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CLUTCH

CONTENTS

Page

lodedView

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Clutch Cover ..............................................

4.2

ClutchCable

.............................................................

4.5

Removal............................................................

4.5

Examination.........................................................

4.5

Assembly...........................................................

4.5

Clutch...................................................................

4.6

Removal............................................................

4-6

Assembly...........................................................

4.8

FrictionPlate Inspection ....................................................

4.11

Frictionplate thickness ................................................

4.11

Frictionplate bend/warp ...............................................

4.11

4-1

Contents3
Warning, Caution and Note4
Introduction4
How to Use this Manual4
Safety Instructions5
Repairs and Replacement5
References5
Dimensions5
Edges6
Tightening Procedure6
Table of Contents7
General Information Contents7
Dan G Eroussubstances9
Engine Oils9
Ignition System Safety Precautions9
Health Protection Precautions9
Environmental Protection Precautions10
Brakes10
Jacking and Lifting11
Precautions against Damage11
Engine Coolant11
Cleaning Components11
Safetyinstructions11
- Joints and Joint Faces12
- Gaskets, O-Rings12
- Liquid Gasket, Non- Permanent Locking Agent12
Lubrication12
- Encapsulated Bolt13
- Lockin G Devices13
- Self Locking Nuts13
- Circlips, Retaining Rings13
- Fuel Handling Precautions14
- Petrol — Gasoline14
- Fuel Tank Removal14
- Chassis Repairs14
- Electrical Precautions15
- Battery Disconnecting15
- Electrical Wires16
- Inspection16
- Replacement Parts16
Disciplines16
- Service Tools and Garage Equipment17
- Special Service Tools17
- Full Specification19
- Tor Q Uewrench Settings27
Transmission28
Fuelsystem and Airbox29
Brakes30
Bodywork31
- Maintenance Contents32
- Service Check Sheets33
- Scheduled Maintenance Chart34
- Cylinder Head Contents35
- Cylinder Head and Valves Exploded View36
- Cam Cover Exploded View37
- Camshaft and Camshaft Drive Exploded View38
- Cylinder Head Description39
- Cam Cover Removal39
- Coil Connections39
- Camshaft Position Sensor39
- Silicone Sealer Areas40
- Cam Cover Installation40
- Cam Cover Bolt Release Sequence40
- Cam Chain Tensioner Removal and Installation41
- Camshaft to Cylinder Head Alignment Marks41
- Tensioner Plunger Set—Up42
- Camshafts Removal43
- Camshaft Cap Numbering43
- Camshaft and Bearing Cap Inspection44
- Camshafts Installation45
- Measuring the Compressed Plastigauge45
- Valve Clearances46
- Valve Clearance Measurement46
- Cam Lobe Pointing Away from Valve46
- Typical Valve Clearance Chart46
- Tool in Position on Inlet Camshaft47
- Valve Clearance Adjustment47
- Tool Mounting Plate Markings47
- Buckets Positioned to Outside of Head47
- Removing/Replacing the Shim48
- Exhaust Valve Clearance Adjustment Chart49
- Inlet Valve Clearance Adjustment Chart50
- Cam Chain Removal and Installation51
- Cylinder Head Removal52
- Cylinder Head Inspection56
- Cylinder Head Bolt Release Sequence56
- Cylinder Head Installation57
- Cam Cover Bolt Tightening Sequence60
- Removal from the Cylinder Head61
- Valves and Valve Stem Seals Installation61
- Valve Face Inspection62
- Valve Guides62
- Valve to Valve Guide Clearance62
- Clutch Contents63
- Exploded View — Clutch Cover64
- Exploded View — Clutch Assembly65
- Exploded View — Clutch Controls66
- Clutch Cable Removal67
- Clutch Cable Examination67
- Clutch Cable Assembly67
- Clutch Disassembly68
- Clutch Assembly70
- Belleville Washer 'Out' Mark71
- Friction Plate Inspection73
- Balancer Contents74
- Exploded View — Balancer Shaft75
- Alignment Inspection76
- Balancers76
- Balancer Shaft Removal77
- Balancers Examination79
- Balancers Assembly79
- Balancers Installation80
- Crankshaft, Bods and Pistons Contents82
- Crankshaft, Connecting Rod, Piston and Liner Exploded View83
- Exploded View — Crankcase84
- Engine Removal/Refit85
