Triumph Rocket III Motorcycle Service Manual

Table of Contents
Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaft Bevel Box and Drive Shaft Balancer Transmission Lubrication Engine Removal and Refit Fuel System/Engine Management Cooling Rear Suspension Front Suspension

''i Brakes

WheelslTyres Frame and Bodywork Electrical System

Service Manual - Rocket III

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ii


Introduction


iii

Introduction

This manual is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job.

A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, an authorised Triumph dealer must undertake all adjustments, maintenance, and repair work.

In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.

All work should be performed with great care and in a clean working area with adequate lighting.

Always use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect safe operation.

Where accurate measurements are required, they can only be made using calibrated, precision instruments.

For the duration of the warranty period, an authorised Triumph Dealer must perform all repairs and scheduled maintenance.

To maximise the life of your Motorcycle:

• Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual.

Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the motorcycle. Rectify all problems as soon as possible (immediately if safety related).

• Use only genuine Triumph parts as listed in the parts catalogue/parts microfiche.

•

• Follow the procedures in this manual carefully and completely. Do not take short cuts.

• Keep complete records of all maintenance and repairs with dates and any new parts installed.

• Use only approved lubricants, as specified in the owner's handbook, in the maintenance of the motorcycle.

How to use this manual

To assist in the use of this manual, the section title is given at the top.

Each major section starts with a contents page, listing the information contained in the section.

The individual steps comprising repair operations are to be followed in the sequence in which they appear.

Adjustment and repair operations include reference to service tool numbers and the associated illustration depicts the tool.

Where usage is not obvious, the tool is shown in use. Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, specialist information and useful assembly details.

Warning, Caution and Note

Particularly important information is presented in the following form:

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

Note:

• This note symbol indicates points of particular interest for more efficient and convenient operation.

iv Service Manual- Rocket III

Introduction

Tampering with Noise Control System Prohibited

Owners are warned that the law may prohibit:

a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

References

References to the left-hand or right-hand side given in this manual are made when viewing the motorcycle from the rear.

Operations covered in this manual do not always include reference to testing the motorcycle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the motorcycle is carried out particularly where safety related items are concerned.

Dimensions

The dimensions quoted are to design engineering specification with service limits where applicable.

During the period of running-in from new, certain adjustments may vary from the specification figures given in this manual. These will be reset by the dealer at the 500 mile/800 km service, and thereafter should be maintained at the figures specified in this manual.

Repairs and Replacements

Before removal and disassembly, thoroughly clean the motorcycle. Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle. Particular attention should be paid when installing a new part, that any dust or metal filings are cleared from the immediate area.

Force

Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Never lever a component as this will cause damage both to the component itself and to the surface being levered against.

Whenever tapping to aid removal of an item is necessary, tap lightly using a hide or plastic faced mallet.

Edges

Watch for sharp edges, especially during engine disassembly and assembly. Protect the hands with industrial quality gloves.

When replacement parts are required, it is essential that only genuine Triumph parts are used.

Safety features and corrosion prevention treatments embodied in the motorcycle may be impaired if other than genuine Triumph parts are fitted. In certain territories, legislation prohibits the fitting of parts not to the manufacturer's specification.

Tightening procedure

Generally, when installing a part with several bolts, nuts or screws, they should all be started in their holes and tightened to a snug fit, evenly and in a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely, bolts, nuts, or screws, should all be loosened (in sequence if specified) by about a quarter of a turn and then removed.

Where there is a tightening sequence specified in this Service Manual, the bolts, nuts, or screws must be tightened in the order and by the method indicated.

Torque wrench setting figures given in this Manual must be observed. The torque tools used must be of accurate calibration.

Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. This applies particularly to micro-encapsulated fixings which must always be replaced if disturbed. Where necessary, the text in this manual will indicate where such a fixing is used.

'ft@JH.

v


Introduction


vi


1 General Information

Table of Contents

Ignition System Safety Precautions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-3

Dangerous Susbstances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-3

Fluoroelastomers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-3

Oils.. .. . . . .. .. .. .. . . . . . . . . . .. .. .. . .. .. . . .. .. .. . .. .. . . . . . .. .. . . .. . .. .. .. .. . . . ... 1-3

Health Protection Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-3

Environmental Protection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-4

Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-4 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-5 Jacking and lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-5

Precautions against damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-5

Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-5

Cleaning components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-6

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-6

Joints and joint faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-6

Gaskets, a-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-6

Liquid gasket, non-permanent locking agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-6

Screw Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-6

Locking Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-7

Fitting a split pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-7

Circlips, retaining rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-7

Self locking nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-7

Encapsulated bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-7

Oil and grease seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 -7

Press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-7

Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1·7

Fuel Handling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-7 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-7 Petrol - Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-8 Fuel tank removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-8 Chassis repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Electrical Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9

Battery disconnecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9

Disciplines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9

Electrical wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10


1.1

General Information

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., 1-10

Service data , 1-10

Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-10

Service tools , 1-11

Special service tools: , 1-11

Torque Wrench Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Cylinder head area , 1-20

Clutch , 1-20

Crankshaft and crankcases , 1-20

Engine Covers , 1-20

Transmission , 1-21

Lubrication System , 1-21

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-21

Fuel System, Exhaust System and Airbox , 1-22

Rear Suspension , 1-22

Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-22

Wheels , 1-22

Front Brakes , 1-23

Rear Brakes , 1-23

Footrests and Control Plates , 1-23

Bodywork , 1-24

Electrical , 1-24

Routings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Clutch Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-25

Handlebar Cable Routing , 1-26

Main Wiring Harness Routing , 1-27

Rear Mudguard Harness Routing ' 1-28

Front Brake Hose Routing , 1-29

Rear Brake Pipe and Hose Routing , 1-30

Throttle Cable Routing , 1-31

Fuel Hose and Fuel Tank Breather Hose Routing (non-evaporative emission control versions) 1-32

Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing , 1-33

1.2


General Information

Ignition System Safety Precautions

The ignition system produces extremely high voltages. Do not touch any part of the ignition system or any cables while the engine is running. An electric shock caused by contact with the ignition system may lead to illness, injury or death.

Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and or diagnostic equipment.

The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death.

Dangerous Susbstances

Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as possible, be kept from contact with the skin. These substances among others include acid, anti-freeze, asbestos, brake fluid, fuel, lubricants, and various adhesives. Always pay close attention to the instructions printed on labels and obey the instructions contained within. These instructions are included for your safety and well-being.

NEVER DISREGARD THESE INSTRUCTIONS!

Fluoroelastomers

Fluoroelastomer material is used in the manufacture of various seals in Triumph motorcycles.

In fire conditions involving temperatures greater than 31SoC this material will decompose and can then be potentially hazardous. Highly toxic and corrosive decomposition products, including hydrogen fluoride, carbonyl fluoride, fluorinated olefins and carbon monoxide can be generated and will be present in fumes from fires.

In the presence of any water or humidity hydrogen fluoride may dissolve to form extremely corrosive liquid hydrofluoric acid.

If such conditions exist, do not touch the material and avoid all skin contact. Skin contact with liquid or decomposition residues can cause painful and penetrating burns leading to permanent, irreversible skin and tissue damage.

Oils

The engine and bevel box oils may be hot to the touch. Contact with hot oil may cause the skin to be scalded or burned.

Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition used engine oil contains potentially harmful contaminants which can cause cancer. Wear suitable clothing and avoid skin contact.

Health Protection Precautions

• Avoid prolonged and repeated contact with oils, particularly used engine oils.

• Wear protective clothing. including impervious gloves where practicable.

• Do not put oily rags in pockets.

• Overalls must be cleaned regularly. Discard heavily soiled clothing and oil impregnated footwear.

• First aid treatment should be obtained immediately for open cuts and wounds. Always

1.3

Service Manual- Rocket III

General Information

be aware of who your nearest first-aider is and where the medical facilitles are kept.

• Use barrier creams, applying before each work period to protect the skin from the effects of oil and grease and to aid removal of the same after completing work.

• Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed.

• Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.

• If skin disorders develop, obtain medical advice without delay.

• Where practicable, de-grease components prior to handling.

Any risk of eye injury must be avoided. Always wear eye protection when using a hammer, air line, cleaning agent or where there is ANY risk of flying debris or chemical splashing.

Environmental Protection Precautions

Do not pour oil on the ground, down sewers or drains, or into water courses. To prevent pollution of water-courses etc., dispose of used oil sensibly. If in doubt contact your local authority.

Burning of used engine oil in small space heaters or boilers can be recommended only for units of approved design. If in doubt, check with the appropriate local authority and/or manufacturer of the approved appliance.

Dispose of used oil and used filters through authorised waste disposal contractors, to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact your local authority for advice on disposal facilities.

Brakes

Brake fluid is hygroscopic which means it will absorb moisture from the air. Any absorbed moisture will greatly reduce the boiling point of the brake fluid causing a reduction in braking efficiency.

Replace brake fluid in line with the routine maintenance schedule. A dangerous riding condition could result if this important maintenance item is neglected!

Do not spill brake fluid onto any area of the bodywork as this will damage any painted or plastic surface.

Always use new brake fluid from a sealed container and never use fluid from an unsealed container or from one that has been previously opened.

Do not mix different brands of fluid. Check for fluid leakage around brake fittings, seals and joints.

Check regularly for brake hose damage.

FAILURE TO OBSERVE ANY OF THE ABOVE WARNINGS MAY REDUCE BRAKING EFFICIENCY LEADING TO AN ACCIDENT.

If there has been an appreciable drop in the level of the fluid in either brake fluid reservoir, consult your authorised Triumph Dealer for advice before riding. If the brake lever or pedal feels soft when it is applied, or if the lever/pedal travel becomes excessive, there may be air in the brake lines or the brake may be defective.

It is dangerous to operate the motorcycle under such conditions and remedial action must be taken by your authorised Triumph dealer before riding the motorcycle.

Failure to take remedial action may reduce braking efficiency leading to an accident.

Use only D.O.T. 4 specification brake fluid as listed in the general information section of this manual. The use of brake fluids other than those D.O.T. 4 fluids listed in the general information section may reduce the efficiency of the braking system leading to an accident.

Failure to change the brake fluid at the interval specified in the routine maintenance schedule may reduce braking efficiency resulting in an accident.

1.4


General Information

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/ • < ~ " +. < • t

Never use mineral based grease in any part of the braking system or in any area where contact with the braking system is possible. Mineral based grease will damage the hydraulic seals in the calipers and master cylinders.

Damage caused by contact with mineral based grease may reduce braking efficiency resulting in an accident.

Safety Instructions

Jacking and lifting

Always ensure that any lifting apparatus has adequate load and safety capacity for the weight to be lifted. Ensure the motorcycle is well supported to prevent any possibility of the machine falling prior during lifting or jacking or while repairs and servicing are carried out.

Never rely on a single means of support when working with the motorcycle. Use additional safety supports and straps to prevent toppling.

Do not leave tools, lifting equipment, spilt oil, etc. in a place where they could become a hazard to health. Always work in a clean, tidy area and put all tools away when the work is finished.

Precautions against damage

Avoid spilling brake fluid or battery acid on any part of the bodywork. Wash spillages off with water immediately.

Disconnect the battery earth lead before starting work, see ELECTRICAL PRECAUTIONS.

Always use the recommended service tool where specified.

Protect exposed bearing and sealing surfaces, and screw threads from damage.

Coolant

Coolant mixture, which is blended with anti-freeze and corrosion inhibitors contains toxic chemicals which are harmful to the human body. Never swallow anti-freeze, corrosion inhibitors or any of the motorcycle coolant.

Do not remove the radiator cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

The coolant anti-freeze contains a corrosion inhibitor which helps prevent damage to the metal surfaces inside the cooling system. Without this inhibitor, the coolant would . attack' the metals and the resulting corrosion would cause blockages in the cooling system leading to engine overheating and damage. Always use the correct anti-freeze as specified in the Owner's Handbook; Never use a methanol based anti-freeze as this does not contain the required corrosion inhibition properties.

Distilled water must be used with the anti-freeze (see specification for anti-freeze) in the cooling system.

If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Reduced cooling system efficiency may lead to the engine overheating and engine damage.

~.

1.5


General Information

Cleaning components

A high flash-point solvent is recommended to reduce fire hazard.

Always follow container directions regarding the use of any solvent.

Always use the recommended cleaning agent or equivalent.

Do not use degreasing equipment for components containing items which could be damaged by the use of this process. Whenever possible, clean components and the area surrounding them before removal. Always observe scrupulous cleanliness when cleaning dismantled components.

Lubrication

The majority of engine wear occurs while the engine is warming up and before all the rubbing surfaces have an adequate lubrication film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface, which has lost its lubrication film. Old grease and dirty oil should be cleaned off. This is because used lubricants will have lost some lubrication qualities and may contain abrasive foreign particfes.

