Triumph Daytona 675, Street Triple and Street Triple R Motorcycle Service Manual

Pa rt Number 3856750 issue 1, 06.2009

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Service Manual - Daytona 675, Street Triple and Street Triple R

Table of Contents
Introduction General Information Scheduled Maintenance Cylinder Head Clutch Crankshaft, Connecting Rods and Pistons Balancer Transmission Lubrication Engine Removal/Refit Fuel System/Engine Management Cooling Rear Suspension Front Suspension Brakes Wheels/Tyres Frame and Bodywork Electrical

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Full Specification Engine
Engine Configuration ................... 3 Cylinder 12 valve DOHC ...........3 Cylinder 12 valve DOHC Arrangement......................... Transverse in-line ...................Transverse in-line Displacement......................... 674.8 cc ..........................674.8 cc Borex Stroke ......................... 74x52.3 mm....................... 74x52.3 mm CompressionRatio ..................... 12.65:1 ...........................12.65:1 CylinderNumbering ................... Left to Right ....................... Left to Right (no.3 adjacent to camchain) ...........(no.3 adjacent to camchain) CylinderSequence..................... Number 1 at left .................... Number 1 at left Firing Order ..........................1-2-3.............................1-2-3 Maximum Power ...................... 125 PS (123 bhp) at 12,500 rpm 1 ......108.2 PS (106.7 bhp) at 11,700 pm 128 PS (126 bhp) at 12,600 rpm
2

Daytona 675

Street Triple/Street Triple R

Maximum Torque ..................... 72 Nm (53.3 ft.lbf) at 11,750 rpm 1 .....68 Nm (50.1 ft.lbf) at 9,200 rpm) 73 Nm (53.3 ft.lbf) at 11,900 rpm Note:

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For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275.

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Full Specification Cylinder Head & Valves
ValveHead Diameter........ In ......... 30.50 mm ......................... 30.50 mm Ex........ 25.50 mm ......................... 25.50 mm ValveLift .................. In ......... 9.25 mm.......................... 8.00 mm Ex........ 8.50 mm .......................... 7.25 mm ValveStem Diameter........ In ......... 3.975-3.990 mm .................. ServiceLimit ............... 3.975-3.990 mm

Daytona 675

Street Triple/Street Triple R

.......... 3.965 mm......................... 3.965 mm 3.955-3.970 mm

ValveStem Diameter........ Ex ........ 3.955-3.970 mm .................. ServiceLimit ...............

.......... 3.945 mm......................... 3.945 mm

Valve Guide Bore Diameter .. In ......... 4.000-4.015 mm .................... 4.000-4.015 mm ServiceLimit ............... .......... 4.043 mm.........................4.043 mm

Valve Guide Bore Diameter . . Ex ........ 4.000-4.015 mm .................... 4.000-4.015 mm ServiceLimit ............... .......... 4.043 mm......................... 4.043 mm

Valve Stem to Guide Clearanceln......... 0.010-0.040 mm ....................0.01 -0.040 nom ServiceLimit ............... .......... 0.078 mm ......................... 0.078 mm 0.030-0.060 mm

Valve Stem to Guide ClearanceEx ........ 0.030-0.060 mm .................. ServiceLimit ...............

.......... 0.098 mm......................... 0.098 mm

ValveSeat Width (in head) ... In ......... 0.80-1.20 mm ...................... 0.80-1.20 mm ServiceLimit ............... .......... 1.50 mm .......................... 1.50 mm 1.00-1.40 mm

ValveSeat Width (in head) ... Ex ........ 1.00-1.40 mm ..................... ServiceLimit ...............

.......... 1.70 mm .......................... 1.70 mm

I

ValveSeat Width (valve) ..... In ......... 1.27-1.56 mm In......... 1.05-1.34 mm

..................... 1.27-1.56 mm

Ex........ 1.34-1.63 mm ..................... ValveSeat Angle ...........

1.34-1.63 mm

.......... 45 .............................. 450 508 N +/-25 N at 27.5 mm ........... 508 N +/-25N at 27.5 mm

Inlet/Exhaust Valve Spring 'Load at Length'

ValveClearance ............ In ......... 0.10-0.20 mm ...................... 0.10-0.20 mm Ex......... 0.275-0.325 mm Ex ........ 0.325-0.375 mm
I

................. 0.275-0.325 mm

Note:

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For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275.

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General Information
Full Specification Cylinder Head & Valves (continued)
Valve Bucket Diameter....... In ......... 26.476-26.490 mm In ........
1

Daytona 675

Street Triple/Street Triple R

................26.47 -26.490 mm

25.376-25.390 mm 2
I

ServiceLimit .......................... 26.468 mm

......................26.468 mm

25.368 mm 2 ValveBucket Diameter....... Ex......... 24.976-24.990 mm Ex......... 25.376-25.390 2 ServiceLimit .......................... 24.968 mm
I 1

................24.97 -24.990 mm

......................24.968 mm

25.368 mm 2 Valve Bucket Bore Diameter . . In ......... 26.515-26.535 mm In ........

I

................26.51 -26.535 mm

25.415-25.435 mm 2
I

ServiceLimit .......................... 26.549 mm 25.449 2 Valve Bucket Bore Diameter ..

......................26.549 mm

Ex.........

