675 Race Manual 2011 PDF

2011 Daytona 675 (VIN 381275>) and
Daytona 675 R
Motorcycle Race Kit Manual
FOR CLOSED-CIRCUIT USE ONLY

© Triumph Designs Ltd 2011. - A9900595 - ADC 10263 issue 1
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gaskets
Side Cover Gasket Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Camshafts and Valves
Camshaft, Valve Spring & Camshaft Sprocket Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manually Adjustable Camshaft Drive Chain Tensioner. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inlet & Exhaust Valve Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bearings
Conrod Bearing Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Main Bearing Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil Pump
Oil Pump Gearing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Induction and Exhaust
Air Funnel Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Secondary Air Injection (SAI) Blanking Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exhaust System, Race (Arrow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Air Filter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Manual Idle Speed Adjuster Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Tranmission
Slipper Clutch Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Slipper Clutch Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Detent Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cooling
Silicon Hose Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Race Alternator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Programmable Race ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Triumph Race Calibration Software (TRACS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TRACS Management Kit
(Programmable Race ECU and Race Calibration Software Bundle). . . . . . . . . . . . . . . . . . 39
Race Harness Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Quickshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chassis Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Quickshifter, Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Rearsets, Race, Reverse Shift (Arrow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rearsets, Race, Standard Shift (Arrow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
© Triumph Designs Ltd 2011
Page 2 of 62
Introduction
2011 Triumph Daytona 675 and Daytona 675R
New for 2011 is the Daytona 675R, a highly specified version of the award-winning Daytona 675 fitted with race-
specification suspension and brake components as standard.
To create the definitive version of the Daytona 675, Triumph turned to Swedish suspension specialists Öhlins.
Together the companies specified Öhlins’ 43mm NIX30 forks and TTX36 rear monoshock units normally
reserved for racetrack use and very close relatives of the items used on the championship winning MotoGP and
world superbike machines.
The iconic gold anodised forks feature 30mm cartridge internals, offering full compression and rebound
damping and preload adjustment. At the rear, the TTX36 shock is smaller and lighter than previous Öhlins
shocks and features a clever twin tube design for improved rider feedback. This twin tube technology creates
positive pressure build up on both the compression and rebound stroke, guaranteeing a well-balanced action. As
one would expect from such a quality unit, the TTX36 unit features a wide range of adjustment for preload,
compression and rebound damping, the latter two made through separate adjusters on the top of the unit. As
further evidence of the bike’s track capability, both front and rear suspension units come equipped to accept the
sensors required for running datalogging equipment.
Stopping the Daytona 675 are new Brembo monoblock calipers gripping 308mm discs and fitted with race
arrangement braided brake lines and a bespoke 18mm Brembo radial master cylinder. The feedback and
stopping power offered by this rigid four-piston set-up provides the kind of outstanding stopping power one
would expect from a top-of-the-range sports machine.
A full range of race parts are available to further develop the Daytona 675 and Daytona 675R under FIM
supersport regulations. These include the Triumph Race Calibration Software (TRACS), which allows adjustment
of many parameters within the race kit ECU, racing harness, camshafts, air funnel kit and a titanium full race
exhaust system developed in conjunction with Arrow Special Parts.
Page 3 of 62
General Information
Please note:
• The Race Kit parts detailed in this publication are made in accordance with FIM technical
regulations and are NOT street legal.
• The Race Kit parts covered in this publication are intended for racing purposes only and any
Triumph motorcycle fitted with such kits MUST NOT be used on public roads.
• The Race Kit parts detailed in this publication may only be used on a closed-circuit in the hands of
experienced riders.
• Before fitting any Race Kit parts, customers should check the technical regulations of their race
class to ensure conformity.
• The information provided in this publication should always be used together with the official
Triumph Daytona 675 service manual.
• Completely read all the instructions before commencing the installation and set up of the Race Kit
in order to become thoroughly familiar with the kit’s features and the installation process.
• When removing components which incorporate a gasket ALWAYS ensure a new gasket is fitted
on 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 6).
• 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:
Warning
This warning symbol identifies special instructions or procedures, which if not correctly followed could result in
personal injury, or loss of life.
Caution
This caution symbol identifies special instructions or procedures, which if not strictly observed, could result in
damage to, or destruction of, equipment.
Note:
• This note symbol indicates points of particular interest for more efficient and convenient
operation.
Page 4 of 62
Warning
These accessory kits are for racing only. They are for use solely during closed-course racing. A motorcycle fitted
with these kits must not be used on public roads. It is illegal to use a motorcycle fitted with these kits on public
roads. A motorcycle fitted with these kits does not comply with local laws and regulations. If you use a
motorcycle fitted with these kits on public roads, you may be prosecuted.
Warning
These accessory kits are designed for use on Triumph Daytona 675 motorcycles only and should not be fitted
to any other Triumph model or to any other manufacturer’s motorcycle. Fitting these accessory kits to any other
Triumph model, or to any other manufacturer’s motorcycle, will affect the performance, stability and handling
of the motorcycle. This may affect the riders ability to control the motorcycle and could cause an accident.
Warning
Always have Triumph approved parts, accessories and conversions fitted by a trained technician of an
authorised Triumph dealer. The fitment of parts, accessories and conversions by a technician who is not of an
authorised Triumph dealer may affect the handling, stability or other aspects of the motorcycles operation
which may result in loss of motorcycle control and an accident.
Warning
Throughout this operation, ensure that the motorcycle is stabilised and adequately supported on a paddock
stand to prevent risk of injury from the motorcycle falling.
Warning
A torque wrench of known accurate calibration must be used when fitting this accessory kit. Failure to tighten
any of the fasteners to the correct torque specification may affect motorcycle performance, handling and
stability. This may result in loss of motorcycle control and an accident.
Warning
If the engine has recently been running, the exhaust system will be hot. Before working on or near the exhaust
system, allow sufficient time for the system to cool, as touching any part of a hot exhaust could cause burn
injuries.
Caution
The use of some of these kits will require changes to the fuelling 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.
Page 5 of 62
Engine Parts
Side Cover Gasket Kit
3
2
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
Note:
• 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.
Page 6 of 62
Cylinder Head Gasket
Caution
The use of the following Race Kit cylinder head gaskets 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.
1
*
* Thickness 'T' marking location
Parts Supplied
A9618112 (0.65 mm), A9618113 (0.60 mm), A9618114 (0.55 mm) or A9618115 (0.50 mm)

