Triumph Bonneville Trophy Tiger 1963-1983 Motorcycle Owners Workshop Manual

Description

This 221 page, Haynes Triumph Bonneville Trophy Tiger 1963 – 1983 Owners Workshop Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1963-1983 Triumph 2-valve Unit Twin motorcycles.

Motorcycles Covered

T6 Thunderbird. 649cc. 1963 – 1966
TR6 Trophy. 649cc. 1963 – 1971
TR6 R Tiger. 649cc. 1970 – 1973
T120 Bonneville. 649cc. 1963 – 1975
TR65 Thunderbird. 649cc. 1982 – 1983
TR65 Trail. 649cc. 1982
T140 V Bonneville. 744cc. 1973 – 1978
T140 V Bonneville Jubilee. 744cc. 1977
T140 E Bonneville. 744cc. 1978 – 1983
TSX 2-valve. 744cc. 1982 – 1983
T140 D Bonneville Special. 744cc. 1979 – 1983
T140 ES Bonneville Electro. 744cc. 1980 – 1983
T140 EX Bonneville Executive. 744cc. 1981 – 1983
T140 LE Bonneville Royal. 744cc. 1981
TR7 V Tiger. 744cc. 1973 – 1978
TR7 Tiger. 744cc. 1978 – 1981
TR7 T Tiger Trail. 744cc. 1981 – 1982

1963 1964 1965 1966 1967 1968 1969
1970 1971 1972 1973 1974 1975 1976 1977 1978 1979
1980 1981 1982 1983

Table of Contents

Acknowledgements
About this manual
Introduction to the Triumph 650 and 750 cc unit construction vertical twins
Guide to machine identification
Ordering spare parts
Routine maintenance
Safety First!
Chapter 1 Engine
Chapter 2 Gearbox
Chapter 3 Clutch and primary transmission
Chapter 4 Fuel system and lubrication
Chapter 5 Ignition system
Chapter 6 Frame and forks
Chapter 7 Wheels, brakes and final drive
Chapter 8 Electrical system
Chapter 9 The 1975 to 1983 models
Wiring diagrams
Metric conversion tables
Conversion factors
English/American terminology
Index

Index of Topics

A
Air cleaner — 83, 85, 181
Alternator — 132, 204, 205
Ammeter — 137
Amplifier — 187
Automatic advance unit — 91

B
Barrel — 20, 33, 38
Battery – 17, 132
Balancing, carburettors — 83, 180
Balancing – wheel — 123
Bearing shells — 31
Bleeding brakes — 118,119
Brakes — 111
Brake adjustment — 123
Brake pedal — 105, 201

C
Capacitor ignition — 137
Calipers — 118
Capacities — 159
Carburettors —50, 78
Centre stand — 102
Cleaning — 109
Clutch plates — 72, 73
Clutch operation — 62, 75, 177
Contact breaker assembly — 24, 37,45,89
Contact breaker adjustment — 88
Contact breaker cam — 24,45
Contact breaker points — 88,89
Conversion factors — 219
Crankshaft — 29
Cylinder head — 22

D
Disc brakes – front and rear — 116, 198 – 201
Dismantling: Clutch – 177 Gearbox — 56, 177
Dual seat — 105

E
Electronic ignition — 186
Engine plates — 23
Exhaust pipes — 18
Exhaust system — 85,183

F
Fairing — 109
Fault diagnosis — 53, 70, 75,86,92,110 and 130
Flashing indicator lamps — 136,137
Flasher unit — 137
Footrests — 18,105
Frame — 102
Frame assembly – oil in frame type — 187
Frame number location — 7, 164 Front forks — 93 – 97, 187, 188 Front wheel — 116etseq, 196 Front wheel assembly -112-115 Front wheel bearings — 119 Fuse location — 137
G
Gearbox — 55 etseq Gearbox components — 62, 177 Gearbox covers — 28, 29, 56 Gearbox removal — 16, 56 Gearchange — 62,177 Generator — 87
H
Headlamp — 132,134 Headlamp dip switch — 137 Horn push — 137 H.T. coils-88,186
I
Ignition coils — 88,186 Ignition cutout — 91 Ignition switch — 137, 207 ignition system — 87 et seq, 186 Ignition timing — 88,89,90,185
K
Kickstarter — 61
L
Lubricants – recommended — 11,163
M
Master cylinder — 117,118, 200 Metric conversion tables — 218
o
Oil filters — 85
Oil pressure release valve — 85 Oil pump — 24,85,183 Oil tank — 105
P
Petrol tank — 17, 78
Petrol tank embellishments — 109
Petrol taps — 78
Pick up — 187
Pistons — 33, 37
Primary chain — 74, 146, 165
Prop stand — 105
Push rods — 18, 47
R
Rear brake pedal – adjustment — 201
Rear suspension units — 102, 106, 193, 194
Rear wheel assembly — 124, 126, 196
Rectifier — 132, 205
Rocker boxes — 18, 47
Routine maintenance — 8 – 9, 164 – 172
s
Security bolt — 128
Shock absorbers – clutch — 74, 1 77
Sidecar alignment – 109
Silencers — 52, 183
Silicon diode rectifier — 132
Sparking plugs and leads — 17, 91, 92
Speedometer — 69, 105, 1 28, 136, 191
Starter motor — 202 – 204
Steering head lock — 109
Steering head races — 97
Stop lamp — 136
Stop lamp switch — 137
Swinging arm fork — 106, 192 Swinging rear arm suspension — 102, 192 Switch – oil pressure — 161
T
Tachometer — 18, 34, 191 Tappets — 34
Telescopic front forks — 98 – 101
Timing cover — 22
Timing marks — 28
Timing pinions — 25
Torque stays — 1 7
Torque wrench settings — 155 – 162
Tyres – 128, 157
Tyre pressures — 9, 111, 160
V
Valves – 32, 33
Valve clearances — 47, 49, 50, 168
w
Warning light console — 207 Wheel balancing — 123 Wiring – 137
Wiring diagrams — 139 et seq, 208 et seq
z
Zener diode — 132, 205, 206