Triumph Daytona 955i 2002 - Rear Suspension - Single Sided Swinging Arm Versions

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Contents2
General Information3
Service Tools and Garage Equipment5
Special Service Tools5
Full Specification8
Torque Wrench Settings15
Maintenance20
Cylinder Head22
Cylinder Head and Valves Exploded View23
Cam Cover Exploded View24
Camshaft and Camshaft Drive Exploded View25
Cylinder Head Description26
Cam Cover Removal26
Cam Cover Installation27
Cam Cover Bolt Release Sequence27
Cam Chain Tensioner Removal29
Camshaft to Cylinder Head Alignment Marks29
Cam Chain Tensioner Installation30
Tensioner Plunger Set-Up30
Cam Chain Removal31
Cam Chain Inspection32
Cam Chain Installation33
Camshafts Removal33
Cam Ladder Bolt Release Sequence34
Camshaft and Bearing Cap Inspection34
Outrigger Journal Diameter35
Standard Journal Diameters35
Measuring the Compressed Plastigage35
Camshaft Journal Clearance Outrigger35
Camshafts Installation36
Cam-Cap and Ladder Bolt Tightening Sequence36
Valve Clearances38
Valve Clearance Measurement38
Typical Valve Clearance Chart38
Valve Clearance Adjustment39
Clearance too Small39
Clearance too Large39
Cylinder Head Removal40
Clutch48
Exploded View - Clutch Cover49
Exploded View - Clutch Assembly50
Exploded View - Clutch Controls51
Clutch Cable Removal52
Clutch Disassembly53
Friction Plate Inspection55
Bend/Warp56
Assembly56
Belleville Washer "Out" Mark57
Balancer59
Exploded View - Balancer Shaft60
Balancer Removal61
Balancer Inspection62
Balancer Assembly/Installation62
Crankshaft, Rods and Pistons65
Crankshaft, Connecting Rod, Piston and Liner Exploded View66
Exploded View - Crankcase67
Engine Removal/Refit68
Engine Installation71
Crankcases Disassembly75
Upper Crankcase Bolt Release Sequence75
Lower Crankcase Bolt Release Sequence75
Crankcases Assembly76
Selector Forks76
Crankshaft Removal78
Crankshaft Installation78
Connecting Rods Removal80
Connecting Rods Installation81
Connecting Rod Big End Bearing Selection/Crankpin Wear Check83
Checking the Measured Clearance83
Connecting Rod Bearing Selection84
Crankshaft Main Bearing/Journal Wear85
Pistons Disassembly86
Removing the Gudgeon Pin Circlip86
Piston Wear Check86
Piston Rings/Ring Grooves86
Piston Ring to Ring Groove Clearance Check87
Aligning Piston Rings Using the Piston87
Piston Assembly87
Piston Ring Identification87
Cylinder Wear88
Test Positions for Bore Wear Check88
Cylinder Liners Removal89
Cylinder Liners Paint Mark89
Cylinder Liners Installation90
Transmission91
Exploded View, Input and Output Shafts92
Exploded View, Sprag Clutch and Starter Gears93
Exploded View, Gear Selectors and Drum94
Exploded View, Gear Change Mechanism95
Selector Shaft, Selector Forks & Drum Removal96
Selector Drum Removal97
Selector Drum Inspection98
Selector Fork to Groove Clearance98
Selector Drum Installation98
Locating the Selector Drum98
Input and Output Shafts Assemblies Removal101
Input and Output Shafts Assemblies Installation101
Input Shaft Disassembly102
Input Shaft Assembly103
Pressing on the Input Shaft Bearing103
Output Shaft Disassembly104
Output Shaft Assembly105
Starter Drive Gears/Sprag Clutch Removal106
Starter Drive Gears/Sprag Clutch Inspection107
Starter Drive Gears/Sprag Clutch Installation108
Lubrication System109
Exploded View - Sump110
Exploded View - Oil Pump and Gears111
Exploded View - Daytona Oil Cooler112
Exploded View - Speed Triple Oil Cooler113
Engine Oil Circuitr - Daytona114
Engine Oil Circuit Description115
Daytona115
Engine Oil Circuit - Speed Triple116
Speed Triple117
Engine Oil Specification118
Triumph Engine Oil118
Oil Level Inspection119
Oil and Oil Filter Change119
Disposal of Used Engine Oil120
Oil Pump Removal121
Oil Pump Inspection121
Oil Pump Installation122
Low Oil Pressure Warning Light Switch123
Sump Removal124
Sump Inspection125
Sump Installation125
Oil Cooler - Daytona Removal126
Oil Cooler - Daytona Inspection126
Oil Cooler - Daytona Installation126
Oil Cooler - Speed Triple Removal127
Oil Cooler - Speed Triple Inspection127
Oil Cooler - Speed Triple Installation127
Fuel System/Engine Management128
