Triumph 650/750 Maintenance & Repairs (pg. 332-345)
Contents
1. ay LO Whap ery PEPE Oy eh YEN ary n ime a STL ao Gh qlee f DLELL Sec pinih im ed FELL FL tobe SIL sored gett phy ine am up a oy e205 pre peor ey pede TE ray FI FH CLL LEU EH tea 1 T Oe E ARA 3 AARAALIRRS SP JAAN RRS RE AARARERANAS PIRA CLEE E ce GT Sue FLIT CS EL jik dpm ag OTA AA CL LL secede gt FH FEA co peasy von Pug 343 Triumph 650 amp 750 Twins 0 9980 in j 0 9945 in 0 9940 in small and large splined gears Also listed are the dates when used in orig inal production Some of the improve ments incorporated in later production ean be installed in earlier transmis sions however it is extremely impor tant to select the correct combination to ensure proper operation Small bore gears should never be installed on a non stepped shaft and large bore gears should never be used on a stepped 344 Fig TM4 45 Views of four speed transmission input shafts mainshatts showing differenc2. M and R The S position should be used with full advanced ignition timing at 37 BTDC The M position should be used with 39 BTDC full advanced ignition timing The R position should be used only if full advance ignition timing is set at 41 BTDC NOTE It is important that ignition timing is correctly set in relation to the rotor location The current generated when the breaker points open may be insufficient to fire the spark plugs if breaker points open too soon or too late If one set of breaker points is faulty both cylinders will be affected If the brown stop light wire is shorted the engine will not run VALVE SYSTEM The valve clear ance should be set with engine cold On 650cc models intake clearance should be 0 002 inch 0 05mm and exhaust clearance should be 0 004 inch 0 10mm On 750cc models intake clearance should be 0 008 inch 0 20mm and exhaust should be 0 006 inch 0 15mm On all models check the clearance of one valve when the similar valve for other cylinder is a maximum opening EXAMPLE Clear ance for the inlet valve for the right cylinder should be set when the inlet valve for the left cylinder is fully open LUBRICATION On 650cc models the engine uses a dry sump lubrication system On models before serial number DU24874 capacity is 6 pints 2 8 liters later models have capacity of 7 pints 3 4 liters Use SAE 40 oil SERVICE Fig TM4 9 Draw
3. Red Spot T120 Serial No DU66246 and up Inner marked Red Spot Outer marked Green Spot T140V Inner marked Red Spot Outer marked Green Spot Valve spring specifications Inner marked with red spot Free length 1 17 32 inches Number of coils Triumph 650 amp 750 Twins MOTORCYCLE Fig TA4 19 Cylinder head retaining screws and siud nuts should be tightened In sequence shown for 650cc models Refer to Fig 48 for 7506 6 models Inner marked with white spot 17 Free length Number of coils 7 Outer marked with red spot Free length 138 inches Number ofeoils pn Quter marked with white spot Free length 2 1 32 inches Number ofcoils 64 When reassembling renew y the push rod tube oil seals and carefully position the cylinder head making certain that push rod tubes are correctly centered On 650ce models start the cylinder head screws 1 6 7 8 amp 9 Fig TM4 19 and install push rods On 6 models install and tighten all ten cyl inder head retaining nuts and screws Fig TM4 19A Turn the crankshaft until both inlet push rods are at bottom of travel then install the rear rocker box and rocker arma assembly NOTE Be sure to install the three stud nuts on bottom before installing the screws and stud nuts on top Turn the crankshaft until both front exhaust push
4. 0 05 0 04 0 20 OE DE I 0 002 0 002 0 008 Exhaust mM 0 10 0 10 0 15 INCH 0 004 0 004 0 006 Electrical Em EE See corer pee A rattles attery termina UNOS ositive Positive Tire nize front 8 ETT t 3 25 x 19 3 25x 19 Rear coana eae t 4 00 x 18 4 00 x 8 Tire pressure Front kKgiem 1 68 1 68 1 68 1 EERO 24 24 24 Rear kg em panes 1 75 1 75 1 68 EIR ERENT 25 25 24 Rear chain een cat Rae tt tt tt Number of speeds 000000005 4 Before serial numbers T140V XH22019 and TR7 and displacement was 724cc Early models are equipped with 6 volt electrical system Various tire sizes have 5 5 V AH24044 standard cylinder bore was 75mm een used including 3 25 x 18 3 50 x 18 4 00 x 18 3 25 x 19 and 3 50 x 19 tRear chain free play should be inch 18mm with weight on wheels or 1 inches 43mm with motorcycle on center stand Illustrations courtesy of Norton Triumph Corp MAINTENANCE SPARK PLUGS Recommended spark plug for normal use is Champion N58R for T120TT models Champion N 4 for other 650cc models Champion 332 N 3 for all 750cc models Spark plugs are 14mm with 4 inch reach and heat range may vary depending upon use Electrode gap should be 0 020 inch 0 5mm for all 650cc models 0 025 inch 0 635mm for 750cc models CARBURETOR Amal Monobloc and Concentric carburetors are used Bonnevi
5. Triumph 650 amp 750 Twins cover Clutch operating cam and gear change ratchets Fig TM3 30 6 removed with the outer cover To remove the gear box inner cover end of output shaft 4 All bushings must be reamed after installation Refer to the following and Fig TM3 32 for finished bushing specifications MOTORCYCLE 1 16 inches Free length of springs 8 is 1 inch Finished diameter of bushing 6 should be 0 623 0 624 inch and shaft 2 should have 0 001 0 003 and gears Fig TM3 31 remove the Bushing 5 inch clearance complete clutch assembly and unscrew diameter css 0 752 0 753 in the output sprocket retaining nut Clearance on shaft The gears and shafts should be as Remove the two screws attaching inner UD E 0 0020 0 0035 in sembled in the inner cover as removed cover to transmission housing and aig 2 7 ee in Check operation before installing remove the inner cover complete with Bushing 12 for 3TA and 5TA models Shift forks 28 amp 30 Fig TM3 32 cam plate shift forks gears and shafts only must be installed correctly To check To remove bearings 3 12 amp 36 Fig Diameter 0 6865 0 6885 in shift the cam plate 25 to both ex TM3 32 the respective housing should Bushing 20 for 3TA and 5TA models tremes first and fourth gears and be heated to approximately 100 C only check position of the guide rollers in 212 F On all medels except 3TA or Diamete
