Triumph Daytona 675 Bedienungsanleitung

Daytona 675 Motorcycle

Race Kit Manual

FOR CLOSED-CIRCUIT USE ONLY

Page 2 of 33

Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Engine Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Head Gasket

0.65 mm - A9618072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

0.60 mm - A9618073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cams, Valve Spring & Sprocket Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cam - Inlet Kit - A9618055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cam - Exhaust Kit - A9618056. . . . . . . . . . . . . . . . . . . . . . . . . . 9

Valve Spring Kit - A9618086 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Camshaft Sprocket Kit - A9618057. . . . . . . . . . . . . . . . . . . . . . . 9

Cam Chain Kit - A9618059 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cam Chain Tensioner Kit (manually adjustable) - A9618060 . . . . . . . . 12

Inlet & Exhaust Valve Kit - A9618061 . . . . . . . . . . . . . . . . . . . . . . . . 14

Conrod Bearing Shell

1.476 mm to 1.482 mm White - A110411 . . . . . . . . . . . . . . . . . 15

1.482 mm to 1.488 mm Red - A110412 . . . . . . . . . . . . . . . . . . 15

Main Bearing Shell

1.491 mm to 1.495 mm White - A1161301 . . . . . . . . . . . . . . . . 16

1.495 mm to 1.499 mm Red - A1161302 . . . . . . . . . . . . . . . . . 16

1.499 mm to 1.503 mm Blue - A1161303 . . . . . . . . . . . . . . . . . 16

1.503 mm to 1.507 mm Green - A1161304 . . . . . . . . . . . . . . . . 16

Air Funnel Kit - A9618063 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Exhaust System, Stage 2 (Arrow) - A9600197. . . . . . . . . . . . . . . . . . 19

Air Filter Kit - A9618075 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Slipper Clutch Kit - A9610014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Slipper Clutch Tool - A3880037 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Transmission Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1st Gear pair & Housing Kit - A9618066. . . . . . . . . . . . . . . . . 24

Shaft, Input Kit - A9618064 (spares only) . . . . . . . . . . . . . . . 25

Gear, Output Kit - A9618065 (spares only) . . . . . . . . . . . . . . 25

Wheel Detent Kit - A9618068 (spares only) . . . . . . . . . . . . . . 25

Alternator Kit - A9618069 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Alternator Puller Tool Kit - A3880206 . . . . . . . . . . . . . . . . . . . . . . . . 27

Manual Idle Speed Adjuster Kit - A9618076 . . . . . . . . . . . . . . . . . . . 29

Race ECU Kit - A9618070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Race Harness Kit - A9618071 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Page 3 of 33

Motorcycle Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Engine Protector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Clutch Cover, Carbon Fibre Kit - A9728028 . . . . . . . . . . . . . . . . 33

Crank Cover, Carbon Fibre Kit - A9728029 . . . . . . . . . . . . . . . . 33

Standard Alternator Cover, Carbon Fibre Kit - A9728031 . . . . . . 33

Race Alternator Cover, Carbon Fibre Kit - A9728032 . . . . . . . . . 33

Page 4 of 33

Introduction

Daytona 675 Race Parts

Triumph's ground-breaking Daytona 675 has not only received global recognition for its

performance on the road, but also for its outstanding ability on the race track. To further

support this exceptional track ability, Triumph have launched a Racing Support Programme,

which is now further complemented by the launch of a range of Triumph Genuine Race Parts.

Factory developed in collaboration with Paul Young Racing, these parts have been designed

to give significant improvements in engine performance for race purposes. This results in

the class-leading Daytona 675 being competitive on the racetrack at the highest level.

Triumph Genuine Race Parts are sold individually and a number of the parts need to be used

in conjunction with each other to ensure the best performance gains are realised and also

to prevent premature wear on associated components. Please ensure you read the user

manual in full to understand this detail prior to fitting or using any of the Triumph Genuine

Race Parts.

