed in the cooling system when the motorcycle leaves the factory. Models built up to VIN 331531 The coolant is coloured blue, contains a 50% solution of ethylene glycol, and has a freezing point of -35C (-15F). Models built from VIN 331532 A year-round, Hybrid Organic Acid Technology (known as Hybrid OAT or HOAT) coolant is installed in the cooling system. It is coloured green, contains a 50% solution of ethylene glycol based antifreeze, and has a freezing point of -3 5C (-31 F). Note: HD4X Hybrid OAT coolant, as supplied by Triumph, is pre-mixed and does not need to be diluted prior to filling or topping up the cooling system.
Warning
The coolant mixture contains anti-freeze and corrosion inhibitors, which both contain toxic chemicals which are harmful to the human body. Never swallow anti-freeze or any of the motorcycle coolant.
Caution
The coolant mixture contains a corrosion inhibitor which helps prevent damage to the metal surfaces inside the cooling system. Without this inhibitor, the coolant would 'attack' the metals and the resulting corrosion would cause blockages in the cooling system leading to engine overheating and damage. Always use the correct antifreeze as specified in the owner's handbook. Never use a methanol based anti-freeze as this does not contain the required corrosion inhibition properties.
All models Always change the coolant at the intervals specified in the scheduled maintenance chart.
Caution
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 cause the engine to overheat and suffer severe damage.
11.4
ILIMP
Cooling
Radiator Hoses
Regularly check all radiator hoses and hose clips for cracks, leaks or deterioration in accordance with the scheduled maintenance chart.
Coolant Level Inspection - Daytona 675
Warning
Radiator and Cooling Fan
Check the radiator fins for obstruction by insects, mud, leaves and general debris. Clean off any obstructions by hand or with a stream of low pressure water. Do not remove the coolant pressure 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. Position the motorcycle on level ground and in an upright position. The expansion tank can be viewed from the left hand side of the motorcycle, between the rear of the lower fairing and the frame. The coolant level should be between the 'MAX' and 'MIN.' marks.
A Warning
2. The cooling fan operates automatically. To prevent injury, keep hands and clothing away from the fan blades at all times.
A. Caution
Using high-pressure water sprays can damage the radiator fins and impair the radiator's efficiency. Do not obstruct or deflect airflow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator airflow can lead to overheating and consequent engine damage.
1. Expansion tank 2. Expansion tank filler cap 3. ' MAX' mark 4. ' MIN.' mark
3. If the level of coolant is low, remove the cap from the expansion tank and add coolant mixture as necessary to bring the level up to the 'MAX' mark. Refit the cap.
Caution
If the coolant level is found to be low, or if coolant has to be added regularly, inspect the cooling system for coolant leaks. If necessary, pressure test the system to locate the source of the leak and rectify as necessary. Loss of coolant may cause the engine to overheat and suffer severe damage.
I UMP
11.5
Cooling
Coolant Level Inspection - Street Triple and Street Triple R Coolant Replacement - Daytona 675
Drainage
A Warning
Do not remove the coolant pressure 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 d amage. 1. 2. 3. Position the motorcycle on level ground and in an upright position. Remove the rider's seat (see page 16-17). The expansion tank is positioned between the rear subframe rails beneath the seat.
Note: Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly. Position the motorcycle on level ground on the sidestand. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first.
1. 2. 3.
Warning
Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside li the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage. 4. 5. Remove the lower fairings (see page 16-20). Remove the coolant pressure cap on the radiator.
1. Expansion tank 2. Expansion tank filler cap 3. ' MAX' mark 4. ' MIN' mark
4. Check the coolant level in the expansion tank. The coolant level must be between the 'MAX and 'MIN' marks. If the coolant is below the minimum level, the coolant level must be adjusted. 5. If the level of coolant is low, remove the cap from the expansion tank and add coolant mixture as necessary to bring the level up to the 'MAX' mark. Refit the cap.
cdmm Radiator Cap 6. Position a container to collect the displaced coolant.
ACaution
If the coolant level is found to be low, or if coolant has to be added regularly, inspect the cooling system for coolant leaks. If necessary, pressure test the system to locate the source of the leak and rectify as necessary. Loss of coolant may cause the engine to overheat and suffer severe damage.
11.6
Il1MP
Cooling
7. Slacken the clip then release the bottom hose from the radiator and allow the coolant to drain. Filling 9. 10. 11. Incorporating a new sealing washer, refit the drain bolt to the coolant outlet tube and tighten to 10 Nm. Reconnect the bottom hose and tighten the hose clip. Remove the bleed screw from the right hand side of the radiator.
1. Bottom hose
8.
Remove the drain bolt from the coolant outlet tube, located next to the heat exchanger and allow the coolant to drain. Discard the sealing washer.
1. Bleed screw
12.
Slowly add coolant mixture to the system, through the filler opening in the radiator, until the system is full. If the system has filled correctly and fully, there should be coolant visible through the bleed screw opening as well as in the filler opening. If there is no coolant visible through the bleed screw opening, but the filler side appears to be full, attach a length of clear tubing to the bleed screw spigot and syphon coolant into the bleed screw side of the radiator.
13.
Note:
1. Coolant outlet tube 2. Drain bolt
A hand operated vacuum pump or similar should be used to syphon the coolant through the system. 14. 15. 16. If necessary, top up the system through the filler and refit the pressure cap. Fit and tighten the bleed screw to 1.5 Nm. With the aid of an assistant, lean the motorcycle fully over to the right hand side, and then the left hand side, to release air trapped in the cooling system. Repeat as necessary. Reconnect the battery, positive (red) lead first. Start the motorcycle and allow to run for approximately 20 to 30 seconds. Briefly raise the engine speed several times to allow any air to be expelled from the system. Stop the engine. Check and top up the coolant level as necessary.
17. 18.
19.
I UMP
11.7
Cooling
20. With the aid of an assistant, lean the motorcycle fully over to the right hand side, and then the left hand side, to release air trapped in the cooling system. 21. Start the motorcycle. Briefly raise the engine speed several times to allow any air to be expelled from the system. Allow the engine to run until the cooling fan operates. Stop the motorcycle and allow the engine to cool.
Coolant Replacement - Street Triple and Street Triple R

Drainage
Note: Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly. 1. 2. 3. Position the motorcycle on level ground on the sidestand. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first.
22. 23.
AWa
r -`^*i n g n
Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the cooling system is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage. 24. Check and top up the coolant level as necessary. 25. Check the expansion tank level and top up if necessary. 26. 27. Refit the rider's seat (see page 16-17). Refit the lower fairings (see page 16-22).
Ak Warning
Do not remove the coolant pressure 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. 4. 5. Release the fixing securing the right hand direction indicator to the radiator cowl. Release the three fixings securing the radiator cowl to the radiator.
1. Radiator cowl 2. Direction indicator fixing
3. Fi xings
6. Without disconnecting the direction indicator connections, tie the radiator cowl aside. Do not allow the radiator cowl to hang from the direction indicator harness. Repeat steps 4 to 6 above for the left hand radiator cowl.
7.
11.8
Il1MP
a.i
Cooling
8. Remove the coolant pressure cap on the radiator Filling 1. 2. 3. Incorporating a new sealing washer, refit the drain bolt to the coolant outlet tube and tighten to 10 Nm. Reconnect the bottom hose and tighten the hose clip. Remove the bleed screw from the right hand side of the radiator.
Radiator Cap 9. Position a container to collect the displaced coolant. 10. Slacken the clip then release the bottom hose from the radiator and allow the coolant to drain.
1. Bleed screw
4.
Remove the bleed screw from the top hose.
1. Bottom hose
11. Remove the drain bolt from the coolant outlet tube, located next to the heat exchanger and allow the coolant to drain. Discard the sealing washer.
1. Top hose 2. Bleed screw
S. Slowly add coolant mixture to the system, through the filler opening in the radiator, until the system is full. If the system has filled correctly and fully, there should be coolant visible through the bleed screw opening as well as in the filler opening. 6. If there is no coolant visible through the bleed screw opening, but the filler side appears to be full, attach a length of clear tubing to the bleed screw spigot and syphon coolant into the bleed screw side of the radiator. Note:
1. Coolant outlet tube 2. Drain bolt
A hand operated vacuum pump or similar should be used to syphon the coolant through the system.
L UMP
11.9
Cooling
7. 8. 9. If necessary, top up the system through the filler and refit the pressure cap. Fit the radiator and top hose bleed screws, and ti ghten to 1 Nm. With the aid of an assistant, lean the motorcycle fully over to the right hand side, and then the left hand side, to release air trapped in the cooling system. Repeat as necessary. Reconnect the battery, positive (red) lead first. Start the motorcycle and allow to run for approximately 20 to 30 seconds. Briefly raise the engine speed several times to allow any air to be expelled from the system. Stop the engine. Check and top up the coolant level as necessary. With the aid of an assistant, lean the motorcycle fully over to the right hand side, and then the left hand side, to release air trapped in the cooling system. Start the motorcycle. Briefly raise the engine speed several times to allow any air to be expelled from the system. Allow the engine to run until the cooling fan operates. Stop the motorcycle and allow the engine to cool.
Water Pump
Note: The oil pump and water pump are supplied as an assembly and cannot be separated. For additional information, refer to Oil Pump (see page 8-9 for removal and page 8-13 for installation).
10. 11.
12. 13.
14.
15. 16.
A Warning.
Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the cooling system is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage. 17. 18. 19. Check and top up the coolant level as necessary. Reposition the right hand radiator cowl and direction indicator to the radiator. Install the three radiator cowl fixings and the direction indicator fixing and tighten as follows: Tighten the radiator cowl fixings to 5 Nm. Tighten the direction indicator fixing to 4 Nm.
20. 21. 22.
Repeat steps 18 and 19 above for the left hand radiator cowl. Check the expansion tank level and top up if necessary. Refit the rider's seat (see page 16-17).
11.10
Il1MP
Cooling
Coolant Pressure Cap
Inspection
Thermostat
Removal Note:
Warning
Do not remove the coolant pressure 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. Check the condition of the upper and lower seals of the coolant pressure cap.
Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Drain the coolant (see page 11-6 for Daytona 675 or page 11-8 for Street Triple and Street Triple R). Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Remove the throttle bodies (see page 10- 106).
1. 2. 3. 4. 5. 6.
Warning
Do not remove the coolant pressure 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. caWr
1. Lower seal 2. Upper seal 3. Spring
7. 8. 9.
Detach the top hose from the thermostat elbow. Release the fixings securing the thermostat elbow to the cylinder head. Remove the thermostat housing. Discard the O-ring.
Note: If there is any sign of damage or deterioration replace the cap.
2. Pressure test the cap to the blow off pressure of 1.1 bar. If the cap opens at a lower pressure or fails to open at 1.1 bar, replace the cap.
1. Thermostat housing 2. Fixings
iliMP
11.11
Cooling
10. Remove the thermostat from the cylinder head 2. Fit a new 0-ring to the thermostat elbow groove.
l" C
^^1enam^ i
, .'C^<<o
'. t
TM
1. O-ring groove
3. 4. Inspection 1. 2. Inspect the thermostat at room temperature. If the valve is open, the thermostat must be replaced. To check the valve opening temperature, suspend the thermostat in a container of water and raise the temperature of the water until the thermostat opens. The thermostat should start to open at 71 C +/- 5C. If the temperature at which thermostat opening takes place is incorrect, replace the thermostat. 5. 6. 7. 8. 9.
Tighten the fi xings to 9 Nm. Reconnect the top hose and tighten the clip. Refit the throttle bodies (see page 10-108). Refit the airbox (see page 10-96). Refi t the fuel tank (see page 10-90). Reconnect the batte ry positive (red) lead first. Refit the rider's seat (see page 16-17).
3.
10. Refill the cooling system (see page 11-7 for Daytona 675 or page 11-9 for Street Triple and Street Triple R).
Installation 1. Locate the thermostat into the cylinder head. Ensure the bleed valve is uppermost as shown below.
1. Thermostat 2. Bleed valve
11.12
ILiMP
Cooling
Radiator - Daytona 675
Removal Note: Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the lower fairings (see page 16-20). Detach the vacuum reservoir and hose from the radiator and position aside.
1. Top hose 2. Bypass hose
6.
Disconnect the top hose and bypass hose at the radiator.
1. 2. 3. 4.
7. 8.
Disconnect the heat exchanger hose from the radiator. Release the radiator lower mounting.
1. Vacuum reservoir 2. Fixing
AWarning
Do not remove the coolant pressure 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. 5. Drain the coolant (see page 11-6).
1. Heat exchanger hose 2. Radiator lower mount fixing
9.
Disconnect the cooling fan connection from above the camshaft cover.
"fl1IIIIMrH
11.13
Cooling
10. Release the bolts securing the radiator to the frame Installation 1. Align the radiator to the frame and lower mounting. Fit the upper mounting bolts and nuts. Tighten the left hand bolt to 12 Nm, and the right hand bolt to 6 Nm. Fit and tighten the lower mounting bolt to 3 Nm. Reconnect the cooling fan. Reconnect the bypass, heat exchanger, top and bottom hoses. Tighten the hose clips, ensuring they are repositioned as noted prior to disassembly. Refit the vacuum reservoir and hose to the radiator and tighten the fixing to 6 Nm.
2. 3. 4.
5.
1. Radiator to frame bolts 11. Remove the radiator.
Inspection 1. 2. 3. Check the radiator for stone damage. Check the radiator core for damage to the fins or obstructions to air flow. Repair any damage and clear all obstructions.
,A
4. 5.
Caution
1. Vacuum reservoir 2. Fixing 6. 7. 8. 9. Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17). Refit the lower fairings (see page 16-22). Refill the cooling system (see page 11-7).
To avoid overheating and consequent engine damage, replace the radiator if the cores are blocked or if the fins are badly deformed or broken. Check that the fan spins freely and without tight spots. Check the fan blades for signs of heat distortion.
11.14
I UMP
Cooling
Radiator - Street Triple and Street Triple R
Removal Note: Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. 5. Disconnect the top hose and bypass hose at the radiator.
1. 2.
Warning
Do not remove the coolant pressure 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. 3. 4. Drain the coolant (see page 11-8). Disconnect the two horn electrical connectors.
1. Top hose 2. Bypass hose
6. 7.
Disconnect the heat exchanger hose from the radiator. Release the radiator lower mounting.
r..
1. Heat exchanger hose 2. Radiator lower mount fixing
8.
1. Horn connectors
Disconnect the cooling fan connection, located above the camshaft cover.
Il.1 MP
11.15
Cooling
9. Release the fixings securing the radiator to the frame. Installation 1. Align the radiator to the frame and lower mounting. Fit the upper mounting bolts and nuts. Tighten the left hand bolt to 12 Nm, and the right hand bolt to 6 Nm. Fit and tighten the lower mounting bolt to 3 Nm. Reconnect the cooling fan. Reconnect the bypass, heat exchanger, top and bottom hoses. Tighten the hose clips, ensuring they are repositioned as noted prior to disassembly. Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16- 17). Refill the cooling system (see page 11-9). Refit the radiator cowls (see page 16-25).
2. 3. 4.
I IIll III 11IIIIIIIIIIIIIIIIIIIIIII II Ill IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
5. 6. 7.
cesm
1. Radiator to frame fixings
8.
10. Remove the radiator.
Inspection 1. 2. 3. Check the radiator for stone damage. Check the radiator core for damage to the fins or obstructions to air flow. Repair any damage and clear all obstructions.
ACaution
To avoid overheating and consequent engine damage, replace the radiator if the cores are blocked or if the fins are badly deformed or broken. 4. 5. Check that the fan spins freely and without tight spots. Check the fan blades for signs of heat distortion.
11.16
ll1MP
12 Rear Suspension
Table of Contents
ExplodedView - Swinging Arm ............................................................
Ex
12.2 12.3 12.4 12.5 12.6 12.7 12.7 12.7 12.7 12.8 12.8 12.9 12.9 12.10 12.10 12.11 12.11 12.12 12.12 12.12 12.12 12.14 12.14 12.15 12.15
lodedView
- Rear Hub and Wheel .......................................................
Exploded View - Rear Suspension Unit - Daytona 675 and Street Triple R ......................... Exploded View - Rear Suspension Unit - Street Triple ..........................................
Ex
p lodedView - Drop/Drag Link ...........................................................
DriveChain ............................................................................. ChainLubrication ................................................................... ChainAdjustment ........................................................................ ChainFree-movement Inspection .............. ....................................... ChainFree-movement adjustment .................................................... ChainWear Inspection .............................................................. RearSuspension Unit ..................................................................... Removal.......................................................................... Inspection......................................................................... Installation.........................................................................
Dra Link
..............................................................................
Removal.......................................................................... Inspection......................................................................... Installation......................................................................... SwingingArm .......................................................................... Removal.......................................................................... Inspection......................................................................... Assembly.......................................................................... DriveChain Replacement ................................................................. Rivetlink type .....................................................................
Il1MP
1 2.1
Rear Suspension
Exploded View - Swinging Arm
Street Triple
I
----
9 Nm
Ô^
0
^ I
Daytona 675 9 Nm 9 Nm 9 Nm
20 Nm 6 Nm NI
110 Nm
12.2
111MP
Rear Suspension
Exploded View - Rear Hub and Wheel
110 Nm
OO
30 Nm
\ o m
^m m
55 Nm
a..
Il1MP
12.3
Rear Suspension
Exploded View - Rear Suspension Unit - Daytona 675 and Street Triple R
52 Nm
_A 1
I
0
48 Nm
1 2.4
Il1MP
Rear Suspension
Exploded View - Rear Suspension Unit - Street Triple
52 Nm
48 Nm
Id vi
ll1MP
1 2.5
Rear Suspension
Exploded View - Drop/Drag Link
9^G
9SD
48 Nm
48 Nm
1 2.6
1lIMP
Rear Suspension
Drive Chain
For safety and to prevent excessive wear, the drive chain must be checked, adjusted and lubricated in accordance with scheduled maintenance requirements. Checking, adjustment and lubrication must be carried out more frequently for extreme conditions such as salty or heavily gritted roads. If the chain is badly worn or incorrectly adjusted (either too loose or too tight) the chain could jump off the sprockets or break.
Chain Adjustment
Chain Free- movement Inspection
Warning
A chain that breaks or lumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing an accident. Never neglect chain maintenance. Note: Lubrication of the drive chain should ideally be carried out with the motorcycle set up so that the rear suspension hangs free. The chain must be adjusted with the motorcycle in an upright position, resting on its wheels, and with no additional weight on it.
cdkv
1. Maximum movement position
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Place the motorcycle on a level surface and hold it in an upright position with no weight on it. Rotate the rear wheel by pushing the motorcycle to find the position where the chain has least slack. Measure the chains vertical movement, mid-way between sprockets. If correct, the vertical movement of the drive chain midway between the sprockets should be: 24 - 30 mm for the Daytona 675; 13 - 32 mm for the Street Triple and Street Triple R.
Chain Lubrication Lubrication is necessary every 200 miles (300 Km) and also after riding in wet weather, on wet roads, or any time that the chain appears dry. Use the special chain lubricant as recommended in the specification section. Correct application is critical for chain lubrication. Apply the lubricant for one full chain revolution only, then leave for eight hours before riding. This allows the lubricant's solvent (used to thin the oil) to evaporate and the oil to 'soak' into all parts of the chain. If the lubricant is applied and the motorcycle is ridden shortly afterwards, the lubricant is unlikely to reach all parts and the majority will be flung off and wasted. Applying excessive amounts is not helpful under any circumstances. It should be noted that the lubricant is applied to the chain to lubricate its action across the sprockets. In an O-ring chain, external lubrication does not penetrate to the bushes and rollers as the O-ring seals prevents this from happening. 2.
3.
Caution
Do not use a power 'jet' wash to clean the chain as this may cause damage to the chain components.
I UMp
1 2.7
Rear Suspension
Chain Free - movement adjustment 1. 2. Loosen the wheel spindle nut. Release the locknuts on both the left hand and right hand chain adjuster bolts.
A Warning
It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident. Chain Wear Inspection
cdIf
\2
1. Adjuster bolt locknut 2. Adjuster bolt 3. Rear wheel spindle nut
3. Moving both adjusters by an equal amount, turn the adjuster bolts clockwise to increase chain free movement and counter clockwise to reduce chain free movement. 4. When the correct amount of chain free movement has been set, push the wheel into firm contact with the adjusters. Note: Check for equal adjustment on both sides using the graduation marks on the swinging arm.
cdkw
1. Measurement across 20 links 2. 10-20kg Weight
A Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. 3. Remove the chain guard from the swinging arm. Stretch the chain taut by hanging a 10-20 kg (20-40 Ib) weight on the chain. Measure a length of 20 links on the straight part of the chain from pin centre of the 1 st pin to pin centre of the 21 st pin. Repeat the test at various sections of the chain to establish an average reading. This is because the chain may wear unevenly. If the length exceeds the service limit of 319 mm (12.56 in), the chain must be replaced.
5. 6.
Tighten both adjuster locknuts to 20 Nm and the rear wheel spindle nut to 110 Nm. Repeat the chain adjustment check. Re-adjust if necessary.
WA Wing
Operation of the motorcycle with insecure adjuster locknuts or a loose wheel spindle may result in impaired stability and handling of the motorcycle. This impaired stability and handling may lead to loss of motorcycle control and an accident. 7. Check the rear brake effectiveness. Rectify if necessary.
4.
AWarning
A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing loss of control and an accident.
1 2.8
I UMP
Rear Suspension
5. Examine the whole length of the chain. If there are any excessively tight or loose sections, loose pins or damaged rollers, the chain should be replaced. Inspect sprockets for unevenly or excessively worn teeth. Also examine the sprockets for damaged teeth.
Rear Suspension Unit