6. 3 2 2or3 Pilot jet 6 siren watt 20 Clip 4 in second groove from top of needle 5 T140V Before Serial No XH220019 Refer to Fig TM4 2 Model left 930 88 E Ree RE RRS 930 87 Main jeti 13 210 Needle jet 11 106 Throttle slide 3 aaaan 3 Clip 4 in second groove from top of needle 1 1 140 After Serial No KH22018 Refer to Fig TM4 2 Model teft 00 0 0 0 000 930 93 A starsat A anes 930 92 Mamet 1S rain 190 Triumph 650 amp 750 Twins Fig TMd4 2 Exploded view of Amal carburetor wiih concentric foai chamber 1 Idle mizture needle tl Needle jah A Floal chamber 1J Main jet 3 Throttle slice 14 Throttle spring 4 Cli iS Cup E Valve needle 15 Ficat Pilot jei IT Fuel mle needte 7 Idle speed slop ere IH Float privet A Fuel filter 12 Primer amp Banyo balt 20 Choke valve 10 Jet holder 21 Cable adjuster Needle jet T1 e Saha 106 Throttle slide J 3 Clip 4 in second groove from top of needle 3 TRIV Refer to Fig TM4 2 Wade e 930 89 Main jet 15 merreni 280 VEST MEET ONAL 106 Throttle slide 3 oo ce eee ee 3M Clip 4 in second groove from top of needle 5 Qn all models idle mixture is ad justed at needle 1 Fig TM4 1 or TM4 2 Idle speed is adjusted at screw 7 On models with du
7. 4 Adjusting acrew 1 Quler cover 5 Pressure plale 11 Rebound rubber Driven plate cushion small long dashes on idler gear as shown at iC Align the correct dot A on ex haust camshaft gear with dot on idler gear On 61 models align the correct dot B on inlet camshaft gear with short dash 5 On all other models 2 nh 1 4 Fig TM4 28 Clutch cushions should be installed at shown Use soap if necessary when installing bul do not use oll or grease 11 Rebound cushion 13 Spider amalli 14 Clutch hub 12 Drive cushion large 1 Gear shift pedal shalt 2 Clutch release plunger 3 Kick starter ahat 16 Spring acrews 17 Chuich drum 18 Throsl wanker 18 Rallers 20 used Z Drive hub 12 Drive rubber cushion ilarge 13 ider 4 Gluich hub 15 Inner cover align inlet camshaft dot B with the long dash L on idler gear CLUTCH Clutch plates can be re moved after removing the primary chain case cover and the spring ad justing nuts 1 Fig TM4 27 Six fric tion discs 7 and six driven plates 6 are used on al models To remove the clutch drum and primary chain it is necessary to remove the alternator rotor and stator then use special pullers to remove crankshaft primary drive sprocket clutch drum and pri mary chain When removing the clutch drum 17 the special puller which at taches to the drive hub 20 should be used When assembling the shock absorber cushions 11 a
8. 0 097 0 122mm TR7V and T14DV All 750ec models 0 00396 0 0042 inch 0 091 0 107mm Maximum cylinder bore taper or out ofround 0 005 inch 0 127mm Ring side clearance in grooves 650cc Compression rings 0 001 0 003 inch 0 025 0 076mm Oil control 0 0005 0 0025 inch 0 013 0 064mm Ring side clearance in groove 750cc Compression TIES Himnit 0 0015 0 0035 inch 0 0038 0 089mm Oil control 0 0015 0 0025 inch 0 038 0 063mm Ring end gap 650cc Allrings 0 016 0 014 inch 0 25 0 36mm SERVICE Ring end gap 750cc Compression rings 0 008 0 013 inch 0 20 0 33mm Oilcontro 0 010 0 040 inch 1 025 1 771 When removing or installing the cyl inder a shock absorber mounting rubber or similar rubber block should be wedged between both sets of cam fol lowers If cam followers are not held in Fig TM4 22 On later 650cc models make certain hele in cylinder base gasket Is over off passages fA in crankcase and B in cyl inder Fig TM4 23 Make certain ihat ihe two screws 5 are removed when saparating crankcase halves position they may fall into the crank case On models after serial number DU24874 the exhaust cam followers are pressure lubricated If the exhaust cam follower bleck is removed make certain that ring 2 Fig TM4 21 is positioned around guide block and locking hole A is aligned with lack screw hole before pressing into c
9. Fig TM3 18 while re moving or installing the Allew screw 14 A 13 16 inch socket with a long extension can be used to hold nut 4 in a similar way if the special tool is not available Coat threads of spring seat 1A with Permatex Super 300 Loc tite Hydraulic Sealant or equivalent to prevent leakage Rear suspension units are sealed and must be renewed if leaking or dam aged Fig TMA 18 Exploded view of front suspension v li used on late models Fark tap bolt amp Inner fork tube end IS Spring seat lu inner fork spring 10 bon for screw 151 3 nner fork tu 11 Duet cover d Damper valve nut 12 Oil sea Damper valve 13 Ouler fork tube 6 Damper washer O drain plug T Damper tube 15 Damper tube holding assembly BETE 8 Recoil spring REPAIRS CYLINDER HEAD AND VALVES To remove the cylinder head remove the fuel tank coils top engine supports stays rocker caps and rocker arm oil line On 650ce models loosen all nine cylinder head screws remove the five stud nuts and two screws attaching rocker boxes to cylinder head and lift off the rocker boxes On 750cc models remove the attaching screws and stud nuts then remove the rocker hoses On all models lift out the push reds and mark for correct assembly in the same location Remove the exhaust pipes On 650cc models remove the five re maining cylinder head retaining screws and lift the cylinder head off NOTE The four cylinder h