Use recommended lubricants. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulphide grease in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants.

Joints and joint faces

Assemble joints dry unless otherwise specified in this Manual.

If gaskets and/or jointing compound is recommended for use; remove all traces of old jointing material prior to reassembly. Do not use a tool which will damage the joint faces and smooth out any scratches or burrs on the joint faces using an oil stone. Do not allow dirt or jointing material to enter any tapped holes.

Gaskets, O-rings

Do not re-use a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.

Liquid gasket, non-permanent locking agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly as excessive amounts of sealer may block engine oil passages and cause serious damage.

Prior to reassembly, blow through any pipes, channels or crevices with compressed air.

To prevent injury, always use eye, face and ear protection when using compressed air. Always wear protective gloves if the compressed air is to be directed in proximity to the skin.

Screw Threads

Metric threads to ISO standard are used.

Damaged nuts, bolts and screws must always be discarded.

Castellated nuts must not be slackened back to accept a split-pin, except in those recommended cases when this forms part of an adjustment.

Do not allow oil or grease to enter blind threaded holes. The hydraulic action on screwing in the bolt or stud could split the housing.

Always tighten a nut or bolt to the recommended torque figure. Damaged or corroded threads can affect the torque reading.

Unless specified, threaded fixings must always be fitted dry (no lubrication).

Never lubricate a thread unless instructed to do so. When a thread of a fixing is lubricated, the thread friction is reduced. When the fixing is tightened, reduced friction will cause overtightening and possible fixing failure.

A fixing which fails in service could cause component detachment leading to loss of control and an accident.

1.6


General Information

Locking Devices

Always release locking tabs and fit new locking washers, do not re-use locking tabs.

Fitting a split pin

Always fit new split-pins of the correct size for the hole in the bolt or stud. Do not slacken back castle nuts when fitting split pin, except in those recommended cases when this forms part of an adjustment.

Always fit new roll pins of an interference fit in the hole.

Circlips, retaining rings

Replace any circlips and retaining rings that are removed. Removal weakens and deforms circlips causing looseness in the circlip groove. When installing circlips and retaining rings, take care to compress or expand them only enough to install them.

Always use the correct replacement circlip as recommended in the Triumph parts catalogue.

Self locking nuts

Self-locking nuts can be re-used, providing resistance can be felt when the locking portion passes over the thread of the bolt or stud.

DO NOT re-use self-locking nuts in critical locations, e.g. suspension components. Always use the correct replacement self-locking nut.

)

Encapsulated bolt

An encapsulated bolt can be identified by a coloured section of thread which is treated with a locking agent.

Unless a specified repair procedure states otherwise, encapsulated bolts cannot be reused and MUST be replaced if disturbed or removed.

Failure to replace an encapsulated bolt could lead to a dangerous riding condition. Always replace encapsulated bolts.

Oil and grease seals

Replace any oil or grease seals that are removed. Removal will cause damage to an oil seal which, if reused, would cause an oil leak.

Ensure the surface on which the new seal is to run is free of burrs or scratches. Renew the component if

the original sealing surface cannot be completely restored.

Protect the seal from any surface which could cause damage over which it has to pass when being fitted. Use a protective sleeve or tape to cover the relevant surface and avoid touching the sealing lip.

Lubricate the sealing lips with a recommended lubricant. This will help to prevent damage in initial use. On dual lipped seals, smear the area between the lips with appropriate grease.

When pressing in a seal which has manufacturer's marks, press in with the marks facing out.

Seals must be pressed into place using a suitable driver. Use of improper tools will damage the seal.

Press

A part installed using a press or driver, such as a wheel bearing, should first be coated with oil or grease on its outer or inner circumference so that it will locate smoothly.

Ball beari ng

When installing a ball bearing, the bearing race which is an interference fit should be pushed by a suitable driver. This prevents severe stress or damage to the load carrying components. Press a ball bearing until it touches the shoulder in the bore or on the shaft.

Press or drift seals to the depth of its housing, with the sealing lip facing the lubricant to be retained if the housing is shouldered, or flush with the face of the housing where no shoulder is provided.

Fuel Handling Precautions

General

The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled safely. It also outlines other areas of risk which must not be ignored. This information is issued for basic guidance only and, if in doubt, appropriate enquiries should be made of your local Fire Officer.

TIQeJR"

1.7


General Information

Petrol - Gasoline

When petrol (gasoline) evaporates it produces 150 times its own volume in vapour which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readify be distributed throughout any indoor environment by air currents, consequently, even a small spillage of petrol (gasoline) is potentially very dangerous.

Petrol (gasoline) is highly flammable and can be explosive under certain conditions. When opening the fuel tank cap always observe all the following items;

Turn the motorcycle ignition switch OFF. Do not smoke.

Always have a fire extinguisher containing FOAM, C02, HALON or POWDER close at hand when handling or draining fuel or fuel systems. Fire extinguishers must also be present in areas where fuel is stored.

Always disconnect the vehicle battery, negative (black) lead first, before carrying out dismantling or draining work on a fuel system.

Whenever petrol (gasoline) is being handled, drained, stored or when fuel systems are being dismantled, make sure the area is well ventilated. All potential forms of ignition must be extinguished or removed (this includes any appliance with a pilot light). Any lead-lamps must be flame-proof and kept clear of any fuel spillage.

Warning notices must be posted at a safe distance from the site of the work to warn others that petrol is being openly handled. The notice must instruct the reader of the precautions which must be taken. Failure to observe any of the above warnings may lead to a fire hazard which could result in personal injury.

No one should be permitted to repair components associated with petrol/gasoline without first having specialist training on the fire hazards which may be created by incorrect installation and repair of items associated with petrol/gasoline.

Repairs carried out by untrained personnel could bring about a safety hazard leading to a risk of personal injury.

Draining or extraction of petrol/gasoline from a vehicle fuel tank must be carried out in a well ventilated area.

The receptacle used to contain the petrol/ gasoline must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations.

When petrol/gasoline has been extracted or drained from a fuel tank, the precautions governing naked lights and ignition sources should be maintained. Failure to observe any of the above warnings could bring about a safety hazard leading to a risk of personal injury.

Fuel tank removal

Fuel tanks should have a 'PETROL (GASOLINE) VAPOUR' warning label attached to them as soon as they are removed from the vehicle. In all cases, they must be stored in a secured, marked area.

Chassis repairs

If the motorcycle is involved in an accident or collision it must be taken to an authorised Triumph dealer for repair or inspection. Any accident can cause damage to the motorcycle, which if not correctly repaired, may cause a second accident which may result in injury or death.

The frame must not be modified as any modification to the frame such as welding or drilling may weaken the frame resulting in an accident.

1.8


General Information

Electrical Precautions

The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the motorcycle. Where necessary, specific precautions are detailed in the relevant sections of this manual which should be referred to prior to commencing repair operations.

Equipment - Prior to commencing any test procedure on the motorcycle ensure that the relevant test equipment is working correctly and any harness or connectors are in good condition, in particular mains leads and plugs.

The ignition system produces extremely high voltages. Do not touch any part of the ignition system or any cables while the engine is running. An electric shock caused by contact with the ignition system may lead to illness, injury or death.

Wearers of surgically implanted heart pacemaker devices should not be in close proximity to ignition circuits and or diagnostic equipment.

The ignition system and any diagnostic equipment may interrupt the normal operation of such devices causing illness or death.

The battery contains harmful materials. Always keep children away from the battery whether or not it is fitted in the motorcycle.

Do not jump start the battery, touch the battery cables together or reverse the polarity of the cables as any of these actions may cause a spark which would ignite battery gasses causing a risk of personal injury.

High Voltage Circuits - Whenever disconnecting live H.T. circuits always use insulated pliers. Exercise caution when measuring the voltage on the coil terminals while the engine is running, high voltage spikes can occur on these terminals.

Connectors and Harness - The engine of a motorcycle is a particularly hostile environment for electrical components and connectors. Always ensure these items are dry and oil free before disconnecting and connecting test equipment. Never force

connectors apart either by using tools or by pulling on the wiring itself. Always ensure locking mechanisms are disengaged before removal and note the orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if disturbed.

Having confirmed a component to be faulty, switch off the ignition and disconnect the battery negative (black) lead first. Remove the component and support the disconnected harness. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking mechanism becomes fully engaged.

Battery disconnecting

Before disconnecting the battery, switch off all electrical equipment.

To prevent the risk of a battery exploding and to prevent damage to electrical components ALWAYS disconnect the battery negative (black) lead first. When reconnecting the battery, always connect the positive (red) lead first, then the negative (black) lead. Always disconnect the battery when working on any part of the electrical system.

Failure to observe the above warnings may lead to electrical damage and a fire hazard which could cause personal injury.

Always ensure that battery leads are routed correctly and are not close to any potential chafing points.

Disciplines

Switch off the ignition prior to making any connection or disconnection in the system. An electrical surge can be caused by disconnecting 'live' connections which can damage electronic components.

Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts.

Prior to commencing any test, and periodically during any test, touch a good earth to discharge body static. This is because some electronic components are vulnerable to static electricity.

11\J!!!JH'

1.9


General Information

Electrical wires

All the electrical wires are either single-colour or twocolour and, with only a few exceptions, must be connected to wires of the same colour. On any of the two-colour wires there is a greater amount of one colour and a lesser amount of a second colour. A two-colour wire is identified by first the primary colour and then the secondary colour. For example, a yellow wire with thin red stripes is referred to as a 'yellow! red' wire; it would be a . red!yellow' wire if the colours were reversed to make red the main colour.

Inspection

Disassembled parts should be visually inspected and replaced with new ones if there are any signs of the following:

Abrasions, cracks, hardening, warping, bending, dents, scratches, colour changes, deterioration, seizure or damage of any nature.

Replacement Parts

Only Triumph genuine parts should be used to service, repair or convert Triumph motorcycles. To ensure that Triumph genuine parts are used, always order parts, accessories and conversions from an authorised Triumph dealer. The fitting of nonapproved parts, accessories or conversions may adversely affect the handling, stability or other aspects of the motorcycle operation which may result in an accident causing serious injury or death.

Always have Triumph genuine parts, accessories and conversions fitted by an authorised Triumph dealer. The fitment of parts, accessories and conversions by a dealer who is not an authorised Triumph dealer may affect the handling, stability or other aspects of the motorcycle operation which may result in an accident causing serious injury or death.

Always have Triumph approved parts, accessories and conversions fitted by a trained technician. To ensure that a trained technician is used, have an authorised Triumph dealer fit the parts. The fitment of parts, accessories and conversions by personnel other than a trained technician at an authorised Triumph dealer may affect the handling, stability or other aspects of the motorcycle operation which may result in an accident causing serious injury or death.

Service data

The service data listed in this manual gives dimensions and specifications for brand new, original parts. Where it is permissible to allow a part to exceed these figures, then the service limit is given.

The terms of the motorcycle warranty will be invalidated by the fitting of other than genuine Triumph parts.

All genuine Triumph parts have the full backing of the motorcycle warranty. Triumph dealers are obliged to supply only genuine Triumph recommended parts.

Specification

Triumph are constantly seeking to improve the specification, design and production of their motorcycles and alterations take place accordingly.

While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular motorcycle.

Authorised Triumph Dealers are not agents of Triumph and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.

1.10


~.

General Information

Service tools

Special service tools have been developed to facilitate removal, dismantling and assembly of certain mechanical components in a practical manner without causing damage. Some operations in this service manual cannot be carried out without the aid of the relevant service tools. Where this is the case, the tools required will be described during the procedure.

Special service tools:

T3880105 - Angular torque gauge

T3880048 - Fuel pressure gauge

jafi

3880160- T0301 - Fork filler evacuator

echo

T3880312 - Oil filter wrench

gahc

TIQem'


1.11

General Information

T3880250 - Diagnostic tool

T3880201 - Anti-rotation jig - alternator

ccgy

3880025-T0301 - Clutch anti-rotation jig

ccno

T3880200 - Puller - alternator

cen.

T3880061 - Extractor, liners

cenb

T3880062 - Castle wrench - 38 mm

ccqu

1.12


~.

