2009-2013 Triumph Daytona 675 Street Triple/Street Triple R OEM Service & Repair Manual

ThH i uMP 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 ^ 4mP 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 v I UMP Service Manual - Daytona 675, Street Triple and Street Triple R iii

Introduction Table of Contents Howto use this manual .................................................................... .vi Warnings, Cautions and Notes .............................................................. .vi Tam p erin g with Noise Control System Prohibited ............................................. .vii References.............................................................................. .vii Dimensions......................................................................... .vii .^, Repairs and Replacements ................................................................. .vii Force.............................................................................. .vii Edges .............................................................................. .vii Tightening procedure ................................................................ .vii Il1MP Service Manual - Daytona 675, Street Triple and Street Triple R V

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. • Follow the procedures in this manual carefully and completely. Do not take short cuts. • Keep complete records of all maintenance and repairs with dates and any new parts installed. • Use only approved lubricants, as specified in the owner's handbook, in the maintenance of the motorcycle. How to use this manual To assist in the use of this manual, the section title is given at the top 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. VI Service Manual - Daytona 675, Street Triple and Street Triple R L UMP

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. References References to the left-hand or right-hand side given in this manual are made when viewing the motorcycle from the rear. Operations covered in this manual do not always include reference to testing the motorcycle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the motorcycle is carried out particularly where safety related items are concerned. Dimensions The dimensions quoted are to design engineering specification with service limits where applicable. During the period of running-in from new, certain adjustments may vary from the specification figures given in this manual. These will be reset by the dealer at the 500 mile/800 km service, and thereafter should be maintained at the figures specified in this manual. Repairs and Replacements Before removal and disassembly, thoroughly clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. Particular attention should be paid when installing 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. Edges Watch for sharp edges, especially during engine disassembly and assembly. Protect the hands with industrial quality gloves. When replacement parts are required, it is essential that only genuine Triumph parts are used. Safety features and corrosion prevention treatments embodied in the motorcycle may be impaired if other than genuine Triumph parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification. Tightening procedure Generally, when installing 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 micro- encapsulated fixings which must always be replaced if disturbed. Where necessary, the text in this manual will indicate where such a fixing is used. I uMP Service Manual - Daytona 675, Street Triple and Street Triple R vii

1 General Information Table of Contents IgnitionSystem Safety Precautions ........................................................... 1.4 Dan g erousSubstances ..................................................................... 1.4 ThirdParty Products ....................................................................... 1.4 Fluoroelastomers ..................................................................... 1.4 Oils..................................................................................... 1.4 HealthProtection Precautions .......................................................... 1.4 EnvironmentalProtection Precautions ........................................................ 1.5 Brakes................................................................................... 1.5 SafetyInstructions ......................................................................... 1.6 Jackingand Lifting .................................................................... 1.6 Precautionsagainst Damage ........................................................... 1.6 Coolant............................................................................. 1.6 CleaningComponents ................................................................. 1.7 Lubrication.......................................................................... 1.7 Jointsand Joint Faces ................................................................. 1.7 ^., Gaskets, O-rings ...................................................................... 1.7 LiquidGasket, Non-permanent Locking Agent ............................................ 1.7 ScrewThreads ....................................................................... 1.7 LockingDevices ...................................................................... 1.8 Fittinga Split Pin ..................................................................... 1.8 Circli p s , Retaining Rings ............................................................... 1.8 SelfLocking Nuts ..................................................................... 1.8 Enca p sulatedBolts .................................................................... 1.8 Oiland Grease Seals .................................................................. 1.8 Press............................................................................... 1.8 BallBearings ......................................................................... 1.8 ChassisBearing Lubrication ............................................................ 1.8 Metalbushes ....................................................................... 1.10 FuelHandling Precautions ................................................................. 1.10 General............................................................................ 1.10 Petrol - Gasoline ..................................................................... 1.10 FuelTank Rem oval ................................................................... 1.11 ChassisRepairs .......................................................................... 1.11 II.I MP Service Manual - Daytona 675, Street Triple and Street Triple R 1.1

