Triumph Trident T150R - Removing and Replacing the Chainwheel and Engine Sprocket

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Engine and Frame Numbers3
Factory Service Arrangements4
Replacement Parts4
Repairs4
Service Exchange Reconditioned Units4
Contents7
General Data9
Gearbox12
Frame and Attachment Details14
Wheels, Brakes and Tyres14
Front Forks14
Lubrication System17
Routine Maintenance18
Guide to Lubrication Points19
Engine Lubrication Diagram20
Recommended Lubricants21
Approved Lubricants21
Engine Lubrication System22
Changing the Engine Oil and Cleaning the Filters22
Crankcase Sump Filter22
Tappet Oil Feed from Central Main Bearings23
Tappet Oil Feed through Cylinder Block23
Oil Pressure24
Underside View of Engine/Gearbox Unit24
Stripping and Reassembling the Oil Pressure Release Valve25
Exploded Oil Pressure Release Valve25
Removing and Replacing the Oil Pump26
Removing and Refitting the Oil Cooler26
Exploded Oil Pump26
Removing and Replacing the Rocker Oil Feed Pipe27
Oil Cooler Mountings27
Anti-Drain Valve28
Contact Breaker Lubrication28
Gearbox Lubrication29
Primary Chaincase Lubrication29
Rear Chain Lubrication and Maintenance30
Section through the Primary Chaincase30
Greasing the Steering Head Ball Races31
Wheel Bearing Lubrication31
Rear Chain Oil Feed Adjustment31
Telescopic Fork Lubrication32
Lubrication Nipples32
Swinging Fork Pivot32
Swinging Fork Pivot Lubrication Nipple32
Lubricating the Control Cables33
Speedometer and Tachometer Cable Lubrication33
Brake Pedal Spindle Lubrication33
Engine34
Exploded View of 750 C.C. Engine/Gearbox Unit35
Description36
Removing and Replacing the Engine Unit37
Location of Engine Lifting Bars38
Removing and Replacing Rocker Boxes39
Inspecting the Pushrods40
Stripping and Reassembling the Rocker Boxes41
Refitting Rocker Spindle Using Service Tool D222141
Inlet42
Exhaust42
Adjusting the Valve Rocker Clearances43
Position of Camshaft for Valve Setting43
Removing and Replacing the Air Cleaner44
Carburetor Description44
Exploded View of Carburetor45
Removing and Replacing the Carburetors46
Inlet Manifold Assembly46
Stripping and Reassembling the Carburetors47
Inspecting the Carburetor Components47
Resetting the Carburetors48
Synchronizing the Throttle Slides48
Removing and Refitting the Cylinder Head Assembly49
Cylinder Head Bolt Tightening Sequence49
Removing and Refitting the Valves50
Renewing the Valve Guides50
Valve Components50
Decarbonizing51
Re-Seating the Valves51
Valve Seating Tools52
Cutting a Valve Seat52
Removing and Replacing the Cylinder Block and Tappets53
Protecting the Con. Rods53
Position of Cam Followers53
Inspecting the Cam Followers54
Inspecting the Tappet Guide Blocks54
Removing and Refitting the Pistons55
Removing and Replacing the Piston Rings56
Inspecting the Pistons and Cylinder Bores56
Refitting a Tapered Piston Ring56
Table of Suitable Rebore Sizes57
Removing and Replacing the Contact Breaker57
Cylinder Bores57
Adjusting the Contact Breaker Points58
Contact Breakers, 7CA58
Re-Setting the Ignition Timing59
Static Timing59
Showing Location Tool in Use59
Locking the Auto Advance Mechanism59
Ignition Timing Using a Stroboscope60
Removing and Refitting the Timing Cover60
Timing Mark on the Rotor60
Extracting and Refitting the Valve Timing Pinions61
Position of Screws61
Camshaft Pinions62
Crankshaft Pinion62
Extracting Camshaft Pinion Using D221362
Refitting the Camshaft Pinions62
Valve Timing63