General Information

T3880063 - Castle wrench - 31 mm

T3880064 - Drift, swinging arm bearings

3880085- T0301 - Fork assembly rod

3880090-T0301 - Fork service tool

cogs

T3880067 - Fork spring compressor

T3880202 - Cam timing jig

cogw


1.13

General Information

Full Specification

Rocket III

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 3 Cylinder 12 Valve DOHC

Arrangement . . . . . . . . . . . . . . . . .. . In line, longitudinal,

Displacement. . . . . . . . . . . . . . . . . . . . . . .. . 2294 cc

Bore x Stroke. . . . . . . . . . . . . . . . . . . . . . .. . 101.6 x 94.3 mm

Compression Ratio. . . . . . . . . . . . . . . . . . .. . 8.7:1

Cylinder Numbering. . . . . . . . . . . . . . . . . .. . Number 1 at front

Firing order. . . . . . . . . . . . . . . . . . . . . . . . .. . 1-2-3

Max. Power (DIN 70020) . . . . . . . . . . . . . .. . 142 PS at 5,750 rpm

Max. Torque. . . . . . . . . . . . . . . . . . . . . . . .. . 200 Nm at 2,500 rpm

Cylinder Head

Valve Head Dia In 37.90 mm

Ex 32.30 mm

Valve Lift. In 8.30 mm

Ex 8.30 mm

Valve Stem Dia In 5.475 - 5.490 mm (std)

Ex 5.475 - 5.490 mm (std)

Valve Guide Bore Dia. . . . . . . . . . . . . . . . .. . 5.485 - 5.500 mm (std)

Valve Seat Width (in head) . 1.000 - 1.100 mm (std)

1.500 mm (service limit)

Valve Seat Width (valve) . . . . . . . . . .. . 1.98 - 2.26 mm (std)

Valve Seat Angle . . . . . . . . . . . . . . . . . . . .. . 900 inclusive

Valve Spring Length. . . . . . . . . . . . . . . . . .. . .43.2 mm (std)

Valve Spring 'Load at Length' In 180 N +/- -1 0 N at 36.2 mm

Ex __ . _ 180 N +/- 10 N at 36.2 mm

Valve Clearance In 0.10 - 0.15 mm

Ex _ .. _ 0.15 - 0.20 mm

Valve Bucket Bore Dia _ _ _ In 28.015 - 28.035 mm

Ex 28.015 - 28.035 mm

Valve Bucket Dia. _ _ In 27.978 - 27.993 mm

Ex _ 27.978 - 27.993 mm

Valve Timing (at 1 mm lift)

Inlet open 120 BTDC

close 280 ABDC

d u ratio n. . . . . . . . . 2200

Exhaust open 410 BBDC

close t 1 0 ATDC

duration 2320

Camshaft Journal Dia. . . . . . . . . . . . . . . . .. . 22.93 - 22.96 mm (std)

Camshaft Journal Clearance. . . . . . . . . . .. . 0;040 - 0.091 mm (std) 0.13 mm (service limit)

1.14


General Information

Full Specification

Rocket III

Camshaft Journal Bore Dia 23.000 - 23.021 mm (std)

Camshaft End Float 0.10 - 0.13 mm (std)

Camshaft Run-out. 0.015 mm (std)

Camchain Tensioner Spring Free Length 73.7 mm

Clutch/Primary Drive

Primary Drive Type Gear, with backlash eliminator

Reduction Ratio .. 1.034:1

Clutch Type Wet, multi-plate

No. of Friction Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Plate Flatness Limit. 0.30 mm

Friction Plate Thickness (new) 3.72 - 3.88 mm

Friction Plate Thickness (service limit) 3.5 mm

Clutch Actuation Method Cable

Cable Free Play (at lever) 2-3 mm

Piston/Crankshaft

Cylinder Liner Dia 101.591 - 101.609 mm (std) 101 .659 mm (service limit)

Piston Diameter 101.561 - 101.577 mm (std) 101.511 mm (service limit)

Piston Ring to Groove Clearance Top 0.002 - 0.006 mm (std) 0.16 mm (service limit)

Second 0.02 - 0.06 mm (std) 0.16 mm (service limit)

Piston Ring Groove Width Top 1.01 - 1 .03 mm (std) 1.11 mm (service limit)


Oil 2.51 - 2.53 mm (std & service limit)

Piston Ring End Gap Top 0.20 - 0.35 mm (std) 0.55 mm (service limit)


Oil 0.20 - 0.70 mm (std) 0.875 mm (service limit)

Gudgeon Pin Bore Dia. In Piston 21.994 - 22.001 mm (std) 22.011 mm (service limit)

Gudgeon Pin Dia 21.982 - 21.987 mm (std) 21.972 mm (service limit)

Connecting Rod Small End Dia 22.005 - 22.018 mm (std) 22.028 mm (service limit)

~.


1.15

General Information

Full Specification

Rocket III

Connecting Rod Big End Dia. . . . . . . . . . .. . 44.000 - 44.009 mm (std)

Connecting Rod Big End Side Clearance.. . 0.15 - 0.30 mm (std) 0.50 mm (service limit)

Crankshaft Big End Journal Dia. . . . . . . . .. . 40.946 - 40.960 mm(std) 40.922 mm (service limit)

Crankshaft Big End Bearing Clearance. . .. . 0.035 - 0.065 mm (std) 0.100 mm (service limit)

Crankshaft Main Journal Dia. . 43.092 - 43.108 mm (std) 43.068 mm (service limit)

Crankshaft Main Bearing Clearance . . . . .. . 0.018 - 0.041 mm (std) 0.10 mm (service limit)

Crankshaft End Float. . . . . . . . . . . . . . . . .. . 0.05 - 0.20 mm (std) 0.40 mm (service limit)

Crankshaft run-out. . . . . . . . . . . . . . . . . . .. . 0.04 mm (std)

0.07 mm (service limit)

Transmission

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 5 Speed Constant Mesh

Gear Ratios Primary 1.034:1

1 st. 2.929:1

2nd 1.947: 1

3rd 1.435:1

4th 1 .160: 1

5th 0.964:1

Secondary 1 .043: 1

Gear Selector Fork Thickness. . . . . . . . . .. . 5.90 - 6.00 mm (std) 5.80 mm (service limit)

Gear Selector Groove Width . . . . . . . . . . .. . 6.05 - 6.15 mm (std) 6.30 (service limit)

Gear Selector Fork to Groove Clearance. .. . 0.05 - 0.25 mm (std) 0.50 (service limit)

Final Drive

Final Drive Type. . . . . . . . . . . . . . . . . . . . .. . Bevel geared crown wheel and pinion

Drive system . . . . . . . . . . . . . . . . . . .. . Universal-jointed shaft with torsional damper

Final Drive Ratio. . . . . . . . . . . . . . . . . . . . .. . 2.846:1

Final Drive Oil. . . . . . . . . . . . . . . . . . . . . . .. . Mobilube SHC 95/W 90 fully synthetic hypoid oil (or equivalent)

Final Drive Oil Capacity. . . . . . . . . . . . . . .. . 0.17 lit res

Lubrication

Oil Capacity (incl. filter, dry fill). . . . . . . . . .. . 5.9 litres

Oil and filter change. . . . . . . . . . . . . . . . . .. . 5.4 litres

1.16


General Information

Full Specification

Rocket III

Oil change only 5.1 litres

Recommended Oil Approval Rating API SH (or higher) and JASO MA

Viscosity 10W/40 or 15W/50

Type Semi or fully synthetic

Oil Pressure (in main gallery) 3.00 - 3.60 Bar at 3,500 rpm

Oil Pump Rotor Tip Clearance , .. , 0.15 mm (std - both pumps) 0.20 (service limit - both pumps)

Oil Pump Body Clearance , 0.15 - 0.22 mm (std - both pumps) 0.20 mm (service limit - both pumps)

Oil Pump Rotor End Float 0.02 - 0.07 mm (std - both pumps) 0.10 mm (service limit - both pumps)

Ignition System

Type , Digital, inductive

Electronic Rev-Limiter 6.500 rpm

Pick up Coil Air Gap Fixed, not adjustable

Pick up Coil Resistance 0.56 Kn

Ignition Coil Type Inductive, twin output

Spark Plug Type NGK DPR8EA9, 2 per cylinder

Spark Plug Gap 0.9 mm

Fuel System

Fuel Type Unleaded, 95 RON ( US - 89 RON/MaN)

Fuel Tank Capacity 251itres

Low Level Warning Lamp 5.5 litres remaining

Fuel Pump Type Submerged, electric

Fuel Pressure (nominal) 3.0 Bar

Purge control system Modulated, vacuum

Fuel Injection System

Type Multi point sequential

Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 rpm

Injector Type Single nozzle

Throttle Twin butterfly

Idle speed control Stepper motor

Control Sensors Coolant temperature, manifold absolute pressure (all cylinders), intake air temperature, barometric pressure, gear position, road speed, primary and secondary throttle position,

Cooling System

Coolant Mixture 50% anti freeze in distilled water

Anti-Freeze Type Mobil Antifreeze


1.17

General Information

Full Specification

Rocket III

Cooling System Capacity. . . . . . . . . . . . . .. . 3.2 litres

Radiator Cap Opening Pressure. . . . . . . .. . 1.2 bar

Thermostat Opening Temperature. . . . . . .. . 85° C

Cooling Fan Switch On Temperature .

Temperature Gauge Sensor Resistance . .. . 187.0 at 100°C

Suspension

Front Fork Travel . . . . . . . . . . .. . 120 mm

Recommended Fork Oil Grade . . . . . . . . .. . Kayaba 01 oil (SAE OW)

Oil Level (fork fully compressed) . . . . . . . .. . 89 mm

Oil Volume (dry fill). . . . . . . . . . . . . . . . . . .. . 667 cm3 +/- 4.0 cm3

Front Fork Pull Through. . . . . . . . . . . . . . .. . 0 mm (top of the outer tube flush with top yoke)

Fork spring rate . . . . . . . . . . . . . . . . . . . . .. . K = 16 N/mm

Rear Wheel Travel . . . . . . . . . . . . . . . . . . .. . 105 mm

Brakes

Front type. . . . . . . . . . . . . . . . . . . . . . . . . .. . Two four piston callipers acting on twin discs

Caliper Piston Dia. . . . . . . . . . . . . . . . . . . .. . 33.96 mm/30.23 mm

Disc Dia.. . . . . . . . . . . . . . . . . . . . . . . . . . .. . 320 mm

Disc Thickness. . . . . . . . . . . . . . . . . . . . . .. . 5.0mm standard (4.0 mm service limit)

Disc Run-out Max. . . . . . . . . . . . . . . . . . . .. . 0.3 mm

Master Cylinder Diameter. . . . . . . . . . . . .. . 14 mm

Recommended Fluid . . . . . . . . . . . . . . . . .. . DOT 4

Rear Type " .

Caliper Piston Dia. . . . . . . . . . . . . . . . . . . .. . 32 mm

Disc Dia " 316 mm

Disc Thickness. . . . . . . . . . . . . . . . . . . . . .. . 7.5 mm standard (6.5 mm service limit)

Disc Run-out Max " 0.15 mm

Master Cylinder Diameter. . . . . . . . . . . . .. . 12.7 mm

Recommended Fluid . . . . . . . . . . . . . . . . .. . DOT 4

Wheels and Tyres

Front Wheel Size. . . . . . . . . . . . . . . . . . . .. . MT 3.5 x 17

Front Wheel Rim Axial Run-out. . . . . . . . .. . 0.5 mm

Front Wheel Rim Radial Run-out. . . . . . . .. . 0.5 mm

Front Tyre Size. . . . . . . . . . . . . . . . . . . . . .. . 150/80 R17

Front Tyre Pressure (cold) . . . . . . . . . . . . .. . 34 Ib/in2

Front Tyre Tread Depth min.. . . . . . . . . . . .. . Over 130 kmh - 3 mm (or minimum legal limit, whichever is greater)

Under 130 kmh - 2 mm (or minimum legal limit, whichever is greater)

Rear Wheel Size . . . . . . . . . . . . . . . . . . . .. . MT 7.5 x 16

1.18


General Information

Full Specification

Rocket III

Rear Wheel Rim Axial Run-out 0.5 mm

Rear Wheel Rim Radial Run-out. 0.5 mm

Rear Tyre Size 240/50 R16

Rear Tyre Pressure (cold) 42 Ib/in2

Rear Tyre Tread Depth min Over 130 kmh - 3 mm (or minimum legal limit, whichever is greater)

Under 130 kmh - 2 mm (or minimum legal limit, whichever is greater)

Frame

Frame Type Tubular steel

Overall Length 2480 mm

Overall Width 880 mm

Wheelbase 1690 mm

Seat Height 740 mm

Castor 32°

Trail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 mm

Dry Weight 320 kg

Max. Payload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 kg (rider, passenger, luggage & accessories)

Electrical Equipment

Battery Rating 12 volt, 18 amp hour

Alternator Rating 37 amps/min at 2,000 rpm 41 amp/min at 6,000 rpm


1.19

General Information

Torque Wrench Settings

Cylinder head area

Appl ication Torque (Nm)
Cam cover to cylinder head 10
Cam chain tensioner to crankcase 9
Cam ladder to head See text
Camshaft sprocket to camshaft 15
Cam chain tensioner blade to crankcase 18
Cam chain top pad to head See text
Cylinder head to crankcase See text
Noise suppression bolt to cam chest 10 Clutch

Application Torque (Nm)
Clutch cover to crankcase 9
Clutch centre nut 105
Clutch pressure plate to basket 10 Crankshaft and crankcases