25.015-25.035 mm

................25.01 -25.035 mm

Ex......... 25.415-25.435 mm 2 ServiceLimit .......................... 25.049 mm

I

......................25.049 mm

25.449 mm 2

Camshafts
Cam Timing ............... Inlet ....... Open 2749 BTDC @ 1.0 mm lift......Open 13.23 BTDC @ 1.0 mm lift Close 51.49 ABDC @ 1.0 mm lift......Close 37.23 ABDC @ 1.0 mm lift Duration... 258.98 ........................... 230.46 Exhaust .... Open 43.09 BBDC Open 43.54 BBDC Close 23.09 ATDC Close 23.54 ATDC Duration...246.1
1 I

@ 1.0 mm lift. ...Open 25.09 BBDC @ 1.0 mm lift

2 I

@ 1.0 mm lift @ 1.0 mm lift .... Close 13.09 ATDC @ 1.0 mm lift

@ 1.0 mm lift

........................... 218.18

247.08 2 Camshaft Journal Diameter .............. 23.900-23.930 mm .................23.90 -23.930 mm Camshaft Journal Clearance ............ 0.070-0.121 mm ....................0.07 -0.121 mm

ServiceLimit .......................... 0.17 mm ..........................0.17 mm Camshaft Journal Bore Diameter ......... 24.000-24.021 mm .................24.00 -24.021 mm CamshaftEnd Float ................... 0.23-0.33 mm .....................0.2 -0.33 mm

ServiceLimit .......................... 0.40 mm ..........................0.40 mm CamshaftRun-out ..................... 0.15 mm max.......................0.15 mm max

Note:

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For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275.

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Full Specification Clutch/Primary Drive
PrimaryDrive Type ......... ReductionRatio ............ ClutchType ............... No. of Friction Plates ........ PlateFlatness .............. FrictionPlate Thickness ...... ServiceLimit ............... ClutchActuation Method .... CableFree Play (at lever) ..... .......... Gear ............................. Gear .......... 1.848 (46/85) ...................... 1.848 (46/85) .......... Wet multi-plate ..................... Wet multi-plate .......... 9 ............................... 9

Daytona 675

Street Triple/Street Triple R

.......... Within 0.2 mm ..................... Within 0.2 mm .......... 3.00 mm.......................... 3.00 mm .......... 2.80 mm .......................... 2.80 mm .......... Cable............................. Cable .......... 2.0-3.0 mm........................ 2.0-3.0 mm

Pistons
Cylinder Bore Diameter ...... .......... 73.985-74.003 mm ................. 73.985-74.003 mm

ServiceLimit ....................... 74.100 mm ........................ 74.100 mm Piston Diameter (at 90 to gudgeon pin) ... 73.970-73.980 mm .................73.964-73.980 mm ServiceLimit ....................... 73.920 mm ....................... 73.920 mm Piston Ring to Groove Clearances Top...................... .......... 0.04-0.08 mm .................... 0.02-0.06 mm

ServiceLimit ....................... 0.095 mm.........................0.075 mm Second........... ........ .......... 0.02-0.06 mm .................... 0.02-0.06 mm

ServiceLimit ....................... 0.075 mm.........................0.075 mm Piston Ring End Gaps Top...................... .......... 0.10-0.25 mm ...................... 0.10-0.25 mm

ServiceLimit ....................... 0.55 mm..........................0.55 mm Second................... .......... 0.25-0.40 mm .................... 0.25-0.40 mm

ServiceLimit ....................... 0.70 mm..........................0.70 mm Oil....................... .......... 0.10-0.35 mm ...................... 0.10-0.35 mm

Gudgeon Pin Bore Diameter in Piston ..... 1 6.004-16.012 mm .................. 16.004-16.012 mm ServiceLimit ....................... 16.040 mm........................ 16.040 mm Gudgeon Pin Diameter ...... .......... 15.995-16.000 mm .................15.995-16.000 mm

ServiceLimit ....................... 15.985 mm........................ 15.985 mm

Connecting Rods
Connecting Rod Small End Diameter...... 16.016-16.029 mm ..................16.016-16.029 mm ServiceLimit ....................... 16.039 mm........................ 16.039 mm Connecting Rod Big End Side Clearance... 0.15-0.30 mm ...................... 0.15-0.30 mm ServiceLimit ....................... 0.50 mm..........................0.50 mm

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General Information
Full Specification Crankshaft
Crankshaft Big End Journal Diameter...... 32.984-33.000 mm .................32.98 -33.000 mm ServiceLimit ....................... 32.960 mm........................32.960 mm Crankshaft Big End Bearing Clearance..... 0.035-0.065 mm ...................0.03 -0.065 mm ServiceLimit ....................... 0.070 mm ......................... 0.070 mm Crankshaft Main Bearing Journal Diameter . 32.984-33.000 mm ................ 32.984-33.000 mm

Daytona 675

Street Triple/Street Triple R

ServiceLimit ....................... 32.960 mm........................32.960 mm Crankshaft Main Bearing Clearance ....... 0.020-0.044 mm ...................0.02 -0.044 mm ServiceLimit ....................... 0.070 mm ......................... 0.070 mm CrankshaftEnd Float .................. 0.15-0.30 mm ......................0.1 -0.30 mm

CrankshaftRun-out .................... 0.02 mm or less ....................0.02 mm or less ServiceLimit ....................... 0.05 mm .......................... 0.05 mm

Transmission
Type............................... 6 Speed, Constant Mesh .............6 Speed, Constant Mesh
1

GearRatios ................ 1st ........ 2.615 (34/13) .........................1st ........ 2.313 (37/16)

......................2.615 (34/13)

2nd....... 1.857 (39/21) ...................... 1.857 (39/21) 3rd........ 1.565 (36/23) ...................... 1.565 (36/23) 4th........ 1.350 (27/20) ......................1.350 (27/20) 5th........ 1.238 (26/21) ...................... 1.238 (26/21) 6th........ 1.136 (25/22) .......................1.136 (25/22) GearSelector Fork Thickness ........... 5.9-6.0 mm ........................ 5.9-6.0 mm

