Triumph Daytona 675 Owners Manual
Triumph Daytona 675 Owners Manual
Triumph Daytona 675 Owners Manual
FOREWORD
This handbook contains information on the Triumph Daytona 675 motorcycle.
Always store this owner's handbook with the motorcycle and refer t o it for
information whenever necessary.
Information
The information contained in this publication is based on the latest
information available at the time of printing. Triumph reserves the right to
make changes at any time without prior notice, or obligation.
Not t o be reproduced wholly or in part without the written permission of
Triumph Motorcycles America Limited.
O Copyright 2006 Triumph Motorcycles America Limited.
Publication part number 3851706 issue 2.
Table of Contents
This handbook contains a number of different sections. The table of contents
below will help you find the beginning of each section where, in the case of
the major sections, a further table of contents will help you find the specific
subject required.
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..17
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
How t o Ride the Motorcycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Accessories, Loading and Passengers. . . . . . . . . . . . . . . . . . . . . . . . . . .58
Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I09
Foreword - Safety First
FOREWORD - SAFETY FIRST
The Motorcycle Fuel and Exhaust Fumes
-- - - - - --- -- --
1
The total w e ~ g h tof the rider, and
any passenger, accessorles and Never start your engine or let i t
luggage must not exceed the run for any length of time in a
maxlmum load llmit of 430 1b closed area. The exhaust fumes
(195 kg). are poisonous and may cause loss
of consciousness and death within
a short time. Always operate your
motorcycle in the open-air or i n an
area with adequate ventilation.
Foreword - Safety First
Safety Helmet and
Clothing
n particular, it is extremely
azardous t o fit o r replace parts or
essories whose fitting requires
dismantling of, or addition to,
er the electrical or fuel systems
any such modification could
se a safety hazard.
e fitting of any non-approved
arts, accessories or conversions
acc~dent, c o l l ~ s ~ oor
n fall, ~t must
aximum limit (when the bank be taken t o an authorized Triumph
le indicator is worn t o a
m u m of 0.19 in (5 mm) in cause damage to
th) will allow t h e motorcycle t o
banked t o an unsafe angle. may cause a
erefore, always replace the bank a t may result in
ngle indicator pegs when they are
worn t o 0.19 in (5 mm) in length.
Banking t o an unsafe angle may
cause instability, loss of
Foreword - Safety First
Riding
Aw a r n i r
T h ~ sTrlumph motorcycle should be
operated w ~ t h i n the legal speed
Never ride the motorcycle when
l ~ m ~ t for
s the particular road
fatigued o r under the influence of
travelled. Operating a motorcycle
alcohol or other drugs.
a t h ~ g hspeeds can be potentially
Riding when under the influence of
dangerous since the time available
alcohol or other drugs is illegal.
t o react t o given traffic situations
Riding when fatigued o r under the
is greatly reduced as road speed
influence of alcohol or other drugs
increases. Always reduce speed in
reduces the rider's ability to
potentially hazardous driving
maintain control of motorcycle and
conditions such as bad weather or
heavy traffic.
-
Bad weather.
Rider error.
the protective equipment
mentioned elsewhere in this
. Remember, in an
, a motorcycle does not ughly famlliar with
same impact protection as and operating
Foreword - Safety First
WARNING LABELS
The labels detailed on this and t h e following pages draw your attention t o
important safety information in this handbook. Before riding, ensure that all
riders have understood and complied with all the information to which these
labels relate.
Gear Position
Warning Labels
PARTS IDENTIFICATION
I
1 Front turn signal 8 Gear-change pedal
2 Headlight 9 Front brake disc
3 Rear lamp 10 Front brake caliper
4 Radiator/coolant pressure cap 11 Fuel tank
5 Oil cooler/heat exchanger 12 Fuel filler cap
6 Drive chain 13 Seat lock
7 Side stand 14 Coolant expansion tank
Parts Identification
SERIAL NUMBERS
GENERAL INFORMATION
Table of Contents
Instrument Panel Layout ................................................................ 20
Speedometer and Odometer ........................................................... 2 1
Tachometer .................................................................................. 2 1
Odometerflrip Meter .....................................................................2 1
Clockflrip Computer ...................................................................... 22
Lap Timer .................................................................................... 24
Gear Change Lights ....................................................................... 28
Gear Position Display .................................................................... 32
Coolant Temperature Gauge ...........................................................33
Warning Lights ............................................................................. 34
Ignition Key ................................................................................. 36
Ignition Switch/Steering Lock .........................................................36
Brake Lever Adjuster ..................................................................... 37
Right Handlebar Switches ..............................................................38
Left Handlebar Switches ................................................................39
Fuel Requirement/Refuelling ........................................................... 40
Fuel Tank Cap ...............................................................................42
Filling the Fuel Tank ......................................................................
42
Tool Kit and Handbook ...................................................................
43
Stand ..........................................................................................43
Seat Lock .................................................................................... 44
Breaking-In ..................................................................................45
Safe Operation .............................................................................46
General Information
-
Tachometer Engine management
Tachometer 'red zone' malfunction indicator light
Speedometer Low fuel level indicator light
Odometer/trip meters Neutral indicator light
Clock/trip computer display High beam indicator light
Scroll/set/trip buttons Turn signal light
Coolant temperature display Gear change lights
Low oil pressure warning light Alarm status indicator light
(alarm is an accessory fit)
High coolant temperature
warning light Gear position indicator
General Information
Tachometer
The tachometer shows the engine
speed in revolutions per minute - 1 Odometer/trip meter display
rpm (r/min). On the right side of the 2 Set button
tachometer face is the 'red zone'. 3 Trip button
Engine rpm (r/min) in the red zone
4 Trip meter 1 display
is above maximum recommended
engine speed and is also above the 5 Trip meter 2 display
range for best performance. The odometer shows the total
distance that the motorcycle has
travelled.
