Race Kit Manual - Triumph Motorcycles
Contents
1. If the cooling is removed the motorcycle will require constant airflow over the radiator in order to maintain a correct operating temperature Extended periods of iding or prolonged rides at very slow speeds may overheat the engine resulting in severe damage The Race Harness does not support the idle speed control motor and therefore this may be removed from the throttle body t 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 e 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 Page 28 Chassis Parts Quickshifter Race Parts Supplied Standard Shift A9930222 Item Description Qty 1 Quickshifter assembly 1 2 Cable tie 2 Note e This part is suitable for fitment with standard control plates or accessory rearsets A9770044 e For fitment refer to the comprehensive fitting instructions supplied with the quickshifter Page 29 Race Wheel Kit ESSES Parts Supplied Wheel Kit Pair Race A9648032 Item Description Qty 1 Wheel assembly Front 17 x MT3 5 1 2 Wheel assembly Rear 17 x MT5 5 1 3 Bolt Disc M8 x 1 25 x 30 Slv 14 Not2. Item Description Qty 1 Rotor race AC Generator 1 2 Stator race AC Generator 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 4 5 Screw skt hd cap M5 x 0 8 x 10 ENC 7 6 Plate wire retainer 1 7 Gasket alternator cover standard part 1 8 Cover alternator unpainted sand casting 1 9 Protector 1 10 Screw cap hd M6 x 1 x 20 3 11 Bracket cable guide ACG stator 1 Alternator Puller Tool A3880206 Item Description Qty 1 Puller tool alternator 1 Page 22 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 M5 x 20 mm screws provided 4 assemble the race stator 2 to the alternator cover provided 8 Tighten to 12 Nm Apply silicone sealant to the cable grommet ThreeBond 1215 is recommended and align the cable to the exit slot
3. 8 Screw M8 x 25 1 9 Locknut M8 1 10 Aluminium lower radiator bracket 1 11 Oxygen sensor adaptor 1 12 Silencer bracket 1 13 Baffle 1 14 Cirdip 1 Note A Baffle and retaining clip are provided in the kit for use as required Page 14 Remove the seat and battery following the procedures detailed in the Daytona 675 service manual Remove the lower fairings cockpit infill panels radiator infill panels radiator pillion foot rest hangers right hand control plate transmission linkage sprocket cover left hand frame finisher purge valve exhaust system and the exhaust butterfly valve actuator and actuator cables following the procedures detailed in the Daytona 675 service manual Retain the exhaust header nuts for re use Replace if required Remove and discard the exhaust header seals Renew exhaust header seals if required 1 Seals 5 Retain the washer grommet and flanged sleeve from the left hand side mount and the M8 x 50 fixing from the left hand side mount for re use 6 Remove the lower radiator mounting bracket retain the fixing and compression limiter for re use 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 7 Fit new exhaust header seals if required ensuring that the face of the seal with the tab is fa
4. 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 s 1 Plunger 2 Plunger locknut 12 When the slack in the camshaft 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 Fita new gasket to the right hand crank cover 16 Refit the crank cover tightening the fixings to 10 Nm l T y i C A Crank cover 2 Fixings 8 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 6
5. fuelling and ignition settings will result in poor engine performance and could result in engine damage Page 4 Engine Parts Cylinder Head and Cylinder Base Gaskets The use of the following Race Kit cylinder head and cylinder base gaskets will require changes to the fuelling and ignition settings Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage 3 1 Cylinder head gasket 2 Cylinder base gasket 3 Thickness t marking location Parts Supplied A9618136 Cylinder Head Gasket 0 45 mm A9618137 Cylinder Head Gasket 0 40 mm A9618138 Cylinder Base Gasket 0 20 mm A9618139 Cylinder Base Gasket 0 15 mm Item Description Qty 1 Cylinder head gasket t 0 45 mm 1 1 Cylinder head gasket t 0 40 mm 1 2 Cylinder base gasket t 0 20 mm 1 2 Cylinder base gasket t 0 15 mm 1 Note e The thickness of the standard cylinder head gasket is 0 5 mm The Race Kit gaskets are available in 0 40 mm and 0 45 mm thicknesses The thickness t of the gasket is clearly marked on the gasket in the location shown above e The thickness of the standard cylinder base gasket is 0 25 mm The Race Kit gaskets are available in 0 20 mm and 0 15 mm thicknesses The thickness t of the gasket is clearly marked on the gasket in the location shown above Page 5 Note Due to variation in production tolerances the Ra