ServiceLimit ....................... 5.80 mm .......................... 5.80 mm GearSelector Groove Width ............. 5.80 mm .......................... 5.80 mm ServiceLimit ....................... 6.27 mm .......................... 6.27 mm Gear Selector Fork to Groove Clearance .. . 0.47 mm max ...................... 0.47 mm max

Final Drive
FinalDrive ........................... Chain ............................. Chain FinalDrive Ratio ....................... 2.937 (16/47) ......................2.937 (16/47) ChainType ........................... RK O-ring ......................... RK O-ring Numberof Links ...................... 116............................... 116 20 Link Length ........................ 319 mm ........................... 319 mm DriveChain Play ......................35-40 mm.........................20-25 mm ChainLubrication ...................... Mobil chain spray ................... Mobil chain spray

Note:

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For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275.

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Full Specification Lubrication
Type ..................... OilCapacity (dry fill) ........ .......... Pressure Lubrication, Wet Sump ....... Pressure Lubrication, Wet Sump .......... 3.5 litres .......................... 3.5 litres

Daytona 675

Street Triple/Street Triple R

Oil Capacity (wet fill including filter) ....... 3.1 litres ........................... 3.1 litres Oil Capacity (wet fill excluding filter) ...... 2.9 litres .......................... 2.9 litres Recommended Oil Approval Rating....... API SH (or higher) and JASO MA...... API SH (or higher) and JASO MA Viscosity.................. Type..................... Oil pressure (in main gallery) . OilPump Rotor Tip Clearance .......... 10W/40 or 15W/50 ................. 10W/40 or 15W/50 .......... Semi or fully synthetic ............... Semi or fully synthetic .......... 30.0 Ib/in2 min. @ 80C ............ 30.0 Ib/in2 min. @ 80C oil temperature @ 5,000 rpm oil temperature @ 5,000 rpm .......... 0.15 mm .......................... 0.15 mm

ServiceLimit ....................... 0.20 mm..........................0.20 mm OilPump Body Clearance .... .......... 0.15-0.22 mm ...................... 0.15-0.22 mm

ServiceLimit ....................... 0.35 mm..........................0.35 mm OilPump Rotor End Float .... ServiceLimit ............... .......... 0.04-0.09 mm .....................0.0 -0.09 mm .......... 0.17 mm .......................... 0.17 mm

Ignition System
Type..................... ElectronicRev Limiter ....... .......... Digital Inductive .................... Digital Inductive .......... 14,000 (rpm)....................... 13,000 (rpm)

Pick-up Coil Resistance ...... .......... 0.21 KW +/-10% @ 20C.............0.21 KW +/-10% @ 20C IgnitionCoil Type ........... .......... Plug-top........................... Plug-top

SparkPlug Type ............ .......... NGK CR9EK....................... NGK CR9EK SparkPlug Gap ............ .......... 0.7 mm........................... 0.7 mm

Fuel System
FuelType ................. FuelTank Capacity .......... Low Level Warning Lamp .... FuelPump Type ............ FuelPressure (nominal) ...... Purge Control System ....... .......... Unleaded, 95 RON ................. Unleaded, 91 RON (U.S. 87 CLC/AKI) (U.S. 89 CLC/AKI) .......... 17.4 litres .......................... 17.4 litres .......... 4 litres remaining ................... 4 litres remaining .......... Submerged ........................ Submerged .......... 3.0 bar ........................... 3.0 bar .......... Electronic, via fuel system ECU ........ Electronic, via fuel system ECU

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General Information
Full Specification Coolant System
Note: Up to VIN 331531 use Triumph HD4X Hybrid OAT coolant when replacing the coolant. From VIN 331532 use Triumph HD4X Hybrid OAT coolant when topping up or replacing the coolant.
water/anti-freeze

Daytona 675

Street Triple/Street Triple R

Coolant Mixture up to VIN 331531 ....... 50/50 Distilled .....................5 /50 Distilled water/anti-freeze

Coolant Mixture from VIN 331532 ....... 50/50 (pre-mixed as supplied .........50/50 (pre-mixed as supplied pre-mixed as supplied by Triumph) pre-mixed as supplied by Triumph)

Anti-Freeze Type up to VIN 331531 ....... Mobil anti-freeze ....................Mobil anti-freeze Anti-Freeze Type from VIN 331532 ....... Triumph HD4X Hybrid :..............Triumph HD4X Hybrid OAT coolant OAT coolant

Freezingpoint ........................- 35C............................ -35C CoolingSystem Capacity ................ 2.4 litres........................... 2.2 litres RadiatorCap Opening Pressure .......... 1.1 bar ............................1.1 bar Thermostat Opening Temperature ........ 71 C (nominal) ..................... 71 C (nominal) CoolingFan Switch On Temperature ..... 103C ............................10 C

Temperature Gauge Sensor Resistance .... 2.9 3.3 KQ@ 15C ................2.9 3.3 KQ @ 15C

Suspension
FrontFork Travel ...................... 110 mm ........................... 120 mm Recommended Fork Oil Grade........... Kayaba KHL15-10 ...................Kayaba KHL15-10 OilLevel ............................ 72 mm (up to VIN 381274)...........107 mm for Street Triple (fork fully compressed, spring removed) ... 89 mm (from VIN 381275) ...........93 mm for Street Triple R Oil Volume (dry fill) .................... 495 cc (up to VIN 381274) ...........465 cc for Street Triple 492 cc (from VIN 381275)............484 cc for Street Triple R ForkPull Through ..................... 4 mm.............................4 mm RearWheel Travel ..................... 130 mm...........................126 mm Rear Suspension Bearing Grease ......... Mobil grease HP 222 ................Mobil grease HP 222