Page 5 of 33

General Information

Please note:

• The Race Kit parts detailed in this publication are made in accordance with FIM

technical regulations and are NOT street legal.

• The Race Kit parts covered in this publication are intended for racing purposes only and

any Triumph motorcycle fitted with such kits MUST NOT be used on public roads.

• The Race Kit parts detailed in this publication may only be used on a closed-circuit in

the hands of experienced riders.

• Before fitting any Race Kit parts, customers should check the technical regulations of

their race class to ensure conformity.

• The information provided in this publication should always be used together with the

official Triumph Daytona 675 service manual.

• Completely read all the instructions before commencing the installation and set up of

the race kit in order to become thoroughly familiar with the kits’ features and the

installation process.

• When removing components which incorporate a gasket ALWAYS ensure a new gasket

is fitted on re-assembly.

• The race kit parts detailed in this publication are not covered by any warranty.

• Prices and specifications are subject to change without notice.

• The information contained in this publication is accurate at the time of final approval,

however, Triumph Motorcycles reserves the right to amend the information at any time

without notice.

Warnings, Cautions and Notes.

Throughout this publication particularly important information is presented in the following

form:

NOTE

• This note symbol indicates points of particular interest for more efficient and

convenient operation.

Warning

This warning symbol identifies special instructions or procedures, which if not correctly

followed could result in personal injury, or loss of life.

Caution

This caution symbol identifies special instructions or procedures, which if not strictly

observed, could result in damage to, or destruction of, equipment.

Page 6 of 33

Warning

These accessory kits are for racing only. They are for use solely during closed-course

racing. A motorcycle fitted with these kits must not be used on public roads. It is illegal to

use a motorcycle fitted with these kits on public roads. A motorcycle fitted with these kits

does not comply with local laws and regulations. If you use a motorcycle fitted with these

kits on public roads, you may be prosecuted.

Warning

These accessory kits are designed for use on Triumph Daytona 675 motorcycles only and

should not be fitted to any other Triumph model or to any other manufacturer’s

motorcycle. Fitting these accessory kits to any other Triumph model, or to any other

manufacturer’s motorcycle, will affect the performance, stability and handling of the

motorcycle. This may affect the riders ability to control the motorcycle and could cause an

accident.

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 motorcycles operation which may result in loss

of motorcycle control and an accident.

Warning

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.

Warning

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.

Warning

If the engine has recently been running, the exhaust system will be hot. Before working

on or near the exhaust system, allow sufficient time for the system to cool, as touching

any part of a hot exhaust could cause burn injuries.

Caution

The use of some of these kits will require changes to the fuelling settings. To alter the

fuelling settings a third party programmable control unit will be required.

Page 7 of 33

Head Gasket

* Thickness “t” marking location

Parts Supplied - A9618072 (0.65 mm) or A9618073 (0.60 mm)

• The thickness of the standard cylinder head gasket is 0.7 mm. The Race Kit

gaskets are available in 0.60 mm and 0.65 mm thicknesses. The thickness (t)

of the gasket is clearly marked on the gasket in the position (*) shown above.

NOTE

• Due to variation in production tolerances, the race kit cylinder head gaskets

may not be suitable for all engines. Use the appropriate gasket to adjust the

squish height (the squish height is the gap between the flat portion of the

piston and the cylinder head). Always ensure that the chosen gasket provides

a minimum squish height of 0.65 mm.

Caution

The use of the following race kit cylinder head gaskets will require changes to the fuelling

settings. To alter fuelling settings a third party programmable control unit will be

required.

Item Description Qty

1 Head gasket (t = 0.65 mm) 1

1 Head gasket (t = 0.60 mm) 1

Warning

Running the engine at less than the minimum recommended squish height can lead to the

pistons contacting the cylinder head, causing major engine damage.

Page 8 of 33

1. Remove the existing cylinder head

gasket in line with the procedures

detailed in the Daytona 675 service

manual.

