A9900428 - Rearsets, Reverse Shifts_UK EN.fm

English
Fitting Instructions:
Daytona 675
A9750539
Thank you for choosing this Triumph genuine accessory kit. This accessory kit is the product of Triumph's use of proven
engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance.
Completely read all of these instructions before commencing the installation of the accessory kit in order to become
thoroughly familiar with the kit’s features and the installation process.
These instructions should be considered a permanent part of your accessory kit, and should remain with it even if your
accessory-equipped motorcycle is subsequently sold.
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6
5
10
9
4
3
1
11
2
7
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Parts Supplied:
1.
Adapter, M6 to M8 - left hand
thread
1 off
7.
Footrest mounting assembly - right
hand side
1 off
2.
Nut, M8 - left hand thread
1 off
8.
Screw, M6
2 off
3.
Gear selector rod
1 off
9.
Washer, M6
2 off
4.
Footrest mounting assembly - left
hand side
1 off
10. Support, rear brake fluid reservoir
1 off
5.
Heel guard - left hand side
1 off
11.
2 off
6.
Heel guard - right hand side
1 off
Publication part number A9900428 issue 3, ADC 9434
© Triumph Designs Ltd. 2010
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Screw, M5
Left Hand Footrest and Mounting Assembly
Warning
Note:
This accessory kit is for racing only. It is to be used solely
during closed-course racing. A motorcycle fitted with
this accessory kit must not be used on public roads.
•
The ball joint and locknut on the transmission
linkage have a left hand thread. This is
identified by either a machined ring on the
gear selector rod on Daytona 675 or on the
ball joint on Street Triple.
1.
Loosen the locknut at the ball joint on the
transmission linkage.
Warning
This accessory kit is designed for use on
Triumph Daytona 675 and Street Triple motorcycles
only and should not be fitted to any other Triumph
model or to any other manufacturer’s motorcycle. Fitting
this accessory kit to any other Triumph model, or to any
other manufacturer’s motorcycle, may interfere with the
rider and could affect the handling, stability or other
aspects of the motorcycle’s operation which may result
in loss of motorcycle control and an accident.
3
Warning
Always have Triumph approved parts, accessories and
conversions fitted by a trained technician of an
authorised Triumph dealer. The fitment of parts,
accessories and conversions by a technician who is not
of an authorised Triumph dealer may affect the
handling, stability or other aspects of the motorcycle’s
operation which may result in loss of motorcycle control
and an accident.
Warning
1
2
cffi
1. Locknut
2. Machined ring, left hand thread identification
(Daytona 675)
3. Machined ring, left hand thread identification
(Street Triple)
2.
Throughout this operation, ensure that the motorcycle is
stabilised and adequately supported on a paddock stand
to prevent risk of injury from the motorcycle falling.
Remove the wire clip retaining the ball joint to the
gear change lever and detach the ball joint. Retain
the wire clip if the motorcycle is to be returned to its
original condition.
Warning
1
A torque wrench of known accurate calibration must be
used when fitting this accessory kit. Failure to tighten
any of the fasteners to the correct torque specification
may affect motorcycle performance, handling and
stability. This may result in loss of motorcycle control and
an accident.
2
Note:
•
Before fitting this accessory kit, ensure the
owner of the motorcycle has been informed of
the warnings contained in these instructions.
1. Wire clip
2. Ball joint
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3.
Remove the two screws and the left hand footrest
mounting assembly. Retain the screws for re-use.
1
6.
Fit the new footrest mounting assembly and tighten
the original screws to 27 Nm.
1
2
2
cfes
cfet1
1. Screws
2. Footrest mounting assembly
1. Footrest mounting assembly
2. Original screws
7.
Caution
It may be difficult to remove the original ball joint from
the gear selector rod. Do not use excessive force. If
necessary, apply a releasing oil to the ball joint threads
to aid removal.
The footrest position can be adjusted to the rider’s
preferred position. To adjust the footrest position,
remove the two screws and the footrest plate.
Recover the spacer from behind the footrest plate.
3
Note:
•
The ball joint on the transmission linkage has a
left hand thread.
4.
Unscrew the gear selector rod from the transmission
linkage ball joint.