The odometer and two trip meters
are located in the same display
Never allow engine RPM to enter
frame as the speedometer. Either
the 'red zone' as severe engine
trip meter shows the distance that
the motorcycle has travelled since
the meter on display was last reset
to zero.
General Information
Clock/Trip Computer
Maximum Speed
The maximum speed achieved since
the last reset is displayed.
Lap Timer
I 1
1 Lap timer display
Lap Time
I I
1 Trip computer display The elapsed time o f the lap (the lap
2 Scroll button number will be displayed i n the
speedometer display position).
3 Set button
Information is recorded for each lap
To reset the trip computer only, since the last reset.
select one o f t h e trip computer The lap timer will record up
displays, press the 'Scroll' and 'Set' to 99 minutes, 59 seconds
buttons simultaneously for 2 and 9 tenths of a second.
seconds. After 2 seconds, the trip After this time, the display
computer, not t h e clock, will reset. will reset to zero.
Number of Laps
Maximum Speed
The maximum speed achieved per
lap (the lap number will be displayed
in the speedometer display position)
or the maximum speed achieved
during all recorded laps.
Average Speed
The average speed per lap (the lap
number will be displayed in the
speedometer display position) or the
average speed during all recorded
laps. I I
1 Lap time display (during a lap)
Distance Travelled 2 Stop watch icon
The distance travelled per lap (the 3 Scroll button
lap number will be displayed in the
speedometer display position) or the After pressing the 'Scroll' button t o
distance travelled for all recorded select the lap timer, the word 'LAP'
laps. will appear in the clock display.
The lap timer has two modes; Data Pressing the starter button (with the
Recording Mode and Data Retrieval engine running only) will start the
lap timer. The display will show the
Mode.
lap time in minutes, seconds and
tenths of a second, and the stop
watch icon will flash.
At the end of the lap, pressing the
starter button again will register the
start of a new lap. The display will
show the last lap time for 15
seconds. After this time, the display
will show the current lap number for
5 seconds before returning to the
time for the current lap.
General Information
I I
1 Starter button 1 Lap time
2 Lap number
Each new lap is recorded by a brief
3 Set button
press of the starter button (with the
engine running only). Whilst in the 4 Trip button
data recording mode, pressing the
Accessing the Data Retrieval
starter button for 2 seconds will
Mode
return the display to the lap timer.
From the lap timer display, press the
The Data Retrieval Mode can be
'Set' button to enter the Data
accessed in one of two ways:
Retrieval Mode.
With the ignition in the 'ON'
position, from the lap timer
display, press the 'Set' button.
From the Data Recording Mode,
with the engine running and the
motorcycle stationary, press the
starter button for 2 seconds.
This will return the display to
the 'LAP' display. From here
press the 'Set' button.
I
1 Gear change lights
2 Display screen
3 Scroll button
Front Suspension The suspension movement will Adjusting Gear Change light
be affected by adjustment LED RPM Modes
Front Fork Inspection settings. 3,000 rprn before
1 s t LED To adjust the gear change light
set change-up modes, turn the ignition to the 'ON'
Examine each fork for any sign of
speed position.
damage, scratching of the slider
surface, or for oil leaks. 2nd LED 2,250 rprn before Press the 'Trip' and 'Scroll' buttons
Riding the motorcycle wit set change-up simultaneously for 4 seconds, after 4
I f any damage or leakage is found defective or damaged suspensio
consult an authorized Triumph speed seconds the current mode will be
dealer. 1,500 rprn before displayed.
3rd LED
To check that the forks operate set change-up
smoothly: speed
Position the motorcycle on level 4th LED 750 rpm before
ground. set change-up
While holding the handlebars
speed
and applying t h e front brake,
LEDs speed
several times.
I I
1 Gear change lights
2 Display screen (OFF mode
I I
shown)
1 Gear change lights
2 Display screen (SCALE mode
Setting Gear Change Light
shown)
Limits
To scroll through t h e four modes
press the 'Set' button. To set the Select the desired gear change light
gear change lights t o the displayed mode as described above. Press the
mode, press the 'Trip' and 'Scroll' 'Trip' and 'Scroll' buttons
buttons simultaneously for 4 simultaneously for 4 seconds. After 4
seconds. seconds, t h e tachometer needle will
move round t o the last set position
and the word 'tAcHo' will appear in
t h e clock display. The corresponding
lights for the current mode will also
remain illuminated.
Maintenance and Adjustment General Information
I I
1 Gear change lights
2 Display screen
position shown)
3 Scroll button
The gear position display indicates
4 Set button
the gear position. When the
5 Trip button transmission is in neutral (no gear
The setting can now be changed in selected), the display will show 'n:
increments of 100 rpm, again up t o
a limit of 14,000 rpm.
Each individual press of the 'Scroll'
button will increase the setting in
increments of 100 rpm, up to a limit
of 14,000 rpm. As the limit cannot
exceed 14,000, when 14,000 rpm is
reached the limit will return t o 4,000
rpm.
When the correct setting is shown,
pressing the 'set' button will confirm
the setting.
When the gear change lights settings
are exited in any mode except 'OFF',
the tachometer needle will quickly
sweep from zero t o maximum and shown)
then return t o zero, and the gear
When the transmission is in gear the
change lights will illuminate
relevant gear number '1' to '6' will
according t o their s e t mode.
be displayed.
32
General Information
I I
1 Coolant temperature gauge
High Beam
When the ignition is
A caution
switched on and the
headlight dip switch is
set t o 'high beam', the
=o
=
Stop the engine immediately if the
low oil pressure warning light
illuminates. Do not restart the
high beam warning light engine until the fault has been
will illuminate. rectified.
Severe engine damage will result
Low Fuel from running the engine when the
low oil pressure warning light is
The low fuel indicator
illuminated.
will illuminate when
there are approximately The low oil pressure warning light in
3.0 litres of fuel the tachometer will illuminate if the
remaining in the tank. ignition is switched on without
running the engine.