- Engine Installation88
- Crankcases Disassembly91
- Upper Crankcase Bolt Release Sequence91
- Lower Crankcase Bolt Release Sequence91
- Crankcases Assembly92
- Selector Forks92
- Lower Crankcase Bolt Tightening Sequence93
- Upper Crankcase Bolt Tightening Sequence93
- Connecting Rods Removal and Installation94
- Crankshaft Removal and Installation96
- Connecting Rod Bearing Selection98
- Checking the Measured Clearance98
- Big End Bearing Selection Chart98
- Connecting Rod Big End Bearing Selection/Crankpin Wear Check98
- Crankshaft Main Bearing/Journal Wear99
- Checking Crankpin Clearance Using Plastigauge99
- Pistons Disassembly100
- Piston Wear Check100
- Piston Rings/Ring Grooves100
- Removing the Gudgeon Pin Circlip100
- Piston Assembly101
- Piston Ring Identification101
- Aligning Piston Rings Using the Piston101
- Piston Ring to Ring Groove Clearance Check101
- Cylinder Wear102
- Test Positions for Bore Wear Check102
- Cylinder Liners Removal (Engine in or out of the Frame)103
- Paint Mark103
- Cylinder Liners Installation104
- Left Hand Crankshaft Cover105
- Cover Removavrefit105
- Seal/Cover Replacement105
- Transmission Contents106
- Exploded View, Input and Output Shafts107
- Exploded View, Auxiliary Gears108
- Exploded View, Selector Mechanism109
- Exploded View, Gear Pedal Etc.110
- Engine Cranking111
- Auxiliary Gears — Operation111
- Transmission Description111
- Auxiliary Gears111
- Alternator Spindle Removal112
- Alternator Spindle Installation113
- Sprag Clutch Removal114
- Sprag Clutch Inspection115
- Sprag Clutch Assembly115
- Starter Idler Gear Removal, Inspection and Assembly117
- Selectors, Selector Shaft and Drum Removal118
- Selectors, Selector Shaft and Drum Inspection and Installation120
- Correct Gear Position at Maximum Extension120
- Detent Position 1St. Gear121
- Detent Position Neutral121
- Input and Output Shaft Assemblies Removal and Installation122
- Input Shaft Disassembly123
- Input Shaft Assembly124
- Pressing on the Input Shaft Bearing124
- Output Shaft Disassembly125
- Output Shaft Assembly126
- Lubrication System Contents127
- Exploded View - Sump128
- Exploded View — Oil Pump and Gears129
- Exploded View - Daytona Oil Cooler130
- Exploded View - Speed Triple Oil Cooler131
- Cylinder Oil Circuit132
- Cylinder Oil Circuit Description133
- Engine Oil Specification134
- Triumph Engine Oil134
- Oil Level Inspection134
- Engine Oil and Filter Change135
- Oil Pump and Gears Removal136
- Oil Pump and Gears Inspection and Installation137
- Low Oil Pressure Warning Light Switch138
- Inset: Selector Shaft Keeper Plate138
- Sump Removal and Inspection139
- Sump Installation140
- Oil Cooler Removal, Inspection and Installation141
- Oil Cooler Hose Disconnection141
- Fuel System/Engine Management Contents142
- Exploded View - Fuel Tank and Pump144
- Fuel Rail, Throttles and Injectors145
- Fuel Rail, Throttles and Injectors (Later Models)146
- Purge and Idle Air Control System (Early Models)147
- Purge and Idle Air Control System (Late Models)148
- Typical Exhaust System (T595 Daytona Illustrated)149
- Methanol150
- Oxygenated Gasoline150
- Ethanol150
- Fuel Rerquirements150
- Glossary of Terms151
- Engine Management System153
- System Description153
- System Sensors153
- Sensor Locations154
- System Actuators155
- Actuator Locations156
- Key to Wiring Circuit Diagram157
- Key to Wiring Colour Codes157
- Circuit Diagram — Engine Management System up to VIN 71698158
- Engine Management System from VIN 71699160
- Triumph Diagnostic Tool161
- On-Board Fault Detection System161
- System Diagnostics161
- Current Data162
- Freeze—Frame Data162
- Function Tests162
- Checks/Adjustments162
- Diagnostic Trouble Codes163
- Checks166
- Service Diagnostic Tool166
- Test Procedure167
- Typical Screen Showing Symbol Examples167
- Tool Keys167
- Return Key167
- Connection and Power-Up173
- Select Language173
- Switch on Bike Ignition174
- Triumph Motorcycles174
- Data Link Fault Retry?175
- Service Data - Dealer175
- Service Data - Date176
- Main Menu176
- Diagnostics177
- Stop Engine178
- To Select `READ STORED DTCS' from the Main Menu178
- Stored DTCS179
- Three Options Are Now Available179