6. 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 e This note symbol indicates points of particular interest for more efficient and convenient operation Page 3 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 These accessory kits are designed for use on Triumph Daytona 675 and Daytona 675R motorcycles from VIN 564948 only and should not be fitted to any other Triumph model or to any other manufacturer s mot
7. to prevent rotation of the rotor then tighten service tool A3880206 to release the taper seating of the rotor from the crankshaft 6 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 23 Race Engine Control Module ECM The Race ECM MUST be used with the following Race Kits A9618160 Camshaft Inlet A9618161 Camshaft Exhaust A9618162 Exhaust Valves A9618086 Valve Spring Kit A9600440 Arrow Race Exhaust System A9618163 Air Filter Kit and A9828020 non ABS or A9828021 ABS Race Harness Kit Failure to use the Race ECM with the Race kits listed above will result in incorrect fuelling and ignition settings Part supplied A9828019 Item Description Qty 1 Race ECM 1 Note The Race ECM will only work with the Race Harnesses A9828020 non ABS and A9828021 ABS e The Race ECM is pre programmed for use with the following set of Race Kits Inlet amp Exhaust Camshafts Exhaust Valves Air Filter 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 15 e The rev limit on the race ECM has been increased from 14400 RPM to 15500 RPM e The indicated speed shown on the instruments is calibrated for the standard gearbox If the final drive rat
8. 0 Vehicle speed sensor 76 Instrument communication error 96 Upper injector 1 97 Upper injector 2 98 Upper injector 3 Continuous Harness or instruments incompatible Short Flash Page 25 Race Harness Kit 8 Standard Part Standard Part Parts Supplied Race Harness Kit Where donor motorcycle is Non ABS A9828020 Race Harness Kit Where donor motorcycle is ABS A9828021 Item Description Qty Mainharness race 2 Sensor road speed ABS kit ony 3 Bolt M6 x 16 ABS kit only 1 Regulator bracket ee 4 5 Bolt M6 x 12 2 7 WelntM5x lBshank JJ 1 2 8 jRediie reguatr sss 4 BoM5x15 10 ScewS fp HHE5x205 0 Note e The Race Harness will not work without the Race ECM A9828019 The regulator unit item 8 must be relocated from its original position within the fairing to a new position under the seat where the alarm unit would be located This is to allow fitment of race bodywork The original fixing bolts item 5 should be retained for re use e The above Race Harness Kits do not support ABS The ABS function will not operate on ABS donor motorcycles once the Race Harness Kit has been fitted Page 26 All Models 1 Disconnect the battery and remove fairings following the procedures detailed in the Daytona 675 service manual 2 Remove the regulator from the original bracket retain the bo
9. 75 service manual Page 10 Exhaust Valve Kit The use of the following Race Kit exhaust valves will require changes to the fuelling and ignition settings Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Jut Parts Supplied A9618162 Item Description Qty 1 Exhaust valve 24 2 dia 6 Note e The valves supplied in the Race Kit are used to increase compression ratio by having a flat face on the combustion chamber side 1 Remove the existing inlet and exhaust valves 2 Assemble the original inlet valves and Race exhaust following the procedure detailed in section 3 of the valves following the procedure detailed in section 3 Daytona 675 service manual of the Daytona 675 service manual Page 11 Secondary Air Injection SAD Blanking Kit 2 x lt C 3 5 A 4 OY jt PS Parts Supplied A9618094 Item Description Oty 1 Reed valve cover single 1 2 Reed valve cover double 1 3 Dowel solid 3 4 Sealing cap air box 1 5 Bolt M6 x 16 mm 4 6 Washer 2 7 Flanged sleeve 2 Note 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 e Refer to the appropriate sections in the Daytona 675 service manual to carry out the procedures outlined in steps 1 to 11 o
10. N 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 REPRESENTATIVES 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 REPRESENTATIVES BE LIABLE FOR ANY GENERAL INDIRECT OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OF THIS RACING KIT Page 32