Neutral
The neutral warning High Coolant Temperature
Warning Light
light indicates when the
transmission
neutral (no
is
gear
in N With the engine
running, i f the engine
selected). The warning coolant temperature
light will illuminate when the becomes dangerously
transmission is in neutral with the high, the high coolant
ignition switch in t h e 'ON' position. temperature warning light in the
tachometer will illuminate.
General Information
I I
1 Key number t a g
I n addition t o operating the steering
c1 Ignition switch/steering lock
lock/ignition switch, the ignition key 2 Off position
is required t o operate the seat lock 3 On position
and fuel tank cap.
4 Lock position
When the motorcycle is delivered
5 Park position
from the factory, two keys are
supplied together with a small tag
bearing the key number. Make a Ignition Switch Positions
note of the key number and store This is a four position, key operated
the spare key and key number tag in switch. The key can be removed
a safe place away from the from the switch only when it is in the
motorcycle. OFF, LOCK or P (PARK) position.
Your authorized Triumph dealer can TO LOCK: Turn t h e key t o the 'OFF'
supply a replacement key cut from position, push and fully release the
details of the key number or can cut key, then rotate it t o the 'LOCK'
a new key using t h e original as a position.
master. 'PARKING': Turn t h e key f r o m t h e
'LOCK' position t o t h e ' P' position.
The steering will remain locked.
&w
b
'RUN' position for the motorcycle t o
operate.
Do not attempt to adjust the lever The engine stop switch is for
with the motorcycle ~n motion as emergency use. I f an emergency
this may lead t o loss of motorcycle arises which requires the engine t o
control and an accident. be stopped, move the engine stop
After adjusting t h e lever, operate switch to the stop position.
the motorcycle i n an area free
from traffic t o gain familiarity with NOTE
the new lever setting. Do not loan Although the engine stop
your motorcycle t o anyone as they switch stops the engine, it
may change the lever setting from does not turn off all the
the one you are familiar with electrical circuits and may
causing loss of control o r an cause difficulty in restarting
accident. the engine due to a
discharged battery.
Ordinarily, only the ignition
Right Handlebar switch should be used t o
Switches stop the engine.
A Caution
Do not leave the ignition switch in
the 'ON' position unless the engine
is running as this may cause
damage to electrical components
and will discharge the battery.
Starter Button
The starter button operates the
electric starter. For the starter t o
operate, the clutch lever must be
pulled to the handlebar.
I I
1 Engine stop switch
NOTE
2 Starter button Even i f the clutch lever i s
pulled to the handlebar, the
Engine Stop Switch starter will not operate if
I n addition t o the ignition switch the side stand is down and a
being turned t o t h e 'ON' position, the gear is engaged.
General Information
Horn Button
When the horn button is pushed,
with the ignition switch turned to the
'ON' position, the horn will sound.
I I Pass Button
1 Headlight dipswitch
When the pass button is pressed the
2 Turn signal switch headlight main beam will be
3 Horn button switched on. I t will remain on as
4 Pass button long as the button is held in and will
turn off as soon as the button is
Headlight Dip Switch released.
High o r low beam can be selected
with the headlight dip switch. To
select high beam, push the switch
forward. To select low beam, push
t h e switch rearwards. When the high
beam is turned on, the high beam
indicator light will illuminate.
General Information
Methanol
Do not smoke.
L cautic Do not use a mobile telephone.
Make sure the refuelling area is
Because of the generally higher well ventilated and free from any
volatility of oxygenated fuels, source of flame or sparks. This
starting, engine response and fuel includes any appliance with a pilot
consumption may be adversely
affected by their use. Should any Never fill the tank until the fuel
of these difficulties be level rises into the filler neck. Heat
experienced, run the motorcycle from sunlight or other sources may
on normal unleaded gasoline. cause the fuel to expand and
overflow creating a fire hazard.
After refuelling always check that
the fuel filler cap is correctly
closed and locked.
Because gasoline (fuel) is highly
flammable, any fuel leak or
spillage, or any failure t o observe
General Information
components.
I I
1 Maximum fuel level
2 Fuel filler neck
3 Air space
General Information
Stand
Side Stand
Whenever the side stand is used, down at the rear t o engage in the
before riding, always ensure that the seat lock.
stand is fully up after first sitting on
the motorcycle.
For instructions on safe parking,
refer t o the 'How t o Ride the
Motorcycle' section. riding, after fitting a
Seat Lock
Rider's Seat seat could cause loss of motorcyc
control and an accident.
1 Seat lock
The seat lock is located on the left
hand side of the battery tray, in line 1 1
with the footrest mounting rail. To 1 Rear seat fixing
remove the seat, insert the ignition
key into the seat lock and turn it To remove the rear seat cover o r
anti-clockwise while pressing down rear seat (where fitted): Remove the
on the rear of the seat. This will fixing located beneath the padding.
release the seat from its lock and This will allow the rear seat/seat
allow it t o be slid rearwards for cover t o be slid forwards for
complete removal from the complete removal from the
motorcycle. motorcycle.
To refit the seat, engage the seat's
tongue under the fuel tank and press
General Information
pF?q
in has been completed:
Breaking-in
Do not over-rev the engine
is the name
when cold.
R.P.M. given to the
Do not let the engine labour.
process that
Always downshift before the
occurs
engine begins to 'struggle'.
during the first hours of a new Do not ride with engine speeds
vehicle's operation. unnecessarily high. Changing
I n particular, internal friction in the up a gear helps reduce fuel
engine will be higher when consumption, reduces noise
components are new. Later on, when and helps to protect the
continued operation of the engine environment.
has ensured that the components
have 'bedded in', this internal
friction will be greatly reduced.
A period of careful breaking in will
ensure lower exhaust emissions, and
will optimise performance, fuel
economy and longevity of the engine
and other motorcycle components.
During the first 500 miles (800
kilometres):
Do not use full throttle.
Avoid high engine speeds at all
times.