Removal
6.
Warning
WORN TOOTH WORN TOOTH (ENGINE SPROCKET) (REAR SPROCKET) If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries.
A
MM
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Sprocket wear is exaggerated for illustration purposes. 2. Raise and support the rear of the motorcycle under the frame or engine. Position a block to support the rear wheel. Remove the seats (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the rear panel(s) (see page 16-18 for Daytona 675 or page 16-19 for Street Triple and Street Triple R). Daytona 675 only: Remove the lower fairings (see page 16-20). Remove the exhaust system (see page 10-116 for Daytona 675 or page 10-122 for Street Triple and Street Triple R). Remove the three drop link plate fixings. Discard the nuts.
Note:
A Warning
The use of non-approved chains may result in a broken chain or may cause the chain to jump off the sprockets. Use a genuine Triumph supplied chain as specified in the Triumph Parts Catalogue. Never neglect chain maintenance and always have chains installed by an authorised Triumph dealer. 7. If there is any irregularity found in any of the components, replace the drive chain and/or any other damaged components. Refit the chain guard, tightening the fixings to 9 Nm.
3. 4.
5. 6.
8.
ll.l MP
1 2.9
Rear Suspension
Note: Both drop link plates are marked as shown below. Both plates are identical, and must be fitted with the bolt hole markings facing the right hand side of the motorcycle. Inspection 1. Clean all components and inspect for damage/wear to: rear suspension unit upper and lower mountings, lower mounting spacer, bearing and seals, drop link bearings, sleeves and seals.
1 2 2. 3. 4. 5.
Renew as necessary. Check the swinging arm drop link bearing for wear. Overhaul as necessary. Check the drag link bearings for wear. Overhaul as necessary (see page 12-12). Inspect the unit for damage and fluid leaks. If there is any damage, or fluid leaks are evident, the unit must be replaced.
Front
1. Swinging arm bolt position 2. Rear suspension bolt position 3. Drag link bolt position
Installation 1. 2. 3. 4. Remove the drag link sleeve and pack the bearing with fresh grease. Refit the sleeve. Remove the rear suspension lower sleeve and pack the bearing with fresh grease. Refit the sleeve. Remove the swinging arm drop link sleeve and pack the bearing with fresh grease. Refit the sleeve. Refit the rear suspension unit to the motorcycle by lowering the unit downwards through the hole in the swinging arm. Locate the rear suspension unit and loosely fit the upper mounting bolt and a new nut.
8.
Noting the orientation of the drop link plates, remove the plates and position the drag link clear.
5.
Note: The drop link plates are marked as shown below. Both plates are identical, and must be fitted with the bolt hole markings facing the right hand side of the motorcycle.
1. Rear suspension unit 2. Drag link 3. Drop link 4. Fixings
1 2
A Warning
Never attempt to disassemble the rear suspension unit or reservoir. It contains fluid under pressure and serious injury could result if any part of the system is disturbed. 9. Remove the rear suspension unit upper mounting nut and bolt, and manoeuvre the unit upwards through the swinging arm and clear of the motorcycle.
Front
1. Swinging arm bolt position 2. Rear suspension bolt position 3. Drag link bolt position
1 2.10
I UMP
Rear Suspension
6. Locate the drop link plates and, from the right hand side, loosely fit the bolts and new nuts.
Drag Link
Removal
Warning
1. Rear suspension unit 2. Drop link plate 3. Drag link 4. Fixings
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Raise and support the rear of the motorcycle beneath the frame or engine. Position a block to support the rear wheel. Remove the seats (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the rear panel(s) (see page 16-18 for Daytona 675 or page 16-19 for Street Triple and Street Triple R). Daytona 675 only: Remove the lower fairings (see page 16-20). Remove the exhaust system (see page 10-116 for Daytona 675 or page 10-122 for Street Triple and Street Triple R). Remove the two fixings securing the drag link. Remove the drag link.
7. 8.
Tighten the three drop link fixings to 48 Nm. With the weight of the motorcycle on its wheels, tighten the rear suspension unit upper mounting to 48 Nm. Refit the exhaust system (see page 10-119 for Daytona 675 or page 10-124 for Street Triple and Street Triple R). Daytona 675 only: Refit the lower fairings (see page 16-22). Fit the rear panel(s) (see page 16-18 for Daytona 675 or page 16-25 for Street Triple and Street Triple R). Connect the battery, red (positive) lead first. Fit the seats (see page 16-17).
9.
2. 3. 4.
10. 11. 12. 13.
5. 6.
7. 8.
..r
1. Drag link 2. Fixings
I uMP
1 2.11
Rear Suspension
Inspection 1. 2. 3. 4. Clean all components and inspect the drag link and bearings for damage/wear. Check the rear suspension unit lower bearings for wear. Check the drop link upper bearings for wear. Renew as necessary.
Swinging Arm
Removal
Warning
Installation 1. 2. 3. Remove the drag link sleeves and pack the bearings with fresh grease. Refit the sleeves. Refit the drag link, fit the bolts and new nuts, and tighten to 48 Nm. Refit the exhaust system (see page 10-119 for Daytona 675 or page 10-124 for Street Triple and Street Triple R). Daytona 675 only: Refit the lower fairings (see page 16-22). Fit the rear panel(s) (see page 16-18 for Daytona 675 or page 16-25 for Street Triple) and Street Triple R. Connect the battery, red (positive) lead first. Fit the seats (see page 16-17).
1. 2. 3.
Warning
4. 5. 6. 7.
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Remove the seats (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the rear panel(s) (see page 16-18 for Daytona 675 or page 16-19 for Street Triple and Street Triple R). Daytona 675 only: Remove the lower fairings (see page 16-20). Remove the exhaust system (see page 10-116 for Daytona 675 or page 10-122 for Street Triple and Street Triple R). Remove the rear wheel (see page 15-8). Support the swinging arm and remove the rear suspension unit (see page 12-9). Remove the sprocket cover. Detach the chain from the output sprocket.
4. 5.
6. 7. 8. 9.
Warning
Do not allow the caliper to hang on the brake hose as this may damage the hose and could lead to an accident.
12.12
Il1MP
Rear Suspension
10. Release the brake hose clips from the swinging arm and tie the rear brake caliper to one side. 13. Engage tool 13880104 in the slots of the frame adjuster sleeve and rotate anti-clockwise to slacken the sleeve fully.
1 2
Cdr
1. Rear brake hose clips
1. Frame adjuster sleeve 2. Tool T3880104
11. Remove and discard the swinging arm spindle nut. 12. Partially withdraw the swinging arm spindle from the right hand side, to allow access to the frame adjuster sleeve located on the left hand side of the frame.
a..
14. Withdraw the swinging arm spindle from the right hand side and remove the swinging arm, together with the drive chain. Support the drive chain while the swinging arm is being removed to protect it from contamination. If the swinging arm is to be replaced remove the drive chain (see page 12- 15). Remove the bearing sleeves from both sides. Remove the right hand bearing by drifting through from the left.
15. 16.
17. Collect the spacer tube. \_ i
1. Swinging arm 2. Spindle f,
4 3
6
8 7
1. Frame adjuster sleeve 2. Sleeve 3. Seal 4. Needle roller bearing 5. Spacer tube 6. Ball Bearing 7. Circlip 8. Seal 9. Spacer
puII1IrH
12.13
Rea r Suspension
Note: The needle roller bearing in the left hand side of the arm cannot be removed undamaged. Assembly 1. Install the bearings (marked faces outwards), sleeves etc. into the swinging arm in the order shown on the previous page. Use new seals throughout. Fit the drive chain rubbing strip and tighten the fixing to 9 Nm. Fit the drive chain to the swinging arm (see page 1215). Position the swinging arm to the frame ensuring the drive chain is in position on the rubbing strip. Refit the swinging arm spindle from the right hand side such that it will support the swinging arm, but not pass all the way through the frame adjuster sleeve. This will allow tool T3880104 to engage in the slot in the frame adjuster sleeve. Using tool T3880104, tighten the frame adjuster sleeve to 6 Nm.
18. Remove the drive chain rubbing strip.
2. 3. 4. 5.
Inspection 1. 2. 3. 4. 5. 6. 7 Check all swinging arm bearings for damage, pitting, and cracks. Replace as necessary. Check the swinging arm for damage. Replace as necessary. Check the wheel bearings for damage, pitting, and cracks. Replace as necessary. Check all bearing seals for damage, splits etc. Replace as necessary. Check the chain for wear, damage etc. Replace as necessary. Check both sprockets for wear, damage etc. Replace as necessary. Check the drive chain rubbing strip for wear and damage. Replace as necessary.
6.
-d4f
r I
Il
1. Frame adjuster 2. Tool T3880104 7. 8. 9. 10. Fully insert the swinging arm spindle. Fit a new swinging arm spindle nut and tighten to 110 Nm. Fit the drive chain to the output sprocket. Refit the sprocket cover and tighten the bolts to 9 Nm.
12.14
I UMP
Rear Suspension
11. Release the caliper and refit the rear brake hose clips to the swinging arm. Tighten the fixings to 6 Nm.
Drive Chain Replacement

Rivet link type As the drive chain passes through the swinging arm casting, the chain must be split for removal from the motorcycle. Removal of the swinging arm is not required for drive chain replacement. The following instructions for the replacement of rivet link type drive chains requires the use of service tool T3880027
A
1. Rear brake hose clips
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. Support the motorcycle on a stand so the rear wheel is clear of the ground. Insert the hollow chain cutting tail piece into the tool body so its larger diameter end is facing towards the large pressure screw as shown.
12. Refit the rear suspension unit (see page 12-10). 13. Refit the rear wheel (see page 15-8). 14. Refit the exhaust system (see page 10-119 for Daytona 675 or page 10-124 for Street Triple and Street Triple R). 15. Daytona 675 only: Refit the lower fairings (see page 16-22). 16. Fit the rear panel(s) (see page 16-18 for Daytona 675 or page 16-25 for Street Triple and Street Triple R). 17 Connect the battery, red (positive) lead first. 18. Fit the seats (see page 16-17). 19. Pump the rear brake pedal several times to position the brake pads in the caliper. Rectify as necessary if correct brake operation is not restored (see page 1439).
Warning
It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
cdqk
1. Tool T3880027 2. Large pressure screw 3. Chain cutting tail piece
Il.
mp
12.15
Rear Suspen sion

3. Position the chain to the tool ensuring that the chain li nk pin which is to be removed is aligned with the holes in the chain cutting tail piece and the large pressure screw. Tighten the large pressure screw by hand to grip the chain. Note: The replacement chain is supplied in a split condition, complete with a link kit to join the two ends.
Caution
The component parts of the new link kit are coated with a special grease which must not be removed. Removal of this special grease will severely reduce the service life of the chain. 9. Use the old drive chain to pull the new chain into position as follows: Temporarily attach the end of the new chain to a free end of the old chain using the old connector link. Carefully pull the other end of the old chain to pull the new chain around the sprockets. Note:
1. Tool T3880027 2. Large pressure screw 3. Chain 4. Chain cutting tail piece
Do not use the new connector link as the special grease on it may be removed.
4. Insert the small pressure screw into the larger pressure screw as shown below, until the cutting pin on the small pressure screw contacts the link pin. Ensure that the cutting pin is centralised on the link pin to be removed.
10. Using the new link supplied with the chain kit, join the two ends of the chain. Ensure that the O-rings are positioned as shown below and the link plate is fitted with its markings facing outwards.
1. O-rings 2. Link 3. Link plate
1. Tool T3880027 2. Small pressure screw
11. Insert the riveting tail piece into the tool body so its larger diameter end is facing towards the large pressure screw as shown. Note: Tool T3880027 includes two link plate holders, one is for riveted link plates (marked PHSO60R), the other is for link plates retained by a spring clip (marked PH4060C). The holder for riveted link plates has a shallow groove to allow for chain link clearance, the holder for clipped link plates has a deep groove to allow for chain link clearance.
S. 6. 7. 8.
Retain the tool body then tighten the small pressure screw until the link pin is pressed out from the chain. Repeat steps 3 to 5 on the remaining chain link pin. Remove the tool and separate the two ends of the chain. Remove the chain cutting tail piece from the body.
12.16
II,I MP
Rear Suspension
12. Insert the link plate holder (marked PHSO60R) into the large pressure screw. 14. Locate the split link pins such that the pins will enter the groove in the link plate holder when the link plate is pressed on to the link.
2 2
1.Tool body 2. Large pressure screw 3. Link plate holder (marked PHSO60R) 4. Riveting tail piece 13. Position the tool to the chain. Ensure the link plate holder is correctly located in the large pressure screw.
1. Link plate holder 2. Link plate 3. Chain link 4. Link plate holder groove 15. Retain the tool body and tighten the large pressure screw until the link plate is pressed fully onto the link. 16. Back off the pressure screw, slide the tool assembly to one side and check that the split link is correctly assembled. 17. Remove the link plate holder from the tool. Do not remove the riveting tail piece from the tool 18. Insert the flare pin into the large pressure screw.
cdgr
1.Tool body 2. Link plate holder (marked PHSO60R) 3. Link plate 4. Link 5. Large pressure screw
1.Tool body 2. Large pressure screw 3. Riveting tail piece 4. Flare pin 19. Locate one of the split link pins into the riveting tail piece and screw the large pressure screw in until the flare pin contacts the split link end. Ensure the split li nk pin is centrally located on the flare pin.
lump
12.17
Rear Suspension
20. Retain the tool body and tighten the large pressure screw until the split link end is riveted-over. 22. Remove the tool from the chain and check that both the split link pins are correctly riveted as shown below.
Vxxx
1.Tool body 2. Large pressure screw 3. Flare pin 21. Back off the large pressure screw and rivet the remaining split link pin as described above.
1. Correct riveting 2. Insufficient riveting 3. Excessive riveting 4. Riveting off-centre
Warning
If either split link pin is not correctly riveted, the split link must be removed and replaced with a new link. Never operate the motorcycle with an incorrectly riveted split li nk as the link could fail resulting in an unsafe riding condition leading to loss of control and an accident.
1 2.18
S UMP
13 Front Suspension
Table of Contents
Exploded View - Front Fork - Daytona 675 and Street Triple R ................................... ExplodedView - Handlebars - Daytona 675 .................................................. ExplodedView - Front Fork - Street Triple .................................................... Exploded View - Handlebars - Street Triple and Street Triple R .................................. FrontSuspension ......................................................................... ForkInspection ..................................................................... FrontFork ............................................................................... Removal.......................................................................... Installation......................................................................... ForkOil Change ......................................................................... Draining.......................................................................... OilRefilling ....................................................................... ForkOil Level Chart ................................................................. FrontFork .............................................................................. Disassembly....................................................................... Inspection........... .............................................................. Assembly.......................................................................... HeadstockBearing Check/Adjustment ...................................................... Check............................................................................
A A
13.2 13.3 13.4 13.5 13.6 13.6 13.6 13.6 13.8 13.8 13.8 13.8 13.9 13.10 13.10 13.12 13.13 13.15 13.15 13.16 13.17 13.19 13.19 13.20 13.21 13.21 13.21 13.22 13.22 13.24 13.25 13.25 13.26
djustme
nt
- Daytona 675 ...........................................................
djus t ment - Street Triple and Street Triple R ...........................................
HeadstockBearing Removal .............................................................. Inspection......................................................................... Installation........................................................................ SteeringDamper - Daytona 675 only ....................................................... Removal.......................................................................... Installation......................................................................... Handlebars Daytona 675 ................................................................ Removal......................................................................... Installation........................................................................ Handlebars- Street Triple and Street Triple R ................................................ Removal......................................................................... Installation........................................................................
-
1 TMP
13.1
Front Suspension
Exploded View - Front Fork - Daytona 675 and Street Triple R
See text
18Nm
20 Nm 17 Nm
mP\
\12Nm
\ 20 Nm 18 Nm/
\ \ ll
Daytona 675
iI1
24 Nm
22 Nm
13.2
I uMP
Front Suspension
Exploded View - Handlebars - Daytona 675
5 Nm
lump
13.3
Front Suspension
Exploded View - Front Fork - Street Triple
See text
20 Nm
17 Nm
25 Nm
22 Nm
1
24 Nm
13.4
I uMP
Front Suspension
Exploded View - Handlebars - Daytona 675
5 Nm
I UMP
1 3.3
Front Suspension
Exploded View - Front Fork - Street Triple
See text
\D
17 Nm
25 Nm
^ 1
24 Nm
22 Nm
13.4
Il1MP
Front Suspension
Exploded View - Handlebars - Street Triple and Street Triple R
5 Nm
000.000
u^ôou,po
4 Nm
I
35 Nm
6 Nm
5 Nm
I UMp
13.5
Front Suspension
Front Suspension
The Daytona 675 and street Triple R are equipped with hydraulic, adjustable, telescopic front forks. Both forks are adjustable for spring pre-load, compression damping and rebound damping. From VIN 3 the Daytona 675 front forks have low stroke speed and high stroke speed compression damping adjusters. The Street Triple is equipped with hydraulic, telescopic front forks. The Street Triple front suspension has no adjustments. Periodic inspection for damage and fluid leaks is essential for safe riding. Always follow the inspection instructions at the intervals stated in the scheduled maintenance chart. On Daytona 675, a hydraulic, non-adjustable, steering damper is fitted beneath the lower yoke. The damper rod is attached to the frame via a bracket above the radiator.
Front Fork
Removal
AWarning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. 3. Raise and support the front of the motorcycle. Remove the front wheel (see page 15-6). Release the four fixings and remove the front mudguard.
Fork Inspection
Examine each fork for any sign of damage or scratching of the slider surface or for oil leaks. If any damage or oil leakage is found, strip and repair as described in this section or consult an authorised Triumph dealer. Check for smooth operation of the forks as follows: Place the motorcycle on level ground. ( "'
1"
O r
O
A e A A
caog U^ A
While holding the handlebars and applying the front brake, pump the forks up and down several times. If roughness or excessive stiffness is detected, repair as described in this section or consult an authorised Triumph dealer.
1. Right hand mudguard fixings (Daytona 675 shown) 4. Detach and the support the front brake calipers; see page 14-21 for Daytona 675 up to VIN 381274 and Street Tiple R; see page 14-17 for Daytona 675 from VIN 381275; see page 14-26 for Street Triple.
A Warning
Riding the motorcycle with defective or damaged suspension can cause loss of motorcycle control and an accident. Never ride with damaged or defective suspension.
A Warning
Never allow the brake calipers to hang on the brake hoses as this may damage the hoses. A damaged brake hose can cause a reduction in braking efficiency leading to loss of motorcycle contr o l and an accident.
13.6
Service Manual - Daytona 675, Street T ri ple and Street Triple R
IUMP
Front Suspension
Note: 5. If the forks are to be dismantled, slacken the fork top caps. Daytona 675 only: Slacken the handlebar and top yoke clamp bolts. 7. Slacken the bottom yoke clamp bolts.
Note: Daytona 675 shown, Street Triple similar.
1. Bottom yoke clamp bolts 1. Handlebar clamp bolt 2. Top yoke clamp bolt 6. Street Triple and Street Triple R: Slacken the top yoke clamp bolts. 8. Using a downward, twisting action, withdraw the forks from between the yokes.
1. Top yoke clamp bolt
Caution
Care must be taken when removing the forks, to ensure that the outer surfaces do not become scratched.
L UMP
13.7
Front Suspension
Installation 1. Position the forks within the yokes so that the lip of the outer tube, not the top cap, is 4 mm above the upper surface of the top yoke. Note: Daytona 675 shown, Street Triple similar.
Fork Oil Change

Draining
A, Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. Remove the fork (see page 13-6). Remove the top cap assembly (see page 13-10). Remove the fork spring (see page 13- 70). Holding the inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. Pump the damper rod to remove all the oil.
i mm
3. 4.
Oil Refilling
1. Outer tube 2. Top cap 3. Top yoke
The oil level is measured from the upper surface of the fork outer tube, with the fork fully compressed and the spring removed.
2. 3. 4.
Tighten the bottom yoke clamp bolts to 20 Nm. Tighten the top yoke clamp bolts to 26 Nm. Daytona 675 only: Tighten the handlebar clamp bolts to 26 Nm. For the measurement, refer to the table below.
Note: 5. 6. 7. If the forks have been dismantled, tighten the fork top caps to 25 Nm. Refit the front mudguard. Tighten the fixings to 6 Nm. Install the front wheel (see page 15-7). Refit the front brake calipers; 8. see page 14-23 for Daytona 675 up to VIN 381274 and Street Tiple; see page 14-25 for Daytona 675 from VIN 381275; see page 14-28 for Street Triple.
thy
Fork Oil Level (fully compressed) Model Daytona 675 up to VIN 381274 Daytona 675 from VIN 381275 Street Triple Street Triple R 1. Oil Level 72 mm 89 mm 107 mm 93 mm
Lower the motorcycle to the ground and park it on the side stand.
Fill the fork with the grade of oil specified in the fork oil table, to a level above that which will finally be required. Pump the fork assembly and damper several times to expel any trapped air then fully compress the fork and support it in an upright position. Leave the fork for a few minutes to allow the oil to stabilise.
2.
13.8
IIIMP
Front Suspension
3. Refer to the fork oil level chart and set the scale on tool 3880160-T0301 to the relevant distance, as shown below. Refer to fork oil level chart
1
Fork Oil Level Chart
Daytona 675 up to VIN 381274 Oil Level* 72 mm Oil Volume 495 cc Oil Grade Fork Pull Through Top of the inner 4 mm tube above the upper face of the top yoke
Kayaba KHL15-10
Daytona 675 from VIN 381275 Oil Level* 89 mm

cbyg
Oil Volume 492 cc
Oil Grade Kayaba KHL15-10
Fork Pull Through Top of the inner mm tube 4 above the upper face of the top yoke
1. Tool 3880160-T0301 2. Adjustment plate 3. Scale area 4. Hole (zero position)
Street Triple Oil Level* 107 mm Oil Volume 465 cc Oil Grade Fork Pull Through Top of the inner 4 mm tube above the upper face of the top yoke
Note: Zero level on the tool is set at the small exit hole in the side of the scale tube, NOT AT THE END TIP. Do not attempt to block this side hole as this will cause the final fluid level to be incorrect. Insert the scale end of the tool into the fork inner tube. Hold the tool adjuster plate level with the upper surface of the fork inner tube and draw fluid into the syringe until fluid flow ceases (empty the syringe if the body becomes full before fluid flow stops). The fluid level in the fork is now set to the height set on the tool scale. Check the tool scale setting and repeat the process if incorrectly set.
Kayaba KHL15-10
4. 5.
Street Triple R Oil Level* 93 mm Oil Volume 475 cc Oil Grade Kayaba KHL15-10 Fork Pull Through Top of the inner mm 4 tube above the upper face of the top yoke
6.
A
Incorrect fork oil levels could result in an unsafe riding condition leading to loss of control and an accident. 7. 8. Assemble the fork (see page 13-13). Refit the fork (see page 13-8).
'Fork Fully Compressed
I UMP
13.9
Front Suspension
Front Fork
Disassembly
A Warning
Warning
Do not change the fork adjustment settings. If they are changed, this will change the handling of the motorcycle from those which the rider is used to. Riding with unfamiliar fork settings may cause unexpected handling characteristics leading to loss of motorcycle control and an accident. 3. Very gently clamp the fork in the soft jawed vice to prevent it from turning, hold the outer tube, then unscrew the top cap from the outer tube.
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Note: Before removing the forks, slacken the top cap a little to allow easier removal during strip-down. The procedure for the disassembly of Daytona 675, Street Triple and Street Triple R front forks is identical unless otherwise stated. The fork seals can be renewed without removal of the damping cylinder. Unless removal of the damping cylinder is necessary, omit items 16 and 17 of this procedure. Remove the forks (see page 13-6). Daytona 675 and Street Triple R only: Note the position of the spring preload adjuster relative to the fork cap to ensure the setting is retained on reassembly. Turn the spring load adjuster until 7 rings are shown on the adjuster.
1. 2.
ccun
1. Fork 2. Soft jaws 3. Top cap
ACaution
Never tightly clamp the outer tube as this will cause the tube to permanently distort. A distorted tube is not serviceable and must be replaced. Note: The top cap is not under spring tension and will not spring upwards when the threads disengage.
1)
4. Holding the inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. Pump the damper rod to remove all the oil.
cdli
5.
Return the fork to the soft jawed vice.
1. Preload adjuster marks 2. Compression/rebound adjuster
13.10
111MP
Front Suspension
Note:
Warning
10.
While compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user. 6. Fit tool 13880067 over the top cap. Position the two adjustable arms to the holes in the spring spacer. Screw in the arms until they positively engage in the spring spacer holes. Note: An assistant may be required to insert the spring holder below the damper locknut.
The spring has a smaller coil diameter at its upper end. Note the orientation of the spring before removal. Remove the washer, spring spacer and spring.
7 Using tool 13880067, manually compress the fork spring and insert the spring holder as shown, below the damper locknut.
1.Washer 2. Spring spacer 3. Spring 4. Damper rod 11. 12. 13. Separate the inner and outer tubes leaving the seals and bushes in place on the outer tube. Invert and mount the fork outer tube to tool T3880002. Remove the dust cover from the outer tube.
Cc'n
1. Damper locknut 2. Tool T3880067 3. Spring holder (part of T3880067) 8. Slacken the locknut, unscrew and remove the top cap and damper rod. If necessary, remove the 0ring seal from the top cap assembly. The top cap assembly cannot be dismantled. Recompress the fork spring to remove the holder.
9.
Es 1. Fork outer tube 2. Dust cover 3. Tool T3880002
A Warning
While compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.
lump
13.11
Front Suspension
14. Carefully remove the circlip, oil seal and bushes from the outer tube. Note the relative positions of all parts before removal. Note: For all models except the Daytona 675 from VIN 381275, the tool T3880028 is designed to fit over the top of the damper rod locknut.
EM
1
1. Bush 2. Washer 3. Oil seal 4. Circlip 5. Outer tube 6. Tool T3880002 Note: For Daytona 675 from VIN 381275 only: The tool T3880028 will not fit over the locknut on the damping rod. To use the tool when removing the damper bolt, remove the locknut. For Daytona 675 from VIN 381275 only: The locknut for the damper rod is only threaded in the top half of the nut. The lower half of the nut is not threaded and the hole diameter is slightly wider. For Daytona 675 from VIN 381275 only: Remove the locknut from the damper rod. Note the orientation of the locknut for installation.
xuy cdnr
1.Tool T3880028 2. Damping cylinder bolt location 17 Remove the tool, then the damping cylinder from the inner tube.
15.
16. Insert the end of tool T3880028 with the lugs over the damper rod and locknut, if fitted, engage the lugs on the tool into the slots in the damping cylinder inside the fork. Hold the flats of the tool to prevent the cylinder from turning while removing the damper bolt from the bottom of the fork. Discard the washer from the damper bolt.
1. Damping cylinder
Inspection 1. Inspect the inner tube for stone chips, scoring, scratches, excessive wear and any other damage. Renew as necessary.
Note: 2. 3. Small inclusions in the inner tube may be removed using a fine grade stone or similar. Inspect the spring for damage, cracks and deformation. Renew the spring if necessary. Inspect all the bushes and seals for damage. Renew any damaged items if necessary.
13.12
I UMP
Front Suspension
Assembly 5. Position the seals and lower bush to the inner tube as noted prior to removal. Use a new circlip.
A, Warning
The front forks comprise many precision machined parts. Total cleanliness must be observed at all times and assembly must take place in a dirt/dust-free environment. Dirt ingress may cause damage to the fork parts, leading to incorrect operation, instability, loss of control or an accident. Note: If the damping cylinder has not been removed, omit operations 1 and 2.
ccupl
/ / 3
1. 2.
Fit the damping cylinder to the inner tube and engage tool T3880028 as during removal. Clean the threads of the damping cylinder bolt and fit a new sealing washer. Apply a drop of ThreeBond 1342 to the threads then install the bolt. Prevent the cylinder from turning by holding the flats at the end of tool T3880028 while tightening the damping cylinder securing bolt to 24 Nm.
1. Dust seal 2. Circlip 3. Oil seal 4. Washer 5. Lower bush 6. Upper bush 6. 7. Using a suitable tool, fit the upper bush to the outer fork outer tube. Position the inner tube assembly to the outer, ensuring that the oil and dust seal lips do not become damaged. Using the narrow end of tool T3880003, push/tap the bush, washer and seal into position.
8.
1
cdnr
1.Tool T3880028 2. Damping cylinder bolt location 3. 4. Invert and position the outer fork tube to tool T3880002. Apply a smear of fork oil to the bushes and seals. 1.Tool T3880003 2. Seal 3. Washer 4. Bush 5. Tool T3880002
ILIMP
13.13
Front Suspension
9. Retain the bush, washer and seal with the new circlip 15. Street Triple only: Screw the damper rod locknut to the bottom of the damper rod threads.
16. Refit the fork spring, close wound end uppermost, spring spacer and washer.
1. Dust seal 2. Circlip 3. Tool T3880002 10. Position the dust seal to the outer tube. 11. Invert tool T3880003 and, using hand pressure only, push the dust seal squarely into the outer tube. 12. Fill the fork with oil (see page 13-8). 13. Position the fork assembly as for compression of the fork spring during strip down. 14. Daytona 675 and Street Triple R only: Rethread the damper rod locknut leaving 13 mm of thread exposed above the nut. 1. Washer 2. Spring spacer 3. Spring 4. Damper rod 17. Attach tool 3880085-T0301 to the threads of the damper rod and pull the damper upwards. u.
Warning
While re-compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in iniury to the user. 18. Refit tool T3880067 as previously described, compress the fork spring and refit the spring holder.
1. Damper locknut 2. Tool T3880067 3. Spring holder (part of T3880067)
13.14
I uMP
Front Suspension
19. Remove tool 3880085-10301 from the damper rod
A Caution
If removed, the damping rod locknut must be fitted with the flat face facing to the top of the fork. The slightly tapered face must face the fork spring. Incorrect orientation may lead to a loosening of the locknut. 20. 21. Fit a new 0-ring to the top cap. Daytona 675 and Street Triple R only: Ensure the damping adjuster rod is installed in to the damper rod. All models: Refit the top cap to the damper rod. Daytona 675 and Street Triple R only: Ensure the damper rod thread is screwed into the top cap to a depth of 13 mm, as set by the locknut at step 14. Street Triple only: Screw the top cap fully on the damper rod. All models: Hold the top cap while tightening the damper rod locknut to 17 Nm.
Headstock Bearing Check/ Adjustment