Exploded View - Fuel Tank and Pump130
Exploded View - Fuel Rail, Throttle and Injectors131
Exploded View - Secondary Air Injection Valves and Controls132
Exploded View - Exhaust System133
Fuel Requirements134
Oxygenated Gasoline134
Methanol134
Ethanol134
Calculated Load135
Catalyst135
Coolant Temperature Sensor135
Idle Fuel Trim135
Long Term Fuel Trim136
Neutral Switch Status136
Off Idle Fuel Trim136
Short Term Fuel Trim136
Engine Management System Description137
Engine Management System Sensors137
Engine Management System Sensor Locations138
Engine Management System Actuators139
Engine Management System Actuator Locations140
Key to Wiring Circuit Diagram141
Key to Wiring Colour Codes141
Circuit Diagram - Engine Management System142
System Diagnosis143
On-Board Fault Detection System143
Triumph Diagnostic Tool143
Current Data144
Freeze-Frame Data144
Function Tests144
Adjustments144
Diagnostic Trouble Codes145
Sensor Data148
Service Diagnostic Tool148
Typical Screen Showing Symbols Examples149
Tool Keys149
Return Key149
Validation Key149
Connection and Power-Up155
Select Language155
Triumph Motorcycles156
Switch on Bike Ignition156
Data Link Fault Retry?157
Service Data - Dealer157
Service Data - Date158
Main Menu158
Diagnostics159
Stop Engine160
Stored DTCS161
Three Options Are Now Available161
Freeze Frame162
Stored DTCS, Erase All DTC Data163
To Select 'Function Tests' from the Main Menu163
To Select 'Checks/Adjustments' from the Main Menu168
Checks169
Build Data169
To Access the "Adjustments" Menu170
Adjust Tune171
Adjust Tune (Closed Throttle Position)172
Adjust Tune (Set Adaptive Stepper Position)172
Adjust Tune (Set Long Term Fuel Trim)173
Update Tune173
Update Tune (Confirm Selected)176
Restarting Tune Download176
Electrical Components177
Before Disconnection177
When Disconnecting a Connector177
When Inspecting a Connector177
Engine Control Module178
Removal of ECM Connectors178
Refitting of ECM Connectors178
ECM Connector Pin Numbering179
Further Diagnosis179
Fault Finding - Non Electrical203
Fuel System Adaption204
Fuel Tank Removal205
Fuel Tank Installation206
Fuel Pump Removal207
Fuel Pump Assembly207
Fuel Filter Removal208
Fuel Filter Assembly208
Fuel Pressure Regulator209
Fuel Pressure Checking209
Fuel Delivery System210
Airbox Removal211
Airbox Inspection211
Airbox Installation212
Air Filter Element Removal212
Air Filter Element Installation213
Intake Air Temperature Sensor Removal213
Intake Air Temperature Sensor Assembly213
Crankshaft Position Sensor Removal214
Crankshaft Position Sensor Installation214
Throttle Cable Adjustment215
Throttle Cable Removal216
Throttle Cable Installation217
Throttle Bodies/Injectors Removal218
Throttle Bodies/Injectors Inspection219
Throttle Bodies/Injectors Installation219
Throttle Body Balancing221
Throttle Position Sensor Removal222
Throttle Position Sensor Installation222
Exhaust System Removal223
Exhaust System Assembly225
Secondary Air Injection226
System Purpose and Operation226
Secondary Air Injection Solenoid Valve Removal227
Secondary Air Injection Solenoid Valve Installation227
Secondary Air Injection Reed Valves Removal228
Secondary Air Injection Reed Valves Inspection229
Secondary Air Injection Reed Valves Installation229
Evaporative Emissions Control System230
Evaporative Control System - Engine off231
Evaporative Control System - Engine Running232
Cooling System233
Exploded View - Cooling System234
Coolant235
Radiator Hoses235
Radiator and Cooling Fan235
Coolant Level Inspection236
Coolant Replacement236
Drainage236
Water Pump Removal238
Water Pump Inspection238
Water Pump Installation238
Coolant Pressure Cap Inspection239
Thermostat Removal240
Thermostat Inspection240
Thermostat Installation240
Radiator Removal242
Radiator Inspection243
Radiator Installation243
Rear Suspension - Twin Sided Swinging Arm Versions244
Exploded View - Swinging Arm245
Exploded View - Rear Wheel and Final Drive246
Exploded View - Drag and Drop Links247
Exploded View - Rear Suspension Unit248
Drive Chain Lubrication249
Chain Adjustment250
Chain Wear Inspection251
Rear Suspension Unit Removal252