Avoid riding at one constant
engine speed, whether fast or
slow, for a long period of time.
Avoid aggressive starts, stops,
and rapid accelerations, except
in an emergency.
Do not ride at speeds greater
than 314 of maximum engine
speed.
From 500 to 1000 miles (800 to
1500 kilometres) :
Engine speed can gradually be
increased to the rev limit for
short periods.
General Information
I I
1 Engine stop switch To Start the Engine
2 Starter button Check that the engine stop switch is
3 Neutral indicator light in the run position.
4 On position Ensure the transmission is in
5 Ignition switch neutral.
Close the throttle completely. Pull the clutch lever fully into the
handlebar.
Select neutral.
Turn the ignition switch on.
Turn the ignition switch off.
Support the motorcycle on a firm, NOTE
level surface with the side stand. When the ignition is
Lock the steering. switched 0% the
tachometer needle will
quickly sweep from zero to
A caution maximum and then return
to zero. The instrument
The engine should normally be warning lights will
stopped by turning the ignition illuminate and will then go
switch to the off position. The off (except those which
engine stop switch is for normally remain on until the
emergency use only. Do not leave
the ignition switched on with the
engine starts - See
"Warning Lights" on page
engine stopped. Electrical damage 34. I t is not necessary to
may result. wait for the needle to return
How to Ride t h e Motorcycle
- Cautia
Do not operate the starter
I f the sidestand is extended
whilst the engine is running,
and the transmission is not i n
continuously for more than 5 neutral then the engine will
seconds as the starter motor will stop irrespective of clutch
overheat and the battery will position.
become discharged. Wait 15
seconds between each operation of
the starter t o allow for cooling and Moving Off
recovery of battery power. Pull i n the clutch lever and select
Do not let the engine idle for long first gear. Open the throttle a little
periods as this may lead to and l e t out the clutch lever slowly. As
overheating which will cause the clutch starts t o engage, open the
damage to the engine. throttle a little more, allowing
enough engine speed to avoid
stalling.
How to Ride the Motorcycle
I
in the clutch lever. Change into Changing down should be done
the next higher or lower gear.
Open the throttle part way,
while releasing the clutch lever.
Always use the clutch when Braking
changing gear.
I - A warning
WHEN BRAKING, OBSERVE
- I C~
For emergency braklng, d~sregard
-,
I I
1 Rear brake pedal
How to Ride t h e Motorcycle
NOTE
When parking near traffic a t
night, or when parking in a
location where parking
How to Ride the Motorcycle
-1
-
ne nandling character~st~cs or a
-
motorcycle a t high speed may vary
from those you are familiar with a t
legal road speeds. Do n o t attempt
high-speed operation unless you
have received sufficient training
and have the required skills as a
serious accident may result from
incorrect operation.
ngerous since t h e time available -
react to given traffic situations
lIll A
Luggage
Make certain that any luggage
containers are closed, locked and
securely fitted t o the motorcycle.
How to Ride the Motorcycle
Fuel
Have sufficient fuel for the increased
fuel consumption that will result
from high-speed operation.
A Caution
The exhaust system is fitted with a
catalytic converter to help reduce
exhaust emission levels. The
catalytic converter can be
permanently damaged if the
motorcycle is allowed t o run out of
fuel o r if the fuel level is allowed to
get very low. Always ensure you
have adequate fuel for your
journey.
Engine Oil
Make certain that the engine oil level
is correct. Ensure that the correct
Accessories and Loading
Do not ~ n s t a l accessortes
l or carry
luggage that impa~rsthe control o f
the motorcycle. Make sure that
Always ensure any loads carried you have not adversely affected
are evenly distributed on both the visibility of any lighting
sides of the motorcycle. Ensure component, road clearance,
hat the load is correctly secured banking capability (i.e. lean
such that it will not move around angle), control operation, wheel
hile the motorcycle is in motion. travel, front fork movement,
visibility in any d~rection, or any
hough not while the other aspect of the motorcycle's
is in motion) and operation.
t the load does not
m u m loading weight is
from the combined
e rider, passenger, any
fitted and any load
Accessories and Loading
A caution
Do not allow luggage to rest on or
against the upper portion of the
rear bodywork.
Allowing luggage to rest on o r
against the upper portion of the
rear bodywork could close the
airgap between the bodywork and
the exhaust potentially causing the
bodywork t o become damaged by
overheating.
Accessories and Loading
MAINTENANCE A N D ADJUSTMENT
Table of Contents
Scheduled Maintenance .................................................................64
Engine Oil ....................................................................................68
Cooling System ............................................................................ 72
Throttle Control ............................................................................7 4
Clutch ......................................................................................... 77
Drive Chain ..................................................................................78
Brakes ........................................................................................82
Windshield Cleaning ......................................................................85
Steering/Wheel Bearings ................................................................ 86
Front Suspension .......................................................................... 88
Tires ...........................................................................................92
Battery ........................................................................................9 6
Fuse Box ..................................................................................... 98
Headlights ................................................................................. 100
Rear Light .................................................................................. 103
Turn Signal Lights .......................................................................103
Licence Plate Light ...................................................................... 103
Cleaning .............................................................................104
Maintenance and Adjustment
malfunction. A
Engine Oil
In order
for the
- engine,
transmiss-
ion, and
clutch to function correctly, maintain
the engine oil a t the correct level,
and change the oil and oil filter in
accordance with scheduled
maintenance requirements.
Maintenance and Adjustment
Oil Level Inspection Start the engine and run a t idle for
approximately five minutes.
Stop t h e engine, then wait for at
least three minutes for the oil to
settle.
Remove the dipstick, wipe the blade
clean and screw fully home.
NOTE
An accurate indication of
the level of oil in the engine
is only shown when the
engine is at normal
operating temperature, the
motorcycle is upright (not
-
Oil and Oil Filter Change Place an oil drain pan beneath the
engine.
) Remove the oil drain plug.
