( \ TriumphRocket Ill, Rocket III Classic and Rocket III Touring Motorcycle Service Manual Part Number 3851160 issue1,09.2007 Thisdocumentisprotectedbycopyright andmaynot,inwholeor part be storedina retrievalsystem,ortransmittedin anyformorbyanymeans,copied,photocopied,translatedorreducedtoanymachine-readableformwithoutprior consent inwritingfromTriumphMotorcyclesLimited. Noliabilitycanbeacceptedforanyinaccuraciesoromissionsinthispublication,althougheverypossiblecarehasbeen takentomakeit ascomplete andaccurate aspossible. TriumphMotorcyclesLimitedreservestheright tomakechanges andalter specificationswithoutpriornoticeandwithout incurringanobligationtomakesuchchangestoproductsmanufacturedpreviously.See yourauthorised Triumphdealer forthelatestinformationonproduct improvementsincorporatedafter thispublication. Allinformationcontainedinthispublicationisbasedonthe latest product informationavailable at the time ofpublication. Illustrationsinthispublication areintendedforreferenceuseonly andmaynot depict actualmodelcomponent parts. TriumphMotorcyclesLtd2007 SelVice Manual- Rocket Ill/ Classic /Touring 1 2 SelVice Manual - Rocket 1111Classic 1 Touring Table of Contents Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaft Bevel Box andDrive Shaft Balancer Transmission Lubrication Engine Removal and Refit FuelSystem/Engine Management Cooling Rear Suspension Front Suspension Brakes WheelslTyres Frame and Bodywork ElectricalSystem Service Manual- Rocket Ill/ Classic /Touring ii SelViceManual - Rocket Ill/ Classic /Touring Introduction SelVice Manual - Rocket Ill/ Classic /Touring iii Introduction Thismanualisdesignedprimarilyforusebytrained techniciansina properly equipped workshop.However,it containsenoughdetailandbasicinformationtomakeit usefultothe owner whodesirestoperformhisownbasic maintenanceandrepairwork.Theworkcanonlybe carriedoutiftheownerhasthenecessaryhandand specialservice toolstocomplete thejob. A basic knowledge of mechanics,including the proper use of toolsandworkshopproceduresisnecessaryinorder to carryoutmaintenanceandrepairworksatisfactorily. Whenever the owner hasinsufficient experience or doubts hisabilitytodothework,anauthorisedTriumphdealer mustundertakealladjustments,maintenance,andrepair work. Inorder toperformthe work efficiently andtoavoidcostly mistakes,readthetext andthoroughlyfamiliariseyourself withproceduresbefore starting work. Allworkshouldbeperformedwithgreatcareandina cleanworkingarea withadequate lighting. Alwaysusethecorrectspecialservicetoolsor equipment specified.Undernocircumstancesusemakeshifttoolsor equipmentsincetheuseofsubstitutesmayadversely affect safeoperation. Whereaccuratemeasurementsarerequired,theycan onlybe madeusingcalibrated,precisioninstruments. Forthedurationofthewarrantyperiod,anauthorised Triumphdealermustperformallrepairsandscheduled maintenance. Tomaximise thelifeof your Motorcycle: Accuratelyfollowthemaintenance requirementsof theperiodic maintenance chart inthe servicemanual. Donotallowproblemstodevelop.Investigate unusualnoisesandchangesintheriding characteristicsofthemotorcycle.Rectifyall problemsassoonaspossible(immediatelyif safety related). Useonlygenuine Triumphpartsaslistedinthe partscatalogue/partsmicrofiche. Followtheproceduresinthismanualcarefully andcompletely.Donot takeshort cuts. Keepcompleterecordsofallmaintenanceand repairswithdatesandany newpartsinstalled. Useonlyapprovedlubricants,asspecifiedin theowner'shandbook,inthemaintenanceof themotorcycle. How to use this manual Toassist intheuseof thismanual, thesectiontitleisgiven at the top. Eachmajorsectionstartswitha contentspage,listingthe informationcontainedinthe section. Theindividualstepscomprisingrepairoperationsareto be followedinthesequence inwhichthey appear. Adjustmentandrepairoperationsincludereferenceto service toolnumbers and the associatedillustrationdepicts thetool. Whereusage isnot obvious,thetoolisshowninuse. Adjustmentandrepairoperationsalsoincludereference towearlimits,relevantdata,torquefigures,specialist informationandusefulassembly details. Warnings, Cautions and Notes Particularlyimportantinformationispresentedinthe followingform: warningsymbolidentifiesspecialinstructionsor procedureswhich,ifnotcorrectlyfollowed,couldresult inpersonalinjury,or lossoflife. Thiscautionsymbolidentifiesspecialinstructionsor procedures which,ifnot strictly observed, couldresultin damage toor destructionof equipment. Note: Thisnotesymbolindicatespointsof particular interestformoreefficientandconvenient operation. iv SelVice Manual - Rocket IIIIClassic ITouring Tampering with Noise Control System Prohibited Owners are warnedthat thelawmayprohibit: a)Theremovalorrenderinginoperativebyany personother thanforpurposes of maintenance, repair orreplacement,of anydeviceor element of designincorporatedintoanynewvehiclefor thepurposeofnoisecontrolpriortoitssaleor deliverytotheultimatepurchaserorwhileitis inuse;and b)theuseofthevehicleaftersuchdeviceor elementofdesignhasbeenremovedor renderedinoperativeby anyperson. References Referencestothelefthand or right handsidegiveninthis manualaremadewhenviewingthemotorcyclefromthe rear. Operationscoveredinthismanualdonotalwaysinclude referencetotestingthemotorcycleafterrepair.Itis essentialthatworkisinspectedandtestedafter completionandifnecessarya roadtestof themotorcycle iscarriedoutparticularlywheresafetyrelateditemsare concerned. Dimensions Thedimensionsquotedaretodesignengineering specificationwithservicelimitswhere applicable. Duringtheperiodofrunning-infromnew,certain adjustmentsmayvaryfromthespecificationfiguresgiven inthismanual. These willbe reset by the dealer at the500 mile/800kmservice, andthereafter shouldbemaintained at thefiguresspecifiedinthismanual. Repairs andReplacements Beforeremovalanddisassembly,thoroughlycleanthe motorcycle.Anydirtenteringtheengineorotherparts willworkasanabrasiveandshortenthelifeofthe motorcycle.Particularattentionshouldbepaidwhen installinganewpart,thatanydustormetalfilingsare clearedfromthe immediate area. Force Commonsenseshoulddictatehowmuchforceis necessaryinassemblyanddisassembly.Ifapartseems especiallydifficulttoremoveorinstall,stopandexamine whatmaybecausingtheproblem.Neverlevera componentasthiswillcausedamagebothtothe component itself andtothe surfacebeinglevered against. Introduction Whenever tappingtoaidremovalof anitemisnecessary, taplightlyusinga hideorplasticfacedmallet. Edges Watchforsharpedges,especiallyduringengine disassemblyandassembly.Protectthehandswith industrialquality gloves. Whenreplacementpartsarerequired,itisessentialthat onlygenuine Triumphpartsareused. Safetyfeaturesandcorrosionpreventiontreatments embodiedinthemotorcyclemaybeimpairedifother thangenuine Triumphparts are fitted.Incertainterritories, legislationprohibitsthefittingofpartsnottothe manufacturer'sspecification. Tightening procedure Generally, wheninstallinga part withseveralbolts,nutsor screws,theyshouldallbestartedintheirholesand tightenedtoa snugfit,evenly andina crosspattern. This istoavoiddistortionofthepart and/orcausinggasoroil leakage.Conversely,bolts,nuts,orscrews,shouldallbe loosened(insequence if specified)byabout a quarter of a turnandthenremoved. Wherethereisatighteningsequencespecifiedinthis ServiceManual,thebolts,nuts,orscrewsmustbe tightenedinthe order andbythemethodindicated. TorquewrenchsettingfiguresgiveninthisManualmust beobserved.Thetorquetoolsusedmustbeofaccurate calibration. Lockingdevices,wherespecified,mustbefitted.Ifthe efficiency of a lockingdeviceisimpairedduringremovalit mustberenewed.Thisappliesparticularlytomicro-encapsulatedfixingswhichmustalwaysbereplacedif disturbed.Wherenecessary,thetextinthismanualwill indicate where sucha fixingisused. ServiceManual - Rocket Ill/ Classic /Touring v Introduction Thispage intentionally leftblank vi SelVice Manual - Rocket Ill/ Classic 1 General Information Table of Contents IgnitionSystem Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Dangerous Substances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 ThirdParty Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Fluoroelastomers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Oils........................ ... ........ ....................... ... ...... ......... ...... ...1.4 HealthProtectionPrecautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Environmental ProtectionPrecautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 Brakes. . .. . . . . .. . . . ... . . . .. . .. . .. . .. .. . .. . . . . . . . .. . . . .. . . . . .. . .. . .. . . .. . .. . .. . . . ... ... .. .1.5 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 JackingandLifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.6 Precautions against Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.6 Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.7 Cleaning components.. . . . . . . . . . . . . . . . . .. . .. . . . . .. . .. . .. . . . . . . . . . . .. . . . . . . .. . . . . . . . . ..1.7 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.7 Joints andjoint faces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.7 Gaskets, O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.7 LiquidGasket, Non-permanent LockingAgent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.8 Screw Threads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.8 LockingDevices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.8 Fitting aSplit Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.8 Circlips,RetainingRings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.8 Self LockingNuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.8 EncapsulatedBolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.8 Oiland Grease Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.9 Press. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . .. . . . . . . . . . . . . . . . . .. . . . . .. . .. . .. . .. ..1.9 BallBearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.9 ChassisBearingLubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.9 Metalbushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.10 FuelHandlingPrecautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.11 Petrol - Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.11 FuelTank Removal.. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . .. . . . . .. . . . ..1.11 ChassisRepairs.