Triumph Trident T160 - TRANSMISSION (J2); WHEELS (J3); FRONT FORKS (J4)

Triumph Trident T160

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J

SERVICE

TOOLS

TRANSMISSION

(CONTINUED)

61-7011

Bottomgearflxture

(for

5

speed

left footshift gearboxes)

61

-6061

Gearbox sprocket nut box spanner

J6

SECTION

J3

WHEELS

61-3694

Wheel

bearing retainer peg spanner

(61-7024)

SECTION

J4

FRONT

FORKS

Fork

damper

valve

removal tool

No.

61

-6113

ClassicBike.biz

Table of Contents

Acknowledgements9
Contents10
General Data13
Primary Drive and Gearshift15
Transmission15
Table of Contents20
Lubrication System20
Routine Lubrication21
- Factory Recommended Lubricants24
- The Sump Filter25
Engine Lubrication System25
Changing the Engine Oil and Cleaning the Oil Filters25
- The Oil Tank26
- The Full Flow Filter26
- Transmission Drain and Filter Plugs26
The Oil Pressure Release Valve27
The Oil Pump28
Removing and Replacing the Oil Pump28
Removing and Replacing the Rocker Oil Feed Pipes29
Removing and Replacing the Rocker Oil Feed Pipe29
Anti-Drain Valve30
Contact Breaker Lubrication30
Transmission (Gearbox) Lubrication31
Primary Chaincase Lubrication31
Rear Chain Lubrication and Maintenance32
Greasing the Steering Head Races32
Wheel Bearing Lubrication33
Telescopic Fork Lubrication33
Lubrication Nipples33
- Speedometer and Tachometer Cable Lubrication34
- Brake Pedal Spindle Lubrication34
Lubricating the Control Cables34
- Changing the Fluid in the Braking System35
- Draining Hydraulic System35
- Engine36
- Exploded View of the Trident Englne·transmlsslon Unit37
- Description38
- Removing and Replacing the Engine Unit39
  - Replacing the Unit40
  - Arrangement of Push Rod Tube Seals42
- Removing and Replacing the Rocker Boxes42
  - Inspecting the Push Rods43
  - Refitting Rocker Spindle Using Service Tool 60-222144
- Stripping and Reassembling the Rocker Boxes44
- Adjusting the Valve Rocker Clearances46
  - Carburetter Description47
  - Removing and Replacing the Air Filter47
  - Exploded View of Carburetter48
- Removing and Replacing the Carburetors49
- Stripping and Reassembling the Carburetors49
- Inspecting the Carburetor Components50
- Resetting the Carburetors50
  - Choke Cables51
  - Pilot Mixture51
  - Primer (or "Tickler")51
  - Slow Running51
  - Altitude52
  - Refitting the Cylinder Head52
- Removing and Refitting the Cylinder Head Assembly52
  - Removing and Refitting the Valves53
  - Removing the Valves53
  - Valve Components53
- Decarbonising54
- Renewing the Valve Guides54
  - Using Assembly Tool to Replace Valve Guide54
  - Cutting a Valve Seat55
- Removing and Replacing the Cylinder Block and Tappets56
- Inspecting the Cam Followers57
- Inspecting the Tappet Guide Blocks57
  - Protecting the Con. Rods57
  - Refitting Cylinder Block57
- Removing and Refitting the Pistons58
  - Piston Ring Removal59
  - Refitting a Tapered Piston Ring59
- Removing and Replacing the Piston Rings59
- Inspecting the Pistons and Cylinder Bores60
- Table of Suitable Rebore Sizes60
- Adjusting the Contact Breaker Points61
- Removing and Replacing the Contact Breaker61
  - Locking the Auto Advance Mechanism62
  - Re-Setting the Spark Timing62
  - Showing Location Tool in Use62
  - Static Timing62
  - Ignition Timing Using a Stroboscope63
  - Removing and Refitting the Timing Cover63
  - Camshaft Pinions64
- Extracting and Refitting the Valve Timing Pinions64
  - Oil Seal Protector64
  - Position of Screws64
  - Crankshaft Pinion65
  - Extracting the Crankshaft Plnjon65
- Valve Timing66
  - Valve Timing Marks66