Corrosion Inhibitors
To protect the cooling system from
corrosion, the use of corrosion
inhibitor chemicals in the coolant is
essential.
I f coolant containing a corrosion
inhibitor is not used, the cooling Expansion tank
system will accumulate rust and
scale i n the water iacket and
radiator. This will block t h e coolant
*
3
Tank cap
MAX mark
passages, and considerably reduce 4 MIN mark
the efficiency of the cooling system.
NOTE
The coolant level should be
A Warning checked when the engine is
cold (at room or ambient
Use coolant mixture conta~ning temperature).
corrosion inhibitors and anti-freeze
suitable for aluminium engines and Position the motorcycle on level
radiators. Always use the anti- ground and in an upright position.
freeze in accordance with the The expansion tank can be viewed
instructions of the manufacturer. from the left hand of the motorcycle,
Coolant mixture that contains anti- between the rear of the lower fairing
freeze and corrosion inhibitors and the frame.
contains toxic chemicals that are
harmful to the human body. Never
swallow anti-freeze o r any of the
motorcycle coolant.
Maintenance and Adjustment
Radiator Hoses
Check the radiator hoses for cracks
o r deterioration, and hose clips for
tightness in accordance with
hot, pressurised coolant will cause scheduled maintenance
requirements. Have your authorized
Triumph dealer replace any defective
Allow the engine t o cool.
items.
The expansion tank cap can be
removed from the left hand of the
motorcycle, between the rear of the
A caution
lower fairing and the frame. A year-round type of antifreeze is
Remove the cap from the expansion installed in the cooling system
tank, and add coolant mixture when the motorcycle leaves the
through the filler opening until the factory. I t is coloured blue,
level reaches the 'MAX' mark. Refit contains a 50% solution of
the cap. ethylene glycol, and has a freezing
point of -31°F (-35OC).
NOTE
I f the coolant level is being Check the radiator grille and fins for
checked because the obstructions by insects, leaves or
coolant has overheated, mud. Clean off any obstructions with
also check the level in the a stream of low-pressure water.
radiator and top-up if
necessary.
In an emergency, water
alone can be added to the
cooling system. However,
the coolant must be
returned to the correct
mixture ratio as soon as
possible.
Maintenance and Adjustment
Throttle Control
- A Caution
Using high-pressure water sprays,
I I
1 I
1 Opening cable adjuster rnm) of play using the adjuster near
2 Closing cable adjuster the throttle grip end of the cable.
3 Closing cable - free play Tighten the adjuster locknut.
measurement point With the throttle fully closed, ensure
4 Throttle grip that there is 0.08-0.12 in (2-3 rnm)
of free play in the 'closing' cable a t
5 Opening cable - free play the throttle cam attached to the
measurement point throttle bodies. I f necessary, adjust
Disconnect the battery, negative at the throttle body end in the same
(black) lead first. way as the 'opening' cable, until
Remove the fuel tank. 0.08-0.12 in (2-3 mm) of play is
present.
Remove the airbox.
Tighten the adjuster locknuts.
Release the locknuts on the
'opening' cable adjusters.
Rotate the 'opening' cable adjuster
at the throttle grip end such that it
has an equal amount of adjustment
in each direction.
Rotate the 'opening' cable adjuster
at the throttle body end of the cable
to give 0.08-0.12 in (2-3 mm) of n incorrectly adjusted, sticking or
play a t the throttle grip. Tighten the tuck throttle can lead to loss of
locknut. cle control and an
Make any minor adjustments as
necessary t o give 0.08-0.12 in (2-3 Refit the airbox.
Maintenance and Adjustment
Adjustment
Loosen the knurled locknut at the
lever end of the clutch cable and
turn the adjuster sleeve until the
correct amount of clutch lever free-
play is achieved.
Tighten the knurled locknut against
the clutch lever assembly.
I \ I I f correct adjustment cannot be
1 Clutch lever made using the lever adjuster, use
2 0.08-0.12 in (2-3 rnm) the cable adjuster a t t h e lower end
of the cable.
The motorcycle is equipped with a
cable-operated clutch. Loosen the adjuster locknut.
I f the clutch lever has excessive Turn the outer cable adjuster to give
free-play, the clutch may not 0.08-0.12 in (2-3 mm) of free-play
disengage fully. This will cause at the clutch lever.
difficulty in changing gear and Tighten the locknut.
selecting neutral. This may cause
the engine t o stall and make the
motorcycle difficult to control.
Maintenance and Adjustment
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1 Maximum movement position
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1 Adjuster bolt
2 Adjuster bolt locknut
3 Rear wheel spindle nut
Loosen the wheel spindle nut.
help prevent injury to the operato
Release the locknuts on both the left
hand and right hand chain adjuster
Place the motorcycle on a level bolts.
surface and hold it in an upright Moving both adjusters by an equal
position with no weight on it. amount, turn the adjuster bolts
Rotate the rear wheel by pushing the clockwise t o increase chain free
the motorcycle to find the position movement and counter clockwise to
where the chain is tightest, and reduce chain free movement.
measure the vertical movement of When the correct amount of chain
the chain midway between the free movement has been set, push
sprockets. the wheel into firm contact with the
adjuster. Tighten both adjuster
locknuts t o 20 lbf ft (27 Nm) and
the rear wheel spindle nut to
81.1 Ibf ft (110 Nrn).
Maintenance and Adjustment
I I
1 Measure across 20 links
2 Weight
motorcycle with defective brakes Remove the chain guard.
and you must have your
Stretch the chain taut by hanging a
authorized Triumph dealer take
22 Ib - 44 Ib (10-20 Kg) weight on
the chain.
re t o take remedial Measure the length of 20 links on the
y reduce braking straight part o f the chain from pin
centre of the lSt pin t o the pin centre
of the 21Stpin. Since the chain may
wear unevenly, take measurements
i n several places.
I f the length exceeds the maximum
service limit o f 12.56 in (319 mm),
the chain must be replaced.
