TableofContents

IntroductionGeneralInformationScheduledMaintenance

CylinderHead

ClutchCrankshaft

BevelBoxandDriveShaft

BalancerTransmissionLubrication

EngineRemovalandRefitFuelSystem/EngineManagement

CoolingRearSuspensionFrontSuspension"' Brakes

Wheels/TyresFrameandBodyworkElectricalSystem

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ⁱⁱ ServiceManual-RocketIll

Introduction

ServiceManual-RocketIll ⁱⁱⁱ

Thismanualisdesignedprimarilyforusebytrainedtechniciansinaproperlyequippedworkshop.However,itcontainsenoughdetailandbasicinformation tomakeitusefultotheownerwhodesiresto performhisownbasicmaintenanceandrepairwork.Theworkcanonlybecarriedoutiftheownerhasthenecessaryhandandspecialservicetoolstocompletethejob.

Abasicknowledgeofmechanics,includingthe properuseoftoolsandworkshopproceduresisnecessaryinordertocarryoutmaintenanceandrepairworksatisfactorily.Whenevertheownerhasinsufficientexperienceordoubtshisabilitytodothework,anauthorisedTriumphdealermustundertakealladjustments,maintenance,andrepairwork.

Inordertoperformtheworkefficientlyandtoavoidcostlymistakes,readthetextandthoroughlyfamiliariseyourselfwith proceduresbeforestartingwork.

All workshouldbeperformedwithgreatcareandinacleanworkingareawithadequatelighting.

Alwaysusethecorrectspecialservicetoolsorequipmentspecified.Undernocircumstancesusemakeshifttoolsorequipmentsincetheuseofsubstitutesmayadverselyaffectsafeoperation.

Whereaccuratemeasurementsarerequired,theycanonlybemadeusingcalibrated,precisioninstruments.

Forthedurationofthewarrantyperiod,anauthorisedTriumphDealermustperformallrepairsandscheduledmaintenance.

TomaximisethelifeofyourMotorcycle:

• Accuratelyfollowthemaintenancerequirementsoftheperiodicmaintenancechartintheservicemanual.

• Donotallowproblemstodevelop.Investigateunusualnoisesandchangesintheridingcharacteristicsofthemotorcycle.Rectifyallproblemsas soon aspossible(immediatelyifsafetyrelated).

Howtousethismanual

Toassistintheuseofthismanual,thesectiontitleisgivenatthetop.

Eachmajorsectionstarts withacontentspage,listingtheinformationcontainedinthesection.

Theindividualstepscomprisingrepairoperationsaretobefollowedinthesequenceinwhichtheyappear.

Adjustmentandrepairoperationsincludereference toservicetoolnumbersandtheassociatedillustrationdepictsthetool.

Whereusageisnotobvious,thetoolisshowninuse.

Adjustmentandrepairoperationsalsoincludereferencetowearlimits,relevantdata, torquefigures,specialistinformation andusefulassemblydetails.

Warning,CautionandNote

Particularlyimportantinformationispresentedinthefollowingform:

Note:

• Thisnotesymbolindicatespointsofparticularinterestformoreefficientandconvenientoperation.

• UseonlygenuineTriumphpartsaslistedinthepartscatalogue/parts microfiche.

• Followtheproceduresinthismanualcarefullyandcompletely.Donottake shortcuts.

• Keepcompleterecordsofallmaintenanceandrepairswithdatesandanynew partsinstalled.

• Useonlyapprovedlubricants,asspecifiedintheowner'shandbook,inthemaintenance ofthemotorcycle.

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Introduction

TamperingwithNoiseControlSystemProhibited

Owners arewarnedthatthelawmayprohibit:

1. Theremovalorrendering inoperativebyanypersonotherthanforpurposesofmaintenance,repairorreplacement,ofanydeviceorelementofdesignincorporatedintoanynewvehicleforthepurposeofnoisecontrolpriortoitssaleordeliverytotheultimatepurchaserorwhileitisinuse;and

2. theuseofthevehicleaftersuchdeviceorelementofdesignhasbeenremovedorrenderedinoperativebyanyperson.

References

Referencestotheleft-handor right-handsidegiveninthismanualaremadewhenviewingthemotorcyclefromthe rear.

Operationscoveredinthismanualdonotalwaysincludereferencetotestingthemotorcycleafterrepair.Itisessentialthat workisinspectedandtestedaftercompletionandifnecessaryaroadtestofthemotorcycleiscarried outparticularlywheresafetyrelateditemsareconcerned.

Dimensions

Thedimensionsquotedaretodesignengineeringspecificationwithservicelimitswhereapplicable.

Duringtheperiodofrunning-infromnew,certainadjustmentsmayvaryfromthespecificationfiguresgiveninthismanual.Thesewill beresetbythedealeratthe500mile/800kmservice,andthereaftershouldbemaintainedatthefiguresspecifiedinthismanual.

RepairsandReplacements

Beforeremovalanddisassembly,thoroughlycleanthemotorcycle.Anydirtenteringtheengineorotherpartswillworkasanabrasiveandshortenthelifeofthemotorcycle.Particularattentionshouldbe paidwheninstallinganewpart,thatanydustormetalfilingsareclearedfromtheimmediatearea.

Force

Commonsense shoulddictatehowmuchforceisnecessaryinassemblyanddisassembly.Ifapartseemsespeciallydifficulttoremoveorinstall,stopandexaminewhatmaybecausingtheproblem.Neverleveracomponentasthiswillcausedamagebothtothecomponentitselfand to thesurfacebeingleveredagainst.

Whenevertappingtoaidremovalofanitemisnecessary,taplightlyusingahideorplasticfacedmallet.

Edges

Watchforsharpedges,especiallyduringenginedisassemblyandassembly.Protectthehandswithindustrialqualitygloves.

Whenreplacementpartsarerequired,itisessentialthatonlygenuineTriumphparts are used.

SafetyfeaturesandcorrosionpreventiontreatmentsembodiedinthemotorcyclemaybeimpairedifotherthangenuineTriumphpartsarefitted.Incertainterritories,legislationprohibitsthefittingofpartsnottothemanufacturer'sspecification.

Tighteningprocedure

Generally,wheninstallingapartwithseveralbolts,nutsorscrews,theyshouldallbestartedintheirholesandtightenedtoasnugfit,evenlyandinacrosspattern.Thisistoavoiddistortionofthepartand/orcausinggasoroilleakage.Conversely,bolts,nuts,orscrews,shouldallbeloosened(insequenceifspecified)byaboutaquarterofaturnandthenremoved.

WherethereisatighteningsequencespecifiedinthisServiceManual,thebolts,nuts,orscrewsmustbetightenedintheorderandbythemethodindicated.

TorquewrenchsettingfiguresgiveninthisManualmustbeobserved.Thetorque toolsusedmustbeofaccuratecalibration.

Lockingdevices,wherespecified,mustbefitted.Iftheefficiencyofalockingdeviceisimpairedduringremoval itmustberenewed.Thisappliesparticularlytomicro-encapsulatedfixingswhichmustalwaysbereplacedifdisturbed.Wherenecessary,thetextinthismanualwillindicatewheresuchafixingisused.

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