- Freeze Frame180
- Stored DTCS, Erase All DTC Data181
- To Select `FUNCTION TESTS' from the Main Menu181
- To Select `CHECKS/ADJUSTMENTS' from the Main Menu186
- Check/Adjust186
- Build Data187
- Sensor Data188
- To Access the `ADJUSTMENTS' Menu188
- Adjust189
- Adjust Tune189
- Adjust Tune (Idle Fuel Adjustment)190
- Adjust Tune (Closed Throttle Position)191
- Adjust Tune (Set Adaptive Stepper Position)191
- Adjust Tune (Set Long Term Fuel Trim)192
- Update Tune192
- Update Tune (Confirm Selected)195
- Restarting Tune Download195
- Electrical Connectors196
- Before Disconnecting196
- When Disconnecting, Inspecting and Connecting a Connector196
- ECM Connector196
- Further Diagnosis197
- ECM Connector Pin Numbering197
- Crankshaft Sensor198
- Pinpoint Tests198
- Circuit Diagram198
- Camshaft Sensor199
- Idle Air Control200
- Fuel Injectors201
- Barometric Pressure Sensor202
- Throttle Position Sensor203
- Purge Valve204
- Ignition Coils205
- Coolant Temperature Sensor206
- Inlet Air Temperature Sensor207
- Fuel Pump Relay208
- Road Speed Sensor209
- Sensor Supply Voltage210
- System Voltage211
- Malfunction Indication Lamp212
- Cooling Fan Relay213
- Coolant Temperature Gauge214
- Tachometer215
- Fault Finding - Non Electrical216
- Fuel Tank217
- Fuel Tank Installation218
- Fuel Pump Removal and Assembly219
- Fuel Filter Removal and Assembly220
- Fuel Filter Inspection/Test220
- Fuel Pressure Regulator221
- Fuel Pressure Regulator Assembly221
- Fuel Hose Connectors Removal and Inspection221
- Fuel Hose Connectors Assembly222
- Fuel Pressure Checking222
- Fuel Delivery System223
- Airbox Removal224
- Airbox Assembly225
- Air Filter Element Removal and Assembly225
- Raising the Housing225
- Replacing the Air Filter Element225
- Barometric Pressure Sensor Removal and Assembly226
- Intake Air Temperature Sensor Removal and Assembly227
- Crankshaft Position Sensor Removal227
- Crankshaft Position Sensor Assembly228
- Camshaft Position Sensor Removal229
- Camshaft Position Sensor Assembly230
- Road Speed Sensor Removal and Assembly230
- Throttle Cable Removal230
- Throttle Cable Examination, Installation and Adjustment231
- Throttle Bodies Removal232
- Throttle Bodies Inspection233
- Later Model Air Bypass System233
- Throttle Bodies Assembly234
- Throttle Body Balancing235
- Typical Analyser Display235
- Typical Display Ofi Imbalanced Throttles235
- Injectors Removal236
- Injectors Inspection, Testing and Assembly237
- Removing the Injectors/Fuel Rail237
- Throttle Position Sensor Removal, Inspection and Assembly238
- Idle Air Control Valve Removal238
- Idle Air Control Valve Inspection and Assembly239
- Early Air Bypass System239
- Exhaust System Removal240
- Exhaust System Assembly241
- Evaporative Loss Control System242
- Component Locations242
- Evaporative Control System — Engine off243
- Evaporative Control System — Engine Running244
- Cooling System Contents245
- Exploded View - Cooling System246
- Coolant247
- Coolant Level Inspection247
- Coolant Replacement248
- Drainage248
- Filling248
- Radiator Hoses249
- Radiator and Cooling Fan249
- Arrowed — Potential Air-Lock Area249
- Water Pump Removal and Inspection250
- Coolant Pressure Cap Inspection250
- Water Pump Installation251
- Radiator Removal252
- Radiator Inspection and Installation253
- Thermostat Removal253
- Thermostat Inspection and Assembly254
- Thermostat Mounting Point254
- Thermostat `Nose' Mounting Point254
- Rear Suspension Contents255
- Exploded View - Swinging Arm256
- Rear Hub257
- Rear Suspension Unit258
- Drop/Drag Link259
- Rear Suspension Unit Removal, Inspection and Installation260
- Drop Link Removal261
- Drop Link Inspection and Installation262
- Removing Drop Link Spindle262
- Drag Link Removal263
- Drag Link Inspection and Installation264
- Drive Chain265
- Chain Slack Inspection265
- Drive Chain Adjustment265
- Chain Lubrication265
- Chain Wear Inspection266
- Swinging Arm/Drive Chain Removal267
- Typical Drive Chain Support268
- Removing the Swinging Arm269
- Swinging Arm/Drive Chain Inspection270
- Swinging Arm/Drive Chain Assembly271
- Staking the Nut272
- Final Drive Removal273
- Final Drive Inspection, Assembly and Installation275