Rotate the rear wheel and inspect
the drive chain for damaged rollers,
and loose pins and links.
Also inspect the sprockets for
unevenly o r excessively worn o r
damaged teeth.
Maintenance and Adjustment
-
A caution
Brakes
Brake Wear Inspection
Riding with defective brakes m lways use new brake fluid from a
ealed container and never use
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1 Front brake fluid reservoir,
upper level line
2 Lower level line
3 Safety clip
The brake fluid level in the reservoirs
must b e kept between the upper and
lower level lines (reservoir held
horizontal).
Remove the safety clip (front only).
Fill the reservoir t o the upper level
line using new DOT 4 fluid from a I
sealed container. 1 Rear brake fluid reservoir, upper
Refit the reservoir cover ensuring level line
that the diaphragm seal is correctly 2 Lower level line
fitted.
Refit the safety clip.
Maintenance and Adjustment
I
An accident causing injury to the Never attempt t o clean the
rider and other road users may w~ndshieldwhile the motorcycle is
In motion as releasing the
handlebars may cause loss of
vehicle control and an accident.
Operation of the motorcycle with a
damaged or scratched windshield
will reduce the rider's forward
vision. Any such reduction in
forward vision is dangerous and
may lead to an accident causing
injury o r death.
A caution
Corrosive chemicals such as
battery electrolyte will damage the
windshield. Never allow corrosive
chemicals to contact the
windshield.
Maintenance and Adjustment General Information
-
peration with worn or damage
ront or rear wheel bearings is
angerous and may cause
aired handling and instability
accident. I f in doubt,
torcycle inspected by
ed Triumph dealer
Front Suspension The suspension movement will Adjusting Gear Change light
be affected by adjustment LED RPM Modes
Front Fork Inspection settings. 3,000 rprn before
1 s t LED To adjust the gear change light
set change-up modes, turn the ignition to the 'ON'
Examine each fork for any sign of
speed position.
damage, scratching of the slider
surface, or for oil leaks. 2nd LED 2,250 rprn before Press the 'Trip' and 'Scroll' buttons
Riding the motorcycle wit set change-up simultaneously for 4 seconds, after 4
I f any damage or leakage is found defective or damaged suspensio
consult an authorized Triumph speed seconds the current mode will be
dealer. 1,500 rprn before displayed.
3rd LED
To check that the forks operate set change-up
smoothly: speed
Position the motorcycle on level 4th LED 750 rpm before
ground. set change-up
While holding the handlebars
speed
and applying t h e front brake,
LEDs speed
several times.
NOTE
This chart is only a guide.
Setting requirements may
vary for rider weight and
personal preferences. See
the following pages for ettings which vary from left to
information regarding
suspension adjustment.
Compression Damping
Spring Pre-Load Adjustment Adjustment
The spring pre-load adjusters are The compression damping adjuster
located at the top of each fork. is located near the bottom of both
TO change the spring pre-load, forks, adjacent to the wheel spindle.
rotate the adjuster clockwise to
increase pre-load, or anti-clockwise
to decrease pre-load. Always set the
pre-load adjusters such that there
are an equal number of graduation
lines visible on both forks.
NOTE
The motorcycle is delivered
from the factory with the
spring pre-load set at
position 5.
Rebound Damping
Adjustment
1 Compression damping force
The rebound damping adjusters are adjuster
located at the top of each fork.
To change the compression damping
To change the rebound damping force rotate the slotted adjuster
force, rotate the slotted adjuster clockwise to increase, or anti-
clockwise to increase, or anti- clockwise to decrease. Always count
clockwise to decrease. Always count the number of turns out from the
the turns out from the screwed fully fully screwed in position and set both
in position and set both forks to the forks to the same setting.
same setting.
NOTE
NOTE The motorcycle is delivered
The motorcycle is delivered from the factory with the
from the factory with the compression damping set at
rebound set a t position 6. position 7.
Rear Suspension Adjustment Rebound Damping
The rear suspension unit is
adjustable for both rebound and
compression damping.
Maintenance and Adjustment
1 I
1 Rebound damping adjuster I I
The rebound damping adjuster is 1 Compression damping adjuster
located a t t h e bottom of the rear The compression damping adjuster
suspension unit on the left hand side is situated adjacent t o the rear
of the motorcycle. suspension unit reservoir.
To adjust the rebound damping To adjust the compression damping
setting, rotate the adjuster clockwise setting rotate the slotted adjuster
to increase rebound damping and clockwise to increase, or anti-
anti-clockwise t o decrease. clockwise t o decrease.
NOTE NOTE
The motorcycle is delivered The motorcycle is delivered
from the factory with the from the factory with the
rebound adjuster set at compression damping set at
position 6. position 11.
Tires
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Wheel marking
m l
Tire marking
Minimum Recommended
Tread Depth
I n accordance with the periodic
maintenance chart, measure the
-
Only operate this Triumph
depth o f the tread with a depth motorcycle at high speed in closed
gauge, and replace any tire that has course on-road competition o r on
worn to, or beyond the minimum closed course race tracks. High
allowable tread depth specified in speed operation should only then
the table below: be attempted by riders who have
been instructed in the techniques
Under 0.08 in necessary for high speed riding
8 0 mph (2 mm) and are familiar with the
(130 km/h) motorcycle's characteristics i n all
conditions. High speed operation in
Over Rear 0.12 in any other circumstances is
80 mph (3 mm) dangerous and will lead t o loss of
(130 km/h) Front 0.08 in motorcycle control and an
(2 mm) accident.
/continued
Check the rims for dents or
deformation. Operation with
damaged or defective wheels or
tlres 1s dangerous and loss of
motorcycle control or an accident
could result.