  - Location of Left Side Crankcase Section67
  - Location of Right Side Crankcase Section67
  - To Dismantle and Reassemble the Crankcase67
  - Crankcase Re-Assembly68
- Refitting the Connecting Rods69
- Servicing the Crankshaft69
- Big-End & Center Main Bearings70
- Inspecting the Crankcase Components70
- Renewing the Main Bearings71
- Camshafts71
- Crankcase Faces and Dowls71
- Main Bearings71
- Replacing a Bearing72
- Removing a Circlip72
- Extracting Right Side Bearing Inner Spool72
- Removing and Replacing the Tachometer Drive73
- Primary Drive74
- Clutch75
- Clutch Description75
- Exploded View of Clutch75
- Primary Chain Adjustment76
- Adjusting the Primary Chain76
- Adjusting the Clutch Operating Mechanism76
- To Remove and Replace the Outer Primary Chaincase Cover77
- Refitting the Clutch Cover78
- Dismantling the Primary Drive78
- Reassembling the Primary Drive79
- Primary Chain Sprocket Alignment80
- Cutaway Outer Primary Cover80
- Extracting the Engine Sprocket80
- Removing and Replacing the Chainwheel and Engine Sprocket83
- Inspection of Primary Drive Components84
- Rear Chain Alterations and Repairs84
- Rear Chain Alterations84
- When Using the Extractor85
- Sequence of Gearshifting88
- Gear Selection Components88
- Dismantling and Reassembling the Kickstart Mechanism91
- Dismantling and Reassembling the Gearshift Cross Shaft92
- Dismantling and Reassembling the Gearshift Mechanism92
- Inspecting the Gearshift and Kickstart Mechanism93
- Renewing Kickstart and Gearshift Spindle Bushes94
- Dismantling the Transmission94
- Showing Removal of Engaging Dog95
- Transmission Inner Cover Retaining Screws95
- Inspection of the Tranmission (Gearbox) Components96
- Renewing Mainshaft and Lays Haft Bearings96
- High Gear Bearing Oil Seal and Housing97
- Mainshaft High Gear Bearings97
- Layshaft97
- Reassembling the Transmission (Gearbox)97
- Changing the Transmission Sprocket100
- Frame and Attachment Details102
- Removing and Replacing the Fuel Tank104
- Removing and Replacing the Styling Covers104
- Removing and Replacing the Oil Tank104
- Removing and Replacing the Battery Carrier105
- Removing and Refitting the Rear Fender, Lifting Handle, Etc.106
- Exploded View of the Rear Suspension Unit106
- Adjusting the Rear Suspension107
- Removing and Refitting the Rear Suspension Units107
- Adjusting the Rear Suspension Unit107
- Dismantling and Reassembling the Suspension Units108
- Using Girling Tool to Dismantle Suspension Unit108
- Removing and Refitting the Swinging Fork109
- Rear Brake Connection at Master Cylinder109
- Exploded View of Swinging Fork Assembly110
- Renewing the Swinging Fork Bushes111
- Removing a Swinging Fork Bush111
- Refitting Bushes with Drift111
- Swinging Fork Grease Nipple111
- Removing and Replacing the Rear Frame112
- Frame Alignment113
- Front Frame113
- Fitting Replacement Seat Covers117
- Steering Lock117
- Fairing Attachment Lugs117
- Repairs118
- Removal of Dents118
- Paintwork Refinishing119
- Paint Stripping119
- Undercoat119
- Wet and Dry Abrasive119
- Polishing120
- Brakes, Wheels, and Tires122
- The Disc123
- Maintenance123
- The Disc Brake123
- Disc Brake Components124
- The Brake Pads125
- Hydraulic Fluid Level125
- Renewing the Brake Pads125
- Flushing the Hydraulic System126
- Bleeding the System126
- Master Cylinder/Control Lever Body127
- Hydraulic Flow Diagram128
- Master Cylinder129
- Exploded View of Master Cylinder129
- Front Brake Cylinder130
- Rear Brake Cylinder131
- Replacement Parts132
- Front and Rear Brake Caliper132
- Removing and Replacing the Front Wheel133