2. Position a piece of solder (with a

diameter approximately 1.3 mm) on

the four squish surfaces of each piston.

Position the solder in line with the

corresponding squish surfaces on the

cylinder head and hold in place with a

small amount of grease.

3. Refit the cylinder head with the head

gasket.

4. Slowly turn the engine over, by hand,

to compress the solder to the same

height as the squish clearance.

5. Remove the cylinder head and head

gasket.

6. Measure the compressed thickness of

the solder. The squish clearance must

be a minimum of 0.65 mm. If the

thickness of the solder is less than

0.65 mm repeat steps 2 to 6 with a

thicker head gasket until the squish

clearance is at an acceptable level.

Note, a race gasket is not always

suitable for use.

7. Fit the chosen cylinder head gasket

following the procedures detailed in the

Daytona 675 service manual.

Page 9 of 33

Camshaft, Valve Spring & Sprocket Kits

Parts Supplied

Camshaft Inlet Kit - A9618055

Camshaft Exhaust Kit - A9618056

Valve Spring Kit - A9618086

Camshaft Sprocket Kit - A9618057

Warning

The race kit must be fitted as a complete set. If it is not fitted as a complete set a failure

may result which could cause loss of motorcycle control and an accident.

Caution

The use of the camshaft, valve spring & sprocket race kits detailed below will require

changes to the fuelling settings. To alter fuelling settings a third party programmable

control unit will be required.

Item Description Qty

1 Cam assy, inlet, race 1

Item Description Qty

2 Cam assy, exhaust, race 1

Item Description Qty

3 Valve spring, 14.4 id, race 12

Item Description Qty

4 Sprocket, camshaft, 34T 2

Socket head cap screw,

encapsulated, M6 x 10

Page 10 of 33

NOTE

• The standard inlet cam is 9.25 mm max lift and 258.50oduration. The race kit

inlet cam is 9.25 mm max lift and 268.74oduration.

• The standard exhaust cam is 8.5 mm max lift and 246oduration. The race kit

exhaust cam is 8.5 mm max lift and 262.21oduration.

• The race kit valve spring must be used in conjunction with the standard

spring platforms and retainers. The fitted length of the race springs is the

same as the standard spring.

1. The race kit valve springs should be

assembled in the same manner as the

standard valve springs. Follow the

procedure detailed in section 3 of the

Daytona 675 service manual. Ensure

the springs are installed with the close

wound, colour coded end of the springs

facing downwards, towards the piston.

2. The race kit camshafts should be

assembled in the same manner as the

standard camshafts. Follow the

procedure detailed in section 3 of the

Daytona 675 service manual.

3. The race kit cam sprockets should be

mounted and secured to the camshafts

using the slotted holes in the sprocket.

The slotted holes allow adjustment of

the valve timing. The circular holes in

the sprockets are for Triumph service

tool T3880102 and should not be used

to mount the sprockets to the

camshafts.

NOTE

• No timing marks are included on

the race sprockets. Race engines

will typically have different depths

skimmed off the cylinder head and,

therefore require specific

individual timing.

4. The camshafts should be timed using

cam degreeing equipment which

typically consists of a degree wheel,

pointer, dial indicator and piston stop.

Optimum cam timing will depend on the

exact specification of the engine, but a

recommended starting point is 104o

IMOP (Inlet Maximum Opening Point)

and 104oEMOP (Exhaust Maximum

Opening Point).

5. Always check the inlet and exhaust

piston to valve clearance for the timing

selected to use, before running the

engine. You must ensure both

clearances are adequate. As a guide,

the standard nominal piston to valve

clearance is 1.3 mm inlet & 1.5 mm

exhaust.

6. When the desired timing has been set

the new socket retaining screws

provided should be tightened to

15 Nm. Note, if the screws are

released for any reason, apply

ThreeBond 1305 to the threads before

re-tightening.

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