2009 Daytona 675 (VIN 381275>) Motorcycle Race Kit Manual
Contents
1. 17 Induction amp Exhaust Air Funnel Kit 9618090 19 SAI Blanking Kit 9618094 21 Exhaust System Race Arrow A9600351 23 Air Filter Kit 9 618075 27 Manual Idle Speed Adjuster Kit A9618076 28 Transmission Slipper Clutch Tool A3880037 ern 29 Slipper Clutch Kit A9610014 29 Detent Wheel Kit 9618068 30 Triumph Designs Ltd 2009 Page 2 of 47 Electrical Parts c ee Race Alternator Kit A9618069 Alternator Puller Tool A3880206 Programmable Race ECU A9618098 Race Calibration Software TRACS A9610051 TRACS Management Kit A9618099 Race Harness Kit A9618100 Quickshifter Race Standard Shift A9930224 Quickshifter Race Reverse Shift A9930225 Chassis PartS 0 00000 cee eee eee Rearsets Race Reverse Shift A9750536 Rearsets Race Standard Shift A9750539 Carbon Fibre Engine Cover Protectors Clutch Cover Protector Carbon Fibre A9728028 Crank Cover Protector Carbon Fibre A9728029 Standard Alternator Cover Protector Carbon Fibre A9728031 Race Alternator Cover Protector Carbon Fibre A9728032 Triumph Designs Ltd 2009 Page 3 of 47 IUMP I ntro2. Page 44 of 47 IUMP Rearsets Race Reverse shift Arrow dt 4 f UG Jf 7 Parts supplied A9750536 Item Description Qty 1 Adaptor M6 to M8 left hand thread 1 2 Nut M8 left hand thread 1 3 Gear selector rod 1 4 Nut M8 right hand thread 1 5 Gear lever assembly 1 6 Mounting spacer 1 7 Bearing cap 1 8 Screw M8 1 9 Footrest mounting assembly left hand side 1 10 Heel guard left hand side 1 11 Screw M5 2 12 Heel guard right hand side 1 13 Footrest mounting assembly right hand side 1 14 Screw M6 2 15 Washer M6 2 16 Support rear brake fluid reservoir 1 For fitment refer to the comprehensive fitting instructions supplied with the rearset kit Triumph Designs Ltd 2009 Page 45 of 47 IUMP Rearsets Race Standard Shift Arrow cfeo Parts supplied A9750539 Item Description Qty Adaptor M6 to M8 left hand thread Nut M8 left hand thread Gear selector rod Footrest mounting assembly left hand side Heel guard left hand side Heel guard right hand side Footrest mounting assembly right hand side Screw M6 MW AJ WY N e Washer M6 m e Support rear brake fluid reservoir NI PI NIN 11 Screw M5 NOTE For fitment refer to the comprehensive fitting instructions supplied with the rears
3. 1 Downpipe 2 Spring 3 Spring mounting hole position 8 Loosely secure the assembly to the outside of the original exhaust mounting point using the original bolt and M8 locknut provided as shown 1 Exhaust mounting point 2 Original bolt Triumph Designs Ltd 2009 9 Insert the end of the intermediate pipe into the collector pipe Secure with the spring provided 1 Intermediate pipe 2 Spring 10 Attach the M8 captive nut provided to the intermediate pipe fixing point Loosely secure the intermediate pipe to the exhaust mounting point using the original bolt as shown AR 1 N 1 Intermediate pipe 2 Original bolt Page 25 of 47 IUMP 11 Fit the silencer to the intermediate pipe 13 If fitting the oxygen sensor remove the and secure with the spring provided threaded blanking plug from the race Loosely secure the silencer bracket exhaust Fit the oxygen sensor and clamp to the silencer mounting point tighten to 25 Nm using the original fixings 14 Fit the correct specification spark plugs as recommended below NOTE Triumph recommends two options of spark plug Choose the correct option depending on the engine compression ratio For a standard compression ratio use NGK CRIOEIX For high compression ratio engines use NGK R0373A 10 Always ensure there is sufficient clearance between spark plug and piston before attempting to start the engine 1 Silencer 2 Intermediate
4. Lower the new tensioner blade provided Do not start the motorcycle engine with into the camshaft drive chain chest the tensioner removed If the motorcycle from the top Locate in position with the engine is started with the tensioner original pin removed it could result in engine damage 5 Refit the camshafts following the Do not start the motorcycle engine with the tensioner removed Remove the camshafts following the procedure detailed in the Daytona 675 service manual Triumph Designs Ltd 2009 procedure detailed in the Daytona 675 service manual Page 12 of 47 IUMP 6 Thoroughly clean the tensioner mounting surface on the cylinder head 7 Back off the plunger locknut on the new tensioner assembly before installation 1 Plunger locknut 8 Lightly coat the two large O rings with oil and fit a new gasket 9 Install the new tensioner assembly and secure with the original fixings 10 Tighten the tensioner fixings to a torque value of 9 Nm 11 Finger tighten the plunger on the new tensioner while turning the crankshaft by hand At certain points during engine rotation you will feel the plunger tighten as it takes up the slack in the camshaft drive chain DO NOT force the plunger continue steady finger tightening only to take up the slack in the chain as you rotate the crankshaft 1 MUN 1 Plunger 2 Plunger locknut Triumph Designs Ltd 2009 12 When the slack in the camshaf
5. same material and have the same mass as the standard valves Remove the existing inlet and exhaust valves following the procedure detailed in section 3 of the Daytona 675 service manual The valve seat widths on the Race Kit valves are narrower than the standard valves therefore the bottom angle 1409 inlet 160 exhaust of the cylinder head valve seats must be modified to ensure the seat on the head matches the seat on the valve Triumph Designs Ltd 2009 3 Check the head seat and valve seat are matched correctly by applying a small amount of engineer s blue to the valve seat assembling the valve to the cylinder head and rotating the valve through 360 When the correct match of head seat and valve seat have been confirmed assemble the race inlet and exhaust valves following the procedure detailed in section 3 of the Daytona 675 service manual Page 14 of 47 IUMP Conrod Bearing Shell Parts supplied A1110411 Item Description Thickness Colour Qty 1 Conrod bearing shell race 1 476 mm to 1 482 mm White 1 Parts supplied A1110412 Item Description Thickness Colour Qty 1 Conrod bearing shell race 1 482 mm to 1 488 mm Red 1 Connecting rod bolts MUST only be used once If the bolts are removed or undone for any reason new bolts MUST always be used Re using bolts can cause connecting rods and their caps to detach from the crankshaft
