Triumph THUNDERBIRD 1952 - Aligning the Front Fork

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Ai~gnlnx TC~LICO~IC

Fork

Fig.

41.

ALIGNING

THE

FRONT

FORK

104

Main Page

Introduction5
Service Arrangements6
Correspondence6
Orders6
Technical Advice6
Proprietary Fittings7
Speed Twin Technical Data8
Thunderbird Technical Data10
Ignition10
Carburetor10
Clutch11
Sprockets11
Chain11
Trophy Technical Data12
Tiger Technical Data14
Control Layout18
Left Hand18
Right Hand18
Controls - Instruments19
Speedometer19
Lighting Switch19
Horn Button19
Ignition Switch20
Ammeter20
Steering Damper20
Oil Pressure Indicator20
Adjustment of Controls and Riding Position21
Kickstarter21
Footrests21
Gearchange Lever21
Taking over the Machine22
Air Cable22
Magneto Cable22
Clutch Cable22
Petrol Tap Positions23
Starting the Engine24
Running-In25
Engine Lubrication System27
Lubrication Maintenance27
Engine27
Oil Tank29
Oil Pump29
Oil Release Valve and Indicator30
Oil Pipes30
Crankcase Scavenge Pipe30
Valve Rockers, Rocker Spindles and Push Rods30
Gearbox31
Primary Chaincase31
Cycle Parts31
Chains31
Changing the Oil32
Oil Tank Filter32
Crankcase Filter32
Routine Maintenance after Running-In Period33
The Engine35
Crankcase35
Flywheel and Crankshaft35
Cylinder Block35
Crankshaft Assembly36
Index37
Tappet Adjustment38
Adjusting the Tappets38
Decarbonising39
Rocker Adjuster Pin39
Dismantling40
Saddle40
Exhaust System40
Torque Strays40
Re-Assembly41
Cylinder Head41
Inlet Rocker Box41
Exhaust Rocker Box41
Removing the Engine from the Frame42
Petrol Tank42
Testing42
Twinseat43
Dynamo43
Control Cables43
Dismantling the Engine44
Oil Pressure Release Valve44
Engine in Vice44
Crankshaft and Camshaft Nuts45
Distributor Gear45
Magneto Gear45
Camwheels45
Removing the Camwheel46
Crankshaft Pinion46
Cylinder Head and Rocker Boxes46
Removing the Crankshaft Pinion47
Crankshaft Pinion Removal Tool47
Dismantling, Preparation and Assembly of the Engine Units48
Rocker Boxes48
Valves and Springs48
Removing Carbon from Cylinder Head49
Replacing the Valve Guides49
Re-Cutting the Valve Seats49
Assembling the Cylinder Head49
Assembling the Tappet Block50
Recommended Rebore Oversizes51
Tappets51
Tappet Blocks51
Pistons51
Taper Faced Piston Ring Position52
Chrome Taper Faced Ring Position52
Valve Push Rods and Cover Tubes53
Crankcase Unit53
Main Bearing53
Scavenge Pipe53
Refitting the Main Bearings54
Timing Cover54
Timing Gears54
Inspection and Identification55
Checking Connecting Rod Bolt Stretch56
Assembling the Engine57
Crankcase, Driving Side57
Camshaft57
Sump Filter57
Valve Timing60
Magneto60
Timing Diagrams60
Installing the Engine63
Positioning the Contact Breaker70
Final Operation70
Sparking Plug Leads70
Replacing the Distributor and Driving Pinion70
Timing71
Setting the Contact Breaker Points71
Piston Positioning71
Correct Positioning of the Distributor72
Check the Timing72
Faulty Gear Selection73
Quadrant Plunger Sticking73
Camplate Plunger Sticking73
Component Parts74
Removing the Gearbox from the Frame76
Dismantling the Gearbox78
Gearbox Outler Cover78
Gearbox Inner Cover78
Gear Cluster78
Gearbox Outer Cover79
Kickstart Assembly79