Check
1. Raise and support the front of the motorcycle.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
22. 23.
24. 25.
Warnings,
While compressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user. 26. Recompress the spring to remove the spring holder.
x^.
Checking Headstock Bearing Adjustment (Daytona 675 shown) 2. Hold the lower end of the front forks as illustrated and 'rock' with a front-to-rear motion. If free play can be detected, the headstock bearings require adjustment.
27 Lubricate the O-ring on the top cap with a smear of fork oil then screw the top cap fully into the inner tube. 28. Tighten the top cap to 25 Nm. Note: 29. It is much easier to tighten the top cap when the fork has been refitted. Refit the fork (see page 13-8).
l ump
13.15
Front Suspension
Adjustment - Daytona 675 1. 2. Raise and support the front of the motorcycle. Release the fixing securing each handlebar to the top yoke. 5. Slacken the headstock top nut.
1. Headstock top nut
6. 7.
1. Handlebar (right hand side shown) 2. Fixing
(Daytona 675 shown) Ease the top yoke from the forks and support while detached.
Adjust the bearing free-play as follows, all using tool T3880023: Remove the locknut and tab washer. Slacken the adjuster nut then tighten to 40 Nm. Slacken the adjuster nut, then retighten to 15 Nm. Fit the tab washer and lock nut.
A Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 3. Detach the bracket for the front brake fluid reservoir from the handlebar. Taking care not to invert the brake fluid reservoir, move it to one side. Slacken the top yoke clamp bolts. 4.
Q wa rn ing
Warning
If the lower yoke fixings are also slackened, the forks will no longer support the weight of the motorcycle. Do not slacken the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage and/or risk of injury.
It is essential that the adjuster nut is not over-tightened. If the adjuster is over-tightened it will cause a pre-load on the headstock bearings. This will introduce tight steering, which could cause loss of control and an accident.
ACaution
Care must be taken when removing the headstock top nut, to ensure that the top nut and top yoke do not become scratched. Protect the surfaces with a suitable cloth or tape to prevent scratching.
13.16
lliMP
Front Suspension
Hold the adjuster nut in position while tightening the locknut to 40 Nm. Adjustment - Street Triple and Street Triple R 1. 2. Raise and support the front of the motorcycle. Release the fixings securing the handlebar clamps to the risers, detach the clamps and release the handlebar. As an assembly, raise the handle bars until clear of the top yoke. Rest the assembly forward of the steering stem such that access to the headstock top nut and the adjustment nuts is unrestricted. Ensure the master cylinder remains in an upright position. Slacken the top yoke clamp bolts.
3.
1
4.
AWarning
CO W /
1. Adjuster nut 2. Locknut 3. Tool 13880023
8. 9.
Refit the top yoke to the forks. Tighten the top nut to 90 Nm.
If the lower yoke fixings are also slackened, the forks will no longer support the weight of the motorcycle. Do not slacken the lower yoke fixings as, in this condition, the motorcycle could topple over causing damage and/or risk of injury.
10. Install the handlebar to top yoke fixings and tighten to 5 Nm. 11. Tighten the top yoke clamp bolts to 26 Nm. 12. Fit the bracket for the front brake fluid reservoir and ti ghten the fixing to 15 Nm. 13. Recheck the bearing adjustment (see page 13-15).
ACaution
Care must be taken when removing the headstock top nut, to ensure that the top nut and top yoke do not become scratched. Protect the surfaces with a suitable cloth or tape to prevent scratching. 5. Slacken the headstock top nut.
6. 7.
Ease the top yoke from the forks and support while detached. Adjust the bearing free-play as follows, all using tool T3880023: Remove the locknut and tab washer. Slacken the adjuster nut then tighten to 40 Nm.
IUMp
13.17
Front Suspension
Slacken the adjuster nut, then retighten to 15 Nm. Fit the tab washer and lock nut. 12. Align the handlebar punch mark with the front right hand split line of the clamp/riser, then tighten the front clamp bolts to 26 Nm, then the rears.
Warning
It is essential that the adjuster nut is not over-tightened. If the adjuster is over-tightened it will cause a pre-load on the headstock bearings. This will introduce tight steering, which could cause loss of control and an accident. Hold the adjuster nut in position while tightening the locknut to 40 Nm.
1. Right hand front clamp split line 2. Handlebar punch mark 13. Recheck the bearing adjustment (see page 13-15).
1. Adjuster nut 2. Locknut 3. Tool T3880023 8. 9. 10. 11. Refit the top yoke assembly to the forks. Tighten the top nut to 90 Nm. Tighten the top yoke clamp bolts to 26 Nm. Locate the handlebar assembly in the lower halves of the clamps. Fit the upper clamps and bolts.
13.18
ILiMP
Front Suspension
Headstock Bearing Removal
5. Using tool T3880023, remove the locknut and tab washer. Discard the tab washer.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help to prevent it falling and causing injury to the operator or damage to the motorcycle. 1. 2. Daytona 675 only: Remove the steering damper (see page 13-21). All models: Remove both forks (see page 13-6).
Caution
W 1. Locknut 2. Adjuster nut 6. 7. Using the same tool, remove the adjuster nut. Remove the bottom yoke from below the frame headstock.
Care must be taken when removing the headstock top nut, to ensure that the top nut and headstock do not become scratched. Protect the surfaces with a suitable cloth or tape to prevent scratching. 3. Remove the headstock top nut.
,A
Warning
Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries if suitable protective apparel is not worn. 8. 9. Using a suitable drift, evenly and progressively drive the bearing races from the frame headstock. Remove the inner race and dust seal from the bottom yoke using a press or puller.
1. Headstock top nut (Daytona 675 shown) 4. As an assembly, raise the top yoke and handle bars until clear of the steering stem. Rest the assembly forward of the steering stem such that access to the adjustment nuts is unrestricted. Ensure the master cylinder remains in an upright position.
Inspection
Warning
Only remove raised witness marks from within the frame. Removal of material below any raised areas will reduce the level of interference between the frame and the bearings. Loss of interference could cause the bearing to become loose in the frame leading to loss of motorcycle control and an accident. 1. Examine the frame for any raised witness marks caused by the removal process. Remove any such marks with fine emery paper or a gentle file.
I UMP
13.19
Front Suspension
Installation 1. Fit a new dust seal to the steering stem on the bottom yoke. 6. 7. 8. 9. Lubricate the upper bearing using multi-purpose grease. Insert the lower yoke to the frame, fit the upper bearing and race, and retain with the adjuster nut. Adjust the headstock bearings (see page 13-15). Locate the upper yoke to the steering stem. Install but do not fully tighten the headstock top nut at this stage.
10. Fit the forks (see page 13-8). 11. Tighten the headstock top nut to 90 Nm. 12. Daytona 675 only: Refit the steering damper (see page 13-21). 13. Check that no freeplay exists in the headstock bearings. Adjust as necessary (see page 13-15).
cdgol
1. Steering stem 2. Dust shield
Caution
Protect the threads of the bottom yoke when using a press or puller as damaged threads may mean replacing the yoke completely. 2. Press a new lower bearing inner race onto the steering stem of the bottom yoke.
1. Bearing 2. Bottom yoke 3. Press bed
3. 4. 5.
Evenly and progressively drive a new complete upper bearing into the frame headstock. Lubricate the lower bearing using multi-purpose grease. Drive a new lower outer bearing into the frame headstock.
13.20
11.1 MP
Front Suspension
Steering Damper - Daytona 675 only
Removal Installation 1. Installation is the reverse of removal noting the following:
Note:
,A
Warning
Refit the steel washer as noted during removal. Refit the flanged sleeve as noted during removal. Tighten the fixings to 18 Nm. Refit the boot over the damper rod fixing.
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help to prevent it falling and causing injury to the operator or damage to the motorcycle. 1. Reposition the damper rod boot and remove the steering damper lower fixing. Noting its position, collect the steel washer located between the damper and the frame bracket.
1. Steering damper lower fixing 2. Damper rod boot 3. Steel washer position 2. Release the steering damper upper fixing and remove the steering damper. Noting its orientation, collect the flanged sleeve located between the damper body and the lower yoke.
1. Steering damper 2. Upper fixing 3. Flanged sleeve
I uMP
13.21
Front Suspension
Handlebars - Daytona 675
8. Release the inner cables from the twist grip.
Q Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Removal
Note: This procedure describes the removal of both handlebars. 1. Opening cable
1. 2. 3.
Remove the seat and disconnect the battery negative (black) lead first. Remove and discard the fixings and remove the end weights from the handlebars. Undo the screws and free the left switch gear assembly from the handlebar. Without disconnecting any wiring, lay the switch aside. Unscrew the bolts and remove the clamp from the clutch lever assembly. Without disconnecting the clutch cable, lay the lever aside. Slide off the rubber boot and release the screws which secure the two halves of the twist grip guide to each other.
2. Closing cable
9.
Slide the twist grip off the handlebar.
10. Undo the screws and free the right hand switch gear assembly from the handlebar. Without disconnecting any wiring, lay the switch aside. 11. Unscrew the bolts and remove the clamp from the front brake master cylinder. Taking care to not invert the brake fluid reservoir, lay the assembly aside. 12. Release the fixing securing each handlebar to the top yoke.
4.
5.
1. Handlebar (right hand shown) 2. Fixing 1. Throttle grip guide 2. Screws 3. Rubber boot
6.
Note the position of the guide relative to the handlebar then separate the two halves of the twist grip guide. Note and mark the position of each cable relative to the twist grip in order to correctly identify their location during reassembly.
7.
13.22
Il1MP
Front Suspension
13. Remove the headstock top nut. 18. If the handlebar end weight assembly is to be removed, gently squeeze the clip with suitable pliers and withdraw the assembly from the handlebar.
^\ 2 43
^\ 4 5
14. Slacken the handlebar and top yoke clamp bolts.
1. Fi xing
2. End weight 3. Clip 4. Damper 5. Internal weight 6. Handlebar
1. Handlebar clamp bolt 2. Top yoke clamp bolt
A Caution
Care must be taken when removing the top yoke or handlebars to ensure that the outer surfaces of the front forks do not become scratched. 15. Slide the top yoke off the front forks and lay aside. 16. Slide the handlebars off the front forks. 17. If required, remove the left hand handlebar grip.
^--
I UMP
13.23
Front Suspension
Installation .
If the bar end weight assembly has been removed from the handlebar, fit a new clip and install the weight into the handlebar. Ensure the two locking tangs on the clip engage fully into the holes in the handlebar. Refit the handlebars to the front forks. Do not tighten the clamp bolts at this stage. Refit the top yoke. Do not tighten the clamp bolts at this stage. Refit the headstock top nut and tighten to 90 Nm. Install the handlebar to top yoke fixings and tighten to 5 Nm. Tighten the top yoke clamp bolts to 26 Nm. Tighten the handlebar clamp bolts to 26 Nm. If removed fit the left hand handlebar grip. Position the clutch lever to the handlebar. Fit the clamp ('UP arrow pointing upwards) and clamp bolts.
1. Throttle grip guide 2. Rubber boot 3. Screws
1 4. Assemble the two halves of the cable guide ensuring that the outer cables are correctly located in the guide and the guide is positioned on the handlebars as noted prior to removal.
14
2. 3. 4. 5. 6. 7. 8. 9.
10 Align the split line of the clutch lever with the punch mark on the upper surface of the handlebar, then tighten the clamp bolts, upper first, to 12 Nm. 11 12 Align the left hand switch cube to the handlebar and secure with the screws. Tighten the screws to 3 Nm. Slide the twist grip onto the right hand side of the handlebar.
15. Tighten the cable guide fixings to 4 Nm. 16. Position the right hand switch cube to the handlebar and tighten the fixings to 3 Nm. 17 Position the front brake master cylinder assembly to the handlebar. Fit the clamp ('UP' arrow pointing upwards) and clamp fixings. 18. Align the split line of the master cylinder clamp to the punch mark on the upper surface of the handlebar and tighten the clamp fixings to 12 Nm. 19. 20. 21. 22. Fit the handlebar end weights, fit new fixings and tighten to 5 Nm. Check the throttle cable free play setting. Adjust as necessary. See page 10-103. Reconnect the battery, positive (red) lead first. Refit the seat.
13 Reconnect the inner throttle cables as noted during removal. Ensure that the positions of the opening and closing cables are not transposed.
1. Opening cable 2. Closing cable
13.24
I uMP
Front Suspensi o n
23. Check for correct operation of the front brake and clutch. Check that the throttle opens and closes without sticking and that the cables do not bind or restrict the steering when the handlebars are turned from lock-to-lock. Rectify as necessary.
Handlebars - Street Triple and Street Triple R
Warning
Warning
Operation of the motorcycle with incorrectly adjusted, incorrectly routed or damaged throttle cables could interfere with the operation of the brakes, clutch or the throttle itself. Any of these conditions could result in loss of control of the motorcycle and an accident.
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Removal 1. Remove the seat and disconnect the battery negative (black) lead first. Undo the fixing screws and remove the end weights from the handlebars. Undo the screws and free the left switch gear assembly from the handlebar. Without disconnecting any wiring, lay the switch aside. Unscrew the bolts and remove the clamp from the clutch lever assembly. Without disconnecting the clutch cable, lay the lever aside. Slide off the rubber boot and release the screws which secure the two halves of the twist grip guide to each other.
Warning
2. 3.
Move the handlebars to left and right full lock while checking that cables and harnesses do not bind or that the steering feels tight or difficult to turn. A cable or harness that binds, or steering that is tight/difficult to turn will restrict the steering and may cause loss of control and an accident.
4.
5.
1. Twist grip 2. Twist grip guide 3. Screws
6.
Note the position of the guide relative to the handlebar then separate the two halves of the twist grip guide. Note and mark the position of each cable relative to the twist grip in order to correctly identify their location during reassembly.
7.
ll. mP
13.25
Front Suspension
8. Release the inner cables from the twist grip Installation 1. Locate the handlebar in the lower halves of the clamps. Fit the upper clamps and bolts.
Note: 2. The Street Triple has a punch mark for the alignment of the handlebar. The Street Triple R has an etched cross mark for the alignment of the handlebar. Align the handlebar mark with the front right hand split line of the clamp/riser, then tighten the front clamp bolts to 26 Nm, then the rears.
iii -
i i
1. Closing inner cable 2. Opening inner cable 9. Slide the twist grip off the handlebar. 10. Undo the screws and free the right hand switch gear assembly from the handlebar. Without disconnecting any wiring, lay the switch aside. 11. Street Triple R only: Remove the fixing and detach the front brake fluid reservoir from the mounting bracket. Ensure the reservoir is supported in an upright position.
12. Unscrew the bolts and remove the clamp from the front brake master cylinder. Taking care to not invert the brake fluid reservoir, lay the assembly aside. 13. Release the fixings securing the handlebar clamps to the risers, detach the clamps and collect the handlebar. 1. Right hand front clamp split line 2. Handlebar punch mark (Daytona 675 shown) 3. 4. 5. Fit the left hand handlebar grip. Position the clutch lever to the handlebar. Fit the clamp (UP arrow pointing upwards) and clamp bolts. Align the split line of the clutch lever with the punch mark on the upper surface of the handlebar, then tighten the clamp bolts, upper first, to 15 Nm. Align the left hand switch cube to the handlebar and secure with the screws. Tighten the screws to 3 Nm. Slide the twist grip onto the right hand side of the handlebar.
6. 7.
1. Upper Clamp 2. Handlebar 3. Riser 14. Remove the left hand handlebar grip.
13.26
I uMP
Front Suspension
8. Reconnect the inner throttle cables as noted during removal. Ensure that the positions of the opening and closing cables are not transposed. 15. Fit the handlebar end weights, tightening the fixings to 5 Nm.
16. Check the throttle cable free play setting. Adjust as necessary. See page 10-103. 17 18. Reconnect the battery, positive (red) lead first. Refit the seat.
19. Check for correct operation of the front brake and clutch. Check that the throttle opens and closes without sticking and that the cables do not bind or restrict the steering when the handlebars are turned from lock-to-lock. Rectify as necessary.
Warning
1. Closing inner cable 2. Opening inner cable
9. Assemble the two halves of the cable guide ensuring that the outer cables are correctly located in the guide and the guide is positioned on the handlebars as prior to removal.
Operation of the motorcycle with incorrectly adjusted, incorrectly routed or damaged throttle cables could interfere with the operation of the brakes, clutch or the throttle itself. Any of these conditions could result in loss of control of the m o t o r cyc l e and an accident.
Q Warning
Move the handlebars to left and right full lock while checking that cables and harnesses do not bind or that the steering feels tight or difficult to turn. A cable or harness that binds, or steering that is tight/difficult to turn will restrict the steering and may cause loss of control and an accident.
1. Twist grip 2. Twist grip guide 3. Screws
10. Tighten the cable guide fixings to 4 Nm. 11. Position the right hand switch cube to the handlebar and tighten the fixings to 4 Nm. 12. Position the front brake master cylinder assembly to the handlebar. Fit the clamp (Up arrow pointing upwards) and clamp fixings. 13. Align the split line of the master cylinder clamp to the mark on the upper surface of the handlebar and ti ghten the clamp fixings to 15 Nm. 14. Street Triple R only: Attach the front brake reservoir to its mounting bracket. Tighten the fixing to 7 Nm.
L UMP
13.27
14 Brakes
Table of Contents
Exploded View - Front Brake Master Cylinder - Daytona 675 and Street Triple R ................... Exploded View - Front Brake Master Cylinder - Street Triple .................................... Exploded View - Front Brake Caliper - Daytona 675 up to VIN 381274 and Street Triple R.......... Exploded View - Front Brake Caliper - Daytona 675 from VIN 381275 ............................
Ex
14.3 14.4 14.5 14.6 14.7 1 4.8 14.9 14.10 14.11 14.11 14.12 14.12 14.12 14.12 1 4.13 14.15 1 4.15 1 4.15 1 4.16 14.17 14.17 14.17 14.18 14.19 14.19 14.19 14.20 14.21 14.21 14.21 1 4.22 14.22
p lodedView - Front Brake Caliper - Street Triple ............................................
Exploded View - Rear Brake Master Cylinder - All Models ...................................... ExplodedView - Rear Brake Caliper - All Models........................ ...................... BrakingSystem Maintenance Safety Precautions ............................................. Front Brake Fluid Level Inspection - Daytona 675 and Street Triple R ............................ FrontBrake Fluid Level Inspection - Street Triple ............................................. RearBrake Fluid Level Inspection - All Models ............................................... ChangingBrake Fluid .................................................................... BrakePads ............................................................................. BrakeWear Inspection ................................................................... Bleedingthe Front Brakes, Renewing Brake Fluid ............................................ Front Brake Pads - Daytona 675 up to VIN 381274 and Street Triple R ........................... Removal.......................................................................... Inspection......................................................................... Installation........... .............................................................. FrontBrake Pads - Daytona 675 from VIN 381275 ............................................ Removal.......................................................................... Inspection......................................................................... Installation......................................................................... FrontBrake Pads - Street Triple ............................................................ Removal.......................................................................... Inspection......................................................................... Installation........................................................................ Front Brake Caliper - Daytona 675 up to VIN 381274 and Street Triple R ......................... Removal.......................................................................... Disassembly....................................................................... Inspection........................................................................ Assembly.........................................................................
lgmP
14.1
Brakes
Installation....................................................................... FrontBrake Caliper - Daytona 675 from VIN 381275 ......................................... Removal......................................................................... Disassembly...................................................................... Inspection........................................................................ Assembly........................................................................ Installation....................................................................... FrontBrake Caliper - Street Triple .......................................................... Removal......................................................................... Disassembly...................................................................... Installation....................................................................... FrontDiscs - All Models .................................................................. Wear............................................................................ Removal......................................................................... Installation....................................................................... Front Brake Master Cylinder - Daytona 675 and Street Triple R ................................. Removal......................................................................... Disassembly...................................................................... Inspection......................................................................... Assembly......................................................................... Installation........................................................................ FrontBrake Master Cylinder - Street Triple .................................................. Removal......................................................................... Disassembly...................................................................... Inspection........................................................................ Assembly........................................................................ Installation....................................................................... Bleedingthe Rear Brakes, Renewing Brake Fluid ............................................. RearBrake Pads ........................................................................ Installation........................................................................ RearBrake Caliper ...................................................................... Removal......................................................................... Disassembly...................................................................... Inspection........................................................................ Assembly........................................................................ Installation....................................................................... RearBrake Disc ......................................................................... Wear............................................................................. RearMaster Cylinder .................................................................... Removal......................................................................... Disassembly...................................................................... Inspection........................................................................ Assembly........................................................................ Installation....................................................................... 14.23 14.23 14.23 14.24 14.24 14.25 14.25 14.26 14.26 14.26 14.28 14.28 14.28 14.29 14.29 14.30 14.30 14.30 14.31 14.31 14.31 14.32 14.32 14.33 14.33 14.34 14.34 14.35 14.37 14.37 14.39 14.39 14.39 14.39 14.39 14.40 14.41 14.41 14.42 14.42 14.42 14.42 14.42 14.43
1 4.2
Ii1MP
Brakes
Exploded View - Front Brake Master Cylinder - Daytona 675 and Street Triple R
7 Nm
revW11
25 Nm
25 Nm
I
I UMP
00
25 Nm
1 4.3
Brakes
Exploded View - Front Brake Master Cylinder - Street Triple
1.5 Nm
a O
1 Nm 12 Nm
D a
0
25 Nm
6Nm
gm v
25 Nm
25Nm
14.4
1L1MP
Brakes
Exploded View - Front Brake Caliper - Daytona 675 up to VIN 381274 and Street Triple R
35 Nm
/7,t \ J
/
I ...-
1 8Nm
omm mo ^ ^ m
^ mm m m mmm m
m ^^^ m
moo m
mm m m o m
22 Nm
m ^
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lliMP
Se rv ice Manual - Daytona 675, Street Triple and Street Triple R
1 4.5
Brakes
Exploded View - Front Brake Caliper - Daytona 675 from VIN 381275
35 Nm
6 N
18 Nm omm
oom
mom
om
22 Nm
omm
om
om
14.6
IL1MP
Brakes
Exploded View - Front Brake Caliper - Street Triple
28 Nm 6 Nm
(5----
3 Nm
18 Nm
22 Nm
I UMP
1 4.7
Brakes
Exploded View - Rear Brake Master Cylinder - All Models
25 Nm
25 Nm
6 Nm
7Nm
r Th
to
G n
----^'
22 Nm
1 Nm `-18
1 4.8
Il1MP
Brakes
Exploded View - Rear Brake Caliper - All Models
22
22 Nm
t^
1L1Mp
1 4.9
Brakes
Braking System Maintenance Safety Precautions
Warning
Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking efficiency resulting in an accident.
Warning
Brake fluid is hygroscopic which means it will absorb moisture from the air. The absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction in braking efficiency. Replace brake fluid in line with the scheduled maintenance chart. A dangerous riding condition could result if this important maintenance item is neglected. Do not spill brake fluid onto any area of the bodywork as this will damage any painted or plastic surface. Always use new brake fluid from a sealed container and never use fluid from an unsealed container or from one which 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.
Warning 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.
A War. inca
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to an accident. Failure to change the brake fluid at the interval specified in the scheduled maintenance chart may reduce braking efficiency resulting in an accident.
1 4.10
tllMP
Brakes
Front Brake Fluid Level Inspection Daytona 675 and Street Triple R Front Brake Fluid Level Inspection Street Triple
Warning
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. In accordance with the scheduled maintenance chart, inspect the brake fluid level in the front and rear master cylinder reservoirs. 1. Ensure that the brake fluid level in the front brake fluid reservoir is between the upper and lower level li nes (reservoir held horizontal).
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. In accordance with the scheduled maintenance chart, inspect the brake fluid level in the front and rear master cylinder reservoirs. 1. Ensure that the brake fluid level in the front brake fl uid reservoir is between the upper and lower level li nes (reservoir held horizontal).
3 /1
1. Front reservoir upper level 2. Front reservoir lower level 3. Safety clip
1. Front reservoir upper level 2. Front reservoir lower level
2.
To adjust the fluid level: Remove the safety clip. Fill the reservoir to the upper level line using new DOT 4 fluid from a sealed container. Refit the reservoir cover ensuring that the diaphragm seal is correctly fitted. Refit the safety clip.
2. To inspect the fluid level, check the level of fluid visible in the window at the front of the reservoir body. 3. To adjust the fluid level: Release the cap screws and detach the cover noting the position of the sealing diaphragm. Fill the reservoir to the upper level line using new DOT 4 fluid from a sealed container.
Refit the cover, ensuring that the diaphragm seal is correctly positioned between the cap and reservoir body. Tighten the cap retaining screws.
L UMP
1 4.11
Brakes
Rear Brake Fluid Level Inspection All Models Changing Brake Fluid
Brake fluid should be changed at the interval specified in the scheduled maintenance chart.
A Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing iniury to the operator or damage to the motorcycle. In accordance with the scheduled maintenance chart, inspect the brake fluid level in the front and rear master cylinder reservoirs. 1. Ensure that the brake fluid level in the rear brake fluid reservoir is between the upper and lower level li nes (reservoir held horizontal).
Brake Pads
Front and rear pad wear is automatically compensated for and has no effect on brake lever or pedal action.
Brake Wear Inspection