6. 70 Vehicle speed sensor 67 Main relay Continuous Harness or instruments Short Flash Triumph Designs Ltd 2009 Page 37 of 47 IUMP Triumph Race Calibration Software TRACS Parts supplied A9610051 Item Description Qty 1 TRACS software CD 1 2 Diagnostic plug connector 1 3 USB lead 1 NOTE TRACS is a computer program which allows all Triumph Daytona 675 Programmable Race ECUs to be tuned using a laptop computer The TRACS software is supplied with a diagnostic plug connector and a USB lead to allow connection to the ECU using the dedicated diagnostic plug on the motorcycle Features include Fully programmable fuel mapping Fully programmable ignition mapping Switchable wet and dry ignition maps Adjustable pit lane speed limiter and speedometer calibration Adjustable Quickshifter cut duration Adjustable rev limiter up to 15 000 rpm Improved software strategies to improve throttle progression Optimised software to cater for higher engine speeds involved in a race environment Unlimited ability to save multiple maps on a PC s hard drive TRACS is compatible with Windows XP Service Pack 2 and above and Vista operating systems only Minimum system requirements 200MHz or higher Pentium compatible CPU 64 MB RAM 300 MB hard drive space TRACS software is suitable for use with Triumph Programmable Race ECU A9618098 marked Part 1290676 and T
7. SN CD RD gt ES IEA SN CN zl ANN 5 Fit a new seal to the camshaft cover Refit the camshaft cover and secure with the original fixings 6 Fit the reed valve covers from the kit as shown below Secure with the M6 x 16 mm bolts provided Tighten to 9 Nm 2 A 3 1 KS 2 rin Ser IVA E f e ul Y AC 0 2107 LO m 27 1 Reed valve cover single 2 Reed valve cover double 3 Bolt M6 x 16 mm 7 Refit the airbox Triumph Designs Ltd 2009 8 Fit the sealing cap provided over the airbox hose connection below as shown 1 Sealing cap Page 22 of 47 IUMP Exhaust System Race Arrow The use of the Arrow Race Exhaust System will require changes to the fuelling and ignition settings To alter these settings a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Parts supplied A9600351 Item Description Qty Downpipe collector assy ntermediate pipe Silencer Spring Primary header bushing Primary header flange Captive nut M8 Locknut M8 nie On nmjujluju m m nmn Capscrew M8 Triumph Designs Ltd 2009 Page 23 of 47 IUMP 1 Remove the seat battery rear bo
8. cause loss of motorcycle control and an accident 1 Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual 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 Refit the cylinder head with the head gasket Slowly turn the engine over by hand to compress the solder to the same height as the squish clearance Triumph Designs Ltd 2009 Page 9 of 47 5 Remove the cylinder head and head gasket 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 some cases it may be necessary to use a standard cylinder head gasket to achieve the correct squish clearance Fit the chosen cylinder head gasket following the procedures detailed in the Daytona 675 service manual IUMP Camshaft Valve Spring amp Camshaft Sprocket Kits The Race Kit camshaft valve Spring and camshaft sprockets must be fitted as a complete set If they are not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident The u
9. for reuse Triumph Designs Ltd 2009 Page 40 of 47 IUMP 1 Remove the regulator from the original Secure the regulator bracket to the bracket retain the bolts for reuse motorcycle frame using the M6 x 25 Discard the bracket and locknuts mm bolts provided Tighten the fixings to 12 Nm 2 Securethe regulator unit 7 to the new regulator bracket provided 4 using the original bolts 8 and M6 locknuts provided 6 Tighten the fixings to 12 Nm M Q 8 b 0 0 2 0 1 Frame 2 Regulator bracket 3 Bolts M6 x 25 mm NOTE The alternator will now plug directly into the regulator The relay and fuse box position has changed on the race harness for ease of access and maintenance They are now located alongside the battery under the seat Ensure they are secured in position so they do not suffer from vibration problems The Race Harness does not support all of the original equipment therefore the following components can be removed from the motorcycle oxygen sensor exhaust valve idle speed control secondary air injection SAI purge control valve and evaporative canister California only lights and air intake flap solenoid The SAI ports must be blocked off with SAI Blanking Kit A9618094 if the system is removed The throttle body purge ports must also be blocked of before use California only The Race Harness still supports the cooling fan and incorporates a relay for the fan You m
10. of 47 IUMP Manual Idle Speed Adjuster Kit Parts supplied A9618076 Item Description Qty 1 Screw manual adjuster 1 2 Spring compression coil 1 1 Remove the throttle body assembly following the procedure detailed in the Daytona 675 service manual 2 Remove item 3 M5 nut and item 4 throttle stop screw from the throttle body assembly 3 Fit the manual adjuster screw and compression spring supplied items 1 amp 2 Triumph Designs Ltd 2009 Refit the throttle body assembly following the procedure detailed in the Daytona 675 service manual Adjust the idle speed using the manual adjuster screw item 1 as required Page 28 of 47 IUMP Slipper Clutch Kit A9610014 The Slipper Clutch Kit is supplied by STM Trading s r l For fitment details refer to the instruction contained in the kit If you have any queries with regard to the slipper clutch kit in the first instance contact STM For contact details see www slipperclutch com Slipper Clutch Tool A3880037 It is recommended to use the Slipper Clutch Tool when fitting the Slipper Clutch Triumph Designs Ltd 2009 Page 29 of 47 Detent Wheel Kit Parts supplied A9618068 Item Description Qty 1 Detent wheel 1 2 Screw Torx head M6 x 20 black 1 2 Release the two fixings and remove the 1 Remove the clutch as described in baffle plate from the crankcase section 5 of the D