- Drive Chain Removal276
- Drive Chain Replacement277
- Fitting Side Plate277
- Front Suspension Contents279
- Exploded View - Front Fork280
- Low Handlebars281
- Tall Handlebars282
- Front Suspension283
- Fork Inspection283
- Fork Oil283
- Oil Change283
- Fork Oil Level Chart285
- Fork Pull through285
- Front Fork Removal and Installation286
- Fork Dismantling/Assembly287
- Preload Adjuster Marks287
- Fork Inspection289
- Headstock Bearing Check/Adjustment290
- Checking Headstock Bearing Adjustment290
- Braking System Contents291
- Exploded View — Front Brake Master Cylinder292
- Front Brake Caliper293
- Rear Brake Master Cylinders294
- Rear Brake Caliper295
- Braking System Maintenance Safety Precautions296
- Fluid Level Inspection297
- Changing Brake Fluid297
- Brake Pads297
- Brake Wear Inspection297
- Safety Clip298
- Bleeding the Front Brakes Renewing Brake Fluid298
- Front Brake Pads Removal299
- Front Brake Pads Installation300
- Front Brake Caliper Removal300
- Front Brake Caliper Disassembly, Inspection, Assembly and Installation301
- Front Discs Wear302
- Front Discs Removal302
- Front Discs Installation303
- Front Brake Master Cylinder Removal and Disassembly303
- Front Brake Master Cylinder Inspection, Assembly and Installation304
- Bleeding the Rear Brakes Renewing Brake Fluid305
- Rear Brake Pads Removal306
- Rear Brake Pads Installation307
- Rear Brake Caliper Removal, Disassembly, Inspection and Assembly308
- Rear Brake Disc Wear309
- Rear Brake Caliper Installation309
- Rear Master Cylinder Removal, Disassembly, Inspection and Assembly310
- Rear Master Cylinder Installation311
- Wheels Contents312
- Exploded View - Front Wheel313
- Tyres315
- Tyre Pressures315
- Rim Marking315
- Tyre Marking315
- Tyre Wear/Wheel Inspection316
- Minimum Recommended Tread Depth316
- Important Tyre Information317
- Front Wheel Removal and Installation318
- Rear Wheel Removal and Installation319
- Front Wheel Bearings Removal and Installation320
- Bearing Tool Selection Chart320
- Rear Wheel Bearings Removal321
- Rear Wheel Bearings Inspection and Installation323
- Bodywork and Frame Contents325
- Exploded View - Frame326
- Seat Rails327
- Cockpit and Mountings328
- Rear Panels329
- Footrests and Mountings330
- Seat Removal and Refit331
- Side Panel Removal and Installation332
- Belly Panel Removal and Installation332
- Side Panel Fixings332
- Lower Fairings Removal and Installation333
- Cockpit Removal and Installation334
- Footrest Wear Limit335
- Frame Renewal335
- Strip down335
- Frame, Footrests and Fixing Inspection335
- Rotate the Handlebars Inboard337
- Lifting the Frame from the Forks337
- Lifting the Frame from the Rear Suspension337
- Electrical System Contents342
- Exploded View — Instruments344
- Alternator and Starter Motor345
- Daytona Headlight346
- Speed Triple Headlight347
- Rear Lights and Indicators348
- Battery349
- Battery Types349
- Direction of Battery Removal350
- Battery Refit350
- Battery Removal350
- Battery Charging - Yuasa Wet Battery351
- Battery Charging - GS Sealed Battery351
- New Battery351
- Battery Already in Service351
- Battery Maintenance352
- Battery Lead Conversion - Wet to Sealed Battery353
- Headlights - Daytona355
- Headlight Adjustment355
- Headlight Bulb Replacement356
- Headlight Removal and Assembly356
- Position Lamp Bulb Replacement356
- Headlights - Speed Triple357
- Headlight Bulb Replacement and Installation358
- Bulb Replacement359
- Tail Light Removal and Installation359
- License Plate Light359
- Bulb Installation360
- Indicator Removal and Replacement360
- Lighting Circuit Diagram361
- Starting/Charging Circuit Diagram up to VIN 71698363
- Starting/Charging Circuit Diagram from VIN 71699365
- Alternator Removal, Inspection and Installation367
- Starter Motor Removal and Installation368
- Instruments Removal and Installation369
- Fuses369
- Fuse Identification369
- Instrument Waring Lights Removal and Installation370
- Relay Pack370
- Identification of Relays370
- Wiring Circuit Diagram372

Triumph Daytona 955i User Manual

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Brand	Triumph
Model	Daytona 955i
Category	Motorcycle
Language	English