- •Introduction
- •Introduction
- •VI ServiceManual-RocketIll
- •1GeneralInformation
- •ServiceManual-RocketIll
- •IgnitionSystemSafetyPrecautions
- •ServiceManual-RocketIll Coolant
- •1.6 ServiceManual-RocketIll
- •1.8 ServiceManual-RocketIll
- •Inspection
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •1.18 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •1.26 ServiceManual-RocketIll
- •1.28 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •1.34 ServiceManual-RocketIll
- •2ScheduledMaintenance
- •Introduction.............................................._. 2-2
- •Introduction
- •2.2 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •3CylinderHead
- •Installation
- •1.'D'sections
- •ServiceManual-RocketIll
- •Installation
- •3.8 ServiceManual-RocketIll
- •Installation
- •3.12 ServiceManual-RocketIll
- •ValveClearances
- •Valve clearance adjustment must becarriedoutwiththeenginecold.
- •ValveClearanceAdjustment
- •Valveclearancecheckingandadjustmentmustbecarriedoutwiththeenginecold.
- •3.14 ServiceManual-RocketIll
- •Inspection
- •Installation
- •Valvesand ValveStemSeals
- •Inspection
- •3.18 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •4Clutch
- •4.4 ServiceManual-RocketIll
- •4.6 ServiceManual-RocketIll
- •4.8 ServiceManual-RocketIll
- •4.10 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •5Crankshaft
- •ServiceManual-RocketIll
- •5.4 ServiceManual-RocketIll
- •5.6 ServiceManual-RocketIll
- •Installingthecrankshaft
- •5.8 ServiceManual-RocketIll
- •Installation
- •Installingthecrankshaft
- •5.10 ServiceManual-RocketIll
- •Ifanycrankpinhasworn beyondtheservicelimit,thecrankshaftmustbereplaced.Duetotheadvancedtechniquesusedduringmanufacture,thecrankshaftcannotberegroundand oversizebearingsarenotavailable.
- •Itisnormalforthebearingsselectedtodifferfromonejournaltoanother.
- •5.14 ServiceManual-RocketIll
- •5.16 ServiceManual-RocketIll
- •2.Directionarrow
- •5.20 ServiceManual-RocketIll
- •6BevelBoxandDriveShaft
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •6.6 ServiceManual-RocketIll
- •7Balancer
- •Introduction 7-3
- •Introduction
- •7.4 ServiceManual-RocketIll
- •7.6 ServiceManual-RocketIll
- •8Transmission
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •1.Gearpositionsensor
- •1.Gearpositionindicatorshaft
- •InputandOutputShaftAssemblies
- •InstallingtheOutputShaft
- •8.16 ServiceManual-RocketIll
- •InputShaft
- •8.20 ServiceManual-RocketIll
- •8.22 ServiceManual-RocketIll
- •9Lubrication
- •ServiceManual-RocketIll
- •9.6 ServiceManual-RocketIll ·
- •ServiceManual-RocketIll
- •Installation
- •Inspection
- •ServiceManual-RocketIll
- •9.12 ServiceManual-RocketIll
- •Installation
- •9.14 ServiceManual-RocketIll
- •Oilnon-returnvalve
- •Oilpressurereliefvalve
- •Inspection
- •Installation
- •1OEngineRemovalandRefit
- •10.2 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •1.Pedal
- •10.6 ServiceManual-RocketIll
- •10.8 ServiceManual-RocketIll
- •11FuelSystem/EngineManagement
- •11.2 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •11.6 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •11.12 ServiceManual-RocketIll
- •11.16 ServiceManual-RocketIll
- •Inthissystem,thestarterlockoutsystem(clutchswitch,neutralswitch,sidestandswitch)alloperatethroughtheenginemanagementEcm.