11. the Race Kit ECU new adjustable camshaft sprockets manually adjustable cam chain tensioner amp guide blade racing oil pump gearing kit plug and play quick shifter lightweight racing harnesses revised air funnel kit and the new Arrow full titanium racing exhaust system The Triumph Race Kit means the Daytona 675 will be competitive on the track at all levels from club to world championship Triumph Designs Ltd 2009 Page 4 of 47 IUMP General I nformation 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 kit s features and the installation process When removing components which incorporate a gasket ALWAYS ensure a new gasket is fitted on
12. CHANTABILITY OR WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE TRIUMPH MOTORCYCLES LTD ITS RELATED COMPANIES AND ITS REPRESENTATIVES IN THE UNITED STATES SPECIFICALLY DISCLAIM ALL LIABILITY ARISING OUT OF THE USE OF THIS RACING KIT IN NO EVENT SHALL TRIUMPH MOTORCYCLES LTD ITS RELATED COMPANIES OR ITS UNITED STATES REPRESENTATI VES BE LIABLE FOR ANY DAMAGES ARISING OUT OF THE USE OF THIS RACING KIT THIS MEANS THAT IN NO EVENT SHALL TRIUMPH MOTORCYCLES LTD ITS RELATED COMPANIES OR ITS UNITED STATES REPRESENTATI VES BE LIABLE FOR ANY GENERAL INDIRECT OR CONSEQUENTI AL DAMAGES ARISING OUT OF THE USE OF THIS RACING KIT Triumph Designs Ltd 2009 Page 47 of 47
13. Camshaft Sprocket A9618061 Inlet amp Exhaust Valves A9618086 Valve Spring Kit A9600351 Arrow Race Exhaust System A9618090 Air Funnel Kit and A9618100 Race Harness Part supplied A9618098 Item Description Qty 1 Programmable Race ECU 1 NOTE The Programmable Race ECU will only work with the Race Harness A9618100 The Programmable Race ECU is pre programmed for use with the following set of Race Kits Inlet amp Exhaust Camshafts Camshaft Sprocket Kit Inlet amp Exhaust Valves Air Filter Kit Air Funnel Kit and Arrow Race Exhaust System The tune has been developed to suit a compression ratio of 14 1 with enlarged and polished inlet ports and the exhaust ports modified as recommended on page 24 However due to variation between race prepared engines fuelling adjustments will be required The tune is for motorcycles fitted with a rubber fuel hose only Triumph Part No 1240177 it is NOT suitable for motorcycles fitted with a plastic fuel hose The air fuel ratio and ignition timing should be checked Any adjustments to the fuelling or ignition settings should be made using the Triumph TRACS Race Calibration Software see page 38 e The rev limit on the ECU has been increased from 13900 rpm to 14500 RPM The indicated speed shown on the instruments is calibrated for the standard gearbox If the final drive ratio is changed the indicated speed will be incorrect Idle speed s
14. TRIUMPH 2009 Daytona 675 VIN 381275 Motorcycle Race Kit Manual FOR CLOSED CIRCUI T USE ONLY Contents 4 General Information rrr 5 Engine lt 7 Gaskets Side Cover Gasket Kit 9618097 7 Cylinder Head Gasket 0 65 mm A9618112 8 Cylinder Head Gasket 0 60 mm A9618113 8 Cylinder Head Gasket 0 55 mm A9618114 8 Cylinder Head Gasket 0 50 mm 9618115 8 Cams amp Valves Camshaft Inlet A9618055 10 Camshaft Exhaust 9618056 10 Valve Spring Kit 9618086 10 Camshaft Sprocket Kit 9618095 10 Manually Adjustable Camshaft Drive Chain Tensioner A9618108 12 Inlet amp Exhaust Valve Kit 9618061 14 Bearings Conrod Bearing Shell 1 476 mm to 1 482 mm White A1110411 15 1 482 mm to 1 488 mm Red A1110412 15 Main Bearing Shell 1 491 mm to 1 495 mm White 1161301 16 1 495 mm to 1 499 mm Red A1161302 aaa 16 1 499 mm to 1 503 mm Blue A1161303 16 1 503 mm to 1 507 mm Green A1161304 16 Oil Pump Oil Pump Gearing Kit 9618096
15. 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 The Camshaft Sprocket Kit contains specific sprockets for the inlet and exhaust camshafts It is important that the correct sprocket is used for the inlet and exhaust camshafts If an exhaust sprocket is fitted to an inlet camshaft or an inlet sprocket is fitted to an exhaust camshaft in error it will result in severe engine damage NOTE The inlet and exhaust sprockets are identified as shown below 1 Inlet sprocket marked N 2 Exhaust sprocket marked E Triumph Designs Ltd 2009 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 Timing marks are included on the race sprockets for guidance only Race engines will typically have different depths skimmed off the cyl
16. Wire Colour Polarity Function ID Tape black red Custom None quickshifter black If a quickshift function is not going to be used leave the harness connector blanked off to prevent a possible short circuit Wet dry map and pit lane speed limiter The combination of race harness programmable race ECU and Triumph TRACS Race Calibration Software provides the ability to select different engine maps for wet and dry conditions and also activate a pit lane speed limiter To utilise the wet dry map feature connect a suitable on off switch to the supplied connector 3 The correct wires on the connector are identified by red ID tape black wire and white blue wire The minimum rating for the switch is 110mA at 14V To utilise the pit lane speed limiter feature connect a suitable push to make switch to the supplied connector 3 The correct wires on the race harness are identified by yellow ID tape purple black wire and pink brown wire The minimum rating for the switch is 0 5mA at 14V Wet dry map and pit lane speed limiter 4 wire connector Wire Colour Polarity Function ID Tape white blue Wet dry map Red black pink brown Pit lane Yellow speed limiter purple black Triumph Designs Ltd 2009 Page 42 of 47 IUMP The wet dry map and pit lane speed limiter connector plugs into the 4 pin connector fitted with a blanking plug If either the we