10. a dulj grey finish for identification and should be tightened to 22 Ft Lbs 3 04 kg m torque The nuts are self locking but the manufacturer also suggested using Loctite to prevent loosening The three flywheel retaining screws 9 Fig TM4 24 should be tightened to 33 Ft Lbs 4 6 kg m torque Make certain that the mating surfaces of crankcase halves are clean and smooth Seal 30 should be installed from in side after removing the roller bearing outer rod Closed side of seal should be toward main bearings 27 To remove or install main bearings 25 amp 27 from crankcase bores the crankcases should be heated to approximately 100 C 212 F When installing camshaft timing gears install gears on shafts using the keyway nearest the correct timing mark on gear Several different gears have been used but marks are similar Early camshaft gears have only one mark and are not interchangable Late gears have two marks The A mark Fig TM4 25 should be used for the exhaust camshaft and the B mark for the inlet camshaft Install the idler gear last making sure that marks are aligned correctly The slot on crank shaft gear should be between the two 340 018 17 15 11 MOTORCYCLE Fig TM4 27 Expioded view of the cluich assembly Rafer to Fig TM3 22 for installation of rubber cushions 11 amp 12 l Spring hula Frictron diac 2 Springs K Not 3 Spring 48 3 Washer
11. bushing 25 Output shalt roller 17 Cluich mt bearing IH Washer 26 Snap ring LS 277 Ohl seal 20 Ratchet spring ZA Chutpul sprocket 21 Kick starter gear ZH Lk washer 30 Nut first gear Install the cover with the top of the second tooth on quadrant aligned with center of foot change spindle bore as shown at A Fig TM4 521 Triumph 650 amp 750 Twins MEVTRAL Fig 4 51 06 of transmission showing positions of shift cam and shift forks in neutral Fig TM4 52 Drawing of inner cover showing the three screws 3 which attach corer Fig TM4 53 The fourth speed gear and the drive gaar are pressed onto the countershatt lay shaft Distance D must be 0 653 0 655 inch 16 58 16 64mm and clearance between gears should be at least 0 007 Inch 0 18mm 345
12. models 39 BTDC for all TR6 and T120 models 38 BTDC for all TR7V and TR140V models Full ad vanced ignition timing can be checked using a degree wheel mounted on the right end of exhaust camshaft and a power timing light All models are equipped with an al ternator mounted at left end of crank shaft which charges the battery if so equipped via a full wave rectifier On MOTORCYCLE later models current is controlled by a zener diode after being rectified Clear ance between alternator coil poles and rotor should be 0 008 inch minimum all the way around Rotor retaining nut should be torqued to 30 Ft Lbs 4 1 kg m for all 650cc models 40 Ft Lbs 5 5 kg m for all 750ce models On all models stator mounting screws should be torqued to 20 Ft Lbs after correctly centered over the rotor Make certain that stator wires do not rub on the pri mary chain On models with AC en ergy transfer ignition the alternator rotor must be correctly timed to the engine to provide the electrical current for ignition Models with energy transfer ignition are equipped with special high tension ignition coils shown in Fig TM4 7 located under 6 fuel tank When assembling models with en ergy transfer ignition observe the fol lowing Install the primary drive sprocket with the rotor locating peg at approximately 9 o clock position when the crankshaft is at top dead center Refer to Fig TM4 8 The rotor has three holes marked S
13. 4 33 The transmission output shaft and fourth gear 4 Fig TM4 34 can be bumped aut of bearing after the output sprocket 28 is removed If needle bearings 11 or 12 are re Fig TM4 33 Whan removing le wed bearings should be installed as or installing transmission Shown in Fig TM4 35 using a special gears be carefulnotiolose drift Bearing i2 Fig TM4 34 is thrust washer 10 or rollers Closed on outside end bearing 11 is open When removing and installing bearings 11 12 14 amp 25 the appro priate case should be heated to 100 C 212 F Oil seal 27 should be in stalled with open side toward the bearing 25 and against snap ring 26 341 Triumph 650 amp 750 Twins Fig TM4 34 Exploded view of four speed transmission assembly Reter to Fig TM4 33 for assem bled view I input shaft B Sliding gear i3rds imainsholli and first 9 Counter shah grar Ilayahal and drive 2 oliding gear vor 3 Sliding peur l rd 10 Thrust washers 4 Output shaft and 11 Needle bearing fourth gear iopen f Bushing 172 Nendle bearing 6 First gear iclowed end T Sliding gear 2nd Bushing 5 should be pressed into shaft 4 with oil groove toward teeth on shaft Bushing should protrude 7 16 inch and must be reamed after installation to provide 0 0032 0 0047 inch clearance on input shaft 1 First gear bushing 13 should have 0 0025 0 0045 inch clearance on counter shaft 9 When assembli
14. al carburetors the carburetors must be synchronized to open exactly the same amount by adjusting the cable guides 21 at the top of each carburetor Idle mixture on carburetor is more easily adjusted after disconnecting the spark plug wire from the other cylinder IGNIFION AND ELECTRICAL Ignition breaker point gap should be 0 014 0 016 inch for all models The ignition breaker point cam and ad vance weights are mounted on the right end of the exhaust camshaft Ig nition timing for the right cylinder is adjusted by moving the breaker point base plate after removing the small 333 Triumph 650 amp 750 Twins Fig TM4 4 The ignition cam and advance as sembly is mounted on the right end of the cam shaft Black and yellow wire goes to breaker points 3 and black and white wire goes to breaker points 4 Fig TM4 7 Coils C for models with AC energy transfer ignition are different than coils for bat tery ignition models round cover from the right side It may be necessary to vary the breaker point gap on the second set of breaker points in order to set ignition timing for the left cylinder Ignition automatic advance range in camshaft degrees Y of crankshaft de grees is stamped on the back of the breaker cam Standard ignition timing is as follows 6T Serial No DU101 DU5824 Crankshaft degrees BTDC EE ny cans e EEEE PE 1 Full advance i secon 35 Advance range stamped
