2003 Onwards Triumph Rocket III Service & Repair Manual

Table of Contents Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaft Bevel Box and Drive Shaft Balancer Transmission Lubrication Engine Removal and Refit Fuel System/Engine Management Cooling Rear Suspension Front Suspension '., Brakes WheelslTyres Frame and Bodywork Electrical System Service Manual - Rocket III

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Service Manual - Rocket III Introduction iii

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. Aiways use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of SUbstitutes may adversely affect safe operation. Where accurate measurements are required, they can only be made using calibrated, precision instruments. For the duration of the warranty period, an authorised Triumph Dealer must perform all repairs and scheduled maintenance. To maximise the life of your Motorcycle: • Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual. • Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the motorcycle. Rectify all problems as soon as possible (immediately if safety related). • Use only genuine Triumph parts as listed in the parts catalogue/parts microfiche. • Follow the procedures in this manual carefully and completely. Do not take short cuts. • Keep complete records of all maintenance and repairs with dates and any new parts installed. • Use only approved lubricants, as specified in the owner's handbook, in the maintenance of the motorcycle. How to use this manual To assist in the use of this manual, the section title is given at the top. Each major section starts with 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. Warning, Caution and Note Particularly important information is presented in the following form: This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. Note: • This note symbol indicates points of particular interest for more efficient and convenient operation. iv Service Manual - Rocket III

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/BOO 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. Introduction 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 tightened 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 tightened in the order and by the method indicated. Torque wrench setting figures given in this Manual must be observed. The torque tools used must be of accurate calibration. Locking devices, where specified, must be fitted. If the efficiency of 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. ~. Service Manual - Rocket III v

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1 General Information Table of Contents Ignition System Safety Precautions ................................................. .. 1-3 Dangerous Susbstances.......................................................... .. 1-3 Fluoroelastomers .......................................................... .. 1-3 Oils ............................................................................ 1-3 Health Protection Precautions ................................................ .. 1-3 Environmental Protection Precautions ............................................... .. 1-4 Brakes........................................................................ .. 1-4 Safety Instructions .............................................................. .. 1-5 Jacking and lifting.......................................................... .. 1-5 Precautions against damage ................................................. .. 1-5 Coolant.................................................................. .. 1-5 Cleaning components....................................................... .. 1-6 Lubrication ............................................................... .. 1-6 Joints and joint faces ....................................................... .. 1-6 Gaskets, O-rings........................................................... .. 1-6 Liquid gasket, non-permanent locking agent. .................................... .. 1-6 Screw Threads............................................................ .. 1-6 Locking Devices........................................................... .. 1-7 Filling a split pin. .......................................................... .. 1-7 Circlips, retaining rings...................................................... .. 1-7 Self locking nuts. .......................................................... .. 1-7 Encapsulated bolt.......................................................... .. 1-7 Oil and grease seals........................................................ .. 1-7 Press. .................................................................. .. 1-7 Ball bearing............................................................... .. 1-7 Fuel Handling Precautions........................................................ .. 1-7 General.................................................................. .. 1-7 Petrol - Gasoline........................................................... .. 1-8 Fuel tank removal.......................................................... .. 1-8 Chassis repairs.............................................................. 1-8 Electrical Precautions............................................................ .. 1-9 Battery disconnecting....................................................... .. 1-9 Disciplines................................................................ .. 1-9 Electrical wires ............................................................. 1-10 Inspection................................................................. 1-10 Service Manual - Rocket III 1.1