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Full Specification Fuel Injection System
Type..................... IdleSpeed ................ Injecto
rTy

Daytona 675

Street Triple/Street Triple R

.......... Electronic, sequential ................ Electronic, sequential .......... 1200 RPM ........................ 1200 RPM .......... Twin jet, solenoid ................... Twin jet, solenoid operated plate valve operated plate valve .......... Cable/twist grip/electronic ............ Cable/twist grip/electronic throttle potentiometer throttle potentiometer .......... Barometric pressure, throttle .......... position, coolant temperature, crankshaft position, vehicle speed, lambda sensor, intake air temperature, gear position, MAP Barometric pressure, throttle position, coolant temperature, crankshaft position, vehicle speed, lambda sensor, intake air temperature, gear position, MAP

...............

Throttle ................... Control Sensors ............

Emissions Controls
Catalysts.................. .......... 1, in down pipe..................... 1, in down pipe

Oxygensensor ............ .......... Heated, in down pipe................ Heated, in down pipe Secondary Air injection ..... .......... Solenoid controlled.................. Solenoid controlled, reed valve type reed valve type Evaporative Control ........ .......... Activated carbon ................... Activated carbon canister (California only) canister (California only)

Brakes
Front Type ................ .......... Two hydraulically actuated ............ Two hydraulically actuated four piston radial calipers twin piston sliding calipers acting on twin discs 1 acting on twin discs .......... 33.96 mm / 30.23 mm 4 x 32.03 mm 2 2 x 27.00 mm * 33.96 mm / 30.23 mm $

Caliper Piston Diameter ...... DiscDiameter ............. DiscThickness .............

.......... 308 mm .......................... 308 mm .......... 4 mm ............................ 4 mm

ServiceLimit ....................... 3.5 mm ........................... 3.5 mm DiscRun-out ............... Master Cylinder Diameter Recommended Fluid ........ .......... 0.3 mm Max ...................... 0.3 mm Max 19.05 mm 14.00 mm for Street Triple 19.05 mm for Street Triple R .......... Mobil universal brake................ Mobil universal brake and clutch fluid DOT4 and clutch fluid DOT4

Note:
1

For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275.

* For Street Triple. # For Street Triple R

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Full Specification Brakes (continued)
Rear Type ........................... Hydraulically actuated single .......... Hydraulically actuated single piston caliper, single disc piston caliper, single disc

Daytona 675

Street Triple/Street Triple R

CaliperPiston Diameter ................. 38.18 mm .........................38.18 mm DiscDiameter ......................... 220 mm ..........................220 mm DiscThickness ........................ 5.0 mm ........................... 5.0 mm ServiceLimit ....................... 4.5 mm ........................... 4.5 mm DiscRun-out .......................... 0.3 mm Max.......................0.3 mm Max MasterCylinder Diameter ............... 14 mm............................14 mm Recommended Fluid ................... Mobil universal brake and ........... Mobil universal brake and

.................................... clutch fluid DOT4 ................... clutch fluid DOT4

Wheels and Tyres

Front Wheel Size ...................... MT 3.5 x 17 ....................... MT 3.5 x 17 FrontTyre Size ........................ 120/70 ZR 17 ...................... 120/70 ZR 17 FrontTyre Pressure ..................... 2.35 Bar (34 lb/in2)..................2.35 Bar (34 lb/in 2) Recommended Front Tyre. . . . Option 1 ... Pirelli Dragon Supercorsa Pro
2
1

. . . . .

. Bridgestone Battlax BT016 F

Pirelli Diablo Super Corsa SP ......... Dunlop Sportmax Qualifier $ Option 2 ... Michelin Pilot Power B Dunlop Qualifier
2 I

.............. Dunlop Sportmax Qualifier

................... Bridgestone BT015 G t

I

Option 3 ... Bridgestone BT014 G Metzeler M3 C

2

............... Pirelli Dragon Supercorsa Pro

Option4 ... N/A .............................. Bridgestone BT015 G Front Wheel Rim Axial Run-out .......... 0.5 mm ...........................0.5 mm Front Wheel Rim Radial Run-out.......... 0.5 mm ...........................0.5 mm RearWheel Size ....................... MT 5.5 x 17 ....................... MT 5.5 x 17 RearTyre Size ......................... 180/55 ZR 17 ...................... 180/55 ZR 17 RearTyre Pressure ..................... 2.5 Bar (36 1b/ft 2 ) ................... 2.9 Bar (42 lb/ft
2)

Recommended Rear Tyres.... Option 1 ... Pirelli Dragon Supercorsa Pro' ........ Bridgestone Battlax BT016 R Pirelli Diablo Super Corsa SP z ......... Dunlop Sportmax Qualifier Option 2 ... Michelin Pilot Power
z

................ B 'Dunlop Sportmax Qualifier

Dunlop Qualifier . .................. Bridgestone BT014 E $ Option 3 ... Bridgestone BT014 G Metzeler M3
2
I

............... Pirelli Dragon Supercorsa Pro

Option4 ... N/A .............................. Bridgestone BT015 E '` RearWheel Rim Axial Run-out ........... 0.5 mm ........................... 0.5 mm RearWheel Rim Radial Run-out .......... 0.5 mm ...........................0.5 mm

Note: ,.,

For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275.

* For Street Triple.