15. ance is felt Back the adjusting screw A out 1 turn and tighten the locknut Adjust the cable guide at hand lever until cable has inch free play If clutch slips with controls properly adjusted remove the primary chain ease cover and adjust the spring pres sure Initial setting is with adjusting nuts flush with ends of studs Each nut must be adjusted to provide even spring pressure To check adjustment of springs shift transmission to neu tral disengage clutch and operate the kick starter Check the pressure plate as it turns and make sure it does not wobble If one section of pressure plate is higher than the rest turn the spring adjuster near the high spot in and re check To turn the adjusting nuts out it is necessary to hold the springs down as shown in Fig TM 4 13 to release the locking lug on bottom of nut PRIMARY CHAIN Tension of the primary chain ia adjusted by turning adjuster T Fig TM4 11 after re moving drain plug D Special hex agon headed screwdriver part No 336 Fig TM4 14 Exploded view of ihe front suspen sion used on early models before serial number 0 502 57 Retar to Fig 1 14 15 for laler type L Fither plug 10 Sleeve nul tep 2 Tube 11 0 senl 3 Spring 12 Seal petamer sleeve 4 Buttom bushing nut 5 Washer 13 Top bushing 6 Aushing nut 14 Dampening sleeve 7 Restrigtar rod 15 Lower tube A Washer 16 Drain plug F Screw 17 Guide lube D496 should be used to turn adj
16. anemis sion detent piunger D should engage notch be twean 2nd and 3rd gears and the camplate C as shown MOTORCYCLE Fig TM4 37 The kick starter return spring should be installed an spline shown cover and gear case with sealer align the center tooth of the gear selector quadrant with center line of transmis sion input shaft as shown at A Fig TM4 32 and install the inner cover Install the gear box outer cover tempo rarily and check for correct shifting NOTE If gears can not be shifted cor rectly remove the covers and check position of camplate C Fig TM4 36 and quadrant A Fig TM4 32 In stall the kickstarter ratchet assembly 18 through 23 Fig TM4 34 over end of shaft and tighten nut 24 45 Ft Lbs torque NOTE Sleeve 19 may be crushed if nut 24 is over tightened When assembling the gear box outer cover refer to Figs TM4 29 and TM4 30 The kick starter return spring should be installed with inner end of spring over the spline shown at L Fig TM4 37 Refer to appropriate paragraphs when assembling the clutch and the alternator assemblies The table on the following page lists details of various transmission parts used in four speed transmission Refer to Figs TM4 45 TM4 46 TM4 47 TM4 48 and TM4 49 for explanation of stepped and non stepped parallel shafts shaved and non shaft gears SERVICE rag a ed dup pe PAA TD Ed FE et ELEL Triu
17. asket 3 Check valves 9 Relief valve plunger Fig TM4 17 Primary chain tase should be filled to leval of plug L through top plug FJ The chaln tension ad juster located inside hole for drain plug 0 TM4 9A The oil should be drained filter F cleaned and reservoir should be filled with new oll every 1000 miles Oil should be maintained between marks on dip stick D On al models installation of hoses to and from the reservoir is important Refer to Fig TM4 9 and Fig TM4 9A Oii is drawn from the reservoir to the pressure pump through hose 1 The scavenge pump delivers oil back to the reservoir from the engine through hose 3 Qil pumped by the scavenge pump is also used to lubricate the rocker arms via hose 4 On some models oil is metered by valve 5 Fig TM4 9 and delivered to the rear chain through hose 6 The engine will probably be damaged because of lack of lubrication if hoses are attached incorrectly The oil pump is located on the right crankease half under the timing gear cover and is driven by an eccentric peg on the nut retaining the timing gear to the inlet camshaft Normal oil pressure 10 Spring Rubber sleeve JI Cap 15 Indicator shaft iz Nul IR Cover 13 Auxiliary spring ET O ring is 20 25 psi at idle and 60 65 psi during normal running Refer to Fig TM4 10 for exploded view of pump and relief valve On early models bottom of Fig TM4 10 free length of re
18. d rings are available in standard size and oversizes Nom inal bore size is 71mm 2 795 inches for 650cc models 75mm 2 953 inches for early 750cc models 76mm 2 992 inches for late 75066 models Piston Skirt Clearance 6T Serial No DU101 DU5824 0 0033 0 0043 inch 0 084 0 109mm 6T Serial No DU5825 DU44393 0 0016 0 0027 inch 0 041 0 069mm TR6 Serial No DU101 DU44393 0 0033 0 0043 inch 0 084 0 109mm TRG Serial No DU44394 and up except 11 1 Compression ratio 0 0046 0 0061 inch 0 117 0 155mm TRS and T120 Serial No DU44394 and up with 11 1 Compression ratio 0 0070 0 0084 inch 0 178 0 213mm T120TT Before Serial No DU44393 with 11 1 Compression TALDO saamiaan 0 0073 0 0083 inch 0 185 0 21 1mm T120 Serial No DU44394 and up except 11 1 Compression ratio AEN 0 0046 0 0061 inch 0 117 0 155mm 8 8 75 1 Fig TM4 20 Triumph pistons can be identified by measuring from center of piston pin Sore Pis fons shown are for 650ce models 1416 1 424 inches C B 1484 1 492 inches 0 1 498 MFA inches 1845 1 449 inchs Lacking hole Dil hale Culaway Cam follower guide seg rin e LEM HFA Fig TM4 21 On models after serial number DU24874 the exhauat cam follower Bre prat sure lubricated and must be Installed with cut away areas C toward outside as shown T120 Before Serial No 24 except 11 1 Compression TALI 0 0038 0 0048 inch