1 Cylinder head gasket (t = 0.65 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.
Page 7 of 62
Warning
Running the engine at less than the minimum recommended squish height can lead to the pistons contacting
the cylinder head, causing major engine damage. This could cause loss of motorcycle control and an accident.
1. Remove the existing cylinder head gasket in line 5. Remove the cylinder head and head gasket.
with the procedures detailed in the Daytona 6. Measure the compressed thickness of the
675 service manual. solder. The squish clearance must be a
2. Position a piece of solder (with a diameter minimum of 0.65 mm.
approximately 1.3 mm) on the four squish 7. If the thickness of the solder is less than 0.65
surfaces of each piston. Position the solder in mm repeat steps 2 to 6 with a thicker head
line with the corresponding squish surfaces on gasket until the squish clearance is at an
the cylinder head and hold in place with a small acceptable level.
amount of grease.
Note:
3. Refit the cylinder head with the head gasket.
4. Slowly turn the engine over, by hand, to • In some cases, it may be necessary to
compress the solder to the same height as the use a standard cylinder head gasket to
squish clearance. achieve the correct squish clearance.
8. Fit the chosen cylinder head gasket following
the procedures detailed in the Daytona 675
service manual.
Page 8 of 62
Camshaft, Valve Spring & Camshaft Sprocket Kits
Warning
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.
Caution
The use 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.
1
4 2
3
5
Parts Supplied
Camshaft, Inlet - A9618055 Valve Spring Kit - A9618086
Item Description Qty Item Description Qty

1 Camshaft, inlet, race 1 3 Valve spring, 14.4 id, race 12
Camshaft, Exhaust - A9618056 Camshaft Sprocket Kit - A9612122
Item Description Qty Item Description Qty

2 Camshaft, exhaust, race 1 4 Sprocket, camshaft, inlet, 34T 2
Socket head cap screw, 4
5
encapsulated, M6 x 10
Page 9 of 62
Note:
• 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 same as the standard spring.
1. The Race Kit valve springs should be assembled 4. The camshafts should be timed using cam
in the same manner as the standard valve degreeing equipment which typically consists of
springs. Follow the procedure detailed in section a degree wheel, pointer, dial indicator and
3 of the Daytona 675 service manual. Ensure piston stop. Optimum cam timing will depend
the springs are installed with the close wound, on the exact specification of the engine, but a
colour coded end of the springs facing recommended starting point is 106° IMOP
downwards, towards the piston. (Inlet Maximum Opening Point) and 106.5°
2. The Race Kit camshafts should be assembled in EMOP (Exhaust Maximum Opening Point).
the same manner as the standard camshafts. 5. Always check the inlet and exhaust piston to
Follow the procedure detailed in section 3 of the valve clearance for the timing selected to use,
Daytona 675 service manual. before running the engine. You must ensure
3. The Race Kit cam sprockets should be mounted both clearances are adequate. As a guide, the
and secured to the camshafts using the slotted standard nominal piston to valve clearance is 1.3
holes in the sprocket. The slotted holes allow mm inlet & 1.5 mm exhaust.
adjustment of the valve timing. The circular 6. When the desired timing has been set the new
holes in the sprockets are for Triumph service socket retaining screws provided should be
tool T3880102 and should not be used to tightened to 15 Nm. Note, if the screws are
mount the sprockets to the camshafts. released for any reason, apply ThreeBond 1305
to the threads before re-tightening.
Note:
• No timing marks are included on the
race sprockets. Race engines will
typically have different depths skimmed
off the cylinder head and, therefore
require specific individual timing.
Page 10 of 62
Manually Adjustable Camshaft Drive Chain Tensioner
Parts supplied - A9618108

1 Manual camshaft drive chain tensioner assembly 1
2 Camshaft drive chain tensioner blade 1
1. Remove the standard tensioner following the 3. Remove the pin locating the tensioner blade to
procedure detailed in the Daytona 675 service the crankcase, retain the pin for reuse. Remove
manual. Discard the gasket, retain the fixings for the tensioner blade from the top of the camshaft
reuse. drive chain chest.
4. Lower the new tensioner blade provided into
the camshaft drive chain chest, from the top.
Caution Locate in position with the original pin.
Do not start the motorcycle engine with the 5. Refit the camshafts following the procedure
tensioner removed. If the motorcycle engine is detailed in the Daytona 675 service manual.
started with the tensioner removed it could result in 6. Thoroughly clean the tensioner mounting
engine damage. surface on the cylinder head.
• Do not start the motorcycle engine with
the tensioner removed.
2. Remove the camshafts following the procedure
detailed in the Daytona 675 service manual.
Page 11 of 62
7. Back off the plunger locknut on the new 12. When the slack in the camshaft drive chain has
tensioner assembly before installation. 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.
1 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.

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 1. Right hand crank cover
camshaft drive chain. DO NOT force the 2. Copper washer position
plunger, continue steady finger tightening only 17. Following the procedure detailed in the Daytona
to take up the slack in the chain as you rotate 675 service manual, check the valve clearances
the crankshaft. and adjust as necessary.
18. Refit the camshaft cover, as described in the
Daytona 675 service manual.
1
2
1. Plunger
2. Plunger locknut
Page 12 of 62
Inlet & Exhaust Valve Kit
Caution
The use of the following Race Kit inlet & 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.