- •11.18 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •11.22 ServiceManual-RocketIll
- •11.24 ServiceManual-RocketIll
- •ItemChecked ResultUnit
- •11.26 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •Validationkey
- •ServiceManual-RocketIll
- •;..,.I.,.NoDtCspresent
- •11.32 ServiceManual-RocketIll
- •1Oo/oComplete
- •11.34 ServiceManual-RocketIll
- •3. Triumphmotorcycles
- •4. Switchonbikeignition
- •11.36 ServiceManual-RocketIll
- •Servicedata-date 8. Mainmenu
- •If'quit'isselectedandthevalidationkey
- •11.38 ServiceManual-RocketIll
- •Stopengine
- •Toselect'readstoreddtcs'(DiagnosticTroubleCodes)fromtheMainmenu:
- •11.40 ServiceManual-RocketIll
- •15.Freezeframe 16.Storeddtcs
- •11.42 ServiceManual-RocketIll
- •Functiontests 20.Functiontest
- •Functiontest
- •Functiontest 23.Functiontest
- •ServiceManual-RocketIll
- •Functiontest
- •Functiontest
- •Check/adjust
- •11.48 ServiceManual-RocketIll
- •Builddata
- •Sensordata 31.Adaptionstatus
- •Adjusttune
- •11.52 ServiceManual-RocketIll
- •Balancethrottles
- •36.Updatetune 37.Updatetune
- •11.54 ServiceManual-RocketIll
- •Updatetune
- •Updatetune
- •Updatetune
- •Updatetune(confirmselected)
- •11.58 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •IdleSpeedConrol
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •Enine Sub·arness
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll ·
- •FuseBox
- •IgnitionCoils
- •11.70 ServiceManual-RocketIll
- •IgnitionCoils
- •11.72 ServiceManual-RocketIll
- •InletAirTemperatureSensor
- •11.74 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •11.78 ServiceManual-RocketIll
- •VehicleSpeedOutput
- •11.84 ServiceManual-RocketIll
- •2NdThrottlePositionSensor
- •ServiceManual-RocketIll
- •2NdThrottleActuator
- •ServiceManual-RocketIll
- •VehicleSpeedSensor
- •11.90 ServiceManual-RocketIll
- •11.92 ServiceManual-RocketIll
- •11.94 ServiceManual-RocketIll
- •FuelLeve FuseBox
- •ServiceManual-RocketIll
- •11.98 ServiceManual-RocketIll
- •11.100 ServiceManual-RocketIll
- •11.102 ServiceManual-RocketIll
- •Inspection
- •Installation
- •11.104 ServiceManual-RocketIll
- •11.106 ServiceManual-RocketIll
- •11.108 ServiceManual-RocketIll
- •Installation
- •11.110 ServiceManual-RocketIll
- •IntakeAirTemperatureSensor
- •11.112 ServiceManual-RocketIll
- •11.114 ServiceManual-RocketIll
- •11.116 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •11.122 ServiceManual-RocketIll
- •Intakeduct
- •Throttlebody
- •Installation
- •1.Transitionpiece
- •InjectorsandFuelRail
- •11.126 ServiceManual-RocketIll
- •Installation
- •ServiceManual-RocketIll
- •Idle SpeedControlStepperMotor
- •11.130 ServiceManual-RocketIll
- •IdleSpeedControlStepperMotor
- •Installation
- •11.130 ServiceManual-RocketIll
- •1.Adjustmentnut.
- •11.132 ServiceManual-RocketIll
- •HeatShieId
- •11.134 ServiceManual-RocketIll
- •Installation
- •11.136 ServiceManual-RocketIll
- •11.140 ServiceManual-RocketIll
- •12Cooling
- •12.4 ServiceManual-RocketIll
- •12.6 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •12.10 ServiceManual-RocketIll
- •12.12 ServiceManual-RocketIll
- •Inspection
- •Installation
- •12.14 ServiceManual-RocketIll
- •13RearSuspension
- •ServiceManual-RocketIll
- •13.4 ServiceManual-RocketIll
- •14FrontSuspension
- •14.2 ServiceManual-RocketIll
- •Inspectingforks
- •14.6 ServiceManual-RocketIll
- •14.8 ServiceManual-RocketIll
- •14.10 ServiceManual-RocketIll
- •14.12 ServiceManual-RocketIll
- •14.14 ServiceManual-RocketIll
- •1.Topnut