11. TRIUMPH 2013 Daytona 675 and Daytona 675 R From VIN 564948 Motorcycle Race Kit Manual FOR CLOSED CIRCUIT USE ONLY Publication part number A9900675 issue 1 ADC12359 Page 1 Triumph Designs Ltd 2013 Table of Contents General Information Y RUNG 3 5 Cylinder Head and Cylinder Base 6 iliis 5 Camshaft and Valve Spring Kits 0 ene mee 7 Manually Adjustable Camshaft Drive Chain Tensioner 0 00 cece e 9 Exhaust Valve Kit i nre 4d otek Aha tae ie Re ae OM ee he CLA eet Res 11 Secondary Air Injection SAD Blanking Kit 2 00 0 0 cece e 12 VERE Be he Es 14 ML TT 18 Manual Idle Speed Adjuster Kit 2 0 2 0 eee I III hl 19 Cover Protectors Kit Superstock 02 0 0 cece nett re 20 Cover Protectors Kit SupersporD 0 6 retis tesia teki orearen neka e ere 21 Electrical Pants ovo NES LAYER 22 Race Alternator Kitse 22 Race Engine Control Module ECM 0 ec s he 24 Race Harness Kl 52 egeo ees ache at pni rh dee ho teh Sea th a eee Oe 26 Chassis Parts us xA CERES o Se ce eit E RUNS n ag OR DR Qe ea a n e c Ra 29 Quickshifter Race e p ode t D RE e DUE te ete e 29 Race Wheel Kit sc ce dads odd iets BUSTO oh ae aires ok peta dare Ra 30 Race Frame Protecto
12. The Race Kit exhaust cam is 8 70 mm max lift and 260 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 same as the standard spring 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 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 Assemble the original camshaft sprockets to the Race Kit camshafts following the procedure detailed in section 3 of the Daytona 675 service manual 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 as follows Inlet Maximum Opening Point IMOP 108 After Top Dead Centre ATDO Exhaust Maximum Opening Point EMOP 108 Before Top Dead Centre BTDO 5 Always check the inlet and exhaust piston to valve dearance for the timing selected to use before running the engine You must ensure both dearances are adequate As a guide t
13. 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 original wire retaining plate and the wire retaining plates supplied in the race kit 6 amp 11 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 7 to the crankshaft dowels then fit the race alternator cover and stator assembly to the crankcase following the procedure detailed in the service manual Using the M6 x 20 screws provided 11 assemble the alternator cover protector 10 to the alternator cover Tighten to 9 Nm Rotor Removal Race AC Generator Do not use tools of any kind to tighten the service tool 13880375 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 2 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 3 With the crankshaft bolt removed locate the spigot of the thrust pad supplied with service tool A3880206 into the end of the crankshaft 4 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 5 Hold the service tool T3880375
14. ce Kit cylinder head and cylinder base gaskets may not be suitable for all engines Use the appropriate gaskets to adjust the squish height the squish height is the gap between the flat portion of the piston and the cylinder head In some cases it may be necessary to use the standard gaskets to achieve the correct squish clearance Always ensure that the chosen gaskets provide a minimum squish clearance of 0 75 mm Running the engine at less than recommended squish height can lead to the pistons contacting the cylinder head and valves causing major engine damage This could cause loss of motorcycle control and an accident the minimum Remove the cylinder head in line with the procedures detailed in the Daytona 675 service manual Position a piece of solder with a diameter of approximately 1 3 mm on the four squish surfaces of each piston and hold in place with a small amount of grease Ensure the solder is positioned in line with the corresponding squish surfaces on the cylinder head Refit the cylinder head with the original cylinder head and base gaskets Slowly turn the engine over by hand to compress the solder to the same height as the squish clearance Remove the cylinder head and measure the compressed thickness of the solder The recommended minimum squish clearance is 0 75 mm Select the appropriate gasket thicknesses to achieve the correct squish clearance For example d If the minimum squish c