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 same material and have the
same mass as the standard valves.
1. Remove the existing inlet and exhaust valves 3. Check the head seat and valve seat are matched
following the procedure detailed in section 3 of correctly by applying a small amount of
the Daytona 675 service manual. engineer’s blue to the valve seat, assembling the
2. The valve seat widths on the Race Kit valves are valve to the cylinder head, and rotating the
narrower than the standard valves, therefore the valve through 360°.
bottom angle (140° inlet / 160° exhaust) of the 4. When the correct match of head seat and valve
cylinder head valve seats must be modified to seat have been confirmed assemble the race
ensure the seat on the head matches the seat on inlet and exhaust valves, following the
the valve. procedure detailed in section 3 of the Daytona
675 service manual.
Page 13 of 62
Conrod Bearing Shell

Item Description Thickness Colour Qty
1 Conrod bearing shell, race 1.476 mm to <1.482 mm White 1

1 Conrod bearing shell, race 1.482 mm to <1.488 mm Red 1
Warning
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
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.
Page 14 of 62
Main Bearing Shell

1 Main bearing shell, race 1.491 mm to <1.495 mm White 1

1 Main bearing shell, race 1.495 mm to <1.499 mm Red 1

1 Main bearing shell, race 1.499 mm to <1.503 mm Blue 1

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
reliability 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.
Page 15 of 62
Oil Pump Gearing Kit

1 Sprocket, oil/water pump 1
2 Chain, 76 link 1
3 Pressure release valve 1
Note: Note:
• Refer to the appropriate sections in the • To remove and fit a drive chain it is
Daytona 675 service manual to carry necessary to remove the clutch
out the procedures outlined in steps 1 assembly.
to 13. 4. Remove the clutch assembly as detailed in the
1. Remove the oil/water pump. Retain the fixings
5. Remove the drive chain. Retain the drive chain if
for reuse.
the motorcycle is to be returned to its original
2. Remove the drive sprocket from the oil/water condition.
pump. Retain the fixings for reuse. Retain the
6. Fit the new drive chain. Ensure the chain runs
sprocket if the motorcycle is to be returned to its
clear within the chain guide/guard.
original condition.
7. Refit the clutch assembly as detailed in the
3. Fit the new sprocket, provided in the kit, to the
oil/water pump. Apply ThreeBond 1374 thread
locking compound to the fixing and tighten to 8. Refit the oil/water pump and secure with the
14 Nm. original fixings.
Page 16 of 62
9. Remove the original pressure release valve. 11. Fit the new pressure release valve. Tighten to
Retain the valve if the motorcycle is to be 15 Nm.
returned to its original condition. 12. Refit the sump and secure with the original
10. Apply ThreeBond TB1305 thread locking fixings.
compound to the new pressure release valve
bolt thread.
Page 17 of 62
Air Funnel Kit
Caution
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.
2
1

1 Air funnel, race 3
2 Fixing retainer 3
Note:
• It is 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.
• Item 3 (6 off) is the standard fixing supplied with the standard air funnel. It is not supplied in
the Race Kit.
Page 18 of 62
1. Remove the airbox lid. 5. Fold the retention tabs, on the fixing retainers,
2. Remove the standard intake air funnels. Retain over the 6 fixings as shown below.
the fixings (2 per air funnel) for reuse.
3. Fit the 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.
2
1. Retention tab
2. Fixing
Page 19 of 62
Secondary Air Injection (SAI) Blanking Kit
2 1
3 5

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:
• 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.
Page 20 of 62
4. Replace the standard hollow dowels with the 8. Refit the airbox.
solid dowels provided in the kit. 9. Fit the sealing cap provided over the airbox
hose connection, as shown below.
1. Dowels
5. Fit a new seal to the camshaft cover. Refit the 1. Sealing cap
camshaft cover and secure with the original
fixings.
6. Fit the reed valve covers from the kit, as shown
below.
7. Secure with the M6 x 16 mm bolts provided.
Tighten to 9 Nm.
2
3
1
1. Reed valve cover, single

2. Reed valve cover, double
3. Bolt, M6 x 16 mm
Page 21 of 62
Exhaust System, Race (Arrow)
Caution
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
3 9
7
4 5
2
6
4
8 1

1 Downpipe collector assembly 1
2 Intermediate pipe 1
3 Silencer 1
4 Spring 5
5 Primary header bushing 3
6 Primary header flange 3
7 Captive nut, M8 1
8 Lock nut, M8 1
9 Capscrew, M8 6
Page 22 of 62
1. Remove the seat, battery, rear bodywork, lower 4. Thoroughly clean the mating surface of the
fairings, radiator, radiator fan, rear light, pillion primary header bushes and exhaust ports.
foot rest hangers and exhaust system following 5. Apply silicone sealant to the mating surface of
the procedures detailed in the Daytona 675 the primary header bush which contacts the
service manual. cylinder head, the recommended sealant is Dow
2. Remove the exhaust valve actuator from its Corning Firestop 700 white silicone.
actuator cables. 6. Fit the three primary header bushes to the
3. Remove and discard the exhaust gaskets and cylinder head and secure using the primary
M8 studs from the cylinder head. header flanges and M8 cap screws provided.
Note:
1
• The primary header bush should be
orientated such that none of the
exhaust port is obscured by the primary
header bush.
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.
2
CDOY 2-
1. M8 Stud 3
2. Gasket
Note:
1
• 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
2
header bush.
1. Downpipe
2. Spring
3. Spring mounting hole position
Page 23 of 62
8. Loosely secure the assembly to the outside of 10. Attach the M8 captive nut provided to the
the original exhaust mounting point using the intermediate pipe fixing point. Loosely secure
original bolt and M8 locknut provided, as the intermediate pipe to the exhaust mounting
shown. point using the original bolt, as shown.
1. Exhaust mounting point 1. Intermediate pipe

