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)

Triumph workshop manual WSM5 covers the 1957–1974 350cc and 500cc unit-construction twins: Tiger 100, Tiger 90, Speed Twin and Twenty-One. Its integrated 1969 supplement covers T100S, T100T Daytona Super Sports, T100C Trophy 500 and T100R Daytona.

This is a 251-page PDF containing the main manual and its supplement in one file.

• Engine repair: Engine-unit removal, rocker-box and cylinder-head overhaul, crankcase separation, crankshaft servicing, valve-seat recutting, and bearing replacement.

• Lubrication: Dry-sump system 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 servicing, and static or stroboscopic ignition timing.

• Transmission and gearbox: Four-speed gearbox inspection, primary chaincase service, shock-absorbing clutch repair, gear selection checks, kickstarter mechanism 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 stator replacement, rectifier and Zener diode tests, and model-specific 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.

Model Changes and Repair Specifications

The main text addresses machines subsequent to H49833, with earlier-model procedures and data, including T100SS references. The supplement applies from H65573 and is interleaved with the original sections.

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 and corrects the crankshaft regrind table. These distinctions help match replacement bearings and repair dimensions to the engine being rebuilt.

Engine and Lubrication Walkthrough

Need to pull the head? The cylinder head bolt tightening sequence, valve-seat specifications and timing cover oil seal location drawings support top-end work. Crankshaft coverage includes oil tube servicing, connecting-rod bolt stretch, and static balancing with Z122 weights.

The lubrication chapters cover the dry-sump layout, oil pump pressure regulation and maintenance intervals for the engine, gearbox and primary chaincase. Low-oil-pressure checks address the pump, filters, oil passages and bearing condition.

The later contact-breaker section warns that wet lubricant on the prelubricated advance spindle can cause it to seize.

Carburetors, Clutch and Gearbox

The twin-carburetor section explains the shared-float-chamber Monobloc arrangement, throttle-cable junction and synchronization. Valve timing and timing gear alignment illustrations distinguish single-carburetor settings from those used on T100T/T100R engines.

Clutch coverage 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.

Chassis and Electrical Testing

Fork coverage includes internal hydraulic damper service, alignment checks and later stanchion modifications. Swinging fork procedures distinguish the spindle arrangements before and after H49833; the brake supplement adds front-brake cam linkage adjustment. Wheel building and spoke alignment are reserved for specialists.

Electrical coverage separates 6- and 12-volt 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.

The rectifier section warns that twisting its plate stack during removal or installation can break internal connections.

Specification and Data Reference

Tables provide piston clearances, valve seat angles, torque settings, head race ball-bearing data and telescopic fork oil capacities. Illustrations include the engine lubrication diagram, exploded view of the engine/gearbox unit and sectional view of the crankshaft showing the oil tube.

Illustrated service-tool sections cover camwheel extractor D2213, bearing-race remover 61-6060 and sprocket extractor 61-6046, with a cross-reference for 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.

File Format and Readability

Contents: The total comprises 196 pages of the main manual and 55 pages of the interleaved supplement, including both covers and 10 blank pages.

Search and navigation: PDF text search is not available, and there are no embedded bookmarks. Printed section contents provide navigation references.

Wiring diagrams: Small wire-color labels and switch-terminal numbers require zooming. Several diagrams are oriented sideways and benefit from page rotation.