Triumph Thruxton 900 2003-2009 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Triumph Model: Thruxton 900 Generation Model Years Covered: 2003, 2004, 2005, 2006, 2007, 2008, 2009 👋 Introduction Market Position Target Audience: Motorcycle owners and independent technicians seeking professional repair information. Competitive Analysis Manual Completeness: Provides dealer-level service information for comprehensive repairs and maintenance. Key Features Benefit To Owner: Enables owners to perform maintenance and repairs like a professional technician, saving time and money. Emphasis: Emphasizes special aspects of the Thruxton 900 for quality service and builds technician reputation. Value Proposition: Helps owners get the best value from their Triumph Thruxton 900 by enabling informed maintenance and repair. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual All Necessary Instructions: Contains all instructions needed for any repair the motorcycle may require, ensuring complete servicing capability. Dealer Service Information: Provides information and procedures previously only available in authorized dealer service departments. Page Count Page Count: 482 Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Repair: Engine disassembly and overhaul, including internal components. Transmission Repair: Transmission disassembly and overhaul, including internal components. Fuel System: Detailed procedures for fuel system components and maintenance. Ignition System: Ignition system diagnostics, maintenance, and repair. Lubrication System: Lubrication system maintenance, oil changes, and component checks. Exhaust System: Exhaust system inspection, maintenance, and repair procedures. Electrical System: Comprehensive electrical system diagnostics, wiring diagrams, and component repair. Bodywork: Body panel removal, installation, and repair procedures. Procedures Included Tune Ups: Detailed instructions for performing tune-ups and performance adjustments. Routine Maintenance: Coverage of all routine maintenance tasks and schedules. Removal Installation: Step-by-step procedures for component removal and installation. Assembly Disassembly: Detailed instructions for assembly and disassembly of various vehicle sub-systems. Troubleshooting: Diagnostic procedures to identify and resolve common and uncommon issues. Safety Precautions: Emphasizes the use of safety equipment and adherence to safety precautions during maintenance and repair. Torque Specifications: Includes critical torque specifications for fasteners to ensure proper assembly and prevent component damage. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures and troubleshooting guides. Repair Scope: Covers everything from basic maintenance to complete engine and transmission overhauls. Proprietary Components: Includes instructions for proprietary components and their manufacturers' recommendations. Diagnostic Tools: References special Triumph-specific tools, essential for accurate diagnostics and repairs. 📊 Manual Specifications File Format Printability: Yes Delivery Method: Fast and Free Electronic Delivery via Email Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, DOHC, parallel-twin Displacement: 865cc (approx.) Bore X Stroke: 90 mm x 68 mm (typical for this engine family) Performance Horsepower: Approx. 69 hp @ 7200 rpm (Varies by specific model year and tuning) Torque: Approx. 53 lb-ft @ 5800 rpm (Varies by specific model year and tuning) Fuel System Fuel Delivery: Carbureted (likely Keihin CVK or similar) or Fuel Injection depending on exact model year within the range. Fuel Type: Unleaded gasoline Carburetor Details: Likely 36mm Keihin CVK carburetors, or potentially electronic fuel injection (EFI) on later models within the 2003-2009 range depending on market. Manual will specify. 🔧 Transmission Standard Transmission Type: 5-speed manual Features Clutch Type: Wet, multi-plate 📐 Dimensions Exterior Wheelbase: Approx. 1500 mm (59.1 in) Seat Height: Approx. 810 mm (31.9 in) Weights Dry Weight: Approx. 205 kg (452 lbs) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety is inherently dependent on rider skill and adherence to road safety principles. Official crash test ratings are not applicable in the same way as for cars. Active Features Braking System: Disc brakes front and rear, with potential for ABS on some later models or specific markets (manual will detail specific braking setup). Passive Features Lighting: Standard headlight, taillight, and turn signals for visibility. 💡 Technology Features Infotainment Infotainment System: N/A (Focus on core motorcycle functionality, not digital infotainment). Driver Assistance Driver Assistance Features: N/A (Traditional motorcycle design). Connectivity Connectivity Features: N/A (Traditional motorcycle design). 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time interval, typically 3,000-6,000 miles or annually. Valve Clearance Check: Refer to manual for specific mileage/time interval, typically every 6,000-12,000 miles. Brake Fluid Change Interval: Refer to manual, typically every 1-2 years or as per condition. Fluid Specifications Engine Oil Type: Refer to manual for specific SAE viscosity (e.g., 10W-40 or 20W-50) and API classification (e.g., SG, SH, SJ, SL). Engine Oil Capacity: Refer to manual for specific capacity with filter change (typically around 3.5 - 4.0 liters). Brake Fluid Type: DOT 4 or DOT 5.1 recommended, refer to manual for exact specification. Coolant Type: Not applicable for this air-cooled model. Known Issues Carburetor Tuning: Carburetors may require periodic adjustment and synchronization for optimal performance. Camchain Tensioner: Some models may benefit from upgrading the automatic camchain tensioner to a manual unit. Regulator Rectifier: While not as prevalent as on some other Triumph models of...
Motorcycle owners and independent technicians seeking professional repair information.
Competitive Analysis
Manual Completeness:
Provides dealer-level service information for comprehensive repairs and maintenance.
Key Features
Benefit To Owner:
Enables owners to perform maintenance and repairs like a professional technician, saving time and money.
Emphasis:
Emphasizes special aspects of the Thruxton 900 for quality service and builds technician reputation.