2. Original bolt 2. Original bolt
9. Insert the end of the intermediate pipe into the 11. Fit the silencer to the intermediate pipe and
collector pipe. Secure with the spring provided. secure with the spring provided. Loosely secure
the silencer bracket/clamp to the silencer
mounting point using the original fixings.
1
2
3
2
1. Intermediate pipe
2. Spring
1. Silencer
2. Intermediate pipe
3. Spring
4. Silencer mounting point
Page 24 of 62
12. Check the exhaust system is correctly aligned 14. Fit the correct specification spark plugs as
with the rear frame and tighten the fixings to recommended below.
the following torque values:
Note:
• Rear exhaust mounting point 27 Nm.
• Triumph recommends two options of
• Intermediate pipe mounting point fixing spark plug. Choose the correct option
22 Nm. depending on the engine compression
ratio. For a standard compression ratio
• Collector pipe front mounting point
use NGK CR10EIX. For high
fixings 27 Nm.
compression ratio engines use NGK
• Primary header flanges, M8 cap screws R0373A-10. Always ensure there is
19 Nm. sufficient clearance between spark plug
and piston, before attempting to start
13. If fitting the oxygen sensor, remove the
the engine.
threaded blanking plug from the race exhaust.
Fit the oxygen sensor and tighten to 25 Nm. 15. Refit the radiator, rear bodywork, lower fairings,
battery and seat as described in the Daytona
675 service manual.
Note:
• The radiator fan, rear light and pillion
footrest hangers are NOT refitted.
Page 25 of 62
Air Filter Kit

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.
• 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.
• 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.
Page 26 of 62
Manual Idle Speed Adjuster Kit
2
1

1 Screw, manual adjuster 1
2 Spring, compression coil 1
1. Remove the throttle body assembly following 4. Refit the throttle body assembly following the
the procedure detailed in the Daytona 675 procedure detailed in the Daytona 675 service
service manual. manual.
2. Remove item 3 (M5 nut) and item 4 (throttle 5. Adjust the idle speed using the manual adjuster
stop screw) from the throttle body assembly. screw (item 1) as required.
3. Fit the manual adjuster screw and compression
spring supplied (items 1 & 2).
Page 27 of 62
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.
Page 28 of 62
Detent Wheel Kit

1 Detent wheel 1
2 Screw, Torx head, M6 x 20, black 1
1. Remove the clutch as described in section 5 of 2. Release the two fixings and remove the baffle
the Daytona 675 service manual. plate from the crankcase breather. Discard the
fixings.
cdnl
1. Crankcase breather baffle plate

2. Fixings
Page 29 of 62
3. If not already removed, note the position and 7. Withdraw the detent arm complete with its
orientation of the gear pedal crank in relation to flanged sleeve, spring and washer.
the shaft, then remove the crank.
4. Remove the E-clip and washer from the gear
pedal end of the gear change shaft.
3
2
2
1
1
1. Detent arm
3 2. Fixing
3. Spring
1. Gear change shaft 4. Detent wheel
2. E-clip 8. Remove the existing detent wheel and fixing
3. Washer from the selector drum assembly, note how the
5. Withdraw the gear change shaft from the clutch detent wheel is timed relative to the selector
end of the crankcase. drum by way of a dowel.
9. 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.
10. Fit the M6 Torx head screw to the selector drum
assembly and tighten to 12 Nm. Ensure the
detent wheel is fully inserted into the bearing,
up to its shoulder.
cdnm
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.
6. Release and remove the fixing securing the
detent arm.
Page 30 of 62
11. Assemble the detent arm as noted on removal 14. Rotate the selector drum to the neutral position.
and place up to the crankcase. Ensure that the detent arm locates in the raised
profile in the detent wheel (neutral position).
1
2 3
4
1
2
1. Spring
2. Washer 1. Detent arm
3. Detent arm 2. Neutral position
4. Flanged sleeve 15. Using clean engine oil, lubricate the lip of the
5. Fixing seal on the gear change shaft.
12. Hold the detent arm assembly in 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.
1
3
2
2 cdnj
1. Gear change shaft seal

2. Gear change shaft bearing
1
Caution
4 Take care to avoid damaging the lip of the seal
when inserting the gear change shaft into the
-3 crankcase. A damaged seal will lead to oil loss and
1. Detent arm
2. Fixing
3. Spring
4. Selector drum detent wheel
Page 31 of 62
16. Insert the gear change shaft into the crankcase. 19. Fit the gear pedal crank to the shaft in the same
Gently push the gear pedal end of the shaft orientation as noted prior to removal. Ensure
through the bearing and lip seal at the clutch the dot mark on the shaft aligns with the split
side of the crankcase, and the sealed bearing, line on the gear pedal crank. Tighten the fixing
located at the gear pedal side of the crankcase. to 9 Nm.
20. Incorporating new fixings, refit the baffle plate
to the crankcase breather. Tighten the fixings to
9 Nm.
21. Refit the clutch and clutch cover as detailed in
section 5 of the Daytona 675 service manual.
3
1
cdnm-2

2. Abutment bolt
3. Spring
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.
18. Fit the washer and E-clip to the gear pedal end
of the gear change shaft.
3
2. E clip
3. Washer
Page 32 of 62
Cooling
Silicon Hose Kit
1 Hose set, silicon 1
2 Clip, 10.5 ger oetker 1
3 Clip, hose, dia 14.0 - 22.0 4
4 Clip, hose, dia 24.0 - 32.0 5
5 Clip, hose, dia 27.0 - 35.0 1
6 Clip, hose, dia 11.0 - 12.5 2
1. Tighten the clamps for the silicon hoses to 2 Nm.

2. Refer to the service manual for more information.
Page 33 of 62
Electrical Parts
Race Alternator Kit
9
8
5 4
6 7
1 3
5
2
Standard Part Standard Part
120 Nm

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, alternator cover (standard part) 1
9 Cover, alternator (unpainted sand casting) 1
Alternator Puller Tool - A3880206