- •14.16 ServiceManual-RocketIll
- •1.Topnut
- •14.18 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •15Brakes
- •15.4 ServiceManual-RocketIll
- •15.8 ServiceManual-RocketIll
- •1.Diaphragm
- •15.10 ServiceManual-RocketIll
- •15.12 ServiceManual-RocketIll
- •Installation
- •15.14 ServiceManual-RocketIll Removal
- •Installation
- •15.18 ServiceManual-RocketIll
- •1.'R'Clips
- •ServiceManual-RocketIll
- •Installation
- •15.24 ServiceManual-RocketIll
- •Installation
- •Inspection
- •1.Piston
- •Installation
- •15.28 ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •16Wheels/Tyres
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •ImportantTyreInformation
- •Removal
- •16.6 ServiceManual-RocketIll
- •Installation
- •16.10 ServiceManual-RocketIll
- •Installation
- •16.12 ServiceManual-RocketIll
- •17FrameandBodywork
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •17.10 ServiceManual-RocketIll
- •17.12 ServiceManual-RocketIll
- •Installation
- •17.14 ServiceManual-RocketIll
- •ServiceManual-RocketIll · SideStand Removal
- •Installation
- •18ElectricalSystem
- •ServiceManual-RocketIll
- •18.6 ServiceManual-RocketIll
- •18.10 ServiceManual-RocketIll
- •1.Verticalbeamadjuster
- •18.14 ServiceManual-RocketIll
- •2.ToolT3880200
- •3.ToolT3880201
- •18.16 ServiceManual-RocketIll
- •Installation
- •Installation
- •Arrowed-0-ring
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •ServiceManual-RocketIll
- •18.26 ServiceManual-RocketIll
- •Ic»l.J!lcsw
11.6 ServiceManual-RocketIll
ExplodedView-FuelTank
ServiceManual-RocketIll
11.7
ExplodedView-FuelPump
10Nm
\
s (/)f:::::JJ(/)r-r.,
1i/
!J Qlf:::::J)Ql 10Nm2Nm <9
10Nm JO
' (\ o @
0
i'i 8' 2Nm
J
e
ServiceManual-RocketIll
ExplodedView - FuelRail,ThrottlesandInjectors
5Nm
1.5Nm
ServiceManual-RocketIll 11.9
ExplodedView_Airbox
\·•
9Nm
l-1.5Nm
11.10
Servi.ceManual-RocketIll
ExplodedView-Exhaust
System
ServiceManual-RocketIll 11.11
ExplodedView-EvaporativeSystem
0 oo
0
11.12 ServiceManual-RocketIll
FuelRequirements
FuelRequirements-allcountriesexceptUSA
OutsideAmerica,theRocketIllmustberunon95
RONunleadedfuel.
FuelRequirements-USA
IntheUnitedStatesofAmericawheretheoctaneratingoffuelismeasuredina differentway,thefollowinginformationmay beapplied:theRocketIllisdesignedtorunonunleadedgasolinewithaCLCorAKIoctanerating(R+M)/2of89orhigher.
Methanol
MTBE(MethylTertiary ButylEther)
Theuseofgasolinescontainingupto15%MTBE(MethylTertiaryButylEther)ispermittedinTriumphmotorcycles.
OxygenatedGasoline
Tohelpinmeetingcleanairstandards,someareasoftheU.S.useoxygenatedgasolinetohelpreduceharmfulemissions.TheRocketIllwillgivebestperformancewhenusingunleadedgasoline.However,'thefollowingshouldbeusedasaguidetotheuseofoxygenatedfuels.
Ethanol
Ethanolfuelisamixtureof10%ethanoland90%gasolineandisoftendescribedunderthenames'gasohol','ethanolenhanced',or'containsethanol'.ThisfuelmaybeusedinTriumphmotorcycles.
ServiceManual-RocketIll 11.13
GlossaryofTerms
Thefollowingtermsandabbreviationswillbefoundinthissection.Belowisgivenabriefexplanationofwhatsomeofthemorecommontermsandabbreviationsmean.
Airtemperature
Theairtemperatureintheairboxandintakehose.
Airtemperaturesensor
Sensorlocated intheairboxtodetectthetemperatureofthe incomingair.
ATDC
AfterTopDeadCentre.
Barometricpressure
Pressureoftheairintheairbox.
Batteryvoltage
ThevoltageattheinputtotheElectronicControlModule(ECM).
BTDC
BeforeTopDeadCentre(TDC).
Catalyst
Deviceplacedintheexhaustsystemwhichreducesexhaustemissions bystimulatingsecondarycombustionoftheexhaustgases.