In accordance with the scheduled maintenance chart, inspect the brake pads for wear. The minimum thickness of lining material for any front or rear brake pad is 1.5 mm. If any pad has worn to the bottom of the groove in the pad centre, replace all the brake pads on that wheel.
cbmz 1. Lining material thickness 1. Rear reservoir 2. Rear rese rv oir upper level 3. Rear rese rv oir lower level 2. Centre groove
Â Warning
Do not replace individual brake pads, replace both pads in the brake caliper. On the front where two calipers are mounted on the same wheel, all the pads in both calipers must be replaced together. Replacing individual pads will reduce braking efficiency and may cause an a ccident.
1 4.12
I UMP
Brakes
Bleeding the Front Brakes, Renewing Brake Fluid
A Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 3. Daytona 675 and Street Triple R only: Remove the screw from the reservoir cover and collect the safety clip. Carefully remove the reservoir cover taking care not to spill any fluid. Street Triple only: Release the cap screws and detach the cover noting the position of the sealing diaphragm. All models: Check the condition of the sealing diaphragm for the reservoir. Replace if necessary. Remove the rubber cap from the bleed nipple on the right hand caliper. Attach a transparent tube to the bleed nipple and place the other end of the tube in a suitable receptacle containing new brake fluid. Keep the tube end below the level of fluid.
A Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Note: Daytona 675 and Street Triple R only: The master cylinder should always be bled last. Bleed each caliper in turn before bleeding the master cylinder. 1. Note the original setting of the brake lever adjuster in order that it can be returned to the same position when the bleeding operation is complete. Set the brake lever adjuster to position No.1.
4. 5.
6. 7.
8.
1. Lever (Daytona 675 shown) 2. Adjuster wheel 3. Triangular mark 2. Turn the handlebars to bring the fluid reservoir to a level position. 1. Bleed nipple (Daytona 675 shown) 2. Bleed tube 3. Container 9. Release the bleed nipple.
A Warning
e.^ Ensure absolute cleanliness when adding brake fluid to the brake fluid reservoir. Do not allow moisture or debris to enter the cylinder, as this will adversely affect the fluid properties. Always use fluid from a sealed container and do not use fluid from a container that has been opened for any period of time. Always check for fluid leakage around hydraulic fittings and for damage to hoses. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
Note: During bleeding, do not allow the fl uid level to fall below the lower level mark in the reservoir. If the fluid level is allowed to fall below this mark, air may enter the system and the sequence of bleeding must be repeated. 10. Get an assistant to slowly pull the brake lever to the handlebar.
l ump
14.13
Brakes
11. With the lever held fully against the handlebar, close the bleed nipple. Once the bleed nipple is closed, release the brake lever. Repeat steps 10 and 11 until no more air appears in the bleed tube. When all air has been expelled from the system, hold the lever fully against the handlebar and close the bleed nipple. 19. Daytona 675 and Street Triple R only: Repeat the bleed procedure for the bleed nipple on the master cylinder. Tighten the bleed nipple to 6 Nm.
12. 13.
Note: Maintain the brake fluid level between the upper and lower reservoir levels whilst bleeding is being carried out. Tighten the bleed nipple to 6 Nm. Remove the bleed tube. Replace the bleed nipple cap. Fill the reservoir to the upper level with new DOT 4 fluid. 1. Bleed nipple (Daytona 675 shown) 2. Spanner 3. Bleed tube 4. Container 20. Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual. 22. When both calipers (and the master cylinder on Daytona 675 and Street Triple R) have been bled, ensure the brake lever operation has a firm resistive feel to it, does not feel spongy and that the lever cannot be pulled directly back to the handlebar. Take remedial action as necessary. Daytona 675 and Speed Triple R only: Refit the diaphragm and reservoir cover. Refit the safety clip and tighten the screw to 1 Nm. Street Triple only: Refit the diaphragm and reservoir cover. Refit the screws and tighten to 1.5 Nm.
14. 15. 16. 17.
Warning
21.
,A Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 18. Repeat the bleed procedure for the left hand caliper.
Warning
Always return the lever adjuster to the original setting as noted in paragraph 1. Operating the motorcycle with lever settings that are unfamiliar may lead to loss of control or an accident. 23. 24. All models: Reset the brake lever adjuster to the original setting. Check the operation of the front brake. Rectify as necessary.
Warning
It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident.
1 4.14
Il1MP
Brakes
Front Brake Pads - Daytona 675 up to VIN 381274 and Street Triple R
Removal 4. Remove both brake pads and inspect for damage and wear beyond the service limit.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing iniury to the operator or damage to t he m oto rcyc l e. 1. Remove the brake pad retaining pin after removing the 'R' clip from its inner end. Inspect the pad retaining pin for damage.
1. Retaining pin 2. Anti - rattle spring 3. Brake pads
1. 'R' clip 2.
11:1 ceqp
V 1
Note: Complete the assembly of the brake pads to one caliper (see assembly for details) before removing the pads from the other caliper.
Inspection 1. Check the 'R' clip, anti-rattle spring and retaining pin. Renew any component which shows signs of damage or corrosion. Check there is no sign of leakage from the piston seals. Rectify any problems before installing the pads.
//V
2.
Remove the anti-rattle spring and inspect the spring for damage.
ACaution
Never lever directly against the disc, caliper or the pad li ning material as this will damage these components. Always use a levering tool made from a soft material which will not cause damage to the load bearing surfaces. Brake fluid will be displaced as the caliper pistons are compressed. To prevent body damage, ensure that the displaced fluid does not come into contact with any part of the bodywork. 3. Ease the brake pads apart to force the caliper pistons back to allow withdrawal of the pads.
Il1MP
14.15
Brakes
Installation
A, A
Warning
Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking efficiency resulting in an accident. 1. Fit new brake pads as an axle set or, if all the pads are in a serviceable condition, clean the pad grooves before refitting all pads in their original positions.
Warning
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual. 7. 8. Check the front brake fluid level and top up as required with new DOT 4 fluid. Check for correct brake operation. Rectify as necessary.
A-- Warning
Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking efficiency and an accident. 2. Lubricate the pad retaining pin using a minimum amount of proprietary high temperature 'Copperslip' type grease. Fit the anti-rattle spring over the pads and push down in the centre to allow the pad retaining pin to slide across the top of the spring. Tighten the pad retaining pin to 18 Nm, and secure with the 'R' clip.
Warning
3.
4.
1. Retaining pin 2. Anti-rattle spring 3. Brake pads 5. 6. Pump the brake lever to correctly position the caliper pistons. Repeat the removal, inspection and installation process for the other caliper.
1 4.16
Il.l MP
Brakes
Front Brake Pads - Daytona 675 from VIN 381275
Removal
2. Remove the pad retaining pin and remove the pads from the caliper. Take care not to lose the anti-rattle spring from the caliper body.
Q Warning
^ o 0000 oo 3
'
d\(Q
up
A Warning
Do not allow the calipers to hang on the brake hoses as this may damage the hoses and could lead to loss of motorcycle control and an accident. 1. Loosen the pad retaining pin, remove the caliper mounting bolts and slide the caliper off the disc. Recover the two dowels.
1. Pad retaining pin 2. Brake pads 3. Dowels
Inspection
1. Check the anti-rattle spring and retaining pin. Renew any component which shows signs of damage or corrosion. Check there is no sign of leakage from the piston seals. Rectify any problems before installing the pads.
2.
2
cd
1. Pad retaining pin M 2. Caliper mounting bolts
t UMP
1 4.17
Brakes
Installation
6. Tighten the pad retaining pin to 18 Nm.
Warning
Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking efficiency resulting in an accident. 2
ACaution
Never lever directly against the disc, caliper or the pad li ning material as this will damage these components. Always use a levering tool made from a soft material which will not cause damage to the load bearing surfaces. Brake fluid will be displaced as the caliper pistons are compressed. To prevent body damage, ensure that the displaced fluid does not come into contact with any part of the bodywork. 1. If new pads are being installed, push the pistons fully back into the caliper body. Keep an eye on the fluid level in the reservoir whilst retracting the pistons to prevent fluid spillage. Ensure the anti-rattle spring is securely clipped onto the caliper body.
m 1. Pad retaining pin 2. Caliper mounting bolts 7. 8. Pump the brake lever to correctly position the caliper pistons. Repeat the removal, inspection and installation process for the other caliper.
Warning
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual. 9. Check the front brake fluid level and top up as required with new DOT 4 fluid.
2.
Warning
Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking efficiency and an accident. 3. Lubricate the pad retaining pin with a thin smear of proprietary high temperature 'Copperslip type grease. Ensure the heat isolation pads are fitted to the back of each brake pad. Fit the pads to the caliper with their friction material surfaces facing each other. Locate the pad upper ends in the mounting bracket retainer then align them with the caliper body and insert the retaining pin. Slide the caliper onto the disc, ensuring the pads pass either side, and fit the mounting bolts. Tighten the mounting bolts to 35 Nm.
10. Check for correct brake operation. Rectify as necessary.
Warning
4.
5.
1 4.18
Il1MP
Brakes
Front Brake Pads - Street Triple
Removal
4. Remove the pad retaining pin and remove the pads from the caliper. Take care not to lose the pad retainer from the mounting bracket or the anti-rattle spring from the caliper body.
A Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Unscrew the pad retaining pin plug from the caliper.
00
^7
oo
00 0 00
00 / \ \ \ 0 0 0
cegv
00000
1. Caliper 2. Brake pad 3. Heat isolation pad 4. Anti-ratt le spring 5. Pad retainer
6. Pad retaining pin
O
c q.
o0
00
7. Pad retaining pin plug
^ O m D ^^
000 Inspection
1. Check the pad retainer, anti-rattle spring and retaining pin. Renew any component which shows signs of damage or corrosion. Check the caliper body slides easily on the mounting bracket pins and check there is no sign of leakage from the piston seals. Rectify any problems before installing the pads.
\
Loosen the pad retaining pin.
1. Pad retaining pin plug 2.
2.
c eqo
1. Pad retaining pin
it
A Warning
Do not allow the calipers to hang on the brake hoses as this may damage the hoses and could lead to loss of motorcycle control and an accident. 3. Slacken and remove the caliper mounting bolts and slide the caliper off the disc.
I UMP
14.19
Brakes
Installation
7. Fit the pad retaining pin plug to the caliper and tighten to 3 Nm.
Warning
Caution
ceqo \ 1. Pad retaining pin plug 8. 9. Pump the brake lever to correctly position the caliper pistons. Repeat the removal, inspection and installation process for the other caliper.
Never lever directly against the disc, caliper or the pad li ning material as this will damage these components. Always use a levering tool made from a soft material which will not cause damage to the load bearing surfaces. Brake fluid will be displaced as the caliper pistons are compressed. To prevent body damage, ensure that the displaced fluid does not come into contact with any part of the bodywork. 1. If new pads are being installed, push the pistons fully back into the caliper body. Keep an eye on the fluid level in the reservoir whilst retracting the pistons to prevent fluid spillage. Ensure the pad retainer is correctly fitted to the mounting bracket and the anti-rattle spring is securely clipped onto the caliper body.
Warning
2.
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual.
Warning
Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking efficiency and an accident. 3. Lubricate the pad retaining pin with a thin smear of proprietary high temperature 'Copperslip type grease. Ensure the heat isolation pads are fitted to the back of each brake pad. Fit the pads to the caliper with their friction material surfaces facing each other. Locate the pad upper ends in the mounting bracket retainer then align them with the caliper body and insert the retaining pin. Slide the caliper onto the disc, ensuring the pads pass either side, and fit the mounting bolts. Tighten the mounting bolts to 28 Nm. Tighten the pad retaining pin to 18 Nm.
10. Check the front brake fluid level and top up as required with new DOT 4 fluid. 11. Check for correct brake operation. Rectify as necessary.
Warning
4.
5.
6.
1 4.20
I UMP
Brakes
Front Brake Caliper - Daytona 675 up to VIN 381274 and Street Triple R
Removal Disassembly
A Ak Warning
Warning
To prevent injury, never place fingers or hands inside the caliper opening when removing the pistons. Always wear eye, hand and face protection when using compressed air. Eye, face and skin damage will result from direct contact with compressed air. 1. Undo and remove the four bolts which secure the two halves of the brake caliper together. Discard the bolts. Carefully split the two halves of the caliper then remove and discard the joint seal. Cover a caliper half with a clean, heavy cloth and, using compressed air, remove the pistons one at a ti me.
2.
ACaution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 1. Disconnect the brake hose at the caliper (two hoses on right hand caliper), and place the free end of the hose(s) in a suitable container to collect the brake fluid.
3.
A Warning
Ensure the seal grooves in the caliper bores are not damaged during the removal of the seals. Damage to the seal grooves may allow brake fluid to leak past the seals resulting in a dangerous riding condition leading to loss of motorcycle control and an accident. 4. Remove the old piston seals and dust seals then thoroughly clean and dry the caliper bores and pistons. Discard the old seals, these must not be reused.
Note: 2. 3. If the calipers are to be removed for access only, do not remove the brake pads. Remove the brake pads (see page 14-15). Remove the two caliper bolts.
1. Caliper bolts 4. Manoeuvre the caliper clear of the disc, taking care not to damage the wheel.
I UMP
14.21
Brakes
Inspection 1. Check the pistons and caliper bores for corrosion, scoring and damage. Renew as necessary. 1. Lubricate the piston seals with clean DOT 4 brake fl uid. Fit the piston seals and the dust seals to the caliper bores in the positions shown below. Note: Warning Always renew caliper seals and pistons after removal from the caliper. An effective hydraulic seal can only be made if new components are used. A dangerous riding condition leading to an accident coul d resu l t if thi s wa rning is ignored. 2. Inspect the brake pads for damage and wear beyond the service limit. Renew as necessary. The piston seals are slightly thicker than the dust seals.
Assembly
Warning
1. Piston seals 2. Dust seals
Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking efficien cy res ulting in an accident.
Warning
Ensure that the caliper bores do not become scratched during piston removal and assembly. Ensure that the pistons remain square to their bores during fitment otherwise damage to the caliper could result. A dangerous riding condition leading to an accident could result if this warning is ignored. 2. 3. Carefully refit the pistons fully into the caliper bores by hand. Once all seals and pistons have been fitted, carefully clean the mating faces of both calipers, then fit a new joint seal to the recess in one half of the caliper.
AWarning
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored.
;A
Warning,
Ensure the mating faces of the caliper halves are clean and free from dust prior to assembly. Failure to ensure that the mating faces are clean and free from dust will result in a dangerous riding condition leading to loss of motorcycle control and an accident. 4. Apply a small drop of Loctite Hydraulic Sealant 569 to the threads of new caliper bolts and secure the two halves of the caliper together. Tighten the caliper bolts to 22 Nm.
1 4.22
lllMP
Brakes
Installation 1. Position the caliper over the disc and tighten the caliper bolts to 35 Nm.
Front Brake Caliper - Daytona 675 from VIN 381275

Removal
Ak Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle
ACaution
1. Caliper bolts 2. 3. Fit the brake pads (see page 14-16). Connect the brake hose(s) to the caliper incorporating new sealing washers on each side of all hose connections. Tighten the banjo bolt to 25 Nm. To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 1. Disconnect the brake hose at the caliper (two hoses on right hand caliper), and place the free end of the hose(s) in a suitable container to collect the brake fl uid. Remove the brake pads (see page 14-17)
4.
2.
Warning
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual. 5. 6. 7 Fill the master cylinder with new, DOT 4 brake fluid from a sealed container. Bleed the front brake line (see page 14-13). Check for correct brake operation.
Warning
lump
1 4.23
Brakes
Disassembly
2. Extract the dust seals and piston seals, taking care not to damage the caliper bores. Discard the old seals, these must not be re-used.
Warning
To prevent injury, never place fingers or hands inside the caliper opening when removing the pistons. Always wear eye, hand and face protection when using compressed air. Eye, face and skin damage will result from direct contact with compressed air. Note: Only the top two pistons (near the brake hose) are Nymfron coated;
Note: The piston seals are slightly thicker than the dust seals.
The Nymfron coated pistons appear to have a matt finish compared to the Nickel plated pistons; Note the position of the Nymfron coated pistons.
1. Cover the caliper opening with a clean heavy cloth and using either compressed air or by reconnecting the master cylinder and pumping the brake lever, remove the pistons one at a time.
1. Piston seals 2. Dust seals
3.
/5
3
Check the pistons, caliper and mounting bracket for signs of damage, paying particular attention to the caliper bores and pistons. If damage is present, renew the worn component or the complete caliper assembly.
2
Inspection 1. Check the pistons and caliper bores for corrosion,
scoring and damage. Renew as necessary.
4 7
1. Piston seal 2. Dust seal 3. Pistons with Nymfron coating 4. Pistons with Nickle coating 5. Caliper 6. Pad retaining pin 7. Anti-rattle spring
A Wa rn ing
Always renew caliper seals and pistons after removal from the caliper. An effective hydraulic seal can only be made if new components are used. A dangerous riding condition leading to an accident could result if this warning is ignored. 2. Inspect the brake pads for damage and wear beyond the service limit. Renew as necessary.
Warning
Ensure the seal grooves in the caliper bores are not damaged during the removal of the seals. Damage to the seal grooves may allow brake fluid to leak past the seals resulting in a dangerous riding condition leading to loss of motorcycle control and an accident.
14.24
Il,1 MP
Brakes
Assembly
1.
Installation
Fit the brake pads (see page 14-25). 1. If all components are serviceable, obtain a piston seal kit and reassemble the caliper as follows: 2. Connect the brake hose(s) to the caliper incorporating new sealing washers on each side of all hose connections.
' Warning
Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking ef fi ciency resulting in an accident.
3. Tighten the banjo bolt to 25 Nm.
A. Warning
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual. 4. 5. 6. Fill the master cylinder with new, DOT 4 brake fluid from a sealed container. Bleed the front brake line (see page 14-13). Check for correct brake operation.
^.
Warning
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored. 2. 3.
a..
A Warning
Ensure all components are clean, then fi t the new seals to their grooves in the caliper bores. Lubricate the fluid seals, caliper bore and the outside of the pistons with clean DOT 4 brake fluid. Ease the pistons squarely back into the bores as noted for removal, taking care not to displace the seals.
4.
a./
L UMP
14.25
Brakes
Front Brake Caliper - Street Triple
Removal Disassembly
Warning
Warning
To prevent injury, never place fingers or hands inside the caliper opening when removing the pistons. Always wear eye, hand and face protection when using compressed air. Eye, face and skin damage will result from direct contact with compressed air. 1. 2. Separate the caliper and mounting bracket. Cover the caliper opening with a clean, heavy cloth and, using either compressed air or by reconnecting the master cylinder and pumping the brake lever, eject both pistons from the caliper at the same time.
1. 2.
Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. Remove the brake pads (see page 14-19). Disconnect the brake hose at the caliper (two hoses on right hand caliper), and place the free end of the hose(s) in a suitable container to collect the brake fluid. 3 2
($0!
1. Dust seals 2. Piston seals 3. Pistons
Warning
Ensure the seal grooves in the caliper bores are not damaged during the removal of the seals. Damage to the seal grooves may allow brake fluid to leak past the seals resulting in a dangerous riding condition leading to loss of motorcycle control and an accident. 3. 4. Extract the dust seals and piston seals, taking care not to damage the caliper bores. Check the pistons, caliper and mounting bracket for signs of damage, paying particular attention to the caliper bores and pistons. If damage is present, renew the worn component or the complete caliper assembly.
1 4.26
It,I MP
Brakes
5. If all components are serviceable, obtain a piston seal kit and reassemble the caliper as follows: 9. Lubricate the mounting bracket pins with a suitable silicone based brake grease then reassemble the bracket and caliper. Ensure the pin gaiters are correctly located on both the bracket and caliper.
A Warning
Always renew caliper seals a ft er removal of the pistons. An effective hydraulic seal can only be made if new seals are fitted. A dangerous riding condition leading to an accident could result if this warning is ignored.
A Warning
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored. 6. 7 8. Ensure all components are clean, then fit the new seals to their grooves in the caliper bores. Lubricate the fluid seals, caliper bore and the outside of the pistons with clean DOT 4 brake fluid. Ease the pistons squarely back into the bores, taking care not to displace the seals.
cl
gg ^J
1. Caliper sliding pin 2. Caliper bracket sliding pin
Warning
I UMP
1 4.27
Brakes
Installation 1. 2. Fit the brake pads (see page 14-25). Connect the brake hose(s) to the caliper incorporating new sealing washers on each side of all hose connections. Tighten the banjo bolt to 25 Nm.
Front Discs - All Models
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Wear 1. Replace any brake disc if worn beyond the service li mit or that exceeds the disc run-out limit.
3.
AWarning
hM
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual. 4. 5. 6. Fill the master cylinder with new, DOT 4 brake fluid from a sealed container. Bleed the front brake line (see page 14-13). Check for correct brake operation.
Front Disc Thickness Standard: Service Limit: Disc Run-out Service Limit: 0.3 mm 4.0 mm 3.5 mm
Measure disc run-out using an accurate dial gauge mounted on a surface plate. Warning It is dangerous to operate the motorcycle with defective brakes; you must have your authorised Triumph dealer take remedial action before you ride the motorcycle again. Failure to take remedial action may result in reduced braking efficiency leading to loss of motorcycle control and an accident.
1. Disc 2. Dial gauge
1 4.28
Il1MP
Brakes
Removal Installation 1. Locate the first disc to the wheel. Fit new bolts and tighten to 22 Nm. Fit the other disc in the same way. Refit the front wheel (see page 15-7). Check for correct brake operation. Rectify as necessary.
Warning
2. 3. 4. 5.
Do not renew front brake discs individually. Discs must always be renewed in pairs even if one of a pair is serviceable. A dangerous riding condition leading to an accident could result if this warning is ignored. 1. 2. Remove the front wheel (see page 15-6). Support the wheel on blocks as illustrated to avoid damage to the wheel centre.
Warning
cdup
1. Wheel 2. Support blocks 3. 4. 5. Remove and discard the bolts. Detach the disc. Repeat for the other disc
I UMP
14.29
Brakes
Front Brake Master Cylinder Daytona 675 and Street Triple R
Removal
6. Disconnect from the master cylinder the: 7. brake hoses, brake light switch connections.
Release the clamp screws from the handlebar to remove the master cylinder.
Disassembly
1. 2. 3. Support or remove the reservoir. Detach the boot and push-rod from the lever end of the cylinder. Remove the circlip from beneath the boot.
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. Remove the rider's seat (see page 16-17). Disconnect the batte ry, negative (black) lead first.
A Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 3. To drain the fluid from the master cylinder, attach a tube to the right hand caliper bleed nipple, slacken the nipple and allow the fluid to drain into a suitable container. Operate the brake lever until all fluid has been expelled. Note the setting of the brake lever adjuster to ensure it is returned to the same position when the overhaul operation is complete. Remove the pivot locknut and bolt securing the brake lever to the master cylinder, and remove the lever. 1. Circlip 4. Remove the piston set from the master cylinder bore noting the relative position of the seals and piston components.
4.
5.
1 2 / ^ 5 I
Ô 3
cdod
1. Master cylinder 1. Pivot bolt 2. Nut 2. Spring 3. Piston seals 4. Piston

5. Circlip
14.30
IuMP
Brakes
Inspection 1. Check the following for wear, damage, cracks or deterioration: 2. 3. Cylinder bore Dust cover Spring Piston Pivot Bolt
Warning
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored. 1. Lubricate the piston and cylinder with new, clean brake fluid.
Always renew the piston and seal set if the cylinder is dismantled. Check that the two ports in the master cylinder bore are not blocked.
Warning
Ensure that the piston and piston seal are fitted facing the same way as noted during removal. A dangerous riding condition leading to an accident could result from incorrect assembly of the master cylinder. 2. 3.
:doe
Fit the new piston set into the master cylinder and retain with a new circlip. Refit the master cylinder boot.
Installation
1. Ports 2. Master cylinder bore
Assembly
Warning
Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking efficiency resulting in an accident. 1. Arrow mark 1. Locate the master cylinder to the handlebars and position the clamp with the 'UP' arrow pointing upwards. Do not tighten the clamp bolts at this stage. Connect the brake hose to the master cylinder incorporating new sealing washers. Tighten the banjo bolt to 25 Nm.
2.
LUMP
14.31
Brakes
3. 4. 5. 6. Align the master cylinder/clamp split line with the 'dot' mark on the handlebar. Tighten the clamp bolts, upper first and then the lower to 12 Nm. Connect the brake light switch. Position the brake lever ensuring that the pivot boss is correctly aligned to the push rod. Fit and tighten the pivot bolt to 1 Nm, and the locknut to 6 Nm.
Front Brake Master Cylinder - Street Triple