# For Street Triple R.

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Full Specification Frame
FrameType ............... OverallLength ............. .......... Twin-spar aluminium ................Twin-spar aluminium .......... 2010 mm (79.1 in) .................. 2000 mm (78.7 in) Street Triple 2030 mm (79.9 in) Street Triple R .......... 700 mm (27.5 in) ................... 750 mm (29.5 in) Street Triple 755 mm (29.7 in) Street Triple R .......... 1120 mm (44.1 in) .................. 1165 mm (45.8 in) Street Triple 1185 mm (46.7 in) Street Triple R .......... 1395 mm (54.9 in).................. 1390 mm (54.7 in) .......... 825 mm (32.5 in)................... 810 mm (31.8 in) Street Triple 805 mm (31.7 in) Street Triple R .......... 23.9 ............................. 24.3 Street Triple 23.9 Street Triple R .......... 89.1 mm .......................... 95.3 mm Street Triple 92.4 mm (3.64 in) Street Triple R .......... 165 kg............................ 1 67 kg .......... 195 kg............................ 195 kg

Daytona 675

Street Triple/Street Triple R

Overall Width ..............

OverallHeight .............

Wheelbase................ SeatHeight ...............

Rake.....................

Trail.....................

DryWeight ................ MaximumPayload ..........

(rider, passenger, luggage and accessories)

Electrical Equipment
BatteryType ............... .......... YT 7B - BS' ........................ YTX9 - BS YTX 9 - BS2 BatteryRating .............. AlternatorRating ........... .......... 12V 6.5 Amp. Hour ............... 12V 8 Amp. Hour .......... 33.5 A at 4,000 rpm ................ 33.5 A at 4,000 rpm

Fuses*... #1 ......Dip and main beam ........... 15 Amp ..................... 20 Amp headlights, starter relay ........ #2 ......Ignition switch, starter circuit .... 1 0 Amp ..................... 1 0 Amp ........ #3 ......Auxilliary li ghting ............. 5 Amp ...................... 5 Amp ........ 1 0 Amp ..................... 1 0 Amp

........ #4 ......Indicators, Alarm, Horn

........ #5 ......Cooling fan .................. 15 Amp ..................... 15 Amp ........ #6 ......Engine management system..... 20 Amp ..................... 20 Amp *The starter solenoid has an additional 30 Amp fuse, attached directly to the solenoid, beneath the rider's seat.

Note:

1 2

For Daytona 675 up to VIN 381274. For Daytona 675 from VIN 381275.

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Torque Wrench Settings
Cylinder Head Area
Application Cam cover to cylinder head Torque (Nm) 10 Notes Fit new bolt seals and lubricate with clean engine oil

Secondary air injection valve covers to cam cover Cam chain tensioner to cylinder head - All models except Daytona 675 from VIN 381275 Cam chain tensioner to cylinder head - Daytona 675 from VIN 381275 Cam chain tensioner to centre bolt - All models except Daytona 675 from VIN 381275 Camshaft bearing caps and camshaft bearing ladder to head Camshaft sprocket to camshaft Cylinder head to crankcase (M6 screws) Cylinder head to crankcase bolts Sound suppression bolt in head Spark plug to cylinder head

9 9 9 7 Use new fixings

See section 3 15 10 See section 3 12 12 Use new fixings

Clutch

Application Clutch cover to crankcase Clutch centre nut Clutch pressure plate to centre Clutch lever clamp bolts to handlebar Clutch cable adjuster bracket to crankcase

Torque (Nm) 9 98 10 12 12

Notes

Crankshaft and Crankcase, Sprag

Application Crankcase upper to lower (M8 fixings) Crankcase upper to lower (M6 fixings) Connecting rod big end nut Sprag clutch to crankshaft Camshaft drive sprocket gear to crankshaft Torque (Nm) See section 6 See section 6 See section 6 See section 7 27 Use new fixing Notes

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Service Manual - Daytona 675, Street Triple and Street Triple R

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General Information
Engine Covers Application Clutch cover to crankcase Sprocket cover to crankcase Alternator cover to crankcase Crank cover to crankcase Balancer cover to crankcase Transmission Application Output sprocket to output shaft Torque (Nm) 85 12 12 12 12 20 5 9 22 6 Use a new fixing Notes Use new tab washer Use a new fixing Use a new fixing Use new fixings Use new fixings Torque (Nm) 9 9 9 9 9 Notes

Detent wheel to selector drum Detent arm bolt Input shaft bearing carrier Selector shaft retainer Spring abutment bolt Gear position sensor Gear pedal pinch bolt Gear pedal pivot bolt Gear change rod adjuster nuts Lubrication System Application Sump to crankcase Sump drain plug to sump Oil pressure relief valve to crankcase

Torque (Nm) 12 25 15

Notes

Use a new washer Apply ThreeBond 1305 to the threads Use new washers

Low oil pressure warning light switch to crankcase Oil filter to adapter Heat exchanger to crankcase

13 10 59

Use a new sealing washer Use new fixings Use new fixings Apply ThreeBond 1374 to the threads

Oil pump drive chain retainer plate Oil pump to crankcase Oil pump drive sprocket to pump shaft

9 12 14

Oil pump rotor cover to pump body bolts Transmission oil feed pipes to crankcase

12 12 Use new fixings

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General Information
Final Drive
Application Rear sprocket to sprocket carrier Rear sprocket studs to sprocket carrier Chain guard bolts Chain rubbing strip to swinging arm Torque (Nm) 55 30 9 9 Use new fixings Notes