17. ator cover standard part 1 9 Cover alternator unpainted sand casting 1 Alternator Puller Tool A3880206 Item Description Qty 1 Puller tool alternator 1 Triumph Designs Ltd 2009 Page 34 of 47 10 IUMP Remove the alternator as described in section 17 of the service manual Remove the starter drive gear and sprag clutch from the alternator rotor as described in section 7 of the service manual Discard the original fixings Using the M6 x 12 mm screws provided 3 fit the sprag clutch and starter drive gear to the race rotor 1 following the procedure detailed in section 7 of the service manual Remove all grease and oil from the taper surfaces on both the crankshaft and rotor before assembly Assemble the race rotor and sprag clutch assembly to the crankshaft following the procedure detailed in section 17 of the service manual Using the M6 x 20 mm screws provided 4 assemble the race stator 2 to the alternator cover provided 9 Tighten to 6 Nm Apply silicone sealant to the cable grommet ThreeBond 1215 is recommended and align the cable to the exit slot Using two of the M5 x 10 mm screws provided 5 assemble the crankshaft sensor to the alternator cover Tighten to 6 Nm Fit the wire retaining plates 6 amp 7 to the alternator cover and secure with the remaining M5 x 10 mm screws provided 5 Tighten to 6 Nm Position the new gasket provided 8 to the crankshaft
18. ay remove the cooling fan but must leave the relay in place The Race Harness does not support the idle speed control motor and therefore this may be removed from the throttle body It is recommended to use the Manual Idle Speed Adjuster A9618076 to replace the throttle stop screw when using the Race Harness Throttle body balance should be checked if the ISC cam is removed from the throttle body assembly The Race Harness is suitable for use with both the standard and Race Kit alternator It is recommended to always run an alternator without it the battery will discharge in a very short period of time Triumph Designs Ltd 2009 Page 41 of 47 IUMP Quickshifters The combination of the programmable race ECU and race harness allows the ability to have ignition cut for quick shift It is recommended to use the following kits A9930224 Quickshifter Race Standard Shift or A9930225 Quickshifter Race Reverse Shift The default cut time is 40ms By using the Triumph TRACS Race Calibration Software the cut time for low medium and high engine speeds can be individually adjusted Alternatively a custom quickshifter can be installed To use this option connect a suitable switch to the supplied connector 2 Mount the switch in a convenient position The connector plugs into a 2 pin connector fitted with a blanking plug The minimum rating for the switch is 2mA at 5V Custom Quickshifter 2 wire connection
19. aytona 675 service breather Discard the fixings manual 1 Crankcase breather baffle plate 2 Fixings Triumph Designs Ltd 2009 Page 30 of 47 IUMP If not already removed note the position and orientation of the gear pedal crank in relation to the shaft then remove the crank Remove the E clip and washer from the gear pedal end of the gear change shaft kakhi 1 Gear change shaft 2 E clip 3 Washer 5 cdnm Withdraw the gear change shaft from the clutch end of the crankcase 1 Gear change shaft NOTE The detent arm is held in position under spring pressure Prior to removal note the orientation of the detent arm fixing and spring relative to the selector drum detent wheel The same orientation must be retained on assembly Triumph Designs Ltd 2009 Release and remove the fixing securing the detent arm Withdraw the detent arm complete with its flanged sleeve spring and washer Detent arm Fixing 1 2 3 Spring 4 Detent wheel 10 Remove the existing detent wheel and fixing from the selector drum assembly note how the detent wheel is timed relative to the selector drum by way of a dowel Assemble the Race Kit detent wheel to the selector drum assembly ensuring it is timed to the drum in the same way as the original detent wheel Fit the M6 Torx head screw to the selector drum assembly and tighten to 12 Nm Ensure the detent wheel is fully inse
20. causing severe engine damage loss of motorcycle control and an accident The Race Kit conrod bearing shells are produced in a higher grade of alloy than the standard parts This improves durability and reduces friction improving engine performance and reliability under racing conditions The Race Kit conrod bearing shells should be assembled in the same manner as the standard conrod bearing shells Follow the procedure detailed in section 5 of the Daytona 675 service manual to remove the connecting rods select the correct bearing shells for each connecting rod and refit the connecting rods Triumph Designs Ltd 2009 Page 15 of 47 Main Bearing Shell IUMP Parts supplied A1161301 Item Description Thickness Colour Qty 1 Main bearing shell race 1 491 mm to 1 495 mm White 1 Parts supplied A1161302 Item Description Thickness Colour Qty 1 Main bearing shell race 1 495 mm to 1 499 mm Red 1 Parts supplied A1161303 Item Description Thickness Colour Qty 1 Main bearing shell race 1 499 mm to 1 503 mm Blue 1 Parts supplied A1161304 Item Description Thickness Colour Qty 1 Main bearing shell race 1 503 mm to 1 507 mm Green 1 The Race Kit main bearing shells are produced in a higher grade of alloy than the standard parts This improves durability and reduces friction improving engine performance and reliab
