UNIT CONSTRUCTION 350 c.c. and 500 c.c. TWINS 7100 - T90 «STA »3TA INCLUDING FROM ENGINE No. H29733 wo © Copyright by TRIUMPH a ENGINEERING CO. LTD MERIDEN WORKS + ALLESEEY - COVENTRY + ENGLAND TELEPHONE HehuDEN 21 “TELEGMAME “rnUSTY" COVENTRY er eecoimo® WORKSHOP MANUAL SUPPLEMENT TWIN CYLINDER MACHINES 500 cc. (30 ins.) Ti00S, T1O0T, T100C, T100R from Engine Number H65573 (updating Workshop Manual WSMS to 1969 condition) © Copyright by TRIUMPH ENGINEERING CO LTD MERIDEN WORKS * ALLESLEY - COVENTRY + ENGLAND ‘yeuerions MERIDEN 33 TELEGRAMS "TRUSTY® COVENTAY cOvENTRY amt "TELEX “TRUSTY 31005@ ae INTRODUCTION THIS manual has been compiled and prepared to provide the necessary service information for workshop, fitter, technical staff and individual owner, wishing to carry out basic maintenance and repalr work on the TRIUMPH 350 c.c, and 500 cc. series of unit construction twin cylinder models, subsequent to engine No. H49833. However, most of what Is written and illustrated here applies equally to carlier models in this range. GENERAL DATA for all models within the above range Is provided In ready reference form.and a separate section covering Service Tools is fully ilustrated at the end of this manual. ‘The manual is divided Into sections dealing with major assemblies, throughout the machine, each section sub-divided Into sequence order corresponding to normal operations of strip down, examination and rebuilding procedure. ENGINE AND FRAME NUMBERS NOTE: The ongine number is located on the left hand side of the engina immediately below the cylinder barrel to crankcase flange. The engine type Is incorporated as a prefix to the engine number, ‘The frame number of the mechine is stamped on the left side of the machine, on the frame headlug, benesth the top fork lug, and forward of the fuel tank. Both the engine and frame numbers should be given IN FULL in any correspondence relating to the machine | either with the main Distributor or che Triumph Service Department, Eastern U.S.A. Distributors: Western U.S.A, Distributors: The Triumph Corporation, Johason Motors Inc, P.O. Box 6790, P.O. Box 2765, Towson, Baltimore 4, ast Huntington Drive, Maryland 21204, Duarte, California, Cables: Triumph, Beleimore s1010.tay CONTENTS GENERAL DATA LUBRICATION SYSTEM ENGINE TRANSMISSION GEARBOX FRAME & ATTACHMENT DETAILS WHEELS, BRAKES & TYRES TELESCOPIC FORK ELECTRICAL SYSTEM SERVICE TOOLS SECTIONFACTORY SERVICE ARRANGEMENTS IN THE UNITED KINGDOM CORRESPONDENCE ‘Technical Advice, Guarantee Claims and Repairs Communications dealing with any of these subjects should be addressed to the SERVICE DEPARTMENT. 5n all communications the full engine number complete with:all prefix.tetters and figures should bestated. This number will be found on the L:H. side of the crankcase Just below the cylinder flange. TECHNICAL ADVICE Ie will be appreciated how very dificule Ie is to dlagnose trouble by correspondence and this Is made Impossible In many cases because the Information seat to us Is so scanty. Every possible poinc which may have some bearing on the matter should be stated so that we can send 2 usefel and dotaled reply. REPLACEMENT PARTS Replacement parts are no longer supplied direes from the factory co the Individual owner, They should be ‘obtained from the nearest local Triumph dealer. ‘There Is 9 nation-wide necwork of stockists,» Ist of which Is available (rom the factory on request. REPAIRS Before a motorc/cle ts sent to our Works an appointment must be made, This can be done by letter or telephone, When an owner wishes to return his machine for guarancee repairs, he should first consult his Dealer a: we do not normally accept machines in our Repair Shop Until the Dealér has inspected them. Froquently che Dealer can overcome the treuble without the delay and expanse of sending the machine to the Works. This avoids the machine being out of use for some days when It could be on the read. Where parts such as cylinders, petrol vanks, ete., are forwarded for repalr. they should be packed securely so as to ‘avoid damage in transit. The owner's namte and address should be enclosed together with full Instructions. In the case of complete motercycles, afabel showing the owner's name and address should always be attached and all accessories such as teols, inflator, handlebar mirrors and other parts removed. SERVICE EXCHANGE RECONDITIONED UNITS. ‘A range of service exchange reconditioned units Is available from the Factory Service Department. This list includes petrot tanks, front forks, front and rear frames, clutch plates, brake shoes, exc., which are supplied after the return of the original equtpment for Inspection and acceptance. Operation of this scheme Is maintained solely through the Dealer necwork.TRIUMPH GUARANTEE For the latest terms of guarantee please consult your nearest dealer or distributor, PROPRIETARY FITTINGS Ancillary equipment which Is fitted to our motorcycles is of the highest quallty and Is guaranteed by the manufacturers and not by ourselves. Any repairs or claims should be sent to the actual maker, or one of thelr accredited agents who will always give owners every possible astltance. The following are the addresses of the various manufacturers, Carburetters —... Amal Ltd., ‘Sparking Plugs Champion Sparking Plugs Co, Led. Holeford Read, Wicton, Feltham Middlesex. Birmingham, 6. ‘Speedometers Smith's Industries Led., Chains... Renold Chains ted, Cricklewood Works, “Wythenshawe, Manchester. London, N.W.2. Electrical Equipment J, Lucas Ltd., ‘Grea: Han pose erate, Tyres. Dunlop Rubber Company Ltd., Birmingham, 18, Fort Dunlop, Rear Suspension... Girling Ltd., Blreingtany 2 Birmingham Road, ‘The Avon Indiz Rubber Co. Led, West Bromwich, Melksham, Staffordshire. Wiles,iP i» v0 Qn ce@) Th ogeerei] (Dan GoF neMi LS.st) GENERAL DATA T100SS—TIGER 100 T100T—DAYTONA TIGER 100 T90—TIGER 90 STA—SPEED TWIN 3TA—MODEL TWENTY-ONE Also Alternative Fitments for T100 Sparts Models Note:—Throughout this Section, read All Models as for T100SS Mode! unless otherwise detailed under the particular Made! GDIGENERAL DATA GENERAL DATA MODEL T100S—TIGER 100 LUBRICATION SYSTEM on,rume Bord dame: Fad SSvenfe (tre Hany YYalve spring lengeh Ball dismater ‘Alueninum eroeesd width ‘Worltng clearance in plunger hezds OL, PRESSURE RELEASE VALVE Piston diameter ‘ Working siearance : : aes OL PRESSURE Neral running. Faling BASIC DETAILS Bore and stroxe Bore and strove Cable cap Compréstion ratio {Cepadley of cambustion cham Bower output (BHP. @ Ri CRANKSHAFT Tye Late mals bearing, ste a: Right cronkabets iain ear jourel i Righe main bearing bore, size ard type Left malin tearing housing die Rg main bearing having 3 Big end journal ds. teh rerind Wa, (Crankshaft end fiost connecrine nos Maverel se Cee csi Alp kralaring jee ‘Sern der’ fearog Sarat detrenes GUDGEON PIN Material. Fiein small'end bush Diameter anes Cength SMALL END BUSH Maver) Outer aia Leng : Fished bore dia Gp 1 I 2 De Brose 3748/2783 1, anf-AT7 In. “4877/4872 In. ‘Bbeaparal ins 4369 /-472In- 4872/4889 in, 0015-0045 in, 405)-510 In. ‘001-001 i SOT fog, 422 belege em oe 60 ibe, tn, 20/25 fsa. 89x65 mn. Ties 78 in, 490 cc (G0 cu ins} oo Bee. (166 en nc) 4G 7.000 1 Forged two throw crank wich elon fiwhast 723:30513 hr. Ball Journal sea75) 4300 In, 4 7390/1908 in, Steel backed ‘oper lend ned besh, Under