Removal
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to t he motorcycle. 1. 2. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first.
Warning
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual. 7. Fill and bleed the front brakes (see page 14-13).
ACaution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 3. To drain the fluid from the master cylinder, attach a tube to the right hand caliper bleed nipple, slacken the nipple and allow the fluid to drain into a suitable container. Operate the brake lever until all fluid has been expelled. Note the setting of the brake lever adjuster to ensure it is returned to the same position when the overhaul operation is complete. Remove the pivot locknut and bolt securing the brake lever to the master cylinder, and remove the lever. Disconnect from the master cylinder the: 7. brake hose, brake light switch connections.
Ak
Warning
Always return the lever adjuster to the original setting noted during removal. Operating the motorcycle with lever settings which are unfamiliar may lead to loss of control or an accident. 8. 9. Reset the brake lever adjuster to the original setting. Examine the system for correct operation and fluid leaks. Rectify as necessary.
4.
5.
10. Connect the battery, positive (red) lead first. 11. Refit the rider's seat (see page 16-17). 12. Check for correct brake operation. Rectify as necessary.
6.
Warning
Release the clamp screws from the handlebar to remove the master cylinder.
1 4.32
Il1MP
Brakes
Disassembly 1. 2. Detach the rubber boot from the lever end of the cylinder. Remove the circlip from beneath the boot. Inspection 1. Check the following for wear, damage, cracks or deterioration: 2. 3. Cylinder bore Rubber boot Spring Piston Pivot Bolt
Always renew the piston and seal set if the cylinder is dismantled. Check that the two ports in the master cylinder bore are not blocked.
1. Circlip
3. Remove the piston set from the master cylinder bore noting the relative position of the seals and piston components.
ceqq 1. Ports
p 3
cequ
1. Master cylinder
2. Spring and piston assembly 3. Circlip 4. Rubber boot
I UMp
1 4.33
Brakes
Assembly Installation
A Warning
Q Warning
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored. 1. Lubricate the piston and cylinder with new, clean brake fluid. 1. 'UP' Arrow 2. 'Dot' mark 1. Locate the master cylinder to the handlebars and position the clamp with the 'UP' arrow pointing upwards. Align the master cylinder/clamp split line with the 'dot' mark on the handlebar. Tighten the clamp bolts, upper first and then the lower to 12 Nm. Connect the brake hose to the master cylinder incorporating new sealing washers. Tighten the banjo bolt to 25 Nm. Connect the brake light switch connections. Position the brake lever ensuring that the pivot boss is correctly aligned to the push rod. Fit and tighten the pivot bolt to 1 Nm, and the locknut to 6 Nm. 2. 3. 4.
5.
AWarninig
Ensure that the piston and piston seal are fitted facing the same way as noted during removal. A dangerous riding condition leading to an accident could result from incorrect assembly of the master cylinder. 2. 3. Fit the new piston set into the master cylinder and retain with a new circlip. Refit the master cylinder boot.
6.
A Warning
1 4.34
ll1MP
Brakes
7 Fill and bleed the front brakes (see page 14-13)
Bleeding the Rear Brakes, Renewing Brake Fluid
Warning
Always return the lever adjuster to the original setting noted during removal. Operating the motorcycle with lever settings which are unfamiliar may lead to loss of control or an accident. 8. 9. Reset the brake lever adjuster to the original setting. Examine the system for correct operation and fluid leaks. Rectify as necessary.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. Remove the cap from the rear bleed nipple. Attach a transparent tube to the bleed nipple.
10. Connect the battery, positive (red) lead first. 11. Refit the rider's seat (see page 16-17). 12. Check for correct brake operation. Rectify as necessary.
arning
1. Bleed nipple 2. Spanner 3. Bleed tube
3.
Place the other end of the tube in a suitable receptacle containing new brake fluid.
Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork.
I uMP
14.35
Brakes
4. Unscrew and remove the rear brake reservoir cover taking care not to spill any fluid. 10. When all air has been expelled from the system, hold down the brake pedal and close the bleed nipple. Tighten the nipple to 6 Nm. 11. Fill the reservoir to the maximum level with new DOT 4 fluid.
Warning
1. Rear reservoir 2. Rear reservoir upper level 3. Rear reservoir lower level
12. Fit the reservoir cover and diaphragm. Check for correct diaphragm fitment before final tightening of the cover. 13. Remove the bleed tube from the nipple.
Warning
Ensure absolute cleanliness when adding brake fluid to the brake fluid reservoir. Do not allow moisture or debris to enter the cylinder as this will adversely affect the fluid properties. Always use fluid from a sealed container and do not use fluid from a container which has been opened for any period of time. Always check for fluid leakage around hydraulic fittings and for damage to hoses. A dangerous riding condition leading to an accident could result if this warning is ignored. 5. 6. Check the condition of the sealing diaphragm. Replace the diaphragm as necessary. Release the bleed nipple.
14. Replace the bleed nipple cap. 15. Check for correct brake operation. Rectify as necessary.
Warning
Note: During bleeding, do not allow the fluid level to fall below the lower level mark in the reservoir. If the level is allowed to fall below this mark, air may enter the system and the sequence of bleeding must be repeated. Slowly depress the brake pedal and, holding the pedal fully down, close the bleed nipple. Repeat steps 6 and 7 until no more air appears in the bleed tube. Maintain the brake fluid level between the upper and lower reservoir levels whilst bleeding is being carried out.
7. 8. 9.
1 4.36
ll1MP
Brakes
Rear Brake Pads
3. Remove the brake caliper bolts and raise the caliper.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. Push the brake caliper inwards towards the wheel in order to displace the caliper piston. Remove the plug protecting the pad retaining pin.
1. Brake caliper bolt 2. Brake pads 3. Pad retaining pin
4. 5.
Remove the pad retaining pin and remove the pads. Remove the anti-rattle spring and inspect for damage.
IV
1. Plug 2. Pad retaining pin
Note: Before removing the brake pads, note the relationship of the pads to the caliper and ensure that, on assembly, they are fitted in the same way.
Warning
1. Anti - rattle spring
Do not allow the caliper to hang on the brake hoses as this may damage the hoses and could lead to loss of motorcycle control and an accident.
Installation
AWarning
ll111A1P
14.37
Brakes
A Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 1. 2. 3. If fitting new pads, use hand pressure to compress the caliper piston fully into its bore. Fit the anti rattle spring into the caliper. Renew the brake pads as a pair or, if both pads are in a serviceable condition, clean the pad grooves before fitting them. Fit the brake pads to the caliper in the positions noted during removal.
12. Check the brake fluid level in the rear reservoir and top-up as required with new D.O.T. 4 fluid.
AWarning
Use only DOT 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those DOT 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to loss of motorcycle control and an accident. Observe the brake fluid handling warnings given earlier in this section of the manual. 13. Check for correct brake operation. Rectify as necessary.
4.
A Warning
Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking efficiency and an accident. 5. Lubricate the pad retaining pin using a minimum amount of proprietary high temperature 'Copperslip' type grease. Install the pad retaining pin. Lower the caliper over the brake disc ensuring that the pads remain in the correct positions.
Warning.
6. 7
1. Plug 2. Pad retaining pin 8. 9. Fit the caliper bolts and tighten to 22 Nm ( M8 bolt) and 27 Nm (M12 bolt). Tighten the pad retaining pin to 18 Nm.
10. Fit the retaining plug and tighten to 3 Nm. 11. Pump the brake pedal to correctly position the caliper pistons.
1 4.38
L UMP
Brakes
Rear Brake Caliper
Removal 4. Cover the caliper opening with a clean, heavy cloth and, using either compressed air or by reconnecting the master cylinder and pumping the brake lever, remove the piston.
Inspection
Warning
1. Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. Check the piston and caliper bore for corrosion, scoring and damage. Renew as necessary.
Warning
Always renew caliper seals and pistons after removal from the caliper. An effective hydraulic seal can only be made if new components are used. A dangerous riding condition leading to an accident could result if this warning is ignored. 2. Inspect the brake pads for damage and wear beyond the service limit. Renew as necessary.
Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 1. Disconnect the rear brake hose at the caliper and place the free end of the hose in a suitable container to collect the brake fluid. 2. 3. Remove the caliper mounting bolts. Remove the brake caliper assembly.
Assembly
Warning
A Warning
1. Caliper mounting bolts
Ensure that the caliper bores do not become scratched during removal and assembly. A dangerous riding condition leading to an accident could result if this warning is ignored.
Disassembly 1. 2. 3. Remove the plug protecting the pad retaining pin. Remove the pad retaining pin. Remove the brake pads and anti-rattle spring.
Warning
To prevent iniury, never place fingers or hands inside the caliper opening when removing the piston. Always wear eye, hand and face protection when using compressed air. Eye, face and skin damage will result from d irect contact w i th co mpressed a ir.
lump
14.39
Brakes
5. Lubricate the pad retaining pin using a minimum amount of proprietary high temperature 'Copperslip' type grease. Fit and tighten the pad retaining pin to 18 Nm. Fit the retaining plug and tighten to 3 Nm. Apply a thin smear of silicone based brake grease to the outside of the sleeve and the sliding section of the bolt as shown below. Do not apply grease to the threads of the bolt.
Warning
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fluid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored. 1. Fit new fluid seals to the caliper. Apply brake fluid to the outside of the caliper piston and fluid seal. 6. 7. 8.
1. Bolt 2. Sleeve
Installation
1. 1. Piston 2. Seals 2. 3. 4. Position the caliper over the disc ensuring the pads are correctly aligned on both sides of the disc. Fit the caliper retaining bolts and tighten to 22 Nm (M8 bolt) and 27 Nm (M12 bolt). Connect the brake hose to the caliper incorporating new washers on each side of the banjo bolt. Tighten the banjo bolt to 25 Nm.
A . Warning
Ensure that the piston does not tip during assembly as this could damage the caliper. A dangerous riding condition leading to an accident could result if this warning is ignored. 2. 3. 4. Carefully push the piston into the caliper by hand Install the anti-rattle spring into the caliper. Position the brake pads in the caliper.
Warning
Warning
Do not apply more than a minimum coating of grease to the pad retaining pins. Excess grease may contaminate the brake pads, hydraulic seals and discs causing reduced braking ef fi ciency and an accident.
1 4.40
Il1MP
Brakes
5. 6. 7. Fill the master cylinder with new, DOT 4 brake fluid from a sealed container. Bleed the rear brake (see page 14-35). Check for correct brake operation. Rectify as necessary.
Rear Brake Disc

Wear
A
Warning
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1.
Replace any brake disc worn beyond the service limit or that exceeds the disc run-out limit.
Rear Disc Thickness Standard: Service Limit: Disc Run-out Service Limit: 0.30 mm 5.0 mm 4.5 mm
Measure disc run-out using an accurate dial gauge mounted on a surface plate.
1. Disc 2. Dial gauge Note: Details of rear brake disc removal and installation can be found in the wheel section.
I UMP
1 4.41
Brakes
Rear Master Cylinder
Removal Disassembly 1. 2. 3. Remove the boot from the cylinder and pushrod. Remove the circlip retaining the pushrod to the cylinder. Remove the pushrod and piston set from the master cylinder bore, noting the relative position of the seals and piston components.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first.
Inspection 1. 2. 3. 4. Visually inspect the master cylinder bore for wear, scratches or corrosion. Replace as necessary. Check the piston and cylinder bore for damage, wear or deterioration. Replace as necessary. Always renew the piston and seal set if the cylinder is dismantled. Examine the pushrod for bends and damage. Replace as necessary.
Caution
To prevent paint damage, do not spill brake fluid onto any area of the bodywork. Spilled brake fluid will damage paintwork. 3. Drain the fluid from the master cylinder by bleeding the system at the rear caliper until all fluid has been expelled. 4. 5. 6. Remove the clip and washer from the clevis pin at the lower end of the brake pushrod. Remove the clevis pin. Disconnect from the master cylinder the: rear brake hose (noting orientation), reservoir hose.
Assembly
Warning Never use mineral based grease (such as lithium or copper based grease) in any area where contact with the braking system hydraulic seals and dust seals is possible. Mineral based grease will damage the hydraulic seals and dust seals in the calipers and master cylinders. Damage caused by contact with mineral based grease may reduce braking efficiency resulting in an accident.
Warning
Before installation, all internal brake components should be cleaned and lubricated with clean new DOT 4 brake fl uid. Never use solvents, petrol (gasoline), engine oil, or any other petroleum distillate on internal brake components as this will cause deterioration of the hydraulic seals in the calipers and master cylinders. A dangerous riding condition leading to loss of motorcycle control and an accident could result if this warning is ignored. 1. 2. Clean the master cylinder bore, piston and seals, with new brake fluid. Ensure all ports are clear of obstruction.
1. Master cylinder fixings 2. Master cylinder 3. Heel guard 7. Remove the screws securing the master cylinder and heel guard to the frame to release the master cylinder.
1 4.42
Il1MP
Brakes
8. Set the pushrod free length to 75.5 mm. Tighten the locknut to 18 Nm.
A Warning
Ensure that the piston and piston seal are fitted facing the same way as noted during removal. A dangerous riding condition leading to an accident could result from incorrect assembly of the master cylinder. 3. 4. 5. 6. Install the spring and piston set together. Apply a small amount of brake grease to the
pushrod.
9.
Installation
1. 2. 3. 4. Fit the reservoir hose to the master cylinder. Secure the master cylinder and heel guard to the frame. Tighten the securing screws to 18 Nm. Connect the push rod to the brake pedal using a new clevis pin and split pin. Incorporating new washers, fit the brake hose to the master cylinder. Ensuring correct orientation of the brake hose, tighten the banjo bolt to 25 Nm.
Install the pushrod in the master cylinder and retain with a new circlip. Refit the boot.
A Warning
^ 3 I 5
1. Reservoir hose 2. Piston set 3. Dust boot 4. Push rod 5. Clevis pin 6. Clip 7. Circlip
7.
If the pushrod has been disassembled, adjust the length of the pushrod as shown below:
M 1. Pushrod 2. Locknut
IUMP
14.43
Brakes
5. 6. 7. 8. Fill and bleed the rear brake system (see page 1435). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16- 17). Check for correct brake operation. Rectify as necessary.
Warning
14.44
illMP
15 Wheels/Tyres
Table of Contents
Explodedview - Front Wheel ...............................................................
Ex
15.2 15.3 15.4 15.4 15.4 15.5 15.6 15.6 15.7 15.8 15.8 15.8 15.10 15.10 15.10 15.10 15.11 15.11 15.12 15.12 15.13 15.13 15.13 15.13
p lodedView - Rear Wheel & Final Drive ...................................................
Tyres................................................................................... TyrePressures ...................................................................... TyreWear/Wheel Inspection ..........................................................

Im
p ortantTyre Information ..........................................................
FrontWheel ............................................................................. Removal.......................................................................... Installation......................................................................... RearWheel ............................................................................. Removal.......................................................................... Installation......................................................................... FrontWheel Bearings .................................................................... Removal.......................................................................... Inspection......................................................................... Installation......................................................................... RearWheel Bearings ..................................................................... Removal.......................................................................... Inspection......................................................................... Installation......................................................................... FinalDrive ............................................................................. Removal.......................................................................... Inspection......................................................................... Installation.........................................................................
Il1MP
15.1
Wheels/Tyres
Exploded view - Front Wheel
65 Nm
15.2
Il1MP
Wheels/Tyres
Exploded View - Rear Wheel & Final Drive
110 Nm
O0
30 Nm
^\ o
55 Nm
----------
1lJMP
15.3
Wheels/Tyres
Tyres
This model is equipped with tubeless tyres, valves, and wheel rims. Only tyres marked 'TUBELESS' and tubeless type tyre valves mounted on rims marked 'SUITABLE FOR TUBELESS TYRES' can be used.
Tyre Pressures
Correct inflation pressure will provide maximum stability, rider comfort and tyre life. Tyre pressures should be checked frequently and adjusted as necessary. Correct tyre pressures are: Daytona Tyre Pressure - Front Tyre Pressure - Rear 2.35 bar (34 psi) 2.50 bar (36 psi)
Street Triple and Street Triple R ^P1TGQC^3 ^ Tyre Pressure - Front Tyre Pressure - Rear 2.35 bar (34 psi) 2.90 bar (42 psi)
A V'Varning
cdlm
Typical Wheel Marking
Incorrect tyre inflation will cause abnormal tread wear and instability problems which may lead to loss of control and an accident. Under-inflation may result in the tyre slipping on, or coming off the rim. Over-inflation will cause instability and accelerated tread wear. Both conditions are dangerous as they may cause loss of control leading to an accident.
Tyre Wear/Wheel Inspection As the ty re tread wears down, the ty re becomes more
susceptible to puncture and failure. It is estimated that 90% of all tyre failures occur during the last 10% of tread life (90% worn). It is false economy and unsafe to use tyres until they are worn to their minimum.
ccomt
Typical Tyre Marking
All tyres are fitted with tread wear indicators. When the tyre becomes worn down as far as the top of a tread wear indicator, the tyre is worn beyond its service life and must be replaced.
Warning
Tyres that have been used on a rolling road dynamometer may become damaged. In some cases, the damage may not be visible on the external surface of the tyre. Tyres must be replaced after such use as continued use of a damaged tyre may lead to instability, loss of control and an accident.
gafj
1. Tread wear indicator
1 5.4
iLlMP
Wheels/Tyres
In accordance with the scheduled maintenance chart, measure the depth of the tread with a depth gauge, and replace any tyre that has worn to, or beyond the minimum allowable tread depth. Inspect wheels for cracks, splits and kerb damage. Always replace wheels that are suspected of having become damaged.
Warning
If a tyre sustains a puncture, the tyre must be replaced. Failure to replace a punctured tyre, or operation with a repaired tyre can lead to instability, loss of control or an accident. Never use an inner tube to repair a punctured tyre. The rough surface inside the tyre can chafe the tube leading to instability, rapid deflation, loss of control and an accident.
Warning
Operation with excessively worn tyres is hazardous and will adversely affect traction, stability and handling which may lead to loss of control or an accident. When tubeless tyres become punctured, leakage is often very slow. Always inspect tyres very closely for punctures. Check the tyres for cuts, embedded nails or other sharp objects. Check the rims for dents or deformation. Operation with damaged or defective wheels or tyres is dangerous and loss of control or an accident could result. Always consult your Triumph dealer for tyre replacement, or for a safety inspection of the tyres. Minimum Recommended Tread Depth The following chart can be used as a guide to the minimum safe tread depth.
Warning
The use of tyres other than those listed in the specification section of the owner's handbook may adversely affect handling leading to loss of control or an accident. Use the recommended tyre options only in the combinations given in the owner's handbook. Do not mix tyres from different manufacturers or tyres from the same manufacturer but from another option.
Warning
Under mph) Over mph)
130 130
km/h km/h
(80 (80
2 mm (0.08 in) Rear 3 mm (0.12 in) Front 2 mm (0.08 in)
Always check tyre pressures before riding when the tyres are cold. Operation with incorrectly inflated tyres may affect handling leading to loss of control and an accident.
A Warning
Operation with excessively worn or damaged tyres will adversely affect handling and control leading to loss of control or an accident.
Warning
Triumph motorcycles must not be operated above the legal road speed limit except in authorised closed course conditions. I mportant Tyre Information All Triumph motorcycles are carefully and extensively tested in a range of riding conditions to ensure that the most effective tyre combinations are approved for use on each model. It is essential that approved tyre combinations are used when purchasing replacement tyres as the use of non approved tyres or approved tyres in non approved combinations may lead to motorcycle instability. Always refer to the owner's handbook data section for details of approved tyres and tyre combinations.
Warning
Do not install tube-type tyres on tubeless rims. The bead will not seat and the tyres could slip on the rims, causing tyre deflation that may result in a loss of vehicle control and an accident. Do not install an inner tube inside a tubeless tyre. This may cause instability and excessive heat build-up may cause the tube to burst resulting in rapid tyre deflation, loss of vehicle control and an accident.
1l, mP
1 5.5
Wheels/Tyres
Front Wheel
Warning
Removal
Accurate wheel balance is necessary for safe, stable handling of the motorcycle. Do not remove or change any wheel balance weights. Incorrect wheel balance may cause instability leading to loss of control and an accident. When wheel balancing is required, such as after tyre replacement, see your authorised Triumph dealer. Only use self-adhesive weights. Clip on weights will damage the wheel and tyre resulting in tyre deflation, loss of control and an accident.
Warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. 2. Position the motorcycle on a paddock stand. Detach and the support the front brake calipers; see page 14-21 for Daytona 675 up to VIN 381274 and Street Tiple R; see page 14-17 for Daytona 675 from VIN 381275; see page 14-26 for Street Triple.
Warning
Note:
When replacement tyres are required, consult your authorised Triumph dealer who will arrange for the tyres to be fitted according to the tyre manufacturers instructions. When tyres are replaced, allow time for the tyre to seat itself to the rim (approximately 24 hours). During this seating period, ride cautiously as an incorrectly seated tyre could cause loss of control or an accident. Initially, the new tyre will not produce the same handling characteristics as the worn tyre and the rider must allow adequate riding distance (approximately 100 miles) to become accustomed to the new handling characteristics. After both 24 hours and 100 miles, the tyre pressures should be checked and adjusted and the tyre examined for correct seating and rectified as necessary. Use of a motorcycle when not accustomed to its handling characteristics may lead to loss of control and an acci dent.
It is not necessary to disconnect the brake hoses.
Warning
Do not allow the calipers to hang on the brake hoses as this may damage the hoses. Damaged hoses could cause brake failure leading to loss of control and an a cci de n t. 3. 4. Raise and support the front of the motorcycle. Slacken both pinch bolts at the lower end of the left hand fork.
1. Fork pinch bolts 5.
Nil x I W\
1 Release and remove the wheel spindle, which is threaded into the right hand fork.
1 5.6
Il1MP
Wheels/Tyres
6. Remove the wheel and the wheel spacers. Installation 1. 2. Lightly smear the wheel spacers with grease and locate in the hubs. Position the wheel between the forks ensuring the spacers remain in position on both sides.
I) J
cdtw
1. Wheel spacers (left hand shown)
7.
Place the wheel on wooden blocks.
Warning
1. Wheel spacers
Do not allow the wheel to rest on either brake disc as this may damage the disc and could lead to an accident.
3. 4.
Refit the wheel spindle from the left hand side and ti ghten to 65 Nm. Lower the motorcycle to the ground and pump the front suspension to allow the left hand fork to 'float' to its natural position on the wheel spindle. Tighten the fork pinch bolts to 22 Nm.
Caution
5.
To prevent wheel and bearing damage, observe absolute cleanliness and ensure there is no dirt ingress to the wheel bearings while the wheel is removed. 8. Thoroughly clean all components and inspect for wear or damage.
1. Fork pinch bolts
6. 7.
Thoroughly clean and degrease the brake discs. Refit the front brake calipers; see page 14-23 for Daytona 675 up to VIN 381274 and Street Tiple R; see page 14-25 for Daytona 675 from VIN 381275; see page 14-28 for Street Triple.
I uMP
15.7
Wheels/Tyres
Rear Wheel
Removal 6. Withdraw the wheel and collect the flanged spacer from the right hand side and the plain spacer from the left hand side. Place the wheel on wooden blocks with the drive sprocket uppermost. Remove the final drive. (See page 1S-13). Reposition the wheel on wooden blocks with the rear brake disc uppermost.
7. 8.
Warning
9.
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Raise and support the rear of the motorcycle to allow removal of the rear wheel.
10. If required, remove the rear brake disc and discard the disc bolts.
Installation 1. 2. Thoroughly clean and degrease the brake disc. Fit the brake disc and tighten new disc bolts to 22 Nm. Refit the final drive assembly (See page 15-13). Position the wheel within the swinging arm and refit the chain to the final drive sprocket.
Warning
3. 4.
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust system, allow sufficient time for the exhaust system to cool as touching any part of a hot exhaust system could cause burn injuries. 2. Remove the nut from the rear wheel spindle.
1. Fitting the chain
cdlf
1. Rear wheel spindle nut 3. 4. Support the wheel and withdraw the wheel spindle. Noting its position, release the brake caliper and carrier from the slot on the swinging arm and roll the wheel forward until the chain can be detached from the rear sprocket.
Warning
Do not allow the caliper to hang on the brake hose as this may damage the hose. Damaged hoses could cause brake failure leading to loss of control and an accident. 5. Tie the rear brake caliper aside.
1 5.8
11,1 MP
Wheels/Tyres
5. Position the rear brake caliper and carrier to the swinging arm as noted prior to removal. Align the boss on the carrier with the raised slot on the swinging arm. 9. Keeping the chain adjuster blocks in contact with the adjuster bolts, tighten the wheel spindle nut to 110 Nm.
1. Rear wheel spindle nut

