1969–1975 Triumph TR25W, T100, 650/750 Twins & T150/T150V Trident Service & Repair Manual

This service and repair manual covers the listed 1969–1975 Triumph TR25W single, T100 and 650/750 twins, and T150/T150V Trident. These pages form the Triumph section of a larger repair reference; the separate General Information section cited for basic maintenance, engine rebuilding, and carburetor theory is not included.

• Engine and primary drive: Engine removal, cylinder-head and crankcase disassembly, crankshaft and main-bearing service, clutch inspection, primary-drive sprocket alignment, and chain adjustment.

• Gearboxes and shifting: Separate transmission procedures, selector-fork and camplate installation, kick-starter repair, and shaft and bearing specifications.

• Tune-up and lubrication: Valve-clearance adjustment, contact-breaker servicing, static and dynamic ignition timing, oil-pump inspection, and pressure-relief-valve service.

• Amal carburetors: Monobloc and Concentric disassembly, assembly, and adjustment, with separate synchronization procedures for twin-carburetor models and Trident throttle linkages.

• Electrical diagnosis: Low- and high-tension fault tracing, coil and condenser checks, alternator and rectifier tests, Zener-diode testing, and model-specific wiring diagrams.

• Chassis and brakes: Steering-head bearings, fork overhaul, swing-arm bushings, wheel-bearing service, rear-shock inspection, hydraulic brake bleeding, and master-cylinder and caliper repair.

This material is suited to mechanics and experienced owners familiar with mechanical disassembly, precision measurement, and electrical test equipment.

Engine, Clutch and Gearbox Differences

The engine chapters distinguish single, twin, and triple layouts, with crankshaft journal dimensions, bearing fits, piston clearances, and component-specific torque tables. TR7V/T140V coverage includes the L/M/H piston and cylinder grading system; the Trident has separate center-main-bearing specifications.

Gear-cluster and shifter-mechanism views show the differences between transmission layouts. The T150V section identifies its separate high-gear-bearing oil-seal housing, while the twin gearbox assembly instructions reference quadrant alignment tool 60-6128.

The twin kick-starter instructions warn that excessive tightening of the ratchet retaining nut can collapse its thin steel sleeve.

Ignition, Carburetion and Oil Supply

Serial-specific breaker assemblies, timing arrangements, and carburetor tables help match the installed components to the appropriate adjustment data before parts are selected. Supporting illustrations include contact-breaker drawings and the 500 Twin Crankshaft Degree Conversion Chart.

Trident carburetor coverage explains the external scissor-spring throttle linkage. The Amal installation notes warn that uneven or excessive flange tightening can distort the carburetor body and cause the throttle slide to bind.

Lubrication coverage includes feed and scavenge pump inspection, non-return valves, and oil-pressure fault checks. The Trident lubrication-system schematic traces the oil cooler, tank return, and timed tappet feed.

Wiring diagrams distinguish the earlier 500 circuits, nacelle and separate-headlight arrangements, and the twin and Trident layouts. Charging-system diagnosis includes alternator output measurements, rectifier bench tests, and circuit continuity checks.

Forks, Wheel Hubs and Hydraulic Brakes

Fork procedures distinguish rod-damper, shuttle-valve, and later slim-line assemblies, including seal replacement and alignment. Tool 61-6113 is specified for slim-line fork disassembly.

Standard and quickly detachable rear hubs receive separate treatment. Swing-arm procedures distinguish the early and later T100 arrangements from the TR7V/T140V bushing installation.

Master-cylinder and caliper exploded views accompany hydraulic brake service, including inspection, seal replacement, bleeding, and disc runout checks. The brake section prohibits splitting the caliper halves and directs separated units to the manufacturer for overhaul.

Rear-shock coverage addresses springs, end bushings, inspection, and replacement of the sealed hydraulic damper unit. Engine and chassis torque tables provide separate references for the covered assemblies.

Selected Head-Bolt Torque and Chaincase Capacity Data

These examples represent a small selection of the manual’s fastening and lubrication specifications.

For the TR7V and T140V, the engine-torque table lists 18 ft-lb for the outer and inner 3/8-in. cylinder-head bolts, compared with 16 ft-lb for the center 5/16-in. bolt.

The maintenance table lists the T150 primary-chaincase capacity as 0.75 pint (426 cc). The lubrication section separately explains the initial refill and automatic oil-level control.

PDF Search, Wiring Detail and Page Count

Search and diagram detail: PDF text search and embedded bookmarks are not available. Small wiring labels require magnification; portions of the TR7V/T140V component legend remain difficult to read when enlarged.

Supplied as one printable, English-language, 76-page PDF, covering printed pages 1035–1110. The opening model-coverage and index page is included in that total; there are no separate supplements.