sta geslible: 0510 ins ~0020In,, - |. RBZ ILNE in. 5 B140 437514380 I 4-4073/44980 i. 008007 tn Alloy "H" Secon RASS 5311/5313 In Sesel backed white mets! aap07 0005/6620 in. eninlmur, tensile seed 0012 in 256 Im, Phosphor Bronze 783 in. 50/910 in. "3805/6800 in,GENERAL DATA GD ‘T1o0s MOPEL—(cont) PISTONS Maerat eae + Ata oy de From Ha8839] ‘Cvore 19833 Clearance: Top of sire. 99597007 in |-SO7S 0085 T. tom of skivc “aco | ‘Su.003 Gudgeon pin bok ta. “eabn}ne is | 2204 680 in, PISTON RINGS eee ‘ cas ron beta, Pe +9615 )-0825 in, Talekness 034/100 in. Freed gap Sl -at0p08 in, Clearance In aoe > 001/009 in, (contrat ring a ‘oats Ce Fw ae, "EE eins ae sun dane : etn ine s rome in . er Be tla tii, Sead BOR, eae 3 ‘thin, VALVE SPRINGS (Inner—Yeliow, Outer—L/Blue Spot) Free length ‘Total aumbor of eos “Total feed ford: vate $26 b, Valve dosed is VALVE TIMING leer apons 34° bare top centre Sec all tappec clearances @ -020 In. (5 mm) for checking Bee: Ge eae Exhsvst dose 20 ler top centre ROCKERS aerit High temile ses forging Bore di cf aia Recker "355/4340 ‘Tapper clearance {cole Inet ‘Baz in (85 Eanes “O04 mn (40 Tarrers Material ea 33 High santa seal forging Sealite np EE Tip rade oe oe Tapper dlomecer, Clearance in guide block ah SN0/3195 in 0005/-0015 in gbaGD 51005 MODEL—(cont) FAPPET GUIDE BLOCK Diamecer of bores (Queride diameter Incerfarence Rt in cylinder block CAMSHAFTS Journal dlamecer: Lefe ite Diamecral clean End fet Cam ie lee Exha ‘ae cirele diameter CAMSHAFT BEARING BUSHES Material « Bore diameter (feted): Lafe Suesida damarer: Left engeh Left Intec Left exhaust Incerference fe in erankece: Lee TIMING GEARS Ine and eau camshae pino "No. of teeth Ineecerence fi an exmshat. Inceroyedings timing gear ‘Ne efeauth Bore damecer lncermedinte timing gear burh: ‘al Lenge ‘Working elearance Ansermedieve wheel spindle Dismater e Incerarence iin erinkense™ spindle Crankease pinion: ‘Ne. of cath Fit on erenueste IGNITION TIMING Crankshaft position: (B:7.0:C.) Seat eiming - Fully advanced Pletan postion: {B:7.D.C.) Advance range: ‘Concace breaker Crankshale CONTACT BREAKER Gap setting os Advance range Fly sévaneed at Gps ‘GENERAL DATA s+ BIg he *.000).9595 in. “200s; Ia. 9010/0095 ‘05:08 in Tain. 36m In. ‘Steel backed bronze ‘Bins/aus $306} in Savajtost in. 5723/98 in. 002-003 fn, 50 ‘o0}-001 2 Soto) s00s Phosphor brome 2990/4995 In. “E775 005 In. g0s}0018 tn, 4900/4905 1, 0005;0015 in. Fa 0003 ts opas in, From Eng. No. | efore Eng, No. fe A908 ry © ” o aia. fein a a Pg * O14 046 In. @5AD men) 2! G4" erantshae) 22000 rp.GENERAL DATA GD T100 MODEL—(cont) CYLINDER BLOCK Material ast ron Boresize 1 EN e9/27165 In, Maximum averse” 2) 4:7366)27365 in, ‘Topper guide block housing sacs "9985/9590 In. CYLINDER HEAD Material Inlet pore size DTD 424 Aleminium Alloy ‘esas Exhaust pore sas iting, Vag eae aint eri ‘Cas Iron FUEL SYSTEM Carburester: "Amal pe wens Man je ai 2 ie0 Poe fet size % Needle ese oe Needle pane 3 Taro aves tos pe t its sping te ent ee CCarbucettar nam hal bore ize Ale leaner EYB@ ene ae Fale or paper element TRANSMISSION CLUTCH DETAILS Type na bp wiek inter heck sone No, of plates: Driving (bonded) Driven (pal) Pressure springs: Number Freafengeh 1. Now of working col Spring rate nan ‘Apprexiace ced iead = SD Beps1-2s00 i, 3317 236 In 43734-3753 in, Clutch sprocket bare diameter 0745" 0755 in, ‘Thrust washer thlsenose 252,054, Engine sprocket veeth 6 Eileedsbrockee teeth Chain dei oe Duplex endlss-2 tn, plech x73 Tinks CLUTCH OPERATING MECHANISM. Conical spring: Sub f working cote o~ wh, Free len moN SD Be Diametar of bls” : Finan. Gttch sporting rods Distnecer of rod Eongh a od In dia, P6298 tn GDSGD GENERAL DATA. GEARBOX r109 MODEL—(cont) RATIOS Inara rs fee ‘ee (exon) 1) 4th (Top) (Overall ratoe: 4th (To $24 Con) Gee (Bereom) = Joe RPM. @ 10 MP Ina (Toph ge Eieitan specs cath + "48" OP) GEAR DETAILS ‘Malnshafe high gears Bore damacer (bush feed) 752047520 1, ‘Working dearance on sate bono} 0035 ie: BUR Tempeh nee Pia Bush proton lengh ; Fn Layttate low gear: Bere clamecer (bush fted one 9/690. ‘Working dearancs on she “2045003. GEARBOX SHAFTS 74951-7509 In. ii ind dete es eas, Lankth (before ain. Lapeer Tae end dlgmeter 60456850 In Right end ameter ‘sero e873 in. conte ig” Sein ample pinger pr Freeones rw veo oH No, of working colt * aa Spriggs cn Ee toefin. BEARINGS Higher poring 3062356 mm. Ball urna! Malnsate bear : S744 mn Ball ournal teri besring ty 2 Hoe tn. Needieroler Uapate Cerin ah) Beibad in, Needle rover KICKSTART OPERATING MECHANISM Racehor spring free length GEARCHANGE MECHANISM Plungers: ‘Goer diameter ‘Workng desrane i bore Plunger springs: oa working cols Free length ‘Oucer bust bore diameter Clearance on shaft ‘Quadrant return spr ‘Nov of working e3 Free length 3407/3412 In 157-0035 I G06GENERAL DATA _ GD FRAME AND ATTACHMENT DETAILS Ss ‘T100 MODEL—(cont) . HEAD RACES No of ta: Top on Baca 28 Ball ameter Bn SWINGING FORK Bech os -Phoaphor bronze tl Bash bore damexar SHS} Spindle dames a sharin. ance betwson fark ends iz REAR SUSPENSION Tie mom 7 : =~ s Swingng fork comraed He combined spring agar Singer uni, (baed up after Hees Spring deal aed tngh : tage Mean eh dizer“ Gilowreade ST fodaeeedienet” 2: WHEELS, BRAKES AND TYRES wHeEts ims Front nd rear Wt cue ea fa Spoke—dotble crass cig Spoke datas: Front = fio S076 veed 548 In. UH, eralghe Rote tet Boot SA0 SW boc Fee URLS tig Bor eioswe ponce ih. Bev ae WHEEL BEARINGS Front and rar, hnarsons and type ean 20364744 mm Bll Journ Fron pings diametne Ge at fourrak) = Toes 78N ie Rearapndle dumecer Qtbewingieurmas) 7 Sl eapreb in 0. REAR WHEEL Beare ps - 423% In al our Bearing sleeve: oral dimers eas Seledren bere Be Bearing seve oul camera ; in Besrng Housings areal carr 9900990 REAR WHEEL DRIVE ‘Gearbox sprocket, Sco “Guarbox* for wie @ efi ovelliner: Soto. im te ite ish a Incrrl Expanding fe Rar : rippeor le. Lining shiknaesFromtaad rea? Serf in. Unig rca root and nar, these in ep7sD GENERAL DATA 100 MODEL—(cont) YRES Size: Front a 3.25x18 In. Dunlop ribbed Tyee eter = ies Suni kre yee pressure: Front . in em: Rear = 2A tbleg In. G7 Ke og, em FELESCOPIC FORK Type wens Tesco with ol damping Spring ders: oe langth as . Sam. No of working cole x OS ay ing Fate mon 26d iaen. ek ae : i = Yeliowibive ‘Bush deralls Marerial ‘Top bush Length Te B70) 575 i, Cuter dames coh 198j1499 tn. $5935)1-4945 In, Tree camera 2 T3068/1-3075 in, | 152485/1-2485 In. Scanchion diameter cr NSD taoas gogo in, ‘Working clearance do vop bush > 0036;.0050 in. forking tere sme ‘ets. ‘Waring clearance oi bottom bush 0935-6068 im, 12 VOLT ELECTRICAL SYSTEM . Lucas 12 vole PUZSA or Battery ne tarler ? Lure 6 vole bacterier epnnecced in series (MKCZ9E) Aretifier type "Euees 2D5506 ‘Atcarmater type Toes AMI livers BH12 vole Tyre Bulbs: Heaalighe f 30/48 waste prefocus Packing ighe B wares HEC" Scop and ell ighe oeas 300°) 6/3 watts fee pins Speedemeter light s Lees 997 | 2 wates MES Fin ear inlet igh (here eee) ueas 251 | 2 wate (BAZ igen warning igh ese 281 | Dace (QA Za zon! Cally Lucas MA? (1204) 2 off Senate brathar ype eae CA (12° range). Fare rating Samp. SPARKING PLUGS. Type ae we Samana Tere seings << S ees) Tee Fema tech GENERAL caraciTies Fue rank 2 el 45, ls 135 ead Gian : Bere) Seton oo ; : Sole see) Heese, ieee (eae lag) Tine (99 | pe o Das C‘T100 MODEL—(cont) BASIC