2
1
cfet
1. Screws
2. Footrest plate
3. Spacer
1
2
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1. Ball joint
2. Gear selector rod
5.
Retain the gear selector rod and footrest mounting
assembly if the motorcycle is to be returned to its
original condition.
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8.
The illustration below shows the nine possible
positions for the lower screw securing the footrest
plate. The remaining holes are for the upper screw.
12. When the footrest position has been established, the
distance between the ball joint housing on the gear
change pedal and the locknut for the adapter must
be checked and, if necessary, adjusted.
1
4
3
1 2 3
A
B
C
2
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Possible Positions for the Lower Screw
Note:
•
9.
To ensure the right hand footrest plate is
positioned at the same height as the left hand
footrest plate, make a note of which hole is
used for the lower screw, for example C1.
Refit the footrest plate and spacer and secure with
the two screws, ensuring the lower screw is in one of
the nine holes shown previously.
1.
2.
3.
4.
13. The table below shows the distance between the ball
joint housing and the locknut in relation to the hole
used by the lower screw securing the footrest plate.
2
1
cfet_2
1. Screw
2. Footrest plate
10. Check to see if the footrest is in the preferred
position for the rider.
11.
Ball joint housing
Locknut
Adapter
Distance to be measured
Repeat steps 7 to 10 until the footrest is at the
preferred position for the rider. Tighten the screws to
27 Nm.
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Lower screw position
Distance
A1
12.5 mm
A2
12.5 mm
A3
12.5 mm
B1
6.5 mm
B2
6.5 mm
B3
6.5 mm
C1
0.5 mm
C2
0.5 mm
C3
0.5 mm
14. To check and adjust the ball joint housing to adapter
locknut distance, remove the footrest and mounting
assembly.
19. Move the locknut along the gear change pedal
adapter until 5 mm of thread is exposed above the
nut.
5 mm
1
1
2
cfet1
cfeq
1. Footrest and mounting assembly
2. Screws
1. Locknut
15. Refer to the table above for the correct ball joint
housing to adapter locknut distance.
16. With the locknut tightened against the adapter,
measure the distance between the ball joint housing
and the locknut, as shown below.
20. The new gear selector rod has a right hand thread at
the smaller (10 mm outside diameter) end, and a left
hand thread at the larger (12 mm outside diameter)
end (adjacent to the spanner flats), as shown below.
2
1
3
1
4
3
4
2
1.
2.
3.
4.
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1.
2.
3.
4.
Ball joint housing
Locknut
Adapter
Distance to be measured
21.
Note:
•
17.
The adjustment of the adapter must be made
by complete turns. This will ensure that the
adapter will point to the front of the
motorcycle when fitted.
To adjust, loosen the locknut and turn the adapter
clockwise to decrease or anti-clockwise to increase
the rod length.
Gear selector rod
Left hand threaded end
Right hand thread end
Spanner flats
Screw the right hand threaded end of the new gear
selector rod on to the adapter and adjust up to the
locknut. Then move the locknut away from the rod
to allow for adjustment.
Note:
•
The ball joint on the transmission linkage and
the M6 to M8 adapter both have a left hand
thread.
22. Fit the M8 locknut, left hand thread, onto the
adapter.
18. Tighten the locknut to 6 Nm and check the distance.
Adjust if necessary.
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23. Attach the M6 to M8 adapter to the transmission
linkage ball joint and tighten to 9 Nm.
26. Refit the footrest and mounting assembly. Tighten
the screws to 27 Nm.
1
1
2
cfev
1.
2.
3.
4.
3
4
cfet2
Transmission linkage
Ball joint
M6 to M8 adapter
Locknut
1. Screws
Note:
•
24. Position the gear selector rod through the motorcycle
frame and attach it to the adapter.
When the top edge of the gear change pedal is
5 mm above the radius curve of the footrest
plate, the pedal is at the standard factory
setting.
27. Using the measurement of 5 mm as a guide, turn
the gear selector rod until the desired angle of the
gear change pedal is achieved.
1
2
3
5 mm
1
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2
1. Adapter
2. Gear selector rod
25. Turn the gear selector rod until it is approximately
halfway along the adapter.
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1. Footrest plate
2. Gear change pedal
3. Distance to be measured
28. Tighten the locknuts on both ends of the gear
selector rod to 6 Nm.