Cooling System
Application Water pump/oil pump assembly to crankcase Upper right hand radiator mounting to frame Upper left hand radiator mounting to frame/steering damper (if fitted) Lower radiator mounting to radiator Lower radiator mounting to engine (Daytona 675) Lower radiator mounting to engine bracket (Street Triple)) Lower radiator engine bracket to water elbow (Street Triple) Water inlet elbow to head Thermostat housing to head Fan to radiator Radiator bleed screw Top hose bleed screw (Street Triple only) Radiator cowl to radiator Torque (Nm) 12 6 12 3 9 9 12 12 9 2.5 1.5 1 5 Notes Use new fixings

Fuel System, Exhaust System and Airbox

Application Fuel tank to frame (front fixing) Fuel tank to frame (rear fixing) Fuel tank front bracket to fuel tank Fuel cap to fuel tank Fuel pump mounting plate to fuel tank Throttle body transition piece to cylinder head Throttle potentiometer to throttle body Exhaust downpipe to cylinder head Exhaust downpipe to frame Exhaust intermediate pipe to frame Silencer mounting bracket to subframe (Daytona 675) Silencer mounting bracket to subframe (Street Triple) Exhaust clamp - header to intermediate pipe Exhaust clamp - silencer to intermediate pipe (Daytona 675) Torque (Nm) 9 9 9 4 9 12 2 See section 10 19 22 27 15 15 15 Notes

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Service Manual - Daytona 675, Street Triple and Street Triple R

1.39

General Information
Fuel System, Exhaust System and Airbox (continued) Application
Exhaust clamps - silencers to intermediate pipe (Street Triple) Exhaust valve actuator bracket to frame (Daytona 675) Exhaust valve actuator to bracket (Daytona 675) Exhaust valve actuator pulley wheel to Actuator shaft (Daytona 675) Airbox upper section to lower Air filter to lower airbox Airbox lower to frame Airbox trumpet to throttle body Carbon canister to bracket Carbon canister bracket to frame Carbon canister bracket to frame (upper screw - Street Triple only)

Torque (Nm)
10 9 12 5 1.5 4 3 6 3 8 4

Notes

Use new fixing

Use new fixings

Rear Suspension Application

Swinging arm spindle bolt Swinging arm rubbing strip bolts Chain adjuster locknut Rear suspension unit upper mounting bolt Rear suspension unit upper clevis to frame Rear suspension unit lower mounting bolt Drag link pivot at frame Drop links to swinging arm Swinging arm end-float adjuster sleeve

Torque (Nm)
110 9 20 48 52 48 48 48 6

Notes

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Service Manual - Daytona 675, Street Triple and Street Triple R

I UMP

General Information
Front Suspension Application Upper yoke pinch bolt Lower yoke pinch bolt Fork top cap Upper yoke centre nut Damping cylinder bolt Handlebar clamp to fork (Daytona 675) Handlebar clamp to riser (Street Triple and Street Triple R) Handlebar riser to upper yoke (Street Triple and Street Triple R) Steering damper to lower yoke (Daytona 675 only) Steering damper to frame bracket (Daytona 675 only) Steering damper frame bracket to frame (Daytona 675 only) Steering damper rod lock nut (Daytona 675 only) Wheels Application Front wheel spindle / axle bolt Front wheel spindle pinch bolts Rear wheel spindle / axle bolt Front Brakes Application Front brake caliper to fork (Daytona 675 and Street Triple R) Front brake caliper half to caliper half (Daytona 675 and Street Triple R) Front brake caliper to fork (Street Triple) Front brake pad retaining pin Front brake pad retaining pin plug (Street Triple) Front brake caliper bleed screw Front brake hose to caliper Front brake master cylinder to handlebar Front brake master cylinder reservoir to mounting ( Daytona 675 and Street Triple R) Front brake master cylinder bleed screw Front brake hose to master cylinder Front brake disc to wheel Torque (Nm) 35 22 28 18 3 6 25 12 7 Use new fixings Notes Torque (Nm) 65 22 110 Notes Torque (Nm) 26 20 See text 90 See text 26 26 35 18 18 12 20 Use new fixings Lubricate threads with engine oil Use a new washer Notes

6 25 22 Use new fixings

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Service Manual - Daytona 675, Street Triple and Street Triple R

1.41

General Information
Rear Brakes Application Rear brake caliper to carrier (M12 fixing) Rear brake caliper to carrier (M8 fixing) Rear brake pad retaining pin Rear brake pad retaining pin plug Rear brake caliper bleed screw Rear brake hose to caliper Rear brake hose clips to swinging arm Rear brake master cylinder to control plate (includes heel guard) Rear brake lever to control plate Torque (Nm) 27 22 18 3 6 25 6 18 22 Apply ThreeBond 1360 to the threads Notes

Rear brake master cylinder reservoir to frame Rear brake hose to master cylinder Rear brake disc to wheel Frame, Footrests, Control Plates and Engine Mountings Application Upper crankcase to frame Lower crankcase to frame Cylinder head to frame Engine mounting bracket to frame Engine mounting bracket to cylinder head Control plate to frame Left hand heel guard to control plate (Daytona 675)

7 25 22 Use new fixings

Torque (Nm) See section 9 See section 9 See section 9 See section 9 See section 9 27 9

Notes

Use new fixings Apply ThreeBond 1360 to left hand fixings

Left hand heel guard to control plate (Street Triple) Rear footrest hanger to frame