Clutch Operating Lever79
Gearchange Mechanism79
Gear Operating Quadrant80
Bearing80
Speedometer Drive80
Gearbox Casing80
High Gear81
Replacing the Chain Sprocket and Nut81
Gearbox Casing in Vice81
Assembling the Gearbox82
Mainshaft Gears82
Layshaft Gears82
Installing the Gearbox83
Rear Chain83
Cables83
Primary Chaincase Inner Cover83
Pivot Bolt84
Rear Engine Plates84
Oil Tank and Air Cleaner Unit84
Clutch and Shock Absorber Unit85
Replacement of the Cork Inserts85
Overhaulting the Clutch Dismantling85
Removal of Clutch Nuts87
Clutch Plates88
Engine Mainshaft Nut88
Brake Pedal88
Removing the Shock Absorber Rubbers89
Replacing New Shock Absorber Rubbers89
Outer Retaining Plate89
Clutch to Mainshaft Nut90
Clutch Housing91
Clutch Hub91
Clutch Locking Tool91
Drive Shaft Adaptor91
Preparation and Inspection92
Clutch Springs92
Cork Plates92
Steel Plates92
Engine Sprocket93
Outer Pressure Plate93
Clutch Cable Adjustment93
Chaincase Outer Cover93
Tachometer Drive94
Tension94
Gearbox Clamp Bolt94
Adjuster94
Rear Chain Adjustment95
Gearbox in Position95
Adjusters95
Securing Wheels95
Primary Chain Adjustment96
Gearbox Pivot Bolt96
Securing Gearbox96
Wheel Nut97
Wheel Securing97
Chain Maintenance97
Cleaning and Greasing the Rear Chain97
Alterations and Repairs98
Maintenance100
Draining100
Re-Filling100
Adjusting the Steering Head Races100
Removing the Fork from the Frame101
Testing the Adjustment of the Steering Head Races101
Handlebar101
Stanchion Cap Nuts101
Telescopic Fork102
Dismantling the Fork104
Dismantling the Pressure Tube Assembly104
Top Lug104
Middle Lug Pinch Bolts104
Dismantling, Preparation and Assembly of Units105
Bottom Cover Tubes105
Springs105
Pressure Tube Assembly105
Aligning the Front Fork106
Alignment107
Assembling and Installing the Fork107
Drain Plugs107
Steering Races107
Assembling the Fork108
Nacelle Top Unit108
Headlamp Assembly108
Mudguard108
Changing the Main Springs109
Cap Nut109
Fork Crown Pinch Bolt109
Headlamp109
Wheels110
Adjusting the Brakes110
Front Brake110
Rear Brake110
Front Wheel111
Removing the Front Wheel from the Forks111
Dismantling the Front Wheel111
Spindle Nut111
To Dismantle the Front Brake Anchor Plate113
Inspection and Replacement of Worn Parts113
Washing113
Brake Drum113
To Assemble the Front Brake Anchor Plate115
Brake Cam115
Brake Shoes115
Assembling the Front Wheel116
Fitting the Front Wheel to the Front Fork116
Spindle116
Anchor Plate116
Correct Alignment of Front Wheel in Forks117
Rear Wheel118
Rigid Frame118
Removing the Rear Wheel from the Frame118
Dismantling the Rear Wheel120
Dismantling the Rear Brake Anchor Plate120
Roller Races120
Return Springs120
Assembling the Rear Brake Anchor Plate121
Assembling the Rear Wheel121
Brake Operating Spindle and Cam121
Bearing Backing Ring121
Fitting the Rear Wheel to the Frame122
Anchor Plate Assembly122
Chain Adjuster Thrust Collar and Spindle Nut122
Positioning the Wheel122
Final Bearing Adjustment123
Brake123
Road Test123
Brake Torque Stay123
Removal of Brake Drum and Sprocket130
Dismantling the Brake and Drum Sprocket Assembly130
Dismantling the Anchor Plate Assembly130
Brake Drum Bearing131
Sleeves131
Felt Washer131