- Removing and Replacing Front Wheel Bearings133
- Removing and Replacing Rear Wheel134
- Removal of Left Side Bearing Lock Ring134
- Exploded View of Front Wheel Bearing Arrangement134
- Removing and Replacing Rear Wheel Bearings135
- Rear Wheel Assembly135
- Front and Rear Wheel Alignment136
- Wheel Balancing136
- Checking the Wheel Alignment136
- Wheel Building137
- Rear Chain Adjustment138
- Suggested Wheel Building Gauge138
- Wheel Alignment138
- The Rear Chain Adjusters138
- Removing and Replacing Tires139
- General139
- Tire Removal139
- Tire Replacement139
- Refitting the Tire to the Wheel140
- Levering the First Bead Onto the Rim140
- Wheels with Security Bolts141
- Security Bolts142
- Placing the Security Bolt in Position142
- Refitting the Second Bead142
- Tire Maintenance143
- Load and Pressure Table143
- Telescopic Forks144
- Fork Assembly Details145
- Steering Head Adjustment146
- Dismantling and Reassembling the Fork Legs146
- Assembly of Bleed Valve147
- Removing the Oil Seal from the Fork Leg148
- Replacing the Oil Seal148
- Renewing Head Bearings149
- Fork Steering Lock149
- Fork Leg Alignment150
- Fork Alignment150
- Sectional View of Assembled Fork Leg151
- Hydraulic Damping152
- Electrical System154
- Battery Inspection and Maintenance155
- Routine Maintenance156
- Maximum Permissable Electrolyte156
- Specific Gravity or Electrolyte for Filling the Battery156
- Coil Ignition System157
- Condenser Pack157
- The Electrical Units157
- Fault Finding in the Low Tension Circuit158
- Checking the Low Tension Circuit for Continuity158
- Ignition Coils159
- Contact Breaker159
- Bench Testing the Ignition Coil159
- Checking the High Tension Circuit160
- Control Breaker Assembly Type 7CA160
- Sparking Plugs161
- Sparking Plug Diagnosis161
- Charging System162
- Schematic Diagram of 12 Volt Charging Circuit162
- Checking the D.C. Output at the Rectifier163
- Checking the Alternator Output163
- Rectifier Maintenance and Testing163
- Refitting the Rectifier163
- Bench Testing the Rectifier164
- Testing the Rectifier164
- Rectifier Test Sequence165
- Checking the Charging Circuit for Continuity165
- Constructing a One OHM Load Resistor165
- Zener Diode Charge Control166
- Test Conclusions167
- Showing Ammeter and Voltmeter Connections167
- Zener Diode Location168
- Electric Horns168
- The Headlight Assembly169
- Headlamp169
- Beam Adjustments169
- Horn Adjustment169
- Removing and Refitting the Headlamp170
- Tail and Stop Lamp Unit170
- Fuses170
- Exploded View of Fuseholder Assembly170
- Removing and Refitting Rear Flasher Lamps171
- Lighting and Ignition Switch171
- Removing and Refitting Front Flasher Lamps171
- Flasher Lamps171
- Warning Lamps172
- Stop Lamp Switches172
- Oil Pressure Switch172
- Capacitor Ignition Alternative System173
- Storage Lift173
- Capacitor and Spring173
- Service Notes174
- Wiring and Installation174
- The Starter Motor Circuit175
- Starter Fails to Operate175
- The Right Handlebar Switch175
- Starter Relay175
- To Remove the Starter Motor176
- To Remove Drive Assembly176
- To Remove Starter Assembly176
- Starter Motor Sluggish176
- Electric Starter Mechanism177
- Wiring Diagram178
- Wiring Diagram Symbols178
- Workshop Service Tools180
- Introduction180
- Decimals to Millimetres189
- Inches to Millimetres189
- Foot Pounds to Kilogrametres193
- Miles to Kilometres193
- Pounds to Kilograms193
- Miles Per Gallon to Litres193
- Pints to Litres194
- Gallons to Litres194
- Screw Threads195
- B.A. Screw Threads195

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