1. Caliper carrier boss 2. Swinging arm slot
10. Lower the motorcycle to the ground.
6. Refit the wheel spacers, flanged spacer to the right hand side (flange facing outwards) and plain spacer to the left.
Warning
It is dangerous to operate the motorcycle with defective brakes and you must have your authorised Triumph dealer take remedial action before you attempt to ride the motorcycle again. Failure to take remedial action may reduce braking efficiency leading to loss of motorcycle control and an accident. 11. Check the operation of the rear brake. 12. Check and, if necessary, adjust the chain (see page 12-7).
1. Wheel spacer (right hand shown)
7.
Lift the rear wheel into position, aligning the wheel, caliper carrier and swinging arm.
Warning
Check that the spacers are still correctly positioned. Incorrectly fitted wheel spacers will cause a dangerous riding condition leading to loss of motorcycle control and an accident. 8. Fit the wheel spindle with the threaded end facing to the left.
'rrII111Av1i
15.9
Wheels/Tyres
Front Wheel Bearings
Removal 1. Remove the front wheel (see page 15-6).
Inspection
Warning
Caution
Do not allow the wheel to rest on the brake discs, as this may damage the discs. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake discs are raised above the ground. 2. 3. Place the wheel on wooden blocks to prevent damage to the brake discs. Remove and discard the seals and the bearing circlip.
Only remove raised witness marks from within the wheel. Removal of material below any raised areas will reduce the level of interference between the wheel and the bearings. Loss of interference could cause the bearing to become loose in the wheel leading to loss of motorcycle control a n d an a ccid e nt. 1. Examine the wheel for any raised witness marks caused by the removal process. Remove any such marks with fine emery paper or a gentle file.
Installation
Note:
Warning
Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries if suitable protective apparel is not worn.
Refer to the chart below for the correct tool and tool face when inserting bearings. Bearings are inserted by means of a draw bolt acting on the insertion tool. A support tool is located on the opposite side of the wheel to the insertion tool and as the bolt is tightened, the bearing is drawn into the wheel. Insert bearings with the marked or shielded side facing outwards and always fit a new bearing circlip and seals. Bearing insertion tool Support tool 3880065 T0301 Large Wheel face to to
Caution
To prevent wheel damage and to aid bearing removal, always apply force evenly on both sides of the bearing to prevent it from 'tipping and becoming stuck. Application of uneven force will lead to difficulty in removing the bearing and to a damaged wheel. 4. Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect the centre sleeve.
Left bearing
T3880053 Small face bearing to
Right bearing
T3880053 Small face bearing to
3880065 T0301 Large wheel face
Wheel Bearing Removal
15.10
Il1MP
Wheels/Tyres
1. Fit the wheel bearings and centre sleeve using the method described on the previous page.
Rear Wheel Bearings

Removal 1. Remove the rear wheel (see page 15-8).
\V
ces 11 V///
/
III I
Q Caution
Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above the ground. 2. Place the wheel on wooden blocks to prevent damage to the brake disc. Remove and discard the seals and the bearing circlip.
I /
I till
3.
1. Tool T3880053 2. Tool 3880065 - T0301
2. 3.
Fit a new circlip. Lubricate and fit new seals to the front wheel. Lubricate the seal's knife-edge with grease to NLGI 2 specification (we recommend Mobil HP222). Fit the front wheel (see page 15-7).
,A Warning
Always wear eye, hand and face protection when using a hammer and drift. Use of a hammer and drift can cause bearings to fragment. Pieces of fragmented bearing could cause eye and soft tissue injuries if suitable protective apparel is not worn.
4.
ACaution
To prevent wheel damage and to aid bearing removal, always apply force evenly on both sides of the bearing to prevent it from 'tipping' and becoming stuck. Application of uneven force will lead to difficulty in removing the bearing and to a damaged wheel. 4. Using a suitable pin punch, through the centre of the wheel, drift out the wheel bearings. Collect the centre sleeve.
gaeo
0
Rear Wheel Bearing Removal
I uMP
15.11
Wheels/Tyres
Inspection
1. Fit the wheel bearings and centre sleeve using the method described on the previous page.
Warning
Only remove raised witness marks from within the wheel. Removal of material below any raised areas will reduce the level of interference between the wheel and the bearings. Loss of interference could cause the bearing to become loose in the wheel leading to loss of motorcycle control and an accident. 1. Examine the wheel for any raised witness marks caused by the removal process. Remove any such marks with fine emery paper or a gentle file.
Installation
Note: Refer to the chart below for the correct tool and tool face when inserting bearings. Bearings are inserted by means of a drawbolt acting on the insertion tool. A support tool is located on the opposite side of the wheel to the insertion tool and as the bolt is tightened, the bearing is drawn into the wheel. Insert bearings with the marked or shielded side facing outwards and always fit a new bearing circlip and seals. Bearing insertion tool Left bearing 3880070 T0301 Small face bearing Right bearing 3880070 T0301 Small face bearing to Support tool 2. 3.
COxh
11\
// / I/ /I
1. Tool T3880070
Fit a new circlip. Lubricate and fit new seals to the rear wheel. Lubricate the seal's knife-edge with grease to NLGI 2 specification (we recommend Mobil H P222), Fit the rear wheel (see page 15-8).
4.
3880065 T0301 Large Wheel face
to
to
3880065 T0301 Large wheel face
to
15.12
L UMP
Wheels/Tyres
Final Drive
Removal 4. Remove the cush drive rubbers.
warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle. 1. Remove the rear wheel (see page 15-8).
Caution
1. Cush drive
Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above the ground. 2. 3. Place the wheel on wooden blocks with the drive sprocket uppermost. Gently lever the drive flange from the wheel hub.
Inspection 1. 2. 3. Check the cush drive rubbers for deterioration, cracks etc. Inspect the sprocket teeth for wear, damage and chips. Check the wheel and drive flange for wear, cracks and damage.
Installation 1. 2. 3. Install the cush drive rubbers to the wheel. Refit the drive flange to the wheel. Refit the rear wheel (see page 15-8).
1. Rear wheel 2. Drive flange
lump
15.13
16 Frame and Bodywork

Table of Contents
Ex
p lodedView - Frame - all Models .........................................................
16.3 16.4 16.5 16.6 16.7 16.8 16.9 16.10 16.11 1 6.12 1 6.13 1 6.14 1 6.15 16.16 16.17 1 6.17 1 6.17 16.17 16.17 1 6.17 16.18 16.18 16.18 16.18 16.18 16.19 1 6.19 1 6.19 16.20 16.20 16.20
ExplodedView - Rear Subframe - Daytona 675 ............................................... Exploded View - Rear Subframe - Street Triple and Street Triple R ............................... Exploded View - Cockpit and Mountings - Daytona 675 up to VIN 381274 ........................ Explode View - Cockpit and mountings - Daytona 675 from VIN 381275 ......................... ExplodedView - Lower Fairings - Daytona 675 ...............................................
Ex
p lodedView - Rear Panels - Daytona 675 ..................................................
Exploded View - Rear Panels - Street Triple and Street Triple R ................................. ExplodedView - Footrests and Mountings - Daytona 675 ...................................... Exploded View - Footrests and Mountings - Street Triple and Street Triple R ...................... ExplodedView - Sidestand - all Models ..................................................... ExplodedView - Front Mudguard - all Models ............................................... ExplodedView - Rear Mudguard - Daytona 675 ............................................. Exploded View - Rear Mudguard - Street Triple and Street Triple R ............................. Rider's Seat - all models .................................................................. Removal.......................................................................... Refit.............................................................................. RearSeat - Daytona 675 only ............................................................. Removal.......................................................................... Refit.............................................................................. Frame, Footrests and Fixings .............................................................. Inspection......................................................................... RearPanel - Daytona 675 ................................................................. Removal.......................................................................... Installation......................................................................... RearPanel - Street Triple and Street Triple R ................................................. Removal.......................................................................... Installation......................................................................... CockpitInfill Panels - Daytona 675 ......................................................... Removal......................................................................... Installation........................................................................
CM
1ClMP
1 6.1
Frame and Bodywork

LowerFairing - Daytona 675 .............................................................. Removal......................................................................... Installation....................................................................... Windscreen- Daytona 675 up to VIN 381274 ............................................... Removal......................................................................... Installation....................................................................... Windscreen- Daytona 675 from VIN 381275 ................................................ Removal......................................................................... Installation....................................................................... Cockpit
-
16.20 16.20 16.22 16.22 16.22 16.22 16.23 16.23 16.23 16.23 16.23 16.24 16.25 16.25 16.25
Daytona 675 ...................................................................
Removal......................................................................... Installation....................................................................... RadiatorCowl - Street Triple and Street Triple R .............................................. Removal......................................................................... Installation.......................................................................
1 6.2
Il1MP
Frame and Bodywork

Exploded View - Frame - all Models
Li
Se
See section 9 48 Nm
\\
0
o
section 9
: 6 Nm 0 48 Nm
48 Nm
48 Nm
See
48 Nm
See
section 9
48 Nm
section 9
..
lliMP
1 6.3
Frame and Bodywork

Exploded View - Rear Subframe - Daytona 675
48 Nm
48 Nm
1 6.4
ILIMP
Frame and Bodywork

Exploded View - Rear Subframe - Street Triple and Street Triple R
48 Nm
IgmP
16.5
Frame and Bodywork

Exploded View - Cockpit and Mountings - Daytona 675 up to VIN 381274
p^ ^ 6
9 Nm
0.5
Nm
8 Nm 8 Nm
1 6.6
Il1MP
Frame and Bodywork

Explode View - Cockpit and mountings - Daytona 675 from VIN 381275
9 Nm
7 Nm
7O.5 N
0.5
Nm
^^ 4
Pa n
3Nm
111MP
16.7
Frame and Bodywork

Exploded View - Lower Fairings - Daytona 675
3 Nm
7 Nm 3 Nm
4 Nm
7 Nm
3 Nm 4Nm L ^
d
Ib
4m
6;,
1 6.8
I UMP
Frame and Bodywork

Exploded View - Rear Panels - Daytona 675
9Nm
^3Nm
6 Nm
ILIMP
1 6.9
Frame and Bodywork

Exploded View - Rear Panels - Street Triple and Street Triple R
no m
Jm
1 6.10
Il1MP
Frame and Bodywork

Exploded View - Footrests and Mountings - Daytona 675
27 Nm
if
O \\\ \l\W'1
^ja4
20 Nm
27 Nm
20 Nm
I UMP
1 6.11
Frame and Bodywork
Exploded View - Footrests and Mountings - Street Triple and Street Triple R
^s
.J
12 Nm
9Nm
1 6.12
IIiMP
Frame and Bodywork

Exploded View - Sidestand - all Models
45 Nm 20 N
7 Nm
O O o
7 Nm
Il1MP
1 6.13
Frame and Bodywork

Exploded View - Front Mudguard - all Models
3 Nm
3 Nm
1 6.14
IL1MP
Frame and Bodywork

Exploded View - Rear Mudguard - Daytona 675
Il1MP
1 6.15
Frame and Bodywork

Exploded View - Rear Mudguard - Street Triple and Street Triple R
3Nm
1 6.16
1lIMP
Frame and Bodywork

Rider's Seat - all models
Removal The seat lock is located on the left hand side of the battery tray, in line with the footrest mounting rail. To remove the seat, insert the ignition key into the seat lock and turn it anti-clockwise while pressing down on the rear of the seat. This will release the seat from its lock and allow it to be slid rearwards for complete removal from the motorcycle.
Rear Seat - Daytona 675 only

Removal To remove the rear seat cover or rear seat (where fitted): Remove the fixing located beneath the padding. This will allow the rear seat/seat cover to be slid forwards for complete removal from the motorcycle.
go
1. Fixing 1. Seat lock
Refit To refit the rear seat, engage the seat's tag under the rear subframe rail and install the fixing. Tighten the seat fixing to 9 Nm.
Refit To refit the seat, engage the seat's tongue under the fuel tank and press down at the rear to engage in the seat lock.
arning
To prevent detachment of the seat during riding, after fitting always grasp the seat and pull firmly upwards. If the seat is not correctly secured it will detach from the lock. A loose or detached seat could cause loss of motorcycle control and an accident.
Caution
To prevent damage to the seat and its cover, care must be taken not to drop the seat. Do not lean the seat against the motorcycle or a wall as it may fall. Instead, place the seat, with the seat cover facing up, on a flat surface which is covered with a soft cloth.
1liMP
1 6.17
Frame and Bodywork

Frame, Footrests and Fixings
Inspection 1. Inspect the frame, footrests and fairings for damage, cracks, chafing and other dangerous conditions. Check fairing and frame fixings for security. Inspect the bank angle indicators on the rider's footrests for wear. The bank angle indicators are worn out when 5mm of the bank indicator remains.
Rear Panel - Daytona 675

Removal 1. 2. 3. Remove the seats (see page 16-17). Disconnect the battery, negative (black) lead first. To release the rear panel assembly, remove the fixings shown in the illustration below.
2.
Rear panel fixings

1. Bank angle indicator (Daytona 675 shown)
4. 5.
Gently pull the panel outwards. Lift and withdraw the rear panel assembly in a rearward direction. Disconnect the rear lamp multi-plug.
Warning
6.
Use of a motorcycle with bank angle indicators worn beyond the maximum limit will allow the motorcycle to be banked to an unsafe angle. Banking to an unsafe angle may cause instability, loss of control and an acci de nt cau s ing injury o r death.
Installation 1. Installation is the reverse of removal noting the following:
Note: Tighten the fixings to 3 Nm. Reconnect the battery, positive (red) lead first.
Warning
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 another accident which may result in injury or death.
Warning
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.
1 6.18
ILIMP
Frame and Bodywork

Rear Panel - Street Triple and Street Triple R
Removal 1. 2. 3. Remove the seat (see page 16-17). Disconnect the battery, negative (black) lead first. To release the rear panel assembly, remove the fi xings shown in the illustration below. Installation 1. Installation is the reverse of removal noting the following:
Note: Ensure the locating peg is correctly inserted in the subframe grommet. Tighten the rear panel fixings to 3 Nm. Reconnect the battery, positive (red) lead first.
1. Rear panel (right hand shown) 2. Fixings
4. 5.
Gently pull the panel outwards. Release the rear panel locating peg from the grommet on the subframe.
1. Subframe grommet 2. Rear panel locating peg
I UMP
1 6.19
Frame and Bodywork

Cockpit Infill Panels - Daytona 675
Removal Note: Follow the same procedure for both left and right hand sides. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. 1. 2. From VIN 381275, the front fixing for the right hand infill panel also secures the front of the regulator/rectifier bracket to the fairing. Remove the two screws securing the cockpit infill panel. 3. 4. Remove the rider's seat (see page 16- 17). Disconnect the battery, negative (black) lead first. Remove the cockpit infill panels (see page 16-20). Remove the four fixings securing the fairing lower halves to each other.
Lower Fairing - Daytona 675

Removal Note: Follow the same procedure for both left and right hand sides. The cockpit does NOT need to be removed in order to remove the lower fairings.
1. 2.
Note:
3.
1. Lower fairing fixings
5.
1. Cockpit infill panel 2. Fixings
Remove the three fixings securing the radiator infill panel to the fairing.
4.
Remove the panel.
Note: Tighten the fixings to 5 Nm. Reconnect the battery, positive (red) lead first.
1. Radiator infill panel (right hand shown) 2. Fixings (one fixing is not shown)
1 6.20
tLiMP
Frame and Bodywork

Note: From VIN 381275, the fixing for the front right hand indicator also secures the rear of the regulator/rectifier bracket to the fairing 6. 7. 8. 9. From VIN 381275 only: If the left hand fairing is being removed, remove the fixing for the indicator. Remove the three screws securing the fairing to the fairing brackets. Remove the screw securing the fairing to the cockpit. Detach the lower fairing stud from the frame grommet. 11. Disconnect the direction indicator connectors. Note: When the lower fairing is removed the lower infill panel may remain in either fairing half. 12. Remove the lower fairing infill panel.
1. Right hand lower fairing 2. Infill panel 3. Fixing stud/grommet
1. Lower fairing 2. Fairing retaining screws 3. Fairing to cockpit screw 4. Fairing stud/grommet location (one on each fairing) Note: If the left hand fairing half is being removed, detach the rear fuse box grommet from the fairing stud. The fuse box will remain attached to its forward fixing stud on the headlamp when the lower fairing is removed.
1. Fuse box grommet/stud 10. Ease the panel away from the cockpit to remove it.
tl,11 P
1 6.21
Frame and Bodywork

Installation 1. 2. 3. 4. 5. Refit the lower fairing infill panel to either fairing half. Position the fairing to the rear of the cockpit. Reconnect the direction indicator connectors. Align the fairing stud to the frame grommet and refit. Align the fairing stud to the fuse box grommet and refit. Removal Note: It is not necessary to remove the mirrors to remove the windscreen.
Windscreen - Daytona 675 up to VIN 381274
EM
1. Windscreen 1. Fuse Box grommet/stud 2. Fixings
6. 7. 8. 9.
Refit the lower fairing infill panel to the opposite fairing half. Refit the fairing to cockpit lower fixing, and tighten to 3 Nm. Refit the fairing to the fairing brackets, tighten the fixings to 4 Nm. From VIN 381275 only: If fitting the right hand fairing, fit the indicator fixing and tighten to 3 Nm. Ensure the fixing secures the alternator rectifier/ regulator to the fairing.
1. 2.
Release the eight windscreen fixings. Slide the windscreen upwards and to the rear.
Installation Installation is the reverse of removal noting the following. Note: Tighten the fixings to 0.5 Nm.
10. Refit the radiator infill panel fixings. 11. Refit the lower fairing fixings. 12. Refit the cockpit infill panels (see page 16-20). 13. Reconnect the battery, positive (red) lead first. 14. Refit the rider's seat (see page 16-17).
1 6.22
I UMP
Frame and Bodywork

Windscreen - Daytona 675 from VIN 381275
Removal 1. Remove the caps on the mirror securing nuts, release the two nuts and remove the mirror, on both sides.
Cockpit - Daytona 675

Removal Note: The cockpit is removed as an assembly. It is not necessary to remove the lower fairings, instruments or windscreen. The headlight will remain in the cockpit upon removal. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the cockpit infill panels (see page 16-20). Remove the caps on the mirror securing nuts and release the two nuts holding each mirror. Remove both mirrors.
1. 2. 3. 4. 5.
1. Mirror fixings
2.
Release the four windscreen fixings.
1. Mirror fixings
6.
Remove the two screws (one on each side) securing the cockpit to each lower fairing.
cfd
1. Windscreen 2. Windscreen fixings
3.
Slide the windscreen upwards and to the rear.

1. Fairing to cockpit screw
Note: Tighten the windscreen fixings to 0.5 Nm. Tighten the mirror fixings to 9 Nm. Refit the nut covers.
tl.1 MP
1 6.23
Frame and Bodywork

7. Remove the two fixings (one on each side) securing the radiator infill panel to the cockpit. 6. Refit the mirrors, tighten the fixings to 9 Nm. Refit the nut covers.
1. Cockpit 2. Radiator infill panel fixing (left hand shown)
1. Mirror fixings
7. 8. 9.
Refit the cockpit infill panels (see page 16-20). Connect the battery, positive (red) lead first. Refit the rider's seat (see page 16- 17).
8.
With the aid of an assistant detach the cockpit and disconnect the headlight multi-plug.
Note: Before removing the cockpit from the motorcycle, note the exact routing of the cockpit harness. Detach the cockpit wiring harness from the cockpit.
9.
10. Remove the cockpit in a forward direction.
Installation 1. 2. 3. 4. 5. With the aid of an assistant position the cockpit to the motorcycle. Refit the cockpit harness following the routing noted during removal. Reconnect the headlight multi-plug. Refit the cockpit to the lower fairings, tighten the two fixings to 3 Nm. Refit the two fixings (one on each side) securing the radiator infill panel to the cockpit.
1 6.24
1lIMP
Frame and Bodywork