15. cing the cylinder head 1 Seals 2 Seal tab 8 Thoroughly dean the mating surfaces of the primary header bushings 5 and downpipe collector assembly 1 9 Apply silicone sealant to the mating surface of the three primary header bushings The recommended sealant is Dow Corning Firestop 700 white silicone 10 Insert the primary header bushings into the downpipe collector assembly 1 Header bushings 2 Downpipe collector assembly 3 Mating surfaces Note The primary header bushings should be orientated such that none of the exhaust port opening is obscured 11 Position the downpipe collector assembly to the cylinder head and align the header pipe flanges to the fixing points Fit the exhaust header nuts retained from disassembly do not fully tighten at this stage Page 15 12 Loosely secure the downpipe collector assembly 14 Place the carbon collar 3 onto the silencer 2 lower mounting point to the frame using the original 15 Push the silencer onto the downpipe collector fixings retained from the left and right hand side assembly and secure using the spring provided 4 mounts 16 Align the carbon collar with the outside of the silencer bracket and secure using the M8 x 25 screw 8 M8 washer 7 and M8 locknut 9 provided Tighten to 9 Nm lesa cT Sex 5 1 Fixing 13 Secure the silencer bracket 12 to the right hand rear footrest hanger mounting p
16. e For fitment refer to the procedures detailed in section 15 of the Daytona 675 service manual Page 30 Race Frame Protector Kit T1825 1 Parts Supplied Frame Protector Kit A9788014 Item Description Qty 1 Frame protector cover RH Assembly 1 2 Frame protector cover LH Assembly 1 3 Frame protector support RH 1 4 Frame Protector support LH 1 5 Infill fairing RH front trim 1 6 Infill fairing RH rear trim 1 7 Infill fairing LH trim 1 8 Screw cap hd M6 x 1 0 x 25 SLV 4 9 Bolt TX M10 x 1 25 x 100 1 10 Bolt TX M10 x 1 25 x 150 1 11 Bolt TX M10 x 1 25 x 60 2 12 Spacer L 45 5 1 13 Locknut FLGD M10 x 1 25 2 Note For fitment refer to the comprehensive fitting instructions supplied with the frame protector kit Page 31 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 DISCLAIMED 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 MERCHANTABILITY OR WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE TRIUMPH MOTORCYCLES LTD ITS RELATED COMPANIES AND ITS REPRESENTATIVES I
17. g the procedures detailed in the Daytona 675 service manual 27 Refit the left hand frame finisher purge valve sprocket cover transmission linkage and control plate as described in the Daytona 675 service manual 28 Fit the correct specification spark plugs as recommended below following the procedure detailed in the Daytona 675 service manual 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 CR10EIX 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 29 Refit the lower fairings cockpit infill panels radiator infill panels and seat as described in the Daytona 675 service manual Note e The pillion footrest hangers are not refitted Page 17 Air Filter Kit 1 Parts Supplied A9618163 Item Description Qty 1 Air filter 1 Note e This kit is supplied by BMC Air Filters For fitment details refer to the instruction contained in the kit e If you have any queries with regard to the air filter kit in the first instance contact BMC For contact details see www bmcairfilters com Page 18 Manual Idle Speed Adjuster Kit ANY LS SASS a NES S Parts Supplied A9618076 Description Screw manual adjuster Spring com
18. he standard nominal piston to valve clearance is 1 0 mm inlet amp 1 4 mm exhaust When the desired timing has been set the sprocket retaining fixings should be tightened to 22 Nm Note Page 8 If the sprocket retaining fixings are released for any reason they must be discarded and replaced with new fixings Apply ThreeBond 1305 to the threads before tightening 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 following the procedure detailed in the Daytona 675 service manual Discard the gasket and retain the fixings for re use Do not start the motorcycle engine with the tensioner removed If the motorcycle engine is started with the tensioner removed it could result in engine damage 2 Remove the camshafts following the procedure detailed in the Daytona 675 service manual Page 9 Remove the pin locating the tensioner blade to the crankcase retain the pin for re use Remove the tensioner blade from the top of the camshaft drive chain chest Lower the new tensioner blade provided into the camshaft drive chain chest from the top Locate in position with the original pin Refit the camshafts following the procedure detailed in the Daytona 675 service manual Thoroughly clean the tensioner mounting surface on