Always consult your authorized
Triumph dealer for tire
replacement, or for a safety Do not install tube-type tires on
inspection of t h e tires. tubeless rims. The bead will not
seat and the tires could slip on the
Tire Replacement
rims, causing rapid tire deflation
All Triumph motorcycles are carefully that may result in a loss of vehicle
and extensively tested in a range of control and an accident. Never
riding conditions t o ensure that the install an inner tube inside a
most effective tire combinations are tubeless tire. This will cause
approved for use on each model. It friction inside the tire and the
is essential t h a t approved tires, resulting heat build-up may cause
fitted in approved combinations, are the tube to burst resulting in rapid
used when purchasing replacement tire deflation, loss of vehicle
tires. The use of non-approved tires, control and an accident.
or approved tires in non-approved
b
combinations, may
motorcycle instability
lead
and
accident. See the specification
to
an
~r tire aamage
-
arning
IS suspeccea, sucn
as after striking the kerb, ask your
combinations. Always have tires
authorized Triumph dealer to
fitted and balanced by your
inspect the tire both internally and
authorized Triumph dealer who has
externally. Remember, tire damage
the necessary training and skills to
may not always be visible from the
ensure safe, effective fitment.
outside. Operation of the
motorcycle with damaged tires
could lead t o loss of control and an
accident.
Maintenance and Adjustment
Battery
EACH OF CHILDREN.
Maintenance and Adjustment
Battery Maintenance
Clean t h e battery using a clean, dry,
cloth. Be sure that the cable
connections are clean.
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1 Battery
2 Negative (black) terminal
3 Positive (red) terminal
4 Battery strap
mbw
1 Fuse box
2 Fuse box cover
3 Spare fuses
NOTE:
The starter solenoid has a n
additional 30 Amp fuse,
attached directly to the
solenoid, beneath the
rider's seat.
Maintenance and Adjustment
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1 Horizontal adjustment screw
(Left hand)
2 Vertical adjustment screw (Left
hand)
Any attempt t o adjust a headlight 3 Horizontal adjustment screw
beam when the motorcycle is i n (Right hand)
result in loss of
4 Vertical adjustment screw
(Right hand)
5 Pivot screws (DO NOT adjust
these screws)
A Caution
Do not adjust the pivot screws as
this will cause the headlight
reflector to become detached from
the pivot screw, leading to
irreparable damage to the
headlight.
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1 Bulb holder
2 Position lamp bulb
2
Installation is the reverse of the
1 removal procedure.
Washing
Prepare a mixture o f water and mild
soap. Do not use a highly alkaline
soap as commonly found a t
n accident could result. Clean the commercial car washes because it
leaves a residue.
Wash the exhaust system with a soft
Unpainted Aluminium Items cloth. Do not use an abrasive
scouring pad or steel wool. They will
I t e m s such as brake and clutch damage the finish.
levers must be correctly cleaned to
Rinse the exhaust system
preserve their appearance.
thoroughly.
Use a proprietary brand of
Ensure no soap or water enters the
aluminium cleaner which does not
mufflers.
contain abrasive o r caustic elements.
Clean aluminium items regularly, in
particular after use in inclement
weather, where the components
must be hand washed and dried
each time the machine is used.
Warranty claims due t o inadequate
maintenance will not be allowed.
Maintenance and Adjustment
Drying
Dry the exhaust system as far as
possible with a soft cloth. Do not run
A ca
the engine t o dry the system or The use of silicone containing
spotting will occur. products will cause discoloration of
the chrome and must not be used.
Protecting Similarly, the use of abrasive
cleaners and polishes will damage
When the exhaust system is dry, rub the system and must not b e used.
'Motorex 645 Clean and Protect' into
the surface. I t is recommended that regular
protection be applied t o the system
as this will both protect and enhance
the system's appearance.
Storage
STORAGE
Preparation after
Storage
Charge the battery if necessary, and
install it in the motorcycle.
Fill the fuel tank with fuel.
Change the engine oil and filter.
Check all the points listed in the
daily safety checks section.
Before starting the engine, remove
one of the spark plugs from each
cylinder.
Put the side stand down.
Crank the engine on the starter
motor several times until the oil
pressure light goes out.
Replace the spark plugs and start
engine.
Check brakes and operation.
Specifications
SPECIFICATIONS
Dimensions
Overall length. . . . . . . . . . . . . . . 79.1 in (2010 mm)
Overall width . . . . . . . . . . . . . . . 27.5 in (700 mm)
Overall height.. . . . . . . . . . . . . . 44.1 in (1120 mm)
Wheelbase. . . . . . . . . . . . . . . . . 54.9 in (1395 mm)
Seat height . . . . . . . . . . . . . . . . 32.5 in (825 m m )
Weights
Dry Weight . . . . . . . . . . . . . . . . 363.7 Ib (165 kg)
Maximum Payload . . . . . . . . . . . 430 Ib (195 kg)
Engine
Type . . . . . . . . . . . . . . . . . . . . .In-line 3 cylinder
Displacement . . . . . . . . . . . . . . .41.2 cu in (674.8 cc)
Bore x Stroke . . . . . . . . . . . . . .2.91 in x 2.06 in (74 x 52.3 mm)
Compression Ratio . . . . . . . . . . .12.65:1
Cylinder Numbering . . . . . . . . . .Left t o Right
Cylinder Sequence .......... .1 at left
Firing Order ............... .l-2-3
Starting System ............ .Electric Starter
Performance
Maximum Power (DIN 70020) ...
123 HP (125 PS)
a t 12,500 rpm
Maximum Torque . . . . . . . . . . . . 53.3 ft.lbf (72 Nm)
a t 11,750 r p m
Lubrication
Lubrication . . . . . . . . . . . . . . . . .Pressure Lubrication
(wetsump)
Engine Oil Capacities
Dry Fill. . . . . . . . . . . . . . . . . . . . 0.79 US gal (3.0 litres)
OilIFilter Change. . . . . . . . . . . . . 0.68 US gal (2.6 litres)
Oil Change Only . . . . . . . . . . . . . 0.63 US gal (2.4 litres)
Specifications
Cooling
Coolant Type . . . . . . . . . . . . . . .Mobil Antifreeze
Waterlanti-freeze ratio . . . . . . . .50/50
Coolant Capacity . . . . . . . . . . . .0.63 US gal (2.4 litres)
Thermostat Opens (nominal) ...