General Information Replacement Parts ............. .. ......................................... .. 1-10 Service data 1-10 Specification .......................................................... .. 1-10 Service tools ............................................................. .. 1-11 Special service tools:....................................................... .. 1-11 Torque Wrench Settings .......................................................... 1-20 Cylinder head area ........................................................ .. 1-20 Clutch................................................................... .. 1-20 Crankshaft and crankcases.................................................. .. 1-20 Engine Covers............................................................ .. 1-20 Transmission............................................................. .. 1-21 Lubrication System ........................................................ .. 1-21 Cooling System. .......................................................... .. 1-21 Fuel System, Exhaust System and Airbox....................................... .. 1-22 Rear Suspension.......................................................... .. 1-22 Front Suspension.......................................................... .. 1-22 Wheels.................................................................. .. 1-22 Front Brakes ... .......................................................... .. 1-23 Rear Brakes.............................................................. .. 1-23 Footrests and Control Plates................................................. .. 1-23 Bodywork................................................................ .. 1-24 Electrical ................................................................ .. 1-24 Routings....................................................................... 1-25 Clutch Cable Routing....................................................... .. 1-25 Handlebar Cable Routing ... ................................................ .. 1-26 Main Wiring Harness Routing................................................ .. 1-27 Rear Mudguard Harness Routing ............................................. .. 1-28 Front Brake Hose Routing................................................... .. 1-29 Rear Brake Pipe and Hose Routing............................................ .. 1-30 Throttle Cable Routing...................................................... .. 1-31 Fuel Hose and Fuel Tank Breather Hose Routing (non-evaporative emission control versions) 1-32 Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing....................... .. 1-33 1.2 Service Manual - Rocket III

Ignition System Safety Precautions The ignition system produces extremely high voltages. Do not touch any part of the ignition system or any cables while the engine is running. An electric shock caused by contact with the ignition system may lead to illness, injury or death. Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and or diagnostic equipment. The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death. Dangerous Susbstances Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as possible, be kept from contact with the skin. These substances among others include acid, anti-freeze, asbestos, brake fluid, fuel, lubricants, and various adhesives. Always pay close attention to the instructions printed on labels and obey the instructions contained within. These instructions are included for your safety and well-being. NEVER DISREGARD THESE INSTRUCTIONS! General Information Fluoroelastomers Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles. In fire conditions involving temperatures greater than 31SoC this material will decompose and can then be potentially hazardous. Highly toxic and corrosive decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated olefins and carbon monoxide can be generated and will be present in fumes from fires. In the presence of any water or humidity hydrogen fluoride may dissolve to form extremely corrosive liquid hydrofluoric acid. If such conditions exist, do not touch the material and avoid all skin contact. Skin contact with liquid or decomposition residues can cause painful and penetrating burns leading to permanent, irreversible skin and tissue damage. Oils The engine and bevel box oils may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned. Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition used engine oil contains potentially harmful contaminants which can cause cancer. Wear suitable clothing and avoid skin contact. Health Protection Precautions • Avoid prolonged and repeated contact with oils, particularly used engine oils. • Wear protective clothing, including impervious gloves where practicable. • Do not put oily rags in pockets. • Overalls must be cleaned regularly. Discard heavily soiled clothing and oil impregnated footwear. • First aid treatment should be obtained immediately for open cuts and wounds. Always Service Manual - Rocket III 1.3

General Information be aware of who your nearest first-aider is and where the medical facilities are kept. • Use barrier creams, applying before each work period to protect the skin from the effects of oil and grease and to aid removal of the same after completing work. • Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. • Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin. • If skin disorders develop, obtain medical advice without delay. • Where practicable, de-grease components prior to handling. Any risk of eye injury must be avoided. Always wear eye protection when using a hammer, air line, cleaning agent or where there is ANY risk of flying debris or chemical splashing. Environmental Protection Precautions Do not pour oil on the ground, down sewers or drains, or into water courses. To prevent pollution of water-courses etc., dispose of used oil sensibly. If in doubt contact your local authority. Burning of used engine oil in small space heaters or boilers can be recommended only for units of approved design. If in doubt, check with the appropriate local authority and/or manufacturer of the approved appliance. Dispose of used oil and used filters through authorised waste disposal contractors, to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact your iocal authority for advice on disposal facilities. Brakes Brake fluid is hygroscopic which means it will absorb moisture from the air. Any absorbed moisture will greatly reduce the boiling point of the brake fluid causing 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. If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir, consult your authorised Triumph Dealer for advice before riding. If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel becomes excessive, there may be air in the brake lines or the brake may be defective. It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the motorcycle. Failure to take remedial action may reduce braking efficiency leading to an accident. Use only D.O.T. 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those D.O.T. 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 accident. 1.4 Service Manual - Rocket III

2003 Onwards Triumph Rocket III Service & Repair Manual

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