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.11 ElectricalPrecautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12 SelVice Manual- Rocket 1111Classic 1 Touring 1.1 General Information 1.2 Battery Disconnecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12 Disciplines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13 Electrical Wires.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13 Electrical Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14 Ohm's law.......... ......................... .............. . .. . ........... ...... ...1.14 BasicElectrical Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14 Circuit Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15 Glossary of Circuit DiagramSymbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15 TracingCircuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16 ToCheck Continuity: ........... , ........................ , . . . . . . . . . .. . . . . . . . .. . . . . . . . .1.17 ToMeasure Voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17 CAN(Controller AreaNetworking>.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18 Alternator/Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19 Diagnosis - Charging Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.20 Starting Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21 GeneralFault Finding - Starter Motor and Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21 Diagnosis - Starter Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22 Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.23 SelViceData. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.23 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.23 SelVicetools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.24 Special selVicetools:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.24 Torque Wrench Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40 Cylinder Head Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.40 Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.40 Crankshaft and Crankcases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.40 Engine Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.40 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.41 Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.41 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.41 FuelSystem, Exhaust System and Airbox.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.42 Rear Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.42 Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.43 Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.43 Front Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.43 Rear Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.44 Footrests and Control Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.44 Bodywork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.44 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.45 Routings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46 Clutch Cable Routing - Rocket IIIand Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.46 Clutch CableRouting - Rocket IIITouring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.47 Handlebar Cable Routing - Rocket IIIand Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.48 Handlebar Cable Routing - Rocket IIITouring ............................... ; . . . . . . . . . . ..1.49 Main WiringHarnessRouting - Rocket IIIand Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.50 SelVice Manual- Rocket 1111Classic 1 Touring General Information Main WiringHarness Routing - Rocket IIITouring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.51 Rear Mudguard Harness Routing - Rocket IIIand Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.52 Rear MudguardHarnessRouting - Rocket IIITouring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.53 Front BrakeHoseRouting - Rocket IIIand Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.54 Front Brake Hose Routing - Rocket IIITouring..........................................1.55 Rear BrakePipe andHoseRouting - Rocket IIIand Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.56 Rear BrakePipe andHoseRouting - Rocket IIITouring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57 Throttle Cable Routing - Rocket IIIand Classic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58 Throttle Cable Routing - Rocket IIITouring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59 FuelHose and Fuel Tank Breather Hose Routing(non-evaporative emission control versions>-Rocket IIIand Classic.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.60 FuelHose andFuel Tank Breather HoseRouting(non-evaporative emission control version> -Rocket IIITouring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.61 FuelHose andEvaporative/Fuel Tank Breather HoseRouting- Rocket IIIand Classic. . . . . . . . . .1.62 FuelHose andEvaporative/Fuel Tank Breather Hose Routing - Rocket IIITouring. . . . . . . . . . . . .1.63 SelVice Manual- Rocket Ill/ Classic /Touring 1.3 General Information Ignition System Safety Precautions Theignitionsystemproducesextremelyhighvoltages. Donottouchanypartoftheignitionsystemorany cableswhilethe engineisrunning. Anelectricshockcausedbycontactwiththeignition systemmay leadtoillness,injury or death. Wearersofsurgicallyimplantedheartpacemaker devicesshouldnotbeincloseproximitytoignition circuitsandor diagnostic equipment. Theignitionsystemandanydiagnosticequipmentmay interruptthenormaloperationofsuchdevicescausing illnessor death. Dangerous Substances Manyliquidsandothersubstancesusedinmotor vehiclesarepoisonousandshouldunderno circumstancesbeconsumedandshould,asfaras possible,bekeptfromcontactwiththeskin.These substancesamongothersincludeacid,anti-freeze, asbestos,brakefluid,fuel,lubricants,andvarious adhesives.Alwayspaycloseattentiontotheinstructions printedonlabelsandobeytheinstructionscontained within.Theseinstructionsareincludedforyoursafety andwell-being. NEVERDISREGARDTHESEINSTRUCTIONS! Third Party Products Manyproprietyproducts,suchaschemicals,solvents andcleaningagents,willcausedamage tocomponents ifusedincorrectlyorinappropriately.Alwaysfollowthe manufacturer'sinstructionsprintedontheproduct container'slabelsandobey the instructionsgiven.These instructionsareincludedforyour safety andwell-being. Damagetothemotorcyclecomponentscausedbythe incorrect or inappropriateuse of chemicals, solventsand cleaningagentsmayreducethecomponentsefficiency, resultinginlossofmotorcyclecontrolandanaccident. Fluoroelastomers Fluoroelastomermaterialisusedinthemanufactureof varioussealsinTriumphmotorcycles. Infireconditionsinvolvingtemperaturesgreaterthan 315Cthismaterialwilldecomposeandcanthenbe potentiallyhazardous.Highlytoxicandcorrosive decompositionproducts,includinghydrogenfluoride, carbonylfluoride,fluorinatedolefinsandcarbon monoxidecanbegeneratedandwillbepresentin fumesfromfires. Inthepresenceofanywaterorhumidityhydrogen fluoridemaydissolvetoformextremely corrosiveliquid hydrofluoric acid. Ifsuchconditionsexist,donottouchthematerialand avoidallskincontact.Skincontactwithliquidor decompositionresiduescancausepainfuland penetratingburnsleadingtopermanent,irreversible skinandtissuedamage. Oils Theengine andbevelboxoilsmaybe hot tothetouch. Contact withhot oilmay causetheskintobe scaldedor burned. Prolongedorrepeatedcontactwithengineoilcanlead toskindryness,irritationanddermatitis.Inadditionused engineoilcontainspotentiallyharmfulcontaminants whichcancausecancer.Wearsuitableclothingand avoidskincontact. Health Protection Precautions Avoidprolongedandrepeatedcontactwith oils, particularly usedengine oils. Wearprotectiveclothing,including impervious gloves where practicable. Donot put oily ragsinpockets. Overallsmustbecleanedregularly.Discard heavilysoiledclothingandoilimpregnated footwear. 1.4 Service Manual - Rocket Ill/ Classic /Touring Firstaidtreatmentshouldbeobtained immediatelyforopencutsandwounds. Alwaysbeawareofwhoyournearestfirst-aiderisandwherethemedicalfacilitiesare kept Usebarriercreams,applyingbeforeeach workperiodtoprotecttheskinfromthe effects of oil and grease and to aidremoval of the same after completing work. Washwithsoapandwater toensure alloilis removed(skincleansers andnailbrushes will help).Preparationscontaininglanolinreplace thenaturalskinoilswhichhavebeen removed. Donotusepetrol,kerosene,dieselfuel,gas oil, thinners or solvents for cleaning skin. Ifskindisordersdevelop,obtainmedical advice without delay. Wherepracticable,de-greasecomponents prior tohandling. Anyrisk of eyeinjurymust be avoided. Alwayswear eye protectionwhenusingahammer,airline,cleaning agentorwherethereisANYriskofflyingdebrisor chemicalsplashing. Environmental Protection Precautions Donotpouroilontheground,downsewersor drains, orintowatercourses.Topreventpollutionofwater-coursesetc.,disposeofusedoilsensibly.Ifindoubt contact yourlocalauthority. Burningofusedengineoilinsmallspaceheatersor boilerscanberecommendedonlyforunitsofapproved design.Ifindoubt,checkwiththeappropriatelocal authority and/or manufacturer of the approvedappliance. Disposeofusedoilandusedfiltersthroughauthorised wastedisposalcontractors,tolicensedwastedisposalsites, ortothewasteoilreclamationtrade.Ifindoubt,contact yourlocalauthorityforadvice ondisposalfacilities. General Information Brakes Brakefluidishygroscopicwhichmeansitwillabsorb moisturefromtheair.Anyabsorbedmoisturewill greatlyreducetheboilingpointofthebrakefluid causinga reductioninbrakingefficiency. Replacebrake fluidinlinewiththeroutinemaintenance schedule.A dangerousridingconditioncouldresultif thisimportant maintenance itemisneglected! Donotspillbrakefluidontoanyareaofthebodywork asthiswilldamage anypaintedorplastic surface. Alwaysusenewbrake fluidfroma sealedcontainer and neverusefluidfromanunsealedcontainer or fromone thathasbeenpreviously opened. Donotmixdifferentbrandsoffluid.Checkforfluid leakage aroundbrakefittings,sealsandjoints. Check regularly forbrakehose damage. FAILURETOOBSERVEANYOFTHEABOVE WARNINGSMAYREDUCEBRAKINGEFFICIENCY LEADINGTOANACCIDENT. Iftherehasbeen anappreciable dropinthelevelof the fluidineitherbrakefluidreservoir,consultyour authorised Triumphdealer foradvicebeforeriding. Ifthe brake lever or pedal feelssoft whenitisapplied, or ifthelever/pedaltravelbecomesexcessive,theremay be airinthebrakelinesor thebrakemaybe