21. dowels then fit the race alternator cover and stator assembly to the crankcase following the procedure detailed in the service manual Triumph Designs Ltd 2009 Rotor removal Race ACG Do not use tools of any kind to tighten the service tool T3880375 Tighten the tool by hand only Over tightening of the service tool will lead to damage of the alternator rotor 1 Clean the alternator rotor removing all traces of oil Fit the service tool T3880375 to the outside diameter of the rotor Retain the tool to prevent the crankshaft from rotating and remove the centre bolt from the crankshaft With the crankshaft bolt removed locate the spigot of the thrust pad supplied with service tool A3880206 into the end of the crankshaft Assemble the threaded portion of service tool A3880206 into the threaded portion of the rotor Ensure the thrust pad does not fall out during assembly of the service tool Hold the service tool 73880375 to prevent rotation of the rotor then tighten service tool A3880206 to release the taper seating of the rotor from the crankshaft Withdraw the rotor and service tools as an assembly and then separate the tools from the rotor Collect the woodruff key and the service tool thrust pad from the crankshaft Page 35 of 47 IUMP Programmable Race ECU The Programmable Race ECU MUST be used with the following Race Kits A9618055 Camshaft Inlet A9618056 Camshaft Exhaust A9618095
22. duction 2009 Triumph Daytona 675 Triumph s award winning Daytona 675 has been enhanced for the 2009 season with a host of modifications amp racing products to improve the bike s already class leading handling and performance Triumph s R amp D department has taken an evolutionary approach with the new Daytona using experience gained from the 2008 Supersport World amp National Championships to develop the new machine and Race Kit parts for 2009 As a result the standard bike now includes a higher ratio first gear previously only available as a Race Kit part revised cylinder head valves and a magnesium cam cover As could be expected from a bike with such sporting aspirations the new Daytona chassis comes equipped with top of the line suspension and brakes The fully adjustable 41mm upside down forks and rear monoshock unit both benefit from highly sophisticated high and low speed damping control allowing riders to set their Daytona up with maximum accuracy New radial mount Nissin monobloc calipers give even greater levels of stopping power and rider feedback and new lightened wheels give significant savings in unsprung mass It s not just the standard parts which have been enhanced the 2009 Daytona 675 has a full range of Race Kit products to allow riders to fully exploit the new bike for the 2009 season Notable additions include the new Triumph Race Calibration Software TRACS which allows adjustment of many parameters within
23. dywork lower fairings radiator radiator fan rear light pillion foot rest hangers and exhaust system following the procedures detailed in the Daytona 675 service manual 2 Remove the exhaust valve actuator from its actuator cables 3 Remove and discard the exhaust gaskets and M8 studs from the cylinder head 1 M8 Stud 2 Gasket NOTE To obtain maximum performance the exhaust port should be machined removing material from the area shown in red The exhaust port shape should match the inside surface of the primary header bush Triumph Designs Ltd 2009 Thoroughly clean the mating surface of the primary header bushes and exhaust ports Apply silicone sealant to the mating surface of the primary header bush which contacts the cylinder head the recommended sealant is Dow Corning Firestop 700 white silicone Fit the three primary header bushes to the cylinder head and secure using the primary header flanges and M8 cap screws provided NOTE The primary header bush should be orientated such that none of the exhaust port is obscured by the primary header bush Page 24 of 47 IUMP 7 Position the downpipe collector assembly to the underside of the engine and insert the downpipe ends fully into the primary header bushes Secure with the three springs provided Ensure the spring mounting holes are positioned as shown below for all three flanges de A MN 2 J
24. et kit Triumph Designs Ltd 2009 Page 46 of 47 IUMP Carbon Fibre Engine Cover Protectors Parts supplied Clutch cover protector carbon fibre A9728028 Item Description Qty 1 Clutch cover protector carbon fibre 1 Crank cover protector carbon fibre A9728029 Item Description Qty 1 Crank cover protector carbon fibre 1 Standard alternator cover protector carbon fibre A9728031 Item Description Qty 1 Standard alternator cover protector carbon fibre 1 Race Alternator cover protector carbon fibre A9728032 Item Description Qty 1 Race alternator cover protector carbon fibre 1 NOTE 1 It is recommended that an RTV silicone adhesive is used This is a high temperature chemical and environmental resistant adhesive Apply a suitable adhesive to the mating surfaces of the carbon fibre cover and corresponding engine cover NO WARRANTIES ARE PROVIDED FOR THIS RACING KIT TRIUMPH MOTORCYCLES DOES NOT PROVIDE ANY WARRANTIES FOR THIS RACING KIT OR FOR ANY OF THE PARTS IN THIS RACING KIT ALL WARRANTIES EXPRESS OR IMPLIED ARE SPECIFICALLY DISCLAI MED TRIUMPH MOTORCYCLES DOES NOT PROVIDE ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL TRIUMPH MOTORCYCLES ITS RELATED COMPANIES OR UNITED STATES REPRESENTATIVES BE LIABLE FOR ANY ALLEGED BREACH OF WARRANTIES INCLUDING WARRANTIES OF MER