DIMENSIONS Wires base (QvaralTengch ‘Overall Overall hetghe Ground clearance WEIGHTS Untaden welghe Engine un (dy) TORQUE WRENCH SETTINGS (ORY) Ely ESinred bcs rons fio bt rte enon ss incor eck, fd tole (1a) Rocker box nuts ., ie + Rocker bor ole 22 Hocker spindle doted nz Sh pump nate ne Klar ech lt sie Svteh cone out foto ding ot Sever fa ae Hedhmp eer bis Haars date et inh bt Stencion pcs ote" Frone whe spnde cap bcs Brake am apiece at Zener dealing we ‘Tein erbrtcr sll seek sere GENERAL DATA S34in. 36 em) i Caton, ee Hi Bad wives 337 Ie, $06 lis rtd SHBrbAseses atu ntitel (3 em {a8 ken) GD GpsGD : GENERAL DATA GENERAL DATA MODEL T100T—“DAYTONA” FOR DATA NOT GIVEN HERE REFER TO GENERAL DATA—MODEL Ti00S ENGINE BASIC DETAILS SESE an ead Boom vauves ats sos eas VALVE TIMING Weve $2 the bot cenere i . Sey ” Exhnure cloves St after top centre Sai ype Pain jecsiza a 2» a i aaa on Nomitai bard se [2.2 ae se = wo tee in tan whee onve GENERAL BASIC DIMENSIONS Wolghe oe ese ane ne HAY Tbs (E47 ey nto i OaGENERAL DATA GD GENERAL DATA MODEL 5TA—SPEED TWIN. (ISCONTINUED AFTER ENGINE NUMBER H.49=03) FOR DATA NOT GIVEN HERE REFER TO GENERAL DATA-MODEL Ti00 ENGINE BASIC DETAILS re and stroke 69.655 mm, Bore and stoke Driesxnse Clie capacey ‘ice Been) Compression rato ‘Cipacity of eomburson chanted” Bee gascuiny Fower aurput (Bi 5 : meee PISTONS Pacer . ‘Aluminium Aitoy dle esting Clearances Top af “ane 2073 i Selim of sire ‘bonzaa in Gcgean pin hoe danetar “ear in, VaLve THING ole opens 24 before tp cenere ‘Sev all rappet clearances @ “020 In. (50 mm.) for checking ww. 2 Exhaust closes 27 air top conte gle (eluded) Teatro ie Stor diameter Inert Shse3000 1, Sahat “Soo 3088 I VALVE GUIDES Cast ron 530/520 in. ors aasrsioh. ee tiie ROCKERS ater. High vena es Bore dle isi, Recker spindle dieser “a5s5;a3u0 ‘Tapper clearance {COI “an (OOS amy “204 In (O10 mie IGNITION TIMING Crs psn i Pal aon - oe cen patton (81.0.6) Suticeming 035 in, Felipadronced <> E530 in 99 me ‘Advance Contact oresber eo m Craigie eT * eonGD GENERAL DATA STA MODEL—(cont) FUEL SYSTEM Geirecee wm = 3 ln fae a Bs fess % Needle rua 0s Needle eka 5 “Trezel ale: vent Sg ; (Reb spting ni ah Carburetter netrinal bore ne ‘Air cleaner 90 2 Feb oe pope lament = GEARBOX RATIOS Inert ii: 4h (Tp) Overall ratoe: Engine RPM. Ee Fi Fa Cr ea” Etter Fete tet Cayshe Eushes, mater | a Bronze Boresze |W ene tno 865-6505 Io. Bore sau R/H 590) i. Interferenes ft in easing RUHL “3008 0018 in. Interference fit In Kickstart assembly [JH 005 -0015 in FRAME AND ATTAGHMENT DETAILS REAR SUSPENSION Spring deli: Pr car tergth Bin uel ay. can eo in. Spring race ‘ish, oo code Bliejyeliow Tone see aaiby WHEELS vote © Mottejo swe paced 54 1, She seaigne whe Rim sac: Front. Spoke decals: Front Rm sizes Rear REAR WHEEL DRIVE Gearbox sprecker teeth See "Gearbox" a esr whee sprocket teeih Chala eral oso ins 103 fin. 3252 1B in, Avon Speedmaster BAO 18m Avon Speedmaster Blieg ins OT he fe 34 Wg. (07 RE oa em) “Tye presses: Frc Gp ee)GENERAL DATA GD. STA MODEL—(cont) FRONT FORKS tie He, ELECTRICAL SYSTEM ELECTRICAL EQUIPMENT RICAL EQUIPMEN’ Lucas 12 vale (eype PUZSA) or alee- BOY FE eee aati Luc Eve (ape MRESE) connated Ie sre Mariel pe ieee anis orm oP iva eH (2 vol) Ne i Bulb: (ot Tei las gia Parking igh Stag and fal ighe Speedomecer lghe ess $99 Ever 380 thes 9a7 coil ype : Lucas MAT (12 vol) Genet brdikerejpe Leas 4CA, Bose tng Ba Sparking Slog: TPE a Sorel Pl gcse 0 r= (3 mm) Theses Eo Yinm. GENERAL BASIC DIMENSIONS Wheel tare + Sb In (36 amy vera fengsh Blin Bison vera wid co Bob in (674 eng} veral heigne : Hin (36 5em} Grove clearance E Tin (em) WEIGHTS Unladen weight a 340 Ibs. (155 ig) Engine unte (Dry) = mM Tints gh G013,GD GENERAL DATA : GENERAL DATA MODEL T90—TIGER 90 FOR DATA NOT GIVEN HERE REFER TO GENERAL DATA MODEL—T1005 ENGINE BASIC DETAILS Bore and stroke... 3825x655 mm Boreand sereke 2278x248, Cube capacity Hee Bt ening Compression sation a Gapaciey of combustion chamber Tisce, {139 sun) ower output (BHP. — RPM) W@rso PISTONS Mararlal a mm te Be oe Aluminium Alley From H-49853}] Before H49093, Charnes op oi 7 “045/079 Thon ‘448 I Godgeon pinbole diameter“ : Sats vaLves Seat angle (lis and axa) on ince cS Exhaue stem dlameer: eee Sets 50" Included angla & in ele, "3655/3100 in. ES "3090/2095 in. VALVE GUIDES Macerlal os Hiurat Bore diame (nit and xno) 31313 i, Outside damecer (infec and exhaust) Soo pst, Lenght nd Geka) 2 Ra VALVE TIMING alec opens 34° before top entra Sor all tappet clearances @ -020 in, (5 mm, for checking, . GN Semen, a alae bebe CHAE. xhaure clone 20" ster top centre ROCKERS Material — sv High censle see! forgh Bore dizmetar » 435-4320 ~ Rocker spindle dlimecer” 4533/4360 ‘appetclearancs eal)! inlet “Gon (05 m Enos “204 In (10 IGNITION TIMING CCrankstefepesetan (8:7.0.C} oe 2 1 Fully sdvance ze ee sa o Piston poateton (B:7-0.C3 Busi ming 860 in. 52 rid Fully vanced 360 im O44 mm) ‘Adanee rungs: “Conaet breaker ra Cranistate Se CYLINDER HEAD Materia DTD 424 Alemintom Alloy Inter poresize Si ea, Exhacee pore tte igh de, Valve setting yee casein sri Ca Iron CONNECTING RODS Maser! “B. Section RA.S6 alloy Material (Before H49833) EN 48 steal stamping entsGENERAL DATA GD TIGER 90—(cont) FUEL SYSTEM aga ite 2D Hos Type Nitra sping fa ang Carburetor fomial bore size Ale dearer pe ene GEARBOX RATIOS Incr or: h (To Fea in 4 ow vera racors BE ROEM) 4h 4 9) a0. Engine RPM. @ 10? Sener FRAME AND ATTACHMENT DETAILS REAR SUSPENSION Spring deve: Priced Jengzh ... Free length WHEELS Fron a. alls Front wrt ADciBPLOSWG butted SY} In, straight a WRB Spoke Bir ste: Rear. REAR WHEEL DRIVE Gearbox sprockes teeth Se "Gearbox" Fear wheel sprocier sexth a Shain desis ke im | in 910GD TIGER 90—(cont) Spring des: Free length ae Nos of worktag coils Spring Fee . aur code ELECTRICAL EQUIPMENT Battory ype Reclfir type ‘Aeron type Horn are Baltes Ticats Paring ge Spang ei ighe 2 Speedomare ight” hin beam indieator light (Whore feted)” Igattion warning fighe oll ype ‘Gonee bretker type Saersting Sparking plugs: Type. " Up eup settings Thread size oe BASIC DIMENSIONS ‘Wheelbase Gvaral angel Overall wieth ‘Overall helzhe Ground eletrance WEIGHTS: Unaden weight Engine unie (Sry) Gps GENERAL DATA FRONT FORKS ELECTRICAL SYSTEM alternatively ‘2 Lies 6 vale baceeries fennecied in secs (MKZ3E) Fear 208506 Ey Et wa Neo. § i Lucas 12 vole battery (PUZSA) or Te Tema | pwns protean : Ste |) eehere® thee S80 | Spi wate eteine : cl otiiay | aac neg ; : tieeay | dwn garg esas | tae ears es Mat? Leas CA ey imp Chareron NA 8 CS ms Hindi ach GENERAL 534 in (136 cn) a3f in {245 em) In, 67-3 em) Bin Ges em) 2 Tle. (9 om} 2 We (she, 304 toe 47-2 ker) a@Qhe x WWGENERAL DATA GD GENERAL DATA 3TA—TWENTY-ONE (DISCONTINUED AFTER ENGINE NUMBER H.49223) FOR DATA NOT GIVEN HERE REFER TO GENERAL DATA—MODEL STA ENGINE BASIC DETAILS Bore and stroke Bare ang techs Cable expec Eompretion rae 5 ‘Capacity of combustion clamber Power aurpse (BHP @ RP) CYLINDER HEAD Material in Ine pore size Exhale port sie Valve slung 5 8252658 om. Haba sin et cain) Tet a S Bec 2 eum) ies @ ston BT.0.424 Aluminium Alloy a Casctn Cs Iron Aluriatum Alley die cesing “9q8/-0088 fn 2033/0043 in, 5618/5674 In. Bote Gudgeon pin hole dlamecer vatves Sct angle (let and exh Head hind ie une Stem clametr: eee ‘ta 50° included angle tinea VALVE GUIDES Material Bore dlamescr (niet and exhaust) Oneside diaritar (niot and exhaust) (engch: Inter ard Gxkaure net opens 2648 before top centre Inter closes 694° ater bottam centre Exlaust onens 814° before bottom centre Exhaust close: 35° war top centre Set all rappet elesrances 020 in. (5 mm.) for checklng VALVE TIMING { IGNITION TIMING rant portion (T.0.