defective. Itisdangeroustooperatethemotorcycleundersuch conditionsandremedialactionmustbetakenbyyour authorised Triumphdealerbeforeridingthemotorcycle. Failuretotakeremedialactionmayreducebraking efficiencyleadingtoanaccident. UseonlyD.O.T.4specificationbrakefluidaslistedin thegeneralinformationsectionofthismanual.Theuse ofbrakefluidsother thanthoseD.O.T.4fluidslistedin thegeneralinformationsectionmayreducethe efficiency of thebrakingsystemleadingtoanaccident. Failuretochange thebrake fluidat theintervalspecified intheroutinemaintenanceschedulemayreduce brakingefficiencyresultinginanaccident. SelViceManual- Rocket 1111Classic 1 Touring 1.5 General Information Neverusemineralbasedgreaseinanypartofthe brakingsystemorinanyareawherecontactwiththe brakingsystemispossible.Mineralbasedgreasewill damagethehydraulicsealsinthecalipersandmaster cylinders. Damagecausedbycontactwithmineralbasedgrease mayreducebrakingefficiencyresultinginanaccident. Beforeinstallation,allinternalbrakecomponentsshould becleanedandlubricatedwithcleannewDOT 4brake fluid. Neverusesolvents,petrol(gasoline),engineoilorany other petroleumdistillateoninternalbrakecomponents asthiswillcausedeteriorationofthehydraulicsealsin the calipersandmaster cylinders. Adangerousridingconditionleadingtolossof motorcyclecontrolandanaccidentcouldresultifthis warningisignored. Safety Instructions Jacking and Lifting Alwaysensurethatanyliftingapparatushasadequate loadandsafetycapacityfortheweighttobelifted. Ensurethemotorcycleiswellsupportedtoprevent any possibility of the machine fallingprior toliftingor jacking or whilerepairsandservicingare carriedout. Neverrelyona singlemeansofsupport whenworking withthemotorcycle.Useadditionalsafetysupportsand strapstoprevent toppling. Donotleavetools,liftingequipment,spiltoil,etc.ina placewheretheycouldbecomeahazardtohealth. Alwaysworkina clean,tidyareaandput alltoolsaway whenthe workisfinished. Precautions against Damage Avoidspillingbrake fluidor battery acidonanypart of the bodywork.Washspillagesoff withwater immediately. Disconnect the battery earthleadbefore startingwork, see ELECTRICAL PRECAUTIONS. Alwaysusetherecommendedservicetoolwhere specified. Protectexposedbearingandsealingsurfaces,andscrew threadsfromdamage. 1.6 SelVice Manual- Rocket Ill/ Classic /Touring Coolant Coolantmixture,whichisblendedwithanti-freezeand corrosioninhibitorscontainstoxicchemicalswhichare harmfultothehumanbody.Neverswallowanti-freeze, corrosioninhibitorsor any of themotorcyclecoolant. Donotremovetheradiator cap whenthe engineishot. Whenthe engine ishot,the coolant inside theradiator is hotandalsounderpressure.Contactwiththe pressurisedcoolant willcause scaldsand skindamage. Thecoolantanti-freezecontainsacorrosioninhibitor whichhelpsprevent damage to the metalsurfacesinside thecoolingsystem.Withoutthisinhibitor,thecoolant would'attack'themetalsandtheresultingcorrosion wouldcauseblockagesinthecoolingsystemleadingto engine overheatinganddamage.Alwaysuse the correct anti-freezeasspecifiedintheOwner'sHandbook. Never use a methanolbasedanti-freeze asthisdoesnot containtherequiredcorrosioninhibitionproperties. Distilledwatermustbeusedwiththeanti-freeze(see specificationforanti-freeze>inthe coolingsystem. Ifhardwaterisusedinthesystem,itcausesscale accumulationinthewaterpassages,andconsiderably reducestheefficiencyofthecoolingsystem.Reduced coolingsystemefficiencymayleadtotheengine overheatingandengine damage. General Information Cleaning components A highflash-pointsolventisrecommendedtoreducefire hazard. Alwaysfollowcontainerdirectionsregardingtheuseof any solvent. Alwaysusetherecommendedcleaningagentor equivalent. Donotusedegreasingequipmentforcomponents containingitemswhichcouldbedamagedbytheuseof thisprocess.Wheneverpossible,cleancomponentsand theareasurroundingthembeforeremoval.Always observescrupulouscleanlinesswhencleaningdismantled components. Lubrication Themajorityofenginewearoccurswhiletheengineis warmingupandbeforealltherubbingsurfaceshavean adequatelubricationfilm.Duringassembly,oilorgrease (whicheverismoresuitable>shouldbeappliedtoany rubbingsurface,whichhaslostitslubricationfilm.Old grease anddirtyoilshouldbecleanedoff.Thisisbecause usedlubricantswillhavelostsomelubricationqualities andmay contain abrasiveforeignparticles. Userecommendedlubricants.Someoilsandgreasesin particular shouldbeusedonlyincertainapplicationsand maybeharmfulifusedinanapplicationforwhichthey arenotintended.Thismanualmakesreferenceto molybdenumdisulphidegreaseinthe assembly of certain engineandchassisparts.Alwayscheckmanufacturer recommendationsbeforeusingsuchspeciallubricants. Joints and joint faces Assemblejointsdryunlessotherwisespecifiedinthis Manual. Ifgasketsand/orjointingcompoundisrecommendedfor use;removealltracesofoldjointingmaterialpriortore-assembly.Donotuseatoolwhichwilldamagethejoint facesandsmoothout anyscratchesorburrsonthejoint facesusinganoilstone.Donotallowdirtorjointing materialtoenter any tappedholes. Gaskets, O-rings Donotre-useagasketorO-ringonceithasbeenin service.Thematingsurfacesaroundthegasket shouldbe freeof foreignmatter andperfectly smoothtoavoidoilor compressionleaks. SelViceManual - Rocket IIIIClassic ITouring 1.7 General Information LiquidGasket, Non-permanent Locking Agent Followmanufacturer'sdirectionsforcleaningand preparingsurfaceswherethesecompoundswillbeused. Apply sparingly asexcessiveamountsof sealermayblock engine oilpassages andcause seriousdamage. Priortore-assembly,blowthroughanypipes,channelsor crevices withcompressed air. Topreventinjury,alwaysuseeye,faceandear protectionwhenusingcompressedair.Alwayswear protectiveglovesifthecompressedairistobe directed inproximity tothe skin. Screw Threads Metric threadstoISOstandardareused. Damagednuts,boltsandscrewsmustalwaysbe discarded. Castellatednutsmustnotbeslackenedbacktoaccepta split-pin,exceptinthoserecommendedcaseswhenthis formspart of anadjustment. Donotallowoilorgreasetoenterblindthreadedholes. Thehydraulic actiononscrewinginthebolt or studcould split thehousing. Alwaystightena nutorbolttotherecommendedtorque figure.Damagedorcorrodedthreadscanaffectthe torquereading. Unlessspecified,threadedfixingsmustalwaysbefitted dry(nolubrication>. Never lubricate a threadunlessinstructedtodoso. Whenathreadofafixingislubricated,thethread frictionisreduced.Whenthefixingistightened, reducedfrictionwillcauseovertighteningandpossible fixingfailure. A fixingwhichfailsinservicecouldcausecomponent detachment leadingtolossof controlandanaccident. LockingDevices Alwaysreleaselockingtabsandfitnewlockingwashers, donotre-uselockingtabs. Fitting aSplit Pin Alwaysfitnewsplit-pinsofthecorrect sizefortheholein theboltorstud.Donotslackenbackcastlenutswhen fittingasplitpin,exceptinthoserecommendedcases whenthisformspart of anadjustment. Alwaysfitnewrollpinsof aninterference fitinthe hole. Circlips,RetainingRings Replaceanycirclipsandretainingringsthat areremoved. Removalweakensanddeformscirclipscausinglooseness inthe circlipgroove.Wheninstallingcirclipsandretaining rings,take caretocompress or expand themonly enough toinstallthem. Alwaysusethecorrectreplacementcirclipas recommendedinthe Triumphpartscatalogue. Self LockingNuts Self-lockingnutscanbere-used,providingresistancecan be feltwhenthelockingportionpassesover thethreadof thebolt or stud. DONOTre-useself-lockingnutsincriticallocations,e.g. suspensioncomponents.Alwaysusethecorrect replacement self-lockingnut. Encapsulated Bolts Anencapsulatedboltcanbeidentifiedbyacoloured sectionof threadwhichistreated witha lockingagent. Unlessaspecifiedrepairprocedurestatesotherwise, encapsulatedboltscannotbereusedandMUSTbe replacedifdisturbedor removed. Failuretoreplaceanencapsulatedboltcouldleadtoa dangerousridingcondition.Alwaysreplace encapsulatedbolts. 1.8 SelVice Manual - RocketIll/ Classic /Touring Oil and Grease Seals Replaceanyoilorgreasesealsthatareremoved. Removalwillcause damage toanoilseal which,ifre-used, wouldcause anoilleak. Ensurethe surfaceonwhichthenewsealistorunisfree of burrs or scratches.Renewthecomponent iftheoriginal sealing surface cannot becompletelyrestored. Protectthesealfromanysurfacewhichcouldcause damage over whichithastopass whenbeing fitted.Use a protective sleeveor tape tocover therelevant surface and avoidtouchingthesealinglip. Lubricatethesealinglipswitharecommendedlubricant. Thiswillhelptopreventdamageininitialuse.Ondual lippedseals,smeartheareabetweenthelipswith appropriate grease. Whenpressingina sealwhichhasmanufacturer'smarks, pressinwiththemarksfacingout. Sealsmustbepressedintoplaceusingasuitabledriver. Useof improper toolswilldamage theseal. Press A partinstalledusingapressordriver,suchasawheel bearing,shouldfirstbecoatedwithoilorgreaseonits outer or inner circumference so that it willlocate smoothly. Ball Bearing Wheninstallingaballbearing,thebearingracewhichis aninterferencefitshouldbepushedbyasuitabledriver. Thispreventsseverestressordamagetotheload carryingcomponents.Pressaballbearinguntilittouches theshoulder inthebore or ontheshaft. Withthesealinglipfacingthelubricant,pressordrifta sealtothedepthofitshousing,ifthehousingis shouldered,orflushwiththefaceofthehousingwhere noshoulder isprovided. General Information Chassis Bearing Lubrication Note: Thisinformationrelatesonlytobearing lubrication.For the procedures necessary to replaceabearing,alwaysrefertothe relevant sectionof this service manual. Bearingsinstalledinengineand transmission applications are not covered by thisinformation.Refertothelubrication chapterortherelevantenginechapterfor additional information. General Fora bearingtobe serviceableforitsanticipatedlifespan itmustbechecked,adjustedandlubricatedatregular intervals,asspecifiedintheserviceschedulesgiveninthe owner'shandbook andthisservicemanual. Acorrectlylubricatedbearingwillhaveafilmof lubricationthat separatesthemovingparts,dispersesheat andprotectsthebearingsurfacesfromcorrosion. Note: In all cases, use the lubricant recommended. Greasethebearing,not thecavitywhereit islocated. Abearingthat isnot regularly checkedand lubricated will have a reduced life span. New Bearings Newbearingsaretypicallyprotectedwithanoil preservativetopreventcorrosionetc.duringstorage.This isNOTthelubricationforthebearingbutDOESNOT needtobewashedoffpriortoassemblyandin-service lubrication. Whenlubricatinga newbearingwithgrease the following steps shouldbe taken: 1.Donot cleanoff theoilpreservative. 