Triumph Bonneville T100 America Speedmaster Thruxton Scrambler Service Manual 2006
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Complete Triumph service manual covering Bonneville, Bonneville T100, America, Speedmaster, Thruxton and Scrambler models. Part number T3859909, Issue 2, dated 01.2006. Covers 790cc and 865cc twin-cylinder engines with full specifications, torque settings, exploded views, maintenance schedules and step-by-step repair procedures.
Description
File Details
- Manual Type: Motorcycle Service Manual
- Brand: Triumph
- Models Covered: Bonneville, Bonneville T100, America, Speedmaster, Thruxton, Scrambler
- Part Number: T3859909
- Issue: Issue 2
- Date: 01.2006
- Language: English
- File Format: PDF
- Page Count: 482
Chapters Covered
- General Information
- Electrical Diagnosis (Ohm’s Law, basic circuits, circuit diagram symbols, CAN bus, tracing circuits, continuity and voltage testing)
- Alternator/Charging System diagnosis
- Starting Circuit diagnosis
- Service Tools
- Full Specifications (790cc and 865cc)
- Torque Wrench Settings
- Maintenance
- Scheduled Maintenance Chart
- Routine checks and service intervals
- Cylinder Head & Camshaft
- Camshaft Cover removal and installation
- Camshafts removal, inspection and installation
- Valve Clearance check and adjustment
- Cam Chain Tensioner
- Camshaft Drive Gear
- Cylinder Head removal, inspection and installation
- Valves removal and installation
- Barrels & Pistons
- Barrels removal, inspection and installation
- Pistons and Rings removal, inspection and installation
- Clutch
- Clutch Cable adjustment, removal, inspection and installation
- Clutch Lever Adjuster
- Clutch Cover removal, inspection and installation
- Clutch Release Mechanism
- Clutch removal, inspection and installation
- Starter Drive
- Crankshaft/Rods/Balancers
- Engine removal and installation (Bonneville, T100, Scrambler & Thruxton; America & Speedmaster)
- Crankcases disassembly and reassembly
- Crankshaft removal, inspection and installation
- Main Bearing Shell Selection and Journal Clearance Check
- Connecting Rods
- Front Balancer and Rear Balancer
- Transmission
- Gearchange Shaft
- Selector Forks
- Selector Drum
- Transmission Shafts
- Input Shaft disassembly, inspection and assembly
- Output Shaft disassembly, inspection and assembly
- Lubrication System
- Engine Oil Specification
- Oil Level Check
- Oil Draining and Refilling
- Oil and Filter Change
- Low Oil Pressure Warning Light Switch
- Oil Cooler (Bonneville, T100, Scrambler & Thruxton; America & Speedmaster)
- Sump
- Oil Pressure Relief Valve
- Oil Pumps
- Fuel System & Exhaust
- Fuel Tank and Fittings
- Carburettor specifications
- Exhaust system torque settings
- Secondary air injection system
- Braking System
- Brake caliper, disc and master cylinder torque settings
- Front and rear brake specifications
- Front Suspension/Steering
- Fork, yoke and handlebar torque settings
- Fork oil and travel specifications
- Rear Suspension
- Rear suspension unit and swinging arm torque settings
- Wheels and Tyres
- Wheel spindle and final drive torque settings
- Tyre pressures and tread depth specifications
- Electrical System/ignition
- Alternator, starter motor and ignition component torque settings
- Battery, fuse and alternator ratings
This Triumph Bonneville T100 America Speedmaster Thruxton Scrambler Service Manual is a comprehensive workshop document covering the complete range of 790cc and 865cc twin-cylinder Triumph motorcycles produced for the 2006 model year. Across its 482 pages, the manual provides full disassembly, inspection, reassembly and adjustment procedures for every major mechanical and electrical system on these machines. The engine chapters walk through cylinder head and camshaft work, barrel and piston removal, valve clearance measurement and shim adjustment, cam chain tensioner servicing, and complete crankshaft, connecting rod and balancer shaft procedures including main and big-end bearing shell selection tables.
The transmission section covers gearchange shaft, selector forks and selector drum removal, plus complete input and output shaft disassembly and reassembly with circlip orientation diagrams. The lubrication chapter details the dual oil pump arrangement, oil cooler servicing, sump removal, oil pressure relief valve and the low oil pressure warning light switch. Clutch and starter drive procedures are covered in full, including the clutch release mechanism and sprag clutch housing.
Beyond the mechanical chapters, the general information section opens with a complete electrical diagnosis guide covering Ohm’s Law, circuit diagram symbols, open and short circuit tracing, continuity and voltage testing, relay and switch checks, and CAN bus communication between the engine ECM and instruments. Alternator and charging system fault-finding flowcharts and starter circuit diagnosis are included, along with a full glossary of circuit diagram symbols.
Model and Engine Coverage
The manual separates specifications for the 790cc Bonneville/T100 and 790cc America/Speedmaster, and for the 865cc Bonneville T100, 865cc Speedmaster, 865cc Scrambler and 865cc Thruxton. Engine data, valve timing, camshaft journal clearances, cylinder bore and piston diameters, piston ring end gaps, crankshaft and connecting rod dimensions, clutch plate thickness, transmission gear ratios, final drive ratios and lubrication capacities are all tabulated separately for each displacement group.
Torque Wrench Settings and Service Data
Extensive torque tables are provided across two sections — one for America and Speedmaster models, and one for Bonneville, Bonneville T100, Scrambler and Thruxton models. These cover cylinder head and camshaft bolts, clutch components, engine mountings, crankshaft and connecting rod fixings, transmission, lubrication system, fuel system and exhaust, braking system, front and rear suspension, footrests, frame and bodywork, wheels, final drive, and electrical system fasteners. Where a torque figure differs by model, the manual lists the specific value for each.
Exploded Views and Diagrams
Throughout the manual, exploded view drawings accompany the procedures. Cylinder head and valve assemblies, barrel and piston groups, clutch and starter drive components, engine mountings for both frame types, crankshaft and connecting rod assemblies, balancer shafts, transmission shafts and selector mechanisms, oil cooler and oil pump assemblies, and fuel tank fittings are all illustrated. Wiring and circuit diagram symbols are explained in the general information chapter, and throttle cable routing is shown for the Thruxton.
What This Manual Enables You to Do
This service manual supports the full range of repair and maintenance tasks on the covered Triumph models — from routine oil and filter changes, valve clearance checks and clutch cable adjustment through to complete engine teardown, crankshaft and connecting rod bearing selection, transmission rebuild, and electrical fault diagnosis. Procedures include the correct torque figures, wear limits and service limits needed to work accurately, and the exploded views show how components fit together so that reassembly is straightforward. Safety warnings, cautions and notes are flagged throughout for ignition system high voltage, fuel handling, brake fluid, lifting and jacking, and other hazards.
Having the correct procedures and specifications matters because these engines use matched crankcase halves, selectively fitted main and big-end bearing shells, angle-tightened cylinder head and connecting rod fixings, and specific valve clearance shim sizes. Working without the manufacturer’s data risks incorrect clearances, oil leaks, premature wear or component failure. This manual provides the reference information needed to carry out each job properly.
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