1957–1974 Triumph Tiger 100 (T100/T100S/T100SS), Daytona (T100T/T100R), Trophy 500 (T100C), Tiger 90 (T90), Speed Twin (5TA) & Twenty-One (3TA) Workshop Manual (P/N 305)

The supplement is interleaved with the original sections and supplies revised procedures and specifications for the later machines. Its corrected crankshaft regrind chart supersedes the original table.

PDF Search, Navigation and Diagram Detail

Text search and wiring labels: PDF text search is not available, and there are no embedded bookmarks. Printed section contents provide navigation references. Small wire-color labels and switch-terminal numbers require zooming; several wiring diagrams also benefit from page rotation.

Both publications are supplied together as one printable, 251-page PDF. The total includes both covers and 10 blank pages.

Unit-Twin Engine, Drivetrain and Electrical Work

The following is a selection of covered work. Other topics include tachometer-drive service and replacement seat-cover fitting.

• Engine repair: Step-by-step procedures for engine removal, rocker-box and cylinder-head overhaul, crankcase separation, crankshaft servicing, valve-seat recutting, and bearing replacement.

• Lubrication: Dry-sump fault diagnosis, oil-pressure checks, oil pump rebuilding, filter service, and pressure-release valve inspection.

• Fuel and ignition: Amal Monobloc overhaul, single-carburetor adjustment, twin-carburetor synchronization, contact-breaker service, and static or stroboscopic ignition timing.

• Clutch and gearbox: Primary chaincase service, shock-absorbing clutch repair, gearbox disassembly and inspection, gear-selection checks, kickstarter service, and mainshaft/layshaft bearing replacement.

• Wheels and suspension: Standard and quick-detach rear hubs, brake relining, twin leading shoe brakes, telescopic forks, swingarm bushings, and steering-head bearings.

• Electrical diagnosis: Coil-ignition fault tracing, alternator output checks, stator replacement, rectifier and Zener diode tests, and wiring diagrams.

Written for workshop staff and owners doing basic maintenance and repair, the manual also contains overhaul procedures requiring specialist tools and measuring equipment.

Engine Build Changes and Rebuilding References

The main text addresses machines subsequent to H49833, while retaining earlier-model procedures and data, including T100SS references. The supplement applies from H65573.

Later engines use a timing-side ball bearing and drive-side roller bearing instead of the earlier plain/ball arrangement. The supplement also covers connecting rods without small-end bushings. These distinctions help match replacement bearings and repair dimensions to the engine being rebuilt.

Top-end references include the cylinder-head bolt tightening sequence, valve-seat specifications and timing-cover oil-seal location drawings. Crankshaft coverage includes oil-tube servicing and static balancing with Z122 weights, supported by dimensioned balancing-sleeve drawings.

The lubrication sections connect low-pressure symptoms with pump condition, blocked filters or oil passages, and bearing wear. Maintenance schedules distinguish the engine, gearbox and primary chaincase.

Carburetors, Clutch and Gear Selection

The twin-carburetor section explains the shared-float-chamber Monobloc arrangement and throttle-cable junction. Valve-timing illustrations distinguish the single-carburetor arrangement from the T100T/T100R settings.

Clutch inspection includes pressure-plate truing and replacement of the drive and rebound rubbers. Gearbox inspection distinguishes the 3TA/5TA bronze layshaft bushings from needle-roller arrangements and explains selector-fork identification and camplate operation.

The supplement adds illustrated gear-by-gear drive paths. Alternative close- and wide-ratio gears are discussed, with conversion-parts selection referred to the separate replacement parts catalog.

Chassis Checks and Electrical Fault Tracing

Fork coverage includes internal hydraulic damper service, alignment checks and later stanchion modifications. Swingarm procedures distinguish the spindle arrangements before and after H49833; the brake supplement adds front-brake cam linkage adjustment.

Frame-checking drawings provide alignment dimensions, while wheel-building notes give hub-to-rim relationships. Wheel building and spoke alignment are reserved for specialists.

Electrical chapters distinguish battery-coil ignition from A.C. energy-transfer ignition. Low- and high-tension fault finding, charging-circuit continuity checks, and U.S./home-market wiring diagrams support diagnosis. Stator winding specifications are included, but winding repair instructions are outside the manual's scope.

Wet lubricant on the later prelubricated advance spindle can cause it to seize. The rectifier section also warns that twisting its plate stack can break internal connections.

Workshop Tables and Illustrated Service Tools

Reference tables cover piston clearances, valve-seat angles, torque settings, steering-head bearing data and fork oil capacities. Illustrations include the engine lubrication diagram, exploded engine/gearbox view and crankshaft section showing the oil tube.

Illustrated tool sections identify camwheel extractor D2213, bearing-race remover 61-6060 and sprocket extractor 61-6046. A cross-reference lists revised tool numbers.

Follow standard shop safety practices and consult a qualified technician if you are unsure about brake work, frame alignment or engine-critical tolerances.

Selected Rod-Bolt and Ignition-Coil Specifications

The connecting-rod section specifies bolt stretch of 0.004–0.005 in. The supplement retains this measurement reference and advises disregarding older center-punch marks on connecting-rod nuts.

For the ignition coils covered by the bench-test section, primary resistance at 20°C is 1.8–2.4 ohms for MA6 coils and 3.0–3.4 ohms for MA12 coils. These limits belong to the identified coil types, rather than every ignition-coil variant discussed elsewhere.