2.Greasemustbeforcedbetweentherollerelements andthe roller cage. 3.Rotatethebearingtoensurethatthegreaseis distributedovertheentirecircumferenceofthe internalparts. 4.Any excessgrease shouldbe smeared onthe outside of therollers. SelViceManual - Rocket Ill/ Classic /Touring 1.9 General Information Lubrication andChecks While Servicing a Bearing 1.Disassemblepartsasnecessarytoaccessthe bearing. 2.Inspecttheoldgreasecoveringthebearing,looking forsignsofbearingdamage,i.e.flakesorspecksof metal. 3.Removetheoldgrease. 4.Checkthebearingforsmoothoperationandvisually check forcorrosion,dentsandflakinginthebearing race,rollersor cage.Replaceifnecessary. Below/overleafseveralcommonbearingtypesandthe lubricationproceduresforeach areidentified: ceon Sealed bearings Note: ceon Sealedbearingscanbeidentifiedbytheir integrated seals. Sealed bearings are lubricated for life by the manufacturer. Anyattempttochangethegreaseina sealedbearingwilldamagetheintegrated seals.Ifthesealsaredamageddirtand water willingress and the life of the bearing will be greatly reduced. Taper bearings 1.Greasemustbeforcedbetweentheinnerraceand theroller carrier. 2.Rotatethebearingtoensurethatthegreaseis distributedovertheentirecircumferenceofthe internalparts. 3.Any excessgrease shouldbe smeared on the outside of therollers. ceon Angular contact and ballbearing 1.Grease the bearing races and the ballbearing carrier. 2.Rotatethebearingtoensurethatthegreaseis distributedovertheentirecircumferenceofthe internalparts. ceop Needle roller bearings 1.Coat theneedlerollerswithgrease. 2.Ensuretheneedlerollersturnsothatthegreaseis distributedovertheentirecircumferenceofthe internalparts. 3.Assemble the parts,adjust andcheck asnecessary. Metalbushes 1.Disassemblethepartsasnecessarytoaccessthe bush. 2.Removethe oldgrease. Apply freshgrease tothemetalbush. 1.10 SelVice Manual - Rocket Ill/ Classic/Touring Fuel Handling Precautions General Thefollowinginformationprovidesbasicprecautions whichmustbeobservedifpetrol(gasoline)istobe handledsafely.Italsooutlinesotherareasofriskwhich mustnotbeignored.Thisinformationisissuedforbasic guidanceonlyand,ifindoubt,appropriateenquiries shouldbemade of yourlocalFireOfficer. Petrol - Gasoline Whenpetrol(gasoline)evaporatesitproduces150times itsownvolumeinvapourwhichwhendilutedwithair becomes a readilyignitable mixture. The vapour isheavier thanairandwillalwaysfalltothelowestlevel.Itcan readilybe distributedthroughout anyindoor environment byaircurrents,consequently,evenasmallspillageof petrol(gasoline)ispotentially very dangerous. Petrol(gasoline)ishighlyflammableandcanbe explosiveundercertainconditions.Whenopeningthe fueltank capalwaysobserve allthefollowingitems; TurnthemotorcycleignitionswitchOFF. Donot smoke. Alwayshave a fireextinguisher containingFOAM, C02, HALONorPOWDERcloseathandwhenhandlingor drainingfuelorfuelsystems.Fireextinguishersmust alsobepresent inareas where fuelisstored. Alwaysdisconnectthevehiclebattery,negative(black) leadfirst,beforecarryingoutdismantlingordraining work ona fuelsystem. Wheneverpetrol(gasoline)isbeinghandled,drained, stored or whenfuelsystems arebeing dismantled,make suretheareaiswellventilated.Allpotentialformsof ignitionmustbeextinguishedorremoved(thisincludes anyappliancewithapilotlight>.Anylead-lampsmust beflame-proof andkept clear of anyfuelspillage. Warningnoticesmustbepostedata safedistancefrom thesiteoftheworktowarnothersthatpetrolisbeing openlyhandled.Thenoticemustinstructthereaderof theprecautions whichmustbe taken. Failuretoobserveanyoftheabovewarningsmaylead toa firehazardwhichcouldresult inpersonalinjury. General Information Nooneshouldbepermittedtorepaircomponents associatedwithpetrol/gasolinewithoutfirsthaving specialisttrainingonthefirehazardswhichmaybe createdbyincorrectinstallationandrepairofitems associatedwithpetrol/gasoline. Repairscarriedoutbyuntrainedpersonnelcouldbring about a safetyhazardleadingto a risk of personalinjury. Drainingor extractionofpetrol/gasolinefroma vehicle fueltank mustbecarriedout ina wellventilatedarea. Thereceptacleusedtocontainthepetrol/gasolinemust bemorethanadequate forthefullamount of fueltobe extractedordrained.Thereceptacleshouldbeclearly markedwithitscontents,andplacedinasafestorage areawhichmeetstherequirementsoflocalauthority regulations. Whenpetrol/gasolinehasbeenextractedordrained froma fueltank, theprecautions governingnakedlights andignitionsources shouldbemaintained. Failuretoobserveanyoftheabovewarningscould bringabout a safetyhazardleadingtoa riskof personal injury. Fuel Tank Removal Fueltanksshouldhavea'PETROL(GASOLINE) VAPOUR'warninglabelattached tothemassoonasthey areremovedfromthevehicle.Inallcases,theymustbe storedina secured,markedarea. ChassisRepairs Ifthemotorcycleisinvolvedinanaccident or collisionit mustbetakentoanauthorisedTriumphdealerfor repair orinspection.Anyaccident cancause damageto themotorcycle,whichifnotcorrectlyrepaired,may causeasecondaccidentwhichmayresultininjuryor death. Theframemustnotbemodifiedasanymodificationto theframesuchasweldingordrillingmayweakenthe frameresultinginanaccident. SelViceManual - Rocket IIIIClassic ITouring 1.11 General Information ElectricalPrecautions Thefollowingguidelinesareintended toensure the safety of theoperator whilstpreventingdamage totheelectrical andelectroniccomponentsfittedtothemotorcycle. Wherenecessary,specificprecautionsaredetailedinthe relevantsectionsofthismanualwhichshouldbereferred toprior tocommencingrepair operations. Equipment- Priortocommencinganytestprocedureon themotorcycleensurethattherelevanttest equipmentis workingcorrectlyandanyharnessorconnectorsarein goodcondition,inparticularmainsleadsandplugs. Theignitionsystemproducesextremelyhighvoltages. Donottouchanypartoftheignitionsystemorany cableswhilethe engineisrunning. Anelectricshockcausedbycontactwiththeignition systemmay leadtoillness,injury or death. Wearersofsurgicallyimplantedheartpacemaker devicesshouldnotbeincloseproximitytoignition circuitsand/or diagnostic equipment. Theignitionsystemandanydiagnosticequipmentmay interruptthenormaloperationofsuchdevicescausing illnessor death. Thebatterycontainsharmfulmaterials.Alwayskeep childrenaway fromthebattery whether ornotitisfitted inthemotorcycle. Donotjumpstartthebattery,touchthebatterycables togetherorreversethepolarityofthecablesasanyof theseactionsmaycauseasparkwhichwouldignite battery gassescausing a riskofpersonalinjury. HighVoltageCircuits- WheneverdisconnectingliveH.T. circuitsalwaysuseinsulatedpliers.Exercisecautionwhen measuringthevoltageonthecoilterminalswhilethe engineisrunning,highvoltagespikescanoccur onthese terminals. Connectors andHarness - Theengine of a motorcycle isa particularlyhostileenvironmentforelectricalcomponents andconnectors.Alwaysensure these itemsare dry andoil freebefore disconnectingandconnectingtestequipment. Neverforceconnectorsaparteitherbyusingtoolsorby pullingonthewiringitself.Alwaysensurelocking mechanisms are disengagedbeforeremovalandnotethe orientationtoenablecorrectreconnection.Ensurethat anyprotectivecoversandsubstancesarereplacedif disturbed. Havingconfirmed a component tobe faulty,switchoff the ignitionanddisconnectthebatterynegative(black)lead first.Removethecomponentandsupportthe disconnectedharness.Whenreplacingthecomponent keepoilyhands away fromelectricalconnectionareas and pushconnectorshomeuntilanylockingmechanism becomesfullyengaged. Battery Disconnecting Beforedisconnectingthebattery,switchoffallelectrical equipment. Toprevent therisk of a battery exploding andtoprevent damagetoelectricalcomponentsALWAYSdisconnect thebatterynegative(black)leadfirst.When reconnectingthebattery,alwaysconnectthepositive (red)leadfirst,thenthenegative(black)lead.Always disconnectthebattery whenworkingonanypartof the electricalsystem. Failuretoobservetheabovewarningsmayleadto electricaldamageandafirehazardwhichcouldcause personalinjury. Alwaysensurethatbatteryleadsareroutedcorrectlyand are notclose toanypotentialchafingpoints. 1.12 SelVice Manual- Rocket1111Classic 1 Touring Disciplines Switchofftheignitionpriortomakinganyconnectionor disconnectioninthesystem.Anelectricalsurgecanbe causedbydisconnecting'live'connectionswhichcan damage electronic components. Ensurehandsandworksurfacesarecleanandfreeof grease,swarf,etc.asgreasecollectsdirtwhichcancause trackingor high-resistancecontacts. Prior tocommencinganytest,andperiodically duringany test,touchagoodearthtodischargebodystatic.Thisis becausesomeelectroniccomponentsarevulnerableto static electricity. General Information Electrical Wires Alltheelectricalwiresareeithersingle-colourortwo-colourand,withonlyafewexceptions,mustbe connectedto wiresof the same colour.On any of the two-colour wiresthere isa greater amount of one colour anda lesseramountofasecondcolour.A two-colourwireis identifiedbyfirsttheprimarycolourandthenthe secondarycolour.Forexample,ayellowwirewiththin redstripesisreferredtoasa 'yellow/red'wire;itwouldbe a'red/yellow'wireifthecolourswerereversedtomake redthemaincolour. SelViceManual - Rocket Ill/ Classic /Touring 1.13 General Information Electrical Testing Foranyelectricalsystemtowork,electricitymustbe able toflowinacompletecircuitfromthepowersource(the battery)viathecomponentsandbacktothebattery.No circuitmeansnoelectricalflow.Oncethepowerhasleft thepositivesideofthebatteryandrunthroughthe componentitmustthenreturntothebatteryonits negativeside(thisiscalledearthorground).Tosaveon wiring,connectionsandspace,thenegativesideofthe batteryisconnecteddirectlytotheframeorengine. Aroundtheframeandenginewillbevariousother groundpointstowhichthewiringcomingfrom componentswillbeconnected.Inthecaseofthestarter motor itboltsdirectly tothe engine,whichisboltedtothe frame.Thereforetheframeandenginealsoformpartof the earthreturnpath. Ohm's Law Therelationshipbetweenvoltage,currentandresistance isdefinedby Ohm'sLaw. Thepotentialofabatteryismeasuredin VoltsM. The flowof current ina circuit (I)ismeasured inAmperes. Thepower ratingof a consumer ismeasured inWatts . Theresistance(R>ofacircuitismeasuredin Ohms (W. Ohms law,forpracticalwork canbe described as-Voltage. Ct = ReSistance urren Power iscalculatedbymUltiplyingVoltsx Amps-Watts =Volts x Amps Bytransposingeitheroftheseformulae,thevalueofany unit canbe calculatediftheother twovaluesareknown. Forexample,ifa battery of12Visconnectedtoa bulbof 60W: thecurrentflowinginthecircuitcanbe calculatedbyusing -W =160 =5 V12 thebulbresistancecanbecalculatedby using -Y= R1 ~ = 2.4 Touseeitherofthefollowingtriangles,putyourfinger overthevalueyouwanttofind.Multiplytheremaining valuesif side-by-side,or divideifone isover theother. Basic Electrical Circuits 11 Basic Circuit Diagram Intheabovecircuitanelectricalreservoir(thebattery)is connectedviaacabletoaterminalonthecontrolling device(theswitch)whosecontactsareeitheropenor closed. The other terminalonthe switchisconnected viaa cable tothe consumer (thebulb), andthe other side of the bulbfilamentisconnectedtoground(earth)byanother cable.Thegroundpointisusuallyapartoftheframeor engine,towhichthebatterynegativeterminalisalso connected. Whentheswitchcontactsareopen(asshowninthe diagram),the circuit isbroken andnocurrent flows.When theswitchcontactsareclosedthecircuitismadeand currentflowsfromthebatterypositiveterminalthrough theswitchcontactsandbulbfilamenttoground.The framecompletesthecircuittothebatterynegative terminalandthebulbilluminates. Althoughsome circuitsonthecircuitdiagrammayatfirst seemmorecomplicated,itwillgenerallybefoundthat they canbe brokendowninto sections whichdonot differ greatly fromthebasiccircuit above. 