12 27 Apply ThreeBond 1360 to threads on Street Triple and Street Triple R only

Side stand mounting bracket Side stand pivot

45 20 Apply ThreeBond 1360 to threads Apply ThreeBond 1360 to threads

Bank angle indicator

1.42

Service Manual - Daytona 675, Street Triple and Street Triple R

Il]MP

General Information
Electrical Application Alternator rotor to crankshaft Alternator stator to cover Alternator regulator to bracket Alternator regulator bracket to frame Starter motor to crankcase Spark plug to cylinder head Bodywork Application Mirror (Daytona 675) Mirror (Street Triple) Rear panels to frame Front mudguard to forks Rear mudguard to subframe Number plate bracket to silencer (Daytona 675) Number plate bracket to subframe (Street Triple) Heat shield to silencer (Daytona 675) Lower fairing fixings (Daytona 675) Cockpit fixings (Daytona 675) Windshield fixings (Daytona 675) Torque (Nm) 9 25 3 6 4 12 23 6 See section 16 See section 16 0.5 Notes Torque (Nm) 120 12 3 12 10 12 Notes

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Service Manual - Daytona 675, Street Triple and Street Triple R

1.43

General Information
Clutch Cable Routing - Daytona 675

1.44

Service Manual - Daytona 675, Street Triple and Street Triple R

IL1MP

General Information
Clutch Cable Routing - Street Triple and Street Triple R

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Service Manual - Daytona 675, Street Triple and Street Triple R

1.45

General Information
Throttle Cable Routing - Daytona 675

1.46

Service Manual - Daytona 675, Street Triple and Street Triple R

IIIMP

General Information
Throttle Cable Routing - Street Triple

I UMP

Service Manual - Daytona 675, Street Triple and Street Triple R

1.47

General Information
Throttle Cable Routing - Street Triple R

1.48

Service Manual - Daytona 675, Street Triple and Street Triple R

I UMP

General Information
Main Wiring Harness Routing - Daytona 675 up to VIN 381274

ILIMP

Service Manual - Daytona 675, Street Triple and Street Triple R

1.49

General Information
Main Wiring Harness Routing - Daytona 675 from VIN 381275

1.50

Service Manual - Daytona 675, Street Triple and Street Triple R

S UMP

General Information
Main Wiring Harness Routing - Street Triple and Street Triple R

ILIMP

Service Manual - Daytona 675, Street Triple and Street Triple R

1.51

General Information
Rear Light Harness Routing - Daytona 675

1.52

Service Manual - Daytona 675, Street Triple and Street Triple R

II.I MP

General Information
Front Brake Hose Routing - Daytona 675

I UMP

Service Manual - Daytona 675, Street Triple and Street Triple R

1.53

General Information
Front Brake Hose Routing - Street Triple

1.54

Service Manual - Daytona 675, Street Triple and Street Triple R

ll1MP

General Information
Front Brake Hose Routing - Street Triple R

lgmp

Service Manual - Daytona 675, Street Triple and Street Triple R

1.55

General Information
Rear Brake Hose Routing - All Models (Daytona 675 shown)

1.56

Service Manual - Daytona 675, Street Triple and Street Triple R

Il1MP

General Information
Fuel Tank Breather Hose Routing - Daytona 675

IIIMP

Service Manual - Daytona 675, Street Triple and Street Triple R

1.57

General Information
Fuel Tank Breather Hose Routing - Street Triple and Street Triple R

1.58

Service Manual - Daytona 675, Street Triple and Street Triple R

II,I MP

General Information
Fuel Tank Breather Hose Routing - Models with Evaporative Emissions Daytona 675

A - Purge Hose to Throttle Bodies B - Breather Hose to Carbon Canister C - Breather hose - Fuel Tank Filler Drain

iiiiiiiij

Service Manual - Daytona 675, Street Triple and Street Triple R

1.59

General Information
Fuel Tank Breather Hose Routing - Models with Evaporative Emissions Street Triple and Street Triple R

B - Breather Hose to Carbon Canister C - Breather hose - Fuel Tank Filler Drain

1.60

Service Manual - Daytona 675, Street Triple and Street Triple R

I UMP

General Information
Intake Air Flap Vacuum Hose Routing - Daytona 675 only

111MP

Service Manual - Daytona 675, Street Triple and Street Triple R

1.61

Electrical
Lighting Circuit - Street Triple and Street Triple R
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Item Description Fuse box (Fuse 1) Starter relay Main / dip beam switch Pass switch LH dip beam bulb LH main beam bulb LH position lamp RH dip beam bulb RH main beam bulb RH position lamp Instrument assembly Engine sub harness Oil pressure switch Coolant temperature sensor Tail light Number plate lamp Fuse box (Fuse 3) Ignition switch Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue

1 7.52

Service Manual - Daytona 675, Street Triple and Street Triple R

1laMP

Electrical
Lighting Circuit - Street Triple and Street Triple R
18
c+

---

C) 0 P I o

2
2

RJ Y

111

JAIX17

III

/+ 2
3 2 UY

16
t

it
2 3

Fe

4 i

1/ 15

T
14
K G KB 2 1

KG K^

13
12 U

12

FH
3

OF

44` 5

F 8 9 10

6 7

Il1MP

Service Manual - Daytona 675, Street Triple and Street Triple R

1 7.53

Electrical
Starting and Charging Circuit - Street Triple and Street Triple R
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Item Description Battery Starter solenoid Alternator Regulator / rectifier Ignition switch Fuse box (Fuses 1, 2,4,5 and 6) Instrument assembly Engine stop switch Starter switch Alarm Fuel pump relay Engine control module Engine control module relay Starter relay Starter motor Key to wiring colours Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue

1 7.54

Service Manual - Daytona 675, Street Triple and Street Triple R

I UMP

Electrical
Starting and Charging Circuit - Street Triple and Street Triple R

15 2
I1/I VVV 0A

F_EII-t
+'

