Triumph T595 Daytona - Service Manual

Triumph T595 Daytona

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T595 DAYTONA

T509 SPEED TRIPLE

DAYTONA 955i

SPEED TRIPLE (955cc)

Table of Contents

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

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