Radiator Cowl - Street Triple and Street Triple R
Removal 1. 2. 3. 4. 5. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Disconnect the front direction indicator connections, located under the airbox. Installation 1. Pass the direction indicator harness through the radiator cowl and position the direction indicator to the radiator cowl. 2. Pass the direction indicator harness through the radiator bracket and align the radiator cowl to its fixing holes. Note: Ensure the direction indicator harness passes through the hole in the radiator bracket and is not trapped by the radiator cowl as it is installed.
1. Left hand direction indicator connections 2. Right hand direction indicator connections
cesn
1. Radiator bracket 2. Direction indicator harness hole 3. Direction indicator fixing hole
6. 7.
Release the fixing securing the direction indicator to the radiator cowl. Release the three fixings securing the radiator cowl to the radiator.
3. Route the direction indicator harness inside the frame rail to a position above the camshaft cover. Reconnect the electrical connectors to the main harness. 4. Install the three radiator cowl fixings and the direction indicator fixing and tighten as follows: Tighten the radiator cowl fixings to 5 Nm. Tighten the direction indicator fixing to 4 Nm.
5. 6. 7.
Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first.
1. Radiator cowl 2. Direction indicator fixing 3. Fixings
8. Remove the radiator cowl and, noting the routing of the direction indicator harness, carefully feed the harness through the radiator bracket as the cowl is removed.
LUMP
Service Manual -
Daytona 675, Street Triple and Street Triple R
1 6.25
Frame and Bodywork
This page intentionally left blank
1 6.26
111MP
17 Electrical
Table of Contents
Ex
p lodedView - Instruments - Daytona 675 ..................................................
17.5 17.6 17.7 17.8 17.9 17.10 17.11 17.12 17.13 17.14 17.14 17.15 17.15 17.15 17.16 17.17 17.17 17.18 17.18 17.18 17.18 17.18 17.18 i/.ri 17.19 17.20 17.20 17.20 17.21 17.21 17.21 17.22
Exploded View - Instruments - Street Triple and Street Triple R .................................. ExplodedView - Headlight - Daytona 675 .................................................... Exploded View - Headlights - Street Triple and Street Triple R ................................... Exploded View - Rear Light & Licence Plate Light - all Models ................................... Exploded View - Direction Indicators - Daytona 675 up to VIN 381274 ........................... Exploded View - Direction Indicators - Daytona 675 from VIN 381275 ............................ Exploded View - Direction Indicators - Street Triple and Street Triple R ........................... ExplodedView - Alternator and Starter - All Models ........................................... Battery................................................................................. BatteryRem oval ....................................................................
BatteryRefit
.......................................................................
BatteryCommissioning and Charging ................................................ NewBattery ....................................................................... BatteryMaintenance.......... ...................................................... BatteryAlready in Service ............................................................ Tableof Battery Charging Times ...................................................... Relays - Daytona 675 ..................................................................... RelayIdentification .................................................................. DirectionIndicator Unit .............................................................. FuelPump Relay ................................................................... Relays- Street Triple and Street Triple R ..................................................... RelayIdentification .................................................................. ruses................................................................................... FuseIdentification - Daytona 675 ..................................................... Fuse Identification - Street Triple and Street Triple R ...................................... InstrumentPack - Daytona 675 ............................................................ Removal.......................................................................... Installation......................................................................... Instrument Pack - Street Triple and Street Triple R ............................................ Removal.......................................................................... Installation.........................................................................
1 7.1
Electrical
Headlights
-
Daytona 675 ................................................................
17.22 17.22 17.23
HeadlightAdjustment ............................................................... Installation........................................................................
HeadlightBulb Replacement .........................................................17.23 PositionLamp Bulb Replacement .....................................................17.23 HeadlightAssembly - Daytona 675 ........................................................ Removal.......................................................................... Installation........................................................................ Headlights- Street Triple and Street Triple R ................................................. 17.24 17.24 17.24 17.24
HeadlightAdjustment ............................................................... 17.24 HeadlightBulb Replacement .........................................................17.25 PositionLamp Bulb Replacement .....................................................17.25 RearLight - Daytona 675 ................................................................. Removal.......................................................................... Installation........................................................................ RearLight - Street Triple and Street Triple R ................................................. Removal.......................................................................... Installation........................................................................ DirectionIndicators ...................................................................... BulbReplacement .................................................................. RearDirection Indicator - Daytona 675 ..................................................... Removal.......................................................................... Installation........................................................................ Rear Direction Indicator - Street Triple and Street Triple R ..................................... Removal.......................................................................... Installation........................................................................ FrontDirection Indicator - Daytona 675 .................................................... Removal.......................................................................... Installation........................................................................ Front Direction Indicator- Street Triple and Street Triple R ..................................... Removal.......................................................................... Installation........................................................................ LicencePlate Light ...................................................................... BulbReplacement .................................................................. StarterMotor ........................................................................... Removal.......................................................................... Inspection......................................................................... Installation........................................................................ Alternator.............................................................................. Removal.......................................................................... Assembly......................................................................... AlternatorRectifier ...................................................................... Daytona675 from VIN 381275 ....................................................... 17.26 17.26 17.26 17.26 17.26 17.27 17.27 17.27 17.28 17.28 17.28 17.28 17.28 17.29 17.30 17.30 17.30 17.30 17.30 17.31 17.31 17.31 17.32 17.32 17.32 17.32 17.33 17.33 17.34 17.35 17.35
Daytona 675 up to VIN 381274, Street Triple and Street Triple R all VINs .................... 17.35
1 7.2
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Electrical
AlternatorStator ........................................................................ PinpointTests ...................................................................... Rectifier/Regulator ...................................................................... PinpointTests ...................................................................... LightingCircuit - Daytona 675 up to VIN 381274 ............................................ Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ LightingCircuit - Daytona 675 up to VIN 381274 ............................................ LightingCircuit - Daytona 675 from VIN 381275 ............................................. Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ LightingCircuit - Daytona 675 from VIN 381275 ............................................. Starting and Charging Circuit - Daytona 675 up to VIN 381274 ................................ Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ Starting and Charging Circuit - Daytona 675 up to VIN 381274 ................................ Starting and Charging Circuit - Daytona 675 from VIN 381275 ................................. Keyto circuit diagram ...............................................................
Keyto
17.36 17.36 17.38 17.38 17.40 17.40 17.40 17.41 17.42 17.42 17.42 17.43 17.44 17.44 17.44 17.45 17.46 17.46 17.46 1747 17.48 17.48 17.48 17.49 17.50 17.50 17.50 1151 17.52 17.52 17.52 17.53 17.54 17.54 17.54 1 755 17.56 17.56 17.56 17.57 17.58 17.58
wiring colours ................................................................
Starting and Charging Circuit - Daytona 675 from VIN 381275 ................................. Auxiliary and Accessory Circuit - Daytona 675 up to VIN 381274 ...............................
Keyto
circuit diagram ...............................................................
Keyto wiring colours.............. .................................................. Auxiliary and Accessory Circuit - Daytona 675 up to VIN 381274 ............................... Auxiliary and Accessory Circuit - Daytona 675 from VIN 381275 ............................... Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ Auxiliary and Accessory Circuit - Daytona 675 from VIN 381275 ............................... LightingCircuit - Street Triple and Street Triple R ............................................. Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ LightingCircuit - Street Triple and Street Triple R ............................................. Starting and Charging Circuit - Street Triple and Street Triple R ................................. Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ Starting and Charging Circuit - Street Triple and Street Triple R ................................. Auxiliary and Accessory Circuit - Street Triple and Street Triple R ............................... Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ Auxiliary and Accessory Circuit - Street Triple and Street Triple R ............................... Complete System - Daytona 675 up to VIN 300525 with/without Fuel Pump Relay Modification .... Keyto circuit diagram ...............................................................
,1
I UMP
1 7.3
Electrical
Complete System - Daytona 675 from VIN 300526 to VIN 323544 with Fuel Pump Relay ......... Keyto circuit diagram ............................................................... Complete System - Daytona 675 - from VIN 323545 to VIN381274 ............................ Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ CompleteSystem - Daytona 675 - from VIN 381275 ......................................... Keyto circuit diagram ............................................................... Complete System - Street Triple and Street Triple R .......................................... Keyto circuit diagram ............................................................... Keyto wiring colours ................................................................ 17.60 17.60 17.62 17.62 17.62 17.64 17.64 17.66 17.66 17.66
1 7.4
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Electrical
Exploded View - Instruments - Daytona 675
IIIMP
1 7.5
Electrical
Exploded View - Instruments - Street Triple and Street Triple R
\ D
3 Nm
P/I
1 7.6
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Electrical
Exploded View - Headlight - Daytona 675
3 Nm
L UMP
1 7.7
Electrical
Exploded View - Headlights - Street Triple and Street Triple R
15 Nm
U 0
0
30 Nm 15 Nm 4Nm
15 Nm i
30 Nm
4Nm
1 7.8
Il1MP
Electrical
Exploded View - Rear Light & Licence Plate Light - all Models
2 Nm
IIIMP
1 7.9
Electrical
Exploded View - Direction Indicators - Daytona 675 up to VIN 381274
3Nm
17.10
ILIMP
Electrical
Exploded View - Direction Indicators - Daytona 675 from VIN 381275
3Nm
3N
4N
4N
`^
IIIMP
17.11
Electrical
Exploded View - Direction Indicators - Street Triple and Street Triple R
3 Nm
4Nm
3Nm
, 4Nm
III1
7Nm
1 7.1 2
Il1MP
Electrical
Exploded View - Alternator and Starter - All Models
r--------------i ' m ^ 3Nm m
----^
,
3Nm
3 Nm
--------------,
12 Nm 12 Nm
3 Nm
Iii
m
3Nm
' 120 Nm 6Nm
L--------------
10 Nm
y,,
IIIMP
17.13
Electrical
Battery Battery Removal Daytona 675
AWarning
The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space. The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. If electrolyte gets on your skin, flush with water immediately.
1.
If electrolyte gets in your eyes, flush with water for at least 15 minutes and SEEK MEDICAL ATTENTION IMMEDIATELY. If electrolyte is swallowed, drink large quantities of water and SEEK MEDICAL ATTENTION IMMEDIATELY. KEEP ELECTROLYTE OUT OF THE REACH OF CHILDREN. 1. Battery 2. Negative (-) terminal 3. Positive (+) terminal 4. Battery strap Street Triple and Street Triple R
A,
Warning
The battery contains harmful materials. Always keep children away from the battery whether or not it is fitted in the motorcycle. Do not jump start the battery, touch the battery cables together or reverse the polarity of the cables as any of these actions may cause a spark which would ignite battery gasses causing a risk of p e rsonal inj ury.
Warning The battery electrolyte is corrosive and poisonous. Never swallow battery electrolyte or allow electrolyte to come into contact with the skin. Always wear eye and skin protection when adjusting the electrolyte level.
1. Battery 2. Negative (-) terminal 3. Positive (+) terminal 4. Battery strap 5. Battery strap band 1. 2. 3. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the battery strap. On Street Triple, note the orientation of the strap and the fitted position of the band around the rear of the battery. Take the battery out of the case.
4.
1 7.14
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Electrical
Warning
Warning
Ensure that the battery terminals do not touch the motorcycle frame as this may cause a short circuit or spark which would ignite battery gases causing a risk of personal injury.
The battery gives off explosive gases; keep sparks, fla mes and cigarettes away. Provide adequate ventilation when charging or using the battery in an enclosed space. The battery contains sulphuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
Battery Refit
Warning
If electrolyte gets on your skin, flush with water immediately.
Ensure that the battery terminals do not touch the motorcycle frame as this may cause a short circuit or spark which would ignite battery gases causing a risk of personal injury. 1. 2. 3. 4. 5. Place the battery in the battery case. Reconnect the battery, positive (red) lead first. Apply a light coat of grease to the terminals to prevent corrosion. Cover the terminals with the protective caps. Refit the battery strap. On Street Triple, ensure the strap is fitted with the band towards the rear of the motorcycle. Hook the battery strap band around the rear of the battery as noted on removal. Refit the rider's seat (see page 16- 17).
If electrolyte gets in your eyes, flush with water for at least 15 minutes and SEEK MEDICAL ATTENTION IMMEDIATELY. If electrolyte is swallowed, drink large quantities of water and SEEK MEDICAL
ATTENTION IMMEDIATELY.
KEEP ELECTROLYTE OUT OF THE REACH OF CHILDREN. 1. Ensure the VIN number printed on the anti-tamper label attached to the battery matches the motorcycle VIN. Read the instructions and warnings delivered with the battery. Place the battery on a flat level surface and remove the sealing foil.
2. 3.
6.
Battery Commissioning and Charging New Battery

In order to correctly and safely commission a new battery, the battery commissioning procedure listed below must be carefully followed. This is the only battery commissioning procedure that Triumph recommends. The procedure is designed to ensure that the battery is at its best when fitted to the motorcycle, and will provide the best possible performance and reliability. Failure to comply with this procedure may lead to reduced battery performance and/or shorten the life of the battery. 5.
Caution
Ensure the electrolyte container part number matches the battery part number to be filled. Battery life will be greatly reduced if the incorrect volume (either too little or too much) of acid is added to the battery. 4. Remove the battery sealing strip from the electrolyte container (if applicable) and save for later in this procedure. Place the sealing strip on a clean surface, with the upper side facing downwards to avoid contamination of the sealing strip. Do not break the seal on the electrolyte container. Place the electrolyte container and adapter (if applicable) on the battery and fill the battery according to the manufacturers instructions. After starting to fill the battery with electrolyte, allow the battery to stand for 30 minutes with the filling container in place. Check that all of the electrolyte has drained from the container. Do not remove the container at this point. If the container has not completely drained, tap the sides of the container to start the electrolyte flowing again.
6.
7.
1LiMP
1 7.15
Electrical
8. After the electrolyte has drained into the battery, allow the battery to stand with the electrolyte container in place for a further 30 minutes for batteries 3Ah - 12Ah or 1 hour for batteries greater than 12Ah. Remove the electrolyte container and adapter carefully, and dispose of immediately. Battery Maintenance The battery is a sealed type and does not require any maintenance other than routine recharging such as during storage. It is not possible to adjust the electrolyte level in the battery. Note: The charge level in the battery must be maintained to maximise the battery life.
9.
10. Place the sealing cap strip LOOSELY over the filling holes of the battery. 11. Charge the battery using the BatteryMate 150-9. Refer to the instructions supplied with the BatteryMate 150-9.
Caution
The caps must be fitted (after charging) within two hours of filling the battery with acid. Leaving the battery open to the atmosphere for longer than is necessary will start to reverse the chemical reaction which takes place within the battery, greatly reducing the battery life. 12. After charging is complete, press down firmly with both hands to seat the caps (do not use tools or force the caps into position). 13. Disconnect the charger and allow the battery to stand for 1 hour before fitting to the motorcycle. 14. Fit the battery to the motorcycle, positive (red) lead first.
With normal use of the motorcycle, the charging system will keep the battery charged. If the motorcycle is unused the battery will gradually discharge due to battery self discharge and the continuous current drain for the clock and the engine control module memory. The rate of battery discharge can be greatly increased by the addition of electrical security systems or other accessories. If the motorcycle is used for very short journeys, the alternator will not have enough time to replenish the charge used to start and run it. Therefore, the battery should be charged after each return journey following the instructions and advice given here and in the owner handbook under the sections Battery Discharge and Battery Discharge During Storage and Infrequent Use of the Motorcycle. Allowing a battery to discharge, or leaving it discharged over a period of time, causes sulphation of the lead plates within the battery. Sulphation is a normal chemical reaction inside the battery and over a period of time sulphate will crystallise on to the lead plates making charging difficult or impossible. The result is a permanently damaged battery, which would not be covered by the motorcycle warranty. Keeping a battery at full charge reduces the chance of it freezing in cold conditions. Allowing a battery to freeze can cause serious internal damage to the battery. When leaving the motorcycle standing for more than a few days, regularly check the battery Voltage using a digital multimeter. Should the battery Voltage fall below 12.8V, charge the battery using the BatteryMate 150-9. Refer to the instructions supplied with the BatteryMate 150-9. For extended periods of storage (beyond two weeks) the battery should be removed and the battery Voltage checked regularly and charged when below 12.8V
1 7.16
(LIMP
Electrical
Battery Already in Service
Use the guidelines in the table below for charging. Always verify the battery condition before charging, and 30 minutes after charging. Note: A fully charged battery should read 12.8 volts or higher after the ba tteryIâs been off battery has been the charger for 30 minutes or more.
Table of Battery Table of Ba tt ery Charging Times

State of charge Voltage 12.8V - 13.OV 12.SV 12.5V - 12.8V Action None. Check at 6 months from date of manufacture May need slight charge. If no charge given, check in 3 - 4 months Needs charge Needs charge Needs recovery using BatteryMate 150-9. Re-test after recovery Charge time (using BatteryMate 150-9) None required 3 - 6 hours
100% 75% - 100%
SO% 75% 50% -- 75% 25% - 50% V 0% - 25%
12.OV - 12.5V 11.5V - 12.OV 11.SV 11.5V or less
5 S - 11 hours at least 13 hours 20 hours
11.1 MP 1!. MP
Service Manual - Daytona 675, Street Triple and Street Triple R -Daytona 675, Street Triple
17.17 1 7.1 7
Electrical
Relays - Daytona 675
The relay pack is located beneath the left hand fairing infill panel, adjacent to the fuse box. To gain access to the relays, remove the left hand infill panel (see page16-20).
Relay Identification Fuel Pump Relay
Relays - Street Triple and Street Triple R

The relay pack is located beneath the fuel tank. To gain access to the relays, raise and support the fuel tank (see page 10-91).
1. 2. 3. 4. Cooling fan relay Engine management system (EMS) main relay Starter relay Fuse box
iii
5
Relay Identification
1 2 3 4 6
/^ 1_
Direction Indicator Unit

The direction indicator unit is located behind the left hand lower fairing, adjacent to the vacuum reservoir for the intake air flap.
\ \
)
1. 2. 3. 4. 5. 6.
Fuel Pump relay Cooling fan relay Engine management system (EMS) main relay Starter relay Direction indicator unit Fuse box
1. Direction indicator unit 2. Vacuum reservoir
1 7.18
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Electrical
Fuses If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of the correct current rating. A blown fuse is indicated when all of the systems protected by that fuse become inoperative. When checking for a blown fuse, use the table below to establish which fuse has blown. Note: On both models, the starter solenoid has an additional 30 Amp fuse attached directly to the solenoid, beneath the rider's seat. Fuse Identification - Daytona 675 Fuses are arranged in the fuse box located beneath the left hand fairing infill panel. To gain access to the fuse box, remove the left hand infill panel (see page 16-20). o _
Imo'
A Warning
Always replace blown fuses with new ones of the correct current rating (as specified on the fuse box cover) and never use a fuse of higher rating. Although no spare 5 Amp. fuse is supplied in the fuse box, it is strongly recommended that a spare 5 Amp. fuse be carried. Fuse No. 1 2 3 4 5 6
Arrowed: Fuse Box
Circuits Protected Dip and main beam headlights, sta rt er relay Ignition switch, sta rt er circuit Auxilia ry lighting Horn, indicators, alarm Cooling fan Engine system management
Fuse Rating 15 10 5 10 15 20
The fuse identification numbers listed correspond with those printed on the fuse box cover.
F
3
115A_ 10o -___JJI 21OA ^5^ ;I 3 5A;oo
4 I c Pr--T ,4 10Aa^C .
15
^ 620A
W
1. Fuse box 2. Fuse box cover 3. Spare fuses
20
OPEN
I UMP
1 7.19
Electrical
Fuse Identification - Street Triple and Street Triple R
Fuses are arranged in the fuse box located beneath the fuel tank. To gain access to the fuse box, raise and support the fuel tank (see page 10-91).
Instrument Pack - Daytona 675

Removal
1. 2. 3. 4. Remove the rider's seat (see page 16-17). Disconnect the batte ry , negative (black) lead first. Remove the cockpit (see page 16-23). Release the four fixings securing the instrument bracket to the air intake duct. Collect the fall detection switch and bracket from the right hand side of the instrument bracket.
Arrowed: Fuse Box Fuse No. 1 2 3 4 5 6 Circuits Protected Dip and main beam headlights, starter relay Ignition circuit switch, starter Fuse Rating 20
v.
10 5 10 15 20
1. Instrument bracket 2. Instrument pack 3. Instrument bracket fixings (right hand shown) 4. Fall detection switch and bracket
Auxilia ry lighting Horn, indicators, alarm Cooling fan Engine system management
5.
Raise the instrument pack and disconnect the electrical connection to the main harness. Remove the pack and bracket. Release the fixing securing the instrument pack to the bracket.
6.
The fuse identification numbers listed correspond with those printed on the fuse box cover.
o ^ o1 C
0A ^D 12 1 3 5A ;oo;
-2
r
i I _ 114 10Aa^C
-6 20A 3 I OPEN
cdvx
1.Fuse box 2.Fuse box cover 3.Spare fuses
1. Ins tr ument pack 2. Instrument bracket 3.
Fi xing
4. Bayonet fixings
1 7.20
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Electrical
7. Remove the instrument pack from the bracket.
Instrument Pack - Street Triple and Street Triple R

Removal 1. 2. 3. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the cover and gasket attached to the rear of the instruments.
Installation 1. 2. 3. 4. 5. Position the instrument pack to the bracket. Insert the bayonet fixings into the grommets. Refit the fixing and tighten to 3 Nm. Connect the instruments to the harness. Place the instrument bracket in position on the air intake duct and reposition the fall detection switch and its bracket. Refit the fixings.
Note: The cover is held in place by bayonet type fixings. Gently pull on the cover to release it.
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1. Instrument bracket 2. Instrument pack 3. Instrument bracket fixings (right hand shown) 4. Fall detection switch and bracket
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- \ \\
1. Instrument cover 2. Bayonet fixings 3. Gasket
6. 7. 8. 9.
Tighten the bracket fixings to 7 Nm. Refit the cockpit (see page 16-24). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
4. 5.
Disconnect the electrical connector from the instruments. Remove the screw and release the instrument pack from the bracket bayonet fixings.
1. Screw 2. Washer 3. Bayonet fixings 4. Electrical connector
S UMP
1 7.21
Electrical
Installation 1. 2. 3. 4. Position the instrument pack to the bracket. Insert the bayonet fixings into the grommets. Refit the fixing and tighten to 3 Nm. Connect the instruments to the harness. Headlight Adjustment Note: Each headlight can be adjusted by means of vertical and horizontal adjustment screws located on the rear of each headlight.
Headlights - Daytona 675
1. Screw 2. Washer 3. Bayonet fixings 4. Electrical connector 1. 2. 3. 4. 5.
5.
Install the cover and gasket to the rear of the instruments, ensuring the bayonet fixings are fully inserted in the grommets on the instrument bracket. Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16-17).
Horizontal adjustment screw (left hand) Vertical adjustment screw (left hand) Horizontal adjustment screw (right hand) Vertical adjustment screw (right hand) Pivot screws (DO NOT adjust these screws)
6. 7.
1.
Switch the headlight dipped beam on.
ACaution
Do not adjust the pivot screws as this could cause the headlight reflector to become detached from the pivot screw, leading to irreparable damage to the headlight. 2. Turn the vertical adjustment screws on each headlight clockwise to raise the beam or anticlockwise to lower the beam. On the right hand headlight turn the horizontal adjustment screw clockwise to move the beam to the left or anti-clockwise to move the beam to the right. On the left hand headlight turn the horizontal adjustment screw clockwise to move the beam to the right or anti-clockwise to move the beam to the left. Switch the headlights off when both beam settings are satisfactorily set.
3.
4.
5.
1 7.22
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Electrical
6. Detach the bulb retainer from the headlight assembly by rotating it anti-clockwise. Remove the bulb from the bulb retainer.
Warning
7.
Adjust road speed to suit the visibility and weather conditions in which the motorcycle is being operated. Ensure that the beam is adjusted to illuminate the road surface sufficiently far ahead without dazzling oncoming traffic. An incorrectly adjusted headlight may impair visibility causing an accident.
Installation
1. Installation is the reverse of removal, noting the following:
Note: When reconnecting the battery, connect the positive (red) lead first.
Headlight Bulb Replacement
Position Lamp Bulb Replacement

The position lamps are fitted to the left and right of each headlight. To replace a bulb, remove the two screws and remove the bulb cover, detach the rubber retainer from the headlight and pull out the bulb. Installation is the reverse of the removal procedure.
- 2
1. Headlight unit 2. Bulb retainer
Each headlight bulb can be replaced as follows:
//
The bulb becomes hot during use. Always allow sufficient time for the bulb to cool before handling. Avoid touching the glass part of the bulb. If the glass is touched or gets dirty, clean with alcohol before re-use.
1. Bulb holder 2. Position lamp bulb
Warning
Do not reconnect the battery until the assembly process has been completed. Premature battery reconnection could result in ignition of the battery gases causing risk of injury. 1. 2. 3. 4. 5. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fairing infill panel (see page 16-20). Remove the four screws and remove the bulb cover from the bulb to be replaced. Disconnect the multi-plug from the bulb retainer.
LUMP
17.23
Electrical
Headlight Assembly - Daytona 675
Removal 1. 2. 3. 4. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the cockpit (see page 16-23). Release the four fixings securing the headlight to the cockpit. Remove the headlight. Headlight Adjustment Note: The vertical beams of the left hand and right hand headlights can only be adjusted together. Independent adjustment is not possible.
Headlights - Street Triple and Street Triple R
c
1. Headlight 2. Fixings 1. Vertical adjuster fixings
1. Installation 1. Installation is the reverse of removal, noting the following: 2. 3. 4. 5. 6. 7. 8.
Switch the headlight dipped beam on. Remove the adjuster cover. Slacken the clamp bolt sufficient to allow restricted movement of the headlights. Adjust the position of the headlights to give the required beam setting. Tighten the clamp bolt to 30 Nm. Re-check the headlight beam settings. Switch the headlights off when both beam settings are satisfactorily set. Refit the adjuster cover.
Note: Tighten the headlight fixings to 3 Nm. Reconnect the battery, positive (red) lead first.
1. Horizontal beam adjusters
1 7.24
ILIMP
Electrical
Note: The horizontal beams of both headlights can be adjusted individually. The same procedure is used to adjust either headlight. Switch the headlight dipped beam on.
Warning
The bulb becomes hot during use. Always allow sufficient time for the bulb to cool before handling. Avoid touching the glass part of the bulb. If the glass is touched or gets dirty, clean with alcohol before reuse.
9.
10. Slacken the headlight bowl fixing. 11. Adjust the horizontal position of the headlight to give the required beam setting. 12. Tighten the clamp bolt to 15 Nm. 13. Repeat for the second headlight. 14. Re-check the headlight beam settings. 15. Switch the headlights off when both beam settings are satisfactorily set.
Warning
Do not reconnect the battery until the assembly process has been completed. Premature battery reconnection could result in ignition of the battery ga s es causi ng risk of injury. 1. 2. 3. 4. Disconnect the battery, negative (black) lead first. Release the clamp screw for the headlight bezel. Support the headlight and remove the bezel. Ease the headlight from the headlight bowl. Disconnect the multi-pin electrical connector from the headlight bulb, then remove the rubber cover. Unhook the wire retaining clip from behind the bulb. Remove the bulb from the headlight unit. Installation is the reverse of the removal procedure. Tighten the clamp screw to 4 Nm.
A Warning
Tj
Adjust road speed to suit the visibility and weather conditions in which the motorcycle is being operated. Ensure that the headlight beam is adjusted to illu minate the road surface sufficiently far ahead without dazzling oncoming traffic. An incorrectly adjusted headlight may impair visibility causing an accident. Headlight Bulb Replacement
5. 6. 7.
Note: When reconnecting the battery, connect the positive (red) lead first.
Position Lamp Bulb Replacement Position lamp bulbs are fitted to both headlight units. To replace a position light bulb, remove the headlight unit from the headlight bowl to gain access for position light bulb replacement.
cbnp
1. Headlight bulb 2. Bulb clip 3. Position lamp
Each headlight bulb can be replaced as follows:
L UMP
1 7.25
Electrical
Rear Light - Daytona 675
Removal Note: The rear light is a sealed for life unit and must be replaced in the event of a failure. Remove the seats (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the rear panel (see page 16-18). Release the fixings securing the light unit to the rear panel. 1. 2. 3. 4. Remove the seat (see page 16- 17). Disconnect the battery, negative (black) lead first. Remove the rear panels (see page 16-19). Loosen the rear light finisher fixing, located below the rear mudguard. Removal Note: The rear light is a sealed for life unit and must be replaced in the event of a failure.
Rear Light - Street Triple and Street Triple R
1. 2. 3. 4.
1 1. Rear light unit 2. Rear light fixings 5. Remove the rear light. 1. Rear light finisher fixing 5. Remove the rear light finisher.
Installation 1. Installation is the reverse of the removal procedure.
Note: Tighten the rear light to rear panel fixings to 4 Nm. Reconnect the battery, positive (red) lead first.
1. Rear light finisher
1 7.26
Il1MP
Electrical
6. Release the fixings securing the rear light unit to the rear subframe.
Direction Indicators
Bulb Replacement Daytona 675 up to VIN 381274
1. Rear light unit 2. Rear light fixings
7.
Disconnect the electrical connector and remove the rear light.
1. Direction indicator lens 2. Screw
Installation 1. Installation is the reverse of the removal procedure
The lens on each direction indicator is held in place by a securing screw located in the body of the light. Release the screw and remove the amber lens to gain access to the bulb for replacement. Daytona 675 from VIN 381275, Street Triple and Street Triple R all VINs
Note: Tighten the rear light to rear subframe fixings to 4 Nm. Tighten the rear light finisher fixing to 3 Nm. Reconnect the battery, positive (red) lead first.
ceic
1. Direction indicator lens 2. Screw
The lens on each direction indicator is held in place by a securing screw located in the lens of the light. Release the screw and remove the lens to gain access to the bulb for replacement.
IllMP
1 7.27
Electrical
Rear Direction Indicator - Daytona 675
Removal 1. 2. 3. 4. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Release the fixing securing the direction indicator to the licence plate bracket and detach the light unit. Disconnect the two direction indicator electrical connectors and remove the light unit.
Rear Direction Indicator - Street Triple and Street Triple R

Removal 1. 2. 3. 4. Remove the seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the rear panels (see page 16- 19). Loosen the rear light finisher fixing, located below the rear mudguard.
1. Rear light finisher fixing 1. Direction indicator (left hand shown) 2. Fixing
5.
Remove the rear light finisher.
Installation 1. Installation is the reverse of the removal procedure, noting the following.
Note: Tighten the direction indicator fixing to 3 Nm. Reconnect the battery, positive (red) lead first.
1. Rear light finisher
1 7.28
Il1MP
Electrical
6. Release the fixings securing the light unit to the rear subframe. 11. Noting the routing of the indicator and licence plate harnesses, remove the direction indicators from the indicator mount panel.
1. Rear li ght unit 2. Rear light fixings
1. Indicator mount panel 2. Right hand direction indicator harness 3. Left hand direction indicator harness 4. Licence plate light harness
7. 8.
Disconnect the electrical connector and remove the rear light. Remove and discard the two fixings securing the indicator mount panel. 2
Installation 1. Installation is the reverse of the removal procedure, noting the following.
JI7'tO cesu
9.
1. Indicator mount panel 2. Fixings
Note: Ensure the direction indicator and licence plate harnesses are routed as noted on removal. Tighten the direction indicator fixings to 3 Nm. Fit new fixings for the indicator mount panel and tighten to 4 Nm. Tighten the rear light to rear subframe fixings to 4 Nm. Tighten the rear light finisher fixing to 3 Nm. Reconnect the battery, positive (red) lead first.
Release the fixings securing the direction indicators to the licence plate bracket and detach the direction indicators together with the indicator mount panel.
10. Disconnect the direction indicator and licence plate li ght electrical connectors.
I!IMP
1 7.29
Electrical
Front Direction Indicator - Daytona 675
Removal
1. 2. 3. 4.
Front Direction Indicator- Street Triple and Street Triple R