25. hould be set to between 1 500 and 1 800 RPM ECU Malfunction indicator light This will flash a sequence of error codes if any faults are present Flash codes have a long flash for the first digit and a short flash for the second digit For example fault code 32 would be long long long short short When a fault has been identified and rectified the ECU can be cleared by the following sequence full throttle ignition ON flick the engine stop switch off on off on off Triumph Designs Ltd 2009 Page 36 of 47 IUMP No ECU faults should be present during motorcycle operation If the motorcycle is used with ECU faults present it will be operating in default limp home mode only which will produce inconsistent operation Fault Code Table Flash Code Problem 02 Crank sensor 33 Number 1 injector 34 Number 2 injector 35 Number 3 injector 37 Number 1 ignition coil 38 Number 2 ignition coil 39 Number 3 ignition coil 06 Throttle position sensor 09 MAP sensor 68 MAP sensor pipe disconnected 12 Coolant sensor 13 Air temperature sensor 14 Atmospheric air pressure sensor 41 Fuel pump 65 EEPROM error 26 5v sensor supply problem 15 Roll over sensor 22 Gear position sensor 24 Ignition switch circuit problem 25 Battery voltage supply problem 43 Cooling fan relay 44 Airflap solenoid 66 Instrument communication error
26. ility under racing conditions The Race Kit main bearing shells should be assembled in the same manner as the standard main bearing shells Follow the procedure detailed in section 5 of the Daytona 675 service manual to remove the standard bearing shells and select the correct bearing shells required Triumph Designs Ltd 2009 Page 16 of 47 TRIUMPH Oil Pump Gearing Kit Parts supplied A9618096 Item Description Qty 1 Sprocket oil water pump 1 2 Chain 76 link 1 3 Pressure release valve 1 NOTE Fit the new sprocket provided in the Refer to the appropriate sections kit to the oil water pump Apply in the Daytona 675 service manual ThreeBond 1374 thread locking to carry out the procedures compound to the fixing and tighten to outlined in steps 1 to 13 14 Nm 1 R the oil t Retain th E To remove and fit a drive chain it is fixings for reuse necessary to remove the clutch 2 Remove the drive sprocket from the oil assembly water pump Retain the fixings for reuse Retain the sprocket if the motorcycle is to be returned to its original condition Triumph Designs Ltd 2009 Remove the clutch assembly as detailed in the Daytona 675 service manual Remove the drive chain Retain the drive chain if the motorcycle is to be returned to its original condition Page 17 of 47 IUMP Fit the new drive chain Ensure the chain runs clear wi
27. inder 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 106 IMOP Inlet Maximum Opening Point and 106 59 EMOP 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 amp 1 5 mm exhaust 6 When the desired timing has been set the new 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 Page 11 of 47 IUMP Manually Adjustable Camshaft Drive Chain Tensioner Parts supplied A9618108 Item Description Qty 1 Manual camshaft drive chain tensioner assembly 1 2 Camshaft drive chain tensioner blade 1 1 Remove the standard tensioner 3 Remove the pin locating the tensioner following the procedure detailed in the blade to the crankcase retain the pin Daytona 675 service manual Discard for reuse Remove the tensioner blade the gasket retain the fixings for reuse from the top of the camshaft drive chain chest 4
28. kcase Gently push the gear pedal end of the shaft through the bearing and lip seal at the clutch side of the crankcase and the sealed bearing located at the gear pedal side of the crankcase A g N 1 Gear change shaft 23 J j 2 E clip N Vy KS SAN 3 Washer ff ALE BE 9s JX aN FLNS 19 Fit the gear pedal crank to the shaft in L Ww gt the same orientation as noted prior to ES a removal Ensure the dot mark on the i NA X shaft aligns with the split line on the S gear pedal crank Tighten the fixing to Ja one 20 Incorporating new fixings refit the cdnm 2 baffle plate to the crankcase breather 1 Gear change shaft Tighten the fixings to 9 Nm 2 Abutment bolt 21 Refit the clutch and clutch cover as 3 Spring detailed in section 5 of the Daytona 675 service manual 17 Ensure that the gear change shaft fingers locate in the detent wheel arm and that the spring fits either side of the abutment bolt Triumph Designs Ltd 2009 Page 33 of 47 IUMP Electrical Parts Race Alternator Kit Standard Part 2 Standard Part 120 Nm Parts supplied A9618069 Item Description Qty 1 Rotor race ACG 1 2 Stator race ACG includes crank sensor 1 3 Screw caphead M6 x 1 x 12 ENC to retain sprag clutch housing 6 4 Screw skt hd cap M5 x 0 8 x 20 6 5 Screw skt hd cap M5 x 0 8 x 10 5 6 Plate wire retainer 1 7 Plate wire retainer 1 8 Gasket altern
29. mph Designs Ltd 2009 Page 19 of 47 IUMP 1 Remove the airbox lid 5 Fold the retention tabs on the fixing retainers over the 6 fixings as shown 2 Remove the standard intake air below funnels Retain the fixings 2 per air funnel for reuse 3 Fitthe Race Kit air funnels 4 Fit one of the fixing retainers provided to each air funnel and retain with the original fixings Apply ThreeBond 1364 locking compound to the threads only and tighten the fixings to a torque value of 6 Nm 1 Retention tab 2 Fixing Triumph Designs Ltd 2009 Page 20 of 47 IUMP Secondary Air Injection SAI Blanking Kit zx 4 0 9f Parts supplied 49618094 Item Description Qty 1 Reed valve cover single 1 2 Reed valve cover double 1 3 Dowel solid 3 4 Sealing cap airbox 1 5 Bolt M6 x 16 mm 4 NOTE e This kit includes the necessary components to blank off the secondary air injection channels in the cylinder head when the system is removed from the motorcycle Refer to the appropriate sections in the Daytona 675 service manual to carry out the procedures outlined in steps 1 to 8 1 Remove the SAI solenoid valve 2 Remove the SAI reed valves 3 Remove the camshaft cover retain the fixings for reuse Triumph Designs Ltd 2009 Page 21 of 47 IUMP 4 Replace the standard hollow dowels with the solid dowels provided in the kit SM ma Tava