1.14 SelVice Manual - Rocket III IClassic ITouring Circuit Diagrams Circuitdiagramsarecreatedtoprovidea'picture'ofthe electricalsystemandtoidentifytheroutetakenbyeach individualwirethroughthesystem,inordertoidentify whichcomponentsitfeedsandwhichconnectorsthe wire runsthrough.Circuitdiagramsareanessentialtoolfor faultfinding,asitispossibletolocatestartandfinish pointsforacircuitwithouthavingtomanuallytracethe wirethroughthemotorcycleitself.Circuitsdiagramsmay lookconfusingatfirstbutwhentheyarestudiedclosely they soonbecomelogical. Duetothe complex circuitsandthenumber of individual wires,Triumphusestwotypesofcircuitdiagraminits servicemanuals. Withinthemanualconventionalcircuit diagramsareusedtoshowthelayoutofthe maincircuitsofthemotorcycle.Theseare: Enginemanagement/ignition,Lighting, StartingandChargingandAuxiliaryand Accessory.Inthesediagramsnoattemptis made to show the components of the system inanyparticular order or positioninrelation to the motorcycle. Atthebackoftheservicemanualafull colour layoutcircuit diagramisusedtoshow themainelectricalcomponentsinaposition similartotheactualpositiononthe motorcycle. 80thofthesecircuitdiagramsusesimilarsymbolsto illustratethevarioussystemcomponentsandwillbe accompaniedby a key tocircuit diagramcomponents and wiringcolour codes. Circuit diagrams alsodepict the inner workingsof a switch cube(I.E.whichwireconnectstowhichwhena switchis turnedfromonepositiontoanother>sothat a testofthat switchcanbemadeusingthewireterminalsinthe connector insteadof disassemblingthe switchitself. Glossary of Circuit Diagram Symbols Thefollowingisa descriptionofthesymbolsfoundinthe circuit diagramsusedinallTriumphServiceManuals. Connector ThisillustrationisusedtoshowallmUlti-plugtype electricalconnectorsonTriumphcircuitdiagrams.The numbersintheboxrelatetotheterminalnumbersof the connectorpins.OnECMswithtwoconnectors,the numberwouldbeprefixedwiththeletters'A'or'8'to General Information identify eachconnector.Anadditionalnumber outside the box willidentify thecomponent. Diode Anelectricalone-wayvalve.Diodesallowcurrenttoflow inonedirectionbut willnotallowittoreturn.Thearrow, whichformspartofthediodesymbol,indicatesthe directionof current flow. Electromagnetic Winding (solenoid) JOOOOO'-Anelectromagneticwinding(orsolenoid>isusedto convert anelectricalcurrentintoalateralmovement.This canthenbe usedtooperate switches(asusedinrelays>or othercomponentssuchasfuelinjectorsor secondaryair injectionsolenoids. Fuse ~ 2 or~ 3A fuseisa devicewhichprotects a circuit inthe event of a fault.Thefusewill'blow'shouldashortcircuitoccur, protectingthatcircuitfromfurtherdamage.Thenumber nexttothefuseonthecircuitdiagramindicatesthe positionof the fuseinthe fusebox. Ground or EarthPoint 1 or1 Thissymbolisusedtoshowgroundpoints.Thisisthe negativeconnectiontoeithertheframeor engine,andis acommoncauseofintermittentfaultsduetolooseor corrodedconnections. Lamp or Bulb Thissymbolisusedtoshowalltypesoflightbulbs.The numbersintheboxrelatetotheterminalnumbersofthe SelVice Manual - Rocket Ill/ Classic /Touring 1.15 General Information connector pins. Anadditionalnumber outside thebox will identify the component. LED (Light Emitting Diode) TriumphuseLEDsforthe alarmwarninglight,instrument illuminationandwarninglights,gearchangelightsand rear light/brake lightsonvariousmodels. Motor Anelectricmotor.Thiscouldbethestartermotorora motorwithinanactuator,forexamplewithintheABS modulator. Relay Arelayiseffectivelyanelectromagneticswitch.Toclose therelaycontactsandcompletethecircuit,an electromagnetintherelayisenergisedwhichcausesthe relay contactstoclose,makingthe circuit complete. Relaysareusedwhenthe electricalcurrent istoogreat for amechanicalswitch,usuallywhentheswitchingmustbe donequicklytoprevent arcingacrosstheswitchcontacts. Ifamechanicalswitchwereused,themechanicalswitch contacts wouldquicklyburnaway. Resistor A deviceplacedinacabletoreducea voltageorrestrict themaximumcurrent a devicecandraw. Splice + A hardcablejoint wheretwoor morecablesarejoinedin thewiringharness.A potentialsourceofbothopenand short circuits. Switches Normally Open or o0 Normally Closed 0--0 or o0 Change Over o0 or '" " ,,0 Cf0 A mechanicaldeviceforcompletingorbreakinga circuit. There arethreecommontypesof switch:Normallyopen, normally closedandchange-over. TracingCircuits Thefollowingisadescriptionoftwotypesofcommon electricalfailures,and some of themethods whichmaybe usedtofindthem. Open circuit 1

Abreakinanelectricalcircuit- currentcannotflow. Usuallycausedby a break ina wireor cable orby a loose connection.Opencircuitscanoftenbeintermittent, makingdiagnosisdifficult. Short circuit A 'shortcut'inanelectricalcircuit- currentby-passesthe intendedcircuit,eithertoearthortoanother,different circuit.Oftencausedbyfailureof the cableinsulationdue tochafingor trappingof thewire.Thereare twodifferent typesof short circuit - short togroundandshort toVbatt. A short togroundmeans that the current isgoingtoearth beforeitreachesthecomponentitissupposedtofeed. Theseareoftencausedbychafingoftheharnesstothe frameor wirestrappedbetween a bolted component, and willoftenblowthe fuseonthat circuit. A shorttoVbattisashorttobatteryvoltage(12Volts> andiscausedbyalivepowersupplywirecontactingan adjacentcable.Notethatitisalsopossiblefora5Volt sensorreferencevoltagetoshorttoanadjacentcircuit, 1.16 SelVice Manual - RocketIII IClassic ITouring whichcanalsocauseelectricalfailuresandDTCs (Diagnostic TroubleCode)tobe stored. Whentracingawirethatissuspect,carefullycheckthe circuit diagrambefore starting.Remember awiremaydivergeat aspliceandgooffto feedothercircuits.Ifthesecircuitsare working,checkforwiringfaultsfromthe splice onwards. thecircuitdiagramisnotanaccurateguide to the actuallocationof theparts when fitted onthebike.Itisaschematicdiagramofthe circuits. particularly where enginemanagement items areconcerned,thecircuitisonlycompleted by the ECM.Ifthe ECMisnot connected, the circuit may register as open. ToCheck Continuity: Ensurethecircuitbeingtestedisswitchedoffbefore measuringcontinuity.DamagetotheDigitalMulti Meter (DMM)may result fromtestinga 'live'circuit with the meter set toresistance (0). Intheexamplebelow,thegroundcircuitcontinuityis being testedfromthe battery tothe frame. Continuity (resistance) Check Locate each end of the wire . SettheDigitalMultiMeter(DMM)to resistance check (0). Probe each end of the wire. Ifthereiscontinuity,themeterwillusually bleep or register the resistance of the cable. A highresistance figure couldindicate a dirty or corroded connection. General Information Ifthereisabreak inthe wire,themeter will not bleep or register aresistance. Byprobingthewireinvariousplaces,the positionofahighresistanceorbreakinthe wire(opencircuit>canbenarroweddown untilitisfound. ToMeasure Voltage: Intheexamplebelow,thecircuitvoltageisbeing measured at thebulbpositive(+)terminal. @@ Voltage Check Turnthe circuit tobe tested 'ON' Set the Digital MultiMeter (DMM) to Voltage check CV).Ensurethe multimeter isset to dc voltsfordirect current circuits(most circuits) oracvoltsforalternatingcurrentcircuits (typically alternator output voltage tests). Set the range of theDMMto the rangebest suitedtothevoltageofthecircuitbeing tested(typically20voltsformostDMMs). RefertotheDMMmanufacturers instructions. Connect the black (ground) leadof the DMM toareliablegroundconnection(usuallythe battery or frame ground). Locatethepositiveterminalofthewireor component tobe tested. connectthered(positive)leadoftheDMM to the positive terminal. Readthe voltage frommeter. SelViceManual - Rocket 1111Classic I Touring 1.17 General Information Splices Splicesareprobablythemostcommoncauseofwiring faultsafterconnectors.Splicesaremadewheretwoor morewirescometogetheranddivergeindifferent directions,usually tofeeda different circuit. Tolocate a splice,itisnecessary topeelback the insulation andexamine thespliceforitsintegrity.Themost common faultiswhereone of thewiresat thejointhascome adrift usuallycausingthecircuititfeedsorearthstobecome 'dead'. Switches Tocheckaswitch,setthemultimetertoresistance/ continuityandprobethetwopinsthatformaclosed circuitwhentheswitchispushed.Iftheswitchisworking correctly,theresistanceshouldregisterorthemeterwill bleep. Relays Allrelaycaseshaveacircuitpathengravedonthem showingthe circuit pathacrosstheelectromagnet andthe switch.Beforemakinganychecks,firstnotethepin designations,currentpaths,andwhether ornotthereisa diodeineither circuitpath. Diode 86...... --1__...... 