Removal
Remove the rider's seat (see page 16- 17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Disconnect the front direction indicator connections, located under the airbox.
Remove the rider's seat (see page 16-17). 1. Disconnect the battery, negative (black) lead first. 2 4 5
Remove the lower fairing (see page 16-20). 3 Release the fixing securing the direction indicator to the lower fairing and remove the light unit.
1. Direction indicator (right hand shown) 2. Fixing 1. Left hand direction indicator connections 2. Right hand direction indicator connections
Installation
1. Installation is the reverse of the removal procedure, noting the following.
6. 7.
Release the fixing securing the direction indicator to the radiator cowl. Release the three fixings securing the radiator cowl to the radiator.
Note: Tighten the direction indicator fixing to 3 Nm. Reconnect the battery, positive (red) lead first.
1. Radiator cowl 2. Direction indicator fixing 3. Fixings
8. Remove the radiator cowl and, noting the routing of the direction indicator harness, carefully feed the harness through the radiator bracket as the cowl is removed.
1 7.30
111MP
Electrical
9. Remove the direction indicator from the radiator cowl.
Licence Plate Light

Bulb Replacement 1. 2. Release the screw and detach the licence plate light from the licence plate bracket. Carefully remove the rubber bulb holder from the back of the light unit and remove the bulb.
Installation 1. Pass the direction indicator harness through the radiator cowl and position the direction indicator to the radiator cowl. 2. Pass the direction indicator harness through the radiator bracket and align the radiator cowl to its fixing holes. Note: Ensure the direction indicator harness passes through the hole in the radiator bracket and is not trapped by the radiator cowl as it is installed.
1. Bulb holder 2. Bulb
3.
Installation is the reverse of the removal procedure.
teen
1. Radiator bracket 2. Direction indicator harness hole 3. Direction indicator fixing hole
3. Route the direction indicator harness inside the frame rail to a position above the camshaft cover. Reconnect the electrical connectors to the main harness. 4. Install the three radiator cowl fixings and the direction indicator fixing and tighten as follows: 5. 6. 7. 8. Tighten the radiator cowl fixings to 5 Nm. Tighten the direction indicator fixing to 4 Nm.
Refit the airbox (see page 10-96). Refit the fuel tank (see page 10-90). Reconnect the battery, positive (red) lead first. Refit the rider's seat (see page 16- 17).
IL1MP
1 7.31
Electrical
Starter Motor
Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the rider's seat (see page 16-17). Disconnect the battery, negative (black) lead first. Remove the fuel tank (see page 10-89). Remove the airbox (see page 10-95). Remove the throttle bodies (see page 10- 106). Disconnect the low oil pressure warning light switch. Ease the boot from the starter cable terminal and then release the cable bolt. Detach the cable. Release the fixings securing the starter to the crankcase. 3. 4. 5. 6. 7. 8. 9. 2. Installation 1. Lubricate the starter motor O-ring with a small amount of petroleum jelly Fit the starter motor to the upper crankcase ensuring that the 0-ring does not become damaged during installation. Fit and tighten the starter bolts to 10 Nm. Refit the starter cable and secure with the bolt. Tighten to 3 Nm. Refit the starter cable boot. Connect the low oil pressure warning light switch. Refit the throttle bodies (see page 10- 108). Refit the airbox (see page 10-96 Refit the fuel tank (see page 10-90). Inspection 1. 2. Ensure the starter turns freely and without binding. Check the starter O-ring for damage and deterioration. Replace as necessary.
10. Reconnect the battery, positive (red) lead first. 11. Refit the rider's seat (see page 16-17).
1. Starter motor 2. Starter cable fixing 3. Fixings
10. Ease the starter motor from the upper crankcase.
1 7.32
IIIMP
Electrical
Alternator
Removal 1. 2. 3. Remove the rider's seat (see page 16-17). Daytona 675 only: Remove the left hand lower fairing (see page 16-20). Disconnect the battery, negative (black) lead first. 7. Release and discard the fixings securing the crankshaft position sensor to the cover.
4. Release the bolts securing the left hand engine cover, noting the position of the copper washer under the head of one of the upper bolts. Collect the solenoid/fairing bracket from under the front two bolts.
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1. Stator 2. Stator fixings 3. Crankshaft position sensor 4. Crankshaft position sensor fixings S. Cable bracket 6. Cable bracket fixing
8.
Withdraw the stator and crankshaft position sensor.
1. Left hand engine cover 2. Copper washer position 3. Solenoid/fairing bracket
5.
Withdraw the cover from the crankcase against the pull of the alternator magnet.
Note: The stator and crankshaft position sensor are supplied as an assembly and cannot be separated.
6. To remove the stator and crankshaft position sensor from the cover, release the three bolts in the centre of the cover and release the bolt securing the cable bracket. Discard the bolts.
I UMP
1 7.33
Electrical
A Caution
Do not use tools to tighten service tool T3880375. Tighten the tool by hand only. Over-tightening of the tool will lead to damage to the alternator rotor. 9. To remove the rotor, clean the alternator rotor to remove all traces of oil, and fit tool T3880375 to the rotor as shown below. Retain the tool to prevent the crankshaft from rotating and remove the centre bolt from the crankshaft.
12. Hold the centre of the tool to prevent rotation then tighten the draw-bolt in the centre of the tool to release the taper seating of the rotor from the crankshaft.
IM 1. Rotor
2. Tool T3880365
13. Withdraw the rotor and tool as an assembly and then separate the tool from the rotor. Collect the Woodruff Key and the tool thrust pad from the crankshaft.
1. Rotor
2. Tool T3880375
Assembly Refit the Woodruff key to the crankshaft. 2. Assemble the rotor to the keyway on the crankshaft, ensuring the Woodruff key remains in position.
3. Centre bolt 10. With the bolt removed, locate the spigot from the larger of the two thrust pads supplied with tool T3880365 to the crankshaft.
ACaution
Do not use tools to tighten service tool T3880375. Tighten the tool by hand only. Over-tightening of the tool will lead to damage to the alternator rotor. 3. Refit tool T3880375 to prevent the crankshaft from rotating, ensuring the rotor is free from oil and the tool is not over-tightened.
1. Thrust pad 11. Assemble tool T3880365 to the threaded centre section of the rotor. Note: Ensure that the thrust pad does not fall out during assembly of the tool.
1 7.34
ll1MP
Electrical
4. Tighten the rotor retaining bolt to 120 Nm 14. 15. Reconnect the battery, positive (red) lead first. Refit the seat (see page 16-17).
Alternator Rectifier
The rectifier does not contain any serviceable parts and must be replaced if faulty.
Daytona 675 up to VIN 381274, Street Triple and Street Triple R all VINs
The alternator rectifier is located in between the rear suspension unit and the gearbox. To access the rectifier connector, remove the fuel tank (see page 10-89).
1. Rotor 2. Tool T3880375 3. Centre bolt 5. Remove tool 13880375. 6. Locate the stator and crankshaft position sensor to the engine cover.
Daytona 675 from VIN 381275

The alternator rectifier is located under the cockpit's right hand infill panel. To access the rectifier, remove the right hand lower fairing (see page 16-20).
7. Apply silicone sealer to the cable grommet (at the factory, ThreeBond 1215 is used) and align the cable to the exit slot. 8. 9. Fit the cable retainer bracket and tighten a new retainer bolt to 6 Nm. Tighten the new stator bolts to 12 Nm.
10. Tighten the new crankshaft position sensor bolts to 6 Nm. 11. Position a new gasket to the crankcase dowels then refit the left hand engine cover. 12. Ensure the bolt with the copper washer is correctly located. Refit the solenoid/fairing bracket to the front two bolts. Tighten the cover bolts to 9 Nm.
1. Left hand engine cover 2. Copper washer position 3. Solenoid bracket 13. Daytona 675 only: Refit the left hand lower fairing (see page 76-22).
I UMP
1 7.35
Electrical
Alternator Stator
The stator is an assembly of 18 coils, arranged into three phases. It is possible to check for continuity, and short circuits through the coils to earth. Note: Only repairs to the stator harness between the connector and the harness entry point into the crankcase are permitted. Fault Code Battery not charging Possible cause Fuse at the starter solenoid Battery Do not attempt to repair the stator coils. If the battery is not fully charged, the charging voltage may be lower than specified when checking at 2000 rpm. Ensure all additional accessories (auxiliary lights, heated grips etc.) are switched off.
Action Check the condition of fuse. Check the condition of the battery. Test the battery using the BatteryMate 150-9. Refer to the instructions supplied with the BatteryMate 150-9. Ensure the battery is serviceable:Proceed to pinpoint test 1. Test the rectifier/regulator page 17-38). (see
Alternator Rectifier/Regulator
Pinpoint Tests Action Proceed to test 2 Rectify fault, proceed to test 6
Test 1 Check cable and terminal integrity: - Battery positive (+) - Battery negative (-) - Rectifier/regulator to main wiring harness connector pin 1 - Rectifier/regulator to main wiring harness connector pin 2 - Rectifier/regulator to main wiring harness connector pin 3 - Rectifier/regulator to main wiring harness connector pin 4 2 Check cable and terminal integrity: - Rectifier/regulator to alternator harness connector pin 1 - Rectifier/regulator to alternator harness connector pin 2 - Rectifier/regulator to alternator harness connector pin 3
Result OK Faulty
OK
Disconnect the battery leads, negative (black) lead first. Disconnect rectifier/regulator to main wiring harness connector (4 pin). Proceed to test 3 Rectify fault, proceed to test 6
Faulty
1 7.36
Il1MP
Electrical
Test 3 Check cable continuity: - Rectifier/regulator main harness connector pin 1 to battery lead negative - Rectifier/regulator main harness connector pin 2 to battery lead negative
Result OK
Action Reconnect the battery leads, positive (red) lead first. Reconnect the rectifier/regulator to main wiring harness connector (4 pin). Disconnect the rectifier/regulator to alternator harness connector (3 pin). Proceed to test 4 Locate and rectify wiring fault, proceed to test 6
- Rectifier/regulator main harness connector Open circuit pin 3 to battery lead positive - Rectifier/regulator main harness connector pin 4 to battery lead positive 4 Check resistance through the coils: - Alternator harness pin 1 to 2 - Alternator harness pin 2 to 3 - Alternator harness pin 3 to 1 0.452 to 0.62
Proceed to test 5
Open circuit or short If the fault is between the connector and the circuit crankcase, repair the harness. Proceed to test 6 If the fault is after the crankcase, replace the unit. Proceed to test 6
Check for short to earth: - Alternator harness pin 1 to metal frame - Alternator harness pin 2 to metal frame - Alternator harness pin 3 to metal frame
Open circuit Short circuit
Proceed to test 6 Replace unit. Proceed to test 6
Reconnect the harness and run the engine. Check the charging voltage at 2000 rpm-
13.5V to 15V Fault still present
Action complete - quit test Test rectifier/regulator (see page 17-38) If rectifier/regulator is serviceable, Triumph service contact
- .
i
l
11
Stator
l: 1.
Starter solenoid
- B
BB
____-N
I
J-`--=_,
YYY
B RR
1 ___ +
Battery
Rectifier/Regulator
1 2
1 2 4 3
00
a
0 0
Regulator/Rectifier main wiring harness connector pin numbers
lliMP
1 7.37
Electrical
Rectifier/ Regulator
Internally the rectifier/regulator consists of: six diodes; a voltage controller and three thyristors. The diodes are arranged with one diode connected between each yellow input wire and each pair of red and black output wires. The diodes convert the ac voltage to dc voltage. Each yellow input wire is also connected to a thyristor which is in turn connected to ground. When the dc voltage at the battery reaches the required level, the voltage controller sends a signal to all three thyristors. The Fault Code Battery not charging Possible cause Fuse at the starter solenoid Battery thyristors then conduct and effectively short circuit the stator until the dc voltage drops to an acceptable level. It is possible for any number of these diodes to fail, reducing the power output of the unit. This may not be obvious until maximum power is required by the ignition, li ghting and accessories etc. The diodes can be checked using a multimeter on DIODE setting. Note: This test does not check for voltage regulation. Action Check the condition of the fuse: Check the condition of the battery. Test the battery using the BatteryMate 150-9. Refer to the instructions supplied with the BatteryMate 150-9. Ensure the battery is serviceable. Disconnect the rectifier regulator connectors from the main wiring harness and the alternator harness. Proceed to pinpoint test 1. Test the alternator stator (see page 1736).
Rectifier/Regulator
Alternator
Pinpoint Tests
Test 1 Check the earth and power for continuity: - Rectifier/regulator connector pin 1 to pin
2
Result OK Open circuit
Action Proceed to test 2 Rectify wiring fault. Proceed to test 5 If no wiring fault found, replace unit. Proceed to test 5
- Rectifier/regulator connector pin 3 to pin 4 2 Check diodes forward bias: - Positive (+) probe to Rectifier/regulator connector pin 1 to: Negative (-) probe to alternator connector pin 1 Negative (-) probe to alternator connector pin 2 Negative (-) probe to alternator connector pin 3 0.4V to 0.7V Open circuit or short circuit
1 7.38
L UMP
Electrical
3 Check diodes forward bias: - Negative (-) probe to Rectifier/regulator connector pin 4 to: Positive (+) probe to alternator connector
pin 1
0.4V to 0.7V Open or short circuit
Positive (+) probe to alternator connector

pin 2

pin 3
Open circuit or 'OL' - Positive (+) probe to Rectifier/regulator on meter connector pin 4 to: A voltage reading or Check diodes reverse bias: Negative (-) probe to alternator connector short circuit pin 1 Negative (-) probe to alternator connector
pin 2
Proceed to test 4
Replace unit. Proceed to test 5
Negative (-) probe to alternator connector pin 3 4 Check diodes reverse bias: - Negative (-) probe to Rectifier/regulator connector pin 1 to:
pin 1
Open circuit or 'OL' on meter
Proceed to test 5
A voltage reading or Positive (+) probe to alternator connector short circuit Positive (+) probe to alternator connector
pin 2
Replace unit. Proceed to test 5

pin 3
Reconnect the harness and run the engine. Check the charging voltage at 2000 rpm:
13.5V to 15V Fault still present
Action complete - quit test Test rectifier/regulator (see page 17-36) If rectifier/regulator is serviceable, Triumph service contact
Diode
R
R
B B
Rectifier/regulator
3
2
connector
Alternator
connector
3
2
1
Y
Y
Y
3 0
3^ ^2 Alternator connector pin numbers Thyristor
:2:]
Rectifier/regulator pin numbers
l! MP
1 7.39
Electrical
Lighting Circuit - Daytona 675 up to VIN 381274
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 Item Description Ignition switch Fuse box (Fuse 1 and 3) Starter relay Number plate lamp Tail light Left hand switch cube assembly Main / dip beam switch Pass switch Instrument assembly Oil pressure switch Oil pressure warning light Main beam warning light Headlight Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.40
I UMP
Electrical
Lighting Circuit - Daytona 675 up to VIN 381274
Il1Mp
1 7.41
Electrical
Lighting Circuit - Daytona 675 from VIN 381275
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 Item Description Ignition switch Fuse box (Fuse 1 and 3) Starter relay Number plate lamp Tail light Left hand switch cube assembly Main / dip beam switch Pass switch Instrument assembly Oil pressure switch Oil pressure warning light Main beam warning light Headlight Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.42
I UMP
Electrical
Lighting Circuit - Daytona 675 from VIN 381275
13
1L1MP
17.43
Electrical
Starting and Charging Circuit - Daytona 675 up to VIN 381274
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Item Description Battery Starter solenoid Starter motor Alternator Regulator / rectifier Starter relay Engine control module Ignition switch Fuse box (Fuses 1, 2 and 6) Engine control module relay Instrument assembly RH switchcube Engine stop switch Starter switch Alarm Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.44
Il.1 MP
Electrical
Starting and Charging Circuit - Daytona 675 up to VIN 381274
15
L UMP
1 7.45
Electrical
Starting and Charging Circuit - Daytona 675 from VIN 381275
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Item Description Battery Starter solenoid Starter motor Alternator Regulator / rectifier Starter relay Engine control module Ignition switch Fuse box (Fuses 1, 2 and 6) Engine control module relay Instrument assembly RH switchcube Engine stop switch Starter switch Alarm Fuel pump relay Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.46
L UMP
Electrical
Starting and Charging Circuit - Daytona 675 from VIN 381275
15
IgmP
17.47
Electrical
Auxiliary and Accessory Circuit - Daytona 675 up to VIN 381274
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Item Description Fuse box (Fuse 4) Ignition switch Indicator relay Front brake light switch Horn switch Direction indicator switch Horn Rear brake light switch Brake light Instrument assembly Diagnostic connector Direction indicator (Instruments) Alarm LED Front right direction Indicator Front left direction Indicator Alarm unit Rear right direction indicator Rear left direction indicator Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.48
1L1MP
Electrical Auxiliary and Accessory Circuit - Daytona 675 up to VIN 381274
14
15
16
17
18
I UMP
1 7.49
Electrical
Auxiliary and Accessory Circuit - Daytona 675 from VIN 381275
Key to circuit diagram
Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Item Description Fuse box (Fuse 4) Ignition switch Indicator relay Front brake light switch Horn switch Direction indicator switch Horn Rear brake light switch Brake light Instrument assembly Diagnostic connector Direction indicator (Instruments) Alarm LED Front right direction Indicator Front left direction Indicator Alarm unit Rear right direction indicator Rear left direction indicator
Key to wiring colours

Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.50
^ uMP
Electrical Auxiliary and Accessory Circuit - Daytona 675 from VIN 381275
14
15
16
17
18
IllMP
1 7.51
Electrical
Lighting Circuit - Street Triple and Street Triple R
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Item Description Fuse box (Fuse 1) Starter relay Main / dip beam switch Pass switch LH dip beam bulb LH main beam bulb LH position lamp RH dip beam bulb RH main beam bulb RH position lamp Instrument assembly Engine sub harness Oil pressure switch Coolant temperature sensor Tail light Number plate lamp Fuse box (Fuse 3) Ignition switch Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.52
1laMP
Electrical
Lighting Circuit - Street Triple and Street Triple R
18
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C) 0 P I o
2
2
RJ Y
111
JAIX17
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/+ 2
3 2 UY
16
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2 3
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1/ 15
T
14
K G KB 2 1
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13
12 U
12
FH
3
OF
44` 5
F 8 9 10
6 7
Il1MP
1 7.53
Electrical
Starting and Charging Circuit - Street Triple and Street Triple R
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Item Description Battery Starter solenoid Alternator Regulator / rectifier Ignition switch Fuse box (Fuses 1, 2,4,5 and 6) Instrument assembly Engine stop switch Starter switch Alarm Fuel pump relay Engine control module Engine control module relay Starter relay Starter motor Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.54
I UMP
Electrical
Starting and Charging Circuit - Street Triple and Street Triple R
15 2
I1/I VVV 0A
F_EII-t
+'
_____ ii i
1
1 3 1
14
31^
EN
13
VS 1AAfl2AJ P
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2
3 r
4 1
I
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ENGINE STOP
START
SWITCH
10
Il]MP
1 7.55
Electrical
Auxiliary and Accessory Circuit - Street Triple and Street Triple R
Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Item Description Fuse box (Fuse 4) Indicator relay Horn LH switch cube Horn switch Direction indicator switch Instrument assembly Direction indicator (Instruments) Alarm LED Front right direction Indicator Front left direction Indicator Alarm unit Rear right direction indicator Rear left direction indicator Diagnostic connector Brake light Rear brake light switch Front brake light switch Ignition switch

Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue
1 7.56
^ uMP
Electrical
Auxiliary and Accessory Circuit - Street Triple and Street Triple R
1 0A
9 19
10
11
12 1
13
14
I UMP
1 7.57
Electrical
Complete System - Daytona 675 up to VIN 300525 with/without Fuel Pump Relay Modification
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Item Description Instrument assembly Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Exhaust control valve actuator Engine control module Gear position sensor Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor 61 MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump Cooling fan relay Cooling fan Intake flap actuator Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light 62 63 64 RH front indicator Fuel pump relay modification Fuel pump relay Engine earth 59 60 55 56 57 58 LH front indicator LH position light RH position light Dip beam bulb Main beam bulb Horn 50 51 52 53 54 48 49 44 45 46 47 38 39 40 41 42 43 RH rear indicator Number plate light LH rear indicator Alarm connector (accessory) Starter motor Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit
1 7.58
I UMP
Electrical
Complete System - Daytona 675 from VIN 300526 to VIN 323544 with Fuel Pump Relay
Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Item Description Instrument assembly Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Exhaust control valve actuator Engine control module Gear position sensor Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump Cooling fan relay Cooling fan Intake flap actuator Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light 49 50 51 52 53 54 55 56 57 58 59 60 61 62 46 47 48 43 44 45 Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit LH front indicator LH position light RH position light Dip beam bulb Main beam bulb Horn RH front indicator Fuel pump relay 38 39 40 41 42 RH rear indicator Number plate light LH rear indicator Alarm connector (accessory) Starter motor
1 7.60
-^y,^
Electrical
Complete System - Daytona 675 - from VIN 323545 to VIN381274
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Item Description Instrument assembly 42 Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Exhaust control valve actuator 47 Engine control module 48 Gear position sensor 49 Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump Cooling fan relay Cooling fan Intake flap actuator Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light RH rear indicator Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue 60 61 62 Horn RH front indicator Fuel pump relay 59 Main beam bulb 57 58 RH position light Dip beam bulb 56 LH position light 50 51 52 53 54 55 Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit LH front indicator Alternator Fuse box Ignition switch 43 44 45 46 Starter solenoid (fused) Battery Starter relay Rectifier / regulator Starter motor 39 40 41 Number plate light LH rear indicator Alarm connector (accessory)
17.62
ll,INIP
Electrical
Complete System - Daytona 675 - from VIN 381275
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Item Description Instrument assembly Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Exhaust control valve actuator Engine control module Gear position sensor Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump Cooling fan relay Cooling fan Intake flap actuator Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light RH rear indicator 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Number plate light LH rear indicator Alarm connector (accessory) Starter motor Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit LH front indicator LH position light RH position light Dip beam bulb Main beam bulb Horn RH front indicator Fuel pump relay Accessory quickshifter
1 7.64
1 uM
1 7.63
Electrical
Complete System - Street Triple and Street Triple R
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Item Description Instrument assembly Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Engine control module Gear position sensor Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump relay Fuel pump Cooling fan relay Cooling fan Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light RH rear indicator Number plate light Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue 54 55 56 57 58 59 60 61 62 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 LH rear indicator Alarm connector (accessory) Starter motor Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit LH front indicator LH position light LH dip beam bulb LH main beam bulb RH position light RH Dip beam bulb RH main beam bulb Horn RH front indicator
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Electrical
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Street Triple - Workshop Manual

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i uMP ThH

DAYTONA 675 STREET TRIPLE STREET TRIPLE R

Pa rt Number 3856750 issue 1, 06.2009

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

.vi .vi .vii .vii .vii .vii .vii .vii .vii

Noise Control System Prohibited .............................................

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

Repairs and Replacements

Service Manual - Daytona 675, Street Triple and Street Triple R

Retaining Rings ...............................................................

SelfLocking Nuts .....................................................................

FuelTank Rem oval ................................................................... ChassisRepairs ..........................................................................

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

Transmission....................................................................... LubricationSystem .................................................................

System, Exhaust System and Airbox ...............................................

FrontBrake Hose Routing - Street Triple .....................................................

Air Flap Vacuum Hose Routing - Daytona 675 only ......................................

Service Manual - Daytona 675, Street Triple and Street Triple R

Third Party Products

Service Manual - Daytona 675, Street Triple and Street Triple R

Environmental Protection Precautions

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

Liquid Gasket, Non-permanent Locking Agent

Joints and Joint Faces

Service Manual - Daytona 675, Street Triple and Street Triple R

Fitting a Split Pin

Circlips, Retaining Rings

Self Locking Nuts

Chassis Bearing Lubrication

Oil and Grease Seals

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

Fuel Handling Precautions

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

the bulb resistance can be calculated by using -

Basic Electrical Circuits

Service Manual - Daytona 675, Street Triple and Street Triple R

Glossary of Circuit Diagram Symbols

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

Service Manual - Daytona 675, Street Triple and Street Triple R

Pair of Twisted Wires

CAN (Controller Area Networking)

Service Manual - Daytona 675, Street Triple and Street Triple R

Rectify any defects as necessary. Diagnosis - Charging Circuit

RECHARGE OR REPLACE FAULTY BATTERY AND/OR REPAIR DIRTY/ LOOSE CONNECTIONS

FAULTY RECTIFIER/ REGULATOR

Below 30 Volts AC FAULTY ALTERNATOR

FAULTY RECTIFIER/ REGULATOR

Service Manual - Daytona 675, Street Triple and Street Triple R

General Fault Finding - Starter Motor and Relay

Service Manual - Daytona 675, Street Triple and Street Triple R

Starter motor turns