¢) Stale eiming Fully sevanced Piston postion (B7.0.C) ‘Sut ming we Fully advanced 2) Advance range: ‘Contact breaker Crarletafe ROCKERS Mi e Ss 00101. (©5 mnt) ozo Im, 2» cre Rocker spindle diameter ‘Tapped clearance (cole igh eat stea!forgh et ibao gee ane “335/360 In 02 In (5 ren) “a4 in: (40 mn} CAMSHAFTS Aournal dame: 1001-2105 in “9940}-0025 in, “225-008 in. Betin. SB In: Bin End float (Carn Me: ise CLUTCH: DETAILS ‘No.of plas: Driving (Bond ones Bair gia Lange of cuech operating rod a ay o 6. 432)0482 in, = GDt7GD GENERAL DATA 7 Fa od e WHEELS, BRAKES AND TYRES 7 WHEELS B Rim size: Front... a - WM2-48 F Rim size: Rear sof wag wine REAR WHEEL DRIVE ‘Gearbox sprocket veath.. Rear wheel sprocket teeth (Chat, deri Nov af inks .. Pitch wieth Spasdometer go TYRES fs ie (47g > ATER Ih (0 Ge FRONT FORKS Syria di, a No, of working calls” a z Bete baie ee es oa 3 * Yhelsion FUEL SYSTEM at ara nse ta fot fe s Nene oe cele postin ; th a ae m Si fale or paper element ELECTRICAL SYSTEM ELECTRICAL EQUIPMENT 4 Lucas 412 volt battery (PUZSA) or see 2 Lueas 6 vole basreries sattey it re Sonne yet CE) eaters : irermator : Homme P ct Sle a2 saty i ™ Ri: pal lesaiate “Teed | S00 ware pretocur Faring ee: cl Beebe | nah Stop ane Sa igte tinae 380 | 67 wares ping Sheadomersr ie tes 967 | Sane Hes colt ype ; we eas Hat Gai) Cone onctker Se cl des aeh! Eos ratng inp Een logs: ye . Sten Moe asp ergs BET CO my eee Fain S3 ne etch GENERAL BASIC DIMENSIONS ‘Wheelbase San. 136 em) Suara engsh BE BRST) Seer wil ible rs om} Steal Ralph Binds en Sound eetrance itm Gen) we TUnladen wage. . Ho is. (255 kam) Engine une for) NG oe joss. (7 Hye) P opieGENERAL DATA GD Bs ALTERNATIVE DATA FOR SPORTS MODELS FITTED WITH = A.C, MAGNETO (E.T.) IGNITION EQUIPMENT {GNITION TIMING AC. Hagset (27) leniton equpmene me tin - et z zis ann. fai er Sto, aaa Seth eker » oe Se CONTACT BREAKER AC. Magno (£7) lion equlpment Gap sesing < 1-68. 5-40 an) Rigen ae Som ne ELECTRICAL SYSTEM ELECTRICAL EQUIPMENT AC. Hogneto (ET) union eoupment name Steve SE (yet Senses (anor ioe seam Sept relic ge eee ea ia ae thos S| ~ opt wens elon oe see ta i emer song ae = Ghanpion NA I oS wsity | ATE reece aE Re, WHEELS FRONT WHEEL Mee ace Mie eleeais ee 3 a8 SE teed Oe te GEARBOX narios Jnvernal ratios (close): Ey (For) id 7 lea) srl es ie Te) FY Benin) f = Gearbox sprocket = ST 18 a9 20 eth co |TUNING INFORMATION OBTAINABLE THROUGH THE SERVICE DEPARTMENT OF YOUR LOCAL TRIUMPH DISTRIBUTOR NOTE:—ENGINE NUMBER MUST BE QUOTED E couGENERAL DATA T100S—TIGER 100 T100T—DAYTONA SUPER SPORTS T100C—TROPHY 500 Ti00R—DAYTONA Note:—Throughout this Section, read All models as for T100SS Model unless detailed under the particular Model. “s @ptSD GENERAL DATA GENERAL DATA e = MODEL Ti00S ENGINE CRANKSHAFT Type ae ame come Fg ehrow era wth bole eh flywheel Late main bearing: Size and ype Lefeerankrhae tn bearing fxr Gf beri raining sie Rlghe motr bearing! ‘ae and pe igh rans main being jsierl i Righe bearing Rousing dia. Bigend Journal dia. wo Fainimem regrine die. (Crankshaft sn float 72.530 x90 man, Roller bearing 4805-1908 in. 2336-28921 in x35 x17 mm. L tanetanrin Hense28004 in. 59375-44380 in, 4075-14080 In o.00e-0917 r. ail bearing SMALL END (No Bath) Diameser eee eee teak a 08.0684 I, GUBGEON PIN (wre Fi) Length Distever icin eval 2nd 1452456 In, -e-0 4868 Ln. (0005-0017 in. VALVE GUIDES Bore dic and‘ oxise x 2 BSFbar2» in, Sua titan eee) 2 : Suareane Wane. oo o Saeote FUEL SYSTEM cangunerTen aie . 1 ‘Throttle valve vs B WHEEL, BRAKES AND TYRES rakes , ME om ww we galego dine imituccia” Sa 2 2 & & 3 a a ee ee ELECTRICAL SYSTEM Wundancal ype ew . cee nes 1H (V2.0) spza GENERAL DATA GD GENERAL DATA MODEL T100T AND T100R “DAYTONA” FOR DATA NOT GIVEN BELOW REFER TO T100S FUEL SYSTEM Carburetrers (ova) WHEELS AND BRAKES Inceenst expanding ein. lerding ‘hoe Diameter: front... ain Lining thickness: front 81/100 in, Lining area front 2. Sable. tee WHEELS: irs WH 19 in TYRES Tootsie: front... 325x195, Tipe ne ‘Avon ribbed 335475 i Type Dunlop 76 FRAME AND ATTACHMENT DETAILS REAR’SUSPENSION “THOOR—Spring devas Ecce ois ead ae ised lergch Bribe Tiooc FOR DATA NOT GIVEN BELOW REFER TO T100S ENGINE VALvE cutpes MEER ee enna wes esos ant WHEELS, BRAKES AND TYRES WHELs Ti sce rant eae eee ae WABI BRAKES ‘Type front Ineaenal exparding twin leading Shoe Drum dlameer: rons Tint Tyres Site front. 325% 1919 “Type rere Eeher Dutlop K70 or Dunlop ‘Teale Universe REAR SUSPENSION Spring dui Fcced lange 84 ‘Spring ate 100 bb, Colour code Green-Green Tog at feted lengeh ibe Go3“tr 2 Om GeSECTION A LUBRICATION SYSTEM Section ROUTINE MAINTENANCE once eaten ate aa A TABLE OF RECOMMENDED LUBRICANTS. : oe we AD ENGINE LUBRICATION SYSTEM... TR Be Sey See toe oye A CHANGING THE ENGINE OIL AND CLEANING THE GIL FILTERS =... At OIL PRESSURE... 7 at mem mg ae TAB STRIPPING AND REASSEMBLING THE OIL PRESSURE RELEASE VALVE wu. use awe AG STRIPPING AND REASSEMBLING THE OIL PUMP ase ee tee tees AT REMOVING AND REPLACING THE OIL PIPE JUNCTION BLOCK. eee ae ae AB REMOVING AND REPLACING THE ROCKER OIL FEED PIPE ne eee AD CONTACT BREAKER LUBRICATION ose ote ane tenes os AIO GEARBOX LUBRICATION ee nee ntact ee ANT PRIMARY CHAINCASE LUBRICATION a, ee ane wee wee eae AND REAR CHAIN LUBRICATION AND MAINTENANCE o.oo a ANB GREASING THE STEERING HEAD RACES... ou, ee one se nea ANH WHEEL BEARING LUBRICATION 0 oo we mt ve see aye I TELESCOPIC FORK LUBRICATION ... sow ANG LUBRICATION NIPPLES. oe me eee eA LUBRICATING THE CONTROL CABLES Meet woes nee ig SPEEDOMETER CABLE LUBRICATION ww. ww. owe oom a AD REAR BRAKE SPINDLE LUBRICATION... wees ne ADT AtA LUBRICATION SYSTEM SECTION Al. 2 ROUTINE MAINTENANCE Every 250 miles (400 Kms.) Check level in oll cank Check level In primary chaincase Every 1,000 miles (1,600 Kms.) Change oil In. primary chaincase .. Lubricate control cables... Grease swinging fork plot. ou see aoe Remove reat chaln for cleaning and greasing Every 4,500 miles (2,400 Kms.) Change engine ole ae Every 3,000 miles (4,800 Kms.) Check gearbox oil level hack front forks for external ol leakage Gresse brake pedal spindle... Every 6,000 miles (9,600 Kms.) Change oll In gearbox ‘Change oil In front forks Every 12,000 miles (19,200 Kms.) Gresde wheel bearings Grease seeering head bearings AD Section we AS An oe AND on MB a AMT AB AM 2 ANG Anz Att ANG AS ANGLUBRICATION SYSTEM 2 A @ 7| WO @ B 5 Pip, At. LUBRICATION CHART ‘Nurnbors in eirelos rafer to right side of machine ‘Numbers in squares refer to left side of machine GUIDE TO LUBRICATION POINTS Mlastration No, Description SAE Oil grade 4 Engineolleatk ny 20 30 2 Gearbox ee 3 Primary chainease wn. 20 4 Wheel hubs wae Grease 5 Steering head Grease 6 Brake cam epindle vee Greate 7 Breke pedal spi Grease 8 Exposed exbles 20 9 Telescopic fork x 200r 30 10 Swinging fork pivot Grease — All brake rod joints and plas 2» ARLUBRICATION. SYSTEM SECTION A2 RECOMMENDED LUBRICANTS UNITED KINGDOM. ao (Dei unit roa an, castaon | e550 sau” [ascent Summer |, Mata A | teen sAE30 | carol xt | Exaieas | Syanxqun70 | Hovtne SNE WRT ce | eA | enegsisnebaw [Chere | Nearest | “ShatSct® |" ktaine we 20W 30 ‘20W SAE 20W on obiotD| GwergaSatso | Cunt (Sua tae | Sh x30 | HevatneSAESO ani | eo ary Sines Hobie aie | Bars sAEa | carole | Batam menace | fais ” Meter O11 20W /30} ‘20w ‘SAE 20W cscopleFori—Summer | _MosialA | faeraisatze | cuwait | Gaoeka ) Siailxs0030_| HavenesAP SHintee” | watt ache | enestsathow | Eane | ezaret | SBagS00".