2002–2004 Triumph Daytona 955i / Speed Triple Service & Repair Manual (P/N 3850595)

This Triumph factory service manual (P/N 3850595, Issue 2, July 2003) covers the 2002–2004 Daytona 955i and Speed Triple, including single-sided and twin-sided swingarm configurations.

• Engine repair: Engine removal, cylinder-head disassembly, valve-clearance measurement, camshaft timing, crankshaft and connecting-rod inspection, and cylinder-liner replacement.

• Clutch and transmission: Clutch disassembly and inspection, gearbox shaft rebuilding, selector mechanism service, balancer shaft timing, and starter sprag clutch replacement.

• Engine management: Diagnostic trouble-code retrieval, sensor and actuator testing, throttle body balancing, fuel-pressure testing, and engine control module diagnostic procedures.

• Lubrication and cooling: Oil pump inspection, oil cooler removal, radiator and water-pump replacement, thermostat testing, and cooling-system bleeding.

• Suspension and steering: Front-fork disassembly, seal replacement, fork oil changes, steering headstock bearing adjustment, rear linkage service, and swingarm removal.

• Hydraulic brakes: Master-cylinder and caliper disassembly, seal inspection, brake disc checks, pad replacement, and system bleeding for the covered configurations.

• Electrical systems: Starter motor removal and inspection, alternator service, fuse and relay identification, and model-specific wiring diagrams.

Written primarily for trained technicians in an equipped workshop, the manual also supports owners performing basic maintenance and repair with the necessary mechanical knowledge and service tools.

Engine, Clutch, and Transmission Repair

The manual delivers hard data on engine teardown and assembly, with wear limits and component-specific torque tables. Cylinder-head and clutch exploded views accompany the inspection and assembly procedures; the scheduled maintenance chart organizes routine service requirements.

Valve timing and head work: Multi-stage cylinder-head bolt procedures sit alongside shim adjustment and camshaft installation instructions. The timing cautions explain how incorrect camshaft positioning can cause valve-to-valve contact, damaging the head and valves.

Bearing selection and repair limits: The Speed Triple big-end bearing charts distinguish machines up to VIN 144667 from those starting at VIN 144668, helping match connecting-rod markings and crankpin measurements before choosing bearing shells. Valve guides worn beyond the service limit require cylinder-head replacement; the manual rules out crankshaft regrinding and oversize-bearing repairs.

Gearbox assembly instructions address gear, bush, and circlip positioning. Their oil-hole cautions explain how incorrect gear-to-shaft positioning can reduce lubrication and damage the engine.

Fuel Injection and Engine Management Diagnosis

The MC1000 engine control module section covers stored fault codes, live data, freeze-frame information, and actuator tests. The engine management circuit diagram supports pinpoint checks for sensors, injectors, plug-top ignition coils, and the idle air control stepper motor.

Diagnostic equipment and adjustments: The documented electronic diagnostic routines use Triumph service tool T3880250. Throttle body balancing, closed-throttle position checks, and adaptive resets are also described.

Evaporative emissions control procedures apply to California models. Secondary air injection coverage includes the solenoid and reed valves where fitted.

Oil Circulation and Cooling-System Service

Engine oil circuit diagrams distinguish Daytona and Speed Triple oil routing; oil pump procedures specify rotor, body, and end-clearance checks. Cooling coverage extends to pressure-cap checks, coolant refilling, and air bleeding.

Suspension, Final Drive, and Brakes

The fork oil level chart identifies Showa SS8 oil specifications. Rear suspension procedures distinguish the swingarm configurations and cover drop and drag links, final drive cush rubbers, and single-sided rear hub service.

Separate rear-caliper procedures follow the swingarm variants, alongside brake master-cylinder repair and hydraulic brake bleeding. Support the motorcycle securely and use calibrated torque wrenches for chassis work.

Starter, Alternator, and Wiring Coverage

Electrical service includes alternator stator and rotor removal and installation, starter motor inspection, and lighting service. Wiring diagrams cover model-specific lighting, starting and charging, and auxiliary circuits.

A Sample of Valve-Clearance and Fuel-Pressure Data

These valve-clearance and fuel-pressure figures are a small sample of the manual's inspection and diagnostic data.

For both the Daytona 955i and Speed Triple, cold valve-clearance specifications are 0.10–0.20 mm at the intake valves and 0.20–0.30 mm at the exhaust valves.

The fuel-pressure test specifies 3.0 bar ±0.25 bar with the engine running. It uses Triumph gauge T3880048 to assess fuel pump, pressure regulation, and hose-related faults.

Search, Bookmarks, and PDF Contents

Text search and wiring detail: An embedded OCR text layer supports searching, although recognition errors affect some words and diagram labels. There are 21 section bookmarks. Small wiring labels need zooming, and scan lines cross parts of the Speed Triple wiring key.

The download is one printable, English-language, 410-page PDF. The total includes the original title page, index, wiring sheets, and 14 blank divider/end pages.