Appl ication Torque (Nm)
Connecting rod big end bolts See text
Crankcase to crankcase bolts See text
Transmission shaft bearing cap See text
Main bearing ladder bolts See text
Lubrication circuit threaded inserts 45 Engine Covers

Clutch cover to crankcase 9
Clutch outer cover to inner cover 9
Alternator cover to crankcase 9
Torsional damper shaft cover to crankcase 2B (MB)
9 (M6)
Cam chain inspection plug to clutch cover 18 1.20


General Information

Transmission

Detent wheel to selector drum 12
Selector drum bearing retaining screw 12
Spring abutment bolt 23
Gear change pinch bolt 9
Gear change pedal pivot bolt 27
Input shaft bearing retainer to crankcase 12
Output gear to output shaft 145 Lubrication System

Sump to crankcase 12
Sump plugs (front and rear) 25
Oil pick up strainers to sump 12
Oil pick up pipes to crankcase 9
Oil tank drain plug to sump 25
Oil pressure relief valve to crankcase 15
Oil filter adapter 10
Oil pumps to crankcase 12
Oil pump chain retainer plate to crankcase 9
Oil pressure relief valve 15 Cooling System

Water pump to crankcase 10
Radiator to frame 9
Thermostat housing to head 4
Fan shroud to radiator 2
Cooling system bleed screw 10 Service Manual - Rocket III

1.21

General Information

Fuel System, Exhaust System and Airbox

Fuel tank to frame (pivot bolt) 9
Fuel tank to frame (front fixing) 9
Fuel pump mounting plate to fuel tank 5
Fuel pump clamp screw 2
Throttle body transition piece to cylinder head 12
Exhaust headers to cylinder head 19
Exhaust headers to cat box clamp bolt 22
Exhaust cat box to frame 27
Silencer mounting bracket to frame 27
Fuel level sensor to fuel tank 10
Air filter cover to airbox 3
Airbox to bracket 9 Rear Suspension

Swinging arm pivot bolt - fixed (left hand) 100
Swinging arm pivot bolt - adjustable (right hand) 15
Swing arm pivot bolt lock ring (right hand) 100
Rear suspension unit upper mounting bolt 28
Rear suspension unit lower mounting bolt 28 Front Suspension

Upper yoke pinch bolt 20
Lower yoke pinch bolt 22
Fork top cap to inner tube 30
Upper yoke centre nut 65
Damping cylinder bolt 45
Handlebar clamp to top yoke 35
Handlebar clamp bolt 26
Handlebar clamp cover plate bolts 3 Wheels

Front wheel spindle/axle bolt 65
Fork to wheel spindle pinch bolts 22
Rear wheel spindle flanged locknut 110 1.22


General Information

Front Brakes

Calliper to fork 40
Pad retaining pin (hexagon drive) 18
Calliper bleed screw 5
Hose to calliper 25
Master cylinder to handlebar 15
Hose to master cylinder 25
Disc to wheel 22
Fluid reservoir to bracket 6 Rear Brakes

Calliper bleed screw 8
Hose to calliper 25
Master cylinder to frame 27
Master cylinder reservoir to frame 7
Hose to brake pipe joint 25
Hose to brake light switch 15
Brake pedal pivot bolt 30
Brake disc to wheel 22 Footrests and Control Plates

Foot rest mounting bar to engine (left and right) 27
Rear footrest to hanger 27
Side stand to engine 40
Side stand pivot bolt 20
Side stand pivot locknut 25
Front footrest end screw to footrest 9
Heel guards to control plate bar 9
Bank angle peg to footrest 10 Service Manual - Rocket III

1.23

General Information

Bodywork

Engine to frame bolts See text
Front mudguard to forks 27
Front mudguard finisher to mudguard 3
Rear mudguard/covers to frame See text
Rear seat to mudguard 9
Side covers to frame 9
Engine infill panels to frame 4 Electrical

Starter motor to engine 28
Alternator rotor to crank 120
Alternator stator to crankcase 12
Alternator rectifier to bracket 9
Alternator cover to crankcase 9
Rear light to mudguard 7
Number plate light to bracket 9
Indicators to brackets 9
Indicator lenses to indicators 2
Headlight horizontal adjuster 15
Headlight vertical adjuster 20
Headlight bezel clamp 4 1.24


General Information

Routings

Clutch Cable Routing

~'


1.25

General Information

Handlebar Cable Routing

(

\

\

\

\

1.26


General Information

Main Wiring Harness Routing


1.27

General Information

Rear Mudguard Harness Routing

1.28

Service Manual ~ Rocket III

General Information

Front Brake Hose Routing


1.29

General Information

Rear Brake Pipe and Hose Routing

1.30


General Information

Throttle Cable Routing


1.31

General Information Fuel Hose and F

uel Tank Breather H

ose Routing (

non-evaporative . .

emission control .

versions)

1.32

Service M

anual- Rocket III

General Information

Fuel Hose and Evaporative/Fuel Tank Breather Hose Routing

~'

Service Manual - Rocket 111

1.33

General Information


1.34


2 Scheduled Maintenance

Table of Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . .. 2-2

Scheduled Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-3


2.1

Scheduled Maintenance

Introduction

To maintain the motorcycle in a safe and reliable condition, the maintenance and adjustments outlined in this section must be carried out as specified in the schedule of daily checks, and also in line with the scheduled maintenance chart.

Weather, terrain and geographical location affects maintenance. The maintenance schedule should be adjusted to match the particular environment in which the vehicle is used and the demands of the individual owner. For advice on adjusting the service schedule, consult your authorised Triumph dealer.

In order to correctly carry out the maintenance items listed in the scheduled maintenance chart, special tools and specialist knowledge will be required. As only an authorised Triumph dealer will have this knowledge and equipment, Triumph strongly recommends that your authorised Triumph dealer carries out all scheduled maintenance.

A dangerous riding condition could result from incorrect maintenance leading to loss of motorcycle control and an accident.

All maintenance is vitally important and must not be neglected. Incorrect maintenance or adjustment may cause one or more parts of the motorcycle to malfunction. A malfunctioning motorcycle is dangerous and may lead to an accident.

Triumph Motorcycles cannot accept any responsibility for damage or injury resulting from incorrect maintenance or improper adjustment carried out by the owner.

Since incorrect or neglected maintenance can lead to a dangerous riding condition, always have an authorised Triumph dealer carry out the scheduled maintenance of this motorcycle.

2.2




2.4



Scheduled Maintenance Chart

Odometer Reading in Miles (Kms) or time period,
whichever comes first.
Operation Description Every 500 10,000 20,000 30,000 40,000 50,000 60,000
(800) (16000) (32000) (48000) (64000) (80000) (96000)
1 month 1 year 2 years 3 years 4 years 5 years 6 years
Engine - check for leaks Day • • • • • • •
Engine oil - renew - • • • • • • •
Engine oil filter - renew - • • • • • • •
Valve clearances - check - • • •
Air cleaner - renew - • • •
Engine ECM - check for stored DTC - • • • • • • •
Spark plugs - check - • • • •
Spark plugs - renew - • •
Throttle bodies - balance - • • • • • •
Throttle cables - check/adjust Day • • • • • • •
Cooling system - check for leaks - • • • • • • •
Coolant level - check/adjust - • • • •
Coolant - renew - • • •
Fuel system - check for leaks Day • • • • • • •
Lights, instruments & electrical systems - check Day • • • • • • •
Fuel filter - renew - • • •
Steering - check for free operation Day • • • • • • •
Headstock bearings - check/adjust - • • • • • • •
Headstock bearings - lubricate - • • •
Forks - check for leaks/smooth operation Day • • • • • • •
Fork oil - renew - •
Brake fluid levels - check Day • • • • • • •
Brake fluid - renew Every 2 years
Brake pad wear - check Day • • • • • • •
Brake calipers - check for leaks and seizures - • • • • • • •
Brake master cylinders - check for leaks - • • • • • • •
Final drive - check for oil leaks - • • • • • • •
Final drive oil - check - • • • •
Final drive oil - renew - • • •
Fasteners - inspect visually for security Day • • • • • • •
Wheels - inspect for damage Day • • • • • • •
Tyre wear/tyre damage - check Day • • • • • • •
Tyre pressures - check/adjust Day • • • • • • •
Clutch cable - check/adjust Day • • • • • • •
Stand - check operation Day • • • • • • • Service Manual - Rocket III

2.3

3 Cylinder Head

Table of Contents

Exploded View - Cam Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-2 Exploded View - Camshaft and Cam Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-3 Exploded View - Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-4

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-5 Cam Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-5

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-5

Installation 3-6

Cam Chain Tensioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-6 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-7

Installation 3-7

Camshafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-9

Camshaft identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-10 Cam sprocket orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-10

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-11

Installation 3-12

Valve Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Valve Clearance Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

I nstallatio n 3-16

Valves and Valve Stem Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-17 Removal from the cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-17

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-17

Cam Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-18 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-18


3.1

Cylinder Head Cover

d View - Cam Explode

~ 10Nm

r

3.2

al - Rocket III Service Manu

Cylinder Head

Exploded View - Camshaft and Cam Drive

18Nm

Q~

ccey

~~ 27Nm

18Nm (j /

12~ ,

TlllnY •• ' .~


3.3

Cylinder Head

Exploded View ~ Cylinder Head

SEE TEXT

SEE TEXT

SNm

ccez

10Nm

;)

r·r

10Nm

~

10Nm

3.4


Cylinder Head

Description

The engine is fitted with an aluminum alloy cylinder head, which carries the camshafts, valves and spark plugs. The cylinder head is cast as a single entity, to which various components are permanently added after machining.

A silenHunning cam chain drives the twin-overhead camshafts, which run directly in the cylinder head without additional bearings. The chain is tensioned by a spring-loaded device fitted to the cylinder head, and is guided by two Teflon-coated rubber-faced blades. Valve clearances are adjusted by changing variable thickness shims that sit between the camshaft and valve tappet bucket. The valves are fitted with single, symmetrical valve springs. Both the tip and seat face of the valves are hardened to give a long service life. Due to assembly methods used, the valve seats and valve guides cannot be replaced.

Oil is supplied to the cylinder head by an internal passageway inside the engine. Once it arrives at the cylinder head, it is passed through a restrictor, and is then delivered to the camshaft bearing journals along grooves in the cam ladder. The camshaft lobes are splash fed by oil coming from the camshaft journals.

Cam Cover

Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Removal

1. Remove the rider's seat (see page 17.9).

2. Disconnect the battery, negative (black) lead first.

3. Raise and prop the fuel tank (see page 11.98).

4. Remove the intake duct (see page 11.105) together with its bracket.

5. Disconnect the spark plug leads from the spark plugs then remove the coil brackets with the coils attached.

6. Remove the bungs from the heads of the cam cover fixings.

7. Release the bolts securing the cam cover to the head.

1. Cam cover

2. Cam cover bolts

3. Bolt seals

8. Remove all the bolts and bolt-seals from the cam cover.

9. Raise the cover and manoeuvre it towards the right hand side of the engine, where it can be removed.

Never use a lever to remove the cam cover from the cylinder head. Using a lever will cause damage to the cylinder head and cam cover, which could lead to an oil leak.

10. Collect the seal from the head.

~.

3.5


Cylinder Head

Installation

1. Check the condition of the cam cover seal and cam cover bolt seals. Replace as necessary.

2. Apply silicone sealant to the cylinder head where four '0' sections of the cam cover seal fit.

cbpq

1. 'D' sections

3. Fit the seal ensuring the four 'D' sections seat in the corresponding half-rounds in the cylinder head. Position the spark plug tower seals to the six plug towers.

4. Fit the cam cover to the cylinder head. Ensure that the seal remains in position, paying particular attention to the six spark plug tower areas.

5. Fit the cam cover bolts, complete with their seals (steel ring side facing upwards) and tighten to finger tight.

6. Progressively and evenly tighten the cam cover

bolts to 10 Nm.

7. Refit the coil bracket and coils.

8. Reattach the plug leads to the plugs.

9. Refit the intake duct bracket, tightening its bolts to 9 Nm.

10. Refit the intake duct (see page 11.109).

11. Seat the fuel tank on the frame and secure it (see page 11.99).

12. Reconnect the battery, positive (red) lead first.

13. Refit the rider's seat.

Cam Chain Tensioner


Removal

1. Remove the cam cover (see page 3.5).

2. Remove the inspection plug from the clutch cover.

1. Inspection plug

3. Turn the engine until the maximum numbers of cam lobes are facing away from the valves. This will prevent the cams from springing around when the cam chain tensioner is removed.

1

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1. Camshafts

2. Lobes

3. Valves

4. Remove the center nut and washer from the cam chain tensioner.

3.6


Cylinder Head

The centre nut of the cam chain tensioner is under spring tension. Always wear hand, eye and facial protection when releasing the centre nut as unprotected areas of the body can be injured if the spring tension released in an unexpected or uncontrolled way.