29. Recheck the torque of the ball joint locknut and both
adapters after adjustment of the gear selector rod is
completed.
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30. Fit the supplied left hand heel guard to the footrest
plate with the supplied M5 screws. Apply
ThreeBond 1305 to the screw threads and tighten to
6 Nm.
2.
Remove the clip from the brake pedal clevis pin.
Remove the clevis pin.
1
2
1
2
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1. Clip
2. Clevis pin
cfet3
1. Left hand heel guard
2. Screws
31.
3.
Operate the gear change pedal throughout the gear
range to ensure there is clearance between the
frame and the gear selector rod. If necessary, repeat
steps 13 to 29 to obtain the clearance.
Remove the screws securing the rear brake master
cylinder and heel guard to the footrest mounting.
Retain the screws for re-use.
Note:
•
Should the rider require the footrest position to
be changed, repeat steps 7 to 31.
3
Right Hand Footrest and Mounting Assembly
1.
2
Loosen the locknut on the rear master cylinder push
rod.
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1
1. Screws
2. Heel guard
3. Rear brake master cylinder
cfew1
1. Locknut
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1
4.
Remove the clevis and position the master cylinder
aside.
All Models
7.
Remove the screws and the right hand footrest
mounting. Retain the screws for re-use.
1
1
2
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1. Clevis
cfez
1. Footrest mounting
2. Screws
Street Triple - with the Arrow Race Exhaust
System 3:1
Caution
8.
Detach the brake light switch spring from the brake
pedal. Retain the spring for re-use.
9.
Release the three clips and detach the rear brake
light switch from the footrest mounting. Retain the
brake light switch for re-use.
To prevent damage to the Arrow exhaust system,
support the exhaust silencer before removing the right
hand footrest mounting screws.
5.
Support the exhaust silencer.
6.
Note the position of the Arrow silencer support
bracket.
1
2
2
3
cffa
4A
1. Rear brake light switch
2. Clips
3. Spring
10. Retain the following if the motorcycle is to be
returned to its original condition:
1. Arrow silencer support bracket
2. Right hand footrest mounting
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•
Clevis;
•
Clevis pin;
•
Clevis pin clip;
•
Footrest mounting;
•
Heel guard.
11.
Attach the new ball joint on the brake pedal to the
push rod.
13. To adjust the footrest position, remove the two
screws and the footrest plate.
2
2
1
1
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1. Brake pedal ball joint
2. Push rod
1. Screws
2. Footrest plate
Note:
14. The illustration below shows the nine possible
positions for the footrest plate lower screw. The
remaining holes are for the footrest plate upper
screw.
•
For motorcycles with the Arrow race exhaust
system 3:1, ensure that the Arrow silencer
support bracket is fitted as noted for removal.
12. Attach the new right hand footrest assembly to the
frame and tighten the original screws to 27 Nm.
2
1
A
B
C
3 2 1
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Possible Positions for the Footrest Plate
Lower Screw
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15. Refit the footrest plate and secure with the two
screws, ensuring the lower screw is in the same hole
location as the left hand footrest plate, for
example C1. Tighten the screws to 27 Nm.
1. Screws
2. Right hand footrest assembly
Caution
Both left hand and right hand footrest plates must be
adjusted to the same position.
Street Triple - with the Arrow Race Exhaust
System 3:1
16. Remove the support for the exhaust silencer fitted
earlier.
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All Models
17.
20. Fit the rear brake light switch.
Fit the brake master cylinder and supplied heel
guard to the footrest plate with the existing
M8 screws. Tighten the screws to 18 Nm.
1
1
cfer
1. Rear brake light switch
21.
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Fit the spring to the rear brake light switch and rear
brake pedal.
1. Screws
Caution
The brake pedal angle must be set to the standard
factory setting to ensure the correct position for the
brake switch operation.
18. Turn the push rod top nut until the top of the brake
pedal is 19.5 mm away from the footrest plate.
1
19. Tighten the locknut against the ball joint to 17 Nm.
cffe
1
1. Spring
3
Caution
4
19.5 mm
With the footrest plate lower screw in any of the nine
positions, the brake fluid reservoir to master cylinder
hose could be touching other components causing
damage to the hose.
2
cffd3
1.
2.