19. io is changed the indicated speed will be incorrect Idle speed should be set to between 1 500 and 1 800 RPM ECM Malfunction Indicator Light e This will flash a sequence of error codes if any faults are present e 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 e When a fault has been identified and rectified the ECM can be cleared by the following sequence full throttle ignition ON flick the engine stop switch off on off on off Page 24 No ECM faults should be present during motorcycle operation If the motorcycle is used with ECM 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 position sensor 06 Throttle position sensor 09 Map sensor 12 Coolant temperature sensor 13 Intake air temperature sensor 14 Atmospheric air pressure sensor 15 Roll over sensor 22 Gear position sensor 24 Ignition switch circuit 25 Battery voltage supply 26 5V sensor supply 27 5V sensor supply 33 Lower injector 1 34 Lower injector 2 35 Lower injector 3 37 Ignition coil 1 38 Ignition coil 2 39 Ignition coil 3 41 Fuel pump 43 Cooling fan relay 65 EEPROM error 66 Instrument communication error 68 MAP sensor pipe disconnected 7
20. learance is measured at 0 90 mm with the standard 0 50 mm head gasket and 0 25 mm base gasket fitted Fit the 0 40 mm head gasket and the 0 20 mm base gasket to achieve a squish clearance of 0 75 mm Note Page 6 In some cases it may be necessary to use the standard gaskets to achieve the correct squish clearance Fit the chosen cylinder head and base gaskets following the procedures detailed in the Daytona 675 service manual Camshaft and Valve Spring Kits The Race Kit camshaft and valve springs 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 use of The Race Kit camshaft and valve springs detailed below will require changes to the fuelling and ignition settings Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Parts Supplied Camshaft Inlet A9618160 Item Description Qty 1 Camshaft inlet race 1 Camshaft Exhaust A9618161 Item Description Qty 2 Camshaft exhaust race 1 Valve Spring Kit A9618086 Item Description Qty 3 Valve spring 14 4 id race 12 Page 7 Note The standard inlet cam is 9 40 mm max lift and 258 98 duration The Race Kit inlet cam is 9 40 mm max lift and 265 duration The standard exhaust cam is 8 70 mm max lift and 247 08 duration
21. lts for re use Retain the bracket and lock nuts if the motorcycle is to be returned to its original condition 3 Remove the seat support Retain the seat support if the motorcycle is to be returned to its original condition 4 Remove the bolt connecting the battery tray to the bridge pressing and retain for re use 5 Insert the Well nuts provided 7 into the corresponding holes on the battery tray 1 Bolt 2 Well nuts 6 Fit the regulator bracket 4 to the motorcycle using the original bolt removed from the bridge pressing and the two M5 x 15 bolts provided 9 Tighten the original bolt and the two M5 x 15 bolts 9 to 4 Nm 7 the M6 captive nuts provided 6 to the regulator bracket 4 1 Regulator bracket 2 Original bolt 3 M5 x 15 bolts 4 M6 captive nuts Fit the regulator to the bracket using the original M6 x 12 bolts 5 and tighten to 4 Nm Route the alternator connector underneath the diagnostic connector N 1 Regulator 2 M6 x 12 bolts 3 Alternator connector 4 Diagnostic connector Page 27 10 Relocate the ambient pressure sensor from the cockpit area to the left hand side of the battery tray and secure using the self tapping screw provided 10 Washers may be used to space the sensor from the battery tray Tighten the screw to 1 5 Nm 1 Ambient pressure sensor 2 Screw ABS Donor Motorcycles Only 11 Remove the fuel tank air box and throttle bodies f
22. oints using the two M8 x 20 Bolts 6 and washers 7 provided Tighten to 22 Nm Downpipe collector assembly Silencer Spring Carbon collar Silencer bracket Capscrew washer and nut 1 Silencer bracket Page 16 17 Tighten the downpipe collector assembly lower mounting point fixing to 19 Nm 1 Fixing 18 Tighten the exhaust header nuts following the sequence shown below Stage 1 Tighten the header nuts in sequence to 2 Nm Stage 2 Tighten the header nuts in sequence to 15 Nm 19 If fitting the oxygen sensor remove the threaded blanking plug from the race exhaust 20 Fit the oxygen sensor adaptor 11 to the downpipe collector assembly tighten to 25 Nm 21 Remove the oxygen sensor from the original exhaust system 22 Fit the oxygen sensor to the Race Kit exhaust system following the procedure detailed in the Daytona 675 service manual 23 Secure the aluminium lower radiator bracket provided 10 to the crankcase using the original lower radiator bracket fixing and compression limiter Note e The fixing and compression limiter should be inserted upwards through the bottom of the crankcase mounting point into the lower radiator bracket 24 Tighten the lower radiator bracket fixing to 6 Nm 25 Refit the radiator using the original fixings following the procedures detailed in the Daytona 675 service manual 26 Refill the cooling system followin