5. Withdraw the spring and nut from the tensioner body.

1. Cam chain tensioner

2. Centre nut

6. Remove the cam chain tensioner body from the head.

Inspection

1. Inspect the tensioner spring for damage and deformation. Renew as necessary.

2. Inspect the tip of the tensioner plunger for wear and damage. Renew as necessary.

Installation

1. Fit a new gasket to the tensioner body.

2. Set the tensioner plunger onto the first tooth of the ratchet by manually lifting the tensioner pawl and pushing the plunger into the tensioner body.

cbpu

1. Tensloner

2. Tensioner plunger

3. Pawl

3. Look into the inspection hole. Rotate the

crankshaft clockwise (as viewed from the front), until No. 1 cylinder is at ToC. No. 1 cylinder is at TOC when a 'dot' mark on the crank gear is in alignment with the line in the upper crankcase.

1. Crankshaft 'dot' mark

2. Upper crankcase line

~.

3.7


Cylinder Head

In addition, timing marks on the camshaft sprockets should point downwards at a point level with the cylinder head. If they do not align as shown, turn the camshafts until they do align.

1. Inlet cam timing marks

2. Exhaust cam timing marks

4. Fit the dowels of tool T3880202 to location holes in the cam sprockets, as shown in the diagram below. This will hold the cams in the correct timing position and prevent them from turning while the chain tensioner is fitted.

1

cbpx

1. Tool T3880202

2. Cam sprocket holes

5. Fit the tensioner to the crankcase (ratchet teeth facing upwards) ensuring the gasket is not damaged during the process.

6. Fit and tighten the tensioner fixings to 9 Nm.

7. Push the tensioner plunger into contact with the chain guide using finger pressure.

1. Tensioner

8. Fit a new washer to the tensioner's centre nut.

9. Fit the spring to the tensioner body. Fit the centre nut and tighten to 23 Nm.

The centre nut of the cam chain tensioner is under spring tension. Always wear hand, eye and facial protection when releasing the centre nut as unprotected areas of the body can be injured if the spring tension released in an unexpected or uncontrolled way.

10. Remove tool T3880202 and turn the crankshaft clockwise (as viewed from the front of the engine) through four complete revolutions. Stop when the timing marks on the crankshaft gear realign with the line in the upper crankcase.



11. Check that the camshaft marks align as described previously. Rectify as necessary.

3.8


Cylinder Head

12. When the timing checks have been satisfactorily completed, refit the inspection plug tightening it to 18 Nm.

13. Refit the cam cover (see page 3.6).

Camshafts


Note:

• Either camshaft can be removed from the cylinder head without complete removal of the cam chain. However, the cam chain must first be detached from the camshafts.

1. Remove the cam cover (see page 3.5>. Note:

• Turn the engine until the maximum number of cam lobes are facing away from the valves. This will prevent the cams from springing around when the cam chain tensioner is removed.

1

1. Camshafts

2. Lobes

3. Valves

2. Remove the cam chain tensioner (see page 3.6).

3. Remove the cam chain top pad.

1. Top pad

To avoid damage to the cam ladder, always ensure as many cam lobes as possible are facing away from the valves. This will reduce stress on the cam ladder during removal. Damage to the cam ladder will result in replacement of the complete head.

4. Progressively and evenly release the remaining cam ladder fixings, half a turn each, until the upward pressure on the bolt heads has been released. Always start from the centre of the engine.

cbqa

1. Cam ladder

2. Cam ladder fixings (2 of 16)

~.

3.9


Cylinder Head

Failure to release the cam ladder fixings progressively and evenly may result in damage to the cam ladder, the camshafts or the cylinder head itself. A damaged cam ladder cannot be replaced as an individual item. It can only be obtained as part of a new cylinder head.

5. Once all the upward force on the cam ladder has been progressively released, collect all the bolts and remove the ladder.

6. Secure the cam chain to prevent it from falling into the front of the engine.

Note:

• The sound suppression bolt will prevent the cam chain from falling completely away from the head.

7. Lift the cam chain from one of the camshafts to allow removal of the shaft from the cylinder head.

1. Removing a camshaft

8. Repeat for the second camshaft.

Camshaft identification

The inlet camshaft can be identified by a groove on a machined surface in its centre. The same surface on the exhaust cam is plain.

1. Inlet cam (grooved)

2. Exhaust cam (plain)

Cam sprocket orientation

The same drive sprocket is used for both inlet and exhaust cams.

To attach the sprocket in the correct relationship to the cams, two pairs of offset bolt holes are used, with inlet and exhaust bolt holes being clearly marked ('IN' for inlet and 'EX' for exhaust), The holes will also prevent the sprockets from being fitted 1800 out of alignment.

1. Sprocket

2. IN marking

3. EX marking

To fit a sprocket to an inlet cam, position the sprocket to the cam and align the hole marked 'IN' with one of the threaded holes in the camshaft. If both bolt-holes in the cam line up correctly with the holes in the sprocket, the sprocket is in the correct place. If the holes do not line up, then the sprocket should be rotated by a half-turn.

3.10


Cylinder Head

cbq.

Inspection

1. Inspect the sprockets for damage and worn or broken teeth.

2. Inspect the bearing surfaces in the cylinder head and cam ladder. If wear or damage is found, the cylinder head must be replaced.

3. Inspect the cam chain (see page 3.7).

4. Check camshaft journal to cam ladder clearance using Plastigage (Triumph part number 3880150- T0301) as follows:

During the flowing procedure, the engine must not be rotated. Damage to valves, pistons and the cylinder head can result from rotating the engine.

a) Position a camshaft to the cylinder head in it's correct location, (inlet cam to inlet valves, exhaust cam to exhaust valves). Ensure that the timing marks on the cam sprocket are positioned as for removal.

b) Release and remove the cam ladder as previously described. Wipe the exposed areas of one of the camshaft journals and the corresponding position on the cam ladder.

c) Apply a thin smear of grease to the wiped camshaft journal and a small quantity of silicone release agent to the corresponding position on the cam ladder.

d) Size a piece of Plastigage to fit across the wiped camshaft journal.

e) Fit the Plastigage to the camshaft journal using the grease to hold it in place.

f) Position the cam ladder to the cylinder head, aligning bearing areas with cam journals. At this stage, it is not necessary to fit the cam chain top pad.

g) Finger-tighten the cam ladder bolts until the under-head areas are in contact with the cam ladder.

h) In the sequence shown below evenly and progressively tighten the cam ladder bolts, approximately half a turn each, until the cam ladder is in full contact with the head.

11 1

cbqf

4

1. Cam ladder tightening sequence

i) In the same sequence, torque each cam ladder bolt to 10 Nm.

j) Release and remove the cam ladder as previously described.

k) Utilising the gauge provided with the Plastigage kit, measure the width of the now compressed Plastigage.

1. Taking a plastigage measurement

5. Calculate the cam journal clearance using the chart provided with the Plastigage kit.

~.

3.11


Cyli nder Head

6. If the journal to cam ladder clearance is within the specified tolerances (see table below). remove the cam ladder and clean off all traces of Plastigage. sificone release agent and grease.

Standard

0.040 - 0.091 mm

Service limit

0.13 mm

7. Check the diameter of the camshaft journals.

I Standard I 22.93 - 22.96 mm

8. If any of the journal to cam ladder clearances are outside the specified tolerances. but the camshaft journals are within their specified tolerances. the cylinder head must be replaced.

Installation

1. Correctly identify the inlet and exhaust cams as previously described.

2. Position the camshafts to the two banks of valves ensuring that the inlet cam is located to the inlet valves and the exhaust cam to the exhaust valves.

3. Turn the engine over so that all three pistons are away from TDC (approximately 150ATDC).

4. Working on one cam at a time, locate the cam chain over the camshaft sprockets.

5. Ease the cam chain away from the sprockets then turn each camshaft until as many lobes as possible are facing away from the valves. Allow the chain to drop back onto the cams.

To avoid damage to the cam ladder, always ensure as many cam lobes as possible are facing away from the valves. This will reduce stress on the cam ladder during assembly. Damage to the cam ladder will result in replacement of the complete head.

Located camshafts

6. Lubricate the cam bearing areas of the cam ladder with a 50/50 solution of engine oil and molybdenum disulphide grease.

cbqh

1. Cam ladder

2. Cam bearing areas

7. Lubricate the threads of the cam ladder bolts with clean engine oil.

8. Position the cam ladder to the cylinder head, aligning bearing areas with cam journals.

9. Finger-tighten the cam ladder bolts until the bolt's under-head areas are in contact with the cam ladder.

3.12


Cylinder Head

10. In the sequence shown below evenly and progressively tighten the cam ladder bolts, approximately half a turn each, until the cam ladder is in full contact with the head.

11 1

713

16

1. Cam ladder tightening sequence

11. In the same sequence, torque each cam ladder bolt to 10 Nm.

12. Fit the cam chain top pad. Tighten the top pad fixings to 10 Nm.

13. Ease the cam chain away from the cams. Rotate the crankshaft clockwise (as viewed from the front), until No. 1 cylinder is at TDC. No. 1 cylinder is at TDG when a 'dot' mark on the crank gear is in alignment with the line in the upper crankcase.



Note:

• After placing each cam in the timing position, it will be necessary to have an assistant hold the cams in position until tool T3880202 is fitted.

• Set the exhaust cam first, then the inlet.

14. Ease the cam chain away from the sprockets and position the cams so that the timing marks align as shown below. Allow the cam chain to drop back onto each sprocket after positioning each cam.

1. Inlet timing mark

2. Exhaust timing mark

15. Fit tool T3880202 to location holes in the cam sprockets as shown in the diagram below. This will hold the cams in the correct timing position and prevent them from turning while the chain tensioner is fitted.

1

cbp<

1. Tool T3880202

2. Cam sprocket holes

16. Refit and assemble the cam chain tensioner plunger, spring and centre nut (see page 3.7).

17. Remove tool T3880202.

18. Turn the engine over at least four times, then check the cam timing again. Reset as necessary

19. Check ali valve clearances (see page 3.14).

Adjust as necessary to give the correct clearances.


~.

3.13


Cyli nder Head

Valve Clearances

Camshaft, valve, valve shim and valve seat wear affect the valve clearances. The effect of this wear is to change the clearance between the camshaft and the adjustment shim, causing engine noise and/or improper running. If the valve clearances are incorrect, permanent damage to components in the valve-train will take place and engine performance will be affected.

Correct valve clearances are in the range given in the table below.

Inlet

0.10 to 0.15 mm

Exhaust

0.15 to 0.20 mm

Note:

• Valve clearance adjustment must be carried out with the engine cold.

1. Remove the cam cover (see page 3.5).

2. Remove a spark plug from each cylinder to reduce compression resistance when turning the engine.

3. Select a high gear and, using the rear wheel, turn the engine over until a pair of camshaft lobes are positioned pointing directly away from the valves.

4. Using feeler gauges, measure and record the clearances for this pair of valves only.

5. Repeat the process until the clearances for all valves have been checked.

If any of the recorded clearances fall outside the specified range, adjustments must be made. If all measured clearances are within tolerance, refit the cam cover (see page 3.6).

Valve Clearance Adjustment

Note:

•

Valve clearance checking and adjustment must be carried out with the engine cold.

1.

Measure and record all valve clearances as described previously.

Remove the camshafts (see page 3.9).

2.

3. Remove a shim from one of the valves whose clearance required adjustment

4. Measure the original shim, using a micrometer.

5. Calculate the shim thickness required to give the correct clearance. Clearance too small; fit a thinner shim. Clearance too large; fit a thicker shim.

Note:

•

Shims are available ranging from 2.00 mm to 3.20 mm in increments of 0.025 mm.

Fit the selected shim to the tappet bucket.

6.

7. Repeat the procedure until all valves requiring adjustment have been correctly set.

B. Refit the camshafts (see page 3.12).

9. Rotate the engine several times to fully seat the shims.

10. Repeat the clearance checks on all valves, adjust as necessary.


3.14


Cylinder Head

Cylinder Head


1. Remove the fuel tank (see page 11.100).

2. Drain the cooling system (see page 12.6).

3. Remove the exhaust header system (see page

11.134).

4. Remove the throttle bodies (see page 11.122).

5. Remove the oil tank (see page 9.16).

6. Remove the camshafts (see page 3.9).

7. Disconnect the top and bypass hoses from the cylinder head.

1. Top hose

2. Bypass hose

8. Disconnect the coolant temperature sensor and low oil pressure switch connections.

1. Low oil pressure warning light switch

9. Remove both engine in-fill panels.

In-fill panel

10. Identify the position of each of the tappet buckets and shims before removing them from the head.

11. Remove the sound suppression bolt from the cam chain chest.

12. Progressively release the cylinder head bolts in the order shown below.

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Head bolt release sequence

13. Remove the head bolts including two smaller bolts situated at the front of the engine.

14. Remove the head from the crankcase.

Note:

• If necessary, lightly tap the head with a

soft-faced mallet to break the gasket seal.