19. ead screws which algo attach the rocker boxes are already removed On 750cc models remove the ten cylinder head retaining screws and stud nuts NOTE Special threaded nuts are used at loca tions 3 4 5 amp 6 Fig TM4 19A When the cylinder head is removed it is necessary te renew the push rod tube oil seals Refer to the following specification data Recker arm bore CED rsta 0 5002 0 5012 in Rocker shaft O D 0 4990 0 4995 in Triumph 650 amp 750 Twins Fig TM4 184 A special tool is helpful ter holding the damper tube while removing screw Valve stem to guide clearance Inlet ova 0 0027 0 0032 in Exhaust 0 0032 0 0047 in Valve seat and face angle 45 degrees Valve seat width 3 32 in Valve springs type installed 6T Serial No 11 101 and up Inner mark ed Red Spot Outer marked Red Spot TR6 Serial No DU101 DU24874 Inner marked White Spot Outer marked White Spot TRE Serial No DU24875 DU66245 Inner marked Quter marked Red Spot TR6 Serial No DU66246 and up tf 1 ab Inner marked Red Spot Quter Marked Green Spot TRIV Inner marked Red Spot Quter marked Green Spot T120 Serial No DU101 DU24874 Inner marked White Spot Outer marked White Spot T120 Serial No DU24875 DU66245 Inner marked Red Spot QGuter marked
20. es between non stepped and siepped types Fig T44 46 Views of four apead counterahatts ftay shafts showing differences behveen stepped and non stopped types Fig TM4 47 Views showing differances betwaen uA shaved and shaved gears SHAVED GEAR shaft Mainshafts have two different types of threads C E I or U N F Be sure that the nuts and spacers are cor rect for the shaft used as well as the gears used Installing late mainshaft high gears in early transmission may necessitate installing later plate and seal at rear of clutch The gearbox casting must be modified to change layshaft countershaft from piain bushing to needle roller type MOTORCYCLE LAYSHAFT Yrd SEAR Fig TM4 48 Crosa section drawing of mainshait second gear with bore diameters for large bore and small bore types MAINGHAFT 2nd GEAA Fig Ti4 49 Cross section drawing of laysheft third gear with bore dlameters for large bore and amali bore types FIVE SPEED GEAR BOX To remove the gear box outer cover re move right side exhaust pipe and foot rest Loosen the clutch cable adjuster and disconnect cable at the hand lever Remove plug from cover and release the cable from actuating arm Discon nect cable and housing from gearbox outer cover Drain gear box and engage fifth gear Remove the two nuts and four screws that attach cover then depress kickstarter slightly and re move cover The clutch operating cam kick sta
21. g FOUR SPEED GEAR BOX To Clutch release Ratchet springs 2 EL Conpegting tink 16 Washer A 1 punge user Befure seral number 1T r pin remove the pee box outer Sede we ee ul aro shat Sie relurn spangs i Hat a E ne starter gear move the ex hau 51 pipe and foot rest naide plati shin 2 Clutch lever 1 if k Ratehet pawl 14 4 Cl rine l3 Bollved used in z Bushing from the right side Loasen clutch cable I reap shill x dal 14 Campli Zl Rick sloner pedal adjuster and disconnect cable from the actuating spoke Drain gear box and engage fourth gear Remove the two nuts and four screws attaching outer cover then remove the outer cover Clutch operating cam kick starter and gear change ratchet Fig TM4 29 are removed with the outer cover To remove the inner cover bend the tab washer back and remove nut 5 Fig TM4 32 then lift off the kick Fig TM4 32 View ofthe gear starter ratchet assembly Unbolt and Bn cones cite Peay ah remove the right rear engine mounting procedure plate Remove nut 4 and withdraw the detent plunger and spring Remove the primary chain cover alternator assembly primary chain crankshaft sprocket and the complete clutch ay sembly On models before serial number DU24875 disconnect the speedameter cable Remove the three screws 1 2 amp 3 and remove the inner cover Remove the shift fork rail then lift out the transmission gears and shafts as shawn in Fig TM
22. ing of engine reservolr and lines typical af 650cc models Fo Filter Rocker arm lubricant F Dron plug Heservoor lo pressure 5 Rear chain melering pump hose needle 2 Ohl manifold Hoge tn reer chain 3 ul return hose 1 Breather tent i howe SO F Fig TM4 94 Orawing of engine oll liner typical of 750ce models Frame tube is reservoir 11 Dipstick 2 O11 manifold F Filter J Oil return hoge G Gaskets 4 Rocker arm iubricant P Drain plug line Aeservol to pressure pump hose above 90 degrees SAE 30 ail from 32 degrees F to 90 degrees F Oil level should be maintained 11 inches 4em below filler cap opening of reservoir Oil reservoir is located on right side under the seat Remove filter F Fig TM4 9 from reservoir to drain oil and clean filter The oil should be drained filters cleaned and reservoir should be filed with new oil every 1500 miles On 750cc models the engine is equipped with a dry sump lubrication system which contains 4 8 pints 2 27 liters Use SAE 20W 50 multi vis cosity motor ail Oil is contained in the frame tubes which forms the reservoir Drain oil by removing plug P Fig 6 Triumph 650 amp 750 Twins y 8 9 12 3 10 14 11 15 Fig TM4 10 The cil pump is located at P and relel valve at A Exploded view of late type rellef valve is shown af top and earlier type below Drive block 5 Gasket 2 Preesure plunger 7 Valve body 3 Stavenge plunger B G