Value Proposition:
Helps owners get the best value from their Triumph Thruxton 900 by enabling informed maintenance and repair.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
All Necessary Instructions:
Contains all instructions needed for any repair the motorcycle may require, ensuring complete servicing capability.
Dealer Service Information:
Provides information and procedures previously only available in authorized dealer service departments.
Page Count
Page Count:
482
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Repair:
Engine disassembly and overhaul, including internal components.
Transmission Repair:
Transmission disassembly and overhaul, including internal components.
Fuel System:
Detailed procedures for fuel system components and maintenance.
Ignition System:
Ignition system diagnostics, maintenance, and repair.
Lubrication System:
Lubrication system maintenance, oil changes, and component checks.
Exhaust System:
Exhaust system inspection, maintenance, and repair procedures.
Electrical System:
Comprehensive electrical system diagnostics, wiring diagrams, and component repair.
Bodywork:
Body panel removal, installation, and repair procedures.
Procedures Included
Tune Ups:
Detailed instructions for performing tune-ups and performance adjustments.
Routine Maintenance:
Coverage of all routine maintenance tasks and schedules.
Removal Installation:
Step-by-step procedures for component removal and installation.
Assembly Disassembly:
Detailed instructions for assembly and disassembly of various vehicle sub-systems.
Troubleshooting:
Diagnostic procedures to identify and resolve common and uncommon issues.
Safety Precautions:
Emphasizes the use of safety equipment and adherence to safety precautions during maintenance and repair.
Torque Specifications:
Includes critical torque specifications for fasteners to ensure proper assembly and prevent component damage.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures and troubleshooting guides.
Repair Scope:
Covers everything from basic maintenance to complete engine and transmission overhauls.
Proprietary Components:
Includes instructions for proprietary components and their manufacturers' recommendations.
Diagnostic Tools:
References special Triumph-specific tools, essential for accurate diagnostics and repairs.
📊 Manual Specifications
File Format
Printability:
Yes
Delivery Method:
Fast and Free Electronic Delivery via Email
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, DOHC, parallel-twin
Displacement:
865cc (approx.)
Bore X Stroke:
90 mm x 68 mm (typical for this engine family)
Performance
Horsepower:
Approx. 69 hp @ 7200 rpm (Varies by specific model year and tuning)
Torque:
Approx. 53 lb-ft @ 5800 rpm (Varies by specific model year and tuning)
Fuel System
Fuel Delivery:
Carbureted (likely Keihin CVK or similar) or Fuel Injection depending on exact model year within the range.
Fuel Type:
Unleaded gasoline
Carburetor Details:
Likely 36mm Keihin CVK carburetors, or potentially electronic fuel injection (EFI) on later models within the 2003-2009 range depending on market. Manual will specify.
🔧 Transmission
Standard
Transmission Type:
5-speed manual
Features
Clutch Type:
Wet, multi-plate
📐 Dimensions
Exterior
Wheelbase:
Approx. 1500 mm (59.1 in)
Seat Height:
Approx. 810 mm (31.9 in)
Weights
Dry Weight:
Approx. 205 kg (452 lbs)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety is inherently dependent on rider skill and adherence to road safety principles. Official crash test ratings are not applicable in the same way as for cars.
Active Features
Braking System:
Disc brakes front and rear, with potential for ABS on some later models or specific markets (manual will detail specific braking setup).
Passive Features
Lighting:
Standard headlight, taillight, and turn signals for visibility.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus on core motorcycle functionality, not digital infotainment).
Driver Assistance
Driver Assistance Features:
N/A (Traditional motorcycle design).
Connectivity
Connectivity Features:
N/A (Traditional motorcycle design).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time interval, typically 3,000-6,000 miles or annually.
Valve Clearance Check:
Refer to manual for specific mileage/time interval, typically every 6,000-12,000 miles.
Brake Fluid Change Interval:
Refer to manual, typically every 1-2 years or as per condition.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific SAE viscosity (e.g., 10W-40 or 20W-50) and API classification (e.g., SG, SH, SJ, SL).
Engine Oil Capacity:
Refer to manual for specific capacity with filter change (typically around 3.5 - 4.0 liters).
Brake Fluid Type:
DOT 4 or DOT 5.1 recommended, refer to manual for exact specification.
Coolant Type:
Not applicable for this air-cooled model.
Known Issues
Carburetor Tuning:
Carburetors may require periodic adjustment and synchronization for optimal performance.
Camchain Tensioner:
Some models may benefit from upgrading the automatic camchain tensioner to a manual unit.
Regulator Rectifier:
While not as prevalent as on some other Triumph models of the era, checking the electrical charging system is prudent.
Technical Specs
Spark Plug Type:
Refer to manual for specific spark plug model and gap (e.g., NGK DPR8EA-9).
Tire Pressure Front:
Refer to manual for specific pressure (e.g., 32 psi / 2.2 bar).
Tire Pressure Rear:
Refer to manual for specific pressure (e.g., 36 psi / 2.5 bar).
📚 Vehicle History
Brand Heritage
Triumph Legacy:
Triumph Motorcycles has a rich heritage dating back to 1902, known for iconic British motorcycles.
Model Evolution
Thruxton Lineage:
The Thruxton name is revived from Triumph's racing heritage, specifically the Bonneville-based racers of the 1960s.
Production
Manufacturing Location:
Hinckley, Leicestershire, United Kingdom
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