1 Puller tool, alternator 1
Page 34 of 62
1. Remove the alternator as described in section 17 Rotor removal - Race ACG
of the service manual.
2. Remove the starter drive gear and sprag clutch Caution
from the alternator rotor as described in section
7 of the service manual. Discard the original Do not use tools of any kind to tighten the service
fixings. tool T3880375. Tighten the tool by hand only.
3. Using the M6 x 12 mm screws provided (3), fit Over-tightening of the service tool will lead to
the sprag clutch and starter drive gear to the damage of the alternator rotor.
race rotor (1) following the procedure detailed
1. Clean the alternator rotor removing all traces of
in section 7 of the service manual.
oil.
4. Remove all grease and oil from the taper
2. Fit the service tool T3880375 to the outside
surfaces on both the crankshaft and rotor before
diameter of the rotor. Retain the tool to prevent
assembly.
the crankshaft from rotating and remove the
5. Assemble the race rotor and sprag clutch centre bolt from the crankshaft.
assembly to the crankshaft following the
3. With the crankshaft bolt removed, locate the
procedure detailed in section 17 of the service
spigot of the thrust pad supplied with service
manual.
tool A3880206 into the end of the crankshaft.
6. Using the M6 x 20 mm screws provided (4),
4. Assemble the threaded portion of service tool
assemble the race stator (2) to the alternator
A3880206 into the threaded portion of the
cover provided (9). Tighten to 6 Nm.
rotor. Ensure the thrust pad does not fall out
7. Apply silicone sealant to the cable grommet during assembly of the service tool.
(ThreeBond 1215 is recommended), and align
5. Hold the service tool T3880375 to prevent
the cable to the exit slot.
rotation of the rotor, then tighten service tool
8. Using two of the M5 x 10 mm screws provided A3880206 to release the taper seating of the
(5), assemble the crankshaft sensor to the rotor from the crankshaft.
alternator cover. Tighten to 6 Nm.
6. Withdraw the rotor and service tools as an
9. Fit the wire retaining plates (6 & 7) to the assembly and then separate the tools from the
alternator cover and secure with the remaining rotor. Collect the woodruff key and the service
M5 x 10 mm screws provided (5). Tighten to tool thrust pad from the crankshaft.
6 Nm.
10. Position the new gasket provided (8) to the
crankshaft dowels, then fit the race alternator
cover and stator assembly to the crankcase
following the procedure detailed in the service
manual.
Page 35 of 62
Programmable Race ECU
Warning
The Programmable Race ECU MUST be used with the following Race Kits; A9618055 Camshaft - Inlet,
A9618056 Camshaft - Exhaust, A9618095 Camshaft Sprocket, A9618061 Inlet & Exhaust Valves, A9618086
Valve Spring Kit, A9600351 Arrow Race Exhaust System, A9618090 Air Funnel Kit and A9618100 Race
Harness.
Part supplied - A9618098

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 & Exhaust Camshafts, Camshaft Sprocket Kit, Inlet & 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 23. 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).
• The rev limit on the race 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 should 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.
Page 36 of 62
Caution
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
37 Number 1 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
70 Vehicle speed sensor
67 Main relay
Continuous Harness or instruments
Short Flash
Page 37 of 62
Triumph Race Calibration Software (TRACS)
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 Triumph 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.
Page 38 of 62
TRACS Management Kit
(Programmable Race ECU and Race Calibration Software Bundle)

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.
Page 39 of 62
Race Harness Kit
(8)
Standard Part
6
1
3
5
7
4
Standard Part
(9) 2

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
6 Locknut, M6 2
7 Sub-harness, air temperature sensor 1
8 Rectifier/regulator 1
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 8) must be relocated from its original position, within the fairing, to a
new position on the frame adjacent to the swing arm pivot. This is to allow fitment of race
bodywork. The original fixing bolts (item 9) should be retained for reuse.
Page 40 of 62
1. Remove the regulator from the original bracket,
retain the bolts for reuse. Discard the bracket
and lock nuts.
2. Secure the regulator unit (8) to the new
regulator bracket provided (4), using the
original bolts (9) and M6 lock nuts provided (6).
Tighten the fixings to 12 Nm.
3. Secure the regulator bracket to the motorcycle
frame using the M6 x 25 mm bolts provided.
1
Tighten the fixings to 12 Nm.
3 2
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
off before use (California only).
• 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.
• 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.
• Sub-harness - There are two options of air temperature sensors. Earlier models will connect
directly to the air temperature sensor. For later models an adapter harness will be required,
this is included in the kit.
Page 41 of 62
Quickshifter
• 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)

Wire Colour Polarity Function ID Tape
black/red +
Custom Quickshifter None
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 speed limiter Yellow
purple/black -
Page 42 of 62
• The wet/dry map and pit lane speed limiter connector plugs into the 4-pin connector fitted
with a blanking plug.
• If either the wet/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.
Page 43 of 62
Chassis Parts
Quickshifter, Race
1
2
Parts supplied - Standard Shift - A9930224

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

1 Quickshifter sensor 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.
Page 44 of 62
Rearsets, Race, Reverse Shift (Arrow)
1
2 15
13
10 12
3
16
17
11
4
14
9
6
8
18
5 7

1 Adapter, M6 to M8 - left hand thread 1
2 Nut, M8 - left hand thread 1
4 Nut, M8 - right hand thread 1
5 Gear change 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 Sprocket cover 1
13 Heel guard - right hand side 1
14 Footrest mounting assembly - right hand side 1
15 Screw, M6 2
16 Washer, M6 2
17 Support, rear brake fluid reservoir 1
18 Shorting plug 1
Page 45 of 62
Notice
Warning
This accessory kit is for racing only. It is to be used
solely during closed-course racing and with the A torque wrench of known accurate calibration
side stand removed. A motorcycle fitted with this must be used when fitting this accessory kit. Failure
kit and with the side stand removed must not be to tighten any of the fasteners to the correct torque
used on public roads. It is illegal to use a specification may affect motorcycle performance,
motorcycle fitted with this kit on public roads. A handling and stability. This may result in loss of
motorcycle fitted with this kit does not comply with motorcycle control and an accident.
local laws and regulations. If you use a motorcycle
fitted with this kit on public roads, you may be
prosecuted.
Warning
The side stand must be removed when this
accessory kit is fitted to the motorcycle. Operating
Warning the gear change lever from this accessory kit with
This accessory kit is designed for use on Triumph the side stand fitted will restrict the movement of
Daytona 675 motorcycles only and should not be the gear change lever. Operating the gear change
fitted to any other Triumph model or to any other lever with restricted movement may result in loss of
manufacturer’s motorcycle. Fitting this accessory kit motorcycle control and an accident.
to any other Triumph model, or to any other
Note:
manufacturer’s motorcycle, may interfere with the
rider and could affect the handling, stability or • Before fitting this accessory kit, ensure
other aspects of the motorcycle’s operation which the owner of the motorcycle has been
may result in loss of motorcycle control and an informed of the warnings contained in
accident these instructions.
Warning
Always have Triumph approved parts, accessories
and conversions fitted by a trained technician of an
authorised Triumph dealer. The fitment of parts,
accessories and conversions by a technician who is
not of an authorised Triumph dealer may affect the
handling, stability or other aspects of the
motorcycle’s operation which may result in loss of
motorcycle control and an accident.
Warning
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.
Page 46 of 62
Left Hand Footrest and Mounting Assembly 6. Remove the wire clip retaining the ball joint to
the transmission linkage, detach the ball joint
1. Remove the rider's seat as described in the and remove the gear selector rod. Retain the
service manual. wire clip for re-use.
2. Disconnect the battery, negative (black) lead
first.
3. Remove the fuel tank as described in the service
manual. 2
Note:
• The ball joint and locknut on the
transmission linkage have a left hand 1
thread. This is identified by a machined
ring on the gear selector rod.
4. Loosen the locknut at the ball joint on the
transmission linkage.
1. Wire clip
2. Ball joint
Caution
It may be difficult to remove the original ball joint
from the gear selector rod. Do not use excessive
force. If necessary, apply a releasing oil to the ball
joint threads to aid removal.
1 2 7. Unscrew the gear selector rod from the