23. ollowing the procedures detailed in the Daytona 675 service manual 12 Remove the road speed sensor blanking plug and discard the fixing Retain the blanking plug if the motorcycle is to be returned to its original condition 13 Fit the road speed sensor 2 using the M6 x 16 bolt provided 3 and tighten to 4 Nm 1 Road speed sensor 2 M6 x 16 bolt 14 Connect the road speed sensor to the corresponding plug on the Race Harness All Models 15 Reconnect the Battery following the procedure detailed in the Daytona 675 service manual Note The alternator will now plug directly into the regulator e The relay and fuse box position has remained unchanged on the race harness for ease of access and maintenance however the fuse box will not locate onto the original fuse box mounting tab so will hang freely e 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 SAD purge control valve and evaporative canister California only and lights 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 off before use California only e The Race Harness still supports the cooling fan and incorporates a relay for the fan You may remove the cooling fan but must leave the relay in place
24. orcycle 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 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 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 Failure to correct the
25. pression coil 1 Remove the throttle body assembly following the 4 Refit the throttle body assembly following the procedure detailed in the Daytona 675 service procedure detailed in the Daytona 675 service manual manual 2 Remove the throttle stop screw and nut from the 5 Adjust the idle speed using the manual adjuster throttle body assembly screw item 1 as required 3 Fit the manual adjuster screw and compression spring supplied items 1 amp 2 Page 19 Cover Protectors Kit Superstock CI Der o Parts Supplied A9618132 Item Description Qty 1 Alternator cover protector 2 Clutch cover protector 3 Crank cover protector 4 Bolt M6 x 1 x 30 5 Bolt M6 x 1 x 20 Note For fitment refer to the comprehensive fitting instructions supplied with the Cover Protectors Kit Page 20 Cover Protectors Kit Supersport 98 B 9 VJ 5 y J 5 B Parts Supplied A9618172 Item Description Qty 1 Clutch cover protector 1 2 Crank cover protector 1 3 Bolt M6 x 1 x 30 5 4 Bolt M6 x 1 x 20 1 Note For fitment go to www triumphinstructions com and enter the kit number A961813 2 Follow Steps 1 to 6 of the comprehensive fitting instructions Page 21 Electrical Parts Race Alternator Kit Standard Standard Standard Part Part 120 Nm Parts Supplied A9618154
26. r Kit 0 neau haga ce 31 Page 2 General Information Please note e The Race Kit parts detailed in this publication are made in accordance with FIM technical regulations and are NOT road legal e 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 e When removing components which incorporate a gasket ALWAYS ensure a new gasket is fitted on re assembly e The Race Kit parts detailed in this publication are not covered by any warranty Specifications are subject to change without notice e The information contained in this publication is accurate at the time of final approval however Triumph Motorcycles LTD reserves the right to amend the information at any time without notice Whilst every effort is made to
27. verleaf Page 12 Remove the fuel tank and air box 9 Refit the air box 2 Remove the SAI solenoid valve 10 Fit the sealing cap provided over the air box hose 3 Remove the SAI reed valves Retain the fixings from connection as shown below the single valve for re use 4 Remove the camshaft cover Retain the fixings for 1 re use 5 Replace the standard hollow dowels with the solid dowels provided 3 F 1 A TEST A KAG N 1 Sealing cap 11 Refit the fuel tank 1 Dowels 6 Fit a new seal to the camshaft cover Refit the camshaft cover and secure with the original fixings 7 Fit the double reed valve cover using the M6 x 16 bolts provided Tighten to 9 Nm 8 Fit the single reed valve cover using the original single reed valve fixings Use the washers and flanged sleeves provided 6 and 7 to space the cover to the correct height Tighten to 9 Nm 1 Reed valve cover single 2 Reed valve cover double Page 13 Exhaust System Race Arrow The use of the Arrow Race Exhaust System will require changes to the fuelling and ignition settings Failure to correct the fuelling and ignition settings will result in poor engine performance and could result in engine damage Parts Supplied A9600440 Item Description Qty 1 Downpipe collector assembly 1 2 Silencer 1 3 Carbon collar 1 4 Spring 1 5 Primary header bushing 3 6 Bolt M8 x 20 2 7 Washer M8 3
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