87 Electromagnet 85e--_.....J30 Makecontinuitychecksacrosstheelectromagnetfirst, usuallyfrompin86(positive)topin85(negative).Ifa diodeappearsinthecircuitusethediodecheckonthe multi meter(voltsscale)inthedirectionofcurrentflow.If thereisnodiode,usetheresistancecheckfacility.An opencircuitorunusuallyhighresistancevalueindicatesa faultyrelay. Tocheck theswitchside,applya12voltsupplybetween pins86and85.Withthesupplyconnectedtherelay shouldbeheardtoclickandthereshouldbecontinuity betweenpins30 and8ZAnopencircuit indicatesa faulty relay. CAN (Controller Area Networking) CAN(sometimescalledCAN bus)isaprotocolfordata communicationbetweenElectronicControlModules (ECMs).EachECMonthenetworkisconnectedbya singlepair of twistedwires(orbus)whichareusedforthe transmissionofvehiclesensordata.ByusingCAN,the overallnumberofsystemsensors,andtheamountof cablingrequiredtoallowECMstocommunicatewith eachother isgreatlyreduced. Thissavescost,weightandspace,andmakesthesystem morereliable,asthephysicalnumberofwiresand connectionsisreduced. Pairof Twisted RWires B284 U s Instrument B27 Pack r- 16 ECM 1 A34 KY3 2 ~VehicleSpeed Sensor Extract from the circuit diagram showing CAN connection between ECMs CANworksbyeachECMsendingout'packets'of information(suchasenginespeedorfuelconsumption information)ontothenetworkbus(note that thenetwork mustbefreeofdatabeforeanyECMisallowedto transmit>.Thisdataisgivenapriorityaccordingtoits importance(forexample'enginespeed'mayhavea higherprioritythan'Iowfuellevel'),sothateveniftwo ECMssenddataatthesametime,highpriority informationisalwayssent first.Lowerprioritydataisthen resent after thehighpriority datahasbeenreceivedby all ECMsonthe network. ThereceivingECMconfirmsthedatahasbeenreceived correctlyandthatthedataisvalid,andthisinformationis thenusedbytheECMasnecessary.Specificdatanot requiredbyanECMwillstillbereceivedand acknowledgedascorrectbutthendisregarded(for exampleifanECMdoesnotrequire'clutchswitch position'information,thisdatapacket wouldbeignored). Thisallowsforaveryhighspeedsystemof communication,whichisalsoveryreliable.Shouldone ECMfailortransmitcorruptedorotherwiseincorrect messages,none of the other ECMsonthenetwork willbe affected,andafteracertaintimethatECMwillbe preventedfromtransmittingfurthermessagesuntilthe faultisrectified.ThisstopstheECMfromcloggingthe networkwithincorrectdataandpreventingother messagesfromgettingthrough.Thefaultwouldthenbe reportedby a DTC(Diagnostic TroubleCode). TriumphcurrentlyuseCANforcommunicationbetween the engineECMandtheinstruments. 1.18 SelVice Manual - RocketIll/ Classic /Touring Alternator/Charging System Thechargingsystemconsistsofanalternator,arectifier/ regulator assembly andthebattery. The alternator ismade upoftwoparts,thestator,whichismountedtothe crankcaseor theengine cover,andtherotor,mountedto theendofthecrankshaft.Thestatorisanassemblyof18 coils,arrangedinto3phases.Therotorisaseriesof magnetsmountedintheengineflywheel,whichare arrangedsoastobepositionedaroundtheoutside of the statorcoils.Astheenginerotatesthealternatorproduces anAC(alternatingcurrent>voltageineachofthethree phasesof the alternator,typicallyof around35to40 volts ACat4000-5000rpm,althoughthisfigurevaries betweenmodels.AsthebatteryrequiresDC(direct current>voltageforcorrect charging, thisAC voltagemust befirstrectifiedtoDCcurrent,andthenregulatedtothe correct voltageforthebatteryof14.5 0.5volts.Thisis donebytherectifier/regulator,whichusesdiodesto convertthealternatoroutputtoDCvoltsandlimitthe resultingoutput tothecorrectfigurerequiredforoptimal battery charging. General Information Ifthechargingcircuitdoesnotoperatecorrectly,the followingbasicchecksmustbecarriedoutbeforefurther diagnosisisperformed: Checkthebatteryterminalsarecleanand tight Checktheframeandengineearth connectionsareclean,tightandfreefrom corrosion. Ensurethebatteryisfullychargedandin good condition. Check that any fuseinthe circuit isnot blown andisofthecorrectrating(Seepage18-15 forRockett IIIandClassic, see page18-16 for Rocket IIITouring>. Rectifyanydefectsasnecessary. SelVice Manual - Rocket Ill/ Classic /Touring 1.19 General Information Diagnosis - Charging Circuit ENSURE THEBATTERY ISINGOOD Not OK RECHARGE OR REPLACE FAULTY CONDITION ANDFULLY CHARGED. BATTERY AND/OR REPAIR DIRTY/ CHECK ALL BATTERY ANDGROUND LOOSE CONNECTIONS TERMINALS ARE CLEAN AND TIGHT OK I OK IFWITH THEENGINERUNNING AT Above AROUND2000 RPM,MEASURE THE 15 Volts FAULTY RECTIFIER! REGULATORBATTERY VOLTAGE AT THE BATTERY. THEBATTERY VOLTAGE SHOULDBE 14.5 0.5 VOLTS Below 14 Volts , STOP THEENGINE AND DISCONNECT THE ALTERNATOR CONNECTOR.RE-START THE ENGINE AND ALLOW TO IDLE. MEASURE THE ALTERNATING CURRENT (AC) VOLTAGE FROM THE 3 ALTERNATOR OUTPUT WIRESIN TURN. THE OUTPUT VOLTAGEMUST EXCEED 10 VOLTS ACFROMEACH WIRE Above10 VollsAC RAISE THE ENGINE SPEED ABOVE 4000 RPM.MEASURE THE Below 30 ALTERNATING CURRENT (AC) VollsAC VOLTAGEFROM THE 3 ALTERNATOR FAULTY ALTERNATOR OUTPUT WIRESIN TURN. THE OUTPUT VOLTAGE MUST NOW EXCEED 30 VOLTS ACFROMEACH WIRE Above 30 VoltsAC r FAULTY RECTIFIER! REGULATOR 1.20 SelVice Manual- Rocket1111Classic 1 Touring Starting Circuit AllTriumphmodelsareequippedwithanelectricstart system.Thissystemconsistsofastarterrelay,starter motor,starter switch,sidestandswitch,engine stop switch, clutchswitchandthespragclutch.Thestartermotoris connectedtothestarterrelayandthebatterybyheavy dutycablesinorder tosupplythelargecurrentsrequired bythemotortostart theengine.Whenthestarterbutton ispressed the relayisenergised, whichthen allowscurrent tothestartermotor.Thestartermotorwillnotoperate unlesstheclutchlever ispulledin.Also,the starter willnot operate ifthe sidestandisdown,unlessthe transmissionis inneutral.Ifthestartermotordoesnotoperate,the followingbasicchecksmustbecarriedoutbeforefurther diagnosisisperformed: Check theengine stopswitchisinthe'RUN' position. Checkthebatteryterminalsarecleanand tight General Information Checktheframeandengineearth connectionsareclean,tightandfreefrom corrosion. Ensurethebatteryisfullychargedandin good condition. Note: Check that any fuseinthe circuit isnot blown andisof the correct rating. Usingthetriumphdiagnostictool,check the operationoftheneutralswitchorgear positionsensor (if fitted), sidestand and clutch switches. OnallnewmodelsfromDaytona675 onwards,whichuseaCANconnection between the instruments and the ECM,the engine willnot crank if the instruments are disconnected. Rectifyany defectsasnecessary. General Fault Finding - Starter Motor and Relay SymptomPossible cause(s) Starter relaydoesnot click,starter motor doesnot turnBatterydischargedor defective Blownmainor starter relay fuse Defective starter relaywiringor starter switch Check that the sidestand, transmissionandclutchlever are positionedforenginestartingI.E.transmissioninneutral, clutchlever pulledinandthe sidestanddown Defective alarmsystem - ensure any alarmfittedisworking correctly Starter motor turns slowlyBattery dischargedor defective Loose,corrodedor dirtybattery connections Loose,corrodedordirtystartermotororstarterrelay connections Defectivestarter motor Loose,corrodedor dirtybattery groundconnections Starter relayclicksbut engine doesturnoverBattery dischargedor defective Crankshaft doesnot turndue toengine defect Defective starter motor Starter cable opencircuit Defectivestarter relay Starter motor turnsbut engine doesnot turnoverStarter motor or starter ringgear SelViceManual - Rocket Ill/ Classic /Touring 1.21 General Information Diagnosis - Starter Circuit 1.22 WITH THE IGNITION SWITCH ON ANDUSING A SUITABLE HEAW DUTY THE ENGINE STOP SWITCH AT 'RUN',ClicksJUMPER CABLE, CONNECT THE CHECK FOR A CLICK AT THESTARTER1---------+1STARTER POSITIVE TERMINAL TO THE RELAY WHEN THE STARTER SWITCHBATTERY POSITIVE TERMINAL IS PRESSED No Click DISCONNECT THE STARTER RELAY SWITCH CONNECTOR. CHECK THE RELAY COIL EARTH (GROUND) WIRE Continuity No Continuity CONNECT THE STARTER RELAYNo Starter motor turns LOOSE OR DISCONNECTED WIRE OR CABLE. FAULTY STARTER RELAY/ SOLENOID Starter motor does not turn FAULTY STARTER MOTOR FAULTY NEUTRAL SWITCH FAULTY CLUTCH SWITCH FAULTY SIDESTAND SWITCH BAD CONTACT AT CONNECTOR OPEN CIRCUIT INWIRING LOOM FAULTY ALARM OR ENGINE ECM(IF FITTED) FAULTY IGNITION SWITCH/ENGINE STOP SWITCH SWITCH CONNECTOR. MEASURE THEVoltage STARTER RELAY VOLTAGE AT THEI - - - - - - - : . . = ~ - - - ~STARTER RELAY SWITCH BROKEN STARTER SWITCH CABLE BAD CONTACT AT CONNECTOR OPEN CIRCUIT IN WIRING LOOM FAULTY ALARM CONNECTOR Voltage Measured CHECK THE STARTER RELAY OPERATION Normal Abnormal LOOSE OR POOR CONTACT AT STARTER RELAY FAULTY STARTER RELAY SelVice Manual- Rocket III IClassic ITouring Specification Triumphareconstantlyseekingtoimprovethe specification,designandproductionoftheirmotorcycles and alterationstakeplaceaccordingly. Whileeveryefforthasbeenmadetoensuretheaccuracy ofthisManual,itshouldnotberegardedasaninfallible guidetocurrentspecificationsofanyparticular motorcycle. AuthorisedTriumphdealersarenotagentsofTriumph andhavenoauthoritytobindthemanufacturerbyany expressedor impliedundertakingor representation. Replacement Parts OnlyTriumphgenuinepartsshouldbeusedtoservice, repairorconvertTriumphmotorcycles.Toensurethat Triumphgenuinepartsareused,alwaysorderparts, accessoriesandconversionsfromanauthorised Triumphdealer.Thefittingofnon-approvedparts, accessoriesorconversionsmayadverselyaffectthe handling,stabilityorotheraspectsofthemotorcycle operationwhichmayresultinanaccidentcausing seriousinjury or death. AlwayshaveTriumphgenuineparts,accessoriesand conversionsfittedby anauthorised Triumphdealer.The fitmentofparts,accessoriesandconversionsby a dealer whoisnot anauthorisedTriumphdealermayaffectthe handling,stabilityorotheraspectsofthemotorcycle operationwhichmayresultinanaccidentcausing seriousinjuryor death. AlwayshaveTriumphapprovedparts,accessoriesand conversionsfittedbyatrainedtechnician.Toensure thatatrainedtechnicianisused,haveanauthorised Triumphdealerfittheparts.Thefitmentofparts, accessoriesandconversionsbypersonnelotherthana trainedtechnicianat anauthorisedTriumphdealermay affectthehandling,stabilityorotheraspectsofthe motorcycleoperationwhichmayresultinanaccident causing seriousinjury or death. General Information Service Data Theservicedatalistedinthismanualgivesdimensions and specifications forbrandnew,originalparts. Where itis permissibletoallowaparttoexceedthesefigures,t h ~ nthe servicelimitisgiven. Thetermsofthemotorcyclewarrantywillbeinvalidated bythe fittingof other thangenuine Triumphparts. AllgenuineTriumphpartshavethefullbackingofthe motorcyclewarranty.Triumphdealersareobligedto supply only genuine Triumphrecommendedparts. Inspection Disassembledpartsshouldbevisuallyinspectedand replacedwithnewonesifthereareanysignsofthe following: Abrasions,cracks,hardening,warping,bending,dents, scratches,colourchanges,deterioration,seizureor damage of anynature. SelViceManual - Rocket Ill/ Classic /Touring 1.23 General Information Service tools Specialservicetoolshavebeendevelopedtofacilitateremoval,dismantlingandassemblyofcertainmechanical componentsina practicalmanner without causingdamage.Some operationsinthisservicemanualcannot be carriedout withouttheaidoftherelevantservicetools.Wherethisisthecase,thetoolsrequiredwillbedescribedduringthe procedure. Special service tools: 3880105-T0301- Angular torquegauge3880160-T0301- Fork filler evacuator cbxtccha T3880047 - Kit - FuelpressuregaugeT3880313- Oil filter wrench 3880080-T0301- Fork seal! bearingdrift3880140-T0301Headraceadjusters kagtl ccgv 1.24 SelVice Manual - Rocket Ill/ Classic /Touring General Information 3880070-T0301- BearingInstaller3880075-T0301- BearingInstaller T3880250 - Diagnostic toolT3880200 - Puller - alternator echo T3880201- Anti-rotationjig- alternatorT3880061- Extractor,liners ccgyechb SelViceManual - RocketIIIIClassic ITouring 1.25 General Information 3880025-T0301- Clutchanti-rotationjigT3880062 - Castle wrench - 38 mm cchdecgu T3880063- Castle wrench - 31mmT3880064 - Drift, swingingarmbearings echc ecgt 3880085-T0301- Fork assembly rod3880090-T0301- Forkpistonholder 3880090 ecgs 1.26 SelViceManual - Rocket III IClassic ITouring General Information T3880067 - Fork springcompressorT3880202 - camshaft timingjig ~ - - ~ - - ~ I ~ ! 