cffi_5 transmission linkage ball joint. Retain the gear
1. Locknut selector rod if the motorcycle is to be returned
2. Machined ring, left hand thread identification to its original condition.
5. Remove the wire clip retaining the ball joint to
the gear change lever and detach the ball joint.
Retain the wire clip if the motorcycle is to be
returned to its original condition.
2
cffi_4
1. Ball joint
2. Gear selector rod
2
1. Wire clip
2. Ball joint
Page 47 of 62
Note: 12. Disconnect the side stand switch from the main
harness.
• The ball joint on the transmission
linkage and the M6 to M8 adapter have
a left hand thread.
8. Fit the M8 nut, left hand thread, fully onto the
M6 to M8 adapter.
3
9. Attach the M6 to M8 adapter to the
transmission linkage ball joint. Do not fully
tighten at this stage.
10. Remove the two screws and the left hand
footrest mounting assembly. Retain the screws 1
for re-use. Retain the footrest mounting
assembly if the motorcycle is to be returned to
its original condition. 2
cfzz
1. Main harness connector

1 2. Side stand connector
2 3. White tape
13. Remove the bolts and washers securing the side
stand to the frame. Retain the bolts and washers
if the motorcycle is to be returned to its original
condition.
fes
1. Screws
2. Footrest mounting assembly
Note:
• The main harness connector for the side
stand switch connector is located under
the fuel tank and can be identified by
the white tape on the harness.
2
11. Follow the route of the side stand switch harness
to its connection with the main harness. cgai
1. Bolts
2. Side stand
14. Carefully feed the side stand switch harness
down the frame and remove the side stand.
Retain the side stand if the motorcycle is to be
returned to its original condition.
Note:
• An audible click can be heard when the
shorting plug is fully fitted.
Page 48 of 62
15. Fit the shorting plug from the kit to the main Note:
harness connector.
• Note the routing of the fuel tank
breather hoses and the wiring harness
in front of the sprocket cover for
installation.
19. Remove the three screws and the sprocket
cover. Retain the screws for re-use.
2 20. Retain the sprocket cover if the motorcycle is to
be returned to its original condition.
21. Position the fuel tank breather hoses and wiring
harness as noted for removal. Fit the sprocket
cover from the kit and tighten the original
screws to 9 Nm.
1
2
cgaj
1 3
1. Shorting plug
2. Main harness connector
Note:
• Note the position of the transmission
linkage in relation to the punch mark on
the gear change mechanism.
16. Remove the transmission linkage bolt. Retain
the bolt for re-use.
17. Detach the transmission linkage from the gear
change mechanism. Using the punch mark as a cfna
2
marker, realign the transmission linkage in an
anti-clockwise direction by 9 splines. 1. Fuel tank breather hoses
2. Screws
3. Sprocket cover
1 2
Note:
• Note the position of the two spacers
3 installed to the lower gearbox bolt, one
on either side of the engine.
5 5
4 4
6
6
mx
1. Original alignment
2. New alignment
3. Bolt
4. Gear change mechanism
5. Punch mark
6. Transmission linkage
18. Refit the transmission linkage bolt and tighten to
9 Nm.
Page 49 of 62
22. Remove and discard the nut securing the rear 24. Screw the M8 nut, right hand thread, fully on to
lower gearbox bolt and remove the bolt. Collect the gear change lever assembly.
the two spacers from the lower bolt.
2
2 1
cfnb
z_1
1. Locknut
1. Rear gearbox bolt 2. Gear change lever assembly
2. Left hand spacer 25. The new gear selector rod has a right hand
23. Refit the rear lower gearbox bolt on the right thread at the smaller (10 mm outside diameter)
hand side of the motorcycle, ensuring the two end, and a left hand thread at the larger (12 mm
spacers are installed as noted for removal. Apply outside diameter) end (adjacent to the spanner
Locktite 243 to the thread of the mounting flats), as shown below.
spacer. Fit and tighten the mounting spacer to
48 Nm.
2
1

cfnm_1
2. Left hand threaded end
1. Mounting spacer 3. Right hand thread end
4. Spanner flats
Page 50 of 62
26. Screw the right hand threaded end of the new 28. Attach the ball joint to the transmission linkage.
gear selector rod on to the gear change lever
assembly up to the locknut.
2 3
2
1
1
fnk_2
1. Ball joint
fnl_1
2. Transmission linkage
1. Gear change lever assembly 29. Refit the wire clip to retain the ball joint. Ensure
2. Locknut the wire clip locates correctly in the ball joint
3. Gear selector rod before rotating the clip to lock in position.
27. Fit the M6 to M8 adapter and ball joint
assembly fully on to the gear selector rod.
1 2 3
4 1
1. Ball joint
cfnl 2. Wire clip
2. Locknut
3. M6 to M8 adapter
4. Ball joint
Page 51 of 62
30. Attach the gear change lever assembly and 32. The footrest position can be adjusted to the
bearing cap to the mounting spacer as shown rider's preferred position. To adjust the footrest
below. Apply Locktite 243 to the thread of the position, remove the two screws and the footrest
screw. Fit and tighten the screw to 20 Nm. plate.
3 2 2
1
3 1
cfnc
n_7
1. Gear change lever assembly 1. Screws