| ™Rteiee seu | RR cal Bean Z| Reljgese | eregges | Gwpgane | Be Set Far Sane? we fs THE | matdetenme | netinwa | Wotipnpen? me Alas ace ing Rowiod Pars Fou ae ae = sat | — Sap secon | rescaxtinon | renewing | reretttngon | pent | restating overseas unr on, caso. | 680 sae | _catrex re Gane | Guam | gcee | fanewe | Gimeee pe eegosnes | erst | Hatwron | Sedctoos | GgrSAkss Baiowae | Mit. | PES aa? | Eset | Magi! | Selina | tensa Ske ion tow | AEB sox oui | FrerglSAESO | _Coazel | ~woiarg | Shao | Cakoe SABO Ee ee re Son Bega, | Gevate | Eagbas “| Santos | Gm abaow Se cre ee geple Fork cart “ARs aE rtopiaro | gor sazse | cSt | tote | shat crsoso | cater se so aa Hebei | Eortatcaae | Sowalee | Neot | Salles | SneeeAesh Below oor. vobialareye | enegetsacaaw | Coane | AW" | SShatsias” | OA aoe SE il Raangs, Svngion | Moklgewe | Emus | cupgeae | tae Sal eri ee Staley Racae | MR " TM | muapttpne | aetna | muidptse 2 etait ing aad Paks ce Targa Coa es Sa Gies Sorngon | Fesetiegou | resting Ot | Peneting on | penser | rence ou MLUBRICATION SYSTEM ey 39ams ‘wrsaduyp uoryeoysany 963g ty ig ads BONgAVOS —: « (1) The two nuts. which secure che right rear engine plate to the frame. 2) The right rear engine plate. @) The: left side front. scud which secures.the ‘torque stzy to the engine. (A) The right footrest. ‘The engine Is now free to be removed, Ie ls recom- mended that removing the engine should-be aided by the use ofa hoist or the help ofa second operator, due to the engine weight, which is approximately. 105 Ibs. DRAIN PLUG ‘When refitting the engine to the frame, place the bottom frame bole in position first. Then place the right rear engine plate in position and tighten the nuts finger tight, Finally place the front engine plate in position and whan all bolts have been inserced, fully tighten up. When replacing the {gnicion coils, : remember. that «the connector “terminal end. of ach coll fates towards the-rear of tha’machine.-To.ensure that the wiring harness Is reconnected correctly, :refer. to. the: appropriate ‘irings¢iagram in Section Htt. Do not forget to fit the distance pleces on the coll mounting bolts, torque stay.mounting bolts, snd, in particular, the lowest engine mounting stud; also, attention is called to the lower panel mounting bolt on the left side of the mackine. For-the.cofrecs.grade and quantity of lubricant for the engine, gearbox and chaincase, see Section AZ. CLUTCH CABLE 203 d= LEVEL PLUG Fig. B2. Clutch cable adjustiment and gearbox laval and draln plugs5 ENGINE SECTION B2 REMOVING AND REPLACING THE ROCKER BOXES jsconnect the leads from the battery terminals nd remove the fuel tank as detailed In Section Et. scennect the.'blgh tension cables and wiring arness from the left and right ignition coils. femove the top and bottom coll mounting boks nd distance pieces. The ignition coils will chen e free to be removed. Care should be taken not o damage the light alloy casings of the Ignition oils as indentations may ultimately resule in gnition failure, Jnscrew the two nuts securing the torque stay to 1e exhaust rocker box and remove the torque ay mounting bol: and dlstance pieces. The torque cays should then be removed. Unscrew the wo domed nuts which secure the rocker oil feed pipe to the recker boxes by means of the centrally mounted ofl feed bolts, which should now be withdrawn, Care should be teken not to bend the pipe excessively as this may ultimately result In a fracture. Remove che rocker inspection caps. Fig. B4, Rocker box securing nuts Unscrew the ewe nuts from the studs fitted to the underside of the exhaust rocker box, Remove the two Phillips screws on top of each rocker box, stacker all elght eylinder heed bolts and unscrew the central cylinder hesd bolts. (Note that, at thls stage the rocker box may rise slightly, due to a valve spring being compressed). The exhaust rocker box is now free to be removed. The above pro- cedure also applies for the removal of the inler rocker box. cy Care should be taken to collect the six platn washers which are fizced (one beneath each of the underside securing nuts), as they sometimes adhere to the cylinder head flanges and may be subsequently lose, ‘After completion of the rocker box removal operation, the push rods should be withdrayn and stored in the order of their removal so that they ‘can be replaced. In their original positions. The junetion surfaces of the rocker boxes and cylinder head should be cleaned for reassembly, by means of a soft metal scraper. Replacement is reversal of the above inscructions, but remember co fir new gaskets between the rocker boxes and cylinder head. When replacing the push rods place 2 small amount of greaseinsothe bottom cup of each ofthe push rods, then locate the push rods, one ata time, by means of feeling the engagemenc of the tappet cup and the push rod ball end and then by testing the resistance to lifting causéd by suction between the dome of the push red and the tappet cup. When the push rods are correctly located, remove the sparking plugs and turn the engine over until the inlet push rods are level and at the bottom of their stroke, The Inlet rocker box should then be assembled. Repeat this procedure for the exhaust rocker box. Remember that the four central cylinder head through folts should be fitted first and that the underside nuss and Phillips screws are tightened fast. Before finelly clamping the rocker boxes In position, check that the valves are being operated by turning tho engine over slowly. De not forget the distance pleces when refitting the xorque stay and coil mounting bolts. NOTE: It can be seen that the four central bolts also serve toretain the cylinder head and should be tightened first. The correct tarque figures are given in GENERAL DATA, and sequence in figure B13. Before fitting the central oil feed bolts and the rocker oll feed pipe the copper washers should be annealed by quenching in water from cherry red heat. Finally, remove any scale that may have formed. Annealing softens the copper thus giving i better sealing qualities.eh ule ENGINE B SECTION B3 INSPECTING THE PUSH RODS. ‘When the push rods have been removed, examine ~ them for worn, chipped or loose end cupst-also check that the push rod Is true by rolling it slowly "- fon a flat-surface (such 252 pieca.of plate glass). Bent push rods are found tobe the cause of “excessive:mechantcal nolse and loss of powar and should be straightened if possible, or, preferably renewed. ‘SECTION B4 STRIPPING AND REASSEMBLING THE ROCKER BOXES Removal of the rocker spindles from the rocker boxes ts bese achieved by. driving out, using a soft meta drift. When the spindles are removed the rocker arms and washers can be withdrawn. All parts should be thoroughly cleaned in parafin {kerosene) and the oil drillings in the spindies and rocker arms should be cleaned with a jet of compressed alr. Remove