Assembling the Q.D. Rear Wheel132
Dust Covers132
Locking Nuts132
Spring Wheel133
Removal of the Wheel from the Frame133
Rear Spring Wheel135
Brake Anchor Plate136
Slipper Roller136
End Plate136
Aluminium Shims136
Plunger Guide Box Assembly137
Brake Drum and Sprocket137
End Plate Bearing137
Dismantling the Plunger Guide Box Assembly138
Plunger Guide Box138
Slipper Pads138
Roller and Slipper Pads138
Brake Cam Spindle139
Casings139
Re-Fitting the Wheel to the Frame140
Large Cast Iron Ring140
Brake Anchor Plate Assembly140
Dust Excluder Assembly140
Tyres141
Tyre Pressure141
Dunlop Recommended Tyre Pressures141
Examination141
Fitting the Tyre142
Removing the First Bead142
Inner Tube142
Removing the Second Bead142
First Bead143
Second Bead143
Valve143
Security Bolt143
Frame144
Swinging Fork144
Girling Suspension Damper Units144
Girling Hydraulic Suspension Unit145
To Increase the Static Spring Rate146
Changing the Springs146
Maximum Movement146
Twistgrip Control147
Cable Thimble147
Rotor Sleeve147
Head147
Grub Screw149
Rotor Sleeve Stop149
Petrol Tap Adjustment150
Push-Pull Type150
Taper Type150
Fitting a Sidecar150
Cleaning Motorcycle151
Amal Carburetor152
Operation of Carburetor Parts152
Throttle Stop Screw152
Pilot Air Screw152
Swinging Arm Frame154
Air Filter154
Defects in Operation159
Check for Air Leaks159
Sticking of Piston159
Bent Needle or Incorrectly Centred Jet160
Eccentricity160
Flooding from Float Chamber or Mouth of Jet161
Leakage from Bottom of Jet161
Hints and Tips161
The Float Chamber161
Plastic Cap162
Piston Spring162
Lucas Electrical Equipment163
Lighting and Magneto Ignition163
Ammeter Readings163
Inspection of Brushgear and Commutator163
Wiring Diagram164
Adjustment of Contact Breaker Setting166
Cleaning Contacts166
Removal of Contacts for Cleaning166
High Tension Pick-Up166
Circuit Details167
Emergency Starting167
Primary Chaincase Cover Removed to Show Rotor and Stator168
Rating170
The Alternator170
Ignition Coil171
Contact Breaker Unit171
Contact Breaker Setting172
High Tension172
Engine will Not Start173
No Spark at Plugs173
Distributor, Coil or Condenser Faulty173
Lamps174
Engine Runs with Swtich on174
Headlamps Fitted to the TRS Models174
Replacing the Headlamp Bulb174
Setting the Headlamp Beam175
Trs175
Headlamp and Top Nacelle Unit176
Parking Lamp176
Rear Lamp176
Retaining Ring176
Battery177
Horn177
Lighting and Ignition Switch177
Checking the Condition of the Battery178
Taking Hydrometer Readings178
Detachable Cable Connectors179
Battery Earth179
Electric Horns179
Sparking Plugs180
Ash White181
Dull Black181
Light Brown181
Toolkit182
Supplementary184
Cylinder Head Bolts185
Fault Finding and Maintenance187
Special Insrtuctions187
Crankcase Assembly188
To Assemble the 3T Crankshaft189
Exploded View of Top Portion192
Lubrication of Parts194
Lubrication Chart200
Recommended Lubricants202
Overseas203
Fault Finding204
Engine Stops205
Engine Misfires205
Loss of Power206
Engine Overheats206
Engine Revolutions Per Minute207
Gear Ratios207
Illustrated Index208
Index of Contents211

Triumph THUNDERBIRD 1952 - Aligning the Front Fork

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