2. Bearing cap 2. Footrest plate
3. Screw 33. The illustration below shows the nine possible
31. Fit the new footrest mounting assembly and positions for the lower screw securing the
tighten the original screws to 27 Nm. footrest plate. The remaining holes are for the
upper screw.
1 23
A
B
C
cffn_4
1. Footrest and mounting assembly Possible Positions for the Lower Screw
2. Original screws
Note:
• To ensure the right hand footrest plate
is positioned at the same height as the
left hand footrest plate, make a note of
which hole is used for the lower screw,
for example C1.
Page 52 of 62
34. Refit the footrest plate and secure with the two 39. Tighten the lock nuts on both ends of the gear
screws, ensuring the lower screw is in one of the selector rod to 6 Nm.
nine holes shown previously.
2 1
1 cfno
cffn_6
1. Lock nuts
1. Lower screw 40. Recheck the torque of both adapters after the
2. Footrest plate adjustment of the gear selector rod is
35. Check to see if the footrest is in the preferred completed.
position for the rider. 41. The length of the gear change lever can be
36. Repeat steps 31 to 34 until the footrest is at the adjusted to the rider’s preferred position. To
preferred position for the rider. Tighten the adjust the gear change lever, remove the two
screws to 27 Nm. screws and slide the gear change peg in or out
37. Tighten the upper adapter to 9 Nm. and secure with the two screws.
38. To adjust the gear change lever angle, turn the
gear selector rod until the desired angle is
achieved.
1
1
2
2 cfnd
3
1. Gear change lever assembly
2. Gear change peg
3. Screws
ne
1. Gear change rod

2. Gear change lever assembly
Warning
Both screws must be used to secure the gear
change peg to the gear change lever. The use of
only one screw may result in the gear change peg
becoming loose or falling off, resulting in loss of
Page 53 of 62
42. Repeat step 41 until the gear change lever is at 45. Disconnect the rear brake light switch from the
the preferred position for the rider. Remove the main harness.
screws, apply Locktite 243 to the screw threads
and tighten to 9 Nm.
43. Fit the supplied left hand heel guard to the
footrest plate with the screws from the kit. Apply
Locktite 243 to the screw threads and tighten to
6 Nm. 1
1
2
1. Rear brake light main harness connector
46. Loosen the locknut on the rear master cylinder
push rod.
fu_3
1. Left hand heel guard

2. Screws
Note: 1
• Should the rider require the footrest
position to be changed, repeat steps 32
to 42.
Right Hand Footrest and Mounting Assembly

Note:
• The new right hand footrest and
mounting assembly is not equipped
with a bracket for the rear brake light w1
switch. 1. Locknut
44. Follow the route of the rear brake light switch
harness to its connection with the main harness.
Page 54 of 62
47. Remove the clip from the brake pedal clevis pin. 49. Remove the clevis and position the master
Remove the clevis pin. cylinder aside.
2
w y
1. Clip 1. Clevis
2. Clevis pin 50. Remove the two screws and the right hand
48. Remove the screws securing the rear brake footrest mounting. Guide the rear brake light
master cylinder and heel guard to the footrest harness through the frame.
mounting. Retain the screws for re-use.
2 1
cfez
1. Footrest mounting
1. Screws 2. Screws
2. Heel guard 51. Retain the screws for re-use.
3. Rear brake master cylinder
52. Retain the following if the motorcycle is to be
returned to its original condition:
• Clevis;
• Clevis pin;
• Clevis pin clip;
• Footrest mounting;
• Heel guard;
• Rear brake light switch;
• Rear brake light switch spring.
Page 55 of 62
53. Attach the new ball joint on the brake pedal to 55. To adjust the footrest position, remove the two
the push rod. screws and the footrest plate.
2
2
1 1
ffb1
ffb
1. Brake pedal ball joint 1. Screws

2. Push rod 2. Footrest plate
54. Attach the new right hand footrest assembly to 56. The illustration below shows the nine possible
the frame and tighten the original screws to positions for the footrest plate lower screw. The
27 Nm. remaining holes are for the footrest plate upper
screw.
A
B
C
3 2 1
ffb
c
1. Screws
2. Right hand footrest assembly Possible Positions for the Footrest Plate Lower
Screw
Caution 57. Refit the footrest plate and secure with the two
screws, ensuring the lower screw is in the same
Both left hand and right hand footrest plates must hole location as the left hand footrest plate, for
be adjusted to the same position. example C1. Tighten the screws to 27 Nm.
Page 56 of 62
58. Fit the brake master cylinder and supplied heel
guard to the footrest plate with the existing
M8 screws. Tighten the screws to 18 Nm.
Caution
With the footrest plate lower screw in any of the
nine positions, the brake fluid reservoir to master
cylinder hose could be touching other components
causing damage to the hose.
61. Check that the rear brake reservoir hose is not