the oll seals from the racker spindles and renew them. IFit Is required co renew the rocker ball pins, che ‘old ones should be removed by means of a sultable drift, New ones should then be pressed In with the rilled flat towards the rocker spindles. To ensure aa oil tight seal between the rocker box and cylinder head, in cases where an oil feake cannot be cured by fitting new gaskets, che joint surface of the rocker box shovid be lintshed to remove any Irregularities, ‘An effective finish can be achleved by ist extracting the rocker box studs (wo nuts locked together on the stud should facilitate removal) chen lighely rubbing the junction surface on a sheet of emery loth mounted om a flat surface (such as a piece of place glass). Fig. BS. Rocker box assembly The following method of assembly Incorporates the use of a home mede alignment bar which can be mage from 2 7 in. x6 In. long bole by grinding a taper at one end. 7B ENGINE Fig. B6. Rofitting the rocker spindle Before cominencing reassembly of each rocker box, note there 's one plain washer in-éach box which has a smaller diameter bore. This is the thrust washer through which the smaller diameter of the spindle enters and is assembled last against the right hand Inner face of the rocker box, ‘Smear the two plain washers with grease and place them one either side of che centre bearing bors. Place the left rocker arm in position, bringing it Inco line wich the alignment cool and slide a plain ‘washer and a spring washer (in the order shown in Fig, BS) into position. Carefully repeat this procedure for the ether rocker arm and spring ‘washer and slide the thrust washer with the smaller internal bore ino position. Finally bring both rocker arms into line wich the allgnment bar. Lubricate the spindle with cif and stide it (complete ‘with oll seal) as fer as possible inco the recker box, finally tapping ic home with a hammer and soft metal drift (éee'Fig. Be). SECTION B5 ADJUSTING THE VALVE ROCKER CLEARANCES The valve rocker clearance should be checked and adjusted if necessary every 3,000 miles (4,800 kms). ‘The correct clearance, for the type of camshafs employed, ensures that a high valve operating efficiency is maintained and that the valves ateain their maximum useful lives. NOTE: Adjustment should only be made when the engine is cold. ‘Access to the rocker arm adjuster screws and lock nuts is gained by removing the slotted inspec- tion caps from the rocker boxes. Adjustment Is sided by the tool kit spanners D361 (In. Whitworth spanner) and D362 (tappat key). As itis dificult to insert a fesler guage betwaen the rocker arm and the valve tip ts recommended thar the clearance is set by using the pitch of the thread fon the adjuster screw as a vernier in order to determine the correct setting. The thread is Fein. x26 CEI. hence the pitch ts 038 in, There~ fore { turn of the adjuster screw represents -010 ins. approximately. To set the valve rocker clearances proceed ss follows :— Be First, remove the left and right sparking plugs in ‘order to relieve the compression, then slacken the four lack nuts securing the square headed adjuster screws} engage top gear. Fig. BY. Adjusting the valve rocter clearance i i ab,3 ENGINE B Inlet valves. Turn the rear wheel forwards uncll the right Inlet valve is fully open whereupon the left Inlet tappet will be resting on the base circle diameter of the cam form; the clearance for the left inlet rocker can now be set. 190, THO0SS, TAOOT (and later STA from 140528). The elearancets-002in. (0-05 min) and this means just the slightest perceptible movement of the rocker, with a faine click when the clearance ts taken up by moving the rocker wich the fingers. BTA and earlier STA. The clearance is 010 in, (0.25 mm.) and the rocker should first be adjusted tozero clearance, rhat Is free to move sideways with ‘no vervleal play. Now screw back the adjuster one quarter turn {one fizt) and hold Ix In this position while tightening the locking nus. Having adjusted the left inlet valve, turn the rear wheel forward until the lef valve Is fully open and repeat the procedure for the right inlet valve, Exhaust valves, The procedure for adjusting the exhaust valves Is the same as described for the Inlet valves, 790; TA00SS, THOOT (and'leter’STA from 140526). ‘The clearante's 004 in: (10 may’) for. these models, Tocobrain thisclearanceradjust the tappet to give nil camshafts caused--by compressed “valve .'springs, :' - Select “fourth:{top)- gear, -apply -the-vrear ‘brake This should be done by-removing the rocker boxes *:'and “enscrewsthesnuts:retalning-the:camshaft:and ‘a detalled:in Section B2, or may be-achleved by 2 erankshafe,then withdraw the tneermediate wheel. + ssuficlencly:slackening the valve clearance adjuster screws; however, this {s not always advisable as tc = may result In a push rod becoming disengaged: = :->NOTI ‘The camshafe-pinionzretalner nuts © haves LEFT-HAND. threads. ‘The crankshaft Remove the contact breaker as detalléd in Section -: pinion “retainer ‘nut ‘has ‘a RIGHT-HAND eu. thread. Fig. BUG, Extracting the crankshaft pinion baCRANKSHAFT PINION ‘The‘crankshaft pinion is removed by using service tool 289. To-extract the pinion, first. remove the pinfon nut, then'screw the extractor body onto the piinldn and finally screw In the extractor bole whereupon the-pinion will be withdrawn from the crankshaft. Remove the key from the erankshaftand place ic in safe k&eping. “Tha crankshaft pion can be raficed esing a hollow rife to assemblé"Ic to the crankshaft. To do this smear the bore of the crankshaft pinion with grease to assist. assembly, align the key and kayway and drive the pinion onto the crankshaft. Fig. B27, Extractor tool Z89 CAMSHAFT PINIONS To facilitsze extraction and replacement of the camshaft pinions, extractor adaptor Z145 and replacer adaptor 2144 should be used in conjunction with existing service tool Z89. To extract the pinion, first screw on the extractor body, then screw In the extractor bolt; the pinion will chen be withdrawn from the camsha‘e (coe Fig. B2), B28 “ENGINE. Inthe case of the ‘exhaust camshaft, extractor. adaptor 2145 should be positioned in the end of the camshaft to avold darsage to the contact breaker location taper. A smear of gresse applied to the adaptor should hold this In position. The focation keys in each of the ‘camshafts are a tight fit and may be left in position, ‘When replacing the pinions, first check chat the keys are located correctly, see Section B30, then screw the replacer adaptor 2144 into the assembler bolt and onto the camshaft. ‘The camshaft pinion should be lubricaced to assist assembly and the body Of the tool screwed onto it. When this Id cone, slide the pinion and body over the replacar bole, align the key and correct keyway and screw on the replacer mut and washer, and draw che camwheel fully home wich the replacer tool. Remove the tool and replace the exhause eamwhes! nut. NOTE: The camshaft nuts have a left hand thread and are stamped LH onthe outer face. ig, BIB, Extracting eamshat piolon using ‘service too3 REFITTING THE INTERMEDIATE WHEEL ~ Turn the camshaft and crankshaft “unt the timing marks are towards Incermediate wheel spindle, ‘cheh offer. the Wiieél to che splidle \7'shown In Fig. B30 and B31."Fourch sgear should then be salucted and ~ ‘the reir brake applied, s0' that #theicamshafe arid crankshafc pinion Having removed beth sparking plugs-and engaged TIMING THE ENGINE : he “top.geary rotate the rear-wheel forwards. unell the “(1) Remove :both sparking ‘plugs: and “all four: plstons.are:just coming:wup,towerds*T.D.C. “Then ** racker box capi.Set the engine’at T.D.C, with- - .