Extracting the Crankshaft Pinion63
To Dismantle and Reassemble the Crankcase64
Crankcase Reassembly65
Location of Right Side Crankcase Section65
Location of Left Side Crankcase Section65
Servicing the Crankshaft66
Cleaning the Crankcase Oilways66
Refitting the Connecting Rods67
Crankshaft Oilways67
Refitting a Connecting Rod67
Checking the Bolt Extension67
Inspecting the Crankcase Components68
Big-End & Centre Main Bearings68
Main Bearings68
Camshafts68
Renewing the Main Bearings69
Crankcase Faces and Dowels69
Removing a Bearing69
Removing a Circlip69
Transmission71
Clutch Description72
Clutch Maintenance72
Exploded View of Clutch72
Adjusting the Clutch Operating Mechanism73
Adjusting the Primary Chain Tension73
Showing Clutch Adjustment73
Primary Chain Adjustment73
To Remove and Replace the Outer Primary Chaincase Cover74
Refitting the Clutch Cover75
Stripping the Primary Transmission75
Reassembling the Primary Transmission76
Primary Chain Alignment77
Shock Absorber Modifications77
Measuring Shock Absorber End Float77
Setting the Shock Absorber to the Normal Running Position78
Checking and Correcting Alignment78
Location of Service Tool78
Refitting the Inner Primary Chaincase80
Renewing Shock Absorber Rubbers81
Removing and Replacing the Chainwheel and Engine Sprocket83
Inspection of Transmission Components84
Rear Chain Alterations and Repairs85
Sequence of Gearchanging88
Gear Selection Components88
Second Gear89
Removing and Replacing the Gearbox Outer Cover Assembly90
Third Gear90
Fourth Gear90
Dismantling and Reassembling the Kickstart Mechanism91
Dismantling and Reassembling the Gearchange Mechanism92
Inspecting the Gearchange and Kickstart Components92
Renewing Kickstart and Gearchange Spindle Bushes93
Dismantling the Gearbox93
Gear Inner Cover Retaining Screws94
Inspection of the Gearbox Components95
Renewing Mainshaft and Layshaft Bearings95
Mainshaft High Gear Bush96
Layshaft96
High Gear Bearing Oil Seal and Housing96
Sketch of Needle Roller and Drift96
Reassembling the Gearbox97
Changing the Gearbox Sprocket99
Five Speed Gearbox100
Plan of Gear Components101
Removing and Replacing the Fuel Tank117
Removing and Replacing the Side Panels117
Removing and Replacing the Oil Tank117
Removing and Replacing the Battery Carrier118
Battery Carrier Mounting118
Removing and Refitting the Rear Mudguard119
Adjusting the Rear Suspension119
Removing and Refitting the Rear Suspension Units120
Stripping and Reassembling the Suspension Units120
Exploded View of the Rear Suspension Unit121
Removing and Refitting the Swinging Fork122
Swinging Fork Grease Nipple122
Renewing the Swinging Fork Bushes123
Exploded View of Swinging Fork Assembly123
Removing a Swinging Fork Bush123
Removing and Replacing the Rear Frame124
Frame Alignment125
Front Frame125
Checking the Front Frame Alignment126
Rear Frame127
Frame Assembly127
Basic Dimension of the Frame Assembly127
Swing Fork128
Checking the Swinging Fork128
Fairing Attachment Lugs and Steering Lock129
Fitting Replacement Seat Covers129
Removal of Dents130
Tools Used for Panel Repairs130
Removing a Dent with a Dolly Block and Spoon130
Paintwork Refinishing131
Paint Stripping131
Undercoat131
Priming131
Polishing132
Removing and Refitting the Front Wheel134
Removing and Refitting the Front Wheel Bearings134
Exploded View of Front Wheel Bearing Arrangement134
Stripping and Reassembling the Front Brake135
Removing Brake Shoes135
Stripping and Reassembling the Rear Brake136