Closedthrottleposition
Throttlepositionatidle(i.e.againstendstop),measured asavoltageandexpressedaspercentage.
Coolanttemperature
Thecoolanttemperatureinthecylinderhead.
Coolanttemperaturesensor
Sensorwhichdetectscoolanttemperature.
Coolingfanstatus
The 'on'or 'off'conditionofthecoolingfan.
OTC
DiagnosticTroubleCode.
ECM
EngineControlModule.
Enginespeed
Thecrankshaftrevolutionsperminute.
Freezeframe
AdatasetcapturedatthetimeaDiagnosticTroubleCode (OTC}isset.
Idlefueltrim
Thepercentageaboveorbelowthenominalfuelrequirementfor thevolumeofairenteringatidle.
Idlefueling
Adjustmentoffuelingatidletosuittheactualairinducted.
Idlereferencespeed
The targetidlespeedasdeterminedbytheElectronicControlModule(ECM).(Itshouldbethesameastheactualidlespeedifthemotorcycleisoperatingcorrectly.)
Ignitionadvance
Thetimingofignitionatthesparkplugrelativetotopdeadcentre.
Ignitionswitchposition
The'on'or'off'positionofeitherorboththeignitionswitchandtheenginestopswitch.
Ignitiontiming
Sameas'ignitionadvance'.
Injectorpulsetime
Thetimeduringwhichaninjectorremainsopen(i.e.deliveringfuel).
Longtermfueltrim
Fuelingafteradaptingtotheengine'slongtermfuelingrequirements(closedlooponly).Seealsoshorttermfueltrim.
11.14 ServiceManual
-RocketIll
MAPsensor
Manifoldabsolutepressure(theairpressureintheintakesystem).
MIL
MalfunctionIndicatorLamp.
IlluminateswhenmostDiagnosticTroubleCodes(DTC's)areset.
Neutralswitchstatus
The'neutral'or'ingear'statusofthegearchange.
Offidlefueltrim
Thepercentageaboveorbelowthenominalfuelrequirementforthevolumeofairenteringatenginespeedsotherthanidle.ThisfunctionisnotcurrentlyusedintheTriumphsystem.
Opencircuit
Abreakinanelectricalcircuit-currentcannotflow.
Overtemp
High temperaturewithintheElectronicControlModule(ECM)causedbyaninternalorexternalfailure.
PrimaryThrottlePositionSensor
Sensorfortheprimary(lower)throttleposition.
PrimaryThrottleStepperMotor
Steppermotorusedtovarythrottleopeningatidleand whentheengineisclod.
Purgevalvedutycycle
ThetimethepurgevalveisopeninanopenIclosecycle,expressedasapercentageofthecycletime.
RoadSpeedSensor
GearboxmountedsensorwhichdeliversinformationtotheECMthatisconvertedtotheroadspeedvaluethatisdisplayedonthespeedometer.
SecondThrottlePositionSensor
Sensorforthesecond(upper)throttleposition.
SecondThrottleStepperMotor
Steppermotorusedtovaryallsecondthrottlepositions,onoroffidle.
Sensorreferencevoltage
Supplyvoltagetothesystemsensors(nominally
5volts).
Shortcircuit
A'shortcut'inanelectricalcircuit-currentby-passestheintendedcircuit(usuallytoearth).
Shorttermfueltrim
Acorrectionappliedtothefuelmixtureduringclosedloopcatalystoperation.This,inturnhasaneffectonthelongtermfueltriminthat,ifanengineconstantlyrequiresmixturecorrection,thelongtermfueltrimwilladapttothisrequirementthusreducingtheneedforconstantshorttermadjustment.
Sidestandstatus
The'up'or'down'positionofthesidestand.
Targetdwelltime
Theactualtimefrom coil'on'tocoil'off'.
Throttleposition
Thepositionofthethrottlebutterflygivenasapercentageofthemovementrange.Whenthedataisdisplayedonthetool,fullyopenneednotbe100%norfullyclosed0%.
Throttlevoltage
Voltageatthethrottlepotentiometer.
Vbatt
Batteryvoltage.