15. Remove and discard the head gasket.

16. Remove the cylinder liners (see page 5.18).

Note:

• Cylinder liners must be resealed if the head is removed.

1ieJR'

3.15


Cylinder Head

Installation

Inspection

1. Thoroughly clean the surface of the cylinder head and check for damage andlor pitting of the combustion chambers.

2. Using a straight edge and feeler gauges, check the cylinder head gasket face for warp, which could lead to gasket failure. Replace the cylinder head if warped beyond the flatness limit.

Checking head flatness

Cylinder head flatness 0.030 mm

tolerance

3. Check the cam chain rubbing blades. Renew if worn or damaged.

Ensure all traces of fluid (coolant, oil etc.) are removed from the threaded holes in the crankcase. Should any fluid remain in any of the threaded holes, severe crankcase damage could result from hydraulic locking of head bolts on assembly of the engine.

1. Thoroughly clean the upper faces of the crankcase and liners. Also clean the liner to crankcase mating faces.

2. Fit the cylinder liners (see page 5.19).

3. Move the cam chain rubbing blades to a position that allows the head to fit over them.

4. Ensure that both head dowels remain in position in the crankcase.

1

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1. Dowels

5. Position a new cylinder head gasket to the crankcase.

6. Lower the cylinder head over the cam chain rubbing blades and locate it onto the dowels.

Cylinder head bolts must never be reused and must always be replaced if removed or loosened.

Use the correct procedure to tighten the cylinder head bolts carefully following the three-stage procedure below. This will ensure the long-term reliability of the cylinder head gasket.

Failure to follow the correct tightening procedure or reuse of old head bolts may lead to engine damage and premature failure of the cylinder head gasket.

3.16

Service Man ual - Rocket III

Cylinder Head

7. In the order shown below, tighten the cylinder head bolts in three stages as follows:

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Cylinder head bolt tightening sequence

8. In the sequence shown above, tighten bolts through 8 to 20 Nm.

9. In the sequence shown above, tighten bolts 1 through 8 to 50 Nm.

10. In the sequence shown above, tighten bolts 1 through 8 through a further 90° using tool T3880105 or similar to measure the torqueangle.

11. Tighten bolts 9 and 10 to 12 Nm.

12. Lubricate the tappet buckets with a 50/50 solution of molybdenum disulphide grease and engine oil, then refit them and the valve shims to their original locations in the head.

13. Refit the camshafts (see page 3.12).

14. Check and adjust the valve clearances (see page

3.14).

15. Reconnect the coolant temperature sensor.

16. Refit the bypass and top hoses.

17. Refit the oil tank (see page 9.16).

18. Refit the throttle bodies (see page 11.123).

19. Refit the exhaust system (see page 11. 136).

20. Refill the cooling system (see page 12.7).

21. Refit the fuel tank (see page 11.101).

22. Refit both engine in-fill panels, tightening the fixings to 4 Nm.

23. Start the engine and allow it to idle while checking for air, oil, coolant and exhaust leaks. Rectify as necessary.

24. Check and top up the cooling system (see page 12.5).

25. Check and top up the oil level (see page 9.7).

Valves and Valve Stem Seals

Removal from the cylinder head

1. Remove each valve from the head using a valve spring compressor. The compressor must act on the top cup to allow removal of the valve collets.

2. Once the collets are released, remove the

following items:

• collets

• valve spring cap

• valve spring

• valve stem seal

• valve spring thrust washer

Installation

1. Apply a thin coat of molybdenum disulphide grease to the valve stem.

2. Install the valve into the valve guide and refit the thrust washer to the valve spring recess (if removed).

3. Fit the valve stem seal over the valve stem and, using a suitable tool, press down fully until the seal is correctly seated over the valve guide.

Note:

• During fitment of the valve stem seal, two distinctly different degrees of resistance will be noted when the seal is correctly fitted.

4. Firstly, press the seal down the valve stem until the lower side of the seal comes into contact with the valve guide. Greater resistance is felt at this contact point and further gentle pressure is then required to locate the seal over the top end of the valve guide.

5. On application of this pressure, the seal can be felt to positively locate over the top face of the valve guide. Once correctly positioned, the seal cannot be pushed down any further.

Incorrect fitment of the valve stem oil seals could lead to high oil consumption and blue smoke emissions from the exhaust system. Do not use excessive force in fitting the seal as this may break the seal ring.

6. Install the valve spring.

~.

3.17


Cylinder Head

7. Compress the valve spring ensuring that the spring is compressed squarely to prevent damage to components.

8. Fit the valve collets ensuring their correct location in the spring cap and valve as the spring compressor is released.

Always check for correct location of the valve collets during and after assembly. If not fitted correctly, the collets may become dislodged when the engine is running allowing the valves to contact the pistons. Any such valve to piston contact will cause severe engine damage.

Cam Chain

Inspection

An in-situ check can be made as follows:

1. Check for significant blue discolouration of the chain plates indicating excessive heat build-up.

2. Examine all pins for signs of rotation.

3. Check for cracking or deep scratching of the chain plates.

4. Check for severe wear of the inner plates as indicated in the diagram below.

cbqo

For a more thorough check, proceed as follows:

1. Remove the chain from the engine.

2. Suspend the chain from a pin or hook with a 13kg weight attached at the lower end.

cbqp

3. Measure across 23 links as shown in the diagram. If the chain is within limits, the measurement should be no longer than 147.63 mm. Measurements beyond 147.63 mm indicate that the chain must be replaced.

3.18


~.

Cylinder Head

1 234

4. Check for severe wear of the inner surface of the outer plates at the side-contact points with the sprocket teeth.

cbqr

5. Check for signs of stiffness or kinking.

6. Check for severe wear of the plates in the area shown below.

If any of these symptoms are evident, the cam chain must be replaced.

~.

3.19


Cylinder Head


3.20


4 Clutch

Table of Contents

Exploded View - Clutch Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.2

Exploded View - Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.3

Exploded View - Clutch Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.4

Clutch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.5 Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.6

Installation 4.6

Clutch Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.7

Removal. . .. . . . .. .. . .. .. .. .. . . . . . . . . . . . .. .. .. . .. .. . . . . . . . .. 4.7

Installation 4.7

Clutch. . ... .. . . .. . . . .. .. .. .. . . . .. .. .. .. .. .. . .. .. .. 4.7

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.7

Friction Plate Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.9

Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

~.


4.1

Clutch

Exploded View - Clutch Controls

15N~e

3Nm

r

3Nm

aau/

-.

3Nm

4.2


Clutch

Exploded View - CI utch

@

.. ~ I

10Nm

4.3


Clutch

Exploded View - Clutch Cover

9Nm

4.4


Clutch

Clutch Cable

Removal


1. Remove the rider's seat as described on page 17.9.

2. Disconnect the battery, negative (black) lead first.

3. Slacken the cable locknut and release the adjuster at the engine end to give maximum play in the cable.

1. Clutch Cable

2. Adjuster

4. Release the clutch cable from the actuating arm by pushing the inner cable nipple through the arm and sliding the cable out. Detach the cable from the bracket.

1. Actuating Arm

2. Inner Cable

5. Align the slots in the lever adjuster and locknut.

1. Locknut

2. Lever adjuster

~.

4.5


Clutch

6. Pull in the clutch lever and turn the inner cable, anti-clockwise through the slots in the adjuster and locknut, until the cable can be detached from the lever.

1. Nut/locknut Slots

2. Cable Release Point

7. Remove the cable from the motorcycle noting the cable routing, particularly where it passes through steering area.

Note:

• To ensure the same route can be followed on installation, tie a length of string to one end while pulling the cable through from the other. When installing the new cable, tie the string to one end of the cable and use it to guide the new cable into position.

Examination

1. Check the inner cable for free movement through the outer cable.

2. Examine the inner cable for frayed strands.

3. Examine the two inner cable nipples for signs of looseness and damage. Replace the cable if necessary.

Installation

1. Position the cable to the motorcycle following the same routing as noted during removal.

2. Attach the inner cable to the clutch lever and actuating arm using a reversal of the removal process.

3. Refit the outer cable to the adjuster bracket at the engine end.

Note:

• Ensure that the two adjuster nuts are positioned, one either side of the bracket.

4. Set the lever adjuster to a point where an equal adjustment is possible in both directions.

5. Set the adjuster at the clutch end to give a preliminary setting of 2-3 mm of free playas measured at the lever.

6. Operate the clutch lever several times and recheck the amount of free-play present.

7. Set the final adjustment of the cable to give 2- 3 mm of free-play at the lever by turning the adjuster nut and locknut at the lever end. Secure the setting with the knurled locknut.

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1. Clutch Lever

2. Correct Setting, 2-3 mm

8. Reconnect the battery positive (red) lead first.

9. Refit the rider's seat.

4.6


Clutch

Clutch Cover

Removal


1. Remove the radiator as described on page 12.11.

2. Remove the water pump as described on page 12.7.

3. Remove the coolant pipe running between the crankcase and water pump.

4. Disconnect the clutch cable as described on page 4.5.

5. Release the ring of bolts securing the clutch cover to the crankcases.

6. Place an oil catch tray beneath the clutch cover to collect any oil that may spill out on removal.

7. Carefully withdraw the cover disengaging the lifter arm as it is eased forward.

Installation

1. Thoroughly clean the cover and crankcase mating faces.

2. Position a new gasket to the crankcase.

3. Refit the cover ensuring that the gasket does not become dislodged.

Note:

• Ensure that the lifter piece engages correctly with the lifter arm during assembly. It way be necessary to pull the lifter arm forward to allow assembly to take place.

4. Fit and tighten the bolts to 9 Nm. Tighten the bolts in a diagonal sequence.

5. Refit the coolant pipe, tightening its fixing to 9Nm.

6. Refit the water pump as described on page 12.8.

7. Refit the radiator as described on page 12.13.

Clutch

Removal


1. Remove the clutch cover as described on page 4.5.

2. Undo the bolts, withdraw the springs and remove the clutch pressure plate.

1. Pressure plate bolts

2. Springs

3. Pressure plate

3. Remove the lifter piece, needle bearing and thrust washer.

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1. Lifter piece

2. Needle bearing

3. Thrust washer

1BJ!!!JR'

4.7


Clutch

4. Remove all the clutch friction plates and steel plates together with the anti-judder seat washer and spring. Note the orientation of all components as they are removed.

4

1

cbvu

1. Friction Plates

2. Steel Plate

3. Anti-judder Seat Washer

4. Anti-judder Spring

Note:

• The inner and outermost friction plates are different to the remainder and are also different to each other. They must not be fitted in any other positions.

• Refer to the following page of this section for details of clutch friction plate inspection.

• It is not normally necessary to disassemble the clutch further, but if the clutch inner and outer drums are to be removed, proceed as follows:

5. Engage any gear and lock the inner and outer clutch drums together using service tool 3880025- T0301 .

1. Service tool 3880025-T0301

6. Depress the rear brake pedal to prevent the engine from turning, and then release the clutch centre nut.

7. Remove the centre nut, Belleville washer, plain washer, clutch inner drum and thrust washer.

2 3

\ 1 ~©J

1

4

1. Centre Nut

2. Belleville washer

3. Plain washer

4. Inner Drum

5. Thrust Washer

8. Slide the clutch outer drum outwards from the engine, collecting the bearing sleeve on removal of the drum.

1. Outer drum

2. Bearing sleeve

4.8


Clutch

Friction Plate Inspection

Thickness

1. If any friction plate thickness is outside the service limit, replace the friction plates as a set.

1. Clutch friction Plate

Friction plate thickness - all plates

Standard 3.72 - 3.88 mm

Service limit

3.5mm

2. Check all plates for bend and warp as follows:

Place the plate being checked on a clean surface plate and attempt to pass a feeler gauge of the maximum service limit thickness between the friction plate and surface plate. If the feeler gauge can be passed beneath the friction plate at any point, renew the plates as a set.

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1. Friction Plate

2. Feeler Gauge

3. Surface Plate

Friction plate bend/warp

Service limit I 0.30 mm

Assembly

1. Position the bearing sleeve then the clutch outer drum to the input shaft.

2. Align the oil pump drive pegs with the corresponding holes in the rear of the clutch outer drum.

1. Clutch outer drum

2. Oil pump sprocket drive pegs

3. Oil pump drive holes

~.

4.9


Clutch

3. Pre-load and align the primary gear and backlash eliminator with the crank gear. Align the gears through the hole arrowed below.