Rear Wheel Removal and Replacement137
Position of Brake Shoes137
Removing and Replacing the Rear Wheel Bearings138
Wheel Bearing Drift138
Drifting the Wheel Bearings138
Brake Adjustment139
Exploded View of Rear Wheel Assembly139
Removing and Replacing the Front Brake Cable140
Renewing Brake Linings140
Front Brake Cable140
Correct Replacement of Cable Abutment140
Wheel Balancing141
Chiselling off Brake Rivets141
Punching Lining Rivets141
Front and Rear Wheel Alignment142
Aligning the Front and Rear Wheels142
Wheel Building143
Rear Chain Adjustment143
Rear Chain143
Removing and Repairing Tyres144
Refitting the Tyre144
Security Bolts145
Tyre Maintenance146
Braking Performance Data147
Telescopic Forks149
Steering Head Adjustment150
Renewing Head Bearings151
Stripping and Reassembling the Fork Legs151
Assembly of Bleed Valve152
Removing the Oil Seal from the Fork Leg153
Replacing the Oil Seal153
Fork Assembly Detail S154
Sectional View of Assembled Fork Leg155
Fork Alignment156
Fork Leg Alignment156
Hydraulic Damping157
Electrical System158
Battery Inspection and Maintenance159
Exploded View of Battery159
Specific Gravity of Electrolyte for Filling the Battery160
Maximum Permissable Electrolyte Temperature During Charge160
Capacitor Pack161
Coil Ignition System161
Checking the Low Tension for Continuity162
Fault Finding in the Low Tension Circuit162
Ignition Coils163
Bench Testing the Ignition Coil163
Contact Breaker163
Checking the High Tension Circuit164
Contact Breaker Assembly Type 7CA164
Sparking Plugs165
Sparking Plug Diagnosis165
Charging System166
Schematic Diagram of 12 Volt Charging Circuit with Zener Diode166
Checking the D.C. Output at the Rectifier167
Checking the Alternator Output167
Rectifier Maintenance and Testing167
Testing the Rectifier168
Bench Testing the Rectifier168
Checking the Charging Circuit for Continuity169
Constructing a One-Ohm Load Resistor169
Checking Forward Resistance169
Checking Back Leakage169
Zener Diode Charge Control170
Showing Ammeter and Voltmeter Connections for Test Purposes171
Zener Diode Location172
Electric Horns172
Horn Relay Showing Terminals172
Headlamp173
Horn Adjustment173
Beam Adjustments173
Removing and Refitting the Headlamp174
Tail and Stop Lamp Unit174
Fuses174
Exploded View of Fuseholder Assembly174
Ignition Switch175
Flasher Lamps175
Removing and Refitting Front Flasher Lamps175
Removing and Refitting Rear Flasher Lamps175
Warning Lamps176
Stop Lamp Switches176
Oil Pressure Switch176
Capacitor Ignition Alternative System177
Identification of Capacitor Terminals177
Storage Life of Model 2MC Capacitor177
Capacitor and Spring177
Wiring and Installation178
Service Notes178
Wiring Diagram179
Workshop Service Tools180
Inches to Millimetres - Units190
Decimals to Millimetres - Fractions190
Fractions to Decimals and Millimetres191
Millimetres to Inches - Units192
Millimetres to Inches - Fractions192
Drill Sizes193
Wire Gauges193
Foot Pounds to Kilogrametres194
Miles to Kilometres194
Pounds to Kilograms194
Miels Per Gallon to Litres Per 100 Kilometres194
Pints to Litres195
Gallons to Litres195
U.N.E.F. Screw Threads196
B.A. Screw Threads196
B.S.W. Screw Threads197
B.S.F. Screw Threads197
U.N.C. Screw Threads197
U.N.F. Screw Threads197

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Triumph Trident T150R - Removing and Replacing the Chainwheel and Engine Sprocket

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