3.
4.
Push rod top nut
Brake pedal
Locknut
Distance to be measured
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22. Check that the rear brake reservoir hose is not
twisted or is touching any other components.
25. Fit the support bracket provided to the frame with
the M6 washer and screw provided. Ensure the
bracket is fitted as shown in the lower illustration
below. Do not tighten the screw at this stage.
1
1
2
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2
4
1
3
1.
2.
3.
4.
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2
2
Support bracket
Screw
Rear brake fluid reservoir
Frame lug
26. Attach the rear brake fluid reservoir to the support
bracket with the M6 washer and screw provided. Do
not tighten the screw at this stage.
1. Correct routing
2. Incorrect routing
Caution
To prevent paint damage, do not spill brake fluid onto
any area of the bodywork. Spilled brake fluid will
damage paintwork.
1
23. Check the brake reservoir hose to exhaust
intermediate pipe clearance. The clearance must be
a minimum of 20 mm. If the clearance is less than
20 mm, fit the supplied support bracket between the
frame and the rear brake fluid reservoir as follows:
24. Detach the brake fluid reservoir from the frame.
Taking care not to invert the brake fluid reservoir, lay
it to one side.
Note:
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•
1. Screw
Discard the screw after removal. If the
motorcycle is to be returned to its original
condition, install a new screw.
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Replacing Components
Warning
The rear brake fluid reservoir and hose must be at least
20 mm from the exhaust pipe. The heat from the
exhaust pipe may cause damage to the reservoir and
hose resulting in loss of brake fluid, loss of motorcycle
control and an accident.
27. Position the rear brake fluid reservoir so that the
reservoir hose is clear from obstruction and the
reservoir has a minimum distance of 20 mm from
the exhaust pipe. Tighten the two screws to 7 Nm.
Refer to the following illustrations for torque figures and
for which fixings require Loctite 243.
Warning
When replacing components on this accessory kit, some
of the fixings are required to have Loctite 243 added to
their threads. This is to ensure that these fixings remain
secure at their specified tightening torque.
Failure to use Loctite 243 may result in component
detachment leading to loss of motorcycle control and an
accident.
1
20 mm
2
cffg
1. Screws
2. Minimum distance from the exhaust pipe
Warning
It is dangerous to operate the motorcycle with defective
brakes; you must have your authorised Triumph dealer
take remedial action before you attempt to ride the
motorcycle again. Failure to take remedial action may
reduce braking efficiency leading to loss of motorcycle
control and an accident.
28. Check for correct brake and brake light operation.
Rectify as necessary.
Note:
•
Should the rider require the footrest position to
be changed, remove the heel guard and repeat
steps 13 to 23.
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Left Hand Footrest and Mounting Assembly
13 Nm
20 Nm
7 Nm
Apply Loctite 243 to
the threads
9 Nm
Apply Loctite 243 to
the threads
Apply Loctite 243 to
the threads
9 Nm
Right Hand Footrest and Mounting Assembly
Apply Loctite 243 to
the threads
20 Nm
3 Nm
7 Nm
4 Nm
9 Nm
13 of 14
Apply Loctite 243 to
the threads
Warning
Warning
After fitting the accessory kit the motorcycle will exhibit
new handling characteristics. Operate the motorcycle in
a safe area free from traffic to gain familiarity with any
new characteristics. Operation of the motorcycle when
not familiar with any new handling characteristics may
result in loss of motorcycle control and an accident.
Warning
If, after fitment of this accessory kit, you have any doubt
about the performance of any aspect of the motorcycle,
contact an authorised Triumph dealer and do not ride
the motorcycle until the authorised dealer has declared
it fit for use. Riding a motorcycle when there is any
doubt as to any aspect of the performance of the
motorcycle may result in loss of control of the
motorcycle leading to an accident.
This motorcycle must not be operated above the legal
road speed limit except in authorised closed course
conditions.
Warning
Only operate this Triumph motorcycle at high speed in
closed-course on road competition or on closed course
racetracks. High speed operation should only be
attempted by riders who have been instructed in the
techniques necessary for high speed riding and are
familiar with the motorcycle’s characteristics in all
conditions.
High speed operation in any other circumstances is
dangerous and will lead to loss of motorcycle control
and an accident.
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