1. Primary gear

2. Backlash eliminator

3. Crank gear

4. Arrowed; alignment hole

Note:

• When the outer drum is correctly fitted and the gears are pre-loaded correctly, the bearing sleeve will be a flush fit with the clutch drum face. In addition, a groove around the input shaft will be visible.

4. Fit the thrust washer to the shaft.

1. Thrust washer

5. Fit the clutch inner drum.

6. Refit the plain washer, fit a new Belleville washer ('out' mark facing outwards), and refit the centre nut.

1. Belleville Washer 'Out' Mark

7. Lock the inner and outer drums together using service tool 3880025-T0301. Depress the rear brake pedal to prevent the engine from turning, and tighten the clutch centre nut to 105 Nm. Remove the service tool,

1.3880025-T0301

8. Disengage second gear and check for free rotation of the clutch inner drum.

9. Coat all clutch friction plates in clean engine oil

10. Fit the friction plates, steel plates, anti-judder seat and spring to the clutch basket, in the same order as noted during removal.

Note:

• The inner and outermost friction plates are different to the remainder and are also different to each other. They must not be fitted in any other positions.

4.10


Clutch

11. Refit the ctutch pull rod.

12. Refit the clutch pressure plate together with the springs and bolts. Tighten the bolts to 10 Nm.

Note:

• The pull rod should be free to move in and out and also it should be free to turn.

13. Fit the clutch cover as described on page 4.7.

4.11

~.


Clutch


4.12


TD'ID1Wmflll"' :..~

5 Crankshaft

Table of Contents

Exploded View - Crankshaft, Connecting Rod and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-2 Exploded View - Crankcase Fixings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-3 Exploded View - Crankcase and Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-4

Crankcases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-5 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-7

Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-9

Installation 5-9

Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Installation 5-10

Right hand (exhaust) side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Connecting Rod Big End Bearing Selection/Crankpin Wear Check. . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Connecting Rod Bearing Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Crankshaft Main Bearing/Journal Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Checking crankshaft clearance using Plastigage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Crankshaft End Float. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-14

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-1;> Piston Wear Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Piston Rings/Ring Grooves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Piston Ring Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-16 Cylinder Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Cylinder Liners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-19

~.

service Manual - Rocket III

5.1

Crankshaft

Exploded View - Crankshaft, Connecting Rod and Piston

~ ~
c ~
<: ~ ~~ LL

SEE TEXT

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5.2


Crankshaft

Exploded View - Crankcase Fixings

ALL FIXINGS - SEE TEXT


5.3

Crankshaft

Exploded View - Crankcase and Liners

c<:gj

~

L 0

5.4

Service Manual - Rocket [II

~.

Crankshaft

Crankcases

The following procedures often require lifting of heavy components. To avoid injury, always lift heavy components with a hoist or block and tackle and never attempt to manually lift items that are too heavy. Injury may result from failure to use the correct lifting equipment.

The upper and lower crankcases are machined as a matched set and must never be assembled to nonmatching halves. Doing so will cause seizure of the engine.

Note:

• The crankcase halves may be separated with the cylinder head fitted.

Removal

1. Remove the engine from the frame (see page

10.2).

2. Remove the clutch (see page 4.7).

3. Remove the starter motor (see page 18.18) .

4. Remove the alternator (see page 18.15).

5. Remove the oil pump drive and pressure oil pump (see page 9.11).

6. Remove the torsional damper shaft (see page 8.11).

7. Remove the sump (see page 9.9).

8. Remove the cam chain (see page 3.6).

Disassembly

1. Remove the oil pipes from the lower crankcase.

1. all pipes

2. Remove the non-return valve from the scavenge oil pump, by gently pulling it outwards from its location.

1. Non-return valve

3. In the sequence shown below, release the bolts securing the main bearing ladder to the crankcases.

e 5 1 9

2

Main bearing ladder bolt release sequence

~.

5.5


Crankshaft

4. Collect the bolts, then detach the ladder and baffle plate from the crankcase noting the position of both location dowels, which should be removed for safe-keeping.

1. Dowels

5. Starting from bolt 11, release the lower crankcase bolts in the sequence shown in the diagram below. Remove and discard the bolts.

Lower Crankcase Bolt Release Sequence

6. From inside the rear of the crankcases, collect the bearing cap securing the output shaft to the lower crankcase.

1. Output shaft bearing cap Note:

• Always check that all bolts have been released before attempting to separate the cases. Bolts are fitted in discreet locations such as under the pressure oil pump and inside hollow bosses.

7. Separate the lower and upper crankcases noting the position of the three location dowels, which should be removed for safe-keeping.

1. Dowel locations

8. At this point, the balancer shaft may be removed.

To detach the crankshaft, the big end caps must also be removed (see page 5.10).

Do not use levers to separate the upper and lower sections of the crankcase as damage to the crankcases could result.

5.6


Crankshaft

Assembly

1. Use high flash-point solvent to clean the crankcase mating faces. Wipe the surfaces clean with a lint-free cloth.

2. Ensure that the three locating dowels are in position in the upper crankcase.

1. Dowels

3. Apply a thin bead of silicone sealant to the lower crankcase mating faces (at the factory, Three Bond 12078 is used).

Sealer areas

Do not use excessive amounts of sealer. The extra sealer may become dislodged and could block the oil passages in the crankcases, causing severe engine damage.

4. Install and lubricate the crankshaft main bearing shells with clean engine oil (see bearing selection on page 5.13 before proceeding).

5. Install the crankshaft to the upper crankcase.

Installing the crankshaft

6. Install and lubricate the balancer ensuring it is 'timed' to the crankshaft correctly (see page 7.4).

7. Lubricate the crankshaft journals with clean engine oil.

8. Position the lower crankcase to the upper. An assistant may be required to support the crankcase during alignment.

9. Fit the screws into the lower crankcase and hand tighten them.

10. Position the main bearing ladder and baffle to the crankcase (baffle lugs facing into the engine).

cbKP

1. Main bearing ladder

2. Baffle

3. Baffle lugs

11. Tighten the crankcase screws as follows:

Note:

• The crankcase screws are tightened in stages.

5.7


Crankshaft

...• :.: -:: ,.

..... : ...

Failure to follow the correct screw sequence may result in permanent damage.

tightening crankcase

Stage 1 - all screws

In the correct sequence, tighten all crankcase fixings to 10 Nm.

30

22 29
3 12
23 31
16
33
35

21 11 Crankcase fixing tightening sequence, all fixings

Stage 2

In the correct sequence, tighten fixings 1 through 8 to 40Nm.

Crankcase bolt tightening sequence, fixings 1-8

Stage 3

In the correct sequence, tighten fixings 9 through 35 to 28 Nm.

Crankcase fixing tightening sequence, fixings 9-35

5.8


Crankshaft

Crankshaft

Removal

1. Remove the engine from the frame (see page 1O.2).

2. Separate the lower and upper crankcases (see page 5.5).

3. Lift the balancer out of the upper crankcase.

Removing the balancer

4. Remove the connecting rod big end caps (see page 5.10). Discard the bolts after removal.

5. Lift the crankshaft from the upper crankcase.

Support the connecting rods during crankshaft removal to prevent damage to the rods, liners and upper crankcase.

Removing the cran kshaft

Installation

Always check the main bearing journal clearance (see page 5.13), before final assembly of the crankshaft. Failure to correctly select crankshaft bearings will result in severe engine damage.

1 . Select and fit new main and big end bearing shells using the selection processes detailed on pages 5.12 and 5.13.

2. Lubricate all bearings with engine oil.

3. Ensure that the crankshaft is clean, and that the oil ways within the crankshaft are clean and free from blockages and debris.

4. Install the crankshaft ensuring that the crankpins align with the corresponding big ends.

Installing the crankshaft

5. Align the connecting rod big ends to the crankpins.

6. Fit the big end caps and tighten them (see page 5.10 for the tightening sequence and torque).

7. Install the balancer (see page 7.4).

8. Assemble the crankcases (see page 5.7).

~.

5.9


Crankshaft

Connecting Rods

Removal Note:

• The connecting rods and cap are etchmarked on one side to identify their correct orientation. However, the cylinder from which they are individually removed should also be identified, using a laundry marker or similar.

1. Remove the engine from the frame (see section 10.2).

2. Separate the lower and upper crankcases (see page 5.5).

3. Remove the cylinder head (see page 3.5).

4. Remove the connecting rod bolts. Discard the bolts.

1. Connecting rod bolts

2. Connecting rod cap

5. Collect the big end caps.

6. Push the connecting rod up through the liner and collect the piston and connecting rod from the linertop.

7. Label the assembly to identify the cylinder from which it was removed.

8. Mark the position of each liner in the crankcase to ensure it is reassembled in its original position.

9. Remove the cylinder liners using tool T3880061, (see page 5.18).

Installation Note:

• Connecting rod bolts and nuts are treated with an anti-rust solution, which must not be removed.

1. Clean the connecting rod with high flash-point solvent.

2. Select new big end bearings (see page 5.12).

3. Fit the selected big end shells to the connecting rods and big end caps.

4. Fit the piston and connecting rod assemblies into the liners as described on page 5.17.

5. Thoroughly clean the liner removing all traces of old silicone sealer.

6. Remove all traces of sealer from the crankcase bores.

7. Apply a thin bead of silicone sealer to the liner to crankcase mating face.

cbvc

1. Liner

2. Sealer Area

5.10


Crankshaft

8. Fit the liner into the crankcase ensuring that the arrow on the piston faces to the right hand side of the engine/bike (the same side as the exhaust headers).

1. Piston

2. Arrow

Right hand (exhaust) side Note:

• Ensure that the piston/liner/connecting rod assemblies align correctly with the crankpins during assembly into the crankcase.

1. Crankpin

2. Big End

Always renew the big end bolts. The bolts are torqued near to their yield point when first installed and are severely weakened if reused. He-usinq the original bolts may cause bolt breakage resulting in engine damage, loss of motorcycle control and an accident.

9. Align the connecting rod to the crankshaft and fit the big end cap. Tighten the NEW cap bolts as follows:

The torque characteristics of the connecting rod bolts are sensitive to the rate at which they are tightened. If all the torque is applied in one action, the bolts will be stretched beyond their yield point. This may cause bolt breakage resulting in engine damage, loss of motorcycle control and an accident.

Lubricate the under-head and thread areas of the bolts with undiluted molybdenum disulphide grease. Tighten the bolts, in two stages as follows'-

a) Tighten to 14 Nm.

b) Tighten through 1200 of bolt rotation as measured using the Triumph torque turn gauge 38801 05~T0301.

Service Tool 3880105-T0301

5.11

~.


Crankshaft

Connecting Rod Big End Bearing Selection/Crankpin Wear Check

1. Measure the bearing and crankpin clearance as follows.

Note:

• The crankpin clearances are measured using 'Plastigage' (Triumph part number 3880150- T0301). Do not turn the connecting rod and crankshaft during the clearance measurement as this will damage the 'Plastigage'.

2. Remove the big end cap from the journal to be checked.

3. Wipe the exposed areas of the crankpin, and the bearing face inside the cap.

4. Apply a thin smear of grease to the journal and a small quantity of silicone release agent to the bearing.

5. Trim a length of the Plastigage to fit across the journal. Fit the strip to the journal using the grease to hold the Plastigage in place.

6. Lubricate the threads of the bolt and under-head area with undiluted molybdenum disulphide grease. Refit the bearing and cap and tighten the big end bolts as described earlier.

7. Release the bolts and remove the cap being measured. Using the gauge provided with the Plastigage kit, measure the width of the compressed Plastigage.

Checking the Measured Clearance

Can rod big end bearing/crankpin clearance


Service Limit

0.100 mm

Note:

• If the measured clearance exceeds the service limit, measure the crankpin diameter.

Crankpin diameter
Standard 40.946 - 40.960 mm
Service limit 40.922 mm Note:

• If any crankpin has worn beyond the service limit, the crankshaft must be replaced. Due to the advanced techniques used during manufacture, the crankshaft cannot be reground and oversize bearings are not available.

5.12


Crankshaft

Connecting Rod Bearing Selection Note:

• Optimum running clearance is achieved by using selective big end bearings. For further information on bearing part number to colour cross-references, refer to the parts information system.

Select the correct big end bearing shell as follows:

1. Measure each crankpin diameter.

2. Select the correct bearings by matching the information found with the chart below.

Big end bearing selection chart

Shell Colour White Red
Crankpin 40.960 to 40.953 to
diameter 40.954 40.946 For instance:

Crankpin diameter Required Bearing Note:

• Repeat the measurements for all connecting rods and their respective crankpins. It is normal for the bearings selected to differ from one connecting rod to another.

40.958

White

Always confirm, using the Plastigage method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance, resulting in loss of motorcycle control and an accident.

Crankshaft Main Bearing/Journal Wear

Using selective bearings compensates for minor differences in crankshaft main bearing journal and crankcase dimensions. For further information on bearing part number to colour cross-references, refer to the parts information system.