twisted or is touching any other components.
1
1
1. Screws
Note:
• When the top edge of the brake pedal is
19.5 mm below the radius curve of the
footrest plate, the pedal is at the
standard factory setting.
2
59. Using the measurement of 19.5 mm as a guide,
turn the push rod top nut until the desired
angle of the brake pedal is achieved.
60. Tighten the locknut against the ball joint to
17 Nm.
1
3 cffl
4 1. Correct routing
2. Incorrect routing
19.5 mm Caution
2 To prevent paint damage, do not spill brake fluid
d3
onto any area of the bodywork. Spilled brake fluid
will damage paintwork.
1. Push rod top nut
2. Brake pedal 62. Check the brake reservoir hose to exhaust
3. Locknut intermediate pipe clearance. The clearance must
4. Distance to be measured be a minimum of 20 mm. If the clearance is less
than 20 mm, fit the supplied support bracket
between the frame and the rear brake fluid
reservoir as follows:
Page 57 of 62
63. Detach the brake fluid reservoir from the frame. 65. Attach the rear brake fluid reservoir to the
Taking care not to invert the brake fluid support bracket with the M6 washer and screw
reservoir, lay it to one side. provided. Do not tighten the screw at this stage.
Note:
• Discard the screw after removal. If the
motorcycle is to be returned to its
original condition, install a new screw.
64. Fit the support bracket provided to the frame 1
with the M6 washer and screw provided. Ensure
the bracket is fitted as shown in the lower
illustration below. Do not tighten the screw at
this stage.
1
1
1. Screw
2
Warning
The rear brake fluid reservoir and hose must be at
least 20 mm from the exhaust pipe. The heat from
the exhaust pipe may cause damage to the
reservoir and hose resulting in loss of brake fluid,
loss of motorcycle control and an accident.
4
66. Position the rear brake fluid reservoir so that the
reservoir hose is clear from obstruction and the
reservoir has a minimum distance of 20 mm
from the exhaust pipe. Tighten the two screws
1 2 to 7 Nm.
2
3
1. Support bracket
2. Screw
3. Rear brake fluid reservoir
1
4. Frame lug
2
20 mm
1. Screws
2. Minimum distance from the exhaust pipe
Page 58 of 62
Note:
• Should the rider require the footrest
position to be changed, remove the Warning
heel guard and repeat steps 55 to 62. It is dangerous to operate the motorcycle with
67. Refit the fuel tank as described in the service defective brakes; you must have your authorised
manual. Triumph dealer take remedial action before you
68. Reconnect the battery, positive (red) lead first. attempt to ride the motorcycle again. Failure to take
69. Refit the rider's seat as described in the service remedial action may reduce braking efficiency
manual. leading to loss of motorcycle control and an
accident.
70. Check for correct brake operation. Rectify as

necessary.
Replacing Components
Refer to the following illustrations for torque figures and for which fixings require Loctite 243.
Warning
When replacing components on this accessory kit, some of the fixings are required to have Loctite 243 added
to their threads. This is to ensure that these fixings remain secure at their specified tightening torque.
Failure to use loctite 243 may result in component detachment leading to loss of motorcycle control and an
accident.
Left Hand Footrest and Mounting Assembly
Apply Loctite 243 to

the threads
9 Nm
20 Nm

9 Nm the threads
Page 59 of 62
Right Hand Footrest and Mounting Assembly

the threads 20 Nm
7 Nm
9 Nm Apply Loctite 243 to

the threads
Warning Warning
After fitting the accessory kit the gear change lever If, after fitment of this accessory kit, you have any
operation has been reversed. Operate the doubt about the performance of any aspect of the
motorcycle in a safe area free from traffic to gain motorcycle, contact an authorised Triumph dealer
familiarity with the reversed operation of the gear and do not ride the motorcycle until the authorised
change lever. Operation of the motorcycle when dealer has declared it fit for use. Riding a
not familiar with the reversed gear change motorcycle when there is any doubt as to any
operation may result in loss of motorcycle control aspect of the performance of the motorcycle may
and an accident. result in loss of control of the motorcycle leading to
an accident.
Warning
After fitting the accessory kit the motorcycle will
exhibit new handling characteristics. Operate the
motorcycle in a safe area free from traffic to gain
familiarity with any new characteristics. Operation
of the motorcycle when not familiar with any new
handling characteristics may result in loss of
Page 60 of 62
Rearsets, Race, Standard Shift (Arrow)
8
6
5
10 9
3
11 7
2
1
cfeo

1 Adaptor, M6 to M8 - left hand thread 1
2 Nut, M8 - left hand thread 1
4 Footrest mounting assembly - left hand side 1
5 Heel guard, left hand side 1
6 Heel guard, right hand side 1
7 Footrest mounting assembly, right hand side 1
8 Screw, M6 2
9 Washer, M6 2
10 Support, rear brake fluid reservoir 1
11 Screw, M5 2
Note:
• For fitment, refer to the comprehensive fitting instructions supplied with the rearset kit.
Page 61 of 62
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 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 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 62 of 62

675 Race Manual 2011 PDF

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2011 Daytona 675 (VIN 381275>) and

FOR CLOSED-CIRCUIT USE ONLY

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

Warnings, Cautions and Notes.

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

Side Cover Gasket Kit

Parts Supplied - A9618097

© Triumph Designs Ltd 2011

* Thickness 'T' marking location

Item Description Qty

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

Item Description Qty Item Description Qty

Camshaft, Exhaust - A9618056 Camshaft Sprocket Kit - A9612122

Item Description Qty Item Description Qty

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

Parts supplied - A9618108

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

Parts Supplied - A9618061

© Triumph Designs Ltd 2011

Parts Supplied - A1110411

Parts Supplied - A1110412

© Triumph Designs Ltd 2011

Parts supplied - A1161301

Parts supplied - A1161302

Parts supplied - A1161303

Parts supplied - A1161304

© Triumph Designs Ltd 2011

Parts Supplied - A9618096

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

Parts supplied - A9618090

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

Parts supplied - A9618094

© Triumph Designs Ltd 2011

1. Reed valve cover, single

© Triumph Designs Ltd 2011

Parts supplied - A9600351

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

1. Exhaust mounting point 1. Intermediate pipe

© Triumph Designs Ltd 2011

© Triumph Designs Ltd 2011

Parts supplied - A9618075

© Triumph Designs Ltd 2011

Parts supplied - A9618076

© Triumph Designs Ltd 2011

Slipper Clutch Tool - A3880037

© Triumph Designs Ltd 2011

Parts supplied - A9618068

1. Crankcase breather baffle plate

© Triumph Designs Ltd 2011