30. ory 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 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 The use of some of these kits will require changes to the fuelling and ignition settings To alter these settings a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Triumph Designs Ltd 2009 Page 6 of 47 Engine Parts IuME Side Cover Gasket Kit Parts Supplied A9618097 Item Description Qty 1 Gasket clutch cover race 1 2 Gasket alternator cover race 1 3 Gasket crank cover race 1 4 Gasket balancer cover race 1 The gaskets contained in the kit are a direct replacement for the standard parts but they have been designed to be reusable Thoroughly clean all mating faces before fitting new gaskets Triumph Designs Ltd 2009 Page 7 of 47 IUMP Cylinder Head Gasket The use of the following Race Kit cylinder head gaskets will require changes
31. pipe 15 Refit the radiator rear bodywork lower fairings battery and seat as described 3 Spring in the Daytona 675 service manual 4 Silencer mounting point NOTE 12 Check the exhaust system is correctly The radiator fan rear light and aligned with the rear frame and tighten pillion footrest hangers are NOT the fixings to the following torque refitted values Rear exhaust mounting point 27 Nm ntermediate pipe mounting point fixing 22 Nm Collector pipe front mounting point fixings 27 Nm Primary header flanges M8 cap screws 19 Nm Triumph Designs Ltd 2009 Page 26 of 47 Air Filter Kit Parts supplied A9618075 Item Description Qty 1 Air filter 1 2 Retaining washer 3 NOTE This kit is supplied by BMC Air Filters For fitment details refer to the instruction contained in the kit f you have any queries with regard to the air filter kit in the first instance contact BMC For contact details see www bmcairfilters com Loctite or similar should NOT be applied to the fixings as described in the supplied instructions as this could strip the insert out of the plastic moulding when removing the filter The kit is supplied with three plastic retaining washers to retain the fixings The three plastic retaining washers should be fitted to the three rear fixings as shown above Tighten the fixings to a torque value of 4 Nm Triumph Designs Ltd 2009 Page 27
32. re assembly The standard engine side cover gaskets can be replaced with re usable items as supplied in the Side Cover Gasket Kit A9618097 see page 7 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 Whilst every effort is made to include the latest information in the service manual this is not always possible The latest information and technical changes are provided to authorised Triumph dealers via Technical News It is recommended you contact an authorised Triumph dealer to request this information Warnings Cautions and Notes Throughout this publication particularly important information is presented in the following form This warning symbol identifies special instructions or procedures which if not correctly followed could result in personal injury or loss of life This caution symbol identifies special instructions or procedures which if not strictly observed could result in damage to or destruction of equipment NOTE This note symbol indicates points of particular interest for more efficient and convenient operation Triumph Designs Ltd 2009 Page 5 of 47 IUMP These accessory kits are for racing onl
33. riumph Programmable Race ECU A9618070 marked Part 1290675 To gain use of the pit lane speed limiter and wet dry ignition map functions the motorcycle must be equipped with Race Harness Kit A9618100 Refer to the user instruction files on the software CD supplied Triumph Designs Ltd 2009 Page 38 of 47 TRACS Management Kit IUMP Programmable Race ECU and Race Calibration Software Bundle Parts supplied A9618099 Item Description Qty 1 TRACS software CD 1 2 Diagnostic plug connector 1 3 USB lead 1 4 Programmable Race ECU 1 NOTE Refer to the user instruction files on the software CD supplied Triumph Designs Ltd 2009 Page 39 of 47 TRIUMPH Race Harness Kit 8 Standard Part Standard Part Parts supplied A9618100 Item Description Qty 1 Main harness race 1 2 Connector custom quickshifter 2 wires 1 3 Connector pit lane speed limiter and wet dry map 4 wires 1 4 Regulator bracket 1 5 Bolt M6 x 25 mm 2 6 Locknut M6 2 NOTE The Race Harness will not work without the Programmable Race ECU A9618098 or Race ECU A9618070 updated using the TRACS system The regulator unit item 7 must be relocated from its original position within the fairing to a new position on the frame adjacent to the swingarm pivot This is to allow fitment of race bodywork The original fixing bolts item 8 should be retained
34. rted into the bearing up to its shoulder Page 31 of 47 IUMP 11 Assemble the detent arm as noted on 14 Rotate the selector drum to the neutral removal and place up to the crankcase position Ensure that the detent arm locates in the raised profile in the detent wheel neutral position Spring Washer Detent arm 2 3 4 Flanged sleeve 1 Detent arm 5 Fixing 2 Neutral position 15 Using clean engine oil lubricate the lip 12 Hold the detent arm assembly in of the seal on the gear change shaft position and insert a new fixing Start the thread and push the detent arm using finger pressure only to locate on the selector drum detent wheel 13 Ensure the detent arm remains correctly located on the detent wheel and the spring is correctly seated in the recess in the crankcase Ensure the shoulder of the flanged sleeve is located in the bore detent arm Tighten the fixing to 12 Nm N A 1 E 6 1 Gear change shaft seal 2 Gear change shaft bearing Detent arm Fixing 1 2 3 Spring 4 Selector drum detent wheel Triumph Designs Ltd 2009 Page 32 of 47 IUMP 18 Fit the washer and E clip to the gear pedal end of the gear change shaft Take care to avoid damaging the lip of the seal when inserting the gear change shaft into the crankcase A damaged seal will lead to oil loss and could result in engine damage 16 Insert the gear change shaft into the cran