1. Measure the bearing to crankshaft main journal clearance using Plastigage (Triumph part number 3880150-T0301). Use the same method as described in connecting rod clearance measurement.

Checking crankshaft clearance using Plastigage

Crankshaft main bearing/journal clearance


Service limit

0.100 mm

2. If the clearance exceeds the service limit, measure the diameter of the crankshaft main bearing journal.

Crankshaft main bearing journal diameter

Standard 43.092 - 43.108 mm

Service limit

43.068 mm

Note:

• If any journal has worn beyond the service limit, the crankshaft must be replaced. Due to the techniques used during manufacture, the crankshaft cannot be reground and oversize bearings are not available.

Select bearings as follows:

1. Measure and record the diameter of each crankshaft main bearing journal.

2. Measure and record each main bearing bore diameter in the crankcase (bearings removed but all crankcase bolts fully torqued (see page 5.8).

Note:

• The original crankcase bolts may be reused for bearing selection. Do not use new bolts as they may only be used once, even if the single use is related to bearing selection.

~.

5.13


Crankshaft

Compare the data found with the chart above to select bearings individually by journal.

Shell White Red Red Blue Blue Green
Colour
Crankcase 46.105 to 46.105 to 46.114to 46.114 to 46.123 to 46.123 to
bore 46.097 46.097 46.106 46.106 46.115 46.115
diameter
Crankshaft 43.108 to 43.099 to 43.108to 43.099 to 43.108 to 43.099 to
journal 43.100 43.092 43.100 43.092 43.100 43.092
diameter For example:

Crankcase Bore

Crankshaft Journal diameter Bearing Required

Note:

• It is normal for the bearings selected to differ from one journal to another.

Crankshaft End Float

46.099 mm

BLUE

Crankshaft end float
Service limit 0040 mm 43.095 mm

It is also normal for there to be two options of bearing shell colour. In such cases, pick the shell size that gives the greater running clearance.

Note:

• Crankshaft end float is controlled by the tolerances in crankshaft and crankcase machining. Thrust washers are not used. If crankshaft end float is outside the specified limit, the crankshaft and/or the crankcases must be replaced.

Always confirm, using the Plastigage method, that the running clearance is correct before final assembly. Severe engine damage could result from incorrect clearance resulting in loss of motorcycle control and an accident.

5.14


Crankshaft

Pistons

Disassembly

1. Remove the cylinder head and liners (see page 3.5).

The cylinder liners and pistons are made of aluminium alloy and can therefore be easily damaged. Handle the cylinder liner and piston with care, ensuring the internal bore of the liner and the piston skirt are not scratched.

Note:

• It is not necessary to remove the connecting rods from the crankshatt, but the piston should be at the top of its stroke.

2. Remove the gudgeon pin circlip from one side of the piston.

1. Gudgeon pin circlip

3. Remove the gudgeon pin by pushing the pin through the piston and rod toward the side from which the circlip was removed.

Note:

If the gudgeon pin is found to be tight in the piston, check the piston for a witness mark caused by the clrcllp, Carefully remove the mark to allow the pin to be removed.

With the gudgeon pin removed, the piston can be detached from the con-rod.

5. Remove the piston rings.

•

4.

Note:

•

The rings may be removed using a proprietary piston ring expander tool or, if a tool is not available, carefully spread the ring opening using thumb pressure then push up on the opposite side of the ring to remove it from the piston.

Piston Wear Check

1 . Measure the piston outside diameter, 10 mm up from the bottom of the piston and at 900 to the direction of the gudgeon pin.

1. Piston outside diameter

2. Measurement point (10 mm Up The Piston Skirt)

3. Gudgeon pin

Piston outside diameter at 90° to Gudgeon Pin

An cylinders 101.561 - 101.577 mm

101.511 mm

Replace the piston If the measured diameter falls outside the specified limit.

~.

5.15


Crankshaft

Piston Rings/Ring Grooves

1 . Check the pistons for uneven groove wear by visually inspecting the ring grooves.

2. Clean the piston ring grooves.

3. Fit the piston rings to the pistons. Check, using feeler gauges, for the correct clearance between the ring grooves and the rings. Replace the piston and rings if outside the specified limit.

Checking piston ring to groove clearances

Piston ring/Groove Clearance
Top - standard 0.02 - 0.06 mm
Top - service limit 0.16 mm
Second - standard 0.02 - 0.06 mm
Second - service limit 0.16 mm Piston Ring Gap Note:

• Before final assembly the piston ring gap, when fitted in the liner, must first be checked.

1. Place the piston ring inside the liner.

2. Push the ring into the top of the cylinder, using the piston to hold the ring square with the inside of the bore. Continue to push the ring into the bore until the third groove of the piston is level with the top of the liner around its full circumference.

cbxx

Aligning piston rings using the piston

3. Remove the piston and measure the gap between the ends of the piston ring using feeler gauges.

Piston Ring End Gap Tolerances
Top - standard 0.20 - 0.35 mm
Top - service limit 0.55 mm
Second - standard 0.30 - 0.50 mm
Second - service limit 0.675 mm
Oil control - standard 0.20 - 0.70 mm
Oil control - service 0.875 mm
limit 4. If the ring gap is found to be too small, the ring end must be carefully filed untif the correct gap is achieved. If the gap is too large, replace the rings with a new set. If the gap remains too large with new rings fitted, both the piston and liner must be replaced.

Piston Assembly

1. Clean the piston ring grooves and fit the piston rings to the piston.

Note:

• The top ring upper surface is marked 'N' and can be identified by a chamfer on the inside edge.

The second ring upper surface is marked '2N' but is plain on the inside edge and has a bronze appearance.

All oil control rings can be fitted with either face upward.

5.16


Crankshaft

Piston ring identification marks

2. Install a new circlip to one side of the piston.

3. Locate the piston to the connecting rod ensuring that the piston direction arrow points to the right hand (exhaust) side of the engine.

1. Piston

2. Direction arrow

4. Align the small end in the connecting rod with the gudgeon pin hole in the piston.

5. Lubricate the piston, small end and gudgeon pin with clean engine oil and fit the gudgeon pin from the opposite side to the installed circlip.

6. Fit a new circlip to the remaining location in the piston then check that both are correctly installed. Rectify if necessary.

Re-using the original circlips may cause gudgeon pin detachment resulting in engine seizure, loss of motorcycle control and an accident.

7. The piston ring gaps must be arranged as shown in the diagram below.

FRONT

+

=3

3=

caqj

1. Top Ring

2. Second Ring

3. Steel Oil Control Rings

8. Oil Control Ring Expander

Note:

• The top ring gap should be positioned in the 7 o'clock position, the second ring gap in the 1 o'clock position and the steel oil control ring gaps in the 9 & 3 o'clock positions (one in each position).

9. Fit the piston into the bottom of the liner using a gentle rocking motion to engage the rings in the bore.

Fitting a piston into a liner

5.17


Crankshaft

Cylinder Wear

1. Measure the internal diameter of each cylinder liner using an internal micrometer or Mercer gauge. Always check in two places, at 90° to each other, as well as at three heights in the liner.

Cylinder liner internal diameter

Standard 101 .591 - 1.609 mm

Service limit

101.659 mm

Check the diameter at points 1, 2 and 3.

1 -

--2-

3

gaep

Checking Positions For Bore Wear Check (bore shown in section)

2. If any reading is outside the specified limits, replace the liner and piston as an assembly.

Cylinder Liners

Removal

1. Mark each liner to identify correct orientation and the cylinder number from which it has been removed.

2. Turn the crankshaft until the piston in the liner to be removed is at the bottom of its stroke.

3. Check that the locking nut on tool T3880061 is loose, then fully unscrew the extraction nut.

coxz

1. Tool T3880061

2. Locking nut

3. Extraction nut

The cylinder liners and pistons are made of aluminium alloy and can therefore be easily damaged. Handle the cylinder liner and piston with care, ensuring the internal bore of the liner and the piston skirt are not scratched.

5.18


Crankshaft

4. Carefully fit the rubber section of the tool fully into the cylinder liner, positloninq studss supplied with the tool diagonally across a pair of head bolt-holes.

cbya

1. Cylinder liner

2. Studs

3. Head-bolt holes

5. Fully engage the bolt threads in the head bolt holes. It is not necessary to fully tighten the bolts.

6. Turn the locking nut clockwise until the rubber sleeve on the tool tightly grips the bore of the liner.

7. Turn the extraction nut clockwise sufficient to raise the liner and break the seal between the liner and crankcase.

Note:

• It is not necessary (or possible) to fully extract the liner using this tool. Once the seal is broken, the tool must be removed and the liner extracted by hand.

S. Turn the locking nut anticlockwise to release the liner.

9. Once the seal on the liner is released, remove the tool and manually remove the liner.

Installation

1. Thoroughly clean the liner removing all traces of old silicone sealer.

2. Remove all traces of sealer from the crankcase bores.


1. Liner

2. Sealer Area


1. Liner

2. Sealer area

~.

5.19


Crankshaft

5. Carefully fit each liner over the piston using a gentle rocking motion to allow compression of the piston rings.

Fitting a piston into a liner

Care must be taken when installing liners such that the silicone sealer is not forced out, blocking passageways in the crankcase.

Note:

• The liners have a large chamfer at the bottom of the bore, enabling fitting of the piston without need for a piston ring compressor.

Fit each liner over whichever piston is at TOC. When turning the engine, do not allow the pistons to contact the inside of the crankcase and also do not allow fitted liners to lift off the crankcase base.

6. Continue fitting each liner in turn until all are fitted and sealed.

Note:

• When the liners have been fitted, they should not be disturbed. If it is necessary to remove the liner after fitting, the sealer must be re-applied.

5.20


6 Bevel Box and Drive Shaft

Table of Contents

Sectioned view - bevel box and drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.2

Bevel box and drive shaft specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.3

Bevel box oil specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.3

Bevel box oil level check , . . . . . . . . .. 6.3

Bevel box oil change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.4

Bevel Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.4

Installation 6.4

Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.5


6.1

Bevel Box and Drive Shaft

Sectioned view - bevel box and drive shaft

6.2



Bevel box and drive shaft specification

The Rocket III is fitted with a shaft drive coupling the transmission to the bevel box at the rear wheel. The drive shaft is fitted with a single Hookes universal joint which requires no maintenance.

The bevel box consists of a crown wheel and pinion arrangement that has no dealer serviceable parts. Maintenance consists solely of routine oil level checks and oil changes.

Under no circumstances should the final drive unit be disassembled. Failure to observe the above warning could lead to a malfunction of the final drive unit causing lock-up of the rear wheel leading to loss of motorcycle control and an accident.

Bevel box oil specltleatlon

The bevel box must be filled and topped up with Mobil Mobilube 1 SHC 75W/90 fully synthetic hypoid oil or equivalent.

Use of an incorrect bevel box lubricant could result in a malfunction of the final drive unit causing lockup of the rear wheel leading to loss of motorcycle control and an accident.

Bevel box oil level check


1. Remove the filler/level plug.

\

1. Bevel box

2. Flllerilevel plug

2. Have an assistant stand the bike upright.

3. Fill the bevel box with Mobilube 1 SHC 75W/90 fully synthetic hypoid oil (or equivalent) until the level of oil inside the unit is level with the bottom of the filler.

4. Refit the plug and tighten to 60 Nm.

6.3



Bevel box oil change


1. Position a container beneath the bevel box drain plug.

)

1. Bevel box

2. Drain plug

2. Remove the drain plug and allow the oil to fully drain out.

3. Wipe the drain plug clean then refit and tighten it to 15 Nm.

Note:

• The drain plug is magnetic. It is normal for metallic deposits to be attached to the drain plug magnet.

4. Remove the filler plug.

5. Have an assistant stand the bike upright during filling;

6. Fill the bevel box with Mobilube 1 SHe 75W/90 fully synthetic hypoid oil or equivalent until the level of oil inside the unit is level with the bottom of the filler.

7. Refit the plug and tighten to 60 Nm.

Bevel Box

Removal


\ 1. Support the motorcycle so that the rear wheel is

clear of the ground.

2. Remove the rear wheel as described on page 16.8.

3. Remove the left hand rear suspension unit as described on page 13.4.

4. Release the four nuts securing the bevel box to the swinging arm.

5. Ease the bevel box towards the rear of the motorcycle, detaching the pinion coupler from the drive shaft.

Installation Note:

• Prior to installation, check that the drive shaft is supported by the sleeve inside the swinging arm. Rectify as necessary.

1. Drive shaft

2. Swinging arm

3. Sleeve

1. Apply a smear of Molybdenum Disulphide grease to the drive shaft splines and wheel driven flange.

2. Position the bevel box to the drive shaft engaging the pinion coupler and drive shaft at the same time.

6.4


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