General Information ElectricalPrecautions ..................................................................... 1.12 BatteryDisconnecting ................................................................ 1.12 Disciplines.......................................................................... 1.12 Electrical Wires ...................................................................... 1.13 ElectricalTesting ......................................................................... 1.13 Ohm's Law ......................................................................... 1.13 BasicElectrical Circuits ............................................................... 1.13 CircuitDiagrams ......................................................................... 1.14 Glossaryof Circuit Diagram Symbols ........................................................ 1.14 TracingCircuits .......................................................................... 1.15 ToCheck Continuity :................................................................. 1.16 ToMeasure Voltage :................................................................. 1.16 Splices............................................................................. 1.17 CAN(Controller Area Networking) .......................................................... 1.17 Alternator/Charging System ............................................................... 1.18 Diagnosis- Charging Circuit .......................................................... 1.18 StartingCircuit .......................................................................... 1.19 GeneralFault Finding - Starter Motor and Relay .............................................. 1.19 Diagnosis- Starter Circuit ................................................................. 1.20 Inspection.......................................................................... 1.21 ReplacementParts ................................................................... 1.21 ServiceData ........................................................................ 1.21 Specification........................................................................ 1.21 ServiceTools and Garage Equipment ........................................................ 1.22 SpecialService Tools ................................................................. 1.22 Engine............................................................................. 1.27 CylinderHead & Valves .............................................................. 1.28 CylinderHead & Valves (continued) .................................................... 1.29 Camshafts.......................................................................... 1.29 Clutch/Primary Drive ................................................................ 1.30 Pistons............................................................................. 1.30 ConnectingRods .................................................................... 1.30 Crankshaft......................................................................... 1.31 Transmission........................................................................ 1.31 FinalDrive .......................................................................... 1.31 Lubrication......................................................................... 1.32 IgnitionSystem ..................................................................... 1.32 FuelSystem ........................................................................ 1.32 CoolantSystem ..................................................................... 1.33 Suspension......................................................................... 1.33 FuelInjection System ................................................................ 1.34 EmissionsControls ................................................................... 1.34 Brakes............................................................................. 1.34 Brakes(continued) ................................................................... 1.35 Wheelsand Tyres .................................................................... 1.35 Frame............................................................................. 1.36 ElectricalEquipment ................................................................. 1.36 1.2 Service Manual - Daytona 675, Street Triple and Street Triple R I UMP

General Information TorqueWrench Settings ................................................................... 1.37 CylinderHead Area ................................................................. 1.37 Clutch............................................................................ 1.37 Crankshaftand Crankcase, Sprag ..................................................... 1.37 En g ineCovers ..................................................................... 1.38 Transmission....................................................................... 1.38 LubricationSystem ................................................................. 1.38 Final Drive ......................................................................... 1.39 CoolingSystem .................................................................... 1.39 Fuel System, Exhaust System and Airbox ............................................... 1.39 Fuel System, Exhaust System and Airbox (continued) .................................... 1.40 RearSuspension .................................................................... 1.40 FrontSuspension .................................................................... 1.41 Wheels ............................................................................. 1.41 FrontBrakes ........................................................................ 1.41 Rear Brakes................ ........................................................ 1.42 Frame, Footrests, Control Plates and Engine Mountings ................................... 1.42 Electrical.......................................................................... 1.43 Bodywork......................................................................... 1.43 Clutch Cable Routing - Daytona 675 ........................................................ 1.44 Clutch Cable Routing - Street Triple and Street Triple R ........................................ 1.45 Throttle Cable Routing - Daytona 675 ....................................................... 1.46 Throttle Cable Routing - Street Triple ........................................................ 1.47 ThrottleCable Routing - Street Triple R ...................................................... 1.48 Main Wiring Harness Routing - Daytona 675 up to VIN 381274 ................................. 1.49 Main Wiring Harness Routing - Daytona 675 from VIN 381275 .................................. 1.50 Main Wiring Harness Routing - Street Triple and Street Triple R ................................. 1.51 Rear Light Harness Routing - Daytona 675 ................................................... 1.52 Front Brake Hose Routing - Daytona 675 .................................................... 1.53 FrontBrake Hose Routing - Street Triple ..................................................... 1.54 c :: Brake Hose Routing - Street Triple R ................................................... 1.55 Rear Brake Hose Routing - All Models (Daytona 675 shown) .................................... 1.56 FuelTank Breather Hose Routing - Daytona 675 .............................................. 1.57 Fuel Tank Breather Hose Routing - Street Triple and Street Triple R .............................. 1.58 Fuel Tank Breather Hose Routing - Models with Evaporative Emissions - Daytona 675 .............. 1.59 Fuel Tank Breather Hose Routing - Models with Evaporative Emissions - Street Triple and Street Triple R ........................................................................... 1.60 Intake Air Flap Vacuum Hose Routing - Daytona 675 only ...................................... 1.61 IN ^ V Service Manual - Daytona 675, Street Triple and Street Triple R 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. Q 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 • A Warning 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! Third Party Products Q 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 c o ntr o l and an accident. Warning Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles. In fire conditions involving temperatures greater than 315°C this material will decompose and can then be potentially hazardous. Highly toxic and corrosive decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated olefins and carbon monoxide can be generated and will be present in fumes from fires. In the presence of any water or humidity hydrogen 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. Oils 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. 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. • First aid treatment should be obtained i mmediately for open cuts and wounds. Always be aware of who your nearest first- 1.4 Service Manual - Daytona 675, Street Triple and Street Triple R L UMP

2009-2013 Triumph Daytona 675 Street Triple/Street Triple R OEM Service & Repair Manual

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