23. lief valve spring 10 shouid be 31 32 inch and auxiliary spring 13 should be 9 32 inch long On models after serial number DU13375 relief valve spring 10 top of Fig TM4 10 should be 1 17 32 inches long On 650cc models oi in primary chain case should be drained every 1000 miles The primary chain case should be filled to level of plug L Fig TM4 11 with SAE 20 ail On 750ce models oll in the primary chain case 1s automatically maintained at correct level by the engine lubri cating system Pour 150cc of engine into the chain case before starting en gine if chain case has been drained On all models the gear box should be drained every 6000 miles The gear box should be filled with EP 90 gear lubri 335 Triumph 650 amp 750 Twins Fig FM4 12 The gear box oli level plug is shown at M and drain plug at D Filler plug is located a top near clutch cable Fig TM4 13 Clutch spring tension can be ad justed as shown after removing the primary chain cover Refer io text cant until oil begins to flaw from the level plug hole When checking gear box oi level it is necessary to fill with oil until above the level pipe Some oil will be inside the pipe when level plug is removed Refer to Fig TM4 12 CLUTCH CONTROLS To adjust the clutch remove the plug from the side of primary chain case cover loosen the locknut and turn the adjusting screw A Fig TM4 11 in until resis t
24. lle T120 models use two car buretors all others use one Refer to the following specification data SERVICE Fig TM4 1 Expioded view af typical Amal Mon ebloc carburetor used Refer to Fig TM4 2 for view of Amal Concentric Hoat carburetor itle tree rog bey Li Steed e jel 2 Jet bhick ar 14 hinin je f Throttle slide Thrattle spring qt yy IF dei block 16 Flipat Bb Piha jut IF Inlet valve T dle spred slop 13 Primer 4 Fuel filler 40 Choke valve 119 Jet holder 21 Cab e guide T Serial No DU101 and up Refer to Fig TM4 1 Model inna RRO ERA 376 303 Malin jet l3 230 Needle jet 11 106 Valve needle 5 C Throttle slide 3 376 4 Pot jet 6 25 Clip 4 in third groove fram top of needle 45 TR6 Serial No DU101 to 17 Refer to Fig TM4 1 Model 376 Main jet 13 swarms 250 Needle jet 11 sarees sean 106 Valve needle Ogee ee C Throttle slide 3 misipa 376 314 PHOEVCLTB eE 25 Clip 4 in third groove from top of needle 5 TR6 Serial No DU5825 DU44393 Refer to Fig TM4 1 Model jie saree renames 389 97 Mamet LD ce can 310 Needle jet 11 106 Valve needle 5 4 0 D Throttle slide 3 389 3 Pilotjet 6 ssu wen avs eaten wees ss 25 Clip 4 in top gro
25. m Bearing in serts are available in standard size as well as undersizes 1 Rotor wetaning mu 2 Tab washer 3 Rator 4 Primary drive sprocket gt Spacer E Rod bearing inserts T Oil lube j a Plu a Screw 13 used D Flywheel I Cranksha pear 12 Nut 13 Bushing 14 Idler gear 15 wut 16 Camshaft gear 15 Fxhaus camshaft 13 Tachometer drive 20 Oil pump drive nul 1 Carsshatt ear A Inlet camahah 23 Spring 23 Hotary breather valve a Hall bearing 26 Washer 27 Rotler bearing 28 Dowel Energy transfer ignition only 29 Hey Callexcept energy transter 1 TIL 30 Oil seal 339 Triumph 650 amp 750 Twins Fig TM4 25 Camshatt timing marks must be correctly aligned as described in 16 The crankshaft left drive side main bearing should be of the roller type On models before serial number DU13375 early type bearing can be changed to the late roller type without changing any other parts On models between serial number DU13375 and DU24874 the late type roller bearing can be in stalled after installing the late type crankshaft timing gear 1 Fig TM4 24 and washer 26 When assembling the projecting tabs on connecting rod bearing Inserts should be on same side The connecting rod nuts should be tightened to the torque Two types of connecting rod nuts have been used The early type has a machined finish and should be tightened to 28 Ft Lbs torque 3 87 kg m The later preferred nuts have
26. mp 12 Fig TM4 28 use soap to lubricate rubber cushions and make certain that drive and rebound cushions are on the correct sides of spider 13 as shown NOTE Do not use oil or grease to lubricate rubber cush J 2 2 OS z Fig TM4 29 View of gear box outer cover Refer to Fig TM4 30 for exploded view of the operating assemblies SERVICE Triumph 650 amp 750 Twins lions Loctite should be used on threads of the three screws attaching outer cover 10 Fig TM4 27 to the hub 14 Install spacer 8 Fig TM4 24 with tapered side toward main bearing Position the crankshaft pri mary drive sprocket chain and clutch drum 17 Fig TM4 27 on shafts at the same time Washer 41 should be installed with cupped side out toward nut On models after serial number DU48144 nut 8 is self locking On earlier models lock washer should be installed between washer 9 and nut 8 with the long tab engaging hole in spider 13 On all models nut 8 should be tightened to 50 Ft Lbs 6 9kg m torque On early models with ipek washer washer should be bent around nut after tightening Refer to ignition and electrical section when installing the alternator rotor and stator Refer to the primary drive chain Fig 1M4 30 Exploded view of parts located in the gear box outer cover Refer to Fig TM4 29 for Paragraphs for adjusting chain tension assembled view i P em pedal shalt 1 Sprin
27. mph 650 amp 750 Twins AA 4 8 RA A nag Hiag eel HR oie Pepe pt hope oy papi py YE ee LA Ce eo phi EFT OL FS 1 EFL Ft HY Sr SLL IE ee lL FEE EL PF LZ ie OCI FE KIEL rag HG Bul hp ae Conn an Li S T L by gE S LEL RAL a Oi inn HAH airy ag be iy ee ey Pe hap ey HH EPA POPUP Phat wih feet oped ipy yhp pe peel ope l sc bon ape pede Feel oped oq apy a ON aa eg epee pH HEH HEE ep eels pa ede mi Hp ged HH paddy LH Le FEL A tg eee TE tai SH TEL arem Egy Fee HY Lele 2 FLY EFL Oph sp Papp Opiti cpg fugit rahi Hua peh ei KII m MI ET ee Pe ee ae Of LY FLY TELE E GT teeter yu gl SMH 1 Hy Fet PEER Tp La HA E1 DHE ry Ca L bL 7 pete SL Le Te ip f DE1 1 pia THEI ei LAR ede 1n FHL Fare LEE FOL QPREL FT ea ea ue Aaaa u MTP FOr ary Gj Ee