35. se of The Race Kit camshaft valve Spring and camshaft sprockets detailed below will require changes to the fuelling and ignition settings To alter these settings a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Parts Supplied Camshaft Inlet A9618055 Valve Spring Kit A9618086 Item Description Qty Item Description Qty 3 Valve spring 14 4 id race 12 1 Camshaft inlet race 1 Camshaft Sprocket Kit A9618095 Camshaft Exhaust A9618056 Item Description Qty Item Description Qty 4 Sprocket camshaft 1 inlet 34T 2 Camshaft exhaust race 1 nietos 5 Sprocket camshaft 1 exhaust 34T 6 Socket head cap screw 4 encapsulated M6 x 10 Triumph Designs Ltd 2009 Page 10 of 47 IUMP The standard inlet cam is 9 25 mm max lift and 258 50 duration The Race Kit inlet cam is 9 25 mm max lift and 268 74 duration The standard exhaust cam is 8 5 mm max lift and 246 duration The Race Kit exhaust cam is 8 5 mm max lift and 262 21 duration 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 NOTE same as the standard spring 1
36. t dry map only function or pit lane speed limiter only function is to be used the remaining unused wires on the connector must be insulated with tape in such a way that the wire ends are protected from each other and any other motorcycle component to prevent a possible short circuit If neither the wet dry map or pit lane speed limiter functions are going to be used leave the harness connector blanked off to prevent a possible short circuit To avoid false triggering in wet conditions all switches used should be of a sealed type Do not connect the black wire to the pink brown wire on the race harness in any circumstances as this will result in a short circuit Triumph Designs Ltd 2009 Page 43 of 47 IUMP Chassis Parts Quickshifter Race Parts supplied Standard Shift A9930224 Item Description Qty 1 Quickshifter sensor 1 2 Gear selector rod 1 3 Cable tie 4 NOTE This part is suitable for fitment to Arrow Rearsets A9750539 only For fitment refer to the comprehensive fitting instructions supplied with the quickshifter Parts supplied Reverse Shift A9930225 Item Description Qty 1 Quickshifter sensor 1 2 Gear selector rod 1 3 Cable tie 4 NOTE This part is suitable for fitment to Arrow Rearsets A9750536 only For fitment refer to the comprehensive fitting instructions supplied with the quickshifter Triumph Designs Ltd 2009
37. t drive chain has been completely taken up back off the plunger by 1 4 turn 13 While holding the plunger in position tighten the plunger locknut to a torque value of 9 Nm Ensure the plunger is not allowed to turn while tightening the locknut 14 Re check the chain tension 15 Fit a new gasket to the right hand crank cover 16 Noting the position of the bolt fitted with the copper washer refit the crank cover tightening the fixings to 9 Nm NP 1 Right hand crank cover 2 Copper washer position 17 Following the procedure detailed in the Daytona 675 service manual check the valve clearances and adjust as necessary 18 Refit the camshaft cover as described in the Daytona 675 service manual Page 13 of 47 IUMP I nlet amp Exhaust Valve Kit The use of the following Race Kit inlet amp exhaust valves will require changes to the fuelling and ignition settings To alter these settings a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Parts supplied A9618061 Item Description Qty 1 Inlet valve 29 65 dia 6 2 Exhaust valve 24 85 dia 6 The valves supplied in the Race Kit are used to increase compression ratio by having a flat face on the combustion chamber side They are made from the
38. thin the chain guide guard Refit the clutch assembly as detailed in the Daytona 675 service manual Refit the oil water pump and secure with the original fixings Triumph Designs Ltd 2009 10 11 12 Remove the original pressure release valve Retain the valve if the motorcycle is to be returned to its original condition Apply ThreeBond TB1305 thread locking compound to the new pressure release valve bolt thread Fit the new pressure release valve Tighten to 15 Nm Refit the sump and secure with the original fixings Page 18 of 47 IUMP Air Funnel Kit The use of the following Race Air Funnel Kit will require changes to the fuelling and ignition settings To alter these settings a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Parts supplied A9618090 Item Description Qty 1 Air funnel race 3 2 Fixing retainer 3 NOTE e It 15 essential that the Programmable Race ECU A9618098 is used with the Race Air Funnel Kit to allow correct fuelling The parts supplied in the Race Kit are designed to replace the standard intake air funnels located in the airbox e Item 3 6 off is the standard fixing supplied with the standard air funnel It is not supplied in the Race Kit Triu
39. to the fuelling and ignition settings To alter these settings a Triumph Programmable Race ECU combined with Triumph TRACS Race Calibration Software will be required Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Thickness t marking location Parts Supplied A9618112 0 65 mm A9618113 0 60 mm A9618114 0 55 mm or A9618115 0 50 mm Item Description Qty 1 Cylinder head gasket t 0 65 mm 1 1 Cylinder head gasket t 0 60 mm 1 1 Cylinder head gasket t 0 55 mm 1 1 Cylinder head gasket t 2 0 50 mm 1 The thickness of the standard cylinder head gasket is 0 7 mm The Race Kit gaskets are available in 0 60 mm 0 65 mm 0 55 mm and 0 50 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 O Triumph Designs Ltd 2009 Page 8 of 47 IUMP Running the engine at less than the minimum recommended squish height can lead to the pistons contacting the cylinder head causing major engine damage This could
40. y 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 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 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 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 A torque wrench of known accurate calibration must be used when fitting this access
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