1999–2000 Triumph Sprint ST & Sprint RS Service Manual (P/N 3850760)

This factory service manual covers the 1999–2000 Triumph Sprint ST and Sprint RS. Triumph publication P/N 3850760, issue 3, October 1999, organizes maintenance, diagnosis, and repair information into 16 numbered chapters.

• Engine repair: Cylinder-head removal, camshaft timing, valve-clearance adjustment, piston and liner inspection, and balancer alignment.

• Clutch and transmission: Wet-clutch disassembly, friction-plate inspection, selector-mechanism service, input and output shaft rebuilding, and starter sprag-clutch procedures.

• EFI diagnostics: MC 2000 and MC 1000 fault codes, freeze-frame data, sensor and actuator tests, throttle-body synchronization, and factory tune-update procedures.

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

• Suspension and final drive: Fork rebuilding, headstock bearing adjustment, rear linkage service, and model-specific swingarm, drive-chain, and cush-drive procedures.

• Brakes and wheels: Caliper and master-cylinder overhaul, hydraulic bleeding, disc wear and runout checks, and front and rear wheel removal.

• Electrical systems: ECM connector pinouts, lighting and starting/charging diagrams, fuse and relay identification, and instrument, starter-motor, and alternator removal.

Written primarily for trained technicians in equipped workshops, the manual also supports basic owner maintenance and repair where mechanical knowledge and the specified service tools are available.

Cylinder Head and Internal Engine Repair

The internal-engine chapters document crankcase separation, piston-ring end-gap checks, crankshaft and connecting-rod bearing selection, and balancer shaft alignment. The transmission section covers the selector drum, forks, shaft assemblies, and auxiliary gears.

Valve service: Shim selection and valve adjustment procedures identify service tool T3880012. Valve and stem-seal work is covered, but the cylinder-head description identifies the valve seats and guides as nonreplaceable parts of the head.

Illustrations include the Camshaft and Camshaft Drive exploded view, the Big End Bearing Selection Chart, and Plastigauge measurement views. Torque-wrench tables cover engine and chassis fasteners, with separate multistage cylinder-head bolt and torque-turn big-end nut procedures.

Camshaft inspection cautions: The manual warns that releasing a bearing cap in isolation can crack the cap. It also identifies oil-soluble Plastigauge residue as a potential cause of blocked oil drillings and engine damage.

ECM Diagnosis, Fuel Delivery and Emissions

Separate MC 2000 and MC 1000 pinpoint-test tables connect fault codes with connector pins, wiring checks, and component tests. Their matching connector views help technicians select the correct test connections before tracing a fault.

Fuel-system testing: Fuel-pressure diagnosis uses gauge T3880048 alongside pump, regulator, and hose checks. Non-electrical troubleshooting addresses symptoms such as poor throttle response, unstable idle, throttle hang-up, and starting followed by immediate stalling.

Throttle-body vacuum synchronization, closed-throttle resets, idle-fuel adjustment, and adaptive stepper settings are described. Factory tune downloads use Triumph’s service diagnostic tool and password-controlled update process.

Closed-loop catalyst operation has its own fuel-trim functions. Evaporative-loss control coverage applies to California models and explains the carbon canister, purge valve, pressure-control valve, and rollover valve.

Cooling, Suspension and Chassis Service

The cooling chapter includes radiator pressure-cap checks, thermostat testing, and coolant filling and bleeding. Lubrication coverage traces the oil circuit and provides oil-pump inspection limits, sump procedures, and oil-cooler removal information.

ST and RS differences: Rear-hub and chain-adjustment procedures distinguish the ST’s eccentric hub from the RS’s wheel-spindle adjusters. Suspension coverage includes fork oil-level setting, steering geometry specifications, and swingarm and linkage bearing checks.

Brake repair extends to caliper piston and seal renewal, master-cylinder inspection, and hydraulic bleeding. Frame, footrest, and fairing inspections sit alongside separate ST and RS cockpit-removal procedures.

Electrical Schematics and Component Identification

Engine-management, lighting, and starting/charging circuit diagrams distinguish the models and electrical configurations. Full-color wiring diagrams and component keys supplement the ECM connector views, diagnostic charts, and fuse and relay identification information.

Follow the manual’s precautions for high-voltage ignition systems and hot, pressurized coolant.

A Sample of Valve and Crankshaft Clearance Data

These valve and bearing figures are a small selection of the inspection and adjustment specifications contained in the manual.

For both models, valve clearances are specified with the engine cold: intake 0.10–0.15 mm and exhaust 0.15–0.20 mm. The accompanying shim-selection charts relate measured clearance to replacement shim thickness.

Standard crankshaft main-bearing/journal clearance is 0.020–0.044 mm. The overhaul chapter also provides bearing color-selection tables based on journal and crankcase-bore measurements.

PDF Search, Wiring Detail and Page Count

Search and diagram readability: PDF text search and embedded bookmarks are not available. Small labels in the full-color wiring diagrams are soft and can remain difficult to read when enlarged.

One printable, English-language PDF contains 410 pages total. This count includes the front and back covers (2 pages) and one blank preliminary page.