- ServiceManual-RocketIll
11.15
EngineManagementSystem
SystemDescription
TheRocketIllisfittedwithanelectronicenginemanagementsystemwhichencompassescontrolofbothignitionandfueldelivery.Theelectroniccontrolmodule(ECM)drawsinformationfromsensorspositionedaroundtheengine,coolingandairintakesystemsandpreciselycalculatesignitionadvanceandfuelingrequirementsforallenginespeedsandloads.
Inaddition,thesystemhasanon-boarddiagnosticfunction.Thisensuresthat, shouldamalfunctionoccurintheenginemanagementsystem,themalfunctiontype,andenginedataatthetimethemalfunctionoccurred,arestoredintheECMmemory.ThisstoreddatacanthenberecoveredusingaspecialservicetoolwhichismandatoryforallTriumphdealers.Inthisway,precisediagnosisofafaultcanbemadeandthefaultquicklyrectified.
SystemSensors
Intakeairtemperaturesensor-situatedatthefrontoftheintakeduct,abovethecamcover.Asthedensityoftheair(andthereforetheamountofoxygenavailabletoignitethefuel)changeswithtemperature,anintakeairtemperaturesensorisfitted.Changesinairtemperature(andthereforeairdensity)arecompensatedforbyadjustingtheamountoffuelinjectedtoalevelconsistentwithcleancombustionandlowemissions.
Barometricpressuresensor-situatedbeneaththemotorcycleseat,inthetopoftheairbox.Thebarometricpressuresensormeasuresatmosphericairpressure.Withthisinformation,theamountoffuelperinjection isadjusted tosuittheprevailingconditions.
ManifoldAbsolutePressure(MAP)sensor-situatedatthefrontoftheintakeduct,abovethecamcover,connectedtoeachofthethreethrottlebodiesbyequallengthtubes.TheMAPsensorprovidesinformationtotheECMwhichisusedatshallowthrottleangles(verysmallthrottleopenings)toprovideaccurateengineloadindicationstotheECM.ThisdegreeofengineloadaccuracyallowstheECMtomakeverysmalladjustmentstofuelandignition whichwouldotheiwisenotbepossiblefromthrottleangledataalone.
Clutchswitch-situatedontheclutchlever.Theclutchmustbepulledinforthestartermotortooperate.
Crankshaftpositionsensor-situatedinthealternatorcover.Thecrankshaftpositionsensordetectsmovementofatoothedwheelattachedtothealternatorrotor.
Thetoothedwheelgivesareferencepointfromwhichtheactualcrankshaftpositioniscalculated.ThecrankshaftpositionsensorinformationisusedbytheECMtodetermineenginespeedandcrankshaftpositioninrelationtothepointwherefuelisinjectedandignitionofthefueloccurs.
Enginecoolanttemperaturesensor-situatedtowardsthe frontof thecylinderhead,onthelefthandside.Coolanttemperatureinformation,receivedbytheECM,is usedtooptimisefuelingatallenginetemperaturesandtocalculatehotandcoldstartfuelingrequirements.
Primarythrottlepositionsensor-situatedattherearofthelowerthrottlespindle.Usedtorelaythrottlepositioninformationto theECM.ThrottleopeningangleisusedbytheECMtodeterminefuelingandignitionrequirementsforallthrottlepositions.
Secondarythrottlepositionsensor-situatedatthefrontoftheupperthrottlespindle.UsedtorelaysecondarythrottlepositioninformationtotheECM.SecondarythrottleangleisusedbytheECMtodeterminesecondary throttleopeningpositionunderallenginerunningconditions.
Roadspeedsensor-situatedinthelowercrankcase,onthelefthandside.TheroadspeedsensorprovidestheECMwithdatafromwhichroadspeediscalculatedanddisplayedonthespeedometer.Avehiclespeedlimitationdevicealsoreceivesinformationfromtheroadspeedsensor.
Lambdasensor-situatedinthe exhaustheadersystemupstreamofthecatalystbox.ThelambdasensorconstantlyfeedsinformationtotheECMonthecontentoftheexhaustgases.Basedonthisinformation,adjustmentstoair/fuelratioaremade.
Sidestandswitch-situatedatthetopofthesidestandleg.Ifthesidestandisinthedownposition,theenginewillnotrununlessthetransmission isinneutral.