-the, plunger ‘s-Inserted.in-the bedy of the too! and + both: valves’ closed: in the:right hand:eylinder, + »the-rear.wheel'is rotated forwards slowly until the (@)Assemble ithe iauto “névance”.unic."into:the + -:plungerslocates itself invthe centre flywheel. The exhaust camshaftlocating on-the‘eamshaft peg .~ T.D.C.%positien-has.now:been established, where it is fitced. @)- Assemble the C.B. plate, aking care not co trap the C.B. leads, assembling the ‘plate-s0" that the C.B. points connected ts the black/yellow leads are located 2t7 o'clock. Loosely assemble the hexagon pillar bolts and flat washers. (4) Lock the auto advance cam Into the taper, using the central fixing bole. NOTE: When the degree disc Is attached to che exhaust camshaft, rhe Indicated setting and advance range wilf be half that ofthe engine, as ‘the camshafe rotates at half engine speed. ESTABLISHING TOP DEAD CENTRE POSITION When- setting. the ignition timing, the T.D.C. position can-be' quickly found using workshop tool ae (D571/2. ‘The blanking-plug on top of the crankease AES eS eng TOC ornate IGNITION TIMING USING A STROBOSCOPIC LIGHT ‘After establishing T.D.C. as described in Section BO, NOTE: To advance the spark, open the fit the timing disc adaptor shaft and timing disc points, approximately 0-001 in. for into the camshaft auto advance unit and set the each engine degree required, and to polnter, fixed to a convenient bolt on the engine retard, close the points setting similarly. to rear T.D.C, Minor adjustments to the left cylinder C.B, points gap setting, to ensure accurate NOTE: When using a stroboscape powered ignition timing are permissible, by 6 or 12 volt batteries as an external power (3), Check back on the stroboscopic reading and source, do not use the machine's own battery slow tlckover for range of advance on both equipment. (A.C. pulses in the low tension cylinders, for efficient action of the autc machine wiring, can trigger the stroboscope, advance unit, remembaring the most imporeent and give false readings), final setting is at fully advanced, both cylinders. Timing the engine stroboscopicelly with a (1) Connect the scroboscope to the right hand timing dise ensures that both plugs are firing spark plug lead and stare the engine. Resd the at exactly similar angular erank rotation (i.e. strobe-light on the disc, revving the engine piston mavement), at fully advanced ignition, up until the auto advance range Is fully that ts at full power, thereby ensuring the achieved. Check agains: the correct specificr- stioothest, most vibration free engine running ton and adjust the C.B. back plate on its slots condition and ensuring maximum engine power untit the correct advanced thming is accurately output. set, Ie also eliminates variations encountered in sliffering auto advance ranges due to possible @) Repeat for LH. plug and adjust the accuracy of non-standard components, uneven wear, ete the sperk on the C.B, potnts adjustment. ec astENGINE”: SECTION B32 STATIC IGNITION TIMING—TO BE USED ONLY WHERE A STROBOSCOPE TO ESTABLISH THE ACCURATE STATIC IGNITION SETTING (1) “Check the General Data Section for the correct * fully advaricéd igniclon seteing for the machine. (Q) Check the'disto advance range stamped on rear _ bf auce adiahea tam mechantem @) Double the?duto advance range and subtract _ the figure (Pm the FULL ADVANCE setting for the machine., This is the correct STATIC SETTING forthe engine. (4) .Use chis figire for setting the pesition of the .B. points opening, when assembling che contsce breaker mechanism, using 2 degree plate or timing élse attached to the engine. (6) Convert this figure in degress to the equivalent plston movernenc B.¥.C. ifa ciming stick fs to be employed. On machines where an engine camshaft peg Is not fitted,’rotate the auto advance mechan- Ism until a position is reached where the rear set of C.B. points will just commence to open. CONVERSION CHART—ENGINE DEGREE TO RELATIVE PISTON POSITIONS Crankshoft position Piston position (8.1.0.C) (BTD.C) Degrees in, mm. r 10 5 8 O15 38 a 020 a 0 25 4 1" 030 % 2 035 9 a 040 +01 “ 048 12 15 055 440 16 060 152 7 970 178 18 080 203 1» 090 229 20 4100 254 2 110 279 EXAMPLE OF STATIC SETTING CALCULATION T1008S IGNITION TIMING=37* B.D. Fully advanced. B32 IS. NOT-AVAILABLE - CB. range stamped on auto advance tam=12". Twice 12°=24° Full advance 37°—24%=13* BIT.C. POSITIONING THE TIMING DISC WHERE ‘THERE IS NO PROVISION FOR THE T.D.C. PLUNGER (Earlier models) (1) Fit the timing disc adaptor shaft and timing disc Inco the camshaft auto advance enit, and set the pointer, fixed to a convenient bolt on the engine, to read T. Engage top gear, and se a timing stick with a suitable mark which aligns along the top of the eylinder head fins at about 1 in. of piston movement, (For greater accuracy, use a Dial Test Indicator through the spark plug hole). Rotate che engine either side of T.D.C. by rocking the rear wheel, to exac:ly the same measured point of movement on the stick (or D.T.l), sotting the pointer so that ie reads an equal number of degrees olther sida of T.D.C. on the degrée disc. timing dise and dlat Fig. B33, Engine feced ‘eat indicator= ENGINE (1) Rotate the engine so that the fibre heal of the C.B. points have just pasted beyond the ramp cof the auto advance cam, and Just reached the full open position. Set-the point gap 0015 in. Har Fig, B34(a), Setting the contact breaker point gap for tthe right cylinder (black/yellow) lead,_ illustrating potitfon of the eam where points are [ust fully open @) Rozace the engine "forwards" through 360° and set the second set of points in the corres- ponding position on the eam. Ser vhese polats ata gap of OOS in, @) ROTATE ENGINE AND ESTABLISH AC- CURATE T.D.C, (See Section B31 and fore going) pos @ u2b B2d{e). "satel 1ct brasker paint gap for the: Ninder (blackwhite) lead, ilustrating the second ilon of the eam, where the points Fave jest achieved ‘"thecfully open position Ifthe machine is put in top gear, small incre~ ments In erank rotation and piston movement ‘can be achieved by rotating the rear wheel slowly, and accurate plston T.D.C. established by “swinging” the engine either side of T.D.C. ‘Mark the timing stick at T.D.C. Mark a second position on the timing stick ABOVE che T.D.C. mark appropriate to the specified timing for the machine, Le. “piston movement before TOC. Rotate the engine "backwards" beyond this mark and then slowly reverse the rotation “forwards” until the timing mark ts set in line with the top of the cylinder head fins. Ifa timing dist Is employed, rotete the engine forwards until the correct “static setcing” is achieved in crankshafs degrees. 833(6) -Rotaté the C.B. back plate on its slots until « position Is reached where the points just open {check using a battery and light, or an 0.0015 in, fecler gauge. Alternatively, if a battery Is “fitted to the machine and the ignition switch turned to. “JGN", the position where the points open ‘can be Identified by the ammeter needle giving “flick” back to zero). 