1 1 I 1 ~ I I I I ~ ~ ! 1 1 I ~ I I I I I ~ ! I I - - ~ - - ~ccgwecgx T3880007 - Mirror locationfixtureT3880208 - Slidehammer cemy12 T3880210 - Adapter tool,input shaft assemblyT3880068 - Gauge,camshaft drive chaintensioner 3880068 cetu SelViceManual- RocketIll/ Classic /Touring 1.27 General Information FullSpecificationRocket IIIand Classic Engine.................................................. 3Cylinder12ValveDOHC Arrangement ............................................. Inline,longitudinal, Displacement ............................................. 2294 cc Bore xStroke ............................................. 101.6x94.3mm CompressionRatio.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7: 1 Cylinder Numbering ....................................... Number 1 at front Firingorder.............................................. 1-2-3 Max. Power (DIN70020) ................................... 142PSat 5,750 rpm Max. Torque .............................................. 200 Nm at 2,500 rpm Cylinder Head ValveHeadDia ......................In.................... 3Z90 mm Ex ..................... 32.30 mm ValveLift...........................In.................... 8.30 mm Ex ..................... 8.30 mm Valve StemDia ......................In.................... 5.475- 5.490 mm (std) Ex ..................... 5.475- 5.490 mm (std) Valve Guide Bore Dia ....................................... 5.500 - 5.515mm (std) ValveSeat Width(inhead).................................. 1.000 - 1.100mm (std) 1.500 mm (servicelimit) ValveSeat Width(valve).................................... 1.98 - 2.26 mm (std) ValveSeat Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 inclusive ValveSpringLength....................................... 43.2mm (std) ValveSpring'Load atLength' .......... In.................... 180N+/- 10Nat 36.2mm Ex ..................... 180N +/- 10N at 36.2mm ValveClearance .....................In.................... 0.10- 0.15mm Ex ..................... 0.15- 0.20 mm ValveBucket BoreDia ................In.................... 28.015- 28.035mm Ex ..................... 28.015- 28.035mm ValveBucket Dia ..................... In.................... 2Z978 - 2Z993mm . . . . . . . . . . . . . . . . . . . . . . . . .Ex ..................... 2Z978 - 2Z993mm Valve Timing(at1 mm lift) Inlet...............................open .................. 120 BTDC close .................. 280 ABDC duration ............... 2200 Exhaust............................ open .................. 410 BBDC close.. . . . . . . . . . . . . . . ..110 ATDC duration ............... 2320 Camshaft JournalDia ....................................... 22.93- 22.96 mm (std) 1.28 SelVice Manual - Rocket IIIIClassic ITouring General Information FullSpecificationRocket IIIand Classic Camshaft JournalClearance. . . . . . . . ... ..................... 0.040 - 0.091mm(std) 0.13mm(servicelimit> Camshaft JournalBoreDia. . . . . . . . . . ... ..................... 23.000 - 23.021mm(std) CamshaftEndFloat. . . . . . . . . . . . . . . ... ..................... 0.10- 0.13mm(std) Camshaft Run-out. . . . . . . . . . . . . . . . ... ..................... 0.015mm(std) CamchainTensioner SpringFreeLength...................... 73.7 mm Clutch/Primary Drive Primary Drive..................... Type.................. Gear, withbacklasheliminator ReductionRatio......... 1.034: 1 Clutch........................... Type.................. Wet multi-plate No.of FrictionPlates. . . . . . . . . . . . . . ........................ 10 PlateFlatnessLimit.. . . . . . . . . . . . . . . ... ..................... 0.30mm FrictionPlate Thickness(new). . . . . . . ... ..................... 3.72- 3.88mm FrictionPlate Thickness(servicelimit>. ... ..................... 3.5mm ClutchActuationMethod. . . . . . . . . . ... ..................... Cable CableFreePlay(at lever).. . . . . . . . . . ... ..................... 2-3mm Piston/Crankshaft Cylinder LinerDia... . . . . . . . . . . . . . . ... ..................... 101.591- 101.609mm(std) 101.659mm(servicelimit> PistonDiameter. . . . . . . . . . . . . . . . . . ... ..................... 101.561- 101.577 mm(std) 101.511mm(servicelimit) PistonRingtoGroove Clearance...... Top................... 0.02- 0.06mm(std) 0.16mm(servicelimit> Second ................ 0.02- 0.06mm(std) 0.16mm(servicelimit> PistonRingGroove Width ............ Top................... 1.01- 1.03mm(std) 1.11mm(servicelimit> Second ................ 1.01- 1.03mm(std) 1.11mm(servicelimit> Oil. ................... 2.51- 2.53mm (std8,servicelimit> PistonRingEndGap................ Top................... 0.20 - 0.35mm(std) 0.55mm(servicelimit> Second ................ 0.30 - 0.50mm(std) 0.675mm(servicelimit> Oil. ................... 0.20 - 0.70mm(std) 0.875mm(servicelimit> GudgeonPinBoreDia.InPiston.. . . ... ..................... 21.994- 22.001mm(std) 22.011mm(servicelimit> GudgeonPinDia.. . . . . . . . . . . . . . . . ... ..................... 21.982- 21.987mm (std) 21.972mm(servicelimit> SelViceManual- Rocket1111Classic 1 Touring 1.29 General Information FullSpecificationRocket III andClassic ConnectingRodSmallEndDia ............................... 22.005 - 22.018mm (std) 22.028mm(servicelimit> ConnectingRodBigEndDia................................ 44.000 - 44.009 mm(std) ConnectingRodBigEndSideClearance ....................... 0.15- 0.30 mm(std) 0.50 mm(servicelimit> CrankshaftBigEnd JournalDia ............................... 40.946 - 40.960 mm (std) 40.922mm(servicelimit> Crankshaft BigEndBearingClearance ......................... 0.035 - 0.065mm (std) 0.100mm(servicelimit) Crankshaft Main JournalDia ................................. 43.092- 43.108mm (std) 43.068mm(servicelimit> Crankshaft MainBearingClearance ........................... 0.018- 0.041mm(std) 0.10mm(servicelimit> CrankshaftEndFloat ....................................... 0.05- 0.20mm(std) 0.40 mm(servicelimit> Crankshaft Run-out ........................................ 0.04mm(std) 0.07 mm(servicelimit> Transmission Type.................................................... 5 SpeedConstant Mesh Gear Ratios ......................... Primary ................ 1.034: 1 1st.................... 2.929: 1 2nd ................... 1.947:1 3rd ................... 1.435: 1 4th................... 1.160: 1 5th................... 0.964:1 Secondary............. 1.043:1 Gear SelectorFork Thickness................................ 5.90 - 6.00mm(std) 5.80mm(servicelimit> Gear Selector Groove Width ................................. 6.05- 6.15mm(std) 6.30(servicelimit> Gear Selector Fork toGroove Clearance....................... 0.05- 0.25mm(std) 0.50 (servicelimit> FinalDrive FinalDrive Type.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bevelgearedcrownwheelandpinion Drive System............................................. Universal-jointedshaft withtorsional damper FinalDrive Ratio ........................................... 2.846:1 FinalDrive Oil............................................ Mobil Mobilube SHC75W/ 90 fully synthetic hypoid oil(or equivalent> FinalDrive Oil Capacity ..................................... 0.17litres 1.30 SelVice Manual - RocketIII IClassic ITouring General Information Full SpecificationRocket III and Classic Lubrication Oil Capacity (incl.filter,dry fill>. . . . . . ... ..................... 5.9litres Oil andFilter Change. . . . . . . . . . . . . ... ..................... 5.4litres Oil changeonly. . . . . . . . . . . . . . . . . . ... ..................... 5.1litres RecommendedOil ApprovalRating.. ... ..................... APISH(or higher) andJASOMA Viscosity.. . . . . . . . . . . . . . . . . . . . . . . ... ..................... 10W/40 or15W/50 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . ... ..................... Semior fully synthetic OilPressure(inmaingallery).... . . . ... ..................... 3.00 - 3.60Bar at3,500rpm Oil PumpRotor TipClearance. . . . . . ... ..................... 0.15mm(std - bothpumps) 0.20 (servicelimit - bothpumps) OilPumpBody Clearance.. . . . . . . . . ... ..................... 0.15- 0.22mm(std- bothpumps) 0.35mm(servicelimit - bothpumps) OilPumpRotor EndFloat.. . . . . . . . . ... ..................... 0.02- 0.07mm(std- bothpumps) 0.10mm(servicelimit - bothpumps) Ignition System Type. . . . . . . . . . . . . . . . . . . . . . . . . . . ... ..................... Digital, inductive Electronic Rev-Limiter. . . . . . . . . . . . . ... ..................... 6,500rpm Pick upCoil Air Gap. . . . . . . . . . . . . . ... ..................... Fixed,not adjustable Pick upCoilResistance. . . . . . . . . . . . ... ..................... 0.56KO IgnitionCoilType.. . . . . . . . . . . . . . . . ... ..................... Inductive, twinoutput Spark PlugType.. . . . . . . . . . . . . . . . . ... ..................... NGK DPR7EA9,2 per cylinder Spark PlugGap........... , .............................. 0.9mm Fuel System FuelType. . . . . . . . . . . . . . . . . . . . . . . ... ..................... Unleaded, 91RON( US- 87RON/MON) FuelTank Capacity. . . . . . . . . . . . . . . . ... ..................... 