_____ ii i

1
1 3 1

14

31^
EN

13

VS 1AAfl2AJ P

6N

j,ii
2

3 r
4 1

I
uP I

ENGINE STOP

START

SWITCH

10

Il]MP

Service Manual - Daytona 675, Street Triple and Street Triple R

1 7.55

Electrical
Auxiliary and Accessory Circuit - Street Triple and Street Triple R
Key to circuit diagram
Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Item Description Fuse box (Fuse 4) Indicator relay Horn LH switch cube Horn switch Direction indicator switch Instrument assembly Direction indicator (Instruments) Alarm LED Front right direction Indicator Front left direction Indicator Alarm unit Rear right direction indicator Rear left direction indicator Diagnostic connector Brake light Rear brake light switch Front brake light switch Ignition switch

Key to wiring colours

Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue

1 7.56

Service Manual - Daytona 675, Street Triple and Street Triple R

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Electrical
Auxiliary and Accessory Circuit - Street Triple and Street Triple R

1 0A

9 19

10

11

12 1

13

14

I UMP

Service Manual - Daytona 675, Street Triple and Street Triple R

1 7.57

Electrical
Complete System - Daytona 675 up to VIN 300525 with/without Fuel Pump Relay Modification
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Item Description Instrument assembly Vehicle speed sensor 42 Front brake lever switch 43 Engine stop switch Starter button Exhaust control valve actuator Engine control module Gear position sensor Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump Cooling fan relay Cooling fan Intake flap actuator Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light 64 Engine earth 62 63 59 60 61 55 56 57 58 LH front indicator LH position light RH position light Dip beam bulb Main beam bulb Horn RH front indicator Fuel pump relay modification Fuel pump relay 50 51 52 53 54 48 49 44 45 46 47 Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit Starter motor 40 41 38 39 RH rear indicator Number plate light LH rear indicator Alarm connector (accessory)

1 7.58

Service Manual - Daytona 675, Street Triple and Street Triple R

I UMP

Electrical
Complete System - Daytona 675 from VIN 300526 to VIN 323544 with Fuel Pump Relay
Key to circuit diagram
Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Item Description Instrument assembly Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Exhaust control valve actuator Engine control module Gear position sensor Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump Cooling fan relay Cooling fan Intake flap actuator Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 38 39 40 41 42 43 44 45 RH rear indicator Number plate light LH rear indicator Alarm connector (accessory) Starter motor Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit LH front indicator LH position light RH position light Dip beam bulb Main beam bulb Horn RH front indicator Fuel pump relay

1 7.60

Service Manual - Daytona 675, Street Triple and Street Triple R

-^y,^

Electrical
Complete System - Daytona 675 - from VIN 323545 to VIN381274
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Item Description Instrument assembly 42 Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Exhaust control valve actuator Engine control module 48 Gear position sensor 49 Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator 56 Fall detection switch Inlet air temperature sensor Throttle potentiometer 59 Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump Cooling fan relay Cooling fan Intake flap actuator Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light RH rear indicator Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue 60 61 62 Horn RH front indicator Fuel pump relay Main beam bulb 57 58 RH position light Dip beam bulb LH position light 50 51 52 53 54 55 Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit LH front indicator 43 44 45 46 47 Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Starter motor 39 40 41 Number plate light LH rear indicator Alarm connector (accessory)

Key to wiring colours

17.62

Service Manual - Daytona 675, Street Triple and Street Triple R

ll,INIP

Electrical
Complete System - Daytona 675 - from VIN 381275
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Item Description Instrument assembly Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Exhaust control valve actuator Engine control module Gear position sensor Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump Cooling fan relay Cooling fan Intake flap actuator Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light RH rear indicator 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Number plate light LH rear indicator Alarm connector (accessory) Starter motor Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit LH front indicator LH position light RH position light Dip beam bulb Main beam bulb Horn RH front indicator Fuel pump relay Accessory quickshifter

1 7.64

Service Manual - Daytona 675, Street Triple and Street Triple R

1 uM

1 7.63

Electrical
Complete System - Street Triple and Street Triple R
Key to circuit diagram Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Item Description Instrument assembly Vehicle speed sensor Front brake lever switch Engine stop switch Starter button Engine control module Gear position sensor Lambda sensor Fuel injector 1 Fuel injector 2 Fuel injector 3 Secondary air injection solenoid Low fuel sensor Idle speed control actuator Fall detection switch Inlet air temperature sensor Throttle potentiometer Oil pressure switch Coolant temperature sensor Ambient pressure sensor MAP sensor EMS main relay Purge valve Ignition coil 1 Ignition Coil 2 Ignition coil 3 Fuel pump relay Fuel pump Cooling fan relay Cooling fan Sidestand switch Engine ground Crankshaft sensor Diagnostic connector Rear brake lever switch Rear light RH rear indicator Number plate light Key B U N G S 0 K R P W Y LG LU Wiring Colour Black Blue Brown Green Slate / Grey Orange Pink Red Purple White Yellow Light Green Light Blue 54 55 56 57 58 59 60 61 62 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 LH rear indicator Alarm connector (accessory) Starter motor Starter solenoid (fused) Battery Starter relay Rectifier / regulator Alternator Fuse box Ignition switch Clutch lever switch Horn button Direction indicator switch Headlamp dip switch Direction indicator unit LH front indicator LH position light LH dip beam bulb LH main beam bulb RH position light RH Dip beam bulb RH main beam bulb Horn RH front indicator

Key to wiring colours

1 7.66

Service Manual - Daytona 675, Street Triple and Street Triple R

I UMP