28. ng observe the fol lowing Install the cam plate C Fig TM4 36 and detent plunger D spring and nut N Turn the camplate until the notch between second and third gears engages detent plunger as shown in Fig TM4 36 Use grease to stick the ASIII Fig TM4 35 4f needle bearings 11 and 12 Fig TM4 34 are removed bearings should be stalled using a special drift Thea bearings should project 0 073 0 078 Inch C into the housing A 1 inches B 11 16 Inch 342 C 0 073 0 075 inch IA First gear bushing 2 Ratchet 4 Ball bearing 23 Tab washer 15 Snap ring 24 Nut l6 Clutch rad bushing 2 Output shalt bearing 17 Clutch rod 26 Snap ning 8 Washer 27 Oii seal 19 Sleeve ZH Output eprockel d Ratchet spring 29 Lock washer 21 Kick starter genr a0 Nut thrust washer 10 in position with grooved side out as shown Stick the rollers 2 Fig TM4 33 onto forks with grease Slide the assembled shafts into housing while carefully sliding gears as required to align rollers 2 with grooves in cam plate C NOTE Be careful not to move the camplate when assembling With parts correctly positioned in housing slide the shift rail through shift forks with shoul dered end toward inside Use grease to stick thrust washer 10 around bearing 11 Fig TM4 34 in the inner eover with the grooved side toward gear 6 Coat mating surfaces of inner Fig FM4 36 When assem bing four speed tr
29. on cam 14 Piston position BTDC Static i 0 015 inch 6T Serial No DU5825 DU44394 Crankshaft degrees BTDC PEDERI 018101 as need 4 11 Full advance SRS oo Advance range stampedoncam 12 Piston position BTDC SEALE neisa 0 038 inch 334 Fig TM4 8 The peg P on the primary drive sprocket should be at approximately 9 o clock position when the crankshaft is at top dead center TDC TR6 and T120 Serial No DU101 DU5824 Crankshaft degrees BTDC SALIENT OREN ST EE Full 30131166 39 Advance range stampedoncam 14 Piston position BTDC EE ae 0 038 inch TR6 and T120 Models with Battery Ignition Serial No DU5825 and up SESE SE URGES 15 Full advance 39 Advance range stamped on cam 12 Piston position BTDC Stati Gide ARES 0 068 inch TR6 and T120 Models with Energy Transfer Ignition Serial No DU44395 and up Crankshaft degrees BTDC 1 ANAA DEEA 29 Full advance AP a Advance range stamped on cam 5 Piston position BTDC SEARO orren eae aS 0 25 inch TR7Vand T140V Crankshaft degrees BTDC SERIE resist nae aaa 14 Full 80 3166 je cpr esses PERAN 38 Advance range of cam 12 Piston position BTDC 839 ensar 0 060 inch 1 5mm Full advanced ignition timing should occur at 35 crankshaft degrees BTDC for all 6T
30. or valve used on some models Body 23 ia atiached to lower tube 15 Fig TM4 15 with screw 9 Fig TM4 15 and must be removed before disassembling 1 Fiiler plug 16 Hod 20 Nut 17 Pin 21 Bushing ia Cup 22 Restrictor cap 19 OA restrictor 23 Restrictar body SERVICE Fig TMtd 17 Exploded view of front suspension used on models from serial number OL66246 1 Filler plug 11 Ohl seal 2 Tube 12 Seal relainer sleeve Spring nut 4 Bottom bushing 13 Top bushing 5 Washer 14 Gompening sleeve Bushing nut 15 Lower tube 7T Hestrictar 16 Drain plug 9 Screw 11 Snap ring 18 Shuttle valve spring Fig TM4 14 On models with external spring Fig TM4 15 or Fig TM4 17 each unit contains 190cc of ail The late type fork Fig TM4 18 used on TR7V and Ti40V models should contain 200cc of Automatic Transmission Fluid ATF Recom mended oil for earlier models is SAE 50 oil above 90 F SAE 30 at temperatures fram 60 F to 90 F and SAE 20 oil below 60 F Oi should be drained and filled with correct type at least every 6000 miles Oil is drained by removing plugs at the bottom of fark lower sliding tubes Forks are filled through the hole in top after removing plug 1 Fig TM4 14 Fig TM4 15 Fig TM4 17 or Fig TM4 18 Disassembly and reassembly of late forks is more easily accomplished using the special tool shown in Fig TM4 13A The tool holds the damper tube assembly 7
31. ove of needle 5 TR6 Serial No DU44394 DU66245 Refer ta Fig TM4 Model 383239 P e Fb a BME ERS a TO e ERR KERGE S68 aha aS 8 eke BP Se SH Pe ST He G MEIGS pimpe a ee 1 1 20 Serial No DU5825 BU66245 and T120R Serial No DU24875 DU44393 Refer to Fig TM4 1 Model 77 389 203 Main jet 13 egestas saa 260 Needle jet Li 106 Valve needle 5J sass cee ees D Thrott leslie auesse 389 3 11 2 25 Clip 4 in third groove from top of needle 5 T120R Serial No DU44394 DU66245 and T120TT Serial No DU24875 DU66245 Refer to Fig TM4 1 Model 0 0 oo 389 95 Mainyetela sc awn cea cessive 330 BETES EL ona E 106 Valve needle 5 za cies ei es D Throttle slide 3 389 3 or 74 noa i Oa HE NF d Ilpo Pilot jet 6 Clip 4 in second groove from top of needle 5 T120R Serial No 66246 and up Refer to Fig TM4 2 Model left asec 930 10 IEE E casters Ea 330 9 Main jet 13 10 or 220 Needle jet 11 0 106 or 0 107 Throttle slide
32. r 0 689 0 690 in the cam plate grooves If shift forks are 5TA the needle bearing 12 should Bushing 18 correctly installed both rollers will project 0 073 0 078 inch into the diameter 0 689 0 690 in reach both ends of the grooves If move housing Installation should be accom Clearance on shaft ment of either roller is incorrect re plished with a drift shown in Fig TM3 11 0 0015 0 0030 in move shift forks 28 amp 30 and ex 33 Bushing 5 Fig TM3 32 should be installed with oil groove toward gear Free length of kick starter spring 22 Fig TM3 32 is inch Free length of ratchet springs 3 Fig TM3 30 is 1 caange places NOTE Shift forks are not interchangeable The rollers for cam plate are offset TRIUMPH UNIT CONSTRUCTION 650 AND 750cc TWINS Bonneville T120 Thunderbird 6T Bonneville Bonneville T140V MODEL Trophy TR6 T120V Tiger Displacement ce s sass ass 649 649 744 BORGO ceset anes es EE 71 71 76 6 112 via cee eee eine eae 82 82 82 Number of cylinders 2 2 2 legion ype Ch N 4 N 4 N 3 park plug t 8110101011 N PAP MM 0 5 0 5 0 635 meh OT 0 020 0 020 0 025 Point gap irin 0 35 0 40 0 35 0 4 0 35 0 40 fle aa 0 014 0 016 0 014 0 016 0 014 0 016 Valve clearance cold Ntake mmM wince