.158OF (71%)
Fuel System
Type . . . . . . . . . . . . . . . . . . . . .Electronic
Fuel
Injection
Injectors . . . . . . . . . . . . . . . . . .Solenoid Operated
Fuel Pump . . . . . . . . . . . . . . . . .Submerged Electric
Fuel Pressure (nominal) ....... .43.5 psi (3 Bar)
Fuel
Type . . . . . . . . . . . . . . . . . . . . .89 (R+M)/2
Tank Capacity . . . . . . . . . . . . . .4.6 US gal (17.4 litres)
Ignition
Ignition System . . . . . . . . . . . . .Digital Inductive
Electronic Rev Limiter (r/min) . . .14,000 (rlmin)
Spark Plug . . . . . . . . . . . . . . . . NGK CR9EK
Spark Plug Gap . . . . . . . . . . . . .0.028 in (0.7 mm)
Gap Tolerance . . . . . . . . . . . . . . +0.001/-0.003 in (+0.05/-0.lmm)
Transmission
Transmission Type . . . . . . . . . . .6 Speed,
Constant Mesh
Clutch Type . . . . . . . . . . . . . . . .Wet, Multi-Plate
Final Drive Chain . . . . . . . . . . . .RK O-ring
Primary Drive Ratio . . . . . . . . . .1.848: 1 (46185)
Gear Ratios:
Final Drive Ratio . . . . . . . . . . . . .2.937:1 (16147)
1st . . . . . . . . . . . . . . . . . . . . . .2.615: 1 (13134)
2nd . . . . . . . . . . . . . . . . . . . . .1.857: 1 (21139)
3rd . . . . . . . . . . . . . . . . . . . . . .1.565: 1 (23136)
4th . . . . . . . . . . . . . . . . . . . . . .1.350: 1 (20127)
5th . . . . . . . . . . . . . . . . . . . . . .1.238: 1 (21126)
6th . . . . . . . . . . . . . . . . . . . . . .l.136: 1 (22125)
Specifications
Tires
Tire Pressures (Cold) :
Front . . . . . . . . . . . . . . . . . . . .34 lb/in2 (2.35 Bar)
Rear . . . . . . . . . . . . . . . . . . . . .36 lb/in2 (2.50 Bar)
Front Size . . . . . . . . . . . . . . . . .120/70 ZR 17
Rear Size . . . . . . . . . . . . . . . ..180/55 ZR 17
Approved tires:
Option 1, Front and Rear ....... Pirelli Dragon Supercorsa Pro
Option 2, Front and Rear . . . . . . .Michelin Pilot Power B
Option 3, Front and Rear . . . . . . .Bridgestone BT014 G
Electrical Equipment
-
Battery Type. . . . . . . . . . . . . . . .M 7 B BS
Battery Rating . . . . . . . . . . . . . .12 volt, 7 Ah
Alternator . . . . . . . . . . . . . . . . .12 volt, 33.5 Amp a t 4,000 rpm
Headlight . . . . . . . . . . . . . . . . .l x 12 volt, 55 watt H7 halogen
(left hand side)
1 x 12 volt, 65 watt H9 halogen
(right hand side)
TailIBrake Light . . . . . . . . . . . . .LED
Turn Signal Lights . . . . . . . . . . .12 volt, 1 0 watt
Frame
Castor . . . . . . . . . . . . . . . . . . . . 23.g0
Trail . . . . . . . . . . . . . . . . . . . . . 3.51 in (89.1 mrn)
Tightening Torques
Oil Filter. . . . . . . . . . . . . . . . . . .7.4 Ibf f t (10 Nm)
Oil Drain Plug . . . . . . . . . . . . . .18.4 Ibf f t (25 Nm)
Spark Plug . . . . . . . . . . . . . . . .13.3 Ibf ft (18 Nrn)
Rear Wheel Spindle. . . . . . . . . . .81.1 Ibf f t (110 Nm)
Chain Adjuster Locknut . . . . . . . .20 Ibf f t (27 Nm)
Specifications
INDEX
A Change, 73
Accessories, 58 Corrosion Inhibitors, 72
B Level Adjustment, 73
Battery, 96 Level Inspection, 72
Disposal, 97 D
Installation, 98 Dimensions, 109
Maintenance, 97 Drive Chain, 78
Removal, 97 Lubrication, 78
Brakes, 82 Movement Adjustment, 79
Brake and Clutch Lever Movement Inspection, 79
Adjusters, 37 Wear Inspection, 80
Bra king, 52 E
Disc Brake Fluid, 83 Electrical Equipment, 111
Fluid Level, 84 Engine
Light Switches, 85 Serial Number, 17
Pad Wear Compensation, 82 Specifications, 109
Wear Inspection, 82 To Start the Engine, 50
Breaking-In, 45 To Stop the Engine, 50
C Engine Oil, 68
Cleaning, 104 Disposal of Oil and Filters, 71
After Washing, 105 Grade and Specification, 71
Drying, 106 Oil and Filter Change, 70
Exhaust System, 105 Oil Level Inspection, 69
Preparation, 104 F
Protecting, 106 Fluids and Lubricants, 112
Unpainted Aluminium Items, Frame, 111
105 Front Suspension, 88
Washing, 105 Compression Damping
Where to be Careful, 104 Adjustment, 90
Clock/Trip Computer, 22 Fork Inspection, 88
Clutch, 77 Rebound Damping
Adjustment, 77 Adjustment, 90
Inspection, 77 Setting Chart, 89
Coolant Temperature Gauge, 24 Spring Pre-Load Adjustment,
Cooling System, 72, 110 90
Index Foreword