0-0015in. ~ 037mm Fig.B35(3). Contact breaker points ust oper HEHE cylinders With the engine set at el STATIC SETTING, ‘the C.B. back plate assembly should be adjusted In the stots, €o a position where the E:B. points just eommance te open B34 ENGINE 0-0015in. (0-037mm) Fig, BIS(t). Contact breaker points fuse opening on Con Nai cplinier | OPenIOE Rotate the engine chrough 360° and repeat (4) above, The other set of C.B points should Just have opened. If nor, the accuracy of spark fon the second sex of C.B points can be core rected by adjusting the points gap. NOTE: To advance the spark, open the points, approximately 0-001 in. for each engine degree required, and to retard, close the points setting similarly. Minor adjustments to left cylinder C.B. points setting to ensure accurate ignition timing are permissible.REMOVING -AND REPLACING THE CAMSHAFTS ONLY ie ismot necessary to part. the crankeases in order to --replace the-camshafes, Remove the cylinder block-and. heed (see Sectlons B13 and B18), “ Remove the timing cover (see Section B27).- Remove “the oll pump by. removal of: the two conieal wuts ‘and locking washers. “To avoid the .loss of, the, ‘engine oll, the necessary. holes in the crankease face. can.be blocked temporarily but ic is most essentia? that these holes are cleared before the oil pump is refitted ats later stage, Extract the Inlet and exhause - camwheels (see Section 829) and che camshaft retaining plates and screws will be seen, ‘The: retaining: place screws are centre punched to. Tock them. A small-érill should berused to remove - ENGINE ‘ SECTION B33 “ithe icentre :punch-tmarks: andthe “screws ican be +s extracted, followed by'the retaining, plates. ‘ Atithls.stage the tamshafts can be.drawn.out from ‘+ the right band side of the crankcases: ‘Care must be + ~taken.thatitha-breather'disc.and spring behind the 77 inlet camshaft aremot.dropped inte the engine.. ts Whieilthe Tiewicitnshatts are fitréd,splace the rotary ~+ breatherivalyesand:spring irto.the camshafe bush +. then assemble boch-camshafts"cnsuring that the slor-in the end of the inlet camshaft engages the projection of the breather cisc valve. The camshaft recalning ‘plates should be refiteed, preferably Using new screws, The screws should -be contre “sspunched and reassembly then’preceeds as reversal ‘of the foregoing. Fig. B36, Camwheols removed to show camshaft retaining plates B35.SECTI ION B34” DISMANTLING AND. REASSEMBLING THE CRANKCASE ASSEMBLY Fig. B37. Removing the eranltease junction screws Ie is advisable to partially dismantle the engine unit ‘whilst is feted to the motorcycle, then remove the remaining erankease sssembly and dismantle it on a work bench, Proceed as described in Section Bt for removal of the engine unit, but leave the rear chain connected and the engine firmly mounted in the frame by means of the front and bottom engine mounting bolts. Remove the outer primary cover as shown in Section C3 then disconnect che generator leads underneath the engine (snap connectors). Unscrew B36 the three nuts securing the stator and withdraw it from over the mounting studs. Do not ery to with> draw the leads at chis sage. Remove the pressure plate and clutch plates as derailed In Section C4. Select fourth gear and apply the rear brake, then unscrew the clutch hub securing nut and extract the clutch hub as shown in Section C9. When the primary chain has tbeon threaded over the stator the sleeve nut should be unscrewed and the stator leads withdrawn,ENGINE Remove the gearbox outer cover and dismantle the = gearbox, "(see Section D) remove thé rocker boxes, cylinder head, block and pistons as shown In Sections 2,813, B18.and B21 respectively, then disconnect the dutch cable and remove, the carburetter. Remove the ‘CB. ‘timing cover and oil purip (Gections .B26, B27 sand B28) then-extract, the crankshaft pinion, -f Ic Is required: to Inspect or change the .camshafts. or bushes, the “camshaft . inions should also be extracted, Remove.the front -and bottom engine. mounting studs, disconnect the rear chaln and remove the ‘crankcase assembly. Grip the crankcase firmly In a vice by means of the botcom mounting tug and unscrew the bole and two screws shown in Fig. B37.. Remove the remalning stud at che front of the-engine and also the two nuts adjacent to the gearbox housing. ‘The crankcase halves may now be parted using extractor toal aumber Z151. When che halves are apart, withdraw the crankshaft assembly and store it carefully, then remove the rotary breather valve from wichin the-inlee camshaft bush In the Jefe half crankcase. ting the crankcase halves REASSEMBLY ‘Prior to reassembly the junction surfaces should be arefully scraped clean, giving special attention to tha location-splget ané dowel. Moune-the:leftihalfserankease‘on its side‘on two wooden blocks;:or.a-bench with 2 hole in for crake ‘shaft. clearance, "lubricate the main :bearing and + eamshafe-bushes. "Place thesrorary breather valve and spring:Into"the camshaft bushy:then assemble sbothveamshafts-ensuring ‘that the slot In the end ~of the inlet camshaft engages the projection of the breather disc valve, Assemble the erankshafe carefully into position ensuring that I is right home In the bearing. Apply:a frash coat of jointing compound co the junction surface of the: left half crankcase then slubeicate::the-main’ bearing and camshaft bushes Jn both: halves of the:crankcase, Position the stlgne of Indentacion and-pocketing. 2 @))MAIN JOURNAL..BEARING (TIMING SIDE) - - ‘phe -correct:diameters ofthe main bearing ‘and:journal.are-given.In-GENERAL DATA. stable of segrindeisizes:for the right ‘main ~ : artbearing-journaland:big:end Journals ts glven bbelovyifor.which replacements are'avaiiable. ‘The ‘timing side plain bearing-can be checked for wear by holding the right end of the crank shaft and moving tt up and down. A more ‘accurate: method of determining wear on che bearingsis.to-attach-2 dial test Indicator to the ‘Intermediate gear “spindle, and locating ‘the pointer. onto.the’end of-che crankshaft: by ‘moving thecrankshaft up and down theamount ‘of wear will be:indicated onthe dial, Examine the-bearing ‘diameter on the crankshaft for wears which will:require. regrinding if tt has been scored In any way. (@) CAMSHAFT AND: BUSHES ‘The camshaft bushes normally show very Hele sign of wear until considerable mileage has been covered. A rough check on the wear can be made by inserting the camshaft into the bearing and feeling the up and down movement. ‘An exact check can be made by measuring the camshaft with a micrometer and measuring the camshaft bushes with eaiipars. The working clearance figures are given In GENERAL DATA. ‘Weer on the cam form will be mainly centred con the opening flank of the cam and on the lobe of the cam. Particular attention should be given to these areas when examining the cam form for grooving. In a case where there Is severe grooving both the camshaft and eappet followers should be renewed, ‘A method of estimating the extent of wear fon the cam form Is that of measuring the ‘overall kelght of the cam and the base circle diameter. The difference is the cam fife. IF all other aspects of the camshaft are satisfactory and the wesr on the cam form doer net exceed -010 in. then the eamshafe may be used for further service. Bat