33. rods are at bottom of travel then install the front rocker box and rocker arms as sembly On 650 models the rocker arm shaft nuts should be tightened to 22 Ft Lbs 3 0 kg m torque Rocker box retaining screw and stud nuta which are inch size should be tightened to 5 Ft Lbs 0 7 kg m torque The nine cylinder head retaining screws and stud nuts should be tightened in the sequence shown in Fig TM4 19 Final torque for the 5 16 inch diameter screws Fig TM 4 19 should be 15 Ft Lbs and 25 Ft Lbs for the inch diameter screws On 750 models the 5 16 inch cyl inder head retaining nuts 1 amp 2 Fig TM4 19A should be tightened to a torque of 16 Ft Lbs 2 21 kg m Tighten the other cylinder head re 333 Fig TM4 19A Cylinder head retaining scrows and stud nuts shouid be tightened in sequence shown for 750cc models Special nuts are used at iocationa 3 4 5 amp 6 whith accept rocker box screws taining stud nuts and screws inch size to 18 Ft Lbs 2 49 kg m torque Tighten cylinder head retaining hard ware evenly and slowly The 4 inch size rocker box screws should be tight ened to 5 Ft Lbs 0 7 kg m torque and the 5 16 inch screws to 10 Ft Lbs 1 38 kg m Torque the rocker splindle domed nuts to 22 Ft Lhs 3 0 kg m On all models refer to the VALVE SYSTEM paragraphs in the Mainte nance section for setting valve clear ance PISTONS RINGS AND CYLIN DERS Pistons an
34. rter and gear change ratchet are removed with cover To remove the inner cover unbolt and remove the right rear engine mounting plate Bend tangs of lock washer down and remove nut 24 Fig TM4 52 Remove the three screws 3 and remove cover from dowels Remainder of disassembly will de pend upon work done The complete clutch assembly must be removed be fore input shaft 1 Fig TM4 50 can be removed The transmission output sprocket 28 must be removed before output shaft 4 can be removed The gearbox or cover should be heated to approximately 100 C when removing or installing bearings Refer to Fig TM4 35 for installing counter shaft layshaft needle bearings The bronze thrust washers on the counter ahaft should be positioned with grooved SERVICE 24 23 22 N W 8 Fig TH4 50 Exploded view of five speed transmission gears and associated parts L Input shaf B First gear rmaineha tty B Bushing Fourth grar 7 Second gear 3 Third gear 4 First and second gear dB Bushing BH Third gear 4 Outpul shaft and L Countershaft fifth pear Hayeahaft with fourth 5 Needle roller ear and drive gear bearings ll First gear drive dug 35 Ohl ges surfaces toward gear on shaft 10 Fig TM4 50 and first gear drive dog 11 Assemble transmission gears shafts shift forks and shift cam with parts in 12 Snap ting 2 Ratchet Ball bearing 23 Tab washer 15 Snap ring FA Nutt IB Clutch rod
35. uster IT The chain should have inch free play as measured through the filler plug hole P Make certain that pri mary chain case is filled to level of plug hole L with SAE 20 oil after adjust ment is complete To remove the primary chain case cover remove the left exhaust pipe loosen the rear brake adjuster until the brake pedal is clear of the primary cover and remove the left foot rest Remove drain plug D Fig TM4 11 and allow primary chain case to drain Remove the two domed nuts and eight attaching screws then lift off the chain cover To remove the primary chain it is necessary to remove the alternator then remove the clutch chain and crankshaft sprocket together When assembling tapered side of spacer 5 Fig TM4 24 must be in stalled toward the sprocket Refer to IGNITION AND ELECTRICAL para graphs for installing alternator rotor and stator Make certain that alter nator wires can not rub on primary drive chain Install chain tension ad juster and adjust the chain free play after the chain case cover is installed SUSPENSION Each front suspen sion unit contains 150cc of oil on all 6T TR6 and T120 models with internal MOTORCYCLE Fig TM4 15 Exploded view of front suspension used from serial number 105825 to OUG6245 On some models restrictor valve may be lyp shown in Fig 1 4 16 Refer to Fig 4 14 for legend ot ql 9 Fig TM3 1 iew of resirict
36. yl Inder Exhaust cam followers 3 Triumph 650 amp 750 Twins should be installed with cut away faces C toward outside Inlet cam follower block on late models and both guide blocks on earlier models should be sim larly pressed into place however these are not pressure lubricated and do not have oil holes B or cut away sections C On late models make cer tain that the cylinder base gasket is installed with hole in gasket over the ol passage A Fig TM4 22 in crank case and oil passage B in cylinder When installing piston rings on all models make certain that side of the two compression rings marked TOP is toward top of piston The cylinder retaining nuts should be tightened to 33 Ft Lbs torque CRANKSHAFT CONNECTING RODS AND CAMSHAFTS To re move the crankshaft or connecting rods it is necessary to separate the crankcase halves Remove the cylinder head cylinder ignition base plate ignition cam timing gear cover oi pump and cam shaft and crankshalt gears NOTE The nuts attaching gear to camshaft are left hand thread Remove the clutch alternator stator and rotor primary drive sprockets primary drive chain gear box cover and transmission gears Remove engine from the frame and remove the remaining screws and stud nuts joining the crankcase halves NOTE Two screws are located at S Fig TM4 23 Connecting rod crankpin standard diameter is 1 6235 1 6240 inches 41 237 41 25m
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