25litres LowLevelWarningLamp. . . . . . . . . . ... ..................... 5.5litresremaining FuelPump Type.. . . . . . . . . . . . . . . . . ... ..................... Submerged,electric FuelPressure(nominal>. . . . . . . . . . . . ... ..................... 3.0Bar PurgeControlSystem. . . . . . . . . . . . . ... ..................... Modulated, vacuum FuelInjection System Type. . . . . . . . . . . . . . . . . . . . . . . . . . . ... ..................... Multi point sequential Idle Speed......................... ..................... 850 rpm Injector Type.. . . . . . . . . . . . . . . . . . . . ... ..................... Single nozzle Throttle.. . . . . . . . . . . . . . . . . . . . . . . . ... ..................... Twinbutterfly Idle SpeedControl.. . . . . . . . . . . . . . . ... ..................... Stepper motor SelViceManual- Rocket Ill/ Classic /Touring 1.31 General Information FullSpecificationRocket III and Classic ControlSensors ........................................... Coolant temperature,manifoldabsolute pressure(allcylinders),intake air temperature, barometric pressure,gear position,roadspeed, primary andsecondary throttleposition. Cooling System Coolant Mixture........................................... 50% antifreezeindistilled water Anti-Freeze Type.......................................... Mobil Antifreeze CoolingSystemCapacity .................................... 3.2litres Radiator CapOpeningPressure.. . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.2bar Thermostat Opening Temperature ............................ 880 C CoolingFanSwitchOn Temperature .......................... 1030 C Temperature Gauge Sensor Resistance. . . . . . . . . . . . . . . . . . . . . . ..187Q at1000 C Suspension Front Fork Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..120mm RecommendedFork Oil Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kayaba01oil(SAEOW> OilLevel(fork fully compressed)............................. 89mm Oil Volume(dry fill) ........................................ 667 cm3 +/- 4.0 cm3 FrontFork PullThrough.................................... 0 mm(top of theouter tube flushwithtopyoke) Fork SpringRate.......................................... K = 16N/mm Rear WheelTravel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..105mm Brakes Front type ................................................ Twofour pistoncalipersacting ontwin discs Front Caliper PistonDia ..................................... 33.96mm/30.23mm FrontDisc Dia ............................................. 320 mm FrontDisc Thickness....................................... 5.Ommstandard(4.5mmservicelimit> FrontDiscRun-out Max ..................................... 0.3mm Front Master Cylinder Diameter ............................. ,14mm RecommendedFluid.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DOT 4 Rear Type ................................................ Twinpiston slidingcaliper actingonsingle disc Rear Caliper PistonDia ...................................... 32mm RearDiscDia .............................................. 316mm RearDisc Thickness ........................................ Z5mmstandard(6.5mmservicelimit> RearDiscRun-out Max..................................... 0.15mm RearMaster Cylinder Diameter .............................. ,12.7 mm RecommendedFluid ....................................... DOT 4 1.32 SelVice Manual - RocketIII IClassic ITouring General Information FullSpecificationRocket IIIand Classic Wheels and Tyres Front WheelSize. . . . . . . . . . . . . . . . . ... ..................... MT 3.5x17 Front WheelRimAxialRun-out. . . . . ... ..................... 0.5mm Front WheelRimRadialRun-out.. . . . ... ..................... 0.5mm Front TyreSize. . . . . . . . . . . . . . . . . . . ... ..................... 150/80 R 17 Front TyrePressure(cold). . . . . . . . . . ... ..................... 2.3Bar Front Tyre TreadDepthmin. . . . . . . . . ... ..................... Over 130kmh - 2mm (or minimumlegallimit, whichever isgreater) Under 130kmh - 2 mm (or minimum legallimit, whichever isgreater) Rear WheelSize ........... , .............................. MT Z5x16 Rear WheelRimAxialRun-out. . . . . . ... ..................... 0.5mm Rear WheelRimRadialRun-out. . . . . ... ..................... 0.5mm Rear TyreSize.. . . . . . . . . . . . . . . . . . . ... ..................... 240150R16 Rear TyrePressure(cold) . . . . . . . . . . . ... ..................... 2.9Bar Rear Tyre TreadDepthmin ......................................... Over 130 kmh - 3 mm (or minimum legallimit, whichever isgreater) Under 130 kmh - 2 mm (or minimumlegallimit, whichever isgreater) Frame Frame Type.. . . . . . . . . . . . . . . . . . . . . ... ..................... Tubular steel OverallLength ........................................... 2500 mm Overall Width ............................................ 970mm (RocketIll>1054mm (RocketIIIClassiC> Wheelbase.. . . . . . . . . . . . . . . . . . . . . ... ..................... 1689mm SeatHeight. . . . . . . . . . . . . . . . . . . . . . ... ..................... 740 mm Castor. . . . . . . . . . . . . . . . . . . . . . . . . . ... ..................... 32 Trail .................................................... 148mm Dry Weight.. . . . . . . . . . . . . . . . . . . . . ... ..................... 320 kg Max. Payload.. . . . . . . . . . . . . . . . . . . ... ..................... 220 kg (rider,passenger,luggage 8. accessories) ElectricalEquipment Battery Rating.. . . . . . . . . . . . . . . . . . . ... ..................... 12volt,18amp hour Alternator Rating.. . . . . . . . . . . . . . . . ... ..................... 37 ampslmin at 2,000 rpm 41ampslmin at 6,000 rpm SelViceManual- Rocket1111Classic 1 Touring 1.33 General Information FullSpecificationRocket III Touring Engine.................................................. 3 Cylinder12ValveDOHC Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inline,longitudinal, Displacement ............................................. 2294 cc Bore x Stroke ............................................. 101.6x94.3mm CompressionRatio ......................................... 8.7: 1 Cylinder Numbering ....................................... Number 1 at front Firingorder.............................................. 1-2-3 Max.Power (DIN) ......................................... 106PSat5,100rpm Max. Torque) ............................................. 206 Nm at2,000 rpm Cylinder Head ValveHeadDia ......................In.................... 3Z90 mm Ex ..................... 32.30 mm ValveLift...........................In.................... 8.30 mm Ex ..................... 8.30 mm ValveStemDia ......................In.................... 5.475 - 5.490 mm (std) Ex ..................... 5.475 - 5.490 mm(std) ValveGuide BoreDia ....................................... 5.500 - 5.515mm(std) ValveSeat Width(inhead). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1.000 - 1.100mm(std) 1.500mm(servicelimit) ValveSeat Width (valve).................................... 1.98 - 2.26 mm(std) ValveSeat Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90' inclusive ValveSpringLength....................................... 43.2mm(std) ValveSpring'Load atLength' .......... In.................... 180N +/- 10N at36.2mm Ex ..................... 180N +/- 10N at 36.2mm ValveClearance .....................In.................... 0.10- 0.15mm Ex ..................... 0.15- 0.20mm ValveBucket BoreDia ................ In.................... 28.015- 28.035mm Ex ..................... 28.015- 28.035mm ValveBucketDia ..................... In.................... 2Z978 - 2Z993mm . . . . . . . . . . . . . . . . . . . . . . . . .Ex ..................... 2Z978 - 2Z993mm Valve Timing(at1 mm lift) Inlet. ..............................open .................. 120 BTDC close .................. 280 ABDC duration ............... 2200 Exhaust............................open .................. 410 BBDC close.. . . . . . . . . . . . . . . ..110 ATDC duration ............... 2320 Camshaft JournalDia ....................................... 22.93 - 22.96mm(std) 1.34 SelViceManual- Rocket1111Classic 1 Touring General Information FullSpecificationRocket III Touring Camshaft JournalClearance. . . . . . . . ... ..................... 0.040 - 0.091mm(std) 0.13mm(servicelimit> Camshaft JournalBoreDia... . . . . . . . ... ..................... 23.000 - 23.021mm(std) CamshaftEndFloat. . . . . . . . . . . . . . . ... ..................... 0.10- 0.13mm (std) Camshaft Run-out. . . . . . . . . . . . . . . . ... ..................... 0.015mm(std) CamchainTensioner SpringFreeLength...................... 73.7 mm Clutch/Primary Drive Primary Drive..................... Type.................. Gear, withbacklasheliminator ReductionRatio......... 1.034:1 Clutch........................... Type.................. Wet,multi-plate No.of FrictionPlates. . . . . . . . . . . . . . ........................ 10 PlateFlatnessLimit.. . . . . . . . . . . . . . . ... ..................... 0.30 mm FrictionPlateThickness(new). . . . . . . ... ..................... 3.72- 3.88mm FrictionPlate Thickness(servicelimit>. ... ..................... 3.5mm ClutchActuationMethod. . . . . . . . . . ... ..................... Cable CableFreePlay(at lever). . . . . . . . . . . ... ..................... 2-3mm Piston/Crankshaft Cylinder LinerDia. . . . . . . . . . . . . . . . . ... ..................... 101.591- 101.609mm(std) 101.659mm (servicelimit> PistonDiameter. . . . . . . . . . . . . . . . . . ... ..................... 101.561- 101.577 mm(std) 101.511mm(servicelimit> PistonRingtoGroove Clearance...... Top................... 0.02 - 0.06mm(std) 0.16mm(servicelimit> Second ................ 0.02 - 0.06mm(std) 0.16mm(servicelimit> PistonRingGroove Width ............ Top................... 1.01- 1.03mm(std) 1.11mm(servicelimit> Second.. . . . . . . . . . . . . . .1.01- 1.03mm(std) 1.11mm(servicelimit> Oil. ................... 2.51- 2.53mm (std8. servicelimit> PistonRingEndGap................ Top................... 0.20 - 0.35mm(std) 0.55mm(servicelimit> Second ................ 0.30 - 0.50 mm(std) 0.675mm(servicelimit> Oil. ................... 0.20 - 0.70 mm(std) 0.875mm(servicelimit> GudgeonPinBoreDia.InPiston. . . . ... ..................... 21.994- 22.001mm(std) 22.011mm(service limit>