Rear Suspension Unit Inspection253
Rear Suspension Unit Installation253
Drag Link Removal254
Drag Link Installation255
Drop Links Removal255
Drop Links Inspection256
Drop Links Installation256
Swinging Arm/Drive Chain Removal257
Swinging Arm/Drive Chain Inspection258
Swinging Arm/Drive Chain Installation259
Final Drive Removal260
Final Drive Inspection260
Final Drive Installation260
Rear Suspension - Single Sided Switching Arm Versions261
Exploded View - Single Sided Swinging Arm262
Exploded View - Single Sided Swinging Arm Rear Hub263
Exploded View - Rear Suspension Units264
Exploded View - Single Sided Swinging Arm Drop/Drag Link265
Final Drive/Rear Hub and Bearings Removal280
Final Drive/Rear Hub and Bearings Inspection282
Final Drive/Rear Hub and Bearings Assembly282
Final Drive/Rear Hub and Bearings Installation282
Staking the Nut283
Front Suspension284
Exploded View - Front Fork285
Exploded View - Low Handlebars286
Exploded View - Tall Handlebars287
Fork Inspection288
Fork Oil Change288
Fork Oil Level Chart290
Fork Pull through290
Fork Oil Level290
Front Fork Removal291
Front Fork Installation291
Fork Dismantling/Assembly292
Preload Adjuster Marks292
Fork Assembly294
Headstock Bearing Check/Adjustment295
Checking Headstock Bearing Adjustment295
Braking System297
Exploded View - Front Brake Master Cylinder299
Exploded View - Front Brake Caliper300
Exploded View - Rear Brake Master Cylinders301
Exploded View - Rear Brake Caliper302
Braking System Maintenance Safety Precautions304
Fluid Level Inspection305
Changing Brake Fluid305
Brake Pads305
Brake Wear Inspection305
Bleeding the Front Brakes, Renewing Brake Fluid306
Front Brake Pads Removal307
Front Brake Pads Installation308
Front Brake Caliper Removal308
Front Brake Caliper Disassembly309
Front Brake Caliper Inspection309
Front Brake Caliper Assembly309
Front Brake Caliper Installation309
Front Discs Wear310
Front Discs Removal310
Front Discs Installation311
Front Brake Master Cylinder Removal311
Bleeding the Rear Brakes, Renewing Brake Fluid313
Rear Brake Pads Removal315
Single Sided Swinging Arm Versions315
Rear Brake Pads Installation315
Rear Brake Caliper Removal316
Rear Brake Caliper Disassembly316
Rear Brake Caliper Inspection317
Rear Brake Caliper Assembly317
Rear Brake Caliper Installation317
Tyres326
Exploded View - Front Wheel327
Tyres Wheel Marking330
Tyre Marking330
Tyre Pressures330
Tyre Wear/Wheel Inspection331
Minimum Recommended Tread Depth331
Important Tyre Information332
Front Wheel Removal333
Front Wheel Installation334
Rear Wheel Removal335
Rear Wheel Installation335
Bodywork & Frame338
Exploded View - Frame339
Exploded View - Seat Rails340
Exploded View - Cockpit and Mountings341
Exploded View - Rear Panels342
Exploded View - Footrests and Mountings344
Frame, Footrests and Fixings Inspection345
Seat Removal345
Seat Refit346
Side Panel Removal346
Side Panel Installation346
Lower Fairings Removal347
Lower Fairings Installation347
Cockpit Removal348
Cockpit Installation348
Electrical System349
Exploded View - Instruments350
Exploded View - Daytona Headlight351
Exploded View - Speed Triple Headlight353
Exploded View - Rear Light and Indicators354
Exploded View - Alternator and Starter355
Battery Removal356
Battery Refit356
Battery Commissioning and Charging357
New Battery357
Table of Charging Times357
Battery Already in Service357
Fuses358
Relay Identification358
Fuse Identification358
Instrument Pack Removal359
Instrument Pack Installation359
Headlights - Daytona 955I360
Headlight Bulb Replacement361
Position Lamp Bulb Replacement361
Headlights - Speed Triple362
Rear Light364
Indicator Light364
Licence Plate Light364
Starter Motor Removal365
Starter Motor Inspection365
Starter Motor Installation365
Alternator Removal366
Alternator Assembly367
Alternator Rectifier367
Lighting Circuit Diagram - Daytona368
Starting and Charging Circuit Diagram373
Auxiliary Circuit Diagram375
Alphabetical Index377

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Triumph Daytona 955i 2002 - Rear Suspension - Single Sided Swinging Arm Versions

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